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Suzuki 2007 XL7, Service Manual

The Suzuki 2007 XL7 service manual is an essential resource for owners of this rugged SUV. Easily download the free manual from manualshive.com to access detailed instructions for maintenance and repair, ensuring your XL7 continues to perform at its best for years to come.

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9B-87 Lighting Systems: 

Repair Instructions

Fog Lamp Switch Replacement

Callout

Component Name

1

Instrument Panel Lower Trim Bezel
Refer to “Instrument Panel Accessory Trim Plate Replacement: ”.

2

Driver Information Center Switch Bracket

3

Rear Wiper Washer and Front Fog Lamp Switch

Summary of Contents for 2007 XL7

Page 1: ...SERVICE MANUAL 99500S78J00 33E 2007 JC636...

Page 2: ...er to Air Bag System Components and Wiring Location View under General Description in air bag system section in order to confirm whether you are performing ser vice on or near the air bag system compo...

Page 3: ...e vehicle When replacing parts or servicing by disassembling it is recommended to use SUZUKI genuine parts tools and service materials as specified in each description All information illustrations an...

Page 4: ......

Page 5: ...and Diagnosis 4A 1 Front Brakes 4B 1 Rear Brakes 4C 1 Parking Brake 4D 1 ABS 4E 1 Transmission Transaxle 5 i Automatic Transmission 5A 1 Steering 6 i Steering Wheel and Column 6B 1 Power Assisted Ste...

Page 6: ......

Page 7: ...ass and Sheet Metal Handling Caution 00 2 Moving Parts and Hot Surfaces Caution 00 2 Protective Goggles and Glove Caution 00 2 Road Test Caution 00 2 Work Stall Test Caution 00 2 Belt Dressing Notice...

Page 8: ...ng consequences may occur Damage to the vehicle Unnecessary vehicle repairs Unnecessary component replacement Improper operation or performance of the system or component under repair Damage to any sy...

Page 9: ...ing all traffic laws Do not attempt any maneuvers that could jeopardize vehicle control Failure to adhere to these precautions could lead to serious personal injury and vehicle damage Work Stall Test...

Page 10: ...fect Component Fastener Tightening Notice CAUTION Replacement components must be the correct part number for the application Components requiring the use of the thread locking compound lubricants corr...

Page 11: ...s DVOM etc into any connector or fuse block terminal The diameter of the test probes will deform most terminals A deformed terminal will cause a poor connection which will result in a system failure A...

Page 12: ...00 5 Precautions...

Page 13: ...stic Starting Point Vibration Diagnosis and Correction 0A 55 Diagnostic System Check Vehicle Diagnostic Information 0A 56 Diagnostic Repair Verification Vehicle Diagnostic Information 0A 58 Symptoms V...

Page 14: ...Brake Horsepower BLK Black BLU Blue BP Back Pressure BPCM Battery Pack Control Module BPMV Brake Pressure Modulator Valve BPP Brake Pedal Position BRN Brown BTDC Before Top Dead Center BTM Battery Th...

Page 15: ...rol E M English Metric EMF Electromotive Force EMI Electromagnetic Interference Eng Engine EOP Engine Oil Pressure EOT Engine Oil Temperature EPA Environmental Protection Agency EPR Exhaust Pressure R...

Page 16: ...L Liter L4 Four Cylinder Engine In Line L6 Six Cylinder Engine In Line lb Pound lb ft Pound Feet Torque lb in Pound Inch Torque LCD Liquid Crystal Display Abbreviation Meaning LDCL Left Door Closed Lo...

Page 17: ...ver Module qt Quart s R R 12 Refrigerant 12 R 134a Refrigerant 134a Abbreviation Meaning RAM Random Access Memory Non permanent memory device memory contents are lost when power is removed RAP Retaine...

Page 18: ...alytic TWC OC Three Way Oxidation Converter Catalytic TXV Thermal Expansion Valve U UART Universal Asynchronous Receiver Transmitter U H Underhood U HEC Underhood Electrical Center U joint Universal J...

Page 19: ...hi DEX COOL DEXOIL DEXRON DEXSTEER DNR Dolby DR Duracell Duraguard Durastop Duramax E Eaton Corporation EMD ETR F FLO LITE G General Motors GM GM Goodwrench Service GM Optikleen GM Parts GM Pass GM Ul...

Page 20: ...C6B GVW RATING 2 475 kg 5 456 lbs C67 HVAC System Air Conditioner Front Electronic Controls C68 HVAC System Air Conditioner Front Auto Electronic Controls C69 HVAC System Rear Air Conditioner DD7 Mir...

Page 21: ...Speedometer Instr Kilo and Miles Kilo Odometer U65 Speaker System 7 Premium V1K Bar Luggage Carrier Center Cross V92 Trailer Provisions YB6 Axle Base Equip Keep as Processing Option YF5 Certification...

Page 22: ...71562 7 16 0 4375 11 1125 29 64 0 453125 11 50937 15 32 0 46875 11 90625 31 64 0 484375 12 30312 1 2 0 5 12 7 33 64 0 515625 13 09687 17 32 0 53125 13 49375 35 64 0 546875 13 89062 9 16 0 5625 14 2875...

Page 23: ...20 and 1 4 28 screws The thread pitch is midway between the English coarse and fine thread pitches Fastener Strength Identification The most commonly used metric fastener strength property classes are...

Page 24: ...hese fasteners accomplish the thread interface by the presence of a thread locking compound on the fastener threads Refer to the appropriate repair procedure in order to determine if the fastener may...

Page 25: ...in 8 mm 0 6 N m 5 lb in 10 mm 1 1 N m 10 lb in 12 mm 1 5 N m 13 lb in 14 mm 2 3 N m 20 lb in 16 mm 3 4 N m 30 lb in 20 mm 5 5 N m 49 lb in 24 mm 8 5 N m 75 lb in Application Specification Metric Engli...

Page 26: ...aged thread If necessary adjust the stop collars on the cutting tool and tap to the required depth 2 Drill out the damaged threads Clean out any chips 3 Lubricate the tap with light engine oil Tap the...

Page 27: ...the vehicle s contents in order to avoid any shifting or any movement that may occur during the vehicle lifting or jacking procedure The lifting equipment or the jacking equipment weight rating must...

Page 28: ...ID and VIN Location Derivative and Usage Position Definition Character Description Vehicle Identification Number VIN System The VIN plate 1 is the legal identifier of the vehicle The VIN plate is loc...

Page 29: ...rmine if a vehicle contains the original engine or transmission by matching the VIN derivative positions to their accompanying positions in the complete VIN AF33 5 M09 M45 Transaxle ID and VIN Derivat...

Page 30: ...ehicle Capacity Weight 11 Original Equipment Tires Size 12 Tire Pressure Front Rear and Spare Cold Service Parts ID Label The vehicle service parts identification label is located in the instrument pa...

Page 31: ...sed A vibrating component operates at a consistent rate km h mph or RPM Measure the rate of vibration in question When the rate speed is determined relate the vibration to a component that operates at...

Page 32: ...t 50 cm 20 in hanging over the edge of the table 2 Pull down on the edge of the stick and release while observing the movement of the stick The motion of the stick occurs in repetitive cycles The cycl...

Page 33: ...ertrain Components The word cycle comes from the same root as the word circle A circle begins and ends at the same point as thus so does a cycle All vibrations consist of repetitive cycles 1 1st Cycle...

Page 34: ...he disturbance A severe disturbance would have a high amplitude a minor disturbance would have a low amplitude Amplitude is measured by the amount of actual movement or the displacement For example co...

Page 35: ...tire follows the same example The nut is the imbalance in the tire The string is the tire wheel and suspension assembly As the vehicle speed increases the disturbing force of the unbalanced tire can b...

Page 36: ...the mass the lower the natural frequency Resonance All objects have natural frequencies The natural frequency of a typical automotive front suspension is in the 10 15 Hz range This natural frequency i...

Page 37: ...he ability of an object or material to dissipate or absorb vibration The automotive shock absorber is a good example The function of the shock absorber is to absorb or dampen the oscillations of the s...

Page 38: ...d in some vehicles Beating occurs when 2 vibrating forces are adding to each other s amplitude However 2 vibrating forces can also subtract from each other s amplitude The adding and subtracting of am...

Page 39: ...icle system voltage There is not a charging system concern All charging system concerns must be repaired before programming a control module Battery voltage is greater than 12 volts but less than 16 v...

Page 40: ...vious category 2 FM PWM Frequency Pulse Width Modulated Failures This category includes faults related to frequency modulated and pulse width modulated inputs and outputs of the electronic control mod...

Page 41: ...Time Failure 17 Signal Shape Waveform Failure 18 Signal Amplitude Less Than Minimum 19 Signal Amplitude Greater Than Maximum 1A Bias Level Out of Range 1F Intermittent 21 Incorrect Period 22 Low Time...

Page 42: ...ons Engine oil GM P N 12345610 Canadian P N 993193 GM 5W 30 GM Goodwrench Various Engine oil Hydraulic lash adjuster Engine Mechanical Section Sealant GM P N 12346004 Canadian P N 10953480 Permatex 56...

Page 43: ...veline Axle Threadlocker Thread lock sealant GM P N 89021297 Canadian P N 10953488 J 42385 109 Hi Temp High Strength Threadlocker LOCKTITE 277 GM Goodwrench Insert OD threads Engine Mechanical and Tra...

Page 44: ...Lord Adhesives Door panel hemming Door outer panel replacement Body Door Section Medium set panel bonding adhesive GM P N 12378567 Canadian P N 88901675 Lord Fusor P N 108B 109B Medium Set Panel Bondi...

Page 45: ...umber The engine block is marked with the VIN on a pad area on the left rear side 1 Engine Plant Sequence Number The engine plant sequence number is located in one place on the engine and is a twelve...

Page 46: ...trategy Based Diagnosis is provided here This provides an overview on how a technician should diagnose a vehicle A link to the Diagnostic Procedure Instructions Vehicle Diagnostic Information is provi...

Page 47: ...e DTC identifies the condition s that must be present in order to fail the diagnostic and when to set the DTC Action Taken When the DTC Sets Actions Taken When the DTC sets identifies the default acti...

Page 48: ...o take place Intrusive diagnostics are performed to locate the system fault System harness connections are disconnected from the module or component to test individual circuit functions The module or...

Page 49: ...ostics Analyze the Concern Develop a plan for the diagnostics The service manual schematics will help you to see system power ground input and output circuits You can also identify splices and other a...

Page 50: ...ead the technician in an organized approach to diagnostics 5 5 Vehicle Operates as Designed This condition exists when the vehicle is found to operate normally The condition described by the customer...

Page 51: ...Detect unusual sounds or odors Gather diagnostic trouble code DTC information in order to achieve an effective repair 5 4 Intermittents An intermittent condition is one that does not occur continuous...

Page 52: ...p Stage 2 SDM DTC B0012 or B0013 B0014 Driver Side Frontal Deployment Loop SDM DTC B0014 B0045 B0015 Driver Pretensioner Loop SDM DTC B0014 B0045 B0016 Left Roof Rail Initiator 1 Deployment Loop SDM D...

Page 53: ...Ground Circuit DRR DTC B1259 B1287 Amplifier Control Signal Circuit Radio DTC B1287 B1325 Device Power Circuit HVSM IPC PPS Radio DTC B1325 B1370 Device Ignition 1 ON and START Circuit BCM DTC B1370...

Page 54: ...ed Transponder Identification Code Received TDM DTC B3060 B3105 Keyless Entry System Key Fobs Not Programmed RCDLR DTC B3105 B3109 Keyless Entry Transmitter 1 Low Battery RCDLR DTC B3109 B3110 Keyless...

Page 55: ...ce EBCM DTC C0550 CCM DTC C0550 C0551 Option Configuration Error EBCM DTC C0551 C0558 Calibration Mismatch CCM DTC C0558 C0561 System Disabled Information Stored EBCM DTC C0561 CCM DTC C0561 C0750 Lef...

Page 56: ...2 HO2S Heater Control Circuit High Voltage Bank 1 Sensor 1 ECM DTC P0030 P0031 P0032 P0036 P0037 P0038 P0050 P0051 P0052 P0056 P0057 or P0058 P0036 Heater Control Circuit Bank 1 Sensor 2 ECM DTC P0030...

Page 57: ...121 P0122 P0123 P0221 P0222 or P0223 P0122 Throttle Position TP Sensor 1 Circuit Low Voltage ECM DTC P0121 P0122 P0123 P0221 P0222 or P0223 P0123 Throttle Position TP Sensor 1 Circuit High Voltage ECM...

Page 58: ...Control Circuit ECM DTC P0201 P0202 P0203 P0204 P0205 P0206 P0261 P0262 P0264 P0265 P0267 P0268 P0270 P0271 P0273 P0274 P0276 or P0277 P0205 Injector 5 Control Circuit ECM DTC P0201 P0202 P0203 P0204...

Page 59: ...or 6 Control Circuit Low Voltage ECM DTC P0201 P0202 P0203 P0204 P0205 P0206 P0261 P0262 P0264 P0265 P0267 P0268 P0270 P0271 P0273 P0274 P0276 or P0277 P0277 Injector 6 Control Circuit High Voltage EC...

Page 60: ...oltage Bank 1 ECM DTC P0341 P0342 P0343 P0346 P0347 P0348 P0366 P0367 P0368 P0391 P0392 or P0393 P0391 Exhaust Camshaft Position CMP Sensor Performance Bank 2 ECM DTC P0341 P0342 P0343 P0346 P0347 P03...

Page 61: ...CM DTC P0520 P0532 Air Conditioning A C Refrigerant Pressure Sensor Circuit Low Voltage ECM DTC P0532 or P0533 P0533 Air Conditioning A C Refrigerant Pressure Sensor Circuit High Voltage ECM DTC P0532...

Page 62: ...olt Reference 1 Circuit High Voltage ECM DTC P0642 or P0643 P0645 Air Conditioning A C Clutch Relay Control Circuit ECM DTC P0645 P0646 or P0647 P0646 Air Conditioning A C Clutch Relay Control Circuit...

Page 63: ...tio TCM DTC P0730 P0731 Incorrect 1st Gear Ratio TCM DTC P0731 P0732 Incorrect 2nd Gear Ratio TCM DTC P0732 P0733 Incorrect 3rd Gear Ratio TCM DTC P0733 P0734 Incorrect 4th Gear Ratio TCM DTC P0734 P0...

Page 64: ...P0977 P0979 P0980 P0982 P0983 P0985 or P0986 P1011 Intake Camshaft Position CMP Actuator Park Position Bank 1 ECM DTC P1011 P1014 P1012 Exhaust Camshaft Position CMP Actuator Park Position Bank 1 ECM...

Page 65: ...7 P2119 Throttle Closed Position Performance ECM DTC P0638 P2100 P2101 or P2119 P2122 Accelerator Pedal Position APP Sensor 1 Circuit Low Voltage ECM DTC P2122 P2123 P2127 P2128 or P2138 P2123 Acceler...

Page 66: ...P2301 P2303 P2304 P2306 P2307 P2309 P2310 P2312 P2313 P2315 or P2316 P2306 Ignition Coil 3 Control Circuit Low Voltage ECM DTC P2300 P2301 P2303 P2304 P2306 P2307 P2309 P2310 P2312 P2313 P2315 or P231...

Page 67: ...h Body Control Module BCM HVSM PPS PSCM RCDLR ROS RSA TDM DTC U0100 U0299 U0151 Lost Communication With Sensing and Diagnostic Module SDM PPS ROS DTC U0100 U0299 U0155 Lost Communication With Instrume...

Page 68: ...gy the J 38792 A Electronic Vibration Analyzer EVA 2 and the J 38792 VS Vibrate Software Reviewing this information will help you determine whether the condition described by the customer is a potenti...

Page 69: ...ed by following the steps of the Vibration Diagnostic Process refer to Vibration Diagnostic Aids Diagnostic System Check Vehicle Diagnostic Information 1 Verify that none of the following preliminary...

Page 70: ...crank refer to Symptoms Engine Electrical 8 Attempt to start the engine Verify the engine starts and runs If the engine does not start and run refer to Engine Cranks but Does Not Run NOTE Do not clear...

Page 71: ...and Correction Body Systems Symptoms Fixed and Moveable Windows Symptoms Horns Symptoms Lighting Systems Symptoms Vehicle Access Symptoms Wipers and Washers Brakes Symptoms Antilock Brake System Sympt...

Page 72: ...on Analysis Driveline Vehicle Speed Sensitive Affected by steering input Go to Vibration Analysis Hub and or Axle Input Engine Speed Sensitive Go to Vibration Analysis Engine Roughness Similar to the...

Page 73: ...sis Tire and Wheel Vehicle Speed Sensitive Affected by torque load Go to Vibration Analysis Driveline Vehicle Speed Sensitive Affected by steering input Go to Vibration Analysis Hub and or Axle Input...

Page 74: ...s No WARNING Refer to Road Test Caution 1 Did you review the Diagnostic Starting Point Vibration Diagnosis Go to Step 2 Go to Diagnostic Starting Point Vibration Diagnosis and Correction 2 Did the cus...

Page 75: ...sensor if available to the pinion area of the drive axle Route the sensor lead wire clear of rotating parts and loosely secure the wire clear of moving parts If it is not possible to install the J 38...

Page 76: ...16 Go to Step 17 16 1 With the J 38792 A sensor still installed in the same position activate engage all wheel drive 2 Select a smooth level road and slowly accelerate the vehicle up to highway speed...

Page 77: ...e duplicating attempts or due to not following the procedures designed to duplicate concerns properly and in the sequence indicated 18 1 Select a smooth level road and slowly accelerate the vehicle up...

Page 78: ...engine accessory drive belt or belts could exhibit a whipping condition if a belt is deteriorating and deposits are building up on the underside of the belt Loose Mounting Brackets or Component Ground...

Page 79: ...of a condition is the driveline Driveline Torque Load Conditions An drive axle that has internal conditions such as excessive runout of components misalignment of components imbalance etc can produce...

Page 80: ...up to the pinion nose and the transmission or transfer case tailshaft housing 12 If the vehicle is equipped with a multiple piece propeller shaft hold the vibration sensor of the J 38792 A up to the p...

Page 81: ...l Module HVAC Schematics Blower Motor Control Module Replacement This device requires no programming or setup Body Control Module Body Control System Schematics Body Control Module Replacement Body Co...

Page 82: ...ement This device requires no programming or setup Theft Deterrent Module Immobilizer Schematics Theft Deterrent Module Replacement Theft Deterrent Control Module Programming and Setup Transmission Co...

Page 83: ...l NOTE indicates the substitute special tool is not available Engine Special Tools Described in This Manual Substitute Special Tools EN 46119 09916 14521 Off Vehicle Valve Spring Compressor Adapter Va...

Page 84: ...cial Tools J 45097 09913 75821 Rear Control Arm Bushing Remover Bearing Installer Attachment J 45400 09943 25010 Strut Spring Compressor Spring Compressor Special Tools Described in This Manual Substi...

Page 85: ...ibed in This Manual Substitute Special Tools J 33832 09913 75821 Output Shaft Seal Installer Bearing Installer Attachment J 8092 Driver Handle J 35910 09943 57010 Drive Axle Seal Clamp Pliers Band Com...

Page 86: ...ute Special Tools J 23327 09926 96040 Clutch Spring Compressor Clutch Spring Compressor No 8 J 35582 09913 85210 Oil Pump Seal Installer Bearing Installer J 41236 09926 98350 Coast Clutch Spring Compr...

Page 87: ...e Sliding Hammer J 45160 09944 96011 Differential Bearing Race Remover Bearing Outer Rase Remover J 45161 09943 88211 Manual Shift Shaft Bearing Replacer Pinion Bearing Installer J 45164 09941 51012 S...

Page 88: ...J 45185 09900 22403 Bore Gage Set Small Bore Gauge 18 35 mm J 45186 09926 95420 Forward and Direct Clutch Spring Compressor Clutch Spring Compressor J 45187 09924 07730 Differential Output Shaft Oil...

Page 89: ...General Information 0A 76 J 45200 09900 20607 Dial Indicator Set Dial Gauge 09900 20701 Magnetic Stand Special Tools Described in This Manual Substitute Special Tools...

Page 90: ...ring Special Tools Described in This Manual Substitute Special Tools J 1859 A 09944 36011 Steering Wheel Puller Steering Wheel Remover J 22610 09943 57010 Keystone Clamp Pliers Band Compressor 09943 5...

Page 91: ...stitute Special Tools GE 47849 09991 06530 Clutch Remover Armature Plate Remover GE 47851 09951 15511 Armature Installer Magnet Clutch Installer J 37872 09991 06310 Universal Spanner Wrench Armature P...

Page 92: ...e J 38792 A vibration sensor is therefore directional sensitive and must be attached to vehicle components such that the side of the sensor marked UP is always facing upright and the sensor body is as...

Page 93: ...will be displayed along the top of the screen to the left of the vibration sensor input port being used When operating the EVA in the averaging mode and the Manual Mode AVG will be displayed along th...

Page 94: ...ough the following the Vibration Analysis diagnostic tables Reed Tachometer Description The reed tachometer consists of 2 rows of reeds arranged side by side Each reed is tuned to vibrate or resonate...

Page 95: ...Driveshaft Inclinometer Adapter J 35819 Flange Runout Gage Illustration Tool Number Description J 38792 A Electronic Vibration Analyzer 2 J 38792 VS Vibrate Software J 38792 20 20 Foot Timing Light Po...

Page 96: ...he system so it can calculate when the next oil change is required If a situation occurs where the oil is changed prior to a CHANGE ENGINE OIL SOON message being turned on reset the system 1 Press the...

Page 97: ...DTC P0111 P0112 or P0113 1A 70 DTC P0116 1A 72 DTC P0117 or P0118 1A 75 DTC P0119 1A 77 DTC P0121 P0122 P0123 P0221 P0222 or P0223 1A 79 DTC P0125 or P0128 1A 82 DTC P0131 or P0151 1A 84 DTC P0132 or...

Page 98: ...15 Specifications 1B 16 Fastener Tightening Specifications Engine Controls 3 6L LY7 1B 16 Special Tools and Equipment 1B 16 Special Tools Engine Controls 3 6L LY7 1B 16 Engine Electrical Devices 1C 1...

Page 99: ...is 1D 41 Vibration Analysis Engine 1D 42 Vibration Analysis Engine Accessory Isolation 1D 44 Vibration Analysis Engine Balance 1D 50 Engine Order Classification 1D 55 Repair Instructions 1D 58 Air Cle...

Page 100: ...uide Removal Upper Third Design 1D 145 Primary Camshaft Drive Chain Guide Removal Upper Fourth Design 1D 145 Primary Camshaft Drive Chain Guide Removal Lower Third Design 1D 146 Primary Camshaft Drive...

Page 101: ...uator Installation Right Side Exhaust Third Design 1D 274 Camshaft Position Actuator Installation Right Side Exhaust Fourth Design 1D 275 Camshaft Position Actuator Installation Left Side Intake Third...

Page 102: ...ssembly Replacement 1E 11 Oil Level Indicator and Tube Removal 1E 12 Oil Filter Adapter Removal 1E 13 Oil Pan Removal 1E 14 Oil Pump Removal 1E 15 Oil Pump Disassemble 1E 15 Oil Pump Cleaning and Insp...

Page 103: ...Diagnosis w Special Tool 1G 31 Repair Instructions 1G 32 Fuel Pressure Relief With J 34730 1A 1G 32 Fuel Pressure Relief Without J 34730 1A 1G 33 Fuel Pressure Gage Installation and Removal 1G 33 Met...

Page 104: ...ator Inoperative 1J 36 Generator Noise Diagnosis 1J 36 Engine Cranks Slowly 1J 38 Battery Inspection Test 1J 38 Battery Electrical Drain Parasitic Load Test 1J 41 Repair Instructions 1J 43 Battery Neg...

Page 105: ...ations 1K 32 Fastener Tightening Specifications Engine Mechanical 3 6L LY7 1K 32 Fastener Tightening Specifications Engine Exhaust 1K 32 Special Tools and Equipment 1K 32 Tools and Equipment 1K 32 Spe...

Page 106: ...7 9900 V 0 122 mv bit 05 02 Lean to Rich Sensor Threshold Voltage 0 0000 to 7 9900 V 0 122 mv bit 05 07 Minimum Sensor Voltage Achieved 0 0000 to 7 9900 V 0 122 mv bit 05 08 Maximum Sensor Voltage Ac...

Page 107: ...r 2 46 81 Sensor Element Impedance 0 to 65535 Ohms 1 Ohms bit Fuel System Monitor Bank 1 81 80 Additive Fuel Offset Correction 327 68 to 327 67 0 01 bit 81 82 Multiplicative Fuel Slope Correction 0 00...

Page 108: ...sfire counts for last 10 driving cycles calculated A4 0C Misfire counts for last current driving cycles calculated A5 0B EWMA Exponential Weighted Moving Average misfire counts for last 10 driving cyc...

Page 109: ...d component damage is identified as an OBD II circuit NOTE Twisted pair wires provide an effective shield that helps protect sensitive electronic components from electrical interference If the wires w...

Page 110: ...1A 5 Engine General Information and Diagnosis Module Power Ground and MIL...

Page 111: ...Engine General Information and Diagnosis 1A 6 5 Volt Reference...

Page 112: ...1A 7 Engine General Information and Diagnosis Low Reference...

Page 113: ...Engine General Information and Diagnosis 1A 8 Mass Air Flow and Engine Coolant Temperature Sensor...

Page 114: ...1A 9 Engine General Information and Diagnosis Camshaft Position Sensors and Actuators...

Page 115: ...Engine General Information and Diagnosis 1A 10 Heated Oxygen Sensors...

Page 116: ...1A 11 Engine General Information and Diagnosis Throttle Actuator Control and Accelerator Pedal Position Sensor...

Page 117: ...Engine General Information and Diagnosis 1A 12 Ignition Coils...

Page 118: ...1A 13 Engine General Information and Diagnosis Knock Sensors and Crank Sensor...

Page 119: ...Engine General Information and Diagnosis 1A 14 Fuel Injectors and Fuel Pump...

Page 120: ...1A 15 Engine General Information and Diagnosis Evaporative Emissions and Fuel Tank Pressure Sensor...

Page 121: ...Engine General Information and Diagnosis 1A 16 Controlled Monitored Systems...

Page 122: ...d 33 YE 5276 Camshaft Position Intake Sensor 2 34 D GN 5273 Camshaft Position Exhaust Sensor 1 35 YE 573 CKP Sensor 1 Signal 36 38 Not Used 39 GY 2701 5 Volt Reference 40 Not Used 41 TN 552 Low Refere...

Page 123: ...ion 16 Not Used 17 OG BK 1786 Park Neutral Signal 18 Not Used 19 WH 1310 EVAP Canister Vent Solenoid Control 20 OG WH 3223 Heated Oxygen Sensor Heater Low Control Bank 2 Sensor 2 21 Not Used 22 TN 276...

Page 124: ...PP Sensor 2 Signal C TN 1274 5 Volt Reference D BN 1271 Low Reference E D BU 1161 APP Sensor 1 Signal F WH BK 1164 5 Volt Reference Connector Part Information OEM 7283 7526 30 Service 88988588 Descrip...

Page 125: ...Fused Supply 4 2 WH BK 5283 Camshaft Phaser Exhaust Solenoid 2 Connector Part Information OEM 7283 7526 30 Service 88988588 Description 2 Way F BK Terminal Part Information Terminal Tray 7116 4026 11...

Page 126: ...amshaft Position Intake Sensor 1 3 GY 705 5 Volt Reference Connector Part Information OEM 1928403968 Service 88988595 Description 3 Way F Kompakt 2 8 Series Sealed BK Terminal Part Information Termina...

Page 127: ...Function 1 TN 452 Low Reference 2 YE 573 CKP Sensor 1 Signal 3 GY 605 5 Volt Reference Connector Part Information OEM 1928403874 Service 88988963 Description 2 Way F Kompakt 2 8 Series Sealed BK Term...

Page 128: ...ay See Terminal Repair Kit Core Insulation Crimp See Terminal Repair Kit Release Tool Test Probe See Terminal Repair Kit Pin Wire Color Circuit No Function A PK 1310 EVAP Canister Vent Solenoid Contro...

Page 129: ...sulation Crimp See Terminal Repair Kit Release Tool Test Probe See Terminal Repair Kit Pin Wire Color Circuit No Function A WH 5292 Ignition 1 Voltage B L BU BK 844 Fuel Injector 4 Control Connector P...

Page 130: ...PU 30 Fuel Level Sensor Signal F BK 850 Ground Connector Part Information OEM 12059595 Service 88986451 Description 3 Way F Metri Pack 150 Series Sealed BK Terminal Part Information Terminal Tray See...

Page 131: ...Sensor 1 Connector Part Information OEM 12160482 Service 88988598 Description 4 Way F Metri Pack 150 Series Sealed BK Terminal Part Information Terminal Tray 12048074 2 Core Insulation Crimp E 1 Rele...

Page 132: ...ervice 88988737 Description 4 Way F Global Terminal 150 BK Terminal Part Information Pins A D B C Terminal Tray 12191819 8 Core Insulation Crimp Pins A D 2 A Core Insulation Crimp Pins B C E A Release...

Page 133: ...Global Terminal 150 BK Terminal Part Information Pins A D B C Terminal Tray 12191819 8 Core Insulation Crimp Pins A D 2 A Core Insulation Crimp Pins B C E A Release Tool Test Probe 15315247 J 35616 2...

Page 134: ...Signal 2 GY 2303 KS 2 Signal Connector Part Information OEM 13520906 Service 19151493 Description 5 Way F GT 150 Sealed BK Terminal Part Information Pins A B D E C Terminal Tray 12191819 8 Core Insul...

Page 135: ...ngine General Information and Diagnosis 1A 30 Component Location Engine Controls Component Views Near the Air Cleaner 1 Mass Air Flow MAF Intake Air Temperature IAT Sensor 3 Air Cleaner Assembly 2 Cow...

Page 136: ...1A 31 Engine General Information and Diagnosis Above the Battery 1 Fuse Block Underhood 3 Engine Control Module ECM 2 LF Strut Tower...

Page 137: ...Diagnosis 1A 32 Front of the Engine 1 Throttle Actuator Control TAC Module 5 Engine Coolant Temperature ECT Sensor 2 Ignition Coil 2 6 Starter 3 Ignition Coil 4 7 Knock Sensor KS 2 4 Ignition Coil 6 8...

Page 138: ...sor Intake Bank 1 4 Ignition Coil 6 14 Camshaft Position CMP Actuator Solenoid Intake Bank 1 5 Fuel Injector 4 15 Camshaft Position CMP Actuator Solenoid Exhaust Bank 1 6 Ignition Coil 4 16 Camshaft P...

Page 139: ...iagnosis 1A 34 Rear if the Engine 1 Evaporative Emissions EVAP Canister Purge Solenoid 5 Knock Sensor KS 1 2 Throttle Actuator Control TAC Module 6 Crankshaft Position CKP Sensor 3 Ignition Coil 3 7 I...

Page 140: ...l Information and Diagnosis Oxygen Sensors 1 Heated Oxygen Sensor HO2S Bank 1 Sensor 1 3 Heated Oxygen Sensor HO2S Bank 2 Sensor 2 2 Heated Oxygen Sensor HO2S Bank 2 Sensor 1 4 Heated Oxygen Sensor HO...

Page 141: ...Engine General Information and Diagnosis 1A 36 Pedal Assemblies 1 Brake Pedal Position Sensor 2 Accelerator Pedal Position APP Sensor...

Page 142: ...l Information and Diagnosis Near the Rear Differential 1 Rear Differential Clutch Control Module 4 Fuel Sending Unit 2 Fuel Tank 5 Fuel Tank Pressure FTP Sensor 3 Evaporative Emissions EVAP Canister V...

Page 143: ...Actuator System This function controls the selected camshaft actuator solenoid The normal commanded state is NONE The system will increase or decrease the angle of the selected camshaft in 5 degree i...

Page 144: ...g this output control This function activates both the EVAP purge solenoid valve and EVAP vent solenoid to seal the EVAP system When activated the purge valve is commanded to 0 percent and the vent va...

Page 145: ...RC solenoid The normal commanded state is NONE When commanded ON OFF the ECM turns the IMRC solenoid ON OFF The scan tool initiates the test when the following conditions are met There are no vehicle...

Page 146: ...nly the parameters listed below are referenced in this service information for use in diagnosis If all values are within the typical range described below refer to Symptoms Engine Controls for diagnos...

Page 147: ...RO CMP Eng EVAP FT HO2S Ign IM IND Trans 65 104 kPa 8 16 psi Varies with altitude BARO IND Volts Varies Brake Pedal Signal Status CT Eng ET TAC Trans Valid Invalid Valid Calculated ECT Closed Loop Fue...

Page 148: ...rature Calculated CH CMP IPC C F Varies Engine Run Time Eng Ign EVAP FT HO2S IM MF TAC CMP CH CT IND Trans 0 00 00 Varies Engine Speed CH CMP CT Eng ET EVAP FF FR FT HO2S Ign IND IPC MF TAC Trans RPM...

Page 149: ...1 or 2 Circuit Status H02S OK Fault Indeterminate OK HO2S Bank 1 or 2 Sensor 1 or 2 Heater Command HO2S 0 99 Varies HO2S Bank 1 or 2 Sensor 1 or 2 Heater Command HO2S ON OFF ON HO2S O2S Monitor Comple...

Page 150: ...e MIL Requested FF FR km miles Varies Misfire Current Cyl 1 6 MF 0 255 Counts 0 Misfire History Cyl 1 6 MF 0 65 535 Counts 0 Moderate Brake Apply Signal CT TAC Applied Released Released PNP Switch Eng...

Page 151: ...TAC 0 5 Volts 5 0 1 0 Volts TP Sensors 1 and 2 TAC Agree Disagree Agree Traction Control Status TAC CT Active Inactive Inactive Vehicle Speed Sensor All Km h mph Varies Volumetric Efficiency Eng Ign...

Page 152: ...te Short Gnd Open Short to B OK OK Ignition 1 Signal Electrical Theft Data Volts Varies PNP Switch Electrical Theft Data Park Neutral In Gear Park Starter Relay Command Electrical Theft Data On Off Of...

Page 153: ...will display a range of values indicating a high air flow when MAP pressure is high and a low air flow when MAP pressure is low This value is listed in grams per second g s Air Fuel Ratio This parame...

Page 154: ...ill display OK if the circuit is operating correctly The scan tool will display Short or Open if there is an open short to ground or a short to voltage on the circuit Cylinder 1 6 Injector Circuit Sta...

Page 155: ...eter displays Indeterminate until the circuit has been commanded ON This parameter may not change if the scan tool is used to command the EVAP vent solenoid ON EVAP Vent Solenoid Command This paramete...

Page 156: ...Sensor 1 or 2 by the control module The scan tool will display a higher value as the heater command is increased and a lower value if the heater is not commanded ON HO2S Bank 1 or 2 Sensor 1 or 2 Hea...

Page 157: ...too rich and fuel is being removed from the combustion event The scan tool will display a positive value if the fuel system is running lean and fuel is being added to the combustion event Loop Status...

Page 158: ...f the scan tool is used to command the relay control circuit ON Starter Relay Command This parameter indicates whether the control module is commanding the starter relay to go on or off Start Up ECT T...

Page 159: ...e vehicle as calculated by the transmission control module TCM from information received from the vehicle speed sensor VSS Volumetric Efficiency This parameter displays the calculated volumetric effic...

Page 160: ...rol module records the operating conditions at the time the diagnostic fails The first time the diagnostic fails the control module stores this information in the Failure Records If the diagnostic rep...

Page 161: ...exceeding a calibrated threshold in the same direction Conditions for Running the DTC DTCs P0010 P0011 P0013 P0014 P0020 P0021 P0023 P0024 P0341 P0342 P0343 P0346 P0347 P0348 P0366 P0367 P0368 P0391 P...

Page 162: ...haft and Bearings Cleaning and Inspection DTC P0010 P0013 P0020 P0023 P2088 P2089 P2090 P2091 P2092 P2093 P2094 or P2095 Diagnostic Instructions Perform the Diagnostic System Check Vehicle Diagnostic...

Page 163: ...when the solenoid is commanded OFF P2089 P2091 P2093 P2095 The ECM detects a short to voltage in the CMP actuator solenoid circuits for more than 4 seconds or a cumulative of 50 seconds when the sole...

Page 164: ...sition Actuator Solenoid Valve Solenoid Replacement Bank 2 Left Side Intake Camshaft Position Actuator Solenoid Valve Solenoid Replacement Bank 2 Left Side Exhaust Control Module References for engine...

Page 165: ...mshaft actuator or timing chain can cause this DTC to set Circuit System Verification NOTE The engine oil level and the oil pressure are critical to the correct operation of the camshaft position CMP...

Page 166: ...esistance is not within the specified range replace the CMP actuator solenoid 2 Test for infinite resistance between each terminal of the CMP actuator solenoid and the CMP actuator solenoid housing If...

Page 167: ...e crankshaft The ECM detects the difference between an actual intake camshaft angle and the locked position angle is more than 20 degrees The ECM detects the difference between an actual exhaust camsh...

Page 168: ...g and Inspection Third Design Camshaft Timing Drive Components Cleaning and Inspection Fourth Design Crankshaft and Bearings Cleaning and Inspection DTC P0030 P0031 P0032 P0036 P0037 P0038 P0050 P0051...

Page 169: ...0 5 18 volts The engine speed is more than 80 RPM The HO2S heater is commanded ON and OFF at least once during the ignition cycle The secondary HO2S is at operating temperature The DTCs run continuous...

Page 170: ...test all the components connected to the ignition circuit and replace as necessary 3 Connect a test lamp between the heater control circuit terminal D and B The test lamp should not illuminate If the...

Page 171: ...rrent is required in order to maintain the hot film at a constant temperature The engine control module ECM uses the MAF sensor in order to provide the correct fuel delivery for all operating conditio...

Page 172: ...within the conditions for running the DTC You may also operate the vehicle within the conditions that are captured in the Freeze Frame Failure Records Data List Circuit System Testing 1 Ignition OFF...

Page 173: ...176 is not set The engine is operating for more than 1 second The MAF sensor signal is more than 1 39 grams per second The ignition voltage is more than 10 5 volts The engine coolant temperature ECT i...

Page 174: ...late or for carbon build up around the throttle plate An unseated engine oil dip stick A loose or missing engine oil fill cap An over filled crankcase If you find any of the above conditions repair as...

Page 175: ...et The engine coolant temperature ECT at engine start is less than 85 C 185 F The ECT is more than 66 C 151 F The vehicle speed is less than 10 km h 6 mph DTC P0111 runs continuously once the above co...

Page 176: ...s probing the underhood fuse block terminals component wire harness terminals or the ECM wire harness connector terminals Reference Information Schematic Reference Engine Controls Schematics Connector...

Page 177: ...in 5 percent of the specification If the Resistance vs Temperature is not within 5 percent replace the IAT sensor Repair Instructions Perform the Diagnostic Repair Verification Vehicle Diagnostic Info...

Page 178: ...the previous engine shut down is more than 75 C 167 F The block heater is not detected The ignition was OFF for greater than 330 minutes after the previous engine shut down DTC P0116 runs once an ign...

Page 179: ...rcuit Damage to the control module may occur due to excessive current draw NOTE The control module or the sensor may be damaged if the circuit is shorted to battery positive voltage 4 Test for less th...

Page 180: ...tion is met Conditions for Setting the DTC P0117 The ECM detects that the ECT is more than 140 C 284 F for more than 4 seconds or a cumulative of 50 seconds P0118 The ECM detects that the ECT is less...

Page 181: ...he low reference circuit for a short to B If the circuit tests normal replace the ECM 4 Ignition OFF remove the fuse that supplies B to circuit terminal C2 56 of the ECM 5 Test for less than 5 ohms be...

Page 182: ...or an accumulation of 50 seconds over time Action Taken When the DTC Sets DTC P0119 is a Type B DTC Conditions for Clearing the MIL DTC DTC P0119 is a Type B DTC Diagnostic Aids Test the ECT sensor at...

Page 183: ...or may be damaged if the circuit is shorted to B 3 Test for less than 1 volt between the low reference circuit terminal 2 and ground If greater than the specified value test the low reference circuit...

Page 184: ...Sensor 2 Circuit High Voltage Diagnostic Fault Information Typical Scan Tool Data TP Sensor Circuit Short to Ground Open High Resistance Short to Voltage Signal Performance 5 Volt Reference P0122 P02...

Page 185: ...om the predicted value for greater than 0 24 second P0122 The ECM detects the TP sensor 1 signal voltage is less than 0 18 volt for greater than 0 14 second P0123 The ECM detects the TP sensor 1 signa...

Page 186: ...DTCs may be set If other DTCs are set review the electrical schematic and diagnose the applicable circuits and components If less than the specified range test the 5 volt reference circuit for a short...

Page 187: ...960 RPM The ECT is less than 71 C 160 F at start up The calculated ambient air temperature is more than 11 C 12 F and less than 70 C 158 F The vehicle speed is more than 15 km h 9 mph The air flow co...

Page 188: ...esistance If the circuit tests normal replace the ECM 3 Ignition ON using a scan tool verify that the ECT sensor parameter is at 40 C 40 F If greater than 40 C 40 F test the signal circuit for a short...

Page 189: ...above bias voltage toward 1 000 mV indicates a rich fuel mixture An HO2S voltage that decreases below bias voltage toward 0 mV indicates a lean fuel mixture The heating elements inside each HO2S heat...

Page 190: ...2 Ignition ON verify that the HO2S voltage parameter is between 350 500 mV If less than the specified value test the signal circuit for a short to ground If the circuit connections test normal replace...

Page 191: ...tage to determine the air to fuel ratio An HO2S voltage that increases above bias voltage toward 1 000 mV indicates a rich fuel mixture An HO2S voltage that decreases below bias voltage toward 0 mV in...

Page 192: ...value test the signal circuit for a short to ground If the circuit connections test normal replace the ECM If greater than the specified value test the signal circuit for a short to voltage If the ci...

Page 193: ...that increases above bias voltage toward 1 000 mV indicates a rich fuel mixture An HO2S voltage that decreases below bias voltage toward 0 mV indicates a lean fuel mixture The heating elements inside...

Page 194: ...below the range of 350 550 mV 3 Operate the vehicle within the conditions for running the DTC DTCs P0133 and P0153 should not set 4 If the vehicle passes the Circuit System Verification test then oper...

Page 195: ...eases above bias voltage toward 1 000 mV indicates a rich fuel mixture An HO2S voltage that decreases below bias voltage toward 0 mV indicates a lean fuel mixture The heating elements inside each HO2S...

Page 196: ...the vehicle within the conditions that are captured in the Freeze Frame Failure Records Data List Circuit System Testing 1 Ignition OFF disconnect the harness connector at the appropriate HO2S 2 Igni...

Page 197: ...nt setup and programming DTC P0135 P0141 P0155 or P0161 Diagnostic Instructions Perform the Diagnostic System Check Vehicle Diagnostic Information prior to using this diagnostic procedure Review Strat...

Page 198: ...F The engine is not in decel fuel cut off DFCO The HO2S is at operating temperature for greater than 10 seconds The internal HO2S resistance is less than 10 000 ohms DTCs P0135 and P0155 run continuou...

Page 199: ...l replace the ECM 4 Idle the engine and verify the test lamp illuminates or flashes with bright intensity If the test lamp is always OFF test the control circuit for an open high resistance If the cir...

Page 200: ...rol module Closed Loop is entered The control module uses the HO2S voltage to determine the air to fuel ratio An HO2S voltage that increases above bias voltage toward 1 000 mV indicates a rich fuel mi...

Page 201: ...ols 3 6L LY7 Scan Tool Output Controls Engine Controls 3 6L LY7 Circuit System Verification 1 With the engine running observe the heated oxygen sensor HO2S voltage parameter The reading should fluctua...

Page 202: ...TC P0202 Injector 2 Control Circuit DTC P0203 Injector 3 Control Circuit DTC P0204 Injector 4 Control Circuit DTC P0205 Injector 5 Control Circuit DTC P0206 Injector 6 Control Circuit DTC P0261 Inject...

Page 203: ...n intermittent condition Refer to Fuel Injector Solenoid Coil Test If the condition is intermittent move the related harnesses and connectors with the engine operating while monitoring the circuit sta...

Page 204: ...DMM should display OL If less than OL repair the short to ground in the fuel injector control circuit 12 Test for continuity between the suspected fuel injector control circuit and all the other cont...

Page 205: ...to cause emissions levels to exceed mandated standards for more than 4 seconds or for a cumulative of 50 seconds Action Taken When the DTC Sets DTCs P0300 P0301 P0302 P0303 P0304 P0305 and P0306 are...

Page 206: ...nd any of the above conditions repair as necessary 4 Remove the fuel pump fuse from the fuse block 5 Install the J 26792 to the boot of the ignition coil and ground NOTE An erratic or weak spark is co...

Page 207: ...pplied If the ECM detects an output response this DTC sets Test Three The ECM internally turns OFF the knock sensor signal circuits The ECM generates an internal test pulse and monitors the return sig...

Page 208: ...ne noise Conditions for Running the DTCs P0326 and P0331 Before the ECM can report DTC P0326 or P0331 failed DTCs P0324 P0335 P0336 and P0338 must run and pass DTCs P0341 P0342 P0343 P0346 P0347 P0348...

Page 209: ...es the Circuit System Verification test then operate the vehicle within the conditions for running the DTC You may also operate the vehicle within the conditions that are captured in the Freeze Frame...

Page 210: ...s run continuously once the above conditions are met for more than 5 seconds Conditions for Setting the DTC P0335 The ECM does not detect a signal from the CKP sensor OR The ECM detects a CKP signal w...

Page 211: ...s of the CKP sensor and verify the engine does not stumble stall or change engine speed 4 If the vehicle passes the Circuit System Verification test then operate the vehicle within the conditions for...

Page 212: ...reluctor wheels are mounted to the camshaft position actuators that are mounted to the end of the camshafts The ECM uses the CMP sensor signals in order to determine the position of the camshafts The...

Page 213: ...652 or P0653 should not be set If a DTC is set refer to DTC P0652 or P0653 2 Engine idling observe the DTC information with a scan tool DTCs P0341 P0342 P0343 P0346 P0347 P0348 P0366 P0367 P0368 P0391...

Page 214: ...t HO2S To determine OSC the ECM commands a rich air fuel mixture until all oxygen is removed from the catalyst The ECM then commands a lean air fuel mixture and monitors the rear heated oxygen sensors...

Page 215: ...Controls 3 6L LY7 Circuit System Testing 1 Verify there are no HO2S or misfire DTCs set If there is an HO2S or misfire DTC set refer to Diagnostic Trouble Code DTC List Vehicle Diagnostic Information...

Page 216: ...32 C 35 90 F at start up The engine coolant temperature ECT is less than 42 C 108 F at start up The ECT and the IAT are within 10 C 18 F of each other at engine start up The barometric pressure BARO i...

Page 217: ...veral minutes for the floating indicator to stabilize 5 Activate the J 41413 200 and compare the flow meter s stable floating indicator position to the red flag The floating indicator should be below...

Page 218: ...for an overview of the diagnostic approach The Diagnostic Procedure Instructions Vehicle Diagnostic Information provide an overview of each diagnostic category DTC Descriptors DTC P0443 Evaporative E...

Page 219: ...ON command the EVAP purge solenoid to 50 with a scan tool You should hear an audible click 2 If the vehicle passes the Circuit System Verification test then operate the vehicle within the conditions f...

Page 220: ...ates the relationship between the ON and OFF states and the OPEN or CLOSED states of the EVAP canister purge and vent valves Conditions for Running the DTC Before the ECM can report DTC P0446 failed D...

Page 221: ...fuel fill cap and connect the GE 41415 50 to the fuel tank filler neck Connect the J 41413 200 to the GE 41415 50 6 Ignition ON seal the EVAP system with a scan tool 7 Turn the nitrogen smoke valve o...

Page 222: ...ge by monitoring the feedback voltage Conditions for Running the DTC Before the ECM can report DTC P0449 P0498 or P0499 failed DTC P0451 must run and pass The engine speed is more than 80 RPM The igni...

Page 223: ...minate test the ignition voltage circuit for a short to ground or an open high resistance If the circuit tests normal and the ignition voltage circuit fuse is open test all components connected to the...

Page 224: ...P0498 P0506 P0507 P0721 P0722 P2227 P2228 and P2229 are not set The engine is operating for greater than 1 second The ambient air temperature is greater than 7 C 19 F The vehicle speed is between 10...

Page 225: ...AP system with nitrogen to 5 inches H20 Compare the Fuel Tank Pressure Sensor parameter to the J 41413 200 pressure vacuum gage The FTP sensor should be within 1 inch H20 of the pressure vacuum gage I...

Page 226: ...rcuit is shorted to ground or shorted to a voltage other 5 volt reference circuits may be affected Reference Information Schematic Reference Engine Controls Schematics Connector End View Reference Eng...

Page 227: ...cement AWD 9 Disconnect the FTP sensor connector 10 Inspect the FTP sensor circuits in the fuel tank harness between the FTP sensor connector and C 406 for the following conditions and repair as neces...

Page 228: ...missing or damaged fuel fill cap can cause this DTC to set A blockage or restriction in the EVAP purge solenoid purge pipe EVAP canister or vapor pipe can cause this DTC to set A temporary blockage i...

Page 229: ...e within the conditions for running the DTC You may also operate the vehicle within the conditions that are captured in the Freeze Frame Failure Records List Circuit System Testing Leak Testing NOTE Y...

Page 230: ...e vacuum source from the EVAP purge solenoid b EVAP purge pipe from the EVAP purge solenoid c EVAP purge pipe at the EVAP canister d EVAP vapor pipe at the EVAP canister 5 If you cannot locate a condi...

Page 231: ...more than 4 seconds or for a cumulative of 50 seconds Action Taken When the DTC Sets DTC P0496 is a Type A B DTC Conditions for Clearing the DTC DTC P0496 is a Type A B DTC Diagnostic Aids Observe the...

Page 232: ...ose the throttle valve in order to maintain the desired idle speed If the ECM detects the actual idle speed and the desired idle speed are not within a predetermined amount this DTC sets Conditions fo...

Page 233: ...ngine operating command the engine speed up to 1 400 RPM down to 600 RPM up to 1 400 RPM and then exit using the scan tool The engine speed should steadily increase and decrease as commanded If the id...

Page 234: ...istance If the circuits test normal replace the ECM 2 Go to Charging System Test Repair Instructions Perform the Diagnostic Repair Verification Vehicle Diagnostic Information after completing the diag...

Page 235: ...ECM replacement setup and programming DTC P0563 Diagnostic Instructions Perform the Diagnostic System Check Vehicle Diagnostic Information prior to using this diagnostic procedure Review Strategy Bas...

Page 236: ...egory DTC Descriptors DTC P0601 Control Module Read Only Memory ROM DTC P0602 Control Module Not Programmed DTC P0603 Control Module Long Term Memory Reset DTC P0604 Control Module Random Access Memor...

Page 237: ...tions that you observed in the Freeze Frame Failure Records data Repair Instructions Perform the Diagnostic Repair Verification Vehicle Diagnostic Information after completing the diagnostic procedure...

Page 238: ...ol circuit is commanded OFF The condition exists for a cumulative of 50 seconds P0629 The ECM detects the fuel pump relay control circuit voltage is greater than 2 74 volts when the control circuit is...

Page 239: ...wing terminals of the fuel pump relay 3 and 2 3 and 5 3 and 1 1 and 5 If continuity is detected replace the fuel pump relay 3 Connect a 15 amp fused jumper wire from the positive terminal of the batte...

Page 240: ...OR The ECM detects that the commanded duty cycle for the range test low is more than 80 percent for more than 5 seconds P2100 The ECM detects the output circuit for the TAC motor is open shorted to gr...

Page 241: ...causes additional DTCs to set 2 Ignition OFF disconnect the harness connector of the throttle body Ignition ON test for 4 0 4 1 volts between the TAC motor control 1 circuit terminal B and ground If...

Page 242: ...ication 1 Ignition ON observe the DTC information with a scan tool DTCs P0642 and P0643 should not set 2 If the vehicle passes the Circuit System Verification test operate the vehicle within the condi...

Page 243: ...Conditions for Setting the DTC The ECM detects an open a short to ground or a short to voltage on the circuit that controls the MIL The condition exists for at least 4 seconds Action Taken When the DT...

Page 244: ...ach reference circuit provides a 5 volt reference for more than one sensor A short to ground or voltage on one of the 5 volt reference circuits will affect all components connected to that 5 volt refe...

Page 245: ...c Repair Verification Vehicle Diagnostic Information after completing the diagnostic procedure Camshaft Position Sensor Replacement Bank 2 Left Side Exhaust Camshaft Position Sensor Replacement Bank 2...

Page 246: ...for a cumulative of 50 seconds Action Taken When the DTC Sets DTCs P0685 P0686 P0687 P0689 and P0690 are Type C DTCs Conditions for Clearing the MIL DTC DTCs P0685 P0686 P0687 P0689 and P0690 are Typ...

Page 247: ...ections test normal replace the ECM NOTE The ignition voltage circuit is between the powertrain relay and the ECM The ignition voltage is a feedback circuit 8 Connect a 15A fused jumper wire between t...

Page 248: ...A C pressure sensor Reference Information Schematic Reference Engine Controls Schematics Connector End View Reference Engine Control Module Connector End Views Engine Controls Connector End Views Ele...

Page 249: ...l data circuit requesting MIL illumination The DTC information for the ECM will only display DTC P0700 but the freeze frame failure records data will display the transmission DTC that set Conditions f...

Page 250: ...ostic procedure Review Strategy Based Diagnosis for an overview of the diagnostic approach Diagnostic Procedure Instructions Vehicle Diagnostic Information provides an overview of each diagnostic cate...

Page 251: ...rmation with a scan tool DTCs P1011 P1012 P1013 and P1014 should not set If the vehicle passes the Circuit System Verification test then operate the vehicle within the conditions for running the DTC Y...

Page 252: ...ification Vehicle Diagnostic Information after completing the diagnostic procedure Control Module References for engine control module replacement setup and programming DTC P1551 Diagnostic Instructio...

Page 253: ...ormation Reference Circuit Testing Connector Repairs Testing for Intermittent Conditions and Poor Connections Wiring Repairs DTC Type Reference Powertrain Diagnostic Trouble Code DTC Type Definitions...

Page 254: ...seconds or for a cumulative of 50 seconds Action Taken When the DTC Sets DTC P167D is a Type B DTC Conditions for Clearing the DTC DTC P167D is a Type B DTC Diagnostic Aids If the condition is interm...

Page 255: ...determine the air to fuel ratio An HO2S voltage that increases above bias voltage toward 1 000 mV indicates a rich fuel mixture An HO2S voltage that decreases below bias voltage toward 0 mV indicates...

Page 256: ...Data List Engine Controls 3 6L LY7 Scan Tool Data Definitions Engine Controls 3 6L LY7 Scan Tool Output Controls Engine Controls 3 6L LY7 Circuit System Verification 1 Observe the HO2S voltage parame...

Page 257: ...o determine the air to fuel ratio An HO2S voltage that increases above bias voltage toward 1 000 mV indicates a rich fuel mixture An HO2S voltage that decreases below bias voltage toward 0 mV indicate...

Page 258: ...Controls 3 6L LY7 Scan Tool Data Definitions Engine Controls 3 6L LY7 Scan Tool Output Controls Engine Controls 3 6L LY7 Circuit System Verification 1 Observe the HO2S voltage parameter with the engin...

Page 259: ...P2105 is a Type A DTC Conditions for Clearing the DTC DTC P2105 is a Type A DTC Diagnostic Aids If DTC P2105 sets the engine will stall and not restart until the ignition is cycled OFF and then ON Add...

Page 260: ...control motor The ECM monitors the actual throttle valve position using throttle position TP sensor 1 and 2 The ECM amplifies the TP sensor 1 signal in order to obtain a more accurate signal The ECM m...

Page 261: ...Performance Accelerator Pedal Position APP Sensor 1 5 Volt Reference Circuit P0343 P0348 P0368 P0393 P0652 P2122 P2122 P2138 P2122 P0653 P2138 P2123 P0652 P0653 P2138 Accelerator Pedal Position APP S...

Page 262: ...e DTC Sets DTCs P2122 P2123 P2127 P2128 and P2138 are Type A DTCs Conditions for Clearing the DTC DTCs P2122 P2123 P2127 P2128 and P2138 are Type A DTCs Diagnostic Aids Test the current out put of the...

Page 263: ...nsor voltage parameters display greater than 4 8 volts test the signal circuits of the APP sensors for a shorted together condition If the circuit connections test normal replace the ECM 8 If all circ...

Page 264: ...t DTC P2177 P2179 P2187 or P2189 Diagnostic Instructions Perform the Diagnostic System Check Vehicle Diagnostic Information prior to using this diagnostic procedure Review Strategy Based Diagnosis for...

Page 265: ...n 7 000 grams DTC P2187 and P2189 run continuously once the above conditions are met Conditions for Setting the DTC P2177 or P2179 The Total Fuel Trim Avg is more than 23 percent for 4 seconds or for...

Page 266: ...ontaminants in Fuel Diagnosis w Special Tool Splits kinks or improper connections at the vacuum hoses Refer to Emission Hose Routing Diagram The fuel system is operating lean Refer to Fuel System Diag...

Page 267: ...P2095 must run and pass The engine speed is between 1 200 3 400 RPM The mass air flow MAF is less than 83 grams second The throttle angle is less than 100 percent The engine load is between 17 45 perc...

Page 268: ...Avg should be between 22 to 23 percent Circuit System Testing 1 Observe the LT FT Bn 1 and Bn 2 Cruise Accel or Idle Decel parameters in order to determine whether the rich condition is effecting onl...

Page 269: ...e MAP and BARO pressure is less than 1 0 kPa for more than 3 seconds The evaporative emission EVAP leak test is not enabled DTC P2227 runs continuously once the above conditions are met for 2 seconds...

Page 270: ...he low reference circuit The HO2S varies the voltage over a range from about 1 000 mV when the exhaust is rich down through about 10 mV when the exhaust is lean The ECM monitors and stores the HO2S vo...

Page 271: ...S voltage parameter The HO2S voltage parameter should be less than 1 025 mV 2 If the vehicle passes the Circuit System Verification Test then operate the vehicle within the conditions for running the...

Page 272: ...oltage is between 350 550 mV after disconnecting the sensor the condition is with the HO2S Inspect the HO2S harness connector for water intrusion Moisture in a connector may cause voltage to bleed to...

Page 273: ...predetermined threshold during power enrichment Conditions for Running the DTC Before the ECM can report DTC P2270 or P2272 failed DTCs P0036 P0037 P0038 P0056 P0057 P0058 P0137 P0138 P0140 P0141 P01...

Page 274: ...If the HO2S parameter does change abruptly while moving the related harnesses repair the circuit as necessary 2 Ignition OFF disconnect the harness connector of the appropriate HO2S 3 Ignition ON ver...

Page 275: ...orced below the threshold within a certain amount of time The ECM monitors the HO2S voltage during fuel cut off to determine if the signal voltage is more than a predetermined threshold Conditions for...

Page 276: ...ctor and the engine control module ECM while monitoring the appropriate HO2S voltage parameter Verify that the HO2S parameter does not change abruptly while moving the related harnesses If the HO2S pa...

Page 277: ...lied to each bank of ignition coils The engine control module ECM controls the ignition system operation The ECM controls each coil using the IC circuits The ECM commands the IC circuit low when a spa...

Page 278: ...in the Freeze Frame Failure Records List Circuit System Testing 1 Ignition OFF disconnect the harness connector at the appropriate ignition coil NOTE The ignition circuit supplies voltage to other com...

Page 279: ...ore than 4 minutes Conditions for Setting the DTC The ECM detects that the right side fuel level is less than 11 percent and the left side fuel level is more than 23 percent The above condition is pre...

Page 280: ...s Diagnostic Instructions Perform the Diagnostic System Check Vehicle Diagnostic Information prior to using this diagnostic procedure Review Strategy Based Diagnosis for an overview of the diagnostic...

Page 281: ...Tester Refer to Electronic Ignition EI System Diagnosis The operation of the transmission torque converter clutch TCC The scan tool should indicate an engine speed drop when the TCC is commanded ON Th...

Page 282: ...turned ON Refer to Fuel Pump Electrical Circuit Diagnosis Hesitation Sag Stumble Test the fuel pressure Refer to Fuel System Diagnosis Test the generator Refer to Symptoms Engine Electrical Repair th...

Page 283: ...n the ignition system components and the wiring in order to check for an engine starting or will not stay running concern Reference Information Schematic Reference Engine Controls Schematics Connector...

Page 284: ...ation provide an overview of each diagnostic category Description Several states require that a vehicle pass on board diagnostic OBD system tests and the inspection maintenance I M emission inspection...

Page 285: ...resent for a DTC associated with one of the I M regulated systems it may prevent other required tests from running For example a DTC for the control circuit of the EVAP purge solenoid may not be liste...

Page 286: ...trical loads including aftermarket add on equipment etc and open the hood 3 Set the vehicle parking brake and ensure the vehicle is in park for automatic transmission or neutral for manual transmissio...

Page 287: ...rm the idle learn procedure with a DTC set 1 Turn OFF the ignition for 30 seconds 2 Turn ON the ignition with the engine OFF for 60 seconds 3 Turn OFF the ignition 4 Turn ON the ignition with the engi...

Page 288: ...ms Resistance Maximum Ohms Intake Air Temperature IAT Sensor 40 40 35 140 43 760 20 4 12 660 15 120 10 14 7 943 9 307 0 32 5 119 5 892 20 68 2 290 2 551 25 77 1 900 2 100 40 104 1 096 1 238 60 140 565...

Page 289: ...iption CH 48096 EVAP Service Access Port Tool GE 41415 50 Interrupted Thread Fuel Tank Cap Adapter J 26792 HEI Spark Tester J 34730 1A Fuel Pressure Gage J 34730 405 Injector Test Lamp J 35616 GM Appr...

Page 290: ...1A 185 Engine General Information and Diagnosis J 41413 300 EVAP Cap and Plug Kit J 41413 SPT High Intensity White Light J 41413 VLV EVAP Service Port Vent Fitting Illustration Tool Number Description...

Page 291: ...nk pressure FTP sensor voltage to verify that the system is able to reach a predetermined level of vacuum within a set amount of time The control module then commands the EVAP purge valve OFF closed s...

Page 292: ...rflow into the EVAP canister The valve is normally open The control module will command the valve closed during some EVAP tests allowing the system to be tested for leaks Fuel Tank Pressure Sensor The...

Page 293: ...ssion Control Devices 1B 3 Schematic and Routing Diagram Emission Hose Routing Diagram 1 Evaporative Emission Purge Line 2 PCV Hose to Intake Manifold 3 Brake Booster Vacuum Hose 4 Crank Case Fresh Ai...

Page 294: ...Recirculation Pipe 2 Fuel Feed Pipe 8 Primary Fuel Tank Module and Fuel Limiter Vent Valve FLVV 3 Evaporative Emissions EVAP Canister Purge Pipe 9 EVAP Canister Vapor Recirculation Pipe 4 EVAP Caniste...

Page 295: ...ge solenoid Refer to Plastic Collar Quick Connect Fitting Service 4 Disconnect the EVAP pipe quick connect fitting 2 from the EVAP purge solenoid Refer to Plastic Collar Quick Connect Fitting Service...

Page 296: ...e EVAP purge solenoid 6 Install the fuel injector sight shield Refer to Fuel Injector Sight Shield Replacement Evaporative Emission Canister Vent Solenoid Valve Replacement Removal Procedure 1 Remove...

Page 297: ...on 3 Install the EVAP canister Refer to Evaporative Emission Canister Replacement Evaporative Emission Canister Vent Hose Replacement Removal Procedure 1 Remove the fuel fill tube Refer to Filler Tube...

Page 298: ...ame type of line 1 Disconnect the negative battery cable Refer to Battery Negative Cable Disconnection and Connection 2 Disconnect the fuel feed pipe quick connect fitting 3 from the fuel rail Refer t...

Page 299: ...r brake line fitting from the rear brake hose 12 Remove the push pin 1 from the underbody side rail hole 13 With the aid of an assistant release the fuel EVAP brake pipe clips 2 from the underbody stu...

Page 300: ...EVAP brake pipe clips 2 to the underbody studs 3 Install the push pin 1 to the underbody side rail hole CAUTION Refer to Fastener Notice 4 Connect the right rear brake line fitting to the rear brake...

Page 301: ...3 to the fuel rail Refer to Metal Collar Quick Connect Fitting Service 13 Connect the EVAP pipe quick connect fitting 3 to the EVAP purge solenoid Refer to Plastic Collar Quick Connect Fitting Servic...

Page 302: ...disconnecting the fuel pipes to avoid contamination of the fuel system 2 Disconnect the EVAP canister fresh air hose pipe from the fuel tank fresh air hose pipe 2 Refer to Plastic Collar Quick Connec...

Page 303: ...l the EVAP canister to underbody nuts 3 Tightening torque Tighten the nuts to 9 N m 80 lb in 4 Connect the EVAP canister purge hose pipe 1 to the EVAP canister 5 Connect the EVAP canister vent hose pi...

Page 304: ...nister filter cover rear retaining tabs 4 Carefully release the canister filter cover forward retaining tabs and remove the cover from the EVAP canister 5 Discard the EVAP canister filter cover 6 Remo...

Page 305: ...ister purge valve and no carbon particles were detected replace the EVAP canister purge valve Return to the published service procedure Cleaning Procedure 1 Raise and support the vehicle Refer to Lift...

Page 306: ...ve Emission EVAP Purge Solenoid Bracket Bolt 10 N m 89 lb in Left Rear Brake Line Fitting to Brake Crossover Pipe 18 N m 13 lb ft Rear Brake Line to Rear Brake Hose Fitting 18 N m 13 lb ft Rear Brake...

Page 307: ...feat the oxygen sensor ground wire where applicable Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor Removal of the ground wire will cause...

Page 308: ...the amount of air flow This air temperature difference also allow for determination of whether the air is flowing in the forward or reverse directions As the air flow increases the delta temperature b...

Page 309: ...ve 7 is controlled by the ECM The crankshaft position CKP sensor and the CMP sensors are used to monitor changes in camshaft positions The ECM uses the following information in order to calculate the...

Page 310: ...ctions If a condition exists in either the intake or exhaust camshaft actuator system the opposite bank intake or exhaust camshaft actuator will default to 0 crankshaft degrees CMP Actuator System Ope...

Page 311: ...sh Malfunction Indicator Lamp MIL The malfunction indicator lamp MIL is inside of the instrument panel cluster IPC The MIL is controlled by the ECM and illuminates when the ECM detects a condition tha...

Page 312: ...agnosing the cause of an emission test failure This can often lead to repairing a condition without further steps Use the following guidelines when performing an inspection Inspect all of the vacuum h...

Page 313: ...following components The throttle position TP sensor 1 The TP sensor 2 The throttle actuator motor The throttle plate The engine control module ECM The ECM monitors the driver demand for acceleration...

Page 314: ...parameter should display 0 then count up to 11 after the procedure is completed If the counter did not start at 0 or if the counter did not end at 11 a fault has occurred and a DTC should set TAC Sys...

Page 315: ...engine wiring harness electrical connector 4 from the engine coolant temperature ECT sensor 2 Remove the ECT sensor Installation Procedure CAUTION Refer to Fastener Notice 1 Install the ECT sensor Ti...

Page 316: ...IAT sensor screws 4 Remove the MAF IAT sensor from the air cleaner assembly 5 Remove the MAF IAT sensor seal Installation Procedure 1 Install the MAF IAT sensor seal to the MAF IAT sensor 2 Install t...

Page 317: ...e Do not damage the sensor pigtail and harness wires in such a way that the wires inside are exposed This could provide a path for foreign materials to enter the sensor and cause performance problems...

Page 318: ...or 2 4 Install the HO2S electrical connector retainer to the camshaft cover 5 Install the fuel injector sight shield if necessary Refer to Fuel Injector Sight Shield Replacement Heated Oxygen Sensor R...

Page 319: ...damage due to water intrusion The engine harness may be repaired using Packard s Crimp and Splice Seals Terminal Repair Kit Under no circumstances should repairs be soldered since this could result in...

Page 320: ...ction of the air reference and degraded sensor performance The following guidelines should be used when servicing the heated oxygen sensor Do not apply contact cleaner or other materials to the sensor...

Page 321: ...or easier to remove New or service replacement sensors already have the compound applied to the threads If the sensor is removed from an exhaust component and if for any reason the sensor is to reinst...

Page 322: ...ls may get into the sensor causing poor performance Do not damage the sensor pigtail and harness wires in such a way that the wires inside are exposed This could provide a path for foreign materials t...

Page 323: ...he threads If the sensor is removed from an exhaust component and if for any reason the sensor is to reinstalled the threads must have anti seize compound applied before the reinstallation 1 If reinst...

Page 324: ...eign materials to enter the sensor and cause performance problems Neither the sensor nor vehicle lead wires should be bent sharply or kinked Sharp bends kinks etc could block the reference air path th...

Page 325: ...ent bolts into the APP assembly Tightening torque Tighten the bolts to 25 N m 18 lb ft 4 Connect the APP sensor harness connector Push the connector in until the lock position is felt then pull back t...

Page 326: ...rical connector 2 from the crankshaft position CKP sensor 4 Remove the crankshaft sensor bolt 5 Remove the crankshaft sensor Installation Procedure 1 Install the crankshaft position sensor CAUTION Ref...

Page 327: ...tor 1 from the bank 1 exhaust camshaft position CMP sensor 3 Remove the CMP sensor bolt 4 Remove the CMP sensor Installation Procedure 1 Install the CMP sensor CAUTION Refer to Fastener Notice 2 Insta...

Page 328: ...tor 2 from the bank 1 intake camshaft position CMP sensor 3 Remove the CMP sensor bolt 4 Remove the CMP sensor Installation Procedure 1 Install the CMP sensor CAUTION Refer to Fastener Notice 2 Instal...

Page 329: ...or 6 from the bank 2 exhaust camshaft position CMP sensor 3 Remove the CMP sensor bolt 4 Remove the CMP sensor Installation Procedure 1 Install the CMP sensor CAUTION Refer to Fastener Notice 2 Instal...

Page 330: ...tor 8 from the bank 2 intake camshaft position CMP sensor 3 Remove the CMP sensor bolt 4 Remove the CMP sensor Installation Procedure 1 Install the CMP sensor CAUTION Refer to Fastener Notice 2 Instal...

Page 331: ...lt 4 Remove the CMP actuator solenoid valve 5 Inspect the CMP actuator solenoid valve seal and replace as necessary Installation Procedure 1 Inspect the CMP actuator solenoid valve seal for damage Rep...

Page 332: ...olt 4 Remove the CMP actuator solenoid valve 5 Inspect the CMP actuator solenoid valve seal and replace as necessary Installation Procedure 1 Inspect the CMP actuator solenoid valve seal for damage Re...

Page 333: ...emove the CMP actuator solenoid valve 5 Inspect the CMP actuator solenoid valve seal for damage and replace as necessary Installation Procedure 1 Inspect the CMP actuator solenoid valve seal for damag...

Page 334: ...Remove the CMP actuator solenoid valve 5 Inspect the CMP actuator solenoid valve seal for damage and replace as necessary Installation Procedure 1 Inspect the CMP actuator solenoid valve seal for dama...

Page 335: ...ld 3 Remove the right catalytic converter Refer to Catalytic Converter Replacement Right Side 4 Disconnect the engine wiring harness electrical connector 2 from the bank 1 knock sensor 5 Loosen the kn...

Page 336: ...en the bolts to 50 N m 37 lb ft 4 Install the right catalytic converter Refer to Catalytic Converter Replacement Right Side 5 Lower the vehicle Knock Sensor Replacement Bank 2 Removal Procedure 1 Rais...

Page 337: ...l case with battery voltage when servicing a control module using battery booster cables or when charging the vehicle battery In order to prevent any possible electrostatic discharge damage to the con...

Page 338: ...ignition OFF 2 Using a scan tool retrieve the percentage of remaining engine oil and the remaining automatic transmission fluid life Record the remaining engine oil and the remaining automatic transm...

Page 339: ...ing or a setup event performed for a complete repair ECM Replacement If the engine control module ECM is replaced the following procedures must be performed 1 ECM Reprogramming Refer to Service Progra...

Page 340: ...following components are replaced an Idle Learn Procedure must be performed Refer to Idle Learn in Engine Controls 3 6L LY7 Throttle body assembly ECM Specifications Fastener Tightening Specification...

Page 341: ...idler pulley which is used to add wrap to the adjacent pulleys Some systems use an idler pulley in place of an accessory drive component when the vehicle is not equipped with the accessory Engine Comp...

Page 342: ...drive shaft sprockets incorporate IT primary timing drive chain sprocket teeth and roller timing drive chain secondary timing drive chain sprocket teeth The third design actuators incorporate a new r...

Page 343: ...he spark plug tube The engine coolant temperature ECT sensor is threaded into the left cylinder head Induction System The intake manifold consists of two cast aluminum components Two short bolts in th...

Page 344: ...Do not overtighten the fasteners Tighten the fasteners to the proper specifications Use of Room Temperature Vulcanizing RTV and Anaerobic Sealer Sealant Types NOTE The correct sealant and amount of s...

Page 345: ...ply the gasket eliminator sealant evenly to get a uniform thickness of the gasket eliminator sealant on the sealing surface Tighten the fasteners in sequence if specified and to the proper torque spec...

Page 346: ...aling surface NOTE Do not overtighten the fasteners Tighten the fasteners in sequence if specified and to the proper torque specifications Schematic and Routing Diagram Camshaft Timing Drive Chain Ali...

Page 347: ...Crankshaft Sprocket Timing Mark 5 Left Secondary Camshaft Timing Drive Chain 14 Crankshaft Sprocket 6 Primary Camshaft Drive Chain Timing Link for the Left Primary Camshaft Intermediate Drive Chain Sp...

Page 348: ...termediate Drive Chain Sprocket Timing Mark Window for the Right Secondary Camshaft Timing Drive Chain 7 Left Primary Camshaft Intermediate Drive Chain Sprocket Timing Mark for the Primary Camshaft Dr...

Page 349: ...Exhaust Camshaft Position Actuator Identifier 2 Right Intake Camshaft Position Actuator Right Side Timing Mark Triangle 6 Exhaust Camshaft Position Actuator Right Side Timing Mark Triangle 3 Left Int...

Page 350: ...Crankshaft Sprocket Timing Mark 5 Left Secondary Camshaft Timing Drive Chain 14 Crankshaft Sprocket 6 Primary Camshaft Drive Chain Timing Link for the Left Primary Camshaft Intermediate Drive Chain S...

Page 351: ...ntermediate Drive Chain Sprocket Timing Mark Window for the Right Secondary Camshaft Timing Drive Chain 7 Left Primary Camshaft Intermediate Drive Chain Sprocket Timing Mark for the Primary Camshaft D...

Page 352: ...Engine Front Cover Assembly 624 Exhaust Manifold Stud 15 Oil Pan Assembly 625 Cylinder Head Exhaust Manifold Bolt 140 Engine Flywheel 630 Right Exhaust Manifold Heat Shield 141 Engine Flywheel Bolt 63...

Page 353: ...l Indicator Tube Bolt 303 Right Cylinder Head Gasket 434 Oil Level Indicator Handle O ring 365 Engine Cooling Thermostat 495 Water Inlet Outlet Pipe 366 Engine Cooling Thermostat Gasket 496 Water Inle...

Page 354: ...r 262 Oil Fill Tube 253 Right Camshaft Cover Gasket 263 Left Camshaft Cover PCV Fitting O ring 254 Camshaft Cover Spark Plug Port Seal 265 Left Camshaft Housing Cover Insulator 255 Camshaft Cover Bolt...

Page 355: ...Timing Chain Guide 155 Primary Timing Chain 182 Right Secondary Timing Chain Guide Bolt 156 Upper Primary Timing Chain Guide 183 Right Secondary Timing Chain Shoe 161 Camshaft Intermediate Drive Shaft...

Page 356: ...ry Timing Chain Guide 155 Primary Timing Chain 183 Right Secondary Timing Chain Shoe 156 Upper Primary Timing Chain Guide 185 Right Secondary Timing Chain Tensioner 161 Camshaft Intermediate Drive Sha...

Page 357: ...ressure Service Valve 503 Upper Intake Manifold 594 Fuel Injector Sight Shield Cover Ball Stud 504 Lower Intake Manifold 700 Fuel Injector Wiring Harness 506 Expansion Plug 701 Throttle Body 509 Upper...

Page 358: ...32 Fuel Rail Bolt 564 Fuel Injector Lower Seal 560 Fuel Rail 565 Fuel Pressure Service Valve Cap 561 Fuel Injector 566 Fuel Pressure Service Valve 562 Fuel Injector Retainer 700 Fuel Injector Wiring H...

Page 359: ...Head Front Bolt 330 Left Exhaust Camshaft 313 Cylinder Head Coolant Hole Threaded Plug 331 Left Intake Camshaft 318 Spark Plug Sleeve 332 Right Intake Camshaft 319 Cylinder Head Oil Gallery Expansion...

Page 360: ...ngine Front Cover Bolt 725 Camshaft Position Sensor 353 Engine Front Cover Seal 726 Camshaft Position Sensor O ring 354 Engine Front Cover Deadener 727 Camshaft Position Sensor Bolt 360 Water Pump Ass...

Page 361: ...54 Lower Primary Timing Chain Guide Bolt 470 Oil Pressure Relief Valve Bore Plug 463 Oil Pump Housing 471 Oil Pressure Relief Valve Spring 464 Oil Pump Cover 472 Oil Pressure Relief Valve 465 Oil Pump...

Page 362: ...ock Oil Gallery Threaded Plug 20 mm 115 Crankshaft Bearing Cap Outboard Bolt 130 Engine Block Core Coolant Expansion Plug 34 3 mm 116 Crankshaft Bearing Cap Side Bolt Short 131 Transaxle Locating Pin...

Page 363: ...cting Rod 212 Piston Pin Retainer 201 Connecting Rod Bolt 213 Piston Upper Compression Ring 202 Connecting Rod Bushing 214 Piston Lower Compression Ring 203 Connecting Rod Bearing 215 Piston Oil Contr...

Page 364: ...l Pan 411 Oil Pan Baffle Scraper Bolt 405 Oil Pump Suction Pipe 412 Oil Pan Drain Plug 406 Oil Pump Suction Pipe Gasket 413 Oil Pan Drain Plug O ring 407 Oil Pump Suction Pipe Bolt 420 Oil Pan Bolt 41...

Page 365: ...er Adapter 440 Oil Filter Adapter 445 Oil Filter Fitting 441 Oil Filter Adapter Gasket 449 Oil Filter 442 Oil Filter Adapter Bolt 728 Engine Oil Pressure Sensor 443 Oil Filter Adapter Bolt Long 729 En...

Page 366: ...lanation refer to Strategy Based Diagnosis Visual Physical Inspection Inspect for aftermarket devices which could affect the operation of the Engine Refer to Checking Aftermarket Accessories Inspect t...

Page 367: ...ure relief valve and intake manifold Replace the intake manifold plenum duct gaskets cylinder heads throttle body and or pressure relief valve as required Improperly installed or damaged MAP sensor an...

Page 368: ...s noises similar to a faulty lower engine and also lead to a misfire condition A misfire code may be present without an actual misfire condition Replace the drive belt Refer to Drive Belt Replacement...

Page 369: ...ted by coolant Refer to Spark Plug Inspection for the 3 6L engine Perform a cylinder leak down test Inspect the cylinder heads and engine block for damage to the coolant passages and or a faulty head...

Page 370: ...ect the engine camshaft lobes 2 Replace the camshaft or camshafts and SHLAs valve lifters as required Worn valve guides or valve stems Inspect the following components and repair as required The valve...

Page 371: ...n the top of the piston facing the front of the engine Piston pins must be centered in the connecting rod pin bore 1 Verify the pistons piston pins and connecting rods are installed correctly 2 Repair...

Page 372: ...ials 2 Repair or replace as required Seized crankshaft or connecting rod bearings 1 Inspect the crankshaft and the connecting rod bearings 2 Repair as required Bent or broken connecting rod 1 Inspect...

Page 373: ...racked cylinder head Replace the cylinder head and gasket Cracked cylinder liner or engine block Replace the components as required Cylinder head or engine block porosity Replace the components as req...

Page 374: ...low on the first stroke and tends to build up on the following strokes but does not reach normal Compression improves considerably with the addition of oil Use approximately 3 squirts of oil from a pl...

Page 375: ...ng or damaged O ring seals on the vent adapter Inspect the cam covers the oil pan gasket and other sealing areas for leaks Results of Incorrect Operation A plugged crankcase ventilation housing or hos...

Page 376: ...installation procedure for that pulley 17 This test is to verify that the pulleys are the correct diameter or width Using a known good vehicle compare the pulley sizes 19 Replacing the drive belt when...

Page 377: ...find the condition Go to Step 18 Go to Step 19 13 Inspect for an accessory drive component seized bearing or a faulty accessory drive component Did you find and correct the condition If diagnosing a...

Page 378: ...nspecting the drive belts is to ensure that they are not causing the noise Small cracks across the ribs of the drive belt will not cause the noise Belt separation is identified by the plys of the belt...

Page 379: ...lt Replacement Did you correct the condition Go to Step 8 Go to Step 7 7 Install a new drive belt Refer to Drive Belt Replacement Did you complete the replacement Go to Step 8 Go to Step 9 8 Operate t...

Page 380: ...k side of the belt is used to drive the pulley 6 Accessory drive component brackets that are bent or cracked will let the drive belt fall off 7 Inspecting of the fasteners can eliminate the possibilit...

Page 381: ...ion Refer to Drive Belt Replacement Did you find this condition Go to Step 16 Go to Step 14 14 Inspect for the proper drive belt Did you find this condition Go to Step 16 Go to Step 15 15 Inspect for...

Page 382: ...can tool and the J 38792 A Electronic Vibration Analyzer EVA 2 if available still installed start the engine 4 Place the transmission in NEUTRAL or PARK 5 Slowly increase the engine RPM to the level a...

Page 383: ...l at which the disturbance was most noticeable in the customer s vehicle 8 Record the engine RPM obtained on the scan tool and the most dominant frequency reading if obtained on the J 38792 A if avail...

Page 384: ...istics have NOT been altered it is NOT likely that these component systems are acting as a transfer path for engine firing frequency or a first order engine disturbance 10 If the mark placed on the fa...

Page 385: ...h COLD and HOT in NEUTRAL FORWARD and REVERSE gears Improper alignment Disconnected and or missing insulators Cracked dry rotted and or oil soaked insulators Stretched twisted broken torn and or colla...

Page 386: ...ace the transmission in NEUTRAL or PARK 6 Increase the engine RPM to the level recorded during duplication of the disturbance 7 Allow the engine to idle then place the transmission in DRIVE 8 Increase...

Page 387: ...ring duplication of the disturbance then maintain that speed 10 Using the J 38792 25 check each of the suspected accessory pulleys to determine if any of them is related to the frequency of the distur...

Page 388: ...d broken torn and or collapsed component insulators Bent twisted cracked and or deformed component brackets Repair replace and or realign the engine driven accessory system components as indicated by...

Page 389: ...nt frequency reading if obtained on the J 38792 A if available 12 If the disturbance has been significantly reduced or eliminated confirm the results by placing the transmission into REVERSE then repe...

Page 390: ...s cracked damaged and or missing balance weights and or a clutch pressure plate and clutch driven plate that has loose springs cracks warpage damage and or missing balance weights can produce a distur...

Page 391: ...cks and or damage Missing balance weights Did the flywheel flexplate exhibit any of the conditions listed Go to Step 8 Go to Step 7 7 1 With the transmission torque converter still secured away from t...

Page 392: ...erside of the engine oil pan along the FRONT edge 3 Lower the vehicle 4 Block the front wheels 5 Apply BOTH the service brakes and the park brake 6 With the scan tool and the J 38792 A still installed...

Page 393: ...tch driven plate from the engine flywheel 2 Inspect the engine flywheel for the following Looseness at the engine crankshaft Cracks warpage and or damage Missing balance weights 3 Inspect the clutch p...

Page 394: ...n the scan tool and the most dominant frequency reading if obtained on the J 38792 A if available 10 Place the transmission in DRIVE 11 Slowly increase the engine RPM to the level at which the disturb...

Page 395: ...d engine speed 20 Hz by 4 cylinders firing 20 Hz X 4 80 Hz The engine firing frequency for a V8 engine at the original engine speed of 1 200 RPM recorded during duplication of the disturbance would be...

Page 396: ...mal Likely Single Cylinder Misfire Abnormal Likely Single Cylinder Misfire Abnormal Likely Single Cylinder Misfire Abnormal Likely Single Cylinder Misfire Abnormal Likely Single Cylinder Misfire and o...

Page 397: ...INE FIRING FREQUENCY Possible Powertrain Isolation Related Possible Engine Driven Accessory Related Possible Engine Driven Accessory Related Possible Engine Driven Accessory Related Possible Engine Dr...

Page 398: ...r flow MAF intake air temperature IAT sensor 4 Remove the air cleaner intake duct from the MAF IAT sensor and the throttle body Installation Procedure 1 Install the air cleaner intake duct to the MAF...

Page 399: ...ture IAT sensor 3 Release the clips 1 on the air cleaner lower half 4 Open and rotate the air cleaner upper half 5 Remove the air cleaner element Installation Procedure 1 Install the air cleaner eleme...

Page 400: ...ssembly remove the MAF IAT sensor Refer to Mass Airflow Sensor Intake Air Temperature Sensor Replacement Installation Procedure 1 If the air cleaner assembly was replaced install the MAF IAT sensor Re...

Page 401: ...bolts 4 Remove the throttle body and gasket Discard the gasket Installation Procedure 1 Position a NEW throttle body gasket to the upper intake manifold 2 Position the throttle body to the upper inta...

Page 402: ...t contains Methyl Ethyl Ketone MEK This solvent may damage fuel system components 3 Clean the throttle body bore and the throttle valve plate using a clean shop towel with GM top engine cleaner GM P N...

Page 403: ...l the engine splash shield Refer to Engine Splash Shield Replacement Right Side 8 Lower the vehicle 9 Install the engine mount strut bracket Refer to Engine Mount Strut Bracket Replacement Right Side...

Page 404: ...efer to Battery Negative Cable Disconnection and Connection 4 Disconnect the generator electrical connector 1 5 Reposition the battery cable boot then disconnect the battery cable from the generator 6...

Page 405: ...fluid is the engine mount not the engine or accessories 1 Install the engine support fixture Refer to Engine Support Fixture 2 Observe the engine mount while raising the engine Raising the engine remo...

Page 406: ...gine mount bolt Tightening torque Tighten the bolt to 50 N m 38 lb ft 2 Install the engine mount to frame bolts 1 Tightening torque Tighten the engine mount bolts to 50 N m 38 lb ft 3 Lower the vehicl...

Page 407: ...racket bolt 1 from the bracket 12 Remove the upper bracket 13 Remove the engine mount 3 from the lower bracket 4 Installation Procedure CAUTION Refer to Fastener Notice in Cautions and Notices 1 Insta...

Page 408: ...lb in Tightening torque Tighten the right upper engine mount bracket bolt to 50 N m 38 lb ft 8 Lower the vehicle 9 Remove the engine support Refer to Engine Support Fixture 10 Install the drive belt R...

Page 409: ...cket 4 from the vehicle 11 Remove the upper bracket Installation Procedure CAUTION Refer to Fastener Notice in Cautions and Notices 1 Install the engine mount 3 and the lower bracket 4 to the vehicle...

Page 410: ...bolts to 110 N m 81 lb ft 7 Lower the vehicle 8 Remove the engine support Refer to Engine Support Fixture 9 Install the air cleaner assembly Refer to Air Cleaner Assembly Replacement Engine Mount Str...

Page 411: ...r cleaner assembly Refer to Air Cleaner Assembly Replacement 2 Remove the engine mount strut to bracket bolts 1 3 Rotate the strut vertical 4 Remove the engine mount strut bracket to cylinder head bol...

Page 412: ...tion Hoses Pipes Replacement Front Removal Procedure 1 Remove the engine cover Refer to Fuel Injector Sight Shield Replacement 2 Disconnect the positive crankcase ventilation PVC fresh air pipe from t...

Page 413: ...Procedure 1 Connect the PVC foul air pipe to the PVC valve 2 Connect the PVC fresh air pipe to the upper intake manifold 3 Install the engine cover Refer to Fuel Injector Sight Shield Replacement Upp...

Page 414: ...e 10 Remove the brake booster vacuum hose from the intake manifold 11 Remove the engine harness retaining clips 12 Remove the upper intake retaining bolts 13 Remove the upper intake manifold and gaske...

Page 415: ...en the bolts to 25 N m 18 lb ft 4 If the upper manifold was replaced complete the following steps a Install the throttle body Refer to Throttle Body Assembly Replacement b Install the EVAP purge solen...

Page 416: ...ect the PCV line 2 to the top of the intake manifold 14 Connect the ETC electrical connector 15 Install the air cleaner outlet duct 16 Install the fresh air PCV line 1 to the air cleaner inlet duct 17...

Page 417: ...lts 1 CAUTION Refer to Fastener Notice 3 Install the fuel injectors and fuel rail Refer to Fuel Injector and Fuel Rail Replacement Tightening torque Tighten the bolts to 23 N m 17 lb ft Crankshaft Bal...

Page 418: ...41816 in order to pull the crankshaft balancer off of the crankshaft 11 Remove the J 41816 from the crankshaft balancer Installation Procedure 1 The EN 46106 must be installed onto the flywheel 2 Use...

Page 419: ...lancer bolt to 100 N m 74 lb ft 2 Tighten the crankshaft balancer bolt an additional 150 degrees using the J 45059 10 Remove the EN 46106 11 Install the starter Refer to Starter Installation Starter I...

Page 420: ...l tool EN 46101 Spark Plug Tube Seal Guide Removal Procedure 1 Remove the left bank spark plugs Refer to Spark Plug Replacement 2 Remove the left camshaft cover bolts 3 Remove the left camshaft cover...

Page 421: ...valent on the engine front cover split lines 1 3 Place the left camshaft cover into position onto the left cylinder head 4 Loosely install the left camshaft cover bolts CAUTION Refer to Fastener Notic...

Page 422: ...lug Replacement 2 Unbolt the power steering reservoir and position aside Refer to Remote Power Steering Fluid Reservoir Replacement 3 Remove the right camshaft cover bolts 4 Remove the right camshaft...

Page 423: ...ace the right camshaft cover into position onto the right cylinder head 4 Loosely install the right camshaft cover bolts CAUTION Refer to Fastener Notice 5 Tighten the right camshaft cover bolts in th...

Page 424: ...er to Water Pump Replacement 7 Remove the power steering pump and position aside Refer to Power Steering Pump Replacement 8 Remove the crankshaft balancer Refer to Crankshaft Balancer Replacement 9 Re...

Page 425: ...the edge of the front cover and the jackscrew shear the RTV sealant 15 Remove the engine front cover 16 Using the EN 46111 rotate the crankshaft until the left cylinder head camshafts align with the E...

Page 426: ...edure 1 Install the 8 mm 0 315 in guide from the EN 46109 into the cylinder block positions as shown 2 Install the engine front cover to cylinder block seal 3 Place a 3 mm 0 118 in bead of RTV sealant...

Page 427: ...Install the camshaft position actuator valves from the front cover Refer to Camshaft Position Sensor Replacement Bank 2 Left Side Exhaust Camshaft Position Sensor Replacement Bank 2 Left Side Intake...

Page 428: ...iate Drive Chain Idler Removal Left Side Fourth Design 9 Remove the left bank secondary camshaft drive chain Refer to Secondary Camshaft Drive Chain Removal Left Side Third Design Secondary Camshaft D...

Page 429: ...ide Refer to Secondary Camshaft Drive Chain Guide Removal Right Side Third Design Secondary Camshaft Drive Chain Guide Removal Right Side Fourth Design 6 Remove the right bank secondary camshaft drive...

Page 430: ...sioner Refer to Secondary Camshaft Drive Chain Tensioner Installation Left Side Third Design Secondary Camshaft Drive Chain Tensioner Installation Left Side Fourth Design 2 Install the spark plugs Ref...

Page 431: ...he spark plugs in order to ease crankshaft engine rotation Refer to Spark Plug Replacement 2 Remove the engine front cover Refer to Engine Front Cover Replacement 3 Remove the left bank secondary cams...

Page 432: ...the engine front cover Refer to Engine Front Cover Replacement 6 Install the spark plugs Refer to Spark Plug Replacement Secondary Camshaft Drive Chain Shoe Replacement Right Side Removal Procedure 1...

Page 433: ...ne Front Cover Replacement 3 Remove the left bank secondary camshaft drive chain tensioner Refer to Secondary Camshaft Drive Chain Tensioner Removal Left Side Third Design Secondary Camshaft Drive Cha...

Page 434: ...e Refer to Secondary Camshaft Drive Chain Guide Removal Right Side Third Design Secondary Camshaft Drive Chain Guide Removal Right Side Fourth Design Installation Procedure 1 Install the right bank se...

Page 435: ...amshaft drive chain guide Refer to Secondary Camshaft Drive Chain Guide Removal Right Side Third Design Secondary Camshaft Drive Chain Guide Removal Right Side Fourth Design 6 Remove the right bank se...

Page 436: ...on the oil pump cover 2 using the EN 46111 Refer to Camshaft Timing Drive Chain Alignment Diagram Third Design Camshaft Timing Drive Chain Alignment Diagram Fourth Design 6 Install the primary camshaf...

Page 437: ...haft drive chain tensioner Refer to Secondary Camshaft Drive Chain Tensioner Removal Right Side Third Design Secondary Camshaft Drive Chain Tensioner Removal Right Side Fourth Design 4 Remove the righ...

Page 438: ...Third Design Camshaft Intermediate Drive Chain Idler Removal Left Side Fourth Design Installation Procedure 1 If you are servicing the left bank idler sprocket perform the following steps a Install t...

Page 439: ...ird Design Secondary Camshaft Drive Chain Guide Installation Right Side Fourth Design 8 Install the right bank secondary camshaft drive chain shoe Refer to Secondary Camshaft Drive Chain Shoe Installa...

Page 440: ...nt cover Refer to Engine Front Cover Replacement 3 Remove the primary camshaft drive chain tensioner Refer to Primary Camshaft Drive Chain Tensionser Removal Third Design Primary Camshaft Drive Chain...

Page 441: ...de Exhaust NOTE Rotate the crankshaft balancer bolt in a clockwise direction ONLY 5 Rotate the crankshaft balancer using the balancer bolt until the camshafts are in a neutral low tension position The...

Page 442: ...clockwise 13 Insert the leg of the tool 1 behind the timing chain guide 2 14 Continue expanding the EN 48313 until the legs 1 3 contact the timing chain Do not tighten at this time NOTE Ensure that th...

Page 443: ...ng chain alignment mark 2 made during disassembly 2 Ensure that the intake camshaft actuator alignment mark 4 and the timing chain alignment mark 3 are also aligned 3 Position the exhaust camshaft act...

Page 444: ...o Torque Reaction Against Timing Drive Chain Notice 2 Install the camshaft Refer to Camshaft Replacement Right Side Camshaft Position Actuator Replacement Bank 2 Left Side Intake Removal Procedure 1 R...

Page 445: ...camshaft and loosely install the bolt CAUTION Refer to Torque Reaction Against Timing Drive Chain Notice NOTE Use an open end wrench at the camshaft hex to prevent camshaft engine rotation 2 Tighten...

Page 446: ...tion Actuator Solenoid Valve Solenoid Replacement Bank 2 Left Side Intake 5 Remove the crankshaft balancer Refer to Crankshaft Balancer Removal 6 Rotate the crankshaft with the EN 46111 until the cams...

Page 447: ...Notice NOTE Use an open end wrench at the camshaft hex to prevent camshaft engine rotation 4 Install and tighten the camshaft position actuators Refer to Camshaft Position Actuator Installation Left S...

Page 448: ...tion Actuator Solenoid Valve Solenoid Replacement Bank 1 Right Side Intake 5 Remove the crankshaft balancer Refer to Crankshaft Balancer Removal 6 Rotate the crankshaft with the EN 46111 until the cam...

Page 449: ...shaft Balancer Installation CAUTION Refer to Torque Reaction Against Timing Drive Chain Notice NOTE Use an open end wrench at the camshaft hex to prevent camshaft engine rotation 5 Install and tighten...

Page 450: ...arms Refer to Valve Rocker Arm Installation Left Side 2 Install the applicable camshaft s Refer to Camshaft Replacement Left Side Valve Rocker Arm Replacement Right Side Removal Procedure 1 Remove th...

Page 451: ...Install the rocker arms Refer to Valve Rocker Arm Installation Left Side 3 Install the applicable camshaft s Refer to Camshaft Replacement Left Side Valve Lifter Replacement Right Side Removal Procedu...

Page 452: ...bly and reassembly of the entire camshaft timing system may be required 2 Install the EN 46106 in order to prevent crankshaft rotation 3 Remove the camshafts and rocker arms Refer to Camshaft Replacem...

Page 453: ...ve the valve spring 13 Use the EN 46116 1 in order to remove the valve stem seal 2 Installation Procedure 1 Use the EN 46116 1 in order to install the valve stem seal 2 2 Install the valve spring 3 In...

Page 454: ...e Spring Replacement Right Side Special tool EN 46106 Flywheel Holding Tool EN 46110 On Vehicle Valve Spring Compressor EN 46116 Valve Stem Seal Remover Installer J 39313 Spark Plug Port Adapter Remov...

Page 455: ...inder as shown 8 Tighten the EN 46110 valve spring compressor nut 2 9 Remove the valve keepers 10 Loosen the EN 46110 valve spring compressor nut 11 Remove the valve spring retainer 12 Remove the valv...

Page 456: ...pring as shown Tighten the EN 46110 valve spring compressor nut 2 5 Install the valve spring keepers 6 Remove the EN 46110 7 Disconnect the J 39313 from the compressed air source 8 Remove the J 39313...

Page 457: ...erter Refer to Catalytic Converter Replacement Left Side 6 Remove the cylinder head with the exhaust manifold Refer to Cylinder Head Removal Left Side 7 Remove and discard the cylinder head gasket 8 C...

Page 458: ...erter Replacement Left Side 5 Connect the wiring harness electrical connector located at the side of the cylinder head CAUTION Refer to Fastener Notice 6 Install the wiring harness ground to the cylin...

Page 459: ...mshaft Removal Right Side Disassemble the cylinder head Refer to Cylinder Head Disassemble Installation Procedure 1 If necessary perform the following steps Assemble the cylinder head Refer to Cylinde...

Page 460: ...ion Procedure 1 Install the engine flywheel and bolts Refer to Engine Flywheel Installation 2 Install the transmission Refer to Transaxle Replacement Crankshaft Rear Oil Seal and Housing Replacement R...

Page 461: ...e Refer to Shift Control Cable Replacement 14 Drain the engine coolant from the cooling system Refer to Draining and Filling Cooling System LY7 GE 47716 Fill Draining and Filling Cooling System LY7 St...

Page 462: ...er to Lower Control Arm Replacement 30 On front wheel drive FWD models place a drain pan under the transaxle then separate the right and left front wheel drive shafts from the transaxle Refer to Front...

Page 463: ...ment Refer to Drivetrain and Front Suspension Frame Reinforcement Replacement 40 Remove the frame to body bolts Discard the bolts NOTE Inspect for areas of body to powertrain contact or entanglement o...

Page 464: ...onnect the engine electrical wiring harness from the following components Battery cable 1 Retainer clips 2 3 Transmission module 4 46 If equipped with an engine coolant heater disconnect the coolant h...

Page 465: ...appropriate component sections in manual if needed Installation Procedure 1 Remove the engine from the engine stand 2 Align the engine to the frame and automatic transaxle CAUTION Refer to Fastener N...

Page 466: ...uipped with an engine coolant heater connect the coolant heater cord 12 Connect the engine electrical wiring harness to the following components Transmission module 4 Retainer clips 3 2 Battery cable...

Page 467: ...arness retaining clips near the right and left shock towers 17 Install NEW frame to body bolts Tightening torque Tighten the bolts to 155 N m 114 lb ft 18 Install the drivetrain and front suspension f...

Page 468: ...tall the right and left front wheel drive shafts into the transaxle Refer to Front Wheel Drive Shaft Replacement AWD Front Wheel Drive Shaft Replacement FWD 26 On all models install the right and left...

Page 469: ...ent 35 Install the radiator outlet hose Refer to Radiator Outlet Hose Replacement 36 Lower the vehicle 37 Install the radiator inlet hose Refer to Radiator Inlet Hose Replacement 38 Connect the heater...

Page 470: ...Fill Draining and Filling Cooling System LY7 Static Fill 53 Check the transaxle fluid level Refer to Sealers Adhesives and Lubricants Transmission General Specifications and Fluid Capacity Specificati...

Page 471: ...center bolt of the J 41816 in order to pull the crankshaft balancer off of the crankshaft 6 Remove the J 41816 from the crankshaft balancer Reference Crankshaft Balancer Cleaning and Inspection Engine...

Page 472: ...rence Engine Flywheel Removal 1 Disconnect and remove the fresh air positive crankcase ventilation PCV hose from the left camshaft cover fitting 2 Remove the engine coolant air bleed pipe bracket bolt...

Page 473: ...onnect and remove the dirty air PCV hose from the intake manifold and the right camshaft cover fitting 6 Disconnect and remove the intake manifold to solenoid evaporative emissions EVAP hose from the...

Page 474: ...the EVAP solenoid 9 Remove the long intake manifold bolts 10 Remove the short intake manifold bolts 11 Remove the intake manifold assembly 12 Remove and discard the lower intake manifold gasket Refer...

Page 475: ...Reference Intake Manifold Removal 1 Remove the ignition coil bolts 2 Remove the ignition coils 3 Remove the spark plugs 4 Remove the left camshaft cover bolts 5 Remove the left camshaft cover from th...

Page 476: ...ence Camshaft Cover Removal Left Side 1 Remove the ignition coil bolts 2 Remove the ignition coils 3 Remove the spark plugs 4 Remove the right camshaft cover bolts 5 Remove the right camshaft cover fr...

Page 477: ...ve the camshaft position sensor bolts 2 Remove the camshaft position sensors 3 Remove the camshaft position actuator valve bolts 4 Remove the camshaft position actuator valves from the front cover 5 R...

Page 478: ...osition sensors or the camshaft position actuators are used to pry against in order to remove the engine front cover 8 Loosely install a 10 x 1 5 mm bolt in the jackscrew hole 1 9 Using the pry points...

Page 479: ...val Special tool EN 46105 Camshaft Locking Tool EN 46111 Crankshaft Rotation Socket 1 Remove the camshaft position sensor bolts 2 Remove the camshaft position sensors 3 Remove the camshaft position ac...

Page 480: ...kscrew hole in order to remove the engine front cover Damage to the camshaft position sensors or the camshaft position actuators may occur if the camshaft position sensors or the camshaft position act...

Page 481: ...Camshaft Drive Chain Tensioner Removal Right Side Third Design Reference Engine Front Cover Removal Third Design 1 Remove the right secondary camshaft drive chain tensioner bolts 2 Remove the right s...

Page 482: ...ft drive chain tensioner gasket 4 Inspect the right secondary camshaft drive chain tensioner mounting surface on the right cylinder head for burrs or any defects that would degrade the sealing of the...

Page 483: ...Drive Chain Guide Removal Right Side Third Design Reference Secondary Camshaft Drive Chain Shoe Removal Right Side Third Design 1 Remove the right secondary camshaft drive chain guide bolts 2 Remove t...

Page 484: ...ove the right secondary camshaft drive chain from the right camshaft position actuators and the right camshaft intermediate drive chain idler sprocket Primary Camshaft Drive Chain Tensionser Removal T...

Page 485: ...gine block for burrs or any defects that would degrade the sealing of the NEW primary camshaft drive chain tensioner gasket Primary Camshaft Drive Chain Guide Removal Upper Third Design Reference Prim...

Page 486: ...urth Design Reference Primary Camshaft Drive Chain Guide Removal Upper Fourth Design 1 Remove the primary camshaft drive chain lower guide bolts 2 Remove the primary camshaft drive chain lower guide P...

Page 487: ...ve chain idler bolt 2 Remove the right camshaft intermediate drive chain idler Secondary Camshaft Drive Chain Tensioner Removal Left Side Third Design Reference Camshaft Intermediate Drive Chain Idler...

Page 488: ...secondary camshaft drive chain tensioner gasket 4 Inspect the left secondary camshaft drive chain tensioner mounting surface on the left cylinder head for burrs or any defects that would degrade the...

Page 489: ...t Drive Chain Guide Removal Left Side Third Design Reference Secondary Camshaft Drive Chain Shoe Removal Left Side Third Design 1 Remove the left secondary camshaft drive chain guide bolts 2 Remove th...

Page 490: ...left secondary camshaft drive chain from the left camshaft position actuators and the left camshaft intermediate drive chain idler sprocket Camshaft Intermediate Drive Chain Idler Removal Left Side Th...

Page 491: ...de Fourth Design Remove the crankshaft sprocket from the nose of the crankshaft Camshaft Position Actuator Removal Left Side Exhaust Third Design Reference Crankshaft Sprocket Removal Third Design CAU...

Page 492: ...Third Design CAUTION Refer to Torque Reaction Against Timing Drive Chain Notice 1 Use an open wrench on the hex cast into the camshaft in order to prevent engine rotation when loosening the camshaft p...

Page 493: ...Torque Reaction Against Timing Drive Chain Notice 1 Use an open wrench on the hex cast into the camshaft in order to prevent engine rotation when loosening the camshaft position actuator bolt 2 Remov...

Page 494: ...Cleaning and Inspection Fourth Design Camshaft Removal Left Side Reference Camshaft Position Actuator Removal Left Side Intake Third Design Reference Camshaft Position Actuator Removal Left Side Inta...

Page 495: ...t followers from the left cylinder head Reference Valve Rocker Arms Cleaning and Inspection Valve Lifter Removal Left Side Reference Valve Rocker Arm Removal Left Side NOTE Do not stroke cycle the sta...

Page 496: ...d Design Reference Camshaft Position Actuator Removal Right Side Intake Fourth Design Special tool EN 46105 Camshaft Locking Tool 1 Remove the EN 46105 1 from the right camshafts 2 Position the camsha...

Page 497: ...followers from the right cylinder head Reference Valve Rocker Arms Cleaning and Inspection Valve Lifter Removal Right Side Reference Valve Rocker Arm Removal Right Side NOTE Do not stroke cycle the s...

Page 498: ...ove the right cylinder head 3 Remove and discard the right cylinder head gasket Reference Cylinder Head Disassemble Crankshaft Rear Oil Seal and Housing Removal Reference Oil Pump Removal 1 Remove the...

Page 499: ...ing Rod and Bearings Cleaning and Inspection e If the connecting rod width is significantly smaller than specified and severe wear is present on the side of the connecting rod replace the connecting r...

Page 500: ...the top of the cylinder DO NOT scratch the crankshaft journal or cylinder wall and DO NOT damage the oil jets when removing the connecting rod and piston assembly 8 Remove the EN 46121 from the connec...

Page 501: ...e the crankshaft to the extreme front and rear positions with a pry tool while monitoring the movement of the dial indicator 3 The crankshaft end play should not exceed specifications Refer to Engine...

Page 502: ...journals are numbered from the front of the engine 2 Remove the crankshaft upper bearing halves from the cylinder block Note the position of the thrust bearing 1 at the number 3 journal 2 3 Place the...

Page 503: ...s Removal 1 Remove oil jet bolts 2 Remove oil jets 3 Remove the right front oil pan rail oil gallery expansion plug 4 Remove the cylinder block to oil pan alignment dowels 5 Remove the M14 right side...

Page 504: ...ded plug 8 Remove the M14 left side coolant drain threaded plug 9 Remove the M20 left side oil gallery threaded plug 10 Remove the coolant expansion plugs 11 Remove the cylinder block to transmission...

Page 505: ...e if the crankshaft bearing journals are damaged the cylinder block assembly must be replaced 2 Inspect the primary camshaft drive chain tensioner mounting surface on the engine block for burrs or any...

Page 506: ...out of round at the upper end of the cylinder 3 Measure both the thrust and non thrust cylinder diameter at 100 mm 3 976 in below the deck surface Record your measurements 4 Calculate the difference b...

Page 507: ...urnals 5 for damage Inspect the crankshaft connecting rod journals 6 for damage Inspect the crankshaft oil passages 7 for obstructions Inspect the crankshaft main bearing thrust wall surfaces 8 for da...

Page 508: ...for dirt embedded into the bearing material 4 Inspect for improper seating indicated by bright polished sections Crankshaft Measurement Special tool J 7872 Magnetic Base Dial Indicator 1 Using a suita...

Page 509: ...measure the journal at the extreme front and rear locations on the journal Call these points A and B b Measure the journal in 2 new locations exactly 90 degrees from the first points Call these point...

Page 510: ...ve belt ribs 4 Damaged webs 5 2 Repair or replace the crankshaft balancer as necessary Reference Crankshaft Balancer Installation Engine Flywheel Cleaning and Inspection Reference Engine Flywheel Remo...

Page 511: ...ugh to fit over the piston lands If the rings are overexpanded the top ring will shatter and the others will distort 1 Remove the piston rings using a piston ring expander Place each ring in a clean s...

Page 512: ...Worn piston pin bores or worn piston pins 3 2 Replace pistons that show any signs of damage or excessive wear Piston Measurement Procedure 1 Measure piston width using the following procedure a Using...

Page 513: ...on ring will travel approximately 25 mm 1 in down from the deck surface Ensure that the ring is square with the cylinder bore by positioning the ring with the piston head b Measure the end gap of the...

Page 514: ...a running engine Connecting Rod Visual Inspection Procedure 1 Inspect the piston pin bushing 4 for scoring or damage 2 Inspect the connecting rod beam 1 for twisting or bending 3 Inspect the rod cap...

Page 515: ...nnecting Rod Assemble Reference Piston Connecting Rod and Bearings Cleaning and Inspection Special tool EN 46121 Connecting Rod Guide Pin Set EN 46745 Piston Pin Clip Remover Installer Piston and Pist...

Page 516: ...piston 2 Using a piston ring expander install the oil control ring assembly using the following procedure a Install the expander ring 3 b Install the 2 oil scraper rings 4 Expand the rings only enoug...

Page 517: ...tall new lower connecting rod bearings into position in the connecting rod cap Roll the bearing into position so that the lock tang engages the alignment slot The bearings must fit flush with the conn...

Page 518: ...ressor and when removing or installing the valve stem keys Failing to use care may cause personal injury CAUTION Do not compress the valve springs less than 24 0 mm 0 943 in Contact between the valve...

Page 519: ...Set J 8358 Carbon Removal Brush J 28410 Gasket Remover J 42096 Valve Guide Reamer Cleaning Procedure 1 Remove any old thread sealant gasket material or sealant using J 28410 2 Clean all cylinder head...

Page 520: ...roperly positioned in the cylinder head The camshaft position actuator oil feed check valve should be flush to 2 mm 0 0787 in below the cylinder head deck surface a 6 Damaged restricted or clogged che...

Page 521: ...cause an excessive oil consumption and may also cause a valve to break Insufficient clearance will result in noisy and sticky functioning of the valve and will disturb the engine assembly smoothness...

Page 522: ...tom out before the camshaft lobe is at peak lift Reference Cylinder Head Assemble Valve and Seat Grinding Reference Cylinder Head Disassemble Valve Cleaning Procedure 1 Use soft bristle wire brush to...

Page 523: ...ngine Mechanical Specifications 4 If the seat widths are acceptable check the valve seat roundness using the Valve Seat Roundness Measurement Procedure 5 If the seat width is not acceptable you must g...

Page 524: ...nd the valve seat to ensure proper valve sealing 1 Coat the valve face lightly with blue dye 3 2 Install the valve in the cylinder head 3 Turn the valve against the seat with enough pressure to wear o...

Page 525: ...le material as possible Cutting valve seat results in lowering the valve spring pressure 6 Install the valve in the cylinder head If you are using refaced valves lap the valves into the seats with a f...

Page 526: ...Assemble Reference Cylinder Head Cleaning and Inspection Reference Valve Spring Inspection and Measurement Reference Valve and Seat Grinding Special tool J 8062 Valve Spring Compressor Head Off EN 461...

Page 527: ...ring retainer onto the valve spring WARNING Compressed valve springs have high tension against the valve spring compressor Valve springs that are not properly compressed by or released from the valve...

Page 528: ...tion Reference Camshaft Removal Left Side Reference Camshaft Removal Right Side Special tool J 7872 Magnetic Base Dial Indicator Cleaning Procedure 1 Clean the camshaft in solvent WARNING Refer to Saf...

Page 529: ...tside micrometer Refer to Engine Mechanical Specifications If the diameter is smaller than specifications replace the camshaft If the out of round exceeds specifications replace the camshaft 3 Measure...

Page 530: ...e a Place the J 7872 at zero b Rotate the camshaft until the indicator tip is at the highest point 3 on the lobe This reading is the lift of the camshaft lobe Refer to Engine Mechanical Specifications...

Page 531: ...sary Reference Valve Rocker Arm Installation Right Side Reference Valve Rocker Arm Installation Left Side Camshaft Timing Drive Components Cleaning and Inspection Third Design Reference Camshaft Posit...

Page 532: ...r hub flange damage 3 4 Inspect the back of the intake camshaft position actuators for the following Sprocket damage 1 Camshaft locating pin damage 2 Camshaft seating sealing inner hub flange damage 3...

Page 533: ...procket for the following Damage to the left secondary camshaft drive chain sprocket 1 Damage to the bearing hub to engine block sealing surface 2 3 Replace a damaged left intermediate sprocket Right...

Page 534: ...for the following Binding or worn rollers 1 Loose links 2 Loose pins 3 2 Replace a damaged secondary timing chain Primary Timing Chain with Inverted Tooth IT Chain 1 Inspect the primary timing chain...

Page 535: ...uide surface 1 Cracked or broken guide surface 2 Cracked or damaged guide base 3 2 Replace a damaged left secondary timing chain guide Right Secondary Timing Chain Guide 1 Inspect the right secondary...

Page 536: ...chain shoe for a damaged worn or missing right secondary timing chain tensioner contact pad 1 3 Replace a damaged right secondary timing chain shoe Primary Timing Chain Tensioner 1 Inspect the primary...

Page 537: ...r moves freely 2 in and out of the body of the tensioner Refer to Secondary Camshaft Drive Chain Tensioner Installation Right Side Third Design Secondary Camshaft Drive Chain Tensioner Installation Ri...

Page 538: ...amage 2 Camshaft seating sealing inner hub flange damage 3 Blockage to the oil passages 4 Loose or missing housing bolts 5 3 Inspect the front of the left intake camshaft position actuators for the fo...

Page 539: ...aged camshaft position actuator Camshaft Position Actuator Oil Control Valves 1 Inspect the camshaft position actuator oil control valves for the following Blockage to the oil passage 1 Missing or dam...

Page 540: ...of the right intermediate sprocket for the following Damage to the right secondary camshaft drive chain sprocket 1 Damage to the hub bearing 2 Ensure the hub bearing spins freely If the hub bearing w...

Page 541: ...ks 1 Loose links 2 Loose pins 3 2 Replace a damaged primary timing chain Primary Timing Chain Upper Guide 1 Inspect the primary timing chain upper guide for the following Worn guide surface 1 Cracked...

Page 542: ...des for the following Worn guide surface 1 Cracked or broken guide surface 2 Cracked or damaged guide base 3 2 Replace a damaged right secondary timing chain guide Left Secondary Timing Chain Shoe 1 I...

Page 543: ...g timing chain tensioner Reset the plunger 3 and ensure the plunger moves freely 2 in and out of the body of the tensioner Refer to Primary Camshaft Drive Chain Tensionser Installation Third Design Pr...

Page 544: ...ondary Camshaft Drive Chain Tensioner Installation Right Side Third Design Secondary Camshaft Drive Chain Tensioner Installation Right Side Fourth Design 3 Replace a damaged right secondary timing cha...

Page 545: ...nt cover with compressed air Inspection Procedure 1 Inspect the exterior of the engine front cover for the following conditions Damage to the camshaft position actuator valve oil seal bores 1 Damage t...

Page 546: ...aft Actuator Valve Seal Remover Installer J 29184 Output Shaft Seal Installer NOTE Do not lubricate the crankshaft front oil seal or crankshaft balancer sealing surfaces The crankshaft balancer is ins...

Page 547: ...ft Cover Removal Right Side Left Camshaft Cover 1 Remove and discard the left camshaft cover bolt grommets 2 Remove the fuel injector sight shield ballstud 3 Remove the oil fill cap NOTE Do not reuse...

Page 548: ...er 1 Remove and discard the right camshaft cover bolt grommets NOTE Do not reuse the camshaft cover gasket and spark plug shield tube seals 2 Remove and discard the right camshaft cover gasket 3 Remov...

Page 549: ...bolt holes 1 Damage to the oil fill hole 2 Damage to the mounting holes 3 for the ignition coil assembly and fuel injector sight shield ballstud Damage to the positive crankcase ventilation PCV hose c...

Page 550: ...ry PCV Orifice Replacement NOTE If the PCV orifice is damaged or plugged and cannot be cleaned out the PCV orifice can be replaced 1 Remove the old PCV orifice by griping the neck of the orifice with...

Page 551: ...e new PCV fitting with a NEW O ring Reference Camshaft Cover Assemble Camshaft Cover Assemble Reference Camshaft Cover Cleaning and Inspection Special tool J 5590 Bearing and Seal Driver J 25254 A Oil...

Page 552: ...er ball stud to 10 N m 89 lb in NOTE The camshaft cover bolt grommet must be installed into the camshaft cover bolt hole before installing the camshaft cover bolt 5 Install the NEW left camshaft cover...

Page 553: ...ference Camshaft Cover Installation Right Side Intake Manifold Disassemble Reference Intake Manifold Removal Upper to Lower Intake Manifold Disassemble Procedure NOTE Do not reuse the upper to lower i...

Page 554: ...Upper Intake Manifold Disassemble Procedure 1 Remove the throttle body bolts 2 Remove the throttle body 3 Remove and discard the throttle body gasket 4 Remove and discard the upper intake manifold exp...

Page 555: ...connect the fuel injector wiring harness connectors and remove the fuel injector wiring harness 2 Remove the fuel injector rail bolts 3 Remove the fuel injector rail 4 Remove the upper to lower intake...

Page 556: ...or restrictions to the EVAP purge solenoid port 2 Damage to the intake manifold bolt bosses 3 Damage to the EVAP purge solenoid mounting boss 4 Damage debris or restrictions to the brake vacuum boost...

Page 557: ...wer intake manifold sealing surface Cylinder head to lower intake manifold sealing surface 2 Clean the following intake manifold areas in solvent Intake manifold gasket sealing surfaces Intake manifol...

Page 558: ...ss of 0 5 mm 0 020 in must be replaced 4 Repair or replace the lower intake manifold as necessary Reference Intake Manifold Assemble Intake Manifold Assemble Reference Intake Manifold Cleaning and Ins...

Page 559: ...iring harness and connect the fuel injector wiring harness connectors Upper Intake Manifold Assemble Procedure 1 If removed install the NEW expansion plugs into the upper intake manifold 2 Install the...

Page 560: ...the upper to lower intake manifold gasket and the intake manifold to cylinder head sealing gaskets 1 Install the NEW upper to lower intake manifold gaskets 2 Install the upper intake manifold to the l...

Page 561: ...larger hole repair may process better using a tap wrench An extension from kit J 43965 may also be necessary to drive the thread repair tooling dependent on access to the hole being repaired Use only...

Page 562: ...hole and just below the surface 2 of the base material NOTE During the drilling process it is necessary to repeatedly remove the drill and clean chips from the hole and the flutes of the drill Do NOT...

Page 563: ...essed air clean out any chips NOTE During the tapping process it is necessary to repeatedly remove the tap and clean chips from the hole and the flutes of the tap Ensure the tap has created full threa...

Page 564: ...39 GM P N 12377981 Canadian P N 10953463 or equivalent into the tapped hole NOTE All chips must be removed from the tapped hole prior to insert installation 8 Using compressed air clean out any chips...

Page 565: ...he insert OD threads 2 12 Install the insert 2 into the tapped hole by hand only NOTE If the insert will not thread down until the flange contacts the counterbored surface remove the insert immediatel...

Page 566: ...or proper installation into the tapped hole A properly installed insert 1 will be either flush or slightly below flush with the surface of the base material 2 16 Any installed insert that restricts or...

Page 567: ...proper depth the flange of the insert 1 will be seated against the counterbore 2 of the drilled tapped hole 1 Install a stop collar 2 on the counterbore drill 1 if required NOTE During the drilling pr...

Page 568: ...ength 4 Using a suitable tapping wrench tap the threads of the drilled hole by hand only NOTE All chips must be removed from the tapped hole prior to insert installation 5 Using compressed air clean o...

Page 569: ...bricate the threads of the driver installation tool 2 with the J 42385 110 1 9 Install the insert 2 onto the driver installation tool 1 10 Apply threadlock sealant GM P N 12345493 Canadian P N 1095348...

Page 570: ...tom of the insert are being formed and the insert is mechanically locking the insert into the base material threads 13 Continue to rotate the driver installation tool 1 through the insert 2 14 Inspect...

Page 571: ...d tapping procedures When installed to the proper depth the flange 1 of the insert will be seated against surface 2 of the base material of the drilled tapped hole NOTE During the drilling process it...

Page 572: ...nsert length 3 Using a suitable tapping wrench tap the threads of the drilled hole by hand only 4 Tap the drilled hole until the threads at the top of the tap 2 are down to the surface of the base mat...

Page 573: ...t allow oil or other foreign material to contact the outside diameter OD of the insert 8 Lubricate the threads of the driver installation tool 2 with the J 42385 110 1 9 Install the insert 2 onto the...

Page 574: ...sert until the flange 2 of the insert contacts the surface of the base material NOTE The driver installation tool will tighten up before screwing completely through the insert This is acceptable The t...

Page 575: ...e cylinder head bolt hole thread repair components consist of the following J 42385 723 Drill 1 J 42385 724 Tap 2 J 42385 725 Installation driver 3 J 42385 303 Alignment pin 4 J 42385 302 Bushing 5 J...

Page 576: ...m the hole and the flutes of the drill Drill the hole until the stop collar contacts the top of the drill bushing 6 Drill out the threads of the damaged hole NOTE All chips must be removed from the dr...

Page 577: ...ushing 2 NOTE Remove the fixture plate prior to installing the insert with the installer tool 10 Remove the fixture plate bolts 2 11 Remove the fixture plate 3 and bushing 1 NOTE All chips must be rem...

Page 578: ...allow oil or other foreign material to contact the outside diameter OD of the insert 15 Lubricate the threads of the driver installation tool 2 with the J 42385 110 1 16 Install the insert 2 onto the...

Page 579: ...the engine block deck 2 23 Inspect the insert for proper installation into the tapped hole Crankshaft Main Bolt Hole Thread Repair Special tool J 42385 700 High Feature Thread Repair Kit J 42385 2000...

Page 580: ...shing 2 installed over the crankshaft main cap bolt hole to be repaired 2 Loosely install the fixture plate bolts 1 into the remaining crankshaft main cap bolt holes 3 Position the alignment pin 1 thr...

Page 581: ...and clean chips from the hole and the flutes of the tap Ensure the tap has created full threads at least to the depth equal to the insert length 8 Using a suitable tapping wrench tap the threads of th...

Page 582: ...lation 12 Using compressed air clean out any chips NOTE Do not remove the fixture plate ensure the fixture plate is installed during the installation process of the insert Do not allow oil or other fo...

Page 583: ...r tapping 18 Install the insert until the flange of the insert contacts the counterbored surface NOTE The driver installation tool will tighten up before screwing completely through the insert This is...

Page 584: ...hing 1 installed over the crankshaft main cap bolt hole to be repaired 2 Loosely install the fixture plate bolts 2 into the remaining crankshaft main cap bolt holes 3 Position the alignment pin 1 thro...

Page 585: ...and clean chips from the hole and the flutes of the tap Ensure the tap has created full threads at least to the depth equal to the insert length 8 Using a suitable tapping wrench tap the threads of th...

Page 586: ...lation 12 Using compressed air clean out any chips NOTE Do not remove the fixture plate ensure the fixture plate is installed during the installation process of the insert Do not allow oil or other fo...

Page 587: ...tall the insert until the flange of the insert contacts the counterbored surface NOTE The driver installation tool will tighten up before screwing completely through the insert This is acceptable The...

Page 588: ...unless otherwise specified This will provide initial lubrication when the engine is first started Reference Engine Block Assemble Engine Block Assemble Reference Engine Block Cleaning and Inspection 1...

Page 589: ...M14 left side coolant drain threaded plug Tightening torque Tighten the M14 left side coolant drain threaded plug to 31 N m 23 lb ft 12 Apply thread sealant GM P N 12346004 Canadian P N 10953480 or e...

Page 590: ...4 right side oil gallery threaded plug to 31 N m 23 lb ft 18 Install the cylinder block to oil pan alignment dowels 19 Install the NEW right front oil pan rail oil gallery expansion plug 20 Ensure the...

Page 591: ...Roll the bearing into position so that the lock tang engages the crank slot The bearing must fit flush with the upper crankcase 4 Install the new lower crankshaft bearings into position in the main be...

Page 592: ...bearing caps are numbered 1 1 through 4 with the front main bearing cap marked with the number 1 The arrow 2 is to be oriented to the front of the engine 3 Install the crankshaft main bearing caps 4 L...

Page 593: ...ard bolts to 15 N m 11 lb ft plus 110 degrees 12 Tighten the short inner bolts 17 20 Tightening torque Tighten the short inner bolts to 30 N m 22 lb ft plus 60 degrees 13 Tighten the long outer bolts...

Page 594: ...ng clearance inspect the following a Re measure the crankshaft journals for the correct specified size and ensure the proper new bearings are being installed If the crankshaft journals are incorrectly...

Page 595: ...ing caps are numbered 1 1 through 4 with the front main bearing cap marked with the number 1 The arrow 2 is to be oriented to the front of the engine 26 Install the crankshaft main bearing caps 27 Loo...

Page 596: ...quence Tighten the inboard bolts 1 8 Tightening torque Tighten the inboard bolts to 20 N m 15 lb ft plus 80 degrees 33 Tighten the outboard bolts 9 16 Tightening torque Tighten the outboard bolts to 1...

Page 597: ...t be installed in the engine block in the proper direction 2 Select the correctly numbered piston connecting rod assembly for the cylinder A dot 1 showing proper piston orientation is located on the t...

Page 598: ...d bearing into the connecting rod cap NOTE The connecting rod is non directional therefore the connecting rod bearing lock tangs can face inboard or outboard 3 Install the connecting rod end cap on it...

Page 599: ...diameter to ensure proper size The connecting rod is not machinable and the connecting rod must be replaced if out of specification 12 Clean the plastic gaging material from the connecting rod bearing...

Page 600: ...or measuring the connecting rod bearing clearance 3 Install the connecting rod bolts into the connecting rod cap Tightening torque Tighten the connecting rod bolts to 30 N m 22 lb ft 4 Loosen the conn...

Page 601: ...ct the clamp load when the connecting rod bolts are torqued Improper clamp load can lead to component failure and extensive engine damage NOTE DO NOT reuse the old connecting rod bolts 5 Install the N...

Page 602: ...nt GM P N 12378521 Canadian P N 88901148 or equivalent to the NEW crankshaft rear oil seal housing as shown 1 NOTE DO NOT allow any engine oil on the area where the crankshaft rear oil seal housing is...

Page 603: ...ion Right Side Reference Cylinder Head Assemble Special tool EN 46111 Crankshaft Rotation Socket J 45059 Angle Meter NOTE Ensure that the crankshaft is in the timing drive assembly position using the...

Page 604: ...alve Lifter Installation Right Side Reference Valve Lifters Cleaning and Inspection NOTE Do not stroke cycle the stationary hydraulic lash adjuster plunger without oil in the lower pressure chamber NO...

Page 605: ...haft followers in position on the valve tip and stationary hydraulic lash adjuster SHLA 3 The rounded head end of the follower goes on the SHLA while the flat end goes on the valve tip 4 Clean the cam...

Page 606: ...gs for the right intake camshaft is machined off 3 Fourth Design Camshaft Timing Drive System d The number 1 4 and 5 identification rings for the right exhaust camshaft is machined off 4 Fourth Design...

Page 607: ...to Fastener Notice 12 Tighten the camshaft bearing cap bolts in the sequence shown Tightening torque Tighten the camshaft bearing cap bolts in sequence to 10 N m 89 lb in 13 Loosen the center intake c...

Page 608: ...ylinder head bolts a first pass to 15 N m 11 lb ft 2 Tighten the M8 cylinder head bolts a second pass in sequence an additional 60 degrees using the J 45059 Reference Valve Lifter Installation Left Si...

Page 609: ...e pivot pocket 1 roller 2 and valve slot 3 areas of the camshaft followers NOTE The follower must be positioned squarely on the valve tip so that the full width of the roller will completely contact t...

Page 610: ...lect the proper camshaft for the particular installation location The ring placement is defined as follows a The number 4 identification ring for the left intake camshaft is machined off 1 Third Desig...

Page 611: ...have the following meanings The raised feature must always be oriented toward the center of the cylinder head The I indicates the intake camshaft The E indicates the exhaust camshaft The number 2 4 6...

Page 612: ...de Intake Fourth Design Camshaft Position Actuator Installation Right Side Intake Third Design Reference Camshaft Timing Drive Components Cleaning and Inspection Third Design 1 Ensure the proper camsh...

Page 613: ...ator is installed Observe the body of the camshaft position actuator for the IN marking 3 The marking is for an intake camshaft position actuator CAUTION Ensure the proper camshaft position actuator i...

Page 614: ...camshaft position actuator bolt to 58 N m 43 lb ft Reference Camshaft Position Actuator Installation Right Side Exhaust Fourth Design Camshaft Position Actuator Installation Right Side Exhaust Third...

Page 615: ...amshaft position actuator 2 Ensure the proper timing mark is used Observe the outer ring of the camshaft position actuator for the triangle marking 2 The marking is for alignment to the highlighted ti...

Page 616: ...n Against Timing Drive Chain Notice 3 Use an open wrench on the hex cast into the camshaft in order to prevent camshaft rotation when tightening the camshaft position actuator bolt 4 Install the left...

Page 617: ...of the reluctor wheel 1 lines up with the peak 2 of the sprocket tooth 4 Ensure the proper timing mark is used Observe the outer ring of the camshaft position actuator for the circle marking 1 The cir...

Page 618: ...ust camshaft position actuator CAUTION Refer to Fastener Notice 5 Install the camshaft position actuator bolt Tightening torque Tighten the camshaft position actuator bolt to 58 N m 43 lb ft Reference...

Page 619: ...Install the crankshaft sprocket on to the nose of the crankshaft 3 Align the notch in the crankshaft sprocket with the pin in the crankshaft 4 Slide the crankshaft sprocket on the crankshaft nose unt...

Page 620: ...nkshaft sprocket timing mark 1 aligned to the stage one timing mark on the oil pump cover 2 using the EN 46111 Refer to Camshaft Timing Drive Chain Alignment Diagram Third Design Camshaft Timing Drive...

Page 621: ...at the left camshaft intermediate drive chain idler 2 is being installed The recessed hub 3 and the larger sprocket of the left camshaft intermediate drive chain idler is installed outward The raised...

Page 622: ...the EN 46105 1 is fully seated onto the camshafts 3 Ensure the crankshaft is in the stage one timing position with the crankshaft sprocket timing mark 1 aligned to the stage one timing mark on the oil...

Page 623: ...ment circle mark 2 with the timing camshaft drive chain link 1 9 Align the left intake camshaft position actuator sprocket alignment circle mark 1 with the timing camshaft drive chain link 2 10 There...

Page 624: ...the EN 46105 1 is fully seated onto the camshafts 3 Ensure the crankshaft is in the stage one timing position with the crankshaft sprocket timing mark 1 aligned to the stage one timing mark on the oi...

Page 625: ...ment circle mark 2 with the timing camshaft drive chain link 1 9 Align the left intake camshaft position actuator sprocket alignment circle mark 1 with the timing camshaft drive chain link 2 10 There...

Page 626: ...uide bolts to 23 N m 17 lb ft Reference Secondary Camshaft Drive Chain Shoe Installation Left Side Third Design Secondary Camshaft Drive Chain Guide Installation Left Side Fourth Design 1 Ensure that...

Page 627: ...in shoe CAUTION Refer to Fastener Notice 3 Install the secondary camshaft drive chain shoe bolt Tightening torque Tighten the secondary camshaft drive chain shoe bolt to 23 N m 17 lb ft Reference Seco...

Page 628: ...oe bolt to 23 N m 17 lb ft Reference Secondary Camshaft Drive Chain Tensioner Installation Left Side Fourth Design Secondary Camshaft Drive Chain Tensioner Installation Left Side Third Design Special...

Page 629: ...tensioner should remain compressed 6 Install a NEW left secondary camshaft drive chain tensioner gasket to the left secondary camshaft drive chain tensioner 7 Install the left secondary camshaft drive...

Page 630: ...ve chain tensioner by pulling out the EN 46112 and unlocking the tensioner plunger 12 Verify the left secondary camshaft drive chain timing mark alignments 1 6 Also refer to Camshaft Timing Drive Chai...

Page 631: ...essure on the left secondary camshaft drive chain tensioner The left secondary camshaft drive chain tensioner should remain compressed 6 Install a NEW left secondary camshaft drive chain tensioner gas...

Page 632: ...to 5 N m 44 lb in b Final Pass Tightening torque Tighten the left secondary camshaft drive chain tensioner bolts to 23 N m 17 lb ft 11 Release the left secondary camshaft drive chain tensioner by pull...

Page 633: ...rive chain idler CAUTION Refer to Fastener Notice 3 Install the camshaft intermediate drive chain idler bolt Tightening torque Tighten the camshaft intermediate drive chain idler bolt to 58 N m 43 lb...

Page 634: ...Camshaft Drive Chain Installation Fourth Design Primary Camshaft Drive Chain Installation Third Design NOTE Ensure that the crankshaft is in the stage one timing drive assembly position 1 Install the...

Page 635: ...timing camshaft drive chain link 1 6 Ensure all the timing marks 2 3 6 are properly aligned with the timing camshaft drive chain links 1 4 5 Reference Primary Camshaft Drive Chain Guide Installation...

Page 636: ...rankshaft sprocket 3 The left camshaft intermediate drive chain idler timing mark 1 will align with a timing camshaft drive chain link 2 4 The right camshaft intermediate drive chain idler timing mark...

Page 637: ...drive chain lower guide bolts Tightening torque Tighten the primary camshaft drive chain lower guide bolts to 23 N m 17 lb ft Reference Primary Camshaft Drive Chain Guide Installation Upper Third Des...

Page 638: ...hain guide bolts to 23 N m 17 lb ft Reference Primary Camshaft Drive Chain Tensionser Installation Third Design Primary Camshaft Drive Chain Guide Installation Upper Fourth Design 1 Ensure the upper p...

Page 639: ...stalled 2 Using the J 45027 reset the primary camshaft drive chain tensioner plunger 3 Install the plunger into the primary camshaft drive chain tensioner body 4 Compress the plunger into the body and...

Page 640: ...e NEW primary camshaft drive chain tensioner gasket 9 Place the primary camshaft drive chain tensioner into position and loosely install the bolts to the block CAUTION Refer to Fastener Notice 10 Veri...

Page 641: ...Chain Alignment Diagram Fourth Design Stage One 13 Remove the EN 46105 1 from the rear of the left camshafts 14 Using the EN 46111 rotate the crankshaft and crankshaft sprocket from the stage 1 align...

Page 642: ...onser Installation Fourth Design Special tool EN 46105 Camshaft Locking Tool EN 46111 Crankshaft Rotation Socket EN 46112 Tensioner Retraction Pins J 45027 Tensioner Tool 1 Ensure that the primary cam...

Page 643: ...bolts through the primary camshaft drive chain tensioner and gasket 8 Ensure the primary camshaft drive chain tensioner mounting surface on the engine block does not have any burrs or defects that wo...

Page 644: ...refer to Camshaft Timing Drive Chain Alignment Diagram Third Design Camshaft Timing Drive Chain Alignment Diagram Fourth Design Stage One 13 Remove the EN 46105 1 from the rear of the left camshafts...

Page 645: ...nto the rear of the right camshafts Reference Secondary Camshaft Drive Chain Installation Right Side Fourth Design Secondary Camshaft Drive Chain Installation Right Side Third Design 1 Ensure that the...

Page 646: ...ner sprocket 4 Wrap the secondary camshaft drive chain around both right actuator drive sprockets 5 Ensure there are 7 links 1 between the timing camshaft drive chain links for the camshaft position a...

Page 647: ...ht Side Third Design Secondary Camshaft Drive Chain Installation Right Side Fourth Design 1 Ensure that the crankshaft is in the stage 2 timing drive assembly position 1 2 Install the right secondary...

Page 648: ...et alignment triangle mark 1 with the timing camshaft drive chain link 2 7 Align the right intake camshaft position actuator sprocket alignment triangle mark 2 with the timing camshaft drive chain lin...

Page 649: ...ide bolts to 23 N m 17 lb ft Reference Secondary Camshaft Drive Chain Shoe Installation Right Side Third Design Secondary Camshaft Drive Chain Guide Installation Right Side Fourth Design 1 Ensure that...

Page 650: ...in shoe CAUTION Refer to Fastener Notice 3 Install the secondary camshaft drive chain shoe bolt Tightening torque Tighten the secondary camshaft drive chain shoe bolt to 23 N m 17 lb ft Reference Seco...

Page 651: ...e bolt to 23 N m 17 lb ft Reference Secondary Camshaft Drive Chain Tensioner Installation Right Side Fourth Design Secondary Camshaft Drive Chain Tensioner Installation Right Side Third Design Special...

Page 652: ...ensioner should remain compressed 6 Install a NEW right secondary camshaft drive chain tensioner gasket to the right secondary camshaft drive chain tensioner 7 Install the right secondary camshaft dri...

Page 653: ...N m 17 lb ft 11 Release the right camshaft drive chain tensioner by pulling out the EN 46112 and unlocking the tensioner plunger CAUTION Ensure that all timing chain tensioners are completely released...

Page 654: ...ondary camshaft drive chain tensioner plunger 3 Install the plunger into the right secondary camshaft drive chain tensioner body 4 Compress the plunger into the body and lock the right secondary camsh...

Page 655: ...of the NEW right secondary camshaft drive chain tensioner gasket 9 Place the right secondary camshaft drive chain tensioner into position and loosely install the bolts to the block CAUTION Refer to Fa...

Page 656: ...Design Camshaft Timing Drive Chain Alignment Diagram Fourth Design Stage Two Reference Engine Front Cover Installation Fourth Design Engine Front Cover Installation Third Design Reference Engine Front...

Page 657: ...position 5 Remove the EN 46109 from the cylinder block 6 Install the engine front cover deadener CAUTION Refer to Fastener Notice 7 Loosely install the engine front cover bolts to hold the engine fro...

Page 658: ...ft position actuator valve bolts to 10 N m 89 lb in 12 Install NEW O rings on the camshaft position sensor 13 Place the camshaft position sensors in position on the front cover 14 Install the camshaft...

Page 659: ...ace a 3 mm 0 118 in bead of RTV sealant GM P N 12378521 Canadian P N 88901148 or equivalent on the engine front cover as shown 1 4 Place the engine front cover onto the EN 46109 and slide into positio...

Page 660: ...e front cover bolts 9 Tighten the engine front cover bolts in the sequence shown 1 22 Tightening torque Tighten the engine front cover bolts in the sequence to 23 N m 17 lb ft 10 Place the camshaft po...

Page 661: ...Pump Installation Camshaft Cover Installation Left Side Reference Camshaft Cover Assemble Special tool EN 46101 Spark Plug Tube Seal Guide EN 46105 Camshaft Locking Tool 1 Remove the EN 46105 2 from...

Page 662: ...valent on the engine front cover split lines 1 6 Place the left camshaft cover into position onto the left cylinder head 7 Loosely install the left camshaft cover bolts CAUTION Refer to Fastener Notic...

Page 663: ...Install the NEW spark plugs into the left cylinder head Tightening torque Tighten the spark plugs to 20 N m 15 lb ft 11 Install the ignition coils 12 Install the ignition coil bolts Tightening torque...

Page 664: ...2 Install the EN 46101 onto the spark plug tubes of the right cylinder head 3 Install the camshaft cover bolt grommets prior to installing the camshaft cover bolts 4 Wipe the camshaft cover sealing su...

Page 665: ...sely install the right camshaft cover bolts CAUTION Refer to Fastener Notice 8 Tighten the right camshaft cover bolts in the sequence shown Tightening torque Tighten the right camshaft cover bolts in...

Page 666: ...spark plugs to 20 N m 15 lb ft 11 Install the ignition coils 12 Install the ignition coil bolts Tightening torque Tighten the ignition coil bolt to 10 N m 89 lb in Reference Intake Manifold Installat...

Page 667: ...y CAUTION Refer to Fastener Notice 3 Loosely install the short intake manifold bolts 4 Loosely install the long intake manifold bolts Tightening torque Tighten all of the intake manifold bolts to 23 N...

Page 668: ...10 N m 89 lb in 7 Install and connect the intake manifold to solenoid EVAP hose to the intake manifold and to the EVAP solenoid 8 Install and connect the dirty air positive crankcase ventilation PCV h...

Page 669: ...0 N m 89 lb in 12 Install and connect the fresh air PCV hose to the left camshaft cover fitting Reference Engine Flywheel Installation Engine Flywheel Installation Reference Engine Flywheel Cleaning a...

Page 670: ...nkshaft Balancer Installation Reference Crankshaft Balancer Cleaning and Inspection Special tool EN 46106 Engine Flywheel Holding Tool J 41998 B Crankshaft Balancer Installer J 45059 Angle Meter 1 The...

Page 671: ...nkshaft balancer bolt CAUTION Refer to Fastener Notice 9 Tighten the crankshaft balancer bolt Tightening torque 1 Tighten the crankshaft balancer bolt to 100 N m 74 lb ft 2 Tighten the crankshaft bala...

Page 672: ...engine preluber into the engine 1 Remove the engine oil filter CAUTION Special new tool EN 47971 must be used Due to the special size and thread pitch of the oil filter adapter fitting ensure the pro...

Page 673: ...ough the flexible hose and into the engine assembly 7 Close the valve of the J 45299 8 Remove the J 45299 flexible hose 9 Remove the fitting from the EN 47971 10 Remove the EN 47971 from the oil filte...

Page 674: ...m 22 lb ft Final Pass 60 Degrees Crankshaft Rear Oil Seal Housing Bolt 10 N m 89 lb in Cylinder Head Bolt M8 First Pass 15 N m 10 lb ft Final Pass 60 Degrees Cylinder Head Bolt M11 First Pass 45 N m 3...

Page 675: ...Position CMP Actuator Solenoid Valve Bolt 10 N m 89 lb in Camshaft Position CMP Sensor Bolt 10 N m 89 lb in Crankshaft Position CKP Sensor Bolt 10 N m 89 lb in Ignition Coil Bolt 10 N m 89 lb in Rear...

Page 676: ...ter Pin End 24 007 24 021 mm 0 9452 0 9457 in Connecting Rod Length Center to Center 150 400 mm 5 9212 in Connecting Rod Side Clearance 0 095 0 355 mm 0 0374 0 0140 in Connecting Rod Width Bearing End...

Page 677: ...ameter 53 310 53 335 mm 2 0988 2 0998 in Housing Hub Diameter 53 380 53 420 mm 2 1016 2 1031 in Inner Gerotor Hub Clearance to Housing 0 045 0 110 mm 0 0018 0 0043 in Piston Rings Piston Ring End Gap...

Page 678: ...ake 0 025 0 065 mm 0 0010 0 0026 in Valve Lifters Valve Lifter Diameter 11 489 12 000 mm 0 4523 0 4724 in Valve Lifter to Bore Clearance 0 037 0 041 mm 0 0015 0 0016 in Rocker Arms Valve Rocker Arm Ra...

Page 679: ...ead Size Drill Counter Bore Tool Stop Collar Tap Driver Insert Drill Depth Maximum Tap Depth Minimum J 42385 MM IN MM IN 1 M6 x 1 0 201 202 N A 203 204 205 22 5 0 885 8 18 0 0 708 7 2 M6 x 1 0 201 202...

Page 680: ...n Thread Size Drill Counter Bore Tool Stop Collar Tap Driver Insert Drill Depth Maximum Tap Depth Minimum J 42385 MM IN MM IN 1 M8 x 1 25 206 207 N A 208 209 210 THRU THRU 2 M12 x 1 75 856 857 N A 858...

Page 681: ...Intake Face Left Cylinder Head Intake Face Hole Location Thread Size Drill Counter Bore Tool Stop Collar Tap Driver Insert Drill Depth Maximum Tap Depth Minimum J 42385 MM IN MM IN 1 M8 x 1 25 206 20...

Page 682: ...ol Stop Collar Tap Driver Insert Drill Depth Maximum Tap Depth Minimum J 42385 MM IN MM IN 1 M10 x 1 5 211 212 N A 213 214 215 33 5 1 318 9 27 0 1 063 0 2 M12 x 1 5 705 706 N A 707 708 709 27 5 1 082...

Page 683: ...ad Rear Face Left Cylinder Head Rear Face Hole Location Thread Size Drill Counter Bore Tool Stop Collar Tap Driver Insert Drill Depth Maximum Tap Depth Minimum J 42385 MM IN MM IN 1 M10 x 1 5 211 212...

Page 684: ...Counter Bore Tool Stop Collar Tap Driver Insert Drill Depth Maximum Tap Depth Minimum J 42385 MM IN MM IN 1 M6 x 1 0 201 202 N A 203 204 205 THRU THRU 2 M6 x 1 0 701 N A N A 203 204 205 28 5 1 122 0...

Page 685: ...p Driver Insert Drill Depth Maximum Tap Depth Minimum J 42385 MM IN MM IN 1 M8 x 1 25 206 207 N A 208 209 210 THRU THRU 2 M6 x 1 0 201 202 N A 203 204 205 22 5 0 888 0 18 0 0 708 7 3 M6 x 1 0 201 202...

Page 686: ...Intake Face Right Cylinder Head Intake Face Hole Location Thread Size Drill Counter Bore Tool Stop Collar Tap Driver Insert Drill Depth Maximum Tap Depth Minimum J 42385 MM IN MM IN 1 M8 x 1 25 206 2...

Page 687: ...read Size Drill Counter Bore Tool Stop Collar Tap Driver Insert Drill Depth Maximum Tap Depth Minimum J 42385 MM IN MM IN 1 M6 x 1 0 201 202 N A 203 204 205 22 5 0 885 8 18 0 0 000 0 2 M10 x 1 5 211 2...

Page 688: ...ad Rear Face Right Cylinder Head Rear Face Hole Location Thread Size Drill Counter Bore Tool Stop Collar Tap Driver Insert Drill Depth Maximum Tap Depth Minimum J 42385 MM IN MM IN 1 M10 x 1 5 211 212...

Page 689: ...IN 1 M8 x 1 25 206 207 N A 208 209 210 28 5 1 122 0 23 0 0 905 5 2 M10 x 1 5 211 212 N A 213 214 215 33 5 1 318 9 27 0 1 063 0 3 M8 x 1 25 206 207 N A 208 209 210 THRU 23 0 0 905 5 4 M8 x 1 25 206 20...

Page 690: ...l Depth Maximum Tap Depth Minimum J 42385 MM IN MM IN 1 M8 x 1 25 206 207 N A 208 209 210 28 5 1 122 0 23 0 0 905 5 2 M20 x 1 5 715 716 N A 717 718 719 30 0 1 181 0 20 0 0 787 4 3 M10 x 1 5 211 212 N...

Page 691: ...op Collar Tap Driver Insert Drill Depth Maximum Tap Depth Minimum J 42385 MM IN MM IN 1 M6 x 1 0 201 202 N A 203 204 205 22 5 0 885 8 18 0 0 708 7 2 M8 x 1 25 206 207 N A 208 209 210 28 5 1 122 0 23 0...

Page 692: ...rill Depth Maximum Tap Depth Minimum J 42385 MM IN MM IN 1 M10 x 1 5 211 212 N A 213 214 420 33 5 1 319 0 27 0 1 063 0 2 M6 x 1 0 201 202 N A 203 204 205 22 5 0 885 8 18 0 0 708 7 3 M14 x 1 5 409 410...

Page 693: ...top Collar Tap Driver Insert Drill Depth Maximum Tap Depth Minimum J 42385 MM IN MM IN 1 M10 x 2 0 720 N A N A 721 722 104 56 0 2 204 7 49 0 1 929 1 2 M8 x 1 25 702 N A N A 703 704 620 46 0 1 8110 40...

Page 694: ...eck Face Hole Location Thread Size Drill Counter Bore Tool Stop Collar Tap Driver Insert Drill Depth Maximum Tap Depth Minimum J 42385 MM IN MM IN 1 M8 x 1 25 206 207 N A 208 209 210 28 5 1 122 0 23 0...

Page 695: ...Deck Face Hole Location Thread Size Drill Counter Bore Tool Stop Collar Tap Driver Insert Drill Depth Maximum Tap Depth Minimum J 42385 MM IN MM IN 1 M11 x 2 0 723 N A N A 724 725 108 102 5 4 035 4 94...

Page 696: ...pth Minimum J 42385 MM IN MM IN 1 M6 x 1 0 201 202 N A 203 204 205 THRU THRU 2 M6 x 1 0 201 202 N A 203 204 205 21 5 0 846 5 18 0 0 708 7 3 M8 x 1 25 206 207 N A 208 209 210 28 5 1 122 0 23 0 0 905 5...

Page 697: ...ake Manifold Top Hole Location Thread Size Drill Counter Bore Tool Stop Collar Tap Driver Insert Drill Depth Maximum Tap Depth Minimum J 42385 MM IN MM IN 1 M6 x 1 0 201 202 N A 203 204 205 THRU THRU...

Page 698: ...ntake Manifold Front Upper Intake Manifold Front Hole Location Thread Size Drill Counter Bore Tool Stop Collar Tap Driver Insert Drill Depth Maximum Tap Depth Minimum J 42385 MM IN MM IN 1 M6 x 1 0 20...

Page 699: ...wer Intake Manifold Top Hole Location Thread Size Drill Counter Bore Tool Stop Collar Tap Driver Insert Drill Depth Maximum Tap Depth Minimum J 42385 MM IN MM IN 1 M6 x 1 0 201 202 N A 203 204 205 THR...

Page 700: ...river Insert Drill Depth Maximum Tap Depth Minimum J 42385 MM IN MM IN 1 M10 x 1 5 211 212 N A 213 214 420 33 5 1 318 9 27 0 1 063 0 2 M12 x 1 75 856 857 N A 858 859 416 39 5 1 555 1 32 0 1 259 8 3 M8...

Page 701: ...an Left Side Oil Pan Left Side Hole Location Thread Size Drill Counter Bore Tool Stop Collar Tap Driver Insert Drill Depth Maximum Tap Depth Minimum J 42385 MM IN MM IN 1 M10 x 1 5 211 212 N A 213 214...

Page 702: ...ze Drill Counter Bore Tool Stop Collar Tap Driver Insert Drill Depth Maximum Tap Depth Minimum J 42385 MM IN MM IN 1 M12 x 1 75 856 857 N A 858 859 416 THRU THRU 2 M8 x 1 25 206 207 N A 208 209 210 28...

Page 703: ...Oil Pan Rear Oil Pan Rear Hole Location Thread Size Drill Counter Bore Tool Stop Collar Tap Driver Insert Drill Depth Maximum Tap Depth Minimum J 42385 MM IN MM IN 1 M10 x 1 5 211 212 N A 213 214 420...

Page 704: ...Oil Pan Top Oil Pan Top Hole Location Thread Size Drill Counter Bore Tool Stop Collar Tap Driver Insert Drill Depth Maximum Tap Depth Minimum J 42385 MM IN MM IN 1 M6 x 1 0 701 N A N A 203 204 205 28...

Page 705: ...flange near both strut towers 3 Install three J 28467 13 1 and two J 28467 5 strut tower adapters 2 to the top of the left and right strut tower 4 Install a 127 cm 50 in engine support fixture cross b...

Page 706: ...mp 3 to secure the longitudinal mounted cross bar to the transverse mounted cross bar 10 Assemble the lift hook wing nut J 28467 34 and the lift hook bracket J 28467 6A to the lift hook J 28467 7A 11...

Page 707: ...7A 14 Install the lift hook and bracket assembly 1 to the longitudinal mounted cross bar 2 15 Position the J 28467 7A bolt hook 1 to the front engine lift bracket J 42451 1 2 16 Evenly tighten both w...

Page 708: ...the following items should be readily available Approved eye protection and safety gloves A clean well lit work area A suitable component cleaning tank A compressed air supply Trays or storage contain...

Page 709: ...staller EN 46119 Off Vehicle Valve Spring Compressor Adapter Illustration Tool Number Description EN 46121 Connecting Rod Guide Pin Set EN 46122 Camshaft Position Actuator Check Ball Valve Remover Ins...

Page 710: ...g and Seal Driver J 6125 1B Slide Hammer Adapter J 7872 Magnetic Base Dial Indicator Illustration Tool Number Description J 8001 Dial Indicator Set J 8037 Ring Compressor J 8062 Valve Spring Compresso...

Page 711: ...ngine Support Fixture Adapter J 28467 B Universal Engine Support Fixture Illustration Tool Number Description J 28467 7A Bolt Hook J 28467 34 Lift Hook Wing Nut and Washer J 29184 Oil Seal Installer J...

Page 712: ...r Remover J 41818 Crankshaft Bearing Cap Remover J 41998 B Crankshaft Balancer Installer Illustration Tool Number Description J 42096 Valve Guide Reamer J 42183 Handle J 42385 700 High Feature Thread...

Page 713: ...100 Rod Bearing Clearance Checking Tool Adapter Kit J 43965 Thread Repair Extension Kit J 45000 Seal Remover J 45027 Tensioner Tool Illustration Tool Number Description J 45059 Angle Meter J 45299 Eng...

Page 714: ...control solenoid valve is used to control the exhaust camshaft position actuator and one camshaft position actuator oil control solenoid valve is used to control the intake camshaft position actuator...

Page 715: ...due to leaks is the use of 0 946 L 1 qt or more of engine oil within 3 200 km 2 000 mi The causes of excessive oil consumption may include the following conditions Preliminary External oil leaks Refe...

Page 716: ...ngine block bolts loose Refer to Oil Pump Replacement Oil pump screen loose plugged or damaged Refer to Oil Pump Suction Pipe and Screen Assembly Replacement and Oil Pump Pipe and Screen Cleaning and...

Page 717: ...sual Inspection Method 1 Bring the vehicle to normal operating temperature 2 Park the vehicle over a large sheet of paper or other clean surface 3 Wait several minutes then check for drippings 4 Ident...

Page 718: ...evel indicator in the oil level indicator tube Black Light and Dye Method 1 A dye and light kit is available for finding leaks Use the J 28428 E High Intensity Black Light Kit or equivalent Refer to t...

Page 719: ...pan under the oil filter 6 Remove the oil filter Allow the oil to drain completely Installation Procedure 1 Lubricate the NEW oil filter gasket with clean engine oil 2 Tighten the oil filter Tighteni...

Page 720: ...ter gasket onto the oil filter adapter 2 Place the oil filter adapter into position CAUTION Refer to Fastener Notice 3 Install the oil filter adapter bolts Ensure the longer bolts 1 is installed in th...

Page 721: ...ect the battery negative cable Refer to Battery Negative Cable Disconnection and Connection 2 Install the engine support fixture Refer to Engine Support Fixture 3 Remove the right side engine mount Re...

Page 722: ...t hole on each side of the engine block 2 Place a 3 mm 0 118 in bead 1 of RTV sealant GM P N 12378521 Canadian P N 88901148 or equivalent on the block pan rail and the crankshaft rear oil seal housing...

Page 723: ...Oil Filter Replacement 11 Install the right side engine mount Refer to Engine Mount Replacement Right Side 12 Remove the engine support fixture Refer to Engine Support Fixture 13 Connect the battery n...

Page 724: ...efer to Primary Camshaft Drive Chain and Sprockets Replacement Oil Pump Suction Pipe and Screen Assembly Replacement Removal Procedure 1 Remove the oil pan Refer to Oil Pan Replacement 2 Remove the oi...

Page 725: ...Notice 3 Install the oil suction pipe bolts Tightening torque Tighten the oil suction pipe bolts to 10 N m 89 lb in 4 Install the oil pan scraper 5 Install the oil pan scraper bolts Tightening torque...

Page 726: ...e tube out from the lower crankcase hole 3 Remove and discard the O ring from the oil level indicator tube Oil Filter Adapter Removal Reference Exhaust Manifold Removal Left Side 1 Remove and properly...

Page 727: ...d discard the oil filter adapter gasket 5 Remove the left knock sensor bolt 6 Remove the left knock sensor Reference Oil Filter Adapter Disassemble Oil Pan Removal Reference Cylinder Head Removal Left...

Page 728: ...Reference Oil Pan Removal 1 Remove the oil pump bolts 2 Remove the oil pump Reference Oil Pump Disassemble Oil Pump Disassemble Reference Oil Pump Removal NOTE There are no serviceable components wit...

Page 729: ...lower guide bolts 3 Remove the primary camshaft drive chain lower guide 4 Remove the bolts holding the oil pump cover to the oil pump housing 5 Remove the oil pump cover from the oil pump housing 6 Re...

Page 730: ...assembled oil pump must be replaced 1 Inspect the oil pump housing for the following Damage scoring or debris on the housing surface for the driven gear 1 Damage to the oil pump mounting bosses 2 Dama...

Page 731: ...inspected 4 Inspect the outer driven gear for damage 5 Inspect the oil pump relief valve components for debris or damage 6 Inspect the primary camshaft drive chain lower guide for damage 1 3 7 If deb...

Page 732: ...TE There are no serviceable components within the oil pump Disassemble the pump only to diagnose an oiling concern A disassembled oil pump must be replaced DO NOT reuse a disassembled oil pump or a se...

Page 733: ...Filter Adapter Removal 1 Remove the oil pressure sender 2 Remove the oil filter fitting Reference Oil Filter Adapter Cleaning and Inspection Oil Filter Adapter Cleaning and Inspection Reference Oil F...

Page 734: ...r damage 5 Inspect the mounting holes 5 for damage 6 Inspect the oil filter adapter housing gasket sealing surface 1 for damage 7 Inspect the oil filter adapter housing passages 2 for damage or blocka...

Page 735: ...the oil pan scraper bolts 3 Remove the oil pan scraper 4 Remove the oil suction pipe bolts 5 Remove the oil suction pipe 6 Remove the oil suction tube seal from the oil suction tube Discard the oil s...

Page 736: ...erior 2 Damage to the oil pan mounting holes 3 Damage to the transmission mounting bolt hole threads 4 Damage to the bracket bolt hole threads 5 2 Inspect the exterior of the oil pan for the following...

Page 737: ...pection Procedure 1 Inspect the mounting surface 1 for possible leakage paths 2 Inspect the oil pump pipe tube 2 for cracks imperfections and or damage 3 Inspect the oil pump pipe support bracket 3 fo...

Page 738: ...in plug and NEW O ring seal Tightening torque Tighten the oil pan drain plug to 20 N m 15 lb ft Reference Oil Pan Installation Oil Pump Installation Reference Oil Pump Assemble 1 Align the oil pump ge...

Page 739: ...nto the center oil pan rail bolt hole on each side of the engine block 2 Place a 3 mm 0 118 in bead 1 of RTV sealant GM P N 12378521 Canadian P N 88901148 or equivalent on the block pan rail and the c...

Page 740: ...der Head Installation Left Side Oil Filter Adapter Installation Reference Oil Filter Adapter Assemble 1 Position the left knock sensor to the cylinder block as shown CAUTION Refer to Fastener Notice 2...

Page 741: ...Ensure the longer bolts 1 is installed in the upper rear position Tightening torque Tighten the oil filter adapter bolts to 23 N m 17 lb ft 7 Install a NEW oil filter Reference Exhaust Manifold Insta...

Page 742: ...ner Tightening Specifications Engine Mechanical 3 6L LY7 Application Specification Metric English Knock Sensor Bolt 23 N m 17 lb ft Oil Drain Plug 25 N m 18 lb ft Oil Filter 25 N m 18 lb ft Oil Filter...

Page 743: ...er tightening of various fasteners To properly service the engine assembly the following items should be readily available Approved eye protection and safety gloves A clean well lit work area A suitab...

Page 744: ...10 volt AC external power and is designed to warm the coolant in the engine block area for improved starting in very cold weather 29 C 20 F The coolant heater helps reduce fuel consumption when a cold...

Page 745: ...causes the vacuum valve to open allowing outside air into the surge tank This equalizes the pressure in the cooling system with atmospheric pressure preventing the radiator and coolant hoses from col...

Page 746: ...em after it has opened This restriction creates a pressure difference which prevents cavitation at the water pump and forces coolant to circulate through the engine block Transmission Oil Cooler The t...

Page 747: ...Engine Cooling System 1F 4 Engine Cooling Schematics...

Page 748: ...tion Crimp 4 5 Release Tool Test Probe 15315247 J 35616 4A PU Pin Wire Color Circuit No Function A L BU 409 Cooling Fan Motor Supply Voltage B BK 1250 Ground Connector Part Information OEM 13517352 Se...

Page 749: ...Engine Cooling System 1F 6 Component Location Cooling System Component Views Front of the Engine Compartment 1 Fuse Block Underhood 3 Cooling Fan Left 2 Battery 4 Cooling Fan Right...

Page 750: ...lay control when the following conditions are met The ignition is ON or the engine is running A C compressor operation is not requested The engine coolant temperature is less than 106 C 224 F Fan Rela...

Page 751: ...air entering the engine coolant temperature and ambient air temperature If the actual engine coolant temperature does not reach this calculated temperature within a predetermined amount of time a DTC...

Page 752: ...sing a low side driver Conditions for Running the DTC The ignition voltage is between 8 18 volts The engine speed is more than 40 RPM The ECM driver transitions from ON to OFF or from OFF to ON Condit...

Page 753: ...disconnect the fan relay 1 2 Ignition ON verify that a test lamp illuminates between the ignition voltage circuit terminal and ground If the test lamp does not illuminate test the ignition voltage cir...

Page 754: ...tery to relay terminal 85 Connect a jumper wire from the negative terminal of the battery to relay terminal 86 Measure for less than 2 ohms between terminals 30 and 87 of the relay If the resistance m...

Page 755: ...d parameters on the scan tool to know which fans are being commanded ON by the ECM The following tables illustrate the FAN 1 relay FAN 2 relay and the FAN 3 relay terminal locations in the underhood f...

Page 756: ...In low speed both fans are turned ON at a reduced speed High speed has both fans turned ON at full speed In low speed operation the ECM applies ground to the coil side of the cooling fan 1 relay This...

Page 757: ...relay switch B circuit terminal 30 and the relay supply circuit terminal 87 at the FAN 2 relay connector This will in complete the left side or main fan ground circuit Leave this jumper in place for t...

Page 758: ...properly 2 Repair the cooling fan system as necessary Does the engine still overheat Go to Step 4 System OK 4 Perform the following inspections Inspect the radiator and the A C condenser cooling fins...

Page 759: ...her diagnostic table Go to Step 2 Go to Symptoms Engine Cooling 2 Repair any present DTCs Refer to Diagnostic Trouble Code DTC List Vehicle Diagnostic Information Is the action complete Go to Step 3 3...

Page 760: ...Pressure test the coolant pressure cap Refer to Pressure Cap Testing Does the coolant pressure cap hold pressure Go to Step 30 Go to Step 21 16 Inspect for the following conditions A coolant smell in...

Page 761: ...ing system Refer to Cooling System Leak Testing 3 Inspect the transmission oil cooler for coolant Is coolant present Go to Step 24 Go to Step 25 24 1 Replace the radiator Refer to Radiator Replacement...

Page 762: ...g fan s Is the electric cooling fan on Go to Step 2 Go to Step 3 2 1 Diagnose and repair the cooling fan system Refer to Cooling Fan Always On 2 Verify the customer complaint Does the engine still fai...

Page 763: ...out over the engine fenders and the person removing the cap Serious bodily injury may result Flammable antifreeze such as alcohol is not recommended for use at any time Flammable antifreeze could cau...

Page 764: ...d Filling Cooling System LY7 GE 47716 Fill Draining and Filling Cooling System LY7 Static Fill Draining and Filling Cooling System LY7 GE 47716 Fill Special tool J 26568 Coolant and Battery Fluid Test...

Page 765: ...sh procedure Refer to Coolant System Flushing Vac N Fill Procedure WARNING To avoid being burned do not remove the radiator cap or surge tank cap while the engine is hot The cooling system will releas...

Page 766: ...r the coolant mixture into the graduated reservoir 7 Place the fill hose in the graduated reservoir NOTE Prior to installing the vacuum tank onto the graduated reservoir ensure that the drain valve lo...

Page 767: ...raw 14 To aid in the fill process position the graduated reservoir above the surge tank 15 Slowly open the valve on the vacuum gauge assembly When the coolant reaches the top of the fill hose close th...

Page 768: ...J 26568 NOTE After filling the cooling system the extraction hose can be used to remove excess coolant to achieve the proper coolant level 24 Detach the vacuum hose from the vacuum gauge assembly 25 A...

Page 769: ...nt System Flushing Filling Procedure CAUTION All entrapped air must be purged from the powertrain cooling system before the final coolant level can be determined Proper coolant level is critical to av...

Page 770: ...ining and Filling Cooling System LY7 Static Fill 2 Remove the surge tank Refer to Surge Tank Replacement 3 Clean and flush the surge tank with clean drinkable water 4 Install the surge tank Refer to S...

Page 771: ...Refer to Draining and Filling Cooling System LY7 GE 47716 Fill Draining and Filling Cooling System LY7 Static Fill Heater Outlet Pipe Replacement Removal Procedure 1 Partially drain the cooling system...

Page 772: ...dure 1 Install a NEW heater inlet pipe O ring CAUTION Refer to Fastener Notice 2 Install the heater outlet pipe 1 3 Install the heater outlet hose 1 to the heater outlet pipe 4 Install the heater inle...

Page 773: ...System LY7 Static Fill 2 Remove the heater outlet hose clamp from the heater core 3 Remove the heater outlet hose clamp from the engine 4 Remove the heater outlet hose clamp from the auxiliary heater...

Page 774: ...placement Callout Component Name Preliminary Procedure Partially drain the cooling system Refer to Draining and Filling Cooling System LY7 GE 47716 Fill Draining and Filling Cooling System LY7 Static...

Page 775: ...the heater outlet hose 6 Remove the heater outlet hose clamp from the surge tank 7 Remove the heater outlet hose from the surge tank 8 Remove the surge tank from the vehicle Installation Procedure 1 I...

Page 776: ...Replacement Callout Component Name Preliminary Procedure Drain the cooling system Refer to Draining and Filling Cooling System LY7 GE 47716 Fill Draining and Filling Cooling System LY7 Static Fill 1 R...

Page 777: ...nary Procedure 1 Drain the cooling system Refer to Draining and Filling Cooling System LY7 GE 47716 Fill Draining and Filling Cooling System LY7 Static Fill 2 Raise and suitably support the vehicle Re...

Page 778: ...he electrical connectors from the fan motors 4 Unclip the wire harness from the fan assembly 5 Remove the condenser radiator fan module CRFM closeout panel retainers from the condenser 6 Remove the CR...

Page 779: ...cket 17 Remove the fan assembly from the vehicle Installation Procedure 1 Install the fan assembly to the vehicle 2 Return the condenser and radiator assembly to the mounted position 3 Install the fan...

Page 780: ...r to Front Bumper Impact Bar Replacement 12 Install the CRFM closeout panel to the condenser 13 Install the CRFM closeout panel retainers to the condenser 14 Clip the engine wire harness to fan assemb...

Page 781: ...l loads must be OFF unless instructed otherwise in these procedures If a tool or equipment could easily come in contact with a live exposed electrical terminal also disconnect the negative battery cab...

Page 782: ...5 mm 0 25 in drill bit 6 Tap the rivets out of the fan shroud 7 Remove the fan motor from the fan shroud NOTE Blow off any excess debris from the fan motor 8 Remove the tape covering the entry points...

Page 783: ...under the running water for a minimum of 60 seconds to heat the fan blade to the temperature of the water Immediately after heating position the fan blade on the fan motor drive plate 4 Install the n...

Page 784: ...t bar Refer to Front Bumper Impact Bar Replacement 5 Remove radiator closeout panel 6 Disconnect the compressor hose pipe from clip at bottom of fan shroud 7 Remove mounting bolts from condenser using...

Page 785: ...en the thermostat housing bolts to 10 N m 89 lb in 2 Install the heater inlet and outlet pipes Refer to Heater Inlet Pipe Replacement and Heater Outlet Pipe Replacement 3 Fill the cooling system Refer...

Page 786: ...Refer to Radiator Surge Tank Inlet Hose Pipe Replacement 3 Reposition the coolant air bleed hose clamp 1 at the coolant air bleed hose 4 Remove the coolant air bleed pipe from the coolant air bleed ho...

Page 787: ...ON Refer to Fastener Notice 3 Install the water outlet housing bolts 1 Tightening torque Tighten the water outlet housing bolts to 10 N m 89 lb in 4 Install the radiator outlet hose Refer to Radiator...

Page 788: ...mp bolts Tightening torque Tighten the water pump bolts to 10 N m 89 lb in 4 Install the water pump pulley and the water pump pulley bolts 5 Use the EN 46104 in order to retain the water pump pulley 6...

Page 789: ...the vehicle 4 Refill the cooling system Refer to Draining and Filling Cooling System LY7 GE 47716 Fill Draining and Filling Cooling System LY7 Static Fill Coolant Heater Cord Replacement Removal Proc...

Page 790: ...icle Refer to Lifting and Jacking the Vehicle 5 Route the coolant heater cord along the engine wiring harness conduit 6 Connect the coolant heater cord to the coolant heater 1 7 Secure the coolant hea...

Page 791: ...water outlet 4 Remove and discard the water outlet gasket and O ring Engine Coolant Thermostat Housing Removal Reference Water Outlet Removal 1 Remove the heater inlet outlet pipe assembly bolts 2 Rem...

Page 792: ...ve and discard the heater inlet outlet pipe gasket and O ring 4 Remove the coolant pipe bolt 5 Remove the coolant pipe 6 Remove and discard the coolant pipe O ring 7 Remove the thermostat housing bolt...

Page 793: ...ght Side Special tool EN 46104 Water Pump Pulley Holding Tool 1 Install the EN 46104 1 onto the water pump pulley 2 Remove the water pump pulley bolts 3 Remove the water pump pulley 4 Remove the water...

Page 794: ...If the hub wobbles is noisy or feels rough when rotated replace the water pump 2 Inspect the exterior of the water pump for the following Damage to the water pump hub bolt threads 2 for the water pump...

Page 795: ...n position on the front cover CAUTION Refer to Fastener Notice 4 Install the water pump bolts Tightening torque Tighten the water pump bolts to 10 N m 89 lb in 5 Install the water pump pulley 6 Loosel...

Page 796: ...astener Notice 3 Install the thermostat housing bolts Ensure to install the short bolts 1 and the long bolt 2 in the proper position Tightening torque Tighten the thermostat housing bolts to 10 N m 89...

Page 797: ...m 89 lb in 7 Install a NEW gasket and O ring onto the heater inlet outlet pipe assembly 8 Install the heater inlet outlet pipe assembly 9 Install the heater inlet outlet pipe assembly bolts Tightenin...

Page 798: ...ing onto the water outlet 2 Install the water outlet CAUTION Refer to Fastener Notice 3 Install the water outlet bolts Tightening torque Tighten the water outlet bolts to 10 N m 89 lb in 4 Connect the...

Page 799: ...itable component cleaning tank A compressed air supply Trays or storage containers to keep components and fasteners organized An adequate set of hand tools Approved engine repair stand An approved eng...

Page 800: ...ing Tool Illustration Tool Number Description GE 47716 Vac N Fill Coolant Refill Tool GE 47827 Socket J 21882 Oil Suction Pipe Installer J 24460 01 Cooling System Pressure Tester J 24731 Tempil Stick...

Page 801: ...fuel system pressure a small amount of fuel may be released when servicing the fuel lines the fuel injection pump or the connections In order to reduce the risk of personal injury cover the fuel syst...

Page 802: ...of the vehicle The fuel tank is molded from high density polyethylene In order to provide space for a driveshaft though the center area of the tank the fuel tank is a saddle configuration Because of...

Page 803: ...nd the fuel pressure regulator maintain fuel pressure in the fuel feed pipe and the fuel rail in order to prevent long cranking times The primary fuel tank module also consists of the following major...

Page 804: ...the fuel that may damage the fuel injection system The filter housing is made to withstand maximum fuel system pressure exposure to fuel additives and changes in temperature Fuel Pressure Regulator T...

Page 805: ...the vapor line to the canister Providing fuel spillage protection in the event of a vehicle rollover by closing the vapor path from the tank to the engine The pressure vacuum relief valve The pressure...

Page 806: ...s the fueling system will turn OFF the injectors for a period of time This is referred to as fuel shut off Fuel shut off is used in order to improve traction save fuel improve emissions and protect th...

Page 807: ...ors when certain conditions are met These fuel shut off modes allow the ECM to protect the engine from damage and also to improve the vehicles driveability The ECM will disable all of the six injector...

Page 808: ...d Special Functions Engine Control Module CMP Actuator System This function controls the selected camshaft actuator solenoid The normal commanded state is NONE When commanded ON OFF the ECM turns the...

Page 809: ...ameter may not change states when using this output control This function controls the EVAP vent solenoid The normal commanded state is NONE When commanded ON the vent valve switches to Not venting Th...

Page 810: ...throttle actuator control TAC system DTCs are set IMRC Solenoid If Equipped Special Functions Engine Control Module Output Controls This function controls the intake manifold runner control IMRC solen...

Page 811: ...OT Cooling HVAC Yes No No A C Pressure Disable Cooling HVAC Yes No No A C Relay Circuit Status Cooling HVAC OK Fault Indeterminate OK A C Relay Command Eng TAC CH IND MF On Off Off A C Request Signal...

Page 812: ...LL 39 C to 140 C 38 F to 284 F Varies Engine Load CH CMP Eng EVAP FF FR FT HO2S Ign IND MF TAC Trans 0 99 25 45 Idle 40 60 2500 RPM Engine OFF EVAP Test Conditions Met EVAP Yes No Varies Engine Off Ti...

Page 813: ...rim Learn FT Enabled Disabled Enabled GEN L Terminal Signal Command ET ON OFF ON Generator F Terminal Signal ET 0 100 Varies HO2S Bank 1 or 2 Sensor 1 Eng EVAP FT HO2S IND 0 1 006 mV Varies 400 700 mV...

Page 814: ...ce Test IND TAC OK Fault OK MAF Sensor CMP Eng EVAP FF FR FT HO2S Ign IND MF TAC Trans 0 655 g s 3 4 6 3 g s MAF Sensor IND 0 9999 Hz 28 Hz MIL Circuit Status Eng IPC OK Fault Indeterminate OK MIL Com...

Page 815: ...MF Counts 0 TP Desired Angle Eng EVAP TAC 0 100 Varies TP Indicated Angle CMP CT Eng EVAP FT FF FR HO2S Ign IND MF TAC Trans 0 100 Varies TP Performance Test IND TAC FT Active Inactive Inactive TP Sen...

Page 816: ...a range of values indicating a high air flow when MAP pressure is high and a low air flow when MAP pressure is low This value is listed in grams per second g s Air Fuel Ratio This parameter displays t...

Page 817: ...if the circuit is operating correctly The scan tool will display Short or Open if there is an open short to ground or a short to voltage on the circuit Cylinder 1 6 Injector Circuit Status This param...

Page 818: ...Indeterminate until the circuit has been commanded ON This parameter may not change if the scan tool is used to command the EVAP vent solenoid ON EVAP Vent Solenoid Command This parameter displays the...

Page 819: ...by the control module The scan tool will display a higher value as the heater command is increased and a lower value if the heater is not commanded ON HO2S Bank 1 or 2 Sensor 1 or 2 Heater Command Thi...

Page 820: ...uel is being removed from the combustion event The scan tool will display a positive value if the fuel system is running lean and fuel is being added to the combustion event Loop Status Bn 1 or 2 Sen...

Page 821: ...as been commanded ON This parameter may not change if the scan tool is used to command the relay control circuit ON Starter Relay Command This parameter indicates whether the control module is command...

Page 822: ...c converter temperature as calculated by the control module Vehicle Speed Sensor This parameter displays the speed of the vehicle as calculated by the transmission control module TCM from information...

Page 823: ...mal replace the fuel pump relay 2 Test the fuel pump fuse The fuse should not be open If the fuel pump fuse is open test for a short to ground in the supply voltage circuit of the fuel pump If the cir...

Page 824: ...nlet chamber is diverted to the primary jet pump and the secondary jet pump through a restrictive orifice located on the pump cover The primary jet pump fills the reservoir of the primary fuel tank mo...

Page 825: ...ore than 14 kPa 2 psi in 5 minutes If the fuel pressure decreases more than the specified value replace the fuel pump 4 Remove the J 37287 and J 34730 1A Refer to Fuel Pressure Gage Installation and R...

Page 826: ...than 3 ohms If the difference is equal to or less than 3 ohms refer to Fuel Injector Balance Test with Special Tool or Fuel Injector Balance Test with Tech 2 for further diagnosis of the fuel injector...

Page 827: ...tem 4 Monitor the fuel pressure gage for 1 minute Verify that the fuel pressure does not drop more than 34 kPa 5 psi If the fuel pressure decreases more than 34 kPa 5 psi refer to Fuel System Diagnosi...

Page 828: ...can Tool Data Definitions Engine Controls 3 6L LY7 Scan Tool Output Controls Engine Controls 3 6L LY7 Special Tools Required J 34730 1A Fuel Pressure Gage Component Testing Fuel Injector Balance Test...

Page 829: ...ce the fuel injector Repair Instructions Perform the Diagnostic Repair Verification Vehicle Diagnostic Information after completing the diagnostic procedure Fuel Injector and Fuel Rail Replacement Fue...

Page 830: ...hicle Diagnostic Information prior to using this diagnostic procedure Review Strategy Based Diagnosis for an overview of the diagnostic approach Diagnostic Procedure Instructions Vehicle Diagnostic In...

Page 831: ...approach Diagnostic Procedure Instructions Vehicle Diagnostic Information provides an overview of each diagnostic category Description Water contamination in the fuel system may cause driveability co...

Page 832: ...l absorb any fuel leakage that occurs during the connection of the fuel pressure gage Place the towel in an approved container when the connection of the fuel pressure gage is complete 4 Wrap a shop t...

Page 833: ...place in an approved gasoline container 6 Install the fuel rail service port cap 7 Install the engine cover if required 8 Tighten the fuel fill cap Fuel Pressure Gage Installation and Removal Special...

Page 834: ...emove the hose on the J 34730 1A from the approved gasoline container f Remove the shop towel from around the fuel rail service port and place in an approved gasoline container CAUTION Clean all of th...

Page 835: ...ng Insert the tool into the female connector then push inward in order to release the locking tabs WARNING Refer to Relieving Fuel Pressure Caution 5 Pull the connection apart 6 Use a clean shop towel...

Page 836: ...e Removal Procedure WARNING Refer to Gasoline Gasoline Vapors Caution NOTE There are several types of plastic collar fuel and evaporative emission quick connect fittings used on this vehicle Bartholom...

Page 837: ...step applies to Bartholomew style connectors ONLY Squeeze the plastic quick connect fitting release tabs 4 This step applies to Q Release style connectors ONLY Release the fitting by Pushing the tab...

Page 838: ...ssing the tab in from the opposite side The tab will only move in one direction WARNING Refer to Relieving Fuel Pressure Caution 7 Pull the connection apart Installation Procedure WARNING Refer to Fue...

Page 839: ...n diameter to adequately catch the fluid CAUTION Fuel Vapor lines cannot be spliced or repaired The line must be replaced if damaged with the same type of line 1 Disconnect the negative battery cable...

Page 840: ...system contamination 10 Disconnect the left rear brake line fitting from the brake crossover pipe 11 Disconnect the right rear brake line fitting from the rear brake hose 12 Remove the push pin 1 fro...

Page 841: ...l EVAP brake pipe assembly clips 2 With the aid of an assistant position and install the fuel EVAP brake pipe clips 2 to the underbody studs 3 Install the push pin 1 to the underbody side rail hole CA...

Page 842: ...ar brake line fittings to the brake pressure module Tightening torque Tighten the fitting to 21 N m 16 lb ft 11 Remove the caps from the fuel and EVAP lines 12 Connect the fuel feed pipe quick connect...

Page 843: ...Collar Quick Connect Fitting Service WARNING Refer to Safety Glasses and Compressed Air Caution 3 Use compressed air in order to remove any debris from the around the area where the fuel injectors en...

Page 844: ...ical connector 8 Remove the fuel injector retainer clip 9 Remove the fuel injector 10 Remove and discard the fuel injector seals Installation Procedure 1 Install NEW fuel injector seals 2 Install the...

Page 845: ...age A reading below 1 4 full indicates that no more than 11 4 L 3 gal are remaining Using The Fuel Pump WARNING Do not allow smoking or the use of open flames in the area where work on the fuel or EVA...

Page 846: ...site end from which the components are being removed 3 Raise the vehicle on a hoist to a comfortable working height keeping the scan tool outside of the vehicle and accessible from under the car WARNI...

Page 847: ...the tank on the primary side only within about 25 4 cm 10 in of the end fitting and tag When connecting the siphon hose to another length of hose connected to the fuel drain tanker DO NOT insert the...

Page 848: ...that the fuel level in the tank is less than 1 4 full If necessary drain the fuel tank to at least this level Refer to Fuel Tank Draining 2 Remove the fuel fill cap 3 Raise and support the vehicle Re...

Page 849: ...eparate the fuel tank fill vent hose from the fuel fill tube Installation Procedure 1 Attach the fuel tank fill vent hose to the fuel fill tube 2 Install the closeout grommet 3 Position the fuel fill...

Page 850: ...e wheel and tire Refer to Tire and Wheel Removal and Installation 10 Lower the vehicle from the hoist 11 Install the fuel fill cap 12 Perform the Service Bay Diagnostic Test for the EVAP emission syst...

Page 851: ...o avoid contamination of the fuel system WARNING Whenever fuel lines are removed catch fuel in an approved container Container opening must be a minimum of 300 mm 12 in diameter to adequately catch th...

Page 852: ...t fitting to the fuel tank Refer to Plastic Collar Quick Connect Fitting Service 8 Connect the EVAP canister fresh air hose pipe to the fuel tank fresh air hose pipe 2 Refer to Plastic Collar Quick Co...

Page 853: ...muffler assembly Refer to Muffler Replacement 5 Remove the propeller shaft Refer to Propeller Shaft Replacement Propeller Shaft Replacement 6 Disconnect the evaporative emission EVAP canister fresh a...

Page 854: ...usly removed install the fuel tank module assemblies Refer to Primary Fuel Tank Module Replacement and Secondary Fuel Tank Module Replacement 2 Install the fuel tank heat shield and fuel tank assembly...

Page 855: ...fer to Battery Negative Cable Disconnection and Connection 15 Tighten the fuel fill cap 16 Prime the fuel system a Cycle the ignition ON for 5 seconds and then OFF for 10 seconds b Repeat the previous...

Page 856: ...l tank module is serviced Obtain NEW seals for both the primary and secondary modules prior to beginning this service procedure WARNING Whenever fuel line fittings are loosened or removed wrap a shop...

Page 857: ...the orientation tabs in the tank and rotate the module 45 degrees 5 Remove the primary fuel pump module assembly NOTE Always replace the fuel pump module to tank seal O ring when the fuel pump module...

Page 858: ...wiring harness to the primary fuel pump module and fuel tank pressure sensor 5 Install the fuel tank Refer to Fuel Tank Replacement FWD Fuel Tank Replacement AWD Secondary Fuel Tank Module Replacement...

Page 859: ...tank seal O ring when the fuel pump module is removed 7 Discard the fuel pump module to tank seal 8 If the fuel level sending unit is being replaced as well remove the fuel level sender Refer to Fuel...

Page 860: ...uel Tank Module Replacement 2 Disconnect the fuel level sender unit and float electrical connector from the underside of the top of the pump module 3 Release the retaining tabs 1 2 and remove the leve...

Page 861: ...ure that the sender cap snaps into place 2 Connect the fuel level sender unit and the float electrical connector 3 Install the fuel pump module into the fuel tank Refer to Secondary Fuel Tank Module R...

Page 862: ...lations 4 Flush the fuel tank with hot water 5 Pour the water out of the fuel sender assembly opening in the fuel tank Rock the fuel tank in order to be sure that the removal of the water from the fue...

Page 863: ...ector Test Adapter GE 41415 50 Interrupted Thread Fuel Tank Cap Adapter J 34730 1A Fuel Pressure Gage J 34730 262 Fuel Pressure Test Gage Adapter J 37088 A Fuel Line Disconnect Tool Set J 37287 Fuel L...

Page 864: ...n System Tester EEST J 42960 02 Fuel Flapper Door Holder J 43244 Relay Puller Pliers J 44175 Fuel Composition Tester Illustration Tool Number Description J 44602 Injector Test Adapter J 45004 Fuel Tan...

Page 865: ...is to properly synchronize the ignition system the fuel injectors and the knock control This sensor is also used in order to detect misfire The CKP sensor uses the following circuits A 5 volt referenc...

Page 866: ...ring Repairs Scan Tool Reference Scan Tool Data List Engine Controls 3 6L LY7 Scan Tool Data Definitions Engine Controls 3 6L LY7 Scan Tool Output Controls Engine Controls 3 6L LY7 Special Tools Requi...

Page 867: ...1 from the ignition coil s 3 Remove the ignition coil bolt s 4 Remove the ignition coil s Installation Procedure 1 Install the ignition coil s CAUTION Refer to Fastener Notice 2 Install the ignition...

Page 868: ...e ignition coil s 3 Remove the ignition coil bolt s 4 Remove the ignition coil s Installation Procedure 1 Install the ignition coil s CAUTION Refer to Fastener Notice 2 Install the ignition coil bolt...

Page 869: ...der head threads 3 Remove the spark plug Installation Procedure CAUTION Use only the spark plugs specified for use in the vehicle Do not install spark plugs that are either hotter or colder than those...

Page 870: ...spark plug and or engine damage Hotter plug Spark Plug Inspection Inspect the terminal post 1 for damage Inspect for a bent or broken terminal post 1 Test for a loose terminal post 1 by twisting and...

Page 871: ...worn or missing platinum pads on the electrodes 3 4 if equipped Inspect for excessive fouling Inspect the spark plug recess area of the cylinder head for debris Dirty or damaged threads can cause the...

Page 872: ...ification Metric English Ignition Coil Bolt 10 N m 89 lb in Rear Drive Module Propeller Shaft Guard Bolt 25 N m 18 lb ft Spark Plug 20 N m 15 lb ft Application Specification Metric English Firing Orde...

Page 873: ...til the switch is opened When the ignition switch is released from the START position the START relay opens and battery voltage is removed from the starter solenoid S terminal Current flows from the m...

Page 874: ...1I 2 Starting System Starting...

Page 875: ...Starting System 1I 3 Charging...

Page 876: ...15315247 J 35616 2A GY Pin Wire Color Circuit No Function A PK 5076 Current Sensor Supply Voltage B BN 5077 Current Sensor Low Reference C WH 5075 Seat Position Switch Low Reference Connector Part Inf...

Page 877: ...Starting System 1I 5 Component Location Engine Electrical Component Views Front of the Engine Compartment 1 Fuse Block Underhood 3 Cooling Fan Left 2 Battery 4 Cooling Fan Right...

Page 878: ...1I 6 Starting System Bottom Front of the Engine 1 Generator 3 A C Refrigerant Pressure Sensor 2 Starter 4 A C Compressor Clutch...

Page 879: ...Starting System 1I 7 LF of the Engine Compartment 1 LF Strut Tower 3 Windshield Washer Fluid Pump 2 G103 4 Battery Current Sensor...

Page 880: ...module ECM commands the generator OFF by removing the 5 volt reference signal from the L terminal of the voltage regulator when you select OFF The generator will then stop generating an output voltage...

Page 881: ...ectrical Theft Data Park Neutral In Gear Park Starter Relay Command Electrical Theft Data On Off Off Starter Relay Circuit Status Electrical Theft Data Incomplete Short Gnd Open Short to B OK OK Scan...

Page 882: ...Start Up State of Charge The scan tool displays 1 100 The scan tool displays the state of charge at initial key up Prev State of Charge The scan tool displays 0 100 The scan tool displays the state o...

Page 883: ...e crank relay control circuit and the crank relay ground circuit of the crank relay 2 Turn the ignition back and forth from the ON to START positions Does the test lamp turn ON and OFF with each comma...

Page 884: ...the Diagnostic System Check Vehicle Go to Step 2 Go to Diagnostic System Check Vehicle Diagnostic Information in Vehicle DTC Information 2 1 Install a scan tool 2 Operate the vehicle within the condit...

Page 885: ...1 Did you perform the Diagnostic System Check Vehicle Go to Step 2 Go to Diagnostic System Check Vehicle Diagnostic Information in Vehicle DTC Information 2 1 Install a scan tool 2 Operate the vehicle...

Page 886: ...d Does Not Click Starter Solenoid Clicks Engine Does Not Crank Engine Cranks Slowly Charge Indicator Always On Charge Indicator Inoperative Battery Inspection Test Battery Electrical Drain Parasitic L...

Page 887: ...oltage circuit of the starter solenoid for a high resistance or open Refer to Circuit Testing and Wiring Repairs Did you find and correct the condition Go to Step 22 Go to Step 14 12 Repair the ground...

Page 888: ...chematics Connector End View Reference Master Electrical Component List 1 Did you perform the Diagnostic System Check Vehicle Go to Step 2 Go to Diagnostic System Check Vehicle Diagnostic Information...

Page 889: ...ut while the starter is still held in the engaged position Go to Step 6 Go to Step 4 4 Do you hear a rumble a growl or in some cases a knock as the starter is coasting down to a stop after starting th...

Page 890: ...ing the Vehicle 3 Remove the front catalytic convertor Refer to Catalytic Converter Replacement Left Side 4 Remove the starter solenoid BAT terminal nut 5 Disconnect the engine harness electrical conn...

Page 891: ...the bolts nuts to 13 N m 115 lb in 5 Install the front catalytic convertor Refer to Catalytic Converter Replacement Left Side 6 Lower the vehicle 7 Connect the negative battery cable Refer to Battery...

Page 892: ...rter Installation 1 Install the starter motor CAUTION Refer to Fastener Notice 2 Install the starter motor bolts Tightening torque Tighten the starter motor bolts to 50 N m 37 lb ft Reference Drive Be...

Page 893: ...English Starter Motor Bolt 50 N m 37 lb ft Application Specification Metric English Starter Solenoid Positive Battery Terminal Nut 10 N m 89 lb in Starter Solenoid S Terminal Nut 3 N m 27 lb in Starte...

Page 894: ...s may cause personal injury and or damage to the vehicle or its components Batteries Produce Explosive Gases Caution WARNING Batteries produce explosive gases Batteries contain corrosive acid Batterie...

Page 895: ...ations issued by OSHA EPA DOT and various state or local agencies Other regulations may also apply in other locations Always know and follow these regulations when handling batteries Batteries that ar...

Page 896: ...e for the cold cranking amperage rating for this vehicle Charging System Description and Operation Electrical Power Management EPM Overview The electrical power management EPM system is designed to mo...

Page 897: ...tery Current Sensor The battery current sensor is a serviceable component that is connected to the negative battery cable at the battery The battery current sensor is a 3 wire hall effect current sens...

Page 898: ...age will be regulated between 13 9 and 14 5 volts Start Up Mode When the engine is started the BCM sets a targeted generator output voltage of 14 5 volts for 30 seconds Voltage Reduction Mode The BCM...

Page 899: ...ion Battery Voltage Calculation Amp hour Calculation Action Taken Idle Boost 1 Start Less Than 15 C 5 F Less Than 13 V First level Idle boost requested Idle Boost 1 Start Battery has a net loss greate...

Page 900: ...1J 7 Charging System Starting...

Page 901: ...Charging System 1J 8 Charging...

Page 902: ...15315247 J 35616 2A GY Pin Wire Color Circuit No Function A PK 5076 Current Sensor Supply Voltage B BN 5077 Current Sensor Low Reference C WH 5075 Seat Position Switch Low Reference Connector Part Inf...

Page 903: ...Charging System 1J 10 Component Location Engine Electrical Component Views Front of the Engine Compartment 1 Fuse Block Underhood 3 Cooling Fan Left 2 Battery 4 Cooling Fan Right...

Page 904: ...1J 11 Charging System Bottom Front of the Engine 1 Generator 3 A C Refrigerant Pressure Sensor 2 Starter 4 A C Compressor Clutch...

Page 905: ...Charging System 1J 12 LF of the Engine Compartment 1 LF Strut Tower 3 Windshield Washer Fluid Pump 2 G103 4 Battery Current Sensor...

Page 906: ...module ECM commands the generator OFF by removing the 5 volt reference signal from the L terminal of the voltage regulator when you select OFF The generator will then stop generating an output voltag...

Page 907: ...lectrical Theft Data Park Neutral In Gear Park Starter Relay Command Electrical Theft Data On Off Off Starter Relay Circuit Status Electrical Theft Data Incomplete Short Gnd Open Short to B OK OK Scan...

Page 908: ...Short to B or OK The scan tool displays the status of the STRTR relay Start Up State of Charge The scan tool displays 1 100 The scan tool displays the state of charge at initial key up Prev State of...

Page 909: ...round Is the measured value in the specified range 9 18 V Go to Step 6 Go to Step 5 5 Test the battery positive voltage circuit for the following A short to ground An open A high resistance Refer to C...

Page 910: ...for Running the DTC The ignition is ON The engine is running Conditions for Setting the DTC The BCM detects a duty cycle of PWM input signal is less than 4 percent or more than 96 percent for more 33...

Page 911: ...each diagnostic category DTC Descriptor DTC B1424 Device 1 Voltage Low Circuit System Description Voltage at theft deterrent module is lower than the voltage being reported on the serial data line Co...

Page 912: ...the DTC The ignition is ON The engine is running Conditions for Setting the DTC B1516 08 The BCM detects a duty cycle of PWM input signal is less than 4 percent or more than 96 percent for more 33 se...

Page 913: ...Other modules also monitor system voltage the system voltage message is sent to the other modules and will default to 12 9 volts DTC Descriptor This diagnostic procedure supports the following DTC DTC...

Page 914: ...2 Measure the voltage between the battery positive voltage circuits of the BCM and the ground circuits of the BCM Does the voltage measure within the specified range 10 5 15 5 V Go to Step 9 Go to St...

Page 915: ...ion Reference Circuit Testing Connector Repairs Testing for Intermittent Conditions and Poor Connections Wiring Repairs Scan Tool Reference Scan Tool Data List Engine Electrical Scan Tool Data Definit...

Page 916: ...he generator turn on signal and ground If greater than the specified range test the generator turn on signal circuit for a short to voltage If the circuit tests normal replace the ECM 3 Engine Running...

Page 917: ...ence Scan Tool Data List Engine Electrical Scan Tool Data Definitions Engine Controls 3 6L LY7 Circuit System Verification Engine running observe the scan tool ECM GEN F Terminal Signal parameter The...

Page 918: ...TC The ECM will command the message OFF after one trip in which the diagnostic test has been run and passed The history DTC will clear after 40 consecutive warm up cycles have occurred without a malfu...

Page 919: ...er IPC and the driver information center DIC if equipped The ECM will not illuminate the malfunction indicator lamp MIL The ECM will store conditions which were present when the DTC set as Failure Rec...

Page 920: ...Testing 1 Ignition OFF disconnect the harness connector at the EBCM 2 Ignition OFF test for less than 1 0 ohm of resistance between the ground circuit and ground If the greater than the specified rang...

Page 921: ...epair Verification Vehicle Diagnostic Information after completing the diagnostic procedure Control Module References for EBCM replacement setup and programming Symptoms Engine Electrical NOTE The fol...

Page 922: ...Battery Inspection Test 3 1 Install a scan tool 2 Start the engine 3 With a scan tool command the GEN L Terminal OFF and ON 4 Observe the Ignition 1 Signal parameter Does the voltage change with each...

Page 923: ...than 15 5 volts Go to Step 12 Go to Step 7 7 1 Leave the vehicle accessories ON or maintain load test value 2 Maintain engine speed at 2 500 RPM 3 Measure the voltage of the battery 4 Measure the vol...

Page 924: ...ol module ECM Refer to Testing for Intermittent Conditions and Poor Connections and Connector Repairs Did you find and correct the condition Go to Step 19 Go to Step 17 14 Inspect for poor connections...

Page 925: ...tabilized and you should wait 12 hours since the last time the battery was used 3 Estimate the battery temperature by determining the average temperature to which the battery has been exposed for the...

Page 926: ...y to the adapter 5 Turn ON the charger and set to the highest setting for normal charging 6 Inspect the battery every half hour after starting the battery charger Charge the battery until the taper ra...

Page 927: ...ld your eyes Avoid leaning over the battery whenever possible Do not expose the battery to open flames or sparks Do not allow battery acid to contact the eyes or the skin Flush any contacted areas wit...

Page 928: ...tic System Check Vehicle Go to Step 2 Go to Diagnostic System Check Vehicle Diagnostic Information 2 1 Start the engine 2 Turn OFF all accessories Does the battery charge indicator remain illuminated...

Page 929: ...u complete the repair Go to Step 4 4 Operate the system in order to verify the repair Did you correct the condition System OK Go to Step 2 Step Action Yes No 1 Test the generator for proper operation...

Page 930: ...eve the tension 2 Reroute the hoses etc away from the generator 3 Start the engine Has the noise decreased or stopped System OK Go to Step 8 8 Inspect the drive belt for proper tension Refer to Drive...

Page 931: ...tained on the J 42000 The battery test using the J 42000 requires correct connections to the battery terminals A failure to obtain the correct connections during the test may result in a failed test o...

Page 932: ...Step 2 Go to Step 15 2 Compare the cold cranking amperage CCA and reserve capacity RC and or amp hour AH rating of the battery to the original battery or original equipment OE specification Refer to B...

Page 933: ...tor ring Did you complete the repair Go to Step 10 10 1 Disconnect the positive battery cable 2 Inspect for the following conditions and repair as needed The cable bolt is too long or deformed at the...

Page 934: ...isted below is a generic specification Refer to chart when testing the battery The battery run down time will vary depending on cold cranking amperage CCA and reserve capacity RC If the CCA and RC are...

Page 935: ...he fuse blows install an inductive ammeter and go to step 20 11 Remove the fused jumper wire 12 Set a digital multimeter to the 10A scale 13 Connect the digital multimeter to the test switch tool term...

Page 936: ...ompleted to make sure that the parasitic current drain is at an acceptable level d When the cause of the excessive current drain has been located and repaired remove the J 38758 20 Connect the battery...

Page 937: ...attery cable end 1 Install the battery negative cable to the battery Tightening torque Tighten the battery negative cable terminal bolt to 17 N m 13 lb ft 2 Insert the battery box cover 3 into the ret...

Page 938: ...ery current sensor prior to removal 6 Slide the battery current sensor 1 off of the negative battery cable Installation Procedure 1 Squeeze the negative battery cable branches together NOTE Ensure the...

Page 939: ...ry cable clip on the side of the battery tray support bracket 4 Disconnect the negative battery cable electrical connector 7 from the body wiring harness electrical connector 2 5 Disconnect the body w...

Page 940: ...nal to the wheelhouse stud 5 Install the negative battery cable ground terminal nut to the wheelhouse stud Tightening torque Tighten the nut to 12 N m 106 lb in 6 Connect the body wiring harness elect...

Page 941: ...ttery cable terminal 2 from the UBEC stud 5 Remove the battery box Refer to Battery Box Replacement 6 Disconnect the positive and negative battery cable clip 3 from the battery tray support bracket 7...

Page 942: ...que Tighten the nut to 10 N m 89 lb in 5 Lower the vehicle 6 Connect the positive and negative battery cable clip 3 to the battery tray support bracket 7 Connect the positive and negative battery cabl...

Page 943: ...Release the locking tab 1 on the side of the battery box 3 Release the alignment tabs 2 on the front of the battery box 4 Remove the battery box lid 3 5 Disconnect the positive and negative battery c...

Page 944: ...ll the hold down bolt 5 Tightening torque Tighten the hold down bolt to 15 N m 11 lb ft 4 Install the positive and negative battery cables Refer to Battery Negative Cable Disconnection and Connection...

Page 945: ...g clips 2 from the battery vent tube 1 4 Remove the battery vent tube 1 from the upper radiator air deflector 3 Callout Component Name Preliminary Procedure Remove the battery box assembly Refer to Ba...

Page 946: ...r to Fastener Notice 2 Install the battery box mounting bolts Tightening torque Tighten the bolts to 20 N m 15 lb ft 3 Install the battery vent tube from the battery box 4 Install the battery Refer to...

Page 947: ...the engine harness electrical connector from the generator 6 Remove the drive belt Refer to Drive Belt Replacement 7 Remove the idler pulley Refer to Drive Belt Idler Pulley Replacement 8 Remove the g...

Page 948: ...ightening Specifications Engine Electrical Application Specification Metric English Air Conditioning A C Evaporator Line to Battery Tray Nut 15 N m 11 lb ft Battery Tray Bolt 15 N m 11 lb ft Battery H...

Page 949: ...p Hours 60 A H Reserve Capacity 100 Minutes Replacement Model Number 47 7YR Application Specification Generator Model SC2 Rated Output 150 Amps Load Test Output 105 Amps Illustration Tool Number Descr...

Page 950: ...is cool Hot Exhaust System Caution WARNING While engine is operating the exhaust system will become extremely hot To prevent burns avoid contacting a hot exhaust system Three Way Catalytic Converter...

Page 951: ...flange connection with a gasket Exhaust hangers and rubber insulators help to support the weight of the exhaust pipe along with insulating any exhaust system vibration rattle or noise Exhaust hangers...

Page 952: ...n monoxide CO and oxides of nitrogen NOx pollutants from the exhaust gas The catalytic converter is comprised of a ceramic monolith substrate supported in insulation and housed within a sheet metal sh...

Page 953: ...s be used in order to resolve a system problem For a detailed explanation refer to Strategy Based Diagnosis Visual Physical Inspection Inspect for aftermarket or non OEM devices such as but not limite...

Page 954: ...Confirming that the condition has been fixed is essential If the symptom still exists and the vehicle has a dual exhaust system proceed to step 2 and repeat diagnostic procedure on the opposite exhaus...

Page 955: ...es the reading exceed the specified value 9 kPa 1 25 psi Go to Step 6 Go to Step 7 6 Inspect the exhaust system for the following conditions Damage in the exhaust pipe Debris in the exhaust pipe Muffl...

Page 956: ...ed or broken Replace the exhaust manifold Refer to Exhaust Manifold Replacement Left Side or Exhaust Manifold Replacement Right Side Exhaust system component connection welds leaking Replace the leaki...

Page 957: ...nt 3 Remove the catalytic converter to exhaust manifold nuts 1 4 Remove the exhaust manifold bolts 1 NOTE Do not reuse the gasket 5 Remove the exhaust manifold and gasket Discard the gasket Installati...

Page 958: ...old Replacement Right Side Removal Procedure WARNING Refer to Exhaust Service Caution WARNING Refer to Protective Goggles and Glove Caution 1 Remove the exhaust manifold heat shield Refer to Exhaust M...

Page 959: ...ighten the bolts to 20 N m 15 lb ft 5 Install the right catalytic converter Refer to Catalytic Converter Replacement Right Side 6 Install the catalytic converter nuts Tightening torque Tighten the nut...

Page 960: ...NEW catalytic converter to flexible pipe gaskets between the catalytic converters and the exhaust flexible pipe 3 Install the exhaust flexible pipe to the catalytic converters CAUTION Refer to Fastene...

Page 961: ...converter to exhaust manifold nuts 1 3 Raise and support the vehicle Refer to Lifting and Jacking the Vehicle 4 Disconnect the heated oxygen sensor HO2S electrical connector 2 from the engine wiring...

Page 962: ...e pipe CAUTION Refer to Fastener Notice 4 Install the left catalytic converter to exhaust flexible pipe bolts Tightening torque Tighten the bolts to 22 N m 16 lb ft 5 Connect the HO2S electrical conne...

Page 963: ...tic converter to exhaust manifold nuts 1 3 Raise and support the vehicle Refer to Lifting and Jacking the Vehicle 4 Disconnect heated oxygen sensor HO2S electrical connector 2 from the engine wiring h...

Page 964: ...e pipe CAUTION Refer to Fastener Notice 4 Install the right catalytic converter to exhaust flexible pipe nuts Tightening torque Tighten the nuts to 22 N m 16 lb ft 5 Connect the HO2S electrical connec...

Page 965: ...With the aid of an assistant remove the muffler assembly from exhaust flexible pipe and the vehicle Installation Procedure 1 With the aid of an assistant install the muffler assembly to the vehicle an...

Page 966: ...nk strap bolt 3 Remove the right fuel tank strap bolt which also secures the rear of the catalytic converter heat shield to the underbody NOTE The heat shields at the dash panel and the catalytic conv...

Page 967: ...the bolts to 25 N m 18 lb ft 5 Install the muffler assembly Refer to Muffler Replacement Exhaust Heat Shield Replacement Dash Panel Removal Procedure 1 Raise and support the vehicle Refer to Lifting a...

Page 968: ...b in 3 Install NEW rivets 4 Lower the vehicle Exhaust Manifold Heat Shield Replacement Removal Procedure 1 Raise and support the vehicle Refer to Lifting and Jacking the Vehicle 2 Remove the rear exha...

Page 969: ...camshaft cover 4 Remove the exhaust manifold heat shield bolts 5 Remove the exhaust manifold heat shield sliding the shield up over the HO2S pigtail Installation Procedure 1 Install the exhaust manifo...

Page 970: ...retainer clip 4 Remove the exhaust manifold heat shield bolts 5 Remove the exhaust manifold heat shield sliding the shield up over the HO2S pigtail Installation Procedure 1 Install the exhaust manifol...

Page 971: ...1 Remove the left exhaust manifold heat shield bolts 2 Remove the left exhaust manifold heat shield 3 Remove the engine coolant temperature ECT sensor 4 Remove the left exhaust manifold lower bolts f...

Page 972: ...ard the left exhaust manifold gasket Reference Exhaust Manifold Cleaning and Inspection Left Side Exhaust Manifold Removal Right Side Reference Oil Filter Adapter Removal 1 Remove the right exhaust ma...

Page 973: ...nder head 4 Remove the right exhaust manifold nuts from the studs in the right cylinder head 5 Remove the right exhaust manifold 6 Remove and discard the right exhaust manifold gasket 7 Remove the stu...

Page 974: ...ve the right knock sensor heat shield 10 Remove the right knock sensor bolt 11 Remove the right knock sensor 12 Remove the crankshaft position CKP sensor bolt 13 Remove the CKP sensor 14 Remove and di...

Page 975: ...d mounting holes 2 Damage to the threaded holes 3 for the heat shield Damage to the exhaust manifold flange bolt holes 4 Damage to the heated oxygen sensor HO2S hole threads 5 2 Inspect the left exhau...

Page 976: ...the heat shield Damage to the exhaust manifold flange bolt holes 4 Damage to the heated oxygen sensor HO2S hole threads 5 2 Inspect the right exhaust manifold for the following Damage to the gasket se...

Page 977: ...asket 2 Install the left exhaust manifold 3 Loosely install the left exhaust manifold upper bolts into the left cylinder head CAUTION Refer to Fastener Notice 4 Loosely install the left exhaust manifo...

Page 978: ...fold heat shield in position 8 Install the exhaust manifold heat shield bolts Tightening torque Tighten the exhaust manifold heat shield bolts to 10 N m 89 lb in Reference Oil Level Indicator and Tube...

Page 979: ...all the CKP sensor bolt Tightening torque Tighten the CKP sensor bolt to 10 N m 89 lb in 5 Install the right knock sensor 6 Install the right knock sensor bolt Ensure the knock sensor is oriented with...

Page 980: ...he right knock sensor heat shield bolts Tightening torque Tighten the right knock sensor heat shield bolts to 50 N m 37 lb ft 9 Install the studs into the right cylinder head Tightening torque Tighten...

Page 981: ...right cylinder head 14 Tighten the right exhaust manifold nuts and bolts Tightening torque Tighten the right exhaust manifold nuts and bolts to 25 N m 18 lb ft 15 Place the right exhaust manifold hea...

Page 982: ...p components and fasteners organized An adequate set of hand tools Approved engine repair stand An approved engine lifting device that adequately supports the weight of the components Special Tools En...

Page 983: ...11 Wheel Stud Replacement 2B 14 Hub Axle Flange and Wheel Stud Runout Inspection 2B 15 Lower Control Arm Replacement 2B 16 Front Lower Control Arm Bushing Replacement Rear Bushing 2B 18 Strut Assembl...

Page 984: ...Description 2D 3 Diagnostic Information and Procedures 2D 4 Component Rotational Speed Calculation 2D 4 Tire Diagnosis Irregular or Premature Wear 2D 7 Tire Diagnosis Waddle Complaint 2D 8 Tire and W...

Page 985: ...le or visible system components for obvious damage or conditions which could cause the symptom Inspect for proper tire size and inflation pressure Refer to Vehicle Certification Tire Placard Anti Thef...

Page 986: ...ng systems for Vehicle trim height Refer to Trim Height Specifications Excessively worn loose or damaged components Did you find and correct the condition Go to Step 9 Go to Step 6 6 Inspect the brake...

Page 987: ...or heard when the vehicle is driven over bumps This condition is commonly noticed when the vehicle trim height is too low 1 Did you review the General Description and perform the necessary inspections...

Page 988: ...1 Drive the vehicle on a straight smooth flat road at 64 97 km h 40 60 mph 2 Remove your foot from the accelerator 3 Shift the transmission into NEUTRAL in order to allow the vehicle to coast 4 Is an...

Page 989: ...nd adjust as necessary Refer to Measuring Wheel Alignment Measuring Wheel Alignment Did you complete the wheel alignment Go to Step 7 7 Operate the vehicle in order to verify the repair Did you correc...

Page 990: ...Inspect the ball joints and steering components for the following conditions Lack of lubrication where applicable Looseness in the ball joints Refer to Ball Joint Inspection Looseness in the tie rods...

Page 991: ...spect the rear wheel bearings Refer to Wheel Bearings Diagnosis Did you find and correct the condition Go to Step 10 Go to Step 6 6 Bounce the rear of the vehicle in order to duplicate the noise Did y...

Page 992: ...ion of the wheel bearing noise Did you locate the source of the wheel bearing noise Go to Step 6 Go to Step 5 5 NOTE Support the vehicle by the lower control arms or the rear axle to prevent movement...

Page 993: ...shock absorber leaking Go to Step 5 Go to Step 4 4 1 Use your hands in order to lift up and push down each corner of the vehicle 3 times 2 Remove your hands from the vehicle 3 Locate a shock or strut...

Page 994: ...ed Step Action Values Yes No 1 Did you review the General Description and perform the necessary inspections Go to Step 2 Go to Symptoms Suspension General Diagnosis 2 1 Raise and support the vehicle R...

Page 995: ...ht as in step 4 9 The true P height is the average of the measurements taken in steps 4 and 8 Refer to Trim Height Specifications 10 Repeat the above steps at the rear of the vehicle for the R heights...

Page 996: ...k 5 Measure from the center of the outer pivot bolt to the alignment rack 6 The difference between these 2 measurements is the D height 7 Lift the rear bumper of the vehicle up about 38 mm 1 5 in 8 Ge...

Page 997: ...the center line of the vehicle The front body height J J is measured at a distance a 445 mm 17 5 in rearward from the center line of the front wheel The rear body height K K is measured at a distance...

Page 998: ...l Diagnosis Measuring A or B Height Special Tools and Equipment Special Tools Suspension General Diagnosis Illustration Tool Number Description J 39570 Chassis Ear J 8001 Dial Indicator Illustration T...

Page 999: ...The strut is filled with oil and has a moveable shaft that connects to a piston inside the strut Valves inside the shock absorber offer resistance to oil flow and consequently inhibit rapid movement o...

Page 1000: ...mall deflections of the wheel support system that occur when the vehicle is rolling forward In other words with the vehicle standing still and the wheels set with toe in the wheels tend to roll parall...

Page 1001: ...h the most downward sloping axle from the differential to the wheels Axles typically slope downward from the differential The slope of the transaxle pan to level ground may be used as an indication of...

Page 1002: ...may produce a vibration Step Action Yes No WARNING Refer to Road Test Caution 1 Has the Vibration Analysis Road Testing table been completed Go to Step 2 Go to Vibration Analysis Road Testing 2 1 Ope...

Page 1003: ...f the inspection indicated that a wheel drive shaft is damaged abnormally and or excessively worn replace the shaft Did you find and correct a condition Go to Step 13 Go to Step 9 8 1 Inspect the whee...

Page 1004: ...and or missing insulators Cracked dry rotted and or oil soaked insulators Stretched twisted broken torn and or collapsed insulators Bent twisted cracked and or deformed brackets 4 Repair replace and...

Page 1005: ...ing the Vehicle 2 Remove the front wheel and tire assembly Refer to Tire and Wheel Removal and Installation 1 Stabilizer Shaft Link Ball Stud Nut Qty 2 CAUTION Refer to Fastener Notice Tip Use the pro...

Page 1006: ...icle Refer to Lifting and Jacking the Vehicle 2 Remove the front wheel and tire assemblies Refer to Tire and Wheel Removal and Installation 1 Stabilizer Shaft Insulator Bolt Qty 2 CAUTION Refer to Fas...

Page 1007: ...end from the steering rack Relocate the outer tie rod end to the side and support if necessary 5 Remove the left and right outer tie rods from the knuckle Refer to Rack and Pinion Outer Tie Rod End R...

Page 1008: ...r Shaft Link Replacement 5 Install the left and right outer tie rod ends on the knuckle Refer to Rack and Pinion Outer Tie Rod End Replacement 6 Install the front tire and wheels Refer to Tire and Whe...

Page 1009: ...ew ball joint The bolts must be installed with the bolt head on top of the ball joint 2 Install the ball joint to control arm bolts Tightening torque Tighten the bolts and nuts to 68 N m 50 lb ft 3 In...

Page 1010: ...t 6 Support the wheel drive shaft with heavy mechanic s wire or equivalent 7 Remove and discard the wheel bearing hub mounting bolts 8 Remove the wheel bearing hub assembly from the steering knuckle I...

Page 1011: ...05 N m 151 lb ft 4 Install the wheel speed sensor electrical connector to the mounting bracket if equipped 5 Connect the wheel speed sensor electrical connector 6 Install the speed sensor Refer to Fro...

Page 1012: ...tallation Procedure 1 Install the wheel stud to the wheel bearing hub assembly from the bearing side of the hub flange 2 Place flat washers over the wheel stud being installer 3 Install the wheel nut...

Page 1013: ...l hub axle flange IS within specification and the vehicle is equipped with wheel bolts proceed to step 19 11 If the runout of the wheel hub axle flange is marginal the wheel hub may or may not be the...

Page 1014: ...Installation 3 Remove the lower ball joint stud cotter pin Discard the cotter pin 4 Loosen the ball stud nut until the nut is level with the top of the ball stud 5 Using J 42188 B separate the lower...

Page 1015: ...control arm front bolt and nut to 120 N m 89 lb ft 4 Position the control arm ball stud into the steering knuckle and install the nut Tightening torque Tighten the nut to 40 N m 30 lb ft NOTE Do not...

Page 1016: ...Refer to Fastener Notice 1 Install the rear bushing to the lower control arm Tightening torque Tighten the nut to 150 N m 11 lb ft 2 Install the lower control arm Refer to Lower Control Arm Replaceme...

Page 1017: ...strut assembly from the vehicle Installation Procedure 1 Position the strut assembly to the vehicle CAUTION Refer to Fastener Notice 2 Install the 3 upper strut mount bolts Tightening torque Tighten...

Page 1018: ...Removal and Installation 7 Lower the vehicle 8 Perform a wheel alignment Refer to Measuring Wheel Alignment Suspension Strut Disposal WARNING Use the proper eye protection when drilling to prevent me...

Page 1019: ...t the strut assembly to insure hooks on the strut compress legs are properly installed on the spring coils d Verify the strut assembly is parallel with the J 45400 2 Compress the spring enough to unlo...

Page 1020: ...ft NOTE The tag identifying the spring will be closer to the bottom of the spring The end of the coil sits up against the tab on the spring seat 3 With the spring in the compressor install the strut i...

Page 1021: ...ighten the strut shaft to 55 N m 41 lb ft 8 Release the tension on the J 45400 9 Remove the strut assembly from the J 45400 Steering Knuckle Replacement Special tool J 42188 B Ball Joint Separator Rem...

Page 1022: ...e knuckle Refer to Rack and Pinion Outer Tie Rod End Replacement 11 Remove the steering knuckle to strut bolts and nuts 12 Remove the steering knuckle from the vehicle Installation Procedure 1 Positio...

Page 1023: ...e s straight path Lead is the vehicle deviation from a straight path on a level road without pressure on the steering wheel Refer to Radial Tire Lead Pull Correction in order to determine if the vehic...

Page 1024: ...wheel alignment set the rear wheel alignment angles first in order to obtain proper front alignment angles 4 Adjust alignment angles to vehicle specification if necessary Refer to Wheel Alignment Spe...

Page 1025: ...nstall the wheel and tire assemblies Refer to Tire and Wheel Removal and Installation Front Toe Adjustment 1 Position and lock the steering wheel with the vehicle with the wheels in the straight forwa...

Page 1026: ...18 lb ft 90 rotation Stabilizer Shaft Insulator Clamp Bolt 50 N m 37 lb ft Stabilizer Shaft to Link Nut 75 N m 55 lb ft Stabilizer Shaft Link to Strut Nut 65 N m 48 lb ft Strut Assembly Shaft Nut 55 N...

Page 1027: ...29 Special Tools and Equipment Special Tools Front Suspension Illustration Tool Number Description J 42188 B Ball Joint Separator J 42991 Strut Rod Nut Socket J 43631 Ball Joint Remover J 45400 Strut...

Page 1028: ...n degrees from the vertical Camber settings influence the directional control and the tire wear Too much positive camber will result in premature wear on the outside of the tire and cause excessive we...

Page 1029: ...the Negative direction moving the RHS rearward and or LHS forward will move the thrust angle towards zero degrees Lead Pull Description At a constant highway speed on a typical straight road lead pull...

Page 1030: ...ation concern 2 While maintaining the concern speed drive the vehicle through slow sweeping turns first in one direction then in the other direction 3 Observe the vehicle for changes in the vibration...

Page 1031: ...ferential if equipped and any powertrain braces for the following conditions Loose and or missing fasteners Improper alignment Cracked dry rotted and or oil soaked insulators Twisted broken torn and o...

Page 1032: ...Inspection Inspect the steering wheel for excessive drag or poor return due to stiff or rusted linkage or suspension components Inspect the fuel level The fuel tank should be full or the vehicle shoul...

Page 1033: ...hub axle flange IS within specification and the vehicle is equipped with wheel bolts proceed to step 19 11 If the runout of the wheel hub axle flange is marginal the wheel hub may or may not be the s...

Page 1034: ...Tire and Wheel Removal and Installation 3 Loosen the stabilizer shaft clamp bolts NOTE Hold the ball shaft secure with a TORX bit when removing the nut 4 Remove the stabilizer link to stabilizer shaf...

Page 1035: ...control arm nut Tightening torque Tighten the nut to 15 N m 11 lb ft NOTE Hold the ball shaft secure with a TORX bit when installing the nut 3 Install the stabilizer link to stabilizer shaft nut Tigh...

Page 1036: ...ilizer Shaft Insulator Bolt Qty 4 CAUTION Refer to Fastener Notice Tightening torque 70 N m 52 lb ft Procedure Lower the rear suspension support Refer to Support Replacement AWD Vehicles Support Repla...

Page 1037: ...aft secure with a TORX bit when removing the nut 4 Remove the stabilizer link to stabilizer shaft nut 5 Remove the stabilizer shaft clamp bolts 6 Remove the stabilizer shaft clamps and bushings from t...

Page 1038: ...ise and support the vehicle Refer to Lifting and Jacking the Vehicle 2 Remove the rear tire and wheel assembly Refer to Tire and Wheel Removal and Installation 3 Remove the brake rotor Refer to Rear B...

Page 1039: ...4 wheel bearing bolts to 125 N m 92 lb ft 3 If equipped with AWD install the rear wheel driveshaft nut Tightening torque Tighten the rear wheel driveshaft nut to 70 N m 52 lb ft 4 Install the wheel sp...

Page 1040: ...ut the wheel stud from the wheel bearing hub assembly Installation Procedure 1 Install the wheel stud to the wheel bearing hub assembly from the bearing side of the hub flange 2 Place flat washers ove...

Page 1041: ...4 Remove the rear brake hose routing nut and bolt 5 Remove the upper control arm to knuckle nut and bolt 6 Remove the upper control to support cam nut and bolt 7 Remove the upper control arm Installa...

Page 1042: ...ing Wheel Alignment Rear Axle Lower Control Arm Replacement Removal Procedure 1 Raise and support the vehicle Refer to Lifting and Jacking the Vehicle 2 Remove the rear tire and wheel assembly Refer t...

Page 1043: ...t frame and loosely install the nut and bolt 3 Position the jackstand under the lower control arm 4 Position the spring with the rubber insulators into the vehicle 5 Raise the jackstand to compress th...

Page 1044: ...Tire and Wheel Removal and Installation 12 Lower the vehicle 13 Check the rear alignment Refer to Measuring Wheel Alignment Shock Absorber Replacement Removal Procedure 1 Raise and support the vehicl...

Page 1045: ...side the top of the tube If the snap ring is removed the contents of the shock absorber will come out with extreme force which may result in personal injury WARNING To prevent personal injury wear saf...

Page 1046: ...ock absorber Coil Spring Replacement Removal Procedure 1 Raise and support the vehicle Refer to Lifting and Jacking the Vehicle 2 Remove the rear tire and wheel assembly Refer to Tire and Wheel Remova...

Page 1047: ...ng Insulators Replacement 2 Position the spring with the rubber insulators into the vehicle 3 Raise the jackstand to compress the spring CAUTION Refer to Fastener Notice 4 Position the lower control a...

Page 1048: ...Insulators Replacement Removal Procedure 1 Remove the coil spring Refer to Coil Spring Replacement 2 Remove the upper and lower rubber insulators from the coil spring Installation Procedure NOTE Spray...

Page 1049: ...e the trailing arm bushing to bracket nut and bolt 6 Remove the trailing arm to knuckle bolts 1 7 Remove the trailing arm Installation Procedure 1 Position the trailing arm to the vehicle CAUTION Refe...

Page 1050: ...rm bushing to bracket nut and bolt 5 Remove the trailing arm bracket Installation Procedure 1 Position the trailing arm bracket to the trailing arm 2 Loosely install the trailing arm bushing to bracke...

Page 1051: ...icle 2 Remove the rear wheel and tire assembly Refer to Tire and Wheel Removal and Installation 1 Adjustment Link to Knuckle Bolt and Nut CAUTION Refer to Fastener Notice Tightening torque 160 N m 118...

Page 1052: ...he vehicle Refer to Lifting and Jacking the Vehicle 2 Remove the rear wheel and tire assembly Refer to Tire and Wheel Removal and Installation 3 Remove the coil spring Refer to Coil Spring Replacement...

Page 1053: ...or equivalent whenever it is separated from its mount and the hydraulic flexible brake hose is still connected Failure to support the caliper in this manner will cause the flexible brake hose to bear...

Page 1054: ...10 Remove the 3 trailing arm to knuckle bolts 11 Remove the knuckle from the vehicle Installation Procedure 1 Install the knuckle to the lower control arm Loosely install the bolt and nut 2 Install th...

Page 1055: ...Bearing and Hub Replacement CAUTION Support the brake caliper with heavy mechanic wire or equivalent whenever it is separated from its mount and the hydraulic flexible brake hose is still connected F...

Page 1056: ...bracket nut and bolt CAUTION Support the brake caliper with heavy mechanic wire or equivalent whenever it is separated from its mount and the hydraulic flexible brake hose is still connected Failure t...

Page 1057: ...to 57 N m 42 lb ft Knuckles Loosely install the upper and lower control arm to knuckle nuts bolts These fasteners will be tightened later in this procedure after the wheel driveshafts are installed 2...

Page 1058: ...brake hose bracket nut and bolt Tightening torque Tighten the rear brake hose bolt and nut to 12 N m 106 lb in 12 Position the wiring harness back to the original location connect the routing clips t...

Page 1059: ...brackets 8 Position the rear park brake cables aside 9 Disconnect the rear wheel speed sensor electrical connectors and the routing clips from the rear support and upper control arms Position the wiri...

Page 1060: ...y Upper Control Arms Tightening torque Tighten the upper control arm to rear support nut and bolt to 160 N m 118 lb ft Lower Control Arms Tightening torque Tighten the lower control arm to rear suppor...

Page 1061: ...fluid leak 9 Remove the supporting wire and position the brake caliper and bracket assemblies back onto the knuckles Refer to Rear Brake Caliper Bracket Replacement 10 Install the rear brake hose brac...

Page 1062: ...ol arm to frame bolt Tightening torque Tighten the bolt to 110 N m 81 lb ft 6 Repeat the procedure for the other rear wheel Rear Toe Adjustment 1 Loosen the suspension adjustment link to frame fastene...

Page 1063: ...zer Shaft Nut 50 N m 37 lb ft Stabilizer Shaft Clamp Bolt 70 N m 52 lb ft Support to Body Bolt 170 N m 125 lb ft Toe Link to Knuckle Bolt Nut 160 N m 118 lb ft Toe Link to Support Bolt 160 N m 118 lb...

Page 1064: ...2C 37 Rear Suspension Special Tools and Equipment Special Tools Rear Suspension Illustration Tool Number Description J 37043 Park Brake Cable Release Tool J 43631 Ball Joint Remover...

Page 1065: ...ts and the bolts are indicated by the following example M12 x 1 5 M Metric 12 Diameter in millimeters 1 5 Millimeters gap per thread Tire Inflation Description When you inflate the tires to the recomm...

Page 1066: ...than the non all season radial tires previously used Other performance areas such as wet traction rolling resistance tread life and air retention are also improved This is done by improvements in bot...

Page 1067: ...components Adverse vehicle steering stability caused by the modified scrub radius Damage to the vehicle caused by the modified ground clearance Speedometer and odometer inaccuracy Replace the wheel th...

Page 1068: ...For example For a P275 55R20 tire the rim diameter of 20 in X 2 54 converts to 50 80 cm 2 Calculate the radius of the rim by dividing the rim diameter by 2 For example For a P275 55R20 tire the rim d...

Page 1069: ...tch then a first order disturbance related to the rotation of the tire wheel assemblies is present If the frequencies do not match then the disturbance may be related to a higher order of tire wheel a...

Page 1070: ...uency of the disturbance recorded during testing either recheck the data or attempt to rematch the figures allowing for 1 8 km h 1 5 mph of speedometer error If the possible tire wheel assembly and or...

Page 1071: ...dle tread blocks are worn more than the outer tread blocks 4 4 Measure the wheel alignment if any of the following conditions exist The tread blocks have feathered edges 3 The outer tread blocks are w...

Page 1072: ...support the vehicle with safety stands Refer to Lifting and Jacking the Vehicle WARNING Wear gloves when inspecting the tires in order to prevent personal injury from steel belts sticking through the...

Page 1073: ...e following conditions Unusual wear such as cupping flat spots and or heel and toe wear These conditions can cause tire growl tire howl slapping noises and or vibrations throughout the vehicle Proper...

Page 1074: ...wheel assembly one more complete revolution and measure the total amount of radial runout Specification Maximum tire and wheel assembly radial runout measured on vehicle 1 52 mm 0 060 in 9 Position th...

Page 1075: ...to zero at the low spot 11 Slowly rotate the tire and wheel assembly one more complete revolution and measure the total amount of radial runout Specification Maximum tire and wheel assembly radial run...

Page 1076: ...tire and wheel assembly one more complete revolution and measure the total amount of wheel lateral runout Specification Maximum aluminum wheel lateral runout measured off vehicle tire mounted 0 762 mm...

Page 1077: ...ero at the low spot 12 Slowly rotate the wheel one more complete revolution and measure the total amount of wheel lateral runout Specification Maximum aluminum wheel lateral runout measured off vehicl...

Page 1078: ...4 different positions on the inboard mounting surface If you can rock the straight edge the mounting surface is bent and you must replace the wheel 4 Inspect the mounting wheel nut holes for damage c...

Page 1079: ...road with no pressure on the steering wheel 1 Did you perform the Diagnostic System Check Vehicle Go to Step 2 Go to Diagnostic System Check Vehicle Diagnostic Information 2 Road test the vehicle to v...

Page 1080: ...t which could cause a vibration disturbance Match mounting or vectoring the tire and wheel assembly to the hub axle flange will modify the amount of combined runout 18 Force variation may be present i...

Page 1081: ...ement On Vehicle Does the measurement indicate a runout concern Go to Step 15 Go to Step 23 12 Inspect the balance of the tire and wheel assemblies Refer to Tire and Wheel Assembly Balancing Off Vehic...

Page 1082: ...es as the cause of the disturbance Go to Step 19 Go to Step 21 19 Replace any tires and or wheels that were isolated as the cause of the disturbance as necessary Did you complete the replacement Go to...

Page 1083: ...re may cause lateral force variation In most cases where excessive lateral force variation exists the vehicle will display a wobble or waddle at low speeds 8 40 km h 5 25 mph on a smooth road surface...

Page 1084: ...CAUTION Removing the wheel may be difficult because of foreign materials or a tight fit between the wheel and the hub rotor Slightly tap the tire side wall with a rubber mallet in order to remove the...

Page 1085: ...the hub 4 Install the wheel nuts CAUTION A torque wrench or J 39544 must be used to ensure that wheel nuts are tightened to specification Never use lubricants or penetrating fluids on wheel stud nuts...

Page 1086: ...facturer for assistance Check the calibration of the tire and wheel assembly balancer according to the manufacturer s recommendations or perform the following test 1 Spin the balancer without a wheel...

Page 1087: ...han to dynamic imbalance however vehicles equipped with low profile wide tread path high performance tires and wheels are susceptible to small amounts of dynamic imbalance As little as 14 21 g oz imba...

Page 1088: ...el and aluminum wheels NOTE Use a nylon or plastic tipped hammer when installing coated clip on wheel balance weights to minimize the possibility of damage to the polyester coating The contour and sty...

Page 1089: ...covering from the adhesive backing on the back of the balance weights DO NOT touch the adhesive surface 8 Apply the wheel balance weights to the wheel press into place with hand pressure 9 Secure the...

Page 1090: ...eel Removal and Installation Always use a 4 wheel rotation After rotation check the wheel nuts for specified torque Then set the tire pressure Tire Mounting and Dismounting CAUTION Use a tire changing...

Page 1091: ...ing tires NEVER inflate beyond 275 kPa 40 pounds pressure to seat beads NEVER stand lean or reach over the assembly during inflation Repairable area on a radial tire NOTE NEVER repair tires worn to th...

Page 1092: ...This step serves to remove dirt and mold lubricants to insure proper adhesion and non contamination of the buffing tool 2 Refer to information on the product or manufacturer s Material Safety Data Sh...

Page 1093: ...ger than the unit so that buffing will not remove the crayon marks 2 Remove the repair unit 3 DO NOT overlap previous or multiple repair units 4 Consult your repair material supplier for proper repair...

Page 1094: ...e repair just reaches the liner Stitch down thoroughly 2 Follow the repair material manufacturer s recommendations for further installation instructions Consult your repair material supplier for the p...

Page 1095: ...ion to the valve stem 6 You may need to lubricate the bead in order to easily rotate the tire on the wheel 5 Reinflate the tire and seat the bead properly 6 Mount the assembly on the tire balancer and...

Page 1096: ...eel assembly in the new position Refer to Tire and Wheel Removal and Installation 6 Remeasure the tire and wheel assembly on vehicle runout Mark the new location of the assembly on vehicle runout high...

Page 1097: ...t Cap 5 N m 44 lb in Application Specification Metric English Tire and Wheel Assembly Lateral and Radial Off Vehicle 1 27 mm 0 050 in On Vehicle 1 52 mm 0 060 in Wheel Aluminum Lateral 0 762 mm 0 030...

Page 1098: ...2D 34 Wheels and Tires...

Page 1099: ...Controls Rear Drive Axle 3B 2 Scan Tool Data List Rear Drive Axle 3B 2 Scan Tool Data Definitions Rear Drive Axle 3B 2 DTC C0393 3B 3 DTC C0394 3B 4 DTC C0550 3B 5 DTC C0558 3B 5 DTC C0561 3B 6 Sympt...

Page 1100: ...Special Tools Transfer Case Getrag 760 3C 30 Propeller Shafts 3D 1 General Description 3D 1 Propeller Shaft Description and Operation 3D 1 Diagnostic Information and Procedures 3D 2 Component Rotatio...

Page 1101: ...as stones dirt water salt etc The seals facilitate angular and axial movement of the inboard joint The seals facilitate angular movement of the outboard joint The function of the clamps is as follows...

Page 1102: ...Assembly 9 Boot Retaining Clamp 2 Retaining Ring 10 Outboard Boot 3 Tripot Joint Spider Assembly 11 Boot Retaining Clamp 4 Boot Retaining Clamp 12 Race Retaining Ring 5 Tripot Trilobal Bushing 13 Chr...

Page 1103: ...nually Any binding or otherwise impeded movement of the joints may indicate damage which could contribute to the concern Refer to the following Click Noise In Turns Clunk When Accelerating from Coast...

Page 1104: ...mpleted Go to Step 2 Go to Vibration Analysis Road Testing 2 Did you duplicate a vibration concern that occurs only during heavy acceleration at launch Go to Step 3 Go to Step 4 3 Is the vehicle equip...

Page 1105: ...tep 14 Go to Vibration Diagnostic Aids 14 Is the vehicle front wheel drive with an all wheel drive system Go to Step 15 Go to Vibration Diagnostic Aids 15 1 Remove the propeller shaft 2 Perform the Vi...

Page 1106: ...tube attached to the drive axle and the joint at the torque tube is a CV joint coupler assembly or bolt on U joint yoke measure the runout of the torque tube input flange Refer to Torque Tube Input F...

Page 1107: ...e prop shaft support bearing if equipped for damaged rubber components worn bearings looseness and or a deformed or cracked bracket Replace components as necessary Did you find and correct a condition...

Page 1108: ...maintaining the concern speed drive the vehicle through slow sweeping turns first in one direction then in the other direction 3 Observe the vehicle for changes in the vibration disturbance 4 Select...

Page 1109: ...rential if equipped and any powertrain braces for the following conditions Loose and or missing fasteners Improper alignment Cracked dry rotted and or oil soaked insulators Twisted broken torn and or...

Page 1110: ...shaft link from the stabilizer shaft Refer to Stabilizer Shaft Link Replacement 7 Using the J 21579 remove the wheel drive shaft from the wheel bearing hub 8 Remove the J 21579 from the steering knuck...

Page 1111: ...and felt as the wheel drive shaft hits the retaining clip 5 Install the wheel drive shaft in the wheel bearing hub and finger tighten 6 Install the lower ball joint in the steering knuckle Refer to Ra...

Page 1112: ...eering knuckle Refer to Rack and Pinion Outer Tie Rod End Replacement 6 Remove the stabilizer shaft link from the stabilizer shaft Refer to Stabilizer Shaft Link Replacement 7 Using the J 21579 remove...

Page 1113: ...e nut 6 Install the lower ball joint in the steering knuckle Refer to Rack and Pinion Outer Tie Rod End Replacement 7 Install the stabilizer shaft link in the stabilizer shaft Refer to Stabilizer Shaf...

Page 1114: ...Shaft Replacement FWD NOTE Remove the retaining ring DO NOT re use the retaining ring discard Use NEW only 3 Remove the retaining clip for the wheel drive shaft 4 Remove the mounting bolts for the int...

Page 1115: ...ft 5 Install the NEW intermediate shaft retaining 6 Install the wheel drive shaft assembly Refer to Front Wheel Drive Shaft Replacement AWD Front Wheel Drive Shaft Replacement FWD 7 Remove the suppor...

Page 1116: ...ing 7 Remove the rear suspension knuckle Refer to Knuckle Replacement 8 Using a suitable tool carefully release the wheel drive shaft from the RDM Rear Drive Module NOTE Because of the design of the i...

Page 1117: ...Rear Axle Shaft Seal Replacement Left Side For the right side refer to Rear Axle Shaft Seal Replacement Right Side NOTE When installing the wheel drive shaft you will notice a slight resistance This...

Page 1118: ...r Joint and Seal Replacement Special tool J 35910 Drive Axle Seal Clamp Pliers Disassembly Procedure 1 Position wheel drive shaft bar in a soft jawed vise and clamp securely 2 Using side cutters remov...

Page 1119: ...rive shaft bar NOTE Ensure the seal clamp is positioned correctly in the seal groove 3 Using the J 35910 crimp the small seal clamp 4 Measure the clamp gap width Specification Clamp gap width should n...

Page 1120: ...axle shaft in a soft jawed vice 2 Use a flat bladed tool and disengage the retaining tabs of the large seal clamp 3 Discard the clamp 4 Remove the small seal clamp using side cutters and discard the...

Page 1121: ...the centerline of the outer race 2 At the same time align the cage windows 3 with the lands of the outer race 17 Lift out the cage 4 and the inner race 18 Remove the inner race 1 from the cage 2 by ro...

Page 1122: ...fication The gap should not exceed 2 15 mm 0 085 in 5 Put a light coat of grease from the service kit on the bearing roller grooves of the inner race and outer race 6 Hold the inner race 90 degrees to...

Page 1123: ...taining clamp over the seal and close using the J 35910 16 Inspect the gap dimension on the clamp ear Continue tightening until the gap dimension is reached Specification Dimension equals 1 9 mm 5 64...

Page 1124: ...inants 10 Dry all parts with compressed air 11 Inspect the tripot joint components for unusual wear cracks and other damage Replace any damaged components Assembly Procedure 1 Install the small seal c...

Page 1125: ...ghtening until the gap dimension is reached Specification Dimension equals 1 9 mm 5 64 in 13 Rotate the housing in a circular motion to distribute the grease in the tripot joint Rear Wheel Drive Shaft...

Page 1126: ...n to remove the opposing bearing roller 15 Repeat the process to remove all 6 of the bearing rollers 16 Pivot the CV joint cage 4 and the inner race 90 degrees to the centerline of the outer race 2 At...

Page 1127: ...re circumference of the seal 3 Crimp the seal clamp using the J 35910 4 Measure the clamp end gap dimension The gap should not exceed 2 15 mm 0 85 in Specification The gap should not exceed 2 15 mm 0...

Page 1128: ...ension is reached Specification Dimension equals 1 9 mm 5 64 in 17 Remove the wheel drive shaft from the bench vise 18 Distribute the grease within the outer CV joint by rotating the joint in a circul...

Page 1129: ...de Hammer w Adapter J 24319 B Steering Linkage and Tie Rod Puller J 35910 Drive Axle Seal Clamp Pliers J 43828 Ball Joint Separator J 44015 Steering Linkage Installer J 44394 Seal Protector J 44467 Ou...

Page 1130: ...by utilizing a clutch pack for transferring torque The engagement mechanism consists of an electromagnetic coil and armature which modulates torque through a pilot clutch and thrust amplification dev...

Page 1131: ...es not resolve the customer concern The Typical Data Values are obtained from a properly operating vehicle under the conditions specified in the first row of the Scan Tool Data List table Comparison o...

Page 1132: ...stic Information prior to using this diagnostic procedure Review Strategy Based Diagnosis for an overview of the diagnostic approach Diagnostic Procedure Instructions Vehicle Diagnostic Information pr...

Page 1133: ...agnostic Information prior to using this diagnostic procedure Review Strategy Based Diagnosis for an overview of the diagnostic approach Diagnostic Procedure Instructions Vehicle Diagnostic Informatio...

Page 1134: ...using this diagnostic procedure Review Strategy Based Diagnosis for an overview of the diagnostic approach Diagnostic Procedure Instructions Vehicle Diagnostic Information provides an overview of each...

Page 1135: ...he DTC resets replace the CCM Repair Instructions Perform the Diagnostic Repair Verification Vehicle Diagnostic Information after completing the diagnostic procedure Control Module References for CCM...

Page 1136: ...al condition CAUTION Do not exceed more than 5 seconds of parking brake application RDM damage may result Rear axle activation and operation may be checked by positioning the four wheels off the groun...

Page 1137: ...odule References for CCM replacement setup and programming Service All Wheel Drive Indicator Always On Circuit Description The SERVICE AWD indicator is located in the instrument panel cluster IPC The...

Page 1138: ...uring acceleration or deceleration Refer to Differential Housing Support Bushing Replacement Front Differential Housing Support Bushing Replacement Rear Worn or damaged axle mounting bushing rear Repl...

Page 1139: ...n or deceleration or wrong orientation Refer to Differential Housing Support Bushing Replacement Front Differential Housing Support Bushing Replacement Rear Worn or damaged axle mounting bushings Rear...

Page 1140: ...ropeller shaft center bearing assembly Replace the center bearing assembly Refer to Propeller Shaft Replacement Bearing noise within axle assembly This type of noise will decrease or increase relative...

Page 1141: ...age 2 Inspect the front bearing for wear or damage A worn bearing may allow excessive movement of the clutch pack input shaft 3 Replace the components as required Leaks at the housing sealing surfaces...

Page 1142: ...id Tightening torque Tighten the fill plug to 39 N m 29 lb ft Callout Component Name Preliminary Procedure Raise the vehicle Refer to Lifting and Jacking the Vehicle 1 Plug Differential Drain Plug CAU...

Page 1143: ...ch Drum Qty 4 CAUTION Refer to Fastener Notice Tightening torque Tighten bolts to 29 N m 21 lb ft Tip Relocate the rear portion of the propeller shaft to the side and support it with mechanics wire or...

Page 1144: ...Differential Mount Nut CAUTION Refer to Fastener Notice Tip Support the rear differential with a jack stand Tightening torque Tighten the nut to 121 N m 89 lb ft 2 Left Rear Differential Mount Bolt Qt...

Page 1145: ...el drive shaft Refer to Rear Wheel Drive Shaft Replacement 7 Support rear differential with a transmission jack stand Callout Component Name Preliminary Procedure Remove the rear differential assembly...

Page 1146: ...tall the J 8092 to the J 33832 2 Using the J 8092 and the J 33832 install the axle shaft seal 1 3 Lift and position the differential in the rear cradle 4 Install the left rear support bolt 5 Remove th...

Page 1147: ...ure with mechanics wire or equivalent 5 Remove the propeller shaft Refer to Propeller Shaft Replacement 6 Remove the right rear wheel drive shaft Refer to Rear Wheel Drive Shaft Replacement 7 Support...

Page 1148: ...1 Raise and support the vehicle Refer to Lifting and Jacking the Vehicle 2 Remove the differential clutch drum assembly Refer to Rear Wheel Drive Module Clutch Housing Replacement 1 Differential Pini...

Page 1149: ...he vehicle Refer to Propeller Shaft Replacement 7 Remove the rear wheel drive module clutch housing Refer to Rear Wheel Drive Module Clutch Housing Replacement 8 Support the rear differential with a t...

Page 1150: ...to Fastener Notice 7 Tighten the front mounting nuts Tightening torque Tighten the nuts to 122 N m 90 lb ft 8 Tighten the rear differential support bushing bolts Tightening torque Tighten the nuts to...

Page 1151: ...the rear differential assembly Refer to Differential Replacement 3 Mark a reference point on the frame and old bushing at the 12 and 6 o clock position to use to alignment the new bushing Callout Com...

Page 1152: ...6 Install the threaded rod bearing and washers 7 Adjust the nuts so that they are touching the J 45725 1A 2 and the J 45725 2A 1 8 Install the proper size wrenches on the nuts NOTE In the following se...

Page 1153: ...ignment of the bushing NOTE The following procedure is to temporarily hold the new bushing in place so that the special tools can be installed for the proper installation This is NOT to be used to ins...

Page 1154: ...ler assembly Refer to Muffler Replacement 4 Remove the rear differential assembly Refer to Differential Replacement 1 Screws Clutch Drum Control Module Qty 2 CAUTION Refer to Fastener Notice Tightenin...

Page 1155: ...e CCM is replaced the following procedures must be performed CCM Reprogramming Refer to Rear Differential Clutch Control Module Calibration Specifications Fastener Tightening Specifications Rear Drive...

Page 1156: ...Special Tools and Equipment Special Tools Rear Drive Axle Illustration Tool Number Description J 8092 Driver Handle J 33832 Output Shaft Seal Installer J 44636 1 Pinion Seal Installer J 45725 A Frame...

Page 1157: ...peller shaft assembly The on demand rear differential and torque tube assembly distributes variable torque power to the rear wheels via individual axle shafts The Getrag 760 transfer case is a single...

Page 1158: ...3C 2 Transfer Transfer Case Control...

Page 1159: ...or Circuit No Function 1 2 Not Used 3 BK 850 Ground 4 Not Used 5 L BU 5986 Serial Data Communication Enable 6 RD WH 1740 Battery Positive Voltage 7 Not Used 8 TN 2501 High Speed GMLAN Serial Data Bus...

Page 1160: ...n Transfer Case Control Component Views Near the Rear Differential 1 Rear Differential Clutch Control Module 4 Fuel Sending Unit 2 Fuel Tank 5 Fuel Tank Pressure FTP Sensor 3 Evaporative Emissions EVA...

Page 1161: ...sfer Case Rear Output Shaft Flange 10 Front Wheel Drive Retainer 28 Transfer Case Rear Output Shaft Oil Slinger 11 O Ring 29 Transfer Case Rear Output Shaft Seal 12 Front Wheel Drive Intermediate Shaf...

Page 1162: ...ons ambient temperature and other specifics Compare the driving characteristics or sounds if applicable to a known good vehicle and ensure you are not trying to correct a normal condition Intermittent...

Page 1163: ...ts as required Loose rear differential torque tube bracket or a damaged bracket bushing Tighten the bracket bolts or replace the bracket as required Worn bearing in the rear axle torque tube assembly...

Page 1164: ...equired 2 If the noise continues repair or replace the internal components as required Contributing factors may include Incorrect backlash between the gear sets Worn or damaged gear teeth Transaxle as...

Page 1165: ...M P N 12345493 Canadian P N 10953488 to the threads 5 Install the fill plug 1 Tightening torque Tighten the fill plug to 39 N m 29 lb ft 6 Lower the vehicle Transfer Case Assembly Replacement Removal...

Page 1166: ...2 from the transaxle Installation Procedure 1 Install the transfer case 2 from the transaxle 2 Install the bolts 1 securing the transfer case to the transaxle CAUTION Refer to Fastener Notice Tighten...

Page 1167: ...50 N m 37 lb ft 11 Install both catalytic converters Refer to Catalytic Converter Replacement Right Side and Catalytic Converter Replacement Left Side 12 Install the right wheel drive shaft Refer to...

Page 1168: ...Vent Assembly Tip Remove the vent only if damaged or blocked 3 Transfer Case Bracket Bolts Qty 6 4 Transfer Case Bracket 5 Transfer Case Heat Shield Bolts Qty 4 6 Transfer Case Heat Shield 7 Transfer...

Page 1169: ...Output Shaft Housing Bolt Qty 6 2 Transfer Case Rear Output Shaft Housing Tip Locate 2 screwdrivers or prybars to the flange area of the housing to ease removal Special Tools J 25070 Heat Gun 500 750...

Page 1170: ...Callout Component Name 1 Transfer Case Half Bolts Qty 11 2 Transfer Case Right 3 Transfer Case Seal 4 Transfer Case Input Shaft 5 Transfer Case Rear Output Drive Shaft 6 Transfer Case Half Locating P...

Page 1171: ...Output Shaft Flange Special Tools DT 48146 Press Support 3 Transfer Case Rear Output Shaft Bearing Assembly Tip Use a press to remove the output shaft from the housing 4 Transfer Case Rear Output Shaf...

Page 1172: ...t Name 1 Half Shaft Retainer 2 O Ring 3 Front Wheel Drive Intermediate Shaft Bearing Retainers Qty 2 4 Front Wheel Drive Intermediate Shaft Bearing Assembly Tip Use a press with the J 22912 B flat sid...

Page 1173: ...paired replace the component or sub component as indicated Clean the left and right transfer case in cleaning solvent and air dry 1 Transfer Case Left and Right NOTE Inspect for cracks broken areas or...

Page 1174: ...cannot be repaired replace the component or sub component as indicated 2 Clean all components in cleaning solvent and air dry 3 The transfer case rear output drive housing is not serviced If damage ca...

Page 1175: ...Output Shaft Splines Tip Inspect for damage and press fit to flange 6 Transfer Case Rear Output Shaft Tip Inspect for pitting excessive wear or damage Callout Component Name 1 Transfer Case Input Sha...

Page 1176: ...ft CAUTION Do not use a screwdriver or punch to remove the seal Using a screwdriver or punch to remove the seal may damage the aluminum housing sealing surface Special Tools DT 48074 Input and Output...

Page 1177: ...out Component Name 1 Front Drive Axle Intermediate Shaft Seal Assembly Tip DT 48078 seats the seal to a specific depth Other installation methods may set the seal to a non functional depth Special Too...

Page 1178: ...t and air dry 3 The transfer case input shaft and transfer case rear output drive shaft is not serviced If damage cannot be repaired the transfer case must be replaced 1 Transfer Case Input Shaft Gear...

Page 1179: ...nt Wheel Drive Intermediate Shaft 2 Front Wheel Drive Intermediate Shaft Bearing Retainers Qty 2 3 Front Wheel Drive Intermediate Shaft Bearing Assembly Tip Use a press with the J 22912 B flat side up...

Page 1180: ...acer 3 Transfer Case Rear Output Shaft Housing 4 Transfer Case Rear Output Shaft Bearing Assembly Tip Use a press with the J 5590 to install the housing and bearings to the output shaft Special Tools...

Page 1181: ...t Shaft Oil Slinger Tip Use a press with the DT 48077 in order to install the slinger Special Tools DT 48077 Output Shaft Slinger Installer 2 Transfer Case Rear Output Shaft Flange Tip Use a press wit...

Page 1182: ...Notice Fastener Tightening Specifications Refer to Fastener Tightening Specifications Transfer Case Getrag 760 1 Transfer Case Half Locating Pins 2 Transfer Case Rear Output Drive Shaft 3 Transfer Ca...

Page 1183: ...nsfer Case Rear Output Shim 3 Transfer Case Rear Output Shaft Housing CAUTION Do not use a drive hammer when the splines are not engaged Use of a drive hammer when the splines are not engaged will dam...

Page 1184: ...ediate Shaft CAUTION DT 48094 must be used over the intermediate shaft prior to installation in order to protect the intermediate shaft seal from damage Special Tools DT 48094 Inner Drive Shaft Seal P...

Page 1185: ...2 Transfer Case Vent Assembly Tip Replace the vent if damaged or blocked 3 Drain Plug Tightening torque 39 N m 29 lb ft 4 Fill Plug Tightening torque 39 N m 29 lb ft 5 Transfer Case Heat Shield 6 Tran...

Page 1186: ...lug 39 N m 29 lb ft Transfer Case Half Bolts Quantity 11 29 N m 21 lb ft Transfer Case Heat Shield Bolts Quantity 4 11 N m 97 lb in Transfer Case Rear Output Drive Gear Nut Quantity 1 235 N m 173 lb f...

Page 1187: ...t J 5590 Pinion Bearing Race Installer Rear J 8092 Driver Handle Illustration Tool Number Description J 08614 A Pinion Flange Holder and Remover J 22912 B Rear Pinion and Axle Bearing Remover J 25070...

Page 1188: ...er yoke which are pressed onto the rear half of the propshaft and retained by a snap ring The front and rear shafts are joined together at the yokes with a universal joint The rear shaft attaches to t...

Page 1189: ...For example For a P275 55R20 tire the rim diameter of 20 in X 2 54 converts to 50 80 cm 2 Calculate the radius of the rim by dividing the rim diameter by 2 For example For a P275 55R20 tire the rim d...

Page 1190: ...tch then a first order disturbance related to the rotation of the tire wheel assemblies is present If the frequencies do not match then the disturbance may be related to a higher order of tire wheel a...

Page 1191: ...uency of the disturbance recorded during testing either recheck the data or attempt to rematch the figures allowing for 1 8 km h 1 5 mph of speedometer error If the possible tire wheel assembly and or...

Page 1192: ...ymptom Verify the exact operating conditions under which the concern exists Note factors such as speed road conditions ambient temperature and other specifics Compare the driving characteristics or so...

Page 1193: ...at various speeds a squeaking sound occurs Lack of lubricant Replace the universal joints as required Refer to Propeller Shaft Replacement Cause Correction When accelerating the vehicle at low speed...

Page 1194: ...rque Sensitive Were you able to duplicate the vibration Go to Step 16 Go to Step 13 13 Perform the Vibration in Service Stall Test Torque Sensitive Were you able to duplicate the vibration Go to Step...

Page 1195: ...ue tube attached to the drive axle and the joint at the torque tube is a CV joint coupler assembly or bolt on U joint yoke measure the runout of the torque tube input flange Refer to Torque Tube Input...

Page 1196: ...the prop shaft support bearing if equipped for damaged rubber components worn bearings looseness and or a deformed or cracked bracket Replace components as necessary Did you find and correct a condit...

Page 1197: ...contact the pilot area as close to the end of the pilot as possible 5 Rotate the transmission or transfer case output flange by hand to locate the low spot 6 Set the dial indicator to zero on the low...

Page 1198: ...port bearing assembly 3 for damaged rubber components worn bearing or bearings or a damaged cracked bracket which could be affecting the runout of the propeller shafts c If the support bearing assembl...

Page 1199: ...he flange must be re indexed or replaced to bring the runout within tolerances before proceeding iii If the pinion or torque tube input flange was re indexed or replaced return the prop shaft to its o...

Page 1200: ...nge c Clean the surface of the flange pilot area d Mount a dial indicator set J 7872 or equivalent and position the dial indicator to contact the pilot area as close to the end of the pilot as possibl...

Page 1201: ...ring preload the pinion flange can only be removed and installed 1 time before the crush type sleeve must be replaced Sleeve replacement requires removal and installation of the ring and pinion gear s...

Page 1202: ...dex the pinion flange until the runout is 0 25 mm 0 010 in or less If the drive axle utilizes a crush type sleeve to achieve pinion bearing preload the pinion flange can only be removed and installed...

Page 1203: ...ompare the runout of the shaft to the runout tolerance specifications guidelines 10 If the drive axle input shaft runout exceeds the specification the flange requires replacement Driveline Working Ang...

Page 1204: ...adapter first verify the accuracy of the J 23498 20 or equivalent by inspecting the angle of an accessible joint using the J 23498 A or equivalent then inspecting the same joint angle using the J 2349...

Page 1205: ...d most vertically aligned yoke This yoke may be part of a transmission output shaft or a transfer case output shaft Measure and record the angle of the shaft 11 Remove the J 23498 A or equivalent 12 I...

Page 1206: ...result 1 Raise and support the vehicle ensure that the drive axle or axles are supported at ride height vehicle body supported by suspension components 2 With the tire and wheel assemblies and the br...

Page 1207: ...should be road tested to determine the effect on the vibration concern 22 If the clamp head over the original light spot is now near the top of the propeller shaft within 180 degrees near or below the...

Page 1208: ...propeller shaft now appear to move erratically compare the current amplitude of the vibration frequency to the original amplitude recorded previously If the amplitude has decreased from the amplitude...

Page 1209: ...ht spot 15 Observe the amount of disturbance to the propeller shaft If the amount of disturbance to the propeller shaft appears to be significantly reduced the balance achieved may be sufficient and t...

Page 1210: ...wnward during rotation Place a small mark on the shaft 180 degrees directly opposite the heavy spot and identify the mark as the light spot Proceed to step 8 8 Install a band type hose clamp to the pr...

Page 1211: ...bance to the propeller shaft appears to be almost unchanged or even increased the propeller shaft may require replacement Driveline Working Angles Adjustment NOTE This procedure is intended to be used...

Page 1212: ...horizontal reference d Rotate the propeller shaft slightly to center the bubble to the indicator The U joint is now vertical e Without disturbing the setting on the J 23498 A or equivalent remove the...

Page 1213: ...he stub shaft is not keyed attempt to re align the front shaft and slip yoke to each other Repeat the inspection procedure to confirm the results d If proper phasing cannot be obtained the propeller s...

Page 1214: ...e output flange 6 Position the center support bearing of the propeller shaft on the vehicle 7 Finger tighten the mounting bolts for the center support bearing 8 Position the propeller shaft on the rea...

Page 1215: ...eller Shaft Guideline 1 17 mm 0 046 in 1 27 mm 0 050 in 1 40 mm 0 055 in 1 Piece Aluminum Graphite Propeller Shaft Guideline 1 17 mm 0 046 in 1 40 mm 0 055 in 2 Piece System Front Propeller Shaft with...

Page 1216: ...3D 29 Propeller Shafts...

Page 1217: ...Brake System Bleeding Manual 4A 28 Hydraulic Brake System Flushing 4A 29 Brake Pedal Assembly Replacement 4A 30 Brake Pedal Pushrod Inspection 4A 33 Brake Pedal Position Sensor Replacement 4A 34 Brake...

Page 1218: ...tor Assembled Lateral Runout Correction Indexing 4C 25 Brake Rotor Assembled Lateral Runout Correction Correction Plates 4C 26 Brake Rotor Assembled Lateral Runout Correction On Vehicle Lathe 4C 27 Br...

Page 1219: ...r Inoperative 4E 44 Repair Instructions 4E 46 Antilock Brake System Automated Bleed Procedure 4E 46 Steering Angle Sensor Centering 4E 47 Electronic Brake Control Module Replacement 4E 47 Electronic B...

Page 1220: ...ts Brake Assist System Description and Operation System Component Description The brake assist system consists of the following Brake Pedal Receives multiplies and transfers brake system input force f...

Page 1221: ...Brake Control System and Diagnosis 4A 2 Schematic and Routing Diagram...

Page 1222: ...4A 3 Brake Control System and Diagnosis Hydraulic Brake Schematics...

Page 1223: ...ormation Terminal Tray 12124075 5 Core Insulation Crimp E C Release Tool Test Probe 12180559 1 J 35616 2A GY Pin Wire Color Circuit No Function A BK WH 651 Ground B TN WH 33 Brake Warning Indicator Co...

Page 1224: ...pe Routing Master Cylinder to ABS 1 Master Cylinder Primary Brake Pipe 4 BPMV Brake Pipe to RR Brake Corner 2 Master Cylinder Secondary Brake Pipe 5 BPMV Brake Pipe to LF Brake Corner 3 BPMV Brake Pip...

Page 1225: ...Brake Control System and Diagnosis 4A 6 Component Location Hydraulic Brake Component Views Near the Brake Booster 1 Brake Fluid Level Switch 3 Electronic Brake Control Module EBCM 2 LF Strut Tower...

Page 1226: ...4A 7 Brake Control System and Diagnosis Park Brake Assembly 1 Park Brake Switch 3 Floor Panel 2 Park Brake Handle...

Page 1227: ...view of the diagnostic approach Diagnostic Procedure Instructions Vehicle Diagnostic Information provides an overview of each diagnostic category DTC Descriptor DTC C0267 Low Brake Fluid Indicated Dia...

Page 1228: ...e specified value test the signal circuit for a short to voltage or an open high resistance If the circuit tests normal replace the IPC 5 If all circuits test normal test or replace the brake fluid le...

Page 1229: ...ied and Release If the parameter does not cycle between the specified values refer to Park Brake Switch Circuit Malfunction 4 Verify the scan tool EBCM Brake Fluid Level Sensor parameter is OK If not...

Page 1230: ...Starting Point Hydraulic Brakes 6 Road test the vehicle in order to confirm proper operation Refer to Brake System Vehicle Road Test Is the condition still present Go to Step 2 System OK Step Action...

Page 1231: ...Were you sent here from the Hydraulic Brake Symptom table Go to Step 2 Go to Diagnostic Starting Point Hydraulic Brakes 2 Inspect the suspension system for proper operation Refer to Diagnostic Startin...

Page 1232: ...OK Step Action Yes No 1 Were you sent here from the Hydraulic Brake Symptom table Go to Step 2 Go to Diagnostic Starting Point Hydraulic Brakes 2 Inspect for proper brake pedal travel Refer to Brake P...

Page 1233: ...2 System OK Step Action Yes No 1 Were you sent here from the Hydraulic Brake Symptom table Go to Step 2 Go to Diagnostic Starting Point Hydraulic Brakes 2 Is the vehicle equipped with an adjustable s...

Page 1234: ...System Diagnosis Did you find and correct a condition Go to Step 14 Go to Diagnostic Starting Point Hydraulic Brakes 14 1 Install or connect components that were removed or disconnected during diagnos...

Page 1235: ...isconnected during diagnosis 2 Road test the vehicle to confirm proper operation Refer to Brake System Vehicle Road Test Is the condition still present Go to Step 2 System OK Step Action Yes No DEFINI...

Page 1236: ...which have been contaminated b Clean out the hydraulic brake pipes using denatured alcohol or equivalent c Dry the brake pipes using non lubricated filtered air d Replace ALL of the following compone...

Page 1237: ...id you find and correct a condition Go to Step 7 Go to Step 12 7 Was there air in the system at a bleeder valve location other than at the repair location except if the brake master cylinder was repla...

Page 1238: ...unrestricted and even per axle during the bleeding procedure Go to Step 21 Go to Step 17 17 1 Inspect the hydraulic brake pipes and flexible brake hoses for signs of a fluid restriction such as being...

Page 1239: ...nt inspection refer to Brake Pedal Pushrod Inspection Inspect the brake pedal bushings for excessive wear and or damage and inspect the brake pedal for a misaligned bent and or damaged condition 2 Rep...

Page 1240: ...ter was deformed and or damaged replace the booster Did you complete the replacement Go to Step 14 14 Perform the vacuum boost functional test 1 Reinstall the master cylinder to the booster 2 If the e...

Page 1241: ...ed position Observe for a slow release of the brake system 10 With the aid of an assistant to observe the vehicle s performance from outside of the vehicle drive the vehicle at a low speed and lightly...

Page 1242: ...akes 8 Subtract the initial measurement unapplied 1 from the averaged applied measurement 2 to obtain the brake pedal travel distance Specification Maximum brake pedal travel Measured with the ignitio...

Page 1243: ...rake pedal If the brake pedal gradually falls away while under foot pressure there may be a brake fluid leak 5 Turn OFF the ignition 6 Visually inspect the following brake system components for brake...

Page 1244: ...ndary piston 1 from the secondary piston primary seal 6 or secondary seal 5 9 If the brake pedal apply did not feel spongy and the brake pedal travel was initially steady and not excessive then fell s...

Page 1245: ...s to be added to the master cylinder auxiliary reservoir clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm Hydraulic Brake System Bleeding Pres...

Page 1246: ...purge air from the wheel hydraulic circuit Allow fluid to flow until air bubbles stop flowing from the bleeder then tighten the bleeder valve 13 With the right rear wheel hydraulic circuit bleeder val...

Page 1247: ...s then repeat steps 3 3 3 7 until all air is purged from the same port of the component i With the brake pipe installed securely to the master cylinder proportioning valve assembly or brake modulator...

Page 1248: ...id Effects on Paint and Electrical Components Notice 1 Inspect the brake fluid for the following conditions indicating brake fluid contamination Fluid separation indicating two types of fluid are pres...

Page 1249: ...nt Rear Brake Caliper Replacement Brake Pressure Modulator Valve Replacement 4 If the brake fluid was NOT contaminated with an oil based or a silicone based substance but WAS contaminated with water o...

Page 1250: ...dash 8 Loosen but do not remove the steering column bracket to cowl nut 9 While simultaneously disengaging the brake pedal bracket pilot bushings from the foam insulation panel pull the brake pedal as...

Page 1251: ...bushings into the foam insulator panel 3 Position the booster studs through dash panel CAUTION Refer to Fastener Notice 4 Install the brake pedal bracket to steering column bracket bolt Tightening tor...

Page 1252: ...d 1 from the brake pedal 2 Inspect the brake pedal pushrod eyelet bushing 2 if equipped for cracks and or excessive wear 3 Reposition the pedal pushrod boot 3 toward the front of the vehicle to expose...

Page 1253: ...lacement Left Side 2 Remove the left side knee bolster Refer to Knee Bolster Replacement 1 Brake Pedal Position Sensor Bolt Tip Calibrate the position sensor Refer to Brake Pedal Position Sensor Calib...

Page 1254: ...lect Module Setup Select the BPPS calibration procedure and follow the directions displayed on the screen Stop Lamp Switch Adjustment Adjustment Procedure 1 Remove the left instrument panel I P insula...

Page 1255: ...ion This will cause a drag condition on the brake 4 Install the switch to the bracket by turning and pushing the switch until the switch bottoms on the brake pedal 5 Connect the electrical connector t...

Page 1256: ...from the brake caliper 10 Remove and discard the copper brake hose gaskets These gaskets may be stuck to the brake caliper and or the brake hose end 11 Cap or plug the opening in the brake caliper and...

Page 1257: ...cket 8 Connect the wheel speed sensor wire harness and harness retainers to the front brake hose 9 Install the tire and wheel assembly Refer to Tire and Wheel Removal and Installation 10 Ensure that t...

Page 1258: ...lb ft 2 Brake Hose Fitting Gasket Qty 2 Tip DO NOT reuse the brake hose fitting gaskets Install NEW gaskets 3 Brake Hose Bolt Tightening torque 12 N m 106 lb in 4 Brake Hose Bracket Bolt Tightening to...

Page 1259: ...design as originally equipped on the vehicle 1 Inspect the area of brake pipe to be repaired or replaced 2 Release the brake pipe to be replaced from the retainers as required 3 Select an appropriate...

Page 1260: ...stripping tool in a clockwise direction ensuring that the brake pipe end remains against the tool roller ledges After each successive revolution of the stripping tool carefully rotate the thumbwheel o...

Page 1261: ...Rotate the hydraulic fluid control valve clockwise to the closed position 22 Rotate the body of the J 45405 until it bottoms against the die cage 23 While guiding the forming mandrel into the exposed...

Page 1262: ...fer to Brake Fluid Irritant Caution CAUTION Refer to Brake Fluid Effects on Paint and Electrical Components Notice 1 Visually inspect all of the brake pipes for the following conditions Kinks improper...

Page 1263: ...he sensor electrical connection carefully pull the sensor from the master cylinder reservoir 4 Remove the low brake fluid level sensor Installation Procedure 1 While noting the proper orientation inst...

Page 1264: ...aulic brake system components CAUTION Refer to Brake Fluid Effects on Paint and Electrical Components Notice 1 Remove the underhood electrical center Refer to Underhood Electrical Center or Junction B...

Page 1265: ...sensor Refer to Master Cylinder Fluid Level Sensor Replacement 5 Connect the brake fluid level sensor electrical connector 6 Install the underhood electrical center Refer to Underhood Electrical Cente...

Page 1266: ...nds 5 Remove master cylinder mounting nuts 6 Remove the master cylinder from the vehicle 7 Drain the master cylinder reservoir of all brake fluid Installation Procedure 1 Bench bleed the master cylind...

Page 1267: ...om the hose nipple on the master cylinder reservoir 3 Install suitable fittings to the master cylinder ports that match the type of flare seat required and also provide for hose attachment 4 Install t...

Page 1268: ...e the check valve and hose from the brake booster by gently turning the check valve right then left while pulling straight out from the grommet 3 Remove the vacuum hose from the check valve Installati...

Page 1269: ...vacuum booster check valve and hose assembly from the booster Refer to Vacuum Brake Booster Check Valve and or Hose Replacement 6 Without disconnecting the electrical connectors remove the transaxle c...

Page 1270: ...er mounting nuts 4 Lightly lubricate the booster push rod pivot pin on the brake pedal with silicone lubricant 5 Install the booster push rod to the pivot pin on the brake pedal 6 Install the foam was...

Page 1271: ...Tightening Specifications Lighting Application Specification Metric English Brake Hose Bolt 12 N m 106 lb in Brake Hose Bracket Bolt 12 N m 106 lb in Brake Hose Fitting Bolt Front 40 N m 30 lb ft Bra...

Page 1272: ...r Bleeder Valve Rear 13 N m 115 lb in Application Specification Metric English Brake Pedal Travel Maximum specification with 445 N 100 lbs of force applied to the brake pedal with the ignition OFF and...

Page 1273: ...Applies mechanical output force from the hydraulic brake calipers to friction surfaces of brake rotors Disc Brake Rotors Uses mechanical output force applied to friction surfaces from the disc brake p...

Page 1274: ...he DISC brake system in order to determine if the DISC brake system is operating properly You will be directed by the appropriate Symptom table to go to other brake system diagnostic tables as appropr...

Page 1275: ...inding or seized hardware Worn damaged or missing hardware components Loose bent cracked or damaged caliper mounting bracket 3 Replace components as required Refer to the following procedures in Disc...

Page 1276: ...ausing contamination of the pads Go to Step 11 Go to Step 10 10 1 Inspect the automatic transmission cooling system lines if equipped for damage and evidence of an external fluid leak which may be the...

Page 1277: ...wing conditions Refer to Front Disc Brake Mounting and Hardware Inspection and or Rear Disc Brake Mounting and Hardware Inspection Binding or seized hardware Distorted worn damaged or missing hardware...

Page 1278: ...n for each brake rotor if the rotor requires refinishing based upon the results of the inspection If the brake rotor exhibits any of the conditions listed previously it requires refinishing Does the b...

Page 1279: ...asured to ensure optimum performance of the disc brakes Replace the brake rotor Refer to Front Brake Rotor Replacement or Rear Brake Rotor Replacement Did you complete the replacement Go to Step 22 20...

Page 1280: ...shed depending upon surface and wear conditions which may be present 6 If the lowest thickness measurement of the brake rotor is at or below the minimum allowable thickness after refinishing specifica...

Page 1281: ...ke pulsation Refer to Brake Rotor Thickness Variation Measurement 1 Matchmark the position of the brake rotor to the wheel studs if this has not been done already NOTE Whenever the brake rotor has bee...

Page 1282: ...runout 0 05 mm 0 002 in Rear brake rotor maximum allowable assembled lateral runout 0 05 mm 0 002 in 13 If the brake rotor assembled LRO is within specifications proceed to step 18 If the brake rotor...

Page 1283: ...use damage to the brake hose and in turn may cause a brake fluid leak Preliminary Procedures 1 Inspect the fluid level in the brake master cylinder reservoir 2 If the brake fluid level is midway betwe...

Page 1284: ...s Using a brake pad spreader tool or equivalent fully seat the caliper pistons in the caliper bores Tightening torque 44 N m 32 lb ft 2 Brake Pad Qty 2 Tip 1 If installing the original brake pads mark...

Page 1285: ...damaged or excessively corroded Replace any missing or damaged shims in order to preserve proper disc brake performance Replace the disc brake pads if any have separated from the mounting plates Insp...

Page 1286: ...4B 14 Front Brakes Front Brake Caliper Replacement...

Page 1287: ...or installing the caliper guide pin bolt DO NOT allow the open end wrench to come in contact with the brake caliper Allowing the open end wrench to come in contact with the brake caliper will cause a...

Page 1288: ...caliper requires overhaul or replacement 4 Inspect for smooth and complete travel of the caliper piston or pistons into the caliper bore or bores The movement of a caliper piston into a caliper bore...

Page 1289: ...Front Brakes 4B 17 Front Disc Brake Hardware Replacement...

Page 1290: ...the brake caliper guide pin in line with the brake caliper while removing or installing the caliper guide pin bolt DO NOT allow the open end wrench to come in contact with the brake caliper Tip Hold t...

Page 1291: ...the brake caliper and move the brake caliper inboard and outboard The brake caliper should slide smoothly with minimal force 9 Ensure the disc brake pads are held firmly in place on the brake caliper...

Page 1292: ...the caliper which may cause damage to the brake hose and in turn may cause a brake fluid leak Preliminary Procedures 1 Raise and support the vehicle Refer to Lifting and Jacking the Vehicle 2 Remove t...

Page 1293: ...hose to bear the weight of the caliper which may cause damage to the brake hose and in turn may cause a brake fluid leak Preliminary Procedures 1 Raise and support the vehicle Refer to Lifting and Ja...

Page 1294: ...o the following specification Specification Brake rotor maximum allowable scoring 1 50 mm 0 059 in 7 If the brake rotor scoring depth exceeds the specification or if an excessive amount of scoring is...

Page 1295: ...when the brake rotors are removed from the drive axle repeat the test with one rotor installed at a time Replace the rotor that is causing or contributing to the vibration concern 7 If a brake rotor...

Page 1296: ...Indexing The correction plate method of correcting assembled LRO involves the addition of a tapered plate between the brake rotor and the hub axle flange The correction plate method can be used to cor...

Page 1297: ...the J 45101 100 1 and one lug nut 2 onto the upper most wheel stud 5 Continue to hold the rotor secure and tighten the lug nut firmly by hand 6 Install the remaining J 45101 100 and lug nuts onto the...

Page 1298: ...that there are no foreign particles or debris remaining 4 Select the correction plate following the manufacturer s instructions which has a specification closest to the assembled LRO measurement For e...

Page 1299: ...RO Thickness variation exceeding the maximum acceptable level can cause brake pulsation Refer to Brake Rotor Thickness Variation Measurement Brake rotor assembled LRO exceeding the maximum allowable s...

Page 1300: ...disc brake rotor friction surface Scoring of the disc brake rotor friction surface less than the maximum allowable specification Before refinishing a brake rotor the rotor MUST first be checked for a...

Page 1301: ...ith 120 grit aluminum oxide sandpaper If the lathe is not equipped with a non directional finishing tool apply the finish with a sanding block and 150 grit aluminum oxide sandpaper c After applying a...

Page 1302: ...akes Illustration Tool Number Description J 39544 KIT Complete Torque Socket Set 10 Pieces J 41013 Rotor Resurfacing Kit J 42450 A Wheel Hub Resurfacing Kit J 45101 Hub and Wheel Runout Gage J 45101 1...

Page 1303: ...pplies mechanical output force from the hydraulic brake calipers to friction surfaces of brake rotors Disc Brake Rotors Uses mechanical output force applied to friction surfaces from the disc brake pa...

Page 1304: ...he DISC brake system in order to determine if the DISC brake system is operating properly You will be directed by the appropriate Symptom table to go to other brake system diagnostic tables as appropr...

Page 1305: ...inding or seized hardware Worn damaged or missing hardware components Loose bent cracked or damaged caliper mounting bracket 3 Replace components as required Refer to the following procedures in Disc...

Page 1306: ...using contamination of the pads Go to Step 11 Go to Step 10 10 1 Inspect the automatic transmission cooling system lines if equipped for damage and evidence of an external fluid leak which may be the...

Page 1307: ...ing conditions Refer to Front Disc Brake Mounting and Hardware Inspection and or Rear Disc Brake Mounting and Hardware Inspection Binding or seized hardware Distorted worn damaged or missing hardware...

Page 1308: ...for each brake rotor if the rotor requires refinishing based upon the results of the inspection If the brake rotor exhibits any of the conditions listed previously it requires refinishing Does the br...

Page 1309: ...sured to ensure optimum performance of the disc brakes Replace the brake rotor Refer to Front Brake Rotor Replacement or Rear Brake Rotor Replacement Did you complete the replacement Go to Step 22 20...

Page 1310: ...shed depending upon surface and wear conditions which may be present 6 If the lowest thickness measurement of the brake rotor is at or below the minimum allowable thickness after refinishing specifica...

Page 1311: ...on Refer to Brake Rotor Thickness Variation Measurement 1 Matchmark the position of the brake rotor to the wheel studs if this has not been done already NOTE Whenever the brake rotor has been separate...

Page 1312: ...runout 0 05 mm 0 002 in Rear brake rotor maximum allowable assembled lateral runout 0 05 mm 0 002 in 13 If the brake rotor assembled LRO is within specifications proceed to step 18 If the brake rotor...

Page 1313: ...ce has been performed on the disc brake system This procedure should be performed whenever the disc brake rotors have been refinished or replaced and or whenever the disc brake pads have been replaced...

Page 1314: ...alling the caliper guide pin bolt DO NOT allow the open end wrench to come in contact with the brake caliper Allowing the open end wrench to come in contact with the brake caliper will cause a pulsati...

Page 1315: ...during wheel rotation Replace the disc brake pads when the friction surface 3 is worn to within 2 mm 0 080 in of the mounting plates Remove the brake calipers and inspect the friction surfaces of the...

Page 1316: ...4C 14 Rear Brakes Rear Brake Caliper Replacement...

Page 1317: ...r installing the caliper guide pin bolt DO NOT allow the open end wrench to come in contact with the brake caliper Allowing the open end wrench to come in contact with the brake caliper will cause a p...

Page 1318: ...caliper requires overhaul or replacement 4 Inspect for smooth and complete travel of the caliper piston or pistons into the caliper bore or bores The movement of a caliper piston into a caliper bore s...

Page 1319: ...ake hose and in turn may cause a brake fluid leak Preliminary Procedures 1 Raise and support the vehicle Refer to Lifting and Jacking the Vehicle 2 Remove the tire and wheel Refer to Tire and Wheel Re...

Page 1320: ...attempt to move the brake caliper vertically The brake caliper should not exhibit excessive looseness 5 Without disconnecting the hydraulic brake flex hose remove the caliper from the caliper bracket...

Page 1321: ...isc brake pad mounting hardware requires replacement 10 Inspect the brake caliper guide pins 1 4 by gently pushing inward without disengaging the slides from the boots then pull outward and observe fo...

Page 1322: ...flexible brake hose to bear the weight of the caliper which may cause damage to the brake hose and in turn may cause a brake fluid leak Preliminary Procedures 1 Raise and support the vehicle Refer to...

Page 1323: ...equivalent whenever it is separated from its mount and the hydraulic flexible brake hose is still connected Failure to support the caliper in this manner will cause the flexible brake hose to bear th...

Page 1324: ...o the following specification Specification Brake rotor maximum allowable scoring 1 50 mm 0 059 in 7 If the brake rotor scoring depth exceeds the specification or if an excessive amount of scoring is...

Page 1325: ...when the brake rotors are removed from the drive axle repeat the test with one rotor installed at a time Replace the rotor that is causing or contributing to the vibration concern 7 If a brake rotor w...

Page 1326: ...127 mm 0 001 0 005 in Indexing is used to achieve the best possible match of high spots to low spots between related components Refer to Brake Rotor Assembled Lateral Runout Correction Indexing The co...

Page 1327: ...n particles or debris remaining 3 Index the brake rotor in a different orientation to the hub axle flange 4 Hold the rotor firmly in place against the hub axle flange and install one of the J 45101 10...

Page 1328: ...that there are no foreign particles or debris remaining 4 Select the correction plate following the manufacturer s instructions which has a specification closest to the assembled LRO measurement For e...

Page 1329: ...RO Thickness variation exceeding the maximum acceptable level can cause brake pulsation Refer to Brake Rotor Thickness Variation Measurement Brake rotor assembled LRO exceeding the maximum allowable s...

Page 1330: ...tors in an attempt to correct the following conditions Brake system noise squeal growl groan Uneven and or premature disc brake pad wear Superficial or cosmetic corrosion rust of the disc brake rotor...

Page 1331: ...ed setting for applying a non directional finish b Using moderate pressure apply the non directional finish If the lathe is equipped with a non directional finishing tool apply the finish with 120 gri...

Page 1332: ...akes Illustration Tool Number Description J 39544 KIT Complete Torque Socket Set 10 Pieces J 41013 Rotor Resurfacing Kit J 42450 A Wheel Hub Resurfacing Kit J 45101 Hub and Wheel Runout Gage J 45101 1...

Page 1333: ...to park brake actuator adjuster Park Brake Actuator Adjuster Uses multiplied input force from apply lever to expand drum brake shoes toward the friction surface of the brake drum Threaded park brake a...

Page 1334: ...brake switch signal circuit With the park brake applied the switch is closed and the signal circuit is grounded The BCM will then send a serial data message to the IPC requesting the red brake warning...

Page 1335: ...Park Brake System Description and Operation Visual Physical Inspection Inspect for aftermarket devices which could affect the operation of the park brake system Inspect the easily accessible or visibl...

Page 1336: ...ables that are accessible on the UNDERSIDE of the vehicle for disconnections and or damage Were any of the park brake cables disconnected and or damaged Go to Step 7 Go to Step 8 7 Reconnect or replac...

Page 1337: ...ing Brake Front Cable Replacement Parking Brake Rear Cable Replacement Did you complete the replacement Go to Step 19 16 Disconnect the front park brake cable connection accessible INSIDE the vehicle...

Page 1338: ...ghten the set screw on the tool in order to ensure the proper measurement when removing the tool from the drum 10 Position the outside measurement contacts of the J 21177 A over the park brake shoe 1...

Page 1339: ...wheels 5 Attempt to rotate the rear wheels There should be no rotation forward or rearward 6 Fully release the park brake lever 7 Verify the park brake is released by rotating the rear wheels The whee...

Page 1340: ...1 Park Brake Shoe Hold Down Spring Qty 2 Procedure Compress the spring and rotate turn to release 2 Park Brake Shoe Hold Down Spring Pin Qty 2 3 Park Brake Shoe Adjuster Spring Procedure Using the J 3...

Page 1341: ...ded rod 6 Disconnect the electrical connector from the park brake warning lamp switch 7 With the park brake lever 1 in the released position release the rear park brake cable 2 ends from the cable equ...

Page 1342: ...N m 18 lb ft 3 Secure the rear cable fittings to the park brake lever bracket Attempt to pull the park brake cables free of the lever bracket to ensure that the retaining tabs on the fittings are pro...

Page 1343: ...ing lamp switch mounting screw 1 Tightening torque Tighten the screw to 4 N m 35 lb in 4 Connect the park brake warning lamp switch electrical connector 2 5 Install the front floor console Refer to Co...

Page 1344: ...bling and Enabling Parking Brake Rear Cable Replacement Removal Procedure Special tool J 37043 Park Brake Cable Release Tool 1 Remove the front floor console Refer to Console Replacement 2 Ensure the...

Page 1345: ...ss through grommet 10 Raise and support the vehicle Refer to Lifting and Jacking the Vehicle 11 Remove the rear tire and wheel assembly Refer to Tire and Wheel Removal and Installation 12 Remove the b...

Page 1346: ...al and Installation 5 Insert the cable 2 through the opening in the vehicle underbody 6 Install the park brake cable retaining bracket to the rear suspension lower trailing arm CAUTION Refer to Fasten...

Page 1347: ...to the cable equalizer 14 Position park brake cable to routing tabs on vehicle interior floor 15 Secure park brake cable to floor by folding routing tabs over park brake cable 16 Reposition the carpet...

Page 1348: ...Refer to Tire and Wheel Removal and Installation 3 Remove the disc brake backing plate Refer to Rear Disc Brake Backing Plate Replacement 1 Park Brake Cable Eye Procedure 1 Using the J 37043 release t...

Page 1349: ...the conditions listed were found which could lead to improper park brake apply and or release the park brake lever requires repair or replacement 7 Visually inspect the park brake cable for the follo...

Page 1350: ...cket to Trailing Arm Bolt and Nut 12 N m 106 lb in Park Brake Cable Bracket to Underbody Bolt 25 N m 18 lb ft Park Brake Lever Assembly Mounting Nuts 25 N m 18 lb ft Park Brake Warning Lamp Switch Mou...

Page 1351: ...split The BPMV directs fluid from the reservoir of the master cylinder to the left front and right rear wheels and fluid from the other reservoir to the right front and left rear wheels The diagonal c...

Page 1352: ...aining a constant force on the brake pedal provides the shortest stopping distance while maintaining vehicle stability Pressure Hold The EBCM closes the inlet valve and keeps the outlet valve closed i...

Page 1353: ...rify that ECE 13 is not the cause of an ABS indicator which is illuminated when no DTCs are set before attempting to diagnose other possible causes Driver Information Indicators and Messages The follo...

Page 1354: ...ence If the wires were covered with shielding install new shielding In order to prevent electrical interference from degrading the performance of the connected components you must maintain the proper...

Page 1355: ...ABS 4E 5 Serial Data Traction Switch and Instrument Panel...

Page 1356: ...4E 6 ABS Wheel Speed Sensor...

Page 1357: ...ABS 4E 7 Yaw Rate and Lateral Accelerator Sensor and Steering Angle Sensor...

Page 1358: ...ns 32 Terminal Tray 7116 4141 02 10 Core Insulation Crimp 4 3 Release Tool Test Probe 12094430 J 35616 42 RD Pins 1 16 Terminal Tray 7116 4142 02 10 Core Insulation Crimp Pins 1 A 3 Core Insulation Cr...

Page 1359: ...eed Sensor Low Reference 43 BN 882 Right Rear Wheel Speed Sensor Signal 44 Not Used 45 L BU 830 Left Front Wheel Speed Sensor Signal 46 YE 873 Left Front Wheel Speed Sensor Low Reference 47 Not Used P...

Page 1360: ...Dimming Signal Connector Part Information OEM 12052644 Service Description 2 Way F Metri Pack 150 Series Sealed GY Terminal Part Information Terminal Tray 12048074 2 Core Insulation Crimp E 1 Release...

Page 1361: ...12162343 Service Description 2 Way M Metri Pack 150 GY Terminal Part Information Terminal Tray 12045773 2 Core Insulation Crimp E 1 Release Tool Test Probe 12094429 J 35616 3 GY Pin Wire Color Circui...

Page 1362: ...4E 12 ABS Component Location Antilock Brake System Component Views LF Suspension 1 C103 Left Shown C104 Right Similar 2 Wheel Speed Sensor WSS LF RF Similar...

Page 1363: ...ABS 4E 13 Near the Brake Booster 1 Brake Fluid Level Switch 3 Electronic Brake Control Module EBCM 2 LF Strut Tower...

Page 1364: ...h Driver Heated Seat Switch Front Passenger 3 Driver Information Center DIC Switch 10 Power Window Switch Main 4 Hazard Switch 11 Traction Control Switch TCS 5 Inflatable Restraint Passenger Air Bag O...

Page 1365: ...e 7 Inflatable Restraint Sensing and Diagnostic Module SDM 3 Yaw Rate and Lateral Acceleration Sensor 8 Seat Belt Pretensioner Left 4 Seat Belt Pretensioner Right 9 Inflatable Restraint Side Impact Se...

Page 1366: ...4E 16 ABS Rear ABS Sensors 1 Rear Cradle 3 Wheel Speed Sensor WSS RR 2 Wheel Speed Sensor WSS LR...

Page 1367: ...the EBCM Scan Tool Data Lists as directed by a diagnostic table or in order to supplement the diagnostic procedures Begin all the diagnostic procedures with the antilock brake system ABS Diagnostic S...

Page 1368: ...als 0 g lateral acceleration Scan Tool Parameter Data List Units Displayed Typical Data Value Operating Conditions Ignition is ON engine OFF and vehicle is stationary ABS Active ABS Yes No No ABS Fail...

Page 1369: ...Command The scan tool displays Active Inactive The scan tool displays Active when the right front Inlet solenoid is commanded on Steering Wheel Position The scan tool displays degrees The steering whe...

Page 1370: ...ltage is greater than 9 5 volts The brake pedal is not pressed A DTC is not set for the other wheel speed circuit on the same axle C0035 C0050 18 The ignition is ON Ignition voltage is greater than 9...

Page 1371: ...End View Reference Antilock Brake System Connector End Views Description and Operation Reference ABS Description and Operation Electrical Information Reference Circuit Testing Testing for Intermitten...

Page 1372: ...ormation DTC C0110 DTC Descriptors DTC C0110 04 Pump Motor Circuit Open Circuit DTC C0110 61 Pump Motor Circuit Actuator Stuck Diagnostic Fault Information NOTE Always perform the Diagnostic System Ch...

Page 1373: ...al going to the ABS pump motor and to ground It is important that the test lamp is connected before the ignition is turned ON 2 With the ignition ON verify that the test lamp illuminates If the test l...

Page 1374: ...e drive cycles Diagnostic Aids The pressure sensor is integral to the brake pressure modulator valve BPMV The pressure sensor is not serviceable Inspect the brake pressure sensor contacts for proper c...

Page 1375: ...ake light switch signal coming from the module sends invalid data to the EBCM in terms of the rolling count value Action Taken When the DTC Sets The ABS TCS remains functional Conditions for Clearing...

Page 1376: ...itch is in the ON position Conditions for Setting the DTC The yaw lateral combination sensor reports an internal failure The yaw lateral combination sensor learns a wrong offset value Incorrectly moun...

Page 1377: ...or 5 Ignition ON test for 0 volts between the communication circuit terminal 5 and ground If greater than the specified value test the communication circuit for a short to voltage 6 Test for 0 volts b...

Page 1378: ...vehicle s yaw motion by applying differential braking to the wheels Conditions for Running the DTC The ignition switch is in the ON position The ignition voltage is greater than 9 5 volts Conditions...

Page 1379: ...or 5 Ignition ON test for 0 volts between the communication circuit terminal 5 and ground If greater than the specified value test the communication circuit for a short to voltage 6 Test for 0 volts b...

Page 1380: ...ning indicator turns ON Conditions for Clearing the DTC The condition for setting the DTC is no longer present The EBCM automatically clears the history DTC when a current DTC is not detected in 100 c...

Page 1381: ...mbined with the differential braking will attempt to bring the delta velocity error toward 0 The VSES activations generally occur during aggressive driving in the turns or bumpy roads with out much us...

Page 1382: ...led The TCS VSES indicators turn ON Conditions for Clearing the DTC The condition for the DTC is no longer present and the DTC is cleared with a scan tool The EBCM automatically clears the history DTC...

Page 1383: ...nt DTC is not detected in 100 consecutive drive cycles Diagnostic Aids If the yaw and lateral accelerometer sensor is disconnected DTCs will set and the EBCM will not provide 5 volt reference Referenc...

Page 1384: ...ed driving direction Conditions for Running the DTC The ignition is ON Ignition voltage is greater than 9 5 volts Conditions for Setting the DTC Steering angle sensor is reporting an internal electron...

Page 1385: ...ostic Information after completing the diagnostic procedure Electronic Brake Control Module Replacement Control Module References for EBCM replacement setup and programming DTC C0550 DTC Descriptor DT...

Page 1386: ...Scan Tool Data List Antilock Brake System for EBCM Circuit System Verification Verify that the EBCM is the correct module for the vehicle If the EBCM is not correct replace the EBCM Reprogram the EBCM...

Page 1387: ...ss than 10 volts for 200 msec Action Taken When the DTC Sets The ABS indicator turns ON until the voltage returns to above 10 volts Conditions for Clearing the DTC The condition for the DTC is no long...

Page 1388: ...t Testing Connector Repairs Testing for Intermittent Conditions and Poor Connections Wiring Repairs Scan Tool Reference Scan Tool Data List Antilock Brake System for EBCM Circuit System Testing 1 Meas...

Page 1389: ...inspect wiring and connectors may result in misdiagnosis causing part replacement with reappearance of the malfunction Thoroughly inspect any circuitry that may be causing the complaint for the follow...

Page 1390: ...A broken wire inside the insulation If an intermittent malfunction exists refer to Inducing Intermittent Fault Conditions in Wiring Systems 2 1 Using a scan tool select the brake control module BCM S...

Page 1391: ...ct ABS Telltale Indicator 4 In the ABS Telltale Test mode you can turn the instrument panel indicators ON or OFF All indicators will turn ON when commanded on Does the ABS indicator turn on then off G...

Page 1392: ...disabling the TCS via the traction control switch The instrument cluster bulb check When the ignition switch is turned to ON the TRAC OFF indicator will turn on for approximately 3 seconds and then tu...

Page 1393: ...an open or high resistance Refer to Testing for Intermittent Conditions and Poor Connections and Connector Repairs in Wiring Systems Did you find and correct the condition Go to Step 10 Go to Step 6 5...

Page 1394: ...isabling the TCS via the traction control switch The instrument cluster bulb check When the ignition switch is turned to ON the TRAC OFF indicator will turn on for approximately 3 seconds and then tur...

Page 1395: ...itch parameter Does the scan tool display Inactive Go to Step 7 Go to Step 5 5 Test the signal circuit of the traction control switch for a short to ground Refer to and Testing for Short to Ground in...

Page 1396: ...painted surfaces Automated Bleed Procedure 1 Raise and support the vehicle Refer to Lifting and Jacking the Vehicle 2 Remove all 4 tire and wheel assemblies Refer to Tire and Wheel Removal and Instal...

Page 1397: ...uired then make the necessary repairs and adjustments prior to the steering position sensor calibration Refer to Symptoms Suspension General Diagnosis NOTE Before performing the calibration procedure...

Page 1398: ...brake pressure modulator valve BPMV area of any dirt or debris 1 Electronic Brake Control Module EBCM Electrical Connector Tip Release the locking tab and rotate the electrical connector cover upward...

Page 1399: ...e to observe this precaution could result in damage to the EBCM EBTCM Preliminary Procedures 1 Place the ignition switch in the OFF position 2 Clean the brake pipe fittings of any dirt or debris 3 Rem...

Page 1400: ...lb ft 5 EBCM to Brake Pressure Modulator Valve BPMV Screw Qty 4 Tip Tighten the screws in a cross pattern Tightening torque 3 N m 27 lb in 6 Electronic Brake Control Module EBCM 7 EBCM to BPMV Seal Qt...

Page 1401: ...FF position 1 Brake Modulator Assembly Bracket Bolt CAUTION Refer to Fastener Notice Tightening torque 20 N m 15 lb ft 2 Brake Modulator Assembly Bracket Nut Qty 2 Tightening torque 10 N m 89 lb in 3...

Page 1402: ...nd wheel Refer to Tire and Wheel Removal and Installation 3 Remove the brake rotor Refer to Front Brake Rotor Replacement 1 Wheel Speed Sensor Electrical Connector Procedure Release the electrical con...

Page 1403: ...to Tire and Wheel Removal and Installation 3 Remove the park brake shoes Refer to Park Brake Shoe Replacement 1 Wheel Speed Sensor Electrical Connector 2 Wheel Speed Sensor Bolt CAUTION Refer to Fast...

Page 1404: ...ame Preliminary Procedure Remove the Instrument Panel Lower Brace Bezel Refer to Instrument Panel Lower Brace Bezel Replacement 1 Traction Control Switch Assembly Tip Release the tabs securing the tra...

Page 1405: ...e 6 N m 53 lb in 2 Yaw Rate Sensor Cover If equipped 3 Yaw Rate Sensor Procedure Disconnect the electrical connector Application Specification Metric English Brake Modulator Assembly Bracket Bolt 20 N...

Page 1406: ...4E 56 ABS...

Page 1407: ...A 56 Component Location 5A 57 Automatic Transmission Electronic Component Views 5A 57 Shift Lock Control Component Views 5A 58 Disassembled Views 5A 59 Bearing Race Thrust Washer and Seal Locations 5A...

Page 1408: ...Shift Lever Can Be Moved without Brake Pedal Depressed 5A 193 Repair Instructions 5A 194 Transmission Fluid Check 5A 194 Line Pressure Check 5A 195 Transaxle Fluid Replacement 5A 197 Transmission Con...

Page 1409: ...nternal Gear and Front Carrier Installation 5A 267 Forward and Direct Clutch Assembly Disassemble 5A 268 Forward and Direct Clutch Assembly Assemble 5A 271 Direct Clutch Piston Travel Check 5A 274 For...

Page 1410: ...emoval 5A 338 Torque Converter Assembly Installation 5A 338 Specifications 5A 339 Fastener Tightening Specifications Automatic Transaxle AF33 5 5A 339 Transmission Fluid Temperature Sensor Specificati...

Page 1411: ...the vehicle to be operated in a rearward direction N Neutral position enables the engine to start and operate without driving the vehicle If necessary this position should be selected to restart the e...

Page 1412: ...ith a sharp instrument and do not properly seal the wire afterward the wire corrodes and an open circuit results Diagnostic test probes are now available that allow you to probe individual wires witho...

Page 1413: ...may also be noticeable in PARK or NEUTRAL operating ranges with the vehicle stationary Final Drive Noise A hum related to vehicle speed which is most noticeable under a light throttle acceleration Pl...

Page 1414: ...d clutch B2 assembly 1 2 reverse clutch B5 assembly 1 2 reverse internal gear 1 2 reverse carrier gear assembly 3rd gear band assembly B4 3rd gear band servo piston assembly 4 5 clutch C3 assembly fro...

Page 1415: ...ission Control Module TCM The transmission control module TCM primarily controls shift points and lockup engagement The transaxle is controlled by an electronic shift system The TCM processes input si...

Page 1416: ...lunger away from the exhaust seat This allows signal fluid to flow past the metering ball and exhaust through the solenoid As a result of this exhaust there is no pressure in the signal fluid circuit...

Page 1417: ...ne pressure control solenoid valve resistance should measure between 5 0 and 5 6 ohms when measured at 20 C 68 F The duty cycle and current flow to the line pressure control solenoid valve are mainly...

Page 1418: ...in seconds is called frequency Typically the operation of an electronically controlled pulse width modulated solenoid is explained in terms of duty cycle and frequency The TCM controls the shift press...

Page 1419: ...orifice 3 into the S1 signal 14 fluid circuit in preparation for a shift The normally open reverse 1st SS valve assembly is OFF allowing any fluid pressure in the S1 signal 14 fluid circuit to exhaust...

Page 1420: ...CLUTCH 24 LOW AND REVERSE CLUTCH 25 REVERSE CONTROL 26 FORWARD CLUTCH 27 DIRECT CLUTCH FEED 1 28 DIRECT CLUTCH FEED 2 29 DIRECT CLUTCH 30 B2 CONTROL 1 31 B2 CONTROL 2 32 SECOND CLUTCH 33 B1 CONTROL 1...

Page 1421: ...Automatic Transmission 5A 11 Park Engine Running...

Page 1422: ...tch piston to apply the low and reverse clutch plates DIRECT CLUTCH C2 ASSEMBLY APPLIES Reverse Shift Solenoid SS Valve Assembly S5 The normally closed reverse SS valve assembly is energized allowing...

Page 1423: ...CLUTCH 24 LOW AND REVERSE CLUTCH 25 REVERSE CONTROL 26 FORWARD CLUTCH 27 DIRECT CLUTCH FEED 1 28 DIRECT CLUTCH FEED 2 29 DIRECT CLUTCH 30 B2 CONTROL 1 31 B2 CONTROL 2 32 SECOND CLUTCH 33 B1 CONTROL 1...

Page 1424: ...5A 14 Automatic Transmission Reverse...

Page 1425: ...st spring force Low and Reverse Clutch B3 Assembly When the M1 shift valve is shifted to the applied position reverse clutch 23 fluid is blocked and low and reverse clutch 24 fluid exhausts through th...

Page 1426: ...CLUTCH 24 LOW AND REVERSE CLUTCH 25 REVERSE CONTROL 26 FORWARD CLUTCH 27 DIRECT CLUTCH FEED 1 28 DIRECT CLUTCH FEED 2 29 DIRECT CLUTCH 30 B2 CONTROL 1 31 B2 CONTROL 2 32 SECOND CLUTCH 33 B1 CONTROL 1...

Page 1427: ...Automatic Transmission 5A 17 Reverse Inhibit...

Page 1428: ...id pressure to build up in the S5 signal 18 fluid circuit Shift Pressure Relay Valve S5 signal 18 fluid is routed to the shift pressure relay valve and applies the valve against spring force Direct Cl...

Page 1429: ...CLUTCH 24 LOW AND REVERSE CLUTCH 25 REVERSE CONTROL 26 FORWARD CLUTCH 27 DIRECT CLUTCH FEED 1 28 DIRECT CLUTCH FEED 2 29 DIRECT CLUTCH 30 B2 CONTROL 1 31 B2 CONTROL 2 32 SECOND CLUTCH 33 B1 CONTROL 1...

Page 1430: ...5A 20 Automatic Transmission Neutral Engine Running...

Page 1431: ...cumulator Forward clutch 26 fluid is also directed to the forward clutch accumulator assembly Forward clutch 26 fluid pressure moves the forward clutch accumulator piston against spring force to cushi...

Page 1432: ...CLUTCH 24 LOW AND REVERSE CLUTCH 25 REVERSE CONTROL 26 FORWARD CLUTCH 27 DIRECT CLUTCH FEED 1 28 DIRECT CLUTCH FEED 2 29 DIRECT CLUTCH 30 B2 CONTROL 1 31 B2 CONTROL 2 32 SECOND CLUTCH 33 B1 CONTROL 1...

Page 1433: ...Automatic Transmission 5A 23 Drive and M Range First Gear...

Page 1434: ...e in the S5 signal 18 fluid circuit to exhaust through the solenoid Shift Pressure Relay Valve S5 signal 18 fluid is exhausted from the shift pressure relay valve and spring force moves the valve to t...

Page 1435: ...CLUTCH 24 LOW AND REVERSE CLUTCH 25 REVERSE CONTROL 26 FORWARD CLUTCH 27 DIRECT CLUTCH FEED 1 28 DIRECT CLUTCH FEED 2 29 DIRECT CLUTCH 30 B2 CONTROL 1 31 B2 CONTROL 2 32 SECOND CLUTCH 33 B1 CONTROL 1...

Page 1436: ...5A 26 Automatic Transmission M Range First Gear Engine Braking...

Page 1437: ...to help cushion the apply of the second clutch Second Clutch B2 Assembly Second clutch 32 fluid is routed to the second clutch piston to apply the second clutch plates SECOND COAST CLUTCH B1 ASSEMBLY...

Page 1438: ...CLUTCH 24 LOW AND REVERSE CLUTCH 25 REVERSE CONTROL 26 FORWARD CLUTCH 27 DIRECT CLUTCH FEED 1 28 DIRECT CLUTCH FEED 2 29 DIRECT CLUTCH 30 B2 CONTROL 1 31 B2 CONTROL 2 32 SECOND CLUTCH 33 B1 CONTROL 1...

Page 1439: ...Automatic Transmission 5A 29 Drive and M Range Second Gear...

Page 1440: ...old the 4 5 clutch drum assembly 1 2 REVERSE CLUTCH B5 ASSEMBLY RELEASES Solenoid Relay Valve 3rd gear band apply 46 fluid also passes through orifice 30 and together with spring force overcomes solen...

Page 1441: ...CLUTCH 24 LOW AND REVERSE CLUTCH 25 REVERSE CONTROL 26 FORWARD CLUTCH 27 DIRECT CLUTCH FEED 1 28 DIRECT CLUTCH FEED 2 29 DIRECT CLUTCH 30 B2 CONTROL 1 31 B2 CONTROL 2 32 SECOND CLUTCH 33 B1 CONTROL 1...

Page 1442: ...5A 32 Automatic Transmission Drive and M Range Third Gear...

Page 1443: ...ion 3rd gear band apply 46 fluid and servo apply 45 fluid exhaust through the valve allowing the 3rd gear band servo piston assembly and the 3rd gear band assembly to release 9 Reverse Shift Restrict...

Page 1444: ...CLUTCH 24 LOW AND REVERSE CLUTCH 25 REVERSE CONTROL 26 FORWARD CLUTCH 27 DIRECT CLUTCH FEED 1 28 DIRECT CLUTCH FEED 2 29 DIRECT CLUTCH 30 B2 CONTROL 1 31 B2 CONTROL 2 32 SECOND CLUTCH 33 B1 CONTROL 1...

Page 1445: ...Automatic Transmission 5A 35 Drive Range Fourth Gear...

Page 1446: ...the valve into the direct clutch 29 fluid circuit 1 Accumulator Check Valve Assembly Direct clutch 29 fluid pressure is routed to the 1 accumulator check valve assembly and moves the check valve agai...

Page 1447: ...CLUTCH 24 LOW AND REVERSE CLUTCH 25 REVERSE CONTROL 26 FORWARD CLUTCH 27 DIRECT CLUTCH FEED 1 28 DIRECT CLUTCH FEED 2 29 DIRECT CLUTCH 30 B2 CONTROL 1 31 B2 CONTROL 2 32 SECOND CLUTCH 33 B1 CONTROL 1...

Page 1448: ...5A 38 Automatic Transmission Drive Range Fifth Gear TCC Released...

Page 1449: ...cycle is ramped up to approximately 50 percent Apply 5 fluid pressure is now strong enough to cause the converter apply to occur Converter feed 3 pressure enters the apply 5 circuit at the lock up re...

Page 1450: ...CLUTCH 24 LOW AND REVERSE CLUTCH 25 REVERSE CONTROL 26 FORWARD CLUTCH 27 DIRECT CLUTCH FEED 1 28 DIRECT CLUTCH FEED 2 29 DIRECT CLUTCH 30 B2 CONTROL 1 31 B2 CONTROL 2 32 SECOND CLUTCH 33 B1 CONTROL 1...

Page 1451: ...Automatic Transmission 5A 41 Drive Range Fifth Gear TCC Applied...

Page 1452: ...d relay valve passes through the U2 shift valve into the S4 signal 17 fluid circuit and continues on to the 3 4 4 5 SS valve assembly where it exhausts into the sump LOCK UP PRESSURE CONTROL SOLENOID...

Page 1453: ...Automatic Transmission 5A 43 Drive Range Emergency Fifth Gear...

Page 1454: ...If the wires were covered with shielding install new shielding In order to prevent electrical interference from degrading the performance of the connected components you must maintain the proper speci...

Page 1455: ...Automatic Transmission 5A 45 Power and Ground...

Page 1456: ...5A 46 Automatic Transmission ISS OSS and TFT Sensors...

Page 1457: ...Automatic Transmission 5A 47 Shift and Pressure Solenoids...

Page 1458: ...5A 48 Automatic Transmission Shift Lock Control Schematics...

Page 1459: ...l 3 D BU 5509 TCC Pressure Control Solenoid Valve Low Control 3 BN 5509 TCC Pressure Control Solenoid Valve Low Control 4 PU WH 5510 Line Pressure Control Solenoid Valve Low Control 4 GY 5510 Line Pre...

Page 1460: ...noid Valve 1 High Control Pin Wire Color Circuit No Function Pin Wire Color Circuit No Function Connector Part Information OEM Service Description Conn 1 Way F GY Terminal Part Information Terminal Co...

Page 1461: ...2879 Shift Solenoid Valve 4 High Control Connector Part Information OEM Service Description Conn 2 Way M BK Terminal Part Information Terminal Core Insulation Crimp Release Tool Test Probe Pin Wire Co...

Page 1462: ...lve 1 High Control Connector Part Information OEM Service Description Conn 1 Way F BN Terminal Part Information Terminal Core Insulation Crimp Release Tool Test Probe Pin Wire Color Circuit No Functio...

Page 1463: ...TCC Pressure Control Solenoid Valve Low Control 2 L GN 5511 TCC Pressure Control Solenoid Valve High Control Connector Part Information OEM 6189 0031 Service Description Conn 2F BU Terminal Part Infor...

Page 1464: ...ansmission Range Switch Signal C 6 YE 772 Transmission Range Switch Signal B 7 Not Used 8 WH 776 Transmission Range Switch Signal P 9 BK WH 451 Ground 10 TN WH 771 Transmission Range Switch Signal A C...

Page 1465: ...Data Bus 37 38 Not Used Connector Part Information OEM 1928403311 Service Description Conn 38F BK Terminal Part Information Terminal Core Insulation Crimp Release Tool Test Probe Pin Wire Color Circui...

Page 1466: ...BK 1230 ISS Sensor High Reference 33 YE 400 OSS Sensor High Reference 34 L GN 1222 Shift Solenoid Valve 1 High Control 35 WH 1994 Line Pressure Control Solenoid Valve High Control 36 GY 5508 Shift Pr...

Page 1467: ...ed Sensor 308 2 3 3 4 Shift Solenoid Valve Assembly S2 73 Automatic Transmission Input Speed Sensor 310 Reverse 1st Shift Solenoid Valve Assembly S1 75 Park Neutral Position Switch 316 Line Pressure C...

Page 1468: ...5A 58 Automatic Transmission Shift Lock Control Component Views Below the Shifter 1 I P Trim 3 Cigar Lighter 2 Console Arm Rest 4 Shift Lock Control Solenoid...

Page 1469: ...verter Housing Bolt Screw TORX M8 x 1 25 x 30 34 Control Valve Body Bolt Screw M6 x 1 0 x 16 2 10 Torque Converter Housing Assembly 35 Control Valve Body Bolt Screw M6 x 1 0 x 28 2 11 2nd Clutch Hub a...

Page 1470: ...ing Seal 22 Transmission Case Cover Bolt Screw M8 x 1 25 x 45 2 47 Control Valve Body Bolt Screw M6 x 1 0 x 55 2 23 Forward and Direct Clutch Assembly 48 Output Gear Retaining Ring 24 Front Carrier Su...

Page 1471: ...56 3rd Gear Band Servo Spring 76 TCM Bolt 57 3rd Gear Band Servo Piston Assembly Selective 80 Front Wheel Drive Shaft Oil Seal 58 3rd Gear Band Servo Piston and Cover O ring Seal 3 83 Lube Fluid Pipe...

Page 1472: ...be Fluid Pipe Retainer 820 Transmission Fluid Drain Plug Washer 806 Lube Fluid Pipe Retainer Bolt Screw M6 x 1 0 x 14 821 Automatic Transmission Case Plug O ring Seal 807 Transmission Fluid Baffle Bol...

Page 1473: ...l 207 Fluid Pump Plate 224 Second Coast Clutch Spring 208 Fluid Pump Cover and Stator Shaft Assembly 225 Second Coast Clutch Spring Retaining Ring 209 Second Clutch Piston Outer Seal 226 Coast Clutch...

Page 1474: ...5A 64 Automatic Transmission Output Gear Assembly 235 Output Gear 237 Output Gear Bearing Assembly Spacer 236 Output Gear Bearing Assembly 238 Output Gear Bearing Assembly Lock Nut...

Page 1475: ...fferential Transfer Drive Gear Ring Gear Retaining Ring 253 Front Differential Transfer Drive Gear Parking Lock Gear 261 Front Differential Transfer Drive Gear Ring Gear 254 Front Differential Transfe...

Page 1476: ...r Control Valve Body Assembly Gasket 308 2 3 3 4 Shift Solenoid Valve Assembly S2 Black 330 No 2 Rear Control Valve Body Assembly 310 Reverse 1st Shift Solenoid Valve Assembly S1 Black 331 Control Val...

Page 1477: ...or Valve Spring Yellow 356 Neutral Relay Valve 348 Solenoid Modulator Valve Bore Plug 4 357 Neutral Relay Valve Spring Light Blue 349 Sleeve Bore Plug Retainer 3 2 x 5 x 10 4 358 2nd Coast Clutch B1 C...

Page 1478: ...Spring Light Blue 374 Reverse Shift Ball Check Valve 391 M1 Shift Valve Bore Plug 375 Reverse Shift Ball Check Valve Bushing Outer 392 U2 Shift Valve 376 Solenoid Relay Valve Sleeve 393 U2 Shift Valv...

Page 1479: ...er Plate Bolt Hexagon M5 x 0 8 x 13 2 430 Shift Pressure Control Valve 417 Rear Valve Body Cover Plate 431 Shift Pressure Control Valve Plunger 418 Rear Valve Body Cover Plate Gasket 432 Shift Pressur...

Page 1480: ...utch B2 Control Valve 454 Lock Up Control Valve 447 2nd Clutch B2 Control Valve Spring Natural Color 455 Lock Up Control Valve Plunger 448 2nd Clutch B2 Control Valve Plug 456 Lock Up Control Valve Sp...

Page 1481: ...d Second Clutch Sprag Assembly 500 Second Coast Clutch Hub 503 Second Clutch Sprag Assembly 501 Coast Clutch Hub Thrust Washer 505 Second Clutch Sprag Outer Race Assembly 502 Second Clutch Sprag End B...

Page 1482: ...tch Plate Retaining Ring 512 Low and Reverse Clutch Piston Outer Seal 520 Low and Reverse Clutch Backing Plate 513 Low and Reverse Clutch Spring Assembly 523 Overrun Roller Clutch Assembly 514 Low and...

Page 1483: ...t Bearing Assembly 542 Front Carrier Assembly 530 Front Internal Gear Thrust Washer Race 543 Front Carrier Thrust Bearing Race 535 Rear Internal Gear Thrust Bearing Assembly 544 Front Sun Gear 536 Rea...

Page 1484: ...t Clutch Backing Plate Retaining Ring 565 Forward Clutch Piston 555 Direct Clutch Backing Plate Selective 566 Forward Clutch Piston Outer Seal 556 Direct Clutch Plate Assembly Fiber 4 567 Forward and...

Page 1485: ...utch Piston Return Spring Assembly 576 4 5 Clutch Backing Plate Selective 581 4 5 Clutch Piston Inner Seal 577 4 5 Clutch Plate Assembly Fiber 4 582 4 5 Clutch Piston 578 4 5 Clutch Plate Steel 4 583...

Page 1486: ...Gear Assembly 594 1 2 Reverse Internal Gear 590 1 2 Reverse Carrier Thrust Washer 2 595 1 2 Reverse Internal Gear Rear Thrust Bearing Assembly 591 1 2 Reverse Carrier Gear Assembly 596 1 2 Reverse Int...

Page 1487: ...orward Clutch Accumulator Cover Bolt Screw M6 x 1 0 x 14 5 2 603 1 2 Reverse Clutch Piston 618 1 2 Reverse Clutch Apply Plate 604 1 2 Reverse Clutch Piston Outer Seal 619 1 2 Reverse Clutch Plate Stee...

Page 1488: ...ifferential Pinion Shaft Retaining Pin 6 mm x 38 mm 1 632 Front Differential Pinion Shaft Thrust Washer 2 640 Front Differential Carrier Assembly FWD 633 Front Differential Pinion Gear 2 640a Front Di...

Page 1489: ...aft Detent Lever Assembly 702 Park Pawl 711 Manual Shaft Detent Lever Spring 703 Park Pawl Spring Pin 712 Manual Shaft Detent Spring Bolt Screw M6 x 1 0 x 14 and Washer 704 Park Pawl Pin Spring 713 Ma...

Page 1490: ...596 1 2 Reverse Internal Gear Shim 501 Coast Clutch Hub Thrust Washer 623 Front Differential Transfer Drive Gear Assembly Rear Bearing Assembly 506 Second Clutch Sprag Outer Race Thrust Washer 625 Inp...

Page 1491: ...iston Sleeve Outer Seal 583 4 5 Clutch Piston Outer Seal 213 Second Clutch Piston Sleeve Inner Seal 602 1 2 Reverse Clutch Piston Inner Seal 221 Second Coast Clutch Piston Inner Seal 604 1 2 Reverse C...

Page 1492: ...Automatic Transmission Fluid Pressure Test Hole Plug UNF 5 16 24 2A 8 Lube 202 Fluid Pump Body 32 Second Clutch 804 Lube Fluid Pipe 36 Second Coast Clutch 815 Automatic Transmission Vent Assembly 46...

Page 1493: ...ransmission 5A 83 Fluid Pump Plate Fluid Passages Fluid Pump Body Side 1 Suction 36 Second Coast Clutch 2 Line 46 3rd Gear Band Apply 4 Release 56 Void 5 Apply 57 Torque Converter Seal Drainback 32 Se...

Page 1494: ...tomatic Transmission Fluid Pump Stator Shaft Assembly Fluid Passages Fluid Pump Body Side 1 Suction 32 Second Clutch 2 Line 36 Second Coast Clutch 4 Release 56 Void 5 Apply 57 Torque Converter Seal Dr...

Page 1495: ...mbly Side 52 3rd Gear Band Apply Tube 8 Lube 54 Automatic Transmission Case Plug M20 x 1 5 x 13 5 32 Second Clutch 66 Automatic Transmission Fluid Pressure Test Hole Plug UNF 5 16 24 2A 36 Second Coas...

Page 1496: ...c Transmission Case Plug M20 x 1 5 x 13 5 24 Low and Reverse Clutch 64 3rd Gear Band Anchor Bolt Screw M20 x 1 5 x 21 26 Forward Clutch 66 Automatic Transmission Fluid Pressure Test Hole Plug UNF 5 16...

Page 1497: ...ase Cover Assembly Fluid Passages Transmission Case Assembly Side 66 Automatic Transmission Fluid Pressure Test Hole Plug UNF 5 16 24 2A 29 Direct Clutch 609 4 5 Clutch Apply Pipe 39 1 2 Reverse B5 Cl...

Page 1498: ...e Body Assembly Side 66 Automatic Transmission Fluid Pressure Test Hole Plug UNF 5 16 24 2A 24 Low and Reverse Clutch 1 Suction 26 Forward Clutch 2 Line 29 Direct Clutch 4 Release 39 1 2 Reverse B5 Cl...

Page 1499: ...Check Valve Assembly 13 TCC Signal 10 Accumulator Check Valve Assembly 19 Drive 11 Accumulator Check Valve Assembly 25 Reverse Control 3 Converter Feed 30 B2 Control 1 4 Release 43 Servo Release 5 Ap...

Page 1500: ...ve Body Gasket Fluid Passages Rear Control Valve Body Assembly Side 3 Converter Feed 19 Drive 4 Release 25 Reverse Control 5 Apply 30 B2 Control 1 6 Exhaust Enable 43 Servo Release 7 Cooler 45 Servo A...

Page 1501: ...e Body Assembly Side 3 Converter Feed 19 0 Drive B2 Control 1 4 Release 25 Reverse Control 5 Apply 30 B2 Control 1 6 Exhaust Enable 41 5 B4 Control Reverse Control 7 Cooler 43 Servo Release 10 Throttl...

Page 1502: ...Fluid Passages Rear Control Valve Body Assembly Side 3 Converter Feed 19 Drive 4 Release 25 Reverse Control 5 Apply 30 B2 Control 1 6 Exhaust Enable 41 B4 Control 7 Cooler 43 Servo Release 10 Throttl...

Page 1503: ...re Test Hole Bolt Screw Pressure Tap M6 x 1 0 x 12 19 Drive 3 Converter Feed 21 Regulated Drive or Reverse 4 Release 24 Low and Reverse Clutch 5 Apply 25 Reverse Control 6 Exhaust Enable 30 B2 Control...

Page 1504: ...7 Cooler 34 B1 Control 2 8 Lube 35 B1 Control 3 10 Throttle Signal SLT 36 Second Coast Clutch 11 Shift Control SLS 37 B5 Control 1 12 Lock Up Control SLU 39 1 2 Reverse B5 Clutch 13 TCC Signal 41 B4...

Page 1505: ...4 Release 33 B1 Control 1 5 Apply 34 B1 Control 2 7 Cooler 35 B1 Control 3 8 Lube 36 Second Coast Clutch 10 Throttle Signal SLT 37 B5 Control 1 11 Shift Control SLS 39 1 2 Reverse B5 Clutch 12 Lock U...

Page 1506: ...elease 33 B1 Control 1 5 Apply 34 B1 Control 2 7 Cooler 35 B1 Control 3 8 Lube 36 Second Coast Clutch 10 Throttle Signal SLT 37 B5 Control 1 11 Shift Control SLS 39 1 2 Reverse B5 Clutch 12 Lock Up Co...

Page 1507: ...y 31 B2 Control 2 6 Accumulator Check Valve Assembly 32 Second Clutch 1 Suction 33 B1 Control 1 2 Line 34 B1 Control 2 3 Converter Feed 35 B1 Control 3 4 Release 36 Second Coast Clutch 5 Apply 37 B5 C...

Page 1508: ...Control Valve Body Fluid Passage Cover 33 B1 Control 1 371 Fluid Strainer 34 B1 Control 2 372 Fluid Strainer 35 B1 Control 3 1 Suction 38 B5 Control 2 2 Line 39 1 2 Reverse B5 Clutch 9 Solenoid Modula...

Page 1509: ...ust 27 Direct Clutch Feed 1 56 Void 2 Line 26 Forward Clutch 9 Solenoid Modulator 33 B1 Control 1 10 Throttle Signal SLT 37 B5 Control 1 11 Shift Control SLS 38 B5 Control 2 12 Lock Up Control SLU 39...

Page 1510: ...22 Reverse 2 7 Line S4 Signal 23 2 Reverse Clutch Reverse 2 8 Line S5 Signal 26 Forward Clutch 9 Solenoid Modulator 26 9 Forward Clutch Drive 10 Throttle Signal SLT 33 B1 Control 1 11 Shift Control SL...

Page 1511: ...y Assembly Side 2 Line 22 Reverse 9 Solenoid Modulator 26 Forward Clutch 10 Throttle Signal SLT 33 B1 Control 1 11 Shift Control SLS 44 Servo Feed 12 Lock Up Control SLU 46 3rd Gear Band Apply 14 S1 S...

Page 1512: ...4 5 Shift Solenoid Valve Assembly S4 Blue 22 Reverse 305 Reverse Shift Solenoid Valve Assembly S5 Green 26 Forward Clutch 308 2 3 3 4 Shift Solenoid Valve Assembly S2 Light Gray 33 B1 Control 1 310 R...

Page 1513: ...eviewing the Transmission Component and System Description information enables you to understand the operation of the system This helps you determine if the condition described by the customer is norm...

Page 1514: ...f output control is attempted while the engine is running the message Output control not allowed while engine is running appears on the scan tool display Line PC Sol Functional The TCM commands the am...

Page 1515: ...ontrol solenoid The duty cycle is represented by a percentage of ON energized time Approximately 90 100 percent duty cycle represents an ON energized commanded state Zero percent represents an OFF non...

Page 1516: ...olled within calibrated limits The scan tool parameter Shift PC Sol Ref Current changes but the parameter Shift PC Sol Actual Current does not change The reference current remains until commanded othe...

Page 1517: ...s OFF there are no limits to this control The solenoid remains OFF until commanded ON and vice versa When the output control is exited the solenoid state is determined by the TCM This output control i...

Page 1518: ...downshift if the vehicle speed exceeds a calibrated limit If a 4 3 downshift is requested and the vehicle speed is too high the message Vehicle speed too high appears on the scan tool display The TCM...

Page 1519: ...atio 7 97 1 Ignition Voltage F0 F2 F3 Volts 12 6 14 0 Last 1 2 Shift Status F2 Good Flare Tie Up Short Long Inconclusive Inconclusive Good Last 2 1 Shift Status F2 Good Flare Tie Up Short Long Inconcl...

Page 1520: ...s F0 F1 F3 OK Open Short to Volts Short to GND OK TCC PC Sol Duty Cycle F0 F1 F2 F3 percent 14 TCC PC Sol Ref Current F0 F1 F3 amps 0 20 TCC Slip Speed F0 F1 F2 RPM 0 20 TR Sw F0 F2 F3 Park Reverse Ne...

Page 1521: ...1 2 gearshift The scan tool displays Good Long Short Tie Up Flare or Inconclusive Inconclusive is displayed if the conditions for determining the last shift status were not met Last 2 1 Shift Status T...

Page 1522: ...tes low shift pressure Shift Sol 1 CKT Status This parameter displays whether an open short to voltage or ground exists in the shift solenoid valve 1 feedback signal circuit The scan tool displays OK...

Page 1523: ...on oil life remaining The scan tool displays remaining oil life in percentage The transmission oil life calculation is based on transmission fluid temperature and engine run time Trans Protection Mode...

Page 1524: ...also illuminates the MIL during the second consecutive trip in which the conditions for setting the DTC are met Type C This DTC is non emissions related The TCM stores the DTC in History and Failure R...

Page 1525: ...7 P0970 or P0971 DTC P0962 A DTC P0963 A DTC P0966 A DTC P0967 A DTC P0970 A DTC P0971 A DTC P0973 P0974 P0976 P0977 P0979 P0980 P0982 P0983 P0985 or P0986 DTC P0973 A DTC P0974 A DTC P0976 A DTC P097...

Page 1526: ...s invalid DTC P0727 The TCM detects that the engine speed signal from the ECM is invalid DTC P0826 The TCM detects that the Tap Up Down mode request or switch status signal from the ECM is invalid DTC...

Page 1527: ...trol Module References for TCM replacement setup and programming DTC P0562 or P0563 Diagnostic Instructions Perform the Diagnostic System Check Vehicle Diagnostic Information prior to using this diagn...

Page 1528: ...istance If the circuit tests normal and the B circuit fuse is open replace the TCM If all circuits test normal replace the TCM Repair Instructions Perform the Diagnostic Repair Verification Vehicle Di...

Page 1529: ...view of each diagnostic category DTC Descriptor DTC P0706 Transmission Range TR Switch Performance DTC P0707 Transmission Range TR Switch Circuit Low Voltage DTC P0708 Transmission Range TR Switch Cir...

Page 1530: ...the TCM refer to Transmission Control Module Removal and Transmission Control Module Installation procedure Repair Instructions Perform the Diagnostic Repair Verification Vehicle Diagnostic Informatio...

Page 1531: ...sable DTC P1719 The TCM will default the transmission oil temperature to 30 C for 15 minutes then to 111 C The TCM inhibits self learning and all adaptive control for 15 minutes Conditions for Clearin...

Page 1532: ...low signal circuit terminal 13 If not within the specified range replace the AT wiring harness refer to Wiring Harness Removal procedure and Wiring Harness Installation procedure Repair Instructions...

Page 1533: ...or C3 at the TCM 2 Ignition ON Test for 9 12 volts between the high signal circuit TCM terminal C3 3 ISS or C3 2 OSS and low signal circuit TCM terminal C3 4 ISS or C3 1 OSS If not within the specifie...

Page 1534: ...cedure Reference Information Schematic Reference Automatic Transmission Controls Schematics Connector End View Reference Automatic Transmission Inline Harness Connector End View Automatic Transmission...

Page 1535: ...e conditions should not be found Stuck shift pressure relay valve Stuck M1 shift valve Line pressure control solenoid valve assembly stuck closed If any of the above conditions are found replace the v...

Page 1536: ...nitions Diagnostic Trouble Code DTC List Type Scan Tool Reference Scan Tool Output Controls Automatic Transaxle AF33 5 Scan Tool Data List Automatic Transaxle AF33 5 Scan Tool Data Definitions Automat...

Page 1537: ...normal replace the transmission Repair Instructions Perform the Diagnostic Repair Verification Vehicle Diagnostic Information after completing the diagnostic procedure DTC P0732 Diagnostic Instructio...

Page 1538: ...malfunctioning replace the Transmission Output Speed Sensor OSS refer to the Output Speed Sensor Replacement procedure 2 Stop the vehicle apply the parking brake engine at idle select P park using th...

Page 1539: ...mission control module TCM calculates the actual gear ratio based on input speed sensor ISS and output speed sensor OSS data The actual gear ratio is compared to the expected gear ratio for each comma...

Page 1540: ...replace the control valve body assembly Refer to Control Valve Body Replacement procedure If the 3rd gear ratio is not within the specified range and is not 1 45 1 or 2 94 1 continue to step 3 3 Obser...

Page 1541: ...the actual gear ratio based on input speed sensor ISS and output speed sensor OSS data The actual gear ratio is compared to the expected gear ratio for each commanded gear If the TCM detects an incor...

Page 1542: ...erly functioning OSS If the OSS is malfunctioning replace the Transmission Output Speed Sensor OSS refer to the Output Speed Sensor Replacement procedure 4 Stop the vehicle apply the parking brake eng...

Page 1543: ...SS Control Circuit DTCs P0973 P0974 P0976 P0977 P0979 P0980 P0982 P0983 P0985 or P0986 No Transmission Torque Delivered Circuit DTC P2637 No Communications DTCs U0100 or U2104 Output speed greater tha...

Page 1544: ...d should click when commanded ON If the solenoid does not click replace the 1st shift solenoid valve assembly Refer to Control Valve Body Assembly Disassemble 7 Command shift solenoid 3 ON and OFF wit...

Page 1545: ...ransmission fluid temperature TFT is greater than 20 C 68 F Engine speed is greater than 400 RPM Ignition voltage is greater than 10 5 volts Conditions for Setting the DTC The following condition is m...

Page 1546: ...solenoid valve assembly If any of the above conditions are found replace the valve body assembly Refer to Control Valve Body Replacement procedure 9 Verify that the control valve body has been servic...

Page 1547: ...Operate the vehicle in D drive Using a scan tool observe the TCC Slip Speed parameter in 3rd 4th and 5th gear while the TCC PC Sol Ref Current parameter is more than 1000 mA The TCC Slip Speed parame...

Page 1548: ...noid valve The solenoid directs the hydraulic fluid for TCC apply and release When the TCC is released the engine is coupled by fluid to the transmission Conditions for Running the DTC No Throttle Pos...

Page 1549: ...rter Assembly Removal Forward and Direct Clutch Assembly Assemble and Fluid Pump Cleaning and Inspection procedures If all conditions test normal test or replace the transmission 6 Verify that the con...

Page 1550: ...s 4 Operate the vehicle under the conditions observed in the Failure Records 5 Observe the DTC information with the scan tool Verify that the DTC does not set Circuit System Testing 1 Using a scan too...

Page 1551: ...rter Inhibit circuit while the TCM is commanding the Starter Inhibit circuit OFF for 0 5 seconds DTC P081B The ECM detects OFF signal from the Starter Inhibit Circuit while the TCM is commanding the S...

Page 1552: ...High Voltage Diagnostic Fault Information Circuit System Description The transmission range TR switch is an integral part of the transmission control module TCM As the gear range selector lever is mov...

Page 1553: ...Switch parameter displayed Park Neutral In Gear If not equal to the specified range test the Starter Inhibit Circuit for a short to ground an open high resistance or a short to voltage If the circuit...

Page 1554: ...procedure Review Strategy Based Diagnosis for an overview of the diagnostic approach Diagnostic Procedure Instructions Vehicle Diagnostic Information provides an overview of each diagnostic category...

Page 1555: ...ols Automatic Transaxle AF33 5 Scan Tool Data List Automatic Transaxle AF33 5 Scan Tool Data Definitions Automatic Transaxle AF33 5 Circuit System Verification 1 Ignition ON observe the DTC informatio...

Page 1556: ...ditions for Running the DTC The engine is running The transmission is not in Emergency Mode Conditions for Setting the DTC The TCM detects that the shift solenoid actual state doesn t match the comman...

Page 1557: ...cified range replace the solenoid Repair Instructions Perform the Diagnostic Repair Verification Vehicle Diagnostic Information after completing the diagnostic procedure DTC P1719 Diagnostic Instructi...

Page 1558: ...to Control Valve Body Cover Removal procedure 3 Inspect the inside of the control valve body cover for excessive sediment There should not be excessive sediment If excessive sediment is found inspect...

Page 1559: ...ansmission Inline Harness Connector End View Automatic Transmission Internal Connector End Views Automatic Transmission Related Connector End Views Electrical Information Reference Circuit Testing Con...

Page 1560: ...Automatic Transmission Internal Connector End Views Automatic Transmission Related Connector End Views Electrical Information Reference Circuit Testing Connector Repairs Testing for Intermittent Cond...

Page 1561: ...tic transmission shift lock control circuit is shorted to ground the automatic transmission shift lock control solenoid will be inoperative The vehicle will shift out of PARK without pressing the brak...

Page 1562: ...Refer to Circuit Testing and Wiring Repairs Did you find and correct the condition Go to Step 13 Go to Step 9 8 Inspect for poor connections at the harness connector of the automatic transmission shi...

Page 1563: ...e Automatic Transmission Controls Schematics Connector End View Reference Automatic Transmission Inline Harness Connector End View Automatic Transmission Internal Connector End Views Automatic Transmi...

Page 1564: ...plays incorrect range Refer to Stall Speed Test Refer to Engagement Delay Test Refer to No Forward and Reverse Refer to Slips in Drive or No Drive Refer to Slips in Reverse or No Reverse Refer to Engi...

Page 1565: ...ission adaptive learn and transmission neutral learn procedure after any of the following service procedures Transmission Control Module TCM replacement TCM calibration change Control valve body repla...

Page 1566: ...fluid is the correct temperature 27 Reset the transaxle adaptive learns using a scan tool Go to the Transmission Special Functions then Trans Output Controls menu and select Reset Transmission Adapts...

Page 1567: ...e of the automatic transmission assembly The pressure control solenoid valve is controlled through a combination of computer controlled switches and sensors Torque Converter Stator The torque converte...

Page 1568: ...e TCC is not likely to slip after the TCC has been applied Engine problems may go unnoticed under light throttle and load but they become noticeable after the TCC apply when going up a hill or acceler...

Page 1569: ...est Purpose Description Of Test A stall test is preformed to inspect the overall performance of the automatic transmission and engine assembly by measuring the stall speed in both the DRIVE and REVERS...

Page 1570: ...acement TCM replacement TCM calibration change Transaxle replacement The adapt learn procedure requires repeat shifting the transaxle from Neutral to Drive to Neutral 5 times Then repeat shifting from...

Page 1571: ...lowing conditions Pitting Flaking Delamination splitting or separation of bonded clutch material Wear Glazing Cracking Charring Chips or metal particles embedded in the lining Replace a composition pl...

Page 1572: ...r has been properly repaired or replaced Fluid Leak Diagnosis CAUTION The transmission fluid level must be checked before fluid leak diagnosis is performed to prevent damage to the transmission Check...

Page 1573: ...f the component Improper sealant used where applicable Incorrect gasket Seals Fluid level pressure is too high Plugged vent or drain back holes Damaged seal bore Damaged or worn seal Improper installa...

Page 1574: ...Case Automatic Transmission Case Cover Assembly or Torque Converter Housing Assembly Porosity 6 Torque Converter Assembly 17 Automatic Transmission Case Cover Assembly to Automatic Transmission Case...

Page 1575: ...owing published procedures for transmission oil cooler flushing and flow checking This procedure includes flow checking and flushing the auxiliary transmission oil cooler if equipped NOTE Use the J 45...

Page 1576: ...Damage to the unit may result To verify the fluid level view the LCD screen display while filling the unit to ensure the fluid level does not exceed 30 L 32 qt 5 Fill the supply tank with Dexron VI th...

Page 1577: ...pair as needed and refer to the appropriate service manual procedures Minimum Flow Rate in Gallons Per Minute GPM Back Flush Procedure 1 Install both of the J 45096 30 onto the oil cooler lines 2 Conn...

Page 1578: ...he supply vessel pressure to dissipate Forward Flush 1 Disconnect the J 45096 at the hose couplings at the adapters and switch the hoses The black hose 2 to the oil cooler supply hose and the clear ho...

Page 1579: ...an the MINIMUM flow rate previously recorded repeat the back flush and forward flush procedures 3 If the TESTED flow rate is less than the MINIMUM flow rate after the second test perform Code Recordin...

Page 1580: ...NITION Transmission overheats Low fluid level Inspect for leaks and repair as necessary Incorrect fluid Replace the fluid with the correct fluid Fluid Filter 42 is restricted Diagnose the cause for th...

Page 1581: ...o the front cover which in turn peels off the internal friction material from the torque converter apply plate Replace the torque converter assembly 1 and install the correct torque converter to flexp...

Page 1582: ...id valve assembly inspect the O ring seal and bore for signs of damage and or missing seal If the valve responded electrically and there are no bore or seal concerns replace the line pressure control...

Page 1583: ...o electrical concerns remove the solenoid valve assembly as needed and inspect the solenoids O ring seals and bores for signs of damage and or missing seals If the valves responded electrically and th...

Page 1584: ...verse clutch assembly 19 and the forward and direct clutch assembly 23 to inspect all forward clutch components and operation Repair or replace as needed Condition Action DEFINITION Engagement time fr...

Page 1585: ...cally and there are no bore or seal concerns replace assembly as required due to a possible internal mechanical concern and retest If after replacing the valve assembly in question a concern is still...

Page 1586: ...embly in question a concern is still present replace the complete control valve body assembly 39 Internal Control Valve Body Assembly 39 M2 Shift Valve 426 Neutral Relay Valve 356 Shift Pressure Relay...

Page 1587: ...necessary Checks Actions DEFINITION No second gear to third gear upshift External Automatic Transmission Control Valve Body Assembly 39 2 3 3 4 Shift Solenoid Valve Assembly S2 308 1 2 2 3 Reverse Sh...

Page 1588: ...der to inspect the 3rd gear brake band assembly 16 Inspect all related components for proper operation Repair or replace as necessary Checks Actions DEFINITION No fourth gear to fifth gear upshift Ext...

Page 1589: ...ch Sprag Assembly 11 Inspect all related components for proper operation Repair or replace as necessary Checks Actions DEFINITION No fourth gear to third gear downshift External Automatic Transmission...

Page 1590: ...cessary Checks Actions DEFINITION No second gear to first gear downshift External Automatic Transmission Control Valve Body Assembly 39 Reverse 1st Shift Solenoid Valve Assembly S1 310 2 3 3 4 Shift S...

Page 1591: ...signs of wear and or damage including internal contamination If unable to verify a repairable concern replace the complete valve body assembly Checks Actions DEFINITION No engine braking in fourth ge...

Page 1592: ...ly 19 and the 1 2 reverse carrier gear assembly 18 in order to inspect the 3rd gear brake band assembly 16 Inspect all related components for proper operation Repair or replace as necessary Checks Act...

Page 1593: ...or damage Drivetrain grounded out to or on the vehicle chassis Inspect the compete drive train for signs of physical contact Correct as necessary Drive Axles Inspect both drive axles for proper insta...

Page 1594: ...lled damaged or restricted Vent hose 814 not secure not installed restricted or damaged Vent pipe 812 not secure not installed restricted or damaged Vent hose clips 813 not installed Inspect and corre...

Page 1595: ...control valve body cover 29 sealing surface If the sealing surface is not repairable replace the control valve body cover 29 Transmission case assembly 17 sealing surface damaged Inspect the transmis...

Page 1596: ...trical connection and or signs of physical damage that could cause erratic output The magnetic end of the sensor should be free of any metal shavings particles including heavy friction material build...

Page 1597: ...necessary Automatic Transmission Fluid Temperature Sensor 36 part of the Automatic Transmission Wiring Harness Assembly 33 Using a scan tool verify that the transmission fluid temperature is correct...

Page 1598: ...ld cause erratic output The magnetic end of the sensor should be free of any metal shavings particles including heavy friction material build up If metal or heavy friction material is found diagnose t...

Page 1599: ...amination If unable to determine if the transmission has the correct type of fluid drain the unit and refill with the correct ATF and retest Calibration Using a scan tool verify that the current calib...

Page 1600: ...Shift Pressure Control Valve 430 2nd Coast Clutch B1 Control Valve 359 2nd Clutch B2 Control Valve 446 3rd Gear B4 Control Valve 423 Remove the automatic transmission control valve body assembly 39 an...

Page 1601: ...39 Verify that all solenoids respond electrically If there is no response perform an electrical diagnosis If there are no electrical concerns remove the solenoid valve assemblies as needed and inspect...

Page 1602: ...Go to Step 7 5 Test the control circuit of the automatic transmission shift lock control solenoid for a short to battery positive voltage Refer to Circuit Testing and Wiring Repairs Did you find and...

Page 1603: ...ch command Go to Step 8 Go to Step 5 5 Does the test lamp remain illuminated Go to Step 6 Go to Step 7 6 Test the control circuit of the automatic transmission shift lock control solenoid for a short...

Page 1604: ...xle 6 Remove the transaxle fluid level indicator 2 7 Wipe away any transaxle fluid from the indicator 8 Insert the indicator into the transaxle until fully seated NOTE Inspecting transaxle fluid level...

Page 1605: ...g and Flow Test Milky or white tint in color from coolant or water Inspect for failure of the transaxle oil cooler Refer to Engine Coolant Water in Transmission Inspect for missing or improperly route...

Page 1606: ...ener Notice in Cautions and Notices 18 Remove the tools and install the automatic transmission fluid pressure test hole plug 66 and a new O ring 67 Tightening torque Tighten the test hole plug to 7 N...

Page 1607: ...I automatic transmission fluid is not compatible with this transaxle If Dexron III ATF is used transaxle failure will result Refer to Sealers Adhesives and Lubricants 5 Add approximately 3 1 L 3 3 Qt...

Page 1608: ...in order to access the shift control knob screw 2 Shift Control Knob Screw CAUTION Refer to Fastener Notice in Cautions and Notices Tightening torque Tighten the screw to 1 5 N m 13 lb in Tip Loosen...

Page 1609: ...o Transmission Control Lever Knob Replacement 2 Remove the shift control lever boot Refer to Transmission Control Boot Replacement 1 Instrument Panel Lower Brace Bezel Refer to Instrument Panel Lower...

Page 1610: ...out Component Name 1 Shift Control Knob Tip Remove the shift control lever knob Refer to Transmission Control Lever Knob Replacement 2 Shift Control Lever Boot Tip Depress the retainer tabs on both si...

Page 1611: ...Control Lever Knob Replacement 3 Remove the shift control boot Refer to Transmission Control Boot Replacement 4 Remove the instrument panel lower brace bezel Refer to Instrument Panel Lower Brace Beze...

Page 1612: ...reliminary Procedures 1 Remove the console side trim panel Refer to Front Floor Console Side Trim Panel Replacement Right Side 2 Disconnect the brake transaxle shift interlock BTSI solenoid harness co...

Page 1613: ...tallation procedure in this section Shift Control Cable Replacement Special tool J 36346 Fascia Retainer Remover Removal Procedure 1 Set the parking brake 2 Disable the supplemental inflatable restrai...

Page 1614: ...ift control cable is routed exactly as originally positioned in the vehicle to avoid coming into contact with potential hazards such as hot sharp and moving objects 1 Secure the shift control cable gr...

Page 1615: ...latable restraint SIR system Refer to SIR Disabling and Enabling 12 Release the parking brake Shift Control Cable Adjustment 1 Position the shift lever in PARK 2 Release the shift control cable adjust...

Page 1616: ...r is in the PARK or NEUTRAL position Shift Control Cable Bracket Replacement Special tool J 36346 Fascia Retainer Remover Removal Procedure 1 Remove the battery tray Refer to Battery Tray Replacement...

Page 1617: ...the transaxle range switch lever 4 5 Install the battery tray Refer to Battery Tray Replacement Automatic Transmission Range Selector Lever Replacement Special tool J 36346 Fascia Retainer Remover Rem...

Page 1618: ...switch lever 4 4 Install the battery tray Refer to Battery Tray Replacement Transmission Control Module Replacement Removal Procedure 1 Remove the battery tray Refer to Battery Tray Replacement NOTE...

Page 1619: ...more than 60 degrees 6 Install the TCM 4 over the manual shaft CAUTION Refer to Fastener Notice 7 Install the bolts 3 Tightening torque Tighten the bolts to 25 N m 18 lb ft 8 Connect the electrical co...

Page 1620: ...software matching the vehicle Refer to up to date Techline equipment user instructions If the TCM fails to program proceed as follows Ensure the TCM connection is good Inspect the Techline equipment...

Page 1621: ...th heat check cracks The rubber is separated from the outer metal sleeve of the mount The rubber is split through the center of the transmission mount The mount is leaking fluid 4 When replacing the t...

Page 1622: ...olt to 100 N m 74 lb ft 2 Tighten the front bolt to 100 N m 74 lb ft 5 Lower the vehicle Transmission Rear Mount Replacement Getrag 760 Transfer Case Removal Procedure 1 Raise and support the vehicle...

Page 1623: ...81 lb ft 4 Lower the stabilizer shaft and connect the stabilizer links Tightening torque Tighten the stabilizer link nuts to 65 N m 48 lb ft 5 Lower the vehicle Transmission Mount Replacement Left Si...

Page 1624: ...ent Left Side 2 Remove the rear transaxle mount Refer to Transmission Rear Mount Replacement Getrag 760 Transfer Case 3 Remove the transaxle mount bracket bolts 2 4 5 4 Remove the transaxle mount brac...

Page 1625: ...t CAUTION Refer to Fastener Notice in Cautions and Notices 3 Install the transaxle mount bracket bolt 1 Tightening torque Tighten the bolts to 37 N m 27 lb ft 4 Install the rear transaxle mount Refer...

Page 1626: ...engine splash shield Refer to Engine Splash Shield Replacement Left Side 5 Remove the transaxle stand 6 Lower the vehicle Fluid Level Indicator Replacement Removal Procedure 1 Clean any dirt or debri...

Page 1627: ...t speed sensor 5 Remove the input speed sensor O ring Discard the O ring Installation Procedure 1 Apply GM T IV automatic transaxle fluid GM P N 88900925 to the new input speed sensor O ring 2 Install...

Page 1628: ...ation Procedure 1 Apply GM T IV automatic transaxle fluid GM P N 88900925 to the new output speed sensor O ring 2 Install the new output speed sensor O ring onto the output speed sensor 2 3 Install th...

Page 1629: ...er lines and seals from the transaxle Refer to Fluid Cooler Pipe Seal Replacement 6 Remove the 9 TORX bolts 2 from the control valve body cover 1 NOTE Do not pry with a tool on the transaxle control v...

Page 1630: ...ield Replacement Left Side and Engine Splash Shield Replacement Right Side 9 Install the left front wheel and the tire assembly Refer to Tire and Wheel Removal and Installation 10 Lower the vehicle 11...

Page 1631: ...Procedure 1 Apply GM T IV automatic transaxle fluid GM P N 88900925 to a NEW transaxle wiring connector O ring seal 46 2 Install the NEW automatic transmission wiring connector seal 46 in the bore for...

Page 1632: ...ensor bolt 31 Tightening torque Tighten the bolt to 10 N m 89 lb in 12 Connect the 8 solenoid wire connectors as follows 1 blue 2 black 3 green 4 black 5 blue 6 gray 7 brown 8 black 13 Install the con...

Page 1633: ...al shift detent lever assembly 710 from the manual valve link 336 5 Move the detent lever assembly clockwise for ease of removing the manual valve 6 Remove the control valve body assembly 39 7 Remove...

Page 1634: ...Tightening torque Tighten the bolts to 10 N m 89 lb in 5 Install a new control valve body fluid passage cover gasket 38 6 Install the control valve body fluid passage cover 37 7 Install the 2 control...

Page 1635: ...Disconnect the upper transaxle oil cooler line from the radiator 4 Raise the vehicle Refer to Lifting and Jacking the Vehicle 5 Disconnect the lower transaxle oil cooler line 6 Disengage the transaxl...

Page 1636: ...900925 8 Add fluid to the transaxle Refer to the Transmission Fluid Check 9 Start the engine a check for leaks Fluid Cooler Pipe Seal Replacement Special tool J 41239 1A Cooler Line Seal Installer J 4...

Page 1637: ...f the J 45201 into the collet 2 7 Tighten the forcing screw 1 until snug 8 Thread the collar piece 1 of the J 45201 onto the collet 3 until snug 9 Turn the collar clockwise in order to remove the cool...

Page 1638: ...used transaxle failure will result This transaxle uses GM T IV fluid P N 88900925 8 Add fluid to the transaxle Refer to Transmission Fluid Check procedure located in this service manual 9 Start the en...

Page 1639: ...the Vehicle 2 Place a drain pan under the transaxle to catch any spilled transaxle fluid 3 Remove the right front wheel drive shaft Refer to Front Wheel Drive Shaft Replacement AWD Front Wheel Drive...

Page 1640: ...cer bolt clockwise to gain access to the torque converter to flywheel bolts through the starter motor hole NOTE Mark the relation of the flywheel to torque converter for reassembly 15 Remove the torqu...

Page 1641: ...ft Refer to Intermediate Shaft Replacement 5 Install the right and left drive shafts Refer to Front Wheel Drive Shaft Replacement AWD Front Wheel Drive Shaft Replacement FWD 6 Turn the crankshaft bala...

Page 1642: ...the shift control cable bracket Refer to Shift Control Cable Bracket Replacement 21 Install the battery tray Refer to Battery Tray Replacement 22 Fill the transaxle with fluid Refer to Transaxle Fluid...

Page 1643: ...ghten the DT 48355 to 25 N m 18 lb ft starting with bolt 3 6 Install the DT 48355 in the J 3289 20 Transmission Fluid Draining Reference Holding Fixture Installation 1 Place a suitable fluid collectio...

Page 1644: ...Remove the speed sensor bolts 61 4 Remove the output speed sensor 62 and the input speed sensor 73 5 Remove the speed sensors O rings 63 6 Inspect the speed sensors for damage Transmission Control Mod...

Page 1645: ...sor clamp 49 4 Remove the fluid temperature sensor 36 and the O ring 32 from the control valve body assembly 5 Remove the A T control wiring harness connector retainer 69 NOTE Do not break the wiring...

Page 1646: ...t 38 3 Remove the six 10 mm control valve body mounting bolts screws 1 6 4 While holding the control valve body assembly disconnect the manual shift detent lever assembly 710 from the manual valve lin...

Page 1647: ...cond Coast Clutch Disassemble Second Coast Second Clutch Hub and Second Clutch Sprag Assembly Removal Reference Fluid Pump Assembly Removal Remove the 2nd coast clutch hub outer race and 2nd coast clu...

Page 1648: ...rter Housing Removal 1 Remove the front differential assembly 13 2 Remove the case fluid passage gasket 89 Reference Front Differential Assembly Cleaning and Inspection Fluid Filter Removal Reference...

Page 1649: ...tainer bolts screws 50 2 Remove the third gear band apply tube retainer 51 NOTE Do not bend or damage the apply tube or the O ring Do not damage the transmission case sealing surface 3 Using J 28585 r...

Page 1650: ...ission case assembly 3 Remove the park pawl actuator rod 709 from the transmission case assembly 4 Remove the manual shift detent lever spring bolt screw 712 and the park pawl actuator bracket bolt sc...

Page 1651: ...7 Remove the park pawl spring 701 8 Remove the park pawl actuator bracket 708 and park pawl 702 9 Remove the park pawl spring pin 703 10 Remove the park pawl bolt screw 706 11 Remove the park pawl pin...

Page 1652: ...assembly Do not let the front differential transfer drive gear assembly or the 4 5 clutch assembly fall to the floor or damage may occur 3 Using J 45053 remove the front differential transfer drive g...

Page 1653: ...Drum Assembly Disassemble Third Gear Band Assembly Removal Reference 4 5 Clutch Assembly Removal Special tool DT 47599 Anchor Bolt Socket 1 Loosen the holding fixture bolt 2 and remove holding fixtur...

Page 1654: ...594 6 Remove the 1 2 reverse internal gear shim 596 7 Remove the 1 2 reverse internal gear rear thrust bearing assembly 595 from the 1 2 reverse internal gear 594 Third Gear Band Servo Piston Assembl...

Page 1655: ...rd Gear Band Servo Piston Assembly Removal 1 Remove the 12 transmission case cover bolts screws NOTE Do not damage the transmission case cover 2 Remove the transmission case cover and 1 2 reverse clut...

Page 1656: ...NOTE Do not bend or damage the lube fluid pipe 3 Remove the lube fluid pipe 85 with J 28585 4 Remove the forward and direct clutch assembly 23 Reference Forward and Direct Clutch Assembly Disassemble...

Page 1657: ...9 Remove the rear internal gear flange retaining ring 548 from the rear internal gear 536 10 Remove the rear internal gear flange 547 from the rear internal gear 11 Remove the other rear internal gea...

Page 1658: ...bushing inner diameter A Measure in three locations and take the average Specification Front carrier bushing 30 056 30 132 mm 1 183 1 186 in 24 If the front carrier bushing is not within specificatio...

Page 1659: ...Reverse Clutch Assembly Removal Reference Rear Internal Gear and Front Carrier Removal Special tool J 28585 Snap Ring Remover 1 Remove the front internal gear thrust bearing 529 2 Remove the low and...

Page 1660: ...smission case assembly 2 Remove the low and reverse clutch spring assembly 513 WARNING Wear safety glasses when using compressed air in order to prevent eye injury 3 While rotating the low and reverse...

Page 1661: ...ions are found Reference Front Differential Bearing Race and Selective Shim Removal Reference Manual Shift Shaft Seal and Bearing Removal Reference Front Wheel Drive Shaft Oil Seal Removal Reference F...

Page 1662: ...y other transmission components Lint from the towels can cause component failure 1 Thoroughly clean the transmission case and all the case threads with solvent 2 Inspect the case exterior and the exte...

Page 1663: ...assembly so that the torque converter housing side is facing up 2 Install the front differential assembly 13 into the empty transmission case 3 Install the torque converter housing assembly 10 to the...

Page 1664: ...he transmission case Reference Output Gear Assembly Installation Reference Transmission Case Inspection Front Differential Bearing Race and Selective Shim Removal Reference Output Gear Assembly Remova...

Page 1665: ...red If the obtained rotational torque measurement was greater than the listed specification then a smaller thinner shim will be required Reference Front Differential Bearing Race and Selective Shim In...

Page 1666: ...e transmission case assembly bore to remove the bearing Reference Manual Shift Shaft Seal and Bearing Installation Manual Shift Shaft Seal and Bearing Installation Reference Manual Shift Shaft Seal an...

Page 1667: ...bly making sure that the seal is flush with the case flange Reference Output Gear Assembly Installation Front Differential Carrier Seal Removal Reference Output Gear Assembly Removal Special tool J 45...

Page 1668: ...t b Place the J 45186 1 on the 4 5 clutch piston return spring assembly 580 c Place the J 21420 2 4 from the J 23327 on top of the forcing screw of J 25024 A 3 d Place the clutch housing with the J 45...

Page 1669: ...sh the clutch components in clean solvent and air dry 2 Inspect the clutch drum for the following conditions Lugs in the drum for excessive grooves that prevent the clutch plates from sliding Sun gear...

Page 1670: ...al tool J 23327 Clutch Spring Compressor J 25024 A Servo Piston Clutch Spring Compressor J 28585 Snap Ring Remover J 45186 Forward and Direct Clutch Spring Compressor NOTE Soak the new clutch discs in...

Page 1671: ...25024 A 3 e With the forcing screw compress the clutch spring to allow the installation of the retaining ring f Use J 28585 2 or snap ring pliers to install the retaining ring 579 NOTE Make sure that...

Page 1672: ...ent Refer to Transmission Clearance Specifications 4 5 Clutch Piston Stroke to determine the correct backing plate 7 If the measurement is out of specifications replace the backing plate with the corr...

Page 1673: ...the transmission case 5 By hand press the low and reverse clutch piston 511 into the transmission case until seated Do not damage the seals 6 Install the low and reverse clutch spring assembly 513 ont...

Page 1674: ...ear and Overrun Clutch Disassemble 1 Clean the front internal gear and overrun roller clutch assembly in solvent and air dry 2 Inspect the front internal gear for the following Clutch teeth for notche...

Page 1675: ...ovement of the overrun roller clutch The inner race should turn freely counterclockwise 1 and should lock clockwise 2 Reference Front Internal Gear and Low and Reverse Clutch Installation Front Intern...

Page 1676: ...Low and Reverse Clutch Piston Travel Measurement Special tool J 45200 Dial Indicator Set J 45166 8 inch Dial Indicator Extension Rod 1 Install the J 45166 1 in one of the holes of the transmission cas...

Page 1677: ...y 529 black side up 2 Install the front carrier assembly 542 3 Install the front sun gear thrust bearing race 543 4 Install the rear internal gear thrust bearing 535 5 Install the rear internal gear 5...

Page 1678: ...ng assembly with input shaft 567 2 Remove the forward clutch housing thrust bearing 569 and the forward clutch housing thrust bearing race 568 from the forward and direct clutch housing assembly with...

Page 1679: ...557 The direct clutch apply plate 558 7 Remove the direct clutch spring retaining ring 559 a Place the J 25024 A 1 in a vise with the forcing screw on the bottom and backed out b Place the J 45186 2 o...

Page 1680: ...piston 562 11 Remove the direct clutch piston inner seal 561 and the direct clutch piston outer seal 563 from the direct clutch piston 562 WARNING Wear safety glasses when using compressed air in ord...

Page 1681: ...nicks or scratches 5 Inspect the clutch plate lugs in the forward clutch piston for grooves 6 Replace the piston if faulty 7 Clean the forward and direct clutch housing assembly and air dry Ensure to...

Page 1682: ...ge the direct clutch piston seals 18 Press by hand the direct clutch piston 562 into the forward clutch piston 19 Install the direct clutch spring assembly 560 onto the direct clutch piston indexing t...

Page 1683: ...g plate retaining ring 554 is not aligned with any of the cut outs 24 Install the direct clutch backing plate retaining ring 554 into the groove in the forward and direct clutch housing assembly with...

Page 1684: ...and J 45166 2 onto the transmission case cover 19 4 Install dial indicator extension OTC 222545 or equivalent 4 on the dial indicator plunger 5 Place the dial indicator plunger on the piston as shown...

Page 1685: ...d to the passage C2 WARNING When you use compressed air in order to clear fluid passages and to dry parts always aim the air pressure away from face and eyes Always wear adequate eye protection in ord...

Page 1686: ...ube fluid pipe 4 Using a plastic hammer install the lube fluid pipe 85 5 Install the lube fluid pipe retainer 84 CAUTION Refer to Fastener Notice in Cautions and Notices 6 Install the lube fluid pipe...

Page 1687: ...direct clutch housing thrust bearing race 628 from the transmission case cover 4 Remove the 3 forward clutch housing fluid seal rings 607 from the transmission case cover 5 Remove the 2 forward clutch...

Page 1688: ...ter of J 23456 2 4 Place the transmission case cover 19 with the 1 2 reverse clutch piston assembly onto J 45184 1 5 Using J 23327 1 3 which is the bridge part of J 23327 compress the 1 2 reverse clut...

Page 1689: ...ves that will prevent the plates for sliding 7 Replace the transmission case cover if any of the above conditions are found Reference 1 2 Reverse Clutch Assemble 1 2 Reverse Clutch Assemble Reference...

Page 1690: ...l the 1 2 reverse clutch piston return spring retaining ring 600 using snap ring pliers 10 Remove the pressure from J 23456 2 11 Remove all tools NOTE Check the position and direction of the 1 2 rever...

Page 1691: ...616 6 Install the forward clutch accumulator cover assembly onto the transmission case cover CAUTION Refer to Fastener Notice in Cautions and Notices 7 Install and tighten 1 of the 2 forward clutch ac...

Page 1692: ...orn or burnt If the plates are worn or burnt replace them 2 Install the J 45166 1 into the forward clutch accumulator bolt hole that was not installed on the prior step Assemble J 45200 2 onto J 45166...

Page 1693: ...23 input shaft until the assembly first bottoms out 5 Record the measurement 6 Compare the measurement with the listed specification Specification Forward and direct clutch assembly end play 0 188 0 5...

Page 1694: ...m 1 8 in bead of sealant GM P N 89020326 Canadian P N 89021188 to the transmission case cover 3 Install the transmission case cover assembly 19 onto the transmission case assembly 17 4 Apply threadloc...

Page 1695: ...hird gear band servo piston assembly 3 Measure the free length and the outer diameter of the outer and inner third gear band servo piston springs Refer to 3rd Gear Band Servo B4 Return Springs in Tran...

Page 1696: ...the transmission case 3 Apply automatic transmission fluid to the 2 new third gear band servo cover O ring seals 58 4 Install the third gear band servo cover O ring seals 58 onto the third gear band s...

Page 1697: ...mbly 593 with the flange up 6 Install a 1 2 reverse carrier thrust washer 590 to the lower side of the 1 2 reverse carrier gear assembly 591 7 Install the 1 2 reverse carrier gear assembly 591 into th...

Page 1698: ...e 4 5 clutch assembly 15 into the transmission case assembly making sure not to disengage the third gear band assembly 16 from its holding points When properly installed the 4 5 clutch assembly 15 sho...

Page 1699: ...stall onto the front differential transfer drive gear assembly 14 4 Install the front differential transfer drive gear thrust bearing assembly 263 onto the front differential transfer drive gear thrus...

Page 1700: ...t the height by changing the thrust washer Reference Manual Shift Detent Lever and Park Pawl Installation Manual Shift Detent Lever and Park Pawl Installation 1 Install the park pawl pin spring 704 2...

Page 1701: ...e manual shift detent spring assembly 711 9 Install and hand tighten the 14 mm manual shift detent lever spring bolt 712 and the 16 7 mm park pawl actuator bracket bolt 715 Tightening torque Tighten t...

Page 1702: ...ference Third Gear Band Apply Tube Installation Third Gear Band Apply Tube Installation 1 Install the 2 third gear band apply tube O ring seals 53 2 Install the third gear band apply tube 52 3 If need...

Page 1703: ...nsmission fluid baffle 44 4 Install the 3 M6 x 1 0 x 14 mm transmission fluid baffle bolts 45 Tightening torque Tighten the transmission fluid baffle bolts to 5 N m 44 lb in Reference Fluid Filter Ins...

Page 1704: ...wear or damage 6 If any of the above conditions are found replace the front differential assembly The front differential assembly is serviced only as a complete assembly Reference Front Differential...

Page 1705: ...e the lube fluid pipe 804 7 Using a plastic hammer install the lube fluid pipe 804 8 Place the 4 chip collector magnets 808 onto the transmission fluid baffle 803 CAUTION Refer to Fastener Notice in C...

Page 1706: ...e seal 89 into the transmission case assembly 3 Apply a 3 mm 1 8 in bead of sealant GM P N 89020326 Canadian P N 89021188 on the inside of the bolt holes of the scaling flange of the torque converter...

Page 1707: ...h Spring Compressor J 45164 Spring Compressor Bridge 1 Using J 45164 2 J 21420 2 4 and J 23327 2 1 which are part of J 23327 compress the second clutch spring 2 Using J 28585 3 remove the second coast...

Page 1708: ...the inner seal 221 and the outer seal 223 from the second coast clutch piston 222 Reference Second Clutch Disassemble Second Clutch Disassemble Reference Second Coast Clutch Disassemble Special tool...

Page 1709: ...Reference Transmission Fluid Pump Disassemble Transmission Fluid Pump Disassemble Reference Second Clutch Disassemble Special tool J 45000 Seal Remover 1 Remove 13 transmission fluid pump cover bolts...

Page 1710: ...scent shaped part of the fluid pump body 202 Specification Driven gear tip to body clearance 0 004 0 298 mm 0 0001 0 618 in 7 Using a steel straight edge and a feeler gage measure the side clearance o...

Page 1711: ...8 188 mm 1 500 1 503 in 3 Using the J 45185 measure the inner diameter of the stator shaft bushing Measure the bushing in different locations and take the average 4 Use micrometer to measure J 45185 r...

Page 1712: ...plate 207 7 Align the fluid pump plate 207 holes with the alignment pins 203 in the fluid pump body 202 8 Align the fluid pump stator shaft assembly 208 with each bolt hole of the fluid pump plate 20...

Page 1713: ...rn or burnt If the clutch plates are worn or burnt replace them 2 Apply automatic transmission fluid to the new second clutch piston and second clutch piston sleeve seals 3 Install the new second clut...

Page 1714: ...ble Reference Second Clutch Piston Travel Measurement Special tool J 28585 Snap Ring Remover J 23327 Clutch Spring Compressor J 41236 Coast Clutch Spring Compressor J 45164 Spring Compressor Bridge 1...

Page 1715: ...been installed 9 Install the second coast clutch backing plate 229 10 Using J 45164 2 J 21420 2 4 and J 23327 2 1 which are part of J 23327 compress the second clutch spring 11 Using J 28585 3 install...

Page 1716: ...Rod 8 inch J 45200 Dial Indicator Set WARNING Wear safety glasses when using compressed air in order to prevent eye injury 1 Using the same special tool setup used to measure the second clutch piston...

Page 1717: ...sembly 505 4 Remove the second clutch sprag end bearing 502 5 Remove the second clutch sprag assembly 503 6 Remove the second clutch end bearing 502 Reference Second Coast Second Clutch Hub and Second...

Page 1718: ...and locks counterclockwise 1 If the hub does not turn clockwise turn the sprag race assembly over 9 Install the second clutch sprag outer race thrust washer 506 aligning the tabs with the hollow of th...

Page 1719: ...x again the clutch hub and plates until within specifications 7 Rotate the transmission assembly as shown 8 Install the J 45053 on the fluid pump assembly Do not allow the second clutch sprag assembly...

Page 1720: ...fluid pump to case bolts to 25 N m 18 lb ft Reference Control Valve Body Assembly Installation Control Valve Body Assembly Disassemble Reference Control Valve Body Assembly Removal NOTE The control va...

Page 1721: ...l solenoid valve assembly 340 6 Remove the 5 solenoid retaining bolts 1 301 2 302 2 307 7 Remove the 5 shift solenoid valves 300 303 305 308 310 and the 5 shift solenoid valve O ring seals 306 8 Remov...

Page 1722: ...d strainers 371 1 fluid strainer 372 2 accumulator check valve assemblies 353 11 Remove the bolt 304 from the middle control valve body 12 Turn the middle control valve body over in order to remove th...

Page 1723: ...e Control Valve Front Body Disassemble Middle Control Valve Body Disassemble Reference Control Valve Body Assembly Disassemble WARNING Valve springs can be tightly compressed Use care when removing re...

Page 1724: ...shift valve bore plug 391 17 Remove the M1 shift valve spring 390 18 Remove the M1 shift valve 389 19 Remove the sleeve bore plug retainer 362 20 Remove the U2 shift valve bore plug 394 21 Remove the...

Page 1725: ...e shift ball check valve bushing inner 373 Reference Middle Control Valve Body Assemble Middle Control Valve Body Assemble Reference Middle Control Valve Body Disassemble 1 Inspect the middle control...

Page 1726: ...ease valve spring 384 13 Install the 3rd gear band B4 release valve 385 14 Install the U2 shift valve bore plug 394 15 Install the sleeve bore plug retainer 362 16 Install the U1 shift valve 386 17 In...

Page 1727: ...e sleeve bore plug retainer 362 33 Install the 5 accumulator check valve assemblies 353 34 Install the cooler by pass valve spring 380 35 Install the cooler by pass valve 381 36 Install the TCC check...

Page 1728: ...ove the line pressure control SLT accumulator piston spring inner 435 8 Remove the line pressure control SLT accumulator piston spring outer 434 9 Remove the line pressure control SLT accumulator pist...

Page 1729: ...and B4 control valve 423 20 Remove the third gear band B4 control valve spring 422 21 Remove the 2 rear valve body cover plate bolts 416 22 Remove the rear valve body cover plate 417 23 Remove the rea...

Page 1730: ...410 casting for the following conditions Porosity Cracks Damaged machine surface Chips or debris Damage to valve bores 2 Inspect all valves springs bushings and clean all components in clean solvent...

Page 1731: ...5 x 0 8 x 13 mm rear valve body cover plate bolts 416 Tightening torque Tighten the cover plate bolts to 7 N m 62 lb in 11 Install the third gear band B4 control valve spring 422 12 Install the third...

Page 1732: ...lator piston 433 23 Install the line pressure control SLT accumulator piston spring outer 434 24 Install the line pressure control SLT accumulator piston spring inner 435 25 Install the secondary regu...

Page 1733: ...valve 450 5 Remove the TCC check valve spring 449 6 Remove the 2 accumulator check valve assemblies 353 7 Remove the sleeve bore plug retainer 459 8 Remove the reverse shift restrict ball check valve...

Page 1734: ...ing for the following conditions Porosity Cracks Damaged machine surface Chips or debris Damage to valve bores 2 Inspect all valves springs bushings and clean all components in clean solvent 3 Install...

Page 1735: ...valve 450 Reference Control Valve Body Assembly Assemble Control Valve Front Body Disassemble Reference Control Valve Body Assembly Disassemble WARNING Valve springs can be tightly compressed Use car...

Page 1736: ...valve spring 357 16 Remove the neutral relay valve 356 17 Remove the sleeve bore plug retainer 349 18 Remove the solenoid modulator valve bore plug 348 19 Remove the second coast clutch B1 control val...

Page 1737: ...id modulator valve 346 4 Install the solenoid modulator valve spring 347 5 Install the solenoid modulator valve bore plug 348 6 Install the sleeve bore plug retainer 349 7 Install the second coast clu...

Page 1738: ...Valve Body Assembly Assemble Control Valve Body Assembly Assemble Reference Middle Control Valve Body Assemble Reference Control Valve Rear Body Assemble Reference No 2 Rear Control Valve Body Assembl...

Page 1739: ...l valve body assembly bolts 333 335 NOTE Align each bolt hole on the valve body with the holes in the gaskets and plates 6 Install the spacer plate 328 and the 2 new gaskets 327 329 onto the No 2 rear...

Page 1740: ...trol valve body assembly 9 Install 4 M5 x 0 8 x 49 5 mm control valve body bolts 332 into the No 2 rear control valve body assembly 10 Hand tighten the 5 control valve body assembly bolts 331 332 11 T...

Page 1741: ...ch bolt hole in the valve body with the holes in the gaskets and spacer plate 18 Install the front control valve body assembly 315 onto the middle control valve body assembly 323 19 Install 1 M5 x 0 8...

Page 1742: ...e line pressure control solenoid valve assembly 316 and the shift pressure control solenoid valve assembly 340 28 Install the control valve body solenoid valve retainer 312 and 1 M5 x 0 8 x 13 mm cont...

Page 1743: ...olding the control valve body assembly 39 connect the manual valve link 336 to the manual shift detent lever assembly 710 5 Install the 6 control valve body assembly to transmission case bolts and han...

Page 1744: ...harness assembly 33 into the transmission case assembly through the wiring harness bore 4 Align the tab of the connector in the transmission case 5 Install the wiring harness connector retainer 69 6 A...

Page 1745: ...ly a 3 mm 1 8 in bead of sealant GM P N 89020326 Canadian P N 89021188 to the cover mounting surface 3 Install the control valve body cover 29 onto the transmission case assembly 4 Apply threadlocker...

Page 1746: ...er and more resistance can be felt 3 Inspect the condition of the connector pins on the wiring harness assembly 33 for foreign material bent pins or broken pins 4 Ensure the TCM seal 72 is installed 5...

Page 1747: ...lb in 4 Connect the input and output speed sensor harness assembly 71 to the speed sensors and the TCM Reference Drain Plug Installation Drain Plug Installation 1 Install a new gasket 820 on the drain...

Page 1748: ...fixture to the transaxle 4 Remove the DT 48355 from the transaxle 5 Install the transmission vent pipe 812 6 Install the vent hose 814 Reference Torque Converter Assembly Installation Torque Converter...

Page 1749: ...Accumulator Cover 616 to Case Cover 606 617 2 M6x1 0x14 5 mm 10 N m 89 lb in Lube Fluid Pipe Retainer 805 to Torque Converter Housing 801 806 1 M6x1 0x14 mm 5 N m 44 lb in Lube Fluid Pipe Retainer 84...

Page 1750: ...M6x1 0x16 mm 10 N m 89 lb in Control Valve Body 39 to Transmission Case Assembly 17 35 2 M6x1 0x50 mm 10 N m 89 lb in Control Valve Body 39 to Transmission Case Assembly 17 47 3 M6x1 0x55 mm 7 N m 62...

Page 1751: ...to Control Valve Body 39 302 1 M5x0 8x28 mm 7 N m 62 lb in Temperature Temperature Minimum Resistance Nominal Resistance Maximum Resistance C F 40 C 40 F 59500 77480 100000 30 C 22 F 39688 44000 4840...

Page 1752: ...ers 8 2 quarts Remove drain plug and fill GM P N 88900925 Canadian P N 22689186 4 06 liters 4 29 quarts Identification Specifications Metric English 70 1 00 mm 0 039 in 71 1 05 mm 0 041 in 72 1 10 mm...

Page 1753: ...4 0 877 in Rear Sun Gear Bushing ID 22 200 22 276 mm 0 874 0 877 in 2nd Coast Clutch and 2nd Clutch Hub and 2nd Clutch Sprag Assembly 11 to Fluid Pump Installed Height 51 09 51 71 mm 2 011 2 036 in Fo...

Page 1754: ...utch 603 Piston Bore Stroke 2 34 2 70 mm 0 092 0 106 in Relaxed Clutch Pack Stack Up Clearance 0 84 1 63 mm 0 033 0 064 in Available 1 2 Reverse Clutch Backing Plate 621 Thickness 5 0 mm 0 197 in 5 1...

Page 1755: ...Internal Gear Thrust Bearing 89 00 mm 3 504 in 73 50 mm 2 894 in F 535 Rear Internal Gear Thrust Bearing 64 00 mm 2 520 in 46 40 mm 1 827 in F 543 Front Carrier Thrust Bearing Race Front 61 00 mm 2 40...

Page 1756: ...OFF ON 1 2 2 3 Rev Shift Solenoid Valve S3 OFF ON OFF ON ON ON OFF OFF OFF ON ON ON ON ON 3 4 4 5 Shift Solenoid Valve S4 OFF OFF OFF OFF OFF ON ON ON OFF OFF OFF ON OFF OFF Reverse Shift Solenoid Val...

Page 1757: ...OFF OFF ON OFF 1 000 The reverse 1st 2 3 3 4 and 3 4 4 5 shift solenoid valves are normally open The 1 2 2 3 reverse and reverse shift solenoid valves are normally closed The reverse shift solenoid va...

Page 1758: ...10 5 0 7 0 6 6 7 8 Greater than 20 M Shift Pressure Control Solenoid Valve SLS 2 9 5 0 7 0 6 6 7 8 Greater than 20 M Reverse 1st Shift Solenoid Valve S1 14 11 16 15 22 Greater than 20 M 2 3 3 4 Shift...

Page 1759: ...lant 89020326 89021188 Bolts Threadlocker 12345382 10953489 Transmission Fluid Automatic Transmission Fluid Type T IV 88900925 22689186 Illustration Tool Number Description DT 47599 Anchor Bolt Socket...

Page 1760: ...essor J 23456 Booster and Clutch Pack Compressor J 25024 A Servo Piston Clutch Spring Compressor Illustration Tool Number Description J 28585 Snap Ring Remover J 35582 Oil Pump Seal Installer J 35616...

Page 1761: ...Installer J 44809 Output Shaft Seal Installer J 45000 Seal Remover Illustration Tool Number Description J 45053 Universal Clamp Press J 45096 Transmission Oil Cooling System Flush and Flow Test Tool J...

Page 1762: ...ridge J 45166 Dial Indicator Extension Rod 8 inch J 45184 Differential Bearing Race Installer J 45185 Bore Gage Set Illustration Tool Number Description J 45186 Forward and Direct Clutch Spring Compre...

Page 1763: ...el and Column Tilt 6B 19 Power Assisted Steering System 6C 1 General Description 6C 1 Power Steering System Description and Operation 6C 1 Diagnostic Information and Procedures 6C 1 Diagnostic Startin...

Page 1764: ...n lock cylinder control actuator s purpose is to prevent the ignition key from being turned to the OFF position when the transmission is in gear and the vehicle may still be moving The column ignition...

Page 1765: ...Column Upper Bolt 12 Steering Column Lower LH Trim Cover 4 Ignition Start Switch Housing 13 Multifunction Turn Signal Switch Housing 5 Ignition Lock Cylinder 14 Multifunction Turn Signal Switch 6 Wip...

Page 1766: ...Step 2 Go to Power Steering System Description and Operation 2 Verify that noise is present in the steering column during operation Is noise present in the steering column during operation Go to Step...

Page 1767: ...te Steering Shaft Replacement Did you complete the repair Go to Step 9 9 Operate the system in order to verify the repair Did you correct the condition System OK Go to Step 3 Step Action Yes No 1 Did...

Page 1768: ...der damaged Go to Step 8 Go to Step 5 5 Inspect the lock cylinder case assembly for damage Is the lock cylinder case assembly damaged Go to Step 9 Go to Step 6 6 Inspect the ignition switch assembly f...

Page 1769: ...Reference Information Schematic Reference Ignition Lock Schematics Connector End View Reference Master Electrical Component List Electrical Information Reference Circuit Testing Connector Repairs Test...

Page 1770: ...lster Reinforcement Replacement 7 Remove the intermediate steering shaft bolt 1 and nut 2 NOTE Place scribe marks on the intermediate steering shaft to the steering column connection prior to removal...

Page 1771: ...ft Side Steering Column Accident Damage Inspection Collapse Measurement A vehicle involved in an accident resulting in sheet metal damage or driver side air bag deployment will require an inspection f...

Page 1772: ...m cover 2 Steering Column Lower Trim Cover Screw Qty 2 CAUTION Refer to Fastener Notice Torque 2 5 N m 22 lb in 3 Steering Column Lower Trim Cover Tip Use gentle pressure to disengage the steering col...

Page 1773: ...ule coil Refer to Inflatable Restraint Steering Wheel Module Coil Replacement 2 Remove the turn signal multifunction switch Refer to Turn Signal Multifunction Switch Replacement 3 Remove the wipers wa...

Page 1774: ...onent Name Preliminary Procedures Remove the steering column trim covers Refer to Steering Column Trim Covers Replacement 1 Turn Signal Multifunction Switch Procedure 1 Disconnect any electrical conne...

Page 1775: ...efer to Fastener Notice Tightening torque 37 N m 27 lb ft 2 Steering Wheel Procedure 1 Disconnect any electrical connectors as needed 2 Remove the steering wheel using puller J 1859 A and puller legs...

Page 1776: ...il 1 Lock the steering wheel in the centered position with the wheels straight forward 2 Remove the inflatable restraint steering wheel module coil Refer to Inflatable Restraint Steering Wheel Module...

Page 1777: ...stall the steering column upper support bracket bolts 1 Tightening torque Tighten the bolts to 25 N m 18 lb ft 3 Install the steering column lower support bracket bolt 1 Tightening torque Tighten the...

Page 1778: ...ing column Refer to Steering Column Replacement 1 Metal Collar Rake Pivot 2 Plastic Bushings Qty 2 Tip During installation use NEW bushings 3 Anti Rotation Bracket Bolts Qty 2 CAUTION Refer to Fastene...

Page 1779: ...Notice Procedure 1 Use a small chisel and hammer to back out the ignition lock cylinder case bolt counterclockwise and remove it 2 When installing a new ignition lock cylinder case bolt continue to t...

Page 1780: ...1 The lock cylinder will back out slightly again 7 Pull the lock cylinder out enough to locate the second retainer to the lock housing access hole 2 8 Depress the retainer though the access hole 2 a s...

Page 1781: ...ement Callout Component Name Preliminary Procedure Remove the ignition lock cylinder case Refer to Ignition Lock Cylinder Case Replacement 1 Ignition Start Switch Bolt Qty 2 CAUTION Refer to Fastener...

Page 1782: ...Bolt 2 N m 18 lb in Application Specification Metric English Anti Rotation Bracket Bolt 5 N m 44 lb in Intermediate Steering Shaft Bolt 34 N m 25 lb ft Intermediate Steering Shaft Lower Bolt 34 N m 2...

Page 1783: ...her side of the piston The pressure assists the movement of the gear piston Tie rods transfer this force to the front wheels which turn the vehicle right or left Diagnostic Information and Procedures...

Page 1784: ...ep tests the following components for the following conditions The pump for internal leaks The power steering pipes for kinks 8 This step tests the ability of the pump to regulate flow at maximum pres...

Page 1785: ...ystem OK 4 1 Turn the ignition switch to the OFF position 2 Place a drain pan under the vehicle in order to catch any power steering fluid 3 Disconnect the power steering pressure pipe hose from the p...

Page 1786: ...stem pressure specifications Is the actual flow reading within specifications Go to Step 11 Go to Step 13 11 Is the difference between the actual flow reading and the maximum flow specification more t...

Page 1787: ...Go to Step 8 Go to Step 5 5 Inspect the power steering pump and the reservoir for leaks Is the power steering pump or reservoir leaking Go to Step 9 Go to Step 6 6 Inspect the power steering pump res...

Page 1788: ...you find looseness in the tie rod ends Go to Step 16 Go to Step 9 9 Inspect the suspension Is the suspension worn Go to Step 17 Go to Step 10 10 Inspect the intermediate shaft Is the intermediate shaf...

Page 1789: ...ering hoses Go to Step 10 Go to Step 2 8 Replace the power steering gear Refer to Steering Gear Replacement Did you complete the repair Go to Step 11 9 Replace the power steering pump Refer to Power S...

Page 1790: ...lt to move replace the tie rod end If equipped with recirculating ball steering ensure that idler and pitman arm joints are not to stiff Repair as necessary Did you find and complete the repair Go to...

Page 1791: ...ring System Test Did you complete the procedure Go to Step 4 4 Operate the system in order to verify the repair Did you correct the condition System OK Go to Step 3 Step Action Yes No 1 Did you review...

Page 1792: ...ne Rotate steering wheel from left to right Check for sign of cavitation or fluid aeration pump noise whining 7 Verify the fluid level Repeat the bleed procedure if necessary Checking and Adding Power...

Page 1793: ...connection and install the fluid return hose to the pump reservoir NOTE Do NOT run the engine without the power steering fluid at a minimum system level 8 Bleed the power steering system Refer to Powe...

Page 1794: ...steering fluid reservoir as possible 2 Place drain pans under the vehicle as needed 2 Power Steering Fluid Reservoir Outlet Hose 3 Power Steering Cooler Pipe Clamp 4 Power Steering Cooler Pipe 5 Remo...

Page 1795: ...Name Preliminary Procedure Remove the power steering pump Refer to Power Steering Pump Replacement 1 Power Steering Pump Pulley Procedure 1 Using the J 25034 C remove the power steering pump pulley 2...

Page 1796: ...Refer to Engine Splash Shield Replacement Right Side 3 Place drain pans under the vehicle as needed 4 Compress the power steering reservoir outlet hose clamp 1 and disconnect the power steering reser...

Page 1797: ...t hose 1 to the power steering pump Tightening torque Tighten to 25 N m 18 lb ft 4 Compress the power steering reservoir outlet hose clamp 1 and connect the power steering reservoir outlet hose 2 to t...

Page 1798: ...llation 1 Rack And Pinion Outer Tie Rod End Nut CAUTION Refer to Fastener Notice Torque 25 N m 18 lb ft plus 90 degrees 2 Steering Linkage Inner Tie Rod Nut Procedure Loosen but do not remove the stee...

Page 1799: ...ve the power steering cooler pipe from the vehicle 3 Rack And Pinion Outer Tie Rod End Procedure 1 Use the J 24319 B to separate the rack and pinion outer tie rod end from the steering knuckle 2 Inspe...

Page 1800: ...assemblies Refer to Tire and Wheel Removal and Installation 8 Install the air cleaner outlet duct Refer to Air Cleaner Outlet Duct Replacement 9 Install the fuel injector sight shield Refer to Fuel In...

Page 1801: ...nnect the power steering reservoir outlet hose 2 to the power steering pump 3 Compress the power steering reservoir outlet hose clamp 1 and connect the power steering reservoir outlet hose 2 to the re...

Page 1802: ...Fluid Reservoir Outlet Hose Clamp 2 Power Steering Fluid Reservoir Outlet Hose 3 Power Steering Pump Inlet Pipe Bolt CAUTION Refer to Fastener Notice Tightening torque Tighten to 8 N m 71 lb in 4 Pow...

Page 1803: ...nlet hose fitting 1 from the steering gear 6 Remove the power steering gear inlet hose from the vehicle Installation Procedure 1 Position the steering gear inlet hose to the vehicle CAUTION Refer to F...

Page 1804: ...es Refer to Rack and Pinion Outer Tie Rod End Replacement 2 Remove the intermediate steering shaft lower bolt Refer to Intermediate Steering Shaft Replacement 3 Place drain pans under the vehicle as n...

Page 1805: ...left wheel house area CAUTION Refer to Fastener Notice 2 Install the power steering gear bolts 1 Tightening torque Tighten to 110 N m 81 lb ft 3 Install the power steering gear hoses bracket bolt 1 Ti...

Page 1806: ...ing knuckles Refer to Rack and Pinion Outer Tie Rod End Replacement 10 Fill and bleed the power steering system Refer to Power Steering System Bleeding 11 Adjust the front toe Refer to Front Toe Adjus...

Page 1807: ...on Procedure 1 Apply approximately 3 4 of the supplied grease packet into the small end of the steering gear boot cavity Apply the remainder of the grease on the shaft where the small end of the boot...

Page 1808: ...r boot clamp 6 Install the power steering gear Refer to Steering Gear Replacement 7 Install the rack and pinion outer tie rods Refer to Rack and Pinion Outer Tie Rod End Replacement 8 Fill and bleed t...

Page 1809: ...rocedure 1 Position the NEW retaining washer 1 2 Attach the steering linkage inner tie rod onto the rack CAUTION Refer to Pipe Wrench Positioning Notice 3 Place a pipe wrench on the rack next to the s...

Page 1810: ...ons Application Specification Metric English Ground Terminal Nut 9 N m 80 lb Power Steering Cooler Pipe Fitting 25 N m 18 lb ft Power Steering Gear Bolt 110 N m 81 lb ft Power Steering Gear Hoses Brac...

Page 1811: ...s Power Steering System Illustration Tool Number Description J 22610 Keystone Clamp Pliers J 24319 B Steering Linkage and Tie Rod Puller J 25033 C Pulley Installer J 25034 C Pulley Remover J 39570 Cha...

Page 1812: ...6C 30 Power Assisted Steering System...

Page 1813: ...lfunction 7A 64 Sun Load Sensor Malfunction 7A 65 Afterblow Enabling 7A 66 Actuator Recalibration 7A 66 Leak Testing 7A 67 Air Conditioning A C System Performance Test w C69 7A 68 Air Conditioning A C...

Page 1814: ...7A 147 Auxiliary Air Distributor Lower Duct Replacement 7A 148 Auxiliary Air Distributor Duct Replacement Upper 7A 149 Auxiliary Heater Core Replacement 7A 150 Auxiliary Air Conditioning Evaporator Th...

Page 1815: ...e achieved by pressing the plus or minus temperature buttons to increase or decrease cabin temperature The temp display on the rear hvac head will display the temp setting increasing or decreasing The...

Page 1816: ...or is an interface between the HVAC control module and the blower motor The blower motor speed control battery positive voltage and ground circuits enable the control processor to operate The HVAC con...

Page 1817: ...The air temperature controls are divided into 4 areas HVAC control components Heating and A C operation Engine coolant A C cycle HVAC CONTROL COMPONENTS HVAC Control Module The HVAC control module is...

Page 1818: ...erature sensor A signal and low reference circuit enables the sensor to operate As the air temperature surrounding the sensor increases the sensor resistance decreases The sensor signal voltage decrea...

Page 1819: ...Protection The refrigerant temperature at the temperature sensor on the evaporator case controls cycling of the compressor clutch to prevent freezing of the evaporator core The compressor is disabled...

Page 1820: ...ve will pop open and release refrigerant from the system Compressed refrigerant enters the condenser in a high temperature high pressure vapor state As the refrigerant flows through the condenser the...

Page 1821: ...Heating Ventilation and Air Conditioning 7A 7 Module Power Ground Serial Data and Front Blower Controls...

Page 1822: ...7A 8 Heating Ventilation and Air Conditioning Air Temperature Sensors Ambient Light Sensor...

Page 1823: ...Heating Ventilation and Air Conditioning 7A 9 Mode Recirculation and Temperature Actuators...

Page 1824: ...7A 10 Heating Ventilation and Air Conditioning Rear HVAC Controls and Actuators...

Page 1825: ...Heating Ventilation and Air Conditioning 7A 11 A C Compressor Controls...

Page 1826: ...K 150 Ground Connector Part Information OEM 12110192 Service 88988301 Description 3 Way F Metri Pack 150 Series BK Terminal Part Information Terminal Tray 12103881 2 Core Insulation Crimp E C Release...

Page 1827: ...61 Low Reference Connector Part Information OEM 15226103 Service 88988507 Description 2 Way F L GY Terminal Part Information Terminal Tray 7116 4122 02 10 Core Insulation Crimp A B Release Tool Test P...

Page 1828: ...88 Rear Blower Motor Low Reference Connector Part Information OEM 13520671 Service Description 6 Way F GT 150 6 3 Series BK Terminal Part Information Terminal Tray See Terminal Repair Kit Core Insulat...

Page 1829: ...r Circuit No Function 1 OG 5988 Rear Blower Motor Low Reference 2 PU 65 Blower Motor Supply Voltage Connector Part Information OEM 15126709 Service Description 20 Way F Receptacle 0 64 Unsealed BN Ter...

Page 1830: ...e 13 16 Not Used Connector Part Information OEM 15126710 Service Description 20 Way F Receptacle 0 64 Unsealed GY Terminal Part Information Terminal Tray 7116 4618 02 14 Core Insulation Crimp P P Rele...

Page 1831: ...Supply Voltage 5 GY BK 1798 Low Reference GY 720 Low Reference 6 9 Not Used 10 GY BK 754 Blower Motor Speed Control 11 OG 2215 Auxiliary Mode Door Control 12 GY 2614 Auxiliary Air Temperature Door Co...

Page 1832: ...633 Description 5 Way F Micro Pack 100 Series BK Terminal Part Information Terminal Tray See Terminal Repair Kit Core Insulation Crimp See Terminal Repair Kit Release Tool Test Probe See Terminal Repa...

Page 1833: ...vice 12102633 Description 5 Way F Micro Pack 100 Series BK Terminal Part Information Terminal Tray See Terminal Repair Kit Core Insulation Crimp See Terminal Repair Kit Release Tool Test Probe See Ter...

Page 1834: ...7A 20 Heating Ventilation and Air Conditioning Component Location HVAC Component Views Bottom Front of the Engine 1 Generator 3 A C Refrigerant Pressure Sensor 2 Starter 4 A C Compressor Clutch...

Page 1835: ...7A 21 Front HVAC Module 1 Recirculation Actuator 5 Blower Motor Control Processor Front 2 Mode Actuator 6 Temperature Actuator 3 Air Temperature Sensor Upper 7 Air Temperature Sensor Lower 4 HVAC Blow...

Page 1836: ...action Control Switch TCS 4 Radio 14 Rear Wiper Washer Fog Lamp Switch 5 HVAC Control Module 15 Inflatable Restraint Passenger Airbag ON OFF Indicator 6 Cigar Lighter 16 Inside Air Temperature Sensor...

Page 1837: ...Heating Ventilation and Air Conditioning 7A 23 Rear HVAC Module C69 1 Mode Actuator Rear 4 HVAC Blower Motor Rear 2 HVAC Control Rear 5 Temperature Actuator Rear 3 Upper Auxiliary HVAC Duct...

Page 1838: ...AC control module commands the blower motor relay ON and an increase or decrease of air When you select OFF the HVAC control module commands the blower motor relay OFF Left Temp Door Position Output C...

Page 1839: ...puts Inactive Active Varies Auxiliary Temp Door Motor Command Door Positions 0 255 Counts Varies Battery Voltage A C Permission Normal Out of Range Normal Blower Speed A C Permission Normal Off Varies...

Page 1840: ...high side pressure sensor voltage signal converted to pressure ECM A C High Side Pressure Switch The scan tool displays the High Pressure Normal status of the high side pressure switch ECM A C Off fo...

Page 1841: ...The HVAC Control Module converts the voltage value to a temperature value of Celsius and Farenhiet that will be displayed by the driver information center DIC Conditions for Running the DTC The igniti...

Page 1842: ...y Based Diagnosis Diagnostic Procedure Instructions Vehicle Diagnostic Information DTC Descriptors DTC B0228 02 Recirculate Position Feedback Circuit Short to Ground DTC B0228 04 Recirculate Position...

Page 1843: ...B0423 61 Passenger Air Temperature Door Control B Circuit B0423 61 B0423 61 Passenger Air Temperature Door Position Signal B0423 61 B0228 61 B0423 02 B0423 04 B0423 61 Passenger Air Temperature 5 Volt...

Page 1844: ...r B circuits are deactivated for the appropriate actuator Conditions for Clearing the DTC The DTC becomes history when the HVAC control module no longer detects the condition that set the DTC The hist...

Page 1845: ...o voltage or an open high resistance If the circuit tests normal replace the HVAC control module 6 Connect a test lamp between the control circuits terminal 4 and 5 of the applicable actuator 7 Comman...

Page 1846: ...gerant will starve causing insufficient cooling An evaporator flooded with refrigerant will also cause poor cooling when there is too much liquid refrigerant that cannot vaporize quickly Conditions fo...

Page 1847: ...module replacement setup and programming DTC P0532 or P0533 Diagnostic Instructions Perform the Diagnostic System Check Vehicle Diagnostic Information prior to using this diagnostic procedure Strategy...

Page 1848: ...1 0 ohm test the low reference circuit for an open high resistance If the circuit tests normal replace the ECM 3 Ignition ON test for 4 8 5 2 volts between the 5 volt reference circuit terminal and g...

Page 1849: ...is less than 600 RPM The ECM driver transitions from ON to OFF or from OFF to ON Conditions for Setting the DTCs The ECM detects an open on the control circuit of the A C compressor clutch relay when...

Page 1850: ...uld turn ON and OFF when changing between the commanded states If the test lamp is always ON test the control circuit for a short to ground If the circuit tests normal replace the ECM If the test lamp...

Page 1851: ...em Noise Diagnosis Blower Motor Odor Diagnosis Odor Diagnosis Step Action Yes No DEFINITION Odor originating or noticed through the HVAC system 1 Were you sent here from Symptoms or another diagnostic...

Page 1852: ...n is less than 100 percent Evaporator temperature is greater than 0 C 32 F ECM does not detect excessive torque load ECM does not detect insufficient idle quality Reference Information Schematic Refer...

Page 1853: ...s not illuminate test the relay switch B circuit for an open high resistance If the A C fuse is open test the relay switch control circuit for a short to ground If all circuits test normal test or rep...

Page 1854: ...onstant until a new speed is selected As the requested blower speed increases the following conditions occur The HVAC control module increases the amount of time that the blower motor speed control ci...

Page 1855: ...HVAC control module If the test lamp is always OFF test the speed control circuit for a short to voltage or an open high resistance If the circuit tests normal replace the HVAC control module 6 Ignit...

Page 1856: ...l This feedback circuit displays in percent on the TECH 2 the commanded output blower speed that the auxiliary blower motor control module is sending to the auxiliary blower motor Auxiliary Blower Mot...

Page 1857: ...from min to max If less than 12 Mv test the control circuit for a short to ground or an open high resistance If the circuit tests normal replace the rear auxiliary HVAC module If greater than 27 Mv te...

Page 1858: ...t for less than 1 0 ohm of resistance between the duct temp sensor ground circuit terminal 2 and ground If greater than the specified range test the ground circuit for an open high resistance 3 Igniti...

Page 1859: ...vehicle for cold air leaks The cowl The recirculation door The HVAC module case 2 Perform the necessary repairs Are the repairs complete Go to Step 10 6 1 Inspect the temperature door operation Refer...

Page 1860: ...function Is the repair complete Go to Step 14 7 Perform the A C system performance test Refer to Air Conditioning A C System Performance Test w C69 Air Conditioning A C System Performance Test w o C69...

Page 1861: ...by feeling the auxiliary blower case Is excess vibration present Go to Step 5 Go to Step 10 5 1 Remove the auxiliary blower motor Refer to Auxiliary Blower Motor Replacement 2 Inspect the auxiliary bl...

Page 1862: ...isten to the blower motor at each speed Is the blower motor making a squeaking or chirping noise Go to Step 9 Go to Step 11 6 1 Remove the blower motor Refer to Blower Motor Replacement 2 Inspect the...

Page 1863: ...tep 24 Go to Step 7 7 Is the A C compressor clutch slipping Go to Step 23 Go to Step 8 8 WARNING Refer to Moving Parts and Hot Surfaces Caution Using a stethoscope listen to the A C compressor for any...

Page 1864: ...te Go to Step 26 20 Repair or replace the A C compressor mounting component Is the repair complete Go to Step 26 21 Repair or replace the component which is causing the moaning concern as needed Is th...

Page 1865: ...rush whistle noise evident only in defrost or floor mode Go to Step 6 Go to Step 6 6 1 Remove the instrument panel accessory trim plate Refer to Instrument Panel Accessory Trim Plate Replacement 2 Re...

Page 1866: ...ditioning A C System Performance Test w C69 Air Conditioning A C System Performance Test w o C69 Inspect the air temperature door and the air temperature actuator for the following conditions A misali...

Page 1867: ...n control circuit terminal A terminal 4 and B If the test lamp illuminates test the control circuit for a short to ground If the circuit tests normal replace the HVAC control module 7 Ignition ON afte...

Page 1868: ...ests normal replace the hvac control module 3 Ignition ON test for 4 8 to 5 2 volts between the 5 volt reference circuit terminal 3 and ground If less than 4 8 volts test the 5 volt reference circuit...

Page 1869: ...control module operate and provide sufficient heating Go to Step 3 Go to Too Cold in Vehicle 3 1 Install a scan tool 2 Turn ON the ignition with the engine OFF 3 Observe the current DTC list in HVAC...

Page 1870: ...Go to Step 18 Go to Step 16 13 Inspect for poor connections at the harness connector of the upper duct temp sensor and lower duct temp sensor Refer to Testing for Intermittent Conditions and Poor Con...

Page 1871: ...control module operate and provide sufficient heating Go to Step 3 Go to Too Cold in Vehicle 3 1 Install a scan tool 2 Turn ON the ignition with the engine OFF 3 Observe the current DTC list in HVAC...

Page 1872: ...o to Step 18 Go to Step 16 13 Inspect for poor connections at the harness connector of the upper duct temp sensor and lower duct temp sensor Refer to Testing for Intermittent Conditions and Poor Conne...

Page 1873: ...the blower motor switch in each speed position Does the blower motor operate in any speed position Go to Step 4 Go to Blower Motor Malfunction 4 Does the blower motor operate in each speed position Go...

Page 1874: ...nnector 5 Place the mode switch in the Defrost position 6 Place the mode switch in the Panel position Does the test lamp illuminate in both positions Go to Step 17 Go to Step 14 14 Test the mode door...

Page 1875: ...No Schematic Reference HVAC Schematics Connector End View Reference HVAC Connector End Views DEFINITION Air does not flow correctly from the auxiliary air distribution outlets 1 Did you perform the D...

Page 1876: ...ct the auxiliary mode door and the auxiliary mode actuator for the following conditions A misaligned auxiliary mode actuator Refer to Auxiliary Mode Actuator Replacement Broken or binding linkages or...

Page 1877: ...on that prevents the recirculation actuator from operating within the full range of motion Missing seals to the recirculation door If the above procedure does not fix the problem test the HVAC control...

Page 1878: ...amp does not illuminate test the control circuit for a short to voltage or an open high resistance If the circuit tests normal test the B circuit of the HVAC control module for a short to ground high...

Page 1879: ...lacement Control Module References for HVAC control module replacement setup and programming Sun Load Sensor Malfunction Diagnostic Instructions Perform the Diagnostic System Check Vehicle Diagnostic...

Page 1880: ...p and programming Afterblow Enabling The afterblow mode can be enabled using the scan tool The afterblow mode allows the blower motor to operate after the engine has been turned off This operation of...

Page 1881: ...ye Box of 24 J 42220 Universal 12V Leak Detection Lamp J 43872 Fluorescent Dye Cleaner J 46297 A C Dye Injector Kit J 46297 12 Replacement Dye Cartridges Refrigerant Leak Testing NOTE This vehicle is...

Page 1882: ...ing items Windshield washing solutions Many solvents and cleaners Some adhesives used in the vehicle Clean and dry all surfaces in order to prevent a false warning Liquids will damage the detector NOT...

Page 1883: ...door window 12 7 15 2 cm 5 6 in 3 Select the following HVAC control settings The A C is ON The coldest temperature setting The maximum blower speed Recirculation mode The panel outlet mode All panel...

Page 1884: ...atures do not Go to Air Conditioning A C Diagnostics Pressure Zone A Go to Step 5 5 Is the low side pressure greater than the specified range but the high side pressure within or less than the specifi...

Page 1885: ...15 C 59 F 18 C 63 F 25 29 C 76 85 F Below 35 206 303 kPa 30 44 psi 1564 1812 kPa 227 263 psi 17 C 61 F 18 C 64 F 35 60 241 337 kPa 35 49 psi 1591 1915 kPa 231 278 psi 18 C 63 F 19 C 66 F Above 60 248...

Page 1886: ...30 C 86 F 47 49 C 116 120 F Below 30 399 502 kPa 58 73 psi 2439 2645 kPa 354 384 psi 29 C 84 F 32 C 88 F Step Action Values Yes No NOTE The ambient air temperature must be at least 16 C 60 F Do not i...

Page 1887: ...t areas Unusual noises NOTE Press the RESET button before using the print function of the J 43600 10 Print the following information The panel outlet air temperatures The low side pressure The high si...

Page 1888: ...o to Air Conditioning A C Diagnostics Pressure Zone B Go to Step 6 6 Are the low and high side pressures both greater than the specified ranges Go to Air Conditioning A C Diagnostics Pressure Zone C G...

Page 1889: ...41 274 psi 15 C 59 F 20 40 213 310 kPa 31 45 psi 1653 1908 kPa 240 277 psi 15 C 59 F Above 40 206 310 kPa 30 45 psi 1626 1853 kPa 236 269 psi 15 C 59 F 42 46 C 106 115 F Below 20 234 337 kPa 34 49 psi...

Page 1890: ...6 6 1 Refer to the pressures recorded during the A C system performance test 2 Inspect for the following conditions The low side pressure is slightly lower than the specified pressure ranges but stil...

Page 1891: ...efrigerant oil drained from the receiver 148 ml 5 oz Go to Step 12 Go to Step 13 12 1 Reinstall the receiver dehydrator Refer to Receiver Dehydrator Replacement 2 Recharge the A C system Refer to Refr...

Page 1892: ...tep 5 Go to Step 3 3 1 Refer to the pressures recorded during the A C System Performance Test 2 Inspect for the following conditions WARNING Refer to Moving Parts and Hot Surfaces Caution The low side...

Page 1893: ...ge the A C system Refer to Refrigerant Recovery and Recharging Is the action complete Go to Step 6 6 1 After you perform the repairs record the following The low and the high side pressures The instru...

Page 1894: ...fy the repair Did you find and correct the condition System OK Go to Symptoms HVAC Systems Automatic Step Action Yes No DEFINITION The low and the high side pressures are both higher than normal Restr...

Page 1895: ...er to Refrigerant Recovery and Recharging Is the action complete Go to Step 9 9 1 Record the low and high side pressures and the instrument panel outlet air temperature after you have performed the re...

Page 1896: ...TXV location for extreme cold possibly accompanied by heavy frost 2 Feel along the liquid line beyond the TXV location for warm temperature Is the liquid line extremely cold at the TXV location and w...

Page 1897: ...lect in the shop towel Go to Step 18 Go to Step 19 13 If the TXV was restricted with a brown or black residue replace the receiver dehydrator Refer to Receiver Dehydrator Replacement Are the actions c...

Page 1898: ...ions a Select the maximum blower speed b Insert the deodorizer extension tube into the hole to the mark on the extension tube c Use short spray bursts and vary the direction of spray for a 2 3 minute...

Page 1899: ...zure may result CAUTION R 12 refrigerant and R 134a refrigerant must never be mixed even in the smallest of amounts as they are incompatible with each other If the refrigerants are mixed compressor fa...

Page 1900: ...ehydrator 3 Inspect the polyalkylene glycol PAG oil for the following conditions The color of the oil is dark brown or black There is a presence of foreign substances metal fillings etc in the oil If...

Page 1901: ...ery and Recharging 2 Remove cooling fan and shroud Refer to Cooling Fan and Shroud Replacement 3 Disconnect the high pressure switch electrical connector 1 Nuts Compressor Hose Assembly Qty 2 CAUTION...

Page 1902: ...and support radiator to aid in compressor removal 4 Remove A C hose assembly for compressor Refer to Compressor Hose Assembly Replacement 5 Remove drive belt Refer to Drive Belt Replacement 6 Raise a...

Page 1903: ...ssor from the vehicle Refer to Compressor Replacement 2 Use J 37872 to hold the compressor clutch 3 Remove the bolt retaining the compressor clutch to the compressor 4 Install GE 47849 to the compress...

Page 1904: ...ws from the compressor 11 Remove the clutch field coil from the compressor Installation Procedure 1 Clean the clutch field coil and the pulley mounting surfaces 2 Install the clutch field coil to the...

Page 1905: ...all the compressor pulley to the compressor NOTE Ensure that the compressor pulley snap ring is installed with the rounded edge face up 6 Install the snap ring to the compressor pulley 7 Install the c...

Page 1906: ...cle Refer to Compressor Replacement Compressor Pressure Relief Valve Replacement Special tool J 39400 A Halogen Leak Detector Removal Procedure 1 Recover the refrigerant Refer to Refrigerant Recovery...

Page 1907: ...he A C refrigerant components for damage or burrs Repair if necessary NOTE DO NOT reuse sealing washer 4 Discard the sealing washer Installation Procedure NOTE Flat washer type seals do not require lu...

Page 1908: ...ring seal Installation Procedure 1 Inspect the new O ring seal for any sign or cracks cuts or damage Replace if necessary 2 Remove the cap or tape from the A C refrigerant components 3 Using a lint f...

Page 1909: ...fer to Battery Replacement 5 Remove the battery box bolts from the battery box 6 Disconnect the negative battery cable nut from the wheelhouse 7 Remove the nut retaining the liquid line to the strut t...

Page 1910: ...Install protective caps to the condenser the evaporator outlet hose and the TXV to prevent contamination and desiccant saturation Installation Procedure 1 Route the liquid line below the battery box...

Page 1911: ...evaporator outlet hose Refer to Sealing Washer Replacement 11 Install the liquid line and the evaporator outlet hose to the TXV 12 Install the liquid line and evaporator outlet hose retainer plate nu...

Page 1912: ...iquid line retainer plate nut from the thermal expansion valve TXV 5 Remove the evaporator outlet hose and liquid line from the TXV 6 Remove evaporator outlet hose from the vehicle 7 Remove and discar...

Page 1913: ...Service Valve Core Replacement Special tool J 39400 A Halogen Leak Detector J 46246 Valve Core Removal Tool Removal Procedure 1 Recover the refrigerant Refer to Refrigerant Recovery and Recharging 2 U...

Page 1914: ...receiver dehydrator mounting clamp from the condenser 5 Remove the lower receiver dehydrator bolt from the condenser 6 Remove the receiver dehydrator from the condenser 7 Install protective caps to th...

Page 1915: ...erant Recovery and Recharging NOTE When removing the thermal expansion valve TXV keep dirt and foreign material from getting on or into the sealing surfaces Clean tools and a clean work area are impor...

Page 1916: ...or pipes Refer to Sealing Washer Replacement 3 Remove the protective caps from the TXV 4 Install the TXV and the backing plate to the evaporator pipes CAUTION Refer to Fastener Notice 5 Install the TX...

Page 1917: ...ectrical connector from the refrigerant pressure sensor NOTE Lubricate the refrigerant pressure sensor O ring with mineral oil Refer to O Ring Replacement 1 Remove the refrigerant pressure sensor from...

Page 1918: ...Installation Procedure 1 Install the temperature sensor to the evaporator case assembly 2 Twist the temperature sensor one quarter turn to engage to the evaporator case assembly 3 Install the tempera...

Page 1919: ...aturation 8 Remove the compressor hose nut from the condenser 9 Remove the compressor hose from the condenser 10 Install a protective cap to the compressor hose to prevent contamination and desiccant...

Page 1920: ...the CRFM brackets to the vehicle 6 Install the CRFM bracket bolts to the radiator support Tightening torque Tighten the bolts to 20 N m 15 lb ft 7 Remove the protective cap from the compressor hose 8...

Page 1921: ...d charge the A C system Refer to Refrigerant Recovery and Recharging 18 Test the affected A C joints leaks using J 39400 A Air Conditioning A C Evaporator Case Assembly Replacement Removal Procedure 1...

Page 1922: ...sembly 6 Remove the evaporator case assembly from the blower case assembly Installation Procedure 1 Install evaporator case assembly to the blower case assembly CAUTION Refer to Fastener Notice 2 Inst...

Page 1923: ...module assembly Refer to HVAC Module Assembly Replacement 2 Remove the evaporator case assembly Refer to Air Conditioning A C Evaporator Case Assembly Replacement 3 Remove the air inlet assembly Refe...

Page 1924: ...htening torque Tighten the screws to 1 5 N m 13 lb in 4 Install the blower motor control module to the blower case assembly 5 Install the blower motor control module screws to the blower case assembly...

Page 1925: ...t 7 Remove the evaporator outlet hose and liquid line from the TXV 8 Remove and discard the sealing washer from the liquid line Refer to Sealing Washer Replacement 9 Install a protective caps to the e...

Page 1926: ...tie bar Refer to Instrument Panel Tie Bar Replacement 22 Disconnect the blower motor electrical connector from the I P wire harness 23 Disconnect the blower motor control module electrical connector...

Page 1927: ...ie Bar Replacement CAUTION Refer to Fastener Notice NOTE New front of dash seal nuts must be used to prevent leaks 6 Tighten the HVAC module seal nuts to the front of dash Draw the HVAC module to the...

Page 1928: ...outlet hose to heater core outlet 21 Install the heater outlet hose clamp to the heater core 22 Ensure the mating surfaces are clean and free of debris and install new seal washers to the evaporator...

Page 1929: ...l Module Refer to Actuator Recalibration Auxiliary Actuator Replacement If an auxiliary actuator is replaced the following procedure must be performed Re Calibrating Actuators Refer to Actuator Recali...

Page 1930: ...AUTION Refer to Fastener Notice 5 Install the blower case assembly screws Tightening torque Tighten the screw to 1 5 N m 13 lb in 6 Install the HVAC module front of dash seal 7 Install new seal washer...

Page 1931: ...the heater inlet hose clamp from the engine 5 Remove the heater inlet hose 2 from the engine 6 Remove the heater inlet hose 2 from the vehicle Installation Procedure 1 Install the heater inlet hose 2...

Page 1932: ...GE 47716 Fill Draining and Filling Cooling System LY7 Static Fill 2 Remove the heater inlet hose clamp from the heater core 3 Remove the heater inlet hose clamp from the engine 4 Remove the heater inl...

Page 1933: ...ne 6 Position the loose end of the heater outlet hose 1 outboard to ease in the removal of the surge tank 7 Remove the surge tank inlet hose clamp from the surge tank 8 Disconnect the surge tank inlet...

Page 1934: ...the surge tank bolts to the surge tank Tightening torque Tighten the bolts to 8 N m 71 lb in 6 Connect the surge tank inlet hose to the surge tank 7 Install the surge tank inlet hose clamp to the sur...

Page 1935: ...ling Cooling System LY7 Static Fill 2 Remove the heater outlet hose clamp from the heater core 3 Remove the heater outlet hose clamp from the engine 4 Remove the heater outlet hose clamp from the auxi...

Page 1936: ...the RH air inlet panel 2 Open the hood 3 Remove the push pins from the top and forward edge of the RH air inlet panel 4 Remove the RH air inlet panel screw 5 Remove the RH air inlet panel 6 Remove the...

Page 1937: ...TE New seal nuts must be used when installing passenger compartment air filter housing to prevent leaks 3 Install the new seal nuts to the filter housing Tightening torque Tighten the nuts to 9 N m 80...

Page 1938: ...r of the RH air inlet panel 2 Open the hood 3 Remove the push pins from the top and forward edge of the RH air inlet panel 4 Remove the RH air inlet panel screw 5 Remove the RH air inlet panel 6 Remov...

Page 1939: ...re 1 Install the filter to the vehicle 2 Install the RH air inlet panel 3 Install the RH air inlet panel screw 4 Install the push pins to the top and forward edge of the RH air inlet panel 5 Close the...

Page 1940: ...e the air inlet assembly screws 6 Remove the air inlet assembly Installation Procedure 1 Install the air inlet assembly CAUTION Refer to Fastener Notice 2 Install the air inlet assembly screws Tighten...

Page 1941: ...odule Tightening torque Tighten the screws to 1 5 N m 13 lb in 3 Connect the electrical connector to the blower motor control module Blower Control Module Programming and Setup Blower Control Module T...

Page 1942: ...ning torque Tighten the screws to 1 5 N m 13 lb in 3 Connect the electrical connector to the blower motor 4 Install the right sound insulator panel Refer to Instrument Panel Insulator Panel Replacemen...

Page 1943: ...Trim Plate Refer to Instrument Panel Accessory Trim Plate Replacement 2 Instrument Panel Air Outlet Center Screws Qty 6 CAUTION Refer to Fastener Notice in Cautions and Notices Tightening torque 2 N m...

Page 1944: ...rument Panel Outer Trim Cover Refer to Instrument Panel Outer Trim Cover Replacement 2 Instrument Panel Air Outlet Screw CAUTION Refer to Fastener Notice in Cautions and Notices Tightening torque 2 N...

Page 1945: ...ner 3 Remove the LH air outlet duct from the instrument panel retainer Installation Procedure 1 Inspect the seals and replace if damaged using Kent Industries adhesive backed foam tape P N 46485 or eq...

Page 1946: ...iner 3 Remove the RH air outlet duct from the instrument panel retainer Installation Procedure 1 Inspect the seals and replace if damaged using Kent Industries adhesive backed foam tape P N 46485 or e...

Page 1947: ...Refer to Shift Control Replacement Rear Floor Air Outlet Replacement Removal Procedure 1 Remove the front seats Refer to Front Seat Replacement Bucket 2 Remove the floor console Refer to Console Repl...

Page 1948: ...center air outlet duct to the cross car beam 3 Install the center air outlet duct push pins to the cross car beam 4 Install the upper I P trim panel Refer to Instrument Panel Upper Trim Panel Replace...

Page 1949: ...N 46485 or equivalent 2 Install the LH defogger duct to the I P upper trim panel CAUTION Refer to Fastener Notice in Cautions and Notices 3 Install the LH defogger duct screws to the I P upper trim p...

Page 1950: ...trument panel I P upper trim panel Refer to Instrument Panel Upper Trim Panel Replacement Defroster Air Outlet Replacement Removal Procedure 1 Remove the instrument panel I P upper trim panel Refer to...

Page 1951: ...ator case assembly Refer to Air Conditioning A C Evaporator Case Assembly Replacement 3 Remove the mode actuator screws from the evaporator case assembly 4 Remove the mode actuator from the evaporator...

Page 1952: ...gn and install the mode cam 2 to the mode cam levers 3 Rotate the mode cam 2 to verify mode door operation 6 Install the mode cam bracket 1 to the evaporator case assembly 7 Install the mode cam brack...

Page 1953: ...nt 3 Remove the mode actuator screws from the evaporator case assembly 4 Remove the mode actuator from the evaporator case assembly 5 Remove the screws retaining the mode cam bracket 1 from the evapor...

Page 1954: ...n and install the mode cam 2 to the mode cam levers 3 Rotate the mode cam 2 to verify mode door operation 6 Install the mode cam bracket 1 to the evaporator case assembly 7 Install the mode cam bracke...

Page 1955: ...nt 3 Remove the mode actuator screws from the evaporator case assembly 4 Remove the mode actuator from the evaporator case assembly 5 Remove the screws retaining the mode cam bracket 1 from the evapor...

Page 1956: ...n and install the mode cam 2 to the mode cam levers 3 Rotate the mode cam 2 to verify mode door operation 6 Install the mode cam bracket 1 to the evaporator case assembly 7 Install the mode cam bracke...

Page 1957: ...screws from the HVAC module 3 Remove the heater core cover from the HVAC module 4 Remove the heater core from the HVAC module Installation Procedure 1 Install the heater core to the HVAC module 2 Inst...

Page 1958: ...nections 3 Remove lower HVAC case screws Refer to 07 193 Aux EVAP Replacement Tip The HVAC lower and side cases must be separated for temperature door removal 1 Auxiliary HVAC Side Case Screws CAUTION...

Page 1959: ...les Support Replacement FWD Vehicles 5 Remove left rear inner wheel house liner Refer to Rear Wheelhouse Liner Panel Replacement 6 Remove auxiliary heat pipes from heater core Refer to HVAC Pipe Repla...

Page 1960: ...anel Replacement 2 Remove the auxiliary HVAC module mounting bolts Qty 3 Refer to 07 193 Aux HVAC Module Replacement 3 Reposition auxiliary HVAC module inward to gain access to the blower control modu...

Page 1961: ...t Component Name Preliminary Procedure Remove the left rear trim panel Refer to Rear Quarter Lower Trim Panel Replacement 1 Auxiliary blower motor screws Qty 3 CAUTION Refer to Fastener Notice Tighten...

Page 1962: ...Replacement Callout Component Name Preliminary Procedure Remove the left rear trim panel Refer to Rear Quarter Lower Trim Panel Replacement 1 Auxiliary Air Distribution Duct Nuts Qty 2 CAUTION Refer t...

Page 1963: ...e vehicle headliner Refer to Headlining Trim Panel Replacement 3 Remove the auxiliary duct from the HVAC module Refer to Auxiliary Air Distributor Duct Replacement Upper 4 Remove the auxiliary air duc...

Page 1964: ...ement 2 Remove the auxiliary HVAC module Refer to Auxiliary HVAC Module Replacement Tip Ensure the lower case gasket is in good condition upon installation 3 Disconnect the electrical connectors 1 Aux...

Page 1965: ...3 Remove the rubber exhaust hangers to gain access to the auxiliary A C and the 3 heater pipes 4 Remove the auxiliary air conditioning A C lines from the thermal expansion valve TXV 1 Thermal Expansi...

Page 1966: ...lacement and Auxiliary Air Distributor Duct Replacement Upper 5 Disconnect the wiring connections 6 Raise and suitably support the vehicle Refer to Lifting and Jacking the Vehicle 7 Remove the tire an...

Page 1967: ...s replaced the following procedure must be performed Reprogram the Auxiliary HVAC Control Module Refer to Actuator Recalibration Auxiliary HVAC Control Module Reprogramming Do not reprogram the Auxili...

Page 1968: ...l connectors 1 HVAC Lower Case Screws Qty 6 CAUTION Refer to Fastener Notice Tip The HVAC lower and side cases must be separated for the evaporator core removal Ensure the lower case gasket is in good...

Page 1969: ...acement 5 Remove rubber exhaust hangers to gain access to A C and heater pipes Qty 3 6 Remove auxiliary evaporator tubes from HVAC module Refer to HVAC Hose Line Replacement CAUTION Refer to Fastener...

Page 1970: ...acking the Vehicle 4 Locate the area that requires repair 5 Obtain a length of replacement line to make the repair 6 Use a tubing cutter in order to cut and remove the section of damaged line NOTE The...

Page 1971: ...placed 7 Remove the section of line being replaced from the vehicle NOTE The length of the replacement line must be the same as the line being replaced 8 Install the replacement line to the vehicle 9...

Page 1972: ...bly Replacement Callout Component Name 1 Instrument Panel Accessory Trim Bezel Refer to Instrument Panel Accessory Trim Plate Replacement 2 HVAC Control Assembly Screw Qty 4 CAUTION Refer to Fastener...

Page 1973: ...l Replacement Callout Component Name 1 Rear Console Trim Plate Refer to Console Rear Trim Plate Replacement 2 Auxiliary HVAC Control Module Screw Qty 4 CAUTION Refer to Fastener Notice Tightening torq...

Page 1974: ...efer to Fastener Notice 2 Install the recirculation actuator screws to the HVAC module Tightening torque Tighten the screws to 1 5 N m 13 lb in 3 Connect the electrical connector to the recirculation...

Page 1975: ...control module is replaced the HVAC control module must be calibrated to ensure proper air distribution 5 Calibrate the actuators Refer to Actuator Recalibration 6 Cycle the ignition and verify prope...

Page 1976: ...ignition and verify proper operation 6 Install the I P compartment Refer to Instrument Panel Compartment Replacement Auxiliary Air Temperature Actuator Replacement Callout Component Name Preliminary...

Page 1977: ...Name Preliminary Procedure 1 Remove the left rear trim panel Refer to Rear Quarter Lower Trim Panel Replacement 2 Disconnect the electrical connector 3 Calibrate the actuators Refer to Actuator Recali...

Page 1978: ...Callout Component Name Preliminary Procedure 1 Remove I P Compartment Refer to Instrument Panel Compartment Replacement 2 Disconnect electrical connections Tip Reposition upper duct to gain access to...

Page 1979: ...mperature Sensor Replacement Lower Callout Component Name Preliminary Procedure 1 Remove I P Compartment Refer to Instrument Panel Compartment Replacement 2 Disconnect electrical connections 1 Air Tem...

Page 1980: ...nary Procedure Remove the left side I P lower trim panel Refer to Instrument Panel Lower Trim Panel Replacement Left Side 1 Inside Air Temperature Sensor Screw Qty 2 CAUTION Refer to Fastener Notice i...

Page 1981: ...mpressor Clutch Coil Connector Bracket Screw 4 3 N m 38 lb in Compressor Clutch Coil Screws 4 9 N m 43 lb in Compressor Hose Assembly to Battery Box Nut 9 N m 80 lb in Compressor Hose Assembly to Comp...

Page 1982: ...rmal Expansion Valve Replacement 20 ml 0 75 oz Total System PAG Oil Capacity 130 ml 4 40 oz Total System PAG Oil Capacity with C69 240 ml 8 10 oz R 134a Refrigerant Charge without C69 0 59 kg 1 30 lb...

Page 1983: ...ing Illustration Tool Number Description GE 47849 Clutch Remover GE 47850 Center Puller GE 47851 Armature Installer J 25031 A Three Jaw Puller J 37872 Universal Spanner Wrench J 39400 A Halogen Leak D...

Page 1984: ...Fluorescent Dye Cleaner J 45037 A C Oil Injector J 45268 A C Flushing Adapter Kit J 46246 Valve Core Tool Illustration Tool Number Description J 46297 A C Dye Injector Kit J 46297 12 Replacement Dye...

Page 1985: ...ensioner Replacement Front 8A 22 Pretensioner Handling and Scrapping 8A 23 Specifications 8A 26 Fastener Tightening Specifications Seat Belts 8A 26 Air Bag System 8B 1 Precautions 8B 1 SIR Caution 8B...

Page 1986: ...Inflatable Restraint Steering Wheel Module Coil Centering 8B 59 Inflatable Restraint Instrument Panel Module Replacement 8B 60 Inflatable Restraint Passenger Presence System Replacement Front 8B 62 P...

Page 1987: ...ocked during normal conditions in order to allow free movement of the upper body of each occupant A pendulum locks the seat belt webbing into position The pendulum causes a locking bar to engage a cog...

Page 1988: ...estraint The child seat may only be used in a forward facing seating location The child seat should be installed and secured according to the manufacturer s directions If the child seat has a top stra...

Page 1989: ...Seat Belts 8A 3 Seat Belt Schematics...

Page 1990: ...olor Circuit No Function A D GN 5016 Seat Belt Switch Left Signal w o AG1 D BU 5016 Seat Belt Switch Left Signal w AG1 B PK 5057 Seat Position Sensor Low Reference w o AG1 TN WH 5057 Seat Position Sen...

Page 1991: ...al 1 Inflatable Restraint Passenger Presence PPS Sensor 5 Heated Seat Element Front Passenger Cushion KA1 2 Seat Frame 6 Heated Seat Control Module KA1 3 Heated Seat Element Front Passenger Back KA1 7...

Page 1992: ...Switch Driver 5 Seat Adjuster Switch Driver AG1 2 Seat Horizontal Motor Driver AG1 6 Seat Rear Vertical Motor Driver AG1 3 Heated Seat Element Driver Cushion KA1 7 Seat Front Vertical Motor Driver AG...

Page 1993: ...l will display Buckled when the passenger seat belt is buckled and Unbuckled when the belt is unbuckled Operational and Functional Checks Front and Rear Seat Belt Retractors Front and rear seat belt r...

Page 1994: ...ent Faulty electrical connections or wiring may be the cause of intermittent conditions Refer to Testing for Intermittent Conditions and Poor Connections Symptom List Refer to Seat Belt Indicator Circ...

Page 1995: ...t the left seat belt switch 2 Test for infinite resistance between the signal circuit terminal B and the low reference terminal A If not the specified value replace the left seat belt switch 3 With th...

Page 1996: ...place the IPC 5 If all circuits test normal test or replace the Inflatable Restraint Passenger Airbag ON OFF Indicator Seat Belt Switch Malfunction 1 Ignition OFF disconnect the harness connector at t...

Page 1997: ...you observe the words REPLACE or CAUTION or if a yellow tag is visible Do not replace a seat belt if only the child seat caution label is visible Replace any seat belt system if you are doubtful abou...

Page 1998: ...t Belt Buckle Bolt Qty 1 CAUTION Refer to Fastener Notice Tightening torque 45 N m 33 lb ft 2 Front Seat Belt Buckle Tip 1 Disconnect the electrical connector under the seat 2 Slide the buckle assembl...

Page 1999: ...seat cushion cover and pad Refer to Rear Seat Cushion Cover and Pad Replacement 1 Rear Seat Belt Buckle Bolt Tip Apply GM P N 12345382 Canadian P N 10953489 Permatex 24200 or equivalent on all restrai...

Page 2000: ...emove third row rear seats Refer to Rear Number 2 Seat Replacement 1 Seat Cushion inner Finish Trim Panel Screw Tightening torque 2 N m 18 lb ft CAUTION Refer to Fastener Notice 2 Seat Cushion inner F...

Page 2001: ...a flat bladed tool to disengage the attaching clips 5 Remove the shoulder belt from the vehicle Installation Procedure NOTE Apply GM P N 12345382 Canadian P N 10953489 Permatex 24200 or equivalent on...

Page 2002: ...ck Pillar Upper Garnish Molding Replacement Left Side Lock Pillar Upper Garnish Molding Replacement Right Side 1 Rear Seat Belt Retractor Bolt Qty 3 CAUTION Refer to Fastener Notice Tip Apply GM P N 1...

Page 2003: ...ent 40 Seat 1 Center Rear Seat Belt Retractor To Seat Bolt CAUTION Refer to Fastener Notice Tip Apply GM P N 12345382 Canadian P N 10953489 Permatex 24200 or equivalent on all seat belt fasteners prio...

Page 2004: ...to Seat Belt Retractor Pretensioner Replacement Front 3 Remove the center pillar upper garnish molding Refer to Center Pillar Upper Garnish Molding Replacement 1 Front Seat Belt Height Adjuster Bolt...

Page 2005: ...he front seat cushion outer trim panel Refer to Front Seat Cushion Outer Trim Panel Replacement Non Fold Flat Front Seat Cushion Outer Trim Panel Replacement Fold Flat 1 Seat Belt Retractor Anchor Pla...

Page 2006: ...ment 1 Seat Belt Retractor Adjuster Bolt CAUTION Refer to Fastener Notice Tip Apply GM P N 12345382 Canadian P N 10953489 Permatex 24200 or equivalent on all restraint fasteners prior to installation...

Page 2007: ...der Belt Callout Component Name CAUTION Refer to Fastener Notice Fastener Tightening Specifications Refer to Fastener Tightening Specifications Seat Belts 1 Rear Seat Shoulder Belt Guide Plastic Push...

Page 2008: ...at Belt Retractor Pretensioner Adjuster Cover 2 Seat Belt Retractor Pretensioner Bolt CAUTION Refer to Fastener Notice Tip Apply GM P N 12345382 Canadian P N 10953489 Permatex 24200 or equivalent on a...

Page 2009: ...or outside of the vehicle The method used depends upon the final disposition of the vehicle Review the following procedures in order to determine which will work best in a given situation Deployment...

Page 2010: ...l the fixture plastic reservoir with water or sand 10 Mount the seat belt pretensioner 1 in the SIR deployment fixture 3 with the open end facing up using the following mounting method Adjust and secu...

Page 2011: ...imum power source such as a vehicle battery near the shorted end of the harness 19 Connect the SIR deployment harness wires to the power source Seat belt pretensioner deployment will occur when contac...

Page 2012: ...7 lb ft Child Seat Tether Anchor Bolt to Seat 25 N m 18 lb ft Front Seat Belt Buckle Quick Connect to Seat Bolt 50 N m 37 lb ft Front Seat Belt Buckle to Seat Bolt 45 N m 33 lb ft Front Seat Belt Heig...

Page 2013: ...y do not dispose of an undeployed inflator module as normal shop waste Undeployed inflator modules contain substances that could cause severe illness or personal injury if their sealed containers are...

Page 2014: ...ON The steering column 1 and knee bolsters 3 are designed to absorb energy and compress during frontal collisions in order to limit leg movement and decrease the chance of injury to the driver and pa...

Page 2015: ...pant sitting in the front passenger seat is measured as a change in current flow within the sensor mat If the sensor determines that the occupant weight is less than a specified value the PPS module w...

Page 2016: ...ipped with a shorting bar that is located in the connector of the seat belt pretensioner The shorting bar shorts the seat belt pretensioner circuitry to prevent unwanted deployment of the seat belt pr...

Page 2017: ...or that performs calculations using the measured accelerations and compares these calculations to a value stored in memory When the generated calculations exceed the stored value the SDM will cause cu...

Page 2018: ...8B 6 Air Bag System SIR Schematics...

Page 2019: ...Air Bag System 8B 7 Power Ground Roll Over Sensor and PPS...

Page 2020: ...8B 8 Air Bag System Modules and Sensors...

Page 2021: ...Air Bag System 8B 9 Pretensioners and Front End Sensor...

Page 2022: ...ng Sensor Low Reference B YE 354 Discriminating Sensor Signal Connector Part Information OEM 15356723 Service 15306439 Description 2 Way F GT 150 Sealed 4 0 YE Terminal Part Information Terminal Tray...

Page 2023: ...rt Information OEM 15398877 Service Description 5 Way F HCM Series NA Terminal Part Information Terminal Tray SHCM A03T P025 20 Core Insulation Crimp J J Release Tool Test Probe 12094429 J 35616 64B L...

Page 2024: ...Repair Kit Pin Wire Color Circuit No Function 1 WH Side Impact Module LF Low Control 2 D GN Side Impact Module LF High Control Connector Part Information OEM Not Available Service Not Available Descri...

Page 2025: ...Pretensioner Right High Control 19 OG 2117 Seat Belt Pretensioner Right Low Control 20 27 Not Used 28 PK 5057 Seat Position Sensor Low Reference 29 30 Not Used 31 RD WH 1340 Battery Positive Voltage...

Page 2026: ...Steering Wheel Module Stage2 High Control 2 PK 3022 Steering Wheel Module Stage2 Low Control Connector Part Information OEM 15356723 Service 15306439 Description 2 Way F GT 150 Sealed 4 0 YE Terminal...

Page 2027: ...GN 5060 Low Speed GMLAN Serial Data 5 YE BK 5229 Roll Over Sensor High Signal 6 BK WH 651 Ground Connector Part Information OEM 252922346 Service Description 2 Way F PU Terminal Part Information Term...

Page 2028: ...Right Located under the headliner extending from the passenger front windshield pillar to the passenger rear windshield pillar 10 Side Impact Sensor SIS LF Located under the trim near the bottom of t...

Page 2029: ...Air Bag System 8B 17 SIR Component Views Near the Hood Latch 1 Inflatable Restraint Front End Sensor Left 3 Cooling Fan Right 2 Radiator Core Support 4 Cooling Fan Left...

Page 2030: ...l Switch TCS 4 Radio 14 Rear Wiper Washer Fog Lamp Switch 5 HVAC Control Module 15 Inflatable Restraint Passenger Airbag ON OFF Indicator 6 Cigar Lighter 16 Inside Air Temperature Sensor 7 Transmissio...

Page 2031: ...tem 8B 19 Steering Column 1 Turn Signal Multifunction Switch 4 Theft Deterent Module 2 Inflatable Restraint Steering Wheel Module Coil 5 Ignition Lock Solenoid 3 Windshield Wiper Washer Switch 6 Ignit...

Page 2032: ...raint Passenger Presence PPS Sensor 5 Heated Seat Element Front Passenger Cushion KA1 2 Seat Frame 6 Heated Seat Control Module KA1 3 Heated Seat Element Front Passenger Back KA1 7 Inflatable Restrain...

Page 2033: ...Console 7 Inflatable Restraint Sensing and Diagnostic Module SDM 3 Yaw Rate and Lateral Acceleration Sensor 8 Seat Belt Pretensioner Left 4 Seat Belt Pretensioner Right 9 Inflatable Restraint Side Imp...

Page 2034: ...cation of the control module which commands the system The ability of the control module to communicate through the serial data circuit The identification of any stored diagnostic trouble codes DTCs a...

Page 2035: ...itch Sensor Switch Driver Seat Belt Switch Sensor Data Buckled Unbuckled Buckled Passenger Seat Belt Switch Sensor Data Buckled Unbuckled Unbuckled Passenger Seat Belt Sensor Sensor Data mA 9 mA Drive...

Page 2036: ...rmines if the VIN stored in SDM memory matches what is stored in the BCM SIR Warning Indicator The scan tool displays whether the SIR warning indicator has been requested ON or OFF DTC B0012 or B0013...

Page 2037: ...module high and or low circuit is open for 120 milliseconds B0012 0D Stage 1 or B0013 0D Stage 2 The steering wheel module deployment loop resistance is more than 5 1 ohms for 120 milliseconds B0012 0...

Page 2038: ...und If not the specified range test the circuit for a short to voltage 11 Test for less than 1 volt between the applicable LOW circuit and ground If not the specified range test the circuit for a shor...

Page 2039: ...etensioner Deployment Loop Short to Battery B0022 02 Passenger Pretensioner Deployment Loop Short to Ground B0022 04 Passenger Pretensioner Deployment Loop Open Circuit B0022 0D Passenger Pretensioner...

Page 2040: ...resistance is less than 1 1 ohms for 120 milliseconds Action Taken When the DTC Sets The SDM commands the AIR BAG indicator ON via serial data communications The SDM will store a DTC if event occurs...

Page 2041: ...ail Module terminal 14 Seat Belt Pretensioner Left terminal 17 Seat Belt Pretensioner Right terminal 18 If not within the specified range test the circuit for an open high resistance 11 Test for less...

Page 2042: ...nt event After the maximum number of deployments has occurred DTC B0052 sets and becomes a latched code which cannot be cleared When DTC B0053 is accompanied by additional DTCs other than B0052 repair...

Page 2043: ...pairs Scan Tool Reference Scan Tool Data List SIR Scan Tool Data Definitions SIR Circuit System Testing 1 Ignition OFF Verify that the vehicle does not show any signs of side impact or frontal inflato...

Page 2044: ...pretensioner deployment If the vehicle displays any signs of inflator deployment refer to Repairs and Inspections Required After a Collision 2 With a scan tool verify DTC B0052 B0053 or B0055 is not s...

Page 2045: ...gnition OFF verify no signs of inflator module or pretensioner deployment exist If any signs of deployment exist refer to Repairs and Inspections Required After a Collision 2 With a scan tool verify D...

Page 2046: ...t to Battery DTC B0073 02 RF Seat Belt Sensor Circuit Short to Ground DTC B0073 04 RF Seat Belt Sensor Circuit Open Circuit DTC B0073 06 Right Front Seat Belt Sensor Circuit Short To Ground or Open Ci...

Page 2047: ...cified range test the signal circuit for a short to voltage 4 If the circuits test normal replace the seat belt buckle Repair Instructions Perform the Diagnostic Repair Verification Vehicle Diagnostic...

Page 2048: ...g connectors inspect for damage or corrosion Damage or corrosion in the following requires repair or replacement of the affected component connector The PPS module The SDM module The PPS module harnes...

Page 2049: ...d sensor When the ignition is turned ON and input power from the SDM is first detected the front end sensor responds by performing internal diagnostics and sending an ID to the SDM The SDM considers t...

Page 2050: ...front end sensor connector Refer to front end sensor replacement for location of connector 2 Remove the SDM connector Refer to SDM replacement for location of connector 3 Test for infinite resistance...

Page 2051: ...S responds by performing internal diagnostics and sending an ID to the SDM The SDM considers the ID to be valid if the response time is less than 5 seconds The SIS continually communicates status mess...

Page 2052: ...high resistance 7 Test for less then 1 ohm of resistance between the voltage circuit SIS connector and SDM connector If greater than the specified range test the circuit for an open high resistance 8...

Page 2053: ...icle application and the components were properly configured Refer to Control Module References for SDM and ROS setup and programming Reference Information Schematic Reference SIR Schematics Connector...

Page 2054: ...Conditions for Clearing the DTC The last 4 digit Primary Data Key in the SDM match the last 4 digits stored in the BCM The VIN that is stored in the SDM matches the VIN stored in the BCM Diagnostic A...

Page 2055: ...ing the DTC Ignition voltage is between 9 16 volts Conditions for Setting the DTC B1019 00 The SDM was programmed with the wrong options for the vehicle The wrong components were installed for the con...

Page 2056: ...condition and has no bent pins terminals or shorting bars If damage is found repair the bent pins terminals or shorting bars as needed and perform the Setup New SDM procedure 4 Reconnect the harness c...

Page 2057: ...0 will set if the low reference circuit is shorted to voltage battery with no sensor code set for one of the following sensors Right or Left front end sensors Right or Left side impact sensors There i...

Page 2058: ...g anytime the seat cushion trim attachments have been removed or the PPS has been replaced The procedures below are designed to assist in the rezeroing of the PPS Before you start read these procedure...

Page 2059: ...tic tests on the SIR system and then commands the IPC to turn the AIR BAG indicator OFF if no SIR malfunction exists The AIR BAG indicator is controlled by the SDM via serial data communications If th...

Page 2060: ...witch states within 5 seconds Circuit System Testing NOTE When removing connectors inspect for damage or corrosion Damage or corrosion in the following requires repair or replacement of the affected I...

Page 2061: ...following components NOTE The front passenger seat is equipped with a PPS which detects an occupant If the requirements for disabling the I P air bag are met then the PPS will communicate with the SD...

Page 2062: ...pply General Service Instructions The following are general service instructions which must be followed in order to properly repair the vehicle and return it to its original integrity Do not expose in...

Page 2063: ...Center Identification Views 3 Turn the ignition switch to the ON position The AIR BAG indicator will flash then turn OFF 4 Perform the Diagnostic System Check Vehicle if the AIR BAG warning indicator...

Page 2064: ...rocedure 1 Disable the supplemental inflatable restraint SIR system Refer to SIR Disabling and Enabling 2 Left supplemental inflatable sensor requires to remove battery box Refer to Battery Box Replac...

Page 2065: ...ake sure that it is securely fastened Failure to observe the correct installation procedures could cause SIR deployment personal injury or unnecessary SIR system repairs Fastener Tightening Specificat...

Page 2066: ...fy no current faults are present Callout Component Name WARNING Refer to SIR Caution Preliminary Procedures 1 Disable the supplemental inflatable restraint SIR system Refer to SIR Disabling and Enabli...

Page 2067: ...ard the front of the vehicle Failure to observe the correct installation procedure could cause SIR deployment personal injury or unnecessary SIR system repairs Preliminary Procedures 1 Disable the SIR...

Page 2068: ...can be cleared NOTE If the SDM was replaced the SIR warning indicator will remain ON SOLID until after the programming event is complete 1 Key ON Engine OFF Program the SDM refer to Service Programmi...

Page 2069: ...r openings place the wheel so that one opening is on top 3 Using a blunt ended tool push the spring fastener inward through the access hole Repeat the step for the other opening 1 Module Steering Whee...

Page 2070: ...efer to Steering Wheel Replacement 2 Remove the steering column trim covers Refer to Steering Column Trim Covers Replacement 1 Inflatable Restraint Steering Wheel Module Coil Bolts Qty 4 CAUTION Refer...

Page 2071: ...the 12 o clock position 2 If available remove the yellow retaining tab 1 from the SIR coil and save the tab for reassembly 3 Hold the SIR coil face up by the casing 2 a Slowly turn the coil hub 3 clo...

Page 2072: ...8B 60 Air Bag System Inflatable Restraint Instrument Panel Module Replacement...

Page 2073: ...2 Remove the I P lower right trim panel Refer to Instrument Panel Lower Trim Panel Replacement Right Side 1 Instrument Panel Inflatable Restraint Module Bolt Qty 4 CAUTION Refer to Fastener Notice Tig...

Page 2074: ...Tightening Specifications Seat Hardware Trim and Upholstery Preliminary Procedure 1 Remove the front seat Refer to Front Seat Replacement Bucket 2 Remove the seat cushion cover and pad Refer to Front...

Page 2075: ...cluster IPC and dash lights will begin dimming ON and OFF This is normal operation during the rezeroing procedure and does not indicate additional system faults If the PPS is replaced or serviced perf...

Page 2076: ...n order to avoid personal injury if any part of the module is damaged replace the entire module Preliminary Procedures 1 Disable the SIR system Refer to SIR Disabling and Enabling 2 Remove the headlin...

Page 2077: ...After replacement of an inflator module under warranty the inflator module may need to be returned undeployed to the manufacturer If the vehicle is the subject of a product liability claim related to...

Page 2078: ...OFF the ignition 2 Remove the ignition key 3 Put on safety glasses 4 Remove the inflator module WARNING Refer to SIR Inflator Module Handling and Storage Caution 5 Place the inflator module on a work...

Page 2079: ...xture during deployment c Adjust and secure the fixture arms 4 to the deployment fixture 3 using the proper nuts and bolts d Attach the roof rail module in the deployment fixture and securely tighten...

Page 2080: ...lator module due to the force of the rapid expansion of gas inside the inflator module If you are deploying a dual stage inflator module with stage 1 already deployed the fixture may not move and the...

Page 2081: ...to the following situations The vehicle has completed all useful life Irreparable damage occurred to the vehicle in a non deployment type accident Irreparable damage occurred to the vehicle during a...

Page 2082: ...ads 9 Cut two 6 1 m 20 ft deployment wires from a 0 8 mm 18 gage or thicker multi strand wire Use these wires to fabricate the driver deployment harness 10 Strip 13 mm 0 5 in of insulation from both e...

Page 2083: ...using electrical tape 16 Twist together the 2 connector wire leads from the low circuits from both stages of the steering wheel module to one set of deployment wires Refer to SIR Connector End Views...

Page 2084: ...n the steering wheel module 21 Route the deployment harness out of the driver side of the vehicle 22 Disconnect the yellow left roof rail harness connector from the vehicle harness connector 23 Cut th...

Page 2085: ...ends of the wires 27 Twist together one end from each of the wires in order to short the wires 28 Twist together one connector wire lead to one deployment wire 29 Bend flat the twisted connection 30 S...

Page 2086: ...or 2 NOTE If the vehicle is equipped with dual stage air bags the steering wheel module and I P module will each have 4 wires Refer to SIR Connector End Views for determining high and low circuits 35...

Page 2087: ...together one end from each of the wires in order to short the wires 40 Twist together the 2 connector wire leads from the high circuits from both stages of the I P module to one set of deployment wir...

Page 2088: ...r End Views in order to determine the correct circuits 45 Inspect that the 3 wire connection is secure 46 Bend flat the twisted connection 47 Secure and insulate the 3 wire connection to the deploymen...

Page 2089: ...13 mm 0 5 in of insulation from each of the connector wire leads 53 Cut two 6 1 m 20 ft deployment wires from a 0 8 mm 18 gage or thicker multi strand wire These wires will be used to fabricate the ro...

Page 2090: ...eld and the front door window openings with a drop cloth 63 Stretch to the full length all of the deployment harness wires on the right side of the vehicle 64 Deploy each deployment loop one at a time...

Page 2091: ...int System SRS requires special wiring repair procedures due to the sensitive nature of the circuitry Follow the specific procedures and instructions when working with the SIR SRS and the wiring compo...

Page 2092: ...a pigtail component SIR SRS Wire Repair NOTE Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing You must obtain this information in order to ensure...

Page 2093: ...or coding of the DuraSeal splice sleeves and the crimp tool nests 5 Use the Splice Crimp Tool from the J 38125 to crimp DuraSeal splice sleeve In order to position the DuraSeal splice sleeve in the pr...

Page 2094: ...placement Connector Repairs Connector Repairs contains a list of all connector repairs The connector repairs are listed by the connector manufacturer and then by connector type If the technician canno...

Page 2095: ...fficult When trying to determine the manufacturer of a connector look for specific identifying marks that are unique to that connector supplier Most of these identify marks are hard to find or see Che...

Page 2096: ...e it JAE connector have JAE in small letters on their connectors JST connectors have JST in small letters on their connectors similar to that above The location of the logo will vary with the connecto...

Page 2097: ...entifiable marks on them Yazaki has a wedge or arrow shape similar to that shown Connector Position Assurance Locks The connector position assurance CPA is a small plastic insert that fits through the...

Page 2098: ...or Module to I P Screws 10 N m 89 lb in Roof Rail Inflator Module to Roof Screws 5 N m 44 lb in Sensing and Diagnostic Module to Floor Nuts 5 N m 44 lb in Side Impact Sensor to Lock Pillar Screw 10 N...

Page 2099: ...Measuring Voltage 9A 155 Measuring Voltage Drop 9A 155 Measuring Frequency 9A 155 Testing for Continuity 9A 155 Testing for Short to Ground 9A 156 Testing for a Short to Voltage 9A 156 Testing for In...

Page 2100: ...Low or High Beams Always On 9B 69 Headlamps Inoperative High Beams 9B 71 Headlamps Inoperative Low Beams 9B 72 Low and High Beams Headlamps Inoperative 9B 74 Headlamps Flash to Pass Inoperative 9B 75...

Page 2101: ...49 Speedometer and or Odometer Inaccurate or Inoperative 9C 50 Tachometer Inaccurate or Inoperative 9C 50 Turn Signal Lamps and or Indicators Always On or Flashing 9C 51 Turn Signal Lamps and or Indi...

Page 2102: ...1 Safety Glasses and Compressed Air Caution 9E 1 Window Retention Caution 9E 1 Window Edge Damage Notice 9E 1 General Description 9E 2 Full Cut Method Description 9E 2 Adhesive Service Kit Descriptio...

Page 2103: ...Functions 9F 24 Diagnostic Starting Point Theft Deterrent 9F 24 Scan Tool Output Controls Vehicle Access 9F 24 Scan Tool Output Controls Remote Functions 9F 24 Scan Tool Data List Vehicle Access 9F 25...

Page 2104: ...Cushion Cover and Pad Replacement 9G 40 Front Seat Adjuster Replacement 9G 41 Front Seat Adjuster Replacement 2 way Manual 9G 42 Front Seat Back Panel Replacement Fold Flat 9G 43 Front Seat Head Restr...

Page 2105: ...r Corner Garnish Molding Replacement 9H 7 Child Restraint Tether Anchor Bezel Replacement 9H 8 Lock Pillar Upper Garnish Molding Replacement Left Side 9H 9 Lock Pillar Upper Garnish Molding Replacemen...

Page 2106: ...eplacement 9J 28 Front Side Door Window Channel Replacement 9J 29 Front Side Door Window Channel Replacement 9J 29 Rear Side Door Window Channel Replacement 9J 30 Rear Side Door Window Channel Replace...

Page 2107: ...ecifications 3M Products 9L 4 Clearcoat Repair Specifications Meguiar Products 9L 6 Exterior Body Panels 9M 1 Precautions 9M 1 Exterior Trim Emblem Removal Notice 9M 1 Repair Instructions 9M 1 Rocker...

Page 2108: ...t System Inoperative 9O 51 Video Entertainment System Remote Control Inoperative 9O 51 Video Entertainment System Wireless Headphone Inoperative 9O 52 Steering Wheel Controls Inoperative 9O 53 Reduced...

Page 2109: ...Function 1 4 Not Used 5 YE 447 Starter Relay Coil Control 6 BK WH 451 Ground 7 PK 439 Ignition 1 Voltage 8 D GN 59 A C Compressor Clutch Supply Voltage 9 PK BK 5294 Powertrain Main Relay Fused Supply...

Page 2110: ...ve Voltage 2 RD BK 742 Battery Positive Voltage 3 D GN 1619 Trailer Right Rear Turn Stop Lamp Supply Voltage V92 4 BN 2109 Trailer Park Lamps Supply Voltage V92 5 D BU WH 1315 Right Front Turn Signal...

Page 2111: ...be 12094430 J 35616 42 RD Pins 3 4 4 5 6 8 9 13 14 15 16 19 20 21 7 17 18 Terminal Tray 15304711 8 Core Insulation Crimp Pins 3 4 4 5 6 8 9 13 14 15 16 19 20 21 E A Core Insulation Crimp Pins 7 17 18...

Page 2112: ...D Dimming Signal K34 10 12 Not Used 13 RD WH 2340 Battery Positive Voltage UUC 14 RD WH 1040 Battery Positive Voltage 15 PK 1139 Ignition 1 Voltage 16 TN 28 Horn Relay Control 17 Not Used 18 L GN 2270...

Page 2113: ...7 J 35616 2A GY Pin Wire Color Circuit No Function 1 TN 294 Door Lock Actuator Unlock Control TN 294 Door Lock Actuator Unlock Control 2 TN 294 Door Lock Actuator Unlock Control 3 TN 694 Driver Door L...

Page 2114: ...ausing the high current is removed Positive Temperature Coefficient PTC Circuit Breaker This type greatly increases its resistance when excessive current passes through it The excessive current heats...

Page 2115: ...plice Clips Electrical Symbols OLD Symbol NEW Symbol Description Supplemental Inflatable Restraint SIR or Supplemental Restraint System SRS Icon This icon is used to alert the technician that the syst...

Page 2116: ...ented in a dashed box the component or its wiring is not shown in its entirety Entire Component When a component is represented in a solid box the component or its wiring is shown in its entirety Fuse...

Page 2117: ...Wiring Systems 9A 9 Connector Attached to Component Pigtail Connector Bolt On or Screw On Eyelet Terminal Inline Harness Connector Splice OLD Symbol NEW Symbol Description...

Page 2118: ...9A 10 Wiring Systems Chassis Ground Case Ground Single Filament Light Bulbs Double Filament Light Bulb Light Emitting Diodes OLD Symbol NEW Symbol Description...

Page 2119: ...Wiring Systems 9A 11 Capacitor Battery Variable Battery Resistor Variable Resistor OLD Symbol NEW Symbol Description...

Page 2120: ...9A 12 Wiring Systems Position Sensor I O Resistors I O Switches Diode Heating Element OLD Symbol NEW Symbol Description...

Page 2121: ...Wiring Systems 9A 13 Motor Solenoid Coil Antenna Twisted Wires OLD Symbol NEW Symbol Description...

Page 2122: ...9A 14 Wiring Systems Shield Switches Single Pole Throw Relay Normally Open Single Pole Throw Relay Normally Closed OLD Symbol NEW Symbol Description...

Page 2123: ...atics Icon Icon Definition WARNING When performing service on or near the SIR components or the SIR wiring the SIR system must be disabled Refer to SIR Disabling and Enabling Failure to observe the co...

Page 2124: ...9A 16 Wiring Systems B BUS 1 of 2...

Page 2125: ...Wiring Systems 9A 17 B BUS 2 of 2...

Page 2126: ...9A 18 Wiring Systems ABS ABS MTR AUX PWR AWD ECMBAT PWR OUTLET REAR APO REAR HVAC and TCM BAT Fuses...

Page 2127: ...Wiring Systems 9A 19 BATT MAIN 1 CAN VENT CLSTR HVAC BLOWER INFO INT LTS ONSTAR REAR DEFOG and RVC Fuses...

Page 2128: ...9A 20 Wiring Systems AMP BCM CHMSL DIMR HVAC RFA and RDO Fuse...

Page 2129: ...Wiring Systems 9A 21 AOS MODULE BATT MAIN 2 HTD SEATS L GATE LT TRN SIG PWR MIRS RT TRN SIG and SIR Fuses and...

Page 2130: ...9A 22 Wiring Systems POWER SEATS Circuit Breaker...

Page 2131: ...Wiring Systems 9A 23 BATT MAIN 3 DR LCK RRWPR RSE KEY CAPTR and S ROOF Fuses and POWER WNDW...

Page 2132: ...9A 24 Wiring Systems IGN SWITCH Fuse and Ignition Switch...

Page 2133: ...Wiring Systems 9A 25 PWR TRN BUS ETC ECM EVEN COILS INJ AND ODDCOILS INJ Fuses...

Page 2134: ...9A 26 Wiring Systems PWR TRN BUS EMM DEV1 EMM DEV2...

Page 2135: ...Wiring Systems 9A 27 RUN CRANK BUS MAF PCM IGN SIR DISPLAY and TRANS Fuses...

Page 2136: ...9A 28 Wiring Systems DRL DRL2 FOG LP LH HIGH BEAM LH LOW BEAM RH HIGH BEAM and RH LOW BEAM Fuses...

Page 2137: ...Wiring Systems 9A 29 LH PRK LP RH PRK LP and RH PRK LP TRLR Fuses...

Page 2138: ...9A 30 Wiring Systems HORN LH TRLR STOP TURN RH TRLR STOP TURN and STOP LP Fuses...

Page 2139: ...Wiring Systems 9A 31 Power Moding Schematics...

Page 2140: ...9A 32 Wiring Systems Power Moding...

Page 2141: ...Wiring Systems 9A 33 Ignition Lock Schematics...

Page 2142: ...9A 34 Wiring Systems Ground Distribution Schematics...

Page 2143: ...Wiring Systems 9A 35 G101...

Page 2144: ...9A 36 Wiring Systems G103 G105 G107 G108 and G109...

Page 2145: ...Wiring Systems 9A 37 G201...

Page 2146: ...9A 38 Wiring Systems G203 and G205...

Page 2147: ...Wiring Systems 9A 39 G301...

Page 2148: ...9A 40 Wiring Systems G311...

Page 2149: ...Wiring Systems 9A 41 G401...

Page 2150: ...9A 42 Wiring Systems G403...

Page 2151: ...Wiring Systems 9A 43 Trailer Connector Provision Schematics...

Page 2152: ...9A 44 Wiring Systems Trailer Wiring...

Page 2153: ...Wiring Systems 9A 45 Harness Routing Views Forward Lamp Harness 1 C109 4 G101 2 C110 5 C101 3 C108...

Page 2154: ...9A 46 Wiring Systems Body Harness Engine Compartment 1 C102 2 C101...

Page 2155: ...Wiring Systems 9A 47 Battery Cable Harness 1 C102 3 G103 2 Battery Current Sensor...

Page 2156: ...9A 48 Wiring Systems Engine Harness Front 1 S110 5 S105 2 S109 6 S100 3 S108 7 G107 4 S107 8 C106...

Page 2157: ...Wiring Systems 9A 49 Engine Harness Top of Engine 1 S115 3 S106 2 S114...

Page 2158: ...9A 50 Wiring Systems Fuel Injector and Transmission Harness 1 C105 3 S101 2 S104...

Page 2159: ...ms 9A 51 I P Harness 1 S210 12 C203 C69 w o UUC 2 S213 13 C307 C69 3 C275 14 C218 4 C276 15 G201 5 S201 16 C219 6 S212 17 C206 7 C216 18 C226 8 S223 19 C207 UUC w o C69 9 C214 20 C204 10 S211 UUC 21 S...

Page 2160: ...9A 52 Wiring Systems Console Harness 1 S301 3 C202 2 S300 4 C305...

Page 2161: ...9A 53 Body Harness Passenger Compartment 1 C219 13 G301 2 C600 14 C305 3 C206 15 S304 4 C218 16 S302 5 S202 17 S204 6 S306 18 C204 7 S307 19 S206 8 C309 20 C210 9 G311 21 S200 10 C800 22 C500 11 C700...

Page 2162: ...9A 54 Wiring Systems Headliner and Sunroof Harness 1 C415 3 C417 U3U 2 C412 UUC...

Page 2163: ...Wiring Systems 9A 55 Body Harness Rear Compartment 1 G403 7 C901 2 S409 8 C900 3 C415 9 C403 4 C417 U3U 10 G401 5 C409 V92 11 C419 C69 6 C404...

Page 2164: ...9A 56 Wiring Systems Body Harness Rear Compartment 1 G403 7 C901 2 S409 8 C900 3 C415 9 C403 4 C417 U3U 10 G401 5 C409 V92 11 C419 C69 6 C404...

Page 2165: ...Wiring Systems 9A 57 Liftgate Harness 1 C900 4 C906 2 C901 5 S908 3 S902 6 Rear WIndow Wiper Motor Connector...

Page 2166: ...J 35616 2A GY Pin Wire Color Circuit No Function A BK 1450 B PU WH 1630 Steering Column Key Cylinder Lock Solenoid Control Connector Part Information OEM HCMPBC06K Service Description 6 Way F HCM Unse...

Page 2167: ...Speed GMLAN Serial Data J Not Used K D GN 5060 Low Speed GMLAN Serial Data L D GN 5060 Low Speed GMLAN Serial Data M D GN 5060 Low Speed GMLAN Serial Data Connector Part Information OEM 7283 5684 10...

Page 2168: ...6 BK 1250 Ground 7 GY 5600 Right Front Discriminating Sensor Low Reference 7 GY 5600 Right Front Discriminating Sensor Low Reference 8 D GN 1409 Discriminating Sensor Right Signal 8 D GN 1409 Discrimi...

Page 2169: ...ries BK Terminal Part Information Terminal Tray 12048074 2 Core Insulation Crimp E 1 Release Tool Test Probe 12094429 J 35616 2A GY Terminal Part Information Terminal Tray 12045773 2 Core Insulation C...

Page 2170: ...es BK Terminal Part Information Terminal Tray 12048074 2 Core Insulation Crimp E 1 Release Tool Test Probe 12094429 J 35616 2A GY Terminal Part Information Terminal Tray 12045773 2 Core Insulation Cri...

Page 2171: ...Crimp See Terminal Repair Kit Release Tool Test Probe See Terminal Repair Kit Pin Wire Color Circuit No Function Pin Wire Color Circuit No Function 1 PK BK 5291 Ignition 1 Voltage 1 WH 5291 Ignition...

Page 2172: ...Circuit No Function 1 PU 1589 Fuel Level Sensor Signal Primary 1 PU 1589 Fuel Level Sensor Signal Primary 2 PU 1272 Low Reference 2 PU 1272 Low Reference 3 L BU 1162 APP Sensor 2 Signal 3 L BU 1162 A...

Page 2173: ...ay 7114 4142 02 10 Core Insulation Crimp A 3 Release Tool Test Probe 12094430 J 35616 43 RD Pin Wire Color Circuit No Function Pin Wire Color Circuit No Function 1 L BU 409 Cooling Fan Motor Supply Vo...

Page 2174: ...98 Description 5 Way F GT 150 Sealed 4 0 BK Connector Part Information OEM 15326827 Service 89046648 Description 5 Way M GT 150 Series Sealed BK Terminal Part Information Terminal Tray 12191819 8 Core...

Page 2175: ...strument Panel Lamp Supply Voltage 2 GY 8 Instrument Panel Lamp Supply Voltage 3 BARE 5346 Video Drain Wire 3 BARE 5346 Video Drain Wire 4 PU 2056 Auxiliary Video High Signal 4 PU 2056 Auxiliary Video...

Page 2176: ...on Terminal Tray 7114 4100 08 9 Core Insulation Crimp E C Release Tool Test Probe 15315247 J 35616 3 GY Pin Wire Color Circuit No Function Pin Wire Color Circuit No Function 1 GY 8 Instrument Panel La...

Page 2177: ...odule Stage2 Low Control B2 PK 3022 Steering Wheel Module Stage2 Low Control Connector Part Information OEM 7283 8391 40 Service Description 26 Way F Receptacle 1 5 2 8 6 3 Unsealed L GY Connector Par...

Page 2178: ...ar Low Level Audio Signal 14 YE 116 Left Rear Speaker Output Except U65 BN 1999 Left Rear Low Level Audio Signal U65 15 L BU 115 Right Rear Speaker Output 15 L BU 115 Right Rear Speaker Output Except...

Page 2179: ...art Information Pins 1 2 3 4 5 Terminal Tray 7114 4721 02 14 Core Insulation Crimp See Terminal Repair Kit Release Tool Test Probe 15315247 J 35616 65B L BU Pins 6 Terminal Tray 7114 4720 02 14 Core I...

Page 2180: ...20 21 22 23 24 25 Terminal Tray 7116 4100 08 9 Core Insulation Crimp E C Release Tool Test Probe 12094430 J 35616 2A GY Pins 1 Terminal Tray 7116 4121 02 10 Core Insulation Crimp C B Release Tool Tes...

Page 2181: ...Serial Data Bus TN BK 2500 High Speed GMLAN Serial Data Bus 12 TN 2501 High Speed GMLAN Serial Data Bus 12 TN 2501 High Speed GMLAN Serial Data Bus TN 2501 High Speed GMLAN Serial Data Bus 13 BN WH 4...

Page 2182: ...on Crimp See Terminal Repair Kit Release Tool Test Probe See Terminal Repair Kit Terminal Part Information Terminal Tray 12034047 2 Core Insulation Crimp E A Release Tool Test Probe 12094430 J 35616 5...

Page 2183: ...N 2273 Mode Door Control D TN 516 Upper Left Air Temperature Sensor Signal D TN 516 Upper Left Air Temperature Sensor Signal E TN 520 Lower Right Air Temperature Sensor Signal E TN 520 Lower Right Air...

Page 2184: ...E A Release Tool Test Probe 12094430 J 35616 4A PU Terminal Part Information Terminal Tray Core Insulation Crimp Release Tool Test Probe Pin Wire Color Circuit No Function Pin Wire Color Circuit No F...

Page 2185: ...minal Part Information Pins 1 Terminal Tray 7116 4618 02 14 Core Insulation Crimp P P Release Tool Test Probe J 38125 215 J 35616 64B L BU Terminal Part Information Pins 1 Terminal Tray 7114 4618 02 2...

Page 2186: ...94430 J 35616 4A PU Terminal Part Information Pins 3 Terminal Tray 7114 4111 02 9 Core Insulation Crimp E A Release Tool Test Probe 12094430 J 35616 5 PU Pins 1 2 4 Terminal Tray 7114 4110 02 9 Core I...

Page 2187: ...ool Test Probe See Terminal Repair Kit Pin Wire Color Circuit No Function Pin Wire Color Circuit No Function 1 PU 1375 Remote Radio Control Supply Voltage 1 YE 1375 Remote Radio Control Supply Voltage...

Page 2188: ...lease Tool Test Probe 12180559 1 J 35616 64B L BU Terminal Part Information Terminal Tray Core Insulation Crimp Release Tool Test Probe Pin Wire Color Circuit No Function Pin Wire Color Circuit No Fun...

Page 2189: ...ation Terminal Tray Core Insulation Crimp Release Tool Test Probe Pin Wire Color Circuit No Function Pin Wire Color Circuit No Function A B Not Used A B Not Used C PU 1375 Remote Radio Control Supply...

Page 2190: ...ray 7114 4111 02 9 Core Insulation Crimp C A Release Tool Test Probe 12094430 J 35616 5 PU Pin Wire Color Circuit No Function Pin Wire Color Circuit No Function A B Not Used A B Not Used C PU 1375 Rem...

Page 2191: ...Way M 110 Unsealed L GY Terminal Part Information Terminal Tray 7116 4111 02 9 Core Insulation Crimp C A Release Tool Test Probe 12094430 J 35616 4A PU Terminal Part Information Terminal Tray 7114 41...

Page 2192: ...No Function Pin Wire Color Circuit No Function 1 GY BK 1798 Low Reference 1 GY BK 1798 Low Reference 2 GY 2599 Auxiliary Mode Door Control 2 GY 2599 Auxiliary Mode Door Control 3 GY 596 5 Volt Refere...

Page 2193: ...J 35616 4A PU Pins A B Terminal Tray 15304713 19 Core Insulation Crimp 4 4 Release Tool Test Probe 15315247 J 35616 4A PU Terminal Part Information Terminal Tray See Terminal Repair Kit Core Insulati...

Page 2194: ...See Terminal Repair Kit Release Tool Test Probe See Terminal Repair Kit Pin Wire Color Circuit No Function Pin Wire Color Circuit No Function A RD BK 542 Battery Positive Voltage A RD BK 542 Battery P...

Page 2195: ...5315247 J 35616 2A GY Terminal Part Information Terminal Tray See Terminal Repair Kit Core Insulation Crimp See Terminal Repair Kit Release Tool Test Probe See Terminal Repair Kit Pin Wire Color Circu...

Page 2196: ...WH 840 Battery Positive Voltage A OG 840 Battery Positive Voltage B BK WH 651 Ground B BK 651 Ground C PK 5057 Seat Position Sensor Low Reference C PK 5057 Seat Position Sensor Low Reference D OG 136...

Page 2197: ...Core Insulation Crimp See Terminal Repair Kit Release Tool Test Probe See Terminal Repair Kit Pin Wire Color Circuit No Function Pin Wire Color Circuit No Function A GY 120 Fuel Pump Supply Voltage A...

Page 2198: ...Test Probe See Terminal Repair Kit Pin Wire Color Circuit No Function Pin Wire Color Circuit No Function A D BU WH 149 Courtesy Lamp Supply Voltage A D BU WH 149 Courtesy Lamp Supply Voltage B GY 157...

Page 2199: ...9 Description 6 Way F GT 150 Series BK Connector Part Information OEM 15332142 Service 89046638 Description 6 Way M GT 150 280 Series Sealed BK Terminal Part Information Terminal Tray See Terminal Rep...

Page 2200: ...epair Kit Terminal Part Information Terminal Tray See Terminal Repair Kit Core Insulation Crimp See Terminal Repair Kit Release Tool Test Probe See Terminal Repair Kit Pin Wire Color Circuit No Functi...

Page 2201: ...Probe 12094430 J 35616 3 GY Pin Wire Color Circuit No Function Pin Wire Color Circuit No Function 1 BK 850 Ground 1 BK 850 Ground 2 L BU 5986 Serial Data Communication Enable 2 L BU 5986 Serial Data...

Page 2202: ...E A Core Insulation Crimp Pins 2 6 5 E 1 Release Tool Test Probe 15313892 J 35616 18 BK Terminal Part Information Terminal Tray See Terminal Repair Kit Core Insulation Crimp See Terminal Repair Kit R...

Page 2203: ...Core Insulation Crimp Pins 2 6 5 E 1 Release Tool Test Probe 15313892 J 35616 18 BK Terminal Part Information Terminal Tray See Terminal Repair Kit Core Insulation Crimp See Terminal Repair Kit Relea...

Page 2204: ...16 4103 08 9 Core Insulation Crimp E 1 Release Tool Test Probe 12094430 J 35616 2A GY Terminal Part Information Pins 1 2 3 Terminal Tray 7114 4102 08 9 Core Insulation Crimp E 1 Release Tool Test Prob...

Page 2205: ...Test Probe 12094430 J 35616 2A GY Terminal Part Information Pins 2 3 4 Terminal Tray 7114 4102 08 9 Core Insulation Crimp E 1 Release Tool Test Probe 12094430 J 35616 3 GY Pins 1 Terminal Tray 7114 4...

Page 2206: ...nal A2 PK BK 5844 Video Bright Control A2 PK BK 5844 Video Bright Control A3 A4 Not Used A3 A4 Not Used A5 YE 343 Accessory Voltage A5 YE 343 Accessory Voltage YE 343 Accessory Voltage A6 WH 1487 Ante...

Page 2207: ...5 2 3 4 7 Terminal Tray 7114 4101 08 9 Core Insulation Crimp Pins 5 C A Core Insulation Crimp Pins 2 3 4 7 E A Release Tool Test Probe 15315247 J 35616 3 GY Pins 6 Terminal Tray 7114 4100 08 9 Core In...

Page 2208: ...rmation Terminal Tray See Terminal Repair Kit Core Insulation Crimp See Terminal Repair Kit Release Tool Test Probe See Terminal Repair Kit Terminal Part Information Terminal Tray See Terminal Repair...

Page 2209: ...Pin Wire Color Circuit No Function Pin Wire Color Circuit No Function A BN 6555 Rear Temperature Motor Supply Voltage A BN 6555 Rear Temperature Motor Supply Voltage B GY 2614 Auxiliary Air Temperatu...

Page 2210: ...inal Repair Kit Core Insulation Crimp See Terminal Repair Kit Release Tool Test Probe See Terminal Repair Kit Pin Wire Color Circuit No Function Pin Wire Color Circuit No Function A D GN Side Impact M...

Page 2211: ...WH Connector Part Information OEM 7182 1581 Service Description 28 Way M 090 Class II Series Sealed WH Terminal Part Information Pins 7 8 9 11 12 10 19 21 Terminal Tray 7116 4020 11 Core Insulation Cr...

Page 2212: ...or Motor Up Control 11 L GN 88 Driver Mirror Motor Up Control 12 WH 81 Driver Mirror Motor Right Control 12 WH 81 Driver Mirror Motor Right Control 13 Not Used 13 BK 746 Right Front Door Ajar Switch S...

Page 2213: ...epair Kit Core Insulation Crimp See Terminal Repair Kit Release Tool Test Probe See Terminal Repair Kit Pin Wire Color Circuit No Function Pin Wire Color Circuit No Function 1 2 Not Used 1 2 Not Used...

Page 2214: ...ight Front Down Signal 26 BN 167 Power Window Master Switch Right Front Down Signal 27 28 Not Used 27 28 Not Used Connector Part Information OEM 7123 1413 Service 88988485 Description 18 Way F WH Conn...

Page 2215: ...Right Front Door Ajar Switch Signal B6 Not Used B6 BK 746 Right Front Door Ajar Switch Signal B7 Not Used B7 Not Used B8 GY 295 Door Lock Actuator Lock Control B8 GY 295 Door Lock Actuator Lock Contr...

Page 2216: ...nal A2 PU 171 Power Window Master Switch Right Rear Down Signal A2 PU 171 Power Window Master Switch Right Rear Down Signal A3 D BU 1307 Power Window Master Switch Lockout Signal A3 D BU 307 Headlamp...

Page 2217: ...imp See Terminal Repair Kit Release Tool Test Probe 15315247 J 35616 65B L BU Pins 2 3 6 5 Terminal Tray 7114 4720 02 14 Core Insulation Crimp J J Release Tool Test Probe 15315247 J 35616 65B L BU Pin...

Page 2218: ...ol Test Probe 12094430 J 35616 35 VT Terminal Part Information Pins 1 6 5 Terminal Tray 7114 4111 02 9 Core Insulation Crimp C A Release Tool Test Probe 12094430 J 35616 5 PU Pins 3 Terminal Tray 7114...

Page 2219: ...nal Tray See Terminal Repair Kit Core Insulation Crimp See Terminal Repair Kit Release Tool Test Probe See Terminal Repair Kit Terminal Part Information Terminal Tray 7114 4100 08 9 Core Insulation Cr...

Page 2220: ...tment All forward of the dash panel 001 099 are additional for the engine compartment Only to be used if all 100 199 items are used 200 299 Within the instrument panel area 300 399 Passenger compartme...

Page 2221: ...shifter assembly Shift Lock Control Component Views Auxiliary Power Outlet Console 1 Inside the center console compartment under the cup holder Power Outlet Connector End Views Auxiliary Power Outlet...

Page 2222: ...n Right At the right front of the engine compartment Cooling System Component Views Cooling System Connector End Views Courtesy Map Lamp At the front of the headliner above the inside rearview mirror...

Page 2223: ...Connector End Views Fog Lamp Right T96 At the RF corner of the vehicle below the headlamp assembly Lighting Systems Component Views Lighting Systems Connector End Views Fog Lamp Switch T96 At the cent...

Page 2224: ...Seat Connector End Views Heated Seat Element Driver Cushion KA1 Inside the driver seat cushion Heated Cooled Seat Component Views Heated Cooled Seat Connector End Views Heated Seat Element Front Pass...

Page 2225: ...End Views Inflatable Restraint Roof Rail Module Right ASF Behind the right side of the headliner above the right doors SIR Component Views SIR Connector End Views Inflatable Restraint Sensing and Diag...

Page 2226: ...Connector End Views Output Shaft Speed OSS Sensor On the top left side of the transmission below the brake master cylinder Automatic Transmission Electronic Component Views Automatic Transmission Rela...

Page 2227: ...ensioner Right At the right side of the passenger compartment at the base of the door pillar part of the seat belt retractor SIR Component Views SIR Connector End Views Seat Belt Switch Left Part of t...

Page 2228: ...trol Component Views Secondary Configurable Control Connector End Views Sunroof Control Module CF5 Under the headliner at the right rear of the sunroof module assembly Sunroof Connector End Views Sunr...

Page 2229: ...e Passenger In the center console right of the shifter assembly Window Systems Component Views Window Systems Connector End Views Window Switch LR In the LR door on the door trim panel Window Systems...

Page 2230: ...ntrol module Harness Routing Views Inline Harness Connector End Views C216 16 cavities I P Harness to the HVAC Harness below the right side of the I P next to the center console Harness Routing Views...

Page 2231: ...ews C410 4 cavities V92 Trailer Harness to the Trailer Jumper Harness below the center rear of the vehicle by the rear bumper Harness Routing Views Inline Harness Connector End Views C412 22 cavities...

Page 2232: ...the carpet Power and Grounding Component Views G311 Beneath the RF seat under the carpet Power and Grounding Component Views G401 At the LR corner of the passenger compartment behind the LR trim pane...

Page 2233: ...ess approximately 6 cm 2 36 in from the C210 breakout Harness Routing Views S210 In the I P harness approximately 8 5 cm 3 35 in from the Inside Air Temperature Sensor breakout Harness Routing Views S...

Page 2234: ...m the rear dome lamp breakout toward the center dome lamp S313 UUC In the sunshade harness S314 UUC In the sunshade harness S401 In the fuel level sender harness approximately 13 cm 5 12 in from C310...

Page 2235: ...02 In the Liftgate harness approximately 22 5 cm 8 86 in from the defogger breakout Harness Routing Views S908 In the Liftgate harness approximately 6 cm 2 36 in from the rear window wiper motor break...

Page 2236: ...9A 128 Wiring Systems Front of the Engine Compartment 1 Fuse Block Underhood 3 Cooling Fan Left 2 Battery 4 Cooling Fan Right...

Page 2237: ...Wiring Systems 9A 129 LF of the Engine Compartment 1 LF Strut Tower 3 Windshield Washer Fluid Pump 2 G103 4 Battery Current Sensor...

Page 2238: ...9A 130 Wiring Systems G112 1 Rear Exhaust Manifold 2 G112...

Page 2239: ...Wiring Systems 9A 131 G107 and G105 1 G107 3 G105 2 Front Cylinder Head 4 Starter...

Page 2240: ...9A 132 Wiring Systems Engine Harness Rear 1 G108 2 G109...

Page 2241: ...s 9A 133 I P Harness 1 S210 12 C203 C69 w o UUC 2 S213 13 C307 C69 3 C275 14 C218 4 C276 15 G201 5 S201 16 C219 6 S212 17 C206 7 C216 18 C226 8 S223 19 C207 UUC w o C69 9 C214 20 C204 10 S211 UUC 21 S...

Page 2242: ...stems Body Harness Passenger Compartment 1 C219 13 G301 2 C600 14 C305 3 C206 15 S304 4 C218 16 S302 5 S202 17 S204 6 S306 18 C204 7 S307 19 S206 8 C309 20 C210 9 G311 21 S200 10 C800 22 C500 11 C700...

Page 2243: ...ems 9A 135 Steering Column 1 Turn Signal Multifunction Switch 4 Theft Deterent Module 2 Inflatable Restraint Steering Wheel Module Coil 5 Ignition Lock Solenoid 3 Windshield Wiper Washer Switch 6 Igni...

Page 2244: ...9A 136 Wiring Systems Body Harness Rear Compartment 1 G403 7 C901 2 S409 8 C900 3 C415 9 C403 4 C417 U3U 10 G401 5 C409 V92 11 C419 C69 6 C404...

Page 2245: ...his information There are 4 possible display parameters depending on the ignition switch position These are Off Accessory Run and Crank Request This parameter should match the actual ignition switch p...

Page 2246: ...ort to Battery DTC B1370 06 Device Ignition 1 ON and START Circuit Open Diagnostic Fault Information Scan Tool Parameter Data List Units Displayed Typical Data Value Operating Conditions Ignition ON E...

Page 2247: ...he vehicle may or may not start Instrument panel indicators may illuminate or not illuminate at inappropriate times Remote start may operate incorrectly Ignition key may not return to OFF Specific Ret...

Page 2248: ...tery positive voltage repair the circuit for an open high resistance NOTE The ignition switch component test must be preformed before proceeding with this test to verify the integrity of the switch 4...

Page 2249: ...ostic category DTC Descriptors DTC B1380 01 Device Ignition Accessory Circuit Short to Battery DTC B1380 06 Device Ignition Accessory Circuit Open Diagnostic Fault Information Ignition Switch Position...

Page 2250: ...Transmission gear selected System Action The vehicle may or may not start Instrument panel indicators may illuminate or not illuminate at inappropriate times Remote start may operate incorrectly Ignit...

Page 2251: ...tery positive voltage repair the circuit for an open high resistance NOTE The ignition switch component test must be preformed before proceeding with this test to verify the integrity of the switch 4...

Page 2252: ...volts The DTC can only run when the output is activated Conditions for Setting the DTC DTC will set when the output is activated and there is a short to ground in the circuit Action Taken When the DT...

Page 2253: ...s of resistance between terminals 30 and 87A If greater then the specified range replace the relay 5 Install a 3 amp fused jumper wire between relay terminal 85 and 12 volts Install a jumper wire betw...

Page 2254: ...ematic Reference Power Moding Schematics Power Distribution Schematics Connector End View Reference Power and Grounding Connector End Views Electrical Information Reference Circuit Testing Connector R...

Page 2255: ...ecessary Other modules which have switched voltage inputs may operate in a default mode if the PMM serial data message does not match what the individual module can see from its own connections The PM...

Page 2256: ...Schematics Connector End View Reference Power and Grounding Connector End Views Electrical Information Reference Circuit Testing Connector Repairs Testing for Intermittent Conditions and Poor Connecti...

Page 2257: ...Ignition 1 voltage If more than 1 0 volt repair the circuit for a short to voltage 7 Test for less than 1 0 ohm of resistance between the BCM and the ignition switch on the following circuits Ignitio...

Page 2258: ...tput is removed or the malfunction is no longer present A history DTC clears when the module ignition cycle counter reaches the reset threshold of 50 without a repeat of the malfunction Reference Info...

Page 2259: ...uits all such circuits are indicated on circuit diagrams with the SIR symbol CAUTION Refer to OBD II Symbol Description Notice OBD II circuits all such circuits are indicated on circuit diagrams with...

Page 2260: ...front of the connector CAUTION Do not insert test equipment probes DVOM etc into any connector or fuse block terminal The diameter of the test probes will deform most terminals A deformed terminal wi...

Page 2261: ...9 Weather Pack Female Probe Adapter orange J 35616 10 100W Male round Probe Adapter green J 35616 11 100W Female round Probe Adapter green J 35616 12 130 Male Probe Adapter blue J 35616 13 130 Female...

Page 2262: ...perform other operations or test driving Refer to Probing Electrical Connectors Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnes...

Page 2263: ...t the negative lead of the DMM to the other point of the circuit 4 Operate the circuit 5 The DMM displays the difference in voltage between the 2 points Measuring Frequency CAUTION Refer to Test Probe...

Page 2264: ...e fuse terminals be sure that the fuse is powered When the DMM displays voltage the short is in the wiring leading to the first connector or switch If the DMM does not display voltage refer to the nex...

Page 2265: ...ves 2 Visually inspect the connector halves for contamination Contamination may result in a white or green build up within the connector body or between terminals This causes high terminal resistance...

Page 2266: ...conditions can cause a sharp electrical surge Normally the condition will occur when the malfunctioning component is operating Improper installation of non factory or aftermarket add on accessories s...

Page 2267: ...wn conductivity This may cause the circuit to fail more easily when sprayed Once the mixture is completed spray the suspect area liberally with the solution Then while monitoring either a scan tool or...

Page 2268: ...er to display the MIN value and note the value 9 Determine the difference between the MIN and MAX values If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an interm...

Page 2269: ...ns when working on GMLAN connectors and terminals The tool kit J 38125 contains the following items in order to repair the GMLAN wiring DuraSeal splice sleeves A wire stripping tool J 38125 8 Crimping...

Page 2270: ...vailable from sewing supply stores in order to cut open the harness in order to avoid wire insulation damage Use the DuraSeal splice sleeves on all types of insulation except coaxial Do not use the Du...

Page 2271: ...per handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest 7 Insert the wire into the splice sleeve barrel until the wire hits the barrel stop 8 Tightly close the handl...

Page 2272: ...protect the splice sleeves A large sampling of common electrical terminals The correct crimp tool to attach the terminals to the wires The correct tools to remove the terminals from the connectors The...

Page 2273: ...sleeve according to the wire size Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests 7 Use the Splice Crimp...

Page 2274: ...ss is taped remove the tape To avoid wiring insulation damage use a sewing ripper in order to cut open the harness If the harness has a black plastic conduit pull out the desired wire 2 Cut the wire C...

Page 2275: ...nsure that no insulation is caught under the clip 8 Center the crimp tool over the splice clip and wires 9 Apply steady pressure until the crimp tool closes Ensure that no strands of wire are cut 10 C...

Page 2276: ...l Use duraseal splice sleeves where there is special requirements such as moisture sealing Follow the instructions below in order to splice copper wire using duraseal splice sleeves 1 Open the harness...

Page 2277: ...op in the middle of the barrel in order to prevent the wire from passing through the splice 3 9 Close the handles of the J 38125 8 GM P N 12085115 until the crimper handles open when released The crim...

Page 2278: ...ve the inoperative diode from the harness with a suitable soldering tool NOTE If the diode is located next to a connector terminal remove the terminal s from the connector to prevent damage from the s...

Page 2279: ...repair procedure There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer The information in this document should help with...

Page 2280: ...on the connector and is often very small In some cases Delphi will actually be printed on the connector If Delphi is not printed on the connector look for PED In both cases there is no specific orien...

Page 2281: ...connector In some cases the connectors may have MX followed by another letter The third letter indicates where the connector was made A connector with MXD is a Molex connector made in Detroit Sumitomo...

Page 2282: ...ween the mating terminals of the connector Terminal Position Assurance Locks The terminal position assurance TPA insert resembles the plastic combs used in the control module connectors The TPA keeps...

Page 2283: ...cover Use a small flat blade tool to release the locking tabs and remove the dress cover Release the rear lower half of the wiredress cover Release the tabs that are holding the wiredress cover to the...

Page 2284: ...h Connectors BSK Special tool J 38125 Terminal Repair Kit Terminal Removal Procedure 1 Disconnect the connector from the component 2 Remove the wire dress cover if necessary 3 Push the wire side of th...

Page 2285: ...een the cover at the connector end and pry up 7 Remove the dress cover 8 Cut the tie wrap on the wire bundle 9 Remove the terminal position assurance TPA by inserting a small flat bladed tool into the...

Page 2286: ...al Removal Procedure 1 Pull out the slider on the connector position assurance CPA until it is at the end of its travel 2 Disconnect the connector from the component 3 Remove the wire dress cover if n...

Page 2287: ...f the connector Move the assist lever to the forward position 2 Disconnect the connector from the component 3 Locate the dress cover locking tabs at the corners of the connector Use a small flat blade...

Page 2288: ...r Always remember never use force when pulling a terminal out of a connector Repair Procedure NOTE Ensure that the dress cover and connector body are both in the released position before reassembling...

Page 2289: ...er to Repairing Connector Terminals 7 Reform the lock tang 2 and reset terminal in connector body 8 Close secondary locks and join connector halves 9 Verify that circuit is complete and working satisf...

Page 2290: ...4 Install the TPA CPA and or the secondary locks Delphi Connectors Pull To Seat Special tool J 38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having...

Page 2291: ...s are very similar but use different terminals and have some minor physical differences also The first connector design of the Micro Pack 100W 1 has a white connector interface that holds the terminal...

Page 2292: ...ne of the locking tabs while gently pulling on the same side of the nose piece 4 Repeat the procedure for the other locking tab and remove the nose piece 5 Remove the wire dress cover The following is...

Page 2293: ...minal Repair Procedure The Micro Pack 100W connectors have small terminals that are difficult to handle and hold when crimping In order to aid the technician when crimping these terminals a new crimpi...

Page 2294: ...erminal is crimped to the wire perform the following procedure in order to replace Micro Pack 100 terminals 1 Slide the new terminal into the correct cavity at the back of the connector 2 Push the ter...

Page 2295: ...ector when released from the component View of another type of Micro 64 connector Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks Vie...

Page 2296: ...ng a small flat blade tool into the small slot on the TPA and pushing down until the TPA releases Gently pry the TPA out of the connector NOTE Be careful not to angle or rock the J 38125 21 tool when...

Page 2297: ...determine if the remaining wire is long enough to reach the connector without putting a strain on the wire If the wire is not long enough splice a small length of the same gage wire to the existing wi...

Page 2298: ...emove the connector position assurance CPA and slide the lever lock away from the connector body 2 Disconnect the connector from the component 3 Locate the dress cover locking tabs on the dress cover...

Page 2299: ...sert the J 38125 12A GM P N 12094429 tool to release the terminals by inserting the tool into the terminal release cavity See the release tool cross reference in the Reference Guide of the J 38125 to...

Page 2300: ...a small flat blade tool to release the locking tabs and remove the dress cover 4 Use a small flat blade tool to slide the terminal position assurance TPA up one notch on both ends of the connector The...

Page 2301: ...and the proper crimp tool can be found in the appropriate connector end view JST Connectors Special tool J 38125 Terminal Repair Kit Removal Procedure 1 While depressing the lock remove the connector...

Page 2302: ...removal tool in place gently pull the wire out of the back of the connector Always remember never use force when pulling a terminal out of a connector Repair Procedure Use the appropriate terminal an...

Page 2303: ...or Only move it to the release point 7 Use a small flat blade tool to move the front TPA to the release position 8 Use the J 38125 213 or the J 38125 560 GM P N 15314260 tool to release the terminals...

Page 2304: ...rminal Removal Procedure 1 Locate the connector position assurance CPA on the top of the wire dress cover Slide the CPA forward 2 Slide the lever lock forward while pressing down on the lever lock rel...

Page 2305: ...ole on the nose piece and gently pull on the back of the wire 10 See the release tool cross reference in the Reference Guide of the J 38125 Terminal Repair Kit to ensure that the correct release tool...

Page 2306: ...ver 3 Relieve the tension on the nose piece retainers by inserting J 38125 12A 12094429 into the single retainer slot on the end of the nose piece and gently prying out the locking tab Repeat the proc...

Page 2307: ...l be inserted and the terminal cavity Terminal 1 Entry Canal 2 7 Insert the J 38125 553 15315247 tool into the entry canal and pry up on the terminal retainer The terminal retainer is a small plastic...

Page 2308: ...sassembly procedure Tyco AMP Connectors CM 42 Way Special tool J 38125 Terminal Repair Kit Removal Procedure 1 Locate the connector position assurance CPA on the connector body and pull the CPA out Th...

Page 2309: ...Insert the J 38125 11A GM P N 12094430 tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over 3 Ensure that the terminal release t...

Page 2310: ...r body but only slightly When the TPA is slightly raised the terminals can be removed Using excessive force to remove the TPA with the terminals still in the connector will damage the connector 3 Repe...

Page 2311: ...en removing a terminal position assurance TPA in order to avoid damaging it 5 Release the TPA by inserting a small flat blade tool into the blue locking tabs on both ends of the connector Gently slide...

Page 2312: ...se force when pulling a terminal out of a connector Repair Procedure Use the appropriate terminal and follow the instructions in the J 38125 Location of the terminal in the repair tray and the proper...

Page 2313: ...ousing 6 Use the J 38125 12A GM P N 12094429 tool to release the terminals by pressing on the tang See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct...

Page 2314: ...contact with the terminal until it stops on the plastic terminal retainer See the release tool cross reference in the Reference Guide of the J 38125 to ensure that the correct release tool is used 6...

Page 2315: ...de of the J 38125 to ensure that the correct release tool is used View of the female half of the connector with male terminals View of the male half of the connector with female terminals 4 While hold...

Page 2316: ...rip and seal in the terminal 6 Hand crimp the core wings 7 Hand crimp the insulation wings For sealed terminals hand crimp the insulation wings around the seal and the cable 8 Solder all of the hand c...

Page 2317: ...fasteners which hold the relay in place 3 Remove any connector position assurance CPA devices or secondary locks NOTE Use care when removing a relay in a wiring harness when the relay is secured by fa...

Page 2318: ...remove the fuse block cover push in on the tabs with a flat bladed tool and lift 2 Underhood Electrical Center Junction Block Power Nut CAUTION Refer to Fastener Notice Procedure Disconnect the batter...

Page 2319: ...ect the battery Refer to Battery Negative Cable Disconnection and Connection 1 Fuse Panel 2 Instrument Panel Wiring Harness Junction Block Screw CAUTION Refer to Fastener Notice in Cautions and Notice...

Page 2320: ...Junction Block Nut 17 N m 13 lb ft Ground Wire to I P Junction Block Screw 10 N m 89 lb in Mega Fuse to Underhood Junction Block 15 N m 133 lb in Underhood Junction Block to Harness Retaining Bolts 4...

Page 2321: ...Wiring Systems 9A 213 J 39200 Digital Multimeter J 42759 Ignition Switch Connector Release Tool J 43244 Relay Puller Pliers J 44020 Terminal Repair Kit Illustration Tool Number Description...

Page 2322: ...ating automatic lamp control ALC The Left High Beam 10A fuse Right High Beam 10A fuse Left Low Beam 10A fuse Right Low Beam 10A fuse DRL 1 15A fuse and DRL 2 15A fuse in the fuse block underhood suppl...

Page 2323: ...low light conditions the BCM grounds the park lamp relay control circuit energizing the park lamp relay The now closed relay supplies voltage on the park lamp supply voltage circuit directly to the l...

Page 2324: ...approximate 20 second delay Interior Lamps Dimming This group includes lamps which may dim This group may use a combination of vacuum fluorescent VF illumination and incandescent lamps HVAC control m...

Page 2325: ...Lighting Systems 9B 4 Headlights Daytime Running Lights DRL Schematics...

Page 2326: ...9B 5 Lighting Systems Fog Lights Schematics...

Page 2327: ...Lighting Systems 9B 6 Exterior Lights Schematics...

Page 2328: ...9B 7 Lighting Systems Left Park Lamps...

Page 2329: ...Lighting Systems 9B 8 License Lamps Right Park Lamps...

Page 2330: ...9B 9 Lighting Systems Turn Signal Lamps...

Page 2331: ...Lighting Systems 9B 10 Stop Lamps...

Page 2332: ...9B 11 Lighting Systems Backup Lamps...

Page 2333: ...Lighting Systems 9B 12 Trailer Tow Connector...

Page 2334: ...9B 13 Lighting Systems Interior Lights Schematics...

Page 2335: ...Lighting Systems 9B 14 Interior Lights Dimming Schematics...

Page 2336: ...51 Ground D L GN BK 1137 DRL Ambient Light Sensor Signal Connector Part Information OEM 10351681 Service Description 2 Way F Lamp Socket Sealed BK Terminal Part Information Terminal Tray See Terminal...

Page 2337: ...ment Sensor Low Reference B D BU 6037 Brake Pedal Displacement Sensor Signal C GY 6036 Brake Pedal Displacement Sensor 5 Volt Reference Connector Part Information OEM 7223 1324 Service 88988460 Descri...

Page 2338: ...B D GN 44 Instrument Panel Lamps Dimmer Switch Signal C BK WH 1551 Ground D OG WH 812 12 Volt Reference E Not Used Connector Part Information OEM 12045813 Service 12101889 Description 4 Way F Metri pa...

Page 2339: ...ack 280 Series BK Terminal Part Information Terminal Tray 12077411 2 Core Insulation Crimp 2 5 Release Tool Test Probe 12094430 J 35616 4A PU Pin Wire Color Circuit No Function A PU 34 Front Fog Lamp...

Page 2340: ...escription 3 Way F Sealed GN Terminal Part Information Terminal Tray See Terminal Repair Kit Core Insulation Crimp See Terminal Repair Kit Release Tool Test Probe See Terminal Repair Kit Pin Wire Colo...

Page 2341: ...Service Description 2 Way F Lamp Socket Wedge Base W2 BK Terminal Part Information Terminal Tray See Terminal Repair Kit Core Insulation Crimp See Terminal Repair Kit Release Tool Test Probe See Termi...

Page 2342: ...F Lamp Socket Sealed BK Terminal Part Information Terminal Tray See Terminal Repair Kit Core Insulation Crimp See Terminal Repair Kit Release Tool Test Probe See Terminal Repair Kit Pin Wire Color Ci...

Page 2343: ...tion 3 Way F Lamp Socket Sealed BK Terminal Part Information Terminal Tray See Terminal Repair Kit Core Insulation Crimp See Terminal Repair Kit Release Tool Test Probe See Terminal Repair Kit Pin Wir...

Page 2344: ...ice Description 3 Way F Lamp Socket Sealed BK Terminal Part Information Terminal Tray See Terminal Repair Kit Core Insulation Crimp See Terminal Repair Kit Release Tool Test Probe See Terminal Repair...

Page 2345: ...Rear Window Wiper Switch Signal 3 L GN 2270 Rear Window Washer Relay Control 4 OG 192 Front Fog Lamp Switch Signal Fog Lamps Enable T96 5 BK 1450 Ground 6 PU WH 1382 LED Dimming Signal T96 Connector P...

Page 2346: ...ignal H D BU WH 1415 Right Front Turn Signal Switch Signal J K Not Used Connector Part Information OEM 12047782 Service 12117371 Description 3 Way M Metri Pack 150 Series BK Terminal Part Information...

Page 2347: ...mponent Location Lighting Systems Component Views Front Lights 1 Headlamp Right 5 Fog Lamp Left T96 2 Headlamp Left 6 Fog Lamp Right T96 3 Marker Lamp LF 7 Park Turn Signal Lamp RF 4 Park Turn Signal...

Page 2348: ...9B 27 Lighting Systems Pedal Assemblies 1 Brake Pedal Position Sensor 2 Accelerator Pedal Position APP Sensor...

Page 2349: ...ol Switch TCS 4 Radio 14 Rear Wiper Washer Fog Lamp Switch 5 HVAC Control Module 15 Inflatable Restraint Passenger Airbag ON OFF Indicator 6 Cigar Lighter 16 Inside Air Temperature Sensor 7 Transmissi...

Page 2350: ...ng Systems Steering Column 1 Turn Signal Multifunction Switch 4 Theft Deterent Module 2 Inflatable Restraint Steering Wheel Module Coil 5 Ignition Lock Solenoid 3 Windshield Wiper Washer Switch 6 Igni...

Page 2351: ...Lighting Systems 9B 30 Front Headliner Components 1 Dome Lamp Center 3 Sunroof Switch CF5 2 Noise Compensation Microphone U3U 4 Courtesy Map Lamp...

Page 2352: ...7 Backup Lamp Right 2 Rear Defogger Grid 8 License Lamp Right 3 Center High Mounted Stop Lamp CHMSL 9 Liftgate Switch 4 Digital Radio Antenna U2K 10 License Lamp Left 5 Park Stop Lamp RR 11 Park Turn...

Page 2353: ...Lamp Light Test The BCM activates the park lamp relay when you select ON The park lamps illuminate until commanded OFF RF Turn DRL Lamp Light Test The BCM activates the right front turn signal lamps w...

Page 2354: ...ON OFF When the headlamp dimmer switch is placed in the HIGH position the scan tool will display ON Scan Tool Parameter Units Displayed Typical Data Value Ignition On Engine Off Ambient Light Sensor...

Page 2355: ...utput of the BCM is displayed as ON when the left turn signal is turned ON or when the BCM turns ON the DRL lamps LR Stop Turn Signal Lamp The scan tool displays ON OFF This output of the BCM is displ...

Page 2356: ...Reference Circuit Testing Connector Repairs Testing for Intermittent Conditions and Poor Connections Wiring Repairs Scan Tool Reference Scan Tool Output Controls Lighting Scan Tool Data List Lighting...

Page 2357: ...en applies a ground to the front fog lamp relay control circuit This engages the fog lamp relay and applies voltage through the fog lamp fuse to the front fog lamps Diagnostic Aids There are certain r...

Page 2358: ...t to the body control module BCM The BCM then applies voltage through the backup lamps voltage supply circuit to the left and right backup lamps Conditions for Running the DTC The battery voltage must...

Page 2359: ...e low beam headlamp relay from battery voltage The low beam headlamp relay is soldered to the Underhood Fuseblock The replacement of the relay is accomplished by replacing the underhood fuseblock Two...

Page 2360: ...e is open test the left and right low beam supply voltage circuits for a short to ground If the circuits test normal replace the appropriate head lamp assembly 4 Disconnect the harness connector at an...

Page 2361: ...from the system Reference Information Schematic Reference Headlights Daytime Running Lights DRL Schematics Connector End View Reference Lighting Systems Connector End Views Electrical Information Refe...

Page 2362: ...gh the park lamp fuses and to all the park lamps Conditions for Running the DTC The ignition is ON The park lamps must be commanded on by the headlamp switch Conditions for Setting the DTC The BCM det...

Page 2363: ...g lamps DRL are controlled by the body control module BCM The BCM grounds the DRL relay control circuit in order to energize the DRL relay coil This action places the right and left headlamps in serie...

Page 2364: ...ol The test lamp should turn ON and OFF when changing between the commanded states If the test lamp is always ON test the control circuit for a short to ground If the circuit tests normal replace the...

Page 2365: ...the fault is removed from the system Reference Information Schematic Reference Interior Lights Dimming Schematics Connector End View Reference Lighting Systems Connector End Views Electrical Informati...

Page 2366: ...CM The BCM then applies voltage to the courtesy lamps voltage supply circuit The courtesy lamps are composed of the following components Dome lamps Reading lamps Cargo Lamps Conditions for Running the...

Page 2367: ...bove Threshold Diagnostic Fault Information Circuit System Description The ambient light sensor is used to monitor outside lighting conditions The ambient light sensor provides a voltage signal that w...

Page 2368: ...an tool parameter is greater than 10 5 volts locate and repair a short to voltage in the ambient light sensor signal circuit 5 If circuits test OK replace the BCM Repair Instructions Perform the Diagn...

Page 2369: ...de from current when the fault is removed from the system Reference Information Schematic Reference Interior Lights Dimming Schematics Connector End View Reference Lighting Systems Connector End Views...

Page 2370: ...ars this code from current when the fault is removed from the system Reference Information Schematic Reference Exterior Lights Schematics Connector End View Reference Lighting Systems Connector End Vi...

Page 2371: ...ver Information Center DIC switch Door lock switches Fog Lamp switch Headlamp switch Hazard switch HVAC Control I P cluster Power window switch Power mirror switches PRNDL Radio Rear Seat Audio if equ...

Page 2372: ...es not set If the DTC resets then test for a short to ground in the I P dimming control circuit If the circuit connections test normal replace the BCM 6 If all circuits connections test normal replace...

Page 2373: ...s ON and OFF with a scan tool The test lamp should turn ON and OFF when changing between the commanded states If the test lamp is always ON test the control circuit for a short to ground If the circui...

Page 2374: ...mand from the scan tool Reference Information Schematic Reference Exterior Lights Schematics Connector End View Reference Lighting Systems Connector End Views Electrical Information Reference Circuit...

Page 2375: ...07 The BCM detects short to voltage on the BPPS circuit C0277 09 The BCM detects the BPPS reading is erroneous C0277 4B The BCM detect that the BPPS is not calibrated C0890 03 The BCM detects a volta...

Page 2376: ...e between the BPPS circuit and the BPPS 5 volt reference circuit 7 Verify the scan tool brake pedal position sensor parameter is between 4 7 5 2 volts If less then 4 7 volts test the BPPS circuit for...

Page 2377: ...uit Testing Connector Repairs Testing for Intermittent Conditions and Poor Connections Wiring Repairs Scan Tool Reference Scan Tool Output Controls Lighting Scan Tool Data List Lighting Scan Tool Data...

Page 2378: ...erial data message from the BCM indicates the brakes are applied Action Taken When the DTC Sets The ECM stores the DTC to memory The ECM will record the operating conditions at the time the diagnostic...

Page 2379: ...erial data message from the BCM indicates the brakes are applied Action Taken When the DTC Sets The ECM stores the DTC to memory The ECM will record the operating conditions at the time the diagnostic...

Page 2380: ...e the cause of intermittent conditions Refer to Testing for Intermittent Conditions and Poor Connections Symptom List Refer to a symptom diagnostic procedure from the following list in order to diagno...

Page 2381: ...tion OFF disconnect the harness connector at the appropriate tail lamp assembly 2 Test for less than 1 0 ohm of resistance between the ground circuit terminal B and ground If greater than the specifie...

Page 2382: ...ON observe the Scan Tool Door Lamp Command parameter while OPENING and CLOSING the drive door The reading should change between OFF and ON Circuit System Testing Dome Lamp Switch Circuit Testing 1 Ign...

Page 2383: ...or BCM replacement setup and programming Courtesy Lamps Inoperative Diagnostic Instructions Perform the Diagnostic System Check Vehicle Diagnostic Information prior to using this diagnostic procedure...

Page 2384: ...for an open high resistance 3 Verify the scan tool dome lamp command parameter is OFF If the dome lamp command is not OFF test the signal circuit for a short to ground If the circuit tests normal repl...

Page 2385: ...ilure of the resistor due to corrosion brought on by the original fastening procedure to the frame has been common on this vehicle If replacing the DRL resistor please pay attention to any replacement...

Page 2386: ...ody control module BCM The BCM then supplies ground to the coil side of the fog lamp relay energizing the relay The fog lamp relay is soldered to the underhood fuseblock circuit board The front fog la...

Page 2387: ...CM replacement setup and programming Underhood Electrical Center or Junction Block Replacement Fog Lamps Inoperative Diagnostic Instructions Perform the Diagnostic System Check Vehicle Diagnostic Info...

Page 2388: ...round on the relay coil control circuit If the circuit tests normal replace the BCM If the test lamp remains OFF all the time test for a short to voltage or an open high resistance on the relay coil c...

Page 2389: ...rmation Reference Circuit Testing Connector Repairs Testing for Intermittent Conditions and Poor Connections Wiring Repairs Scan Tool Reference Scan Tool Data Definitions Lighting Scan Tool Data List...

Page 2390: ...switch in the ON position for manual operation Second with the headlamp switch placed in the OFF position activating automatic lamp control ALC The LH HDLP and RH HDLP fuse in the fuse block underhoo...

Page 2391: ...witch which is part of the turn signal multifunction switch Headlamp Relay Circuit Testing 1 Ignition OFF disconnect the high and low beam headlamp relay terminals C2 pin 18 C2 pin 8 C3 pin 9 and C3 p...

Page 2392: ...rence Scan Tool Data Definitions Lighting Scan Tool Data List Lighting Scan Tool Output Controls Lighting Circuit System Verification Ignition ON turn on the headlamps ON with the headlamp switch Cycl...

Page 2393: ...h Testing 1 Ignition OFF disconnect the harness connector at the headlamp switch terminal C1 pin 4 2 Test for infinite resistance between the signal terminal and the voltage supply terminal with the s...

Page 2394: ...ation Ignition ON turn on the headlamps ON with the headlamp switch Cycle the headlamp setting on the multifunction switch between high and low beams Observes the headlamps the headlamps should cycle...

Page 2395: ...or Intermittent Conditions and Poor Connections Wiring Repairs Scan Tool Reference Scan Tool Data Definitions Lighting Scan Tool Data List Lighting Scan Tool Output Controls Lighting Circuit System Ve...

Page 2396: ...ded Circuit System Testing 1 Ignition OFF disconnect the harness connector at the headlamp switch 2 Ignition OFF test for less than 1 ohm of resistance between the ground circuit and ground If greater...

Page 2397: ...the I P dimmer switch Diagnostic Aids An open high resistance in the dimmer switch circuit could cause the back lighting not to dim Reference Information Schematic Reference Interior Lights Dimming Sc...

Page 2398: ...or Connections Wiring Repairs Scan Tool Reference Scan Tool Data Definitions Lighting Scan Tool Data List Lighting Scan Tool Output Controls Lighting Circuit System Verification Ignition ON turn the p...

Page 2399: ...the harness connector at the headlamp switch 2 Verify that the park lamps are OFF If not OFF test the signal circuit for a short to ground If the circuit tests normal replace the BCM 3 Install a 3 amp...

Page 2400: ...within the underhood fuseblock The park lamp relay The headlamp switch turn signal multifunction switch supply circuit The headlamp switch turn signal multifunction switch ground circuit The turn sign...

Page 2401: ...formation provides an overview of each diagnostic category Diagnostic Fault Information Circuit System Description When the roof rail reading lamps switches are in the OFF position the body control mo...

Page 2402: ...ing 1 Ignition OFF remove the reading lamp bulb 2 Test for 1 0 to 4 5 ohms of resistance between the control terminal and the voltage supply terminal of the reading lamp bulb If the resistance is not...

Page 2403: ...amp illuminates between the voltage supply circuit and ground If the test lamp does not illuminate repair the voltage supply circuit for a short to ground or an open high resistance If the voltage sup...

Page 2404: ...test lamp does not illuminate repair the voltage supply circuit for a short to ground or an open high resistance If the voltage supply circuit fuse is open also test the signal circuit for a short to...

Page 2405: ...tion ON observe the right or left turn signal while engaging the turn signal multifunction switch in the appropriate position Circuit System Testing 1 Ignition OFF disconnect the harness connector at...

Page 2406: ...nate Circuit System Testing Turn Signal Multifunction Switch Circuit Testing 1 Ignition OFF disconnect the harness connector at the turn signal multifunction switch 2 Ignition ON install a test lamp b...

Page 2407: ...s connector at the turn signal multifunction switch 2 Test for infinite resistance between the signal terminals C2 pins G and H and the voltage supply terminal C1 pin 3 with the turn signal multifunct...

Page 2408: ...ons Fog Lamp Switch Replacement Callout Component Name 1 Instrument Panel Lower Trim Bezel Refer to Instrument Panel Accessory Trim Plate Replacement 2 Driver Information Center Switch Bracket 3 Rear...

Page 2409: ...acement Callout Component Name 1 Instrument Panel Center Air Outlet Assembly Refer to Instrument Panel Center Air Outlet Replacement 2 Hazard Warning Switch Tip Squeeze tabs together and remove throug...

Page 2410: ...onent Name 1 Instrument Panel Lower Left Trim Panel Assembly Refer to Instrument Panel Lower Trim Panel Replacement Left Side 2 Instrument Panel Dimmer Switch Screw Qty 2 Tightening torque 2 N m 18 lb...

Page 2411: ...r Replacement Callout Component Name 1 Instrument Panel Trim Panel Procedure Remove the instrument panel upper trim pad Refer to Instrument Panel Upper Trim Panel Replacement 2 Ambient Light Sensor Ti...

Page 2412: ...es Remove the front bumper fascia Refer to Front Bumper Fascia Replacement 1 Forward Lamp Wiring Harness Assembly 2 Daytime Running Lamp Resistor Assembly Bolt CAUTION Refer to Fastener Notice Tighten...

Page 2413: ...Lighting Systems 9B 92 Reading Lamp Bulb Replacement Without CF5 Callout Component Name 1 Reading Lamp Lens Tip Use a small flat bladed tool to aid in the removal of the lens 2 Reading Lamp Bulb...

Page 2414: ...9B 93 Lighting Systems Reading Lamp Bulb Replacement With CF5 Callout Component Name Procedure Remove the Overhead Console Assembly Refer to Roof Console Replacement 1 Reading Lamp Bulb...

Page 2415: ...amp Lens Tip Use a small flat bladed tool to aid in the removal of the lens 2 Dome Lamp Assembly Tip 1 Using a small flat bladed tool disengage the dome lamp attaching clips by gently prying at each s...

Page 2416: ...hout DVD Callout Component Name CAUTION Refer to Fastener Notice Fastener Tightening Specifications Refer to Fastener Tightening Specifications Lighting 1 Dome Lamp Lens Tip Use a small flat bladed to...

Page 2417: ...th DVD Callout Component Name CAUTION Refer to Fastener Notice Fastener Tightening Specifications Refer to Fastener Tightening Specifications Lighting 1 Dome Lamp Lens Tip Use a small flat bladed tool...

Page 2418: ...the front bumper fascia Refer to Front Bumper Fascia Replacement 1 Headlamp Bolts Qty 4 CAUTION Refer to Fastener Notice Tightening torque Tighten the bolts in the mandatory sequence as shown to 9 N m...

Page 2419: ...adlamp Replacement 1 Turn Lamp Bulb Socket 2 Turn Lamp Bulb Tip Pull the turn lamp bulb straight from the lamp socket 3 WARNING Refer to Halogen Bulb Caution Headlamp Bulb Hi Lo 4 Park Auxiliary Bulb...

Page 2420: ...ocation it is necessary to paint a reference line on the floor directly under the lens of the lamps to indicate the proper location of the headlamps when they are being aimed Distance between headlamp...

Page 2421: ...ht headlamp bulb centerline 7 At the screen measure from the reference line and place the vertical tape at the measured distance NOTE Do not cover the headlamp this may cause excessive heat build up 8...

Page 2422: ...the fog lamp bracket and lamp assembly 1 Count the number of turns when removing the adjuster screw for a reference upon installation 2 Aim the fog lamps after installation Refer to Fog Lamp Aiming 2...

Page 2423: ...ward Lamp Harness Connector 2 WARNING Refer to Halogen Bulb Caution Fog Lamp Bulb Tip Rotate the lamp socket a quarter turn counter clockwise and remove the bulb socket Callout Component Name Prelimin...

Page 2424: ...height of the vehicle 4 Close the doors and verify that the luggage compartment is empty 5 Stabilize the suspension by rocking the vehicle sideways 6 Ensure that the fuel level is full 7 Ensure that t...

Page 2425: ...ly Refer to Headlamp Replacement 1 Side Marker Lamp Bulb Socket Tip Turn the lamp socket a quarter turn counter clockwise in order to remove the socket from the headlamp assembly 2 Side Marker Lamp Bu...

Page 2426: ...amp Replacement 1 Park Auxiliary Bulb Socket 2 Park Auxiliary Bulb Callout Component Name 1 High Mounted Stop Cargo Lamp Screws Qty 2 CAUTION Refer to Fastener Notice Tightening torque Tighten the scr...

Page 2427: ...ns Tip Use a small flat bladed tool to aid in the removal of the lens 2 Cargo Lamp Assembly Tip 1 Using a small flat bladed tool disengage the cargo lamp attaching clips by gently prying at each side...

Page 2428: ...nt Callout Component Name CAUTION Refer to Fastener Notice Fastener Tightening Specifications Refer to Fastener Tightening Specifications Lighting 1 Cargo Lamp Lens Tip Use a small flat bladed tool to...

Page 2429: ...cket a quarter turn counter clockwise in order to access the bulb 2 Reverse Lamp Bulb Callout Component Name 1 Rear License Plate Lamp Assembly Tip Depress the very small lamp tabs inboard towards the...

Page 2430: ...ftgate 2 License Plate Lamp Socket Tip Twist the lamp socket electrical connector counter clockwise and remove from the lens Replace the bulbs as needed Callout Component Name Preliminary Procedure Op...

Page 2431: ...Callout Component Name Preliminary Procedure Remove either the LR or RR tail lamp assembly Refer to Tail Lamp Replacement 1 Tail Lamp Harness Sockets Tip Turn the socket a quarter turn counter clockwi...

Page 2432: ...ects a loss of class 2 communications with the BCM The BCM detects a loss of CAN communications with the PCM Fuel Gage The PCM sends fuel level percent to the BCM via CAN serial data The IPC displays...

Page 2433: ...BCM via a class 2 message The PCM determines the engine speed and sends a CAN serial data message to the BCM indicating the engine speed The tachometer will default to 0 RPM if The PCM detects a malf...

Page 2434: ...fer to Exterior Lighting Systems Description and Operation Symbol Description Engine Coolant Temperature Refer to the following Cooling System Description and Operation Transmission Indicators and Mes...

Page 2435: ...to ABS Description and Operation MIL Refer to Engine Control Module Description Symbol Description Passenger Air Bag Off Refer to SIR System Description and Operation Passenger Air Bag On Refer to SIR...

Page 2436: ...is low REDUCED ENGINE POWER The instrument panel cluster IPC illuminates the REDUCED POWER indicator when a serial data message from the body control module BCM requests illumination The BCM receives...

Page 2437: ...iver door is open and the signal circuit is low The BCM determines that the key in ignition switch is closed and the signal circuit is low Lights On Warning The BCM activates the lights on warning The...

Page 2438: ...gh personalization For further information refer to Keyless Entry System Description and Operation Circuit Operation Battery positive voltage is applied at all times to the horn relay coil and the hor...

Page 2439: ...Instrumentation Driver Info Horn 9C 8 Indicators...

Page 2440: ...9C 9 Instrumentation Driver Info Horn Gages...

Page 2441: ...Instrumentation Driver Info Horn 9C 10 Driver Information System Schematics...

Page 2442: ...9C 11 Instrumentation Driver Info Horn Audible Warnings Schematics...

Page 2443: ...Instrumentation Driver Info Horn 9C 12 Cigar Lighter Power Outlet Schematics...

Page 2444: ...9C 13 Instrumentation Driver Info Horn Horn Schematics...

Page 2445: ...formation Terminal Tray See Terminal Repair Kit Core Insulation Crimp See Terminal Repair Kit Release Tool Test Probe See Terminal Repair Kit Pin Wire Color Circuit No Function A GY 120 Fuel Pump Supp...

Page 2446: ...on Crimp Pins A E A Core Insulation Crimp Pins B 2 A Release Tool Test Probe 15315247 J 35616 2A GY Pin Wire Color Circuit No Function A BK 1250 Ground B D GN 29 Horn Control Pin Wire Color Circuit No...

Page 2447: ...n Wire Color Circuit No Function A RD WH 2540 Battery Positive Voltage B Not Used C BK 650 Ground Connector Part Information OEM 12176836 Service 15305923 Description 3 Way F Metri Pack 280 Series GY...

Page 2448: ...r 3 Hazard Switch 13 Traction Control Switch TCS 4 Radio 14 Rear Wiper Washer Fog Lamp Switch 5 HVAC Control Module 15 Inflatable Restraint Passenger Airbag ON OFF Indicator 6 Cigar Lighter 16 Inside...

Page 2449: ...Instrumentation Driver Info Horn 9C 18 Horn Component Views Horn Location 1 Horn...

Page 2450: ...9C 19 Instrumentation Driver Info Horn Steering Wheel Components 1 Horn Switch 3 Steering Wheel Control Switch Left UK3 K34 2 Steering Wheel Control Switch Right UK3 K34...

Page 2451: ...itch 13 Traction Control Switch TCS 4 Radio 14 Rear Wiper Washer Fog Lamp Switch 5 HVAC Control Module 15 Inflatable Restraint Passenger Airbag ON OFF Indicator 6 Cigar Lighter 16 Inside Air Temperatu...

Page 2452: ...s DTCs and their status The use of the Diagnostic System Check will identify the correct procedure for diagnosing the system and where the procedure is located Scan Tool Output Controls Displays and G...

Page 2453: ...properly operating vehicle under the conditions specified in the first row of the scan tool data list table Comparison of the parameter values from the suspect vehicle with the typical data values may...

Page 2454: ...jar Sw Doors Door Closed Door Ajar Door Closed Scan Tool Parameter Data List Units Displayed Typical Data Value Operating Conditions Ignition ON Engine OFF Seat Belt Buckled High Beams Off Park Brake...

Page 2455: ...a CMP Actuator Data EVAP Data Fuel Trim Data HO2S Data Ignition Data Induction Data Misfire Data TAC Data Cooling HVAC Data IPC Data Auto Transmission Data Celsius Fahrenheit 85 105 C 185 220 F Engine...

Page 2456: ...rcuit Status IPC Data OK Open Short Invalid State OK MIL Command Engine Data IPC Data On Off Off Reduced Engine Power TAC Data Active Inactive Inactive Vehicle Speed Sensor Engine Data EVAP Data Fuel...

Page 2457: ...coolant temperature Coolant Warning Lamp The scan tool displays On or Off The state of the coolant warning indicator as commanded by the IPC Cruise Control Active The scan tool displays Yes or No The...

Page 2458: ...tool displays On or Off The state of the engine oil pressure indicator as commanded by the IPC Passenger Door Ajar Switch The scan tool displays Door Closed or Door Ajar The state of the passenger doo...

Page 2459: ...econds Action Taken When the DTC Sets The BCM disables the output to the horn relay until the next ignition cycle Conditions for Clearing the DTC The DTC clears when the fault is no longer detected Th...

Page 2460: ...riptor DTC B2965 Key In Ignition Circuit Open Diagnostic Fault Information Circuit Description The ignition switch closes signal circuit is low when the key is in the ignition and opens signal circuit...

Page 2461: ...s the signal circuit of the fuel level sender in order to determine fuel level When the fuel tank is full the sender resistance is low and the ECM senses a low signal voltage When the fuel tank is emp...

Page 2462: ...System Testing 1 Ignition OFF remove the fuel level senders and verify that there is no obstructions interfering with the fuel level senders If interference is present remove the obstruction 2 If no i...

Page 2463: ...rm up cycles 3 The ECM receives the clear code command from the scan tool Diagnostic Aids Using the Failure Records data may help locate an intermittent condition If you cannot duplicate the DTC the i...

Page 2464: ...seconds Action Taken When the DTC Sets The fuel gage defaults to empty The ECM records the operating conditions at the time the diagnostic fails The ECM displays the failure information in the Failur...

Page 2465: ...sender resistance is low and the ECM senses a low signal voltage When the fuel tank is empty the sender resistance is high and the ECM senses a high signal voltage The ECM uses the signal circuit of t...

Page 2466: ...Level Remaining parameter displays the correct fuel level percent If the fuel level percent is incorrect test the signal circuit and the low reference circuit for an open high resistance If the circui...

Page 2467: ...ngine Control Module Connector End Views Electrical Information Reference Circuit Testing Connector Repairs Testing for Intermittent Conditions and Poor Connections Wiring Repairs Scan Tool Reference...

Page 2468: ...Circuit Malfunction Driver Seat Belt Indicator Circuit Malfunction Passenger Traction Control Indicator Always On Traction Control Indicator Inoperative Turn Signal Lamps and or Indicators Inoperative...

Page 2469: ...nce Headlights Daytime Running Lights DRL Schematics Connector End Views Lighting Systems Connector End Views Electrical Information Reference Circuit Testing Connector Repairs Testing for Intermitten...

Page 2470: ...should change between OFF and ON Circuit System Testing 1 Ignition OFF disconnect the harness connector at the fog lamp switch 2 Ignition OFF test for less than 1 ohm of resistance between the ground...

Page 2471: ...cal Information Reference Circuit Testing Connector Repairs Testing for Intermittent Conditions and Poor Connections Wiring Repairs Scan Tool Reference Scan Tool Data Definitions Lighting Scan Tool Da...

Page 2472: ...uit System Testing 1 Ignition OFF disconnect the harness connector at the ignition key alarm switch 2 Ignition ON verify the scan tool Key In Ignition Status parameter is Key Out If not Key Out test t...

Page 2473: ...r ajar switches supply a ground to the BCM when the door is open Once the door is closed the door ajar switch opens canceling the ground to the BCM The BCM sends a signal to the IPC to turn on the doo...

Page 2474: ...Horns Scan Tool Data List Horns Scan Tool Output Controls Horns Circuit System Verification 1 Ignition OFF connect a test lamp between the horn fuse test point and ground 2 Press and release the horn...

Page 2475: ...rhood fuse block and the control circuit terminal B at the horn If greater than the specified range test the control circuit for a high resistance 5 If all circuits test normal test or replace the hor...

Page 2476: ...Module References for the IPC replacement setup and programming Engine Oil Pressure Indicator Always On Diagnostic Instructions Perform the Diagnostic System Check Vehicle Diagnostic Information prio...

Page 2477: ...Testing Connector Repairs Testing for Intermittent Conditions and Poor Connections Wiring Repairs Scan Tool Reference Scan Tool Data List Displays and Gages Circuit System Testing 1 Ignition OFF disc...

Page 2478: ...ch Inoperative Diagnostic Instructions Perform the Diagnostic System Check Vehicle Diagnostic Information prior to using this diagnostic procedure Review Strategy Based Diagnosis for an overview of th...

Page 2479: ...3 Verify the scan tool liftgate ajar switch parameter is low If not low test the signal circuit for a short to ground If the circuit tests normal replace the BCM If the rear hatch indicator is still...

Page 2480: ...igh resistance 3 Verify the scan tool liftgate ajar switch parameter is low If not low test the signal circuit for a short to ground If the circuit tests normal replace the BCM If the rear hatch indic...

Page 2481: ...operly replace the IPC Repair Instructions Perform the Diagnostic Repair Verification Vehicle Diagnostic Information after completing the diagnostic procedure Control Module References for IPC replace...

Page 2482: ...ion Ignition ON observe the right or left turn signal while engaging the turn signal multifunction switch in the appropriate position Circuit System Testing 1 Ignition OFF disconnect the harness conne...

Page 2483: ...ld illuminate Circuit System Testing Turn Signal Multifunction Switch Circuit Testing 1 Ignition OFF disconnect the harness connector at the turn signal multifunction switch 2 Ignition ON install a te...

Page 2484: ...e harness connector at the turn signal multifunction switch 2 Test for infinite resistance between the signal terminals C2 pins G and H and the voltage supply terminal C1 pin 3 with the turn signal mu...

Page 2485: ...Panel Insulator Panel Replacement Right Side Callout Component Name 1 Instrument Panel Closeout Insulator Panel Screws Qty 2 CAUTION Refer to Fastener Notice in Cautions and Notices Tightening torque...

Page 2486: ...sulator Panel Replacement Left Side Callout Component Name 1 Instrument Panel Closeout Insulator Panel Screws Qty 2 CAUTION Refer to Fastener Notice in Cautions and Notices Tightening torque 2 N m 18...

Page 2487: ...er in the neutral position 3 Remove the Shifter Knob Refer to Transmission Control Lever Knob Replacement 1 Instrument Panel Lower Brace Bezel Assembly Tip 1 Use a flat bladed plastic trim tool in ord...

Page 2488: ...Knee Bolster Replacement Callout Component Name 1 Instrument Panel Knee Bolster Screws Qty 2 CAUTION Refer to Fastener Notice in Cautions and Notices Tightening torque 2 N m 18 lb in 2 Instrument Pan...

Page 2489: ...ent Name Preliminary Procedure Remove the Instrument Panel Knee Bolster Refer to Knee Bolster Replacement 1 Instrument Panel Knee Bolster Reinforcement Bolts Qty 4 CAUTION Refer to Fastener Notice in...

Page 2490: ...Panel Lower Brace Bezel Refer to Instrument Panel Lower Brace Bezel Replacement 1 Instrument Panel Accessory Trim Plate Assembly Tip 1 Use a flat bladed plastic trim tool in order to remove the access...

Page 2491: ...trumentation Driver Info Horn 9C 60 Instrument Panel Outer Trim Cover Replacement Callout Component Name 1 Instrument Panel Outer Trim Cover Right or Left 2 Retainer Clips Qty 5 3 Left Side 2 Right Si...

Page 2492: ...Refer to Front Floor Console Side Trim Panel Replacement Right Side 3 Remove the Instrument Panel Accessory Trim Plate Refer to Instrument Panel Accessory Trim Plate Replacement 4 Remove the Instrume...

Page 2493: ...to Instrument Panel Outer Trim Cover Replacement 4 Remove the Right Instrument Panel Lower Trim Panel Refer to Instrument Panel Lower Trim Panel Replacement Right Side 1 Instrument Panel Upper Trim Pa...

Page 2494: ...ument panel upper trim panel Refer to Instrument Panel Upper Trim Panel Replacement 3 Remove the left console trim panel Refer to Front Floor Console Side Trim Panel Replacement Left Side 4 Remove the...

Page 2495: ...rument Panel Upper Trim Panel Refer to Instrument Panel Upper Trim Panel Replacement 3 Remove the left Console Trim Panel Refer to Front Floor Console Side Trim Panel Replacement Left Side 1 Lower Ins...

Page 2496: ...ve the left Console Trim Panel Refer to Front Floor Console Side Trim Panel Replacement Left Side 1 Lower Instrument Panel Trim Panel Assembly Screws Qty 4 CAUTION Refer to Fastener Notice in Cautions...

Page 2497: ...Panel Compartment Door Latch Replacement Callout Component Name 1 Instrument Panel Compartment Latch Screws Qty 3 CAUTION Refer to Fastener Notice in Cautions and Notices Tightening torque 2 N m 18 lb...

Page 2498: ...rtment Door Screws Qty 3 CAUTION Refer to Fastener Notice in Cautions and Notices Tightening torque 2 N m 18 lb in 2 Instrument Panel Compartment Door Assembly Tip 1 Disconnect the Instrument Panel co...

Page 2499: ...Assembly Refer to Instrument Panel Compartment Door Replacement 1 Instrument Panel Compartment Screws Qty 9 CAUTION Refer to Fastener Notice in Cautions and Notices Tightening torque 2 N m 18 lb in 2...

Page 2500: ...el Compartment Door Lock Striker Replacement Callout Component Name 1 Instrument Panel Compartment Assembly Refer to Instrument Panel Compartment Replacement 2 Rivets Qty 4 3 Instrument Compartment St...

Page 2501: ...t Door Dampener Replacement Callout Component Name 1 Instrument Panel Compartment Assembly Refer to Instrument Panel Compartment Replacement 2 Instrument Compartment Dampener Assembly Tip Rotate the D...

Page 2502: ...rumentation Driver Info Horn Ambient Air Temperature Sensor Replacement Callout Component Name 1 Ambient Air Temperature Sensor Retainer 2 Ambient Air Temperature Sensor Tip Disconnect the electrical...

Page 2503: ...ver Information Display Switch Replacement Callout Component Name 1 Instrument Panel Lower Brace Bezel Assembly Refer to Instrument Panel Lower Brace Bezel Replacement 2 Drivers Information Switch Bra...

Page 2504: ...lout Component Name Preliminary Procedure Remove the Instrument Panel Cluster Bezel Refer to Instrument Panel Cluster Trim Plate Bezel Replacement 1 Instrument Panel Cluster Assembly Screws Qty 4 CAUT...

Page 2505: ...ment Panel Cluster Trim Plate Cover Replacement Callout Component Name 1 Instrument Panel Cluster Assembly Refer to Instrument Cluster Replacement 2 Instrument Panel Cluster Trim Plate Tip Unsnap the...

Page 2506: ...panel inflatable restraint Refer to Inflatable Restraint Instrument Panel Module Replacement 5 Remove the radio Refer to Radio Replacement 6 Remove the global positioning system antenna Refer to Globa...

Page 2507: ...ner Assembly Procedures 1 Remove the screws securing the HVAC ducts to the retainer assembly 2 Note the location and routing of the wiring harness and ground straps prior to removal to ensure proper r...

Page 2508: ...g torque 4 N m 36 lb in 2 Instrument Panel Tie Bar to HVAC Module Assembly Nut Qty 1 Tightening torque 4 N m 36 lb in Tip This nut is driven from front of vehicle rearward 3 Instrument Panel Tie Bar t...

Page 2509: ...eptacle can be pulled straight out b Place one side of the T portion of the J 42059 into the tab window The J 42059 will not fit straight into the receptacle Angle the J 42059 slightly for insertion i...

Page 2510: ...Application Specification Metric English Instrument Panel Center Lower Trim Panel Assembly Screws 2 N m 18 lb in Instrument Panel Compartment Screws 2 N m 18 lb in Instrument Panel Compartment Door S...

Page 2511: ...directly to readings taken from the vehicle primary or secondary sending units The values in the table are approximate values based on information obtained from properly operating vehicles Actual res...

Page 2512: ...he wipers at a steady low speed During intermittent operation the BCM will selectively supply B providing the intermittent delay High Operation Front Wipers In the High position the windshield wiper w...

Page 2513: ...Wipers Washers 9D 2 Front Wiper Washer...

Page 2514: ...9D 3 Wipers Washers Rear Wiper Washer...

Page 2515: ...w Wiper Switch Signal F PK BK 1303 Liftgate Ajar Switch Signal Connector Part Information OEM HCMPB 06 K Service 19115655 Description 6 Way F HCM Series BK Terminal Part Information Terminal Tray SHCM...

Page 2516: ...nction A Not Used B YE 196 Windshield Wiper Motor Park Switch Signal C BK 1250 Ground D PU 92 Windshield Wiper Motor High Speed E D GN 95 Windshield Wiper Motor Low Speed Connector Part Information OE...

Page 2517: ...Wipers Washers 9D 6 Component Location Wiper Washer Component Views LF of the Engine Compartment 1 LF Strut Tower 3 Windshield Washer Fluid Pump 2 G103 4 Battery Current Sensor...

Page 2518: ...s Washers Steering Column 1 Turn Signal Multifunction Switch 4 Theft Deterent Module 2 Inflatable Restraint Steering Wheel Module Coil 5 Ignition Lock Solenoid 3 Windshield Wiper Washer Switch 6 Ignit...

Page 2519: ...Switch TCS 4 Radio 14 Rear Wiper Washer Fog Lamp Switch 5 HVAC Control Module 15 Inflatable Restraint Passenger Airbag ON OFF Indicator 6 Cigar Lighter 16 Inside Air Temperature Sensor 7 Transmission...

Page 2520: ...ay and D5 being the longest Wiper High Speed Relay Cmd The scan tool displays the commanded state of the WIPER HIGH PCB relay The parameter displays On when the high speed wipers are commanded on Wipe...

Page 2521: ...tected in the windshield wiper low speed relay control circuit Action Taken When the DTC Sets Low speed wiper operation is suspended Conditions for Clearing the DTC A current DTC will clear when the c...

Page 2522: ...ocedure Review Strategy Based Diagnosis for an overview of the diagnostic approach Diagnostic Procedure Instructions Vehicle Diagnostic Information provides an overview of each diagnostic category DTC...

Page 2523: ...BCM 4 If all circuits test normal replace the underhood fuse block Repair Instructions Perform the Diagnostic Repair Verification Vehicle Diagnostic Information after completing the diagnostic procedu...

Page 2524: ...Reference Wiper Washer Connector End Views Description and Operation Wiper Washer System Description and Operation Electrical Information Reference Circuit Testing Connector Repairs Testing for Inter...

Page 2525: ...iper switch low signal circuit Action Taken When the DTC Sets The BCM will only operate the windshield wipers in the high speed mode Conditions for Clearing the DTC A current DTC will clear when the c...

Page 2526: ...ground Verify the scan tool Windshield Wiper Switch parameter is Switch Fault If not the specified value test the signal circuit for a short to voltage or an open high resistance If the circuit tests...

Page 2527: ...r to a symptom diagnostic procedure from the following list in order to diagnose the symptom Windshield Wiper System Malfunction Front Windshield Wiper System Malfunction Rear Washer Malfunction Front...

Page 2528: ...dshield Wiper Switch Circuit Malfunction 3 Wiper switch in the OFF position verify the scan tool Wiper High Speed Switch parameter is Inactive If not the specified value refer to Windshield Wiper Swit...

Page 2529: ...resistance If the circuit tests normal replace the BCM 4 Connect a test lamp between the control circuit terminal 31 and B 5 Command the high speed wipers ON and OFF using the wiper switch The test la...

Page 2530: ...e Wipers Washer Switch Replacement Wiper Motor Replacement Underhood Electrical Center or Junction Block Replacement Control Module References for BCM replacement setup and programming Windshield Wipe...

Page 2531: ...the ignition circuit terminal D and ground If the test lamp does not illuminate test he ignition circuit for a short to ground or an open high resistance If the circuit tests normal replace the BCM 7...

Page 2532: ...itch ON and OFF The parameter should cycle between Active and Inactive If the parameter does not cycle between the specified values refer to Windshield Wiper Switch Circuit Malfunction 2 Operate the w...

Page 2533: ...test lamp is always ON test the control circuit for a short to ground If the circuit tests normal replace the underhood fuse block If the test lamp is always OFF test the control circuit for a short t...

Page 2534: ...ON test for B between the signal circuit terminal E and ground If less the specified value test the signal circuit for a short to ground or an open high resistance 3 Rear washer switch closed test fo...

Page 2535: ...t Callout Component Name Preliminary Procedures Remove the steering column trim covers Refer to Steering Column Trim Covers Replacement 1 Wipers Washer Switch Electrical Connector 2 Wipers Washer Swit...

Page 2536: ...otice Fastener Tightening Specifications Refer to Fastener Tightening Specifications Wipers Washer Systems 1 Air Inlet Grille Panel Assembly Refer to Air Inlet Grille Panel Replacement 2 Front Windshi...

Page 2537: ...ield Washer Hose Replacement Callout Component Name 1 Rear Windshield Washer Nozzle Tip Rotate the rear washer nozzle 45 degrees counterclockwise and lift the nozzle from the liftgate 2 Rear Liftgate...

Page 2538: ...omponent Name Preliminary Procedure 1 Remove the driver side wheelhouse liner in order to access the washer container fasteners Refer to Front Wheelhouse Liner Replacement 2 Drain the washer solvent i...

Page 2539: ...ent Name Preliminary Procedure Remove the windshield washer container Refer to Washer Solvent Container Replacement 1 Windshield Washer Pump Tip 1 Disconnect the front washer hose from the pump 2 Disc...

Page 2540: ...mponent Name Preliminary Procedure Open the hood in order to access the wiper arm assemblies 1 Windshield Washer Wiper Arm Nut Qty 2 CAUTION Refer to Fastener Notice Tightening torque 28 N m 21 lb ft...

Page 2541: ...torque 28 N m 21 lb ft Tip Hold the blade tip on the first defroster grid line while torquing the wiper arm nut 3 Windshield Washer Arm Assembly Tip Position wiper blade assembly above the blackout st...

Page 2542: ...indshield Wiper Qty 1 Tip Hold the arm and release the locking tab before sliding the blade from the wiper arm 2 Blade Windshield Wiper Qty 1 Tip Slide the blade rearward out of the wiper arm sheep ho...

Page 2543: ...de 3 Insert Wiper Arm Blade Tip 1 Hold the wiper arm blade firmly and pull blade element from blade bear claws 2 Passenger and driver side inserts are not interchangeable Callout Component Name Fasten...

Page 2544: ...efer to Air Inlet Grille Panel Replacement 1 Windshield Washer System Module Assembly Bolts Qty 3 CAUTION Refer to Fastener Notice Tightening torque Tighten the bolts in the mandatory sequence as show...

Page 2545: ...tor Module Replacement 2 Remove the grommets and the bushings from the module Installation Procedure NOTE The metal bushing inserts need to be installed with the flat side underneath the module bolts...

Page 2546: ...to Wiper Motor Module Replacement 1 Windshield Wiper Motor Nut CAUTION Refer to Fastener Notice Fastener Tightening Specifications Refer to Fastener Tightening Specifications Wipers Washer Systems Ti...

Page 2547: ...ds over the right side wheel housing and up the right side pillar where it connects to the washer nozzle hose at the top of the lift gate opening Removal Procedure 1 Locate the damaged section of the...

Page 2548: ...requires the rear washer hose to be removed in the front of dash grommet do the following Cut out the auxiliary washer hose hole from the grommet Pass new section of the rear washer hose through the n...

Page 2549: ...WARNING Wear safety glasses when using compressed air in order to prevent eye injury Window Retention Caution WARNING When replacing stationary windows use Urethane Adhesive Kit GM P N 12346392 Canadi...

Page 2550: ...h warnings Use the urethane adhesive caulking kit for replacement of any urethane adhesive installed window using the full cut method In the United States or Canada you may use any of the following eq...

Page 2551: ...wn position the power window motor down control circuit is switched to 12 volts which is applied to the down side of the rear passenger power window motor Since the other side of the rear passenger po...

Page 2552: ...h through the driver mirror motor left down control circuit then to ground and the mirror will move up If the down switch is pressed the driver mirror motor left down control circuit supplies battery...

Page 2553: ...ntil the letter C or CAL is displayed 3 Drive the vehicle in circles at a speed of less than 8 km h 5 mph until the C or CAL is replaced by a proper vehicle heading The calibration procedure is now co...

Page 2554: ...9E 6 Glass Windows Mirrors Moveable Window Schematics...

Page 2555: ...Glass Windows Mirrors 9E 7 Defogger Schematics...

Page 2556: ...9E 8 Glass Windows Mirrors Inside Rearview Mirror Schematics...

Page 2557: ...Glass Windows Mirrors 9E 9 Outside Rearview Mirror Schematics...

Page 2558: ...1 02 27 Core Insulation Crimp C D Release Tool Test Probe 12094430 J 35616 42 RD Pin Wire Color Circuit No Function 1 BK 550 Ground Connector Part Information OEM 7283 5565 40 Service Description 2 Wa...

Page 2559: ...Tray See Terminal Repair Kit Core Insulation Crimp See Terminal Repair Kit Release Tool Test Probe See Terminal Repair Kit Pin Wire Color Circuit No Function Pin Wire Color Circuit No Function 1 BN 6...

Page 2560: ...sory Voltage E Not Used F L GN 170 Power Window Master Switch Right Rear Up Signal G BK 650 Ground H PU 171 Power Window Master Switch Right Rear Down Signal Connector Part Information OEM 6098 0245 S...

Page 2561: ...BN 671 Power Window Motor Right Rear Down Control 2 PU 171 Power Window Master Switch Right Rear Down Signal 3 Not Used 4 D BU 670 Power Window Motor Right Rear Up Control 5 D BU 1307 Power Window Ma...

Page 2562: ...Repair Kit Pin Wire Color Circuit No Function 1 7 Not Used 8 BK 850 Ground 9 L GN 24 Backup Lamp Supply Voltage 10 12 Not Used 13 YE 643 Accessory Voltage 14 16 Not Used Connector Part Information OEM...

Page 2563: ...r Mirror Motor Left Down Control B WH 881 Passenger Mirror Motor Right Control C L GN 889 Passenger Mirror Motor Down Control Connector Part Information OEM 15327190 Service Description 8 Way F Ducon...

Page 2564: ...rd Switch 13 Traction Control Switch TCS 4 Radio 14 Rear Wiper Washer Fog Lamp Switch 5 HVAC Control Module 15 Inflatable Restraint Passenger Airbag ON OFF Indicator 6 Cigar Lighter 16 Inside Air Temp...

Page 2565: ...Glass Windows Mirrors 9E 17 Rear Window Defogger 1 Rear Defogger Grid 2 Liftgate...

Page 2566: ...9E 18 Glass Windows Mirrors RR Door 1 Window Switch RR 3 Window Motor RR 2 Door Latch RR...

Page 2567: ...Glass Windows Mirrors 9E 19 LR Door 1 Door Latch LR 3 Window Motor LR 2 Window Switch LR...

Page 2568: ...9E 20 Glass Windows Mirrors Passenger Door 1 Door Latch Front Passenger 3 Window Motor Front Passenger 2 Door Lock Switch Front Passenger 4 Outside Rearview Mirror Passenger...

Page 2569: ...Glass Windows Mirrors 9E 21 Driver Door 1 Outside Rearview Mirror Driver 3 Door Lock Switch Driver 2 Window Motor Driver 4 Door Latch Driver...

Page 2570: ...9E 22 Glass Windows Mirrors Mirror Component Views Top of the Windshield 1 Inside Rearview Mirror ISRVM 2 Hood...

Page 2571: ...trol Switch TCS 4 Radio 14 Rear Wiper Washer Fog Lamp Switch 5 HVAC Control Module 15 Inflatable Restraint Passenger Airbag ON OFF Indicator 6 Cigar Lighter 16 Inside Air Temperature Sensor 7 Transmis...

Page 2572: ...9E 24 Glass Windows Mirrors Passenger Door 1 Door Latch Front Passenger 3 Window Motor Front Passenger 2 Door Lock Switch Front Passenger 4 Outside Rearview Mirror Passenger...

Page 2573: ...Glass Windows Mirrors 9E 25 Driver Door 1 Outside Rearview Mirror Driver 3 Door Lock Switch Driver 2 Window Motor Driver 4 Door Latch Driver...

Page 2574: ...round to the rear defog relay control circuit Rear Defog Switch The scan tool displays On Off The BCM receives an input from the HVAC control head indicating On when the rear defog system is turned On...

Page 2575: ...eading does not change between the commanded states refer to Rear Defogger Switch Malfunction in Circuit System Testing 2 Command the rear window defogger ON and OFF with the scan tool The rear window...

Page 2576: ...l module and BCM replacement setup and programming Symptoms Fixed and Moveable Windows NOTE The following steps must be completed before using the symptom tables 1 Perform the Diagnostic System Check...

Page 2577: ...motor is internally circuit breaker protected Battery voltage is supplied to the main power window switch through the accessory voltage supply circuit The main power window switch also receives a cons...

Page 2578: ...rify that a test lamp illuminates between the B circuit terminal 1 and ground If the test lamp does not illuminate test the B circuit for an open high resistance If the PWR WDW fuse is open check the...

Page 2579: ...st lamp remains OFF during either of the commands test for a short to ground on either control circuit If the circuits test normal test or replace the appropriate rear door Window Switch 13 If all cir...

Page 2580: ...riate rear Window switch 4 Test for less than 2 ohms of resistance between the signal terminal 1 and the B circuit terminal 5 with the switch in the DOWN position If greater than 2 ohms replace the ap...

Page 2581: ...DEFOG relay 2 Ignition OFF test for less than 1 0 ohm of resistance between the relay coil ground circuit terminal 25 and ground If greater than the specified range test for an open high resistance 3...

Page 2582: ...and a high light condition from behind at the headlight sensor the inside rearview mirror will automatically darken the face of the mirror Diagnostic Aids The automatic day night feature of the insid...

Page 2583: ...Switch Circuit Testing 1 Ignition OFF disconnect the harness connector at the outside rearview mirror switch 2 Test for less than 1 ohm of resistance between the ground circuit and ground If greater...

Page 2584: ...or an overview of the diagnostic approach Diagnostic Procedure Instructions Vehicle Diagnostic Information provides an overview of each diagnostic category Circuit System Description The inside rearvi...

Page 2585: ...temperature should not be taken from a radio station a sign displaying the temperature ECT A temperature measuring tool such as a thermometer should be used Some temperature measuring tools may be wit...

Page 2586: ...t air temperature sensor resistance reading with the chart above If the resistance is not within the specified range replace the ambient air temperature sensor Repair Instructions NOTE Always perform...

Page 2587: ...been eliminated or other leak areas exist 5 When all the reported leak conditions are located make permanent repairs using the proper alignment techniques and the sealing materials Interior Windnoise...

Page 2588: ...r quarter aiming the water spray 30 degrees down and 45 degrees toward the rear 7 In order to check the back window aim the water spray 30 degrees down and 30 degrees toward the front 1 Pipe 0 5 x 36...

Page 2589: ...points inside of the vehicle for any points where the light shines through Inspect the weld joints Inspect the body mounts 10 Seal any leaks with an air drying body sealing compound Water Hose Test N...

Page 2590: ...ector on high speed and in the defrost mode 4 Unlock and close the doors 5 Listen for escaping air along the door and the window seals with a stethoscope or a length of heater hose Soap Suds or Bubble...

Page 2591: ...r mounting base will be at the intersection of these lines 2 Scrape the inside windshield glass thoroughly with a safety razor or utility knife in order to remove all old adhesive 3 If reinstalling th...

Page 2592: ...pe around the perimeter of the painted surfaces and the interior trim 1 Open the hood 2 Remove the windshield wiper arms and blades Refer to Wiper Arm Replacement 3 Remove the air inlet grille Refer t...

Page 2593: ...f Stationary Windows Windshield Adhesive Installation of Stationary Windows Liftgate 2 Install the rearview mirror Refer to Rearview Mirror Replacement 3 Install the windshield frame appliques Refer t...

Page 2594: ...provide a clean primer only surface Materials such as BASF DE15 DuPont 2610 Sherwin Williams PSE 4600 and NP70 and Martin Semour 5120 and 5130 PPG DP90LF SPIES HECKER 3688 8590 3688 5150 4070 5090 STA...

Page 2595: ...an assistant dry fit the window 1 to the opening in order to determine the correct position 12 If equipped ensure that the windshield locator pins are positioned into the locator slots on the upper pi...

Page 2596: ...lean lint free cloth 16 Apply a second coat of the glass prep clear 1 to the same area of the glass NOTE The glass primer black 2 is effective up to 8 hours after applying it to the glass The primed s...

Page 2597: ...ane adhesive 22 Use the edge of the window or the inside edge of the reveal molding as a guide for the nozzle in order to apply the urethane adhesive 1 to the inner surface of the window 3 23 With the...

Page 2598: ...at the leak point 31 Retest the window for leaks WARNING Insufficient curing of urethane adhesive may allow unrestrained occupants to be ejected from the vehicle resulting in personal injury For the...

Page 2599: ...out of the window regulator guide plate 7 Slide the window down and out of the primary window run channels 8 Remove the window by tilting outboard and pulling the window out of the door Installation P...

Page 2600: ...ector Refer to Rear Side Door Water Deflector Replacement 4 Remove the door frame appliques Refer to Front Door Frame Applique Replacement 5 Lower window to access the window release tab 6 Remove the...

Page 2601: ...tices 3 Install the window run channel bolts Tightening torque Tighten the bolts to 8 N m 71 lb in 4 Install the rear door water deflector Refer to Rear Side Door Water Deflector Replacement 5 Install...

Page 2602: ...ohol or equivalent Cartridge type Caulking Gun Commercial type Utility Knife Razor Blade Scraper Suction Cups Plastic Paddle Removal Procedure WARNING Refer to Cracked Window Caution 1 Remove the rear...

Page 2603: ...e adhesive Leave a base of urethane approximately 2 mm 0 078 in on the pinch weld flange The only suitable lubrication is clear water Use the J 24402 A J 39032 or equivalent in order to remove the qua...

Page 2604: ...e refinished in order to restore the bonding area strength If paint repairs are required mask the flange bonding area prior to applying the color coat in order to provide a clean primer only surface M...

Page 2605: ...23 Use a soft spray of warm water in order to immediately water test the window 24 Inspect the window for leaks 25 If any leaks are found use a plastic paddle in order to apply extra urethane adhesiv...

Page 2606: ...to protect from broken glass Upper dash pad Defroster outlets and A C outlets Seats and carpeting WARNING Refer to Glass and Sheet Metal Handling Caution NOTE Keep the cutting edge of the tool against...

Page 2607: ...P70 and Martin Semour 5120 and 5130 PPG DP90LF SPIES HECKER 3688 8590 3688 5150 4070 5090 STANDOX 11158 13320 14653 14980 products are approved for this application 5 After repairing the opening as in...

Page 2608: ...ndow from the opening NOTE Use care when applying clear 1 glass prep on the window This primer dries almost instantly and may stain the viewing area of the window if not applied evenly 15 Use a new da...

Page 2609: ...dge of the reveal molding as a guide for the nozzle in order to apply the urethane adhesive 1 to the inner surface of the window 3 NOTE The liftgate glass must be installed to the liftgate opening wit...

Page 2610: ...may allow unrestrained occupants to be ejected from the vehicle resulting in personal injury For the moisture curing type of urethane adhesive allow a minimum of 6 hours at 21 C 70 F or greater and wi...

Page 2611: ...the window if not applied evenly 2 Use a new dauber in order to apply glass prep clear 1 to the channel area approximately 13 mm 1 2 in to the upper edge of the window 3 Wipe the glass primed area imm...

Page 2612: ...Door Window Switch Replacement Callout Component Name 1 Instrument Panel Lower Trim Bezel Refer to Instrument Panel Accessory Trim Plate Replacement 2 Power Window Switch Assembly Tip Use a flat blad...

Page 2613: ...Specifications Fixed and Moveable Windows Preliminary Procedure 1 Remove rear door handle bezel Refer to Door Handle Bezel Replacement 2 Remove rear door trim panel Refer to Rear Side Door Trim Panel...

Page 2614: ...arness at the door jamb 10 Remove the window regulator module from the door Installation Procedure 1 Install the window regulator module into the door 2 Connect the door harness at the door jamb CAUTI...

Page 2615: ...ighten the front door window regulator motor to door screws to 8 N m 71 lb in 3 Connect the electrical connector to the front door window regulator motor 4 Install the water deflector Refer to Front S...

Page 2616: ...Radio Rear Side Door Speaker Replacement in Entertainment 7 Install the rear door window run channel assembly Refer to Rear Side Door Window Channel Replacement 8 Install the rear door outside handle...

Page 2617: ...trical connector to the rear door window regulator motor 4 Install the water deflector Refer to Rear Side Door Water Deflector Replacement 5 Install the rear door trim panel Refer to Rear Side Door Tr...

Page 2618: ...89 lb in 3 Connect the electrical connector to the mirror if equipped 4 Inspect the operation of the mirror 5 Install the front door upper trim panel extension Refer to Front Side Door Trim Panel Repl...

Page 2619: ...FF inspect the SDM mounting area including the carpet If any significant soaking or evidence of significant soaking is detected you must perform the following tasks 1 Remove all water 2 Repair the wat...

Page 2620: ...could result in possible air bag deployment personal injury or otherwise unneeded SIR system repairs 1 If the floor carpet is wet refer to Floor Carpet Drying 2 Remove the trim moldings or the headli...

Page 2621: ...oveable Windows Illustration Tool Number Description J 39570 Chassis Ear J 41416 Ultrasonic Leak Detector Illustration Tool Number Description J 24402 A Glass Sealant Cold Knife Remover J 33431 C Sign...

Page 2622: ...ltage This will energize the appropriate lock or unlock relay s The relay will supply voltage to the door lock actuator lock or unlock control circuits to one side of the lock actuator Since the oppos...

Page 2623: ...rammed to a single vehicle Keyless Entry Antenna The keyless entry antenna is used to receive radio frequency RF communications sent by the keyless entry transmitters The keyless entry antenna also re...

Page 2624: ...S event while already operating in RVS the first timer will expire and the second timer will start For example if 7 minutes after the initial RVS request the RVS event is extended the total time for t...

Page 2625: ...e drivers For mode descriptions and programming instructions refer to the vehicle owners manual Rolling Code The Keyless Entry System uses rolling code technology Rolling code technology prevents anyo...

Page 2626: ...Circuit Description The following is a description of each component used in the content theft deterrent CTD system Body Control Module BCM The CTD system is an internal function of the body control...

Page 2627: ...Security and Locks 9F 6 Schematic and Routing Diagram Door Lock Indicator Schematics...

Page 2628: ...9F 7 Security and Locks Door Lock Motors and Relays...

Page 2629: ...Security and Locks 9F 8 Door Latches and Switches...

Page 2630: ...9F 9 Security and Locks Release Systems Schematics...

Page 2631: ...Security and Locks 9F 10 Remote Function Schematics...

Page 2632: ...9F 11 Security and Locks Theft Deterrent System Schematics...

Page 2633: ...Security and Locks 9F 12 Theft Deterrent...

Page 2634: ...ock Actuator Unlock Control 3 GY 295 Door Lock Actuator Lock Control 4 RD BK 745 Left Front Door Ajar Switch Signal 5 PU 294 Door Lock Actuator Unlock Control 6 BK 651 Ground Connector Part Informatio...

Page 2635: ...ce 88986251 Description 6 Way F Sealed BK Terminal Part Information Terminal Tray See Terminal Repair Kit Core Insulation Crimp See Terminal Repair Kit Release Tool Test Probe See Terminal Repair Kit...

Page 2636: ...round Connector Part Information OEM 15476199 Service 88988358 Description 6 Way F GT 280 Sealed GN Terminal Part Information Terminal Tray 15304719 19 Core Insulation Crimp E 5 Release Tool Test Prob...

Page 2637: ...ase Tool Test Probe 15315247 J 35616 2A GY Pin Wire Color Circuit No Function A PK BK 109 Hood Ajar Switch Signal B PU 5531 Hood Closed Switch Signal C BK 1250 Ground Connector Part Information OEM IL...

Page 2638: ...9F 17 Security and Locks Component Location Vehicle Access Component Views Driver Door 1 Outside Rearview Mirror Driver 3 Door Lock Switch Driver 2 Window Motor Driver 4 Door Latch Driver...

Page 2639: ...Security and Locks 9F 18 Passenger Door 1 Door Latch Front Passenger 3 Window Motor Front Passenger 2 Door Lock Switch Front Passenger 4 Outside Rearview Mirror Passenger...

Page 2640: ...9F 19 Security and Locks LR Door 1 Door Latch LR 3 Window Motor LR 2 Window Switch LR...

Page 2641: ...Security and Locks 9F 20 RR Door 1 Window Switch RR 3 Window Motor RR 2 Door Latch RR...

Page 2642: ...R 7 Backup Lamp Right 2 Rear Defogger Grid 8 License Lamp Right 3 Center High Mounted Stop Lamp CHMSL 9 Liftgate Switch 4 Digital Radio Antenna U2K 10 License Lamp Left 5 Park Stop Lamp RR 11 Park Tur...

Page 2643: ...Security and Locks 9F 22 Liftgate Latch Location 1 Liftgate Latch...

Page 2644: ...9F 23 Security and Locks Remote Function Component Views Below the RR Window 1 Remote Control Door Lock Receiver RCDLR 2 Remote Control Door Lock Receiver RCDLR Antenna...

Page 2645: ...ng Point Theft Deterrent Begin the system diagnosis with the Diagnostic System Check Vehicle Diagnostic Information The Diagnostic System Check will provide the following information The identificatio...

Page 2646: ...anic Cmd Door Locks Yes No No Remote Unlock Cmd Door Locks Yes No No Unlock Switch Door Locks Switch Inputs On Off Off Scan Tool Parameter Data List Units Displayed Typical Data Value Operating Condit...

Page 2647: ...Closure Rel Lt Sliding Ctrl Rt Sliding Ctrl Panic Fuel Door Power Window Power Top Engine Start Engine Stop Fob Program Locate R Closure Close R Closure Open Double Lock R Closure Stop R Closure Star...

Page 2648: ...ircuit Remote Lock Cmd The scan tool displays Yes No This input to the BCM displays the state of the door lock request from the remote keyless entry RKE transmitter Yes is displayed when the RKE trans...

Page 2649: ...nstructions Perform the Diagnostic System Check Vehicle Diagnostic Information prior to using this diagnostic procedure Review Strategy Based Diagnosis for an overview of the diagnostic approach Diagn...

Page 2650: ...air Verification Vehicle Diagnostic Information after completing the diagnostic procedure Control Module References for BCM replacement setup and programming Instrument Panel Electrical Center or Junc...

Page 2651: ...c Procedure Instructions Vehicle Diagnostic Information provides an overview of each diagnostic category DTC Descriptor DTC B3109 Keyless Entry Transmitter 1 or Generic Low Battery Circuit System Desc...

Page 2652: ...ns Wiring Repairs Scan Tool Reference Scan Tool Data List Remote Functions Circuit System Testing 1 Replace the batteries in the transmitter and with the scan tool clear the DTC 2 Operate the transmit...

Page 2653: ...B3112 Keyless Entry Transmitter 4 or Generic Low Battery Circuit System Description This fault sets if the key fob programmed to slot 4 has a low battery Conditions for Running the DTC The remote fun...

Page 2654: ...ontrol circuit while commanding the door lock relay Action Taken When the DTC Sets The BCM stores the DTC to memory The power door locks will not operate Conditions for Clearing the DTC This DTC will...

Page 2655: ...p is always OFF test the control circuit for a short to voltage or and open high resistance If the circuit tests normal replace the BCM 8 If all circuits tests normal replace the I P fuse block Repair...

Page 2656: ...Reference Scan Tool Data List Vehicle Access Scan Tool Data Definitions Vehicle Access Scan Tool Output Controls Vehicle Access Circuit System Testing 1 Ignition OFF disconnect the harness connector...

Page 2657: ...he DTC to memory The lift switch will be inoperative Conditions for Clearing the DTC This DTC will change from current to history when the fault is no longer present A history DTC will clear after 100...

Page 2658: ...s include the following Inspect for aftermarket devices which could affect the operation of the power door systems Refer to Checking Aftermarket Accessories Inspect the easily accessible or visible sy...

Page 2659: ...he following list in order to diagnose the symptom Keyless Entry System Inoperative Remote Vehicle Start Inoperative Symptoms Theft Deterrent NOTE The following steps must be completed before using th...

Page 2660: ...Trunk Liftglass Rel Sw parameter while pressing and releasing the liftgate switch The reading should change between Active and Inactive If the reading does not change between Active and Inactive refer...

Page 2661: ...te release ON and OFF by pressing the liftgate switch The test lamp should turn ON and OFF when changing between the commanded states If the test lamp is always ON test the control circuit for a short...

Page 2662: ...osed contacts of the lock or unlock relay the doors will then lock appropriately The remaining unlock relays receive voltage from the underhood fuse block the BCM upon receipt of a unlock signal or dr...

Page 2663: ...ll circuits test normal test or replace the appropriate door lock switch Door Lock Malfunction 1 Ignition OFF disconnect the harness connector C1 at the I P fuse block 2 Ignition OFF test for less tha...

Page 2664: ...FF disconnect the harness connector at the applicable door lock switch 2 Test for infinite resistance between the signal terminals U and L and the ground terminal C with the switch in the open positio...

Page 2665: ...to determine that it is the correct model for the vehicle A wrong model transmitter may pass the test but it will not activate the vehicle remote system Reference Information Schematic Reference Remo...

Page 2666: ...nt hazard switch DTC is set The vehicle hood is ajar A current hood ajar DTC is set The CTD system detects an alarm trigger Excessive engine RPM Excessive coolant temperature Accelerator pedal positio...

Page 2667: ...he keyless entry system by pressing the transmitter LOCK button twice Verify the scan tool CTD Status parameter displays Armed If the parameter does not equal the specified value refer to Keyless Entr...

Page 2668: ...er wire between the control circuit terminal 7 and ground 4 Ignition ON verify the security indicator is illuminated If indicator does not illuminate test the circuit for an open high resistance If ci...

Page 2669: ...dle housing 2 Installation Procedure 1 Install the lock cylinder to the outside door handle housing 2 2 Install the lock cylinder retainer clip 1 3 Install the front door window regulator module Refer...

Page 2670: ...ove the latch from the latch arm by twisting Installation Procedure 1 Install the latch to the latch arm by twisting 2 Connect the inside handle rod and lock button rod by aligning the rods with clips...

Page 2671: ...tor module Refer to Front Side Door Window Regulator Replacement Rear Side Door Latch Replacement Removal Procedure 1 Remove the rear door window regulator module Refer to Rear Side Door Window Regula...

Page 2672: ...wisting the latch 7 Remove the latch from the latch arm by twisting Installation Procedure 1 Install the latch to the latch arm by twisting 2 Connect the inside handle rod and lock button rod by align...

Page 2673: ...rity and Locks 9F 52 5 Install the outside handle bracket 6 Connect the outside handle rod to the latch 7 Install the rear door window regulator module Refer to Rear Side Door Window Regulator Replace...

Page 2674: ...Procedure Remove the liftgate lower trim panel Refer to Liftgate Trim Panel Replacement Upper Liftgate Trim Panel Replacement Lower 1 Liftgate Latch Bolts Qty 2 CAUTION Refer to Fastener Notice Tight...

Page 2675: ...drags on the striker causing the door to move upward or downward upon contact with the striker Also note the closing effort to fully engage the latch 3 Using a grease pencil mark around the striker f...

Page 2676: ...illar in the area of the side impact sensor SIS Turn OFF the ignition and remove the key when performing service in the area of the SIS 1 Front Side Door Lock Striker Bolt Qty 2 CAUTION Refer to Faste...

Page 2677: ...drags on the striker causing the door to move upward or downward upon contact with the striker Also note the closing effort to fully engage the latch 3 Using a grease pencil mark around the striker f...

Page 2678: ...nt Name 1 Rear Side Door Latch Striker Bolt Qty 2 CAUTION Refer to Fastener Notice Tightening torque 25 N m 18 lb ft 2 Rear Side Door Latch Striker Tip Ensure proper alignment after installation Refer...

Page 2679: ...er with a grease pencil for reference of original position 3 Loosen striker bolts 4 Move the striker to eliminate drag on striker and liftgate latch and to achieve proper liftgate position within the...

Page 2680: ...tgate Door Sill Plate Replacement 1 Liftgate Lock Striker Screws Qty 2 CAUTION Refer to Fastener Notice Tip Mark the location of the striker with a grease pencil for installation purposes Tightening t...

Page 2681: ...pper Extension Trim Panel Replacement Front Side Door 2 Remove front door handle bezel Refer to Door Handle Bezel Replacement 3 Remove front door trim panel Refer to Front Side Door Trim Panel Replace...

Page 2682: ...volt battery or equivalent 1 Use a small coin or flat head screwdriver to separate the bottom of the transmitter from the top CAUTION Do not use sharp objects to help slide the battery out of the cli...

Page 2683: ...he keyless entry program mode This prevents the programming of the transmitters to the incorrect vehicle 1 With a scan tool access the Remote Control Door Lock Receiver Module Setup menu Select Progra...

Page 2684: ...ing the remote control door lock receiver module Transmitter Programming Callout Component Name Preliminary Procedures Remove the right side lock pillar upper garnish molding Refer to Lock Pillar Uppe...

Page 2685: ...t Info under Service Programming System and follow the scan tool on screen instructions 11 Disconnect the scan tool from the vehicle and connect the scan tool to a Techline Terminal with the current S...

Page 2686: ...rn OFF the ignition and wait 2 minutes 19 With a master vehicle key turn the ignition to the RUN position for 15 seconds then start the vehicle The TDM and ECM have now relearned the pre release passw...

Page 2687: ...omponents Driver seat adjuster switch Controls the up down and recline operation of the drivers seat Driver seat horizontal motor Moves the seat rearward and forward Driver seat vertical motor Moves t...

Page 2688: ...sends a GMLAN message back to the CCP to either illuminate or turn off the appropriate temperature indicator Temperature Regulation When the ignition is turned to the ON position the heated seats will...

Page 2689: ...Seats 9G 3 Driver Seat Schematics...

Page 2690: ...9G 4 Seats Heated Cooled Seat Schematics...

Page 2691: ...l Motor Forward Control C BK 284 Driver Seat Horizontal Motor Rearward Control D D GN 286 Driver Seat Front Vertical Motor Up Control E D BU 287 Driver Seat Front Vertical Motor Down Control F L BU 28...

Page 2692: ...ice 12126020 Description 2 Way M Metri Pack 150 Series GN Terminal Part Information Terminal Tray See Terminal Repair Kit Core Insulation Crimp See Terminal Repair Kit Release Tool Test Probe See Term...

Page 2693: ...erminal Part Information Terminal Tray See Terminal Repair Kit Core Insulation Crimp See Terminal Repair Kit Release Tool Test Probe See Terminal Repair Kit Pin Wire Color Circuit No Function A GY 243...

Page 2694: ...e 7 Not Used 8 PK 2435 Passenger Heated Seat Cushion Temperature Sensor Low Reference Connector Part Information OEM 7283 9040 Service 15127042 Description 10 Way F BK Terminal Part Information Termin...

Page 2695: ...ver Seat 1 Seat Belt Switch Driver 5 Seat Adjuster Switch Driver AG1 2 Seat Horizontal Motor Driver AG1 6 Seat Rear Vertical Motor Driver AG1 3 Heated Seat Element Driver Cushion KA1 7 Seat Front Vert...

Page 2696: ...flatable Restraint Passenger Presence PPS Sensor 5 Heated Seat Element Front Passenger Cushion KA1 2 Seat Frame 6 Heated Seat Control Module KA1 3 Heated Seat Element Front Passenger Back KA1 7 Inflat...

Page 2697: ...witch Driver 5 Seat Adjuster Switch Driver AG1 2 Seat Horizontal Motor Driver AG1 6 Seat Rear Vertical Motor Driver AG1 3 Heated Seat Element Driver Cushion KA1 7 Seat Front Vertical Motor Driver AG1...

Page 2698: ...pressed a second time Low will be displayed indicating the low temperature setting Driver Seat HVC Mode The scan tool displays Off Back Cushion When the heated seat is enabled the scan tool parameter...

Page 2699: ...s Vehicle Diagnostic Information provides an overview of each diagnostic category DTC Descriptors DTC B1395 02 Analog Reference Voltage Below Threshold DTC B1395 05 Analog Reference Voltage Above Thre...

Page 2700: ...rcuit of the heating elements ON and OFF in order to maintain the desired seat temperature based on the feedback voltage from the sensor Conditions for Running the DTC The heated seat module must be p...

Page 2701: ...est the signal circuit for a short to ground If the circuit tests normal replace the heated seat module 6 If all circuits test normal replace the heated seat module B2170 Right Seat Cushion Sensor 1 I...

Page 2702: ...g the DTC The heated seat module must be powered Conditions for Setting the DTC B2345 00 After the heated seat is activated the heated seat module detects a short on either the heating element supply...

Page 2703: ...nd 5 Ignition ON verify that a test lamp does not illuminate between the supply voltage circuit terminal 6 and ground If the test lamp illuminates test the supply voltage circuit and the heating eleme...

Page 2704: ...driver seat cushion When the heated seat is active the module applies power through a common voltage supply circuit to the seat heater elements The module controls the seat temperature by providing a...

Page 2705: ...upply voltage circuit terminal A and the control circuit terminal B If greater than the specified range replace the seat back heating element 3 Connect the harness connector at the seat back heating e...

Page 2706: ...erence circuit for a short to voltage or an open high resistance If the circuits test normal replace the seat temperature sensor If less than the specified range test for a short between the signal an...

Page 2707: ...C The heated seat module must be powered Conditions for Setting the DTC B2508 01 The heated seat module detects a short to voltage on the heater element supply voltage circuit or control circuit B2508...

Page 2708: ...ir Verification Vehicle Diagnostic Information after completing the diagnostic procedure Driver Seat Back Cushion Heater and Passenger Seat Back Cushion Heater Replacement Non Fold Flat Driver Seat Ba...

Page 2709: ...gnostic procedure from the following list in order to diagnose the symptom Power Seat Inoperative Symptoms Seat Heating and Cooling NOTE The following steps must be completed before using the symptom...

Page 2710: ...appropriate seat adjuster switch in both directions Does the test lamp illuminate while the switch is operated in both directions Go to Step 11 Go to Step 7 7 1 Disconnect the power seat switch conne...

Page 2711: ...adjusters as an assembly Replace both sides at the same time The seat adjusters were not parallel during installation 1 Loosen the rear seat bolts 2 Position the seat fully forward 3 Tighten the bolt...

Page 2712: ...iate seat temperature indicator Reference Information Schematic Reference Heated Cooled Seat Schematics Connector End View Reference Heated Cooled Seat Connector End Views Electrical Information Refer...

Page 2713: ...Seats 9G 27 Repair Instructions Front Seat Adjuster Switch Knob Replacement Callout Component Name 1 Front Seat Adjuster Switch Knob Tip Using a flat bladed tool remove the knob from the seat switch...

Page 2714: ...ecliner Outer Trim Panel Replacement Fold Flat Callout Component Name 1 Front Seat Outer Recliner Finish Panel Screw Qty 2 CAUTION Refer to Fastener Notice Tightening torque 2 N m 18 lb in 2 Front Sea...

Page 2715: ...ecliner Inner Trim Panel Replacement Fold Flat Callout Component Name 1 Front Seat Inner Recliner Finish Panel Screw Qty 2 CAUTION Refer to Fastener Notice Tightening torque 2 N m 18 lb in 2 Front Sea...

Page 2716: ...cliner handle by pulling firmly forward 3 Remove the front seat outer adjuster finish cover Refer to Front Seat Cushion Outer Trim Panel Replacement Non Fold Flat Front Seat Cushion Outer Trim Panel R...

Page 2717: ...Seats 9G 31 Driver Seat Recliner Handle and Passenger Seat Recliner Handle Replacement Callout Component Name 1 Front Seat Recliner Handle Tip Pull firmly forward on the handle to remove...

Page 2718: ...recliner cable from the inner recliner cable clip 4 Remove the seat recliner cable from the outer recliner mechanism Installation Procedure 1 Install the seat recliner cable mechanism into the outer...

Page 2719: ...ish Cover Screw Qty 2 CAUTION Refer to Fastener Notice Tightening torque 2 5 N m 22 lb in 3 Front Seat Outer Adjuster Finish Cover Tip Disconnect the electrical connector 4 Front Seat Adjuster Switch...

Page 2720: ...ent Name 1 Front Seat Recliner Handle Tip Pull firmly forward on the handle to remove 2 Front Seat Outer Adjuster Finish Cover Screw Qty 2 CAUTION Refer to Fastener Notice Tightening torque 2 5 N m 22...

Page 2721: ...me 1 Front Seat Outer Recliner Finish Panel Screw Qty 2 CAUTION Refer to Fastener Notice Tightening torque 2 N m 18 lb in 2 Front Seat Outer Recliner Finish Panel 3 Front Seat Outer Adjuster Finish Pa...

Page 2722: ...me 1 Front Seat Belt Buckle Bolt CAUTION Refer to Fastener Notice Tightening torque 2 N m 18 lb in 2 Front Seat Belt Buckle Refer to Front Seat Belt Buckle Replacement 3 Front Seat Inner Adjuster Fini...

Page 2723: ...ront Seat Inner Adjuster Lower Finish Cover Screw Qty 2 CAUTION Refer to Fastener Notice Tightening torque 2 N m 18 lb in 2 Front Seat Inner Adjuster Lower Finish Cover 3 Seat Inner Adjuster Upper Fin...

Page 2724: ...ulder belt from the seat quick disconnect feature by using a flat bladed tool to press the tab 3 Remove the front seat adjuster bolts 4 Move the seat to the full rearward position 5 Disconnect the sea...

Page 2725: ...ront adjuster hooks in the floor pan 3 Connect the seat electrical connectors 4 Position the seat in the fully forward position to expose the rear bolt locations CAUTION Refer to Fastener Notice in Ca...

Page 2726: ...Finish Panel Refer to Front Seat Cushion Inner Trim Panel Replacement Non Fold Flat Front Seat Cushion Inner Trim Panel Replacement Fold Flat 5 Front Seat Lumbar Support Actuator Knob Tip 1 Adjust th...

Page 2727: ...and Pad Replacement 1 Front Seat Back Recliner Nut Qty 6 CAUTION Refer to Fastener Notice Tightening torque 45 N m 33 lb ft 2 Front Seat Cushion Frame Bolt Qty 4 Tightening torque 12 N m 9 lb ft 3 Fr...

Page 2728: ...Cushion Cover and Pad Replacement 1 Front Seat Back Recliner Nuts CAUTION Refer to Fastener Notice Tightening torque 45 N m 33 lb ft 2 Front Seat Cushion Frame Bolt Qty 4 Tightening torque 12 N m 9 l...

Page 2729: ...43 Front Seat Back Panel Replacement Fold Flat Callout Component Name 1 Front Seat Back Finish Panel Screw Qty 2 CAUTION Refer to Fastener Notice Tightening torque 2 N m 18 lb in 2 Front Seat Back Fin...

Page 2730: ...ead Restraint Guide Replacement Non Fold Flat Callout Component Name 1 Front Seat Head Restraint Tip 1 Push the button in and raise the head restraint to the full up position 2 Insert a small round to...

Page 2731: ...up the trim cover disengaging the hook and loop retainers until the headrest guides are exposed 3 Squeeze the locking tabs on the headrest guide and pull the guides up and out of the seat back pad Ca...

Page 2732: ...re 1 Remove the front seat Refer to Front Seat Replacement Bucket 2 Remove the seat cushion cover and pad Refer to Front Seat Cushion Cover and Pad Replacement 1 Front Seat Cushion Frame Bolt Qty 4 CA...

Page 2733: ...fer to Front Seat Cushion Inner Trim Panel Replacement Non Fold Flat Front Seat Cushion Inner Trim Panel Replacement Fold Flat 4 Front Seat Head Restraint Refer to Front Seat Head Restraint Replacemen...

Page 2734: ...ment Fold Flat 4 Front Seat Inner Adjuster Finish Panel Refer to Front Seat Cushion Inner Trim Panel Replacement Non Fold Flat Front Seat Cushion Inner Trim Panel Replacement Fold Flat 5 Front Seat Ba...

Page 2735: ...nt guide and pull the guides up and out of the seat back pad 3 Seat Back Cushion Cover and Pad Refer to Front Seat Back Cushion Cover and Cushion Pad Replacement Non Fold Flat Front Seat Back Cushion...

Page 2736: ...9G 50 Seats Lumbar Support Knob Replacement Callout Component Name 1 Front Seat Manual Lumbar Knob Tip Remove the lumbar knob by pulling firmly on the knob...

Page 2737: ...Cover Refer to Front Seat Cushion Outer Trim Panel Replacement Non Fold Flat Front Seat Cushion Outer Trim Panel Replacement Fold Flat 3 Front Seat Belt Buckle Refer to Front Seat Belt Buckle Replace...

Page 2738: ...sition of least support b Pull back on the lumbar cable sleeve c Remove the barrel end of the cable from the lumbar actuator WARNING The seat back frame springs are under tension To avoid personal inj...

Page 2739: ...Assure that the locating triangles on the seat back frame are properly seated in the mating holes in the adjusters CAUTION Refer to Fastener Notice 2 If you loosened the bolts on the rear seat cushio...

Page 2740: ...s from the notches in the frame to the pin 9 Adjust the seat back to ensure proper operation 10 If the seat is equipped with lumbar support perform the following procedure a Pull back on the lumbar ca...

Page 2741: ...lacement Fold Flat 4 Front Seat Inner Adjuster Finish Panel Refer to Front Seat Cushion Inner Trim Panel Replacement Non Fold Flat Front Seat Cushion Inner Trim Panel Replacement Fold Flat 5 Front Sea...

Page 2742: ...ed or if the module needs to be reprogrammed refer to Service Programming System SPS Callout Component Name Preliminary Procedure Remove the front passenger seat Refer to Front Seat Replacement Bucket...

Page 2743: ...rim Panel Replacement Fold Flat 4 Front Seat Head Restraint Refer to Front Seat Head Restraint Replacement 5 Front Seat Head Restraint Guides Tip 1 Disconnect the lower J hook retainer from the seat b...

Page 2744: ...4 Front Seat Inner Adjuster Finish Panel Refer to Front Seat Cushion Inner Trim Panel Replacement Non Fold Flat Front Seat Cushion Inner Trim Panel Replacement Fold Flat 5 Front Seat Back Finish Pane...

Page 2745: ...cement Fold Flat 3 Front Seat Belt Buckle Refer to Front Seat Belt Buckle Replacement 4 Front Seat Inner Adjuster Finish Panel Refer to Front Seat Cushion Inner Trim Panel Replacement Non Fold Flat Fr...

Page 2746: ...t Callout Component Name 1 Rear Seat Armrest Finish Cover Procedure Remove the screw that holds the finish cover in place 2 Rear Seat Armrest Pivot Bolt CAUTION Refer to Fastener Notice Tightening tor...

Page 2747: ...to Seat Belt Replacement Center Rear 1 Rear Seat No 1 Back Shoulder Belt Opening Bezel Screw Qty 2 CAUTION Refer to Fastener Notice Tightening torque 2 N m 18 lb in Tip Lift up the seat belt to acces...

Page 2748: ...9G 62 Seats Rear Seat Strut Replacement Callout Component Name 1 Rear Seat No 1 Strut Tip Remove the seat strut from the seat cushion frame and seat riser...

Page 2749: ...eplacement Inner Callout Component Name 1 Rear Center Seat Head Restraint Tip 1 Push the button in and raise the head restraint to the full up position 2 Insert a small round tool into the guide hole...

Page 2750: ...t Replacement Outer Callout Component Name 1 Rear Seat Head Restraint Tip 1 Push the button in and raise the head restraint to the full up position 2 Insert a small round tool into the guide hole 3 Pu...

Page 2751: ...h the button in and raise the head restraint to the full up position 2 Insert a small round tool into the guide hole 3 Pull up to remove the head restraint 2 Rear Seat Center Head Restraint Guides Tip...

Page 2752: ...h the button in and raise the head restraint to the full up position 2 Insert a small round tool into the guide hole 3 Pull up to remove the head restraint 2 Rear Seat Head Restraint Guides Tip 1 Disc...

Page 2753: ...e 1 Rear Seat No 1 Back Release Handle Screw Qty 2 CAUTION Refer to Fastener Notice Tightening torque 2 N m 18 lb in Tip Pull on the release handle to access the screws 2 Rear Seat No 1 Back Release H...

Page 2754: ...t Back Recliner Cover Replacement Inner Callout Component Name 1 Rear Seat Inner Recliner Finish Cover Screw Qty 2 CAUTION Refer to Fastener Notice Tightening torque 2 N m 18 lb in 2 Rear Seat Inner R...

Page 2755: ...t Back Recliner Cover Replacement Outer Callout Component Name 1 Rear Seat Outer Recliner Finish Cover Screw Qty 2 CAUTION Refer to Fastener Notice Tightening torque 2 N m 18 lb in 2 Rear Seat Outer R...

Page 2756: ...9G 70 Seats Rear Seat Front Riser Finish Cover Replacement Callout Component Name 1 Rear Seat Riser Front Finish Cover Qty 4 Tip Pull forward and upward to remove...

Page 2757: ...ut Component Name Preliminary Procedure Remove the seat latch finish covers 1 Rear Seat No 1 Latch Bolt Qty 6 CAUTION Refer to Fastener Notice Tightening torque 25 N m 18 lb ft 2 Rear Seat No 1 Latch...

Page 2758: ...eld nut located on the upper pivot bracket of the outboard pivot assembly Tightening torque Tighten the bolts to 15 N m 11 lb ft 2 Remove the stud caps and the 6 attachment nuts 1 from the front and s...

Page 2759: ...of the seat by pushing down on the back of the seat ensuring that the seat latch 2 is securely latched 3 Install the 6 attachments nuts 1 to the front and side risers of the seat Tightening torque Tig...

Page 2760: ...r recliner cover Refer to Rear Seat Back Recliner Cover Replacement Inner Rear Seat Back Recliner Cover Replacement Outer 3 Remove the rear seat latch covers 1 Rear Seat No 1 Seat Cushion Cover Tip 1...

Page 2761: ...the rear seat latch Refer to Rear Seat Latch Replacement 3 Remove the rear seat cushion cover and pad Refer to Rear Seat Cushion Cover and Pad Replacement 1 Rear Seat No 1 Cushion Frame Bolt Qty 4 CA...

Page 2762: ...Replacement 2 Remove the rear seat back cover and pad Refer to Rear Seat Back Cushion Cover and Pad Replacement 60 Seat Rear Seat Back Cushion Cover and Pad Replacement 40 Seat 1 Rear Seat No 1 Back R...

Page 2763: ...straint Refer to Rear Seat Head Restraint Replacement Outer Rear Seat Head Restraint Replacement Inner 7 Remove the rear seat center head restraint Refer to Rear Seat Head Restraint Replacement Outer...

Page 2764: ...Rear No 1 4 Remove the rear seat should belt guide Refer to Guide Replacement Rear Seat Shoulder Belt 5 Remove the rear seat back filler panel Refer to Rear Seat Back Filler Panel Replacement 6 Remove...

Page 2765: ...nt 2 Loosen the seat back cover from the seat back filler panel It is hooked into the slots of the panel 3 Slide the rear seat back cover up the seat back enough to gain access to the seat back filler...

Page 2766: ...n Cover and Pad Replacement 60 Seat Rear Seat Back Cushion Cover and Pad Replacement 40 Seat 3 Remove the rear seat back release cables Refer to Rear Seat Back Cushion Latch Cable Replacement 1 Rear S...

Page 2767: ...estraint Replacement Callout Component Name 1 Front Seat Head Restraint Tip 1 Push the button in and raise the head restraint to the full up position 2 Insert a small round tool into the guide hole 3...

Page 2768: ...efer to Rear Seat Number 2 Back Cushion Panel Replacement 1 Rear Seat Head Restraint Tip 1 Push the button in and raise the head restraint to the full up position 2 Insert a small round tool into the...

Page 2769: ...e 1 Rear Seat No 2 Back Release Handle Screw Qty 2 CAUTION Refer to Fastener Notice Tightening torque 2 N m 18 lb ft Tip Pull on the release handle to access the screws 2 Rear Seat No 2 Back Release H...

Page 2770: ...onent Name 1 Rear Seat No 2 Back Release Handle Screw Qty 2 CAUTION Refer to Fastener Notice Tightening torque 2 N m 18 lb ft Tip Pull on the release handle to access the screws 2 Rear Seat No 2 Back...

Page 2771: ...nt Callout Component Name 1 Rear Seat No 1 Latch Finish Cover Screw Qty 4 CAUTION Refer to Fastener Notice Tightening torque 2 N m 18 lb in Tip Fold and tumble the seat forward to access the screws an...

Page 2772: ...ame 1 Rear Seat No 2 Back Panel Procedure 1 Loosen the screws from the recliner handle to allow for easier removal of the panel 2 Use a J 38778 Door Trim Pad Clip Remover to aid in the removal of the...

Page 2773: ...Seat Number 2 Cushion Trim Panel Replacement Callout Component Name 1 Rear Seat Cushion Front Finish Cover Tip Pull forward to disengage the retainer clips 2 Rear Seat Cushion Front Finish Cover Reta...

Page 2774: ...t 2 Remove the rear floor stowage compartment Refer to Rear Storage Compartment Replacement 1 Rear Seat No 2 Bolt Qty 8 CAUTION Refer to Fastener Notice Tightening torque 45 N m 33 lb ft Tip Flip up t...

Page 2775: ...cedure Remove the rear seat Refer to Rear Number 2 Seat Replacement 1 Rear Seat No 2 Drive Link Cover Screw Qty 2 CAUTION Refer to Fastener Notice Tightening torque 2 N m 18 lb ft 2 Rear Seat No 2 Dri...

Page 2776: ...Seat Number 2 Hinge Front Link Replacement Callout Component Name 1 Rear Seat No 2 Drive Link Cover Screw Qty 2 CAUTION Refer to Fastener Notice Tightening torque 2 N m 18 lb ft 2 Rear Seat No 2 Driv...

Page 2777: ...recliner cover Refer to Rear Seat Back Recliner Cover Replacement Inner Rear Seat Back Recliner Cover Replacement Outer 3 Remove the rear seat back outer finish panel 4 Remove the seat cushion front f...

Page 2778: ...efer to Rear Seat Recliner Handle Replacement Rear No 2 Rear Seat Recliner Handle Replacement Rear No 1 1 Rear Seat No 2 Back Cover and Pad Refer to Rear Seat Number 2 Back Cushion Cover and Pad Repla...

Page 2779: ...recliner cover Refer to Rear Seat Back Recliner Cover Replacement Inner Rear Seat Back Recliner Cover Replacement Outer 1 Rear Seat No 2 Cushion Cover and Pad Refer to Rear Seat Number 2 Cushion Cove...

Page 2780: ...Number 2 Head Restraint Guide Replacement 5 Remove the rear seat back recliner handle Refer to Rear Seat Recliner Handle Replacement Rear No 2 Rear Seat Recliner Handle Replacement Rear No 1 6 Remove...

Page 2781: ...o Rear Seat Recliner Handle Replacement Rear No 2 Rear Seat Recliner Handle Replacement Rear No 1 1 Rear Seat No 2 Back Cover and Pad Refer to Rear Seat Number 2 Back Cushion Cover and Pad Replacement...

Page 2782: ...ar seat back recliner handle Refer to Rear Seat Recliner Handle Replacement Rear No 2 Rear Seat Recliner Handle Replacement Rear No 1 5 Remove the rear seat outer recliner cover Refer to Rear Seat Bac...

Page 2783: ...2 5 N m 22 lb in Front Bucket Seat Recliner Handle Bolt Non Fold Flat 10 N m 89 lb in Front Bucket Seat Teardrop Washer Bolt Non Fold Flat 35 N m 26 lb ft Front Seat Back Recliner Trim Panel Screw 2 5...

Page 2784: ...ource In cases such as water leaks use this product with diagnostic procedures to first eliminate the primary cause of the odor Then use further applications on the residual odor to permanently correc...

Page 2785: ...reliminary Procedures 1 Remove rear floor storage bin Refer to Rear Storage Compartment Replacement 2 Remove cargo hooks from liftgate door sill plate 1 Liftgate Door Sill Plate Push Pin Fasteners Qty...

Page 2786: ...to SIR Disabling and Enabling 1 Windshield Side Garnish Molding Cover 2 Windshield Side Garnish Screw CAUTION Refer to Fastener Notice in Cautions and Notices Tightening torque 9 N m 80 lb in 3 Windsh...

Page 2787: ...d Paneling Preliminary Procedure 1 Remove the rear carpet retainer Refer to Rear Carpet Retainer Replacement 2 Lift up the rear of the front carpet retainer Refer to Front Carpet Retainer Replacement...

Page 2788: ...ster cover bolt and guide ONLY from the center pillar Refer to Seat Belt Retractor Pretensioner Replacement Front 2 Remove the center pillar lower garnish molding Refer to Center Pillar Lower Garnish...

Page 2789: ...ut Component Name Preliminary Procedure Open rear compartment stowage tray assembly lid 1 Rear Compartment Stowage Tray Bolt Qty 3 Tightening torque 7 N m 62 lb in CAUTION Refer to Fastener Notice in...

Page 2790: ...Callout Component Name Preliminary Procedure Remove rear quarter lower garnish molding Refer to Rear Quarter Lower Trim Panel Replacement 1 Rear Corner Garnish Molding Clip Qty 5 2 Rear Corner Garnis...

Page 2791: ...t Callout Component Name CAUTION Refer to Fastener Notice Fastener Tightening Specifications Refer to Fastener Tightening Specifications Interior Trim and Paneling 1 Rear Seat Anchor Plate Bezel Screw...

Page 2792: ...lower trim panel Refer to Rear Quarter Lower Trim Panel Replacement 2 Remove rear corner garnish molding Refer to Body Rear Corner Garnish Molding Replacement 1 Lock Pillar Upper Garnish Molding Escut...

Page 2793: ...lower trim panel Refer to Rear Quarter Lower Trim Panel Replacement 2 Remove rear corner garnish molding Refer to Body Rear Corner Garnish Molding Replacement 1 Lock Pillar Upper Garnish Molding Escu...

Page 2794: ...Front Floor Console Armrest Replacement Callout Component Name 1 Console Armrest Assembly Screws Qty 3 CAUTION Refer to Fastener Notice in Cautions and Notices Tightening torque 2 N m 18 lb in 2 Conso...

Page 2795: ...AUTION Refer to Fastener Notice in Cautions and Notices Tightening torque 2 N m 18 lb in 3 Console Bolt Covers Qty 4 Procedure Use a flat bladed plastic trim tool to remove the covers 4 Console Bolts...

Page 2796: ...bolt covers 2 Use a flat bladed plastic trim tool to remove the covers 2 Console Trim Plate Screws Qty 4 CAUTION Refer to Fastener Notice in Cautions and Notices Tightening torque 2 N m 18 lb in 3 Con...

Page 2797: ...strument Panel lower Brace Bezel Refer to Instrument Panel Lower Brace Bezel Replacement 2 Remove the Console Rear Trim Plate Refer to Console Rear Trim Plate Replacement 1 Console Trim Plate Screws Q...

Page 2798: ...llout Component Name Preliminary Procedures 1 Remove the console Refer to Console Replacement 2 Remove the Console Upper Trim Plate Refer to Front Floor Upper Console Trim Plate Replacement 1 Console...

Page 2799: ...ure Remove the Floor Console Refer to Console Replacement 1 Instrument Panel Lower Brace Bezel Refer to Instrument Panel Lower Brace Bezel Replacement 2 Console Trim Panel Assembly Screws Qty 4 CAUTIO...

Page 2800: ...Remove the console Refer to Console Replacement 2 Remove the Console Upper Trim Plate Refer to Front Floor Upper Console Trim Plate Replacement 1 Console Side Trim Panel Screw Qty 1 CAUTION Refer to F...

Page 2801: ...de Trim Panel Replacement Left Side Callout Component Name Preliminary Procedure Remove the Right Console Trim Panel Refer to Front Floor Console Side Trim Panel Replacement Right Side 1 Console Trim...

Page 2802: ...Remove the console Refer to Console Replacement 2 Remove the Console Upper Trim Plate Refer to Front Floor Upper Console Trim Plate Replacement 1 Console Side Trim Panel Screw Qty 1 CAUTION Refer to F...

Page 2803: ...Callout Component Name 1 Front Side Door Opening Floor Carpet Retainer Tip Pull inward at the front of the carpet retainer to disengage the retainer clips from the kick panel area then pull up to dis...

Page 2804: ...ment Callout Component Name 1 Rear Side Door Opening Floor Carpet Retainer Tip Pull up at the front of the carpet retainer to disengage the retainer clips then rotate the rear of the retainer away fro...

Page 2805: ...ent 3 Remove the front carpet retainer Refer to Front Carpet Retainer Replacement 4 Remove the rear carpet retainer Refer to Rear Carpet Retainer Replacement 5 Remove the center console trim panels an...

Page 2806: ...tached to a synthetic padding dry the carpet using the method described below For a 2 piece carpet assembly with a synthetic padding dry the assembly using the method described below Drying Method 1 I...

Page 2807: ...Component Name 1 Front Overhead Console Screw Qty 2 Tightening torque 2 N m 18 lb in CAUTION Refer to Fastener Notice in Cautions and Notices 2 Front Overhead Console Assembly Tip Disconnect electric...

Page 2808: ...acement 7 Remove center pillar upper molding Refer to Center Pillar Upper Garnish Molding Replacement 8 Remove upper body lock pillar molding Refer to Lock Pillar Upper Garnish Molding Replacement Lef...

Page 2809: ...ate Replacement 4 Remove the rear carpet retainer Refer to Rear Carpet Retainer Replacement 5 Remove rear seat 2 seat belt anchor bolt Refer to Seat Belt Retractor Replacement No 2 Rear 1 Rear Quarter...

Page 2810: ...Console Screws 2 N m 18 lb in Console Armrest Assembly Screws 2 N m 18 lb in Console Trim Plate Screws 2 N m 18 lb in Front Overhead Console Screw 2 N m 18 lb in Application Specification Metric Engli...

Page 2811: ...r edge of the sunroof glass then sliding open with the sunshade allowing the wind deflector to raise upward The sunroof glass will continue to express open until The sunroof glass reaches a predetermi...

Page 2812: ...ted the sunroof module will drive the motor to the closed position until the limit switch closes indicating a flush close position As the sunroof glass nears the closed position the wind deflector wil...

Page 2813: ...Sun Roof T Top Convertible Top 9I 3 Sunroof Schematics...

Page 2814: ...e 6 BN 100 Sunroof Switch Open Signal 7 OG BK 144 Sunroof Switch Open Vent Signal 8 OG 132 Sunroof Limit Switch Soft Stop Signal Connector Part Information OEM 12052856 Service 12125636 Description 4...

Page 2815: ...e See Terminal Repair Kit Pin Wire Color Circuit No Function 1 OG 132 Sunroof Limit Switch Soft Stop Signal 2 Not Used 3 YE 133 Sunroof Limit Switch Low Reference Connector Part Information OEM 120649...

Page 2816: ...I 6 Sun Roof T Top Convertible Top Component Location Sunroof Component Views Front Headliner Components 1 Dome Lamp Center 3 Sunroof Switch CF5 2 Noise Compensation Microphone U3U 4 Courtesy Map Lamp...

Page 2817: ...system functions Refer to Sunroof Description and Operation Visual Physical Inspection Inspect for aftermarket devices which could affect the operation of the sunroof system Refer to Checking Aftermar...

Page 2818: ...each Sunroof switch open signal circuit Sunroof switch open vent signal circuit 3 Attempt to slide the sunroof glass towards the closed position by connecting the other ends of the jumper wires at the...

Page 2819: ...to Step 16 Go to Step 14 14 1 Disconnect the sunroof module harness connector that contains the power sunroof fuse supply voltage circuit 2 Measure the battery positive voltage circuit of the sunroof...

Page 2820: ...p 38 Go to Step 35 26 Test the sunroof motor close control circuit for an open a short to ground or high resistance Refer to Circuit Testing and Wiring Repairs Did you find and correct the condition G...

Page 2821: ...e any jumper wires 2 Reconnect all previously disconnected components 3 Replace sunroof fuse if necessary 4 Turn ON the ignition with the engine OFF 5 Operate the system in order to verify the repair...

Page 2822: ...9 7 Inspect for a poor connection at the sunroof switch Refer to Testing for Intermittent Conditions and Poor Connections and Connector Repairs Did you find and correct the condition Go to Step 10 Go...

Page 2823: ...ions and Connector Repairs Did you find and correct the condition Go to Step 14 Go to Step 12 8 Test the sunroof limit switch low reference for an open or high resistance Refer to Circuit Testing and...

Page 2824: ...ush the left front side of the air deflector towards the right side Pull up on the left side until the lower tab clears the roof opening 4 Swing the air deflector in an upward arc rearward to disengag...

Page 2825: ...clears the roof opening 5 Close the sunroof window Sunroof Housing Front Drain Hose Replacement Removal Procedure 1 Lower the headliner Refer to Headlining Trim Panel Replacement 2 Remove the front d...

Page 2826: ...rain Hose Replacement Removal Procedure 1 Remove the headliner Refer to Headlining Trim Panel Replacement 2 Remove the rear drain hoses from the sunroof module 3 Remove the tape from the drain hose 4...

Page 2827: ...hose Refer to Sunroof Housing Front Drain Hose Replacement 2 Ensure the rear drain hoses are routed through the rear pillars and out of the rocker panel Ensure the rear hoses are properly routed in t...

Page 2828: ...Window Replacement 2 Remove the screws from the sunroof drip channel 3 Remove the sunroof drip channel 4 Slide the sunshade forward to the closed position 5 Push the spring retainer clips on the righ...

Page 2829: ...rom sunroof switch 4 Remove sunroof switch fasteners and remove sunroof switch Installation Procedure 1 Install sunroof switch with fasteners Tightening torque Tighten sunroof switch to 2 5 N m 22 lb...

Page 2830: ...nroof window adjustment screws Tightening torque Tighten the sunroof window adjusting screws to 6 N m 53 lb in 5 Cycle sunroof window through all positions 6 Inspect the sunroof window adjustment Adju...

Page 2831: ...s the tab on the side of the control module 3 With the tab depressed slide the sunroof control module toward the sunroof motor This will release the control module from the sunroof module 4 Remove the...

Page 2832: ...ation Procedure 1 With the aid of an assistant position the new sunroof module into the roof opening 2 Install the bolts which secure the sunroof module to the roof and tighten the bolts by hand 3 Pla...

Page 2833: ...ance of a 44 5 mm 1 75 in between the left slide and track bracket 2 Manually adjust the track to achieve a distance of a 44 5 mm 1 75 in between the right slide and track bracket 3 Install the sunroo...

Page 2834: ...cifications Interior Trim and Paneling Preliminary Procedure 1 Disable the SIR Refer to SIR Disabling and Enabling 2 Remove the center pillar upper garnish molding Refer to Center Pillar Upper Garnish...

Page 2835: ...Replacement Callout Component Name CAUTION Refer to Fastener Notice Fastener Tightening Specifications Refer to Fastener Tightening Specifications Interior Trim and Paneling 1 Coat Hook Screw Tighteni...

Page 2836: ...Name CAUTION Refer to Fastener Notice Fastener Tightening Specifications Refer to Fastener Tightening Specifications Interior Trim and Paneling 1 Sunshade Screw Qty 2 Tightening torque 2 5 N m 22 lb...

Page 2837: ...ce Fastener Tightening Specifications Refer to Fastener Tightening Specifications Interior Trim and Paneling 1 Sunshade Screw Qty 2 Tightening torque 2 5 N m 22 lb in 2 Sunshade Assembly Tip Disconnec...

Page 2838: ...h Coat Hook Screws 2 5 N m 22 lb in Center Pillar Assist Handle Bolts 25 N m 18 lb ft D Ring Bolts 50 N m 37 lb ft Sunshade Screws 2 5 N m 22 lb in Sunshade Support Screws 2 5 N m 22 lb in Application...

Page 2839: ...r Instructions Hood Bumper Replacement Callout Component Name 1 Hood Overslam Bumper Tips A small amount of silicone spray will help with installation Move the bumper to the most rearwards spot in the...

Page 2840: ...WARNING When a hood hold open device is being removed or installed provide alternate support to avoid the possibility of damage to the vehicle or personal injury Tips 1 Prop the hood before removing t...

Page 2841: ...st the hood fore and aft and cross vehicle Position the hood as needed 2 Adjust the hood bumpers to adjust the hood up and down at the front of the hood CAUTION Refer to Fastener Notice 3 Tighten the...

Page 2842: ...the possibility of damage to the vehicle or personal injury Preliminary Procedures 1 Prop and support the hood 2 Mark the location of the hinge to the hood with a grease pencil to aid in alignment 1 H...

Page 2843: ...of damage to the vehicle or personal injury Preliminary Procedures 1 Use a grease pencil to outline the upper hood hinges 2 Prop the hood and disconnect the hood strut rod Refer to Hood Strut Replacem...

Page 2844: ...9J 6 Hood Fenders Doors Hood Insulator Replacement Callout Component Name 1 Hood Insulator Plastic Retainers Qty 7 2 Hood Insulator...

Page 2845: ...nt 2 Remove the underhood electrical center junction block Refer to Underhood Electrical Center or Junction Block Replacement 3 Remove the left closeout insulator panel Refer to Instrument Panel Insul...

Page 2846: ...9J 8 Hood Fenders Doors Hood Primary Latch Striker Replacement Callout Component Name 1 Hood Primary Latch Striker CAUTION Refer to Fastener Notice Tightening torque 25 N m 18 lb ft...

Page 2847: ...Bolts Qty 3 CAUTION Refer to Fastener Notice Tip Mark the hood latch location to the support bracket with a grease pencil before removing the bolts Tightening torque 10 N m 89 lb in 2 Primary Hood Lat...

Page 2848: ...ent Callout Component Name 1 Secondary Hood Latch Bolts Qty 2 CAUTION Refer to Fastener Notice Tip Mark the hood latch location to the support bracket with a grease pencil before removing the bolts Ti...

Page 2849: ...r Seal Replacement Callout Component Name 1 Hood Front Seal Plastic Retainers Qty 8 2 Hood Front Seal Callout Component Name 1 Hood Rear Seal Tip 1 Pull the hood rear seal from the cowl panel flange 2...

Page 2850: ...er Seal Replacement Callout Component Name 1 Hood Rear Side Seal Tip 1 Pull the rear side hood seal located at the end of the hood seal from the fender 2 To clean the area using isopropyl alcohol befo...

Page 2851: ...Replacement Callout Component Name Preliminary Procedure Remove the hood strut rod Refer to Hood Strut Replacement 1 Hood Assist Rod Ball Stud Bolts Qty 2 CAUTION Refer to Fastener Notice Tightening...

Page 2852: ...ry Procedure Remove the wiper arm Refer to Wiper Arm Replacement 1 Air Inlet Grille Panel Retainer Qty 4 2 Air Inlet Grille Panel 3 Air Inlet Grille Panel Retainer Qty 4 4 Air Inlet Grille Panel Tip D...

Page 2853: ...the front bumper upper fascia support to the fender Refer to Front Bumper Fascia Upper Support Replacement 3 Remove the rocker panel molding Refer to Rocker Panel Molding Replacement 1 Front Fender B...

Page 2854: ...Doors Front Fender Upper Bracket Replacement Callout Component Name Preliminary Procedure Remove the front fender Refer to Front Fender Replacement 1 Front Fender Upper Bracket Rivets Qty 2 2 Front Fe...

Page 2855: ...Fenders Doors 9J 17 Front Fender Insulator Replacement Callout Component Name Preliminary Procedure Remove the front wheelhouse liner Refer to Front Wheelhouse Liner Replacement 1 Fender Sound Insula...

Page 2856: ...ulling away from the door 5 Remove the gasket if necessary Installation Procedure 1 Install the gasket if necessary 2 Install the handle by placing into position and sliding rearward ensuring to engag...

Page 2857: ...ing away from the door 5 Remove the gasket if necessary Installation Procedure 1 Install the gasket if necessary 2 Install the handle by placing into position and sliding rearward ensuring to engage t...

Page 2858: ...s Doors Door Handle Bezel Replacement Callout Component Name 1 Side Door Handle Bezel Screw Tightening torque 2 5 N m 22 lb in CAUTION Refer to Fastener Notice in Cautions and Notices 2 Side Door Hand...

Page 2859: ...im Panel Retainer Qty 1 2 Front Side Door Upper Trim Panel Assembly Procedures 1 Pull on the top end of extension panel to disengage attaching clip 2 Lift extension panel out from behind the door trim...

Page 2860: ...tension Trim Panel Replacement Front Side Door 2 Remove door handle bezel Refer to Door Handle Bezel Replacement 1 Front Side Door Trim Panel Plug 2 Front Side Door Trim Panel Screw Qty 2 Tightening t...

Page 2861: ...emove door handle bezel Refer to Door Handle Bezel Replacement 1 Rear Side Door Trim Panel Plug 2 Rear Side Door Trim Panel Screw Qty 2 Tightening torque 2 5 N m 22 lb in CAUTION Refer to Fastener Not...

Page 2862: ...Remove side door trim panel Refer to Front Side Door Trim Panel Replacement and Rear Side Door Trim Panel Replacement 1 Side Door Inside Handle Screw Qty 2 Tightening torque 2 5 N m 22 lb in CAUTION R...

Page 2863: ...or Trim Panel Replacement 1 Front Side Door Trim Panel Seal Assembly Tip 1 To remove door seal start at top left corner and pull downward 2 When re installing door seal align locating tabs near top ed...

Page 2864: ...Door Trim Panel Replacement 1 Rear Side Door Trim Panel Seal Assembly Tip 1 To remove door seal start at top left corner and pull downward 2 When re applying door seal align top trimline to door feat...

Page 2865: ...w Belt Outer Sealing Strip Replacement Removal Procedure 1 Remove the belt seal retaining screw at the rear edge of the door 2 Remove the outside rearview mirror Refer to Mirror Replacement 3 Remove t...

Page 2866: ...belt seal 2 Install the front door trim panel Refer to Rear Side Door Trim Panel Replacement Rear Door Window Belt Outer Sealing Strip Replacement Removal Procedure 1 Remove the belt seal retaining s...

Page 2867: ...channel onto the door flange b Ensure the channel is fully secured into the upper corners of the door frame 2 Install the inner belt seal Refer to Front Side Door Window Belt Inner Sealing Strip Repl...

Page 2868: ...5 Install the front door window Refer to Front Side Door Window Replacement Rear Side Door Window Channel Replacement Removal Procedure 1 Lower the rear door window 2 Remove the rear door trim panel R...

Page 2869: ...assembly a Starting from the front corner of the door remove the seal from the door header flange b Remove the seal assembly from the door Installation Procedure 1 Install the window run channel seal...

Page 2870: ...ure 3 Locate an exposed end of the ripcord at the seal joint and pull the ripcord around the door opening If the seal lip is positioned under any door trim this process will bring the seal lip over th...

Page 2871: ...ssary SIR system repairs do not strike the door or the door pillar in the area of the side impact sensor SIS Turn OFF the ignition and remove the key when performing service in the area of the SIS 1 R...

Page 2872: ...o the approximate proper position 6 Adjust the door striker Refer to Rear Side Door Lock Striker Adjustment 7 Inspect the door weatherstrips for proper fit Front Side Door Hinge Replacement Removal Pr...

Page 2873: ...side impact sensor SIS Turn OFF the ignition and remove the key when performing service in the area of the SIS 1 Mark around the hinge location with a soft marker for installation alignment purposes 2...

Page 2874: ...or Speaker Replacement in Entertainment 3 Remove the check link bolts at the hinge pillar 4 Remove the check link nuts from the door frame 5 Remove the check link from the door through the speaker ope...

Page 2875: ...or Speaker Replacement in Entertainment 3 Remove the check link bolts at the hinge pillar 4 Remove the check link nuts from the door frame 5 Remove the check link from the door through the speaker ope...

Page 2876: ...6 With the aid of an assistant remove the door hinge to body bolts 7 With the aid of an assistant remove the front door from the vehicle Installation Procedure 1 With the aid of an assistant position...

Page 2877: ...s 5 With the aid of an assistant remove the door hinge to body bolts 6 With the aid of an assistant remove the rear door from the vehicle Installation Procedure 1 With the aid of an assistant position...

Page 2878: ...9J 40 Hood Fenders Doors Liftgate Bumper Replacement Callout Component Name 1 Liftgate Bumper Tip Adjust the fit of the liftgate to body by turning the bumpers in either direction as needed...

Page 2879: ...mponent Name Preliminary Procedure Remove the liftgate center applique Refer to Liftgate Center Applique Replacement 1 Liftgate Handle Screws Qty 2 CAUTION Refer to Fastener Notice Tightening torque 3...

Page 2880: ...Component Name Preliminary Procedure Remove lower liftgate trim panel Refer to Liftgate Trim Panel Replacement Upper Liftgate Trim Panel Replacement Lower 1 Liftgate Trim Panel Assembly Tip Pull away...

Page 2881: ...Trim Panel Screw Qty 2 Tightening torque 2 N m 18 lb in CAUTION Refer to Fastener Notice in Cautions and Notices 2 Liftgate Trim Panel Nut Qty 2 Tightening torque 2 N m 18 lb in 3 Liftgate Trim Panel...

Page 2882: ...9J 44 Hood Fenders Doors Liftgate Weatherstrip Replacement Callout Component Name 1 Liftgate Weatherstrip Tip Clean any excess adhesive after the installation with an adhesive cleaner...

Page 2883: ...s 9J 45 Liftgate Strut Replacement Callout Component Name 1 Liftgate Strut Tips 1 Support the liftgate before removing either strut 2 Use a flatbladed screwdriver to release the tabs that hold the str...

Page 2884: ...eplacement Callout Component Name Preliminary Procedure Remove the liftgate strut Refer to Liftgate Strut Replacement 1 Liftgate Strut Ball Stud Bolts Qty 2 CAUTION Refer to Fastener Notice Tightening...

Page 2885: ...adjustment 5 Move the liftgate within the liftgate opening to achieve the best alignment and operation 6 Install striker to approximately the proper position 7 Adjust the striker to achieve the best...

Page 2886: ...efer to Liftgate Replacement 2 Prop and secure the liftgate and remove the bolts from the appropriate hinge if only replacing one hinge Refer to Liftgate Replacement 3 Lower the rear of the headliner...

Page 2887: ...t Body Side Callout Component Name Preliminary Procedure Remove the tail lamp assembly Refer to Tail Lamp Replacement 1 Body Side Liftgate Wedge Bolts Qty 2 CAUTION Refer to Fastener Notice Tightening...

Page 2888: ...ers Doors Liftgate Wedge Replacement Liftgate Side Callout Component Name 1 Lidtgate Side Liftgate Wedge Bolts Qty 2 CAUTION Refer to Fastener Notice Tightening torque 10 N m 89 lb in 2 Liftgate Side...

Page 2889: ...Bolts Qty 4 CAUTION Refer to Fastener Notice Tip Mark the location of the liftgate hinges to the liftgate with a grease pencil Tightening torque 25 N m 18 lb ft 2 Liftgate Assembly Tip 1 Disconnect th...

Page 2890: ...Tank Filler Door Replacement Callout Component Name 1 Fuel Filler Door Bolts Qty 2 CAUTION Refer to Fastener Notice Tightening torque 2 5 N m 22 lb in 2 Fuel Filler Door Tip Disconnect the fuel cap st...

Page 2891: ...in Outer Belt Sealing Strip Screw 1 5 N m 13 lb in Rear Door Window Run Channel Seal Lower Bolts 18 N m 11 lb ft Application Specification Metric English Body Side Liftgate Wedge Bolts 10 N m 89 lb in...

Page 2892: ...9J 54 Hood Fenders Doors Special Tools and Equipment Special Tools Fixed and Moveable Windows Illustration Tool Number Description J 33431 C Signal Generator and Instrument Panel Tester...

Page 2893: ...s specifically documented in a Service Bulletin or Manual If in doubt use only the procedures referenced in the Service Manual for the specific vehicle being repaired Always follow the system manufact...

Page 2894: ...e in the plastic identification chart to determine whether the plastic is thermoplastic or thermoset plastic and whether the plastic is rigid or flexible Refer to Plastic Identification and Refinishin...

Page 2895: ...or Finish Trim Panel Headlamp Bezel Quarter Panel Extension Capron Minlon Nylon Rilsan Vydyne Wellamid Zytel Rigid Thermoset PA PPE Polymide Polypheneylene Ether Exterior Trim Fender GTX Rigid Thermos...

Page 2896: ...nel EPI EPII TPO TPR Thermoplastic Rubber Flexible Thermoplastic TPO Thermal Plastic Oletin Bumper Covers TPO Flexible Thermoplastic TPU TPUR Polyurethane Polyolefin Bumper Fascia Gravel Deflector Sof...

Page 2897: ...er to Front Wheelhouse Liner Replacement 1 Front Bumper Fascia Plastic Retainers Qty 11 2 Headlamp Tip Disconnect the electrical connections Refer to Headlamp Replacement 3 Front Bumper Fascia Bolts Q...

Page 2898: ...a Energy Absorber Replacement Callout Component Name Preliminary Procedure Remove the front bumper fascia Refer to Front Bumper Fascia Replacement 1 Front Energy Absorber Tip Release the two retaining...

Page 2899: ...ut Component Name Preliminary Procedure Remove the front energy absorber Refer to Front Bumper Fascia Energy Absorber Replacement 1 Front Bumper Impact Bar Bolts Qty 8 CAUTION Refer to Fastener Notice...

Page 2900: ...Preliminary Procedure Remove the front energy absorber Refer to Front Bumper Fascia Energy Absorber Replacement 1 Front Bumper Lower Grille NOTE Do not use excessive force to release the lower grille...

Page 2901: ...inary Procedure Remove the front bumper fascia Refer to Front Bumper Fascia Replacement 1 Front Bumper Upper Grille Clips Qty 4 2 Front Bumper Upper Grille Screws Qty 4 CAUTION Refer to Fastener Notic...

Page 2902: ...Preliminary Procedure Remove the front bumper lower grille Refer to Front Bumper Lower Fascia Grille Replacement 1 Front Bumper Lower Fascia Bolts Qty 6 CAUTION Refer to Fastener Notice Tightening to...

Page 2903: ...nt Bumper Upper Fascia Replacement Callout Component Name Preliminary Procedure Remove the front bumper lower fascia Refer to Front Bumper Lower Fascia Replacement 1 Front Bumper Upper Fascia Tip Tran...

Page 2904: ...od overslam bumpers Refer to Hood Bumper Replacement 2 Remove the primary hood latch Refer to Hood Primary Latch Replacement 3 Remove the front headlamps Refer to Headlamp Replacement 1 Front Bumper F...

Page 2905: ...mary hood latch Refer to Hood Primary Latch Replacement 3 Remove the visible upper bolts for the front headlamps Refer to Headlamp Replacement 4 Remove the plastic push pins from the upper fascia as n...

Page 2906: ...Retainers Qty 4 2 Rear Bumper Lower Fascia Bolts Qty 2 CAUTION Refer to Fastener Notice Tightening torque 6 N m 53 lb in Tip Remove the plastic covers to access the bolts 3 Rear Bumper Lower Fascia Ti...

Page 2907: ...Replacement Callout Component Name Preliminary Procedure Remove the rear bumper lower fascia Refer to Rear Bumper Lower Fascia Replacement 1 Rear Bumper Bracket Rivets Qty 7 2 Rear Bumper Bracket Tip...

Page 2908: ...Name Preliminary Procedure Remove the rear bumper lower fascia Refer to Rear Bumper Lower Fascia Replacement 1 Rear Bumper Upper Fascia Bolts Qty 11 CAUTION Refer to Fastener Notice Tightening torque...

Page 2909: ...r Energy Absorber Replacement Callout Component Name Preliminary Procedure Remove the rear bumper lower fascia Refer to Rear Bumper Lower Fascia Replacement 1 Rear Energy Absorber Tip Absorber is held...

Page 2910: ...ent Callout Component Name Preliminary Procedure Remove the rear energy absorber Refer to Rear Energy Absorber Replacement 1 Rear Bumper Impact Bar Bolts Qty 8 CAUTION Refer to Fastener Notice Tighten...

Page 2911: ...t Callout Component Name Preliminary Procedure Remove the rear bumper lower fascia Refer to Rear Bumper Lower Fascia Replacement 1 Rear Bumper Fascia Reflector Nut CAUTION Refer to Fastener Notice Tig...

Page 2912: ...ls from the repair area as necessary Refer to Anti Corrosion Treatment and Repair NOTE Do not damage any inner panels or reinforcements 6 Locate and drill out all factory welds Note the number and loc...

Page 2913: ...0 Connect the negative battery cable Refer to Battery Negative Cable Disconnection and Connection 11 Enable the SIR system Refer to SIR Disabling and Enabling Front Wheelhouse Replacement Removal Proc...

Page 2914: ...2 in apart Some panels may have structural weld thru adhesive It is necessary to replace the weld thru adhesive with an additional spot weld between each factory spot weld 1 Drill 8 mm 5 16 in plug we...

Page 2915: ...Refer to SIR Disabling and Enabling Front Wheelhouse Extension Replacement Removal Procedure WARNING Refer to Approved Equipment for Collision Repair Caution 1 Disable the supplemental inflatable rest...

Page 2916: ...2 in apart Some panels may have structural weld thru adhesive It is necessary to replace the weld thru adhesive with an additional spot weld between each factory spot weld 1 Drill 8 mm 5 16 in plug we...

Page 2917: ...n 12 Enable the SIR system Refer to SIR Disabling and Enabling Front Compartment Upper Side Rail Replacement Removal Procedure WARNING Refer to Approved Equipment for Collision Repair Caution 1 Disabl...

Page 2918: ...2 in apart Some panels may have structural weld thru adhesive It is necessary to replace the weld thru adhesive with an additional spot weld between each factory spot weld 1 Drill 8 mm 5 16 in plug we...

Page 2919: ...r to Approved Equipment for Collision Repair Caution 1 Disable the supplemental inflatable restraint SIR system Refer to SIR Disabling and Enabling 2 Disconnect the negative battery cable Refer to Bat...

Page 2920: ...he sealers and anti corrosion materials to the repair area as necessary Refer to Anti Corrosion Treatment and Repair 8 Paint the repair area Refer to Basecoat Clearcoat Paint Systems 9 Install all rel...

Page 2921: ...weld holes can not be determined space the plug weld holes every 40 mm 1 1 2 in apart Some panels may have structural weld thru adhesive It is necessary to replace the weld thru adhesive with an addit...

Page 2922: ...proved Equipment for Collision Repair Caution 1 Disable the supplemental inflatable restraint SIR system Refer to SIR Disabling and Enabling 2 Disconnect the negative battery cable Refer to Battery Ne...

Page 2923: ...Corrosion Treatment and Repair 5 Slide the replacement service part behind the original panel at the sectioning joint 6 Position the front lower inner rail to the vehicle using 3 dimensional measurin...

Page 2924: ...remove the sealers and anti corrosion materials from the repair area as necessary Refer to Anti Corrosion Treatment and Repair NOTE Do not damage any inner panels or reinforcements 6 Locate and drill...

Page 2925: ...Refer to Battery Negative Cable Disconnection and Connection 12 Enable the SIR system Refer to SIR Disabling and Enabling Underbody Outer Front Side Rail Sectioning Removal Procedure WARNING Refer to...

Page 2926: ...Corrosion Treatment and Repair 5 Slide the replacement service part behind the original panel at the sectioning joint 6 Position the front lower outer rail to the vehicle using 3 dimensional measurin...

Page 2927: ...1 Disable the supplemental inflatable restraint SIR system Refer to SIR Disabling and Enabling 2 Disconnect the negative battery cable Refer to Battery Negative Cable Disconnection and Connection 3 Re...

Page 2928: ...int where there is no reinforcement 3 Drill 8 mm 5 16 in plug weld holes along the sectioning cut on the remaining original part Locate these holes 13 mm 1 2 in from the edge and spaced 40 mm 1 in apa...

Page 2929: ...r procedure includes an installation procedure for either metal inert gas welding or adhesive bonding WARNING Refer to Approved Equipment for Collision Repair Caution NOTE When replacing panels that i...

Page 2930: ...ecessary in locations noted from the original panel NOTE If the location of the original plug weld holes can not be determined or if structural weld thru adhesive is present space the plug weld holes...

Page 2931: ...the SIR system Refer to SIR Disabling and Enabling Front Side Door Outer Panel Replacement Removal Procedure WARNING Refer to Approved Equipment for Collision Repair Caution NOTE Before beginning the...

Page 2932: ...r must be replaced Failure to do so may compromise the structural integrity of the vehicle and may cause personal injury if the vehicle is involved in a collision 8 Remove the outer door panel 9 Remov...

Page 2933: ...llow the door to totally cure off the vehicle as proper alignment of the door outer panel to the door shell will be difficult 5 Apply a 3 6 mm 1 8 1 4 in bead of metal panel bonding adhesive GM P N 12...

Page 2934: ...epare all welded surfaces 14 Apply Fusor super flexible anti flutter foam fast set Fusor P N 121 124 or equivalent in 4 5 evenly spaced locations between the door outer panel and the inner safety beam...

Page 2935: ...to Dimensions Body 5 Remove the door assembly Refer to Rear Door Replacement 6 Locate and drill out all factory welds Note the number and location of welds at the upper window frame and the mirror loc...

Page 2936: ...s to bare steel 2 Scuff the opposing mating surfaces of the door outer panel to remove the gloss of the E Coat 3 Drill 8 mm 5 16 in plug weld holes as necessary in the locations noted from the origina...

Page 2937: ...NOT pull the panels apart after being joined together Slide the panels against each other to realign the panels 7 Install the door outer panel to the door shell 8 Clamp the door outer panel into posi...

Page 2938: ...he rearward edge of the number 5 crossbar 1 and the service part is cut so that the new floor section extends to the forward edge of the 5 crossbar 2 This allows the two sections to overlap where the...

Page 2939: ...he replacement sectioning compartment panel NOTE If the location of the original plug weld holes can not be determined or if structural weld thru adhesive is present space the plug weld holes every 40...

Page 2940: ...nection and Connection 14 Enable the SIR system Refer to SIR Disabling and Enabling Body Rear End Panel Replacement Removal Procedure WARNING Refer to Approved Equipment for Collision Repair Caution 1...

Page 2941: ...2 in apart Some panels may have structural weld thru adhesive It is necessary to replace the weld thru adhesive with an additional spot weld between each factory spot weld 1 Drill 8 mm 5 16 in plug we...

Page 2942: ...developed as a more cost effective alternative to complete replacement The specific area to be sectioned is determined by the extent of the damage to the vehicle 1 Disable the supplemental inflatable...

Page 2943: ...n in corresponding locations to fit the original panel The sectioning joint should be trimmed to allow 1 times the metal thickness at the sectioning joint 2 Create a 50 mm 2 in backing plate A from th...

Page 2944: ...t Systems 14 Install all related panels and components 15 Connect the negative battery cable Refer to Battery Negative Cable Disconnection and Connection 16 Enable the SIR system Refer to SIR Disablin...

Page 2945: ...erform additional sectioning procedures Refer to Structure Identification 8 Locate and drill out all factory welds Note the number and location of the welds for installations of the service part 9 Rem...

Page 2946: ...ch the weld sectioning joint 11 Clean and prepare all welded surfaces 12 Apply the sealers and anti corrosion materials to the repair area as necessary Refer to Anti Corrosion Treatment and Repair 13...

Page 2947: ...4 bar and the floor reinforcement Note the number and location of the welds for installation 6 Remove the number 4 bar and the floor reinforcement 7 Locate and drill out all factory welds on the oute...

Page 2948: ...have structural weld thru adhesive Replace the weld thru adhesive with an additional spot weld between each factory spot weld 1 Drill 8 mm 5 16 in plug weld holes in the service part as necessary in...

Page 2949: ...ment Rear Section Removal Procedure WARNING Refer to Approved Equipment for Collision Repair Caution 1 Disable the supplemental inflatable restraint SIR system Refer to SIR Disabling and Enabling 2 Di...

Page 2950: ...necessary 4 Apply GM approved Weld Thru Coating or equivalent to all mating surfaces Refer to Anti Corrosion Treatment and Repair 5 Position the rear rail lower rear section rear rail upper and No 5...

Page 2951: ...nect the negative battery cable Refer to Battery Negative Cable Disconnection and Connection 3 Remove all related panels and components 4 Repair as much of the damage as possible to factory specificat...

Page 2952: ...isconnection and Connection 10 Enable the SIR system Refer to SIR Disabling and Enabling MIG Welded Full Panel Replacement NOTE Use this procedure for all panels that are replaced at the factory seams...

Page 2953: ...e all mating surfaces as necessary 4 Apply GM approved Weld Thru Coating or equivalent to all mating surfaces Refer to Anti Corrosion Treatment and Repair 5 Position the service part Clamp in place 6...

Page 2954: ...r Fascia Support Bolts 10 N m 89 lb in Front Bumper Fascia Upper Support Bolts 10 N m 89 lb in Front Bumper Front Impact Bar Bolts 25 N m 18 lb ft Front Bumper Lower Fascia Bolts 2 N m 18 lb in Rear B...

Page 2955: ...Body Structure 9K 63 Body Side Opening Underbody...

Page 2956: ...eel Tie Bar Replacement 2 Front Wheelhouse Assembly Mild Steel Front Wheelhouse Replacement Front Wheelhouse Extension Replacement 3 Roof Panel Mild Steel Roof Outer Panel Replacement 4 Rear End Panel...

Page 2957: ...el Sectioning 8 Upper Rail Mild Steel Front Compartment Upper Side Rail Replacement 9 Front Rail High Strength Front Compartment Front Rail Replacement Front Compartment Front Side Lower Inner Rail Re...

Page 2958: ...ing and repairing of all flexible plastics Requires GM P N 12378462 on TPO plastics Will also bond e coated primed metals 90 seconds 10 minutes TPO TEO Polyolefin Plastics require the application of p...

Page 2959: ...ler Retailer Dynatron Dyna Weld Plio Grip or equivalent OE structural adhesive Refer to local paint supplier Most rigid plastic parts Adhesive structural bonding GM Goodwrench Structural Bonding Epoxy...

Page 2960: ...le bare metal surfaces must be treated with metal conditioner and reprimed Refer to the GM Approved Refinish Materials book GM P N GM4901M D which identifies the paint systems you may use Anti corrosi...

Page 2961: ...lation Cleaning of the interior and underbody panel surfaces is necessary when original galvanized or other anti corrosion materials have been burned off during welding or heating operations Removal o...

Page 2962: ...etic gages have improved accuracy ranges Most gages are confined to checking either ferrous metal steel non ferrous metal or aluminum panel At this time there are no viable gages for reading film thic...

Page 2963: ...ation Perfect It 3000 Swirl Mark Remover P N 06064 Perfect It Foam Polishing Pad P N 05725 38 Hookit SBS Perfect it Backup Pad P N 05717 18 Perfect It 3000 Swirl Mark Remover P N 06064 Perfect It Foam...

Page 2964: ...Pad P N 05717 18 Perfect It 3000 Swirl Mark Remover P N 06064 Perfect It Foam PolishingPad P N 05725 38 Hookit DA 6 in Backup Pad P N 05776 Perfect It 3000 Swirl Mark Remover P N 06066 Perfect It III...

Page 2965: ...ade Unigrit Sanding Block Compound Power Cleaner M 84 W 7000 Cutting Pad Swirl Free Polish M 2 W 9000 Finishing Pad Minor scratches or acid rain pitting 2000 Grade Unigrit Sanding Paper Compound Power...

Page 2966: ...ons Rocker Panel Molding Replacement Callout Component Name 1 Rocker Panel Molding Screw CAUTION Refer to Fastener Notice Tightening torque 2 N m 18 lb in 2 Rocker Panel Molding Nut 3 Rocker Panel Int...

Page 2967: ...r Notice Fastener Tightening Specifications Refer to Fastener Tightening Specifications Exterior Trim Preliminary Procedure Remove the rocker panel Refer to Rocker Panel Molding Replacement 1 Rocker P...

Page 2968: ...e the tire wheel assembly Refer to Tire and Wheel Removal and Installation 1 Front Wheelhouse Liner Screw CAUTION Refer to Fastener Notice Tightening torque 6 N m 53 lb in 2 Front Wheelhouse Liner Bol...

Page 2969: ...tire wheel assembly Refer to Tire and Wheel Removal and Installation 1 Rear Wheelhouse Liner Panel Nut CAUTION Refer to Fastener Notice Tightening torque 4 N m 35 lb in 2 Rear Wheelhouse Liner Panel B...

Page 2970: ...Shield Replacement Left Side Callout Component Name Preliminary Procedure Remove the front tire wheel assembly Refer to Tire and Wheel Removal and Installation 1 Left Engine Splash Shield Plastic Reta...

Page 2971: ...hield Replacement Right Side Callout Component Name Preliminary Procedure Remove the front tire wheel assembly Refer to Tire and Wheel Removal and Installation 1 Right Engine Splash Shield Plastic Ret...

Page 2972: ...ont covers using a trim tool or equivalent 2 Remove the luggage carrier side rail rear covers using a trim tool or equivalent 3 Remove the luggage carrier center rails by flipping up the side retainer...

Page 2973: ...at attach the rear of the side rails to the roof 6 Remove the side rails from the vehicle 7 Remove the rubber gasket from the side rails Installation Procedure 1 Install the rubber gasket to the side...

Page 2974: ...nuts that attach the front of the side rails to the roof Tightening torque Tighten the nuts to 9 N m 80 lb in NOTE To avoid windnoise the center rails must be installed with the arrows pointing forwar...

Page 2975: ...acement With Sunroof Callout Component Name 1 Front Luggage Rack Rail 2 Front Luggage Rack Cover 3 Rear Luggage Rack Cover 4 Front Luggage Rack Nuts Qty 5 CAUTION Refer to Fastener Notice Tightening t...

Page 2976: ...me 1 Front Side Door Frame Applique Screw CAUTION Refer to Fastener Notice Tightening torque 2 N m 20 lb in 2 Front Side Door Frame Applique Assembly Tip Clean around the edge of the outer door frame...

Page 2977: ...Applique Replacement Callout Component Name Preliminary Procedure Open the rear door in order to access the pillar panel 1 C Pillar Panel Applique Assembly Integral Clips Qty 7 2 C Pillar Panel Appli...

Page 2978: ...r Applique Nuts Qty 4 Tip Release the four lower nuts first and ensure the foam gaskets are in place on the studs prior to re assembly 2 Integral Retainers Qty 5 Tip Release the five upper retainers s...

Page 2979: ...Preliminary Procedure Remove the rear door trim panel Refer to Rear Side Door Trim Panel Replacement 1 Rear Side Door Window Frame Rear Applique Screw Tightening torque 5 N m 44 lb in 2 Rear Side Door...

Page 2980: ...ct with dirt or any foreign matter prior to adhesion Use a J 25070 or equivalent to remove old nameplate Clean all adhesive from rear liftgate wipe surface dry with a clean lint free towel prior to in...

Page 2981: ...m 18 lb in Liftgate Center Applique Assembly Nuts 4 N m 35 lb in Liftgate Center Applique Assembly Screw 2 N m 18 lb in Liftgate Garnish Molding Nut 4 N m 35 lb in Liftgate Garnish Molding Bolt 2 N m...

Page 2982: ...ing to backlight their control graphics when the power mode is OFF and the park lights are ON Amplifier Interface The main amplifier power is provided by a 20A fuse located in the body control module...

Page 2983: ...way harness connector is present on OnStar equipped vehicles Additional service length is provided in the radio harnesses to allow connection prior to radio installation Radio amplifier outputs to th...

Page 2984: ...ive skips and ERR shown on the radio display or a jam in the loading mechanism Some incompatible CD types are Special shaped CDs any that are not round Re Writeable CDs CD RW type are incompatible Rec...

Page 2985: ...Ws may contain either standard audio cda or compressed audio mp3 Customers who record their own music CD R RWs should be aware of the following The files can be recorded on a CD R RW disc with a maxim...

Page 2986: ...n system map with routing information displayed on the navigation radio screen Provides verbal guidance to the operator Global Positioning System GPS Antenna The global positioning system GPS antenna...

Page 2987: ...passengers to use the rear seat entertainment RSE functions without disturbing the listening of front seat passengers The wireless headphones receive audio signals from an infrared transmitter on the...

Page 2988: ...9O 7 Cellular Entertainment Navigation Audio Radio UC1...

Page 2989: ...Cellular Entertainment Navigation Audio 9O 8 Radio U65...

Page 2990: ...9O 9 Cellular Entertainment Navigation Audio Speaker U65...

Page 2991: ...Cellular Entertainment Navigation Audio 9O 10 Digital Radio Receiver U2K...

Page 2992: ...9O 11 Cellular Entertainment Navigation Audio Steering Wheel Controls...

Page 2993: ...Cellular Entertainment Navigation Audio 9O 12 Power Ground and Video Signal...

Page 2994: ...9O 13 Cellular Entertainment Navigation Audio Audio Signals...

Page 2995: ...Cellular Entertainment Navigation Audio 9O 14 Steering Wheel Secondary Configurable Control Schematics...

Page 2996: ...9O 15 Cellular Entertainment Navigation Audio Remote Radio Steering Wheel Controls UK3...

Page 2997: ...H 346 Subwoofer Speaker Output 3 D GN 1795 Right Subwoofer Speaker Output 4 L BU BK 315 Right Subwoofer Speaker Output 5 BK 850 Ground 6 7 Not Used 8 RD WH 2040 Battery Positive Voltage Connector Part...

Page 2998: ...io Signal 5 7 Not Used 8 WH 1487 Antenna Enable Signal 9 L GN WH 512 Right Front Low Level Audio Signal 10 D GN 1947 Left Front Low Level Audio Signal 11 L GN 1948 Right Front Low Level Audio Signal 1...

Page 2999: ...Audio Drain Wire 12 15 Not Used 16 RD WH 2340 Battery Positive Voltage Connector Part Information OEM 15429806 Service Description 16 Way F Micro 64 Series BN Terminal Part Information Terminal Tray...

Page 3000: ...Dimming Signal 8 BK WH 1551 Ground 9 GY 118 Left Front Speaker Output 10 TN WH 1985 5 Volt Reference 11 12 Not Used 13 D GN 5060 Low Speed GMLAN Serial Data 14 Not Used Connector Part Information OEM...

Page 3001: ...Auxiliary Video High Signal 9 BARE 5345 Drain Wire 10 BN WH 5846 Video Power Mode Signal 11 PU 6979 DVD Audio Common 12 BARE 6980 DVD Audio Shield 13 TN WH 5830 Remote Infra Red Signal 14 BARE 6976 D...

Page 3002: ...l Repair Kit Core Insulation Crimp See Terminal Repair Kit Release Tool Test Probe See Terminal Repair Kit Pin Wire Color Circuit No Function 1 GY 118 Left Front Speaker Output 2 TN 201 Left Front Spe...

Page 3003: ...art Information OEM 626064 0 Service Description 2 Way F Faston 2 8 Series NA Terminal Part Information Terminal Tray See Terminal Repair Kit Core Insulation Crimp See Terminal Repair Kit Release Tool...

Page 3004: ...ubwoofer Speaker Output Connector Part Information OEM 31068 1010 Service Description 4 Way F HDAC64 SR Housing BK Pin Wire Color Circuit No Function 1 BK 1450 Ground 2 PU WH 7005 LED Dimming Signal 3...

Page 3005: ...GY Pin Wire Color Circuit No Function 1 PU 1375 Remote Radio Control Supply Voltage 2 Not Used 3 GY 1884 Cruise Control Switch Signal 4 5 Not Used 6 PU WH 7005 LED Dimming Signal 7 Not Used 8 BK 1450...

Page 3006: ...le Driver 3 Hazard Switch 13 Traction Control Switch TCS 4 Radio 14 Rear Wiper Washer Fog Lamp Switch 5 HVAC Control Module 15 Inflatable Restraint Passenger Airbag ON OFF Indicator 6 Cigar Lighter 16...

Page 3007: ...Cellular Entertainment Navigation Audio 9O 26 Below the LR Window 1 Digital Radio Receiver U2K 3 LR Wheel Panel 2 Rear Floor...

Page 3008: ...27 Cellular Entertainment Navigation Audio Audio Components 1 Radio 6 Speaker Subwoofer U65 2 Speaker RF Tweeter 7 Speaker LR 3 Speaker RF 8 Speaker LF 4 Speaker RR 9 Speaker LF Tweeter 5 Amplifier U...

Page 3009: ...Cellular Entertainment Navigation Audio 9O 28 Front Headliner Components 1 Dome Lamp Center 3 Sunroof Switch CF5 2 Noise Compensation Microphone U3U 4 Courtesy Map Lamp...

Page 3010: ...top Lamp LR 7 Backup Lamp Right 2 Rear Defogger Grid 8 License Lamp Right 3 Center High Mounted Stop Lamp CHMSL 9 Liftgate Switch 4 Digital Radio Antenna U2K 10 License Lamp Left 5 Park Stop Lamp RR 1...

Page 3011: ...ertainment Navigation Audio 9O 30 Secondary Configurable Control Component Views Steering Wheel Components 1 Horn Switch 3 Steering Wheel Control Switch Left UK3 K34 2 Steering Wheel Control Switch Ri...

Page 3012: ...identification of any stored DTCs and their status The use of the Diagnostic System Check Vehicle will identify the correct procedure for diagnosing the system and where the procedure is located Scan...

Page 3013: ...unter Data Numeric Varies Power Mode Data Alphanumeric Run Scan Tool Parameter Data List Units Displayed Typical Data Value Operating Conditions Ignition ON Engine OFF Radio ON Battery Voltage Signal...

Page 3014: ...seconds continuously Action Taken When the DTC Sets No action taken Conditions for Clearing the DTC The condition must be corrected A history DTC clears after 100 malfunction free ignition cycles The...

Page 3015: ...to battery One of the speaker output circuits is shorted to ground Action Taken When the DTC Sets The radio disables the audio output to the speaker with the current fault producing no sound from the...

Page 3016: ...OFF disconnect the antenna coax from the DRR Connect the test antenna to the DRR 2 Turn the ignition ON radio ON tuned to XM Verify that DTC B1259 is not current If the DTC B1259 is still current rep...

Page 3017: ...st 9 volts and no more than 16 volts Conditions for Setting the DTC Circuit failure 400 ms after radio activates Remote Enable Action Taken When the DTC Sets Radio sets the DTC and continues to output...

Page 3018: ...mal mode Conditions for Clearing the DTC The condition must be corrected A history DTC clears after 100 malfunction free ignition cycles The radio receives the clear code command from the scan tool Re...

Page 3019: ...itions for Clearing the DTC The condition must be corrected A history DTC clears after 100 malfunction free ignition cycles The radio receives the clear code command from the scan tool Reference Infor...

Page 3020: ...that is above 16 volts Action Taken When the DTC Sets The BCM will ignore the switch command Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present A history D...

Page 3021: ...r at the suspect steering wheel control switch 2 Test for infinite resistance between the ignition terminal 3 and the signal terminal 4 with the switch in the open position If less than specified valu...

Page 3022: ...s normal replace the radio Repair Instructions Perform the Diagnostic Repair Verification Vehicle Diagnostic Information after completing the diagnostic procedure Control Module References for radio r...

Page 3023: ...roach Diagnostic Procedure Instructions Vehicle Diagnostic Information provides an overview of each diagnostic category DTC Descriptor DTC B3622 07 Steering Wheel Controls Signal Circuit Circuit Syste...

Page 3024: ...conditions that affect radio operation may be corrected without removing the radio from the car Verify the condition and follow the diagnostic procedures in order to isolate and correct the condition...

Page 3025: ...wires such as sensor and communication circuits should not be suppressed Battery and ignition voltage circuits are the best choices for suppressing Capacitors work best on switch pops and low frequen...

Page 3026: ...ter that is used to power the auxiliary device The power inverters tend to introduce noisy signals into the vehicle electrical system Video Entertainment System Wireless Headphone Inoperative NOTE The...

Page 3027: ...ge and insert the CD from the J 39916 A to identify the suspect speaker 2 Disconnect the suspect speaker harness connector 3 Ignition ON test for greater than 9 volts on the suspect audio output signa...

Page 3028: ...agnostic procedure Auxiliary Audio Video Input Control Replacement Digital Radio Poor or No Reception Diagnostic Fault Information Perform the Diagnostic System Check Vehicle Diagnostic Information pr...

Page 3029: ...m the radio If the radio still displays CAL ERR replace the radio Repair Instructions Perform the Diagnostic Repair Verification Vehicle Diagnostic Information after completing the diagnostic procedur...

Page 3030: ...ion System Schematics Connector End View Reference Entertainment Communication Connector End Views Diagnostic System Check Vehicle Perform the Diagnostic System Check Vehicle before proceeding with th...

Page 3031: ...ion Vehicle Diagnostic Information after completing the diagnostic procedure Control Module References for radio replacement setup and programming Global Positioning System GPS Antenna Replacement Vid...

Page 3032: ...diagnostic procedure Video Display Replacement Video Entertainment System Remote Control Inoperative Diagnostic Fault Information Perform the Diagnostic System Check Vehicle Diagnostic Information pri...

Page 3033: ...e the rear seat audio control module 4 At the infrared module connector harness test for AC voltage between the low reference circuit and the left and right infra red audio signal circuits Verify ther...

Page 3034: ...tool SWC Bank 1 status while pressing and releasing the switches The reading should be SW1 SW7 identifying the switch pressed and Idle when released Circuit System Testing NOTE It is recommended that...

Page 3035: ...replace the radio If the recorded AC voltage is the same level as other speaker low level audio signal AC outputs replace the suspect speaker With Amplifier 1 Center the balance and fade adjustment on...

Page 3036: ...udio signal radio harness connector terminal and the suspect remote radio audio signal digital radio C2 harness connector terminal If greater than specified value repair open or high resistance 8 If a...

Page 3037: ...and Cleaning Care of CDs Handle CDs carefully Store them in their original cases or other protective cases and away from direct sunlight and dust The CD player scans the bottom surface of the disc If...

Page 3038: ...Name 1 Front Overhead Console Assembly Refer to Roof Console Replacement 2 Mobile Telephone Microphone Assembly Tip 1 Disconnect the microphone electrical connector 2 From the top side of the overhead...

Page 3039: ...1 Front Overhead Console Assembly Refer to Roof Console Replacement 2 Mobile Telephone Microphone Assembly Procedure 1 Disconnect the microphone electrical connector 2 From the top side of the overhea...

Page 3040: ...onent Name Preliminary Procedures Remove the right rear quarter lower trim panel Refer to Rear Quarter Lower Trim Panel Replacement 1 Radio Rear Compartment Speaker Refer to Radio Rear Speaker Replace...

Page 3041: ...rocedure must be performed Perform the radio setup procedure Refer to Radio Setup Callout Component Name Preliminary Procedure Remove the instrument panel accessory trim plate Refer to Instrument Pane...

Page 3042: ...the following procedure must be performed Perform the digital radio receiver setup Refer to Digital Radio Receiver Setup Callout Component Name Preliminary Procedure Remove the left rear quarter lowe...

Page 3043: ...front of the headliner Refer to Headlining Trim Panel Replacement 1 Mobile Telephone and Vehicle Location Antenna Assembly Bolt CAUTION Refer to Fastener Notice Tightening torque 5 N m 44 lb in 2 Mobi...

Page 3044: ...ightening Specifications Refer to Fastener Tightening Specifications Cellular Entertainment and Navigation Preliminary Procedure Lower the rear of the headliner Refer to Headlining Trim Panel Replacem...

Page 3045: ...ve the instrument panel upper trim pad Refer to Instrument Panel Upper Trim Panel Replacement Instrument Panel Upper Trim Panel Replacement 2 Remove the radio Refer to Radio Replacement 1 Navigation A...

Page 3046: ...Procedure Lower the rear of the headliner Refer to Headlining Trim Panel Replacement 1 Digital Radio Coaxial Cable Tips 1 Disconnect all electrical antenna connections 2 If the old antenna is wrapped...

Page 3047: ...lding Replacement 3 Lower the rear of the headliner as needed Refer to Headlining Trim Panel Replacement 4 Remove the IP compartment Refer to Instrument Panel Compartment Replacement 5 Remove the radi...

Page 3048: ...orque 2 N m 18 lb in NOTE The bolts have captured washers on them to keep them as part of the video display assembly ensure that the washers are still on the assembly when reinstalling the display ass...

Page 3049: ...placement Callout Component Name 1 Rear Console Trim Plate Assembly Refer to Console Rear Trim Plate Replacement 2 Auxiliary Audio Video Input Control Assembly Screw Qty 2 CAUTION Refer to Fastener No...

Page 3050: ...t Component Name 1 Rear Console Trim Plate Assembly Refer to Console Rear Trim Plate Replacement 2 Auxiliary Heater and A C and Radio Control Module Screw Qty 4 CAUTION Refer to Fastener Notice Tighte...

Page 3051: ...Fastener Tightening Specifications Cellular Entertainment and Navigation 1 Front Door Trim Panel Upper Extension Tip 1 Pull at the top of the trim panel to disengage the trim clip 2 Lift up to remove...

Page 3052: ...ner Tightening Specifications Refer to Fastener Tightening Specifications Cellular Entertainment and Navigation Preliminary Procedure Remove the front door inner trim panel Refer to Front Side Door Tr...

Page 3053: ...er to Rear Quarter Lower Trim Panel Replacement 1 Radio Rear Compartment Speaker Bolt Qty 2 CAUTION Refer to Fastener Notice Tightening torque 2 5 N m 22 lb in 2 Radio Rear Compartment Speaker Nut Qty...

Page 3054: ...ener Tightening Specifications Refer to Fastener Tightening Specifications Cellular Entertainment and Navigation Preliminary Procedure Remove the rear door inner trim panel Refer to Rear Side Door Tri...

Page 3055: ...Tip Right hand steering wheel control switch shown Left hand similar 1 Steering Wheel Trim Cover Bolt Qty 4 2 Steering Wheel Trim Cover Qty 2 3 Steering Wheel Control Switch Assembly Screw Qty 6 Tip...

Page 3056: ...Base Bolt 5 N m 44 lb in Digital Radio Receiver Nut 4 N m 35 lb in Front Door Speaker Screw 2 5 N m 22 lb in Mobile Telephone and Vehicle Location Antenna Assembly Bolt 5 N m 44 lb in Radio Screw 2 N...

Page 3057: ...ication Component Views 10B 17 Diagnostic Information and Procedures 10B 18 Diagnostic Starting Point Data Communications 10B 18 DTC B1000 10B 18 DTC B1001 10B 19 DTC B1016 10B 20 DTC U0073 10B 20 DTC...

Page 3058: ...e Monitoring 10D 2 Scan Tool Output Controls Tire Pressure Monitoring 10D 2 Scan Tool Data List Tire Pressure Monitoring 10D 3 Scan Tool Data Definitions Tire Pressure Monitoring 10D 4 DTC C0750 C0755...

Page 3059: ...ES switch or the SET switch is active The RES switch or the SET switch will remain inactive when the BCM has not received the predetermined voltage signal from the on off switch Cruise Control Engaged...

Page 3060: ...ned voltage signal on the cruise control function switch circuit The vehicle speed stored in the memory of the engine control module will be erased when the cruise control On Off switch is turned OFF...

Page 3061: ...Cruise Control System 10A 3 Cruise Control Schematics...

Page 3062: ...5315247 J 35616 2A GY Pin Wire Color Circuit No Function A OG BK 6035 Brake Pedal Displacement Sensor Low Reference B D BU 6037 Brake Pedal Displacement Sensor Signal C GY 6036 Brake Pedal Displacemen...

Page 3063: ...se Control System 10A 5 Component Location Cruise Control Component Views Steering Wheel Components 1 Horn Switch 3 Steering Wheel Control Switch Left UK3 K34 2 Steering Wheel Control Switch Right UK3...

Page 3064: ...10A 6 Cruise Control System Pedal Assemblies 1 Brake Pedal Position Sensor 2 Accelerator Pedal Position APP Sensor...

Page 3065: ...Cruise Control Data Yes No No Cruise Disengage 1 6 History Cruise Control Data The last reason for cruise control disengagement Varies Cruise Mode Signal Cruise Control Data Volts 0 0 Volts Cruise On...

Page 3066: ...override has occurred DTC Set The ECM detects that a DTC has been set which affects the cruise control operation ECM Inhibit The ECM detects a RAM corruption associated to the cruise control system E...

Page 3067: ...CM detects an invalid voltage signal on the cruise control switch signal circuit The above condition is present for 0 5 second Action Taken When the DTC Sets The BCM stores the DTC information into me...

Page 3068: ...e component If the circuits and the component tests are normal replace the BCM Component Testing NOTE The cruise control ON OFF switch must be ON in order to properly measure the resistance of the SET...

Page 3069: ...TC Sets The BCM stores DTC B0835 in memory The cruise control system becomes inoperative Conditions for Clearing the DTC The DTC becomes history when the conditions for setting the DTC are no longer p...

Page 3070: ...been applied The BCM also sends a high voltage signal on the stop lamp switch signal circuit to the ECM This DTC will set if the serial data message and the voltage signal on the stop lamp switch sign...

Page 3071: ...uns and fails The malfunction indicator lamp MIL will not illuminate The ECM records the operating conditions at the time the diagnostic fails The ECM stores this information in the Failure Records Al...

Page 3072: ...pressed ON the cruise control switch is closed and the signal circuit is low When the cruise on off switch is pressed OFF the cruise control switch is open and the signal circuit is high Reference Inf...

Page 3073: ...fication NOTE Repair any brake system related symptoms and DTCs before performing this diagnostic NOTE If a BCM has been replaced the brake pedal position BPP sensor must be calibrated Refer to Brake...

Page 3074: ...ructions Perform the Diagnostic Repair Verification Vehicle Diagnostic Information Steering Wheel Control Switch Assembly Replacement Control Module References for BCM or ECM replacement setup and pro...

Page 3075: ...el Refer to Instrument Panel Insulator Panel Replacement Left Side 9 Use the scan tool to monitor CRUISE BRAKE SWITCH in the engine control module ECM General Information data table while depressing a...

Page 3076: ...nector index notch pointing to the 1 o clock position Slide the switch in the retainer until the plunger is fully depressed into the barrel Rotate the switch clockwise until the travel stop has been r...

Page 3077: ...low speed GMLAN network If one network is lost the BCM can still communicate with the scan tool A lost communication DTC typically is set in modules other than the module with a communication failure...

Page 3078: ...ices which represents a collection of signals owned by a single physical device So any physical device can have one or more virtual devices The signal supervision is the process of determining whether...

Page 3079: ...ontrolled Power Mode The body control module BCM uses the discrete ignition switch inputs Run Crank Ignition 1 Voltage Accessory Voltage and Ignition 1 Voltage to distinguish the correct power mode Th...

Page 3080: ...ower RAP The body control module BCM keeps the retained accessory power RAP relay energized during all power modes except Off Awake and Crank The relay is also energized for approximately 10 minutes a...

Page 3081: ...Data Communications 10B 5 Low Speed GMLAN...

Page 3082: ...10B 6 Data Communications High Speed GMLAN...

Page 3083: ...Data Communications 10B 7 Body Control System Schematics...

Page 3084: ...10B 8 Data Communications Power and Ground Starting and Charging...

Page 3085: ...Data Communications 10B 9 Exterior LIghts Radio Data Communications ABS Automatic Transmission and Ignition Lock...

Page 3086: ...10B 10 Data Communications Shift Lock Headlights Cruise Wiper and I P...

Page 3087: ...Data Communications 10B 11 Interior Lights Door Locks Exterior Lights Release Systems Movable Windows and Horns...

Page 3088: ...gnition 1 Voltage 15 L BU WH 1414 Left Front Turn Signal Switch Signal Left Turn Signal Switch Signal 16 D BU WH 1415 Right Front Turn Signal Switch Signal Right Turn Signal Switch Signal 17 PU 1375 R...

Page 3089: ...2 13 14 15 16 17 17 18 19 21 22 Terminal Tray SNAC3 A021T M0 64 20 Core Insulation Crimp J J Release Tool Test Probe 12094429 J 35616 64B L BU Pin Wire Color Circuit No Function 1 BK WH 1551 Ground 2...

Page 3090: ...otor Park Switch Signal 8 Not Used 9 BK 50 Ground 10 RD WH 2440 Battery Positive Voltage 11 D GN WH 1317 Fog Lamp Relay Control T96 12 YE 5187 Right Trailer Turn Signal Lamp V92 13 OG 5186 Left Traile...

Page 3091: ...igh Signal 22 Not Used 23 PK WH 1970 Headlamp Low Beam Relay Control 24 WH 1080 Park Lamp Relay Control 25 Not Used Connector Part Information OEM HITPB 25 F PK Service Description 25 WAY F Receptacle...

Page 3092: ...Lock Signal 13 D GN 5706 Endgate Latch Relay Supply Voltage 14 28 Not Used Connector Part Information OEM 348822 2 Service 89046778 Description 16 Way F Diagnostic Connector BK Terminal Part Informati...

Page 3093: ...Data Communications 10B 17 Component Location Data Communication Component Views Left Side of the I P 1 Splice Pack SP200 3 Data Link Connector DLC 2 I P Harness...

Page 3094: ...c trouble codes DTCs and their status The use of the Diagnostic System Check Vehicle will identify the correct procedures to begin vehicle diagnosis These must be performed before system DTC or sympto...

Page 3095: ...s retrieved as both a current and history DTC replace the module that the DTC set for Circuit System Verification If this DTC is retrieved as a current DTC replace the module that set the DTC Repair I...

Page 3096: ...ent A history DTC clears when the module ignition cycle counter reaches the reset threshold without a repeat of the malfunction Circuit System Verification 1 Program the VIN information to the body co...

Page 3097: ...provides an overview of each diagnostic category DTC Descriptors DTC U0100 00 Lost Communication With Engine Powertrain Control Module ECM PCM DTC U0101 00 Lost Communication With Transmission Control...

Page 3098: ...arness connector of the module that is not communicating NOTE Only the high speed GMLAN modules have a the serial data communication enable circuit Refer to the module schematics to identify which mod...

Page 3099: ...e system voltage is between 9 16 volts The vehicle power mode master requires serial data communication to occur Conditions for Setting the DTC A no communication condition exists on the CAN bus seria...

Page 3100: ...he ignition switch is in the ACC or RUN position or anytime the body control module BCM determines that communication is needed from the powertrain When the ignition switch is in the ACC or RUN positi...

Page 3101: ...sistance repair the voltage circuit for a short to ground 4 If all tests normal replace the BCM Repair Instructions Perform the Diagnostic Repair Verification Vehicle Diagnostic Information after comp...

Page 3102: ...for GMLAN high speed modules Reference Information Schematic Reference Body Control System Schematics Data Communication Schematics Connector End View Reference Master Electrical Component List Electr...

Page 3103: ...s default values for all parameters received on the serial data circuits The module inhibits the setting of all other communication DTCs Conditions for Clearing the DTC A current DTC clears when the m...

Page 3104: ...ort is found in that circuit ensure that no module output voltage circuit is shorted to ground before replacing the module Reference Information Schematic Reference Data Communication Schematics Contr...

Page 3105: ...when the ignition key is in ACC ON or START The EBCM Yaw Rate Sensor and the Steering Angle Sensor are the only modules connected to the CAN bus serial data circuits For more information on CAN bus se...

Page 3106: ...test the serial data circuit for open high resistance 6 If all circuits test normal replace the module that is not communicating Repair Instructions Perform the Diagnostic Repair Verification Vehicle...

Page 3107: ...ctions of the DLC are functioning properly the malfunction must be due to the scan tool CANdi module Use the DMM MIN MAX function to capture locate intermittent conditions Reference Information Schema...

Page 3108: ...U0100 U0299 for diagnostics An open in the DLC ground circuit terminal 5 will allow the scan tool to operate to set up the vehicle on the tool and then not communicate with the vehicle When the scan...

Page 3109: ...l replace the VCIM 12 Ignition OFF disconnect BCM harness connector C3 13 Test for infinite resistance between the serial data circuits of BCM harness connector C3 terminal 8 and ground and between BC...

Page 3110: ...effected and the other modules will still communicate An open in the DLC ground circuit terminal 5 will allow the scan tool to operate to set up the vehicle on the tool and then not communicate with t...

Page 3111: ...Verification Vehicle Diagnostic Information after completing the repair Control Module References for module replacement setup and programming GMLAN Wiring Repairs Illuminated Entry Lamps Inoperative...

Page 3112: ...Instructions Perform the Diagnostic Repair Verification Vehicle Diagnostic Information after completing the diagnostic procedure Control Module References for BCM replacement setup and programming Pow...

Page 3113: ...e at inappropriate times Remote start may operate incorrectly Ignition key may not return to OFF Specific retained accessory power RAP functions may operate while others do not Diagnostic Aids A short...

Page 3114: ...e Ignition 1 voltage If more than 1 0 volt repair the circuit for a short to voltage 7 Test for less than 1 0 ohm of resistance between the BCM and the ignition switch on the following circuits Igniti...

Page 3115: ...esting for Intermittent Conditions and Poor Connections Wiring Repairs Circuit System Testing NOTE If any door open switch input to the BCM is reporting a door open when it is not the RAP function wil...

Page 3116: ...ice Heated Vented Seat Module HVSM Low Speed GMLAN Scan Tool Does Not Communicate with Low Speed GMLAN Device HVAC Control Module Low Speed GMLAN Scan Tool Does Not Communicate with Low Speed GMLAN De...

Page 3117: ...Refer to Instrument Panel Lower Brace Bezel Replacement 4 Disconnect the BCM electrical harnesses 5 Remove the BCM 1 from the instrument panel I P retainer a Pry the BCM tabs from the locking tabs on...

Page 3118: ...t BCM is not properly set up The following procedures must be followed 1 Programming the BCM 2 Learning the restraints ID NOTE After the procedure is completed the personalization settings of the BCM...

Page 3119: ...wer Management Illustration Tool Number Description J 35616 GM Approved Terminal Test Kit J 35616 200 Test Light Probe Kit J 36169 A Fused Jumper Wire J 38125 Terminal Repair Kit J 42759 Ignition Swit...

Page 3120: ...that contains its unique value which is received by the TDM The TDM then compares this value to the learned key code stored in memory The TDM then performs one of the following functions If the trans...

Page 3121: ...Immobilizer Control System 10C 2 Vehicle Theft Deterrent...

Page 3122: ...Service 88988353 Description 5 Way F SL Series Unsealed BK Terminal Part Information Terminal Tray 16 02 1110 20 Core Insulation Crimp H H Release Tool Test Probe J 38125 213 J 35616 64B L BU Pin Wire...

Page 3123: ...nt Location Immobilizer Component Views Steering Column 1 Turn Signal Multifunction Switch 4 Theft Deterent Module 2 Inflatable Restraint Steering Wheel Module Coil 5 Ignition Lock Solenoid 3 Windshie...

Page 3124: ...ectrical Counts Varies VTD Auto Learn Timer Engine Electrical Active Inactive Inactive VTD Password Learn Enabled Engine Electrical Yes No No VTD Security Code Accepted Engine Electrical Yes No Yes VT...

Page 3125: ...ous TDM State The scan tool displays the TDM state of the last ignition cycle Security Indicator Command The scan tool displays the state of the BCM commanding the security indicator The scan tool dis...

Page 3126: ...cription and Operation Immobilizer Description and Operation Electrical Information Reference Circuit Testing Connector Repairs Testing for Intermittent Conditions and Poor Connections Wiring Repairs...

Page 3127: ...diagnostic approach Diagnostic Procedure Instructions Vehicle Diagnostic Information provides an overview of each diagnostic category DTC Descriptor DTC B3031 Security System Controller In Learn Mode...

Page 3128: ...nder Circuit System Description When an ignition key is inserted into the ignition lock cylinder and the ignition is switched ON the transponder embedded in the head of the key is energized by the exc...

Page 3129: ...ignition lock cylinder and the ignition is switched ON the transponder embedded in the head of the key is energized by the exciter coils surrounding the ignition lock cylinder The energized transpond...

Page 3130: ...in memory This stored value is the learned key code If the value is correct the TDM will send the prerelease password via the serial data circuit to the engine control module ECM If the transponder va...

Page 3131: ...ol Data Definitions Immobilizer Circuit System Verification NOTE When using this diagnostic more than one vehicle key is required to ensure proper diagnosis If more than one key is not available at th...

Page 3132: ...ompleting the diagnostic procedure Control Module References for ECM replacement setup and programming DTC P0633 Diagnostic Instructions Perform the Diagnostic System Check Vehicle Diagnostic Informat...

Page 3133: ...Diagnostic Procedure Instructions Vehicle Diagnostic Information provides an overview of each diagnostic category DTC Descriptor DTC P1629 Theft Deterrent Fuel Enable Signal Not Received Circuit Syst...

Page 3134: ...n Conditions for Setting the DTC The ECM receives an incorrect prerelease password from the TDM Action Taken When the DTC Sets The security indicator will illuminate Vehicle starting will be disabled...

Page 3135: ...to the ECM by the TDM is reliant on the communications between the transponder located in the vehicle key and the TDM Failure to establish communications or an interruption in the communications betw...

Page 3136: ...he scan tool will display Programming Successful Turn OFF Ignition The vehicle is now ready to relearn the key information and or the passwords on the next ignition switch transition from OFF to CRANK...

Page 3137: ...ehicle is now ready to relearn the key information and or the passwords on the next ignition switch transition from OFF to CRANK 12 Turn OFF the ignition and wait 2 minutes 13 With a master vehicle ke...

Page 3138: ...ion once every 60 seconds The RCDLR receives and translates the data contained in each sensor RF transmission into sensor presence sensor mode and tire pressure The RCDLR then sends the tire pressure...

Page 3139: ...Monitoring Perform the Diagnostic System Check Vehicle Diagnostic Information prior to using this diagnostic procedure Review the systems description and operation in order to familiarize yourself wit...

Page 3140: ...re Sensor Mode Data Display Learn Re measure Rolling Entering Off Exiting Off Remeasure Learn LR Tire Pressure Data Display kPa psi 35 psi LR Tire Pressure Sensor Battery Status Data Display OK Low OK...

Page 3141: ...can tool LR Tire Pressure The scan tool displays 0 703 kPa 0 102 psi The actual pressure of the left rear tire RF Pressure Status The scan tool displays the overall condition of the tire The condition...

Page 3142: ...esence sensor mode and tire pressure Once vehicle speed is 20 mph or greater the RCDLR waits for the first sensor to go into drive mode then checks if all sensors have gone into drive mode If one or m...

Page 3143: ...5 If no faults are found go to Diagnostic Aids Repair Instructions Perform the Diagnostic Repair Verification Vehicle Diagnostic Information after completing the diagnostic procedure Tire Pressure Se...

Page 3144: ...Monitoring Scan Tool Data List Tire Pressure Monitoring Scan Tool Data Definitions Tire Pressure Monitoring Special Tools Required J 46079 Tire Pressure Monitor Diagnostic Tool Circuit System Testing...

Page 3145: ...tire pressure sensor 3 With the scan tool observe tire pressures in the scan tool data display Verify pressure readings from special tool do not differ 2 psi or more than scan tool data display If th...

Page 3146: ...re mounting Position the mounting dismounting head 180 degrees from the valve stem Position the bead transition area 45 degrees counterclockwise of the valve stem Using the tire machine rotate the tir...

Page 3147: ...reaking fixture 90 degrees from the valve stem when separating the tire bead from the wheel Position the mounting dismounting head so the tire iron or pry bar can be inserted slightly clockwise of the...

Page 3148: ...ensor ID has been learned the RCDLR sends a serial data message to the BCM to sound a horn chirp This verifies the sensor has transmitted its ID and the RCDLR has received and learned it The RCDLR mus...

Page 3149: ...hirp sounds or use the scan tool and select Special Functions Sensor Learn Mode Enable Enable soft key A horn chirp will sound indication the mode has been enabled WARNING Over inflating tires may cau...

Page 3150: ...10D 13 Tire Pressure Monitoring System...

Page 3151: ...1 Repair Instructions 11A 1 Drivetrain and Front Suspension Frame Reinforcement Replacement 11A 1 Frame Replacement 11A 2 Front Frame Cushion or Insulator Replacement 11A 6 Underbody Inspection 11A 7...

Page 3152: ...y the dimensional accuracy of the vehicle underbody Set vertical pointers equally as needed per your application Repair Instructions Drivetrain and Front Suspension Frame Reinforcement Replacement Rem...

Page 3153: ...ure Refer to Engine Support Fixture 3 Raise and support the vehicle Refer to Lifting and Jacking the Vehicle 4 Remove the front wheels Refer to Tire and Wheel Removal and Installation 5 Remove the sid...

Page 3154: ...ps from the frame 14 Lower the vehicle until the frame contacts J 39580 15 Remove the reinforcement bolts 3 16 Remove the rear frame to body bolts 2 DISCARD the bolts 17 Remove the reinforcement 1 fro...

Page 3155: ...e reinforcement 1 to the vehicle 5 Loosely install NEW rear frame to body bolts 2 6 Loosely install the reinforcement bolts 3 7 Raise the vehicle away from the J 39580 8 Install the power steering coo...

Page 3156: ...orcement bolts 3 Tightening torque Tighten the bolts 3 to 50 N m 37 lb ft 15 Tighten the frame to body bolts Tightening torque Tighten the bolts to 155 N m 114 lb ft 16 Install the front air dam faste...

Page 3157: ...insulator from the frame Installation Procedure 1 Clean the frame insulator opening NOTE The frame insulator tabs should be aligned horizontally or left to right on the vehicle and the recessed area...

Page 3158: ...e that the drain provisions in the floor pan reinforcement members are open Open the drain holes in the body side panels using a punch and a drift Specifications Fastener Tightening Specifications Fra...

Page 3159: ...Prepared by 1st Ed Dec 2006 3154...

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