Chevrolet Cruze 2013 Repair Manual

2013 Chevrolet Cruze
2013 GENERAL INFORMATION Dangers, Warnings, and Cautions - Cruze
2013 GENERAL INFORMATION

Dangers, Warnings, and Cautions - Cruze
INTRODUCTION
DEFINITION OF DANGER, WARNING, CAUTION, AND NOTE
The diagnosis and repair procedures in a GM Service Information contain both general and specific Dangers,
Warnings, Cautions, Notes or Importants. GM is dedicated to the presentation of service information that helps
the technician to diagnose and repair the systems necessary for the proper operation of the vehicle, however,
certain procedures may present a hazard to the technician if they are not followed in the recommended manner.
Dangers, Warnings, Cautions and Notes or Importants are elements designed to prevent these hazards, however,
not all hazards can be foreseen. This information is placed at strategic locations within the service manual. This
information is designed to prevent the following from occurring:
Serious bodily injury or death to the technician

Damage to the vehicle
Unnecessary vehicle repairs
Unnecessary component replacement
Improper repair or replacement of vehicle components.
Any warning or caution that appears in this service category is referenced from the individual service
categories.
DANGER Defined
When encountering a DANGER, you will be asked to take a necessary action or not to take a prohibited action.
If a DANGER is not heeded, the following consequences may occur:
Serious bodily injury or death to the technician

Serious bodily injury or death to other technicians in the workplace area
WARNING Defined
When encountering a WARNING, you will be asked to take a necessary action or not to take a prohibited
action. If a WARNING is not heeded, the following consequences may occur:
Serious bodily injury to the technician

Serious bodily injury to other technicians in the workplace area
Serious bodily injury to the driver and/or passenger(s) of the vehicle, if the vehicle has been improperly
repaired
CAUTION Defined
CAUTIONS call special attention to a necessary action or to a prohibited action. If a CAUTION is not heeded,

the following 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 systems or components which are dependent upon the proper operation of the system or
component under repair
Improper operation or performance of any systems or components which are dependent upon the proper
operation or performance of the system or component under repair
Damage to fasteners, basic tools, or special tools
The leakage of coolant, lubricant, or other vital fluids
NOTE or IMPORTANT Defined
NOTE and IMPORTANT statements emphasize a necessary characteristic of a diagnostic or repair procedure.
NOTE or IMPORTANT statements are designed to do the following:
Clarify a procedure
Present additional information for accomplishing a procedure
Give insight into the reason or reasons for performing a procedure in the manner recommended
Present information that will help to accomplish a procedure in a more effective manner
Present information that gives the technician the benefit of past experience in accomplishing a procedure
with greater ease
ABS COMPONENT HANDLING WARNING

WARNING: Certain components in the Antilock Brake System (ABS) are not intended
to be serviced individually. Attempting to remove or disconnect certain
system components may result in personal injury and/or improper system
operation. Only those components with approved removal and installation
procedures should be serviced.
ACTIONS TO TAKE WHEN WORKING WITH FUEL WARNING
WARNING: Fuel Vapors can collect while servicing fuel system parts in enclosed
areas such as a trunk. To reduce the risk of fire and increased exposure
to vapors:
Use forced air ventilation such as a fan set outside of the trunk.
Plug or cap any fuel system openings in order to reduce fuel vapor
formation.
Clean up any spilled fuel immediately.

Avoid sparks and any source of ignition.

Use signs to alert others in the work area that fuel system work is in
process.
APPROVED EQUIPMENT FOR COLLISION REPAIR WARNING

WARNING: To avoid personal injury when exposed to welding flashes or to
galvanized (Zinc Oxide) metal toxic fumes while grinding/cutting on any
type of metal or sheet molded compound, you must work in a properly
ventilated area, wearing an approved respirator, eye protection, earplugs,
welding gloves, and protective clothing.
ASSISTANT DRIVING WARNING
WARNING: An assistant should drive the vehicle while the technician checks for the
location of the reported condition. Otherwise, personal injury could result.
BATTERY DISCONNECT WARNING
WARNING: Unless directed otherwise, the ignition and start switch must be in the
OFF or LOCK position, and all electrical loads must be OFF before
servicing any electrical component. Disconnect the negative battery cable
to prevent an electrical spark should a tool or equipment come in contact
with an exposed electrical terminal. Failure to follow these precautions
may result in personal injury and/or damage to the vehicle or its
components.
For Vehicles equipped with OnStar (UE1) with Back Up Battery:
The Back Up Battery is a redundant power supply to allow limited
OnStar functionality in the event of a main vehicle battery power
disruption to the VCIM (OnStarmodule). Do not disconnect the main
vehicle battery or remove the OnStar fuse with the ignition key in any
position other than OFF. Retained accessory power should be allowed to
time out or be disabled (simply opening the driver door should disable
retained accessory power) before disconnecting power. Disconnecting
power to the OnStar module in any way while the ignition is On or with
retained accessory power activated may cause activation of the OnStar
Back-Up Battery system and will discharge and permanently damage the
back-up battery. Once the Back-Up Battery is activated it will stay on until
it has completely discharged. The back-up battery is not rechargeable and
once activated the back-up battery must be replaced.
BRAKE DUST WARNING

WARNING: Avoid taking the following actions when you service wheel brake parts:
Do not grind brake linings.

Do not sand brake linings.
Do not clean wheel brake parts with a dry brush or with compressed
air.
Some models or aftermarket brake parts may contain asbestos fibers

which can become airborne in dust. Breathing dust with asbestos fibers
may cause serious bodily harm. Use a water-dampened cloth in order to
remove any dust on brake parts. Equipment is available commercially in
order to perform this washing function. These wet methods prevent fibers
from becoming airborne.
BRAKE FLUID IRRITANT WARNING
WARNING: Brake fluid may irritate eyes and skin. In case of contact, take the
following actions:
Eye contact-rinse thoroughly with water.

Skin contact-wash with soap and water.
If ingested-consult a physician immediately.
BRAKE FLUID WARNING

WARNING: Use only Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or
equivalent DOT 3 brake fluid from a clean, sealed container. Do not use
fluid from an open container that may be contaminated with water.
Improper or contaminated fluid could result in damage to components, or
loss of braking, with possible injury.
CHECKING HOT TRANSMISSION FLUID THROUGH DRAIN PLUG HOLE WARNING
WARNING: The engine must be running when the transmission fluid fill plug is
removed, or excessive fluid loss will occur. Transmission fluid may be
hot. Since the actual fluid level is unknown, stand clear when removing
the fill plug. Have a container ready to capture any lost fluid. Do not turn
the engine off with the fill plug removed, as you can be injured by hot
transmission fluid being expelled out of the oil fill opening.
CLEANING SOLVENT WARNING
WARNING: Bodily injury may occur if the cleaning solvent is inhaled or exposed to
the skin.

CLUTCH ACTUATOR CYLINDER WARNING

WARNING: Do not apply any pressure to the clutch actuator cylinder with the
transmission removed. The clutch actuator cylinder is not pressureresistant and must only be actuated between two solid surfaces, such as
the transmission and clutch assembly. Failure to follow this warning may
cause personal injury and/or damage the clutch actuator cylinder.
COLLISION SECTIONING WARNING
WARNING: Sectioning should be performed only in the recommended areas. Failure
to do so may compromise the structural integrity of the vehicle and cause
personal injury if the vehicle is in a collision.
CRACKED WINDOW WARNING
WARNING: If a window is cracked but still intact, crisscross the window with masking
tape in order to reduce the risk of damage or personal injury.
DEFROSTER OUTLET WARNING
WARNING: If broken glass falls into the defroster outlets, it can be blown into the
passenger compartment and cause personal injury.
EXHAUST SERVICE WARNING
WARNING: In order to avoid being burned, do not service the exhaust system while it
is still hot. Service the system when it is cool.
EXPRESS WINDOW DOWN WARNING
WARNING: Disconnect the power window switch when working inside the driver
door. When operated, the Express Up/Down Feature allows the door
window to move very quickly, without stopping, which could cause
personal injury.
EYE PROTECTION WARNING
WARNING: Approved safety glasses and gloves should be worn when performing
this procedure to reduce the chance of personal injury.
FOAM SOUND DEADENERS WARNING

WARNING: Foam sound deadeners must be removed from areas within 152.4 mm (6
in) of where flame is to be used for body repairs. When reinstalling foam
sound deadeners, avoid inhaling fumes as bodily injury may result.
FUEL AND EVAPORATIVE EMISSION PIPE WARNING
WARNING: In order to reduce the risk of fire and personal injury observe the
following items:
Replace all nylon fuel pipes that are nicked, scratched or damaged
during installation, do not attempt to repair the sections of the nylon
fuel pipes
Do not hammer directly on the fuel harness body clips when
installing new fuel pipes. Damage to the nylon pipes may result in a
fuel leak.
Always cover nylon vapor pipes with a wet towel before using a
torch near them. Also, never expose the vehicle to temperatures
higher than 115C (239F) for more than one hour, or more than 90C
(194F) for any extended period.
Apply a few drops of clean engine oil to the male pipe ends before
connecting fuel pipe fittings. This will ensure proper reconnection
and prevent a possible fuel leak. (During normal operation, the Orings located in the female connector will swell and may prevent
proper reconnection if not lubricated.)
FUEL GAUGE LEAK WARNING

WARNING: Wrap a shop towel around the fuel pressure connection in order to reduce
the risk of fire and personal injury. The towel will absorb any fuel leakage
that occurs during the connection of the fuel pressure gauge. Place the
towel in an approved container when the connection of the fuel pressure
gauge is complete.
FUEL PIPE FITTING WARNING
WARNING: Always apply a few drops of clean engine oil to the male pipe ends before
connecting the fuel pipe fittings. This will ensure proper reconnection and
prevent a possible fuel leak. Always replace O-rings.
FUEL STORAGE WARNING
WARNING: Do not drain the fuel into an open container. Never store the fuel in an
open container due to the possibility of a fire or an explosion.
FUEL VAPORS IN EVAPORATIVE EMISSION COMPONENTS WARNING

WARNING: Do not breathe the air through the EVAP component tubes or hoses. The
fuel vapors inside the EVAP components may cause personal injury.
GASOLINE/GASOLINE VAPORS WARNING
WARNING: Gasoline or gasoline vapors are highly flammable. A fire could occur if an
ignition source is present. Never drain or store gasoline or diesel fuel in
an open container, due to the possibility of fire or explosion. Have a dry
chemical (Class B) fire extinguisher nearby.
GLASS AND SHEET METAL HANDLING WARNING
WARNING: When working with any type of glass or sheet metal with exposed or
rough edges, wear approved safety glasses and gloves in order to reduce
the chance of personal injury.
HALOGEN BULB WARNING
WARNING: Halogen bulbs contain gas under pressure. Handling a bulb improperly
could cause it to shatter into flying glass fragments. To help avoid
personal injury:
Turn off the lamp switch and allow the bulb to cool before changing
the bulb.
Leave the lamp switch OFF until the bulb change is complete.
Always wear eye protection when changing a halogen bulb.
Handle the bulb only by its base. Avoid touching the glass.
Keep dirt and moisture off the bulb.
Properly dispose of the used bulb.
Keep halogen bulbs out of the reach of children.
HOOD HOLD-OPEN DEVICE WARNING

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.
HOT EXHAUST SYSTEM WARNING
WARNING: While engine is operating, the exhaust system will become extremely hot.
To prevent burns avoid contacting a hot exhaust system.
MOVING PARTS AND HOT SURFACES WARNING

WARNING: Avoid contact with moving parts and hot surfaces while working around a
running engine in order to prevent physical injury.
PARKING BRAKE AND DRIVE WHEELS WARNING
WARNING: Apply the parking brake and block the drive wheels before performing
this procedure in order to prevent bodily injury.
PROTECTIVE GOGGLES AND GLOVE WARNING
WARNING: Always wear protective goggles and gloves when removing exhaust parts
as falling rust and sharp edges from worn exhaust components could
result in serious personal injury.
RELIEVING FUEL PRESSURE WARNING
WARNING: Remove the fuel tank cap and relieve the fuel system pressure before
servicing the fuel system in order to reduce the risk of personal injury.
After you relieve the 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
system components with a shop towel before disconnection. This will
catch any fuel that may leak out. Place the towel in an approved container
when the disconnection is complete.
ROAD TEST WARNING
WARNING: Road test a vehicle under safe conditions and while obeying 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.
SAFETY GLASSES AND COMPRESSED AIR WARNING
WARNING: Wear safety glasses when using compressed air in order to prevent eye
injury.
SAFETY GLASSES WARNING
WARNING: Wear safety glasses in order to avoid eye damage.
SAFETY GOGGLES AND FUEL WARNING

WARNING: Always wear safety goggles when working with fuel in order to protect the
eyes from fuel splash.
SIR DEPLOYED INFLATOR MODULES ARE HOT WARNING
WARNING: After deployment, the metal surfaces of the SIR component may be very
hot. To help avoid a fire or personal injury:
Allow sufficient time for cooling before touching any metal surface
of the SIR component.
Do not place the deployed SIR component near any flammable
objects.
SIR INFLATABLE MODULE DEPLOYMENT OUTSIDE VEHICLE WARNING

WARNING: When you are deploying an inflator module for disposal, perform the
deployment procedures in the order listed. Failure to follow the
procedures in the order listed may result in personal injury.
SIR INFLATOR MODULE DISPOSAL WARNING
WARNING: In order to prevent accidental deployment and the risk of personal injury,
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 damaged during
disposal. Use the following deployment procedures to safely dispose of
an undeployed inflator module. Failure to observe the following disposal
methods may be a violation of federal, state, or local laws.
SIR INFLATOR MODULE HANDLING AND STORAGE WARNING
WARNING: When carrying an undeployed inflator module:
Do not carry the inflator module by the wires or connector.

Make sure the air bag opening points away from you.
When storing an undeployed inflator module:
Make sure the air bag opening points away from the surface on
which the inflator module rests.
Provide free space for the air bag to expand in case of an accidental
deployment.
When storing a steering column, do not rest the column with the air
bag opening facing down and the column vertical. Lay the column

on its side.
Failure to observe these guidelines may result in personal injury.
SIR SEATBELT PRETENSIONER HANDLING WARNING
WARNING: When carrying an undeployed inflatable restraint seat belt retractor
pretensioner:
Do not carry the seat belt pretensioner by the seat belt webbing or
pigtail connector, if equipped.
Carry the seat belt pretensioner by the housing, keeping hands and
fingers away from the seat belt webbing.
Make sure the opening, from which the seat belt webbing extends,
faces downward and the seat belt webbing hangs freely.
Failure to observe these guidelines may result in personal injury.

SIR SPECIAL TOOL WARNING
WARNING: Failure to observe the special tool recommendations and instructions
could cause SIR deployment, personal injury, or unnecessary SIR system
repairs.
SIR WARNING
WARNING: This vehicle is equipped with a Supplemental Inflatable Restraint (SIR)
System. Failure to follow the correct procedure could cause the following
conditions:
Air bag deployment

Personal injury
Unnecessary SIR system repairs
In order to avoid the above conditions, observe the following guidelines:
Refer to SIR Component Views in order to determine if you are

performing service on or near the SIR components or the SIR wiring.
If you are performing service on or near the SIR components or the
SIR wiring, disable the SIR system. Refer to SIR Disabling and
Enabling .
STEERING ANGLE SENSOR INITIALIZATION WARNING

WARNING: For vehicles with electric power steering (EPS) and without a vehicle
stability enhancement program, the steering angle sensor MUST always
be initialized after the battery has been disconnected. Failure to initialize
the steering angle sensor could limit the operation of the EPS system and
result in personal injury.
To ensure proper initialization of the EPS system, do the following:
1. The engine should be on with the vehicle stationary.
2. Turn the steering wheel counterclockwise until it stops.
3. Turn the steering wheel clockwise until it stops.
TORQUE-TO-YIELD FASTENER WARNING
WARNING: This component is equipped with torque-to-yield fasteners. Install a NEW
torque-to-yield fastener when installing this component. Failure to replace
the torque-to-yield fastener could cause bodily injury and damage to the
vehicle or component.
WINDOW RETENTION WARNING
WARNING: When replacing stationary windows, only use a single component
adhesive kit, or an adhesive system meeting GM Specifications, to
maintain original installation integrity. Failure to use the single
component adhesive kit will result in poor retention of the window which
may allow unrestrained occupants to be ejected from the vehicle resulting
in personal injury.
WORK STALL TEST WARNING
WARNING: One or more of the following guidelines may apply when performing
specific required tests in the work stall:
When a test requires spinning the drive wheels with the vehicle
jacked up, adhere to the following precautions:
Do not exceed 56 km/h (35 mph) when spinning one drive
wheel with the other drive wheel stopped. This limit is
necessary because the speedometer indicates only one-half
the actual vehicle speed under these conditions. Personal
injury may result from excessive wheel spinning.
If all of the drive wheels are spinning at the same speed, do not
exceed 112 km/h (70 mph). Personal injury may result from
excessive wheel spinning.
All persons should stay clear of the rotating components and
the balance weight areas in order to avoid possible personal

injury.
When running an engine in the repair stall for an extended
period of time, use care not to overheat the engine and the
transmission.
When a test requires jacking up the vehicle and running with the
wheels and brake rotors removed, adhere to the following
precautions:
Support the suspension at normal ride height.
Do not apply the brake with the brake rotors removed.
Do not place the transmission in PARK with the drive axles
spinning.
Turn Off the ignition in order to stop the powertrain
components from spinning.
When running an engine in the work stall, use the exhaust removal
system to prevent breathing dangerous gases.
AIR IN THE POWER STEERING SYSTEM CAUTION

CAUTION: If the power steering system has been serviced, an accurate fluid level
reading cannot be obtained unless air is bled from the steering system.
The air in the fluid may cause pump cavitation noise and may cause pump
damage over a period of time.
AVOID CHIPPING OR SCRATCHING THE COATING CAUTION
CAUTION: Care should be taken to avoid chipping or scratching the coating when
handling the suspension coil spring. Damage to the coating can cause
premature failure.
BALL STUD REMOVAL CAUTION
CAUTION: Do not free the ball stud by using a pickle fork or a wedge-type tool.
Damage to the seal or bushing may result.
BELT DRESSING CAUTION
CAUTION: Do not use belt dressing on the drive belt. Belt dressing causes the
breakdown of the composition of the drive belt. Failure to follow this
recommendation will damage the drive belt.
BRAKE CALIPER CAUTION
CAUTION: Support the caliper with a piece of wire to prevent damage to the brake

line.
BRAKE FLUID EFFECTS ON PAINT AND ELECTRICAL COMPONENTS CAUTION
CAUTION: Avoid spilling brake fluid onto painted surfaces, electrical connections,
wiring, or cables. Brake fluid will damage painted surfaces and cause
corrosion to electrical components. If any brake fluid comes in contact
with painted surfaces, immediately flush the area with water. If any brake
fluid comes in contact with electrical connections, wiring, or cables, use a
clean shop cloth to wipe away the fluid.
CLEAN, DRY, LOW PRESSURE GAS SOURCE CAUTION
CAUTION: Use the Evaporative Emission (EVAP) System Tester (EEST) GE 41413-A in
order to provide a clean, dry, low pressure nitrogen gas source. Do not
substitute any other pressurized source, gas or otherwise. Damage may
result to the EVAP system, test equipment or cause a safety risk.
CLEARCOAT/ULTRAVIOLET SCREENERS CAUTION
CAUTION: Removing more than 0.5 mils of the clearcoat can result in early paint
failure. The clearcoat contains ultraviolet screeners. Do not finesse sand
more than what is required to remove the defect.
CLUTCH ACTUATOR CYLINDER AND SEAL CAUTION
CAUTION: Do not contaminate the clutch actuator cylinder or the clutch actuator
cylinder seal with oil. The clutch actuator cylinder and the clutch actuator
cylinder seal are not oil resistant. Failure to follow this caution may cause
a leak or damage to the clutch actuator cylinder.
CLUTCH ACTUATOR CYLINDER MOUNTING SLEEVE CAUTION
CAUTION: Use a mounting sleeve when installing the clutch actuator cylinder to the
transmission. The transmission input shaft has sharp edges and can
damage the clutch actuator cylinder. Failure to follow this caution may
cause a leak and damage to the clutch actuator cylinder.
COMPONENT FASTENER TIGHTENING CAUTION
CAUTION: Replacement components must be the correct part number for the
application. Components requiring the use of the thread locking
compound, lubricants, corrosion inhibitors, or sealants are identified in
the service procedure. Some replacement components may come with
these coatings already applied. Do not use these coatings on components

unless specified. These coatings can affect the final torque, which may
affect the operation of the component. Use the correct torque specification
when installing components in order to avoid damage.
DRIVE AXLE CAUTION
CAUTION: Support the lower control arms in the normal horizontal position in order
to avoid damage to the drive axles. Do not operate the vehicle in gear with
the wheels hanging down at full travel.
ENGINE COOLANT THERMOSTAT HOUSING CAUTION
CAUTION: Use care when performing this procedure. Use of excessive force may
damage the coolant thermostat.
EXTERIOR TRIM EMBLEM REMOVAL CAUTION
CAUTION: Use a plastic, flat-bladed tool to prevent paint damage when removing an
emblem/name plate.
FASTENER CAUTION
CAUTION: Use the correct fastener in the correct location. Replacement fasteners
must be the correct part number for that application. Do not use paints,
lubricants, or corrosion inhibitors on fasteners, or fastener joint surfaces,
unless specified. These coatings affect fastener torque and joint clamping
force and may damage the fastener. Use the correct tightening sequence
and specifications when installing fasteners in order to avoid damage to
parts and systems. When using fasteners that are threaded directly into
plastic, use extreme care not to strip the mating plastic part(s). Use hand
tools only, and do not use any kind of impact or power tools. Fastener
should be hand tightened, fully seated, and not stripped.
FILLING THE MASTER CYLINDER CAUTION
CAUTION: When filling the master cylinder, use only Delco Supreme 11, GM P/N
12377967 (Canadian P/N 992667), or equivalent DOT 3 brake fluid. Do not
use a container which has been used for petroleum based fluids, or a
container which is wet with water. Petroleum based fluids will cause
swelling and distortion of rubber parts in the hydraulic brake system, and
water will mix with brake fluid, lowering the boiling point. Keep all fluid
containers capped to prevent contamination.
FUEL AND EVAPORATIVE EMISSION HOSE/PIPE CONNECTION CLEANING CAUTION

CAUTION: Clean all of the following areas before performing any disconnections in
order to avoid possible contamination in the system:
The fuel pipe connections

The hose connections
The areas surrounding the connections
HEATED OXYGEN AND OXYGEN SENSOR CAUTION

CAUTION: Do not remove the pigtail from either the heated oxygen sensor (HO2S) or
the oxygen sensor (O2S). Removing the pigtail or the connector will affect
sensor operation.
Handle the oxygen sensor carefully. Do not drop the HO2S. Keep the inline electrical connector and the louvered end free of grease, dirt, or other
contaminants. Do not use cleaning solvents of any type.
Do not repair the wiring, connector or terminals. Replace the oxygen
sensor if the pigtail wiring, connector, or terminal is damaged.
This external clean air reference is obtained by way of the oxygen sensor
signal and heater wires. Any attempt to repair the wires, connectors, or
terminals could result in the obstruction 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 or

vehicle harness connectors. These materials 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 to enter the sensor and cause performance
problems.
Ensure the sensor or vehicle lead wires are not bent sharply or
kinked. Sharp bends or kinks could block the reference air path
through the lead wire.
Do not remove or defeat 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 poor engine performance.
Ensure that the peripheral seal remains intact on the vehicle harness
connector in order to prevent 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 the air reference being obstructed.
HEATED OXYGEN SENSOR RESISTANCE LEARN RESET CAUTION
CAUTION: When replacing the HO2S perform the following:
A code clear with a scan tool, regardless of whether or not a DTC is

set
HO2S heater resistance learn reset with a scan tool, where available
Perform the above in order to reset the HO2S resistance learned value and
avoid possible HO2S failure.
INSTALLING HOSES WITHOUT TWISTS OR BENDS CAUTION
CAUTION: The inlet and outlet hoses must not be twisted during installation. Do not
bend or distort the inlet or outlet hoses to make installation easier. Failure
to follow these procedures could result in component damage.
PIPE WRENCH POSITIONING CAUTION
CAUTION: The pipe wrench must be placed at the valve end of the steering gear and
positioned up against the inner tie rod housing. Placing the pipe wrench in
any other location will cause damage to the steering gear.
POWER STEERING HOSE DISCONNECTED CAUTION
CAUTION: Do not start the vehicle with any power steering gear inlet or outlet hoses
disconnected. When disconnected, plug or cap all openings of
components. Failure to do so could result in contamination or loss of
power steering fluid and damage to the system.
SILICON CONTAMINATION OF HEATED OXYGEN SENSORS CAUTION
CAUTION: Contamination of the oxygen sensor can result from the use of an
inappropriate RTV sealant (not oxygen sensor safe) or excessive engine
coolant or oil consumption. Remove the HO2S and visually inspect the
portion of the sensor exposed to the exhaust stream in order to check for
contamination. If contaminated, the portion of the sensor exposed to the
exhaust stream will have a white powdery coating. Silicon contamination
causes a high but false HO2S signal voltage (rich exhaust indication). The
control module will then reduce the amount of fuel delivered to the engine,
causing a severe driveability problem. Eliminate the source of
contamination before replacing the oxygen sensor.

STEERING COLUMN IN LOCK POSITION CAUTION

CAUTION: With wheels of the vehicle facing straight ahead, secure the steering wheel
utilizing steering column anti-rotation pin, steering column lock, or a strap
to prevent rotation. Locking of the steering column will prevent damage
and a possible malfunction of the SIR system. The steering wheel must be
secured in position before disconnecting the following components:
The steering column

The steering shaft coupling
The intermediate shaft(s)
After disconnecting these components, do not rotate the steering wheel or

move the front tires and wheels. Failure to follow this procedure may
cause the SIR coil assembly to become un-centered and cause possible
damage to the SIR coil. If you think the SIR coil has became un-centered,
refer to your specific SIR coil's centering procedure to re-center SIR Coil.
STEERING GEAR PRELOAD ADJUSTMENT CAUTION
CAUTION: Do not change the steering gear preload adjustment before moving the
inner tie rod from the steering gear. Changing the steering gear preload
adjustment before moving the inner tie rod could result in damage to the
pinion and the steering gear.
STEERING WHEEL IN THE FULL TURN POSITION CAUTION
CAUTION: Do not hold the steering wheel in the full turn position longer than 5
seconds, as damage to the steering pump may result.
STEERING WHEEL STRAIGHT AND COLUMN LOCKED CAUTION
CAUTION: With wheels of the vehicle facing straight ahead, secure the steering wheel
utilizing steering column anti-rotation pin, steering column lock, or a strap
to prevent rotation. Locking of the steering column will prevent damage
and a possible malfunction of the SIR system. The steering wheel must be
secured in position before disconnecting the following components:
The steering column

The steering gear
After disconnecting these components, do not rotate the steering wheel or

move the front tires and wheels. Failure to follow this procedure may
cause the SIR coil assembly to become un-centered and cause possible

damage to the SIR coil. If you think the SIR coil has became un-centered,
refer to your specific SIR coil's centering procedure to re-center SIR Coil.
TEST PROBE CAUTION
CAUTION: Do not insert test equipment probes (DMM 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. Always use the EL-35616 GM Approved Terminal Test
Probe Kit in order to front probe terminals. Do not use paper clips or other
substitutes to probe terminals.
When using the EL-35616 GM Approved Terminal Test Probe Kit, ensure
the terminal test adapter choice is the correct size for the connector
terminal. Do not visually choose the terminal test adapter because some
connector terminal cavities may appear larger than the actual terminal in
the cavity. Using a larger terminal test adapter will damage the terminal.
Refer to the EL-35616 GM Approved Terminal Test Probe Kit label on the
inside of the EL-35616 GM Approved Terminal Test Probe Kit for the
correct adapter along with the connector end view.
THREE-WAY CATALYTIC CONVERTER DAMAGE CAUTION
CAUTION: In order to avoid damaging the replacement three-way catalytic converter,
correct the engine misfire or mechanical fault before replacing the threeway catalytic converter.
TORQUE REACTION AGAINST TIMING DRIVE CHAIN CAUTION
CAUTION: A wrench must be used on the hex of the camshaft when loosening or
tightening in order to prevent component damage. Failure to prevent the
torque reaction against the timing drive chain can lead to timing drive
chain failure.
TORQUE-TO-YIELD FASTENER CAUTION
CAUTION: This vehicle is equipped with torque-to-yield or single use fasteners.
Install a NEW torque-to-yield or single use fastener when installing this
component. Failure to replace the torque-to-yield or single use fastener
could cause damage to the vehicle or component.
TRANSMISSION FLUID VENT CAP REMOVAL CAUTION
CAUTION: The fluid vent cap must be removed before checking the fluid level, in
order to ensure the proper level. Improper fluid level may damage the

transmission.
TRANSMISSION OVERFILL CAUTION
CAUTION: Check the transmission fluid level immediately after adding fluid and
before vehicle operation. Do not overfill the transmission. An overfilled
transmission may result in foaming or fluid to be expelled out the vent
tube when the vehicle is operated. Overfilling will result in possible
damage to the transmission.
TRANSMISSION SHIFT FORK CAUTION
CAUTION: Do not move the transmission shift forks while removing or installing the
transmission shifter. The shift forks must remain in the neutral position.
Failure to follow this caution can cause severe damage to the
transmission.
USING PROPER POWER STEERING FLUID CAUTION
CAUTION: When adding fluid or making a complete fluid change, always use the
proper power steering fluid. Failure to use the proper fluid will cause hose
and seal damage and fluid leaks.
VALVE LIFTER PRIMING CAUTION
CAUTION: Ensure each valve lifter is filled with clean engine oil and the valve lifter
does not tip over (plunger down) before the installation of the valve lifters.
The loss of oil in the valve lifter lower pressure chamber or the dry
stroking/cycling of the valve lifter plunger will allow air to travel into the
high pressure chamber of the valve lifter. Air in the high pressure chamber
of the valve lifter may not be purged causing extensive engine component
damage.
WINDOW EDGE DAMAGE CAUTION
CAUTION: Avoid damage to the window from impacting objects due to an exposed
edge. The window must be 1 mm (0.025 in) below the surface of the sheet
metal to avoid window damage.

2013 GENERAL INFORMATION General Information - Cruze

General Information - Cruze
SPECIFICATIONS
VOLATILE MEMORY PROGRAMMING
Electric Window Lifters
Move all the windows to the topmost position and hold the switch pressed down for 2 seconds.
Sliding Sunroof
Move the sliding roof to the respective end stops to recalibrate the sensors.
Initialize Steering Angle Sensor (Vehicles without ESP and with Electric Power Steering)
WARNING: For vehicles with electric power steering (EPS) and without a vehicle
stability enhancement program, the steering angle sensor MUST always
be initialized after the battery has been disconnected. Failure to initialize
the steering angle sensor could limit the operation of the EPS system and
To ensure proper initialization of the EPS system, do the following:
1. The engine should be on with the vehicle stationary.
2. Turn the steering wheel counterclockwise until it stops.
3. Turn the steering wheel clockwise until it stops.
INTRODUCTION
ARROWS AND SYMBOLS
This service manual uses various symbols in order to describe different service operations.

Fig. 1: Identifying Different Service Operations Symbols

Courtesy of GENERAL MOTORS COMPANY
Callout
Component Name

1
2
2
Front of Vehicle
View Detail
View Detail
Ambient Air Mixed with Another Gas or Indicate Temperature
Change
Motion or Direction
View Angle
Dimension (1:2)
Ambient/Clean Air Flow or Cool Air Flow
Lubrication Point- Oil or Fluid
Task Related
Sectioning (1:3)
Gas Other Than Ambient Air or Hot Air Flow
Lubrication Point- Grease or Jelly
Multidirectional Arrow
3
4
5
6
7
8
9
10
11
12
13
ACRONYMS AND UNITS
Acronyms
Acronym
Meaning
2WD
Two-Wheel Drive
4WD
Four-Wheel Drive
A/C
Air Conditioning
A/D
Analog to Digital
ABS
Antilock Braking System
AC
Alternating Current
Definition
Indicates that a vehicle has 2 driven wheels
OR that a 4WD vehicle uses only 2 wheels
for propulsion. So it can be the description
of a vehicle configuration OR the
operational mode of the drivetrain.
Four-wheeled vehicle with a drivetrain that
allows all four wheels to receive power
from the engine simultaneously which
provides better control on various surfaces.
Can be used to describe the configuration of
the vehicle OR as the operational mode of
the drivetrain. 4WD vehicles usually can
turn 2 wheels off to be in a 2WD mode. See
also AWD.
The cooling and dehumidification of indoor
air for thermal comfort.
Used in context of converting electrical
analog signals to digital signals.
System on motor vehicles which prevents
the wheels from locking while braking
which helps the driver maintain control in
heavy braking conditions.
An electrical current whose magnitude and
direction vary cyclically.

AM
Amplitude Modulation
APP
Accelerator Pedal Position
AWD
All-Wheel Drive
AWG
American Wire Gauge
B+
Battery Positive Voltage
BARO
Barometric Pressure
BCM
Body Control Module
BECM
Battery Energy Control Module
BPP
Brake Pedal Position
CAN
Controller Area Network
CCM
Chassis Control Module
CD
Compact Disc
CNG
Compressed Natural Gas
CO
Carbon Monoxide
Method of impressing data onto an

alternating-current (AC) carrier waveform.
A pedal that controls the throttle valve.
All-wheel-drive systems are designed to
function on all types of surfaces, both onand off-road, and most of them cannot be
switched off. This can also be called fulltime four wheel drive. See also 4WD.
American wire gauge is a standardized wire
gauge system used since 1857
predominantly in the United States for the
diameters of round, solid, nonferrous,
electrically conducting wire.
E.g. a wire of AWG10 has a diameter of
2.588mm, AWG20 corresponds to a
diameter of 0.812mm.
The electrical potential on the positive
terminal of the battery.
Atmospheric pressure as measured by a
barometer.
This module supplies vehicle occupants
with visual and audible information and
controls various vehicle functions,
Control module used to regulate the battery
voltage.
Position of the foot pedal that moves a
piston in the master brake cylinder.
Serial data connection between control
modules by Bosch
The module that controls various vehicle
functions on the Chassis, like Engine/Trans
Mount, Active Grille Air Shutter, Load
Leveling, etc
A small optical disk on which data such as
music, text, or graphic images is digitally
encoded.
This a substitute for gasoline or diesel fuel.
It is made by compressing natural gas
(which is mainly composed by methane
(CH4), in a percentage range of 70% to
98%)
This is a product of the incomplete
combustion of carbon-containing
compounds, at room temperature this is a
gas. It consists of one carbon atom
covalently bonded to one oxygen atom.

CO2
CPA
CPP
CV
CVT
D
DAB
DC
DLC
DMM
DOHC
DPF
Chemical compound composed of two

oxygen atoms covalently bonded to a single
carbon atom.
Part of an electrical connector that prevents
the connector from moving out of its
Connector Position Assurance
socket. Usually needs to be pressed to
unlock the connector when disconnecting it.
A lever operated with the foot that controls
the coupling that connects or disconnects
Clutch Pedal Position
driving and driven parts of a driving
mechanism.
Used in conjunction with CV joints, which
connect two shafts at an angle while both
Constant Velocity
shafts always have the same rotational
speed without variations.
A transmission in which the ratio of the
rotational speeds of two shafts, as the input
shaft and output shaft of a vehicle or other
Continuously Variable Transmission machine, can be varied continuously within
a given range, providing an infinite number
of possible ratios which improves fuel
economy.
Drive
D on the transmission gear selector lever.
Technology for broadcasting of audio using
digital radio (carries information via digital
Digital Audio Broadcast
signal) transmission.
Continuous current, constant flow of
Direct Current
electric charge.
This is an electronic connector typically
located underneath the driver's side
Data Link Connector
dashboard, just above the pedals. The
connector has 16 pins.
Electronic measuring instrument that
combines several functions in one unit. The
Digital Multimeter
most basic instruments include an ammeter,
voltmeter, and ohmmeter.
Dual overhead camshafts (DOHC) are
higher performance engines, they produce
more power, and can run at higher speeds
because they allow an engine to have four
Dual Overhead Camshaft
valves per cylinder.
Each camshaft operates two of the valves,
one camshaft handles the intake valves, and
one handles the exhaust valves
Carbon Dioxide
Diesel Particulate Filter
Device designed to remove diesel

particulate matter or soot from the exhaust

DRL
DSCC
DSP
DTC
DVD
EBCM
ECM
ECT
EEPROM
EGR
gas of a diesel engine.

White lights mounted on the front of an
automobile that automatically switch on
Daytime Running Lamps
when the key is turned and are intended for
daytime use, to increase the visibility of the
automobile.
A type of cruise control that automatically
Distance Sensing Cruise Control
maintains the distance between vehicles.
A specialized microprocessor designed
specifically for digital signal processing,
Digital Signal Processor
generally in real-time computing.
An electronic signal stored in an automotive
Diagnostic Trouble Code
computer, indicating the presence of a fault
detected by that computer.
A popular optical disc storage media format
the size of a CD. Used mainly for movies
but also for data. DVD has no spelled out
DVD
version (officially it does not mean Digital
Video Disc or Digital Versatile Disc, it just
means DVD).
This module contains a microprocessor and
Electronic Brake Control Module
software for antilock braking system
operation.
This electronic module works with a
vehicle's sensors and engine control devices
to insure that the engine operates at
maximum efficiency and performance. It
performs three vital functions. Receives
Engine Control Module
electronic signals from engine sensors.
Analyzes the data and makes an engine
performance decision (based on the pre-set
parameters within the unit). Sends an
"output command" to an actuator that
adjusts engine performance.
A measure of how hot or cold the fluid
which flows through the engine in order to
Engine Coolant Temperature
prevent its overheating, transferring the heat
produced by the device to other devices that
utilize or dissipate it.
A non-volatile storage chip used in
Electrically Erasable Programmable computers and other devices to store small
amounts of volatile data, e.g. calibration
Read-Only Memory
tables or device configuration.
Exhaust Gas Recirculation
Is an NOx (nitrogen oxide and nitrogen

dioxide) reduction technique used in most
gasoline and diesel engines. EGR works by

EMI
ESD
EV
EVAP
FM
FWD
GMLAN
GPS
GSM
GVW
HD
HID
recirculating a portion of an engine's

exhaust gas back to the engine cylinders.
Electromagnetic interference (also called
radio frequency interference) is a
disturbance that affects an electrical circuit
Electromagnetic Interference
due to either electromagnetic conduction or
electromagnetic radiation emitted from an
external source.
The sudden and momentary electric current
Electrostatic Discharge
that flows between two objects at different
electrical potentials.
A category of vehicles that only have an
Electric Vehicle
electric drive system.
A system that controls the fuel fumes in the
Evaporative Emission
fuel tank.
In telecommunication this is a way to
Frequency Modulation
convey information over a carrier wave by
varying its frequency.
A form of engine/transmission layout used
in motor vehicles, where the engine drives
Front-Wheel Drive
the front wheels only.
A local-area network is a computer network
covering a small geographic area, like a
home or vehicle. This specific type of LAN
General Motors Local Area Network
connects several controllers inside the
vehicle and was developed by General
Motors.
Satellite-based navigation system made up
Global Positioning System
of a network of 24 satellites placed into
orbit by the U.S. Department of Defense.
Global System for Mobile
Globally accepted standard for digital
Communications
cellular communication.
Maximum total weight of a road vehicle or
trailer that is loaded, including the weight
Gross Vehicle Weight
of the vehicle itself plus fuel, passengers,
cargo, and trailer tongue weight.
Robust design to accommodate large work
Heavy Duty
loads.
A type of light that produces a bright light
by using gas filled bulbs. (gas is usually
High Intensity Discharge
mercury, metal halide, and high-pressure
sodium) Uses very little battery power and
is a very "cool" light.
Heated oxygen sensors have an internal
heater circuit that brings the sensor up to
operating temperature more quickly than an

HO2S
HVAC
I2 C
IAT
ICE
ID
ISP
ISS
LAN
LCD
LED
LIN
LPG
unheated sensor. An oxygen sensor must be

hot (about 600-650F) before it will
generate a voltage signal. The hot exhaust
Heated Oxygen Sensor
from the engine will provide enough heat to
bring an O2 sensor up to operating
temperature.
This system is sometimes referred to as
climate control. Ventilation air ducts
Heating Ventilation Air Conditioning installed throughout a vehicle that supply
conditioned air to a room through
rectangular or round outlet vents.
Serial data connection between Integrated
Inter-Integrated Circuit
Circuits (microchips) inside a control
module invented by Phillips
Temperature of the air entering intake air
Intake Air Temperature
flow system of the engine.
An engine in which the combustion of fuel
and an oxidizer (typically air) occurs in a
Internal Combustion Engine
confined space called a combustion
chamber.
Number or Code that identifies a
component or control module. Can be
Identification
written on the part or be transmitted on a
bus or via radio.
A company that furnishes corporations and
Internet Service Provider
individual consumers with various services,
mainly access to the Internet.
Rotational speed of the input shaft of a
Input Shaft Speed
transmission.
Local Area Network
Standard network connection PC's.
A thin, flat display device made up of any
number of color or monochrome pixels
Liquid Crystal Display
arrayed in front of a light source or
reflector.
Small light bulbs that fit easily into an
electrical circuit they do not have a filament
that will burn out, and they do not get
Light Emitting Diode
especially hot. They are illuminated solely
by the movement of electrons in a
semiconductor material.
Computer networking bus system used
within automotive network architectures.
Local Interconnect Network
Similar to CAN, but cheaper and less
powerful.
Liquefied Petroleum Gas
A mixture of mainly propane and butane,

produced commercially and stored under

MAF
Mass Air Flow
MAP
Manifold Absolute Pressure
MDI
Multiple Diagnostics Interface
MIL
Malfunction Indicator Lamp
MOST
Media Oriented Systems Transport
Neutral
NiMH
Nickel Metal Hydride
NOx
Nitrogen Oxides
O2
Oxygen
O2S
Oxygen Sensor
OBD
On-Board Diagnostic
OEM
Original Equipment Manufacturer
OSS
Output Shaft Speed
Park
PCB
Printed Circuit Board
PCM
Powertrain Control Module
pressure to keep it in a liquid state.

The amount of air drawn into the engine
Pressure in the engine intake system after
the throttle valve referenced to a perfect
vacuum.
A device used by GM dealers that enables a
PC to communicate with the control
modules in a vehicle.
An indicator of the internal status of a car
engine.
Serial communication bus to transmit audio
and video information.
A state of the transmission in which it is not
engaged.
A type of rechargeable battery that uses a
hydrogen absorbing alloy for the negative
electrode.
Refers to any of the following oxygen
compounds of nitrogen or a mixture of
them. Nitric Oxide, Nitrogen dioxide,
Nitrous Oxide, Dinitrogen trioxide,
Dinitrogen tetroxide, Dinitrogen pentoxide.
A colorless, odorless, tasteless, gaseous
chemical element with the chemical symbol
O and atomic number 8.
An electronic device that measures the
proportion of oxygen (O2) in the gas or
liquid being analyzed.
A generic term referring to a vehicle's selfdiagnostic and reporting capability.
A producer that provides a product to its
customers, who proceed to modify or
bundle it before distributing it to their
customers.
Rotational speed of the output shaft of a
transmission.
A state in which the transmission is set so
one can leave the vehicle.
A thin plate on which chips and other
electronic components are placed.
A control module that features the functions
of both, the engine and the transmission
control module.
An international standards body and trade
association with over 100 member

PCMCIA
Personal Computer Memory Card

Industry Association
PIN
Personal Identification Number
PPE
Personal Protective Equipment
PRNDL
Park, Reverse, Neutral, Drive, Low
PTC
Positive Temperature Coefficient
PTO
Power Take-Off
PVC
Polyvinyl Chloride
PWM
Pulse Width Modulation
Reverse
RAM
Random Access Memory
RCT
Radiator Coolant Temperature
RDS
Radio Data System
companies that was founded in 1989 to

establish standards for Integrated Circuit
cards and to promote interchangeability
among mobile computers where
ruggedness, low power, and small size were
critical.
A secret numeric password shared between
a user and a system that can be used to
authenticate the user to the system.
Protective clothing, helmets, goggles, or
other garment designed to protect the
wearer's body from injury.
Park, Reverse, Neutral, Drive, Low
(automatic transmission positions).
Refers to materials that experience an
increase in electrical resistance when their
temperature is raised.
A splined driveshaft, usually on a tractor or
truck that can be used to provide power to
an attachment or separate machine. This
mechanism allows implements to draw
energy from the tractor's engine.
A thermoplastic copolymer.
Square shaped type of signal that carries the
information in the ratio between on and off
times.
Rearward: directed or moving toward the
rear;
A type of computer data storage. It today
takes the form of integrated circuits that
allow the stored data to be accessed in any
order.
This is the heat intensity of the radiator
coolant measured in degrees. The radiator is
a part of the cooling system that removes
the engine heat. Coolant is a mixture of
water and antifreeze (ethylene glycol)
which lowers the freezing point of the water
in the coolant system, this fluid also picks
up heat from the engine and transfers it to
the air.
A standard from the European Broadcasting
Union for sending small amounts of digital
information using conventional FM radio
broadcasts.
A frequency or rate of oscillation within the

RF
Radio Frequency
ROM
Read-Only Memory
RPO
Regular Production Option
RSA
Rear Seat Audio
RWD
Rear-Wheel Drive
SCV
Speed Controlled Volume
SDM
Sensing and Diagnostic Module
SIM
Subscriber Identity Module
SIR
Supplemental Inflatable Restraint
SPI
Serial Peripheral Interface
range of about 3 Hz and 300 GHz. This

range corresponds to frequency of
alternating current electrical signals used to
produce and detect radio waves.
A class of storage media used in computers
and other electronic devices. Data stored in
ROM cannot be modified.
A three digit/letter code given to parts,
assemblies, and systems originally installed
on the vehicle. These RPO codes designate
options and are assigned by General
Motors.
An auxiliary set of controls that operate the
main audio system from the rear seat. Rear
passengers can also operate a different
media source than the front passengers.
A common engine/transmission layout in
which the engine is in the front of the
vehicle, but the front mid-engine, rear midengine and rear engine layouts are also
used.
The volume control is set for a desired
sound level in the vehicle as the vehicle
increases its speed, the sound level is
adjusted.
The name given to air bag modules used in
General Motors vehicles.
Part of a removable smart card Integrated
Circuit Card. This is used for mobile
cellular telephone devices such as mobile
computers and mobile phones. SIM cards
securely store the service-subscriber key
used to identify a subscriber. The SIM card
allows users to change phones by simply
removing the SIM card from one mobile
phone and inserting it into another mobile
phone or broadband telephony device.
Technical term for the air bag. Air bag is a
stretchable membrane, which inflates
during an automobile accident to provide
cushioning to the passenger's head and torso
to prevent injury to the passengers.
This is an interface that enables the serial
(one bit at a time) exchange of data between
two devices. An SPI operates in full duplex
mode. This means that data can be

SPS
Service Programming System
SUV
Sport Utility Vehicle
SVS
Service Vehicle Soon
TA
Traffic Announcement
TAC
Throttle Actuator Control
TAP
Transmission Adaptive Pressure
TCC
Torque Converter Clutch
TCM
Transmission Control Module
TDC
Top Dead Center
TIS
Techline Information System
TPA
Terminal Position Assurance
transferred in both directions at the same

time. It is a standard bus technology like
CAN or I2C.
System that enables repair facilities to
update the software in control modules.
A passenger vehicle which combines the
towing capacity of a pickup truck with the
passenger-carrying space of a minivan.
Indicator lamp or symbol for a malfunction
related to a vehicle component or system.
Message spoken on radio regarding the
movement of vehicles or pedestrians
through an area or along a route. The
buttons on radios that enable this
announcements are also often labeled TA.
A motor which moves the engine throttle
plate or valve, controlled by the engine
control module. A throttle plate limits the
amount of air entering a internal
combustion gasoline engine.
The transmission control module learns
each component's characteristics and
adjusts fluid pressure accordingly.
Resides in a torque converter to connect an
engine to an automatic transmission. The
clutch is applied when conditions are
correct to achieve a 1:1 ratio of engine
crankshaft to transmission input shaft.
A module that controls electronic automatic
transmissions. It uses sensors from the
vehicle as well as data provided by the
Engine Control Module to calculate how
and when to change gears in the vehicle for
optimum performance, fuel economy and
shift quality.
The piston is in its highest position relative
to the combustion chamber.
The PC-based global dealership diagnostic
software that provides the technician the
ability to reference the most recent service
information via the service department's
computer.
An additional locking mechanism inside an
electric connector that holds the pins in
place.
A telecommunication system for

TV
Television
USB
Universal Serial Bus
VCI
Vehicle Communications Interface
VIN
Vehicle Identification Number
VSCM
Vehicle Stability Control Module
VSS
Vehicle Speed Sensor
WOT
Wide Open Throttle
WLAN
Wireless Local Area Network
XM
XM (Satellite Radio)
XML
Extensible Markup Language
broadcasting and receiving moving pictures

and sound over a distance.
A type of communication bus connection
between a computer and a peripheral
device.
A diagnostic tool that communicates to
modules of multiple communication
protocols in a vehicle by converting vehicle
serial data into PC serial data
communication.
Used by manufacturers to uniquely identify
motor vehicles using 17 characters.
This module uses information from several
sensors to detect a loss of vehicle traction,
then works with the antilock brake system
to apply individual brakes to help keep the
vehicle on its intended path.
Sends data regarding how fast the car is
traveling at the moment of driving. It is
designed to be able to record the rate at
which the vehicle's crankshaft is spinning.
When the throttle blade or valve is at its
maximum open position, allowing
maximum air to enter an internal
combustion gasoline engine.
Standard to transmit digital data via radio
frequency.
XM Satellite Radio Holdings (XM) is one
of two satellite radio services in the United
States and Canada. XM provides pay-forservice radio, analogous to cable television.
Its service includes 73 different music
channels, 39 news, sports, talk, and
entertainment channels, 21 regional traffic
and weather channels and 23 play-by-play
sports channels (2008).
A markup language that defines a set of
rules for encoding documents in a format
that is both human-readable and machinereadable.
Units
Unit
m2
A
Meaning
Square Meter
Ampere
Definition
Area
Electrical

Ah
C
dBm
dBmV
mV/DIV
mV/s
ohms
V
V/DIV
V/ms
W
mm3 /stroke
gal/h
g/s
g/stroke
kg/100km
kg/h
km/L
L/100km
L/h
L/min
MPG
mg/s
mg/stroke
ft
in
m
mi
bar
bar/min
in. H2O
in. H2O/s
kPa/s
N
Pa
Pa/s
lb ft
PSI
Counts
Cycles
Ampere Hour
Coulomb
Decibel Meter
Decibel Millivolt
Millivolts per Division
Millivolts per Second
Ohm
Volt
Volts per Division
Volts per Millisecond
Watt
Cubic Millimeters per Stroke
Gallons per Hour
grams per second
Grams per Stroke
Kilograms per 100 Kilometer
Kilograms per Hour
kilometer/liter
Liters per 100 Kilometers
Liters per Hour
Liters per Minute
Miles per Gallon
Milligrams per Second
Milligrams per stroke
feet
Inch
Meter
Mile
Bar
Bars per Minute
Inches of Water
Inches of Water per second
Kilopascals per Second
Newton
Newton Meter
Pascal
Pascals per Second
Pound Foot
Pound-Force per Square Inch
Counts
Cycles
Electrical
Electrical
Electrical
Electrical
Electrical
Electrical
Electrical
Electrical
Electrical
Electrical
Electrical
Flow
Flow
Flow
Flow
Flow
Flow
Flow
Flow
Flow
Flow
Flow
Flow
Flow
Length
Length
Length
Length
Mechanical
Mechanical
Mechanical
Mechanical
Mechanical
Mechanical
Mechanical
Mechanical
Mechanical
Mechanical
Mechanical
Misc.
Misc.

dB
C
CA
F
/s
Hz
kbit/s
lx
ppm
%
%/min
%/sec
Pulses
:1
RPM
Steps
W/m2
g
km/h
m/s
m/s3
m/s2
MPH
mm/s
d
h
hh:mm:ss
ms/DIV
min
s
s/DIV
yy-mm-dd
yyyy-mm-dd
m3
gal
L
mL
US gal
US pt
Decibel
Degree
Degree Centigrade
Degree Crankshaft Angle
Degree Fahrenheit
Degree per Second
Hertz
Kilobit per second
Lux
Parts per Million
Percent
Percents per Minute
Percents per Second
Pulses
Ratio
Revolutions per Minute
Steps
Watts per Square Meter
g (Acceleration)
Kilometers per Hour
Meters per Second
Meters per Second Cubed
Misc.
Misc.
Misc.
Misc.
Misc.
Misc.
Misc.
Misc.
Misc.
Misc.
Misc.
Misc.
Misc.
Misc.
Misc.
Misc.
Misc.
Misc.
Movement
Movement
Movement
Movement
Meters per Second Squared

Miles per Hour
Millimeters per Second
Day
Hour
Hour:Minute:Second
Milliseconds per Division
Minute
Second
Seconds per Division
Year-Month-Day (2 digits)
Year-Month-Day (4 digits, preferred)
Cubic Meter
Gallon
Liter
milliliters
US Gallon
US Pint
Movement
Movement
Movement
Time
Time
Time
Time
Time
Time
Time
Time
Time
Volume
Volume
Volume
Volume
Volume
Volume

US qt
kg
US Quart
Kilogram
Volume
Weight
CUSTOMER CONCERN VERIFICATION SHEETS

The GM Customer Concern Verification Sheets have been designed to improve communications between the
service customer and the technician. The more clearly the technician understands the concern and its symptoms,
the more likely the concern will be fixed right the first time.
The GM-wide Customer Concern Verification Sheets are available in GM GlobalConnect. The Customer
Concern Verification Sheets may be printed and reproduced locally.
TRAINING
Dealers
All U.S. Dealers participating in the Common Training Program can enroll through the Common Training
System Website at https://www.gmtraining.com. Within the website, there are individual training paths that are
designed to assist in planning the training needs for each individual. Technicians should advise their Service
Manager of their training needs including course names and course numbers. Dealers who have questions about
Common Training should contact the Common Training help desk at 1-888-748-2687. The help desk is
available Monday through Friday, 8:00 am-8:00pm Eastern Standard Time, excluding holidays. For GM Access
support, contact the GM Access Help Desk at 1-888-337-1010.
Fleets
GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training
through Common Training/GM Service Technical College (STC).
Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via
www.gmtraining.com using the "Contact Us" button on the site and/or the Common Training Help Desk at 1888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters
at 1-800-393-4831.
Most GM STC course materials have associated charges.
To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800393-4831.
Non-GM Dealer Technicians
Technicians training for non-GM dealers is available through ACDelco. This training is for ACDelco customers
employed in the automotive or truck service industry.
ACDelco courses are available at all approved GM Training Centers. Availability and schedules can be
obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the
training button. Clinics are also offered through ACDelco Warehouse Distributors. Contract your dealer directly

for more information.

VEHICLE, ENGINE AND TRANSMISSION ID AND VIN LOCATION, DERIVATIVE AND USAGE
VIN Plate
Fig. 2: View Of VIN Plate Location

The VIN plate is the legal identifier of the vehicle. The VIN plate is located on the upper left corner of the
instrument panel (I/P) and can be seen through the windshield from the outside of the vehicle.
VIN Body Stamping

Fig. 3: VIN Body Stamping

The stamping is located on the front floor panel under the front right-hand floor mat. It can be seen under the
VIN plate opening access cover (1).
Vehicle, Engine and Transmission ID and VIN Location, Derivative and Usage
Position
Definition
Character
Description
1
Region of Build
1
United States
2
Manufacturer
G
General Motors
3
Vehicle Brand/Type
1
Chevrolet Passenger Car
Chevrolet Cruze 2LS (Canada P/A
Automatic)
Chevrolet Cruze 1LS (US P/B
Manual)/2LS (Canada - Manual)
Chevrolet Cruze 2LS (US P/C
Automatic)/1LS (Canada Automatic)

D
7
Chevrolet Cruze 2LS (US Manual)/1LS (Canada - Manual)

Chevrolet Cruze 1FL (Automatic)
Chevrolet Cruze 1LT (Automatic)
Chevrolet Cruze 2LT (Automatic)
Chevrolet Cruze LTZ (Automatic)
Chevrolet Cruze Eco (Automatic)
Chevrolet Cruze Eco (Manual)
Chevrolet Cruze 1LT (Manual)
Chevrolet Cruze 2LT (Manual)
69 - Sedan, 4 - Door, 4 Window,
Notchback
Active Manual Belts, Airbags Driver & Passenger Front (1st row),
Front Seat Side (1st row) & Rear
Seat Side (2nd row), Roof Side (all
seating rows), Knee (1st row)
LUV - ENGINE GAS, 4 CYL,
1.4L, MFI, DOHC, TURBO, VVT,
ALUM, 0~9, X - Calculated by
POMS GME E85 MAX
LWE - ENGINE GAS, 4 CYL,
1.8L, MFI, DOHC, VVT, 103 KW,
GME
LUW - ENGINE GAS/ETHANOL,
4 CYL, 1.8L, MFI, 103KW, DOHC,
E85
Check Digit
2013
Lordstown, OH GMNA
Production Sequence Number
P/D
P/E
P/F
P/G
P/H
P/J
P/K
P/L
P/M
4-5
Vehicle Line/Series
Body Style
Restraint System
Engine Type
H
9
10
11
12-17
Check Digit
Model Year
Plant Code
Production Sequence
Number
1.4L (LUV) Engine ID and VIN Derivative Location

Refer to Engine Identification .
1.8L (LUW / LWE) Engine ID and VIN Derivative Location
Refer to Engine Identification .
Automatic Transmission - 6T30/6T40/6T45/6T50 ID and VIN Derivative Location
Refer to Transmission Identification Information .

Manual Transmission - M32 ID and VIN Derivative Location

Refer to Transmission Identification Information .
VEHICLE CERTIFICATION, TIRE PLACARD, ANTI-THEFT, AND SERVICE PARTS ID LABEL
Fig. 4: Vehicle Certification, Tire Placard, Anti-Theft, and Service Parts ID Label
Vehicle Certification, Tire Placard, Anti-Theft, and Service Parts ID Label
Callout
Description
Vehicle Certification Label
The vehicle certification label is located on the driver side B pillar and displays the following
assessments:
Gross Vehicle Weight Rating (GVWR)

Gross Axle Weight Rating (GAWR), front and rear
The gross vehicle weight (GVW) is the weight of the vehicle and everything it carries. The gross

vehicle weight must not exceed the Gross Vehicle Weight Rating. Include the following items
when figuring the GVW:
The base vehicle weight (factory weight)
The weight of all vehicles accessories
The weight of the driver and the passengers
The weight of the cargo
1
Logo
2
Name of Manufacturer
3
Gross Vehicle Weight Rating
4
Gross Axle Weight Rating (Front, Rear)
5
Vehicle Class Type (Pass Car, etc.)
6
Canadian Safety Mark (w/RPO Z49)
7
National Emission Mark (w/RPO Z49)
8
Certification Statement
9
10
Final Manufacturers Date (Month/Year)
Tire Placard
The tire placard label is located on the driver side B pillar and displays the following assessments:
11
Specified Occupant Seating Positions (Total, Front and Rear)
12
Maximum Vehicle Capacity Weight (kg and lbs)
13
Tire Pressure, Front, Rear, and Spare (Cold)
14
Original Equipment Tires Size
Service Parts ID Label
The vehicle service parts identification label is located on the inner side of the glove box lid. The label is
use to help identify the vehicle original parts and options.
15
Model Designation (Vehicle Division, Line, and Body Style)
16
GM Order Number
17
Wheel Base
18
19
Interior/Exterior Color (Number)
Regular Production Options/Special Equipment Options (RPO/SEO)
20
Printed in Alpha-Numeric Sequence
21
Interior/Exterior Color (Number)
22
Paint Technology
Anti-Theft Label
23
The Federal law requires that General Motors label certain body parts
on this vehicle with the VIN. The purpose of the law is to reduce the
number of motor vehicle thefts by helping in the tracing and recovery
of parts from stolen vehicles.
Labels are permanently affixed to an interior surface of the part. The
label on the replacement part contains the letter R, the manufacturer's
logo, and the DOT symbol.

The anti-theft label must be covered before any painting, rustproofing

procedures, and uncovered after the procedures. Failure to follow the
precautionary steps may result in liability for violation of the Federal
Vehicle Theft Prevention Standard and possible suspicion to the
owner that the part was stolen.
RPO CODE LIST
The following table provides the description of the Regular Production Option (RPO) codes that are available
on the vehicle. The vehicle's RPO list is printed on the Service Parts Identification Label.
RPO
01A
01B
01K
01S
03C
04Y
1AC
1AR
1BF
1BY
1CN
4AA
4BO
5A7
5GN
5VM
9L3
A51
A64
A69
AAW
AAX
AAY
ABX
ABY
ACB
ACI
ACC
ADS
Description
TRIM COLOR SEAT- JET BLACK
TRIM COLOR SEAT- LT NEUTRAL
TRIM COLOR SEAT- BRICK
TRIM COLOR SEAT- MED TITANIUM
TRIM COLOR SEAT- FURY RED
TRIM COLOR SEAT- Midnight Onyx
TRIM COLOR DR PANEL- LT NEUTRAL
TRIM COLOR DR PANEL- MED TITANIUM
TRIM COLOR DR PANEL- BRICK
TRIM COLOR DR PANEL - FURY RED
TRIM COLOR DR PANEL - Midnight Onyx
INTERIOR TRIM - JET BLACK
INTERIOR TRIM - COCOA/LIGHT NEUTRAL
WHEEL SPARE - NONE
TIRE ALL - 215/55R17 SL 94V BW ALS
ACCESSORY - GROUND EFFECTS PACKAGE - ALTERNATE DESIGN
TIRE SPARE - NONE
SEAT - FRT BKT, CUSTOM
SEAT RR - SPLIT, FOLDING, 40/60
RESTRAINT - SEAT BELT TENSIONER, FRT, VAR. 2
INTERIOR TRIM CONFIG - #17
ADJUSTER FRT ST - POWER, MULTI-DIRECTIONAL, RECLINER
MANUAL, DRIVER

AEC
AED
AEQ
AFB
AFC
AFF
AFG
AFK
AFN
AFO
AFP
AG6
AH3
AHN
AJC
AKK
AKP
AKX
ASV
ATH
AU3
AWO
AXG
AXJ
AYF
B34
B35
B76
BAG
BAH
BS1
BTM
BTV
BVG
C42
C49
C67
C68
C91
WINDOW - POWER OPERATED, DRIVER EXPRESS DOWN

WINDOW - POWER OPERATED, PASSENGER, EXPRESS DOWN
WINDOW - POWER OPERATED, RR DRS, EXPRESS DOWN
ADJUSTER PASS ST - MANUAL, 4 WAY
ADJUSTER FRT ST - MANUAL, 4 WAY, DRIVER
RESTRAINT PROVISIONS - LATCH
RESTRAINT - HEAD, FRT SEAT, UP/DOWN ADJUSTMENT
WINDSHIELD STYLE - ACOUSTIC PVB
WINDOW TYPE - SOLAR ABSORBING
WINDSHIELD TYPE - SOLAR ABSORBING
EQUIPMENT - SENSOR AIR MOISTURE& W/S TEMP
LOCK CONTROL, ENTRY - REMOTE ENTRY, EXTENDED RANGE,
PASSIVE ENTRY
LOCK CONTROL - SIDE DR, ELEC
RESTRAINT SYSTEM RR - SEAT BELT, REAR, 3 POINT, CTR
WINDOW - POWER OPERATED-EXPRESS DRIVER UP/DOWN
VEHICLE TYPE - PASSENGER CAR
RESTRAINT SYSTEM - SEAT, INFLATABLE, DRIVER& PASS FRT, FRT
SEAT SIDE& RR SEAT SIDE, ROOF SIDE, KNEE
COVERING FRT - FLOOR MATS, CARPETED INSERT
COVERING REAR - FLOOR MATS, CARPETED INSERT
CLUSTER COLOR - INST, BLACK
PARTS PKG - EXPORT
EQUIPMENT- SECURITY SYSTEM, IMMOBILIZATION, STEP TWO
INSULATION - ACOUSTICAL PKG
SWITCH-ENGINE START, KEYLESS
REMOTE START - ENGINE
KIT - BODY KIT, SPORT
HVAC SYSTEM - HEATER, OUTSIDE AIR, DELUXE
DEFOGGER- RR WINDOW, ELECTRIC
HVAC SYSTEM- AIR CONDITIONER FRT, ELECTRONIC CONTROLS
HVAC SYSTEM- AIR CONDITIONER FRT, AUTO, ELECTRONIC
CONTROLS
LAMP- INTR, ROOF, COURTESY

C95
CF5
D31
D6I
D75
D7A
DA1
DBU
DD8
DLV
DP6
DT4
DWE
DWT
DWY
DVR
E17
E3E
EA1
EA2
EBF
EBJ
EF7
EN4
FCT
FCU
FE9
FJW
FV1
FW7
FX1
FX3
FXH
GAN
GAR
GAZ
GBE
LAMP- INTR, ROOF, COURTESY& DUAL READING

ROOF- SUN, GLASS, SLIDING, ELEC
MIRROR I/S R/V- TILT
MIRROR I/S FRT VAN- SUNSHADE, DRIVER, W/MIRROR, COVER,
ILLUM, PASS, W/MIRROR, COVER, ILLUM
HANDLE O/S DOOR- BODY COLOR
HANDLE O/S DOOR- BODY COLOR, CHROME STRIP
ARM REST- RR SEAT, STORAGE
CONSOLE- FRT COMPT, FLOOR, ARM REST SLIDING
MIRROR I/S R/V- LT SENSITIVE
MIRROR I/S FRT VAN- SUNSHADE, DRIVER& PASS, W/MIRROR&
COVER
MIRROR PROVISIONS- HOUSING, PAINTED
ASHTRAY-CIGARETTE LIGHTER
MIRROR O/S- LH& RH, RC, ELEC, HEAT, AUX WFOV/DRVR, MANFOLD,
CNVX/PASS
MIRROR O/S- LH& RH, RC, MANFOLD, AUX WFOV/DRVR, CNVX/PASS
MIRROR O/S- LH& RH, RC, ELEC, MANFOLD, AUX WFOV/DRVR,
CNVX/PASS
CLUSTER COLOR- INST, BLACK, TRANSLUCENT RINGS W/CHROME
TOP
BUMPER- 2.5 MPH
HANDLE- O/S, L/GATE, R/CMPT, CHROME
POCKET- FRONT SEAT BACK, LH
POCKET- FRONT SEAT BACK, RH
TRIM SEAT- LEATHER, MERIDIAN
TRIM SEAT- CLOTH, MESH
COUNTRY - UNITED STATES OF AMERICA (USA)
COVER, RR COMPT - HARD, RR COMPT, CARGO
TRIM DOOR - MESH FABRIC
TRIM DOOR - PU LEATHER
CERTIFICATION - EMISSION, FEDERAL
VEHICLE FUEL - GASOLINE E15
RATIO - TRANSAXLE FINAL DRIVE 3.72
RIDE AND HANDLING - AUTOMATIC ELECTRONIC CONTROLLED
PRIMARY COLOR - EXTERIOR, SWITCHBLADE SILVER MET (G) 636R
PRIMARY COLOR - EXTERIOR, CARBON FLASH MET (G) 501Q
PRIMARY COLOR - EXTERIOR, OLYMPIC WHITE (G) 8624
PRIMARY COLOR - EXTERIOR, CRYSTAL CLARET TINTCOAT (G) 505Q

GBV
GCN
GGT
GNA
GNG
GNF
GTS
GWT
GWY
GXG
J67
J93
JJ2
K34
KA1
KC7
KCL
KG8
KPK
KRD
KTA
KTF
KTI
LHD
LOD
LUV
LUW
LWE
MDB
MDC
MF3
MH8
MH9
MR5
MZ0
N34
N37
PRIMARY COLOR - EXTERIOR, CYBER GRAY MET (G) 637R

PRIMARY COLOR - EXTERIOR, VICTORY RED 9260
PRIMARY COLOR - EXTERIOR, SERAPH ORANGE MET (715S) (90U)
CHASSIS EQUIP FRONT - STRUT ASM
CHASSIS EQUIP REAR - REAR AXLE, COMPOUND CRANK,
ADDITIONAL WATT LINKAGE
CHASSIS EQUIP REAR - REAR AXLE, COMPOUND CRANK
PRIMARY COLOR - EXTERIOR, LUXO BLUE MET (933L) (44U)
PRIMARY COLOR - EXTERIOR, CHAMPAGNE SILVER MET (102V)
PRIMARY COLOR - EXTERIOR, ATLANTIS MET (106V)
PRIMARY COLOR - EXTERIOR, IRIDIUM MET (121V)
BRAKE SYSTEM - POWER, FRT& RR DISC, ABS, 15"
BRAKE SYSTEM - POWER, FRT DISC, RR DRUM, ABS, 15"
BRAKE LINING - BRAKE NOISE AND DUST PERFORMANCE
CRUISE CONTROL - AUTOMATIC, ELECTRONIC
HEATER - SEAT, FRT
RECEPTACLE - ELECTRICAL, RR SEAT
HEATER - DUCT, RR PASS (2ND POSN)
GENERATOR - 130 AMP
HEATER - OIL PAN
FUEL RATING - OCTANE NO. 91
AUDIO INTERFACE
KEY- PRIMARY FOLDABLE, ADDITIONAL FOLDABLE
KIT, TIRE - INFLATOR
VEHICLE DRIVE - LEFTHAND DRIVE
PLANT CODE - LORDSTOWN, OH, USA
ENGINE - GAS, 4 CYL, 1.4L, MFI, DOHC, TURBO, VVT, ALUM, GME, E85
MAX
ENGINE - GAS, 4 CYL, 1.8L, MFI, 103KW, DOHC, E85 MAX
ENGINE - GAS, 4 CYL, 1.8L, MFI, DOHC, VVT, 103 KW, GME
MOLDING B/S UPPER - BLACK
MOLDING B/S UPPER - BRIGHT
TRANSMISSION - MAN 6 SPD, OPEL, 76.5 MM, 4.273 1ST, 2.158 2ND, 1.302
3RD, 0.959 4TH, 0.744 5TH, 0.614 6TH, M32-6 WR
TRANSMISSION - AUTO 6 SPD, HMD, X23F
TRANSMISSION - AUTO 6 SPD, HMD, X24F
TRANSMISSION - MAN 6 SPD, OPEL, 76.5 MM, 4.273 1ST, 2.353 2ND, 1.475
3RD, 1.067 4TH, 0.875 5TH, 0.744 6TH, M32-6 WR
TRANSMISSION - MAN 6 SPD, OPEL, 76.5 MM, 3.82 1ST, 0.74 6TH, (M32
WR)
STEERING WHEEL - LEATHER, 3 SPOKES
STEERING COLUMN - TILT, TELESCOPING

N45
NAG
NE1
NJ1
NL6
NT7
NU5
NU6
PWM
PZV
QOI
QYF
QYW
RBU
RTN
RU5
RWI
RWK
RXZ
RYT
S0M
S0O
S3U
S47
S52
SAH
SAO
SB2
SBZ
SE1
SFE
SRR
T4A
T43
T74
T83
T3U
T3W
TM7
STEERING WHEEL - 3 SPOKES

COVER, WHEEL - BOLT-ON, VAR 1
CERTIFICATION - EMISSION, GEOGRAPHICALLY RESTRICTED
REGISTRATION FOR VEHICLES UP TO 14, 000 LBS GVW
STEERING - POWER, NON-VARIABLE RATIO, ELECTRIC
FUEL TANK - 49L, 13 GAL, SINGLE
EMISSION SYSTEM - FEDERAL, TIER 2
EMISSION SYSTEM - CALIFORNIA, BIN 4
EMISSION SYSTEM - CALIFORNIA, PZEV
WHEEL - 16 X 6.5, STEEL, DESIGN2
WHEEL - 18 X 7, 5, J, ALUMINUM, DESIGN 7
TIRE ALL - P225/45R18-SL 91W BW AL3
TIRE ALL - P225/50R17 SL 93 H BW AL3
TIRE ALL - P215/60R16-94S BW R/PE ST TL ALS
WHEEL - 17 X 7.0, J, ALUMINUM, DESIGN 17
WHEEL SPARE - 16 X 4.0, J, STEEL, DESIGN 1
ACCESSORY - BODY SIDE MOLDINGS - CHROME
ACCESSORY - BODY SIDE MOLDINGS - PAINTED
ACCESSORY - CRUISE CONTROL KIT
ACCESSORY - FIRST AID KIT
ACCESSORY - ILLUMINATED DOOR SILLS
ACCESSORY - ILLUMINATED FOOT WELLS
ACCESSORY - LAMP KIT - FRONT FOG
ACCESSORY - LUG NUTS
ACCESSORY - MOLDED HOOD PROTECTOR - SMOKED
ACCESSORY - SILL PLATES - CHROME
ACCESSORY - SMOKERS PACKAGE
ACCESSORY - SPOILER - DECKLID - FLUSH MOUNT
ACCESSORY - SPORT PEDAL KIT
ACCESSORY - WHEEL - 17" - ALUMINUM - DESIGN 2
ACCESSORY - WHEEL LOCKS
MODEL CONVERSION - 2LT
HEADLAMPS- HALOGEN
SPOILER- RR
HEADLAMPS CONTROL- AUTOMATIC, DELAY
HEADLAMPS CONTROL- AUTOMATIC ON-OFF
LAMP- FRT FOG
LAMP SYSTEM- DAYTIME RUNNING, REDUCED INTENSITY LOW
BEAM
BATTERY- LN2, FLA, 12V, 60AH, 438 ENCCA

TPV
TS6
TTX
TU2
U04
U07
U19
U25
U91
U2K
UAG
UD0
UD7
UDC
UDY
UE1
UEC
UFG
UFT
UFU
UH0
UH1
UHQ
UJ2
UJM
ULS
UMN
UP9
UPF
UQA
USR
UTJ
UVC
UYE
UZ6
V48
GRILLE- RADIATOR, BLACK, W/CHROME BAR

LAMP- STOP, HIGH LEVEL
RADIO EQUIPMENT- AUX CONNECTOR (LINE IN)
LAMP- MARKER, SIDE
HORN- SINGLE NOTE
HORN- FANFARE
SPEEDOMETER- INST, KILO& MILES, KILO ODOMETER
LAMP-INTR, RR COMPT, COURTESY
ANTENNA - SHORT, ROOF, RADIO
DIGITAL AUDIO SYSTEM - S-BAND
INFOTAINMENT DISPLAY - GRAPHIC INFO DISPLAY (GID), VAR 1
SENSOR INDICATOR - INFLATABLE RESTRAINT, FRT RH/CHILD
PRESENCE DETECTOR
SENSOR INDICATOR - REAR PARKING ASSIST
DISPLAY INSTRUMENT - DRIVER INFO ENHANCED (ONE COLOR
GRAPHIC)
INFOTAINMENT DISPLAY - COLOR INFO DISPLAY (CID) 7", WVGA,
TOUCH SCREEN
COMMUNICATION SYSTEM - VEHICLE, G.P.S. 1
SENSOR INDICATOR - AUTOMATIC AIR RECIRCULATION
SENSOR INDICATOR - REAR CROSS TRAFFIC ALERT
SENSOR INDICATOR - SIDE OBSTACLE DETECTION
RADIO - AM/FM STEREO, SINGLE CD, MP3 (AUX IN), USB
INDICATOR - SEAT BELT WARNING, LH
INDICATOR - SEAT BELT WARNING, RH
RADIO - AM/FM STEREO, SINGLE CD, MP3 (AUX IN), USB,
NAVIGATION
INDICATOR - ENGINE OIL LIFE
TIRE PRESS INDICATOR - MANUAL LEARN
LOCK CONTROL - STEERING COLUMN
SPEEDOMETER - INST, MILES& KILO, MILES ODOMETER
WIRELESS INTERFACE - SHORT RANGE, VOICE RECOG, MUSIC
NAVIGATOR, STREAMING AUDIO
WIRELESS INTERFACE - SHORT RANGE, VOICE REC
SPEAKER SYSTEM - PREMIUM AUDIO BRANDED WITH AMPLIFIER
RECEPTACLE - USB
THEFT DETERENT - ELECTRICAL, UNAUTHORIZED ENTRY
CAMERA - REAR VIEW
RADIO - AM/FM STEREO, CD-ROM, CAF, RSA, MUSIC NAVIGATOR
(GMNA VERSION)
SPEAKER SYSTEM - 6, PREMIUM
COOLANT - ENGINE MAXIMUM PROTECTION

VAS
VAV
VCG
VG1
VHY
VK3
VKX
VKY
VPH
VQK
VTB
VTG
VTW
VTX
VWC
VY7
VYW
VZ3
W1Y
W2D
WA7
WGK
WR6
XJ2
XL7
Y8X
YF5
Z49
Z54
Z64
ZAD
ACCESSORY - GRILLE / GRILLE INSERTS - ALTERNATE FINISH - BODY

COLOR
ACCESSORY - FLOOR MATS - ALL WEATHER
PROVISIONS - INTERNATIONAL SWITCH/CONTROL SYMBOLS
PROTECTOR - UNDERHOOD COMPOUND, CORROSION PREVENTIVE,
WATER BASED, CLEAR
PROTECTOR - BODY SHEET METAL, HIGH CORROSION PREVENTIVE
LICENSE PLATE FRONT - FRT MOUNTING PKG
ACCESSORY - SPARE WHEEL & TIRE
ACCESSORY - DOOR HANDLES - ALTERNATE FINISH - CHROME
VEHICLE PREPARATION - OVERSEAS DELIVERY
ACCESSORY - SPLASH GUARDS - CUSTOM MOLDED
ACCESSORY - PROTECTOR - REAR BUMPER
ACCESSORY - INTERIOR TRIM KIT
COMPARTMENT - STOWAGE, I/P, W/LID
COMPARTMENT - STOWAGE, I/P, WO/LID
PANEL CENTER - INSTRUMENT, HIGH GLOSS BLACK
KNOB - TRANS CONT LEVER, LEATHER
ACCESSORY - FLOOR MATS - PREMIUM CARPET
LABEL - MERCURY DISPOSAL NOTIFICATION
CONTROL - STEERING WHEEL, RADIO, REDUNDANT CONTROLS
ACCESSORY - CARGO NET
PERFORMANCE PACKAGE - AERO
ACCESSORY - INTERIOR TRIM KIT - DESIGN 1
CHASSIS - SPORT, LOWERED
FREQUENCIES RATING - 315 MHZ, LONG DISTANCE
FUEL ECONOMY- ENGINE IMPROVEMENT
CERTIFICATION- EMISSION, CALIFORNIA
COUNTRY- CANADA
MODEL CONVERSION- LT
MODEL CONVERSION- LTZ
TIRE SPARE-T115/70R16 SL 92M BW SPR
FASTENERS
Metric Fasteners
This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in
diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter,
thread pitch, and strength.
A number marking identifies the OE metric fasteners except cross-recess head screws. The number also

indicates the strength of the fastener material. A Posidrive or Type 1A cross-recess identifies a metric crossrecess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive recess head
screws.
GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard
metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best
thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and
25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the
English coarse and fine thread pitches.
Fastener Strength Identification
Fig. 5: Identifying Fastener Strength Marks

Callout
1
2
3
4
5
6
Component Name
English Bolt, Grade 2 (Strength Class)
Metric Nut, Strength Class 9
Metric Bolts, Strength Class Increases as Numbers Increase
The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is
embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial

lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the
head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the
bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face.
The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts
channels are designed to metric standards of countries other than the United States, and may exhibit the
following:
Lower strength
No numbered head marking system
Wrong thread pitch
The metric fasteners on GM products are designed to new, international standards. The following are the
common sizes and pitches, except for special applications:
M6.0 X 1
M8 X 1.25
M10 X 1.5
M12 X 1.75
M14 X 2.00
M16 X 2.00
Prevailing Torque Fasteners
Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to
prevent the fastener from loosening.
All Metal Prevailing Torque Fasteners
These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener.
Nylon Interface Prevailing Torque Fasteners
These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads.
Adhesive Coated Fasteners
These 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 be reused and the
applicable thread-locking compound to apply to the fastener.

Fig. 6: Identifying Adhesive Coated Fasteners

Callout
1
2
3
4
5
6
7
8
9
Component Name
Prevailing Torque Nut, Center Lock Type
Prevailing Torque Nut, Top Lock Type
Prevailing Torque Nut, Nylon Patch Type
Prevailing Torque Nut, Nylon Washer Insert Type
Prevailing Torque Nut, Nylon Insert Type
Prevailing Torque Bolt, Dry Adhesive Coating Type
Prevailing Torque Bolt, Thread Profile Deformed Type
Prevailing Torque Bolt, Nylon Strip Type
Prevailing Torque Bolt, Out-of-Round Thread Area Type
A prevailing torque fastener may be reused ONLY if:

The fastener and the fastener counterpart are clean and not damaged
There is no rust on the fastener
The fastener develops the specified minimum torque against its counterpart prior to the fastener seating
Metric Prevailing Torque Fastener Minimum Torque Development

Specification
Application
Metric
English
6 mm
0.4 N.m
4 lb in
8 mm
0.8 N.m
7 lb in
10 mm
1.4 N.m
12 lb in
12 mm
2.1 N.m
19 lb in
14 mm
3 N.m
27 lb in
16 mm
4.2 N.m
37 lb in
20 mm
7 N.m
62 lb in
10.5 N.m
93 lb in
24 mm
6 mm
0.3 N.m
3 lb 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
English Prevailing Torque Fastener Minimum Torque Development

Specification
Application
Metric
English
1/4 in
0.5 N.m
4.5 lb in
5/16 in
0.8 N.m
7.5 lb in
3/8 in
1.3 N.m
11.5 lb in
7/16 in
1.8 N.m
16 lb in
1/2 in
2.3 N.m
20 lb in
9/16 in
3.2 N.m
28 lb in

5/8 in
3/4 in
4 N.m
36 lb in
7 N.m
54 lb in
1/4 in
0.3 N.m
3 lb in
5/16 in
0.6 N.m
5 lb in
3/8 in
1 N.m
9 lb in
7/16 in
1.3 N.m
12 lb in
1/2 in
1.8 N.m
16 lb in
9/16 in
2.5 N.m
22 lb in
5/8 in
3.4 N.m
30 lb in
3/4 in
5 N.m
45 lb in
THREAD INSERTS
General Purpose Thread Repair Kits.
These kits are available commercially.
Repair Procedure

Fig. 7: Drilling & Tapping Damaged Threads

WARNING: Refer to Safety Glasses Warning .
NOTE:
Refer to the thread repair kit manufacturer's instructions regarding the

size of the drill and tap to use.
Avoid any buildup of chips. Back out the tap every few turns and remove
the chips.
1. Determine the size, the pitch, and the depth of the damaged 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 hole. Clean the threads.

Fig. 8: View Of Thread Insert

4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the
mandrel.
NOTE:
The insert should be flush to one turn below the surface.
5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert.
6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift.
REGISTERED AND NON-REGISTERED TRADEMARKS
Listed below are Registered Trademarks () or Non-Registered Trademarks () which may appear in this
service information.
Registered and Non-Registered Trademarks

A
AC
ACCUTURN
ACDelco
Active Fuel Management
Acuzinc
Airbank
Allison
AMMCO
AUTOFUSE
AUTOTRAC
B
Bendix
Bluetooth
BON-AMI
Bosch
Bose
C
Caterpillar
CAT
C-Quam
D
Delco
Delco Bose
Delco Electronics
Delco Freedom
Delco LOC II
Delco Moraine
Delco Remy
Delco Sound
Delco Supreme
Delco Tech
DELCORE
Delphi
DEX-COOL
DEXOIL
DEXRON
DEXSTEER
DNR
Dolby
DR
D
ll

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 Ultralite
GMAC
Goodwrench
GTP
H
Homelink
HYDRA-MATIC
I
Illumination
INSTA-TRAC
Intune
L
LOCTITE
Lord Fusor
M
MAGNASTEER
Maxifuse
Metripack
Micropack
Minifuse
Mr Goodwrench
N
Northstar
O
OnStar

P
PASS-KEY
PASS-KEYII
PASSLOCK
PK3
Posidrive
Pro
Q
Quad 4
R
RAINSENSE
Rapid Fire
S
ScotchBrite
Scotchguard
Signals
Sikkens
Soft-Ray
Solar-Ray
Stabilitrak
Sunrayce
Superlube
Syclone
T
Tech 2
Techline
Teflon
Tefzel
Theft-I
Theftlock
Tiltmaster
TORX
Transjel
Transguide
Twilight Sentinel
U
Ultralite
V
Velcro
W
W th

KEY AND LOCK CYLINDER CODING

Special Tools
BO-49753 Assembly Tool

Ignition Lock Cylinder

Fig. 9: Lock Cylinder Coding - Ignition

The ignition lock cylinder uses 8 key cut positions, 1-8. The ignition cylinder tumblers (3) are located on
alternate sides of the cylinder (5). They are not snap-in and are not self-retaining. It follows the key code with

the first tumbler being the first depth of the key code, closest to the head of the key.
NOTE:
All lock cylinders for side milled keys have right and left tumblers. The
location of the tooth of the tumbler determines whether it is right of left.
Illustrations in this procedure show the right tumblers on the top and the
left tumblers on the bottom. All tumblers are marked 1R, 1L, 2R, or 2L. The
number being cut depth and the letter meaning right or left.
1. Hold the ignition cylinder assembly (5) so the side with the tumbler spring pocket located closest to the
head of the cylinder is facing up.
2. Insert the tumbler spring (7) into each of the 4 spring pockets of the cylinder assembly. This side of the
cylinder used left tumblers.
3. The first tumbler (3) to be loaded will be the first key cut position, which is the first number in the key
code. Install the tumbler in the slot over the spring. Install the remaining right tumblers following the key
code and same process, pressing the tumblers in place until they are secure.
4. Rotate the cylinder assembly. Insert the tumbler spring into each of the spring pockets of the cylinder
assembly. This side of the cylinder used right tumblers.
5. The first tumbler (3) to be loaded will be the second key cut position, the second number in the key code.
Install the first tumbler in the slot over the spring. Install the remaining left tumblers following the key
code and same process, pressing the tumblers in place until they are secure.
6. Inspect for correct loading of the tumblers by inserting the key into the cylinder. All tumblers should drop
flush with the lock cylinder body diameter.
7. With the key in the cylinder assembly insert the round connector (6), insert the retainer spring (2) in the
retainer slot located in the cylinder assembly. Insert the retainer (1) lining it up in the slot over the spring.
Depress the retainer and hold.
8. Insert the cylinder into the sleeve (4) as shown in the print. Make sure the actuator stays located properly
in the cylinder.
9. When the key is removed, the lock should stay together.
10. Lightly lubricate the outside surface in the tumbler area of in the lock body and down the key slot using
the provided grease. Insert and extract the key 5 times to lubricate the keyway.
11. Insert the key and function the lock 3 times to distribute the grease inside the sleeve.
12. Verify the key position for inserting the lock into the column.
Front Side Door Lock Cylinder

Fig. 10: Identifying Lock Components

The door lock cylinder uses 8 of the 8 cut positions. The tumbler positions are staggered from side to side, 4 on

one side and 4 on the other, are not self-retaining, and are not snap in.
NOTE:
All lock cylinders for side milled keys have right and left tumblers. The
location of the tooth of the tumbler determines whether it is right of left.
Illustrations in this procedure show the right tumblers on the top and the
left tumblers on the bottom. All tumblers are marked 1R, 1L, 2R, or 2L. The
number being cut depth and the letter meaning right or left.
1. Hold the door lock cylinder (1) so the side with the 4 tumbler spring pockets faces up, pocket nearest to
the cylinder head.
2. Insert the tumbler springs (2) into the 4 spring pockets. This side uses left tumblers.
3. Install the tumbler (3) for key cut position one in the slot nearest to the front of the lock cylinder. Install
the remaining tumblers, key cut positions 3, 5, and 7, following the key code and same process. Press the
tumblers in place until they are secure.
4. Check the correct loading of the tumblers by inserting the key into the cylinder. All tumblers should be
flush with the lock cylinder body.
5. Turn the cylinder so the side with the 4 tumbler spring wells faces up. This side uses right tumblers.
6. Insert the tumbler springs into the 4 spring pockets.
7. The first tumbler closest to the front of the lock cylinder to be loaded will be the second key cut position,
the second number in the key code. Install the remaining tumblers for the key cut positions 4, 6, and 8.
Press the tumblers in place until they are secure.
8. Check the correct loading of the tumblers by inserting the key into the cylinder. All tumblers should be
flush with the lock cylinder body.
9. Insert the key and lightly lubricate the cylinder body diameter and tumbler surfaces and a small amount in
the head of the cylinder using the supplied grease.
10. Insert the sleeve (4) onto the cylinder assembly.
11. Insert the clutch (5) and driver (6) onto the cylinder (1).

Fig. 11: Loading Cylinder Into Special Tool

12. Load the cylinder into the BO-49753 assembly tool so that the clutch (1) indexes with the notch in the
opening of the tool (2).

Fig. 12: Loading Assembly Tool Into Vise

13. Load the assembly tool with the lock cylinder into a vice and tighten the vice ONLY enough to hold the
tool and lock the cylinder in place.

Fig. 13: Identifying Lock Components

14. Insert the roll pin (7) into the driver (6) and install it using a 1/16 inch pin punch.

15. Insert the buffer (8) in the case (9), verify the buffer is properly seated.
16. Install the free wheel pin (11) in the sleeve (4) and clutch (5) and insert the assembly into the case (9).
17. With the lock cylinder assembly installed in the case (9), install the retainer (10) and stake the retainer in
place using a small punch and hammer to peen the case material onto the exposed ends of the installed
retainer (10).
18. Insert the key into the lock and function the lock to check for proper assembly and smooth operation.
LIFTING AND JACKING THE VEHICLE
NOTE:
The use of a LOW PROFILE LIFT ARMS SYSTEM may be required to avoid
unwanted contact with the vehicle's body and structure depending on lifting
equipment used. Refer to the manufacture's recommendation for their
applications of low profile lift arms system for their lifting equipment.
Fig. 14: Vehicle Lifting Points

WARNING: To avoid any vehicle damage, serious personal injury or death when
major components are removed from the vehicle and the vehicle is
supported by a hoist, support the vehicle with jack stands at the opposite
end from which the components are being removed and strap the vehicle
to the hoist.
WARNING: To avoid any vehicle damage, serious personal injury or death, always

use the jackstands to support the vehicle when lifting the vehicle with a
jack.
CAUTION: Perform the following steps before beginning any vehicle lifting or jacking
procedure:
Remove or secure all of the vehicle 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
meet or exceed the weight of the vehicle and any vehicle contents.
The lifting equipment or the jacking equipment must meet the
operational standards of the lifting equipment or jacking equipment
manufacturer.
Perform the vehicle lifting or jacking procedure on a clean, hard, dry,
level surface.
Perform the vehicle lifting or jacking procedure only at the identified
lift points. DO NOT allow the lifting equipment or jacking equipment
to contact any other vehicle components.
Failure to perform the previous steps could result in damage to the lifting
equipment or the jacking equipment, the vehicle, and/or the vehicle
contents.
Vehicle Lifting- Frame Contact Lift
Front Lift Pads

When lifting the vehicle with a frame-contact lift, place the front lift pads on the rocker outer panel weld flange,
as shown
Rear Lift Pads
When lifting the vehicle with a frame-contact lift, place the rear lift pads on the rocker outer panel weld flange,
as shown.
Vehicle Jacking
CAUTION: When you are jacking the vehicle at the front locations, be certain that the
jack or the jack lift pad does not contact the front fascia, front fascia air
dam, or the front fenders. If such contact occurs, vehicle damage may
result. When jacking at selected front locations additional clearance may
be required for the jacking points.
NOTE:
When you are lifting a vehicle with a service jack, block the wheels at the

opposite end from which you are lifting. Use jack stands to provide additional
support.
Front of Vehicle
When using a service jack under the front of the vehicle use one of the following locations:
Place the service jack pad in the same location as shown for the front lift pads.
Rear of Vehicle
NOTE:
Place jackstands ONLY under strong and stable vehicle structures.
Place the service jack pad in the same location as shown for the rear lift pads.
SPECIAL TOOLS AND EQUIPMENT

SPECIAL TOOLS ORDERING INFORMATION
The special service tools shown in this service manual that have product numbers beginning with BO, CH, DT,
EL, EN, or GE are available for worldwide distribution from:
OE Tool and Equipment Group
Kent-Moore
28635 Mound Road
Warren
MI, U.S.A
48092-3499
Phone: 1-800-345-2233 or 586-574-2332
Monday through Friday
8:00 am-7:00 pm Eastern Standard Time
Fax: 1-800-578-7375 or 586-578-7321
The Multi Diagnostic Interface MDI and accessories can be purchased through:
Dealer Equipment and Services

5775 Enterprise Dr.

Warren
MI, U.S.A
48092-3463
Phone: 1-800-GM-TOOLS or 586-574-2332
Monday through Friday
8:00 am-6:00 pm EST
Fax: 1-586-578-7205

2013 GENERAL INFORMATION Vehicle Diagnostic Information - Cruze

Vehicle Diagnostic Information - Cruze
SPECIFICATIONS
BODY CONTROL MODULE SCAN TOOL INFORMATION
Body Control Module Scan Tool Data Parameters
System
Parameter
State
Expected Value
Definition
Operating Conditions: Ignition ON, Vehicle in Park, All Doors Closed
The scan tool displays Off,
Accessory / Key
Accessory, Run, or Crank. This
5 V Ignition Switch
Out
parameter displays the ignition
switch mode.
This parameter displays the interior
Accent Lighting 1 Command
Varies
lighting ambient 1 command as a
percentage.
The scan tool displays Active or
Accessory
Active
Inactive.
This parameter displays ignition
Accessory Power Mode Indicator
Varies
switch accessory LED PWM
Command
command as a percentage.
Accessory Relay Command
Active
Inactive.
Accessory/Retained Accessory
Inactive. This parameter displays
Active
Power Relay Command
the retained accessory power relay
status.
All Door Lock Command
Inactive
the door lock status.
The scan tool displays volts. This
Ambient Light Sensor
Varies
parameter displays the ambient
light sensor signal voltage.
The scan tool displays Unknown,
Night, or Day. This parameter
Ambient Light Status
Night
displays the ambient light level
status.
Automatic Headlamps Disable
Inactive
Switch
the headlamp disable switch status.
Automatic Transmission Manual
Off
The scan tool displays Off or On.

This parameter displays the

Shift Switch
Backup Lamps Relay Command -
Inactive
Battery Low at Start
Inactive
Battery Reconnect Detected
No
Battery Voltage
Varies
BCM-Controlled Charging
Voltage
Active
BCM-Requested Charging
Voltage Reduction
Inactive
Boot Software Part Number
Varies
Brake Lamp Command
Inactive
Brake Pedal Initial Travel

Position Achieved
Brake Pedal Position Sensor High
Voltage During Learn
No
The scan tool displays No or Yes.
No
Brake Pedal Position Sensor

Learn
No

Learned Home Position
Yes
Brake Pedal Position Sensor Low

Voltage During Learn
transmission tap up tap down

switch status.
the backup lamps relay status.
Active when the battery level is low
when the vehicle starts.
The scan tool displays No or Yes
when a battery
disconnect/reconnect event has
been detected.
The scan tool displays the current
battery voltage.
Inactive.
Active when the BCM has detected
a low battery voltage condition.
The scan tool displays the boot
software part number.
the brake lamp command status.

This parameter displays Yes when
the brake pedal position sensor has
learned.
This parameter displays Yes when
the brake pedal position sensor has
learned the home position.
No

Move During Learn
No

This parameter displays the brake
pedal sensor learn status.

Pulled Up from Home Position
No


Reference
Varies
The scan tool displays the brake

pedal position as voltage value.
This parameter displays the current
brake pedal position sensor
reference.
Brake Pedal Pulled Up from

Home Position
No
Brake Transmission Shift

Interlock Solenoid Actuator
Inactive
Brake Transmission Shift

Interlock Solenoid Actuator
Command
Inactive
Calibration Part Number 1-20
Varies
Center Brake Lamp Command
Inactive
Central Door Lock Switch on

Center Console
Inactive
Child Security Lock Indicator

Command
Inactive
Content Theft Deterrent Alarm

Status
Disarmed
Content Theft Deterrent Disarmed

Until Vehicle Closed
No
Content Theft Deterrent Mode
Inactive
Content Theft Deterrent Trigger

History 1-3
None

the remote start diagnostic status
history.
the last remote start diagnostic
status history.
The scan tool displays the software
module calibration part number.
the center brake lamp status.
the driver door lock switch status.
the child security lock indicator
command status.
The scan tool displays Off, Armed,
or Disarmed. This parameter
displays the content theft alarm
status.
This parameter displays the content
theft deterrent system status.
the remote start diagnostic status
history or the last remote start
diagnostic status history.
The scan tool displays None, Driver
door, Passenger door, Left rear
door, Right rear door, Rear closure,
Midgate, Tonneau Cover, Hood,
Ignition Voltage, Intrusion,
Inclination, Telematics enhanced
service alarm, Battery reconnect

Courtesy Lamps Duty Cycle

Command
Varies
Crank Abort
Inactive
Cruise Charging Set Level
Varies
Cruise Control Switch Status
OFF
Current Content Theft Deterrent

Trigger
None
Current Driver
1-8
Disable Battery Saver Relay

Command
Inactive
Dome Lamp Switch
Inactive
Driver Door Ajar Switch
Inactive
Driver Door Unlock Command
Inactive
Driver Window Learned
Yes
detected, Unauthorized PWM

change, Security Indicates Tamper,
or Glass Breakage. This parameter
displays the content theft deterrent
trigger history status.
This parameter displays the interior
lights dimming command as a
percentage.
This parameter displays the remote
start diagnostic status history or the
last remote start diagnostic status
history.
This parameter displays cruise
charging set level.
The scan tool displays CANCEL,
OFF, ON, RESUME, SET or
ERROR. This parameter displays
the cruise control switch status.
The scan tool displays None, Driver
door, Passenger door, Left rear
door, Right rear door, Rear closure,
Midgate, Tonneau Cover, Hood,
Ignition Voltage, Intrusion,
Inclination, Telematics enhanced
service alarm, Battery reconnect
detected, Unauthorized PWM
change, Security Indicates Tamper,
Glass Breakage. This parameter
displays the content theft deterrent
current alarm trigger.
driver in vehicle.
Inactive.
the dome lamp switch status.
the driver door Ajar switch status.
the driver door unlock command
status.

Driver Window Main Control

Down Switch
Inactive
Driver Window Main Control

Express Switch
Inactive
Driver Window Main Control Up

Switch
Inactive
Driver Window Motor Mode
Local Switch
Overridden
Enable Battery Saver Relay

Command
Inactive
End Model Part Number
Varies
Engine Stalled
Inactive
Environment Identification
Unknown
Inactive
Front Fog Lamps Relay

Command
Inactive
Front Fog Lamps Switch
Inactive
Front Passenger Window Main

Control Down Switch
Inactive

Control Express Switch
Inactive

the driver window main control
down switch input status.
the driver window switch express
input status.
the driver window switch UP input
status.
The scan tool displays Down,
Express Down, Express, Up, Error,
Inhibit, or Local Switch
Overridden. This parameter
displays the driver window motor
mode status.
Inactive.
This parameter displays the end
model part number.
history.
The parameter displays the vehicle
environment identification
successful status.
the front fog lamps status.
the front fog lamp relay status.
the front fog lamp switch status.
the front passenger window down
switch status.
the passenger window switch
express input status.


Control Up Switch
Inactive
Front Tire Pressure on Placard
Varies
Fuel Economy Mode Inhibited Low Charging Voltage
Inactive
Generator Regulator Setpoint
Varies
Hazard Lamps Switch
Inactive
Hazard Lamps Switch Backlight

Command
Varies
Headlamps On Switch
Inactive
Headlamps Flash Switch
Inactive
High Beam Select Switch
Inactive
High Beam Command
Inactive
Hood Ajar Switch
Inactive
Hood Ajar Switch Signal 1
Inactive
Hood Position
CLOSED
Horn Relay Command
Inactive

the passenger window switch UP
input status.
The scan tool displays kPa or PSI.
specified tire pressure placard
information programmed in the
BCM for tire pressure monitoring.
the fuel economy mode status.
The scan tool displays percentage.
the hazard lamps switch status.
This parameter displays hazard
switch backlight level PWM
command status.
the headlamp on switch status.
the headlamps flash to pass switch
status.
the high beam switch status.
the high beam command status.
This parameter display the remote
history.
This parameter display the remote
history.
The scan tool displays CLOSED,
AJAR, or OPENED. This
parameter displays the hood
position.
Inactive.

Horn Switch
Inactive
Idle Boost Level 2-3 Counter
Varies
Idle Charging Set Level
Varies
Ignition Mode Switch Dimming

Command
Varies
Ignition Switch Reference
Varies
Ignition Switch Signal Voltage
Varies
Ignition Switch Status
Inactive
Immobilizer Allows Engine To

Start
Unknown
Immobilizer Automatic Learn

Timer
Inactive

Inactive.
This parameter displays the state of
the idle boost level as counts.
This parameter displays idle
charging set level.
The scan tool displays as a
percentage.
This parameter displays the ignition
switch voltage reference.
switch signal voltage.
switch status.
Incorrect, Not Allowed, or Valid.
immobilizer status.
the automatic learn timer status.
The scan tool displays Incorrect,
Correct, Not Received, Not
Programmed or Unknown. This
parameter displays the immobilizer
source status.
the password learn status.
This parameter displays the auto
learn timer status.
Immobilizer Environment Device

1-4
Unknown
Immobilizer Password Learn
Inactive
Varies
No
No
Yes
In Park Switch Status
On
Inadvertent Load Command
Active
Indicator Dimming Duty Cycle

Command
Varies
Immobilizer Password Learn

Scan Tool Delay
Immobilizer Security Code
Accepted
Lockout
Programmed
The scan tool displays On or Off.

This parameter displays the park
switch status.
Inactive.
This parameter displays indicator
lighting PWM command status.

Interior/Courtesy Lighting Master

Switch
Interior Trunk Lid/Liftgate
Window Unlatch Switch
Door
Inactive
Key Capture Solenoid Actuator
Active
Key Fob 1-4 Battery Status
OK
Key Fob 1-4 Function
Undefined
Key Fob in Vehicle
Inactive
Key In Cylinder Switch
Active
Key In Cylinder Switch/Key Fob

in Vehicle
Yes
Key in Ignition Status
Inactive
Key Part Number
Varies
Key Type
Master Key
The scan tool displays Door or

other lighting switch status.
Inactive.
The scan tool display Active or
column lock input status.
The scan tool displays OK or other
key fob battery status. This
parameter displays the key fob
battery status.
The scan tool displays Inactive,
Lock, Unlock Driver Door, All
Door Unlock, Release Rear
Closure, Actuate Left Sliding Door,
Actuate Right Sliding door, Panic
Alarm, Release Fuel door, Actuate
Power Windows, Actuate Folding
Top, Start Engine, Stop Engine,
Programmed, Locator Alarm, Close
Liftgate, Open Liftgate, Stop
Liftgate While Closing, Stop
Liftgate While opening, Deadlock
All Doors, Stop Liftgate Motion,
Start Liftgate Motion, Stop Left
Sliding Door Motion, Stop Right
Sliding Door Motion, Comfort
open, or Comfort close. This
parameter displays the key fob
function status.
key fob in the vehicle.
Inactive.
The scan tool displays Key Out or
Key In. This parameter displays the
key in ignition status.
This parameter displays the key part
number.
Master Key, Valet Key, Fleet Key,
or Unconfigured. This parameter
displays the key type.
The scan tool displays NO Action,

Last Door Lock Function
LED Backlight Dimming

Command
Left Brake Lamp Command
Left Dedicated Daytime Running

Lamp Command
Left Front Tire Pressure
Left Front Tire Pressure

Identification
Left Front Tire Pressure Sensor

Location Learned
Left Front Tire Pressure Sensor

Mode
Left Front Tire Pressure Status
Left Front Turn Signal Bulb Out

Feedback
Left Front Turn Signal/Hazard
Lamp Command
Left Low Beam/Daytime Running
Lamp Command
Left Park Lamps Command
PC UNDB Lock, PC Unlock,

Unlock, Unlock Driver, Unlock
Passenger, Unlock Left Rear,
Unlock Right Rear, Unlock Cargo
All Doors Lock
Liftgate, Unlock Driver Side,
Unlock Passenger Side, Unlock
Non Driver, Unlock All, Lock All,
DBL Lock, or UNDBL Lock.
The scan tool displays as a
percentage. This parameter displays
Varies
LED backlight dimming PWM
command status.
Varies
This parameter displays left brake
lamp command status.
This parameter displays left
Varies
dedicated daytime running lamp
command status.
This parameter displays left front
Varies
tire pressure in PSI.
This parameter displays left front
Varies
tire pressure sensor ID.
This parameter display tire pressure
Yes
monitor system learned status.
The scan tool parameter displays
Learn Mode, Undefined,
Learn Mode Remeasure Data Mode, Rolling
Pressure Triggered Mode, Enter Off Mode, Exit Off
Mode, or Learn Mode Pressure
Triggered.
Normal
Normal, Very Low Pressure, Low,
Weak Signal, or High.
Inactive
Inactive.
Inactive
Inactive.
This parameter displays left low
Varies
beam/daytime running lamp status.
Varies
This parameter displays rear
exterior lighting status.
This parameter displays Active or

Left Rear Door Ajar Switch
Inactive
Left Rear Tire Pressure
Varies
Left Rear Tire Pressure

Identification
Varies
Left Rear Tire Pressure Sensor

Location Learned
Yes
Left Rear Tire Pressure Sensor

Mode
Stationary
Left Rear Tire Pressure Status
Normal
Left Rear Turn Signal Bulb Out

Feedback
Inactive
Left Rear Turn Signal/Hazard

Lamp Command
Inactive
Left Rear Window Main Control

Down Switch
Inactive

Express Switch
Inactive

Up Switch
Inactive
Left Rear Window Motor Mode
Local Switch
Overridden
Left Rear Window Switch at

Door
Inactive
Left Turn Signal Switch
Inactive
License Plate Lamps Command
Inactive
Load Reduction Level 2-3

Counter
Varies

the left rear door ajar switch status.
This parameter displays left rear tire
pressure in PSI.
This parameter displays left rear tire
pressure sensor ID.
This parameter displays tire
pressure monitor system learned
status.
The scan tool displays Learn Mode,
Undefined, Remeasure Data Mode,
Rolling Mode, Enter Off Mode,
Exit Off Mode, or Learn Mode
Pressure Triggered.
Inactive. The parameter displays
turn lamp outage status.
Inactive.
driver window switch inputs.
Express, Up, Inhibit, or Local
Switch Overridden.
Inactive.
the left turn signal switch status.
Inactive.
The scan tool display as counts.

Low Beam Relay Command
Inactive
Manufacturers Enable Counter
Varies
Master Keys Learned
Varies
Module Diagnostic Address
Varies
Number of Key Fobs In Vehicle
Odometer
Varies
Outside Rear View Mirror

Courtesy Lamp Command
Inactive
Park Brake Switch
Active
Park Lamps Switch
Inactive
Passenger Door Ajar Switch
Inactive
Passenger Door Lock Switch
Inactive
Passenger Door Unlock Switch
Inactive
Passenger Door(s) Unlock

Command
Inactive
Passenger Window Learned
Yes
Passenger Window Motor Mode Passenger Window Switch at
Local Switch
Overridden

the headlamp low beam relay
status.
This parameter tool displays
various counter values.
This parameter displays the total
number of master keys learned.
This parameter displays module
diagnostic address.
This parameter displays the number
of fobs located in the vehicle.
This parameter displays the vehicle
mileage.
front exterior lighting status.
front exterior lighting status.
Active when the parklamp switch is
activated.
the passenger door ajar switch
status.
the passenger door lock switch
status.
the passenger door unlock switch
status.
the passenger door unlock status.
passenger window learned status.
Switch Overridden.

Door
Inactive
Previous Key Type
Unknown
Primary Key Status
Yes
Push Button Ignition Switch
Inactive
Push Button Ignition Switch

Voltage
Varies
Rear Closure Ajar Switch
Active
Inactive
Inactive
Varies
Rear Closure Cylinder Lock

Switch
Rear Closure Cylinder Unlock
Switch
Rear Tire Pressure on Placard
Regulated Voltage Control Mode -
Voltage
Remote Vehicle Start Attempts

Exhausted
Varies
Remote Vehicle Start Crank Time -
Inactive
Remote Vehicle Start Disabled by

Driver
Inactive
Remote Vehicle Start Source
Ignition Switch
Start
Remote Vehicle Starts Exhausted -
Varies
Right Brake Lamp Command
Varies

the passenger window switch status.
This parameter displays previous
driver identification device type.
Inactive.
This parameter displays the push
button ignition switch voltage.
Inactive.
Inactive.
Inactive.
This parameter displays the rear tire
pressure in kPa or PSI. This
parameter displays the specified tire
pressure placard information
programmed in the BCM for tire
pressure monitoring.
The scan tool displays voltage.
history or remaining start attempts.
history.
history.
The scan tool displays Body
Control module or Power Take-off
Start.
history or remaining remote starts.
The scan tool display percentage.
This parameter displays right brake
lamp PWM command status.
The scan tool display percentage.

Right Dedicated Daytime

Running Lamp Command
Varies
Right Front Tire Pressure
Varies
Right Front Tire Pressure

Identification
Right Front Tire Pressure Sensor
Location Learned
Varies
Yes
Right Front Tire Pressure Sensor

Mode
Stationary
Right Front Tire Pressure Status
Normal
Right Front Turn Signal Bulb Out

Feedback
Right Front Turn Signal/Hazard
Lamp Command
Inactive
Inactive
This parameter displays right

dedicated DRL PWM command
status.
This parameter displays right front
This parameter displays right front
Exit Off Mode or Learn Mode
Pressure Triggered.
Inactive.
Inactive.
This parameter displays right low
beam/daytime running lamp status.
This parameter displays rear
exterior lighting status.
Inactive.
This parameter displays right rear
This parameter displays right rear
Right Low Beam/Daytime

Running Lamp Command
Varies
Right Park Lamps Command
Varies
Right Rear Door Ajar Switch
Inactive
Right Rear Tire Pressure
Varies
Varies
Yes
Right Rear Tire Pressure Sensor

Mode

Learn Mode Exit Off Mode, or Learn Mode
Pressure Triggered
Pressure Triggered. This parameter
displays the pressure sensor mode
status.
Right Rear Tire Pressure Status
Normal
Right Rear Tire Pressure

Identification
Right Rear Tire Pressure Sensor
Location Learned

Weak Signal or High. This

Right Rear Turn Signal Bulb Out

Feedback
Right Rear Turn Signal/Hazard
Lamp Command
Right Rear Window Main Control
Down Switch
Express Switch
Up Switch
Inactive
Inactive
Inactive
Inactive
Inactive
Right Rear Window Motor Mode -
Local Switch
Overridden
Right Rear Window Switch at

Door
Inactive
Right Turn Signal Switch
Inactive
Run Abort
Inactive
Run Relay Command
Active
Run/Crank
Inactive
Run/Crank Relay Command
Active
Run/Start Power Mode Indicator

Command
Varies
Secondary Key Status
No
Security Indicator Command
Varies
Selected Front Tire Type
Standard Load
parameter displays the right rear tire

pressure status.
Inactive.
Inactive.
Inactive.
Inactive.
Inactive.
Switch Overridden.
Inactive.
the right turn signal switch status.
history.
Inactive.
Inactive.
Inactive.
This parameter displays ignition
switch run LED PWM command
status.
This parameter displays security
LED PWM command status.
The scan tool displays No Tire
Type, Metric Standard Load, Metric
Extra Load, Load Range C, Load
Range D, or Load Range E. This
parameter displays the front tire
type.
The scan tool displays No Tire

Selected Rear Tire Type
Standard Load
Start-Up State of Charge
Varies
State of Charge
Varies
Sunroof Enabled
Active
Sunroof Motor Overtemperature -
Inactive
Sunroof Not Learned
Inactive
Sunroof Position
Closed
Sunroof Remote Command
Inactive
Sunroof Slide Switch
Inactive
Sunroof Slide Switch
Inactive
Sunroof/Sunshade Motor
Overtemperature
Inactive
Sunroof/Sunshade Switch
Inactive
Type, Metric Standard Load, Metric

Extra Load, Load Range C, Load
Range D, or Load Range E. This
parameter displays the rear tire
type.
This parameter displays startup
state of charge status.
This parameter displays state of
charge status.
Inactive.
Inactive.
Inactive.
The scan tool displays Closed,
Open, Venting, Comfort Open,
Closing, Opening. This parameter
displays the current sunroof
position.
The scan tool displays Sunroof
Secure Close, Venting, Close, or
Open. This parameter displays the
last sunroof remote command.
Express Open, Open, Express
Close, Close, Short to Ground,
Short to Battery, or Stuck. This
parameter displays the sunroof slide
switch status.
Open, Close, Short to Ground,
Short to Battery or Stuck. This
parameter displays the sunroof tilt
switch status. When the switch
experiences a malfunction Short to
Ground, Short to Battery or Stuck
will be displayed.
Inactive.
Express Open, Open, Express
Close, Close, Short to Ground,
Short to Battery, or Stuck. This

Sunshade Enabled
Active
Sunshade Not Learned
Inactive
Sunshade Position
Closed
Sunshade Remote Command
Inactive
Tamper Status
No
Telematics Enhanced Service

Override Active
No
Total Keys Learned
Varies
Traction Control Switch
Inactive
Transponder Authentication
Initializing
Transponder Key Status
OK
Trunk Lamp Command
Varies
Inactive
Inactive
Trunk Lid/Liftgate Window

Exterior Unlatch Switch
Trunk Lid/Liftgate Window
Unlatch Command
parameter displays the sunroof or

sunshade switch status.
Inactive.
Inactive.
The scan tool displays Ajar, Closed,
Opened, Closing, or Opening. This
parameter displays the sunshade
position status.
The scan tool displays Close or
Open. This parameter displays the
last sunshade remote command.
This parameter displays vehicle
theft deterrent system status.
of keys learned.
Active when the traction control
switch is active.
Initializing, ID Received, Password
Received, Data Reception
Complete, or Data Transmission
Complete. This parameter displays
the transponder key communication
status.
The scan tool displays OK, LIN
Bus Initialization Malfunction,
Antenna Initialization Malfunction,
Password Error, No Valid Key
Detected, LIN Bus Communication
Malfunction, or Antenna
Malfunction. This parameter
displays the transponder key
communication error status.
The scan tool displays as
percentage.
Inactive.
Inactive.

Valet Keys Learned
Varies
Valet Mode Status
Inactive
Valet switch
Inactive

(VIN)
Varies
Window Lockout Switch
Inactive
Window Lockout Switch

Indicator Command
Inactive
Windshield Washer Relay

Command
Inactive
Windshield Washer Switch
Inactive
Windshield Wiper Park Switch
Active
Inactive
Inactive
Inactive
Windshield Wiper Stalled During

Sweep
Inactive
Windshield Wiper Stalled in Park

Position
Inactive
Windshield Wiper Switch
Off
Windshield Wiper High Speed

Relay Command
Windshield Wiper High Speed
Switch
Windshield Wiper Motor Relay
Command
of valet keys learned.

history.
Active when the valet switch is on.
This parameter displays the vehicle
identification number.
Inactive.
Inactive.
the windshield washer relay status.
the windshield washer switch
status.
Inactive.
Inactive.
Inactive.
the windshield wiper relay status.
Inactive.
the windshield wiper stalled status.
The scan tool displays Off, Delay 1,
Delay 2, Delay 3, Delay 4, Delay 5,
or Low. This parameter displays the
windshield wiper switch status.
Body Control Module Scan Tool Output Controls

Scan Tool Output Control
Description
The BCM activates the accent lighting when you select
Accent Lighting 1 Command
On. The value should be 100%. All accent lighting
should illuminate until commanded Off.

Accessory Power Mode Indicator Command
Accessory/Retained Accessory Power Relay

Command
All Doors Lock Command
Backup Lamps Command
Battery Saver Relay
Brake Pedal Position Sensor Learn
Center Brake Lamp Command

Child Security Lock Motors Command
Clear Driver Window Learned Values
Clear Passenger Window Learned Values
Courtesy Lamps Command
Driver Door Unlatch Command
Driver Door Unlock Command

Driver Window Motor Mode
Front Fog Lamps Command
The BCM activates the accessory indicator when you

select On. The value should be 100%. The yellow LED
accessory indicator on start button should illuminate
until commanded Off.
The BCM actuates the retained accessory power relay
when you select On. The retained accessory power relay
should turn on allowing specific vehicle functions to
operate.
The BCM activates all doors lock when you select Lock.
All doors should lock.
The BCM actuates the backup lamps relay when you
select On. The backup lamps should illuminate until
commanded Off. Engine must be running.
The BCM activates the battery saver relay when you
select Enable. This command sets the low power mode
relay in the state in which it does not supply power to the
non-essential parts of the vehicle. This is used to prevent
the battery from being depleted when the vehicle is not
used for a long period of time.
The BCM activates the brake pedal position sensor learn
when you select Learn. The brake pedal position sensor
learn procedure should start.
The BCM activates the center brake lamp when you
select On. The center brake lamp should illuminate until
commanded Off.
The BCM actuates the child security door motor when
you select Lock. The child security doors should lock.
When you select Clear the clear driver window learn
procedure should start.
When you select Clear the clear left rear window learn
procedure should start.
The BCM activates the courtesy lamps when you select
On. The value should be 100%. The courtesy lamps
The BCM activates the output circuit to unlatch the
driver door with a passive entry passive start when you
select Unlatch. There is NO door handle on this type of
vehicle to open the door. Instead, there is a pad that you
press to unlatch the door.
The BCM pulses the driver door unlock motor when you
select Unlock. The driver door should unlock.
The BCM activates the driver window motor when you
select Up/Down/Stop/Express Up/Express Down. The
driver window should follow the appropriate command.
The BCM actuates the front fog lamps relay when you
select On. The front fog lamps relay should turn on.

Hazard Lamps Switch Backlight Command
High Beams
Horn Relay
Inadvertent Load Command
LED Backlight Dimming Command
Left Brake Lamp Command

Left Dedicated Daytime Running Lamp
Command
Left Front Turn Signal Lamp Command
Left Park Lamps Command
Left Rear Turn Signal Lamp Command
Left Rear Window Motor
License Plate Lamps Command
Liftgate Unlatch
LIN Bus Device Identification Data
The BCM activates the hazard lamps switch when you

select On. The value should be 100%. The hazard lamps
switch backlight should illuminate until commanded
Off.
The BCM activates the high beam command when you
select On. The high beam lights should illuminate. The
headlamps have to be on.
The BCM activates the horn when you select On. The
horn should sound.
The BCM activates the inadvertent load command when
you select On. (It is an electronic request to shut down
an electrical or electronic device that is drawing power
from the battery at a time when there should be no
activity, usually after the key has been removed from the
ignition for a period of time.)
The BCM activates the LED backlight dimming when
you select On. The values should be 100%. The LED
backlight dimming for control switches should
illuminate until commanded Off.
The BCM activates the left brake lamp when you select
On. The values should be 100%. The left brake lamp
The BCM activates the left dedicated daytime running
lamp when you select ON. The value changes to 100%.
The left daytime running lamp should illuminate.
The BCM activates the left front turn signal lamp when
you select On. The left front turn signal lamp should
The BCM activates the left park lamps when you select
ON with a value of 100%. The left park lamps should
illuminate.
The BCM activates the left rear turn signal lamp when
you select On. The left rear turn signal lamp should
The BCM activates the left rear window motor when
you select Up/Down/Stop/Express Down. The left rear
window should follow the appropriate command.
The BCM activates the license plate lamps when you
select On. The license plate lights should turn on until
commanded Off.
The BCM actuates the rear compartment lid release
actuator when you select Unlatch. The trunk or liftgate
should open.
When you select Update the LIN Bus Device part
number and calibration part number should be updated.
The BCM activates the low beams when you select On.

Low Beam Relay Command

Outside Rear View Mirror Courtesy Lamp
Command
Passenger Door(s) Unlatch Command
Passenger Door(s) Unlock Command
Passenger Window Motor
Right Brake Lamp Command

Right Dedicated Daytime Running Lamp
Command
Right Front Turn Signal Lamp Command
Right Park Lamps Command
Right Rear Turn Signal Lamp Command
Right Rear Window Motor

Run Relay Command
Run/Crank Relay Command
Run/Start Power Mode Indicator Command
Security Indicator Command
The low beam lights should turn on.

The BCM activates the outside rear view mirror courtesy
lamp when you select On. The outside rear view mirror
courtesy lamp (at the bottom) should illuminate.
The BCM activates the output circuit to unlatch the
passenger door with a passive entry passive start when
you select Unlatch. There is NO door handle on this type
of vehicle to open the door. Instead, there is a pad that
you press to unlatch the door.
The BCM pulses the passenger door unlock motor when
you select Unlock. The passenger door should unlock.
The BCM activates the passenger window motor when
you select Up/Down/Stop/Express Up/Express Down.
The passenger window should follow the appropriate
command.
The BCM activates the right brake lamp when you select
On. The value should be 100%. The right brake lamp
The BCM activates the right dedicated daytime running
lamp when you select On. The value should be 100%.
The right daytime running lamp should illuminate.
The BCM activates the right front turn signal lamp when
you select On. The right front turn signal/hazard lamp
should illuminate.
The BCM activates the right park lamps when you select
ON with a value of 100%. The right park lamps should
illuminate.
The BCM activates the right rear turn signal/hazard lamp
when you select On. The right rear turn signal lamp
The BCM activates the right rear window motor when
you select Up/Down/Stop/Express Down. The right rear
window should follow the appropriate command.
The BCM actuates the run relay when you select On.
The run relay should turn on.
The BCM actuates the run/crank relay when you select
On. The run/crank relay should turn on.
The BCM activates the run/start lamp when you select
On. The value should be 100%. The green LED on
engine start/stop button should illuminate until
commanded Off.
The BCM activates the security indicator command
when you select On. The security indicator at center of
dash (or at DRL sensor) should illuminate until
commanded Off.

The BCM activates the tire pressure sensor learn

procedure when you select Learn.
When you select OK, you can change tire type and load
Tire Type/Pressure Selection
range.
The BCM activates the transmission range indicator
Transmission Range Indicator
when you select On. The transmission range indicator at
the shifter should illuminate until commanded Off.
The BCM activates the trunk lamp when you select On.
Trunk Lamp Command
The value should be 100%. The trunk lamp should
The BCM actuates the windshield washer relay when
Windshield Washer Relay Command
you select On. The windshield washer relay should turn
on.
The BCM actuates the windshield wiper high speed
Windshield Wiper High Speed Relay Command relay when you select On. The windshield wiper high
speed relay should turn on.
The BCM actuates the windshield wiper motor relay
when you select On. The windshield wiper motor relay
Windshield Wiper Motor Relay Command
should turn on.
Tire Pressure Sensors Learn
COMMUNICATION INTERFACE MODULE SCAN TOOL INFORMATION

Telematics Communication Interface Control Module Scan Tool Data Parameters
Parameter
System State Expected Value
Description
Operating Conditions: Ignition ON
GPS Data
Calibrated or Not Indicates the dead reckoning
Dead Reckoning Calibration
Calibrated
calibration status.
Status
Indicates the method used to
determine current location.
(0) GPS, (1) Wheel Speed
Dead Reckoning only, (2)
Varies
Position Calibration Method
Combined Wheel Speed and
GPS, (3) Gyro only, (4)
Combined Gyro and GPS,
(5) No Fix
This displays the current
MM
Month
month.
This displays the current day
DD
Day
of the month.
This displays the current
YY
Year
year.
This displays the GPS
HH
current hour (24 hour format
Hour
- GMT).

Minute
MM
Second
SS
GPS Signal
Varies

current minute.
current second.
The scan tool displays Yes
or No. Yes is displayed if
there is a GPS signal
received by the telematics
communication interface
control module.
Signal Strength Data
Current Transceiver Identifier
Varies
GSM Signal Strength
Varies
Signal Type
Digital
The scan tool displays a 2-5

digit value. This is the
transceiver identification
number.
The scan tool displays 0127. This is the telematics
control module signal
strength.
This is the signal type
received by the telematics
control module.
Bluetooth Data
Bluetooth
Bluetooth Link Status
Bluetooth Link Quality
Bluetooth Phone to Telematics

Communication Interface Control
Module Authentication Status
Bluetooth Phone to Telematics

Communication Interface Control
Module Communication Status
Indicates if the Bluetooth

system is enabled or
disabled.
Indicates the current link
status. (0) Unconnected, (1)
Varies
Connected / Idle, (2) Call
active, (3) 3-way calling
active
The scan tool displays a
decimal value between 0 and
Varies
255.
Displays the bluetooth
phone to telematics
Active or Inactive communication interface
control module
authentication status.
phone to telematics
Active or Inactive
control module status.
Enabled

Bluetooth Phone Voice

Recognition Status
phone to voice recognition

Active or Inactive status.
Telematics Communication Interface Control Module Scan Tool Output Controls

Output Control
Description
This shows the data recorded when DTC B1000 was set in
B1000 Information
the telematics communication interface control module.
The telematics communication interface control module
Green Indicator
illuminates the green LED when ON is selected.
When ON is selected, telematics communication interface
Phone Call Test
control module commands OnStar to connect to the OnStar
Center.
Red Indicator
illuminates the red LED when ON is selected.
Preferred Roaming List Update
performs a preferred roaming list (PRL) update when this
is selected.
Remote Vehicle Speed Limiting Reset
This function resets the speed limiting feature.
DRIVER SEAT AND PASSENGER SEAT HEATER CONTROL MODULE SCAN TOOL
INFORMATION
Front Seat Heating Control Module Scan Tool Data Parameters
Parameter
Expected Value
Operating Conditions: Engine Running
Driver Seat Cushion Heating Command
Inactive
Driver Seat Cushion Temperature Sensor
Varies
Driver Seat Heating/Venting/Cooling Level
Off
Description
The scan tool displays Inactive
or Active. This parameter
displays the commanded output
from the seat heating control
module to the seat heater
elements.
The scan tool displays 0 - 5 V.
The voltage displayed is an
input to the seat heating control
module from the seat cushion
temperature sensor. Higher
voltage readings indicate cooler
seat temperatures while lower
voltage readings indicate
warmer seat temperatures.
High Medium, or Low. When
the heated seat is active, this
parameter displays the selected
temperature setting.

Driver Seat Heating/Venting/Cooling Mode
Off
Passenger Seat Cushion Heating Command
Inactive
Passenger Seat Cushion Temperature Sensor
Varies
Passenger Seat Heating/Venting/Cooling Level
Off
Passenger Seat Heating/Venting/Cooling Mode
Off
The scan tool displays Off or

Back & Cushion Heat. This
parameter indicates the heated
seat mode of operation.
The scan tool displays Inactive
or Active. This parameter
displays the commanded output
from the seat heating control
module to the seat heater
elements.
The scan tool displays 0 - 5 V.
The voltage displayed is an
input to the seat heating control
module from the seat cushion
temperature sensor. Higher
voltage readings indicate cooler
seat temperatures while lower
voltage readings indicate
warmer seat temperatures.
High Medium, or Low. When
the heated seat is active, this
parameter displays the selected
temperature setting.
The scan tool displays Off or
Back & Cushion Heat. This
parameter indicates the heated
seat mode of operation.
Front Seat Heating Control Module Scan Tool Output Controls

Control Functions
Description
This output control is used to command the driver seat heater
Driver Seat Cushion Heating
elements On.
This output control is used to command the passenger seat
Passenger Seat Cushion Heating
heater elements On.
ELECTRONIC BRAKE CONTROL MODULE SCAN TOOL INFORMATION
The electronic brake control module (EBCM) scan tool data parameters list contains all ABS related parameters
that are available on the scan tool. The list is arranged in alphabetical order. A given parameter may appear in
any one of the data lists.
Electronic Brake Control Module Scan Tool Data Parameters
Parameter
System State
Expected Value
Description

ABS Pump Motor Voltage
0V
Acceleration Sensor
Longitudinal Signal
Varies
Antilock Braking System
On
Brake Fluid Level Sensor
OK
Brake pedal
released
Brake pedal
applied
Brake pedal
released
Brake Pressure Sensor
Brake pedal
applied
Delivered Torque
Inactive
Active
0-1 V
1-5 V
Varies
Dynamic Rear Proportioning

Status
On
Lateral Acceleration Signal
Varies
Left Front Inlet Solenoid

Valve Feedback
Inactive
Left Front Outlet Solenoid

Valve Feedback
Inactive
Left Front Wheel Speed

Sensor
0 km/h (0 MPH)
Left Rear Inlet Solenoid

Valve Feedback
Inactive
The scan tool displays the

commanded pump motor voltage.
The scan tool displays 0-5 V
depending on the vehicle's
longitudinal acceleration.
Off is displayed when the ABS is
disabled.
The scan tool displays OK when
the brake fluid is at correct level
and Low when the brake fluid is
low.
The scan tool displays Inactive or
Active depending on the state of
the brake pedal.
depending on the applied
hydraulic brake pressure.
The scan tool displays 0-100%
depending on the how much
torque the engine is delivering.
Off is displayed when the
dynamic rear proportioning
system is disabled.
depending on the vehicle's lateral
acceleration.
Active. Active is displayed when
the left front inlet solenoid valve
is commanded ON.
the left front outlet solenoid valve
is commanded ON.
The scan tool displays km/h
(MPH) depending on the current
speed of the left front wheel
speed sensor.
the left rear inlet solenoid valve
is commanded ON.

Left Rear Outlet Solenoid

Valve Feedback
Inactive
Left Rear Wheel Speed

Sensor
0 km/h (0 MPH)
Pump Motor Relay Feedback -
Inactive
Primary Isolation Solenoid

Valve Feedback
Inactive
Primary Prime Solenoid

Valve Feedback
Inactive
Requested Torque
Varies
Right Front Inlet Solenoid

Valve Feedback
Inactive
Right Front Outlet Solenoid

Valve Feedback
Inactive
Right Front Wheel Speed

Sensor
0 km/h (0 MPH)
Right Rear Inlet Solenoid

Valve Feedback
Inactive
Right Rear Outlet Solenoid

Valve Feedback
Inactive
Right Rear Wheel Speed

Sensor
0 km/h (0 MPH)

the left rear outlet solenoid valve
is commanded ON.
speed of the left rear wheel speed
sensor.
the pump motor is commanded
ON.
the isolation solenoid valve is
commanded ON.
the prime solenoid valve is
commanded ON.
The scan tool displays 0-100%
depending on the how much
torque is requested.
the right front inlet solenoid
valve is commanded ON.
the right front outlet solenoid
speed of the right front wheel
speed sensor.
the right rear inlet solenoid valve
is commanded ON.
the right rear outlet solenoid
speed of the right rear wheel

speed sensor.
the isolation solenoid valve is
commanded ON.
the prime solenoid valve is
commanded ON.
Secondary Isolation Solenoid

Valve Feedback
Inactive
Secondary Prime Solenoid

Valve Feedback
Inactive
Steering Column Position
Steering wheel in
-5 to +5
straight position
Steering wheel
turned left until 450-550
stop
Steering wheel
turned right until -550 to -450
stop
The scan tool displays . This is

the current position of the
steering angle sensor.
System Voltage
The scan tool displays V. This is

the current battery voltage.
Traction Control System
Traction control
switch released
Traction control
switch pressed
11-14 V
On
Off

Off is displayed when traction
control is disabled.
The scan tool displays A. This is
the current applied to the variable
effort steering solenoid valve.
The scan tool displays A. This is
the variable effort steering
solenoid valve feedback signal.
Active depending on the state of
the stability control.
Variable Effort Steering

Solenoid Valve Command
Varies
Variable Effort Steering

Solenoid Valve Feedback
Varies
Vehicle Stability
Enhancement System Relay
Feedback
Inactive
Vehicle Stability System
Traction control
On
switch released
Traction control
switch pressed for Off
5s

Off is displayed when stability
control is disabled.

depending on the vehicle's yaw
rate.
Yaw Rate Signal
Varies
Electronic Brake Control Module Scan Tool Output Controls

Output Control
Description
ABS Left Front Solenoid Valves
Commands the solenoid valves ON or OFF.
ABS Left Rear Solenoid Valves

ABS Pump Motor

ABS Right Front Solenoid Valves
ABS Right Rear Solenoid Valves
Automated Brake Bleed
Brake Pressure Sensor Calibration
Pressure Control Solenoid Valve
Steering Wheel Angle Sensor Learn
Traction Control Left Front Solenoid
Valves
Traction Control Left Rear Solenoid Valves
Traction Control Right Front Solenoid
Valves
Traction Control Right Rear Solenoid
Valves
Yaw Rate Sensor Learn
Commands the ABS pump motor Increase or Decrease.

This is used in order to bleed ABS hydraulics. Refer to
Hydraulic Brake System Bleeding (Manual Bleeding) ,
Hydraulic Brake System Bleeding (Pressure Bleeding)
This is used in order to calibrate the brake pressure sensor.
Commands the variable effort steering solenoid valve
Increase or Decrease.
This function activates the steering wheel angle sensor learn
procedure.
This function activates the yaw rate sensor learn procedure.
K20 ENGINE CONTROL MODULE: SCAN TOOL INFORMATION

The Engine Control Module Scan Tool Data List contains all engine related parameters that are available on the
scan tool. The list is arranged in alphabetical order. A given parameter may appear in any one of the data lists,
and in some cases may appear more than once, or in more than one data list in order to group certain related
parameters together.
Use the Engine Scan Tool Data List only after the following is determined:
The Diagnostic System Check - Vehicle is completed.

No diagnostic trouble codes (DTCs) are set.
On-board diagnostics are functioning properly.
The scan tool values from a properly running engine may be used for comparison with the engine you are
diagnosing. The Engine Scan Tool Data List represents values that may be seen on a normally running engine.
NOTE:
A scan tool that displays faulty data should not be used. The scan tool concern
should be reported to the manufacturer. Use of a faulty scan tool can result in
misdiagnosis and unnecessary parts replacement.
Only the parameters listed below are referenced in this service manual for use in diagnosis. If all values are
within the typical range described below, refer to Symptoms - Engine Controls for engine diagnosis.
Engine Control Module Scan Tool Data Parameters

Parameter
System State
Expected Value
Description
Operating Conditions: Engine Idling/Radiator Hose Hot/Closed Throttle/Park or Neutral/Closed
Loop/Accessories Off/Brake Pedal Released
voltage sensed on the 5 V
reference circuits at the
5 Volt Reference 1, 2,
control module. The scan tool
Ignition ON
5V
or 3
will display a higher value at
higher voltage. The scan tool
will display a lower value at
lower voltage.
This parameter displays OK if
there is no 5 V reference
circuit condition. If the circuit
5 Volt Reference 1, 2,
Ignition ON
OK
is shorted to ground or
or 3 Circuit Status
shorted to B+, Fault is
displayed.
A/C OFF
0.75-1.5 V*
voltage from the A/C high
A/C High Side
side pressure sensor signal
Pressure Sensor
circuit to the control module.
*Varies with temperature and
A/C ON
1.3-2.5 V*
relative humidity.
450-650 kPa* (65-95
A/C OFF
pressure from the A/C high
(PSI)*
A/C High Side
side pressure sensor signal
Pressure Sensor
circuit to the control module.
Engine Speed at 2 000 1 117-2 350 kPa* (162*Varies with temperature and
RPM
341 PSI)*
relative humidity.
This parameter displays
whether the control module is
commanding the A/C
A/C Off for WOT
A/C ON
No
compressor clutch relay OFF
for wide open throttle
(WOT).
whether the A/C pressure is
A/C Disable A/C
A/C ON
No
out of range for normal
Pressure Out of Range
operation as determined by
the control module.
A/C Compressor
state of the air conditioning
Clutch Relay
A/C ON
On
(A/C) clutch relay control
Command
circuit as commanded by the
control module.

A/C Request Signal
Accelerator Pedal
Position
A/C ON
Yes
Accelerator pedal not

actuated
0%
Accelerator pedal fully

100%
actuated
Air/Fuel Equivalence
Ratio Command

actuated
Varies
0.88-1.08 V
APP Sensor 1
4.17-4.37 V
actuated
actuated
0.39-0.59 V
APP Sensor 2
2.02-2.22 V
actuated
BARO
Control Module
65-104 kPa (8-16 PSI)

Varies with altitude
state of the A/C request input

to the control module from
the heating, ventilation, and
air conditioning (HVAC)
controls.
angle of the accelerator pedal
position (APP) as calculated
by the control module using
the signals from the APP
sensors.
ratio of air to fuel as
calculated by the control
module based on various
sensor inputs. The scan tool
will display a lower air fuel
ratio when a richer air to fuel
mixture is commanded. The
scan tool will display a higher
air fuel ratio when a leaner air
to fuel mixture is
commanded. In closed loop
operation the air fuel ratio
should normally be
approximately 14.7 : 1.
actual voltage on the
accelerator pedal position
(APP) Sensor 1 signal circuit
as measured by the control
module.
actual voltage on the
accelerator pedal position
(APP) Sensor 2 signal circuit
module.
barometric pressure (BARO).
The control module uses the
barometric pressure sensor
input for fuel control to
compensate for altitude
differences.
state of the ignition system

Voltage Signal
B+
Cooling Fan Relay 1

Command
Varies
Cooling Fan Relay 2

Command
Varies
Cooling Fan Relay 3

Command
Varies
CPP Learned Apply

Position
CPP Learned Release

Position
voltage available at the

control module.
commanded state of the
cooling fan relay 1 control
circuit. The cooling fan relay
1 should be ON when the
scan tool indicates the fan
control relay 1 command is
ON. The cooling fan relay 1
should be OFF when the scan
tool indicates the fan control
Relay 1 Command is OFF.
control Relay 2 command is
Relay 2 command is OFF.
control Relay 3 command is
Relay 3 command is OFF.
position learned for the clutch
pedal position (CPP) sensor
when the clutch pedal is fully
applied during the associated
learn procedure.
position learned for the clutch
pedal position sensor when
the clutch pedal is released.
displacement of the clutch

CPP Sensor
Varies
CPP Sensor
Varies
Current Gear
Transmission in Park or
1-6
Neutral
Desired ECT
Varies
Desired Idle Speed
600-950 RPM
Desired Throttle
Position
2-6%
Distance Since DTC

Cleared
Varies
Distance Since Last

Malfunction
Varies
Distance This Driving

Cycle
Varies
pedal (corrected and

normalized based upon its
learned released and fully
applied positions), where 0%
corresponds to the clutch
pedal being released and
100% corresponds to the
clutch pedal being fully
applied.
clutch pedal position sensor
analog input as a percentage
of its reference voltage.
Displays Unknown, 1, 2, 3, 4,
5, or 6. This parameter
indicates the current
commanded gear position.
desired engine coolant
temperature (ECT) in
degrees.
desired engine idle speed as
commanded by the control
module.
desired throttle position angle
module.
distance accumulated since an
emission diagnostic trouble
code was cleared. The scan
tool will display increasing
distance as the vehicle is
driven.
distance accumulated when
the emission diagnostic
trouble code last failed.
distance accumulated since an
emission diagnostic trouble
code was cleared. The scan
tool will display increasing
distance as the vehicle is
driven.

ECT Sensor 1
-39 to +140C (-38 to

+284F)
Varies
ECT Sensor 2
-39 to +140C (-38 to

+284F)
Varies
Engine Controls
Ignition Relay
Feedback Signal
B+
Engine Coolant
Temperature
-39 to +140C (-38 to

+284F)
Varies
Engine Coolant
Thermostat Heater
Command
0-100%
Engine Idling
11-20%
Varies
Engine speed at 2 500

RPM
25-40%
Engine Oil Level

Switch
OK
Engine Oil Pressure

Switch
OK
Engine Load

temperature of the engine
coolant based on input to the
control module from the
engine coolant temperature
(ECT) sensor 1.
temperature of the radiator
radiator coolant temperature
(ECT) sensor 2.
voltage available at the
engine control ignition relay
pin of the control module.
temperature of the engine
engine coolant temperature
(ECT) sensor 1.
commanded duty cycle for
the engine coolant thermostat.
calculated engine load in
percent based on inputs to the
control module from various
engine sensors.
This parameter displays if the
level of the engine oil is
within range as determined by
the control module from
information received from the
engine oil level switch.
state of the engine oil
pressure as determined by the
control module. The control
module monitors the engine
oil pressure switch to
determine if the engine oil
pressure is sufficient. The
scan tool displays Low when
the engine oil pressure is
below a predetermined value.

Engine Run Time
Engine Operating
Varies
Engine Cranking
Greater than 60 RPM
Engine Idling
Approximately 650-950
RPM
Engine Speed
EVAP Purge Solenoid

Valve Command
10-20%
Exhaust Camshaft
Position Active
Counter
Engine Idling
0-255
Exhaust Camshaft
Position Command
45-75%
Fuel Level Sensor
Varies
Ignition ON, engine

time elapsed since the engine
was started. The scan tool
will display the time in hours,
minutes and seconds. The
engine run time will reset to
zero when the engine stops
running.
speed of the engine
crankshaft rotation from
crankshaft position sensor.
on-time or duty cycle of the
evaporative emission (EVAP)
canister purge solenoid
module. Zero percent
indicates no purge. One
hundred percent indicates full
purge.
This parameter displays an
incrementing counter when
the control module receives a
signal from the exhaust
camshaft position (CMP)
sensor.
the exhaust camshaft as
module.
approximate fuel level in the
fuel tank as a voltage. The
control module calculates this
level using the signal from
the sensor used to monitor the
fuel in the tank. The scan tool
will display a low reading
when the fuel level in the tank
is near empty. The scan tool
will display a high reading
when the fuel level in the tank
is high or near full.

OFF
Fuel pump on for 2 s
Engine idling
On
Fuel Tank Pressure

Sensor
0.00 inch
Fuel Tank Pressure

Sensor
1.3-1.7 V
Fuel Pump Relay

Command
Generator F-Terminal
Signal
40-70%
Ignition ON, Engine

OFF
50-900 mV
Engine Operating
Varies
HO2S 1 or HO2S 2
HO2S Heater Sensor 1

or 2
0.42-0.62 A
HO2S 1 or HO2S 2
Heater Command
0-99%
IAT Sensor
-39 to +140C (-38 to
control modules commanded

state of the fuel pump relay
control circuit.
pressure/vacuum inside the
fuel tank. A negative value
indicates a vacuum, while a
positive value indicates a
pressure.
voltage signal received by the
control module from the fuel
tank pressure sensor.
This parameter indicates the
generator field duty cycle as
commanded by the voltage
regulator or control module.
The scan tool will display a
higher value for a higher
commanded generator output,
and a lower value for a lower
commanded generator output.
heated oxygen sensor (HO2S)
sensor 1 or 2, output voltage
module. The scan tool will
display a higher value during
a rich condition, and a lower
value during a lean condition.
amperage of the HO2S heater
module.
HO2S 1 or HO2S 2 heater 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.
temperature of the air
entering the air induction
system based on input to the

+284F)
IAT Sensor
0-5 V
Ignition Accessory
Signal
ON
Ignition Switch Status -
Active
Intake Camshaft
Position Command
45-75%
Intake Manifold
Tuning Control Valve
Control Circuit
Command
Off
Long Term Fuel Trim -
-5 to +5%
MAP Sensor
26-52 kPa
MAP Sensor
0.98-1.42 V
Park/Neutral Position
Switch
Reduced Engine
Park/Neutral
Inactive

intake air temperature (IAT)
sensor.
voltage calculated by the
intake air temperature sensor.
state of the ignition accessory
position input to the control
module from the ignition
switch.
active when the ignition
switch is supplying battery
voltage to the control module
ignition circuit.
the intake camshaft as
module.
state of the intake manifold
tuning valve solenoid control
circuit as commanded by the
control module.
commanded Long Term Fuel
Trim correction by the control
module.
pressure from the manifold
absolute pressure (MAP)
sensor to the control module.
signal voltage from the MAP
sensor to the control module.
position of the transmission
selection as Park/Neutral or in
gear.
status of the operating mode
of the control module used to
reduce engine power to

Power
Remaining Fuel in
Tank
0-100%
Varies
Reverse Position
Switch
OFF
Short Term Fuel Trim -
-5 to +5%
Starter Relay
Command
OFF
TAC Forced Engine

Shutdown
NO
prevent catalyst or engine

damage or due to an affected
throttle actuator control
(TAC) system.
amount of fuel remaining in
the fuel tank as measured in
percentage. The control
module determines the
amount of fuel remaining in
the tank by using information
from the fuel level sensors.
The scan tool will display a
higher value with a full fuel
tank, and a lower value with
an empty fuel tank.
Manual Transmission
Reverse Switch ON indicates
that the reverse switch hard
wire input to the ECM is
active.
short term correction to the
fuel delivery by the control
module in response to oxygen
sensor. If the oxygen sensor
indicates a lean air/fuel
mixture, the control module
will add fuel increasing the
short term fuel trim above 0.
If the oxygen sensor indicates
a rich air/fuel mixture, the
control module will reduce
fuel decreasing the short term
fuel trim below 0.
The scan tool displays ON or
OFF. The scan tool displays
OFF until the ignition is
placed into the CRANK
position.
status of TAC control by the
control module. The scan tool
will display YES if the engine
has been shut down due to a
throttle control fault. The
scan tool will display NO if

TAC Motor
Enabled
TAC Motor Command -
0-100%
Varies
Throttle Position
2-6%

actuated
4.14-4.34 V
Throttle Position
Sensor 1
3.50-3.37 V
actuated

actuated
0.68-0.88 V
Throttle Position
Sensor 2
1.35-1.55 V
actuated
Torque Delivered
Signal
Varies
the engine has not been shut

down by a throttle control
fault.
status of the TAC motor
driver by the ECM. The scan
tool will display Enabled if
TAC motor operation is
allowed. The scan tool will
display disabled if the TAC
motor is disabled.
percentage of the commanded
state of the TAC motor by the
control module.
actual throttle position angle
indicated by the control
module using information
from the two throttle position
sensors.
voltage signal sent to the
control module from throttle
position sensor 1 of the
throttle assembly. The throttle
position sensor 1 is a range of
values indicating a high
voltage when the throttle is
closed to a low voltage when
the throttle plate is fully open.
voltage signal sent to the
control module from throttle
position sensor 2 of the
throttle assembly. The throttle
position sensor 2 is a range of
values indicating a low
voltage when the throttle is
closed to a high voltage when
the throttle plate is fully open.
This parameter displays a
calculated valve based on
engine load, throttle position,
and other engine inputs. This
parameter is calculated to
within 20 N m (15 lb ft) of

Total Knock Retard
0 Degrees
Total Misfire
Counts
Vehicle Speed Sensor -
0 km/h (0 MPH)
Warm-ups Since DTC

Cleared
Varies
actual measured engine

torque.
This parameter indicates how
much ignition spark timing is
being retarded due to all
control systems monitored by
the control module. The scan
tool will display a high valve
during extreme conditions
such as high temperatures and
antilock braking. The scan
tool will display a lower
value during lighter driving
conditions.
total number of cylinder
firing events that the control
module detected as misfires
for the last 200 crankshaft
revolution sample period.
speed of the vehicle as
calculated by the transmission
control module (TCM) from
vehicle speed sensor (VSS).
number of warm-ups since
the DTC was cleared.
Engine Control Module (ECM) Scan Tool Output Controls

Output Control
Description
This function activates the A/C compressor relay. The normal
commanded state of the A/C relay is None. The A/C
compressor will turn ON or OFF when commanded ON or
OFF. The system remains in the commanded state until
cancelled by the scan tool. The scan tool initiates the test when
the following conditions are met:
A/C Clutch Relay
In the correct power mode
A/C high side pressure is in range
Engine speed is in range
Ignition voltage is in range.
There are no A/C pressure sensor DTCs set.
Clutch Pedal Position Learn
This device control is used to trigger the procedure to learn the

Cooling Fan
clutch pedal fully applied position.

This function controls the cooling fan relay 1. The normal
commanded state of the fan relay is None. The scan tool
initiates the test when the following conditions are met:
Engine coolant temperature is not out of range
In the correct power mode.
This function is used to reset the engine oil life. The engine oil
remaining life is determined from engine revolutions and the
distance driven since the last oil change.
This function controls the EVAP purge solenoid valve. The
normal commanded state is None. The system will increase or
decrease the amount of purge by changing the duty cycle of the
purge valve in 10% increments within a range of 0-100%. The
scan tool initiates the test when the following conditions are
met:
Engine Oil Life Reset
EVAP Purge Solenoid Valve

The vacuum level in the EVAP purge system is within
range.
There are no EVAP DTCs set.
The EVAP system test is not in progress.
In the correct Power Mode.
Activates the on-board EVAP diagnostic test.
This function controls the EVAP vent solenoid. The normal
commanded state is none. When commanded ON, the vent
valve switches to not venting. When commanded OFF, the vent
valve switches to venting. The scan tool indicates the test when
EVAP Test
EVAP Vent Solenoid Valve
Exhaust Camshaft Position Actuator
The vacuum level in the EVAP purge system is within

range.
There are no EVAP DTCs set.
The EVAP system test in not in process.
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
increments. The scan tool initiates the test when the following
conditions are met:
The engine is operating.

The commanded camshaft position is not out of range.
There are no crankshaft position or camshaft position
sensor DTCs set.

Engine oil temperature is not out of range.

If the actuator is disabled after 30 s, the actuator control is not

allowed again on the same actuator for 60 s.
This function controls the fuel pump relay. The normal
commanded state is None. When commanded ON or OFF, the
ECM turns the fuel pump ON or OFF. The scan tool initiates
the test when the following conditions are met:
Fuel Pump Relay
Fuel Trim Reset
The engine speed is 0 RPM.

The output control timer has not expired.
The ignition voltage is within range.
This function is used to reset the learned fuel trim values to
their initial values.
This function is used to override the state of the generator L
terminal output. The commanded states are ON and OFF.
Selecting OFF commands the ECM to turn OFF the generator
and stop generating an output voltage. The scan tool initiates
the test when the following conditions are met:
Generator L-Terminal
The engine is operating to turn OFF the component.
The vehicle speed is 0 km/h (0 MPH).
The output control timer has not expired.
This function controls the selected HO2S heater. The normal
commanded state is None, on, and off. Commanding the HO2S
heater ON turns on the heater driver. The scan tool initiates the
test when the following conditions are met:
HO2S Heater Sensor 1 or 2

The exhaust temperature is within range.
The HO2S heaters are not over temperature.
The ignition voltage is not out of range while
commanding the heaters ON.
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
increments. The scan tool initiates the test when the following
conditions are met:

Intake Camshaft Position Actuator
Intake Manifold Runner Control Valve
Malfunction Indicator Lamp (MIL)
Throttle Position

The commanded camshaft position is not out of range.
There are no crankshaft position or camshaft position
sensor DTCs set.
Engine oil temperature is not out of range.
If the actuator is disabled after 30 s, the actuator control is not

allowed again on the same actuator for 60 s.
This device control is used to override the state of the intake
manifold tuning valve output. A output test is used to select
whether commanding the intake manifold tuning valve output
on or off results in the valve being commanded closed or open.
This function controls the malfunction indicator lamp (MIL).
The normal commanded state is None. When commanded ON
or OFF, the ECM turns the malfunction indicator lamp (MIL)
ON or OFF. This output can also be monitored on the scan tool
data parameter MIL Command. The system remains in the
commanded state until cancelled by the scan tool.
This function controls the throttle valve in 10% increments.
The scan tool initiates the test when the following conditions
are met:
The engine speed is 0 RPM.

The vehicle speed is 0 km/h (0 MPH).
The system remains in the commanded state until cancelled by

the scan tool.
FUEL PUMP FLOW CONTROL MODULE SCAN TOOL INFORMATION
Fuel Pump Flow Control Module Scan Tool Data Parameters
Parameter
System State
Expected Value
Description
Operating Conditions: Ignition ON/Engine Idling at Normal Operating Temperature / Vehicle is in Park
or Neutral
This displays kPa (psi).
Desired Fuel Pressure
306.8 kPa (44.5 psi) This is the desired fuel
pressure.
The scan tool displays On
or Off. This is the current
Fuel Pump Command
On
state of the fuel pump
command.

Fuel Pump Signal

Command
Fuel Pressure Sensor
Ignition 1 Signal
LT Fuel Pump Trim
ST Fuel Pump Trim
This displays %. This is

the commanded fuel
Varies
pump signal measured in
percentage.
This displays kPa (psi).
296.4-310.3 kPa (43-45 This is the current
psi)
pressure at the fuel
pressure sensor.
This displays Volts. This
4.90-5.01 Volts
is the fuel pressure sensor
voltage.
Varies
is the current ignition 1
signal.
This displays a numeric
value. This is the long
Varies
term (LT) fuel pump
trim.
Varies
value. This is the short
term (ST) fuel pump trim.
Fuel Pump Flow Control Module Scan Tool Output Controls

Output Control
Description
Fuel Pressure Control
This output control is used to control the fuel pressure.
This output control is used to command the fuel pump ON and
Fuel Pump
OFF.
Fuel Pump Trim Reset
This output control is used to reset the fuel pump trim.
Active Grille Air Shutter Scan Tool Data Parameters (If Equipped)
Parameter
System State
Expected Value
Description
or Neutral
Active Grille Air Shutter
Varies
the commanded active
Position Command
grille air shutter position.
Active Grille Air Shutter
the actual active grille air
Varies
Position
shutter position.
or Off. This is the current
Cold Temperature Mode
On / Off
state of the Cold
Temperature Mode.
Ambient Air Temperature
Varies
The scan tool displays C

(F). This is the current

ambient air temperature.

Active Grille Air Shutter Scan Tool Output Controls (If Equipped)
Output Control
Description
This output control is used to perform the Active Grille Air Shutter
Actuator test. It is used to cycle the active grille air shutter open
Active Grille Air Shutter Actuator
and closed. The test result will display pass or fail based on the
ability of the louvers to cycle open and closed.
Exhaust Flow Control Valve Scan Tool Data Parameters (If Equipped)
Parameter
System State
Expected Value
Description
or Neutral
Exhaust Flow Control
Exhaust Flow Valve
Open/Closed
Valve Command
Commanded State
Exhaust Flow Valve
%
Commanded Duty Cycle
Valve Command
(0%-100%)
Exhaust Flow Valve
Active/Inactive
Valve Performance Mode
Control Status
Exhaust Flow Valve
Active/Inactive
Valve Rumble Mode
Control Status
Exhaust Flow Valve
Active/Inactive
Valve
Control Status
Exhaust Flow Control Valve Scan Tool Output Controls (If Equipped)
Output Control
Description
This output control is used to cycle the exhaust flow control
Exhaust Flow Control Valve Command
valve open and closed.
HEATING, VENTILATION AND AIR CONDITIONING CONTROL MODULE SCAN TOOL
INFORMATION
Heating Ventilation and Air Conditioning Control Module Scan Tool Data Parameters
Parameter
System State
Expected Value
Description
reason why the activation of
A/C Compressor Clutch
Varies
the A/C compressor is
Inhibit Reason
inhibit.
The scan tool displays
Engine running, A/C
Disengaged
A/C Compressor Clutch Off
Engaged or Disengaged
Status
depending on the state of the
Engine running, A/C On Engaged
A/C compressor.

A/C Evaporator
Temperature Sensor
A/C High Side Pressure

Sensor
A/C Indicator
-40 to +80C (-40 to +

176F)
Varies
A/C Off
Off
A/C On
On
A/C Off
Inactive
A/C On
Active
A/C Switch released
Inactive
A/C Switch pressed
Active
A/C Request Signal
A/C Switch
Air recirculation mode
is deactivated
Air Recirculation LED
is activated
Air recirculation switch
Air Recirculation Mode released
Switch
Air recirculation switch
pressed
Off
On
Inactive
Active
Ambient Air
Temperature (Filtered)
-40 to +80C (-40 to +

176F)
Air Quality Sensor

Indicator
Varies
Air Quality Sensor

Switch
Varies
Auto HVAC Button
Auto HVAC Indicator
Auto HVAC button

released
Auto HVAC button
pressed
Auto mode is
deactivated
Inactive
Active
Off
The scan tool displays C (

F). This is the current
temperature at the A/C
evaporator temperature
sensor.
The scan tool displays kPa.
This is the current pressure
of the A/C refrigerant.
The scan tool displays On or
Off depending on the state
of the A/C mode.
Active or Inactive depending
on the state of the A/C
mode.
on the state of the A/C
switch.
of the Recirculation mode.
on the state of the air
recirculation mode switch.
temperature at the ambient
air temperature sensor.
of the automatic
recirculation switch.
of the automatic
recirculation switch.
of the Auto HVAC button.

Auto mode is activated On

Auxiliary Heater Output
Status
OK
Battery Voltage
11-14 V
Blower Motor Speed
0-100%
Blower Motor Speed

Command
0-100%
Blower Motor Switch
Varies
Desired Left Duct

Temperature
Varies
Desired Left
Temperature
Varies
Desired Left
Temperature Motor Door Position
Varies
Engine Coolant
Temperature
-40 to +215C (-40 to

+419F)
Enhanced Defrost
Indicator
Enhanced defrost mode

Off
is deactivated
Enhanced defrost mode
On
is activated
Enhanced defrost switch
Off
released
of the Auto mode.

The scan tool displays OK
or Malfunction. Malfunction
is displayed if there is an
auxiliary heater malfunction.
The scan tool displays V.
This is the current battery
voltage.
The scan tool displays %
selected blower motor
speed. The value increases
stepwise from 0-100%
depending the selected
speed.
The scan tool displays %
selected blower motor
speed. The value increases
stepwise from 0-100%
depending the selected
speed.
The scan tool displays OFF,
1-8 depending on the state of
the selected blower motor
speed.
F). This is the desired
temperature at the left duct
temperature sensor.
F) depending on the selected
left temperature.
Counts. This is the desired
position of the left
temperature actuator.
F). This is the current engine
coolant temperature.
of the enhanced defrost
mode.

Enhanced Defrost Switch

Floor Mode Indicator
Floor Mode Switch
Front Defrost Indicator
Front Defrost Switch
Front HVAC System

Status
Enhanced defrost switch

On
pressed
Floor mode is
Off
deactivated
Floor mode is activated On
Floor mode switch
Off
released
Floor mode switch
On
pressed
Front defrost mode is
Off
deactivated
Front defrost mode is
On
activated
Front defrost switch
Off
released
Front defrost switch
On
pressed
-
Varies
HVAC Actuators Supply

Voltage
Active
Instrument panel vents

mode is deactivated
mode is activated
Instrument Panel Vents switch released
Switch
switch pressed
Left front seat heating
Left Front Seat Heating switch released
Switch
Left front seat heating
switch pressed
Left front seat
ventilation switch
released
Left Front Seat
Ventilation Switch
Left front seat
ventilation switch
pressed
Instrument Panel Vents
Indicator
Off
On
Inactive
Active
Off
On
Off
On
of the enhanced defrost

switch.
of the floor mode.
of the floor mode switch.
of the front defrost mode.
of the front defrost switch.
of the POWER switch.
Active or Inactive. Inactive
is displayed if there is a
malfunction at the actuators
supply voltage circuit.
of the instrument panel vents
mode.
on the state of the instrument
panel vents switch.
of the left front seat heating
switch.
of the left front seat
ventilation switch.
The scan tool displays Stop,

Left Mode Door Motor

Direction
Varies
Left Temperature Door

Motor Calibration Status
Varies

Motor Direction

Position
Varies
Left Temperature Knob

Position
Varies
Lower Left Duct

Temperature Sensor
-40 to +80C (-40 to +

176F)
During the movement of the

door, the scan tool shows
Increase or Decrease
depending the movement
direction. When the position
of the door is reached, the
scan tool displays Stop.
The scan tool displays Not
Running, In Progress,
Complete or Failed
depending the calibration
status.
The scan tool displays Stop,
During the movement of the
left temperature door, the
scan tool shows Increase or
Decrease depending the
movement direction. When
the selected position of the
door is reached, the scan
tool displays Stop.
Counts. This is the current
position of the left
temperature actuator.
counts.
Only with C67
The value varies between -7
to +7 depending the selected
temperature knob position.
At the left end position is the
value 16 and at the right end
position -16.
Only with C68
The value varies between -5
to +5 depending the selected
temperature knob position.
At the left end position is the
value 18 and at the right end
position -18.
temperature at the lower left
duct temperature sensor.
The scan tool displays Not

Mode Door Motor

Calibration Status
Varies
Mode Switch
Varies
Odor Sensor
5-95%
Passenger Compartment
Air Temperature
(Filtered Data)
-40 to +80C (-40 to +

176F)
Air Temperature
(Unfiltered Data)
-40 to +80C (-40 to +

176F)
Humidity
3-100%
Humidity Sensor
Temperature
-40 to +80C (-40 to +

176F)
Rear defogger is
deactivated
Rear Defogger Indicator
Rear defogger is
activated
Rear defogger is
deactivated
Rear Defogger Status
Engine running/Rear
defogger is activated
Rear defogger switch
released
Rear Defogger Switch
Rear defogger switch
pressed
Off
On
Off
On
Inactive
Active
Outside Air
Running, In Progress,
Complete or Failed
depending the calibration
status.
The scan tool displays Up or
Inactive depending on the
state of the mode switch.
The scan tool displays %.
The value increases with the
increasing of the pollution of
the ambient air.
temperature at the passenger
compartment air temperature
sensor.
temperature at the passenger
compartment air temperature
sensor.
The scan tool displays %.
This is the current relative
humidity level at the
windshield temperature and
inside moisture sensor.
temperature at the humidity
sensing element temperature
sensor.
of the rear defogger.
of the rear defogger.
on the state of the rear
defogger switch.
The scan toll displays Stop,
Outside Air, Increase,
Recirculation, Decrease or

is deactivated
Recirculation Door
Motor Direction

Recirculation
is activated
Right front seat heating

Right Front Seat Heating switch released
Switch
Right front seat heating
switch pressed
Right front seat
ventilation switch
released
Right Front Seat
Ventilation Switch
Right front seat
ventilation switch
pressed
Inactive
Active
Inactive
Active
Sun Azimuth
0-90
Sun Elevation
0-360
Sunload
0-1 200 W/m2
Upper Left Duct

Temperature Sensor
-40 to +80C (-40 to +

176F)
Windshield Temperature -
-40 to +80C (-40 to +

176F)
Not Used depending on the

state of the recirculation
door. During the movement
of the door, the scan tool
shows Increase or Decrease
depending the movement
direction.
on the state of the right front
seat heating switch.
on the state of the right front
seat ventilation switch.
The scan tool displays .
This is the current angle in
the horizontal plane between
the sun and the vehicle
driving direction.
The scan tool displays .
This is the current angle in
the vertical sun height.
W/m2 . This is the current
sun heat intensity.
temperature at the upper left
duct temperature sensor.
temperature at the
windshield temperature
sensor.
Heating Ventilation and Air Conditioning Control Module Scan Tool Output Controls
Output Control
Description
The HVAC control module illuminates the A/C
A/C Indicator
indicator when commanded from the scan tool.
This control function simulates the state of the A/C
A/C Switch
switch.
The HVAC control module illuminates the Air

Air Recirculation LED Command
Air Recirculation Mode Switch
Auto HVAC Indicator

Auxiliary Heater Request
Blower Motor Switch
Enhanced Defrost Indicator
Floor Mode Indicator
Front Defrost Indicator
HVAC Actuators
HVAC Afterblow Configuration
Instrument Panel Vents Indicator
Left Temperature Door Motor Direction
Left Temperature Door Position

Mode Door Motor Command
Mode Door Position
Rear Defog
Rear Defogger Indicator
Recirculation Door
Recirculation indicator when commanded from the

scan tool.
When On is selected, the HVAC control module
commands the air recirculation door from outside air to
recirculation. When Off is selected, the HVAC control
module commands the air recirculation door from
recirculation to outside air.
The HVAC control module illuminates the Auto
When On is selected, the HVAC control module sends
a request signal to the auxiliary heater.
This control function simulates the state of the blower
motor switch.
The HVAC control module illuminates the enhanced
defrost indicator when commanded from the scan tool.
The HVAC control module illuminates the floor mode
The HVAC control module illuminates the front
defrost indicator when commanded from the scan tool.
The HVAC control module executes the Motor Learn
Routine when commanded from the scan tool.
This control function disables and enables the
afterblow configuration.
The HVAC control module illuminates the instrument
panel vents indicator when commanded from the scan
tool.
When Increase is selected, the left temperature door
position increases stepwise. When Decrease is
selected, the left temperature door position decreases
stepwise.
This commands the left temperature door position from
Cold to Hot.
The HVAC control module commands the mode
actuator stepwise from defrost to floor and back again.
When Floor is selected, the HVAC control module
commands the mode actuator to the floor position.
When Defrost is selected, the HVAC control module
commands the actuator to the defrost position.
The HVAC control module commands the rear
defogger On and Off.
The HVAC control module commands the rear
defogger indicator On and Off.
The HVAC control module commands the
recirculation actuator stepwise from outside air to
recirculation and back again.

INFLATABLE RESTRAINT PASSENGER PRESENCE SYSTEM SCAN TOOL INFORMATION

Passenger Presence Module Scan Tool Data Parameters
Parameter
Expected Value
Base Model Part Number
Varies, 8 Digit Number
Battery Voltage
Volts
Calibration Part Number
Manufacturer's Traceability
Number
Passenger Classification
Passenger Presence Module

Primary Key
Passenger Presence System
Reporting DTC(s)
Passenger Seat Occupancy Status
Power Mode
Empty Seat
Hex Value
Yes/No
Empty Seat
Definition
The scan tool displays the part
number of the PPS module which is
stored in non volatile memory.
The scan tool will display battery
voltage.
number of the calibration file in the
PPS module.
number of the PPS module in
production.
The scan tool displays the 16 digit
traceability number in the PPS
module.
Calibration Mode, Empty Seat,
Small Occupant Type 1, Small
Occupant Type 2, Small Occupant
Type 3, Small Occupant Type 4,
Large Occupant Type 1, Large
Occupant Type 2, Large Occupant
Type 3, Large Occupant Type 4,
Module Setup, Not Available, Child
Seat Facing Rearward, Child Seat
Facing Forward, Child Seat Facing
Unknown Direction. This is the state
of what occupies the passenger seat,
as monitored by the passenger
presence system.
The scan tool indicates the primary
key Hex value.
The PPS module will report if there
are DTCs set in the passenger
presence module.
The scan tool displays Undefined,
Empty Seat, Occupied, or Invalid.
This is the state of the passenger seat
if it is occupied or empty and
monitored by the passenger presence
system.
Off / Accessory / Run / Crank The scan tool will display the power

Request
Primary Key Status
Received Primary Key

Software Part Number
Valid/Invalid
Hex Value
mode of the vehicle.

The scan tool displays Valid if the
primary key matches what is stored
to memory in the PPS module.
The scan tool displays a Hex value
indicating the PPS module received
primary key data.
The scan tool displays the software
part number in the PPS module.
INFLATABLE RESTRAINT SENSING AND DIAGNOSTIC MODULE SCAN TOOL INFORMATION

Sensing and Diagnostic Module Scan Tool Data Parameters
Parameter
Expected Value
2nd Row Left Seat Belt
Reminder Sensor Pad
Enable Status
Disabled/Enabled

Reminder Sensor Pad
Learn Status
Learned/Not Learned

Status
Buckled/Unbuckled
2nd Row Middle Seat Belt

Reminder Sensor Pad
Enable Status
Disabled/Enabled

Reminder Sensor Pad
Learn Status
Learned/Not Learned

Status
Buckled/Unbuckled
Definition
The scan tool displays if the
left rear seat belt reminder
sensor pad is enabled to the
SDM.
Learned or Not Learned.
Learned is displayed if the
left rear seat belt reminder
sensor pad has been learned
by the SDM.
Buckled or Unbuckled. This
is the state of the left rear
seat belt switch when the
seat belt is buckled or
unbuckled.
rear middle seat belt
reminder sensor pad is
enabled to the SDM.
rear middle seat belt
reminder sensor pad has
been learned by the SDM.
is the state of the middle
rear seat belt switch when
the seat belt is buckled or


Reminder Sensor Pad
Enable Status
Disabled/Enabled

Reminder Sensor Pad
Learn Status
Learned/Not Learned
2nd Row Right Seat Belt

Status
Buckled/Unbuckled
Air Bag Malfunction

Indicator
On/Off/Flashes
Base Model Part Number
Calibration Part Number
Deployment Loop 1-18

Enable Status
Enabled/Disabled

Learn Status
Learned/Not Learned

Resistance
1.44-4.25 Ohms
unbuckled.
rear right seat belt reminder
SDM.
rear right seat belt reminder
by the SDM.
is the state of the right rear
unbuckled.
The scan tool will display
On or Flashes if there is a
problem with the SIR
system. Any problems
within the SIR system will
illuminate the air bag
indicator. The indicator will
either flash or stay on.
part number of the SDM
which is stored in non
volatile memory.
part number of the
calibration file in the SDM.
Enabled or Disabled. This is
the status of the air bag or
pretensioner.
Learned or Not learned.
SDM has defined the
number loop programmed
from an air bag or
pretensioner.
resistance of the learned
loop of the air bag or


Type
Varies
Driver Seat Belt Reminder

Indicator
On/Off
Driver Seat Belt Sensor

Enable Status
Enabled/Disabled
Driver Seat Belt Sensor

Learn Status
Learned/Not learned
Driver Seat Belt Status
Buckled/Unbuckled
Driver Seat Position Sensor
Rearward/Forward

Enable Status
Enabled/Disabled

Learn Status
Learned/Not Learned
Impact Sensor 1-8 Enable

Status
Enabled/Disabled
pretensioner when
connected to the SDM.
name of the air bag or
pretensioner associated with
the loop type 1-18.
The scan tool displays On if
this indicator is on. If the
indicator is on it means the
seat belt has not been
buckled.
seat belt sensor in the seat
belt buckle is enabled to the
SDM.
driver seat belt sensor has
been learned by the SDM.
is the state of the driver seat
belt switch when the seat
belt is buckled or
unbuckled.
The scan tool will display if
the driver seat is forward or
rearward of the sensor set
position.
seat position sensor is
enabled to the SDM.
driver seat position sensor
has been learned by the
SDM.
part number of the SDM in
production.
Enabled or Disabled This is
the status of the impact
sensor.

Impact Sensor 1-8 Learn

Status
Learned/Not Learned
Impact Sensor 1-8 Type
Equipped/Not Equipped
Inflatable Restraint Sensing

and Diagnostic Module
Primary Key
Hex Value
Manufacturer's Traceability
Number
Module Setup
Incomplete/Complete
Passenger Air Bag

Disabled Switch
On/Off
Passenger Air Bag Off

Indicator
On/Off
Passenger Air Bag On

Indicator
On/Off
Passenger Air Bag Status
Enabled/Disabled
Passenger Air Bag Disable

Indicator Enable Status
Enabled/Disabled

Indicator Learn Status
Learned/Not Learned

Learned or Not learned.
SDM has learned and has
assigned a number to that
impact sensor.
name of the impact sensor
associated with the type 1-8.
The scan tool indicates the
primary key Hex value.
16 digit traceability number
in the SDM.
The scan tool indicates if the
SDM is set up.
The scan tool displays Off
when the customer manually
turns the passenger airbag
off with this switch.
The scan tool displays Off
when the passenger
indicator is not illuminated.
This indicator is off when
the disable switch is in the
off position or no one is
sitting in the passenger seat.
when the passenger
indicator is illuminated. This
indicator is on when the
disable switch is in the on
position and someone is
passenger air bag is enabled
to the SDM.
passenger air bag disable
indicator is enabled to the
SDM.
SDM has learned the status


Switch Enable Status
Enabled/Disabled

Switch Learn Status
Learned/Not Learned
Passenger Air Bag Enable

Indicator Enable Status
Enabled/Disabled
Passenger Air Bag Enable

Indicator Learn Status
Learned/Not Learned
Passenger Classification
00-07
Passenger Presence
Detection System Enable
Status
Enabled/Disabled
Passenger Presence
Detection System Learn
Status
Learned/Not Learned
Passenger Presence
Detection System
Reporting DTC(s)
Yes/No
Passenger Seat Belt

Reminder Indicator
On/Off
Passenger Seat Belt

Reminder Indicator Enable
Status
Disabled/Enabled
of the passenger air bag

disable indicator.
passenger air bag disable
switch is enabled to the
SDM.
disable switch.
passenger air bag enable
SDM.
enable indicator.
what type of individual is
passenger presence system
is enabled to the SDM.
SDM has learned the
passenger presence system.
The SDM will report if there
are DTCs set in the
passenger presence module.
The scan tool displays On if
this indicator is on. If the
indicator is on it means the
seat belt has not been
buckled.
passenger seat belt reminder
SDM.

Passenger Seat Belt

Reminder Indicator Learn
Status
Learned/Not Learned
Passenger Seat Belt

Reminder Sensor Pad
Enable Status
Disabled/Enabled
Passenger Seat Belt

Reminder Sensor Pad
Learn Status
Learned/Not Learned
Passenger Seat Belt Sensor

Enable Status
Enabled/Disabled
Passenger Seat Belt Sensor

Learn Status
Learned/Not learned
Passenger Seat Belt Status
Buckled/Unbuckled
Passenger Seat Occupancy

Status
Empty Seat/Occupied
Passenger Seat Position

Sensor
Rearward/Forward

Sensor Enable Status
Disabled/Enabled

Sensor Learn Status
Learned/Not Learned

indicator has been learned
by the SDM.
SDM.
by the SDM.
seat position sensor is
enabled to the SDM.
passenger seat belt sensor
has been learned by the
SDM.
is the state of the passenger
unbuckled.
Occupied if someone is
The scan tool will display if
the passenger seat is forward
or rearward of the sensor set
position.
passenger seat position
SDM.
passenger seat position
sensor has been learned by

Power Mode
Off/Accessory/Run/Crank Request
Primary Key Status
Valid/Invalid
Primary Key Status Last

Ignition Cycle
Invalid/Valid
Received Primary Key
Hex Value
Rollover Sensor Enable

Status
Disabled/Enabled
Rollover Sensor Learn

Status
Learn/Unlearn
Security Code Accepted
Yes/No
Security Code Lockout
Yes/No
Security Code Lockout

Active Timer
Random Value
Security Code Programmed
Yes/No
Security Code
Programming Counter
Random Value
Security Code Reset

Counter
Random Value
Software Part Number
the SDM.
the power mode of the
vehicle.
The scan tool displays Valid
if the primary key matches
what is stored to memory in
the SDM.
The SDM checks to see if
the primary key data
received is valid.
The scan tool displays a Hex
value indicating the SDM
received primary key data.
rollover sensor is enabled to
the SDM.
rollover sensor has been
learned by the SDM.
The SDM either accepts the
security code or it does not.
if the security code has been
accepted by the SDM.
if the SDM has been locked
out because of the security
code not being accepted.
The SDM uses a timer
before the security code is
locked in the SDM.
if the SDM has been
programmed with the
security code.
The SDM uses a counter for
the value of the security
code programming.
The SDM uses a counter to
reset the value of the
security code.
software part number in the

Vehicle Identification
Number
VIN Programmed
VIN Programming Counter
Yes/No
Random Value
SDM.
The VIN number of the
vehicle programmed into the
SDM.
if the VIN has been
programmed into the SDM.
The SDM uses this counter
while programming the
VIN.
INSTRUMENT CLUSTER SCAN TOOL INFORMATION

Instrument Cluster Scan Tool Data Parameters
Parameter
Expected Value
Battery Voltage
Key in Ignition Status
12-14 V
Active/Inactive
Driver Information Center

Switch
Varies

Switch
Inactive
Reset Switch
Active/Inactive
15C
Washer Fluid Level Switch
Open
Odometer Lock Status
Active/Inactive
Engine Speed
0 RPM
Vehicle Speed
0 km/h
Fuel Level Sensor
Description
The scan tool displays Volts. This is
the current battery voltage signal.
Inactive. This is the state of the key
in ignition switch.
The scan tool displays Volts. This is
the current driver information center
switch input voltage.
The scan tool displays either
Inactive, Up, Down, or Menu. This
is the state of the driver information
center switch.
Inactive. This is the state of the reset
switch.
The scan tool displays outside
temperature in C.
The scan tool displays either Open,
Closed, or Not Available.
Inactive depending on the state of
the odometer.
The scan tool displays the filtered
value of engine speed.
vehicle speed value.
value of the fuel level.

Engine Coolant Temperature
Engine Oil Pressure
Head-Up Display Dimming

Level
Head-Up Display Switch
Steering Wheel Control
Switches
percentage
value of the engine coolant

temperature.
value of the engine oil pressure.
dimming intensity level.
Head-Up Display Movement, Head

Up Page Switch, Head-Up Display
HUD button being pushed.
Dimming Level
Left, Select, Right, Volume UP,
steering wheel controls button being
Volume Down
pushed.
Instrument Cluster Scan Tool Output Controls

Output Control
Description
This function is used to command the gauges to sweep
Instrument Cluster Gauge Sweep
from minimum to maximum.
This function is used to command the dimming of the
Driver Information Center Dimming
driver information display to Increase or Decrease by
10%.
Instrument Panel Dimmer Switch
instrument cluster to Increase or Decrease by 10%.
This function is used to command the driver information
Driver Information Center Segments
center segments ON and OFF.
This function is used to command all the indicators ON
All Indicators
or OFF.
This function is used to command the driver information
Driver Information Center Options
center buttons using the scan tool.
This function is used to Reset the source ID for low
CAN Bus Configuration Learn
speed CAN Bus communications.
Head Up Display Dimming Level
head up display to Increase or Decrease.
This function is used to command the head up display to
Head Up Display Pattern Check
display a striped test pattern.
KEYLESS ENTRY CONTROL MODULE SCAN TOOL INFORMATION
Keyless Entry Control Module Scan Tool Data Parameters
Parameter
Expected Value
Battery Voltage
Definition
This parameter indicates the battery

voltage as measured at the module
Active/Inactive
This parameter indicates that the

driver door is ajar; it is open, but the

Driver Door Open Switch
Active/Inactive
Driver Door Unlock Switch
Active/Inactive
Exterior Driver Door

Handle Switch
Active/Inactive
Exterior Driver Door

Handle Proximity Sensor
Active, Inactive, Fault
Passenger Door Open

Switch
Active/Inactive
Passenger Door Ajar

Switch
Active/Inactive
Exterior Passenger Door

Handle Switch
Active/Inactive
Exterior Passenger Door

Handle Proximity Sensor
Active, Inactive, Fault
Active/Inactive
Exterior Left Rear Door

Handle Switch
Active/Inactive
Right Rear Door Ajar
safety latch is engaged.

driver door is more than just ajar, it is
open.
This parameter indicates if the driver
door is locked or unlocked.
This switch begins the challenge and
response to determine if the door
should be unlocked. If the vehicle
responds correctly to the challenge,
the door will be unlocked or
unlatched.
This is a capacitive proximity sensor
on the exterior of the driver door
handle. It allows the user to lock the
door by pressing a small rectangle on
the outside of the door handle if a key
is detected leaving the vehicle.
passenger door is more than just ajar,
it is open.
passenger door is ajar; it is open, but
the safety latch is engaged.
unlatched.
This is a capacitive proximity sensor
on the exterior of the driver door
handle. It allows the user to lock the
door by pressing a small rectangle on
the outside of the door handle if a key
is detected leaving the vehicle.
driver's side rear door is ajar; it is
open, yet the safety latch is engaged.
unlatched.

Switch
Exterior Right Rear Door

Handle Switch
Liftgate Ajar Switch
Liftgate Handle Switch
Active/Inactive
Active/Inactive
Active/Not Active
Active/Inactive
passenger's side rear door is ajar; it is

open, yet the safety latch is engaged.
unlatched.
This switch indicates if the rear
closure of the vehicle is ajar.
response to determine if the rear
closure should be unlatched. If the
vehicle responds correctly to the
challenge, the rear liftgate will be
unlatched.
MULTIMEDIA PLAYER INTERFACE MODULE SCAN TOOL INFORMATION

Multimedia Player Interface Module Scan Tool Data Parameters
Parameter
Expected Value
Definition
Operating Conditions: Ignition ON/Engine OFF/Radio ON
GM Part Number
Varies
The scan tool displays the part number.
The scan tool displays the primary
Calibration Part Number 1
Varies
software part number.
The scan tool displays the primary
Varies
calibration part number
The scan tool displays volts. This is the
Battery Voltage
Varies
voltage input supplied to the Multimedia
Player Interface Module.
The scan tool displays Active or Inactive.
USB Device Detection
Inactive
Being active indicates a USB device is
connected.
Sensing& Status. This parameter displays
Aux IN Detection
Inactive
active when a device present on AUX In
(ministereo plug).
USB over current detection indicates a
USB Overcurrent Protection
Inactive
USB device is drawing too much current
and the USB functionality of the device is
turned OFF.
Bluetooth Device Detection
Inactive
Active indicates a Bluetooth device
connected.

Mute Status
Audio Source Status
Mute OFF
Internal
USB Power Status
OFF
Connected Device Type 1
None
None
None
None
Bluetooth Signal Strength
DB
The scan tool displays Mute OFF or Mute

ON. This parameter displays the status of
the mute.
The scan tool displays Internal Source,
AUX or Bluetooth.This parameter displays
the source of the audio.
The scan tool displays OFF or ON. This is
the status of the USB power.
The scan tool displays None, USB Mass
Storage Device, USB Media Transfer
Protocol Device, Media Player- iPod,
Bluetooth, AUX, Media Player- Zune, or
Device Inserted But Not Supported. This
parameter displays the type of auxiliary
input source connected.
The scan tool displays the signal strength
of the Bluetooth connection.
OBJECT ALARM MODULE SCAN TOOL INFORMATION

Parking Assist Control Module Scan Tool Data Parameters
Parameter
System State
Expected Value
Operating Conditions: Ignition ON/Engine OFF/Parking Assist ON
Description
Active or Inactive

Advanced Parking
Assist Switch
Calculated
Transmission Range
Front Red LED
Front Yellow 1 LED
Front Yellow 2 LED
Active/Inactive
Transmission in reverse
Varies
Parking assist Active,

No object in front of the
vehicle
Object between 0.3-0.6
m (1-1.9 ft) in front of
the vehicle
vehicle
Object between 1-2.5 m
(3.3-8.2 ft) in front of
the vehicle
vehicle
Object between 0.6-1 m
(1.9-3.3 ft) in front of
the vehicle
Off
and Off.
On
Off
and Off.
On
Off
and Off.
On
Parking Assist Attached

Object Status
Yes/No
Parking Assist Chime
Varies
Parking Assist Disable

History 1
depending on the state of

the advanced parking assist
switch.
The scan tool displays Park,
Reverse, Neutral, Drive or
Unknown depending on the
state of the commanded
gear.
Varies

or No. Yes is displayed if
there is an object within the
measuring range of the
object sensors.
or Off. On is displayed if
there is an object within the
measuring range of the
object sensors.
None, Manual Disable,
Park Brake Applied, Trailer
or Other Attached Object,
Excessive Speed in
Reverse, No or Invalid
Sensor Signals, Sensor


History 2
Varies

History 3
Varies

History 4
Varies
Varies
Disturbance, Sensors Dirty,

Sound Signal Return Time
Not Plausible. This is the
state of the park assist
disable history.
Excessive Speed in
disable history.
Excessive Speed in
disable history.
Excessive Speed in
disable history.
Excessive Speed in

History 5

History 6
Varies

History 7
Varies
Parking Assist Sensors
Varies
Parking Assist Sensors

Reference Voltage
7.3-9.1 V
Parking Assist Speaker

Voltage
Parking Assist Switch
Varies
Parking Assist Switch

LED
Varies

disable history.
Excessive Speed in
disable history.
Excessive Speed in
disable history.
or Off.
This is the amount of
voltage being sent to the
object sensors.
The scan tool displays V
depending on the voltage
supplied to the parking
assist speaker.
Active or Inactive
depending on the state of
the parking assist switch.
or Off depending on the
state of the parking assist

Parking Assist System

Status
Enable
Power Mode
Run
Rear Red LED
Rear Yellow 1 LED
Rear Yellow 2 LED
Side Object Detection

Disable History 1

Disable History 2

No object behind the
vehicle
Object between 0.3-0.6
m (1-1.9 ft) behind the
vehicle
vehicle
Object between 1-2.5 m
(3.3-8.2 ft) behind the
vehicle
vehicle
Object between 0.6-1 m
(1.9-3.3 ft) behind the
vehicle
switch LED.
Disable, Enable, Inhibited
or Failed. This is the state
of the parking assist
system.
Accessory, Run or Crank.
This is the state of the
ignition switch.
Off
and Off.
On
Off
and Off.
On
Off
and Off.
On
Varies

None, Invalid Signal
Received, Manual Disable,
Sensors Dirty, Temporarily
Unavailable or Not
Plausible. This is the state
of the side object detection
disable history.
Varies

Unavailable or Not


Disable History 3
Varies

Disable History 4
Varies

Disable History 5
Varies

Disable History 6
Varies

Disable History 7
Varies
System Voltage
11-14 V
Parking Assist Control Module Scan Tool Output Controls

Output Control
disable history.
Unavailable or Not
disable history.
Unavailable or Not
disable history.
Unavailable or Not
disable history.
Unavailable or Not
disable history.
Unavailable or Not
disable history.
This is the current battery
voltage.
Description

The parking assist control module illuminates the advanced

park assist LED of the when commanded from the scan tool.
The parking assist control module clears the disable history
data when commanded from the scan tool.
The parking assist control module illuminates the front red
LED of the parking assist indicator when commanded from the
scan tool.
The parking assist control module illuminates the 1st front
yellow LED of the parking assist indicator when commanded
from the scan tool.
The parking assist control module illuminates the 2nd front
from the scan tool.
The parking assist control module illuminates the rear red LED
of the parking assist indicator when commanded from the scan
tool.
The parking assist control module illuminates the 1st rear
from the scan tool.
The parking assist control module illuminates the 2nd rear
from the scan tool.
Advanced Park Assist LED

Clear Disable History Data
Front Red LED
Front Yellow 1 LED
Front Yellow 2 LED
Rear Red LED
Rear Yellow 1 LED
Rear Yellow 2 LED
POWER STEERING CONTROL MODULE SCAN TOOL INFORMATION

Power Steering Control Module Scan Tool Data Parameters
Parameter
System State
Expected Value
Battery Voltage
Varies
Ignition Voltage
Varies
Motor Voltage +
Motor Voltage -
Varies
Varies
Steering Calibration
Varies
Steering Shaft Torque
Varies
Vehicle Speed
0 km/h (0 mph)
RADIO SCAN TOOL INFORMATION
Description
is the current battery
voltage.
is the current ignition
voltage.
This displays Volts.
This displays Volts.
value.
This displays Y.
This displays km/h
(mph). This is the current
vehicle speed.

Radio Scan Tool Data Parameters

Parameter
Expected Value
Antenna Module
Enabled
Auxiliary Audio Input
Present
Battery Voltage
Varies
Digital Radio Receiver
Present
Phone Signal
Present
Power Mode
Run
Rear Seat Audio

Radio Signal Strength
Theft Lock Armed
Not Present
Varies
Learned VIN
Radio Theft Lock Status
Inactive
Valet Mode Status
Inactive
Video Display 1
Inactive
Video Display 2
Inactive
Varies
Boot Software Part Number
Varies
Varies
Definition
The scan tool displays Enabled or Disabled.
This indicates if the system uses an antenna
module and the output status between the
radio and the antenna module.
The scan tool displays Present or Not
Present. This parameter displays active
when an auxiliary input is connected.
The scan tool displays volts. This is the
voltage at the input to the radio.
Present. This is the state of the Digital
Audio Broadcast.
Present. This parameter will display wether
this system uses discrete a phone arbitration
or not.
The scan tool displays Off, Accessory, Run
or Crank Request. This is the power mode
radio.
Present. This parameter displays Present if
the system detects a rear seat audio module.
This displays the signal strength in dB. This
is the signal strength of the radio signal.
The scan tool displays Learned VIN or No
VIN. This is the state of the VIN
programming in the radio.
This is the state of the theft lock system.
This is the state of the valet mode.
When the rear video display 1 is ON, the
scan tool will display Active.
When the rear video display 2 is ON, the
scan tool will display Active.
The scan tool displays the end model part
number.
The scan tool displays the boot software ID
number.
The scan tool displays the software module

Varies
Varies
Varies
Varies
Varies
Varies
Varies
Varies
Varies
Varies
Varies
Varies
Varies
Varies
Varies
Vin Digits 2-17
Varies
Digital Radio Receiver ID
Varies
DVD Region Code
Varies
DVD Region Code Changes

Remaining
Varies
Radio Scan Tool Output Controls

Scan Tool Output Control
Left Front Speaker
ID 1.
ID 2.
ID 3.
ID 4.
ID 5.
ID 6.
ID 7.
ID 8.
ID 9.
ID 10.
ID 11.
ID 12.
ID 13.
ID 14.
ID 15.
ID 16.
The scan tool displays the vin digits 2-17.
The scan tool displays the Digital Audio
Broadcast receiver ID.
The scan tool displays the DVD region
code.
The scan tool displays the number DVD
region code changes remaining.
Description
This output control is used to command the
speaker ON and OFF. Commanding the
speaker ON will generate a test tone to be

Left Rear Speaker
Right Front Speaker
Right Rear Speaker
Center Speaker
Subwoofer Speaker
Eject
Info Display/Infotainment Faceplate Reset
Info Display/Infotainment Faceplate Wakeup
Clear Hard Disc Drive
generated through the selected loudspeaker.

This output is a reset command to eject the
disc.
This output is a reset command to reset the
radio display.
This output commands a wakeup at the
display and the faceplate controls.
This output commands a HDD to clear all
customer data. This includes music files,
eBooks and navigation addresses. This does
not clear Nav database data.
STEERING COLUMN LOCK CONTROL MODULE SCAN TOOL INFORMATION

Scan Tool Data Parameters
Parameter
Expected Value
Column Lock Status
Varies
Turn Steering Wheel, Start

On/Off
Vehicle Again Display Message
Description
The scan tool displays Failed, Unknown,
Locked and Unlocked. The scan tool
displays the current state of the column
lock.
The scan tool displays On/Off. If the wheels
are against a curb, the lock pin may not be
able to pull out. A message for the driver
that is displayed on the Driver Information

Steering Column Lock Indicator On/Off

Steering Column Lock Pin
Position
counts
Center. The scan tool displays the need to

turn the steering wheel, turn off the vehicle
and then restart the vehicle.
The scan tool displays On/Off. The scan
tool displays the current state of the column
lock.
The scan tool displays the current counts of
the column lock pin position.
TRANSMISSION CONTROL MODULE SCAN TOOL INFORMATION

The Transmission Control Module Scan Tool Data List contains all transmission related parameters that are
available on the scan tool. The list is arranged in alphabetical order. A given parameter may appear in any one
of the data lists, and in some cases may appear more than once, or in more than one data list in order to group
certain related parameters together.
The values below represent a typical display recorded from a properly functioning system.
NOTE:
Do not use a scan tool that displays faulty data. Report the condition to the
scan tool manufacturer. The use of a faulty scan tool can result in misdiagnosis
and the unnecessary replacement of components.
Only the parameters listed below are used/referenced in this manual for diagnosis. If a scan tool displays other
parameters, those values are not recommended by General Motors for use in diagnosis.
If all values are within the expected range described below, refer to Symptoms - Automatic Transmission for
diagnosis.
The scan tool values from a properly functioning transmission may be used for comparison with the
transmission you are diagnosing. The values below represent a typical display recorded from a properly
functioning system.
Scan Tool Data Parameters
Parameter
System State
Expected Value
Description
Operating Conditions: Engine at idle, upper radiator hose hot, closed throttle, transmission in Park,
closed loop operation, accessories OFF, brake pedal not applied.
This parameter displays the actual
time of the last adaptable 1-2 shift.
1-2 Shift Time
Varies
Seconds
The shift time is based on the gear
ratio change after the commanded 1-2
shift.
2-3 Shift Time
Varies
Seconds
shift.

3-4 Shift Time
Varies
Seconds
4-5 Shift Time
Varies
Seconds
5-6 Shift Time
Varies
Seconds
Brake Pedal Switch
Released
Applied/Released
Calculated Throttle
Position
Varies
9-19
Volts
Inactive
Active/Inactive
Control Module
Voltage Signal
Driver Shift Control

Mode

shift.
The actual shift time is obtained by
measuring the time required for the
input shaft to decelerate from the
previous ratio to the current ratio.
time of the last 5-6 shift. The shift
time is base on the gear ratio change
after the commanded 5-6 shift.
This parameter displays the status of
the brake switch circuit input.
Applied indicates a zero voltage
input, brake pedal applied. Released
indicates a voltage input, brake pedal
released. The scan tool displays
Applied or Released.
This parameter displays a calculated
value, which is determined by the
accelerator pedal position and the
actual throttle position, used to
optimize transmission controls. It
represents the driver's intended
request for torque or acceleration.
The range is 0-100%, where 0%
represents an idle or coast request and
100% represents a request for wide
open throttle (WOT).
This parameter displays the system
voltage measured at the module wake
up signal feed.
This parameter displays Active or
Inactive. The scan tool displays
Active when the gear selector is in the
manual mode (M) position or left of
the D position, which enables TAP
shift. The scan tool displays Inactive
when the gear selector is not in the M
or left of D position, TAP shift
disabled.
request from the TAP Shift System.

Driver Shift Request
None
Upshift / Downshift /
None / Invalid
Engine Coolant
Temperature
Varies
C (F)
Engine Speed
Varies
RPM
Engine Torque
Varies
Y (lb ft)
Gear Command
1, 2, 3, 4, 5, or 6
Varies
Ratio
Gear Ratio
This parameter will display up shift,

downshift or invalid depending on the
amount of voltage measured at the
remote shift selector input and also
will display none when there is no
request.
This parameter displays the input
signal from the engine coolant
temperature (ECT) sensor. ECT is
high at 151C (304F) when the
signal voltage is low (0 V). ECT is
low at -40C (-40F) when the signal
voltage is high (5 V). This parameter
value is determined by the engine
control module and communicated to
the TCM through the High Speed
GMLAN Serial Data link.
This parameter displays the rotational
speed of the engine expressed as
revolutions per minute. This
parameter value is determined by the
engine control module and
communicated to the TCM through
the High Speed GMLAN Serial Data
link.
This parameter displays a calculated
value based on engine load, throttle
position, mass air flow, and other
engine inputs. This parameter is
accurate to within 20 N.m (15 lb ft) of
actual measured engine torque. This
parameter value is determined by the
engine control module and
communicated to the TCM through
the High Speed GMLAN Serial Data
link.
commanded state of the shift solenoid
valves. The scan tool displays 1, 2, 3,
4, 5, or 6.
transmission gear ratio. The scan tool
displays the gear ratio calculated from
the automatic transmission (AT) input
speed sensor (ISS) and the automatic
transmission (AT) output speed
sensor (OSS) inputs.

High Side Driver 1
On
High Side Driver 1

Circuit Low Voltage
Test Status
OK
High Side Driver 1

Circuit High Voltage
Test Status
OK
High Side Driver 1

Circuit Open Test
Status
OK
Ignition Voltage
9-19
Internal Mode
Switch
Park
Internal Mode
Switch A/B/C/P
Varies
ISS/OSS Supply
Voltage
OK
Last Shift Time
Varies
This parameter displays the state of

the High Side Driver 1. The scan tool
displays On or Off.
This parameter displays whether a
short to ground exists in the high side
OK, Malfunction, Not Run driver 1 circuit. The scan tool
displays OK, Malfunction, or Not
Run.
short to voltage exists in the high side
OK, Malfunction, Not Run driver 1 circuit. The scan tool
Run.
This parameter displays whether an
open exists in the high side driver 1
OK, Malfunction, Not Run
circuit. The scan tool displays OK,
Malfunction, or Not Run.
This parameter displays the system
Volts
voltage measured at the ignition feed.
This parameter displays PARK,
PARK/REVERSE, REVERSE,
REVERSE/NEUTRAL, NEUTRAL,
NEUTRAL/DRIVE 4, DRIVE 4,
DRIVE 4/DRIVE 3, DRIVE 3,
DRIVE 3/DRIVE 2, DRIVE 2,
Park-Drive 1, Open, Invalid DRIVE 2/DRIVE 1, DRIVE 1 or
INVALID. The IMS Range display
represents a decoded status of the
four inputs from the IMS. The
combination of IMS inputs are used
to determine what position the
manual valve is in at any time.
This parameter displays the status of
the four A/B/C/P inputs from the
automatic transmission internal mode
switch. HI indicates an ignition
High/Low
voltage signal and LOW indicates a 0
voltage signal. The scan tool will
display High/Low, High/Low,
High/Low, High/Low.
This parameter displays OK, Out of
OK, Out of Range
Range.
time of the last up shift. This value is
Seconds
only accurate if the shift was
adaptable.
On/Off

Line Pressure
Control Solenoid
Valve Control
Circuit Low Voltage
Test Status
Line Pressure
Control Solenoid
Valve Control
Test Status
Line Pressure
Control Solenoid
Valve Performance
Test Status
Line Pressure
Control Solenoid
Valve Pressure
Command
OK
OK
OK
Varies
Pressure Control
Solenoid Valve 2
Control Circuit Low
Voltage Test Status
OK
Pressure Control
Solenoid Valve 2
Control Circuit High
Voltage Test Status
OK
Pressure Control
Solenoid Valve 2
Performance Test
Status
OK
Pressure Control
Solenoid Valve 2
Pressure Command
Pressure Control
Solenoid Valve 3
Control Circuit Low
Voltage Test Status
Varies
OK

short to ground exists in the line
OK, Malfunction, Not Run pressure control valve 2 control
short to ground exists in the line
OK, Malfunction, Not Run pressure control valve 2 control
performance issue exists in the line
pressure control solenoid valve
OK, Malfunction, Not Run control circuit by comparing the
commanded current with the expected
current. The scan tool displays OK,
kPa (psi)
This parameter displays results in kPa

(psi).

short to ground exists in the pressure
OK, Malfunction, Not Run control solenoid valve 2 control
short to voltage exists in the pressure
performance issue exists in the
pressure control solenoid valve 2
kPa (psi)
This parameter displays kPa (psi).


Pressure Control
Solenoid Valve 3
Voltage Test Status
OK
Pressure Control
Solenoid Valve 3
Performance Test
Status
OK
Pressure Control
Solenoid Valve 3
Pressure Command
Varies
Pressure Control
Solenoid Valve 4
Control Circuit Low
Voltage Test Status
OK
Pressure Control
Solenoid Valve 4
Voltage Test Status
OK
Pressure Control
Solenoid Valve 4
Performance Test
Status
OK
Pressure Control
Solenoid Valve 4
Pressure Command
Varies
Pressure Control
Solenoid Valve 5
Control Circuit Low
Voltage Test Status
OK
Pressure Control
Solenoid Valve 5
Voltage Test Status
OK

kPa (psi)

kPa (psi)


Pressure Control
Solenoid Valve 5
Performance Test
Status
Pressure Control
Solenoid Valve 5
Pressure Command
OK
Varies
Replicated OSS
CKT Status
OK
Shift Solenoid Valve

1
On

1 Control Circuit
Low Voltage Test
Status
OK
1-2 Shift Solenoid

Valve Control
Test Status
OK

1 Control Circuit
Open Test Status
OK
Steady State TAP 1st

Gear
Varies
Steady State TAP 1st

Gear TCC Applied
Varies
Steady State TAP

2nd Gear
Varies
Steady State TAP

2nd Gear TCC
Applied
Varies

control circuit by comparing the
OK, Malfunction, Not Run
kPa (psi)
OK, Open/Short to GND, This parameter displays OK,

Short to Volts,
Open/Short to GND, Short to Volts,
Indeterminate
Indeterminate.
commanded state of the reverse, 1st
On/Off
shift solenoid valve (S1). The scan
tool displays On/Off.
short to ground exists in the shift
OK, Malfunction, Not Run solenoid valve 1 control circuit. The
scan tool displays OK, Malfunction,
or Not Run.
short to voltage exists in the shift
OK, Malfunction, Not Run solenoid valve 1 control circuit. The
scan tool displays OK, Malfunction,
or Not Run.
This parameter displays whether an
open exists in the shift solenoid valve
OK, Malfunction, Not Run 1 control circuit. The scan tool
Run.
This parameter displays the amount
of transmission adaptive pressure
kPa (psi)
(TAP), which modifies the
commanded clutch apply pressures.
kPa (psi)
kPa (psi)
kPa (psi)


Steady State TAP

3rd Gear
Varies
Steady State TAP

3rd Gear TCC
Applied
Varies
Steady State TAP

4th Gear
Varies
Steady State TAP

4th Gear TCC
Applied
Varies
Steady State TAP

5th Gear
Varies
Steady State TAP

5th Gear TCC
Applied
Varies
Steady State TAP

6th Gear
Varies
Steady State TAP

6th Gear TCC
Applied
Varies
Steady State TAP

Reverse
Varies
TCC Pressure
Control Solenoid
Valve Control
Circuit Low Voltage
Test Status
TCC Pressure
Control Solenoid
Valve Control
OK
OK

kPa (psi)
kPa (psi)
kPa (psi)
kPa (psi)
kPa (psi)
kPa (psi)
kPa (psi)
kPa (psi)
kPa (psi)
short to ground exists in the TCC
OK, Malfunction, Not Run pressure control solenoid valve
control circuit. The scan tool displays
OK, Malfunction, or Not Run.
OK, Malfunction, Not Run short to voltage exists in the TCC
control circuit. The scan tool displays

Test Status
TCC Pressure
Control Solenoid
Valve Performance
Test Status
TCC Pressure
Control Solenoid
Valve Pressure
Command
OK
Varies
OK, Malfunction, or Not Run.

performance issue exist in the TCC
kPa (psi)
TCC Slip Speed
Varies
RPM
TCM Power-Up
Temperature
Varies
C (F)
TCM Temperature
Varies
C (F)
Transmission Fluid
Pressure Switch 1
High/Low
High/Low
Transmission Fluid
Pressure Switch 3
High/Low
High/Low
This parameter displays results in kPa

(psi).
difference between transmission input
speed and engine speed. A negative
value indicates that the engine speed
is less than the input speed,
deceleration. A positive value
indicates that the engine speed is
greater than the input speed,
acceleration. A value of zero
indicates that the engine speed is
equal to the input speed, TCC
applied.
This displays the value of the
temperature sensor inside the control
solenoid and valve assembly.
This displays the temperature of the
TCM. This parameter displays results
in C (F).
This parameter indicates the state of
the normally closed transmission
fluid pressure switch 1. Pressure to
the switch is dependent on the
position of the 3-5-Reverse clutch
regulator valve. The scan tool
displays High/Low.
position of the 2-6 clutch regulator
valve. The scan tool displays
High/Low.

Transmission Fluid
Pressure Switch 4
High/Low
High/Low
Transmission Fluid
Pressure Switch 5
High/Low
High/Low
Transmission Fluid
Life
Varies
Transmission Fluid
Temperature
Varies
C (F)
Transmission Hot
Mode
On/Off
On/Off
Transmission ISS
Varies
RPM
Transmission OSS
Varies
RPM
Scan Tool Output Controls

Output Control

position of the 1-2-3-4 clutch
displays High/Low.
position of the R1/4-5-6 clutch
displays High/Low.
transmission oil life remaining. The
scan tool displays the remaining oil
life as a percentage. The transmission
oil life is calculated based on fluid
temperature and engine run time.
This parameter displays the input
signal of the transmission fluid
temperature sensor. Transmission
fluid temperature is high 151C (304
F) when signal voltage is low, 0 V,
and transmission fluid temperature is
low -40C (-40F) when signal
voltage is high, 5 V.
When The transmission fluid
temperature is above a temperature
which varies by calibration, the TCM
will alter the shift pattern until the
temperature drops below a value
which varies by calibration.
speed of the transmission input shaft.
The scan tool displays input shaft
speed is revolutions per minute
(RPM).
speed of the transmission output shaft
expressed as revolutions per minute.
Description
The transmission control module (TCM) commands the

torque converter clutch pressure control (TCC PC) solenoid
pressure in order to apply and release the TCC.
When the ignition is ON, and the engine is OFF, there are

TCC Pressure Control Solenoid Valve
Shift Solenoid:
Shift Solenoid Valve 1
no limits to this control. The solenoid remains ON until

commanded OFF and vice versa.
When the engine is running, the following control limits
apply:
If the transmission range is Park, and the transmission
is in hot mode, the TCC PC solenoid may not be
commanded OFF. If the solenoid is requested OFF,
the message "TCC OFF command disabled in Hot
Mode" appears on the scan tool display.
The TCC PC solenoid may not be commanded OFF
for more than a calibrated amount of time. If the
solenoid is commanded OFF, for a certain amount of
time, the message "TCC OFF time has been
exceeded" appears on the scan tool display.
The TCM commands Shift Solenoid 1 ON and OFF.
commanded OFF, and vice versa. When the output control
is exited, the solenoid state is determined by the TCM.
apply:
The transmission range must be in Park or Neutral. If
the transmission range is not Park or Neutral, the
message "Engine running and transmission range is
not Park/Neutral" appears on the scan tool display.
The solenoid remains ON until commanded OFF, and
vice versa. When the output control is exited, the
solenoid state is determined by the TCM.
Transmission range DTCs must not be active. If a
transmission range DTC is active, the message
"Engine running with transmission DTC present"
appears on the scan tool display.
The scan tool is used to request pressure in increments of
207 kPa (30 psi) from 0-1862 kPa (0-270 psi). The TCM
will then command the solenoid to achieve the requested
pressure.
When the ignition is ON, and the engine is OFF, the
pressure request may be controlled within calibrated limits.
There are no limits to the output control when the engine is
OFF.
apply:
When the transmission range is Park or Neutral, the
pressure request may be controlled within calibrated

Line Pressure Control Solenoid Valve
Clutch PC Solenoids:
Pressure Control Solenoid

Valve 2
Valve 3
Valve 4
Valve 5
limits. The engine speed must be less than 1, 500

RPM. If the engine speed is greater than 1, 500 RPM,
the message "TR in park/neutral and engine speed
over 1, 500 RPM" appears on the scan tool display.
When the transmission range is not Park or Neutral,
the requested pressure can only be controlled equal to
or greater than the pressure determined by the TCM.
The TCM does not allow a pressure to be selected
that may cause damage to the transmission. If the
requested pressure is less than allowed by the TCM,
the message "Requested pressure for the Line PC
Solenoid is too low" appears on the scan tool display.
The TCM commands the pressure control solenoids in order

to apply and release the clutches.
commanded OFF, and vice versa. When the output control
is exited, the solenoid state is determined by the TCM.
apply:
The transmission range must be in Park or Neutral. If
the transmission range is not Park or Neutral, the
message "Engine running and transmission range is
not Park/Neutral" appears on the scan tool display.
The solenoid remains ON until commanded OFF, and
vice versa. When the output control is exited, the
solenoid state is determined by the TCM.
The TCM commands upshifts and downshifts. The scan tool
Commanded Gear parameter should correspond with the
shift solenoid combination. Refer to Shift Solenoid Valve
State and Gear Ratio .
no limits to this control. The scan tool shift solenoid states
change to match the Commanded Gear selected.
apply:

The TCM does not allow a shift if it causes the engine

RPM to exceed a calibrated limit. If a gear is
requested and the engine speed is too high, the
message "Engine speed too high" appears on the scan
tool display.
The TCM does not allow a 3-2 or 2-1 downshift if the
vehicle speed exceeds a calibrated limit. If either
downshift is requested and the vehicle speed is too
high, the message "Eng. is on and veh. speed too hi
for 3-2 or 2-1 downshift" appears on the scan tool
display.
The TCM does not allow a 4-3 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 does not allow an upshift if the vehicle
speed exceeds a calibrated limit. If an upshift is
requested and the vehicle speed is too high, the
message "Vehicle speed too high" appears on the scan
tool display.
The TCM does not allow an upshift that is greater
than the current selected transmission range
(PRNDL). For example, 3rd gear is not allowed if the
transmission range is D2. If an upshift is requested
that is greater than the current selected transmission
range, the message "Eng. running and gear request is
greater than the current TR" appears on the scan tool
display.
The TCM commands pressure to the clutches to learn the
transmission adaptive values. As the procedure is being
performed, the scan tool provides operator instructions.
Test may not start or may abort for the following conditions:
Shift Transmission Gear
Transmission Adaptive Values Learn
Transmission fluid temperature must be between 70-100C

(158-212F).
Brakes and brake switch must function properly.
Closed throttle and engine speed increases above 1500
RPM.
Park/neutral position switch must be properly adjusted and
functioning.
Line pressure control is able to command 1, 000 kPa (145
psi).
Vehicle must be stopped.
Vehicle must not be vibrating excessive.

DIAGNOSTIC INFORMATION AND PROCEDURES

STRATEGY BASED DIAGNOSIS
The goal of Strategy Based Diagnosis is to provide guidance when you create a plan of action for each specific
diagnostic situation. Following a similar plan for each diagnostic situation, you will achieve maximum
efficiency when you diagnose and repair vehicles. Although each of the Strategy Based Diagnosis boxes is
numbered, you are not required to complete every box in order to successfully diagnose a customer concern.
The first step of your diagnostic process should always be Understand and Verify the Customer's Concern. The
final step of your diagnostic process should be Repair and verify the Fix. Refer to the following chart for the
correct Strategy Based Diagnosis.
Fig. 1: Strategy Based Diagnosis Flow Chart

1. Understand and Verify the Customer's Concern: The first part of this step is to obtain as much
information as possible from the customer. Are there aftermarket accessories on the vehicle? When does
the condition occur? Where does the condition occur? How long does the condition last? How often does

2.
3.
4.
5.
6.
7.
8.
the condition occur? In order to verify the concern, the technician should be familiar with the normal
operation of the system and refer to the owner or service manual for any information needed.
Vehicle Operating as Designed: This condition exists when the vehicle is found to operate normally. The
condition described by the customer may be normal. Compare with another like vehicle that is operating
normally under the same conditions described by the customer. Explain your findings and the operation
of the system to the customer. If the customer is dissatisfied submit a Field Product Report.
Preliminary Checks: Conduct a thorough visual inspection. Review the service history. Detect unusual
sounds or odors. Gather diagnostic trouble code (DTC) information in order to achieve an effective
repair.
Perform Published Diagnostic System Check- Vehicle: The Diagnostic System Check - Vehicle verifies
the proper operation of the system. This will lead the technician in an organized approach to diagnostics
and identify what category of diagnostic to perform.
Check for related Bulletins, Recalls and Preliminary Information (PI).
Diagnostic categories:
1. Current DTC: Follow the designated DTC diagnostic in order to make an effective repair. Refer to
Diagnostic Trouble Code (DTC) List - Vehicle.
2. Symptom - No DTC: Select the appropriate symptom diagnostic. Follow the diagnostic steps or
suggestions in order to complete the repair. Refer to Symptoms - Vehicle.
3. No Published Diagnostics: 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 areas where multiple circuits are tied together. Look at component
locations to see if components, connectors or harnesses may be exposed to extreme temperature,
moisture, or corrosives (road salt, battery acid, oil or other fluids). Utilize the wiring diagrams,
system description and operation, and system circuit description.
4. Intermittent/History DTC: An intermittent condition is one that does not occur continuously, may
be difficult to duplicate, and will only occur when certain conditions are met. Generally, an
intermittent is caused by faulty electrical connections and wiring, malfunctioning components,
electromagnetic/radio frequency interference, driving conditions, or aftermarket equipment. The
following approaches/tools may prove to be beneficial in locating and repairing an intermittent
condition or history DTC.
Combining technicians knowledge with the available service information.
Evaluate the symptoms and conditions described by the customer on the Customer Concern
Verification Sheets .
Follow the suggestions on Testing for Intermittent Conditions and Poor Connections .
Use the available scan tool, digital multi-meter, or J-42598-B vehicle data recorder with data
capturing capabilities.
Isolate the Root Cause then Repair and Verify Fix: After isolating the root cause, make the repairs and
validate for the correct operation by performing the Diagnostic Repair Verification. Verifying that the
DTC or symptom has been corrected may involve road testing the vehicle.
Re-examine the Concern: If a technician cannot successfully find or isolate the concern, a re-evaluation is
necessary. Re-verify the concern. The concern could be an intermittent or normal condition.
DIAGNOSTIC PROCEDURE INSTRUCTIONS

The following is an overview of instructions for all 16 categories which may be included in a diagnostic
procedure.
Diagnostic Instructions
A link to the Diagnostic System Check - Vehicle is provided here. This procedure should be performed prior
to performing other diagnostic procedures, as this prevents misdiagnosis where there are integrated system
dependencies.
A link to the Strategy Based Diagnosis is provided here. This provides an overview on how a technician
should diagnose a vehicle.
A link to the Diagnostic Procedure Instructions is provided here. This information is an overview of
instructions for all 16 categories which may be included in a diagnostic procedure.
DTC Descriptor
Describes what DTCs are diagnosed in this procedure. The DTC number, with Symptom Description when
applicable, and descriptor are written out.
Diagnostic Fault Information
The diagnostic Fault Information table identifies each circuit that makes up an electrical subsystem and the
associated circuit faults. DTCs and symptoms are listed in the table for all circuit fault modes. This information
can be used to diagnose an electrical fault, or as a quick visual aid showing how the different symptoms and
DTCs apply for the subsystem being diagnosed.
Even though all the DTCs and symptoms are shown in this table it does not mean they will all be diagnosed in
the same procedure.
An example table from an engine coolant temperature (ECT) procedure:
Circuit
ECT Sensor Signal
ECT Low Reference
Short to
Ground
P0117
-
Open/High
Resistance
P0118
P0118
Short to
Voltage
P0118
P0118
Signal Performance
P0125, P0128
P0125, P0128
Typical Scan Tool Data
The Typical Scan Tool Data table identifies a scan tool data parameter and its value in reference to potential
circuit faults.
An example table from an ECT procedure:
ECT Sensor Temperature - PCM
Circuit
Short to Ground
Open
Short to Voltage

Parameter Normal Range: -32 to +130C (-26 to +275F)

ECT Signal
140C (284F)
Low Reference
* Internal ECM damage may occur if shorted to B+
-40C (-40F)
-40C (-40F)
-40C (-40F)
-40C (-40F)*
Circuit/System Description
Circuit/System Description identifies how a circuit/system normally functions.

Conditions for Running the DTC
Conditions for Running the DTC, identifies what conditions must be present to allow the diagnostic to run.
Conditions for Setting the DTC
Conditions for Setting the 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 actions taken when a control module sets a DTC.
Conditions for Clearing the DTC
Conditions for Clearing the DTC, identifies the conditions that must be met in order to clear the DTC.
Diagnostic Aids
Diagnostic Aids are suggestions which explain other methods to diagnose the condition. It also provides unique
information about the system used to assist the technician in finding and repairing a vehicle condition.
Reference Information
Reference Information includes links providing additional information for the diagnostic procedure.
For example:
Schematic Reference
Connector End View Reference
Description and Operation
Electrical Information Reference
DTC Type Reference
Scan Tool Reference
Special Tools Required
Circuit/System Verification

The diagnostic format does not force a technician to any of the 3 diagnostic categories (Circuit/System
Verification, Circuit/System Testing and Component Testing). However, performing the Circuit/System
Verification category first, aids in determining if a vehicle condition is current. Some diagnostic categories may
state that another category must be performed first when there are testing dependencies.
This category also serves to route the technician to other diagnostic procedures which should be performed first;
for example, a DTC with a higher priority.
NOTE:
Any diagnostic step that asks if a DTC is set is referring to a Set, Current,
Present, Active DTC status. This does not include any other DTC status. For
example History, Not Run, Passed and Failed.
Circuit/System Verification is a non-intrusive procedure outlining how to verify that a system or a portion of a
system is functioning correctly. During the verification process, the vehicle is kept intact and tested as a
complete system. This verification is used to assist the technician in determining whether a condition is current
or intermittent. When a condition is determined to be intermittent, a technician can use the link in Electrical
Information Reference: Testing for Intermittent Conditions and Poor Connections for additional testing
information.
The technician should be able to identify if the fault is occurring on the input circuit - signal or on the output
circuit - control when applicable. The technician will need to decide from the verification results if the system is
working correctly or if further diagnosis needs to be performed in either Circuit/System Testing and/or
Component Testing.
To assist the technician in identifying a common part a component code is used. These codes are not translated
so they will always be the same even though the part name may have slight variance. The component codes will
always be the same once assigned to a unique part name and will be found on the schematics and in the
diagnostic procedure categories Circuit/System Verification, Circuit/System Testing, and Component Testing
categories.
Component Codes
The component codes used on the schematics will have the base code with an extension to identify location or
quantity. For example the ABS wheel speed sensors are identified on the schematic with a base code (B5) and a
location extension (LF, RF, LR, and RR) as seen below:
B5LF Wheel Speed Sensor (WSS)-Left Front

B5RF Wheel Speed Sensor (WSS)-Right Front
B5LR Wheel Speed Sensor (WSS)-Left Rear
B5RR Wheel Speed Sensor (WSS)-Right Rear
B5 is the base code for the wheel speed sensor and the LF, RF, LR, and RR indicate the on vehicle location.
The diagnostic procedures will use the base code (B5) for a wheel speed sensor but may or may not use the
extension identifying location (LF, RF, LR, and RR). Example: Ignition OFF, disconnect the harness connector
at the appropriate B5 wheel speed sensor. This is done so the diagnostic procedure can be common for all four
wheel speed sensors and not have to take into account part location or quantity.

Where the diagnostic states "the appropriate" it is up to the technician to identify which component is being
diagnosed by the symptom stated on the RO (drivers door lock is inoperative) or by the DTC descriptor (DTC
C0585 04: Left Rear Actuator Circuit Open).
Circuit/System Testing
Verification, Circuit/System Testing and Component Testing). However, beginning with the Circuit/System
Verification category aids in determining if a vehicle condition is current. Some diagnostic categories may state
that another category must be performed first when there are testing dependencies.
Circuit/System Testing is a step by step, positive-flow, testing sequence which allows the technician to perform
each test step, in sequence, until a fault is detected. If the result of a numbered test step is achieved, the normal
flow is to proceed to the next numbered test step (indicated by the down pass arrow). If the result of a numbered
test step is NOT achieved, the right repair arrow bullet below the failed test will identify what actions need to
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 component will be used to
assist in verifying the circuit function. When a test does not pass, the repair steps (right arrow) will indicate
what circuit faults to test for example, short to voltage, short to ground or open/high resistance.
When testing for individual circuit faults, the technician is expected to include terminal inspections such as
connection surfaces and terminal tension at both the harness and component/module. Additionally, a technician
can use the links in Electrical Information Reference: Testing for Intermittent Conditions and Poor
Connections , or Circuit Testing for additional information.
The control modules and components will also be diagnosed during these test steps. A retest of a control
module or component should always be performed before replacement. For example, re-connect all components
and modules and retest the system to verify the condition still exists before replacing modules or components.
Component Testing
Verification, Circuit/System Testing and Component Testing). However, beginning with the Circuit/System
Verification category aids in determining if a vehicle condition is current. Some diagnostic categories may state
that another category must be performed first when there are testing dependencies.
Component Testing can offer static and/or dynamic component tests. These tests can be used to verify if a
component is operating correctly to avoid unnecessary replacement.
Testing modules in this category will not be offered. In most cases, the module is used to verify the harness
circuits in the Circuit/System Testing category and a retest of the module should always be performed before
replacement.
Repair Instructions
Repair Instructions provides a link to Diagnostic Repair Verification. This link describes how to verify the

vehicle is repaired.
All links to Repair or Replacement procedures are located here.
Repair Verification
Repair Verification describes how to verify the vehicle is repaired when additional instructions are needed
beyond what is in Diagnostic Repair Verification.
DIAGNOSTIC SYSTEM CHECK INSTRUCTIONS
The following is an overview of instructions for the general information and 13 step System Verification
included in the Diagnostic System Check - Vehicle procedure.
A link to Strategy Based Diagnosis is provided as an overview on how a technician should diagnose a vehicle.
A link to the Diagnostic System Check Instructions is provided. This provides an overview of instructions and
examples for the general information and 13 step System Verification included in the Diagnostic System Check
- Vehicle procedure. The examples in this document are intended to give the technician a general idea of what
the test step is referring to. They are not intended to list every possible condition or situation.
Diagnostic Systems Check steps are listed by priority to guide the technician to the appropriate diagnostic
procedure to correct the customer concern. There are many ways to determine the priority of diagnosing a
vehicle concern. Some faults can cause customer perceived symptoms in areas unrelated to the fault. Using an
example from the System Check, after reading DTCs, the technician is asked to verify there are no Electronic
Control Unit Internal Performance Faults present. It is important that any internal performance issues are
addressed prior to continuing through the System Check. There is no benefit addressing other DTCs that could
be set due to an internal fault to a control module. If the fault is present, performing the diagnostic procedure for
that fault will likely correct the customer perceived concern and possibly eliminate other DTCs that may be set.
Not all steps of the Diagnostic System Check have to be performed. The Diagnostic System Check tries to
prioritize the test steps with the highest priority faults first. The technician is then lead to another document to
do the actual diagnosis or repair. The strategy is to repair higher level faults that may be the cause of other
system or component level symptoms. Additionally, the Diagnostic System Check can only be used for a single
fault at a time. If additional faults are present, the technician must perform the diagnostic system check for each
concern until all customer concerns are corrected.
Once a repair has been completed, General Motors diagnostic strategy is to always have the technician verify
that the customer concern has been corrected. This is to prevent comebacks and to ensure customer satisfaction
with their dealership experience. Therefore a link has been provided to Diagnostic Repair Verification
procedure for the technician to verify the customer concern has been corrected.
There are some assumptions made when General Motors prepares service information. They include the
following areas which are presumed to function as designed:
The 12-volt battery is fully charged. General Motors assumes the majority of vehicles brought in for

repair will be able to start and be driven into the service stall. If the vehicle has a dead battery, it is slow
cranking or for any other reason the technician feels the customer concern may be battery related, a link is
provided to Battery Inspection/Test . This procedure will guide the technician through inspecting and
verifying the battery functions properly.
Fuses should not be open. General Motors does not call out in diagnostic procedures to verify a fuse. The
technician is expected to find an open fuse when the diagnostic test step states to check for an open circuit
condition. Therefore a link has been provided to Power Distribution Schematics , and Electrical Center
Identification Views for technicians to reference power sources and fuse locations if they feel there may
be loss of power due to an open fuse condition.
Ground circuits are clean, tight, and in the correct location. General Motors assumes that the original
ground circuits have not been compromised. The technician is expected to find a poor ground connection
when the diagnostic test step states to test the ground circuit for an open/high resistance. Therefore a link
has been provided to Ground Distribution Schematics , and Harness Routing Views for technicians to
reference ground locations and which ground circuits may be related to the customer concern.
All connections/connectors are fully seated. General Motors assumes that all connections are properly
installed. The technician is expected to find an open or poor connection when the diagnostic test step asks
to test the circuit for an open/high resistance. Therefore a link has been provided to COMPONENT
CONNECTOR END VIEWS - INDEX for technicians to reference which connections may be related
to the customer concern.
There are no aftermarket devices that affect the operation of the system. General Motors can only author
diagnostic and repair information for vehicle systems and components that are original equipment or
genuine GM Accessories. Aftermarket equipment can negatively affect original equipment operation and
lead a technician's diagnosis of a concern in the wrong direction. Therefore a link has been provided to
Checking Aftermarket Accessories that guides a technician through the possible causes of vehicle
problems related to aftermarket accessories.
The scan tool powers up. General Motors assumes that power is available at the Data Link Connector and
the scan tool will power on. Therefore a link has been provided to Scan Tool Does Not Power Up if the
technician finds that the scan tool does not power on.
Diagnostic System Check
1. VERIFY CUSTOMER CONCERN-This step is to obtain as much information as possible from the
customer. Are there aftermarket accessories on the vehicle? When does the condition occur? Where does
the condition occur? How long does the condition last? How often does the condition occur? Review the
service history of the vehicle for previous repairs that could help diagnose the current concern.
Now that the technician understands the customer concern, they should validate the concern on the
vehicle. In order to verify the concern, the technician should be familiar with the normal operation of the
system and refer to the owner or service manual for any information needed. Inspect the visible system
components for obvious damage or conditions that could cause the concern. Conduct a thorough visual
inspection. Detect unusual sounds or odors.
The condition described by the customer may be normal. If the technician finds the vehicle to operate
normally, compare with another like vehicle that is operating normally, under the same conditions
described by the customer. If this is the case, explain your findings and the operation of the system to the
customer. If the customer is dissatisfied, submit a Field Product Report.

2. BULLETIN SEARCH-By searching for related bulletins, recall/field actions and preliminary information
documents, a procedure for a known field issue may resolve the customer concern with little or no
diagnosis necessary saving the technician diagnostic time.
3. MECHANICAL CONCERNS-This step is designed to take the technician directly to a list of symptom
diagnostic procedures. The technician is asked to verify the symptoms exhibited by the system are
mechanical in nature and not related to an electrical system, see some examples below. If the technician
feels the concern could be related to an electrical system, they should continue through the Diagnostic
System Check to verify the electrical functionality of vehicle. If the technician feels the concern is
exclusively related to a mechanical system, a link to Symptoms - Vehicle is provided to select the
appropriate symptom diagnostic procedure for the customer concern.
Examples:
Brake noise or diagnosing irregular pad wear
Water leak diagnosis
Engine or transmission fluid leak diagnosis
Manual window or door lock diagnosis
Vehicle vibration diagnosis
Exhaust noise or leak diagnosis
4. VEHICLE POWER UP VERIFICATION-The technician is asked in this step to turn the ignition key ON
and verify that the vehicle powers up. The technician should look for clues that multiple vehicle systems
are receiving vehicle powermode messages, such as the cluster waking up, the radio powers on, the
HVAC blower is operational, windshield wipers turn on, etc, with the key ON. This would be a rare
condition as both the powermode master and back-up powermode master would have to be inoperable,
however, if the vehicle does not power up, a link to Power Mode Mismatch is provided.
5. CONTROL MODULE COMMUNICATION and DTC CHECK-The technician is asked in this step to
record the following three pieces of data on the Repair Order; any control module that the scan tool
determined is not communicating, any DTC and symptom byte set current or history, and the control
module that has set the DTC.
This is considered a setup step for the rest of the Diagnostic System Check. The technician is not
expected to do anything other than record the three pieces of data provided by the scan tool on the Repair
Order. This provides the information needed to complete the rest of the diagnostic system check.
To complete this step, the technician is asked to utilize the scan tool Vehicle DTC Information function.
This function will query every possible control module on the vehicle requesting all DTCs. During the
DTC query, the scan tool will try to establish communication with each control module. If the scan tool
can communicate with the control module during the DTC request, it will display PRESENT and provide
the number of DTCs set in the control module. If the scan tool cannot communicate with a control
module, it will only display NOT COMMUNICATING. Since the scan tool cannot determine if a given
control module should be present or not, the technician is asked in a future step to verify that the vehicle
was not built with control modules listed as NOT COMMUNICATING.
If the scan tool cannot establish communications with ALL of the vehicles control modules, a link to
Data Link References is provided. A faulty control module or fault with the serial data circuit can cause

no communication with all of the control modules on the vehicle. If any control module communicates on
the serial data circuit, continue through the Diagnostic System check, as a future step will address any
specific non communicating or group of non communicating control modules.
Once the scan tool has completed the routine, the technician should review each control module that has
set a DTC and document them on the Repair Order. When reviewing the DTCs, the technician should
take notice if any DTCs are powertrain related, and if so, navigate in the scan tool to the Powertrain area
and utilize the Capture Info function. This will upload any Freeze Frame/Failure Records stored in the
control module to the scan tool in case the data is lost from the control module. As an example, if the
technician commands a Clear DTCs function on a powertrain controller, all diagnostic information stored
in the controller is erased. This includes Freeze Frame/Failure Records and Inspection/Maintenance
System Status indicators, if required for your region.
6. CONTROL MODULE INTERNAL PERFORMANCE FAULTS-The technician is asked to review the
DTCs recorded in step 5 and verify there are no control module internal performance faults set current.
This type of fault may be the cause of other symptoms or DTCs displayed by the vehicle. By addressing
this fault first, the technician may find the other concerns are resolved. The technician should always
follow the diagnostic procedure for these types of faults prior to replacing any control module. If the
technician finds a control module has an internal performance fault, a link is provided to Diagnostic
Trouble Code (DTC) List - Vehicle to select the appropriate DTC diagnostic procedure.
Examples:
B1000 Electronic Control Unit Performance
B101D ECU Hardware Performance
C0550 Electronic Control Unit Performance
C056D ECU Hardware Performance
C0570 Auxiliary Electronic Control Unit Performance
P0606 Control Module Internal Performance
P0607 Control Module Performance
7. CONTROL MODULE COMMUNICATION VERIFICATION-This step is used to ensure the control
modules that are NOT COMMUNICATING were not built on the vehicle. To understand if the vehicle
was built with that option, we provide a link to the Data Link References , document where Regular
Production Options (RPOs) are listed next to the names of optional ECU's and can be compared to those
the vehicle was built with. If the technician determines that a control that is NOT COMMUNICATING
should be present, the technician is asked to follow the appropriate diagnostic procedure listed in the
Data Link References document.
8. COMMUNICATION and POWERMODE FAULTS-This step is asking the technician to look for
communication DTCs or DTCs related to control modules powering up based on power mode,
communication enable or wake-up circuits. See in the below table some examples of the DTCs the
technician should diagnose prior to continuing through the Diagnostic System Check. The technician
should review the list of DTCs recorded in step 4 and verify that none of these type of DTCs are present.
If so, the technician is referred to the Diagnostic Trouble Code (DTC) List - Vehicle to select the
appropriate DTC diagnostic procedure.
Examples:

U0140 Lost Communication With Body Control Module

U0164 Lost Communication With HVAC Control Module
U0170 Lost Communication With Passenger Presence Detection Module
U0402 Invalid Data Received From Transmission Control Module
U0452 Invalid Data Received From Inflatable Restraint Sensing and Diagnostic Module
U1814 Powertrain High Speed Communication Enable Circuit
B1428 Ignition Switched Power Run/Crank Relay Circuit
B137B Accessory Power Module Wake Up Circuit
C0897 Control Module Power Moding
P2536 Ignition Accessory Switch Circuit
9. POWER MODE VERIFICATION-This step verifies the Power Mode Master is receiving the proper
output state of the ignition switch. The technician should use the main power mode input, this being
either the ignition key or, on vehicles equipped with Passive Entry Passive Start, the push button switch.
The test should not be performed using a key fob, if the MIL is illuminated the powertrain controller may
disable this input. The technician is asked to perform the test with the driver door open. This ensures the
retained accessory power mode is inactive during this test which could result in different scan tool
readings. The technician is only asked to verify the current Power Mode parameter in the power mode
data display list. If the parameter does not match the actual ignition switch position, a link is provided to
perform the Power Mode Mismatch diagnostic procedure.
10. ENGINE CRANK and RUN VERIFICATION-Here the technician is asked to verify that the engine
cranks and runs. The technician should use the main power mode input, this being either the ignition key
or, on vehicles equipped with Passive Entry Passive Start, the push button switch, to complete this step.
The test should not be performed using a key fob, if the MIL is illuminated the powertrain controller may
disable this input. The technician should know at this point whether the engine cranks and runs without
having to actually performing this test step. One of the follow has probably already occurred and this step
can be skipped: The technician drove the vehicle into the stall or verified when checking the Crank and
Run parameter in step 8. If the technician has not already somehow verified the engine cranks in previous
steps, the technician should perform this test step. Regardless of how this step was performed, if the
engine does not crank, a link is provided to Engine Does Not Crank, or if the engine cranks but does not
run, a link is provided to Engine Cranks But Does Not Run for the technician to choose the correct
diagnostic procedure for the actual engine application being used.
11. REMAINING DTC REVIEW-Here the technician is asked to review any remaining DTCs that were not
addressed in previous steps. The technician is asked first to verify there are no control module supply
voltage, system voltage or 5V circuit DTCs present. Control modules, systems or components with
insufficient or zero voltage can cause one or multiple symptoms to exist on the vehicle. Control module
voltage issues could also be the cause of failures during a programming event. The technician should
correct voltage issues prior to addressing any programming or configuration DTCs. The technician should
then check for any ECU programming, setup or configuration DTCs. By programming software or
configuring a control module, the technician could correct the customer concern unobtrusively. The
remaining DTCs, which are usually specific system or component faults, are diagnosed last. They can
include ECU input and output circuit DTCs or individual circuit faults that usually cause single symptoms
or failure modes on the vehicle and can be fixed following the proper DTC diagnostic procedure. In
general, the technician should think about what DTCs or faults could be caused by another DTC or fault.
A failed sensor may set a component DTC and then the system may set a DTC indicating the system
cannot operate properly. By correcting the sensor fault, the system may now operate properly and the

system level DTC will transition to history. Refer to the examples within each category below to
understand the differences between these DTCs. If DTCs of these type are current, the technician is
referred to Diagnostic Trouble Code (DTC) List - Vehicle to choose the correct DTC diagnostic
procedure.
1. Voltage DTCs
B1325 Device Power 1 Circuit
C0875 Device Voltage Reference Input 2 Circuit
C1001 Adaptive Cruise Control Indicators Supply Voltage Circuit
P0641 5-Volt Reference Circuit
P0787 Downshift Timing Solenoid Control Circuit Low Voltage
2. Programming, Setup, Configuration or Software Performance DTCs
B3943 Steering Column Lock has Not Learned Column Integration Module
B101E ECU Software Performance
B1019 System Configuration Error
C0558 Calibration Data Not Programmed
P0630 VIN Not Programmed or Mismatched - Powertrain Control Module (PCM)
3. Component related DTCs
B0013 Driver Frontal Deployment Loop Stage 2
B0163 Passenger Compartment Temp Sensor Circuit
C0045 Left Rear Wheel Speed Sensor Circuit
P0565 Cruise Control Switch Circuit
P0751 1-2 Shift Solenoid (SS) Valve Performance
4. System related DTCs
B1010 System Sensors Data Mismatch
C0176 System Thermal Error
C0561 System Disabled Information Stored
P1564 Vehicle Acceleration Too High - Cruise Control Disabled
P1625 Transmission Control Module (TCM) System Reset
5. Any other remaining DTCs-The technician should diagnose and correct any other DTCs that are
left that were not from the categories above.
12. EMISSION RELATED INSPECTION/MAINTENANCE TESTING CONCERNS-Several regions
require that a vehicle pass on-board diagnostic system tests and the inspection/maintenance emission tests
in order to renew license plates or vehicle registration. This is accomplished by viewing the
Inspection/Maintenance System Status display on a scan tool. Using a scan tool, the technician can
observe the Inspection/Maintenance System Status in order to verify that the vehicle meets the criteria
that comply with the local area requirements. If inspection and maintenance checks are required in your
region, and the customer concern is related to not passing an Inspection/Maintenance test, a link is
provided to Inspection/Maintenance System Check where the technician can choose the appropriate
Inspection/Maintenance System Check for the actual engine application being used.
13. SYMPTOM DIAGNOSIS-At this step, the diagnostics are assuming that the only information the
technician has available to diagnose the customer concern are symptoms of a problem. There are no

DTCs set current or history. There may be a Driver Information Center display message or a system
indicator to aid in identifying the root cause. The technician should evaluate the symptoms and conditions
described by the customer and perform the symptoms diagnostics for the area of customer concern. A link
is provided to Symptoms - Vehicle which contains a list of all symptoms related to this service manual
publication.
DIAGNOSTIC STARTING POINT - VEHICLE
Begin the system diagnosis with Diagnostic System Check - Vehicle. The Diagnostic System Check - Vehicle
will provide a complete strategy to locate and repair a mechanical or electrical vehicle fault. Not following this
strategy may cause additional diagnostic time and/or misdiagnosis.
The Diagnostic System Check - Vehicle will provide the following strategy:
When to verify the customer concern and identify related bulletins, recalls and preliminary information
When to identify a control module that is not communicating, a control module that has set a DTC, and
the DTC diagnostic priority
When to address power mode concerns
When to verify the engine cranks and runs
When to diagnose symptom related concerns
DIAGNOSTIC SYSTEM CHECK - VEHICLE

Review Strategy Based Diagnosis for an overview of the diagnostic approach.

Diagnostic System Check Instructions provides an overview of each diagnostic step.
Continue through the Diagnostic System Check until you are directed to follow a particular diagnostic or
repair procedure. Once a repair has been completed, perform the Diagnostic Repair Verification and
verify the customer concern has been corrected.
The diagnostic procedures within this manual are developed on the assumption that the following areas function
as designed:
The 12 V battery is fully charged and cables are clean and tight. Refer to Battery Inspection/Test .
Fuses are not open. Refer to Power Distribution Schematics , and Electrical Center Identification
Views .
Ground circuits for the area of customer concern are clean, tight, and in the correct location. Refer to
Ground Distribution Schematics , and Harness Routing Views .
All connections/connectors for the area of concern are fully seated. Refer to COMPONENT
CONNECTOR END VIEWS - INDEX .
There are no aftermarket devices that affect the operation of the system. Refer to Checking Aftermarket
Accessories .
The scan tool powers up. Refer to Scan Tool Does Not Power Up .

Diagnostic System Check
1. VERIFY CUSTOMER CONCERN-Understand and validate the customer concern. Inspect the visible
system components for obvious damage or conditions that may cause the concern.
2. BULLETIN SEARCH-Check for related bulletins, recall/field actions and preliminary information.
3. MECHANICAL CONCERNS-Verify the symptom is not exclusively a mechanical concern.
If the symptom is exclusively a mechanical concern
Refer to Symptoms - Vehicle.
If the symptom is not a mechanical concern
NOTE:
Do not clear any DTCs unless instructed to do so by a diagnostic

procedure. If any DTC is Powertrain related, select Capture Info to store
DTC and Freeze Frame/Failure Records to the scan tool.
4. VEHICLE POWER UP VERIFICATION-Ignition ON, verify the vehicle powers up.

If the vehicle does not power up
Refer to Power Mode Mismatch .
If the vehicle powers up
5. CONTROL MODULE COMMUNICATION and DTC CHECK-Using a scan tool, perform the Vehicle
DTC Information function and verify at least one control module communicates with the scan tool.
Record on the Repair Order the following information:
Any control module that is not communicating.
Any DTC, including symptom byte, and the control module that has set the DTC.
If the scan tool does not communicate with any control module on the vehicle
Refer to Data Link References .

If the scan tool communicates with any control module
6. CONTROL MODULE INTERNAL PERFORMANCE FAULTS-Verify there are no current control
module Internal Hardware Performance DTCs set.
If any DTC of this type is set
Refer to Diagnostic Trouble Code (DTC) List - Vehicle.

If no DTC of this type is set
7. CONTROL MODULE COMMUNICATION VERIFICATION-Verify the vehicle is not built with any
control module listed as not communicating with the scan tool, refer to Data Link References .
If the vehicle is built with a control module that is not communicating
Refer to Data Link References .

If all control modules the vehicle is built with are communicating

8. COMMUNICATION and POWERMODE FAULTS-Verify there are no current control module Power
Mode or Communication DTCs set.
If any DTC of this type is set
Refer to Diagnostic Trouble Code (DTC) List - Vehicle.
If no DTC of this type is set
NOTE:
The engine may start during this test. Ensure the vehicle is out of gear and
the parking brake is applied. Turn the engine OFF as soon as the crank
power mode parameter has been observed.
9. POWER MODE VERIFICATION-Driver door open, observe the scan tool Power Mode parameter while
cycling the ignition switch through all the power modes. Verify the current Power Mode parameter
matches the actual ignition switch positions.
If the Power Mode parameter does not match the actual ignition switch positions
If the Power Mode parameter matches the actual ignition switch positions
10. ENGINE CRANK and RUN VERIFICATION-Verify that the engine cranks and runs.
If the engine does not crank
Refer to Engine Does Not Crank.
If the engine does not run

Refer to Engine Cranks But Does Not Run.
If the engine cranks and runs

11. REMAINING DTC REVIEW-Verify there are no other DTCs set.
If other DTCs are set
Diagnose them in the order listed below. Refer to Diagnostic Trouble Code (DTC) List - Vehicle.
1.
2.
3.
4.
5.
Voltage DTCs
Programming, Setup, Configuration or Software Performance DTCs
Component related DTCs
System related DTCs
Any remaining DTCs
If no other DTCs are set
12. EMISSION RELATED INSPECTION/MAINTENANCE TESTING CONCERNS-If inspection and

maintenance checks are required in your region, verify the customer concern is not related to
inspection/maintenance testing.
If the customer concern is related to inspection/maintenance testing
Refer to Inspection/Maintenance System Check.
If the customer concern is not related to inspection/maintenance testing
13. SYMPTOM DIAGNOSIS-Diagnose any remaining customer concern. Refer to Symptoms - Vehicle.
POWERTRAIN DIAGNOSTIC TROUBLE CODE (DTC) TYPE DEFINITIONS

Emissions Related DTCs
Action Taken When the DTC Sets - Type A
The control module illuminates the malfunction indicator lamp (MIL) when the diagnostic runs and fails.
The control module records the operating conditions at the time the diagnostic fails. The control module
stores this information in the Freeze Frame/Failure Records.
Action Taken When the DTC Sets - Type B
The control module illuminates the MIL on the second consecutive ignition cycle that the diagnostic runs
and fails.
The control 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
reports a failure on the second consecutive ignition cycle, the control module records the operating
conditions at the time of the failure. The control module writes the operating conditions to the Freeze
Frame and updates the Failure Records.
The following applies to misfire DTCs:
If the control module detects a low level or an emission level misfire condition during 2
consecutive trips, the control module illuminates the MIL.
If the control module detects a high level or catalyst damaging misfire, the control module flashes
the MIL at a rate of once per second.
If the control module detects a misfire during 2 non-consecutive trips, the stored conditions are
compared with the current conditions. The control module illuminates the MIL when the following
conditions occur:
The engine load is within 20 percent of the previous test that failed.
The engine speed is within 375 RPM of the previous test that failed.
The engine coolant temperature is in the same range of the previous test that failed.
The following applies to fuel trim DTCs:
If the control module detects a fuel trim condition during 2 consecutive trips, the control module
illuminates the MIL.
If the control module detects a fuel trim condition during 2 non-consecutive trips, the stored

conditions are compared with the current conditions. The control module illuminates the MIL when
the following conditions occur:
The engine load is within 20 percent of the previous test that failed.
The engine speed is within 375 RPM of the previous test that failed.
The engine coolant temperature is in the same range of the previous test that failed.
Conditions for Clearing the MIL/DTC - Type A or Type B
The control module turns OFF the MIL after 4 consecutive ignition cycles that the diagnostic runs and
does not fail.
A current DTC, Last Test Failed, clears when the diagnostic runs and passes.
A history DTC clears after 40 consecutive warm-up cycles, if no failures are reported by this or any other
emission related diagnostic.
Clear the MIL and the DTC with a scan tool.
Non-Emissions Related DTCs
Action Taken When the DTC Sets - Type C
The control module stores the DTC information into memory when the diagnostic runs and fails.
The MIL will not illuminate.
The control module records the operating conditions at the time the diagnostic fails. The control module
stores this information in the Failure Records.
The driver information center, if equipped, may display a message.
Conditions for Clearing the DTC - Type C
A current DTC Last Test Failed clears when the diagnostic runs and passes.
A history DTC clears after 40 consecutive warm-up cycles, if no failures are reported by this or any other
non-emission related diagnostic.
Clear the DTC with a scan tool.
DIAGNOSTIC CODE INDEX

DTC
Diagnostic Trouble Code (DTC) List - Vehicle
Description
DIAGNOSTIC TROUBLE CODE (DTC) LIST - VEHICLE

This master DTC list includes all applicable DTCs in alphanumeric order.
DTC
Diagnostic Procedure

B0012
B0013
B0014
B0015
B0016
B0017
B0018
B0019
B001A
B001B
B0020
B0021
B0022
B0023
B0024
B0025
B0031
B0038
B0052
B0074
B0081
B0083
B0084
B0085
B0086
B0087
B0088
B0158
B0163
B0173
B0178
B0183
B018A
B0193
B0223
B0233
B023A
B0283
B0408
DTC B0012 or B0013

DTC B0014, B0021, B0031, or B0038
DTC B0015, B001A, B001B, or B0022
DTC B0016, B0018, B0023, or B0025
DTC B0017 or B0024
DTC B0016, B0018, B0023, or B0025
DTC B0019 or B0020
DTC B0015, B001A, B001B, or B0022
DTC B0019 or B0020
DTC B0014, B0021, B0031, or B0038
DTC B0015, B001A, B001B, or B0022
DTC B0016, B0018, B0023, or B0025
DTC B0017 or B0024
DTC B0016, B0018, B0023, or B0025
DTC B0014, B0021, B0031, or B0038
DTC B0052
DTC B0074
DTC B0081 (Passenger Presence Module) , DTC B0081 (Inflatable Restraint
Sensing and Diagnostic Module)
DTC B0083 or B0084
DTC B0085 or B0088
DTC B0086 or B0087
DTC B0085 or B0088
DTC B0158
DTC B0163
DTC B0173, B0178, or B3933
DTC B0183
DTC B018A, B048C, B048F, or B1395
HVAC Control Module - Automatic - DTC B0193
or
HVAC Control Module - Manual - DTC B0193
HVAC Control Module - Automatic - DTC B0223, B0233, B023A, or B0408
or
HVAC Control Module - Manual - DTC B0223, B0233, B023A, or B0408
DTC B0283
HVAC Control Module - Automatic - DTC B0223, B0233, B023A, or B0408
or

HVAC Control Module - Manual - DTC B0223, B0233, B023A, or B0408

B048C
B048F
B0550
B067F
B0680
B0958
B0959
B0960
B0961
B096A
B1000
B1001
B1015
B1019
B101D
B101E
B1020
B1025
B1035
B1045
B1055
B125A
B125C
B1271
B1278
B1279
B1325
B1330
DTC B018A, B048C, B048F, or B1395

DTC B0550
DTC B067F or B0680
DTC B0958, B0959, B0960, or B0961

DTC B096A
DTC B1000
All Modules - Data Communications - DTC B1001
or
SDM - DTC B1001 (Passenger Presence System) , DTC B1001 (Inflatable
Restraint Sensing and Diagnostic Module)
DTC B1015
DTC B1019
DTC B101D
DTC B101E
DTC B1020
DTC B1025, B1035, B1045, or B1055
DTC B125A
DTC B125C
DTC B1271
DTC B1278 or B1279
DTC B1325, B1330, B1517, C0800, P0560, P0562, or P0563
B1370
Displays and Gages - DTC B1370

or
Wiring Systems and Power Management - DTC B1370-B1379, B1380-B1389, or
B1440-B1443
B1371
B1372
B1373
B1374
DTC B1370-B1379, B1380-B1389, or B1440-B1443
B1375
B1376
B1377
B1378
DTC B1370-B1379, B1380-B1389, or B1440-B1443

B1379
B1380
B1381
B1382
B1383
B1384
B1385
B1386
B1387
B1388
B1389
B1395
B1405
B1440
B1441
B1442
B1443
B1448
B144B
B1451
B147E
B147F
B1516
B1517
B151A
B1527
B1529
B1925
B2170
B2345
B2425
B242A
B2430
B2455
B2462
B2470
B2476
B2482
B2530
B2545
DTC B1370-B1379, B1380-B1389, or B1440-B1443
DTC B1370-B1379, B1380-B1389, or B1440-B1443
BCM - DTC B1395

or
HVAC Control Module - Automatic - DTC B018A, B048C, B048F, or B1395
BCM - DTC B1405
or
Object Alarm Module - DTC B1405
DTC B1370-B1379, B1380-B1389, or B1440-B1443
DTC B1448
DTC B144B
DTC B1451
DTC B1516
DTC B1325, B1330, B1517, C0800, P0560, P0562, or P0563
DTC B151A
DTC B1527
DTC B1529
DTC B1925 or B2170
DTC B2345
DTC B2425 or B2430
DTC B242A
DTC B2425 or B2430
DTC B2455
DTC B2462
DTC B2470
DTC B2476 or B2482
DTC B2530
DTC B2545

B2575
B257A
B257B
B2585
B2645
B2699
B270A
B2745
B2750
B2955
B3006
B302A
B3031
B3055
B305C
B3060
B3101
B3105
B3106
B3109
B3110
B310D
B310E
B310F
B3111
B3112
B3113
B3119
B3120
B3121
B3122
B3123
B3124
B3125
B3130
B3135
B3140
B3150
B316B
B317A
B318A
B319A
B3205
DTC B2575 or B2699

DTC B257A
DTC B257B
DTC B2585 or B3867
DTC B2645
DTC B2575 or B2699
DTC B270A
DTC B2745
DTC B2750
DTC B2955 (with BTM) , DTC B2955 (without BTM)
DTC B3006
DTC B302A
DTC B3031
DTC B3055
DTC B305C
DTC B3060
DTC B3101
DTC B3105
DTC B3106
DTC B3109-B3113
DTC B310D-B310F
DTC B3109-B3113
DTC B3119
DTC B3120
DTC B3121
DTC B3122
DTC B3123
DTC B3124
DTC B3125, B3130, or B3135
DTC B3140 or B3150
DTC B316B, B317A, B318A, or B319A (AEC) , DTC B316B, B317A, B318A,
or B319A (AXG)
DTC B3205

B3265
B3567
B3596
B3600
B3618
B3622
B3650
B3697
B3715
B3794
B3806
B3843
B3867
B3873
B3875
B3883
B389A
B3902
B3930
B3933
B3935
B3948
B3949
B3950
B3951
B3976
B3984
C0035
C0040
C0045
C0050
C0110
C0131
C0161
C0176
C0186
C018B
C0196
C019B
C0267
DTC B3265
DTC B3567
DTC B3596
DTC B3600
DTC B3618
DTC B3622
DTC B3650
DTC B3697
DTC B3715 or B3875
Cruise Control Malfunction - DTC B3794, P0564, P0565, P0567, P0568,
P056C, P0580, P0581, P155A-P155C, or P162C
DTC B3806
DTC B3843
DTC B2585 or B3867
DTC B3873
DTC B3715 or B3875
DTC B3883
DTC B389A
DTC B3902
DTC B3930
HVAC Control Module - Manual - DTC B3933
or
HVAC Control Module - Automatic - DTC B0173, B0178, or B3933
DTC B3935
DTC B3948 or B3949
DTC B3950 or B3951
DTC B3976
DTC B3984
DTC C0035, C0040, C0045, or C0050
DTC C0110
DTC C0131
DTC C0161
DTC C0176
DTC C0186, C018B, C0196, C019B, or C0287
DTC C0267

C0277
C0280
C0287
C0475
C047A
C0545
C0565
C0569
C056D
C056E
C0710
C0750
C0755
C0760
C0765
C0775
C1207
C1208
C1209
C1210
C1221
C1222
C1223
C1224
C1225
C1226
C1227
C1228
C1232
C1233
C1234
C1235
C0800
C0890
P0010
P0011
P0013
P0014
DTC C0277 or C0890

DTC C0280
DTC C0186, C018B, C0196, C019B, or C0287
DTC C0475 (NJ1)
DTC C047A (NJ1)
DTC C0545 (NJ1)
DTC C0565 (NJ1)
Power Steering Control Module - DTC C0569 (NJ1)
or
Tire Pressure Monitoring - DTC C0569
DTC C056D
DTC C056E
DTC C0710
DTC C0750, C0755, C0760, or C0765
DTC C0775
DTC C1207-C1210, C1221-C1228, or C1232-C1235
DTC C1207-C1210, C1221-C1228, or C1232-C1235
DTC C1207-C1210, C1221-C1228, or C1232-C1235
DTC B1325, B1330, B1517, C0800, P0560, P0562, or P0563

DTC C0277 or C0890
DTC P0010, P0013, or P2088-P2091
or
DTC P0010, P0013, or P2088-P2091
DTC P0011 or P0014
DTC P0010, P0013, or P2088-P2091
or
DTC P0010, P0013, or P2088-P2091
DTC P0011 or P0014

P0016
P0017
P0030
P0031
P0032
P0033
P0034
P0035
P0036
P0037
P0038
P0053
P0054
P0053
P0054
P0068
P0096
P0097
P0098
P00B3
P00B4
P00B6
P00B7
P00C7
P00E9
P00EA
P00EB
ECM - 1.2L (L2Q LDC LWD) or 1.4L (L2I L2N L2Z LDD LUH LUJ LUV)
engine - DTC P0016 or P0017
or
ECM - 1.6L (LDE LED LFJ LGE LLU LXV) or 1.8L (2H0 LFH LUW LWE)
engine - DTC P0030-P0032, P0036-P0038, P0053, P0054, P0135, or P0141
or
DTC P0033-P0035
or
or
DTC P0030-P0032, P0036-P0038, P0053, P0054, P0135, or P0141
or
or
DTC P0097 or P0098
DTC P00B3 or P00B4
DTC P00B6
DTC P00B7
DTC P00C7
DTC P00E9
DTC P00EA or P00EB

P0101
P0102
P0103
P0106
P0107
P0108
P0111
P0112
P0113
P0114
P0116
P0117
P0118
P0119
P0121
P0122
P0123
engine - DTC P0101
or
engine - DTC P0101
or
engine - DTC P0106
or
engine - DTC P0106
or
or
engine - DTC P0112, P0113, or P0114
or
engine - DTC P0116
or
engine - DTC P0116 (LUW)
or
engine - DTC P0121-P0123, P0222, P0223, or P2135 (LUV)
or
engine - DTC P0121-P0123, P0222, P0223, or P2135

P0128
P0131
P0132
P0133
P0134
P0135
P0137
P0138
P013A
P013B
P013E
P013F
P0140
P0141
engine - DTC P0128

or
engine - DTC P0128
engine - DTC P0131, P0132, P0134, P0137, P0138, or P0140
or
engine - DTC P0133, P013A, P013B, P013E, P013F, P015A, P015B, P2270, or
P2271
or
P2271
or
or
or
P2271
or
P2271
or
or

P015A
P015B
P0171
P0172
P018B
P018C
P018D
P0201
P0202
P0203
P0204
P0222
P0223
P0231
P0232
P0234
P0236
P0237
P0238

P2271
or
P2271
or
engine - DTC P018B-P018D
or
engine - DTC P018B-P018D
engine - DTC P0201, P0202, P0203, P0204, P0261, P0262, P0264, P0265,
P0267, P0268, P0270, or P0271
or
P0267, P0268, P0270, or P0271
or
engine - DTC P0231, P0232, or P023F
or
DTC P0234 or P0299
DTC P0236
DTC P0237 or P0238
P023F
or
P0243
P0245
DTC P0243, P0245, or P0246

P0246
P025A
P0261
P0262
P0264
P0265
P0267
P0268
P0270
P0271
P0299
P0300
P0301
P0302
P0303
P0304
P0313
P0315
P0324
P0325
engine - DTC P025A
or
engine - DTC P025A
P0267, P0268, P0270, or P0271
or
P0267, P0268, P0270, or P0271
P0267, P0268, P0270, or P0271
or
P0267, P0268, P0270, or P0271
DTC P0234 or P0299
engine or
engine - DTC P0300-P0304 or P0313
DTC P0300-P0304 or P0313
DTC P0300-P0304 or P0313
engine - DTC P0315
or
engine - DTC P0315 (LUW)
engine - DTC P0324, P0326, or P06B6
or
or

P0326
P0327
P0328
P0335
P0336
P0340
P0341
P0351
P0352
P0353
P0354
P0365
P0366
P0411
P0412
P0418
P0420
P0442
P0443
or
or
or
engine - DTC P0340, P0341, P0365, or P0366
or
engine - DTC P0351-P0354
or
or
DTC P0411
DTC P0412 or P0418
engine - DTC P0420
or
engine - DTC P0420
engine - DTC P0442
or
engine - DTC P0442
engine - DTC P0443
or

P0446
P0449
P0451
P0452
P0453
P0454
P0455
engine - DTC P0443
engine - DTC P0446
or
engine - DTC P0446
engine - DTC P0449
or
engine - DTC P0449
or
engine - DTC P0455
or
engine - DTC P0455
P0461
P0462
P0463
P0464
DTC P0461-P0464
P0496
engine - DTC P0496
or
engine - DTC P0496
P0502
P0503
DTC P0502 or P0503
P0506
P0507
P0513
P0520
P0521
P0530
P0532
P0533
P0560
P0562
or
DTC P0513
DTC P0520
DTC P0521
DTC P0530, P0532, or P0533
DTC B1325, B1330, B1517, C0800, P0560, P0562, or P0563

P0563
P0564
P0565
P0567
P0568
P056C
P057C
P057D
P0580
P0581
P0597
P0598
P0599
DTC B1325, B1330, B1517, C0800, P0560, P0562, or P0563

P056C, P0580, P0581, P155A-P155C, or P162C
DTC P057C or P057D

P056C, P0580, P0581, P155A-P155C, or P162C
DTC P0597-P0599
P0601
P0602
ECM - 1.2L (L2Q LDC LWD) or 1.4L (L2I L2N L2Z LDD LUH LUJ
LUV) engine - DTC P0601-P0604, P0606, P062B, P062F, P0630, P16F3,
or P262B (ECM)
ECM - 1.6L (LDE LED LFJ LGE LLU LXV) or 1.8L (2H0 LFH LUW
LWE) engine - DTC P0601-P0604, P0606, P062B, P062F, P0630, P16F3,
or P262B (ECM)
Fuel Pump Control Module - 1.2L (L2Q LDC LWD) or 1.4L (L2I L2N L2Z
LDD LUH LUJ LUV) engine - DTC P0601-P0604, P0606, or P062F (Fuel
Pump Control Module)
Fuel Pump Control Module - 1.6L (LDE LED LFJ LGE LLU LXV) or 1.8L
(2H0 LFH LUW LWE) engine - DTC P0601-P0604, P0606, or P062F
(Fuel Pump Control Module)
All Modules - Data Communications - DTC P0601-P0604, P0606, or
P062F
TCM - Automatic Transmission 6T30/6T40/6T45/6T50 - DTC P0601,
P0603, P0604, or P062F
or P262B (ECM)
or P262B (ECM)
P062F

P0603
P0604
P0606
P0615
P0616
P0617
P0621
P0622
P0627
P0628
P0629
or P262B (ECM)
or P262B (ECM)
P062F
P0603, P0604, or P062F
or P262B (ECM)
or P262B (ECM)
P062F
DTC P0615, P0616, or P0617

DTC P0621
DTC P0622
or
or P262B (ECM)

or P262B (ECM)
P062F
P0603, P0604, or P062F
engine - DTC P0601-P0604, P0606, P062B, P062F, P0630, P16F3, or P262B
(ECM)
or
(ECM)
DTC P0633
DTC P0634
P062F
P0630
P0633
P0634
LUV) engine - DTC P0641, P0651, P0697, or P06A3 (ECM)
LWE) engine - DTC P0641, P0651, P0697, or P06A3 (ECM)
LDD LUH LUJ LUV) engine - DTC P0641 or P06A6 (Fuel Pump
Control Module)
(2H0 LFH LUW LWE) engine - DTC P0641 or P06A6 (Fuel Pump
Control Module)
HVAC Control Module - Automatic - DTC P0645, P0646, or P0647
or
HVAC Control Module - Manual - DTC P0645, P0646, or P0647
engine - DTC P1255 or P064A
or
P0641
P0645
P0646
P0647
P064A
P0650
engine - DTC P0650
or

P0651
P0658
P0659
P0660
P0661
P0662
P0667
P0668
P0669
P0685
P0686
P0687
P0689
P0690
P0697
P069E
P06A3
P06A6
engine - DTC P0650, P263A, or P263B

engine - DTC P0641, P0651, P0697, or P06A3 (ECM)
or
DTC P0658 or P0659
DTC P0660, P0661, or P0662
DTC P0667, P0668, or P0669

or
or
engine - DTC P069E
or
engine - DTC P069E
or
engine - DTC P0641 or P06A6 (Fuel Pump Control Module)
or
engine - DTC P0641 or P06A6 (Fuel Pump Control Module)
P06AC
P06AD
P06AE
DTC P06AC, P06AD, or P06AE
P06B6
or

P0700
P0703
P0711
P0712
P0713
P0716
P0717
P071D
P0722
P0723
P0741
P0742
P0751
P0752
P0776
P0777
P077C
P077D
P0796
P0797
P07BF
P07C0
P0806
P0807
P0808
P080A
P0815
P0816
P0826
P0850
P0851
P0852
P0856
P0961
P0962
P0963
P0965
P0966
P0967
P0969

engine - DTC P0700
or
engine - DTC P0700
DTC P0703
DTC P0711-P0713
DTC P0716, P0717, P07BF, or P07C0
DTC P071D
DTC P0722, P0723, P077C, or P077D
DTC P0741 or P0742 (Gen 2 with 1.4L (LUV) 1.8L (LUW, LWE))
DTC P0722, P0723, P077C, or P077D
DTC P0716, P0717, P07BF, or P07C0
DTC P0806-P0808
DTC P080A
DTC P0815, P0816, or P0826
DTC P0850-P0852
DTC P0856
DTC P0961-P0963
DTC P0965-P0967

P0970
P0971
P0973
P0974
DTC P0969-P0971
DTC P0973 or P0974
P1101
or
P11C2
P11C3
DTC P11C2 or P11C3
P1255
P1400
P150C
P1516
P155A
P155B
P155C
P162B
P162C
P1631
P1649
P1682
or
engine - DTC P1400
or
engine - DTC P1400
engine - DTC P150C
or
engine - DTC P150C
or
P056C, P0580, P0581, P155A-P155C, or P162C
DTC P162B
P056C, P0580, P0581, P155A-P155C, or P162C
DTC P1631
DTC P1649
or

P16F3
P1761
P182E
P1876
P1915
P2070
P2071
P2076
P2077
P2078
P2088
P2089
P2090
P2091
P2096
P2097
P2101
P2119
P2122
P2123
P2127
P2128
P2135
(ECM)
or
(ECM)
DTC P1761
DTC P182E or P1915
DTC P1876
DTC P182E or P1915
DTC P2070 or P2071
DTC P2076
DTC P2077 or P2078
DTC P0010, P0013, or P2088-P2091
or
DTC P0010, P0013, or P2088-P2091
engine - DTC P2096
or
engine - DTC P2096
engine - DTC P2097
or
engine - DTC P2097
or
or
engine - DTC P2122, P2123, P2127, P2128, or P2138
or
or

P2138
P2176
P2199
P2227
P2228
P2229
P2230
P2261
P2270
P2271
P2430
P2431
P2432
P2433
P2440
P2444
P2534
P2544
P2610
or
or
DTC P2199
DTC P2227-P2230
DTC P2261
P2271
or
P2271
DTC P2430 or P2431
DTC P2432 or P2433
DTC P2440
DTC P2444
engine - DTC P2534 (Fuel Pump Control Module)
or
DTC P2544
(ECM)
or
(ECM)

P2635
P263A
P263B
P2714
P2715
P2719
P2720
P2721
P2723
P2724
P2728
P2729
P2730
P2762
P2763
P2764
U0001
U0020
U0073
U0074
U0078
U0100-U02FF
U0301
U0302
U0315
U0400-U05FF
U1500-U15BF
U1814
U18B9
U18BF
U2099
U2100
or
DTC P0650, P263A, or P263B
DTC P2719-P2721
DTC P2728-P2730
DTC P2762, P2763, or P2764

DTC U0001
DTC U0020
DTC U0073 or U2100
DTC U0074
DTC U0078
DTC U0100-U02FF
DTC U0300-U0336
DTC U0400-U05FF
DTC U1500-U15FF
DTC U1814
DTC U18B9-U18BF
DTC U2099
DTC U0073 or U2100
SYMPTOM BYTE LIST

Symptom Byte List
Symptom Byte
Symptom Byte Description
Symptom Byte Definition
(00-0F) General Electrical Failures
This category includes standard wiring failure modes (for example, shorts and opens), direct current (DC)
quantities related by Ohm's Law and quantities related to amplitude, frequency or rate of change, and
wave shape.
This sub type is used for failures

00
01
Short to Battery
02
Short to Ground
03
Low Voltage
04
Open
05
High Voltage/Open
06
Low Voltage/Open
07
High Voltage
08
Performance - Signal Invalid
that cannot be assigned to a

specific sub type. No additional
information is available.
where the Electronic Control
Unit measures vehicle system
(battery positive) potential for
greater than a specified time
period or when some other
value is expected.
Unit measures ground (battery
negative) potential for greater
than a specified time period or
when some other value is
expected.
Unit measures a voltage below a
specified range but not
necessarily a short to ground.
Unit determines an open circuit
via lack of bias voltage, low
current flow, no change in state
of an input in response to an
output, etc.
where the condition detected by
the Electronic Control Unit is
the same for either indicated
failure mode.
where the condition detected by
the Electronic Control Unit is
the same for either indicated
failure mode.
Unit measures a voltage above a
specified range but not
necessarily a short to battery.
where the value of the signal is
not plausible given the operating

09
Too Fast Transitions
0A
Too Slow Transitions
0B
High Current
0C
Low Current
0D
High Resistance
0E
Low Resistance
0F
Signal Erratic
(10-1F) Additional General Electrical Failures

This category includes the overflow from category 0.
10
11
High Input
12
Low Input
13
Low Voltage/High Temperature
conditions.
where the signal transitions
more quickly than is reasonably
allowed.
where the signal transitions
more slowly than is reasonably
allowed.
Unit measures current flow
above a specified range.
Unit measures current flow
below a specified range.
Unit infers a circuit resistance
Unit infers a circuit resistance
where the signal is momentarily
implausible (not long enough
for Signal Invalid) or
discontinuous.
Currently not used.

where some circuit quantity is
where some circuit quantity is
where a temperature sensor with
a negative temperature
coefficient detects a voltage
where a temperature sensor with

14
High Voltage/Low Temperature
15
Performance - Signal Rising Time Failure
16
Performance - Signal Falling Time Failure
17
Performance - Signal Shape/Waveform Failure
18
Low Signal Amplitude
19
High Signal Amplitude
1A
Performance - Bias Level Out of Range
1B
Signal Cross Coupled
1C
1D
1E
1F
Erratic
a negative temperature
coefficient detects a voltage
where the signal rise time is
outside a specified range.
where the signal fall time is
outside a specified range.
where the shape of the signal
(plot of the amplitude with
respect to time) is not correct
(for example, improper circuit
impedance.)
Unit measures a signal voltage
below a specified range but not
necessarily a short to ground
(for example, gain too low).
Unit measures a signal voltage
above a specified range but not
necessarily a short to battery
(for example, gain too high).
Unit applies a bias voltage to a
circuit upon which is
superimposed a signal voltage
(for example, Oxygen Sensor
Circuit.)
Unit detects a circuit shorted to
another circuit when both
circuits are controlled by the
Electronic Control Unit.
Currently not used.
Currently not used.
Currently not used.
Unit momentarily detects one of

the conditions defined above but

not long enough to set a specific
sub type.
(20-2F) FM / PWM Failures
This category includes faults related to Frequency Modulated (FM) and Pulse Width Modulated (PWM)
inputs and outputs of the Electronic Control Unit and faults where position is determined by counts.
20
Currently not used.
21
Incorrect Period
Unit measures an incorrect
duration for one cycle of the
output.
22
Too Short Low-Time
Unit detects the low pulse is too
narrow with respect to time.
23
Too Long Low-Time
Unit detects the low pulse is too
wide with respect to time.
24
Too Short High-Time
Unit detects the high pulse is too
narrow with respect to time.
25
Too Long High-Time
Unit detects the high pulse is too
wide with respect to time.
26
Low Frequency
Unit detects too few cycles in a
given time period.
27
High Frequency
Unit detects too many cycles in
a given time period.
28
Incorrect Frequency
Unit measures an incorrect
number of cycles in a given time
period.
29
Too Few Pulses

Unit measures too few pulses
(for example, position is
calibrated in counts from one

2A
Too Many Pulses
2B
Missing Reference
extreme to the other).

Unit measures too many pulses
(for example, position is
calibrated in counts from one
extreme to the other).
Unit does not detect a reference
for a signal circuit or a group of
signal circuits.
Currently not used.
Currently not used.
Currently not used.
Currently not used.
2C
2D
2E
2F
(30-3F) Electronic Control Unit Internal Failures
This category includes faults related to memory, software, and internal electrical circuitry; requiring
component replacement.
30
Currently not used.
This sub type is used by the
Electronic Control Unit to
indicate an incorrect checksum
31
Internal Checksum Error
calculation where memory type
is not specified.
32
General Memory Malfunction
indicate a memory failure where
memory type is not specified.
33
Special Memory Malfunction
indicate a memory failure where
the specific memory type is not
defined in this category.
34
RAM Malfunction
indicate a Random Access
Memory (RAM) failure.
35
ROM Malfunction
indicate a Read Only Memory
(ROM) failure.
36
EEPROM Performance/Malfunction
indicate an Electrically Erasable
Programmable Read Only

37
Software Malfunction
38
Supervision Software Malfunction
39
Internal Malfunction
3A
Incorrect Component Installed
3B
Self-Test Malfunction
3C
Internal Communication Malfunction
Memory (EEPROM) failure.

indicate a failure in the
execution of operational
software
indicate a loop time error in the
execution of the operational
software.
indicate the detection of an
internal circuit failure.
indicate a mismatch between the
hardware connected to the
Electronic Control Unit and the
hardware expected by the
indicate a sensor self-test failure
launched by an Electronic
Control Unit command.
indicate loss of an internal
communication line, for
example, between
microprocessors in a dual
microprocessor configuration.
Currently not used.
Currently not used.
Currently not used.
3D
3E
3F
(40-4F) Electronic Control Unit Programming Failures
This category includes faults related to operational software, calibrations, and options; remedied by
programming the Electronic Control Unit.
40
Currently not used.
This sub type is used to indicate
that only boot software is
41
Not Programmed
present in the Electronic Control
Unit.

42
Calibration Not Programmed
43
EEPROM Incorrect Programming
44
Security Access Not Activated
45
Variant Not Programmed
46
Configuration Not Programmed
47
VIN Not Programmed
48
Security Code Not Programmed
49
RAM Incorrect Programming
4A
Programming Checksum Error
4B
Calibration Not Learned
4C
DTC Memory Full
that operational software is

present but calibration data is
not.
an EEPROM error that may be
remedied by reprogramming the
module.
that programming was
attempted without unlocking the
the need to enter (program) the
sub system option content.
vehicle option content.
vehicle identification number
(VIN).
theft / security code.
indicate a Random Access
Memory (RAM) error remedied
by reprogramming.
indicate an incorrect checksum
calculation where memory type
is not specified.
indicate that a password,
operational range, etc. for a
sensor or actuator must be
learned by the Electronic
Control Unit.
indicate that more DTCs have
been detected than can be
accommodated by the memory

4D
Stack Overflow
allocated for DTC storage.

This subtype is used by the
indicate that more memory has
been used in a stack than is
allocated to a program.
Currently not used.
Currently not used.
4E
4F
(50-5F) Algorithm Based Failures
This category includes faults based on comparing two or more input parameters for plausibility or
comparing a single parameter to itself with respect to time.
50
Currently not used.
51
Currently not used.
52
Currently not used.
Unit calculates a low
53
Low Temperature
temperature condition based
upon the duration of certain
operating parameters.
Unit calculates a high
54
High Temperature
temperature condition based
upon the duration of certain
operating parameters.
Unit monitors a parameter over
55
Too Few Transitions
time within specified limits and
detects fewer than the expected
number of transitions.
Unit monitors a parameter over
56
Too Many Transitions
time within specified limits and
detects more than the expected
number of transitions.
57
Currently not used.
Unit does not see the expected
58
Performance
change to a parameter or group
of parameters in response to a
particular event.

59
Protection Time-Out
5A
Not Plausible

Unit detects a function is active
for greater than a specified time
period.
Unit compares two or more
input parameters for plausibility.
Currently not used.
Currently not used.
Currently not used.
Currently not used.
Currently not used.
5B
5C
5D
5E
5F
(60-6F) Mechanical Failures
This category includes faults detected by inappropriate motion in response to an Electronic Control Unit
controlled output.
60
Currently not used.
61
Stuck
Unit does not detect any motion
in response to energizing a
motor, solenoid, relay, etc.
62
Stuck Open
upon commanding the operation
of a motor, solenoid, relay, etc.,
to close some piece of
equipment.
upon commanding the operation
63
Stuck Closed
of a motor, solenoid, relay, etc.,
to open some piece of
equipment.
Unit detects excessive duration
64
Slip Detected
to command a motor, solenoid,
relay, etc., to move a piece of
equipment to a desired position.
65
Emergency Position Not Achievable

Unit is unable to command a
motor, solenoid, relay, etc., to

66
Incorrect Mounting
67
Incorrect Assembly
move a piece of equipment to

the emergency position.
where the server detects
incorrectly mounted
components, for example,
acceleration sensor showing a
position error of 90.
where the control module has
detected that the component has
been incorrectly installed (for
example, hydraulic pipes
crossed over, circuits cross
wired) or polarity errors.
Currently not used.
Currently not used.
Currently not used.
Currently not used.
Currently not used.
Currently not used.
Currently not used.
Currently not used.
68
69
6A
6B
6C
6D
6E
6F
(70-7F) Bus Signal / Message Failures
This category includes faults related to bus hardware and signal integrity. This category is also used when
the physical input for a signal is located in one Electronic Control Unit and another Electronic Control
Unit diagnoses the circuit.
70
Currently not used.
indicate a signal was received
71
Invalid Data
with the corresponding validity
bit equal to Invalid or post
processing of the signal
determines it is invalid.
indicate a signal was received
72
Message Counter Incorrect
without the corresponding
rolling count value being
properly updated.
73
Parity Error

indicate a message was
processed with an incorrect

74
Bus Signal Checksum Error
75
Serial Data Link High Input
76
Serial Data Link Low Input
77
78
79
7A
7B
7C
7D
7E
7F
Bus Signal Erratic
parity calculation.
indicate a message was
processed with an incorrect
protection (checksum)
calculation.
where some circuit quantity,
reported via serial data, is above
a specified range.
where some circuit quantity,
reported via serial data, is below
a specified range.
Currently not used.
Currently not used.
Currently not used.
Currently not used.
Currently not used.
Currently not used.
Currently not used.
Currently not used.
where the signal, reported via
serial data, is momentarily
implausible or discontinuous.
(80-FF) Reserved
Unique System Specific - See specific diagnostic procedures for symptom byte information if these
symptom bytes are used.
SYMPTOMS - VEHICLE
Body Repair
Symptoms - Bolted Exterior Body Panels and Closures

Body Systems
Symptoms - Fixed and Moveable Windows

Symptoms - Horns
Symptoms - Lighting
Symptoms - Mirrors
Symptoms - Vehicle Access

Symptoms - Wiper/Washer Systems
Brakes
Symptoms - Antilock Brake System

Symptoms - Hydraulic Brakes
Symptoms - Park Brake
Driveline/Axle
Symptoms - Wheel Drive Shafts

Driver Information and Entertainment
Symptoms - Cellular Communication

Symptoms - Entertainment
Symptoms - Displays and Gauges
Symptoms - Secondary and Configurable Customer Controls
Engine
Symptoms - Cruise Control

Symptoms - Engine Controls for the 1.2L (L2Q LDC LWD) or 1.4L (L2I L2N LDD LUH LUJ LUV)
engine
Symptoms - Engine Controls for the 1.6L (LDE LED LFJ LGE LLU LXV) or 1.8L (2H0 LFH LUW
LWE) engine
Symptoms - Engine Cooling
Symptoms - Engine Electrical
Symptoms - Engine Exhaust
Symptoms - Engine Mechanical for the 1.2L (L2Q LDC LWD) or 1.4L (L2I L2N LDD LUH LUJ
LUV) engine
Symptoms - Engine Mechanical for the 1.6L (LDE LED LFJ LGE LLU LXV) or 1.8L (2H0 LFH LUW
LWE) engine
General Information
Symptoms - Squeaks and Rattles

Symptoms - Vibration Diagnosis and Correction
HVAC
Symptoms - HVAC Systems - Automatic

Symptoms - HVAC Systems - Manual

Power and Signal Distribution
Symptoms - Data Communications

Symptoms - Power Outlets
Symptoms - Wiring Systems
Roof
Symptoms - Roof
Safety and Security
Symptoms - Immobilizer
Symptoms - Object Detection
Symptoms - Remote Functions
Symptoms - Seat Belts
Symptoms - SIR
Symptoms - Theft Deterrent
Seats
Symptoms - Power Seats

Symptoms - Seat Heating and Cooling
Steering
Symptoms - Power Steering System

Symptoms - Steering Wheel and Column
Suspension
Symptoms - Suspension General Diagnosis

Symptoms - Tire Pressure Monitoring
Transmission
Symptoms - Automatic Transmission

Symptoms - Clutch
Symptoms - Manual Transmission
Symptoms - Automatic Transmission Shift Lock Control
ENGINE DOES NOT CRANK

Refer to the appropriate diagnostic procedure below for the symptom observed.

Starter Solenoid Does Not Click

Starter Solenoid Clicks, Engine Does Not Crank
Engine Cranks Slowly
ENGINE CRANKS BUT DOES NOT RUN

Refer to the appropriate diagnostic procedure below for the vehicle being serviced.
Engine Cranks But Does Not Run for the 1.2L (L2Q LDC LWD) or 1.4L (L2I L2N LDD LUH LUJ
LUV) engine
Engine Cranks But Does Not Run for the 1.6L (LDE LED LFJ LGE LLU LXV) or 1.8L (2H0 LFH
LUW LWE) engine
INSPECTION/MAINTENANCE SYSTEM CHECK

Refer to the appropriate diagnostic procedure below for the vehicle being serviced.
Inspection/Maintenance System Check for the 1.2L (L2Q LDC LWD) or 1.4L (L2I L2N LDD LUH
LUJ LUV) engine
Inspection/Maintenance System Check for the 1.6L (LDE LED LFJ LGE LLU LXV) or 1.8L (2H0
LFH LUW LWE) engine
DIAGNOSTIC REPAIR VERIFICATION

NOTE:
After a repair has been made, some DTCs require the ignition to be turned OFF
then back ON before the scan tool function will clear the DTC.
1. Ignition OFF.
2. Install any components or connectors that have been removed or replaced during diagnosis.
3. Perform any adjustment, programming or setup procedures that are required when a component or
module is removed or replaced.
4. Ignition ON.
5. Clear the DTCs.
6. Turn the ignition OFF for 60 seconds.
7. If the repair was related to a DTC, duplicate the Conditions for Running the DTC and use the Freeze
Frame/Failure Records, if applicable, in order to verify the DTC does not set. If the DTC sets or another
DTC is present, refer to the Diagnostic Trouble Code (DTC) List - Vehicle and perform the appropriate
diagnostic procedure.
Or
If the repair was symptom related, duplicate the conditions under which the customer concern occurred to
verify the repair. If the customer concern reoccurs or another symptom is present, return to Symptoms Vehicle and perform the appropriate symptom diagnostic.

2013 GENERAL INFORMATION Vibration Diagnosis and Correction - Cruze

Vibration Diagnosis and Correction - Cruze
SPECIFICATIONS
TIRE AND WHEEL RUNOUT SPECIFICATIONS
Tire and Wheel Runout Specifications
Specification
Application
Tire and Wheel Assembly- Lateral and Radial
Metric
English
Off-Vehicle
1.27 mm
0.050 in
On-Vehicle
Wheel, Aluminum
1.52 mm
0.060 in
Lateral
0.762 mm
0.030 in
Radial
Wheel, Steel
0.762 mm
0.030 in
Lateral
1.143 mm
0.045 in
1.015 mm
0.132 mm
0.25 mm
0.040 in
0.0052 in
0.010 in
Radial
Wheel Hub/Axle Flange- Guideline
Wheel Stud- Guideline

VIBRATION ANALYSIS - ROAD TESTING
Special Tools
EL-38792-A Electronic Vibration Analyzer

For equivalent regional tools, refer to Special Tools and Equipment.
Test Description
The numbers below refer to the step numbers on the diagnostic table.
4
Obtaining rotational speed for the components rotating at tire/wheel speed is critical to systematically
eliminating specific vehicle component groups. These component rotational speeds can be generated by
using an electronic vibration analyzer, or through calculating them manually.

9
NOTE:
Be certain to OBSERVE for disturbances that match the customer's

description FIRST, then look at the vibration analyzer frequency which
corresponds with that disturbance.
Proper location of the vibration analyzer sensor onto the component which is most excited by the
vibration disturbance is critical to obtaining an accurate frequency reading.
This test will duplicate virtually any disturbance which occurs while the vehicle is in motion.
10
Accelerate to a speed high enough above the speed of the disturbance to allow for the time needed to shift
into NEUTRAL and for the engine to decrease in RPM to idle speed, before coasting down through the
disturbance range.
11
This test will either eliminate or confirm the engine as a contributing cause of the customer concern.
Vibration Analysis - Road Testing
Step
Action
Yes
No
Go to Step 5
Go to Step 2
Go to Step 4
Go to Step 3
Go to Step 4
Go to Step 2
WARNING:
Refer to Road Test Warning .
Did the customer concern indicate that the

vibration occurs ONLY while the vehicle is
standing still?
Visually inspect the tire and wheel assemblies,
steering components and suspension components
for any possible faults.
Are the tire and wheel assemblies, steering
components and suspension components in good
working condition?
NOTE:
Do NOT operate the vehicle until the faults are
corrected.
Correct the faults with the tire and wheel

assemblies, steering components, and/or the
suspension components before proceeding.Did
you correct the faults with the tire and wheel
assemblies, steering components, and/or the
suspension components?
1. Obtain the drive axle final drive ratio.

2. If the vibration analyzer has suitable

software, obtain the transmission gear
ratios.
3. If the a vibration analyzer is not available,
take note of the tire size on each axle, then
calculate the tire rotational speed for each
size tire used. Refer to Component
Rotational Speed Calculation.
Did you obtain the powertrain ratios for use with
the vibration analyzer, or calculate the component
rotational speeds, if a vibration analyzer is NOT
available?
7
8
Go to Step 5
1. Install a scan tool.

2. With the scan tool, bring up the Powertrain
Control Module data list and select Engine
Speed.
Is the scan tool operating properly?
Go to Step 6
Using a vibration analyzer is the preferred
method for gathering necessary vibration
frequency data.
If a vibration analyzer is not available, the
necessary vibration frequency data will have to
be obtained based on symptoms observed during
testing. Review Symptoms - Vibration
Diagnosis and Correction to become familiar
with the possible frequency ranges. Review
Symptoms - Vibration Diagnosis and Correction,
as necessary throughout the remainder of
diagnostics.
Is a vibration analyzer available for use?
Go to Step 7
Install the vibration analyzer.
Go to Step 8
Is the vibration analyzer operating properly?
Did the customer concern indicate that the
Go to Vibration
vibration occurs ONLY while the vehicle is
standing still?
Analysis - Engine
1. Install the vibration analyzer sensor, if
available, to the component identified by
the customer as most respondent to the
vibration. If no component was identified,
install the vibration analyzer sensor, if
available, to the steering column. You may
have to move the sensor to other locations
later.
Go to Step 8
Check the Vibration
Analyzer
Go to Step 9

2. Select a smooth, level road and slowly

accelerate the vehicle up to highway speed.
3. Observe the vehicle for disturbances that
match the customer's description and note
the following conditions:
The vehicle speed
The engine RPM
The transmission gear range and the
specific gear
The vibration frequency reading, if
detected by the vibration analyzer
The feel and/or sound of the
disturbance
4. If the vibration seems to excite a particular
component of the vehicle more than the
steering column, then move the vibration
analyzer sensor, if available, onto that
component and repeat steps 2 and 3.
Were you able to duplicate the customer's
concern?
Go to Step 10
Go to Vibration
Diagnostic Aids
1. Accelerate the vehicle to a speed higher

than the speed at which the disturbance
occurs.
10
NOTE:
If the vehicle is equipped with an
automatic transmission, let the vehicle
coast to a stop before shifting back into
gear.
2. Shift the vehicle into NEUTRAL and allow

the vehicle to coast down through the
disturbance range.
Does the disturbance still occur while coastingdown in NEUTRAL?
11
1. Select a smooth, level road and slowly

accelerate the vehicle up to the speed at
which the disturbance occurs.
2. Decelerate and safely downshift by one
gear range.
3. Operate the vehicle at the same VEHICLE
SPEED at which the disturbance occurs.
Go to Step 12
Go to Step 11

12
Does the same disturbance still occur while going Go to Vibration

Analysis - Hub
the same vehicle speed in a lower gear range?
and/or Axle Input
If the vibration analyzer is not available, refer to
Symptoms - Vibration Diagnosis and
Correction.
Did the vibration analyzer detect a dominant
frequency?
Go to Step 13
Go to Vibration
Analysis - Engine
Go to Symptoms Vibration Diagnosis

and Correction
1. If the vibration analyzer HAS the features,

use the drive axle final drive ratio, the
specific transmission gear ratio, and the
engine RPM to make a comparison to the
dominant frequency reading recorded.
2. If the vibration analyzer does NOT have
the features, compare the dominant
frequency reading recorded to the
component rotational data which you
calculated previously.
13
Does the frequency data clearly fall within the

tire/wheel parameters ONLY?
Go to Vibration
Go to Symptoms Analysis - Tire and Vibration Diagnosis
Wheel
and Correction
COMPONENT ROTATIONAL SPEED CALCULATION

Special Tools
EL-38792-A Electronic Vibration Analyzer (EVA) 2

Tire Rotational Speed
Determining Tire Revolutions Per Second at 8 km/h (5 mph) - Using EVA

Tire and wheel assembly rotational speed can be obtained through using the EL-38792-A Electronic Vibration
Analyzer (EVA) 2. Perform the following steps using the EL-38792-A Electronic Vibration Analyzer (EVA) 2
to obtain the rotational speed at 8 km/h (5 mph). Use the Enter key to advance and the Exit key to backup.
1.
2.
3.
4.
On the Main Menu screen, select Auto Mode.

On the Suspected Source screen, select Vehicle Speed.
On the Tire Info Source screen, select Manual Entry.
On the Tire Width screen, enter the specific width of the tires.
For example: For a P245/45/R18 tire, enter 245.
5. On the Aspect Ratio screen, enter the specific aspect ratio of the tires.

For example: For a P245/45/R18 tire, enter 0.45.

6. On the Rim Diameter screen, enter the specific rim diameter size.
For example: For a P245/45/R18 tire, enter 18.0.
7. On the Driveshaft Configuration screen, enter FWD, even if the vehicle is a rear wheel drive.
8. The next screen will display the tire size just entered for confirmation.
For example: 245 0.45 18.0 -Front Wheel Drive. If the tire size displayed is correct, press Enter.
9. On the Vehicle Speed Units screen, press Enter, disregard mph or km/h.
10. Press the Exit key several times slowly while watching the backwards progression of the screens. Stop at
the Tire Info Source screen.
11. On the Tire Info Source screen, select RPS at 5 mph.
12. The next screen will display the revolutions per second (RPS) at 8 km/h (5 mph) for that specific tire size.
For example: The P245/45/R18 will display 1.08 RPS.
Calculating Tire Revolutions Per Second at 8 km/h (5 mph) - Without EVA
If the EL-38792-A Electronic Vibration Analyzer (EVA) 2 is not available, the tire and wheel assembly
rotational speed can be calculated approximately by performing the following steps.
1. Convert the rim diameter size from inches to centimeters.
For example: For a P245/45/R18 tire, the rim diameter of 18 in X 2.54 converts to 45.72 cm.
2. Calculate the radius of the rim by dividing the rim diameter by 2.
For example: For a P245/45/R18 tire, the rim diameter of 18 is converted to 45.72 cm divided by 2 = rim
radius 22.86 cm.
3. Calculate the approximate tire sidewall height by multiplying the specific tire tread width by the aspect
ratio, then reduce 7 percent from the amount by multiplying by 93 percent to approximate load on the tire
reducing the sidewall height.
For example: For a P245/45/R18 tire, tread width 245 mm X aspect ratio as a decimal 0.45 = 110 mm X
0.93 = approximate sidewall height 102.30 mm.
4. Convert the calculated approximate tire sidewall height from millimeters to centimeters.
For example: For a P245/45/R18 tire, approximate sidewall height 102.30 mm converts to 10.23 cm.
5. Calculate the approximate tire and wheel assembly radius by adding the rim radius and approximate
sidewall height, both in cm.

For example: For a P245/45/R18 tire, rim radius 22.86 cm + 10.23 cm = approximate tire and wheel
assembly radius 33.09 cm.
6. Calculate the approximate circumference of the tire and wheel assembly by multiplying 2 X pi, or
6.283185 X the approximate tire and wheel assembly radius.
For example: For a P245/45/R18 tire, 6.283185 X approximate tire and wheel assembly radius 33.09 cm
= approximate tire and wheel assembly circumference 207.911 cm.
7. Calculate the approximate revolutions per kilometer by dividing the number of cm in 1 km, 100, 000 cm
by the approximate tire and wheel assembly circumference.
For example: For a P245/45/R18 tire, 100, 000 cm divided by approximate tire and wheel assembly
circumference 207.911 cm = approximate revolutions per kilometer 480.975.
8. Calculate the approximate revolutions per second (RPS), or Hz, by dividing the approximate revolutions
per kilometer by the number of seconds to travel 1 km at a speed of 8 km per hour, 450 seconds.
For example: For a P245/45/R18 tire, approximate revolutions per kilometer 480.975 divided by the
number of seconds to travel 1 km at a speed of 8 km per hour, 450 seconds = approximate RPS, or Hz
1.069 rounded to 1.07.
Calculating Tire Revolutions Per Second, or Hz at Concern Speed
A size P235/75R15 tire rotates ONE complete revolution per second (RPS), or 1 Hz, at a vehicle speed of 8
km/h (5 mph). This means that at 16 km/h (10 mph), the same tire will make TWO complete revolutions in one
second, 2 Hz, and so on.
1. Determine the rotational speed of the tires in revolutions per second (RPS), or Hertz (Hz), at 8 km/h (5
mph), based on the size of the tires. Refer to the preceding Tire Rotational Speed information.
For example: According to the Tire Rotational Speed information, a P245/45R18 tire makes 1.08
revolutions per second (Hz) at a vehicle speed of 8 km/h (5 mph). This means that for every increment of
8 km/h (5 mph) in vehicle speed, the tire's rotation increases by 1.08 revolutions per second, or Hz.
2. Determine the number of increments of 8 km/h (5 mph) that are present, based on the vehicle speed in
km/h (mph) at which the disturbance occurs.
For example: Assume that a disturbance occurs at a vehicle speed of 96 km/h (60 mph). A speed of 96
km/h (60 mph) has 12 INCREMENTS of 8 km/h (5 mph):
96 km/h (60 mph) divided by 8 km/h (5 mph) = 12 increments
3. Determine the rotational speed of the tires in revolutions per second, or Hz, at the specific vehicle speed
in km/h (mph) at which the disturbance occurs.
For example: To determine the tire rotational speed at 96 km/h (60 mph), multiply the number of
increments of 8 km/h (5 mph) by the revolutions per second, or Hz, for one increment:

12 increments X 1.08 Hz = 12.96 Hz, rounded to 13 Hz

NOTE:
If the EL-38792-A Electronic Vibration Analyzer (EVA) 2 is not available,

compare the calculated rotational speed to the frequency range associated
with the symptoms of the vibration concern. Refer to Symptoms Vibration Diagnosis and Correction.
4. Compare the rotational speed of the tires at the specific vehicle speed at which the disturbance occurs, to
the dominant frequency recorded on the EL-38792-A Electronic Vibration Analyzer (EVA) 2 during
testing. If the frequencies match, 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
assembly rotation.
5. To compute higher order tire/wheel assembly rotation related disturbances, multiply the rotational speed
of the tires at the specific vehicle speed at which the disturbance occurs, by the order number:
13 Hz X 2, for second order = 26 Hz second-order tire/wheel assembly rotation related
13 Hz X 3, for third order = 39 Hz third-order tire/wheel assembly rotation related
If any of these computations match the frequency of the disturbance, a disturbance of that particular
order, relating to the rotation of the tire/wheel assemblies and/or driveline components, also rotating at the
same speed, is present.
Component Rotational Speed Worksheet
Utilize the following worksheet as an aid in calculating the first, second and third order of tire/wheel assembly
rotational speed related disturbances that may be present in the vehicle.
If after completing the Tire/Wheel Rotation Worksheet, the frequencies calculated do NOT match the dominant
frequency of the disturbance recorded during testing, either recheck the data, or attempt to rematch the figures
allowing for 1 1/2 -8 km/h (1-5 mph) of speedometer error.
If the possible tire/wheel assembly rotational speed related frequencies still do not match the dominant
frequency of the disturbance, the disturbance is most likely torque/load sensitive.
If after completing the Tire/Wheel Rotation Worksheet, one of the frequencies calculated DOES match the
dominant frequency of the disturbance, the disturbance is related to the rotation of that component group tire/wheel assembly related.

Fig. 1: Tire/Wheel Rotation Worksheet

VIBRATION ANALYSIS - TIRE AND WHEEL

Fig. 2: Tire & Wheel Vibration Analysis

WARNING: Refer to Work Stall Test Warning .
Wheel imbalance causes most highway speed vibration problems. A vibration can remain after dynamic
balancing because:
A tire is out of round (2).

A rim is out of round (4).
A tire stiffness variation exists (3).
Measuring tire and wheel free runout will uncover only part of the problem. All 3 causes, known as loaded
radial runout (1), must be checked using a method of substituting known good tire and wheel assemblies on the
problem vehicle.
Low-speed variations, which occur below 64 km/h (40 mph), are usually caused by runout. High-speed
vibrations, which occur above 64 km/h (40 mph), can be caused by either imbalance or runout.
Correcting Non-Uniform Tires
There are 2 ways to correct properly balanced tires which still vibrate. One method uses an automatic machine
which loads the tire and buffs small amounts of rubber from high spots on the outer 2 tread rows. Correction by
this method is usually permanent and, if it is done properly, does not significantly affect the appearance or the
tread life of the tire. Tire truing with a blade type machine is not recommended because it substantially reduces

the tread life and often does not correct the problem permanently.
Another method is to dismount the tire and rotate it 180 degrees on the rim. Do this only on the tire and wheel
assemblies which are known to be causing a vibration because this method is just as likely to cause good
assemblies to vibrate.
VIBRATION ANALYSIS - HUB AND/OR AXLE INPUT
Test Description
The numbers below refer to the step numbers on the diagnostic table:
2
This test will determine the effect of turning input on the vibration.
6
This test will determine the effect of an initial heavy torque load on the vibration.
7
Damaged or worn wheel drive shafts may cause a noise or vibration that may be transferred into the
passenger compartment.
8
Damaged or worn wheel bearings may cause a noise or vibration that may be transferred into the
9
Damaged or worn suspension components may cause a noise or vibration that may be transferred into the
10
Damaged or worn powertrain mounts and/or exhaust mounts may cause a noise or vibration that may be
transferred into the passenger compartment.
11
Incorrect trim height may cause binding and/or interference between components that may produce a
vibration.
Vibration Analysis - Hub and/or Axle Input
Step
Action
Yes
No

WARNING:
Refer to Road Test Warning .
3
4
5
Has the Vibration Analysis - Road Testing table been

completed?
Go to Vibration
Go to Step Analysis - Road
2
Testing
1. Operate the vehicle at the speed of the vibration

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
disturbance.
4. Select a smooth, level surface, such as an empty
parking lot or a remote road.
5. While maintaining the vehicle at the concern speed
if possible, drive the vehicle through sharp turns;
360 degrees - first in one direction, then in the other
direction.
disturbance.
Did the characteristics of the vibration change
Go to Step
significantly-become worse or go away-during these steps?
3
Did you hear a clicking noise and/or feel a shudder during Go to Step
these steps?
7
Did you hear a growling noise during these steps?
Go to Step
8
Did you hear a popping noise during these steps?
Go to Step
9
Go to Step 6
Go to Step 4
Go to Step 5
Go to Step 12
1. With the vehicle at a stand-still, apply the regular

brake and place the transmission in the lowest
forward gear.
NOTE:
Do not accelerate to the point of causing the drive
wheels to squeal, slip or hop-this would obscure
the results of the test.
2. Release the regular brakes and accelerate

aggressively to 32 km/h (20 mph).
disturbance.
Did you feel a shudder or shaking during these steps?
Go to Step Go to Vibration
7
Diagnostic Aids

1. Inspect the wheel drive shafts, if equipped, for

damage, abnormal and/or excessive wear.
2. If 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 9
1. Inspect the wheel bearings for wear and/or damage.

2. Replace any of the wheel bearings found to be worn
and/or damaged.
Go to Step
12
12
Diagnostic Aids
1. Inspect the following suspension components for

wear, damage, looseness and/or possible contact
with other vehicle components:
Struts/shock absorbers
Springs
Bushings
Insulators
2. Replace any of the suspension components found to
be worn, damaged, loose and/or contacting other
vehicle components.
1. Inspect the powertrain mounts-engine, transmission,
transfer case, and direct-mount differential, 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 collapsed
insulators
Bent, twisted, and/or deformed brackets
2. Replace powertrain mounts as necessary.
3. Inspect the exhaust system components for the
following:
Heat Shields
Joints and/or couplings:
Go to Step
12
Go to Step 10

Nuts, bolts, studs, clamps, straps

Bracket and/or insulator mounting
Inadequate clearance to body and/or chassis
components
Inspect with the exhaust system both COLD

and HOT; in NEUTRAL, FORWARD and
REVERSE gears
Improper alignment
Disconnected and/or missing insulators
insulators
Stretched, twisted, broken, torn, and/or
collapsed insulators
Bent, twisted, cracked, and/or deformed
brackets
4. Repair, replace, and/or realign exhaust system
components as necessary.
10
11

Inspect the vehicle trim height and adjust as necessary.
Refer to Trim Height Inspection .
Go to Step 11
Diagnostic Aids
12
1. Install or connect any components that were

removed or disconnected during diagnosis.
2. Perform the Vibration Analysis - Road Testing table.
Refer to Vibration Analysis - Road Testing.
12
Is the vibration still present?

VIBRATION ANALYSIS - ENGINE
Special Tools

Test Description
2
Go to Step
12
Go to Step
2
System OK

If powertrain related DTCs are present, there may be a powertrain performance condition present which
could be a contributing cause to the customer's concern.
5
Making comparisons of the customer's vehicle with an equally equipped, same model year and type,
KNOWN GOOD vehicle will help determine if certain disturbances may be characteristic of a vehicle
design.
Vibration Analysis - Engine
Step
Action
Yes
No
WARNING:
Refer to Work Stall Test Warning .
Has the Vibration Analysis Road Testing table been

completed?
Using a scan tool, determine if
any DTCs are set.
Were any DTCs set?
1. Block the front wheels.
2. Apply BOTH the service
brakes and the park brake.
3. With the scan tool and the
EL-38792-A 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 at which
the disturbance is most
noticeable.
6. Record the engine RPM
obtained on the scan tool
and the most dominant
frequency reading if
obtained on the EL-38792A analyzer (EVA) 2, if
available.
DRIVE.
the disturbance is most
noticeable.
Go to Step 2
Go to Vibration Analysis Road Testing
Go to Step 3


available.
10. If no frequency data was
obtained, or if the EL38792-A analyzer (EVA)
2, is not available, place
the transmission into
REVERSE, then repeat
steps 8 and 9. Reverseloading of the powertrain
may increase or change the
characteristics of the
vibration.
Were you able to duplicate the

customer's concern?
Go to Step 4
Did the EL-38792-A analyzer
(EVA) 2 detect a dominant
frequency, or was a significant Go to Vibration Analysis Engine/Accessory Isolation
vibration present?
Compare the test results of the
customer's vehicle to the results
of the same tests run, at the same
engine RPM, on an equallyequipped, same model year and
type, KNOWN GOOD vehicle.
Refer to Vehicle-to-Vehicle
Diagnostic Comparison.
1. Install a scan tool into the
known good vehicle.
2. Install the EL-38792-A
analyzer (EVA) 2, if
available, into the known
good vehicle; place the
sensor in exactly the same
location as it was placed in
the customer's vehicle.
4. Apply BOTH the service
brakes and the park brake.
Go to Vibration Diagnostic
Aids
Go to Step 5

5. Start the engine.

NEUTRAL or PARK.
the disturbance was most
noticeable in the customer's
vehicle.
available.
DRIVE.
the disturbance was most
noticeable in the customer's
vehicle.
available.
12. If no frequency data was
obtained, or if the EL38792-A analyzer (EVA)
2, is not available, place
the transmission into
REVERSE, then repeat
steps 10 and 11. Reverseloading of the powertrain
may increase or change the
characteristics of the
vibration.
Did both of the vehicles exhibit
the same characteristics?
ENGINE ORDER CLASSIFICATION
Aids
Go to Vibration Analysis Engine/Accessory Isolation

Special Tools
EL-38792-VS Vibrate Software

Engine First Order Classification
1. Convert the engine speed in revolutions per minute (RPM), recorded during duplication of the
disturbance into Hertz, revolutions per second (RPS), by dividing the RPM by 60 seconds. Refer to the
following example:
1.200 RPM divided by 60 = 20 Hz (or RPS)
2. Compare the dominant frequency in Hz, recorded during duplication of the disturbance with the engine
speed just converted into Hz, to determine if they are related.
3. If the dominant frequency in Hz, recorded during duplication of the disturbance and the engine speed,
converted into Hz, ARE related, then an engine FIRST ORDER related disturbance is present. Engine
first order disturbances are usually related to an imbalanced component. Refer to the Engine Order
Related Disturbances table.
4. If the dominant frequency in Hz, recorded during duplication of the disturbance and the engine speed,
converted into Hz, are NOT related, then determine if the disturbance is related to the engine's firing
frequency. Proceed to Engine Firing Frequency Classification.
Engine Firing Frequency Classification
Engine firing frequency is a term used to describe the number of firing pulses (one firing pulse = one cylinder
firing) that occur during ONE complete revolution of the crankshaft, multiplied by the number of crankshaft
revolutions per second, Hz.
1. Calculate the engine firing frequency.
To determine the firing frequency of a 4-stroke engine during ONE complete revolution of the
crankshaft, multiply the engine speed, converted into Hz, by HALF of the total number of cylinders
in the engine.
For example: The engine speed, converted into Hz, was 20 Hz; if the vehicle was equipped with a
V8 engine, 4 of the 8 cylinders would actually fire during ONE complete revolution of the
crankshaft.
Multiply the converted 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 80 Hz.
In like manner, a 6-cylinder engine would have a firing frequency of 60 Hz at the same
engine speed of 1, 200 RPM.

20 Hz X 3 = 60 Hz
2. Compare the dominant frequency in Hz, recorded during duplication of the disturbance with the engine
firing frequency in Hz, just calculated, to determine if they are related.
3. If the dominant frequency in Hz, recorded during duplication of the disturbance and the engine firing
frequency in Hz, just calculated ARE related, then an engine FIRING FREQUENCY related disturbance
is present. Engine firing frequency disturbances are usually related to improper isolation of a component.
Refer to the Engine Order Related Disturbances table.
4. If the dominant frequency in Hz, recorded during duplication of the disturbance and the engine firing
frequency in Hz, just calculated are NOT related, then determine if the disturbance is related to another
engine order classification. Proceed to Other Engine Order Classification.
Other Engine Order Classification
1. Multiply the engine speed, converted into Hz, recorded during duplication of the disturbance by different
possible order-numbers, other than 1 (first order) or the number used to determine the firing frequency of
the engine.
2. Compare the dominant frequency in Hz, recorded during duplication of the disturbance with the other
possible engine orders just calculated, to determine if they are related.
3. If the dominant frequency in Hz, recorded during duplication of the disturbance and one of the other
engine order frequencies in Hz, just calculated ARE related, then an engine related disturbance of that
order is present. If an engine related disturbance is present that is NOT related to first order or firing
frequency, then it could be related to an engine driven accessory system. Proceed to Engine Driven
Accessories Related to Engine Order.
Engine Driven Accessories Related to Engine Order
Engine driven accessory systems can be related to specific engine orders depending upon the relationship of the
accessory pulley diameter to the crankshaft pulley diameter. For example:
If the crankshaft pulley measured 20 cm (8 in) in diameter and one of the engine driven accessory pulleys
measured 10 cm (4 in) in diameter, then that accessory pulley would rotate 2 times for every one rotation
of the crankshaft pulley. If that accessory system was not isolated properly, or was not operating properly,
it would be identifiable as a 2nd order engine related disturbance.
In like manner, if an engine driven accessory pulley measured 5 cm (2 in) in diameter, then that accessory
pulley would rotate 4 times for every one rotation of the crankshaft pulley. If that accessory system was
not isolated properly, or was not operating properly, it would be identifiable as a 4th order engine related
disturbance.
Engine driven accessories that contribute to, are excited by, or are the sole cause of a disturbance are usually
doing so because of improper isolation that causes a transfer path into the passenger compartment or to another
major component of the vehicle body.
Using the EL-38792-VS software, accurately measuring the diameters of the accessory pulleys and the
crankshaft pulley, and performing the appropriate diagnostic procedures completely will lead to the specific
accessory system which is either contributing to, or causing the customer's concern.

Engine Order Related Disturbances

Engine Arrangement
Engine Order
1/2 Order
Torque Sensitive
1st Order
1 1/2 Order
Torque Sensitive
2nd Order
Non Torque Sensitive
2nd Order
Torque Sensitive
2 1/2 Order
Torque Sensitive
3rd Order
Torque Sensitive
4th Order
Torque Sensitive
L4
W/O Balance Shaft
Abnormal - Likely Single Cylinder
Misfire
Abnormal - Likely Component
Imbalance
Possible Engine Driven Accessory
Related
Characteristic of Engine
Arrangement
- Possible Powertrain Isolation
Related
Characteristic - ENGINE FIRING
FREQUENCY
Related
Related
Related
Related
Characteristic - Minimal Amount of Engine Arrangement
Related
Related
L4
With Balance Shaft
Abnormal - Likely Single Cylinder
Misfire
Abnormal - Likely Component
Imbalance
Related
Related
Characteristic - ENGINE FIRING
FREQUENCY
Related
Related
Related
Related
Characteristic - Minimal Amount of Engine Arrangement
Related
Related
VIBRATION ANALYSIS - ENGINE/ACCESSORY ISOLATION

Test Description
5
A loose, damaged, misaligned, or defective powertrain insulator and/or bracket may create a transfer path
into the passenger compartment.
6
A loose, damaged, misaligned, or defective exhaust system insulator and/or bracket may create a transfer
path into the passenger compartment.

7
Incorrectly seated and/or aligned powertrain components and/or exhaust system components may create a
transfer path into the passenger compartment.
When loosening powertrain mounts in order to re-bed the powertrain observe the following:
Do not loosen the mount bracket-to-engine bolts/nuts, do not loosen the mount bracket-to-vehicle frame
bolts/nuts if mount brackets are used.
Loosen the mount-to-mount bracket bolts/nuts if mount brackets are used, or loosen the mount-to-slotted
holes in vehicle frame bolts/nuts if a direct-mount design is used.
8
Non-rotating engine driven accessory component systems can no longer produce a unique disturbance.
9
Non-rotating engine driven accessory components can no longer produce a unique disturbance. If a
disturbance is still present, but the characteristics have been altered, it is possible that these component
systems are acting as a transfer path for engine firing frequency or a first order engine disturbance.
If a disturbance is still present, but the characteristics 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 face of an engine driven accessory pulley seems to stand still while running this
test, then that accessory system is either responding to an existing frequency, such as engine firing pulses,
or creating a disturbance.
11
A loose, damaged, misaligned, or defective engine driven accessory system insulator and/or bracket may
create a transfer path into the passenger compartment.
12
Removing the engine driven accessory and bracket, or brackets from the engine allows a thorough
inspection to determine if any conditions are present that may create a transfer path into the passenger
compartment.
Vibration Analysis - Engine/Accessory Isolation
Step
Action
Yes
No

WARNING:
Refer to Work Stall Test Warning .
1
2
Were you sent here from the Vibration Analysis

- Engine table?
Is the EL-38792-A Electronic Vibration
Analyzer (EVA) 2, available?
Go to Step 2
Go to Vibration
Analysis - Engine
Go to Step 3
Go to Step 5
Go to Step 5
Go to Step 4
Go to Step 8
Go to Step 5
Go to Step 13
Go to Step 6
1. Using the engine RPM and frequency

data recorded for the customer's vehicle,
determine the order of engine rotation to
which the disturbance is related.
2. Determine the possible causes of the
disturbance as it relates to a specific
order of engine rotation.
Refer to Engine Order Classification.Does the
Engine Order Classification table indicate that
the disturbance is of the same order as the
engine firing frequency?
Does the Engine Order Classification table
indicate that the disturbance is likely related to
engine driven accessories?
Inspect the powertrain mounts-engine,
transmission, transfer case, and direct-mount
drive axle, if equipped-and any powertrain
braces for the following conditions:

Improper alignment
insulators
Twisted, broken, torn, and/or collapsed
insulators
Bent, twisted, and/or deformed brackets
Realign or replace powertrain mounts as

indicated by the inspection.
Inspect the exhaust system components for the
following:

Heat Shields


Inadequate clearance to body and/or
chassis components
Inspect with the exhaust system both

COLD and HOT; in NEUTRAL,
FORWARD and REVERSE gears
Improper alignment
insulators
collapsed insulators
Bent, twisted, cracked, and/or deformed
brackets
Repair, replace, and/or realign exhaust system

components as indicated by the inspection.
Go to Step 13
Go to Step 7
Perform the Powertrain Mount Balance

Procedure if available or perform the following
procedure to re-bed the powertrain:
1. Loosen, but do not remove, all

powertrain mounts and exhaust system
hangers.
2. Ensure that the exhaust flexible coupling,
if equipped, moves freely.
4. Settle the powertrain by shifting the
transmission from DRIVE to REVERSE.
5. Place the transmission into NEUTRAL.
6. Turn OFF the ignition.
7. Tighten all of the loosened fasteners with
the powertrain in a relaxed position.
Did you complete the operation?
CAUTION:
Do not run the engine for longer than 60
Go to Step 13

seconds with the accessory drive belt, or

belts removed, or overheating and/or
damage may result.
1. Remove the engine accessory drive belt,

or belts.
3. Apply BOTH the service brakes and the
park brake.
4. With the scan tool still installed, start the
engine.
5. Place 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 the engine RPM to the level
recorded during duplication of the
disturbance.
10. Install the engine accessory drive belt, or
belts.
Was the disturbance significantly reduced or
eliminated?
Were the characteristics of the disturbance
altered but still present?
1. Mark the face of the suspected accessory
pulleys, including any related idler
pulleys, near the outer edge with a paint
mark.
2. Install the EN-38792-25 Inductive
Pickup Timing Light, to the EL-38792-A
Electronic Vibration Analyzer (EVA) 2.
For information on the use of the EVA
features, refer to Electronic Vibration
Analyzer (EVA) Description and
Operation.
Go to Step 10
Go to Step 9
Go to Step 11
Go to Step 15

5.
6.
7.
8.
9.
10.
10
park brake.
With the scan tool and the EL-38792-A
Electronic Vibration Analyzer (EVA) 2,
still installed, start the engine.
Select the Smart Strobe feature on the
EL-38792-A Electronic Vibration
Analyzer (EVA) 2.
Enter the recorded frequency of the
disturbance as the initial frequency for
strobe operation.
Have an assistant place the transmission
in NEUTRAL or PARK.
Slowly increase the engine RPM to the
level recorded during duplication of the
disturbance, then maintain that speed.
Using the EL-38792-A Inductive Pickup
Timing Light, check each of the
suspected accessory pulleys to determine
if any of them is related to the frequency
of the disturbance.
Check each of the accessory systems,
both engaged and under maximum load
and disengaged or under minimum load.
11. Allow the engine to idle, then place the

transmission in DRIVE.
12. Slowly increase the engine RPM to the
level recorded during duplication of the
disturbance, then maintain that speed
closely.
13. Using the EN-38792-25 Inductive Pickup
Timing Light, check each of the
suspected accessory pulleys to determine
if any of them is related to the frequency
of the disturbance.
Check each of the accessory systems,
both engaged and under maximum load
and disengaged or under minimum load.
Did you identify an engine driven accessory
system as being related to the frequency of the
Go to Step 11
Go to Vibration
Diagnostic Aids

disturbance?
Inspect the components of the engine driven
accessory system for the following:

Heat Shields, if equipped
Inadequate clearance to body and/or
chassis components
Inspect with the accessory system both

under a LOAD and NOT loaded
11
Improper alignment
Bent or damaged pulleys
component insulators
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 the inspection.
12
1. Remove the engine driven accessory and

bracket, or brackets from the engine.
2. Thoroughly inspect the accessory
bracket, or brackets, bolts/nuts/studs, and
the accessory itself for signs of the
following:
Bent, twisted, cracked and/or deformed
conditions
3. Replace any of the components found to
exhibit any of these conditions.
Go to Step 13
Go to Step 12

4. Reinstall the components to the engine.

Check the vehicle to determine if the
disturbance is now significantly reduced or
eliminated. Perform the following steps:
13
1. Install a scan tool into the customer's

vehicle.
2. Install the EL-38792-A Electronic
Vibration Analyzer (EVA) 2, if available,
into the customer's vehicle; place the
sensor in exactly the same location as it
was originally placed in the vehicle.
park brake.
6. Place the transmission in NEUTRAL or
PARK.
level at which the disturbance was most
noticeable.
8. Record the engine RPM obtained on the
scan tool and the most dominant
frequency reading if obtained on the EL38792-A Electronic Vibration Analyzer
(EVA) 2, if available.
9. Place the transmission in DRIVE.
level at which the disturbance was most
noticeable.
11. Record the engine RPM obtained on the
scan tool and the most dominant
frequency reading if obtained on the EL38792-A Electronic Vibration Analyzer
(EVA) 2, if available.
12. If the disturbance has been significantly
reduced or eliminated, confirm the results
by placing the transmission into
REVERSE, then repeat steps 10 and 11.
Reverse-loading of the powertrain may
increase or change the characteristics of
the vibration.
Go to Step 13
Go to Step 17

14
15
16
17
18
Has the disturbance been significantly reduced

or eliminated?
Go to Step 18
Have you investigated powertrain isolation as a
possible cause of the disturbance?
Go to Step 15
Have you investigated engine driven
Go to Vibration
accessories as a possible cause of the
Analysis - Engine
disturbance?
Balance
Analyzer (EVA) 2 available?
Go to Step 8
Replace the engine driven accessory component
causing the disturbance.
Go to Step 18
Did you complete the replacement?
Go to Step 14
Go to Step 5
Go to Step 16
Go to Vibration
Diagnostic Aids
-
1. Install or connect any components that

were removed or disconnected during
diagnosis.
2. Perform the Vibration Analysis - Road
Testing table. Refer to Vibration
Analysis - Road Testing.
Is the disturbance still present?
Go to Step 2
System OK
VIBRATION ANALYSIS - ENGINE BALANCE

Test Description
4
If sufficient clearance exists to separate the transmission torque converter from the engine
flywheel/flexplate, then further tests can be used to isolate the transmission from the engine.
5
An engine flywheel/flexplate that has excessive lateral runout, when combined with the mass of the
transmission torque converter, can produce a disturbance.
6
An engine flywheel/flexplate that is loose at the engine crankshaft or that is cracked or damaged, when
combined with the mass of the transmission torque converter, can produce a disturbance.
7
This step is designed to isolate the transmission from the engine to determine if the disturbance is related

to the engine ONLY.

9
Re-indexing the transmission torque converter to the engine flywheel/flexplate alters the balance
relationship between the torque converter and the rear of the engine.
11
Placing the EL-38792-A Electronic Vibration Analyzer (EVA) 2 sensor onto the underside of the engine
oil pan along the FRONT and the REAR edge allows for a determination to be made, which will help to
narrow down the cause of the disturbance.
13
An engine flywheel that has excessive lateral runout, when combined with the extra mass of the clutch
pressure plate and clutch driven plate, can produce a disturbance.
14
The clutch pressure plate and the engine flywheel are marked for proper indexing of the heavy-spot of
one to the light-spot of the other. Improper indexing of the pressure plate to the flywheel can produce a
disturbance.
15
An engine flywheel that is loose at the engine crankshaft or that is 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 disturbance when their mass is
combined.
16
An engine flywheel that is loose at the engine crankshaft or that is 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 disturbance when their mass is
combined.
17
Re-indexing the pressure plate to the engine flywheel alters the balance relationship between the pressure
plate/flywheel assembly and the rear of the engine.
18
An engine flywheel/flexplate that is damaged, misaligned, and/or imbalanced, can produce a disturbance.

19
An engine crankshaft balancer that is damaged, misaligned, and/or imbalanced, can produce a
disturbance.
Vibration Analysis - Engine Balance
Step
Action
Were you sent here from the Vibration
1
Analysis - Engine/Accessory Isolation
table?
2
Analyzer (EVA) 2, available?
Is the vehicle equipped with a manual
3
transmission?
Go to Step 2
Go to Step 3
No
Go to Vibration Analysis Engine/Accessory Isolation
Aids
Go to Step 11
Go to Step 4
Go to Step 5
Go to Step 11
1. Raise and support the vehicle. Refer

to Lifting and Jacking the Vehicle .
2. Remove the flywheel/flexplate-totorque converter bolts access cover,
if equipped.
3. Determine if sufficient clearance
exists to separate the transmission
torque converter away from the
engine flywheel/flexplate and safely
secure the torque converter from
accidentally engaging with the
flywheel/flexplate.
Is there sufficient clearance to separate and
safely secure the transmission torque
converter away from the engine
flywheel/flexplate?
Yes
1. With the flywheel/flexplate-totorque converter access cover still

removed, and with the vehicle still
raised, mark the position of the
transmission torque converter in
relation to the engine
flywheel/flexplate.
2. Disconnect the torque converter and
move it away from the
flywheel/flexplate.
3. Secure the transmission torque
converter away from the engine
flywheel/flexplate to avoid
accidental engagement with the

4.
5.
6.
7.
8.
flywheel/flexplate.
Lower the vehicle, start the engine
and allow the engine to idle.
Raise and support the vehicle. Refer
Visually inspect the
flywheel/flexplate for excessive
lateral runout.
Lower the vehicle.
Turn OFF the ignition.
Did the flywheel/flexplate exhibit

excessive lateral runout?
Go to Step 6
Go to Step 8
Go to Step 7

2. Inspect the flywheel/flexplate for the
following:
Looseness at the engine
crankshaft
Cracks and/or damage
Missing balance weights
Did the flywheel/flexplate exhibit any of
the conditions listed?
Go to Step 8
1. With the transmission torque

converter still secured away from the
engine flywheel/flexplate to avoid
accidental engagement with the
flywheel/flexplate, lower the vehicle.
3. Apply BOTH the service brakes and
the park brake.
4. With the scan tool and the EL38792-A Electronic Vibration
Analyzer (EVA) 2 still installed,
start the engine.
5. Place the transmission in NEUTRAL
or PARK.
6. Slowly increase the engine RPM to
the level at which the disturbance is
most noticeable.
7. Record the engine RPM obtained on
the scan tool and the most dominant

frequency reading if obtained on the

Analyzer (EVA) 2.
Has the disturbance been significantly
reduced or eliminated?
1. If the flywheel/flexplate is loose at

the engine crankshaft, tighten the
flywheel/flexplate mounting bolts in
sequence and to specification.
2. If the flywheel/flexplate is cracked,
damaged, and/or has missing balance
weights, replace the damaged
flywheel/flexplate.
Did you complete the tightening or
replacement?
Go to Step 9

2. Re-index the transmission torque
converter to the engine
flywheel/flexplate, 120 degrees from
its original position.
3. Reconnect the transmission torque
converter to the engine
flywheel/flexplate.
4. Lower the vehicle.
the park brake.
Analyzer (EVA) 2 still installed,
start the engine.
or PARK.
most noticeable.
Go to Step 11
Go to Step 20

Analyzer (EVA) 2.
11. If the disturbance is still noticeable,
re-index the torque converter again
to obtain the least amount of
disturbance.
10
11

Replace the out-of-balance transmission
torque converter.
Go to Step 20
Go to Step 10
-
Go to Step 20

2. Position the EL-38792-A Electronic
Vibration Analyzer (EVA) 2 sensor
onto the underside of the engine oil
pan, along the FRONT edge.
the park brake.
Analyzer (EVA) 2, still installed,
start the engine.
or PARK.
most noticeable.
Analyzer (EVA) 2 from the
underside of the engine oil pan.
10. Repeat steps 1 through 9, placing the
Analyzer (EVA) 2 sensor onto the
underside of the engine oil pan,
along the REAR edge.
Is the disturbance greater along the
FRONT of the engine?
Go to Step 19
Go to Step 12

12
13
14
15
Is the vehicle equipped with an automatic

transmission?
Go to Step 18
Go to Step 13
Go to Step 18
Go to Step 14
Go to Step 16
Go to Step 15
Go to Step 18
Go to Step 17

2. Remove the flywheel inspection
cover.
3. Start the engine. Allow the engine to
idle.
4. Visually inspect the engine flywheel
clutch surface for excessive lateral
runout.
Does the engine flywheel clutch surface
exhibit excessive lateral runout?
Inspect the clutch pressure plate to engine
flywheel mounting for proper factory
indexing.
Is the clutch pressure plate properly
indexed to the engine flywheel?
1. Remove the clutch pressure plate and
clutch driven plate from the engine
flywheel.
2. Inspect the engine flywheel for the
following:
crankshaft
Cracks, warpage and/or
damage
3. Inspect the clutch pressure plate and
clutch driven plate for the following:
Loose and/or damaged clutch
driven plate damper springs
pressure plate diaphragm
springs
damage
Do any of the above conditions exist?
1. Remove the clutch pressure plate and
clutch driven plate from the engine

16
17
18
19
flywheel.
2. Inspect the engine flywheel for the
following:
crankshaft
damage
3. Inspect the clutch pressure plate and
clutch driven plate for the following:
driven plate damper springs
pressure plate diaphragm
springs
damage
Re-index the pressure plate to the engine
flywheel.
Did you complete the re-indexing?
Replace the engine flywheel/flexplate.
Replace the engine crankshaft balancer.
Check the vehicle to determine if the
disturbance is now significantly reduced or
eliminated. Perform the following steps:
1. Install or connect any components
that were removed or disconnected
during diagnosis.
2. Install a scan tool into the customer's
vehicle.
3. Install the EL-38792-A Electronic
Vibration Analyzer (EVA) 2, if
available, into the customer's
vehicle; place the sensor in exactly
the same location as it was originally
placed in the vehicle.
Go to Step 18
Aids
-
Go to Step 20
Go to Step 20
Go to Step 20

20
21

the park brake.
or PARK.
the level at which the disturbance
was most noticeable.
Analyzer (EVA) 2, if available.
10. Place the transmission in DRIVE.
the level at which the disturbance
was most noticeable.
Analyzer (EVA) 2, if available.
13. If the disturbance has been
significantly reduced or eliminated,
confirm the results by placing the
transmission into REVERSE, then
repeat steps 11 and 12. Reverseloading of the powertrain may
increase or change the characteristics
of the vibration.
Go to Step 21
Perform the Vibration Analysis - Road
Testing table. Refer to Vibration Analysis
- Road Testing.
Go to Vibration
Diagnostic Aids
Is the disturbance still present?
Aids
System OK
VIBRATION DIAGNOSTIC AIDS

The diagnostic information contained in this diagnostic aids section will help you determine the correct course
of action to take for the following 4 main conditions. Refer to the appropriate condition from this list:
Vibration Diagnostic Aids - Vibration Intermittent or Not Duplicated

Vibration Diagnostic Aids - Vibration Duplicated, Component Not Identified

Vibration Diagnostic Aids - Vibration Duplicated, Difficult to Isolate/Balance Component
Vibration Diagnostic Aids - Vibration Duplicated, Appears to Be Potential Operating
Characteristic
VIBRATION DIAGNOSTIC AIDS - VIBRATION INTERMITTENT OR NOT DUPLICATED

NOTE:
If you have not completed the Vibration Analysis tables as indicated and
reviewed Vibration Diagnostic Aids, refer to Vibration Diagnostic Aids BEFORE
proceeding.
If you have not been able to duplicate the vibration concern or have only been able to duplicate the concern
intermittently, review the following information.
Most vibration concerns that cannot be duplicated are due to either specific conditions that are not present
during the duplicating attempts, or due to not following the procedures designed to duplicate concerns properly
and in the sequence indicated.
Specific Conditions Can Affect the Condition
Consider the following conditions which may not have been present while attempts were made to duplicate the
vibration concern. Attempt to obtain more specific information from the customer as to the EXACT conditions
that are present when they experience the vibration which they are concerned about. Attempt to duplicate the
vibration concern again while recreating the EXACT conditions necessary, except those which pose a safety
concern or are outside the boundaries of normal operating conditions, such as loading the vehicle beyond its
designed weight ratings, etc.
Most attempts to duplicate a vibration concern are made after the vehicle has been driven to the repair facility
and perhaps even sat inside the building for a time; the vehicle may be too warm to detect the concern during
duplication efforts. The opposite could also occur; perhaps the vehicle has sat out in the cold for a time and fails
to reach full operating temperatures during attempts to duplicate the concern.
Temperature, Ground-Out, Accessory Load
Flat Spots on Tires

Tires which have sat and been cool for a time can develop flat spots.
Irregular Wear on Tire Treads
Tires which have sat and been cool for a time will be stiffer and any irregular wear conditions will be more
noticeable than they will be once the tires have warmed and softened.
Exhaust System Growth
Exhaust systems may exhibit a ground-out condition when cool which goes away once the system is hot. The
opposite may be true that the exhaust system is fine when cool but a ground-out condition occurs once the

system reaches operating temperatures. Exhaust systems can grow by 2 1/2 -5 cm (1-2 in) when hot.
Engine-Driven Accessory Noises
NOTE:
When a stethoscope equipped with a probe is used to assist in identifying

possible vibrating components, the results must be compared to the sound
quality of the same accessory, in a equally-equipped, same model year and
type, KNOWN GOOD vehicle, and under the same conditions. Refer to Vehicleto-Vehicle Diagnostic Comparison.
A stethoscope equipped with a probe can be used as an additional means to assist in identifying accessories
which may be causing or contributing to a vibration concern.
Belt Whipping
An 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-Out

Engine-driven accessories such as a generator, a power steering pump, or an air conditioning compressor
could exhibit noise conditions due to either loose mounting brackets or due to related components of the
system in a ground-out condition during certain operation of that accessory system.
Cold or Hot
Accessories could exhibit noise conditions when cool which go away once they are fully warmed-up, or
the opposite may be true.
Load on an Accessory Component

Accessories could exhibit a noise condition while under a heavy load - perhaps when combined with a
cool or fully warmed-up condition.
Bent or Misaligned Pulleys

Bent or mis-aligned pulleys in one or more engine-driven accessory systems could contribute to a noise or
vibration condition.
Fluid Level in Accessory Systems

Accessories could exhibit a noise condition due to an abnormal amount of fluid contained in the system
of which the accessory is a part. For example:
An improper power steering fluid level could produce noises in the power steering system.
An improper air conditioning refrigerant level or an excessive amount of refrigerant oil could
produce noises or possibly vibrations in the air conditioning system.

Incorrect Fluid Type in Accessory Systems

Accessories could exhibit a noise condition due to the incorrect type of fluid contained in the system of
which the accessory is a part.
Vehicle Payload
The vibration concern may only occur when the vehicle is carrying heavy payloads or towing a trailer; the
vehicle may have been empty during duplication efforts.
Heavy Payload
The vehicle may have been empty during attempts to duplicate the vibration concern, but the customer may
actually experience the vibration concern while the vehicle is carrying a large payload.
Trailer Towing
The customer may experience the vibration concern only while towing a trailer.
Roadway Selection
The selection of roadways used to perform the vibration duplication procedures is likely to be in the near
vicinity of the repair facility and may not provide a road surface that is similar enough to the surface on which
the customer usually drives the vehicle.
The customer may only experience the vibration on a particular roadway. Perhaps the roadway is overly
crowned or is very bumpy or rough.
VIBRATION DIAGNOSTIC AIDS - VIBRATION DUPLICATED, COMPONENT NOT IDENTIFIED
NOTE:
proceeding.
Aftermarket Add-On Accessories
Aftermarket accessories which have been added to the vehicle can actually transmit and magnify INHERENT
component rotational frequencies, if the accessories were not installed correctly.
An accessory should be installed in such a way that it is isolated from becoming a possible transfer path into the
rest of the vehicle. For example, if a set of running boards has been installed improperly and they are sensitive
to a particular frequency of a rotating component, the running boards could begin to respond to the frequency
and actually create a disturbance once the amplitude of the frequency reaches a high enough point, probably at a
higher vehicle speed.
If the same set of running boards were installed properly-isolated properly-the transfer path would be removed
and the disturbance would no longer be present.

VIBRATION DIAGNOSTIC AIDS - VIBRATION DUPLICATED, DIFFICULT TO

ISOLATE/BALANCE COMPONENT
NOTE:
proceeding.
If you have duplicated the vibration concern but have had difficulty in balancing a component or isolating a
component, refer to the following information.
Most vibration concerns are corrected or eliminated through correcting excessive runout of a component,
correcting balance of a component or isolating a component which has come into abnormal contact with another
object/component.
Components which can generate a lot of energy and are experiencing excessive runout, imbalance or ground-out
can produce a vibration with a strong enough amplitude that the vibration can transmit to components which are
closely related. This type of a condition is usually related to and sensitive to torque-load. The most likely
system that could exhibit this type of a condition is the driveline.
VIBRATION DIAGNOSTIC AIDS - VIBRATION DUPLICATED, APPEARS TO BE POTENTIAL
OPERATING CHARACTERISTIC
NOTE:
proceeding.
Check Service Bulletins
If BOTH of the following statements are TRUE, then check service bulletins for the condition identified. If the
condition has already been identified and investigated prior to this vehicle, and has been determined to be
something that is not truly an operating characteristic or that perhaps is not design-intent, there will likely be
adjustments or corrections identified which will address the condition.
You CAREFULLY followed the steps indicated through reviewing the Diagnostic Starting Point Vibration Diagnosis and completing the Vibration Analysis tables identified and you have duplicated the
vibration concern.
You have come to the conclusion through comparison with a very equally-equipped, same model year
and type, KNOWN GOOD vehicle that the customer's concern is a condition that appears to be a potential
operating characteristic of the vehicle.
SYMPTOMS - VIBRATION DIAGNOSIS AND CORRECTION

NOTE:
Perform the following steps in sequence BEFORE using these symptom tables.
Perform the Vibration Analysis - Road Testing table before using these symptom tables in order to duplicate
and effectively diagnose the customer's concern.

Symptom Tables
Refer to a Vibration Analysis table as indicated in the following symptom tables, based on the most dominant
characteristic of the customer's vibration concern, felt or heard, that is evident during the appropriate condition
of the occurrence.
Vibration Symptoms that are Felt
Category
Shake
Roughness
Buzz
Tingling
Description
Can sometimes be seen

or felt in the steering
wheel, seat or console.
Related terminology:
shimmy, wobble, waddle,
shudder, hop
Similar to the feeling of

holding a jigsaw.
Similar to the feeling of

holding an electric razor.
May be felt in the hands
through the steering
wheel, in the feet through
the floor, or in the seat of
the pants.
May produce a "pins and
needles" sensation or
may put hands or feet "to
sleep".
Highest vibration
frequency range that can
Typical
Frequency Range
Condition of
Occurrence
Vehicle Speed
Sensitive
Still occurs during
coast down in
NEUTRAL
Vehicle Speed
5-20 Hz
Sensitive
Affected by
torque/load and/or
steering input
Engine Speed
Sensitive
Vehicle Speed
Sensitive
Still occurs during
coast down in
NEUTRAL
Vehicle Speed
20-50 Hz
Sensitive
Affected by
torque/load and/or
steering input
Engine Speed
Sensitive
Vehicle Speed
Sensitive
Affected by
torque/load and/or
50-100 Hz
steering input
Engine Speed
Sensitive
Vehicle Speed
Sensitive
Affected by
Greater than 100
torque/load and/or
Hz
steering input
Engine Speed
Area of Focus
Go to Vibration
Analysis - Tire
and Wheel
Go to Vibration
Analysis - Hub
and/or Axle
Input
Go to Vibration
Analysis - Engine
Go to Vibration
Analysis - Tire
and Wheel
Go to Vibration
Analysis - Hub
and/or Axle
Input
Go to Vibration
Analysis - Engine
Go to Vibration
Analysis - Hub
and/or Axle
Input
Go to Vibration
Analysis - Engine
Go to Vibration
Analysis - Hub
and/or Axle
Input
Go to Vibration

still be felt.
Sensitive
Analysis - Engine
Vibration Symptoms that are Heard
Category
Boom
Moan or
Drone
Description
Usually heard as an interior
noise similar to the noise of a
bowling ball rolling down an
alley, deep thunder, or a bass
drum.
Related terminologydroning, growling,
moaning, roaring,
rumbling, humming
May not be
accompanied by a
perceptible vibration or
roughness
Similar to the sound of a
bumblebee or blowing air
across the top of a bottle.
Howl
Whine
Related terminologyhumming, buzzing,

resonance
May be accompanied
by a perceptible
vibration such as a
buzz
Similar to the sound of the

wind howling.
Similar to the sound of

mosquitoes, turbine engines,
or vacuum cleaners.
Typical
Frequency
Range
Condition of
Occurrence
Area of Focus
Vehicle Speed
Sensitive
Still occurs during
coast down in
NEUTRAL
Go to Vibration
Analysis - Tire
and Wheel
Vehicle Speed
Sensitive
Affected by
torque/load and/or
steering input
Go to Vibration
Analysis - Hub
and/or Axle Input
Vehicle Speed
Sensitive
Affected by
torque/load and/or
steering input
Go to Vibration
Analysis - Hub
and/or Axle Input
Engine Speed
Sensitive
Go to Vibration
Analysis - Engine
20-60 Hz
60-120 Hz
120-300 Hz
300-500 Hz
Vehicle Speed
Sensitive
Affected by
torque/load and/or
steering input
Engine Speed
Sensitive
Vehicle Speed
Sensitive
Affected by
torque/load
Go to Vibration
Analysis - Hub
and/or Axle Input
Go to Vibration
Analysis - Engine
Go to transmission
diagnostic
information
VEHICLE-TO-VEHICLE DIAGNOSTIC COMPARISON

Comparing the customer's vehicle to a KNOWN GOOD vehicle that is essentially identical will help determine

if the customer's concern may be characteristic of a vehicle design. To arrive at a valid conclusion, the
comparison must be performed under the same conditions, using the same criteria, on a vehicle that has the
same option content as the customer's vehicle.
The comparison vehicle must match the customer's vehicle in the following areas:
Model Year
Make
Model
Body style
Powertrain configuration
Driveline configuration
Final drive ratio
Tire/wheel size and type
Suspension package
Trailering package
GVW rating
Performance options
Luxury options
TIRE AND WHEEL INSPECTION

Fig. 3: Identifying Tire Performance Criteria (TPC) Rating Markings

The tires on all new production models have a tire performance criteria (TPC) rating number molded on the
sidewall. The TPC rating will appear as a 4-digit number preceded by the letters TPC SPEC on the tire wall
near the tire size. A replacement tire should have the same TPC rating.
Tire Wear

Fig. 4: Identifying Types Of Tire Wear

Callout
1
2
3
4
5
Component Name
Hard Cornering/Underinflation
Incorrect Alignment/Lack of Rotation
Incorrect Alignment/Non-uniform Tire
Heavy Acceleration/Over inflation
Wear Indicator
Inspect the tire and wheel assemblies for the 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 inflation to specifications for the vehicle

Bulges in the sidewalls
Do not confuse bulges, which are an abnormal condition, with normal ply splices which are commonly
seen as indentations in the sidewall.
Bent rim flanges
TIRE AND WHEEL ASSEMBLY RUNOUT MEASUREMENT - ON-VEHICLE

1. Raise and support the vehicle.
2. Closely inspect each tire for proper and even bead seating.
3. If any of the tire beads were not properly or evenly seated, reseat the tire bead, then proceed to step 4.
Refer to Tire and Wheel Removal and Installation .

Fig. 5: Measuring Tire & Wheel Assembly Radial Runout

4. Wrap the circumference of each tire with tape (1) in the center tread area.
Wrapping the tread with tape allows for a smooth and accurate reading of radial runout to be obtained.
5. Position the dial indicator on the taped portion of the tire tread such that the dial indicator is perpendicular
to the tire tread surface.
6. Slowly rotate the tire and wheel assembly one complete revolution in order to find the low spot.
7. Set the dial indicator to zero at the low spot.
8. 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 runout - measured on-vehicle: 1.52 mm (0.060 in)

Fig. 6: Measuring Tire & Wheel Assembly Lateral Runout

9. Position the dial indicator on a smooth portion of the tire sidewall, as close to the tread as possible, such
that the dial indicator is perpendicular to the tire sidewall surface.
10. Slowly rotate the tire and wheel assembly one complete revolution in order to find the low spot. Ignore
any jumps or dips due to sidewall splices.
lateral runout. Ignore any jumps or dips due to sidewall splices and attain an average runout
measurement.
Specification
Maximum tire and wheel assembly lateral runout - measured on-vehicle: 1.52 mm (0.060 in)
13. Repeat steps 4 through 12 until all of the tire and wheel assembly radial and lateral runout measurements
have been taken.


TIRE AND WHEEL ASSEMBLY RUNOUT MEASUREMENT - OFF VEHICLE
2. Mark the location of the wheels to the wheel studs and mark the specific vehicle position on each tire and
wheel - LF, LR, RF, RR.
3. Remove the tire and wheel assemblies from the vehicle.
4. Closely inspect each tire for proper and even bead seating.
5. If any of the tire beads were not properly or evenly seated, reseat the tire bead, then proceed to step 6.
Refer to Tire and Wheel Removal and Installation .
6. Mount a tire and wheel assembly on a spin-type wheel balancer.
Locate the tire and wheel assembly on the balancer with a cone through the back side of the center pilot
hole.
Fig. 7: Measuring Tire & Wheel Assembly Radial Runout


7. Wrap the outer circumference of each tire with tape (1) in the center tread area.
Wrapping the tread with tape allows for a smooth and accurate reading of radial runout to be obtained.
8. Position the dial indicator on the taped portion of the tire tread such that the dial indicator is perpendicular
to the tire tread surface.
radial runout.
Specification
Maximum tire and wheel assembly radial runout - measured off-vehicle: 1.27 mm (0.050 in)
Fig. 8: Measuring Tire & Wheel Assembly Lateral Runout


12. Position the dial indicator on a smooth portion of the tire sidewall, as close to the tread as possible, such
that the dial indicator is perpendicular to the tire sidewall surface.
13. Slowly rotate the tire and wheel assembly one complete revolution in order to find the low spot. Ignore
any jumps or dips due to sidewall splices.
lateral runout. Ignore any jumps or dips due to sidewall splices and attain an average runout
measurement.
Specification
Maximum tire and wheel assembly lateral runout - measured off-vehicle: 1.27 mm (0.050 in)
16. Repeat steps 6 through 15 until all of the tire and wheel assembly radial and lateral runout measurements
have been taken.
17. If ANY of the tire and wheel assembly runout measurements were NOT within specifications, proceed to
step 19.
18. If ALL of the tire and wheel assembly runout measurements WERE within specifications, then the offvehicle tire and wheel assembly runout is considered acceptable.

Fig. 9: Measuring Wheel Radial Runout (Off-Vehicle, Tire Mounted)

19. Position the dial indicator on the horizontal outer surface of the wheel rim flange - with the tire still
mounted - such that the dial indicator is perpendicular to the rim flange surface.
Wheel runout should be measured on both the inboard and outboard rim flanges, unless wheel design will
not permit. Ignore any jumps or dips due to paint drips, chips, or welds.
wheel radial runout.
Specification
Maximum aluminum wheel radial runout - measured off-vehicle, tire mounted: 0.762 mm (0.030

in)
Maximum steel wheel radial runout - measured off-vehicle, tire mounted: 1.015 mm (0.040 in)
Fig. 10: Measuring Wheel Lateral Runout (Off-Vehicle, Tire Mounted)

23. Position the dial indicator on the vertical outer surface of the wheel rim flange - with the tire still mounted
- such that the dial indicator is perpendicular to the rim flange surface.
Wheel runout should be measured on both the inboard and outboard rim flanges, unless wheel design will
not permit. Ignore any jumps or dips due to paint drips, chips, or welds.
wheel lateral runout.

Specification
Maximum aluminum wheel lateral runout - measured off-vehicle, tire mounted: 0.762 mm (0.030
in)
Maximum steel wheel lateral runout - measured off-vehicle, tire mounted: 1.143 mm (0.045 in)
Repeat steps 19 through 26 until all of the wheel radial and lateral runout measurements have been taken
on each of the - tire and wheel - assemblies with assembly runout measurements which were NOT within
specifications.
If any of the wheel runout measurements were NOT within specifications, proceed to Measuring Wheel
Runout - Tire Dismounted.
For any of the wheel runout measurements which WERE within specifications, while the - tire and wheel
- assembly runout measurements were NOT within specifications, replace the tire, then balance the
assembly. Refer to Tire and Wheel Assembly Balancing - Off Vehicle.
After replacement of any tires, always re-measure the runout of the affected tire and wheel assembly, or
assemblies.
Using the matchmarks made prior to removal, install the tire and wheel assemblies to the vehicle.
Lower the vehicle.
27.
28.
29.
30.
31.
32.
Wheel Runout Measurement - Tire Dismounted
1. On the tire and wheel assembly, or assemblies with wheel runout measurements - tire mounted - which
were NOT within specifications, mark each tire and wheel in relation to each other.
2. Dismount the tire from the wheel. Refer to Tire Dismounting and Mounting .
3. Mount the wheel on a spin-type wheel balancer.
4. Locate the wheel on the balancer with a cone through the back side of the center pilot hole.

Fig. 11: Measuring Wheel Radial Runout (Off-Vehicle, Tire Dismounted)

5. Position the dial indicator on the horizontal inner surface of the wheel rim flange - with the tire
dismounted - such that the dial indicator is perpendicular to the rim flange surface.
Wheel runout should be measured on both the inboard and outboard rim flanges. Ignore any jumps or dips
due to paint drips, chips, or welds.
6. Slowly rotate the wheel one complete revolution in order to find the low spot.
8. Slowly rotate the wheel one more complete revolution and measure the total amount of wheel radial
runout.
Specification
Maximum aluminum wheel radial runout - measured off-vehicle, tire dismounted: 0.762 mm (0.030

in)
Maximum steel wheel radial runout - measured off-vehicle, tire dismounted: 1.015 mm (0.040 in)
Fig. 12: Measuring Wheel Lateral Runout (Off-Vehicle, Tire Dismounted)

9. Position the dial indicator on the vertical inner surface of the wheel rim flange - with the tire dismounted such that the dial indicator is perpendicular to the rim flange surface.
Wheel runout should be measured on both the inboard and outboard rim flanges. Ignore any jumps or dips
due to paint drips, chips, or welds.
10. Slowly rotate the wheel one complete revolution in order to find 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-vehicle, tire dismounted: 0.762 mm
(0.030 in)
Maximum steel wheel lateral runout - measured off-vehicle, tire dismounted: 1.143 mm (0.045 in)
13. Repeat steps 2 through 12 until all of the wheel radial and lateral runout measurements - tire dismounted have been taken on each wheel with runout measurements - tire mounted - which were NOT within
specifications.
14. If any of the wheel runout measurements - tire dismounted - were NOT within specifications, replace the
wheel.
Always measure the runout of any replacement wheels.

15. For any of the wheel runout measurements which WERE within specifications, while the - tire and wheel
- assembly runout measurements were NOT within specifications, replace the tire, then balance the
assembly. Refer to Tire and Wheel Assembly Balancing - Off Vehicle.
16. Using the matchmarks made prior to dismounting the tire, or tires, mount the tire, or tires to the wheel, or
wheels, then balance the assembly, or assemblies. Refer to Tire and Wheel Assembly Balancing - Off
Vehicle.
Always measure the runout of any of the tire and wheel assemblies which have had the tires dismounted
and mounted.
17. Using the matchmarks made prior to removal, install the tire and wheel assemblies to the vehicle.
BRAKE ROTOR/DRUM BALANCE INSPECTION
1. Support the vehicle drive axle on a suitable hoist. Refer to Lifting and Jacking the Vehicle .
2. Remove the tire and wheel assemblies from the drive axle. Refer to Tire and Wheel Removal and
Installation .
WARNING: Refer to Work Stall Test Warning .
3. Reinstall the wheel nuts in order to retain the brake rotors.

4. Run the vehicle at the concern speed while inspecting for the presence of the vibration.
CAUTION: Do not depress the brake pedal with the brake rotors and/or the brake
drums removed, or with the brake calipers repositioned away from
the brake rotors, or damage to the brake system may result.
5. If the vibration is still present, remove the rotors from the drive axle, then run the vehicle back to the
concern speed.

6. If the vibration is eliminated 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.
Fig. 13: Balancing Brake Drum

7. If a brake rotor was replaced as a result of following the previous steps, or if necessary to confirm the
results obtained during the previous steps, and/or to check the non-drive axle components, perform the
following:
1. Mount the brake rotor/drum on a balancer in the same manner as a tire and wheel assembly.
NOTE:
Check brake rotors/drums for static imbalance only; ignore the

dynamic imbalance readings.
2. Inspect the rotor/drum for static imbalance.

There is not a set tolerance for brake rotor/drum static imbalance. However, any brake rotor/drum measured in

this same manner which is over 21 g (3/4 oz) may have the potential to cause or contribute to a vibration.
Rotors/drums suspected of causing or contributing to a vibration should be replaced. Any rotor/drum that is
replaced should be checked for imbalance in the same manner.
HUB/AXLE FLANGE AND WHEEL STUD RUNOUT INSPECTION
Special Tools
GE-8001 Dial Indicator Set, or equivalent
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
3. Remove the tire and wheel assemblies from the vehicle. Refer to Tire and Wheel Removal and
Installation .
4. Remove the brake rotors and/or brake drums from the vehicle. Clean the mounting surfaces of the brake
rotors, the brake drums, if equipped, and the hub/axle flanges of any loose debris, rust, and corrosion.

Fig. 14: Measuring Wheel Hub/Axle Flange Runout

5. Position the GE-8001 Dial Indicator Set, or equivalent, on the machined surface of the wheel hub/axle
flange outside of the wheel studs.
6. Rotate the hub one complete revolution in order to find the low spot.
7. Set the GE-8001 Dial Indicator Set, or equivalent, to zero at the low spot.
8. Rotate the hub one more complete revolution and measure the total amount of wheel hub/axle flange
runout.
Specification - Guideline
Wheel hub/axle flange runout tolerance guideline: 0.132 mm (0.005 in)
9. If the runout of the wheel hub/axle flange IS within specification and the vehicle is equipped with wheel
studs, proceed to step 13.
10. If the runout of the wheel 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 source of the
disturbance.
12. If the runout of the wheel hub/axle flange is excessive, replace the wheel hub/axle flange. Measure the
runout of the new wheel hub/axle flange.
Fig. 15: Measuring Wheel Stud Runout

13. Position the GE-8001 Dial Indicator Set, or equivalent, in order to contact the wheel mounting studs.
Measure the stud runout as close to the flange as possible.
14. Turn the hub one complete revolution to register on each of the wheel studs.
15. Zero the GE-8001 Dial Indicator Set, or equivalent, on the lowest stud.
16. Rotate the hub one more complete revolution and measure the total amount of wheel stud - stud circle runout.

Specification - Guideline
Wheel stud runout tolerance guideline: 0.254 mm (0.010 in)
17. If the runout of the wheel studs - stud circle - is marginal, the wheel studs may or may not be contributing
to the disturbance.
18. If the runout of the wheel studs - stud circle - is excessive, replace the wheel studs as necessary. Measure
the runout of the new wheel studs.
19. Inspect the threads and the tapered seat portion on each of the wheel bolts for damage.
20. Wheel bolts exibiting damaged threads and/or damaged tapered seats require replacement.
21. Place the threaded portion of each wheel bolt along a straight edge to inspect for straightness.
22. Wheel bolts that are not straight require replacement.
TIRE AND WHEEL ASSEMBLY ISOLATION TEST
Force Variation
Force variation refers to a radial or lateral movement of the tire and wheel assembly which acts much like
runout, however, force variation has to do with variations in the construction of the tire. These variations in tire
construction may actually cause vibration in a vehicle, even though the tire and wheel assembly runout and
balance may be within specifications.
Radial Force Variation

Fig. 16: Identifying Radial Force Variation

Radial force variation refers to the difference in the stiffness of a tire sidewall as the tire rotates and contacts the
road. Tire sidewalls have some stiffness due to splices in the different plies of the tire, but these stiffness
differences do not cause a problem unless the force variation is excessive. Stiff spots (1) in a tire sidewall can
deflect a tire and wheel assembly upward as the assembly contacts the road.
Lateral Force Runout

Fig. 17: Identifying Tire Wobble/Waddle

Lateral force variation refers to the difference in the stiffness or conformity of the belts within a tire as the tire
rotates and contacts the road. Tire belts may have some stiffness or conformity differences, but these differences
do not cause a problem unless the force variation is excessive. These variations in the belts of the tire can
deflect the vehicle sideways or laterally. A shifted belt inside a tire 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.
Isolation Test Procedure
Perform the following test in order to determine if force variation is present in the vehicle.
1. Substitute a set of KNOWN GOOD, pre-tested tire and wheel assemblies of the same size and type for
the suspected original assemblies. Refer to Tire and Wheel Removal and Installation .
2. Road test the vehicle to determine if the vibration is still present. Refer to Vibration Analysis - Road

3.
4.
5.
6.
Testing.
If the vibration is still present while using the known good set of tire and wheel assemblies, then force
variation is not the cause of the vibration.
If the vibration is eliminated when using the known good set of tire and wheel assemblies, install one of
the original tire and wheel assemblies using the matchmarks made prior to removal. Refer to Tire and
Wheel Removal and Installation . Road test the vehicle to determine if the vibration has returned. Refer
to Vibration Analysis - Road Testing.
Continue the process of installing the original tire and wheel assemblies one at a time, then road testing
the vehicle, until the tire and wheel assembly, or assemblies which is causing the vibration has been
identified.
Replace the tire, or tires on the vibration-causing tire and wheel assembly, or assemblies, then balance the
assembly, or assemblies. Refer to Tire and Wheel Assembly Balancing - Off Vehicle.
REPAIR INSTRUCTIONS
TIRE AND WHEEL ASSEMBLY BALANCING - OFF VEHICLE
WARNING: Failure to adhere to the following precautions before tire balancing can
result in personal injury or damage to components:
Clean away any dirt or deposits from the inside of the wheels.
Remove any stones from the tread.
Wear eye protection.
Use coated weights on aluminum wheels.
Tire and Wheel Assembly Balancer Calibration
Tire and wheel balancers can drift out of calibration over time, or can become inaccurate as a result of heavy
use. There will likely not be any visual evidence that a calibration problem exists. If a balancer is not calibrated
within specifications, and a tire and wheel assembly is balanced on that machine, the assembly may actually be
imbalanced.
Tire and wheel assembly balancer calibration should be checked approximately every 2 weeks, if the machine is
used frequently, and/or whenever the balance readings are questionable.
Tire and Wheel Assembly Balancer Calibration Test
NOTE:
If the balancer fails any of the steps in this calibration test, the balancer should
be calibrated according to the manufacturer's instructions. If the balancer
cannot be calibrated, contact the manufacturer for assistance.
Inspect the calibration of the tire and wheel assembly balancer according to the manufacturer's
recommendations, or perform the following test.

Fig. 18: View Of Tire & Wheel Assembly Balancer

1. Spin the balancer without a wheel or any of the adapters on the shaft.
2. Inspect the balancer readings.
Specification
Zero within 7 g (1/4 oz)
3. If the balancer is within the specification range, balance a tire and wheel assembly - that is within radial
and lateral runout tolerances - to ZERO, using the same balancer.
4. After the tire and wheel assembly has been balanced, add an 85 g (3 oz) test weight to the wheel at any
location.
5. Spin the tire and wheel assembly again. Note the readings.
In the static and dynamic modes, the balancer should call for 85 g (3 oz) of weight, 180 degrees
opposite the test weight.
In the dynamic mode, the weight should be called for on the flange of the wheel opposite the test

weight.
6. With the assembly imbalanced to 85 g (3 oz), cycle the balancer 5 times.
7. Inspect the balancer readings:
Specification
Maximum variation: 7 g (1/4 oz)
8. Index the tire and wheel assembly on the balancer shaft, 90 degrees from the previous location.
9. Cycle the balancer with the assembly at the new location.
10. Inspect the balancer readings:
Specification
Maximum variation: 7 g (1/4 oz)
11. Repeat steps 8 through 10 until the tire and wheel assembly has been cycled and checked at each of the 4
locations on the balancer shaft.
Tire and Wheel Assembly Balancing Guidelines
There are 2 types of tire and wheel balance:

Static Balance

Fig. 19: View Of Static Balance

Static balance is the equal distribution of weight around the wheel circumference. The wheel balance weights
(2) are positioned on the wheel in order to offset the effects of a heavy spot (3). Wheels that have static
imbalance can produce a bouncing action called tramp.
Dynamic Balance

Fig. 20: View Of Dynamic Balance

Dynamic balance is the equal distribution of weight on each side of the tire and wheel assembly centerline. The
wheel balance weights (2) are positioned on the wheel in order to offset the effects of a heavy spot (3). Wheels
that have dynamic imbalance have a tendency to move from side to side and can cause an action called shimmy.
Most off-vehicle balancers are capable of checking both types of balance simultaneously.
As a general rule, most vehicles are more sensitive to static imbalance than 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 (1/2 - 3/4 oz) imbalance is capable of inducing a vibration
in some vehicle models.
Balancing Procedure
NOTE:
When balancing tire and wheel assemblies, use a known good, recently
calibrated, off-vehicle, two-plane dynamic balancer set to the finest balance

mode available.
3. Remove the tire and wheel assemblies one at a time and mount on a spin-type wheel balancer. Refer to
Tire and Wheel Removal and Installation .
4. Carefully follow the wheel balancer manufacturer's instructions for proper mounting techniques to be
used on different types of wheels.
Regard aftermarket wheels, especially those incorporating universal lug patterns, as potential sources of
runout and mounting concerns.
5. Be sure to use the correct type of wheel balance weights for the type of wheel rim being balanced. Be
sure to use the correct type of coated wheel balance weights on aluminum wheels. Refer to Wheel Weight
Usage.
6. Balance all four tire and wheel assemblies as close to zero as possible.
7. Using the matchmarks made prior to removal, install the tire and wheel assemblies to the vehicle. Refer to
Wheel Weight Usage
Tire and wheel assemblies can be balanced using either the static or dynamic method.
Clip-on Weights

Fig. 21: Identifying Clip-On Wheel Weight Types

NOTE:
When balancing factory aluminum wheels with clip-on wheel balance weights,

be sure to use special polyester-coated weights. These coated weights reduce

the potential for corrosion and damage to aluminum wheels.
These coated weights reduce the potential for corrosion and damage to aluminum wheels.
MC (1) and AW (2) series weights are approved for use on aluminum wheels.
P (3) series weights are approved for use on steel wheels only.
T (4) series coated weights are approved for use on both steel and aluminum wheels.
Fig. 22: Attaching Clip-On Wheel Weight

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 style of the wheel rim flange will determine which type of clip-on wheel weight (1) should be
used. The weight should follow the contour of the rim flange. The weight clip should firmly grip the rim flange.

Wheel Weight Placement - Clip-on Weights
Fig. 23: View Of Wheel Weight Placement - Static Balancing

When static balancing, locate the wheel balance weights on the inboard flange (2) if only 28 g (1 oz) or less is
called for. If more than 28 g (1 oz) is called for, split the weights as equally as possible between the inboard (2)
and outboard (1) flanges.
When dynamic balancing, locate the wheel balance weights on the inboard (2) and outboard (1) rim flanges at
the positions specified by the wheel balancer.
Adhesive Weights

Fig. 24: Identifying Adhesive Weight Wheel Placement


NOTE:
When installing adhesive balance weights on flangeless wheels, do NOT install

the weight on the outboard surface of the rim.
Adhesive wheel balance weights may be used on factory aluminum wheels. Perform the following procedure to
install adhesive wheel balance weights.
1. Determine the correct areas for placement of the wheel weights on the wheel.
When static balancing, locate the wheel balance weights along the wheel centerline (1) on the inner
wheel surface if only 28 g (1 oz) or less is called for. If more than 28 g (1 oz) is called for, split the
weights as equally as possible between the wheel centerline and the inboard edge of the inner wheel
surface (2).
When dynamic balancing, locate the wheel balance weights along the wheel centerline and the
inboard edge of the inner wheel surface (2) at the positions specified by the wheel balancer.
2. Ensure that there is sufficient clearance between the wheel weights and brake system components.
NOTE:
Do not use abrasives to clean any surface of the wheel.
3. Using a clean cloth or paper towel with a general purpose cleaner, thoroughly clean the designated
balance weight attachment areas of any corrosion, overspray, dirt or any other foreign material.
4. To ensure there is no remaining residue, wipe the balance weight attachment areas again, using a clean
cloth or paper towel with a mixture of half isopropyl alcohol and half water.
5. Dry the attachment areas with hot air until the wheel surface is warm to the touch.
6. Warm the adhesive backing on the wheel balance weights to room temperature.
7. Remove the protective 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 wheel balance weights to the wheel with a 90 N (21 lb) force applied with a roller.
TIRE AND WHEEL ASSEMBLY BALANCING - ON-VEHICLE
Special Tools
For equivalent regional tools. Refer to Special Tools and Equipment.
If after following the tire and wheel vibration diagnostic process, some amount of tire and wheel vibration is
still evident, an on-vehicle high-speed spin balancer may be used to perform an on-vehicle balance in an attempt
to finish balance the tire and wheel assemblies, wheel hubs, brake rotors, brake drums, if equipped, and wheel
trim, if equipped, simultaneously. On-vehicle balancing can also compensate for minor amounts of residual
runout encountered as a result of mounting the tire and wheel assembly on the vehicle, as opposed to the
balance which was achieved on the off-vehicle balancer.
In order to perform an on-vehicle balancing procedure, carefully follow the on-vehicle balancer manufacturer's

specific operating instructions and carefully consider the following information before proceeding:
Vehicles equipped with low profile, wide tread path, high performance tires and wheels are susceptible to
small amounts of dynamic imbalance.
When performing an on-vehicle balance, great care must be taken when placing the wheel balance
weights on the wheels. If the wheel balance weights are not placed accurately, they can actually induce
dynamic imbalance and thus increase the severity of the vibration.
Inspect the vehicle wheel bearings to ensure that they are in good condition.
Thoroughly inspect all on-vehicle balancing equipment and ensure that it is fully within the
manufacturer's recommended specifications.
Do not remove the off-vehicle balance weights. The purpose of on-vehicle balance is to fine tune the
assembly balance already achieved off-vehicle, not to start over.
Leave all wheel trim installed whenever possible.
If the on-vehicle balancer calls for more than 56 g (2 oz) of additional weight, split the weight between
the inboard and outboard flanges of the wheel, so as not to upset the dynamic balance of the assembly
achieved in the off-vehicle balance. For wheel balance weight information, refer to Tire and Wheel
Assembly Balancing - Off Vehicle.
If available, tape-off an area on top of the fenders and the quarter panels, then place the vibration sensor
of the EL-38792-A analyzer on the fender or quarter panel above the specific tire and wheel assembly
while it is being on-vehicle balanced.
The EL-38792-A analyzer will provide a visual indication of the amplitude of the vibration, and the
effect that the on-vehicle balance has on it.
TIRE-TO-WHEEL MATCH-MOUNTING (VECTORING)

Fig. 25: View Of Tire-to-Wheel Match-Mounting

NOTE:
After remounting a tire to a wheel or after replacing a tire and/or a wheel,

remeasure the tire and wheel assembly runout in order to verify that the amount
of runout has been reduced and brought to within tolerances. Ensure that the
tire and wheel assembly is properly balanced before reinstalling to the vehicle.
1. Mark the location of the high spot (3) on the tire as determined during the off-vehicle tire and wheel
assembly runout measurement.
2. Place a reference mark (2) on the tire sidewall at the location of the valve stem (5).
Always refer to the valve stem as the 12 o'clock position.
Refer to the location of the high spot (3) by its clock position on the wheel, relative to the valve
stem.
3. Mount the tire and wheel assembly on a tire machine and break down the bead. Do not dismount the tire
from the wheel at this time.

4. Rotate the tire 180 degrees on the rim so that the valve stem reference mark (8) is now at the 6 o'clock
position in relation 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 remeasure the runout. Mark the new location of the assembly
runout high spot on the tire.
7. If the assembly runout has been reduced and is within tolerance, no further steps are necessary. Balance
the tire and wheel assembly, then install the assembly to the vehicle. Refer to the following:
Tire and Wheel Assembly Balancing - Off Vehicle
Tire and Wheel Removal and Installation
8. If the clock location of the high spot remained at or near the original clock location of the high spot (7)
and the assembly runout has NOT been reduced, the wheel is the major contributor to the assembly
runout concern.
Fig. 26: View Of Match-Mounting Tire-To-Wheel


9. If the clock location of the high spot has moved, however the assembly runout has NOT been reduced,
perform the following steps:
1. If the clock location of the high spot (7) is now at or near a position 180 degrees from the original
clock location of the high spot, the tire is the major contributor to the assembly runout concern.
2. If the clock location of the high spot is now in-between the 2 extremes, then both the tire and the
wheel are both contributing to the assembly runout concern. Rotate the tire an additional 90 degrees
in both the clockwise and the counterclockwise directions to obtain the lowest amount of assembly
runout.
TIRE AND WHEEL ASSEMBLY-TO-HUB/AXLE FLANGE MATCH-MOUNTING
NOTE:
After remounting a tire and wheel assembly to a hub/axle flange, remeasure the
tire and wheel assembly on-vehicle runout in order to verify that the amount of
runout has been reduced and brought to within tolerances.
1. Mark the location of the high spot on the tire and wheel assembly as determined during the on-vehicle tire
and wheel assembly runout measurement.
2. Place a reference mark on the wheel stud that is located closest to the wheel valve stem.
Always refer to the reference mark on the wheel stud as the 12 o'clock position.
Refer to the location of the high spot by its clock position on the tire and wheel assembly, relative
to the marked wheel stud.
3. Remove the tire and wheel assembly from the hub/axle flange. Refer to Tire and Wheel Removal and
Installation .
4. Rotate the tire and wheel assembly as close to 180 degrees as possible on the hub/axle flange, so that the
wheel valve stem is now approximately at the 6 o'clock position in relation to the marked wheel stud.
5. Reinstall the wheel lug nuts to secure the tire and wheel 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 onvehicle runout high spot on the tire. Refer to Tire and Wheel Assembly Runout Measurement - OnVehicle.
7. If the assembly on-vehicle runout has been reduced and is within tolerance, no further steps are necessary.
8. If the assembly runout has NOT been reduced, perform the following steps:
1. If the clock location of the high spot remained at or near the original clock location of the high spot,
the hub/axle flange and/or the brake rotor/drum mounting flange is the major contributor to the
assembly on-vehicle runout concern.
2. If the clock location of the high spot is now at or near a position 180 degrees from the original
clock location of the high spot, the tire and wheel assembly is the major contributor to the assembly
on-vehicle runout concern.
3. If the clock location of the high spot is now in-between the 2 extremes, then both the tire and wheel
assembly and the hub/axle flange are contributing to the assembly on-vehicle runout concern.
Rotate the tire and wheel assembly as close to an additional 90 degrees as possible in both the
clockwise and the counterclockwise directions to obtain the lowest amount of assembly on-vehicle
runout.

DESCRIPTION AND OPERATION

VIBRATION THEORY AND TERMINOLOGY
Vibration Theory
The designs and engineering requirements of vehicles have undergone drastic changes over the last several
years.
Vehicles are stiffer and provide more isolation from road input than they did previously. The structures of
today's stiffer vehicles are less susceptible to many of the vibrations which could be present in vehicles of
earlier designs, however, vibrations can still be detected in a more modern vehicle if a transfer path is created
between a rotating component and the body of the vehicle.
There are not as many points of isolation from the road in many vehicles today. If a component produces a
strong enough vibration, it may overcome the existing isolation and the component needs to be repaired or
replaced.
The presence/absence of unwanted noise and vibration is linked to the customer's perception of the overall
quality of the vehicle.
Vibration is the repetitive motion of an object, back and forth, or up and down. The following components
cause most vehicle vibrations:
A rotating component
The engine combustion process firing impulses
Rotating components will cause vibrations when excessive imbalance or runout is present. During vibration
diagnosis, the amount of allowable imbalance or runout should be considered a TOLERANCE and not a
SPECIFICATION. In other words, the less imbalance or runout the better.
Rotating components will cause a vibration concern when they not properly isolated from the passenger
compartment: Engine firing pulses can be detected as a vibration if a motor mount is collapsed.
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 an equal
rate/speed in order to pinpoint the source. Vibrations also tend to transmit through the body structure to other
components. Therefore, just because the seat vibrates does not mean the source of vibration is in the seat.
Vibrations consist of the following three elements:
The source - the cause of the vibration

The transfer path - the path the vibration travels through the vehicle
The responder - the component where the vibration is felt

Fig. 27: Identifying Unbalanced Tire Vibration

In the preceding picture, the source is the unbalanced tire. The transfer path is the route the vibrations travels
through the vehicle's suspension system into the steering column. The responder is the steering wheel, which the
customer reports as vibrating. Eliminating any one of these three elements will usually correct the condition.
Decide, from the gathered information, which element makes the most sense to repair. Adding a brace to the
steering column may keep the steering wheel from vibrating, but adding a brace is not a practical solution. The
most direct and effective repair would be to properly balance the tire.

Fig. 28: Identifying Exhaust Pipe Noise

Vibration can also produce noise. As an example, consider a vehicle that has an exhaust pipe grounded to the
frame. The source of the vibration is the engine firing impulses traveling through the exhaust. The transfer path
is a grounded or bound-up exhaust hanger. The responder is the frame. The floor panel vibrates, acting as a
large speaker, which produces noise. The best repair would be to eliminate the transfer path. Aligning the
exhaust system and correcting the grounded condition at the frame would eliminate the transfer path.
Basic Vibration Terminology
The following are the 2 primary components of vibration diagnosis:
The physical properties of objects

The object's properties of conducting mechanical energy
The repetitive up and down or back and forth movement of a component cause most customer vibration
complaints. The following are the common components that vibrate:

The steering wheel

The seat cushion
The frame
The IP
Vibration diagnosis involves the following simple outline:

1. Measure the repetitive motion and assign a value to the measurement in cycles per second or cycles per
minute.
2. Relate the frequency back on terms of the rotational speed of a component that is operating at the same
rate or speed.
3. Inspect and test the components for conditions that cause vibration.
For example, performing the following steps will help demonstrate the vibration theory:
Fig. 29: Demonstrating Vibration Theory


1. Clamp a yardstick to the edge of a table, leaving about 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 cycle begins at midpoint, continues through the lowest
extreme of travel, then back past the midpoint, through the upper extreme of travel, and back to the midpoint
where the cycle begins again.
The cycle occurs over and over again at the same rate, or frequency. In this case, about 10 cycles in one second.
If we measure the frequency to reflect the number of complete cycles that the yardstick made in one minute, the
measure would be 10 cycles x 60 seconds = 600 cycles per minute (cpm).
We have also found a specific amount of motion, or amplitude, in the total travel of the yardstick from the very
top to the very bottom. Redo the experiment as follows:
1. Reclamp the yardstick to the edge of a table, leaving about 25 cm (10 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 stick vibrates at a much faster frequency: 30 cycles per second (1, 800 cycles per minute).
Cycle
Fig. 30: Identifying Powertrain Vibration Cycles

Callout
1
2
3
4
Component Name
1st Cycle
2nd Cycle
3rd Cycle
Time

Vibration Cycles in Powertrain Components
Fig. 31: Identifying Vibration Cycles In Powertrain Components

Callout
1
2
Component Name
Spindle
Pinion Nose
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.
Frequency

Fig. 32: Identifying Vibration Frequency

Callout
1
2
3
4
Component Name
Amplitude
Reference
Time in Seconds
1 Second
Frequency is defined as the rate at which an event occurs during a given period of time. With a vibration, the
event is a cycle, and the period of time is 1 second. Thus, frequency is expressed in cycles per second.
The proper term for cycles per seconds is Hertz (Hz). This is the most common way to measure frequency.
Multiply the Hertz by 60 to get the cycles or revolutions per minute (RPM).
Amplitude

Fig. 33: Identifying Vibration Amplitude

Callout
1
2
3
4
Component Name
Maximum
Minimum
Zero-to-Peak Amplitude
Peak-to-Peak Amplitude
Amplitude is the maximum value of a periodically varying quantity. Used in vibration diagnostics, we are
referring it to the magnitude of the 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, consider the
vibration caused by an out-of-balance wheel at 80 km/h (50 mph) as opposed to 40 km/h (25 mph). As the
speed increases, the amplitude increases.

Free Vibration
Free vibration is the continued vibration in the absence of any outside force. In the yardstick example, the
yardstick continued to vibrate even after the end was released.
Forced Vibration
Forced vibration is when an object is vibrating continuously as a result of an outside force.

Centrifugal Force Due to an Imbalance
Fig. 34: Identifying Centrifugal Force Components

Callout
1
2
Component Name
Location of Imbalance (Degrees)
Centrifugal Force Acting on Spindle
A spinning object with an imbalance generates a centrifugal force. Performing the following steps will help to
demonstrate centrifugal force:
1. Tie a nut to a string.
2. Hold the string. The nut hangs vertically due to gravity.
3. Spin the string. The nut will spin in a circle.

Centrifugal force is trying to make the nut fly outward, causing the pull you feel on your hand. An unbalanced
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 be felt in the steering
wheel, the seat, and the floor. This disturbance will be repetitive (Hz) and the amplitude will increase. At higher
speeds, both the frequency and the amplitude will increase. As the tire revolves, the imbalance, or the
centrifugal force, will alternately lift the tire up and force the tire downward, along with the spindle, once for
each revolution of the tire.
Natural or Resonant Frequency
Fig. 35: View Of Natural Frequency

The natural frequency is the frequency at which an object tends to vibrate. Bells, guitar strings, and tuning forks
are all examples of objects that tend to vibrate at specific frequencies when excited by an external force.
Suspension systems, and even engines within the mounts, have a tendency to vibrate at certain frequencies. This
is why some vibration complaints occur only at specific vehicle speeds or engine RPM.

The stiffness and the natural frequency of a material have a relationship. Generally, the stiffer the material, the
higher the natural frequency. The opposite is also true. The softer a material, the lower the natural frequency.
Conversely, the greater the mass, the lower the natural frequency.
Resonance
Fig. 36: Natural Frequency Of A Typical Automotive Front Suspension

Callout
1
2
3
4
5
Component Name
Frequency - cps
Suspension Frequency
Unbalanced Excitation
Point of Resonance
Problem Speed
All objects have natural frequencies. The natural frequency of a typical automotive front suspension is in the

10-15 Hz range. This natural frequency is the result of the suspension design. The suspension's natural
frequency is the same at all vehicle speeds. As the tire speed increases along with the vehicle speed, the
disturbance created by the tire increases in frequency. Eventually, the frequency of the unbalanced tire will
intersect with the natural frequency of the suspension. This causes the suspension to vibrate. The intersecting
point is called the resonance.
The amplitude of a vibration will be greatest at the point of resonance. While the vibration may be felt above
and below the problem speed, the vibration may be felt the most at the point of resonance.
Damping
Fig. 37: Identifying Low & High Damping

Callout
1
2
Component Name
Low Damping
High Damping
Damping is the 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 suspension
system.
Beating (Phasing)

Fig. 38: Identifying Beating Or Phasing

Two separate disturbances that are relatively close together in frequency will lead to a condition called beating,
or phasing. A beating vibration condition will increase in intensity or amplitude in a repetitive fashion as the
vehicle travels at a steady speed. This beating vibration can produce the familiar droning noise heard 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 amplitudes in similar frequencies is
called beating. In many cases, eliminating either one of the disturbances can correct the condition.
Order
Order refers to how many times an event occurs during 1 revolution of a rotating component.

Fig. 39: Identifying First-Order Vibration

For example, a tire with 1 high spot would create a disturbance once for every revolution of the tire. This is
called first-order vibration.

Fig. 40: Identifying Second-Order Vibration

An oval-shaped tire with 2 high spots would create a disturbance twice for every revolution. This is called
second-order vibration. Three high spots would be third-order, and so forth. Two first-order vibrations may add
or subtract from the overall amplitude of the disturbance, but that is all. Two first-order vibrations do not equal
a second-order. Due to centrifugal force, an unbalanced component will always create at least a first-order
vibration.
ELECTRONIC VIBRATION ANALYZER (EVA) DESCRIPTION AND OPERATION
Special Tools
EL-38792-25 Inductive Pickup Timing Light

EL-38792-A Electronic Vibration Analyzer 2 (EVA 2)

The EL-38792-A Electronic Vibration Analyzer 2 (EVA 2), is a 12-volt powered hand-held device, similar to a
scan tool, which receives input from an attached vibration sensor or accelerometer and displays the most
dominate input frequency(ies) (up to three) on its liquid crystal display. The vibration concern frequency(ies)
are obtained through the use of the EL-38792-A Electronic Vibration Analyzer 2 (EVA 2) while following the
Vibration Analysis Diagnostic Tables. The frequency(ies) obtained, when applied to the Vibration Analysis
Diagnostic Tables, are used as a primary input to help determine the source of the vibration concern.
EVA Vibration Sensor
The EL-38792-A Electronic Vibration Analyzer 2 (EVA 2) vibration sensor incorporates a 6.1 m (20 ft) cord,
that allows the sensor to be placed on virtually any component of the vehicle where a vibration concern is felt.
The EL-38792-A Electronic Vibration Analyzer 2 (EVA 2) contains 2 sensor input ports which can be activated
individually to allow for 2 individual vibration sensor inputs. The vibration sensors can then be placed in 2
different locations in the vehicle and their individual inputs can be read without having to stop a test, move the
sensor and resume the test. The use of 2 vibration sensors can help in more quickly finding and recording an
accurate frequency of the vibration concern, and in more quickly making comparisons between 2 different areas
of a single component, or a vehicle system, during the diagnostic process.
EVA Vibration Sensor Placement
Proper placement of the EL-38792-A Electronic Vibration Analyzer 2 (EVA 2) vibration sensor
(accelerometer) is critical to ensure that proper vibration readings are obtained by the EL-38792-A Electronic
Vibration Analyzer 2 (EVA 2). The vibration sensor should be placed on the specific vehicle component
identified as being the most respondent to the vibration. If no component has been identified, install the sensor
to the steering column as a starting point.
EVA Vibration Sensor-to-Component Attachment
NOTE:
The EL-38792-A Electronic Vibration Analyzer 2 (EVA 2) vibration sensor must

be attached to vehicle components in the manner indicated in order to achieve
accurate frequency readings of the vibration disturbance.
The vibration sensor of the EL-38792-A Electronic Vibration Analyzer 2 (EVA 2) is designed to pickup
disturbances which primarily occur in the vertical plane, since most vibrations are felt in that same up-anddown direction. The EL-38792-A Electronic Vibration Analyzer 2 (EVA 2) 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 close to horizontal as possible. The sensor must be installed in
the exact same position each time tests are repeated or comparisons are made to other vehicles.
The EL-38792-A Electronic Vibration Analyzer 2 (EVA 2) vibration sensor can be attached to vehicle
components in various ways. For non-ferrous surfaces, such as the shroud of a steering column, the sensor can
be attached using putty, or hook and loop fasteners. For ferrous surfaces, the sensor can be attached using a
magnet supplied with the sensor.
EVA Software Cartridge
The EL-38792-A Electronic Vibration Analyzer 2 (EVA 2) uses a software cartridge, the GE-38792-60, which

provides various information to the EL-38792-A Electronic Vibration Analyzer 2 (EVA 2). The GE-38792-60
provides the EL-38792-A Electronic Vibration Analyzer 2 (EVA 2) with an additional feature which can be
selected and utilized to assist in diagnosing vibration concerns.
NOTE:
The Auto-Mode function of the EL-38792-A Electronic Vibration Analyzer 2 (EVA

2) cartridge, GE-38792-60, is designed to be used in SUPPORT of the Vibration
Analysis Diagnostic Tables ONLY.
This support-feature is available through the EL-38792-A Electronic Vibration Analyzer 2 (EVA 2) Auto-Mode
function. When selected, the EL-38792-A Electronic Vibration Analyzer 2 (EVA 2) will prompt the user to
select which one of 2 vehicle systems (vehicle speed or engine speed), is the SUSPECTED source of the
vibration concern. Using the inputted vehicle data parameters along with the most dominate vibration frequency
obtained, it will identify a SUSPECTED source of the vibration concern, such as first-order tire and wheel. This
can be a useful feature when used in conjunction with the Vibration Analysis Diagnostic Tables, to confirm
results obtained through the diagnostic process.
EVA Smart Strobe Function
The EL-38792-A Electronic Vibration Analyzer 2 (EVA 2) can be used to identify some rotating
components/systems which exhibit imbalance IF the component rotational speed is the dominant frequency of
the vibration concern. The EL-38792-A Electronic Vibration Analyzer 2 (EVA 2) is equipped with a strobe
light trigger wire which can be used with an inductive pickup timing light, EL-38792-25 Inductive Pickup
Timing Light, or equivalent included with the GE-38792-25-KIT, or available separately. Using the Smart
Strobe function enables the user to input the vibration frequency to which the strobe will flash. By marking the
suspected rotating component, such as a pulley, adjusting the strobe frequency to match the dominant vibration
frequency at the engine RPM noted during diagnosis, and then operating the engine at that specific RPM, the
mark on the object will appear to be stationary if that object is imbalanced.
EVA Strobe Balancing Function
The EL-38792-A Electronic Vibration Analyzer 2 (EVA 2) can be used to identify the light spot on a propeller
shaft IF the propeller shaft rotational speed is the dominant frequency of the vibration concern. The EL-38792A Electronic Vibration Analyzer 2 (EVA 2) is equipped with a strobe light trigger wire which can be used with
an inductive pickup timing light, GE-38792-25 Inductive Pickup Timing Light, or equivalent included with the
J-38792-25-KIT, or available separately, and in conjunction with the EL-38792-A Electronic Vibration
Analyzer 2 (EVA 2) vibration sensor to identify the light spot on a propeller shaft and to help in making a
determination as to when propeller shaft balance is obtained.
Averaging/Non-Averaging Modes
The EVA provides 2 modes of displaying the most dominate frequencies which the EVA vibration sensor
(accelerometer) detects; averaging and non-averaging (instantaneous).
The averaging mode uses multiple vibration samples taken over a period of time and then displays the most
dominant frequencies which have been averaged-out. Using the averaging mode minimizes the distractions
caused by a sudden vibration frequency being displayed that is not related to the concern vibration, such as from
pot holes or from uneven road surfaces.

The non-averaging (instantaneous) mode is more sensitive to vibration disturbances than the averaging mode.
Using the non-averaging mode will generate instantaneous frequency displays which are not averaged across
multiple samples over a period of time; the specific vibration frequencies that occur at a specific moment during
diagnostic testing will be displayed at that moment. The non-averaging (instantaneous) mode is useful when
measuring a vibration disturbance that exists for only a short period of time or during acceleration/deceleration
testing.
When operating the EVA in the averaging mode along with the Auto Mode, "A" 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 the top center of the screen.
When operating the EVA in the non-averaging (instantaneous) mode along with the Auto Mode, "I" 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 non-averaging (instantaneous) mode and the Manual Mode, the top center of the screen will be
blank.
EVA Display

Fig. 41: View Of EVA Display

The most dominant input frequencies, up to three, received from the EL-38792-A Electronic Vibration
Analyzer 2 (EVA 2) vibration sensor, are displayed in descending order of amplitude strength.
The frequency readings are displayed along the left side of the screen, followed to the right by either a bar graph
or the suspected source of the vibration - depending upon the mode selected, then the amplitude reading for
each frequency along the right side of the screen. The top row of the screen indicates the units of measure being
displayed for the frequencies along the left side and for the amplitudes along the right side. The top row also
indicates the vibration sensor input port which was selected on the keypad (A or B) and which mode was
selected: averaging or non-averaging (instantaneous).
The frequency(ies) can be displayed in either revolutions per minute (RPM) or revolutions per second; Hertz
(Hz). The selected display type (RPM or Hz) will be indicated at the left side of the screen, above the frequency
readings.
When the AUTO MODE function is not in use, a bar graph is displayed next to each frequency to provide a
quick visual indication of the relative amplitude strength.
When the AUTO MODE function is being used, the suspected source of the vibration is displayed next to each
frequency to provide support to the diagnostic process.
The actual amplitude strength of each frequency is displayed at the right side of the screen and shown in G's-ofacceleration force.
VIBRATE SOFTWARE DESCRIPTION AND OPERATION
The EL-38792-VS Vibrate Software, is a computer software program which is designed to be used in support of
the Vibration Analysis diagnostic tables, along with the EL-38792-A Electronic Vibration Analyzer (EVA) 2,
and a scan tool, to help in determining the source of a vibration concern. The EL-38792-VS Vibrate Software is
designed to provide quick calculations and produce a chart of the rotational speeds and frequency ranges for
specific vehicle systems and components, based upon vehicle data parameters inputted by the user.
The EL-38792-VS Vibrate Software uses the vehicle data parameters, such as axle ratio, number of engine
cylinders, etc. to create the base chart, depicting the relationships of the various vehicle systems and/or
components. The chart view can be modified to show data related to vehicle speed only, engine speed only, or
both vehicle speed and engine speed. The user can then plot the dominant frequency reading obtained on the
EL-38792-A Electronic Vibration Analyzer (EVA) 2 which correlates with the vibration concern, and the
engine RPM obtained on a scan tool which correlates with the concern. Once these pieces of data are correctly
plotted, the chart will point to the source of the vibration concern, which should confirm the results obtained
through the Vibration Analysis diagnostic tables.
REED TACHOMETER DESCRIPTION

Fig. 42: Identifying Reed Tachometer

The reed tachometer consists of 2 rows of reeds arranged side-by-side. Each reed is tuned to vibrate or resonate
when it is excited by a specific frequency. The reeds are arranged by their specific resonant frequency,
increasing from left to right, ranging from 10-80 Hz. This arrangement allows for a visual display of the most
dominate frequencies which fall within this range.
The reed tachometer can be a helpful diagnostic tool, however it is extremely sensitive to external inputs that
are not related to the vibration concern, such as rough road surfaces, etc., and it is difficult to master its use. Due
to these conditions, the reed tachometer has limited diagnostic capability.
Due to the limited diagnostic capability, limited availability and increasing costs of the reed tachometer, it is
NOT recommended as the primary tool to use in diagnosing a vibration concern.
When diagnosing a vibration concern, use the EL-38792-A Electronic Vibration Analyzer (EVA) 2. The EL38792-A Electronic Vibration Analyzer (EVA) 2 has been designed to overcome the shortcomings to the reed
tachometer. Refer to Electronic Vibration Analyzer (EVA) Description and Operation.


Illustration
Tool Number / Description

EL-38792-A
J-38792
Electronic Vibration Analyzer

2013 DTC INDEX Cruz
2013 DTC INDEX

Cruz
ANTILOCK BRAKE SYSTEM - DIAGNOSTIC TROUBLE CODES

ANTILOCK BRAKE SYSTEM - DIAGNOSTIC TROUBLE CODES
DTC
Description
DTC B2745
DTC B2745 02 Traction Control Switch Circuit Short to Ground
DTC C0035, C0040, C0045, or
DTC C0035 06 Left Front Wheel Speed Sensor Circuit Low
C0050
Voltage/Open
DTC C0035 0F Left Front Wheel Speed Sensor Circuit Signal Erratic
DTC C0035 18 Left Front Wheel Speed Sensor Circuit Low Signal
Amplitude
DTC C0035 5A Left Front Wheel Speed Sensor Circuit Not Plausible
DTC C0040 06 Right Front Wheel Speed Sensor Circuit Low
Voltage/Open
DTC C0040 0F Right Front Wheel Speed Sensor Circuit Signal Erratic
DTC C0040 18 Right Front Wheel Speed Sensor Circuit Low Signal
Amplitude
DTC C0040 5A Right Front Wheel Speed Sensor Circuit Not Plausible
DTC C0045 06 Left Rear Wheel Speed Sensor Circuit Low
Voltage/Open
DTC C0045 0F Rear Wheel Speed Sensor Circuit Signal Erratic
DTC C0045 18 Left Rear Wheel Speed Sensor Circuit Low Signal
Amplitude
DTC C0045 5A Left Rear Wheel Speed Sensor Circuit Not Plausible
DTC C0050 06 Right Rear Wheel Speed Sensor Circuit Low
Voltage/Open
DTC C0050 0F Right Rear Wheel Speed Sensor Circuit Signal Erratic
DTC C0050 18 Right Rear Wheel Speed Sensor Circuit Low Signal
Amplitude
DTC C0050 5A Right Rear Wheel Speed Sensor Circuit Not Plausible
DTC C0110
DTC C0110 00 Pump Motor Circuit Malfunction
DTC C0110 04 Pump Motor Circuit Open
DTC C0110 61 Pump Motor Stuck
DTC C0131
DTC C0131 00 Traction Control System Pressure Circuit Malfunction
DTC C0131 4B Traction Control System Pressure Circuit Calibration
Not Learned
DTC C0131 5A Traction Control System Pressure Circuit Not
Plausible
DTC C0161
DTC C0161 5A Antilock Braking System Brake Switch Circuit Not
Plausible
DTC C0186, C018B, C0196,
DTC C0186 5A Lateral Acceleration Sensor Circuit Not Plausible
DTC C0186 71 Lateral Acceleration Sensor Circuit Invalid Data
C019B, or C0287
DTC C018B 5A Multi-Axis Acceleration Sensor Signal Not Plausible

2013 DTC INDEX Cruz
DTC C0280
DTC C0710
DTC C1207-C1210, C1221C1228, or C1232-C1235
DTC C1251
DTC P0856
DTC C0196 00 Yaw Rate Circuit Malfunction

DTC C0196 5A Yaw Rate Signal Not Plausible
DTC C0196 71 Yaw Rate Signal Invalid Data
DTC C019B 5A Yaw Rate Signal Not Plausible
DTC C0287 4B Longitudinal Acceleration Sensor Circuit Calibration
Not Learned
DTC C0287 5A Longitudinal Acceleration Sensor Circuit Not
Plausible
DTC C0287 71 Longitudinal Acceleration Sensor Circuit Invalid Data
DTC C0280 54 Stability System Active Too Long High Temperature
DTC C0710 00 Steering Position Signal Malfunction
DTC C0710 42 Steering Position Signal Calibration Not Programmed
DTC C0710 71 Steering Position Signal Invalid Data
DTC C0710 5A Steering Position Signal Not Plausible
DTC C1207 00 Left Front Wheel Speed Sensor Circuit High Input
DTC C1208 00 Right Front Wheel Speed Sensor Circuit High Input
DTC C1209 00 Left Rear Wheel Speed Sensor Circuit High Input
DTC C1210 00 Right Rear Wheel Speed Sensor Circuit High Input
DTC C1221 00 Left Front Wheel Speed Sensor Circuit Malfunction
DTC C1222 00 Right Front Wheel Speed Sensor Circuit Malfunction
DTC C1223 00 Left Rear Wheel Speed Sensor Circuit Malfunction
DTC C1224 00 Right Rear Wheel Speed Sensor Circuit Malfunction
DTC C1251 Lateral Acceleration Sensor Performance
DTC P0856 Traction Control Torque Request Circuit
AUTOMATIC TRANSMISSION - 6T40 - DIAGNOSTIC TROUBLE CODES

AUTOMATIC TRANSMISSION - 6T40 - DIAGNOSTIC TROUBLE CODES
DTC
Description
DTC P0562 or P0563
DTC P0562 System Voltage Low Voltage
DTC P0563 System Voltage High Voltage
DTC P057C or P057D
DTC P057C Brake Pedal Position Sensor Circuit Low Voltage
DTC P057D Brake Pedal Position Sensor Circuit High Voltage
DTC P0601-P0604 or P062F
DTC P0601 Control Module Read Only Memory Performance
DTC P0602 Control Module Not Programmed
DTC P0603 Control Module Long Term Memory Reset
DTC P0604 Control Module Random Access Memory Performance
DTC P062F Control Module Long Term Memory Performance
DTC P0634
DTC P0634 Control Module Overtemperature
DTC P0658 or P0659
DTC P0658 Actuator High Control Circuit Group 1 Low Voltage
DTC P0659 Actuator High Control Circuit Group 1 High Voltage
DTC P0667, P0668, or P0669
DTC P0667 Control Module Temperature Sensor Performance
DTC P0668 Control Module Temperature Sensor Circuit Low Voltage
DTC P0669 Control Module Temperature Sensor Circuit High Voltage
DTC P06AC, P06AD, or
DTC P06AC Control Module Power Up Temperature Sensor

2013 DTC INDEX Cruz
P06AE
Performance
DTC P06AD Control Module Power Up Temperature Sensor Circuit
Low Voltage
DTC P06AE Control Module Power Up Temperature Sensor Circuit
High Voltage
DTC P0711-P0713
DTC P0711 Transmission Fluid Temperature Sensor Performance
DTC P0712 Transmission Fluid Temperature Sensor Circuit Low
Voltage
DTC P0713 Transmission Fluid Temperature Sensor Circuit High
Voltage
DTC P0716, P0717, P07BF, or
DTC P0716 Input Speed Sensor Performance
P07C0
DTC P0717 Input Speed Sensor Circuit No Signal
DTC P07BF Input Speed Sensor Circuit Low Voltage
DTC P07C0 Input Speed Sensor Circuit High Voltage
DTC P071D
DTC P071D Transmission Sport Mode Switch circuit
DTC P0722, P0723, P077C, or
DTC P0722 Output Speed Sensor Circuit No Signal
P077D
DTC P0723 Output Speed Sensor Intermittent
DTC P077C Output Speed Sensor Circuit Low Voltage
DTC P077D Output Speed Sensor Circuit High Voltage
DTC P0741 or P0742 (Gen 2
DTC P0741 Torque Converter Clutch (TCC) System Stuck Off
with 1.4L - LUJ)
DTC P0742 Torque Converter Clutch (TCC) System Stuck On
DTC P0741 Torque Converter Clutch (TCC) System Stuck Off
with 1.8L - LUW)
DTC P0742 Torque Converter Clutch (TCC) System Stuck On
DTC P0751 Shift Solenoid 1 Valve Performance - Stuck Off
with 1.4L - LUJ)
DTC P0752 Shift Solenoid 1 Valve Performance - Stuck On
DTC P0751 Shift Solenoid 1 Valve Performance - Stuck Off
with 1.8L - LUW)
DTC P0752 Shift Solenoid 1 Valve Performance - Stuck On
DTC P0776 Pressure Control Solenoid Valve 2 Stuck Off
with 1.8L - LUW)
DTC P0777 Pressure Control Solenoid Valve 2 Stuck On
with 1.4L - LUJ)
with 1.8L - LUW)
with 1.4L - LUJ)
DTC P0815, P0816, or P0826
DTC P0815 Upshift Switch Circuit
DTC P0816 Downshift Switch Circuit
DTC P0826 Up and Down Shift Switch Circuit
DTC P0842 or P0843 (Gen 1 DTC P0842 Transmission Fluid Pressure Switch 1 Circuit Low Voltage
DTC P0843 Transmission Fluid Pressure Switch 1 Circuit High Voltage
with 1.8L - LUW)
DTC P0850-P0852
DTC P0850 Park/Neutral Position Switch Circuit
DTC P0851 Park/Neutral Position Switch Circuit Low Voltage
DTC P0852 Park/Neutral Position Switch Circuit High Voltage
DTC P0872 or P0873 (Gen 1 DTC P0872 Transmission Fluid Pressure Switch 3 Circuit Low Voltage
with 1.8L - LUW)

2013 DTC INDEX Cruz

with 1.8L - LUW)
DTC P0961-P0963
DTC P0965-P0967
DTC P0969-P0971
DTC P0973 or P0974

with 1.8L - LUW)
DTC P150C
DTC P1761
DTC P182E or P1915
DTC P1876
DTC P2534
DTC P2537
with 1.8L - LUW)
with 1.4L - LUJ)
DTC P2719-P2721

with 1.8L - LUW)
with 1.4L - LUJ)
DTC P2728-P2730
DTC P0877 Transmission Fluid Pressure Switch 4 Circuit Low Voltage

DTC P0961 Line Pressure Control Solenoid Valve System Performance
DTC P0962 Line Pressure Control Solenoid Valve Control Circuit Low
Voltage
DTC P0963 Line Pressure Control Solenoid Valve Control Circuit High
Voltage
DTC P0965 Pressure Control Solenoid Valve 2 Performance
DTC P0966 Pressure Control Solenoid Valve 2 Control Circuit Low
Voltage
DTC P0967 Pressure Control Solenoid Valve 2 Control Circuit High
Voltage
Voltage
Voltage
DTC P0973 Shift Solenoid Valve 1 Control Circuit Low Voltage
DTC P0974 Shift Solenoid Valve 1 Control Circuit High Voltage
DTC P0989 Transmission Fluid Pressure Switch 5 Circuit Low Voltage
DTC P150C Transmission Control Module Engine Speed Request
Signal Message Counter Incorrect
DTC P1761 Up and Down Shift Switch Signal Message Counter
Incorrect
DTC P182E Internal Mode Switch Indicates Invalid Range
DTC P1915 Internal Mode Switch Does Not Indicate Park/Neutral
During Start
DTC P1876 Up and Down Shift Enable Switch Circuit Low Voltage
DTC P2534 Ignition On/Start Switch Circuit Low Voltage
DTC P2537 Ignition Accessory Switch Circuit Low Voltage
Voltage
Voltage
DTC P2728 Pressure Control Solenoid Valve 5 System Performance

2013 DTC INDEX Cruz
DTC P2762, P2763, or P2764

Voltage
Voltage
DTC P2762 Torque Converter Clutch (TCC) Pressure Control Solenoid
Valve Performance
Valve Control Circuit High Voltage
Valve Control Circuit Low Voltage
BATTERY, CHARGING SYSTEM AND STARTING SYSTEM - DIAGNOSTIC

TROUBLE CODES
BATTERY, CHARGING SYSTEM AND STARTING SYSTEM - DIAGNOSTIC TROUBLE CODES
DTC
Description
DTC B1325, B1330, B1517,
DTC B1325 03 Control Module Power Circuit Low Voltage
C0800, P0560, P0562, or
DTC B1325 07 Control Module Power Circuit High Voltage
P0563
DTC B1330 03 Device Power 2 Circuit Low Voltage
DTC B1517 03 Battery Voltage Low Voltage
DTC B1517 07 Battery Voltage High Voltage
DTC B1517 5A Battery Voltage Plausibility Failure
DTC C0800 03 Control Module Power Circuit Low Voltage
DTC C0800 07 Control Module Power Circuit High Voltage
DTC C0800 08 Control Module Power Circuit Voltage Signal Invalid
DTC C0800 11 Control Module Power Circuit High Input
DTC C0800 12 Control Module Power Circuit Low Input
DTC C0800 0D Control Module Power Circuit High Resistance
DTC P0560 System Voltage
DTC B1516
DTC B1516 08 Battery Current Sensor Performance - Signal Invalid
DTC B1516 66 Battery Current Sensor Incorrect Mounting
DTC B151A
DTC B151A 58 Battery Capacity Performance
DTC B1527
DTC B1527 00 Parasitic Load
DTC P0615, P0616, or
DTC P0615 Starter Relay Control Circuit
P0617
DTC P0616 Starter Relay Control Circuit Low Voltage
DTC P0617 Starter Relay Control Circuit High Voltage
DTC P0621
DTC P0621 Generator L-Terminal Circuit
DTC P0622
DTC P0622 Generator F-Terminal Circuit
CELLULAR SYSTEM, ENTERTAINMENT SYSTEM, AND NAVIGATION

SYSTEM - DIAGNOSTIC TROUBLE CODES
CELLULAR SYSTEM, ENTERTAINMENT SYSTEM, AND NAVIGATION SYSTEM - DIAGNOSTIC

2013 DTC INDEX Cruz
TROUBLE CODES
DTC
DTC B0000
DTC B0997
DTC B1020
DTC B1025, B1035, B1045,
or B1055
DTC B125A
DTC B125C
DTC B1265
DTC B1271
DTC B1278 or B1279
DTC B1287
DTC B1446 or B1447

DTC B2455
DTC B2462
DTC B2470
DTC B2476 or B2482
Description
DTC B0000 5A Vehicle Speed Information Circuit Not Plausible
DTC B0997 00 Info Display Module Malfunction
DTC B1020 00 Auxiliary Electronic Control Unit (ECU) Performance
DTC B1025 01 Left Front Audio Output Circuit Short to Battery
DTC B1025 02 Left Front Audio Output Circuit Short to Ground
DTC B1025 04 Left Front Audio Output Circuit Open
DTC B1035 01 Front Audio Output Circuit Short to Battery
DTC B1035 02 Right Front Audio Output Circuit Short to Ground
DTC B1035 04 Right Front Audio Output Circuit Open
DTC B1045 01 Left Rear Audio Output Circuit Short to Battery
DTC B1045 02 Left Rear Audio Output Circuit Short to Ground
DTC B1045 04 Left Rear Audio Output Circuit Open
DTC B1055 01 Right Rear Audio Output Circuit Short to Battery
DTC B1055 02 Right Rear Audio Output Circuit Short to Ground
DTC B1055 04 Right Rear Audio Output Circuit Open
DTC B125A 02 Antenna Signal Circuit Short to Ground
DTC B125A 04 Antenna Signal Circuit Open Circuit
DTC B125C 01 Satellite Antenna Circuit Short to Battery
DTC B125C 02 Satellite Antenna Circuit Short to Ground
DTC B125C 04 Satellite Antenna Circuit Open
DTC B1265 02 Switched 14 Volt Performance Short to Ground
DTC B1271 00 Theft Protection Active
DTC B1278 01 Left Auxiliary Input Signal Circuit Short to Battery
DTC B1278 02 Left Auxiliary Input Signal Circuit Short to Ground
DTC B1279 01 Right Auxiliary Input Signal Circuit Short to Battery
DTC B1279 02 Right Auxiliary Input Signal Circuit Short to Ground
DTC B1287 01 Amplifier Control Signal Circuit Short to Battery
DTC B1287 02 Amplifier Control Signal Circuit Short to Ground
DTC B1287 04 Amplifier Control Signal Circuit Open
DTC B1446 Replace Backup Power Source Below Minimum Threshold
DTC B1447 Backup Power Source Open Circuit
DTC B2455 02 Cellular Phone Microphone Circuit Short to Ground
DTC B2455 04 Cellular Phone Microphone Circuit Open/High
Resistance
DTC B2462 01 Global Positioning System Short to Battery
DTC B2462 02 Global Positioning System Short to Ground
DTC B2462 04 Global Positioning System Open
DTC B2470 02 Cellular Phone Antenna Circuit Malfunction Short to
Ground
DTC B2470 04 Cellular Phone Antenna Circuit Malfunction Open
Circuit
DTC B2476 04 Cellular Phone Select Service Switch Open
DTC B2476 59 Cellular Phone Select Service Switch Protection Time-

2013 DTC INDEX Cruz
DTC B2485
DTC U0255-U0257
out
DTC B2482 00 Cellular Phone Select Service Switch
Range/Performance
DTC B2485 02 Wireless Communication (BT) Antenna Circuit Short to
Ground
DTC B2485 04 Wireless Communication (BT) Antenna Circuit Open
DTC U0255 Lost Communication with Info Display Module
DTC U0256 Lost Communication with Infotainment Faceplate Control
Module
DTC U0257 Lost Communication with Info Display
Module/Infotainment Faceplate Control Module
CRUISE CONTROL SYSTEM - DIAGNOSTIC TROUBLE CODES

CRUISE CONTROL SYSTEM - DIAGNOSTIC TROUBLE CODES
DTC
Description
DTC P0571
DTC P0571 Cruise Control Brake Switch Circuit
DTC P0572 or P0573
DTC P0572 Brake Switch Circuit 1 Low Voltage
DTC P0573 Brake Switch Circuit 1 High Voltage
DTC P0575
DTC P0575 Cruise Control Switch Signal Message Counter Incorrect
DTC P0703
DTC P0703 Brake Switch Signal Message Counter Incorrect
DATA COMMUNICATIONS SYSTEM - DIAGNOSTIC TROUBLE CODES

DATA COMMUNICATIONS SYSTEM - DIAGNOSTIC TROUBLE CODES
DTC
Description
DTC B1000
DTC B1000 Electronic Control Unit
DTC B1001
DTC B1001 Option Configuration
DTC B101D
DTC B101D Electronic Control Unit Hardware
DTC B101E
DTC B101E Electronic Control Unit Software
DTC C056D
DTC C056D Electronic Control Unit Hardware
DTC C056E
DTC C056E Electronic Control Unit Software
DTC P0601-P0604, P0606,
or P062F
DTC P0606 Control Module Processor Performance
DTC U0001
DTC U0001 00 High Speed CAN Communication Bus Malfunction
DTC U0020
DTC U0020 Low Speed CAN Bus
DTC U0073 or U2100
DTC U0073 Control Module Communication Bus A Off
DTC U2100 CAN Bus Communication
DTC U0074
DTC U0074 Control Module Communication Bus B Off

2013 DTC INDEX Cruz
DTC U0077
DTC U0078
DTC U0100-U02FF
DTC U0300-U0336
DTC U0400-U05FF
DTC U1500-U15FF
DTC U1814
DTC U18B9-U18BF
DTC U2099
DTC U0077 00 Control Module Communication Chassis Expansion CAN

Bus Off
DTC U0078 Control Module Communication Low Speed CAN Bus Off
See Control Module U Code List
DTC U1814 Powertrain Wake-Up Communication Circuit
DTC U18B9 Primary High Speed CAN Bus Subnet Configuration List
DTC U18BF Secondary High Speed CAN Bus Subnet Configuration List
DTC U2099 High Speed Communication Enable Circuit
ENGINE CONTROLS/FUEL - 1.4L - DIAGNOSTIC TROUBLE CODES

DTC
Description
DTC P0010 or P0013
DTC P0010 Intake Camshaft Position Actuator Solenoid Valve Control
(LUJ)
Circuit
DTC P0013 Exhaust Camshaft Position Actuator Solenoid Valve Control
Circuit
DTC P0011 or P0014
DTC P0011 Intake Camshaft Position System Performance
(LUJ)
DTC P0014 Exhaust Camshaft Position System Performance
DTC P0016 or P0017
DTC P0016 Crankshaft Position - Intake Camshaft Position Not Plausible
(LUJ)
DTC P0017 Crankshaft Position - Exhaust Camshaft Position Not Plausible
DTC P0030, P0036, P0053,
DTC P0030 HO2S Heater Control Circuit Sensor 1
P0054, P0135, or P0141
DTC P0036 HO2S Heater Control Circuit Sensor 2
(LUJ)
DTC P0053 HO2S Heater Resistance Sensor 1
DTC P0054 HO2S Heater Resistance Sensor 2
DTC P0135 HO2S Heater Performance Sensor 1
DTC P0141 HO2S Heater Performance Sensor 2
DTC P0033-P0035
DTC P0033 Turbocharger Bypass Solenoid Valve Control Circuit
DTC P0034 Turbocharger Bypass Solenoid Valve Control Circuit Low
Voltage
DTC P0035 Turbocharger Bypass Solenoid Valve Control Circuit High
Voltage
DTC P0068 or P1101
DTC P0068 Throttle Body Airflow Performance
DTC P1101 Intake Air Flow System Performance
DTC P0096 or P0111
DTC P0096 Intake Air Temperature (IAT) Sensor 2 Performance
DTC P0111 Intake Air Temperature (IAT) Sensor 1 Performance
DTC P0097 or P0098
DTC P0097 Intake Air Temperature (IAT) Sensor 2 Circuit Low Voltage
DTC P0098 Intake Air Temperature (IAT) Sensor 2 Circuit High Voltage
DTC P00C7
DTC P00C7 Intake Air Pressure Measurement System - Multiple Sensors
Not Plausible
DTC P0101
DTC P0101 Mass Air Flow (MAF) Sensor Performance

2013 DTC INDEX Cruz
DTC P0102 or P0103
DTC P0102 Mass Air Flow (MAF) Sensor Circuit Low Frequency
DTC P0103 Mass Air Flow (MAF) Sensor Circuit High Frequency
DTC P0106
DTC P0106 Manifold Absolute Pressure (MAP) Sensor Performance
DTC P0107 or P0108
DTC P0107 Manifold Absolute Pressure (MAP) Sensor Circuit Low
Voltage
DTC P0108 Manifold Absolute Pressure (MAP) Sensor Circuit High
Voltage
DTC P0112, P0113, or
DTC P0112 Intake Air Temperature (IAT) Sensor Circuit Low Voltage
P0114
DTC P0113 Intake Air Temperature (IAT) Sensor Circuit High Voltage
DTC P0114 Intake Air Temperature (IAT) Sensor Circuit Intermittent
DTC P0116 (LUJ)
DTC P0116 Engine Coolant Temperature (ECT) Sensor Performance
DTC P0117 or P0118
DTC P0117 Engine Coolant Temperature (ECT) Sensor Circuit Low
(LUJ)
Voltage
DTC P0118 Engine Coolant Temperature (ECT) Sensor Circuit High
Voltage
DTC P0119 (LUJ)
DTC P0119 Engine Coolant Temperature (ECT) Sensor Circuit Intermittent
DTC P0121-P0123, P0222,
DTC P0121 Throttle Position Sensor 1 Performance
P0223, or P2135 (LUJ)
DTC P0122 Throttle Position Sensor 1 Circuit Low Voltage
DTC P0123 Throttle Position Sensor 1 Circuit High Voltage
DTC P2135 Throttle Position Sensors 1-2 Not Plausible
DTC P0128
DTC P0128 Engine Coolant Temperature (ECT) Below Thermostat
Regulating Temperature
DTC P0131, P0132, P0134,
DTC P0131 HO2S Circuit Low Voltage Sensor 1
P0137, P0138, or P0140
DTC P0132 HO2S Circuit High Voltage Sensor 1
DTC P0134 HO2S Circuit Insufficient Activity Sensor 1
DTC P0133, P013A,
DTC P0133 HO2S Slow Response Sensor 1
DTC P013A HO2S Slow Response Rich to Lean Sensor 2
P013B, P013E, P013F,
DTC P013B HO2S Slow Response Lean to Rich Sensor 2
P015A, P015B, P2270, or
P2271
DTC P013E HO2S Delayed Response Rich to Lean Sensor 2
DTC P013F HO2S Delayed Response Lean to Rich Sensor 2
DTC P015A HO2S Delayed Response Rich to Lean Bank 1 Sensor 1
DTC P015B HO2S Delayed Response Lean to Rich Bank 1 Sensor 1
DTC P2270 HO2S Signal Stuck Lean Sensor 2
DTC P2271 HO2S Signal Stuck Rich Sensor 2
DTC P0171 or P2097
DTC P0171 Fuel Trim System Lean
DTC P2097 Post Catalyst Fuel Trim System High Limit
DTC P0172 or P2096
DTC P0172 Fuel Trim System Rich
DTC P2096 Post Catalyst Fuel Trim System Low Limit
DTC P018B-P018D
DTC P018B Fuel Pressure Sensor Performance
DTC P018C Fuel Pressure Sensor Circuit Low Voltage
DTC P018D Fuel Pressure Sensor Circuit High Voltage

2013 DTC INDEX Cruz
DTC P0201-P0204
DTC P0231, P0232, or

P023F
DTC P0234 or P0299
DTC P0236
DTC P0237 or P0238
DTC P0243, P0245, or
P0246
DTC P025A
DTC P0300 (LUJ)
DTC P0315 (LUJ)
DTC P0324, P0326, or
P06B6
DTC P0325, P0327, or
P0328
DTC P0335 or P0336
(LUJ)
DTC P0340 or P0365
(LUJ)
DTC P0341 or P0366
(LUJ)
DTC P0351-P0354 (LUJ)
DTC P0420 (LUJ)

DTC P0442
DTC P0443
DTC P0446
DTC P0449
DTC P0451-P0454
DTC P0201 Cylinder 1 Injector Control Circuit

DTC P0231 Fuel Pump Control Circuit Low Voltage
DTC P0232 Fuel Pump Control Circuit High Voltage
DTC P023F Fuel Pump Control Circuit
DTC P0234 Engine Overboost
DTC P0299 Engine Underboost
DTC P0236 Turbocharger Boost Sensor Performance
DTC P0237 Turbocharger Boost Sensor Circuit Low Voltage
DTC P0238 Turbocharger Boost Sensor Circuit High Voltage
DTC P0243 Turbocharger Wastegate Solenoid Valve Control Circuit
DTC P0245 Turbocharger Wastegate Solenoid Valve Control Circuit Low
Voltage
DTC P0246 Turbocharger Wastegate Solenoid Valve Control Circuit High
Voltage
DTC P025A Fuel Pump Control Module Enable Circuit
DTC P0300 Engine Misfire Detected
DTC P0315 Crankshaft Position System Variation Not Learned
DTC P0324 Knock Sensor Module Performance
DTC P0326 Knock Sensor Performance
DTC P06B6 Control Module Knock Sensor Processor 1 Performance
DTC P0325 Knock Sensor Circuit
DTC P0327 Knock Sensor Circuit Low Voltage
DTC P0328 Knock Sensor Circuit High Voltage
DTC P0335 Crankshaft Position Sensor Circuit
DTC P0336 Crankshaft Position Sensor Performance
DTC P0340 Intake Camshaft Position Sensor Circuit
DTC P0365 Exhaust Camshaft Position Sensor Circuit
DTC P0341 Intake Camshaft Position Sensor Performance
DTC P0366 Exhaust Camshaft Position Sensor Performance
DTC P0351 Ignition Coil 1 Control Circuit
DTC P0420 Catalyst System Low Efficiency
DTC P0442 Evaporative Emission (EVAP) System Small Leak Detected
DTC P0443 Evaporative Emission (EVAP) Purge Solenoid Valve Control
Circuit
DTC P0446 Evaporative Emissions (EVAP) Vent System Performance
DTC P0449 Evaporative Emission (EVAP) Vent Solenoid Valve Control
Circuit
DTC P0451 Fuel Tank Pressure Sensor Performance
DTC P0452 Fuel Tank Pressure Sensor Circuit Low Voltage

2013 DTC INDEX Cruz
DTC P0453 Fuel Tank Pressure Sensor Circuit High Voltage

DTC P0454 Fuel Tank Pressure Sensor Circuit Intermittent
DTC P0455
DTC P0455 Evaporative Emission (EVAP) System Large Leak Detected
DTC P0496
DTC P0496 Evaporative Emission (EVAP) System Flow During Non-Purge
DTC P0506 or P0507
DTC P0506 Idle Speed Low
(LUJ)
DTC P0507 Idle Speed High
DTC P0601-P0604, P0606,
DTC P0601 Control Module Read Only Memory (ROM)
or P062F (Fuel Pump
Control Module)
DTC P0604 Control Module Random Access Memory (RAM)
DTC P0606 Control Module Internal Performance
DTC P0601-P0604, P0606,
P062F, P16F3, or P2610
(LUJ)
DTC P16F3 Control Module Redundant Memory Performance
DTC P2610 Control Module Ignition Off Timer Performance
DTC P0627-P0629
DTC P0627 Fuel Pump Enable Circuit
DTC P0628 Fuel Pump Enable Circuit Low Voltage
DTC P0629 Fuel Pump Enable Circuit High Voltage
DTC P0630 (LUJ)
DTC P0630 VIN Not Programmed or Mismatched - Engine Control Module
(ECM)
DTC P0641 or P06A6
DTC P0641 5 V Reference Circuit
DTC P06A6 5 V Reference Performance
(Fuel Pump Control
Module)
DTC P0641, P0651, P0697,
DTC P0641 5V Reference 1 Circuit
or P06A3 (LUJ)
DTC P06A3 5V Reference 4 Circuit
DTC P0650 (LUJ)
DTC P0650 Malfunction Indicator Lamp (MIL) Control Circuit
DTC P0685, P0689, P0690,
DTC P0685 Engine Controls Ignition Relay Control Circuit
DTC P0689 Engine Controls Ignition Relay Feedback Circuit Low Voltage
or P1682
DTC P0690 Engine Controls Ignition Relay Feedback Circuit High Voltage
DTC P1682 Ignition 1 Switch Circuit 2
DTC P069E
DTC P069E Fuel Pump Control Module Requested MIL Illumination
DTC P0700 (LUJ)
DTC P0700 Transmission Control Module Requested MIL Illumination
DTC P112B
DTC P112B Intake Air Temperature (IAT) Sensor 3 Performance
DTC P112C or P112D
DTC P112C Intake Air Temperature (IAT) Sensor 3 Circuit Low Voltage
DTC P112D Intake Air Temperature (IAT) Sensor 3 Circuit High Voltage
DTC P11C2 or P11C3
DTC P11C2 Intake Air Humidity Sensor Circuit Low Voltage
DTC P11C3 Intake Air Humidity Sensor Circuit High Voltage
DTC P1255 or P064A
DTC P064A Fuel Pump Control Module Performance

2013 DTC INDEX Cruz
DTC P1400
DTC P150C (LUJ)
DTC P1516, P2101, P2119,
or P2176 (LUJ)
DTC P2122, P2123, P2127,

P2128, or P2138 (LUJ)
DTC P2199
DTC P2227-P2230 (LUJ)
DTC P2261
DTC P2534 (Fuel Pump
Control Module)
DTC P2544

Control Module)
DTC P1255 Fuel Pump Control Module Driver Over-temperature

DTC P1400 Cold Start Emission Reduction Control System
DTC P150C Transmission Control Module Engine Speed Request Signal
DTC P1516 Throttle Actuator Control (TAC) Module Throttle Actuator
Position Performance
DTC P2101 Throttle Actuator Position Performance
DTC P2119 Throttle Closed Position Performance
DTC P2176 Minimum Throttle Position Not Learned
DTC P2122 Accelerator Pedal Position (APP) Sensor 1 Circuit Low
Voltage
DTC P2123 Accelerator Pedal Position (APP) Sensor 1 Circuit High
Voltage
DTC P2127 Accelerator Pedal Position (APP) Sensor 2 Circuit Low
Voltage
DTC P2128 Accelerator Pedal Position (APP) Sensor 2 Circuit High
Voltage
DTC P2138 Accelerator Pedal Position (APP) Sensors 1-2 Not Plausible
DTC P2199 Intake Air Temperature (IAT) Sensor 1-2 Correlation
DTC P2227 Barometric Pressure (BARO) Sensor Performance
DTC P2228 Barometric Pressure (BARO) Sensor Circuit Low Voltage
DTC P2229 Barometric Pressure (BARO) Sensor Circuit High Voltage
DTC P2230 Barometric Pressure (BARO) Sensor Circuit Erratic
DTC P2261 Turbocharger Bypass Valve Stuck
DTC P2534 Ignition 1 Switch Circuit Low Voltage
DTC P2544 72 Transmission Torque Request Circuit Message Counter
Incorrect
DTC P2544 74 Transmission Torque Request Circuit Bus Signal Checksum
Error
DTC P2635 Fuel Pump Flow Performance

DTC
Description
DTC P0010 Or P0013 (LUW)
DTC P0010 Intake Camshaft Position Actuator Solenoid Valve
Control Circuit
DTC P0013 Exhaust Camshaft Position Actuator Solenoid Valve
Control Circuit
DTC P0011 Intake Camshaft Position System Performance
DTC P0014 Exhaust Camshaft Position System Performance
DTC P0016 Crankshaft Position - Intake Camshaft Position Not
Plausible

2013 DTC INDEX Cruz
DTC P0017 Crankshaft Position - Exhaust Camshaft Position Not

Plausible
DTC P0030-P0032, P0036P0038, P0053, P0054, P0135, Or
P0141 (LUW)
DTC P0068 Throttle Body Air Flow Performance

DTC P1101 Intake Air Flow System Performance
DTC P0101 (LUW)
DTC P0101 Mass Air Flow (Maf) Sensor Performance
DTC P0102 Mass Air Flow (Maf) Sensor Circuit Low Frequency
DTC P0103 Mass Air Flow (Maf) Sensor Circuit High Frequency
DTC P0106 (LUW)
DTC P0106 Manifold Absolute Pressure (Map) Sensor Performance
DTC P0107 Manifold Absolute Pressure (Map) Sensor Circuit Low
Voltage
DTC P0108 Manifold Absolute Pressure (Map) Sensor Circuit High
Voltage
DTC P0111 (LUW)
DTC P0111 Intake Air Temperature (Iat) Sensor Performance
DTC P0112, P0113, Or P0114
DTC P0112 Intake Air Temperature (Iat) Sensor Circuit Low Voltage
DTC P0113 Intake Air Temperature (Iat) Sensor Circuit High Voltage
(LUW)
DTC P0114 Intake Air Temperature (Iat) Sensor Circuit Intermittent
DTC P0116 (LUW)
DTC P0116 Engine Coolant Temperature (Ect) Sensor Performance
DTC P0117 Engine Coolant Temperature (Ect) Sensor Circuit Low
Voltage
DTC P0118 Engine Coolant Temperature (Ect) Sensor Circuit High
Voltage
DTC P0119 (LUW)
DTC P0119 Engine Coolant Temperature (Ect) Sensor Circuit
Intermittent
DTC P0121-P0123, P0222,
DTC P0121 Throttle Position Sensor 1 Performance
P0223, Or P2135 (LUW)
DTC P2135 Throttle Position Sensors 1-2 Not Plausible
DTC P0128
DTC P0128 Engine Coolant Temperature (Ect) Below Thermostat
Regulating Temperature
DTC P0131, P0132, P0134,
P0137, P0138, Or P0140 (LUW)
DTC P0133, P013A, P013B,
DTC P0133 HO2S Slow Response Sensor 1
DTC P013A HO2S Slow Response Rich To Lean Sensor 2
P013E, P013F, P015A, P015B,
DTC P013B HO2S Slow Response Lean To Rich Sensor 2
P2270, Or P2271 (LUW)
DTC P013E HO2S Delayed Response Rich To Lean Sensor 2
DTC P013F HO2S Delayed Response Lean To Rich Sensor 2

2013 DTC INDEX Cruz

DTC P018B-P018D
DTC P0201-P0204 (LUW)
DTC P025A
DTC P0231, P0232, Or P023F
DTC P0300-P0304 Or P0313

(LUW)
DTC P0315 (LUW)

DTC P0324, P0326, Or P06B6
DTC P0325, P0327, Or P0328

(LUW)
DTC P0351-P0354 (LUW)
DTC P0420 (LUW)

DTC P0442
DTC P015A HO2S Delayed Response Rich To Lean Sensor 1

DTC P015B HO2S Delayed Response Lean To Rich Sensor 1
DTC P2270 HO2S Signal Stuck Lean Sensor 2
DTC P2271 HO2S Signal Stuck Rich Sensor 2
DTC P0171 Fuel Trim System Lean
DTC P2097 Post Catalyst Fuel Trim System High Limit
DTC P0172 Fuel Trim System Rich
DTC P2096 Post Catalyst Fuel Trim System Low Limit
DTC P018B Fuel Pressure Sensor Performance
DTC P018C Fuel Pressure Sensor Circuit Low Voltage
DTC P018D Fuel Pressure Sensor Circuit High Voltage
DTC P025A Fuel Pump Control Module Enable Circuit
DTC P0231 Fuel Pump Control Circuit Low Voltage
DTC P0232 Fuel Pump Control Circuit High Voltage
DTC P023F Fuel Pump Control Circuit
DTC P0300 Engine Misfire Detected
DTC P0301 Cylinder 1 Misfire Detected
DTC P0313 Misfire Detected With Low Fuel Level
DTC P0315 Crankshaft Position System Variation Not Learned
DTC P0324 Knock Sensor Module Performance
DTC P0326 Knock Sensor Performance
DTC P06B6 Control Module Knock Sensor Processor 1 Performance
DTC P0325 Knock Sensor Circuit
DTC P0327 Knock Sensor Circuit Low Voltage
DTC P0328 Knock Sensor Circuit High Voltage
DTC P0335 Crankshaft Position Sensor Circuit
DTC P0336 Crankshaft Position Sensor Performance
DTC P0340 Intake Camshaft Position Sensor Circuit
DTC P0365 Exhaust Camshaft Position Sensor Circuit
DTC P0341 Intake Camshaft Position Sensor Performance
DTC P0366 Exhaust Camshaft Position Sensor Performance
DTC P0420 Catalyst System Low Efficiency
DTC P0442 Evaporative Emission (Evap) System Small Leak
Detected

2013 DTC INDEX Cruz
DTC P0443
DTC P0443 Evaporative Emission (Evap) Purge Solenoid Valve

Control Circuit
DTC P0446
DTC P0446 Evaporative Emissions (Evap) Vent System Performance
DTC P0449
DTC P0449 Evaporative Emission (Evap) Vent Solenoid Valve
Control Circuit
DTC P0451-P0454
DTC P0451 Fuel Tank Pressure Sensor Performance
DTC P0452 Fuel Tank Pressure Sensor Circuit Low Voltage
DTC P0453 Fuel Tank Pressure Sensor Circuit High Voltage
DTC P0454 Fuel Tank Pressure Sensor Circuit Intermittent
DTC P0455
DTC P0455 Evaporative Emission (Evap) System Large Leak
Detected
DTC P0496
DTC P0496 Evaporative Emission (Evap) System Flow During NonPurge
DTC P0506 Idle Speed Low
DTC P0507 Idle Speed High
DTC P0601-P0604, P0606, Or
DTC P0601 Control Module Read Only Memory (Rom)
P062F (Fuel Pump Control
Module)
DTC P0604 Control Module Random Access Memory (Ram)
DTC P0606 Control Module Internal Performance
DTC P0601-P0604, P0606,
P062F, P16F3, Or P2610 (LUW,
ECM)
DTC P16F3 Control Module Redundant Memory Performance
DTC P2610 Control Module Ignition Off Timer Performance
DTC P0627-P0629 (LUW)
DTC P0627 Fuel Pump Enable Circuit Open
DTC P0628 Fuel Pump Enable Circuit Low Voltage
DTC P0629 Fuel Pump Enable Circuit High Voltage
DTC P0630 (LUW)
DTC P0630 Vin Not Programmed Or Mismatched - Engine Control
Module (ECM)
DTC P0641 Or P06A6 (Fuel
DTC P0641 5 V Reference Circuit
DTC P06A6 5 V Reference Performance
DTC P0641, P0651, P0697, Or
P06A3 (LUW, ECM)
DTC P06A3 5V Reference 4 Circuit
DTC P0650 (LUW)
DTC P0650 Malfunction Indicator Lamp (Mil) Control Circuit
DTC P0660 (LUW)
DTC P0660 Intake Manifold Tuning Control Valve Control Circuit
DTC P0685, P0689, P0690, Or
DTC P0685 Engine Controls Ignition Relay Control Circuit
P1682 (LUW)
DTC P0689 Engine Controls Ignition Relay Feedback Circuit Low
Voltage

2013 DTC INDEX Cruz
DTC P069E (LUW)

DTC P0700 (LUW)
DTC P1255 Or P064A
DTC P1400 (LUW)
DTC P150C (LUW)
DTC P1516, P2101, P2119, Or
P2176 (LUW)

DTC P2076, P2077, Or P2078
(LUW)
DTC P2122, P2123, P2127,

P2128, Or P2138 (LUW)

Control Module)
Control Module)
DTC P0690 Engine Controls Ignition Relay Feedback Circuit High

Voltage
DTC P1682 Ignition 1 Switch Circuit 2
DTC P069E Fuel Pump Control Module Requested Mil Illumination
DTC P0700 Transmission Control Module Requested Mil Illumination
DTC P064A Fuel Pump Control Module Performance
DTC P1255 Fuel Pump Control Module Driver Over-Temperature
DTC P1400 Cold Start Emission Reduction Control System
DTC P150C Transmission Control Module Engine Speed Request
Signal Message Counter Incorrect
DTC P1516 Throttle Actuator Control (Tac) Module Throttle Actuator
Position Performance
DTC P2101 Throttle Actuator Position Performance
DTC P2119 Throttle Closed Position Performance
DTC P2176 Minimum Throttle Position Not Learned
DTC P2070 Intake Manifold Tuning Control Valve Stuck Open
DTC P2071 Intake Manifold Tuning Control Valve Stuck Closed
DTC P2076 Intake Manifold Tuning Control Valve Position Sensor
Performance
Circuit Low Voltage
DTC P2122 Accelerator Pedal Position (App) Sensor 1 Circuit Low
Voltage
DTC P2123 Accelerator Pedal Position (App) Sensor 1 Circuit High
Voltage
DTC P2127 Accelerator Pedal Position (App) Sensor 2 Circuit Low
Voltage
DTC P2128 Accelerator Pedal Position (App) Sensor 2 Circuit High
Voltage
DTC P2138 Accelerator Pedal Position (App) Sensors 1-2 Not
Plausible
DTC P2534 Ignition 1 Switch Circuit Low Voltage
DTC P2635 Fuel Pump Flow Performance
ENGINE COOLING SYSTEM - DIAGNOSTIC TROUBLE CODES

ENGINE COOLING SYSTEM - DIAGNOSTIC TROUBLE CODES
DTC
Description
DTC P00B3 or P00B4
DTC P00B3 Radiator Coolant Temperature (RCT) Sensor Circuit Low
Voltage
DTC P00B4 Radiator Coolant Temperature (RCT) Sensor Circuit High

2013 DTC INDEX Cruz
DTC P00B6
DTC P00B7
DTC P0480, P0481,
P0691, P0692, P0693, or
P0694
DTC P0597-P0599
DTC P2181
Voltage
DTC P00B6 Radiator Coolant Temperature (RCT)-Engine Coolant
Temperature (ECT) Not Plausible
DTC P00B7 Engine Coolant Flow Insufficient
DTC P0480 Cooling Fan Relay 1 Control Circuit
DTC P0481 Cooling Fan Relays 2 and 3 Control Circuit
DTC P0691 Cooling Fan Relay 1 Control Circuit Low Voltage
DTC P0692 Cooling Fan Relay 1 Control Circuit High Voltage
DTC P0693 Cooling Fan Relays 2 and 3 Control Circuit Low Voltage
DTC P0694 Cooling Fan Relays 2 and 3 Control Circuit High Voltage
DTC P0597 Engine Coolant Thermostat Heater Control Circuit
DTC P0598 Engine Coolant Thermostat Heater Control Circuit Low
Voltage
DTC P0599 Engine Coolant Thermostat Heater Control Circuit High
Voltage
DTC P2181 Engine Cooling System Performance
FIXED AND MOVEABLE WINDOWS - DIAGNOSTIC TROUBLE CODES

FIXED AND MOVEABLE WINDOWS - DIAGNOSTIC TROUBLE CODES
DTC
Description
DTC B0283
DTC B0283 02 Rear Defrost Circuit Short To Ground
DTC B0283 05 Rear Defrost Circuit Short To Battery or Open
DTC B316B, B317A, B318A,
DTC B316B Driver Window Switch
or B319A (AEC)
DTC B317A Passenger Window Switch
DTC B318A Left Rear Window Switch
DTC B319A Right Rear Window Switch
DTC B316B, B317A, B318A,
or B319A (AXG)
DTC B3205
DTC B3205 Driver Window Motor
HORN SYSTEM - DIAGNOSTIC TROUBLE CODES

HORN SYSTEM - DIAGNOSTIC TROUBLE CODES
DTC
DTC B2750
Description
DTC B2750 Horn Relay Secondary Circuit
HVAC SYSTEM - AUTOMATIC - DIAGNOSTIC TROUBLE CODES

HVAC SYSTEM - AUTOMATIC - DIAGNOSTIC TROUBLE CODES
DTC
Description
DTC B0163
DTC B0163 02 Passenger Compartment Temperature Sensor Circuit

2013 DTC INDEX Cruz
Short to Ground
DTC B0163 05 Passenger Compartment Temperature Sensor Circuit
High Voltage/Open
DTC B0173, B0178, or B3933
DTC B0173 02 Upper Left Duct Air Temperature Sensor Circuit
Short to Ground
DTC B0173 05 Upper Left Duct Air Temperature Sensor Circuit High
Voltage/Open
DTC B0178 02 Lower Left Duct Air Temperature Sensor Circuit
Short to Ground
DTC B0178 05 Lower Left Duct Air Temperature Sensor Circuit High
Voltage/Open
DTC B3933 02 Air Conditioning Evaporator Temperature Sensor
Circuit Short to Ground
DTC B3933 05 Air Conditioning Evaporator Temperature Sensor
Circuit High Voltage/Open
DTC B018A, B048C, B048F, or
DTC B018A 02 Windshield Temperature Sensor Circuit Short to
B1395
Ground
DTC B018A 05 Windshield Temperature Sensor Circuit High
Voltage/Open
DTC B048C 02 Humidity Sensor Humidity Circuit Short to Ground
DTC B048C 05 Humidity Sensor Humidity Circuit High
Voltage/Open
DTC B048F 02 Humidity Sensor Temperature Circuit Short to
Ground
DTC B048F 05 Humidity Sensor Temperature Circuit High
Voltage/Open
DTC B1395 03 Control Module Voltage Reference Output Circuit
Low Voltage
DTC B1395 07 Control Module Voltage Reference Output Circuit
High Voltage
DTC B0183
DTC B0183 02 Solar Load Sensor Circuit Short to Ground
DTC B0183 05 Solar Load Sensor Circuit High Voltage/Open
DTC B0193
DTC B0193 01 Front Blower Motor Speed Circuit Short to Battery
DTC B0193 06 Front Blower Motor Speed Circuit Low Voltage/Open
DTC B0223, B0233, B023A, or
DTC B0223 01 Recirculate Position Command 1 Circuit Short to
B0408
Battery
DTC B0223 06 Recirculate Position Command 1 Circuit Low
Voltage/Open
DTC B0233 01 Air Flow Control Circuit Short to Battery
DTC B0233 06 Air Flow Control Circuit Low Voltage/Open
DTC B023A 02 HVAC Actuators Supply Voltage Short to Ground
DTC B0408 01 Main Temperature Control Circuit Short to Battery
DTC B0408 06 Main Temperature Control Circuit Low Voltage/Open
DTC B3843
DTC B3843 02 Air Quality Sensor Circuit Short to Ground
DTC B3843 05 Air Quality Sensor Circuit High Voltage/Open
DTC B3843 08 Air Quality Sensor Circuit Performance - Signal
Invalid

2013 DTC INDEX Cruz
DTC B393B
DTC P0530, P0532, or P0533
DTC P0645, P0646, or P0647
DTC B393B 04 Air Conditioning Compressor Valve Control Circuit

Open
DTC B393B 0B Air Conditioning Compressor Valve Control Circuit
High Current
DTC P0530 03 Air Conditioning (A/C) Refrigerant Pressure Sensor
Circuit Low Voltage
Circuit Low Voltage
DTC P0645 Air Conditioning (A/C) Compressor Clutch Relay
Control Circuit
Control Circuit Low Voltage
Control Circuit High Voltage
HVAC SYSTEM - MANUAL - DIAGNOSTIC TROUBLE CODES

HVAC SYSTEM - MANUAL - DIAGNOSTIC TROUBLE CODES
DTC
Description
DTC B0193
DTC B0193 01 Front Blower Motor Speed Circuit Short to Battery
DTC B0193 06 Front Blower Motor Speed Circuit Low Voltage/Open
DTC B0223, B0233, B023A, DTC B0223 01 Recirculate Position Command 1 Circuit Short to Battery
DTC B0223 06 Recirculate Position Command 1 Circuit Low
or B0408
Voltage/Open
DTC B0233 01 Air Flow Control Circuit Short to Battery
DTC B0233 06 Air Flow Control Circuit Low Voltage/Open
DTC B023A 02 HVAC Actuators Supply Voltage Short to Ground
DTC B0408 01 Main Temperature Control Circuit Short to Battery
DTC B0408 06 Main Temperature Control Circuit Low Voltage/Open
DTC B3933
DTC B3933 02 Air Conditioning Evaporator Temperature Sensor Circuit
Short to Ground
High Voltage/Open
High Temperature
DTC B393B
DTC B393B 04 Air Conditioning Compressor Valve Control Circuit
Open
DTC B393B 0B Air Conditioning Compressor Valve Control Circuit
High Current
DTC P0532 or P0533
Circuit Low Voltage

2013 DTC INDEX Cruz
DTC P0645, P0646, or P0647

DTC P0645 Air Conditioning (A/C) Compressor Clutch Relay Control
Circuit
Circuit Low Voltage
HYDRAULIC BRAKE SYSTEM - DIAGNOSTIC TROUBLE CODES

HYDRAULIC BRAKE SYSTEM - DIAGNOSTIC TROUBLE CODES
DTC
Description
DTC C0267
DTC C0267 00 Low Brake Fluid Indicated
DTC C027B
DTC C027B 00 Brake Booster Electric Vacuum Pump
DTC C0299
DTC C0299 5A Brake Booster Large Vacuum Leak Detected Not Plausible
DTC C1100
DTC C1100 00 Brake Booster Vacuum Sensor Circuit Malfunction
DTC C1100 01 Brake Booster Vacuum Sensor Circuit Short to Battery
DTC C1100 02 Brake Booster Vacuum Sensor Circuit Short to Ground
DTC C1100 08 Brake Booster Vacuum Sensor Circuit Performance Signal
Invalid
DTC C1100 09 Brake Booster Vacuum Sensor Circuit Too Fast Transitions
IMMOBILIZER SYSTEM - DIAGNOSTIC TROUBLE CODES

IMMOBILIZER SYSTEM - DIAGNOSTIC TROUBLE CODES
DTC
Description
DTC B2955 (with BTM)
DTC B2955 Security Sensor Data Circuit
DTC B2955 (without BTM)
DTC B302A
DTC B302A Mobile Telephone Communications Interface Requested
Immobilization
DTC B3031
DTC B3031 Security Controller In Learn Mode
DTC B3055
DTC B3055 No Transponder Modulation or No Transponder
DTC B305C
DTC B305C Immobilizer Transponder of Wrong Type Programmed
DTC B3060
DTC B3060 Unprogrammed Transponder Identification Code Received
DTC B389A
DTC B389A Environment Identification
DTC B3902
DTC B3902 Incorrect Immobilizer Identifier Received
DTC B3935
DTC B3935 Transponder Authentication
DTC B3976
DTC B3976 Unconfigured Transponder
DTC B3984
DTC B3984 Device 1 Environment Identifier Not Programmable
DTC P0513
DTC P0513 Immobilizer Key Incorrect
DTC P0633
DTC P0633 Immobilizer Key Not Programmed
DTC P162B
DTC P162B Remote Vehicle Speed Limiting Signal Message Counter
Incorrect

2013 DTC INDEX Cruz
DTC P1630
DTC P1631
DTC P1649
DTC P1630 Immobilizer Learn Mode Active

DTC P1631 Immobilizer Fuel Enable Signal Not Correct
DTC P1649 Immobilizer Security Code Not Programmed
INSTRUMENT PANEL SYSTEM DISPLAYS AND GAUGES - DIAGNOSTIC

TROUBLE CODES
INSTRUMENT PANEL SYSTEM DISPLAYS AND GAUGES - DIAGNOSTIC TROUBLE CODES
DTC
Description
DTC B0158
DTC B0158 02 Ambient Air Temperature Sensor Circuit Short to Ground
DTC B0158 05 Ambient Air Temperature Sensor Circuit High
Voltage/Open
DTC B0550
DTC B0550 32 Odometer Circuit General Memory Malfunction
DTC B1370
DTC B1370 01 Control Module Ignition On and Start Circuit Short to
Battery
DTC B1370 06 Control Module Ignition On and Start Circuit Open
DTC B3567
DTC B3567 01 Info Display Select Switch Circuit Short to Battery
DTC B3567 02 Info Display Select Switch Circuit Short to Ground
DTC B3567 04 Info Display Select Switch Circuit Open
DTC B3567 59 Info Display Select Switch Circuit Protection Time-Out
DTC P0461-P0464
DTC P0461 Fuel Level Sensor Performance
DTC P0462 Fuel Level Sensor Circuit Low Voltage
DTC P0463 Fuel Level Sensor Circuit High Voltage
DTC P0464 Fuel Level Sensor Circuit Intermittent
DTC P0520
DTC P0520 Engine Oil Pressure Switch Circuit
DTC P0521
DTC P0521 Engine Oil Pressure Sensor Performance
KEYLESS ENTRY SYSTEM AND REMOTE FUNCTIONS - DIAGNOSTIC

TROUBLE CODES
KEYLESS ENTRY SYSTEM AND REMOTE FUNCTIONS - DIAGNOSTIC TROUBLE CODES
DTC
Description
DTC B3101
DTC B3101 Keyless Entry Data Link Circuit
DTC B3105
DTC B3105 Keyless Entry Transmitters
DTC B3106
DTC B3106 Keyless Entry Data Link
DTC B3109-B3113
DTC B3109 Keyless Entry Transmitter 1 Battery
DTC B310D-B310F
DTC B310D Keyless Entry Transmitter 6 Battery
DTC B310E Keyless Entry Transmitter 7 Battery
DTC B310F Keyless Entry Transmitter 8 Battery

2013 DTC INDEX Cruz
DTC B3119
DTC B3120
DTC B3121
DTC B3122
DTC B3123
DTC B3124
DTC B3119 Keyless Entry Antenna 1

DTC B3120 Keyless Entry Antenna 2 Short to Ground
DTC B3120 Keyless Entry Antenna 2 High Voltage/Open
LIGHTING SYSTEM - DIAGNOSTIC TROUBLE CODES

LIGHTING SYSTEM - DIAGNOSTIC TROUBLE CODES
DTC
Description
DTC B096A
DTC B096A 01 Hazard Lamps Switch Backlighting Circuit Short to Battery
DTC B096A 02 Hazard Lamps Switch Backlighting Circuit Short to Ground
DTC B096A 04 Hazard Lamps Switch Backlighting Circuit Open
DTC B1395
DTC B1395 03 Control Module Voltage Reference Output 1 Circuit Low
Voltage
DTC B1395 07 Control Module Voltage Reference Output 1 Circuit High
Voltage
DTC B1480
DTC B1480 02 Battery Rundown Protection Circuit Short to Ground
DTC B2530
DTC B2530 01 Front Fog Lamps Control Circuit Short to Battery
DTC B2530 02 Front Fog Lamps Control Circuit Short to Ground
DTC B2530 04 Front Fog Lamps Control Circuit Open
DTC B2545
DTC B2545 01 Backup Lamps Circuit Short to Battery
DTC B2545 02 Backup Lamps Circuit Short to Ground
DTC B2545 04 Backup Lamps Circuit Open
DTC B2575 or B2699
DTC B2575 01 Headlamps Control Circuit Short to Battery
DTC B2575 02 Headlamps Control Circuit Short to Ground
DTC B2575 04 Headlamps Control Circuit Open
DTC B2699 01 Right Headlamp Control Circuit Short to Battery
DTC B2699 02 Right Headlamp Control Circuit Short to Ground
DTC B2699 04 Right Headlamp Control Circuit Open
DTC B257A
DTC B257A 00 Headlamp Switch Input Signals Correlation Malfunction
DTC B257B
DTC B257B 03 Lighting Control Switch Signal Low Voltage
DTC B257B 07 Lighting Control Switch Signal High Voltage
DTC B2580
DTC B2580 01 High Beam Control Circuit Short to Battery
DTC B2580 02 High Beam Control Circuit Short to Ground
DTC B2580 04 High Beam Control Circuit Open
DTC B2585 or B3867
DTC B2585 01 Left Park Lamps Control Circuit Short to Battery
DTC B2585 02 Left Park Lamps Control Circuit Short to Ground
DTC B2585 04 Left Park Lamps Control Circuit Open

2013 DTC INDEX Cruz
DTC B2645
DTC B3596
DTC B3600
DTC B3650
DTC B3806
DTC B3883
DTC B3948 or B3949
DTC B3950 or B3951
DTC C0277 or C0890
DTC C0297
DTC B3867 01 Right Park Lamps Control Circuit Short to Battery

DTC B3867 02 Right Park Lamps Control Circuit Short to Ground
DTC B3867 04 Right Park Lamps Control Circuit Open
DTC B2645 03 Ambient Light Sensor Circuit Low Voltage
DTC B2645 07 Ambient Light Sensor Circuit High Voltage
DTC B3596 00 Hazard Lamps Request Circuit Malfunction
DTC B3600 03 Passenger Compartment Dimming Request Signal Circuit
Low Voltage
DTC B3600 07 Passenger Compartment Dimming Request Signal Circuit
High Voltage
DTC B3650 08 High Beam Request Signal Circuit Performance - Signal
Invalid
DTC B3806 00 High Beam and Headlamp Flash Select Circuit Malfunction
DTC B3883 01 License Plate Lamp Circuit Short to Battery
DTC B3883 02 License Plate Lamp Circuit Short to Ground
DTC B3883 04 License Plate Lamp Circuit Open
DTC B3948 01 Left Front Turn Signal Circuit Short to Battery
DTC B3948 02 Left Front Turn Signal Circuit Short to Ground
DTC B3948 04 Left Front Turn Signal Circuit Open
DTC B3949 01 Right Front Turn Signal Circuit Short to Battery
DTC B3949 02 Right Front Turn Signal Circuit Short to Ground
DTC B3949 04 Right Front Turn Signal Circuit Open
DTC B3950 01 Left Rear Turn Signal Circuit Short to Battery
DTC B3950 02 Left Rear Turn Signal Circuit Short to Ground
DTC B3950 04 Left Rear Turn Signal Circuit Open
DTC B3951 01 Right Rear Turn Signal Circuit Short to Battery
DTC B3951 02 Right Rear Turn Signal Circuit Short to Ground
DTC B3951 04 Right Rear Turn Signal Circuit Open
DTC C0277 06 Brake Pedal Position Sensor Circuit Low Voltage/Open
DTC C0277 07 Brake Pedal Position Sensor Circuit High Voltage
DTC C0277 09 Brake Pedal Position Sensor Circuit Too Fast Transitions
DTC C0277 4B Brake Pedal Position Sensor Circuit Calibration Not Learned
DTC C0890 03 Control Module Voltage Reference Output 3 Circuit Low
Voltage
DTC C0890 07 Control Module Voltage Reference Output 3 Circuit High
Voltage
DTC C0297 02 Brake Applied Output Circuit Short to Ground
MANUAL TRANSMISSION - M32 - DIAGNOSTIC TROUBLE CODES

MANUAL TRANSMISSION - M32 - DIAGNOSTIC TROUBLE CODES
DTC
Description
DTC P0502 or P0503
DTC P0502 Vehicle Speed Sensor (VSS) Circuit - Low Voltage
DTC P0503 Vehicle Speed Sensor (VSS) Circuit - Intermittent
DTC P0806-P0808
DTC P0806 Clutch Pedal Position (CPP) Sensor Performance

2013 DTC INDEX Cruz
DTC P080A
DTC P0812
DTC P0807 Clutch Pedal Position (CPP) Sensor Circuit Low Voltage
DTC P0808 Clutch Pedal Position (CPP) Sensor Circuit High
Voltage
DTC P080A Clutch Pedal Position (CPP) Not Learned
DTC P0812 00 Reverse Position Switch Circuit - Malfunction
OBJECT DETECTION SYSTEM - PARK ASSIST SYSTEM - DIAGNOSTIC

TROUBLE CODES
OBJECT DETECTION SYSTEM - PARK ASSIST SYSTEM - DIAGNOSTIC TROUBLE CODES
DTC
Description
DTC B094B or B094C
DTC B094B 00 Left Side Object Detection Control Module Malfunction
DTC B094B 08 Left Side Object Detection Control Module Performance - Signal Invalid
DTC B094B 45 Left Side Object Detection Control Module Variant Not Programmed
DTC B094B 54 Left Side Object Detection Control Module - High
Temperature
DTC B094B 58 Left Side Object Detection Control Module Performance
DTC B094C 00 Right Side Object Detection Control Module Malfunction
DTC B094C 08 Right Side Object Detection Control Module Performance - Signal Invalid
DTC B094C 45 Right Side Object Detection Control Module Variant Not Programmed
DTC B094C 54 Right Side Object Detection Control Module - High
Temperature
DTC B094C 58 Right Side Object Detection Control Module Performance
DTC B094D or B094E
DTC B094D 01 Left Side Object Detection Indicator Circuit Short to
Battery
DTC B094D 02 Left Side Object Detection Indicator Circuit Short to
Ground
DTC B094E 01 Right Side Object Detection Indicator Circuit Short
to Battery
DTC B094E 02 Right Side Object Detection Indicator Circuit Short
to Ground
DTC B0958, B0959, B0960, or
DTC B0958 01 Parking Assist Rear Sensor Left Corner Circuit Short
B0961
to Battery
DTC B0958 06 Parking Assist Rear Sensor Left Corner Circuit Low
Voltage/Open
DTC B0958 08 Parking Assist Rear Sensor Left Corner Circuit
DTC B0958 21 Parking Assist Rear Sensor Left Corner Circuit

2013 DTC INDEX Cruz
DTC B0967 or B0968
DTC B1015
DTC B1405
Incorrect Period
DTC B0958 3A Parking Assist Rear Sensor Left Corner Circuit
DTC B0959 01 Parking Assist Rear Sensor Left Middle Circuit
Short to Battery
DTC B0959 06 Parking Assist Rear Sensor Left Middle Circuit Low
Voltage/Open
Incorrect Period
DTC B0959 3A Parking Assist Rear Sensor Left Middle Circuit
DTC B0960 01 Parking Assist Rear Sensor Right Middle Circuit
Short to Battery
Low Voltage/Open
Incorrect Period
DTC B0960 3A Parking Assist Rear Sensor Right Middle Circuit
DTC B0961 01 Parking Assist Rear Sensor Right Corner Circuit
Short to Battery
Low Voltage/Open
Incorrect Period
DTC B0961 3A Parking Assist Rear Sensor Right Corner Circuit
DTC B0967 02 Parking Assist On/Off Switch Circuit Short to
Ground
DTC B0968 01 Parking Assist On/Off Switch Indicator Circuit Short
to Battery
DTC B0968 06 Parking Assist On/Off Switch Indicator Circuit Low
Voltage/Open
DTC B1015 00 Vehicle Identification Number Information
Malfunction
DTC B1405 02 Control Module Voltage Reference Output 2 Circuit
Short to Ground
Low Voltage
High Voltage

2013 DTC INDEX Cruz
POWER DOOR LOCK SYSTEM AND RELEASE SYSTEMS - DIAGNOSTIC

TROUBLE CODES
POWER DOOR LOCK SYSTEM AND RELEASE SYSTEMS - DIAGNOSTIC TROUBLE CODES
DTC
Description
DTC B1474 or B3849
DTC B1474 02 Passenger Exterior Door Handle Switch Circuit Short to
Ground
DTC B3849 02 Driver Exterior Door Handle Switch Circuit Short to
Ground
DTC B1534 or B1535
DTC B1534 02 Left Rear Door Handle Switch Circuit Short to Ground
DTC B1535 02 Right Rear Door Handle Switch Circuit Short to Ground
DTC B2494
DTC B2494 00 Liftgate Handle Switch Circuit Malfunction
DTC B297B or B297C
DTC B297B 5A Driver Door Open Switch Circuit Not Plausible
DTC B297C 5A Passenger Door Open Switch Circuit Not Plausible
DTC B3125, B3130, or
DTC B3125 Driver Door Only Unlock Circuit
B3135
DTC B3130 All Doors Unlock Circuit
DTC B3135 All Doors Lock Circuit
DTC B3140 or B3150
DTC B3140 00 Driver Door Unlock Switch Circuit
DTC B3150 00 Driver Front Door Lock Switch Circuit
DTC B3265
DTC B3265 Trunk Lid Unlatch Output Circuit
DTC B3618
DTC B3618 00 Exterior Liftgate Unlatch Switch Circuit Malfunction
DTC B3930
DTC B3930 02 Child Security Lock Motors Circuit Short to Ground
POWER STEERING SYSTEM - DIAGNOSTIC TROUBLE CODES

POWER STEERING SYSTEM - DIAGNOSTIC TROUBLE CODES
DTC
Description
DTC C005B (NJ1)
DTC C005B 00 Power Steering Softstops Learn
DTC C0176
DTC C0176 54 Control Module Temperature Sensor High Temperature
DTC C044A (NJ1)
DTC C044A 71 Steering System Engine Speed Signal Circuit Invalid Data
DTC C0456 (NJ1)
DTC C0456 4B Steering Position Sensor Calibration not Learned
DTC C0460 (NJ1)
DTC C0460 00 Steering Wheel Angle Sensor Malfunction
DTC C0460 4B Steering Wheel Angle Sensor Calibration Not Learned
DTC C0475 (NJ1)
DTC C0475 00 Electric Steering Motor Circuit Malfunction
DTC C0475 59 Electric Steering Motor Circuit Protection Time-Out
DTC C047A (NJ1)
DTC C047A Electric Steering Motor Position Sensor Circuit Malfunction
DTC C0544 (NJ1)
DTC C0544 5A Steering Wheel Angle Sensor Signal Not Plausible
DTC C0545 (NJ1)
DTC C0545 Steering Wheel Torque Sensor Malfunction
DTC C055C (NJ1)
DTC C055C 00 Steering Gear Performance Malfunction
DTC C055C 64 Steering Gear Performance Slip Detected
DTC C0565 (NJ1)
DTC C0565 5A Vehicle Identification Number Not Plausible
DTC C0569 (NJ1)
DTC C0569 3A System Configuration Incorrect Component Installed
DTC C056E (NJ1)
DTC C056E 41 Electronic Control Unit Hardware Not Programmed

2013 DTC INDEX Cruz
DTC C0710 (NJ1)
DTC C056E 4B Electronic Control Unit Hardware Calibration Not Learned

DTC C0710 71 Steering Position Signal Invalid Data
SEAT BELT SYSTEM - DIAGNOSTIC TROUBLE CODES

SEAT BELT SYSTEM - DIAGNOSTIC TROUBLE CODES
DTC
Description
DTC B0072 or B0073
DTC B0072 Driver Seat Belt Switch Circuit
DTC B0073 Passenger Seat Belt Switch Circuit
DTC B059A
DTC B059A 01 Passenger Seat Belt Indicator Circuit Short to Battery
DTC B059A 02 Passenger Seat Belt Indicator Circuit Short to Ground
DTC B059A 04 Passenger Seat Belt Indicator Circuit Open
SEAT HEATING SYSTEM AND SEAT COOLING SYSTEM - DIAGNOSTIC

TROUBLE CODES
SEAT HEATING SYSTEM AND SEAT COOLING SYSTEM - DIAGNOSTIC TROUBLE CODES
DTC
Description
DTC B1925 or B2170
DTC B1925 02 Driver Seat Cushion Heater Sensor Circuit Short to Ground
DTC B1925 05 Driver Seat Cushion Heater Sensor Circuit High
Voltage/Open
DTC B2170 02 Passenger Seat Cushion Heater Sensor Circuit Short to
Ground
DTC B2170 05 Passenger Seat Cushion Heater Sensor Circuit High
Voltage/Open
DTC B2345
DTC B2345 13 Seat Heater Disable Circuit Low Voltage High/Temperature
DTC B2425 or B2430
DTC B2425 0B Driver Seat Cushion Heater Circuit High Current
DTC B2425 0D Driver Seat Cushion Heater Circuit High Resistance
DTC B2425 0E Driver Seat Cushion Heater Circuit Low Resistance
DTC B2430 0B Passenger Seat Cushion Heater Circuit High Current
DTC B2430 0D Passenger Seat Cushion Heater Circuit High Resistance
DTC B2430 0E Passenger Seat Cushion Heater Circuit Low Resistance
DTC B242A
DTC B242A 01 Seat Heaters Common Circuit Short to Battery
DTC B242A 02 Seat Heaters Common Circuit Short to Ground
SECONDARY AND CONFIGURABLE CUSTOMER CONTROL SYSTEM DIAGNOSTIC TROUBLE CODES

SECONDARY AND CONFIGURABLE CUSTOMER CONTROL SYSTEM - DIAGNOSTIC
TROUBLE CODES
DTC
Description
DTC B242A
Voltage

2013 DTC INDEX Cruz
DTC B1529
DTC B3622
Voltage
Voltage
Voltage
DTC B3622 07 Steering Wheel Controls Signal Circuit High Voltage
SHIFT LOCK CONTROL SYSTEM - DIAGNOSTIC TROUBLE CODES

SHIFT LOCK CONTROL SYSTEM - DIAGNOSTIC TROUBLE CODES
DTC
Description
DTC B270A
DTC B270A 01 Park Lock Solenoid Control Circuit Short to Battery
DTC B270A 02 Park Lock Solenoid Control Circuit Short to Ground
DTC B270A 04 Park Lock Solenoid Control Circuit Open
SUNROOF SYSTEM - DIAGNOSTIC TROUBLE CODES

SUNROOF SYSTEM - DIAGNOSTIC TROUBLE CODES
DTC
Description
DTC B3664
DTC B3664 02 Sunroof Position Select Switch High Signal Circuit Short to
Ground
DTC B3664 05 Sunroof Position Select Switch High Signal Circuit High
Voltage/Open
DTC B3664 59 Sunroof Position Select Switch High Signal Circuit Protection
Time-Out
DTC B3697
DTC B3697 00 Sunroof Actuator Malfunction
DTC B3697 39 Sunroof Actuator Internal Malfunction
DTC B3697 42 Sunroof Actuator Calibration Not Programmed
DTC B3697 4B Sunroof Actuator Calibration Not Learned
DTC B369C
DTC B369C 02 Sunroof Tilt Position Select Switch Circuit Short to Ground
DTC B369C 05 Sunroof Tilt Position Select Switch Circuit High
Voltage/Open
DTC B369C 59 Sunroof Tilt Position Select Switch Circuit Protection TimeOut
SUPPLEMENTAL INFLATABLE RESTRAINT SYSTEM - DIAGNOSTIC

TROUBLE CODES
SUPPLEMENTAL INFLATABLE RESTRAINT SYSTEM - DIAGNOSTIC TROUBLE CODES
DTC
Description
DTC B0012 or B0013
DTC B0012 01 Driver Steering Wheel Air Bag Deployment Loop Stage 1
Short to Battery
Short to Ground

2013 DTC INDEX Cruz
Open
DTC B0012 0D Driver Steering Wheel Air Bag Deployment Loop Stage 1
High Resistance
DTC B0012 0E Driver Steering Wheel Air Bag Deployment Loop Stage 1
Low Resistance
DTC B0014, B0021, B0031,
DTC B0014 01 Driver Seat Side Air Bag Deployment Loop Short to
or B0038
Battery
DTC B0014 02 Driver Seat Side Air Bag Deployment Loop Short to
Ground
DTC B0014 04 Driver Seat Side Air Bag Deployment Loop Open
DTC B0014 0D Driver Seat Side Air Bag Deployment Loop High
Resistance
DTC B0014 0E Driver Seat Side Air Bag Deployment Loop Low
Resistance
DTC B0021 01 Passenger Seat Side Air Bag Deployment Loop Short to
Battery
DTC B0021 02 Passenger Seat Side Air Bag Deployment Loop Short to
Ground
DTC B0021 04 Passenger Seat Side Air Bag Deployment Loop Open
DTC B0021 0D Passenger Seat Side Air Bag Deployment Loop High
Resistance
DTC B0021 0E Passenger Seat Side Air Bag Deployment Loop Low
Resistance
DTC B0031 01 Left Rear Seat Side Air Bag Deployment Loop Short to
Battery
DTC B0031 02 Left Rear Seat Side Air Bag Deployment Loop Short to
Ground
DTC B0031 04 Left Rear Seat Side Air Bag Deployment Loop Open
DTC B0031 0D Left Rear Seat Side Air Bag Deployment Loop High
Resistance
DTC B0031 0E Left Rear Seat Side Air Bag Deployment Loop Low
Resistance
DTC B0038 01 Right Rear Seat Side Air Bag Deployment Loop Short to
Battery
DTC B0038 02 Right Rear Seat Side Air Bag Deployment Loop Short to
Ground
DTC B0038 04 Right Rear Seat Side Air Bag Deployment Loop Open
DTC B0038 0D Right Rear Seat Side Air Bag Deployment Loop High
Resistance
DTC B0038 0E Right Rear Seat Side Air Bag Deployment Loop Low
Resistance
DTC B0015, B001A, B001B, DTC B0015 01 Driver Seat Belt Retractor Pretensioner Deployment Loop
or B0022
Short to Battery
DTC B0015 02 Driver Seat Belt Retractor Pretensioner Deployment Loop
Short to Ground
DTC B0015 04 Driver Seat Belt Retractor Pretensioner Deployment Loop
Open

2013 DTC INDEX Cruz
DTC B0015 0D Driver Seat Belt Retractor Pretensioner Deployment Loop

High Resistance
DTC B0015 0E Driver Seat Belt Retractor Pretensioner Deployment Loop
Low Resistance
DTC B001A 01 Driver Seat Belt Anchor Pretensioner Deployment Loop
Short to Battery
Short to Ground
Open
DTC B001A 0D Driver Seat Belt Anchor Pretensioner Deployment Loop
High Resistance
DTC B001A 0E Driver Seat Belt Anchor Pretensioner Deployment Loop
Low Resistance
DTC B001B 01 Passenger Seat Belt Anchor Pretensioner Deployment
Loop Short to Battery
Loop Short to Ground
Loop Open
DTC B001B 0D Passenger Seat Belt Anchor Pretensioner Deployment
Loop High Resistance
DTC B001B 0E Passenger Seat Belt Anchor Pretensioner Deployment
Loop Low Resistance
DTC B0022 01 Passenger Seat Belt Retractor Pretensioner Deployment
Loop Short to Battery
Loop Short to Ground
Loop Open Circuit
DTC B0022 0D Passenger Seat Belt Retractor Pretensioner Deployment
Loop High Resistance
DTC B0022 0E Passenger Seat Belt Retractor Pretensioner Deployment
Loop Low Resistance
DTC B0016, B0018, B0023, DTC B0016 01 Left Roof Rail Air Bag Deployment Loop Short to Battery
or B0025
DTC B0016 02 Left Roof Rail Air Bag Deployment Loop Short to Ground
DTC B0016 04 Left Roof Rail Air Bag Deployment Loop Open
DTC B0016 0D Left Roof Rail Air Bag Deployment Loop High
Resistance
DTC B0016 0E Left Roof Rail Air Bag Deployment Loop Low Resistance
DTC B0023 01 Right Roof Rail Air Bag Deployment Loop Short to
Battery
DTC B0023 02 Right Roof Rail Air Bag Deployment Loop Short to
Ground
DTC B0023 04 Right Roof Rail Air Bag Deployment Loop Open
DTC B0023 0D Right Roof Rail Air Bag Deployment Loop High
Resistance
DTC B0023 0E Right Roof Rail Air Bag Deployment Loop Low

2013 DTC INDEX Cruz
DTC B0017 or B0024
DTC B0019 or B0020
DTC B0052
DTC B0074
DTC B0081 (Inflatable
Restraint Sensing and
Diagnostic Module)
DTC B0081 (Passenger
Presence Module)
DTC B0083 or B0084
Resistance
DTC B0017 01 Driver Knee Air Bag Deployment Loop Short to Battery
DTC B0017 02 Driver Knee Air Bag Deployment Loop Short to Ground
DTC B0017 04 Driver Knee Air Bag Deployment Loop Open
DTC B0017 0D Driver Knee Air Bag Deployment Loop High Resistance
DTC B0017 0E Driver Knee Air Bag Deployment Loop Low Resistance
DTC B0024 01 Passenger Knee Air Bag Deployment Loop Short to
Battery
DTC B0024 02 Passenger Knee Air Bag Deployment Loop Short to
Battery
DTC B0024 04 Passenger Knee Air Bag Deployment Loop Open
DTC B0024 0D Passenger Knee Air Bag Deployment Loop High
Resistance
DTC B0024 0E Passenger Knee Air Bag Deployment Loop Low
Resistance
DTC B0019 01 Passenger Instrument Panel Air Bag Deployment Loop
Stage 1 Short to Battery
Stage 1 Short to Ground
Stage 1 Open
DTC B0019 0D Passenger Instrument Panel Air Bag Deployment Loop
Stage 1 High Resistance
DTC B0019 0E Passenger Instrument Panel Air Bag Deployment Loop
Stage 1 Low Resistance
Stage 2 Short to Battery
Stage 2 Short to Ground
Stage 2 Open
DTC B0020 0D Passenger Instrument Panel Air Bag Deployment Loop
Stage 2 High Resistance
DTC B0020 0E Passenger Instrument Panel Air Bag Deployment Loop
Stage 2 Low Resistance
DTC B0052 00 Deployment Commanded
DTC B0052 56 Deployment Commanded Too Many Transitions
DTC B0074 0D Passenger Presence Sensor High Resistance
DTC B0074 0E Passenger Presence Sensor Low Resistance
DTC B0081 00 Passenger Presence Module Malfunction
DTC B0081 3A Passenger Presence Module Incorrect Component
Installed
DTC B0081 71 Passenger Presence Module Invalid Serial Data Received
DTC B0081 11 Passenger Presence Module High Input
DTC B0081 4B Calibration Not Programmed
DTC B0083 02 Left Front Impact Sensor Short to Ground
DTC B0083 05 Left Front Impact Sensor High Voltage/Open

2013 DTC INDEX Cruz
DTC B0085 or B0088
DTC B0086 or B0087
DTC B067F or B0680
DTC B1001 (Passenger

Presence System)
DTC B1001 (Inflatable
Diagnostic Module)
DTC B1019
DTC B0083 39 Left Front Impact Sensor Internal Electronic Failure

DTC B0083 3A Left Front Impact Sensor Incorrect Component Installed
DTC B0083 71 Left Front Impact Sensor Invalid Serial Data Received
DTC B0084 02 Right Front Impact Sensor Short to Ground
DTC B0084 05 Right Front Impact Sensor High Voltage/Open
DTC B0084 39 Right Front Impact Sensor Internal Electronic Failure
DTC B0084 3A Right Front Impact Sensor Incorrect Component Installed
DTC B0084 71 Right Front Impact Sensor Invalid Serial Data Received
DTC B0085 02 Left Front Side Impact Sensor Short to Ground
DTC B0085 05 Left Front Side Impact Sensor High Voltage/Open
DTC B0085 39 Left Front Side Impact Sensor Internal Malfunction
DTC B0085 3A Left Front Side Impact Sensor Incorrect Component
Installed
DTC B0085 71 Left Front Side Impact Sensor Invalid Data
DTC B0088 02 Right Rear Side Impact Sensor Short to Ground
DTC B0088 05 Right Rear Side Impact Sensor High Voltage/Open
DTC B0088 39 Right Rear Side Impact Sensor Internal Malfunction
DTC B0088 3A Right Rear Side Impact Sensor Incorrect Component
Installed
DTC B0088 71 Right Rear Side Impact Sensor Invalid Data
DTC B0086 02 Right Front Side Impact Sensor Short to Ground
DTC B0086 05 Right Front Side Impact Sensor High Voltage/Open
DTC B0086 39 Right Front Side Impact Sensor Internal Malfunction
DTC B0086 3A Right Front Side Impact Sensor Incorrect Component
Installed
DTC B0086 71 Right Front Side Impact Sensor Invalid Data
DTC B0087 02 Left Rear Side Impact Sensor Short to Ground
DTC B0087 05 Left Rear Side Impact Sensor High Voltage/Open
DTC B0087 39 Left Rear Side Impact Sensor Internal Malfunction
DTC B0087 3A Left Rear Side Impact Sensor Incorrect Component
Installed
DTC B0087 71 Left Rear Side Impact Sensor Invalid Data
DTC B067F 01 Passenger Air Bag On Indicator Circuit Short to Battery
DTC B067F 02 Passenger Air Bag On Indicator Circuit Short to Ground
DTC B067F 04 Passenger Air Bag On Indicator Circuit Open
DTC B0680 01 Passenger Air Bag Off Indicator Circuit Short to Battery
DTC B0680 02 Passenger Air Bag Off Indicator Circuit Short to Ground
DTC B0680 04 Passenger Air Bag Off Indicator Circuit Open
DTC B1001 00 Option Configuration Error
DTC B1001 00 Option Configuration
DTC B1019 00 System Configuration Error
TIRE PRESSURE MONITORING SYSTEM - DIAGNOSTIC TROUBLE CODES

2013 DTC INDEX Cruz
TIRE PRESSURE MONITORING SYSTEM - DIAGNOSTIC TROUBLE CODES

DTC
Description
DTC C0569
DTC C0569 00 System Configuration Malfunction
DTC C0750, C0755, C0760, or
DTC C0750 03 Left Front Tire Pressure Sensor Low Voltage
C0765
DTC C0750 29 Left Front Tire Pressure Sensor Too Few Pulses
DTC C0750 39 Left Front Tire Pressure Sensor Internal Malfunction
DTC C0755 03 Right Front Tire Pressure Sensor Low Voltage
DTC C0755 29 Right Front Tire Pressure Sensor Too Few Pulses
DTC C0755 39 Right Front Tire Pressure Sensor Internal Malfunction
DTC C0760 03 Left Rear Tire Pressure Sensor Low Voltage
DTC C0760 29 Left Rear Tire Pressure Sensor Too Few Pulses
DTC C0760 39 Left Rear Tire Pressure Sensor Internal Malfunction
DTC C0765 03 Right Rear Tire Pressure Sensor Low Voltage
DTC C0765 29 Right Rear Tire Pressure Sensor Too Few Pulses
DTC C0765 39 Right Rear Tire Pressure Sensor Internal Malfunction
DTC C0775
DTC C0775 00 Tire Pressure Monitoring System Sensors Malfunction
WIPER SYSTEM AND WASHER SYSTEM - DIAGNOSTIC TROUBLE CODES

WIPER SYSTEM AND WASHER SYSTEM - DIAGNOSTIC TROUBLE CODES
DTC
Description
DTC B3715 or B3875
DTC B3715 01 Windshield Wiper Relay Circuit Short to Battery
DTC B3715 02 Windshield Wiper Relay Circuit Short to Ground
DTC B3715 04 Windshield Wiper Relay Circuit Open
DTC B3875 01 Windshield Wiper High Speed Relay Circuit Short to
Battery
DTC B3875 02 Windshield Wiper High Speed Relay Circuit Short to
Ground
DTC B3875 04 Windshield Wiper High Speed Relay Circuit Open
DTC B3873
DTC B3873 01 Front Washer Relay Circuit Short to Battery
DTC B3873 02 Front Washer Relay Circuit Short to Ground
DTC B3873 04 Front Washer Relay Circuit Open Circuit
WIRING SYSTEMS AND POWER MANAGEMENT - DIAGNOSTIC TROUBLE

CODES
WIRING SYSTEMS AND POWER MANAGEMENT - DIAGNOSTIC TROUBLE CODES
DTC
Description
DTC B097B
DTC B097B 00 Power Mode Start Switch Circuit Malfunction
DTC B097B 02 Power Mode Start Switch Circuit Short to Ground
DTC B097B 04 Power Mode Start Switch Circuit Open
DTC B097B 05 Power Mode Start Switch Circuit High Voltage/Open
DTC B097B 08 Power Mode Start Switch Circuit Performance - Signal
Invalid
DTC B097B 61 Power Mode Start Switch Circuit Stuck

2013 DTC INDEX Cruz
DTC B097C
DTC B1370-B1379, B1380B1389, or B1440-B1443
DTC B1448
DTC B144B
DTC B1451
DTC B147E
DTC B147F
DTC B097C 01 Power Mode Run/Start Indicator Circuit Short to Battery

DTC B097C 02 Power Mode Run/Start Indicator Circuit Short to Ground
DTC B097C 04 Power Mode Run/Start Indicator Circuit Open
DTC B1370 01 Control Module Ignition ON and Start Circuit Short to
Battery
DTC B1370 04 Control Module Ignition ON and Start Circuit Open
DTC B1380 01 Control Module Ignition Accessory Circuit Short to
Battery
DTC B1380 04 Control Module Ignition Accessory Circuit Open
DTC B1441 01 Control Module Ignition OFF, Run, and Start Circuit
Short to Battery
DTC B1441 04 Control Module Ignition OFF, Run, and Start Circuit
Open
DTC B1448 01 Accessory Power Relay Circuit Short to Battery
DTC B1448 02 Accessory Power Relay Circuit Short to Ground
DTC B1448 04 Accessory Power Relay Circuit Open
DTC B144B 01 Run/Crank Power Relay Circuit Short to Battery
DTC B144B 02 Run/Crank Power Relay Circuit Short to Ground
DTC B144B 04 Run/Crank Power Relay Circuit Open
DTC B1451 01 Accessory Power Circuit Short to Battery
DTC B1451 02 Accessory Power Circuit Short to Ground
DTC B1451 04 Accessory Power Circuit Open
DTC B147E 01 Battery Saver Relay Set Secondary Circuit Short to
Battery
DTC B147E 02 Battery Saver Relay Set Secondary Circuit Short to
Ground
DTC B147E 04 Battery Saver Relay Set Secondary Circuit Open
DTC B147F 01 Battery Saver Relay Reset Secondary Circuit Short to
Battery
DTC B147F 02 Battery Saver Relay Reset Secondary Circuit Short to
Ground
DTC B147F 04 Battery Saver Relay Reset Secondary Circuit Open

2013 ACCESSORIES & EQUIPMENT Cellular, Entertainment, and Navigation - Cruze
2013 ACCESSORIES & EQUIPMENT

Cellular, Entertainment, and Navigation - Cruze
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
Fastener Tightening Specifications
Specification
Application
Mobile Telephone Control Module Bolt
Radio Antenna Base
Radio Antenna Module Bolt
Radio Bolt
Radio Front Side Door Speaker Bolt
Radio Front Speaker Bolt
Radio Rear Compartment Speaker Bolt
Radio Rear Side Door Speaker Bolt
Radio Speaker Amplifier Nut
Radio Antenna Coil Nut
Radio Control Module Bolt
Metric
5 N.m
10 N.m
8 N.m
2.5 N.m
2.5 N.m
2.5 N.m
2.5 N.m
2.5 N.m
9 N.m
8 N.m
2.5 N.m
SCHEMATIC WIRING DIAGRAMS

RADIO/NAVIGATION SYSTEM WIRING SCHEMATICS
Power, Ground, Serial Data, Antenna, and Display Wiring Schematics
English
44 lb in
89 lb in
71 lb in
22 lb in
22 lb in
22 lb in
22 lb in
22 lb in
80 lb in
71 lb in
22 lb in

Fig. 1: Power, Ground, Serial Data, Antenna, and Display Wiring Schematics
Callout
CAV_28
CAV 18
3140
CAV_1
3140_RD/GN
3140_RD/GN
40
40_RD/GN
CAV_44
CONN_X1
5060
5060_GN
CAV_14
CONN_X5
COAX
COAX
Component Name
28
18
1
3140 RD/GN
3140 RD/GN
40 RD/GN
44
X1
Low Speed GMLAN Serial
Data
5060 GN
14
X5
COAX
COAX

7532
7532_GN/BU
CAV 4
CAV_3
3140_RD/GN
CAV_1
7460
7460_BARE
CAV_6
CAV 3
CONN_X1
7458
7458_VT
CAV_7
CAV_16
7459
7459_YE
CAV_8
CAV_2
3290
3290_VT
CAV_5
CAV_27
3291
3291_GY/GN
CAV_4
CAV_13
1750
1750_BK
CAV_38
CAV_2
1750_BK
1650
1650_BK
CAV_2
F5DA
Linear Interconnect Network

Bus 10
7532 GN/BU
4
3
3140 RD/GN
1
Integrated Center Stack Serial
Data Shield
7460 BARE
6
3
X1
Center Integrated Center
Stack Serial Data High
7458 VT
7
16
Integrated Center Stack Serial
Data Low
7459 YE
8
2
Integrated Center Stack Reset
Signal
3290 VT
5
27
Integrated Center Stack Wake
Up Signal
3291 GY/GN
4
13
Ground
1750 BK
38
2
1750 BK
Ground
1650 BK
2
F5DA 7.5A

F4DA
X206
TWIST_9
Data_Communication_Schematics_REF
P17
A11
A22
A90
T4G
KR104A
X51A
F4DA 20A
X206
9
Data Communication
Schematics
Logic
Door Speakers (without UQA) Wiring Schematics
Fig. 2: Door Speakers (without UQA) Wiring Schematics

Callout
118
118 BN/BU
Component Name
Left Front Speaker Signal (-) (1)
118 BN/BU

CAV_1
CAV_32
CONN_X1
201
201_BU
CAV_2
CAV_40
117
117_YE/BK
CAV_1
CAV_31
200
200 YE
CAV_2
CAV_39
116
116_GN/BK
CAV_1
CAV_34
199
199_GN
CAV_2
CAV_42
115
115_BU/BK
CAV_1
CAV_33
46
46_WH
CAV 2
CAV_41
118_BN/BU
201_BU
117_YE/BK
200_YE
116_GN/BK
199_GN
115_BU/BK
46_WH
CAV_1
201_BU
C V 2
1
32
X1
Left Front Speaker (+) (1)
201 BU
2
40
Right Front Speaker Signal (-) (1)
117 YE/BK
1
31
Right Front Speaker (+) (1)
200 YE
2
39
Left Rear Speaker Signal (-)
116 GN/BK
1
34
Left Rear Speaker (+)
199 GN
2
42
Right Rear Speaker Signal (-)
115 BU/BK
1
33
Right Rear Speaker (+)
46 WH
2
41
118 BN/BU
201 BU
117 YE/BK
200 YE
116 GN/BK
199 GN
115 BU/BK
46 WH
1
201 BU

CAV_1
200_YE
CAV_2
118_BN/BU
117_YE/BK
118_BN/BU
201_BU
201_BU
118_BN/BU
117_YE/BK
200_YE
200 YE
117_YE/BK
116_GN/BK
199_GN
115_BU/BK
46_WH
X500
CAV_15
CAV_14
X210
CAV_11
CAV_10
X600
CAV_17
CAV_18
X210
CAV_12
CAV 13
X700
CAV_20
CAV_19
X800
CAV_20
CAV_19
X200
CAV_12
CAV_23
CAV_13
CAV_24
C V 14
2
1
200 YE
2
118 BN/BU
117 YE/BK
118 BN/BU
201 BU
201 BU
118 BN/BU
117 YE/BK
200 YE
200 YE
117 YE/BK
116 GN/BK
199 GN
115 BU/BK
46 WH
X500
15
14
X210
11
10
X600
17
18
X210
12
13
X700
20
19
X800
20
19
X200
12
23
13
24

CAV_25
CAV_15
CAV_26
TWIST_9
TWIST_9
TWIST_9
TWIST_9
TWIST_9
TWIST_9
TWIST_9
TWIST_9
TWIST 9
TWIST_9
TWIST_9
TWIST_9
TWIST_9
TWIST_9
TWIST_9
TWIST_9
X500
X210
X600
X210
X700
X800
X200
A11
P19H
P19V
P19AG
P19AH
P19AL
P19AM
Amplifier (UQA) Wiring Schematics
14
25
15
26
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
X500
X210
X600
X210
X700
X800
X200

Fig. 3: Amplifier (UQA) Wiring Schematics

Callout
1040
1040 RD/WH
CAV_4
CONN_X1
CAV_71
CONN_X2
450
450_BK
CAV_8
CONN_X1
7066
7066_GN/YE
CAV_8
CONN_X3
CAV_43
CONN_X1
6978
Component Name
1040 RD/WH
4
X1
71
X2
Ground
450 BK
8
X1
Entertainment Remote Enable Signal
7066 GN/YE
8
X3
43
X1
Amplifier Control

6978_VT/BU
CAV_16
CAV_37
511
511_BU
CAV_12
CAV_40
1947
1947_BN/BU
CAV_11
CAV_32
512
512 YE
CAV_9
CAV_39
1546
1546_BU/BN
CAV_10
CAV_31
2011
2011_BARE
CAV_29
599
599_GN/BK
CAV_1
CAV_42
1999
1999 BN/VT
CAV_2
CAV 34
546
546_BN/WH
CAV_4
CAV_41
1946
1946_BU/BK
CAV_3
CAV_33
2099
CAV_30
2099_BARE
7066 GN/YE
6978 VT/BU
16
37
Left Front Low Level Audio Signal
511 BU
12
40
Left Front Low Level Audio (-)
1947 BN/BU
11
32
Right Front Low Level Audio Signal
512 YE
9
39
Front Low Level Audio (-)
1546 BU/BN
10
31
Left Front Audio Drain Wire
2011 BARE
29
Left Rear Low Level Audio Signal
599 GN/BK
1
42
Left Rear Low Level Audio (-)
1999 BN/VT
2
34
Right Rear Low Level Audio Signal
546 BN/WH
4
41
Right Rear Low Level Audio (-)
1946 BU/BK
3
33
Left Rear Audio Drain Wire
30
2099 BARE

6978_VT/BU
511_BU
1947_BN/BU
512_YE
1546_BU/BN
2011_BARE
599_GN/BK
1999_BN/VT
546_BN/WH
1946_BU/BK
2099_BARE
X205
CAV_5
CAV_8
CAV_12
CAV_9
CAV_6
CAV_3
CAV_11
CAV_10
CAV_4
CAV_7
CAV_1
CAV_2
G402
F35UA
TWIST 9
TWIST_9
TWIST 9
TWIST_9
TWIST_9
TWIST_9
TWIST_9
TWIST_9
X205
X50A
T3
A11
Door Speakers (UQA) Wiring Schematics
7066 GN/YE
6978 VT/BU
511 BU
1947 BN/BU
512 YE
1546 BU/BN
2011 BARE
599 GN/BK
1999 BN/VT
546 BN/WH
1946 BU/BK
2099 BARE
X205
5
8
12
9
6
3
11
10
4
7
1
2
G402
F35UA 30A
9
9
9
9
9
9
9
9
X205
(UQA)

Fig. 4: Door Speakers (UQA) Wiring Schematics

Callout
119
CAV 1
CAV_2
CONN_X2
201
201_BU
CAV_2
CAV_1
CAV_1
117
CAV_1
CAV_12
200
CAV_2
CAV_11
116
CAV_1
Component Name
Mode Door Control
1
2
X2
Left Front Speaker (+) (1)
201 BU
2
1
1
Right Front Speaker Signal (-) (1)
1
12
Right Front Speaker (+) (1)
2
11
Left Rear Speaker Signal (-)
1

CAV_4
115
CAV_1
CAV_9
199
CAV_2
CAV_3
48
CAV_2
CAV_10
118
CAV_1
210
CAV_2
117_YE/BK
CAV_1
209
CAV_2
119_BN/BU
119_BN/BU
201_BU
201_BU
210_BU
210_BU
118_BN/BU
118_BN/BU
117_YE/BK
117 YE/BK
200_YE
200 YE
209_YE
209_YE
117_YE/BK
116_GN/BK
116_GN/BK
199_GN
199_GN
115_BU/BK
115_BU/BK
48_WH
48_WH
X500
4
Right Rear Speaker Signal (-)
1
9
Left Rear Speaker (+)
2
3
Clutch Pedal Position Switch Anticipate Signal
2
10
Left Front Speaker Signal (-) (1)
1
Passenger Power Seat Lumbar Motor Rearward Control
2
117 YE/BK
1
Low Brake Fluid Indicator Control
2
119 BN/BU
119 BN/BU
201 BU
201 BU
210 BU
210 BU
118 BN/BU
118 BN/BU
117 YE/BK
117 YE/BK
200 YE
200 YE
209 YE
209 YE
117 YE/BK
116 GN/BK
116 GN/BK
199 GN
199 GN
115 BU/BK
115 BU/BK
48 WH
48 WH

CAV_15
CAV_14
X210
CAV_11
CAV_10
X600
CAV_17
CAV_18
X210
CAV_12
CAV_13
X700
CAV_20
CAV_19
X800
CAV_20
CAV_19
TWIST_9
TWIST_9
TWIST_9
TWIST_9
TWIST_9
TWIST_9
TWIST_9
TWIST_9
TWIST_9
TWIST 9
TWIST_9
TWIST 9
X500
X210
X600
X210
X700
X800
P19H
P19V
T3
P19AG
P19AH
P19 L
X500
15
14
X210
11
10
X600
17
18
X210
12
13
X700
20
19
X800
20
19
9
9
9
9
9
9
9
9
9
9
9
9
X500
X210
X600
X210
X700
X800
(UQA)

P19AM
Center Speaker and Subwoofers (UQA) Wiring Schematics
Fig. 5: Center Speaker and Subwoofers (UQA) Wiring Schematics

Callout
1960
CAV_1
CAV_8
CONN X2
1960_BU/YE
1960 BU/YE
1860
CAV_2
CAV_7
1860_YE/WH
1860_YE/WH
1794
Component Name
Front Center Speaker (-)
1
8
X2
1960 BU/YE
1960 BU/YE
Front Center Speaker (+)
2
7
1860 YE/WH
1860 YE/WH
Left/Rear Subwoofer Speaker (-)

1794_GY/BK
CAV_1
CAV_2
CONN_X1
346
346_GN/VT
CAV_2
CAV_3
315
315_GN/BK
CAV_1
CAV_5
1795
1795_BU/GY
CAV_2
CAV_1
X200
CAV_1
CAV_2
TWIST_9
TWIST_9
TWIST_9
TWIST_9
X200
T3
P19N
P19AA
P19B
Navigation System (UHQ) Wiring Schematics
1794 GY/BK
1
2
X1
Left/Rear Subwoofer Speaker (+)
346 GN/VT
2
3
Right Subwoofer Speaker (-)
315 GN/BK
1
5
Right Subwoofer Speaker (+)
1795 BU/GY
2
1
X200
1
2
9
9
9
9
X200
(UQA)
(UQA)

Fig. 6: Navigation System (UHQ) Wiring Schematics

Callout
CAV_28
CAV BU
CONN_X7
COAX
COAX
3140
CAV_1
CONN_X1
3140_RD/GN
3140_RD/GN
7066
7066_GN/YE
CAV_6
CAV_43
CONN_X1
3364
3364_BN/GN
Component Name
28
BU
X7
COAX
COAX
1
X1
3140 RD/GN
3140 RD/GN
Entertainment Remote Enable Signal
7066 GN/YE
6
43
X1
Navigation Display Reset Signal
3364 BN/GN

CAV_5
CAV_10
CONN_X2
3369
3369_GY
CAV_4
CAV_9
3370
3370_VT
CAV_8
CAV_19
3368
3368 BARE
CAV_7
CAV_8
TWINAX
TWINAX
CONN_X2
CONN_X5
1750
1750_BK
CAV_2
1750_BK
CAV_2
CONN_X1
3290
3290_VT
CAV 8
CAV_27
CONN X1
3291
3291_GY/GN
CAV_7
CAV_13
7458
7458_VT
CAV_4
CAV_16
7459
7459_YE
CAV_5
C V 2
5
10
X2
Touch Screen Display Signal (+)
3369 GY
4
9
Touch Screen Display Signal (-)
3370 VT
8
19
Touch Screen Display Drain Wire
3368 BARE
7
8
TBD
TWINAX
X2
X5
Ground
1750 BK
2
1750 BK
2
X1
Integrated Center Stack Reset Signal
3290 VT
8
27
X1
Integrated Center Stack Wake Up Signal
3291 GY/GN
7
13
Center Integrated Center Stack Serial Data High
7458 VT
4
16
Integrated Center Stack Serial Data Low
7459 YE
5

7460
7460_BARE
CAV_6
CAV_3
3140_RD/GN
CAV_1
G203
F5DA
X207
TWIST_9
TWIST_9
J203
A11
P17
A22
T4G
KR104A
X51A
Audio Input (without KTA) Wiring Schematics
2
Integrated Center Stack Serial Data Shield
7460 BARE
6
3
3140 RD/GN
1
G203
F5DA 7.5
X207
9
9
J203

Fig. 7: Audio Input (without KTA) Wiring Schematics

Callout
2060
2060_BU
CAV_11
CONN_X1
CAV 1
5843
5843_VT
CAV_23
CAV_5
5839
5839_GY
CAV_24
CAV_2
5841
5841_GN
CAV_10
CAV_4
Component Name
Auxiliary Detection Signal
2060 BU
11
X1
1
Auxiliary Audio Common Signal
5843 VT
23
5
Left Auxiliary Audio Signal (2)
5839 GY
24
2
Right Auxiliary Audio Signal (2)
5841 GN
10
4

5842
5842_BARE
CAV_17
5842_BK
2060_BU
5843_VT
5839_GY
5841_GN
USB
USB
USB
X300
CAV 21
CAV_12
CAV_14
CAV_13
CAV_22
X301
X300
W7
A11
X83
Auxiliary Audio Screen (2)

5842 BARE
17
5842 BK
2060 BU
5843 VT
5839 GY
5841 GN
USB Cable
USB
USB
X300
21
12
14
13
22
X301
X300
Multimedia Player Interface (KTA) Wiring Schematics

Fig. 8: Multimedia Player Interface (KTA) Wiring Schematics

Callout
CAV_20
3140
3140_RD/GN
CAV_1
3140_RD/GN
5060
5060_GN
CAV_8
2060
2060_BU
CAV 2
CAV_1
5842
5842_BK
CAV_18
5842_BARE
Component Name
20
3140 RD/GN
1
3140 RD/GN
Data
5060 GN
8
Auxiliary Detection Signal
2060 BU
2
1
Auxiliary Audio Screen (2)
5842 BK
18
5842 BARE

5843
5843_VT
CAV 3
CAV_5
5839
5839_GY
CAV_12
CAV_2
5841
5841_GN
CAV_13
CAV_4
USB
USB
2060_BU
5843_VT
5839 GY
5841_GN
3375
3375_BARE
CAV_5
3376
3376_GN
CAV_23
CONN_X1
CAV_4
3377
3377_VT
CAV_24
CAV_14
3378
3378_BN
CAV_10
CAV_15
1750
Auxiliary Audio Common

Signal
5843 VT
3
5
Left Auxiliary Audio Signal
(2)
5839 GY
12
2
Right Auxiliary Audio Signal
(2)
5841 GN
13
4
USB Cable
USB
2060 BU
5843 VT
5839 GY
5841 GN
Auxiliary Audio Drain Wire
(3)
3375 BARE
5
Auxiliary Audio Common
Signal (3)
3376 GN
23
X1
4
Left Auxiliary Audio Signal
(3)
3377 VT
24
14
Right Auxiliary Audio Signal
(3)
3378 BN
10
15
Ground

1750_BK
CAV_11
USB
X300
CAV_22
CAV_21
CAV_13
CAV_14
CAV_12
G203
F5DA
X301
TWIST 9
TWIST_9
X300
A11
T11
W7
W7
X83
KR104A
X51A
ONSTAR WIRING SCHEMATICS
Power, Ground, Serial Data, Microphone, and Display Wiring Schematics
1750 BK
11
USB
X300
22
21
13
14
12
G203
F5DA 7.5
X301
9
9
X300
(KTA)
Data Communication
Schematics

Fig. 9: Power, Ground, Serial Data, Microphone, and Display Wiring Schematics
Callout
CAV_17
840
840_RD/BU
CAV_15
CONN_X1
5060
5060_GN
CAV_1
2500
2500_BU
CAV_10
2501
2501_WH
CAV_12
Component Name
17
840 RD/BU
15
X1
Data
5060 GN
1
High Speed GMLAN Serial
Data (+) (1)
2500 BU
10
Data (-) (1)
2501 WH
12

5986
5986_WH/BU
CAV 7
2500_BU
CAV_3
2501_WH
CAV_4
655
CAV_B
654
CAV_10
CAV_A
CONN_X2
CAV_9
655_BU
655_BU
655 BU
654_BK/BN
654 BK/BN
654_BK/BN
2517
2517_BN/WH
CAV_7
CAV_2
CONN_X1
2516
2516_YE/VT
CAV_6
CAV_3
2515
2515_GN/BK
CAV_4
CAV_6
2514
2514_GN/WH
CAV_3
CAV_11
2517_BN/WH
2517_BN/WH
Serial Data Communication

Enable
5986 WH/BU
7
2500 BU
3
2501 WH
4
Cellular Telephone
Microphone Signal
B
Cellular Telephone
Microphone Low Reference
10
A
X2
9
655 BU
655 BU
655 BU
654 BK/BN
654 BK/BN
654 BK/BN
Keypad Red LED
2517 BN/WH
7
2
X1
Keypad Green LED
2516 YE/VT
6
3
Keypad Supply Voltage
2515 GN/BK
4
6
Keypad Signal
2514 GN/WH
3
11
2517 BN/WH
2517 BN/WH

2516_YE/VT
2516_YE/VT
2515_GN/BK
2515_GN/BK
2514_GN/WH
2514_GN/WH
1750
1750_BK
1550
1550_BK
CAV_5
CAV_7
X211
CAV_7
CAV_8
X200
CAV_73
CAV_74
X211
CAV_12
CAV_9
CAV_10
CAV_11
X200
CAV_75
CAV_76
CAV_56
CAV 77
F1DA
G203
G305
X211
X200
X211
X200
K73
B24
A10
KR104A
2516 YE/VT
2516 YE/VT
2515 GN/BK
2515 GN/BK
2514 GN/WH
2514 GN/WH
Ground
1750 BK
Ground
1550 BK
5
7
X211
7
8
X200
73
74
X211
12
9
10
11
X200
75
76
56
77
F1DA 10A
G203
G305
X211
X200
X211
X200
(UE1)
(UE1)
Data Communication
Schematics
(DD8)

X51A
Antenna Wiring Schematics
Fig. 10: Antenna Wiring Schematics

Callout
CAV_BU
CONN_X5
COAX
COAX
COAX
COAX
CAV BU
CONN_X7
5152
5152_BK/GY
CAV_6
CONN_X2
CAV_6
Component Name
BU
X5
COAX
COAX
COAX
COAX
BU
X7
Voice Recognition Audio Low Reference
5152 BK/GY
6
X2
6

CONN_X2
5149
5149_GY/YE
CAV_12
CAV_16
659
659_BK/YE
CAV_2
CAV_6
CONN_X1
658
658_YE
CAV 1
CAV_20
1782
1782_BARE
CAV_8
1792
1792_BARE
CAV_5
UHQ
UHQ
UHQ
UHQ
X207
TWIST_9
TWIST_9
A11
W7
T15
K73
W7
T4G
X2
Voice Recognition Audio Signal
5149 GY/YE
12
16
Cellular Telephone Voice Low Reference
659 BK/YE
2
6
X1
Cellular Telephone Voice Signal
658 YE
1
20
Drain Wire
1782 BARE
8
Drain Wire
1792 BARE
5
RADIO-AM/FM STEREO, SINGLE CD, MP3 (AUX
IN), USB, NAVIGATION (GMNA VERSION)
X207
9
9
(UE1 and UYS)

(UE1)



DTC
DTC B0000
DTC B0997
DTC B1020
DTC B1025, B1035, B1045, or B1055
DTC B125A
DTC B125C
DTC B1265
DTC B1271
DTC B1278 or B1279
DTC B1287
Description
DTC B0000 5A Vehicle Speed Information Circuit Not
Plausible
DTC B0997 00 Info Display Module Malfunction
DTC B1020 00 Auxiliary Electronic Control Unit (ECU)
Performance
DTC B1025 01 Left Front Audio Output Circuit Short to
Battery
DTC B1025 02 Left Front Audio Output Circuit Short to
Ground
DTC B1025 04 Left Front Audio Output Circuit Open
DTC B1035 01 Front Audio Output Circuit Short to Battery
DTC B1035 02 Right Front Audio Output Circuit Short to
Ground
DTC B1035 04 Right Front Audio Output Circuit Open
DTC B1045 01 Left Rear Audio Output Circuit Short to
Battery
DTC B1045 02 Left Rear Audio Output Circuit Short to
Ground
DTC B1045 04 Left Rear Audio Output Circuit Open
DTC B1055 01 Right Rear Audio Output Circuit Short to
Battery
DTC B1055 02 Right Rear Audio Output Circuit Short to
Ground
DTC B1055 04 Right Rear Audio Output Circuit Open
DTC B125A 02 Antenna Signal Circuit Short to Ground
DTC B125A 04 Antenna Signal Circuit Open Circuit
DTC B125C 01 Satellite Antenna Circuit Short to Battery
DTC B125C 02 Satellite Antenna Circuit Short to Ground
DTC B125C 04 Satellite Antenna Circuit Open
DTC B1265 02 Switched 14 Volt Performance Short to
Ground
DTC B1271 00 Theft Protection Active
DTC B1278 01 Left Auxiliary Input Signal Circuit Short to
Battery
DTC B1278 02 Left Auxiliary Input Signal Circuit Short to
Ground
DTC B1279 01 Right Auxiliary Input Signal Circuit Short
to Battery
DTC B1279 02 Right Auxiliary Input Signal Circuit Short
to Ground
DTC B1287 01 Amplifier Control Signal Circuit Short to
Battery
DTC B1287 02 Amplifier Control Signal Circuit Short to
Ground

DTC B1446 or B1447
DTC B2455
DTC B2462
DTC B2470
DTC B2476 or B2482
DTC B2485
DTC U0255-U0257
DTC B1287 04 Amplifier Control Signal Circuit Open

DTC B1446 Replace Backup Power Source Below
Minimum Threshold
DTC B1447 Backup Power Source Open Circuit
DTC B2455 02 Cellular Phone Microphone Circuit Short to
Ground
DTC B2455 04 Cellular Phone Microphone Circuit
Open/High Resistance
DTC B2462 01 Global Positioning System Short to Battery
DTC B2462 02 Global Positioning System Short to Ground
DTC B2462 04 Global Positioning System Open
DTC B2470 02 Cellular Phone Antenna Circuit Malfunction
Short to Ground
DTC B2470 04 Cellular Phone Antenna Circuit Malfunction
Open Circuit
DTC B2476 04 Cellular Phone Select Service Switch Open
Protection Time-out
Range/Performance
DTC B2485 02 Wireless Communication (BT) Antenna
DTC B2485 04 Wireless Communication (BT) Antenna
Circuit Open
Module
DTC U0256 Lost Communication with Infotainment
Faceplate Control Module
Module/Infotainment Faceplate Control Module
DTC B0000
Perform the Diagnostic System Check - Vehicle prior to using this diagnostic procedure.
Diagnostic Procedure Instructions provides an overview of each diagnostic category.
DTC Descriptor
DTC B0000 5A
Vehicle Speed Information Circuit Not Plausible

Circuit
Vehicle Speed Signal Circuit
Short to
Ground
B0000 5A
Open/High
Resistance
B0000 5A
Short to
Voltage
B0000 5A
Signal
Performance
B0000 5A
The radio receives a vehicle speed signal from the electronic brake control module in order to correlate actual
vehicle speed to the movement of the vehicle calculated by the navigation system and reported serial data.
Radio ON.
Battery voltage must be between 9-16 V.
Vehicle speed from serial data is more than 5 km/h (3 mph) and vehicle speed pulse from the electronic
brake control module is 0 km/h (0 mph).
Vehicle speed calculated from the navigation processing software is more than 36 km/h (22 mph) and
vehicle speed pulse from the electronic brake control module is 0 km/h (0 mph) for 10 seconds
continuously.
Turn by turn route navigation may be inoperative.

Vehicle indicated location may be inaccurate.
The condition responsible for setting the DTC no longer exists.

A history DTC clears after 100 malfunction-free ignition cycles.
Schematic Reference
Radio/Navigation System Schematics
COMPONENT CONNECTOR END VIEWS - INDEX
Radio/Audio System Description and Operation (with Color Display), Radio/Audio System Description
and Operation (with Monochrome Display)

Circuit Testing
Connector Repairs
Testing for Intermittent Conditions and Poor Connections
Wiring Repairs
Scan Tool Reference

Control Module References for scan tool information
NOTE:
Diagnose any antilock brake system (ABS) related DTCs before performing this
diagnostic.
1. Ignition OFF, disconnect the X2 harness connector at the A11 Radio.

2. Ignition ON.
3. Test for less than 1 V between the signal circuit terminal 20 and ground.
If 1 V or greater
1. Ignition OFF, disconnect the harness connector at the K17 Electronic Brake Control Module.
Ignition ON.
2. Test for less than 1 V between the signal circuit and ground.
If 1 V or greater, repair the short to voltage on the circuit.
If less than 1 V, replace the K17 Electronic Brake Control Module.
If less than 1 V
4. Test for 3-7 Hz between the signal circuit terminal 20 and ground while operating the vehicle drive
wheels at 5 mph (8 km/h).
If not 3-7 Hz
2. Test for infinite resistance between the signal circuit and ground.
If less than infinite resistance, repair the short to ground on the circuit.
If infinite resistance
3. Test for less than 2 ohms in the signal circuit end to end.
If 2 ohms or greater, repair the open/high resistance in the circuit.
If less than 2 ohms, replace the K17 Electronic Brake Control Module.
If 3-7 Hz
5. Test or replace the A11 Radio.
Repair Instructions
Perform the Diagnostic Repair Verification after completing the repair.

Control Module References for radio or electronic brake control module replacement, programming, and
setup.
DTC B0997
DTC Descriptor
DTC B0997 00
Info Display Module Malfunction
The radio communicates with the information display via serial data. This DTC indicates a fault in the
information display. No external circuits are involved. The radio and display may continue to operate normally
when this DTC is set.
Ignition is ON or in the ACC position.

The system voltage is at least 9.5 V and no more than 15.5 V.
All the above conditions are present for greater than 10 seconds.
The radio receives an improper status response indicating an internal ECU fault in the information display.
Action Taken when the DTC Sets
No action is taken.
A current DTC clears when the radio receives a proper status response message back from the
information display.
Diagnostic Aids
This DTC may be stored as a history DTC without affecting the operation of the information display.
If stored only as a history DTC and not retrieved as a current DTC, do not replace the information

display.
If this DTC is retrieved as both a current and history DTC, replace the information display.
Schematic Reference
Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference

1. Ignition ON
2. Verify DTC B0997 is not set
If DTC B0997 is set
Replace the P17 Info Display Module
If DTC B0997 is not set
3. All OK.
Repair Instructions

Driver Information Display Replacement

DTC B1020
DTC Descriptor
DTC B1020 00
Auxiliary Electronic Control Unit (ECU) Performance
The radio communicates with the radio controls via serial data. This DTC indicates a fault in the radio controls.
The radio may continue to respond normally to faceplate functions when this DTC is set.
Ignition is ON or in the ACC position.

All the above conditions are present for greater than 10 seconds.
The radio receives an improper status response indicating an internal ECU fault in the radio controls.
Action Taken when the DTC Sets
No action is taken.
A current DTC clears when the radio receives a proper status response message back from the radio
control assembly.
Diagnostic Aids
This DTC may be stored as a history DTC without affecting the operation of the radio controls.
If stored only as a history DTC and not retrieved as a current DTC, do not replace the radio controls.
If this DTC is retrieved as both a current and history DTC, replace the radio controls.

Schematic Reference
Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference

1. Ignition ON.
2. Verify DTC B1020 is not set.
If DTC B1020 is set
Replace the A22 Radio Controls.
3. All OK.
Repair Instructions

Control Module References for radio controls replacement, programming, and setup.
DTC B1025, B1035, B1045, OR B1055


Diagnostic Procedure Instructions provide an overview of each diagnostic category.
DTC Descriptors
DTC B1025 01
Left Front Audio Output Circuit Short to Battery
DTC B1025 02
Left Front Audio Output Circuit Short to Ground
DTC B1025 04
Left Front Audio Output Circuit Open
DTC B1035 01
Front Audio Output Circuit Short to Battery
DTC B1035 02
Right Front Audio Output Circuit Short to Ground
DTC B1035 04
Right Front Audio Output Circuit Open
DTC B1045 01
Left Rear Audio Output Circuit Short to Battery
DTC B1045 02
Left Rear Audio Output Circuit Short to Ground
DTC B1045 04
Left Rear Audio Output Circuit Open
DTC B1055 01
Right Rear Audio Output Circuit Short to Battery
DTC B1055 02

Right Rear Audio Output Circuit Short to Ground

DTC B1055 04
Right Rear Audio Output Circuit Open
Short to
Ground
Circuit
Left Front Audio Signal
B1025 02*
Circuit
Right Front Audio Signal
B1035 02*
Circuit
Left Rear Audio Signal
B1045 02*
Circuit
Right Rear Audio Signal
B1055 02*
Circuit
* Noticeable audio distortion possible.
** No or reduced sound from speaker.
Open/High
Resistance
Short to
Voltage
Signal Performance
B1025 04**
B1025 01*
B1035 04**
B1035 01*
B1045 04**
B1045 01*
B1055 04**
B1055 01*
Each of the audio output channel circuits (+) and (-), at the radio and audio amplifier have a DC bias voltage
that is approximately one half of battery voltage. When using a DMM, each of the audio output channel circuits
will measure approximately 6.5 V DC. The audio being played on the system is produced by a varying AC
voltage that is centered around the DC bias voltage on the same circuit. The AC voltage is what causes the
speaker cone to move and produce sound. The frequency (Hz) of the AC voltage signal is directly related to the
frequency of the input (audio source playing) to the audio system. Both the DC bias voltage and the AC voltage
signals are needed for the audio system to properly produce sound.
Ignition is ON or in the ACC position

The system voltage is 9-16 V
The test is run once during radio wake up
B1025 01, B1035 01, B1045 01, B1055 01

The radio detects a short to voltage on the specified audio (+) or (-) circuit.
B1025 02, B1035 02, B1045 02, B1055 02
The radio detects a short to ground on the specified audio (+) or (-) circuit.

B1025 04, B1035 04, B1045 04, B1055 04

The radio detects an open on the specified audio (+) or (-) circuit.
The radio continues to send the output signal to the speaker signal circuit with the current fault.
A current DTC clears when the conditions for setting the DTC are no longer present and the ignition has
been cycled from OFF to ON.
Diagnostic Aids
Improper speaker mounting or loose trim may cause an audible buzz or distortion. Inspect the appropriate
speaker and the surrounding interior trim for proper and secure mounting. If the speaker or surrounding
interior trim is found to be loose or improperly secured, correctly secure the item.
When equipped with an amplifier, the radio does not set DTCs for the audio outputs.
Schematic Reference
Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference


1. Ignition ON, A11 Radio ON, mute OFF.

2. Verify clear audio is heard from each speaker, adjusting fade and balance controls to test each speaker
individually.
If audio is inoperative from one or more speakers, or the audio emitted is not clear.
Refer to Circuit/System Testing below.
If clear audio is heard from all speakers.
3. All OK.
1. Ignition OFF, disconnect the harness connector at the appropriate P19 Speaker. Ignition ON, A11 Radio
ON, mute OFF.
2. Test for 5-7 V between each audio signal circuit terminal 1 and terminal 2 and ground.
If less than 5 V
If less than 2 ohms, replace the A11 Radio.
If greater than 7 V
1. Ignition OFF, disconnect the X1 harness connector at the A11 Radio. Ignition ON.
If less than 1 V, replace the A11 Radio.
If between 5-7 V
3. Test or replace the P19 Speaker.
Repair Instructions
Speaker Replacement Reference

Control Module References for radio replacement, programming, and setup.
DTC B125A

DTC Descriptors
DTC B125A 02
Antenna Signal Circuit Short to Ground
DTC B125A 04
Antenna Signal Circuit Open Circuit
Short to
Ground
Circuit
Radio Antenna Coax
B125A 02
Ground
1. May exhibit possible AM/FM interference.
Open/High
Resistance
B125A 04
1
Short to
Voltage
1
-
Signal
Performance
-
The multi-band antenna is located on the roof of the vehicle. The radio antenna is enabled when the radio is
turned on. The radio provides battery voltage to the antenna using the center conductor of the antenna coaxial
cable. When a 12 V signal is seen on the center conductor of the antenna coax, both AM and FM signals are
amplified.
Ignition ON.
B125A 02
The radio detects a short to ground in the antenna signal circuit center conductor.
B125A 04
The radio detects an open in the antenna signal circuit center conductor.

Radio reception may be poor or not available.


A history DTC will clears after 50 consecutive malfunction-free ignition cycles have occurred.
Schematic Reference
Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference

1. Ignition ON, A11 Radio ON.

2. Verify station reception is normal when tuned to several known good AM and FM stations.
If AM or FM reception is poor.
Refer to Circuit/System Testing below
If reception is normal
3. All OK.

1. Ignition OFF, disconnect the radio antenna coax cable from the A11 Radio and from the T4G Cellular
Phone, Navigation, and Digital Radio Antenna.
2. Verify the antenna coax cable passes the coax cable component test. Refer to Component Testing below.
If the coax cable does not pass the test
Replace the antenna coax cable
If the coax cable passes the test
3. Connect the radio antenna coax cable to the A11 Radio.
4. Ignition ON, A11 Radio ON. Verify a test lamp illuminates between the antenna coax cable center
terminal and ground at the T4G Cellular Phone, Navigation, and Digital Radio Antenna.
If the test lamp does not illuminate
replace the A11 Radio.

If the test lamp illuminates
5. Test or replace the T4G Cellular Phone, Navigation, and Digital Radio Antenna.
Component Testing
CAUTION: Refer to Test Probe Caution .
NOTE:
Before testing the coax cable, check the cable exterior for being pinched, cut,
damaged, or having loose connections at the components, which can cause
reception issues.
To prevent false reading when testing the center coax terminals, use care not to
ground the test probe on the outer housing/shield.
Coax Cable Test

1. Ignition OFF, disconnect the coax cable at both components.
2. Test for less than 5 ohms between coax cable center terminal end to end.
If 5 ohms or greater
Replace the coax cable
If less than 5 ohms
3. Test for less than 5 ohms between the coax cable outer shield end to end.

If less than 5 ohms

4. Test for infinite resistance between the coax cable center terminal and the coax cable outer shield.
If less than infinite resistance

5. All OK
Repair Instructions
Radio Antenna Base Replacement

Control Module References for Radio replacement, programming, and setup.
DTC B125C
DTC Descriptors
DTC B125C 01
Satellite Antenna Circuit Short to Battery
DTC B125C 02
Satellite Antenna Circuit Short to Ground
DTC B125C 04
Satellite Antenna Circuit Open
The digital radio receiver, located inside the radio, receives digital radio information from the digital radio
antenna located on the outside of the vehicle. The digital radio receiver is connected to the digital radio antenna
via a shielded coax cable. The digital radio antenna contains an amplifier which is powered by the radio through
the coax cable.

This DTC is run every 300 milliseconds.

The radio detects a circuit fault in the digital radio antenna.

The radio displays No XM Signal or Check Antenna.

A current DTC clears when the condition for setting the DTC is no longer present.
Diagnostic Aids
The digital radio antenna requires a clear line of sight to the sky to operate properly. Reception may be limited,
intermittent, or unavailable inside structures.
Schematic Reference
Circuit Testing
Connector Repairs
Wiring Repairs
Special Tools
EL-48028 Digital Radio Test Antenna

1. With the vehicle outside in an area with an unobstructed view of the southern sky, tune to XM.
2. Verify DTC B125C is not set as current and the No XM Signal message is not displayed on the radio.
If DTC B125C is set as current or the No XM Signal message is displayed.
If DTC B125C is not set as current and the No XM Signal message is not displayed.
3. All OK.
1. Ignition OFF, disconnect the digital radio antenna coax cable from the A11 Radio. Connect the EL-48028
Digital Radio Test Antenna to the radio and place on the roof of the vehicle.
2. Ignition ON, radio tuned to XM channel 1.
3. Verify DTC B125C is not set as current and XM reception is improved.
If DTC B125C is set as current or XM reception is not improved
Replace the A11 Radio.
If DTC B125C is not set as current and XM reception is improved
4. Ignition OFF, disconnect the digital radio antenna coax cable from the T4G Cellular Phone, Navigation,
and Digital Radio Antenna.
5. Verify the digital radio antenna coax cable passes the coax cable component test. Refer to Component
Testing below.

Component Testing
NOTE:
reception issues.
Coax Cable Test


If less than 5 ohms

If less than 5 ohms

5. All OK
Repair Instructions

DTC B1265
DTC Descriptor
DTC B1265 02
Switched 14 Volt Performance Short to Ground

Short to
Open/High
Short to
Signal Performance
Ground
Resistance
Voltage
DTC B1265 0
Remote Enable
**
***
*
* all components requiring remote enable inoperative
** fault may affect one or more components, dependant on fault location and vehicle equipment
*** components will not power off with infotainment system
Circuit
When the radio is on, a discrete 12 V signal is supplied on the entertainment remote enable circuit to the Audio
Amplifier and the Color/Navigation Info Display Module (if equipped). This signal is used to control the power
state of the components.
The following are conditions that must be present in order for the radio to enable diagnostics:
The radio is ON.

The system voltage is 9 -16 V
The radio detects a short to ground on the entertainment remote enable circuit.
The above condition is present for greater than 250 mS.
The radio implements a current limiting mode and disables the output on the entertainment remote enable
circuit.
All components connected on the entertainment remote enable circuit will be inoperative.
The condition for setting the DTC no longer exists.

After the ignition has been OFF for a sufficient amount of time to allow the radio to enter a low
power/sleep state, the radio will re-enable the output on the following ignition cycle and the DTC will
become history.
Diagnostic Aids
This DTC may be stored as a history DTC without affecting the operation of the radio/infotainment
systems.
The radio's current limiting logic may not re-enable the output on the entertainment remote enable circuit
until after the radio performs a full power-down. It may be necessary to wait 5 minutes between each test

attempt with the key OFF and retained accessory power OFF.
Schematic Reference
Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference

1. Ignition OFF, radio OFF, radio B+ fuse removed. Disconnect all of the harness connectors listed below:
T3 Audio Amplifier X3 (if equipped)
P17 Info Display Module X1 (if equipped)
2. Install the radio B+ fuse. Ignition ON, A11 Radio ON.
3. Verify that a test lamp illuminates between the control circuit terminals listed below and ground:
T3 Audio Amplifier X3 terminal 8 (if equipped)
P17 Info Display Module X1 terminal 6 (if equipped)
If the test lamp does not illuminate.
1. Ignition OFF. Disconnect the X1 harness at the A11 Radio.
2. Test for infinite resistance between the control circuit and ground.
If infinite resistance.
3. Test for less than 2 ohms in the control circuit end to end.

If greater than 2 ohms, repair the open/high resistance in the circuit.

If the test lamp illuminates.
4. Verify that DTC B1265 does NOT set as each component is connected one at a time.
If DTC B1265 sets.
Replace the module/component that was just connected

If DTC B1265 does not set.
5. All OK.
Repair Instructions

Control Module References for radio and amplifier replacement, programming, and setup.
DTC B1271
DTC Descriptor
DTC B1271 00
Theft Protection Active
When the radio is initially installed in the vehicle, the radio receives VIN information via serial data. The radio
stores a portion of the VIN and compares this sequence to the VIN information received each time the radio
powers on. The VIN in the radio is a single one-time learn.
The radio theft deterrent system is intended to disable or limit radio functionality if incorrect vehicle
information is received by the radio. The radio disables functionality if the VIN information received by the
radio does not match the VIN information that has been learned by the radio. This DTC is generated by the
module when the Theft Protection is activated.

This DTC test runs when the radio changes from OFF to ON.
The radio has learned a correct VIN sequence and the VIN information received via serial data does NOT match
the learned VIN sequence.
The radio may be disabled or have limited functionality.

The radio display will indicate that theft protection is active.
The radio receives the correct VIN information via serial data.
Diagnostic Aids
A possible cause of incorrect VIN info could be the radio was originally installed in another vehicle.
Schematic Reference
Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference



If DTC B1271 is set
3. All OK.
Repair Instructions

Control Module References for Radio replacement, programming, and setup
DTC B1278 OR B1279
DTC Descriptors
DTC B1278 01
Left Auxiliary Input Signal Circuit Short to Battery
DTC B1278 02
Left Auxiliary Input Signal Circuit Short to Ground
DTC B1279 01
Right Auxiliary Input Signal Circuit Short to Battery
DTC B1279 02
Right Auxiliary Input Signal Circuit Short to Ground
Circuit
B+
Short to
Ground
-
Open/High
Resistance
U0237, 4
Short to
Voltage
-
Signal Performance
-

Detection Signal Circuit

4
5
5
Left Audio Signal Terminal
B1278 02, 3
3
B1278 01, 3
12
Left Audio Signal Terminal
3
3
3
14
Right Audio Signal
B1279 02, 2
2
B1279 01, 2
Terminal 13
Right Audio Signal
2
2
2
Terminal 15
Audio Common Circuit
1, 5
Ground
4
1. No or distorted audio from both sides
2. No or distorted right side audio
3. No or distorted left side audio
4. External audio inputs inoperative
5. AUX selection always available with or without device connected
A remote 3.5 mm auxiliary stereo jack allows playback of audio signals from remote devices (e.g., laptop
computer, IPOD, MP3 player, etc.). The auxiliary audio jack has an internal mechanical detection switch. The
switch is normally closed, connecting the detection circuit to the audio common circuit. When a device is
inserted to the auxiliary audio jack, the switch opens and the multimedia player interface module detects a high
voltage on the detection circuit. A serial data message is sent to the radio, the radio will switch to AUX as the
audio source. The multimedia player interface module receives the analog audio signals from the connected
device and sends the signals to the radio.
Ignition in RUN or ACC position.

The multimedia player interface module detects a device has been connected to the auxiliary audio input
jack.
B1278 01, B1279 01
The multimedia player interface module detects a short to battery on either of the audio signal circuits
from the auxiliary audio jack.
The condition is present for greater than 250 mS.
B1278 02, B1279 02
The multimedia player interface module detects a short to ground on either of the audio signal circuits
from the auxiliary audio jack.

The condition is present for greater than 250 mS.
No or reduced audio is heard from the remote audio device.

The conditions for setting the DTC are no longer present on the auxiliary input signal circuits.
Diagnostic Aids
Playback of an audio device that is connected to the 3.5 mm jack can only be controlled using the controls
on the device.
The volume control on the device may need to be adjusted to ensure sufficient playback volume through
the infotainment system.
This DTC may be stored as a history DTC without affecting the operation of the module.
If stored only as a history DTC and not retrieved as a current DTC, do not replace the module.
Schematic Reference
Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference


Auxiliary Audio Input Jack

1. Ignition ON, radio ON.
2. Verify the infotainment system switches to AUX as the audio source with a portable audio playback
device connected to the auxiliary audio input jack.
If the infotainment system does not switch to AUX as the audio source
Refer to Auxiliary Audio Input Malfunction.
If the infotainment system switches to AUX as the audio source
3. Verify DTC B1278 or DTC B1279 is not set.
If DTC B1278 or DTC B1279 is set

If DTC B1278 or DTC B1279 is not set
4. Verify the audio from the device is heard through the vehicle infotainment system while operating the
device to begin audio playback, adjusting the volume on the device if necessary.
If audio is not heard from the device
1. Connect a different device to the auxiliary audio jack.
2. Verify the audio from the device is heard through the vehicle infotainment system while operating
the device to begin audio playback, adjusting the volume on the device if necessary.
If audio cannot be heard from any device connected to the auxiliary audio input jack, refer to
Auxiliary Audio Input Malfunction.
If audio can be heard from device.
3. The malfunction is related to the external device connected to the input.
If audio is heard from the device
5. All OK
1. Ignition OFF, disconnect the X1 harness connector at the X83 Auxiliary Audio Input. Ignition ON, radio
ON.
2. Test for less than 1 V between the signal circuits listed below and ground:
left auxiliary audio signal circuit terminal 2
right auxiliary audio signal circuit terminal 4
auxiliary audio common signal circuit terminal 5
If 1 V greater
1. Ignition OFF, disconnect the harness connector at the T11 Multimedia Player Interface Module.
Ignition ON.

If less than 1 V, replace the T11 Multimedia Player Interface Module.
If less than 1 V
3. Ignition OFF, disconnect the harness connector at the T11 Multimedia Player Interface Module.
4. Test for infinite resistance between the signal circuits listed below and ground:
Repair the short to ground on the circuit.
5. Test for less than 5 ohms between the signal circuit terminals listed below:
T11 Multimedia Player Interface Module X1 terminal 3 and the X83 Auxiliary Audio Input X1
terminal 5
terminal 2
terminal 4
If 5 ohms greater
Repair the open/high resistance in the circuit.

If less than 5 ohms
6. Replace the X83 Auxiliary Audio Input. Connect all harness connectors.
7. Connect and operate the portable audio playback device.
8. Verify DTC B1278 or DTC B1279 is not set.
If DTC B1278 or DTC B1279 is set
Replace the T11 Multimedia Player Interface Module.

If DTC B1278 or DTC B1279 is not set
9. All OK.
Repair Instructions
Audio Disc Player Receptacle Replacement

Control Module References for multimedia player interface module replacement, programming, and

setup.
DTC B1287
DTC Descriptors
DTC B1287 01
Amplifier Control Signal Circuit Short to Battery
DTC B1287 02
Amplifier Control Signal Circuit Short to Ground
DTC B1287 04
Amplifier Control Signal Circuit Open
Circuit
Amplifier Control
Short to
Ground
DTC B1287
02,**
Open/High
Resistance
DTC B1287 04,**
Short to
Voltage
DTC B1287
01,*
Signal Performance
-
* No audio output.
** 4 Channel unmute, possible noise in speakers when radio muted or turned off
The radio amplifier control circuit provides varying pulse width modulated (PWM) signals to control overall
muting of the amplifier. The PWM signals are varying duty cycle percentages ranging from 0-100 percent. A
low duty cycle unmutes all amplifier channels and a high duty cycle mutes all amplifier channels. The amplifier
control circuit will measure less than 1 V when the mute function is OFF, and approximately 8 V DC when at
full mute. The radio monitors the amp control circuit for faults.
The following are conditions that must be present in order for the radio to enable the diagnostics.
The radio is in ACCESSORY, RUN, or RAP power mode.

The system voltage is 9-16 V.

The radio performs the test once during wake up.
The radio detects a fault on the amplifier control circuit 400 ms after radio activates the remote enable circuit.
Radio sets the DTC and continues to output correct state.

The condition must be corrected.

Schematic Reference
Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference

NOTE:
To prevent misdiagnosis, the door chime must be OFF during testing.

Ensure the driver door latch is closed during testing.

1. Ignition OFF, disconnect the X3 harness connector at the T3 Audio Amplifier. Ignition ON, A11 Radio
ON, mute ON.
2. Test for 7.5-8.5 V between the control circuit terminal 16 and ground.
If greater than 8.5 V
2. Test for less than 1 V between the control circuit and ground.
If less than 7.5 V
If between 7.5-8.5 V
3. A11 Radio ON, mute OFF.
4. Test for less than 1 V between the control circuit terminal 16 and ground.
If 1 V or greater
If less than 1 V
5. Test or replace the T3 Audio Amplifier.
Repair Instructions

Control Module References for radio and audio amplifier replacement, programming, and setup.
DTC B1446 OR B1447
DTC Descriptors

DTC B1446
Replace Backup Power Source Below Minimum Threshold
DTC B1447
Backup Power Source Open Circuit
For symptom byte information refer to Symptom Byte List
Circuit
Backup Battery B+
Backup Battery Low
Reference
Short to
Ground
B1447 03
Open/High
Resistance
B1447 04
Short to
Voltage
-
Signal Performance
-
B1447 03
B1447 04
The backup power source provides voltage to the telematics tommunication interface control module, to be able
to successfully place a call in the event of a main battery disconnect during a collision event.
B1446 03
Ignition is ON.
System voltage is between 9.5 and 15.5 V.
DTC B1447 is not set.
B1447 04
Ignition is ON.
System voltage is between 9.5 and 15.5 V.
The above conditions are present for greater than 10 s.
B1446 03
The telematics communication interface control module detects that the backup power source voltage has
dropped below the minimum threshold value.
B1447 04

The telematics communication interface control module detects no voltage from the backup power source.
B1446 03
The OnStar status LED turns red.
B1447 04

The telematics communication interface control module will be unable to place a call in the event of a
main battery disconnect during a collision event.
A current DTC B1446 will clear when the telematics communication interface control module detects the
voltage of the backup power source is above the minimum threshold value.
A current DTC B1447 will clear when the telematics communication interface control module detects
voltage from the backup power source.
Diagnostic Aids
Shorting the backup power source positive voltage circuit to the backup power source ground circuit or
chassis ground will activate the internal circuit protection of the backup power source, rendering the
backup power source inoperative.
DTC B1447 may set if the K73 Telematics Communication Interface Control Module has been
incorrectly disconnected or serviced. When disconnecting the K73 Telematics Communication Interface
Control Module, disconnect the harness connector X1 at the K73 Telematics Communication Interface
Control Module prior to disconnecting any other harness connectors. This will ensure the backup power
source is preserved when voltage is removed from the K73 Telematics Communication Interface Control
Module.
Schematic Reference
OnStar Schematics
OnStar Description and Operation


Circuit Testing
Wiring Repairs
Connector Repairs
1. Ignition OFF and all vehicle systems OFF, disconnect the X1 harness connector at the K73 Telematics
Communication Interface Control Module. It may take up to 2 minutes for all vehicle systems to power
down.
2. Test for greater than 9.5 V between the B+ circuit terminal 14 and the low reference circuit terminal 13.
If 9.5 V or less
Test or replace the C3 Telematics Communication Interface Control Module Battery.
3. Replace the K73 Telematics Communication Interface Control Module.
Repair Instructions
Communication Interface Module Battery Replacement

Control Module References for telematics communication interface control module replacement,
programming and setup.
DTC B2455
DTC Descriptors
DTC B2455 02
Cellular Phone Microphone Circuit Short to Ground
DTC B2455 04
Cellular Phone Microphone Circuit Open/High Resistance

Circuit
Microphone Signal
Microphone Low Signal
Short to
Ground
B2455 02
B2455 02
Open/High
Resistance
B2455 04
B2455 04
Short to
Voltage
B2455 04
B2455 04
Signal Performance
-
The telematics communication interface control module provides the cellular phone microphone with a supplied
voltage on the cellular phone microphone high signal circuit. When the microphone is in use, voice data from
the user is sent back to the telematics communication interface control module on the microphone low signal
circuit.
The ignition must be in the RUN or ACC position.

All the above conditions are present for greater than 10 s.
B2455 02
The telematics communication interface control module detects an short to ground in the cellular phone
microphone high signal circuit for 10 s or greater.
B2455 04
The following conditions will set this DTC:
The telematics communication interface control module detects an open/high resistance in the cellular
phone microphone high signal circuit for 10 s or greater.
The telematics communication interface control module detects an open/high resistance in the
microphone low signal circuit for 10 s or greater.

The telematics communication interface control module will not receive a signal from the cellular phone
microphone.
Calls can be placed but the caller cannot be heard.

A history DTC will clear once 50 consecutive malfunction-free ignition cycles have occurred.
Schematic Reference
OnStar Schematics
Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference

1. Ignition OFF, disconnect the harness connector at the B24 Cellular Phone Microphone, ignition ON.
2. Test for 8.0-10.5 V between the signal circuit terminal B and ground.
If less than 8.0 V
1. Ignition OFF, disconnect the X2 harness connector at the K73 Telematics Communication Interface
Control Module.
If less than infinite resistance, repair the short to ground in the circuit.
If less than 2 ohms, replace the vehicle K73 Telematics Communication Interface Control
Module.
Control Module, ignition ON.

If less than 1 V, replace the K73 Telematics Communication Interface Control Module.
3. Test for less than 1 V between the signal circuit terminal A and ground.
If greater than 1 V
If 1 V or greater, repair the short to voltage in the circuit.
If less than 1 V, repair the K73 Telematics Communication Interface Control Module.
If less than 1 V
4. Test for greater than 8 V between the signal circuit terminal B and the signal circuit terminal A.
If less than 8 V
Control Module.
2. Test for infinite resistance between the low signal circuit and ground.
Module.
If greater than 8 V
5. Test or replace the B24 Cellular Phone Microphone.
Repair Instructions
Mobile Telephone Microphone Replacement

DTC B2462

DTC Descriptors
DTC B2462 01
Global Positioning System Short to Battery
DTC B2462 02
Global Positioning System Short to Ground
DTC B2462 04
Global Positioning System Open
The navigation antenna is connected to the telematics communication interface control module and the radio
through the navigation signal splitter. The navigation signal splitter distributes the navigation signal to both the
telematics communication interface control module and the navigation radio. The telematics communication
interface control module supplies 5 V through the coax cable to power the internal antenna amplifier through
the signal splitter. The radio supplies 5 V through the center conductor of the coax cable to power the splitter.
Radio On.
System voltage is greater than 9 V and less than 16 V.
The navigation radio tests the GPS antenna every 10 seconds.
B2462 01
The navigation radio detects a short to B+ on the GPS antenna signal circuit.
B2462 02
The navigation radio detects a short to ground on the GPS antenna signal circuit.
B2462 04
The navigation radio detects an open/high resistance on the GPS antenna signal circuit.
The radio uses the last reported position and the vehicle speed signal to calculate the vehicle position.
Route guidance may be inaccurate.
Turn by turn navigation may be inaccurate or inoperative.


Diagnostic Aids
This DTC can only be retrieved from the radio. The telematics communication interface control module
does not set this DTC.
The radio only monitors the connection between the navigation signal splitter and the radio. The radio
cannot detect faults between the signal splitter and the navigation antenna. Faults between the signal
splitter and the navigation antenna will result in a loss of GPS signal without setting DTC B2462.
The navigation antenna requires a clear line of sight to the sky to operate properly. The GPS may have
limited, intermittent, or no reception near tall buildings or inside structures.
Schematic Reference
OnStar Schematics


Radio/Audio System Description and Operation (with Color Display), Radio/Audio System
Description and Operation (with Monochrome Display)
Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference

Special Tools
EL-49903 OnStar Antenna Diagnostic Tool Kit

1. Ignition OFF, disconnect the navigation antenna coax cable connector at the A11 Radio. Connect the EL49903 GM OnStar antenna diagnostic tool kit to the A11 Radio, place the test antenna on the roof of the
vehicle.
2. Ignition ON, radio ON, navigation selected.
If DTC B2462 is set
4. Ignition OFF, disconnect the radio navigation coax cable at the T15 Navigation Antenna Signal Splitter.
5. Verify the radio navigation coax cable passes the coax cable component test. Refer to Component Testing
below.

6. Test or replace the T15 Navigation Antenna Signal Splitter.
Component Testing
NOTE:
reception issues.
Coax Cable Test

If less than 5 ohms

If less than 5 ohms


5. All OK
Repair Instructions
Navigation Signal Splitter Replacement

DTC B2470
DTC Descriptors
DTC B2470 02
Cellular Phone Antenna Circuit Malfunction Short to Ground
DTC B2470 04
Cellular Phone Antenna Circuit Malfunction Open Circuit
Circuit
Cellular Antenna Signal
Short to
Ground
B2470 02
Open/High
Resistance
B2470 04
Short to
Voltage
-
Signal Performance
-

The cellular phone and navigation antenna is connected to the telematics communication interface control
module. This module supplies 5 V to the cellular phone and navigation antenna to power the internal amplifier.
When the vehicle is equipped with the optional navigation radio, a navigation antenna signal splitter is installed
to distribute the GPS signal to both the telematics communication interface control module and the navigation
radio. The navigation radio supplies 5 V through the GPS antenna coaxial cable to the navigation antenna signal
splitter to power the internal navigation radio signal amplifier.
Ignition in the RUN or ACC position.

System voltage is between 9.5 volts and 15.5 volts.
The telematics communication interface control module does not detect the presence of a cellular antenna.
The vehicle is unable to connect to the OnStar Call Center.

The telematics communication interface control module detects the presence of a cellular antenna.
Schematic Reference
OnStar Schematics
Circuit Testing
Connector Repairs


Wiring Repairs
Scan Tool Reference

Special Tools
EL-49903 GM OnStar Antenna Diagnostic Tool Kit
NOTE:
The vehicle may be equipped with sectioned coax. Test each section and
replace only the faulty section, not the entire length of coax.
The following verification requires the vehicle to be outside with an
unobstructed view of the southern sky. Allow 5 minutes after turning the
ignition ON for the GPS satellites to acquire vehicle signal.
Without Navigation Radio

1. Ignition OFF and all vehicle systems OFF, disconnect the GPS and cellular coax cable connector at the
K73 Telematics Communication Interface Control Module. It may take up to 2 min for all vehicle
systems to power down.
2. Using the EL-49903-3 kit (EL-49903-5 adapter and EL-49903-4 coax cable), connect the EL-49903 GM
OnStar antenna diagnostic tool kit to the K73 Telematics Communication Interface Control Module.
Place the test antenna on the roof of the vehicle, ignition ON.
3. Verify the DTC does not set while operating the vehicle within the conditions for running the DTC.
If the DTC sets
Replace the K73 Telematics Communications Interface Control Module.
If the DTC does not set
4. Ignition OFF.
5. Disconnect the EL-49903 GM OnStar antenna diagnostic tool kit from the K73 Telematics
Communication Interface Control Module
6. Test the coax cable. Refer to Component Testing below.
Replace the coax cable.


With Navigation Radio

If the DTC sets
Replace the K73 Telematics Communication Interface Control Module.
Ignition OFF.
Disconnect the EL-49903 GM OnStar antenna diagnostic tool kit from the K73 Telematics
Connect the coax cable to the K73 Telematics Communications Interface Control Module and disconnect
the coax cable from the T15 Navigation Antenna Signal Splitter, ignition ON.
Test for 4.5-5.5 V between the coax cable center conductor and the outer shield.
If less than 4.5 V
1. Ignition OFF.
If the coax cable does not pass the test, replace the coax cable.
If the coax cable passes the test, test or replace the K73 Telematics Communications
Interface Control Module.
1. Ignition OFF.
Ignition OFF, connect the coax cable to the T15 Navigation Antenna Signal Splitter and disconnect the
coax cable from the T4G Cellular Phone, Navigation, and Digital Radio Antenna, ignition ON.
If less than 4.5 V
1. Ignition OFF.
If the coax cable passes the test, test or replace the T15 Navigation Antenna Signal Splitter.
4.
5.
6.
7.
8.
9.


1. Ignition OFF.
Component Testing
CAUTION: Refer to Test Probe Caution
NOTE:
Before testing the coax cable, check the cable exterior for being pinched,
cut, damaged, or having loose connections at the components, which can
cause reception issues.
To prevent false readings when testing the center coax terminals, use care
not to ground the test probe on the outer housing/shield.
Coax Cable Test

2. Test for less than 5 ohms between the coax cable center terminal end to end.
If less than 5 ohms
3. Test for greater than 5 ohms between the coax cable outer shield end to end.

If less than 5 ohms

5. All OK.

Repair Instructions

Control Module References for Telematics Communication Interface Control Module replacement,
DTC B2476 OR B2482

DTC Descriptors
DTC B2476 04
Cellular Phone Select Service Switch Open
DTC B2476 59
Cellular Phone Select Service Switch Protection Time-out
DTC B2482 00
Cellular Phone Select Service Switch Range/Performance
Short to
Ground
Circuit
10 V Reference
B2476 04
Signal Terminal 3
1
Ground
1. OnStar Buttons Inoperative
Open/High
Resistance
B2476 04
B2476 04
B2476 04
Short to
Voltage
B2476 04
B2476 59
-
Signal Performance
B2476 59, B2482 00
-
The OnStar button assembly consists of 3 buttons: Call/Answer, OnStar Call Center, and OnStar
Emergency. The telematics communication interface control module supplies the OnStar button assembly
with 10 V via the 10 V reference circuit. Each of the buttons, when pressed, completes the circuit across a
resistor allowing a specific voltage to be returned to the telematics communication interface control module

over the keypad signal circuit. Depending upon the voltage range returned, the telematics communication
interface control module is able to identify which button has been pressed.
Ignition ON.
B2476 04
The telematics communication interface control module detects a short to voltage or an open/high resistance on
the keypad 10 V reference circuit.
B2482 and B2476 59
The telematics communication interface control module detects a valid signal on the keypad signal circuit for
longer than 15 s. If one of the OnStar buttons is held or stuck for 15 s or greater, the telematics
communication interface control module will set this DTC.

No calls can be placed.
The telematics communication interface control module will ignore all inputs from the OnStar button
assembly.

Schematic Reference
OnStar Schematics

Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference

NOTE:
Contact the OnStar Call Center first before pressing the emergency button in
order to notify them of the test.
1. Ignition ON.
2. Verify that each button of the S51 Telematics Button Assembly operates normally by pressing each
button individually.
If none of the buttons operate normally
Refer to Circuit/System testing below
If some, but not all, of the buttons operate normally

Test or replace the A10 Inside Rearview Mirror
If all of the buttons operate normally

3. All OK.
1. Ignition OFF and all vehicle systems OFF, disconnect the harness connector at the A10 Inside Rearview
Mirror. It may take up to 2 min for all vehicle systems to power down.
2. Test for less than 10 ohms between the ground circuit terminal 5 and ground.
1. Ignition OFF.
2. Test for less than 2 ohms in the ground circuit end to end.
If less than 2 ohms, repair the open/high resistance in the ground connection.
If less than 10 ohms
3. Ignition ON.
4. Test for 8.0-10.5 V between the 10 V reference circuit terminal 4 and ground.

If less than 8.0 V

1. Ignition OFF, disconnect the harness connector at the K73 Telematics Communication Interface
Control Module.
2. Test for infinite resistance between the 10 V reference circuit and ground.
3. Test for less than 2 ohms in the 10 V reference circuit end to end.
If less than 2 ohms, replace the K73 Telematics Communication Interface Control Module.
2. Test for less than 1 V between the 10 V reference circuit and ground.
5. Ignition OFF.
6. Test for 500-900 ohms between the signal circuit terminal 3 and ground.
1. Disconnect the X1 harness connector at the K73 Telematics Communication Interface Control
Module.
If infinite resistance, replace the K73 Telematics Communication Interface Control Module.
If greater than 900 ohms
Module, ignition ON.
If less than 1 V
3. Ignition OFF.
If between 500-900 ohms
7. Test or replace the A10 Inside Rearview Mirror.
Repair Instructions

Perform the Diagnostic Repair Verification after completing the repair procedure.
Inside Rearview Mirror Replacement

programming, and setup.
DTC B2485
DTC Descriptors
DTC B2485 02
Wireless Communication (BT) Antenna Circuit Short to Ground
DTC B2485 04
Wireless Communication (BT) Antenna Circuit Open
Circuit
Signal
Short to
Ground
B2485 02
Open/High
Resistance
B2485 04
Short to
Voltage
-
Signal Performance
-
Bluetooth wireless technology is a short-range communications technology intended to replace the cables
connecting portable and/or fixed devices while maintaining high levels of security. The operating range of the
signal is approximately 30 feet.
The Bluetooth antenna is a small fixed antenna connected directly to the telematics communication interface
control module and is used to send and receive signals from a Bluetooth enabled cellular phone.
The ignition is in OFF, ACCESSORY or RUN position.

The system voltage is between 9-16 V.
The telematics communication interface control module tests the antenna once every second.

B2485 02
The signal voltage is less than 1 V.

The above conditions must be met for 500 ms.
B2485 04
The signal voltage is greater than 2 V.

The above conditions must be met for 500 ms.
Actions Taken When the DTC Sets

Bluetooth functionality is disabled.

Diagnostic Aids
Verify the mobile device is properly configured for the feature being used. Refer to the device
manufacturers information.
Verify the function/feature that is being used is supported by the mobile device.
The device must be paired to the telematics communication interface control module to use the available
Bluetooth feature(s). The pairing process must only be performed once for each device, unless that
device's information is deleted.
The system can store pairing information for multiple devices, but can only be actively connected to one
at any given time.
Schematic Reference
OnStar Schematics

Circuit Testing
Connector Repairs
Wiring Repairs
Special Tools
EL-50334-20 Multi-Media Interface Tester (Multi-Media Interface Tool)
1. Verify that the T4S Wireless Communication Antenna - Bluetooth is properly connected to the K73
Telematics Communication Interface Control Module and is not damaged.
If the antenna is disconnected
Connect the T4S Wireless Communication Antenna - Bluetooth to the module.
If the antenna is damaged

Test or replace the T4S Wireless Communication Antenna - Bluetooth .
If the antenna is connected and not damaged
NOTE:
The Multi-Media Interface Tool tool can be used to test either cellular
phone or streaming audio functions. Refer to the tool instructions, and
perform the appropriate test(s) related to the customers concern in the
following steps.
2. Ignition ON, infotainment system ON.

3. Verify the infotainment system successfully pairs with the Multi-Media Interface Tool.
If the infotainment system does not successfully pair with the Multi-Media Interface Tool.
1. Test or replace the T4S Wireless Communication Antenna - Bluetooth .
2. Clear the DTC, ignition OFF.
3. Ignition ON.
4. Verify the DTC is not set.
If the DTC is set, replace the K73 Telematics Communication Interface Control Module.
If the DTC is not set
5. All OK.
If the infotainment system successfully pairs with the Multi-Media Interface Tool.
4. All OK.
Repair Instructions


DTC U0255-U0257
DTC Descriptors
DTC U0255
Lost Communication with Info Display Module
DTC U0256
Lost Communication with Infotainment Faceplate Control Module
DTC U0257
Lost Communication with Info Display Module/Infotainment Faceplate Control Module
The radio information display and controls are separate components from the radio. One or more configurations
may be possible, dependent upon the available content for the vehicle. The DTC(s) that can set when a
malfunction occurs can vary due to calibration differences required for the vehicle content.
Diagnosis of these communication DTCs is based upon the symptom observed in the vehicle.
Monochrome Displays
When the vehicle is equipped with a monochrome display, the radio and the display communicate with each
other via CGI serial data. The radio controls communicate with the display via LIN communications, and the
control messages are passed through to the radio.
When the display and controls are combined in an assembly, the communication between the two components
occurs within the assembly. If the two components are separate, the communication between the display and the
controls is external, via the wiring harness.
Color Displays

When the vehicle is equipped with a color display, the display and controls communicate individually with the
radio. The radio communicates directly with the controls via CGI serial data. A dedicated video cable is used to
communicate graphical information between the radio and the display.
For non-touch color displays, a dedicated dimming circuit is used. The radio provides an output to the display
based on dimming level information the radio receives.
Touch screen color displays use touch serial data communication between the display and the radio to exchange
touch data, backlighting, and dimming levels.
Diagnostic Aids
When equipped with a monochrome display, if the display is inoperative, the main radio controls will also
be inoperative.
The functions available on the steering wheel controls (if equipped) will continue to operate if the main
radio controls are inoperative.
The DTC may be stored as a history DTC without affecting the operation of the display or controls.
Schematic Reference
Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference



2. Verify the P17 Info Display Module turns on and information is shown on the display.
If P17 Info Display Module does not turn on, or information is not shown in the display.
Refer to Radio Information Display Malfunction (with Monochrome Display), Radio
Information Display Malfunction (with Color Display).
If the P17 Info Display Module turns on and information is shown on the display.
3. Verify that all radio controls operate and perform the correct function.
If some, but not all, controls operate normally.
Replace the appropriate A20 Radio/HVAC Controls or the A22 Radio Controls.
If all controls are inoperative.

Refer to Radio Controls Malfunction (with Monochrome Display), Radio Controls
Malfunction (with Color Display).
If all controls operate and perform the correct function.

4. All OK.
Repair Instructions

SYMPTOMS - CELLULAR COMMUNICATION
NOTE:
The following steps must be completed before using the symptom table.
1. Perform the Diagnostic System Check - Vehicle before using the Symptom Tables in order to verify that
all of the following are true:
There are no DTCs set.
The control modules can communicate via the serial data link.
2. Review the system operation in order to familiarize yourself with the system functions. Refer to OnStar
Description and Operation.
Visual/Physical Inspection
Inspect for aftermarket devices which could affect the operation of the Radio/Audio System. Refer to
Checking Aftermarket Accessories .
Inspect for easily accessible or visible system components for obvious damage or conditions which could
cause the symptom.
Intermittent

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 a symptom diagnostic procedure from the following list in order to diagnose the symptom:
Bluetooth Malfunction (Radio), Bluetooth Malfunction (OnStar)
OnStar Microphone Malfunction

OnStar Audio Malfunction
OnStar Button LED Malfunction
OnStar Call Center Remote Function Requests Malfunction
OnStar Button Malfunction
Unable to Contact OnStar Call Center
OnStar Voice Recognition Malfunction
OnStar Steering Wheel Control Functions Malfunction
SYMPTOMS - ENTERTAINMENT
IMPORTANT: The following steps must be completed before using the symptom table.
2. Review the system operation in order to familiarize yourself with the system functions. Refer to
Description and Operation (with Monochrome Display).
Inspect for aftermarket devices which could affect the operation of the Radio/Audio System. Refer to
Inspect for easily accessible or visible system components for obvious damage or conditions which could
cause the symptom.
Intermittent
Symptom List

Application Malfunction
Auxiliary Audio Input Malfunction
Bluetooth Malfunction (Radio), Bluetooth Malfunction (OnStar)
Digital Radio Poor or No Reception
Navigation System - Voice Recognition Malfunction
No Global Positioning System (GPS) Reception
Radio Controls Malfunction (with Monochrome Display), Radio Controls Malfunction (with Color
Display)
Radio Information Display Malfunction (with Monochrome Display), Radio Information Display
Malfunction (with Color Display)
Radio Poor Reception
Speaker Malfunction
APPLICATION MALFUNCTION
The term application refers to any piece of software that works on a system (hardware) that is being operated by
its own software. Applications are typically small software programs which uses the hardware to perform a
specific task, as opposed to operating the entire system.
Diagnostic Aids
For an application to be used, it must be installed on both the vehicle infotainment system and a
compatible mobile device.
The application must work correctly on the device to work with the vehicle infotainment system.
The user may be required to log-in to the application on the mobile device before using the application
from the vehicle controls.
Applications use the mobile device and connection to a service provider to operate. Connection quality
issues, or service provider data transmission issues can give the appearance of a vehicle malfunction.
The device must be connected to the system. This may be done wirelessly via Bluetooth , or via the
vehicle USB port.
When a mobile device is connected via Bluetooth, some or all of the device controls may be unavailable
from the radio controls. This varies dependant upon the device being used. Refer to the vehicle owners
manual, supplements, and the device manufacturers information for information on devices, control, and

operation.
Refer to the device manufacturers information for the preferred connection method.
The device must be unlocked, and any additional applications should be closed.
If the device has any sound enhancement features such as noise reduction or echo control, these features
should be turned off.
A low battery condition in the mobile device may not allow the device to connect to the system, or can
create communication issues with the device. Verify the device battery state of charge and re-charge or
replace as needed.
If a 'Please See Device' or similar type error message is displayed, this may indicate the device has lost its
connection to the vehicle, or the device has lost its external data connection.
If a cable is used for connection, attempt to connect the device using a different cable; cables can
deteriorate over time or become damaged.
Schematic Reference
Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference

1. Verify the application is installed on the mobile device and is up to date.

If the application is not installed or is not up to date.

Install or update the application on the device.

If the application is installed on the mobile device and is up to date
2. Verify the application operates correctly on the mobile device.
If the application is not operating correctly on the mobile device.
Refer to the application website.

If the application is operating correctly on the mobile device.
3. Verify the A11 Radio calibrations are current.
If the radio calibrations are not current
Reprogram the A11 Radio and re-evaluate the concern.

If no update calibrations are available
4. Verify the application is installed on the A11 Radio and is up to date.
If the application is not installed or is not up to date.
Install or update the application on the A11 Radio.

If the application is installed on the A11 Radio and is up to date
Ignition ON, A11 Radio ON.
Verify the mobile device can connect to the infotainment system. Refer to the owners manual for
information on the preferred connection method for the device.
If the mobile device cannot connect to the vehicle infotainment system.
If unable to connect via Bluetooth, refer to Bluetooth Malfunction (Radio), Bluetooth
Malfunction (OnStar).
If unable to connect via USB, refer to Auxiliary Audio Input Malfunction.
If the mobile device connects to the vehicle infotainment system.
Launch the application.
Verify the applications operates properly with the vehicle infotainment system.
If the application does not function properly
5.
6.
7.
8.
Refer to diagnostic aids.

If the application functions properly
9. All OK.
Repair Instructions


AUXILIARY AUDIO INPUT MALFUNCTION

Short to
Open/High
Short to
Circuit
Ground
Resistance
Voltage
Multimedia Player B+
4
Detection Signal Circuit
4
5
5
Left Audio Signal
Multimedia Player
B1278 02, 3
3
B1278 01, 3
Terminal 12
Left Audio Signal Radio
3
3
3
Terminal 24
Right Audio Signal
Multimedia Player
B1279 02, 2
2
B1279 01, 2
Terminal 13
Right Audio Signal Radio
2
2
2
Terminal 10
Multimedia Player
1, 5
Terminal 3
1
Radio Terminal 23
USB Cable
6
6
6
Multimedia Player Ground
4
1. No or distorted audio from both sides
2. No or distorted right side audio
3. No or distorted left side audio
4. External audio inputs inoperative
5. AUX selection always available with or without device connected
6. USB port Inoperative
Signal Performance
-

The 3.5 mm (1/8 in.) auxiliary audio input jack is located in the console. The auxiliary input jack circuits may
be connected directly to the radio, or to the multimedia player interface module (if equipped). When a portable
audio playback device is connected to the auxiliary jack, an internal switch opens the detection signal circuit
and the radio will switch to AUX as the audio source.

When not equipped with the multimedia player interface module, all circuits from the auxiliary jack are
connected directly to the radio. When a device is connected to the auxiliary jack an internal switch opens. The
radio detects the device and switches to AUX as the audio source. Audio signals from the device are sent to the
radio from the auxiliary input jack via the left, right, and common audio signal circuits.
When equipped with the multimedia player interface module, all circuits from the auxiliary jack are connected
directly to the multimedia player interface module. When a device is connected to the auxiliary jack an internal
switch opens. The multimedia player interface module detects the device and sends a serial data request to radio
to switch to AUX as the audio source. Audio signals from the device are sent to the multimedia player interface
module from the auxiliary input jack via the left, right, and common audio signal circuits. The multimedia
player interface module then outputs these signals to the radio.
USB Port (USR)
The vehicle may be equipped with a USB port in the console. When equipped with the console USB port, the
vehicle will also be equipped with a multimedia player interface module. This port allows USB connectivity to
the infotainment system from portable media players or a USB storage device (memory stick/ flash drive).
When a device is connected to the USB port, the system detects the device and switches to USB as the audio
source. Once connected, the device can be controlled from the radio controls.
The USB port is connected to the multimedia player interface module via a standard USB cable. A Mini type
USB connector is used to connect the cable at the USB port and at the multimedia player interface module.
Standard USB male to female connections are typically used for connecting USB cables together where an inline connection is required. An in-line cable connection is typically found between the console and I/P harness.
Not all portable media player devices are compatible. Memory stick/flash drive capability is limited to MP3 and
WMA file types only. Video transfer from any device is not supported. Refer to the owner's manual for
information on USB devices, control, and operation.
Multimedia Player Interface Module (if equipped)
The multimedia player interface module is a device that is capable of receiving inputs from analog or digital
audio playback devices. Inputs can be received via the auxiliary input jack or USB. The multimedia player
interface module and the radio communicate via serial data. Messages are used for the radio to control the input
source, and for the multimedia player interface module to send detection information to the radio when devices
are connected. The multimedia player interface module is used to provide capability for these inputs in systems
where the radio does not provide native support.
The multimedia player interface module receives the inputs from the device, and transfers the audio signals to
the radio for playback. All multimedia player interface module inputs are transferred to the radio as analog
audio signals via left, right, and common audio circuits.
Diagnostic Aids
When a device is first connected to the 3.5 mm (1/8 in) input jack the infotainment system automatically
switches to that device. If an auxiliary device has already been connected, press the AUX or CD/AUX

button to select the device.

If the system detects the device, but the audio is not heard or is not clear, attempt to connect the device
using a different cable; cables can deteriorate over time or become damaged.
Playback of an audio device that is connected to the 3.5 mm jack can only be controlled using the controls
on the device.
USB
When a device is first connected to the USB port, the infotainment system automatically switches to that
device. If an auxiliary device has already been connected, press the AUX or CD/AUX button to select the
device.
A low battery condition in a portable media player may not allow the device to connect to the system, or
can create communication issues with the device. Verify the device battery state of charge and re-charge
or replace as needed.
Connect the device directly to the USB port if possible. Only use a cable if it is required to connect the
device. The use of extension cables can cause communication issues.
If a cable is required for connection, attempt to connect the device using a different cable; cables can
deteriorate over time or become damaged.
Attempt audio playback from multiple USB devices when diagnosing USB concerns. Device
compatibility can vary based on vehicle equipment. If the infotainment system is capable of operating any
USB type device, the cause of the concern is not with the vehicle system. The inoperative device(s) may
be incompatible or contain no recognized media types.
If a 'Device Not Supported' or similar type error message is displayed, this indicates the system has
connected to the device but cannot communicate with it properly. This does not indicate an issue with the
vehicle system. The device may be incompatible, may require a 'reset', or may require an update to its
software/firmware.
If a 'No Supported Data Found' or similar type error message is displayed, this indicates the system has
connected to the device and is communicating, but cannot find any compatible files/data. This does not
indicate an issue with the vehicle system. Verify the device contains compatible media/ file types.
Poor connections or damaged USB cables can cause intermittent or no operation of USB devices. Inspect
connectors, terminals, and cables for damage and replace components as necessary. Ensure all USB inline
connections and connections at components are fully seated and connector position retainers/locks are
secure.
Schematic Reference


Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference

Special Tools
EL-50334-20 Multi-Media Interface Tester (MIT)

EL-50334-50 USB Cable and Adapter Kit

1. Verify no DTCs are present.
If any DTCs are present
Refer to Diagnostic Trouble Code (DTC) List - Vehicle .
If no DTCs are present
3. Verify the infotainment system switches to AUX as the audio source with the EL-50334-20 Multi-Media
Interface Tester (MIT) connected to the auxiliary audio input jack.
If the infotainment system does not switch to AUX as the audio source
Refer to Circuit/System Testing below- Auxiliary Input Jack.

If the infotainment system switches to AUX as the audio source
4. Verify the audio from the EL-50334-20 Multi-Media Interface Tester (MIT) is heard through the vehicle
infotainment system while operating the test tool to begin audio playback.
If audio is not heard from the test tool.
Refer to Circuit/System Testing below- Auxiliary Input Jack.

If audio is heard from the test tool.

5. All OK.
USB Port
3. Verify the infotainment system switches to USB as the audio source with the EL-50334-20 Multi-Media
Interface Tester (MIT) connected to the USB port.
If the infotainment system does not switch to USB as the audio source
Refer to Circuit/System Testing below- USB Port.

If the infotainment system switches to USB as the audio source
4. Verify the audio from the EL-50334-20 Multi-Media Interface Tester (MIT) is heard through the vehicle
infotainment system while operating the system to play audio from the test tool.
If audio is not heard from the test tool.
Refer to Circuit/System Testing below- USB Port.

If audio is heard from the device
5. All OK.
Auxiliary Audio Input Jack without Multimedia Player Interface Module

1. Ignition OFF, disconnect the X1 harness connector at the X83 Auxiliary Audio Input. Ignition ON, A11
Radio ON.
2. Test for 2.5-3.5 V between the signal circuit terminal 5 and ground.
If less than 2.5 V
3. Test for less than 2 ohms in the signal circuit end to end


1. Ignition OFF, disconnect the X1 harness connector at the A11 Radio, ignition ON.
2. Test for less than 1 V between the detection circuit and ground.
If 1 V greater
If less than 1 V

A11 Radio terminal 24 X1 and the X83 Auxiliary Audio Input terminal 1 X1
If 5 ohms greater

If less than 5 ohms
8. Connect and operate the EL-50334-20 Multi-Media Interface Tester (MIT).
9. Verify the audio from the test tool is heard through the vehicle infotainment system.
If audio is not heard from the test tool


If audio is heard from the test tool
10. All OK.
Auxiliary Audio Input Jack with Multimedia Player Interface Module

1. Ignition OFF, disconnect the X1 harness connector at the X83 Auxiliary Audio Input. Ignition ON, A11
Radio ON.
If less than 2.5 V
1. Ignition OFF, disconnect the X1 harness connector at the T11 Multimedia Player Interface Module.
3. Test for less than 2 ohms in the signal circuit end to end
If less than 2 ohms, replace the T11 Multimedia Player Interface Module.
1. Ignition OFF, disconnect the X1 harness connector at the T11 Multimedia Player Interface Module,
ignition ON.
2. Test for less than 1 V between the detection circuit and ground.
If 1 V greater
Ignition ON.
If less than 1 V


T11 Multimedia Player Interface Module terminal 12 X1 and the X83 Auxiliary Audio Input
terminal 1 X1
terminal 2 X1
terminal 3 X1
If 5 ohms greater

If less than 5 ohms
Ignition ON.
Test for less than 1 V between the signal circuits listed below and ground:
T11 Multimedia Player Interface Module terminal 4 X1
If 1 V greater
If less than 1 V
Ignition OFF, disconnect the X1 harness connector at the A11 Radio.
Test for infinite resistance between the signal circuits listed below and ground:
7.
8.
9.
10.

A11 Radio terminal 10 X1 and the T11 Multimedia Player Interface Module terminal 15 X1

If 5 ohms greater
If less than 5 ohms

1. Replace the T11 Multimedia Player Interface Module.

4. All OK.
15. All OK.
USB Port
1. Ignition OFF, disconnect the USB cable connection at the T11 Multimedia Player Interface Module.
NOTE:
USB cables and adapters for the following tests are found in the EL-5033450 USB cable and adapter kit.
2. Connect the EL-50334-2 Type A female to Mini B male USB Cable to the T11 Multimedia Player
Interface Module. Ignition ON, radio ON.
3. Connect the EL-50334-20 Multi-Media Interface Tester (MIT) to the EL-50334-2 cable.
4. Verify the infotainment system switches to USB as the audio source.
Replace the T11 Multimedia Player Interface Module.
5. Ignition OFF, connect the vehicle USB cable to the T11 Multimedia Player Interface Module. Disconnect
the I/P to floor console inline USB cable connector. Ignition ON, radio ON.

NOTE:
The EL-50334-3 or EL-50334-4 adapter may be required for the following

test.
6. Connect the EL-50334-20 Multi-Media Interface Tester (MIT) to the I/P side of the inline USB cable
connector.
Replace the I/P USB cable assembly.
Ignition OFF, connect the I/P to floor console inline USB cable connector.
Disconnect the USB cable at the X83 Auxiliary Audio Input. Connect the EL-50334-4 Type A female to
Mini B female adapter to the USB cable. Ignition ON, radio ON.
Connect the EL-50334-20 Multi-Media Interface Tester (MIT) to the EL-50334-4 adapter.
Verify the infotainment system switches to USB as the audio source.
8.
9.
10.
11.
Replace the console USB cable assembly.

12. Ignition OFF, connect the vehicle USB cable to the X83 Auxiliary Audio Input. Ignition ON, radio ON.
13. Connect the EL-50334-20 Multi-Media Interface Tester (MIT) to the X83 Auxiliary Audio Input.
Replace the X83 Auxiliary Audio Input.

Ignition ON.
If 1 V greater
If less than 1 V

If 5 ohms greater

If less than 5 ohms
20. Replace the T11 Multimedia Player Interface Module. Connect all harness connectors. Ignition ON, radio
ON.

23. All OK.
Repair Instructions

USB Receptacle Replacement
Control Module References for radio or multimedia player interface module replacement, programming,
and setup
BLUETOOTH MALFUNCTION (RADIO)


The available features and functions are determined by the type of device and the software within the devices
being used. For a feature or function to operate, it must be supported in both devices.
The Bluetooth hardware is internal to the radio. The radio supports streaming of data (music, voice,
information) from cellular phones and other mobile devices that support those features. The radio may also be
capable of interfacing with cellular phones for hands-free features.
Refer to the vehicle owners manual, supplements, and the device manufacturers information for information on
devices, control, operation. and pairing instructions.
Diagnostic Aids
Verify the mobile device is properly configured for the feature being used. Refer to the device
manufacturers information.
Verify the function/feature that is being used is supported by the mobile device.
The device must be paired to the radio to use the available Bluetooth feature(s). The pairing process
must only be performed once for each device, unless that device's information is deleted.
The system can store pairing information for multiple devices, but can only be actively connected to one
at any given time.
Schematic Reference

Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference

Special Tools
EL-50334-20 Multi-Media Interface Tester (MIT)

2. Verify the A11 Radio calibrations are current.
If the radio calibrations are not current
Reprogram the A11 Radio and re-evaluate the concern.
If no update calibrations are available
NOTE:
The MIT tool can be used to test either cellular phone or streaming audio
functions. Refer to the tool instructions, and perform the appropriate test
(s) related to the customers concern in the following steps.

4. Verify the infotainment system successfully pairs with the MIT tool.
If the infotainment system does not successfully pair with the MIT tool.
If the infotainment system successfully pairs with the MIT tool.
5. Verify the infotainment system successfully completes the desired feature test using the MIT tool.
If the feature test is not successful

If the feature test is successful

6. All OK. Refer to Diagnostic Aids.
Repair Instructions

Control Module References for radio replacement, programming, and setup
BLUETOOTH MALFUNCTION (ONSTAR)
The Bluetooth antenna is internal to, or is a small fixed antenna connected directly to, the telematics
communication interface control module and is used to send and receive signals from a Bluetooth enabled
cellular phone. The antenna utilizes no cabling and is not external to the vehicle.
In order to use hands-free calling, the cellular phone must be paired to the vehicle. Up to five devices can be
paired to the vehicle at one time, but only one can be connected at any given time. To pair a phone, the
customer must know how to operate the Bluetooth functionality of their phone. The pairing process must
only be done one time for each phone, unless that phone's information is deleted. For safety reasons, the pairing
process is disabled while the vehicle is moving.
Diagnostic Aids
The purpose of this diagnostic is to verify the ability of the telematics communication interface control
module to pair to a Bluetooth device.
Before performing this test, verify compatibility of the cellular phone(s) the customer is attempting to use
with the vehicle. Based on the cellular phone's service provider and the manufacturer's implementation of
Bluetooth , not all phones support all available Bluetooth functionality. A vehicle and feature
compatibility list will be provided via the GM Bluetooth website:
http://www.onstar.com/web/Bluetooth/
If the vehicle passes the following tests and a compatible device is being used, the concern may be due to
a device malfunction or an incomplete/improper pairing attempt.
A Bluetooth test tool or equivalent can also be used to verify the ability of the customers cellular phone
(s) to pair with another device.
Schematic Reference
OnStar Schematics


Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference

Special Tools
EL-50334-20 Multi-Media Interface Tester (Multi-Media Interface Tool)
1. Ignition ON.
If DTC B2485 is set
Refer to DTC B2485
NOTE:
The Multi-Media Interface Tool can be used to test either cellular phone or
streaming audio functions. Refer to the tool instructions, and perform the
appropriate test(s) related to the customers concern in the following steps.

If the infotainment system does not successfully pair with the Multi-Media Interface Tool.
1. Verify the vehicle is equipped with an external Bluetooth Antenna.
If not equipped with an external Bluetooth Antenna, replace the K73 Telematics
If equipped with an external Bluetooth Antenna

2. Replace the Bluetooth Antenna.

If the infotainment system does not successfully pair with the Multi-Media Interface Tool,
replace the K73 Telematics Communication Interface Control Module.
4. All OK.
5. All OK.
Repair Instructions
DIGITAL RADIO POOR OR NO RECEPTION
DTC Descriptors
DTC B125C 01
Satellite Antenna Circuit Short to Battery
DTC B125C 02
Satellite Antenna Circuit Short to Ground
DTC B125C 04
Satellite Antenna Circuit Open
The digital radio receiver, located inside the radio, receives digital radio information from the digital radio
antenna located on the outside of the vehicle. The digital radio receiver is connected to the digital radio antenna
via a shielded coax cable. The digital radio antenna contains an amplifier which is powered by the radio through
the coax cable.

This DTC is run every 300 milliseconds.

The radio detects a circuit fault in the digital radio antenna.

The radio displays No XM Signal or Check Antenna.

A current DTC clears when the condition for setting the DTC is no longer present.
Diagnostic Aids
The digital radio antenna requires a clear line of sight to the sky to operate properly. Reception may be limited,
intermittent, or unavailable inside structures.
Schematic Reference
Circuit Testing
Connector Repairs
Wiring Repairs
Special Tools
EL-48028 Digital Radio Test Antenna

1. With the vehicle outside in an area with an unobstructed view of the southern sky, tune to XM.
2. Verify DTC B125C is not set as current and the No XM Signal message is not displayed on the radio.
If DTC B125C is set as current or the No XM Signal message is displayed.
If DTC B125C is not set as current and the No XM Signal message is not displayed.
3. All OK.
1. Ignition OFF, disconnect the digital radio antenna coax cable from the A11 Radio. Connect the EL-48028
Digital Radio Test Antenna to the radio and place on the roof of the vehicle.
2. Ignition ON, radio tuned to XM channel 1.
3. Verify DTC B125C is not set as current and XM reception is improved.
If DTC B125C is set as current or XM reception is not improved
If DTC B125C is not set as current and XM reception is improved
4. Ignition OFF, disconnect the digital radio antenna coax cable from the T4G Cellular Phone, Navigation,
and Digital Radio Antenna.
5. Verify the digital radio antenna coax cable passes the coax cable component test. Refer to Component
Testing below.

Component Testing
NOTE:
reception issues.

Coax Cable Test

If less than 5 ohms

If less than 5 ohms

5. All OK
Repair Instructions

ONSTAR MICROPHONE MALFUNCTION

Circuit
Microphone High Signal
Terminal 9
Short to
Ground
Open/High
Resistance
Short to
Voltage
Signal Performance
B2455 02
B2455 04
B2455 04

Microphone Low Signal

B2455 02
B2455 04
B2455 04
Terminal 10
Cellular Telephone Voice
2
1
2
Signal Terminal 6
Cellular Telephone Voice
2
2
Low Signal Terminal 12
1. Voice Cannot be Heard by Telephone Conversation Partner
2. Customer Voice may be distorted for Telephone Conversation Partner
The telematics communication interface control module provides the Cellular Phone Microphone with a
supplied voltage on the cellular phone microphone signal circuit. When the cellular phone microphone is in use,
voice data from the user is sent back to the telematics communication interface control module on the signal
circuit.
Schematic Reference
OnStar Schematics
Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference

NOTE:
It is necessary to have the vehicle in a quiet, open outside area where a cellular
call can be successfully placed and GPS data can be received from satellites.

1. Ignition ON.
2. Verify that DTC B2455 is not set.
If DTC B2455 is set
Refer to DTC B2455.
3. Verify that a successful OnStar voice command can be made.
If your voice can not be heard clearly
Refer to Circuit/System Testing below- Microphone Malfunction.

If your voice can be heard clearly
4. Verify that your voice is heard clearly by the OnStar Call Center after completing a blue button press.
Refer to Circuit/System Testing below - Cellular Telephone Voice Malfunction.

5. All OK.
Microphone Malfunction
1. Ignition OFF, disconnect the harness connector at the B24 Cellular Phone Microphone, ignition ON.
2. Test for 8.0-10.5 V between the signal circuit terminal B and ground.
If less than 8.0 V
Control Module.
Module.

3. Test for less than 1 V between the signal circuit terminal A and ground.
If greater than 1 V
If less than 1 V, repair the K73 Telematics Communication Interface Control Module.
If less than 1 V
4. Test for greater than 8 V between the signal circuit terminal B and the signal circuit terminal A.
If less than 8 V
Control Module.
Module.
If greater than 9 V
5. Test or replace the B24 Cellular Phone Microphone.
Cellular Telephone Voice Malfunction

1. Ignition OFF and vehicle systems OFF, disconnect the X2 harness connector at the K73 Telematics
Communication Interface Control Module and the X4 harness connector at the A11 Radio, ignition ON.
2. Test for less than 1 V between the signal circuits listed below and ground.
K73 Telematics Communication Interface Control Module signal circuit Terminal 6
If greater than 1 V
Repair the short to voltage in the circuit.
If less than 1 V
3. Ignition OFF.
4. Test for infinite resistance between the between the signal circuits listed below and ground.


5. Test for less than 2 ohms in the the signal circuits listed below end to end.

If less than 2 ohms
7. Verify that your voice is heard clearly by the OnStar Call Center after completing a blue button press.

8. All OK.
Repair Instructions

Control Module References for radio or telematics communication interface control module
replacement, programming, and setup.
NAVIGATION SYSTEM - VOICE RECOGNITION MALFUNCTION

Circuit
Voice Recognition Audio
Signal
Short to
Ground
Open/High
Resistance
Short to
Voltage
Signal Performance

Voice Recognition Audio

Low Reference
1. navigation voice recognition inoperative
When voice recognition for the navigation equipped infotainment system is started, voice signals from the
cellular phone microphone are passed through the telematics communication interface control module to the
radio via the voice recognition audio circuits.
Diagnostic Aids
Refer to the Navigation System Owners Manual for voice recognition use and commands.
Voice recognition only works if the map database is installed in the system.
Navigation voice commands are not available until the OK button has been selected.
If the radio is off, the only commands available will be Hands Free and Help.
When the system recognizes the command the system will either perform the function or ask to confirm
the choice by clearly saying "yes" or "no".
If experiencing difficulty with the system recognizing a command, confirm that the command is correct.
Background noise such as a climate control fan positioned on high, open windows, or very loud outside
noises, can cause voice commands to be misunderstood.
Schematic Reference
OnStar Schematics
Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference


1. Verify the OnStar voice recognition system is operating normally.

If the OnStar voice recognition system is not operating normally.
Refer to OnStar Voice Recognition Malfunction.
If the OnStar voice recognition system is operating normally.
NOTE:
Refer to the Navigation System Owners Manual for voice recognition use
and commands.
3. Begin voice recognition for the radio and clearly speak one of the available commands.
4. Verify the infotainment system responds correctly to the command.
If the infotainment system does not respond correctly to the command.
1. Clearly speak a different command.
If the infotainment system does not respond correctly to any commands, refer to
Circuit/System Testing below.
If the infotainment system responds correctly to the command.
3. Refer to the navigation system owners manual for hints on speaking commands.
If the infotainment system responds correctly to the command.
5. All OK
Control Module.
2. Test for less than 10 ohms between the low reference circuit terminal 12 and ground.
2. Test for less than 2 ohms in the low reference circuit end to end.
If 1 V greater

If less than 1 V
6. Test for infinite resistance between the circuits listed below and ground:
voice recognition signal circuit A11 Radio X2 terminal 6
voice recognition low reference circuit A11 Radio X2 terminal 16
7. Test for less than 5 ohms between the terminals listed below:
A11 Radio X2 terminal 6 and the K73 Telematics Communication Interface Control Module X2
terminal 6
A11 Radio X2 terminal 16 and the K73 Telematics Communication Interface Control Module X2
terminal 12
If 5 ohms greater

If less than 5 ohms
8. Replace the A11 Radio. Connect all harness connectors.
NOTE:
Refer to the Navigation System Owners Manual for voice recognition use
and commands.
9. Begin voice recognition for the radio and clearly speak one of the available commands.
If the infotainment system does not respond correctly to the command
1. Clearly speak a different command.
If the infotainment system does not respond correctly to any commands, replace the K73
Telematics Communication Interface Control Module.
If the infotainment system responds correctly to the command
11. All OK
Repair Instructions

Control Module References for radio or telematics communication interface control module replacement,
ONSTAR AUDIO MALFUNCTION
Short to
Circuit
Ground
Audio High Signal terminal
1
1
Audio Low Signal terminal
1
2
1. No (or Noisy) OnStar Audio
Open/High
Resistance
Short to
Voltage
Signal Performance
When an OnStar keypress is made, a serial data message is sent to the audio system to mute all radio functions
and output OnStar originated audio. After the audio system is muted, the telematics communication interface
control module transmits signals to the audio system on the audio signal and audio common circuits.
Schematic Reference
OnStar Schematics

Circuit Testing
Connector Repairs


Wiring Repairs
Scan Tool Reference


2. Verify that audio is heard clearly through all speaker channels when tuning radio to a known good station.
If audio is not heard clearly
Refer to Speaker Malfunction
If audio is heard clearly
3. Verify that the Connecting to OnStar message is heard clearly through the audio system when the
OnStar blue button is pressed.
If OnStar message is noisy or distorted

If OnStar message is heard clearly
4. All OK.
1. Ignition OFF and vehicle systems OFF, disconnect the X2 harness connector at the K73 Telematics
Communication Interface Control Module, ignition ON.
2. Test for less than 4 V between each of the signal circuits listed below and ground:
Terminal 1
Terminal 2
If 4 V or greater
1. Ignition OFF, disconnect the X1 harness connector at the A11 Radio, ignition ON.
2. Test for less than 1 V between the signal circuits and ground.
If greater than 1 V, repair the short to voltage in the circuit.
If less then 1 V, replace the A11 Radio.
If less than 4 V
3. Ignition OFF.
4. Test for infinite resistance between each of the signal circuits listed below and ground:
Terminal 1
Terminal 2


5. Disconnect the X1 harness connector at the A11 Radio.
6. Test for less than 2 ohms in each of the signal circuits listed below end to end:
K73 Telematics Communication Interface Control Module Terminal 1 X2
K73 Telematics Communication Interface Control Module Terminal 2 X2

If less than 2 ohms
8. Verify that the Connecting to OnStar message is heard clearly through the audio system when the
OnStar blue button is pressed.
If audio is not heard clearly

If audio is heard clearly
9. All OK.
Repair Instructions
Control Module References for radio or telematics communication interface control module replacement,
NO GLOBAL POSITIONING SYSTEM (GPS) RECEPTION
The navigation antenna is connected to the telematics communication interface control module. The module
supplies 5 V to the antenna to power the internal amplifier through the center conductor of the antenna coax
cable.

When the vehicle is equipped with the optional navigation radio, a navigation signal splitter is installed to
distribute the navigation signal to both the telematics communication interface control module and the
navigation radio. The telematics communication interface control module supplies 5 V through the coax cable
to power the internal antenna amplifier through the signal splitter.
Diagnostic Aids
The telematics communication interface control module GPS signal title on the scan tool will display a
Yes or No dependent upon whether or not the module sees an increment of the seconds transmitted by
GPS signals to the telematics communication interface control module. Upon entering this screen, the
GPS signal title will initially display Yes, regardless of the presence of time increment, for at least 2
seconds, while the algorithm in the scan tool determines the status of the clock. If increment is found, Yes
is continually displayed. If the clock remains static, No is displayed. The scan tool looks for increment
every second, regardless of current display.
Inaccurate or aged GPS position concerns which are no longer present may have been due to the
temporary loss of GPS signal reception by the vehicle. Conditions such as tunnels or parking structures
will restrict the cellular phone and navigation antenna from a clear view of the satellites in the sky and
may have caused this temporary data loss.
The GPS requires a clear line of sight to the sky to operate properly. In most cases the GPS will not have
reception near tall buildings or inside structures.
Schematic Reference
OnStar Schematics


Description and Operation (with Monochrome Display)
Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference


Special Tools
NOTE:

1. Ignition ON.
2. Verify that no DTCs are set.
If any DTCs are set
Refer to Diagnostic Trouble Code (DTC) List - Vehicle
If no DTCs are set
3. Verify that an OnStar advisor can locate the vehicle after performing a blue button press.
If the advisor can not locate the vehicle and the vehicle is not equipped with a navigation
radio
Refer to Circuit System Testing below - Without Navigation Radio.
If the advisor can not locate the vehicle and the vehicle is equipped with a navigation radio
Refer to Circuit System Testing below - With Navigation Radio.
If the advisor can locate the vehicle

4. Verify that the NO GPS symbol/message is not displayed on the radio.
If the NO GPS symbol/message is displayed
Refer to Circuit System Testing below - With Navigation Radio.

If the NO GPS symbol/message is not displayed
5. All OK.
Circuit/System Testing (without Navigation Radio)
NOTE:


1. Ignition OFF, disconnect the GPS and cellular coax cable connector at the K73 Telematics
Communication Interface Control Module.
OnStar antenna diagnostic tool kit to the K73 telematics communication interface module. Place the test
antenna on the roof of the vehicle, ignition ON.
If the advisor can not locate the vehicle
4. Ignition OFF, disconnect the EL-49903 GM OnStar antenna diagnostic tool kit from the K73 Telematics
5. Disconnect the K73 telematics communication interface module coax at the T4G Cellular Phone,
Navigation, and Digital Radio Antenna.
6. Test the coax cable between the K73 Telematics Communication Interface Control Module and the T4G
Cellular Phone, Navigation, and Digital Radio Antenna. Refer to component testing.

Circuit/System Testing (with Navigation Radio)
NOTE:
1. Ignition OFF, disconnect the coax cable at the T15 Navigation Antenna Signal Splitter.
OnStar antenna diagnostic tool kit to the T15 Navigation Antenna Signal Splitter. Place the test antenna
on the roof of the vehicle, ignition ON.
3. Verify that the customer GPS concern is still present.
If the GPS concern is not present
1. Ignition OFF, disconnect the EL-49903 GM OnStar antenna diagnostic tool kit from the K73
Telematics Communication Interface Control Module
2. Connect the GPS, T15 navigation antenna signal splitter, and cellular coax cable connector at the

K73 telematics communication interface control module.

3. Disconnect the coax cable at the T4G Cellular Phone, Navigation, and Digital Radio Antenna.
4. Test the coax cable between the T15 Navigation Antenna Signal Splitter and the T4G Cellular
Phone, Navigation, and Digital Radio Antenna. Refer to Component Testing below.
5. Replace the T4G Cellular Phone, Navigation, and Digital Radio Antenna.
If the GPS concern is still present
4. Ignition OFF, disconnect the coax cable between the T15 Navigation Antenna Signal Splitter and the K73
Telematics Communication Interface Control Module.
OnStar antenna diagnostic tool kit to the telematics communication interface module. Place the test
antenna on the roof of the vehicle, ignition ON
If the advisor can not locate the vehicle

7. Ignition OFF.
8. Test the coax cable between the T15 Navigation Antenna Signal Splitter and the K73 Telematics
Communication Interface Control Module. Refer to Component Testing below.

Ignition OFF, disconnect the coax cable between the T15 Navigation Antenna Signal Splitter and the A11
Radio.
Connect the test antenna to the radio and place the test antenna on the roof of the vehicle.
Ignition ON.
Verify that the NO GPS symbol/message is not displayed on the radio.
If the NO GPS symbol/message is displayed
9.
10.
11.
12.
Replace the A11 Radio

If the NO GPS symbol/message is not displayed
13. Ignition OFF.
14. Test the coax cable between the T15 Navigation Antenna Signal Splitter and the A11 Radio. Refer to

Component Testing below.

15. Replace the T15 Navigation Antenna Signal Splitter.
Component Testing
NOTE:
reception issues.
Coax Cable Test

If less than 5 ohms

If less than 5 ohms

5. All OK.
Repair Instructions


ONSTAR BUTTON LED MALFUNCTION

DTC Descriptors
DTC B2476 04
DTC B2476 59
DTC B2482 00
Short to
Ground
B2476 04
1
1
B2476 04
-
Circuit
10 V Reference
Control Terminal 6
Control Terminal 7
Signal Terminal 3
Ground
1. OnStar LED Inoperative
2. LED Illuminated At All Times
Open/High
Resistance
B2476 04
1
1
B2476 04
B2476 04
Short to
Voltage
B2476 04
2
2
B2476 59
-
Signal Performance
B2476 59, B2482 00
-
Circuit Description
The OnStar status LEDs are located in the inside rearview mirror telematic button assembly. The green LED
is illuminated when the system is ON and operating normally. When the green LED is green and flashing, it is

an indication that a call is in progress. When the red LED is illuminated, a system malfunction is present. In the
event there is a system malfunction and the OnStar system is still able to make a call, the LED will flash red
during the call. The OnStar LEDs are controlled by the telematics communication interface control module
via the keypad green LED control circuit and the keypad red LED control circuit.
Ignition ON.
B2476 04
B2482 and B2476 59

assembly.

Schematic Reference
OnStar Schematics


Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference

NOTE:
If the green LED is off with the ignition ON and the LED functions correctly
when commanded with the scan tool, contact the OnStar Center to confirm the
vehicle has a current subscription.
1. Ignition ON.
2. Verify no DTC are set.
If any DTC are set
If no DTC are set
3. Verify that the green LED turns ON and OFF when commanding the Green Indicator ON and OFF with a
scan tool.
If the green LED does not turn ON and OFF
Refer to Circuit/System Testing below - Green LED Test

If the green LED turns ON and OFF
4. Verify that the red LED turns ON and OFF when commanding the Red Indicator ON and OFF with a
scan tool.
If the red LED does not turn ON and OFF
Refer to Circuit/System Testing below - Red LED Test

If the red LED turns ON and OFF
5. All OK.
Green LED Test

1. Ignition OFF, and all vehicle systems OFF, disconnect the harness connector at the A10 Inside Rearview
Mirror. It may take up to 2 min for all vehicle systems to power down. Doors closed, courtesy lamps
OFF.
1. Ignition OFF.
3. Ignition ON.
4. Test for less than 1 V between the control circuit terminal 6 and ground while commanding the Green
Indicator OFF with a scan tool.
If 1 V or greater
If less than 1 V
5. Test for greater than 8 V between the control circuit terminal 6 and ground while commanding the Green
Indicator ON with a scan tool.
If 8 V or less
Control Module.
2. Test for infinite resistance between the control circuit terminal 6 and ground.
If greater than 8 V
Red LED Test
1. Ignition OFF, and all vehicle systems OFF, disconnect the harness connector at the A10 Inside Rearview
Mirror. It may take up to 2 min for all vehicle systems to power down. Doors closed, courtesy lamps
OFF.

1. Ignition OFF.
Ignition ON.
Test for less than 1 V between the control circuit terminal 7 and ground while commanding the Red
Indicator OFF with a scan tool.
If 1 V or greater
If less than 1 V
Test for greater than 8 V between the control circuit terminal 7 and ground while commanding the Red
Indicator ON with a scan tool.
If 8 V or less
Control Module.
If greater than 8 V
Test or replace the A10 Inside Rearview Mirror.
3.
4.
5.
6.
Repair Instructions

ONSTAR CALL CENTER REMOTE FUNCTION REQUESTS MALFUNCTION


The telematics communication interface control module has the capability of commanding the horn, initiating
door lock/unlock, or operating the exterior lamps using the serial data circuits. These functions are commanded
by the OnStar Call Center per a customer request.
Diagnostic Aids
The customer concern may have been due to a lack of cellular service in a given area, or a failure in the
National Cellular Network infrastructure that has since been corrected.
Schematic Reference
OnStar Schematics
Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference

NOTE:
It is necessary to inform the OnStar Call Center advisor that this call is
for vehicle diagnostic purposes.
It is necessary to have the vehicle in an open outside area where a cellular

call can be successfully placed and GPS data can be received from
satellites.
1. Ignition ON.
2. Verify that the horn, lights, and the door locks on the vehicle operate properly.
If an applicable vehicle system does not operate properly
Refer to Diagnostic System Check - Vehicle .
If all applicable vehicle systems operate properly
3. Verify that a call can be successfully placed to the OnStar Call Center by pressing the blue OnStar button.
If unable to contact the OnStar call center
Refer to Unable to Contact OnStar Call Center

If able to contact the OnStar Call Center
4. Verify with the OnStar advisor that all remote functions (door locks, lights, and horn) work.
If the remote functions do not operate when requested
Replace the K73 Telematics Communication Interface Control Module

If the remote functions operate when requested
5. All OK.
Repair Instructions

ONSTAR BUTTON MALFUNCTION
DTC Descriptors
DTC B2476 04

DTC B2476 59
DTC B2482 00
Short to
Ground
Circuit
10 V Reference
B2476 04
Signal Terminal 3
B2476 04
Ground
1. OnStar Buttons Inoperative
Open/High
Resistance
B2476 04
B2476 04
B2476 04
Short to
Voltage
B2476 04
B2476 59
-
Signal Performance
B2476 59, B2482 00
-
The OnStar button assembly consists of 3 buttons: Call/Answer, OnStar Call Center, and OnStar
Emergency. The telematics communication interface control module supplies the OnStar button assembly
with 10 V via the 10 V reference circuit. Each of the buttons, when pressed, completes the circuit across a
resistor allowing a specific voltage to be returned to the telematics communication interface control module
over the keypad signal circuit. Depending upon the voltage range returned, the telematics communication
interface control module is able to identify which button has been activated.
Ignition ON.
B2476 04
B2482 and B2476 59


assembly.

Schematic Reference
OnStar Schematics
Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference

NOTE:
Contact the OnStar Call Center first before pressing the emergency button in
order to notify them of the test.
1. Ignition ON.
2. Verify no DTCs are set.
If any DTCs are set

If no DTCs are set

3. Verify that each button of the S51 Telematics Button Assembly operates normally by pressing each
button individually.
If none of the buttons operate normally
If some, but not all, of the buttons operate normally

Test or replace the A10 Inside Rearview Mirror.
If all of the buttons operate normally

4. All OK.
Mirror. It may take up to 2 min for all vehicle systems to power down.
1. Ignition OFF.
3. Ignition ON.
If less than 8.0 V
Control Module.

5. Ignition OFF.
6. Test for 500-900 ohms between the signal circuit terminal 3 and ground.
Module.
If infinite resistance, replace the K73 Telematics Communication Interface Control Module.
If less than 1 V
3. Ignition OFF.
Repair Instructions

ONSTAR STEERING WHEEL CONTROL FUNCTIONS MALFUNCTION

Some vehicles equipped with the OnStar system have the capability of accessing voice mailboxes and other
automated phone systems by means of the steering wheel controls, while the OnStar Personal Calling feature
is in use. If the "Talk" or "Mute" button (depending upon the vehicle) on the steering wheel controls is
depressed during an OnStar Personal Calling call, the telematics communication interface control module
receives the message on the serial data bus from either the radio or body control module. This message is
interpreted as a request to turn any spoken numbers into dual tone multi-frequency tones to be delivered over
the airwaves to the phone system the user is communicating with. Complete instructions for operation of these
features can be found in the information provided to the customer with the OnStar system.

The steering wheel controls are a resistor network that consist of multiple momentary contact switches and a
series of resistors. The switches and resistor network are arranged so that each switch has a different resistance
value. When a switch is pressed, a voltage drop occurs in the resistor network, which produces a specific
voltage value unique to the switch selected, to be interpreted by either the radio or BCM. In the event the
OnStar steering wheel control functions are inoperative, technicians should refer to Steering Wheel Controls
Malfunction , to begin diagnosis of the steering wheel control concern.
RADIO CONTROLS MALFUNCTION (WITH MONOCHROME DISPLAY)
Short to
Open/High
Short to
Ground
Resistance
Voltage
Circuit
Signal Performance
Radio Controls B+
U0257, 1, 2, 3
2, 4
Radio Display B+
U0257, 1, 2, 3
U0257, 1, 3, 4
Radio Display Reset
U0257, 1, 2
Radio Display Wakeup
U0257, 1, 2
U0257, 1, 2
CGI Serial Data +
U0257, 1, 2
U0257, 1, 2
U0257, 1, 2
CGI Serial Data U0257, 1, 2
U0257, 1, 2
U0257, 1, 2
LIN Serial Data
2
2
2
Radio Controls ground
2
Radio Display Ground
1. Display Inoperative
2. Controls inoperative
3. Fault affects multiple components, dependant on vehicle equipment additional communication DTCs
may be set
4. Fault may affect one or more components, dependant on fault location
The radio controls and information display are separate components from the radio. Each component is supplied
battery voltage and ground. The radio uses the wake up circuit to control the power state of the display. The
radio controls communicate with the info display module through the LIN serial data circuit. Display
backlighting dimming level, graphical data, and radio control inputs are communicated over the CGI data
circuits between the display and the radio.
Schematic Reference


Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference



If all radio controls operate and perform the correct function.

3. All OK.
1. Ignition OFF, disconnect the harness connector at the A22 Radio Controls.
1. Ignition OFF.

Verify that a test lamp illuminates between the B+ circuit terminal 1 and ground.
If the test lamp does not illuminate and the circuit fuse is good.
1. Ignition OFF.
2. Test for less than 2 ohms in the B+ circuit end to end.
If less than 2 ohms, refer to Power Mode Mismatch .
If the test lamp does not illuminate and the circuit fuse is open.
1. Ignition OFF.
2. Test for infinite resistance between the B+ circuit and ground.
If infinite resistance, replace the A22 Radio Controls.
Ignition ON.
Test for 2-11.5 V between the serial data circuit terminal 4 and ground.
If less than 2 V
1. Ignition OFF, disconnect the X1 harness connector at the P17 Info Display Module.
2. Test for infinite resistance between the serial data circuit and ground.
3. Test for less than 2 ohms in the serial data circuit end to end.
If less than 2 ohms, replace the P17 Info Display Module.
1. Ignition OFF, disconnect the X1 harness connector at the P17 Info Display Module. Ignition ON.
2. Test for less than 1 V between the serial data circuit and ground.
If less than 1 V, replace the P17 Info Display Module.
If between 2-11.5 V
Test or replace the A22 Radio Controls.
3.
4.
5.
6.
Repair Instructions

Control Module References for radio control assembly replacement, programming, and setup.

RADIO CONTROLS MALFUNCTION (WITH COLOR DISPLAY)

Short to
Open/High
Short to
Circuit
Ground
Resistance
Voltage
Signal Performance
Radio Controls B+
U0257, 1, 2, 3
2, 4
Radio Display B+
U0257, 1, 2, 3
U0257, 1, 3, 4
Remote Enable Circuit
U0257, 1, 4
U0257, 1, 4
Radio Controls Reset
U0257, 1, 2
Radio Controls Wakeup
U0257, 1, 2
U0257, 1, 2
Radio Display Reset
U0257, 1
CGI Serial Data +
U0257, 1, 2
U0257, 1, 2
U0257, 1, 2
CGI Serial Data U0257, 1, 2
U0257, 1, 2
U0257, 1, 2
Touch Screen Serial Data + U0257, 1
U0257, 1
U0257, 1
Touch Screen Serial Data U0257, 1
U0257, 1
2
may be set
The radio controls are supplied battery voltage and ground. The radio controls the power state of the controls
via a wake up circuit. Communications between the radio controls and the radio are through the CGI serial data
circuits.
Schematic Reference


Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference




3. All OK.
1. Ignition OFF, disconnect the harness connector at the A22 Radio Controls.
1. Ignition OFF.
3. Test for less than 20 ohms between the data shield circuit terminal 6 and ground.

4.
5.
6.
7.
1. Ignition OFF, disconnect the X1 connector at the A11 Radio.

2. Test for less than 2 ohms in the data shield circuit end to end.
If the test lamp does not illuminate and the circuit fuse is good
1. Ignition OFF.
If the test lamp does not illuminate and the circuit fuse is open
1. Ignition OFF.
If infinite resistance, replace the A22 Radio Controls.
Ignition ON.
Test for 2-3 V between the serial data circuit terminals listed below and ground.
terminal 4
terminal 5
If less than 2 V
If greater than 3 V
If between 2-3 V
Test for less than 1 V between the control circuit terminals listed below and ground.
terminal 7
terminal 8

If greater than 1 V
If less than 1 V
9. Test for infinite resistance between the control circuit terminals listed below and ground.
A22 Radio Controls terminal 7
A22 Radio Controls terminal 8
If less than infinite resistance,

10. Test for less than 2 ohms between the control circuits listed below.
A22 Radio Controls terminal 7 and the A11 Radio terminal 13 X1
A22 Radio Controls terminal 8 and the A11 Radio terminal 27 X1

If less than 2 ohms.
11. Replace the A22 Radio Controls. Connect all harness connectors.
If the radio controls still malfunction.

14. All OK
Repair Instructions

Control Module References for radio or radio control assembly replacement, programming, and setup.
RADIO INFORMATION DISPLAY MALFUNCTION (WITH MONOCHROME DISPLAY)

Short to
Ground
U0257, 1, 2, 3
U0257, 1, 2, 3
U0257, 1, 2
U0257, 1, 2
U0257, 1, 2
2
-
Open/High
Resistance
2, 4
U0257, 1, 3, 4
U0257, 1, 2
U0257, 1, 2
U0257, 1, 2
2
2
-
Short to
Voltage
U0257, 1, 2
U0257, 1, 2
U0257, 1, 2
2
-
Circuit
Signal Performance
Radio Controls B+
Radio Display B+
Radio Display Reset
Radio Display Wakeup
Serial Data +
Serial Data LIN Serial Data
Radio Controls Ground
may be set
The radio controls and information display are separate components from the radio. Each component is supplied
battery voltage and ground. The radio uses the wake up circuit to control the power state of the display. The
radio controls communicate with the info display module through the LIN serial data circuit. Display
backlighting dimming level, graphical data, and radio control inputs are communicated over the data circuits
between the display and the radio.
Schematic Reference

Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference

1. Ignition OFF, disconnect the harness connector at the P17 Info Display Module.
If 10 ohms or greater.
1. Ignition OFF.
3. Test for less than 20 ohms between the data shield circuit terminal 6 and ground.
If 20 ohms or greater.
4. Verify that a test lamp illuminates between the B+ circuit terminal 1 and ground.
If the test lamp does not illuminate and the circuit fuse is good.
1. Ignition OFF.
If the test lamp does not illuminate and the circuit fuse is open.
1. Ignition OFF.
If infinite resistance, replace the P17 Info Display Module.

5. Ignition ON.
6. Test for 2-3 V between the data circuit terminals listed below and ground.
terminal 7
terminal 8
If less than 2 V
2. Test for infinite resistance between the data circuit and ground.
3. Test for less than 2 ohms in the data circuit end to end.
If greater than 3 V
If 2-3 V
7. Test for less than 1 V between the control circuit terminals listed below and ground.
terminal 4
terminal 5
If greater than 1 V
If less than 1 V
9. Test for infinite resistance between the control circuit terminals listed below and ground.
P17 Info Display Module terminal 4
P17 Info Display Module terminal 5
10. Test for less than 2 ohms between the control circuits listed below.
P17 Info Display Module terminal 4 and the A11 Radio terminal 13 X1

P17 Info Display Module terminal 5 and the A11 Radio terminal 27 X1

11. Replace the P17 Information Display Module. Connect all harness connectors.
If the information display still malfunctions.

If the info display module turns on and information is shown on the display.
14. All OK.
Repair Instructions

RADIO INFORMATION DISPLAY MALFUNCTION (WITH COLOR DISPLAY)

Circuit
Radio Controls B+
Radio Display B+
Remote Enable Circuit
Radio Controls Reset
Radio Controls Wakeup
Radio Display Reset
CGI Serial Data +
CGI Serial Data -
Short to
Ground
U0257, 1, 2, 3
U0257, 1, 2, 3
U0257, 1, 4
U0257, 1, 2
U0257, 1
U0257, 1, 2
U0257, 1, 2
Open/High
Resistance
2, 4
U0257, 1, 3, 4
U0257, 1, 4
U0257, 1, 2
U0257, 1, 2
U0257, 1, 2
Short to
Voltage
U0257, 1, 2
U0257, 1, 2
U0257, 1, 2
Signal Performance
-

Touch Screen Serial Data + U0257, 1

U0257, 1
U0257, 1
Touch Screen Serial Data U0257, 1
U0257, 1
2
may be set
The radio info display module is supplied battery voltage and ground. The radio controls the power state of the
display through the remote enable circuit, which is also used to control the power state of other infotainment
devices. The info display module receives digital video data from the radio for on-screen display information
through the video signal circuits. The radio communicates with the info display module over the touch screen
serial data circuits for touch screen inputs and backlighting dimming level.
Schematic Reference
Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference



If DTC B1265 is set.
If DTC B1265 is not set.
If the P17 Info Display Module does not turn on, or information is not shown in the display.

If the P17 Info Display Module turns on and information is shown on the display.
4. All OK.
1. Ignition OFF.
2. Verify the video interface cable is properly connected at the P17 Info Display Module X2 and A11 Radio
X3 connections and there is no damage to the cable or connections.
If connection problems or cable damage is noted.
Perform the appropriate repair or replacement to correct any issues.
If no issues are found with the video interface cable.
Disconnect the X1 harness connector at the P17 Info Display Module.
Test for less than 10 ohms between the ground circuit terminal 2 and ground.
1. Ignition OFF.
Test for less than 20 ohms between the data shield circuit terminal 7 and ground.
3.
4.
5.
6.

1. Ignition OFF.
1. Ignition OFF.
If infinite resistance, replace the P17 Info Display Module.
8. Verify that a test lamp illuminates between the control circuit terminal 6 and ground.
If the test lamp does not illuminate.
9. Test for 2-3 V between the data circuit terminals listed below and ground.
terminal 4
terminal 8
If less than 2 V
2. Test for infinite resistance between the data circuit and ground.
3. Test for less than 2 ohms in the data circuit end to end.
If greater than 3 V

If between 2-3 V
Ignition ON.
Test for less than 1 V between the control circuit terminal 5 and ground.
If greater than 1 V
If less than 1 V
Ignition OFF, disconnect the X2 harness connector at the A11 Radio.
Test for infinite resistance between the P17 Info Display Module control circuit terminal 5 X1 and
ground.
10.
11.
12.
13.

14. Test for less than 2 ohms between the P17 Info Display Module control circuit terminal 5 X1 and the A11
Radio control circuit terminal 10 X2.

Replace the video interface cable.
Connect all harness connectors.
Ignition ON, radio ON.
Verify the P17 Info Display Module turns on and information is shown on the display.
If the P17 Info Display Module does not turn on, or information is not shown in the display.
1. Replace the P17 Info Display Module.
If the information display malfunctions, replace the A11 Radio.
4. All OK.
All OK
15.
16.
17.
18.
19.
Repair Instructions


RADIO POOR RECEPTION

DTC Descriptors
DTC B125A 02
Antenna Signal Circuit Short to Ground
DTC B125A 04
Antenna Signal Circuit Open Circuit
Short to
Circuit
Ground
Radio Antenna Coax
B125A 02
Ground
1. May exhibit possible AM/FM interference.
Open/High
Resistance
B125A 04
1
Short to
Voltage
1
-
Signal
Performance
-
The multi-band antenna is located on the roof of the vehicle. The radio antenna is enabled when the radio is
turned on. The radio provides battery voltage to the antenna using the center conductor of the antenna coaxial
cable. When a 12 V signal is seen on the center conductor of the antenna coax, both AM and FM signals are
amplified.
Ignition ON.
B125A 02

The radio detects a short to ground in the antenna signal circuit center conductor.
B125A 04
The radio detects an open in the antenna signal circuit center conductor.
Radio reception may be poor or not available.


A history DTC will clears after 50 consecutive malfunction-free ignition cycles have occurred.
Schematic Reference
Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference


2. Verify station reception is normal when tuned to several known good AM and FM stations.
If AM or FM reception is poor.


If reception is normal
3. All OK.
1. Ignition OFF, disconnect the radio antenna coax cable from the A11 Radio and from the T4G Cellular
Phone, Navigation, and Digital Radio Antenna.
2. Verify the antenna coax cable passes the coax cable component test. Refer to Component Testing below.
3. Connect the radio antenna coax cable to the A11 Radio.
4. Ignition ON, A11 Radio ON. Verify a test lamp illuminates between the antenna coax cable center
terminal and ground at the T4G Cellular Phone, Navigation, and Digital Radio Antenna.
replace the A11 Radio.

Component Testing
NOTE:
reception issues.
Coax Cable Test


If less than 5 ohms


If less than 5 ohms

5. All OK
Repair Instructions

SPEAKER REPLACEMENT REFERENCE

Component
Center I/P Speaker
Front Side Door Speakers
Front Tweeter Speakers
Rear Side Door Speakers
Subwoofer Speakers
Repair Instruction
Radio Front Speaker Replacement
Radio Front Side Door Speaker Replacement
Radio Windshield Side Garnish Molding
Speaker Replacement
Radio Rear Side Door Speaker Replacement
Radio Rear Compartment Speaker Replacement
SPEAKER MALFUNCTION
Short to
Open/High
Short to

Circuit
Amplifier B+
Amplifier Center Audio
Signal
Amplifier LF Audio Signal
Amplifier LR Audio Signal
Amplifier RF Audio Signal
Amplifier RR Audio Signal
Amplifier Subwoofer
Audio Signal
Ground
1
Resistance
1
Voltage
-
Signal Performance
-
2, 3
2
2
2
2
2
2
2
2
2, 3
2, 3
2, 3
2, 3
2
2
2
2
2, 3
Radio LF Audio Signal
B1025 02*, 2
B1025 02*, 2
Radio LR Audio Signal
B1035 02*, 2
B1035 02*, 2
Radio RF Audio Signal
B1045 02*, 2
B1045 02*, 2
Radio RR Audio Signal
B1055 02*, 2
B1055 02*, 2
B1025 02*, 2,
3
B1035 02*, 2,
3
B1045 02*, 2,
3
B1055 02*, 2,
3
B1287 01
-
Remote Enable Signal

B1265 02, 1
1, 4
Amplifier Control
B1287 02
B1287 04
Amplifier Ground
1
1
1. Audio inoperative, no sound from all speakers.
2. No or reduced audio from speaker(s) on the affected audio circuit.
3. Noticeable audio distortion may be present.
4. Fault may affect one or more components, dependant on vehicle equipment.
* When equipped with an amplifier, the radio does not set this DTC.
2
2
2
2
-
Each of the audio output channel circuits (+) and (-), at the radio and audio amplifier have a DC bias voltage
that is approximately one half of battery voltage. When using a DMM, each of the audio output channel circuits
will measure approximately 6.5 V DC. The audio being played on the system is produced by a varying AC
voltage that is centered around the DC bias voltage on the same circuit. The AC voltage is what causes the
speaker cone to move and produce sound. The frequency (Hz) of the AC voltage signal is directly related to the
frequency of the input (audio source playing) to the audio system. Both the DC bias voltage and the AC voltage
signals are needed for the audio system to properly produce sound.
Diagnostic Aids
Improper speaker mounting or loose trim may cause an audible buzz or distortion. Inspect the appropriate
speaker and the surrounding interior trim for proper and secure mounting.
The EL-50334-6 Audio System Diagnostic CD contains audio tracks that can be used to duplicate and
isolate such concerns. Tracks 11 and 12 contain audio sweep tones for testing for speaker and grill rattles.

If the speaker or surrounding interior trim is found to be loose or improperly secured, correctly secure the
item.
The test tones on the CD may be copied to a USB drive or other device to use during testing.
When equipped with an amplifier, it is possible for some individual circuit faults to affect more than one
speakers operation. Perform diagnostic tests in the sequence listed to avoid misdiagnosis.
The amplifier control circuit will measure less than 1 V when the mute function is OFF, and
approximately 8 V DC when at full mute. When mute is active, the radio stops sending the varying AC
voltage to the amplifier/speakers.
Schematic Reference
Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference

Special Tools
EL-50334-50 USB Cable and Adapter Kit
Without Amplifier

individually.
If audio is inoperative from one or more speakers, or the audio emitted is not clear
Refer to Speaker Malfunction below - without Amplifier.
If clear audio is heard from all speakers
3. All OK.
With Amplifier
individually.
If audio is inoperative from one or more speakers, or the audio emitted is not clear
Refer to Speaker Malfunction below- with Amplifier.
If clear audio is heard from all speakers
3. All OK.
Speaker Malfunction - without Amplifier

1. Ignition OFF, disconnect the harness connector at the appropriate P19 Speaker. Ignition ON, radio ON,
mute OFF.
2. Test for 5-7 V between each audio signal circuit terminal 1 and terminal 2 and ground.
If less than 5 V
If greater than 7 V
If between 5-7 V

NOTE:
In the following tests, audio signal frequencies (Hz) will be tested. To

prevent misdiagnosis, the door chime must be OFF during testing. Ensure
the driver door latch is closed during testing.
3. Play track number three (50 Hz bass test tone) from the EL-50334-6 Audio Test CD.
4. Test for 49-51 Hz AC between each signal circuit terminal 1 and terminal 2 and ground.
If not between 49-51 Hz AC
If between 49-51 Hz AC
Speaker Malfunction- with Amplifier

NOTE:
In the following tests, audio signal frequencies (Hz) will be tested. To

prevent misdiagnosis, the door chime must be OFF during testing. Ensure
the driver door latch is closed during testing.
1. Ignition OFF, disconnect the X1 harness connector at the T3 Audio Amplifier.

1. Ignition OFF.
1. Ignition OFF.
1. Ignition OFF.
If infinite resistance, replace the T3 Audio Amplifier.
4. Disconnect the X3 harness connector at the T3 Audio Amplifier.

5. Verify a test lamp does not illuminate between the control circuit terminal 8 and ground.
1. Disconnect the X1 harness at the A11 Radio.
2. Verify a test lamp does not illuminate between the control circuit and ground.
If the test lamp illuminates, repair the short to voltage on the circuit.
If the test lamp does not illuminate, replace the A11 Radio.
7. Verify a test lamp illuminates between the control circuit terminal 8 and ground.
1. Ignition OFF. Disconnect the X1 harness at the A11 Radio.
8. Radio ON, mute ON.
9. Test for 7.5-8.5 V between the control circuit terminal 16 and ground.
If less than 7.5 V
10. Radio ON, mute OFF.
If greater than 1 V
If less than 1 V

12. Test for 5-7 V between the signal circuit terminals listed below and ground:
Left front low level audio signal (+) terminal 12
Left front low level audio signal (-) terminal 11
Right front low level audio signal (+) terminal 9
Right front low level audio signal (-) terminal 10
Left rear low level audio signal (+) terminal 1
Left rear low level audio signal (-) terminal 2
Right rear low level audio signal (+) terminal 4
Right rear low level audio signal (-) terminal 3
If less than 5 V
If greater than 7 V
If between 5-7 V
14. Test for 49-51 Hz AC between the audio signal circuit terminals listed below and ground:
Left front low level audio signal (+) terminal 12
Left front low level audio signal (-) terminal 11
Right front low level audio signal (+) terminal 9
Right front low level audio signal (-) terminal 10
Left rear low level audio signal (+) terminal 1
Left rear low level audio signal (-) terminal 2
Right rear low level audio signal (+) terminal 4
Right rear low level audio signal (-) terminal 3

15. Ignition OFF, connect all harness connectors.

16. Disconnect the harness connector at the appropriate P19 Speaker. Ignition ON, A11 Radio ON.
17. Test for 5-7 V between each signal circuit terminal 1 and terminal 2 and ground.
If less than 5 V
1. Ignition OFF, disconnect the X1 and X2 harness connectors at the T3 Audio Amplifier.
If less than 2 ohms, replace the T3 Audio Amplifier.
If greater than 7 V
1. Ignition OFF, disconnect the X1 and X2 harness connectors at the T3 Audio Amplifier. Ignition
ON.
If less than 1 V, replace the T3 Audio Amplifier.
If between 5-7 V
19. Test for 49-51 Hz AC between each signal circuit terminal 1 and terminal 2 and ground.
Replace the T3 Audio Amplifier.
Repair Instructions

Control Module References for amplifier or radio replacement, programming and setup
UNABLE TO CONTACT ONSTAR CALL CENTER


The telematics communication interface control module is a cellular device that allows the user to communicate
data and voice signals over the national cellular network. When an OnStar keypress is made, the telematics
communication interface control module activates and connects the system to the cellular carriers
communication system by interacting with the national cellular infrastructure. The module sends and receives
all cellular communications over the cellular phone and navigation antenna and cellular antenna coax.
Diagnostic Aids
The customer concern may have been due to a lack of cellular service in a given area. A failure in the
National Cellular Network infrastructure at the time of the customers failed connection that has since
been repaired may also have been the cause.
If an OnStar emergency call is able to successfully connect the vehicle to the OnStar Call Center
when an OnStar Call Center button press is not, there may be a failure in the ability of the OnStar
system in the vehicle to be recognized by the local cellular carrier.
If the prompt "OnStar request ended" is heard, without pressing the white dot button at the end of the
OnStar keypress, the OnStar system at one time has made a successful cellular connection, but was
unable to complete the call.
It is important to have the vehicle in an open outside area where a cellular call can be successfully placed
and GPS data can be received from satellites.
Schematic Reference
OnStar Schematics
Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference


Special Tools
NOTE:

unobstructed view of the southern sky. Allow 5 min after turning the ignition ON
for the GPS satellites to acquire vehicle signal.
1. Ignition ON.
If DTC B2470 is set
Refer to DTC B2470
3. Verify that a call can be successfully placed to the OnStar Call Center by pressing the blue OnStar button.
If unable to connect with the OnStar Call Center.

If able to connect with the OnStar Call Center
4. All OK.
NOTE:
unobstructed view of the southern sky. Allow 5 min after turning the
Without Navigation Radio

If the DTC sets

Replace the K73 Telematics Communications Interface Control Module.

4. Ignition OFF.
5. Disconnect the EL-49903 GM OnStar antenna diagnostic tool kit from the K73 Telematics

With Navigation Radio

If the DTC sets
Ignition OFF.
Disconnect the EL-49903 GM OnStar antenna diagnostic tool kit from the K73 Telematics
Connect the coax cable to the K73 Telematics Communications Interface Control Module and disconnect
the coax cable from the T15 Navigation Antenna Signal Splitter, ignition ON.
If less than 4.5 V
1. Ignition OFF.
1. Ignition OFF.
4.
5.
6.
7.


8. Ignition OFF, connect the coax cable to the T15 Navigation Antenna Signal Splitter and disconnect the
coax cable from the T4G Cellular Phone, Navigation, and Digital Radio Antenna, ignition ON.
9. Test for 4.5-5.5 V between the coax cable center conductor and the outer shield.
If less than 4.5 V
1. Ignition OFF.
1. Ignition OFF.
Component Testing
NOTE:
reception issues.
Coax Cable Test


If less than 5 ohms


If less than 5 ohms

5. All OK.
Repair Instructions
ONSTAR VOICE RECOGNITION MALFUNCTION

The telematics communication interface control module is capable of interpreting voice commands received
over the cellular microphone circuit. Speech recognition allows the user to speak to one computer in the vehicle,
and one reached over the cellular communication network. The module attempts to understand the users
command, and responds by speaking back, or by taking the appropriate action, e.g. dialing the phone.
Schematic Reference
OnStar Schematics


Circuit Testing
Connector Repairs
Wiring Repairs
NOTE:
It is necessary to have the vehicle in an open outside area where a cellular

call can be successfully placed and GPS data can be received from
satellites.
The vehicle should be located in a quiet area.
1. Ignition ON, press the blue OnStar Call button.

2. Verify that your voice is heard clearly by the OnStar Call center.
Refer to OnStar Microphone Malfunction
3. Verify that the system responds appropriately to all voice commands by pressing the voice command
button and attempting to operate the system using multiple voice commands.
If the OnStar system does not respond to any voice commands
Replace the K73 Telematics Communication Interface Control Module
If the OnStar system responds to some, but not all voice commands
Refer to OnStar Description and Operation for tips on proper pronunciation
If the OnStar system responds to all voice commands

4. All OK.
Repair Instructions

REPAIR INSTRUCTIONS
MOBILE TELEPHONE MICROPHONE REPLACEMENT
Fig. 11: Mobile Telephone Microphone

Callout
Component Name
1
Dome Lamp Bezel
Mobile Telephone Microphone
2
Procedure
Disconnect electrical connector.
COMMUNICATION INTERFACE MODULE REPLACEMENT

Fig. 12: Communication Interface Module

Communication Interface Module Replacement
Callout
Component Name
Preliminary Procedure
Remove the communication interface module bracket. Refer to Communication Interface Module
Bracket Replacement.
Communication Interface Module
Procedure
1
1. Disconnect the electrical connections.

2. If replacing the communication interface module be sure to transfer
Bluetooth antenna, if equipped.
3. For programming and set up procedures, refer to Control Module
References .
COMMUNICATION INTERFACE MODULE BATTERY REPLACEMENT

Fig. 13: Communication Interface Module Battery

Communication Interface Module Battery Replacement
Callout
Component Name
Communication Interface Module Battery
Procedure
1
1. Disconnect the electrical connector.

2. Reprogramming of the Module may be necessary after losing battery
power.
References .
WIRELESS COMMUNICATION INTERFACE ANTENNA REPLACEMENT

Fig. 14: View Of Wireless Communication Interface Antenna Module

Wireless Communication Interface Antenna Replacement
Callout
Component Name
Remove the communication interface module. Refer to Communication Interface Module
Replacement
Wireless Communication Interface Antenna Bluetooth Module
Procedure
1
Unsnap the Antenna from Communication Module.
COMMUNICATION INTERFACE MODULE BRACKET REPLACEMENT

Fig. 15: Communication Interface Module Bracket

Communication Interface Module Bracket Replacement
Callout
Component Name
Remove the instrument panel compartment. Refer to Instrument Panel Compartment Replacement
Communication Interface Module Bracket Bolts (Qty: 3)
1
CAUTION:
Refer to Fastener Caution .
Communication Interface Module Bracket

2
Procedure
2. Transfer components as necessary.
COMPACT DISC CARE 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 the surface of a CD is damaged, such as
cracked, broken, scratched, or wrinkled labeling, the CD will not play properly or not at all. If the surface of a

CD is soiled, take a soft, lint free cloth or dampen a clean, soft cloth in a mild, neutral detergent solution mixed
with water, and clean it. Make sure the wiping process starts from the center to the edge. Do not touch the
bottom side of a CD while handling it. This could damage the surface. Pick up CDs by grasping the outer edges
or the edge of the hole and the outer edge.
Care of CD Player
The use of CD lens cleaners for CD players is not advised, due to the risk of contaminating the internal lens of
the CD optics with lubricants.
Stuck CDs
Interrupting the battery power by pulling the fuse will sometimes release a stuck CD. If a CD is stuck, and
removed, inspect it for warps, cracks, etc. If the CD is damaged, do not replace the radio.
Labelling CDs
Paper labels can eventually warp and wrinkle, and this will cause the disc to jam inside the CD player. Try
labeling the top of the discs with a soft magic marker instead.
RADIO REPLACEMENT
Fig. 16: Radio Mounting Hardware

Radio Replacement

Callout
Preliminary Procedures
Component Name
1. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and
Connection .
2. Remove the radio control module. Refer to Radio Control Module Replacement.
3. Remove the driver information display bezel. Refer to Driver Information Display Bezel
Replacement .
Radio Bolt (Qty: 4)
1
2
CAUTION:
Radio Bolt Washer (Qty: 4)

Radio
Procedure
3
1. Disconnect electrical components.
2. After replacement, refer to Control Module References for
programming and set up information.
AUDIO DISC PLAYER RECEPTACLE REPLACEMENT
Fig. 17: Audio Disc Player Receptacle


Callout
Component Name
Open armrest floor console.
Audio Disc Player Receptacle
WARNING:
Refer to Battery Disconnect Warning .
Procedure
AUDIO DISC PLAYER, USB, AUXILIARY IN, AND MEMORY CARD RECEPTACLE
REPLACEMENT
Fig. 18: Audio Disc Player, USB, Auxiliary In, and Memory Card Receptacle
Audio Disc Player, USB, Auxiliary In, and Memory Card Receptacle Replacement
Callout
Component Name
Remove the front floor console compartment. Refer to Front Floor Console Compartment

Replacement .
Audio Disc Player and USB and Auxiliary In and Memory Card
Receptacle
1
Procedure
1. Use a suitable screwdriver in order to disengage receptacle from
the front floor console.
RADIO SPEAKER AMPLIFIER REPLACEMENT
Fig. 19: Radio Speaker Amplifier & Nuts

Radio Speaker Amplifier Replacement
Callout
Component Name
1. Disconnect negative battery cable. Refer to Battery Negative Cable Disconnection and
Connection .
2. Remove rear compartment side trim. Refer to Rear Compartment Side Trim Replacement Right Side .
Radio Speaker Amplifier Nuts (Qty: 3)

CAUTION:
1
Tighten
9 N.m(80 lb in)
Radio Speaker Amplifier.
2
Procedure
2. After repairs, refer to Control Module References .
MULTIMEDIA PLAYER INTERFACE MODULE REPLACEMENT
Fig. 20: Multimedia Player Interface Module

Multimedia Player Interface Module Replacement
Callout
Component Name
1. Remove heater and air conditioning control. Refer to Heater and Air Conditioning Control
Replacement .

2. Remove front floor console storage tray. Refer to Front Floor Console Stowage Tray
Replacement .
Multimedia Player Interface Module
Procedure
1
1. Disconnect electrical connector.
2. After repair, refer to Control Module References for programming
and set up procedures.
NAVIGATION SIGNAL SPLITTER REPLACEMENT
Fig. 21: Navigation Signal Splitter

Callout
Component Name
Navigation Signal Splitter

Procedure


References .
MOBILE TELEPHONE CONTROL MODULE REPLACEMENT
Fig. 22: Mobile Telephone Control Module

Mobile Telephone Control Module Replacement
Callout
Component Name
Remove instrument panel compartment. Refer to Instrument Panel Compartment Replacement .
Mobile Telephone Control Module Bolt (Qty: 3)
CAUTION:
Tighten
2.5 N.m(23 lb in)
Telephone Transceiver Bracket.
Mobile Telephone Control Module Assembly.

Procedure
References .
RADIO ANTENNA COIL REPLACEMENT - HIGH SIDE
Fig. 23: Radio Antenna Coil Replacement - High Side

Radio Antenna Coil Replacement - High Side
Callout
Component Name
Remove quarter window garnish molding. Refer to Quarter Window Garnish Molding Replacement .
Radio Antenna High Side Coil Bolt
CAUTION:
Tighten
8 N.m(71 lb in)
Radio Antenna High Side Coil Washer

Radio Antenna Coil - High Side

Procedure
RADIO ANTENNA COIL REPLACEMENT - GROUND SIDE
Fig. 24: Radio Antenna Coil Replacement - Ground Side

Radio Antenna Coil Replacement - Ground Side
Callout
Component Name
Remove the quarter window garnish molding. Refer to Quarter Window Garnish Molding
Replacement .
Radio Antenna Coil Bolt
CAUTION:
Tighten
8 N.m(71 lb in)
Radio Antenna Coil Washer
Radio Antenna Coil - Ground Side

Procedure
RADIO ANTENNA BASE REPLACEMENT

Removal Procedure
1. Remove headlining trim panel. Refer to Headlining Trim Panel Replacement (without Sunroof) ,
Headlining Trim Panel Replacement (with Sunroof) .
Fig. 25: Radio Antenna Base Bolt

2. Remove the radio antenna base bolt (1).

Fig. 26: Radio Antenna Base

3. Remove the radio antenna base (1).
4. Disconnect the electrical connectors.
Installation Procedure
1. Connect the electrical connectors.

Fig. 27: Radio Antenna Base

2. Install the radio antenna base (1).

Fig. 28: Radio Antenna Base Bolt

CAUTION: Refer to Fastener Caution .
3. Install the radio antenna base bolt (1) and tighten to 10 N.m (89 lb in).
4. Install the headlining trim panel. Refer to Headlining Trim Panel Replacement (without Sunroof) ,
RADIO ANTENNA REPLACEMENT

Fig. 29: Radio Antenna

Radio Antenna Replacement
Callout
1
Component Name
Radio Antenna
RADIO CONTROL MODULE REPLACEMENT

Fig. 30: Radio Control Module

Radio Control Module Replacement
Callout
Component Name
Remove instrument panel accessory bezel. Refer to Instrument Panel Accessory Bezel Replacement .
Radio Control Module Bolts (Qty: 2)
CAUTION:
Tighten
2.5 N.m (22 lb in)
Radio Control Module
Procedure
Disconnect electrical connectors.
DIGITAL RADIO ANTENNA CABLE REPLACEMENT

Fig. 31: Radio Antenna Cable (Radio Cable)

Digital Radio Antenna Cable Replacement
Callout
Component Name
Remove the instrument panel assembly. Refer to Instrument Panel Assembly Replacement .
Digital Radio Antenna Cable
Procedures
1
1. Locate the digital radio antenna cable in the instrument panel

wiring harness assembly.
2. Carefully cut the electrical tape.
3. Disconnect electrical connectors.
4. Replace the radio antenna cable.
5. Secure the radio antenna cable within the electrical conduit.
DIGITAL RADIO, MOBILE TELEPHONE, AND VEHICLE LOCATION ANTENNA CABLE

REPLACEMENT (DIGITAL SATELLITE CABLE)

Fig. 32: Radio, Mobile Telephone And Vehicle Location Antenna Cable
Digital Radio, Mobile Telephone, and Vehicle Location Antenna Cable Replacement (Digital Satellite
Cable)
Callout
Component Name
1. Remove the front floor panel carpet. Refer to Front Floor Panel Carpet Replacement .
2. Remove the headlining trim panel. Refer to Headlining Trim Panel Replacement (without
Sunroof) , Headlining Trim Panel Replacement (with Sunroof) .
Radio, Mobile Telephone, and Vehicle Location Antenna Cable
Procedures
1
1. Locate the radio, mobile telephone and vehicle location antenna

cable in the body wiring harness assembly.
DIGITAL RADIO, MOBILE TELEPHONE, AND VEHICLE LOCATION ANTENNA CABLE

REPLACEMENT (GPS CELLULAR CABLE)

Fig. 33: Radio, Mobile Telephone And Vehicle Location Antenna Cable (GPS Cellular Cable)
Digital Radio, Mobile Telephone, and Vehicle Location Antenna Cable Replacement (GPS Cellular
Cable)
Callout
Component Name
Procedures
1

cable in the instrument panel wiring harness assembly.
RADIO, MOBILE TELEPHONE, AND VEHICLE LOCATION ANTENNA CABLE REPLACEMENT

(GPS CELLULAR CABLE)

Fig. 34: Radio, Mobile Telephone And Vehicle Location Antenna Cable (GPS Cellular Cable)
Radio, Mobile Telephone, and Vehicle Location Antenna Cable Replacement (GPS Cellular Cable)
Callout
Component Name
Procedures
1

cable in the instrument panel wiring harness assembly.
RADIO, MOBILE TELEPHONE, AND VEHICLE LOCATION ANTENNA CABLE REPLACEMENT

(DIGITAL SATELLITE CABLE)

Fig. 35: Radio, Mobile Telephone And Vehicle Location Antenna Cable
Radio, Mobile Telephone, and Vehicle Location Antenna Cable Replacement (Digital Satellite Cable)
Callout
Component Name
Procedures
1

cable in the body wiring harness assembly.
RADIO ANTENNA CABLE REPLACEMENT (ANTENNA CABLE)

Fig. 36: Radio Antenna Cable

Radio Antenna Cable Replacement (Antenna Cable)
Callout
Component Name
Radio Antenna Cable
Procedures
1
1. Locate the radio antenna cable in the body wiring harness

assembly.
RADIO ANTENNA CABLE REPLACEMENT (RADIO CABLE)

Fig. 37: Radio Antenna Cable (Radio Cable)

Radio Antenna Cable Replacement (Radio Cable)
Callout
Component Name
Radio Antenna Cable
Procedures
1
1. Locate the radio antenna cable in the instrument panel wiring

harness assembly.
RADIO FRONT SPEAKER REPLACEMENT

Fig. 38: Radio Front Speaker

Radio Front Speaker Replacement
Callout
Component Name
Remove instrument panel upper trim pad insert. Refer to Instrument Panel Upper Trim Pad Insert
Replacement .
Radio Front Speaker Bolt (Qty: 2)
CAUTION:
Tighten
2.5 N.m (22 lb in)
Radio Front Speaker
RADIO WINDSHIELD SIDE GARNISH MOLDING SPEAKER REPLACEMENT

Fig. 39: Radio Windshield Side Garnish Molding Speaker

Radio Windshield Side Garnish Molding Speaker Replacement
Callout
Component Name
Remove windshield garnish molding. Refer to Windshield Garnish Molding Replacement .
1
Radio Windshield Side Garnish Molding Speaker Bracket
2
Radio Windshield Side Garnish Molding Speaker
USB RECEPTACLE REPLACEMENT

Fig. 40: USB Receptacle

USB Receptacle Replacement
Callout
Component Name
1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and
Connection .
2. Open armrest floor console.
USB Receptacle
1
Procedure
RADIO FRONT SIDE DOOR SPEAKER REPLACEMENT

Fig. 41: View Of Radio Front Side Door Lower Speaker

Radio Front Side Door Speaker Replacement
Callout
Component Name
Remove front side door trim replacement. Refer to Front Side Door Trim Replacement .
Radio Front Side Door Speaker Bolt
CAUTION:
Tighten
2.5 N.m (22 lb in)
Radio Front Side Door Speaker
Procedure
Disconnect the electrical connector.
RADIO CONTROL SWITCH REPLACEMENT - STEERING WHEEL

Fig. 42: Steering Wheel Radio Control Switch

Radio Control Switch Replacement - Steering Wheel
Callout
Component Name
Connection .
2. Remove inflatable restraint steering wheel module. Refer to Airbag Steering Wheel Module
Replacement .
3. Remove the steering wheel spoke lower cover. Refer to Steering Wheel Spoke Lower Cover
Replacement
1
Radio Control Switch Bolt - Steering Wheel (Qty:2)
2
Radio Control Switch - Steering Wheel
RADIO REAR SIDE DOOR SPEAKER REPLACEMENT

Fig. 43: Radio Rear Side Door Speaker

Radio Rear Side Door Speaker Replacement
Callout
Component Name
Remove rear side door trim replacement. Refer to Rear Side Door Trim Replacement .
Radio Rear Side Door Speaker Bolt
CAUTION:
Tighten
2.5 N.m (22 lb in)
Radio Rear Side Door Speaker
Procedure
RADIO REAR COMPARTMENT SPEAKER REPLACEMENT

Fig. 44: Radio Rear Compartment Speaker & Bolt

Radio Rear Compartment Speaker Replacement
Callout
Component Name
Remove rear window panel trim. Refer to Rear Window Panel Trim Replacement .
Radio Rear Speaker Compartment Bolt
CAUTION:
Tighten
2.5 N.m (22 lb in)
Radio Rear Compartment Speaker
Procedure

ONSTAR DESCRIPTION AND OPERATION
This OnStar system consists of the following components:

Telematics communication interface control module

OnStar three button assembly
Microphone
Cellular antenna
Navigation antenna
Bluetooth antenna (If equipped)
Back up battery (If equipped)
This system also interfaces with the factory installed vehicle audio system.
Telematics Communication Interface Control Module
The telematics communication interface control module is a cellular device that allows the user to communicate
data and voice signals over the national cellular network. Power is provided by a dedicated, fused B+ circuit.
Ground is provided through the vehicle wiring harness attached to the module. The ignition state is determined
by the telematics communication interface control module through serial data messaging.
Dedicated circuits are used to connect the telematics communication interface control module to a microphone,
the button assembly, and to command the status LED. The telematics communication interface control module
communicates with the rest of the vehicle over the serial data bus.
The module houses 2 technology systems, one to process GPS data, and another for cellular information. The
cellular system connects the OnStar system to the cellular carrier's communication system by interacting with
the national cellular infrastructure. The module sends and receives all cellular communications over the cellular
antenna and cellular antenna coax. GPS satellites orbiting earth are constantly transmitting signals of their
current location. The OnStar system uses the GPS signals to provide location on demand.
The module also has the capability of activating the horn, initiating door lock/unlock, or activating the exterior
lamps using the serial data circuits. These functions can be commanded by the OnStar Call Center per a
customer request.
OnStar Three Button Assembly
Base Mirror
The OnStar button assembly may be part of the rearview mirror, or a separate, stand alone unit. The
button assembly is comprised of 3 buttons and a status LED. The buttons are defined as follows:
The answer/end call button, which is black with a white phone icon, allows the user to answer and
end calls or initiate speech recognition.
The blue OnStar call center button, which displays the OnStar logo, allows the user to connect
to the OnStar call center.
The emergency button, which displays a white cross with a red background, sends a high priority
emergency call to the OnStar call center when pressed.
The telematics communication interface control module supplies 10 volts to the OnStar button assembly on

the keypad supply voltage circuit. When pressed, each button completes a circuit across a resistor allowing a
specific voltage to be returned to the telematics communication interface control module on the keypad signal
circuit. Depending upon the voltage range returned the telematics communication interface control module is
able to identify which button has been pressed.
The OnStar status LED is located with the button assembly. The LED is green when the system is ON and
operating normally. When the status LED is green and flashing, it is an indication that a call is in progress.
When the LED is red, this indicates a system malfunction is present. In the event there is a system malfunction
and the OnStar system is still able to make a call, the LED will flash red during the call.
If the mirror has the rear vision camera display in the mirror, the LED's are then interior to the mirror and
controlled via data communication on the Low Speed GMLAN bus from the Telematics Communication
Interface Control Module to the mirror.
If the LED does not illuminate, this may indicate that the customers OnStar subscription is not active or has
expired. Push the blue OnStar button to connect to an advisor who can then verify the account status.
Each LED is controlled by the telematics communication interface control module over dedicated LED signal
circuits. Ground for the LED is provided by the wiring harness attached to the button assembly.
Prismatic Mirror (If Equipped)
The OnStar button assembly is apart of the rearview mirror. The button assembly is comprised of 3
capacitive touch buttons and a status LED. The buttons are defined as follows:
The answer/end call button, which is a white driver figure seated with voice signals near it's face,
allows the user to answer and end calls or initiate speech recognition.
The blue OnStar call center button, which displays the blue OnStar logo, allows the user to
connect to the OnStar call center.
The emergency button, which displays red letters "SOS" as an illuminated Indicator, sends a high
priority emergency call to the OnStar call center when pressed.
the keypad supply voltage circuit. When pressed, each button press is processed and completes a circuit across
an internal resistor allowing a specific voltage to be returned to the telematics communication interface control
module on the keypad signal circuit. Depending upon the voltage range returned the telematics communication
interface control module is able to identify which button has been pressed.
The OnStar status LED is located within the mirror near the buttons. The LED is green when the system is
ON and operating normally. When the status LED is green and flashing, it is an indication that a call is in
progress. When the LED is red, this indicates a system malfunction is present. In the event there is a system
malfunction and the OnStar system is still able to make a call, the LED will flash red during the call.
If the LED does not illuminate, this may indicate that the customers OnStar subscription is not active or has
Each LED is controlled by the telematics communication interface control module over dedicated LED signal
circuits. Ground for the LED is provided by the wiring harness attached to the button assembly.

Electrochromic Mirror (If Equipped)
The OnStar button assembly is apart of the rearview mirror. The button assembly is comprised of 3
capacitive touch buttons and an error indicator. The buttons are defined as follows:
The answer/end call button, which is a white driver figure seated with voice signals near it's face,
allows the user to answer and end calls or initiate speech recognition.
The blue OnStar call center button, which displays the blue OnStar logo, allows the user to
connect to the OnStar call center.
The emergency button, which displays red letters "SOS" as an illuminated Indicator, sends a high
priority emergency call to the OnStar call center when pressed.
the keypad supply voltage circuit. When pressed, each button press is processed and completes a circuit across
an internal resistor allowing a specific voltage to be returned to the telematics communication interface control
module on the keypad signal circuit. Depending upon the voltage range returned the telematics communication
interface control module is able to identify which button has been pressed and illuminate associated indicator
above each button.
The OnStar error indicator is located within the mirror above the buttons between the OnStar indicator and
emergency "SOS" indicator. All three indicators associated with a button press are illuminated when the system
is ON and operating normally. When any indicator is illuminated and flashing, it is an indication that a call is in
progress. When the OnStar error indicator is illuminated, this indicates a system malfunction is present. In the
event there is a system malfunction and the OnStar system is still able to make a call, the OnStar error
indicator will remain illuminated during the call.
If the indicators do not illuminate, this may indicate that the customers OnStar subscription is not active or has
Secondary OnStar Controls
Some vehicles may have an additional button that when pushed can engage the OnStar system. The button
may be a symbol of a face with sound waves, or may say MUTE, or be a symbol of a radio speaker with a slash
through it.
By engaging the OnStar system with this feature, the user can interact with the system by use of voice
commands. A complete list of these commands is supplied in the information provided to the customer. If the
information is not available for reference, at any command prompt the user can say "HELP" and the telematics
communication interface control module will return an audible list of available commands.
OnStar Microphone
The OnStar, or cellular microphone, can be a part of the rearview mirror assembly, or on some vehicle lines, a
separate, stand alone unit. In either case, the telematics communication interface control module supplies
approximately 10 volts to the microphone on the cellular microphone signal circuit, and voice data from the
user is sent back to the telematics communication interface control module over the same circuit. A cellular
microphone low reference circuit or a drain wire provides a ground for the microphone.

Cellular and GPS Antennas
This vehicle will be equipped with one of the following types of antennas:
A combination cellular and navigation antenna, which brings the functions of both into a single part
A cellular, GPS, and digital radio receiver antenna, which also incorporates the functionality of the digital
radio receiver satellite antenna (XM).
A cellular, GPS, and digital radio receiver antenna, which also incorporates the AM/FM antenna.
The cellular antenna is the component that allows the OnStar system to send and receive data over airwaves
by means of cellular technology. The antenna is connected at the base to a coax cable that plugs directly into the
telematics communication interface control module.
The GPS antenna is used to collect the signals of the orbiting GPS satellites. Within the antenna is housed a low
noise amplifier that allows for a more broad and precise reception of this data. The antenna is connected at the
base to a coax cable that plugs directly into the telematics communication interface control module. The cable
also provides a path for DC current for powering the antenna.
The OnStar Call Center also has the capability of communicating with the vehicle during an OnStar call to
retrieve the latest GPS location and transmit it to the OnStar Call Center. A history location of the last
recorded position of the vehicle is stored in the module and marked as aged, for as long as the module power is
not removed. Actual GPS location may take up to 10 minutes to register in the event of a loss of power.
OnStar RemoteLink
OnStar RemoteLink is a mobile app to link mobile devices to a vehicle for limited diagnostics and feature
controls. After downloading the app and registering the device, vehicle owners with an eligible vehicle can use
their mobile devices to access real-time data from their vehicle and perform specific commands remotely.
All communication between the app and the vehicle is powered by OnStar's advanced connected vehicle
technology. An active OnStar account as well as a valid OnStar username and password are required to use
the app. The remote commands must be enabled by logging into the user's OnStar account prior to using the
app.
Vehicle Control Features
Lock/Unlock doors
Start vehicle remotely
Activate your Horn & Lights
Contact an OnStar Advisor, Roadside Assistance or your Preferred Dealer
Available Vehicle Data:
Real-time fuel information, including fuel range, fuel remaining, and lifetime MPG
Lifetime mileage
Remaining oil life

Current tire pressure information

OnStar account information
Compass Heading
The telematics communication interface module has a compass feature to calculate vehicle direction which is
displayed via the instrument panel cluster or designated display. The compass heading is determined by dead
reckoning until the GPS 3d fix is established. The dead reckoning is accomplished by using the yaw rate sensors
and wheel ticks to determine heading changes from a GPS known heading. The GPS 3d fix heading is
determined by the deferential of two locations.
Bluetooth (If Equipped)
connecting portable and/or fixed devices while maintaining high levels of security. Only vehicles with steering
wheel controls will have Bluetooth functionality. In order to utilize the vehicle's Bluetooth system, a
Bluetooth equipped cellular phone is required.
The Bluetooth antenna is a small fixed antenna connected directly to the telematics communication interface
control module and is used to send and receive signals from a Bluetooth enabled cellular phone. The antenna
utilizes no cabling and is not external to the vehicle. The available features and functions are determined by the
software within the device being used and the telematics communication interface control module. The
operating range of the signal from the vehicle is approximately 30 feet. Note that the operating range is
dependent upon the cellular phone being used and battery level of the phone.
With Bluetooth technology customers can experience hands-free calling as their Bluetooth capable cellular
phones are wirelessly connected to the vehicle. It will allow customers to place and receive calls using the
steering wheel controls and voice recognition. The vehicle audio system will allow you to listen to your call
through the vehicle speakers and adjust volume through steering wheel or radio controls.
Not all Bluetooth cellular phones are guaranteed to work with the vehicle's Bluetooth system. Based on the
cellular phone's service provider and the manufacturer's implementation of Bluetooth, not all phones support
all available Bluetooth functionality. Bluetooth enabled cellular phones will be tested for vehicle
compatibility and a feature compatibility list will be provided via the GM Bluetooth website:
http://www.gm.com/vc/bluetooth/
Bluetooth Features Supported
The following is a list of features supported by the Bluetooth system. Note that not all devices will support all
of the listed functions.
Automatic reconnection - highest priority phone will automatically be connected to vehicle when vehicle
ignition is on
Hands-free dialing- via digits, redial, name tags (phone number saved to a nametag via voice recognition)
Answering a call
Ending a call

Mute a Call
Rejecting a call - ignore an incoming call
Call Waiting
Three-way Calling - initiated from hands-free system
Send Number During a Call - this is used when calling a menu-driven phone system
Transfer a Call - transfer call from vehicle to cellular phone and visa versa
Voice Pass-Thru - allow access to the voice recognition commands on the cellular phone
Pairing a Bluetooth Cellular Phone to the Vehicle
In order to use hands-free calling, the cellular phone must be paired to the vehicle. Up to five devices can be
paired to the vehicle at one time, but only one can be connected at any given time. To pair a phone, the
customer must know how to operate the Bluetooth functionality of their phone. The pairing process must only
be done one time for each phone, unless that phone's information is deleted. For safety reasons, the pairing
process is disabled while the vehicle is moving.
Once the Bluetooth cellular phone has been paired with vehicle, it will automatically connect to the vehicle
when the ignition is on and the device is on. When more than one paired phone is in the vehicle, the phone with
the highest priority will be connected. If the cellular phone is in use while getting into the vehicle, the phone can
be switched to hands-free mode with the press of a button. In addition, a call in progress can be transferred from
the vehicle hands-free mode to the phone to continue the call as the customer exits the vehicle.
Complete pairing instructions are provided in the Vehicle Owners Manual.
Back-up Battery (If Equipped)
IMPORTANT: Do not disconnect the main vehicle battery or remove the OnStar fuse with
the ignition key in any position other than OFF. Disconnecting power to the
OnStar module in any way while the ignition is ON or with retained accessory
power activated may cause activation of the OnStar Back-Up Battery. This
action is per design as the back-up battery is designed to provide power to the
telematics communication interface control module so an emergency
notification call can be made after an event where the main battery is disabled.
Once the Back-Up Battery is activated it will stay on until the power is restored
back to the telematics communication interface control module. The telematics
communication interface control module naturally chooses the main supply
voltage as it's default supply, but if the main supply is removed or lost for any
reason the OnStar module will use the Back-Up Battery as a power supply as
long as the default supply can not be detected. The back-up battery is not
rechargeable and once discharged below 9.5 volts the back-up battery must be
replaced.
Certain OnStar equipped vehicles may also be equipped with a back-up battery. The back-up battery is a nonrechargeable, lithium battery intended to provide an auxiliary power source for the telematics communication
interface control module in the event where power from the main vehicle battery is lost.

The back-up battery is intended to have a limited life span of approximately 4 years and is designed to maintain
an open circuit voltage between 16 V and 9 V throughout this period. This allows the battery to power the basic
functions of the telematics communication interface control module for least one 200 second (5 minute) call at
the end of the 4 year span, should the main vehicle battery be lost. In the case of a vehicle losing vehicle battery
power, OnStar will switch over to the backup battery based on an internal algorithm. It will look for an air-bag
deploy, or near-deploy, messages from the SDM. If there are no messages the OnStar module will stay wake for
a few minutes longer and monitor the buttons in the mirror. If not pressed, the modules will power down and
shut off completely.
The back-up battery is connected to the telematics communication interface control module through the back-up
battery positive voltage circuit and back-up battery ground circuit and is protected from a short circuit by means
of an internal fuse. In the event the back-up battery, battery positive voltage circuit is shorted to the back-up
battery ground circuit or chassis ground, the fuse will open and render the back-up battery permanently
inoperable. The status of the back-up battery and its associated wiring is monitored by the telematics
communication interface control module.
Audio System Interface
When the OnStar requires audio output, a serial data message is sent to the audio system to mute all radio
functions and transmit OnStar originated audio. The OnStar audio is transmitted to the vehicle audio system
by a dedicated signal circuit and a low reference circuit.
The audio system will mute and an audible ring will be heard though the speakers if the vehicle receives a call
with the radio ON.
On some vehicles, the HVAC blower speed may be reduced when the OnStar system is active to aid in
reducing interior noise. When the system is no longer active, the blower speed will return to its previous setting.
OnStar Sleep Cycle
The OnStar system uses a unique sleep cycle to allow the system to receive cellular calls while the ignition is
in the OFF position and retained accessory power mode has ended. This cycle enables the telematics
communication interface control module to perform remote functions, such as door unlock, as commanded over
the air by the OnStar Call Center, and to continue to maintain an acceptable level of battery electrical drain.
The OnStar system uses 4 states of readiness, depending upon the type of cellular market the vehicle is in
when the ignition is put into the OFF state:
High power
Low power
Sleep
Digital standby
The high power state is in effect whenever the ignition is in the ON or RUN position, or retained accessory
power is enabled, and the OnStar system is sending or receiving calls or when the system is performing a
remote function.

The low power state is in effect when the OnStar system is idle with the ignition in the ON or RUN position,
or with retained accessory power enabled.
The sleep state is entered after the vehicle has been shut off and the retained accessory power has timed out
while in an analog cellular area. At a predetermined time recorded within the telematics communication
interface control module, the system re-enters the low power state to listen for a call from the OnStar Call
Center for 1 minute. After this interval, the system will again return to the sleep state for 9 minutes. If a call is
sent during the 1 minute interval, the OnStar system will receive the call and immediately go into the high
power mode to perform any requested functions. If no call is received during the 1 minute interval, the system
will go back into the sleep mode for another 9 minutes. This process will continue for up to 48 hours, after
which the OnStar system will turn off until the ignition is turned to the ON or RUN position.
The digital standby power state is entered after the vehicle has been shut off and the retained accessory power
has timed out while in a digital cellular area. When in digital standby mode, the OnStar module is able to
perform all remote functions as commanded by an OnStar advisor at any time, for a continuous 120 hours.
After 120 hours, the OnStar module will go into sleep mode until a wake up signal from the vehicle is seen by
the telematics communication interface control module. If the OnStar module loses the digital cellular signal it
will revert to analog mode and follow the standard sleep state (9 minutes OFF, 1 minute standby) based on the
time of the GPS signals, this will continue until a digital cellular signal is again received.
If the OnStar system loses battery power while the system is in a standby or sleep mode, the system will
remain OFF until battery power is restored and the ignition is turned to the ON or RUN position.
Features
OnStar Personal Calling

The hands free, OnStar personal calling cellular phone feature is an additional feature of the OnStar system.
This feature is embedded within the telematics communication interface control module; however it must be
activated by an OnStar advisor. OnStar personal calling operates similar to most hand held cellular phones
in that the availability for its usage is based on minutes or units. The customer must have a current OnStar
subscription, as this feature cannot be utilized without it. To use OnStar personal calling, the customer must
also purchase units (minutes) as outlined in the owners guide provided with the OnStar system. Units begin to
deplete, 1 unit is equal to 1 minute, as the customer makes outbound phone calls, answers inbound phone calls,
or while connected to the OnStar virtual advisor. In addition, units may also have an expiration date,
depending upon the type of units purchased.
Customers have the ability to store telephone numbers within the module, referenced by a nametag for the
convenience of frequently dialed numbers. After storing a nametag, the user can dial this number by initiating
the OnStar personal calling feature, speaking the word "call," and repeating the nametag assigned.
Turn by Turn Navigation
Turn by Turn Navigation allows the driver to contact OnStar to obtain directions for driving from a current
location to a desired location. The Turn by Turn Navigation system stores your planned route and continually
checks your position along that route, when you deviate from the planned route, the system will recognize this
and prompt the driver with verbal prompts for how to proceed. The driver then responds verbally to direct the
system to continue the current routing or to recalculate the route because of a missed turn.

Advisor Record Feature

The Advisor Record Feature allows the user to store any information given during a call with an OnStar
Advisor. Recording is activated by pressing the blue OnStar button during a call; pressing the button a second
time stops the recording. The stored information can be played back by pressing the phone button on the three
button assembly and using the voice command "Advisor Playback".
Deactivated OnStar Accounts
In the event a customer has not renewed their OnStar account after expiration or the account was never
activated, OnStar will make a discrete cellular call to the vehicle to deactivate the OnStar system. Before
taking this action, customers are notified that the OnStar system in their vehicle will be deactivated unless
they elect to renew the account. After the OnStar account has been deactivated, customers will experience the
following:
The OnStar status LED will not illuminate.

The OnStar system will NOT attempt to connect to the OnStar Call Center in the event of a collision
or if the vehicle's front air bags deploy for any other reason.
An emergency button press will play a demo message indicating the service has been deactivated.
An OnStar Call Center button press will connect the customer with a dedicated sales team who can sell
an OnStar subscription and reactivate the vehicle. Depending on the type of OnStar hardware in the
vehicle, the customer may first hear a demonstration message stating there is no current OnStar
subscription for the vehicle, and directing the customer what to do to activate services.
OnStar personal calling will not be available, as this feature requires the customer to have a current
OnStar account. Attempts to use this feature may result in cellular connection failure messages and the
inability to connect to the number dialed.
Certain vehicles that have never had an active OnStar account, or that have been deactivated, may be unable
to establish a connection with the OnStar Call Center. When normal published diagnostic procedures do not
indicate a possible cause for the no connect concern, the vehicle may have been deactivated. For deactivated
vehicles, a no connect response should be considered normal operation. Further diagnosis and subsequent repair
is only necessary should the customer elect to become an active OnStar subscriber or renew the account
subscription.
OnStar Cellular, GPS, and Diagnostic Limitations
The proper operation of the OnStar System is dependent on several elements outside the components
integrated into the vehicle. These include the National Cellular Network Infrastructure, the cellular telephone
carriers within the network, and the GPS.
The cellular operation of the OnStar system may be inhibited by factors such as the users range from an
analog or digital cellular tower, the state of the cellular carrier's equipment, and the location where the call is
placed. Making an OnStar key press in areas that lack sufficient cellular coverage or have a temporary
equipment failure will result in either the inability of a call to complete with a data transfer or the complete
inability to connect to the OnStar Call Center. The OnStar system may also experience connection issues if
the identification numbers for the module, station identification number, electronic serial number or
manufacturers electronic ID, are not recognized by the cellular carriers local signal receiving towers.

The satellites that orbit earth providing the OnStar system with GPS data have almost no failures associated
with them. In the event of a no GPS concern, the failure will likely lie with the inability of the system to gain
GPS signals because of its location, i.e. in a parking structure, hardware failure, or being mistaken with an
OnStar call which has reached the Call Center without vehicle data.
During diagnostic testing of the OnStar system, the technician should ensure the vehicle is located in an area
that has a clear unobstructed view of the open sky, and preferably, an area where analog or digital cellular calls
have been successfully placed. These areas can be found by successfully making an OnStar keypress in a
known good OnStar equipped vehicle and confirming success with the OnStar Call Center advisor. Such
places can be used as a permanent reference for future OnStar testing.
Mobile Identification Number and Mobile Directory Number
The telematics communication interface control module utilizes 2 numbers for cellular device identification,
call routing and connection, a mobile identification number and a mobile directory number. The mobile
identification number represents the number used by the cellular carrier for call routing purposes while the
mobile directory number represents the number dialed to reach the cellular device.
Operation of the OnStar Speech Recognition Systems
OnStar users communicate with 2 speech recognition systems. Speech recognition allows the user to speak to
one computer in the vehicle, and one reached over a phone line. The computer tries to understand the users
command, and responds by speaking back, or by taking the appropriate action, e.g. dialing the phone.
Personal Calling uses a speech recognition system that resides in the vehicle. When the user presses the
phone button, the system states, Ready, and listens for the user's command. The user can speak
commands to control the hands-free phone.
Virtual advisor is a remote speech recognition system that the caller can access by making a phone call.
The user connects to virtual advisor by requesting it during personal calling use. The user is then
transferred to the virtual advisor server and talks to it via a cellular connection.
The OnStar speech recognition systems use speech technology that is designed to understand a wide range of
American English speakers. Although there is no one right way to speak English, the system will work best
when users try to modify their pronunciation should they encounter difficulty. Users who do not obtain good
results are advised to try the tips and workarounds found in this section.
General Tips for Better Speech Recognition
Concern
Tip for Better Result
Noise
Noise may confuse the speech recognition system. You usually
get better performance from the system in quieter conditions:
The HVAC fan creates noise. Turn it down or OFF for

better speech system performance.
Driving at high speeds creates louder engine noise and
wind noise. You may get better results at lower speeds.
An open window or an open sunroof allows more noise to
enter the vehicle. Close all windows for better results.

Noisy rainstorms can also reduce performance.

If passengers are talking while you use the speech system,
it may be confused by their speech. You will get better
results if all occupants of the vehicle are quiet while the
system is listening for commands.
In Personal Calling, the system is only listening after it prompts
you to speak with a beep.
When to Speak
How to Speak
When the system prompts you to speak, you have about 5

seconds to respond. If the system does not hear a response,
it will prompt you again, or cancel the transaction.
If you begin to speak too soon, try pausing for a half
second before speaking after the beep.
In the Virtual Advisor, the system is always listening for
commands, even while it is speaking.
Speak forcefully, and clearly.
What to Say
The noisier the environment, the louder you need to speak.

If you are in the driver seat, speak facing the front of the
car. If you are a passenger, speak facing the rearview
mirror.
Speak calmly, and naturally. The system may sometimes
fail your repeated attempts to give a command. If your
speech is distorted by shouting or frustration, this may
cause more errors.
People with high-pitched voices may have better results by
speaking in a deeper, lower-pitched voice. However, do not
lower the volume of the voice.
Avoid speaking with a rising intonation, like asking a
question. Use a flat or falling intonation, like giving an
answer.
Personal Calling: One-word commands
The Personal Calling system listens for only one word at a

time. There are some exceptions, 2-word phrases that are
spoken and understood as a single word, e.g. "virtual
advisor", "voice feedback", and "my number". You can
enter phone numbers only one digit at a time, and the
system repeats each digit as it hears it.
Say "Help" at the Ready prompt to hear the list of Personal
Calling commands.
Virtual Advisor can understand sentences with more than
one word. It also expects to hear a 4-digit number all at
once when it asks for your PIN.

Entering a phone number
Storing or dialing a number
Creating nametags
Virtual Advisor 4-digit PIN

Interrupting
Say, "What are my choices?" to hear a list of commands

that the Virtual Advisor understands.
If you have trouble getting numbers correctly into the

system, store your frequently-called number in the
directory, so the system will remember them. After you
have stored a number with a nametag, then you simply say
"call" and the nametag in order to call the number.
If the system cannot understand your numbers, ask another
person to help you enter your frequently-called numbers.
This person can speak the numbers, then you can speak the
nametag.
When you have finished speaking your phone number, you do not
need to say "store" or "dial" to indicate that you are done. If you
pause and say nothing, the system will ask you if you want to
store or dial. Say "yes".
Short nametags that are similar may be easily confused by

the system. You may get better recognition of your
nametags if you make them longer, for example "George
Washington" without pause, instead of "George" only.
If you want to use nametags while driving, it is best to store
the nametag with some vehicle noise in the background. If
you are in park while you are storing nametags, you can
turn the fan on low or open windows in order to create
some background noise.
Say the 4 digits in a natural way, without pausing between digits.
When the Virtual Advisor is speaking, you can interrupt it

with another command. The first word in your command
helps to get its attention.
If the Virtual Advisor has trouble understanding your
commands when you interrupt, try speaking the first word
loudly and clearly, then pause for an instant, then continue
with the rest of the command. For example: "Get... my
weather" or "Lookup... a quote for General Motors".
RADIO/AUDIO SYSTEM DESCRIPTION AND OPERATION (WITH COLOR DISPLAY)

The entertainment system on this vehicle may have several different configurations available to it. To determine
the specific configuration of the vehicle, please see the Service Parts ID Label, and refer to RPO Code List .
Each item in the list below represents topics covered in detail below.
Radio Circuit Operation

Information Display and Controls
Antenna System

Radio Reception
Speaker Operation
Audio Amplifier (If equipped)
Theft Deterrent
Bluetooth (UP9) (if equipped)
Applications (if equipped)
Auxiliary Audio Input Jack (If equipped)
USB Port (If equipped)
Navigation System Components and Features (if equipped)
OnStar
Steering Wheel Controls (If equipped)
Auto Volume Control
Radio Power
The radio does not use a discrete ignition feed circuit for power moding. The power mode master provides the
system power mode to the radio via serial data messages. The power mode master determines the system power
mode by processing power mode information from ignition switch inputs. Serial data power modes supported
by the radio are OFF, ACCESSORY, RUN, and CRANK REQUEST.
Radio Grounds
The vehicle harness provides a ground for the radio circuits. The radio may also be case grounded.
Radio Data Link Communication
The radio communicates with other modules via serial data.
Radio Audio Outputs
Each of the audio output channel circuits (+) and (-), at the radio have a DC bias voltage that is approximately
one half of battery voltage. The audio being played on the system is produced by a varying AC voltage that is
centered around the DC bias voltage on the same circuit. The AC voltage is what causes the speaker cone to
move and produce sound. The frequency (Hz) of the AC voltage signal is directly related to the frequency of the
input (audio source playing) to the audio system. Both the DC bias voltage and the AC voltage signals are
needed for the audio system to properly produce sound.
Remote Enable Output
The remote enable circuit is a discrete 12 V signal supplied to infotainment system components when the radio
is producing audio, needs the front display on, needs video entertainment system components on, or needs to
produce chimes. This signal is used to control the power state of the components. There is no output on radio

the remote enable circuit when the vehicle is in the CRANK powermode, this is to minimize current
consumption from the attached modules and also to avoid audio pops during crank events.
Fig. 45: Radio/HVAC Communications Diagram

Callout
1
2
3
4
5
6
a
b
c
d
e
Component Name
Radio Controls
Info Display Module
Radio
HVAC Control Module
Data Link Connector
HVAC Controls
GMLAN
Local Interconnect Network- HVAC
CAN Graphical Interface
Digital Video
Touch Screen Serial Data
The info display module has continuous power and ground. When the radio is on, a discrete 12 V signal is
supplied on the remote enable circuit to the color display module. This signal is used to control the power state
of the module, which is active when the signal is high and inactive when the signal is low.
The info display module receives digital video data from the radio for on-screen display information through a
dedicated video cable. The radio communicates with the info display module over the touch screen serial data
circuits for touch screen inputs and backlighting dimming level.
The radio controls communicate radio control inputs directly to the radio through the CAN Graphical Interface
(CGI) data circuits. After receiving the message the radio will perform the requested function. Messages
communicated between the radio and the radio/HVAC controls include the following:

Button presses/knob rotations

Commands for the state of indicators
Radio control back-lighting
The HVAC controls are a separate component from the radio controls. HVAC data for controls and status
indicators is communicated between the HVAC controls and the HVAC control module with a separate LIN
serial data circuit. HVAC status screen information from the HVAC control module is transmitted to the radio
on the GMLAN serial data circuit. The radio then displays the desired screen information on the info display
using the video data circuits.
Antenna System
Multi-Band Antenna
The multi-band antenna is located on the roof of the vehicle. This type of antenna may be used with the AM/FM
radio, but is primarily for cellular and GPS signals, if the vehicle has these features. Keep this antenna clear of
snow and ice build up for clear reception. If the vehicle has a sunroof, the performance of the system may be
affected if the sunroof is open. Loading items onto the roof of the vehicle can interfere with the performance of
the system, ensure the multi-band antenna is not obstructed.
The radio antenna is enabled when the radio is turned on. The radio provides battery voltage to the antenna
using the center conductor of the antenna coaxial cable. This DC voltage does not affect the incoming radio
signal. When a 12 V signal is seen by the on the center conductor of the antenna coax, both AM and FM signals
are amplified.
Radio Reception
AM/FM Radio Signal

The radio signal is sent from a broadcast station and is then received by an antenna. The strength of the signal
received depends on the following:
The power output (wattage) of the broadcasting station

The location of the vehicle (or receiver) relative to the broadcast tower.
Height of the broadcast antenna
Height of the receiving antenna
Obstacles between the tower and the receiver
Atmospheric conditions
What band (AM or FM) the station is broadcasting
Type of antenna and the ground plane
Digital Radio Receiver (If equipped)

The XM satellite receiver is integrated into the radio. XM satellite radio provides digital radio reception. The
XM signal is broadcast from two satellites and, where necessary, terrestrial repeaters. The high power satellites

allow the antenna to receive the XM signal even when foliage and other partial obstructions block the antennas
view of the satellite. Terrestrial repeaters are used in dense urban areas. These repeaters will receive the satellite
signal and re-broadcast them at much higher power levels in order to ensure reception in areas with densely
packed tall buildings. A service fee is required in order to receive the XM service.
Radio Data System (RDS)
The RDS feature is available only on FM stations that broadcast RDS information. This system relies upon
receiving specific information from these stations and only works when the information is available. While the
radio is tuned to an FM-RDS station, the station name or call letters display. RDS data is carried in what is
known as a "subcarrier". A subcarrier is a frequency that the FM broadcaster is authorized to use to send data
that is not audible in the main audio program.
RDS functions will only work with FM broadcast stations that are broadcasting RDS data. Not all FM
Broadcast stations broadcast RDS data or offer all of the RDS services.
The information displayed is dependent upon the information broadcast by the particular station. The
information may vary greatly between stations. RDS functions may not work properly when reception is weak,
reception is of poor quality, or RDS is not implemented properly by the FM Broadcaster. In some cases, a radio
station broadcasting incorrect information may cause the RDS features of the radio to appear to work
improperly.
With RDS, the radio can do the following:
Display text information such as: station identification, type of programming, and general information
(artist and song title, station messages, call in phone numbers, etc.).
Seek to stations broadcasting the selected type of programming
Receive announcements concerning local and national emergencies
Receive alert warnings of local or national emergencies. When an alert announcement comes on the
current radio station, ALERT! displays. You will hear the announcement, even if the volume is low or a
CD is playing. If a CD is playing, play stops during the announcement. Alert announcements cannot be
turned off. ALERT! is not affected by tests of the emergency broadcast system. This feature is not
supported by all RDS stations.
Speaker Operation
Speakers turn electrical energy into mechanical energy to move air, using a permanent magnet and an
electromagnet. The electromagnet is energized when the radio or amplifier (if equipped) delivers current to the
voice coil on the speaker. The voice coil will form a north and south pole that will cause the voice coil and the
speaker cone to move in relation to the permanent magnet. The current delivered to the speaker is rapidly
changing alternating current (A/C). This causes the speaker cone to move in two directions producing sound.
Amplifier Interface
A fused battery voltage circuit provides the main amplifier power. A switched 12 V output from the radio is

used to control the power - state of the amplifier. To respond quickly to audio input and control signals, the
amplifier is ON in all vehicle power modes except OFF and CRANK Request. The internal amplifier bridges
are fully powered and unmuted when the amplifier receives the switched 12 V input.
Amplifier Operation
The purpose of the amplifier is to increase the power of a voltage or current signal. The output signal of an
amplifier may consist of the same frequencies as the input signal or it may consist of only a portion of the
frequencies as in the case of a subwoofer or midrange speaker. The radio creates a low level stereo audio output
signal, which is sent at the user-defined volume level to the audio amplifier. The audio amplifier amplifies the
signal and sends it to the appropriate speakers. Each of the audio output channel circuits (+) and (-), from the
amplifier have a DC bias voltage that is approximately one half of battery voltage. The audio being played on
the system is produced by a varying AC voltage that is centered around the DC bias voltage on the same circuit.
The AC voltage is what causes the speaker cone to move and produce sound. The frequency (Hz) of the AC
voltage signal is directly related to the frequency of the input (audio source playing) to the audio system. Both
the DC bias voltage and the AC voltage signals are needed for the audio system to properly produce sound.
Theft Deterrent
radio does not match the VIN information that has been learned by the radio. The radio receives this
information via serial data. A possible cause of incorrect VIN info could be the radio was originally installed in
another vehicle.
The radio has the following theft operating modes as part of the theft deterrent system:
Normal Mode: The radio has learned a correct VIN sequence and the VIN information received via serial
data matches the learned VIN sequence. In this mode the radio has full functionality.
No VIN Mode: The radio has not received or learned a correct VIN sequence. In this mode the radio has
limited functionality.
Theft Detected Mode: The radio has learned a correct VIN sequence and the VIN information received
via serial data does NOT match the learned VIN sequence. In this mode the radio may be disabled or have
limited functionality. The radio display will indicate that theft protection is active.
Bluetooth (UP9) (If equipped)
The available features and functions are determined by the type of device and the software within the devices
being used. For a feature or function to operate, it must be supported in both devices.
The first connection between devices is established through a process called pairing. In order to pair two
devices, a password (passkey) has to be exchanged between the two devices. One device will generate the
password, the other device accepts the password to complete the process. Once the devices are paired, future

connections between the devices will occur automatically when the devices are on and within range of each
other.
The Bluetooth hardware is internal to the radio. The radio supports streaming of data (music, voice,
information) from cellular phones and other mobile devices that support those features. The radio may also be
capable of interfacing with cellular phones for hands-free features.
The device must be paired to the radio to use the available Bluetooth feature(s). The pairing process
must only be performed once for each device, unless that device's information is deleted.
Up to five devices can be paired to the system, but only one can be connected at any given time.
Streaming Audio allows playing music from the mobile device wirelessly. Music stored on the mobile
device can be viewed and controlled from the display.
To stream audio from a mobile device, the device must be unlocked, and any additional applications
should be closed.
Refer to the vehicle owners manual, supplements, and the device manufacturers information for pairing
instructions.
Applications (If equipped)
When the system is equipped with Bluetooth , the system is capable of using applications, commonly referred
to as apps.
The term application refers to any piece of software that works on a system (hardware) that is being operated by
it's own software. Applications are typically small software programs which uses the hardware to perform a
specific task, as opposed to operating the entire system.
For an application to be used, it must be installed on both the vehicle infotainment system and a
compatible mobile device.
The device must be connected to the system. this may be done wirelessly via Bluetooth , or via the
vehicle USB port. Refer to the device manufacturers information for the proper connection method.
When the device is connected, the application on the radio is used to remotely access and control the
application on the mobile device.
The application must work correctly on the device to work with the vehicle infotainment system.
The user may be required to log-in to the application on the mobile device before using the application
from the vehicle controls.
Using applications will use the device's data plan.
The device must be unlocked, and any additional applications should be closed.
Refer to the owner's manual and supplements for information on mobile devices, control, and operation.
The infotainment system may have a 3.5mm (1/8 in.) auxiliary audio input jack located in the center console.
The auxiliary audio input jack interfaces directly with the radio. When a portable audio playback device is

connected to the auxiliary jack, an internal switch detects the connection and the radio will switch to AUX as
the audio source. Audio signals from the device are sent to the radio from the auxiliary jack via the left, right,
and common audio signal circuits.
When a device is first connected to the 3.5mm (1/8 in.) input jack the infotainment system automatically
Playback of an audio device that is connected to the 3.5mm jack can only be controlled using the controls
on the device.
USB Port (If Equipped)
The infotainment system may have a USB connector located in the center console. The USB connector
interfaces directly with the radio. The USB connector supports both USB standards 1.1 and 2.0.
USB Supported Devices:
USB Flash Sticks (Thumb Drives)

Portable USB Hard Drives
Portable Digital Media Players (iPOD, ZUNE, etc)
Depending on the USB device, some devices may not be recognized, or some features/functions may not be
able to be controlled with the radio controls. USB HUB devices are not supported.
Refer to the owner's manual for information on USB devices, control, and operation.
Navigation System Components and Features (if equipped)
The navigation system, if equipped, provides the following:
Connection to the global positioning system (GPS) antenna, which provides the vehicle position
information.
Map data for navigation and map route guidance, stored internally.
Route guidance with verbal prompts to the operator.
Traffic and weather information for display on the navigation system map (with active subscription,
where available).
Global Positioning System (GPS) Antenna

The global positioning system (GPS) antenna is part of the multi-band antenna located on the roof of the
vehicle. The GPS antenna is used to collect the signals of the orbiting GPS satellites. Within the antenna is
housed a low noise amplifier that allows for a more broad and precise reception of this data. The GPS antenna
amplifier is powered through the coaxial cable.

The antenna is connected to the navigation radio through a signal splitter. The signal splitter is a component for
dividing the navigation signal into two paths without any transmission loss. This allows the use of a single GPS
antenna to provide a signal to both the navigation radio and the telematics communication interface module.
Route Guidance
The map will display the route to the selected destination. Voice prompts alert the operator of upcoming events
(turns) and arrivals at the destination. The navigation system will automatically recalculate if the route is not
followed. The navigation radio uses data received from the global positioning system (GPS) satellites, the
vehicle speed signal. and serial data information to accurately display the current position of the vehicle.
Points of Interest
The map database provides point of interest information. Points of interests are locations that are frequently
visited. Points of interest can be can be displayed on the map or set as a destination. The following are some of
the available Points of interests:
Gas Station
Restaurant
College
Police Station
OnStar (If equipped)
When OnStar is activated, a serial data message is sent to the radio that activates a software program. When the
software begins its process, the fade goes to the front, Bass and Treble are set to the mid range, the outputs are
mono, and the audio source is OnStar. OnStar takes priority over any other audio source. All of these actions are
preset values stored in the radio.
For additional OnStar information, refer to OnStar Description and Operation.
Some audio functions are available using the steering wheel controls. The steering wheel controls duplicate the
function of the primary controls available on the radio.
For additional information on steering wheel controls, refer to Steering Wheel Controls Description and
Operation .
Auto Volume Control
With auto volume control, the audio system will adjust automatically to make up for road and wind noise as you
drive, by increasing the volume as vehicle speed increases. To use auto volume control, set the volume at the
desired level, and then select either Low, Medium, or High. To turn auto volume control off, select the Off
screen button.
RADIO/AUDIO SYSTEM DESCRIPTION AND OPERATION (WITH MONOCHROME DISPLAY)

The entertainment system on this vehicle may have several different configurations available to it. To determine
the specific configuration of the vehicle, please see the Service Parts ID Label, and refer to RPO Code List .
The entertainment system on this vehicle is configured with either a base or an uplevel system. The base and
uplevel systems each contain a radio, antenna, speakers, and on some systems an audio amplifier. The uplevel
system differs from the base system by providing the customer with enhanced audio system features.
Each item in the list below represents topics covered in detail below.

Antenna System
Radio Reception
Speaker Operation
Theft Deterrent
USB Port (If equipped)
Multimedia Player Interface Module (If equipped)
OnStar
Auto Volume Control
Radio Power
The radio does not use a discrete ignition feed circuit for power moding. The power mode master provides the
system power mode to the radio via serial data messages. The power mode master determines the system power
mode by processing power mode information from ignition switch inputs. Serial data power modes supported
by the radio are OFF, ACCESSORY, RUN, and CRANK REQUEST.
Radio Grounds
The vehicle harness provides a ground for the radio circuits. The radio may also be case grounded.
Radio Data Link Communication
The radio communicates with other modules via serial data.
Radio Audio Outputs
Each of the audio output channel circuits (+) and (-), at the radio have a DC bias voltage that is approximately

one half of battery voltage. The audio being played on the system is produced by a varying AC voltage that is
centered around the DC bias voltage on the same circuit. The AC voltage is what causes the speaker cone to
move and produce sound. The frequency (Hz) of the AC voltage signal is directly related to the frequency of the
input (audio source playing) to the audio system. Both the DC bias voltage and the AC voltage signals are
needed for the audio system to properly produce sound.
Remote Enable Output
The remote enable circuit is a discrete 12 V signal supplied to infotainment system components when the radio
is producing audio, needs the front display on, needs video entertainment system components on, or needs to
produce chimes. This signal is used to control the power state of the components. There is no output on radio
the remote enable circuit when the vehicle is in the CRANK powermode, this is to minimize current
consumption from the attached modules and also to avoid audio pops during crank events.
Radio/HVAC Communications
Fig. 46: Radio/HVAC Communication Diagram

Callout
1
2
3
4
5
6
a
b
c
d
Component Name
Radio Controls
Info Display Module
Radio
HVAC Control Module
Data Link Connector
HVAC Controls
GMLAN
Local Interconnect Network-HVAC
CAN Graphical Interface
Local Interconnect Network-Radio

The radio controls are a separate component from the radio. The radio controls contain the radio control knobs
and buttons for all audio functions.
The radio controls operate radio functions through serial data messages. The radio controls communicate to the
info display module through LIN serial data. The info display module communicates to the radio through CGI
serial data.
Messages communicated between the radio, the radio controls, and the info display include the following:
Button presses/knob rotations

Info display module dimming
Radio controls back-lighting
Graphics and text information
The HVAC controls are a separate component from the radio controls. HVAC data for controls and status
indicators is communicated between the HVAC controls and the HVAC control module with a separate LIN
serial data circuit. HVAC status screen information from the HVAC control module is transmitted to the radio
on the GMLAN serial data circuit. The radio then displays the desired screen information on the info display
using the CGI data circuits.
Antenna System
Multi-Band Antenna
The multi-band antenna is located on the roof of the vehicle. This type of antenna may be used with the AM/FM
radio, but is primarily for OnStar cellular and GPS signals and the XM Satellite Radio Service System, if
the vehicle has these features. Keep this antenna clear of snow and ice build up for clear reception. If the vehicle
has a sunroof, the performance of the system may be affected if the sunroof is open. Loading items onto the roof
of the vehicle can interfere with the performance of the system, ensure the multi-band antenna is not obstructed.
The radio antenna is enabled when the radio is turned on. The radio provides battery voltage to the antenna
using the center conductor of the antenna coaxial cable. This DC voltage does not affect the incoming radio
signal. When a 12 V signal is seen by the on the center conductor of the antenna coax, both AM and FM signals
are amplified.
Radio Reception
AM/FM Radio Signal

The radio signal is sent from a broadcast station and is then received by an antenna. The strength of the signal
received depends on the following:
The power output (wattage) of the broadcasting station

The location of the vehicle (or receiver) relative to the broadcast tower.
Height of the broadcast antenna
Height of the receiving antenna

Obstacles between the tower and the receiver

Atmospheric conditions
What band (AM or FM) the station is broadcasting
Type of antenna and the ground plane
Digital Radio Receiver (If equipped)

The XM satellite receiver is integrated into the radio. XM satellite radio provides digital radio reception. The
XM signal is broadcast from two satellites and, where necessary, terrestrial repeaters. The high power satellites
allow the antenna to receive the XM signal even when foliage and other partial obstructions block the antennas
view of the satellite. Terrestrial repeaters are used in dense urban areas. These repeaters will receive the satellite
signal and re-broadcast them at much higher power levels in order to ensure reception in areas with densely
packed tall buildings. A service fee is required in order to receive the XM service.
The RDS feature is available only on FM stations that broadcast RDS information. This system relies upon
receiving specific information from these stations and only works when the information is available. While the
radio is tuned to an FM-RDS station, the station name or call letters display. RDS data is carried in what is
known as a "subcarrier". A subcarrier is a frequency that the FM broadcaster is authorized to use to send data
that is not audible in the main audio program.
RDS functions will only work with FM broadcast stations that are broadcasting RDS data. Not all FM
Broadcast stations broadcast RDS data or offer all of the RDS services.
The information displayed is dependent upon the information broadcast by the particular station. The
information may vary greatly between stations. RDS functions may not work properly when reception is weak,
reception is of poor quality, or RDS is not implemented properly by the FM Broadcaster. In some cases, a radio
station broadcasting incorrect information may cause the RDS features of the radio to appear to work
improperly.
With RDS, the radio can do the following:
Display text information such as: station identification, type of programming, and general information
(artist and song title, station messages, call in phone numbers, etc.).
Seek to stations broadcasting the selected type of programming
Receive announcements concerning local and national emergencies
Receive alert warnings of local or national emergencies. When an alert announcement comes on the
current radio station, ALERT! displays. You will hear the announcement, even if the volume is low or a
CD is playing. If a CD is playing, play stops during the announcement. Alert announcements cannot be
turned off. ALERT! is not affected by tests of the emergency broadcast system. This feature is not
supported by all RDS stations.
Speaker Operation
Speakers turn electrical energy into mechanical energy to move air, using a permanent magnet and an

electromagnet. The electromagnet is energized when the radio or amplifier (if equipped) delivers current to the
voice coil on the speaker. The voice coil will form a north and south pole that will cause the voice coil and the
speaker cone to move in relation to the permanent magnet. The current delivered to the speaker is rapidly
changing alternating current (A/C). This causes the speaker cone to move in two directions producing sound.
Amplifier Interface
A fused battery voltage circuit provides the main amplifier power. A switched 12 V output from the radio is
used to control the power - state of the amplifier. To respond quickly to audio input and control signals, the
amplifier is ON in all vehicle power modes except OFF and CRANK Request. The internal amplifier bridges
are fully powered and unmuted when the amplifier receives the switched 12 V input.
Amplifier Operation
The purpose of the amplifier is to increase the power of a voltage or current signal. The output signal of an
amplifier may consist of the same frequencies as the input signal or it may consist of only a portion of the
frequencies as in the case of a subwoofer or midrange speaker. The radio creates a low level stereo audio output
signal, which is sent at the user-defined volume level to the audio amplifier. The audio amplifier amplifies the
signal and sends it to the appropriate speakers. Each of the audio output channel circuits (+) and (-), from the
amplifier have a DC bias voltage that is approximately one half of battery voltage. The audio being played on
the system is produced by a varying AC voltage that is centered around the DC bias voltage on the same circuit.
The AC voltage is what causes the speaker cone to move and produce sound. The frequency (Hz) of the AC
voltage signal is directly related to the frequency of the input (audio source playing) to the audio system. Both
the DC bias voltage and the AC voltage signals are needed for the audio system to properly produce sound.
Theft Deterrent
radio does not match the VIN information that has been learned by the radio. The radio receives this
information via serial data. A possible cause of incorrect VIN info could be the radio was originally installed in
another vehicle.
The radio has the following theft operating modes as part of the theft deterrent system:
Normal Mode: The radio has learned a correct VIN sequence and the VIN information received via serial
data matches the learned VIN sequence. In this mode the radio has full functionality.
No VIN Mode: The radio has not received or learned a correct VIN sequence. In this mode the radio has
limited functionality.
Theft Detected Mode: The radio has learned a correct VIN sequence and the VIN information received
via serial data does NOT match the learned VIN sequence. In this mode the radio may be disabled or have
limited functionality. The radio display will indicate that theft protection is active.

The infotainment system may have a 3.5mm (1/8 in.) auxiliary audio input jack located in the center console.
The auxiliary audio input jack may interface directly with the radio, or be connected to the infotainment system
via a Multimedia Player Interface Module. When a portable audio playback device is connected to the auxiliary
jack, an internal switch detects the connection and the radio will switch to AUX as the audio source. Audio
signals from the device are sent to the radio from the auxiliary jack via the left, right, and common audio signal
circuits.
When a device is first connected to the 3.5mm (1/8 in.) input jack the infotainment system automatically
Playback of an audio device that is connected to the 3.5mm jack can only be controlled using the controls
on the device.
USB Port (If Equipped)
The infotainment system may have a USB connector located in the center console. The USB connector may
interface directly with the radio, or be connected to the infotainment system via a Multimedia Player Interface
Module. The USB connector supports both USB standards 1.1 and 2.0.
USB Supported Devices:
USB Flash Sticks (Thumb Drives)

Portable USB Hard Drives
Portable Digital Media Players (iPOD, ZUNE, etc)
Depending on the USB device, some devices may not be recognized, or some features/functions may not be
able to be controlled with the radio controls. USB HUB devices are not supported.
Refer to the owner's manual for information on USB devices, control, and operation.
Multimedia Player Interface Module (MPIM) (If Equipped)
The vehicle may be equipped with a Multimedia Player Interface Module. This module can receive signals via
the USB connector, the auxiliary audio input jack, or a Bluetooth connection. This module receives the
incoming signals, then sends the signals as analog audio inputs to the radio.
To allow the radio controls to be used to control portable media devices (USB, Bluetooth, iPOD, ZUNE,
etc); the MPIM translates the USB signals to GMLAN signals to allow the bi-directional communication
between the radio and the device. Depending on the device, some devices may not be recognized, or some
features/functions may not be able to be controlled with the radio controls. USB HUB devices are not
supported.
OnStar (If equipped)
When OnStar is activated, a serial data message is sent to the radio that activates a software program. When the

software begins its process, the fade goes to the front, Bass and Treble are set to the mid range, the outputs are
mono, and the audio source is OnStar. OnStar takes priority over any other audio source. All of these actions are
preset values stored in the radio.
For additional OnStar information, refer to OnStar Description and Operation.
Some audio functions are available using the steering wheel controls. The steering wheel controls duplicate the
function of the primary controls available on the radio.
For additional information on steering wheel controls, refer to Steering Wheel Controls Description and
Operation .
Auto Volume Control
With auto volume control, the audio system will adjust automatically to make up for road and wind noise as you
drive, by increasing the volume as vehicle speed increases. To use auto volume control, set the volume at the
desired level, and then select either Low, Medium, or High. To turn auto volume control off, select the Off
screen button.

SPECIAL TOOLS
Illustration
Tool Number/Description
EL-50334-20
Multi-Media Interface Tester (MIT)
EL-50334-50
USB Cable and Adapter Kit
EL-48028
Digital Radio Test Antenna
EL-49903
OnStar Antenna Diagnostic Tool Kit


2013 ACCESSORIES & EQUIPMENT Cruise Control - Cruze

Cruise Control - Cruze

CRUISE CONTROL WIRING SCHEMATICS
K34 Wiring Schematics
Fig. 1: Cruise Control (K34) Wiring Schematics

Callout
1444
1444_WH/RD
CAV 6
CONN_X3
CAV_1
1444_YE
1884
Component Name
12 Volt Reference
1444 WH/RD
6
X3
1
1444 YE
Cruise Control
Set/Coast/Resume/Accelerate

1884_BN/GN
CAV_8
CAV_3
1444_WH/RD
CAV_5
CONN_X1
5737
5737_GY/GN
CAV_9
CAV_3
7556
7556_YE
CAV_4
CONN_X3
7556_YE
6311
6311_WH/BU
CAV_12
CONN_X5
CAV_33
CONN_X1
6311_WH/BU
CAV_10
SD
J200
X190
A90
K20
P16
X85
K9
S70L
Fog_Lights_Schematics_REF
Steering_Wheel_Secondary/Configurable_Control_Schematics_REF
Switch Signal
1884 BN/GN
8
3
1444 WH/RD
5
X1
Adaptive Cruise Control Gap
Up/Down Switch Signal
5737 GY/GN
9
3
Lighting Control Switch
Reference
7556 YE
4
X3
7556 YE
Cruise/ETC/TCC Brake Signal
6311 WH/BU
12
X5
33
X1
6311 WH/BU
10
Serial Data
Data Communication
Schematics
J200
X190
Logic
(K34)
Fog Lights Schematics
Steering Wheel
Secondary/Configurable
Control Schematics


DTC
DTC P0571
DTC P0572 or P0573
DTC P0575
DTC P0703
Description
DTC P0571 Cruise Control Brake Switch Circuit
DTC P0572 Brake Switch Circuit 1 Low Voltage
DTC P0573 Brake Switch Circuit 1 High Voltage
DTC P0575 Cruise Control Switch Signal Message
Counter Incorrect
DTC P0703 Brake Switch Signal Message Counter
Incorrect
DTC P0571
DTC Descriptor
DTC P0571
Cruise Control Brake Switch Circuit
The engine control module (ECM) monitors the brake pedal position sensor. When the brake pedal is applied,
the ECM detects a predetermined voltage signal. The ECM sends a serial data message to the engine control
module (BCM) indicating the status of the stop lamps.
This diagnostic test functions on the assumption that a sudden decrease in vehicle speed is caused by a brake
pedal application. When the ECM detects that there is a 4.2 km/h (2.6 mph) or greater decrease in vehicle speed
within 0.25 seconds without a transition of the stop lamp switch, the ECM sets DTC P0571.
The engine speed is greater than 700 RPM.

The traction control system or the antilock brake system are not active and have not failed.
The vehicle speed is greater than 48 km/h (30 mph).
The diagnostic will disable when the wheel speed is less than 16 km/h (10 mph).

The BCM detects either a low voltage signal on the stop lamp switch signal circuit when the serial data message
from the ECM indicates the brakes are applied, or a high voltage signal on the stop lamp switch signal circuit
when the serial data message from the ECM indicates the brakes are not applied.
The cruise control system is disabled.

The malfunction indicator lamp (MIL) will not illuminate.

A history DTC will clear after 40 malfunction-free ignition cycles have occurred.
Schematic Reference
Cruise Control Schematics

Exterior Lights Schematics
Antilock Brake System Schematics

Cruise Control Description and Operation
Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference

1. Ignition ON.

2. Verify that no DTCs are set, except DTC P0571.

If any other DTC is set, except DTC P0571
If only DTC P0571 is set
3. Replace the K20 Engine Control Module.
4. Verify DTC P0571 does not set when operating the vehicle within the conditions for running the DTC.
If the DTC sets
Replace the K 9 Body Control Module.

5. All OK.
Repair Instructions

Control Module References for BCM or ECM replacement, programming and setup.
DTC P0572 OR P0573
DTC Descriptors
DTC P0572
Brake Switch Circuit 1 Low Voltage
DTC P0573
Brake Switch Circuit 1 High Voltage
Circuit
Stop Lamp Switch Signal
Short to
Ground
C0297 02,
P0572
Open/High
Resistance
Short to
Voltage
Signal Performance
P0572
P0573
P0572, P0573

The stop lamp switch signal circuit is a B+ input from the body control module (BCM) to the engine control
module (ECM). The ECM monitors the stop lamp switch circuit to detect when the brake pedal has been
applied. The BCM monitors the brake pedal position sensor to determine when the brake pedal is applied. When
the brake pedal is applied, the BCM supplies B+ on the stop lamp switch signal circuit and also sends a serial
data message to the ECM indicating that the brake pedal has been applied.
The engine is running.

Battery voltage is greater than 11.5 V.
Brakes applied.
P0572
This DTC will set when the ECM detects a short to ground or an open on the discrete brake signal circuit when
the serial data message from the BCM indicates the brakes are applied. This diagnostic will run when the serial
data message and the voltage signal on the brake switch signal circuit do not match for 8 out 10 times, and the
condition is present for greater than 2 seconds.
P0573
This DTC will set when the ECM detects a short to voltage on the discrete brake signal circuit when the serial
data message from the BCM indicates the brakes are NOT applied. This diagnostic will run when the serial data
message and the voltage signal on the brake switch signal circuit do not match for 8 out 10 times, and the
condition is present for greater than 2 seconds.


Schematic Reference


Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference

1. Ignition OFF, disconnect the X1 harness connector at the K20 Engine Control Module, ignition ON.
2. Connect a test lamp between the signal circuit terminal 57 and ground.
3. Verify the test lamp turns ON and OFF when pressing and releasing the brake pedal.
If the test lamp is always OFF
1. Ignition OFF, disconnect the harness connector at the K9 Body Control Module.
If not infinite resistance, repair the short to ground on the circuit.
If less than 2 ohms, replace the K9 Body Control Module.
If the test lamp is always ON
1. Ignition OFF, disconnect the harness connector at the K9 Body Control Module, ignition ON.
If less than 1 V replace the K9 Body Control Module.
If the test lamp turns ON and OFF
Repair Instructions

Control Module References for BCM or ECM programming, replacement, and setup
DTC P0575
DTC Descriptor
DTC P0575
Cruise Control Switch Signal Message Counter Incorrect
When a cruise control function switch is activated, the body control module (BCM) detects a predetermined
voltage. The BCM sends a serial data message to the engine control module (ECM) indicating the function that
has been requested.
The ignition is ON.

The vehicle speed is greater than 40 km/h (25 MPH) and the cruise control is engaged.
The ECM receives an invalid cruise control switch status serial data message from the BCM.
This diagnostic runs continuously.
DTC P0575 is a type C DTC.

DTC P0575 is a type C DTC.

Schematic Reference


Circuit Testing
Connector Repairs
Wiring Repairs
DTC Type Reference

Powertrain Diagnostic Trouble Code (DTC) Type Definitions
Scan Tool Reference
1. Ignition ON.
3. Replace the K9 Body Control Module.
4. Verify DTC P0575 does not set when operating the vehicle within the Conditions for Running the DTC.
If the DTC sets
Replace the K20 Engine Control Module.

5. All OK.
Repair Instructions

Control Module References for BCM or ECM programming, replacement, and setup.

DTC P0703
DTC Descriptor
DTC P0703
Brake Switch Signal Message Counter Incorrect
The body control module (BCM) monitors the brake pedal position sensor. When the brake pedal is applied, the
BCM detects a predetermined voltage signal. The BCM sends a serial data message to the engine control
module (ECM) indicating the status of the stop lamps.
The engine is ON.

The ECM receives an invalid brake pedal status serial data message from the BCM.
This diagnostic runs continuously.


Schematic Reference


Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference

1. Ignition ON.
4. Verify DTC P0703 does not set when operating the vehicle within the conditions for running the DTC.
If the DTC sets

5. All OK.
Repair Instructions

Control Module References for BCM or ECM programming, replacement, and setup.
SYMPTOMS - CRUISE CONTROL
NOTE:
The following steps must be completed before using the symptom tables.

1. Before using the symptom diagnostic table, perform the Diagnostic System Check - Vehicle in order to
verify the following conditions:
The module can communicate via the serial data.
2. Review the system operation in order to understand the system functions. Refer to Cruise Control
Inspect for aftermarket devices which can affect the operation of the Cruise Control System. Refer to
Inspect the accessible system components or the visible system components for obvious damage or for
obvious conditions which can cause the symptom.
Intermittent
Symptom List
Cruise Control Malfunction - DTC B3794, P0564, P0565, P0567, P0568, P056C, P0580, P0581,
P155A-P155C, or P162C
Cruise Control Indicator Malfunction
CRUISE CONTROL INDICATOR MALFUNCTION

The instrument cluster illuminates the cruise control engaged indicator based on serial data messages received
from the engine control module (ECM). The indicator is commanded ON when the cruise control system is
controlling vehicle speed, and turned OFF with the system disengaged.
Schematic Reference


Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference

1. Ignition ON.
2. Verify the cruise control indicator turns ON and OFF when commanding the All Indicators ON and OFF
with a scan tool.
If the indicator does not turn ON and OFF
Replace the P16 Instrument Cluster.
If the indicator turns ON and OFF
3. All OK.
Repair Instructions

Control Module References for instrument cluster replacement, programming and setup.
CRUISE CONTROL MALFUNCTION - DTC B3794, P0564, P0565, P0567, P0568, P056C, P0580,
P0581, P155A-P155C, OR P162C

DTC Descriptors
DTC B3794 08
Cruise Control Function Request Circuit
DTC B3794 61
Cruise Control Function Request Circuit
DTC P0564
Cruise Control Multifunction Switch Circuit
DTC P0565
Cruise Control Switch Circuit
DTC P0567
Cruise Control Resume Switch Circuit
DTC P0568
Cruise Control Set Switch Circuit
DTC P056C
Cruise Control Cancel Switch Circuit
DTC P0580
Cruise Control Multifunction Switch Circuit Low Voltage
DTC P0581
Cruise Control Multifunction Switch Circuit High Voltage
DTC P155A
Cruise Control Switch State Undetermined
DTC P155B
Cruise Control Set/Coast Switch 2 Circuit
DTC P155C

Cruise Control Resume/Acceleration Switch 2 Circuit

DTC P162C
Vehicle Speed Limiting/Warning Switch Circuit
Circuit
Ignition
Signal
Short to
Ground
1
Open/High
Resistance
1
P0564
Short to
Voltage
B3794 08,
P0567, P0568
Signal Performance
B3794 61, P0564
1. Cruise Control Malfunction

The cruise control switch is an input to the body control module (BCM). The BCM monitors the cruise control
on/off, set/coast, resume/accelerate and cancel switches via the cruise control switch signal circuit in order to
detect when the driver has requested to perform a cruise control function. The BCM detects a specific voltage
signal on the cruise control switch signal circuit when a switch is applied. The engine control module (ECM)
receives the requested cruise control switch function from the BCM via a serial data message.
The cruise switch is ON.

The ignition is ON.
B3794 08
The BCM detects an invalid voltage signal on the cruise control switch signal circuit for 1 second.
B3794 61
Stuck switch for either Resume/Accel or Set/Coast button for 60 seconds.
P0564, P0565, P0567, P0568, P056C
The BCM detects an invalid voltage signal on the cruise control switch signal circuit for greater than 2
seconds and sends a serial data message to the ECM. The ECM sets these DTCs when the message is
received.
The ECM runs this diagnostic continuously.
P0580, P0581

The ECM detects an invalid voltage signal on the cruise control switch signal circuit.
The above condition is present for greater than 2 seconds.
The ECM runs this diagnostic continuously.
P155A
The ECM is unable to determine the state of the cruise control switch.
P162C
The ECM is unable to determine the state of the vehicle speed limiting switch.
B3794

P0564, P0565, P0567, P0568, P056C, P0580, P0581, P155A, P162C

DTCs P0564, P0565, P0567, P0568, P056C, P0580, P0581, P155A and P162C are type C DTCs
B3794

P0564, P0565, P0567, P0568, P056C, P0580, P0581, P155A, P162C

DTCs P0564, P0565, P0567, P0568, P056C, P0580, P0581, P155A and P162C are type C DTCs.
Schematic Reference


Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference

1. Ignition ON.
2. Verify the scan tool ECM Cruise Control Switch Status parameter changes between Off and On, Resume
and Set when switching between each position on the cruise control switch.
If the parameter does not change
Refer to Circuit/System Testing.
If the parameter changes
3. All OK.
NOTE:
An open ignition circuit or fuse before the control module will cause
communication DTCs or power mode mismatch DTCs to set against or in
the control module. This failure mode will be diagnosed in the no
communications diagnostic procedure or power mode mismatch.
This test assumes the ignition circuit has a driver that will open under a
high current condition before the fuse opens.
The driver can open under normal conditions such as battery run down
protection or a retained accessory power mode.
1. Ignition OFF, disconnect the harness connector at the S70L Steering Wheel Controls Switch-Left,
ignition ON.
2. Verify a test lamp illuminates between the ignition circuit terminal 1 and ground.
2. Test for greater than 100 ohms between the ignition circuit and ground.
If 100 ohms or less, repair the short to ground on the circuit.


3. Test for less than 2 ohms in the ignition circuit end to end.
If less than 2 ohms, test or replace the K9 Body Control Module.
Verify the scan tool ECM Cruise Control Switch Status parameter is Off.
If not Off
If less than 1 V, replace the K9 Body Control Module.
If Off
Install a 3 A fused jumper wire between the signal circuit terminal 3 and the ignition circuit terminal 1.
Verify the scan tool ECM Cruise Control parameter is Disabled.
If not Error
2. Test for infinite resistance between the signal circuit terminal 9 and ground.
If Error
Test or replace the S70L Steering Wheel Controls Switch-Left.
3.
4.
5.
6.
Repair Instructions

Control Module References for BCM replacement, programming and setup.
REPAIR INSTRUCTIONS
CRUISE CONTROL SWITCH REPLACEMENT

Fig. 2: Cruise Control Switch & Steering Wheel Lower Cover Fasteners
Cruise Control Switch Replacement
Callout
Component Name
Remove the steering wheel lower cover. Refer to Steering Wheel Spoke Lower Cover Replacement .
Steering Wheel Lower Cover Fastener (Qty: 2)
1
CAUTION:
Cruise Control Switch Assembly

Procedure

CRUISE CONTROL DESCRIPTION AND OPERATION
Cruise control is a speed control system that maintains a desired vehicle speed under normal driving conditions
at speeds above 40 km/h (25 mph). Steep grades may cause variations in the selected vehicle speeds.
The following are the main components of the Cruise Control System:
The accelerator pedal

The brake pedal position (BPP) sensor

The body control module (BCM)
The cruise on/off switch
The cruise control cancel switch
The + RES switch (equivalent to resume/accel switch)
The - SET switch (equivalent to set/coast switch)
The engine control module (ECM)
The throttle actuator control (TAC) motor
The vehicle speed sensor
The body control module (BCM) monitors the signal circuit of the cruise control switches, which are located on
the steering wheel. The BCM relays the cruise control switch status to the engine control module (ECM) via the
serial data circuit. The ECM uses the status of the cruise control switch to determine when to capture and
maintain the vehicle speed. The ECM monitors the vehicle speed signal circuit in order to determine the desired
vehicle speed.
Voltage is supplied to the cruise control switch via the steering wheel control switch reference voltage circuit
supplied by the BCM. The cruise control function switches are arranged in a resistive ladder design, with each
cruise control function switch having a different resistance value. The BCM detects a specific voltage value that
is associated with the cruise control function switch being activated. The BCM sends a serial data message to
the ECM indicating that the on/off switch is active. Similarly, when the normally open + RES switch or the
normally open - SET switch are pressed, the switch closes and the BCM detects the predetermined voltage
signal on the cruise control resume/accel and set/coast switch signal circuit. The BCM sends a serial data
message to the ECM indicating that the + RES 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
The Cruise Control System will engage and adjust vehicle speeds, based on the activation of the following
cruise control switches, which are located on the steering wheel:
On/Off
+ RES
- SET
To engage the Cruise Control System, ensure that the vehicle speed is above 40.2 km/h (25 mph), turn the
cruise On/Off switch ON and momentarily press the - SET switch. The ECM will engage the Cruise Control
System and record the vehicle speed. The ECM sends a serial data message to the instrument panel cluster
(IPC) in order to illuminate the Cruise Engaged indicator in the IPC. Refer to the vehicle owner's manual for the
location and operation of the cruise control On/Off indicators and driver information center (DIC) messages.
Pressing the accelerator pedal while the Cruise Control System is engaged, allows the driver to override the
Cruise Control System in order to accelerate the vehicle beyond the current set vehicle speed. When the
accelerator pedal is released, the vehicle will decelerate and resume the current set vehicle speed.

The driver can also override the current set vehicle speed via the - SET switch and the + RES switch. When the
Cruise Control System is engaged, pressing and holding the - SET switch will allow the vehicle to decelerate
from the current set vehicle speed without deactivating the Cruise Control System. When the - SET switch is
released, the ECM will record the vehicle speed and maintain the vehicle speed as the new set vehicle speed.
When the Cruise Control System is engaged, momentarily pressing the - SET switch will allow the vehicle to
decelerate at 1.6 km/h (1 mph) increments for each time that the - SET is momentarily pressed, with a minimum
vehicle speed of 38 km/h (24 mph).
Pressing and holding the + RES switch, when the Cruise Control System is engaged, will allow the vehicle to
accelerate to a greater vehicle speed than the current set vehicle speed. When the + RES switch is released, the
ECM will record the vehicle speed and maintain the vehicle speed as the new set vehicle speed. When the
Cruise Control System is engaged, momentarily pressing the + RES switch will allow the vehicle to accelerate
at 1.6 km/h (1 mph) increments for each time that the + RES switch is momentarily pressed. Momentarily
activating the + RES switch will recall the previous vehicle speed, after the cruise control system has been
disengaged by pressing the brake pedal, or CANCEL switch.
Cruise Control Disengaged
The engine control module (ECM) disengages the cruise control operation based on the signals from the
following switches:
The brake pedal position (BPP) sensor

The On/Off switch
The cruise control cancel switch
The Cruise Control System will disengage when the brake pedal is applied. The body control module (BCM)
monitors the BPP sensor via the BPP sensor signal circuit as the voltage signal increases while the pedal reaches
the fully applied position. The ECM monitors the BPP signal through a discrete input and a serial data message
signal from the BCM indicating the brake status. When either signal indicates the brake pedal is applied, the
ECM will disengage the cruise control system.
The Cruise Control System will also disengage when the cruise control on/off switch is switched OFF, or the
cruise control cancel switch is activated. The body control module (BCM) determines when the cruise control
cancel switch is activated. When the normally open cancel switch is closed, the BCM detects the predetermined
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, or the ignition
switch is turned OFF. The BCM sends a serial data message to the ECM in order to disengage the cruise control
system. When the Cruise Control System has been disengaged, the ECM sends a serial message to the
instrument panel cluster (IPC) in order to turn OFF the Cruise Engaged indicator.
Every time the Cruise Control System is disengaged, the ECM will keep track of the reason for system
disengagement. The last 8 disengagement reasons will be recorded within the ECM memory. The scan tool will
display the last 8 Cruise Disengage History parameters, in which one out of approximately 50 possible reasons
will be displayed in each of these 8 parameters. For the disengagement reason to be displayed within the scan
tool parameter the Cruise Control System is active and disengagement is requested.
When engagement of the system is requested but an engagement inhibit is present, the most recent inhibit

reason is recorded in the ECM history. The scan tool will display the most recent inhibit reason, in which one
out of approximately 50 possible reasons will be displayed.
Cruise Control Inhibited
The engine control module (ECM) inhibits the cruise control operation when any of the following conditions
exist:
The ECM has not detected a brake pedal activation from the body control module (BCM) this ignition
cycle.
A Cruise Control System DTC has been set.
The vehicle speed is less than 38.6 km/h (24 mph).
The vehicle speed is too high.
The vehicle is in PARK, REVERSE, NEUTRAL, or 1st gear.
The engine RPM is low.
The engine RPM is high.
The system voltage is not between 9 volts and 16 volts.
The Antilock Brake System (ABS)/Traction Control System (TCS) is active for more than 0.5 seconds.
Cruise Control Inhibit Reasons
This is a general list of inhibit reasons. Not every inhibit reason is applicable to all vehicles. Refer to the scan
tool inhibit reason list for the last 8 reasons that have been recorded during the current ignition cycle.
Scan Tool Name
BRAKE
Description
Brake pedal apply
PEDAL INITIALIZE
Brake before cruise
CANCEL
CLUTCH
Cancel switch active

Clutch switch active
COAST DISENGAGE
Coast disengage
COAST SPEED LOW
Coast below low speed inhibit
Long Description
Brake Pedal was applied.
The brake pedal has not been seen as
applied prior to driver request to
engage cruise with set switch. A
brake pedal apply must be seen
before allowing cruise engagement
during each key cycle. On a vehicle
equipped with a manual
transmission, a clutch pedal apply
may satisfy the brake pedal apply
criteria.
Cancel Switch was depressed.
Clutch Pedal was applied.
Cruise control is in coast mode with
the Set/Coast switch depressed and is
requesting no throttle
Set / Coast switch was depressed.
Vehicle slowed below minimum
cruise operating speed.

TAC INHIBIT
ACCEL RATE
DECEL RATE
HIGH SPEED
ILLEGAL MODE
LOW SPEED
NONE
CRUISE SW. OFF
OVER SET SPEED
S/C ON SPEED HI
ECM INHIBIT
SIMUL S/C-R/A
TCS
UNDER SET SPEED
DLC OVERRIDE
MEMORY DTC
ENG RUN TIME
Electronic Throttle Control has

detected a failure in the throttle
control hardware
High acceleration
Vehicle acceleration rate is too high.
High deceleration
Vehicle deceleration rate is too high.
Vehicle speed exceeds high speed Vehicle speed has exceeded
threshold
maximum cruise operating speed
Cruise control mode is incorrect
Illegal cruise mode
based on switch states.
Vehicle speed dropped below the
cruise control minimum operating
speed. May be due to hilly terrain
Vehicle speed drops below low
and low vehicle speed. Manual
speed threshold
transmission gear selection and
engine torque may contribute to this
disengagement reason.
This disengagement reason may be
displayed after a dead battery repair
None
or module replacement.
On/Off switch in Off state
Cruise On/Off switch turned Off
Vehicle speed has exceeded driver
selected set speed by more than an
allowable amount. This may occur
Over schedule
while driving down a significant
grade or driver overriding cruise
while performing a passing
maneuver.
Set/Coast switch selected, vehicle
speed is above set speed and does
Over schedule tap-down
not decrease. May be due to
traveling down hill
PCM/ECM inhibit (RAM
ECM internal communication error
corruption)
SET and RESUME switches
Set/Coast and Resume Accelerate
simultaneously active
switches pressed simultaneously
Traction control active
Traction Control was Active
Vehicle speed is below cruise control
Under schedule
set speed by more than an allowable
amount
Scan Tool plugged into ALDL
ALDL
connector
Control module memory failure
Memory Failure
detected.
Engine has not been running long
Engine run time not elapsed
enough, typically five seconds.
ETC prevents cruise operation

ENGINE SPEED
DTC SET
RPM LIMIT
FIRST GEAR
APP OVERRIDE
LOW VOLTAGE
LOST FWD GEAR
MPH LIMIT
SW. INVALID
HIGH VOLTAGE
D WHL SPD LOW
D WHL SPD HI
CRUISE S/W
CRUISE SW DATA
ECT OVERTEMP
VSES
AXLE RANGE
TRANS DTC
BPP DATA
BPP DTC
PARK BRAKE
Engine RPM too low (near stall) or

too high (near engine RPM fuel
shutoff).
Malfunction in PCM/ECM (DTC DTC is active or in history that
active)
inhibits cruise control operation.
Injectors Disabled (Engine
Engine RPM limiter active with fuel
overspeed fuel cut-off active)
cut off active.
1st Gear
Transmission is engaged in 1st gear
Driver has overridden cruise control
Pedal greater than cruise (override) set speed with accelerator pedal for
greater than an allowable time.
Voltage below low voltage
Ignition Voltage Low at ECM
threshold
(typically 9 volts)
Transmission in neutral. Reverse or
Gear selector not in forward gear
park
MPH Limited Fuel (Vehicle
Vehicle overspeed protection active
overspeed fuel cut-off active)
with fuel cut off active
Analog cruise switch input out of Cruise switch voltage signal in
range
invalid range
Voltage above high voltage
Ignition Voltage High at ECM
threshold
(typically 18 volts)
Non Driven wheel speed greater than
Un-driven Whl speed Greater
driven wheel speed
Driven Whl Spd Greater (wheel
Driven wheel speed greater than Non
slip detection)
Driven wheel speed (slip detection)
Cruise control software execution
Sequence of completion checks
error has occurred.
Cruise switch serial data fault is
Serial data fault (Cruise switch
active or communication has been
serial communication fault)
lost with module sending cruise
switch states
Engine over temperature.
Engine metal overtemp active
Overheated.
Vehicle stability active
Vehicle Stability Control was active
Rear Axle Low
Rear axle in low range
Transmission DTC is active or in
Trans Gear Fault
history that inhibits cruise control
operation
Serial data fault is active or
DTC P0703 active or maximum
communication has been lost with
time elapsed without receiving
module sending brake pedal apply
valid Brake Pedal Position signal.
state
Brake Pedal Apply Circuit fault has
Brake Pedal Position signal invalid
been detected.
Park Brake Switch signal Active Parking Brake Applied
Engine speed too low or too high

ACC INHIBIT
ACC BRAKE INOP
ACC OPTION
ACC DATA
PTO ACTIVE
ECM RESET
Ram DTC
BPP Not Learned
Accel Time
4WD Low
M/T Gear Changed
Brk Ped Press
SL/W Sys On
Calc Eng Torque

Cruise Brk Inop
Auto Brk Data
Adaptive Cruise Control Inhibited Adaptive Cruise Control Inhibited

Adaptive Cruise Control
Adaptive Cruise Control Automatic
Automatic Braking Failed
Braking Inoperative
Cruise control type (adaptive cruise
Adaptive Cruise Control option
or conventional cruise) mismatched
mismatch
between ECM and BCM.
Serial data fault for Adaptive
Adaptive Cruise Control Module
Cruise Control Throttle Control
serial data fault is active or
and Brake Control signals sent by communication has been lost
Adaptive Cruise Control module between ACC module and ECM.
Power Take Off Active
Power Take Off is active.
ECM Running Reset
ECM Running Reset occurred
Processor Integrity Fault (Ram
ECM software error has occurred
corruption)
Brake Apply Sensor Home
Position Not Learned
Released Position Not Learned.
Cruise torque request rate limiting
Rate Limiting Fault
active too long
4WD Low
Transfer case in low range
Manual transmission shifted to
Manual transmission out of gear
Neutral without clutch pedal being
with no clutch pedal apply
applied.
A Brake Pedal Apply has been
Brake Pedal Driver Applied
detected based on brake pedal
Pressure Detected
pressure as measured by the EBCM.
Driver has turned on the Speed
Limiter/Warning on/off switch.
Speed Limiter / Warning On/Off
Cruise is disabled / inhibited and
switch turned on
cruise on/off switch will be set to
OFF.
Engine torque calculation is
Calculated Torque
incorrect.
EBCM has detected a failure that
Brake System Malfunction
does not allow automatic braking to
be performed.
Automatic Braking Engine Torque ECM to EBCM serial data fault is
Request Signal Communication
active or communication has been
Malfunction
lost between ECM and EBCM.

2013 ACCESSORIES & EQUIPMENT Data Communications - Cruze

Data Communications - Cruze
SPECIFICATIONS
Specification
Application
Body Control Module Bracket Bolt

DATA COMMUNICATION WIRING SCHEMATICS
Low Speed GMLAN Wiring Schematics
Fig. 1: Low Speed GMLAN Wiring Schematics

Metric
2.5 N.m
English
22 lb in

Callout
CAV_20
540
540_RD/BU
5060
5060_GN
CAV_23
CONN_X7
CAV_6
CONN_X1
CAV_3
CONN_X1
5060 BU
CAV_11
CONN_X3
5060_GN
5060_WH
CAV_2
5060_WH
CAV_3
5060_GN
5060_GN
840
840_RD/BU
2150
2150_BK
2150_BK
5043
5043_BN/WH
5060 GN
CAV_16
CAV_4
CAV_5
CAV_7
CAV_1
5060_GN
CAV_22
CONN_X2
5060_GN
CAV_15
CONN_X1
5060 GN
Component Name
20
540 RD/BU
Low Speed GMLAN Serial Data
5060 GN
23
X7
6
X1
3
X1
5060 BU
11
X3
5060 GN
5060 WH
2
5060 WH
3
5060 GN
5060 GN
840 RD/BU
Ground
2150 BK
2150 BK
Keyword 2000 Serial Data
5043 BN/WH
5060 GN
16
4
5
7
1
5060 GN
22
X2
5060 GN
15
X1

CAV_1
CONN_X1
CAV_26
5060_GN
CAV_8
5060_GN
CAV_14
CONN_X1
5060_GN
CAV_3
CONN_X2
5060 GN
CAV_8
CONN_X1
5060_GN
KTA
ULS
UE1
5060_GN
CAV_18
CAV_11
KA1
AL0
ATH
UD7
ATH
AL0
KA1
UD7
UD7
AL0
ATH
KA1
CAV_78
CAV_55
5060 GN
1
X1
26
5060 GN
8
5060 GN
14
X1
5060 GN
3
X2
5060 GN
8
X1
5060 GN
AUDIO INTERFACESTEERING COLUMN LOCK-MECHANICAL
COMMUNICATION SYSTEM-VEHICLE, ONSTAR
5060 GN
18
11
HEATER SEAT FRT-DRVR and PASS
LOCK CONTROL, ENTRY-REMOTE ENTRY,
EXTENDED RANGE, PASSIVE ENTRY, ALL
DOORS
PARK ASSIST-REAR
DOORS
PARK ASSIST-REAR
PARK ASSIST-REAR
DOORS
78
55

2ORMOREOFAL0
ATH
KA1
UD7
G201
F14DA
X310
X320
J317
J313
J204
X200
X200
K9
P16
A11
K33
X84
K36
T11
K73
K60
K29
K84
K41R
X51A
K85
High Speed GMLAN Wiring Schematics

DOORS
PARK ASSIST-REAR
G201
F14DA 7.5A
X310
X320
J317
J313
J204
X200
X200
(KTA)
(UE1)
(ULS)
(KA1)
(ATH)
(UD7)

Fig. 2: High Speed GMLAN Wiring Schematics

Callout
2500
2500 BU
CAV_24
CONN_X2
2501
2501_WH
CAV_23
2500_BU
CAV_18
CAV_24
CONN_X6
2501_WH
CAV_19
CAV_25
2500_BU
CAV_7
CONN_X1
Component Name
High Speed GMLAN Serial Data (+) (1)
2500 BU
24
X2
High Speed GMLAN Serial Data (-) (1)
2501 WH
23
2500 BU
18
24
X6
2501 WH
19
25
2500 BU
7
X1

CAV_29
CONN_X1
2501_WH
CAV_8
CAV_43
2501_WH
2500_BU
2501_WH
CAV_5
CAV_14
2500_BU
CAV_3
CONN X1
CAV_6
CONN_X1
2501_WH
CAV_9
CAV_4
2500_BU
CAV_11
CAV_2
CONN_X1
2501_WH
CAV_18
CAV_10
2500_BU
CAV_6
CAV 12
2500_BU
CAV 10
CONN_X1
CAV_25
CONN_X1
2501_WH
CAV_12
CAV_24
2500_BU
CAV_5
CAV_3
CONN_X2
2501_WH
C V 17
29
X1
2501 WH
8
43
2501 WH
2500 BU
2501 WH
5
14
2500 BU
3
X1
6
X1
2501 WH
9
4
2500 BU
11
2
X1
2501 WH
18
10
2500 BU
6
12
2500 BU
10
X1
25
X1
2501 WH
12
24
2500 BU
5
3
X2
2501 WH

CAV_4
UE1
UE1
CAV_6
CAV_14
2501_WH
2500_BU
2501_WH
2500_BU
2501_WH
2500_BU
2501 WH
2500_BU
2501_WH
2500_BU
UE1
UE1
UE1
UE1
MH8
MH9
MH8
MH9
MH8
MH9
MH8
MH9
MF3
MZ0
MF3
MZ0
X190
CAV_13
CAV_14
X100
17
4
6
14
2501 WH
2500 BU
2501 WH
2500 BU
2501 WH
2500 BU
2501 WH
2500 BU
2501 WH
2500 BU
TRANSMISSION-AUTO 6 SPD, HMD, X23F
TRANSMISSION-MAN 6 SPD, OPEL, 76.5 MM, 4.273 1ST,
2.158 2ND, 1.302 3RD, 0.959 4TH, 0.744 5TH, 0.614 6TH, M32-6
WR
TRANSMISSION-MAN 6 SPD, OPEL, 76.5 MM, 3.82 1ST, 0.74
6TH, (M32 WR)
2.158 2ND, 1.302 3RD, 0.959 4TH, 0.744 5TH, 0.614 6TH, M32-6
WR
6TH, (M32 WR)
X190
13
14
X100

CAV_12
CAV_11
X114
CAV_C
CAV_D
X114
CAV_A
CAV_B
X100
CAV_10
CAV_9
X200
CAV 88
CAV_87
TWIST_5.5
TWIST_5.5
TWIST_5.5
TWIST_5.5
TWIST_5.5
TWIST_5.5
TWIST_5.5
TWIST_5.5
TWIST_5.5
TWIST_5.5
TWIST_5.5
TWIST_5.5
TWIST_5.5
TWIST 5.5
X190
X100
X114
X114
X100
X200
K9
Q8
K20
K43
T12
K73
K17
K27
12
11
X114
C
D
X114
A
B
X100
10
9
X200
88
87
5.5
5.5
5.5
5.5
5.5
5.5
5.5
5.5
5.5
5.5
5.5
5.5
5.5
5.5
X190
X100
X114
X114
X100
X200
(MH8/MH9)
(MH8/MH9)
(UE1)

X84
Chassis Expansion Bus Wiring Schematics
Fig. 3: Chassis Expansion Bus Wiring Schematics

Callout
6105
6105_BU/YE
CAV_3
6106
6106_WH
CAV 1
6106_WH
CAV_2
6105_BU/YE
CAV_4
6106_WH
CAV_6
Component Name
High Speed GMLAN Serial Data (+) (2)
6105 BU/YE
3
High Speed GMLAN Serial Data (-) (2)
6106 WH
1
6106 WH
2
6105 BU/YE
4
6106 WH
6

CAV_1
6105_BU/YE
CAV_5
CAV_3
6105_BU/YE
6106_WH
6106_WH
6105_BU/YE
CAV_12
CAV_13
X200
CAV_19
CAV 20
CAV_81
CAV_82
TWIST_9
TWIST_9
TWIST_9
TWIST_9
TWIST_9
X200
K17
B99
X84
B119
Enable Serial Data Wiring Schematics
1
6105 BU/YE
5
3
6105 BU/YE
6106 WH
6106 WH
6105 BU/YE
12
13
X200
19
20
81
82
9
9
9
9
9
X200
(FX3)
(FX3)

Fig. 4: Enable Serial Data Wiring Schematics

Callout
5985
5985 VT/YE
CAV_18
CONN_X1
CAV_22
CONN_X4
5985_VT/YE
5985_VT/YE
5985_BU
5985_BU
5985_VT/YE
CAV_13
CONN_X1
5985_BU
5986
5986_WH/BU
CAV_8
Component Name
Accessory Wakeup Serial Data
5985 VT/YE
18
X1
22
X4
5985 VT/YE
5985 VT/YE
5985 BU
5985 BU
5985 VT/YE
13
X1
5985 BU
Serial Data Communication Enable
5986 WH/BU
8

CAV_23
5986_WH/BU
CAV_1
CONN_X1
5986_WH/BU
CAV_7
CONN_X2
5986_WH/BU
CAV_8
5986_WH/BU
5986_WH/BU
5986_WH/BU
5986 WH/BU
CAV_80
CAV_L
CAV_13
CAV_11
LUV
LUW
LWE
LUV
LUV
LUW
LWE
LUW
LWE
MH8
MH9
MF3
MZ0
X200
23
5986 WH/BU
1
X1
5986 WH/BU
7
X2
5986 WH/BU
8
5986 WH/BU
5986 WH/BU
5986 WH/BU
5986 WH/BU
80
L
13
11
ENGINE-GAS, 4 CYL, 1.4L, MFI, DOHC, TURBO, VVT,
ALUM, GME, E85 MAX
ENGINE-GAS, 4 CYL, 1.8L, MFI, 103KW, DOHC, E85
MAX
ENGINE-GAS, 4 CYL, 1.8L, MFI, DOHC, VVT, 103
KW, GME
ALUM, GME, E85 MAX
ALUM, GME, E85 MAX
MAX
KW, GME
MAX
KW, GME
TRANSMISSION-MAN 6 SPD, OPEL, 76.5 MM, 4.273
1ST, 2.158 2ND, 1.302 3RD, 0.959 4TH, 0.744 5TH, 0.614
6TH, M32-6 WR
1ST, 0.74 6TH, (M32 WR)
X200

X114
X100
X190
J119
J311
Q8
T12
K9
K20
K17
K43
K73
K27
X114
X100
X190
J119
J311
(MH8/MH9)
(MH8/MH9)
(UE1)
Linear Interconnect Network (LIN) Serial Data Wiring Schematics
Fig. 5: Linear Interconnect Network (LIN) Serial Data Wiring Schematics

Callout
6132
Component Name
Linear Interconnect Network Bus 1

6132_GN/BN
CAV_4
CAV_16
CONN_X6
6134
6134_GN/YE
CAV_5
CAV_10
6134_GN/YE
CAV_5
6135
6135_GN/GY
CAV 1
CAV_21
CONN_X2
7531
7531_GN/YE
CAV_1
CAV_4
CONN_X2
6135_GN/GY
CAV_1
6134_GN/YE
CAV_4
7532
7532_GN/BU
CAV_4
CAV 3
6135_GN/GY
6135 GN/GY
6135_GN/GY
6135_GN/GY
6134_GN/YE
6134_GN/YE
6134_GN/YE
6134_GN/YE
6132_GN/BN
CAV_4
CAV_18
CAV_15
CAV_51
C V 9
6132 GN/BN
4
16
X6
6134 GN/YE
5
10
6134 GN/YE
5
6135 GN/GY
1
21
X2
7531 GN/YE
1
4
X2
6135 GN/GY
1
6134 GN/YE
4
7532 GN/BU
4
3
6135 GN/GY
6135 GN/GY
6135 GN/GY
6135 GN/GY
6134 GN/YE
6134 GN/YE
6134 GN/YE
6134 GN/YE
6132 GN/BN
4
18
15
51

CAV_9
AXG
AEC
CF5
C67
C68
UDY
X211
X500
X600
X200
X700
X800
J315
J501
J314
K61
M74D
S79D
S79P
S79LR
S79RR
K33
P17
A22
K9
A26
9
9
WINDOW-POWER OPERATED-EXPRESS DRIVER
UP/DOWN
WINDOW-POWER OPERATED, DRIVER EXPRESS
DOWN
ROOF-SUN, GLASS, SLIDING, ELEC
HVAC SYSTEM-AIR CONDITIONER FRT,
ELECTRONIC CONTROLS
HVAC SYSTEM-AIR CONDITIONER FRT, AUTO,
ELECTRONIC CONTROLS
"INFOTAINMENT DISPLAY-COLOR INFO DISPLAY
(CID) 7"", WVGA, TOUCH SCREEN"
X211
X500
X600
X200
X700
X800
J315
J501
J314
(CF5)
BODY CONTROL SYSTEM WIRING SCHEMATICS

Power, Ground, Data Communications, and Subsystem References (1 of 4) Wiring Schematics

Fig. 6: Power, Ground, Data Communications, and Subsystem References (1 of 4) Wiring Schematics
Callout
CAV_44
CAV 45
CAV_26
CAV_35
CAV_34
CAV_33
1440
1440_RD/BN
CAV_20
CONN_X4
CAV_72
CONN_X2
2640
2640_RD/VT
CAV_4
CONN_X5
CAV_68
Component Name
44
45
26
35
34
33
1440 RD/BN
20
X4
72
X2
2640 RD/VT
4
X5
68

2740
2740_RD/WH
CAV_3
CAV_67
2140
2140_RD/GY
CAV_1
CONN_X2
2240
2240_RD/BN
CAV_4
CONN_X1
2540
2540_RD/KBU
CAV_3
CONN_X2
2840
2840_RD/GY
CAV_4
2440
2440_RD/GN
CAV_2
CONN_X1
2340
2340_RD/YE
CAV_3
2501
2501_WH
CAV_19
CONN_X6
CAV_25
2500
2500_BU
CAV_18
CAV_24
5060
5060_GN
CAV_22
CONN_X2

2740 RD/WH
3
67
2140 RD/GY
1
X2
2240 RD/BN
4
X1
2540 RD/KBU
3
X2
2840 RD/GY
4
2440 RD/GN
2
X1
2340 RD/YE
3
Data (-) (1)
2501 WH
19
X6
25
Data (+) (1)
2500 BU
18
24
Data
5060 GN
22
X2

5060_GN
CAV_23
CONN_X7
6135
6135_GN/GY
CAV_21
CONN_X2
6132
6132_GN/BN
CAV 16
CONN_X6
6134
6134_GN/YE
CAV_10
2501_WH
CAV_24
CONN X1
2500_BU
CAV 25
2501_WH
CAV_23
CONN_X2
2500_BU
CAV_24
5986
5986_WH/BU
CAV_23
CONN_X4
5985
5985_VT/YE
CAV 22
CF5
981_BK
CAV_26
1650
1650_BK
5060 GN
23
X7
Bus 4
6135 GN/GY
21
X2
Bus 1
6132 GN/BN
16
X6
Bus 3
6134 GN/YE
10
2501 WH
24
X1
2500 BU
25
2501 WH
23
X2
2500 BU
24
Serial Data Communication
Enable
5986 WH/BU
23
X4
Accessory Wakeup Serial
Data
5985 VT/YE
22
ROOF-SUN, GLASS,
SLIDING, ELEC
981 BK
26
Ground
1650 BK

CAV_3
CONN_X6
1650_BK
CAV_1
CONN_X1
850
850_BK
CAV_2
CONN_X2
G100
G202
G307
F69UA
F32UA
F31UA
F23DA
F24DA
F3DA
F10DA
F9DA
F8DA
X50A
K9
X51A
Subsystem References (2 of 4) Wiring Schematics
3
X6
1650 BK
1
X1
Ground
850 BK
2
X2
G100
G202
G307
F69UA 5A
F32UA 20A
F31UA 20A
F23DA 20A
F24DA 20A
F3DA 25A
F10DA 30A
F9DA 30A
F8DA 30A
Data Communication
Schematics

Fig. 7: Subsystem References (2 of 4) Wiring Schematics

Callout
7554
7554_YE
CAV_11
CONN_X2
28
28_BN/WH
CAV_19
CONN_X5
2268
2268_BN/GY
CAV_14
CONN_X4
860
860_WH/VT
Component Name
Park Lock Solenoid Soft
Control
7554 YE
11
X2
Horn Relay Control
28 BN/WH
19
X5
Control
2268 BN/GY
14
X4
Front Windshield Wiper
Switch High Signal
860 WH/VT

CAV_24
CONN_X5
294_BN/YE
CAV_4
3271
3271_GY/GN
CAV_2
24
X5
Windshield Wiper Motor
Relay Coil Supply Voltage
91 GY
16
X4
High Signal
1715 GY
20
X3
Low Signal
1714 YE/BU
13
Low Reference
6009 BK/GY
10
Signal
94 WH/BK
25
Park Switch Signal
196 BN/GN
17
X4
Door Lock Actuator Lock
Control 2
5911 GY
1
X6
Door Lock Actuator
Unlock Control
294 BN/YE
4
Door Lock Control (2)
3271 GY/GN
2
3267
Child Security Lock Relay
91
91_GY
CAV_16
CONN_X4
1715
1715_GY
CAV_20
CONN X3
1714
1714_YE/BU
CAV_13
6009
6009_BK/GY
CAV_10
94
94_WH/BK
CAV_25
196
196 BN/GN
CAV_17
CONN X4
5911
5911_GY
CAV_1
CONN_X6
294

3267_VT/YE
CAV_8
CONN_X4
3287
3287_GN/WH
CAV_18
CONN_X3
7553
7553_VT/BK
CAV_6
CONN_X7
780
780_BN/YE
CAV_19
CONN_X2
781
781_BN/WH
CAV 15
1303
1303_VT/GY
CAV 5
CONN_X6
5737
5737_GY/GN
CAV_9
CONN_X3
7556
7556_YE
CAV_4
CONN_X3
6819
6819_GN/WH
CAV_8
Control
3267 VT/YE
8
X4
Horn Switch Signal
3287 GN/WH
18
X3
Park Lock Solenoid
Control
7553 VT/BK
6
X7
Driver Door Lock Switch
Lock Signal
780 BN/YE
19
X2
Unlock Signal
781 BN/WH
15
Lift Gate Ajar Switch
Signal (1)
1303 VT/GY
5
X6
Adaptive Cruise Control
Gap Up/Down Switch
Signal
5737 GY/GN
9
X3
Reference
7556 YE
4
X3
Steering Wheel Resistor
Ladder Signal #2
6819 GN/WH
8

3277
3277_GN/GY
CAV 1
7533
7533_GN/VT
CAV_2
3276
3276_GY/BK
CAV_3
109
109_BN/GN
CAV_24
CONN_X4
3272
3272_GY/WH
CAV_25
CONN_X2
3275
3275_BU/WH
CAV_27
3273
3273_GY
CAV_16
3274
3274_YE/GN
CAV_26
CONN_X1
MH8
MH8
Horn_Schematics_REF
Wiper/Washer_Schematics_REF
Horn Schematics REF
Vehicle Anti-Theft System

Immobilizer Return
3277 GN/GY
1
Linear Interconnect
Network Bus 11
7533 GN/VT
2
Immobilizer Supply
Voltage
3276 GY/BK
3
Hood Ajar Switch Signal
109 BN/GN
24
X4
Remote Function Actuator
Supply Voltage
3272 GY/WH
25
X2
Receive Signal
3275 BU/WH
27
Return
3273 GY
16
Transmit Signal
3274 YE/GN
26
X1
TRANSMISSION-AUTO
6 SPD, HMD, X23F
TRANSMISSION-AUTO
6 SPD, HMD, X23F
Horn Schematics
Wiper/Washer Schematics
Horn Schematics
Shift Lock Control

Shift_Lock_Control_Schematics_REF
Steering_Wheel_Secondary/Configurable_Control_Schematics_REF
Immobilizer_Schematics_REF
Remote_Function_Schematics_REF
Schematics
Steering Wheel
Secondary/Configurable
Control Schematics
Immobilizer Schematics
Remote Function
Schematics
K9
Automatic_Transmission_Controls_Schematics_REF
Door_Lock/Indicator_Schematics_REF
Cruise_Control_Schematics_REF
Automatic Transmission
Controls Schematics
Door Lock/Indicator
Schematics
Door Lock/Indicator
Schematics

Callout
Component Name

1969
1969_BN/VT
CAV 18
CONN_X5
712
712_YE
CAV_2
CONN_X4
312
312_YE
CAV_1
6817
6817_YE
CAV_8
CONN_X2
6817_YE
CAV_9
CONN_X7
5065
5065_VT/WH
CAV_11
CONN_X4
1134
1134_BU/VT
CAV_15
CONN_X7
524
524_WH
CAV_11
CONN_X3
307
307_YE/BN
CAV_17
306
Headlamp High Beam Relay

Control
1969 BN/VT
18
X5
Left Headlamp Low Beam
Supply Voltage
712 YE
2
X4
Right Headlamp Low Beam
Supply Voltage
312 YE
1
LED Backlight Dimming
Control
6817 YE
8
X2
6817 YE
9
X7
Stop Lamp Relay Coil Supply
Voltage
5065 VT/WH
11
X4
Park Brake Switch Signal
1134 BU/VT
15
X7
Headlamp Dimmer Switch High
Beam Signal
524 WH
11
X3
Headlamp Switch Flash To Pass
Signal
307 YE/BN
17
Headlamp Switch Headlamps
Off Signal Control

306_GN/BN
CAV_11
CONN_X1
103
103_WH/VT
CAV_16
13
13_GN/GY
CAV_22
278
278_WH/BU
CAV_10
CONN_X2
1317
1317_BN/WH
CAV_13
CONN_X5
7555
7555_WH/BN
CAV 9
CONN_X1
6846
6846_GN/YE
CAV_13
CONN_X4
309
309_GY/BN
CAV_5
709
709_VT/GY
CAV_6
7542
7542_GY/YE
CAV_7
7541
7541_WH/YE
CAV_7
306 GN/BN
11
X1
Headlamp Switch On Signal
103 WH/VT
16
Headlamp Switch Park Lamp
Signal
13 GN/GY
22
Ambient Light Sensor Signal
278 WH/BU
10
X2
Fog Lamp Relay Control
1317 BN/WH
13
X5
Lighting Control Switch Signal
7555 WH/BN
9
X1
Rear License Lamp Supply
Voltage
6846 GN/YE
13
X4
Right Park Lamp Supply
Voltage
309 GY/BN
5
Left Park Lamp Supply Voltage
709 VT/GY
6
Left Rear Stop Lamp Supply
Voltage
7542 GY/YE
7
Right Rear Stop Lamp Supply
Voltage
7541 WH/YE
7

CONN_X5
1315
1315 GN/VT
CAV_3
CONN_X4
1314
1314_BU/WH
CAV_2
CONN_X5
1334
1334_BU/WH
CAV_1
1335
1335_BU/VT
CAV_4
CONN_X4
663
663_WH/GN
CAV_12
CONN_X3
664
664_VT/BU
CAV_24
111
111_GN/WH
CAV_26
CONN_X2
1717
1717_BU/VT
CAV_17
CONN_X1
6311
6311_WH/BU
CAV_12
CONN_X5
1324
X5
Right Front Turn Signal Lamp
Supply Voltage
1315 GN/VT
3
X4
Left Front Turn Signal Lamp
Supply Voltage
1314 BU/WH
2
X5
Left Rear Turn Signal Lamp
Supply Voltage
1334 BU/WH
1
Right Rear Turn Signal Lamp
Supply Voltage
1335 BU/VT
4
X4
Hazard Switch Left Turn Signal
663 WH/GN
12
X3
Hazard Switch Right Turn
Signal
664 VT/BU
24
Hazard Switch Signal
111 GN/WH
26
X2
Hazard Switch Turn Flasher
Control
1717 BU/VT
17
X1
Cruise/ETC/TCC Brake Signal
6311 WH/BU
12
X5
Backup Lamp Supply Voltage

1324_GN/WH
CAV_3
CONN_X7
5361
5361_BU/YE
CAV_7
CONN_X2
5359
5359_WH
CAV_13
5360
5360 BK/BN
CAV_19
CONN_X1
Exterior_Lights_Schematics_REF
Interior_Lights_Dimming_Schematics_REF
1324 GN/WH
3
X7
Brake Apply Sensor Signal
5361 BU/YE
7
X2
Brake Apply Sensor Supply
Voltage
5359 WH
13
Brake Apply Sensor Low
Reference
5360 BK/BN
19
X1
Interior Lights Dimming
Schematics
K9
Headlights/Daytime_Running_Lights_(DRL)_Schematics_REF
Hydraulic_Brake_Schematics_REF
Exterior Lights Schematics REF
Exterior Lights Schematics REF
Headlights/Daytime Running
Lights (DRL) Schematics
Hydraulic Brake Schematics


Callout
5103
5103 GN/BK
CAV_16
CONN_X7
7546
7546_YE
CAV_9
CONN_X4
3
3_VT/BK
CAV 12
1594
1594_BN/VT
CAV_15
5076
Component Name
Technology Identification
5103 GN/BK
16
X7
Logistics Relay Control
7546 YE
9
X4
Run/Crank Ignition 1
Voltage
3 VT/BK
12
Ignition 3 Relay Control
1594 BN/VT
15
Current Sensor Supply
Voltage

5076_BU/VT
CAV_21
5075
5075_WH/YE
CAV_18
5077
5077_BK/VT
CAV_6
CONN_X5
746
746_GY
CAV 14
CONN_X7
745
745_GY
CAV_25
1073
1073_WH/BK
CAV_22
CONN_X3
1020
1020 WH/VT
CAV_15
4
4_VT/YE
CAV_5
3_VT/BK
CAV_6
728
728_GY
CAV_21
CONN_X1
6188
6188_GY/YE
CAV_11
CONN_X5
5076 BU/VT
21
Current Sensor Signal
5075 WH/YE
18
Current Sensor Low
Reference
5077 BK/VT
6
X5
Right Front Door Ajar
Switch Signal
746 GY
14
X7
Left Front Door Ajar
Switch Signal
745 GY
25
Ignition Key Resistor
Signal
1073 WH/BK
22
X3
Off/Run/Crank Voltage
1020 WH/VT
15
Accessory Voltage
4 VT/YE
5
3 VT/BK
6
Security Indicator Control
728 GY
21
X1
Lift Glass/Trunk Motor
Release Control
6188 GY/YE
11
X5
Rear Closure Handle

5797
5797_YE/BU
CAV_15
CONN_X6
737
737_GN/GY
CAV_7
CONN_X7
6815
6815_WH/BN
CAV_2
157
157 GY
CAV_1
6998
6998_GN/BN
CAV_19
328
328_GY/GN
CAV_14
CONN_X1
3572
3572_WH/BN
CAV_5
CONN_X7
ATH
3573
3573_BU
CAV_15
ATH
K9
Switch Open Signal

5797 YE/BU
15
X6
Trunk Lamp Control
737 GN/GY
7
X7
Inadvertent Power Control
6815 WH/BN
2
Interior Lamp Control
157 GY
1
Inadvertent Load 1 Supply
Voltage
6998 GN/BN
19
Interior Lamp Defeat
Switch Signal
328 GY/GN
14
X1
Driver Door Unlatch
Enable Signal
3572 WH/BN
5
X7
LOCK CONTROL,
ENTRY-REMOTE
ENTRY, EXTENDED
RANGE, PASSIVE
ENTRY, ALL DOORS
Non Driver Door Unlatch
Enable Signal
3573 BU
15
LOCK CONTROL,
ENTRY-REMOTE
ENTRY, EXTENDED
RANGE, PASSIVE
ENTRY, ALL DOORS

Power_Moding_Schematics_REF
Starting_and_Charging_Schematics_REF
Theft_Deterrent_System_Schematics_REF
Interior_Lights_Dimming_Schematics_REF
Power_Distribution_Schematics_REF
Release_Systems_Schematics_REF
Power Moding Schematics

Starting and Charging
Schematics
Theft Deterrent System
Schematics
Interior Lights Dimming
Schematics
Door Lock/Indicator
Schematics
Power Distribution
Schematics
Release Systems
Schematics
Door Lock/Indicator
Schematics

DTC
Control Module U Code List
DTC B1000
DTC B1001
DTC B101D
DTC B101E
DTC C056D
DTC C056E
DTC P0601-P0604, P0606, or P062F
DTC U0001
DTC U0020
DTC U0073 or U2100
Description
DTC B1000 Electronic Control Unit
DTC B1001 Option Configuration
DTC B101D Electronic Control Unit Hardware
DTC B101E Electronic Control Unit Software
DTC C056D Electronic Control Unit Hardware
DTC C056E Electronic Control Unit Software
DTC P0601 Control Module Read Only Memory
Performance
DTC P0603 Control Module Long Term Memory
Reset
DTC P0604 Control Module Random Access
Memory Performance
DTC P062F Control Module Long Term Memory
Performance
DTC U0001 00 High Speed CAN Communication
Bus Malfunction
DTC U0020 Low Speed CAN Bus
DTC U0073 Control Module Communication Bus A
Off

DTC U0074
DTC U0077
DTC U0078
DTC U2100 CAN Bus Communication

DTC U0074 Control Module Communication Bus B
Off
DTC U0077 00 Control Module Communication
Chassis Expansion CAN Bus Off
DTC U0078 Control Module Communication Low
Speed CAN Bus Off
DTC U0100-U02FF
DTC U0300-U0336
DTC U0400-U05FF
DTC U1500-U15FF
DTC U1814
DTC U18B9-U18BF
DTC U2099
DTC U1814 Powertrain Wake-Up Communication

Circuit
DTC U18B9 Primary High Speed CAN Bus Subnet
Configuration List
DTC U18BF Secondary High Speed CAN Bus
Subnet Configuration List
DTC U2099 High Speed Communication Enable
Circuit
CONTROL MODULE U CODE LIST

This list includes all Data Communications related U-code DTCs in alphanumeric order with descriptors for all
devices. Not all DTCs listed will be applicable to all vehicles.
For symptom byte information, refer to Symptom Byte List .
Control Module U Code List
DTC
DTC Descriptor
U0001
High Speed CAN Bus Malfunction
U0002
High Speed CAN Bus
U0020
Low Speed CAN Bus
U0028
MOST Bus
U0029
MOST Bus Performance
U0073
Control Module Communication Bus A Off
U0074
Control Module Communication Bus B Off
U0075
Control Module Communication Object Detection CAN Bus Off
U0077
Control Module Communication Chassis Expansion CAN Bus Off
U0078
Control Module Communication Low Speed CAN Bus Off
Control Module Communication High Voltage Energy Management CAN
U007A
Bus Off
U0100
Lost Communication With Engine Control Module
U0101
Lost Communication With Transmission Control Module

U0102
U0103
U0104
U0105
U0109
U010E
U010F
U0111
U0112
U0115
U0117
U0121
U0122
U0125
U0126
U0128
U0129
U012A
U0130
U0131
U0132
U0133
U0136
U0137
U0139
U0140
U0146
U0151
U0155
U0158
U0159
U0160
U0164
U0166
U0167
U0168
U016B
U0170
U0181
U0182
Lost Communication with Transfer Case Control Module

Lost Communication with Shift Lever Module
Lost Communication With Cruise Control Module
Lost Communication with Fuel Injector Control Module
Lost Communication with Fuel Pump Control Module
Lost Communication with Reductant Sensor Module
Lost Communication with Air Conditioning Control Module
Lost Communication with Battery Energy Control Module
Lost Communication with Battery Energy Control Module
Lost Communication with Engine Control Module B
Lost Communication With Power Take-Off Control Module
Lost Communication With Electronic Brake Control Module
Lost Communication With Vehicle Stability Control Module
Lost Communication With Multi-axis Acceleration Sensor Module
Lost Communication With Steering Wheel Angle Sensor Module
Lost Communication With Park Brake Control Module
Lost Communication with Brake System Control Module
Lost Communication With Chassis Control Module
Lost Communication With Electric Power Steering Control Module
Lost Communication With Power Steering Control Module
Lost Communication With Suspension Control Module
Lost Communication With Air Suspension Control Module
Lost Communication With Differential Control Module - Rear
Lost Communication with Trailer Brake Control Module
Lost Communication With Suspension Control Module
Lost Communication With Body Control Module
Lost Communication with Infotainment Gateway Module
Lost Communication With Inflatable Restraint Sensing and Diagnostic
Module
Lost Communication With Instrument Cluster
Lost Communication With Head-Up Display
Lost Communication With Parking Assist Control Module
Lost Communication With Chime Alarm Control Module
Lost Communication with HVAC Control Module
Lost Communication with Auxiliary Heater Control Module
Lost Communication with Immobilizer Control Module
Lost Communication With Keyless Entry Control Module
Lost Communication with Electric A/C Compressor Control Module
Lost Communication with Passenger Presence Detection Sensor Module
Lost Communication With Headlamp Leveling Control Module
Lost Communication With Lighting Control Module - Front

U0184
U0186
U0196
U0191
U0193
U0197
U0198
U0201
U0203
U0204
U0207
U0208
U0209
U0210
U0230
U0232
U0233
U0236
U0237
U023A
U0248
U0249
U0250
U0252
U0254
U0255
U0256
U0257
U0264
U0265
U0268
U0269
U026A
U026B
U0293
U029D
U029E
U0301
Lost Communication With Radio

Lost Communication With Speaker Amplifier Module
Lost Communication With Rear Audio Control Module
Lost Communication With Television
Lost Communication With Digital Radio Receiver Control Module
Lost Communication With Telephone Control Module
Lost Communication With Telematic Control Module
Lost Communication With Transfer Case Control Module
Lost Communication With Left Rear Door Switch Panel Control Module
Lost Communication With Right Rear Door Switch Panel Control Module
Lost Communication With Moveable Roof Control Module
Lost Communication with Seat Memory Control Module
Lost Communication With Front Seat Heating Control Module
Lost Communication With Rear Seat Heating Control Module
Lost Communication With Liftgate Control Module
Lost Communication with Side Object Detection Control Module - Left
Lost Communication with Side Object Detection Control Module - Right
Lost Communication With Steering Column Lock Module
Lost Communication With Multimedia Player Interface Module
Lost Communication With Vehicle Direction Camera Control Module
(without UGN)
Lost Communication With Active Safety Control Module (with UGN)
Lost Communication with Remote Accessory Module
Lost Communication with Entertainment Control Module - Rear
Lost Communication with Impact Classification System Module
Lost Communication With Trailer Interface Control Module
Lost Communication With Remote Start Module
Lost Communication With Info Display Module
Lost Communication With Infotainment Faceplate Control Module
Lost Communication With Info Display Module/Infotainment Faceplate
Control Module
Lost Communication With Camera Module - Rear
Lost Communication with Left Front Short Range Radar Sensor Module
Lost Communication with Right Front Short Range Radar Sensor Module
Lost Communication with Front Long Range Object Sensor
Lost Communication with Frontview Camera Module
Lost Communication with Rear Short Range Object Sensor
Lost Communication with Hybrid/EV Powertrain Control Module
Lost Communication with NOx Sensor 1 Module
Lost Communication with NOx Sensor 2 Module
Software Incompatibility with Engine Control Module

U0302
U0305
U0315
U0401
U0402
U0403
U0405
U0415
U0416
U0417
U0418
U0420
U0421
U0422
U0423
U0424
U0428
U0431
U0432
U0437
U0438
U0452
U0465
U0499
U053B
U056B
U0594
U1501
U1502
U1505
U150E
U150F
U1510
Software Incompatibility with Transmission Control Module

Software Incompatibility With Cruise Control Module
Software Incompatibility with Electronic Brake Control Module
Invalid Data Received From Engine Control Module
Invalid Data Received From Transmission Control Module
Invalid Data Received From Transfer Case Control Module
Invalid Data Received From Cruise Control Module
Invalid Data Received From Electronic Brake Control Module
Invalid Data Received From Vehicle Dynamics Control Module
Invalid Data Received From Park Brake Control Module
Invalid Data Received From Brake System Control Module
Invalid Data Received From Power Steering Control Module
Invalid Data Received From Suspension Control Module
Invalid Data Received From Body Control Module
Invalid Data Received From Instrument Cluster
Invalid Data Received From HVAC Control Module
Invalid Data Received From Steering Wheel Angle Sensor Module
Invalid Data Received From Body Control Module "A"
Invalid Data Received From Multi-axis Acceleration Sensor Module
Invalid Data Received From Differential Control Module - Rear
Invalid Data Received From Trailer Brake Control Module
Invalid Data Received From Inflatable Restraint Sensing and Diagnostic
Module
Invalid Data Received From Power Take-Off Control Module
Invalid Data Received From Telematic Control Module
Invalid Data Received From Active Safety Control Module
Invalid Data Received From Camera Module - Front
Invalid Data Received From Hybrid/EV Powertrain Control Module
LIN Bus 1
LIN Bus 2
LIN Bus 5
LIN Bus 14
LIN Bus 15
(K9 Body Control Module) LIN Bus 1 Lost Communication With Device 0
(B67 Ultrasonic Intrusion Sensor)
(K33 HVAC Control Module) LIN Bus 1 Lost Communication With Device
0 (A26 HVAC Controls)
(A11 Radio) LIN Bus 1 Lost Communication with Device 0 (A20
Radio/HVAC Control)
(P16 Instrument Cluster) LIN Bus 1 Lost Communication with Device 0
(S70R Steering Wheel Controls Switch - Right)
(K26 Headlamp Control Module / K28 Headlamp Leveling Control Module)

U1511
U1512
U1513
U1514
U1515
U1516
U1517
U1518
U1519
U151A
U151B
U151C
U1520
U1521
U1522
U1523
U1524
U1526
LIN Bus 1 Lost Communication With Device 1 (E13L Headlamp - Left)

(K40 Seat Memory Control Module) LIN Bus 1 Lost Communication With
Device 1 (K99 Steering Column Position Control Module)
LIN Bus 1 Lost Communication With Device 2 (E13R Headlamp - Right)
(M75 Windshield Wiper Motor)
(B110 Battery Sensor Module)
(K62 Sunroof Sunshade Motor Module)
(P16 Instrument Cluster) LIN Bus 1 Lost Communication with Device 8 (P29
Head-Up Display)
Device 9 (S52 Outside Rearview Mirror Switch)
Device 9 (K96 Mirror Control Module / K96L Mirror Control Module - Left)
(B117 Rain Sensor)
(K61 Sunroof Control Module)
Device 11 (S79P Window Switch - Passenger)
(K33 HVAC Control Module) LIN Bus 1 Lost Communication With Device
0 (K33A HVAC Control Module - Auxiliary)
(P25 Power Sounder Content Theft Deterrent Alarm Module)
(K65 Tire Pressure Indicator Module)
(K29F Seat Heating Control Module - Front)

U152C
U152D
U1530
U1531
U1532
U1534
U1538
U153A
U1540
U1544
U1548
U154A
U154B
U1556
U15E1
U15E3
U15F0
U1793
U1795
U179A
U1803
U1804
U1806
(K29R Seat Heating Control Module - Rear)

(K18 Compass Module)
(P2 Transmission Shift Lever Position Indicator)
(M74P Window Motor - Passenger)
LIN Bus 3 Lost Communication with Device 1 (E13LA Headlamp Assembly
- Left)
LIN Bus 3 Lost Communication with Device 2 (E13RA Headlamp Assembly
- Right)
(M74D Window Motor - Driver)
(S79D Window Switch - Driver)
(S79P Window Switch - Passenger)
(M74RR Window Motor - Right Rear)
(M74LR Window Motor - Left Rear)
(S79LR Window Switch - Left Rear)
(S79RR Window Switch - Right Rear)
(K49 Rear Seat Control Module)
(K38 Chassis Control Module) LIN Bus 5 Lost Communication with Device
6 (K133 Trailer Brake Power Control Module)
(A11 Radio) LIN Bus 14 Lost Communication with Device 1 (A26 HVAC
Controls)
(A11 Radio) LIN Bus 14 Lost Communication with Device 3
(K74 Human Interface Control Module) LIN Bus 15 Lost Communication
with Device 0 (P17 Info Display Module)
14V Power Module Lost Communication with Hybrid/EV Powertrain
Control Module on Powertrain Expansion Communication Bus
14V Power Module Powertrain Expansion Communication Bus Off
Lost Communication with Hybrid/EV Powertrain Control Module 2
Lost Communication with Hybrid/EV Powertrain Control Module 2
Lost Communication with Inside Rearview Mirror Control Module
Battery Energy Control Module High Voltage Energy Management CAN
Bus Off

U1807
U180A
U180B
U180C
U180D
U1811
U1814
U1815
U1816
U1817
U1818
U1821
U1826
U1827
U182A
U182D
U182E
U182F
U1831
U1833
U1838
U1839
U183A
U183B
U183C
Battery Charger Control Module High Voltage Energy Management CAN

Bus Off
Electric A/C Compressor Control Module High Speed CAN Bus Off
Battery Energy Control Module High Speed CAN Bus Off
Battery Charger Control Module High Speed CAN Bus Off
Electronic Brake Control Module Chassis Expansion CAN Bus Off
Battery Energy Control Module Powertrain Expansion CAN Bus Off
Powertrain Wake-Up Communication Circuit
Lost Communication with Drive Motor Control Module 1 on Bus B
Lost Communication with Drive Motor Control Module B on Bus B
Lost Communication with Hybrid/EV Powertrain Control Module on
Powertrain Expansion CAN Bus
Lost Communication with Engine Control Module on Powertrain Expansion
Communication Bus
Lost Communication with 14V Power Module on Powertrain Expansion
Communication Bus
Lost Communication with Multi-Axis Acceleration Sensor Module on
Powertrain Expansion CAN Bus
Lost Communication with Steering Angle Sensor Module on Powertrain
Expansion CAN Bus
Hybrid/EV Powertrain Control Module Lost Communication with Battery
Energy Control Module on Powertrain Expansion CAN Bus
Lost Communication with Hybrid/EV Powertrain Control Module 2 on
Powertrain Expansion Communication Bus
Drive Motor Control Module 1 Lost Communication with Hybrid/EV
Powertrain Control Module 2 on Powertrain Expansion Communication Bus
Powertrain Control Module 2 on Powertrain Expansion Communication Bus
Powertrain Control Module on Powertrain Expansion CAN Bus
Lost Communication with Electronic Brake Control Module on Chassis
Expansion CAN Bus
Lost Communication with Battery Charger Control Module on High Voltage
Energy Management CAN Bus
Auxiliary Transmission Fluid Pump Control Module Lost Communication
with Engine Control Module
Lost Communication with Telematics Communication Interface Control
Module on High Speed CAN Bus
with Transmission Control Module
with Hybrid/EV Powertrain Control Module 2 on Powertrain Expansion
Communication Bus
Lost Communication with Telematics Communication Interface Control

U183E
U1844
U1845
U1846
U1847
U1849
U184A
U184B
U184C
U184D
U184E
U184F
U1850
U1858
U185A
U185B
U185C
U185D
U185E
U1860
U1861
U186A
U186B
Module on Low Speed CAN Bus

Battery Energy Control Module Lost Communication with Hybrid/EV
Powertrain Control Module on Bus B
Drive Motor Control Module 1 Lost Communication with Battery Energy
Control Module on Powertrain Expansion CAN Bus
Drive Motor Control Module 1 Lost Communication with Transmission
Control Module
Lost Communication with Body Control Module on Low Speed CAN Bus
Lost Communication with Remote Heater and Air Conditioning Control
Lost Communication with Instrument Cluster on Low Speed CAN Bus
Lost Communication with Radio on Low Speed CAN Bus
Lost Communication with Inflatable Restraint Sensing and Diagnostic
Electric A/C Compressor Control Module Lost Communication with Engine
Control Module
Drive Motor Control Module 2 Lost Communication with Transmission
Control Module
Electronic Brake Control Module Lost Communication with Hybrid/EV
Powertrain Control Module on Chassis Expansion CAN Bus
Lost Communication with Battery Energy Control Module on High Voltage
Energy Management CAN Bus
Powertrain Control Module 2 on High Voltage Energy Management CAN
Bus
Battery Charger Control Module Lost Communication with Hybrid/EV
Powertrain Control Module 2 on High Voltage Energy Management CAN
Bus
Fuel Injector Control Module Lost Communication with Engine Control
Module
Fuel Injector Control Module Lost Communication with Body Control
Module
Electric A/C Compressor Control Module Lost Communication with
Hybrid/EV Powertrain Control Module 2
Battery Charger Control Module Lost Communication with Engine Control
Module
Electronic Brake Control Module Lost Communication with Engine Control
Module
Electronic Brake Control Module Lost Communication with Transmission
Control Module

U1875
U1876
U1879
U1885
U1886
U1888
U18A1
U18A2
U18A3
U18A4
U18A5
U18B9
U18BF
U1900
U1901
U2098
U2099
U209E
U209F
U2100
U2101
U2103
U2105
U2106
U2107
U2108
U2125
U2127
U2139
U2144
U2176
U2178
Drive Motor Control Module 1 Lost Communication with Battery Energy

Control Module
Drive Motor Control Module 1 Lost Communication with Engine Control
Module
Drive Motor Control Module 2 Lost Communication with Engine Control
Module
Battery Energy Control Module Lost Communication with Engine Control
Module
Hybrid/EV Powertrain Control Module Lost Communication with Battery
Energy Control Module
Lost Communication with Coolant Temperature Control Module on High
Voltage Energy Management CAN Bus
Lost Communication with Fuel Pump Driver Control Module
Lost Communication with Human Machine Interface Control Module
Lost Communication with Hybrid/EV Battery DC Charging Communications
Gateway Module on High Voltage Energy Management CAN Bus
Lost Communication with Fuel Injector Control Module on Powertrain
Expansion CAN Bus
Primary High Speed CAN Bus Subnet Configuration List
Secondary High Speed CAN Bus Subnet Configuration List
Lost Communication With Speech to Text Interface Module
Lost Communication with Infotainment Multifunction Switch Module
MOST Communication Enable Circuit
High Speed Communication Enable Circuit
Object Detection Control Module High Speed Communication Enable
Circuit 1
Object Detection Control Module High Speed Communication Enable
Circuit 2
CAN Bus Communication
CAN Bus Maximum List of Control Modules
Fewer Controllers On Bus Than Programmed
Lost Communication with Engine Control Module
Lost Communication with Transmission Control Module
Lost Communication with Body Control Module
Lost Communication with Electronic Brake Control Module
Lost Communication with Telematic Unit
Lost Communication with Front HVAC Control Module
Lost Communication with Column Integration Module
Lost Communication with Distance Sensing Cruise Control Module
Lost Communication with Power Take-Off Control Module
Lost Communication With Trailer Interface Control Module

U2400
U2401
U2501
U2502
U2503
U2504
U2505
U2506
U2507
U2508
U2602
U2603
U2604
U2605
U2606
U2608
U2609
U2611
U2612
U2613
U2614
U2615
U2616
U2617
U2618
U2619
Fuel Injector Control Module High Speed CAN Bus Off

Battery Energy Control Module Dedicated Bus 1 Off
Invalid Data Received From Hybrid/EV Powertrain Control Module 2
Invalid Data Received From Electronic Brake Control Module on Chassis
Expansion CAN Bus
Invalid Data Received From Object Detection Control Module
Invalid Data Received From Trailer Brake Driver Control Module
Invalid Data Received from Human Machine Interface Control Module on
MOST Bus
Invalid Data Received From Dual Battery Control Module
Invalid Data Received from Instrument Cluster on MOST Bus
Invalid Data Received from Audio Amplifier on MOST Bus
Powertrain Control Module 2
Battery Interface Control Module 1
Electric A/C Compressor Control Module Lost Communication with
Hybrid/EV Powertrain Control Module
with Hybrid/EV Powertrain Control Module
Drive Motor 1 Control Module Lost Communication with Hybrid/EV
Drive Motor 2 Control Module Lost Communication with Hybrid/EV
with Hybrid/EV Powertrain Control Module 2
Fuel Pump Driver Control Module Lost Communication with ECM

U2620
U2621
U2622

DTC B1000
DTC Descriptor
DTC B1000
Electronic Control Unit
The internal fault detection is handled inside the device. The symptom byte information is for engineering
reference only. No external circuit diagnosis is involved.
The device runs the program to detect an internal fault when power up is commanded. The only requirements
are voltage and ground. This program runs even if the voltage is out of the valid operating range.
The device has detected an internal malfunction.

The device refuses all additional inputs.

A current DTC clears when the malfunction is no longer present.

A history DTC clears when the device ignition cycle counter reaches the reset threshold of 50, without a
repeat of the malfunction.
Diagnostic Aids

This DTC may be stored as a history DTC without affecting the operation of the device.
If stored only as a history DTC and not retrieved as a current DTC, do not replace the device.
If this DTC is retrieved as both a current and history DTC, replace the device that set the DTC.
Schematic Reference
Data Communication Schematics

Control Module References

Data Link Communications Description and Operation
Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference

1. Ignition ON.
If DTC B1000 is set
Replace the device that set the DTC.
3. All OK
Repair Instructions

Control Module References for device replacement, programming and setup

DTC B1001
DTC Descriptor
DTC B1001
Option Configuration
Some devices must be configured with serial numbers, vehicle options, or other information. If a device was not
properly configured after installation that device may set DTC B1001. The symptom byte information is for
engineering reference only. No external circuit diagnosis is involved.
Battery voltage is between 9-16 V and data link communications operate normally.
The device is not configured properly.


A history DTC clears when the device ignition cycle counter reaches the reset threshold, without a repeat
of the malfunction.
Schematic Reference



Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference

1. Ignition ON.
If DTC B1001 is set
1. Program the device that set the DTC.
2. Verify the DTC does not set.
If the DTC sets, replace the device that set the DTC.
3. All OK.
3. All OK
Repair Instructions

DTC B101D

DTC Descriptor
DTC B101D
Electronic Control Unit Hardware
The device runs the program to detect an internal fault when power up is commanded. The only
requirements are voltage and ground. This program runs even if the voltage is out of the valid operating
range.
The keyless entry control module will set this DTC with symptom byte 39 when the keyless entry control
module antenna is activated.



Diagnostic Aids
Do not replace a device based only on DTC B101D being set in history with the exception of the
following devices:
K36 Inflatable Restraint Sensing and Diagnostic Module (SDM)
K85 Passenger Presence Detection Module
If DTC B101D is set as current, replace the appropriate device.
Schematic Reference



Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference

1. Ignition ON.
2. Verify DTC B101D is not set.
If DTC B101D is set with symptom byte 43
3. All OK.
If DTC B101D is set with any symptom byte, except symptom byte 43
If DTC B101D is not set
3. All OK
Repair Instructions


DTC B101E
DTC Descriptor
DTC B101E
Electronic Control Unit Software
Some devices must be configured with specific software, serial numbers, vehicle options, or other information.
If a device was not properly configured after installation that module may set DTC B101E. The symptom byte
information is for engineering reference only. No external circuit diagnosis is involved.


of the malfunction.
Schematic Reference




Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference

1. Ignition ON.
2. Verify that DTC U0028 or U0029 is not set.
If any of the DTCs are set
If none of the DTCs are set
3. Verify DTC B101E is not set.
If DTC B101E is set
3. All OK.
If DTC B101E is not set
4. All OK
Repair Instructions

DTC C056D

DTC Descriptor
DTC C056D
Electronic Control Unit Hardware
The device runs the program to detect an internal fault when power up is commanded. The only requirements
are voltage and ground. This program runs even if the voltage is out of the valid operating range.



Diagnostic Aids
If this DTC is retrieved as both a current and history DTC, replace the device that set the DTC.
Schematic Reference


Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference

1. Ignition ON.
2. Verify DTC C056D is not set.
If DTC C056D is set in a device that can be programmed
3. All OK.
If DTC C056D is set in a device that cannot be programmed
If DTC C056D is not set
3. All OK
Repair Instructions


DTC C056E
DTC Descriptor
DTC C056E
Electronic Control Unit Software
If a device was not properly configured after installation that module may set DTC C056E. The symptom byte
information is for engineering reference only. No external circuit diagnosis is involved.


of the malfunction.
Schematic Reference


Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool References

1. Ignition ON.
2. Verify DTC C056E is not set.
If DTC C056E is set
3. All OK.
If DTC C056E is not set
3. All OK
Repair Instructions

DTC P0601-P0604, P0606, OR P062F
DTC Descriptor
DTC P0601

Control Module Read Only Memory Performance

DTC P0602
Control Module Not Programmed
DTC P0603
Control Module Long Term Memory Reset
DTC P0604
Control Module Random Access Memory Performance
DTC P0606
Control Module Processor Performance
DTC P062F
Control Module Long Term Memory Performance
This diagnostic applies to internal microprocessor integrity conditions within the device. This diagnostic also
addresses if the device is not programmed. The device monitors its ability to read and write to the memory. It
also monitors a timing function. No external circuits are involved.
The ignition is ON.

The system voltage is greater than 9.5 V.
The device detects an internal malfunction or incomplete programming.

DTCs P0601, P0602, P0603, P0604, P0606, and P062F are Type A DTCs.
DTCs P0601, P0602, P0603, P0604, P0606, and P062F are Type A DTCs.
Diagnostic Aids

Schematic Reference
Circuit Testing
Connector Repairs
Wiring Repairs
DTC Type Reference

Scan Tool References
1. Ignition ON.
2. Verify DTC P0602 is not set.
If DTC P0602 is set
3. All OK.
If DTC P0602 is not set
3. Verify DTC P0601, P0603, P0604, P0606, or P062F is not set.
If DTC P0601, P0603, P0604, P0606, or P062F is set


If DTC P0601, P0603, P0604, P0606, or P062F is not set
4. All OK
Repair Instructions

DTC U0001
DTC Descriptor
DTC U0001 00
High Speed CAN Communication Bus Malfunction
Circuit Description
Devices connected to the GMLAN serial data circuits monitor for serial data communications on the GMLAN
network during normal vehicle operation. Operating information and commands are exchanged among the
devices. Each device on GMLAN network maintains a transmit error counter and a receive error counter. The
counter values increase with detected errors and will decrease with error-free messages. If the transmit error
counter value exceeds 255 the device removes itself from the network and a DTC U0001 will be set.
System voltage is in the normal operating voltage range.

The vehicle power mode requires serial data communication to occur.
A certain number of no valid transmitted messages on the GMLAN serial data circuits are detected by the
device.
The device suspends all message transmission.

The device uses default values for all parameters received on the GMLAN serial data circuits.

The device inhibits the setting of all other GMLAN communication DTCs.

of the malfunction.
This DTC may not be retrieved with a current status. Diagnosis is accomplished via the symptom, Scan Tool
Does Not Communicate with High Speed GMLAN Device. Refer to Scan Tool Does Not Communicate with
High Speed GMLAN Device in order to isolate an intermittent condition caused by a short on the GMLAN
serial data circuits.
DTC U0020
DTC Descriptors
DTC U0020
Low Speed CAN Bus
Devices connected to the GMLAN serial data circuits monitor for serial data communications during normal
vehicle operation. Operating information and commands are exchanged among the devices. The devices have
programmed information about what messages are needed to be exchanged on the serial data circuits. The
messages are also supervised and some periodic messages are used by the receiver device as an availability
indication of the transmitter device.
Conditions for Running the DTCs
Supply voltage to the devices is in the normal operating range.

The DTC U2100 does not have a current status.

A supervised periodic message that includes the transmitter device availability has not been received.
Action Taken When the DTCs Sets
The device uses a default value for the missing parameter.


of the malfunction.
Diagnosis of this DTC is accomplished via the symptom or an additional DTC. Refer to Scan Tool Does Not
Communicate with Low Speed GMLAN Device, or Diagnostic Trouble Code (DTC) List - Vehicle .
DTC U0073 OR U2100
DTC Descriptors
DTC U0073
Control Module Communication Bus A Off
DTC U2100
CAN Bus Communication
The serial data circuits are used to communicate information between the devices. The serial data circuits also
connect directly to the data link connector (DLC).
Supply voltage to the devices is in the normal operating range.

The vehicle power mode requires serial data communications.

The device setting the DTC has attempted to establish communications on the serial data circuits more than 3
times in 5 s.
Action Taken When the DTCs Sets

The device uses default values for all parameters received on the serial data circuits.
In the transmission control module, DTC U0073 will cause the transmission to go into default gears.
In the engine control module and transmission control module, DTC U0073 will cause the malfunction
indicator lamp (MIL) to illuminate.
If equipped with eAssist, DTC U0073 in the hybrid powertrain control module is a type B DTC and will
cause the malfunction indicator lamp to illuminate and result in the engine operating in conventional
engine mode and will maintain 14 V module operation.
The device inhibits the setting of all other communication DTCs.
The engine control module or transmission control module turns OFF the MIL after 4 consecutive
ignition cycles that the diagnostic runs and does not fail.
If equipped with eAssist, the hybrid powertrain control module turns off the MIL after the diagnostic runs
and does not fail during subsequent ignition cycles. Normal operation will resume 5 s after subsequent
ignition cycle.
1. Refer to Data Link References to determine which serial data communication system is used for a
specific device.
2. This DTC may not be retrieved with a current status. Diagnosis is accomplished using the symptom.
Refer to Symptoms - Data Communications.
DTC U0074
DTC Descriptor

DTC U0074
Control Module Communication Bus B Off
Short to
Ground
Open/High
Short to
Circuit
Signal Performance
Resistance
Voltage
Chassis High Speed
U0074, U0100U0074
U0074
GMLAN Serial Data (+)
U02FF*
Chassis High Speed
U0074, U0100U0074
U0074
GMLAN Serial Data (-)
U02FF*
Ground (DLC, terminal 5)
1
* An open between the data link connector (DLC) and the first splice/device will only affect the
communication with the scan tool. The devices will still communicate. An open in only one chassis high
speed GMLAN serial data circuit may allow degraded communication between the devices.
1. No communication with any chassis high speed GMLAN device.
The devices connected to the chassis high speed GMLAN serial data circuits monitor for serial data
communications during normal vehicle operation. Operating information and commands are exchanged among
the devices when the ignition switch is in any position other than OFF. The chassis high speed GMLAN serial
data bus uses terminating resistors that are in parallel with the chassis high speed GMLAN (+) and (-) circuits.

Specific subsystems will not function.


Diagnostic Aids

Use the Data Link References to identify the chassis high speed GMLAN devices.
Sometimes, while diagnosing a specific customer concern or after a repair, you may notice a history Ucode present. However, there is no associated "current" or "active" status. Loss-of-communication Ucodes such as these can set for a variety of reasons. Many times, they are transparent to the vehicle
operator and technician, and/or have no associated symptoms. Eventually, they will erase themselves
automatically after a number of fault-free ignition cycles. This condition would most likely be attributed
to one of these scenarios:
A device on the data communication circuit was disconnected while the communication circuit is
awake.
Power to one or more devices was interrupted during diagnosis.
A low battery condition was present, so some devices stop communicating when battery voltage
drops below a certain threshold.
Battery power was restored to the vehicle and devices on the communication circuit did not all reinitialize at the same time.
If a loss-of-communication U code appears in history for no apparent reason, it is most likely
associated with one of the scenarios above. These are all temporary conditions and should never be
interpreted as an intermittent fault, causing you to replace a part.
Do not replace a device reporting a U code. The U code identifies which device needs to be diagnosed for
a communication issue.
Communication may be available between some devices and the scan tool with the chassis high speed
GMLAN serial data system inoperative. This condition is due to those devices using multiple serial data
communication systems.
An open in the DLC ground circuit terminal 5 will allow the scan tool to operate but not communicate
with the vehicle.
Technicians may find various Local Area Network (LAN) communication Diagnostic Trouble Codes
(DTC).
Some devices may not have internal protection for specific voltage outputs and may open a battery
positive voltage or ignition voltage source fuse. If a voltage input fuse is open and no short is found in
that circuit, ensure that no device output voltage circuit is shorted to ground before replacing the device.
Schematic Reference



Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference

1. Ignition ON.
2. Verify two or more devices are not communicating on the chassis high speed GMLAN serial data circuit.
Refer to Data Link References to determine how many devices should be communicating on the bus.
If only one device is not communicating
Refer to Circuit/System Testing below - Testing the Device Circuits.
If two or more devices are not communicating
Ignition OFF, all access doors closed, all vehicle systems OFF, and all keys at least 3 m (9.8 ft) away
from vehicle. Disconnect the scan tool from the X84 Data Link Connector. The following tests will be
done at the X84 Data Link Connector. It may take up to 2 minutes for all vehicle systems to power down.
1. Ignition OFF.
Ignition ON.
Test for less than 4.5 V between the serial data circuits listed below and ground:
Chassis high speed GMLAN serial data terminal 12
If 4.5 V or greater
3.
4.
5.
6.
Refer to Circuit/System Testing below- Testing the Serial Data Circuits for a Short to Voltage.
If less than 4.5 V
7. Ignition OFF, all access doors closed, all vehicle systems OFF, and all keys at least 3 m (9.8 ft) away
from vehicle. It may take up to 2 minutes for all vehicle systems to power down.

8. Test for greater than 100 ohms between the serial data circuits listed below and ground:
If 100 ohms or less
Refer to Circuit/System Testing below- Testing the Serial Data Circuits for a Short to Ground.
9. Test for 50-70 ohms between the serial data circuit terminals 12 and 13:
Refer to Circuit/System Testing below- Testing the Serial Data Circuits for a Short between the
Circuits.

There may be a third terminating resistor between the serial data circuits. This can happen if the
incorrect device is installed. Some devices are available with and without the terminating resistors
installed to reduce the need of terminating resistors in the wiring harness. Refer to Circuit/System
Testing below- Testing the Serial Data Circuits for a Short between the Circuits.
If greater than 70 ohms but less than infinite

Refer to Circuit/System Testing below- Testing the Serial Data Circuits for an Open/High
Resistance.
Repair the open/high resistance in the circuit between the X84 Data Link Connector and the first
splice/device in the serial data circuit.

10. Refer to Circuit/System Testing below- Testing the Device Circuits.
NOTE:
Each device may need to be disconnected to isolate a circuit fault.

Use the schematic to identify the following:
Chassis high speed GMLAN devices the vehicle is equipped with

Chassis high speed GMLAN serial data circuit terminating resistors
Device locations on the chassis high speed GMLAN serial data circuits
Each device's ground, B+, ignition, and chassis high speed GMLAN serial

data circuit terminals

Some devices with an internal terminating resistor have a loop in the harness
that connects the internal terminating resistor to the serial data circuit. When
wired this way, test these loop circuits for the appropriate failure mode short to
voltage, short to ground, or open/high resistance prior to replacing the device
for each of the following tests.
Testing the Serial Data Circuits for a Short to Voltage
1. Ignition OFF, disconnect the harness connectors with the chassis high speed GMLAN serial data circuits
at an easily accessible device, ignition ON.
2. Test for greater than 4.5 V between each serial data circuit at the device connector that was just
disconnected and ground.
If each serial data circuit is 4.5 V or less
1. Ignition OFF.
2. Test for less than 10 ohms between each of the device's ground circuit terminals and ground.
If less than 10 ohms, replace the device that was disconnected.
If any serial data circuit is greater than 4.5 V
at another device, in the direction of the circuit shorted to voltage, ignition ON.
1. Ignition OFF.
5. Repeat step 3 until one of the following conditions are isolated:
A short to voltage on the serial data circuit between two devices or splice packs, if equipped.
A short to voltage on the serial data circuit between a device and a terminating resistor.
Testing the Serial Data Circuits for a Short to Ground
2. Disconnect the harness connectors with the chassis high speed GMLAN serial data circuits at an easily
accessible device.
3. Test for greater than 100 ohms between each serial data circuit at the device connector that was just

If each serial data circuit is 100 ohms or greater

Replace the device that was disconnected.
If any serial data circuit is less than 100 ohms

4. Disconnect the harness connectors with the chassis high speed GMLAN serial data circuits at another
device, in the direction of the circuit shorted to ground.
If both serial data circuits are 100 ohms or greater

A short to ground on the serial data circuit between two devices or splice packs, if equipped.
A short to ground on the serial data circuit between a device and a terminating resistor.
A short to ground on the serial data circuit between the X84 Data Link Connector and the first
device or splice pack.
Testing the Serial Data Circuits for a Short between the Circuits
accessible device that is not communicating.
3. Test for greater than 110 ohms between each pair of serial data circuits at the device connector that was
just disconnected.
If each pair of serial data circuits is 110 ohms or greater
If any pair of serial data circuits is less than 110 ohms
4. Connect the harness connectors at the device that was disconnected.
device, in the direction of the circuit shorted together.
just disconnected.


Serial data circuits shorted together between two devices or splice packs, if equipped.
Serial data circuits shorted together between a device and a terminating resistor.
Serial data circuits shorted together between the X84 Data Link Connector and the first device or
splice pack.
A shorted terminating resistor.
Testing the Serial Data Circuits for an Open/High Resistance
3. Test for less than 130 ohms between each pair of serial data circuits at the device connector that was just
disconnected.
If each pair of serial data circuits is 130 ohms or less
If any pair of serial data circuits is greater than 130 ohms
device, in the direction of the circuit with the open/high resistance.
disconnected.

An open/high resistance on the serial data circuit between two devices or splice packs, if equipped.
An open/high resistance on the serial data circuit between a device and a terminating resistor.
An open/high resistance terminating resistor.
Testing the Device Circuits

2. Disconnect the harness connectors at an easily accessible device that is not communicating.
3. Test for less than 10 ohms between each ground circuit terminal and ground.

4.
5.
6.
7.
1. Ignition OFF.
If equipped, verify a test lamp illuminates between each B+ circuit terminal and ground.
1. Ignition OFF.
If less than 2 ohms, verify the fuse is not open and there is voltage at the fuse.
1. Ignition OFF.
If infinite resistance, replace the disconnected device.
Ignition ON.
If equipped, verify a test lamp illuminates between each ignition circuit terminal, which has a fuse in the
circuit, and ground.
1. Ignition OFF.
If less than 2 ohms, verify the fuse is OK and there is voltage at the fuse.
1. Ignition OFF.
2. Test for infinite resistance between the ignition circuit and ground.
If equipped, verify a test lamp illuminates between each ignition circuit terminal, which is controlled by a
control module, and ground.
1. Ignition OFF, disconnect the harness connectors at the control module that controls the ignition
circuit.

If less than 2 ohms, replace the control module that controls the ignition circuit.
9. Test for less than 130 ohms between each pair of chassis high speed GMLAN serial data circuits at the
device connector that was just disconnected.
Repair the open/high resistance in the serial data circuits between the disconnected device and the
circuit splice in the serial data circuits.
10. Replace the device that was disconnected.
Repair Instructions
GMLAN and Media Oriented Systems Transport (MOST) Wiring Repairs

DTC U0077
DTC Descriptor
DTC U0077 00
Control Module Communication Chassis Expansion CAN Bus Off
Circuit
Chassis High Speed
Short to
Ground
U0077
Open/High
Resistance
U0077, U0100U02FF*
Short to
Voltage
Signal Performance
U0077

Chassis High Speed

U0077, U0100U0077
U0077
U02FF*
1
* An open between the data link connector (DLC) and the first splice/device will only affect the
communication with the scan tool. The devices will still communicate. An open in only one chassis high
speed GMLAN serial data circuit may allow degraded communication between the devices.
The devices connected to the chassis high speed GMLAN serial data circuits monitor for serial data
communications during normal vehicle operation. Operating information and commands are exchanged among
the devices when the ignition switch is in any position other than OFF. The chassis high speed GMLAN serial
data bus uses terminating resistors that are in parallel with the chassis high speed GMLAN (+) and (-) circuits.



Diagnostic Aids
Use the Data Link References to identify the chassis high speed GMLAN devices.
awake.


If a loss-of-communication U-code appears in history for no apparent reason, it is most likely
Communication may be available between some devices and the scan tool with the chassis high speed
GMLAN serial data system inoperative. This condition is due to those devices using multiple serial data
with the vehicle.
(DTC).
Some devices may not have internal protection for specific voltage outputs and may open a battery
positive voltage or ignition voltage source fuse. If a voltage input fuse is open and no short is found in
that circuit, ensure that no device output voltage circuit is shorted to ground before replacing the device.
Schematic Reference


Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference


1. Ignition ON.
2. Verify DTC U0077 is not set.
If DTC U0077 is set
Refer to Scan Tool Does Not Communicate with Chassis High Speed GMLAN Device.
If DTC U0077 is not set
3. All OK
Repair Instructions

DTC U0078
DTC Descriptor
DTC U0078
Control Module Communication Low Speed CAN Bus Off
The low speed GMLAN serial data bus is used to communicate information between the devices. The serial
data is transmitted over a single wire to the appropriate devices. The low speed GMLAN serial data circuits also
connect directly to the data link connector (DLC).
Supply voltage to the devices are in the normal operating range.

The vehicle power mode requires serial data communications.

The device setting the DTC has attempted to establish communications on the serial data circuits more than 3
times in 5 s.

The device uses default values for all parameters received on the serial data circuits.
The device inhibits the setting of all other communication DTCs.

1. Ignition ON.
2. Verify DTC U0078 is not set.
If DTC U0078 is set
Refer to Scan Tool Does Not Communicate with Low Speed GMLAN Device.
If DTC U0078 is not set
3. All OK
DTC U0100-U02FF
DTC Descriptor
For device DTC descriptors, refer to Control Module U Code List.

Circuit
B+
Ignition
Short to
Ground
U0100-U02FF
Open/High
Resistance
U0100-U02FF
Short to
Voltage
-
Signal Performance
-
U0100U02FF,
U0100-U02FF

U1814, U2099
Object High Speed
U0075
U0100-U02FF
U0075
Object High Speed
U0075
U0100-U02FF
U0075
Chassis High Speed
U0074,
U0074, U0077
U0100-U02FF
U0077
Chassis High Speed
U0074,
U0074, U0077
U0100-U02FF
U0077
Mid Speed GMLAN Serial
U0074
U0100-U02FF
U0074
Data (+)
Mid Speed GMLAN Serial
U0074
U0100-U02FF
U0074
Data (-)
High Speed GMLAN
U0073, 2
U0100-U02FF
U0073, 2
Serial Data (+)
High Speed GMLAN
U0073, 2
U0100-U02FF
U0073, 2
Serial Data (-)
U0078, 1
U0100-U02FF
U0078, 1
Data
Ground
U0100-U02FF
1. Scan tool does not communicate with most low speed GMLAN device
2. Scan tool does not communicate with most high speed GMLAN device
The serial data circuit is the means by which the devices in the vehicle communicate with each other. Once the
scan tool is connected to the serial data circuit through the data link connector (DLC), the scan tool can be used
to monitor each device for diagnostic purposes and to check for DTCs. When the ignition switch is in RUN,
each device communicating on the serial data circuit sends a state of health message to ensure that the device is
operating properly. When a device stops communicating on the serial data circuit, for example if the device
loses power or ground, the state of health message it normally sends on the serial data circuit disappears. Other
devices on the serial data circuit, which expect to receive that state of health message, detect its absence; those
devices in turn set a DTC associated with the loss of state of health of the non-communicating device. The DTC
is unique to the device which is not communicating and one or more devices may set the same exact code. A
loss of serial data communications DTC does not represent a failure of the devices that contain the stored code.



DTC U0100 in the transmission control module will cause the transmission to go into default gears.
Both DTC U0100 in the transmission control module and DTC U0101 in the engine control module will
cause the MIL to illuminate.
The engine control module or transmission control module turns OFF the MIL after 4 consecutive
ignition cycles that the diagnostic runs and does not fail.
Diagnostic Aids
Sometimes, while diagnosing a specific customer concern or after a repair, you may notice a history Ucode present. However, there is no associated "current" or "active" status. Loss-of- communication Ucodes such as these can set for a variety of reasons. Many times, they are transparent to the vehicle
awake.
A device may have a U-code stored in history that does not require any repairs. Issues with late or
corrupted messages between devices can be temporary with no apparent symptom or complaint; this does
not mean the device is faulty. Do not replace a device based only on a history U-code.
Do not replace a device reporting a U-code. The U-code identifies which device needs to be diagnosed for
Communication may be available between some devices and the scan tool with either the low or high
speed GMLAN serial data system inoperative. This condition is due to those devices using multiple serial
data communication systems.
Use Data Link References to determine what serial data communications the device uses.
Some devices may not have internal protection for specific control circuits and may open a B+ or ignition
fuse. If a fuse is open and the B+ or ignition circuit is not shorted to ground, ensure none of the control
circuits are shorted to ground before replacing the device.
Some intermittent communication concerns may be caused by fretting corrosion on the serial data circuit

terminals. Inspect all connectors at the device that set the communication DTC, the device that the
communication DTC was set against, and any inline harness connectors between the two devices. Do not
replace a device based only on fretting corrosion. Refer to bulletin 09-06-03-004 for assistance with the
diagnosis and repair of this condition, if applicable.
This diagnostic can be used for any device that is not communicating, regardless of the type of serial data
circuit it is connected to, providing the vehicle is equipped with the device.
Schematic Reference


Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference

1. Determine the device that is not communicating. Refer to Control Module U Code List.
2. Verify that DTC U0073, U2100, U0074, U0078, U1814, U2099, B1325, B1330, B1370, B1380, B1424,
B1440, B1441, B1517, C0800, C0899, C12E1, P0560, or P0562 is not set.
3. Verify that DTC U0125 and DTC U0126 are not set together.
If both of the DTCs are set together

Refer to Scan Tool Does Not Communicate with Chassis High Speed GMLAN Device.
If both of the DTCs are not set together
4. Engine running for 10 s.
5. Ignition ON, engine OFF, verify that DTC U0100-U02FF is not set.
If the DTC U0100-U02FF is set in any device, except the K17 Electronic Brake Control
Module
If the DTC U0100-U02FF is set in the K17 Electronic Brake Control Module with any
symptom byte, except symptom bytes 71, 72, and 74
If the DTC U0100-U02FF is set in the K17 Electronic Brake Control Module with symptom
byte 71, 72, or 74 along with other DTCs set
Diagnose all other DTCs first. Refer to Diagnostic Trouble Code (DTC) List - Vehicle .
If the DTC U0100-U02FF is set in the K17 Electronic Brake Control Module with symptom
byte 71, 72, or 74 and without other DTCs set
1. Program the K17 Electronic Brake Control Module.
If the DTC sets, replace the K17 Electronic Brake Control Module.
3. All OK.
If the DTC U0100-U02FF is not set
6. All OK.
NOTE:
Use the schematics and connector end views to identify the device's ground,
B+, ignition, accessory wakeup serial data, serial data communication enable,
and serial data circuit terminals.
from vehicle. Disconnect all the harness connectors at the device that is not communicating. It may take
up to 2 minutes for all vehicle systems to power down.
1. Ignition OFF.


Ignition ON.
If equipped, verify a test lamp illuminates between each B+ circuit terminal and ground.
1. Ignition OFF.
1. Ignition OFF.
Ignition ON.
If equipped, verify a test lamp illuminates between each ignition circuit terminal and ground.
1. Ignition OFF.
1. Ignition OFF.
Ignition ON.
circuit.
3.
4.
5.
6.
7.
8.

NOTE:
This test step is only applicable to a low speed GMLAN device.
9. Test for less than 4.5 V between each low speed GMLAN serial data circuit terminal and ground.
If 4.5 V or greater
Refer to Scan Tool Does Not Communicate with Low Speed GMLAN Device to test for a short
to voltage in the serial data circuit.
If less than 4.5 V
11. Test for less than 2 ohms in each of the serial data circuits end to end between the device harness
connector and the X84 Data Link Connector terminals listed below.
Low speed GMLAN serial data circuit terminal 1
High speed GMLAN serial data circuit terminal 6 or 14
Mid speed GMLAN serial data circuit terminal 3 or 11
Chassis high speed GMLAN serial data circuit terminal 12 or 13
Object high speed GMLAN serial data circuit terminal 3 or 11
Repair the open/high resistance in the serial data circuit between the non communicating device
and the device setting the DTC or a serial data splice pack.
If less than 2 ohms
NOTE:
The following test step is only applicable to a high speed GMLAN device
with 2 pairs of serial data circuits or a high speed GMLAN device with an
internal terminating resistor.
12. Test for 110-130 ohms between each pair of high speed GMLAN serial data circuits.
Refer to Scan Tool Does Not Communicate with High Speed GMLAN Device to test for a short
to ground or a short between the serial data circuits.

Refer to Scan Tool Does Not Communicate with High Speed GMLAN Device to test for an

open/high resistance in the serial data circuit.

13. Replace the device that is not communicating.
Repair Instructions

DTC U0300-U0336
DTC Descriptor
Refer to Control Module U Code List.

If a device was not properly configured after installation that device may set the appropriate communication
DTCs. No external circuit diagnosis is involved.


of the malfunction.
Schematic Reference



Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference

1. Ignition ON.
2. Verify DTC U0300-U0336 is not set.
If DTC U0300-U0336 is set
1. Program the device specified by the DTC descriptor.
If the DTC sets, replace the device specified by the DTC descriptor.
3. All OK.
If DTC U0300-U0336 is not set
3. All OK
Repair Instructions

DTC U0400-U05FF

DTC Descriptor
Refer to Control Module U Code List.

Some devices are constantly receiving information from other devices through serial data communication
network. The invalid data code will be set when a receiving device detects a discrepancy in information it
receives from another device causing its integrity to be questioned. The symptom byte listed in the DTC
Descriptor is for engineering reference only. No external circuit diagnosis is involved.


of the malfunction.
Schematic Reference


Circuit Testing

Connector Repairs
Wiring Repairs
Scan Tool Reference

1. Engine running for 10 s.

2. Ignition ON, engine OFF, verify DTC U0400-U05FF is not set.
If DTC U0400-U05FF is set along with other DTCs set
If DTC U0400-U05FF is set without other DTCs set
1. Program the device specified by the DTC descriptor.
If the DTC sets, replace the appropriate device.
3. All OK.
If DTC U0400-U05FF is not set
3. All OK
Repair Instructions

DTC U1500-U15FF
DTC Descriptor
For device DTC descriptors, refer to Control Module U Code List.


B+
Ignition
Short to
Ground
U1500-U15BF
U1500-U15BF
Open/High
Resistance
U1500-U15BF
U1500-U15BF
LIN Serial Data
U1500-U15BF
U1500-U15BF
U1500-U15BF
Circuit
Ground
Short to
Voltage
U1500U15BF
-
Signal Performance
-
The serial data is transmitted over a Local Interconnect Network (LIN) single wire network circuit bus between
a master control module and other LIN devices within a particular subsystem. If serial data communication is
lost between any of the LIN devices on the LIN bus network, a no communication code against the noncommunicating LIN device will be set. A master control module is the one that reports the non communication
code.



Diagnostic Aids
awake.


A device may have a U-code stored in history that does not require any repairs. Issues with late or
corrupted messages between devices can be temporary with no apparent symptom or complaint; this does
not mean the device is faulty. Do not replace a device based only on a history U-code.
Communication will be available between the master control module and the scan tool if there is a loss of
communications with any of the other LIN devices on the LIN bus network.
Some devices may not have internal protection for specific control circuits and may open a B+ or ignition
fuse. If a fuse is open and the B+ or ignition circuit is not shorted to ground, ensure none of the control
circuits are shorted to ground before replacing the device.
Some intermittent communication concerns may be caused by fretting corrosion on the serial data circuit
terminals. Inspect all connectors at the device that set the communication DTC, the device that the
communication DTC was set against, and any inline harness connectors between the two devices. Do not
replace a device based only on fretting corrosion. Refer to bulletin 09-06-03-004 for assistance with the
diagnosis and repair of this condition, if applicable.
An open in the LIN bus serial data circuit between the splice pack and a LIN device will only affect that
specific LIN device. This type of failure will set a loss of communication DTC for each LIN device
affected and the other LIN devices will still communicate.
Schematic Reference


Circuit Testing
Connector Repairs

Wiring Repairs
Scan Tool Reference

1. Determine the LIN device that is not communicating. Refer to Control Module U Code List.
2. Verify that DTC B1325, B1330, B1370, B1380, B1424, B1440, B1441, B1517, C0800, C0899, C12E1,
P0560, or P0562 is not set.
3. Refer to Circuit/System Testing below.
NOTE:
The master control module and the LIN devices on the same LIN serial
data circuit
The master control module's LIN serial data circuit terminal and the LIN
device's B+, ignition, ground, and LIN serial data circuit terminals
from vehicle. Disconnect the harness connector at a LIN device that is not communicating. It may take up
to 2 minutes for all vehicle systems to power down.
1. Ignition OFF.
3. Ignition ON.
4. Verify a test lamp illuminates between each B+ circuit terminal and ground, if equipped.
1. Ignition OFF.

1. Ignition OFF.
If infinite resistance, replace the disconnected LIN device.
Ignition ON.
Verify a test lamp illuminates between each ignition circuit terminal and ground, if equipped.
1. Ignition OFF.
1. Ignition OFF.
If infinite resistance, replace the disconnected LIN device.
Ignition ON.
Verify a test lamp illuminates between each ignition circuit terminal, which is controlled by a control
module, and ground, if equipped.
circuit.
Ignition ON.
5.
6.
7.
8.
9.
NOTE:
For accurate voltage reading, disconnect the battery charger prior to

performing the following test step.
10. Test for 2-13 V between the LIN serial data circuit terminal and ground.

If less than 2 V
1. Ignition OFF, disconnect the harness connector at the control module setting the DTC and all LIN
devices that share the same LIN serial data circuit.
If less than 2 ohms
4. Reconnect the control module that set the DTC, ignition ON.
If less than 2 V, replace the control module setting the DTC.
If greater than 2 V, replace the LIN device that causes a current DTC to set when connected.
If greater than 13 V
1. Ignition OFF, disconnect the harness connector at the control module setting the DTC and all LIN
devices that share the same LIN serial data circuit.
2. Ignition ON.
If less than 1 V
4. Ignition OFF, reconnect the control module that set the DTC, ignition ON.
If greater than 13 V, replace the control module setting the DTC.
If less than 13 V, replace the LIN device that causes a current DTC to set when connected.
If between 2-13 V
11. Replace the disconnected LIN device.
Repair Instructions

DTC U1814

DTC Descriptor
DTC U1814
Powertrain Wake-Up Communication Circuit
Circuit
Ignition
* Vehicle may not start.
Short to
Ground
U1814 02*
Open/High
Resistance
U0100-U02FF
Short to
Voltage
-
Signal Performance
-
The body control module (BCM) activates the ignition circuit, when the ignition key is in ACC, ON or START.
The ignition circuit wakes up the devices for serial data bus communication.

The vehicle power mode master requires serial data communication to occur.
The BCM senses a short to ground on the ignition circuit.

The output command is turned off while the malfunction is present.

The devices use a default value for the missing parameters until the next ignition cycle.
The device(s) is never signaled. Therefore, the specific subsystem(s) will not function.
The vehicle will not start while the circuit is shorted to ground.

Schematic Reference



Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference

NOTE:
Use the schematic to determine which devices are on the K9 Body Control
Module's ignition circuit terminal 22 X4. Use the connector end view to identify
the ignition circuit terminal for each of those devices.
1. Ignition OFF, disconnect the harness connectors at an easily accessible device that shares the K9 Body
Control Module's ignition circuit terminal 22 X4. Ignition ON.
2. Verify that the DTC U1814 remains current.
If the DTC becomes history
Replace the device that was just disconnected.
If the DTC remains current
3. With the prior devices disconnected, repeat steps 1 and 2 for each device on the ignition circuit except the
K9 Body Control Module.
4. Ignition OFF, disconnect the X4 harness connector at the K9 Body Control Module.
5. Test for infinite resistance between the ignition circuit terminal 22 X4 at the K9 Body Control Module
and ground.

Repair Instructions

DTC U18B9-U18BF
DTC Descriptor
DTC U18B9
Primary High Speed CAN Bus Subnet Configuration List
DTC U18BF
Secondary High Speed CAN Bus Subnet Configuration List
Devices on the high speed GMLAN serial data bus and the chassis high speed GMLAN serial data bus must be
programmed with software that specifically identifies the correct type and quantity of devices on the bus based
on RPO configuration. If a device was not properly configured after installation, the appropriate U Code may be
set for that device. No external circuit diagnosis is involved.
Voltage supplied to the device is in the normal operating voltage range.


Control unit recognises a programming error.

CAN-Bus configuration is invalid

of the malfunction.
Schematic Reference


Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference

1. Ignition ON.
2. Verify DTC U18B9-U18BF is not set.
If DTC U18B9-U18BF is set along with other DTCs set
If DTC U18B9-U18BF is set without other DTCs set
2. Ignition OFF, remove the scan tool, open and close the driver door. Wait 60 s.


If the DTC sets, replace the appropriate device.
4. All OK.
If DTC U18B9-U18BF is not set
3. All OK
Repair Instructions

DTC U2099
DTC Descriptor
DTC U2099
High Speed Communication Enable Circuit
Circuit
Ignition
* Vehicle may not start.
Short to
Ground
U2099*
Open/High
Resistance
U0100-U02FF
Short to
Signal Performance
Voltage
U0100-U02FF
-
The body control module (BCM) activates the ignition circuit, when the ignition key is in ACC, ON or START.
The ignition circuit wakes up the devices for serial data bus communication.

The vehicle power mode master requires serial data communication to occur.

The BCM senses a short to ground on the ignition circuit.

The output command is turned off while the malfunction is present.

The devices use a default value for the missing parameters until the next ignition cycle.
The device(s) is never signaled. Therefore, the specific subsystem(s) will not function.
The vehicle will not start while the circuit is shorted to ground.

Schematic Reference


Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference


NOTE:
Use the schematic to determine which devices are on the K9 Body Control
Module's ignition circuit terminal 23 X4. Use the connector end view to identify
the ignition circuit terminal for each of those devices.
1. Ignition OFF, disconnect the harness connectors at an easily accessible device that shares the K9 Body
Control Module's ignition circuit terminal 23 X4. Ignition ON.
2. Verify that the DTC U2099 remains current.
If the DTC becomes history
Replace the device that was just disconnected.
If the DTC remains current
3. With the prior devices disconnected, repeat steps 1 and 2 for each device on the ignition circuit except the
K9 Body Control Module.
5. Test for infinite resistance between the ignition circuit terminal 23 X4 at the K9 Body Control Module
and ground.

Repair Instructions

SYMPTOMS - DATA COMMUNICATIONS

NOTE:
1. Perform the Diagnostic System Check - Vehicle before using the symptom tables in order to verify that
There are no Diagnostic Trouble Codes (DTC) set.
The devices can communicate via the serial data links.
2. Review the system operation in order to familiarize yourself with the system functions. Refer to Data
Link Communications Description and Operation.

Inspect for aftermarket devices which could affect the operation of the systems. Refer to Checking
Aftermarket Accessories .
Inspect the easily accessible or visible system components for obvious damage or conditions which could
cause the symptom.
Intermittent
Symptom List
Scan Tool Does Not Power Up

Scan Tool Does Not Communicate with High Speed GMLAN Device
Scan Tool Does Not Communicate with Low Speed GMLAN Device
Scan Tool Does Not Communicate with Chassis High Speed GMLAN Device
SCAN TOOL DOES NOT POWER UP

Short to
Ground
Circuit
Data Link Connector B+
1
Data Link Connector
Ground
1. Scan Tool Does Not Power Up
Open/High
Resistance
1
Short to
Voltage
-
Signal Performance
-
The data link connector (DLC) is a standardized 16 cavity connector. Connector design and location is dictated
by an industry wide standard, and is required to provide the following:
Scan tool B+ voltage at terminal 16

Scan tool ground at terminal 4
Common ground at terminal 5

Diagnostic Aids
The scan tool will power up with the ignition OFF. Some devices however, will not communicate unless
the ignition is ON and the power mode master device sends the appropriate power mode message.
If the B+ circuit, ground circuits, and connections of the data link connector are functioning properly, the
malfunction must be due to the scan tool.
Schematic Reference


Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference

2. Test for less than 2 ohms between each of the X84 Data Link Connector ground circuit terminals listed
below and ground.
Ground circuit terminal 4
Ground circuit terminal 5
1. Ignition OFF.

If less than 2 ohms
3. Ignition ON.
4. Verify a test lamp illuminates between the B+ circuit terminal 16 at the X84 Data Link Connector and
ground.
1. Ignition OFF.
1. Ignition OFF.
5. Refer to the scan tool user guide.
SCAN TOOL DOES NOT COMMUNICATE WITH CHASSIS HIGH SPEED GMLAN DEVICE
Short to
Ground
Open/High
Resistance
Short to
Voltage
Circuit
Signal Performance
Chassis High Speed
1
U0100-U02FF*
1
Chassis High Speed
1
U0100-U02FF*
1
1
* No communications with one or more chassis high speed GMLAN devices. An open in only one
chassis high speed GMLAN serial data circuit may allow degraded communication between the devices.
An open between the data link connector (DLC) and the first splice/device will only affect the
communication with the scan tool. The devices will still communicate.

The chassis high speed GMLAN bus functions the same as the primary high speed GMLAN bus, and the two
buses operate in parallel. The chassis high speed GMLAN bus is added to reduce message congestion on the
primary high speed bus. Since the chassis high speed GMLAN bus and primary high speed GMLAN bus
operate in the same manner, the diagnostics for each are the same.
The serial data is transmitted on two twisted wires that allow speeds up to 500 kbit/s. The twisted pair is
terminated with two 120 ohms resistors, one is internal to the electronic brake control module and the other can
be a separate resistor in a connector assembly or in another device. The resistors are used as the load for the
chassis high speed GMLAN bus during normal vehicle operation. The chassis high speed GMLAN is a
differential bus. The chassis high speed GMLAN serial data bus (+) and chassis high speed GMLAN serial data
(-) are driven to opposite extremes from a rest or idle level of approximately 2.5 V. Driving the lines to their
extremes, adds 1 V to the chassis high speed GMLAN serial data bus (+) circuit and subtracts 1 V from the
chassis high speed GMLAN serial data bus (-) circuit. If serial data is lost, devices will set a no communication
code against the non-communicating device. Note that a loss of serial data DTC does not represent a failure of
the device that set it.
Diagnostic Aids
awake.
Communication may be available between some devices and the scan tool with one or more GMLAN
serial data systems inoperative. This condition is due to those devices using multiple serial data
with the vehicle.
(DTC).

Schematic Reference


Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference

1. Ignition ON.
2. Verify two or more devices are not communicating on the chassis high speed GMLAN serial data circuit.
Refer to Data Link References to determine how many devices should be communicating on the bus.
Refer to Circuit/System Testing below- Testing the Device Circuits.
from vehicle. Disconnect the scan tool from the X84 Data Link Connector. The following tests will be
done at the X84 Data Link Connector. It may take up to 2 minutes for all vehicle systems to power down.
1. Ignition OFF.

5. Ignition ON.
6. Test for less than 4.5 V between the serial data circuits listed below and ground.
Terminal 12
Terminal 13
If 4.5 V or greater
If less than 4.5 V
8. Test for greater than 100 ohms between the serial data circuits listed below and ground.
Terminal 12
Terminal 13
If 100 ohms or less
9. Test for 50-70 ohms between the serial data circuit terminals 12 and 13.
Circuits.


Resistance.
Repair the open/high resistance in the circuit between the X84 Data Link Connector and the first


NOTE:

Chassis high speed GMLAN devices the vehicle is equipped with

Chassis high speed GMLAN serial data circuit terminating resistors
Device locations on the chassis high speed GMLAN serial data circuits
Each device's ground, B+, ignition, and chassis high speed GMLAN serial
data circuit terminals
at an easily accessible device, ignition ON.
1. Ignition OFF.
at another device, in the direction of the circuit shorted to voltage, ignition ON.
1. Ignition OFF.


accessible device.
device, in the direction of the circuit shorted to ground.

A short to ground on the serial data circuit between the X84 Data Link Connector and the first
device or splice pack.
just disconnected.


device, in the direction of the circuit shorted together.
just disconnected.
Serial data circuits shorted together between the X84 Data Link Connector and the first device or
splice pack.

disconnected.
If each pair of serial data circuit is 130 ohms or less
device, in the direction of the circuit with the open/high resistance.
disconnected.



1. Ignition OFF.
4. If equipped, verify a test lamp illuminates between each B+ circuit terminal and ground.
1. Ignition OFF.
1. Ignition OFF.
5. Ignition ON.
6. If equipped, verify a test lamp illuminates between each ignition circuit terminal, which has a fuse in the
1. Ignition OFF.
1. Ignition OFF.


7. If equipped, verify a test lamp illuminates between each ignition circuit terminal, which is controlled by a
circuit.
9. Test for less than 130 ohms between each pair of chassis high speed GMLAN serial data circuits at the
device connector that was just disconnected.
Repair Instructions

SCAN TOOL DOES NOT COMMUNICATE WITH HIGH SPEED GMLAN DEVICE

Short to
Open/High
Short to
Circuit
Signal Performance
Ground
Resistance
Voltage
High Speed GMLAN
1
U0100-U02FF*
1
Serial Data (+)
High Speed GMLAN
1
U0100-U02FF*
1
Serial Data (-)
1
* No communications with one or more high speed GMLAN devices. An open in only one high speed
GMLAN serial data circuit may allow degraded communication between the devices. An open between
the data link connector (DLC) and the first splice/device will only affect the communication with the scan
tool. The devices will still communicate.
1. No communication with any high speed GMLAN device
The serial data is transmitted on two twisted wires that allow speeds up to 500 Kb/s. The twisted pair is
terminated with two 120 ohms resistors, one is internal to the engine control module (ECM) and the other can
be a separate resistor in a connector assembly or in another device. The resistors are used as the load for the
High Speed GMLAN bus during normal vehicle operation. The high speed GMLAN is a differential bus. The
high speed GMLAN serial data bus (+) and high speed GMLAN serial data (-) are driven to opposite extremes
from a rest or idle level of approximately 2.5 V. Driving the lines to their extremes, adds 1 V to the high speed
GMLAN serial data bus (+) circuit and subtracts 1 V from the high speed GMLAN serial data bus (-) circuit. If
serial data is lost, devices will set a no communication code against the non-communicating device. Note that a
loss of serial data DTC does not represent a failure of the device that set it.
Diagnostic Aids
awake.

Communication may be available between some devices and the scan tool with the high speed GMLAN
serial data system inoperative. This condition is due to those devices using multiple serial data
with the vehicle.
The engine will not start when there is a total malfunction of the high speed GMLAN serial data bus.
(DTC) and no low speed GMLAN communications with the scan tool.
These conditions may be caused by the installation of an aftermarket navigation radio module (see
bulletins). Some customers may comment of one or more of the following concerns:
Vehicle will not crank
Vehicle cranks but will not start
Vehicle stability enhancement system warning lights and messages
PRNDL gear indicator position errors
Schematic Reference


Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference

1. Ignition ON.

2. Verify two or more devices are not communicating on the high speed GMLAN serial data circuit. Refer
to Data Link References to determine how many devices should be communicating on the bus.
Refer to Circuit/System Testing below- Testing the Device Circuits.
Ignition OFF, all access doors closed, all vehicle systems OFF, and all keys at least 3 meters (9.8 feet)
away from vehicle. Disconnect the scan tool from the X84 data link connector. The following tests will
be done at the X84 data link connector. It may take up to 2 minutes for all vehicle systems to power
down.
1. Ignition OFF.
Ignition ON.
Test for less than 4.5 V between the serial data circuits listed below and ground.
Terminal 6
Terminal 14
If 4.5 V or greater
3.
4.
5.
6.
If less than 4.5 V
7. Ignition OFF, all access doors closed, all vehicle systems OFF, and all keys at least 3 meters (9.8 feet)
away from vehicle. It may take up to 2 minutes for all vehicle systems to power down.
8. Test for greater than 100 ohms between the serial data circuits listed below and ground.
Terminal 6
Terminal 14
If 100 ohms or less
9. Test for 50-70 ohms between the serial data circuit terminals 6 and 14.
Circuits.



Resistance.
Repair the open/high resistance in the circuit between the X84 data link connector and the first

NOTE:

High speed GMLAN devices the vehicle is equipped with

High speed GMLAN serial data circuit terminating resistors
Device locations on the high speed GMLAN serial data circuits
Each device's ground, B+, ignition, and high speed GMLAN serial data
circuit terminals
1. Ignition OFF, disconnect the harness connectors with the high speed GMLAN serial data circuits at an
easily accessible device, ignition ON.

1. Ignition OFF.
3. Ignition OFF, disconnect the harness connectors with the high speed GMLAN serial data circuits at
another device, in the direction of the circuit shorted to voltage, ignition ON.
1. Ignition OFF.
2. Disconnect the harness connectors with the high speed GMLAN serial data circuits at an easily accessible
device.
4. Disconnect the harness connectors with the high speed GMLAN serial data circuits at another device, in
the direction of the circuit shorted to ground.


A short to ground on the serial data circuit between the X84 data link connector and the first device
or splice pack.
device that is not communicating.
just disconnected.
the direction of the circuit shorted together.
just disconnected.

Serial data circuits shorted together between the X84 data link connector and the first device or
splice pack.

device that is not communicating.

disconnected.
the direction of the circuit with the open/high resistance.
disconnected.


1. Ignition OFF.
1. Ignition OFF.
1. Ignition OFF.

5.
6.
7.
8.
9.

Ignition ON.
If equipped, verify a test lamp illuminates between each ignition circuit terminal, which has a fuse in the
1. Ignition OFF.
1. Ignition OFF.
circuit.
Ignition OFF, all access doors closed, all vehicle systems OFF, and all keys at least 3 meters (9.8 feet)
Test for less than 130 ohms between each pair of high speed GMLAN serial data circuits at the device
connector that was just disconnected.


Repair Instructions

SCAN TOOL DOES NOT COMMUNICATE WITH LOW SPEED GMLAN DEVICE
Short to
Open/High
Short to
Signal
Circuit
Ground
Resistance
Voltage
Performance
1
U0100-U02FF*
1
1*
* An open between the data link connector (DLC) and the first splice pack/device will only affect the
communication with the scan tool.
1. No communication with any low speed GMLAN device
The serial data is transmitted over a single wire to the appropriate devices. The transmission speed for GMLAN
low speed is up to 83.33 kbit/s. Under normal vehicle operating conditions, the speed of the bus is 33.33 kbit/s.
The devices toggle the serial data circuit between 0-5 V during normal communications. To wake the devices
connected to the low speed GMLAN serial data circuit, a voltage wake up pulse of 10 V is sent out. If serial
data is lost, devices will set a no communication code against the non-communicating device. A loss of serial
data communications DTC does not represent a failure of the device that set it.
Diagnostic Aids
awake.

Power to one or more devices was interrupted during diagnosis

Communication may be available between the device and the scan tool with the low speed GMLAN serial
data system inoperative. This condition is due to the device using both the high and low speed GMLAN
systems.
An open in the low speed GMLAN serial data circuit between the splice pack and a device will only
affect that specific device. This type of failure will set a loss of communication DTC for each device
affected, and the other devices will still communicate.
An open in the data link connector (DLC) ground circuit terminal 5 will allow the scan tool to operate but
not communicate with the vehicle.
The engine may not start when there is a total malfunction of the low speed GMLAN serial data circuit.
(DTC) and no low speed LAN communications with the scan tool.
These conditions may be caused by the installation of an aftermarket navigation radio device (see
bulletins). Some customers may comment of one or more of the following concerns:
Vehicle will not crank
Vehicle cranks but will not start
Vehicle stability enhancement system warning lights and messages
PRNDL gear indicator position errors
Schematic Reference



Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference

NOTE:
Devices the vehicle is equipped with

Device and splice pack locations on the low speed GMLAN serial data
circuit
The low speed GMLAN serial data circuit terminals for each device or
splice pack
1. Attempt to communicate with all devices on the low speed GMLAN serial data circuit. Refer to Data
Link References.
2. Verify which devices are communicating on the low speed GMLAN serial data circuit.
Diagnose that device only. Refer to DTC U0100-U02FF.
If one or more devices are communicating but not all

Refer to Circuit/System Testing below- Testing the Serial Data Circuit for an Open/High
Resistance.
If none of the devices are communicating

3. Ignition OFF, all access doors closed, all vehicle systems OFF, all keys at least 3 m (9.8 ft) away from
vehicle. Disconnect the scan tool from the X84 Data Link Connector. The following tests will be done at
the X84 Data Link Connector. It may take up to 2 minutes for all vehicle systems to power down.
1. Ignition OFF.


5. Ignition ON.
6. Test for less than 4.5 V between the serial data circuit terminal 1 and ground.
If 4.5 V or greater
If less than 4.5 V
7. Ignition OFF, all access doors closed, all vehicle systems OFF, all keys at least 3 m (9.8 ft) away from
vehicle. It may take up to 2 minutes for all vehicle systems to power down.
8. Test for greater than 100 ohms between the serial data circuit terminal 1 and ground.
If 100 ohms or less
9. Disconnect the appropriate harness connector at the first splice pack closest in the circuit to the X84 Data
Link Connector.
10. Test for less than 2 ohms between the X84 Data Link Connector's serial data circuit terminal 1 and the
splice pack harness connector's serial data input terminal.
Repair the open/high resistance in the serial data circuit.

If less than 2 ohms
11. Replace the splice pack.

1. Ignition OFF, disconnect the appropriate harness connectors at all low speed GMLAN serial data splice
packs, ignition ON.
2. Test for less than 4.5 V between the serial data circuit terminal 1 at the X84 Data Link Connector and
ground.
If 4.5 V or greater
Repair the short to voltage on the serial data circuit.
If less than 4.5 V
3. Test for less than 4.5 V between each low speed GMLAN serial data circuit at a splice pack and ground.
1. Ignition OFF, disconnect all devices on the failed serial data circuit, ignition ON.

2. Test for less than 1 V between each section of the failed serial data circuit and ground.
If less than 1 V
3. Connect the splice pack and connect the first device on the failed serial data circuit, ignition ON.
4. Verify the scan tool communicates or not with the low speed GMLAN serial data circuit.
If the scan tool does not communicate, replace the device that was just connected.
If the scan tool communicates and there are more devices to connect, connect the next device
and repeat step 3.4.
If the scan tool communicates and there are no more devices to connect
5. All OK.
If all serial data circuits are less than 4.5 V
4. All OK.
from vehicle. Disconnect the appropriate harness connectors at all low speed GMLAN serial data splice
packs.
2. Test for infinite resistance between the serial data circuit terminal 1 at the X84 Data Link Connector and
ground.
Repair the short to ground on the serial data circuit.
3. Test for greater than 100 ohms between each low speed GMLAN serial data circuit at a splice pack and
ground.
If any serial data circuit is 100 ohms or less
1. Disconnect all devices on the failed serial data circuit.
2. Test for greater than 2 ohms between each section of the failed serial data circuit and ground.
If 2 ohms or less, repair the short to ground in the circuit.
3. Connect the splice pack and connect the first device on the failed serial data circuit, ignition ON.
4. Verify the scan tool communicates or not with the low speed GMLAN serial data circuit.
If the scan tool does not communicate, replace the device that was just connected.
If the scan tool communicates and there are more devices to connect, connect the next device
and repeat step 3.4.
If the scan tool communicates and there are no more devices to connect
5. All OK.
If all serial data circuits are greater than 100 ohms

4. All OK.
Testing the Serial Data Circuit for an Open/High Resistance
1. Ignition OFF and all vehicle systems OFF, disconnect the splice pack containing the devices that are not
communicating on the low speed GMLAN serial data circuit.
2. Test for less than 2 ohms between the X84 Data Link Connector terminal 1 and the disconnected splice
pack.
If less than 2 ohms
3. Disconnect all devices on the failed serial data circuit.
4. Test for less than 2 ohms between each section of the failed serial data circuit end to end.

If less than 2 ohms
5. Connect the splice pack and connect the first device on the failed serial data circuit.
6. Verify if the device communicates or not with the scan tool.
If the device does not communicates
Replace the device.
If the device communicates and there are more devices to connect

Connect the next device on the failed serial data circuit and repeat step 6.
If all devices are connected and communicating

7. All OK.
Repair Instructions

DATA LINK REFERENCES

This table identifies which serial data link that a particular device uses for in-vehicle data transmission. Some
devices may use more than one data link to communicate. Some devices may have multiple communication

circuits passing through them without actively communicating on that data link. This table is used to assist in
correcting a communication malfunction. Not all devices listed will be applicable to all vehicles. Refer to the
schematics to determine which devices apply. For the description and operation of these serial data
communication circuits, refer to Data Link Communications Description and Operation.
Data Link References
Code
Device
Data Link Type
Diagnostic Procedure
Schematic Reference: Data Communication Schematics
Scan Tool Does Not
A11
Radio
Low Speed GMLAN
Communicate with Low Speed
GMLAN Device
A22
Radio Controls
DTC U1500-U15FF
(LIN)
Scan Tool Does Not
Steering Wheel Angle
B99
Chassis High Speed GMLAN Communicate with Chassis
Sensor
High Speed GMLAN Device
Scan Tool Does Not
Multi-axis Acceleration
B119
Chassis High Speed GMLAN Communicate with Chassis
Sensor
High Speed GMLAN Device
K9
Body Control Module
High Speed GMLAN

Low Speed GMLAN
Local Interconnect
Network (LIN)
Scan Tool Does Not

Communicate with High
Speed GMLAN Device
Scan Tool Does Not
Communicate with Low
Speed GMLAN Device
DTC U1500-U15FF
Scan Tool Does Not

Speed GMLAN Device
Scan Tool Does Not
Communicate with
Chassis High Speed
GMLAN Device
Scan Tool Does Not
Communicate with High Speed
GMLAN Device
Scan Tool Does Not
GMLAN Device
Scan Tool Does Not
GMLAN Device
High Speed GMLAN

Chassis High Speed
GMLAN
K17
Electronic Brake Control

Module
K20
High Speed GMLAN
K27
Fuel Pump Control

Module
High Speed GMALN
K29
Seat Heating Control

Module
Low Speed GMLAN
K33
HVAC Control Module
Low Speed GMLAN

Local Interconnect
Scan Tool Does Not


Network (LIN)
Speed GMLAN Device

DTC U1500-U15FF
Scan Tool Does Not
GMLAN Device
Scan Tool Does Not
GMLAN Device
Scan Tool Does Not
GMLAN Device
Scan Tool Does Not
GMLAN Device
Inflatable Restraint
Sensing and Diagnostic
Module
Low Speed GMLAN
Rear Parking Assist

Control Module
Low Speed GMLAN
K43
Power Steering Control

Module
High Speed GMALN
K60
Steering Column Lock

Module
Low Speed GMLAN
K61
Sunroof Control Module

(LIN)
DTC U1500-U15FF
K71
Transmission Control
Module
High Speed GMLAN
Scan Tool Does Not

GMLAN Device
K36
K41R
Scan Tool Does Not

Speed GMLAN Device
Scan Tool Does Not
Speed GMLAN Device
Scan Tool Does Not
GMLAN Device
Scan Tool Does Not
GMLAN Device
K73
Telematics
Communication Interface
Control Module
High Speed GMLAN

Low Speed GMLAN
K84
Keyless Entry Control

Module
Low Speed GMLAN
K85
Passenger Presence
Detection Module
Low Speed GMLAN
Window Motor - Driver

(LIN)
DTC U1500-U15FF
P16
Instrument Cluster
Low Speed GMLAN
Scan Tool Does Not

GMLAN Device
P17
Info Display Module
M74D
S34
S79D
S79LR

(LIN)
HVAC Controls Switch Local Interconnect Network
Assembly
(LIN)
Window Switch - Driver
(LIN)
Window Switch - Left
Rear
(LIN)
DTC U1500-U15FF
DTC U1500-U15FF
DTC U1500-U15FF
DTC U1500-U15FF

S79P
S79RR
T11
Window Switch Passenger

Window Switch - Right
Rear

(LIN)
(LIN)
Multimedia Player
Interface Module
Low Speed GMLAN
DTC U1500-U15FF
DTC U1500-U15FF
Scan Tool Does Not
GMLAN Device
REPAIR INSTRUCTIONS
BODY CONTROL MODULE REPLACEMENT
Fig. 10: Body Control Module

Body Control Module Replacement
Callout
Component Name
1. Prepare body control module for replacement. Refer to Control Module References .
Connection .
3. Remove instrument panel lower trim panel - right side. Refer to Instrument Panel Lower Trim
Panel Replacement - Right Side .

Body Control Module Fastener

1
CAUTION:
Body Control Module

Procedure
2

2. Unclip body control module from body control module bracket.
3. After replacement, refer to Control Module References for
programming and set up procedures.
BODY CONTROL MODULE BRACKET REPLACEMENT
Fig. 11: Body Control Module Bracket

Body Control Module Bracket Replacement
Callout
Component Name
Connection .

2. Remove instrument panel lower trim panel - right side. Refer to Instrument Panel Lower Trim
Panel Replacement - Right Side .
3. Remove the body control module.
Body Control Module Bracket Bolt
1
2
CAUTION:
Body Control Module Bracket

BODY CONTROL SYSTEM DESCRIPTION AND OPERATION
The body control system consists of the body control module (BCM), communications, and various input and
outputs. Some inputs, outputs and messages require other modules to interact with the BCM. The BCM also has
discrete input and output terminals to control the vehicle's body functions. The BCM is wired to the high speed
GMLAN serial data bus, low speed GMLAN serial data bus and Multiple LIN buses and acts as a gateway
between them.
Power Mode Master
This vehicle body control module (BCM) functions as the power mode master (PMM). The ignition switch is a
low current switch with multiple discrete ignition switch signals to the PMM for determining the power mode
that will be sent over the serial data circuits to the other modules that need this information; the PMM will
activate relays and other direct outputs of the PMM as needed. Refer to Power Mode Description and
Operation for a complete description of power mode functions.
Gateway
The body control module (BCM) in this vehicle functions as a gateway or translator. The purpose of the
gateway is to translate serial data messages between the GMLAN high speed bus and the GMLAN low speed
bus for communication between the various modules. The gateway will interact with each network according to
that network's transmission protocol.
All communication between the BCM and a scan tool is on the high speed GMLAN serial data circuits. A lost
communication DTC typically is set in modules other than the module with a communication failure.
Body Control
The various body control module (BCM) input and output circuits are illustrated in the corresponding functional
areas on the BCM electrical schematics. Refer to the Body Control System Schematics for more detailed
information.
DATA LINK COMMUNICATIONS DESCRIPTION AND OPERATION
NOTE:
This is an overview of different serial data buses used by GM devices to

communicate with each others. Use Data Communication Schematics to find

out which serial data buses are configured for a specific vehicle.
Circuit Description
There are many components in a vehicle that rely on information from other sources, transmit information to
other sources, or both. Serial data communication networks provide a reliable, cost effective, way for various
components of the vehicle to "talk" to one another and share information.
GM uses a number of different communication buses to insure the timely and efficient exchange of information
between devices. When compared to each other, some of these buses are different in nature as far as speed,
signal characteristics, and behavior. An example of this is the High Speed GMLAN and Low Speed GMLAN
buses.
On the other hand, when other buses are compared to each other they have similar characteristics and simply
operate in parallel. In this case they are used to group together components which have high interaction.
Examples are the High Speed GMLAN, Powertrain Expansion, and Chassis Expansion buses. This allows them
to communicate with each other on a bus with reduced message congestion insuring faster and the more timely
exchange of information than if all vehicle devices were on a single bus.
The majority of information that exists within a given network generally stays local; however some information
will have to be shared on other networks. Control modules designated as Gateway's perform the function of
transferring information between the various buses. A Gateway module is connected to at least 2 buses and will
interact with each network according to its message strategy and transmission models.
GMLAN provides the capability for a receiving device to monitor message transmissions from other devices in
order to determine if messages of interest are not being received. The primary purpose is to allow reasonable
default values to be substituted for the information no longer being received. Additionally, a device may set a
Diagnostic Trouble Code to indicate that the device it is expecting information from is no longer
communicating.
High Speed GMLAN Circuit Description
High Speed GMLAN Block Diagram

Fig. 12: High Speed GMLAN Block Diagram

Callout
DA
DA
DA
DA
DA
DA
DA
UE1
UE1
DA
UE1
X84
K9
K73
K27
K17
K43
Q8
Component Name
Serial Data
Serial Data
Serial Data
Serial Data
Serial Data
Serial Data
Serial Data
OnStar
OnStar
Serial Data
OnStar

K20
A High Speed GMLAN Bus is used where data needs to be exchanged at a high enough rate to minimize the
delay between the occurrence of a change in sensor value and the reception of this information by a control
device using the information to adjust vehicle system performance.
The High Speed GMLAN serial data network consists of two twisted wires. One signal circuit is identified as
GMLAN-High and the other signal circuit is identified as GMLAN-Low. At each end of the data bus there is a
120 ohms termination resistor between the GMLAN-High and GMLAN-Low circuits.
Data symbols (1's and 0's) are transmitted sequentially at a rate of 500 Kbit/s. The data to be transmitted over
the bus is represented by the voltage difference between the GMLAN-High signal voltage and the GMLANLow signal voltage.
When the two wire bus is at rest the GMLAN-High and GMLAN-Low signal circuits are not being driven and
this represents a logic "1". In this state both signal circuits are at the same voltage of 2.5 V. The differential
voltage is approximately 0 V.
When a logic "0" is to be transmitted, the GMLAN-High signal circuit is driven higher to about 3.5 V and the
GMLAN-Low circuit is driven lower to about 1.5 V. The differential voltage becomes approximately 2.0 (+/0.5) V.
Devices on High Speed GMLAN Bus enable or disable communication based on the voltage level of the
communication enable circuit. When the circuit voltage is high (around 12 V), communications are enabled.
When the circuit is low, communications are disabled.
Chassis High Speed GMLAN Circuit Description
Chassis Expansion Bus Block Diagram
Fig. 13: Chassis Expansion Bus Block Diagram


Callout
DA
DA
X84
B119
B99
K17
Component Name
Serial Data
Serial Data
The GMLAN Chassis Expansion Bus is basically a copy of the High Speed GMLAN Bus except that its use is
reserved for chassis components. This implementation splits message congestion between two parallel buses
helping to insure timely message transmission and reception. Sometimes communication is required between
the Chassis Expansion Bus and the primary High Speed GMLAN Bus. This is accomplished by using the K17
Electronic Brake Control Module (EBCM) as the Gateway module. Since the High Speed GMLAN Chassis
Expansion Bus and primary High Speed GMLAN Bus operate in the same manner, the diagnostics for each are
similar.
Low Speed GMLAN Circuit Description
Low Speed GMLAN Block Diagram

Fig. 14: Low Speed GMLAN Block Diagram

Callout
DA
DA
ULS
KTA
UE1
KA1
ATH
UD7
X84
A11
P16
K33
Component Name
Serial Data
Serial Data
Audio Interface
OnStar
Driver and Passenger Heated Seats
Extended Range Remote Control
Rear Parking Assist

T11
K73
K60
K36
K9
K29
K85
K41R
K84
Low Speed GMLAN Bus is used in applications where a high data rate is not required which allows for the use
of less complex components. It is typically used for operator controlled functions where the response time
requirements are slower than those required for dynamic vehicle control.
The Low Speed GMLAN Serial Data Network consists of a single wire, ground referenced bus with high side
voltage drive. During on road vehicle operation data symbols (1's and 0's) are transmitted sequentially at the
normal rate of 33.3 Kbit/s. For component programming only, a special high speed data mode of 83.3 Kbit/s
may be used.
Unlike the high speed dual wire networks, the single wire low speed network does not use terminating resistors
at either end of the network.
The data symbols to be transmitted over the bus are represented by different voltage signals on the bus. When
the Low Speed GMLAN Bus is at rest and is not being driven, there is a low signal voltage of approximately
0.2 V. This represents a logic "1". When a logic "0" is to be transmitted, the signal voltage is driven higher to
around 4.0 V or higher.
Local Interconnect Network (LIN) Circuit Description
The Local Interconnect Network (LIN) Bus consists of a single wire with a transmission rate of 10.417 Kbit/s.
This bus is used to exchange information between a master control module and other smart devices which
provide supporting functionality. This type of configuration does not require the capacity or speed of either a
High Speed GMLAN Bus or Low Speed GMLAN Bus and is thus relatively simpler.
The data symbols (1's and 0's) to be transmitted are represented by different voltage levels on the
communication bus. When the LIN Bus is at rest and is not being driven, the signal is in a high voltage state of
approximately Vbatt. This represents a logic "1". When a logic "0" is to be transmitted, the signal voltage is
driven low to about ground (0.0 V).
Data Link Connector (DLC)
The X84 Data Link Connector (DLC) is a standardized 16-cavity connector. Connector design and location is
dictated by an industry wide standard, and is required to provide the following:
Pin 1 Low speed GMLAN communications terminal

Pin 2 Class 2 communications terminal

Pin 3 Mid speed GMLAN serial bus (+) terminal or Object high speed GMLAN serial bus (+) terminal
Pin 4 Scan tool power ground terminal
Pin 5 Common signal ground terminal
Pin 6 High speed GMLAN serial data bus (+) terminal
Pin 7 Keyword communications terminal
Pin 11 Mid speed GMLAN serial bus (-) terminal or Object high speed GMLAN serial bus (-) terminal
Pin 12 Chassis high speed GMLAN serial bus (+) terminal
Pin 13 Chassis high speed GMLAN serial bus (-) terminal
Pin 14 High speed GMLAN serial data bus (-) terminal
Pin 16 Scan tool power, battery positive voltage terminal
Serial Data Reference
The scan tool communicates over the various buses on the vehicle. When a scan tool is installed on a vehicle,
the scan tool will try to communicate with every device that could be optioned into the vehicle. If an option is
not installed on the vehicle, the scan tool will display No Comm (or Not Connected) for that optional device. In
order to avert misdiagnoses of No Communication with a specific device, refer to Data Link References for a
list of devices, the buses they communicate with, and the RPO codes for a specific device.

2013 ACCESSORIES & EQUIPMENT Displays and Gauges - Cruze

Displays and Gauges - Cruze
SPECIFICATIONS
Specification
Application
Instrument Cluster Bolt
Metric
2.5 N.m
English
22 lb in
AMBIENT AIR TEMPERATURE SENSOR RESISTANCE

Ambient Air Temperature Sensor Resistance
Ambient Air Temp Ambient Air Temp Ambient Air Temp
Temperature
Sensor
Sensor (Min)
Sensor (Max)
C
F
(kohms)
(kohms)
(kohms)
-40
-40
169.4
158.46
181.19
-30
-22
88.74
83.39
94.47
-20
-4
48.58
47.19
50.02
-10
14
27.67
26.93
28.44
0
32
16.33
15.92
16.75
10
50
9.95
9.71
10.19
20
68
6.24
6.1
6.38
30
86
4.02
3.94
4.11
40
104
2.66
2.61
2.71
50
122
1.8
1.73
1.87
60
140
1.24
1.2
1.29

INSTRUMENT CLUSTER WIRING SCHEMATICS
Power, Ground, Gauges, and Serial Data Wiring Schematics

Fig. 1: Power, Ground, Gauges, and Serial Data Wiring Schematics

Callout
CAV_42
140
140_RD/WH
CAV_32
239
239_VT/WH
CAV_31
CAV_26
CONN_X2
239_VT/WH
CAV_70
1650
1650_BK
CAV_16
5060
5060_GN
CAV_26
Component Name
42
140 RD/WH
32
Run/Crank Ignition 1 Voltage
239 VT/WH
31
26
X2
239 VT/WH
70
Ground
1650 BK
16
5060 GN
26

3098
3098_GN
CAV_55
CONN_X3
MF3
MZ0
1589
1589_BU/VT
CAV_64
CAV_4
6281
6281 BK/GN
CAV_27
CAV 3
6281_BK/GN
6281_BK/GN
6281_BK/GN
6281_BK/GN
1589_BU/VT
1589_BU/VT
X190
CAV_6
CAV_22
X401
CAV_B
CAV_R
G201
F21DA
F52UA
X200
J127
X190
X401
A90

Output Speed (Digital) Signal
3098 GN
55
X3
TRANSMISSION-MAN 6 SPD,
OPEL, 76.5 MM, 4.273 1ST,
2.158 2ND, 1.302 3RD, 0.959
4TH, 0.744 5TH, 0.614 6TH,
M32-6 WR
OPEL, 76.5 MM, 3.82 1ST, 0.74
6TH, (M32 WR)
Primary Fuel Level Sensor Signal
1589 BU/VT
64
4
Fuel Level Sensor Low
Reference
6281 BK/GN
27
3
6281 BK/GN
6281 BK/GN
6281 BK/GN
6281 BK/GN
1589 BU/VT
1589 BU/VT
X190
6
22
X401
B
R
G201
F21DA 15A
F52UA 5A
X200
J127
X190
X401
Logic

K20
KR73
X50A
P16
X51A
Manual_Transmission_Schematics_REF
A7
Engine_Controls_Schematics_REF
Manual Transmission Schematics

Engine Controls Schematics
Indicators Wiring Schematics
Fig. 2: Indicators Wiring Schematics

Callout
419
419_BN/WH
CAV_25
SD
Component Name
Check Engine Indicator
Control
419 BN/WH
25
Serial Data
Data Communication

231
231_YE/BU
CAV_31
CONN_X2
CAV_1
A90
B37
Engine_Controls_Schematics_REF
K20
P16
Schematics
Oil Pressure Switch Signal
231 YE/BU
31
X2
1
Logic
Air Temperature and Driver Information Center Wiring Schematics
Fig. 3: Air Temperature and Driver Information Center Wiring Schematics

Callout
636
CAV_1
CAV_12
Component Name
Outside Ambient Air Temperature Sensor Signal
1
12

61
CAV_2
CAV_11
636_BU/GY
61_BK/BU
61_BK/BU
61_BK/BU
61_BK/BU
636_BU/GY
636_BU/GY
636_BU/GY
OJP
OJP
OJP
OJP
CAV_5
893
893_GY/BU
CAV_5
CAV_28
1358
1358_GN/WH
CAV_12
CAV_10
897
897_BK/BN
CAV_6
CAV 9
X200
CAV 41
CAV_49
X100
CAV_21
CAV_22
X108
CAV_1
CAV_2
X200
X100
X108
A90
B9
Outside Ambient Temperature Sensor Low Reference

2
11
636 BU/GY
61 BK/BU
61 BK/BU
61 BK/BU
61 BK/BU
636 BU/GY
636 BU/GY
636 BU/GY
5
Driver Information Center Select Menu Switch Signal
893 GY/BU
5
28
Driver Information Center Switch Signal
1358 GN/WH
12
10
Driver Information Center Switch Low Reference
897 BK/BN
6
9
X200
41
49
X100
21
22
X108
1
2
X200
X100
X108
Logic

P16
S78
P9
AUDIBLE WARNINGS WIRING SCHEMATICS
Audible Warning Wiring Schematics
Fig. 4: Audible Warning Wiring Schematics

Callout
CAV_43
340
340_RD/VT
CAV_2
1020
1020_WH/VT
CAV_15
CONN_X3
Component Name
43
340 RD/VT
2
1020 WH/VT
15
X3

CAV_4
103
103_WH/VT
CAV_16
CONN_X1
13
13_GN/GY
CAV_22
SD
AEC
AXG
F22DA
A11
S79D
S39
X51A
4
Headlamp Switch On Signal
103 WH/VT
16
X1
Headlamp Switch Park Lamp
Signal
13 GN/GY
22
Serial Data
WINDOW-POWER OPERATED,
DRIVER EXPRESS DOWN
WINDOW-POWER OPERATEDEXPRESS DRIVER UP/DOWN
F22DA 2A
(without BTM)
K9
M74D

DTC
DTC B0158
DTC B0550
DTC B1370
Description
DTC B0158 02 Ambient Air Temperature Sensor
DTC B0158 05 Ambient Air Temperature Sensor
DTC B0550 32 Odometer Circuit General Memory
Malfunction
DTC B1370 01 Control Module Ignition On and
Start Circuit Short to Battery
DTC B1370 06 Control Module Ignition On and
Start Circuit Open
DTC B3567 01 Info Display Select Switch Circuit
Short to Battery


Short to Ground
Open
Protection Time-Out
DTC P0461 Fuel Level Sensor Performance
DTC P0462 Fuel Level Sensor Circuit Low Voltage
DTC P0463 Fuel Level Sensor Circuit High Voltage
DTC P0464 Fuel Level Sensor Circuit Intermittent
DTC P0520 Engine Oil Pressure Switch Circuit
DTC P0521 Engine Oil Pressure Sensor
Performance
DTC B3567
DTC P0461-P0464
DTC P0520
DTC P0521
DTC B0158
DTC Descriptors
DTC B0158 02
Ambient Air Temperature Sensor Circuit Short to Ground
DTC B0158 05
Ambient Air Temperature Sensor Circuit High Voltage/Open
Circuit
Sensor Signal
Low Reference
Short to
Ground
Open/High
Resistance
Short to
Voltage
Signal Performance
B0158 02
B0158 05
B0158 05
B0158 05
B0158 05
The instrument cluster monitors the ambient air temperature sensor with a low reference circuit and 5 V signal
circuit. The instrument cluster monitors the voltage drop across the sensor, which is proportional to temperature.
When the ambient air temperatures are cold, the resistance of the sensor is high and the voltage signals are high.
When the ambient air temperatures are hot, the resistance of the sensors is low and the voltage signals are low.

The instrument cluster converts the voltage value to a temperature value of Celsius or Fahrenheit that will be
displayed by the driver information center.

B0158 02
The instrument cluster detects the sensor signal circuit is more than 88C (190F).
B0158 05
The instrument cluster detects the sensor signal circuit is less than -40C (-40F).
The instrument cluster uses a default air temperature value for further calculations. The driver information
center displays no ambient air temperature information.
The DTC will become history if the instrument cluster no longer detects a malfunction.
Schematic Reference
Instrument Cluster Schematics
Instrument Cluster Description and Operation

Driver Information Center (DIC) Description and Operation
Circuit Testing
Connector Repairs
Wiring Repairs

Scan Tool Reference

1. Ignition ON.
2. Verify the scan tool Ambient Air Temperature parameter between -40C (-40F) to +88C (+190F) and
changes with air temperature changes.
If parameter is not between -40C (-40F) to +88C (+190F) or changes with air temperature
changes
If parameter is between -40C (-40F) to +88C (+190F) and changes with air temperature
changes
3. All OK.
1. Ignition OFF and all vehicle systems OFF, disconnect the harness connector at the B9 ambient air
temperature sensor. It may take up to 2 minutes for all vehicle systems to power down.
2. Test for less than 1 V between the low reference circuit terminal 2 and ground.
If 1 V or greater
repair the short to voltage on the circuit.
If less than 1 V
1. Ignition OFF, disconnect the harness connector at the P16 instrument cluster.
If less than 2 ohms, replace the P16 instrument cluster.
4. Ignition ON.
5. Verify the scan tool Ambient Air Temperature parameter is greater than 98%.
If 98% or less
If infinite resistance, replace the P16 instrument cluster.

If greater than 98%

6. Install a 3 A fused jumper wire between the signal circuit terminal 1 and the low reference circuit
terminal B.
7. Verify the scan tool Ambient Air Temperature parameter is less than 8%.
If 8% or greater
1. Ignition OFF, disconnect the harness connector at the P16 instrument cluster, ignition ON.
If less than 1 V
3. Ignition OFF
If less than 8%
8. Test or replace the B9 Ambient Air Temperature Sensor.
Component Testing
Static Test
1. Test the B9 Ambient Air Temperature Sensor by varying the sensor temperature while monitoring the
sensor resistance.
2. Compare the readings with the Ambient Air Temperature Sensor Resistance
If not within the specified range
Replace the B9 Ambient Air Temperature Sensor.
If within specified range
3. All OK.
Repair Instructions
Ambient Air Temperature Gauge Sensor Replacement

Control Module References for module replacement, programming, and setup
DTC B0550

DTC Descriptor
DTC B0550 32
Odometer Circuit General Memory Malfunction
The Instrument Cluster is equipped with odometers that indicate the distance traveled by the vehicle. One type
of odometer is the season odometer where the traveled distance can not be reset by the driver. This information
is also stored in the Body Control Module (BCM). In addition to storing the season odometer value for the
vehicle, the Instrument Cluster and the BCM store the VIN. Software checks are performed to ensure these
modules, and their stored season odometer information, can not be moved or transferred between different
vehicles.
The ignition is ON.

The BCM has detected an internal memory malfunction.

DTC B0550 32 is stored in the BCM memory.

The BCM no longer detects a malfunction.

Schematic Reference

Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference

1. Ignition ON.
2. Verify DTC B0550 32 is not set.
If DTC B0550 32 is set
1. Program the K9 Body Control Module.
If the DTC sets, replace the K9 Body Control Module.
3. All OK.
If DTC B0550 32 is not set
3. All OK
Repair Instructions

Control Module References for BCM replacement, programming and setup
DTC B1370
DTC Descriptors
DTC B1370 01
Control Module Ignition On and Start Circuit Short to Battery
DTC B1370 06

Control Module Ignition On and Start Circuit Open

Circuit
Ignition Main Relay Control
Terminal 2
Ignition Main Relay Ignition terminal
5/ Instrument Cluster ignition voltage
terminal 31
Ignition Main Relay Ground terminal
1
Ignition Main Relay B+ terminal 3
Short to
Ground
Open/High
Resistance
Short to
Voltage
Signal
Performance
B1370 06
B1370 06
B1370 01
B1370 06
B1370 06
B1370 01
B1370 06
B1370 06
The vehicle power mode master is the body control module (BCM). The ignition switch is a low current switch
with multiple discrete circuits to the BCM.
The power mode master will activate relays and other direct outputs of the power mode master as needed
according to the calculated power mode. Some relays controlled by the BCM are switched ignition voltage
outputs that are pass through circuits within the BCM directly from the ignition switch. If these circuits short to
ground, the B+ circuit fuse to the ignition switch will open.
B1370 01
Ignition switch is in the Accessory position.
B1370 06
Ignition switch is in the Accessory, Run, or Crank positions.
B1370 01
Ignition circuit is shorted to voltage.
B1370 06
Ignition circuit is open.

Ignition or run/crank relay circuit is shorted to ground.
B+ circuit of the ignition run/crank relay is open or shorted to ground.

Ignition run/crank relay control circuit open, including relay coil and ground.
The Instrument Cluster still functions except check engine light is always off.

Schematic Reference

Power Distribution Schematics
Power Moding Schematics


Power Mode Description and Operation
Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference

1. Verify that DTC B144B or B1380 is not set.

If DTC B144B or B1380 is set

If DTC B144B or B1380 is not set

1. Ignition OFF, disconnect the KR73 Ignition Main Relay.

Test the ground circuit for an open/high resistance.

Verify that a test lamp does not illuminate between the control circuit terminal 2 and ground.
1. Disconnect the harness connector at the K9 Body Control Module.
Ignition ON, verify that a test lamp illuminates between the control circuit terminal 2 and ground.
Ignition OFF, reconnect the KR73 Ignition Main Relay.
Disconnect the harness connector at the P16 Instrument Cluster.
Verify that a test lamp does not illuminate between the ignition circuit terminal 31 and ground.
1. Test for less than 1 V between the ignition circuit and ground.
If less than 1 V, replace the KR73 Ignition Main Relay.
4.
5.
6.
7.
8.

9. Ignition ON, verify that a test lamp illuminates between the ignition terminal 31 and ground.
If the test lamp does not illuminate and the Ignition fuse is good
1. Test for less than 2 ohms in the ignition circuit end to end
If less than 2 ohms, replace the KR73 Ignition Main Relay.
If the test lamp does not illuminate and the Ignition fuse is open
10. Replace the P16 instrument cluster.
Repair Instructions
Instrument Cluster Replacement

Relay Replacement (Within an Electrical Center) , Relay Replacement (Attached to Wire Harness)
DTC B3567
DTC Descriptors
DTC B3567 01
Info Display Select Switch Circuit Short to Battery
DTC B3567 02
Info Display Select Switch Circuit Short to Ground
DTC B3567 04
Info Display Select Switch Circuit Open
DTC B3567 59

Info Display Select Switch Circuit Protection Time-Out

The driver information center switch is a multiplexed switch. Battery power is provided to the driver
information center switch via the instrument cluster. The driver information center switch signal circuit is pulled
up to battery voltage in the instrument cluster. The instrument cluster also provides the driver information
center switch with a low reference. The switch input to the instrument cluster is pulled low when a switch is
activated. The driver information center switch is a momentary contact switch that connects a series of resistors
in a resistor ladder format. The instrument cluster monitors the driver information center switch signal circuit to
determine the driver information center switch inputs. Each switch state Menu, Up, Down, Clear corresponds to
a certain resistance value. The instrument cluster determines the switch pressed by the voltage drop across the
resistors.
The ignition is in OFF, ACCESSORY or RUN position.

B3567 01
The instrument cluster detects that the driver information center switch signal circuit is shorted to battery.
B3567 02
The instrument cluster detects that the driver information center switch signal circuit is shorted to ground.
B3567 04
The instrument cluster detects that the driver information center switch signal circuit is open.
B3567 59
The instrument cluster detects that the driver information center switch is stuck.
The instrument cluster ignores the driver information center switch inputs.
The DTC will become history if the instrument cluster no longer detects a malfunction.
Schematic Reference


Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference

1. Ignition ON.
2. Verify the driver information center set, up and down function changes when pressing the set, up or down
switch.
If the driver information center does not change
Refer to Set, Up and Down Switch Malfunction below
If the driver information center changes
3. Verify the driver information center menu function changes when pressing the menu switch.
Refer to Menu Switch Malfunction below

4. All OK.
Menu Switch Malfunction

1. Ignition ON.

If less than 4.8 V

1. Ignition OFF, disconnect the harness connector at the P16 Instrument Cluster.
If less than 2 ohms, replace the P16 Instrument Cluster.
1. Ignition OFF, disconnect the harness connector at the P16 Instrument Cluster, ignition ON.
If less than 1 V, replace the P16 Instrument Cluster.
Repair the open/high resistance in the circuit

4. Test or replace the S78 Turn Signal/Multifunction Switch.
Set, Up and Down Switch Malfunction

1. Ignition OFF and all vehicle systems OFF, disconnect the X1 harness connector at the S78 Turn
Signal/Multifunction Switch, ignition ON.
If less than 11.8 V

1. Ignition OFF, disconnect the harness connector at the P16 Instrument Cluster, ignition ON.
If less than 1 V, replace the P16 Instrument Cluster.
4. Test or replace the S78 Turn Signal/Multifunction Switch.
Repair Instructions
Turn Signal Switch Replacement

Control Module References for instrument cluster replacement, programming and setup
DTC P0461-P0464
DTC Descriptors
DTC P0461
Fuel Level Sensor Performance
DTC P0462
Fuel Level Sensor Circuit Low Voltage
DTC P0463
Fuel Level Sensor Circuit High Voltage
DTC P0464
Fuel Level Sensor Circuit Intermittent

Circuit
Fuel Level Sensor 1 Signal
Low Reference
1. Fuel Gauge Malfunction
Short to
Ground
P0462
-
Open/High
Resistance
P0463
1
Short to
Voltage
P0463
P0463, P0464
Signal Performance
P0461
P0461
The fuel level sensor changes resistance based on fuel level. The engine control module (ECM) monitors the
signal circuit of the fuel level sensor in order to determine the fuel level. When the fuel tank is full, the
resistances of the fuel level sensor is low and the ECM senses a low signal voltage on the signal circuit of the
fuel level sensor. When the fuel tank is empty, the resistance of the fuel level sensor is high and the ECM senses
a high signal voltage. The ECM uses the signal circuit of the fuel level sensor in order to calculate the
percentage of remaining fuel in the tank. The ECM sends the fuel level percentage via High Speed CAN-Bus to
the body control module (BCM). The BCM then sends the fuel level percentage via Low Speed CAN-Bus to the
instrument cluster in order to control the fuel gauge.
The engine is running

The system voltage is between 11-16 V
P0461 00
The ECM detects a change in fuel level of less than a specified amount (typically 3-10 L or 0.8-2.6 gal) over a
specified driving distance (typically 240-320 km or 150-200 miles).
P0462
The signal voltage is less than 0.25 V.

The above conditions must be met for 5 seconds.
P0463
The signal voltage is greater than 4.7 V.

P0464
The fuel level change is greater than 10%.

DTC P0464 runs and fails 2 out of 3 test cycles.

P0461, P0462, P0463, and P0464 are Type B DTCs

The fuel gauge defaults to empty
The low fuel indicator illuminates
P0461, P0462, P0463, and P0464 are Type B DTCs

The DTC becomes history when the conditions for setting the DTC are no longer present.
The history DTC clears after 40 malfunction-free warm-up cycles.
Schematic Reference
Circuit Testing
Connector Repairs
Wiring Repairs
DTC Type Reference

Scan Tool Reference
1. Ignition ON.
2. Verify the scan tool Fuel Level Sensor parameter is between 0.5-3.5 V and varies with fuel level.

If not between 0.5-3.5 V or does not vary with fuel level

If between 0.5-3.5 V and varies with fuel level

3. Verify the all fuel level gauge segments illuminate when performing the scan tool Driver Information
Center Segments control function.
If any fuel level gauge segments do not illuminate
Replace the P16 instrument cluster

If all fuel level gauge segments illuminate
4. All OK.
1. Ignition OFF and all vehicle systems OFF, disconnect the X1 harness connector at the A7 Fuel Pump and
Level Sender Assembly. It may take up to 2 minutes for all vehicle systems to power down.
1. Ignition OFF, disconnect the harness connector at the K20 Engine Control Module.
If less than 2 ohms, replace the K20 Engine Control Module.
3. Ignition ON.
4. Verify the scan tool Remaining Fuel In Tank parameter is less than 5%.
If 5% or greater
If infinite resistance, replace the K20 Engine Control Module.
If less than 5%
terminal 3.
6. Verify the scan tool Remaining Fuel In Tank is greater than 90%.
If 90% or less
1. Ignition OFF, disconnect the harness connector at the K20 Engine Control Module, ignition ON.
If less than 1 V

3. Ignition OFF
If greater than 90%
7. Test or replace the B46 Fuel Level Sensor.
Component Testing
1. Ignition OFF, remove the A7 Fuel Pump and Level Sender Assembly.
2. Sweep the fuel Level Sensor through its full range of motion while measuring resistance between the
signal terminal 4 and the low reference terminal 3.
3. Test for a minimum resistance value of 37-43 ohms and a maximum value of 245-255 ohms without any
spikes or dropouts.
If minimum resistance is not 37-43 ohms, maximum resistance is not 245-255 ohms, or if
there are any spikes or dropouts
Replace the B46 Fuel Level Sensor.
If minimum resistance is 37-43 ohms, maximum resistance is 245-255 ohms, and if there are
no spikes or dropouts
4. All OK.
Repair Instructions
Fuel Tank Fuel Pump Module Replacement for the 1.4L engine
Fuel Level Sensor Replacement for the 1.8L engine
Control Module References for the ECM replacement, programming and setup
DTC P0520
DTC Descriptor
DTC P0520
Engine Oil Pressure Switch Circuit

Short to
Ground
Signal
1
1. Engine Oil Pressure Indicator Malfunction
Circuit
Open/High
Resistance
P0520
Short to
Voltage
1
Signal Performance
P0521
ECM - Engine Oil Pressure Switch

Circuit
Short to Ground
Parameter Normal Range: OK
Signal
Low
Open
Short to Voltage
OK
OK
The engine oil pressure switch is a normally closed switch that opens with the proper oil pressure. With the
ignition switch turned ON and the engine not running, the engine control module (ECM) should detect a low
signal voltage input. With the engine running, the engine oil pressure switch opens and the ECM should detect a
high signal voltage input. When the oil pressure is low, the ECM sends a message via High Speed CAN-Bus to
the body control module (BCM). The BCM then sends a message via Low Speed CAN-Bus to the instrument
cluster requesting the engine oil pressure indicator turned ON.

The ECM detects that the engine oil pressure switch signal circuit is pulled low.
The instrument cluster illuminates the service vehicle soon indicator and the oil pressure low indicator.
Schematic Reference



Indicator/Warning Message Description and Operation
Circuit Testing
Connector Repairs
Wiring Repairs
DTC Type Reference

Scan Tool Reference
1. Ignition ON.
2. Verify the scan tool Engine Oil Pressure parameter is Low.
If not Low
If Low
3. Engine running.
4. Verify the scan tool Engine Oil Pressure parameter is OK.
If not OK

If OK
5. All OK.

1. Ignition OFF, disconnect the harness connector at the B37 Engine Oil Pressure Switch, ignition ON.
2. Verify the scan tool Engine Oil Pressure Switch parameter is OK.
If not OK
If OK
3. Install a 3 A fused jumper wire between the signal circuit terminal 1 and ground.
4. Verify the scan tool Engine Oil Pressure Switch parameter is Low.
If not Low
If less than 1 V
If Low
5. Test or replace the B37 Engine Oil Pressure Switch.
Repair Instructions
Engine Oil Pressure Indicator Switch Replacement for the 1.4L engine
Control Module References for ECM replacement, programming and setup
DTC P0521
DTC Descriptor
DTC P0521

Engine Oil Pressure Sensor Performance

Short to
Ground
Signal
1
Circuit
Open/High
Resistance
P0521
Short to
Voltage
1
Signal Performance
P0521
ECM - Engine Oil Pressure Switch

Circuit
Short to Ground
Parameter Normal Range: OK
Signal
Low
Open
Short to Voltage
OK
OK
The engine oil pressure switch is a normally closed switch that opens with the proper oil pressure. With the
ignition switch turned ON and the engine not running, the engine control module (ECM) should detect a low

The ECM detects that the engine oil pressure switch signal circuit is pulled low.
The instrument cluster illuminates the service vehicle soon indicator and the oil pressure low indicator.
Schematic Reference



Circuit Testing
Connector Repairs
Wiring Repairs
DTC Type Reference

Scan Tool Reference
1. Ignition ON.
If not Low
If Low
3. Engine running.
If not OK

If OK
5. All OK.

1. Ignition OFF, disconnect the harness connector at the B37 engine oil pressure switch, ignition ON.
If not OK
1. Ignition OFF, disconnect the harness connector at the K20 engine control module.
If infinite resistance, replace the K20 engine control module.
If OK
If not Low
1. Ignition OFF, disconnect the harness connector at the K20 engine control module, ignition ON.
If less than 1 V
If less than 2 ohms, replace the K20 engine control module.
If Low
5. Test or replace the B37 engine oil pressure switch.
Repair Instructions
SYMPTOMS - DISPLAYS AND GAUGES

NOTE:
The following steps must be completed before using the symptom diagnostic
tables.
1. Before using the symptom diagnostic tables, perform the Diagnostic System Check - Vehicle
2. Review the system operation in order to understand the system functions. Refer to the following
description and operations:


Audible Warnings Description and Operation
Inspect for aftermarket devices which can affect the operation of the instrument panel cluster or the
audible warning systems. Refer to Checking Aftermarket Accessories
Inspect for the proper fluid levels.
Intermittent
Intermittent Conditions and Poor Connections
Symptom List
Gauges and Odometer
Instrument Cluster Gauges Malfunction

Fuel Gauge Malfunction
Speedometer and/or Odometer Malfunction
Indicators
ABS Indicator Malfunction

Air Bag Indicator Circuit Malfunction (Driver) , Air Bag Indicator Circuit Malfunction
(Passenger)
Brake Warning Indicator Malfunction
Charge Indicator Malfunction
Cruise Control Indicator Malfunction
Door Ajar Indicator Malfunction
Engine Oil Pressure Indicator Malfunction
Front Fog Lamps Malfunction
Headlamps Malfunction
Interior Backlighting Malfunction
Malfunction Indicator Lamp (MIL) Diagnosis
Seat Belt Indicator Malfunction - Driver
Seat Belt Indicator Malfunction - Passenger
Security Indicator Malfunction (with C67) , Security Indicator Malfunction (with C68)

Traction Control/Stability Control Indicator Malfunction

Trunk Ajar Indicator Malfunction
Turn Signal Lamps and/or Indicators Malfunction
Washer Malfunction
Driver Information Center Switch Malfunction

Outside Air Temperature Display Malfunction
Audible Warnings
Chime Malfunction
CHARGE INDICATOR MALFUNCTION
The engine Control Module (ECM) uses the generator turn ON signal circuit to control the load of the generator
on the engine. A high side driver in the ECM applies voltage to the voltage regulator. This signals the voltage
regulator to turn the field circuit ON and OFF. The ECM monitors the state of the generator turn ON signal
circuit. The ECM should detect low voltage on the generator turn on signal circuit when the ignition is ON and
the engine is OFF, or when the charging system malfunctions. With the engine running, the ECM should detect
high voltage on the generator turn on signal circuit. The ECM performs key ON and RUN tests to determine the
status of the generator turn on signal circuit. If a malfunction is detected the ECM will illuminate the charge
indicator in the instrument cluster.
Schematic Reference

Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference

1. Ignition ON, engine running.

2. Verify the scan tool Battery Voltage parameter is between 12.5-15.5 V.
If not 12.5-15.5 V
Refer to Charging System Test .
If 12.5-15.5 V
3. Verify the charge indicator turns on and off when commanding the All Indicators test ON and OFF with
the scan tool.
If the charge indicator always stays on or always stays off

If the charge indicator turns on and off as commanded
4. All OK.
Repair Instructions

Control Module References for Instrument Cluster replacement, programming, and setup
CHIME MALFUNCTION

The radio generates the audible warnings. The instrument cluster, the body control module (BCM), the
inflatable restraint sensing and diagnostic module (SDM) or the object alarm module request audible warnings
via serial data.
Schematic Reference
Audible Warnings Schematics
Audible Warnings Description and Operation
Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference

NOTE:
Before performing this diagnostics, make sure no indicators are illuminated

after the instrument cluster performs a lamp test. If any indicators are
illuminated after the bulb test, perform the indicator diagnostics before this
diagnostics.
1. Ignition ON.
2. Verify all the radio speakers operate by adjust the radio balance and fade to each speaker.
If any speaker does not operate properly
Refer to Speaker Malfunction .
If the speakers operate properly
3. Verify the scan tool Driver Seat Belt Status and Passenger Seat Belt Status parameters are Buckled when
both front seat belts are buckled.

If not Buckled
Refer to Seat Belt Indicator Malfunction - Driver .
If buckled
4. Verify the scan tool Headlamp On Switch parameter is Inactive when the headlamps are OFF.
If not Inactive
Refer to Headlamps Malfunction .

If Inactive
5. Verify the scan tool Park Lamps Switch parameter is Inactive when the park lamp switch is OFF.
If not Inactive
Refer to Park, License, and/or Tail Lamps Malfunction .

If Inactive
6. Verify the scan tool Left Turn Signal Switch and Right Turn Signal Switch parameters are Inactive while
the turn signal switch is OFF.
If not Inactive
Refer to Turn Signal Lamps and/or Indicators Malfunction .

If Inactive
7. Verify the scan tool Park Brake Switch parameter is Inactive when the park brake is OFF.
If not Inactive
Refer to Park Brake System Diagnosis (Drum Brakes) , Park Brake System Diagnosis (Disc
Brakes) .
If Inactive
8. Verify that all scan tool parameters listed below are Inactive when all the doors are closed.
Passenger Door Ajar Switch
If not Inactive
Refer to Door Ajar Indicator Malfunction .

If Inactive
9. Verify the scan tool Key in Ignition Status parameter is Inactive when the key is out of the ignition.
If not Inactive


If Active
10. All OK
1. Ignition ON, disconnect the harness connector at the S39 Ignition Switch while the ignition is ON.
2. Verify a test lamp illuminates between the B+ circuit terminal 2 and ground.
Test for less than 2 ohms in the B+ circuit end to end.
If infinite resistance, replace the K9 Body Control Module.
Verify the scan tool Key in Ignition Status parameter is Inactive.
If not Inactive
1. Disconnect the X3 harness connector at the K9 Body Control Module.
If Inactive
Install a 3 A fused jumper wire between the signal circuit terminal 4 and the B+ circuit terminal 2.
Verify the scan tool Key in Ignition Status parameter is Active.
If not Active
If Active
Test or replace the S39 Ignition Switch.
3.
4.
5.
6.

Repair Instructions

Control Module References for BCM or Radio replacement, programming and setup
DRIVER INFORMATION CENTER SWITCH MALFUNCTION
The driver information center switches are multiplexed switches that are part of the Turn Signal/Multifunction
Switch.
The Instrument Cluster provides 5 volts to the MENU switch. The MENU switch is a momentary contact switch
that is provided ground through the Turn Signal/Multifunction Switch ground circuit.
The Instrument Cluster provides battery voltage to the UP, DOWN, SET switches. The UP, DOWN, SET
switch signal circuits are pulled up to battery voltage in the Instrument Cluster. The Instrument Cluster also
provides the UP, DOWN, SET switches with a low reference circuit. The UP, DOWN, SET switch signal
circuit is pulled low when a switch is activated. The driver information center UP, DOWN, SET switches are
momentary contact switches that connect a series of resistors in a resistor ladder format. The instrument cluster
monitors the driver information center UP, DOWN, SET switch signal circuit to determine the switch position.
Each switch state - UP, DOWN, SET- corresponds to a certain resistance value. The instrument cluster
determines the switch pressed by the voltage drop across the resistors.
Schematic Reference

Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference

1. Ignition ON.
2. Verify the driver information center set, up and down function changes when pressing the set, up or down
switch.
Refer to Set, Up and Down Switch Malfunction below
3. Verify the driver information center menu function changes when pressing the menu switch.
Refer to Menu Switch Malfunction below

4. All OK.
Menu Switch Malfunction

1. Ignition ON.
If less than 4.8 V

If less than 1 V, replace the P16 instrument cluster.
Repair the open/high resistance in the circuit
4. Test or replace the S78 Turn Signal/ Multifunction Switch.
Set, Up and Down Switch Malfunction

1. Ignition OFF and all vehicle systems OFF, disconnect the X1 harness connector at the S78 Turn Signal/
Multifunction Switch, ignition ON.
If less than 11.8 V
If less than 1 V, replace the P16 instrument cluster.

4. Test or replace the S78 Turn Signal/ Multifunction Switch.

Repair Instructions
Turn Signal Switch Replacement

Control Module References for the instrument cluster replacement, programming and setup
ENGINE OIL PRESSURE INDICATOR MALFUNCTION

Short to
Ground
Signal
1
Ground
Circuit
Open/High
Resistance
P0520, P0521
P0520, P0521
Short to
Voltage
1
-
Signal Performance
P0521
P0521
The Engine Oil Pressure Switch is a normally closed switch that opens with the proper oil pressure. With the
ignition switch turned ON and the engine not running, the Engine Control Module (ECM) should detect a low
Schematic Reference


Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference

1. Ignition ON.
If not Low
If Low
3. Engine running.
If not OK

If OK
5. All OK.
1. Ignition OFF, disconnect the harness connector at the B37 Engine Oil Pressure Switch, ignition ON.
If not OK
If OK

If not Low
If less than 1 V
If Low
5. Test or replace the B37 Engine Oil Pressure Switch.
Repair Instructions
Control Module References for instrument cluster or ECM replacement, programming and setup
FUEL GAUGE MALFUNCTION

The instrument cluster displays the fuel level based on the information from the engine control module (ECM).
The ECM converts the data from the fuel level sensors to a fuel level signal. The ECM sends the fuel level
signal via a High Speed CAN-Bus signal to the body control module (BCM). The BCM then sends the
information via a Low Speed CAN-Bus signal to the instrument cluster to display the fuel level. When the fuel
level falls below 11% the instrument cluster illuminates the low fuel level indicator.
Schematic Reference


Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference

1. Ignition ON, perform the Instrument Cluster Gauge Sweep test with the scan tool, verify that the fuel
level gauge sweeps from its low to high position.
If the fuel level gauge does not sweep
If the fuel level gauge sweeps
2. Command the All Indicators test ON and OFF with the scan tool, verify that the low fuel level indicator
turns ON and OFF.
If the low fuel level indicator does not turn ON or OFF as commanded

If the low fuel level indicator turns ON and OFF as commanded
3. Observe the scan tool ECM Fuel Level Sensor parameter. The reading should be 0.5-3.5 V and vary with
fuel level.
If the reading does not vary with fuel level
Refer to DTC P0461-P0464.

If the reading varies with fuel level
4. All OK.
Repair Instructions

Control Module References for instrument cluster or ECM replacement, programming and setup.

INSTRUMENT CLUSTER GAUGES MALFUNCTION

The instrument cluster displays the engine coolant temperature, fuel level, vehicle speed and the engine speed
based on the information from the engine control module (ECM). The ECM sends information via a serial data
to the body control module (BCM). The BCM then sends the information via serial data to the instrument
cluster to display the engine coolant temperature, fuel level, the engine speed, the vehicle speed and the distance
travelled, either in kilometers or miles, based on the vehicle requirements.
Schematic Reference
Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference

1. Verify no DTC is set.

If any DTC is set


If no DTCs are set
2. Ignition ON, perform the Instrument Cluster Gauge Sweep test with the scan tool, verify that all gauges
sweep from their low to high position.
If any gauge does not sweep

If all gauges sweep
3. Drive the vehicle, verify the gauge values matches the values on the scan tool.
If the values do not match

If the values match the scan tool
4. All OK.
Repair Instructions

Control Module References for Instrument Cluster or ECM replacement, programming, and setup.
OUTSIDE AIR TEMPERATURE DISPLAY MALFUNCTION
Circuit
Sensor Signal
Low Reference
Short to
Ground
Open/High
Resistance
Short to
Voltage
Signal Performance
B0158 02
B0158 05
B0158 05
B0158 05
B0158 05
The instrument cluster monitors the ambient air temperature sensor with a low reference circuit and 5 V signal
circuit. The instrument cluster monitors the voltage drop across the sensor, which is proportional to temperature.
When the ambient air temperatures are cold, the resistance of the sensor is high and the voltage signals are high.

When the ambient air temperatures are hot, the resistance of the sensors is low and the voltage signals are low.
The instrument cluster converts the voltage value to a temperature value of Celsius or Fahrenheit that will be
displayed by the display.
Schematic Reference
Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference

Ignition ON, observe the scan tool Ambient Air Temperature parameter. The reading should be between -40C
(-40F) to +88C (+190F) and change with air temperature changes.
1. Ignition OFF and all vehicle systems OFF, disconnect the harness connector at the B9 ambient air
temperature sensor. It may take up to 2 minutes for all vehicle systems to power down.
2. Test for less than 1 V between the low reference circuit terminal B and ground.
If 1 V or greater
repair the short to voltage on the circuit.
If less than 1 V
3. Test for less than 10 ohms between the low reference circuit terminal B and ground.

4.
5.
6.
7.
8.
Ignition ON.
Verify the scan tool Ambient Air Temperature parameter is greater than 98%.
If 98% or less
If greater than 98%
Install a 3 A fused jumper wire between the signal circuit terminal A and the low reference circuit
terminal B.
Verify the scan tool Ambient Air Temperature parameter is less than 8%.
If 8% or greater
If less than 1 V
3. Ignition OFF
If less than 8%
Test or replace the B9 Ambient Air Temperature Sensor.
Repair Instructions

Control Module References for instrument cluster or display replacement, programming, and setup
SPEEDOMETER AND/OR ODOMETER MALFUNCTION



The instrument cluster displays the engine coolant temperature, fuel level, vehicle speed and the engine speed
based on the information from the engine control module (ECM). The ECM sends information via a High Speed
CAN-Bus signal to the body control module (BCM). The BCM then sends the information via a Low Speed
CAN-Bus signal to the instrument cluster to display the engine coolant temperature, fuel level, the engine
speed, the vehicle speed and the distance travelled, either in kilometers or miles, based on the vehicle
requirements. The instrument cluster will display dashes when its VIN does not match the VIN received from
the BCM.
Diagnostic Aids
If the VIN mismatch is corrected the odometer will once again be displayed in the instrument cluster. If the
vehicle is driven for a calibrated distance with a VIN mismatch, it will cause the instrument cluster odometer to
enter into an error mode and lock itself. When this occurs the dashes will remain on the display even after
correcting the VIN mismatch. The vehicle odometer status data display on the scan tool can be used to identify
a locked odometer. The only way to unlock the instrument cluster (clear the dashes from the display) is to
perform an SPS programming event. Failure to follow the diagnostic and programming procedures may result in
either an improper odometer value or a module replacement.
Schematic Reference
Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference


1. Verify no DTC is set.

If any DTC is set
Diagnose DTCs first. Refer to Diagnostic Trouble Code (DTC) List - Vehicle .
If no DTCs are set
2. Ignition ON, perform the Speedometer Sweep Test with the scan tool, verify the speedometer sweeps
from low to high position.
If speedometer does not sweep

If speedometer sweeps properly
3. Drive the vehicle, verify the speedometer gauge value matches the Vehicle Speed parameter on the scan
tool.
If the values do not match

If the speedometer value matches the scan tool parameter
4. Drive the vehicle, verify the odometer display and the displayed distance counts up while driving.
If the odometer displays only "----" (dashes)
If the odometer display does not count up

If speedometer sweeps and displays the correct value, and the odometer display counts up
5. All OK.
NOTE:
If there are multiple modules not original to the vehicle and are not new
correctly configured service parts, SPS may not be able to proper read or
recover the vehicle odometer value. Follow government rules and
documentation (including vehicle identification) regarding inaccurate/unknown
odometer values.
Perform circuit/system verification first.

Instrument Cluster is Showing "----" (Dashes)

Correcting VIN mismatch - odometer is still Inactive.
1. Verify the vehicle odometer status with a scan tool. The reading should be Inactive.
If the reading is Active
Refer to correcting VIN mismatch - odometer Active below.
If the reading is Inactive
2. Using the scan tool, verify the BCM VIN matches the vehicle VIN placard.
If the VIN does not match
Reprogram the BCM, then proceed to Step 3.

If the VIN matches
3. Using the scan tool, verify the instrument cluster VIN matches the vehicle VIN placard.
Reprogram the instrument cluster. Then proceed with step 4.

If the VIN matches
4. Ignition ON, verify the instrument cluster is displaying the correct value.
If the instrument cluster is still displaying "----" (dashes)

Instrument Cluster is Showing "----" (Dashes)
Correcting VIN mismatch - odometer is Active.
1. Verify the vehicle odometer status with a scan tool. The reading should be Inactive.
If the reading is Inactive
Refer to Correcting VIN mismatch - odometer Inactive below.
If the reading is Active
2. Using the scan tool, verify the instrument cluster VIN matches the vehicle's VIN placard.
Reprogram the Instrument Cluster. Then proceed with step 3.

If the VIN matches
3. Perform the BCM setup procedure in SPS.

4. Ignition ON, verify the instrument cluster is displaying the correct value.
If the instrument cluster is still displaying "----" (dashes)
If instrument cluster is displaying the correct value
5. All OK.
Repair Instructions

Control Module References for instrument cluster, BCM or ECM replacement, programming, and setup
REPAIR INSTRUCTIONS
AMBIENT AIR TEMPERATURE GAUGE SENSOR REPLACEMENT
Fig. 5: Ambient Air Temperature Gauge Sensor

Callout
Component Name

Remove the front compartment insulator. Refer to Front Compartment Insulator Replacement .
Ambient Air Temperature Gauge Sensor
Procedure
1
DRIVER INFORMATION DISPLAY REPLACEMENT
Fig. 6: Driver Information Display (UDY)

Callout
Component Name
Remove driver information display bezel. Refer to Driver Information Display Bezel Replacement .
Driver Information Display Screw (Qty: 2)
1
2
3
CAUTION:
Driver Information Display Washer (Qty: 2)

Driver Information Display
Procedure
Slide the driver information display bezel from driver information
display.

INSTRUMENT CLUSTER REPLACEMENT
Fig. 7: Instrument Cluster

Callout
Component Name
Connection .
2. Remove the lower instrument panel cluster trim plate. Refer to Instrument Panel Cluster Lower
Trim Plate Replacement .
3. Remove the steering column upper trim cover. Refer to Steering Column Upper Trim Cover
Replacement .
Instrument Cluster Screw (Qty: 4)
CAUTION:
Tighten
2.5 (22 lb in)
Instrument Cluster

Procedure
2

2. After replacement, refer to Control Module References , for
programming and set up procedures.

AUDIBLE WARNINGS DESCRIPTION AND OPERATION
The audible warnings alert the driver of a system concern or a critical vehicle condition. The radio generates the
audible warnings through the speakers. The radio receives audible warning requests via the serial data circuit. If
the radio receives multiple audible warning requests, the warning with the highest priority sounds first. The
radio is the chime producer. The following lists the audible warning sounds:
1.
2.
3.
4.
5.
6.
Single pulse gong

Multiple pulse gong
Single pulse beep
Multiple pulse beep
Click
Clack
Fasten Safety Belt Warning
The chime producer activates the fasten safety belt audible warning as requested by the body control module
(BCM). The BCM sends a serial data message to the chime producer indicating the chime as a multiple gong.
The fasten safety belt warning sounds and the fasten safety belt indicator illuminates when the following occurs:
The ignition switch transitions to ON.

The inflatable restraint sensing and diagnostic module (SDM) detects that the drivers seat belt is not
buckled and the signal is low. The SDM sends a serial data message to the BCM indicating the seat belt
status. The instrument cluster receives a serial data message from the BCM indicating the driver seat belt
status.
If the seat belt is buckled when the ignition is turned ON, the chime does not sound. If the seat belt is buckled
while the chime is sounding, the chime stops. If the seat belt is unbuckled after the initial transition to ON, the
chime does not sound.
Lights On Warning
The chime producer activates the lights on warning as requested by the BCM. The BCM sends a serial data
message to the chime producer indicating the chime as a multiple gong. The lights on warning sounds when the
following occurs:
The ignition is OFF.

The BCM determines that the driver door is open and the signal circuit is low.
The BCM determines that the headlamp switch is in the park or head position.
Brake Warning
The chime producer activates the brake audible warning as requested by multiple control modules. The BCM,
electronic brake control module or the parking brake control module sends a serial data message to the chime
producer indicating the chime as a multiple gong. The brake warning sounds and the BRAKE indicator
illuminates when the following occurs:
The ignition is ON.

The vehicle speed is greater than 8 km/h (4.9 MPH). The instrument cluster receives a serial data message
from the engine control module (ECM) indicating the vehicle speed.
The BCM determines that the parking brake is engaged and the signal circuit is low.
The brake fluid is low.
Key-In-Ignition Warning
The chime producer activates the key-in-ignition audible warning as requested by the BCM. The BCM sends a
serial data message to the chime producer indicating the chime as a multiple gong. The key-in-ignition warning
sounds when the following occurs:
The ignition switch is OFF.

The BCM determines that the driver door is open and the signal circuit is low.
Door Ajar Warning
The chime producer activates the door ajar audible warning as requested by the BCM. The BCM sends a serial
data message to the chime producer indicating the chime frequency of a medium rate and continuous duration.
The door ajar warning sounds and the appropriate door ajar indicator illuminates in the driver information
center when the BCM determines that a door (driver door, passenger door, left rear door, right rear door) is open
and the signal circuit is low. The instrument cluster also receives a serial data message from the BCM indicating
the door ajar status.
Object Detection
The chime producer activates the object detection audible warning as requested by the object alarm module.
When an object is within the measuring range of the sensor, the ultrasonic pulse is reflected and is received by
the sending or a neighboring sensor. The sensor converts this signal into a voltage signal and sends this signal to
the object alarm module. The object alarm module evaluates the received sensor signals. As soon as an object is
within the measuring range, the object alarm module sends a message via CAN-Bus to the chime producer in
order to give out the acoustic distance signal. The measuring range is between 30-120 cm (11.81-47.24 in).
From a distance of 120 cm (47.24 in), the acoustic signal is active. The frequency of the beep sound increases
with decreasing distance. From a distance less than 30 cm (11.81 in), the sound becomes continuous.
Additional Warnings

The following warnings have an associated instrument cluster indicator or driver information center message:
Turn Signal Indicators-The chime producer activates the audible warning as requested by the BCM. The
chime produces two different chimes, one when the turn signal turns off and another when the turn signal
turns on.
Vehicle Overspeed Message-The chime producer activates the audible warning as requested by the BCM.
The BCM sends a serial data message to the chime producer.
Fuel Level Low Message-The chime producer activates the audible warning as requested by the BCM.
Oil Pressure Indicator-The chime producer activates the audible warning as requested by the BCM. The
BCM sends a serial data message to the chime producer.
Park Assist Fault Clean Rear Bumper Message-The chime producer activates the audible warning as
requested by the BCM. The BCM sends a serial data message to the chime producer.
Tire Pressure Low Indicator-The chime producer activates the audible warning as requested by the BCM.
Refer to Indicator/Warning Message Description and Operation.

COMPASS CALIBRATION AND MAGNETIC VARIANCE (DRIVER INFORMATION CENTER
(DIC))
Compass Calibration
The compass direction will show CAL if it needs to be calibrated. Before calibrating the compass, drive the
vehicle to an area that is magnetically clean (free of large metallic objects).
1. Turn ON the ignition.
2. Before calibrating the compass, make sure the compass is set to the variance zone in which the vehicle is
travelling. See Compass Magnetic Variation Adjustment below.
3. Press the vehicle information button until the PRESS TO CALIBRATE COMPASS screen is displayed.
4. Press the set/reset button to start the compass calibration.
5. The DIC will display CALIBRATING: DRIVE IN CIRCLES. Drive the vehicle in circles at less than 8
km/h (5 mph) to complete the calibration. The DIC will display CALIBRATION COMPLETE when the
calibration is complete.
Compass Magnetic Variation Adjustment
Compass variance is the difference between the earth's magnetic north and true geographic north. If not adjusted
to account for compass variance, the compass in the vehicle could give false readings. Under certain
circumstances, such as during a long distance cross-country trip, it will be necessary to compensate for compass
variance and reset the zone through the DIC.

Fig. 8: Illustrating Magnetic Variation Zones

1.
2.
3.
4.
5.
Locate your geographic location. Refer to the variation zone map.

Turn ON the ignition with the engine OFF.
Press the vehicle information button until PRESS TO CHANGE COMPASS ZONE displays on the DIC.
Press the set/reset button to scroll through and select the appropriate variance zone.
Navigate to one of the trip/fuel menu screens to view the direction the vehicle is moving. This will be
shown in the top right corner of the DIC display.
If the compass needs to be calibrated, use the compass calibration procedure above.
DRIVER INFORMATION CENTER (DIC) DESCRIPTION AND OPERATION
In the lower middle of the instrument cluster, an additional display is installed. Its task is to give additional

information, such as an odometer or error codes/warning messages. Refer to Indicator/Warning Message

There are 4 switch functions for the driver information center:
Menu
Set/Clear
Up
Down
Menu
The Menu switch is used to navigate between the Vehicle Information Menu and the Trip/Fuel Information
Menu. Cycle through the following vehicle parameters by successive pressing of the Menu switch.
Up and Down
The Up and the Down switches are used to navigate within the menus. Cycle through the following menu
parameters by successive pressing of the Down switch.
Vehicle Information Menu
Units Menu
Speed Warning
Trip/Fuel Information Menu
Trip A
Fuel Range
Average Fuel Economy
Instantaneous Fuel Economy
Average Vehicle Speed
Trip A
The trip odometer can be accessed through the driver information center switch Up/Down function.
Trip Display
Driver Information Center Trip
Display
TRIP A
Europe-SI
####.#km
Range
USA
####.# miles
GB
####.# miles
Fuel Range
This message indicates the estimated distance that the vehicle can travel under the current fuel economy and

fuel level conditions since the last battery connection to the instrument cluster. Fuel Range is calculated using
the equation: Fuel Range = Range Distance/Range Fuel Used.
Range Distance = The accumulated distance travelled since the last reset of this value.
Fuel Used = The accumulated fuel delivered since the last reset of this value
The engine control module (ECM) sends the fuel range value to the instrument cluster. The instrument cluster
receives a serial data message with fuel information. The fuel range value is retained during ignition OFF and
can be changed between Europe-SI, USA and GB units by accessing the driver information center Units menu.
The Fuel Range display cannot be reset. LOW is displayed when fuel range is below a predetermined value.
Average Fuel Economy
Average fuel economy is calculated using the equation: Average Fuel Economy = Distance/Fuel
Distance = The accumulated distance travelled since the last reset of this value
Fuel = The accumulated fuel consumption since the last reset of this value
The ECM sends the average fuel economy serial data message to the instrument cluster. The value of this mode
is retained during ignition OFF and can be changed between English units and metric units by selecting from
the driver information center options menu.
Instantaneous Fuel Economy
The ECM sends the instantaneous fuel economy serial data message to the instrument cluster. The value of this
mode can be changed between English units and metric units by selecting from the driver information center
options menu.
Average Vehicle Speed
Average speed is calculated using the equation: Average Speed = Average Speed Distance/Average Speed Time
Distance = The accumulated distance travelled since the last reset of this value
Ignition ON = The accumulated ignition on time since the last reset of this value
Outside Air Temperature

On vehicles with radio delete, the outside air temperature is displayed on the driver information center. On
vehicles with a radio, the outside air temperature is displayed on the center stack display screen. The outside air
temperature sensor is wired directly to the instrument cluster. The sensor is varies it's resistance with
temperature. The instrument cluster reads the resistance value to determine temperature. The time of and rate of
the temperature update is based on an algorithm in the cluster software. Factors such as, last reading, current
reading, length of time vehicle is been off/on, power mode, vehicle speed, driven distance, and sensor location
are all considered by the cluster to know when to update the displayed temperature. For example, if the sensor is
located near the engine compartment, and the vehicle has been turned off for only 10 minutes then restarted, the
cluster will wait until the vehicle is driven to get more accurate air flow across the sensor before it updates the
display.

Units Menu
The unit mode is used to toggle between Europe-SI, USA and GB units and can be accessed through the driver
information center Menu switch and the driver information center Set/Reset switch.
Compass
The vehicle may have a compass display on the Driver Information Center. The compass receives its heading
and other information from the Global Positioning System (GPS) antenna. If applicable, the GPS antenna is
located with the telematics communication interface control module. For GPS diagnostic information refer to
No Global Positioning System (GPS) Reception .
Odometer
The instrument cluster displays the vehicle odometer in the driver information center. The ECM send a distance
rolling count message on GMLAN to the body control module (BCM). The BCM uses this information to
calculate the vehicle odometer. This odometer value is then sent to the instrument cluster on GMLAN. The
instrument cluster does not calculate the odometer. The odometer displays miles or kilometers as selected in the
Units menu.
The odometer value is stored in multiple modules. The instrument cluster is a secondary storage module for the
odometer, while the BCM is the primary storage and accumulator.
In addition to storing the odometer value for the vehicle, the instrument cluster and the BCM store the VIN.
Software checks are performed to ensure these modules, and their stored odometer information, can not be
move or transferred between different vehicles.
If the VINs do not match, the instrument cluster will go into an error mode and display "----" (dashes). If the
VIN mismatch exists over a calibrated distance, the instrument cluster will "lock" the odometer display and only
show dashes, even if the VIN mismatch is subsequently correct. The only way to clear or "unlock" the
instrument cluster is to perform a BCM programming event using SPS.
Language
The driver information center is capable of displaying in different languages, corresponding to the radio
language settings. The instrument cluster receives a serial data message with language information from the
radio. This message is only sent one time, after a new language is selected. To set the language, see the owners
manual.
INDICATOR/WARNING MESSAGE DESCRIPTION AND OPERATION
INDICATOR LIGHT ON
Refer to the OWNER'S MANUAL for the descriptions and explanations of all indicator lights.
For diagnosis and repair information related to an indicator light refer to the System Diagnosis and the
Description of Operation that the message relates to.

MESSAGE DISPLAYED
Refer to the OWNER'S MANUAL for descriptions and explanations of all messages displayed.
For diagnosis and repair information related to a displayed message refer to the System Diagnosis and the
Description of Operation that the message relates to.
CHANGE TIMING BELT MESSAGE
The Instrument Cluster monitors the odometer mileage to determine when timing belt (if equipped) replacement
may be necessary. After the vehicle has accumulated approximately 100, 000 miles (160, 000 kilometers), the
Instrument Cluster may display the CHANGE TIMING BELT message. After the engine timing belt has been
replaced, reset the CHANGE TIMING BELT message by locating and removing the fuses that supply power to
the Instrument Cluster for two minutes.
INSTRUMENT CLUSTER DESCRIPTION AND OPERATION
Displays Test
Certain instrument cluster features are tested when the ignition is turned on in order to verify the features are
working properly. The following occurs when the ignition is turned on:
The ABS indicator illuminates briefly.

The airbag indicator illuminates briefly.
The battery indicator illuminates briefly.
The brake indicator illuminates briefly.
The door ajar indicator illuminates briefly.
The fuel level low indicator illuminates briefly.
The oil pressure low indicator illuminates briefly.
The park assist service indicator illuminates briefly.
The press clutch indicator illuminates briefly.
The security indicator illuminates briefly.
The service vehicle soon indicator illuminates briefly.
The vehicle dynamic caution service indicator illuminates briefly.
The vehicle dynamics caution off indicator illuminates briefly.
Indicators and Warning Messages
Refer to Indicator/Warning Message Description and Operation

Engine Coolant Temperature Gauge (if equipped)
The instrument cluster displays the engine coolant temperature as determined by the engine control module
(ECM). The ECM sends the engine coolant temperature information via a High Speed CAN-Bus signal to the
body control module (BCM). The BCM then sends the information via a Low Speed CAN-Bus signal to the

instrument cluster to display the engine coolant temperature. The engine coolant temperature gauge defaults to
40C (104F) or below if:
The ECM detects a malfunction in the engine coolant temperature sensor circuit.
The BCM detects a loss of serial data communications with the ECM.
The instrument cluster detects a loss of serial data communications with the BCM.
Fuel Level Gauge
The instrument cluster displays the fuel level based on the information from the ECM. The ECM converts the
data from the fuel level sensors to a fuel level signal. The ECM sends the fuel level signal via a High Speed
CAN-Bus signal to the BCM. The BCM then sends the information via a Low Speed CAN-Bus signal to the
instrument cluster to display the fuel level. If the fuel level falls under 11% the instrument cluster switches on
the low fuel level indicator. The fuel gauge defaults to empty if:
The ECM detects a malfunction in the fuel level sensor circuit.

Speedometer
The instrument cluster displays the vehicle speed based on the information from the ECM. The ECM sends the
vehicle speed information via a High Speed CAN-Bus signal to the BCM. The BCM then sends the vehicle
speed information via a Low Speed CAN-Bus signal to the instrument cluster in order to display the vehicle
speed, either in kilometers or miles, based on the vehicle requirements. The speedometer defaults to 0 km/h (0
MPH) if:
Tachometer (if equipped)
The instrument cluster displays the engine speed based on the information from the ECM. The ECM converts
the data from the engine speed sensor to an engine revolution signal. The ECM sends the engine speed
information via a High Speed CAN-Bus signal to the BCM. The BCM then sends the information via a Low
Speed CAN-Bus signal to the instrument cluster to display the engine speed. The tachometer defaults to 0 RPM
if:
The ECM detects a malfunction in the engine speed sensor circuit.

Driver Information Center Display
In the lower middle of the instrument cluster, an additional display is installed. Its task is to give additional
information, such as an odometer or error codes. This part of the instrument cluster is available in 4 different

variants, mostly depending on the assembled engine. For further information refer to Driver Information
Center (DIC) Description and Operation.

2013 ACCESSORIES & EQUIPMENT Fixed and Moveable Windows - Cruze

Fixed and Moveable Windows - Cruze
SPECIFICATIONS
Specification
Application
Front Side Door Window Regulator Bolt
Front Side Door Window Regulator Motor Bolt
Front Side Door Window Regulator Sash Nut
Rear Side Door Stationary Window Divider
Channel Belt Support Bolt
Rear Side Door Window Regulator Bolt
Rear Side Door Window Regulator Motor Bolt
Rear Side Door Window Regulator Sash Nut
Rear Side Door Stationary Window Bolt

MOVEABLE WINDOW WIRING SCHEMATICS
Driver Door (AXG) Wiring Schematics
Metric
9 N.m
6 N.m
9 N.m
English
80 lb in
53 lb in
80 lb in
8 N.m
9 N.m
6 N.m
9 N.m
8 N.m
71 lb in
80 lb in
53 lb in
80 lb in
71 lb in

Fig. 1: Driver Door (AXG) Wiring Schematics

Callout
1540
1540 RD/GN
CAV_4
CAV_28
CONN_X2
1540_RD/GN
1540_RD/GN
CAV_2
CAV_36
1540_RD/GN
1540_RD/GN
1550
1550_BK
CAV_1
1550_BK
CAV_1
Component Name
1540 RD/GN
4
28
X2
1540 RD/GN
1540 RD/GN
2
36
1540 RD/GN
1540 RD/GN
Ground
1550 BK
1
1550 BK
1

6134
6134_GN/YE
CAV_4
6134_GN/YE
CAV_5
3381
3381_GN
CAV_5
CAV 2
3380
3380_GY
CAV_7
CAV_3
3379
3379_GN/WH
CAV_3
CAV_6
X500
CAV_4
CAV_1
F24UA
G305
F55UA
X500
A90
S79D
M74D
A90
X50A
K9
Driver Door (AEC) Wiring Schematics
Bus 3
6134 GN/YE
4
6134 GN/YE
5
Data Communication
Schematics
Power Window Switch
Driver Express Signal
3381 GN
5
2
Power Window Switch
Driver Down Signal
3380 GY
7
3
Power Window Switch
Driver Up Signal
3379 GN/WH
3
6
X500
4
1
F24UA 30A
G305
F55UA 7.5A
X500
Logic
Logic

Fig. 2: Driver Door (AEC) Wiring Schematics

Callout
1540
CAV 4
CAV_36
CONN_X2
1540_RD/GN
1540_RD/GN
1540_RD/GN
CAV_1
6134
6134_GN/YE
CAV 5
3382
3382_GN/GY
Component Name
4
36
X2
1540 RD/GN
1540 RD/GN
1540 RD/GN
1
Bus 3
6134 GN/YE
5
Data Communication
Schematics
Power Window Motor Driver
Up Control
3382 GN/GY

CAV_2
CAV_2
3383
3383_YE/VT
CAV_3
CAV_1
2050
2050_BK
CAV_1
G305
F24UA
X500
A90
S79D
X50A
K9
M74D
Passenger Door Wiring Schematics
2
2
Power Window Motor Driver
Down Control
3383 YE/VT
3
1
Ground
2050 BK
1
G305
F24UA 30A
X500
Logic

Fig. 3: Passenger Door Wiring Schematics

Callout
1540
1540_RD/GN
CAV_4
CAV_36
CONN_X2
CAV_5
1540_RD/GN
1540_RD/GN
CAV 1
3387
3387_GN/GY
CAV_2
CAV_2
3388
3388_YE/BU
CAV_3
CAV_1
2050
2050_BK
CAV_1
6134
6134_GN/YE
G308
F24UA
X600
A90
X50A
K9
S79P
M74P
Rear Doors Wiring Schematics
Component Name
1540 RD/GN
4
36
X2
5
1540 RD/GN
1540 RD/GN
1
Power Window Motor CoDriver Up Control
3387 GN/GY
2
2
Power Window Motor CoDriver Down Control
3388 YE/BU
3
1
Ground
2050 BK
1
Bus 3
Data Communication
Schematics
6134 GN/YE
G308
F24UA 30A
X600
Logic

Fig. 4: Rear Doors Wiring Schematics

Callout
2940
2940 RD/BN
CAV_8
CAV_33
CONN_X2
2940_RD/BN
2940_RD/BN
2940_RD/BN
CAV_8
2940_RD/BN
CAV_2
CAV_2
6135
6135_GN/GY
CAV_1
6135_GN/GY
Component Name
2940 RD/BN
8
33
X2
2940 RD/BN
2940 RD/BN
2940 RD/BN
8
2940 RD/BN
2
2
Bus 4
6135 GN/GY
1
6135 GN/GY

CAV_1
668
668_BU/VT
CAV_A
CAV_6
669
669_YE/BU
CAV_7
CAV_B
2350
2350_BK
CAV_3
2350_BK
CAV_5
670
670_BU/GY
CAV_A
CAV_6
671
671_GN/BK
CAV_7
CAV_B
2350_BK
CAV_5
G309
G402
F21UA
X700
X800
J301
A90
X50A
K9
S79LR
M74LR
A90
1
Data Communication
Schematics
Power Window Motor Left
Rear Up Control
668 BU/VT
A
6
Power Window Motor Left
Rear Down Control
669 YE/BU
7
B
Ground
2350 BK
3
2350 BK
5
Power Window Motor Right
Rear Up Control
670 BU/GY
A
6
Power Window Motor Right
Rear Down Control
671 GN/BK
7
B
2350 BK
5
G309
G402
F21UA 30A
X700
X800
J301
Logic
Logic

S79RR
M74RR
DEFOGGER WIRING SCHEMATICS
Defogger Wiring Schematics
Fig. 5: Defogger Wiring Schematics

Callout
7531
7531_GN/YE
CAV_4
CONN_X2
CAV_1
193
CAV_61
CONN_X2
CAV_19
CONN_X2
Component Name
7531 GN/YE
4
X2
1
Rear Defog Relay Control
61
X2
19
X2

193_BN/VT
193_BN/VT
CAV_61
CAV_86
CAV_30
CAV_85
CAV_87
1150
1150_BK
CAV_71
CONN_X1
293
293 BN/VT
CAV_1
CONN_X1
CAV_39
CONN_X2
1650
1650_BK
CAV_1
CONN_X1
G400
G101
X200
F28UA
E18
A90
KR5
X50A
K33
A26
COMPONENT LOCATOR
WINDOW SYSTEMS COMPONENT VIEWS
193 BN/VT
193 BN/VT
61
86
30
85
87
Ground
1150 BK
71
X1
Rear Defog Element Supply Voltage
293 BN/VT
1
X1
39
X2
Ground
1650 BK
1
X1
G400
G101
X200
F28UA 40A
Logic

Fig. 6: Window Systems Components (4-Door Notchback 69)

Window Systems Component Views
Number
Description
1
Rear Window
Rear Side Door Stationary
2
Window
3
Rear Side Door Window
4
Front Side Door Window
5
Windshield
6
Regulator
7
Regulator Motor
8
Regulator Motor
9
Regulator
Procedure
Rear Window Replacement
Rear Side Door Stationary Window
Replacement
Rear Side Door Window Replacement
Front Side Door Window Replacement
Windshield Replacement
Front Side Door Window Regulator
Replacement
Front Side Door Window Regulator
Motor Replacement
Rear Side Door Window Regulator
Motor Replacement
Rear Side Door Window Regulator
Replacement



DTC
DTC B0283
DTC B316B, B317A, B318A, or B319A (AEC)
DTC B316B, B317A, B318A, or B319A (AXG)

DTC B3205
Description
DTC B0283 02 Rear Defrost Circuit Short To
Ground
DTC B0283 05 Rear Defrost Circuit Short To
Battery or Open
DTC B3205 Driver Window Motor
DTC B0283
DTC Descriptors
DTC B0283 02
Rear Defrost Circuit Short To Ground
DTC B0283 05
Rear Defrost Circuit Short To Battery or Open
Circuit
Control
Ground
Short to
Ground
B0283 02
-
Open/High
Resistance
B0283 05
B0283 05
Short to
Voltage
B0283 05
-
Signal Performance
-
When the HVAC control module receives a rear window defog request from the HVAC control faceplate, the
HVAC control module will supply voltage to the relay coil. Battery positive voltage is supplied at all times to
the relay switched input and the relay coil is always grounded. This allows battery positive voltage from the

relay switched input to flow through the switch contacts and out the relay switched output to the rear window
defogger grid.

B0283 02
The HVAC control module detects a short to ground in the relay coil control circuit.
B0283 05
The HVAC control module detects a short to voltage or an open/high resistance in the relay coil control circuit
or an open/high resistance in the relay coil ground circuit
B0283 02
The rear window defogger will be inoperative.
B0283 05
The rear window defogger will be inoperative or continuously active depending upon the fault.
The DTC will be current for as long as the fault is present.

When the fault is no longer present, the DTC will be a history DTC.
A history DTC will clear after 50 ignition cycles.
Schematic Reference
Defogger Schematics
Rear Window Defogger Description and Operation

Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference

1. Engine running.
2. Verify the rear window defogger turns ON and OFF when commanding the Rear Defogger On and Off
with a scan tool.
If the rear window defogger does not turn ON or OFF
If the rear window defogger turns ON and OFF
3. All OK.
1. Ignition OFF and all vehicle systems OFF, disconnect the KR5 rear defogger relay. It may take up to 2
minutes for all vehicle systems to power down.
1. Ignition OFF.
3. Connect a test lamp between the control circuit terminal 1 and the ground circuit terminal 2, engine
running.
4. Verify the test lamp turns ON and OFF when commanding the Rear Defogger On and Off with a scan
tool.
1. Ignition OFF, disconnect the harness connector at the K33 HVAC control module.

If less than 2 ohms, replace the K33 HVAC control module.
1. Ignition OFF, disconnect the harness connector at the K33 HVAC control module, engine running.
If less than 1 V, replace the K33 HVAC control module.
5. Test or replace the KR5 rear defogger relay.
Component Testing
Relay Test
1. Ignition OFF, disconnect the KR5 rear defogger relay.
2. Test for 60-180 ohms between terminals 2 and 1.
If less than 60 ohms or greater than 180 ohms
Replace the KR5 rear defogger relay.
3. Test for infinite resistance between the terminals listed below:
3 and 1
3 and 5
3 and 2
2 and 5

4. Install a 3 A fused jumper wire between relay terminal 2 and 12 V. Install a jumper wire between relay
terminal 1 and ground.
5. Test for less than 2 ohms between terminals 3 and 5.
If less than 2 ohms

6. All OK
Repair Instructions
Control Module References for HVAC control module replacement, programming and setup
DTC B316B, B317A, B318A, OR B319A (AEC)

DTC Descriptors
DTC B316B
Driver Window Switch
DTC B317A
Passenger Window Switch
DTC B318A
Left Rear Window Switch
DTC B319A
Right Rear Window Switch
For symptom byte information refer to: Symptom Byte List
The body control module (BCM) monitors, receives and transmits serial data messages to each of the door
window switches. The driver master control contains switches to control the passenger and rear windows. When
a switch is used on the driver master control, a serial data message is sent to the BCM which sends a serial data
message to the appropriate passenger or rear window switch to move in the window in the direction
commanded.

Ignition ON.
B316B 00
The BCM has detected the right front or left rear or right rear switch on the driver master control is active for
greater than 60 seconds.
B316B 02
The BCM has detected the driver left front window switch is active for greater than 60 seconds.
B316B 39
The BCM has received simultaneous conflicting commands from the driver window switch
B317A 02
The BCM has detected the passenger window switch is active for greater than 60 seconds.
B318A 02
The BCM has detected the left rear window switch is active for greater than 60 seconds
B319A 02
The BCM has detected the right rear window switch is active for greater than 60 seconds
The affected power window will malfunction.

B316B 00, B316B 02, B317A 02, B318A 02, B319A 02

The DTC will change from current to history when the fault is no longer present.
A history DTC will clear after 100 consecutive ignition cycles if the condition for the malfunction is no
longer present.
B316B 39
If the DTC is current, the driver window switch must be replaced before the DTC can be cleared.

Schematic Reference
Moveable Window Schematics
Power Windows Description and Operation
Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference

1. Ignition ON.
2. Verify the driver window moves while commanding the window UP and DOWN with the driver window
master control
If the driver window does not move, refer to Circuit/System Testing below.
If the driver window moves
3. Verify the passenger, left rear and right rear windows move while commanding each window UP and
DOWN with the switches on the driver window master control.
If a window does not move, refer to Circuit/System Testing below.
If the passenger, left rear and right rear windows move
4. Verify the passenger window moves while commanding the window UP and DOWN with the S79P
Window Switch - Passenger.
If the passenger window does not move, refer to Circuit/System Testing below.
If the passenger window moves
5. Verify the left rear window moves while commanding the window UP and DOWN with the S79LR
Window Switch - Left Rear.
If the left rear window does not move, refer to Circuit/System Testing below.
If the left rear window moves
6. Verify the right rear window moves while commanding the window UP and DOWN with the S79RR

Window Switch - Right Rear.

If the right rear window does not move, refer to Circuit/System Testing below.
If the right rear window moves
7. All OK.
1. Ignition ON.
2. Verify the scan tool Left Rear Window Main Control Down Switch, Left Rear Window Main Control
Express Switch, Left Rear Window Main Control Up Switch, Right Rear Window Main Control Down
Switch, Right Rear Window Main Control Express Switch, Right Rear Window Main Control Up Switch,
Front Passenger Window Main Control Down Switch, Front Passenger Window Main Control Express
Switch, and the Front Passenger Window Main Control Up Switch parameter changes between Inactive
and Active when pressing and pulling the right front, right rear and left rear switches on the S79D
Window Switch - Driver.
If the parameters do not change
Replace the S79D Window Switch - Driver.
If the parameters changes
3. Verify the scan tool Left Rear Window Switch at Door parameter changes between Inactive and Active
when pressing and pulling the S79LR Window Switch - Left Rear.
Replace the S79LR Window Switch - Left Rear.

4. Verify the scan tool Passenger Window Switch at Door parameter changes between Inactive and Active
when pressing and pulling the S79P Window Switch - Passenger.
Replace the S79P Window Switch - Passenger.

5. Verify the scan tool Right Rear Window Switch at Door parameter changes between Inactive and Active
when pressing and pulling the S79RR Window Switch - Right Rear.
Replace the S79RR Window Switch - Right Rear.

6. All OK.
Repair Instructions

Front Side Door Window Switch Replacement - Right Side

Front Side Door Window Switch Replacement - Left Side
Rear Side Door Window Switch Replacement
DTC B316B, B317A, B318A, OR B319A (AXG)

DTC Descriptors
DTC B316B
DTC B317A
DTC B318A
DTC B319A
Short to
Ground
Circuit
Driver Window Motor
B316B 02
Down Control
Driver Window Motor
B316B 02
Express Control
Driver Window Motor Up
B316B 02
Control
1. Driver Window Malfunction
Open/High
Resistance
Short to
Voltage
Signal Performance

The driver window motor supplies 12V signal circuits to the driver window switch, when a window switch has
been activated, a switch closes providing a ground to the appropriate signal circuit causing the voltage to drop
to 0V. The driver window motor will detect the voltage drop in the signal circuit and will command the window
to move in the desired direction.
The driver window master control switch also contains control switches for the passenger, left rear and right
rear window functions. When a window switch is pressed, a serial data message is sent to the body control
module (BCM). The BCM examines the request and checks for messages from other power window motors that
may prohibit window movement. If no prohibitive messages have been received, the BCM will send a serial
data message to the appropriate passenger or rear window switch which will perform the command as
requested.

B316B 00
The BCM has detected a control switch on the driver window master switch has been active for greater than 60
seconds.
B316B 02
The driver window motor has detected the driver window master switch is active for greater than 60 seconds.
B316B 39
The driver window motor has detected an internal failure within the driver window switch
B317A 02
The BCM has detected the passenger window switch is active for greater than 60 seconds.
B317A 39
The BCM has detected an internal failure within the passenger window switch
B318A 02
The BCM has detected the left rear window switch is active for greater than 60 seconds
B318A 39
The BCM has detected an internal failure within the left rear window switch

B319A 02
The BCM has detected the right rear window switch is active for greater than 60 seconds
B319A 39
The BCM has detected an internal failure within the right rear window switch
The affected power window will malfunction.

B316B 00, B316B 02, B317A 02, B318A 02, B319A 02

The DTC will change from current to history when the fault is no longer present.
A history DTC will clear after 100 consecutive ignition cycles if the condition for the malfunction is no
longer present.
B316B 39, B317A 39, B318A 39, B319A 39

If the DTC is current, the affected window switch must be replaced before the DTC can be cleared.
Schematic Reference
Circuit Testing
Connector Repairs
Wiring Repairs

Scan Tool Reference

1. Ignition ON.
2. Verify the scan tool parameters listed below change when pressing and pulling the switches for the
passenger, left rear and right rear window on the driver window master control;
Left Rear Main Control Down Switch - Inactive and Active
Left Rear Main Control Express Switch - Inactive and Active
Left Rear Main Control Up Switch - Inactive and Active
Right Rear Main Control Down Switch - Inactive and Active
Right Rear Main Control Express Switch - Inactive and Active
Right Rear Main Control Up Switch - Inactive and Active
Front Passenger Main Control Down Switch - Inactive and Active
Front Passenger Main Control Express Switch - Inactive and Active
Front Passenger Main Control Up Switch - Inactive and Active
If any parameter does not change
Replace the S79D Window Switch-Driver.
If the parameters change
3. Verify the scan tool parameters listed below change when pressing and pulling the S79P Window SwitchPassenger, the S79LR Window Switch-Left Rear and the S79RR Window Switch-Right Rear.
Passenger Window Switch at Door - Inactive, Up, Down, Express Down
Left Rear Window Switch at Door - Inactive, Up, Down, Express Down
Right Rear Window Switch at Door - Inactive, Up, Down, Express Down
Test or replace the appropriate passenger or rear S79 Window Switch

If all the parameters change
4. Verify the scan tool parameters listed below change when pressing and pulling the driver window control
switch on the driver window master control:
Driver Window Main Control Down Switch - Inactive and Active
Driver Window Main Control Up Switch - Inactive and Active
Driver Window Main Control Express Switch - Inactive and Active


5. All OK.
1. Ignition OFF and all vehicle systems OFF, disconnect the harness connector at the S79D Window
Switch-Driver. It may take up to 2 minutes for all vehicle systems to power down.
1. Ignition OFF.
3. Ignition ON.
1. Ignition OFF.
1. Ignition OFF.
If infinite resistance, replace the S79D Window Switch-Driver.
5. Verify the scan tool Driver Window Main Control Down Switch parameter is Inactive.
If not Inactive
1. Ignition OFF, disconnect the harness connector at the M74D Window Motor-Driver.
2. Test for infinite resistance between the S79D Window Switch-Driver signal circuit terminal 3 and
ground.
If infinite resistance, replace the M74D Window Motor-Driver.
If Inactive
6. Install a 3 A fused jumper wire between the signal circuit terminal 3 and the ground circuit terminal 1.
7. Verify the scan tool Driver Window Main Control Down Switch parameter is Active
If not Active
1. Ignition OFF, remove the 3 A fused jumper wire, disconnect the harness connector at the M74D

8.
9.
10.
11.
12.
13.
Window Motor-Driver, ignition ON.

2. Test for less than 1 V between the S79D Window Switch-Driver signal circuit terminal 3 and
ground.
If less than 1 V
If less than 2 ohms, replace the M74D Window Motor-Driver.
If Active
Verify the scan tool Driver Window Main Control Up Switch parameter is Inactive.
If not Inactive
ground.
If Inactive
Install a 3 A fused jumper wire between the signal circuit terminal 6 and the ground circuit terminal 1.
Verify the scan tool Driver Window Main Control Up Switch parameter is Active
If not Active
2. Test for less than 1 V between the S79D Window Switch-Driver signal circuit 6 and ground.
If less than 1 V
If Active
Verify the scan tool Driver Window Main Control Express Switch parameter is Inactive.
If not Inactive
ground.
If Inactive
Verify the scan tool Driver Window Main Control Express Switch parameter is Active

If not Active
If less than 1 V
If Active
14. Test or replace the S79D Window Switch-Driver.
Repair Instructions

Rear Side Door Window Regulator Motor Replacement
Front Side Door Window Regulator Motor Replacement
DTC B3205
DTC Descriptors
DTC B3205
Driver Window Motor
The body control module (BCM) monitors, receives and transmits serial data to each of the doors switches and
window motors. When a window switch has been activated on the driver window switch, a signal is sent to the
BCM which sends a signal to the appropriate window motor and the window motor will move in the direction
commanded.

The ignition switch is in the ON position.

B3205 00
The BCM has detected that the compatibility code stored in the driver window motor does not match the
compatibility code stored in the BCM.
B3205 39
An internal malfunction has been detected by the BCM in the driver window motor while commanding the
window UP or DOWN.
B3205 42
The BCM will automatically attempt to download the calibration program into the driver window motor (As
will occur when the window motor has been replaced), if the first calibration program fails to load, the BCM
will attempt to download the calibration program a second time. If this download fails, the BCM will set
appropriate DTC.
B3205 4B
The BCM has detected that the driver window is not "normalized" and can set for the following reasons:
When the battery has been disconnected

When the battery has been replaced
When the door wiring harness has been disconnected
When the window motor has been disconnected.
The driver power window will malfunction.

B3205 00
Installing a compatible window motor for that specific make and model vehicle.
B3205 39
The driver window motor must be replaced before the DTC can be cleared.

B3205 42
The driver window motor must be replaced before the DTC can be cleared.
B3205 4B
The driver window motor must be normalized before the DTC can be cleared.
Schematic Reference
Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference

1. Ignition ON
2. Verify the driver window functions while commanding the Driver Window Motor Up and Down with a
scan tool.
If the Up and Down does not work
Replace the M74D Window Motor - Driver.
If the UP and DOWN works
3. Verify the driver window performs the Express Up and Express Down functions with the driver window
switch.
If the driver window does not Express Up and Express Down

Normalize the driver window motor, refer to Window Motor Programming - Express Function.
If the driver window performs the Express Up and Express Down functions
4. All OK.
Repair Instructions

SYMPTOMS - FIXED AND MOVEABLE WINDOWS
Important Preliminary Checks Before Starting:
2. Review the power window system operation or rear window defogger system operation in order to
familiarize yourself with the system functions. Refer to the following:
Inspect for aftermarket devices which could affect the operation of the rear window defogger. Refer to
cause the symptom.
Intermittent
NOTE:
Inspect for proper installation of electrical components if an intermittent

condition exists. Inspect for aftermarket theft deterrent devices, lights, and
cellular phones. Ensure that no aftermarket equipment is connected to the
class 2 circuit. If you can not locate an intermittent condition, a cellular
phone signal may cause the condition. Faulty electrical connections or
wiring may be the cause of intermittent conditions. Refer to Testing for
The problem may or may not turn ON the SERVICE VEHICLE SOON
indicator or store a DTC. Do not use the symptom tables to diagnose
intermittent conditions. The malfunction must be present in order to locate
the problem.

Poor electrical connections or wiring cause most intermittent conditions. Perform a careful visual/physical
check for the following conditions:
Poor mating of the connector halves or a terminal not fully seated in the connector body
An improperly formed or damaged terminal
Reform or replace connector terminals in the problem circuit in order to ensure proper contact tension.
Poor terminal to wire connection requires removing the terminal from the connector body in order to
perform the check.
Use a scan tool in order to help detect intermittent conditions. The scan tool has several features that can be
used to locate an intermittent condition. The snapshot feature can capture and store data parameters within the
scan tool when the malfunction occurs. This information can then be reviewed in order to see what caused the
malfunction.
Symptom List
Rear Window Defogger Malfunction

Power Windows Malfunction (AEC), Power Windows Malfunction (AXG)
REAR WINDOW DEFOGGER MALFUNCTION

Short to
Ground
Circuit
Rear Defog Relay Switch
1
B+
Rear Defog Relay Control
B0283 02
Rear Defogger Grid
1
Control
Rear Defog Relay Coil
Ground
Rear Defogger Grid
Ground
1. Rear Defogger Inoperative
2. Rear Defogger Always ON
Open/High
Resistance
Short to
Voltage
Signal Performance
B0283 05
B0283 05
B0283 05

When the HVAC Control Module receives a rear window defog request from the HVAC control faceplate, the
HVAC Control Module will supply voltage to the relay coil. Battery positive voltage is supplied at all times to
the relay switched input and the relay coil is always grounded. This allows battery positive voltage from the
relay switched input to flow through the switch contacts and out the relay switched output to the rear window
defogger grid.
Diagnostic Aids
The rear window defogger indicator will still function when the rear defogger switch is pressed, but if the
Remote Start Enable ambient temperature is greater than 5C (40F) may cause the rear window defogger grid
not to function:
Schematic Reference
Defogger Schematics
Circuit Testing
Connector Repairs
Wiring Repairs
1. Engine running.
2. Verify the scan tool Rear Defogger Switch parameter changes between On and Off when pressing the rear
window defogger switch.
If the parameter does not change between On and Off
Replace the A26 HVAC controls.
If the parameter changes between On and Off
3. Verify the E18 Rear Defogger Grid turns ON and OFF when commanding the Rear Defogger On and Off

with a scan tool.

If the E18 Rear Defogger Grid does not turn ON and OFF
Refer to Circuit/System Testing
If the E18 Rear Defogger Grid turns ON and OFF
4. Verify the rear defogger indicator turns ON and OFF when pressing the rear window defogger switch.
If the rear defogger indicator does not turn ON and OFF
Replace the A26 HVAC controls.

If the rear defogger indicator turns ON and OFF
5. All OK.
1. Ignition OFF and all vehicle systems OFF, disconnect the KR5 Rear Defogger Relay. It may take up to 2
1. Ignition OFF.
3. Connect a test lamp between the control circuit terminal 1 and the ground circuit terminal 2, engine
running.
tool.
1. Ignition OFF, disconnect the harness connector at the K33 HVAC Control Module.
If less than 2 ohms, replace the K33 HVAC Control Module.
1. Ignition OFF, disconnect the harness connector at the K33 HVAC Control Module, ignition ON.

If less than 1 V, replace the K33 HVAC Control Module.

5. Verify that a test lamp does not illuminate between the control circuit terminal 5 and ground.
Repair the short to voltage on the control circuit

Ignition OFF and all vehicle systems OFF, disconnect the X2 harness connector at the E18 Rear Defogger
Grid. It may take up to 2 minutes for all vehicle systems to power down.
1. Ignition OFF.
Connect the X2 harness connector at the E18 Rear Defogger Grid.
Ignition ON, connect a 40 A fused jumper wire between the B+ circuit terminal 3 and the control circuit
terminal 5.
Verify the E18 Rear Defogger Grid is activated.
If the E18 Rear Defogger Grid does not activate
1. Ignition OFF, disconnect the X1 harness connector at the E18 Rear Defogger Grid.
If less than 2 ohms, replace the E18 Rear Defogger Grid.
If the E18 Rear Defogger Grid activates
Test or replace the KR5 Rear Defogger Relay.
6.
7.
8.
9.
10.
11.
Component Testing
Relay Test
1. Ignition OFF, disconnect the KR5 Rear Defogger Relay.

Replace the KR5 Rear Defogger Relay.

3 and 1
3 and 5
3 and 2
2 and 5


If less than 2 ohms
6. All OK
Rear Defogger Grid Test

NOTE:
Lightly touch the grid lines when testing with the test lamp. If the test lamp
point is scraped through the grid line it can cause an open in the circuit
1. Engine running, command the Rear Defogger ON with a scan tool.

2. Verify that a test lamp illuminates between each rear window defogger grid line and ground. The test
lamp should be off when testing at the ground side of the grid and get brighter as the test lamp moves
closer to the voltage supply side of the grid. The test lamp should be dim when testing each grid line in
the middle
If the test lamp remains bright at the middle of the grid line.
The grid line is open between the test point and the ground side of the grid.
Replace the rear window
If the test lamp remains off at the middle of the grid line.
The grid line is open between the test point and the voltage supply side of the grid.
Replace the rear window

If the test lamp remains dim at the middle of each grid line.
3. All OK
Repair Instructions
Rear Window Replacement

Control Module References for HVAC Control Module and HVAC controls replacement, programming
and setup
POWER WINDOWS MALFUNCTION (AEC)

Circuit
Driver Window Switch B+
Serial Data
Ground
Driver Window Motor
Control
B+
Serial Data
Ground
Control
B+
Short to
Ground
U1538 00
U1534 00,
U1538 00,
U153A 00
Open/High
Resistance
U1538 00
Short to
Voltage
-
Signal Performance
-
U1538 00
U1538 00
U1538 00
U153A 00
U153A 00
U1534 00,
U1538 00,
U153A 00
U153A 00
U153A 00
U153A 00
U1534 00
U1534 00
U1534 00
U1534 00
U1534 00,

Serial Data
U154A 00
Ground
3
Control
U154A 00
B+
Right Rear Window Switch U154A 00,
Serial Data
U1548 00
Ground
4
Control
1. Driver Window Motor Inoperative
2. Passenger Window Motor Inoperative
3. Left Rear Window Motor Inoperative
4. Right Rear Window Motor Inoperative
U1534 00
U154A 00
U154A 00
U154A 00
U154A 00
When the ignition switch is in the RUN or ACCY position, or retained accessory power is enabled and the
driver or passenger window switch or rear window switch is pressed in the down position, voltage is applied to
the appropriate window motor causing that window to open. When the driver or passenger window switch is
pulled in the up position, voltage is applied to the appropriate window motor in the opposite direction causing
that window to close.
When the driver wishes to command a passenger or rear window, a window switch is pressed on the driver
window switch. A serial data message is then sent to the body control module (BCM) from the driver window
switch. The BCM will examine the request and check for messages from other power window switches that
may prohibit the window movement. If no prohibitive messages have been received, the BCM will send a serial
data message to the passenger or rear window switch which will command the window motor to perform as
requested.
Schematic Reference

Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference

1. Ignition ON.
2. Verify the driver, passenger, left rear and right rear window move while commanding the window UP and
DOWN with a scan tool.
If the window does not move UP and DOWN as commanded
If the window moves UP and DOWN as commanded
3. Verify the scan tool Left Rear Main Control Down Switch, Left Rear Main Control Express Switch, Left
Rear Main Control Up Switch, Right Rear Main Control Down Switch, Right Rear Main Control Express
Switch, Right Rear Main Control Up Switch, Front Passenger Main Control Down Switch, Front
Passenger Main Control Express Switch, and the Front Passenger Main Control Up Switch parameter
changes between Inactive and Active when pressing and pulling each switch on the driver window
switch.
Replace the S79D window switch-driver.

If the parameters change
4. Verify the scan tool Child Security Lockout Switch parameter changes between Inactive and Active when
pressing the window lockout switch.
Refer to Power Door Child Lock Malfunction .

5. Verify the lockout indicator turns ON and OFF when commanding the Child Security Lock Indicator ON
and OFF with a scan tool.
Replace the S79D window switch-driver.


6. Command the rear window lockout by pressing the window lockout switch on the driver window switch.
7. Verify the left rear and right rear window does not move while commanding the window UP and DOWN
with the left rear window switch and right rear window switch.
If a rear window moves UP and DOWN as commanded

If the rear windows do not move UP and DOWN
8. All OK.
1. Ignition OFF and all vehicle systems OFF, disconnect the harness connector at the appropriate S79
window switch. It may take up to 2 minutes for all vehicle systems to power down.
2. Test for less than 10 ohms between the ground circuit terminal listed below and ground:
S79D window switch-driver - ground circuit terminal 1
S79P window switch-passenger - ground circuit terminal 1
S79LR window switch-left rear - ground circuit terminal 5
S79RR window switch-right rear - ground circuit terminal 5
1. Ignition OFF.
3. Ignition ON.
4. Verify a test lamp illuminates between the B+ circuit terminal listed below and ground:
S79D window switch-driver - B+ circuit terminal 4
S79P window switch-passenger - B+ circuit terminal 4
S79LR window switch-left rear - B+ circuit terminal 8
S79RR window switch-right rear - B+ circuit terminal 8
1. Ignition OFF.
1. Ignition OFF.

If infinite resistance, replace the S79 window switch
Test for 5-10 V between the serial data circuit terminal listed below and ground
S79D window switch-driver - serial data circuit terminal 5
S79P window switch-passenger - serial data circuit terminal 5
S79LR window switch-left rear - serial data circuit terminal 1
S79RR window switch-right rear - serial data circuit terminal 1
If less than 5 V
1. Ignition OFF, disconnect the harness connector at the K9 body control module.
2. Test for infinite resistance between the serial data and ground.
If 2 ohms or greater, repair the open/high resistance on the circuit.
If less than 2 ohms, replace the K9 body control module.
1. Ignition OFF, disconnect the harness connector at the K9 body control module, ignition ON.
If less than 1 V, replace the K9 body control module
If between 5-10 V
Ignition OFF connect the harness connector at the S79 window switch and disconnect the harness
connector at the M74 window motor.
Test for less than 5 ohms between the control circuit terminal 1 and ground.
1. Ignition OFF, disconnect the harness connector at the S79 window switch.
If less than 2 ohms, replace the S79 window switch.
If less than 5 ohms
5.
6.
7.
8.


If less than 2 ohms, replace the S79 window switch.
If less than 5 ohms
9. Connect a test lamp between the control circuit terminal 1 and control circuit terminal 2, ignition ON.
10. Verify the test lamp illuminates when commanding the UP and DOWN states with the S79 window
switch.
If the test lamp does not illuminate during either of the commands
2. Test for infinite resistance between each control circuit and ground.
If infinite resistance, replace the S79 window switch.
If the test lamp illuminates during each of the commands
11. Test or replace the M74 window motor.
Component Testing
Window Motor
1. Ignition OFF, disconnect the harness connector at the appropriate M74 window motor.
2. Install a 25 A fused jumper wire between one of the control terminals and 12 V. Momentarily install a
jumper wire between the other control terminal and ground. Reverse the jumper wires at least two times,
the M74 window motor should perform the UP and DOWN functions.
If the function does not perform the UP and DOWN functions
Replace the M74 window motor.
If the function performs the UP and DOWN functions
3. All OK
Repair Instructions
Perform the Diagnostic Repair Verification after completing the diagnostic procedure.

POWER WINDOWS MALFUNCTION (AXG)


Circuit
Driver Window Switch B+
Serial Data
Ground
Driver Window Motor B+
Driver Window Motor
Serial Data
Driver Window Motor
Down Control
Driver Window Motor
Express Control
Driver Window Motor Up
Control
Driver Window Motor
Ground
B+
Serial Data
Ground
Control
B+
Serial Data
Ground
Control
Short to
Ground
U1538 00
U1534 00,
U1538 00,
U153A 00
Open/High
Resistance
U1538 00
Short to
Voltage
-
Signal Performance
-
U1538 00
U1538 00
U1538 00
U1534 00
U1534 00,
U1538 00,
U153A 00
U1534 00
U1534 00
U1534 00
B316B 02
B316B 02
B316B 02
U1534 00
U153A 00
U153A 00
U1534 00,
U1538 00,
U153A 00
U153A 00
U153A 00
U153A 00
U1534 00
U1534 00
U1534 00,
U154A 00
U1534 00
U1534 00
U1534 00
U154A 00
U154A 00

B+
Right Rear Window Switch U154A 00,
Serial Data
U1548 00
Ground
4
Control
1. Driver Window Malfunction
2. Passenger Window Inoperative
3. Left Rear Window Inoperative
4. Right Rear Window Inoperative
U154A 00
U154A 00
U154A 00
The driver window motor supplies 12 V signal circuits to the driver window switch, when a window switch has
been activated, a switch closes providing a ground to the appropriate signal circuit causing the voltage to drop
to 0 V. The driver window motor will detect the voltage drop in the signal circuit and will command the
window to move in the desired direction.
The driver window master control switch also contains control switches for the passenger, left rear and right
rear window functions. When a window switch is pressed, a serial data message is sent to the body control
module (BCM). The BCM examines the request and checks for messages from other power window motors that
may prohibit window movement. If no prohibitive messages have been received, the BCM will send a serial
data message to the appropriate passenger or rear window switch which will perform the command as
requested.
Diagnostic Aids
The loss of the express up and express down functions for the driver window may have occurred for the
following reasons:
The battery was disconnected

The battery was replaced
The door wiring harness was disconnected
The window motor was disconnected
The driver window motor will need to be normalized in order to restore the express functions, refer to Window
Motor Programming - Express Function for the proper procedure.
Schematic Reference


Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference

1. Ignition ON.
2. Verify the driver window functions while commanding the Driver Window Motor Up and Down with a
scan tool.
If the window does not move UP and DOWN as commanded
Refer to Circuit/System Testing below- Driver Window Motor Malfunction.
If the window moves UP and DOWN as commanded
3. Verify the driver window functions while commanding the window UP, express UP, DOWN and express
DOWN with the S79D Window Switch-Driver.
If the driver window does not move UP or DOWN as commanded
Refer to Circuit/System Testing below- Driver Window Switch Malfunction.
If the driver window does not express UP or express DOWN

Normalize the M74D Window Motor-Driver, refer to Window Motor Programming - Express
Function.
If after normalization, the driver window does not express UP or express DOWN
If the driver window moves UP, express UP, DOWN and express DOWN as commanded
4. Verify the scan tool parameters listed below change when pressing and pulling the switches for the
passenger, left rear and right rear window on the driver window master control;

Left Rear Main Control Down Switch - Inactive and Active

Left Rear Main Control Express Switch - Inactive and Active
Left Rear Main Control Up Switch - Inactive and Active
Right Rear Main Control Down Switch - Inactive and Active
Right Rear Main Control Express Switch - Inactive and Active
Right Rear Main Control Up Switch - Inactive and Active
Front Passenger Main Control Down Switch - Inactive and Active
Front Passenger Main Control Express Switch - Inactive and Active
Front Passenger Main Control Up Switch - Inactive and Active

5. Verify the scan tool Child Security Lockout Switch parameter changes between Inactive and Active when
pressing the window lockout switch.
Refer to Power Door Child Lock Malfunction

6. Verify the lockout indicator turns ON and OFF when commanding the Child Security Lock Indicator On
and Off with a scan tool.

7. Verify the passenger, left rear and right rear window functions while commanding the Passenger Window
Motor, Left Rear Window Motor and Right Rear Window Motor Up and Down with a scan tool.
If the window does not move Up and Down as commanded
Refer to Circuit/System Testing below- Passenger Power Window Inoperative.

If the window moves Up and Down as commanded
8. Command the rear window lockout by pressing the window lockout switch on the S79D Window SwitchDriver.
9. Verify the left rear and right rear window does not move while commanding the window UP and DOWN
with the S79LR Window Switch-Left Rear and S79RR Window Switch-Right Rear
If a rear window moves UP and DOWN as commanded

If the rear windows do not move UP and DOWN

10. All OK.
Driver Window Motor Malfunction

1. Ignition OFF and all vehicle systems OFF, disconnect the harness connector at the M74D Window
Motor-Driver. It may take up to 2 minutes for all vehicle systems to power down.
1. Ignition OFF.
3. Ignition ON.
1. Ignition OFF.
1. Ignition OFF.
5. Test or replace the M74D Window Motor-Driver.
Driver Window Switch Malfunction
1. Ignition OFF and all vehicle systems OFF, disconnect the harness connector at the S79D Window
1. Ignition OFF.

Ignition ON.
Verify a test lamp illuminates between the B+ circuit terminal 4 and ground.
1. Ignition OFF.
1. Ignition OFF.
If infinite resistance, replace the S79D Window Switch-Driver.
Verify the scan tool Driver Window Main Control Down Switch parameter is Inactive.
If not Inactive
ground.
If Inactive
Verify the scan tool Driver Window Main Control Down Switch parameter is Active
If not Active
Window Motor-Driver, Ignition ON.
2. Test for less than 1 V between the S79D Window Switch-Driver signal circuit terminal 3 and
ground.
If less than 1 V
If Active
Verify the scan tool Driver Window Main Control Up Switch parameter is Inactive.
If not Inactive
3.
4.
5.
6.
7.
8.

9.
10.
11.
12.
13.
ground.
If Inactive
Verify the scan tool Driver Window Main Control Up Switch parameter is Active
If not Active
If less than 1 V
If Active
Verify the scan tool Driver Window Main Control Express Switch parameter is Inactive.
If not Inactive
ground.
If Inactive
Verify the scan tool Driver Window Main Control Express Switch parameter is Active
If not Active
If less than 1 V
If Active

14. Test or replace the S79D Window Switch-Driver.

Passenger Power Window Inoperative
1. Ignition OFF and all vehicle systems OFF, disconnect the harness connector at the appropriate passenger
or rear S79 Window Switch. It may take up to 2 minutes for all vehicle systems to power down.
S79P Window Switch-Passenger - ground circuit terminal 1
S79LR Window Switch-Left Rear - ground circuit terminal 5
S79RR Window Switch-Right Rear - ground circuit terminal 5
1. Ignition OFF.
3. Ignition ON.
4. Verify a test lamp illuminates between the B+ circuit terminal listed below and ground:
S79P Window Switch-Passenger - B+ circuit terminal 4
S79LR Window Switch-Left Rear - B+ circuit terminal 8
S79RR Window Switch-Right Rear - B+ circuit terminal 8
1. Ignition OFF.
1. Ignition OFF.
If infinite resistance, replace the S79 Window Switch
5. Ignition OFF, connect the harness connector at the S79 Window Switch and disconnect the harness
connector at the M74 Window Motor.
6. Test for less than 5 ohms between the control circuit terminal 1 and ground.
1. Ignition OFF, disconnect the harness connector at the S79 Window Switch.

If less than 2 ohms, replace the S79 Window Switch.

If less than 5 ohms
1. Ignition OFF, disconnect the harness connector at the S79 Window Switch.
If less than 2 ohms, replace the S79 Window Switch.
If less than 5 ohms
Connect a test lamp between the control circuit terminal 1 and control circuit terminal 2, ignition ON.
Verify the test lamp turns ON when commanding the UP and DOWN states with the S79 Window
Switch.
If the test lamp remains OFF during either of the commands
1. Ignition OFF, remove the test lamp, disconnect the harness connector at the S79 Window Switch.
If infinite resistance, replace the S79 Window Switch.
If the test lamp turns ON during each of the commands
Test or replace the M74 Window Motor.
7.
8.
9.
10.
Component Testing
1. Ignition OFF, disconnect the harness connector at the appropriate passenger or rear M74 Window Motor.
the M74 Window Motor should perform the UP and DOWN functions.
If the function does not perform the UP and DOWN functions
Replace the passenger or rear M74 Window Motor.
If the function performs the UP and DOWN functions
3. All OK
Repair Instructions


REPAIR INSTRUCTIONS
WINDSHIELD REPLACEMENT
Special Tools
BO-24402-A Glass Sealant Remover (Cold Knife)

BO-39032 Stationary Glass Removal Tool
Use an adhesive that is approved by GM
For equivalent regional tools, refer to Special Tools.

Removal Procedure
WARNING: Refer to Cracked Window Warning .
NOTE:
1.
2.
3.
4.
Before cutting out a stationary window, apply a double layer of masking

tape around the perimeter of the painted surfaces and the interior trim.
Disconnect the battery. Refer to Battery Negative Cable Disconnection and Connection .
Remove the air inlet grille. Refer to Air Inlet Grille Panel Replacement .
Remove the windshield garnish molding. Refer to Windshield Garnish Molding Replacement .
Remove the inside rearview mirror. Refer to Inside Rearview Mirror Replacement .
WARNING: Refer to Defroster Outlet Warning .
5. Cover the following parts to protect from broken glass:

Upper dash pad
Defroster outlets and A/C outlets
Seats and carpeting

Fig. 7: Using Utility Knife To Remove Reveal Molding

WARNING: Refer to Glass and Sheet Metal Handling Warning .
NOTE:
If the original window is being reused the window lace is not serviceable.
6. Using the appropriate tool, carefully cut around the lace (1), start in the center working from side to side
of the windshield to access the urethane adhesive bead.

Fig. 8: Separating Urethane Adhesive From Window

NOTE:
Use care when removing the window not to cut off the locator pins on the
left and right sides. If the locating pins are cut off it will be necessary to
use masking tape to tape the window in place until the auto-adhesive
cures.
NOTE:
Keep the cutting edge of the tool against the window.
7. Remove the window from the urethane adhesive.

Leave a base of urethane approximately 2 mm (0.078 in) on the pinch-weld flange.
The only suitable lubrication is clear water.
BO-24402-A Glass Sealant Remover (Cold Knife).
BO-39032 Stationary Glass Removal Tool, or equivalent in order to remove the window.

Fig. 9: Separating Bottom Of Window

NOTE:
Keep the cutting edge of the appropriate tool against the window. Do this
from inside the vehicle.
8. If necessary, use the appropriate tool to remove the bottom corners of the windshield from the urethane
adhesive.

Fig. 10: Removing Windshield With Aid Of An Assistant

9. Remove the windshield from the vehicle with an assistant.
1. Install the windshield into the opening with an assistant. Refer to Adhesive Installation of Stationary
Windows (Rear Window), Adhesive Installation of Stationary Windows (Windshield).
2. Install the inside rearview mirror. Refer to Inside Rearview Mirror Replacement .
3. Install the windshield garnish molding. Refer to Windshield Garnish Molding Replacement .
4. Install the air inlet grille. Refer to Air Inlet Grille Panel Replacement .
5. Remove the double layer of masking tape around the perimeter of the painted surfaces and the interior
trim.
6. Connect the battery. Refer to Battery Negative Cable Disconnection and Connection ..
FRONT SIDE DOOR WINDOW ADJUSTMENT

Fig. 11: Front Side Door Window And Regulator Sash Nuts
Front Side Door Window Adjustment
Callout
Component Name
WARNING:
Refer to Glass and Sheet Metal Handling Warning .
WARNING:
Refer to Express Window Down Warning .
1. Remove the front side door trim. Refer to Front Side Door Trim Replacement .
2. Remove the front side door water deflector. Refer to Front Side Door Water Deflector
Replacement .
Front Side Door Window Regulator Sash Nut (Qty: 2)
CAUTION:
Tighten
10 N.m (89 lb in)


Procedure
1. Loosen the window regulator sash nuts.

2. Connect the door trim panel wire connector.
3. Start the vehicle to ensure maximum power to the window motor.
This is required in order to fully seat the window for adjustment.
4. Using the power window switch, raise the window to the full up
position.
5. Tighten the front side door window regulator sash nuts.
6. Inspect for proper window operation and a tight seal.
7. Shut off the vehicle.
FRONT SIDE DOOR WINDOW REPLACEMENT
Fig. 12: Front Side Door Window And Regulator Sash Nuts
Front Side Door Window Replacement
Callout
Component Name

1. Position the window approximately half way down in the door.

Replacement .
3. Remove the front side door window outer sealing strip. Refer to Front Side Door Window Outer
Sealing Strip Replacement.
Front Side Door Window Regulator Sash Nut (Qty: 2)
CAUTION:
Tighten
9 N.m (80 lb in)
Procedure
2
1. Loosen the window regulator sash nuts, pull upward to release

the window from the sash.
2. Rotate the front door window as necessary to remove it from
the door.
REAR SIDE DOOR WINDOW ADJUSTMENT

Fig. 13: Rear Side Door Window And Regulator Sash Nuts
Rear Side Door Window Adjustment
Callout
Component Name
WARNING:
WARNING:
Refer to Express Window Down Warning .
1. Remove the rear side door trim. Refer to Rear Side Door Trim Replacement .
2. Remove the rear side door water deflector. Refer to Rear Side Door Water Deflector
Replacement .
Rear Side Door Window Regulator Sash Nut (Qty: 2)
CAUTION:
Tighten
10 N.m (89 lb in)
Procedure
1. Loosen the window regulator sash nuts.

2. Connect the door trim panel wire connector.
3. Start the vehicle to ensure maximum power to the window motor.
This is required in order to fully seat the window for adjustment.
Using the power window switch, raise the window to the full up
position.
4. Tighten the rear side door window regulator sash nuts.
5. Inspect for proper window operation and a tight seal.
6. Shut off the vehicle.
REAR SIDE DOOR WINDOW REPLACEMENT

Fig. 14: Rear Side Door Window And Regulator Sash Nuts
Rear Side Door Window Replacement
Callout
Component Name
1. Position the window approximately half way down in the door.

Replacement .
3. Remove the rear side door window outer sealing strip. Refer to Rear Side Door Window Outer
Sealing Strip Replacement.
Rear Side Door Window Regulator Sash Nut (Qty: 2)
CAUTION:
Tighten
9 N.m (80 lb in)

Procedure

1. Loosen the window regulator sash nuts, pull upward to release

the window from the sash.
2. Rotate the rear door window as necessary to remove it from the
door.
REAR SIDE DOOR STATIONARY WINDOW REPLACEMENT
Fig. 15: Rear Side Door Stationary Window

Rear Side Door Stationary Window Replacement
Callout
Component Name
Remove the rear side door window weatherstrip with the rear side door stationary window. Refer to Rear
Side Door Window Weatherstrip Replacement.
Rear Door Stationary Window
1
Procedure
Remove the rear side door stationary window from the weatherstrip.
REAR SIDE DOOR STATIONARY WINDOW DIVIDER CHANNEL REPLACEMENT

Fig. 16: Rear Side Door Stationary Window Divider Channel And Bolts
Rear Side Door Stationary Window Divider Channel Replacement
callout
Component Name
Remove the rear side door window. Refer to Rear Side Door Window Replacement
Rear Side Door Stationary Window Divider Channel Bolt (Qty: 3)
CAUTION:
Tighten
9 N.m(80 lb in)
Rear Side Door Stationary Window Divider Channel
REAR WINDOW REPLACEMENT

Special Tools
BO-24402-A Glass Sealant Remover (Cold Knife)

BO-39032 Stationary Glass Removal Tool
Use an adhesive that is approved by GM

For equivalent regional tools, refer to Special Tools

Removal Procedure
WARNING: Refer to Cracked Window Warning .
NOTE:
Before cutting out a stationary window, apply a double layer of masking

tape around the perimeter of the painted surfaces and the interior trim.
1. Disconnect the battery. Refer to Battery Negative Cable Disconnection and Connection .
2. Remove the quarter window garnish molding. Refer to Quarter Window Garnish Molding
Replacement .
3. Disconnect the rear window radio antenna connector.
4. Disconnect the electrical connectors from the rear window defogger bus bars.
5. Protect the following parts from broken glass:
Seats
Carpeting

Fig. 17: Using Utility Knife To Remove Reveal Molding

NOTE:
If the original window is being reused the window lace is not serviceable.
6. Using the appropriate tool, carefully cut around the lace (1), start in the center working from side to side
of the windshield to access the urethane adhesive bead.
WARNING: Refer to Defroster Outlet Warning .
7. Cover the following parts to protect from the broken glass:

Upper dash pad
Defroster outlets and A/C outlets

Seats and carpeting
Fig. 18: Separating Urethane Adhesive From Window

NOTE:
Use care when removing the rear window not to cut off the locator pins on
the left and right sides. If the locating pins are cut off it will be necessary
to use masking tape to tape the window in place until the auto-adhesive
cures.
NOTE:
Keep the cutting edge of the tool against the window.
8. Remove the window from the urethane adhesive.

Leave a base of urethane approximately 2 mm (0.078 in) on the pinch-weld flange.
The only suitable lubrication is clear water.
BO-24402-A Glass Sealant Remover (Cold Knife).
BO-39032 Stationary Glass Removal Tool, or equivalent in order to remove the window.

Fig. 19: View Of Rear Window

9. With the an assistant, remove the window from the vehicle.
1. Install the rear window into the opening with an assistant. Refer to Adhesive Installation of Stationary
Windows (Rear Window), Adhesive Installation of Stationary Windows (Windshield).
2. Connect the rear window defogger electrical connectors to the bus bars.
3. Connect the rear window radio antenna connector.
4. Install the quarter window garnish molding. Refer to Quarter Window Garnish Molding
Replacement .
5. Remove the double layer of masking tape around the perimeter of the painted surfaces and the interior
trim.
6. Connect the battery. Refer to Battery Negative Cable Disconnection and Connection .

REAR SIDE DOOR WINDOW CHANNEL INSULATOR REPLACEMENT
Fig. 20: Rear Side Door Window Channel Insulator

Rear Side Door Window Channel Insulator Replacement
Callout
Component Name
Remove the rear side door water deflector. Refer to Rear Side Door Water Deflector Replacement .
1
Rear Side Door Window Channel Insulator
FRONT SIDE DOOR WINDOW SWITCH REPLACEMENT - RIGHT SIDE

Fig. 21: Right Front Side Door Window Switch

Callout
Component Name
Remove the front side door window switch bezel. Refer to Front Side Door Window Switch Bezel
Replacement .
1
Front Side Door Window Switch Assembly
FRONT SIDE DOOR WINDOW SWITCH REPLACEMENT - LEFT SIDE

Fig. 22: Left Front Side Door Window Switch

Callout
Component Name
Replacement .
1
Front Side Door Window Switch Assembly
FRONT SIDE DOOR WINDOW AND MULTIFUNCTION SWITCH REPLACEMENT

Fig. 23: Front Side Door Window and Multifunction Switch

Front Side Door Window and Multifunction Switch Replacement
Callout
Component Name
Replacement .
Front Side Door Window and Multifunction Switch
Procedure
1
REAR SIDE DOOR WINDOW SWITCH REPLACEMENT

Fig. 24: Rear Side Door Window Switch Assembly

Callout
Component Name
Remove the rear side door window switch bezel. Refer to Rear Side Door Window Switch Bezel
Replacement .
1
Rear Side Door Window Switch Assembly
FRONT SIDE DOOR WINDOW REGULATOR REPLACEMENT

Fig. 25: Front Side Door Window Regulator Assembly And Screws
Front Side Door Window Regulator Replacement
Callout
Component Name
Remove the front side door water deflector. Refer to Front Side Door Water Deflector Replacement .
Front Side Door Window Regulator Screw (Qty: 5)
CAUTION:
Procedure
After detaching window from regulator, manually move window to
it's full up position and securely tape to window frame.
Tighten
9 N.m (80 lb in)
Front Side Door Window Regulator Assembly
Procedure
Remove all components as needed.
WINDOW MOTOR PROGRAMMING - EXPRESS FUNCTION

Window Motor Normalized Procedure

A window motor that has not been normalized will no longer perform the express up and express down
functions, this may occur during the following conditions:
When a window motor has been disconnected or replaced

When a door harness has been disconnected
When the battery has been disconnected or replaced
NOTE:
When DTC B3205 4B & 3210 4B are set, the following warnings will be displayed
on the driver information center:
Open, then Close Driver Window
Open, then Close Passenger Window
These warnings will clear once the windows have been "Normalized" and the
respective DTC will clear.
To normalize the window motor, follow these steps:

NOTE:
The doors must be completely closed prior to normalizing the windows, a

door that is open or ajar may cause the power window to function
abnormally or to become inoperative while performing the normalizing
procedure. If this occurs, verify that the door is completely closed then
repeat the normalizing procedure.
NOTE:
For vehicles equipped with a folding convertible top, the top must be
closed and firmly latched prior to normalizing the windows.
1. Ignition ON.
2. Starting with the window completely UP, press and hold the power window switch until the window is
fully open and continue holding the switch down for approximately 5 seconds after the window is
completely open.
3. Pull the power window switch up until the window is fully closed and continue holding the switch up for
approximately 5 seconds after the window is completely closed.
The window should now be normalized and the window should perform the express up and express down
functions.
Window Motor Relearn Procedure
A relearn procedure may need to be performed for any Local Interconnect Network (LIN) window motor for the
When the window glass is out of alignment

When the window glass has been replaced

When the door has been replaced

When the window regulator has been replaced
NOTE:
Prior to performing the relearn procedure the vehicle must have all 4 wheels
properly inflated and mounted, the vehicle must be sitting on a level surface
and all doors must be completely closed and for vehicles equipped with a
folding convertible top, the top must be closed and firmly latched..
To relearn the window motor, follow these steps:

1. Ignition ON.
2. With a scan tool, select Module Diagnosis, Body Control Module, Configuration/Reset Functions and
then select the appropriate Clear Window Learn Values for the window motor requiring the relearn
procedure.
3. After the learn procedure, exit the scan tool learn procedure completely, the power window cannot be
normalized and will not function until you exit the program.
4. Starting with the window completely UP, press and hold the power window switch until the window is
fully open and continue holding the switch down for approximately 5 seconds after the window is
completely open.
5. Pull the power window switch up until the window is fully closed and continue holding the switch up for
approximately 5 seconds after the window is completely closed.
The window is now reprogrammed.
FRONT SIDE DOOR WINDOW REGULATOR MOTOR REPLACEMENT

Fig. 26: Front Side Door Window Regulator Motor Assembly And Screws
Callout
Component Name
Remove the front side door window regulator. Refer to Front Side Door Window Regulator
Replacement.
Front Side Door Window Regulator Motor Screw (Qty: 3)
CAUTION:
Tighten
9 N.m (80 lb in)
Front Side Door Window Regulator Motor Assembly
REAR SIDE DOOR WINDOW REGULATOR REPLACEMENT

Fig. 27: Rear Side Door Window Regulator Assembly And Screws
Rear Side Door Window Regulator Replacement
Callout
Component Name
Remove the rear side door water deflector. Refer to Rear Side Door Water Deflector Replacement .
Rear Side Door Window Regulator Screw (Qty: 3)
CAUTION:
Procedure
After detaching window from regulator, manually move window to
it's full up position and securely tape to window frame.
Tighten
9 N.m (80 lb in)
Rear Side Door Window Regulator Assembly
Procedure
Remove all components as needed.
REAR SIDE DOOR WINDOW REGULATOR MOTOR REPLACEMENT

Fig. 28: Rear Side Door Window Regulator Motor Assembly And Screws
Callout
Component Name
Remove the rear side door window regulator. Refer to Rear Side Door Window Regulator
Replacement.
Rear Side Door Window Regulator Motor Screw (Qty: 3)
CAUTION:
Tighten
9 N.m (80 lb in)
Rear Side Door Window Regulator Motor Assembly
FRONT SIDE DOOR WINDOW OUTER SEALING STRIP REPLACEMENT

Fig. 29: Front Side Door Window Outer Sealing Strip

Front Side Door Window Outer Sealing Strip Replacement
Callout
Component Name
Front Side Door Window Outer Sealing Strip Assembly
1
Procedure
Pull up and away from the door flange to remove.
FRONT SIDE DOOR WINDOW INNER SEALING STRIP REPLACEMENT

Fig. 30: Front Side Door Window Inner Sealing Strip

Front Side Door Window Inner Sealing Strip Replacement
Callout
Component Name
Remove the front side door trim. Refer to Front Side Door Trim Replacement
1
Front Side Door Window Inner Sealing Strip
REAR SIDE DOOR WINDOW INNER SEALING STRIP REPLACEMENT

Fig. 31: Rear Side Door Window Inner Sealing Strip

Rear Side Door Window Inner Sealing Strip Replacement
callout
Component Name
Remove the rear side door trim. Refer to Rear Side Door Trim Replacement .
1
Rear Side Door Window Inner Sealing Strip
REAR SIDE DOOR WINDOW OUTER SEALING STRIP REPLACEMENT

Fig. 32: Rear Side Door Window Outer Sealing Strip Assembly
Rear Side Door Window Outer Sealing Strip Replacement
Callout
Component Name
1
Rear Side Door Window Outer Sealing Strip Assembly
FRONT SIDE DOOR WINDOW WEATHERSTRIP REPLACEMENT

Fig. 33: Front Side Door Window Weatherstrip

Front Side Door Window Weatherstrip Replacement
Callout
Component Name
1. Remove the outside rearview mirror. Refer to Outside Rearview Mirror Replacement .
2. Remove the front side door window rear cover. Refer to Front Side Door Window Frame Rear
Cover Replacement .
3. Remove the front side door window. Refer to Front Side Door Window Replacement.
Front Side Door Window Weatherstrip
Procedure
1
Pull the front side door window weatherstrip away from the outer
window flange to remove.
REAR SIDE DOOR WINDOW WEATHERSTRIP REPLACEMENT

Fig. 34: Rear Side Door Window Weatherstrip

Rear Side Door Window Weatherstrip Replacement
Callout
Component Name
1. Remove the rear side door window frame front cover. Refer to Rear Side Door Window Frame
Front Cover Replacement .
2. Remove the rear side door window. Refer to Rear Side Door Window Replacement.
Rear Side Door Window Weatherstrip
Procedure
1
1. Pull the rear side door window weatherstrip away from the outer
window flange to remove.
2. Remove the rear side door stationary window from the rear side
door window weatherstrip.
ADHESIVE INSTALLATION OF STATIONARY WINDOWS (WINDSHIELD)


1. Use a urethane adhesive systems which meet GM Specification GM 3651G.

2. Remove all mounds or loose pieces of urethane adhesive from the pinch-weld area.
3. If the original window is being reused, remove all but approximately 2 mm (3/64 in) of the existing bead
of urethane adhesive from the pinch-weld flange surface and window by using a clean utility knife or
razor blade scraper.
4. Inspect for any of the following problems in order to help prevent future breakage of the window:
High weld
Solder spots
Hardened sealer
Any other obstruction or irregularity in the pinch-weld flange
NOTE:
If corrosion of the pinch-weld flange is present or if sheet metal repairs or

replacements are required, the pinch-weld flange must be 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. 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 STANDOX 11158/13320 - 14653/14980 products are approved for
this application.
5. After repairing the opening as indicated, perform the following steps:

1. Remove all traces of broken glass from the outer cowl panel, seats, floor, and defroster ducts.
2. Clean around the edge of the inside surface of the window with a 50/50 mixture of isopropyl
alcohol and water by volume on a dampened lint free cloth.
WARNING: Refer to Window Retention Warning .
6. Verify all primers and urethane adhesive are within expiration dates.

Fig. 35: Applying Pinch-Weld Primer

WARNING: Failure to prep the area prior to the application of primer may cause
insufficient bonding of urethane adhesive. Insufficient bonding of
urethane adhesive may allow unrestrained occupants to be ejected
from the vehicle resulting in personal injury.
NOTE:
Do not apply the black #3 primer to the existing bead (1) of the urethane
adhesive on the pinch-weld flange. Apply the primer only to nicks,
scratches, or the primed surfaces.
7. Shake the pinch-weld primer black #3 for at least 1 minute.

8. Use a new dauber in order to apply the primer to the surface of the pinch-weld flange (1).
9. Allow the pinch-weld primer to dry for approximately 10 minutes.

Fig. 36: Removing/Installing Windshield

10. With the aid of an assistant, dry fit the window (1) to the opening in order to determine the correct
position.

Fig. 37: Identifying Locator Slots On Upper Pinch-Weld Flange

11. If equipped, ensure that the windshield locator pins are positioned into the locator slots on the upper
pinch-weld flange.

Fig. 38: Aligning Tape Lines On Window To Body

12. Use masking tape in order to mark the locations (1) of the window (2) in the opening.
13. Cut the masking tape in the center and remove the window from the opening.

Fig. 39: Applying Glass Prep

NOTE:
Use care when applying glass prep clear #1 on the window. This primer
dries almost instantly, and may stain the viewing area of the window if not
applied evenly.
14. Use a new dauber in order to apply glass prep clear #1 to the area approximately 18 mm (0.71 in) around
the entire perimeter of the window inner surface.
Immediately wipe the glass primed area using a clean, lint-free cloth.


15. Apply a second coat of the glass prep clear #1 to the same area of the glass.

Fig. 41: Applying Glass Primer

NOTE:
The glass primer black #2 is effective up to 8 hours after applying it to the

glass. The primed surface of the glass must be kept clean.
16. Shake the glass primer black #2 for at least 1 minute.

17. Use a new dauber in order to apply the glass primer black #2 to the same areas (2) that glass prep clear #1
was applied.
18. Allow the glass primer to dry for approximately 10 minutes.

Fig. 42: View Of Modified Applicator Nozzle

19. Cut the applicator nozzle in order to provide a minimum urethane bead of 8 mm (0.31 in) wide and 16
mm (0.63 in) high.

Fig. 43: Applying Continuous Bead Of Urethane Adhesive

20. Use a cartridge-type caulking gun in order to apply a smooth, continuous bead of urethane adhesive.

Fig. 44: Applying Urethane Adhesive To Inner Surface Of Window

21. Use the edge of the window as a guide for the nozzle in order to apply the urethane adhesive (1) to the
inner surface of the window (3).

Fig. 45: Removing/Installing Windshield

22. With the aid of an assistant, place the window (1) in the opening.


23. Align the masking tape (1) lines on the window (2) and the body.

Fig. 47: Pressing Window Into Place

NOTE:
To prevent damage to the window due to objects impacting an exposed

edge, upon installation, the window must rest 1 mm (0.04 in) below the
surface of the sheet metal.
24. Press firmly around the entire periphery of the windshield in order to wet-out the urethane bead.
25. Tape the window to the body in order to minimize movement until the urethane adhesive cures.

Fig. 48: Cleaning Excess Urethane Adhesive From Body

26. Clean any excess urethane adhesive from the body.

Fig. 49: Performing Water Hose Test

NOTE:
27.
28.
29.
30.
Do not direct a hard stream of high pressure water to the freshly applied
urethane adhesive.
Use a soft spray of warm water in order to immediately water test the window.
Inspect the window for leaks.
If any leaks are found, use a plastic paddle in order to apply extra urethane adhesive at the leak point.
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 moisture-curing type of urethane adhesive, allow a

minimum of 6 hours at 21C (70F) or greater and with at least

30 percent relative humidity. Allow at least 24 hours for the

complete curing of the urethane adhesive.
For the chemical-curing type of urethane adhesive, allow a
minimum of 1 hour.
Do NOT physically disturb the repair area until after these minimum
times have elapsed.
31. Maintain the following conditions in order to properly cure the urethane adhesive:
Partially lower a door window in order to prevent pressure buildups when closing doors before the
urethane adhesive cures.
Do not drive the vehicle until the urethane adhesive is cured. Refer to the above curing times.
Do not use compressed air in order to dry the urethane adhesive.
32. Complete the window installation.
ADHESIVE INSTALLATION OF STATIONARY WINDOWS (REAR WINDOW)
1. Use a urethane adhesive systems which meet GM Specification GM 3651G.

2. Remove all mounds or loose pieces of urethane adhesive from the pinch-weld area.
3. If the original window is being reused, remove all but approximately 2 mm (3/64 in) of the existing bead
of urethane adhesive from the pinch-weld flange and window by using a clean utility knife or razor blade
scraper.
4. Inspect for any of the following problems in order to help prevent future breakage of the window:
High weld
Solder spots
Hardened sealer
Any other obstruction or irregularity in the pinch-weld flange
NOTE:
If corrosion of the pinch-weld flange is present or if sheet metal repairs or

replacements are required, the pinch-weld flange must be 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. 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 STANDOX 11158/13320 - 14653/14980 products are approved for
this application.
5. After repairing the opening as indicated, perform the following steps:

1. Remove all traces of broken glass from the outer cowl panel, seats, floor and defroster ducts.

2. Clean around the edge of the inside surface of the window with a 50/50 mixture of isopropyl
alcohol and water by volume on a dampened lint free cloth.
WARNING: Refer to Window Retention Warning .
6. Verify all primers and urethane adhesive are within expiration dates.
Fig. 50: Applying Pinch-Weld Primer

WARNING: Failure to prep the area prior to the application of primer may cause
insufficient bonding of urethane adhesive. Insufficient bonding of
urethane adhesive may allow unrestrained occupants to be ejected
from the vehicle resulting in personal injury.
NOTE:
Do not apply the black #3 primer to the existing bead (1) of the urethane

adhesive on the pinch-weld flange. Apply the primer only to nicks,

scratches or the primed surfaces.
7. Shake the pinch-weld primer black #3 for at least 1 minute.
8. Use a new dauber in order to apply the primer to the surface of the pinch-weld flange (2).
9. Allow the pinch-weld primer to dry for approximately 10 minutes.
Fig. 51: Installing Rear Window

10. With the aid of an assistant, dry fit the window (2) to the opening in order to determine the correct
position.
11. Ensure that the locator pins (1) are positioned into the locator slots on the upper pinch-weld flange.


12. Use masking tape 91) to mark the locations of the window (2) in the opening.
13. Cut the masking in the center and remove the window from the opening.


NOTE:
Use care when applying glass prep clear #1 on the window. This primer
dries almost instantly, and may stain the viewing area of the window if not
applied evenly.
14. Use a new dauber in order to apply glass prep clear #1 to the area approximately 18 mm (0.71 in) around
the entire perimeter of the window inner surface.
Immediately wipe the glass primed area using a clean, lint-free cloth.


15. Apply a second coat of the glass prep clear #1 to the same area of the glass.

Fig. 55: Applying Glass Primer

NOTE:
The glass primer black #2 is effective up to 8 hours after applying it to the

glass. The primed surface of the glass must be kept clean.
16. Shake the glass primer black #2 for at least 1 minute.

17. Use a new dauber in order to apply the glass primer black #2 to the same areas (2) that glass prep clear #1
was applied.
18. Allow the glass primer to dry for approximately 10 minutes.

Fig. 56: View Of Modified Applicator Nozzle

19. Cut the applicator nozzle in order to provide a minimum urethane bead of 8 mm (0.31 in) wide and 16
mm (0.63 in) high.

Fig. 57: Applying Continuous Bead Of Urethane Adhesive

20. Use a cartridge-type caulking gun in order to apply a smooth, continuous bead of urethane adhesive.

Fig. 58: Applying Urethane Adhesive To Inner Surface Of Window

21. Use the edge of the window as a guide for the nozzle in order to apply the urethane adhesive (1) to the
inner surface of the window (3).

Fig. 59: Installing Rear Window

22. With the aid of an assistant, place the window (2) and locator (1) in the opening.


23. Align the masking tape (1) lines on the window (2) and the body.

Fig. 61: Pressing Window Into Place

NOTE:
To prevent damage to the window due to objects impacting an exposed

edge, upon installation, the window must rest 1 mm (0.040 in) below the
surface of the sheet metal.
24. Press firmly around the entire periphery of the window in order to wet-out the urethane bead.
25. Tape the window to the body in order to minimize movement until the urethane adhesive cures.

Fig. 62: Cleaning Excess Urethane Adhesive From Body

26. Clean any excess urethane adhesive from the body.


NOTE:
27.
28.
29.
30.
Do not direct a hard stream of high pressure water to the freshly applied
urethane adhesive.
Use a soft spray of warm water in order to immediately water test the window.
Inspect the window for leaks.
If any leaks are found, use a plastic paddle in order to apply extra urethane adhesive at the leak point.
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 moisture-curing type of urethane adhesive, allow a

minimum of 6 hours at 21C (70F) or greater and with at least

30 percent relative humidity. Allow at least 24 hours for the

complete curing of the urethane adhesive.
For the chemical-curing type of urethane adhesive, allow a
minimum of 1 hour.
Do NOT physically disturb the repair area until after these minimum
times have elapsed.
31. Maintain the following conditions in order to properly cure the urethane adhesive:
Partially lower a door window in order to prevent pressure buildups when closing doors before the
urethane adhesive cures.
Do not drive the vehicle until the urethane adhesive is cured. Refer to the above curing times.
Do not use compressed air in order to dry the urethane adhesive.
32. Complete the window installation.

ADHESIVE SERVICE KIT DESCRIPTION
Use the urethane adhesive for replacement of any urethane adhesive-installed windows.
Use these materials based on specific manufacturer.
Do NOT intermix primers or adhesives from one manufacturer to another.
Always follow the system manufacturer's instructions for application, handling, and curing.
POWER WINDOWS DESCRIPTION AND OPERATION
Power Windows System Components
The power window system consists of the following components:
Driver window switch

Passenger window switch
Left rear window switch
Right rear window switch
Window motors in each of the doors
30A Fuse
Body control module (BCM)
Power Window System
This vehicle can be configured as follows:

Driver express up and express down power window motor (Optional)

Driver, passenger, left rear and right rear express down only window motors
Driver Express Up and Express Down Window Motor
The driver door contains a window motor is smart motor that will detect excessive resistance while performing
the express up function and automatically reverse direction to prevent injury to any occupants that may become
trapped between the closing window and the door frame. The automatic reverse safety feature can be overridden
by pulling and holding the window switch.
The logic circuit within the window motor monitors the up, down and express signal circuits which are
normally equal to B+ voltage. When a switch is used on the driver window switch, the contacts close causing a
voltage drop within the appropriate signal circuit. The driver window motor will detect the voltage drop and
will command the window to move in the direction requested.
All Doors with Express Down Only Window Motors
For the driver, passenger, right rear and left rear doors, when their window switch is pressed in the down
position, battery positive voltage is applied to their respective window motor control circuit and ground to the
other window motor control circuit causing that window to open. When the individual window switch is pulled
in the up position, voltage and ground is applied to the window motor in the opposite direction causing that
window to close. The return path to ground is supplied through the inactive control circuit being normally
grounded through the window switch.
Each window switch communicates to the BCM by a serial data circuit. When the driver wishes to control the
passenger, left rear or right rear window, the driver will use the appropriate switch on the driver window switch.
When this switch is used, a serial data message is sent to the BCM requesting a window motor command, the
BCM will then send a serial data message to the appropriate door window switch which will then command that
window to move in the direction requested.
Lockout Switch Feature
The child door lockout switch is on the driver door lock/window switch and controls the child locks on the rear
doors as well as the rear window switches. When the BCM receives a command from the window lockout
switch, it will apply voltage to the door lock security relay coil, this will energize the relay and the contact
within the relay will then direct the voltage to lock the left rear and right rear child locks and then isolate them
from the normal door lock system to prevent the rear doors from being opened by using the interior rear door
handles.
The BCM monitors the voltage level of the rear lock status signal circuits to determine if the rear door latches
have been locked out. A switch within the rear door latch will be open or closed depending upon the lockout
status of the rear latch. If the rear latches are locked out, the switch will be open and the BCM will disable the
functions of the rear window switches. If the latches have not been lockout, the switch will be closed, pulling
the voltage within the signal circuit to 0 volts and the BCM will permit normal rear window switch functions.
REAR WINDOW DEFOGGER DESCRIPTION AND OPERATION
Rear Window Defogger System Components

The rear window defogger system consists of the following components:
HVAC Control Module

HVAC Control Head
Rear Window Defogger Relay
Rear Defogger Grid
F28UA 40A Fuse
Rear Window Defogger Operation
The rear defog control system utilizes a single zone backlight design, driven with a single relay configuration.
Additionally, up to two outside rear view mirrors can be heated if required. A switch for the customer to control
the system is provided within the HVAC control head. Also included in the HVAC control head is an indicator
to inform the customer with the current state of the system. The system is only operational when engine is
running or during remote start.
Pressing the heated rear window switch on the HVAC control face plate causes the HVAC control head to send
a serial data message to the HVAC control module requesting rear window defog operation. The HVAC control
module upon receipt of the serial data message will provide voltage to the coil side of the rear window defogger
relay, this will energize the relay causing the relay switch contacts to close allowing B+ voltage to flow through
the rear defogger grid control circuit to the rear defogger grid.
When the rear heated window switch is pressed and the engine is running, the rear defog control system will
remain active for 10 minutes. After the initial cycle has lapsed, pressing the switch again will continue rear
window defogger operation, but the cycle will only last 5 minutes. The rear defog control system will function
continuously if the vehicle speed is greater than 70 kilometers per hour (45 mph).
STATIONARY WINDOW DESCRIPTION
Most stationary windows, specifically windshields, are retained to the body with urethane adhesive which
adheres the window to the body. This increases structural integrity. The reinstallation of windows with urethane
adhesive requires complete replacement of the urethane adhesive bead:
The extended method (also known as long method, full strip or full cut) is the only recommended procedure for
General Motors Vehicle.

SPECIAL TOOLS
Illustration

BO-569-A
KM-569-A
M-680156
Plug Lifter

GE-604-D
MKM-604-D
Torx Bit and Socket Set
BO-641
MKM-641
Suction Holder
BO-6626
KM-6626
Wiper Arm Puller
DT-6459-B
MKM-J-6459-B
Torque Wrench
BO-24402-A
J-24402-A
Glass Sealant Cold Knife Remover
BO-39032
J-39032
Stationary Glass Removal Tool
EL-47955
J-2534
Multi Diagnostic Interface MDI

BO-50169
KM-317-B
Remover, Window Crank

2013 ACCESSORIES & EQUIPMENT Horns - Cruze

Horns - Cruze
SPECIFICATIONS
Specification
Application
Horn Nut
Steering Wheel Horn Contact Bolt

HORN WIRING SCHEMATICS
Horn Wiring Schematics
Fig. 1: Horn Wiring Schematics

Metric
17 N.m
5.5 N.m
English
13 lb ft
49 lb in

Callout
28
28_BN/WH
CAV_19
CONN_X5
CAV_25
CONN_X2
29
29_BN/GY
CAV_2
CAV_11
CONN_X1
3287
3287_GN/WH
CAV_1
CONN_X1
CAV_18
CONN_X3
3287_BN/WH
CAV_10
CONN_X3
CAV_1
1650
1650_BK
CAV_2
1050
1050_BK
CAV 1
_BK
BK
F51UA
G101
G202
X50A
K9
S33
KR3
P12
X85
Component Name
Horn Relay Control
28 BN/WH
19
X5
25
X2
Horn Control
29 BN/GY
2
11
X1
Horn Switch Signal
3287 GN/WH
1
X1
18
X3
3287 BN/WH
10
X3
1
Ground
1650 BK
2
Ground
1050 BK
1
BK
BK
F51UA 15A
G101
G202


DTC
DTC B2750
Description
DTC B2750 Horn Relay Secondary Circuit
DTC B2750
DTC Descriptors
DTC B2750
Horn Relay Secondary Circuit
Circuit
Control
Short to
Ground
B2750 02
Open/High
Resistance
B2750 04
Short to
Voltage
B2750 01
Signal Performance
-
The Body Control Module provides a ground for the Horn printed circuit board relay within the underhood fuse
block. The underhood fuse block will then provide B+ voltage to the horn control circuit, sounding the horn.
When the horn output is actively being requested by the Body Control Module.
B2750 01
The Body Control Module detects a short to voltage in the horn relay control circuit.
B2750 02
The Body Control Module detects a short to ground in the horn relay control circuit.

B2750 04
The Body Control Module detects an open/high resistance in the horn relay control circuit.
The Body Control Module will command the horn when requested but the horn will be inoperative.
The DTC clears when the fault is no longer detected.

The current DTC will become history when the request for the output is removed.
The history DTC will clear after 50 consecutive fault-free ignition cycles have occurred.
Schematic Reference
Horn Schematics
Horns System Description and Operation
Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference

1. Ignition ON.
2. Verify the operation of the P12 Horn when commanding the Horn Relay On and Off with a scan tool.
If the P12 Horn is always ON or always OFF

If the P12 Horn turns ON and OFF

3. All OK.
1. Ignition OFF, disconnect the X1 harness connector at the X50A Fuse Block-Underhood, ignition ON.
2. Verify the P12 Horn is not activated.
If the P12 Horn is activated
1. Ignition OFF, disconnect the harness connector at the P12 Horn, ignition ON.
If less than 1 V, test or replace the P12 Horn.
If the P12 Horn is not activated
3. Connect a 15A fused jumper wire between the control circuit terminal 9 and B+.
4. Verify the P12 Horn activates.
If the P12 Horn does not activate
1. Ignition OFF, remove the jumper wire, disconnect the harness connector at the P12 Horn, ignition
ON.
If less than Infinite resistance, repair the short to ground on the circuit.
If less than 2 ohms, test or replace the P12 Horn.
If the P12 Horn activates
5. Ignition OFF, connect the X1 harness connector at the X50A Fuse Block-Underhood. Disconnect the X5
harness connector at the K9 Body Control Module, ignition ON.
6. Verify the P12 Horn is not activated.
1. Ignition OFF, disconnect the X2 harness connector at the X50A Fuse Block-Underhood.
2. Test for infinite resistance between the control circuit terminal 19 X5 at the K9 Body Control
Module and ground.
If infinite resistance, test or replace the X50A Fuse Block-Underhood.
7. Connect a 3 A fused jumper wire between the control circuit terminal 19 and ground.
8. Verify the P12 Horn activates.
1. Ignition OFF, remove the jumper wire, disconnect the X2 harness connector at the X50A Fuse

Block-Underhood, ignition ON.

2. Test for less than 1 V between the control circuit terminal 19 X5 at the K9 Body Control Module
and ground.
If less than 1 V
If less than 2 ohms, test or replace the X50A Fuse Block-Underhood.
Repair Instructions
Fuse Block Replacement

Control Module References for Body Control Module replacement, programming and setup
SYMPTOMS - HORNS
IMPORTANT: The following steps must be completed before using the symptom tables:
1. Perform Diagnostic System Check - Vehicle , before using the symptom
tables in order to verify that all of the following are true:
There are no DTCs set
The control modules can communicate via the serial data link
2. Review the system operation in order to familiarize yourself with the
system functions. Refer to Horns System Description and Operation.
Inspect for aftermarket devices which could affect the operation of the horn system. Refer to Checking
cause the symptom.
Perform the following if a horn buzzes or has a harsh tone.
Inspect for debris in the joint where the horn fastens to the vehicle.
Test the torque of the horn mounting hardware. The horn mounting hardware should be tightened to
a torque of 10 N.m (7 lb ft).
Intermittent


Symptom List
Refer to a symptom diagnostic procedure Horns Malfunction in order to diagnose the symptom.
HORNS MALFUNCTION
Short to
Ground
Circuit
Horn Switch Signal
1
Horn Relay Control
B2750 02
Horn Control
2
Horn Ground
Horn Switch Ground
1. Horns Always On
2. Horns Inoperative
3. Horns Inoperative From Horn Pad
Open/High
Resistance
3
B2750 04
2
2
3
Short to
Voltage
3
B2750 01
1
-
Signal Performance
-
The body control module (BCM) monitors the Horn Switch signal circuit, when the horn pad is pressed, the
BCM detects the drop in the Horn Switch signal circuit and provides a ground for the Horn printed circuit board
relay within the underhood fuse block. The underhood fuse block will then provide B+ voltage to the horn
control circuit, sounding the horn.
Diagnostic Aids
OnStar RemoteLink applications or "apps" downloads are available to owners of certain mobile devices.
Unwanted or inadvertent horn activations have been associated with these applications to which the customer
may be unaware. Contact the GM Technical Assistance Center regarding information on a remedy for this
situation.
A short to ground in the horn relay control circuit or a short to voltage in the horn control circuit will cause the
horns to sound continuously until the horns overheat and become inoperative.
Rotate the steering wheel while pressing the horn pad to identify intermittent and poor connections within the
steering column.

If diagnosing a Horn- Poor Tone condition, inspect the following:
Debris or water in the horn assembly

Proper horn mounting hardware torque-Refer to Fastener Tightening Specifications.
Debris in the joint where the horns attach to the vehicle
Debris in direct contact with the horn
Vehicle components vibrating while the horn is sounding
Schematic Reference
Horn Schematics
Horns System Description and Operation
Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference

1. Ignition ON.
2. Verify the scan tool Horn Switch parameter changes between Active and Inactive when pressing and
releasing the horn pad.
Refer to Circuit/System Testing below - Horn Switch Malfunction.
3. Verify the P12 Horn turns ON and OFF and emit a clear and even tone when commanding the Horn
Relay On and Off with a scan tool.

If the P12 Horn does not turn ON and OFF

Refer to Circuit/System Testing below - Horns or Horn Command Malfunction.
If the sound emitted is not clear and even

Refer to Circuit/System Testing below - Horn - Poor Tone.
If the P12 Horn turns ON and OFF and emit a even and clear tone
4. All OK.
Horn Switch Malfunction

1. Ignition OFF and all vehicle systems OFF, disconnect the harness connector at the S33 Horn Switch. It
may take up to 2 minutes for all vehicle systems to power down.
1. Ignition OFF.
3. Ignition ON.
4. Verify the scan tool Horn Switch parameter is Inactive.
If not Inactive
If Inactive
6. Verify the scan tool Horn Switch parameter is Active.
If not Active
1. Ignition OFF, remove the jumper wire, disconnect the harness connector at the K9 Body Control
If less than 1 V


If Active
7. Test or replace the S33 Horn Switch.
Horns or Horn Command Malfunction

1. Ignition OFF, and all vehicle systems OFF. Disconnect the harness connector at the P12 Horn. It may
take up to 2 minutes for all vehicle systems to power down.
1. Ignition OFF.
If less than 1 ohms
3. Connect a test lamp between the control circuit terminal 2 and ground, ignition ON.
4. Verify the test lamp does not turn ON and OFF when commanding the Horn Relay On and Off with a
scan tool.
Test or replace the P12 Horn.
If the test lamp does not turn ON and OFF
Ignition OFF, connect the harness connector at the P12 Horn. Disconnect the X1 harness connector at the
X50A Fuse Block-Underhood, ignition ON.
Verify the P12 Horn is not activated.
1. Ignition OFF, disconnect the harness connector at the P12 Horn, ignition ON.
If less than 1 V, test or replace the P12 Horn.
Connect a 15 A fused jumper wire between the control circuit terminal 11 and B+.
Verify the P12 Horn activates.
1. Ignition OFF, remove the jumper wire, disconnect the harness connector at the P12 Horn, ignition
ON.
5.
6.
7.
8.

If less than 2 ohms, test or replace the P12 Horn.
Ignition OFF, connect the X1 harness connector at the X50A Fuse Block-Underhood. Disconnect the X5
Verify the P12 Horn is not activated.
2. Test for infinite resistance between the K9 Body Control Module control circuit terminal 19 X5 and
ground.
If infinite resistance, replace the X50A Fuse Block-Underhood.
Connect a 3 A fused jumper wire between the control circuit terminal 19 and ground.
Verify the P12 Horn activates.
Block-Underhood, ignition ON.
2. Test for less than 1 V between the K9 Body Control Module control circuit terminal 19 X5 and
ground.
If less than 1 V
If less than 2 ohms, replace the X50A Fuse Block-Underhood.
Replace the K9 Body Control Module.
9.
10.
11.
12.
13.
Horn - Poor Tone

1. Ignition OFF and all vehicle systems OFF, disconnect the harness connector at the P12 Horn. It may take
up to 2 minutes for all vehicle systems to power down.
1. Ignition OFF.
If 2 ohms or greater, repair the high resistance in the circuit.

If less than 2 ohms, repair high resistance in the ground connection.

If less than 1 ohms
4. Test for less than 2 ohms between the P12 Horn control circuit terminal 2 and the X50A Fuse BlockUnderhood control circuit terminal 11 X1.
Repair the high resistance in the control circuit.

If less than 2 ohms
5. Test or replace the P12 Horn.
Component Testing
Horn Test
1. Ignition OFF, disconnect the harness connector at the P12 Horn.
2. Install a 15 A fused jumper wire between the control terminal 2 and 12 V. Install a jumper wire between
the ground terminal 1 and ground.
3. Verify the P12 Horn turns ON and OFF
If the P12 Horn does not turn ON and OFF
Replace the P12 Horn.
If the P12 Horn turns ON and OFF
4. All OK
Horn Switch
1. Ignition OFF, disconnect the harness connector at the S33 Horn Switch.
2. Test for infinite resistance between the signal terminal 1 and the ground terminal 2 with the switch in the
open position.
Replace the S33 Horn Switch.
3. Test for less than 3 ohms between the signal terminal 1 and the ground terminal 2 with the switch in the
closed position.
Replace the S33 Horn Switch.
If less than 3 ohms

4. All OK
Repair Instructions

Horn Replacement
Steering Wheel Horn Contact Replacement
Control Module References for body control module replacement, programming and setup
REPAIR INSTRUCTIONS
HORN REPLACEMENT
Fig. 2: Identifying Horn Components

Horn Replacement
Callout
Component Name
Remove the front bumper fascia. Refer to Front Bumper Fascia Replacement .
Horn Nut

CAUTION:
Tighten
17 N.m (13 lb ft)
Horn
Procedure
STEERING WHEEL HORN CONTACT REPLACEMENT
Fig. 3: Steering Wheel Horn Contact Components

Steering Wheel Horn Contact Replacement
Callout
Component Name
Remove inflatable restraint steering wheel module. Refer to Airbag Steering Wheel Module
Replacement .
Steering Wheel Horn Contact Bolt (Qty: 3)
1
CAUTION:

Tighten
5.5 N.m (49 lb in)
Steering Wheel Horn Contact
Procedure

HORNS SYSTEM DESCRIPTION AND OPERATION
System Description
The horn system consists of the following components:
HORN fuse
Horn relay
Horn switch
Horn assembly
System Operation
The vehicle horn system is activated under the following conditions:
When the horn switch is depressed

The BCM commands the horns ON under any of the following conditions:
When the content theft deterrent system detects a vehicle intrusion-For further information refer to
Theft Systems Description and Operation .
When the panic button is depressed on the remote control door lock transmitter-For further
information refer to Keyless Entry System Description and Operation (without BTM) , Keyless
Entry System Description and Operation (with BTM) .
When the keyless entry system is used to lock the vehicle, a horn chirp may sound to notify the
driver that the vehicle has been locked. The notification feature may be enabled or disabled through
personalization. For further information refer to Keyless Entry System Description and
Operation (without BTM) , Keyless Entry System Description and Operation (with BTM) .
When the OnStar system is used to sound the horns if equipped-For further information, refer to
OnStar Description and Operation .
Circuit Operation
Battery positive voltage is applied at all times to the horn relay coil and the horn relay switch. Pressing either of
the horn switches applies ground to the horn relay control circuit. The BCM may also apply ground to the horn
relay control circuit as described above. When the horn relay control circuit is grounded, the horn relay is
energized and battery positive voltage is applied to the horns through the horn control circuit. The horns sound

as long as ground is applied to the horn relay control circuit.

2013 ACCESSORIES & EQUIPMENT Immobilizer - Cruze

Immobilizer - Cruze

IMMOBILIZER WIRING SCHEMATICS
Immobilizer Wiring Schematics
Fig. 1: Immobilizer Wiring Schematics

Callout
3276
CAV_3
CONN_X3
CAV_3
3276_GY/BK
7533
Component Name
Immobilizer Supply Voltage
3
X3
3
3276 GY/BK
Bus 11

7533_GN/VT
CAV_2
CAV_2
3277
3277_GN/GY
CAV_1
CAV_1
109
CAV_B
CAV_24
CONN_X4
CAV_A
109_BN/GN
109_BN/GN
1350
1350_BK
CAV_C
SD
CAV_17
CAV_15
CAV_11
CAV_8
ATH
ATH
ATH
ATH
7533 GN/VT
2
2
Immobilizer Return
3277 GN/GY
1
1
Hood Ajar Switch Signal
B
24
X4
A
109 BN/GN
109 BN/GN
Ground
1350 BK
C
Serial Data
Data Communication
Schematics
17
15
11
8
LOCK CONTROL, ENTRYREMOTE ENTRY,
EXTENDED RANGE,
PASSIVE ENTRY, ALL
DOORS
EXTENDED RANGE,
PASSIVE ENTRY, ALL
DOORS
EXTENDED RANGE,
PASSIVE ENTRY, ALL
DOORS
EXTENDED RANGE,
PASSIVE ENTRY, ALL

DOORS
EXTENDED RANGE,
PASSIVE ENTRY, ALL
DOORS
G104
X300
X300
X300
X100
ATH
G104
X300
X300
X300
X100
K89
A90
K20
K9
P16
B55
Logic

DTC
DTC B2955 (with BTM)
DTC B2955 (without BTM)
DTC B302A
DTC B3031
DTC B3055
DTC B305C
DTC B3060
DTC B389A
DTC B3902
DTC B3935
DTC B3976
DTC B3984
DTC P0513
DTC P0633
Description
DTC B302A Mobile Telephone Communications
Interface Requested Immobilization
DTC B3031 Security Controller In Learn Mode
DTC B3055 No Transponder Modulation or No
Transponder
DTC B305C Immobilizer Transponder of Wrong Type
Programmed
DTC B3060 Unprogrammed Transponder
Identification Code Received
DTC B389A Environment Identification
DTC B3902 Incorrect Immobilizer Identifier Received
DTC B3935 Transponder Authentication
DTC B3976 Unconfigured Transponder
DTC B3984 Device 1 Environment Identifier Not
Programmable
DTC P0513 Immobilizer Key Incorrect
DTC P0633 Immobilizer Key Not Programmed

DTC P162B Remote Vehicle Speed Limiting Signal

DTC P1630 Immobilizer Learn Mode Active
DTC P1631 Immobilizer Fuel Enable Signal Not
Correct
DTC P1649 Immobilizer Security Code Not
Programmed
DTC P162B
DTC P1630
DTC P1631
DTC P1649
DTC B2955 (WITH BTM)
DTC Descriptor
DTC B2955
Security Sensor Data Circuit
Circuit
Ignition
Serial Data
Low Reference
Short to
Ground
B2955 00
B2955 00
-
Open/High
Resistance
B2955 00
B2955 00
B2955 00
Short to
Voltage
B2955 00
-
Signal Performance
B2955 00
-
When a keyless entry transmitter is inserted into the transmitter pocket/slot and the ignition mode switch is
pressed, the transponder embedded in the transmitter is energized by the immobilizer antenna exciter coil. The
transponder transmits a signal to the body control module (BCM). The BCM then compares this value to a
value stored in memory. If the value is correct, the BCM will send the prerelease password via the serial data
circuit to the engine control module (ECM). If the learned key code does not match or a transponder value is not
received, the BCM will send the start disable password to the ECM.
Ignition is in the Accessory or Run position.


The BCM detects a circuit fault on the immobilizer antenna circuits.

Vehicle starting will be disabled.

The security indicator in the instrument cluster will be illuminated. A service message will be displayed
in the driver information center.
A current DTC will be cleared when the condition for setting the DTC are no longer present.
A history DTC will be cleared after 100 malfunction-free ignition cycles.
Schematic Reference
Immobilizer Description and Operation
Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference

1. Ignition OFF and all vehicle systems OFF, disconnect the harness connector at the K89 Immobilizer
Control Module. It may take up to 2 min for all vehicle systems to power down.
2. Verify a test lamp illuminates between the low reference circuit terminal 1 and B+.

3. Ignition ON.
NOTE:
In some instances, the K9 Body Control Module may only apply voltage for
3 s immediately after the ignition is turned ON. It may be necessary to
monitor the DMM while turning the ignition ON to observe the voltage.
4. Test for greater than 9 V between the ignition circuit terminal 3 and ground.
If 9 V or less
If greater than 9 V
5. Ignition ON.
6. Test for 10-13 V between the serial data circuit terminal 2 and ground.
If less than 10 V
If between 10-13 V
7. Replace the K89 Immobilizer Control Module.
8. Verify DTC B2955 does not set while operating the vehicle under the conditions for running the DTC.

If DTC B2955 is set


9. All OK.
Repair Instructions

Control Module References for body control module or immobilizer control module replacement,
programming, and setup
DTC B2955 (WITHOUT BTM)
DTC Descriptor
DTC B2955
Security Sensor Data Circuit
Circuit
B+
Serial Data
Low Reference
Short to
Ground
B2955 00
B2955 00
-
Open/High
Resistance
B2955 00
B2955 00
B2955 00
Short to
Voltage
B2955 00
-
Signal Performance
B2955 00
-
When an ignition key is inserted into the ignition lock cylinder and the ignition is switched ON, the transponder
embedded in the key is energized by the exciter coil surrounding the ignition lock cylinder. The transponder
transmits a signal to the body control module (BCM). The BCM then compares this value to a value stored in
memory. If the value is correct, the BCM will send the prerelease password via the serial data circuit to the
engine control module (ECM). If the learned key code does not match or a transponder value is not received,
the BCM will send the start disable password to the ECM.


The BCM detects a circuit fault on the immobilizer antenna circuits.


A current DTC will be cleared when the condition for setting the DTC are no longer present.
Schematic Reference
Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference

1. Ignition OFF and all vehicle systems OFF, disconnect the harness connector at the K89 Immobilizer

Control Module. It may take up to 2 min for all vehicle systems to power down.
2. Verify a test lamp illuminates between the low reference circuit terminal 1 and B+.
3. Ignition ON.
NOTE:
In some instances, the K9 Body Control Module may only apply voltage for
3 s immediately after the ignition is turned ON. It may be necessary to
monitor the DMM while turning the ignition ON to observe the voltage.
4. Test for greater than 9 V between the B+ circuit terminal 3 and ground.
If 9 V or less
If greater than 9 V
5. Test for greater than 4 V between the serial data circuit terminal 2 and ground.
If 4 V or less
If greater than 4 V
6. Ignition OFF, disconnect the X3 harness connector at the K9 Body Control Module, ignition ON.
7. Test for less than 1 V between the K89 Immobilizer Control Module serial data circuit terminal 2 and
ground.
If 1 V or greater

Repair the short to voltage on the circuit.

If less than 1 V
8. Replace the K89 Immobilizer Control Module.
If DTC B2955 is set

10. All OK.
Repair Instructions

Control Module References for body control module or immobilizer control module replacement,
DTC B302A
DTC Descriptor
DTC B302A
Mobile Telephone Communications Interface Requested Immobilization
As part of the vehicle telematics enhanced services, a request may be sent to the body control module (BCM) to
disable vehicle starting. If a valid message is received by the BCM requesting that starting be disabled, the start
enable message will not be sent to the engine control module (ECM).
The BCM continuously monitors for this DTC.


A start disable message has been received from the telematics module.
Vehicle starting will be suspended and the security indicator will be illuminated.
A current DTC will clear when the telematics start disable request is no longer received.
A history DTC will clear after 100 ignition cycles in which the telematic start disable request is not seen.
Diagnostic Aids
DTC B302A is only an indicator that a start disable request has been received from the vehicle telematics
system and does not indicate a fault in the immobilizer or telematics system.
To remove the start disable request, the vehicle account must be updated with the OnStar stolen vehicle
team. This will require that a law enforcement agency or the customer contact OnStar to indicate that the
vehicle has been successfully and safely recovered.
If the OnStar system has been disabled or damage during a theft attempt, the system will not be able to
communicate and the start disable request will not be removed. OnStar must be functioning properly for
the start disable request to be removed.
Schematic Reference
Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference


1. Verify the OnStar system is not damaged and is operating properly, with no DTCs set.
If the OnStar system is damaged, inoperative, or any OnStar DTCs are set
These concerns must be corrected before the start disable can be removed.
If the OnStar system is not damaged and is operating properly
2. Press the blue OnStar button and ask the advisor to be transferred to the stolen vehicle team to verify the
vehicle account has been updated.
3. Verify that OnStar is aware the vehicle has been recovered and that the vehicle account has been updated.
If OnStar has not been notified that the vehicle has been recovered
Contact the customer and advise them that for security purposes, they must contact OnStar and the
law enforcement agency to update the vehicle account.
If the account has been properly updated
4. Once the vehicle account has been updated and the start disable request has been removed, DTC B302A
will transition to a history DTC. Clear the history DTC.
DTC B3031
DTC Descriptor
DTC B3031
Security Controller In Learn Mode
When learning a coded key, the body control module (BCM) is placed in learn mode. DTC B3031 will set
automatically as an indicator that the system is in learn mode and not as a fault indicator. Once the coded key is
learned, learn mode will be exited and the DTC cleared. If the BCM does not exit learn mode, DTC B3031 will
remain current and indicate a fault. The instrument cluster security indicator will illuminate and the driver
information center will display a message.

The immobilizer system is the learn coded keys state.

The DTC will set any time the BCM enters the learn coded keys state.
The security indicator will illuminate. The driver information center will display a message.
A current DTC B3031 will be cleared upon the successful exit of learn mode.
Schematic Reference
Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference

1. Verify all available keys are correct for the vehicle. This can be accomplished by comparing the part
number that is laser etched on the key to the part number listed in the parts catalog.
If a key is not correct

Replace the key

If all keys are correct
2. Perform the Replacing Keys procedure. Refer to Key with Integrated Transmitter Programming (with
BTM), Key with Integrated Transmitter Programming (without BTM).
3. Verify the K9 Body Control Module learns the vehicle key and exits the learn coded key state. The scan
tool Master Keys Learned parameter should increment to 1.
If the K9 Body Control Module does not exit the learn coded key state after the programming
attempt
Replace the K9 Body Control Module

If the K9 Body Control Module exits the learn coded key state after the programming
attempt
4. All OK.
Repair Instructions

Control Module References for body control module replacement, programming, and setup.
DTC B3055
DTC Descriptor
DTC B3055
No Transponder Modulation or No Transponder
Without BTM and/or ATH/ATS


With BTM and/or ATH/ATS
When a ignition key is inserted into the key pocket/slot and the ignition mode switch is pressed, the transponder
embedded in the key is energized by the immobilizer antenna exciter coil. The transponder transmits a signal to
the body control module (BCM). The BCM then compares this value to a value stored in memory. If the value
is correct, the BCM will send the prerelease password via the serial data circuit to the engine control module
(ECM). If the learned key code does not match or a transponder value is not received, the BCM will send the
start disable password to the ECM.

The BCM is unable to measure the ignition key transponder value.


The security indicator will illuminate. A service message will be displayed in the driver information
center.
A current DTC will be cleared when the BCM detects a valid transponder value from the ignition key.
Diagnostic Aids
Because DTC B3055 may be caused by a malfunctioning vehicle key, it is necessary to have all available
vehicle keys at the time of diagnosis. A possible scenario would be a customer leaving the vehicle with a
spare key during the service visit, but the key which they use everyday, not the spare key, is the cause of
the DTC. Not having all available keys in this instance would result in the customer concern not being
duplicate or a misdiagnosis.
Ensure that the immobilizer control module is properly installed and fully seated. An audible and/or
tactile click will indicate that the immobilizer control module is fully seated. To ensure proper
transponder communication, the key must be in a specific location in relation to the immobilizer control
module. If the immobilizer control module is not fully seated, transponder communication may not occur
and DTC B3055 will set.
For vehicle without BTM and/or ATH/ATS, verify the customer is not attempting to turn the ignition
with the vehicle key partially folded. To ensure proper transponder communication, the key must be in a
specific location in relation to the immobilizer control module. Attempting to start the vehicle with the
key in the ignition and partially folded will result in no transponder communication and DTC B3055 will

set.
Schematic Reference
Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference


1. Ignition ON.
2. Verify that DTC B1370, B1380, or B1441 is not set.
3. Verify the scan tool body control module Accessory parameter changes between Active and Inactive
when turning the ignition ON and OFF.
Refer to Vehicle Will Not Change Power Mode .

Replace the appropriate key.
5. Verify that DTC B3055 does not set while attempting to start the vehicle which each available key.
If DTC B3055 sets when attempting to start the vehicle with only one of the available keys
If DTC B3055 sets when attempting to start the vehicle with all of the available keys
Replace the K89 Immobilizer Control Module.
If DTC B3055 does not set

6. All OK.

1. Ignition ON.
3. Verify the scan tool body control module Accessory parameter changes between Active and Inactive
when turning the ignition ON and OFF.


5. Remove the battery from each of the available vehicle keys.
6. Verify that DTC B3055 does not set while attempting to start the vehicle which each available key. To

start the vehicle with the key battery removed, the key must be placed in the key pocket/slot.
If DTC B3055 sets when attempting to start the vehicle with only one of the available keys
If DTC B3055 sets when attempting to start the vehicle with all of the available keys
Replace the K89 Immobilizer Control Module.
If DTC B3055 does not set

7. All OK.
Repair Instructions

Control Module References for immobilizer control module replacement, programming, and setup.
DTC B305C
DTC Descriptor
DTC B305C
Immobilizer Transponder of Wrong Type Programmed


Ignition is in the Accessory or Run position

Battery voltage is greater than 9 volts
Transponder authentication has occurred
The programed transponder type does not match the equipped system on the vehicle.
A transponder used for vehicles without BTM and/or ATH/ATS has been programmed to a vehicle with
BTM and/or ATH/ATS.
A transponder used for vehicles with BTM and/or ATH/ATS has been programmed to a vehicle without
BTM and/or ATH/ATS.
No action is taken.
A current DTC will be cleared when the BCM detects a programed transponder type that matches the
equipped system on the vehicle.
Schematic Reference

Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference

1. Ignition ON.
2. Verify all available keys/transmitters are correct for the vehicle. This can be accomplished by comparing
the part number that is laser etched on the key to the part number listed in the parts catalog.
3. Verify the scan tool Key Part Number parameter displays a Key Part Number when turning the ignition
ON with each key.
If a Key Part Number is not read

If a Key Part Number is read for each key
4. All OK.
DTC B3060
DTC Descriptor
DTC B3060
Unprogrammed Transponder Identification Code Received



The transponder value measured by the BCM is incorrect or not learned to the vehicle.

The security indicator in the instrument cluster will be illuminated. The driver information center will
display a service message.
A current DTC will be cleared when the BCM detects a valid transponder value from the ignition key.
Schematic Reference


Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference

1. Perform the Replacing Keys procedure. Refer to Key with Integrated Transmitter Programming (with
BTM), Key with Integrated Transmitter Programming (without BTM).
2. Verify the K9 Body Control Module learns the vehicle key. The scan tool Master Keys Learned
parameter should increment to indicate another key has been learned.
If the BCM does not learn the key
Replace the key.
If the BCM learns the key
3. All OK.
DTC B389A
DTC Descriptor
DTC B389A

When certain modules are programmed and configured during installation, the module learns a specific
environment identifier which is unique to the vehicle. The environment identifier is used to prevent the
swapping modules between vehicles. The body control module (BCM) is the keeper of the environment
identifier. The Instrument Cluster, Electronic Brake Control Module, HVAC Control Module, Inflatable
Restraint Sensing and Diagnostic Module, engine control module (ECM), and Steering Column Lock Module
(if equipped) each learn the environment identifier during their configuration process. During vehicle operation,
the BCM sends the immobilizer identifier as a challenge and each module responds to the challenge by sending
the environment identifier back to the BCM. If the BCM sends an incorrect immobilizer identifier or a specific
number of incorrect environment identifiers are received, vehicle starting is disabled.
Ignition is in the ACCESSORY or RUN position.

An incorrect immobilizer identifier was broadcast by the BCM.

The security indicator in the instrument cluster will illuminate.

A current DTC will be cleared when the BCM broadcasts a correct immobilizer identifier.
Diagnostic Aids
If BCM programming is not completed after BCM replacement, the immobilizer identifier will not be learned.
If DTC B389A sets immediately after the replacement and programming of a BCM, perform the programming
procedure again.
Schematic Reference

Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference

1. Verify DTC B389A did not set immediately following the replacement and programming of the K9 Body
Control Module.
If the DTC set immediately after the replacement and programming of the K9 Body Control
Module
The immobilizer learn procedure was not properly completed. Perform the BCM immobilizer learn
using the body control module IMMO Function with Existing Transponder or Remote Key in SPS.
Refer to Immobilizer System Component Programming (with BTM), Immobilizer System
Component Programming (without BTM).
If the DTC did not set immediately after the replacement and programming of the K9 Body
Control Module
2. Verify DTC B3902 is not set in any of the control modules listed below:
K20 Engine Control Module
K36 Inflatable Restraint Sensing and Diagnostic Module
K17 Electronic Brake Control Module
K33 HVAC Control Module
P16 Instrument Cluster
K60 Steering Column Lock Module (if equipped)
If DTC B3902 is set in any of the modules
Refer to DTC B3902.

If DTC B3902 is not set in any of the modules
3. Perform the K9 Body Control Module immobilizer learn using body control module IMMO Function
with Existing Transponder or Remote Key in SPS. Refer to Immobilizer System Component
Programming (with BTM), Immobilizer System Component Programming (without BTM).
4. Verify DTC B389A does not set after programming.
If the DTC sets after programming

If the DTC does not set after programming

5. All OK.
Repair Instructions

DTC B3902
DTC Descriptor
DTC B3902
Incorrect Immobilizer Identifier Received
identifier. The Instrument Cluster, Electronic Brake Control Module, HVAC Control Module, Inflatable
Restraint Sensing and Diagnostic Module, engine control module (ECM), and Steering Column Lock Module
(if equipped) each learn the environment identifier during their configuration process. During vehicle operation,
the BCM sends the immobilizer identifier as a challenge and each module responds to the challenge by sending
the environment identifier back to the BCM. If the BCM sends an incorrect immobilizer identifier or a specific

The control module's environment identifier does not match the environment identifier stored by the BCM.


A current DTC will be cleared when the module learns a correct environment identifier.
Schematic Reference
Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference

1. Perform the Programming and Setup procedure for the control module that set DTC B3902.
2. Verify DTC B3902 does not set after programming.
Replace the control module that set the DTC.
3. All OK.
Repair Instructions


Control Module References for Instrument Cluster, Electronic Brake Control Module, HVAC Control
Module, Inflatable Restraint Sensing and Diagnostic Module, engine control module, or Steering Column Lock
Module replacement, programming, and setup.
DTC B3935
DTC Descriptor
DTC B3935
Transponder Authentication

engine control module (ECM). If the learned key code does not match, the BCM will send the start disable
password to the ECM.
circuit to the engine control module (ECM). If the learned key code does not match, the BCM will send the start
disable password to the ECM.

A valid transponder value has been read.

The transponder calculation of the challenge from the BCM does not match the BCM calculation.

The security indicator will illuminate. The driver information center will display a service message.
A current DTC will be cleared when a valid transponder value has been read and authenticated.
Schematic Reference
Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference

1. Replace the suspected inoperative or malfunctioning key.

If the DTC is set


3. All OK.
Repair Instructions

DTC B3976
DTC Descriptor
DTC B3976
Unconfigured Transponder



The BCM is in the learn coded key state.
The BCM has determined the current key is not configured as a proper vehicle key.

A current DTC will be cleared when the BCM detects a properly configured vehicle key.
Schematic Reference
Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference

1. Verify the engine starts with each available key.

If the engine does not start with a key

Replace the key.
If the engine starts with all keys

2. All OK.
DTC B3984
DTC Descriptor
DTC B3984
Device 1 Environment Identifier Not Programmable
identifier. The instrument cluster, electronic brake control module, HVAC control module, inflatable restraint
sensing and diagnostic module, engine control module (ECM), and steering column lock module (if equipped)
each learn the environment identifier during their configuration process. During vehicle operation, the BCM
sends the immobilizer identifier as a challenge and each module responds to the challenge by sending the
environment identifier back to the BCM. If the BCM sends an incorrect immobilizer identifier or a specific

An incorrect environment identifier is programmed or no environment identifier is programmed.



A current DTC will be cleared when the module learns a correct environment identifier.
Schematic Reference
Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference

1. Perform the Programming and Setup procedure for the control module that set DTC B3984.
2. Verify DTC B3984 does not set after programming.
Replace the control module that set the DTC.
3. All OK.
Repair Instructions

Control Module References for instrument cluster, electronic brake control module, HVAC control module,
inflatable restraint sensing and diagnostic module, engine control module, and steering column lock module

replacement, programming, and setup.

DTC P0513
DTC Descriptor
DTC P0513
Immobilizer Key Incorrect
The body control module (BCM) sends the pre-release information to the engine control module (ECM) via the
serial data circuit. The ECM then sends a challenge to the BCM. Both the ECM and BCM perform a calculation
on this challenge. If the calculated response from the BCM equals the calculation performed by the ECM, the
ECM will allow vehicle starting.

The calculated response from the BCM does not equal the calculation performed by the ECM.

A current DTCwill be cleared when a valid calculation is received.

Schematic Reference


Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference

1. Verify there are no immobilizer DTCs set in the K9 Body Control Module.
If any immobilizer DTCs are set in the K9 Body Control Module
If no immobilizer DTCs are set in the K9 Body Control Module
2. Perform the K9 Body Control Module immobilizer learn using the body control module IMMO Function
3. Verify the engine starts after the K9 Body Control Module completes the learn procedure.
If the engine does not start
Perform the K20 Engine Control Module immobilizer learn using the engine control module
IMMO Learn in SPS. Refer to Immobilizer System Component Programming (with BTM),
Immobilizer System Component Programming (without BTM).
If the engine starts
4. All OK.
DTC P0633


DTC Descriptor
DTC P0633
Immobilizer Key Not Programmed
When learning the immobilizer data, as well as the challenge and response sequence, the engine control module
(ECM) is placed in learn mode. DTC P0633 will set automatically as an indicator that the system is in learn
mode and not as a fault indicator. Once the immobilizer data and challenge/response are learned, learn mode
will be exited when the engine is successfully started. If the ECM does not exit learn mode, DTC P0633 will
remain current and indicate a fault.
The ECM is in learn mode.

DTC P0633 will set any time the ECM enters learn mode.

A current DTC will be cleared upon a successful engine start after exit of learn mode.
Schematic Reference

Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference

NOTE:
DTC P0633 will clear upon a successful engine start. Any malfunction that will
cause a no-start condition will prevent DTC P0633 from clearing. Prior to
diagnosing DTC P0633, ensure that all power moding and engine control
systems are operating properly and all conditions that may cause a no-start
have been corrected. Do not replace the K20 Engine Control Module. Replacing
the K20 Engine Control Module will not correct the no-start condition.
2. Perform the K20 Engine Control Module immobilizer learn using the engine control module IMMO
Learn in SPS. Refer to Immobilizer System Component Programming (with BTM), Immobilizer
System Component Programming (without BTM).
3. Verify the engine starts after the K20 Engine Control Module completes the learn procedure.
An undiagnosed no-start condition exists. Refer to the appropriate subsection and diagnostic to
correct the no-start condition.
4. All OK.
DTC P162B

DTC Descriptor
DTC P162B
Remote Vehicle Speed Limiting Signal Message Counter Incorrect
When a remote slow-down request is sent from OnStar, the vehicle communication interface module sends a
serial data message to the engine control module (ECM) indicating that reduced vehicle speed has been
requested. Once the request is active, the ECM begins reducing engine torque to match requested vehicle speed
and the REDUCED ENGINE POWER message is displayed.
The engine run time is greater than 5 s

A remote slow-down request is sent from OnStar
The VIN embedded in the slow-down request does not match the VIN stored in the ECM.
The rolling code counter embedded in the slow-down request does not increment for ten consecutive
messages.
ECM ignores all reduced vehicle speed request messages from the vehicle communication interface
module.
The ECM stores DTC P162B in history.

Schematic Reference
OnStar Schematics

Remote Vehicle Speed Limiting Description and Operation

Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference

1. Perform the Stolen Vehicle Slow-Down Clear procedure with the scan tool.
2. Verify DTC P162B is not set.
If DTC P162B is set
If DTC P162B is not set
3. All OK.
Repair Instructions

Control Module References for Telematics Communication Interface Control Module replacement,
DTC P1630
DTC Descriptor
DTC P1630
Immobilizer Learn Mode Active

When learning the security code, as well as the challenge and response sequence, the engine control module is
placed in learn mode. Once the security code and challenge/response are learned, learn mode will be exited
when the engine is successfully started.
The engine control module is in learn mode.

The engine control module has not learned a security code.

The security indicator in the Instrument Cluster will illuminate.

A current DTC P1649 will be cleared upon a successful engine start after exit of learn mode.
Schematic Reference
Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference



4. All OK
Repair Instructions

Control Module References for engine control module replacement, programming, and setup
DTC P1631
DTC Descriptor
DTC P1631
Immobilizer Fuel Enable Signal Not Correct
The body control module (BCM) sends the pre-release information to the engine control module (ECM) via the
serial data circuit. The ECM then sends a challenge to the BCM. Both the ECM and BCM perform a calculation
on this challenge. If the calculated response from the BCM equals the calculation performed by the ECM, the
ECM will allow vehicle starting. The BCM follows this action by sending the remaining immobilizer data to the
ECM. If the immobilizer data sent by the BCM matches that stored by the ECM, the ECM will allow the engine
to remain running.


The ECM receives incorrect immobilizer data from the BCM.


A current DTC will be cleared when correct immobilizer data is received.

Schematic Reference
Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference




2. Perform the K9 Body Control Module immobilizer learn using the body control module IMMO Function
3. Verify the engine starts after the K9 Body Control Module completes the learn procedure.
Perform the K20 Engine Control Module immobilizer learn using the engine control module
IMMO Learn in SPS. Refer to Immobilizer System Component Programming (with BTM),
Immobilizer System Component Programming (without BTM).
4. All OK.
DTC P1649
DTC Descriptor
DTC P1649
Immobilizer Security Code Not Programmed
When learning the security code, as well as the challenge and response sequence, the engine control module
(ECM) is placed in learn mode. Once the security code and challenge/response are learned, learn mode will be
exited when the engine is successfully started.
The ECM is in learn mode.

The ECM has not learned a security code.


A current DTC will be cleared upon a successful engine start after exit of learn mode.
Schematic Reference
Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference




4. All OK.
Repair Instructions

Control Module References for engine control module replacement, programming, and setup.
SYMPTOMS - IMMOBILIZER
IMPORTANT: The following steps must be completed before using the symptom tables.
The control modules can communicate via the serial data links.
2. Review the system operation in order to familiarize yourself with the system functions. Refer to
Immobilizer Description and Operation.
cause the symptom.
Intermittent
Symptom List
Refer to OnStar Stolen Vehicle Slowdown Active to diagnose the symptom.

ONSTAR STOLEN VEHICLE SLOWDOWN ACTIVE
NOTE:
This procedure is not used in Brazil.

When a remote slow-down request is sent from OnStar, the Telematics Communication Interface Control
Module sends a serial data message to the engine control module (ECM) indicating that reduced vehicle speed
has been requested. Once the request is active, the ECM begins reducing engine torque to match requested
vehicle speed and the REDUCED ENGINE POWER message is displayed.
Schematic Reference
OnStar Schematics
Remote Vehicle Speed Limiting Description and Operation
Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference

1. Verify the vehicle is not in the OnStar initiated Stolen Vehicle Slowdown mode. This can be
accomplished by verifying the scan tool Telematics Enhanced Service Immobilization parameter is No.
If the scan tool Telematics Enhanced Service Immobilization parameter is Yes
1. Perform the Remote Vehicle Speed Limiting Reset procedure with the scan tool.
2. Press the blue OnStar button and inform the advisor that you need to be transferred to the stolen
vehicle team to update the vehicle account.
If the scan tool BCM Telematics Enhanced Service Immobilization parameter is No

2. All OK.
REPAIR INSTRUCTIONS
THEFT DETERRENT MODULE REPLACEMENT (WITHOUT BTM)
Fig. 2: Theft Deterrent Module & Fasteners

Theft Deterrent Module Replacement (without BTM)
Callout
Component Name
Remove the steering column lower trim cover. Refer to Steering Column Lower Trim Cover
Replacement .
Theft Deterrent Module Fastener (Qty: 2)
1
CAUTION:
Refer to Fastener Caution
Theft Deterrent Module

Procedure
Disconnect the electrical connector. After repairs, refer to Control
Module References for programming and set up information.
THEFT DETERRENT MODULE REPLACEMENT (WITH BTM)

Fig. 3: Theft Deterrent Module

Theft Deterrent Module Replacement (with BTM)
Callout
Component Name
Remove the front floor console. Refer to Front Floor Console Replacement .
Theft Deterrent Module Fastener (Qty: 2)
1
CAUTION:

2
Procedure
2. After repairs, refer to Control Module References .
IMMOBILIZER SYSTEM COMPONENT PROGRAMMING (WITH BTM)

This procedure will learn the immobilizer function and require greater than 15 minutes to complete. If the
battery voltage is low, charge the battery before proceeding with the learn. If the body control module (BCM) or
engine control module (ECM) have been replaced, they must be programmed before performing this learn
procedure.

Depending on the immobilizer function being learned or the component replaced, different learn functions are
required to be performed. These learn functions are as follows:
Immobilizer System Component Programming (with BTM)
Function name on SPS
When the function
Function description:
tool:
should be used:
The BCM has been
Body Control Module The BCM will relearn the replaced and the existing
IMMO Function with
immobilizer passwords
vehicle keys are being
Existing Transponder or and data while reusing reused or a diagnostic has
Remote Key
the existing vehicle keys instructed to perform the
learn
Body Control Module The BCM will relearn the
The BCM has been
IMMO Function with
replaced and new vehicle
New Transponder or and data while using new
keys are being reused
Remote Key
vehicle keys
The ECM has been
The ECM will relearn the
replaced or a diagnostic
has instructed to perform
IMMO Learn
and data
the learn
Both the ECM and BCM
Engine Control Module The ECM and BCM will have been replaced (this
and Body Control Module learn new immobilizer selection will REQUIRE
new vehicle keys be
IMMO Learn
passwords and data
used)
Program Transponder or
Remote Key (Add)
A new vehicle key will

A new vehicle key is
learn the immobilizer
being added (does not
passwords and data
affect other vehicle keys)
All vehicle keys are

All existing vehicle keys desired to be invalidated
Program Transponder or will be invalidated and
and certain keys
Remote Key (Delete)
any desired keys are
relearned or a diagnostic
relearned
the learn
1.
2.
3.
4.
5.
6.
7.
Notes:
Because both the ECM

and BCM have been
replaced and are learning
new immobilizer
passwords and data, all
vehicle keys must also be
replaced
This function may not be
available in all sales
regions
This procedure may be
used if a customer has
had their keys lost or
stolen and wishes to
invalidate the keys,
making them unable to
start the vehicle
Connect a scan tool to the vehicle and access SPS.

Turn ON the ignition, with the engine OFF.
Ensure that all power consuming devices are turned OFF on the vehicle.
Select SPS application and follow the on-screen instructions.
Select Reprogram ECU.
Select IMMO Immobilizer Learn - Setup.
Select the appropriate programming function based on the component that was replaced or is being

programmed. Refer to the table at the top of this document for assistance in choosing the correct
programming function.
NOTE:
At multiple times during the learn procedure, SPS will instruct you to
turn the ignition to the run position. Make sure the vehicle is actually
in the run mode before continuing on the SPS terminal. If the ignition
is not in the run mode, the learn procedure will fail. To verify the
vehicle is in Run mode, verify the green LED is illuminated on the
ignition mode switch.
The key slot is located inside the center console storage area. To
access the slot, use a pick tool to remove the triangular cover at the
bottom of the storage area located just forward of the cup holders.
Insert the key into the exposed key slot.
8. Follow the on-screen instructions.

NOTE:
If the programming does not complete or hangs during the programming

operation, refer to Unable to Complete Programming below.
9. After programming all keys "Programming Complete" is displayed.

10. Press and hold the ignition mode switch for 15 seconds.
11. Press the lock and unlock button on each transmitter that was programmed. This will awaken each
transmitter and allow passive and active keyless entry functions to be established.
12. With a scan tool, clear any DTCs.
13. Verify each key is operating properly. Operate each of the keyless entry functions using the buttons on
the transmitter and then start the vehicle. When verifying operation, make sure that no other keys are near
the vehicle.
Unable to Complete Programming
When attempting to program immobilizer conponents, various conditions may prevent the programming
operation from completing. These conditions may be caused by normal system operation, a system malfunction,
or an external influence. Common symptoms of a incomplete programming is receiving an error message during
the attempt or having the SPS application become unresponsive.
DTCs are set in the body control module (BCM)

The immobilizer system is a function of the BCM software. If immobilizer DTCs are set in the BCM,
such as DTC B2955, a fault has been identified in the immobilizer system. If this is not corrected before
attempting to program components, the programming may not complete. Correct all immobilizer DTCs
before attempting to program any immobilizer components.
The key has been programmed to another vehicle or is not the correct type for the vehicle
A key can only be programmed to a single vehicle. Once a key is programming to a vehicle, it is paired

for the life of the key. The key can be learned to the same vehicle again and again, but it is not able to be
programmed to a different vehicle.
Many vehicle are available with both a base keyless entry system and an optional passive entry system.
These keys typically look identical but cannot be substituted for one another. To verify the key is correct,
compare the part number that is etched on the key to the part number identified in the parts catalog. The
key should be correct for the system installed in the vehicle.
The theft deterrent module is not properly secured or the key is not properly positioned in the pocket/slot.
A theft deterrent module that is not fully seated or is otherwise not properly secured may prevent a
coupling between the transponder located in the key and the theft deterrent module. Being out of place by
as little as 1 mm may prevent programming from completing. Make sure the theft deterrent module is
properly installed and fully seated in it's clip.
The key shank must be fully extended so that the entire key shank fits into the programming slot.
To determine if the theft deterrent module is properly secured, remove the battery from the key and place
the key into the pocket/slot. Attempt to change the vehicle mode by pressing the vehicle ON/OFF switch.
The vehicle should change modes. If the NO REMOTE DETECTED message is displayed on the DIC,
the theft deterrent module may not be properly secured.
External interference is interrupting the programming operation

External RF interference and EMI may interrupt the low frequency coupling between the key and theft
deterrent module. This interference may come from many different locations. Devices plugged into the
vehicle power outlets such as cell phone chargers, laptop computers, GPS devices, etc. may cause
interference. Vehicle location may also cause interference. Locations near airports and military
installations may causer interference. Remove all customer installed devices and, if necessary, move the
vehicle if interference is suspected.
IMMOBILIZER SYSTEM COMPONENT PROGRAMMING (WITHOUT BTM)

This procedure will learn the immobilizer function and require greater than 15 minutes to complete. If the
battery voltage is low, charge the battery before proceeding with the learn. If the body control module (BCM) or
engine control module (ECM) have been replaced, they must be programmed before performing this learn
procedure.
Depending on the immobilizer function being learned or the component replaced, different learn functions are
required to be performed. These learn functions are as follows:
Immobilizer System Component Programming (without BTM)
Function name on SPS
When the function
tool:
should be used:
Function description:
Body Control Module
IMMO Function with
The BCM has been

The BCM will relearn the replaced and the existing
vehicle keys are being
Notes:
-

Existing Transponder or and data while reusing reused or a diagnostic has

Remote Key
the existing vehicle keys instructed to perform the
learn
Body Control Module The BCM will relearn the
The BCM has been
IMMO Function with
replaced and new vehicle
New Transponder or and data while using new
keys are being reused
Remote Key
vehicle keys
The ECM has been
The ECM will relearn the
replaced or a diagnostic
IMMO Learn
and data
the learn

and Body Control Module
IMMO Learn
Remote Key (Add)
Remote Key (Delete)
1.
2.
3.
4.
5.
6.
7.
Because both the ECM

Both the ECM and BCM
and BCM have been
The ECM and BCM will have been replaced (this replaced and are learning
new immobilizer
learn new immobilizer selection will REQUIRE
new vehicle keys be
passwords and data, all
passwords and data
used)
vehicle keys must also be
replaced
This function may not be
available in all sales
A new vehicle key will
A new vehicle key is regions. Refer to the SPS
learn the immobilizer
being added (does not application to determine
passwords and data
affect other vehicle keys) if a particular vehicle is
able to add keys using
this method.
This procedure may be
All vehicle keys are
used if a customer has
All existing vehicle keys desired to be invalidated
had their keys lost or
will be invalidated and
and certain keys
stolen and wishes to
any desired keys are
relearned or a diagnostic
invalidate the keys,
relearned
making them unable to
the learn
start the vehicle

Turn ON the ignition, with the engine OFF.
Select SPS application and follow the on-screen instructions.
Select the appropriate programming function based on the component that was replaced or is being
programmed. Refer to the table at the top of this document for assistance in choosing the correct
programming function.
9. After programming all keys "Programming Complete" is displayed.

10. Press the lock and unlock button on each transmitter that was programmed. This will awaken each
transmitter and allow keyless entry functions to be established.
the transmitter and then start the vehicle. When verifying operation, make sure that no other keys are near
the vehicle.
KEY WITH INTEGRATED TRANSMITTER PROGRAMMING (WITH BTM)
Keys can be programming in various ways using the procedures outlined below. Using the Replacing Keys
procedure will first erase all the known keys from the vehicle. Any existing keys and any new keys will then be
programmed. This procedure should be used any time a key is required to be unlearned or erased from a
vehicle. If a new key is being learned to a vehicle to replace a damaged, inoperative, missing, or stolen key, the
Replacing Keys procedure must be used. This ensures that the old key cannot be used to access or start the
vehicle after programming.
The Adding Keys procedure does not erase any keys prior to programming. The procedure will simply program
the key into the next available slot. The Adding Keys procedure should only be used when adding an additional
keys to the vehicle. The Adding Keys procedure should never be used to program a key to a vehicle that is
having a key replaced, regardless of the cause for the replacement.
Replacing Keys (Without SPS)
NOTE:
This procedure will unlearn all previously learned keys. All keys that are to
be programmed must be with the vehicle.
This procedure will take approximately 30 minutes to complete.
A total of eight keys maybe be learned to a single vehicle.
This procedure will only learn the vehicle key information. This procedure
will not learn any immobilizer information between the body control
module (BCM) and engine control module (ECM).
This procedure may be used with or without existing learned keys being
present. If existing keys are present, keep the keys away from the vicinity
of the vehicle. Failure to keep learned keys away from the vehicle will
result in the learn changing to the Adding Keys procedure.
The keys to be learned must duplicate the mechanical cut of the current
key.
1. Insert the mechanical key of the new key into the key lock cylinder located on the outside of the driver
door and turn the key to the unlock position five times within ten seconds. The Driver Information Center
(DIC) will display Remote Learn Pending, Please Wait.
2. After ten minutes, the DIC will display Press Engine Start Button To Learn. Press the ignition mode
switch. The DIC will again display Remote Learn Pending, Please Wait.
3. Repeat Step 2 two additional times, for a total of thirty minutes. All previously known keys have now
been unlearned. Remaining keys can be learned during the next steps. The DIC display will now display
Ready For Remote # 1.

NOTE:
The key slot is located inside the center console storage area. To access
the slot, use a pick tool to remove the triangular cover at the bottom of the
storage area located just forward of the cup holders. Insert the key into the
exposed key slot.
4. Place the new key into the key slot.

NOTE:

5. Press the ignition mode switch. When the key is learned the DIC will indicate that it is ready to program
the next key.
6. Remove the key from the key slot and press the unlock button. To program additional keys, repeat Steps 4
through 6.
7. When all additional keys are programmed, press and hold the ignition mode switch for 5 seconds to exit
programming mode.
Replacing Keys (With SPS)
NOTE:
1.
2.
3.
4.
5.
6.
This procedure will unlearn all previously learned keys. All keys that are to
be programmed must be with the vehicle.
present. If no existing keys are available, this procedure must be used.
This procedure will take more than 15 minutes to complete.
If the battery voltage is low, charge the battery before continuing with the
procedure.

Select the SPS application and follow the on-screen instructions.
Select the Program Transponder or Remote Key (Delete) function.
NOTE:
is not in the run mode, the learn procedure will fail.


NOTE:

8. After programming all keys, Programming Complete, is displayed.

10. Press the lock and unlock button on each key that was programmed. This will awaken each key and allow
passive and active keyless entry functions to be established.
the key and then start the vehicle. When verifying operation, make sure that no other keys are near the
vehicle.
Adding Keys (Without SPS)
NOTE:
To initiate, this procedure requires that 1 learned key be available.

This procedure adds keys only. The procedure does not erase previously
learned keys.
key.
1. Place the recognized key(s) in the vehicle cupholder.

2. Insert the mechanical key of the new key into the key lock cylinder located on the outside of the driver
door and turn the key to the unlock position five times within ten seconds. The Driver Information Center
(DIC) will display Ready For Remote #2, 3, 4 or 5.
NOTE:
The key slot is located inside the center console storage area. To access
the slot, use a pick tool to remove the triangular cover at the bottom of the
storage area located just forward of the cup holders. Insert the key into the
exposed key slot.
3. Place the new key into the key slot.

NOTE:


4. Press the ignition mode switch. When the key is learned the DIC will indicate that it is ready to program
the next key.
5. Remove the key from the key slot and press the unlock button. To program additional keys, repeat Steps 3
through 5.
6. When all additional keys are programmed, press and hold the ignition mode switch for 5 seconds to exit
programming mode.
Adding Keys (With SPS)
NOTE:
1.
2.
3.
4.
5.
6.
present. If no existing keys are available, this procedure must be used.
This procedure will only learn the vehicle key information.
procedure.

Select the Program Transponder or Remote Key (Add) function.
NOTE:
is not in the run mode, the learn procedure will fail.

NOTE:

8. After programming all keys, Programming Complete, is displayed.

10. Press the lock and unlock button on each key that was programmed. This will awaken each key and allow
passive and active keyless entry functions to be established.


vehicle.
Unable to Complete Programming
When attempting to program immobilizer components, various conditions may prevent the programming
operation from completing. These conditions may be caused by normal system operation, a system malfunction,
or an external influence. Common symptoms of a incomplete programming is receiving an error message during
the attempt or having the SPS application become unresponsive.
DTCs are set in the body control module (BCM)

The immobilizer system is a function of the BCM software. If immobilizer DTCs are set in the BCM,
such as DTC B2955, a fault has been identified in the immobilizer system. If this is not corrected before
attempting to program components, the programming may not complete. Correct all immobilizer DTCs
before attempting to program any immobilizer components.
The key has been programmed to another vehicle or is not the correct type for the vehicle
A key can only be programmed to a single vehicle. Once a key is programming to a vehicle, it is paired
for the life of the key. The key can be learned to the same vehicle again and again, but it is not able to be
programmed to a different vehicle.
Many vehicle are available with both a base keyless entry system and an optional passive entry system.
These keys typically look identical but cannot be substituted for one another. To verify the key is correct,
compare the part number that is etched on the key to the part number identified in the parts catalog. The
key should be correct for the system installed in the vehicle.
The theft deterrent module is not properly secured or the key is not properly positioned in the pocket/slot.
A theft deterrent module that is not fully seated or is otherwise not properly secured may prevent a
coupling between the transponder located in the key and the theft deterrent module. Being out of place by
as little as 1 mm may prevent programming from completing. Make sure the theft deterrent module is
properly installed and fully seated in it's clip.
The key shank must be fully extended so that the entire key shank fits into the programming slot.
To determine if the theft deterrent module is properly secured, remove the battery from the key and place
the key into the pocket/slot. Attempt to change the vehicle mode by pressing the vehicle ON/OFF switch.
The vehicle should change modes. If the NO REMOTE DETECTED message is displayed on the DIC,
the theft deterrent module may not be properly secured.
External interference is interrupting the programming operation

External RF interference and EMI may interrupt the low frequency coupling between the key and theft

deterrent module. This interference may come from many different locations. Devices plugged into the
vehicle power outlets such as cell phone chargers, laptop computers, GPS devices, etc. may cause
interference. Vehicle location may also cause interference. Locations near airports and military
installations may causer interference. Remove all customer installed devices and, if necessary, move the
vehicle if interference is suspected.
KEY WITH INTEGRATED TRANSMITTER PROGRAMMING (WITHOUT BTM)
Keys can be programming in various ways using the procedures outlined below. Using the Replacing Keys
procedures will first erase all the known keys from the vehicle. Any existing keys and any new keys will then
be programmed. This procedure should be used any time a key is required to be unlearned or erased from a
vehicle. If a new key is being learned to a vehicle to replace a damaged, inoperative, or stolen key, the
Replacing Keys procedure must be used. This ensures that the old key cannot be used to access or start the
vehicle after programming.
The Adding Keys procedure does not erase any keys prior to programming. The procedure will simply program
the key into the next available slot. The Adding Keys procedure should only be used when adding an additional
key to the vehicle. The Adding Keys procedure should never be used to program a key to a vehicle that is
having a key replaced, regardless of the cause for the replacement.
Replacing Keys (With SPS)
NOTE:
1.
2.
3.
4.
5.
6.
7.
8.
9.
present.
procedure.

Select the Program Transponder or Remote Key (Delete) function.
Follow the on-screen instructions.
After programming all keys, "Programming Complete" is displayed.
Press the lock and unlock button on each key that was programmed. This will awaken each key and allow
keyless entry functions to be established.

vehicle.
Replacing Keys (Without SPS) - United States only
NOTE:
1.
2.
3.
4.
This procedure should be used without existing learned keys being

present.
procedure.
With an unlearned master vehicle key, turn ON the ignition, with the engine OFF.
Observe the security indicator, after approximately 10 min the indicator will turn off.
Turn OFF the ignition and wait 5 s.
Repeat steps 1 - 3 two more times for a total of 3 cycles or 30 min.
NOTE:
The body control module learns the key transponder information upon the
ignition transition from OFF to ON. You must turn the ignition OFF before
attempting to start the vehicle.
5. Start the vehicle. The vehicle has now learned the key transponder information.
6. Additional keys may be learned using the Adding Keys procedure.
7. Clear all DTCs.
Adding Keys (Without SPS) - North America, except Canada
NOTE:

learned keys.
key.
1. With a previously learned key, turn the ignition ON.

2. Turn the ignition OFF and remove the key.
3. Within 10 seconds of turning OFF the ignition, insert the key to be learned and turn ON the ignition. The
vehicle has now learned the new key and key.

Adding Keys (Without SPS) - Canada, Europe, South America, Asia, and Middle East
NOTE:
1.
2.
3.
4.
5.

learned keys.
key.
With a previously learned key, turn the ignition ON.

Turn the ignition OFF and remove the key.
With a second previously learned key, turn the ignition ON.
Turn the ignition OFF and remove the key.
Within 10 seconds of turning OFF the ignition, insert the key to be learned and turn ON the ignition. The
vehicle has now learned the new key and key.
Adding Keys (With SPS) - North America
NOTE:
1.
2.
3.
4.
5.
6.
7.
8.
9.
present.
procedure.

Select the Program Transponder or Remote Key (Add) function.
Follow the on-screen instructions.
After programming all keys, "Programming Complete" is displayed.
Press the lock and unlock button on each key that was programmed. This will awaken each key and allow
keyless entry functions to be established.

vehicle.

IMMOBILIZER DESCRIPTION AND OPERATION
Without BTM
The immobilizer system functions are provided by the Immobilizer Control Module, the Body Control Module
(BCM) and the Engine Control Module (ECM), as well as any modules which store and report the environment
identifier.
When an ignition key is inserted into the ignition lock cylinder and the ignition is turned ON, the transponder in
the key is energized by the immobilizer coil surrounding the ignition lock cylinder. This immobilizer coil is part
of the Immobilizer Control Module. The transponder transmits a signal that contains its unique value, which is
received by the BCM through the Immobilizer Control Module. The BCM then compares this value to a value
stored in memory. The BCM also monitors various control modules to determine if the stored environment
identifiers match.
If both the environment identifier and the value received from the transponder match, the BCM will send the
prerelease password via serial data to the ECM. If the encrypted code's unique value is incorrect or the
environment identifier does not match, the BCM will send the fuel disable message to the ECM.
When the ECM receives the BCM prerelease password, the ECM will challenge the password. The ECM sends
this challenge to the BCM via serial data. Both the ECM and BCM perform a calculation on this challenge. If
the BCM calculated response to the challenge equals the calculation performed by the ECM, the ECM will
allow vehicle starting.
The components of the immobilizer system are as follows:
BCM
ECM
Immobilizer Control Module
Ignition key
Security indicator
Various control modules which store and report the environment identifier
With BTM
The immobilizer system functions are provided by the Keyless Entry Control Module, the Remote Control Door
Lock Receiver, the Immobilizer Control Module, the Body Control Module (BCM) and the Engine Control
Module (ECM), as well as any control modules which store and report the environment identifier. The Keyless
Entry Control Module uses low frequency antennas in three different locations on the vehicle to determine the
location of the transmitter. Multiple antenna are used to ensure complete coverage of the vehicle interior and
rear compartment.

When the vehicle ON/OFF switch is pressed, the low frequency antennas emit a challenge to the keyless entry
transmitter. The transmitter receives this challenge and emits it's response as an RF message. The transmitter
transmits a signal that contains its unique value, which is received by the BCM through the Remote Control
Door Lock Receiver. The BCM then compares this value to a value stored in memory. The BCM also monitors
various control modules to determine if the stored environment identifiers match.
If both the environment identifier and the value received from the transponder match, the BCM will send the
prerelease password via serial data to the ECM. If the encrypted code's unique value is incorrect or the
environment identifier does not match, the BCM will send the fuel disable message to the ECM.
this challenge to the BCM via serial data. Both the ECM and BCM perform a calculation on this challenge. If
the BCM calculated response to the challenge equals the calculation performed by the ECM, the ECM will
allow vehicle starting.
If RF communication is interrupted, a "No Remote Detected" message will be displayed on the DIC. In these
cases, the transmitter can be placed in the transmitter slot/slot. The Immobilizer Control Module is located in
the immediate vicinity of the transmitter pocket/slot. Placing the transmitter in the pocket/slot will create a low
powered coupling between the transmitter and Immobilizer Control Module, allowing communications to occur
and enabling vehicle starting.
The components of the immobilizer system are as follows:
BCM
ECM
Remote Control Door Lock Receiver
Low frequency antenna
Ignition key/Keyless entry transmitter
Security indicator
Various control modules which store and report the environment identifier
Body Control Module (BCM)
The immobilizer system is an integral part of the BCM and is controlled internally within the BCM. The BCM
can learn up to 8 keys (transponder values).
The BCM uses the following inputs:
Environment identifier exchange with various modules

Encrypted code from the vehicle key, received by the Immobilizer Control Module
Encrypted code from the vehicle key, received by the Remote Control Door Lock Receiver (with BTM)
The BCM uses the following outputs:

Prerelease password communication with ECM

Challenge/response with ECM
When a transponder value is received by the BCM, the BCM will compare this value to the learned key code
stored in memory. The BCM then performs one of the following functions:
If the encrypted code value matches the values stored in the BCM memory, the BCM will send the
prerelease password to the ECM via serial data.
If the encrypted code unique value does not match the value stored in the BCM, the BCM will send the
start disable message to the ECM via serial data.
If the BCM is unable to measure the ignition key encrypted code value, the BCM will not send any
messages to the ECM.
Engine Control Module (ECM)
this challenge to the BCM via the serial data circuit. Both the ECM and BCM perform a calculation on this
challenge. If the calculated response from the BCM equals the calculation performed by the ECM, the ECM
will allow vehicle starting.
The ECM will disable vehicle starting if any of the following immobilization conditions occur:
The prerelease password is invalid.

The start disable password is sent by the BCM.
No passwords are received. There is no communication with the BCM.
The BCM calculated response to the challenge does not equal the calculation performed by the ECM.
The Immobilizer Control Module contains an immobilizer coil which surrounds the ignition cylinder (without
BTM) or is located near the transmitter pocket/slot (with BTM). The coil passively powers the transponder
located in the ignition key. When powered, the key transmits its unique value to the Immobilizer Control
Module, which is then relayed to the BCM via a LIN serial data circuit. The Immobilizer Control Module also
receives B+ and ground from the BCM.
The Immobilizer Control Module is used to:
1. Learn keys
2. To start vehicle with or without RF interference
3. To start vehicle when key battery is dead
Keyless Entry Control Module (with BTM)
The Keyless Entry Control Module uses low frequency antennas in three different locations on the vehicle to
determine the location of the transmitter. Multiple antenna are used to ensure complete coverage of the vehicle

interior and rear compartment. The Keyless Entry Control Module monitors the ignition mode switch. When the
ignition mode is changed, the Keyless Entry Control Module will command, or "ping", the low frequency
antenna.
Low Frequency Antenna (with BTM)
When commanded, or "pinged", the low frequency antenna broadcast a challenge to the keyless entry
transmitter. Because of the low power of the antenna, this challenge is only broadcast in an approximate three
meter range of the antenna. Multiple antenna are used to ensure complete coverage of the vehicle interior and
rear compartment.
Remote Control Door Lock Receiver (with BTM)
When the keyless entry transmitter is challenged by a low frequency antenna, is responds by emitting a response
as an RF message. The transmitter transmits a signal that contains its unique value, which is received by the
Remote Control Door Lock Receiver. The Remote Control Door Lock Receiver relays this information to the
BCM via a discreet serial data circuit.
Ignition Key or Keyless Entry Transmitter
Each ignition key or keyless entry transmitter contains a transponder with a unique encrypted value. The
transponder's encrypted value is fixed and unable to be changed. The immobilizer system uses the ignition key
transponder value to determine if a valid ignition key is being used to start the vehicle.
Environment Identifier
Various modules throughout the vehicle learn a specific environment identifier during the module programming
process. The environment identifier is learned by each individual module and matches the environment
identifier stored in the BCM. Prior to starting after a battery disconnect, each of the modules which store a
environment identifier will compare their identifier to that of the identifier stored in the BCM. If all the
identifiers match, the engine starting process will continue. If the environment identifiers do not match, engine
starting will be disabled.
Security Indicator
The BCM will command the Instrument Cluster to illuminate the security indicator when the ignition key is in
the ON position to indicate a fault has occurred within the immobilizer system and when the engine starting is
disabled.
REMOTE VEHICLE SPEED LIMITING DESCRIPTION AND OPERATION
Certain vehicles equipped with OnStar now have an additional feature that allows for remote limiting of the
vehicle's speed. This OnStar feature is called Stolen Vehicle Slow-Down and is now part of the OnStar
Stolen Vehicle Assistance service. This feature, when used in conjunction with local law enforcement and strict
guidelines at the OnStar Call Center, will slow the vehicle by interacting with the engine control system.
When the engine control system receives a valid request from the OnStar telematics communications interface
module, it will enter into a reduced engine power/vehicle speed limiting mode, which will decelerate the

vehicle. Once the request is active the engine control module begins reducing engine torque to match requested
vehicle speed and a REDUCED ENGINE POWER indication is displayed. No DTCs will be set during this
process.

2013 ACCESSORIES & EQUIPMENT Mirrors - Cruze

Mirrors - Cruze
SPECIFICATIONS
Specification
Application
Inside Rearview Mirror
Outside Rearview Mirror
Outside Rearview Mirror Housing Screw
Outside Rearview Mirror Motor (Actuator) Bolt
Metric
2 N.m
9 N.m
2.5 N.m
2.5 N.m

INSIDE REARVIEW MIRROR WIRING SCHEMATICS
DD8 Wiring Schematics
English
18 lb in
80 lb in
22 lb in
22 lb in

Fig. 1: Inside Rearview Mirror (DD8) Wiring Schematics

Callout
2839
2839_VT/WH
CAV_2
CAV_31
CONN_X2
CAV_5
2839_VT/WH
1324
1324 GN/WH
CAV_1
1550
1550_BK
CAV_5
G305
F53UA
X211
A90
A10
KR73
X50A
A1
OUTSIDE REARVIEW MIRROR WIRING SCHEMATICS
Outside Rearview Mirror Wiring Schematics
Component Name
2839 VT/WH
2
31
X2
5
2839 VT/WH
1324 GN/WH
1
Ground
1550 BK
5
G305
F53UA 10A
X211
Logic
(DD8)

Fig. 2: Outside Rearview Mirror Wiring Schematics

Callout
2267
2267 BN/YE
CAV_62
CONN_X2
2840
2840_RD/GY
CAV_4
CAV_28
DWE
2840_RD/GY
CAV 26
1550
1550_BK
CAV_5
3396
3396_GN/BK
Component Name
Mirror Heating Element Supply Voltage
2267 BN/YE
62
X2
2840 RD/GY
4
28
MIRROR O/S-LH and RH, RC, ELEC, HEAT, AUX
WFOV/DRVR, MANFOLD, CNVX/PASS
2840 RD/GY
26
Ground
1550 BK
5
Co-Driver Mirror Motor Right (+) Left (-) Control
3396 GN/BK

CAV_C
CAV_9
3398
3398_WH
CAV_A
CAV_8
3397
3397_YE/VT
CAV_B
CAV_7
2267_BN/YE
CAV_F
3390
3390_VT/BU
CAV_B
CAV_1
3391
3391_YE/BN
CAV_A
CAV_2
3389
3389_BN/BK
CAV_C
CAV_3
2267_BN/YE
CAV_F
2050
2050 BK
CAV_G
1550 BK
CAV_G
CAV_28
2267_BN/YE
2267_BN/YE
3396_GN/BK
3398_WH
3397_YE/VT
3396_GN/BK
3398_WH
3397_YE/VT
X600
C V 23
C
9
Co-Driver Mirror Motor Common Control
3398 WH
A
8
Co-Driver Mirror Motor Up (+) Down (-) Control
3397 YE/VT
B
7
2267 BN/YE
F
Driver Mirror Motor Up (+) Down (-) Control
3390 VT/BU
B
1
Driver Mirror Motor Common Control
3391 YE/BN
A
2
Driver Mirror Motor Right (+) Left (-) Control
3389 BN/BK
C
3
2267 BN/YE
F
Ground
2050 BK
G
1550 BK
G
28
2267 BN/YE
2267 BN/YE
3396 GN/BK
3398 WH
3397 YE/VT
3396 GN/BK
3398 WH
3397 YE/VT
X600

CAV_11
CAV_14
CAV_13
X500
CAV_24
CAV_23
CAV_22
G308
G305
F60UA
F55UA
X500
J316
X500
X600
X500
S52
A9A
A9B
X50A
KR5
23
11
14
13
X500
24
23
22
G308
G305
F60UA 7.5A
F55UA 7.5A
X500
J316
X500
X600
X500

SYMPTOMS - MIRRORS
NOTE:
2. Review the system operation in order to familiarize yourself with the system functions. Refer to the
following system descriptions:
Automatic Day-Night Mirror Description and Operation
Outside Mirror Description and Operation
Inspect for aftermarket devices which could affect the operation of the system. Refer to Checking

cause the symptom.
Intermittent
Symptom List
Automatic Day-Night Mirrors Malfunction

Heated Mirrors Malfunction
OnStar Button LED Malfunction
OnStar Button Malfunction
Power Mirror Malfunction
HEATED MIRRORS MALFUNCTION

Short to
Ground
Circuit
Left Heated Mirror
2
Element Control
Driver Outside Rearview
Mirror Ground
Right Heated Mirror
2
Element Control
Passenger Outside
Rearview Mirror Ground
1. Single Heated Mirror Inoperative
2. Both Heated Mirrors Inoperative
3. Heated Mirrors Always On
Open/High
Resistance
Short to
Voltage
Signal Performance

The rear defogger relay supplies voltage to the outside rearview mirror heater elements based on the current
state of the rear window defogger. The relay supplies B+ through the driver/passenger mirror heating element
control circuit when a request is seen.
Schematic Reference
Outside Rearview Mirror Schematics
Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference

Control Module References for scan tool information.
1. Engine running.
2. Verify the E18 Rear Defogger Grid turns ON and OFF when commanding the Rear Defogger On and Off
with a scan tool.
If the E18 Rear Defogger Grid does not turn ON or OFF
Refer to Rear Window Defogger Malfunction .
If the E18 Rear Defogger Grid turns ON and OFF
3. Verify the mirror glass of the A9A Outside Rearview Mirror-Driver and the A9B Outside Rearview
Mirror-Passenger become warm when commanding the Rear Defogger On with a scan tool.
If the mirror glass of the A9A Outside Rearview Mirror-Driver and the A9B Outside
Rearview Mirror-Passenger do not become warm

Rearview Mirror-Passenger become warm
4. All OK.
1. Ignition OFF and all vehicle systems OFF, disconnect the harness connector at the appropriate A9
Outside Rearview Mirror. It may take up to 2 minutes for all vehicle systems to power down.
2. Test for less than 10 ohms between the ground circuit terminal G and ground.
1. Ignition OFF.
3. Engine Running, connect a test lamp between the control circuit terminal F and the ground circuit
terminal G.
tool.
1. Ignition OFF, remove the test lamp, disconnect the harness connector at the X50A Fuse BlockUnderhood.
If less than 2 ohms, replace the A9 Outside Rearview Mirror.
1. Ignition OFF, remove the test lamp, disconnect the harness connector at the X50A Fuse BlockUnderhood, ignition ON.
If less than 1 V, replace the X50A Fuse Block-Underhood
5. Test or replace the A9 Outside Rearview Mirror.
Repair Instructions

Outside Rearview Mirror Glass Replacement

Front Compartment Fuse Block Replacement
AUTOMATIC DAY-NIGHT MIRRORS MALFUNCTION
Review Strategy Based Diagnosis for an overview of the diagnostic approach
Diagnostic Procedure Instructions provides an overview of each diagnostic category
Short to
Open/High
Ground
Resistance
Ignition
1
1
Backup Lamp Control
B2545 02
2
Ground
1
1. Automatic Mirror Dimming Inoperative
2. Mirror Automatic Day-Night Disable Feature Malfunction
Circuit
Short to
Voltage
2
-
Signal Performance
-
The inside rearview mirror uses 2 photocell sensors. One sensor is the rear light sensor, located on the face side
of the mirror, facing the rear of the vehicle. The rear light sensor is used to determine light conditions present at
the mirror face. The other sensor is the front light sensor, located on the backside of the mirror, facing the front
of the vehicle. The front light sensor is used to determine the exterior light conditions at the front of the vehicle.
With a low exterior light condition detected by the front light sensor and a high light condition from the rear
light sensor, the inside rearview mirror will automatically darken the face of the inside rearview mirror.
With the gear selector lever in the REVERSE position and the engine running, backup lamp control voltage is
supplied as an input to the inside rearview mirror. The mirror monitors this input to disable the automatic daynight feature. This allows the driver to see objects in the mirror clearly when backing up, regardless of the rear
light sensor status.
Schematic Reference
Inside Rearview Mirror Schematics


Automatic Day-Night Mirror Description and Operation
Circuit Testing
Connector Repairs
Wiring Repairs
1. Ignition ON.
2. Cover the windshield with a blanket or other suitable item.
3. Verify the A10 Inside Rearview Mirror face dims when shining a bright light into the rear light sensor
If the A10 Inside Rearview Mirror does not dim
Refer to Circuit/System Testing below - Inside Review Mirror Dimming Inoperative
If the A10 Inside Rearview Mirror dims
4. Verify the A10 Inside Rearview Mirror face transitions from dim to bright while commanding the Backup
Lamps Active and Inactive with a scan tool.
If the A10 Inside Rearview Mirror does not transition between dim and bright.
Refer to Circuit/System Testing below- Day-Night Disable Malfunction

If the A10 Inside Rearview Mirror transitions between bright and dim states
5. All OK.
Inside Review Mirror Dimming Inoperative

Mirror. It may take up to 2 minutes for all vehicle systems to power down.
1. Ignition OFF.

3. Ignition ON.
1. Ignition OFF.
If less than 2 ohms, refer to Retained Accessory Power Malfunction .
1. Ignition OFF.
If infinite resistance, replace the A10 Inside Rearview Mirror.
5. Replace the A10 Inside Rearview Mirror.
Day-Night Disable Malfunction
1. Ignition OFF, disconnect the harness connector at the A10 Inside Rearview Mirror.
2. Connect a test lamp between the control circuit terminal 1 and ground
3. Ignition ON, verify the test lamp turns ON and OFF while commanding the Backup Lamps Active and
Inactive with a scan tool.
1. Ignition OFF, remove the test lamp, disconnect the harness connector at the K9 Body Control
Module.
If less than 2 ohms, refer to Backup Lamps Malfunction (Manual Transmission) ,
Backup Lamps Malfunction (Automatic Transmission) .
If less than 1 V, refer to Backup Lamps Malfunction (Manual Transmission) , Backup
Lamps Malfunction (Automatic Transmission)

4. Replace the A10 Inside Rearview Mirror.

Repair Instructions
Perform the Diagnostic Repair Verification after completing the repair

POWER MIRROR MALFUNCTION
Short to
Ground
Circuit
1
Switch B+
Driver Mirror Motor
1
Horizontal Control
Driver Mirror Motor
1
Vertical Control
Passenger Mirror Motor
1
Horizontal Control
Passenger Mirror Motor
1
Vertical Control
Switch Ground
1. Both Outside Power Mirrors Inoperative
2. Driver Outside Power Mirror Malfunction
3. Passenger Outside Power Mirror Malfunction
Open/High
Resistance
Short to
Voltage
Signal Performance
The outside rearview mirror switch controls the outside rearview mirrors based on the position of the mirror
selector switch and which movement position is selected. The outside rearview mirror switch has four positions:
up, down, left, and right. B+ is applied to the switch from the power mirror fuse and when a movement position
switch is selected, voltage is sent to the commanded mirror via a mirror control circuit. The opposite mirror
control circuit acts as a ground circuit for the bi-directional mirror motor. Ground is the applied through the
switch.

Schematic Reference
Outside Rearview Mirror Schematics
Circuit Testing
Connector Repairs
Wiring Repairs
1. Verify the mirror glass of the A9A Outside Rearview Mirror-Driver and the A9B Outside Rearview
Mirror-Passenger move UP, DOWN, LEFT and RIGHT with the S52 Outside Rearview Mirror Switch.
If both outside mirror glasses do not move
Refer to Circuit/System Testing below - Both Outside Rearview Mirrors Inoperative.
If the driver outside mirror glass does not move UP, DOWN, LEFT or RIGHT
Refer to Circuit/System Testing below - Driver Outside Mirror Movement Malfunction.
If the passenger outside mirror glass does not move UP, DOWN, LEFT or RIGHT
Refer to Circuit/System Testing below- Passenger Outside Mirror Movement Malfunction.
Rearview Mirror-Passenger move UP, DOWN, LEFT and RIGHT
2. All OK.
Both Outside Rearview Mirrors Inoperative

1. Ignition OFF and all vehicle systems OFF, disconnect the harness connector at the S52 Outside Rearview
Mirror Switch. It may take up to 2 minutes for all vehicle systems to power down.

1. Ignition OFF.
1. Ignition OFF.
1. Ignition OFF.
3. Test for infinite resistance between each of the control circuit terminals listed below and ground:
Control circuit terminal 1
If infinite resistance, replace the appropriate M77 Outside Rearview Mirror Motor.
4. Test or replace the S52 Outside Rearview Mirror Switch.
Driver Outside Mirror Movement Malfunction

1. Ignition OFF, disconnect the harness connector at the A9A Outside Rearview Mirror-Driver. Ignition ON
2. Connect a test lamp between the control circuit terminal A and control circuit terminal B.
3. Verify the test lamp turns ON when commanding the UP and DOWN states with the S52 Outside
Rearview Mirror Switch.
1. Ignition OFF, remove the test lamp, disconnect the harness connector at the S52 Outside Rearview
Mirror Switch.

3. Test for less than 2 ohms in each control circuit end to end.
If less than 2 ohms, test or replace the S52 Outside Rearview Mirror Switch.
Mirror Switch, ignition ON.
2. Test for less than 1 V between each control circuit and ground.
If less than 1 V, test or replace the S52 Outside Rearview Mirror Switch
4. Connect a test lamp between the control circuit terminal A and control circuit terminal C.
5. Verify the test lamp turns ON when commanding the LEFT and RIGHT states with the S52 Outside
Mirror Switch.
6. Test or replace the M77D Outside Rearview Mirror Motor-Driver.
Passenger Outside Mirror Movement Malfunction

1. Ignition OFF, disconnect the harness connector at the A9B Outside Rearview Mirror-Passenger. Ignition
ON
2. Connect a test lamp between the control circuit terminal A and control circuit terminal B.
3. Verify the test lamp turns ON when commanding the UP and DOWN states with the S52 Outside


Mirror Switch.
4. Connect a test lamp between the control circuit terminal A and control circuit terminal C.
5. Verify the test lamp turns ON when commanding the LEFT and RIGHT states with the S52 Outside
Mirror Switch.
6. Test or replace the M77P Outside Rearview Mirror Motor-Passenger.
Repair Instructions

Outside Rearview Mirror Remote Control Switch Replacement

Outside Rearview Mirror Inner Actuator Replacement
REPAIR INSTRUCTIONS
OUTSIDE REARVIEW MIRROR REPLACEMENT
Fig. 3: View Of Outside Rearview Mirror And Mount Plate Bolts

Outside Rearview Mirror Replacement
Callout
Component Name
Remove the front side door upper trim cover. Refer to Front Side Door Upper Trim Cover
Replacement .
Outside Rearview Mirror Mount Plate Bolt (Qty: 3)
CAUTION:
Tighten
9 N.m (80 lb in)

Procedure
OUTSIDE REARVIEW MIRROR HOUSING COVER REPLACEMENT
Fig. 4: Outside Rearview Mirror Housing Cover

Outside Rearview Mirror Housing Cover Replacement
Callout
Component Name
Outside Rearview Mirror Housing Cover
Procedure
1. Using plastic pry tools, insert tools on top and bottom between
the housing cover and mirror body.
2. Pry carefully and equally on top and bottom to release housing
toward the front of vehicle.
3. Install housing cover to mirror body by applying pressure on
housing cover toward the rear of vehicle until retainers are
engaged.
OUTSIDE REARVIEW MIRROR REMOTE CONTROL SWITCH REPLACEMENT

Fig. 5: View Of Outside Remote Control Rearview Mirror Switch And Bezel
Outside Rearview Mirror Remote Control Switch Replacement
Callout
Component Name
Remove front side door window switch bezel. Refer to Front Side Door Window Switch Bezel
Replacement .
1
Side Window Switch Bezel
Outside Remote Control Rearview Mirror Switch
Procedure
2
Using a plastic pry tool, gently pry on the sides to release the switch.
OUTSIDE REARVIEW MIRROR INNER ACTUATOR REPLACEMENT

Fig. 6: Outside Rearview Mirror Inner Actuator

Outside Rearview Mirror Inner Actuator Replacement
Callout
Component Name
Remove the outside rearview mirror glass. Refer to Outside Rearview Mirror Glass Replacement.
Outside Rearview Mirror Inner Actuator Bolt (Qty: 3)
1
CAUTION:
Outside Rearview Mirror Inner Actuator

Procedure
OUTSIDE REARVIEW MIRROR GLASS REPLACEMENT

Fig. 7: View Of Outside Rearview Mirror Glass

Callout
Component Name
Outside Rearview Mirror Glass
WARNING:
Procedure
1. Release the mirror glass backing from the mirror housing by
pulling outward.
2. Disconnect electrical connector if equipped.
OUTSIDE REARVIEW MIRROR HOUSING REPLACEMENT

Fig. 8: Outside Rearview Mirror Housing

Outside Rearview Mirror Housing Replacement
Callout
Component Name
Remove outside rearview mirror glass. Refer to Outside Rearview Mirror Glass Replacement.
Outside Rearview Mirror Housing Screw (Qty: 4)
2
3
CAUTION:
Tighten
2.5 N.m (22 lb in)
Lower Outside Rearview Mirror Housing Screw
Tighten
2.5 N.m (22 lb in)
Outside Rearview Mirror Housing
INSIDE REARVIEW MIRROR REPLACEMENT

Fig. 9: Inside Rearview Mirror

Callout
Component Name
Remove the inside rearview mirror mount plate cover. Refer to Inside Rearview Mirror Mount Plate
Cover Replacement .
Inside Rearview Mirror Bolt
1
CAUTION:
Inside Rearview Mirror

2
Procedure
2. Slide the mirror in an upward motion in order to remove.

AUTOMATIC DAY-NIGHT MIRROR DESCRIPTION AND OPERATION
Inside Rearview Mirror with the Automatic Day-Night Feature System Operation

The inside rearview mirror uses 2 photocell sensors. One sensor is the headlight sensor, located on the face side
of the mirror. The headlight sensor is used to determine light conditions present at the mirror face. The other
sensor is the ambient light sensor, located on the rear of the mirror or windshield side. The ambient light sensor
is used to determine the exterior light conditions. With a low exterior light condition detected, and a high light
condition from behind of the car, at the headlight sensor, the inside rearview mirror will automatically darken
the face of the mirror.
In the daytime, the mirror is in a normal state because of the high exterior light condition that is indicated by the
ambient light sensor. With the gear selector lever in the REVERSE position, backup lamp supply voltage is
supplied as an input to the inside rearview mirror. The mirror monitors this input to disable the automatic daynight feature. This allows the driver to see objects in the mirror clearly when backing up, even during the night.
OUTSIDE MIRROR DESCRIPTION AND OPERATION
Power Mirror System Components
The power mirror system consists of the following components:
Outside rearview mirror switch

Mirror selector switch
Driver outside rearview mirror
Passenger outside rearview mirror
Each of the outside rearview mirror contains two motors. The vertical motor operates the mirror in the up and
down directions, and the horizontal motor operates the mirror in the left and right directions.
Power Mirror System Controls
The outside rearview mirror switch is a four position directional switch: Up, Down, Left and Right.
The mirror select switch is a three position switch: left, neutral/fold, and right.
Power Mirror System Operation
The outside rearview mirror switch receives battery voltage from the underhood fuse block The power mirror
switch also receives a constant ground.
The four positions of the direction switch have dual switch contacts. Each of the contacts are connected to
opposing sides of the appropriate power mirror motors through the selector switch. The selector switch
completes these circuits depending on the position of the selector switch, L or R.
If the selector switch is placed in the L position and the up switch is pressed, battery voltage will be supplied to
the left outside rearview mirror vertical motor through the left mirror motor vertical control circuit and ground
through the left mirror motor common control circuit. If the down switch is pressed, battery voltage will be
supplied to the left outside rearview mirror vertical motor through the left mirror motor common control circuit
and ground through the left mirror motor vertical control circuit.

The remainder of the mirror functions operate in the same manner as described above. Placing the power mirror
switch in opposing positions, left/right or up/down, will reverse the polarity to the mirror motor, reversing the
direction of movement.
Heated Mirrors (If Equipped)
The heated mirrors are controlled through the rear defog relay. Whenever the rear window defogger is turned on
battery voltage is supplied to the mirror heater elements through the left and right mirror heater element control
circuits.

2013 ACCESSORIES & EQUIPMENT Object Detection - Cruze

Object Detection - Cruze

OBJECT DETECTION WIRING SCHEMATICS
UD7 Wiring Schematics
Fig. 1: Object Detection (UD7) Wiring Schematics

Callout
CAV_28
3140
3140 RD/GN
CAV_1
CONN_X1
3140_RD/GN
3140_RD/GN
CAV_54
Component Name
28
3140 RD/GN
1
X1
3140 RD/GN
3140 RD/GN
54

5060
5060_GN
CAV 6
2550
2550_BK
CAV_7
CONN_X1
2374
2374_BN/WH
CAV 1
CAV_4
CONN X2
2374_BN/WH
2374_BN/WH
2375
2375_YE
CAV 3
CAV_5
2375 YE
2376
2376_YE/BU
CAV 3
2376_YE/BU
2374 BN/WH
CAV_1
2379
2379_BK/GY
CAV_2
2379_BK/GY
CAV_2
2379_BK/GY
CAV_2
2379_BK/GY
CAV_2
2374_BN/WH
CAV_1
2374_BN/WH
CAV_1

Data
5060 GN
6
Ground
2550 BK
7
X1
Object Sensor Supply
Voltage
2374 BN/WH
1
4
X2
2374 BN/WH
2374 BN/WH
Left Rear Corner Object
Sensor Signal
2375 YE
3
5
2375 YE
Left Rear Middle Object
Sensor Signal
2376 YE/BU
3
2376 YE/BU
2374 BN/WH
1
Object Sensor Low Reference
2379 BK/GY
2
2379 BK/GY
2
2379 BK/GY
2
2379 BK/GY
2
2374 BN/WH
1
2374 BN/WH
1

2377
2377_YE/WH
CAV 3
CAV_2
2377_YE/WH
2378
2378_YE/VT
2378_YE/VT
CAV_3
CAV 1
2379_BK/GY
CAV 8
2379_BK/GY
CAV_3
X402
CAV_D
CAV_E
CAV_C
CAV_B
CAV_A
CAV_F
F5DA
X200
J499
X402
B78G
B78H
B78E
B78F
X51A
K41R
KR104A
Rear View Camera (UVC) Wiring Schematics
Right Rear Middle Object

Sensor Signal
2377 YE/WH
3
2
2377 YE/WH
Right Rear Corner Object
Sensor Signal
2378 YE/VT
2378 YE/VT
3
1
2379 BK/GY
8
2379 BK/GY
3
X402
D
E
C
B
A
F
F5DA 7.5A
X200
J499
X402
(UD7)
(UD7)
(UD7)
(UD7)
Data Communication
Schematics
(UD7)

Fig. 2: Rear View Camera (UVC) Wiring Schematics

Callout
239
239 VT/WH
CAV_29
CONN_X2
339
339_VT/BK
1324
1324_GN/WH
CAV_3
CONN_X7
24
24_GN/WH
339_VT/BK
1324_GN/WH
339_VT/BK
339_VT/BK
24_GN/WH
Component Name
239 VT/WH
29
X2
339 VT/BK
1324 GN/WH
3
X7
24 GN/WH
339 VT/BK
1324 GN/WH
339 VT/BK
339 VT/BK
24 GN/WH

6972
6972_GN/YE
6972_GY/YE
CAV_5
CONN_X2
1324_GN/WH
6973
6973_WH/BU
CAV_15
6972_GY/YE
6973_WH/BU
6973_WH/BU
6974
6974_BARE
6974_BARE
6974_BARE
2350
2350_BK
2350_BK
CAV_5
CAV_6
CAV_3
CAV_1
CAV_4
CAV_2
6972_GY/YE
6973_WH/BU
6974 BARE
6974_BARE
6972 GY/YE
6973_WH/BU
6974_BARE
6974_BARE
X900
CAV_21
CAV_20
CAV_17
CAV_16
CAV_15
X915
CAV_10
C V 5
Camera Signal #2 +
6972 GN/YE
6972 GY/YE
5
X2
1324 GN/WH
Camera Signal #2
6973 WH/BU
15
6972 GY/YE
6973 WH/BU
6973 WH/BU
Camera Drain Wire
6974 BARE
6974 BARE
6974 BARE
Ground
2350 BK
2350 BK
5
6
3
1
4
2
6972 GY/YE
6973 WH/BU
6974 BARE
6974 BARE
6972 GY/YE
6973 WH/BU
6974 BARE
6974 BARE
X900
21
20
17
16
15
X915
10

CAV_3
CAV_8
CAV_4
X200
CAV_6
CAV_7
CAV_18
G309
F54UA
F32UA
J302
TWIST 9
TWIST_9
TWIST_9
TWIST_9
X900
X915
X200
K9
B87
X50A
W7
KR73
A11
Side Blind Zone Alert (UFT) Wiring Schematics
5
3
8
4
X200
6
7
18
G309
F54UA 5A
F32UA
J302
9
9
9
9
X900
X915
X200
(UVC)

Fig. 3: Side Blind Zone Alert (UFT) Wiring Schematics

Callout
3140
3140 RD/GN
CAV_5
3140_RD/GN
3140_RD/GN
3140_RD/GN
3140_RD/GN
3140_RD/GN
CAV_28
CAV_54
CAV_G
3140_RD/GN
CAV_5
5853
5853_GY/YE
CAV_4
Component Name
3140 RD/GN
5
3140 RD/GN
3140 RD/GN
3140 RD/GN
3140 RD/GN
3140 RD/GN
28
54
G
3140 RD/GN
5
Driver Side Object Detection
LED Signal (1)
5853 GY/YE
4

5853_GY
5853_GY/YE
CAV_D
CAV_K
CAV_29
1550
1550_BK
CAV_9
2350
2350_BK
CAV_8
CAV_8
2350 BK
CAV_3
2350_BK
2050
2050_BK
CAV_9
5060
5060 GN
CAV_7
5060_GN
CAV_2
5060_GN
CAV_7
5861
5861 GY
CAV_D
CAV_4
CAV_L
CAV_29
G309
F5DA
X200
X402
J495
X402
X500
X402
5853 GY
5853 GY/YE
D
K
29
Ground
1550 BK
9
Ground
2350 BK
8
8
2350 BK
3
2350 BK
Ground
2050 BK
9
Data
5060 GN
7
5060 GN
2
5060 GN
7
Passenger Side Object
Detection LED Signal (1)
5861 GY
D
4
L
29
G309
F5DA 7.5A
X200
X402
J495
X402
X500
X402

X600
A9A
A9B
A90
A90
B218L
B218R
X600
Logic
Logic
Data Communication
Schematics
X51A
KR104A

DTC
DTC B094B or B094C
DTC B094D or B094E
Description
DTC B094B 00 Left Side Object Detection Control
Module - Malfunction
Module - Performance - Signal Invalid
Module - Variant Not Programmed
Module - High Temperature
Module - Performance
DTC B094C 00 Right Side Object Detection
Control Module - Malfunction
Control Module - Performance - Signal Invalid
Control Module - Variant Not Programmed
Control Module - High Temperature
Control Module - Performance
DTC B094D 01 Left Side Object Detection
Indicator Circuit Short to Battery
DTC B094D 02 Left Side Object Detection
Indicator Circuit Short to Ground
DTC B094E 01 Right Side Object Detection
DTC B094E 02 Right Side Object Detection

DTC B0958, B0959, B0960, or B0961
DTC B0967 or B0968
Indicator Circuit Short to Ground

DTC B0958 01 Parking Assist Rear Sensor Left
Corner Circuit Short to Battery
Corner Circuit Low Voltage/Open
Corner Circuit Performance - Signal Invalid
Corner Circuit Incorrect Period
DTC B0958 3A Parking Assist Rear Sensor Left
Corner Circuit Incorrect Component Installed
Middle Circuit Short to Battery
Middle Circuit Low Voltage/Open
Middle Circuit Performance - Signal Invalid
Middle Circuit Incorrect Period
DTC B0959 3A Parking Assist Rear Sensor Left
Middle Circuit Incorrect Component Installed
DTC B0960 01 Parking Assist Rear Sensor Right
Middle Circuit Short to Battery
Middle Circuit Low Voltage/Open
Middle Circuit Performance - Signal Invalid
Middle Circuit Incorrect Period
DTC B0960 3A Parking Assist Rear Sensor Right
Middle Circuit Incorrect Component Installed
Corner Circuit Short to Battery
Corner Circuit Low Voltage/Open
Corner Circuit Performance - Signal Invalid
Corner Circuit Incorrect Period
DTC B0961 3A Parking Assist Rear Sensor Right
Corner Circuit Incorrect Component Installed
DTC B0967 02 Parking Assist On/Off Switch
Indicator Circuit Low Voltage/Open

DTC B1015
DTC B1405
DTC B1015 00 Vehicle Identification Number

Information Malfunction
DTC B1405 02 Control Module Voltage Reference
Output 2 Circuit Short to Ground
Output 2 Circuit Low Voltage
Output 2 Circuit High Voltage
DTC B094B OR B094C

DTC Descriptor
DTC B094B 00
Left Side Object Detection Control Module - Malfunction
DTC B094B 08
Left Side Object Detection Control Module - Performance - Signal Invalid
DTC B094B 45
Left Side Object Detection Control Module - Variant Not Programmed
DTC B094B 54
Left Side Object Detection Control Module - High Temperature
DTC B094B 58
Left Side Object Detection Control Module - Performance
DTC B094C 00
Right Side Object Detection Control Module - Malfunction
DTC B094C 08
Right Side Object Detection Control Module - Performance - Signal Invalid

DTC B094C 45
Right Side Object Detection Control Module - Variant Not Programmed
DTC B094C 54
Right Side Object Detection Control Module - High Temperature
DTC B094C 58
Right Side Object Detection Control Module - Performance
The B218L Side Object Sensor Module - Left or B218R Side Object Sensor Module - Right can set this code if
the module determines there is a fault due to the reason listed in the symptom byte.
Ignition ON.
The control module has detected a malfunction.

The Side Blind Zone and Rear Cross Traffic Alert Systems will not function.
The DIC will display "Service Side Detection System".

A history DTC clears when the control module ignition cycle counter reaches the reset threshold of 50,
without a repeat of the malfunction.
Diagnostic Aids
If DTC B094B 58 or B094C 58 is set, check for anything that can interfere with the radar signal. Verify area in
front of radar is clean of mud, ice, snow, etc. Also verify the fascia panels in front of the radar are damage-free
and not obstructed by any add-on accessories such as emblems, etc.
Schematic Reference
Object Detection Schematics


Object Detection Description and Operation (with Side Blind Spot Alert (UFT)), Object Detection
Description and Operation (with Parking Assist (UD7)), Object Detection Description and Operation
(with Rearview Camera (UCV))
Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference

1. Ignition ON.
2. Verify that B094B 45 or B094C 45 is not set.
If DTC is set
1. Program the appropriate B218 Side Object Sensor Module.
If the DTC sets, replace the appropriate B218 Side Object Sensor Module.
3. All OK.
If DTC is not set
3. Verify that B094B 00, B094C 00, B094B 08, B094C 08, B094B 54 or B094C 54 is not set.
If DTC is set
Replace the appropriate B218 Side Object Sensor Module.
4. Verify that B094B 58 or B094C 58 is not set.
If DTC is set
Verify the area in front of the sensor is clean, unobstructed, and damage-free.

If not clean, unobstructed, and damage-free, clean or repair as necessary.

If clean, unobstructed, and damage-free, replace the appropriate B218 Side Object Sensor Module.
If DTC is not set
5. All OK.
Repair Instructions

Control Module References for side object sensor module replacement, programming and setup
DTC B094D OR B094E
DTC Descriptors
DTC B094D 01
Left Side Object Detection Indicator Circuit Short to Battery
DTC B094D 02
Left Side Object Detection Indicator Circuit Short to Ground
DTC B094E 01
Right Side Object Detection Indicator Circuit Short to Battery
DTC B094E 02
Right Side Object Detection Indicator Circuit Short to Ground
Circuit
Left Side Object Detection
Indicator Control Circuit
Right Side Object
Detection Indicator Control
Short to
Ground
Open/High
Resistance
Short to
Voltage
Signal Performance
B094D 02
B094D 01
B094E 02
B094E 01

Circuit
Two Side Object Sensor Modules are located on each side of the vehicle near the corners of the rear fascia. The
modules are provided with B+ and ground. The Side Object Sensor Module - Right has an additional ground to
distinguish it from the Side Object Sensor Module - Left. The Side Object Sensor Module - Left is connected to
the serial data line. The serial data line is passed through the module to the Side Object Sensor Module - Right.
When vehicle speed is greater than 10 km/h (6.2 MPH) and either Side Object Sensor Module detects an object
in the detection area, the module provides a signal to the appropriate Outside Rearview Mirror to illuminate the
amber telltale LED.
Engine running.
The Side blind zone alert is active from speeds of 10 km/h (6.2 MPH) up to 140 km/h (87 MPH).
B094D 02
The module has detected a short to ground in the outside rearview mirror - driver circuit.
B094D 01
The module has detected a short to voltage in the outside rearview mirror - driver circuit.
B094E 02
The module has detected a short to ground in the outside rearview mirror - passenger circuit.
B094E 01
The module has detected a short to voltage in the outside rearview mirror - passenger circuit.
The side blind zone alert system is inoperative and Service Blind Zone Alert System is displayed on the Driver
Information Center.
The condition for setting the DTC is no longer present.


Schematic Reference
Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference

1. Ignition ON.
2. Verify the scan tool can communicate with the right side object sensor.
If the scan tool can not communicate with the right side object sensor
Refer to Circuit/System Testing below - Right Side Object Sensor Malfunction.
If the scan tool can communicate with the right side object sensor
3. Verify the scan tool can communicate with the left side object sensor.
If the scan tool can not communicate with the left side object sensor
Refer to Circuit/System Testing below - Left Side Object Sensor Malfunction.

If the scan tool can communicate with the left side object sensor
4. Ignition OFF, ignition ON.
5. Verify that both side blind zone alert system indicators located in the outside rearview mirrors briefly turn
ON and then turn OFF during the system self test when ignition is initially turned ON.
If both side blind zone alert indicators do not briefly turn ON and OFF

The system may have been disabled, refer to Diagnostic Aids. If system has not been disabled refer
to Circuit/System Testing below - Side Object Indicator Malfunction.
If only one indicator does not briefly illuminate during the self test
Refer to Circuit/System Testing below- Side Object Indicator Malfunction.
If both side blind zone alert indicators briefly turn ON and OFF
6. All OK.
Right Side Object Sensor Malfunction

1. Ignition OFF and all vehicle systems OFF. It may take up to 2 minutes for all vehicle systems to power
down. Disconnect the harness connector at the B218R Side Object Sensor Module - Right.
2. Test for less than 10 ohms between the following ground circuit terminals and ground.
Terminal 3
Terminal 8
1. Ignition OFF.
1. Ignition Off.
1. Ignition OFF.
If infinite resistance, replace the B218R Side Object Sensor Module - Right.
down.
5. Test for less than 2 ohms in each of the serial data circuits end to end between the control module harness
connector terminal 7 and the DLC terminal 1.

If less than 2 ohms

6. Replace B218R Side Object Sensor Module - Right.
Left Side Object Sensor Malfunction

down. Disconnect the harness connector at the B218L Side Object Sensor Module - Left.
2. Test for less than 10 ohms between ground circuit terminal 8 and ground.
1. Ignition OFF.
1. Ignition Off.
1. Ignition OFF.
If infinite resistance, replace the B218L Side Object Sensor Module - Left.
down.
If less than 2 ohms
6. Replace B218L Side Object Sensor Module - Left.

Side Object Indicator Malfunction

1. Ignition OFF.
3. Ignition ON, connect a test lamp between the control circuit terminal D and the ground circuit terminal 9.
4. Verify the test lamp turns ON and OFF when commanding the Object Detection Alert Indicators ON and
OFF with a scan tool.
1. Ignition OFF, disconnect the harness connector at the appropriate B218 Side Object Sensor
Module.
If less than 2 ohms, replace the B218 Side Object Sensor Module.
1. Ignition OFF, disconnect the harness connector at the B218 Side Object Sensor Module, ignition
ON.
If less than 1 V, replace the B218 Side Object Sensor Module.
5. Test or replace the A9 Outside Rearview Mirror Glass.
Repair Instructions

Control Module References for Side Object Sensor Module replacement, programming and setup.
DTC B0958, B0959, B0960, OR B0961

DTC Descriptors
DTC B0958 01
Parking Assist Rear Sensor Left Corner Circuit Short to Battery
DTC B0958 06
Parking Assist Rear Sensor Left Corner Circuit Low Voltage/Open
DTC B0958 08
Parking Assist Rear Sensor Left Corner Circuit Performance - Signal Invalid
DTC B0958 21
Parking Assist Rear Sensor Left Corner Circuit Incorrect Period
DTC B0958 3A
Parking Assist Rear Sensor Left Corner Circuit Incorrect Component Installed
DTC B0959 01
Parking Assist Rear Sensor Left Middle Circuit Short to Battery
DTC B0959 06
Parking Assist Rear Sensor Left Middle Circuit Low Voltage/Open
DTC B0959 08
Parking Assist Rear Sensor Left Middle Circuit Performance - Signal Invalid
DTC B0959 21
Parking Assist Rear Sensor Left Middle Circuit Incorrect Period
DTC B0959 3A
Parking Assist Rear Sensor Left Middle Circuit Incorrect Component Installed

DTC B0960 01
Parking Assist Rear Sensor Right Middle Circuit Short to Battery
DTC B0960 06
Parking Assist Rear Sensor Right Middle Circuit Low Voltage/Open
DTC B0960 08
Parking Assist Rear Sensor Right Middle Circuit Performance - Signal Invalid
DTC B0960 21
Parking Assist Rear Sensor Right Middle Circuit Incorrect Period
DTC B0960 3A
Parking Assist Rear Sensor Right Middle Circuit Incorrect Component Installed
DTC B0961 01
Parking Assist Rear Sensor Right Corner Circuit Short to Battery
DTC B0961 06
Parking Assist Rear Sensor Right Corner Circuit Low Voltage/Open
DTC B0961 08
Parking Assist Rear Sensor Right Corner Circuit Performance - Signal Invalid
DTC B0961 21
Parking Assist Rear Sensor Right Corner Circuit Incorrect Period
DTC B0961 3A
Parking Assist Rear Sensor Right Corner Circuit Incorrect Component Installed
The object sensors are 3-wire sensors that are used to determine the distance between the vehicle and an object
of interest. The rear parking assist control module supplies 8 V to the object sensors via the 8 V reference
circuit and provides ground via the low reference circuit. The rear parking assist control module triggers the
sensors in a sequential loop. After each sensor transmits, the rear parking assist control module uses the sensor
echo received through the signal circuit to calculate the distance and position of an object.

Ignition ON
The parking assist is activated. The activation takes place through putting in the reverse gear or through
operating the park assist switch.
B0958 01, B0959 01, B0960 01, or B0961 01

The rear parking assist control module has detected the voltage at the sensor circuit is greater than 11.5 V or the
object sensor is not grounded.
B0958 06, B0959 06, B0960 06, or B0961 06
The rear parking assist control module has detected the voltage at the sensor circuit less than 0.5 V.
B0958 08, B0959 08, B0960 08, or B0961 08
The rear parking assist control module has received an invalid signal.
B0958 21, B0959 21, B0960 21, or B0961 21
The object sensor determines no change in the position of an object while the vehicle is in motion.
B0958 3A, B0959 3A, B0960 3A, or B0961 3A
The rear parking assist control module determines the wrong sensor type is installed.
The parking assist is disabled.

The driver information center displays SERVICE PARK ASSIST.

Schematic Reference


Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference

1. Ignition ON.
If the DTC is set
Refer to DTC B1405
3. Verify that DTC B0958 01, B0959 01, B0960 01 or B0961 01 is not set.
If the DTC is set
Check the appropriate sensor for contamination with mud. If no contamination is diagnosed, refer
to Circuit/System Testing below.
4. Verify that DTC B0958 21, B0959 21, B0960 21 or B0961 21 is not set.
If the DTC is set
Check the appropriate sensor for contamination with mud, ice or snow. If no contamination is
diagnosed, replace the sensor.
5. Verify that DTC B0958 3A, B0959 3A, B0960 3A or B0961 3A is not set.
If the DTC is set
Replace the appropriate sensor with a sensor of correct sensor type.


6. Ignition ON, transmission in REVERSE, verify the scan tool Parking Assist System Status parameter
displays Enabled.
If the Parking Assist System displays Disabled

If the Parking Assist System displays Enabled
7. All OK.
1. Ignition OFF for 1 min, scan tool must be disconnected for steps 1 and 2 to allow module to power down.
Disconnect the harness connector at the appropriate B78 Rear Object Sensor.
1. Ignition OFF, disconnect the harness connector X2 at the K41R Rear Parking Assist Control
Module.
If less than 2 ohms replace the K41R Rear Parking Assist Control Module.
3. Ignition ON.
If less than 7.5 V
1. Ignition OFF, disconnect the harness connector at the K41R Rear Parking Assist Control Module.
If less than 2 ohms, replace the K41R Rear Parking Assist Control Module.
1. Ignition OFF, disconnect the harness connector at the K41R Rear Parking Assist Control Module,
ignition ON.
If less than 1 V, replace the K41R Rear Parking Assist Control Module.
5. Ignition ON.

If less than 4.8 V
ignition ON.
7. Test or replace the appropriate B78 rear object sensor.
Repair Instructions
Rear Parking Assist Alarm Sensor Replacement

Control Module References for rear parking assist control module replacement, programming and setup.
DTC B0967 OR B0968

DTC Descriptor
DTC B0967 02
Parking Assist On/Off Switch Circuit Short to Ground
DTC B0968 01
Parking Assist On/Off Switch Indicator Circuit Short to Battery

DTC B0968 06
Parking Assist On/Off Switch Indicator Circuit Low Voltage/Open
The parking assist can be activated/deactivated by pressing the parking assist switch. By engaging the reverse
gear the parking assist can also be activated. By subsequently pressing the parking assist switch the parking
assist can be disabled again.
The indicator in the parking assist switch shows the status of the parking assist. If the lamp is ON, the parking
assist is activated.
Ignition ON
The parking assist is activated. The activation takes place by putting in the reverse gear or by pressing the
parking assist switch.
B0967 02
The parking assist control module has detected a short to ground.
B0968 01
The parking assist control module has detected a short to battery.
B0968 06
The parking assist control module has detected a short to ground or open.


Schematic Reference


Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference

1. Ignition ON.
2. Verify that DTC B0967 02 is not set.
If the DTC is set
Refer to Parking Assist Switch Malfunction below.
3. Verify that B0968 01 or B0968 06 is not set.
If the DTC is set
Refer to Parking Assist Switch Indicator Malfunction below.

4. Activate and deactivate the parking assist switch and verify the scan tool Park Assist Switch parameter
changes between Active and Inactive.
If the Parking Assist Switch parameter does not change between Active and Inactive

If the Parking Assist Switch parameter changes between Active and Inactive
5. All OK.

Parking Assist Switch Malfunction

1. Ignition OFF, disconnect the harness connector at the S48D Multifunction Switch 2 - Instrument Panel.
2. Test for less than 10 ohms between the S48D Multifunction Switch 2 - Instrument Panel terminal 1 and
ground.
1. Ignition OFF.
If 2 ohms or greater, repair the open/high resistance in the ground circuit.
3. Connect a test lamp between the control circuit terminal 5 and ground circuit terminal 1.
4. Verify the test lamp turns On and Off when commanding the Parking Assist Switch On and Off with a
scan tool.
ignition ON.
If 1 V or greater, repair the short to voltage on the circuit
5. All OK.
Parking Assist Switch Indicator Malfunction
2. Test for less than 10 ohms between the S48D Multifunction Switch 2 - Instrument Panel terminal 1 and
ground.
1. Ignition OFF.

3. Connect a test lamp between the voltage circuit terminal 6 and ground circuit terminal 1.
4. Verify the test lamp turns ON and OFF when Commanding the Parking Assist Switch On and Off with a
scan tool.
2. Test for infinite resistance between the voltage circuit and ground.
ignition ON.
2. Test for less than 1 V between the voltage circuit and ground.
5. All OK.
Repair Instructions
Rear Object Alarm Control Module Replacement

Control Module References for parking assist control module replacement, programming and setup.
DTC B1015
DTC Descriptor

DTC B1015 00
Vehicle Identification Number Information Malfunction
When the ignition is turned ON, the advanced rear parking assist control module and the vehicle direction
camera control module receives the vehicle identification number (VIN) from the body control module. The
advanced control module will compare the VIN received to the VIN stored in memory.
Ignition voltage is between 9-16 V.

The stored VIN does not match the received VIN.

The parking assist system or the lane departure warning system is disabled.
The driver information center displays SERVICE PARK ASSIST or SERVICE LANE DEPARTURE
SYSTEM.
The stored VIN matches the VIN stored in the body control module.
Schematic Reference
Circuit Testing

Connector Repairs
Wiring Repairs
Scan Tool Reference

1. Ignition ON.
2. Verify the DTC B1015 is not.
If the DTC B1015 is set
1. Program the control module the DTC originally set in.
If the DTC is sets, replace the control module the DTC set in.
3. All OK
If the DTC B1015 is not set
3. All OK
Repair Instructions

Control Module References for the rear parking assist control module, vehicle direction camera control
module replacement, programming and setup.
DTC B1405
DTC Descriptors
DTC B1405 02
Control Module Voltage Reference Output 2 Circuit Short to Ground
DTC B1405 03

Control Module Voltage Reference Output 2 Circuit Low Voltage

DTC B1405 07
Control Module Voltage Reference Output 2 Circuit High Voltage
The object sensors are 3-wire sensors that are used to determine the distance between the vehicle and an object
of interest. The parking assist control module supplies 8 V to the object sensors via the object sensor supply
voltage circuit and provides ground via the object sensor low reference circuit. The parking assist control
module triggers the sensors in a sequential loop. After each sensor transmits, the parking assist control module
uses the sensor echo received through the object sensor signal circuit to calculate the distance and position of an
object.
Ignition ON
Transmission in REVERSE
B1405 02
The parking assist control module has detected the object sensor supply voltage circuit is shorted to ground.
B1405 03
The parking assist control module has detected the object sensor supply voltage circuit is less than 7.2 V.
B1405 07
The parking assist control module has detected the object sensor supply voltage circuit is greater than 9.2 V.


Schematic Reference


Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference

Ignition ON, transmission in REVERSE, observe the scan tool Park Assist Sensor Reference Voltage
parameter. The reading should be between 7.2-9.2 V.
1. Ignition OFF, disconnect the harness connector at each of the object sensors, ignition On, transmission in
REVERSE
2. Test for 7.2-9.2 V between the object sensor reference circuit terminal 1 at all B78 Rear Object Sensor
harness connectors and ground.
If less than 7.2 V
1. Ignition OFF, disconnect the harness connector at the K41 Parking Assist Control Module.
If less than 2 ohms, replace the K41 Parking Assist Control Module.
1. Disconnect the harness connector X 2 at the K41 Parking Assist Control Module, igniton ON.

2. Test for less than 1 V between the 8 V supply voltage circuit and ground.
If less than 1 V, replace the K41 Parking Assist Control Module.
3. All OK.
Repair Instructions

Control Module References for parking assist control module replacement, programming and setup
SYMPTOMS - OBJECT DETECTION

NOTE:
The following steps must be completed before using the symptom tables:
all of the following are true: before using the Symptom Tables in order to verify that all of the following
are true:
2. Review the system operation in order to familiarize yourself with the system functions. Refer to Object
Detection Description and Operation (with Side Blind Spot Alert (UFT)), Object Detection
Description and Operation (with Parking Assist (UD7)), Object Detection Description and
Operation (with Rearview Camera (UCV)).
Inspect for aftermarket devices which may affect the operation of the system. Refer to Checking
Inspect the easily accessible or visible system components for obvious damage or conditions which may
cause the symptom.
Make sure the parking assist sensors located on the vehicle front and rear bumper are clear. Remove any
snow, mud or ice that is blocking the sensors.
Intermittent
Symptom List
Side Blind Spot Alert System Malfunction

Parking Assist System Malfunction

Rear Vision Camera System Malfunction
PARKING ASSIST SYSTEM MALFUNCTION

The ultrasonic parking assist system is designed to identify and notify the driver of an object in the vehicle's
path when moving revers at speeds of less than 8 km/h (5 MPH). The distance and location of the object is
determined by four object sensors, located in the rear bumper. The parking assist system will notify the driver
using an audible signal through the radio.
Diagnostic Aids
For Symptom Byte 21 the module only run diagnostic when the vehicle is driven greater than 40 km/h (25
MPH). Therefore, even with clean sensor with no obstruction (i.e. snow or ice melted off) drive the vehicle
greater than 40 km/h (25 MPH).
The following is a list of reasons this failure type byte 21 might have set:
One or more of the sensors may be blocked by snow, mud, ice, or other debris. This might happen after
going through a car wash in cold weather.
Silicone insulator surrounding sensor maybe missing, cut, or twisted.
Improperly installed sensor, sensor maybe be crooked due to a tight wire harness.
One or more of the sensors may be scratched or the paint maybe chipped.
Excessive paint thickness on a sensor may cause an excessive sensor ring time. When replacing or
refinishing a sensor, do not apply an excessive amount of paint or clear coat.
Schematic Reference

Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference

1. Ignition ON.
2. Verify the park assist system is enabled through the parking assist switch.
If the park assist system is manually disabled, enable the system.
Refer to the vehicle owners manual for instructions on enabling the system.
If the park assist system does not manually change
3. Verify the scan tool Park Assist Switch parameter while pressing and releasing the parking assist switch.
The parameter should change between Active and Inactive.
If the parameter does not change between Active and Inactive Refer to Parking Assist Switch
Circuit Malfunction.
If the parameter changes between Active and Inactive
4. Command the Park Assist Switch LED output control On and Off with the scan tool. The parking assist
switch indicator should turn On and Off when changing between the commanded states.
Refer to Parking Assist Switch Indicator Circuit Malfunction below.

If the indicator does turn ON and OFF
5. Transmission in reverse, verify the Engine Control Module (ECM) scan tool Reverse Position Switch
parameter is Active.
If the parameter is not Active
Refer to Backup Lamps Malfunction (Manual Transmission) , Backup Lamps Malfunction

(Automatic Transmission) .
If the parameter is Active

6. Transmission in REVERSE, verify the scan tool Park Assist System Status parameter displays Enable.
If the parameter is not Enabled
Refer to Diagnostic Aids to determine the cause of the inhibit.
If the parameter is Enabled
7. All OK.
Parking Assist Switch Circuit Malfunction

1. Ignition OFF.
3. Ignition ON.
4. Verify the scan tool Parking Assist Switch Status parameter is inactive.
If not Inactive
1. Ignition OFF, disconnect the harness connector at the K41 Parking Assist Control Module.
If infinite resistance, replace the K41 Parking Assist Control Module.
If Inactive
If 1 V or greater
If less than 1 V
6. Connect a test lamp between the control circuit terminal 5 and the ground circuit terminal 1.
7. Verify that a test lamp turns On and Off when Commanding the Parking Assist Switch On and Off with a
scan tool.
1. Ignition OFF, disconnect the harness connector at the K41 Parking Assist Control Module

If less than 2 ohms, replace the K41 Parking Assist Control Module.
1. Ignition OFF, disconnect the harness connector at the K41 Parking Assist Control Module, ignition
ON.
If less than 1 V, replace the K41 Parking Assist Control Module
8. All OK.
Parking Assist Switch Indicator Circuit Malfunction

1. Ignition OFF, disconnect the harness connector at the S48D Multifunction Switch 2 - Instrument Panel,
Ignition ON.
2. Test for greater than 11 V between the terminal 3 and ground.
If less than 11 V
Test the voltage circuit for a short to ground or an open/high resistance.
3. Command the Park Assist Switch LED output control ON with the scan tool. Test for greater than 11 V
between the ignition circuit terminal 3 and the signal circuit terminal 5.
If less than 11 V
Test the signal circuit for an open/high resistance.

4. Command the Park Assist Switch Indicator Off with the scan tool.
5. Test for less than 1 V between the terminal 6 and ground.
If 1 V or greater
Test the signal circuit for a short to voltage.

6. If all circuits test normal, replace the S48D Multifunction Switch 2 - Instrument Panel.
Repair Instructions

Control Module References for Parking Assist Control Module replacement, programming and setup
REAR VISION CAMERA SYSTEM MALFUNCTION

When the transmission is placed into REVERSE, a 12 V signal is sent to the rearview camera indicating that
camera operation is requested. Ignition voltage and ground are supplied to the rearview camera. The rearview
camera sends video information to the radio through a video signal + and a video signal - circuit. A grounded
shielding also wraps the video signal circuits to reduce electronic interference which may degrade the video
signal and cause a distorted or otherwise degraded image.
Diagnostic Aids
A poor video image can be caused by ice, snow, and mud buildup on the lens of the rearview camera. Also,
extreme lighting conditions can affect performance, such as operating in the dark or with bright sunlight shining
on the camera. Extreme high or low temperatures can also affect the image quality. An open in the shield of the
video signal circuit can also cause a distorted screen.
Schematic Reference
Circuit Testing
Connector Repairs

Wiring Repairs
Scan Tool Reference

1. Ignition ON.
If the DTC is set
Refer to DTC B2545 .
3. Verify the rearview camera there is no debris on the lens and that the bezel or bezel seal is not damaged.
If debris are found on the lens
Clean the lens. If the lens, bezel, or bezel seal are damaged, replace as necessary.
If no debris on the lens
4. Ignition ON, transmission in REVERSE.
5. Verify the backup lamps are On.
If the backup lamps are not ON
Refer to Backup Lamps Malfunction (Manual Transmission) , Backup Lamps Malfunction

(Automatic Transmission) .
If the backup lamps are ON
6. Engine running, transmission in REVERSE.
7. Verify a clear rear vision image is displayed on the radio.
If a clear image is not displayed

If a clear image is displayed
8. All OK.
NOTE:
Circuit/System Verification must be performed before Circuit/System Testing.
1. Ignition OFF, disconnect the harness connector at the B87 Rearview Camera.

Test for less than 2 ohms in the ground circuit end to end.

Ignition ON.
Verify a test lamp illuminates between the ignition circuit terminal 6 and ground.
1. Ignition OFF.
3. If the circuit tests normal, test or replace the KR74 Ignition Run Relay.
Engine running, park brake applied, transmission in REVERSE.
Test for greater than 11 V between the control circuit terminal 3 and ground.
If less than 11 V
Ignition OFF, disconnect the X4 harness connector at the A11 Radio, ignition ON.
Test for less than 1 V between the signal circuit terminal listed below and ground:
Signal (+) circuit terminal 1 at the B87 Rearview Camera.
Signal (-) circuit terminal 4 at the B87 Rearview Camera.
If 1 V or greater
3.
4.
5.
6.
7.
8.

If less than 1 V
9. Test for infinite resistance between the signal circuit terminal listed below and ground:
Signal (+) circuit terminal 1 at the B87 Rearview Camera.
Signal (-) circuit terminal 4 at the B87 Rearview Camera.


10. Test for less than 2 ohms in the signal (+) circuit end to end.

If less than 2 ohms
11. Test for less than 2 ohms in the signal (-) circuit end to end.
Test the signal circuit for an open/high resistance.

If less than 2 ohms
12. Replace the B87 Rearview Camera.
13. Engine running, transmission in REVERSE, verify a clear rear vision image is displayed on the A11
Radio.
If a clear rear vision image is not displayed on the A11 Radio

If a clear rear vision image displayed on the A11 Radio
14. All Ok.
Repair Instructions
Rearview Camera Image Display Module Replacement

Control Module References for body control module or radio replacement, programming and setup
SIDE BLIND SPOT ALERT SYSTEM MALFUNCTION


Two Side Object Sensor Modules are located on each side of the vehicle near the corners of the rear fascia. The
modules are provided with B+ and ground. The Side Object Sensor Module - Right has an additional ground to
distinguish it from the Side Object Sensor Module - Left. The Side Object Sensor Module - Left is connected to
the serial data line. The serial data line is passed through the module to the Side Object Sensor Module - Right.
When vehicle speed is greater than 10 km/h (6.2 MPH) and either Side Object Sensor Module detects an object
in the detection area, the module provides a signal to the appropriate Outside Rearview Mirror to illuminate the
amber telltale LED.
Diagnostic Aids
The conditions for disabling the side blind zone alert system are captured by DTCs and/or a history buffer
that stores the last 16 events, including changes made by the driver and messages displayed in the drivers
information center. The history buffer for each side object sensor can be accessed using the scan tool.
The side blind zone system can be disabled if any off the following occur:
The driver has selected the Off mode through vehicle personalization menus. The selected mode is
retained over ignition cycles. A driver information center message stating that the side blind zone
system is off shall be displayed and the outside mirror indicators will be OFF.
Vehicle Speed Average Validity signal is set Invalid
Transmission Shift Lever Position Validity signal set to Invalid
Transmission Virtual Device Availability signal is set to Unavailable or has not been received in
the last LOSS OF TRANSMISSION VDA PERIODIC UPDATE calibration
Engine Virtual Device Availability signal is set to Unavailable or has not been received in the last
LOSS OF ENGINE VDA PERIODIC UPDATE calibration
There is a loss of serial data communication or a side blind zone system DTC is set.
A blockage condition exists (i.e. mud/snow buildup in front of the sensor). A driver information
message stating that the side blind zone system is temporarily unavailable will be displayed. The
side blind zone system transitions back to the normal operating state when the blockage is removed.
Bumper sticks, labels, and heavy rain storms may also cause this condition. The blockage
determination is performed with the vehicle in a drive gear.
The side blind zone system shall read the GPS latitude and longitude on the serial data bus and
calculate if the vehicle is within a Radio Astronomy zone. These zones are located in Europe and
require the sensors to be turned off. The "Side Blind Zone Alert System Temporarily Unavailable"
message shall be displayed to the driver when this occurs.
Because the sensors are identical, they may be swapped from one side of the vehicle to the other in an
attempt to isolate a concern. Sensors should NOT be swapped from one vehicle to another.
The side blind zone system is designed to ignore stationary objects; however, the system may
occasionally detect guard rails, signs, trees, shrubs, or other stationary objects as an object in the blind
zone. This is normal system operation and does not require service.
The side blind zone system may indicate an object in the blind zone if a trailer is attached to the vehicle,
or a bicycle or object is extending out to either side of the vehicle.
Schematic Reference


Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference

1. Ignition ON.
2. Verify the scan tool can communicate with the right side object sensor.
If the scan tool can not communicate with the right side object sensor
Refer to Circuit/System Testing below - Right Side Object Sensor Malfunction.
If the scan tool can communicate with the right side object sensor
3. Verify the scan tool can communicate with the left side object sensor.
If the scan tool can not communicate with the left side object sensor
Refer to Circuit/System Testing below - Left Side Object Sensor Malfunction.

If the scan tool can communicate with the left side object sensor
4. Ignition OFF, ignition ON.
5. Verify that both side blind zone alert system indicators located in the outside rearview mirrors briefly turn
ON and then turn OFF during the system self test when ignition is initially turned ON.
If both side blind zone alert indicators do not briefly turn ON and OFF
The system may have been disabled, refer to Diagnostic Aids. If system has not been disabled refer
to Circuit/System Testing below - Side Object Indicator Malfunction.

If only one indicator does not briefly illuminate during the self test
Refer to Circuit/System Testing below - Side Object Indicator Malfunction.
If both side blind zone alert indicators briefly turn ON and OFF
6. All OK.
Right Side Object Sensor Malfunction

down. Disconnect the harness connector at the B218R Side Object Sensor Module - Right.
2. Test for less than 10 ohms between the following ground circuit terminals and ground.
Terminal 3
Terminal 8
1. Ignition OFF.
1. Ignition Off.
1. Ignition OFF.
If infinite resistance, replace the B218R Side Object Sensor Module - Right.
down.

If less than 2 ohms

6. Replace B218R Side Object Sensor Module - Right.
Left Side Object Sensor Malfunction

down. Disconnect the harness connector at the B218L Side Object Sensor Module - Left.
2. Test for less than 10 ohms between ground circuit terminal 8 and ground.
1. Ignition OFF.
1. Ignition Off.
1. Ignition OFF.
If infinite resistance, replace the B218L Side Object Sensor Module - Left.
down.
If less than 2 ohms
6. Replace B218L Side Object Sensor Module - Left.
Side Object Indicator Malfunction


1. Ignition OFF.
3. Ignition ON, connect a test lamp between the control circuit terminal D and the ground circuit terminal 9.
4. Verify the test lamp turns ON and OFF when commanding the Object Detection Alert Indicators ON and
OFF with a scan tool.
1. Ignition OFF, disconnect the harness connector at the appropriate B218 Side Object Sensor
Module.
If less than 2 ohms, replace the B218 Side Object Sensor Module.
1. Ignition OFF, disconnect the harness connector at the B218 Side Object Sensor Module, ignition
ON.
If less than 1 V, replace the B218 Side Object Sensor Module.
5. Test or replace the A9 Outside Rearview Mirror Glass.
Repair Instructions

Control Module References for Side Object Sensor Module replacement, programming and setup.
REPAIR INSTRUCTIONS
REAR OBJECT ALARM CONTROL MODULE REPLACEMENT

Fig. 4: Rear Object Alarm Module And Clips

Callout
Component Name
Remove the rear compartment side trim. Refer to Rear Compartment Side Trim Replacement - Left
Side .
1
Rear Object Alarm Module Clip (Qty: 3)
2
Rear Object Alarm Module
REAR PARKING ASSIST ALARM SENSOR REPLACEMENT
Removal Procedure

Fig. 5: Identifying Rear Object Sensor Housing

1. Remove the rear bumper fascia. Refer to Rear Bumper Fascia Replacement
2. Disconnect electrical from the rear object sensor.
3. Lift the locking tabs on the housing and remove the rear object sensor.


1. Insert the sensor into the housing.
2. Connect the electrical connector to the rear object sensor.
3. Install the rear bumper fascia. Refer to Rear Bumper Fascia Replacement .
REAR OBJECT SENSOR HOUSING REPLACEMENT
1. Remove the rear fascia. Refer to Rear Bumper Fascia Replacement .


2. Disconnect the sensor harness.
3. Remove the sensor from the sensor housing.
The sensor housing must be painted if replaced. If reinstalled, painting will not be necessary.

Fig. 8: Sanding/Grinding Sonic Weld Plastic Residue From Fascia

IMPORTANT: Do Not grind off alignment tabs.
4. Sand/grind sonic weld plastic residue from the fascia.

Fig. 9: View Of Structural Adhesive Epoxy On Fascia

5. Apply structural adhesive epoxy, Lord Fusor 127EZ or equivalent, to fascia at mating surface.

Fig. 10: Identifying Sensor Housing & Tabs

6. Using the alignment tabs, install the sensor housing to the fascia.
7. Allow adhesive to cure according to manufacturer's directions.


8. Install the sensor to the sensor housing.
9. Connect the electrical harness.
10. Install the rear fascia. Refer to Rear Bumper Fascia Replacement .
REARVIEW CAMERA IMAGE DISPLAY MODULE REPLACEMENT

Fig. 12: Rearview Camera Image Display Module

Rearview Camera Image Display Module Replacement
Callout
Component Name
Remove the rearview camera image display module bracket. Refer to Rearview Camera Image Display
Module Bracket Replacement.
Rearview Camera Image Display Module
Procedure
1
Use a suitable tool to remove.
REARVIEW CAMERA IMAGE DISPLAY MODULE BRACKET REPLACEMENT

Fig. 13: Rearview Camera Image Display Module Bracket

Rearview Camera Image Display Module Bracket Replacement
Callout
Component Name
Remove the rear compartment lid applique. Refer to Rear Compartment Lid Applique Replacement .
Rearview Camera Image Display Module Bracket
Procedure
1
1. Use a suitable tool to remove.
2. Remove the rearview camera image display module. Refer to
Rearview Camera Image Display Module Replacement.

OBJECT DETECTION DESCRIPTION AND OPERATION (WITH SIDE BLIND SPOT ALERT
(UFT))
The side blind zone alert system shall detect and report "objects of interest" on either side of the vehicle, within
a specified "blind spot" zone. The system is designed to alert the driver, with a visual display placed on the side
view mirror, to the presence of objects of interest that may not be visible in the inside rearview mirror and
outside rear view mirrors. Although this system is intended to help drivers avoid lane change crashes, it does
not replace driver vision and therefore should be considered a lane change aid. Even with the side blind zone

alert system, the driver must check carefully for objects outside of the reporting zone (e.g., a fast approaching
vehicle) before changing lanes. In the event that the system senses a malfunction through its diagnostic routines,
the system will be disabled and the driver will be visually notified.
When the system detects a vehicle in the side blind zone while driving forward, an amber warning symbol will
light up in the appropriate outside mirror. This indicates that it may be unsafe to change lanes. If the driver then
activates the turn signal, the amber warning symbol starts flashing as an extra warning not to change lanes.
Side blind zone alert is active when the vehicle is out of park or the parking brake is off on manual transmission
vehicles and from speeds of 10 km/h (6.2 MPH) up to 140 km/h (87 MPH). Driving faster deactivates the
system, indicated by dimly lighting the warning symbols in the mirrors. Driving under this speed again will turn
off the warning symbols. If then a vehicle is detected in the blind zone, the warning symbols will lit normal on
the appropriate side. When the vehicle is started, both outside mirror displays will briefly come on to indicate
that the system is operating.
Side Blind Zone Alert System Components
The side blind zone alert system is made up of the following components:
Left side object sensor module (also used for rear cross traffic alert)
Right side object sensor module (also used for rear cross traffic alert)
Driver outside rearview mirror
Passenger outside rearview mirror
Side Object Sensor Modules

The side object sensor modules are located on each side of the vehicle behind the rear fascia and are not directly
visible from outside the vehicle. The sensors use radar to determine the presence of objects nearby. When an
object is detected in the side blind zone, the side object sensor module supplies voltage to illuminate the visual
indicator on the appropriate side rear view mirror. Each sensor is supplied B+ and ground. The right sensor
receives an additional ground. Both sensors communicate independently on the serial data line. The serial data
enters the left sensor in a pass-thru configuration, that connects to the right sensor. The scan tool is able to
individually communicate with each sensor.
Outside Rearview Mirrors
The outside rearview mirrors contain an icon that is backlit with high intensity, amber-colored LED's located on
the mirror surface. The display brightness adapts to day/night conditions. The side blind zone alert indicator
icon in the left or right outside rearview mirror is illuminated if the left or right side object sensor module
detects a vehicle in the side blind zone to inform the driver that there is a vehicle driving in the blind spot zone.
Side Blind Zone Alert Operation
When the vehicle is started, both outside mirror displays will briefly come on to indicate that the system is
operating. The system is designed to detect objects of interest as small as a 125cc motorcycle with rider. The
detection zone starts at the outside rearview mirror and extends out to 3.5 m (11 ft) at the back corner of the
vehicle and 3 m (10 ft) behind the vehicle at a height of 0.5 m (1.5 ft) to 2.0 m (6 ft) above the ground. The side

blind zone system does not detect stationary objects such as guardrails, posts, curbs, walls, berms, bridges, or
parked vehicles.
When the system detects a vehicle in the side blind zone while driving forward, independent if passing a vehicle
or being passed, an amber warning symbol will light up in the appropriate outside mirror. This indicates that it
may be unsafe to change lanes. If the driver then activates the turn signal, the amber warning symbol starts
flashing as an extra warning not to change lanes.
Foul weather may affect the operation of the side blind zone system. Occasional missed alerts can occur under
normal circumstances and will increase in wet conditions. The number of missed alerts will increase with
increased rainfall or road spray. Heavy rainfall, as well as mud, dirt, snow, ice, or slush build-up on the rear
fascia, can completely disable the system.
If the vehicle is towing a trailer or has an object, such as a bicycle rack, attached to the rear of the vehicle, the
side blind zone system may not function properly and the indicators may remain illuminated at all time.
Side Blind Zone Alert Driver Information Center Messages
SIDE BLIND ZONE ALERT OFF

This message indicates that the system has been disabled through the driver information center. Refer to the
vehicle owners manual for instructions on how to set personalization options on the driver information center.
SERVICE SIDE DETECTION SYSTEM
This message indicates that the system requires service. When the message is displayed, the indicators will
remain illuminated at all times, notifying the driver that the side blind zone system should not be relied upon
when changing lanes. Since the sensors are also used for rear cross traffic alert, this feature will also be
inoperative.
SIDE DETECTION SYSTEM UNAVAILABLE
This message indicates that the system has been temporarily disabled because the sensor is blocked or can
otherwise not accurately detect vehicles or objects. Such instances may be mud, dirt, snow, ice, or slush buildup on the rear fascia, heavy rainfall, excessive road spray, fascia damage or stickers.
The rear cross traffic alert system will read the GPS latitude and longitude on the serial data bus and calculate if
the vehicle is within a Radio Astronomy zone. These zones are located in Europe and Japan and require the
sensors to be turned off. The "Side Detection System Unavailable" message will be displayed to the driver when
this occurs.
OBJECT DETECTION DESCRIPTION AND OPERATION (WITH PARKING ASSIST (UD7))
The ultrasonic parking assist system is designed to identify and notify the driver of an object in the vehicles
path when reversing at speeds of less than 8 km/h (5 MPH). The distance and location of the object is
determined by 4 object sensors located in the rear bumper. The parking assist system will notify the driver using
an audible beep signal through the radio rear speakers.

The parking assist system is made up of the following components:
Parking assist control module

Rear object alarm sensors
Parking Assist Control Module

The parking assist control module provides an 8 V reference and a low reference to the four object alarm
sensors. The parking assist control module receives individual signals from each of the four sensors and
determines the location and distance of an object based on these inputs. When an object is detected, the parking
assist control module will send a data message via CAN-Bus to the radio requesting an audible alert.
Rear Object Alarm Sensors
The object alarm sensors are located in the rear bumper of the vehicle. The sensors are used to determine the
distance between an object and the bumper. Each sensor emits an ultrasonic frequency which is reflected off
any object located behind the vehicle. These reflections are received by the sensors. The time difference
between the emission of the frequency and when the reflection is received is known as sensor echo time, it is
used to determine the distance to the object. The sensors report this information to the parking assist control
module.
Rear Parking Assist Operation
When the vehicle is first placed into reverse there will be one audible beep through the rear speakers, to indicate
that the system is working. If rear speakers are inoperable no audible signals will occur.
When backing up at speed of less than 8 km/h (5 MPH), the system is constantly monitoring for object of
interest located behind the vehicle. The rear parking assist system can detect objects greater than 7.6 cm (3 in)
wide and 25.4 cm (10 in) tall. The system cannot detect objects below the bumper, underneath the vehicle. If an
object is detected within 2.5 m (8 ft) there will be a audible beep notification out of both rear speakers based
upon the distance to the object. As the vehicle gets closer to an object, the time between the beeps become
shorter.
If the vehicle stops in a range zone the beeping will stop after 5 s. When the distance between the object and the
vehicle changes, beeping will start again.
If the rear parking assist system detects a malfunction the single audible beep will not chime when put into
reverse along with a DTC being stored. The object alarm module will send a serial data message to the
instrument panel cluster to display the SERVICE PARK ASSIST message on the driver information center.
Parking Assist System Driver Information Center Messages
SERVICE PARK ASSIST

The driver information center displays SERVICE PARK ASSIST when the parking assist control module
detects a malfunction in the rear parking assist system and the system is disabled. The driver information center
also displays SERVICE PARK ASSIST when a loss of communication occurs with the parking assist control
module.

PARK ASSIST OFF

The PARK ASSIST OFF message is displayed in the driver information center when the parking assist system
is disabled due to conditions that disable or inhibit the system. The parking assist control module requests the
driver information center display PARK ASSIST OFF when it detects that one of the following conditions:
The rear parking assist system is manually disabled by the vehicle operator through the audio system
personalization menu.
The park brake is applied or not fully released.
An object is attached to the rear of the vehicle, such as a trailer, bicycle rack, trailer hitch receiver, or tow
bar. Also, an object extending beyond a lowered endgate will disable the system.
The parking assist sensors are covered by snow, mud, dirt or ice.
The vehicle bumper is damaged.
Excessive paint thickness on a replacement parking assist sensor.
The parking assist sensors are disrupted by vibrations, like those caused by a large nearby vehicle or from
heavy equipment such as a jackhammer.
OBJECT DETECTION DESCRIPTION AND OPERATION (WITH REARVIEW CAMERA (UCV))

Rear Vision Camera System Operation
The rear vision camera system consists of a video camera/module located at the rear of the vehicle and the
infotainment display.
When the transmission is placed into REVERSE, a 12 volt signal is sent to the rear vision camera by the body
control module (BCM). This signal indicates to the camera that the vehicle is in reverse and image display is
requested. The rear vision camera receives ignition voltage and a constant ground to power the camera. Video
signal + and video signal - circuits carry the video image from the rear vision camera to the infotainment
display. Additionally, the video signal circuits are shielded to prevent any interference which may lead to a loss
of video signal resolution and a degraded video image. The shield is provided a ground path by the rear vision
camera.
The following conditions may cause a degraded rear vision camera image:
Ice, snow, or mud has built up on the rear vision camera

Dark conditions
Extreme light conditions, such as glare from the sun or the headlights of another vehicle
Damage to the rear of the vehicle
Extreme high temperatures or extreme temperature changes
If a malfunction is detected in the system, Service Rear Vision Camera may be displayed on the infotainment
display as an indicator to the customer that a problem exists that requires service.

2013 ACCESSORIES & EQUIPMENT Power Seats - Cruze

Power Seats - Cruze

DRIVER SEAT WIRING SCHEMATICS
ADS Wiring Schematics
Fig. 1: Driver Seat (ADS) Wiring Schematics

Callout
702
702_RD/BN
CAV D
702_RD/BN
702_RD
CAV_91
CAV_1
CAV_38
Component Name
702 RD/BN
D
702 RD/BN
702 RD
91
1
38

287
287_GY
CAV_5
CAV_H
286
286_BU
CAV_1
CAV_A
282
282_WH
CAV_5
CAV_E
283
283_GN
CAV_1
CAV_G
284
284_BN
CAV_5
CAV_F
285
285_YE
CAV_1
CAV_C
2150
2150_BK
CAV_B
F13DA
X200
X310
M50D
S64D
X51A
M55D
M51D
Driver Power Seat Front Vertical Motor Down Control

287 GY
5
H
Driver Power Seat Front Vertical Motor Up Control
286 BU
1
A
Driver Power Seat Rear Vertical Motor Up Control
282 WH
5
E
Driver Power Seat Rear Vertical Motor Down Control
283 GN
1
G
Driver Power Seat Horizontal Motor Rearward Control
284 BN
5
F
Driver Power Seat Horizontal Motor Forward Control
285 YE
1
C
Ground
2150 BK
B
F13DA 25A
X200
X310
(ADS)
(ADS)
(ADS)
(ADS)

SYMPTOMS - POWER SEATS
NOTE:
Review the system description in order to familiarize yourself with the system

functions. Refer to Power Seats System Description and Operation.

Inspect for aftermarket devices which could affect the operation of the seat systems. Refer to Checking
cause the symptom.
Intermittent
Symptom List
Refer to Power Seat Malfunction diagnostic procedure in order to diagnose the symptom.
POWER SEAT MALFUNCTION
Circuit
B+
Front Vertical Motor Down
Control
Front Vertical Motor Up
Control
Horizontal Motor Forward
Control
Horizontal Motor Rearward
Control
Rear Vertical Motor Down
Control
Rear Vertical Motor Up
Control
Ground
1. Power seat inoperative
Short to
Ground
1
Open/High
Resistance
1
Short to
Voltage
-
Signal Performance
-

Power seat is completely controlled through the seat adjuster switch. Battery voltage is supplied at all times to
the seat switch through a 20 A fuse located in the instrument panel fuse block. When the seat switches are in an
inactive state, the switch contacts are closed to the switch ground circuit.
All seat motors are reversible. For example, when the seat horizontal forward switch is pressed to move the
entire seat forward, battery voltage is applied through the switch contacts and the seat horizontal motor
rearward control circuit to the motor. With the horizontal motor rearward switch contacts closed to the switch
ground circuit, the motor runs in order to drive the entire seat forward until the switch is released. Moving the
entire seat rearward works similarly to moving the entire seat forward, except that battery positive voltage and
ground are applied on opposite circuits causing the motor to run in the opposite direction. All seat motors are
powered this way.
Schematic Reference
Driver Seat Schematics
Power Seats System Description and Operation
Circuit Testing
Connector Repairs
Wiring Repairs
1. Verify the driver seat directional motors listed below operate while operating the seat switches in both
directions.
M51D Seat Horizontal Motor - Driver
M50D Seat Front Vertical Motor - Driver
M55D Seat Rear Vertical Motor - Driver
If all seat motors do not operate
Refer to Circuit/System Testing below - Seat Adjuster Switch Circuit Test.

If 1 or more seat motors operate

Refer to Circuit/System Testing below - Seat Motor Circuit Test.
If all seat motors operate

2. All OK.
Seat Adjuster Switch Circuit Test

1. Ignition OFF, disconnect the harness connector at the S64D Seat Adjuster Switch - Driver.
2. Test for less than 10 ohms between the ground circuit terminal B and ground.
1. Ignition OFF.
3. Ignition ON.
4. Verify a test lamp illuminates between the B+ circuit terminal D and ground.
1. Ignition OFF
If less than 2 ohms, verify the circuit breaker is not open and there is voltage at the circuit
breaker.
5. Test or replace the S64D Seat Adjuster Switch - Driver.
Seat Motor Circuit Test
1. Ignition OFF, disconnect the harness connector at the appropriate seat motor listed below:
2. Connect a test lamp between control circuit terminal 1 and control circuit terminal 5, ignition ON.
3. Verify the test lamp illuminates when commanding the seat motor Up and Down or Forward and

Rearward using the seat adjuster switch.

If the test lamp does not illuminate during either of the commands
If less than 2 ohms, test or replace the S64D Seat Adjuster Switch - Driver.
If the test lamp illuminates during each of the commands
4. Test or replace the seat motor.
Component Testing
Seat Adjuster Switch Test

2. Test for infinite resistance between the B+ terminal D and each control terminal with the switch in the
open position.
Replace the S64D Seat Adjuster Switch - Driver.
3. Test for less than 2 ohms between the B+ terminal D and each control terminal with the appropriate
switch in the closed position.

If less than 2 ohms
4. Test for less than 2 ohms between the ground terminal B and each control terminal with the switch in the
open position.

If less than 2 ohms
5. All OK.
Seat Motor
1. Ignition OFF, disconnect the harness connector at the appropriate seat motor listed below:


NOTE:
When performing the following tests, make sure that the seat is not
already in the position the test is attempting to produce.
2. Install a 30 A fused jumper wire between control terminal 1 and 12 V.

3. Momentarily install a jumper wire between control terminal 5 and ground. The seat motor should
momentarily perform the appropriate FORWARD/ REARWARD/ UP/ DOWN function.
If the motor does not perform the FORWARD/ REARWARD/ UP/ DOWN function
Replace the motor.
If the motor performs the FORWARD/ REARWARD/ UP/ DOWN function
4. Reverse the jumper wires; the motor should perform FORWARD/ REARWARD/ UP/ DOWN function.
If the motor does not perform the FORWARD/ REARWARD/ UP/ DOWN function
Replace the motor.

If the motor performs the FORWARD/ REARWARD/ UP/ DOWN function
5. All OK.
Repair Instructions
Driver Seat Adjuster Switch Replacement

Front Seat Tilt Adjuster Actuator Replacement
Front Seat Adjuster Actuator Replacement
Driver Seat Outer Adjuster Rear Vertical Actuator Replacement
REPAIR INSTRUCTIONS
DRIVER SEAT ADJUSTER SWITCH REPLACEMENT

Fig. 2: Driver Seat Adjuster Switch

Driver Seat Adjuster Switch Replacement
Callout
Component Name
1
Seat Adjuster Switch Knob
Seat Cushion Outer Trim Panel
2
Refer to Front Seat Cushion Outer Trim Panel Replacement .
Front Seat Adjuster Switch
3
Procedure
FRONT SEAT TILT ADJUSTER ACTUATOR REPLACEMENT

Fig. 3: Identifying Front Seat Tilt Adjuster Actuator, Screw And Roll Pin
Front Seat Tilt Adjuster Actuator Replacement
Callout
Component Name
Remove the front seat. Refer to Driver or Passenger Seat Removal and Installation .
Front Seat Tilt Actuator Screw
CAUTION:
Tighten
10 N.m (89 lb in)
Roll Pin
Procedure
Use a hammer and small round tool to tap the roll pin out.
Front Seat Tilt Adjuster Actuator
Procedure
FRONT SEAT ADJUSTER ACTUATOR REPLACEMENT

Fig. 4: Identifying Front Seat Adjuster Actuator, Adjuster Track And Screw
Front Seat Adjuster Actuator Replacement
Callout
Component Name
Front Seat Adjuster Track Screw
2
3
CAUTION:
Tighten
42 N.m (31 lb ft)
Front Seat Adjuster Track
Front Seat Adjuster Actuator
Procedure
DRIVER SEAT OUTER ADJUSTER REAR VERTICAL ACTUATOR REPLACEMENT

Fig. 5: View Of Driver Seat Outer Adjuster Rear Vertical Actuator, Screw And Roll Pin
Driver Seat Outer Adjuster Rear Vertical Actuator Replacement
Callout
Component Name
Front Seat Outer Adjuster Rear Vertical Actuator Screw
CAUTION:
Tighten
42 N.m (31 lb ft)
Roll Pin
Procedure
Use a hammer and small round tool to tap the roll pin out.
Front Seat Outer Adjuster Rear Vertical Actuator
Procedure

POWER SEATS SYSTEM DESCRIPTION AND OPERATION

The power seat system consists of the following components:
Seat adjuster switch

Seat horizontal motor
Seat front vertical motor
Seat rear vertical motor
Seat Adjuster Switch
The seat switches provide both power and ground to the selected seat motors. Battery positive voltage is
supplied at all times to the driver seat switches through a 25 A circuit breaker located in the instrument panel
fuse block.
Motors
All of the seat motors operate independently of each other. Each motor contains an electronic circuit breaker
(PTC) that opens in the event of a circuit overload and will reset only after voltage has been removed from the
circuit. There are three seat position motors. These are the horizontal motor, front vertical motor, and the rear
vertical motor. The horizontal motor moves the entire seat forward and rearward. The seat vertical motors may
operate independently to tilt the front or rear of the seat cushion up or down. Both motors can also run
simultaneously to move the entire seat up or down.
Seat Operation
All seat motors are reversible. For example, when the seat horizontal forward switch is pressed to move the
entire seat forward, ground is applied through the switch contacts and the seat horizontal motor forward control
circuit to the motor. With the horizontal motor rearward switch contacts closed to the switch B+ circuit, the
motor runs in order to drive the entire seat forward until the switch is released. Moving the entire seat rearward
works similarly to moving the entire seat forward, except that battery voltage and ground are applied on
opposite circuits causing the motor to run in the opposite direction. All seat motors are powered this way.

2013 ACCESSORIES & EQUIPMENT Programming and Setup - Cruze

Programming and Setup - Cruze

CONTROL MODULE REFERENCES
Data Link References

Diagnostic System Check - Vehicle
Symptoms - Vehicle

Control
Code Module/Scan Tool
Schematic
Information
Radio Scan Tool Radio/Navigation
A11
Information
System Schematics
Radio/Navigation
A22
Radio Controls
System Schematics
Front Passenger
Mass Sensor
Inflatable
Restraint
B60
Passenger
SIR Schematics
Presence System
Scan Tool
Information
(Passenger
Presence Sensor)
Body Control
Body Control
K9
Module Scan Tool
System Schematics
Information
Electronic Brake
Control Module Antilock Brake
K17
Scan Tool
System Schematics
Information
Engine
Controls
Schematics
for the 1.2L
Repair Instruction
Programming and Setup
Radio Programming and

Setup
Radio Control
Radio Control
Module Replacement Programming and Setup
Radio Replacement
Airbag Front
Passenger Presence
Passenger Presence System Programming and
Sensor Replacement Setup
Body Control
Body Control Module
Module Replacement Programming and Setup
Brake Pressure
Modulator Valve
Replacement
Engine Control
Module
Replacement
for the 1.2L
Electronic Brake Control

Module Programming and
Setup

K20
K27
K29
K33
K20 Engine
Control Module:
Scan Tool
Information
(L2Q, LDC
LWD) or 1.4L
(L2I L2N
LDD LUH
LUJ LUV)
engine
Engine
Controls
Schematics
for the 1.6L
(LDE LED
LFJ LGE LLU
LXV) or 1.8L
(2H0 LFH
LUW LWE)
engine
(L2Q, LDC
LWD) or 1.4L
(L2I L2N LDD
LUH LUJ
LUV) engine
Engine Control
Module
K20 Engine Control
Replacement Module: Programming
for the 1.6L
and Setup
(LDE LED LFJ
LGE LLU
LXV) or 1.8L
(2H0 LFH
LUW LWE)
engine
Fuel Pump Flow

Engine Controls
Control Module
Schematics for the Replacement for the
1.2L (L2Q, LDC
1.2L (L2Q, LDC
LWD) or 1.4L (L2I LWD) or 1.4L (L2I
L2N LDD LUH LUJ L2N LDD LUH LUJ
Fuel Pump Flow
LUV) engine
LUV) engine
Fuel Pump Control
Control Module
or
or
Scan Tool
Engine Controls
Fuel Pump Flow
Setup
Information
Schematics for the Control Module
1.6L (LDE LED LFJ Replacement for the
LGE LLU LXV) or 1.6L (LDE LED LFJ
1.8L (2H0 LFH
LGE LLU LXV) or
LUW LWE) engine 1.8L (2H0 LFH LUW
LWE) engine
Driver Seat and
Passenger Seat
Front Seat Heater
Heated Seat Control
Heated/Cooled Seat
Heater Control
Control Module
Schematics
Module Scan Tool
Replacement
Setup
Information
Heater and Blower
and Air
Conditioning
Heating,
HVAC Schematics Control Module
Ventilation and
with C68
Replacement with
Air Conditioning
or
C68
Control Module
HVAC Schematics or
Scan Tool
with C67
Heater and Blower
Information
and Air
Conditioning
Control Module
HVAC System Control

Setup

Replacement with
C67
K36
K41R
K43
K60
K61
K71
K73
K77
K84
Inflatable
Restraint Sensing
and Diagnostic
Module Scan Tool
SIR Schematics
Information
(Supplemental
Inflatable
Restraint)
Object Alarm
Object Detection
Module Scan Tool
Schematics
Information
Power Steering
Control Module Power Steering
Scan Tool
Schematics
Information
Steering Column
Lock Control
Column Lock
Module Scan Tool Schematics
Information
Sunroof Control
Module
Control Solenoid
Valve and
Transmission
Control Module
Assembly
Transmission
Control Module
Scan Tool
Information
Communication
Interface Module
Scan Tool
Information
Remote Control
Door Lock
Receiver
Keyless Entry
Control Module
Scan Tool
Airbag Sensing and
Sensing and Diagnostic
Diagnostic Module
Replacement
Setup
Rear Object Alarm

Control Module
Replacement
Object Alarm Module

Power Steering
Assist Motor
Replacement
Power Steering Control

Setup
Steering Column
Replacement

Control Module
Sunroof Module
Sunroof Schematics Assembly
Replacement

(New Motor), Sunroof
Control Module
(Existing Motor)
Control Solenoid
Valve and
Transmission
Control Module
Assembly
Replacement
Control Solenoid Valve

and Transmission Control
Module Assembly
(6T30/6T40/6T45/6T50)
Communication
OnStar Schematics Interface Module
Replacement
Setup
Automatic
Transmission
Controls
Schematics
Remote Function
Schematics
Remote Control
Remote Control Door
Door Lock Receiver Lock Receiver
Replacement
Remote Function
Schematics
Keyless Entry
Control Module
Replacement
Keyless Entry Control

Setup

K85
K89
P16
T3
T11
Information
Inflatable
Restraint
Passenger
SIR Schematics
Presence System
Scan Tool
Information
Immobilizer
Control Module
Immobilizer
Schematics
Passenger Presence
Front Passenger
System Programming and
Presence Module
Setup
Replacement
Theft Deterrent
Module Replacement
(without BTM) ,
Theft Deterrent
Module Replacement
(with BTM)
Instrument
Instrument Cluster Instrument Cluster
Cluster Scan Tool
Schematics
Replacement
Information
Radio Speaker
Radio/Navigation
Audio Amplifier
Amplifier
System Schematics
Replacement
Multimedia
Multimedia Player
Player Interface Radio/Navigation
Interface Module
Module Scan Tool System Schematics
Replacement
Information
Instrument Cluster
Audio Amplifier
Multimedia Player
Interface Module
REPAIR INSTRUCTIONS
AUDIO AMPLIFIER PROGRAMMING AND SETUP
Replace and Program ECU or Reprogram ECU
This ECU does not require SPS programming or any setup procedures.
BODY CONTROL MODULE PROGRAMMING AND SETUP
Special Tools
EL-49642 SPS Programming Support Tool

EL-46079 Tire Pressure Monitor Diagnostic Tool

NOTE:
DO NOT program a control module unless directed to by a service

procedure or a service bulletin. If the control module is not properly
configured with the correct calibration software, the control module will
not control all of the vehicle features properly.

Ensure the programming tool is equipped with the latest software and is
securely connected to the data link connector. If there is an interruption
during programming, programming failure or control module damage may
occur.
Stable battery voltage is critical during programming. Any fluctuation,
spiking, over voltage or loss of voltage will interrupt programming. When
required install the EL-49642 SPS Programming Support Tool to maintain
system voltage. If not available, connect a fully charged 12 V jumper or
booster pack disconnected from the AC voltage supply. DO NOT connect a
battery charger.
Turn OFF or disable systems that may put a load on the vehicles battery
such as; interior lights, exterior lights (including daytime running lights),
HVAC, radio, etc.
During the programming procedure, follow the SPS prompts for the
correct ignition switch position.
Clear DTCs after programming is complete. Clearing powertrain DTCs will
set the Inspection/Maintenance (I/M) system status indicators to NO.
Replace and Program Control Module
To program a replacement Body Control Module (BCM), perform the following procedure:
1. Install EL-49642 SPS programming support tool.
NOTE:
Make sure the vehicle ignition switch state is in appropriate position for
the following step.
For Key Ignition System, begin with the ignition in the RUN position.
For Push Button Start System, begin with the vehicle in vehicle OFF
power mode. The Service Programming System will power mode the
vehicle.
2. Access the Service Programming System (SPS) and follow the on-screen instructions.
NOTE:
The BCM Configuration is only required if this option is available on the

SPS Supported Controllers screen.
3. On the SPS Supported Controllers screen, select BCM Body Control Module - Configuration and follow
the on-screen instructions (if applicable).
4. On the SPS Supported Controllers screen, select BCM Body Control Module - Programming and follow
the on-screen instructions.
5. Perform the following for the appropriate ignition type prior to proceeding with the next step:
Key Ignition System: Key in the ignition and any additional keys must be away from the vehicle at
least 3 meters.

Push Button Start System: Keyless entry transmitter must be in the programming pocket. Refer to
the owner manual for the exact pocket location. All additional transmitters must be away from the
vehicle at least 3 meters.
NOTE:
The following programming step may take between 10-12 min. and
progress will appear to have stopped during this process. This is a normal
security timer response and a restart should not be performed. If the DTC
B389A set immediately after programming a replacement BCM, the
Immobilizer Learn procedure was not properly completed. The Immobilizer
Learn procedure needs to be performed again.
6. On the SPS Supported Controllers screen, select IMMO Immobilizer Learn - Setup. On the next screen,
select Body Control Module IMMO Learn with Existing Transponder or Remote Key and follow the onscreen instructions. When Immobilizer Learn is complete, press the Unlock button on the keyless entry
transmitter to allow the keyless entry transmitter to exit the Immobilizer Learn mode.
NOTE:
When performing the Tire Pressure Monitor Sensor Learn during BCM
setup, the EL-46079 tire pressure monitor diagnostic tool must be used to
activate each tire pressure sensor for vehicles with UJM.
For Push Button Start System, begin with the vehicle in vehicle ON
power mode.
7. On the SPS Supported Controllers screen, select BCM Body Control Module - Setup and follow the onscreen instructions.
8. Check the driver information center display for additional messages regarding further calibration
instructions. If there are no additional driver information center instructions present, programming is
complete.
9. At the end of programming, choose the "Clear DTCs" function on the SPS screen.
10. If ABS, Traction Control and/or Stabilitrak indicators are ON and DTC C0161 is set in the electronic
brake control module after performing BCM programming and setup, do the following:
1. Disconnect the scan tool from the data link connector.
2. Ignition OFF, all access doors closed, all vehicle systems OFF, and all keys at least 3 meters away
from the vehicle. It may take up to 2 minutes to power down.
3. Ignition ON, verify DTC C0161 is in history. If not, repeat the above step to make sure the vehicle
is in sleep mode.
4. Use the scan tool to clear the DTCs.
Reprogram Control Module
To program an existing BCM, perform the following procedure:


NOTE:
Make sure the vehicle ignition switch state is in appropriate position for
the following step.
For Push Button Start System, begin with the vehicle in vehicle ON
power mode.
3. On the SPS Supported Controllers screen, select BCM Body Control Module - Programming and follow
NOTE:
When performing the Tire Pressure Monitor Sensor Learn during BCM
setup, the EL-46079 tire pressure monitor diagnostic tool must be used to
activate each tire pressure sensor for vehicles with UJM.
4. On the SPS Supported Controllers screen, select BCM Body Control Module - Setup and follow the onscreen instructions.
5. Check the driver information center display for additional messages regarding further calibration
instructions. If there are no additional driver information center instructions present, programming is
complete.
6. At the end of programming, choose the "Clear All DTCs" function on the SPS screen.
7. If ABS, Traction Control and/or Stabilitrak indicators are ON and DTC C0161 is set in the electronic
brake control module after performing BCM programming and setup, do the following:
1. Disconnect the scan tool from the data link connector.
2. Ignition OFF, all access doors closed, all vehicle systems OFF, and all keys at least 3 meters away
from the vehicle. It may take up to 2 minutes to power down.
3. Ignition ON, verify DTC C0161 is in history. If not, repeat the above step to make sure the vehicle
is in sleep mode.
4. Use the scan tool to clear the DTCs.
Unsuccessful Programming Recovery
In the event of an interrupted or unsuccessful programming event, perform the following steps:
1. Ignition ON. Ensure the control module, DLC and programming tool connections are secure and the SPS
software is up to date.
2. Verify the control module can be reprogrammed.
If the control module cannot be reprogrammed
1. Ignition OFF for one minute, ignition ON.
If the control module cannot be reprogrammed, replace the control module.
If the control module can be reprogrammed.
3. All OK.

If the control module can be reprogrammed

3. All OK.
Repair Instructions

Control Module References for Control Module replacement, programming and setup
COMMUNICATION INTERFACE MODULE PROGRAMMING AND SETUP
Special Tools

Each of the following service procedures require programming or setup procedures to be performed on the
communication interface module.
Communication Interface Module Replacement
NOTE:
It is critical to use the service replacement Communication Interface

Module only in the vehicle for which it was ordered.
Failure to perform the following procedures will result in a red LED, DTC(s)
being set, and limited or incomplete OnStar services.
An OnStar button press to the OnStar call center is not required to
complete the procedure.
It may take up to 24 hours for OnStar service to become fully activated
after performing the procedures.
Perform the following procedure only once. Repeat attempts of the
procedure may result in a delay of the activation process.
To fully activate an OnStar module, both the setup and activation request
procedures must be completed on all vehicles with and without an active
OnStar subscription to insure the unit has been setup properly for the
vehicle it has been installed into and also to update the OnStar with the
correct unit information.
To initialize the Turn-by-Turn feature, the vehicle must first be driven In
open sky condition at speeds greater than 10 mph (16 kph) or more for a
minimum of 5 miles (8 km), and perform at least 2 left and 2 right 90 degree
turns coming to complete stops prior to each turn.
On vehicles up fitted with TTY capabilities, it is necessary to perform a
power cycle of the OnStar Interface Module (OTIM), and toggle the TTY
mode after completing the Communication Interface Module installation
and setup procedures.


3. On the SPS Supported Controllers screen, select ONSU Onstar Module Setup and Service Activation
and follow the on-screen instructions.
5. The default language for the new Communication Interface Module is English. To change to an alternate
language, access the scan tool.
6. Inform the customer that it may take up to 24 hours for the OnStar service to become fully activated.
CONTROL SOLENOID VALVE AND TRANSMISSION CONTROL MODULE ASSEMBLY
PROGRAMMING AND SETUP (6T30/6T40/6T45/6T50)
The following service procedures require either a programming or a setup event be performed for a complete
repair. The transmission control module (TCM) is part of the control solenoid valve assembly, and is not
serviced separately.
Transmission Control Module (TCM) Replacement
If the TCM is replaced, the following procedures must be performed:

1. TCM Reprogramming
2. The Transmission Adaptive Values Learn. Refer to Transmission Adaptive Values Learn .
TCM Reprogramming
NOTE:
Use a scan tool to view and record the Transmission Control Module
- End Model Part Number in the original TCM prior to starting the
TCM reprogramming procedure.
In some cases, the TCM and ECM may have to be reprogrammed.
When a selection for TCM Transmission Control Module Programming is not available, select SEQ Programming Sequence
ECM/TCM (Automatic Transmission Only).
1. If the TCM needs to be reprogrammed. Refer to Service Programming System (SPS).

2. Perform the Transmission Adaptive Values Learn. Refer to Transmission Adaptive Values Learn .
NOTE:
1.
2.
3.
4.
After programming, perform the following to avoid future misdiagnosis:
Turn the ignition OFF for 30 seconds.

Turn the ignition ON with the engine OFF.
Use the scan tool in order to retrieve history DTCs from all modules.
Clear all history DTCs.
Setup for Component Replacement

The replacement of some components will require a setup procedure for complete repair.
If any of the following components are replaced, the Transmission Adaptive Values Learn procedure must be
performed:
Transmission replacement
Any internal transmission repair
Any speed sensor
Refer to Transmission Adaptive Values Learn .

ELECTRONIC BRAKE CONTROL MODULE PROGRAMMING AND SETUP
NOTE:

procedure or a service bulletin. If the control module is not properly
configured with the correct calibration software, the control module will
not control all of the vehicle features properly.
during programming, programming failure or control module damage may
occur.
spiking, over voltage or loss of voltage will interrupt programming. When
required install the EL-49642 SPS Programming Support Tool to maintain
system voltage. If not available, connect a fully charged 12 V jumper or
booster pack disconnected from the AC voltage supply. DO NOT connect a
battery charger.
HVAC, radio, etc.
Replace and Program Control Module or Reprogram Control Module
To program a replacement or an existing control module, perform the following procedure:

2. On the SPS Supported Controllers screen, select K17 Electronic Brake Control Module - Programming
3. On the SPS Supported Controllers screen, select K17 Electronic Brake Control Module - Setup and
follow the on-screen instructions.

4. On the SPS Supported Controllers screen, select K17 Electronic Brake Control Module - Configuration
6. With a scan tool, perform the Brake Pressure Sensor Calibration. Refer to Brake Pressure Modulator
Valve Pressure Sensor Calibration .
7. With a scan tool, perform the Steering Wheel Angle Sensor Learn. Refer to Steering Angle Sensor
Centering .
1. Ignition ON. Ensure the control module, DLC and programming tool connections are secure and the SPS
If the control module cannot be reprogrammed, replace the control module.
If the control module can be reprogrammed.
3. All OK.
3. All OK.
Repair Instructions

K20 ENGINE CONTROL MODULE: PROGRAMMING AND SETUP
The following service procedures require either a programming or a setup event performed for a complete
repair.
Before Programming The Engine Control Module
NOTE:
DO NOT program a control module unless you are directed by a service

procedure or you are directed by a service bulletin. Programming a control
module at any other time will not permanently correct a customers concern.
The following criteria must be met before performing the programming or learning procedure:
There are no charging system concerns. All charging system concerns must be repaired before

programming a control module.

Battery voltage is between 12-16 V. The battery must be charged before programming the control module
if the battery voltage is low.
A battery charger is NOT connected to the vehicle battery. Incorrect system voltage or voltage
fluctuations from a battery charger may affect programming or control module damage.
Note the engine oil Life remaining percentage.
Turn OFF or disable any of the following systems that may put a load on the vehicle battery:
Twilight sentinel
Interior lights
Daytime running lights
HVAC systems
Radio
Engine cooling fans, etc
The ignition switch is in the proper position. The scan tool prompts you to turn ON the ignition, with the
engine OFF. DO NOT change the position of the ignition switch during the programming procedure,
unless instructed to do so.
All of the following tool connections are secure:
The connection at the data link connector (DLC)
The voltage supply circuits
DO NOT disturb the tool harnesses while programming. If an interruption occurs during the programming
procedure, the control module programming may be affected or control module damage may occur.
If the engine control module (ECM) is replaced, the following procedures must be performed:
1. Connect a scan tool to the vehicle and access SPS. Refer to Service Programming System (SPS).
2. Before removing the old control module, perform the SPS function Prepare Control Module for Removal,
if available.
NOTE:
3.
4.
5.
6.
The Prepare Control Module for Removal function can only be performed
when communication with the old control module is still possible.
Replace the ECM.

Perform the SPS function Engine Control Module - Programming and follow the on-screen instructions.
Clear the DTCs after completing the Programming procedure.
Perform the SPS function Immobilizer Learn and follow the on-screen instructions. Refer to Immobilizer
System Component Programming (with BTM) , Immobilizer System Component Programming
(without BTM) .
7. Perform the SPS function Engine Control Module - Configuration & Setup and follow the on-screen
instructions.

8. Clear DTCs after completing the Configuration & Setup procedure.

To reprogram an existing ECM, perform the following procedure:

1.
2.
3.
4.
Connect a scan tool to the vehicle and access SPS. Refer to Service Programming System (SPS).
Perform the SPS function Engine Control Module - Programming and follow the on-screen instructions.
Clear DTCs after completing the Programming procedure.
Perform the SPS Function Immobilizer Learn and follow the on-screen instructions. Refer to
Immobilizer System Component Programming (with BTM) , Immobilizer System Component
Programming (without BTM) .
5. Perform the SPS function Engine Control Module - Configuration & Setup and follow the on-screen
instructions, if available.
6. Clear DTCs after completing the Configuration & Setup procedure.
In the event of an interrupted or unsuccessful programming event, perform the following:

1. Ignition ON. Ensure the control module, DLC, and programming tool connections are secure and the SPS
If the control module cannot be reprogrammed, replace the K20 Engine Control Module.
3. All OK.
3. All OK.
Repair Instructions

Control Module References for ECM replacement, programming and setup.
FUEL PUMP CONTROL MODULE PROGRAMMING AND SETUP
The fuel pump control module must be programmed with the proper calibration software. The module stores
and utilizes this information however if it is not properly configured with the correct calibration software, the
fuel pump control module will not control all of the vehicle features properly.

Ensure that the following conditions exist in order to prepare for fuel pump control module programming:
1.
2.
3.
4.
5.
The battery is fully charged.

The MDI data link connectors are secure.
The scan tool is loaded with the most current software version.
All disconnected modules and devices are reconnected securely.
This entire procedure has been reviewed before proceeding.
Do not reprogram the fuel pump control module unless directed by a service procedure or a service bulletin.
Fuel Pump Control Module Programming
To program and setup an existing or new replacement fuel pump control module, perform the following
procedure:
1. Access the Service Programming System (SPS) and follow the on-screen instructions. Refer to Service
Programming System (SPS).
2. On the SPS Supported Controllers screen, select K27 Fuel Pump Control Module - Programming and
If the fuel pump control module fails to accept the program, verify all scan tool and fuel pump control module
connections are secure.
NOTE:
After programming is completed, perform the following to avoid future

misdiagnosis:
1.
2.
3.
4.
5.

Open and close the door.
Connect the scan tool to the data link connector.
Ignition ON, engine OFF.
Clear all DTC's from all modules.
HEATED SEAT CONTROL MODULE PROGRAMMING AND SETUP

The seat heating control module must be programmed with the proper calibration software. The module stores
and utilizes this information however if it is not properly configured with the correct calibration software, the
seat heating control module will not control all of the vehicle features properly.
Ensure that the following conditions exist in order to prepare for seat heating control module programming:
1.
2.
3.
4.


5. This entire procedure has been reviewed before proceeding.

Do not reprogram the seat heating control module unless directed by a service procedure or a service bulletin.
Seat Heating Control Module Programming
To program and setup an existing or new replacement seat heating control module, perform the following
procedure:
1. Access the Service Programming System (SPS) and follow the on-screen instructions. Refer to Service
Programming System (SPS).
2. On the SPS Supported Controllers screen, select HVSMF Front Seat Heating Control Module Programming and follow the on-screen instructions.
If the HVSMF Front Seat Heating Control Module fails to accept the program, verify all scan tool and seat
heating control module connections are secure.
NOTE:
After programming is completed, perform the following to avoid future

misdiagnosis:
1.
2.
3.
4.
5.

Open and close the door.
Connect the scan tool to the data link connector.
Clear all DTCs from all modules.
HVAC SYSTEM CONTROL MODULE PROGRAMMING AND SETUP

repair.
HVAC Control Module Replacement
If the HVAC control module needs to be replaced, the following procedures must be performed:
1. Connect a scan tool to the vehicle and access SPS. Refer to Service Programming System (SPS).
2. Perform the SPS function Remote Heater and Air Conditioning Control Module - Programming and
3. Perform the SPS function Remote Heater and Air Conditioning Control Module - Setup and follow the
on-screen instructions.
4. Clear DTCs after completing the programming procedure.
HVAC Control Module Reprogramming
Do not reprogram the HVAC control module unless directed by a service procedure or a service bulletin.

1. Connect a scan tool to the vehicle and access SPS.

2. Perform the SPS function Remote Heater and Air Conditioning Control Module - Programming and
Setup for Component Replacement
If an actuator is replaced, the following procedure must be performed:

Recalibrating actuators for the HVAC system. Refer to Actuator Recalibration .
INFLATABLE RESTRAINT SENSING AND DIAGNOSTIC MODULE PROGRAMMING AND
SETUP
The inflatable restraint sensing and diagnostic module (SDM) must be programmed with the proper calibration
software. The module stores and utilizes this information however if it is not properly configured with the
correct calibration software, the SDM will not control all of the vehicle features properly.
Ensure that the following conditions exist in order to prepare for SDM programming:
1.
2.
3.
4.
5.

This entire procedure has been reviewed before proceeding.
Do not reprogram the SDM unless directed by a service procedure or a service bulletin.
NOTE:
The air bag indicator light may remain ON after the body control module
(BCM), or SDM is replaced, and during the programming procedure for the
BCM until after the procedure is completed. When installing a new SDM,
there may be several DTCs set prior to programming. Once programmed,
these DTCs should be in history and can be cleared.
Failure to complete the following Setup procedure may cause DTC B1001
to be set in the SDM.
repair:
Sensing and Diagnostic Module Replacement and/or Programming
If the inflatable restraint sensing and diagnostic module needs to be replaced and/or reprogrammed, the
following procedures must be performed:
1. Access SPS. Refer to Service Programming System (SPS).

2. Perform the SPS function Inflatable Restraint Sensing and Diagnostic Module Programming and follow
3. Perform the SPS function Inflatable Restraint Sensing and Diagnostic Module Setup and follow the onscreen instructions.
If the control module fails to program, proceed as follows:
1. Ensure the DLC and Accessory Power Module connections are good.
2. Inspect the Techline equipment for the latest software version.
3. Attempt to program the SDM. If the SDM still cannot be programmed properly, replace the SDM.
INSTRUMENT CLUSTER PROGRAMMING AND SETUP
Special Tools

NOTE:

procedure or a service bulletin. If the ECU is not properly configured with
the correct calibration software, the ECU will not control all of the vehicle
features properly.
during programming, programming failure or ECU damage may occur.
spiking, over voltage or loss of voltage will interrupt programming. Install
the EL-49642 SPS programming support tool to maintain system voltage. If
not available, connect a fully charged 12 V jumper or booster pack
disconnected from the AC voltage supply. DO NOT connect a battery
charger.
HVAC, radio, etc.
To program a replacement or an existing ECU, perform the following procedure:


3. On the SPS Supported Controllers screen, select Instrument Cluster - Programming and follow the onscreen instructions.
4. On the SPS Supported Controllers screen, select Instrument Cluster - Configuration and follow the onscreen instructions.
5. On the SPS Supported Controllers screen, select Instrument Cluster - Setup and follow the on-screen
instructions.
1. DO NOT turn the ignition OFF. Ensure that all ECU, DLC and programming tool connections are secure
and the TIS terminal operating software is up to date.
2. Attempt to reprogram the ECU.
3. If the ECU can still not be programmed, turn the ignition OFF for at least one minute.
4. Turn the ignition ON and attempt to reprogram the ECU. The ECU should program.
If the ECU still cannot be programmed, replace the ECU.
KEYLESS ENTRY CONTROL MODULE PROGRAMMING AND SETUP
Special Tools

NOTE:

features properly.
charger.

HVAC, radio, etc.


3. On the SPS Supported Controllers screen, select Keyless Entry Control Module - Programming and
MULTIMEDIA PLAYER INTERFACE MODULE PROGRAMMING AND SETUP
Special Tools

NOTE:

features properly.
the EL-49642 SPS Programming Support Tool to maintain system voltage.
If not available, connect a fully charged 12 V jumper or booster pack


charger.
HVAC, radio, etc.
Diagnostic Aids
The Multimedia Player Interface Module is programmed with operational software during manufacturing. If it
is verified during the following procedure that the latest calibrations are already programmed in the module, no
further action is required. Do not attempt to program the module with the same calibration.

1. Install EL-49642 SPS Programming Support Tool.
3. On the SPS Supported Controllers screen, select Multimedia Player Interface Module - Programming and
OBJECT ALARM MODULE PROGRAMMING AND SETUP
repair.
Parking Assist Control Module Replacement
If the parking assist control module needs to be replaced, the following procedures must be performed:

1. Connect a scan tool to the vehicle and access SPS. Refer to Service Programming System (SPS)
2. Perform the SPS function Parking Assist Control Module Programming and follow the on-screen
instructions.
3. Perform the SPS function Parking Assist Control Module Configuration & Setup and follow the onscreen instructions.
Parking Assist Control Module Reprogramming
Do not reprogram the parking assist control module, unless directed by a service procedure, or a service
bulletin.
1. Connect a scan tool to the vehicle and access SPS. Refer to Service Programming System (SPS)
2. Perform the SPS function Parking Assist Control Module Programming and follow the on-screen
instructions.
PASSENGER PRESENCE SYSTEM PROGRAMMING AND SETUP
When the passenger presence system is replaced or serviced, perform the rezeroing procedure for the passenger
presence system. Refer to Passenger Presence System Rezeroing for the rezeroing procedure.
POWER STEERING CONTROL MODULE PROGRAMMING AND SETUP
NOTE:

features properly.
charger.
HVAC, radio, etc.

Diagnostic Aids
The electronic power steering control module is part of the power steering assist motor assembly and is
electronically paired with the steering gear's sensors. The programming procedure for replacing the electronic
power steering control module ONLY, is different from the replacing the steering gear assembly programming
procedure.
Replace Control Module ONLY

To program a replacement control module ONLY, perform the following procedure;
NOTE:
During the procedures listed below, critical data is retrieved from vehicle
components and stored in the scan tool computer's hard drive. This data is
needed during the programming and setup sequences.
Ensure the same scan tool is used and capable of reading, storing, and writing
the vehicle's system data.
1. On the SPS Supported Controllers screen, select Electronic Power Steering Control Module - Prepare
Control Module for Removal and follow the on-screen instructions.
NOTE:
Step 1 copies the worm gear wear counter data from the power steering
control module PRIOR to the module's removal and stores it on the scan
tool computer's hard drive.
AFTER completing step 1, the power steering control module can now be
removed and replaced.
2. Replace the Power Steering Assist Motor containing the Power Steering Control Module. Refer to Power
Steering Assist Motor Replacement .
NOTE:
The next two steps will transfer the vehicle's critical data, including the
worm gear wear counter data saved in step 1, back to the vehicle
components.
3. On the SPS Supported Controllers screen, select Electronic Power Steering Control Module Programming and follow the on-screen instructions.
4. On the SPS Supported Controllers screen, select Electronic Power Steering Control Module Configuration and follow the on-screen instructions.
down.
6. Ignition ON.
7. On the SPS Supported Controllers screen, select Electronic Power Steering Control Module - Setup and

8. Perform the Steering Angle Sensor Centering and Software Endstop Learning procedure. Refer to Power
Steering Control Module Calibration .
9. Clear all DTCs after completing the programming and setup procedures.
Replace Steering Gear Assembly
To program a new steering gear assembly, perform the following procedure;
down.
6. Ignition ON.
To reprogram an existing Electric Power Steering Control Module WITHOUT replacement, perform the
following procedure;
down.
6. Ignition ON.

Repair Instructions

RADIO CONTROL PROGRAMMING AND SETUP
RADIO PROGRAMMING AND SETUP
Special Tools

NOTE:

features properly.
charger.
HVAC, radio, etc.

Diagnostic Aids
During radio programming you may be required to select multiple calibrations dependant upon vehicle
equipment. Have the vehicle build/RPO information available during the following procedure to ensure
the correct calibrations are selected.
The XM satellite radio (if equipped) is integrated into the radio. If XM was activated in the previous
radio, the replacement radio will require no additional activation steps. Customer subscription
information is transferred to the replacement radio when a replacement radio is ordered.

1. Install EL-49642 SPS Programming Support Tool.
3. On the SPS Supported Controllers screen, select Radio - Programming and follow the on-screen
instructions.
REMOTE CONTROL DOOR LOCK RECEIVER PROGRAMMING AND SETUP
Diagnostic Aids
The remote control door lock receiver only functions as an antenna, receiving the signals sent by the keyless
entry transmitter and forwarding them to the body control module (BCM). The keyless entry software is
contained wholly within the BCM.

SERVICE PROGRAMMING SYSTEM (SPS)
Special Tools
For step-by-step control module programming instructions, please refer to the techline information system (TIS)
terminal.
Review the information below to ensure proper programming protocol.
NOTE:
DO NOT program a control module unless you are directed by a service

procedure or you are directed by a General Motors service bulletin.
Programming a control module at any other time will not permanently
correct a customers concern.
It is essential that the TIS terminal, MDI, and/or Scan Tool, is equipped with
the latest software before performing service programming.
Due to the time requirements of programming a controller, install EL-49642
SPS Programming Support Tool to maintain system voltage. Stable battery
voltage is critical during programming. Any fluctuation, spiking, over
voltage or loss of voltage will interrupt programming. If the above tool is
not available, DO NOT connect a battery charger, connect a fully charged
12V jumper or booster pack disconnected from the AC voltage supply.
Some modules will require additional programming/setup events to be
performed before or after programming.
Some vehicles may require the use of a CANDi or MDI module for
programming.
Review the appropriate service information for these procedures.
DTCs may set during programming. Clear DTCs after programming is
complete.
Clearing powertrain DTCs will set the Inspection/Maintenance (I/M) system
status indicators to NO.
Ensure the following conditions are met before programming a control module:
Vehicle 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 volts. The battery must be fully charged
before programming the control module.

Turn OFF or disable any system that may put a load on the vehicles battery, such as the following
components:
Interior lights
Exterior lights including daytime running lights (DRL)-Applying the parking brake, on most
vehicles, disables the DRL system
Heating, ventilation, and air conditioning (HVAC) systems
Engine cooling fans
Radio, etc.
The ignition switch must be in the proper position. SPS prompts you to turn ON the ignition, with the
engine OFF. DO NOT change the position of the ignition switch during the programming procedure,
unless instructed to do so.
Make certain all tool connections are secure, including the following components and circuits:
Scan Tool
The RS-232 communication cable port
The voltage supply circuits
MDI
The USB, Ethernet or Wireless communication port
DO NOT disturb the tool harnesses while programming. If an interruption occurs during the
programming procedure, programming failure or control module damage may occur.
1. DO NOT turn the ignition OFF. Ensure that all control module and DLC connections are secure and the
TIS terminal operating software is up to date.
2. Attempt to reprogram the control module.
3. If the control module can still not be programmed, turn the ignition OFF for at least one minute.
4. Turn the ignition ON and attempt to reprogram the control module. The control module should program.
If the control module still cannot be programmed, replace the control module.
After successfully programming the control module, ensure that all post programming procedures are
performed; refer to Control Module References for the appropriate control module Programming and Setup
document for any required procedures.
SIDE OBJECT SENSOR PROGRAMMING AND SETUP
NOTE:

features properly.

charger.
HVAC, radio, etc.

2. On the SPS Supported Controllers screen, select B218 Side Object Sensor Module - Programming and
3. At the end of programming, choose the "Clear DTCs" function on the SPS screen.
STEERING COLUMN LOCK CONTROL MODULE PROGRAMMING AND SETUP
NOTE:

features properly.


charger.
HVAC, radio, etc.
Replace and Program Steering Column Lock Control Module
To program a replacement steering column lock control module, perform the following procedure:
3. On the SPS Supported Controllers screen, select Steering Column Lock Control Module - Programming
Reprogram Steering Column Lock Control Module
To reprogram an existing steering column lock control module, perform the following procedure:
3. On the SPS Supported Controllers screen, select Steering Column Lock Control Module - Programming
1. DO NOT turn the Vehicle OFF. Ensure that all ECU, DLC and programming tool connections are secure

4. Turn the Vehicle in Service Mode and attempt to reprogram the ECU. The ECU should program.
SUNROOF CONTROL MODULE PROGRAMMING AND SETUP (NEW MOTOR)
"Manual" indicates the first switch detent.
"Express" indicates the second switch detent.
1. Ensure that the electrical harness on the headliner is connected to the sunroof window motor.
2. Put the ignition in the RUN position. (CAL file will be automatically downloaded by Body Control
housing, BCM).
NOTE:
"Manual close" is allowed and limited "manual open" is allowed.
3. Initialization (Normalization) - Press "manual close switch" until window finds the hard stop and moves
sightly back, after initialization "express open" is allowed but not "express close".
4. Learn Process:
1. Open the sunroof window with the express or manual open switch to the full open position and
release the switch.
2. Press "Manual Open Switch and hold for more then 10 seconds, Do Not release the switch, at this
time the sunroof window will automatically begin to move to the fully Close position.
5. During this time it is necessary to keep the switch active until the process completes.
6. Verify the operation of the sunroof window.
7. The Initialization/Teach Process is not complete if any of the following actions take place before the
initialization cycle is done.
1. The sunroof window switch is not held in the close position.
2. The ignition and/or battery power has been removed.
3. The window panel has not reached the closed position.
The Programming and Setup Process must be restarted if the procedure is not carried out completely.
SUNROOF CONTROL MODULE PROGRAMMING AND SETUP (EXISTING MOTOR)
NOTE:
The Programming and Setup Process is not complete if any of the following
actions take place before the initialization cycle is done:
The sunroof window switch is not held in the close position.

The ignition and/or battery power has been removed.
The window panel has not reached the closed position.
The Programming and Setup Process must be restarted if the procedure is not
carried out completely.

Perform the Programming and Setup Process for the sunroof window any time a new sunroof window motor
actuator is installed in the vehicle.
1. Ensure that the electrical harness on the headliner is connected to the sunroof motor.
housing, BCM).
"Manual close" is allowed and limited "manual open" is allowed.
3. Re-initialization (Normalization), ensure that the sunroof window is in the fully closed position.
4. Press "Manual Close Switch and hold for more then 10 seconds, do Not release the switch, at this time the
sunroof window will automatically begin to move to the fully Close position.
5. Do Not release the switch until the window finds the hard stop and move sightly back.
6. Learn:
1. Open the sunroof window with the express or manual open the switch to the full open position the
release the switch.
2. Press "Manual Open Switch and hold for more then 10 seconds, do Not release the switch, at this
time the sunroof window will automatically begin to move to the fully Close position.
During this time it is necessary to keep the switch active until the process completes.
THEFT DETERRENT MODULE PROGRAMMING AND SETUP

SPECIAL TOOLS
Illustration
Tool Number/ Description

EL 46079
J 46079
Tire Pressure Monitor Diagnostic Tool
EL 49642

EL 50113
Europe- Use recommended equivalent workshop
equipment
SPS Programming Support Tool

2013 ACCESSORIES & EQUIPMENT Remote Functions - Cruze

Remote Functions - Cruze

REMOTE FUNCTION WIRING SCHEMATICS
Keyless Entry (without ATH) Wiring Schematics
Fig. 1: Keyless Entry (without ATH) Wiring Schematics

Callout
3272
3272_GY/WH
CAV 25
CONN_X2
CAV_4
3272_GY/WH
3272_GY/WH
3274
Component Name
Remote Function Actuator Supply Voltage
3272 GY/WH
25
X2
4
3272 GY/WH
3272 GY/WH
Remote Function Actuator Transmit Signal

3274_YE/GN
CAV_26
CONN_X1
CAV_3
3274_YE/GN
3274_YE/GN
3275
3275_BU/WH
CAV_27
CONN_X2
CAV_2
3275_BU/WH
3275 BU/WH
3273
3273_GY
3273_GY
3273_GY
CAV_16
CAV_1
X210
CAV_3
CAV_5
CAV_4
CAV_2
X200
CAV_38
CAV_36
CAV 37
CAV_39
X210
X200
K9
K77
Keyless and Passive Entry (ATH) Wiring Schematics
3274 YE/GN
26
X1
3
3274 YE/GN
3274 YE/GN
Remote Function Actuator Receive Signal
3275 BU/WH
27
X2
2
3275 BU/WH
3275 BU/WH
Remote Function Actuator Return
3273 GY
3273 GY
3273 GY
16
1
X210
3
5
4
2
X200
38
36
37
39
X210
X200

Fig. 2: Keyless and Passive Entry (ATH) Wiring Schematics

Callout
3140
3140 RD/GN
CAV_5
CONN_X2
CAV_42
CONN_X2
1140
1140_RD/BN
CAV_1
3272
3272 GY/WH
CAV_25
CONN_X2
CAV_4
3274
Component Name
3140 RD/GN
5
X2
42
X2
1140 RD/BN
1
Supply Voltage
3272 GY/WH
25
X2
4
Transmit Signal

3274_YE/GN
CAV_26
CONN_X1
CAV_3
3275
3275_BU/WH
CAV_27
CAV_2
CONN_X2
3273
3273_GY
CAV 16
CAV_1
5060
5060_GN
CAV_3
CONN X1
1050
1050 BK
CAV_6
350
350_BK
CAV_2
CONN_X2
3272_GY/WH
3274_YE/GN
3275_BU/WH
3273_GY
3272_GY/WH
3274_YE/GN
3275_BU/WH
3273_GY
1140_RD/BN
CAV_34
CAV_43
X200
CAV_38
3274 YE/GN
26
X1
3
Receive Signal
3275 BU/WH
27
2
X2
Return
3273 GY
16
1
Data
5060 GN
3
X1
Ground
1050 BK
6
Ground
350 BK
2
X2
Data Communication
Schematics
3272 GY/WH
3274 YE/GN
3275 BU/WH
3273 GY
3272 GY/WH
3274 YE/GN
3275 BU/WH
3273 GY
1140 RD/BN
34
43
X200
38

CAV_36
CAV_37
CAV_39
X210
CAV_3
CAV_5
CAV_4
CAV_2
F27UA
F22DA
X200
X200
X210
K9
K77
X50A
X51A
K84
Passive Entry and Passive Start Antennas (ATH) Wiring Schematics
36
37
39
X210
3
5
4
2
F27UA 30A
F22DA 2A
X200
X200
X210
(ATH)

Fig. 3: Passive Entry and Passive Start Antennas (ATH) Wiring Schematics
Callout
3560
3560_VT
CAV_6
CONN_X4
3561
3561_VT/GY
CAV_7
3562
3562 GN/YE
CAV_20
3563
3563_GN/BK
CAV_9
3568
3568_BN/GN
CAV_16
CAV_1
3569
3569_GN/GY
CAV_18
CAV_2
3554
3554_BU
CAV_1
CAV_20
CONN X1
3555
3555_GY/BK
CAV_2
CAV_15
3552
3552_BN/BK
CAV_1
CAV_16
3553
3553_WH
CAV_2
Component Name
Passive Entry Driver Door Antenna Signal Hi
3560 VT
6
X4
Passive Entry Driver Door Antenna Signal Lo
3561 VT/GY
7
Passive Entry Co_Driver Door Antenna Signal Hi
3562 GN/YE
20
Passive Entry Co Driver Door Antenna Signal Lo
3563 GN/BK
9
Passive Entry Rear Closure Antenna Signal Hi
3568 BN/GN
16
1
Passive Entry Rear Closure Antenna Signal Lo
3569 GN/GY
18
2
Passive Start Interior Antenna 2 Signal Hi
3554 BU
1
20
X1
Passive Start Interior Antenna 2 Signal Lo
3555 GY/BK
2
15
3552 BN/BK
1
16
3553 WH
2

CAV_17
3556
3556_WH/GN
CAV_1
CAV_18
3557
3557_GN
CAV_2
CAV_19
3552_BN/BK
3553_WH
3554_BU
3555 GY/BK
3554_BU
3555_GY/BK
3560_VT
3561_VT/GY
3562_GN/YE
3563_GN/BK
CAV_1
CAV_2
CAV_1
CAV_2
X200
CAV_9
CAV_10
CAV_8
CAV 11
X300
CAV 6
CAV_20
X600
CAV_33
CAV_34
X500
CAV_33
CAV_34
TWIST_9
TWIST_9
TWIST_9
TWIST_9
TWIST 9
17
3556 WH/GN
1
18
3557 GN
2
19
3552 BN/BK
3553 WH
3554 BU
3555 GY/BK
3554 BU
3555 GY/BK
3560 VT
3561 VT/GY
3562 GN/YE
3563 GN/BK
1
2
1
2
X200
9
10
8
11
X300
6
20
X600
33
34
X500
33
34
9
9
9
9

TWIST_9
TWIST_9
TWIST_9
TWIST_9
TWIST_9
TWIST_9
X200
X300
X600
X500
K84
T10E
T10G
T10N
A24P
T10M
A24D
T10K
T10J
9
9
9
9
9
9
9
X200
X300
X600
X500
(ATH)
(ATH)
(ATH)
(ATH)
(ATH)
(ATH)
(ATH)
Door Handle Switches and References (ATH) Wiring Schematics

Fig. 4: Door Handle Switches and References (ATH) Wiring Schematics

Callout
6655
6655_GN/WH
CAV_15
CONN_X4
3576
3576_GY/BU
CAV_5
3570
3570_GN/WH
CAV_12
CONN_X4
3571
3571 VT/WH
Component Name
Driver Door Unlatch Switch
Signal
6655 GN/WH
15
X4
Co-Driver Door Exterior
Switch Lock Signal
3576 GY/BU
5
Driver Door Handle Switch
Signal
3570 GN/WH
12
X4
Co_Driver Door Handle
Switch Signal
3571 VT/WH

CAV_11
6157
6157 BN/YE
CAV_2
6158
6158_YE/GY
CAV_1
350
350_BK
350 BK
CAV_4
CAV 4
3576_GY/BU
CAV_3
CAV_16
6655_GN/WH
CAV_3
CAV_16
G305
G308
X600
X500
K84
A24P
A24D
B210P
B210D
11
Left Rear Door Handle
Switch Signal
6157 BN/YE
2
Right Rear Door Handle
Switch Signal
6158 YE/GY
1
Ground
350 BK
350 BK
4
4
3576 GY/BU
3
16
6655 GN/WH
3
16
G305
G308
X600
X500
Door Lock/Indicator
Schematics
(ATH)

DTC
DTC B3101
DTC B3105
DTC B3106
Description
DTC B3101 Keyless Entry Data Link Circuit
DTC B3105 Keyless Entry Transmitters
DTC B3106 Keyless Entry Data Link

DTC B3109-B3113
DTC B310D-B310F
DTC B3119
DTC B3120
DTC B3121
DTC B3122
DTC B3123
DTC B3124

DTC B310D Keyless Entry Transmitter 6 Battery
DTC B310E Keyless Entry Transmitter 7 Battery
DTC B310F Keyless Entry Transmitter 8 Battery
DTC B3119 Keyless Entry Antenna 1
DTC B3120 Keyless Entry Antenna 2 Short to
Ground
DTC B3120 Keyless Entry Antenna 2 High
Voltage/Open
Ground
Voltage/Open
Ground
Voltage/Open
Ground
Voltage/Open
Ground
Voltage/Open
DTC B3101
DTC Descriptor
DTC B3101
Keyless Entry Data Link Circuit

Circuit
B+
Serial Data - Enable Line
Serial Data - Receive
Low Reference
Short to
Ground
B3101 00
B3101 00
B3101 00
-
Open/High
Resistance
B3101 00
B3101 00
B3101 00
B3101 00
Short to
Voltage
B3101 00
B3101 00
-
Signal Performance
B3101 00
B3101 00
-
The body control module communicates with the remote control door lock receiver through the keyless entry
serial data circuits. When any button on the keyless entry transmitter is pressed, the transmitter sends a signal to
the remote control door lock receiver. The remote control door lock receiver sends a function request to the
body control module, depending on which button is pressed on the transmitter. The body control module
receives the message and performs the appropriate function.
The body control module monitors for this DTC at all times.
No response is received from the remote control door lock receiver after the body control module requests
information from or sends configuration commands to the remote control door lock receiver.
In the case of power loss, the remote control door lock receiver is disabled for 65 s. Otherwise no action is
taken.
A current DTC will clear when the fault is no longer present.

A history DTC will clear after 40 consecutive ignition cycles without a fault present.
Schematic Reference
Remote Function Schematics
Component Connector End Views
Keyless Entry System Description and Operation (without BTM), Keyless Entry System Description and

Operation (with BTM)

Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference

1. Ignition OFF and all vehicle systems OFF, scan tool disconnected, disconnect the harness connector at
the K77 Remote Control Door Lock Receiver. It may take up to 2 min for all vehicle systems to power
down.
3. Ignition ON.
4. Test for greater than 11.5 V between the B+ circuit terminal 4 and ground.
If 11.5 V or less
If Infinite resistance.
5. Test for 1-6 V between the serial data circuit terminal 2 and ground.
If less than 1 V

If greater than 6 V
If between 3-6 V
6. Ignition OFF, disconnect the X1 and X2 harness connectors at the K9 Body Control Module, ignition
ON.
7. Test for less than 1 V between the K9 Body Control Module serial data circuit terminal 26 X1 and
ground.
If 1 V or greater

If less than 1 V
8. Ignition OFF.
9. Test for infinite resistance between the K9 Body Control Module serial data circuit terminal 26 X1 and
ground.

10. Test for less than 2 ohms between the K9 Body Control Module serial data circuit terminal 26 X1 and the
K77 Remote Control Door Lock Receiver serial data circuit terminal 3.

If less than 2 ohms
11. Replace the K77 Remote Control Door Lock Receiver.
If the DTC sets
Replace the K9 Body Control Module

13. All OK.

Repair Instructions

Control Module References for body control module or remote control door lock receiver replacement,
DTC B3105
DTC Descriptor
DTC B3105
Keyless Entry Transmitters
The body control module monitors the number of keyless entry transmitters programmed. Until at least one
transmitter is programmed, the body control module determines a malfunction condition exists.
The body control module has been set up without transmitters being programmed.
No keyless entry transmitter programmed to the body control module.

The keyless entry system is inoperative.

A current DTC is cleared when at least one transmitter has been programmed to the body control module.
Schematic Reference


Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference

1. Verify that the transmitter is a correct transmitter for the vehicle. This can be accomplished by comparing
the part number printed on the transmitter to the appropriate part number in the parts catalog.
If the transmitter is incorrect
Replace the transmitter.
If the transmitter is correct
2. Program the transmitter. Refer to Key with Integrated Transmitter Programming (with BTM) , Key
with Integrated Transmitter Programming (without BTM) .
3. Verify the transmitter has successfully completed the programming procedure.
If the transmitter does not program successfully
Replace the transmitter.

If the transmitter programs successfully
4. All OK.
Repair Instructions

Key with Integrated Transmitter Programming (with BTM) , Key with Integrated Transmitter
Programming (without BTM)
DTC B3106
DTC Descriptor
DTC B3106
Keyless Entry Data Link
The body control module communicates with the remote control door lock receiver through the keyless entry
serial data circuits. When any button on the keyless entry transmitter is pressed, the transmitter sends a signal to
the remote control door lock receiver. The remote control door lock receiver sends a function request to the
body control module, depending on which button is pressed on the transmitter. The body control module
receives the message and performs the appropriate function.
A keyless transmitter button is pressed.

The transmitter that is sending a signal to the remote control door lock receiver is different from those
transmitters stored in the body control module.
No action is taken.
A current DTC will clear when the fault is no longer present and the ignition switch is cycled.

Schematic Reference
Component Connector End Views
Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference

1. With a valid and learned transmitter, press and release a button on the transmitter.
If DTC B3106 is set
Replace the K77 Remote Control Door Lock Receiver.
3. All OK.
Repair Instructions

Control Module References for remote control door lock receiver replacement, programming, and setup.
DTC B3109-B3113


DTC Descriptors
DTC B3109
Keyless Entry Transmitter 1 Battery
DTC B3110
DTC B3111
DTC B3112
DTC B3113
With each press of a keyless entry transmitter button, a message containing the current battery state of the
transmitter is sent to the remote control door lock receiver, along with the commanded keyless entry function.
The remote control door lock receiver sends this to the body control module to perform the requested function.

Three consecutive low battery signals are received from the same transmitter.


The DTC is cleared when a normal transmitter voltage signal is received from the transmitter that set the DTC.
Schematic Reference
Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference

1. Verify none of the DTCs listed below are set:

DTC B3109
DTC B3110
DTC B3111
DTC B3112
DTC B3113
1. Replace the battery in the appropriate keyless entry transmitter and operate the transmitter three
consecutive times.
If the DTC sets, replace the keyless entry transmitter.
3. All OK.

2. All OK.
DTC B310D-B310F
DTC Descriptors
DTC B310D
DTC B310E
DTC B310F
With each press of a keyless entry transmitter button, a message containing the current battery state of the
transmitter is sent to the remote control door lock receiver, along with the commanded keyless entry function.
The remote control door lock receiver sends this to the body control module to perform the requested function.

Three consecutive low battery signals are received from the same transmitter.

The DTC is cleared when a normal transmitter voltage signal is received from the transmitter that set the DTC.

Schematic Reference
Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference

1. Verify none of the DTCs listed below are set:

DTC B310D
DTC B310E
DTC B310F
1. Replace the battery in the appropriate keyless entry transmitter and operate the transmitter three
consecutive times.
If the DTC sets, replace the keyless entry transmitter.
3. All OK.
2. All OK.
DTC B3119

DTC Descriptors
DTC B3119
Keyless Entry Antenna 1
Circuit
Keyless Entry Antenna
Signal - Driver Door
Low Reference - Driver
Door
Short to
Ground
Open/High
Resistance
Short to
Voltage
Signal Performance
B3119 02
B3119 05
B3119 05
B3119 02
B3119 05
B3119 05
The driver door handle antenna is located in the driver door handle assembly and is used to establish low
frequency communications with the keyless entry transmitter. As a vehicle with locked doors is approached
with a keyless entry transmitter and the exterior door handle button is pressed, the keyless entry control module
communicates with the driver door handle keyless entry antenna.
The exterior driver door handle button is pressed within 15 min of last door closing.
B3119 02
The keyless entry control module detects a short to ground on the driver door keyless entry antenna signal
circuit.
B3119 05
The keyless entry control module detects a short to voltage or an open on the driver door keyless entry antenna
signal circuit.

Doors will not unlock/lock when the driver exterior door handle button is pressed.
A current DTC will clear when the conditions for setting the DTC are no longer present.
A history DTC will clear after 40 malfunction-free ignition cycles.
Schematic Reference
Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference

1. Ignition ON.
2. Verify DTC B3122, B3123, or B3124 is not set.
3. Refer to Circuit/System Testing.

1. Ignition OFF, disconnect the harness connector at the T10M Keyless Entry Antenna - Driver Door
Handle, ignition ON.
If 1 V or greater
1. Ignition OFF, disconnect the harness connector at the K84 Keyless Entry Control Module, ignition
ON.
If less than 1 V, replace the K84 Keyless Entry Control Module.
If less than 1 V
NOTE:
When using the MIN MAX function, autorange on the DMM may not
function properly. To ensure accurate test results, turn off autorange and
manually set the DMM range to 000.0 V.
3. Ignition OFF, install a DMM between the signal circuit terminal 1 and ground. Set the DMM to capture
DC voltage using the MIN MAX function. Turn off autorange and manually set the DMM range to 000.0
V.
4. Lock the vehicle doors using the keyless entry transmitter. Activate the antenna by pressing the exterior
door handle button.
5. Verify the MAX voltage captured by the DMM is greater than 1 V.
If 1 V or less
1. Ignition OFF, disconnect the harness connector at the K84 Keyless Entry Control Module.
If less than 2 ohms, replace the K84 Keyless Entry Control Module.
If greater than 1 V
If 1 V or greater
ON.
2. Test for less than 1 V between the low reference circuit and ground.
If less than 1 V

NOTE:
7. Install a DMM between the signal circuit terminal 1 and the low reference circuit terminal 2. Set the
DMM to capture DC voltage using the MIN MAX function. Turn off autorange and manually set the
DMM range to 000.0 V.
door handle button.
If 1 V or less
2. Test for infinite resistance between the low reference circuit and ground.
If greater than 1 V
10. Replace the T10M Keyless Entry Antenna - Driver Door Handle.
door handle button.
If DTC B3119 is set
Replace the K84 Keyless Entry Control Module.
13. All OK.
Repair Instructions
Front Side Door Outside Handle Bracket Replacement

Control Module References for keyless entry control module replacement, programming, and setup
DTC B3120

DTC Descriptors
DTC B3120
Keyless Entry Antenna 2 Short to Ground
DTC B3120
Keyless Entry Antenna 2 High Voltage/Open
Circuit
Signal - Passenger Door
Low Reference - Passenger
Door
Short to
Ground
Open/High
Resistance
Short to
Voltage
Signal Performance
B3120 02
B3120 05
B3120 05
B3120 02
B3120 05
B3120 05
The passenger front door handle antenna is located in the passenger front door handle assembly and is used to
establish low frequency communications with the keyless entry transmitter. As a vehicle with locked doors is
approached with a keyless entry transmitter and the exterior door handle button is pressed, the keyless entry
control module communicates with the passenger front door handle keyless entry antenna.
The exterior door handle button in the passenger front door handle is pressed within 15 min of the last change of
door ajar status for any door.
B3120 02
The keyless entry control module detects a short to ground on the passenger front door keyless entry antenna
signal circuit.
B3120 05
The keyless entry control module detects a short to B+ or an open on the passenger front door keyless entry
antenna signal circuit.

Doors will not unlock/unlock when the passenger exterior door handle button is pressed.
Schematic Reference
Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference

1. Ignition ON.

1. Ignition OFF, disconnect the harness connector at the T10N Keyless Entry Antenna - Passenger Door
Handle, ignition ON.
If 1 V or greater
ON.
If less than 1 V
NOTE:
V.
door handle button.
If 1 V or less
If greater than 1 V
If 1 V or greater
ON.
If less than 1 V

NOTE:
door handle button.
If 1 V or less
If greater than 1 V
10. Replace the T10N Keyless Entry Antenna - Passenger Door Handle.
door handle button.
If DTC B3120 is set
13. All OK.
Repair Instructions

DTC B3121

DTC Descriptors
DTC B3121
DTC B3121
Circuit
Signal - Rear Fascia
Low Reference - Rear
Fascia
Short to
Ground
Open/High
Resistance
Short to
Voltage
Signal Performance
B3121 02
B3121 05
B3121 05
B3121 02
B3121 05
B3121 05
The rear fascia antenna is located in the rear fascia assembly and is used to establish low frequency
communications with the keyless entry transmitter. As a vehicle with locked doors is approached with a keyless
entry transmitter and the exterior rear closure touch pad is pressed, the keyless entry control module
communicates with the rear fascia keyless entry antenna.
The rear closure touch pad is pressed.

The scan tool activates a device control function to simulate the above action.
B3121 02
The keyless entry control module detects a short to ground on the rear fascia keyless entry antenna signal
circuit.
B3121 05
The keyless entry control module detects a short to B+ or an open on the rear fascia keyless entry antenna signal
circuit.

Rear closure will not open when rear closure touch pad is pressed.
Schematic Reference
Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference

1. Ignition ON.

1. Ignition OFF, disconnect the harness connector at the T10G Keyless Entry Antenna - Rear Fascia,
ignition ON.
If 1 V or greater
ON.
If less than 1 V
NOTE:
V.
4. Lock the vehicle doors using the keyless entry transmitter. Activate the antenna by pressing the rear
closure touch pad.
If 1 V or less
If greater than 1 V
If 1 V or greater
ON.
If less than 1 V

NOTE:
closure touch pad.
If 1 V or less
If greater than 1 V
10. Replace the T10G Keyless Entry Antenna - Rear Fascia.
closure touch pad.
If DTC B3121 is set
13. All OK.
Repair Instructions
Ignition Lock Key Transmitter Antenna Replacement - Rear Bumper Fascia

DTC B3122

DTC Descriptors
DTC B3122
DTC B3122
Circuit
Signal - Center Console
Front
Low Reference - Center
Console Front
Short to
Ground
Open/High
Resistance
Short to
Voltage
Signal Performance
B3122 02
B3122 05
B3122 05
B3122 02
B3122 05
B3122 05
The front center console antenna is located in front of the center console assembly and is used to establish low
frequency communications with the keyless entry transmitter. When the driver attempts to change the ignition
status of the vehicle, the keyless entry control module communicates with the front center console antenna.
Pressing the ignition mode switch.

B3122 02
The keyless entry control module detects a short to ground on the front center console keyless entry antenna
signal circuit.
B3122 05
The keyless entry control module detects a short to B+ or an open on the front center console keyless entry

Vehicle will not detect the transmitter in some locations inside the vehicle. If the transmitter is not detected then
vehicle will not change ignition modes when ignition mode switch is pressed.
Schematic Reference
Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference

1. Ignition OFF, disconnect the harness connector at the T10J Keyless Entry Antenna - Center Console
Front, ignition ON.
If 1 V or greater
ON.


If less than 1 V
NOTE:
V.
4. Activate the antenna by pressing the ignition mode switch.
If 1 V or less
If greater than 1 V
If 1 V or greater
ON.
If less than 1 V
NOTE:
If 1 V or less

If greater than 1 V
10. Replace the T10J Keyless Entry Antenna - Center Console Front.
If DTC B3122 is set
13. All OK.
Repair Instructions
Ignition Lock Key Transmitter Antenna Replacement - Instrument Panel

DTC B3123
DTC Descriptors
DTC B3123
DTC B3123


Circuit
Signal - Center Console
Rear
Low Reference - Center
Console Rear
Short to
Ground
Open/High
Resistance
Short to
Voltage
Signal Performance
B3123 02
B3123 05
B3123 05
B3123 02
B3123 05
B3123 05
The rear center console antenna is located in rear of the center console assembly and is used to establish low
frequency communications with the keyless entry transmitter. When the driver attempts to change the ignition
status of the vehicle, the keyless entry control module communicates with the rear center console antenna.

B3123 02
The keyless entry control module detects a short to ground on the rear center console keyless entry antenna
signal circuit.
B3123 05
The keyless entry control module detects a short to B+ or an open on the rear center console keyless entry

Schematic Reference
Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference

1. Ignition OFF, disconnect the harness connector at the T10K Keyless Entry Antenna - Center Console
Rear, ignition ON.
If 1 V or greater
ON.
If less than 1 V
NOTE:
V.


If 1 V or less
If greater than 1 V
If 1 V or greater
ON.
If less than 1 V
NOTE:
If 1 V or less
If greater than 1 V
10. Replace the T10K Keyless Entry Antenna - Center Console Rear.


If DTC B3123 is set
13. All OK.
Repair Instructions
Ignition Lock Key Transmitter Antenna Replacement - Floor Console

DTC B3124
DTC Descriptors
DTC B3124
DTC B3124
Circuit
Keyless Entry Antenna Signal - Rear
Compartment
Keyless Entry Antenna Low
Reference - Rear Compartment
Short to
Ground
Open/High
Resistance
Short to
Voltage
Signal
Performance
B3124 02
B3124 05
B3124 05
B3124 02
B3124 05
B3124 05

The rear compartment antenna is located on the rear compartment floor near the seat back, centered, and is used
to establish low frequency communications with the keyless entry transmitter. When the driver attempts to
change the ignition status of the vehicle, the keyless entry control module communicates with the rear
compartment antenna.

B3124 02
The keyless entry control module detects a short to ground on the rear compartment keyless entry antenna
signal circuit.
B3124 05
The keyless entry control module detects a short to B+ or an open on the rear compartment keyless entry
Schematic Reference

Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference

1. Ignition OFF, disconnect the harness connector at the T10E Keyless Entry Antenna - Rear Compartment,
ignition ON.
If 1 V or greater
ON.
If less than 1 V
NOTE:
V.
If 1 V or less
If greater than 1 V

If 1 V or greater
ON.
If less than 1 V
NOTE:
If 1 V or less
If greater than 1 V
10. Replace the T10E Keyless Entry Antenna - Rear Compartment.
If DTC B3124 is set
13. All OK.
Repair Instructions

Ignition Lock Key Transmitter Antenna Replacement - Rear Compartment

SYMPTOMS - REMOTE FUNCTIONS

NOTE:
1. Perform Diagnostic System Check - Vehicle before using the Symptom Tables in order to verify that all
of the following are true:
2. Review the system operation in order to familiarize yourself with the system functions. Refer to Keyless
Entry System Description and Operation (without BTM), Keyless Entry System Description and
Operation (with BTM).
Inspect for aftermarket devices which could affect the operation of the Keyless Entry System. Refer to
cause the symptom.
Intermittent
Symptom List
No Remote Detected
Keyless Entry System Malfunction (Active), Keyless Entry System Malfunction (Passive)
Remote Vehicle Start Malfunction
NO REMOTE DETECTED

Circuit
Keyless Entry Antenna Signal Center Console Front
Reference - Center Console Front
Keyless Entry Antenna Signal Center Console Rear
Reference - Center Console Rear
Keyless Entry Antenna Signal - Rear
Compartment
Reference - Rear Compartment
Short to
Ground
Open/High
Resistance
Short to
Voltage
Signal
Performance
B3122 02
B3122 05
B3122 05
B3122 02
B3122 05
B3122 05
B3123 02
B3123 05
B3123 05
B3123 02
B3123 05
B3123 05
B3124 02
B3124 05
B3124 05
B3124 02
B3124 05
B3124 05
When a transmitter authentication is requested, the front console, rear console, and rear compartment antennas
simultaneously broadcast a challenge within the passenger compartment to the transmitter. If the response from
the transmitter via radio frequency (RF) is a valid response, the body control module (BCM) determines there is
a transmitter within the vehicle. If no response is received, the BCM determines that no transmitter is in the
vehicle, and NO REMOTE DETECTED will be displayed on the DIC.
Diagnostic Aids
A low transmitter battery or radio frequency (RF) interference from aftermarket devices such as 2-way radios,
power inverters, cellular phone chargers, computers, etc. may cause a system malfunction. High RF traffic
areas, such as gas stations which use pay-at-the-pump RF transponders, may also cause interference that could
lead to a malfunction.
Conditions caused by external influences such are these are considered to be normal. Following this diagnostic
will not diagnose an RF interference condition. If RF interference is suspected, question the customer about the
conditions or location where the NO REMOTE DETECTED condition occurs.
Schematic Reference


Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference

NOTE:
This condition may be caused by low vehicle battery voltage. If the battery is
not sufficiently charged (above 10 volts), the system will have difficulties
detecting the transmitter and the NO REMOTE DETECTED message will be
displayed. Correct the low battery voltage condition to eliminate this condition.
1. Verify that DTC B3119, B3120, B3121, B3122, B3123, or B3124 is not set.
2. Lock the vehicle using the keyless entry transmitter.
3. Verify that each door unlocks and opens by approaching the vehicle with a valid transmitter and operating
their respective exterior door handle button.
If both doors do not unlock/unlatch and open
Refer to Keyless Entry System Malfunction (Active), Keyless Entry System Malfunction
(Passive).
If both doors unlock/unlatch and open
4. Verify the vehicle starts with the transmitter located in the key pocket/slot.
If the vehicle does not start
Perform the Key with Integrated Transmitter Programming (with BTM) , Key with
Integrated Transmitter Programming (without BTM) procedure.
If the vehicle starts
5. Verify the NO REMOTE DETECTED message is not displayed on the DIC while attempting to start the
vehicle, placing the keyless entry transmitter in various locations within the vehicle interior at each start
attempt. The vehicle should start.

If the NO REMOTE DETECTED message is displayed at any time

Refer to Circuit/System Testing.
If the NO REMOTE DETECTED message is not displayed and the vehicle starts
6. Inspect for any sources of RF interference such as cell phone chargers, power supplies, etc. that would
interrupt transmitter and antenna communication. If inspection does not reveal any items causing RF
interference, discuss with the customer the conditions or location where the NO REMOTE DETECTED
condition occurs. Discuss any devices that are normally kept in the vehicle, such as a laptop or cell phone
charger, which may have been removed when the vehicle was brought in for service. It may be necessary
to explain to the customer how RF interference degrades the performance of the system.
NOTE:
To determine the appropriate T10 Keyless Entry Antenna to disconnect

and diagnose, place the transmitter in various location within the vehicle's
interior and attempt to start. The location of the transmitter when the NO
REMOTE DETECTED message occurs will correspond with the T10
Keyless Entry Antenna that requires diagnosis.
1. Ignition OFF, disconnect the harness connector at the appropriate T10 Keyless Entry Antenna, ignition
ON.
If 1 V or greater
ON.
If less than 1 V
NOTE:
DC voltage using the MIN MAX function.
If 1 V or less

If greater than 1 V
If 1 V or greater
ON.
If less than 1 V
NOTE:
DMM to capture DC voltage using the MIN MAX function.
If 1 V or less
If greater than 1 V
10. Replace the appropriate T10 Keyless Entry Antenna.
12. Verify the NO REMOTE DETECTED message is not displayed and the vehicle starts.
If the NO REMOTE DETECTED message is displayed and the vehicle does not start
If the NO REMOTE DETECTED message is not displayed and the vehicle starts
13. All OK.

Repair Instructions

KEYLESS ENTRY SYSTEM MALFUNCTION (ACTIVE)

The keyless entry transmitter is part of the vehicle key. The keyless entry system will unlock the vehicle doors
or open/unlock the rear compartment when a corresponding button on the keyless entry transmitter is pressed.
This is accomplished by the keyless entry transmitter sending a radio frequency to the remote control door lock
receiver, which then sends the signal to the body control module (BCM). The BCM interprets the signal and
activates the requested function. A low transmitter battery or radio frequency (RF) interference from
aftermarket devices such as 2-way radios, power inverters, cellular phone chargers, computers, etc. may cause a
system malfunction. High RF traffic areas, such as gas stations which use pay-at-the-pump RF transponders,
may also cause interference that could lead to a malfunction.
Diagnostic Aids
Unwanted or inadvertent door lock/unlock activation may be requested by the OnStar Remote Link app.
It is possible that a customer may be unaware of account usage, result in an unwanted or phantom door
lock/unlock. If normal system diagnosis does results in an inability to verify the customer's concern,
contact Technical Assistance Center (TAC).
If available, the EL 43241 Keyless Entry Tester may be used to diagnose a low transmitter battery or a
malfunctioning transmitter. To test, place the transmitter on the test pad of the EL 43241 and press each
transmitter button one at a time, holding each button for three seconds. If the green light on the tester does
not illuminate and a tone does not sound, first replace the transmitter battery and retest. If the malfunction
continues after replacing the transmitter battery, replace the transmitter.
When using the EL 43241 Keyless Entry Tester, first inspect the keyless entry transmitter part number to
determine that it is the correct model for the vehicle. An incorrect part number transmitter may pass the
test, but it will not activate the keyless entry system.
When the vehicle key is in the ignition, the keyless entry functions are disabled from all keyless entry
transmitters.

Schematic Reference
Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference

Special Tools
EL 43241 Keyless Entry Tester
1. Verify that the vehicle key is correct for the vehicle. This can be accomplished by comparing the part
number printed on the key to the appropriate part number in the parts catalog.
If the vehicle key is incorrect
Replace the vehicle key.
If the vehicle key is correct
2. Operate the transmitter while observing the scan tool Key Fob Function parameter for the appropriate
transmitter.
3. Verify the scan tool Key Fob Function parameter corresponds with the function selected on the
transmitter.
If the Key Fob Function parameter does not correspond with the transmitter selection
NOTE:
Before replacing the transmitter, inspect the transmitter battery

contacts for any corrosion or damage. If no corrosion or damage is

found, replace the transmitter battery and retest before replacing the
transmitter.
1. Replace the vehicle key.
2. Operate the new transmitter while observing the scan tool Key Fob Function parameter for the
transmitter.
3. Verify the scan tool Key Fob Function parameter correspond with the function selected on the
transmitter.
If the Key Fob Function parameter does not correspond with the transmitter selection, replace
the K9 Body Control Module
If the Key Fob Function parameter corresponds with the transmitter selection
4. All OK.
If the Key Fob Function parameter corresponds with the transmitter selection
4. All OK.
Repair Instructions
Control Module References for body control module replacement, programming, and setup
KEYLESS ENTRY SYSTEM MALFUNCTION (PASSIVE)

Circuit
Signal - Driver Door
Low Reference - Driver
Door
Signal - Passenger Door
Low Reference - Passenger
Short to
Ground
Open/High
Resistance
Short to
Voltage
Signal Performance
B3119 02
B3119 05
B3119 05
B3119 02
B3119 05
B3119 05
B3120 02
B3120 05
B3120 05
B3120 02
B3120 05
B3120 05

Door
Signal - Rear Fascia
Low Reference - Rear
Fascia
B3121 02
B3121 05
B3121 05
B3121 02
B3121 05
B3121 05
The keyless entry antennas are used as short range low frequency transmitters. As a vehicle with locked doors is
approached with a keyless entry transmitter and the exterior door handle button/rear closure touch pad is
pressed, the keyless entry antenna broadcasts a challenge to the transmitter in an approximate one meter range.
If the response from the transmitter via radio frequency (RF) is valid, the locked door will be passively
unlocked/unlatched and allow the door to be opened. A low transmitter battery or radio frequency (RF)
interference from aftermarket devices such as 2-way radios, power inverters, cellular phone chargers,
computers, etc. may cause a system malfunction. High RF traffic areas, such as gas stations which use pay-atthe-pump RF transponders, may also cause interference that could lead to a malfunction.
Diagnostic Aids
Unwanted or inadvertent door lock/unlock activation may be requested by the OnStar Remote Link app. It is
possible that a customer may be unaware of account usage, result in an unwanted or phantom door lock/unlock.
If normal system diagnosis does results in an inability to verify the customer's concern, contact Technical
Assistance Center (TAC).
Schematic Reference
Circuit Testing
Connector Repairs
Wiring Repairs

Scan Tool Reference

1. Ignition ON.
3. Verify that the vehicle key is correct for the vehicle. This can be accomplished by comparing the part
number printed on the key to the appropriate part number in the parts catalog.
If the vehicle key is incorrect
Replace the vehicle key.

If the vehicle key is correct
4. Verify the scan tool Exterior Driver Door Handle Switch, Exterior Passenger Door Handle Switch, and
Trunk Lid Exterior Unlatch Switch parameters change between Active and Inactive while operating their
respective exterior door handle button/rear closure touch pad.
If any of the parameters does not change
Refer to Exterior Door Handle Switch Malfunction .

If all of the parameters change
6. Verify that each door and the rear compartment unlocks and opens by approaching the vehicle with a
valid transmitter and operating their respective exterior door handle button/rear closure touch pad.
If both doors and the rear compartment do not unlock/unlatch and open
Refer to Passive Transmitter Malfunction in Circuit/System Testing below.
If only one door or the rear compartment does not unlock/unlatch and open
Refer to Antenna Circuit Malfunction in Circuit/System Testing below.
If both doors and the rear compartment unlocks/unlatches and opens

7. All OK.
Passive Transmitter Malfunction


2. Verify that each door and rear compartment unlocks and opens by approaching the vehicle with a valid
transmitter and operating their exterior door handle button/rear closure touch pad.
If both doors and the rear compartment do not unlock/unlatch and open
1. Replace the transmitter battery.
3. Verify that each door and rear compartment unlocks and opens by approaching the vehicle with a
valid transmitter and operating their respective release handle/touch pad.
If both doors and the rear compartment do not unlock/unlatch and open, replace the vehicle
key.
If both doors and the rear compartment unlock/unlatch and open
4. All OK.
If both doors and the rear compartment unlock/unlatch and open
3. The concern may be caused by temporary RF interference. Discuss the conditions in which the concern
occurs with the customer. RF interference from aftermarket devices such as 2-way radios, power
inverters, cellular phone chargers, computers, etc. may cause a system malfunction. High RF traffic areas,
such as gas stations which use pay-at-the-pump RF transponders, may also cause interference that could
lead to a malfunction.
Antenna Circuit Malfunction
1. Ignition OFF, disconnect the harness connector at the inoperative T10 Keyless Entry Antenna, ignition
ON.
If 1 V or greater
ON.
If less than 1 V
NOTE:
V.
4. Lock the vehicle doors using the keyless entry transmitter. Activate the antenna by operating the
appropriate exterior door handle button/rear closure touch pad.

If 1 V or less
If greater than 1 V
If 1 V or greater
ON.
If less than 1 V
NOTE:
If 1 V or less
If greater than 1V
10. Replace the appropriate T10 Keyless Entry Antenna.

12. Verify that the door/rear compartment unlocks and opens when the exterior door handle button/rear
closure touch pad is operated.
If the door/rear compartment does not unlock and open
If the door/rear compartment unlocks and opens
13. All OK.
Repair Instructions
REMOTE VEHICLE START MALFUNCTION

Review Strategy Based Diagnosis for an overview of each diagnostic approach.
Remote vehicle start begins as an radio frequency message received by the body control module (BCM) from a
keyless entry transmitter. The BCM monitors system conditions such as content theft deterrent, hood ajar status,
and body DTCs to determine if a remote vehicle start event will occur. If conditions are determined to be
acceptable, the remote vehicle start message is sent to the Engine Control Module (ECM). The ECM monitors
system conditions such as engine control parameters and vehicle theft deterrent to determine if engine starting
will be allowed. If conditions are acceptable, the ECM will initiate engine starting. During the engine run time
in a remote vehicle start attempt, before the operator enters the vehicle, the ECM may discontinue engine
operation if system conditions require it or a message is received from the BCM requesting the engine be turned
OFF.
Diagnostic Aids
Unwanted or inadvertent door lock/unlock activation may be requested by the OnStar Remote Link app.
It is possible that a customer may be unaware of account usage, result in an unwanted or phantom door
lock/unlock. If normal system diagnosis does results in an inability to verify the customer's concern,
contact Technical Assistance Center (TAC).
If the vehicle has a current DTC that illuminates the malfunction indicator lamp (MIL), the cause of the

DTC must be diagnosed before proceeding with the Remote Vehicle Start Inoperative diagnostic.
The remote vehicle start system will not operate if any of the following conditions are present:
A current vehicle DTC that illuminates the malfunction indicator lamp (MIL)
The vehicle is in valet mode.
More than 2 remote starts have been attempted.
The hazard switch is in the ON position.
A current hazard switch DTC is set.
The vehicle hood is ajar.
A current hood ajar DTC is set.
Incorrect BCM software is installed and vehicle start is not enabled.
The content theft deterrent system detects an alarm trigger.
Excessive engine RPM
Excessive coolant temperature
Accelerator pedal position greater than 0 percent
Vehicle not in park
Vehicle theft deterrent malfunction
A current automatic transmission shift lock control system DTC is set.
A vehicle speed sensor signal is detected by the ECM.
Schematic Reference
Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference


1. Verify that the keyless entry functions operate with all available keyless entry transmitters.
If any keyless entry functions do not operate properly
Refer to Keyless Entry System Malfunction (Active), Keyless Entry System Malfunction
(Passive).
If all keyless entry functions operate properly
2. Verify that no Diagnostic Status History or Start Disable items are present in the scan tool BCM Remote
Start Diagnostic Status History and the ECM Remote Vehicle Start Disable History parameters.
If remote vehicle start disable history items are present
Refer to the appropriate subsection in which the malfunction occurred.

If remote vehicle start disable history items are not present
3. Verify all scan tool BCM Content Theft Trigger History parameters display None.
If any BCM Content Theft Trigger History parameter does not display None
Refer to Content Theft Deterrent Malfunction .

If all BCM Content Theft Trigger History parameters display None
4. All OK.
REPAIR INSTRUCTIONS
IGNITION LOCK KEY TRANSMITTER ANTENNA REPLACEMENT - INSTRUMENT PANEL

Fig. 5: Ignition Lock Key Transmitter Antenna - Instrument Panel

Callout
Component Name
Remove the instrument panel lower trim panel. Refer to Instrument Panel Lower Trim Panel
Replacement - Left Side .
Ignition Lock Key Transmitter Antenna - Instrument Panel
1
Procedure
1. To access the antenna remove the air duct.
IGNITION LOCK KEY TRANSMITTER ANTENNA REPLACEMENT - FLOOR CONSOLE

Fig. 6: Ignition Lock Key Transmitter Antenna

Callout
Component Name
Remove the Front Floor Console Rear Cover. Refer to Front Floor Console Rear Cover Replacement .
Ignition Lock Key Transmitter Antenna
1
Procedure
Disconnect the electrical connection.
IGNITION LOCK KEY TRANSMITTER ANTENNA REPLACEMENT - REAR COMPARTMENT

Fig. 7: Ignition Lock Key Transmitter Antenna - Rear Compartment

Callout
Component Name
Ignition Lock Key Transmitter Antenna - Rear Compartment
1
Procedure
1. Remove the rear compartment floor panel carpet.
IGNITION LOCK KEY TRANSMITTER ANTENNA REPLACEMENT - REAR BUMPER FASCIA

Fig. 8: Ignition Lock Key Transmitter Antenna - Rear Bumper Fascia

Callout
Component Name
Remove the rear bumper fascia. Refer to Rear Bumper Fascia Replacement .
Ignition Lock Key Transmitter Antenna Fastener
1
CAUTION:
Ignition Lock Key Transmitter Antenna - Rear Bumper Fascia

Procedure
IGNITION LOCK KEY TRANSMITTER ANTENNA BRACKET REPLACEMENT

Fig. 9: Ignition Lock Key Transmitter Antenna Bracket

Ignition Lock Key Transmitter Antenna Bracket Replacement
Callout
Component Name
Remove the ignition lock key transmitter antenna - rear compartment. Refer to Ignition Lock Key
Transmitter Antenna Replacement - Rear Compartment.
Ignition Lock Key Transmitter Antenna Bracket
Procedure
1
1. Use a suitable tool to release the bracket.

2. Remove double sided tape and clean surfaces using a appropriate
solvent. When installing the bracket, apply new double sided
tape. Press in place until secure.
KEYLESS ENTRY CONTROL MODULE REPLACEMENT

Fig. 10: Keyless Entry Control Module

Keyless Entry Control Module Replacement
Callout
Component Name
1. Remove the right instrument panel insulator panel. Refer to Instrument Panel Insulator Panel
Replacement - Right Side .
2. Remove the front side door sill trim plate. Refer Front Side Door Sill Trim Plate Replacement .
Keyless Entry Control Module
Procedure
1
2. For programming and setup information refer to Control Module
References .
KEYLESS ENTRY CONTROL MODULE BRACKET REPLACEMENT

Fig. 11: Keyless Entry Control Module Bracket

Keyless Entry Control Module Bracket Replacement
Callout
Component Name
Remove the keyless entry control module. Refer to Keyless Entry Control Module Replacement.
Keyless Entry Control Module Bracket
1
Procedure
Use a suitable tool to release the bracket.
REMOTE CONTROL DOOR LOCK RECEIVER REPLACEMENT

Fig. 12: Remote Control Door Lock Receiver

Remote Control Door Lock Receiver Replacement
Callout
Component Name
Remove the inside rearview mirror mount plate cover. Refer to Inside Rearview Mirror Mount Plate
Cover Replacement .
1
Procedure
1. Disconnect wiring connector.
2. Remove from bracket.

KEYLESS ENTRY SYSTEM DESCRIPTION AND OPERATION (WITHOUT BTM)
The keyless entry system is a vehicle entry device. The keyless entry system is used in conjunction with the
door locks to unlock the vehicle. Keyless entry will lock/unlock the vehicle doors or open the rear compartment
lid when a corresponding button on the keyless entry transmitter is pressed. This is accomplished by the
transmitter sending a radio frequency to the Remote Control Door Lock Receiver antenna that has a direct link
to the Body Control Module (BCM). The BCM interprets the signal and activates the requested function or
request the appropriate control module to activate the function via a serial data message. A low transmitter

battery or radio frequency interference from aftermarket devices, such as 2-way radios, power inverters,
computers, etc., may cause a system malfunction. High radio frequency traffic areas, such as gas stations that
use pay-at-the-pump radio frequency transponders, may also cause interference that could lead to a malfunction.
Keyless entry allows you to operate the following features:
Door lock/unlock
Liftgate lock/unlock, if equipped
Trunk release, if equipped
Power liftgate, if equipped
Vehicle locator/Panic alarm
Remote vehicle starting, if equipped
The keyless entry system has the following components:
Keyless entry transmitters

Body Control Module
NOTE:
When the vehicle key is in the ignition, keyless entry functions from all keyless
entry transmitter are disabled.
The keyless entry transmitters are used to perform various entry functions while away from the immediate are
of the vehicle. Keyless entry functions may work at up to 20 m (65 ft) away from the vehicle. Ambient
conditions may affect the performance of the keyless entry transmitter and reduce the range at which keyless
entry functions operate. Up to eight transmitters may be programmed to a single vehicle. The keyless entry
transmitter is an integral part of the vehicle key.
OnStar Remote Link (if equipped)
A vehicle operator may have the ability to perform some of the keyless entry functions using applications on
personal devices such as a smart phone. Unwanted or inadvertent door lock/unlock activation may be requested
by the OnStar Remote Link app. It is possible that a customer may be unaware of account usage, result in an
unwanted or phantom door lock/unlock. If normal system diagnosis does results in an inability to verify the
customer's concern, contact Technical Assistance Center (TAC).
The BCM is a multifunction module that operates the keyless entry system. When an radio frequency message
is received from a keyless entry transmitter, the BCM interprets this signal and performs the specific function,
i.e. door lock, door unlock, or vehicle locate.
The Remote Control Door Lock Receiver acts as an antenna for the keyless entry system and communicates

with the BCM through a dedicated serial data link. When a button is pressed on a keyless entry transmitter, the
Remote Control Door Lock Receiver receives this signal and sends the request to the BCM. The BCM interprets
the signal and performs the specific function, i.e. door lock, door unlock, or vehicle locate.
Unlock Doors
Momentarily press the transmitter UNLOCK button in order to perform the following functions:
Unlock only the driver door or all doors and liftgate (if equipped); this is customized through the DIC.
Illuminate the interior lamps for a determined length of time or until the ignition is turned ON.
Flash the exterior lights; this is customized through the DIC.
Disarm the content theft deterrent system, if equipped.
Deactivate the content theft deterrent system when in the alarm mode.
Lock All Doors
Press the transmitter LOCK button to perform the following functions:
Lock all vehicle doors.

Immediately turn OFF the interior lamps.
Flash the exterior lights and/or sound the horn; this is customized through the DIC.
Arm the content theft deterrent system.
Trunk Release, if equipped
Press the trunk release button on the transmitter to open the trunk.
Power Liftgate, if equipped
Press and hold the power liftgate button to perform the following functions:
Open or close the liftgate using the power liftgate function.

Flash the tail lamps.
Sound the interior power liftgate chime.
Vehicle Locator/Panic Alarm
A single press of the panic button performs the following functions. Some functions may be dependent on
personalization settings:
Pulse the horn three times.

Flash the exterior lamps three times.
A press and hold of the panic button performs the following functions:

Illuminate the interior lamps.

Pulse the horn and flash the exterior lamps for 30 seconds or until the following conditions occur:
The panic button is pressed.
The ignition switch is turned to the RUN position with a valid key.
Remote Vehicle Start, if equipped
The remote vehicle start function allows engine starting while not in the vehicle. It also allows the vehicle
HVAC system and other vehicle systems to enable, providing a comfortable vehicle upon entry. The remote
vehicle start sequence begins by pressing and releasing the lock button and then pressing and holding the
remote vehicle start buttons on the keyless entry transmitter. The turn signal lamps will illuminate to indicate
the vehicle has received the remote start request. Each time an remote vehicle start is performed, the vehicle
doors are locked, however they may then be unlocked/locked with the transmitter or vehicle key at any time.
Once activated, the engine is allowed to run for 10 minutes. The remote vehicle start time may be extended by
an additional 10 minutes by again pressing and releasing the lock button and then pressing and holding the
remote vehicle start buttons on the transmitter. This feature is called a remote vehicle start continue and allows
a maximum of 20 minutes of engine running. If the remote vehicle start continue is performed at seven minutes
into the initial 10 minute time-out, a total of 17 minutes of engine running would occur. The remote vehicle
start event may be suspended at any time by pressing only the remote vehicle start button on the transmitter or
by entering the vehicle and pressing the hazard lamp switch.
In between ignition cycles, only two remote vehicle start events may occur or be attempted. Once two events or
attempts have been made, future remote vehicle start events will be suspended until the vehicle is started using
the ignition.
Enable/Disable Remote Vehicle Start
Using the driver information center, remote vehicle start may be enabled or disabled as a part of vehicle
personalization. Refer to the vehicle owners manual for more information.
Hood Ajar Switch
The hood switch provides status of the hood to the BCM for remote vehicle start purposes. The switch is
integrated into the hood latch assembly.
Remote Vehicle Start Circuit Description
The BCM receives a signal from the keyless entry transmitter indicating a remote vehicle start request. A
message is then sent to the BCM which determines if a crank request message will be sent to the ECM to allow
engine starting. To determine if conditions are correct for an remote vehicle start event, the BCM will ensure
A valid hood ajar switch closed signal is present.

The doors are locked.
The hazard switch is OFF.
The vehicle power mode is correct.

No content theft deterrent alarm triggers are present.
When the BCM determines all conditions meet those required for an remote vehicle start event, a message is
sent via serial data to the ECM. The ECM relies on the remote vehicle start message from BCM to enable
remote vehicle start when the crank request signal is received. If the ECM does not receive a valid remote
vehicle start message, it will not attempt to start the engine. While the ECM is in remote vehicle start mode it
will suspend engine operation if any of the following additional conditions occur:
Vehicle speed is greater than 0.

Transmission is not in PARK.
Excessive engine coolant temperature
Low oil pressure
The malfunction indicator lamp (MIL) is commanded ON.
Engine crank time is greater than 30 seconds.
Excessive engine speed
Accelerator pedal position too high
Remote start timer equals 0.
Immobilizer system indicates tamper
Keyless Entry Personalization
Vehicle lock/unlock functions and remote vehicle start remote vehicle start settings may be personalized. For
functional descriptions and personalization instructions, refer to the vehicle owners manual.
KEYLESS ENTRY SYSTEM DESCRIPTION AND OPERATION (WITH BTM)
NO TITLE

Fig. 13: Keyless Entry System Description And Operation Diagram (With BTM)
Solid line - Hard Wire I/O
Dash line - Serial Data
K9
K77
T10
15
With RPO ATH
A23D
A23LR
A23P
A23RR
K84
T10G
T10M
T10N
With RPO BTM
T10E
T10J
T10K

Keyless Entry Transmitter
Door Latch - Driver
Door Latch - Left Rear
Door Latch - Passenger
Door Latch - Right Rear
Keyless Entry Antenna - Rear Fascia
Keyless Entry Antenna - Driver Door Handle
Keyless Entry Antenna - Passenger Door Handle
Keyless Entry Antenna - Rear Compartment
Keyless Entry Antenna - Center Console Front
Keyless Entry Antenna - Center Console Rear
Keyless Entry System Description and Operation - Active

The keyless entry system is a vehicle entry device. The keyless entry system is used in conjunction with the
door locks to unlock the vehicle. Keyless entry will lock/unlock a door or open the rear compartment lid when a
corresponding button on the keyless entry transmitter is pressed. This is accomplished by the transmitter
sending a radio frequency to the remote control door lock receiver antenna that has a direct link to the body
control module (BCM). The BCM interprets the signal and activates the requested function or request the
appropriate ECU to activate the function via a serial data message. A low transmitter battery or radio frequency
interference from aftermarket devices, such as 2-way radios, power inverters, computers, etc., may cause a
system malfunction. High radio frequency traffic areas, such as gas stations that use pay-at-the-pump radio
frequency transponders, may also cause interference that could lead to a malfunction. Keyless entry allows you
to operate the following features:
Door lock/unlock
Rear compartment lid release
Illuminated entry lamps
Panic alarm/Vehicle locator
Remote vehicle start
Automatic window express down, if equipped. Automatic window express up, if equipped
Keyless Entry System Description and Operation - Passive

Passive keyless entry allows entry to a locked vehicle without pressing any buttons on the keyless entry
transmitter. You must only have the transmitter with you. The passive entry system use low frequency antennas
in several different areas on the vehicle to determine the location of the transmitter. When passively opening a
locked door or the rear compartment, you must have a programmed transmitter with you in your pocket, purse,
or briefcase within a one meter range.
When an exterior door handle button is pressed or the rear compartment touch pad is pressed, the low frequency
antenna sends out a challenge to the keyless entry transmitter. Because of the low frequency, communication
range is limited. The antenna will emit the challenge in a one meter range. The transmitter must be within this
range to receive the challenge. The transmitter receives this challenge and emits it's response as an RF message,
which is received by the remote control door lock receiver. If the response is correct, entry into the vehicle will
be allowed.
As a customer convenience feature, the keyless entry system will notify the driver if the transmitter has been
left in the vehicle after exiting by chirping the vehicle horn three times. This may be turned off using vehicle
personalization. Also, if the transmitter is left in the vehicle after the central door lock switch has been used to
lock the vehicle, the driver door will remain unlock after exiting the vehicle. This is intended to prevent locking
the transmitter in the vehicle and being unable to access it.
Keyless Entry System Description and Operation - Keyless Start
The keyless start portion of the keyless entry system allows vehicle starting, having only the transmitter as your
key. The keyless start system use low frequency antennas in three different locations on the vehicle to determine
the location of the transmitter. Multiple antenna are used to ensure complete coverage of the vehicle interior and
rear compartment. When using the keyless start system, a programmed transmitter must be in the vehicle's
interior, in the driver's pocket, purse, or briefcase.

When the ignition mode switch is pressed, the low frequency antennas emit a challenge to the keyless entry
transmitter. The transmitter receives this challenge and emits it's response as an RF message, which is received
by the remote control door lock receiver. If the response is correct, vehicle starting will be allowed. If RF
communication is interrupted, a "No Remote Detected" message will be displayed on the DIC. In these cases,
the transmitter can be placed in the transmitter pocket located in the center console, under the cupholder. The
immobilizer antenna coil is located directly beneath the transmitter pocket. Placing the transmitter in the pocket
will create a low powered coupling between the transmitter and immobilizer antenna, allowing communications
to occur and enabling vehicle starting.
The keyless entry system has the following components:
Keyless entry integrated key/transmitter

Driver and front passenger door antennas (part of the door handle assembly)
Driver and front passenger door handle switches (part of the door handle assembly)
Rear fascia antenna
Front console antenna
Rear console antenna
Trunk antenna (rear compartment)
Keyless entry control module
Immobilizer antenna coil assembly
Remote control door lock receiver
By operating any of the exterior door handle buttons, a nearby transmitter is challenged by a keyless entry
antenna. The transmitter will send an RF response to the remote control door lock receive, which communicates
with the BCM. The BCM will interpret this communication and either allow entry into the vehicle or deny it.
Door Antennas
The keyless entry door antennas are used to transmit low frequency communications to the keyless entry
transmitters.
The keyless entry door antennas are located in the left front and right front exterior door handle bracket. The
antennas are serviced as part of the door handle assembly. The antennas are controlled by the keyless entry
control module. When the exterior door handle button is pressed, the respective antenna will send out a
challenge to the keyless entry transmitter, which begins the passive entry communications.
Rear Fascia Antenna
The rear fascia antenna is used to transmit low frequency communication to the keyless entry transmitters for
entry to rear compartment.
The rear fascia antenna is located behind the rear fascia. The antenna is controlled by the keyless entry control

module. When the rear compartment touch pad is pressed, the antenna sends out a challenge to the keyless entry
transmitter, which begins the passive entry communications.
Front Console Passive (Instrument Panel) Antenna
This antenna is located in the lower instrument panel near the front of the center console.
The front console antenna is used for vehicle starting functions. When the ignition mode switch is pressed, the
antenna is energized or "pinged". This emits a low frequency challenge signal that is received by the keyless
entry transmitter. The transmitter will then reply to this challenge with a response and, if correct, vehicle
starting will occur.
Rear Console Antenna
This antenna is located in the rear of the center console.

The rear console antenna is used for vehicle starting functions. When the ignition mode switch is pressed, the
antenna is energized or "pinged". This emits a low frequency challenge signal that is received by the keyless
Rear Compartment Antenna
This antenna is located in the center of the rear compartment metal floor pan, near the seatback.
The rear compartment antenna is used for vehicle starting functions. When the ignition mode switch is pressed,
the antenna is energized or "pinged". This emits a low frequency challenge signal that is received by the keyless
Immobilizer Antenna Coil Assembly
The immobilizer coil assembly is located in the center console, directly beneath the transmitter pocket. If the
transmitter battery is dead, weak, or the RF signal is being interrupted, the transmitter may be placed in the
pocket to create a low powered coupling between the transmitter and immobilizer antenna, allowing
communications to occur and enabling vehicle starting.
The immobilizer antenna coil is controlled by the BCM. The immobilizer control module is also active when
learning vehicle keys.
The keyless entry control module is a multi-function module which performs the following keyless entry system
functions:
Activating vehicle antennas for passive keyless entry functions

Activating vehicle antennas for keyless start functions
Backup control for the ECM accessory wakeup and the run/crank relay

If equipped, controls the electronic steering column lock

Receiver of the exterior door handle switch inputs and door open switch (not the door ajar switch)
Ignition mode switch monitoring
OnStar Remote Link (if equipped)
A vehicle operator may have the ability to perform some of the keyless entry functions using applications on
personal devices such as but not limited to smart phones. A condition may appear as if there is a malfunction in
the vehicle. If it is suspected that this may be the case contact Technical Assistance if a condition cannot be
determined through normal vehicle diagnostics.
The BCM is a multi-function module that performs the following functions:
Receive and authenticate active transmitter and keyless start signals from the remote control door lock
receiver
Determines the functionality requested by the transmitter signal
Performs the function requested by the transmitter signal
Unlock Driver Door Only - Active
Momentarily press the transmitter UNLOCK button in order to perform the following functions:
Unlock only the driver door

Illuminate the interior lamps for a determined length of time, or until the ignition is turned ON
Flash the exterior lights, if enable through personalization
Disarm the Content Theft Deterrent (CTD) system
Deactivate the CTD system when in the alarm mode
Unlock All Doors - Second Operation - Active
Momentarily press the transmitter UNLOCK button a second time, within 5 seconds of the first press, to
perform the following function:
Unlock the remaining doors
Unlock Driver Door Only - Passive
If enabled through personalization, approach the driver door with a valid keyless entry transmitter and press the
door handle button to perform the following functions:
Unlock and open only the driver door

Disarm the CTD system, if equipped

Unlock All Doors - Passive
Approach any non driver door (front or rear) or, if enabled through personalization, the driver door with a valid
keyless entry transmitter and press the door handle button to perform the following functions:
Unlock all vehicle doors

Disarm the CTD system, if equipped
Lock All Doors - Active
Press the transmitter LOCK button to perform the following functions:
Lock all vehicle doors

Immediately turn off the interior lamps
Flash the exterior lights, if enabled through personalization
Chirp the horn, if enabled through personalization
Arm the CTD system
Lock All Doors - Passive
Exit the vehicle (with ignition off) with the keyless entry transmitter to automatically perform the following
functions, if equipped.
Lock all vehicle doors after a delay

Flash the exterior lights, if enabled through personalization
Chirp horn, if enabled through personalization
Arm the CTD system
When all doors are closed, they can also be locked from the exterior by pressing a front door handle button
while having a valid transmitter within range.
If more than one keyless entry transmitter is within a vehicle and the Keyless Entry System detects that one or
more transmitters have been left in the vehicle after vehicle is locked, any transmitter left within the vehicle will
be temporarily deactivated until:
A button on the deactivated key fob is pressed (will only activate the fob whose button is pressed)
A passive unlock of vehicle occurs
Change in power mode occurs
Rear Compartment Lid Release - Active
If the vehicle transaxle is in PARK or NEUTRAL and the ignition is in the OFF position, a single press of the
transmitter rear compartment release button will open the rear compartment lid.

Rear Compartment Lid Release - Passive
Approach the rear of the vehicle with a valid keyless entry transmitter. Press the rear compartment lid release
touch pad. The rear compartment lid will open.
If vehicle is not equipped with trunk antenna, a keyless entry transmitter left inside the truck will allow the
trunk to be reopened at any time. This feature will not allow a customer to lock the transmitter in the trunk.
If vehicle has a trunk antenna and one or more transmitters are left in the trunk or interior of the vehicle, those
transmitter(s) will be deactivated when the vehicle becomes locked.
Vehicle Locator/Panic Alarm/Active
A single press of the panic button performs the following functions. Some functions may be dependent on
personalization settings:
Pulses the horn three times

Flashes the exterior lamps three times
Pulses the horn and flashes the parking lamps for 30 second or until the following conditions occur:
The panic button is pressed
The ignition switch is turned to the RUN position with a valid key
Remote Vehicle Start/Active
The remote vehicle start function allows engine starting while not in the vehicle. It also allows the vehicle
HVAC system and other vehicle systems to enable, providing a comfortable vehicle upon entry. Remote vehicle
start functions have an operating range of up to 195 feet, depending on conditions. The remote vehicle start
sequence begins by pressing and releasing the lock button and then pressing and holding the remote vehicle
start buttons on the keyless entry transmitter. The turn signal lamps will illuminate to indicate the vehicle has
received the remote start request. Each time a remote vehicle start is performed, the vehicle doors are locked,
however they may then be unlocked/locked with the transmitter or vehicle key at any time. Once activated, the
engine is allowed to run for 10 minutes. The remote vehicle start time may be extended by an additional 10
minute by again pressing and releasing the lock button and then pressing and holding the remote vehicle start
buttons on the transmitter. This feature is called a remote vehicle start continue and allows a maximum of 20
minutes of engine running. If the remote vehicle start continue is performed at 7 minutes into the initial 10
minute time-out, a total of 17 minutes of engine running would occur. The remote vehicle start event may be
suspended at any time by pressing only the remote vehicle start button on the transmitter or by entering the
vehicle and turning ON the hazard lamps.
In between ignition cycles, only two remote vehicle start events may occur or be attempted. Once two events or
attempts have been made, future remote vehicle start events will be suspended until the vehicle is started using
the ignition.

Enable/Disable Remote Vehicle Start/Active
Using the driver information center, remote vehicle start may be enabled or disabled as a part of vehicle
personalization. Refer to the vehicle owners manual for more information.
Hood Ajar Switch/Active
The hood switch provides status of the hood to the BCM for remote vehicle start purposes. The switch is
integrated into the hood latch assembly. The hood ajar switch provides 2 separate inputs to the BCM. These
separate inputs allow the BCM to actively monitor for a hood ajar switch fault.
Remote Vehicle Start Circuit Description/Active
The BCM receives a signal from the keyless entry transmitter indicating a remote vehicle start request. The
BCM uses the following inputs to verify the system is ready for a remote vehicle start event:
Vehicle is not in valet mode

All vehicle doors are closed
Rear compartment lid is not ajar
The hood is closed
The doors are locked
The hazard switch is OFF
Battery reconnect has not occurred
Vehicle power mode is correct.
When the BCM determines all conditions meet those required for an remote vehicle start event, a message is
sent via serial data to the ECM. The ECM relies on the remote vehicle start message from the BCM to enable
remote vehicle start when the crank request signal is received. If the ECM does not receive a valid remote
vehicle start message, it will not ground the control circuit of the crank relay and start the engine. While the
ECM is in remote vehicle start mode it will cut fuel to the engine if any of the following additional conditions
occur:
Vehicle speed is greater than 0.

Transmission is not in P.
Excessive engine coolant temperature
Low oil pressure
The malfunction indicator lamp (MIL) is commanded ON.
Engine crank time is greater than 30 seconds.
Excessive engine speed.
Accelerator pedal position too high.
Remote start timer equals 0.
Immobilizer system indicates a theft attempt
Keyless Entry Personalization

Vehicle lock/unlock functions and remote vehicle start settings may be personalized for the vehicle. For
functional descriptions and programming instructions, refer to the vehicle owners manual.

SPECIAL TOOLS
Illustration
EL 43241
Keyless Entry Tester

2013 ACCESSORIES & EQUIPMENT Seat Heating and Cooling - Cruze

Seat Heating and Cooling - Cruze
SPECIFICATIONS
Specification
Application
Front Seat Heater Control Module

HEATED/COOLED SEAT WIRING SCHEMATICS
KA1 Wiring Schematics
Fig. 1: Heated/Cooled Seat (KA1) Wiring Schematics

Metric
2.5 N.m
English
22 lb in

Callout
2040
CAV_B
CONN_X1
CAV_69
CONN_X2
2040_RD/WH
2040_RD
CAV_3
2150
2150_BK
CAV_A
CONN X1
2080
2080_BK
CAV_13
CONN_X2
CAV Y
2079
2079_RD
CAV_3
CONN_X3
CAV_Z
2077
2077_YE
CAV_3
CONN_X2
CAV_W
2424
2424_BK
CAV_1
CAV_2
2078
2020_GN
CAV_X
CAV_1
Component Name
B
X1
69
X2
2040 RD/WH
2040 RD
3
Ground
2150 BK
A
X1
Driver Heated Seat NTC Low
Reference
2080 BK
13
X2
Y
Driver Heated Seat NTC
Signal
2079 RD
3
X3
Z
Driver Heated Seat Element
Supply Voltage
2077 YE
3
X2
W
Driver Heated Back Element
Return
2424 BK
1
2
Driver Heated Seat Element
Return
2020 GN
X
1
Passenger Heated Seat NTC

2435
2435_BK
CAV_14
2435_BK
2435_BK
CAV_Y
2434
2434_RD
CAV_4
CONN_X3
CAV_Z
2434_RD
2434_RD
2479
2479_YE
CAV_5
CONN_X2
2479_YE
2479_YE
CAV_W
2433
2433_BK
CAV_2
2433_BK
2433_BK
CAV_2
2480
2019_GN
CAV_X
CAV_1
5060
5060_BU
CAV 11
CONN_X3
X310
Low Reference
2435 BK
14
2435 BK
2435 BK
Y
Passenger Heated Seat NTC
Signal
2434 RD
4
X3
Z
2434 RD
2434 RD
Passenger Heated Seat
Element Supply Voltage
2479 YE
5
X2
2479 YE
2479 YE
W
Passenger Heated Back
Element Return
2433 BK
2
2433 BK
2433 BK
2
Element Return
2019 GN
X
1
Data
5060 BU
11
X3
Data Communication
Schematics
X310

CAV_6
CAV_7
CAV_2
CAV_4
X320
CAV_6
CAV_7
CAV_2
CAV_4
F33UA
X310
X310
X320
A90
X50A
K29
E14C
E14D
E14A
E14B
A26
6
7
2
4
X320
6
7
2
4
F33UA 30A
X310
X310
X320
Logic
(KA1)
(KA1)
(KA1)
(KA1)
(KA1)

DTC
DTC B1925 or B2170
DTC B2345
Description
DTC B1925 02 Driver Seat Cushion Heater Sensor
DTC B1925 05 Driver Seat Cushion Heater Sensor
DTC B2170 02 Passenger Seat Cushion Heater Sensor
DTC B2170 05 Passenger Seat Cushion Heater Sensor
DTC B2345 13 Seat Heater Disable Circuit Low
Voltage High/Temperature
DTC B2425 0B Driver Seat Cushion Heater Circuit
High Current
DTC B2425 0D Driver Seat Cushion Heater Circuit
High Resistance
DTC B2425 0E Driver Seat Cushion Heater Circuit Low

Resistance
DTC B2430 0B Passenger Seat Cushion Heater Circuit
High Current
DTC B2430 0D Passenger Seat Cushion Heater Circuit
High Resistance
DTC B2430 0E Passenger Seat Cushion Heater Circuit
Low Resistance
DTC B242A 01 Seat Heaters Common Circuit Short to
Battery
DTC B242A 02 Seat Heaters Common Circuit Short to
Ground
DTC B2425 or B2430
DTC B242A
DTC B1925 OR B2170

DTC Descriptors
DTC B1925 02
Driver Seat Cushion Heater Sensor Circuit Short to Ground
DTC B1925 05
Driver Seat Cushion Heater Sensor Circuit High Voltage/Open
DTC B2170 02
Passenger Seat Cushion Heater Sensor Circuit Short to Ground
DTC B2170 05
Passenger Seat Cushion Heater Sensor Circuit High Voltage/Open
Circuit
Driver Heated Seat
Element Control Terminal
3 X2
Driver Heated Seat
Short to
Ground
Open/High
Resistance
Short to
Voltage
Signal Performance
B242A 02
B2425 0D
B242A 01
B2425 0B, B2425 0E


1 X2
Driver Heated Seat
Cushion Temperature
Sensor Signal
Driver Heated Seat
Cushion Temperature
Sensor Low Reference
5 X2
2 X2
Cushion Temperature
Sensor Signal
Cushion Temperature
B242A 02
B2425 0D
B242A 01
B2425 0B, B2425 0E
B1925 02
B1925 05
B1925 05
B2345 13
B1925 05
B2345 13
B242A 02
B2430 0D
B242A 01
B2430 0B, B2430 0E
B242A 02
B2430 0D
B242A 01
B2430 0B, B2430 0E
B2170 02
B2170 05
B2170 05
B2345 13
B2170 05
B2345 13
The heated seat temperature sensor is located in the seat cushion just under the seat cover with the seat heating
element. The seat heating control module supplies a 5 V reference voltage through the temperature sensor signal
circuit and a ground through the low reference circuit to the sensor. The module monitors the voltage of the
sensor signal circuit to determine the temperature of the seat. The temperature sensor varies in resistance based
on the temperature of the heating element causing the signal voltage to change. Once the seat reaches the set
temperature, the module will then cycle the control circuit of the heating elements ON and OFF in order to
maintain the desired seat temperature based on the feedback voltage from the sensor.
DTC B1325 must not be present.

The seat heating control module must be powered.
B1925 02 or B2170 02
The temperature sensor voltage drops below 0.6 V for more than 1 second.
B1925 05 or B2170 05
The temperature sensor voltage is greater than 5 V for more than 1 second.

The heated seat function for the affected seat will be disabled.
The current DTC will clear and set the code to history 3 seconds after the reference voltage returns to
normal operating range and the ignition is cycled OFF then back to ACC or RUN.
Schematic Reference
Heated/Cooled Seat Schematics
Heated Seats Description and Operation
Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference

1. Ignition OFF and all vehicle systems OFF, disconnect the harness connector at the appropriate E14B or
E14D Seat Heating Element - Cushion. It may take up to 2 min for all vehicle systems to power down.
1. Ignition OFF, disconnect the X2 harness connector at the K29 Seat Heating Control Module.
I less than 2 ohms, replace the K29 Seat Heating Control Module.

3. Ignition ON.
If less than 4.8 V
1. Ignition OFF, disconnect the X3 harness connector at the K29 Seat Heating Control Module.
If less than 2 ohms, replace the K29 Seat Heating Control Module.
1. Ignition OFF, disconnect the X3 harness connector at the K29 Seat Heating Control Module,
ignition ON.
If less than 1 V, replace the K29 Seat Heating Control Module.
5. Test or replace the E14 Seat Heating Element - Cushion.
Component Testing
Seat Cushion Heating Element

1. Ignition OFF, disconnect the harness connector at the appropriate E14B or E14D Seat Heating Element Cushion.
2. Test for 500 ohms-300 kohms between the signal circuit terminal 2 and the low reference circuit terminal
3.
If not between 500 ohms-300 kohms
Replace the E14 Seat Heating Element - Cushion.
If between 500 ohms-300 kohms
3. All OK.
Repair Instructions
Driver Seat Cushion Heater Replacement

Passenger Seat Cushion Heater Replacement
Control Module References for K29 Seat Heating Control Module replacement, programming and setup

DTC B2345
DTC Descriptors
DTC B2345 13
Seat Heater Disable Circuit Low Voltage High/Temperature
Circuit
Driver Heated Seat
3 X2
Driver Heated Seat
1 X2
Driver Heated Seat
Cushion Temperature
Sensor Signal
Driver Heated Seat
Cushion Temperature
5 X2
2 X2
Cushion Temperature
Sensor Signal
Cushion Temperature
Short to
Ground
Open/High
Resistance
Short to
Voltage
Signal Performance
B242A 02
B2425 0D
B242A 01
B2425 0B, B2425 0E
B242A 02
B2425 0D
B242A 01
B2425 0B, B2425 0E
B1925 02
B1925 05
B1925 05
B2345 13
B1925 05
B2345 13
B242A 02
B2430 0D
B242A 01
B2430 0B, B2430 0E
B242A 02
B2430 0D
B242A 01
B2430 0B, B2430 0E
B2170 02
B2170 05
B2170 05
B2345 13
B2170 05
B2345 13
The seat heating control module controls seat heating operation for both the driver and front passenger seats.

The heating elements are controlled through individual high side and low side control circuits. The low side
control circuits for both seats are connected to a common reference point internal to the module. This reference
point is biased to approximately 2.5 V. Before the seat heating control module will allow heated seat operation,
it checks to see if this biased voltage is shorted to ground or voltage. Once the module verifies that it is not
closing to a shorted heating element, it allows for heated seat operation. The module will then continue to
monitor the heating elements for a shorted circuit.

B2345 13
Any temperature sensor input that remains below 1.5 V for more than 1 second.
The heated seat function for both seats will be disabled.

The current DTC will clear and set the code to history 3 seconds after the reference voltage returns to the
normal operating range and the ignition is cycled OFF then back to ACC or RUN.
Schematic Reference
Circuit Testing
Connector Repairs
Wiring Repairs

Scan Tool Reference

1. Ignition OFF, disconnect the X2 and X3 harness connectors at the K29 Seat Heating Control Module.
2. Test for greater than 3.0 kohms between the signal and the low reference circuit terminals listed below:
Driver seat cushion terminal 3 X3 and terminal 13 X2
Passenger seat cushion terminal 4 X3 and terminal 14 X2
If less than 3.0 kohms
1. Ignition OFF, disconnect the harness connector at the appropriate E14B or E14D Seat Heating
Element - Cushion.
2. Test for Infinite resistance between the signal and low reference circuits.
If less than infinite resistance, repair the short between the circuits.
If infinite resistance, test or replace the E14 Seat Heating Element - Cushion.
If greater than 3.0 kohms
3. Replace the K29 Seat Heating Control Module.
Repair Instructions

DTC B2425 OR B2430

DTC Descriptors
DTC B2425 0B
Driver Seat Cushion Heater Circuit High Current
DTC B2425 0D
Driver Seat Cushion Heater Circuit High Resistance

DTC B2425 0E
Driver Seat Cushion Heater Circuit Low Resistance
DTC B2430 0B
Passenger Seat Cushion Heater Circuit High Current
DTC B2430 0D
Passenger Seat Cushion Heater Circuit High Resistance
DTC B2430 0E
Passenger Seat Cushion Heater Circuit Low Resistance
Circuit
Driver Heated Seat
3 X2
Driver Heated Seat
1 X2
Driver Heated Seat
Cushion Temperature
Sensor Signal
Driver Heated Seat
Cushion Temperature
5 X2
2 X2
Cushion Temperature
Sensor Signal
Cushion Temperature
Short to
Ground
Open/High
Resistance
Short to
Voltage
Signal Performance
B242A 02
B2425 0D
B242A 01
B2425 0B, B2425 0E
B242A 02
B2425 0D
B242A 01
B2425 0B, B2425 0E
B1925 02
B1925 05
B1925 05
B2345 13
B1925 05
B2345 13
B242A 02
B2430 0D
B242A 01
B2430 0B, B2430 0E
B242A 02
B2430 0D
B242A 01
B2430 0B, B2430 0E
B2170 02
B2170 05
B2170 05
B2345 13
B2170 05
B2345 13

The driver and front passenger heated seats are controlled by the seat heating control module that is located
under the 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 pulse
width modulation (PWM) ground through the seat heater element control circuit to the heater elements. The
module then monitors the current flow through the heating elements and the rate of change of the temperature
sensor to verify correct heated seat operation.

Engine must be ON.
The seat heating control module must be powered and the heated seat must be enabled.
B2425 0D or B2430 0D
By measuring current and voltage output to the seat heating elements every 10 seconds, the seat heating control
module calculates that the heating element resistance is above the maximum resistance.
B2425 0B, B2425 0E, B2430 0B, or B2430 0E
By measuring current and voltage output to the seat heating elements every 10 seconds, the seat heating control
module calculates that the heating element resistance is below the minimum resistance.
The heated seat function for the affected seat will be disabled.
The current DTC clears when the malfunction is no longer present, and the power mode changes to OFF
then back to ACC or RUN.
Schematic Reference


Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference

B2425 0B, B2425 0D, or B2425 0E

1. Ignition OFF, disconnect the harness connector at the E14A Seat Heating Element - Driver Back.
NOTE:
Element resistance must be measured twice to ensure that all failure

conditions are simulated. First with the seat unoccupied, then with the
seat occupied.
2. Test for 0.5-2 ohms between control circuit terminal 1 and control circuit terminal 2.
If not between 0.5-2 ohms
Replace the E14A Seat Heating Element - Driver Back.
If between 0.5-2 ohms
3. Connect the harness connector at the E14A Seat Heating Element - Driver Back and disconnect the X2
harness connector at the K29 Seat Heating Control Module.
NOTE:

seat occupied.
4. Test for 1-5 ohms between control circuit terminal 3 and control circuit terminal 1.
If less than 1 ohms
1. Ignition OFF, disconnect the harness connector at the E14B Seat Heating Element - Driver
Cushion.
2. Test for infinite resistance between the control circuits.
If infinite resistance, test or replace the E14B Seat Heating Element - Driver Cushion.

1. Ignition OFF, disconnect the harness connector at the E14B Seat Heating Element - Driver
Cushion.
2. Test for less than 2 ohms between the control circuits end to end.
If less than 2 ohms, test or replace the E14B Seat Heating Element - Driver Cushion.
If between 1-5 ohms
B2430 0B, B2430 0D, or B2430 0E
1. Ignition OFF, disconnect the harness connector at the E14C Seat Heating Element - Passenger Back.
NOTE:

seat occupied.
2. Test for 0.5-2 ohms between control circuit terminal 1 and control circuit terminal 2.
If not between 0.5-2 ohms
Replace the E14C Seat Heating Element - Passenger Back.
If between 0.5-2 ohms
3. Connect the harness connector at the E14C Seat Heating Element - Passenger Back and disconnect the X2
harness connector at the K29 Seat Heating Control Module.
NOTE:

seat occupied.
4. Test for 1-5 ohms between control circuit terminal 5 and control circuit terminal 2.
If less than 1 ohms
1. Ignition OFF, disconnect the harness connector at the E14D Seat Heating Element - Passenger
Cushion.
2. Test for infinite resistance between the control circuits.
If infinite resistance, test or replace the E14D Seat Heating Element - Passenger Cushion.
1. Ignition OFF, disconnect the harness connector at the E14D Seat Heating Element - Passenger
Cushion.
2. Test for less than 2 ohms between the control circuits end to end.
If less than 2 ohms, test or replace the E14D Seat Heating Element - Passenger Cushion.

If between 1-5 ohms

Repair Instructions

DTC B242A
DTC Descriptors
DTC B242A 01
Seat Heaters Common Circuit Short to Battery
DTC B242A 02
Seat Heaters Common Circuit Short to Ground
Circuit
Driver Heated Seat
3 X2
Driver Heated Seat
1 X2
Driver Heated Seat
Cushion Temperature
Sensor Signal
Driver Heated Seat
Cushion Temperature
Short to
Ground
Open/High
Resistance
Short to
Voltage
Signal Performance
B242A 02
B2425 0D
B242A 01
B2425 0B, B2425 0E
B242A 02
B2425 0D
B242A 01
B2425 0B, B2425 0E
B1925 02
B1925 05
B1925 05
B2345 13
B1925 05
B2345 13


5 X2
2 X2
Cushion Temperature
Sensor Signal
Cushion Temperature
B242A 02
B2430 0D
B242A 01
B2430 0B, B2430 0E
B242A 02
B2430 0D
B242A 01
B2430 0B, B2430 0E
B2170 02
B2170 05
B2170 05
B2345 13
B2170 05
B2345 13
The seat heating control module controls the seat heating operation for both the driver and front passenger seats.
The module controls the heating elements through individual high side and low side control circuits. The low
side control circuits for both seats are connected to a common reference point internal to the module. This
reference point is biased to approximately 2.5 V. Before the seat heating control module will allow heated seat
operation, it checks to see if this biased voltage is shorted to ground or voltage. Once the module verifies that it
is not closing to a shorted heating element, it allows for heated seat operation. The module then continues to
monitor the heating elements for a shorted circuit.

B242A 01
The seat heating control module detects a short to voltage on the heater element control circuits.
B242A 02
The seat heating control module detects a short to ground on the heater element control circuits.
The heated seat function for both seats will be disabled.

The current DTC will clear and set a history code 3 seconds after the reference voltage returns to normal
operating range and the ignition is cycled OFF then back to ACC or RUN.

Schematic Reference
Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference

1. Ignition OFF, disconnect the X2 harness connector at the K29 seat heating control module.
2. Test for infinite resistance between the control circuit terminals listed below and ground:
Terminal 3
Terminal 5
3. Ignition ON.
4. Test for less than 1 V between the control circuit terminals listed below and ground:
Terminal 3
Terminal 5
If 1 V or greater

If less than 1 V
5. Replace the K29 seat heating control module.
Repair Instructions

Control Module References for seat heating control module replacement, programming and setup
SYMPTOMS - SEAT HEATING AND COOLING
NOTE:
1. When diagnosing a heated seat system condition perform the Diagnostic System Check - Vehicle ,
before using the symptom tables in order to verify that all of the following are true:
The control module(s) can communicate via the serial data link.
2. Review the system operation in order to familiarize yourself with the system functions. Refer to Heated
Seats Description and Operation.
Inspect for aftermarket devices which could affect the operation of the power seats. Refer to Checking
cause the symptom.
Inspect the seat adjuster track for conditions which may cause binding or objects within the seat
adjustment range which obstruct movement or interfere with wiring.
Intermittent
Symptom List
Refer to the Front Heated Seat Malfunction diagnostic procedure in order to diagnose the symptom.
FRONT HEATED SEAT MALFUNCTION

Circuit
Driver Heated Seat
3 X2
Driver Heated Seat
1 X2
Driver Heated Seat
Cushion Temperature
Sensor Signal
Driver Heated Seat
Cushion Temperature
5 X2
2 X2
Cushion Temperature
Sensor Signal
Cushion Temperature
Short to
Ground
Open/High
Resistance
Short to
Voltage
Signal Performance
B242A 02
B2425 0D
B242A 01
B2425 0B, B2425 0E
B242A 02
B2425 0D
B242A 01
B2425 0B, B2425 0E
B1925 02
B1925 05
B1925 05
B2345 13
B1925 05
B2345 13
B242A 02
B2430 0D
B242A 01
B2430 0B, B2430 0E
B242A 02
B2430 0D
B242A 01
B2430 0B, B2430 0E
B2170 02
B2170 05
B2170 05
B2345 13
B2170 05
B2345 13
The driver and passenger heated seats are controlled by separate heated seat switches that are located in the
HVAC controls. When a heated seat switch is pressed, a serial data message is sent from the HVAC controls to
the HVAC control module indicating the heated seat command. The HVAC control module then serves as a
gateway to transmit the message to the seat heating control module via the serial data line. In response to this
message, the seat heating control module applies battery positive voltage through the element supply voltage
circuit to the appropriate seat heating elements. The seat heating control module then sends a serial data
message back to the HVAC control module to gateway the information to the HVAC controls to either
illuminate or turn off the appropriate temperature indicator.
Schematic Reference


Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference

1. Engine ON.
2. Verify that no heated seat DTCs are set.
If any heated seat DTC is set
If no heated seat DTCs are set
3. Verify the scan tool Front Seat Heating Control Module Driver Seat Heating/Venting/Cooling Mode
parameter changes between Off and Back & Cushion Heat after pressing the driver heated seat switch.
Replace the A26 HVAC Controls.

4. Verify the scan tool Passenger Front Seat Heating/Venting/Cooling Mode Switch parameter changes
between Off and Back & Cushion Heat after pressing the passenger heated seat switch.
Replace the A26 HVAC Controls.

Repair Instructions

Heater and Air Conditioning Control Replacement

REPAIR INSTRUCTIONS
FRONT SEAT HEATER CONTROL MODULE REPLACEMENT
Fig. 2: Front Seat Heater Control Module

Front Seat Heater Control Module Replacement
Callout
Component Name
Front Seat Heater Control Module Bolt (Qty: 2)
CAUTION:
Tighten
2.5 N.m (22 lb in)
2
Front Seat Heater Control Module

Procedure


DRIVER OR PASSENGER SEAT BACK CUSHION HEATER REPLACEMENT
Fig. 3: Driver Or Passenger Seat Back Cushion Heater

Driver or Passenger Seat Back Cushion Heater Replacement
Callout
Component Name
Remove the front seat back cushion cover and cushion pad. Refer to Driver or Passenger Seat Back
Cover and Pad Replacement .
1
Driver or Passenger Seat Back Cushion Heater
DRIVER SEAT CUSHION HEATER REPLACEMENT

Fig. 4: Driver Seat Cushion Heater

Callout
Component Name
Remove the front seat cushion cover and pad. Refer to Front Seat Cushion Cover and Pad
Replacement .
Driver Seat Cushion Heater
Procedure
1
1. Carefully remove the cushion heater from cushion.
2. When installing the heater, glue on the heater starting on the
rear side of the cushion and fix it bit by bit moving forward.
PASSENGER SEAT CUSHION HEATER REPLACEMENT

Fig. 5: Passenger Seat Cushion Heater

Callout
Component Name
WARNING:
Refer to SIR Warning .
WARNING:
Replace the passenger presence system as a complete assembly to prevent possible injury to the
occupant. All the components in the service kit are assembled and calibrated as a unit. Using only
some of the components in the service kit will cause the passenger presence system to operate
improperly.
WARNING:
To avoid personal injury, perform a preload test on the passenger presence system whenever you
remove or replace the seat cushion trim. Failure to do so may cause the system to malfunction.
1. Disable the SIR system. Refer to SIR Disabling and Enabling .
2. Remove the front seat. Refer to Driver or Passenger Seat Removal and Installation .
3. Remove the front seat cushion cover and pad. Refer to Front Seat Cushion Cover and Pad
Replacement .

Inflatable Restraint Front Passenger Presence Sensor

Passenger Seat Cushion Heater
Procedure
1. When replacing the front passenger seat cushion, you must also
replace the inflatable restraint passenger presence sensor. Refer to
Airbag Front Passenger Presence Sensor Replacement .
2. Program the inflatable restraint passenger presence system after
replacement. Refer to Control Module References .

HEATED SEATS DESCRIPTION AND OPERATION
Heated Seat Components
The driver and passenger heated seats consist of the following components:
Left heated seat switch

Right heated seat switch
HVAC controls switch assembly
Seat heating control module
Driver seat cushion heating element
Driver seat back heating element
Driver seat cushion temperature sensor
Passenger seat cushion heating element
Passenger seat back heating element
Passenger seat cushion temperature sensor
Power and Ground
Battery positive voltage is supplied at all times to the seat heating control module through a fuse located in the
underhood fuse block. This voltage is used by the module to supply power to the seat heating elements. Ground
is provided through the vehicle and seat wiring harnesses to the module.
Heated Seat Operation
The driver and passenger heated seats are controlled by a single seat heating control module that is located
under the driver seat cushion. Both heated seats are controlled by separate heated seat switches that are located
in the HVAC controls switch assembly. When a heated seat switch is pressed, a serial data message is sent from
the HVAC controls switch assembly to the seat heating control module indicating the heated seat command. In
response to this message, the seat heating control module applies battery positive voltage through the element
supply voltage circuit to the appropriate seat heating elements. The seat heating control module then sends a

serial data message back to the HVAC controls switch assembly to either illuminate or turn off the appropriate
temperature indicator.
Temperature Regulation
When the engine ON, the heated seats will initialize in the OFF state. With each activation of the heated seat
switch, the seat heating control module will cycle the temperature setting in the following manner: HIGH,
MEDIUM, LOW, and OFF.
The seat heating control module monitors the seat temperature through the temperature sensor signal circuit and
the temperature sensor (thermistor) that is located in the seat cushion. The temperature sensor is a variable
resistor, it's resistance changes as the temperature of the seat changes. When the temperature sensor resistance
indicates to the seat heating control module that the seat has reached the desired temperature, the module opens
the ground path of the seat heating elements through the heated seat element control circuit. The module will
then cycle the element control circuit open and closed in order to maintain the desired temperature.
Load Management
The electrical power management function is designed to monitor the vehicle electrical load and determine
when the battery is potentially in a high discharge condition. The heated seat system is one of the vehicle loads
that is subject to reduction during a battery discharge condition. For more information on load management
refer to Electrical Power Management Description and Operation .

2013 ACCESSORIES & EQUIPMENT Secondary and Configurable Customer Controls - Cruze

Secondary and Configurable Customer Controls - Cruze

STEERING WHEEL SECONDARY/CONFIGURABLE CONTROL WIRING SCHEMATICS
W1Y Wiring Schematics
Fig. 1: Steering Wheel Secondary/Configurable Control (W1Y)Wiring Schematics

Callout
7556
7556_YE
CAV_4
CONN_X3
1444
1444_WH/RD
CAV_5
Component Name
Reference
7556 YE
4
X3
12 Volt Reference
1444 WH/RD
5

CONN_X1
7556_YE
6819
6819_GN/WH
CAV_4
CAV_8
1444_WH/RD
CAV_1
CAV_6
CONN_X3
K34
6819 GN
CAV_2
CAV_7
1444_WH/RD
J200
X85
S70R
K9
Cruise_Control_Schematics_REF
X1
7556 YE
Steering Wheel Resistor Ladder
Signal #2
6819 GN/WH
4
8
1444 WH/RD
1
6
X3
CRUISE CONTROLAUTOMATIC, ELECTRONIC
6819 GN
2
7
1444 WH/RD
J200
(W1Y)

DTC
DTC B1405
DTC B1529
DTC B3622
DTC B1405
Description
DTC B3622 07 Steering Wheel Controls Signal

DTC Descriptors
DTC B1405 03
DTC B1405 07
Electrical DTCs
Short to
Ground
B1529 03,
12 V Reference
B1405 03
Signal
1
1. Steering Wheel Controls Inoperative
Circuit
Open/High
Resistance
Short to
Voltage
Signal Performance
B1529 07
B1529 07
B3622 07
The body control module (BCM) monitors the system voltage to make sure that the voltage stays within the
proper range. Damage to components and/or incorrect operation can occur when the voltage is out of range.
Battery voltage is between 9-16 V.

The ignition is ON.
The BCM detects a low/high voltage on the control circuit.


A history DTC will clear once 100 consecutive malfunction free ignition cycles have occurred.

Schematic Reference
Steering Wheel Secondary/Configurable Control Schematics
Steering Wheel Controls Description and Operation
Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference

1. Engine running, accessories OFF, measure and record the battery voltage at the battery terminals.
2. Verify the voltage measured at the battery terminals is between 12.6-15.0 V.
If not between 12.6-15.0 V
Refer to Charging System Test .
1. Ignition OFF and all vehicle systems OFF, disconnect the harness connector at the S70R Steering Wheel
Controls Switch - Right, ignition ON.
2. Test for 11.8-12.2 V between the reference voltage circuit terminal 1 and ground.
If less than 11.8 V
2. Test for infinite resistance between the reference voltage circuit and ground.

3. Test for less than 2 ohms in the reference voltage circuit end to end.
2. Test for less than 1 V between the reference voltage circuit and ground.
3. Test for 11.8-12.2 V between the reference voltage circuit terminal 1 and signal circuit terminal 2.
If less than 1 V
If less than 2 ohms replace the K9 Body Control Module.
4. Test or replace the S70R Steering Wheel Controls Switch - Right.
Component Testing
1. Ignition OFF, disconnect the harness connector at the S70R Steering Wheel Controls Switch - Right.
2. Test the resistance between the signal terminal 2 and the reference voltage terminal 1 while pressing the
appropriate steering wheel controls switch button listed below:
If not the specified value
Replace the S70R Steering Wheel Controls Switch - Right.
If the specified value
3. All OK
Function Switch
Hang Up-Mute
Telephone Switch
Source Switch
Arrow Down
Arrow Up
Volume Down
Minimum Resistance Value Maximum Resistance Value

5.0 kohms
5.5 kohms
3.6 kohms
4 kohms
2.8 kohms
3.1 kohms
2.2 kohms
2.6 kohms
1.7 kohms
2 kohms
1.4 kohms
1.6 kohms

Volume Up
No Switch Pressed
1.1 kohms
Infinite
1.3 kohms
Infinite
Repair Instructions

DTC B1529
DTC Descriptors
DTC B1529 03
DTC B1529 07
Electrical DTCs
Short to
Circuit
Ground
B1529 03,
12 V Reference
B1405 03
Signal
1
Open/High
Resistance
Short to
Voltage
Signal Performance
B1529 07
B1529 07
B3622 07
The body control module (BCM) supplies voltage to the steering wheel control switches and monitors the return
signal. Each switch state is associated to a set resistance value and when pressed a specific voltage drop occurs
across the resistor unique to the switch. The BCM identifies the switch selection and activates the feature.

The ignition is ON.
B1529 03
The BCM detects a short to ground in the 12 V reference circuit.

B1529 07
The BCM detects a short to voltage in the 12 V reference circuit.

The BCM will ignore switch inputs.


Schematic Reference
Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference


If less than 11.8 V
If less than 1 V
Component Testing


3. All OK
Function Switch
Hang Up-Mute
Telephone Switch
Source Switch
Arrow Down
Arrow Up
Volume Down
Volume Up
No Switch Pressed

5.0 kohms
5.5 kohms
3.6 kohms
4 kohms
2.8 kohms
3.1 kohms
2.2 kohms
2.6 kohms
1.7 kohms
2 kohms
1.4 kohms
1.6 kohms
1.1 kohms
1.3 kohms
Infinite
Infinite
Repair Instructions

DTC B3622
DTC Descriptor
DTC B3622 07
Steering Wheel Controls Signal Circuit High Voltage
Circuit
12 V Reference
Signal
Short to
Ground
B1529 03,
B1405 03
1
Open/High
Resistance
Short to
Voltage
Signal
Performance
B1529 07
B1529 07
B3622 07

The body control module (BCM) monitors the steering wheel control signal circuit voltage. If the voltage level
is too high, damage may result in the system. When a high voltage condition is detected, the BCM will ignore
the switch command.

The ignition is ON.
The BCM detects a short to voltage in the steering wheel control switch signal circuit.
The BCM will ignore switch inputs.


Schematic Reference
Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference


If less than 11.8 V
If less than 1 V
Component Testing


3. All OK
Function Switch
Hang Up-Mute
Telephone Switch
Source Switch
Arrow Down
Arrow Up
Volume Down
Volume Up
No Switch Pressed

5.0 kohms
5.5 kohms
3.6 kohms
4 kohms
2.8 kohms
3.1 kohms
2.2 kohms
2.6 kohms
1.7 kohms
2 kohms
1.4 kohms
1.6 kohms
1.1 kohms
1.3 kohms
Infinite
Infinite
Repair Instructions

SYMPTOMS - SECONDARY AND CONFIGURABLE CUSTOMER CONTROLS
NOTE:
2. Review the system description and operation in order to familiarize yourself with the system functions.
Refer to Steering Wheel Controls Description and Operation.
Inspect for aftermarket devices which could affect the operation of the steering wheel controls. Refer to
Inspect the easily accessible or visible system components, for obvious damage or conditions, which
could cause the symptom.
Intermittent
Symptom List

Refer to Steering Wheel Controls Malfunction in order to diagnose the symptom.
STEERING WHEEL CONTROLS MALFUNCTION
Circuit
12 V Reference
Signal
Short to
Ground
B1529 03,
B1405 03
1
Open/High
Resistance
Short to
Voltage
Signal
Performance
B1529 07
B1529 07
B3622 07
The body control module (BCM) supplies voltage to the audio steering wheel control switches and monitors the
return signal. Each switch state is associated to a set resistance value and when pressed a specific voltage drop
occurs across the resistor unique to the switch. The BCM identifies the switch selection and activates the
feature.
Schematic Reference
Circuit Testing
Connector Repairs


Wiring Repairs
Scan Tool Reference

1. Ignition ON.
2. Verify the primary controls of the associated component are functioning properly.
If any of the primary controls do not function properly
Refer to Symptoms - Entertainment
If all of the primary controls function properly
If less than 11.8 V


If less than 1 V
Component Testing
3. All OK
Function Switch
Hang Up-Mute
Telephone Switch
Source Switch
Arrow Down
Arrow Up
Volume Down
Volume Up
No Switch Pressed

5.0 kohms
5.5 kohms
3.6 kohms
4 kohms
2.8 kohms
3.1 kohms
2.2 kohms
2.6 kohms
1.7 kohms
2 kohms
1.4 kohms
1.6 kohms
1.1 kohms
1.3 kohms
Infinite
Infinite
Repair Instructions


STEERING WHEEL CONTROLS DESCRIPTION AND OPERATION
The steering wheel control switches duplicate the function of the primary controls of the associated component,
through a network of momentary contact switches and a series of resistors. The body control module (BCM)
supplies voltage to the switches and monitors the return signal. When a switch is pressed, a specific voltage

drops across the resistor unique to that switch. The BCM identifies the switch selected and sends a serial data
message to the component controlled by the switch, activating the feature.
This section is intended to diagnose the circuits between the BCM and the steering wheel control switches. If
the primary control for the device is inoperative, refer to the appropriate section for the component the steering
wheel control switch is used for.

2013 ACCESSORIES & EQUIPMENT Theft Deterrent - Cruze

Theft Deterrent - Cruze
SPECIFICATIONS
Specification
Application
Theft Deterrent Alarm Nut

THEFT DETERRENT SYSTEM WIRING SCHEMATICS
Theft Deterrent Wiring Schematics
Fig. 1: Theft Deterrent Wiring Schematics

Metric
9 N.m
English
80 lb in

Callout
2140
2140_RD/GY
CAV_1
CONN_X2
CAV_44
745
745_GY
CAV_6
AXG
AEC
746
746_GY
CAV_6
747
747_GY
CAV_2
748
748_GY
CAV_2
SD
28
28_BN/WH
CAV 19
CONN_X5
309
309_GY/BN
CAV_5
709
709_VT/GY
CAV_6
312
312_YE
CAV_1
712
Component Name
2140 RD/GY
1
X2
44
Left Front Door Ajar Switch Signal
745 GY
6
WINDOW-POWER OPERATEDEXPRESS DRIVER UP/DOWN
DRIVER EXPRESS DOWN
Right Front Door Ajar Switch Signal
746 GY
6
Left Rear Door Ajar Switch Signal
747 GY
2
Right Rear Door Ajar Switch Signal
748 GY
2
Serial Data
Horn Relay Control
28 BN/WH
19
X5
Right Park Lamp Supply Voltage
309 GY/BN
5
Left Park Lamp Supply Voltage
709 VT/GY
6
Right Headlamp Low Beam Supply
Voltage
312 YE
1
Left Headlamp Low Beam Supply
Voltage

712_YE
CAV_2
CONN_X4
1303
1303_VT/GY
CAV_4
CAV_5
CONN_X6
1303_VT/GY
CAV_2
7566
7566_BK/BU
CAV_7
CONN_X1
7566_BK/BU
CAV_6
1650
1650 BK
728
728 GY
CAV_1
CAV_21
CONN_X1
650
650_BK
CAV_2
C68
7566_BK/BU
C68
F23DA
X900
J213
Door Lock/Indicator Schematics REF
Horn_Schematics_REF
B10B
X51A
K9
712 YE
2
X4
Lift Gate Ajar Switch Signal (1)
1303 VT/GY
4
5
X6
1303 VT/GY
2
Humidity/Windscreen Temp Sensor
Low Reference
7566 BK/BU
7
X1
7566 BK/BU
6
Ground
1650 BK
Security Indicator Control
728 GY
1
21
X1
Ground
650 BK
2
HVAC SYSTEM-AIR
CONDITIONER FRT, AUTO,
ELECTRONIC CONTROLS
7566 BK/BU
HVAC SYSTEM-AIR
CONDITIONER FRT, AUTO,
ELECTRONIC CONTROLS
F23DA 20A
X900
J213
Door Lock/Indicator Schematics
Horn Schematics

M40
HVAC_Schematics_REF
A90
S79D
A90
S79P
A90
S79LR
A90
S79RR
HVAC_Schematics_REF
M74D
K33
HVAC Schematics
Logic
Logic
Logic
Logic
Headlights/Daytime Running Lights
(DRL) Schematics
HVAC Schematics

SYMPTOMS - THEFT DETERRENT
NOTE:
1. Perform Diagnostic System Check - Vehicle in order to verify that all of the following are true:
following Theft Systems Description and Operation.
Inspect for aftermarket devices which could affect the operation of the Theft Deterrent System. Refer to
cause the symptom.
Intermittent

Symptom List
Content Theft Deterrent Malfunction

Security Indicator Malfunction (with C67), Security Indicator Malfunction (with C68)
CONTENT THEFT DETERRENT MALFUNCTION

The content theft deterrent system is a software based system in which the body control module (BCM) actively
monitors certain inputs to determine if unauthorized vehicle access is being attempted. Based on inputs such as
the door ajar switches, the rear compartment ajar switch, and the hood ajar switch, the BCM determines whether
a content theft deterrent alarm is warranted. If unauthorized access is being detected, the BCM will pulse the
vehicle horn and flash the exterior lamps as a means of theft deterrence. If equipped, the BCM will also activate
a siren as an additional theft deterrence.
Diagnostic Aids
The scan tool Content Theft Deterrent Trigger History 1, 2, and 3 parameters can be used to help isolate an
intermittent unwanted content theft deterrent alarm. These parameters are a rolling history of the previous three
causes of a theft deterrent alarm. If all three parameters are indicating the same alarm trigger, the indicated input
should be the starting point when diagnosing an intermittent concern.
Schematic Reference
Theft Deterrent System Schematics
Theft Systems Description and Operation

Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference

1. Ignition ON.
2. Verify each indicator/message transitions between the ajar and closed state while opening and closing
each vehicle door, hood, and rear compartment.
If any indicator/message does not change
Refer to Hood Ajar Indicator/Message Malfunction ,, Door Ajar Indicator Malfunction ,, or
Trunk Ajar Indicator Malfunction .
If each indicator/message changes
3. Completely lower the driver door window and close all vehicle doors, ignition OFF.
4. Arm the content theft deterrent system by locking the doors with the keyless entry transmitter.
5. Verify the scan tool Content Theft Deterrent Alarm Status parameter is Armed.
If not Armed
Refer to Keyless Entry System Malfunction (Active) , Keyless Entry System Malfunction
(Passive) .
If Armed
6. Without disarming the system, reach in through the open driver window and open the driver door.
7. Verify the scan tool Content Theft Deterrent Alarm Status parameter is Alarm.
If not Alarm

If Alarm
8. All OK.
Repair Instructions


SECURITY INDICATOR MALFUNCTION (WITH C67)

Circuit
Control
Ground
1. Security LED always ON
2. Security LED inoperative
Short to
Ground
2
-
Open/High
Resistance
2
2
Short to
Voltage
1
-
Signal Performance
-
The security LED is controlled by the Body Control Module (BCM) based on commands from the content theft
deterrent system. The security LED is located in the instrument panel as part of the ambient light sensor and is
supplied ground at all times. When the content theft deterrent system requests the LED be illuminated, the BCM
applies voltage to the control circuit, illuminating the LED.
Schematic Reference
Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference


1. Arm the content theft deterrent system.

2. Verify the security LED illuminates or flashes during the arming sequence.
If the security LED does not illuminate or flash
If the security LED illuminates or flashes
3. All OK.
1. Ignition OFF and all vehicle systems OFF, disconnect the harness connector at the B10B Ambient
Light/Sunload Sensor. It may take up to 2 minutes for all vehicle systems to power down.
1. Ignition OFF.
3. Ignition ON, connect a test lamp between the control circuit terminal 1 and the ground circuit terminal 6.
4. Verify the test lamp turns ON and OFF when commanding the Security Indicator On and Off with a scan
tool.

5. Test or replace the B10B Ambient Light/Sunload Sensor.

Repair Instructions
Headlamp Automatic Control Ambient Light Sensor Replacement

Control Module References for Body Control Module replacement, programming, and setup
SECURITY INDICATOR MALFUNCTION (WITH C68)

Circuit
Control
Low Reference
1. Security LED always ON
2. Security LED inoperative
Short to
Ground
2
-
Open/High
Resistance
2
2
Short to
Voltage
1
-
Signal Performance
-
The security LED is controlled by the Body Control Module (BCM) based on commands from the content theft
deterrent system. The security LED is located in the instrument panel as part of the ambient light sensor and is
supplied ground at all times. When the content theft deterrent system requests the LED be illluminated, the
BCM applies voltage to the control circuit, illuminating the LED.
Schematic Reference

Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference

1. Arm the content theft deterrent system.

2. Verify the security LED illuminates or flashes during the arming sequence.
If the security LED does not illuminate or flash
If the security LED illuminates or flashes
3. All OK.
1. Ignition OFF and all vehicle systems OFF, disconnect the harness connector at the B10B Ambient
Light/Sunload Sensor. It may take up to 2 minutes for all vehicle systems to power down.
1. Ignition OFF, disconnect the harness connector at the K33 HVAC Control Module.
If less than 2 ohms, replace the K33 HVAC Control Module.
3. Ignition ON, connect a test lamp between the control circuit terminal 1 and the low reference circuit
terminal 6.
4. Verify the test lamp turns ON and OFF when commanding the Security Indicator On and Off with a scan
tool.

5. Test or replace the B10B Ambient Light/Sunload Sensor.
Repair Instructions
Headlamp Automatic Control Ambient Light Sensor Replacement

Control Module References for Body Control Module or HVAC Control Module replacement,
REPAIR INSTRUCTIONS
THEFT DETERRENT ALARM REPLACEMENT

Fig. 2: Theft Deterrent Alarm And Theft Deterrent Alarm Nut

Theft Deterrent Alarm Replacement
Callout
Component Name
Remove the air inlet grille panel. Refer to Air Inlet Grille Panel Replacement .
Theft Deterrent Alarm Nut
CAUTION:
Tighten
9 N.m (80 lb in)
Theft Deterrent Alarm
Procedure
Disconnect wiring connector.

THEFT SYSTEMS DESCRIPTION AND OPERATION
When armed, the content theft deterrent system is designed to deter vehicle content theft by pulsing the horns
and exterior lamps for approximately 30 seconds when an unauthorized vehicle entry is detected. If equipped, a
siren will also be activated. However, the content theft deterrent system does not affect engine starting.
An unauthorized entry can be any of the following with the content theft deterrent system armed:
Unauthorized entry into the underhood area

Unauthorized entry into the rear compartment
When any door is opened without receiving a valid unlock command
After a battery reconnect, if the battery was disconnected with the content theft deterrent system armed
The components of the content theft deterrent system are:

Keyless Entry Control Module (RPO ATH)
Security LED
Door ajar switches
Rear compartment ajar switch
Hood ajar switch

External siren, if equipped
Arming the Content Theft Deterrent System
Use the following procedure in order to arm the system:

1.
2.
3.
4.
Place the shift lever in P (park).

Turn OFF the ignition.
Open any door.
Lock the doors with the power door lock switch, locking the door manually using the door lock rod, or by
pressing the LOCK button on the transmitter.
5. The system will begin the arm sequence immediately after the last door is closed. If the keyless entry
transmitter is used to arm the system after the vehicle doors are closed, the arm sequence will begin as
soon as the LOCK command is received from the transmitter.
6. Pressing the LOCK button on the keyless entry transmitter a second time will bypass the delayed arming
function and force the system to arm.
Locking the Vehicle Without Arming the Content Theft Deterrent System
Locking the vehicle may be accomplished without arming the content theft deterrent system. Use of the exterior
door lock cylinder will lock the vehicle, but will not arm the content theft deterrent system.
Disarming an Armed System/Silencing an Alarm
If system arming has been requested, it must be disarmed before the vehicle is opened again.
NOTE:
Disconnecting the battery or removing fuses does not disable the arm or alarm
modes, since the BCM stores the content theft deterrent mode status in
memory.
To disarm the content theft deterrent system in standby mode, perform one of the following:
Press the UNLOCK button on the keyless entry transmitter.
Approach the vehicle with a valid keyless entry transmitter and press the exterior door handle
button (RPO ATH).
Insert a valid key into the ignition and switch to the ON position.
To disarm the content theft deterrent system in the armed mode (non-event) or when activated (during an
alarm event):
Press the UNLOCK button on the keyless entry transmitter.
Insert a valid key into the ignition and switch to the ON position
Content Theft Deterrent Circuit Description
The following is a description of each component used in the content theft deterrent system:

Body Control Module

The content theft deterrent system is an internal function of the BCM which utilizes serial data and various
switch inputs information to perform content theft deterrent functions. When the BCM detects an unauthorized
entry, it activates the horns and exterior lamps. If equipped, a siren will also be activated. The BCM has 4 basic
modes (disarmed, standby, armed, and alarm) for operating the content theft deterrent system. The different
modes are described below.
1. The BCM has the content theft deterrent system in a disarmed mode until the following conditions are
detected:
Ignition key turned to the OFF position.
Doors locked using the power door lock switch, the door lock rod, or the LOCK button on the
transmitter.
2. The BCM enters the standby mode when the above conditions are detected. If a door was already opened
when the arm mode was requested, the standby mode does not start the timer until the last door is closed.
3. When the last door is closed, a 15 second timer is activated. Once the timer has expired, the BCM enters
the armed mode. After this delay, any unauthorized entry will activate the alarm mode.
4. When the BCM detects an unauthorized entry, the BCM enters the alarm mode. The BCM activates the
horns and exterior lamps for 30 seconds. If equipped, a siren will also be activated. This is followed by a
three minute time-out with the horn no longer active. If no new intrusions are detected after the time-out,
the horn is not active. The system must be disarmed or the intrusion condition removed after the time-out
for the system to exit alarm mode.
Keyless Entry Control Module (RPO ATH)
The passive keyless entry system can arm and disarm the content theft deterrent system. When a valid keyless
entry transmitter is detected while attempting to passively access the vehicle, the keyless entry module will send
a message via serial data to disarm the content theft deterrent system.
The keyless entry system can arm and disarm the content theft deterrent system. When the remote control door
lock receiver receives a door lock or unlock signal from the transmitter, the remote control door lock receiver
sends a message to the BCM via serial data to perform the appropriate arm/disarm functions.
Security LED
The security LED is illuminated on the instrument panel by the BCM. The content theft deterrent system uses
the security LED to inform the driver of system status prior to arming.
Door Ajar Switches
The content theft deterrent system uses the door ajar switches as a status indicator to activate the alarm. The
door ajar switches are monitored by the body control module via a discrete input from each door ajar switch. If
the BCM receives a signal indicating a door is opened when the content theft deterrent system is armed, the
BCM activates the alarm.

Hood Ajar Switch

The content theft deterrent system uses the hood ajar switch as a status indicator to activate the alarm. The BCM
monitors the hood ajar switch via a discrete input from the switch. If the BCM receives a signal indicating the
hood has been opened when the content theft deterrent system is armed, the BCM activates the alarm.
Rear Compartment Ajar Switch
The content theft deterrent system uses the rear compartment ajar switch as a status indicator to activate the
alarm. The BCM monitors the rear compartment ajar switch via a discrete input from the switch. If the BCM
receives a signal indicating the rear compartment has been opened when content theft deterrent system is armed,
the BCM activates the alarm.
Inputs
The BCM monitors the following inputs for content theft deterrent:
The door ajar switches

The keyless entry transmitter LOCK/UNLOCK buttons; a message from the remote control door lock
receiver
The immobilizer status - The BCM uses the immobilizer status for disarming the system or silencing an
alarm when the correct vehicle key is used to start the vehicle
The rear compartment ajar switch
The hood ajar switch
Outputs
The BCM controls the following for content theft deterrent:
The horn relay

The exterior lamps
If equipped, an external siren.

2013 ACCESSORIES & EQUIPMENT Vehicle Access - Cruze

Vehicle Access - Cruze
SPECIFICATIONS
Specification
Application
Door Lock Switch
Front Side Door Handle Bracket Bolt
Front Side Door Latch Bolt
Front Side Door Lock Striker Bolt
Front Side Door Outside Handle Bolt
Rear Compartment Lid Latch Bolt
Rear Compartment Lid Latch Striker Bolt
Rear Side Door Handle Bracket Bolt
Rear Side Door Outside Handle Bolt
Rear Side Door Latch Bolt
Rear Side Door Lock Striker Bolt

DOOR LOCK/INDICATOR WIRING SCHEMATICS
Switches Wiring Schematics
Metric
1.5 N.m
2.5 N.m
10 N.m
25 N.m
9 N.m
9 N.m
9 N.m
2.5 N.m
9 N.m
10 N.m
25 N.m
English
13 lb in
22 lb in
89 lb in
18 lb ft
80 lb in
80 lb in
80 lb in
22 lb in
80 lb in
89 lb in
18 lb ft

Fig. 1: Switches Wiring Schematics

Callout
CAV_26
2540
2540_RD/BU
CAV_3
CONN_X2
781
781_BN/WH
CAV_3
CAV 15
CONN_X2
780
780_BN/YE
CAV_4
CAV_19
SD
Component Name
26
2540 RD/BU
3
X2
Unlock Signal
781 BN/WH
3
15
X2
Lock Signal
780 BN/YE
4
19
Serial Data

3269
3269_BN/WH
CAV_9
CAV_12
CONN_X7
3269_BN/WH
CAV_17
1303
1303_VT/GY
CAV_4
CAV_5
CONN_X6
1303_VT/GY
CAV_2
3268
3268_GY/BK
CAV_4
CAV_18
CONN_X7
CAV_17
3268 GY/BK
748
748_GY
CAV_1
CAV_2
2350
2350_BK
CAV_8
650
650 BK
CAV_2
2050
2050_BK
CAV_3
3270
Data Communication
Schematics
Child Security Lock Motor
Status Signal Left Rear
3269 BN/WH
9
12
X7
3269 BN/WH
17
Lift Gate Ajar Switch Signal
(1)
1303 VT/GY
4
5
X6
1303 VT/GY
2
Child Security Lock Motor
Status Signal Right Rear
3268 GY/BK
4
18
X7
17
3268 GY/BK
Signal
748 GY
1
2
Ground
2350 BK
8
Ground
650 BK
2
Ground
2050 BK
3
Driver Door Lock Motor
Status

3270_WH/VT
CAV_4
CAV_7
745
CAV_6
745_GY
CAV_6
CAV_6
2050_BK
CAV_3
1550
1550_BK
CAV_8
1650
1650_BK
CAV_1
AEC
AEC
AXG
AXG
746
746_GY
CAV_1
CAV_6
747
747_GY
CAV_6
CAV_2
3270 WH/VT
4
7
Left Front Door Ajar Switch
Signal
6
745 GY
6
6
2050 BK
3
Ground
1550 BK
8
Ground
1650 BK
1
WINDOW-POWER
OPERATED, DRIVER
EXPRESS DOWN
WINDOW-POWER
OPERATED, DRIVER
EXPRESS DOWN
WINDOW-POWER
OPERATED-EXPRESS
DRIVER UP/DOWN
WINDOW-POWER
OPERATED-EXPRESS
DRIVER UP/DOWN
Right Front Door Ajar Switch
Signal
746 GY
1
6
Signal
747 GY
6
2
Data Communication
Schematics
Data Communication
Schematics

G305
G202
G309
G308
G402
F3DA
X700
X900
X800
S13D
M74D
S79P
M40
S79RR
X51A
S79LR
A23P
S79D
A23D
K9
A23RR
A23LR
Actuators Wiring Schematics
G305
G202
G309
G308
G402
F3DA 25A
X700
X900
X800

Fig. 2: Actuators Wiring Schematics

Callout
CAV_35
2840
2840_RD/GY
CAV_4
CONN_X2
294
294_BN/YE
CAV_2
CAV_4
CONN_X6
294_BN/YE
CAV_7
294_BN/YE
CAV_2
294_BN/YE
CAV_7
294_BN/YE
Component Name
35
2840 RD/GY
4
X2
Door Lock Actuator Unlock Control
294 BN/YE
2
4
X6
294 BN/YE
7
294 BN/YE
2
294 BN/YE
7
294 BN/YE

CAV_4
294_BN/YE
CAV_9
294_BN/YE
294_BN/YE
294_BN/YE
294_BN/YE
294_BN/YE
294_BN/YE
294_BN/YE
CAV_5
CAV_3
CAV 3
CAV_10
295
295_GY
CAV_8
295_GY
CAV_3
3266
3266_WH/BU
CAV_7
295_GY
CAV_8
3266_WH/BU
CAV_5
CAV_2
5911
5911_GY
CAV 1
CAV_3
3271
3271_GY/GN
CAV_12
CONN_X2
CAV_2
3267
3267_VT/YE
CAV_13
CAV_8
CONN_X4
295 GY
4
294 BN/YE
9
294 BN/YE
294 BN/YE
294 BN/YE
294 BN/YE
294 BN/YE
294 BN/YE
294 BN/YE
5
3
3
10
Door Lock Actuator Lock Control
295 GY
8
295 GY
3
Child Security Lock Motor Unlock Control
3266 WH/BU
7
295 GY
8
3266 WH/BU
5
2
Door Lock Actuator Lock Control 2
5911 GY
1
3
Door Lock Control (2)
3271 GY/GN
12
X2
2
Child Security Lock Relay Control
3267 VT/YE
13
8
X4

CAV_4
CONN_X2
1150
1150_BK
CAV_71
CONN_X1
295_GY
3266_WH/BU
295_GY
295_GY
3266_WH/BU
3266 WH/BU
295_GY/BK
5911_GY
CAV_9
CAV_9
X700
CAV_4
CAV_18
X800
CAV_4
CAV_18
F10DA
J308
J704
J803
X600
X700
X800
X500
G101
J307
X600
X500
X700
X800
A23LR
A23P
K9
A23RR
23D
295 GY
4
X2
Ground
1150 BK
71
X1
295 GY
3266 WH/BU
295 GY
295 GY
3266 WH/BU
3266 WH/BU
295 GY/BK
5911 GY
9
9
X700
4
18
X800
4
18
F10DA 30A
J308
J704
J803
X600
X700
X800
X500
G101
J307
X600
X500
X700
X800

X50A
X51A
KR114
Passive Entry - Module Power, Ground, and Latches (ATH) Wiring Schematics
Fig. 3: Passive Entry - Module Power, Ground, and Latches (ATH) Wiring Schematics
Callout
3140
3140 RD/GN
CAV_5
CONN X2
CAV_42
CONN_X2
3572
3572_WH/BN
CAV_3
CONN_X4
Component Name
3140 RD/GN
5
X2
42
X2
Driver Door Unlatch Enable Signal
3572 WH/BN
3
X4

CAV_5
CONN_X7
3573
3573_BU
CAV_14
CAV_17
3574
3574_WH/YE
CAV_7
CAV_9
CONN_X1
6666
6666 VT/BU
CAV_10
CAV_5
CONN_X3
3578
3578_GY
CAV_5
CAV_10
3574_WH/YE
6666_VT/BU
3578_GY
1050
1050_BK
CAV_6
CONN_X2
2050
2050_BK
CAV 3
1550
1550_BK
CAV_8
3575
3575_GY/GN
CAV_2
CAV_10
CONN_X1
3583
3583_YE/GN
CAV_5
C V 4
5
X7
Non Driver Door Unlatch Enable Signal
3573 BU
14
17
Driver Door Open Switch Signal
3574 WH/YE
7
9
X1
Driver Door Unlatch Motor Unlatch Control
6666 VT/BU
10
5
X3
Driver Door Unlatch Motor Unlatch Return
3578 GY
5
10
3574 WH/YE
6666 VT/BU
3578 GY
Ground
1050 BK
6
X2
Ground
2050 BK
3
Ground
1550 BK
8
Co_Driver Door Open Switch Signal
3575 GY/GN
2
10
X1
Co Driver Door Unlatch Motor Unlatch Control
3583 YE/GN
5

CONN_X3
3579
3579_GY/BK
CAV_10
CAV_9
3575_GY/GN
3583_YE/GN
3579_GY/BK
6667
6667_BU/WH
CAV_10
CAV 3
3580
3580_BU/YE
CAV_5
CAV_8
6669
6669_GN/BK
CAV_5
CAV_2
3581
3581_GN/WH
CAV_10
CAV_7
6667_BU/WH
3580_BU/YE
6669 GN/BK
3581_GN/WH
X500
CAV_40
CAV_41
CAV_32
X600
CAV_40
CAV_41
CAV_32
X800
CAV_7
CAV_8
X700
C V 7
4
X3
Co Driver Door Unlatch Motor Unlatch Return
3579 GY/BK
10
9
3575 GY/GN
3583 YE/GN
3579 GY/BK
Left Rear Door Unlatch Motor Unlatch Control
6667 BU/WH
10
3
Left Rear Door Unlatch Motor Unlatch Return
3580 BU/YE
5
8
Right Rear Door Unlatch Motor Unlatch Control
6669 GN/BK
5
2
Right Rear Door Unlatch Motor Unlatch Return
3581 GN/WH
10
7
6667 BU/WH
3580 BU/YE
6669 GN/BK
3581 GN/WH
X500
40
41
32
X600
40
41
32
X800
7
8
X700

CAV_8
G305
G308
F27UA
F31UA
F10DA
X500
X600
X800
X700
X50A
A23D
A23P
A23LR
A23RR
K9
K84
7
8
G305
G308
F27UA 30A
F31UA
F10DA
X500
X600
X800
X700
(ATH)
Passive Entry - Antennas and Switches (ATH) Wiring Schematics

Fig. 4: Passive Entry - Antennas and Switches (ATH) Wiring Schematics

Callout
3570
CAV_2
CAV_12
CONN_X4
3570_GN/WH
3570_GN/WH
6655
CAV_3
CAV 15
6655_GN/WH
6655 GN/WH
3571
CAV_2
CAV_11
3571_VT/WH
3571_VT/WH
3576
CAV_3
CAV_5
3576_GY/BU
3576_GY/BU
6157
CAV_2
CAV_2
6157_BN/YE
6157 BN/YE
6158
CAV_2
CAV_1
6158_YE/GY
6158_YE/GY
CAV_5
CAV_5
1550
1550_BK
CAV_1
350
Component Name
Driver Door Handle Switch Signal
2
12
X4
3570 GN/WH
3570 GN/WH
Driver Door Unlatch Switch Signal
3
15
6655 GN/WH
6655 GN/WH
Co_Driver Door Handle Switch Signal
2
11
3571 VT/WH
3571 VT/WH
Co-Driver Door Exterior Switch Lock Signal
3
5
3576 GY/BU
3576 GY/BU
Left Rear Door Handle Switch Signal
2
2
6157 BN/YE
6157 BN/YE
Right Rear Door Handle Switch Signal
2
1
6158 YE/GY
6158 YE/GY
5
5
Ground
1550 BK
1
Ground

350_BK
CAV_4
2050
2050_BK
CAV_1
350_BK
CAV_4
2350
2350_BK
CAV_1
2350_BK
CAV_1
X500
CAV_31
CAV_16
X600
CAV_31
CAV_16
G308
G305
G309
G402
X700
X800
X500
X600
B27LR
B27RR
K84
B27D
B27P
B210D
A24D
B210P
A24P
RELEASE SYSTEMS WIRING SCHEMATICS
Trunk Release Wiring Schematics
350 BK
4
Ground
2050 BK
1
350 BK
4
Ground
2350 BK
1
2350 BK
1
X500
31
16
X600
31
16
G308
G305
G309
G402
X700
X800
X500
X600
(ATH)

Fig. 5: Trunk Release Wiring Schematics

Callout
CAV_31
CAV 44
CAV_2
CAV_4
CAV_3
CAV_5
CAV_1
5240
5240_RD/BU
1650
1650_BK
1650_BK
6795
6795_BU/YE
CAV_1
6188
6188_GY/YE
Component Name
31
44
2
4
3
5
1
5240 RD/BU
Ground
1650 BK
1650 BK
Lift Glass/Trunk Motor Release Control 2
6795 BU/YE
1
Lift Glass/Trunk Motor Release Control
6188 GY/YE

CAV_11
CONN_X5
2140
2140_RD/GY
CAV_1
CONN_X2
5797
5797_YE/BU
CAV_2
CAV_15
CONN_X6
5797_YE/BU
5797 BK
6795_BU/YE
6795_BU/YE
6188_GY/YE
1650_BK
CAV_1
650
650_BK
CAV_2
CAV_4
CAV_7
UVC
UVC
X200
CAV_69
CAV 58
X900
CAV 1
CAV_10
G309
G201
F16DA
F23DA
X915
X200
X900
M40
X51A
K9
S58
11
X5
2140 RD/GY
1
X2
Rear Closure Handle Switch Open Signal
5797 YE/BU
2
15
X6
5797 YE/BU
5797 BK
6795 BU/YE
6795 BU/YE
6188 GY/YE
1650 BK
1
Ground
650 BK
2
4
7
VISION-REAR VIEW, MONO
X200
69
58
X900
1
10
G309
G201
F16DA 10A
F23DA 20A
X915
X200
X900

KR95B

DTC
DTC B1474 or B3849
DTC B1534 or B1535
DTC B2494
DTC B297B or B297C
DTC B3125, B3130, or B3135
DTC B3140 or B3150

DTC B3265
DTC B3618
DTC B3930
Description
DTC B1474 02 Passenger Exterior Door Handle
Switch Circuit Short to Ground
DTC B3849 02 Driver Exterior Door Handle Switch
DTC B1534 02 Left Rear Door Handle Switch
DTC B1535 02 Right Rear Door Handle Switch
DTC B2494 00 Liftgate Handle Switch Circuit
Malfunction
DTC B297B 5A Driver Door Open Switch Circuit
Not Plausible
DTC B297C 5A Passenger Door Open Switch
Circuit Not Plausible
DTC B3125 Driver Door Only Unlock Circuit
DTC B3130 All Doors Unlock Circuit
DTC B3135 All Doors Lock Circuit
DTC B3140 00 Driver Door Unlock Switch Circuit
DTC B3150 00 Driver Front Door Lock Switch
Circuit
DTC B3265 Trunk Lid Unlatch Output Circuit
DTC B3618 00 Exterior Liftgate Unlatch Switch
Circuit Malfunction
DTC B3930 02 Child Security Lock Motors Circuit
Short to Ground
DTC B1474 OR B3849

DTC Descriptors

DTC B1474 02
Passenger Exterior Door Handle Switch Circuit Short to Ground
DTC B3849 02
Driver Exterior Door Handle Switch Circuit Short to Ground
Short to
Ground
Circuit
B3849 02
Signal
Ground
Passenger Door Handle
B1474 02
Switch Signal
Switch Ground
1. Driver Door Handle Switch Malfunction
2. Passenger Door Handle Switch Malfunction
Open/High
Resistance
Short to
Voltage
Signal Performance
The exterior door handle switch signal circuits provide inputs to the keyless entry control module when the
exterior door handle switches are activated. These inputs allow the keyless entry control module to detect a door
lock or a door unlock request. The keyless entry control module provides a 12 V signal to each exterior door
handle switch via the door handle switch signal circuits. When a door handle switch is pressed, the switch
closes and the voltage signals from the keyless entry control module are pulled to ground.

B1474 02
The keyless entry control module detects the passenger exterior door handle switch signal circuit is shorted to
ground or closed for greater than 180 seconds.
B3849 02
The keyless entry control module detects the driver exterior door handle switch signal circuit is shorted to
ground or closed for more than 180 seconds.

The keyless entry control module will ignore input from the affected door switch and the doors will not lock or
unlock when the affected door handle switch is pressed.

Schematic Reference
Power Door Locks Description and Operation
Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference

1. Ignition ON.
2. Verify the scan tool Exterior Driver Door Handle Switch or the Exterior Passenger Door Handle Switch
parameters changes between Active and Inactive when pressing and releasing the B27D Door Handle
Switch-Driver Exterior or the B27P Door Handle Switch-Passenger Exterior.


3. All OK.
1. Ignition OFF and all vehicle systems OFF, disconnect the harness connector at the appropriate B27 Door
Handle Switch-Exterior. It may take up to 2 minutes for all vehicle systems to power down.
1. Ignition OFF.
3. Ignition ON.
4. Verify the scan tool Exterior Door Handle Switch parameter is Inactive.
If not Inactive
If infinite resistance, replace the K84 Keyless Entry Control Module.
If Inactive
6. Verify the scan tool Exterior Door Handle Switch parameter is Active.
If not Active
1. Ignition OFF, remove the jumper wire, disconnect the harness connector at the K84 Keyless Entry
If less than 1 V
If Active
7. Test or replace the B27 Door Handle Switch-Exterior.
Component Testing
1. Ignition OFF, disconnect the harness connector at the appropriate B27 Door Handle Switch-Exterior.

open position.
Replace the B27 Door Handle Switch-Exterior.
closed position.

If less than 5 ohms
4. All OK
Repair Instructions
Front Side Door Outside Handle Replacement

Control Module References for keyless entry control module replacement, programming and setup
DTC B1534 OR B1535

DTC Descriptors
DTC B1534 02
Left Rear Door Handle Switch Circuit Short to Ground
DTC B1535 02
Right Rear Door Handle Switch Circuit Short to Ground
Circuit
Short to
Ground
Open/High
Resistance
Short to
Voltage
Signal Performance
B1534 02

Switch Signal
Switch Ground
B1535 02
Switch Signal
Switch Ground
1. Left Rear Door Handle Switch Malfunction
2. Right Rear Door Handle Switch Malfunction

B1534 02
The keyless entry control module detects the left rear exterior door handle switch signal circuit is shorted to
B1535 02
The keyless entry control module detects the right rear exterior door handle switch signal circuit is shorted to


Schematic Reference
Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference

1. Ignition ON.
2. Verify the scan tool Exterior Left Rear Door Handle Switch or the Exterior Right Rear Door Handle
Switch parameters changes between Active and Inactive when pressing and releasing B27LR Door
Handle Switch-Left Rear Exterior or the B27RR Door Handle Switch-Right Rear Exterior.
3. All OK.
Handle Switch-Rear Exterior. It may take up to 2 minutes for all vehicle systems to power down.
1. Ignition OFF.

Ignition ON.
Verify the scan tool Exterior Door Handle Switch parameter is Inactive.
If not Inactive
If Inactive
Verify the scan tool Exterior Door Handle Switch parameter is Active.
If not Active
If less than 1 V
If Active
Test or replace the B27 Door Handle Switch-Rear Exterior.
3.
4.
5.
6.
7.
Component Testing
1. Ignition OFF, disconnect the harness connector at the appropriate B27 Door Handle Switch-Rear
Exterior.
open position.
Replace the B27 Door Handle Switch-Rear Exterior.
closed position.
Replace the B27 Door Handle Switch-Rear Exterior.

If less than 5 ohms

4. All OK
Repair Instructions
Rear Side Door Outside Handle Replacement

DTC B2494
DTC Descriptor
DTC B2494 00
Liftgate Handle Switch Circuit Malfunction
Short to
Open/High
Ground
Resistance
Signal
B2494 00
1
Ground
1
1. Exterior Rear Compartment Lid Release Switch Malfunction
Circuit
Short to
Voltage
1
-
Signal Performance
-
When the ignition is ON, the body control module (BCM) supplies a signal to the liftgate unlatch switch
through the liftgate release switch signal circuit. When the liftgate unlatch switch is pressed, the voltage within
the signal circuit is pulled low and in response, the BCM will energize the liftgate unlatch relay.

The BCM detects a short to ground in the liftgate release switch signal circuit for greater than 60 seconds

The BCM ignores the input from the liftgate unlatch switch.
This DTC will be current for as long as the fault is present.

Schematic Reference
Release Systems Schematics
Luggage Compartment Description and Operation
Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference

1. Ignition ON.
2. Verify the scan tool Trunk Lid/Liftgate Window Exterior Unlatch Switch parameter changes between
Active and Inactive when pressing and releasing the liftgate unlatch switch.
3. All OK.

1. Ignition OFF and all vehicle systems OFF, disconnect the harness connector at the S46B liftgate unlatch
switch. It may take up to 2 minutes for all vehicle systems to power down.
1. Ignition OFF.
3. Ignition ON.
4. Verify the scan tool Trunk Lid/Liftgate Window Exterior Unlatch Switch parameter is Inactive.
If not Inactive
If infinite resistance, replace the K9 body control module.
If Inactive
6. Verify the scan tool Trunk Lid/Liftgate Window Exterior Unlatch Switch parameter is Active.
If not Active
If less than 1 V
If Active
7. Test or replace the S46B liftgate unlatch switch.
Component Testing
1. Ignition OFF, disconnect the harness connector at the S46B liftgate unlatch switch.
open position.
Replace the S46B liftgate unlatch switch.

closed position.
Replace the S46B liftgate unlatch switch.

If less than 3 ohms
4. All OK
Repair Instructions
DTC B297B OR B297C

DTC Descriptors
DTC B297B 5A
Driver Door Open Switch Circuit Not Plausible
DTC B297C 5A
Passenger Door Open Switch Circuit Not Plausible
Circuit
Driver Door Open Switch
Signal
Passenger Door Open
Switch Signal
Driver Door Latch Ground
Passenger Door Latch
Short to
Ground
Open/High
Resistance
Short to
Voltage
Signal Performance
B297B 5A
B297B 5A
B297B 5A
B297C 5A
B297C 5A
B297C 5A

Ground
1. Ajar Indicator Malfunction
The Keyless Entry Control Module provides a 12V signal to the driver and passenger door open switch signal
circuits. The driver window motor provides a 12V signal to the driver door ajar switch signal circuit. The
passenger window switch provides a 12V signal to the passenger door ajar switch signal circuit. The door open
switches and the door ajar switches are integral to each Door Latch Assembly.
The door open switch and the door ajar switch contacts will be open with the door is fully closed, the door
switches within the door latch are designed so that the when the door is ajar, the contact in the door ajar switch
closes, the voltage is pulled low and the window motor will then send a serial data message to the BCM
indicating that the door is ajar. When the door is opened further, the contact in the door open switch will then
close providing a ground for the door open signal circuit, the Keyless Entry Control Module will then detect
that the door is open.

B297B 5A
The keyless entry control module detects the driver door open switch is Active while receiving a serial
data message from the BCM that the driver door ajar switch is Inactive.
The condition must be present for greater than 30 seconds
B297C 5A
The keyless entry control module detects the passenger door open switch is Active while receiving a
serial data message from the BCM that the passenger door ajar switch is Inactive.
The condition must be present for greater than 30 seconds.
B297B 5A or B297C 5A
The driver information center will display the message: Service Steering Column Lock.

When the keyless entry control module receives a serial data message from the BCM that the door is ajar
before the keyless entry control module detects the door open switch is active, then the DTC will be a
history DTC.

Schematic Reference
Steering Wheel and Column Description and Operation
Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference

1. Ignition ON.
2. Verify the scan tool Body Control Module Driver Door Ajar Switch parameter changes between Inactive
and Active when opening and closing the driver door.
Refer to Door Ajar Indicator Malfunction
3. Verify the scan tool Keyless Entry Control Module Driver Door Ajar Switch parameter changes between
Inactive and Active when opening and closing the driver door.

4. Verify the scan tool Body Control Module Passenger Door Ajar Switch parameter changes between

Inactive and Active when opening and closing the passenger door.
Refer to Door Ajar Indicator Malfunction
5. Verify the scan tool Keyless Entry Control Module Passenger Door Ajar Switch parameter changes
between Inactive and Active when opening and closing the passenger door.

6. All OK.
1. Ignition OFF and all vehicle systems OFF, disconnect the harness connector at the appropriate A23 Door
Latch Assembly. It may take up to 2 minutes for all vehicle systems to power down.
A23D Door Latch Assembly-Driver - ground circuit terminal 8
A23P Door Latch Assembly-Passenger - ground circuit terminal 3
1. Ignition OFF.
3. Ignition ON.
4. Verify the scan tool Door Ajar Switch parameter is Inactive.
If not Inactive
2. Test for infinite resistance between the signal circuit terminal listed below and ground.
A23D Door Latch Assembly-Driver - signal circuit terminal 7
A23P Door Latch Assembly-Passenger - signal circuit terminal 2
If Inactive
5. Install a 3 A fused jumper wire between the circuit terminals listed below and ground.
A23D Door Latch Assembly-Driver - signal circuit terminal 7
A23P Door Latch Assembly-Passenger - signal circuit terminal 2

6. Verify the scan tool Door Ajar Switch parameter is Active.

If not Active
1. Ignition OFF, remove the fused jumper wire, disconnect the harness connector at the K84 Keyless
Entry Control Module, ignition ON.
If less than 1 V
If Active
7. Test or replace the A23 Door Latch Assembly.
Component Testing
Static Test
1. Ignition OFF, disconnect the harness connector at the appropriate A23 Door Latch Assembly.
2. With the door in the closed position, test for infinite resistance between the signal and the ground
terminals listed below:
A23D Door Latch Assembly-Driver - signal terminal 7 and ground terminal 8
A23P Door Latch Assembly-Passenger - signal terminal 2 and ground terminal 3
If not the specified value, replace the A23 Door Latch Assembly.
3. With the door in the open position, test for less than 5 ohms between the signal and the ground terminals
listed below:
A23D Door Latch Assembly-Driver - signal terminal 7 and ground terminal 8
A23P Door Latch Assembly-Passenger - signal terminal 2 and ground terminal 3
If greater than the specified range, replace the A23 Door Latch Assembly.
Repair Instructions
Front Side Door Latch Replacement

DTC B3125, B3130, OR B3135


DTC Descriptors
DTC B3125
Driver Door Only Unlock Circuit
DTC B3130
All Doors Unlock Circuit
DTC B3135
All Doors Lock Circuit
Circuit
BCM B+
Door Latch Control

Driver Door Lock Motor
Lock Control
Door Lock Actuator
Unlock Control
Short to
Ground
B3125 02,
B3130 02,
B3135 02
B3125 02,
B3130 02,
B3135 02
B3125 02,
B3130 02,
B3135 02
B3125 02,
B3130 02,
B3135 02
Open/High
Resistance
Short to
Voltage
Signal Performance
B3125 02, B3130

02, B3135 02
B3125 04, B3130

04, B3135 04
B3125 04, B3130
04, B3135 04
B3125 04, B3130
04, B3135 04
B3125 01,
B3130 01,
B3135 01
B3125 01,
B3130 01,
B3135 01
B3125 01,
B3130 01,
B3135 01
The body control module (BCM) powers the reversible door latch assemblies by providing battery positive
voltage and ground to the appropriate lock and unlock control circuits of the door latch assemblies. The lock
and unlock control circuits of the rear doors and passenger door latch assemblies are all connected together.
When the door latch assemblies are not active, all actuator lock and unlock control circuits are supplied a
floating voltage door driver by the BCM. Transitioning of the lock actuators to the lock or unlocked position
depends upon which control circuits receive voltage and which control circuits receive ground.
Ignition ON

B3125 01, B3130 01, B3135 01

The BCM detects a short to battery on a door latch control circuit
B3125 02, B3130 02 and B3135 02
A short to ground or an open/high resistance in the BCM B+ circuit.

The BCM detects a short to ground on a door latch control circuit.
B3125 04, B3130 04, B3135 04

The BCM detects an open/high resistance on a door latch control circuit
All the power door locks will be inoperative.


Schematic Reference

Body Control System Schematics

Circuit Testing
Connector Repairs
Wiring Repairs

Scan Tool Reference

1. Ignition ON.
2. Verify the scan tool BCM Central Door Lock Switch on Console parameter changes from Inactive to
Lock and Unlock when cycling the door lock switch between LOCK and UNLOCK.
Refer to Power Door Locks Malfunction
3. Verify all vehicle doors Lock and Unlock when commanding the All Doors Lock/Unlock with a scan
tool.
If only the driver door LOCK or UNLOCK functions do not work
Refer to Circuit/System Testing below - Driver Door Lock Malfunction.
If one or more, but not all, passenger door LOCK or UNLOCK functions do not work
Refer to Circuit/System Testing below - Passenger Door Lock Malfunction.
If all door LOCK and UNLOCK functions do not work

Refer to Circuit/System Testing below- All Door Lock Inoperative.
If the LOCK and UNLOCK function for all doors works

4. All OK.
Driver Door Lock Malfunction

1. Ignition OFF, disconnect the harness connector at the A23D Door Latch Assembly-Driver. Ignition ON.
NOTE:
Leaving the DMM connected between a control circuit and ground for
greater than 20 seconds will cause the K9 Body Control Module to
interpret the test as a system fault and will cause the voltage on the
control circuit to drop to 0 V. If the voltage drops to 0 V, operate the door
locks using the central door lock switch to restore the voltage for testing.
2. Test for greater than 7 V between the control circuit terminal 3 and ground.
If 7 V or less

If greater than 7 V
NOTE:
locks using the central door lock switch to restore the voltage for testing.
If 7 V or less
If greater than 7 V
4. Test or replace the A23D Door Latch Assembly-Driver.
Passenger Door Lock Malfunction
1. Ignition OFF, verify the harness connector is firmly seated and secure for the appropriate passenger or
rear A23 Door Latch Assembly.
If the harness connector not seated or secure
Firmly seat and secure the harness connector at the passenger or rear A23 Door Latch Assembly.
If the harness connector is firmly seated and secure
2. Disconnect the harness connector at the appropriate passenger or rear A23 Door Latch Assembly. Ignition
ON.
NOTE:


locks using the door lock switch to restore the voltage for testing.
3. Test for greater than 7 V between the control circuit terminal listed below and ground:
A23P Door Latch Assembly-Passenger - control circuit terminal 7
A23RR Door Latch Assembly-Right Rear - control circuit terminal 7
A23LR Door Latch Assembly-Left Rear - control circuit terminal 2
If 7 V or less
If greater than 7 V
NOTE:
If 7 V or less
3. Test for less than 2 ohms between the control circuit terminals listed below:
X50A Fuse Block-Underhood control circuit terminal 4 X2 and A23P Door Latch AssemblyPassenger control circuit terminal 8
X50A Fuse Block-Underhood control circuit terminal 12 X2 and K9 Body Control Module
control circuit terminal 2 X6
If greater than 2 ohms, repair the open/high resistance on the circuit.
4. Connect the X2 harness connector at the X50A Fuse Block-Underhood
5. Test for less than 2 ohms between the A23P Door Latch Assembly-Passenger control circuit
terminal 8 and the K9 Body Control Module control circuit terminal 2 X6
If greater than 2 ohms, replace the X50A Fuse Block-Underhood.

6. Connect the X6 harness connector at the K9 Body Control Module

7. Ignition ON, test for greater than 7 V between the A23P Door Latch Assembly-Passenger control
circuit terminal 8 and ground
If 7 V or less, replace the K9 Body Control Module
If greater than 7 V
All Door Locks Inoperative
1. Ignition OFF.
3. Ignition OFF.
5. Disconnect the harness connector at each of the A23 Door Latch Assemblies.
If infinite resistance, replace the appropriate A23 Door Latch Assembly.
3. Ignition OFF, connect the X2 harness connector at the K9 Body Control Module. Disconnect the harness
connector at the A23D Door Latch Assembly-Driver, ignition ON.
NOTE:
If 7 V or less
2. Test for infinite resistance between the control circuit terminal listed below and ground:
Control circuit terminal 1 X6


If greater than 7 V
Component Testing
the A23 Door Latch Assembly should perform the LOCK and UNLOCK function.
If the actuator does not perform the LOCK and UNLOCK function
Replace the A23 Door Latch Assembly.
If the actuator performs the LOCK and UNLOCK function
3. All OK
Repair Instructions

Rear Side Door Latch Replacement
DTC B3140 OR B3150

DTC Descriptors
DTC B3140 00
Driver Door Unlock Switch Circuit
DTC B3150 00

Driver Front Door Lock Switch Circuit

Short to
Open/High
Circuit
Ground
Resistance
Lock Signal
B3150 00
1
Unlock Signal
B3140 00
2
Ground
3
1. Door Lock Switch Lock Function Inoperative
2. Door Lock Switch Unlock Function Inoperative
3. Door Lock Switch Lock and Unlock Functions Inoperative
Short to
Voltage
1
2
-
Signal Performance
-
The body control module (BCM) monitors the voltage level of the door lock and door unlock signal circuits.
When the driver door lock switch is in the open position, the voltage level in the signal circuit will be near 0 V.
When the driver door lock switch is pressed to the lock or unlock position, a signal will be sent to the BCM
requesting a lock or unlock command.

B3140 00
The BCM detects short to ground in the unlock signal circuit for greater than 60 seconds.
B3150 00
The BCM detects a short to ground in the lock signal circuit for greater than 60 seconds.
B3140 00
The BCM will ignore the unlock signal and the doors will not unlock when using the driver door lock switch.
B3150 00
The BCM will ignore the lock signal and the doors will not lock when using the driver door lock switch.

Schematic Reference
Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference

1. Ignition ON.
2. Verify the scan tool Central Door Lock Switch on Console parameter changes from Inactive to Lock and
Unlock when pushing the appropriate switch on the S13D Door Lock Switch-Driver.
3. All OK.
1. Ignition OFF and all vehicle systems OFF, disconnect the harness connector at the S13D Door Lock

1. Ignition OFF.
Ignition ON.
Verify the scan tool Central Door Lock Switch on Console parameter is Inactive.
If not Inactive
2. Test for infinite resistance between the S13D Door Lock Switch-Driver signal circuit terminal 3
and ground.
3. Test for infinite resistance between the S13D Door Lock Switch-Driver signal circuit terminal 4
and ground.
If Inactive
Verify the scan tool Central Door Lock Switch on Console parameter is Unlock.
If not Unlock
1. Ignition OFF, remove the 3 A fused jumper wire, disconnect the X2 harness connector at the K9
Body Control Module, ignition ON.
If less than 1 V
If Unlock
Verify the scan tool Central Door Lock Switch on Console parameter is Lock.
If not Lock
1. Ignition OFF, remove the 3 A fused jumper wire, disconnect the X2 harness connector at the K9
Body Control Module, ignition ON.
If less than 1 V
3.
4.
5.
6.
7.
8.

If Lock
9. Test or replace the S13D Door Lock Switch-Driver.
Component Testing
1. Ignition OFF, disconnect the harness connector at the S13D Door Lock Switch-Driver.
open position.
Replace the S13D Door Lock Switch-Driver.
open position.

Lock position.
Replace theS13D Door Lock Switch-Driver.

If less than 2 ohms
Unlock position.

If less than 2 ohms
6. All OK
Repair Instructions
Door Lock Switch Replacement

DTC B3265
DTC Descriptor
DTC B3265
Trunk Lid Unlatch Output Circuit
Circuit
Control
Ground
Short to
Ground
B3265 02
-
Open/High
Resistance
B3265 04
B3265 04
Short to
Voltage
B3265 01
-
Signal Performance
-
The body control module (BCM) applies battery positive voltage to the rear compartment lid unlatch relay
control circuit, which energizes the coil side of the rear compartment lid unlatch relay. The switch side of the
rear compartment lid unlatch relay then closes, supplying battery positive voltage through the relay and the
latch motor voltage control circuit to the rear compartment lid latch. The rear compartment lid latch then
releases the rear compartment lid so that it may be manually raised to an open position.
When the relay is being actively commanded by the BCM

B3265 01
The BCM detects a short to voltage on the rear compartment lid unlatch relay control circuit.
B3265 02
The BCM detects a short to ground on the rear compartment lid unlatch relay control circuit.

B3265 04
The BCM detects an open/high resistance on the rear compartment lid unlatch relay control circuit or an
open/high resistance on the relay ground circuit.
The rear compartment lid latch will malfunction.


Schematic Reference
Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference

1. Ignition ON.
2. Verify the M40 Rear Compartment Lid Latch releases when commanding the Trunk Lid Unlatch with a
scan tool.
If the M40 Rear Compartment Lid Latch does not UNLATCH


If the M40 Rear Compartment Lid Latch does UNLATCH
3. All OK.
1. Ignition OFF and all vehicle systems OFF, disconnect the KR95B Rear Compartment Lid Unlatch Relay.
It may take up to 2 minutes for all vehicle systems to power down.
1. Ignition OFF.
4. Verify the test lamp briefly turns ON and OFF when commanding the Trunk Lid Unlatch with a scan
tool.
5. Test or replace the KR95B Rear Compartment Lid Unlatch Relay.
Component Testing
Relay Test
1. Ignition OFF, disconnect the KR95B Rear Compartment Lid Unlatch Relay.


Replace the KR95B Rear Compartment Lid Unlatch Relay.

4 and 3
4 and 5
4 and 1
5 and 1


If less than 2 ohms
6. All OK
Repair Instructions
DTC B3618
DTC Descriptor
DTC B3618 00

Exterior Liftgate Unlatch Switch Circuit Malfunction

Short to
Open/High
Ground
Resistance
Signal
B3618 00
1
Ground
1
1. Exterior Rear Compartment Lid Release Switch Malfunction
Circuit
Short to
Voltage
1
-
Signal Performance
-
When the ignition is ON, the body control module (BCM) supplies a signal to the rear compartment lid unlatch
switch through the trunk release switch signal circuit. When the exterior rear compartment lid release switch is
pressed, the voltage within the signal circuit is pulled low and in response, the BCM will energize the rear
compartment lid unlatch relay.

The BCM detects a short to ground in the rear compartment lid unlatch switch signal circuit for greater than 60
seconds
The BCM ignores the input from the rear compartment lid unlatch switch.

Schematic Reference


Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference

1. Ignition ON.
Active and Inactive when pressing and releasing the S58A Rear Compartment Lid Unlatch SwitchExterior.
3. All OK.
1. Ignition OFF and all vehicle systems OFF, disconnect the X915 inline harness connector at the S58A
Rear Compartment Lid Unlatch Switch-Exterior. It may take up to 2 minutes for all vehicle systems to
power down.
1. Ignition OFF.
3. Ignition ON.
If not Inactive

If Inactive
If not Active
1. Ignition OFF, remove the 3 A fused jumper wire, disconnect the harness connector at the K9 Body
If less than 1 V
If Active
7. Test or replace the S58A Rear Compartment Lid Unlatch Switch-Exterior.
Component Testing
Trunk Release Switch

1. Ignition OFF, disconnect the X915 inline harness connector at the S58A Rear Compartment Lid Unlatch
Switch-Exterior.
2. Test for infinite resistance between the signal circuit terminal 4 and the ground circuit terminal 3 with the
switch in the open position.
Replace the S58A Rear Compartment Lid Unlatch Switch-Exterior.
3. Test for less than 3 ohms between the signal circuit terminal 4 and the ground circuit terminal 3 with the

If less than 3 ohms
4. All OK
Repair Instructions

Rear License Plate Lamp Wiring Harness Replacement
Control Module References for BCM replacement, setup, and programming
DTC B3930
DTC Descriptor
DTC B3930 02
Child Security Lock Motors Circuit Short to Ground
Short to
Ground
Control
B3930 02
Ground
1. Child Security Door Lock Malfunction
Circuit
Open/High
Resistance
1
1
Short to
Voltage
1
-
Signal Performance
-
The child door lockout switch is on the driver door lock/window switch and controls the function of the rear
interior door handles as well as the function of the rear window switches. When the body control module
receives a command from the window lockout switch, it will apply voltage to the door lock security relay coil,
this will energize the relay and the contact within the relay will then direct the voltage to lock the left rear and
right rear child locks and then isolate them from the normal door lock system to prevent the rear doors from
being opened by using the interior rear door handles.
When the relay is being actively commanded by the body control module.
The body control module detects a short to ground in the child security lock relay circuit.
The interior rear door handles will always function or will always be disabled depending upon the state of

the rear door latch when the fault occurred.

The body control module will command the lockout indicator to flash ON and OFF when the lockout
switch is pressed.

Schematic Reference
Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference

1. Ignition ON.
2. Verify both interior rear door handles do not open the rear doors when commanding the Child Security
Lock Motors ON with a scan tool.
If both interior door handles open the rear doors
If both interior door handles do not open the rear doors

3. Verify both interior rear door handles will open the rear doors when commanding the Child Security Lock
Motors OFF with a scan tool.
4. All OK.
1. Ignition OFF and all vehicle systems OFF, disconnect the X1 harness connector at the X50A Fuse BlockUnderhood. It may take up to 2 minutes for all vehicle systems to power down.
1. Ignition OFF.
ground.
If less than 1 V, replace the X50A Fuse Block-Underhood.
If the test lamp is not illuminated
6. Listen as the KR113 Child Security Lock Disable Relay activates.
If the KR113 Child Security Lock Disable Relay does not activate
Block-Underhood.
ground.


If the KR113 Child Security Lock Disable Relay activates
Repair Instructions

Control Module References for body control module replacement, setup and programming
SYMPTOMS - VEHICLE ACCESS

NOTE:
1. Perform the Diagnostic System Check - Vehicle , before using the Symptom Tables in order to verify
that all of the following are true:
There are no DTCs set
The control modules can communicate via the serial data link
following systems description:
Door Ajar Indicator Description and Operation
Inspect for aftermarket devices which may affect the operation of the system. Refer to Checking
cause the symptom.
Intermittent
Symptom List
Exterior Door Handle Switch Malfunction

Power Door Child Lock Malfunction
Door Ajar Indicator Malfunction

Power Door Locks Malfunction

Trunk Release Malfunction
Trunk Ajar Indicator Malfunction
EXTERIOR DOOR HANDLE SWITCH MALFUNCTION

DTC Descriptors
DTC B1474 02
Passenger Exterior Door Handle Switch Circuit Short to Ground
DTC B1534 02
Left Rear Door Handle Switch Circuit Short to Ground
DTC B1535 02
Right Rear Door Handle Switch Circuit Short to Ground
DTC B3849 02
Driver Exterior Door Handle Switch Circuit Short to Ground
Circuit
Signal
Ground
Switch Signal
Switch Ground
Switch Signal
Short to
Ground
Open/High
Resistance
Short to
Voltage
Signal Performance
B3849 02
B1474 02
B1534 02

Switch Ground
B1535 02
Switch Signal
Switch Ground
1. Driver Door Handle Switch Malfunction
2. Passenger Door Handle Switch Malfunction
3. Left Rear Door Handle Switch Malfunction
4. Right Rear Door Handle Switch Malfunction

B1474 02
The keyless entry control module detects the passenger exterior door handle switch signal circuit is shorted to
B1534 02
The keyless entry control module detects the left rear exterior door handle switch signal circuit is shorted to
B1535 02
The keyless entry control module detects the right rear exterior door handle switch signal circuit is shorted to
B3849 02
The keyless entry control module detects the driver exterior door handle switch signal circuit is shorted to



Schematic Reference
Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference

1. Ignition ON.
2. Verify the scan tool Exterior Driver Door Handle Switch, Exterior Passenger Door Handle Switch,
Exterior Left Rear Door Handle Switch and Exterior Right Rear Door Handle Switch parameters changes
between Active and Inactive when pressing and releasing each B27 Door Handle Switch-Exterior.
3. All OK.

Handle Switch-Exterior. It may take up to 2 minutes for all vehicle systems to power down.
1. Ignition OFF.
3. Ignition ON.
4. Verify the scan tool Exterior Door Handle Switch parameter is Inactive.
If not Inactive
If Inactive
6. Verify the scan tool Exterior Door Handle Switch parameter is Active.
If not Active
If less than 1 V
If Active
7. Test or replace the B27 Door Handle Switch-Exterior.
Component Testing
1. Ignition OFF, disconnect the harness connector at the appropriate B27 Door Handle Switch-Exterior.
open position.


closed position.

If less than 5 ohms
4. All OK
Repair Instructions

DOOR AJAR INDICATOR MALFUNCTION

Diagnostic Procedure Instructions provides an overview of each diagnostic category
Circuit
Left Front Door Ajar
Switch Signal
Signal
Right Front Door Ajar
Switch Signal
Right Rear Door Ajar
Switch Signal
Driver Door Latch Ground
Passenger Door Latch
Ground
Left Rear Door Latch
Ground
Short to
Ground
Open/High
Resistance
Short to
Voltage
Signal Performance

Right Rear Door Latch

Ground
1. Ajar indicator always illuminated
2. Ajar indicator inoperative
If the vehicle is equipped with power windows, the window motors or the window switches each provide a 12 V
signal to their respective door ajar switch signal circuits. The door ajar switches are integral to each door latch
assembly. When a door is opened, the normally open door ajar switch closes. With the door ajar switch closed,
ground is provided to the door ajar switch signal circuit and the voltage within the signal circuit drops. The
window motor or the window switches will detect the voltage drop and will send a serial data message to the
body control module which will then send a message to the instrument panel cluster to command the door ajar
message.
Schematic Reference
Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference

1. Ignition ON.
2. Verify the appropriate scan tool Door Ajar Switch parameter changes between Inactive and Active when
opening and closing the driver door, the passenger door, the left rear door and right rear door.


3. All OK.
1. Ignition OFF and all vehicle systems OFF, disconnect the harness connector at the appropriate A23 door
latch assembly. It may take up to 2 minutes for all vehicle systems to power down.
2. Test for less than 10 ohms between the ground circuit terminal listed below and ground.
A23D door latch assembly-driver - ground circuit terminal 8
A23P door latch assembly-passenger - ground circuit terminal 3
A23LR door latch assembly-left rear - ground circuit terminal 8
A23RR door latch assembly-right rear - ground circuit terminal 3
1. Ignition OFF.
3. Ignition ON.
4. Verify the appropriate scan tool Door Ajar Switch parameter is Inactive.
If not Inactive
1. Ignition OFF, disconnect the harness connector at the appropriate component listed below:
M74D window motor - driver (AXG)
S79D window switch - driver (AEC)
S79P window switch - passenger
S79LR window switch - left rear
S79RR window switch - right rear
A23D door latch assembly-driver - signal circuit terminal 6
A23P door latch assembly-passenger - signal circuit terminal 1
A23LR door latch assembly-left rear - signal circuit terminal 6
A23RR door latch assembly-right rear - signal circuit terminal 1
If infinite resistance, replace the appropriate component.
If Inactive
5. Install a 3 A fused jumper wire between the signal circuit terminal listed below and ground.
A23D door latch assembly-driver - signal circuit terminal 6

A23P door latch assembly-passenger - signal circuit terminal 1

A23LR door latch assembly-left rear - signal circuit terminal 6
A23RR door latch assembly-right rear - signal circuit terminal 1
6. Verify the scan tool Door Ajar Switch parameter is Active.
If not Active
1. Ignition OFF, disconnect the harness connector at the appropriate component listed below, ignition
ON.
M74D window motor - driver (AXG)
S79D window switch - driver (AEC)
S79P window switch - passenger
S79LR window switch - left rear
S79RR window switch - right rear
If less than 1 V
If less than 2 ohms, replace the appropriate component.
If Active
7. Test or replace the A23 door latch assembly.
Component Testing
1. Ignition OFF, disconnect the harness connector at the appropriate A23 door latch assembly.
2. Test for infinite resistance between the terminals listed below with the switch in the open position.
Driver door latch signal terminal 6 and ground terminal 8
Left rear door latch signal terminal 6 and ground terminal 8
Right rear door latch signal terminal 1 and ground terminal 3
Passenger door latch signal terminal 1 and ground terminal 3
Replace the A23 door latch assembly.
3. Test for less than 5 ohms between the terminals listed below with the switch in the closed position.
Driver door latch signal terminal 6 and ground terminal 8
Left rear door latch signal terminal 6 and ground terminal 8
Right rear door latch signal terminal 1 and ground terminal 3
Passenger door latch signal terminal 1 and ground terminal 3

Replace the A23 door latch assembly.
If less than 5 ohms

4. All OK
Repair Instructions

POWER DOOR CHILD LOCK MALFUNCTION

Circuit
Left Rear Door Latch Lock
Status Signal
Left Rear Door Latch Child
Lock Control
Left Rear Door Latch
Ground
Lock Status Signal
Child Lock Control
Ground
Door Lock Security Relay
Control
Short to
Ground
Open/High
Resistance
Short to
Voltage
Signal Performance
B3125 02,
B3130 02,
B3135 02
B3125 02,
B3130 02,
B3135 02
B3930 02

Underhood Fuse Block

1
Ground
1. Both Child Door Lockouts Inoperative
2. Left Rear Child Door Lockout Inoperative
3. Right Rear Child Door Lockout Inoperative
4. Rear Windows Always Function From Local Rear Window Switches
The child door lockout switch is on the driver door lock/window switch and controls the child locks on the rear
doors as well as the rear window switches. When the body control module receives a command from the
window lockout switch, it will apply voltage to the door lock security relay coil, this will energize the relay and
the contact within the relay will then direct the voltage to lock the left rear and right rear child locks and then
isolate them from the normal door lock system to prevent the rear doors from being opened by using the interior
rear door handles.
The body control module monitors the voltage level of the rear lock status signal circuits to determine if the rear
door latches have been locked out. A switch within the rear door latch will be open or closed depending upon
the lockout status of the rear latch. If the rear latches are not locked out, the switch will be open and the body
control module will allow normal functions of the rear window switches. If the latches have been lockout, the
switch will be closed, pulling the voltage within the signal circuit to 0 volts and the body control module will
send a serial data message to the rear window switches which will disable the functions of the rear windows
from the local rear window switches
Schematic Reference
Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference


1. Ignition ON.
2. Verify both interior rear door handles do not open the rear doors when commanding the Child Security
If both interior rear door handles open the rear doors
Refer to Circuit/System Testing below- Security Lockout Inoperative.
If a single interior rear door handle opens the rear door

Refer to Circuit/System Testing below- Single Door Security Lockout Malfunction.

3. Verify both interior rear door handles will open the rear doors when commanding the Child Security Lock
Motors OFF with a scan tool.
If both interior rear door handles do not open the rear doors
Refer to Circuit/System Testing - Security Lockout Inoperative.
If a single interior rear door handle does not open the rear door
Refer to Circuit/System Testing below- Single Door Security Lockout Malfunction.

4. Verify both rear window switches do not open the rear windows when commanding the Child Security
If a rear window switch continues to function
Refer to Circuit/System Testing below- Rear Window Lockout Inoperative.

If the rear window switches areinoperative
5. Verify the scan tool Window Lockout Switch parameter changes between On and Off when pressing the
lockout switch on the S79D Window Switch-Driver.

6. All OK.

Security Lockout Inoperative

1. Ignition OFF and all vehicle systems OFF, disconnect the X1 harness connector at the X50A Fuse BlockUnderhood. It may take up to 2 minutes for all vehicle systems to power down.
1. Ignition OFF.
ground.
If less than 1 V, replace the X50A Fuse Block-Underhood.
If the test lamp is not illuminated
6. Listen as the KR113 Child Security Lock Disable Relay activates.
If the KR113 Child Security Lock Disable Relay does not activate
Block-Underhood.
ground.
If the KR113 Child Security Lock Disable Relay activates
Single Door Security Lockout Malfunction
1. Ignition OFF, disconnect the harness connector at the appropriate A23 Door Latch Assembly-Rear.
Ignition ON

2. Connect a test lamp between control circuit terminals listed below:

A23LR Door Latch Assembly-Left Rear - control circuit terminal 4 and control circuit terminal 7
A23RR Door Latch Assembly-Right Rear - control circuit terminal 2 and control circuit terminal 9
3. Verify the test lamp turns ON and OFF when commanding the Child Security Lock Motors ON and OFF
with a scan tool.
1. Ignition OFF, remove the tests lamp, disconnect the harness connector at the K9 Body Control
Module.
4. Test or replace the A23 Door Latch Assembly-Rear.
Rear Window Lockout Inoperative
1. Ignition OFF and all vehicle systems OFF, disconnect the harness connector at the appropriate A23 Door
Latch Assembly-Rear. It may take up to 2 minutes for all vehicle systems to power down.
2. Test for less than 10 ohms between the ground circuit terminal listed below and ground.
A23LR Door Latch Assembly-Left Rear - ground circuit terminal 8
A23RR Door Latch Assembly-Right Rear - ground circuit terminal 3
1. Ignition OFF.
3. Ignition ON.
4. Verify the scan tool Rear Child Security Lock Switch parameter is Inactive.
If not Inactive
A23LR Door Latch Assembly-Left Rear - signal circuit terminal 9
A23RR Door Latch Assembly-Right Rear - signal circuit terminal 4
If Inactive
5. Install a 3 A fused jumper wire between the signal and the ground circuit terminals listed below:
A23LR Door Latch Assembly-Left Rear - signal circuit terminal 9 and ground circuit terminal 8

A23RR Door Latch Assembly-Right Rear - signal circuit terminal 4 and ground circuit terminal 3
6. Verify the scan tool Rear Child Security Lock Switch parameter is Active.
If not Active
1. Ignition OFF, remove the 3A fused jumper wire, disconnect the harness connector at the K9 Body
If less than 1 V
If Active
7. Test or replace the A23 Door Latch Assembly-Rear.
Component Testing
Door Latch Test

1. Ignition OFF, disconnect the harness connector at the appropriate A23 Door Latch Assembly-Rear.
the A23 Door Latch Assembly-Rear should perform the LOCK and UNLOCK functions.
If the function does not perform the LOCK and UNLOCK function
Replace the A23 Door Latch Assembly-Rear.
If the function performs the LOCK and UNLOCK function
3. All OK
Repair Instructions

Control Module References for body control module replacement, programming and setup
POWER DOOR LOCKS MALFUNCTION



Circuit
BCM B+
Driver Door Unlock
Control
Doors Lock Control
Passenger Doors Unlock
Control
Short to
Ground
B3125 02,
B3130 02,
B3135 02
B3125 02,
B3130 02,
B3135 02
B3125 02,
B3130 02,
B3135 02
B3125 02,
B3130 02,
B3135 02
B3150 00
B3140 00
Open/High
Resistance
Short to
Voltage
Signal Performance
B3125 02, B3130

02, B3135 02
B3125 04, B3130

04, B3135 04
B3125 04, B3130
04, B3135 04
B3125 04, B3130
04, B3135 04
Door Lock Switch Signal

1
Door Unlock Switch Signal
2
Central Door Lock Switch
3
Ground
1. Door Lock Switch Lock Function Inoperative
2. Door Lock Switch Unlock Function Inoperative
3. Door Lock Switch Lock and Unlock Functions Inoperative
B3125 01,
B3130 01,
B3135 01
B3125 01,
B3130 01,
B3135 01
B3125 01,
B3130 01,
B3135 01
1
2
-
The body control module (BCM) powers the reversible door latch assemblies by providing battery positive
voltage and ground to the appropriate lock and unlock control circuits of the door latch assemblies. The lock
and unlock control circuits of the rear doors and passenger door latch assemblies are all connected together.
When the door latch assemblies are not active, all actuator lock and unlock control circuits are supplied a
floating voltage door driver by the BCM. Transitioning of the lock actuators to the lock or unlocked position
depends upon which control circuits receive voltage and which control circuits receive ground.
The BCM supplies a 12 V signal to each of the door lock and door unlock signal circuits. When the door lock
switches are in the open position, the voltage level in the signal circuit will be near 12 V. When any door lock
switch is pressed to the lock or unlock position, the voltage level in the appropriate signal circuit will drop to 0
V and the BCM will detect the voltage drop and command the door latches to perform the requested lock or
unlock command.
The underhood fuse block contains a PCB relay which controls the functions of the electronic child locks which
is part of the rear door latch assemblies. When the relay is in it's inactive state and the BCM commands the
latches to LOCK and UNLOCK, voltage will pass through the relay contacts for normal LOCK and UNLOCK
functions of the passenger, left rear and right rear door latch assemblies

Schematic Reference

Body Control System Schematics

Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference

1. Ignition ON.
2. Verify the scan tool Central Door Lock Switch on Console parameter changes from Inactive to Lock and
Unlock when cycling the S13D Door Lock Switch-Driver between LOCK and UNLOCK.
Refer to Circuit/System Testing below- Driver Door Lock Switch Malfunction.
3. Verify all vehicle doors LOCK and UNLOCK when commanding the All Door Lock/Unlock with a scan
tool.
If only the driver door LOCK or UNLOCK functions do not work
Refer to Circuit/System Testing below- Driver Door Lock Malfunction.
If one or more, but not all, passenger door LOCK or UNLOCK functions do not work
Refer to Circuit/System Testing below- Passenger Door Lock Malfunction.

If all door LOCK and UNLOCK functions do not work

Refer to Circuit/System Testing below- All Door Lock Inoperative.
If the LOCK and UNLOCK function for all doors works

4. All OK.
Driver Door Lock Switch Malfunction

1. Ignition OFF and all vehicle systems OFF, disconnect the harness connector at the S13D Door Lock
1. Ignition OFF.
3. Ignition ON.
4. Verify the scan tool Central Door Lock Switch on Console parameter is Inactive.
If not Inactive
2. Test for infinite resistance between the K9 Body Control Module signal circuit terminal 15 X2 and
ground.
3. Test for infinite resistance between the K9 Body Control Module signal circuit terminal 19 X2 and
ground.
If Inactive
6. Verify the scan tool Central Door Lock Switch on Console parameter is Unlock.
If not Unlock
1. Ignition OFF, remove the fused jumper wire, disconnect the harness connector at the K9 Body
2. Test for less than 1 V between the signal circuit terminal and ground.
If less than 1 V


If Unlock
8. Verify the scan tool Central Door Lock Switch on Console parameter is Lock.
If not Lock
1. Ignition OFF, remove the fused jumper wire, disconnect the harness connector at the K9 Body
2. Test for less than 1 V between the signal circuit terminal and ground.
If less than 1 V
If Lock
9. Test or replace the S13D Door Lock Switch-Driver.
Driver Door Lock Malfunction

1. Ignition OFF, verify the harness connector is firmly seated and secure for the A23D Door Latch
Assembly-Driver.
Firmly seat and secure the harness connector at the A23D Door Latch Assembly-Driver.
2. Disconnect the harness connector at the A23D Door Latch Assembly-Driver. Ignition ON.
NOTE:
If 7 V or less


If greater than 7 V
NOTE:
If 7 V or less
If greater than 7 V
5. Test or replace the A23D Door Latch Assembly-Driver.
Passenger Door Lock Malfunction
1. Ignition OFF, verify the harness connector is firmly seated and secure for the appropriate passenger or
rear A23 Door Latch Assembly.
Firmly seat and secure the harness connector at the passenger or rear A23 Door Latch Assembly.
2. Disconnect the harness connector at the appropriate passenger or rear A23 Door Latch Assembly. Ignition
ON.
NOTE:


If 7 V or less
If greater than 7 V
NOTE:
If 7 V or less
3. Test for less than 2 ohms between the control circuit terminals listed below:
X50A Fuse Block-Underhood control circuit terminal 4 X2 and A23P Door Latch AssemblyPassenger control circuit terminal 8
X50A Fuse Block-Underhood control circuit terminal 12 X2 and K9 Body Control Module
control circuit terminal 2 X6
If greater than 2 ohms, repair the open/high resistance on the circuit.
4. Connect the X2 harness connector at the X50A Fuse Block-Underhood
5. Test for less than 2 ohms between the A23P Door Latch Assembly-Passenger control circuit
terminal 8 and the K9 Body Control Module control circuit terminal 2 X6
If greater than 2 ohms, replace the X50A Fuse Block-Underhood.
6. Connect the X6 harness connector at the K9 Body Control Module
7. Ignition ON, test for greater than 7 V between the A23P Door Latch Assembly-Passenger control
circuit terminal 8 and ground
If 7 V or less, replace the K9 Body Control Module
If greater than 7 V


All Door Locks Inoperative
1. Ignition OFF.
3. Ignition OFF.
5. Disconnect the harness connector at each of the A23 Door Latch Assemblies.
If infinite resistance, replace the appropriate A23 Door Latch Assembly.
3. Ignition OFF, connect the X2 harness connector at the K9 Body Control Module. Disconnect the harness
connector at the A23D Door Latch Assembly-Driver, ignition ON.
NOTE:
If 7 V or less
2. Test for infinite resistance between the control circuit terminal listed below and ground:
If greater than 7 V


Component Testing

1. Ignition OFF, disconnect the harness connector at the S13D Door Lock Switch-Driver.
open position.
open position.

Lock position.

If less than 2 ohms
Unlock position.

If less than 2 ohms
6. All OK
Door Latch Assembly

the A23 Door Latch Assembly should perform the LOCK and UNLOCK function.
If the actuator does not perform the LOCK and UNLOCK function

Replace the A23 Door Latch Assembly.

If the actuator performs the LOCK and UNLOCK function
3. All OK
Repair Instructions

TRUNK RELEASE MALFUNCTION

Short to
Open/High
Circuit
Ground
Resistance
Rear Compartment Lid
1
1
Unlatch Relay B+
B3618 00
2
Unlatch Switch Signal
1
1
Latch Control
B3265 02
B3265 04
Unlatch Relay Control
1
Latch Ground
2
Unlatch Switch Ground
B3265 04
Unlatch Relay Ground
1. Trunk Release Malfunction
2. Trunk Release Exterior Switch Malfunction
Short to
Voltage
Signal Performance
B3265 01

The body control module (BCM) supplies a reference voltage to the rear compartment lid unlatch switch
through the release switch signal circuit. When the rear compartment lid unlatch switch is pressed, the release
switch signal circuit is grounded through the rear compartment lid unlatch switch ground circuit and the
reference voltage is pulled low within the BCM. In response, the BCM applies battery positive voltage to the
rear compartment lid unlatch relay control circuit, which energizes the coil side of the relay. The switch side of
the rear compartment lid unlatch relay then closes, supplying battery positive voltage through the relay and the
rear compartment lid latch control circuit activating the latch so that the trunk lid may be manually raised to an
open position.
Schematic Reference
Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference

1. Ignition ON.
Active and Inactive when pressing and releasing the S58A Rear Compartment Lid Unlatch SwitchExterior.
Refer to Circuit/System Testing below- Trunk Release Switch Inoperative
3. Verify the M40 Rear Compartment Lid Latch activates when commanding the Trunk Lid Unlatch with a

scan tool.
If the M40 Rear Compartment Lid Latch does not UNLATCH
Refer to Circuit/System Testing below- Release Actuator Inoperative
If the M40 Rear Compartment Lid Latch does UNLATCH
4. All OK.
Trunk Release Switch Inoperative

1. Ignition OFF and all vehicle systems OFF, disconnect the X920 inline harness connector at the S58A
Rear Compartment Lid Unlatch Switch-Exterior. It may take up to 2 minutes for all vehicle systems to
power down.
1. Ignition OFF.
3. Ignition ON.
If not Inactive
If Inactive
If not Active
1. Ignition OFF, remove the 3 A fused jumper wire, disconnect the harness connector at the K9 Body
If less than 1 V

If Active
7. Test or replace the S58A Rear Compartment Lid Unlatch Switch-Exterior.
Release Actuator Inoperative

1. Ignition OFF and all vehicle systems OFF, disconnect the KR95B Rear Compartment Lid Unlatch Relay.
It may take up to 2 minutes for all vehicle systems to power down.
1. Ignition OFF.
3. Ignition ON.
1. Ignition OFF.
1. Ignition OFF.
If infinite resistance,
3. Disconnect the harness connector at the M40 Rear Compartment Lid Latch.
If infinite resistance, replace the KR95B Rear Compartment Lid Unlatch Relay
6. Verify the test lamp briefly turns ON when commanding the Trunk Lid Unlatch with a scan tool.
Module.

Repair the short to voltage on the control circuit
Ignition OFF and all vehicle systems OFF, disconnect the harness connector at the M40 Rear
Compartment Lid Latch. It may take up to 2 minutes for all vehicle systems to power down.
1. Ignition OFF.
Connect the harness connector at the M40 Rear Compartment Lid Latch
terminal 5.
Verify the M40 Rear Compartment Lid Latch is activated.
If the M40 Rear Compartment Lid Latch does not activate
1. Ignition OFF, remove the 10 A fused jumper wire, disconnect the harness connector at the M40
Rear Compartment Lid Latch.
If less than 2 ohms, replace the M40 Rear Compartment Lid Latch.
If the M40 Rear Compartment Lid Latch activates
Test or replace the KR95B Rear Compartment Lid Unlatch Relay.
8.
9.
10.
11.
12.
13.
Component Testing

Rear Compartment Lid Latch

1. Ignition OFF, disconnect the harness connector at the M40 Rear Compartment Lid Latch.
2. Install a 10 A fused jumper wire between the B+ terminal 1 and 12 V. Install a jumper wire between the
ground terminal 2 and ground.
3. Verify the M40 Rear Compartment Lid Latch activates
If the M40 Rear Compartment Lid Latch does not activate.
Replace the M40 Rear Compartment Lid Latch.
If the M40 Rear Compartment Lid Latch does activate.
4. All OK
Trunk Release Switch

1. Ignition OFF, disconnect the X920 inline harness connector at the S58A Rear Compartment Lid Unlatch
Switch-Exterior.

If less than 3 ohms
4. All OK
Relay Test
1. Ignition OFF, disconnect the KR95B Rear Compartment Lid Unlatch Relay.
4 and 3

4 and 5
4 and 1
5 and 1

If less than 2 ohms
6. All OK
Repair Instructions
Rear License Plate Lamp Wiring Harness Replacement
Rear Compartment Lid Latch Replacement
TRUNK AJAR INDICATOR MALFUNCTION

Circuit
Signal
Ground
Short to
Ground
1
-
1. Trunk Ajar Message Always Illuminated

2. Trunk Ajar Message Inoperative
Open/High
Resistance
2
3
Short to
Voltage
2
-
Signal Performance
-

3. Trunk Release Inoperative

The body control module (BCM) provides a 12 V signal to the rear compartment lid ajar switch signal circuit.
When the rear compartment lid latch releases the rear compartment lid, the rear compartment lid ajar switch,
which is internal to the rear compartment lid latch, is supplied with ground which causes the trunk ajar switch
signal circuit to be pulled low. The BCM interprets this and communicates via serial data to the driver
information center which will display the Trunk Open message.
Schematic Reference
Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference

1. Ignition ON.
2. Verify the scan tool Rear Closure Ajar Switch parameter changes between Inactive and Active when
opening and closing the trunk.
3. All OK.

1. Ignition OFF and all vehicle systems OFF, disconnect the harness connector at the M40 rear compartment
lid latch. It may take up to 2 minutes for all vehicle systems to power down.
1. Ignition OFF.
3. Ignition ON.
4. Verify the scan tool Rear Closure Ajar Switch parameter is Inactive.
If not Inactive
If infinite resistance, replace the K9 body control module.
If Inactive
6. Verify the scan tool Rear Closure Ajar Switch parameter is Active.
If not Active
If less than 1 V
If Active
7. Test or replace the M40 rear compartment lid latch.
Component Testing
1. Ignition OFF, disconnect the harness connector at the M40 rear compartment lid latch.
open position.
Replace the M40 rear compartment lid latch.

closed position.
Replace the M40 rear compartment lid latch.

If less than 3 ohms
4. All OK
Repair Instructions

REPAIR INSTRUCTIONS
FRONT SIDE DOOR INSIDE HANDLE CABLE REPLACEMENT
Fig. 6: Rear Side Door Inside Handle Cable


Front Side Door Inside Handle Cable Replacement

Callout
Component Name
Remove the front side door latch. Refer to Front Side Door Latch Replacement.
1
Front Side Door Inside Handle Cable
REAR SIDE DOOR INSIDE HANDLE CABLE REPLACEMENT
Fig. 7: Rear Side Door Inside Handle Cable

Rear Side Door Inside Handle Cable Replacement
Callout
Component Name
Remove the rear side door latch. Refer to Rear Side Door Latch Replacement.
1
Rear Side Door Inside Handle Cable
FRONT SIDE DOOR LOCK CYLINDER REPLACEMENT

Fig. 8: Front Side Door Lock Cylinder, Bolt & Access Plug
Front Side Door Lock Cylinder Replacement
Callout
Component Name
Bolt Access Plug
1
Procedure
Use a plastic flat-bladed tool to remove.
CAUTION:
Tighten
9 N.m (80 lb in)
Front Side Door Lock Cylinder
Procedure
3
1. Pull the lock cylinder from the housing to remove.

2. Inspect the lock, lock cylinder and handle adjustments. Refer to
Front Side Door Outside Handle Rod Adjustment.

TIP: Pull the front side door outside handle to unlock the door lock
cylinder.
FRONT SIDE DOOR INSIDE HANDLE REPLACEMENT
Fig. 9: Front Side Door Inside Handle

Front Side Door Inside Handle Replacement
Callout
Component Name
Front Side Door Inside Handle Bracket Cap
1
Procedure
Use a flat-bladed tool to remove.
Front Side Door Inside Handle Bracket Bolt
2
CAUTION:
Front Side Door Inside Handle

Procedure
3
1. Use a flat bladed plastic tool to remove.

2. Unlock the 4 retaining tabs.
3. Unlock the front side door inside handle cable.

FRONT SIDE DOOR OUTSIDE HANDLE REPLACEMENT
Fig. 10: Front Side Door Outside Handle Components

Callout
Component Name
Bolt Access Plug
1
Procedure
CAUTION:
3
4
Procedure
Loosen the front side door outside handle bolt until the front side door
outside handle cap could be removed.
Tighten
9 (80 lb in)
Front Door Outside Handle Cap
Front Door Outside Handle Cap Gasket
Procedure

Front Door Outside Handle

Procedure
5
1. Pull the outside handle rearward to release it from the inside

handle housing.
2. Disconnect the Passive Entry Passive Start connector, if
equipped.
Front Door Outside Handle Gasket
Procedure
Inspect the lock, lock cylinder and handle adjustments. Refer to Front
Side Door Outside Handle Rod Adjustment.
FRONT AND REAR SIDE DOOR OUTSIDE HANDLE ROD CLIP REPLACEMENT
Removal Procedure
Fig. 11: Outside Door Handle Rod Clip


NOTE:
It maybe necessary to remove the front or rear side door latch from some
of the vehicles to access the rod clip, refer to the appropriate procedure in
this sub-section.
1. Using the appropriate tool, open the outside door handle rod clip (1) on the latch.
Fig. 12: Retaining Tabs

NOTE:
The clip for the outside door handle rod is designed for one use only, a
new clip Must be installed to the door latch to retain the outside handle
rod.
NOTE:
Use the appropriate tool to push in on the retaining tabs (1) located on
each side of the old clip to remove.

2. Remove the old outside door handle rod clip (1) from the door latch.
Fig. 13: Outside Door Handle Rod Clip

NOTE:
When replacing the old designed outside door handle rod clip with the
new designed clip (1) the anti rotation tab (2) will need to be removed.
NOTE:
When installing the outside door handle rod to latch in order to prevent
outside handle lever pre-load, the outside handle shall be fully secured to
the door prior to securing integral latch clip to outside handle release rod.
Push upward at the bottom the rod clip.
1. Install the new outside door handle rod clip (1) to the latch.
2. Verify the outside door handle will release the door latch.

FRONT SIDE DOOR OUTSIDE HANDLE BRACKET REPLACEMENT
Fig. 14: Front Side Door Outside Handle Bracket And Bolt
Callout
Component Name
Replacement .
3. Remove the front side door outside handle. Refer to Front Side Door Outside Handle
Replacement.
Front Side Door Outside Handle Bracket Bolt
1
CAUTION:
Front Side Door Outside Handle Bracket

2
Procedure
1. Disconnect the front side door latch (lock) and handle rods to
remove the housing.

2. Unclip the Passive Entry Passive Start wiring harness.

3. Inspect the latch, lock cylinder and handle adjustments. Refer to
REAR SIDE DOOR OUTSIDE HANDLE BRACKET REPLACEMENT
Fig. 15: Rear Side Door Outside Handle Bracket And Bolt
Rear Side Door Outside Handle Bracket Replacement
Callout
Component Name
Replacement .
3. Remove the rear side door outside handle. Refer to Rear Side Door Outside Handle
Replacement.
Rear Side Door Handle Bracket Bolt
1
CAUTION:
Rear Side Door Outside Handle Bracket

Procedure
1. Transfer the handle and lock rods to the new outside door handle
housing.
2. Unclip the passive entry passive start wiring harness.
3. Inspect the lock, lock cylinder and handle adjustments. Refer to
Rear Side Door Outside Handle Rod Adjustment.
REAR COMPARTMENT LID INSIDE HANDLE REPLACEMENT
Fig. 16: Rear Compartment Lid Inside Handle And Cover

Rear Compartment Lid Inside Handle Replacement
Callout
Component Name
Remove the rear compartment lid inner panel trim. Refer to Rear Compartment Lid Inner Panel Trim
Replacement
1
Rear Compartment Lid Latch Cover
2
Rear Compartment Lid Inside Handle
REAR SIDE DOOR INSIDE HANDLE REPLACEMENT

Fig. 17: Rear Side Door Inside Handle

Rear Side Door Inside Handle Replacement
Callout
Component Name
Rear Side Door Inside Handle Bracket Cap
1
Procedure
Use flat-bladed tool to remove.
Rear Side Door Inside Handle Bracket Bolt
2
CAUTION:
Rear Side Door Inside Handle

Procedure
3
1. Use a flat bladed tool to remove.

2. Unlock the 4 retaining tabs.
3. Unlock the rear side door inside handle cable.
REAR SIDE DOOR OUTSIDE HANDLE REPLACEMENT

Fig. 18: Rear Side Door Outside Handle Components

Callout
Component Name
Bolt Access Plug
1
Procedure
Rear Side Door Outside Handle Cap Bolt
CAUTION:
3
4
Tighten
9 (80 lb in)
Procedure
Pull the outside handle rearward to release it from the handle housing.
Rear Door Outside Handle Cap
Rear Door Outside Handle
Procedure
Disconnect the passive entry passive start wiring harness.
Rear Door Outside Handle Gasket
Procedure

1. Use a plastic flat-bladed tool to remove.

2. Inspect the lock and handle adjustments. Refer to Rear Side Door
Outside Handle Rod Adjustment.
FRONT SIDE DOOR LATCH REPLACEMENT
Fig. 19: Front Side Door Latch

Callout
Component Name
Replacement .
3. Remove the front side door lock cover. Refer to Front Side Door Lock Cover Replacement.
Front Side Door Latch Screw (Qty: 2)
CAUTION:
Procedure

1. Remove and DISCARD the screw.

2. Cut the thread.
NOTE:
Service may offer bolts that are not microencapsulated. If this is the
case apply thread lock agent to the bolt.
Tighten
10 N.m (89 lb in)
Front Side Door Latch
Procedure
2
1.
2.
3.
4.
5.
Release the door lock cable retainers from the door.

Disconnect the door lock electrical connector.
Remove the door lock with the handle housing.
Remove the handle and lock rods from the lock.
Inspect the lock, lock cylinder and handle adjustments. Refer to
Front Side Door Outside Handle Rod Adjustment
REAR COMPARTMENT LID LATCH REPLACEMENT
Fig. 20: Rear Compartment Lid Latch And Bolt


Callout
Component Name
Replacement .
Rear Compartment Lid Latch Bolt (Qty: 2)
CAUTION:
Tighten
9 N.m (80 lb in)
REAR SIDE DOOR LATCH REPLACEMENT
Fig. 21: Rear Side Door Latch And Bolts

Callout
Component Name

1. Remove the rear side door trim panel. Refer to Rear Side Door Trim Replacement .
Replacement .
3. Remove the rear side door outside handle bracket. Refer to Rear Side Door Outside Handle
Rear Side Door Latch Bolt (Qty: 2)
CAUTION:
Procedure
1. Remove and DISCARD the screw.

2. Cut the thread.
NOTE:
Service may offer bolts that are not microencapsulated. If this is the
case apply thread lock agent to the bolt.
Tighten
10 N.m (89 lb in)
Rear Side Door Latch
Procedure
1. Release the inside handle cable retainers before removing the door
latch.
2. Disconnect the door latch electrical connector.
3. Remove the door latch with the handle bracket.
4. Transfer the handle and lock rods to the new door latch.
5. Inspect the latch, lock cylinder and handle adjustments. Refer to Rear
Side Door Outside Handle Rod Adjustment.
FRONT SIDE DOOR LOCK COVER REPLACEMENT

Fig. 22: Front Side Door Lock Cover

Front Side Door Lock Cover Replacement
Callout
Component Name
Remove the front side door water deflector. Refer to Front Side Door Water Deflector Replacement .
Front Side Door Lock Cover Bolt (Qty: 2)
2
3
CAUTION:
Tighten
6 (53 lb in)
Front Side Door Lock Cover Bolt
Tighten
2, 5 (22 lb in)
Front Side Door Lock Cover
FRONT SIDE DOOR LOCKING ROD REPLACEMENT

Fig. 23: Rear Side Door Locking Rod

Front Side Door Locking Rod Replacement
Callout
Component Name
Front Side Door Locking Rod
Procedure
1
Inspect the lock, lock cylinder and handle adjustments. Refer to
FRONT SIDE DOOR LOCK CYLINDER ROD REPLACEMENT

Fig. 24: Rear Side Door Outside Handle Rod

Front Side Door Lock Cylinder Rod Replacement
Callout
Component Name
1
Front Side Door Lock Cylinder Rod
FRONT SIDE DOOR OUTSIDE HANDLE ROD ADJUSTMENT

Fig. 25: Front Side Door Outside Handle Rod And Clip
Front Side Door Outside Handle Rod Adjustment
Callout
Component Name
Remove the water deflector. Refer to Front Side Door Water Deflector Replacement .
Outside Door Handle Rod Clip
Procedure
1
Using a flat-bladed tool, open the clip on the threaded rod connecting
the lock to the outside handle.
Outside Door Handle Rod
Procedure
2
1. Position the outside door handle rod in the outside door handle
rod clip to eliminate any free play in the outside door handle.
2. Adjust the travel of the handle by moving the threaded rod in
the clip.
3. Close the clip cover on the threaded outside door handle rod.
4. Inspect the door lock system for proper operation.
FRONT SIDE DOOR OUTSIDE HANDLE ROD REPLACEMENT

Fig. 26: Front Side Door Outside Handle Rod

Front Side Door Outside Handle Rod Replacement
Callout
Component Name
Remove the front side door outside handle bracket. Refer to Front Side Door Outside Handle Bracket
Replacement.
Front Side Door Outside Handle Rod
Procedure
1
1. Open the mechanism by releasing the clip at the shift linkage lever.
2. Adjust front side door outside handle rod. Refer to Front Side
Door Outside Handle Rod Adjustment.
REAR SIDE DOOR LOCKING ROD REPLACEMENT

Fig. 27: Rear Side Door Locking Rod And Clip

Rear Side Door Locking Rod Replacement
Callout
Component Name
2. Remove the water deflector. Refer to Rear Side Door Water Deflector Replacement .
3. Remove the rear side door latch. Refer to Rear Side Door Latch Replacement.
1
Rear Side Door Locking Rod
2
Rear Side Door Locking Rod Clip
REAR SIDE DOOR OUTSIDE HANDLE ROD ADJUSTMENT
Removal Procedure

Fig. 28: View Of Handle Rod To Lock Clip

1. Remove the rear door water deflector as needed. Refer to Rear Side Door Water Deflector
Replacement .
2. Use a flat-bladed tool to open the clip on the threaded rod connecting the lock to the outside handle.
3. Adjust the travel of the handle by removing the threaded rod from the clip.

Fig. 29: Positioning Outside Door Handle Rod In Clip

1. Position the outside door handle rod (2) in the clip (1) to eliminate any free play in the outside door
handle.
2. Close the clip cover over the threaded outside door handle rod.
3. Inspect the door lock system for proper operation.
4. Install the rear door water deflector. Refer to Rear Side Door Water Deflector Replacement .
REAR SIDE DOOR OUTSIDE HANDLE ROD REPLACEMENT

Fig. 30: Rear Side Door Outside Handle Rod

Rear Side Door Outside Handle Rod Replacement
Callout
Component Name
Remove the rear side door latch. Refer to Rear Side Door Latch Replacement.
1
Rear Side Door Outside Handle Rod
FRONT SIDE DOOR LOCK STRIKER REPLACEMENT

Fig. 31: Front Side Door Lock Striker And Bolts

Front Side Door Lock Striker Replacement
Callout
Component Name
Front Side Door Lock Striker Bolt (Qty: 2)
CAUTION:
Tighten
25 N.m (18 lb ft)
Front Side Door Lock Striker
REAR COMPARTMENT LID LATCH STRIKER REPLACEMENT

Fig. 32: Rear Compartment Lid Latch Striker And Bolts

Rear Compartment Lid Latch Striker Replacement
Callout
Component Name
Remove the rear compartment sill trim plate. Refer to Rear Compartment Sill Trim Plate
Replacement .
Rear Compartment Lid Latch Striker Bolt (Qty: 2)
CAUTION:
Procedure
Use a grease pencil to outline the striker before removing the bolts.
Tighten
9 N.m (80 lb in)
Rear Compartment Lid Latch Striker
Procedure
Adjust the rear compartment lid latch striker after replacing, if
needed.
REAR SIDE DOOR LOCK STRIKER REPLACEMENT

Fig. 33: Rear Side Door Lock Striker And Bolts

Rear Side Door Lock Striker Replacement
Callout
Component Name
Rear Side Door Lock Striker Bolt (Qty: 2)
CAUTION:
Tighten
25 N.m (18 lb ft)
Rear Side Door Lock Striker
DOOR LOCK SWITCH REPLACEMENT

Fig. 34: Door Lock Switch And Screws

Callout
Component Name
Remove instrument panel accessory bezel. Refer to Instrument Panel Accessory Bezel Replacement .
Door Lock Switch Screw (Qty: 2)
CAUTION:
Tighten
1.5 N.m (13 lb in)
Door Lock Switch
Procedure

DOOR AJAR INDICATOR DESCRIPTION AND OPERATION
Door Ajar Indicator System Components

The door ajar indicator system consists of the following components:
Body control module

Instrument cluster
Driver door latch
Passenger door latch
Left rear door latch
Right rear door latch
Driver window motor (AXG)
Driver window switch (AEC)
Passenger window switch (AED)
Left rear window switch (AEQ)
Right rear window switch (AEQ)
Door Ajar System
Depending upon if the vehicle is equipped with express up/down power windows, express down only power
windows affects how the driver and passenger door ajar signal circuits are configured and monitored.
Driver Door Ajar (AXG)
The driver window motor will provide a 12V signal to the driver door ajar switch within the door latch to
indicate the status of the door. When the driver door is open, the contract within the ajar switch closes providing
a ground part for the signal circuit. The driver window motor will detect the voltage drop in the ajar signal
circuit and will send a serial data message to the body control module. The body control module will then send
a message to the instrument cluster which will illuminate the door ajar icon.
Driver, Passenger and Rear Doors Ajar (AEC, AED and AEQ)
The driver, passenger and rear window switches provide a 12V signal to the respective door ajar switch within
the door latch to indicate the status of the door. When the door is open, the contract within the ajar switch closes
providing a ground part for the signal circuit. The window switch will detect the voltage drop in the ajar signal
circuit and will send a serial data message to the body control module. The body control module will then send
a message to the instrument cluster which will illuminate the door ajar icon.
LUGGAGE COMPARTMENT DESCRIPTION AND OPERATION
Rear Compartment Lid Release System Components

Exterior rear compartment lid release switch
Rear compartment lid latch
Rear compartment lid release relay
Rear Compartment Lid Release Operation

Rear Compartment Lid Release Switch

The BCM monitors a voltage signal to the exterior rear compartment lid release switch so that when the switch
is pressed, the voltage within the signal circuit is pulled low and in response, the BCM will detect the voltage
drop and check the status of the door lock system. If the vehicle doors are locked, the BCM will ignore the
exterior rear compartment lid release switch, if the vehicle doors have been unlocked, the BCM will recognize
the request and will provide voltage to the rear compartment lid relay.
When BCM receives a rear compartment lid release command from the exterior rear compartment lid release
switch, the BCM applies brief pulse of voltage to the compartment lid release relay control circuit, which
energizes the coil side of the relay. The switch side of the compartment lid release relay then momentarily
closes, supplying a brief pulse of battery positive voltage to the rear compartment lid latch. The rear
compartment lid latch is continuously grounded and when it receives the voltage pulse, it will become energized
and the latch will activate releasing the trunk lid so that the trunk lid may be manually raised to an open
position.
Keyless Entry Transmitter
The BCM may also get a rear compartment lid release command from the remote keyless entry module. When
the trunk button is pressed on the keyless entry transmitter, a rear compartment lid release request is sent to the
remote keyless entry module, the remote keyless entry module will then send a serial data message to the BCM
to command the release of the rear compartment lid.
Trunk Open Message
The body control module (BCM) monitors the voltage level of the trunk ajar signal circuit which is normally at
the system voltage when the trunk lid is closed. When the trunk lid is ajar or open, a switch within the latch
assembly closes providing a path to ground for the trunk ajar signal circuit. The voltage within the signal circuit
will then drop to 0 volts, the BCM will then detect the voltage drop and will send a serial data message to the
instrument panel cluster (IPC). The IPC will then display the Trunk Open message.
POWER DOOR LOCKS DESCRIPTION AND OPERATION
Door Lock System Components
The power door lock system consists of the following components:
Central door lock switch

Rear window/door lockout switch, located on the driver window switch
Driver door latch
Passenger door latch
Left rear door latch
Right rear door latch

Door lock security PCB relay

Exterior door handle switches
Keyless entry control module
Door Lock and Unlock Operation
When the central door lock switch is activated in the lock or unlock position, the BCM will receive a ground
signal on either the door lock switch lock or unlock signal circuits.
The BCM, upon receipt of a lock switch lock or unlock signal, will supply battery voltage to the door lock
actuator lock or unlock control circuits. Since the opposite side of the lock actuator is connected to ground
through the other lock actuator control circuit, the doors will then lock or unlock as commanded.
The following three circuits are used to operate the lock:
Driver door unlock

Passenger door unlock
All door lock
The driver door lock actuator is isolated so it can be unlocked by itself using the keyless entry transmitter.
Passive Door Lock/Unlock Operation
closes and the voltage signal within the signal circuit is pulled to ground. The keyless entry control module will
detect the voltage drop and a low frequency antenna will transmit a challenge to the keyless entry transmitter. If
the challenge is met, the keyless entry transmitter will respond, and the keyless entry control module will send a
serial data message to the body control module to command the door(s) to be locked or unlocked
Rear Window and Rear Door Lockout Operation
The operator has the option to disable the interior rear door handles to prevent the unauthorized opening of the
rear door doors while still retaining normal driver and passenger door handle functions. The driver door window
switch has a lockout switch that will disable the interior rear door handles and the local rear window switches.
When the lockout switch is pressed, the BCM will command the child lockout latches and will also send a
disable command to the local rear window switches. The driver and passenger doors will still function normally
by pressing a door lock switch which will unlock the doors but the child lockout latches will continue to disable
the interior rear door handles.
Pressing the lockout switch again will signal a command to the BCM to unlatch the rear doors, restore normal
interior rear door handle functions and restore normal function of the rear window switches
If the lockout indicator flashes while commanding the lockout system, indicates that the BCM has detected a
fault in the system and that one or both interior rear door handles are not locked out and/or the local rear

window switches are not locked out.

2013 ACCESSORIES & EQUIPMENT Wipers and Washers - Cruze

Wipers and Washers - Cruze
SPECIFICATIONS
Specification
Application
Windshield Washer Solvent Container Bolt
Windshield Washer Solvent Container Nut
Windshield Wiper Arm Nut
Windshield Wiper Motor Bolt
Windshield Wiper Motor Nut
Windshield Wiper and Windshield Washer Meter
Bolt

WIPER/WASHER WIRING SCHEMATICS
Wiper Wiring Schematics
Metric
15 N.m
5 N.m
24.5 N.m
10 N.m
10 N.m
English
11 lb ft
44 lb in
18 lb ft
89 lb in
89 lb in
10 N.m
89 lb in

Fig. 1: Wiper Wiring Schematics

Callout
95
95 YE/BN
CAV_B
CAV_73
CONN_X1
92
92_WH
CAV_D
CAV_72
196
196_BN/GN
CAV_A
CAV_17
CONN_X4
196_BN/GN
CAV_34
860
Component Name
Windshield Wiper Motor Low Speed Control
95 YE/BN
B
73
X1
Windshield Wiper Motor High Speed Control
92 WH
D
72
Windshield Wiper Motor Park Switch Signal
196 BN/GN
A
17
X4
196 BN/GN
34
Front Windshield Wiper Switch High Signal

860_WH/VT
CAV_24
CONN_X5
CAV_45
CONN_X2
91
91_GY
CAV_16
CONN_X4
CAV_22
2640
2640_RD/VT
CAV 4
CONN_X5
CAV_68
1350
1350_BK
CAV_74
CONN_X1
6009
6009_BK/GY
CAV_2
CAV_10
CONN_X3
1714
1714_YE/BU
CAV_3
CAV 13
1715
1715 GY
CAV_1
CAV_20
1350_BK
CAV_C
CAV_30
CAV_85
CAV_86
CAV_87
CAV_87A
CAV_30
CAV_86
C V 85
860 WH/VT
24
X5
45
X2
Windshield Wiper Motor Relay Coil Supply Voltage
91 GY
16
X4
22
2640 RD/VT
4
X5
68
Ground
1350 BK
74
X1
Windshield Wiper Switch Low Reference
6009 BK/GY
2
10
X3
Windshield Wiper Switch Low Signal
1714 YE/BU
3
13
Windshield Wiper Switch High Signal
1715 GY
1
20
1350 BK
C
30
85
86
87
87A
30
86

CAV_87
CAV_87A
F6UA
G104
G103
F32UA
X100
S82
M75
KR12C
KR12B
X50A
K9
S82
Washer Wiring Schematics
Fig. 2: Washer Wiring Schematics

85
87
87A
F6UA 30A
G104
G103
F32UA 20A
X100

Callout
CAV_44
2140
2140_RD/GY
CAV_1
CONN_X2
2268
2268_BN/GY
CAV_14
CONN_X4
CAV_60
CONN_X2
94
94_WH/BK
CAV_5
CAV_25
CONN_X3
228
228_GY/VT
CAV_1
CAV_30
CONN_X1
1350
1350_BK
CAV_2
1350_BK
CAV_74
G104
G103
F23DA
F56UA
S82
G24
K9
S82
KR11
X50A
X51A
Component Name
44
2140 RD/GY
1
X2
Windshield Washer Relay Control
2268 BN/GY
14
X4
60
X2
Windshield Washer Switch Signal
94 WH/BK
5
25
X3
Windshield Washer Pump Control
228 GY/VT
1
30
X1
Ground
1350 BK
2
1350 BK
74
G104
G103
F23DA 20A
F56UA 15A


DTC
DTC B3715 or B3875
DTC B3873
Description
DTC B3715 01 Windshield Wiper Relay Circuit
Short to Battery
Short to Ground
Open
DTC B3875 01 Windshield Wiper High Speed
Relay Circuit Short to Battery
Relay Circuit Short to Ground
Relay Circuit Open
DTC B3873 01 Front Washer Relay Circuit Short to
Battery
DTC B3873 02 Front Washer Relay Circuit Short to
Ground
DTC B3873 04 Front Washer Relay Circuit Open
Circuit
DTC B3715 OR B3875

DTC Descriptors
DTC B3715 01
Windshield Wiper Relay Circuit Short to Battery
DTC B3715 02
Windshield Wiper Relay Circuit Short to Ground
DTC B3715 04
Windshield Wiper Relay Circuit Open
DTC B3875 01

Windshield Wiper High Speed Relay Circuit Short to Battery

DTC B3875 02
Windshield Wiper High Speed Relay Circuit Short to Ground
DTC B3875 04
Windshield Wiper High Speed Relay Circuit Open
Short to
Circuit
Ground
1
Low Signal terminal 3
4
High Signal terminal 1
Park Switch Signal
3
terminal A
Front Wiper Relay Control
B3715 02
terminal 86
Windshield Wiper High
Speed Relay Control
B3875 02
terminal 86
Front Wiper Motor Low
1
Speed Control terminal B
Low Reference terminal 2
Ground terminal C
Windshield Wiper Relay
Ground terminal 85
1. Delay or Low Speed Wipers Inoperative
2. High Speed Wipers Inoperative
3. Wipers Do Not Park
4. Wipers Always ON
Open/High
Resistance
Short to
Voltage
Signal Performance
B3715 04
B3715 01
B3875 04
B3875 01
1, 2
1, 2
1, 2, 3
The body control module (BCM) controls the wiper motor based on input from the windshield wiper/washer
switch. The BCM monitors the wiper/washer switch through two separate signal circuits and a low reference
circuit. The windshield wiper switch high signal circuit is used to determine high speed wiper operation, the
windshield wiper switch low signal is used to determine low speed, intermittent, and mist operation through the
use of a resistor ladder, and the windshield washer switch signal circuit is used to determine washer operation.

The BCM controls the windshield wiper motor through two output controls, controlling two relays which
determine the desired wiper speed, high or low.
The DTC runs only when a wiper output is actively being requested by the BCM.
A short to ground is detected in the Front Wiper Relay control circuit or in the High Speed Relay control
circuit.
A short to voltage or an open/high resistance is detected in the Front Wiper Relay control circuit or in the
High Speed Relay control circuit.
The BCM will not activate the wiper output.

A current DTC will clear when the condition for setting the fault is no longer present.
Schematic Reference
Wiper/Washer System Description and Operation
Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference


1. Ignition ON.
2. Verify the scan tool Windshield Wiper High Speed Switch parameter changes between Active and
Inactive when activating the high speed windshield wipers.
Refer to Circuit/System Testing below - Windshield Wiper/Washer Switch Malfunction.
3. Verify the scan tool Windshield Wiper Switch parameter changes between Off and Low when activating
the low speed windshield wipers.
Refer to Circuit/System Testing below- Windshield Wiper/Washer Switch Malfunction.

4. Verify the scan tool Windshield Wiper Switch parameter changes between Delay 1 and Delay 5 when
cycling the intermittent speed windshield wipers.
Test or replace the S82 Windsheild Wiper/Washer Switch.

5. Verify the M75 Windshield Wiper Motor changes between Off, Low, and High when cycling the S82
Windshield Wiper/Washer Switch between Off, Low, and High.
If the Windshield Wiper Motor does not cycle between Off, Low, and High
Refer to Circuit/System Testing below- Windshield Wiper Motor Malfunction

If the Windshield Wiper Motor cycles between Off, Low, and High
6. Ignition OFF.
7. Verify the scan tool Windshield Wiper Park Switch parameter is Active.
Refer to Circuit/System Testing below- Windshield Wiper Motor Malfunction.

8. All OK.

Windshield Wiper/Washer Switch Malfunction

1. Ignition OFF and all vehicle systems OFF, disconnect the harness connector at the S82 Windshield
Wiper/Washer Switch. It may take up to 11 min for all vehicle systems to power down.
3. Ignition ON.
4. Verify the scan tool Windshield Wiper High Speed Switch parameter is Inactive.
If not Inactive
If Inactive
terminal 2.
6. Verify the scan tool Windshield Wiper High Speed Switch parameter is Active.
If not Active
If less than 1 V
If Active
7. Test for greater than 8 V between the signal circuit terminal 3 and ground.
If less than 8 V
2. Test for infinite resistance between the signal circuit and ground


If 8 V or greater
9. Test for less than 1 V between the S82 Windshield Wiper/Washer Switch signal circuit terminal 3 and
ground.
If 1 V or greater

If less than 1 V
10. Test or replace the S82 Windshield Wiper/Washer Switch.
Windshield Wiper Motor Malfunction

1. Ignition OFF and all vehicle systems OFF, disconnect the harness connector at the M75 Windshield
Wiper Motor. It may take up to 2 min for all vehicle systems to power down.
2. Test for less than 10 ohms between the ground circuit terminal C and ground.
1. Ignition OFF.
3. Ignition ON.
4. Verify the scan tool Windshield Wiper Park Switch parameter is Inactive.
If not Inactive
2. Test for infinite resistance between the signal circuit terminal A and ground.
If Inactive
5. Install a 3 A fused jumper wire between the signal circuit terminal A and the ground circuit terminal C.
If not Active
If less than 1 V

7.
8.
9.
10.
If Active
Ignition OFF and all vehicle systems OFF, disconnect the KR12B Windshield Wiper Relay. It may take
up to 2 min for all vehicle systems to power down.
Test for less than 10 ohms between each ground circuit terminal listed below and ground:
Terminal 85
Terminal 87A
1. Ignition OFF.
Ignition ON.
Verify a test lamp illuminates between the B+ circuit terminal 87 and the ground circuit terminal 87A.
Replace the X50A Fuse Block - Underhood.
1. Ignition OFF, remove the test lamp. Disconnect the KR12C Windshield Wiper Speed Control
Relay.
2. Test for infinite resistance between each control circuit listed below and ground:
Terminal 87A
Terminal 87
If infinite resistance, replace the M75 Windshield Wiper Motor
12. Verify the test lamp turns ON and OFF when commanding the Windshield Wiper Motor Relay Low and
Off with a scan tool.
Module.

13. Ignition OFF, connect the KR12B Windshield Wiper Relay and disconnect the KR12C Windshield Wiper
Speed Control Relay, ignition ON.
14. Test for less than 10 ohms between the control circuit terminal 30 and ground.
Test or replace the KR12B Windshield Wiper Relay.
15. Connect a test lamp between the control circuit terminal 30 and ground.


18. Connect a test lamp between the B+ circuit terminal 85 and the control circuit terminal 86.
19. Verify the test lamp turns ON and OFF when commanding the Windshield Wiper High Speed Relay High
If less than 1 V

20.
21.
22.
23.
24.
3. Ignition OFF.
Module.
Ignition OFF, connect the KR12C Windshield Wiper Speed Control Relay.
Connect a test lamp between the M75 Windshield Wiper Motor control circuit terminal B and ground
circuit terminal C, ignition ON.
Verify the test lamp turns ON and OFF when commanding the Windshield Wiper Motor Relay Low and
1. Ignition OFF, remove the test lamp, disconnect the KR12C Windshield Wiper Speed Control
Relay.
If less than 2 ohms, test or replace the KR12C Windshield Wiper Speed Control Relay.
Relay, ignition ON.
If less than 1 V, test or replace the KR12C Windshield Wiper Speed Control Relay.
Connect a test lamp between the M75 Windshield Wiper Motor control circuit terminal D and ground
Verify the test lamp turns ON and OFF when commanding the Windshield Wiper High Speed Relay High
Relay.

Relay, ignition ON.
25. Test or replace the M75 Windshield Wiper Motor.
Component Testing
Windshield Wiper/Washer Switch

1. Ignition OFF, disconnect the harness connector at the S82 Windshield Wiper/Washer Switch.
2. Test for infinite resistance between the signal terminal 1 and the low reference terminal 2 with the high
speed switch in the open position.
Replace the S82 Windshield Wiper/Washer Switch.
3. Test for less than 2 ohms between the signal circuit terminal 1 and the low reference circuit terminal 2
with the high speed switch in the closed position.

If less than 2 ohms
4. Test for infinite resistance between the signal terminal 3 and the low reference terminal 2 with the low

5. Verify the resistance readings are within the specified range listed below between the signal circuit

terminal 3 and the low reference circuit terminal 1 by pushing the switch in the listed positions below:
Delay 1 : 3.75-3.85kohms
Delay 5 : 765-775ohms
If within the specified range
6. All OK
Relay Test
1. Ignition OFF, disconnect the appropriate relay.
If less than 60 or greater than 200
Replace the relay.
30 and 86
30 and 87
30 and 85
85 and 87
Replace the relay.

4. Test for less than 5 ohms between terminals 30 and 87A.
Replace the relay.

If less than 5 ohms

Replace the relay.

If less than 5 ohms
7. All OK
Repair Instructions
Windshield Wiper Motor Replacement

Windshield Wiper and Washer Switch Replacement
DTC B3873
DTC Descriptors
DTC B3873 01
Front Washer Relay Circuit Short to Battery
DTC B3873 02
Front Washer Relay Circuit Short to Ground
DTC B3873 04
Front Washer Relay Circuit Open Circuit
Circuit
Signal
Windshield Washer Pump
Control
Short to
Ground
Open/High
Resistance
Short to
Voltage
Signal Performance
B3873 02
B3873 04
B3873 01

Control
Ground
1. Washer Inoperative
2. Washer Always ON
The body control module (BCM) controls the windshield washer pump based on an input from the windshield
wiper/washer switch. The BCM monitors the washer switch through the windshield washer switch signal
circuit. When the washer switch is closed, low reference is supplied to the windshield washer switch signal
circuit. When this is the case, the BCM will command the windshield washer pump and the low speed wipers
on.
Ignition ON.
A short to ground or an open/high resistance is detected in the windshield washer relay control circuit.
A short to voltage is detected in the windshield washer relay control circuit.
Washer operation is suspended.

A current DTC clears when the diagnostic runs and passes.

Schematic Reference

Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference

1. Ignition ON.
2. Verify the scan tool Windshield Washer Switch parameter changes between Active and Inactive when
pressing and releasing the windshield washer switch.
3. Verify the windshield washers turn ON when commanding the Windshield Washer Relay Active with a
scan tool.
If the Windshield Washers do not turn ON
Refer to Circuit/System Testing below- Windshield Washer Pump Malfunction

If the Windshield Washers turn ON
4. All OK.

1. Ignition OFF.
3. Ignition ON.
4. Verify the scan tool Windshield Washer Switch parameter is Inactive.

If not Inactive
If Inactive
terminal 2.
6. Verify the scan tool Windshield Washer Switch parameter is Active.
If not Active
If less than 1 V
If Active
Windshield Washer Pump Malfunction

1. Ignition OFF, and all vehicle systems OFF. Disconnect the harness connector at the G24 Windshield
Washer Pump. It may take up to 2 minutes for all vehicle systems to power down.
3. Connect a test lamp between the control circuit terminal 1 and the ground circuit terminal 2, ignition ON.
4. Verify the test lamp does NOT turn ON and OFF when commanding the Windshield Washer Relay
Active and Inactive with a scan tool.
Test or replace the G24 Windshield Washer Pump.
5. Ignition OFF, connect the harness connector at the G24 Windshield Washer Pump. Disconnect the X1

6.
7.
8.
9.
10.
11.
12.
13.
harness connector at the X50A Fuse Block - Underhood, It may take up to 2 minutes for all vehicle
Ignition ON.
Verify the G24 Windshield Washer Pump is not activated.
If the G24 Windshield Washer Pump is activated
1. Ignition OFF, disconnect the harness connector at the G24 Windshield Washer Pump, ignition ON.
If less than 1 V, replace the G24 Windshield Washer Pump.
If the G24 Windshield Washer Pump is not activated
Verify the G24 Windshield Washer Pump activates.
If the G24 Windshield Washer Pump does not activate
1. Ignition OFF, remove the jumper wire, disconnect the harness connector at the G24 Windshield
Washer Pump.
If less than 2 ohms, replace the G24 Windshield Washer Pump.
If the G24 Windshield Washer Pump activates
Ignition OFF, connect the X1 harness connector at the X50A Fuse Block - Underhood. Disconnect the X4
1. Ignition OFF, disconnect the X2 harness connector at the X50A Fuse Block - Underhood, ignition
ON.
If less than 1 V, replace the X50A Fuse Block - Underhood.

14. Verify the G24 Windshield Washer Pump activates.

Block - Underhood.
If less than 2 ohms, test or replace the X50A Fuse Block - Underhood.
Component Testing

2. Test for infinite resistance between the signal terminal 5 and the low reference terminal 2 with the switch
in the open position.
with the switch in the closed position.

If less than 2 ohms
4. All OK
Repair Instructions

Windshield Washer Pump Replacement
Control Module References for BCM and instrument cluster replacement and programming and setup

SYMPTOMS - WIPER/WASHER SYSTEMS

NOTE:
The following steps must be completed before using the symptom tables:
1. Perform Diagnostic System Check - Vehicle , in order to verify that all of the following conditions are
true:
No DTCs are set.
2. Refer to Wiper/Washer System Description and Operation in order to familiarize yourself with the
system functions.
Inspect for aftermarket devices which may affect the operation of the windshield wiper/washer system.
Refer to Checking Aftermarket Accessories .
cause the symptom.
Inspect the washer fluid reservoir for the proper fluid level.
Intermittent
Symptom List
Windshield Wiper System Malfunction

Washer Malfunction
WINDSHIELD WIPER SYSTEM MALFUNCTION

DTC Descriptors
DTC B3715 01
Windshield Wiper Relay Circuit Short to Battery

DTC B3715 02
Windshield Wiper Relay Circuit Short to Ground
DTC B3715 04
Windshield Wiper Relay Circuit Open
DTC B3875 01
Windshield Wiper High Speed Relay Circuit Short to Battery
DTC B3875 02
Windshield Wiper High Speed Relay Circuit Short to Ground
DTC B3875 04
Windshield Wiper High Speed Relay Circuit Open
Circuit
Low Signal terminal 3
High Signal terminal 1
Park Switch Signal
terminal A
Front Wiper Relay Control
terminal 86
Windshield Wiper High
Speed Relay Control
terminal 86
Front Wiper Motor Low
Speed Control terminal B
Low Reference terminal 2
Ground terminal C
Ground terminal 85
Short to
Ground
Open/High
Resistance
Short to
Voltage
Signal Performance
B3715 02
B3715 04
B3715 01
B3875 02
B3875 04
B3875 01
1, 2
1, 2
1, 2, 3
1. Delay or Low Speed Wipers Inoperative

2. High Speed Wipers Inoperative

3. Wipers Do Not Park

4. Wipers Always ON
The body control module (BCM) controls the wiper motor based on input from the windshield wiper/washer
switch. The BCM monitors the wiper/washer switch through two separate signal circuits and a low reference
circuit. The windshield wiper switch high signal circuit is used to determine high speed wiper operation, the
windshield wiper switch low signal is used to determine low speed, intermittent, and mist operation through the
use of a resistor ladder, and the windshield washer switch signal circuit is used to determine washer operation.
The BCM controls the windshield wiper motor through two output controls, controlling two relays which
determine the desired wiper speed, high or low.
The DTC runs only when a wiper output is actively being requested by the BCM.
A short to ground is detected in the Front Wiper Relay control circuit or in the High Speed Relay control
circuit.
A short to voltage or an open/high resistance is detected in the Front Wiper Relay control circuit or in the
High Speed Relay control circuit.
The BCM will not activate the wiper output.

A current DTC will clear when the condition for setting the fault is no longer present.
Schematic Reference


Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference

1. Ignition ON.
2. Verify the scan tool Windshield Wiper High Speed Switch parameter changes between Active and
Inactive when activating the high speed windshield wipers.
3. Verify the scan tool Windshield Wiper Switch parameter changes between Off and Low when activating
the low speed windshield wipers.

4. Verify the scan tool Windshield Wiper Switch parameter changes between Delay 1 and Delay 5 when
cycling the intermittent speed windshield wipers.
Test or replace the S82 Windsheild Wiper/Washer Switch.

5. Verify the M75 Windshield Wiper Motor changes between Off, Low, and High when cycling the S82
Windshield Wiper/Washer Switch between Off, Low, and High.
If the Windshield Wiper Motor does not cycle between Off, Low, and High
Refer to Circuit/System Testing below- Windshield Wiper Motor Malfunction
If the Windshield Wiper Motor cycles between Off, Low, and High

6. Ignition OFF.
Refer to Circuit/System Testing below- Windshield Wiper Motor Malfunction.
8. All OK.

3. Ignition ON.
4. Verify the scan tool Windshield Wiper High Speed Switch parameter is Inactive.
If not Inactive
If Inactive
terminal 2.
6. Verify the scan tool Windshield Wiper High Speed Switch parameter is Active.
If not Active
If less than 1 V


If Active
If less than 8 V
2. Test for infinite resistance between the signal circuit and ground
If 8 V or greater
9. Test for less than 1 V between the S82 Windshield Wiper/Washer Switch signal circuit terminal 3 and
ground.
If 1 V or greater

If less than 1 V
Windshield Wiper Motor Malfunction

1. Ignition OFF and all vehicle systems OFF, disconnect the harness connector at the M75 Windshield
Wiper Motor. It may take up to 2 min for all vehicle systems to power down.
1. Ignition OFF.
3. Ignition ON.
4. Verify the scan tool Windshield Wiper Park Switch parameter is Inactive.
If not Inactive


If Inactive
Install a 3 A fused jumper wire between the signal circuit terminal A and the ground circuit terminal C.
Verify the scan tool Windshield Wiper Park Switch parameter is Active.
If not Active
If less than 1 V
If Active
Ignition OFF and all vehicle systems OFF, disconnect the KR12B Windshield Wiper Relay. It may take
up to 2 min for all vehicle systems to power down.
Test for less than 10 ohms between each ground circuit terminal listed below and ground:
Terminal 85
Terminal 87A
1. Ignition OFF.
Ignition ON.
Verify a test lamp illuminates between the B+ circuit terminal 87 and the ground circuit terminal 87A.
5.
6.
7.
8.
9.
10.

1. Ignition OFF, remove the test lamp. Disconnect the KR12C Windshield Wiper Speed Control
Relay.
2. Test for infinite resistance between each control circuit listed below and ground:
Terminal 87A
Terminal 87
If infinite resistance, replace the M75 Windshield Wiper Motor


Connect a test lamp between the control circuit terminal 86 and the ground circuit terminal 85.
Module.
Ignition OFF, connect the KR12B Windshield Wiper Relay and disconnect the KR12C Windshield Wiper
Speed Control Relay, ignition ON.
11.
12.
13.
14.




Connect a test lamp between the B+ circuit terminal 85 and the control circuit terminal 86.
Verify the test lamp turns ON and OFF when commanding the Windshield Wiper High Speed Relay High
If less than 1 V
3. Ignition OFF.
Module.
Ignition OFF, connect the KR12C Windshield Wiper Speed Control Relay.
Connect a test lamp between the M75 Windshield Wiper Motor control circuit terminal B and ground
Relay.
Relay, ignition ON.
18.
19.
20.
21.
22.


23. Connect a test lamp between the M75 Windshield Wiper Motor control circuit terminal D and ground
24. Verify the test lamp turns ON and OFF when commanding the Windshield Wiper High Speed Relay High
Relay.
Relay, ignition ON.
25. Test or replace the M75 Windshield Wiper Motor.
Component Testing

2. Test for infinite resistance between the signal terminal 1 and the low reference terminal 2 with the high
with the high speed switch in the closed position.


If less than 2 ohms
4. Test for infinite resistance between the signal terminal 3 and the low reference terminal 2 with the low

5. Verify the resistance readings are within the specified range listed below between the signal circuit
terminal 3 and the low reference circuit terminal 1 by pushing the switch in the listed positions below:
Delay 5 : 765-775ohms

6. All OK
Relay Test
1. Ignition OFF, disconnect the appropriate relay.
If less than 60 or greater than 200
Replace the relay.
30 and 86
30 and 87
30 and 85
85 and 87
Replace the relay.

4. Test for less than 5 ohms between terminals 30 and 87A.

Replace the relay.
If less than 5 ohms
Replace the relay.

If less than 5 ohms
7. All OK
Repair Instructions

WASHER MALFUNCTION
DTC Descriptors
DTC B3873 01
Front Washer Relay Circuit Short to Battery
DTC B3873 02
Front Washer Relay Circuit Short to Ground
DTC B3873 04

Front Washer Relay Circuit Open Circuit

Circuit
Signal
Control
Control
Ground
1. Washer Inoperative
2. Washer Always ON
Short to
Ground
Open/High
Resistance
Short to
Voltage
Signal Performance
B3873 02
B3873 04
B3873 01
The body control module (BCM) controls the windshield washer pump based on an input from the windshield
wiper/washer switch. The BCM monitors the washer switch through the windshield washer switch signal
circuit. When the washer switch is closed, low reference is supplied to the windshield washer switch signal
circuit. When this is the case, the BCM will command the windshield washer pump and the low speed wipers
on.
Ignition ON.
A short to ground or an open/high resistance is detected in the windshield washer relay control circuit.
A short to voltage is detected in the windshield washer relay control circuit.
Washer operation is suspended.


Schematic Reference

Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference

1. Ignition ON.
2. Verify the scan tool Windshield Washer Switch parameter changes between Active and Inactive when
pressing and releasing the windshield washer switch.
3. Verify the windshield washers turn ON when commanding the Windshield Washer Relay Active with a
scan tool.
If the Windshield Washers do not turn ON
Refer to Circuit/System Testing below- Windshield Washer Pump Malfunction

If the Windshield Washers turn ON
4. All OK.


2.
3.
4.
5.
6.
7.
Test for less than 10 ohms between the low reference circuit terminal 2 and ground.
1. Ignition OFF.
Ignition ON.
Verify the scan tool Windshield Washer Switch parameter is Inactive.
If not Inactive
If Inactive
Install a 3 A fused jumper wire between the signal circuit terminal 5 and the low reference circuit
terminal 2.
Verify the scan tool Windshield Washer Switch parameter is Active.
If not Active
If less than 1 V
If Active
Test or replace the S82 Windshield Wiper/Washer Switch.
Windshield Washer Pump Malfunction

1. Ignition OFF, and all vehicle systems OFF. Disconnect the harness connector at the G24 Windshield
Washer Pump. It may take up to 2 minutes for all vehicle systems to power down.

3. Connect a test lamp between the control circuit terminal 1 and the ground circuit terminal 2, ignition ON.
4. Verify the test lamp does NOT turn ON and OFF when commanding the Windshield Washer Relay
Active and Inactive with a scan tool.
Test or replace the G24 Windshield Washer Pump.

Ignition OFF, connect the harness connector at the G24 Windshield Washer Pump. Disconnect the X1
harness connector at the X50A Fuse Block - Underhood, It may take up to 2 minutes for all vehicle
Ignition ON.
1. Ignition OFF, disconnect the harness connector at the G24 Windshield Washer Pump, ignition ON.
If less than 1 V, replace the G24 Windshield Washer Pump.
Verify the G24 Windshield Washer Pump activates.
1. Ignition OFF, remove the jumper wire, disconnect the harness connector at the G24 Windshield
Washer Pump.
If less than 2 ohms, replace the G24 Windshield Washer Pump.
5.
6.
7.
8.
9.
10.

11. Ignition OFF, connect the X1 harness connector at the X50A Fuse Block - Underhood. Disconnect the X4
12. Verify the G24 Windshield Washer Pump is not activated.
1. Ignition OFF, disconnect the X2 harness connector at the X50A Fuse Block - Underhood, ignition
ON.
If less than 1 V, replace the X50A Fuse Block - Underhood.
13. Connect a 10 A fused jumper wire between the control circuit terminal 14 and B+.
14. Verify the G24 Windshield Washer Pump activates.
Block - Underhood.
If less than 2 ohms, test or replace the X50A Fuse Block - Underhood.
Component Testing

2. Test for infinite resistance between the signal terminal 5 and the low reference terminal 2 with the switch
in the open position.
with the switch in the closed position.

If less than 2 ohms

4. All OK
Repair Instructions

Windshield Washer Pump Replacement
Control Module References for BCM and instrument cluster replacement and programming and setup
REPAIR INSTRUCTIONS
WINDSHIELD WIPER AND WASHER SWITCH REPLACEMENT
Fig. 3: Windshield Wiper And Washer Switch

Callout
Component Name
Remove the steering column trim covers. Refer to Steering Column Lower Trim Cover Replacement .
Windshield Wiper and Washer Switch

Procedure
1
1. Disconnect any electrical connectors as needed.

2. Release the plastic retaining tabs to remove the windshield wiper
and washer switch.
WINDSHIELD WASHER NOZZLE HOSE REPLACEMENT
Fig. 4: Windshield Washer Nozzle Hose, Pump Hose, Hose Connector And Hose Retainer
Windshield Washer Nozzle Hose Replacement
Callout
Component Name
1. Remove the hood insulator. Refer to Hood Insulator Replacement .

2. Place a clean container under the front driver side near where the windshield washer nozzle and
windshield washer pump hose will be disconnected.
3. Recover all lost windshield washer solvent.
Windshield Washer Nozzle Hose
Procedure
1
Disconnect the washer hose from both hood mounted washer
nozzles.

2
3
4
Windshield Washer Hose Retainer to Hood Hinge

Windshield Washer Nozzle Hose Integral Connector
Procedure
Disconnect the hoses in order to remove the windshield washer
nozzle hose.
Windshield Washer Pump Hose
WINDSHIELD WASHER NOZZLE REPLACEMENT
Fig. 5: Windshield Washer Nozzle

Windshield Washer Nozzle Replacement
Callout
Component Name
1. Disconnect the washer hose from the washer nozzles.

2. Remove the hood insulator. Refer to Hood Insulator Replacement .
Windshield Washer Nozzle Assembly
Procedure
1
Pinch the washer nozzle from the bottom side in order to release the
nozzle and push the nozzle outboard from the hood to remove.
WINDSHIELD WASHER SOLVENT CONTAINER FILLER TUBE REPLACEMENT

Fig. 6: Windshield Washer Solvent Container Filler Tube

Windshield Washer Solvent Container Filler Tube Replacement
Callout
Component Name
Windshield Washer Solvent Container Filler Tube Assembly
Procedure
1
1. Pull the upper tube assembly from the lower washer container
and inspect the grommet, replace if damaged.
2. Insert the tube rib flush to the top seal at the lower container.
WINDSHIELD WASHER SOLVENT CONTAINER GROMMET REPLACEMENT

Fig. 7: Windshield Washer Solvent Container Grommet

Windshield Washer Solvent Container Grommet Replacement
Callout
Component Name
Remove the windshield washer solvent container filler tube assembly. Refer to Windshield Washer
Solvent Container Filler Tube Replacement.
1
Windshield Washer Solvent Container Grommet
WINDSHIELD WASHER SOLVENT CONTAINER REPLACEMENT

Fig. 8: Windshield Washer Solvent Container And Nuts

Windshield Washer Solvent Container Replacement
Callout
Component Name
1. Remove the windshield washer solvent container filler tube. Refer to Windshield Washer Solvent
Container Filler Tube Replacement
2. Remove the front wheelhouse liner. Refer to Front Wheelhouse Liner Replacement .
3. Remove the windshield washer pump. Refer to Windshield Washer Pump Replacement.
Windshield Washer Solvent Container Nut (Qty: 3)
1
2
CAUTION:
Windshield Washer Solvent Container
WINDSHIELD WASHER PUMP REPLACEMENT

Removal Procedure

Fig. 9: Windshield Washer Pump Components

1.
2.
3.
4.
5.
6.
Remove the front wheelhouse liner. Refer to Front Wheelhouse Liner Replacement .
Disconnect the washer pump electrical connector (1).
Disconnect the washer pump hose (2) from the washer pump (3).
Using a small flat-bladed tool, remove the washer pump from the washer solvent container (5).
Drain the windshield washer solvent into a clean suitable container.
Using a small flat-bladed tool, remove the washer pump terminal seal (4) from the washer solvent
container (1).

Fig. 10: Windshield Washer Pump Components

1. Position the washer pump terminal seal (4) to the washer solvent container (5), pressing in until fully
seated.
2. Using full strength windshield washer solvent as a lubricant on the terminal seal, position the washer
pump (3) to the washer solvent container (5) pressing in until fully seated.
3. Connect the washer pump electrical connector (1).
4. Connect the washer pump hose (2) to the washer pump (5).
5. Install the front wheelhouse liner. Refer to Front Wheelhouse Liner Replacement .
6. Fill the washer solvent container with washer solvent.
7. Inspect the washer system for proper operation.
WINDSHIELD WASHER PUMP SEAL REPLACEMENT
Removal Procedure

Fig. 11: Windshield Washer Pump Seal

1. Open the hood.
2. Remove the windshield washer pump. Refer to Windshield Washer Pump Replacement
3. Using a small flat-bladed tool, remove the washer pump terminal seal (1) from the washer solvent
container (2).

Fig. 12: Windshield Washer Pump Seal

1. Position the washer pump terminal seal (1) to the washer solvent container (2), pressing in until fully
seated.
2. Install the windshield washer pump. Refer to Windshield Washer Pump Replacement
3. Close the hood.
AIR INLET GRILLE PANEL REPLACEMENT

Fig. 13: Air Inlet Grille Panel And Clips

Air Inlet Grille Panel Replacement
Callout
Component Name
1. Remove the wiper arms. Refer to Windshield Wiper Arm Replacement.

2. Remove hood rear weatherstrip. Refer to Hood Rear Weatherstrip Replacement .
1
Air Inlet Grille Panel Clip (Qty: 5)
2
Air Inlet Grille Panel Assembly
WINDSHIELD WIPER ARM REPLACEMENT

Fig. 14: Windshield Wiper Arm Components

Windshield Wiper Arm Replacement
Callout
Component Name
Windshield Wiper Arm Finish Cap
1
Procedure
Use a small flat-bladed tool to remove finish cap.
Windshield Wiper Arm Nut
CAUTION:
Procedure
2
1. Locate the transparent circle with a black dot in the center at the
lower windshield blackout area.
2. Position the wiper arm to the pivot shaft so that the wiper blade
is centered across the transparent circle.
3. Lift the arm blade portion while pushing down the arm onto the
pivot shaft.
4. Install the wiper arm nut.
5. Hold the wiper arm stationary in position as previously stated.
6. Torque the wiper arm nut.

7. Release the wiper arm assembly.

8. Repeat the same procedure for the other wiper arm.
Tighten
24.5 N.m (18 lb ft)
Windshield Wiper Arm Assembly
Procedure
Grasp the end of the wiper arm at the wiper transmission pivot shaft
and rock the arm side to side in order to release the windshield wiper
arm from the wiper transmission pivot shaft.
WINDSHIELD WIPER BLADE REPLACEMENT
Fig. 15: Windshield Wiper Blade, Removal Tab And Wiper Arm
Windshield Wiper Blade Replacement
Callout
Component Name
Raise the wiper arm up off the windshield.
1
Windshield Washer Arm
Windshield Wiper Arm Blade Removal Tab
Procedure
2
1. Push inward the square tab at the center top side of the wiper
blade.
2. Rotate the wiper blade downward slightly.
3. Slide the wiper blade from the wiper arm.
4. Carefully release the wiper arm back to the windshield.

Windshield Washer Blade
WINDSHIELD WIPER MOTOR REPLACEMENT
Fig. 16: Windshield Wiper Motor, Bolts And Nut

Callout
Component Name
1. Remove the windshield wiper arms. Refer to Windshield Wiper Arm Replacement
2. Remove the air inlet grille panel. Refer to Air Inlet Grille Panel Replacement.
3. Remove the wiper drive system module.
Windshield Wiper Motor Bolts (Qty: 2)
CAUTION:
Tighten
10 N.m (89 lb in)
2
Windshield Wiper Motor Nut

Tighten

10 N.m (89 lb in)

Windshield Wiper Motor Assembly
WINDSHIELD WIPER TRANSMISSION REPLACEMENT
Fig. 17: Windshield Wiper Transmission, Bolts And Electrical Connector

Windshield Wiper Transmission Replacement
Callout
Component Name
1. Remove the wiper arms. Refer to Windshield Wiper Arm Replacement.

2. Remove the air inlet grille panel. Refer to Air Inlet Grille Panel Replacement.
1
Electrical Connector
Windshield Wiper Transmission Bolts (Qty: 3)
CAUTION:
Tighten
10 N.m (89 lb in)
Windshield Wiper Transmission

Procedure
Remove components as needed.
WIPER BLADE ELEMENT CLEANING

Lift each blade assembly off of the windshield and clean the element with a cloth saturated with full strength
washer solvent. Then rinse the blade assemblies with clear water.
WINDSHIELD WIPER ARM ADJUSTMENT
1. Loosen the windshield wiper arms from windshield wiper transmission. Refer to Windshield Wiper
Arm Replacement
Fig. 18: Windshield Wiper Arm Adjustment

2. Measure the upper edge of water deflector (rubber lip) to wiper arm attachment point.

3. Position the wiper arm to the basic setting.

Driver side (a) approximately 6.5 cm (2.6 in)
Passenger side (b) approximately 8.5 cm (3.3 in).

WIPER/WASHER SYSTEM DESCRIPTION AND OPERATION
Wiper/Washer System Components
The wiper/washer system consists of the following electrical components:

Windshield Wiper Speed Control Relay
Windshield Washer Pump Relay
Windshield Washer Fluid Pump
Window Wiper/Washer Switch
Rain sensor module
Windshield Wiper System
The BCM determines the front wipe/wash system mode of operation by monitoring several signals from the
front wipe/wash switch as indicated in the wiper switch.
The front wipe/wash switch receives a reference ground signal from the BCM. Each input of the BCM provides
a switched battery pull-up for each front wiper/washer switch output signal it receives. All the BCM inputs are
recognized as active when the wiper switch provides a path to the referenced ground signal. The first signal
received by the BCM is the result of 6 resistors in the front wiper switch configured as a resistor ladder
network. This signal is connected to a BCM analog to digital input. Depending on the function selected (High,
Low, Intermittent 1 to 5, Mist, Off), the front wiper control switch connects a different set of resistors into the
circuit resulting in different voltages appearing on the BCM A/D input. By monitoring this voltage, the BCM
determines how to control the wiper motor On/Off Relay. It should be noted that High, Low, and Mist all have
the same value on this signal circuit. The second signal received from the front wiper switch is active only when
the front wiper switch is in the high speed wiper position. When the wiper switch is not in the high speed
position, the switch is open and the signal circuit is pulled to battery by the BCM. When the wiper switch is in
the high speed position, the switch pulls the circuit low. The BCM determines how to control the Wiper
high/low speed relay from this input. The third signal received from the front wiper switch is from the
momentary windshield wash control switch. When the washer switch is not active the switch is open and the
signal circuit is pulled to battery by the BCM. When the washer switch is active, the switch pulls the circuit
low. The BCM controls the windshield wash and windshield wash activated wiper operation based on this input.
The BCM controls front wiper motor operation through two output signals and the monitoring of one input
signal. The two outputs (one high side drive, one low side drive) are used to control two external wiper motor

relays: front wiper motor on/off relay: which provides the wiper motor with battery power when it is activated
by the high side drive signal (switched battery) from the BCM. When left deactivated, the normally closed
contacts provide a ground to the wiper motor. Wiper high/low speed relay: when activated by a low side drive
signal (ground) from the BCM, it switches the power supplied by the wiper motor's on/off relay to the motors
high speed input. When left deactivated, the normally closed contacts connect the power supplied by the wiper
motor's on/off relay to the motor's low speed input. The input used by the BCM is from the park switch located
in the wiper motor assembly. When the wiper blades are not in the park position, the wiper park switch is open
and the circuit is pulled up to battery by the BCM. When the wiper blades are in the park position at the bottom
of the glass, the wiper park switch closes to ground pulling the park signal circuit low.
To initiate low speed operation, the BCM only energizes the front wiper motor on/off relay. This allows battery
voltage from the wiper fuse to be applied through the switched contacts of the wiper motor on/off relay, through
the normally closed contacts of the wiper high/low speed relay, to the low speed control circuit of the
windshield wiper motor.
The BCM provides redundant circuitry which places battery power on its wiper motor on/off relay output with
activation of its low assertion high speed wiper switch input. The BCM shall be capable of doing this, even if
the module has lost all microprocessor control. This redundant circuit shall supply power while in the RUN and
CRANK power modes. however; while in the CRANK power mode, the pass through shall only be active if the
BCM is NOT in a computer operating properly state.
To initiate high speed operation, the BCM energizes both the front wiper motor on/off relay and the wiper
high/low speed relay. This allows battery voltage from the wiper fuse to be applied through the switched
contacts of the wiper motor on/off relay, through the switched contacts of the wiper high/low speed relay, to the
high speed control circuit of the windshield wiper motor.
In order to perform an accurate read of the park switch and to ensure the wipers will come to rest while still in
the park position, parking of the wipers only occurs while in a low speed wiper mode. This requires that if the
wipers are performing a high speed wiper operation at the time they are required to park, the BCM shall
transition the Wipers to low speed by deactivating the wiper high/low relay before attempting to park. In order
to park the wipers, the BCM monitors the park circuit until the park switch pulls the park circuit to ground. At
this time, the BCM will immediately deactivate the wiper motor on/off relay. The relay contacts will switch
back to their normally closed position and will apply ground to the wiper motor power inputs through the
normally closed contacts of the wiper high/low relay. This deactivates and dynamically brakes the wiper motor
in the park position. When the wiper switch is turned to the OFF position while the wiper motor is somewhere
in mid-cycle, the BCM will continue to operate the motor until the wipers reach the park position. If the BCM is
running the wiper motor and does not see a state transition of the park switch after 8 s, the wipers will stop
immediately when the wiper switch is turned to OFF. If the ignition is turned OFF while the wipers are in midcycle, the wipers will stop immediately, regardless of position. The BCM will park the wipers next time the
ignition is turned ON.
The windshield wiper system MIST operation is identical to LOW speed operation, except that the MIST switch
is a press and release type switch. When the wiper switch is moved to the MIST position and released, low
speed wiper motor operation is started and will continue until 1 cycle is complete. If the wiper switch is moved
to the MIST position and held, the wiper motor will operate in the LOW speed mode until the switch is
released.
Windshield wiper intermittent operation is a low speed wiper motor function with a variable delay interval

between the wiper motor cycles. The duration of the delay is controlled by the front wiper control switch's
intermittent 1 to intermittent 5 settings. The wiper operation is as follows:
1. The BCM will initiate a single wipe by activating its front wiper ON/OFF relay output.
2. At the completion of a single wipe, the BCM will park the wipers as described above.
3. The BCM will then pause the wipers in their park position for the time duration associated with
intermittent delay switch setting.
4. When the delay time expires repeat Steps 1 and 3 until the system is turned off or taken out of intermittent
mode. If the wiper switch is moved from a longer delay interval to a shorter delay interval, the BCM will
command an immediate wipe cycle and reset the delay timer to the shorter delay interval.
Intermittent wiper operation may be vehicle speed sensitive. When enabled, the speed compensated intermittent
feature causes the intermittent wiper delay intervals to become shorter as a function of increased speed. As
vehicle speed is reduced the intervals will become closer to the predetermined.
Intermittent wiper operation may be vehicle speed sensitive. When enabled, the speed compensated intermittent
feature causes the intermittent wiper delay intervals to become shorter as a function of increased speed. As
vehicle speed is reduced the intervals will become closer to the predetermined.
Windshield Washer System
The BCM controls the windshield wash operation and windshield wash activated wiper operation. When the
BCM detects the activation of the momentary windshield wash control switch, it activates its washer pump
relay drive output which supplies battery power to the coil of the washer pump relay. This energizes the relay,
which switches battery power to the pump motor. The BCM will also activate continuous low speed windshield
wipes as described above. Upon deactivation of the windshield wash control switch, the wiper control module
(BCM) shall deactivate the wash motor and will also park the wiper motor as described above unless the drip
wipe feature is enabled. On some vehicles the drip wipe feature will be enabled and cause the system to provide
additional wiping of the windshield after the switch has been released and fluid is no longer being applied. The
front wash feature may attempt to detect a stuck switch. When enabled, activation of the wash feature shall be
limited to 10 s.
Moisture Sensitive Wipers
The outside moisture sensor monitors moisture accumulation on the windshield and uses a windshield
wiper/washer switch status input to provide wipe commands to the body control module (BCM). The DELAY
positions on the wiper/washer switch are used to activate the AUTOMATIC rain sensing operating mode. They
are also used to adjust the level of sensitivity to moisture accumulation, which determines the dwell time for
commanding a wiper motor wipe cycle.
Accessory voltage is supplied to the outside moisture sensor through the 10A RAP Fuse, located in the rear fuse
block. The sensor is grounded through the ground circuit and G402. Whenever the ignition is in the run or
accessory positions, the BCM sends the wiper/washer switch status using a pulse width modulation (PWM)
signal through the outside moisture sensor signal 1 circuit to the outside moisture sensor. When a wipe cycle is
needed, the moisture sensor sends a PWM voltage signal through the moisture sensor signal 2 circuit back to the
BCM requesting the wiper operation.

The outside moisture sensor uses the moisture sensor signal 2 circuit to command wiper motor wipe cycles and
to confirm the moisture sensor signal 1 is being received. If at anytime communication between the outside
moisture sensor and BCM is lost, the BCM will use the inputs from the windshield wiper/washer switch in the
delay positions to operate the wiper motor at continuous variable delay intervals.

2013 ACCESSORIES & EQUIPMENT Wiring Systems and Power Management - Repair Instructions - Cruze

Wiring Systems and Power Management - Repair Instructions - Cruze
REPAIR INSTRUCTIONS
GMLAN AND MEDIA ORIENTED SYSTEMS TRANSPORT (MOST) WIRING REPAIRS
Special Tools
EL-38125-10 Splice Sleeve Crimping Tool

DuraSeal splice sleeves
A wire stripping tool
For equivalent regional tools, refer to Special Tools .

The DuraSeal splice sleeves have the following 2 critical features:
A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing
adhesive inside.
A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy
circuits.
The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive
nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors
and terminals.
GMLAN Repairs
NOTE:
When making a repair to any GMLAN network, the original wire length after the
repair must be the same length as before the repair. If the network is a twisted
pair, the twist must be maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works
at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more
information on GMLAN, refer to Data Link Communications Description and Operation .
GMLAN Connector Terminal Repair
NOTE:
A terminated lead can be used to replace damaged connector terminals for both
high speed and low speed GMLAN systems. When making a connector terminal
repair on a GMLAN high speed system with twisted pair wires, do not untwist
the wires more than necessary to make the repair.
If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair
procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair

procedure.
GMLAN Wire Repair
NOTE:
Refer to Wiring Repairs in the service information connector end views or the
vehicle schematics in order to determine the correct wire size for the circuit you
are repairing. You must obtain this information in order to ensure circuit
integrity.
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge
size (0.5 mm2 , 0.8 mm2 , 1.0 mm2 etc.). Use the DuraSeal splice sleeves and EL-38125-10 tool. For wiring
repair, refer to Splicing Copper Wire Using Splice Sleeves .
INSTRUMENT PANEL WIRING HARNESS FUSE BLOCK DISASSEMBLE
NOTE:
To remove wires from the top part using terminal release tools, only steps 1, 3,
8, 9, 10, 11, 12 and 13 are required. Use release tool J-38125-38 for cavities 1618, 20-34, 37-47.
Fuse Block Disassemble Procedure

Fig. 1: Fuse Block & Locking Arms

1. Push the locking arms (1) and unlock the fuse block (2).

Fig. 2: Fuse Block In Unlocked Position

2. Fuse block unlocked.

Fig. 3: Fuse Block & Bracket

3. Pull out and remove the fuse block from bracket.

Fig. 4: Fuse Block & Brackets

4. Fuse block after removed from bracket.

Fig. 5: Fuse Block & Relay Protection Cover

5. Push and open the relay protection cover.

Fig. 6: Fuse Block Micro Relays

6. Remove micro relays (3x).

Fig. 7: Micro Relays

7. Fuse block with relays removed.

Fig. 8: Fuse Block Components

8. Remove mini fuses (22x), J-case fuses (2x), and circuit breakers (2x) from fuse block.

Fig. 9: View Of Fuse Block Components

9. Fuse block with all fuses and circuit breakers removed.

Fig. 10: Fuse Block Cover

10. Unlock (6 locking points) and remove bottom protection cover from fuse block.

Fig. 11: Fuse Block Wires & Straps

11. Remove straps (4x) from wires.

Fig. 12: Fuse Block Locking Arm Components

12. To place the top part (1) in pre-assembled position, press together locking arms on both sides of the
bottom part (2), insert a pry tool into an appropriate hole in the top part and lever the top part upward
until it remains in the pre-assembled position. Release the locking arms.

Fig. 13: Fuse Block Tabs

13. When the top part is in the pre-assembled position (required to release wire terminals), the tabs of the top
part are on top of the tabs of the bottom part (left close-up view).
When the top part is in the end-locking position (required after wires are inserted), the tabs of the bottom
part are on top of the tabs of the top part (right close-up view).

Fig. 14: Fuse Block Relays

14. Unlock and remove relay socket from fuse block.

Fig. 15: Fuse Block Relay Socket & Locking Caps

15. Unlock (6 locking points) and remove locking caps (3x) from relay socket.

Fig. 16: Relay Socket & Locking Caps

16. Relay socket with locking caps removed.
RELAY REPLACEMENT (ATTACHED TO WIRE HARNESS)
Removal Procedure

Fig. 17: Identifying Relay & Wire Harness Connector

1. Locate the relay. Refer to the Master Electrical Component List to locate the relay in the vehicle.
2. Remove any 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 fasteners or tape.
4. Separate the relay (1) from the wire harness connector (2).


1. Connect the relay (1) to the wire harness connector (2).
2. Install any connector position assurance (CPA) devices or secondary locks.
3. Install the relay using any fasteners or tape that originally held the relay in place.
RELAY REPLACEMENT (WITHIN AN ELECTRICAL CENTER)
Special Tools
EL-43244 Relay Puller Pliers

Removal Procedure
1. Remove the electrical center cover.

NOTE:
Always note the orientation of the relay.

If equipped with a notch style relay; observe the location of the notch
on the old relay to verify the new relay is installed with the notch in
the same location.
Ensure that the electrical center is secure, as not to put added stress
on the wires or terminals.
2. Locate the relay. Refer to Electrical Center Identification Views to locate the electrical center where the
relay exists.

Fig. 19: Removing/Installing Relay

3. Using the EL-43244 (1) position the tool on opposing corners of the relay (2).

CAUTION: Use EL-43244 to pull the relay straight out from the electrical center
terminals. The use of pliers or a flat bladed tool could damage the
electrical center.
4. Remove the relay (2) from the electrical center.


1. Install the relay (2) in the same position as removed.
2. Install the electrical center cover.

GROUND REPAIR
Electrical Grounds
Proper electrical system function relies on secure, positive, corrosion-free ground connections. Loose, stripped,
or corroded connections increase the possibility of improper system function and loss of module
communication. These conditions may also lead to unnecessary repairs and component replacements.
In general, electrical ground connections are accomplished using one, or a combination of, three attachment
methods:
Welded M6 stud and nut

Welded M6 nut and bolt
CAUTION: Use GM approved replacement fasteners with conductive finish for
electrical ground repair.
Determine which attachment method is used, and carry out the appropriate repair.
M6 Weld Stud Replacement
1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance
behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 rivet stud flange.
2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow
to dry.
NOTE:
Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be

drilled.
3. Drill a 10 mm (0.40 in) diameter hole through the panel.

4. Carefully remove paint and primer from the area surrounding the rivet stud flange until bare metal is
visible.
5. Select a replacement conductive M6 rivet stud. Refer to GM parts catalog for the correct part number and
application.
6. Using a rivet stud installer, install the replacement conductive M6 rivet stud.
7. Ensure the new rivet stud is securely fastened, with no detectable movement.
NOTE:
The rivet stud and surrounding panel area must be properly refinished
prior to the installation of the ground terminal and nut to maintain positive

electrical grounding.
8. Completely wrap the threads of the rivet stud with painters tape or equivalent.
9. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and
Repair .
10. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the
rivet stud threads.
11. Remove the painters tape or equivalent from the rivet stud threads.
12. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove
any adhesive and allow to dry.
13. Carefully remove any corrosion from the electrical ground wire terminal. Refer to Testing for
14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the new
conductive M6 rivet stud threads.
15. Install the ground terminal to the new rivet stud.
16. Select a new, conductive M6 nut. Refer to GM parts catalog for the correct part number and application.
17. Install the M6 nut and tighten to 8 N.m (71 lb in).

18. Check for proper system operation.
M6 Weld Nut
1. If the M6 weld nut at the electrical ground location is damaged or stripped, a new, conductive selfthreading M7 bolt may be used to secure the ground terminal. Refer to GM parts catalog for the correct
part number and application.
2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding
the weld nut and allow to dry.
3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush.
4. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the new,
conductive, self-threading M7 bolt threads.
5. Carefully remove any corrosion from the electrical ground terminal. Refer to Testing for Intermittent
Conditions and Poor Connections .
6. Install the electrical ground terminal to the new, conductive M7 bolt.

7. Install the M7 bolt and tighten to 9 N.m (80 lb in).

M6 Weld Nut (Alternative Repair)
1. If the electrical ground location is accessible from both sides of the panel, a conductive M6 bolt and a
conductive M6 nut may be used to secure the electrical ground terminal. Refer to GM parts catalog for
the correct part number and application.
2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79) clearance behind the panel
surface and 20 mm (0.79) clearance surrounding the new electrical ground site.
the ground location and allow to dry.
NOTE:

drilled.

5. Carefully remove paint and primer from the area surrounding the new ground site until bare metal is
visible.
conductive M6 bolt threads.
8. Install the electrical ground terminal and new, conductive M6 bolt to the ground location.
9. Install the conductive M6 nut and tighten to 8 N.m (71 lb in).

NOTE:
The repair area must be properly refinished to maintain positive electrical

grounding.
Repair .
M8 Weld Nut


1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a conductive M8
bolt and a conductive M8 nut may be used to secure the ground terminal. Refer to GM parts catalog for
the correct part numbers and application.
2. Select a location adjacent to M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and
20 mm (0.79 in) clearance surrounding the new electrical ground site.
NOTE:

drilled.

visible.
9. Install the conductive M8 nut and tighten to 22 N.m (16 lb ft).

NOTE:

grounding.
Repair .
1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a conductive
M6 rivet stud and a conductive M6 nut may be used to secure the ground terminal. Refer to GM parts
catalog for the correct part numbers and application.

2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel
surface and 20 mm (0.79 in) clearance surrounding the new, conductive M6 rivet stud flange.
to dry.
NOTE:

drilled.

visible.
NOTE:
Repair .
rivet stud threads.
15. Install the ground terminal to the new, conductive M6 rivet stud.
FUSE BLOCK REPLACEMENT
Removal Procedure
1. Disconnect battery negative cable. Refer to Battery Negative Cable Disconnection and Connection .

Fig. 21: Battery Fuse Box Cover

2. Unlock the retaining tab (1) on the battery fuse box cover.
3. Use a suitable screwdriver (2) to unlock the clip (4) through the window (3).

Fig. 22: View Of Fuse Box Cover, Battery Cable And Nut
NOTE:
4.
5.
6.
7.
Pull the battery fuse box housing. DO NOT pull the flap.
Open the battery fuse box cover (1).

Remove the positive battery cable to starter nut (2).
Remove the positive battery cable to starter (3) from the battery.
Remove the positive battery cable. Refer to Battery Positive Cable Replacement .

Fig. 23: Identifying Fuse Block, Body Wiring Harness And Nuts
8. Remove 2 body wiring harness nuts (1) and body wiring harness.
9. Remove fuse block (2).
1. Install fuse block.

CAUTION: Refer to Fastener Caution
2. Install body wiring harness and 2 body wiring harness nuts and tighten to 4.7 N.m (42 lb in).
3. Install the positive battery cable. Refer to Battery Positive Cable Replacement .

4. Install the positive battery cable to starter (3).
5. Install the positive battery cable to starter nut (2) and tighten to 9 N.m (80 lb in).


6. Close the battery fuse box cover and lock the retaining tabs (1) and (4).
7. Connect battery negative cable. Refer to Battery Negative Cable Disconnection and Connection .
FRONT COMPARTMENT FUSE BLOCK REPLACEMENT
Removal Procedure
2. Remove the front compartment fuse block cover. Refer to Front Compartment Fuse Block Cover
Replacement.

Fig. 26: View Of Front Compartment Fuse Block, Wiring Harness Supply And Fuse Block Bolt
NOTE:
Bolts (1) are encapsulated on the end of threads so that they can not be
removed from the fuse block. The fuse block must be pulled out to expose
the positive cable lug.
3. Remove the 3 front compartment fuse block bolts (1).

4. Unlock retaining tabs and remove the front compartment fuse block (3).
5. Remove the front compartment fuse block wiring harness supply (2).

Fig. 27: Wiring Harness Supply, Front Compartment Fuse Block And Electrical Connectors
1. Install front compartment fuse block wiring harness supply (1) and tighten to 12 N.m (106 lb in).
2. Push down the 3 electrical connectors (3) before installation of the front compartment fuse block (2).

Fig. 28: Identifying Front Compartment Fuse Block Bolt

3. Install 3 front compartment fuse block bolts (1) and tighten to 6 N.m (53 lb in).
4. Install the front compartment fuse block cover. Refer to Front Compartment Fuse Block Cover
Replacement.
FRONT COMPARTMENT FUSE BLOCK HOUSING REPLACEMENT

Fig. 29: Identifying Front Compartment Fuse Block Housing And Nut
Front Compartment Fuse Block Housing Replacement
Callout
Component Name
Connection .
Container Filler Tube Replacement .
3. Remove front compartment fuse block. Refer to Front Compartment Fuse Block Replacement.
Front Compartment Fuse Block Housing Nut
CAUTION:
Tighten
22 N.m(16 lb ft)
Front Compartment Fuse Block Housing

Procedure

1. Remove 3 electrical connectors from front compartment fuse block

housing.
2. Remove attaching parts and unclip wiring harnesses from front
compartment fuse block housing.
FRONT COMPARTMENT FUSE BLOCK COVER REPLACEMENT
Fig. 30: Identifying Front Compartment Fuse Block Cover

Front Compartment Fuse Block Cover Replacement
Callout
Component Name
Front Compartment Fuse Block Cover
Procedure
1
Squeeze 3 tabs to release cover.
IGNITION LOCK CYLINDER REPLACEMENT
Removal Procedure
Connection .
2. Remove the steering column lower trim cover. Refer to Steering Column Lower Trim Cover
Replacement .

Fig. 31: Key & Ignition Lock Cylinder

3. Insert the key into the ignition lock cylinder and turn the key to the RUN position.

Fig. 32: Access Hole

4. Depress the retainer through the lock housing access hole (1) with a small Allen wrench or similar picktype tool.
5. Remove the ignition lock cylinder from the lock housing.
1. If you are installing a new ignition lock cylinder, code the lock cylinder. Refer to Key and Lock
Cylinder Coding .


2. Turn the key to the RUN position and insert ignition lock cylinder into the lock housing.
3. Turn the key to the LOCK position and remove the key from the ignition lock cylinder.
4. Install the steering column lower trim cover. Refer to Steering Column Lower Trim Cover
Replacement .
5. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection .
IGNITION AND START SWITCH REPLACEMENT

Fig. 34: Ignition Switch And Bolts

Ignition and Start Switch Replacement
Callout
Component Name
Connection .
Replacement
Ignition and Start Switch Bolt (Qty: 2)
CAUTION:
Procedure
Reposition the steering column wiring harness retainers in order to
gain access to the switch bolts.
Ignition and Start Switch
ENGINE STOP/START MODE CONTROL SWITCH REPLACEMENT

Fig. 35: Engine Stop/Start Mode Control Switch

Engine Stop/Start Mode Control Switch Replacement
Callout
Component Name
Remove the instrument panel lower trim pad cover. Refer to Instrument Panel Lower Trim Pad Cover
Replacement (without Knee Airbag) , Instrument Panel Lower Trim Pad Cover Replacement (with
Knee Airbag) .
Engine Stop/Start Mode Control Switch
Procedure
1
Unlock the retaining tabs.
IGNITION AND START SWITCH HOUSING REPLACEMENT

Fig. 36: Ignition And Start Switch Housing

Ignition and Start Switch Housing Replacement
Callout
Component Name
1. Remove the ignition lock cylinder. Refer to Ignition Lock Cylinder Replacement
2. Remove the turn signal switch bracket. Refer to Turn Signal Switch Bracket Replacement
Ignition Lock Cylinder Bolt
CAUTION:
1
Procedure
1. Use a suitable chisel to remove bolt.
2. Install NEW bolt and tighten until head tears off.
Ignition and Start Switch Housing
2
Procedure
2. Remove ignition and start switch. Refer to Ignition and Start

Switch Replacement.

2013 ACCESSORIES & EQUIPMENT Air/Wind Noise - Cruze

Air/Wind Noise - Cruze

AIR/WIND NOISE
Special Tools
CH-39570 Chassis Ear

GE-41416 Ultrasonic Leak Detector

WARNING: Refer to Assistant Driving Warning .
To analyze a reported windnoise condition, test drive the vehicle to determine the origin of the noise.
Choose a regular route with smooth and straight streets that run in all 4 directions: North, South, East, and
West. The area should have little traffic or little noise in order to eliminate interference with the test.
NOTE:
Often there is one primary leak source and one or more secondary leaks that
contribute to the noise condition. Repairing only one of the contributing leak
sources may not completely repair the total condition but only reduce the
condition.
Drive the vehicle at the speed in which the noise was noticed, or until the noise is heard. Maintain safe and legal
speeds.
Many of the waterleak diagnosis tests are also used for the windnoise diagnosis.
Most windnoise is caused either by leaking seals or by misaligned body surfaces. You can diagnose the
following types of windnoise with the aid of CH-39570 ear or GE-41416 detector.
Wind whistle
Wind roar
Wind rush
When moving at highway speeds, air pressure inside the vehicle becomes greater than the air pressure outside.
When a leak occurs, the escaping air causes a hiss or a whistle.
Wind roar occurs when air passes over or through an opening between the 2 body surfaces. To correct the
condition, adjust the alignment to the body surfaces.

Wind rush occurs when air presses over the vehicle's body, and is related to the aerodynamics of the vehicle.
Wind whistle and wind roar are repairable. Rule out wind whistle and wind roar before concluding that the wind
noise is due to wind rush.
Use the following inspections in order to aid in diagnosing wind whistle or wind roar:
1. Note the details for wind noise:
The perceived location
The location where the noise is loudest
When the noise occurs
The vehicle speed
The interior fan speed
The position of the windows
What the noise sounds like
2. Inspect the vehicle for the possible cause of the windnoise.
3. Test drive the vehicle and determine if the windnoise is external or internal.
4. Perform a visual inspection of the following components:
Loose fasteners
Torn weatherstrips
Broken weld joints
Sealer and/or adhesive skips
TRACING POWDER OR CHALK TEST
Clean the weatherstrips and the contact surfaces with cleaning solvent.
1. Apply powder or chalk in an unbroken line to the contact surface of the weatherstrip surrounding the
perimeter of the suspected areas.
2. Close the panel completely without slamming the panel. Closing the panel completely presses the
weatherstrip firmly against the mating surface.
3. Inspect the applied line on the weatherstrip. The applied line is marred where contact is good. A
corresponding imprint is on the mating surfaces.
4. Gaps or irregularities in the powder or the chalk line on the mating surfaces indicate the areas with a poor
seal.
AIR PRESSURE TEST
1. Mask off both the pressure relief valves.
2. Close all the windows.
3. Turn the vehicles ventilation fan to the on position, with the selector 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 TEST
1. Mask off the pressure relief valves.
2. Close all the windows and the doors.
3. Turn the vehicles ventilation fan to the on position, with the selector on high speed and in the defrost
mode.
4. Unlock and close the doors.
5. Apply the soap solution to the potential leak areas.
6. Look for bubbles revealing escaping air.
REPAIR INSTRUCTIONS
EXTERIOR WINDNOISE
Exterior windnoise is louder when the vehicle is driven with one or more windows down. Exterior windnoise
occurs when air passes over the body panels, the seams, or the openings. Use the following items during the test
drive in order to aid in the detection of leaks:
Mechanic's stethoscope or heater hose

Masking tape-51 mm (2 in) width
Strip caulk
A water soluble marking pencil
1. While driving, determine the location of the exterior windnoise by lowering one window at a time. If the
location corresponds with the condition in step 2, pull over and make a temporary repair with 51 mm (2
in) wide masking tape.
2. Tape over the gaps and the moldings one at a time. Test between each taping. Taping over the gaps and
moldings will correct the condition.
3. Temporarily repair the condition with masking tape. Adjust the tape when needed.
4. Continue testing in order to determine if the noise has 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

Interior windnoise is not heard when the window is lowered. Interior windnoise is caused by the air leaving the
inside of the vehicle through a seal or a seam.
1. Tape over the relief valves to cause added air pressure within the vehicle.
2. Test drive the vehicle and listen for windnoise or a whistle.
3. Pull the vehicle over and make the temporary repairs using masking tape. If you cannot determine the
source of the windnoise, perform one or more of the following diagnostic tests:
Air Pressure Test
Soap Suds or Bubble Test
Tracing Powder or Chalk Test

SPECIAL TOOLS
Illustration

CH-39570
J 39570
Chassis Ear
GE-41416
J 41416
Ultrasonic Leak Detector

2013 ACCESSORIES & EQUIPMENT Bolted Exterior Body Panels and Closures - Cruze

Bolted Exterior Body Panels and Closures - Cruze
SPECIFICATIONS
Application
Front Fender Bolt
Front Fender Bracket Bolt
Front Side Door Check Link Bolt
Front Side Door Check Link Nut
Front Side Door Hinge Bolt - Body Side
Front Side Door Hinge Bolt - Door Side
Headlamp and Front Bumper Fascia Mount Panel Bolt
Hood Hinge Bolt
Hood Hinge Reinforcement Nut
Rear Compartment Lid Hinge Bolt
Rear Side Door Check Link Bolt
Rear Side Door Check Link Nut
Rear Side Door Hinge Bolt - Body Side
Rear Side Door Hinge Bolt - Door Side
CLEARANCE AND FLUSHNESS SPECIFICATIONS
Specification
Metric
English
8 N.m
71 lb in
9 N.m
80 lb in
25 N.m
19 lb ft
9 N.m
80 lb in
32 N.m
24 lb ft
25 N.m
19 lb ft
22 N.m
17 lb ft
26 Y
20 lb ft
26 Y
20 lb ft
9Y
80 lb in
25 N.m
19 lb ft
9 N.m
80 lb in
32 N.m
24 lb ft
25 N.m
19 lb ft

Fig. 1: Clearance And Flushness Specifications

Callout
1
2
3
4
5
6
7
8
9
10
11
12
13
Component Name
Hood to Front Bumper Fascia
Hood to Headlamp
Hood to Headlamp
Hood to Fender
Front Side Door to Fender
Front Side Door to Body Side
Outer Upper Panel
Rear Side Door to Body Side
Outer Upper Panel
Rear Side Door to Quarter Outer
Panel
Rear Side Door to Rocker Outer
Panel
Front Side Door to Rocker Outer
Panel
Front Side Door to Rear Side Door
Rear Compartment Lid to Quarter
Outer Panel
Tail Lamp to Tail Lamp
Rear Compartment Lid to Rear
Clearance
4.0 mm 1.0 mm
4.5 mm 1.5 mm
3.0 mm 1.0 mm
3.0 mm 0.75 mm
3.5 mm 0.75 mm
6.0 mm 1.0 mm
6.0 mm 1.0 mm
3.5 mm 0.75 mm
4.5 mm 1.0 mm
4.5 mm 1.0 mm
3.5 mm 0.75 mm
3.0 mm 0.75 mm
4.0 mm 1.5 mm

14
Bumper Fascia
5.5 mm 1.5 mm

DTC
DTC B3006
Description
DTC B3006 Hood Ajar Circuit
DTC B3006
DTC Descriptors
DTC B3006
Hood Ajar Circuit
Circuit
Signal
Ground
Short to
Ground
B3006 02
-
Open/High
Resistance
B3006 01, B3006 04
B3006 01, B3006 04
Short to
Voltage
B3006 01
-
Signal Performance
-
The body control module (BCM) applies B+ to the hood ajar signal circuit and monitors the voltage to
determine the position of the hood. When the hood is closed, the switch is open and voltage remains high. When
the hood is open, the switch is closed and the voltage is pulled low.
The BCM continuously monitors for this DTC

B3006 01

The BCM detects that the hood ajar switch signal circuit is shorted to battery.
B3006 02
The BCM detects that the hood ajar switch signal circuit is shorted to ground.
B3006 04
The BCM detects that the hood ajar switch signal circuit is open.
The hood ajar switch input will be ignored as a content theft deterrent trigger.
Remote vehicle start (if equipped) will be disabled.
A history DTC will clear after 40 malfunction free ignition cycles.
Schematic Reference
Keyless Entry System Description and Operation (without BTM) , Keyless Entry System Description and
Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference


1. Ignition ON.
2. Verify the scan tool Hood Ajar Switch parameter is Open when the hood is open and Closed when the
hood is closed.
3. All OK.
1. Ignition OFF and all vehicle systems OFF, disconnect the harness connector at the B55 Hood Ajar
Switch. It may take up to 2 min for all vehicle systems to power down.
1. Ignition OFF
3. Ignition ON.
4. Test for greater than 10.5 V between the signal circuit terminal B and ground.
If 11.5 V or less
5. Ignition OFF, disconnect the X4 and X7 harness connector at the K9 Body Control Module, ignition ON.
6. Test for less than 1 V between the signal circuit terminal B and ground.
If 1 V or greater
If less than 1 V

7. Test or replace the B55 Hood Ajar Switch.

Component Testing
1. Ignition OFF, disconnect the harness connector at the B55 Hood Ajar Switch.
2. Test for 2738-3350 ohms between the signal terminal A and the signal terminal B with the hood latch in
the closed position.
If not between 2738-3350 ohms
Replace the B55 Hood Ajar Switch.
3. Test for 658-806 ohms between the signal terminal A and the ground terminal C with the hood latch in

4. Test for 2080-2545 ohms between the signal terminal B and the ground terminal C with the hood latch in

the open position.

the open position.

the open position.


8. All OK.
Repair Instructions
Hood Primary and Secondary Latch Replacement

SYMPTOMS - BOLTED EXTERIOR BODY PANELS AND CLOSURES

IMPORTANT: The following steps must be completed before using the symptom tables.
The control modules can communicate via the serial data links.
2. Review the system operation in order to familiarize yourself with the system functions. Refer to Hood
Ajar Indicator Description and Operation.
cause the symptom.
Intermittent
Symptom List
Refer to Hood Ajar Indicator/Message Malfunction in order to diagnose the symptom.

HOOD AJAR INDICATOR/MESSAGE MALFUNCTION

DTC Descriptors
DTC B3006
Hood Ajar Circuit
Circuit
Signal
Ground
Short to
Ground
B3006 02
-
Open/High
Resistance
B3006 01, B3006 04
B3006 01, B3006 04
Short to
Voltage
B3006 01
-
Signal Performance
-
The BCM continuously monitors for this DTC

B3006 01
The BCM detects that the hood ajar switch signal circuit is shorted to battery.
B3006 02
The BCM detects that the hood ajar switch signal circuit is shorted to ground.
B3006 04
The BCM detects that the hood ajar switch signal circuit is open.
The hood ajar switch input will be ignored as a content theft deterrent trigger.
Remote vehicle start (if equipped) will be disabled.

A history DTC will clear after 40 malfunction free ignition cycles.
Schematic Reference
Keyless Entry System Description and Operation (without BTM) , Keyless Entry System Description and
Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference

1. Ignition ON.
2. Verify the scan tool Hood Ajar Switch parameter is Open when the hood is open and Closed when the
hood is closed.
3. All OK.
1. Ignition OFF and all vehicle systems OFF, disconnect the harness connector at the B55 Hood Ajar

1. Ignition OFF
3. Ignition ON.
4. Test for greater than 10.5 V between the signal circuit terminal B and ground.
If 11.5 V or less
5. Ignition OFF, disconnect the X4 and X7 harness connector at the K9 Body Control Module, ignition ON.
6. Test for less than 1 V between the signal circuit terminal B and ground.
If 1 V or greater
If less than 1 V
7. Test or replace the B55 Hood Ajar Switch.
Component Testing
1. Ignition OFF, disconnect the harness connector at the B55 Hood Ajar Switch.



the open position.

the open position.

the open position.

8. All OK.
Repair Instructions

REPAIR INSTRUCTIONS
FRONT END UPPER TIE BAR REPLACEMENT

Fig. 2: Front End Upper Tie Bar

Front End Upper Tie Bar Replacement
Callout
1.
2.
3.
4.
Component Name
Remove the front bumper fascia. Refer to Front Bumper Fascia Replacement
Remove the radiator support bracket. Refer to Radiator Support Bracket Replacement
Remove the radiator grille reinforcement support. Refer to Front Grille Support Replacement
Remove the hood primary and secondary latch. Refer to Hood Primary and Secondary Latch
Replacement
Headlamp and Front Bumper Fascia Mount Panel Bolt (Qty: 4)
CAUTION:
Tighten
22 N.m (17 lb ft)
Front End Upper Tie Bar
FRONT FENDER FRONT LOWER BRACKET REPLACEMENT

Fig. 3: Front Fender Front Lower Bracket

Front Fender Front Lower Bracket Replacement
Callout
Component Name
1. Remove the front bumper fascia. Refer to Front Bumper Fascia Replacement .
2. Remove the headlamp. Refer to Headlamp Replacement .
3. Remove the front fender. Refer to Front Fender Replacement.
Front Fender Bracket Bolt
CAUTION:
Tighten
9 N.m(80 lb in)
Front Fender Front Lower Bracket
HOOD PRIMARY LATCH RELEASE CABLE REPLACEMENT

Fig. 4: Hood Primary Latch Release Cable

Hood Primary Latch Release Cable Replacement
Callout
Component Name
1. Remove hood primary latch release cable handle. Refer to Hood Primary Latch Release Cable
Handle Replacement.
3. Remove the radiator grille support. Refer to Front Grille Support Replacement.
4. Remove the air inlet grille panel. Refer to Air Inlet Grille Panel Replacement .
Hood Primary Latch Release Cable
Procedure
1
To release the hood primary latch release cable, unhook from hood
primary and secondary latch.
REAR SIDE DOOR CHECK REPLACEMENT

Fig. 5: Rear Side Door Check

Rear Side Door Check Replacement
Callout
Component Name
1. Remove rear side door trim panel. Refer to Rear Side Door Trim Replacement
Replacement
Rear Side Door Check Bolt
CAUTION:
TIP: Place the door in the full open position.

Tighten
25 N.m (18 lb ft)
Rear Side Door Check Nut
Procedure
Remove the water deflector.
Tighten
9 N.m (79 lb in)
Rear Side Door Check

FRONT SIDE DOOR REPLACEMENT
Fig. 6: Front Side Door Mounting Hardware

Front Side Door Replacement
Callout
Component Name
Remove the front side door trim panel. Refer to Front Side Door Trim Replacement .
CAUTION:
Procedure
1
1. Remove the water deflector. Refer to Front Side Door Water
Deflector Replacement .
2. Disconnect the battery. Refer to Battery Negative Cable
Disconnection and Connection .
3. Disconnect the door electrical connector.
4. Support the door before removing the hinge bolts.
5. With the aid of an assistant, remove the door.

Tighten
25 N.m (18 lb ft)
Front Side Door Lower Hinge Bolt (Qty: 2)
Tighten
25 N.m (18 lb ft)
Front Side Door Upper Hinge Bolt (Qty: 2)
Tighten
25 N.m (18 lb ft)
Front Side Door
Procedure
4
1. Transfer all of the internal components.
2. Adjust the front side door as needed. Refer to Clearance and
Flushness Specifications.
REAR SIDE DOOR REPLACEMENT
Fig. 7: Rear Side Door Mounting Hardware

Rear Side Door Replacement
Callout
Component Name

Remove the rear side door trim panel. Refer to Rear Side Door Trim Replacement .
Rear Side Door Check Link Bolt
CAUTION:
Procedure
1. Remove the water deflector. Refer to Rear Side Door Water

Deflector Replacement .
2. Disconnect the battery. Refer to Battery Negative Cable
3. Disconnect the door electrical connector.
4. Support the door before removing the hinge bolts.
5. With the aid of an assistant, remove the door.
Tighten
25 N.m (18 lb ft)
Rear Side Door Lower Hinge Bolt (Qty: 2)
Tighten
25 N.m (18 lb ft)
Rear Side Door Upper Hinge Bolt (Qty: 2)
Tighten
25 N.m (18 lb ft)
Rear Side Door
Procedure
4
1. Transfer all of the internal components.
2. Adjust the rear side door as needed. Refer to Clearance and
FRONT FENDER REPLACEMENT

Fig. 8: Front Fender Mounting Hardware

Front Fender Replacement
Callout
1.
2.
3.
4.
5.
6.
7.
Component Name
Remove the front bumper fascia. Refer to Front Bumper Fascia Replacement
Remove front bumper fascia guide. Refer to Front Bumper Fascia Replacement
Remove the wheelhouse liner. Refer to Front Wheelhouse Liner Replacement
Remove the headlamp. Refer to Headlamp Replacement
Remove the air inlet grille panel. Refer to Air Inlet Grille Panel Replacement
Remove the front fender shipping cover. Refer to Front Fender Shipping Cover Replacement
Remove the front fender insulator. Refer to Front Fender Insulator Replacement
Front Fender Bolt (Qty: 7)
CAUTION:
Tighten
8 N.m (70 lb in)
Front Fender Bolt

3
4
Tighten
8 N.m (70 lb in)
Front Fender Bolt
TIP: Simply loosen the bolt rather than remove.
Tighten
8 N.m(70 lb in)
Front Fender
FRONT FENDER SHIPPING COVER REPLACEMENT
Fig. 9: Front Fender Shipping Cover

Front Fender Shipping Cover Replacement
Callout
Component Name
1
Front Fender Shipping Cover Retainer
2
Front Fender Shipping Cover
HOOD PRIMARY LATCH RELEASE CABLE HANDLE REPLACEMENT

Fig. 10: Hood Primary Latch Release Cable Handle Hood Primary Latch Release Cable Handle
Hood Primary Latch Release Cable Handle Replacement
Callout
Component Name
Remove the front side door sill trim plate. Refer to Front Side Door Sill Trim Plate Replacement .
Hood Primary Latch Release Cable Handle
Procedure
1
1. Pull down the hood primary latch release cable handle.
2. To release the handle, pull down the cable and unhook from
the handle.
FRONT SIDE DOOR UPPER HINGE AND LOWER HINGE REPLACEMENT

Fig. 11: Front Side Door Upper Hinge and Door Lower Hinge
Front Side Door Upper Hinge and Lower Hinge Replacement
Callout
Component Name
2. Remove the front fender insulator. Refer to Front Fender Insulator Replacement.
3. Remove the front side door. Refer to Front Side Door Replacement.
Front Side Door Hinge Bolt (Qty: 4)
HOOD HINGE REPLACEMENT
CAUTION:
Tighten
32 N.m (24 lb ft)
Front Side Door Hinge
Procedure
Adjust front side door as needed. Refer to Clearance and Flushness
Specifications.

Fig. 12: Hood Hinge

Hood Hinge Replacement
Callout
Component Name
1. Remove the hood. Refer to Hood Replacement.

2. Remove the front fender. Refer to Front Fender Replacement.
Hood Hinge Bolt (Qty: 2)
CAUTION:
Tighten
26 N.m (19 lb ft)
Hood Hinge
REAR COMPARTMENT LID REAR HINGE REPLACEMENT

Fig. 13: Rear Compartment Lid Rear Hinge

Rear Compartment Lid Rear Hinge Replacement
Callout
Component Name
1. Remove the rear compartment lid. Refer to Rear Compartment Lid Replacement.
2. Remove the rear window panel trim. Refer to Rear Window Panel Trim Replacement .
3. Remove the rear compartment lid hinge torque rod. Refer to Rear Compartment Lid Hinge
Torque Rod Replacement.
Rear Compartment Lid Rear Hinge Bolt (Qty: 2)
CAUTION:
Tighten
9 N.m (80 lb in)
Rear Compartment Lid Rear Hinge
Procedure
Adjust rear compartment lid as needed. Refer to Clearance and

REAR SIDE DOOR UPPER HINGE AND LOWER HINGE REPLACEMENT
Fig. 14: Rear Side Door Upper Hinge and Door Lower Hinge
Rear Side Door Upper Hinge and Lower Hinge Replacement
Callout
Component Name
Remove the rear side door. Refer to Rear Side Door Replacement.
Rear Side Door Hinge Bolt (Qty: 4)
HOOD REPLACEMENT
CAUTION:
Tighten
32 N.m (24 lb ft)
Rear Side Door Hinge
Procedure
Adjust rear side door as needed. Refer to Clearance and Flushness
Specifications.

Fig. 15: Hood Hinge Reinforcement Nuts

Hood Replacement
Callout
Component Name
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.
Preliminary Procedure Remove the windshield washer nozzle hose. Refer to Windshield Washer
Nozzle Hose Replacement .
Hood Hinge Reinforcement Nut (Qty: 4)
CAUTION:
Tighten
26 N.m (19 lb ft)
Hood
2
Procedure

2. Adjust hood as needed. Refer to Clearance and Flushness

Specifications.
FRONT FENDER INSULATOR REPLACEMENT
Fig. 16: Front Fender Insulator

Front Fender Insulator Replacement
Callout
Component Name
1
Front Fender Insulator Retainer
2
Front Fender Insulator
HOOD INSULATOR REPLACEMENT

Fig. 17: Hood Insulator

Hood Insulator Replacement
Callout
1
2
Component Name
Hood Insulator Retainer (Qty: 9)
Hood Insulator
HOOD PRIMARY AND SECONDARY LATCH REPLACEMENT

Fig. 18: Hood Primary Latch and Hood Secondary Latch

Callout
Component Name
2. Remove the radiator grille support reinforcement. Refer to Front Grille Support Replacement.
Hood Primary and Secondary Latch Retainer Bolt (Qty: 2)
CAUTION:
Tighten
20 N.m (15 lb ft).
Hood Primary and Secondary Latch
Procedure
2
1. To release the hood primary and secondary latch unhook the
hood primary latch release cable.
2. Disconnect electrical connectors as needed.

REAR COMPARTMENT LID REPLACEMENT
Fig. 19: Rear Compartment Lid Hinge Bolts

Rear Compartment Lid Replacement
Callout
Component Name
Replacement .
Rear Compartment Lid Hinge Bolt (Qty: 4)
CAUTION:
Tighten
9 N.m (80 lb ft)
Procedure
2
2. Adjust rear compartment as needed. Refer to Clearance and


FRONT SIDE DOOR CHECK REPLACEMENT
Fig. 20: Front Side Door Check

Front Side Door Check Replacement
Callout
Prliminary Procedure
Component Name
1. Remove front side door trim panel. Refer to Front Side Door Trim Replacement
Replacement
CAUTION:
1
TIP: Place the door in the full open position.
Tighten
25 N.m (18 lb ft)
Front Side Door Check Link Nut

2
3
Procedure
Remove the water deflector.
Tighten
9 N.m (79 lb in)
Front Side Door Check
FUEL TANK FILLER DOOR REPLACEMENT
Fig. 21: Fuel Tank Filler Door Fuel Tank Filler Door
Fuel Tank Filler Door Replacement
Callout
Fuel Tank Filler Door
1
Component Name
Procedure
1. Open the fuel tank filler door.
2. Unclip the fuel tank filler door.
FUEL TANK FILLER PIPE HOUSING REPLACEMENT

Fig. 22: Fuel Tank Filler Pipe Housing

Fuel Tank Filler Pipe Housing Replacement
Callout
Component Name
Remove rear wheelhouse panel liner. Refer to Rear Wheelhouse Liner Replacement .
Fuel Tank Filler Door Lock Actuator
1
Procedure
Fuel Tank Filler Pipe Housing
Procedure
2
Unclip 4 clips and remove.
TIP: Push fuel tank filler door lock actuator locking rod in closed
position.
HOOD HOLD-OPEN ROD REPLACEMENT

Fig. 23: Hood Hold-Open Rod

Hood Hold-Open Rod Replacement
Callout
Component Name
WARNING:
Refer to Hood Hold-Open Device Warning .
Preliminary Procedure Remove the radiator grille reinforcement support. Refer to Front Grille
Support Replacement.
1
Hood Hold Open Rod Pivot (Qty: 2)
2
Hood Hold Open Rod
REAR COMPARTMENT LID HINGE TORQUE ROD REPLACEMENT

Fig. 24: Rear Compartment Lid Hinge Torque Rods & Components
Rear Compartment Lid Hinge Torque Rod Replacement
Callout
Component Name
WARNING:
When a rear compartment lid hold open device is being removed or installed, provide alternate
support to avoid the possibility of damage to the vehicle or personal injury.
Rear Compartment Lid Hinge Torque Rod - Right Side

Procedure
1
1. Using a suitable pair of pliers, rotate the torque rod upward to

release it from the swing bracket and slowly rotate the torque
rod downward until the tension is released.
2. Unclip torque rod from hinge retainers.
3. Remove the torque rod from the center support.
4. Remove the torque rod from the vehicle.
Rear Compartment Lid Hinge Torque Rod - Left Side
Procedure
1. Using a suitable pair of pliers, rotate the torque rod upward to
release it from the swing bracket and slowly rotate the torque

rod downward until the tension is released.

2. Unclip torque rod from hinge retainers.
3. Remove the torque rod from the center support.
4. Remove the torque rod from the vehicle.
HOOD REAR WEATHERSTRIP REPLACEMENT
Fig. 25: Hood Rear Weatherstrip

Hood Rear Weatherstrip Replacement
Callout
Component Name
1
Hood Rear Weatherstrip
FRONT GRILLE SUPPORT REPLACEMENT

Fig. 26: Radiator Grille Reinforcement Support

Front Grille Support Replacement
Callout
Component Name
Radiator Grille Reinforcement Support Bolt (Qty: 4)
2
3
CAUTION:
Tighten
10 N.m (89 lb in).
Radiator Grille Reinforcement Support Retainer (Qty: 3)
Radiator Grille Reinforcement Support
FRONT OR REAR SIDE DOOR LOWER WEATHERSTRIP REPLACEMENT

Fig. 27: Side Door Lower Weatherstrip

Front or Rear Side Door Lower Weatherstrip Replacement
Callout
Component Name
Front and Rear Side Door Lower Weatherstrip
Procedure
1
1. Open the side doors at full opening position.
2. Unclip the front and rear side door lower weatherstrip from the
rocker outer panel.
FRONT SIDE DOOR WEATHERSTRIP REPLACEMENT - DOOR SIDE

Fig. 28: Front Side Door Weatherstrip - Door Side

Front Side Door Weatherstrip Replacement - Door Side
Callout
Component Name
Front Side Door Check Bolt
CAUTION:
Tighten
25 N.m (19 lb ft)
Front Side Door Weatherstrip - Door Side
Procedure
2
1. Unclip weatherstrip from front side door.

2. When removing protective liners from adhesive tape, be careful
not to touch tape with hands and do not allow tape to come in
contact with dirt or any foreign matter prior to adhesion.
FRONT SIDE DOOR WEATHERSTRIP REPLACEMENT - BODY SIDE

Fig. 29: Front Side Door Weatherstrip - Body Side

Front Side Door Weatherstrip Replacement - Body Side
Callout
Component Name
Front Side Door Weatherstrip- Body Side
Procedure
1. Start at the rear upper corner of the door opening and pull the
weatherstrip away from the door opening flange.
2. Position the weatherstrip in the upper corner of the center pillar.
3. Working downward along the front edge, install the weatherstrip
on the door opening flange ensuring that the carrier is fully seated
in the corners.
4. Using a rubber mallet, ensure that the weatherstrip is seated on the
entire door opening flange.
REAR COMPARTMENT LID WEATHERSTRIP REPLACEMENT

Fig. 30: Rear Compartment Lid Weatherstrip

Rear Compartment Lid Weatherstrip Replacement
Callout
Component Name
Rear Compartment Lid Weatherstrip
Procedure
1. Start at the upper corner of the rear compartment opening and pull
the weatherstrip away from the rear compartment opening flange.
2. Position the weatherstrip in the upper corner of the rear
compartment opening.
3. Working downward along the edge, install the weatherstrip on the
rear compartment opening flange ensuring that the carrier is fully
seated in the corners.
entire trunk opening flange.
REAR SIDE DOOR WEATHERSTRIP REPLACEMENT - DOOR SIDE

Fig. 31: Rear Side Door Weatherstrip - Door Side

Rear Side Door Weatherstrip Replacement - Door Side
Callout
Component Name
Rear Side Door Check Bolt
CAUTION:
Tighten
25 N.m (19 lb ft)
Rear Side Door Weatherstrip - Door Side
Procedure
2
1. Unclip weatherstrip from rear side door.

2. When removing protective liners from adhesive tape, be careful
REAR SIDE DOOR WEATHERSTRIP REPLACEMENT - BODY SIDE

Fig. 32: Rear Side Door Weatherstrip - Body Side

Rear Side Door Weatherstrip Replacement - Body Side
Callout
Component Name
Rear Side Door Weatherstrip- Body Side
Procedure
1. Start at the front upper corner of the door opening and pull the
weatherstrip away from the door opening flange.
2. Position the weatherstrip in the upper corner of the center pillar.
3. Working downward along the front edge, install the weatherstrip
on the door opening flange ensuring that the carrier is fully seated
in the corners.
entire door opening flange.

HOOD AJAR INDICATOR DESCRIPTION AND OPERATION
Hood Ajar Switch

The BCM uses the hood ajar switch as a content theft deterrent alarm trigger.
Hood Ajar Indicator/Message
When the hood is ajar, a message is displayed on the DIC or the hood ajar indicator will be illuminated.

2013 ACCESSORIES & EQUIPMENT Bumpers and Fascias - Cruze

Bumpers and Fascias - Cruze
SPECIFICATIONS
Specification
Application
Drivetrain and Front Suspension Frame Bolt Front
Front Bumper Energy Absorber Bracket Bolt
Front Bumper Fascia Air Deflector Bolt
Front Bumper Fascia Bolt
Front Bumper Impact Bar Bolt
Front Wheelhouse Liner Bolt
Rear Bumper Energy Absorber Nut
Rear Wheelhouse Liner Bolt

ACTIVE GRILLE AIR SHUTTER WIRING SCHEMATICS
Active Grille Air Shutter (Y8X) Wiring Schematics
Metric
160 N.m
22 Y
2.5 N.m
9 N.m
110 N.m
2.5 N.m
40 N.m
2.5 N.m
English
118 lb ft
16 lb ft
22 lb in
80 lb in
81 lb ft
22 lb in
30 lb ft
22 lb in

Fig. 1: Active Grille Air Shutter (Y8X) Wiring Schematics

Callout
1039
1039 VT/GY
CAV_3
CAV_65
CONN_X1
3437
3437_GY/BK
CAV_3
3437_GY/BK
CAV_1
CAV_12
1150
1150_BK
CAV_2
3437_GY/BK
3437_GY/BK
CAV_2
Component Name
1039 VT/GY
3
65
X1
Shutter Valve Solenoid Control
3437 GY/BK
3
3437 GY/BK
1
12
Ground
1150 BK
2
3437 GY/BK
3437 GY/BK
2

G101
F16UA
X100
J312
KR73
X50A
A90
M96
K27
G101
F16UA 7.5A
X100
J312
Logic
(Y8K)

DTC
DTC P059F or U0284
Description
DTC U0284 Lost Communication with Active Grille
Air Shutter 1 Motor Module
DTC P059F Active Grille Air Shutter Performance
DTC P059F OR U0284

DTC Descriptors
DTC U0284
Lost Communication with Active Grille Air Shutter 1 Motor Module
DTC P059F
Active Grille Air Shutter Performance
Circuit
Ignition
Control - Terminal 3
Short to
Ground
U0284, P059F
U0284, P059F
Open/High
Resistance
U0284, P059F
U0284, P059F
Short to
Signal Performance
Voltage
--U0284, P059F
U0284, P059F

Ground
U0284, P059F
-
U0284, P059F
U0284, P059F
U0284, P059F
-
U0284, P059F
--
The active grille air shutter actuator closes louvers at the front bumper to enhance vehicle aerodynamics in
driving situations where cooling and A/C loads are relatively low and high levels of front end airflow are not
required. If high levels of airflow are required the active grille air shutter actuator opens the louvers. The control
signal from the fuel pump control module, ignition and ground circuits enable the active grille air shutter
actuator to operate. If the conditions for opening the louvers are reached the fuel pump control module
commands the active grille air shutter actuator to open the louvers.
The ambient temperature is above 2.5C (36.5F).

The ignition voltage is greater than 10 V.
The DTC runs continuously when the above conditions are met.
If the ambient temperature is below 10C (50F) when the vehicle is first started, this DTC will be
disabled.
The DTC P059F will be set during a key cycle when the commanded louver position can not be achieved
after 3 attempts are made to move the louver. The DTC will be stored as current for this key cycle but the
malfunction indicator lamp (MIL) will not be illuminated.
On the next key cycle the louver will be commanded to move again. If the commanded louver position
can not be achieved after 3 more attempts, the MIL will be illuminated and DTC P059F will be set as
current.
The DTC U0284 will set if there is no communication on the bi-directional control circuit.
DTC P059F is a type B DTC.


Schematic Reference
Active Grille Air Shutter Schematics


Active Grille Air Shutter Description and Operation
Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference

1. Ignition ON.
2. Verify DTC P069E, or U0109 is not set
Refer to Diagnostic Trouble Code (DTC) List - Vehicle for further diagnosis.
3. Verify the active grille air shutter actuator opens and closes the louvers at the front bumper when
performing the Active Grille Air Shutter Actuator test with a scan tool.
If the louvers at the front bumper do not open and close and the test result is fail

If the louvers at the front bumper open and close and the test result is pass
4. Verify none of the following conditions are present:
Snow or ice packed in the front fascia which prevents the louvers from moving.
Debris or foreign objects which prevent the louvers from moving.
If any of the conditions are present
Clear any snow, ice or foreign objects from the front grille.
If none of the conditions are present
5. All OK

1. Ignition OFF, and all vehicle systems OFF, disconnect the harness connector at the M96 active grille air
shutter actuator. It may take up to 2 minutes for all vehicle systems to power down.
1. Ignition OFF.
3. Ignition ON.
1. Ignition OFF.
1. Ignition OFF.
If infinite resistance, replace the M96 active grille air shutter actuator.
5. Connect a test lamp between the control circuit terminal 1 and the ignition circuit terminal 3.
6. Verify the test lamp blinks ON and OFF.
1. Ignition OFF, disconnect the harness connector at the K27 fuel pump control module, ignition ON.
If less than 1 V
3. Ignition OFF.
4. Test for less than 2 ohms between the K27 fuel pump control module control circuit terminal 3 and
the M96 active grille air shutter actuator terminal 1.
If less than 2 ohms, replace the K27 fuel pump control module.
1. Ignition OFF, disconnect the harness connector at the K27 fuel pump control module.

If infinite resistance, replace the K27 fuel pump control module.

Ignition OFF, connector the harness connector at the M96 active grille air shutter actuator. Disconnect the
harness connector at the K27 fuel pump control module, Ignition ON.
If 11 V or less
1. Ignition OFF, disconnect the harness connector at the M96 active grille air shutter actuator.
2. Test for less than 2 ohms between the K27 fuel pump control module control circuit terminal 12
and the M96 active grille air shutter actuator terminal 1.
If less than 2 ohms, replace the M96 active grille air shutter actuator.
Test or replace the M96 active grille air shutter actuator.
Verify DTC U0284 is not set.
If the DTC is set
7.
8.
9.
10.
Replace the K27 fuel pump control module.

11. All OK
Repair Instructions
Front Bumper Fascia Air Deflector Actuator Replacement

Control Module References for fuel pump control module replacement, programming and setup
ACTIVE GRILLE AIR SHUTTER MALFUNCTION

DTC Descriptors
DTC U0284
Lost Communication with Active Grille Air Shutter 1 Motor Module
DTC P059F

Active Grille Air Shutter Performance

Circuit
Ignition
Ground
Short to
Ground
U0284, P059F
U0284, P059F
U0284, P059F
-
Open/High
Resistance
U0284, P059F
U0284, P059F
U0284, P059F
U0284, P059F
Short to
Voltage
Signal Performance
--U0284, P059F
U0284, P059F
U0284, P059F
U0284, P059F
--
The ambient temperature is above 2.5C (36.5F).

If the ambient temperature is below 10C (50F) when the vehicle is first started, this DTC will be
disabled.
The DTC P059F will be set during a key cycle when the commanded louver position can not be achieved
after 3 attempts are made to move the louver. The DTC will be stored as current for this key cycle but the
malfunction indicator lamp (MIL) will not be illuminated.
On the next key cycle the louver will be commanded to move again. If the commanded louver position
can not be achieved after 3 more attempts, the MIL will be illuminated and DTC P059F will be set as
current.
The DTC U0284 will set if there is no communication on the bi-directional control circuit.


Schematic Reference
Active Grille Air Shutter Schematics
Active Grille Air Shutter Description and Operation
Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference

1. Ignition ON.
2. Verify DTC P069E, or U0109 is not set
3. Verify the active grille air shutter actuator opens and closes the louvers at the front bumper when
performing the Active Grille Air Shutter Actuator test with a scan tool.
If the louvers at the front bumper do not open and close and the test result is fail

If the louvers at the front bumper open and close and the test result is pass
4. Verify none of the following conditions are present:
Snow or ice packed in the front fascia which prevents the louvers from moving.
Debris or foreign objects which prevent the louvers from moving.
If any of the conditions are present

Clear any snow, ice or foreign objects from the front grille.
If none of the conditions are present
5. All OK
1. Ignition OFF, and all vehicle systems OFF, disconnect the harness connector at the M96 active grille air
shutter actuator. It may take up to 2 minutes for all vehicle systems to power down.
1. Ignition OFF.
3. Ignition ON.
1. Ignition OFF.
1. Ignition OFF.
If infinite resistance, replace the M96 active grille air shutter actuator.
5. Connect a test lamp between the control circuit terminal 1 and the ignition circuit terminal 3.
6. Verify the test lamp blinks ON and OFF.
If less than 1 V
3. Ignition OFF.
4. Test for less than 2 ohms between the K27 fuel pump control module control circuit terminal 3 and
the M96 active grille air shutter actuator terminal 1.


If infinite resistance, replace the K27 fuel pump control module.
Ignition OFF, connector the harness connector at the M96 active grille air shutter actuator. Disconnect the
harness connector at the K27 fuel pump control module, Ignition ON.
If 11 V or less
1. Ignition OFF, disconnect the harness connector at the M96 active grille air shutter actuator.
2. Test for less than 2 ohms between the K27 fuel pump control module control circuit terminal 12
and the M96 active grille air shutter actuator terminal 1.
If less than 2 ohms, replace the M96 active grille air shutter actuator.
Test or replace the M96 active grille air shutter actuator.
Verify DTC U0284 is not set.
If the DTC is set
7.
8.
9.
10.
Replace the K27 fuel pump control module.

11. All OK
Repair Instructions

REPAIR INSTRUCTIONS
FRONT BUMPER ENERGY ABSORBER REPLACEMENT

Fig. 2: Front Bumper Energy Absorber

Front Bumper Energy Absorber Replacement
Callout
Component Name
Remove the front bumper fascia. Refer to Front Bumper Fascia Replacement.
Front Bumper Energy Absorber
1
Procedure
Unclip from front bumper fascia.
FRONT BUMPER IMPACT BAR REPLACEMENT
Removal Procedure
WARNING: Refer to Approved Equipment for Collision Repair Warning .
1. Disable the SIR System. Refer to SIR Disabling and Enabling .

Connection .

3. Remove all related panels and components.
Fig. 3: Front Bumper Impact Bar And Front Bumper Impact Bar Bolts
4. Remove the 8 front bumper impact bar bolts (1).

Fig. 4: Front Bumper Impact Bar Cut Points

5. Cut the front bumper impact bar left and right.
6. Locate and mark all factory welds.

Fig. 5: Drilling Factory Welds

7. Drill all factory welds.

Fig. 6: Remaining Parts Of Front Bumper Impact Bar

8. Remove the remaining parts of the front bumper impact bar.

Fig. 7: Front Bumper Impact Bar

1. Position the front bumper impact bar on the vehicle.

Fig. 8: Front Bumper Impact Bar And Front Bumper Impact Bar Bolts
NOTE:
2.
3.
4.
5.
6.
Use only the original front bumper impact bar bolts. Replace bolts if
damaged.
Install the 8 front bumper impact bar bolts (1) and tighten to 110 N.m (81 lb ft).
Paint the repaired area. Refer to Basecoat/Clearcoat Paint Systems .
Install all related panels and components.
Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
Enable the SIR system. Refer to SIR Disabling and Enabling .

FRONT BUMPER FASCIA REPLACEMENT

Removal Procedure
1. Remove the front bumper fascia opening lower cover. Refer to Front Bumper Fascia Opening Lower
Cover Replacement.
Fig. 9: Front Bumper Fascia Upper And Bolts

2. Remove the front bumper fascia upper bolts (1).
3. Remove the front bumper fascia upper retainers (2).

Fig. 10: Front Wheelhouse Liner

4. Remove the front wheelhouse liner bolts (1) on both sides.

Fig. 11: Lower Stiffener Bolts

5. If equipped, remove the lower stiffener bolts (1).

Fig. 12: Pulling Front Bumper Fascia Carefully Outward

NOTE:
Use a plastic trim tool if necessary. Use care when removing the fascia.
Fascia might rip apart if forced.
6. Pull the front bumper fascia (1) carefully outward in order to release the retaining tabs from front bumper
fascia guides.
7. Disconnect any electrical connectors.

Fig. 13: Front Bumper Fascia

8. With the aid of an assistant remove the front bumper fascia (1).
9. Transfer or replace parts as needed.

Fig. 14: Front Bumper Fascia

1. With the aid of an assistant install the front bumper fascia (1).
2. Carefully push in the retaining tabs of front bumper fascia into the front bumper fascia guides.
3. Connect any electrical connectors.

Fig. 15: Lower Stiffener Bolts

4. If equipped, install the lower stiffener bolts (1) and tighten to 2.5 (22 lb in).


5. Install the front wheelhouse liner bolts (1) and tighten to 2.5 (22 lb in).

Fig. 17: Front Bumper Fascia Upper And Bolts

6. Install the front bumper fascia upper retainers (2).
7. Install the front bumper fascia upper bolts (1) and tighten to 9 (80 lb in).
8. Install the front bumper fascia opening lower cover. Refer to Front Bumper Fascia Opening Lower
Cover Replacement.
FRONT BUMPER FASCIA GUIDE REPLACEMENT

Fig. 18: Front Bumper Fascia Guide

Front Bumper Fascia Guide Replacement
Callout
Component Name
1
Front Bumper Fascia Guide Rivet (Qty: 2)
Headlamp Bolt
CAUTION:
Tighten
2.5 N.m (23 lb in)
Front Bumper Fascia Guide
FRONT BUMPER LOWER FASCIA BRACKET REPLACEMENT

Fig. 19: Front Bumper Lower Fascia Bracket

Front Bumper Lower Fascia Bracket Replacement
Callout
Component Name
Remove the aero shutter front bumper fascia air deflector. Refer to Aero Shutter Front Bumper Fascia
Air Deflector Replacement.
1
Front Bumper Lower Fascia Bracket Bolt (Qty: 5)
Front Bumper Lower Fascia Bracket
Procedure
2
Remove the front bumper lower fascia grille. Refer to Front
Bumper Lower Fascia Grille Replacement .
FRONT BUMPER FASCIA OPENING LOWER COVER REPLACEMENT

Fig. 20: Front Bumper Fascia Opening Lower Cover

Front Bumper Fascia Opening Lower Cover Replacement
Callout
Component Name
Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
1
Front Bumper Fascia Opening Lower Cover Retainer (Qty: 4)
Front Bumper Fascia Opening Lower Cover Bolt (Qty: 6)
CAUTION:
Tighten
2.5 N.m (23 lb in)
Front Bumper Fascia Opening Lower Cover
FRONT BUMPER FASCIA OUTER BRACKET REPLACEMENT

Fig. 21: Front Bumper Fascia Outer Bracket

Front Bumper Fascia Outer Bracket Replacement
Callout
Component Name
1
Front Bumper Fascia Outer Bracket Bolt (Qty: 3)
2
Front Bumper Fascia Outer Bracket
FRONT BUMPER FASCIA AIR DEFLECTOR REPLACEMENT

Fig. 22: Front Bumper Fascia Air Deflector

Front Bumper Fascia Air Deflector Replacement
Callout
Component Name
Remove the front bumper fascia opening lower cover. Refer to Front Bumper Fascia Opening Lower
Cover Replacement.
Front Bumper Fascia Air Deflector Bolt (Qty: 4)
CAUTION:
Tighten
2.5 N.m (23 lb in)
Front Bumper Fascia Air Deflector
Procedure
Unclip from front bumper fascia.
FRONT BUMPER FASCIA AIR DEFLECTOR ACTUATOR REPLACEMENT

Fig. 23: Front Bumper Fascia Air Deflector Actuator

Callout
Component Name
Air Deflector Replacement.
Front Bumper Fascia Air Deflector Actuator
Procedure
Unclip from aero shutter front bumper fascia air deflector.
1
NOTE:
The aero shutter actuator have splines and can be installed in
multiple positions.
AERO SHUTTER FRONT BUMPER FASCIA AIR DEFLECTOR REPLACEMENT

Fig. 24: Aero Shutter Front Bumper Fascia Air Deflector

Aero Shutter Front Bumper Fascia Air Deflector Replacement
Callout
Component Name
1
Aero Shutter Front Bumper Fascia Air Deflector Bolt (Qty: 4)
Aero Shutter Front Bumper Fascia Air Deflector
2
Procedure
Release the 3 integral clips retaining aero shutter to fascia.
REAR BUMPER FASCIA REPLACEMENT
Removal Procedure
2. Remove the tail lamps. Refer to Tail Lamp Replacement .

Fig. 25: Rear Wheelhouse Liner And Bolts

3. Remove the rear wheelhouse liner bolts (1) on both sides.

Fig. 26: Rear Bumper Fascia Lower Retainers

4. Remove the rear bumper fascia lower retainers (1).

Fig. 27: Carefully Pulling Rear Bumper Fascia Outward

NOTE:
Use care when removing the fascia. Fascia might rip apart if forced.
5. Pull the rear bumper fascia (1) carefully outward and use a plastic tool in order to release the retaining
tabs from rear bumper fascia guides.

Fig. 28: Releasing Rear Bumper Retainer Tabs

6. Use a plastic trim tool to release the retaining tabs of rear bumper fascia (1).
7. Disconnect any electrical connectors.

Fig. 29: Rear Bumper Fascia

8. With the aid of an assistant remove the rear bumper fascia (1).
9. Transfer or replace parts as needed.

Fig. 30: Rear Bumper Fascia

1. With the aid of an assistant install the rear bumper fascia (1).
2. Carefully push in the retaining tabs of rear bumper fascia into the rear bumper fascia guides.
3. Connect any electrical connectors.

Fig. 31: Rear Bumper Fascia Lower Retainers

4. Install the rear bumper fascia lower retainers (1).

Fig. 32: Rear Wheelhouse Liner And Bolts

5. Install the rear wheelhouse liner bolts (1) and tighten with 2.5 N.m (22 lb in).
6. Install the tail lamps. Refer to Tail Lamp Replacement .
REAR BUMPER FASCIA BRACKET REPLACEMENT - OUTER

Fig. 33: Rear Bumper Fascia Bracket - Outer

Rear Bumper Fascia Bracket Replacement - Outer
Callout
Component Name
Remove the rear wheelhouse panel liner. Refer to Rear Wheelhouse Liner Replacement .
1
Rear Bumper Fascia Outer Bracket Bolt
Rear Bumper Fascia Outer Bracket
2
Procedure
Unclip the rear bumper fascia outer bracket from rear bumper fascia.
REAR BUMPER FASCIA GUIDE REPLACEMENT

Fig. 34: Rear Bumper Fascia Guide

Rear Bumper Fascia Guide Replacement
Callout
Component Name
Remove the rear bumper fascia. Refer to Rear Bumper Fascia Replacement.
1
Rear Bumper Fascia Guide Rivet (Qty: 4)
2
Rear Bumper Fascia Guide
REAR BUMPER FASCIA INNER GUIDE REPLACEMENT

Fig. 35: Rear Bumper Fascia Inner Guide

Rear Bumper Fascia Inner Guide Replacement
Callout
Component Name
1
Rear Bumper Fascia Inner Guide Rivet (Qty: 2)
2
Rear Bumper Fascia Inner Guide.
REAR BUMPER FASCIA OUTER GUIDE REPLACEMENT

Fig. 36: Rear Bumper Fascia Outer Guide

Rear Bumper Fascia Outer Guide Replacement
Callout
Component Name
1
Rear Bumper Fascia Outer Guide Rivet (Qty: 3)
2
Rear Bumper Fascia Outer Guide
REAR BUMPER IMPACT BAR REPLACEMENT

Fig. 37: Rear Bumper Impact Bar

Rear Bumper Impact Bar Replacement
Callout
Component Name
Rear Bumper Energy Absorber Nut (Qty: 6)
CAUTION:
Tighten
40 N.m (30 lb ft)
Rear Bumper Impact Bar

ACTIVE GRILLE AIR SHUTTER DESCRIPTION AND OPERATION

The single active grille air shutter system consists of an individual motor operated mechanism hinged behind
the vehicle front grille for controlling the amount of air entering the engine compartment. It includes three
wires, ground, power and pulse width modulated signal to the actuator. The fuel pump control module
determines shutter state based on various vehicle conditions such as vehicle speed, coolant temperature, fan
state, refrigerant system pressure, A/C compressor state and ambient temperature. The pulsed signal controlling
the shutter mechanism will be able to control the shutter to close/open positions.
The actuator is powered by an ignition circuit that is active when the key is in the RUN position. The vehicle
may have to be driven for up to 13 minutes at speeds greater than 41 kph (25 mph) before the shutter begins to
move. If low ambient temperature is detected, the shutter will remain in the closed position.

2013 ACCESSORIES & EQUIPMENT Collision Repair - Cruze

Collision Repair - Cruze
SPECIFICATIONS
DIMENSIONS - BODY
Point-to-Point Measurements
Point-to-point measurements are for reference only. All measurements are given in millimeters. Use these
measurements for diagnosing and estimating. Point-to-point measurements are duplicated with tram bar pointers
set at equal lengths. All die marks, holes, slots, and fasteners are measured to the center. All dimensions are
symmetrical unless otherwise specified
Front End - Part 1
Fig. 1: Front End Body Dimensions - Part 1

Front End - Part 2

Fig. 2: Front End Body Dimensions - Part 2

Engine Compartment - Part 1

Fig. 3: Engine Compartment Dimensions - Part 1

Engine Compartment - Part 2
Fig. 4: Engine Compartment Dimensions - Part 2

Front End Lower

Fig. 5: Front End Lower Dimensions

Rear End Lower

Fig. 6: Rear End Lower Dimensions

Rear End
Fig. 7: Rear End Dimensions

Side

Fig. 8: Side Dimensions

Front Seat Mounting Points

Fig. 9: Front Seat Mounting Points

VISUAL IDENTIFICATION
STRUCTURE IDENTIFICATION
Fig. 10: Body Panel System Component Identification (Front)

View Front
Number
1
Description
Front Wheelhouse Front
Panel
Material
High Strength Low Alloy Steel
Front Wheelhouse Panel Mild Steel
Front Rail
Roof Outer Panel
Center Pillar Inner Panel Dual Phase Steel
Mild Steel
High Strength Low Alloy
Steel
Mild Steel
Procedure
Front Wheelhouse Front
Panel Replacement
Front Wheelhouse Panel
Replacement
Front Rail Replacement
Roof Outer Panel
Replacement
Center Pillar Inner
Panel Replacement
Body Side Inner Panel

Body Side Inner Panel
Mild Steel
Outer Panel Reinforcement

Center Pillar
Mild Steel - Mild Steel
Reinforcement
Center Pillar Stiffener Dual
Replacement
Phase Steel - Dual Phase
Steel
Quarter Outer Panel
Mild Steel
Sectioning
Center Pillar Sectioning
Mild Steel
- Outer
Rocker Outer Panel
Mild Steel
Replacement
Front Hinge Pillar Body
Mild Steel
Sectioning
Body Side Outer Panel
Dual Phase Steel
Reinforcement
Replacement
Body Hinge Pillar Lower
Mild Steel
Reinforcement
Replacement
Ultra High Strength Dual Phase Rocker Inner Panel
Steel
Replacement
Front Compartment
High Strength Low Alloy Steel Upper Side Rail
Replacement
Headlamp Mount Panel
Mild Steel
Replacement
Mild Steel
Rear Reinforcement
Replacement
Front End Upper Tie
Mild Steel
Bar Support
Replacement
Front Bumper Impact
Mild Steel
Bar Replacement
Center Pillar
Reinforcement
Quarter Outer Panel
Center Pillar - Outer
10
Rocker Outer Panel
11
Front Hinge Pillar Body
12
Body Side Outer Panel

Reinforcement
13
Body Hinge Pillar Lower

Reinforcement
14
Rocker Inner Panel
15
Front Compartment
Upper Side Rail
16
Headlamp Mount Panel
17

Rear Reinforcement
18
Front End Upper Tie Bar

Support
19
Front Bumper Impact Bar
Sectioning

Fig. 11: Body Panel System Component Identification (Rear)

View Rear
Number
Description
Material
Procedure
Body Rear End Panel
Replacement
Rear Side Door Outer Panel
Replacement
Front Side Door Outer
Panel Replacement
Rear Wheelhouse Panel
Replacement
Body Rear End Panel
Mild Steel
Rear Side Door Outer Panel
Mild Steel
Front Side Door Outer Panel
Mild Steel
Rear Wheelhouse Panel
Mild Steel
Rear Rail
High Strength Low

Alloy Steel
Rear Rail Sectioning
Rear Compartment Floor

Panel
Mild Steel
Rear Compartment Floor

Panel Sectioning
REPAIR INSTRUCTIONS
HEADLAMP MOUNT PANEL REPLACEMENT
Removal Procedure



Connection .
4. Visually inspect the damage. Repair as much of the damage as possible.
5. Remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to AntiCorrosion Treatment and Repair .
Fig. 12: Drilling Out Factory Welds On Headlamp Mount Panel


6. Locate and mark all the necessary factory welds of the headlamp mount panel (1).
7. Drill all factory welds. Note the number and location of welds for installation of the service assembly.
Fig. 13: Adhesive Cutting Points

8. Cut the adhesive (1) with an appropriate tool.

Fig. 14: Headlamp Mount Panel

9. Remove the headlamp mount panel (1).

Fig. 15: Drilling Holes For Plug Welding Headlamp Mount Panel
1. Drill 8 mm (5/16 in) for plug welding instead of the adhesive noted from the original panel.
2. Drill 8 mm (5/16 in) for plug welding along the edges of the headlamp mount panel (1) as noted from the
original panel.
3. Clean and prepare the attaching surfaces for welding.

Fig. 16: Headlamp Mount Panel

4. Position the headlamp mount panel (1) on the vehicle.
5. Verify the fit of the headlamp mount panel.
6. Clamp the headlamp mount panel into position.

Fig. 17: Welding Headlamp Mount Panel

7. Plug weld the headlamp mount panel (1) accordingly.
8. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion
Treatment and Repair .
9. Paint the repaired area. Refer to Basecoat/Clearcoat Paint Systems .
10. Install all related panels and components.
11. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
12. Enable the SIR system. Refer to SIR Disabling and Enabling .
FRONT END UPPER TIE BAR SUPPORT REPLACEMENT
NOTE:
According to different corrosion warranties, only the regional mandatory joining

methods are allowed.

Removal Procedure
WARNING: Refer to Approved Equipment for Collision Repair Warning
WARNING: Refer to Glass and Sheet Metal Handling Warning
1.
2.
3.
4.
5.
Disable the SIR System. Refer to SIR Disabling and Enabling

Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection
Remove all related panels and components.
Visually inspect the damage. Repair as much of the damage as possible.
Remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to AntiCorrosion Treatment and Repair

Fig. 18: Hood Front Bumper Bracket

6. Locate and mark all the necessary factory welds of the hood front bumper bracket (1).
Fig. 19: Drilling Factory Welds On Front End Sheet Metal Cross Panel Reinforcement
7. Locate and mark all the necessary factory welds of the front end sheet metal cross panel reinforcement
(1).

Fig. 20: Front End Sheet Metal Cross Panel Reinforcement

9. Remove the front end sheet metal cross panel reinforcement (1).

Fig. 21: Grinding Factory Welds At Front End Upper Tie Bar Support
11. Grind factory welds of the front end upper tie bar support (1).

Fig. 22: Front End Upper Tie Bar Support

12. Remove the front end upper tie bar support (1).

Fig. 23: Front End Upper Tie Bar Support

1. Position the front end upper tie bar support (1) on the vehicle.
2. Verify the fit of the front end upper tie bar support.
3. Clamp the front end upper tie bar support into position.

Fig. 24: Welding Front End Upper Tie Bar Support

4. Weld accordingly (1).

Fig. 25: Welding Front End Upper Tie Bar Support

5. Weld accordingly (1).
6. Grind down weld seams as needed for related panels and components.

Fig. 26: Drilling Holes For Plug Welding Front End Sheet Metal Cross Panel Reinforcement
7. Drill 8 mm (5/16 in) holes for plug welding along the edges of the front end sheet metal cross panel
reinforcement as noted from the original panel (1).

Fig. 27: Front End Sheet Metal Cross Panel Reinforcement

9. Position the front end sheet metal cross panel reinforcement (1) on the vehicle.
10. Verify the fit of the front end upper tie bar.
11. Clamp the front end sheet metal cross panel reinforcement into position.

Fig. 28: Welding Front End Sheet Metal Cross Panel Reinforcement
12. Plug weld accordingly (1).
13. Use factory slots for slot brazing.

Fig. 29: Drilling Holes For Plug Welding Panel

14. Drill 8 mm (5/16 in) holes for plug welding as noted from the original panel (1).

Fig. 30: Hood Front Bumper Bracket

15. Position the hood front bumper bracket (1) on the vehicle.
16. Clamp the hood front bumper bracket into position.

Fig. 31: Welding Hood Front Bumper Bracket

18. Install front bumper impact bar before applying the sealers and anti-corrosion materials. Refer to Front
Bumper Impact Bar Replacement
Treatment and Repair
20. Paint the repaired area.
22. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection
23. Enable the SIR system. Refer to SIR Disabling and Enabling
FRONT WHEELHOUSE FRONT PANEL REPLACEMENT
Removal Procedure


Connection .
Fig. 32: Drilling Factory Welds At Front Wheelhouse Front Panel


6. Locate and mark all the necessary factory welds of the front wheelhouse front panel (1).
Fig. 33: Drilling Hidden Factory Weld Where Front Wheelhouse Front Panel And Front
Wheelhouse Overlap
8. Drill hidden factory weld (1) where front wheelhouse front panel and front wheelhouse overlap.

Fig. 34: Front Wheelhouse Front Panel

9. Remove the front wheelhouse front panel (1).

Fig. 35: Drilling 8 mm (5/16 in) Hole For Plug Welding New Front Wheelhouse Front Panel
1. Drill 8 mm (5/16 in) for plug welding along the edges of the front wheelhouse front panel (1) as noted
from the original panel.

Fig. 36: Drilling Hole For Welding Where Front Wheelhouse Front Panel And Front Wheelhouse
Overlap
2. Drill 8 mm (5/16 in) for plug welding (1) where front wheelhouse front panel and front wheelhouse
overlap.

Fig. 37: Front Wheelhouse Front Panel

4. Position the front wheelhouse front panel (1) on the vehicle.
5. Verify the fit of the front wheelhouse front panel.
6. Clamp the front wheelhouse front panel into position.

Fig. 38: Welding Front Wheelhouse Front Panel

7. Plug weld the front wheelhouse front panel (1) accordingly.

Fig. 39: Welding Joint From Front Wheelhouse Front Panel To Front Wheelhouse
8. Plug weld (1) the joint from front wheelhouse front panel to front wheelhouse accordingly.
FRONT WHEELHOUSE PANEL REPLACEMENT
Removal Procedure


Connection .
Fig. 40: Front Wheelhouse Rear Panel Brace


NOTE:
Front wheelhouse rear panel brace (1) remains to the body.
6. Locate and mark all the necessary factory welds of the front wheelhouse panel (2).
Fig. 41: Drilling All Factory Welds At Front Wheelhouse Panel

7. Drill all factory welds of the front wheelhouse panel (1). Note the number and location of welds for
installation of the service assembly.

Fig. 42: Adhesive Cutting Area Where Front Wheelhouse And Front Compartment Side Rail
Overlap
8. Cut the adhesive in the front area (1) and where the front wheelhouse and the front compartment side rail
overlap (2) with an appropriate tool.

Fig. 43: Front Wheelhouse Panel

9. Remove the front wheelhouse panel (1).

Fig. 44: Front Wheelhouse Rear Panel Brace

1. Remove the front wheelhouse rear panel brace (1) from service panel.

Fig. 45: Drilling 8 mm (5/16 in) Hole For Plug Welding

2. Drill 8 mm (5/16 in) for plug welding (1) instead of the adhesive noted from the front area of the original
panel.

Fig. 46: Drilling Hole For Plug Welding Front Wheelhouse Panel
NOTE:
Double the number of drills at the flange where front wheelhouse panel
and front compartment side rail overlap (1).
3. Drill 8 mm (5/16 in) for plug welding along the edges of the front wheelhouse panel (2) as noted from the
original panel.

Fig. 47: Front Wheelhouse Panel

5. Position the front wheelhouse panel (1) on the vehicle.
6. Verify the fit of the front wheelhouse.
7. Clamp the front wheelhouse into position.

Fig. 48: Welding Front Wheelhouse Panel

8. Plug weld the front wheelhouse panel (1) accordingly.
FRONT WHEELHOUSE PANEL REAR REINFORCEMENT REPLACEMENT
Removal Procedure


Connection .
Fig. 49: Drilling Factory Welds At Front Wheelhouse Panel Rear Reinforcement

6. Locate and mark all the necessary factory welds of the front wheelhouse panel rear reinforcement (1).
Fig. 50: Front Wheelhouse Panel Rear Reinforcement

8. Remove the front wheelhouse panel rear reinforcement (1).

Fig. 51: Drilling Hole For Plug Welding New Front Wheelhouse Panel Rear Reinforcement
1. Drill 8 mm (5/16 in) for plug welding along the edges of the front wheelhouse panel rear reinforcement
(1) as noted from the original panel.

Fig. 52: Drilling Hole For Welding Where Front Wheelhouse Front Panel And Front Wheelhouse
Overlap
2. Drill 8 mm (5/16 in) for plug welding (1) where front wheelhouse front panel and front wheelhouse panel
rear reinforcement overlap.

Fig. 53: Front Wheelhouse Panel Rear Reinforcement

4. Position the front wheelhouse panel rear reinforcement (1) on the vehicle.
5. Verify the fit of the front wheelhouse panel rear reinforcement.
6. Clamp the front wheelhouse panel rear reinforcement into position.

Fig. 54: Welding Front Wheelhouse Panel Rear Reinforcement

7. Plug weld the front wheelhouse panel rear reinforcement (1) accordingly.

Fig. 55: Welding Joint From Front Wheelhouse Panel Rear Reinforcement To Front Wheelhouse
Front Panel
8. Plug weld (1) the joint from front wheelhouse panel rear reinforcement to front wheelhouse front panel
accordingly.
FRONT COMPARTMENT UPPER SIDE RAIL REPLACEMENT
Removal Procedure


Connection .
Fig. 56: Drilling Factory Welds And Weld Seams Of Front Compartment Upper Side Rail


6. Locate and mark all the necessary factory welds and weld seams of the front compartment upper side rail
(1).
Fig. 57: Grinding Factory Weld Seams Of Front Compartment Upper Side Rail
8. Grind factory weld seams (1) of the front compartment upper side rail.

Fig. 58: Front Compartment Upper Side Rail

9. Remove the front compartment upper side rail (1).

Fig. 59: Drilling Hole For Plug Welding New Front Compartment Upper Side Rail
1. Drill 8 mm (5/16 in) for plug welding along the edges of the front compartment upper side rail (1) as
noted from the original panel.
3. Position the front compartment upper side rail on the vehicle.
4. Verify the fit of the front compartment upper side rail.
5. Clamp the front compartment upper side rail into position.

Fig. 60: Welding Front Compartment Upper Side Rail

NOTE:
Plug weld factory slots in the front hinge pillar body area (1) as noted from
the original panel.
6. Plug weld the front compartment upper side rail (2) accordingly.
FRONT HINGE PILLAR BODY SECTIONING

Removal Procedure
WARNING: Refer to Collision Sectioning Warning .

Connection .

Fig. 61: Identifying Cut Lines On Front Hinge Pillar Body

6. Create cut lines on the front hinge pillar body (1).

Fig. 62: Cutting Front Hinge Pillar Body

NOTE:
Do not damage any inner panels or reinforcements.
7. Cut the front hinge pillar body (1) where sectioning is to be performed.

Fig. 63: Drilling Factory Welds From Front Hinge Pillar Body
8. Locate and mark all the necessary factory welds of the front hinge pillar body (1).

Fig. 64: Front Hinge Pillar Body

10. Remove the damaged front hinge pillar body (1).

Fig. 65: Cutting New Front Hinge Pillar Body

1. Cut the front hinge pillar body (1) in corresponding locations to fit the remaining original panel. The
sectioning joint should be trimmed to allow a gap of one-and-one-half-times the metal thickness at the
sectioning joint.
2. Create a 50 mm (2 in) backing plate from the unused portion of the service part.
3. Drill 8 mm (5/16 in) along the sectioning cut on the remaining original part. Locate these holes 13 mm
(1/2 in) from the edge of part and spaced 40 mm (1 1/2 in) apart.
4. Prepare all mating surfaces as necessary.
5. Fit the backing plates halfway into the sectioning joints, clamp in place and plug weld to the vehicle.
6. Align the front hinge pillar body.

Fig. 66: Drilling Hole For Plug Welding New Front Hinge Pillar Body
7. Drill 8 mm (5/16 in) for plug welding along the edges of the front hinge pillar body (1) as noted from the
original panel.
9. Position the front hinge pillar body on the vehicle.
10. Verify the fit of the front hinge pillar body.
11. Clamp the front hinge pillar body into position.

Fig. 67: Welding Front Hinge Pillar Body

12. Plug weld the front hinge pillar body (1) accordingly.
13. To create a solid weld with minimum heat distortion, make 25 mm (1 in) stitch welds along the seam with
25 mm (1 in) gaps between them. Then go back and complete the stitch weld.
BODY HINGE PILLAR LOWER REINFORCEMENT REPLACEMENT
Removal Procedure


Connection .

Fig. 68: Drilling Factory Welds Of Body Hinge Pillar Lower Reinforcement
6. Locate and mark all the necessary factory welds of the body hinge pillar lower reinforcement (1).

Fig. 69: Body Hinge Pillar Lower Reinforcement

8. Remove the damaged body hinge pillar lower reinforcement (1).

2. Align the body hinge pillar lower reinforcement.

Fig. 70: Drilling Hole For Plug Welding Body Hinge Pillar Lower Reinforcement
3. Drill 8 mm (5/16 in) for plug welding along the edges of the body hinge pillar lower reinforcement (1) as

Fig. 71: Applying Adhesive To Body Hinge Pillar Lower Reinforcement

5.
6.
7.
8.
Apply adhesive (1) to body hinge pillar lower reinforcement (2).

Position the body hinge pillar lower reinforcement on the vehicle.
Verify the fit of the body hinge pillar lower reinforcement.
Clamp the body hinge pillar lower reinforcement into position.

Fig. 72: Welding Body Hinge Pillar Lower Reinforcement

9. Plug weld the body hinge pillar lower reinforcement (1) accordingly.
ROOF OUTER PANEL REPLACEMENT
Removal Procedure


Connection .
Fig. 73: Drill All Roof Outer Panel Factory Welds


7. Drill all factory welds (1). Note the number and location of welds for installation of the service assembly.
8. Cut the adhesive with an appropriate tool.
Fig. 74: Roof Panel

9. Remove the damaged roof panel (1).

Fig. 75: Drilling New Roof Outer Panel For Welding

1. Drill 8 mm (5/16 in) for plug welding along the edges of the service panel (1) as noted from the original
panel.

Fig. 76: Applying One-Part Windshield Urethane Adhesive

3.
4.
5.
6.
Apply one-part windshield urethane adhesive (1) as noted from the original panel.
Position the roof panel on the vehicle.
Verify the fit of the panel.
Clamp the panel into position.

Fig. 77: Welding Roof Outer Panel

7. Plug weld the roof outer panel (1) accordingly.
ROCKER INNER PANEL REPLACEMENT
Removal Procedure


Connection .

Fig. 78: Body Side Inner Panel

6. Create cut lines on the body side inner panel (1).

Fig. 79: Cutting Body Side Inner Panel

NOTE:
7. Cut the body side inner panel (1) where sectioning is to be performed.

Fig. 80: Drilling Out Factory Welds Of Body Side Inner Panel
8. Locate and mark all the necessary factory welds of the body side inner panel (1).

Fig. 81: body side inner panel

10. Remove the body side inner panel (1).

Fig. 82: Drilling Out Factory Welds Of Rocker Inner Panel

11. Locate and mark all the necessary factory welds of the rocker inner panel (1).

Fig. 83: Rocker Inner Panel

13. Remove the damaged rocker inner panel (1).
1. Align the rocker inner panel.

Fig. 84: Drilling Holes For Welding Rocker Inner Panel

2. Drill 8 mm (5/16 in) for plug welding along the edges of the rocker inner panel (1) as noted from the
original panel.
4. Position the rocker inner panel on the vehicle.
5. Verify the fit of the quarter outer panel.
6. Clamp the rocker inner panel into position.

Fig. 85: Welding Rocker Inner Panel

7. Plug weld the rocker inner panel (1) accordingly.

Fig. 86: Welding Body Side Inner Panel

8. Plug weld the body side inner panel (1) accordingly.
ROCKER OUTER PANEL REPLACEMENT

NOTE:
According to different corrosion warranties, only the regional mandatory joining

methods are allowed.
Removal Procedure

Connection .

Fig. 87: Locating Cut Lines On Rocker Outer Panel

6. Create cut lines on the rocker outer panel (1).

Fig. 88: Cutting Rocker Outer Panel

NOTE:
7. Cut the rocker outer panel (1) where sectioning is to be performed.

Fig. 89: Drilling Factory Welds Of Rocker Outer Panel

8. Locate and mark all the necessary factory welds of the rocker outer panel (1).

Fig. 90: Rocker Outer Panel

10. Remove the damaged rocker outer panel (1).

Fig. 91: Cutting Rocker Outer Panel

1. Cut the rocker outer panel (1) in corresponding locations to fit the remaining original panel. The
sectioning joint.
2. Create 50 mm (2 in) backing plates from the unused portion of the service part.
3. Drill 8 mm (5/16 in) holes for plug welding along the sectioning cut on the remaining original part.
Locate these holes 13 mm (1/2 in) from the edge of part and spaced 40 mm (1 1/2 in) apart.
5. Fit the backing plates halfway into the sectioning joints, clamp in place and weld to the vehicle.
6. Align the rocker outer panel.

Fig. 92: Drilling Hole For Plug Welding New Rocker Outer Panel
7. Drill 8 mm (5/16 in) for plug welding along the edges of the rocker outer panel (1) as noted from the
original panel.

Fig. 93: Rocker Outer Panel

9. Position the rocker outer panel (1) on the vehicle.
10. Verify the fit of the rocker outer panel.
11. Clamp the rocker outer panel into position.

Fig. 94: Welding Rocker Outer Panel

12. Plug weld the rocker outer panel (1) accordingly.
15. Paint the repaired area.
BODY SIDE OUTER PANEL REINFORCEMENT REPLACEMENT
Removal Procedure


Connection .

Fig. 95: Drilling Factory Welds Of The Body Side Outer Panel Reinforcement
6. Locate and mark all the necessary factory welds of the body side outer panel reinforcement (1).

Fig. 96: Body Side Outer Panel Reinforcement

8. Remove the damaged body side outer panel reinforcement (1).
1. Align the body side outer panel reinforcement.

Fig. 97: Body Side Outer Panel Reinforcement

2. Drill 8 mm (5/16 in) for plug welding along the edges of the body side outer panel reinforcement (1) as

Fig. 98: Drilling Hole For Plug Welding New Body Side Outer Panel Reinforcement
4. Position the body side outer panel reinforcement (1) on the vehicle.
5. Verify the fit of the body side outer panel reinforcement.
6. Clamp the body side outer panel reinforcement into position.

Fig. 99: Welding Body Side Outer Panel Reinforcement

7. Plug weld the body side outer panel reinforcement (1) accordingly.
BODY SIDE INNER PANEL SECTIONING
Removal Procedure


Connection .

Fig. 100: Body Lock Pillar Upper Reinforcement

6. Create cut lines on the body lock pillar upper reinforcement (1).

Fig. 101: Cutting Body Lock Pillar Upper Reinforcement

NOTE:
Do not damage any other panels or reinforcements.
7. Cut the body lock pillar upper reinforcement (1) where sectioning is to be performed.

Fig. 102: Drilling Factory Welds From Body Lock Pillar Upper Reinforcement
8. Locate and mark all the necessary factory welds of the body lock pillar upper reinforcement (1).

Fig. 103: Lock Pillar Upper Reinforcement

10. Remove the damaged body lock pillar upper reinforcement (1).


NOTE:
Cut the body side inner panel (a) 30 mm (1.2 in) above the body side outer
panel reinforcement.
11. Create cut lines on the body side inner panel (1).


NOTE:
12. Cut the body side inner panel (1) where sectioning is to be performed.

Fig. 106: Drilling Factory Welds Of Body Side Inner Panel

NOTE:
Drill hidden factory welds where body side outer rear panel drain gutter (2)
and body side inner panel overlap.
13. Locate and mark all the necessary factory welds of the body side inner panel (1).


15. Remove the damaged body side inner panel (1).

Fig. 108: Rear End Upper Panel Extension

1. Remove rear end upper panel extension (1) from service part.


NOTE:
Cut the body side inner panel lower 30 mm (1.2 in) longer. It should
overlap with the remaining of the original panel.
2. Cut the body side inner panel in corresponding locations to fit the remaining original panel. The
sectioning joint.


7. Position the body side inner panel (1).
8. Verify the fit of the panel.
9. Clamp the body side inner panel into position.

Fig. 111: Drilling Rivet Attachment Holes Of Service Body Side Inner Panel
10. Using a 7 mm (17/64 in) bit, drill the rivet attachment holes (1) into the service body side inner panel.
11. Remove the service body side inner panel.

Fig. 112: Drilling Hole For Welding Body Side Inner Panel
12. Drill 8 mm (5/16 in) for plug welding along the edges of the body side inner panel (1) as noted from the
original panel.
13. Prepare the bonding mating areas by grinding to bare steel the surface of the panels in the repair area.
14. Apply GM-approved weld-thru coating or equivalent to all mating surfaces. Refer to Anti-Corrosion


15. Position the body side inner panel (1).
17. Clamp the body side inner panel into position.

Fig. 114: Welding Body Side Inner Panel

18. Plug weld the body side inner panel (1) accordingly.

Fig. 115: Body Side Inner Panel Lower Rivets

20. Install the 14 mm (17/32 in) long rivets (1) to the body side inner panel lower.

Fig. 116: Cutting Body Lock Pillar Upper Reinforcement

21. Cut the body lock pillar upper reinforcement (1) in corresponding locations to fit the remaining original
panel. The sectioning joint should be trimmed to allow a gap of one-and-one-half-times the metal
thickness at the sectioning joint.
26. Align the body lock pillar upper reinforcement.

Fig. 117: Drilling Body Lock Pillar Upper Reinforcement For Welding
27. Drill 8 mm (5/16 in) for plug welding along the edges of the body lock pillar upper reinforcement (1) as

Fig. 118: Lock Pillar Upper Reinforcement

29. Position the body lock pillar upper reinforcement (1).
31. Clamp the body lock pillar upper reinforcement into position.

Fig. 119: Welding Body Lock Pillar Upper Reinforcement

32. Plug weld the body lock pillar upper reinforcement (1) accordingly.
37. Enable the SIR System. Refer to SIR Disabling and Enabling .
REAR COMPARTMENT FLOOR PANEL SECTIONING
Removal Procedure


Connection .
Fig. 120: Drilling Welds Of Rear Compartment Floor Panel


6. Locate and mark all the necessary factory welds of the rear compartment floor panel (1).
7. Note the number and location of weld studs for installation of the service assembly.
Fig. 121: Rear Compartment Floor Panel

9. Remove the damaged rear compartment floor panel (1).
1. Align the rear compartment floor panel.

Fig. 122: Drilling Holes For Welding New Rear Compartment Floor Panel
2. Drill 8 mm (5/16 in) for plug welding along the edges of the rear compartment floor panel (1) as noted
4. Position the rear compartment floor panel on the vehicle.
5. Verify the fit of the rear compartment floor panel.
6. Clamp the rear compartment floor panel into position.

Fig. 123: Welding Rear Compartment Floor

7. Plug weld the rear compartment floor (1) accordingly.
8. Weld accordingly the weld studs as noted.
REAR WHEELHOUSE PANEL REPLACEMENT
Removal Procedure


Connection .
Fig. 124: Drilling Factory Welds Of Rear Inner Wheelhouse Panel


6. Locate and mark all the necessary factory welds of the rear inner wheelhouse panel (1).
NOTE:
Note the number and location of welds for installation of the service
assembly.
Fig. 125: Rear Inner Wheelhouse Panel

8. Remove the rear inner wheelhouse panel (1).

Fig. 126: Drilling Holes For Welding New Rear Inner Wheelhouse Panel
NOTE:
If the location of the original plug weld holes can not be determined, space
the plug weld holes every 40 mm (1 1/2 in).
1. Drill 8 mm (5/16 in) for plug welding along the edges of the rear inner wheelhouse panel (1) as noted

Fig. 127: Rear Inner Wheelhouse Panel

3. Position the rear inner wheelhouse panel (1) on the vehicle.
4. Verify the fit of the rear inner wheelhouse.
5. Clamp the rear inner wheelhouse into position.

Fig. 128: Welding Rear Inner Wheelhouse Panel

6. Plug weld the rear wheelhouse panel (1) accordingly.
QUARTER OUTER PANEL SECTIONING
Removal Procedure


Connection .

Fig. 129: Cut Lines On Quarter Outer Panel

6. Create cut lines on the quarter outer panel (1).

Fig. 130: Cutting Quarter Outer Panel

NOTE:
7. Cut the quarter outer panel (1) where sectioning is to be performed.

Fig. 131: Cutting Wheelhouse Flanging

8. Open the wheelhouse flanging (1).

Fig. 132: Drilling Factory Welds On Quarter Outer Panel

9. Locate and mark all the necessary factory welds of the quarter outer panel (1).

Fig. 133: Quarter Outer Panel

11. Remove the damaged quarter outer panel (1).

Fig. 134: Cutting Quarter Outer Panel

1. Cut the quarter outer panel (1) in corresponding locations to fit the remaining original panel. The
sectioning joint.
6. Align the quarter outer panel.

Fig. 135: Drilling Holes For Welding New Quarter Outer Panel
7. Drill 8 mm (5/16 in) for plug welding along the edges of the quarter outer panel (1) as noted from the
original panel.

Fig. 136: Applying One-Part Windshield Urethane Adhesive

9.
10.
11.
12.
Apply structural adhesive (1) as noted from the original panel.

Position the quarter outer panel on the vehicle.
Verify the fit of the quarter outer panel.
Clamp the quarter outer panel into position.

Fig. 137: Welding Quarter Outer Panel

13. Plug weld the quarter outer panel (1) accordingly.
15. Using a hammer re-hem the hem flanges of the wheelhouse flanging of the quarter outer panel (1)..

Fig. 138: Hammering In Stages Along Hem Flanges

16. Continue to hammer in stages along the hem flanges.
BODY REAR END PANEL REPLACEMENT
Removal Procedure


Connection .
Fig. 139: Drilling Factory Welds Of Body Rear End Panel


6. Locate and mark all the necessary factory welds of the body rear end panel (1).
NOTE:
Note the number and location of welds for installation of the service
assembly.
Fig. 140: Body Rear End Panel

8. Remove the body rear end panel (1).

Fig. 141: Drilling Holes For Welding New Body Rear End Panel
NOTE:
the plug weld holes every 40 mm (1 1/2 in).
1. Drill 8 mm (5/16 in) for plug welding along the edges of the body rear end panel (1) as noted from the
original panel.

Fig. 142: Body Rear End Panel

3. Position the body rear end panel (1) on the vehicle.
4. Verify the fit of the body rear end panel.
5. Clamp the body rear end panel into position.

Fig. 143: Welding Body Rear End Panel

6. Plug weld the body rear end panel (1) accordingly.
FRONT RAIL REPLACEMENT
Removal Procedure


Connection .
4. Repair as much of the damage as possible to factory specifications. Refer to Dimensions - Body.
5. Note the location and remove the sealers and anti-corrosion materials from the repair area. Refer to AntiCorrosion Treatment and Repair .
Fig. 144: Drilling Outl Factory Welds From Front Rail

NOTE:
6. Locate and drill out all factory welds. Note the number and location of the welds for installation of the

front rail (1).
Fig. 145: Front Rail

7. Remove the damaged front rail (1).

Fig. 146: Drilling Plug Weld Holes In New Front Rail

NOTE:
the plug weld holes every 40 mm (1 1/2 in) apart.
Some panels may have structural weld-thru adhesive. Replace the weldthru 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 front rail (1) as necessary in the locations noted
3. Apply GM-approved Weld-Thru Coating or equivalent to all mating surfaces. Refer to Anti-Corrosion

Fig. 147: Front Rail

4. Position the front rail (1) to the vehicle using 3-dimensional measuring equipment. Clamp the rail in
place.

Fig. 148: Welding Front Rail

5.
6.
7.
8.
Plug weld the front rail (1) accordingly.

Clean and prepare all welded surfaces.
Install all related panels and components.
Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion
9. Paint the repair area. Refer to Basecoat/Clearcoat Paint Systems .
CENTER PILLAR INNER PANEL REPLACEMENT
Removal Procedure


Connection .

Fig. 149: Drilling Factory Welds From Lower Center Pillar Inner Panel
7. Drill all factory welds lower of the center pillar inner panel (1). Note the number and location of welds
for installation of the service assembly.
Fig. 150: Drilling Factory Welds From Upper Center Pillar Inner Panel
8. Drill all factory welds upper of the center pillar inner panel (1). Note the number and location of welds
for installation of the service assembly.

Fig. 151: Center Pillar Inner Panel

9. Remove the damaged center pillar inner panel (1).

Fig. 152: Drilling Holes Plug Welding Holes In New Center Pillar Inner Panel
1. Drill 8 mm (5/16 in) for plug welding along the edges of the center pillar inner panel (1) as noted from
the original panel.

Fig. 153: Center Pillar Inner Panel

3. Position the center pillar inner panel (1) on the vehicle.
5. Clamp the center pillar inner panel into position.

Fig. 154: Welding Upper And Lower Center Pillar Inner Panel
6. Plug weld accordingly center pillar inner panel (1) upper and lower.
CENTER PILLAR REINFORCEMENT REPLACEMENT
Removal Procedure


Connection .
Fig. 155: Drilling Factory Welds Of Center Pillar Reinforcement


6. Locate and mark all the necessary factory welds of the center pillar reinforcement (1)
Fig. 156: center pillar reinforcement

8. Remove the damaged center pillar reinforcement (1).

2. Align the center pillar reinforcement.

Fig. 157: Drilling Plug Weld Holes For New Center Pillar Reinforcement
3. Drill 8 mm (5/16 in) for plug welding along the edges of the center pillar reinforcement (1) as noted from
the original panel.

Fig. 158: Center pillar reinforcement

5. Position the center pillar reinforcement (1) on the vehicle.
6. Verify the fit of the center pillar reinforcement.
7. Clamp the center pillar reinforcement into position.

Fig. 159: Welding Center Pillar Reinforcement

8. Plug weld the center pillar reinforcement (1) accordingly.
CENTER PILLAR SECTIONING - OUTER
Removal Procedure


Connection .

Fig. 160: Locating Cut Lines On Center Pillar

6. Create cut lines on the center pillar (1).

Fig. 161: Cutting Center Pillar

NOTE:
7. Cut the center pillar (1) where sectioning is to be performed.

Fig. 162: Drilling Factory Welds Of Center Pillar

8. Locate and mark all the necessary factory welds of the center pillar (1).

Fig. 163: Center Pillar

10. Remove the damaged center pillar (1).

Fig. 164: Center Pillar Cut Lines

1. Cut the center pillar (1) in corresponding locations to fit the remaining original panel. The sectioning joint
should be trimmed to allow a gap of one-and-one-half-times the metal thickness at the sectioning joint.
6. Align the center pillar.

Fig. 165: Drilling Holes For Plug Welding New Center Pillar
7. Drill 8 mm (5/16 in) for plug welding along the edges of the center pillar (1) as noted from the original
panel.

Fig. 166: Center Pillar

9. Position the center pillar (1) on the vehicle.
10. Verify the fit of the center pillar.
11. Clamp the center pillar into position.

Fig. 167: Welding Center Pillar

12. Plug weld the center pillar (1) accordingly.
FRONT SIDE DOOR OUTER PANEL REPLACEMENT
Removal Procedure


Connection .
3. Remove the front side door. Refer to Front Side Door Replacement .
4. Remove the front side door outside handle. Refer to Front Side Door Outside Handle Replacement .
5. Remove the outside rearview mirror. Refer to Outside Rearview Mirror Replacement .
Fig. 168: Grinding Edges Of Front Side Door Outer Panel


7. Grind the edges of the front side door outer panel (1) to separate the outer door panel from the door shell.
Fig. 169: Front Side Door Outer Door Panel

8. Remove the front side door outer door panel (1).
9. Note the location of the adhesive for installation of the service assembly.
11. Straighten the edges of the door shell.

Fig. 170: Applying Urethane Adhesive To Front Side Door

1.
2.
3.
4.
5.
Apply urethane adhesive (1) to the front side door as noted from the original panel.
Align the front side door outer panel.
Verify the fit of the front side door outer panel.
Clamp the front side door outer panel into position.
Using a hammer re-hem the hem flanges around the door shell.

Fig. 171: Hammering In Stages Along Hem Flanges Of Front Side Door Outer Panel
6. Continue to hammer in stages along the hem flanges of the front side door outer panel (1).
8. Install the outside rearview mirror. Refer to Outside Rearview Mirror Replacement .
9. Install the front side door outside handle. Refer to Front Side Door Outside Handle Replacement .
10. Install the front side door. Refer to Front Side Door Replacement .
REAR SIDE DOOR OUTER PANEL REPLACEMENT

Removal Procedure

Connection .
3. Remove the rear side door. Refer to Rear Side Door Replacement .
4. Remove the rear side door outside handle. Refer to Rear Side Door Outside Handle Replacement .
Fig. 172: Grinding Edges Of Rear Side Door Outer Panel


6. Grind the edges of the rear side door outer panel (1) to separate the outer door panel from the door shell.
Fig. 173: Rear Side Door Outer Door Panel

7. Remove the rear side door outer door panel (1).
9. Straighten the edges of the door shell.

Fig. 174: Applying Urethane Adhesive To Rear Side Door

1.
2.
3.
4.
5.
Apply urethane adhesive (1) to the rear side door as noted from the original panel.
Align the rear side door outer panel.
Verify the fit of the rear side door outer panel.
Clamp the rear side door outer panel into position.
Using a hammer re-hem the hem flanges around the door shell.

Fig. 175: Hammering In Stages Along Hem Flanges Of Rear Side Door Outer Panel
6. Continue to hammer in stages along the hem flanges of the rear side door outer panel (1).
8. Install the rear side door outside handle. Refer to Rear Side Door Outside Handle Replacement .
9. Install the rear side door. Refer to Rear Side Door Replacement .
REAR RAIL SECTIONING
Removal Procedure


Connection .

Fig. 176: Cut Lines On Rear Side Rail

6. Create cut lines on the rear side rail (1).

Fig. 177: Cutting Rear Side Rail

NOTE:
7. Cut the panel (1) where sectioning is to be performed.

Fig. 178: Drilling Factory Welds Of Rear Side Rail

8. Locate and mark all the necessary factory welds of the rear side rail (1).

Fig. 179: Rear Side Rail

10. Remove the damaged rear side rail (1).

Fig. 180: Cutting New Rear Side Rail

1. Cut the rear side rail (1) in corresponding locations to fit the remaining original panel. The sectioning
joint should be trimmed to allow a gap of one-and-one-half-times the metal thickness at the sectioning
joint.
3. Align the rear side rail.

Fig. 181: Drill Holes For Plug Welding New Rear Side Rail
4. Drill 8 mm (5/16 in) for plug welding along the edges of the rear side rail (1) as noted from the original
panel.

Fig. 182: Rear Side Rail

6. Position the rear side rail (1) on the vehicle.
7. Verify the fit of the rear side rail.
8. Clamp the rear side rail into position.

Fig. 183: Welding Rear Side Rail

9. Plug weld the rear side rail (1) accordingly.
15. Enable the SIR System. Refer to SIR Disabling and Enabling .
RESISTANCE SPOT WELDED FULL PANEL REPLACEMENT

NOTE:
Use this procedure for all panels that are replaced at the factory seams, unless
a specific procedure exists in the Collision Repair section of this vehicle's
Removal Procedure

Connection .
4. Repair as much of the damage as possible to factory specifications.
WARNING: Refer to Foam Sound Deadeners Warning .
5. Note the location and remove the sealers and anti-corrosion materials from the repair area, as necessary.
Refer to Anti-Corrosion Treatment and Repair .

Fig. 184: Drilling Out Factory Welds (Full Panel)

NOTE:
6. Locate and drill out all factory welds (1). Note the number and location of the welds for installation of the
service part.

Fig. 185: View Of Damaged Part (Full Panel)

7. Remove the damaged part (1).
NOTE:
If the location of the original plug weld holes cannot be determined, space
the plug weld holes every 40 mm (1 1/2 in) apart. Where structural
adhesive was present, space the plug weld holes every 20 mm (3/4 in)
apart.

3. Position the service part. Clamp in place.

Fig. 186: Welding New Part (Full Panel)

4. Apply welds accordingly (1).
5. Clean and prepare all welded surfaces.
MIG WELDED FULL PANEL REPLACEMENT
Removal Procedure

NOTE:
Use this procedure for all panels that are replaced at the factory seams, unless
a specific procedure exists in the Collision Repair section of this vehicle's

Connection .
4. Repair as much of the damage as possible to factory specifications.
WARNING: Refer to Foam Sound Deadeners Warning .
5. Note the location and remove the sealers and anti-corrosion materials from the repair area, as necessary.
Refer to Anti-Corrosion Treatment and Repair .

Fig. 187: Drilling Out Factory Welds (Full Panel)

NOTE:
6. Locate and drill out all factory welds (1). Note the number and location of the welds for installation of the
service part.

Fig. 188: View Of Damaged Part (Full Panel)

7. Remove the damaged part (1).

Fig. 189: Drilling Plug Weld Holes (Full Panel)

NOTE:
the plug weld holes every 40 mm (1 1/2 in) apart. Where structural
adhesive was present, space the plug weld holes every 20 mm (3/4 in)
apart.
1. Drill 8 mm (5/16 in) plug weld holes in the service part as necessary in the locations noted from the
original panel (1).
2. Prepare all attachment surfaces as necessary.
5. Position the service part. Clamp in place.

Fig. 190: Plug Welding Service Part (Full Panel)

7. Clean and prepare all welded surfaces.

DUAL PHASE STEEL
This information provides repair recommendations and general guidelines for steel classified as Dual Phase

Steel, also known as DP. This type of steel normally has a tensile strength below 780 MPa.
General Motors recommends the following when repairing or replacing this type of steel during collision repair.
NOTE:
The use of heat to repair damage is not recommended for this classification of
steel.
Recommended Repairs
Cold repairs can be performed on this type of steel, unless the damage includes kinks. If the damage
includes kinks, the part should be replaced.
Sectioning or partial replacement of this type of steel is recommended only at approved locations, in a
specific sectioning procedure.
This type of steel can be used as a sleeve, or backer plate, when recommended in a specific sectioning
procedure.
Squeeze Resistance Spot Welding can be used to replace factory spot welds, where applicable.
MIG plug welding and MIG stitch welding can be used on this type of steel.
MIG Brazing can be used on this type of steel.
HIGH STRENGTH LOW ALLOY STEEL

This information provides repair recommendations and general guidelines for steel classified as High Strength
Low Alloy Steel, also known as HSLA. This type of steel normally has a tensile strength range from 300-700
MPa.
Recommended Repairs
Controlled use of heat can be used to repair damage, if the heat does not exceed 650C (1200F). The
heat should be applied a maximum of 2 times, for up to 90 seconds.
This type of steel can be used as a sleeve, or backer plate, during sectioning procedures.
MILD STEEL
This information provides repair recommendations and general guidelines for steel classified as Mild Steel. This
type of steel normally has a tensile strength less than 270 MPa. This includes the common steel names of:

Mild Steel
Bake Hardenable Steel (BH)
Solid Solution Strengthened Steel
Recommended Repairs:
Controlled use of heat can be used to repair damage, if the heat does not exceed 650C (1200F). The
heat should be applied a maximum of 2 times, for up to 90 seconds.
This type of steel can be used as a sleeve, or backer plate, when recommended in a specific sectioning
procedure.
Squeeze Resistance Spot Welding can be used to replace factory spot welds, where applicable
ULTRA HIGH STRENGTH DUAL PHASE STEEL

This information provides repair recommendations and general guidelines for steel classified as Ultra High
Strength Dual Phase Steel, also known as DPX. This type of steel normally has a tensile strength of 780 MPa,
or greater.
NOTE:
Repair of this type of steel is not recommended.

This type of steel should be replaced at factory joints only. Sectioning or
partial replacement is not recommended.
The use of heat to repair damage is not recommended for this type of
steel.
Stitch Welding is not recommended for this type of steel (unless replacing
a factory installed stitch weld).
This type of steel should not be used as a backing reinforcement or a
sleeve for a sectioning joint.
Recommended Repairs:
MIG plug welding can be used to replace factory spot welds.
MIG Brazing can be used to replace factory spot welds.

2013 ACCESSORIES & EQUIPMENT Exterior Trim - Cruze

Exterior Trim - Cruze
SPECIFICATIONS
Specification
Application
Front Fog Lamp Bezel Bolt
Front Side Door Window Frame Cover Bolt
Radiator Grille Bolt
Radiator Grille Emblem Screw
Radiator Grille Support Bolt
Radiator Lower Grille Bolt
Radiator Upper Grille Bolt
Rear Side Door Window Frame Cover Bolt
Metric
2.5 N.m
2 N.m
2.5 N.m
2.5 N.m
4.5 N.m
2.5 N.m
2.5 N.m
2 N.m
REPAIR INSTRUCTIONS
BODY SIDE UPPER REAR APPLIQUE REPLACEMENT
English
23 lb in
18 lb in
23 lb in
23 lb in
40 lb in
23 lb in
23 lb in
18 lb in

Fig. 1: Body Side Upper Rear Applique

Body Side Upper Rear Applique Replacement
Callout
Component Name
Open either the left rear or right rear door in order to access the backside of the body side upper rear
applique.
Body Side Upper Rear Applique
1
Procedure
Use flat bladed tool to unclip the body side upper rear applique clips.
REAR COMPARTMENT LID APPLIQUE REPLACEMENT
Fig. 2: Rear Compartment Lid Applique

Rear Compartment Lid Applique Replacement
Callout
Component Name
Replacement .
Rear Compartment Lid Applique Assembly Nut (Qty: 4)
CAUTION:

Tighten:
7 N.m (62 lb in)
Rear Compartment Lid Applique Clip (Qty: 2)
TIP: Depress the clip fingers and push outward in order to remove the
rear applique.
Rear Compartment Lid Applique Assembly
Procedure

2. Disengage the electrical harness grommet from the rear
compartment inner panel.
3. Remove the applique assembly from the rear compartment lid.
4. Transfer parts as needed to the new applique.
FRONT FOG LAMP BEZEL REPLACEMENT
Fig. 3: View Of Front Fog Lamp Bezel And Screw

Front Fog Lamp Bezel Replacement

Callout
Component Name
2. Remove the front fog lamp. Refer to Front Fog Lamp Replacement .
Front Fog Lamp Bezel Screw
CAUTION:
Tighten
2.5 N.m (23 lb in)
Front Fog Lamp Bezel
Procedure
2
1. Disengage the four inner retainer tabs securing the bezel to the
front bumper fascia.
2. Pull outward from the outer edge in order to release the outer
retention clips securing the bezel to the front bumper fascia.
3. Remove the front fog lamp bezel.
ROCKER PANEL DECAL REPLACEMENT

Fig. 4: Rocker Panel Decal

Rocker Panel Decal Replacement
Callout
Rocker Panel Decal
Component Name
CAUTION:
Refer to Exterior Trim Emblem Removal Caution .
Procedure
1. The part and surface should be 21C (70F) prior to installation.

The vehicle should remain 21C (70F) for one hour after
assembly to allow adhesive to develop sufficient bond strength.
2. Use a Heat Gun or equivalent to remove the old decal. Clean all
adhesive from the rocker panel and wipe the surface dry with a
clean lint free towel prior to installing the new decal.
3. When removing protective liners from the adhesive tape, be
careful not to touch tape with hands and do not allow the tape to
come in contact with dirt or any foreign matter prior to adhesion.
4. Using the palm of the hand, wet out the decal to the rocker panel
to ensure full adhesion of the emblem is made.

FRONT SIDE DOOR WINDOW FRAME COVER REPLACEMENT
Fig. 5: Identifying Front Side Door Window Frame Cover And Bolts
Front Side Door Window Frame Cover Replacement
Callout
Component Name
Remove the front side door window weatherstrip. Refer to Front Side Door Window Weatherstrip
Replacement
Front Side Door Window Frame Cover Bolt (Qty: 3)
1
2
CAUTION:
Front Side Door Window Frame Cover
FRONT SIDE DOOR WINDOW FRAME REAR COVER REPLACEMENT

Fig. 6: Front Side Door Window Frame Rear Cover

Front Side Door Window Frame Rear Cover Replacement
Callout
Component Name
Front Side Door Window Frame Rear Cover Bolt (Qty: 3)
CAUTION:
Procedure
Pull the window weatherstrip aside.
Tighten
2 N.m (18 lb in)
Front Side Door Window Frame Rear Cover
REAR SIDE DOOR WINDOW FRAME FRONT COVER REPLACEMENT

Fig. 7: View Of Rear Side Door Window Frame Front Cover And Bolts
Rear Side Door Window Frame Front Cover Replacement
Callout
Component Name
Rear Side Door Window Frame Front Cover Bolt (Qty: 3)
CAUTION:
Procedure
To access the bolts, loosen the rear side door window weatherstrip.
Rear Side Door Window Frame Front Cover
RADIATOR GRILLE EMBLEM/NAMEPLATE REPLACEMENT

Fig. 8: View Of Radiator Grille Emblem

Radiator Grille Emblem/Nameplate Replacement
Callout
Component Name
1
Radiator Grille Emblem
REAR COMPARTMENT LID EMBLEM/NAMEPLATE REPLACEMENT (BOWTIE)

Fig. 9: View Of Rear Compartment Lid Emblem

Rear Compartment Lid Emblem/Nameplate Replacement (Bowtie)
Callout
Component Name
Rear Compartment Lid Emblem
CAUTION:
Procedure

The vehicle should remain 21C (70F) for one hour after assembly
to allow adhesive to develop sufficient bond strength.
2. Use a Heat Gun or equivalent to Remove the old nameplate. Clean
all adhesive from the rear compartment panel and wipe the surface
dry with a clean lint-free towel prior to installing the new
nameplate.
3. When removing protective liners from the adhesive tape, be careful
4. Close the rear compartment lid prior to adhesion.
5. Using the palm of the hand, wet out the emblem to the rear

compartment lid to ensure full adhesion of the emblem is made.

REAR COMPARTMENT LID EMBLEM/NAMEPLATE REPLACEMENT (CHEVROLET)
Fig. 10: Rear Compartment Lid Emblem/Nameplate (Chevrolet)

Rear Compartment Lid Emblem/Nameplate Replacement (Chevrolet)
Callout
Component Name
CAUTION:
Procedure
1

nameplate.

REAR COMPARTMENT LID EMBLEM/NAMEPLATE REPLACEMENT (LT OR LTZ)
Fig. 11: View Of Rear Compartment Lid Emblem

Rear Compartment Lid Emblem/Nameplate Replacement (LT or LTZ)
Callout
Component Name
CAUTION:
Procedure
2. Use a Heat Gun or equivalent to Remove the old emblem. Clean all

adhesive from the rear compartment panel and wipe the surface dry
with a clean lint-free towel prior to installing the new emblem.
REAR COMPARTMENT LID EMBLEM/NAMEPLATE REPLACEMENT (CRUZE - RIGHT SIDE)
Fig. 12: Rear Compartment Lid Emblem/Nameplate (Cruze - Right Side)

Rear Compartment Lid Emblem/Nameplate Replacement (Cruze - Right Side)
Callout
Component Name
CAUTION:
Procedure

2.
3.
4.
5.
Use a Heat Gun or equivalent to Remove the old nameplate. Clean
nameplate.
When removing protective liners from the adhesive tape, be careful
Close the rear compartment lid prior to adhesion.
Using the palm of the hand, wet out the emblem to the rear
REAR COMPARTMENT LID EMBLEM/NAMEPLATE REPLACEMENT (CRUZE - LEFT SIDE)
Fig. 13: Rear Compartment Lid Emblem/Nameplate (Cruze - Left Side)

Rear Compartment Lid Emblem/Nameplate Replacement (Cruze - Left Side)
Callout
Component Name
CAUTION:

Procedure

nameplate.
FRONT BUMPER LOWER FASCIA GRILLE REPLACEMENT
Fig. 14: Identifying Front Bumper Lower Fascia Grille

Front Bumper Lower Fascia Grille Replacement
Callout
Component Name

Air Deflector Replacement .
Front Bumper Lower Fascia Grille
1
Procedure
Unclip from front bumper lower fascia bracket.
FRONT BUMPER LOWER FASCIA CENTER GRILLE REPLACEMENT
Fig. 15: Identifying Front Bumper Lower Fascia Center Grille

Front Bumper Lower Fascia Center Grille Replacement
Callout
Component Name
Remove the front bumper energy absorber. Refer to Front Bumper Energy Absorber Replacement .
Front Bumper Lower Fascia Center Grille
1
Procedure
Release the retaining tabs using a flat bladed tool.
FRONT UPPER GRILLE REPLACEMENT

Fig. 16: View Of Radiator Upper Grille, Clips And Screws

Front Upper Grille Replacement
Callout
Component Name
1
Radiator Upper Grille Clip (Qty: 4)
Radiator Upper Grille Screw (Qty: 8)
CAUTION:
Tighten
2.5 N.m (22 lb in)
Radiator Upper Grille
FRONT LOWER GRILLE REPLACEMENT

Fig. 17: View Of Radiator Lower Grille And Screws

Front Lower Grille Replacement
Callout
Component Name
Radiator Lower Grille Screw (Qty: 4)
CAUTION:
Tighten
2.5 N.m (22 lb in)
Radiator Lower Grille
Procedure
Release 12 retainers using a flat bladed tool.
ROCKER PANEL MOLDING REPLACEMENT

Fig. 18: View Of Rocker Panel Molding And Retainers

Rocker Panel Molding Replacement
Callout
Component Name
1
Rocker Panel Molding Retainer (Qty: 16)
2
Rocker Panel Molding
REAR END SPOILER REPLACEMENT

Fig. 19: Rear End Spoiler

Rear End Spoiler Replacement
Callout
Component Name
Replacement .
Rear End Spoiler Fastener (Qty: 6)
2
3
4
CAUTION:
Tighten
9 N.m (80 lb in)
Rear End Spoiler Retainer (Qty: 2)
Rear End Spoiler Tape
Rear End Spoiler

WATER MANAGEMENT DESCRIPTION AND OPERATION

Plenum Water Flow Direction and Cleaning
A large percentage of water will flow off the windshield area into the plenum chamber drain system and then
down the outside on the plenum to the underside of the vehicle. To ensure that the plenum chamber water
management system performs properly, the air inlet grille panel, plenum chamber, and drains must not be
blocked with debris.
In the graphic below the gray arrows show the water flow direction in the plenum chamber and drains system.
Fig. 20: Plenum Water Flow Direction And Cleaning

Plenum Chamber and Drain Valve-Cleaning
The plenum chamber is located in front of the windshield and below the air inlet grille panel.
1.
2.
3.
4.
Remove the air inlet grille panel. Refer to Air Inlet Grille Panel Replacement .
Clean the plenum chamber, drains and the air inlet grille panel of debris blockage.
Flush the plenum chamber, drains and the air inlet grille panel with clean water.
Install the air inlet grille panel. Refer to Air Inlet Grille Panel Replacement

2013 ACCESSORIES & EQUIPMENT Floor Coverings and Headlinings - Cruze

Floor Coverings and Headlinings - Cruze
REPAIR INSTRUCTIONS
FLOOR CARPET DRYING
If the carpet or the pad or insulator is wet, use the following criteria for drying or for replacing the components:
For a 1-piece carpet assembly bonded to a cotton or a fiber padding, replace the entire assembly.
For a 2-piece carpet assembly with a cotton or a fiber padding, replace the padding only. While the carpet
is out of the vehicle, dry the carpet using the method described below.
For a 1-piece carpet assembly bonded to a foam padding or attached 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. If you observe puddles of liquid on the carpet face, use a wet vacuum to remove the excess moisture.
2. Blot the face of the carpet with a towel in order to absorb as much moisture as possible.
3. Point a fan at the affected area and air dry the carpet.
FRONT FLOOR PANEL CARPET REPLACEMENT

Fig. 1: View Of Front Floor Panel Carpet Assembly

Front Floor Panel Carpet Replacement
Callout
Component Name
1. Remove front seats. Refer to Driver or Passenger Seat Removal and Installation .
2. Remove rear seat. Refer to Rear Seat Removal and Installation (40 Percent Seat) , Rear Seat
Removal and Installation (60 Percent Seat) .
3. Remove the front floor console. Refer to Front Floor Console Replacement .
4. Remove front sill panels. Refer to Front Side Door Sill Trim Plate Replacement .
5. Remove rear sill panels. Refer to Rear Side Door Sill Trim Plate Replacement .
6. Remove center pillar lower garnish moldings. Refer to Center Pillar Lower Garnish Molding
Replacement .
Front Floor Panel Carpet Assembly
1
Procedure
Loosen Transmission Control.
FLOOR CARPET RETAINER REPLACEMENT (ITW)
Removal Procedure

1. Remove the front floor panel carpet. Refer to Front Floor Panel Carpet Replacement.
Fig. 2: Floor Panel Carpet Retainer

2. Disengage the front floor panel carpet retainer (1) on the rear side of the front floor panel carpet.
3. Remove the front floor panel carpet retainer (1) upwards.

Fig. 3: Floor Panel Carpet Retainer

1. Align the front floor panel carpet retainer (1) to the cutout in the carpet.
2. Engage the front floor panel carpet retainer (1) on the rear side of the front floor panel carpet.
3. Install the front floor panel carpet. Refer to Front Floor Panel Carpet Replacement.
FLOOR CARPET RETAINER REPLACEMENT (SAXONIA)
Removal Procedure
1. Remove the front floor panel carpet. Refer to Front Floor Panel Carpet Replacement.

Fig. 4: Floor Carpet Retainer

2. Remove the upper part of the floor carpet retainer (1) with a suitable tool. Remove the remaining pieces
through the cutout in the floor panel carpet.

Fig. 5: Floor Carpet Retainer

1. Align the lower part of the floor panel carpet retainer to the cutout in the carpet. Turn over the carpet,
while maintaining the center position of the retainer.
2. Position the upper part of the retainer (1) aligning to the lower part of the retainer. Hold the lower part of
the retainer with a suitable tool and push down hard on the upper part of the retainer to engage several
retention rings.
3. While still holding the lower part of the retainer, lightly tap on the upper part of the retainer using a
rubber mallet to engage the remaining retention rings.
4. Install the front floor panel carpet. Refer to Front Floor Panel Carpet Replacement.
FLOOR CARPET AUXILIARY MAT RETAINER REPLACEMENT
Auxiliary Mat Retainer Identification
There are two different suppliers of auxiliary floor mat retainers for this vehicle, ITW and Saxonia. The style of

the retainers for the mats and carpet are different for both suppliers. Additionally, the mat retainers and carpet
retainers are NOT interchangeable between the two suppliers. Always determine the style of retainer used for a
specific vehicle prior to replacing auxiliary mat retainers or carpet retainers.
Fig. 6: Auxiliary Mat Fastener


Perform the following visual inspection of the auxiliary mat retainers to determine which style of retainer was
used:
1. Remove the auxiliary mat from the vehicle.
2. Look at the backside of the retainer on the auxiliary mat. If the center of the lower section is round, the
retainer was made by Saxonia (1). If the center of the lower section has a triangle, the retainer was made
by ITW (2).
3. Once identification is complete, continue with the following replacement procedure. If replacement of the
floor carpet retainer is necessary, refer to Floor Carpet Retainer Replacement (ITW), Floor Carpet
Retainer Replacement (Saxonia).
Removal Procedure

Fig. 7: Cutting Carpet Retainer

1. From the backside of the floor mat, cut four lines (1) through the plastic at the shown locations using a
pair of cutters.
2. Using suitable pliers, break off each piece and push the remaining piece through the mat retainer hole.

Fig. 8: Mat Retainer

1. Align the upper piece of the mat retainer (1) to center of the mat retainer hole. Turn the mat over while
maintaining the center position of the retainer.
2. Install the lower piece of the mat retainer (2) onto the mat, aligning it with the upper retainer. Push down
hard to engage several retention rings.
3. Lightly tap on the retainer with a rubber mallet to engage the remaining retention rings.
4. Install floor mat to vehicle.
HEADLINING TRIM PANEL REPLACEMENT (WITHOUT SUNROOF)

Fig. 9: Headlining Trim Panel (Without Sunroof)

Headlining Trim Panel Replacement (without Sunroof)
Callout
Component Name
WARNING:
Do not attempt to repair or alter the head impact energy-absorbing material glued to the headliner or
to the garnish trims. If the material is damaged, replace the headliner and/or the garnish trim. Failure
to do so could result in personal injury.
CAUTION:
If a vehicle is equipped with a head curtain inflator module ensure that the inflator module and tether
are undamaged. If tether or curtain airbag are damaged in any way, they must be replaced.
CAUTION:
Use care when working around the head curtain inflator module. Sharp tools may puncture the
curtain airbag. If the head curtain inflator module is damaged in any way, it must be replaced.
1.
2.
3.
4.
Disable the SIR system. Refer to SIR Disabling and Enabling .

Remove the sunshades. Refer to Sunshade Replacement .
Remove the sunshade supports. Refer to Sunshade Support Replacement .
Remove the roof console. Refer to Roof Console Replacement .

5. Remove the inside rearview mirror mount plate cover. Refer to Inside Rearview Mirror Mount
Plate Cover Replacement .
6. Remove the assist handles. Refer to Assist Handle Replacement .
7. Remove the windshield garnish moldings. Refer to Windshield Garnish Molding Replacement .
8. Remove the center pillar upper garnish moldings. Refer to Center Pillar Upper Garnish Molding
Replacement .
9. Remove the quarter window garnish moldings. Refer to Quarter Window Garnish Molding
Replacement .
10. Remove the rear and both front seats. Refer to Rear Seat Cushion Removal and Installation ,
and Driver or Passenger Seat Removal and Installation .
1
Headliner Trim Panel Retainer (Qty: 3)
Headliner Trim Panel Assembly
Procedure
1. To disconnect the front harness, remove the instrument panel

compartment. Refer to Instrument Panel Compartment
Replacement .
3. When replacing the headliner transfer all the foams to the new
headliner.
NOTE:
Removal and installation of the headliner must be completed through
the rear door opening. Always service with the aid of an assistant to
prevent kinking or damage to the headliner. When installing a new
headliner, tape any unused connector to the headliner with a high
adhesive tape.
HEADLINING TRIM PANEL REPLACEMENT (WITH SUNROOF)

Fig. 10: Headlining Trim Panel (With Sunroof)

Headlining Trim Panel Replacement (with Sunroof)
Callout
Component Name
WARNING:
Do not attempt to repair or alter the head impact energy-absorbing material glued to the headliner or
to the garnish trims. If the material is damaged, replace the headliner and/or the garnish trim. Failure
to do so could result in personal injury.
CAUTION:
If a vehicle is equipped with a head curtain inflator module ensure that the inflator module and tether
are undamaged. If tether or curtain airbag are damaged in any way, they must be replaced.
CAUTION:
Use care when working around the head curtain inflator module. Sharp tools may puncture the
curtain airbag. If the head curtain inflator module is damaged in any way, it must be replaced.
1.
2.
3.
4.

Remove the sunshades. Refer to Sunshade Replacement .
Remove the sunshade supports. Refer to Sunshade Support Replacement .

5. Remove the inside rearview mirror mount plate cover. Refer to Inside Rearview Mirror Mount
Plate Cover Replacement .
6. Remove the assist handles. Refer to Assist Handle Replacement .
7. Remove the windshield garnish moldings. Refer to Windshield Garnish Molding Replacement .
8. Remove the center pillar upper garnish moldings. Refer to Center Pillar Upper Garnish Molding
Replacement .
9. Remove the quarter window garnish moldings. Refer to Quarter Window Garnish Molding
Replacement .
10. Remove the rear and both front seats. Refer to Rear Seat Cushion Removal and Installation ,
and Driver or Passenger Seat Removal and Installation .
1
Headliner Trim Panel Retainer (Qty: 3)
Headliner Trim Panel Assembly
Procedure
1. To disconnect the front harness, remove the instrument panel

compartment. Refer to Instrument Panel Compartment
Replacement .
3. When replacing the headliner transfer all the foams to the new
headliner.
NOTE:
Removal and installation of the headliner must be completed through
the rear door opening. Always service with the aid of an assistant to
prevent kinking or damage to the headliner. When installing a new
headliner, tape any unused connector to the headliner with a high
adhesive tape.

2013 ACCESSORIES & EQUIPMENT Frame and Underbody - Cruze

Frame and Underbody - Cruze
SPECIFICATIONS
Specification
Application
Drivetrain and Front Suspension Frame Bolt Front
Drivetrain and Front Suspension Frame Bolt Rear
Front Compartment Insulator Bolt
Front Compartment Splash Shield Bolt
Front Wheelhouse Liner Bolt
Intermediate Steering Shaft Lower Bolt
Power Steering Fluid Cooling Pipe Bolt
Power Steering Inlet and Outlet Hose Bolt
Rear Wheelhouse Liner Bolt
Stabilizer Shaft Link Nut (1)
Steering Linkage Tie Rod Nut
Transmission Front Mount Bolt
Transmission Rear Mount Bracket Bolt
(1) = Use new fastener
REPAIR INSTRUCTIONS
ENGINE SHIELD REPLACEMENT
Metric
160
160
3
3
2.5
34
9
11
2.5
65
65
100
100
English
118 lb ft
118 lb ft
27 lb in
27 lb in
22 lb in
25 lb ft
80 lb in
97 lb in
22 lb in
48 lb ft
48 lb ft
74 lb ft
74 lb ft

Fig. 1: View Of Engine Shield And Bolts

Engine Shield Replacement
Callout
Component Name
Engine Shield Bolt (Qty: 4)
CAUTION:
Tighten
40 N.m (30 lb ft)
Engine Shield
FRONT COMPARTMENT INSULATOR REPLACEMENT

Fig. 2: Identifying Front Compartment Insulator, Screws And Plastic Retainers

Front Compartment Insulator Replacement
Callout
Component Name
Front Compartment Insulator Screw (Qty: 8)
2
3
CAUTION:
Tighten
3 N.m (27 lb in)
Front Compartment Insulator Plastic Retainer (Qty: 5)
Front Compartment Insulator
FRONT COMPARTMENT AIR DEFLECTOR REPLACEMENT

Fig. 3: Identifying Front Compartment Insulator, Screws And Plastic Retainers

Front Compartment Air Deflector Replacement
Callout
Component Name
Front Compartment Air Deflector (Qty: 8)
2
3
CAUTION:
Tighten
3 N.m (27 lb in)
Front Compartment Air Deflector Plastic Retainer (Qty: 5)
Front Compartment Air Deflector
UNDERBODY FRONT AIR DEFLECTOR REPLACEMENT - LEFT SIDE

Fig. 4: Underbody Front Air Deflector And Retainers - Left Side

Underbody Front Air Deflector Replacement - Left Side
Callout
Component Name
Raise the vehicle. Refer to Lifting and Jacking the Vehicle .
1
Underbody Front Air Deflector Retainer (Qty: 8)
2
Underbody Front Air Deflector - Left Side
UNDERBODY FRONT AIR DEFLECTOR REPLACEMENT - RIGHT SIDE

Fig. 5: Underbody Front Air Deflector - Right Side

Callout
Component Name
1
Underbody Front Air Deflector Retainer (Qty: 8)
2
Underbody Front Air Deflector - Right Side
UNDERBODY REAR AIR DEFLECTOR REPLACEMENT

Fig. 6: Underbody Rear Air Deflector And Nuts

Underbody Rear Air Deflector Replacement
Callout
Component Name
Underbody Rear Air Deflector Nut (Qty: 6)
1
2
CAUTION:
Underbody Rear Air Deflector
DRIVETRAIN AND FRONT SUSPENSION FRAME REPLACEMENT

Removal Procedure

Fig. 7: Lower Steering Intermediate Shaft Bolts

CAUTION: With wheels of the vehicle facing straight ahead, secure the steering
wheel utilizing steering column anti-rotation pin, steering column
lock, or a strap to prevent rotation. Locking of the steering column
will prevent damage and a possible malfunction of the SIR system.
The steering wheel must be secured in position before disconnecting
the following components:
The steering column

The steering gear
After disconnecting these components, do not rotate the steering

wheel or move the front tires and wheels. Failure to follow this

procedure may cause the SIR coil assembly to become un-centered

and cause possible damage to the SIR coil. If you think the SIR coil
has become un-centered, refer to your specific SIR coil's centering
procedure to re-center SIR Coil.
1.
2.
3.
4.
5.
6.
7.
Support the radiator and condenser from above using the condenser tabs on each side.
Remove the lower steering intermediate shaft bolt (1).
Raise the vehicle on a hoist. Refer to Lifting and Jacking the Vehicle .
Remove the tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation .
Remove the exhaust front pipe. Refer to Exhaust Front Pipe Replacement .
Remove the wheelhouse liners. Refer to Front Wheelhouse Liner Replacement.
Remove the front compartment insulator, if equipped. Refer to Front Compartment Insulator
Replacement.
8. Remove the front bumper fascia opening lower cover. Refer to Front Bumper Fascia Opening Lower
Cover Replacement .

Fig. 8: Radiator Wiring Harness, Wheel Speed Sensor Wiring Harness And Retainers
9. Remove the wheel speed sensor wiring harness (2) from the frame on both sides.
Remove the wiring harness retainers (3) from the frame and the lower control arm.
10. Remove the radiator wiring harness (1) from the frame.
Remove the wiring harness retainers (4) from the frame.
11. Remove the lower ball joints from the steering knuckles. Refer to Lower Control Arm Replacement .

Fig. 9: Stabilizer Link Nut

12. Remove and DISCARD the stabilizer link nut (1) from the strut.
13. Remove the outer tie rods and tie rod nuts from the steering knuckles. Refer to Steering Linkage Outer
Tie Rod Replacement .
14. Install the engine support fixture. For the 1.4L engine, refer to Engine Support Fixture .
For the 1.8L engine, refer to Engine Support Fixture .

Fig. 10: Identifying Front And Rear Transmission Mount Bracket Bolts
15. Remove the front (1) and the rear (2) transmission mount bracket bolts.

Fig. 11: Transmission Wiring Harness, Plugs, Bracket & Bolts

16. Carefully disconnect 2 wiring harness plugs (3) from the steering gear with a suitable tool. Refer to FEP
Connectors (Steering Gear) .
17. Using a suitable engine support table or equivalent, lower the vehicle until the drivetrain and front
suspension frame contacts the engine support table.

Fig. 12: Front Suspension Frame And Bolts

18.
19.
20.
21.
22.
23.
Remove the frame front bolts (1).

Remove the frame rear bolts (2).
Remove and DISCARD the rear frame reinforcement bolts (3).
Remove the frame reinforcements (4).
Remove the frame (5) from the vehicle.
Remove the following components if replacing the frame:
The lower control arms-Refer to Lower Control Arm Replacement .
The stabilizer shaft-Refer to Stabilizer Shaft Replacement .
The radiator support brackets.
The steering gear-Refer to Steering Gear Replacement .


CAUTION: Refer to Torque-to-Yield Fastener Caution .
1. Install the following components on the drivetrain and front suspension frame if removed:
The radiator support brackets and tighten to 22 N.m (16 lb ft) plus 45 degrees.
The stabilizer shaft-Refer to Stabilizer Shaft Replacement .
The lower control arms-Refer to Lower Control Arm Replacement .
The steering gear-Refer to Steering Gear Replacement .
Fig. 13: Front Suspension Frame And Bolts

2. Install the frame (5) into the vehicle.
3. Install the frame reinforcements (4).

4.
5.
6.
7.
Install the frame rear bolts (2) and tighten to 160 N.m (118 lb ft).
Install NEW frame reinforcement bolts (3) and tighten to 60 N.m (44 lb ft) plus 45 degrees.
Install the frame front bolts (1) and tighten to 160 N.m (118 lb ft).
Remove the support for the power steering gear.
Fig. 14: Transmission Wiring Harness, Plugs, Bracket & Bolts

8.
9.
10.
11.
Install and tighten 2 wiring harness bracket bolts (4) to 9 N.m (80 lb in).
Tighten wiring harness retainer (1) to steering gear.
Connect 2 wiring harness plugs (3).
Install the front bumper energy absorber bracket bolt.

Fig. 15: Identifying Front And Rear Transmission Mount Bracket Bolts
12. Install the front transmission mount bolt (1) and tighten to 100 N.m (74 lb ft).
13. Install the rear transmission mount bracket bolt (2) and tighten to 100 N.m (74 lb ft).
14. Install the outer tie rods and tie rod nuts to the steering knuckles. Refer to Steering Linkage Outer Tie
Rod Replacement .


15. Install the NEW steering linkage tie rod nuts and tighten to 35 N.m (26 lb ft).
16. Install the lower ball joints to the steering knuckles. Refer to Lower Control Arm Replacement .

Fig. 17: Radiator Wiring Harness, Wheel Speed Sensor Wiring Harness And Retainers
17. Install the wheel speed sensor wiring harness (2) to the frame on both sides.
Install the wiring harness retainers (3) to the frame and the lower control arm.
18. Install the radiator wiring harness (1) to the frame.
Install the wiring harness retainers (4) to the frame.

Fig. 18: Lower Steering Intermediate Shaft Bolts

19. Install the NEW lower steering intermediate shaft (1) bolt and tighten to 25 N.m (18 lb ft) plus 180
degrees.
20. Remove the support of the radiator and condenser.
21. Lower the vehicle on a hoist. Refer to Lifting and Jacking the Vehicle .
22. Install the wheelhouse liners. Refer to Front Wheelhouse Liner Replacement.
23. Install the tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation .
24. Install the exhaust front pipe. Refer to Exhaust Front Pipe Replacement .
25. Install the front compartment insulator, if equipped. Refer to Front Compartment Insulator
Replacement.
26. Install the front bumper fascia opening lower cover. Refer to Front Bumper Fascia Opening Lower
Cover Replacement .
27. Perform a wheel alignment. Refer to Front Camber Adjustment .

DRIVETRAIN AND FRONT SUSPENSION FRAME INSULATOR REPLACEMENT

Special Tools
CH-906-14 Adapter
CH-906-42 Adapter
CH-50342 Threaded Rod
For equivalent regional tools. Refer to Special Tools.

Removal Procedure
1. Remove the drivetrain and front suspension frame. Refer to Drivetrain and Front Suspension Frame
Replacement.
Fig. 19: View Of Frame And Insulator


2. Mark installation position of insulator (2) at frame (1).
Fig. 20: Identifying Frame Insulator And Core

NOTE:
Drilling holes into the insulator rubber to ease removal of the core.
3. Cut out frame insulator core (1) from frame insulator (2).

Fig. 21: View Of Frame Insulator And Core

4. Remove frame insulator core (1) from outer frame insulator (2).

Fig. 22: View Of Front Suspension Frame, Insulator And Chisel

5. Remove the frame insulator (3) from drivetrain and front suspension frame (1) using a chisel (2) or
equivalent.

Fig. 23: View Of Frame And Insulator

1. Install the following components on the drivetrain and front suspension frame:
CH-906-14 Adapter.
CH-906-42 Adapter.
CH-50342 Threaded Rod.
NOTE:
Check marking of frame insulator.
Align the insulator tab with the alignment marks (1) on the frame.
2. Carefully install the frame insulator in to the front suspension frame.
3. Install the drivetrain and front suspension frame. Refer to Drivetrain and Front Suspension Frame
Replacement.
FRONT WHEELHOUSE LINER REPLACEMENT


Front Wheelhouse Liner Replacement
Callout
Component Name
Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation .
Front Wheelhouse Liner Screw (Qty: 5)
2
3
CAUTION:
Tighten
2.5 N.m (23 lb in)
Front Wheelhouse Liner Plastic Retainer (Qty: 9)
Front Wheelhouse Liner
REAR WHEELHOUSE LINER REPLACEMENT

Fig. 25: View Of Rear Wheelhouse Panel Liner, Retainers, Nuts And Screws
Rear Wheelhouse Liner Replacement
Callout
Component Name
Rear Wheelhouse Panel Liner Screw (Qty: 4)
2
3
4
CAUTION:
Tighten
2.5 N.m (23 lb in)
Rear Wheelhouse Panel Liner Nut (Qty: 2)
Tighten
2.5 N.m (23 lb in)
Rear Wheelhouse Panel Liner Plastic Retainer (Qty: 2)
Rear Wheelhouse Panel Liner

SPECIAL TOOLS

Illustration

CH 906-14
Adapter
CH 906-42
Adapter
CH 50342
Threaded Rod

2013 ACCESSORIES & EQUIPMENT Instrument Panel and Console Trim - Cruze

Instrument Panel and Console Trim - Cruze
SPECIFICATIONS
Specification
Application
Driver Information Display Bezel Screw
Driver Information Display Screw
Front Floor Console Screw
Front Floor Console Storage Tray Screw
Front Floor Console Armrest Bolt
Instrument Carrier Support Bolt
Instrument Carrier Support Screw
Instrument Cluster Screw
Instrument Cluster Display Switch Screw
Instrument Panel Accessory Bezel Screw
Instrument Panel Assembly Screw
Instrument Panel Bolt
Instrument Panel Screw
Instrument Panel Cluster Lower Trim Plate Screw
Instrument Panel Compartment Bracket Bolt
Instrument Panel Compartment Bracket Screw
Instrument Panel Compartment Screw
Instrument Panel Inflatable Restraint Module
Bracket Nut
Instrument Panel Lower Trim Pad Screw
Instrument Panel Outer Air Outlet Duct Screw
Instrument Panel Steering Column Lower Trim
Cover Bolt
Instrument Panel Tie Bar Bolt
Instrument Panel Tie Bar Brace Bolt
Instrument Panel Upper Compartment Screw
Instrument Panel Upper Trim Pad Screw
Steering Column Lower Trim Cover Bolt
Metric
2.5 N.m
2.5 N.m
2.5 N.m
2.5 N.m
2.5 N.m
9 N.m
2.5 N.m
2.5 N.m
1.5 N.m
2.5 N.m
9Y
9 N.m
2.5 N.m
2.5 N.m
9 N.m
2.5 N.m
2.5 N.m
English
22 lb in
22 lb in
22 lb in
22 lb in
22 lb in
80 lb in
22 lb in
22 lb in
13 lb in
22 lb in
80 lb in
80 lb in
22 lb in
22 lb in
80 lb in
22 lb in
22 lb in
9Y
2.5 N.m
2.5 N.m
80 lb in
22 lb in
22 lb in
2.5 N.m
20 N.m
20 N.m
2.5 N.m
2.5 N.m
2.5 N.m
22 lb in
15 lb ft
15 lb ft
22 lb in
22 lb in
22 lb in
REPAIR INSTRUCTIONS
INSTRUMENT PANEL INSULATOR SEAL REPLACEMENT

Fig. 1: View Of Instrument Panel Insulator Seal

Instrument Panel Insulator Seal Replacement
Callout
Component Name
Remove the instrument panel assembly. Refer to Instrument Panel Assembly Replacement.
1
Instrument Panel Insulator Seal
INSTRUMENT PANEL INSULATOR PANEL REPLACEMENT - RIGHT SIDE

Fig. 2: Instrument Panel Insulator Panel - Right Side

Instrument Panel Insulator Panel Replacement - Right Side
Callout
Component Name
Instrument Panel Insulator Panel Fastener (Qty: 2)
1
2
CAUTION:
Instrument Panel Insulator Panel
INSTRUMENT PANEL CENTER UPPER MOLDING REPLACEMENT

Fig. 3: View Of Instrument Panel Center Upper Molding Assembly

Instrument Panel Center Upper Molding Replacement
Callout
Component Name
Instrument Panel Center Upper Molding Assembly
Procedure
1
1. Use a flat-bladed plastic trim tool to remove the instrument panel

center upper molding.
2. When replacing the instrument panel center upper molding, remove
both instrument panel center air outlet. Refer to Instrument Panel
Center Air Outlet Replacement .
INSTRUMENT PANEL UPPER TRIM PANEL REPLACEMENT - RIGHT SIDE

Fig. 4: Instrument Panel Upper Trim Panel - Right Side

Instrument Panel Upper Trim Panel Replacement - Right Side
Callout
Component Name
Remove the instrument panel compartment. Refer to Instrument Panel Compartment Replacement.
Instrument Panel Upper Trim Panel Screw (Qty 2)
CAUTION:
Tighten
2.5 N.m (22 lb in)
Instrument Panel Upper Trim Panel
INSTRUMENT PANEL UPPER TRIM PANEL REPLACEMENT - LEFT SIDE

Fig. 5: Instrument Panel Upper Trim Panel - Left Side

Instrument Panel Upper Trim Panel Replacement - Left Side
Callout
Component Name
Remove instrument panel cluster. Refer to Instrument Cluster Replacement .
Instrument Panel Upper Trim Panel- Left Side
Procedure
1
When replacing the instrument panel upper trim panel, transfer the
instrument panel outer air outlet.
INSTRUMENT PANEL ACCESSORY BEZEL REPLACEMENT

Fig. 6: View Of Instrument Panel Accessory Bezel And Screws

Instrument Panel Accessory Bezel Replacement
Callout
Component Name
1. Remove the instrument panel center upper molding. Refer to Instrument Panel Center Upper
Molding Replacement.
2. Remove the front floor console stowage tray. Refer to Front Floor Console Stowage Tray
Replacement.
Instrument Panel Accessory Bezel Screw (Qty: 4)
CAUTION:
Tighten
2.5 N.m (22 lb in).
Instrument Panel Accessory Bezel
2
Procedure
1. Gently pry the outer edges of the bezel to release clips.


3. Transfer parts as needed.
DRIVER INFORMATION DISPLAY BEZEL REPLACEMENT
Fig. 7: View Of Driver Information Display Bezel And Screws

Driver Information Display Bezel Replacement
Callout
Component Name
Remove the radio control module. Refer to Radio Control Module Replacement .
Driver Information Display Bezel Screw (Qty: 2)
CAUTION:
Tighten
2.5 N.m (22 lb in)
Driver Information Display Bezel
Procedure

1. Depress tabs on side of bezel.

2. When replacing the driver information display bezel, remove the
driver information display. Refer to Driver Information Display
Replacement .
INSTRUMENT PANEL CLUSTER TRIM PLATE REPLACEMENT
Fig. 8: View Of Instrument Panel Cluster Trim Plate Assembly

Instrument Panel Cluster Trim Plate Replacement
Callout
Component Name
Instrument Panel Cluster Trim Plate Assembly
Procedure
1
Remove the instrument panel cluster lower trim plate, if needed.
Refer to Instrument Panel Cluster Lower Trim Plate
Replacement
INSTRUMENT PANEL OUTER TRIM COVER REPLACEMENT - RIGHT SIDE

Fig. 9: View Of Instrument Panel Outer Trim Cover - Right Side

Instrument Panel Outer Trim Cover Replacement - Right Side
Callout
Component Name
1
Instrument Panel Outer Trim Cover- Right Side.
INSTRUMENT PANEL OUTER TRIM COVER REPLACEMENT - LEFT SIDE

Fig. 10: View Of Instrument Panel Outer Trim Cover - Left Side
Instrument Panel Outer Trim Cover Replacement - Left Side
Callout
Component Name
1
Instrument Panel Outer Trim Cover- Left Side.
INSTRUMENT PANEL LOWER TRIM PAD COVER REPLACEMENT (WITHOUT KNEE AIRBAG)

Fig. 11: View Of Instrument Panel Lower Trim Pad Cover Assembly And Screws
Instrument Panel Lower Trim Pad Cover Replacement (without Knee Airbag)
Callout
Component Name
Remove the left outer trim cover. Refer to Instrument Panel Outer Trim Cover Replacement - Left
Side.
Instrument Panel Lower Trim Pad Cover Screw (Qty: 3)
CAUTION:
Tighten
2.5 N.m (23 lb in)
Instrument Panel Lower Trim Pad Cover Assembly
Procedure
2
1. Remove headlamp switch. Refer to Headlamp Switch

Replacement
3. When replacing the lower trim pad cover, transfer all necessary

components.
INSTRUMENT PANEL LOWER TRIM PAD COVER REPLACEMENT (WITH KNEE AIRBAG)
Fig. 12: Instrument Panel Lower Trim Pad Cover (With Knee Airbag)
Instrument Panel Lower Trim Pad Cover Replacement (with Knee Airbag)
Callout
Component Name
Remove the left outer trim cover. Refer to Instrument Panel Outer Trim Cover Replacement - Left
Side.
1
Instrument Panel Lower Trim Pad Cover Screw Cover (Qty: 2)
Instrument Panel Lower Trim Pad Cover Screw (Qty: 5)
CAUTION:
Tighten
2.5 N.m (22 lb in)
Instrument Panel Lower Trim Pad Cover Assembly
Procedure

1. Remove headlamp switch. Refer to Headlamp Switch

Replacement .
3. When replacing the lower trim pad cover, transfer all necessary
components.
INSTRUMENT PANEL LOWER TRIM PANEL REPLACEMENT - LEFT SIDE
Fig. 13: View Of Instrument Panel Lower Trim Panel - Left Side
Instrument Panel Lower Trim Panel Replacement - Left Side
Callout
Component Name
1
Instrument Panel Lower Trim Panel Replacement - Left Side
INSTRUMENT PANEL CLUSTER LOWER TRIM PLATE REPLACEMENT

Fig. 14: Instrument Panel Cluster Lower Trim Plate

Instrument Panel Cluster Lower Trim Plate Replacement
Callout
Component Name
Remove instrument panel cluster trim plate. Refer to Instrument Panel Cluster Trim Plate
Replacement.
Instrument Panel Cluster Lower Trim Plate Screw (Qty: 4)
CAUTION:
Tighten
2.5 N.m (22 lb in)
Instrument Panel Cluster Lower Trim Plate
INSTRUMENT PANEL LOWER TRIM PANEL REPLACEMENT - RIGHT SIDE

Fig. 15: View Of Instrument Panel Lower Trim Panel - Right Side
Instrument Panel Lower Trim Panel Replacement - Right Side
Callout
Component Name
1
Instrument Panel Lower Trim Panel Replacement - Right Side
INSTRUMENT PANEL UPPER COMPARTMENT REPLACEMENT

Fig. 16: View Of Instrument Panel Upper Compartment Assembly And Screws
Instrument Panel Upper Compartment Replacement
Callout
Component Name
Instrument Panel Upper Compartment Screw (Qty: 2)
CAUTION:
Procedure
Before removing the instrument panel upper compartment screws,
remove mat.
Tighten
2.5 N.m (23 lb in)
Instrument Panel Upper Compartment Assembly
INSTRUMENT PANEL COMPARTMENT REPLACEMENT

Fig. 17: View Of Instrument Panel Compartment And Screws

Instrument Panel Compartment Replacement
Callout
Component Name
1. Remove the instrument panel insulator panel. Refer to Instrument Panel Insulator Panel
Replacement - Right Side.
2. Remove the inflatable restraint instrument panel lower module, if equipped. Refer to Instrument
Panel Lower Airbag Replacement - Passenger Side .
3. Remove the instrument panel outer trim cover - right side. Refer to Instrument Panel Outer Trim
Cover Replacement - Right Side.
Instrument Panel Compartment Screw (Qty: 5)
CAUTION:
Tighten
2.5 N.m (22 lb in)
Instrument Panel Compartment
INSTRUMENT PANEL MOLDING REPLACEMENT

Fig. 18: View Of Instrument Panel Molding Assembly

Instrument Panel Molding Replacement
Callout
Component Name
1
Instrument Panel Molding Assembly.
INSTRUMENT PANEL UPPER TRIM PAD INSERT REPLACEMENT

Fig. 19: Instrument Panel Upper Trim Pad Insert

Instrument Panel Upper Trim Pad Insert Replacement
Callout
Component Name
Instrument Panel Upper Trim Pad Insert Screw (Qty: 6)
CAUTION:
Tighten
2.5 N.m (22 lb in)
Instrument Panel Upper Trim Pad Insert
INSTRUMENT PANEL INFLATABLE RESTRAINT MODULE BRACKET REPLACEMENT

Fig. 20: View Of Instrument Panel Inflatable Restraint Module Bracket Assembly And Nuts
Instrument Panel Inflatable Restraint Module Bracket Replacement
Callout
Component Name
Instrument Panel Inflatable Restraint Module Bracket Nut (Qty: 2)
CAUTION:
Tighten
9 N.m (80 lb in)
Instrument Panel Inflatable Restraint Module Bracket Assembly
INSTRUMENT PANEL ASSEMBLY REPLACEMENT

Fig. 21: View Of Instrument Panel Assembly And Screws

Instrument Panel Assembly Replacement
Callout
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Component Name

Remove the windshield garnish moldings. Refer to Windshield Garnish Molding Replacement .
Remove the front floor console assembly. Refer to Front Floor Console Replacement.
Remove the radio assembly. Refer to Radio Replacement .
Remove the driver information display bezel. Refer to Driver Information Display Bezel
Replacement.
Remove the instrument panel accessory bezel. Refer to Instrument Panel Accessory Bezel
Replacement.
Remove the steering column. Refer to Steering Column Replacement .
Remove the left instrument panel outer trim cover. Refer to Instrument Panel Outer Trim Cover
Replacement - Left Side.
Remove the instrument panel compartment assembly. Refer to Instrument Panel Compartment
Replacement.
Remove the instrument panel molding. Refer to Instrument Panel Molding Replacement.
Remove the instrument panel upper trim panels. Refer to Instrument Panel Upper Trim Panel
Replacement - Right Side, and Instrument Panel Upper Trim Panel Replacement - Left Side.

Instrument Panel Assembly Screw (Qty: 9)
CAUTION:
Tighten
9 N.m (80 lb in)
Instrument Panel Assembly
Procedure
1. Note location and routing of the instrument panel wiring harness

prior to removal of the instrument panel assembly to ensure proper
reinstallation.
2. Disconnect the wiring harness from the instrument panel assembly.
3. With the aid of an assistant, remove the instrument panel assembly
from the vehicle.
4. When replacing the instrument panel assembly, transfer all
necessary components.
INSTRUMENT PANEL TIE BAR REPLACEMENT

Removal Procedure
1. Remove instrument panel assembly. Refer to Instrument Panel Assembly Replacement.

Fig. 22: Instrument Panel Wiring Harness And Instrument Panel Tie Bar
2. Remove instrument panel wiring harness (2) from instrument panel tie bar (1).

Fig. 23: Instrument Panel Tie Bar, Bolts And Nuts

3. Remove instrument panel tie bar (2).
1. Remove 4 instrument panel tie bar bolts (3, 4).
2. Remove 2 instrument panel tie bar nuts (1).

Fig. 24: Instrument Panel Tie Bar, Bolts And Nuts

1. Install instrument panel tie bar (2).

1. Install 4 instrument panel tie bar bolts (3, 4) and tighten to 22 N.m (16 lb ft).
2. Install 2 instrument panel tie bar nuts (1) and tighten to 9 N.m (80 lb in).

Fig. 25: Instrument Panel Wiring Harness And Instrument Panel Tie Bar
2. Install instrument panel wiring harness (2) to instrument panel tie bar (1).
Connect electrical connectors.
3. Install instrument panel assembly. Refer to Instrument Panel Assembly Replacement.
INSTRUMENT PANEL TIE BAR BRACE REPLACEMENT

Fig. 26: Instrument Panel Tie Bar Brace

Instrument Panel Tie Bar Brace Replacement
Callout
Component Name
Remove the front floor console. Refer to Front Floor Console Replacement.
Instrument Panel Tie Bar Brace Fastener (Qty: 3)
CAUTION:
Tighten
22 N.m (16 lb ft)
Instrument Panel Tie Bar Brace
FRONT FLOOR CONSOLE STOWAGE TRAY REPLACEMENT

Fig. 27: View Of Front Floor Console Storage Tray And Screws
Front Floor Console Stowage Tray Replacement
Callout
Component Name
Remove the automatic or manual transmission control lever trim cover. Refer to Automatic or Manual
Transmission Control Lever Trim Cover Replacement.
Front Floor Console Storage Tray Screw (Qty: 2)
CAUTION:
Tighten
2.5 N.m (22 lb in)
Front Floor Console Storage Tray
FRONT FLOOR CONSOLE COMPARTMENT REPLACEMENT

Fig. 28: Front Floor Console Compartment

Front Floor Console Compartment Replacement
Callout
Component Name
Front Floor Console Compartment Fastener (Qty: 4)
CAUTION:
1
Procedure
To gain access to the lower inner fasteners, remove the front floor console
compartment liner.
Front Floor Console Compartment
Procedure
2

2. If replacing the front floor console compartment, transfer the audio
disc player, USB, auxiliary in and memory card receptacle. Refer to
Audio Disc Player, USB, Auxiliary In, and Memory Card
Receptacle Replacement .
AUTOMATIC OR MANUAL TRANSMISSION CONTROL LEVER TRIM COVER REPLACEMENT

Fig. 29: View Of Transmission Control Lever Trim Cover Assembly

Automatic or Manual Transmission Control Lever Trim Cover Replacement
Callout
Component Name
Transmission Control Lever Trim Cover Assembly
1
Procedure
1. Unclip and reposition the shift boot (manual transmission)
2. Disconnect the electrical connection as necessary.
FRONT FLOOR CONSOLE REPLACEMENT

Fig. 30: View Of Front Floor Console And Screws

Front Floor Console Replacement
Callout
Component Name
1. Remove the instrument panel lower trim panel - left side. Refer to Instrument Panel Lower Trim
Panel Replacement - Left Side.
2. Remove the instrument panel lower trim panel - right side. Refer to Instrument Panel Lower
Trim Panel Replacement - Right Side.
3. Remove transmission control lever trim cover. Refer to Automatic or Manual Transmission
Control Lever Trim Cover Replacement.
Front Floor Console Screw (Qty: 6)
CAUTION:
Tighten
2.5 N.m (22 lb in)
2
Front Floor Console

Procedure


2. Transfer parts as needed.
FRONT FLOOR CONSOLE ARMREST REPLACEMENT
Fig. 31: View Of Front Floor Console Armrest And Bolts

Front Floor Console Armrest Replacement
Callout
Component Name
1. Remove the front floor console rear cover. Refer to Front Floor Console Rear Cover
Replacement.
2. Remove the front floor console compartment. Refer to Front Floor Console Compartment
Replacement.
Front Floor Console Armrest Bolt (Qty: 3)
CAUTION:
Tighten
2.5 N.m (22 lb in)

Front Floor Console Armrest
FRONT FLOOR CONSOLE REAR COVER REPLACEMENT
Fig. 32: View Of Front Floor Console Rear Cover Assembly

Front Floor Console Rear Cover Replacement
Callout
Component Name
Front Floor Console Rear Cover Assembly
Procedure
1
1. Grasp the cover assembly and pull rearward disengaging the

retainer clips securing the cover to the floor console.
3. When replacing the front floor console rear cover assembly,
transfer all necessary components.
ROOF CONSOLE REPLACEMENT

Fig. 33: View Of Roof Console Assembly, Reading Lamp Bezel And Screws
Roof Console Replacement
Callout
Component Name
1
Reading Lamp Bezel
Roof Console Screw (Qty: 2)
CAUTION:
Tighten
2.5 N.m (22 lb in)
Roof Console Assembly
Procedure
3

2. If equipped, transfer the mobile telephone microphone when
replacing the roof console. Refer to Mobile Telephone Microphone
Replacement .

SPECIAL TOOLS
Illustration

BO-569-A
KM-569-A
Plug Lifter
DT-6459-B
DW240-090
MKM-J-6459-B
Torque Wrench
GE-604-D
MKM-604-D
Torx Bit and Socket Set

2013 ACCESSORIES & EQUIPMENT Interior Trim and Paneling - Cruze

Interior Trim and Paneling - Cruze
SPECIFICATIONS
Specification
Application
Assist Handle
Front Side Door Armrest Pull Cup Bolt
Front Side Door Inside Handle Bolt
Front Side Door Trim Bolt
Front Side Door Trim Bracket Bolt
Front Side Door Window Switch Bezel Screw
Rear Side Door Armrest Pull Cup Bolts
Rear Side Door Inside Handle Bolt
Rear Side Door Trim Bolt
Rear Side Door Trim Bracket Bolt
Rear Side Door Window Switch Bezel Screw
Sunshade Bolt
Sunshade Support Bolt
Metric
6 N.m
2 N.m
2 N.m
2.5 N.m
2.5 N.m
2.5 N.m
2 N.m
2 N.m
2.5 N.m
2.5 N.m
2.5 N.m
3 N.m
3 N.m
REPAIR INSTRUCTIONS
FRONT SIDE DOOR WINDOW SWITCH BEZEL REPLACEMENT
English
53 lb in
18 lb in
18 lb in
23 lb in
23 lb in
23 lb in
18 lb in
18 lb in
23 lb in
23 lb in
23 lb in
27 lb in
27 lb in

Fig. 1: Identifying Front Side Door Window Switch Bezel

Front Side Door Window Switch Bezel Replacement
Callout
Component Name
Remove the front side door trim. Refer to Front Side Door Trim Replacement.
Front Side Door Window Switch Bezel Screw (Qty: 8)
CAUTION:
Procedure
Remove screws from the backside of the door trim panel.
Tighten
2.5 N.m (22 lb in)
Front Side Door Window Switch Bezel
Procedure
Lift and remove the switch bezel from the door trim panel.
REAR SIDE DOOR WINDOW SWITCH BEZEL REPLACEMENT

Fig. 2: Rear Side Door Window Switch Bezel

Rear Side Door Window Switch Bezel Replacement
Callout
Component Name
Remove the rear side door trim. Refer to Rear Side Door Trim Replacement.
Rear Side Door Window Switch Bezel Screw (Qty: 7)
CAUTION:
Procedure
Remove screws from the backside of the door trim panel.
Tighten
2.5 N.m (22 lb in)
Rear Side Door Window Switch Bezel
Procedure
Lift and remove the switch bezel from the door trim panel.
FRONT OR REAR SIDE DOOR LOCKING ROD KNOB TRIM COVER REPLACEMENT

Fig. 3: Side Door Locking Rod Knob Trim Cover

Front or Rear Side Door Locking Rod Knob Trim Cover Replacement
Callout
Component Name
1
Side Door Locking Rod Knob Trim Cover Assembly
FRONT SIDE DOOR UPPER TRIM COVER REPLACEMENT

Fig. 4: Front Side Door Upper Trim Cover

Front Side Door Upper Trim Cover Replacement
Callout
Component Name
Front Side Door Upper Trim Cover Clip (Qty: 2)
CAUTION:
To prevent damage to the trim cover and clips, remember the
following:
1. DO NOT disengage the clips by pulling the trim cover for

removal, since trim cover clips damage could result.
2. If a detached clip is damaged or broken, it must be replaced.
3. Properly align and gently press the trim cover for installation.
Procedure
Use B0-38778 remover or equivalent tools to disengage the front side
door trim cover from the door.
Special Tools
B0-38778 Door Trim Panel Clip Remover
Front Side Door Upper Trim Cover

FRONT SIDE DOOR TRIM REPLACEMENT
Fig. 5: Locating Front Side Door Trim Components

Front Side Door Trim Replacement
Callout
Component Name
Remove the front side door upper trim cover. Refer to Front Side Door Upper Trim Cover
Replacement.
Front Side Door Pull Handle Bolt
CAUTION:
Tighten
2 N.m (18 lb in)
Front Side Door Inside Handle Bolt Finish Cap
Procedure
Pull handle back to remove cap. Use suitable tool to unsnap.
Front Side Door Inside Handle Bolt
Tighten
2.5 N.m (22 lb in)
Front Side Door Trim Clip (Qty: 8)

NOTE:
Use a NEW retainer before installing the front side door trim.
4
Special Tools
BO-38778 Door Trim Panel Clip Remover
Front Side Door Trim
Procedure
1. Pull upwards on the door lock retainer cable to disengage.

TIP: Only use BO-38778 remover to disengage the door trim clips
from the door. Do not disengage the clips by pulling from the map
pocket area, since this can distort the trim panel.
FRONT SIDE DOOR WATER DEFLECTOR REPLACEMENT
Fig. 6: Front Side Door Water Deflector


Front Side Door Water Deflector Replacement

Callout
Component Name
Front Side Door Trim Panel Bracket Fastener (Qty: 2)
1
2
3
CAUTION:
Front Side Door Trim Panel Bracket

Front Side Door Water Deflector
Procedure
Pull the water deflector from the door. Guide electrical connectors
through the water deflector while removing it from the door.
REAR SIDE DOOR WATER DEFLECTOR REPLACEMENT
Fig. 7: Rear Side Door Water Deflector

Rear Side Door Water Deflector Replacement
Callout
Component Name
Rear Side Door Trim Panel Bracket Fastener (Qty: 2)

1
2
3
CAUTION:
Rear Side Door Trim Panel Bracket

Rear Side Door Water Deflector
Procedure
Pull the water deflector from the door. Guide electrical connectors
through the water deflector while removing it from the door.
REAR SIDE DOOR WINDOW GARNISH MOLDING REPLACEMENT
Fig. 8: Rear Side Door Window Garnish Molding

Rear Side Door Window Garnish Molding Replacement
Callout
Component Name
1
Rear Side Door Window Garnish Molding
FRONT SIDE DOOR WINDOW GARNISH MOLDING REPLACEMENT

Fig. 9: Identifying Front Side Door Window Garnish Molding

Front Side Door Window Garnish Molding Replacement
Callout
Component Name
1
Front Side Door Window Garnish Molding
FRONT SIDE DOOR SILL TRIM PLATE REPLACEMENT

Fig. 10: Identifying Front Side Door Sill Trim Plate

Front Side Door Sill Trim Plate Replacement
Callout
Component Name
Front Side Door Sill Trim Plate Clip (Qty: 4)
1
NOTE:
On the outboard side of the trim plate, start from the rear of the
trim plate and work toward the front of the vehicle. The trim tool
should be positioned close to the trim plate clips.
Front Side Door Sill Trim Plate
REAR SIDE DOOR SILL TRIM PLATE REPLACEMENT

Fig. 11: Rear Side Door Sill Trim Plate

Rear Side Door Sill Trim Plate Replacement
Callout
Component Name
1
Rear Side Door Sill Trim Plate Clip (Qty: 2)
2
Rear Side Door Sill Trim Plate
ASSIST HANDLE REPLACEMENT

Fig. 12: Identifying Assist Handle & Screws

Assist Handle Replacement
Callout
Component Name
Assist Handle Screw (Qty: 2)
CAUTION:
Procedure
1
1. Fold the assist handle downward and hold.

2. Use a small flat-bladed tool to open the assist handle covers to
access the screws.
Tighten
6 N.m (53 lb in)
Assist Handle Assembly
INSIDE REARVIEW MIRROR MOUNT PLATE COVER REPLACEMENT

Fig. 13: Inside Rearview Mirror Mount Plate Cover

Inside Rearview Mirror Mount Plate Cover Replacement
Callout
Component Name
1
Inside Rearview Mirror Mount Plate Cover
SUNSHADE REPLACEMENT

Fig. 14: Sunshade Components

Sunshade Replacement
Callout
Component Name
Lower the front of the headliner to access the sunshade electrical connector, if necessary. Refer to
Headlining Trim Panel Replacement (without Sunroof) , Headlining Trim Panel Replacement (with
Sunroof) .
1
Sunshade Support Bolt Cover
Sunshade Fastener (Qty: 3)
2
3
CAUTION:
Sunshade Retainer
Sunshade
Procedure
2. Unclip the sunshade retainer from the headliner and sunshade.
SUNSHADE SUPPORT REPLACEMENT

Fig. 15: View Of Sunshade Anchor

Sunshade Support Replacement
Callout
Component Name
Sunshade Support Screw
CAUTION:
Procedure
Open the sunshade support screw access cover with a appropriate
tool.
Tighten
3 N.m (27 lb in)
Sunshade Support
WINDSHIELD GARNISH MOLDING REPLACEMENT

Fig. 16: Windshield Garnish Molding

Windshield Garnish Molding Replacement
Callout
Component Name
Windshield Garnish Molding
Procedure
1
1. Loosen tether clip and steel clips.

3. The tether clip at the upper portion of the garnish molding MUST
be replaced any time the garnish molding is removed.
CENTER PILLAR UPPER GARNISH MOLDING REPLACEMENT

Fig. 17: Identifying Center Pillar Upper Garnish Molding

Center Pillar Upper Garnish Molding Replacement
Callout
Component Name
1. Remove the center pillar lower garnish molding. Refer to Center Pillar Lower Garnish Molding
Replacement.
2. Remove the seat belt from the front seat. Refer to Driver or Passenger Seat Retractor Side Belt
Replacement .
1
Center Pillar Upper Garnish Molding Clip
Center Pillar Upper Garnish Molding
Procedure
2
When replacing the center pillar upper garnish molding, remove the
seat belt through the molding.
CENTER PILLAR LOWER GARNISH MOLDING REPLACEMENT

Fig. 18: Identifying Center Pillar Lower Garnish Molding

Center Pillar Lower Garnish Molding Replacement
Callout
Component Name
1. Remove the front side door sill trim plate. Refer to Front Side Door Sill Trim Plate
Replacement.
2. Remove the rear side door sill trim plate. Refer to Rear Side Door Sill Trim Plate Replacement.
1
Center Pillar Lower Garnish Molding Retainer (Qty: 6)
2
Center Pillar Lower Garnish Molding
QUARTER WINDOW GARNISH MOLDING REPLACEMENT

Fig. 19: Quarter Window Garnish Molding

Quarter Window Garnish Molding Replacement
Callout
Component Name
Quarter Window Garnish Molding Bolt Cap
1
Procedure
Use a small flat bladed trim tool to aid in removal of the cap.
Quarter Window Garnish Molding Bolt
2
CAUTION:
Quarter Window Garnish Molding

Procedure
Use a small flat bladed trim tool to aid in removal of the cap.
BODY SIDE TRIM PANEL REPLACEMENT

Fig. 20: Body Side Trim Panel

Body Side Trim Panel Replacement
Callout
Component Name
1. Remove rear side door sill trim plate. Refer to Rear Side Door Sill Trim Plate Replacement.
2. Remove quarter window garnish molding. Refer to Quarter Window Garnish Molding
Replacement.
3. Remove rear seat. Refer to Rear Seat Removal and Installation (40 Percent Seat) , Rear Seat
Removal and Installation (60 Percent Seat) .
1
Body Side Trim Panel Clip
Body Side Trim Panel
Procedure
2
Remove the trim panel forward in driving direction in order to
release from the body clips.
RADIO FRONT SIDE DOOR SPEAKER GRILLE BEZEL REPLACEMENT

Fig. 21: Radio Front Side Door Speaker Grille Bezel

Radio Front Side Door Speaker Grille Bezel Replacement
Callout
Component Name
1
Radio Front Side Door Speaker Grille Bezel Assembly
RADIO REAR SIDE DOOR SPEAKER GRILLE BEZEL REPLACEMENT

Fig. 22: Radio Rear Side Door Speaker Grille Bezel

Radio Rear Side Door Speaker Grille Bezel Replacement
Callout
Component Name
1
Radio Rear Side Door Speaker Grille Bezel Assembly
REAR WINDOW PANEL TRIM REPLACEMENT

Fig. 23: Rear Window Panel Trim

Rear Window Panel Trim Replacement
Callout
Component Name
1. Remove the rear seat back.

2. Remove the high mount stop lamp. Refer to High Mount Stop Lamp Replacement .
1
Rear Window Panel Trim Clip (Qty: 6)
2
Rear Window Panel Trim
REAR COMPARTMENT FLOOR PANEL TRIM REPLACEMENT

Fig. 24: Rear Compartment Floor Panel Trim

Rear Compartment Floor Panel Trim Replacement
Callout
Component Name
1
Rear Compartment Convenience Hook
2
Rear Compartment Floor Panel Trim
REAR SIDE DOOR TRIM REPLACEMENT

Fig. 25: Rear Side Door Trim

Rear Side Door Trim Replacement
Callout
Component Name
Rear Side Door Inside Handle Bolt Finish Cap
1
Procedure
Pull handle back to remove cap. Use suitable tool to unsnap.
Rear Side Door Inside Handle Screw
CAUTION:
Tighten
2.5 N.m (22 lb in)
Rear Side Door Pull Handle Screw
Tighten
2.5 N.m (22 lb in)
Rear Side Door Trim Clip (Qty: 5)

NOTE:
Use a NEW retainer before installing the rear side door trim.

Special Tools
BO-38778 Door Trim Panel Clip Remover
Rear Side Door Trim Assembly
Procedure
1. Pull upwards on the door lock retainer cable to disengage.

TIP: Only use BO-38778 remover to disengage the door trim clips
from the door. Do not disengage the clips by pulling from the map
pocket area, since this can distort the trim panel.
REAR COMPARTMENT LID PULL HANDLE REPLACEMENT
Fig. 26: Rear Compartment Lid Pull Handle

Rear Compartment Lid Pull Handle Replacement
Callout
Component Name
Rear Compartment Lid Pull Handle Fastener (Qty: 2)

CAUTION:
Rear Compartment Lid Pull Handle
REAR COMPARTMENT SILL TRIM PLATE REPLACEMENT
Fig. 27: Rear Compartment Sill Trim Plate

Rear Compartment Sill Trim Plate Replacement
Callout
Component Name
1
Rear Compartment Lid Latch Striker Cover
2
Rear Compartment Sill Trim Plate Clip (Qty: 4)
Rear Compartment Sill Trim Plate Retainer (Qty: 2)
Procedure
3
Push in retainers in order to release trim plate.
4
Rear Compartment Sill Trim Plate
REAR COMPARTMENT LID INNER PANEL TRIM REPLACEMENT

Fig. 28: Rear Compartment Lid Inner Panel Trim

Rear Compartment Lid Inner Panel Trim Replacement
Callout
Component Name
1. Remove the rear compartment lid pull handle. Refer to Rear Compartment Lid Pull Handle
Replacement.
2. Remove the rear compartment lid latch cover. Refer to Rear Compartment Lid Latch Cover
Replacement.
1
Rear Compartment Lid Inner Panel Trim Retainer (Qty: 12)
Rear Compartment Lid Inner Panel Trim
2
Procedure
Reposition the emergency release handle as required.
REAR COMPARTMENT LID LATCH COVER REPLACEMENT

Fig. 29: Rear Compartment Lid Latch Cover

Rear Compartment Lid Latch Cover Replacement
Callout
Component Name
Rear Compartment Lid Latch Cover
Procedure
1
Use a small flat-bladed tool to pull and release the rear compartment
lid latch cover.
REAR COMPARTMENT SIDE TRIM REPLACEMENT - LEFT SIDE

Fig. 30: Rear Compartment Side Trim - Left Side

Rear Compartment Side Trim Replacement - Left Side
Callout
Component Name
Remove rear compartment sill trim plate. Refer to Rear Compartment Sill Trim Plate Replacement.
1
Rear Compartment Side Trim Retainer (Qty: 3)
Rear Compartment Side Trim Fastener
2
3
CAUTION:
Rear Compartment Side Trim
REAR COMPARTMENT SIDE TRIM REPLACEMENT - RIGHT SIDE

Fig. 31: Identifying Rear Compartment Side Trim - Right Side

Rear Compartment Side Trim Replacement - Right Side
Callout
Component Name
Remove rear compartment sill trim plate. Refer to Rear Compartment Sill Trim Plate Replacement
1
Body Side Trim Panel Retainer (Qty: 4)
2
Body Side Trim Panel Assembly

SPECIAL TOOLS
Illustration

BO-38778
J-38778
Door Trim Pad Clip Remover

2013 ACCESSORIES & EQUIPMENT Paint and Coatings - Cruze

Paint and Coatings - Cruze
SPECIFICATIONS
CLEARCOAT REPAIR SPECIFICATIONS - 3M PRODUCTS
Clearcoat Repair Specifications - 3M Products
Paint
Scratch
Condition Wet Sanding Refinement
Compounding
Rotary Polisher
Dual Action
Orbital
Polisher
New
vehicle
prep or
fine wheel
marks
Swirl
marks,
water
spotting,
or light
oxidation
Perfect-It
3000 Swirl
Mark
Remover
P/N 06064
Perfect-It
Foam
Polishing
Pad P/N
05725/38
Hookit
SBS/Perfectit Backup
Pad P/N
Perfect-It
3000
Swirl
Mark
Remover
P/N
06064
Perfect-It
Foam
Polishing
Pad P/N
05725/38
Hookit
DA 6inch
Backup
Pad P/N
05776
Perfect-It
3000
Swirl
Mark
Remover
P/N
06064
Perfect-It
Foam
Polishing
Pad P/N
05725/38
Hookit
DA 6inch
Hand Glazing
Polishing
Perfect-It
Wax P/N
39026/395
Detail Clo
P/N 06016
Perfect-It
3000 Swirl
Mark
Remover
P/N 06066
Perfect-It I
Foam DA
Pad P/N
05729
Detail Clo
P/N 06016
Perfect-It
Wax P/N

05717/18
Backup
Pad P/N
05776
Overspray
or
medium
oxidation
Perfect-It
III
Cleaning
Clay P/N
38070
Perfect-It
3000
Rubbing
Compound
P/N
06060/62
Superbuff
III Buff
Pad P/N
05703/04
Perfect-It
3000 Swirl
Mark
Remover
P/N 06064
Perfect-It
Foam
Polishing
Pad P/N
05725/38
Hookit
SBS/Perfectit Backup
Pad P/N
05717/18
Heavy
oxidation
Micro Fine
or minor
2000
acid rain
pitting
Trizact
Hookit
II Foam
Disc 6
in 3000
P/N
02075
Perfect-It
3000
Rubbing
Compound
P/N
06060/62
Superbuff
III Buff
Pad P/N
05703/04
Perfect-It
3000 Swirl
Mark
Remover
P/N 06064
Perfect-It
Foam
Polishing
Pad P/N
05725/38
Hookit
SBS/PerfectIt Backup
Pad P/N
05717/18
Perfect-It
3000
Perfect-It
3000 Swirl
Mark
Remover
P/N 06064
Perfect-It
3000
Swirl
Mark
Remover
P/N
06064
Perfect-It
Foam
Polishing
Pad P/N
05725/38
Hookit
DA 6inch
Backup
Pad P/N
05776
Perfect-It
3000
Swirl
Mark
Remover
P/N
06064
Perfect-It
Foam
Polishing
Pad P/N
05725/38
Hookit
DA 6 in
Backup
Pad P/N
05776
Perfect-It
3000
Swirl
Mark
Remover
P/N
39026/395
Perfect-It
3000 Swirl
Mark
Remover
P/N 06066
Perfect-It I
Foam DA
Pad P/N
05729
Detail Clo
P/N 06016
Perfect-It
Wax P/N
39026/395
Perfect-It
3000 Swirl
Mark
Remover
P/N 06066
Perfect-It I
Foam DA
Pad P/N
05729
Detail Clo
P/N 06016
Perfect-It
Wax P/N
39026/395
Perfect-It
3000 Swirl
Mark
Remover
P/N 06066

Dust nibs,
minor
scratches, Micro Fine
or major 1500 or 2000
acid rain
pitting
Orange
peel, paint
runs or
sags
Hookit
II Film
Disc 6
in
P1200
P/N
00868
Hookit
II Film
Disc 6
in
P1500
P/N
000850
Hookit
II
Painters
Disc
Pad
P/N
05251
Hookit
II Soft
Interface
Pad 6 in
P/N
05274
Hookit
II
Painters
Disc
Pad 6 in
P/N
05251
Trizact
Hookit
II Foam
Disc 6
in 3000
P/N
02075
Hookit
II Soft
Interface
Pad 6 in
P/N
05274
Hookit
II
Painters
Disc
Pad 6 in
P/N
05251
Rubbing
Compound
P/N
06060/62
Superbuff
III Buff
Pad P/N
05703/04
Perfect-It
Foam
Polishing
Pad P/N
05725/38
Hookit
Pad P/N
05717/18
Perfect-It
3000
Rubbing
Compound
P/N
06060/62
Superbuff
III Buff
Pad P/N
05703/04
Perfect-It
3000 Swirl
Mark
Remover
P/N 06064
Perfect-It
Foam
Polishing
Pad P/N
05725/38
Hookit
Pad P/N
05717/18
06064
Perfect-It
Foam
Polishing
Pad P/N
05725/38
Hookit
DA 6 in
Backup
Pad P/N
05776
Perfect-It
3000
Swirl
Mark
Remover
P/N
06064
Perfect-It
Foam
Polishing
Pad P/N
05725/38
Hookit
DA 6 in
Backup
Pad P/N
05776
Perfect-It I
Foam DA
Pad P/N
05729
Detail Clo
P/N 06016
Perfect-It
Wax P/N
39026/395
Perfect-It
3000 Swirl
Mark
Remover
P/N 06066
Perfect-It I
Foam DA
Pad P/N
05729
Detail Clo
P/N 06016
Perfect-It
Wax P/N
39026/395
INTRODUCTION
BASECOAT/CLEARCOAT PAINT SYSTEMS
WARNING: Exposure to isocyanates during paint preparation and application
processes can cause severe breathing problems. Read and follow all of
the instructions from the manufacturers of painting materials, equipment,
and protective gear.
All paint finish repairs of rigid exterior surfaces must meet GM standards. Refer to the latest revision of the GM

Approved Refinish Materials book to identify the paint systems you may use that have been engineered to meet
GM standards. The GM Approved Refinish Materials book supplies all approved products, including volatile
organic compound (VOC) compliant regulations recommended by the individual manufacturer, and detailed
procedures for materials used in their paint system.
The latest revision of the GM Approved Refinish Materials booklet is located on the Genuine GM Parts website
at www.genuinegmparts.com.
ANTI-CORROSION TREATMENT AND REPAIR
WARNING: When applying sound deadeners, or anti-corrosion materials due care
and preventative measures must be exercised to prevent any material
from being sprayed into door and quarter panel mechanisms such as
door locks, window run channels, window regulators and seat belt
retractors, as well as any moving or rotating mechanical or suspension
parts on the underbody, particularly the parking brake cable. After
material application, be sure that all body drain holes are open. Improper
application may increase chance of corrosion damage or limit the
operation of moving parts, resulting in personal injury.
Any procedure that disturbs these special treatments, such as panel replacement or collision damage repair
operations, may leave the metal unprotected and result in corrosion. Proper recoating of these surfaces with
service-type anti-corrosion material is essential.
After repair and/or replacement parts are installed, all accessible bare metal surfaces must be treated with metal
conditioner and reprimed. Refer to the GM Approved Refinish Materials book which identifies the paint
systems you may use.
The latest revision of the GM Approved Refinish Materials booklet is located on the Goodwrench website at
www.gmgoodwrench.com.
Anti-corrosion compounds are light-bodied materials designed to penetrate between metal-to-metal surfaces,
such as pinch-weld joints, hem flanges, and integral panel attaching points where metal surfaces are difficult to
coat with conventional undercoating materials, and are inaccessible for painting. The materials that are suitable
for interior and exterior are listed in the chart below. Conventional undercoating is recommended in order to
coat large areas, such as replacement door and quarter outer panels, floor pan sections, lids, hoods, fenders, etc.
During undercoating operations, care should be taken to prevent the material from being sprayed into door and
quarter panel hardware mechanisms, such as door locks, window run channels, window regulators, and seat belt
retractors. On the underbody, the material should not be applied to any moving or rotating part, energy
absorbing bumper components, or shock absorbers. After undercoating, ensure that all body drain holes are
open.
Interior Protectant
The following products are available from GM Dealer Equipment. For technical information, call 187-Permatex
(1-877-376-2839):

Permatex Part Number

310-JDI-UCA1
310-81881
310-81882
Description
Permatex Canister and Wand Assembly
Permatex Amber Rust Proofing (24 oz) (Qty of 12)
Permatex Amber Rust Proofing (1 gal)
Exterior Protectants
The following product is available from *ECP, Inc. Contact them at 1-800-323-3521 or www.ecpinc.net.
Part Number
178660
Description
Nox Rust X-121B (12 cans per case)
The following products are available from your local *3M distributor, or call 1-800-521-8180, ext. 779-5165.
3M Part Number
08804
08801
05917
08891
Description
Water-Based Undercoat
No Clean-Up Applicator Gun
Weld-Thru Coating
Rust Fighter-I
The following product is available from *Transtar Autobody Technologies. Contact the company at 1-800-8242843 or www.tat-co.com
Part Number
4353
Description
Weld-Through Primer
*We believe these sources and their products to be reliable. There may be additional manufacturers of such
material. General Motors does not endorse, indicate any preference for, or assume any responsibility for the
products from these firms, or for any such items which may be available from other sources.
These sealers are intended to prevent water and dust from entering the vehicle and also are anti-corrosion
barriers. Sealers are applied to such areas as rear compartment lid hem flanges, wheelhouse, quarter outer, floor,
cowl, roof, and various other panel to panel attaching points. The originally sealed joints are obvious and any
damage to these sealed locations should be corrected by resealing. Attaching points of new replacement panels
should be resealed. Replacement lids and doors will also require sealing in the hem flange areas.
Flanged joints, overlap joints, and seams should be sealed using a quality sealer of medium-bodied consistency.
The sealer used must retain its flexible characteristics after curing and be paintable.
Open joints which require bridging of the sealer in order to close a gap should be sealed using a heavy-bodied
caulking material. Follow the label directions for the material selected.
Color application may be required in order to restore repaired areas such as hood, fenders, doors, quarters, lid,
roof, engine compartment, underbody, and inner panels to original appearance. When this is necessary,
conventional refinishing preparation, undercoat buildup, and color application techniques should be followed.

Deadener materials, spray-on type, are used on various metal panels in order to provide corrosion resistance and
joint sealing. They control the general noise level inside the passenger area of the vehicle. When deadeners are
disturbed because of damage, are removed during repair operations, or a new replacement panel is installed, the
deadener material must be replaced by a service equivalent material. The application pattern and location of
deadener materials can be determined by observing the original production installation.
Cleaning of the interior and underbody panel surfaces is necessary when original galvanized or other anticorrosion materials have been burned off during welding or heating operations. Removal of the residue from
burning will require additional care in such areas as interior surfaces of box-type construction and when
configurations of the metal panels limit access to interior surfaces.
PAINT IDENTIFICATION
WARNING: Exposure to isocyanates during paint preparation and application
processes can cause severe breathing problems. Read and follow all of
the instructions from the manufacturers of painting materials, equipment,
and protective gear.
NOTE:
Always refer to the GM Approved Refinish Materials book. This book identifies
the paint systems you may use.
The latest revision of the GM Approved Refinish Materials booklet is located on the Goodwrench website at
www.gmgoodwrench.com.
Use the service parts identification label to identify the type of paint technology, paint codes, trim level, and any
special order paint colors on the vehicle. Refer to Vehicle Certification, Tire Placard, Anti-Theft, and
Service Parts ID Label .
REPAIR INSTRUCTIONS
CLEARCOAT REPAIR WITHOUT REPAINTING
Repair Procedure
1. Thoroughly wash the repair area with Liquid Wash and Wax GM P/N 1052870 or the equivalent.
2. Environmental damage may be corrected. Refer to Environmental Fallout (Acid Rain), or Rail Dust
Damage Repair.
IMPORTANT: Follow all of the instructions from the manufacturer of the polishing
material.
3. Use a paint gauge before, during, and after sanding and/or polishing, to avoid removing too much
clearcoat. Refer to Paint Gauges.
ENVIRONMENTAL FALLOUT (ACID RAIN)

CAUTION: Refer to Clearcoat/Ultraviolet Screeners Caution .
NOTE:
Always refer to the manufacturer's packaged instructions for the detailed

procedures of materials used for compounding and/or polishing.
Since the severity of the condition varies from area to area, proper diagnosis of the contamination extent is
critical to the success of the repairs. Perform the diagnosis under high intensity fluorescent lighting on the
horizontal surfaces (hood, roof panel, rear compartment lid), after the surfaces have been properly cleaned by
washing the vehicle with GM Wash and Wax GM P/N 1237841 (Canadian P/N 10953203), or equivalent.
There are 3 basic types of acid rain damage:
Surface Level Contamination
May be repaired by simply washing the vehicle, cleaning the surface with a silicone wax and grease
remover, neutralizing acidic residue, and finesse polishing-Refer to Surface Level Contamination Repair.
Clearcoat Etching
Slight etching is still noticeable after the above washing and finesse polishing procedure. Refer to Slight
Clearcoat Damage - Wet Sanding, Finesse Polishing.
Basecoat Etching
Severe etching beyond the clearcoat into the basecoat in the affected areas will require refinishing. Refer
to Basecoat/Clearcoat Paint Systems.
Surface Level Contamination Repair
1. Thoroughly wash and dry the contaminated area with GM Wash and Wax GM P/N 1237841 (Canadian
P/N 10953203), or equivalent.
2. Clean the affected area with silicone, wax and grease remover.
3. Remove and neutralize acidic residue by cleaning the contaminated areas with a mixture of baking soda
and water (1 tablespoon of baking soda per 1 liter or 1 quart of water). Rinse thoroughly and dry the panel
completely.
4. Apply finesse-type polish with a foam panel. If damage has been repaired, remove any swirl marks with a
dual action orbital polisher and foam pad. Refer to Clearcoat Repair Specifications - 3M Products.
5. If some damage remains, refer to Slight Clearcoat Damage - Wet Sanding, Finesse Polishing.
Slight Clearcoat Damage - Wet Sanding, Finesse Polishing
1. Select a small contaminated test area.

2. Film thickness should be taken prior to the sanding and polishing. Refer to Paint Gauges.
3. Wet sand and finesse polish the contaminated test area. Refer to Clearcoat Repair Specifications - 3M

Products. If during the polishing you suspect or observe that etching has penetrated into the basecoat, too
much clearcoat has been removed during sanding, or base color is transferred to the polishing pad during
polishing, then the affected areas will require refinishing. Refer to Basecoat/Clearcoat Paint Systems.
PAINT GAUGES
Paint thickness gauges measure the total thickness of the vehicle finish. It is important to accurately measure the
thickness of the finish on each vehicle as the thickness of the finish will vary on each vehicle. Use a paint gauge
before the sanding process in order to accurately measure how much finish there is to remove before, during,
and after the sanding process. Paint gauges range from magnetic pull type to sophisticated electronic types, and
are available from a variety of sources. The older magnetic type gauges, at best have a 5 percent accuracy range
and are not sensitive enough to detect removal of 0.02 mm 0.5 mil (0.0005 in) clearcoat. The newer type
magnetic gauges have improved accuracy ranges. Most gauges are confined to checking either ferrous metal,
steel, non-ferrous metal, or aluminum panel. At this time, there are no viable gauges for reading film thickness
on composite (SCM doors, RIM fenders) panels. The more sophisticated (ETG) electronic paint thickness
gauges digital type gauges are able to read film thickness on both ferrous and non-ferrous metal panel. Digital
ETG gauges may have an accuracy range of 1 percent and include thickness standards for recalibration. The
following paint thickness gauges are available. Call 1-800-GM-TOOLS for information:
Paint Thickness Gauges
147-5437-ETG Standard model

147-5437-ETG-P Standard model with print option
147-5437-N-ETG-N Non-ferrous model for aluminum panels
147-5437-NP-ETG-NP Non-ferrous model with print option
147-54437-SD-ETG Steel and aluminum gauge
CLEARCOAT THICKNESS
The clearcoat on the vehicle is typically 0.059-0.078 mm (1.5-2 mils [0.0015-0.0020 in]) thick. The clearcoat
contains ultraviolet screeners. Removing more than 0.5 mils (0.019 in) of the clearcoat may result in early paint
failure.
RAIL DUST DAMAGE REPAIR
WARNING: Refer to Eye Protection Warning .
NOTE:
If rail dust has penetrated into the basecoat, the panel requires refinishing.
Ensure all the rail dust has been removed prior to refinishing or the rust spots
will return.
Rail dust damage comes from the tiny iron particles produced from the friction between the train wheels and the
track. It can also be deposited on vehicles if stored near any operation producing iron dust (i.e., steel ore yards).
This dust can either lay on top of, or embed into the paint surface. It is usually diagnosed as bumps in the paint
surface or rust colored spots in the paint.

1. Move the vehicle to a cool shaded area and ensure the vehicle surfaces are cool during the removal
process.
2. Thoroughly wash the repair area with Liquid Wash and Wax GM P/N 1052870, or equivalent.
3. Wipe the area dry.
4. Clean the affected area with silicone, wax and grease remover.
5. Perform the removal process according to the manufacturer's directions of the type of repair material used
(Gel Type Oxalic Acid or Clay Type Non-Acid Based). If, upon inspection, some particles are still
present, the process may be repeated. If the damage has been repaired, complete the repair to the entire
panel.
6. Polish the entire panel after the removal process. Refer to Clearcoat Repair Specifications - 3M
Products. If small pits remain in the clearcoat after all of the damage has been repaired, refer to
Clearcoat Repair without Repainting.

2013 ACCESSORIES & EQUIPMENT Plastic Panel Information and Repair - Cruze

Plastic Panel Information and Repair - Cruze
SPECIFICATIONS
FLEXIBLE PLASTIC PART REPAIR MATERIALS
Product- 88861039, *88861040, High Strength Plastic Repair 50 ml
Components- 12 cartridges with 2 mixers each
Structural and Cosmetic
Recommended Repair Material
Recommended
Handling Strength
Repair Material Work Time 70F
at 70F
Structural and
cosmetic bonding
and repairing of all
88861039
flexible plastics.
*88861040
12 cartridges with 2 Requires GM P/N
High
90 seconds
10 minutes
mixers each
12378462 on TPO
Strength Plastic
plastics. Will also
Repair 50 ml
bond ecoated/primed
metals.
* TPO, TEO, (Polyolefin Plastics) require the application of polyolefin adhesive primer before the GM
P/N 88861039 repair compound is applied.
Product
Components
Working Time
Adhesive
Part Paintability at Adhesive Full Cure
Product
Sandability at 70F
70F
at 70F
Program
88861039
Bumper covers,
*88861040
emblems, door
High
20 minutes
30 minutes
24 hours
trims, exterior and
Strength Plastic
interior repairs*
Repair 50 ml
* TPO, TEO, (Polyolefin Plastics) require the application of polyolefin adhesive primer before the GM
P/N 88861039 repair compound is applied.
RIGID PLASTIC PART REPAIR MATERIALS
Rigid Plastic Part Repair Materials
Thermoset Plastic Type
Type of Repair
Recommended Repair
Material
Availability

GM Goodwrench
Structural Bonding Epoxy
GM Dealer
(GM P/N 12345726 or
Sheet metal compound
equivalent)
(SMC), RIM rigid plastic
Cosmetic filling
parts
Sikkens Polystop LP or
Refer to a local paint
equivalent polyester
supplier
repair putty
GM Goodwrench
GM Dealer
(GM P/N 12345726 or
Cosmetic repair, adhesive
equivalent)
Most rigid plastic parts
bonding
Lord Fusor SMC Body
Refer to local paint
Panel Repair Adhesive or
supplier
equivalent
GM Goodwrench
GM Dealer
(GM P/N 12345726 or
equivalent)
Adhesive bonding
Dynatron Dyna-Weld Plio
Refer to local paint
Grip or equivalent (OE
supplier
structural adhesive)
GM Goodwrench
Adhesive structural* Structural Bonding Epoxy
GM Dealer
bonding
(GM P/N 12345726 or
equivalent)
Ashland Pliogrip
7773B-3-minute
Supplied by Crest
Adhesive bonding
Ashland Pliogrip
Industries
Structural bonding
7779B-10-minute
1-800-822-4100
Ashland Pliogrip
fax 1-800-344-4461
7770B-35-minute
GM Goodwrench
SRIM repair kit (GM
P/N 12378523) or
SIA Adhesives, INC.
SIA Adhesives, INC.
SRIM most rigid plastic Cosmetic repair, adhesive SRIM repair kit P/N
customer service 1-330parts
bonding
30208030001 adhesive
374-2468
200ML TUBES P/N
30208020001 50ML
TUBES P/N
30208010001
* Structural adhesive bonding may require the use of a pneumatic applicator,
Kent-Moore 1-800-GMA8-37479-1A, or equivalent, to speed the application of the GM P/N 12345726
TOOLS
epoxy.
REPAIR INSTRUCTIONS

GENERAL PLASTIC REPAIR

WARNING: In order to reduce the risk of personal injury when exposed to toxic fumes
while grinding, cutting, or applying repair material on any type of sheet
molded compound or RIM rigid plastic, observe the following guidelines:
Work in a properly ventilated area

Apply protective cream to any exposed skin
Remove any mixture that comes into contact with skin
Wash skin with cold water to remove glass and resin dust
Use a sander with a vacuum attachment
Follow the repair material manufacturer's instructions
Also, always wear the following:
An approved respirator, or air supplied respirator

Eye protection
Rubber gloves
Earplugs
Protective clothing
The following procedures should be followed when repairing all types of thermoset plastic:
Follow the manufacturer's application and curing recommendations.

Do not intermix systems. Use the supplies and the repair materials from the same manufacturer.
Clean the inner and outer surfaces of the repair area with a soap impregnated scouring pad in order to
remove any dirt or mold release agent.
Clean the area with a wax and grease remover, using only enough of the remover to dampen a cloth.
Allow the panel to dry thoroughly.
Remove the surface finish from the area to be repaired. Adhesives are designed to adhere to the plastic
substrate, not the finish.
Prime a metal surface before applying the repair material.
Inspect the rear side of the work area before making repairs in order to avoid possible damage to wires,
motors, etc.

HOW TO IDENTIFY PLASTIC PARTS

Fig. 1: Identifying SAE Code

Plastic parts can be identified by the SAE code, which is usually found on the rear of the part, and/or by the
characteristics of the plastic. Knowing the type of plastic aids in selecting the proper repair materials and in
selecting the proper repair procedure.
Look for the SAE code stamped into the part.
Code Found
Match the code to those 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 Refinishing
Systems.
No Code Found
WARNING: Do NOT use a plastic burn test to distinguish the type of plastic. The burn

test produces vapors which are harmful.

Perform one or both of the following tests to determine if the part is thermoplastic polyolefin or thermoset nonpolyolefin.
Float Test
1. Cut a shaving of plastic from the back of the part.

The shaving should be free of mold release agents and paint.
2. Place the shaving in a container of water.
Thermoplastic polyolefin floats.
Thermoset non-polyolefin sinks.
Abrasion Test
Sand a spot near the damaged area with Grade 36 Roloc Disc.
Thermoplastic polyolefin material melts or frays when sanded.
Thermoset non-polyolefin material sands cleanly.
Thermoplastic and thermoset plastics can be either rigid or flexible. Thermoplastic plastic parts are best repaired
with a hot iron plastic material-feed welder, but are usually replaced. Thermoset plastic can be repaired with
epoxy or other more rigid 2 package repair material.
For rigid thermoset repair materials, refer to Rigid Plastic Part Repair Materials.
For flexible thermoset repair materials, refer to Flexible Plastic Part Repair Materials.
For general repair instructions, refer to General Plastic Repair.
PLASTIC IDENTIFICATION AND REFINISHING SYSTEMS

Plastic Identification and Refinishing Systems
Identifying
Chemical
Typical Area(s)
Symbol- Old
Composition or
Where Part is
Symbol in ()s Plastic Family Name
Used
Armrest Support,
Console, IPC,
Acrylonitrile /
ABS
Steering Column
Butadiene-Styrene
Bracket / Jacket,
Trim Molding
Acrylonitrile /
Instrument Panel,
ABS + PC
Butadiene-Styrene +
IPC
Polycarbonate
Head Rest Cover,
Instrument Panel
Examples of
Common / Trade
Names
Type of Plastic
ABS, Absafil,
Magnum, Cycolac,
Dyel, Kralastic,
Lustran
Thermoplastic
Bayblend, Cycoloy,
KHA, Pulse
Rigid

Pad, Trim
ABS Vinyl
Molding / Panel
Body Panel,
Ethylene Propylene
EPDM
EPDM, Nordel
Bumper Impact
Diene Monomer
Strip
Ethylene / Vinyl
Head Rest Cover,
EVA (EVAC)
Elvax, Microthane
Acetate
Misc Soft Trim
Headlamp Bezels,
Quarter Panel Nylon, Capron, Zytel,
Rilsan, Minion,
PA
Polyamide
Extensions,
Vydyne, Welland
Exterior Finish
Trim Panels
Exterior Finish
Capron, Minlon,
Trim Panel,
Nylon, Rilsan,
PA, PAG,
Polyamide
Headlamp Bezel,
Vydyne, Wellamid,
PAGG
Quarter Panel
Zytel
Extension
Polymide +
Exterior Trim,
PA + PPE
GTX
Polypheneylene Ether
Fender
Polybutylene,
PBT + TEEE Terephthalate + Ether, Fascia, Rocker
Bexloy M
(PBTP + EEBC)
Ester Block
Panel Molding
Compound
Interior Rigid /
Calibre, Lexan,
PC
Polycarbonate
Hard Trim Panel,
Merlon, Makrolon
Valance Panel
Polycarbonate +
Macroblend, Valox,
PC + PETP
Polybutylene,
Bumper Fascia
Xenoy
Terephthalate
Fuel Tank Shield,
Alathon, Dylan,
Inner Fender Panel,
Foriflex, Hi-fax,
PE
Polyethylene
Interior Trim Panel,
Hosalen, Marlex,
Seat Belt Cover,
Paxon
Spoiler, Valance
Amberol, Bakelite,
Durez, Genal,
PF
Phenol Formaldehyde
Ashtray
Phenolic, Plyophen,
Resinox
ABS / PVC
PP
ABS/Vinyl (Soft)
Polypropylene
Bumper Fascia,
Cowl Panel,
Deflector Panel,
Door Panel, Inner
Fender, Interior
Molding, Kick
Panel, Load Floor,
Radiator Shroud,
Azdel, Daplen,
Escorene, Marlex,
Novolen, Oleflo,
Profax, Tenite
Flexible, Vinyl
Rigid
Flexible
Rigid
Rigid, Thermoset
Rigid, Thermoset
Rigid
Rigid, Thermoset
Flexible, Thermoset
Rigid,
Thermoplastic
Rigid, Thermoset
Flexible,
Thermoplastic

Wheel Cover
Bezels, Chromed
PPE (PPO)
Polyphenylene Ether Plastic, Headlamp Noryl, Oleflo, Prevex
Door, Ornaments
Durathon, Dylan,
Dash Panel, Door
PS
Polystyrene
Lustrex, Polystyrol,
Panel
Styron
Bumper Fascia,
Polyurethane,
Bayflex, Castethane,
Filler Panel,
PUR
Thermoset
Front/Rear Body RIM, RRIM, SRIM
(Unsaturated)
Panel, Pickup Box
Interior Soft Trim,
Geon, Pliovic,
Polyvinyl Chloride
PVC
I/P Skins, Roof
Unichem, Vinoflex,
(Vinyl)
Cover
Vinyl, Vinylite
Center Console,
Foracryl, Lustran,
SAN (SA)
Styrene Acrylonitrite Glove Box Door,
Tyril
Interior Trim Panel
Air Dam, Bumper EPI, EPII, TPO, TPR
TEO (EP, EPM, Ethylene / Propylene
Fascia, Valance
(Thermoplastic
TPO)
(Rubber)
Panel
Rubber)
TPO
Thermal Plastic Oletin
Bumper Covers
TPO
Rigid, Thermoset
Flexible, Soft
Thermoset
Flexible, Vinyl
Rigid
Flexible,
Thermoplastic
Flexible
Thermoplastic
Bumper Fascia,
Gravel Deflector, Estane, Pellethane,
Flexible,
TPU (TPUR)
Soft Filler Panel,
Roylar, Toxin
Thermoplastic
Window Molding
Air Scoop, Air
Spoiler, Fascia
Extension, Hood,
Fiberglass, PremiInstrument
UP
Polyester / Thermoset
glass, Selectron,
Rigid, Thermoset
Housing, Rear
SMC, Vibrinmat
Compartment Lid,
Roof, Ventilation
Grid
For symbols not listed in this table, contact the Society of Automotive Engineers, 400 Commonwealth
Drive, Warrendale, PA 15096-0001.
Polyurethane,
Polyolefin

2013 ACCESSORIES & EQUIPMENT Seat Hardware, Trim, and Upholstery - Cruze

Seat Hardware, Trim, and Upholstery - Cruze
SPECIFICATIONS
Specification
Application
Front Seat Adjuster Bolt
Front Seat Anchor Plate Bolt
Front Seat Backrest Bolt
Front Seat Belt Buckle Bolt
Front Seat Cushion Inner Trim Panel Screw
Front Seat Cushion Outer Trim Panel Screw
Front Seat Mounting Bolt
Rear Seat Back Armrest Hinget Nut
Rear Seat Back Armrest Hinge Bolt
Metric
20 N.m
9 N.m
34.5 N.m
45 N.m
2.5 N.m
2.5 N.m
45 N.m
4.5 N.m
9 N.m
English
15 lb ft
80 lb in
25 lb ft
33 lb ft
22 lb in
22 lb in
33 lb ft
40 lb in
80 lb in
REPAIR INSTRUCTIONS
DRIVER OR PASSENGER SEAT REMOVAL AND INSTALLATION
Removal Procedure
WARNING: When carrying a live inflator module, make sure the bag opening is
pointed away from you. This minimizes the chance of injury in the
case of an accidental deployment. Never carry the inflator module by
the wires. Never carry the inflator module by the connector on the
underside of the module.
Make sure that the bag and trim cover are facing up whenever you
place a live inflator module on any surface. This is necessary to
provide a free space for the bag to expand in the unlikely event of
accidental deployment.
Never rest the steering column assembly on the steering wheel with
the inflator module face down, and the column vertical. This may
WARNING: Refer to SIR Warning .

1. Disable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling .
2. Disconnect the seat belt from the seat belt tensioner. Refer to Front Seat Belt Anchor Plate Tensioner
Replacement
Fig. 1: Front Seat Components

3. Unscrew the 2 bolts (1).
4. Release and disconnect the wiring harness plug (3) front seat.
5. Remove the front seat (4) from the guide in front.

Fig. 2: Front Seat Components

1. Perform the front seat track synchronization. Refer to Front Seat Track Synchronization.
2. Install the front seat (4) to the guide in front.
3. Connect and latch the wiring harness plug (3) front seat.
4. Install the 2 bolts (1) and tighten to 45 N.m (33 lb ft).

5. Connect the seat belt to the seat belt tensioner. Refer to Front Seat Belt Anchor Plate Tensioner
Replacement
FRONT SEAT OUTER RECLINER UPPER FINISH COVER REPLACEMENT

Fig. 3: Front Seat Outer Recliner Upper Finish Cover

Front Seat Outer Recliner Upper Finish Cover Replacement
Callout
Component Name
1
Front Seat Outer Recliner Upper Finish Cover
DRIVER OR PASSENGER SEAT ADJUSTER VERTICAL ACTUATOR HANDLE REPLACEMENT

Fig. 4: Seat Adjuster Vertical Actuator Handle, Bolt & Cap

Driver or Passenger Seat Adjuster Vertical Actuator Handle Replacement
Callout
Component Name
1
Front Seat Adjuster Vertical Actuator Handle Cap Bolt
Front Seat Adjuster Vertical Actuator Handle Bolt
2
3
CAUTION:
Front Seat Adjuster Vertical Actuator Handle
DRIVER OR PASSENGER SEAT ADJUSTER HANDLE REPLACEMENT

Fig. 5: Driver Or Passenger Seat Adjuster Handle

Driver or Passenger Seat Adjuster Handle Replacement
Callout
Component Name
Front Seat Adjuster Handle Bolt
1
2
CAUTION:
Front Seat Adjuster Handle
FRONT SEAT TILT ADJUSTER LEVER REPLACEMENT

Fig. 6: Front Seat Tilt Adjuster Lever

Front Seat Tilt Adjuster Lever Replacement
Callout
Component Name
1
Front Seat Tilt Adjuster Lever Bolt Cap
Front Seat Tilt Adjuster Lever Fastener (Qty: 2)
CAUTION:
Tighten
20 N.m (15 lb ft)
Front Seat Tilt Adjuster Lever
Procedure
Use a small flat-bladed tool to release the front seat tilt adjuster lever
bolt cap.
FRONT SEAT TRACK SYNCHRONIZATION

Fig. 7: Inboard Track Assembly And Outboard Track Assembly

The fore/aft manual adjuster is composed of an inboard track assembly (5), and outboard track (4) assembly,
and an adjuster handle (1). Each track assembly is made of an upper track (2) and a lower track (3). Both tracks
need to be aligned prior to installing in the vehicle.
To align the front seat tracks, do the following:
1. Remove the seat from the vehicle.

Fig. 8: Seat
2. Put the seat (1) upside down on a table, or on the floor as shown.
3. Unlock both tracks by pushing the adjuster handle down.
4. While pushing the adjuster handle down, move each lower track rearward until contact between the end
travel stops.
5. Release the adjuster handle.
6. Move each lower track forward until an audible noise is heard, indicating that the track is fully locked.
7. At this stage both manual tracks are aligned.

Fig. 9: Identifying Overhang Measurement

8. Measure the overhang from the front edge of the plastic end cap (1) on the lower track to the front edge of
the upper track (2). Measurement for each track must be 138 mm or as close as possible.
9. Install the seat in the vehicle without touching the adjuster handle. Then tighten the rear bolts prior to any
track adjustment.
10. While sitting in the seat, cycle the tracks fore/aft and lock the tracks at different positions. Check to see
whether the tracks are aligned.

Fig. 10: Inboard And Outboard Tracks

11. Visually inspect the tracks, adjust the upper tracks flush with the front of the lower tracks. Check that the
configuration in locked position is identical for both inboard (1) and outboard tracks (2).
DRIVER OR PASSENGER SEAT HEAD RESTRAINT REPLACEMENT

Fig. 11: Driver Or Passenger Seat Head Restraint

Driver or Passenger Seat Head Restraint Replacement
Callout
Component Name
Front Seat Head Restraint
Procedure
1
1. Raise the headrest to the full upward position.

2. Push both flush button on the head restraint guide.
3. Remove the head restraint by pulling up on the restraint.
DRIVER OR PASSENGER SEAT HEAD RESTRAINT GUIDE REPLACEMENT

Fig. 12: Driver Or Passenger Seat Head Restraint Guide

Driver or Passenger Seat Head Restraint Guide Replacement
Callout
Component Name
Remove front seat head restraint. Refer to Driver or Passenger Seat Head Restraint Replacement.
Front Seat Head Restraint Guide
1
Procedure
Use a flat-bladed tool to release guide for removal.
DRIVER OR PASSENGER SEAT CUSHION CLOSEOUT COVER REPLACEMENT

Fig. 13: Driver or Passenger Seat Outer Adjuster Finish Cover

Driver or Passenger Seat Cushion Closeout Cover Replacement
Callout
Component Name
1
Drive or Passenger Seat Cushion Closeout Cover
FRONT SEAT CUSHION OUTER TRIM PANEL REPLACEMENT

Fig. 14: Front Seat Cushion Outer Trim Panel

Front Seat Cushion Outer Trim Panel Replacement
Callout
Component Name
1. Remove the front seat. Refer to Driver or Passenger Seat Removal and Installation
2. Remove the front seat adjuster vertical actuator, if equipped. Refer to Driver or Passenger Seat
Adjuster Vertical Actuator Handle Replacement.
3. Remove the front seat tilt adjuster lever, if equipped Front Seat Tilt Adjuster Lever
Replacement.
4. Remove the front seat recliner handle. Refer to Front Seat Back Recliner Handle Replacement
Front Seat Cushion Outer Trim Panel Screw (Qty: 3)
CAUTION:
Tighten
2.5 N.m (22 lb in)
2
Front Seat Cushion Outer Trim Panel

Procedure
Transfer driver seat adjuster switch, if equipped. Refer to Driver

Seat Adjuster Switch Replacement .

FRONT SEAT CUSHION INNER TRIM PANEL REPLACEMENT
Fig. 15: Front Seat Cushion Inner Trim Panel

Front Seat Cushion Inner Trim Panel Replacement
Callout
Component Name
Remove the front seat. Refer to Driver or Passenger Seat Removal and Installation.
Front Seat Cushion Inner Trim Panel Screw (Qty: 2)
CAUTION:
Tighten
2.5 N.m (22 lb in)
Front Seat Cushion Inner Trim Panel
FRONT SEAT CUSHION COVER AND PAD REPLACEMENT

Removal Procedure

WARNING: Replace the passenger presence system as a complete assembly to

prevent possible injury to the occupant. The bladder, the pressure sensor,
the seat cushion, and the control module are assembled and calibrated as
a unit. Using only some of the components in the service kit will cause
the passenger presence system to operate improperly.
WARNING: To avoid personal injuries, re-zero the passenger presence system
whenever you remove or replace the seat cushion or trim. Failure to do so
may cause the system to malfunction.
1.
2.
3.
4.
Remove driver or passenger seat. Refer to Driver or Passenger Seat Removal and Installation.
Remove front seat recliner handle. Refer to Front Seat Back Recliner Handle Replacement.
Remove seat cushion inner trim panel. Refer to Front Seat Cushion Inner Trim Panel Replacement.
Remove seat cushion outer trim panel. Refer to Front Seat Cushion Outer Trim Panel Replacement.

Fig. 16: Wiring Harness Plug

5.
6.
7.
8.
9.
Detach cushion cover from backrest below.

Disconnect wiring harness plug (1), if equipped.
Release the seat wiring harness as required from the seat bottom.
Remove front seat backrest 4 screw (2).
Remove backrest.

Fig. 17: Cushion Cover, Seat Frame And Pad

10. Detach cushion cover (1) from seat frame (3) all the way round.
11. Remove cushion cover (1) with pad (2) from frame (3).
12. Remove cushion cover (1) from pad (2).


1. Install cushion cover (1) to pad (2).
2. Install cushion cover (1) with pad (2) to frame (3).
3. Attach cushion cover (1) from seat frame (3) all the way round.


4. Install backrest.
5.
6.
7.
8.
9.
10.
11.
Install 4 screws (2) and tighten to 35 N.m (26 lb ft).

Connect the wiring harness plug (1), if equipped.
Install the seat wiring harness as required to the seat bottom.
Attach cushion cover to backrest below.
Install seat cushion outer trim panel. Refer to Front Seat Cushion Outer Trim Panel Replacement.
Install seat cushion inner trim panel. Refer to Front Seat Cushion Inner Trim Panel Replacement.
Install front seat recliner handle. Refer to Front Seat Back Recliner Handle Replacement.

12. Install driver or passenger seat. Refer to Driver or Passenger Seat Removal and Installation.
13. After working on the passenger seat, program or re-zero the inflatable restraint passenger presence system
after repairs or replacement. Refer to Control Module References .
DRIVER OR PASSENGER SEAT CUSHION PAD WIRE REPLACEMENT
Fig. 20: Driver Or Passenger Seat Cushion Pad Wire

Driver or Passenger Seat Cushion Pad Wire Replacement
Callout
Component Name
Remove the front seat cushion cover and pad. Refer to Front Seat Cushion Cover and Pad
Replacement.
1
Front Seat Cushion Pad Wire.
DRIVER OR PASSENGER SEAT BACK COVER AND PAD REPLACEMENT
Removal Procedure
WARNING: Replace the passenger presence system as a complete assembly to

prevent possible injury to the occupant. The bladder, the pressure sensor,
the seat cushion, and the control module are assembled and calibrated as
a unit. Using only some of the components in the service kit will cause
the passenger presence system to operate improperly.
WARNING: Do not repair or replace the seat stitching or seams in the seat back trim
cover with an internal mounted seat side airbag module. Replace the
complete seat back trim cover from the OEM. Non-OEM seat stitching may
cause improper airbag deployment which could result in personal injury.
1. Remove driver or passenger seat. Refer to Driver or Passenger Seat Removal and Installation.
2. Remove the seat adjuster handle, if equipped. Refer to Driver or Passenger Seat Adjuster Handle
Replacement
3. Remove front seat recliner handle. Refer to Front Seat Back Recliner Handle Replacement.
4. Remove seat cushion inner trim panel. Refer to Front Seat Cushion Inner Trim Panel Replacement.
5. Remove seat cushion outer trim panel. Refer to Front Seat Cushion Outer Trim Panel Replacement.
6. Remove front seat head restraint guide. Refer to Driver or Passenger Seat Head Restraint Guide
Replacement.


7.
8.
9.
10.
Disengage the trim clips and bungee straps from the seat cushion springs beneath the seat cushion.
Release and disconnect wiring harness plug (1), if equipped.
Remove the 4 front seat back fasteners (2).
Remove the seat back assembly from the cushion assembly and place on a protected surface.

Fig. 22: Cushion Cover, Pad And Frame

CAUTION: Do not pull up on the rear portion of the seat back cover without
releasing the upper channel retainer. This retainer secures the seat
back cover to the seat back frame. Failure to release the upper
channel retainer prior to seat back cover removal will damage the
seat back cover.
11. Loosen the front seat back cover (1) from the frame (3).
Disengage the J-channel retainer at the bottom of the seat back cover and separate the front and rear
portions of the seat back cover.
Open the 2 zippers on the backside of the seat back cover.
Disengage the visible seat back cover retainers.

Fig. 23: Front Seat Back Cover Upper Retainer

12. Remove the front seat back cover upper retainer (1) from the frame.
Position the front portion of the seat back cover forward on the seat back frame.
Lift the front portion of the seat back cover and seat back pad enough to gain access to the upper
retainer.
Disengage the upper retainer from the seat back frame.


13. Remove the front seat back cover (1) from the pad (2).
Remove the seat back cover (1) from velcro on the vertical trench attachments.
Separate the cross-seat retainer on lower tie downs.
Starting at the rear, pull the trim cover up over the top of the seat.
14. Remove the seat side airbag. Refer to Front Seat Outboard Seat Back Airbag Replacement .
15. Remove the front seat back cushion pad (2).
16. Remove the front seat back cushion heater, if equipped. Refer to Driver or Passenger Seat Back
Cushion Heater Replacement .
1. Install the front seat back cushion heater to the new cushion pad, if equipped. Refer to Driver or
Passenger Seat Back Cushion Heater Replacement .


2. Install the seat back cover (1) to the seat back pad (2).
Install the seat back cover (1) onto velcro on vertical trench attachments.
Attach the cross-seat retainer on lower tie downs.
Position the seat back cover (1) and pad (2) to the seat back frame (3).
3. Install the seat side airbag. Refer to Front Seat Outboard Seat Back Airbag Replacement .
4. Secure the seat back cover (1) to seat back frame (3).
Install the seat back cover upper retainer to the seat back frame.
Position the front portion of the seat back cover around the bottom of the seat back frame.
Secure the seat back cover retainers all the way around.
Close the 2 zippers on the backside of the seat back cover.
Connect the J-retainer to secure the front and rear portions of the seat back cover.


5. Install the seat back to the seat cushion.
6.
7.
8.
9.
10.
Install the front seat back bolts (2) and tighten to 35 N.m (26 lb ft).
Connect the wiring harness plug (1), if equipped.
Install the seat wiring harness as required to the seat cushion frame.
Attach cushion cover below the seat back.
Install front seat head restraint guide. Refer to Driver or Passenger Seat Head Restraint Guide
Replacement.
11. Install seat cushion outer trim panel. Refer to Front Seat Cushion Outer Trim Panel Replacement.

12. Install seat cushion inner trim panel. Refer to Front Seat Cushion Inner Trim Panel Replacement.
13. Install front seat recliner handle. Refer to Front Seat Back Recliner Handle Replacement.
14. Install seat adjuster handle, if equipped. Refer to Driver or Passenger Seat Adjuster Handle
Replacement.
15. Install driver or passenger seat. Refer to Driver or Passenger Seat Removal and Installation.
FRONT SEAT BACK RECLINER HANDLE REPLACEMENT
Fig. 27: Driver Or Passenger Seat Recliner Handle

Front Seat Back Recliner Handle Replacement
Callout
Component Name
Front Seat Recliner Handle Panel
1
Procedure
Use flat blade to remove panel.
Front Seat Recliner Handle
Procedure
2
Use flat blade to remove handle.
DRIVER SEAT FRAME REPLACEMENT
Removal Procedure


1. Remove front seat cushion cover (1) and pad (2) from frame (3). Refer to Front Seat Cushion Cover
and Pad Replacement

Fig. 29: Driver Seat Frame Wire Harness

2. Remove the wire harness (1), if equipped.


3. Remove front seat back cushion cover (1) and pad (2) from frame (3). Refer to Driver or Passenger Seat
Back Cover and Pad Replacement

Fig. 31: Inner Seat Frame Cover

4. Remove inner seat frame cover (1).
5. Remove the wire harness, if equipped.


1. Install the wire harness, if equipped.
2. Install inner seat frame cover (1).


3. Install front seat back cushion cover (1) and pad (2) to frame (3). Refer to Driver or Passenger Seat


4. Install the wire harness (1), if equipped.


5. Install front seat cushion cover (1) and pad (2) to frame (3). Refer to Front Seat Cushion Cover and
Pad Replacement
PASSENGER SEAT FRAME REPLACEMENT
Removal Procedure


1. Remove front seat cushion cover (1) and pad (2) from frame (3). Refer to Front Seat Cushion Cover
and Pad Replacement


2. Remove the wire harness (1), if equipped.


3. Remove front seat back cushion cover (1) and pad (2) from frame (3). Refer to Driver or Passenger Seat


4. Remove inner seat frame cover (1).
5. Remove the wire harness, if equipped.


1. Install the wire harness, if equipped.
2. Install inner seat frame cover (1).


3. Install front seat back cushion cover (1) and pad (2) to frame (3). Refer to Driver or Passenger Seat


4. Install the wire harness (1), if equipped.


5. Install front seat cushion cover (1) and pad (2) to frame (3). Refer to Front Seat Cushion Cover and
Pad Replacement
REAR SEAT REMOVAL AND INSTALLATION (40 PERCENT SEAT)

Fig. 44: Rear Seat (40 Percent Seat)

Rear Seat Removal and Installation (40 Percent Seat)
Callout
Component Name
Remove the rear seat cushion. Refer to Rear Seat Cushion Removal and Installation.
Rear Seat Back - Left Side
1
Procedure
1. Fold down rear seat backrest.
2. Remove rear seat backrest from both side guide.
REAR SEAT REMOVAL AND INSTALLATION (60 PERCENT SEAT)

Fig. 45: Rear Seat (60 Percent Seat)

Rear Seat Removal and Installation (60 Percent Seat)
Callout
Component Name
1. Remove the right rear seat back cushion bolster. Refer to Rear Seat Back Bolster Replacement.
2. Remove the rear seat belt buckle. Refer to Rear Seat Buckle Side Belt Replacement .
Rear Seat Back- Right Side
Procedure
1
1. Fold down the rear seat back.

2. Lift up on the outer side of the seat back to disengage from the
outer guide.
3. Pull the seat back outboard to disengage from the inner guide.
REAR SEAT ARMREST REPLACEMENT

Fig. 46: Rear Seat Armrest

Rear Seat Armrest Replacement
Callout
Component Name
Remove the rear seat back - right side. Refer to Rear Seat Removal and Installation (40 Percent Seat),
Rear Seat Removal and Installation (60 Percent Seat).
Rear Seat Armrest Hinge Cover
Procedure
1
Release four tabs and carefully slide the cover forward.
Rear Seat Armrest Hinge Nut
CAUTION:
Tighten
4.5 N.m (40 lb in)
Rear Seat Armrest Hinge Bolt
Tighten
9 N.m (80 lb in)
Rear Seat Armrest
Procedure
Position the stud so that it could pass the armrest bracket.

REAR SEAT HEAD RESTRAINT REPLACEMENT
Fig. 47: Rear Seat Head Restraint

Rear Seat Head Restraint Replacement
Callout
Component Name
Rear Seat Head Restraint
1
Procedure
Push the head restraint guide button and remove the head restraint.
REAR SEAT HEAD RESTRAINT GUIDE REPLACEMENT

Fig. 48: Rear Seat Head Restraint Guide

Rear Seat Head Restraint Guide Replacement
Callout
Component Name
Remove the rear seat head restraint. Refer to Rear Seat Head Restraint Replacement.
Rear Seat Head Restraint Guide (Qty: 2)
1
Procedure
Unclip the rear seat head restraint guide with a suitable device.
REAR SEAT BACK BOLSTER REPLACEMENT

Fig. 49: Rear Seat Back Cushion Bolster

Rear Seat Back Bolster Replacement
Callout
Component Name
Rear Seat Back Cushion Bolster
WARNING:
Refer to SIR Warning .
WARNING:
Do not repair or replace the seat stitching or seams in the seat back trim
cover with an internal mounted seat side airbag module. Replace the
complete seat back trim cover from the OEM. Non-OEM seat stitching
may cause improper airbag deployment which could result in personal
injury.
Procedure
1. Pull bolster very hard from top to disengage retainers.
2. Replace all damaged retainers and tap back holes in body sheet metal,
if necessary.

4. Remove rear seat back cushion bolster.

5. Remove the rear seat side inflatable module, if equipped. Refer to
Rear Seat Outboard Seat Back Airbag Replacement .
REAR SEAT BACK SIDE CUSHION COVER REPLACEMENT
Fig. 50: Rear Seat Back Side Cushion Cover

Rear Seat Back Side Cushion Cover Replacement
Callout
Component Name
WARNING:
Do not repair or replace the seat stitching or seams in the seat back trim cover with an internal
mounted seat side airbag module. Replace the complete seat back trim cover from the OEM. NonOEM seat stitching may cause improper airbag deployment which could result in personal injury.
Remove the rear seat side inflatable restraint module. Refer to Rear Seat Outboard Seat Back Airbag
Replacement .
Rear Seat Back Side Cushion Cover
Procedure

1.
2.
3.
4.
Loosen the rear seat back side cushion cover.

Remove the hog rings.
Remove the rear seat back side cushion cover.
Attach the rear seat back side cushion cover and install the hog
rings.
5. Install the rear seat back side cushion cover.
REAR SEAT BACK CUSHION PIVOT SUPPORT REPLACEMENT
Fig. 51: Rear Seat Back Cushion Pivot Support & Components
Rear Seat Back Cushion Pivot Support Replacement
Callout
Component Name
Remove the rear seat back. Refer to Rear Seat Removal and Installation (40 Percent Seat), Rear Seat
Removal and Installation (60 Percent Seat).
Rear Seat Back Outer Pivot Bolt
1
CAUTION:

2
3
4
Tighten
23 N.m (17 lb ft)
Rear Seat Back Cushion Pivot Bolt Bushing
Rear Seat Back Cushion Outer Pivot Bolt Spring
Rear Seat Back Cushion Pivot Support
REAR SEAT CUSHION COVER AND PAD REPLACEMENT
Fig. 52: Identifying Rear Seat Cushion Cover & Pad

Rear Seat Cushion Cover and Pad Replacement
Callout
Component Name
Remove the rear seat cushion. Refer to Rear Seat Cushion Removal and Installation.
Rear Seat Cushion Cover
Procedure
1
1. Remove the hog rings that secure the rear seat cushion cover to
the pad.
2. Remove seat cushion cover from Velcro.
Rear Seat Cushion Pad

REAR SEAT CUSHION REMOVAL AND INSTALLATION
Fig. 53: Rear Seat Cushion

Rear Seat Cushion Removal and Installation
Callout
Rear Seat Cushion
Component Name
Procedure
1. Pull up on the front of the seat cushion to disengage the retainers,

and lift out of the vehicle. A high amount of upward force will be
required.
2. After removal of the retainers, the sheet metal will be slightly
deformed outward. Use a small hammer and pound the sheet
metal back to its original, flat appearance.
3. When re-installing the seat, the hooks at the rear of the seat must
go over and behind the mushroom clips at the rear of the floor.
4. When installing new plastic retainers on the front of the seat,
ONLY seat the retainer to the first click, otherwise the insertion
force into the sheet metal will be greatly increased.
Seat Cushion Retainer (Qty: 2)
REAR SEAT BACK LATCH REPLACEMENT (40 PERCENT SEAT)

Fig. 54: Rear Seat Back Latch (40 Percent Seat)

Rear Seat Back Latch Replacement (40 Percent Seat)
Callout
Component Name
1. Remove the rear seat - left side. Refer to Rear Seat Removal and Installation (40 Percent Seat),
Rear Seat Removal and Installation (60 Percent Seat).
2. Remove the rear seat back cushion cover and pad - left side. Refer to Rear Seat Back Cushion
Cover and Pad Replacement - Left Side.
Rear Seat Back Latch Bolt (Qty: 2)
CAUTION:
Tighten
45 N.m (33 lb ft)
Rear Seat Back Latch
REAR SEAT BACK LATCH REPLACEMENT (60 PERCENT SEAT)

Fig. 55: Rear Seat Back Latch (60 Percent Seat)

Rear Seat Back Latch Replacement (60 Percent Seat)
Callout
Component Name
1. Remove the rear seat - right side. Refer to Rear Seat Removal and Installation (40 Percent
Seat), Rear Seat Removal and Installation (60 Percent Seat).
2. Remove the rear seat armrest. Refer to Rear Seat Armrest Replacement.
3. Remove the rear seat back cushion cover and pad - right side. Refer to Rear Seat Back Cushion
Cover and Pad Replacement - Right Side.
Rear Seat Back Latch Bolt (Qty: 2)
CAUTION:
Tighten
45 N.m (33 lb ft)
Rear Seat Back Latch
REAR SEAT BELT OPENING COVER REPLACEMENT

Fig. 56: Rear Seat Shoulder Belt Opening Cover

Rear Seat Belt Opening Cover Replacement
Callout
Component Name
1
Rear Seat Shoulder Belt Opening Cover
REAR SEAT BACK CUSHION PANEL REPLACEMENT (40 PERCENT SEAT)

Fig. 57: Rear Seat Back Cushion Panel, Cover And Pad (40 Percent Seat)
Rear Seat Back Cushion Panel Replacement (40 Percent Seat)
Callout
Component Name
2. Remove the rear seat back cushion latch release knob bezel. Refer to Rear Seat Back Cushion
Latch Release Knob Bezel Replacement (60 Percent Seat), Rear Seat Back Cushion Latch
Release Knob Bezel Replacement (40 Percent Seat).
3. Remove the rear seat head restraint guide. Refer to Rear Seat Head Restraint Guide
Replacement.
4. Remove the rear seat back cushion pivot support. Refer to Rear Seat Back Cushion Pivot
Support Replacement.
1
Rear Seat Back Cushion Cover and Pad
2
Rear Seat Back Cushion Panel
REAR SEAT BACK CUSHION PANEL REPLACEMENT (60 PERCENT SEAT)

Fig. 58: Rear Seat Back Cushion Panel, Cover And Pad (60 Percent Seat)
Rear Seat Back Cushion Panel Replacement (60 Percent Seat)
Callout
Component Name
2. Remove the rear seat back cushion latch release knob bezel. Refer to Rear Seat Back Cushion
Latch Release Knob Bezel Replacement (60 Percent Seat), Rear Seat Back Cushion Latch
Release Knob Bezel Replacement (40 Percent Seat).
3. Remove the rear seat shoulder belt opening cover. Refer to Rear Seat Belt Opening Cover
Replacement.
4. Remove the rear seat head restraint guides. Refer to Rear Seat Head Restraint Guide
Replacement.
1
Rear Seat Back Cushion Cover and Pad
2
Rear Seat Back Cushion Panel
REAR SEAT BACK CUSHION COVER AND PAD REPLACEMENT - LEFT SIDE

Fig. 59: Rear Seat Back Cushion Cover And Pad - Left Side
Rear Seat Back Cushion Cover and Pad Replacement - Left Side
Callout
Component Name
Remove the rear seat - left side. Refer to Rear Seat Removal and Installation (40 Percent Seat), Rear
Seat Removal and Installation (60 Percent Seat).
Rear Seat Back Cushion Cover
1
Procedure
1. Remove the staples from the seat back cover.
2. Remove seat back cushion cover from Velcro.
Rear Seat Back Cushion Pad
REAR SEAT BACK CUSHION COVER AND PAD REPLACEMENT - RIGHT SIDE

Fig. 60: Rear Seat Back Cushion Cover And Pad - Right Side
Rear Seat Back Cushion Cover and Pad Replacement - Right Side
Callout
Component Name
1. Remove the rear seat back - right side. Refer to Rear Seat Removal and Installation (40 Percent
2. Remove the rear seat armrest. Refer to Rear Seat Armrest Replacement.
3. Remove the rear seat belt opening cover. Refer to Rear Seat Belt Opening Cover Replacement
4. Remove the rear seat head restraint guides. Refer to Rear Seat Head Restraint Guide
Replacement
5. Remove the right rear seat back cushion latch release knob bezel. Refer to Rear Seat Back
Cushion Latch Release Knob Bezel Replacement (60 Percent Seat), Rear Seat Back Cushion
Latch Release Knob Bezel Replacement (40 Percent Seat)
6. Remove the rear seat back cushion pivot support. Refer to Rear Seat Back Cushion Pivot
Support Replacement
Rear Seat Back Cushion Cover
1
Procedure
1. Remove the J-channels from the seat back cover.
2. Remove seat back cushion cover from Velcro.

Rear Seat Back Cushion Pad
REAR SEAT BACK CUSHION HINGE REPLACEMENT
Fig. 61: Rear Seat Back Cushion Hinge & Fasteners

Rear Seat Back Cushion Hinge Replacement
Callout
Component Name
Remove the rear seat back (60 percent seat). Refer to Rear Seat Removal and Installation (40 Percent
Rear Seat Back Cushion Hinge Fastener (Qty: 3)
CAUTION:
Tighten
45 N.m (33 lb ft)
Rear Seat Back Cushion Hinge
Procedure
Detach the rear seat back cushion hinge from the guide pin.
REAR SEAT BACK CUSHION LATCH RELEASE KNOB BEZEL REPLACEMENT (40 PERCENT

SEAT)
Fig. 62: Rear Seat Back Cushion Latch Release Knob Bezel (40 Percent Seat)
Rear Seat Back Cushion Latch Release Knob Bezel Replacement (40 Percent Seat)
Callout
Component Name
Rear Seat Back Cushion Latch Release Knob Bezel
Procedure
1
Release the rear seat back cushion latch release knob bezel using a
commercial screwdriver.
REAR SEAT BACK CUSHION LATCH RELEASE KNOB BEZEL REPLACEMENT (60 PERCENT
SEAT)

Fig. 63: Rear Seat Back Cushion Latch Release Knob Bezel (60 Percent Seat)
Rear Seat Back Cushion Latch Release Knob Bezel Replacement (60 Percent Seat)
Callout
Component Name
Rear Seat Back Cushion Latch Release Knob Bezel
Procedure
1
Release the rear seat back cushion latch release knob bezel using a
commercial screwdriver.
THREAD REPAIR
General purpose thread repair kits are available commercially.

Fig. 64: Drilling & Tapping Damaged Threads

NOTE:
Refer to the thread repair kit manufacturer's instructions regarding the size of
the drill and which tap to use.
Always avoid any buildup of chips. Back out the tap every few turns and
remove the chips.
1.
2.
3.
4.
5.
6.
7.
Determine the size, the pitch, and the depth of the damaged thread.
Adjust the stop collars on the cutting tool as needed. Tap the stop collars to the required depth.
Drill out the damaged thread.
Remove the chips.
Apply clean engine oil to the top thread.
Use the tap in order to cut new thread.
Clean the thread.

Fig. 65: View Of Thread Insert

NOTE:
The thread insert should be flush to 1 turn below the surface.
8. Screw the thread insert onto the mandrel of the thread insert installer. Engage the tang of the thread insert
onto the end of the mandrel.
9. Lubricate the thread insert with clean engine oil - except when installing in aluminum - and install the
thread insert.
10. If the tang of the thread insert does not break off when backing out the thread insert installer, break off the
tang using a drift punch.

2013 ACCESSORIES & EQUIPMENT Squeaks and Rattles - Cruze

Squeaks and Rattles - Cruze

SQUEAKS AND RATTLES
NOTE:
Squeaks and rattles are caused by improperly controlled relative motion

between vehicle components. There are 4 ways to prevent squeaks and
rattles.
Attach the component that squeaks or rattles securely.

Separate the components that squeak or rattle to prevent contact.
Insulate the components that squeak or rattle.
Insulate low uniform friction surfaces to eliminate stickslip motion.
SYMPTOMS - SQUEAKS AND RATTLES

Rattle Coming From the Side Rail
Checks
Action
Check the brake lines.
Rattle Under Vehicle at Higher RPM

Checks
Check for heat shield contact with the
underbody.
Action
Raise the vehicle and perform a visual inspection.

Bend the heat shield slightly to gain clearance from the
underbody.
Thump From Rear of Vehicle on Bumps

Checks
Action
Check for a properly secured spare tire or

tire repair kit in the rear compartment.
Tap lightly on the brake lines and listen for a rattle.

Install plastic tie straps to secure the brake lines
tightly together.
Open the rear compartment and perform a visual

inspection of the spare tire or the tire repair kit and the
tools.
Tightly secure the spare tire or the tire repair kit and
all tools.
Perform a road test to verify that the noise is
eliminated.
Glass Knock Coming From the Rear of the Vehicle When Driving Over Bumps

Checks
Check for an out-of-adjustment
hatchback latch.
Action
Test drive the vehicle in order to verify this condition.

Loosen the latch nuts and adjust the latch downward.
Rattle Coming From Door

Checks
Check for rattling electrical connectors
inside the door trim panel.
Action
Tap on the trim panel and listen for a rattle.

Remove the trim panel and wrap foam padding around
the connectors as required.
Squeak When Operating Doors

Checks
Action
Check for a lack of lubrication of the door

hinge pins.
Operate the doors and listen for squeaks.

Lubricate the door hinge pins with light oil and coat
with lithium grease.
Squeak Coming From Console When Shifting Manual Transmission Condition Occurs In Cold Weather
with a Cold Engine
Checks
Action
Check the manual transaxle control lever

lower boot.
Move the control lever between gears and listen for

squeaks.
Remove the floor console and replace the lower shift
boot or apply talcum powder to the lower shift boot.
Buzz From the Left Side of Instrument Panel

Checks
Action
Check for vibration of the fuse box cover

against the instrument panel side trim.
Tap on the cover with a finger and listen for a buzz.

Apply felt pads to the side trim where the cover makes
contact.
Squeak Coming From Instrument Cluster Trim Plate

Checks
Check for rubbing the cluster trim plate
on the instrument panel.
Action
Test drive the vehicle in order to verify this condition.

Remove the instrument cluster trim plate and install felt
tape to the edges.

SPECIAL TOOLS
Illustration

CH 39570
J 39570
Chassis Ear
GE 41416
J 41416
Ultrasonic Leak Detector

2013 ACCESSORIES & EQUIPMENT Sunroof - Cruze

Sunroof - Cruze
SPECIFICATIONS
Specification
Application
Sunroof Module Bolt
Sunroof Module Bracket Screw
Sunroof Sunshade Bolt
Sunroof Window Motor Bolt
Sunroof Window Screw

SUNROOF WIRING SCHEMATICS
CF5
Metric
9 N.m
9 N.m
9 N.m
4 N.m
4 N.m
English
80 lb in
80 lb in
80 lb in
36 lb in
36 lb in

Fig. 1: Sunroof (CF5) Wiring Schematics

Callout
128
140
CAV_1
CAV_70
CONN_X2
5027
5027_BU/VT
CAV_4
CAV 5
3030
3030_BK/BN
CAV_1
128_BK/GY
CAV_1
CAV_3
Component Name
Sunroof Switch Low
Reference
1
70
X2
Sunroof Switch Data (1)
5027 BU/VT
4
5
Sunroof Vent Switch Low
Reference
3030 BK/BN
1
128 BK/GY
1
3

3031
3031_WH/GN
CAV_4
CAV_6
2050
2050_BK
CAV_2
6132
6132_GN/BN
CAV_4
140_RD/WH
140_RD/WH
CAV_20
F34UA
X211
S72
X50A
K61
A90
S88
COMPONENT LOCATOR
SUNROOF COMPONENT VIEWS
Sunroof
Sunroof Vent Switch Signal

3031 WH/GN
4
6
Ground
2050 BK
2
Bus 1
6132 GN/BN
4
140 RD/WH
140 RD/WH
20
F34UA 25A
X211
Data Communication
Schematics
(CF5)
(CF5)
Logic
(CF5)

Fig. 2: Sunroof Components

Callout
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Component Name
Sunroof Frame
Sunroof Sunshade
Sunroof Window
Sunroof Window Seal
Sunroof Housing Rear Drain Hose
Sunroof Housing Drain Gutter
Sunroof Frame Bolts
Sunroof Window Guide
Sunroof Air Deflector Cover
Sunroof Window Motor
Sunroof Window Seal
Sunroof Air Deflector
Sunroof Housing Front Drain Hose
Sunroof Window Bolts



DTC
DTC B3664
DTC B3697
DTC B369C
Description
DTC B3664 02 Sunroof Position Select Switch
High Signal Circuit Short to Ground
High Signal Circuit High Voltage/Open
High Signal Circuit Protection Time-Out
DTC B3697 00 Sunroof Actuator Malfunction
DTC B3697 39 Sunroof Actuator Internal
Malfunction
DTC B3697 42 Sunroof Actuator Calibration Not
Programmed
DTC B3697 4B Sunroof Actuator Calibration Not
Learned
DTC B369C 02 Sunroof Tilt Position Select Switch
Circuit Protection Time-Out
DTC B3664
DTC Descriptors
DTC B3664 02
Sunroof Position Select Switch High Signal Circuit Short to Ground
DTC B3664 05
Sunroof Position Select Switch High Signal Circuit High Voltage/Open
DTC B3664 59
Sunroof Position Select Switch High Signal Circuit Protection Time-Out

Short to
Ground
Signal
B3664 02
Low Reference
1. Power Sunroof Slide Malfunction
Circuit
Open/High
Resistance
B3664 05
1
Short to
Voltage
B3664 05
1
Signal Performance
-
The sunroof switch is connected directly to the sunroof control module and provides detent positions for open,
express open, off, close, and express close. The sunroof switch completes the circuit between two signals
proved by the sunroof control module, a reference ground input and a pull-up voltage provided by an analog to
digital switch input. The sunroof switch places a different resistor ladder network in the circuit depending on the
function selected.
The ignition is ON.

B3664 02
The sunroof control module has detected and reported via serial data that the sunroof switch signal is shorted to
ground.
B3664 05
The sunroof control module has detected and reported via serial data that the sunroof switch signal is open or
shorted to voltage.
B3664 59
The sunroof control module has detected and reported via serial data that the sunroof switch has been in the
same active position for 20 seconds after the glass has stopped moving in the requested direction due to
reaching the end of the allowable motion.
DTC B3664 is stored in the body control module (BCM) memory.

The BCM no longer detects a malfunction in the sunroof switch signal circuit.
Schematic Reference

Sunroof Schematics
Sunroof Description and Operation
Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference

1. Ignition OFF and all vehicle systems OFF, disconnect the harness connector at the S72 Sunroof Switch. It
1. Ignition OFF, disconnect the harness connector at the K61 Sunroof Control Module.
If less than 2 ohms, test or replace the K61 Sunroof Control Module.
3. Ignition ON.
4. Verify the scan tool Slide Switch parameter is Short to Battery.
If not Short to Battery
1. Ignition Off, disconnect the harness connector at the K61 Sunroof Control Module.
If infinite resistance, replace the K61 Sunroof Control Module.
If Short to Battery
terminal 1.

6. Verify the scan tool Slide Switch parameter is Short to Ground.

If not Short to Ground
If less than 1 V
If less than 2 ohms, replace the K61 Sunroof Control Module.
If Short to Ground
7. All OK.
Component Testing
Sunroof Switch
Static Test
1. Ignition OFF, disconnect the harness connector at the S72 Sunroof Switch.
2. Test for 3.3-4.0k ohms between the control terminal 4 and the low reference terminal 1.
If not between 3.3-4.0k ohms
Replace the S72 Sunroof Switch.
If between 3.3-4.0k ohms
3. Test for 390-480 ohms between the control terminal 4 and the low reference terminal 1 while pressing the
open switch.

express open switch.

5. Test for 1.6-2.0k ohms between the control terminal 4 and the low reference terminal 1 while pressing the
close switch.


6. Test for 830-1030 ohms between the control terminal 4 and the low reference terminal 1 while pressing
the express close switch.

7. All OK
Repair Instructions
Sunroof Switch Replacement

Sunroof Module Assembly Replacement
Control Module References for sunroof control module replacement, programming and setup
DTC B3697
DTC Descriptors
DTC B3697 00
Sunroof Actuator Malfunction
DTC B3697 39
Sunroof Actuator Internal Malfunction
DTC B3697 42
Sunroof Actuator Calibration Not Programmed
DTC B3697 4B
Sunroof Actuator Calibration Not Learned

The sunroof glass is controlled by its own integrated motor/controller containing the necessary electronics,
motor, hall effect position sensors, as well as the interface to the driver control switches. The motor/controller is
capable of controlling motion based on control switch activation and serial data message commands from the
body control module (BCM).
The ignition is ON.

B3697 00
The sunroof module has detected and reported via serial data that the sunroof actuator has a malfunction.
B3697 39
The sunroof module has detected and reported via serial data that the sunroof actuator has a internal
malfunction.
B3697 42
The sunroof module has detected and reported via serial data that the sunroof actuator is not programmed.
B3697 4B
The sunroof module has detected and reported via serial data that the sunroof actuator calibration is not learned.
DTC B3697 is stored in the BCM memory.

The BCM no longer detects a malfunction in the sunroof actuator.

Schematic Reference
Sunroof Schematics


Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference

1. Ignition ON.
2. Verify DTC B3697 42 or DTC B3697 4B is not set.
If DTC B3697 42 or DTC B3697 4B is set
1. Calibrate the K61 Sunroof Control Module. Refer to Control Module References .
2. Verify DTC B3697 42 or DTC B3697 4B does not set while operating the sunroof.
If DTC B3697 42 or DTC B3697 4B sets, replace the K61 Sunroof Control Module.
If DTC B3697 42 or DTC B3697 4B does not set
3. All OK.
If DTC B3697 42 or DTC B3697 4B is not set
3. Verify DTC B3697 00 or DTC B3697 39 is not set
If DTC B3697 00 or DTC B3697 39 is set, replace the K61 Sunroof Control Module.
If DTC B3697 00 or DTC B3697 39 is not set
4. All OK.
Repair Instructions

DTC B369C

DTC Descriptors
DTC B369C 02
Sunroof Tilt Position Select Switch Circuit Short to Ground
DTC B369C 05
Sunroof Tilt Position Select Switch Circuit High Voltage/Open
DTC B369C 59
Sunroof Tilt Position Select Switch Circuit Protection Time-Out
Short to
Ground
Signal
B369C 02
Low Reference
1. Power Sunroof Tilt Malfunction
Circuit
Open/High
Resistance
B369C 05
1
Short to
Voltage
B369C 05
1
Signal Performance
-
The sunroof tilt switch is connected directly to the sunroof control module and provides detent positions for
open, off and close. The sunroof tilt switch completes the circuit between two signals provided by the control
module, a reference ground input and a pull-up voltage provided by the analog to digital switch input. The
sunroof tilt switch places a different resistor ladder network in the circuit depending on the function selected.
The controllers analog to digital switch input reads the resulting voltage range and determines the function.
The ignition is ON.

B369C 02
The sunroof control module has detected and reported via serial data that the sunroof tilt switch circuit is
shorted to ground.
B369C 05
The sunroof control module has detected and reported via serial data that the sunroof tilt select switch circuit is
open or shorted to voltage.

B369C 59
The sunroof control module has detected and reported via serial data that the sunroof tilt switch has been the
same active position for 20 seconds after the glass has stopped moving in the requested direction due to
reaching the end of the allowable motion.
DTC B369C is stored in the body control module (BCM) memory.

The BCM no longer detects a malfunction in the sunroof tilt switch circuit.
Schematic Reference
Sunroof Schematics
Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference

1. Ignition OFF and all vehicle systems OFF, disconnect the harness connector at the S88 Sunroof Tilt

3.
4.
5.
6.
7.
If less than 2 ohms, test or replace the K61 Sunroof Control Module.
Ignition ON.
Verify the scan tool Sunroof Tilt Switch parameter is Short to Battery.
If not Short to Battery
If Short to Battery
terminal 1.
Verify the scan tool Sunroof Tilt Switch parameter is Short to Ground.
If not Short to Ground
If less than 1 V
If less than 2 ohms, replace the K61 Sunroof Control Module.
If Short to Ground
All OK.
Component Testing
Sunroof Ventilation Switch

Static Test
1. Ignition OFF, disconnect the harness connector at the S88 Sunroof Tilt Switch.
2. Test for 830-1030 ohms between the control terminal 4 and the low reference terminal 1.
Replace the S88 Sunroof Tilt Switch.

open switch.
4. Test for 390-480 ohms between the control terminal 4 and the ground terminal 1 while pressing the close
switch.

5. All OK.
Repair Instructions

SYMPTOMS - ROOF
NOTE:
Complete the following procedures before using the symptom tables.
1. Perform the Diagnostic System Check - Vehicle in order to verify that all of the following conditions are
true:
2. Review the system description and operation in order to learn the system functions. Refer to Sunroof
Inspect for aftermarket devices which may affect the operation of the power sunroof system. Refer to
Inspect the accessible system components for obvious damage or for conditions which can cause the
symptom.
Intermittent

Symptom List
Refer to Power Sunroof Malfunction.

POWER SUNROOF MALFUNCTION
Circuit
B+ Sunroof Control Module
Sunroof Control Module Serial Data
Bus
Sunroof Switch Signal
Sunroof Vent Switch Signal
Sunroof Vent Switch Low Reference
Sunroof Switch Low Reference
Sunroof Control Module Ground
1. Power Sunroof Malfunction
Short to
Ground
1
Open/High
Resistance
1
Short to
Voltage
-
Signal
Performance
-
1
1
1
1
-
1
1
1
1
1
1
1
1
1
-
The sunroof electrical system uses a master/slave configuration utilizing a serial data based system for
communication. The body control module (BCM) is designated as the master, while the sunroof control module
is configured as the slave.
As the system master, the BCM uses the serial data communication bus to enable or disable sunroof operation,
communicate vehicle information to each controller, and request sunroof movement. The sunroof controller
provide system status and diagnostic information to the BCM for diagnostic reporting and operational purposes.
The control switches places a different resistor ladder network in the circuit depending on the function selected.
The controllers analog to digital switch input reads the resulting voltage range and determines the function
Schematic Reference
Sunroof Schematics


Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference

1. Ignition ON.
2. Verify the sunroof opens and closes when pressing the open and close sunroof switch.
If the sunroof does not open or close
If the sunroof opens and closes
3. Verify the sunroof opens and closes to the vent position when pressing the open and close sunroof vent
switch.
If the sunroof does not open or close to the vent position

If the sunroof opens and closes to the vent position
4. All OK.
NOTE:
Because of the accessibility of the switches, perform the switch component

testing before beginning the circuit/system testing.
1. Ignition OFF and all vehicle systems OFF, disconnect the harness connector at the K61 Sunroof Control
Module. It may take up to 2 minutes for all vehicle systems to power down.

1. Ignition OFF.
If test lamp does not illuminate and the circuit fuse is good
1. Ignition OFF.
1. Ignition OFF.
4. Ignition ON.
5. Test for less than 1 V between the signal circuit terminals listed below and ground:
Terminal 3 - K61 Sunroof Control Module
If 1 V or greater
Repair the short to voltage on the signal circuit.
If less than 1 V
6. Ignition OFF.
7. Test for infinite resistance between the signal circuit terminals listed below and ground:
Repair the short to ground on the signal circuit

8. Disconnect the harness connector at the S72 Sunroof Switch and the S88 Sunroof Tilt Switch.
9. Test for less than 5 ohms between the circuit terminals listed below:

S72 Sunroof Switch terminal 1 and K61 Sunroof Control Module terminal 3
S72 Sunroof Switch terminal 4 and K61 Sunroof Control Module terminal 5
S88 Sunroof Tilt Switch terminal 1 and K61 Sunroof Control Module terminal 3
S88 Sunroof Tilt Switch terminal 4 and K61 Sunroof Control Module terminal 6
If less than 5 ohms

10. Test or replace the K61 Sunroof Control Module.
Component Testing
Sunroof Switch
Static Test
1. Ignition OFF, disconnect the harness connector at the S72 Sunroof Switch.
2. Test for 3.3-4.0k ohms between the control terminal 4 and the low reference terminal 1.
open switch while pressing the open switch.

express open switch.

5. Test for 1.6-2.0k ohms between the control terminal 4 and the low reference terminal 1 while pressing the
close switch.


6. Test for 840-1030 ohms between the control terminal 4 and the low reference terminal 1 while pressing
the express close switch.

7. All OK
Sunroof Ventilation Switch

Static Test
1. Ignition OFF, disconnect the harness connector at the S88 Sunroof Tilt Switch.
open switch.

4. Test for 390-480 ohms between the control terminal 4 and the ground terminal 1 while pressing the close
switch.

5. All OK
Repair Instructions

Sunroof Window Motor Replacement

REPAIR INSTRUCTIONS
SUNROOF AIR DEFLECTOR REPLACEMENT
Fig. 3: Sunroof Air Deflector

Sunroof Air Deflector Replacement
Callout
Component Name
Sunroof Air Deflector
1
TIP: Cycle the sunshade window to the full rearward position.
SUNROOF AIR DEFLECTOR COVER REPLACEMENT

Fig. 4: Sunroof Air Deflector Cover

Sunroof Air Deflector Cover Replacement
Callout
Component Name
Sunroof Air Deflector Cover
1
Procedure
1. Cycle the sunshade window to the vent position.
2. Unclip the sunroof air deflector cover out of the guide.
SUNROOF FRAME REPLACEMENT

Fig. 5: Sunroof Frame

Sunroof Frame Replacement
Callout
Component Name
2. Remove the sunroof window. Refer to Sunroof Window Replacement.
3. Remove the sunroof air deflector cover. Refer to Sunroof Air Deflector Cover Replacement.
4. Remove the sunroof sunshade. Refer to Sunroof Sunshade Replacement.
5. Remove the sunroof window motor. Refer to Sunroof Window Motor Replacement.
6. Remove the sunroof air deflector. Refer to Sunroof Air Deflector Replacement.
7. Remove the Sunroof Housing Drain Gutter. Refer to Sunroof Housing Drain Gutter
Replacement.
8. Disconnect the Front and Rear Drain Hose.
Sunroof Module Bolt (Qty: 12)
1
CAUTION:

Tighten
9 N.m (80 lb in)
Sunroof Frame
Procedure
With the aid of an assistant, lower the sunroof frame and remove the
sunroof frame out through the passenger side door.
SUNROOF HOUSING DRAIN GUTTER REPLACEMENT
Fig. 6: Sunroof Housing Drain Gutter

Sunroof Housing Drain Gutter Replacement
Callout
Component Name
1. Remove the sunroof module assembly. Refer to Sunroof Module Assembly Replacement.
2. Cycle the sunroof window to the vent position.
Sunroof Housing Drain Gutter
1
Procedure
Clip the sunroof housing drain gutter out from guide.
SUNROOF HOUSING FRONT DRAIN HOSE REPLACEMENT

Fig. 7: Sunroof Housing Front Drain Hose

Sunroof Housing Front Drain Hose Replacement
Callout
Component Name
1. It is only necessary to lower the headliner. Only perform the steps in the headliner replacement
procedure that will lower the headliner enough to gain access to the part. Refer to Headlining
Trim Panel Replacement (without Sunroof) , Headlining Trim Panel Replacement (with
Sunroof) .
Sunroof Housing Front Drain Hose
Procedure
1
Disengage the sunroof drain hose from the attachment points on the
windshield pillar.
SUNROOF HOUSING REAR DRAIN HOSE REPLACEMENT

Fig. 8: Sunroof Housing Rear Drain Hose

Sunroof Housing Rear Drain Hose Replacement
Callout
Component Name
1. It is only necessary to lower the headliner. Only perform the steps in the headliner replacement
procedure that will lower the headliner enough to gain access to the part. Refer to Headlining
Trim Panel Replacement (without Sunroof) , Headlining Trim Panel Replacement (with
Sunroof) .
2. Remove the rear compartment side trim panel. Refer to Rear Compartment Side Trim
Replacement - Right Side , or Rear Compartment Side Trim Replacement - Left Side .
Sunroof Housing Rear Drain Hose
Procedure
1
Disengage the sunroof drain hose from the attachment clips on the
roof rail, the C-pillar, and the rear compartment.
SUNROOF MODULE ASSEMBLY REPLACEMENT

Fig. 9: Sunroof Module assembly

Callout
Component Name
Remove the headlining trim panel. Refer to Headlining Trim Panel Replacement (without Sunroof) ,
Sunroof Module Bolt (Qty: 12)
CAUTION:
Tighten
9 N.m (80 lb in)
Sunroof Module Assembly
Procedure
A new sunroof module assembly does not include the sunroof
window, the motor, the sunshade, or the finishing lace as
components. You must install the old components to the new sunroof
module assembly.
SUNROOF WINDOW MOTOR REPLACEMENT

Fig. 10: Sunroof Window Motor

Sunroof Window Motor Replacement
Callout
Component Name
It is only necessary to lower the headliner. Only perform the steps in the headliner replacement procedure
that will lower the headliner enough to gain access to the part. Refer to Headlining Trim Panel
Replacement (without Sunroof) , Headlining Trim Panel Replacement (with Sunroof) .
Sunroof Window Motor Bolt (Qty: 3)
CAUTION:
Tighten
4 (36 lb in)
Sunroof Window Motor
2
Procedure
2. After repairs or replacement, initialize the sunroof motor. Refer to
Sunroof Motor/Actuator Initialization/Teach Process.

3. Verify the operation of the sunroof before installing the headliner.

SUNROOF MOTOR/ACTUATOR INITIALIZATION/TEACH PROCESS
Perform the Initialization/Teach Process any time a sunroof window motor actuator is installed in the vehicle.
Use only the slide button for the these steps.
1. Ensure that the electrical harness on the headliner is connected to the sunroof motor.
housing, BCM).
3. Ensure that the sunroof window is in the fully closed position. This is Not required for a new motor.
4. Press and hold the "Manual Close Switch. After 10 seconds the sunroof window will move to the vent
and then slightly back. Do not release the switch until the sunroof window stops moving. A 10 second
delay is not required for a new motor.
5. Learn Process:
1. Open the sunroof window using the express or manual open switch to the full open position then
release the switch.
2. Press and hold "Manual Open Switch. After 10 seconds, the window will move to the close
position, vent and then close. Do not release the switch during the movement until the window
stops in the fully closed position.
NOTE:
The Initialization/Teach Process is not complete if any of the following

actions take place before the initialization cycle is done.

1. The slide button is not held as instructed.
2. The ignition and/or battery power has been removed.
3. The window panel has not reached the closed position.
The Initialization/Teach Process must be restarted if the procedure is not carried out completely.
SUNROOF SUNSHADE REPLACEMENT

Fig. 11: Sunroof Sunshade

Sunroof Sunshade Replacement
Callout
Component Name
1. Remove the headliner. Refer to Headlining Trim Panel Replacement (without Sunroof) ,
2. It is only necessary to lower the sunroof module assembly. Only perform the steps in the sunroof
module assembly replacement procedure that will lower the sunroof module assembly enough to
gain access to the sunroof module bracket screws. Refer to Sunroof Module Assembly
Replacement.
Sunroof Module Bracket Screw (Qty: 2)
2
3
CAUTION:
Tighten
9 N.m (80 lb in)
Sunroof Module Bracket
Sunroof Sunshade
Procedure
Push the sunshade assembly down to release from sunshade guide.

SUNROOF WINDOW SEAL REPLACEMENT
Fig. 12: Sunroof Window Seal

Sunroof Window Seal Replacement
Callout
Component Name
Remove the sunroof window. Refer to Sunroof Window Replacement.
Sunroof Window Seal
Procedure
1
1. Wipe the perimeter of the frame area with a clean cloth.
2. Ensure that the seal is properly seated around the entire
perimeter of the window frame.
SUNROOF WINDOW SEAL REPLACEMENT - FRONT

Fig. 13: Sunroof Window Seal - Front

Sunroof Window Seal Replacement - Front
Callout
Component Name
Open the sunroof until it's in full opening position.
1
Sunroof Window Seal- Front
SUNROOF SWITCH REPLACEMENT

Fig. 14: Sunroof Switch

Callout
Component Name
Sunroof Switch
1
Procedure
1. Unsnap the switch from the console.
SUNROOF WINDOW HEIGHT AND OPENING FIT ADJUSTMENT

Fig. 15: Properly Adjusting Sunroof Window Height And Opening Fit
Sunroof Window Height and Opening Fit Adjustment
Callout
Component Name
Remove the sunroof air deflector cover. Refer to Sunroof Air Deflector Cover Replacement.
Sunroof Window Fastener (Qty: 4)
CAUTION:
Procedure
1. Cycle the sunroof window from full open to closed position.

2. Loosen the adjusting screws on the sunroof window.
3. Adjust the front of the sunroof window to window to 0-1 mm
(0.00-0.04 in) below the top surface of the roof panel.
4. Adjust the rear center line of the sunroof window to 0-1 mm
(0.00-0.04 in) above the top surface of the roof panel.
5. Cycle sunroof window through all positions.
6. Inspect the sunroof window adjustment. Adjust if necessary.

Tighten
4 N.m (35 lb in)
SUNROOF WINDOW REPLACEMENT
Fig. 16: Sunroof Window

Sunroof Window Replacement
Callout
Component Name
Remove the sunroof air deflector cover. Refer to Sunroof Air Deflector Cover Replacement.
Sunroof Window Bolt (Qty: 4)
CAUTION:
Tighten
4 N.m (36 lb in)
Sunroof Window
Procedure

1.
2.
3.
4.
Turn the ignition on.

Lift up the sunroof window to the vent position.
Slide the sunshade to the full rearward position.
After the installation adjust the sunroof window. Refer to Sunroof
Window Height and Opening Fit Adjustment.

SUNROOF DESCRIPTION AND OPERATION
The tilt/slide sunroof consists of a moving glass panel and a manual sunshade. In the tilt/slide sunroof system
the rear of the glass tilts up for venting and slides between the head liner and roof panel as it slides open. The
glass is controlled by an integrated motor/controller. The sunshade has a mechanical connection to the glass
causing it to open with the glass and keeping it from closing more than the glass.
The electrical portion of the tilt/slide sunroof system consists of:

Sunroof glass control module
Sunroof control switch assembly
Vent control switch assembly
Local interconnected network (LIN-Bus)
The sunroof electrical system uses a master/slave configuration utilizing a LIN-Bus based system for
communication. The BCM is designated as the master, while the sunroof control module is configured as the
slave.
As the system master, the BCM uses the LIN-Bus communication bus to enable or disable sunroof operation,
communicate vehicle information to the sunroof controller, and request sunroof movement. The sunroof
controller provides system status and diagnostic information to the BCM for diagnostic reporting and
operational purposes.
The sunroof glass is controlled by a integrated motor/controller containing the necessary electronics, motor, hall
effect position sensors, as well as the interface to the driver control switches. The motor/controller is capable of
controlling motion based on control switch activation and LIN-Bus message commands from the system master.
The operational calibrations for the sunroof integrated motor/controller are loaded over the LIN-Bus
communication bus by the sunroof system master, the BCM.
Sunroof Glass and Sunshade Control Switches
The sunroof control switches are connected directly to the controller. The sliding glass switches provide detent
positions for open, express open, off, close, and express close. The vent switches provide detent positions for
open, off, and close. The control switch completes the circuit between two signals provided by the control
module, a reference ground input and a pull-up voltage provided by an analog to digital switch input. The

control switches place a different resistor ladder network in the circuit depending on the function selected. The
controller's analog to digital switch input reads the resulting voltage range and determines the function as
indicated in the included charts.
System Protection Functions
Normal operation of the sunroof system may be altered by one of the following events.
Obstacle or Blockage Detection
When enabled, obstacle detection is active only while the sunroof opening is approximately 4-200 mm (0.167.87 in) when moving in the closing direction. When an obstacle is detected in this range, the motion in the
closing direction will stop and the sunroof will reverse direction for a short distance. The reversal shall
complete regardless of operating Mode. If the travel is outside the range defined above, the sunroof will try to
continue closing until it detects a motor stall condition or the system is at one of it's defined stops.
Motor Stall
If the sunroof is moving in the open or close direction and stops moving for 350 ms while the switch or LINBus command is active, and no obstacle has been detected, the motor shall be turned off to prevent overheating.
Sunroof System Thermal Protection
The sunroof controllers have a thermal protection algorithm to protect the sunroof controller and motor from
damage due to overheating conditions resulting from immoderately switch actuations. The thermal protection
algorithm will cause any new sunroof open commands to be ignored until the motor is allowed to cool. A
number of close requests during an over temperature condition will be allowed. If the thermal protection is
triggered during an obstacle detection event, the sunroof reversal shall be finished.
Sunroof Operation
Vent - Open to Vent Position

When the sunroof is closed or in a partial vent position and the sunroof vent open switch becomes active, the
sunroof shall begin to 'Express open' to the vent position. sunroof motion shall cease when the Sunroof reaches
the vent position or if the sunroof sliding glass switch becomes active.
Vent - Close from Vent
When the sunroof is in the vent position and the sunroof vent switch enters the 'Close' state, the sunroof will
begin to express close the sunroof. Motion will continue until the sunroof has reached its fully closed position
or if the sunroof sliding glass switch becomes active.
Sliding Class - Normal Open (Non-Express)
When the sunroof is not in a vent position and the sunroof sliding glass switch is held in the 'Open' position, the
sunroof will begin opening. Motion will continue until the switch returns to the 'Off' state or the vent switch
transitions to any active state.

Sliding Class - Sunroof Express Open

When the sunroof control switch transitions to the 'Express Open' state and the sunroof is not in a vent position,
the sunroof will express open until the controller determines the sunroof has reached the comfort stop position
or the fully 'Open' position, the switch transitions to another state after first returning to the 'Off' position, or the
vent switch transitions to an active state.
Sliding Class - Normal Close (Non-Express)
When the sunroof switch is in the 'Close' state and the sunroof is not in the vent position, the controller will
begin moving the sunroof in the close direction. If the vent switch becomes active the motor will be turned off.
Sliding Class - Sunroof Express Close
When the sunroof switch is in the 'Express Close' state and the sunroof is not in a vent position, the sunroof will
express close until the controller determines the sunroof has reached the fully closed position, or the switch
transitions to another state after first returning to the 'Off ' position. The sunroof motion will cease if the switch
transitions back to the 'Close' or 'Express Close' state after returning to the 'Off ' position first or the vent switch
transitions to any active state.
WATER MANAGEMENT DESCRIPTION AND OPERATION
Fig. 17: Sunroof Tray Tubes

Any water that passes the roof seal is drained from the sunroof tray by 2 tubes in the front (1) and 2 tubes in the

back (2) of the sunroof module assembly that lead from the corners of the tray to the rocker panels of the
vehicle. The tray which acts as a framework for the sunroof assembly, has a water channel that encircles the
sunroof opening and directs the water to the drain tubes.
In the graphic below the arrows show the water flow direction in the tray which acts as a framework for the
sunroof assembly and drains system.

2013 ACCESSORIES & EQUIPMENT Waterleaks - Cruze

Waterleaks - Cruze

WATERLEAK TEST PREPARATION
GM vehicles are designed to operate under normal environmental conditions.

The design criteria for sealing materials and components takes into consideration the sealing forces
required to withstand the natural elements. These specifications cannot take into consideration any
artificial conditions, i.e., high pressure car washes.
The water leak test procedure has been correlated to the natural elements and will determine the ability of
a vehicle to perform under normal operating conditions.
The first step in diagnosing a leak is determining the conditions under which a leak occurs. If the general
leak area can be found, the exact entry point can be isolated using a water hose or an air hose. Some trim
panels or components may need to be removed in order to repair the leak.
If leaks are found around a door, door window, rear compartment lid or liftgate area this does not
necessarily indicate a bad weatherstrip. An adjustment to these areas may resolve the condition.
1. Watertest Stand Assembly

Fig. 1: View Of Watertest Stand Assembly


Assemble the water test stand as shown.

Component
Callout
Name
Pipe (0.5 x 36
1
in)
Reducing Tee,
Right Stand
2
Only (0.5 x 0.5
x 0.25 in)
Coupling, Left
3
Stand Only,
(0.5 in)
Tee, Left Stand
4
Only (0.5 in)
Cross, Right
5
Stand Only
(0.5 in)
Pipe to Hose
Nipple, Right
6
Stand Only
(0.5 in)
Female Hose
7
Coupling (5/8
in)
Input Hose,
Right Stand
8
Only (2.0 ft)
(5/8 in
diameter)
Close Nipple
9
(0.5 in)
Cross (0.5 in)
10 with Weld-On
Cap (0.5 in)
Nipple (0.5 x
11
12 in)
12 Cap (0.5 in)
Female Hose
13 Coupling (5/8
in)
Cross Hose (12
14 ft) (5/8 in
diameter)
15
Hose Quick

16
17
18
19
20
Connect
Pipe to Hose
Nipple (0.5 in)
Pipe (0.5 x 60
in)
Water Pressure
Gauge, Right
Stand Only
Full Jet Spray
Nozzle, No.
1/2GG-25 or
Equivalent
Coupling (0.5
in)
Fig. 2: Illustrating How Water Spray From Stands Should Overlap Vehicle

2. Position the stands as shown.

The water spray from the stands should overlap the vehicle as shown.
3. Have an assistant inside of the vehicle during the test in order to locate any leaks.
4. The water pressure at the nozzle should maintain a 155 kPa (22 psi), for at least 4 minutes.
Fig. 3: Identifying Proper Water Spray Angles

5. In order to check the windshield, aim the water spray 30 degrees down and 45 degrees toward the rear.
Aim the water towards the corner of the windshield.
6. In order to check the side windows for leaks, position the water stand towards the center of the rear
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.

WATER HOSE TEST

NOTE:
Use a water hose without the nozzle attached.
1. Have an assistant inside of the vehicle in order to locate the leak.

2. Begin testing at the base of the window or the windshield.
3. Slowly move the hose upward and across the top of the vehicle.
AIR HOSE TEST

Fig. 5: Performing Air Hose Test

CAUTION: The air hose test should only be used on fully cured urethane
adhesive. Otherwise, damage to the urethane adhesive bead could
result in additional leaks.
1. Using a liquid detergent, diluted with water in a spray bottle, spray the window at the edges. Begin at the
bottom and gradually move up and across the top.
NOTE:
The compressed air should not exceed 205 kPa (30 psi).
2. Have an assistant inside of the vehicle with an air hose.

3. Have the assistant aim the compressed air at the suspected areas.
Bubbles will form in the soap solution at the location of the leak.

REPAIR INSTRUCTIONS
BODY WATERLEAK REPAIR
Fig. 6: Cutting Out A Portion Of The Adhesive Caulking (1 Of 2)

WARNING: If the vehicle interior is exposed to moisture and becomes soaked up to
the level of the sensing and diagnostic module (SDM), the SDM and SDM
harness connector must be replaced. The SDM could be activated when
powered, which could cause airbag deployment and result in personal
injury.
Depending on the location of the waterleak, you may have to remove certain interior components in order to
repair the leak.
1. If the floor carpet is wet refer to Floor Carpet Drying .

Fig. 7: Cutting Out A Portion Of The Adhesive Caulking (2 Of 2)

2.
3.
4.
5.
6.
7.
Cut out a portion of the adhesive caulking in the leak area from inside or outside of the vehicle.
Clean and remove all loose particles of the adhesive old caulking from the area.
Apply joint body and seam sealer where the old adhesive caulking was removed.
Allow the adhesive caulking to dry for several hours.
Test for leaks.
Install the trim, if removed.
STATIONARY WINDOW WATERLEAK REPAIR

WARNING: If the vehicle interior is exposed to moisture and becomes soaked up to
the level of the sensing and diagnostic module (SDM), the SDM and SDM
harness connector must be replaced. The SDM could be activated when
powered, which could cause airbag deployment and result in personal
injury.

1.
2.
3.
4.
If the floor carpet is wet refer to Floor Carpet Drying .

Remove the trim moldings or the headliner in order to repair the leak, if needed.
Determine the source of water entry.
If water is leaking at the edge of the windshield, reseal the windshield using a urethane adhesive caulking
kit or the equivalent.
5. If water leaks into the vehicle at the sides of the stationary windows, reseal the window using a urethane
adhesive caulking kit or the equivalent.

2013 BRAKES Antilock Brake System - Cruze
2013 BRAKES
Antilock Brake System - Cruze
SPECIFICATIONS
Specification
Application
Brake Pipe Fitting
Brake Pressure Modulator Valve (BPMV) Bracket Bolt
Electronic Brake Control Module (EBCM) Bolt
Front Wheel Speed Sensor Bolt
Rear Wheel Speed Sensor Bolt
Traction Control Module to Brake Pressure Module Bolt
Yaw Sensor Nut

ANTILOCK BRAKE SYSTEM WIRING SCHEMATICS
Power, Ground, Serial Data, and Traction Control Wiring Schematics
Metric
18 N.m
20 N.m
3 N.m
6 N.m
6 N.m
10 N.m
9 N.m
English
13 lb ft
15 lb ft
27 lb in
53 lb in
53 lb in
89 lb in
80 lb in

Fig. 1: Power, Ground, Serial Data, and Traction Control Wiring Schematics
Callout
1840
1840 RD/GN
CAV_25
CAV_56
CONN_X2
1640
1640_RD/VT
CAV_1
CAV_41
SD
6105
6105_BU/YE
CAV_5
6106
Component Name
1840 RD/GN
25
56
X2
1640 RD/VT
1
41
Serial Data
High Speed GMLAN Serial Data
(+) (2)
6105 BU/YE
5
(-) (2)

6106_WH
CAV_6
2500
2500_BU
CAV_11
2500_BU
CAV_12
2501
2501_WH
CAV 9
2501_WH
CAV 10
5896
5896_WH/BU
CAV_8
1750
1750_BK
CAV_4
1650
MH8
MH9
1450
1450 BK
CAV_13
1788
1788_BU/VT
CAV_2
CAV 14
CONN_X2
MF3
6106 WH
6
(+) (1)
2500 BU
11
2500 BU
12
(-) (1)
2501 WH
9
2501 WH
10
Driver Seat Bolster Motor
Position Sensor Voltage
Reference
5896 WH/BU
8
Ground
1750 BK
4
1650
TRANSMISSION-AUTO 6 SPD,
HMD, X23F
TRANSMISSION-AUTO 6 SPD,
HMD, X24F
Ground
1450 BK
13
Traction Control Switch Signal
(1)
1788 BU/VT
2
14
X2
OPEL, 76.5 MM, 4.273 1ST,
2.158 2ND, 1.302 3RD, 0.959
4TH, 0.744 5TH, 0.614 6TH,
M32-6 WR
OPEL, 76.5 MM, 4.273 1ST,

MR5
MZ0
G120
G203
F30UA
F26UA
P16
K9
S75
X50A
Q5
A90
K17
Wheel Speed Sensors Wiring Schematics
Fig. 2: Wheel Speed Sensors Wiring Schematics

2.353 2ND, 1.475 3RD, 1.067

4TH, 0.875 5TH, 0.744 6TH,
M32-6 WR
OPEL, 76.5 MM, 3.82 1ST, 0.74
6TH, (M32 WR)
G120
G203
F30UA 15A
F26UA 40A
(FX3)
Logic

Callout
7064
7064_GY/WH
CAV_36
830
830_GY
CAV_37
7065
7065_GY/BN
CAV_27
872
872_YE
CAV 1
CAV_1
CAV_2
CAV_2
7127
7127_GY/BK
CAV_29
884
884_BU
CAV_30
7064_GY/WH
830_GY
7065_GY/BN
872_YE
CAV_2
CAV 1
7128
7128 GY/YE
CAV_34
882
882_VT
CAV_33
CAV_2
CAV_1
CAV_26
X100
CAV_35
CAV_36
CAV_37
CAV 38
Component Name
Wheel Speed Sensor Supply Voltage Left Front
7064 GY/WH
36
Wheel Speed Sensor Signal Left Front
830 GY
37
Wheel Speed Sensor Supply Voltage Right Front
7065 GY/BN
27
Wheel Speed Sensor Signal Right Front
872 YE
1
1
2
2
Wheel Speed Sensor Supply Voltage Left Rear
7127 GY/BK
29
Wheel Speed Sensor Signal Left Rear
884 BU
30
7064 GY/WH
830 GY
7065 GY/BN
872 YE
2
1
Wheel Speed Sensor Supply Voltage Right Rear
7128 GY/YE
34
Wheel Speed Sensor Signal Right Rear
882 VT
33
2
1
26
X100
35
36
37

38
9
9
9
9
9
9
X100
TWIST_9
TWIST_9
TWIST_9
TWIST_9
TWIST_9
TWIST_9
X100
B5LF
B5RF
B5LR
B5RR
K17
Stability Control Wiring Schematics
Fig. 3: Stability Control Wiring Schematics

Callout
2087
Component Name
Combined Vehicle Inertial

2087_GN/BN
CAV_5
CAV_15
2087_GN/BN
CAV_5
2087_GN/BN
CAV_68
6106
6106_WH
CAV_2
6105
6105_BU/YE
CAV_3
6106_WH
CAV_1
6105_BU/YE
CAV_4
1650
1650_BK
CAV_6
6105_BU/YE
CAV_3
6106_WH
CAV_1
1337
1337_GY/RD
CAV_6
X200
G202
G307
B119
B99
K17
Sensor Supply Voltage

2087 GN/BN
5
15
2087 GN/BN
5
2087 GN/BN
68
Data (-) (2)
6106 WH
2
Data (+) (2)
6105 BU/YE
3
6106 WH
1
6105 BU/YE
4
Ground
1650 BK
6
6105 BU/YE
3
6106 WH
1
Yaw Rate Sensor Volt
Reference
1337 GY/RD
6
X200
G202
G307
(FX3)
(FX3)
Data Communication
Schematics
Data Communication
Schematics


DTC
DTC B2745
DTC C0035, C0040, C0045, or C0050
DTC C0110
DTC C0131
Description
DTC B2745 02 Traction Control Switch Circuit
Short to Ground
DTC C0035 06 Left Front Wheel Speed Sensor
Circuit Low Voltage/Open
DTC C0035 0F Left Front Wheel Speed Sensor
Circuit Signal Erratic
Circuit Low Signal Amplitude
DTC C0035 5A Left Front Wheel Speed Sensor
DTC C0040 06 Right Front Wheel Speed Sensor
DTC C0040 0F Right Front Wheel Speed Sensor
DTC C0040 5A Right Front Wheel Speed Sensor
DTC C0045 06 Left Rear Wheel Speed Sensor
DTC C0045 0F Rear Wheel Speed Sensor Circuit
Signal Erratic
DTC C0045 5A Left Rear Wheel Speed Sensor
DTC C0050 06 Right Rear Wheel Speed Sensor
DTC C0050 0F Right Rear Wheel Speed Sensor
DTC C0050 5A Right Rear Wheel Speed Sensor
DTC C0110 00 Pump Motor Circuit Malfunction
DTC C0110 04 Pump Motor Circuit Open
DTC C0110 61 Pump Motor Stuck
DTC C0131 00 Traction Control System Pressure
Circuit Malfunction
DTC C0131 4B Traction Control System Pressure
Circuit Calibration Not Learned

DTC C0161
DTC C0186, C018B, C0196, C019B, or C0287
DTC C0280
DTC C0710
DTC C1207-C1210, C1221-C1228, or C1232C1235
DTC C0131 5A Traction Control System Pressure

DTC C0161 5A Antilock Braking System Brake
Switch Circuit Not Plausible
DTC C0186 5A Lateral Acceleration Sensor Circuit
Not Plausible
DTC C0186 71 Lateral Acceleration Sensor Circuit
Invalid Data
DTC C018B 5A Multi-Axis Acceleration Sensor
Signal Not Plausible
DTC C0196 00 Yaw Rate Circuit Malfunction
DTC C0196 5A Yaw Rate Signal Not Plausible
DTC C0196 71 Yaw Rate Signal Invalid Data
DTC C019B 5A Yaw Rate Signal Not Plausible
DTC C0287 4B Longitudinal Acceleration Sensor
Circuit Calibration Not Learned
DTC C0287 5A Longitudinal Acceleration Sensor
DTC C0287 71 Longitudinal Acceleration Sensor
Circuit Invalid Data
DTC C0280 54 Stability System Active Too Long
High Temperature
DTC C0710 00 Steering Position Signal
Malfunction
DTC C0710 42 Steering Position Signal Calibration
Not Programmed
DTC C0710 71 Steering Position Signal Invalid
Data
DTC C0710 5A Steering Position Signal Not
Plausible
Circuit High Input
Circuit High Input
Circuit High Input
Circuit High Input
Circuit Malfunction
Circuit Malfunction
Circuit Malfunction
Circuit Malfunction
DTC C1251 Lateral Acceleration Sensor

DTC C1251
DTC P0856
Performance
DTC P0856 Traction Control Torque Request
Circuit
DTC B2745
DTC Descriptor
DTC B2745 02
Traction Control Switch Circuit Short to Ground
Short to
Ground
Signal
B2745 02
Ground
1. Traction control switch inoperative
Circuit
Open/High
Resistance
1
1
Short to
Voltage
1
-
Signal Performance
-
The body control module monitors the traction control switch. When the traction control switch is pressed once,
the body control module will request the electronic brake control module via serial data to disable the traction
control. The electronic brake control module will request the instrument cluster via serial data to turn the
traction control off indicator ON to notify the driver of the deactivation.
When the traction control switch is pressed and held for five seconds, the body control module will request the
electronic brake control module to disable the electronic stability control. The electronic brake control module
will request the instrument cluster via serial data to turn the traction control off and stability control off
indicator ON to notify the driver of the deactivation.
Ignition ON.
The body control module detects a short to ground on the signal circuit.

The body control module ignores the traction control switch signal input.

Schematic Reference
ABS Description and Operation
Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference

1. Ignition ON.
2. Verify the scan tool Body Control Module, Traction Control Switch parameter changes between Active
and Inactive when pressing and releasing the S75 Traction Control Switch.
3. All OK.

1. Ignition OFF and all vehicle systems OFF, disconnect the harness connector at the S75 Traction Control
Switch. It may take up to 2 minutes for all vehicle systems to power down.
1. Ignition OFF.
3. Ignition ON
4. Verify the scan tool Body Control Module, Traction Control Switch parameter is Inactive.
If not Inactive
If Inactive
6. Verify the scan tool Traction Control Switch parameter is Active.
If not Active
If less than 1 V
If Active
7. Test or replace the S75 Traction Control Switch.
Component Testing
1. Ignition OFF, disconnect the harness connector at the S75 Traction Control Switch.
open position.
Replace the S75 Traction Control Switch.

closed position.
If less than 2 ohms
4. All OK.
Repair Instructions

Control Module References for Body Control Module replacement, programming and setup
DTC C0035, C0040, C0045, OR C0050

DTC Descriptors
DTC C0035 06
Left Front Wheel Speed Sensor Circuit Low Voltage/Open
DTC C0035 0F
Left Front Wheel Speed Sensor Circuit Signal Erratic
DTC C0035 18
Left Front Wheel Speed Sensor Circuit Low Signal Amplitude
DTC C0035 5A
Left Front Wheel Speed Sensor Circuit Not Plausible
DTC C0040 06
Right Front Wheel Speed Sensor Circuit Low Voltage/Open

DTC C0040 0F
Right Front Wheel Speed Sensor Circuit Signal Erratic
DTC C0040 18
Right Front Wheel Speed Sensor Circuit Low Signal Amplitude
DTC C0040 5A
Right Front Wheel Speed Sensor Circuit Not Plausible
DTC C0045 06
Left Rear Wheel Speed Sensor Circuit Low Voltage/Open
DTC C0045 0F
Rear Wheel Speed Sensor Circuit Signal Erratic
DTC C0045 18
Left Rear Wheel Speed Sensor Circuit Low Signal Amplitude
DTC C0045 5A
Left Rear Wheel Speed Sensor Circuit Not Plausible
DTC C0050 06
Right Rear Wheel Speed Sensor Circuit Low Voltage/Open
DTC C0050 0F
Right Rear Wheel Speed Sensor Circuit Signal Erratic
DTC C0050 18
Right Rear Wheel Speed Sensor Circuit Low Signal Amplitude
DTC C0050 5A
Right Rear Wheel Speed Sensor Circuit Not Plausible
Short to
Open/High
Short to

Circuit
Sensor Signal
Sensor Signal
Sensor Signal
Sensor Signal
Ground
Resistance
Voltage
C0035 06
C0035 06
C0035 06
C0035 06
C0040 06
C0040 06
C0040 06
C0040 06
C0045 06
C0045 06
C0045 06
C0045 06
C0050 06
C0050 06
C0050 06
C0050 06
Component
Condition
Wheel Speed Sensor
Physical damage
Debris on the wheel speed sensor or
the encoder ring
Loose or worn wheel bearing
Loose or improperly mounted sensor
Air gap between the wheel speed
sensor and the encoder ring too large
Water intrusion in the wiring harness
Signal Performance
C0035 0F, C0035 18,
C0035 5A
C0035 0F, C0035 18,
C0035 5A
C0040 0F, C0040 18,
C0040 5A
C0040 0F, C0040 18,
C0040 5A
C0045 0F, C0045 18,
C0045 5A
C0045 0F, C0045 18,
C0045 5A
C0050 0F, C0050 18,
C0050 5A
C0050 0F, C0050 18,
C0050 5A
DTC Symptom Bytes
0F, 18 or 5A
The wheel speeds are detected by active wheel speed sensors and encoder rings. The encoder ring consists of
permanent magnets. Each wheel speed sensor receives ignition voltage through the signal circuit from the
electronic brake control module. As the wheel spins, the wheel speed sensor produces square wave signal on the
signal circuit to the electronic brake control module. The electronic brake control module uses the frequency of
the square wave signal to calculate the actual wheel speed.
C0035 06 - C0050 06
Ignition ON.
C0035 0F - C0050 0F

Ignition ON.
Vehicle speed is greater than 35 km/h (22 MPH).
C0035 18 - C0050 18
Ignition ON.
C0035 5A - C0050 5A
Ignition ON.
C0035 06 - C0050 06
A short to voltage, is detected on the wheel speed sensor signal circuit.

A short to ground or an open/high resistance is detected on the wheel speed sensor signal circuit.
An open/high resistance is detected in the wheel speed sensor low reference circuit.
C0035 0F - C0050 0F
An erratic wheel speed sensor signal is detected.
C0035 18 - C0050 18
A missing wheel speed sensor signal is detected.
C0035 5A - C0050 5A
The difference between the fastest and the slowest wheel speed is greater than 50%.
The ABS indicator turns ON.

A message may be displayed.
The traction/stability control indicator turns ON.
The electronic brake control module disables the ABS, the traction control, and the electronic stability
control for the duration of the ignition cycle.

The history DTC will clear after 40 consecutive fault-free drive cycles have occurred.

Diagnostic Aids
Do not use a magnet to clean the encoder ring.

Inspect the wheel hub bearing encoder ring for rust or corrosion.
If two or more wheel speed sensors are inoperative, diagnose each wheel speed sensor individually.
If any of the symptom codes 0F, 18 or 5A are set, refer to the Diagnostic Fault Information table for
possible mechanical faults or conditions.
If the customer comments that the ABS indicator is ON only during moist environmental conditions (rain,
snow, vehicle wash, etc.), inspect the wheel speed sensor wiring for signs of water intrusion.
Schematic Reference
Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference

1. Test drive the vehicle in a straight line at a speed greater than 40 km/h (25 MPH).
2. Verify all scan tool Wheel Speed Sensor parameters are within 1.6 km/h (1 MPH) of each other.
If any parameter is not within 1.6 km/h (1 MPH) of each other
If each parameter is within 1.6 km/h (1 MPH) of each other
3. All OK.

NOTE:
If any of the symptom codes 0F, 18 or 5A are set, refer to the Diagnostic Fault
Information table for possible mechanical faults or conditions.
1. Ignition OFF, disconnect the harness connector at the appropriate B5 Wheel Speed Sensor. It may take up
to 2 minutes for all vehicle systems to power down.
If less than 5 ohms
3. Ignition ON.
If less than 11 V
If 11 V or greater
5. Install a 3 A fused jumper wire at the signal circuit terminal 1, ignition ON.
6. Verify the scan tool Wheel Speed Sensor parameter changes while rapidly tapping the fused jumper wire
to the low reference circuit terminal 2.
1. Ignition OFF, disconnect the harness connector at the K17 Electronic Brake Control Module,
ignition ON.
If less than 1 V
3. Replace the K17 Electronic Brake Control Module.
7. Test or replace the B5 Wheel Speed Sensor.
Repair Instructions

Front Wheel Speed Sensor Replacement

Rear Wheel Speed Sensor Replacement (Disc Brake), Rear Wheel Speed Sensor Replacement
(Drum Brake)
Control Module References for Electronic Brake Control Module replacement, programming and setup
DTC C0110
DTC Descriptors
DTC C0110 00
Pump Motor Circuit Malfunction
DTC C0110 04
Pump Motor Circuit Open
DTC C0110 61
Pump Motor Stuck
Circuit
B+
Ground
Short to
Ground
C0110 00,
C0110 04
-
Open/High
Resistance
Short to
Voltage
Signal Performance
C0110 00, C0110 04
C0110 61
U0121
Component
Condition
Pump Motor
Wear
Damage
Lock
DTCs
C0110 00 or C0110
61
The pump motor is an integral part of the brake pressure modulator, while the pump motor relay is integral to

the electronic brake control module. The pump motor relay is not engaged during normal system operation.
When the ABS, and the traction/stability operation is required, the electronic brake control module activates the
pump motor relay and turns the pump motor ON.
Ignition ON.
A faulty pump motor or pump motor relay is detected.

A short to ground or an open/high resistance circuit is detected.

The electronic brake control module disables the ABS, the traction control, and the stability control for
the duration of the ignition cycle.

The electronic brake control module will turn off the indicators and enable the system functions in the
next ignition cycle after driving at a speed of greater than 16 km/h (10 MPH) with no faults detected.
Schematic Reference
Circuit Testing
Connector Repairs
Wiring Repairs

Scan Tool Reference

1. Ignition ON.
2. Verify the ABS Pump Motor turns ON and OFF when commanding the ABS Pump Motor Increase and
Decrease with a scan tool.
If the pump motor does not turn ON and OFF
If the pump motor turns ON and OFF
3. All OK.
1. Ignition OFF and all vehicle systems OFF, disconnect the harness connector at the K17 Electronic Brake
Control Module. It may take up to 2 minutes for all vehicle systems to power down.
1. Ignition OFF.
If 2 ohms or greater, repair the open high/resistance in the circuit.
If less than 2 ohms, repair open high/resistance in the ground connection.
3. Ignition ON.
1. Ignition OFF.
1. Ignition OFF.
If infinite resistance, replace the K17 Electronic Brake Control Module.
5. Replace the Q5 Brake Pressure Modulator.

6. Verify the DTC does not set while operating the vehicle within the Conditions for Running the DTC.
If the DTC sets
Replace the K17 Electronic Brake Control Module.
7. All OK.
Repair Instructions
Brake Pressure Modulator Valve Replacement

DTC C0131
DTC Descriptors
DTC C0131 00
Traction Control System Pressure Circuit Malfunction
DTC C0131 4B
Traction Control System Pressure Circuit Calibration Not Learned
DTC C0131 5A
Traction Control System Pressure Circuit Not Plausible
The electronic brake control module monitors the brake pressure sensor which is integral to the brake pressure
modulator. The body control module monitors the brake pedal position sensor signal when the brake pedal is
applied and sends a serial data message to the electronic brake control module indicating the brake pedal
position. The electronic brake control module compares the brake pressure to the brake pedal position and uses
this information for vehicle stability control.

Ignition ON.
C0131 00
The electronic brake control module detects the brake pressure is out of the specified range.
C0131 4B
The electronic brake control module detects the brake pressure sensor is not calibrated.
C0131 5A
The electronic brake control module detects an invalid or erratic brake pressure.
The brake pressure is not plausible with the vehicle acceleration or deceleration.
The brake pressure is not plausible with the brake pedal position sensor signal.

The electronic brake control module disables the traction control and stability control for the duration of
the ignition cycle.

Diagnostic Aids
Diagnose all other stop lamp DTCs or Symptoms prior to performing this diagnostic procedure.
This DTC may set if the electronic brake control module is loosely attached to the hydraulic unit. The
fasteners should be checked for proper torque.
Schematic Reference


Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference

DTC C0131 4B
1. Ignition ON.
2. Verify that DTC C0131 4B is not set.
If the DTC is set
1. Perform the Brake Pressure Modulator Valve Pressure Sensor Calibration.
If the DTC sets, replace the Q5 Brake Pressure Modulator.
If the DTC does not set.
3. All OK.
3. All OK.
DTC C0131 00 or C0131 5A
1. Ignition ON.
2. Verify that DTCs C0131 00 or C0131 5A are not set.
If either DTC is set
1. Replace the Q5 Brake Pressure Modulator.
2. Ignition ON.
If the DTC sets, replace the K17 Electronic Brake Control Module.
If the DTC does not set.
4. All OK.
If the DTCs are not set
3. All OK.

Repair Instructions

DTC C0161
DTC Descriptor
DTC C0161 5A
Antilock Braking System Brake Switch Circuit Not Plausible
When the brake pedal is applied, the body control module sends a serial data message to the electronic brake
control module in reference to the brake pedal positions. The electronic brake control module compares the
correlation between the brake pedal position and the amount of brake pressure it senses from the brake pressure
sensor, which is internal to the brake pressure modulator. It uses this information to control the vehicle during
an stability event.
Ignition ON.
The electronic brake control module detects four accelerations from standstill to a vehicle speed greater
40 km/h (26 MPH) without any brake pedal position signal changes.
The electronic brake control module detects the vehicle speed is greater than 20 km/h (13 MPH), the
brake pedal is applied for six minutes, and brake pressure is less than 15 bar (218 PSI).

No actions are taken

Diagnostic Aids
This DTC may set if the brake pedal is applied while accelerating.
Schematic Reference
Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference

1. Ignition ON.
2. Verify DTC C0277 or C0890 is not set.
If either DTC is set
Refer to DTC C0277 or C0890 .
If either DTC is not set
3. Verify the brake pedal position sensor or the brake pedal is not binding causing residual brake pressure to
be detected, while the brake lights operate properly.
If a condition is found
Repair or replace the applicable component.
If a condition is not found

4. Verify the scan tool Electronic Brake Control Module Brake Pedal Position Sensor parameter changes
between Active and Inactive while applying and releasing the brake pedal.
If the parameter does not change between Active and Inactive
Refer to Symptoms - Lighting .
If the parameter changes between Active and Inactive
5. Refer to Diagnostic Aids, All OK.
DTC C0186, C018B, C0196, C019B, OR C0287

DTC Descriptors
DTC C0186 5A
Lateral Acceleration Sensor Circuit Not Plausible
DTC C0186 71
Lateral Acceleration Sensor Circuit Invalid Data
DTC C018B 5A
Multi-Axis Acceleration Sensor Signal Not Plausible
DTC C0196 00
Yaw Rate Circuit Malfunction
DTC C0196 5A
Yaw Rate Signal Not Plausible
DTC C0196 71
Yaw Rate Signal Invalid Data
DTC C019B 5A
Yaw Rate Signal Not Plausible

DTC C0287 4B
Longitudinal Acceleration Sensor Circuit Calibration Not Learned
DTC C0287 5A
Longitudinal Acceleration Sensor Circuit Not Plausible
DTC C0287 71
Longitudinal Acceleration Sensor Circuit Invalid Data
Short to
Ground
U0125, U0126
Open/High
Resistance
U0125, U0126
U0073,
U0100,
CAN Bus High Serial Data
U0101,
U0125,
U0126, U0140
U0073, U0100,
U0101, U0125,
U0126, U0140
U0073,
U0100,
U0101,
CAN Bus Low Serial Data
U0125,
U0126, U0140
U0073, U0100,
U0101, U0125,
U0126, U0140
Circuit
12V Reference
Ground
U0125
Short to
Voltage
U0073,
U0100,
U0101,
U0125,
U0126,
U0140
U0073,
U0100,
U0101,
U0125,
U0126,
U0140
-
Signal Performance
C0186 5A, C0186 71,
C018B 5A, C0196 00,
C0196 5A, C0196 71,
C019B 5A, C0287 5A,
C0287 71
C0186 5A, C0186 71,
C018B 5A, C0196 00,
C0196 5A, C0196 71,
C019B 5A, C0287 5A,
C0287 71
-
The yaw rate and lateral acceleration sensors are combined into one multi-axis acceleration sensor module,
external to the electronic brake control module. The electronic brake control module supplies a 12 V reference
voltage to the multi-axis acceleration sensor module. The multi-axis acceleration sensor module communicates
with the electronic brake control module via serial data circuit. The electronic brake control module activates
the stability control function depending on multi-axis acceleration sensor module input.
Ignition ON.
C0186 5A

The lateral acceleration sensor signal is not plausible with the yaw rate sensor signal, steering angle sensor
signal and vehicle speed for 0.5-2 s.
C0186 71
The lateral acceleration sensor signal offset is out of specified range.
C018B 5A
The multi-axis acceleration sensor signal is not plausible.
C0196 00
The yaw rate sensor signal is out specified range.
C0196 5A or C019B 5A
The yaw rate sensor signal is not plausible with the lateral acceleration sensor signal, steering angle sensor
signal and vehicle speed. for 0.25-2 s.
C0196 71
The yaw rate sensor offset is out of specified range.
C0287 4B
The longitudinal acceleration sensor is not calibrated.
C0287 5A
The longitudinal acceleration sensor signal is not plausible with the vehicle speed.
C0287 71
The longitudinal acceleration sensor offset is out of specified range.
The electronic brake control module disables the stability control for the duration of the ignition cycle.
The traction control/stability control-active indicator turns ON.

The electronic brake control module will turn OFF the indicator in the next ignition cycle.

Schematic Reference
Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference

1. Ignition ON
2. Verify that DTC C0287 4B is not set.
If the DTC is set
Perform the Vehicle Yaw Sensor Learn.
3. Verify the B119 Multi-axis Acceleration Sensor is installed correctly.
If loose or incorrect installation
Correct the installation of the component.

If installed correctly
4. Ignition OFF, scan tool disconnected, and all vehicle systems OFF, disconnect the harness connector at
the B119 Multi-axis Acceleration Sensor. It may take up to 2 minutes for all vehicle systems to power
down.
1. Ignition OFF.

6. Ignition ON.
7. Verify a test lamp illuminates between the 12 V reference circuit terminal 5 and ground.
1. Ignition OFF, disconnect the harness connector at the B99 Steering Wheel Angle Sensor and the
K17 Electronic Brake Control Module.
8. Replace the B119 Multi-axis Acceleration Sensor.
Repair Instructions
Vehicle Yaw Sensor Replacement

Control Module References for Electronic Brake Control Module replacement, programming and setup.
DTC C0280
DTC Descriptor
DTC C0280 54
Stability System Active Too Long High Temperature
The solenoid valves are integral parts of the brake pressure modulator. The modulator contains an isolation
solenoid valve and a dump solenoid valve for each wheel along with a traction/stability control supply solenoid

valve and isolation solenoid valve for each brake circuit. The solenoid valves are not engaged during normal
system operation. When the ABS, traction control or stability control operation is required the electronic brake
control module turns the required solenoid valves ON. The electronic brake control module detects an over
temperature condition with one or more of the solenoids due to an extended ABS, traction control or stability
control event lasting more than fifteen seconds.
Ignition ON
Stability control is active for more than 15 seconds.


A Brakes Overheated message may be displayed.
The traction/stability control indicator turns ON, if equipped with electronic stability control.
The electronic brake control module disables the ABS, the traction control system and the electronic
stability control system for the duration of the ignition cycle.

Diagnostic Aids
This DTC may set due to extended operation of the ABS, the traction control or the stability control.
Schematic Reference
Circuit Testing

Connector Repairs
Wiring Repairs
Scan Tool Reference

NOTE:
Since most occurrences of this DTC are caused by excessive ABS, traction
control or stability control usage, review with the customer the conditions
under which the DTC set.
1. Ignition ON.
2. Verify that DTC C0186, C018B, C0196, C019B, C0287, or C0710 is not set.
3. Ignition OFF, allow the Q5 Brake Pressure Modulator to cool down to ambient temperature, ignition ON.
4. Verify that DTC C0280 54 does not set while driving the vehicle under normal braking conditions.
If the DTC is set

5. All OK.
Repair Instructions

DTC C0710

DTC Descriptors
DTC C0710 00
Steering Position Signal Malfunction
DTC C0710 42
Steering Position Signal Calibration Not Programmed
DTC C0710 71
Steering Position Signal Invalid Data
DTC C0710 5A
Steering Position Signal Not Plausible
Circuit
12 V Reference
Short to
Ground
U0125, U0126
Ground
Open/High
Resistance
U0125, U0126
U0125, U0126,
C0710 5A
Short to
Voltage
-
Signal Performance
-
The steering wheel angle sensor receives a 12 V reference voltage from the electronic brake control module.
The electronic brake control module receives serial data inputs from the steering wheel angle sensor identifying
the position and direction of the steering wheel rotation. The module utilizes this signal to calculate the driver
intended driving direction.
Ignition ON.
C0710 00
The steering angle signal is invalid.
C0710 42
The steering wheel angle sensor is not calibrated.

C0710 5A
No steering angle signal

The steering angle signal is not plausible with the yaw rate signal.
The steering wheel angle sensor offset is out of the specified range.

The electronic brake control module disables the traction control, the stability control and the hill start
assist for the duration of the ignition cycle.
The DTC clears the DTC when the diagnostic runs and passes.
Diagnostic Aids
Improperly mounted or loose steering wheel angle sensor.

The car should not pull in either direction causing the steering wheel to be off center while driving in a
straight line on a level surface.
Confirm that all tires are of the proper size and that all are matching brands. Check and adjust all tires to
the stated cold air pressure as identified on the tire placard. If a mis-sized or non-matching brand tire is
present, inform the customer that in order for the vehicle stability enhanced system to function normally,
tires need to be a uniform size and rolling diameter.
Schematic Reference
Circuit Testing
Connector Repairs

Wiring Repairs
Scan Tool Reference

1. Ignition ON.
2. Verify the scan tool Steering Wheel Angle parameter value constantly changes from +550 to -550 as the
steering wheel is turned through its entire range from left to right.
3. All OK.
1. Ignition ON.
2. Verify that DTC U0125 or U0126 is not set.
If DTC U0125 or U0126 is set
If DTC U0125 or U0126 is not set
3. Verify that DTC C0710 42 or C0710 5A is not set.
If DTC C0710 42 or C0710 5A is set
Perform the Steering Angle Sensor Centering.

If DTC C0710 42 or C0710 5A is not set
4. Verify the B99 Steering Wheel Angle Sensor is installed correctly.
If loose or incorrect installation
Correct the installation or replace the component.

If correct installation
5. Ignition OFF and all vehicle systems OFF, disconnect the harness connector at the B99 Steering Wheel
Angle Sensor. It may take up to 2 minutes for all vehicle systems to power down.
1. Ignition OFF.

7. Ignition ON.
8. Verify a test lamp illuminates between the 12 V reference circuit terminal 5 and ground.
1. Ignition OFF, disconnect the harness connector at the B119 Multi-axis Acceleration Sensor and the
K17 Electronic Brake Control Module.
9. Replace the B99 Steering Wheel Angle Sensor.
Repair Instructions
Steering Angle Sensor Replacement

DTC C1207-C1210, C1221-C1228, OR C1232-C1235

DTC Descriptors
DTC C1207 00
Left Front Wheel Speed Sensor Circuit High Input
DTC C1208 00
Right Front Wheel Speed Sensor Circuit High Input

DTC C1209 00
Left Rear Wheel Speed Sensor Circuit High Input
DTC C1210 00
Right Rear Wheel Speed Sensor Circuit High Input
DTC C1221 00
Left Front Wheel Speed Sensor Circuit Malfunction
DTC C1222 00
Right Front Wheel Speed Sensor Circuit Malfunction
DTC C1223 00
Left Rear Wheel Speed Sensor Circuit Malfunction
DTC C1224 00
Right Rear Wheel Speed Sensor Circuit Malfunction
Each Wheel Speed Sensor receives ignition voltage through the signal high circuit from the Electronic Brake
Control Module. Wheel speeds are detected by Active Wheel Speed Sensors and Encoder Rings. The Magnetic
Encoder Rings consists of multiple North and South Pole pairs surrounding the outer circumference. When the
Encoder Ring rotates and passes by the Wheel Speed Sensor; it generates a sign wave in the Wheel Speed
Sensor. The sensor converts the signal to a digital square wave; the square wave values switch between 7mA
(Low) and 14mA (High) DC current. As the wheel spins, the module uses the frequency of the square wave
signal to calculate the wheel speeds.
Vehicle speed is greater than 12.9 km/h (8 MPH).

A supervised periodic message indicates the wheel speed serial data has not been received.
The Traction/stability Control indicator turns ON.

The Electric Brake Control Module disables the traction control, the stability control and the Hill Start
Assist for the duration of the ignition cycle.

The DTC clears when the diagnostic runs and passes.

The history DTC will clear after 40 consecutive fault-free drive cycles have occurred.
Schematic Reference
Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference

1. Verify DTC C0035, C0040, C0045, or C0050 is not set.

Refer to DTC C0035, C0040, C0045, or C0050.
2. Replace the K17 Electronic Brake Control Module.
3. Verify DTC C1207, C1208, C1209, C1210, C1221, C1222, C1223, or C1224 does not set while operating
the vehicle within the Conditions for Running the DTC.
Replace the module that set the DTC.


4. All OK.
Repair Instructions

Control Module References for Electronic Brake Control Module or module replacement, programming and
setup
DTC C1251
DTC Descriptors
DTC C1251
Lateral Acceleration Sensor Performance
For symptom byte information refer to Symptom Byte List .
The yaw rate, lateral acceleration and longitudinal acceleration sensors are combined into one multi-axis
acceleration sensor, external to the electronic brake control module. The electronic brake control module
supplies ignition voltage to the multi-axis acceleration sensor. The multi-axis acceleration sensor communicates
with the electronic brake control module via serial data. The electronic brake control module activates the
stability control function depending on the multi-axis acceleration sensor input. The transmission control
module sets this DTC.
Engine running
The transmission control module detects a fault that prevents it from performing a hill hold start assist function.

The electronic brake control module disables the traction control and the stability control for the duration

of the ignition cycle.

The DTC clears when the diagnostic runs and passes.

Schematic Reference
Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference

1. Ignition ON.
2. Verify that no other DTCs are set except for C1251 is set.
If any other DTCs are set
3. Replace the K71 Transmission Control Module.
4. Verify that DTC C1251 does not set while operating the vehicle within the Conditions for Running the
DTC.
If the DTC sets


5. All OK.
Repair Instructions

Control Module References for Electronic Brake Control Module or Transmission Control Module
replacement, programming and setup
DTC P0856
DTC Descriptor
DTC P0856
Traction Control Torque Request Circuit
When traction control is active, the electronic brake control module sends a serial data message to the engine
control module requesting torque reduction. When certain electronic brake control module DTCs are set, the
engine control module will not be able to perform the torque reduction for traction control. A serial data
message is sent to the electronic brake control module indicating that traction control is not allowed.
Engine running.
The engine control module detects a fault that prevents it from performing a traction control function and sends
a serial data message to the electronic brake control module indicating that torque reduction is not allowed.

the ignition cycle.


Schematic Reference
Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference

1. Verify that no other DTCs are set except for P0856.

3. Verify the DTC does not set while operating the vehicle within the Conditions for Running the DTC.
If DTC sets
If DTC does not set

4. All OK.
Repair Instructions

Control Module References for Electronic Brake Control Module and Engine Control Module replacement,
programming and setup
SYMPTOMS - ANTILOCK BRAKE SYSTEM
NOTE:
2. Review the system description and operation in order to familiarize yourself with the system functions.
Refer to ABS Description and Operation.
Inspect for aftermarket devices which could affect the operation of the ABS. Refer to Checking
Intermittent
Symptom List
ABS Indicator Malfunction

Traction Control/Stability Control Indicator Malfunction
ABS INDICATOR MALFUNCTION



The instrument cluster turns On the ABS indicator for five seconds after the ignition is ON or when the
electronic brake control module detects a fault and sends a serial data message to the instrument cluster
commanding the ABS indicator ON.
Schematic Reference
Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference

1. Ignition ON.
2. Verify the Instrument Cluster ABS Indicator turns On and Off when commanding the All Indicators On
If the ABS indicator does not turn On and Off
If the ABS indicator turns On and Off
3. Verify the ABS Indicator turns Off five seconds after the ignition is turned On.

If the ABS indicator does not turn Off

If the ABS indicator turns Off

4. All OK.
Repair Instructions

Control Module References for Electronic Brake Control Module or Instrument Cluster replacement,
programming and setup
TRACTION CONTROL/STABILITY CONTROL INDICATOR MALFUNCTION
Circuit
Signal
Ground
1. Stability Control Switch Malfunction
Short to
Ground
B2745 02
-
Open/High
Resistance
1
1
Short to
Voltage
1
-
Signal
Performance
-
The body control module monitors the traction control switch. When the traction control switch is pressed once,
the body control module will request the electronic brake control module via serial data to disable the traction
control. The electronic brake control module will request the instrument cluster via serial data to turn the
traction control off indicator ON to notify the driver of the deactivation.
When the traction control switch is pressed and held for five seconds, the body control module will request the
electronic brake control module to disable the electronic stability control. The electronic brake control module
will request the instrument cluster via serial data to turn the traction control off and stability control off
indicator ON to notify the driver of the deactivation.
Schematic Reference


Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference

1. Ignition ON.
2. Verify the instrument cluster indicators listed below turn ON and OFF when commanding the All
Indicators ON and OFF with a scan tool.
Traction/stability Control indicator
Traction Control Off indicator
Stability Control Off indicator
If any indicator does not turn ON and OFF
If all indicator turn ON and OFF
3. Verify the scan tool Body Control Module, Traction Control Switch parameter changes between Active
and Inactive when pressing and releasing the S75 Traction Control Switch.

4. All OK.

NOTE:
1. Ignition OFF and all vehicle systems OFF, disconnect the harness connector at the S75 Traction Control
Switch. It may take up to 2 minutes for all vehicle systems to power down.
1. Ignition OFF.
3. Ignition ON.
4. Verify the scan tool Body Control Module, Traction Control Switch parameter is Inactive.
If not Inactive
1. Ignition OFF, disconnect the X2 harness connector at the K9 body control module.
If Inactive
6. Verify the scan tool Traction Control Switch parameter is Active.
If not Active
If less than 1 V
If Active
7. Test or replace the S75 Traction Control Switch.
Component Testing
1. Ignition OFF, disconnect the harness connector at the S75 Traction Control Switch.


If less than 2 ohms
4. All OK.
Repair Instructions

Control Module References for Body Control Module or Instrument Cluster replacement, programming
and setup
REPAIR INSTRUCTIONS
ANTILOCK BRAKE SYSTEM AUTOMATED BLEED
WARNING: Refer to Brake Fluid Irritant Warning .
CAUTION: Refer to Brake Fluid Effects on Paint and Electrical Components Caution .
NOTE:
Before performing the ABS Automated Bleed Procedure, first perform a

pressure bleed of the base brake system. Refer to Hydraulic Brake System
Bleeding (Manual Bleeding) , Hydraulic Brake System Bleeding (Pressure
Bleeding) . The automated bleed procedure is recommended when one of the
following conditions exist:
Base brake system bleeding does not achieve the desired pedal height or
feel
Extreme loss of brake fluid has occurred
Air ingestion is suspected in the secondary circuits of the brake modulator
assembly
The ABS Automated Bleed Procedure uses a scan tool to cycle the system solenoid valves and run the pump in
order to purge any air from the secondary circuits. These circuits are normally closed off, and are only opened

during system initialization at vehicle start up and during ABS operation. The automated bleed procedure opens
these secondary circuits and allows any air trapped in these circuits to flow out toward the brake corners.
Performing the Automated Bleed Procedure
CAUTION: The Auto Bleed Procedure may be terminated at any time during the
process by pressing the EXIT button. No further Scan Tool prompts
pertaining to the Auto Bleed procedure will be given. After exiting the
bleed procedure, relieve bleed pressure and disconnect bleed
equipment per manufacturers instructions. Failure to properly relieve
pressure may result in spilled brake fluid causing damage to
components and painted surfaces.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
Remove all four tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation .
Inspect the brake system for leaks and visual damage. Repair or replace components as needed.
Lower the vehicle.
Inspect the battery state of charge. Refer to Battery Inspection/Test .
Install a scan tool.
Turn the ignition ON, with the engine OFF.
With the scan tool, establish communications with the ABS system. Select Control Functions. Select
Automated Bleed from the Control Functions menu.
Following the directions given on the scan tool, pressure bleed the base brake system. Refer to Hydraulic
Brake System Bleeding (Manual Bleeding) , Hydraulic Brake System Bleeding (Pressure Bleeding) .
Follow the scan tool directions until the desired brake pedal height is achieved.
If the bleed procedure is aborted, a malfunction exists. Perform the following steps before resuming the
bleed procedure:
If a DTC is detected, refer to Diagnostic Trouble Code (DTC) List - Vehicle , and diagnose the
appropriate DTC.
If the brake pedal feels spongy, perform the conventional brake bleed procedure again. Refer to
Hydraulic Brake System Bleeding (Manual Bleeding) , Hydraulic Brake System Bleeding
(Pressure Bleeding) .
When the desired pedal height is achieved, press the brake pedal to inspect for firmness.
Lower the vehicle.
Remove the scan tool.
Install the tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation .
Inspect the brake fluid level. Refer to Master Cylinder Reservoir Filling .
Road test the vehicle while inspecting that the pedal remains high and firm.
STEERING ANGLE SENSOR REPLACEMENT

Fig. 4: View Of Steering Wheel Position Sensor

Steering Angle Sensor Replacement
Callout
Component Name
Remove the steering wheel inflatable restraint module coil. Refer to Steering Wheel Airbag Coil
Replacement .
Steering Wheel Position Sensor
WARNING:
Never rotate the steering angle sensor. Rotating the steering angle
sensor could limit the operation of the electronic power steering
(EPS) system, and result in personal injury.
1
Procedure
1. Press in the clip on the inflatable restraint steering wheel module
clock-spring coil to remove the sensor.
2. Calibrate the steering angle sensor. Refer to Steering Angle
Sensor Centering.
STEERING ANGLE SENSOR CENTERING
WARNING: An inaccurate or not centered steering angle sensor could limit the

operation of the electric power steering (EPS) and result in personal

injury.
For vehicles WITHOUT electronic stability control program and INTERNAL Steering Angle Sensor
Refer to the Steering Angle Centering procedure in Power Steering Control Module Calibration .
For vehicles WITH electronic stability control program and EXTERNAL Steering Angle Sensor
The external, column mounted, steering angle sensor does not require a centering often. Centering of the
external steering angle sensor might be required after certain service procedures are performed. Some of these
procedures are as follows:
Electronic brake control module (EBCM) replacement

Steering angle sensor replacement
Steering gear replacement
Steering column replacement
Collision or other physical damage
The external steering angle sensor centering procedure can be completed with a scan tool using the following
steps:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
Using the steering wheel, align the front wheels forward.

Apply the parking brake, or set the transmission in the P position.
Install the scan tool to the data link connector.
Ignition ON, engine OFF
Select Steering Wheel Angle Sensor Reset in the Steering Wheel Angle Sensor Module
Configuration/Reset Functions list.
Follow the scan tool directions to complete the learn procedure.
Select Steering Wheel Angle Sensor Learn in the Steering Wheel Angle Sensor Module
Configuration/Reset Functions list.
Select Steering Wheel Angle Sensor Learn in the EBCM Configuration/Reset Functions list.
If the vehicle is equipped with electronic power steering, perform the Software Endstop Learning
procedure. Refer to Power Steering Control Module Calibration .
Clear any DTCs that may be set.
ELECTRONIC BRAKE CONTROL MODULE REPLACEMENT

Fig. 5: Electronic Brake Control Module, Modulator Valve & Bolts

Electronic Brake Control Module Replacement
Callout
Component Name
WARNING:
Refer to Brake Fluid Irritant Warning .
CAUTION:
Refer to Brake Fluid Effects on Paint and Electrical Components Caution .
CAUTION:
Always connect or disconnect the wiring harness connector from the EBCM/EBTCM with the ignition
switch in the OFF position. Failure to observe this precaution could result in damage to the
EBCM/EBTCM.
1. Prepare electronic brake control module for replacement. Refer to Control Module References .
2. Disconnect the battery. Refer to Battery Negative Cable Disconnection and Connection .
3. Remove the BPMV from BPMV bracket. Refer to Brake Pressure Modulator Valve
Replacement.
Electronic Brake Control Module Bolt (Qty: 2)

CAUTION:
Tighten
3 N.m (26 lb in)
Brake Pressure Modulator Valve
Electronic Brake Control Module
Procedure
1. Carefully separate the EBCM from the BPMV, do not pry the
components apart.
2. Clean the sealing surface of the BPMV with denatured alcohol and a
clean shop cloth and allow to dry.
3. Fill the master cylinder reservoir.
4. Program the EBCM, IF installing a new EBCM. Refer to Electronic
Brake Control Module Programming and Setup .
5. Bleed the brake system. Refer to Hydraulic Brake System Bleeding
(Manual Bleeding) , Hydraulic Brake System Bleeding (Pressure
Bleeding) .
6. Perform the automated brake bleed. Refer to Antilock Brake System
Automated Bleed.
7. Perform a diagnostic system check. Refer to Diagnostic System
Check - Vehicle .
8. If equipped, calibrate the brake pedal position sensor. Refer to Brake
Pedal Position Sensor Calibration .
9. Centering the steering angle sensor. Refer to Steering Angle Sensor
Centering.
BRAKE PRESSURE MODULATOR VALVE REPLACEMENT

Removal Procedure
1. Prepare electronic brake control module for replacement. Refer to Control Module References .
2. Turn the ignition to the OFF position.

Fig. 6: View Of Radiator Surge Tank And Radiator Surge Tank Clip
NOTE:
Do NOT disconnect engine coolant hoses.
3. Remove the radiator surge tank clip (2).

4. Remove the radiator surge tank (1).
Position the radiator surge tank (1) aside.
CAUTION: Always connect or disconnect the wiring harness connector from the
EBCM/EBTCM with the ignition switch in the OFF position. Failure to
observe this precaution could result in damage to the EBCM/EBTCM.
5. Disconnect the electrical connector from the EBCM/EBTCM.

Fig. 7: Brake Pipe Fittings At BPMV

NOTE:
Cap the brake pipe fittings to prevent brake fluid loss and contamination.
6. Remove the 6 brake pipes (1, 2) from the BPMV.

Fig. 8: BPMV and BPMV Bracket Bolts

7. Remove the 2 BPMV bracket bolts (2).
8. Remove the BPMV bracket assembly (1).


9. Remove the 3 BPMV bracket bolts.
10. Remove the BPMV (2).
11. Remove the BPMV insulator (1) from the BPMV bracket (3).


1. Install the BPMV insulator (1) to the BPMV bracket (3).
2. Install the BPMV (2).
3. Install the 3 BPMV bracket bolts (4) and tighten to 10 N.m(89 lb in).


4. Install the BPMV bracket assembly (1).
5. Install the 2 BPMV bracket bolts (2) and tighten to 20 N.m(15 lb ft).


6. Install the 6 brake pipes (1, 2) to the BPMV and tighten to 18 N.m(14 lb ft).
7. Connect the electrical connector to the EBCM/EBTCM.

8.
9.
10.
11.
12.
Install the radiator surge tank (1).

Install the radiator surge tank clip (2).
Program the EBCM. Refer to Electronic Brake Control Module Programming and Setup .
Perform the diagnostic system check - Vehicle. Refer to Diagnostic System Check - Vehicle .
Calibrate the brake pressure modulator valve pressure sensor. Refer to Brake Pressure Modulator Valve
Pressure Sensor Calibration.
CAUTION: Only use products that comply with GM specifications and check
manufacturer information respectively. We recommend the use of GM
genuine products. Instructions must be followed at all times. The use
of any type of fluid other than the recommended type of brake fluid,
may cause contamination which could result in damage to the
internal rubber seals and/or rubber linings of hydraulic brake system

components.
13. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding (Manual Bleeding) ,
Hydraulic Brake System Bleeding (Pressure Bleeding) .
14. Center the steering angle sensor. Refer to Steering Angle Sensor Centering.
BRAKE PRESSURE MODULATOR VALVE PRESSURE SENSOR CALIBRATION
The brake pressure sensor does not require calibration often. Calibration of the brake pressure sensor might be
required after certain service procedures are performed. Some of these procedures are as follows:

Brake pressure modulator valve assembly replacement
The Brake Pressure Sensor Calibration procedure can be completed with a scan tool using the following steps:
1.
2.
3.
4.
5.
6.
7.

Release the brake pedal.
Ignition ON, engine OFF
Select Brake Pressure Sensor Calibration in the EBCM Configuration/Reset Functions list.
Follow the scan tool directions to complete the calibration procedure.
BRAKE PRESSURE MODULATOR VALVE BRACKET REPLACEMENT

Removal Procedure

NOTE:



NOTE:


6. Remove the 2 BPMV bracket bolts (2).


8. Remove the 3 BPMV bracket bolts.
9. Remove the BPMV (2).
10. Remove the BPMV insulator (1) from the BPMV bracket (3).


1. Install the BPMV insulator (1) to the BPMV bracket (3).
2. Install the BPMV (2).
3. Install the 3 BPMV bracket bolts (4). Tighten the BPMV bracket bolts 10 N.m (89 lb in).


5. Install the 2 BPMV bracket bolts (2) and tighten to 20 N.m (15 lb ft).


6. Install the 6 brake pipes (1, 2) to the BPMV and tighten to 18 N.m (14 lb ft).
7. Connect the electrical connector to the EBCM/EBTCM.

8.
9.
10.
11.
12.

Program the EBCM. Refer to Electronic Brake Control Module Programming and Setup .
Perform the diagnostic system check - Vehicle. Refer to Diagnostic System Check - Vehicle .
Calibrate the brake pressure modulator valve pressure sensor. Refer to Brake Pressure Modulator Valve
Pressure Sensor Calibration.
CAUTION: When adding fluid to the brake master cylinder reservoir, use only
GM approved or equivalent DOT-3 brake fluid from a clean, sealed
brake fluid container. The use of any type of fluid other than the
recommended type of brake fluid may cause contamination which
could result in damage to the internal rubber seals and/or rubber
linings of hydraulic brake system components.

14. Center the steering angle sensor. Refer to Steering Angle Sensor Centering.
FRONT WHEEL SPEED SENSOR REPLACEMENT
Removal Procedure
2. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation .
Fig. 22: Wheel Speed Sensor And Wheel Speed Sensor Screw
3. Remove the wheel speed sensor screw (2) from the steering knuckle.
4. Remove the wheel speed sensor (1).

Fig. 23: Wheel Speed Sensor Wiring Harness

5. Remove the wiring harness retainers from the frame.
7. Remove wheel speed sensor (1) from the vehicle.


1. Install the wheel speed sensor (1) to the vehicle.
2. Connect the electrical connector.
3. Install the wiring harness retainers to the frame.

4. Install the wheel speed sensor (1) to the steering knuckle.
5. Install the wheel speed sensor screw (2) and tighten to 6 N.m (53 lb in).
6. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation .
REAR WHEEL SPEED SENSOR REPLACEMENT (DISC BRAKE)
Removal Procedure
1. Remove rear wheelhouse panel liner. Refer to Rear Wheelhouse Liner Replacement .

4. Remove the wiring harness (3) from the bracket (4).


5. Remove the wiring harness (2) retainers (3) from the brake hose (4).
6. Remove the wiring harness (2) from the body retainer (1).
7. Replace the body retainer (1).

Fig. 28: Wheel Speed Sensor Electrical Connector

8. Disconnect the electrical connector (1).
9. Remove wheel speed sensor from the vehicle.


1. Install the wheel speed sensor to the vehicle.
2. Connect the electrical connector (1).


3. Install the wiring harness (2) retainers (3) to the TOP SIDE of brake hose (4), using the marking points of
old wiring harness.
4. Install the wiring harness (2) to the NEW body retainer (1).

5. Install the wheel speed sensor (1) to the steering knuckle.
6. Install the wiring harness (3) at the bracket (4).

Fig. 32: Wheel Speed Sensor Wiring Harness Retainers

8. Check the correct installation position of the wiring harness (1). The wiring harness MUST be routed on
top of the brake hose. If necessary adjust retainers (2) to the marking positions on the brake hose.
9. Apply tension to the wiring harness (1) between the retainers (2) for the correct routing.
10. Push down the brake hose by hand, to assure the correct installation position.
11. Install the rear wheelhouse panel liner. Refer to Rear Wheelhouse Liner Replacement .
REAR WHEEL SPEED SENSOR REPLACEMENT (DRUM BRAKE)
Removal Procedure
1. Remove rear wheelhouse panel liner. Refer to Rear Wheelhouse Liner Replacement .
2. Remove the rear brake hose from the wheel cylinder and the rear backing plate. Refer to Rear Brake
Hose Replacement (Drum Brake) , Rear Brake Hose Replacement (Disc Brake)

4. Remove wheel speed sensor (1).
5. Remove wiring harness (3) from bracket (4).


7. Remove wheel speed sensor from vehicle.


1. Install the wheel speed sensor to the vehicle.
2. Connect the electrical connector (1).

3. Install the wheel speed sensor (1) to steering knuckle.
4. Install wiring harness (3) at the bracket (4).
6. Install the rear brake hose to the wheel cylinder and the rear backing plate. Refer to Rear Brake Hose
Replacement (Drum Brake) , Rear Brake Hose Replacement (Disc Brake)
7. Install rear wheelhouse panel liner. Refer to Rear Wheelhouse Liner Replacement .
VEHICLE YAW SENSOR LEARN

The yaw sensor does not require calibration often. Calibration of the yaw rate sensor might be required after
certain service procedures are performed. Some of these procedures are as follows:

Multi-axis acceleration sensor replacement
The yaw rate sensor calibration procedure can be completed with a scan tool using the following steps:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Place vehicle on a level surface

Select Yaw Rate Sensor Reset in the Multi-axis Acceleration Sensor Module Configuration/Reset
Functions list.
Select Yaw Rate Sensor Learn in the Multi-axis Acceleration Sensor Module Configuration/Reset
Functions list.
Select Yaw Rate Sensor Learn in the EBCM Configuration/Reset Functions list.
VEHICLE YAW SENSOR REPLACEMENT

Fig. 37: Vehicle Yaw Sensor

Vehicle Yaw Sensor Replacement
Callout
Component Name
Vehicle Yaw Sensor Nut (Qty: 2)
CAUTION:
Tighten
9 N.m (80 lb in)
Vehicle Yaw Sensor
Procedure
2
2. After the installation is complete, perform the yaw sensor learn
procedure. Refer to Vehicle Yaw Sensor Learn

ABS DESCRIPTION AND OPERATION

This vehicle is equipped with a Continental Teves Mk60/Mk70 brake system. The electronic brake control
module (EBCM) and the brake pressure modulator valve assembly are serviced separately. The brake pressure
modulator valve assembly uses a 4 circuit configuration to control hydraulic pressure to each wheel
independently.
Depending on options, the following vehicle performance enhancement systems are provided.
Antilock brake system (ABS)

Traction control
Stability control
Dynamic rear proportioning
Hydraulic brake assist
The following components are involved in the operation of the above systems:
EBCM - The EBCM controls the system functions and detects failures. It supplies voltage to the solenoid
valves and pump motor.
Brake pressure modulator valve assembly - The brake pressure modulator valve assembly contains the
following components:
Hydraulic pump with pump motor
Four isolation vales
Four dump valves
Two traction control/stability control supply valves
Two traction control/stability control isolation valves
Pressure sensor
High pressure accumulator
Low pressure accumulator
Multi-axis acceleration sensor - The yaw rate and lateral acceleration sensors are combined into one
multi-axis acceleration sensor, external to the EBCM. The EBCM receives serial data message inputs
from the yaw rate and lateral acceleration sensor and activates stability control depending on multi-axis
acceleration sensor input.
Steering angle sensor - The EBCM receives serial data message inputs from the steering angle sensor.
The steering angle sensor signal is used to calculate the desired yaw rate.
Traction control switch - Traction control and stability control are manually disabled or enabled by
pressing the traction control switch.
Wheel speed sensors - The EBCM sends a 12 V reference voltage to each wheel speed sensor. As the
wheel spins, the wheel speed sensor produces an alternating current square wave signal. The EBCM uses
the frequency of the square wave signal to calculate the wheel speed.
Initialization Sequence

The initialization sequence cycles each solenoid valve and the pump motor, as well as the necessary relays, for
approximately 30 milliseconds to check component operation. The electronic brake control module sets a DTC
if any error is detected. The initialization sequence may be heard and felt while it is taking place, and is
considered part of normal system operation. The active test is initiated by the electronic brake control module at
the start of the ignition cycle and the speed of the fastest wheel exceeds 8 km/h (5 MPH).
ABS
When wheel slip is detected during a brake application, an ABS event occurs. During ABS braking, hydraulic
pressure in the individual wheel circuits is controlled to prevent any wheel from slipping. A separate hydraulic
line and specific solenoid valves are provided for each wheel. The ABS can decrease, hold, or increase
hydraulic pressure to each wheel. The ABS does not, however, increase hydraulic pressure above the amount
which is transmitted by the master cylinder during braking.
During ABS braking, a series of rapid pulsations is felt in the brake pedal. These pulsations are caused by the
rapid changes in position of the individual solenoid valves as the EBCM responds to wheel speed sensor inputs
and attempts to prevent wheel slip. These pedal pulsations are present only during ABS braking and stop when
normal braking is resumed or when the vehicle comes to a stop. A ticking or popping noise may also be heard
as the solenoid valves cycle rapidly. During ABS braking on dry pavement, intermittent chirping noises may be
heard as the tires approach slipping. These noises and pedal pulsations are considered normal during ABS
operation.
Vehicles equipped with ABS may be stopped by applying normal force to the brake pedal. Brake pedal
operation during normal braking is no different than that of previous non ABS systems. Maintaining a constant
force on the brake pedal provides the shortest stopping distance while maintaining vehicle stability. The typical
ABS activation sequence is as follows.
Pressure Hold
The EBCM closes the isolation valve and keeps the dump valve closed in order to isolate the slipping wheel
when wheel slip occurs. This holds the pressure steady on the brake so that the hydraulic pressure does not
increase or decrease.
Pressure Decrease
If a pressure hold does not correct the wheel slip condition, a pressure decrease occurs. The EBCM decreases
the pressure to individual wheels during deceleration when wheel slip occurs. The isolation valve is closed and
the dump valve is opened. The excess fluid is stored in the accumulator until the pump can return the fluid to
the master cylinder or fluid reservoir.
Pressure Increase
After the wheel slip is corrected, a pressure increase occurs. The EBCM increases the pressure to individual
wheels during deceleration in order to reduce the speed of the wheel. The isolation valve is opened and the
dump valve is closed. The increased pressure is delivered from the master cylinder.
Traction Control

When drive wheel slip is noted, the EBCM will enter traction control mode.
First, the EBCM requests the engine control module (ECM) to reduce the amount of torque to the drive wheels
via a serial data message. The ECM reduces torque to the drive wheels and reports the amount of delivered
torque.
If the engine torque reduction does not reduce drive wheel slip, the EBCM will actively apply the brakes on the
slipping drive wheel. During traction control braking, hydraulic pressure in each drive wheel circuit is
controlled to prevent the drive wheels from slipping. The EBCM commands the pump motor and appropriate
solenoid valves ON and OFF to apply brake pressure to the slipping wheel.
Traction control can be manually disabled or enabled by pressing the traction control switch.
Stability Control
Stability control provides added stability during aggressive maneuvers. Yaw rate is the rate of rotation about the
vehicle's vertical axis. The stability control is activated when the EBCM determines that the desired yaw rate
does not match the actual yaw rate as measured by the yaw rate sensor.
The desired yaw rate is calculated by the EBCM using the following inputs:
Steering wheel position

Vehicle speed
Lateral acceleration
The difference between the desired yaw rate and the actual yaw rate is the yaw rate error, which is a
measurement of oversteer or understeer. When a yaw rate error is detected, the EBCM attempts to correct the
vehicle's yaw motion by applying brake pressure to one or more of the wheels. The amount of brake pressure
which is applied varies, depending on the correction required. The engine torque may be reduced also, if it is
necessary to slow the vehicle while maintaining stability.
Stability control activations generally occur in turns during aggressive driving. When braking during stability
control activation, the brake pedal may pulsate.
Stability control can be manually disabled or enabled by pressing the traction control switch for 5 s.
Dynamic Rear Proportioning
The dynamic rear proportioning is a control system that replaces the mechanical proportioning valve. Under
certain driving conditions the EBCM will reduce the rear wheel brake pressure by commanding the appropriate
solenoid valves ON and OFF.
Hydraulic Brake Assist
The hydraulic brake assist function is designed to support the driver in emergency braking situations.
The EBCM receives inputs from the brake pressure sensor. When the EBCM senses an emergency braking

situation, the EBCM will actively increase the brake pressure to a specific maximum.
Driver Information Indicators
Brake Warning Indicator

The instrument cluster turns the brake warning indicator ON when the following occurs:
The instrument cluster performs the bulb check.

The EBCM detects a fault and sends a serial data message to the instrument cluster requesting
illumination.
The body control module (BCM) detects that the park brake is engaged. The instrument cluster receives a
serial data message from the BCM requesting illumination.
ABS Indicator
The instrument cluster turns the ABS indicator ON when the following occurs:

The EBCM detects a malfunction which disables the ABS and sends a serial data message to the
instrument cluster requesting illumination.
Traction Control/Stability Control Active Indicator

The instrument cluster turns the traction control/stability control-active indicator ON when the following
occurs:

The ABS system is in traction control or stability control mode.
The EBCM detects a malfunction which disables the traction control or stability control and sends a serial
data message to the instrument cluster requesting illumination.
Traction Control Off Indicator

The instrument cluster turns the traction control off indicator ON when the following occurs:

The driver manually disables the traction control by pressing the traction control switch. The EBCM
sends a serial data message to the instrument cluster requesting illumination.
Stability Control Off Indicator

The instrument cluster turns the stability control off indicator ON when the following occurs:

The driver manually disables the stability control by pressing the traction control switch. The EBCM

sends a serial data message to the instrument cluster requesting illumination.

2013 BRAKES Disc Brakes - Cruze
2013 BRAKES
Disc Brakes - Cruze
SPECIFICATIONS
Specification
Application
Brake Caliper Bleeder Valve
Brake Hose and the Brake Hose-To-Caliper Bolt
Brake Pipe Fitting Bolt
Front Brake Caliper Bracket Bolt
Front Brake Caliper Guide Pin Bolt
Rear Brake Caliper Bracket Bolt
Rear Brake Caliper Guide Pin Bolt
Vibration Dampener
Vibration Dampener Stud
Wheel Bearing/Hub Mounting Bolts
Wheel Speed Sensor Bolt
(1) = Use NEW Fastener
Metric
English
17 N.m
13 lb ft
40 Y
30 lb ft
18 N.m
13 lb ft
100 N.m + 60-75 (1) 74 lb ft + 60-75 (1)
28 N.m
21 lb ft
100 N.m + 60-- 75 74 lb ft + 60-- 75
(1)
(1)
28 N.m
21 lb ft
9 N.m
80 lb in
28 N.m
21 lb ft
50 N.m + 30 (1)
37 lb ft + 30 (1)
6 N.m
53 lb in
DISC BRAKE COMPONENT SPECIFICATIONS

Disc Brake Component Specifications
Specification
Application
Metric
English
Front Brakes
Caliper Bore Diameter-Rear (15" Brake System)
40.0 mm
1.574 in
Rotor Diameter (15" Brake System)
276.0 mm
10.866 in
Rotor Thickness (15" Brake System)
26 mm
1.024 in
Rotor Discard Thickness* (15" Brake System)
23 mm
0.905 in
Rotor Maximum Allowable Assembled Lateral

Runout (15" Brake System)
0.1 mm
0.004 in
Rotor Maximum Allowable Scoring (15" Brake

System)
0.4 mm
0.0157 in
Rotor Minimum Allowable Thickness After

Refinish (15" Brake System)
23.2 mm
0.913 in

Rotor Maximum Allowable Thickness Variation

(15" Brake System)
0.006 mm
0.0002 in
Rotor Thickness New
26.0 mm
1.023 in
Brake Pad Thickness New without Pad Plate
12.0 mm
0.472 in
2.0 mm
0.078 in
Brake Pad Discard Thickness without Pad Plate

Rear Brakes
Caliper Bore Diameter-Rear (15" Brake System)
38.0 mm
1.50 in
Rotor Diameter (15" Brake System)
268.0 mm
10.551
Rotor Thickness (15" Brake System)
12 mm
0.472 in
Rotor Discard Thickness* (15" Brake System)
10 mm
0.393 in
Rotor Maximum Allowable Assembled Lateral

Runout (15" Brake System)
0.1 mm
0.004 in
Rotor Maximum Allowable Scoring (15" Brake

System)
0.4 mm
0.0157 in
Rotor Minimum Allowable Thickness After

Refinish (15" Brake System)
10.2 mm
0.402 in
Rotor Maximum Allowable Thickness Variation

(15" Brake System)
0.006 mm
0.0002 in
Rotor Thickness New
12.0 mm
0.472 in
Brake Pad Thickness New without Pad Plate
10.25 mm
0.403 in
Brake Pad Discard Thickness without Pad Plate
2.0 mm
0.078 in
ADHESIVES, FLUIDS, LUBRICANTS, AND SEALERS

Adhesives, Fluids, Lubricants, and Sealers
Application
Hydraulic Brake
System
Type of Material
DOT 3 Motor Vehicle
Brake Fluid
GM Part Number
United States
Canada
88863461

BRAKE ROTOR THICKNESS MEASUREMENT
WARNING: Refer to Brake Dust Warning .
88863462

Fig. 1: Measuring Brake Rotor Thickness

1. If the inboard friction surface of the brake rotor is not accessible, reposition and support the caliper with
the brake pads. Refer to Front Disc Brake Pads Replacement, and/or Rear Disc Brake Pads
Replacement, if equipped.
2. Clean the friction surfaces of the brake rotor with denatured alcohol, or an equivalent approved brake
cleaner.
3. Using a micrometer (1) calibrated in thousandths-of-a-millimeter, or ten-thousandths-of-an-inch, measure
and record the lowest thickness of the brake rotor at 4 or more points, equally spaced around the rotor.
Ensure that the measurements are only taken within the friction surfaces and that the micrometer is
positioned the same distance from the outside edge of the rotor, about 13 mm (0.5 in), for each
measurement.
4. Compare the lowest thickness measurement to the disc brake component specifications.
5. If the lowest thickness measurement of the brake rotor is above the minimum allowable thickness after

refinishing specification, the rotor may be able to be refinished, 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 specification, the rotor may not be refinished.
7. If the lowest thickness measurement of the brake rotor is at or below the discard thickness specification,
the rotor requires replacement. Refer to Front Brake Rotor Replacement (J60), Front Brake Rotor
Replacement (J67), and/or Rear Brake Rotor Replacement.
BRAKE ROTOR THICKNESS VARIATION MEASUREMENT
NOTE:
Any disc brake rotor that exhibits thickness variation exceeding the maximum
acceptable level must be refinished or replaced. Thickness variation exceeding
the maximum acceptable level can cause brake pulsation.
the brake pads. Refer to Front Disc Brake Pads Replacement, and/or Rear Disc Brake Pads
Replacement, if equipped.
cleaner.


3. Using a micrometer (1) calibrated in thousandths-of-a-millimeter, or ten-thousandths-of-an-inch, measure
and record the thickness of the brake rotor at 4 or more points, evenly spaced around the rotor.
Ensure that the measurements are only taken within the friction surfaces and that the micrometer is
positioned the same distance from the outer edge of the rotor, about 13 mm (0.5 in), for each
measurement.
4. Calculate the difference between the highest and lowest thickness measurements recorded to obtain the
amount of thickness variation.
5. Compare the thickness variation measurement to the disc brake component specifications.
NOTE:
Whenever a brake rotor is refinished or replaced, the assembled lateral

runout (LRO) of the rotor must be measured to ensure optimum
performance of the disc brakes.

6. If the brake rotor thickness variation measurement exceeds the specification, the rotor requires refinishing
or replacement. Refer to Front Brake Rotor Replacement (J60), Front Brake Rotor Replacement
(J67),, Rear Brake Rotor Replacement, or Brake Rotor Refinishing.
BRAKE ROTOR SURFACE AND WEAR INSPECTION
the brake pads. Refer to Front Disc Brake Pads Replacement, or/and Rear Disc Brake Pads
Replacement.
cleaner.
3. Inspect the friction surfaces of the brake rotor for the following Braking Surface Conditions:
Heavy rust and/or pitting.
Light surface rust can be removed with an abrasive disc. Heavy surface rust and/or pitting must be
removed by refinishing the rotor. Refer to Brake Rotor Refinishing.
Cracks and/or heat spots.
Excessive blueing discoloration.
4. If the friction surfaces of the brake rotor exhibit one or more of the Braking Surface Conditions, the rotor
requires refinishing or replacement. Refer to Front Brake Rotor Replacement (J60), Front Brake
Rotor Replacement (J67),, Rear Brake Rotor Replacement, or Brake Rotor Refinishing.


5. Using an appropriate tool (1) for measurement, calibrated in thousandths-of-a-millimeter, or tenthousandths-of-an-inch, measure and record the scoring depth of any grooves present on the rotor friction
surfaces.
6. Compare the groove scoring depth recorded disc brake component Specifications.
7. If the brake rotor scoring depth exceeds the specification, or if an excessive amount of scoring is present,
the rotor requires refinishing or replacement. Refer to Front Brake Rotor Replacement (J60), Front
Brake Rotor Replacement (J67),, Rear Brake Rotor Replacement, or Brake Rotor Refinishing.
BRAKE ROTOR ASSEMBLED LATERAL RUNOUT MEASUREMENT
Special Tools
CH-41013 Rotor Resurfacing Kit

CH-42450-A Wheel Hub Resurfacing Kit

CH-45101 Hub and Wheel Runout Gauge

CH-45101-100 Conical Brake Rotor Washers

NOTE:
Brake rotor assembled lateral runout (LRO) exceeding the maximum

allowable specification can cause thickness variation to develop in the
brake rotor over time, usually between 4, 800-11, 300 km (3, 000-7, 000 mi).
Brake rotor thickness variation MUST be checked BEFORE checking for
assembled lateral runout (LRO). Thickness variation exceeding the
maximum acceptable level can cause brake 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 been separated from the hub/axle flange,
any rust or contaminants should be cleaned from the hub/axle flange and
the brake rotor mating surfaces. Failure to do this may result in excessive
assembled lateral runout (LRO) of the brake rotor, which could lead to
brake pulsation.
2. Inspect the mating surface of the hub/axle flange and the brake rotor to ensure that there are no foreign
particles, corrosion, rust, or debris remaining. If the wheel hub/axle flange and/or if the brake rotor
mating surfaces exhibit these conditions, perform the following steps:
1. Remove the brake rotor from the vehicle. Refer to Front Brake Rotor Replacement (J60), Front
Brake Rotor Replacement (J67), and/or Rear Brake Rotor Replacement.
2. Using the CH-42450-A wheel hub resurfacing kit, thoroughly clean any rust or corrosion from the
mating surface of the hub/axle flange.
3. Using the CH-41013 rotor resurfacing kit, thoroughly clean any rust or corrosion from the mating
surface of the brake rotor.
4. Clean the friction surfaces of the brake rotor with denatured alcohol, or an equivalent approved
brake cleaner.
3. Install the rotor to the hub/axle flange using the matchmark made prior to removal.

Fig. 4: Identifying Special Tool J 45101-100 & Lug Nut

4. Hold the rotor firmly in place against the hub/axle flange and install one of th CH-45101-100 conical
brake rotor washers (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.

Fig. 5: Identifying All Special Tools J 45101-100s & Lug Nuts

6. Install the remaining CH-45101-100 conical brake rotor washers and lug nuts onto the wheel studs and
tighten the nuts firmly by hand in a star-pattern.
7. Tighten the lug nuts in a star-pattern to specification. Refer to Tire and Wheel Removal and
Installation .
8. If the brake rotor has been REFINISHED or REPLACED with a new rotor, proceed to step 14.
9. If the brake rotor meets the following criteria, proceed to step 10.
The rotor is within specifications and is being REUSED.
The rotor has NOT been refinished.
The rotor does NOT exhibit thickness variation exceeding the maximum allowable level.

Fig. 6: Using Dial Indicator To Measure Lateral Runout

10. Mount a dial indicator, CH-45101 hub and wheel runout gauge, or equivalent, to the steering knuckle and
position the indicator button so it contacts the brake rotor friction surface at a 90 degree angle,
approximately 13 mm (0.5 in) from the outer edge of the rotor.
11. Measure and record the assembled LRO of the brake rotor.
1. Rotate the rotor until the lowest reading is displayed on the indicator dial, then set the dial to zero.
2. Rotate the rotor until the highest reading is displayed on the dial.
3. Mark the location of the high spot relative to the nearest wheel stud, or studs.
4. Measure and record the amount of LRO.
12. Compare the brake rotor assembled LRO to the following specification:
Specification
Front brake rotor maximum allowable assembled lateral 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 assembled LRO exceeds the specification, refinish the rotor to ensure true parallelism.
Refer to Brake Rotor Refinishing. After refinishing the rotor, proceed to step 14.
14. Mount a dial indicator, CH-45101 hub and wheel runout gauge, or equivalent, to the steering knuckle and
position the indicator button so it contacts the brake rotor friction surface at a 90 degree angle,
approximately 13 mm (0.5 in) from the outer edge of the rotor.
15. Measure and record the assembled LRO of the brake rotor.
1. Rotate the rotor until the lowest reading is displayed on the indicator dial, then set the dial to zero.
2. Rotate the rotor until the highest reading is displayed on the dial.
3. Mark the location of the high spot relative to the nearest wheel stud, or studs.
4. Measure and record the amount of LRO.
16. Compare the brake rotor assembled LRO to the following specification:
Specification
Front brake rotor maximum allowable assembled lateral runout: 0.05 mm (0.002 in)
Rear brake rotor maximum allowable assembled lateral runout: 0.05 mm (0.002 in)
17. If the brake rotor assembled LRO measurement exceeds the specification, bring the LRO to within
specifications. Refer to Brake Rotor Assembled Lateral Runout Correction.
18. If the brake rotor assembled LRO measurement is within specification, install the brake caliper and
depress the brake pedal several times to secure the rotor in place before removing the CH-45101-100
conical brake rotor washers and the lug nuts.
BRAKE PAD INSPECTION

Special Tools
CH-230-A Disc Gauge
1. Remove brake pads. Refer to Front Disc Brake Pads Replacement, and/or Rear Disc Brake Pads
Replacement.

Fig. 7: Measuring Brake Pad Thickness

2. Measure remaining brake pad thickness at several points, using the CH-230-A disc gauge (1).
3. Compare brake pad thickness to disc brake component specifications.
BRAKE CALIPER INSPECTION

Fig. 8: Exploded View Of Brake Caliper

1. Inspect the brake caliper housing (1) for cracks, excess wear, and/or damage. If any of these conditions
are present, the brake caliper requires replacement.
2. Inspect the caliper piston dust boot seal (6) for cracks, tears, cuts, deterioration and/or improper seating in
the caliper body. If any of these conditions are present, the brake caliper requires overhaul or
replacement.
3. Renew brake caliper bleeder valve cap (3) if missing.
4. Check for blocked bleeder valve (2).

Fig. 9: Compressing Caliper Piston

5. Inspect for smooth and complete travel of the caliper pistons into the caliper bores:
The movement of the caliper pistons into the caliper bores should be smooth and even. If the caliper
piston is frozen or difficult to bottom, the caliper requires overhaul or replacement.
Insert a discarded inner brake pad (2) or block of wood in front of the piston. Using a large C-clamp (1)
installed over the body of the caliper (3) and against the brake pad or block of wood, slowly bottom the
piston in the bore.
FRONT DISC BRAKE MOUNTING AND HARDWARE INSPECTION

Fig. 10: Exploded View Of Brake Pads And Brake Caliper Mounting Bracket
1. Inspect the fluid level in the brake master cylinder reservoir.
2. If the brake fluid level is midway between the maximum-full point and the minimum allowable level then
no brake fluid needs to be removed from the reservoir before proceeding.
3. If the brake fluid level is higher than midway between the maximum-full point and the minimum
allowable level then remove brake fluid to the midway point before proceeding.
6. Grasp the brake caliper housing and try to move the brake caliper housing up/down and forward/reverse
in relation to the brake caliper mounting bracket (3). If excessive looseness is observed the brake caliper
bracket bushings and/or the brake caliper mounting bolts may need to be replaced. Compress the front
caliper pistons
7. Compress the front caliper pistons.
1. Install a large C-clamp over the top of the caliper housing and against the back of the outboard pad

8.
9.
10.
11.
12.
13.
(1).
2. Slowly tighten the C-clamp until the pistons are pushed completely into the caliper bores.
3. Remove the C-clamp from the caliper.
With the pistons compressed into the caliper bores, grasp the brake caliper housing and slide it back and
forth on the brake caliper mounting bolts. Check for smooth operation. If the brake caliper housing slide
force is high or the brake caliper housing does not slide smoothly, inspect the brake caliper mounting
bolts and/or the brake caliper mounting bracket bushings for wear or damage. If wear or damage
conditions are found, replacement of the brake caliper mounting bolts and/or the brake caliper mounting
bracket bushings is necessary.
Remove the brake caliper mounting bolts from the brake caliper mounting bracket and support the brake
caliper using heavy mechanics wire. Do Not remove the hydraulic brake hose from the caliper. Refer to
Front Brake Caliper Replacement.
Remove the disc brake pads (1, 2) from the brake caliper mounting bracket (3).
Inspect the disc brake pad mounting hardware for the following:
Missing mounting hardware.
Excessive corrosion.
Bent pad retainer spring (2).
Looseness at the brake caliper mounting bracket (3).
Looseness at the disc brake pads (1, 4).
Excessive contaminants in the brake caliper mounting bracket (3) surface and threads.
If any of the conditions listed are found, the disc brake pad mounting hardware requires replacement.
Ensure the disc brake pads are held firmly in place on the brake caliper mounting bracket, yet slide easily
on the mounting hardware without binding.

Fig. 11: View Of Caliper, Pin, Boots & Caliper Mounting Bracket
14. Inspect the brake caliper mounting hardware for the following:
Binding
Seizing
Looseness in the brake caliper mounting bracket (3).
Bent or damaged brake caliper mounting bolts (1).
Cracked or torn boots (4).
Missing boots.
Bent or damaged brake caliper mounting bracket (3).
Cracked or damaged brake caliper (2).
15. If any of the conditions listed are found then the brake caliper mounting hardware requires replacement.
16. Install the disc brake pads to the brake caliper mounting bracket.
17. Install the disc brake caliper to the brake caliper mounting bracket. Refer to Front Brake Caliper

Replacement.
REAR DISC BRAKE MOUNTING AND HARDWARE INSPECTION
1. Remove rear brake caliper bracket. Refer to Rear Brake Caliper Bracket Replacement.
Fig. 12: Exploded View Of Brake Pads And Brake Caliper Mounting Bracket
2. Remove the disc brake caliper from the caliper mounting bracket (2).
3. Remove the disc brake pads (1) from the caliper mounting bracket (2).
4. Inspect the disc brake pad mounting hardware (3) for the following:
Missing mounting hardware.

Excessive corrosion.
Bent pad retainer spring.
Looseness at the brake caliper mounting bracket.
Looseness at the disc brake pads.
Excessive contaminants in the brake caliper mounting bracket surface and threads.
If any of the conditions listed are found, the disc brake pad mounting hardware requires replacement.
Ensure the disc brake pads are held firmly in place on the caliper mounting bracket, yet slide easily on the
mounting hardware without binding.
Install the disc brake pads to the caliper mounting bracket.
Install the disc brake caliper to the mounting bracket.
Install rear brake caliper bracket. Refer to Rear Brake Caliper Bracket Replacement.
5.
6.
7.
8.
9.
REPAIR INSTRUCTIONS
FRONT DISC BRAKE PADS REPLACEMENT
Removal Procedure
NOTE:
Always replace disc brake pads in axle sets.

2. If the brake fluid level is midway between the maximum-full point and the minimum allowable level, no
brake fluid needs to be removed from the reservoir before proceeding.
allowable level, remove brake fluid to the midway point before proceeding.

Fig. 13: View Of Brake Caliper And Brake Caliper Guide Pin Bolt
6. Remove the brake caliper lower guide pin bolt (2).
7. Without disconnecting the hydraulic brake flexible hose, pivot the caliper (1) upward and secure the
caliper with heavy mechanics wire, or equivalent.

Fig. 14: View of Installed Brake Pads

8. Remove the brake pads (1) from the caliper mounting bracket.

Fig. 15: Pushing Disc Brake Caliper Piston Inward

9. Push the disc brake caliper piston (1) into the caliper bore using a disc brake piston installation tool.

Fig. 16: View Of Brake Pad Retainer Springs

10. Remove the brake pad retainer springs (1) from the caliper bracket.
11. Thoroughly clean the brake pad hardware mating surfaces of the caliper bracket of any debris and
corrosion.
12. Inspect the brake caliper guide pins for freedom of movement and inspect the condition of the guide pin
boots. Move the guide pins inboard and outboard within the bracket bores, without disengaging the slides
from the boots, and observe for the following:
Restricted caliper guide pin movement
Looseness in the brake caliper mounting bracket
Seized or binding caliper guide pins
Split or torn boots
13. If any of the conditions listed are found, the brake caliper guide pins and/or boots require replacement.


1. Ensure the brake pad hardware mating surfaces are clean.
2. Install the brake pad retainer springs (1) to the brake caliper bracket.
Apply a thin coat of high temperature silicone lube to the brake pad retainers.


NOTE:
The wear sensor equipped disc brake pad must be mounted inboard of the
rotor with the leading edge of the sensor facing the brake rotor during
forward wheel rotation, or at the top of the pad when installed in vehicle
position.
3. Install the brake pads (1) to the caliper bracket.

4. Remove the support, and rotate the brake caliper into position over the disc brake pads and to the caliper
mounting bracket.
5. Install the lower brake caliper guide pin bolt and tighten to 28 N.m (21 lb ft).

6.
7.
8.
9.
10.
Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation .
Lower the vehicle.
With the engine OFF, gradually apply the brake pedal approximately 2/3 of its travel distance.
Slowly release the brake pedal.
Wait 15 seconds, then gradually apply the brake pedal approximately 2/3 of its travel distance again until
a firm brake pedal apply is obtained. This will properly seat the brake caliper pistons and brake pads.
11. Fill the master cylinder auxiliary reservoir to the proper level. Refer to Master Cylinder Reservoir
Filling .
12. Burnish the brake pads and the brake rotor. Refer to Brake Pad and Rotor Burnishing.
REAR DISC BRAKE PADS REPLACEMENT
Removal Procedure
NOTE:
Always replace disc brake pads in axle sets.


Fig. 19: Brake Caliper Mass Dampener

6. Remove the brake caliper mass dampener (2).
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 to support the caliper in this
manner will cause the 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.
Mark the brake caliper piston position to the brake caliper (1).

Fig. 20: View Of Installed Brake Pads

8. Remove the brake pads (1) from the caliper mounting bracket (2).


9. Remove the brake pad retainer springs (1) from the caliper bracket (2).
10. Thoroughly clean the brake pad hardware mating surfaces of the caliper bracket, of any debris and
corrosion.
11. Inspect the brake caliper guide pins for freedom of movement, and inspect the condition of the guide pin
Split or torn boots.


2. Install the brake pad retainers springs (1) to the brake caliper bracket (2) and apply a thin coat of high
temperature silicone lube to the brake pad retainers.


NOTE:
position.
3. Install the brake pads (1) to the caliper bracket (2).

Fig. 24: Brake Caliper Piston And Pin Notch

4. Rotate the brake caliper piston (1) into the brake caliper bore.
5. Align the notch on the brake caliper piston with the pin (2) on the disc brake pad.

Fig. 25: Brake Caliper Mass Dampener

6. Remove the support, and rotate the brake caliper (1) into position over the disc brake pads and to the
caliper mounting bracket.
7.
8.
9.
10.
11.
12.
Install the lower brake caliper mass dampener (2) and tighten to 28 N.m (21 lb ft).
Lower the vehicle.

13. Fill the master cylinder reservoir to the proper level. Refer to Master Cylinder Reservoir Filling .
14. Burnish the brake pads and the brake rotor. Refer to Brake Pad and Rotor Burnishing
BRAKE PAD AND ROTOR BURNISHING
Burnishing the brake pads and brake rotors is necessary in order to ensure that the braking surfaces are properly
prepared after service 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.
1. Select a smooth road with little or no traffic.
2. Accelerate the vehicle to 48 km/h (30 mph).
NOTE:
Use care to avoid overheating the brakes while performing this step.
3. Using moderate to firm pressure, apply the brakes to bring the vehicle to a stop. Do not allow the brakes
to lock.
4. Repeat steps 2 and 3 until approximately 20 stops have been completed. Allow sufficient cooling periods
between stops in order to properly burnish the brake pads and rotors.
FRONT BRAKE CALIPER REPLACEMENT
Removal Procedure
WARNING: Use of eye goggles is necessary to prevent personal injury.


Fig. 26: Caliper Brake Hose And Brake Hose-To-Caliper Bolt

6. Remove the brake hose-to-caliper bolt (3) from the brake caliper.
7. Remove the brake hose (2) from the brake caliper.
Remove and discard the copper brake hose washers. These washers may be stuck to the brake caliper
and/or the brake hose end.
8. Cap or plug the opening in the brake caliper and the brake hose to prevent fluid loss and contamination.
9. Remove the brake caliper guide pin bolts (1).

10. Remove the brake caliper from the caliper bracket.

11. Inspect the brake caliper guide pins for freedom of movement, and inspect the condition of the guide pin
Split or torn boots
1. Install the brake caliper to the brake caliper bracket.


NOTE:
Do not reuse the brake hose washers.
2. Install NEW copper brake hose washers (1) to the brake hose-to-caliper bolt and to the brake hose.

3.
4.
5.
6.
7.
Install the brake caliper guide pin bolts (1) and tighten to 28 N.m (21 lb ft).
Remove the caps or plugs from the brake caliper opening and the brake hose.
Install the brake hose (2) to the caliper.
Install brake hose-to-caliper bolt (3) to the caliper and tighten to 40 N.m (30 lb ft).
Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding (Manual Bleeding) ,

8.
9.
10.
11.
12.

Lower the vehicle.
With the engine OFF, gradually apply the brake pedal to approximately 2/3 of its travel distance.
Wait 15 seconds, then repeat steps 10 and 11 until a firm brake pedal is obtained. This will properly seat
the brake caliper piston and brake pads.
REAR BRAKE CALIPER REPLACEMENT

Removal Procedure
CAUTION: Refer to Brake Fluid Effects on Paint and Electrical Components

Caution .
4. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle .

Fig. 29: Brake Hose And Brake Hose-To-Caliper Bolt

6. Remove the brake hose to caliper bolt (2) from the brake caliper.
8. Remove and discard the 2 copper brake hose gaskets (3). These gaskets may be stuck to the brake caliper

Fig. 30: Rear Parking Brake Lever

9. Remove the park brake cable from the rear parking brake lever (1).

Fig. 31: Brake Caliper Pin Bolt And Brake Caliper Vibration Dampener
11. Remove the upper brake caliper pin bolt (1).
12. Remove the brake caliper vibration dampener (3).


13. Remove the park brake cable from the rear parking brake lever (1).
14. Remove the brake caliper from the brake caliper bracket.
1. Inspect the caliper slide boots for cuts, tears, or deterioration. If damaged, replace the slides and boots.
Refer to Rear Brake Caliper Hardware Replacement.

Fig. 33: Brake Caliper Pin Bolt And Brake Caliper Vibration Dampener
2. Install the brake caliper to the brake caliper bracket.
3. Install the lower brake caliper pin bolt (1) and tighten to 28 N.m (20 lb ft).
4. Install the brake caliper vibration dampener (3) and tighten to 28 N.m (20 lb ft).


5. Install the park brake cable to the rear parking brake lever (1).

Fig. 35: Brake Hose And Brake Hose-To-Caliper Bolt

6. Remove the caps or plugs from the brake caliper opening and the brake hose.
NOTE:
DO NOT reuse the copper brake hose gaskets.
7. Install NEW copper brake hose gaskets (3) to the brake hose-to-caliper bolt (2) and to the brake hose.
8. Install the brake hose and the brake hose-to-caliper bolt to the brake caliper and tighten the bolt to 40 N.m
(30 lb ft).
10. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of its travel distance.
11. Slowly release the brake pedal.
12. Wait 15 seconds, then repeat steps 9 and 10 until a firm brake pedal is obtained. This will properly seat
the brake caliper pistons and brake pads.

15. Apply and release the park brake lever 4 times.
FRONT BRAKE CALIPER OVERHAUL
Disassembly Procedure
WARNING: Do not place fingers in front of the caliper piston(s) in an attempt to

catch or protect it when applying compressed air. The piston(s) can
fly out with force and could result in serious bodily injury.
CAUTION: Use clean cloths to pad interior of caliper housing during piston
removal. Use just enough air to ease the pistons out of the bores. If
the pistons are blown out, even with the padding provided, it may be
damaged.
1. Remove the brake caliper from the vehicle. Refer to Front Brake Caliper Replacement.

Fig. 36: Using Low Pressure Compressed Air To Remove Brake Caliper Piston
2. Remove the brake caliper piston from the caliper bore by directing low pressure compressed air into the
caliper (1) through the fluid inlet hole.


3. Remove the piston dust boot seal (1) from the seal counterbore in the caliper (4). Discard the boot seal.
4. Using a small wooden or plastic tool, remove the piston seal (3) from the caliper bore. Discard the piston
seal.
5. Remove the bleeder valve cap (6).
6. Remove the bleeder valve (5).
NOTE:
Do not use abrasives to clean the brake caliper piston.
7. If cracks, scoring, pitting, excessive rust, and/or excessive corrosion are present in the caliper bore,
replace the caliper assembly.
8. If light rust or light corrosion are present in the caliper bore, attempt to remove the imperfection with a
fine emery paper. If the imperfection cannot be removed, replace the caliper assembly.
9. Clean the brake caliper piston bore and seal counterbore, and the caliper piston with denatured alcohol, or

equivalent.
10. Dry the caliper piston bore and counterbore, and the piston with non-lubricated, filtered, compressed air.
11. Inspect the caliper piston for cracks, scoring, and/or damage to the plating. Replace the caliper piston if
any of these conditions exist.
12. Inspect the caliper mounting holes for cracks, scoring, pitting, rust and/or excessive corrosion. Replace
the caliper assembly if any of these conditions exist.
Assembly Procedure

1. Lubricate the new piston seal (3) with brake fluid from a clean, sealed brake fluid container. Refer to
Adhesives, Fluids, Lubricants, and Sealers for the recommended brake fluid.
2. Install the lubricated, new piston seal (3) into the caliper bore.
3. Apply a thin coat of brake fluid from a clean, sealed brake fluid container. Refer to Adhesives, Fluids,

Lubricants, and Sealers for the recommended brake fluid.
Fig. 39: View Of Caliper Piston And Caliper Piston Dust Boot Seal
4.
5.
6.
7.
Install the bottom half of the caliper piston (2) into the caliper bore.
Install the new piston dust boot seal (1) over the caliper piston (2).
Compress the caliper piston (2) to the bottom of the caliper bore.
Fully seat the piston dust boot seal (1) into caliper counterbore.
8. Install the bleeder valve to the caliper and tighten the valve to 17 N.m (13 lb ft).
9. Install the bleeder valve cap.

10. Install the brake caliper to the vehicle. Refer to Front Brake Caliper Replacement.
REAR BRAKE CALIPER VIBRATION DAMPENER REPLACEMENT
Removal Procedure
Fig. 40: Brake Caliper Vibration Damper

2. Open the cap (2) of the brake caliper vibration damper (1), to gain access to the internal torx.

Fig. 41: Brake Caliper Vibration Damper And Brake Caliper Vibration Damper Stud
3. Remove the brake caliper vibration damper (2) from the brake caliper vibration damper stud (1).
Hold against internal torx of damper stud (1).
4. Remove the damper stud (1) from the rear brake.

Fig. 42: Brake Caliper Vibration Damper And Brake Caliper Vibration Damper Stud
1. Install the damper stud (1) to the rear brake and tighten to 28 N.m (21 lb ft).
2. Attach the brake caliper vibration damper (2) to the stud (1) by turn in 2 threads ONLY.
3. Tighten the brake caliper vibration damper (2) to 9 N.m (80 lb in) with a suitable tool.

Fig. 43: Brake Caliper Vibration Damper

4. Close the cap (2) of the brake caliper vibration damper (1).
FRONT BRAKE CALIPER HARDWARE REPLACEMENT
Removal Procedure


Fig. 44: Brake Caliper Supported With Wire

6. Remove the brake caliper lower guide pin bolt (2).


8. Remove the brake pads (1) from the caliper mounting bracket


9. Remove the brake pad retainer springs (1) from the caliper bracket.

Fig. 47: Brake Caliper Guide Pin, Brake Caliper Pin Boot And Brake Caliper Mounting Bracket
10. Remove the brake caliper guide pins (3) from the brake caliper mounting bracket (1).
11. Remove the brake caliper pin boots (2) from the brake caliper mounting bracket (1).

Fig. 48: Brake Caliper Guide Pin, Brake Caliper Pin Boot And Brake Caliper Mounting Bracket
1. Apply a thin coat of high temperature silicone lube to the brake caliper guide pin boots.
2. Install the brake caliper pin boots (2) into the brake caliper mounting bracket (1). Do not hammer the
caliper pin boots into the bracket. Ensure that the caliper pin boots are fully seated in the bracket.
3. Apply a thin coat of high temperature silicone lube to the brake caliper guide pins.
4. Install the brake caliper guide pins (3) to the brake caliper mounting bracket (1).


6. Install the brake pad retainers (1) to the brake caliper bracket.


NOTE:
position.
7. Install the brake pads (1) to the caliper bracket.

Fig. 51: Brake Caliper Supported With Wire

8. Remove the support, and rotate the brake caliper (1) into position over the disc brake pads and to the
caliper mounting bracket.
9.
10.
11.
12.
13.
14.
Install the lower brake caliper guide pin bolts (2) and tighten to 28 N.m (21 lb ft).
Lower the vehicle.

Filling .
REAR BRAKE CALIPER HARDWARE REPLACEMENT
Removal Procedure

6. Without disconnecting the hydraulic brake system, remove the rear brake caliper. Refer to Rear Brake
Caliper Replacement.


7. Remove the brake pads (1) from the caliper mounting bracket (2).


8. Remove the brake pad retainer springs (1) from the caliper bracket (2).

Fig. 54: Brake Caliper Mounting Bracket, Guide Pins And Boots
9. Remove the brake caliper guide pins (3) from the brake caliper mounting bracket (1).
10. Remove the brake caliper pin boots (2) from the brake caliper mounting bracket (1).

Fig. 55: Brake Caliper Mounting Bracket, Guide Pins And Boots
1. Apply a thin coat of high temperature silicone lube to the brake caliper guide pin boots.
2. Install the brake caliper pin boots (2) into the brake caliper mounting bracket (1). Do not hammer the
caliper pin boots into the bracket. Ensure that the caliper pin boots are fully seated in the bracket.
3. Apply a thin coat of high temperature silicone lube to the brake caliper guide pins.
NOTE:
The lower brake caliper guide pin is equipped with a ribbed insert.
4. Install the brake caliper guide pins (3) to the brake caliper mounting bracket (1).


6. Install the brake pad retainers (1) to the brake caliper bracket and apply a thin coat of high temperature
silicone lube to the brake pad retainers.


NOTE:
7.
8.
9.
10.
11.
12.
13.
position.
Install the brake pads (1) to the caliper bracket.

Install the rear brake caliper. Refer to Rear Brake Caliper Replacement.
Lower the vehicle.

Filling .
FRONT BRAKE CALIPER BRACKET REPLACEMENT
Removal Procedure


Fig. 58: Brake Caliper, Flex Hose, Brake Pads And Guide Pin Bolt
6. Remove the lower brake caliper guide pin bolt (4). Do NOT disconnect the hydraulic brake flexible hose
(1) from the caliper (2).
7. Without disconnecting the hydraulic brake flexible hose (1), pivot the caliper (2) upward and separate
from caliper bracket in direction of arrow.
8. Remove the brake pads (3).


9. Remove the brake pad retainer springs (1).
10. If reusing the bracket, thoroughly clean the pad hardware mating surfaces of the caliper bracket, of any
debris and corrosion.
11. Inspect the brake pad retainer springs (1) for the following:
Bent mounting tabs
Excessive corrosion
Looseness at the brake caliper mounting bracket
Looseness at the disc brake pads
12. If any of the conditions listed are found, the disc brake pad retainers require replacement.

Fig. 60: Brake Caliper Bracket Mounting Bolts

13. Remove and DISCARD caliper bracket bolts (2).
14. Remove brake caliper bracket (1) from steering knuckle.

Fig. 61: Brake Caliper And Mounting Hardware

15. Inspect the caliper bracket (5). If the brake caliper bracket (5) is bent, cracked, or damaged, it requires
replacement.
16. Inspect the brake caliper guide pins (3) for freedom of movement, and inspect the condition of the guide
pin boots (4). Move the brake caliper guide pins (3) inboard and outboard within the brake caliper bracket
(5), without disengaging the slides from the boots (4), and observe for the following:
Split or torn boots
17. If any of the conditions listed are found, the brake caliper guide pins (3) and/or boots (4) require
replacement.

Fig. 62: Brake Caliper Bracket Mounting Bolts

1. Install the brake caliper bracket (1) to the steering knuckle.
WARNING: Refer to Torque-to-Yield Fastener Warning .
2. Install the NEW brake caliper bracket bolts (2) and tighten to 100 N.m (74 lb ft) + 60 - 75


3. Apply a very thin coating of high temperature silicone brake lubricant to the pad hardware mating
surfaces of the caliper bracket only.
4. Install the brake pad retainer springs (1).

Fig. 64: Brake Caliper, Flex Hose, Brake Pads And Guide Pin Bolt
NOTE:
position.
5. Install the brake pads (3) to the brake caliper bracket.

6. Remove the support and reposition the brake caliper (2) over the brake pads and to the caliper bracket.
Assure that guide pin bolts boots apply firmly.
7. Install guide pin bolts and tighten to 28 N.m (21 lb ft).
10. With the engine OFF, gradually apply the brake pedal approximately 2/3 of its travel distance.

11. Slowly release the brake pedal.

12. Wait 15 seconds, then gradually apply the brake pedal approximately 2/3 of its travel distance again until
Filling .
REAR BRAKE CALIPER BRACKET REPLACEMENT
Special Tools
EN-45059 Angle Meter

Removal Procedure

Fig. 65: Brake Caliper Mounting Bracket And Brake Pads

NOTE:
Remove and discard the brake caliper pin bolts.
3. Remove the brake caliper from the brake caliper bracket (3) and support the brake caliper with heavy
mechanic's wire, or equivalent. Do NOT disconnect the hydraulic brake flexible hose from the caliper.
Refer to Rear Brake Caliper Replacement.
4. Remove the brake pads from the brake caliper bracket (3).

5. Remove the brake pad retainers from the brake caliper bracket.
Fig. 66: Brake Caliper Bracket Bolts

6.
7.
8.
9.
10.
Remove and DISCARD the brake caliper bracket bolts (1).

Remove the rear brake caliper bracket.
Inspect the brake mounting and hardware. Refer to Rear Brake Caliper Hardware Replacement.
Inspect the brake caliper bracket.
Replace the brake caliper bracket if cracked or damaged.


1. Install the brake caliper bracket.
CAUTION: This is a self-retaining fastener joint that does not require thread
locking compounds. Do not attempt to clean the threads with a
standard tap. If a standard tap is used, damage to the joint threads
will occur.
2. Install the NEW brake caliper mounting bracket bolts (1) and tighten a first pass to 100 N.m (74 lb ft).

3. Tighten the NEW brake caliper mounting bracket bolts (1) a final pass to an additional 60 - 75 degrees,
using the EN-45059 meter.
Fig. 68: Brake Caliper Mounting Bracket And Brake Pads

4.
5.
6.
7.
8.
9.
Install the brake pad retainers (2) to the brake caliper bracket (3).
Install the brake pads (1) to the brake caliper bracket.
Install the brake caliper. Refer to Rear Brake Caliper Replacement.
Install the rear tire and wheel assembly. Refer to Tire and Wheel Removal and Installation .
Lower the vehicle.
Pump the brake pedal 2-3 times in order to seat the rear disc brake pads to the rotor.
FRONT BRAKE ROTOR REPLACEMENT (J60)

Special Tools


Removal Procedure

Fig. 69: Compressing Caliper Piston Into Caliper Bore

3. Install a C-clamp (1) over the body of the brake caliper, with the C-clamp ends against the rear of the
caliper body and the outboard disc brake pad.
4. Tighten the C-clamp (1) until the caliper piston is compressed into the caliper piston bore enough, to
allow the caliper to slide past the brake rotor.
5. Remove the C-clamp (1).

6. Remove and DISCARD the brake caliper bracket bolts (1).

Fig. 71: Brake Caliper And Caliper Mounting Bracket Assembly

NOTE:
Do NOT disconnect the hydraulic brake flexible hose from the caliper.
7. Remove the brake caliper and the caliper mounting bracket as an assembly (1) from the steering knuckle
and support the assembly with heavy mechanics wire, or equivalent. Ensure that there is no tension on the
hydraulic brake flexible hose.

Fig. 72: Brake Rotor And Brake Rotor Retaining Screw

8. Remove the brake rotor bolt (2).
9. Remove the brake rotor (1) from the wheel hub.

Fig. 73: Inspecting Hub/Axle Flange And Brake Rotor Mounting Surfaces
NOTE:
brake pulsation.
1. Using the CH-42450-A resurfacer, thoroughly clean any rust or corrosion from the mating surface of the
hub/axle flange (1).
2. Using the CH-41013 resurfacer, thoroughly clean any rust or corrosion from the mating surface and the
mounting surface of the brake rotor (2).
3. Inspect the mating surfaces of the hub/axle flange and the rotor to ensure that there are no foreign
particles or debris remaining.


4. Install the brake rotor (1) to the hub/axle flange and tighten bolt (2) to 9 N.m (80 lb in).
5. If the brake rotor was removed and installed as a part of a brake system repair, measure the assembled
lateral runout of the brake rotor to ensure optimum performance of the disc brake. Refer to Brake Rotor
Assembled Lateral Runout Measurement.
6. If the brake rotor assembled lateral runout measurement exceeds the specification, bring the lateral runout
to within specifications. Refer to Brake Rotor Assembled Lateral Runout Correction.
7. Remove the support and install the brake caliper and the brake caliper bracket as an assembly to the
steering knuckle.


8. Install NEW brake caliper bracket bolts (1) and tighten first pass to 150 N.m (111 lb ft).
9. Tighten the NEW brake caliper bracket bolts in a final pass to an additional 45 to 60 degrees using the
EN-45059 meter.
FRONT BRAKE ROTOR REPLACEMENT (J67)
Special Tools



Removal Procedure
Fig. 76: Compressing Caliper Piston Into Caliper Bore


3. Install a C-clamp (1) over the body of the brake caliper, with the C-clamp ends against the rear of the
caliper body and the outboard disc brake pad.
4. Tighten the C-clamp (1) until the caliper piston is compressed into the caliper bore enough to allow the
caliper to slide past the brake rotor.
5. Remove the C-clamp (1).

6. Remove and DISCARD the brake caliper bracket bolts (1).

Fig. 78: Brake Caliper And Caliper Mounting Bracket Assembly

NOTE:
Do NOT disconnect the hydraulic brake flexible hose from the caliper.
7. Remove the brake caliper and the caliper mounting bracket as an assembly (1) from the steering knuckle
and support the assembly with heavy mechanic's wire, or equivalent. Ensure that there is no tension on
the hydraulic brake flexible hose.


8. Remove the brake rotor screw (2).
9. Remove the brake rotor (1) from the wheel hub.

Fig. 80: Inspecting Hub/Axle Flange And Brake Rotor Mounting Surfaces
NOTE:
brake pulsation.
1. Using the CH-42450-A resurfacer, thoroughly clean any rust or corrosion from the mating surface of the
hub/axle flange (1).
2. Using the CH-41013 resurfacer, thoroughly clean any rust or corrosion from the mating surface and
mounting surface of the brake rotor (2).
4. Install the brake rotor to the hub/axle flange. Use the mark made prior to removal to ensure proper

orientation to the flange.

5. Install the brake rotor screw and tighten to 9 N.m (80 lb in).
6. If the brake rotor was removed and installed as part of a brake system repair, measure the assembled LRO
of the brake rotor to ensure optimum performance of the disc brakes. Refer to Brake Rotor Assembled
Lateral Runout Measurement.
7. Remove the support, and install the brake caliper and the brake caliper bracket as an assembly to the
steering knuckle.

8. Install NEW brake caliper bracket bolts (1) and tighten a first pass to 100 N.m (74 lb ft).

9. Tighten the NEW brake caliper bracket bolts a final pass to an additional 60 - 75 degrees, using the EN45059 meter.
REAR BRAKE ROTOR REPLACEMENT
Special Tools


Removal Procedure

Fig. 82: Brake Rotor And Brake Rotor Retaining Bolt

1. Remove the brake caliper and the caliper mounting bracket as an assembly from the steering knuckle.
Refer to Rear Brake Caliper Bracket Replacement.
2. Matchmark the position of the brake rotor to the wheel studs.

3. Remove the rear brake rotor bolt (2).

4. Remove rear brake rotor (1) from the wheel hub.
1. Using the CH-42450-A kit, thoroughly clean any rust or corrosion from the mating surface of the
hub/axle flange.
2. Using the CH-41013 kit, thoroughly clean any rust or corrosion from the mating surface and mounting
surface of the brake rotor.
Fig. 83: Brake Rotor And Brake Rotor Retaining Bolt

4. Install the brake rotor (1) to the hub/axle flange. Use the matchmark made prior to removal for proper


5. Install rear brake rotor bolt (2) and tighten to 9 N.m (80 lb in).
6. Install the brake caliper and the caliper mounting bracket assembly to the steering knuckle. Refer to Rear
Brake Caliper Bracket Replacement.
7. If the brake rotor was removed and installed as part of a brake system repair, measure the assembled
lateral run out (LRO) of the brake rotor to ensure optimum performance of the disc brakes. Refer to
Brake Rotor Assembled Lateral Runout Measurement.
FRONT BRAKE SHIELD REPLACEMENT
Special Tools

Removal Procedure
2. Remove the brake rotor. Refer to Front Brake Rotor Replacement (J60), Front Brake Rotor
Replacement (J67).

Fig. 84: Wheel Speed Sensor And Wheel Speed Sensor Mounting Bolt
3.
4.
5.
6.
Remove the wheel speed sensor bolt (1).

Remove the wheel speed sensor (2).
Remove the wheel speed sensor wiring harness from the steering knuckle.
Remove and DISCARD the wheel drive shaft from the wheel bearing/hub. Refer to Front Wheel Drive
Shaft Replacement - Right Side , or Front Wheel Drive Shaft Replacement - Left Side .

Fig. 85: Wheel Bearing/Hub Mounting Bolts

7. Remove and DISCARD the wheel bearing/hub mounting bolts (1).

Fig. 86: Wheel Bearing/Hub, Front Brake Shield And Steering Knuckle
8. Remove the wheel bearing/hub (1) and front brake shield (2) from the steering knuckle.

Fig. 87: Wheel Bearing/Hub, Front Brake Shield And Steering Knuckle
1. Position the front brake shield (2) and wheel bearing/hub assembly (1) in the steering knuckle.


CAUTION: This is a self-retaining fastener joint that does not require thread
locking compounds. Do not attempt to clean the threads with a
standard tap. If a standard tap is used, damage to the joint threads
will occur.
2. Tighten the bearing/hub bolts (1) a first pass to 90 N.m (66 lb ft).

3. Tighten the NEW bearing/hub bolts (1) a final pass to an additional 60 - 75 degrees, using the EN-45059
meter.
4.
5.
6.
7.
Install the wheel speed sensor wiring harness to the steering knuckle.
Install the wheel speed sensor (2).
Install the wheel speed sensor bolt (1) and tighten to 6 N.m (53 lb in).
Install the brake rotor. Refer to Front Brake Rotor Replacement (J60), Front Brake Rotor
Replacement (J67).
8. Install the NEW wheel drive shaft retaining nut and washer. Refer to Front Wheel Drive Shaft
Replacement - Right Side , or Front Wheel Drive Shaft Replacement - Left Side .
9. Remove the support and lower the vehicle.
REAR BRAKE SHIELD REPLACEMENT

Special Tools

Removal Procedure
3. Remove the brake rotor. Refer to Rear Brake Rotor Replacement.

4. Remove the wheel speed sensor bolt (1).

6. Remove and DISCARD the wheel bearing/hub mounting bolts (1).

Fig. 92: Wheel Bearing/Hub, Rear Brake Shield And Steering Knuckle
7. Remove the wheel bearing/hub assembly (2) and rear brake shield (1) from the rear axle assembly.

Fig. 93: Wheel Bearing/Hub, Rear Brake Shield And Steering Knuckle
1. Position the rear brake shield (1) and wheel bearing/hub assembly (2) onto the rear axle assembly.


2. Install NEW wheel bearing/hub mounting bolts (1) and tighten a first pass to 50 N.m (37 lb ft).
3. Tighten the NEW wheel bearing/hub mounting bolts (1) a final pass to an additional 30 - 45 degrees,
using the EN-45059 meter.

4.
5.
6.
7.
8.
Install the wheel speed sensor (2).

Install the wheel speed sensor bolt (1) and tighten to 6 N.m (54 lb in).
Install the brake rotor. Refer to Rear Brake Rotor Replacement.
Lower the vehicle.
BRAKE ROTOR ASSEMBLED LATERAL RUNOUT CORRECTION

NOTE:

Rotor Thickness Variation Measurement.

Brake rotor assembled lateral runout (LRO) exceeding the maximum

allowable specification can cause thickness variation to develop in the
brake rotor over time, usually between 4 800-11 300 km (3, 000-7, 000 mi).
Refer to Brake Rotor Assembled Lateral Runout Measurement.
Review the following acceptable methods for bringing the brake rotor assembled LRO to within specifications.
Determine which method to use for the specific vehicle being repaired.
The indexing method of correcting assembled LRO is most effective when the LRO specification is only
exceeded by a relatively small amount: 0.025-0.127 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 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 correct LRO
that exceeds the specification by up to 0.23 mm (0.009 in). Refer to Brake Rotor Assembled Lateral
Runout Correction - Correction Plates.
The on-vehicle brake lathe method is used to bring the LRO to within specifications through
compensating for LRO while refinishing the brake rotor. Refer to Brake Rotor Assembled Lateral
Runout Correction - On Vehicle Lathe.
If the assembled LRO cannot be corrected using these methods, then other components must be suspected as
causing and/or contributing to the LRO concern.
BRAKE ROTOR ASSEMBLED LATERAL RUNOUT CORRECTION - INDEXING
Special Tools
NOTE:

Rotor Thickness Measurement.
Brake rotor assembled LRO exceeding the maximum allowable
specification can cause thickness variation to develop in the brake rotor
over time, usually between 4, 800-11, 300 km (3, 000-7, 000 mi). Refer to


1. Remove the CH-45101-100 washers and the lug nuts that were installed during the assembled LRO
measurement procedure.
2. Inspect the mating surface of the hub/axle flange and the brake rotor to ensure that there are no foreign
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 CH-45101-100 washers
(1) and one lug nut (2) onto the upper-most wheel stud.

Fig. 97: Tightening Lug Nuts In A Star-Pattern To Secure Rotor

6. Install the remaining CH-45101-100 washers (1) and lug nuts onto the wheel studs and tighten the nuts
firmly by hand in a star-pattern.
7. Tighten the lug nuts in a star-pattern to specification, in order to properly secure the rotor. Refer to Tire
and Wheel Removal and Installation .
8. Measure the assembled LRO of the brake rotor. Refer to Brake Rotor Assembled Lateral Runout
Measurement.
9. Compare the amount of change between this measurement and the original measurement.
10. If this measurement is within specifications, proceed to step 14.
11. If this measurement still exceeds specifications, repeat steps 1-9 until the best assembled LRO
measurement is obtained.
12. Matchmark the final location of the rotor to the wheel studs if the orientation is different than it was
originally.
13. If the brake rotor assembled LRO measurement still exceeds the maximum allowable specification, refer

to Brake Rotor Assembled Lateral Runout Correction.

14. If the brake rotor assembled LRO is within specification, install the brake caliper and depress the brake
pedal several times to secure the rotor in place before removing the CH-45101-100 washers and the lug
nuts.
BRAKE ROTOR ASSEMBLED LATERAL RUNOUT CORRECTION - CORRECTION PLATES
Special Tools
NOTE:


Fig. 98: Identifying Correction Plate, High Spot Mark & V-Shaped Notch
1. Rotate the brake rotor to position the high spot, identified and marked during the brake rotor assembled

LRO measurement procedure, to face upward.

measurement procedure and/or the indexing correction procedure.
3. Inspect the mounting surface of the hub/axle flange and the brake rotor to ensure that there are no foreign
4. Select the correction plate, following the manufacturer instructions, which has a specification closest to
the assembled LRO measurement.
For example: If the assembled LRO measurement was 0.076 mm (0.003 in), the 0.076 mm (0.003 in)
correction plate would be used. If the measurement was 0.127 mm (0.005 in), the 0.152 mm (0.006 in)
correction plate would be used.
5. Determine the positioning for the correction plate (1) using the high spot mark (3) made during the brake
rotor assembled LRO measurement procedure.
NOTE:
Do NOT install used correction plates in an attempt to correct brake

rotor assembled LRO.
Do NOT stack up, or install more than one correction plate onto one
hub/axle flange location, in an attempt to correct brake rotor
assembled LRO.
6. Install the correction plate (1) onto the hub/axle flange, with the V-shaped notch (2) orientated to align
with the high spot mark (3) that was positioned to face upward.


7. Install the brake rotor to the hub/axle flange. Use the matchmark made prior to removal for proper
8. Hold the rotor firmly in place against the hub/axle flange and install one of the CH-45101-100 washers
(1) and one lug nut (2) onto the upper-most wheel stud.

Fig. 100: Tightening Lug Nuts In A Star-Pattern To Secure Rotor

10. Install the remaining CH-45101-100 washers (1) and lug nuts onto the wheel studs and tighten the nuts
firmly by hand in a star-pattern.
11. Tighten the lug nuts in a star-pattern to specification, in order to properly secure the rotor. Refer to Tire
and Wheel Removal and Installation .
Measurement.
nuts.
BRAKE ROTOR ASSEMBLED LATERAL RUNOUT CORRECTION - ON VEHICLE LATHE

Special Tools
NOTE:

1. Ensure that the caliper and caliper bracket that are already being supported, are clear from contacting any
rotating components, such as the brake rotor.
measurement procedure and/or the indexing correction procedure.
3. Inspect the mounting surface of the hub/axle flange and the brake rotor to ensure that there are no foreign
4. Set up the lathe, following the manufacturer instructions.
5. Refinish the brake rotor, following the brake lathe manufacturer instructions. Refer to Brake Rotor
Refinishing.
6. After each successive cut, inspect the brake rotor thickness. Refer to Brake Rotor Thickness
Measurement.
7. If at any time the brake rotor exceeds the minimum allowable thickness after refinish specification, the
brake rotor must be replaced. After replacing the rotor, proceed to step 10.
8. After refinishing the brake rotor, use the following procedure in order to obtain the desired nondirectional finish:
1. Follow the brake lathe manufacturer recommended speed setting for applying a non-directional
finish.
2. Using moderate pressure, apply the non-directional finish:
If the lathe is equipped with a non-directional finishing tool, apply the finish with 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.
3. After applying a non-directional finish, clean each friction surface of the brake rotor with denatured
alcohol, or an equivalent approved brake cleaner.
9. Remove the lathe from the vehicle.

Measurement.
nuts.
BRAKE ROTOR REFINISHING
Special Tools


NOTE:
The disc brake rotors do not require refinishing as part of routine brake
system service. New disc brake rotors do not require refinishing.
Do not refinish disc brake rotors 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 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
adequate thickness to allow the rotor to be refinished and remain above
the minimum allowable thickness after refinish specification. Refer to
Brake Rotor Thickness Measurement.
Disc brake rotors should only be refinished if they have adequate

thickness to be refinished and if one or more of the following conditions
exist:
Thickness variation in excess of the maximum allowable

specification
Excessive corrosion/rust and/or pitting

Cracks and/or heat spots

Excessive blueing discoloration
Scoring of the disc brake rotor surface in excess of the maximum
allowable specification
Disc brake rotors may need to be refinished as part of the process for
correcting brake rotor assembled lateral runout (LRO) that exceeds the
maximum allowable specification.
NOTE:
NOTE:
If the vehicle is equipped with cross-drilled rotors, use a lathe with positive rake
tooling. This setup requires less cutting pressure, which will result in less
vibration, and a better surface finish. Also, use a vibration dampener when
cutting. Otherwise, refinish according to the following instructions.
clean any rust or contaminants from the hub/axle flange and the brake
rotor mating surfaces. Failure to do this may result in increased
brake pulsation.
1. Using the CH-42450-A Wheel Hub Resurfacing Kit, thoroughly clean any rust or corrosion from the
mating surface of the hub/axle flange.
2. Using the CH-41013 Rotor Resurfacing Kit, thoroughly clean any rust or corrosion from the mating
surface and mounting surface of the brake rotor.
4. Mount the brake rotor to the brake lathe according to the lathe manufacturer's instructions, ensuring that
all mounting attachments and adapters are clean and free of debris.
5. Ensure that any vibration dampening attachments are securely in place.
6. With the brake lathe running, slowly bring in the cutting tools until they just contact the brake rotor
friction surfaces.
7. Observe the witness mark on the brake rotor. If the witness mark extends approximately three-quarters or
more of the way around the brake rotor friction surface on each side, the brake rotor is properly mounted
to the lathe.
8. If the witness mark does not extend three-quarters or more of the way around the brake rotor, re-mount
the rotor to the lathe.
9. Following the brake lathe manufacturer's instructions, refinish the brake rotor.
10. After each successive cut, inspect the brake rotor thickness. Refer to Brake Rotor Thickness
Measurement.
11. If at any time the brake rotor exceeds the minimum allowable thickness after refinish specification, the
brake rotor must be replaced.
12. After refinishing the brake rotor, use the following procedure in order to obtain the desired nondirectional finish:

1. Follow the brake lathe manufacturer's recommended speed setting for applying a non-directional
finish.
2. Using moderate pressure, apply the non-directional finish:
If the lathe is equipped with a non-directional finishing tool, apply the finish with 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.
NOTE:
Thoroughly cleaning the brake rotor will prevent the possible transfer
of finite metal dust left as a by-product of machining to the brake pad
material during the burnishing process, thereby reducing the
possibility for brake squeal or other brake noises to occur.
3. After applying a non-directional finish, clean each friction surface of the brake rotor with a solution
of mild dish washing detergent and water, or a GM approved brake cleaner and a clean shop towel
to remove metal particles remaining from machining. Repeat the cleaning process if necessary to
remove all metal particles.
13. Remove the brake rotor from the brake lathe.
14. Measure the assembled LRO of the brake rotor to ensure optimum performance of the disc brakes. Refer
to Brake Rotor Assembled Lateral Runout Measurement.

DISC BRAKE SYSTEM DESCRIPTION AND OPERATION
System Component Description
The disc brake system consists of the following components:

Disc Brake Pads: 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 pads to slow
speed of tire and wheel assembly rotation.
Disc Brake Pad Hardware: Secures disc brake pads firmly in proper relationship to the hydraulic brake
calipers. Enables a sliding motion of brake pads when mechanical output force is applied.
Disc Brake Caliper Hardware: Provides mounting for hydraulic brake caliper and secures the caliper firmly in
proper relationship to caliper bracket. Enables a sliding motion of the brake caliper to the brake pads when
mechanical output force is applied.
System Operation

Mechanical output force is applied from the hydraulic brake caliper pistons to the inner brake pads. As the
pistons press the inner brake pads outward, the caliper housings draw the outer brake pads inward. This allows
the output force to be equally distributed. The brake pads apply the output force to the friction surfaces on both
sides of the brake rotors, which slows the rotation of the tire and wheel assemblies. The correct function of both
the brake pad and brake caliper hardware is essential for even distribution of braking force.

SPECIAL TOOLS
Illustration

CH-230-A
MKM-230-A
J-21177-A
Disc Gauge
CH-41013
J-41013
Rotor Resurfacing Kit
CH-42450-A
J-42450-A
Wheel Hub Resurfacing Kit
CH-45101
J-45101
Hub and Wheel Runout Gauge
CH-45101-100
J-45101-100
Conical Brake Rotor Washers
EN-45059
J 45059
Angle Meter

2013 BRAKES Drum Brakes - Cruze
2013 BRAKES
Drum Brakes - Cruze
SPECIFICATIONS
Specification
Application
Metric
18 N.m
7 N.m
10 N.m
Brake Pipe Fittings

Drum Brake Mounting Bolt
Wheel Cylinder Mounting Bolts
English
11 lb ft
62 lb in
89 lb ft
DRUM BRAKE COMPONENT SPECIFICATIONS

Drum Brake Component Specifications
Specification
Application
Brake Drum Discard Diameter
Brake Drum Diameter- New
Brake Drum Maximum Allowable Radial Runout
Brake Drum Maximum Allowable Scoring
Brake Drum Maximum Diameter After Refinish
Brake Shoe Lining Minimum Thickness
Brake Shoe Lining-to-Drum Clearance
Brake Shoe Lining Thickness- New
Metric
256 mm
254 mm
0.05 mm
1 mm
256 mm
1.6 mm
0.4-0.9 mm
5.0 mm
English
10.078 in
10 in
0.002 in
0.039 in
10.078 in
0.063 in
0.016-0.035 in
0.197 in

Application
Type of Material
Rear Backing Plate
Lubricant
COMPONENT LOCATOR
REAR DRUM BRAKES COMPONENT VIEWS
GM Part Number
Refer to Electronic Parts Catalog

Fig. 1: Exploded View Of Brake Drum Assembly

Callout
1
2
3
4
5
6
7
8
9
10
11
12
13
Component Name
Wheel Cylinder Bleeder Valve
Wheel Cylinder Mounting Bolts
Hold Down Spring Pins
Brake Shoes
Brake Shoe Return Spring
Brake Shoe Hold Down Springs
Brake Shoe Hold Down Spring Caps
Brake Drum Mounting Bolt
Brake Drum
Adjuster Spring
Adjuster Assembly
Wheel Cylinder
Parking Brake Cable

BRAKE DRUM DIAMETER MEASUREMENT

Fig. 2: Measuring Brake Drum Diameter

1. Remove brake drum. Refer to Brake Drum Replacement

2. Clean the brake shoe lining contact surface of the brake drum (2) with denatured alcohol or an equivalent
approved brake cleaner.
3. Using a brake drum micrometer (1) calibrated in thousandths-of-an-inch, measure and record the largest
diameter of the brake drum at four or more points, equally spaced around the drum.
Ensure the measurements are only taken within the brake shoe lining contact area. The micrometer must
be positioned the same distance from the outside edge of the drum for each measurement.
4. Compare the largest diameter measurement recorded to the brake drum component specifications. Refer

5.
6.
7.
8.
to Drum Brake Component Specifications.

If the largest diameter measurement of the brake drum is less than the maximum allowable inside
diameter after refinishing specification; the drum may be refinished, depending upon surface and wear
conditions.
If the largest diameter measurement of the brake drum is equal to or greater than the maximum allowable
diameter after refinishing specification; the drum may not be refinished.
If the largest diameter measurement of the brake drum is equal to or greater than the discard diameter
specification; the drum requires replacement.
Install brake drum. Refer to Brake Drum Replacement.
BRAKE DRUM SURFACE AND WEAR INSPECTION

Special Tools
GE 572 Dial Indicator
1. Remove brake drum. Refer to Brake Drum Replacement.

2. Inspect the braking surface of the brake drum for the following braking surface conditions:
Heavy rust and/or pitting
Light surface rust can be removed with an abrasive disc; heavy surface rust and/or pitting must be
removed by refinishing the drum.

If the braking surface of the brake drum exhibits one or more of the Braking Surface Conditions
listed, the drum requires refinishing or replacement. Refer to Brake Drum Replacement, or Rear
Brake Drum Refinishing.

Fig. 3: Measuring Brake Drum Diameter

3. Using a brake drum micrometer (1) calibrated in thousandths-of-an-inch, measure and record any grooves
present on the drum braking surface.
Ensure that the measurements are only taken within the brake shoe lining contact area.
4. Compare the groove, or scoring depth recorded to brake drum component specification. Refer to Drum
Brake Component Specifications.
5. If the brake drum scoring depth exceeds the specification, or if an excessive amount of scoring is present,
the drum requires refinishing or replacement. Refer to Brake Drum Replacement, or Rear Brake Drum
Refinishing.
6. Mount the brake drum on a brake lathe.

Fig. 4: Measuring Brake Drum Radial Runout

7. Mount a dial indicator, GE 572 dial indicator (1) or equivalent, and position the indicator button so it
contacts the braking surface of the brake drum (2) at a 90 degree angle, approximately 19 mm (0.75 in)
from the outer edge of the drum.
8. Measure and record the radial runout of the brake drum.
1. Rotate the drum until the lowest reading is displayed on the indicator dial, then zero the dial.
2. Rotate the drum until the highest reading is displayed on the dial.
3. Compare the radial runout of the brake drum to the brake drum component specifications. Refer to
Drum Brake Component Specifications.
4. If the brake drum radial runout exceeds the specification, the drum requires refinishing or
replacement. Refer to Brake Drum Replacement, or Rear Brake Drum Refinishing.
DRUM BRAKE HARDWARE INSPECTION

Fig. 5: Identifying Drim Brake Hardware

1. Visually inspect the drum brake system brake shoe springs (3) for the following conditions:
The brake shoe springs (3) being bent, damaged, or broken at any point along the spring
Excessive corrosion of brake drum components
Excessive stretching, twisting, or binding of brake drum components
Damages or leakage to the wheel cylinder boots (2)
2. If any of the conditions listed were found the brake shoe springs and/or the wheel cylinder require
replacement. Refer to Brake Shoe Replacement, and/or Rear Brake Cylinder Replacement.
DRUM BRAKE ADJUSTING HARDWARE INSPECTION

Fig. 6: Identifying Drim Brake Hardware

1. Visually inspect the adjuster actuator spring (3) for the following conditions:
The spring being bent, or broken at any point along the spring
Excessive corrosion
Missing
2. Visually inspect the adjuster assembly (1) for the following conditions:
The adjuster being bent, or broken
Excessively worn, damaged, or missing teeth
3. Visually inspect the adjuster actuator lever for the following conditions:
The lever being bent, or broken

The lever to adjuster surface being excessively worn

Broken spring attachment tab
Missing
4. If any of the conditions listed were found, the affected part, or parts require replacement. Refer to Drum
Brake Hardware Replacement.
REPAIR INSTRUCTIONS
BRAKE SHOE INSPECTION
Special Tools
CH 230 Disc Gauge

Fig. 7: Measuring Brake Shoe Thickness

1. Measure the brake shoe lining thickness, using the CH 230 gauge (1).
2. Compare the brake shoe lining thickness recorded to the brake drum component specification. Refer to
Drum Brake Component Specifications.
NOTE:
Replace the shoe and lining assembly in axle sets only.
3. If the brake shoe lining thickness is less than the specification, or if a defect is found, replace the linings.
Refer to Brake Shoe Replacement.
BRAKE DRUM REPLACEMENT
Special Tools


Removal Procedure
1. Check to ensure that the park brake is fully released.

3. Remove the rear tire and wheel assembly. Refer to Tire and Wheel Removal and Installation .

Fig. 8: Brake Drum And Brake Drum Retaining Screw

4. Remove the brake drum screw (1).
5. Remove the brake drum (2).
6. If the brake drum is to be reinstalled to the vehicle, use the CH-41013 resurfacer or equivalent to clean
any rust or corrosion from the hub/flange mating surface of the brake drum (2).
7. Use the CH-42450-A resurfacer or equivalent to clean the wheel hub flange.

Fig. 9: Brake Drum And Brake Drum Retaining Screw

1. If installing a new brake drum (2), use denatured alcohol or an equivalent approve brake cleaner and a
clean shop towel to remove the protective coating from the friction surface of the drum.
2. Adjust the drum brakes. Refer to Drum Brake Adjustment.
3. Install the drum brake.
4.
5.
6.
7.
Install drum brake screw (1) and tighten to 7 N.m (62 lb in).
Lower the vehicle.
Apply the brakes approximately three times in order to seat and center the brake shoes within the drum.

REAR BRAKE DRUM REFINISHING

Special Tools
CH 41013 Resurfacing Kit
NOTE:
Do NOT refinish the brake drums in order to correct any of the following
complaints:
Brake noise (growl/squeal)

Premature brake lining wear
Cosmetic or superficial corrosion of the drum braking surface
Drum discoloration
Refinish the brake drums ONLY when one or more of the following conditions
exist:
Severe scoring of the drum braking surface (groove depth in excess of 1

mm (0.039 in)
Brake pulsation caused by the following:
Brake drum out of round
Corrosion or pitting that is deeper than the drum braking surface
1. Use a micrometer in order to measure the largest diameter of the brake drum. If the largest diameter of the
brake drum exceeds the brake drum maximum refinish diameter, do NOT refinish the brake drum.
Replace the brake drum.
2. Use the CH 41013 resurfacer in order to thoroughly clean the rust from the brake drum flange.
3. Refinish the brake drum. Refer to the brake lathe manufacturer's operating instructions.
NOTE:
Failure to obtain the best possible braking surface finish may cause the
vehicle to stop with difficulty.
4. After machining the brake drum, use 120 grit aluminum oxide sandpaper in order to create a nondirectional braking surface.
CAUTION: Improperly tightened wheel bolts or nuts can lead to brake pulsation
and rotor damage. In order to avoid expensive brake repairs, evenly
tighten the wheel bolts or nuts to the proper torque specification.
5. Clean the braking surfaces with denatured alcohol or with a suitable brake cleaner.
BRAKE SHOE REPLACEMENT

Special Tools
CH 346 Mounting Tool

For equivalent regional tool, refer to Special Tools.
Removal Procedure
NOTE:
Always replace brake shoes in axle sets.
3. Remove the brake drum. Refer to Brake Drum Replacement.

Fig. 10: Identifying Brake Shoe Adjuster Spring

CAUTION: Do not over stretch the adjuster spring. Damage can occur if the
spring is over stretched.
4. Remove the adjuster spring (1). Disengage the adjuster spring hook end from the tab on the adjuster
actuator lever, then release the spring from the brake shoe web hole.

Fig. 11: Drum Brake Adjuster Actuator Lever And Adjuster Assembly
5. Release the adjuster actuator lever (1) from the adjuster assembly (2).
Remove the adjuster assembly (2).

Fig. 12: Brake Shoe Springs

6. Remove the brake shoe springs (1), using the CH 346 mounting tool to twist spring caps (2).

Fig. 13: Drum Brake Components

7. Remove the brake shoes (1).
Remove the lower spring (4) from front brake shoe.
8. Remove the parking brake cable (3) from the parking brake lever (2).

1. Install the adjuster assembly (2) to the adjuster actuator lever (1).
Turn in the adjuster as far as possible.

Fig. 15: Drum Brake Components

2.
3.
4.
5.
Install the parking brake cable (3) to the parking brake lever (2).
Install the lower spring (4) to front brake shoe.
Install the brake shoes (1).
Install the brake shoe springs (1), using the CH 346 mounting tool to twist spring caps.


6. Install the adjuster spring (1). Ensure that the loop end of the spring fully engages the tab on the actuator
lever.
7. Install the brake drum. Refer to Brake Drum Replacement.
8. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation
REAR BRAKE BACKING PLATE REPLACEMENT
Removal Procedure

1.
2.
3.
4.
5.
Remove the brake drum. Refer to Brake Drum Replacement.
Remove the brake shoes. Refer to Brake Shoe Replacement.
Remove the wheel cylinder. Refer to Rear Brake Cylinder Replacement.
Fig. 17: Park Brake Cable End

6. Release the rear park brake cable end fitting (1) from the drum brake backing plate.
7. Remove the wheel bearing/hub assembly. Refer to Rear Wheel Bearing and Hub Replacement (Drum
Brake) , Rear Wheel Bearing and Hub Replacement (Disc Brake)

Fig. 18: Brake Backing Plate

8. Remove the brake backing plate (1).

Fig. 19: Brake Backing Plate

1. Install the brake backing plate (1).
2. Install the wheel bearing/hub assembly. Refer to Rear Wheel Bearing and Hub Replacement (Drum
Brake) , Rear Wheel Bearing and Hub Replacement (Disc Brake)

Fig. 20: Park Brake Cable End

3.
4.
5.
6.
7.
8.
Secure the rear park brake cable end fitting (1) to the brake backing plate.
Install the wheel cylinder. Refer to Rear Brake Cylinder Replacement.
Install the brake shoes. Refer to Brake Shoe Replacement.
Adjust the drum brakes. Refer to Drum Brake Adjustment.
Install the brake drum. Refer to Brake Drum Replacement.
DRUM BRAKE HARDWARE REPLACEMENT
Special Tools

CH 346 Mounting Tool

Removal Procedure



5. Remove the brake shoe springs (1), using the CH 346 mounting tool to twist spring caps (2).
6. Remove the lower spring from front brake shoe.


1. Install the lower spring to front brake shoe.
2. Install the brake shoe springs (1), using the CH 346 mounting tool to twist spring caps.


lever. Ensure that the loop end of the spring fully engages the tab on the actuator lever.
DRUM BRAKE ADJUSTING HARDWARE REPLACEMENT
Removal Procedure



5. Release the adjuster actuator lever (1) from the adjuster assembly (2).
Remove the adjuster assembly (2).
6. Remove the adjuster assembly (2) and inspect for the following conditions:
Binding or seized threaded adjuster assembly.
Damaged or missing adjuster screw teeth.
7. Replace the adjuster assembly if any of the conditions listed are present.

1. Install the adjuster assembly (2) to the adjuster actuator lever (1).
Turn in the adjuster as far as possible.


lever.
REAR BRAKE CYLINDER REPLACEMENT
Removal Procedure

1.
2.
3.
4.
5.
Remove the brake shoes. Refer to Brake Shoe Replacement.
Clean any debris and contaminants from around the wheel cylinder.
Fig. 29: Brake Pipe Fitting And Wheel Cylinder Mounting Bolts

6. Disconnect the brake pipe fitting (1) from the wheel cylinder. Cap the exposed brake pipe end to prevent
fluid loss.
7. Remove the 2 wheel cylinder mounting bolts (2).
Fig. 30: Wheel Cylinder

8. Remove the wheel cylinder (1) from the backing plate.

Fig. 31: Wheel Cylinder

1. Install the wheel cylinder (1) to backing plate.

Fig. 32: Brake Pipe Fitting And Wheel Cylinder Mounting Bolts
2.
3.
4.
5.
6.
Install wheel cylinder mounting bolts (2) and tighten to 10 N.m (89 lb in).
Connect the brake pipe fitting (1) at the wheel cylinder and tighten to 18 N.m (14 lb ft).
Install the brake shoes. Refer to Brake Shoe Replacement.

DRUM BRAKE ADJUSTMENT

Special Tools
CH-21177-A Drum to Brake Shoe Clearance Gauge
1.
2.
3.
4.
Ensure the park brake lever is in the fully released position.

Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle
Fig. 33: Installing J 21177-A Inside Brake Drum Diameter


5. Position the CH-21177-A gauge to the widest point of the brake drum inside diameter.
6. Firmly hand tighten the set screw on the CH-21177-A gauge.
Fig. 34: Positioning J 21177-A Over Brake Shoe Assembly

7. Remove the CH-21177-A gauge from the brake drum and position it over the corresponding brake shoe
assembly at its widest point.
8. While holding the CH-21177-A gauge in position, insert a proper feeler gauge between one side of the
CH-21177-A gauge, and the corresponding brake shoe lining.
9. Rotate the brake shoe adjuster screw until the brake shoe linings contact the CH-21177-A gauge and the
feeler gauge.
Specification
Brake shoe lining-to-drum clearance: 0.4-0.9 mm (0.016-0.035 in)

10.
11.
12.
13.
14.
Repeat the above steps for the opposite brake drum and brake shoe assembly.
Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation
Lower vehicle.
Apply the brake pedal at least 10 times. Verify the clicking sound of the adjuster assembly is not audible
from either brake drum.
15. Adjust the park brake. Refer to Parking Brake Adjustment (Mechanical Parking Brake) .

DRUM BRAKE SYSTEM DESCRIPTION AND OPERATION
The drum brake system consists of the following:

Drum Brake Shoes
Applies mechanical output force, from hydraulic brake wheel cylinders, to friction surface of brake
drums.
Brake Drums
Uses mechanical output force applied to friction surface from drum brake shoes to slow speed of tire and
wheel assembly rotation.
Drum Brake Hardware
Secures drum brake shoes firmly in proper relationship to hydraulic brake wheel cylinders. Enables
sliding motion of brake shoes needed to expand toward friction surface of drums when mechanical output
force is applied. Provides return of brake shoes when mechanical output force is relieved.
Drum Brake Adjusting Hardware
Provides automatic adjustment of brake shoes to brake drum friction surface whenever brake apply
occurs.
System Operation
Mechanical output force is applied from the hydraulic brake wheel cylinder pistons to the top of the drum brake
shoes. The output force is then distributed between the primary and secondary brake shoes as the shoes expand
toward the friction surface of the brake drums. The brake shoes apply the output force to the friction surface of
the brake drums, which slows the rotation of the tire and wheel assemblies. The proper function of both the
drum brake hardware and adjusting hardware is essential to the proper distribution of braking force.


SPECIAL TOOLS
Illustration

CH-230-A
MKM-230-A
J-21177-A
Disc Gauge
CH-346
KM-346
Mounting Tool
CH-21177
J-21177-A
Drum to Brake Shoe Clearance Gauge
CH-41013
J-41013
Rotor Resurfacing Kit
CH-42450-A
J-42450-A
Wheel Hub Resurfacing Kit
GE-572
MKM-572
GE-7872
J-8001
Dial Indicator

2013 BRAKES Hydraulic Brakes - Cruze
2013 BRAKES
Hydraulic Brakes - Cruze
SPECIFICATIONS
Specification
Application
Brake Booster Bolts
Brake Hose-To-Brake Caliper Bolt
Brake Master Cylinder Nut
Brake Master Cylinder Reservoir Bolt
Brake Pedal Bracket Bolt
Brake Pipe Fitting
Brake Pressure Modulator Valve Bracket Bolt
Clutch Master Cylinder Nut
Master Cylinder Primary Brake Pipe Fitting
Rear Brake Hose Bracket Bolt
Power Brake Booster Pump Bolt
Power Brake Booster Pump Bracket Bolts
1 = Use NEW Fastener.
Metric
19 Y
40 Y
50 N.m (1)
2.5 N.m
20 N.m
18 N.m
20 N.m
18 Y
18 Y
8 N.m
7.5 N.m
22 N.m
English
14 lb ft
30 lb ft
37 lb ft (1)
22 lb in
15 lb ft
13 lb ft
15 lb ft
13 lb ft
13 lb ft
71 lb in
66 lb in
15 lb ft
BRAKE COMPONENT SPECIFICATIONS

Brake Component Specifications
Specification
Application
Brake Caliper Bleeder Valve- Front
Brake Caliper Bleeder Valve- Rear
Metric
17 N.m
17 N.m
English
12 lb ft
12 lb ft
BRAKE SYSTEM SPECIFICATIONS

Brake System Specifications
Application
Specification
Metric
English
40 to 55 mm
1.57 to 2.17 in
Brake Pedal Travel
Maximum specification with 445 N (100 lb F)

of force applied to the brake pedal with the

ignition OFF and the booster power reserve

depleted
Application
Hydraulic Brake
System
Type of Material
DOT 3 Motor Vehicle
Brake Fluid
GM Part Number
United States
Canada
12377967
89021320

HYDRAULIC BRAKE WIRING SCHEMATICS
Hydraulic Brakes Wiring Schematics
Fig. 1: Hydraulic Brakes Wiring Schematics

Callout
1940
Component Name

1940_RD/VT
CAV_5
CONN_X1
CAV_40
CONN_X2
6305
6305_BN
CAV_2
CAV_35
6031
6031_YE/RD
CAV_3
CAV_17
6032
6032_BK/YE
CAV_24
CAV_2
6030
6030_YE/VT
CAV_22
CAV_1
1470
1470_RD
CAV_1
CONN_X2
1809
1809_WH
CAV_2
1050
1050_BK
CAV_1
CONN_X1
1550
1550_BK
CAV_2
333
333_GN/GY
1940 RD/VT
5
X1
40
X2
Brake Vacuum Switch Signal
6305 BN
2
35
Brake Vacuum Sensor 5 Volt
Reference
6031 YE/RD
3
17
Brake Vacuum Sensor Low
Reference
6032 BK/YE
24
2
Brake Vacuum Sensor Signal
6030 YE/VT
22
1
Brake Booster Pump Motor
Supply Voltage
1470 RD
1
X2
Brake Booster Vacuum
Sensor Signal
1809 WH
2
Ground
1050 BK
1
X1
Ground
1550 BK
2
Brake Fluid Level Sensor
Signal
333 GN/GY

CAV_1
CAV_29
1134
1134_BU/VT
CAV_A
CAV_15
CONN_X7
SD
G120
G305
F25UA
K9
B80
X50A
M9
KR14
K17
B20
B19B
P16
P9
A90
1
29
Park Brake Switch Signal
1134 BU/VT
A
15
X7
Serial Data
Data Communication
Schematics
G120
G305
F25UA 20A
Logic

DTC
DTC C0267
DTC C027B
DTC C0299
DTC C1100
Description
DTC C0267 00 Low Brake Fluid Indicated
DTC C027B 00 Brake Booster Electric Vacuum
Pump
DTC C0299 5A Brake Booster Large Vacuum Leak
Detected Not Plausible
DTC C1100 00 Brake Booster Vacuum Sensor
Circuit Malfunction
Circuit Short to Battery

Circuit Performance Signal Invalid

Circuit Too Fast Transitions
DTC C0267
DTC Descriptor
DTC C0267 00
Low Brake Fluid Indicated
Circuit
Signal
Ground
Short to
Ground
-
Open/High
Resistance
C0267 00
C0267 00
Short to
Voltage
-
Signal Performance
-
The brake fluid level switch monitors the level of brake fluid in the brake fluid reservoir. When the electronic
brake control module sees the brake fluid level switch input open, the DTC is set.
Ignition ON.
An open is detected on the brake fluid level signal circuit for 20 s.

Low brake fluid level is detected for 20 s.
the ignition cycle.
The traction control/stability control-active indicator turns ON.
The brake warning indicator turns ON.


Schematic Reference
Hydraulic Brake System Description and Operation
Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference

1. Verify that the brake fluid has the proper level. The fluid level should be above minimum level.
If low
Refer to Brake Fluid Loss.
If above minimum level
2. Ignition ON.
3. Verify the scan tool Brake Fluid Level Sensor parameter is Ok.
If the parameter is Low

If the parameter is Ok
4. All OK.

1. Ignition OFF, disconnect the harness connector at the B20 Brake Fluid Level Switch.
1. Ignition OFF.
3. Ignition ON.
4. Verify the scan tool Brake Fluid Level Sensor parameter is Low.
If the parameter is not Low
6. Verify the scan tool Brake Fluid Level Sensor parameter is Ok.
If the parameter is not Ok
ignition ON.
If less than 1 V.
7. Test or replace the B20 Brake Fluid Level Switch.
Repair Instructions
Brake Fluid Level Indicator Switch Replacement

Control Module References for electronic brake control module replacement, programming and setup
DTC C027B

DTC Descriptors
DTC C027B 00
Brake Booster Electric Vacuum Pump
Circuit
Vacuum Pump Relay B+
Vacuum Pump Relay
Control
Vacuum Pump Relay
Ground
Short to
Ground
-
Open/High
Resistance
-
Short to
Voltage
-
Signal Performance
-
C027B 00
C027B 00
C027B 00
The brake booster vacuum sensor measures the vacuum in the brake booster assembly. The electronic brake
control module supplies a 5 V reference and a low reference circuit to the brake booster vacuum sensor. The
vacuum sensor supplies a voltage signal in relation to the pressure in the brake booster to the electronic brake
control module. When the vacuum within the system becomes weak, the electronic brake control module turns
ON the brake booster pump motor by providing battery voltage to the brake booster pump motor relay. The
relay activates and supplies ground to the brake booster pump motor.
Ignition ON.
A short to ground, short to voltage or open/high resistance is detected on the control circuit.

Schematic Reference


Brake Assist System Description and Operation
Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference

1. Verify that the brake booster vacuum system has no damage, leakage or incorrect installation.
If damage, leakage or incorrect installation is found
Refer to Brake Assist System Diagnosis
If no damage, leakage or incorrect installation is found
2. Ignition ON.
3. Verify the brake booster pump motor turns ON and OFF when commanding the brake booster electric
vacuum pump ON and OFF with a scan tool.
If the brake booster pump motor does not turn ON and OFF

If the brake booster pump motor turn ON and OFF
4. All OK.
1. Ignition OFF and all vehicle systems OFF, disconnect the X1 harness connector at the KR14 Brake
Booster Pump Motor Relay. It may take up to 2 min for all vehicle systems to power down.

3.
4.
5.
6.
7.
Ignition ON.
1. Ignition OFF.
1. Ignition OFF.
If infinite resistance, replace the M9 Brake Booster Pump Motor.
Connect a test lamp between the control circuit terminal 2 and ground.
Verify the test lamp turns ON and OFF when commanding the brake booster electric vacuum pump ON
ignition ON.
Replace the KR14 Brake Booster Pump Motor Relay.
Repair Instructions

Power Brake Booster Pump Replacement

Control Module References for electronic brake control module replacement, programming and setup.
DTC C0299
DTC Descriptor
DTC C0299 5A
Brake Booster Large Vacuum Leak Detected Not Plausible
control module.
Engine running.
The electronic brake control module detected a weak vacuum in the brake booster assembly for 120 s.
The DTC is stored in memory.


Schematic Reference


Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference

1. Ignition ON.
2. Verify that DTC C1100 is not set.
If the DTC is set
Refer to DTC C1100.
Refer to Brake Assist System Diagnosis.

If the inspection is OK
4. Replace the B19B Brake Booster Vacuum Sensor.
5. Verify the DTC does not set while operating the vehicle under the Conditions for Running the DTC.
If the DTC sets

6. All OK.

Repair Instructions
Power Brake Booster Vacuum Pipe Replacement (without Electric Pump), Power Brake Booster
Vacuum Pipe Replacement (with Electric Pump) for Brake Booster Vacuum Sensor replacement.
DTC C1100
DTC Descriptors
DTC C1100 00
Brake Booster Vacuum Sensor Circuit Malfunction
DTC C1100 01
Brake Booster Vacuum Sensor Circuit Short to Battery
DTC C1100 02
Brake Booster Vacuum Sensor Circuit Short to Ground
DTC C1100 08
Brake Booster Vacuum Sensor Circuit Performance Signal Invalid
DTC C1100 09
Brake Booster Vacuum Sensor Circuit Too Fast Transitions
5 V Reference
Short to
Ground
C1100 02
Open/High
Resistance
C1100 00
Short to
Voltage
C1100 01
Signal
C1100 00
C1100 00
C1100 00
C1100 00
Circuit
Low Reference
Signal
Performance
C1100 08,
C1100 09
-

The brake booster vacuum sensor monitors the pressure in the brake booster. The electronic brake control
module supplies a 5 V reference and a low reference circuit to the brake booster vacuum sensor. The vacuum
sensor supplies a voltage signal in relation to the pressure in the brake booster to the electronic brake control
module.
Ignition ON.
C1100 00
A short to ground, short to voltage or open/high resistance is detected on the 5 V reference circuit.
The electronic brake control module detects an erratic vacuum sensor signal.
C1100 01
A short to voltage is detected on the vacuum sensor signal circuit.
C1100 02
A short to ground is detected on the vacuum sensor signal circuit.
C1100 08, 09
The vacuum sensor signal is not plausible.
The brake warning indicator turns ON.


The electronic control module will turn OFF the indicator in the next ignition cycle.
Schematic Reference


Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference

1. Ignition OFF and all vehicle systems OFF, disconnect the harness connector at the B19B Brake Booster
Vacuum Sensor. It may take up to 2 minutes for all vehicle systems to power down.
1. Disconnect the harness connector at the K17 Electronic Brake Control Module.
3. Ignition ON.
If less than 4.8 V
ignition ON.

5. Ignition OFF, disconnect the harness connector at the K17 Electronic Brake Control Module, Ignition
ON.
6. Test for less than 1 V between the B19B Brake Booster Vacuum Sensor signal circuit terminal 1 and
ground.
If greater than 1 V
If less than 1 V
7. Ignition OFF.
8. Test for infinite resistance between the B19B Brake Booster Vacuum Sensor signal circuit terminal 1 and
ground.

9. Test for less than 2 ohms in the B19B Brake Booster Vacuum Sensor signal circuit terminal 1 and the
K17 Electronic Brake Control Module signal circuit terminal 22.

If less than 2 ohms
10. Replace the B19B Brake Booster Vacuum Sensor.
11. Verify the DTC does not set while operating the vehicle under Conditions for Running the DTC.
If the DTC sets

12. All OK.
Repair Instructions


SYMPTOMS - HYDRAULIC BRAKES

NOTE:
1. Perform the Brake System Vehicle Road Test before using the hydraulic brake symptom tables in order
to duplicate the customers concern.
following:
Brake Warning System Description and Operation
Inspect for aftermarket devices which could affect the operation of the hydraulic brake system. Refer to
Intermittent
Symptom List

Brake Pulsation
Brake System Noise
Braking Action Uneven - Front to Rear
Brake Pedal Excessive Travel
Brake Pedal Excessive Effort
Brakes Drag
Brake System Slow Release
Brake Fluid Loss
BRAKE BOOSTER PUMP MOTOR MALFUNCTION


Short to
Ground
Circuit
Vacuum Pump Relay B+
1
Vacuum Pump Relay
C027B 00
Control
Vacuum Pump Relay
Ground
1. Brake Booster Pump Motor Always Off
Open/High
Resistance
1
Short to
Voltage
-
Signal Performance
-
C027B 00
C027B 00
control module. When the vacuum within the system becomes weak, the electronic brake control module turns
ON the brake booster pump motor by providing battery voltage to the brake booster pump motor relay. The
relay activates and supplies ground to the brake booster pump motor.
Schematic Reference
Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference


Refer to Brake Assist System Diagnosis
If no damage, leakage or incorrect installation is found
2. Ignition ON.
3. Verify the brake booster pump motor turns ON and OFF when commanding the brake booster electric
vacuum pump ON and OFF with a scan tool.
If the brake booster pump motor does not turn ON and OFF

If the brake booster pump motor turn ON and OFF
4. All OK.
1. Ignition OFF and all vehicle systems OFF, disconnect the X1 harness connector at the KR14 Brake
Booster Pump Motor Relay. It may take up to 2 minutes for all vehicle systems to power down.
3. Ignition ON.
1. Ignition OFF.
1. Ignition OFF.
If infinite resistance, replace the M9 Brake Booster Pump Motor.

6. Verify the test lamp turns ON and OFF when commanding the brake booster electric vacuum pump ON
ignition ON.
7. Replace the M9 Brake Booster Pump Motor.
Repair Instructions
Power Brake Booster Pump Replacement

BRAKE WARNING INDICATOR MALFUNCTION

Circuit
Brake Fluid Level Signal
Park Brake Signal
Ground
Short to
Ground
1
1
-
Open/High
Resistance
C0267 00
1
1
Short to
Voltage
1
1
-
Signal Performance
-

1. Brake Warning Indicator Malfunction

The instrument cluster turns ON the brake warning indicator for 5 s after ignition ON. The body control module
monitors the parking brake switch and will request the instrument cluster via serial data to turn the brake
warning indicator ON when the parking brake is applied. When the electronic brake control module detects a
fault, it sends a serial data message to the instrument cluster commanding the indicator ON.
Schematic Reference
Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference

1. Verify that the brake fluid has the proper level. The fluid level should be above minimum level.
If low
Refer to Brake Fluid Loss.
If above minimum level
2. Ignition ON.
3. Verify the scan tool Electronic Brake Control Module, Brake Fluid Level Sensor parameter. The reading
should be Ok.


Refer to Brake Fluid Level Switch Malfunction below.
4. Verify the scan tool Body Control Module, Park Brake Switch parameter changes between Active and
Inactive while applying and releasing the parking brake.
Refer to Park Brake Switch Malfunction below.

5. Verify the brake warning indicator turns ON and OFF, when commanding the instrument cluster All
Indicators ON and OFF with a scan tool.
If the brake warning indicator does not turn ON and OFF

If the brake warning indicator turns ON and OFF
6. All OK.
NOTE:
Brake Fluid Level Switch Malfunction

1. Ignition OFF, disconnect the harness connector at the B20 Brake Fluid Level Switch.
1. Ignition OFF.
3. Ignition ON.
4. Verify the scan tool Electronic Brake Control Module, Brake Fluid Level Sensor parameter is Low.
If the parameter is not Low


6. Verify the scan tool Electronic Brake Control Module, Brake Fluid Level Sensor parameter is OK.
If the parameter is not OK
ignition ON.
If less than 1 V.
7. Test or replace the B20 Brake Fluid Level Switch.
Park Brake Switch Malfunction

1. Ignition OFF, disconnect the harness connector at the B80 Park Brake Switch.
2. Verify that the B80 Park Brake Switch has no physical damage or incorrect installation.
If physical damage or incorrect installation is found
Test or replace the B80 Park Brake Switch.
If the inspection is OK
Ignition ON.
Verify the scan tool Body Control Module, Park Brake Switch parameter is Inactive.
If the parameter is Inactive
Install a 3 A fused jumper wire between the signal circuit terminal A and ground.
Verify the scan tool Body Control Module, Park Brake Switch parameter is Active.
If the parameter is Inactive
If less than 1 V.
3.
4.
5.
6.

7. Test or replace the B80 Park Brake Switch.
Repair Instructions

Parking Brake Indicator Switch Replacement
Control Module References for Control Module replacement, programming and setup.
BRAKE PULSATION
Brake Pulsation
Step
Action
Yes
No
DEFINITION: Fluctuation or pulsation is felt through the brake pedal, steering wheel, seat, floor, and/or
in the vehicle ONLY when braking.
Were you sent here from the Hydraulic Brake
Go to Step Go to Symptoms 1
Symptom table?
2
Hydraulic Brakes
1. Inspect the disc brake system for the following

conditions.
Excessive thickness variation of rotor
friction surfaces
Excessive assembled lateral runout (LRO)
of rotor friction surfaces
Hard spots, heat checks, blueing
discoloration of rotor friction surfaces;
possibly due to brake drag
Excessive corrosion of rotor friction
surfaces; including red, gray or black
oxidation
Loose, damaged or missing caliper or
lining hardware
Bent or damaged caliper or mounting
component
Excessive LRO of wheel hub/axle flange;
due to damage and/or loose or excessively
worn bearings
2. Adjust, repair or replace components as
necessary. Refer to Disc Brake System

Diagnosis.
Go to Step 3
1. Inspect the drum brake system, if equipped, for

the following conditions.
Out of round or damaged drum
Excessive radial runout of drum friction
surface
discoloration of drum friction surface;
Bent or damaged drum
Excessive radial runout of wheel hub/axle
flange; due to damage and/or loose or
excessively worn bearings
2. Adjust, repair or replace components as
necessary. Refer to Drum Brake System
Diagnosis.
Go to Step
4
Hydraulic Brakes
1. Install or connect components that were removed

or disconnected during diagnosis.
2. 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
BRAKE SYSTEM NOISE

Brake System Noise
Step
Action
Yes
No
DEFINITION: Vehicle exhibits abnormal noise when braking; vehicle may exhibit abnormal noise
during motion just after brake pedal release.
Were you sent here from the Hydraulic Brake Symptom Go to Step Go to Symptoms 1
table?
2
Hydraulic Brakes
conditions.
Lining wear indicator contact with rotor
Debris trapped between rotor and splash
shield or backing plate; and/or debris
trapped between rotor and linings
Contaminated linings

Aftermarket linings
Glazed linings
Distorted, cracked or damaged linings
Excessively worn linings
Damaged or excessively worn caliper
hardware and/or lining hardware
Incorrectly installed, loose or missing
caliper hardware and/or lining hardware
Lack of lubrication or excessive corrosion
on metal to metal contact surfaces
Bent or damaged splash shield or backing
plate
discoloration of rotor friction surfaces
Glazed rotor friction surfaces
component
2. Adjust, repair or replace components as necessary.
Refer to Disc Brake System Diagnosis.

Glazed linings
Aftermarket linings
Distorted, damaged or excessively worn
linings
Improper adjustment
Weak or damaged return spring or springs
Weak or damaged hold down spring or
springs
Cracked, scored, excessively worn or
damaged drum
discoloration of drum friction surface
Threaded or spiral grooves in drum friction
surface
Distorted or damaged backing plate
Go to Step
10
Go to Step 3

Lack of lubrication on backing plate

Excessive dust or foreign matter in drum
Refer to Drum Brake System Diagnosis.
Go to Step 4
Go to Step
10
Go to Step 5
Go to Step
10
Go to Step 6
1. Inspect the brake assist system for the following

conditions.
Lack of lubrication or excessively worn
pushrod or pedal pivots or pivot bushings
Bent or damaged pedal pushrod, pedal, or
pedal bracket
Damaged or improperly operating vacuum
booster and/or check valve, if equipped
Low power steering fluid level, if equipped
with hydraulic boost
Improperly tensioned, excessively worn or
damaged power steering belt, if equipped
with hydraulic boost
Restricted return hose from hydraulic
booster, if equipped
Improperly operating hydraulic booster, if
equipped
Improperly functioning power steering
system, if equipped with a hydraulic booster
assembly
Contaminated power steering fluid, if
equipped with hydraulic boost
Go to Step
10
1. Inspect the hydraulic brake system for the

following conditions.
Improper operation of wheel cylinder
pistons, if equipped
Improper operation of caliper pistons
Contaminated brake fluid
Refer to Hydraulic Brake System Diagnosis.

6
7
10
Is the vehicle equipped with a drum-in-rotor type of park Go to Step

brake system?
7
Ensure the park brake shoes are not adjusted too tightly,
Go to Step
possibly causing a noise under certain conditions.
8
Are the park brake shoes adjusted too tightly?
Go to Step 9
Go to Step 9
1. Clean and inspect the park brake shoes for

excessive wear and/or damage.
2. Inspect the drum portion of the rotors for
excessive wear, blueing discoloration, heat spots,
and excessive radial runout.
3. If any of these conditions are present, replace the
affected components.
4. Adjust the park brake system.
Inspect the park brake system for proper operation.
Refer to Park Brake System Diagnosis (Drum
Brakes) , Park Brake System Diagnosis (Disc
Brakes) .
Go to Step
10
Go to Step 9
Hydraulic Brakes

Test.
Go to Step
2
System OK
BRAKING ACTION UNEVEN - PULLS TO ONE SIDE

Test Description
5
Suspension components that are not operating properly may cause a disturbance to the vehicle during
application of the brake system.
6
Steering components that are not operating properly may cause a disturbance to the vehicle during
Braking Action Uneven - Pulls to One Side

Step
Action
Yes
No
DEFINITION: Vehicle pulls to one side only when braking.
table?
2
Hydraulic Brakes

Kinked, pinched or damaged brake pipe or
flexible brake hose
Sticking or improperly operating caliper
piston
Sticking or improperly operating wheel
cylinder pistons, if equipped
Brake fluid leak
Go to Step
7
Go to Step 3
Go to Step
7
Go to Step 4

conditions.
Glazed linings
Distorted, cracked or damaged linings on
one side
Loose, damaged or missing caliper
Incorrect linings on one side
discoloration of rotor friction surfaces;
component
Improper adjustment or improper adjuster
operation

Glazed linings
Distorted or damaged linings
Incorrect linings on one side
Excessively worn or damaged drum on one
side
Go to Step
7
Go to Step 6
1. Inspect the steering system for the following

conditions.
Loose steering component connections
Excessively worn or damaged steering
components
Refer to Symptoms - Power Steering System .
Go to Step 5
1. Inspect the suspension system for the following

conditions.
Incorrect tire pressures
Loose suspension component connections
Excessively worn or damaged suspension
components
Refer to Symptoms - Suspension General
Diagnosis .
Go to Step
7
Hydraulic Brakes

Test.
BRAKING ACTION UNEVEN - FRONT TO REAR

Test Description
Go to Step
2
System OK

The number below refer to the step number on the diagnostic table:
5
Suspension components that are not operating properly may cause a disturbance to the vehicle during
Braking Action Uneven - Front to Rear
Step
Action
Yes
No
DEFINITION: Braking action or stopping force sensitive or grabbing and/or more pronounced at the
front or at the rear axle. Sensitive or grabbing brakes: Excessive brake jump-in force relative to brake
pedal input.
table?
2
Hydraulic Brakes

Kinked, pinched or damaged brake pipe or
flexible brake hose
Brake fluid leak
Improperly functioning proportioning valve,
if equipped
Improper operation of dynamic rear
proportioning (DRP) system, if equipped

conditions.
Glazed linings
Distorted, cracked or damaged linings
Aftermarket linings
Go to Step
7
Go to Step 3


Go to Step
7
Go to Step 5
Go to Step
7
Go to Step 6
1. Inspect the suspension system for the following

conditions.
Loose suspension component connections
Excessively worn or damaged suspension
components
Refer to Symptoms - Suspension General
Diagnosis .
Go to Step 4

Improper adjustment
Excessively worn or damaged linings
Excessively worn or damaged drums
Go to Step
7

conditions.
Binding, bent or damaged pedal pushrod,
pedal, or pedal bracket
Damaged or improperly operating hydraulic
Hydraulic Brakes


Test.
Go to Step
2
System OK
BRAKE PEDAL EXCESSIVE TRAVEL

Brake Pedal Excessive Travel
Step
Action
Yes
No
DEFINITION: Brake pedal travels further than expected to obtain firm pedal and/or firm pedal cannot be
obtained, pedal fades away, or pedal is spongy.
Were you sent here from the Hydraulic Brake Symptom
table?
2
Hydraulic Brakes
Inspect the travel and feel of brake pedal applies. Perform
the following:
1. Apply the brake pedal several times to fully deplete

the power reserve.
2. With power reserve depleted, apply the brake pedal
with light, steady pressure and hold for 15 seconds.
Observe pedal travel and feel.
3. Apply the brake pedal with light, steady pressure,
then without pumping the pedal, reduce pressure and
reapply pressure several times. Observe pedal travel
and feel for each apply.
4. Apply the brake pedal slowly, then release and apply
the pedal quickly. Observe pedal travel and feel for
each apply.
Did you complete the brake pedal travel and feel
inspections?
1. Inspect the hydraulic brake system for the conditions
listed, based on the following symptoms observed
during the pedal travel and feel inspections.
Pedal feel was spongy.
Air in hydraulic system
External brake fluid leaks
Soft, weak or damaged hydraulic hoses;
expanding under pressure
Pedal fell away and/or traveled to or almost to
floor.
Go to Step
3


Poor brake fluid quality; low boiling
point
Internal brake fluid leaks; improperly
functioning master cylinder
Pedal was somewhat firm then dropped
slightly, or pedal rose with successive applies,
or pedal travel was different between slow and
quick applies.
Poor brake fluid quality; low boiling
point
Binding wheel cylinder pistons, if
equipped
Pedal returned to rest slowly after any of the
applies.
Internally damaged flexible brake hoses;
hindering fluid return
Binding caliper pistons
Binding wheel cylinder pistons, if
equipped
2. Repair or replace components as necessary. Refer to
Hydraulic Brake System Diagnosis.
3. Re-inspect brake pedal apply travel and feel.
1. Inspect the drum brake system, if equipped, for the

operation
Glazed or excessively worn linings
Cracked, distorted or damaged linings
Cracked, excessively worn, distorted or
damaged drums
Bell-mouth or barrel-shaped drum friction
surface
Hard spots, heat checks, blueing discoloration
of drum friction surface
Go to Step
9
Go to Step 4


Go to Step
9
Go to Step 5
Go to Step
9
Go to Step 6

conditions:
Cracked, excessively worn or damaged linings
Cracked, excessively worn or damaged rotors
Improperly operating, binding or damaged
Loose or missing caliper hardware and/or
lining hardware
Excessive assembled lateral runout (LRO) of
rotor friction surfaces
component
Inspect for proper brake pedal travel. Refer to Brake Pedal
Travel Measurement and Inspection.
Is the brake pedal travel distance within the acceptable
Go to Step
limits?
8
Go to Step 7
1. Inspect for worn, missing, misaligned, bent or

damaged brake pedal system components.
For the brake pedal pushrod component
inspection, refer to Brake Pedal Pushrod
Inspection.
Inspect the brake pedal bushings for binding,
excessive wear and/or damage and inspect the
brake pedal for a misaligned, bent, and/or
damaged condition.
2. Replace the brake pedal system components that are
worn, missing, misaligned, bent or damaged.
Did you find and replace any worn, missing, misaligned,
bent or damaged brake pedal system components?
conditions:
Go to Step
9
Go to Step 8

Vacuum leaks and/or improperly operating

check valve, if equipped with vacuum assist
Power steering fluid leaks, if equipped with
hydraulic power assist
Damaged or improperly operating brake
booster assembly
Hydraulic Brakes
1. Install or connect components that were removed or

disconnected during diagnosis.
Test.
Go to Step
2
System OK
BRAKE PEDAL EXCESSIVE EFFORT

Brake Pedal Excessive Effort
Step
Action
Yes
No
DEFINITION: Brake pedal requires an increased amount of input from the driver to obtain good braking
action and/or stopping distance is increased.
table?
2
Hydraulic Brakes

conditions:
Vacuum leaks, if equipped with vacuum
power assist
Power steering fluid leaks, if equipped with
hydraulic power assist
Lack of lubrication, binding or excessively
worn pushrod or pedal pivots or pivot
bushings
Bent or damaged pedal pushrod, pedal, or
pedal bracket
Damaged or improperly operating brake
booster assembly
Go to Step
6
Go to Step 3


Binding caliper pistons
Binding wheel cylinder pistons, if equipped
hindering fluid flow
Kinked or damaged flexible brake hoses
and/or pipes
operating master cylinder
Poor brake fluid quality; low boiling point
Go to Step
6
Go to Step 4
Go to Step
6
Go to Step 5

conditions:
Glazed linings
Binding, damaged or excessively worn
Excessively worn or corroded rotor friction
surfaces
operation
Glazed linings


Bell-mouth or barrel-shaped drum friction
surface
Excessive dust or foreign matter in drum
Hydraulic Brakes

Test.
Go to Step
2
System OK
BRAKES DRAG
Brakes Drag
Step
Action
Yes
No
DEFINITION: Brake system does not fully release or has delayed release; vehicle motion may be
hindered by brake system without applying brakes.
table?
2
Hydraulic Brakes
Is the vehicle equipped with an adjustable stop lamp
switch and/or an adjustable cruise control release
2
Go to Step
switch?
Go to Step 4
3
4
5
1. Inspect the stop lamp switch for proper adjustment

to ensure that the brake pedal is fully releasing.
2. Inspect the cruise control release switch, if
equipped, for proper adjustment to ensure that the
brake pedal is fully releasing.
Go to Step
15
Is the vehicle equipped with a drum-in-rotor type of park Go to Step
brake system?
5
Ensure the park brake shoes are not adjusted too tightly,
possibly causing drag under certain conditions.
Go to Step
Go to Step 4
Go to Step 7

Are the park brake shoes adjusted too tightly?
Go to Step 8
Go to Step
15
Go to Step 8
Go to Step
15
Go to Step 8
Go to Step
15
Go to Step 9
1. Clean and inspect the park brake shoes for

excessive wear and/or damage.
2. Inspect the drum portion of the rotors for
excessive wear, blueing discoloration and heat
spots.
3. If any of these conditions are present, replace the
affected components.
4. Adjust the park brake system.

Improper adjustment
Weak or damaged hold down spring or
springs
Inspect the park brake system for proper operation.
Refer to Park Brake System Diagnosis (Drum
Brakes) , Park Brake System Diagnosis (Disc
Brakes) .
conditions:
Binding, incorrectly installed or missing
caliper hardware and/or lining hardwareensure free movement of linings and of
caliper, if equipped with sliding type
caliper.


component
10
13
14
Go to Step
12
Go to Step 11
1. Inspect the pushrod for improper positioning

and/or damage. Correctly position or replace the
pushrod if necessary.
2. Inspect the brake pedal assembly for damage and
replace if necessary.
Did you complete the repair or replacement?
12
Go to Step 10
1. Separate the brake booster pushrod from the brake

pedal.
2. Inspect the brake corners to determine if the brake
drag condition is still present.
Do the brake corners still exhibit the brake drag
condition?
11
Go to Step
15
Go to Step
15
1. For vacuum boost systems, disconnect the

vacuum check valve from the booster to relieve
vacuum reserve.
2. Separate the master cylinder from the brake
booster. Do not disconnect any brake pipes.
3. Inspect the brake corners to determine if the brake
drag condition is still present.
Do the brake corners still exhibit the brake drag
condition?
Replace the brake booster assembly.
hindering brake release
Damaged or improperly operating master
cylinder
Go to Step
14
Go to Step
15
Go to Step 13
-


15
Hydraulic Brakes

Test.
Go to Step
2
System OK
BRAKE SYSTEM SLOW RELEASE

Brake System Slow Release
Step
Action
Yes
No
DEFINITION: Brake system releases and returns to rest slowly; vehicle motion is hindered by brake
system briefly after release of brake pedal.
table?
2
Hydraulic Brakes

hindering brake release
Damaged or improperly operating master
cylinder

conditions:
Binding, bent or damaged pedal pushrod,
pedal, or pedal bracket
Restricted return hose from hydraulic
Go to Step
6
Go to Step 3

Damaged or improperly operating hydraulic

Go to Step
6
Go to Step 5

conditions:
component
Go to Step 4

Go to Step
6
Hydraulic Brakes

Test.
Go to Step
2
System OK
BRAKE FLUID LOSS

Brake Fluid Loss
Step
Action
Yes
No

DEFINITION: Brake fluid level is low not related to lining wear.

Were you sent here from the Hydraulic Brake
Go to Symptoms 1
Symptom table?
Go to Step 2 Hydraulic Brakes
1. Inspect the following hydraulic brake system

components for brake fluid leaks:
Flexible brake hose connections; threaded
and bolted
Flexible brake hose crimp joints
Brake pipe fittings
Caliper piston seals
Wheel cylinder piston seals, if equipped
Master cylinder reservoir
Master cylinder reservoir low pressure
hose, if equipped
Brake pressure modulator valve (BPMV)
assembly, if equipped
2. Repair or replace components as necessary.
Go to Step 8
Is the vehicle equipped with a vacuum brake booster? Go to Step 4
Go to Step 3
Go to Step 6
1. Disconnect the vacuum check valve from the

booster to relieve vacuum reserve.
2. Separate the master cylinder from the vacuum
brake booster. Do not disconnect any brake
pipes.
3. Inspect the rear of the master cylinder for a brake
fluid leak.
4. Inspect for brake fluid in the vacuum brake
booster.
Did you find a brake fluid leak?
Replace the brake master cylinder and the vacuum
brake booster.
1. Wipe clean the external surface of the master
cylinder to hydraulic brake booster area, if
equipped.
2. Separate the master cylinder from the hydraulic
brake booster, if equipped. Do not disconnect
any brake pipes.
3. Inspect the rear of the master cylinder for a brake
Go to Symptoms Go to Step 5 Hydraulic Brakes

Go to Step 8

fluid leak.
Did you find a brake fluid leak?

Replace the brake master cylinder.
Go to Symptoms Go to Step 7 Hydraulic Brakes

Go to Step 8

2. Road test the vehicle to confirm proper
Test.
Go to Step 2
System OK
DISC BRAKE SYSTEM DIAGNOSIS

Test Description
9
Lubricant leaks from non-brake system components may come in contact with and contaminate brake
system components.
10
Lubricant leaks from non-brake system components may come in contact with and contaminate brake
system components.
12
Disc brake rotor shields/backing plates that come in contact with disc brake rotors may cause brake
system noise.
15
Disc brake rotor thickness variation that exceeds the maximum acceptable level can cause brake
pulsation.
19
Disc brake rotor thickness variation that exceeds the maximum acceptable level can cause brake
pulsation.
22

Disc brake rotor assembled lateral runout (LRO) that exceeds the maximum acceptable level can lead to
thickness variation.
Disc Brake System Diagnosis
Step
Action
Yes
No
DEFINITION: This diagnostic table is designed to diagnose ONLY the components of the 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 appropriate.
1
Were you sent here from a Brake Symptom table?
Go to Step 2
Visually inspect the disc brake pads for the following
conditions:
Refer to Brake Pad Inspection .
3
4
5
Lining thickness below specifications

Uneven and/or abnormal wear - edge-to-edge and/or
side-to-side
Looseness or damage - including pad hardware
Evidence of contamination from an external
substance
Did you find any conditions to indicate a concern with any

of the front and/or rear disc brake pads?
Are any of the front and/or rear disc brake pads
contaminated?
Are any of the front and/or rear disc brake pads worn
unevenly?
Are any of the front and/or rear disc brake pads and/or pad
hardware loose or damaged?
Go to Step 3
Go to Step 8
Go to Step 7
Go to Step 7
1. Remove and inspect the worn disc brake pads for

glazing, looseness, heat spots or damage.
2. Replace the worn disc brake pads as a complete axle
set. Refer to Front Disc Brake Pads Replacement ,
and/or Rear Disc Brake Pads Replacement .
Did you complete the inspection and 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. Failure to support the caliper in
this manner will cause the 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.
Go to Step
12
Go to Step
4
Go to Step
5
Go to Step
6
Go to Step 12

NOTE:
Do NOT disconnect the hydraulic brake flex hoses
from the calipers.
1. Remove the front and/or rear disc brake calipers, as

appropriate, from the mounting brackets and support
the calipers. Refer to Front Brake Caliper
Replacement , and/or Rear Brake Caliper
Replacement .
2. Inspect the disc brake caliper mounting bracket and
the mounting/sliding hardware for the following
conditions:
Refer to Front Disc Brake Mounting and
Hardware Inspection , and/or Rear Disc Brake
Mounting and Hardware Inspection .
Binding 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, as required:
Front Brake Caliper Bracket Replacement
Rear Brake Caliper Bracket Replacement
Front Brake Caliper Hardware
Replacement
Rear Brake Caliper Hardware Replacement
4. Replace the unevenly-worn, loose or damaged disc
brake pads as a complete axle set. Refer to Front
Disc Brake Pads Replacement , and/or Rear Disc
Brake Pads Replacement .
1. Inspect the disc brake calipers, brake hoses and brake

pipes for evidence of an external brake fluid leak.
2. Replace any components found to be leaking brake
fluid. Refer to the following procedures as required:
Front Brake Caliper Overhaul , or Front
Brake Caliper Replacement
Rear Brake Caliper Replacement
Front Brake Hose Replacement
Go to Step 12

Rear Brake Hose Replacement (Drum

Brake), Rear Brake Hose Replacement
(Disc Brake)
Brake Pipe Replacement
Did you find and correct the source of the leak causing
contamination of the pads?
Go to Step 11
Go to Step
10
1. Inspect the wheel drive shaft outer seals for damage

and evidence of a grease leak.
2. Replace any wheel drive shaft seal that is found to be
leaking grease which may be the source of the
contamination to the pads. Refer to Front Wheel
Drive Shaft Outer Joint and Boot Replacement .
10
Go to Step 11
Go to Step
9
1. Inspect the automatic transmission cooling system

lines, if equipped, for damage and evidence of an
external fluid leak which may be the source of the
contamination to the pads.
2. Inspect the power steering system hoses for damage
and evidence of an external fluid leak which may be
the source of the contamination to the pads.
3. Replace any components found to be leaking fluid
which may be the source of the contamination to the
pads.
1. Clean the remaining disc brake system components
to remove any traces of the contaminant.
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 to support the caliper in
this manner will cause the 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.
NOTE:
Do NOT disconnect the hydraulic brake flex hoses
from the calipers.
Go to Step 11

2. Remove the front and/or rear disc brake calipers, as

appropriate, from the mounting brackets and support
the calipers. Refer to Front Brake Caliper
Replacement , and/or Rear Brake Caliper
Replacement .
3. Inspect the disc brake caliper mounting/sliding
hardware for the following conditions:
Refer to Front Disc Brake Mounting and
Hardware Inspection , and/or Rear Disc Brake
Mounting and Hardware Inspection .
11
12
13
Binding or seized hardware

Distorted, worn, damaged or missing hardware
components
4. Replace the caliper mounting/sliding hardware
components as required. Refer to Front Brake
Caliper Hardware Replacement , and/or Rear
Brake Caliper Hardware Replacement .
5. Replace the contaminated disc brake pads as a
complete axle set. Refer to Front Disc Brake Pads
Replacement , and/or Rear Disc Brake Pads
Replacement .
Did you complete the cleaning, inspection and

replacement?
Visually inspect each of the rear disc brake rotor
shields/backing plates, if equipped, for evidence of contact
with the brake rotors.
Are any of the brake rotor shields/backing plates contacting
the brake rotors?
Repair or replace the disc brake rotor shields/backing
plates as required. Refer to Rear Wheel Bearing and Hub
Replacement (Drum Brake) , Rear Wheel Bearing and
Hub Replacement (Disc Brake) .
1. Check the thickness of each of the disc brake rotors.
14
NOTE:
Make the following determination AND ANSWER
the question INDIVIDUALLY for EACH rotor.
2. Make a determination for each brake rotor if the

rotor can be REFINISHED and REMAIN ABOVE
the minimum requirements.
Go to Step 12
Go to Step 13
Go to Step
14
Go to Step 14

Refer to Brake Rotor Thickness Measurement .Does the

disc brake rotor meet the minimum requirements for
REFINISHING?
Go to Step 15
Go to Step
18
Go to Step 17
Go to Step
16
Go to Step 17
Go to Step
22
NOTE:
Perform the following inspection AND ANSWER the
question INDIVIDUALLY for EACH rotor.
15
Inspect each of the disc brake rotors for thickness variation

that exceeds the maximum acceptable level. Refer to
Brake Rotor Thickness Variation Measurement .Does
the brake rotor exhibit thickness variation that exceeds the
maximum acceptable level?
1. Inspect each of the disc brake rotors for the
following surface and wear conditions:
Refer to Brake Rotor Surface and Wear
Inspection .

Deep or excessive scoring beyond maximum
acceptable level
16
NOTE:

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 brake rotor require REFINISHING?
17
18
1. Refinish the brake rotor. Refer to Brake Rotor

Refinishing .
2. Inspect the brake rotor thickness. Refer to Brake
Rotor Thickness Measurement .
Were you able to REFINISH the brake rotor within the
minimum requirements?
Is the brake rotor at or below the DISCARD requirements?
Go to Step 22
Go to Step 21
Go to Step
21
Go to Step
19

NOTE:
19
Inspect each of the disc brake rotors for thickness variation

Brake Rotor Thickness Variation Measurement .Does
the brake rotor exhibit thickness variation that exceeds the
maximum acceptable level?
Go to Step 21
Go to Step
20
Go to Step 21
Go to Step
22
1. Inspect each of the disc brake rotors for the

following surface and wear conditions:
Refer to Brake Rotor Surface and Wear
Inspection .

Deep or excessive scoring beyond maximum
acceptable level
20
NOTE:

rotor requires replacement based upon the results of
the inspection.
If the brake rotor exhibits any of the conditions listed
previously, it requires replacement.
Does the brake rotor require REPLACEMENT?
NOTE:
Whenever a brake rotor is replaced, the assembled
lateral runout (LRO) of the rotor must be measured to
ensure optimum performance of the disc brakes.
21
Replace the brake rotor. Refer to Front Brake Rotor

Replacement (J60) , Front Brake Rotor Replacement
(J67) , or Rear Brake Rotor Replacement .Did you
complete the replacement?
NOTE:
Go to Step 24

22
23
24
Inspect each of the disc brake rotors for assembled LRO

Brake Rotor Assembled Lateral Runout
Measurement .Does the brake rotor exhibit assembled
LRO that exceeds the maximum acceptable level?
Go to Step
24
Go to Step 23
Correct the LRO for each brake rotor that was determined
to have LRO exceeding the maximum acceptable level.
Refer to Brake Rotor Assembled Lateral Runout
Correction .
Go to Step 24
Install or connect components that were removed or
Disc Brake System
OK
Return to Symptom
Table
DRUM BRAKE SYSTEM DIAGNOSIS

Test Description
The number below refers to the step number on the diagnostic table:
18
Drum brake backing plates that come in contact with brake drums may cause brake system noise.
Drum Brake System Diagnosis
Step
Action
Yes
No
DEFINITION: This diagnostic table is designed to diagnose ONLY the components of the DRUM brake
system in order to determine if the DRUM brake system is operating properly. You will be directed by
the appropriate Symptom table to go to other brake system diagnostic tables as appropriate.
1
Go to Step 2
-
1. Remove the brake drums. Refer to Brake Drum

Replacement .
2. Inspect the drum brake shoes for the following
conditions:
Lining thickness below specifications
Uneven and/or abnormal wear - edge-to-edge
and/or side-to-side
Contamination from an external substance
Looseness, damage, glazing, or incorrect
lining material
Did you find any conditions to indicate a concern with any
of the drum brake shoes?
Go to Step 3
Go to Step 7

Are any of the brake shoes contaminated?

1. Inspect the wheel cylinders for evidence of an
external brake fluid leak.
2. Replace any wheel cylinder that is found to be
leaking brake fluid. Refer to Rear Brake Cylinder
Replacement .
Go to Step 6
Go to Step 8
1. Clean the remaining drum brake system components

to remove any traces of the contaminant.
2. Inspect the drum brake hardware for any
components which are worn, damaged, discolored
due to stress, broken or missing. Refer to Drum
Brake Hardware Inspection .
3. Replace the drum brake hardware components as
required. Refer to Drum Brake Hardware
Replacement .
4. Replace the contaminated brake shoes. Refer to
Brake Shoe Replacement .
Did you complete the cleaning, inspection and
replacement?
Go to Step 8

2. Replace components as required. Refer to Drum
Brake Hardware Replacement .
Did you complete the inspection and, if necessary, the
replacement?
1. Check the diameter of each of the brake drums.
Go to Step 5

2. Replace components as required. Refer to Drum
Brake Hardware Replacement .
3. Replace the drum brake shoes. Refer to Brake Shoe
Replacement .
Go to Step 4
Go to Step 8

NOTE:
the question INDIVIDUALLY for EACH drum.
2. Make a determination for each brake drum if the

drum can be REFINISHED and REMAIN ABOVE
the minimum requirements.
Refer to Brake Drum Diameter Measurement .Does the
brake drum meet the minimum requirements for
REFINISHING?
1. Inspect each of the brake drums for the following
surface and wear conditions:
Refer to Brake Drum Surface and Wear
Inspection .
Braking Surface Conditions

Braking Surface Wear Conditions
Deep or excessive scoring beyond
maximum acceptable level
Radial runout beyond maximum
acceptable level
NOTE:

drum requires refinishing based upon the results of
the inspection.
If the brake drum exhibits any of the following
conditions, it requires refinishing.
Drum exhibits one or more of the Braking

Surface Conditions listed previously
Drum is beyond the acceptable level in one or
more of the Braking Surface Wear Conditions
listed previously
Go to Step 9
Go to Step 11

Does the brake drum require REFINISHING?
10
11
Go to Step 10
Go to Step 14
Go to Step 14
Go to Step 13
Go to Step 13
Go to Step 12
1. Refinish the brake drum. Refer to Rear Brake

Drum Refinishing .
2. Inspect the brake drum diameter. Refer to Brake
Drum Diameter Measurement .
Were you able to REFINISH the brake drum within the
minimum requirements?
Is the brake drum at or below the DISCARD
requirements?
1. Inspect each of the brake drums for the following
surface and wear conditions:
Refer to Brake Drum Surface and Wear
Inspection .
12
Braking Surface Conditions

Braking Surface Wear Conditions
Deep or excessive scoring beyond
maximum acceptable level
Radial runout beyond maximum
acceptable level
NOTE:

drum requires replacement based upon the results of
the inspection.
If a brake drum exhibits any of the following
conditions, it requires replacement.
Drum exhibits one or more of the Braking

Surface Conditions listed previously
Drum is beyond the acceptable level in one or
more of the Braking Surface Wear Conditions
listed previously

13
14
15
16
17
Does the brake drum require REPLACEMENT?

Replace the brake drum. Refer to Brake Drum
Replacement .
Inspect the brake shoes for proper adjustment. Refer to
Drum Brake Adjustment .
Are the brake shoes adjusted properly?
Inspect the components of the brake drum adjustment
hardware system for free movement and correct operation.
Refer to Drum Brake Adjusting Hardware Inspection .
Do the drum brake adjusting hardware components
operate freely and correctly?
Replace the drum brake adjusting hardware components
as necessary. Refer to Drum Brake Adjusting Hardware
Replacement .
Is the replacement complete?
Adjust the drum brake shoes. Refer to Drum Brake
Adjustment .
Were you able to complete the adjustment?
Inspect the drum brake backing plate for the following:
18
19
20
Go to Step 13
Go to Step 14
-
Go to Step 14
Go to Step 18
Go to Step 15
Go to Step 17
Go to Step 16
-
Go to Step 17
Go to Step 20
Return to
Symptom Table
Go to Step 19
Go to Step 20
Excessive wear or rust

Damage and/or evidence of contact with the brake
drum
Does the drum brake backing plate exhibit any of these

conditions?
Repair or replace the drum brake backing plate as
necessary. Refer to Rear Brake Backing Plate
Replacement .
Go to Step 20
Drum Brake
System OK
Return to
Symptom Table
HYDRAULIC BRAKE SYSTEM DIAGNOSIS

Hydraulic Brake System Diagnosis
Step
Action
Yes
No
DEFINITION: This diagnostic table is designed to diagnose ONLY the components of the HYDRAULIC
brake system in order to determine if the HYDRAULIC brake system is operating properly. You will be
directed by the appropriate Symptom table to go to other brake system diagnostic tables as appropriate.
1
Go to Symptoms -

Inspect and adjust the brake fluid level in the brake master
cylinder. Refer to Master Cylinder Reservoir Filling.
Was the brake fluid level low?
Hydraulic Brakes
Go to Step 3
Go to Step 4
Go to Step 5
Go to Step 6
Go to Step 5
Go to Step 12
1. Inspect the brake fluid for the following conditions,

indicating brake fluid contamination:
Fluid separation, indicating two types of fluid
are present
Swirled appearance - oil-based
substance
Layered appearance - silicone-based
substance
Fluid discoloration
Cloudy appearance - moisture
Dark appearance/ suspended particles
in fluid - dirt, rust, corrosion, brake
dust
2. Inspect the master cylinder reservoir cap diaphragm
and the reservoir-to-master cylinder grommets for
swelling, indicating fluid contamination.
Go to Step 2
1. Inspect the brake fluid for the following conditions,

indicating brake fluid contamination:
Fluid separation, indicating two types of fluid
are present
Swirled appearance - oil-based
substance
Layered appearance - silicone-based
substance
Fluid discoloration
Cloudy appearance - moisture
Dark appearance/ suspended particles
in fluid - dirt, rust, corrosion, brake
dust
2. Inspect the master cylinder reservoir cap diaphragm
and the reservoir-to-master cylinder grommets for
swelling, indicating fluid contamination.
1. Flush the hydraulic brake system. Refer to
Hydraulic Brake System Flushing.

2. If the brake fluid WAS contaminated with an oilbased or a silicone-based fluid, indicated by fluid
separation and/or a swollen master cylinder
reservoir cap diaphragm and/or swollen reservoirto-master cylinder grommets, perform the following
steps. Refer to the procedures indicated.
1. Remove ALL of the following components
listed. Each component contains internal
rubber seals/linings which have been
contaminated.
2. Clean out the hydraulic brake pipes using
denatured alcohol, or equivalent.
3. Dry the brake pipes using non-lubricated,
filtered air.
4. Repair or replace ALL of the following
components listed. Each component contains
internal rubber seals/linings which have been
contaminated.
Replace the brake master cylinder
reservoir cap diaphragm.
Master Cylinder Replacement
Brake master cylinder reservoir: Clean
the brake master cylinder reservoir
using denatured alcohol, or equivalent,
then dry the reservoir using nonlubricated, filtered air, or if necessary,
replace the brake master cylinder
reservoir.
Rear Brake Hose Replacement
(Drum Brake), Rear Brake Hose
Replacement (Disc Brake)
Front Brake Caliper Overhaul , or
Front Brake Caliper Replacement
Rear Brake Caliper Replacement , if
equipped
Rear Brake Cylinder Replacement ,
if equipped
Replacement
3. If the brake fluid was NOT contaminated with an
oil-based fluid, but WAS contaminated with water
or dirt, rust, corrosion, and/or brake dust, replace
the brake master cylinder reservoir cap diaphragm

which may have allowed moisture or dirt to enter

the system.
4. Refill and bleed the hydraulic brake system. Refer
to Hydraulic Brake System Bleeding (Manual
Bleeding), Hydraulic Brake System Bleeding
(Pressure Bleeding).
Did you complete the operation and any required repairs
and/or replacements?
1. Inspect the following hydraulic brake system

components for external fluid leaks. Repair or
replace any of the components found to be leaking
brake fluid. Refer to the appropriate procedures:
Brake master cylinder reservoir cap
diaphragm
(Disc Brake)
Front Brake Caliper Overhaul , or Front
Brake Caliper Replacement
Rear Brake Caliper Replacement , if
equipped
Rear Brake Cylinder Replacement , if
equipped
Replacement
2. If you repaired or replaced any of the brake system
components listed, bleed the hydraulic brake
system. Refer to Hydraulic Brake System
Bleeding (Manual Bleeding), Hydraulic Brake
System Bleeding (Pressure Bleeding). While
bleeding the hydraulic brake system, observe for the
The presence of air in the system at a bleeder
valve location other than at the repair
location, except if the brake master cylinder,
and/or the proportioning valve assembly, was
replaced
An unrestricted and even flow of brake fluid
per axle during the bleeding procedure
Go to Step 9

10
11
12
13

Was there air in the system at a bleeder valve location
other than at the repair location, except if the brake master
cylinder, and/or the proportioning valve assembly, was
replaced?
Was the flow of brake fluid unrestricted and even per axle
during the bleeding procedure?
Inspect the hydraulic function of the brake calipers and/or
wheel cylinders, if equipped for proper operation. Refer to
Hydraulic Brake Component Operation Visual
Inspection.
Was the hydraulic function of the brake calipers/wheel
cylinders operating properly?
Was the flow of brake fluid restricted or uneven through
front axle hydraulic components during the bleeding
procedure?
Was the flow of brake fluid restricted or uneven through
rear axle hydraulic components during the bleeding
procedure?
Inspect the hydraulic function of the brake calipers/wheel
cylinders for proper operation. Refer to Hydraulic Brake
Component Operation Visual Inspection.
Was the hydraulic function of the brake calipers/wheel
cylinders operating properly?
Determine if the brake caliper is restricting the flow of
brake fluid and/or not operating properly:
Go to Step 7
Go to Step 12
Go to Step 19
Go to Step 8
Go to Step 9
Go to Step 10
Go to Step 21
Go to Step 14
Go to Step 13
Go to Step 11
-
Go to Step 17
Go to Step 15
Go to Step 13
Go to Step 17
Go to Step 14
1. Raise and support the vehicle. Refer to Lifting and

Jacking the Vehicle .
2. Remove the tire and wheel assemblies. Refer to
3. Open the suspected caliper bleeder valve.
4. Using a large C-clamp, compress the caliper piston
and observe for an unrestricted flow of brake fluid
and for free movement of the caliper piston.
5. Close the caliper bleeder valve.
Was the flow of brake fluid unrestricted and did the
caliper piston move freely?
Repair or replace any brake caliper/wheel cylinder that
was not operating properly. Refer to the appropriate
procedure.
Front Brake Caliper Overhaul , or Front Brake

14
15
16
17
18
19
Caliper Replacement
Rear Brake Caliper Replacement , if equipped
Rear Brake Cylinder Replacement , if equipped
Did you complete the repair and/or replacement?

Bleed the hydraulic brake system to observe for the
presence of air in the system and to observe for an
unrestricted and even flow of brake fluid per axle during
the bleeding procedure. Refer to Hydraulic Brake
System Bleeding (Manual Bleeding), Hydraulic Brake
System Bleeding (Pressure Bleeding).
Was there air in the system?
Was the flow of brake fluid unrestricted and even per axle
during the bleeding procedure?
Go to Step 21
Go to Step 19
Go to Step 16
Go to Step 21
Go to Step 17
Go to Step 21
Go to Step 18
1. Inspect the hydraulic brake pipes and flexible brake

hoses for signs of a fluid restriction; such as being
bent, kinked, pinched or damaged. Refer to Brake
Pipe and Hose Inspection.
2. Replace any of the hydraulic brake pipes and/or
flexible brake hoses found to be bent, kinked,
pinched, or damaged. Refer to the following
procedures as necessary:
(Disc Brake)
3. If none of the hydraulic brake pipes or flexible
brake hoses were visibly bent, kinked, pinched, or
damaged, replace the hydraulic brake flex hose at
the restricted location.
Replace the brake modulator assembly, in order to correct
the hydraulic brake dynamic rear proportioning
mechanical operation. Refer to Brake Pressure
Modulator Valve Replacement .
1. Inspect the hydraulic brake system components for
brake fluid seepage at a seal and/or fitting location,
which may have drawn air into the system.
2. Inspect the hydraulic brake system components for
evidence of a recent repair, which may have
Go to Step 21

introduced air into the system.

3. Repair or replace any of the components found to
be installed incorrectly or seeping brake fluid.
20
21
Go to Step 21
Go to Step 20
1. Inspect the brake master cylinder for internal fluid

leaks. Refer to Brake System Internal Leak Test.
2. Repair or replace the brake master cylinder if it is
found to be leaking brake fluid internally. Refer to
Master Cylinder Replacement.
Return to Symptom
Go to Step 21 Table
Hydraulic Brake
System OK
Return to
Symptom Table
BRAKE ASSIST SYSTEM DIAGNOSIS

Brake Assist System Diagnosis
Step
Action
Yes
No
DEFINITION: This diagnostic table is designed to diagnose ONLY the components of the brake ASSIST
system in order to determine if the brake ASSIST system is operating properly. You will be directed by
the appropriate Symptom table to go to other brake system diagnostic tables as appropriate.
Were you sent here from a Brake Symptom
1
table?
Go to Step 3
Go to Step 2
Were you sent here directly from an electrical
2
diagnostic to investigate vacuum as a possible
Go To Symptoms Go to Step 5
concern?
Hydraulic Brakes
Inspect for proper brake pedal travel. Refer to
Brake Pedal Travel Measurement and
3
Inspection.
Is the brake pedal travel distance within the
acceptable limits?
Go to Step 5
Go to Step 4
1. Inspect for worn, missing, misaligned, bent

or damaged brake pedal system
components.
For the brake pedal pushrod
component 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. Replace the brake pedal system

components that are worn, missing,
misaligned, bent or damaged.
8
9
10
11
12
Did you find and replace any worn, missing,

misaligned, bent or damaged brake pedal system
components?
Check the engine vacuum source that supplies
vacuum to the vacuum brake booster. Refer to
Brake System Vacuum Source Test.
Is the vacuum reading within the acceptable
limits?
Does the condition occur during cold start-up
conditions?
Check engine vacuum, and vacuum pump
operation, if equipped, under the same cold startup conditions. Refer to Engine Controls
Diagnostics.
During the vacuum source test, did the vacuum
booster check valve operate properly?
Replace the vacuum booster check valve. Refer
to Power Brake Booster Replacement.
If equipped with a booster mounted separate
vacuum sensor, inspect the vacuum sensor
grommet for cracks, cuts, dry-rot, or damage.
Does the vacuum sensor grommet exhibit any of
the conditions listed?
Replace the vacuum sensor grommet.
Go to Step 6
Go to Hydraulic Brake
System Diagnosis to
check for internal and
external fluid leaks and
air in the hydraulic
brake system
Go to Engine Controls
Diagnostics Information
to check for vacuum
issues, including
vacuum pump
operation, if equipped
Go to Step 7
Go to Step 8
Go to Step 22
Go to Step 9
Go to Step 10
Go to Step 9
Go to Step 5
Go to Step 10
Go to Step 11
Go to Step 12
Go to Step 12
-
1. If the vehicle is equipped with a vacuum

sensor, install a scan tool.
2. Using the Data Display function,
determine if brake booster vacuum sensor
data is available within either the chassis
brake controls area or the powertrain
engine controls area.
Is vacuum sensor data available through the scan
tool?
Perform the vacuum booster leak-down test

using a scan tool:
Go to Step 13
Go to Step 16

1. Release the brake pedal.

2. Accelerate the engine to approximately
3000 RPM, then release the throttle. Wait
2-3 seconds and repeat once.
3. Turn the ignition OFF.
4. Turn the ignition ON. Do not start the
engine.
5. Observe and record the vacuum sensor
reading on the scan tool over a period of
60 seconds.
13
NOTE:
Vacuum readings will decrease by
approximately 2.7 kPa (0.8 Hg) for every
305 m (1000 ft) of elevation above sea
level.
6. Determine the rate of vacuum leak.

Specification
Maximum allowable vacuum leak rate: 10
kPa (3 in Hg) in 60 seconds
Was the rate of vacuum leak within the specified
allowable range?
14
Go to Step 18
1. Deplete the vacuum reserve by pressing

the brake pedal several times, or by
removing the vacuum booster check valve.
2. Separate the master cylinder from the
vacuum brake booster. Do not disconnect
any brake pipes. Refer to Master
Cylinder Replacement.
3. If equipped with a vacuum seal on the rear
of the master cylinder, inspect the seal for
damage and correct positioning on the
master cylinder. Replace the vacuum seal
as necessary.
4. Carefully reinstall the master cylinder to
the brake booster. Refer to Master
Perform the vacuum booster leak-down test
Go to Step 14
Go to Step 15

using a scan tool:

4. Turn the ignition ON. Do not start the
engine.
5. Observe and record the vacuum sensor
reading on the scan tool over a period of
60 seconds.
15
NOTE:
Vacuum readings will decrease by
approximately 2.7 kPa (0.8 Hg) for every
305 m (1000 ft) of elevation above sea
level.
6. Determine the rate of vacuum leak.

Specification
Maximum allowable vacuum leak rate: 10
kPa (3 in Hg) in 60 seconds
Was the rate of vacuum leak within the specified
allowable range?
16
Go to Step 22
Go to Step 21
Go to Step 17
Go to Step 18
1. Separate the master cylinder from the

vacuum brake booster. Do not disconnect
any brake pipes. Before removing the
master cylinder, first deplete the vacuum
by removing the check valve or applying
the brake pedal several times. Refer to
Master Cylinder Replacement.
of the master cylinder, inspect the seal for
damage and correct positioning on the
master cylinder.
3. If equipped with a vacuum seal that is part
of the booster, inspect the seal for damage.
Does the vacuum seal exhibit any of the
conditions listed?

17

of the master cylinder, replace the vacuum
seal as necessary. Ensure the seal is
positioned correctly during installation.
2. If equipped with a vacuum seal that
requires replacement and which is part of
the booster, the booster assembly must be
replaced.
3. Carefully reinstall the master cylinder to
the brake booster. Refer to Master
Perform the vacuum boost functional test:
Go to Step 18
1. If still separated, reinstall the master

cylinder to the booster. Refer to Master
2. If the engine was started after reinstalling
the master cylinder to the booster, perform
the following:
With the engine OFF, depress the brake
pedal several times to deplete the vacuum
reserve.
18
3. Depress and maintain moderate foot
pressure on the brake pedal.
4. Start the engine and observe pedal
operation.
5. Observe for audible vacuum leaks.
The brake pedal should fall slightly, then
hold.
19
Is there an audible vacuum leak coming from the

brake pedal area?
Did the brake pedal fall slightly after the engine
was started, then hold?
Perform the vacuum booster leak-down test:
Go to Step 21
Go to Step 19
Go to Step 20
Go to Step 21

20
21
22

4. Wait 60 seconds.
5. Depress the brake pedal 2 times to check
for vacuum booster available vacuum
reserve. Observe pedal effort.
Both pedal applies should be
assisted
The amount of assist could diminish
slightly with the second apply
Were both pedal applies power assisted?
Go to Step 22
Replace the power brake booster. Refer to Power
Brake Booster Replacement.
Go to Step 22
Install or connect any components that were
Brake Assist
System OK
Return to Symptom
Table
Go to Step 21
-
BRAKE SYSTEM VEHICLE ROAD TEST

Preliminary Inspections
1. Visually inspect easily accessible brake system components for obvious damage and/or leaks which may
indicate that the vehicle should not be driven until further inspections have been completed.
2. Inspect the brake master cylinder reservoir fluid level and adjust only if necessary for brake system road
testing. Refer to Master Cylinder Reservoir Filling.
3. Inspect the tire inflation pressures and adjust as necessary.
4. Inspect the tire tread patterns to ensure that they are the same or very similar, especially per axle.
5. Ensure that the vehicle is not loaded unevenly prior to brake system road testing.
Road Testing Procedure
1. Start the engine and allow it to idle.
2. Check to see if the brake system warning lamp remains illuminated.
3. If the brake system warning lamp remains illuminated, DO NOT proceed to test drive the vehicle until it
is diagnosed and repaired. Refer to Symptoms - Hydraulic Brakes.

4. Select a smooth, dry, clean and level road or large lot that is as free of traffic and obstacles as possible for
brake system low speed road testing.
5. With the transmission in PARK, lightly apply the brake pedal. Observe both the pedal feel and the pedal
travel.
6. If the brake pedal apply felt spongy, or the pedal travel was excessive, DO NOT drive the vehicle until it
is repaired.
7. If the brake pedal apply did not feel spongy and the pedal travel was not excessive, proceed to step 8.
8. Release and apply the brakes.
9. While continuing to apply the brakes, shift the transmission into DRIVE, release the brakes and allow the
engine to idle the vehicle away from the stopped 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 apply the brakes while driving past the assistant. Have the assistant
observe for brake system noise from the side of the vehicle closest to them, while you observe both the
pedal effort and the pedal travel.
11. If the brake pedal apply effort was excessive, or the pedal travel was excessive, DO NOT continue to test
drive the vehicle until it is repaired.
12. If the brake pedal apply effort was not excessive and the pedal travel was not excessive, proceed to step
13.
13. Drive the vehicle in the opposite direction, at the same low speed and lightly apply the brakes while
driving past the assistant. Have the assistant observe for brake system noise from the side of the vehicle
closest to him.
14. Drive the vehicle at a low speed and shift the transmission into NEUTRAL without applying the brakes.
Observe for a rapid deceleration in vehicle speed, indicating possible brake drag.
15. Select a smooth, dry, clean and level road that is as free of heavy traffic as possible for brake system
moderate speed road testing.
16. Drive the vehicle at a moderate speed. Observe for a pull and/or incorrect tracking of the vehicle without
the brakes applied.
17. While continuing to drive the vehicle at a moderate speed, perform several light applies of the brakes.
Observe the pedal effort and the pedal travel, observe for brake system noise, pulsation and/or brake drag.
19. If the brake pedal apply effort was not excessive and the pedal travel was not excessive, proceed to step
20.
20. While continuing to drive the vehicle at a moderate speed, perform several moderate applies of the
brakes. Observe the pedal effort and the pedal travel, observe for brake system pulsation and/or uneven
braking action - either side to side, or front to rear.
A small amount of vehicle front end dip is expected during a moderate apply of the brakes.
BRAKE PEDAL TRAVEL MEASUREMENT AND INSPECTION

Special Tools
CH-28662 Brake Pedal Effort Gauge
1. With the ignition OFF and the brakes cool, apply the brakes 3-5 times, or until the brake pedal becomes
firm, in order to deplete the brake booster power reserve.
2. Install the CH-28662 gauge to the brake pedal.
Fig. 2: Measuring Brake Pedal Travel

3. Measure and record the distance (1) from the brake pedal to the rim of the steering wheel; note the points
of measurement.
4. Apply and maintain the brakes with 445 N (100 lb F) of force to the brake pedal, as indicated on the CH28662 gauge.
5. While maintaining 445 N (100 lb F) of force to the brake pedal, measure and record the distance (2) from

6.
7.
8.
9.
the same point on the brake pedal to the same point on the rim of the steering wheel.
Release the brakes and repeat steps 3 and 4 to obtain a second measurement. After obtaining a second
measurement, proceed to step 7.
Average the first and second measurements recorded during the two applies of the brakes.
Subtract the initial measurement, unapplied (1), from the averaged, applied measurement (2) to obtain the
brake pedal travel distance.
For the maximum brake pedal travel (measured with the ignition OFF, brake booster power assist
depleted, and the brakes cool), refer to Brake System Specifications.
BRAKE SYSTEM VACUUM SOURCE TEST

NOTE:
1.
2.
3.
4.
Engine temperature, accessory load, and elevation level will affect

engine vacuum.
Vacuum readings will decrease by approximately 2.7 kPa (0.8 in Hg)
for every 305 m (1000 ft) of elevation above sea level.
Disconnect the engine vacuum hose from the vacuum brake booster check valve.
Install a vacuum gauge to the engine vacuum hose.
Start the engine and allow the engine to idle until normal operating temperatures are reached.
With the vehicle in PARK, the engine idling, and the air conditioning (A/C) system OFF, check to see if
the engine vacuum reading is within the specified normal engine vacuum range.
Specification
47-68 kPa (14-20 in Hg)

6. If the engine vacuum reading was within the specified normal range, proceed to step 10.
7. If the engine vacuum reading was NOT within the specified normal range, inspect the engine vacuum
hose for the following conditions:
Loose connection to the engine
Collapse, deformation or contamination
Cracks, cuts, dry-rot
8. If any of these conditions were found with the engine vacuum hose, replace the hose, then repeat steps 24.
9. If none of these conditions were found with the engine vacuum hose, then there is an engine vacuum
source problem, check the engine vacuum system.
10. Remove the vacuum brake booster check valve from the booster.
11. Install the check valve to the engine vacuum hose.
12. Install the vacuum gauge to the check valve.
13. Start the engine and allow the engine to idle in PARK with the A/C system OFF, until normal operating
temperatures are reached.


15. Check to see if the engine vacuum reading is maintained within the specified normal engine vacuum
range.
Specification
47-68 kPa (14-20 in Hg)
16. If the engine vacuum reading is maintained within the specified normal range, proceed to step 18.
17. If the engine vacuum reading is NOT maintained within the specified normal range, replace the brake
booster check valve, then repeat steps 11-15.
18. Inspect the brake booster check valve grommet for the following conditions:
Loose connection to the vacuum brake booster
Deformation or contamination
Cracks, cuts, dry-rot
19. If any of these conditions were found with the check valve grommet, replace the grommet.
BRAKE SYSTEM EXTERNAL LEAK INSPECTION
1. In order to inspect for external brake fluid leaks, first check the fluid level in the master cylinder.
While a slight brake fluid level drop can be considered a normal condition due to brake lining wear, a
very low level may indicate a brake fluid leak in the hydraulic system.
If the fluid level is abnormally low, adjust the brake fluid level. Refer to Master Cylinder Reservoir
Filling.
2. Start the engine and allow it to idle.
3. Apply constant, moderate foot pressure to the brake pedal.
If the brake pedal gradually falls away while under foot pressure, there may be a brake fluid leak.
5. Visually inspect the following brake system components for brake fluid leaks, excessive corrosion, and
damage. Give particular attention to all brake pipe and flexible hose connections to ensure that there are
not any slight brake fluid leaks - even though the brake pedal may feel firm and hold steady:
Master cylinder brake pipe fittings

All brake pipe connections

Brake pipes
Brake hoses and connections
Brake calipers and/or wheel cylinders, if equipped
6. While slight dampness around the master cylinder reservoir can be considered acceptable, brake fluid
leaking from any of the brake system components requires immediate attention. If any of these
components exhibit signs of brake fluid leakage, repair or replace those components. After the repair or
replacement, reinspect the hydraulic brake system to assure proper function.
BRAKE SYSTEM INTERNAL LEAK TEST

1.
2.
3.
4.
Start the engine and allow it to idle.

Apply light, steady pressure to the brake pedal. Observe both the brake pedal feel and travel.
Release the brakes and turn OFF the ignition.
If the brake pedal apply felt spongy, but the brake pedal travel was not excessive, perform the following
steps:
1. Inspect the brake system for external leaks. Refer to Brake System External Leak Inspection.
2. Pressure bleed the brake system in order to purge any air that may be trapped in the system. Refer
to Hydraulic Brake System Bleeding (Manual Bleeding), Hydraulic Brake System Bleeding

Fig. 3: Identifying Brake Master Cylinder (Cross Sectional View)

5. If the brake pedal apply did not feel spongy, but the brake pedal travel was excessive, perform the
following steps:
1. Loosen the master cylinder-to-brake power booster mounting nuts.
2. Carefully pull the master cylinder away from the brake power booster just enough to inspect the
mounting surface of the master cylinder.
3. Inspect the master cylinder mounting surface at the primary piston (2) for brake fluid leaks.
6. If the master cylinder exhibits any leakage around the primary piston (2), then the primary piston primary
seal (4) and/or secondary seal (3) is leaking and the master cylinder requires overhaul or replacement.
7. If the master cylinder primary piston (2) does not exhibit any leakage, pressure bleed the brake system.
Refer to Hydraulic Brake System Bleeding (Manual Bleeding), Hydraulic Brake System Bleeding
8. If the brake pedal apply did not feel spongy, and the brake pedal travel was initially steady and not
excessive, but then gradually fell, then the master cylinder requires overhaul or replacement due to an
internal leak past the secondary 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 slightly, then became steady again, then the brake pressure modulator valve (BPMV)
may be leaking internally, and may require replacement.
HYDRAULIC BRAKE COMPONENT OPERATION VISUAL INSPECTION

Fig. 4: Identifying Brake Caliper/Pad Inspection Areas



Caution .
1. With the tire and wheel assemblies removed and the brake rotors retained by wheel lug nuts, visually
inspect the caliper piston dust boot (2) sealing area to ensure that there are no brake fluid leaks.
2. If any evidence of a brake fluid leak is present, the brake caliper requires overhaul or replacement.
3. While the brake system is at rest (4), observe the position of the caliper piston (1) in relation to the caliper
housing.
4. Have an assistant apply and release the brake pedal several times while you observe the operation of the
hydraulic brake caliper.
1. Observe the caliper piston (1) for unrestricted and even movement during each apply of the brake
system (5).
2. Observe the caliper piston (1) for an unrestricted and even return motion during each release of the
brake system (6).
5. If the caliper piston (1) did not exhibit unrestricted and even movement during brake system apply and/or
release, the piston square seal (3) may be worn or damaged and the caliper may require overhaul or
replacement.
BRAKE PIPE AND HOSE INSPECTION
1. Visually inspect all of the brake pipes for the following conditions:
Kinks, improper routing, missing or damaged retainers
Leaking fittings, excessive corrosion
2. If any of the brake pipes exhibited any of the conditions listed, then the identified pipe, or pipes, require
replacement.
3. Ensure that the vehicle axles are properly supported at ride height in order to maintain the proper
relationship of the flexible brake hoses to the chassis.

Fig. 5: Identifying Flexible Brake Hose Failure Conditions

4. Visually inspect all of the flexible brake hoses for the following conditions:
Kinks (1), improper routing, twists, chafing, missing or damaged retainers
Leaking connections, cracking, dry-rot, blisters, bulges
5. If any of the flexible brake hoses exhibited any of the conditions listed, then the identified flexible brake
hose, or hoses require replacement.
6. Squeeze the flexible brake hoses with firm finger pressure to check for soft spots (2), indicating an
internal restriction. Check the entire length of each flexible brake hose.
7. If any of the flexible brake hoses were found to have soft spots (2), then the identified flexible brake hose,
or hoses require replacement.
BRAKE PEDAL PUSHROD INSPECTION

Fig. 6: View of Brake Pedal Pushrod

1. Disconnect the brake pedal pushrod (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 as much of the pedal
pushrod (1) as possible.
4. Inspect the brake pedal pushrod (1) for straightness.
5. If the brake pedal pushrod eyelet bushing (2) exhibited cracks and/or excessive wear, then the bushing
requires replacement.
6. If the brake pedal pushrod (1) is not straight, then the pushrod requires replacement.
7. Return the pedal pushrod boot (3) to its original position on the pedal pushrod (1).
8. Connect the brake pedal pushrod (1) to the brake pedal.
REPAIR INSTRUCTIONS
MASTER CYLINDER RESERVOIR FILLING

CAUTION: When adding fluid to the brake master cylinder reservoir, use only GM
approved or equivalent DOT-3 brake fluid from a clean, sealed brake fluid
container. The use of any type of fluid other than the recommended type of
brake fluid may cause contamination which could result in damage to the
internal rubber seals and/or rubber linings of hydraulic brake system
components.
1. Visually inspect the brake fluid level through the brake master cylinder auxiliary reservoir.
2. If the brake fluid level is at or below the half-full point during routine fluid checks, the brake system
should be inspected for wear and possible brake fluid leaks.
3. If the brake fluid level is at or below the half-full point during routine fluid checks, and an inspection of
the brake system did not reveal wear or brake fluid leaks, the brake fluid may be topped-off up to the
maximum-fill level.
4. If brake system service was just completed, the brake fluid may be topped-off up to the maximum-fill
level.
5. If the brake fluid level is above the half-full point, adding brake fluid is not recommended under normal
conditions.
6. If brake fluid is 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.
MASTER CYLINDER RESERVOIR REPLACEMENT

Fig. 7: Master Cylinder Reservoir

Master Cylinder Reservoir Replacement
Callout
Component Name
WARNING:
CAUTION:
Preliminary Procedure Remove and discard the brake fluid from the master cylinder reservoir.
Brake Fluid Level Indicator Switch
1
Procedure
2. Rotate level indicator clockwise and remove upwards.
Master Cylinder Reservoir Bolt
CAUTION:

Tighten
2.5 N.m (22 lb in)
Master Cylinder Reservoir
Procedure
3
1. Inspect the master cylinder for damage and replace, if necessary.

2. Clean the reservoir with denatured alcohol.
3. Dry the reservoir with filtered, non-lubricated compressed air.
Master Cylinder Reservoir Seal (Qty: 2)
CAUTION:
Only use products that comply with GM specifications and check
genuine products. Instructions must be followed at all times. The use
of any type of fluid other than the recommended type of brake fluid,
may cause contamination which could result in damage to the internal
rubber seals and/or rubber linings of hydraulic brake system
components.
Procedure
1. Lubricate the seals and the reservoir caps with brake fluid. Refer to
Brake Fluid and Brake Fluid Handling for the recommended
brake fluid.
2. Lubricate the seals and the reservoir bayonets with brake fluid. Refer
to Adhesives, Fluids, Lubricants, and Sealers.
MASTER CYLINDER REPLACEMENT
Removal Procedure

NOTE:

2. Remove the radiator surge tank (1) and put beside.
3. Disconnect the brake fluid level indicator switch electrical connector and separate from brake fluid
reservoir.

Fig. 9: Master Cylinder Secondary Brake Pipe Fitting

4. Disconnect the master cylinder secondary brake pipe fitting (1).
Cap the brake pipe fitting and plug the master cylinder outlet port to prevent brake fluid loss and
contamination.

Fig. 10: Master Cylinder Primary Brake Pipe Fitting

5. Disconnect the master cylinder primary brake pipe fitting (1).
Cap the brake pipe fitting and plug the master cylinder outlet port to prevent brake fluid loss and
contamination.

Fig. 11: Master Cylinder Nuts

6.
7.
8.
9.
Remove and DISCARD master cylinder nuts (1).

Remove master cylinder with brake fluid reservoir.
Inspect the master cylinder to vacuum brake booster seal for damage and replace, if necessary.
Remove the master cylinder reservoir, if necessary. Refer to Master Cylinder Reservoir Replacement.
1. Install the brake fluid reservoir to master cylinder. Refer to Master Cylinder Reservoir Replacement.
2. Ensure the master cylinder to vacuum brake booster seal is properly seated on the master cylinder barrel.
3. Perform the master cylinder bench bleeding. Refer to Master Cylinder Bench Bleeding.

Fig. 12: Master Cylinder Nuts

4. Install the master cylinder.
5. Install NEW master cylinder nuts (1) and tighten to 50 N.m (37 lb ft).
6. Install the brake fluid level indicator switch harness to the brake fluid reservoir and connect the electrical
connector.


7. Connect the master cylinder primary brake pipe fitting (1) and tighten to 18 N.m (13 lb ft).


8. Connect the master cylinder secondary brake pipe fitting (1) and tighten to 18 N.m (13 lb ft).

9. Reposition and install the radiator surge tank (1).
10. Install the radiator surge tank clip (2).
11. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding (Manual Bleeding),
Hydraulic Brake System Bleeding (Pressure Bleeding).
MASTER CYLINDER BENCH BLEEDING

Fig. 16: Master Cylinder Reservoir


Caution .
1. Secure the mounting flange of the brake master cylinder in a bench vise so that the rear of the primary
piston is accessible.
2. Remove the master cylinder reservoir cap and diaphragm.
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 transparent hoses to the fittings installed to the master cylinder ports, then route the hoses into the

master cylinder reservoir (1).

5. Fill the master cylinder reservoir to at least the half-way point with brake fluid. Refer to Adhesives,
Fluids, Lubricants, and Sealers for the recommended brake fluid.
6. Ensure that the ends of the transparent hoses running into the master cylinder reservoir are fully
submerged in the brake fluid.
7. Using a smooth, round-ended tool, depress and release the primary piston as far as it will travel, a depth
of about 25 mm (1 in), several times. Observe the flow of fluid coming from the ports.
As air is bled from the primary and secondary pistons, the effort required to depress the primary piston
will increase and the amount of travel will decrease.
8. Continue to depress and release the primary piston until fluid flows freely from the ports with no
evidence of air bubbles.
9. Remove the transparent hoses from the master cylinder reservoir (1).
10. Install the master cylinder reservoir cap and diaphragm.
11. Remove the fittings with the transparent hoses from the master cylinder ports. Wrap the master cylinder
with a clean shop cloth to prevent brake fluid spills.
12. Remove the master cylinder from the vise.
BRAKE FLUID LEVEL INDICATOR SWITCH REPLACEMENT
Fig. 17: Brake Fluid Level Indicator Switch



Callout
Component Name
WARNING:
CAUTION:
Preliminary Procedure Remove and discard the brake fluid from the master cylinder reservoir.
Brake Fluid Level Indicator Switch
1
Procedure
2. Rotate indicator switch clockwise to remove.
BRAKE, ACCELERATOR, AND CLUTCH PEDAL REPLACEMENT

Special Tools
DT-6202-A Pliers
DT-6202-B Pliers
DT-6202-20 Adapter to DT-6202-A
DT-50894 Remover

Removal Procedure
1. Remove the battery. Refer to Battery Replacement .

2. Remove the battery tray. Refer to Battery Tray Replacement .

NOTE:
Do NOT disconnect the engine coolant hoses.

5. Position the radiator surge tank (1) aside.

Fig. 19: BPMV Bracket Bolts

6. Remove the BPMV bracket bolts (1).

Fig. 20: Brake Booster Bolts

7. Remove the brake booster bolts (1).

Fig. 21: Identifying Brake Pedal Bracket Nuts

NOTE:
Do NOT open the hydraulic brake system.

Second mechanic is required.
8. Pull the brake booster and the BPMV assembly forward in order to get an access to the brake pedal
bracket nuts (1).
9. Remove the brake pedal bracket nuts (1).
10. Remove the instrument panel lower trim pad cover. Refer to Instrument Panel Lower Trim Pad Cover
Knee Airbag) .
11. Remove the steering column upper trim cover. Refer to Steering Column Upper Trim Cover
Replacement .
Replacement .

13. Remove the intermediate steering shaft. Refer to Intermediate Steering Shaft Replacement .
14. Remove the steering column. Refer to Steering Column Replacement .
Fig. 22: Brake Pedal Pushrod


Fig. 23: Click Fit Connector

16. Replace the click fit connector (1) between the booster pushrod and the brake pedal with new part.
17. Remove the brake pedal position sensor. Refer to Brake Pedal Position Sensor Replacement .
18. Remove the accelerator pedal position sensor.
For 1.4L LUJ, refer to Accelerator Pedal Position Sensor Replacement .
For 1.8L LUW, refer to Accelerator Pedal Position Sensor Replacement .

Fig. 24: Clutch Pedal And Push Rod Removal Tools

19. If equipped, disconnect the clutch master cylinder push rod from the clutch pedal (3), using either the
DT-6202-A pliers (1) and the DT-6202-20 adapters in conjunction with the DT-50894 remover (2), or the
DT-6202-B pliers (1) in conjunction with the DT-50894 remover (2).

Fig. 25: Clutch Master Cylinder Nuts At Clutch Pedal Bracket

20. Remove the clutch master cylinder nuts (1) from the pedal bracket, if equipped.

Fig. 26: Clutch Pedal And Brake Pedal Bracket Bolts

21.
22.
23.
24.
25.
Remove the brake pedal bracket bolt (1) from the tie bar.
Separate the wiring harness from the pedal bracket.
Disconnect the electrical connectors.
Remove the brake and accelerator and clutch pedal assembly from the vehicle.
Transfer component parts as needed.

Fig. 27: Clutch Pedal And Brake Pedal Bracket Bolts

1. Install the brake and accelerator and clutch pedal assembly to the vehicle.
2. Install the wiring harness to the brake pedal bracket.
3. Connect the electrical connectors.
4. Install the brake pedal bracket bolts and tighten to 20 N.m (15 lb ft).
5. Connect clutch master cylinder pushrod (1) to the clutch pedal, if equipped.

Fig. 28: Clutch Master Cylinder Nuts At Clutch Pedal Bracket

6. Install the clutch master cylinder nuts (2) to the pedal bracket, if equipped and tighten to 18 N.m (13 lb
ft).
7. Install the accelerator pedal position sensor.
For 1.4L LUJ, refer to Accelerator Pedal Position Sensor Replacement .
For 1.8L LUW, refer to Accelerator Pedal Position Sensor Replacement .
8. Install the brake pedal position sensor. Refer to Brake Pedal Position Sensor Replacement .


9.
10.
11.
12.
Connect the brake pedal pushrod (1) to the brake pedal.

Install the steering column. Refer to Steering Column Replacement .
Install the intermediate steering shaft. Refer to Intermediate Steering Shaft Replacement .
Install the steering column lower trim cover. Refer to Steering Column Lower Trim Cover
Replacement .
13. Install the steering column upper trim cover. Refer to Steering Column Upper Trim Cover
Replacement .
14. Install the instrument panel lower trim pad cover. Refer to Instrument Panel Lower Trim Pad Cover
Knee Airbag) .

Fig. 30: Identifying Brake Pedal Bracket Nuts

NOTE:
Do NOT open the hydraulic brake system.

Second mechanic is required.
15. Pull the brake booster and the BPMV assembly forward in order to get an access to the brake pedal
bracket nuts (1).
16. Install the pedal bracket nuts (1) and tighten to 20 N.m (15 lb ft).


17. Install the brake booster bolts (1) and tighten to 19 N.m (14 lb ft).

Fig. 32: BPMV Bracket Bolts

18. Install the BPMV bracket bolts (1) and tighten to 20 N.m (15 lb ft).



NOTE:
21.
22.
23.
24.
25.
Do NOT disconnect the engine coolant hoses.

Install the battery tray. Refer to Battery Tray Replacement .
Install the battery. Refer to Battery Replacement .
Calibrate the brake pedal position sensor. Refer to Brake Pedal Position Sensor Calibration .
BRAKE PIPE REPLACEMENT

Special Tools
CH-45405 Pipe Flaring Tool Kit


WARNING: Always use double walled steel brake pipe when replacing brake pipes.
The use of any other pipe is not recommended and may cause brake
system failure. Carefully route and retain replacement brake pipes.
Always use the correct fasteners and the original location for replacement
brake pipes. Failure to properly route and retain brake pipes may cause
damage to the brake pipes and cause brake system failure.
NOTE:
When servicing the brake pipes, note the following:
If sectioning the brake pipe, use replacement pipe of the same type and
outside diameter.
Use fittings of the appropriate size and type.
Only create flares of the same type or design as originally equipped on the
vehicle.

Fig. 35: Sectioning Brake Pipe Using Pipe Cutter

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 location to section the brake pipe, if necessary.
Allow adequate clearance in order to maneuver the CH-45405 flaring tool.
Avoid sectioning the brake pipe at bends or mounting points.
4. Using a string or wire, measure the length of the pipe to be replaced including all pipe bends.
5. Add to the measurement taken the appropriate additional length required for each flare to be created.
Specification
6.35 mm (0.250 in) for 4.76 mm (3/16 in) diameter pipe


NOTE:
Ensure that the brake pipe end to be flared is cut at a square, 90

degreeangle to the pipe length.
6. Using the pipe cutter included in the CH-45405 flaring tool, carefully cut the brake pipe squarely to the
measured length.
7. Remove the sectioned brake pipe from the vehicle.
8. Select the appropriate size of brake pipe and tube nuts, as necessary. The brake pipe outside diameter
determines brake pipe size.
Fig. 36: Stripping Nylon Coating From Brake Pipe Ends

9. Strip the nylon coating from the brake pipe end to be flared, if necessary.
Select the appropriate blade on the coating stripping tool included in the CH-45405 flaring tool, by
unthreading the blade block from the stripping tool and installing the block with the desired blade
facing the tool rollers.
Specification

6.35 mm (0.250 in) blade for 4.76 mm (3/16 in) diameter pipe
9.50 mm (0.374 in) blade for 6.35 mm (1/4 in) and 7.94 mm (5/16 in) diameter pipe
Insert the brake pipe end to be flared into the stripping tool to the depth of the ledge on the tool
rollers.
While holding the brake pipe firmly against the stripping tool roller ledges, rotate the thumbwheel
of the tool until the blade contacts the brake pipe coated surface.
NOTE:
Rotate the 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 of the tool
clockwise, in order to continue stripping the coating from the brake pipe until the metal pipe
surface is exposed.
Loosen the thumbwheel of the tool and remove the brake pipe.
NOTE:
Do not gouge the metal surface of the brake pipe.
Ensure that all loose remnants of the nylon coating have been
removed from the brake pipe.
Inspect the stripped end of the brake pipe to ensure that the proper amount of coating has been
removed.
Specification

9.50 mm (0.374 in) for 6.35 mm (1/4 in) and 7.94 mm (5/16 in) diameter pipe

Fig. 37: Chamfering Pipe Using De-Burring Tool

10. Chamfer the inside and outside diameter of the pipe with the de-burring tool included in the CH-45405
flaring tool.
11. Install the tube nuts on the brake pipe, noting their orientation.
12. Clean the brake pipe and the CH-45405 flaring tool of lubricant, contaminants, and debris.

Fig. 38: Die Halves And Die Cage

13. Loosen the die clamping screw of the CH-45405 flaring tool.
14. Select the corresponding die set and install the die halves into the die cage with the full, flat face of one
die facing the clamping screw, and the counterbores of both dies facing the forming ram.

Fig. 39: View Of Clamping Screw & Unused Die

15. Place the flat face of an unused die (1) against the die halves in the clamping cage and hold firmly against
the counterbored face of the dies.
16. Insert the prepared end of the pipe to be flared through the back of the dies until the pipe is seated against
the flat surface of the unused die (1).
17. Remove the unused die (1).
18. Ensure that the rear of both dies are seated firmly against the enclosed end of the die cage.
19. Firmly hand tighten the clamping screw (2) against the dies.

Fig. 40: View Of J 45405 And Die Cage

20. Select the appropriate forming mandrel and place into the forming ram.
21. Rotate the hydraulic fluid control valve clockwise to the closed position.
22. Rotate the body of the CH-45405 flaring tool until it bottoms against the die cage.

Fig. 41: View Of J 45405

23. While guiding the forming mandrel into the exposed end of pipe to be flared, operate the lever of the CH45405 flaring tool until the forming mandrel bottoms against the clamping dies.
24. Rotate the hydraulic fluid control valve counterclockwise to the open position to allow the hydraulic
forming ram to retract.

Fig. 42: Using Pipe Flaring Tool

25.
26.
27.
28.
Insert the finishing cone into the forming ram.

Rotate the hydraulic fluid control valve clockwise to the closed position.
Rotate the body of the CH-45405 flaring tool until it bottoms against the die cage.
While guiding the finishing cone into the exposed end of pipe to be flared, operate the lever of the CH45405 flaring tool until the finishing cone bottoms against the dies.
29. Rotate the hydraulic fluid control valve counterclockwise to the open position to allow the hydraulic
forming ram to retract.
30. Loosen the die clamping screw and remove the dies and pipe.
31. If necessary, lightly tap the dies until the die halves separate.

Fig. 43: Identifying Correct Brake Pipe Flare Shape & Diameter
32. Inspect the brake pipe flare for correct shape and diameter (a).
Specification
6.74-7.10 mm (0.265-0.279 in) flare diameter for 4.76 mm (3/16 in) diameter pipe
33. If necessary, using the removed section of brake pipe as a template, shape the new pipe with a suitable
brake pipe bending tool.
NOTE:
When installing the pipe, maintain a clearance of 19 mm (3/4 in) from all
moving or vibrating components.
34. Install the pipe to the vehicle with the appropriate brake pipe unions, as required.
35. If previously released, secure the brake pipe to the retainers.

37. With the aid of an assistant, inspect the brake pipe flares for leaks by starting the engine and applying the
brakes.
FRONT BRAKE HOSE REPLACEMENT
Removal Procedure

Fig. 44: Brake Pipe Fitting, Brake Hose And Brake Hose Retainer
3. Clean all dirt and foreign material from the brake hose ends and the brake pipe fitting.
4. Use a flare nut wrench on the brake pipe fitting (1) and a backup wrench on the brake hose (3) under the
brake hose retainer (2) as shown.

Fig. 45: Brake Pipe Fitting Disconnected From Brake Hose

5. Disconnect the brake pipe fitting (1) from the brake hose (3). Cap or plug the brake pipe fitting end and
the brake hose end to prevent fluid loss and contamination.
6. Remove the brake hose retainer.
7. Remove the brake hose from the strut.
8. Remove the brake hose-to-caliper bolt from the brake caliper.
10. Remove and discard the 2 copper brake hose gaskets. These gaskets may be stuck to the brake caliper
1. Remove the caps or plugs from the opening in the brake caliper and the brake hose.

NOTE:
Install NEW copper brake hose gaskets.
2. Assemble the NEW copper brake hose gaskets and the brake hose bolt to the brake hose.
3. Install the brake hose-to-brake caliper bolt to the brake caliper and tighten the bolt to 40 N.m (30 lb ft).
Fig. 46: Brake Hoses And Struts

NOTE:
If replacing the brake hose, compare the old and new brake hose. There is
a new version of brake hoses, which has a labeling to differentiate left and
right side. The new version has a brake grommet with a flattened side,
which has to face to the open side of the brake hose bracket.

4. Install the brake hose to the strut.

Align the blue marking at the front brake hose grommet with the center of the bracket notch for the right
front brake hose.
Align the white marking at the front brake hose grommet with the center of the bracket notch for the left
front brake hose.

5.
6.
7.
8.
9.
Remove the caps or plugs from the brake pipe fitting end and the brake hose end.
Install the brake hose to the brake hose body bracket.
Install the brake hose retainer (2) over the anti-rotation tabs of the brake hose (3).
Connect the brake pipe fitting (1) to the brake hose.
Use a backup wrench on the brake hose.

10. Tighten the brake pipe fitting to 18 N.m (14 lb ft).

11. Ensure that the hose does not make contact with any part of the suspension. Check the hose in extreme
right and extreme left turn conditions. If the hose makes contact, remove the hose and correct the
condition.
REAR BRAKE HOSE REPLACEMENT (DISC BRAKE)
Removal Procedure
3. Remove rear wheel speed sensor from brake hose. Refer to Rear Wheel Speed Sensor Replacement
(Disc Brake) , Rear Wheel Speed Sensor Replacement (Drum Brake) .

brake hose retainer (2).


7. Remove the brake hose retainer (2).

Fig. 50: Brake Hose Bracket

8. Remove the brake hose bolt (2) attaching the hose to the rear brake caliper bracket.
9. Remove wiring harness (1) from brake hose bracket.

Fig. 51: Brake Hose-To-Caliper Bolt

10. Remove the brake hose-to-caliper bolt (1) from the brake caliper (4).
12. Remove and discard the 2 copper brake hose gaskets (2). These gaskets may be stuck to the brake caliper

Fig. 52: Brake Hose-To-Caliper Bolt

1. Remove the caps or plugs from the opening in the brake caliper and the brake hose.
NOTE:
Install NEW copper brake hose gaskets.
2. Assemble the NEW copper brake hose gaskets (2), and the brake hose bolt (1), to the brake hose (3).
3. Install the brake hose-to-brake caliper bolt to the brake caliper (4) and tighten the bolt to 40 N.m (30 lb
ft).

Fig. 53: Brake Hose Bracket

4. Install the brake hose bolt (2) attaching the hose to the rear brake caliper bracket and tighten the bolt to 9
N.m (80 lb in).
5. Install wiring harness (1) at the brake hose bracket.


6.
7.
8.
9.
10.
11.
12.
Connect the brake pipe fitting (1) to the brake hose (3).
Use a backup wrench on the brake hose (3).
Tighten the brake pipe fitting to 18 N.m (13 lb ft).
Ensure that the hose does not make contact with any part of the suspension. Check the hose in extreme
condition.
13. Install rear wheel speed sensor to brake hose. Refer to Rear Wheel Speed Sensor Replacement (Disc
Brake) , Rear Wheel Speed Sensor Replacement (Drum Brake) .


REAR BRAKE HOSE REPLACEMENT (DRUM BRAKE)
Removal Procedure
3. Remove rear wheel speed sensor from brake hose. Refer to Rear Wheel Speed Sensor Replacement
(Disc Brake) , Rear Wheel Speed Sensor Replacement (Drum Brake) .

brake hose retainer (2).


7. Remove the brake hose retainer (2).

Fig. 57: Brake Hose Bracket And Wiring Harness

8. Remove the brake hose bolt (2) attaching the hose to the rear backing plate.
9. Remove wiring harness (1) from brake hose bracket.

Fig. 58: Brake Hose And Pipe Fitting

10. Remove the brake hose / pipe fitting (1) from the wheel cylinder and cap the opening to prevent brake
fluid contamination.

Fig. 59: Brake Hose And Pipe Fitting

1. Remove the caps or plugs from the opening in the wheel cylinder and the brake hose / pipe fitting.
2. Install the brake hose / pipe fitting (1) to the wheel cylinder and tighten the brake pipe fitting to 18 N.m
(13 lb ft)

Fig. 60: Brake Hose Bracket And Wiring Harness

3. Install the brake hose bolt (2) attaching the hose to the rear backing plate and tighten the bolt to 8 N.m (71
lb in).
4. Install wiring harness (1) at the brake hose bracket.


5.
6.
7.
8.
9.
10.
11.
Connect the brake pipe fitting (1) to the brake hose (3).
Use a backup wrench on the brake hose (3).
Tighten the brake pipe fitting to 18 N.m (13 lb ft).
Ensure that the hose does not make contact with any part of the suspension. Check the hose in extreme
condition.
12. Install rear wheel speed sensor to brake hose. Refer to Rear Wheel Speed Sensor Replacement (Disc
Brake) , Rear Wheel Speed Sensor Replacement (Drum Brake) .


HYDRAULIC BRAKE SYSTEM BLEEDING (PRESSURE BLEEDING)
genuine products. Instructions must be followed at all times. The use of
any type of fluid other than the recommended type of brake fluid, may
cause contamination which could result in damage to the internal rubber
seals and/or rubber linings of hydraulic brake system components.
If hydraulic components were serviced on only one wheel hydraulic circuit, perform the following procedure.
Bleeding a Single Hydraulic Brake Circuit
1. With the ignition OFF and the brakes cool, apply the brakes 3-5 times, or until the brake pedal effort
increases significantly, in order to deplete the brake booster power reserve.
2. Place a clean shop cloth beneath the brake master cylinder to catch brake fluid spills.
3. Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and
diaphragm.
4. Fill the brake master cylinder reservoir to the maximum-full level with GM approved brake fluid from a
clean, sealed brake fluid container. Refer to Fluid and Lubricant Recommendations .
NOTE:
The pressure bleeding equipment must be the diaphragm type. The rubber
diaphragm between the air supply and the brake fluid prevents air,
moisture, oil, and other contaminants from entering the hydraulic system.
5. Following the brake pressure bleeder manufacturer's instructions, fill the brake pressure bleeder with GM
approved brake fluid from a clean, sealed brake fluid container.
6. Install the appropriate master cylinder reservoir adapter and connect the brake pressure bleeder.
7. Charge the brake pressure bleeder air tank to 170-200 kPa/1.7-2.0 bar (25-30 psi), or as recommended by
the brake pressure bleeder manufacturer's instructions.
8. Open the brake pressure bleeder fluid tank valve to allow pressurized brake fluid to enter the brake
hydraulic system.

NOTE:
Any brake fluid leaks identified require repair prior to completing this
procedure.
9. Wait approximately 30 seconds, then inspect the entire hydraulic brake system for external brake fluid
leaks.
10. Install a proper box-end wrench onto the wheel hydraulic circuit bleeder valve which has been serviced.
11. Install a transparent hose over the end of the bleeder valve.
12. Submerge the open end of the transparent hose into a transparent container partially filled with brake fluid
from a clean, sealed brake fluid container.
13. Loosen the bleeder valve to purge air from the wheel hydraulic circuit.
14. Allow fluid to flow until air bubbles stop flowing from the bleeder.
15. After all air has been purged from the hydraulic circuit, tighten the bleeder valve and install the dust cap.
NOTE:
The brake reservoir may have residual pressure after the bleeding
operation is complete. Wrap a clean shop towel around the bleeder
adapter and all hose connections before disconnecting the pressure
bleeding equipment to prevent brake fluid from contacting and damaging
vehicle components and painted surfaces.
16. Close the brake pressure bleeder fluid tank valve then disconnect the brake pressure bleeder from the
master cylinder reservoir bleeder adapter.
17. Remove the master cylinder reservoir bleeder adapter from the master cylinder reservoir.
18. Fill the brake master cylinder reservoir to the maximum-fill level with GM approved brake fluid from a
clean, sealed brake fluid container.
19. Slowly press and release the brake pedal. Observe the brake pedal feel.
20. If the brake pedal feels spongy, perform the Bleeding the Complete Brake Hydraulic System procedure:
21. Turn the ignition key ON, with the engine OFF. Check to see if the brake system warning lamp remains
illuminated.
NOTE:
DO NOT allow the vehicle to be driven until it is diagnosed and repaired.
22. If the brake system warning lamp remains illuminated, refer to Diagnostic Starting Point - Vehicle .
Bleeding the Complete Brake Hydraulic System
diaphragm.
5. If the master cylinder was replaced, the master cylinder must be bench bled. Refer to Master Cylinder

Bench Bleeding.
6. If the brake pipes have been removed from the master cylinder, the following steps must be performed.
1. With the rear brake pipe installed securely to the master cylinder, loosen and separate the front
brake pipe fitting from the front port of the brake master cylinder.
2. Allow a small amount of brake fluid to gravity bleed from the open port of the master cylinder.
Capture and properly dispose of the brake fluid in an approved container.
3. Install the front brake pipe fitting to the front port of the brake master cylinder and tighten the
fitting.
4. Have an assistant slowly press the brake pedal fully and maintain steady pressure on the pedal.
5. Loosen the front brake pipe fitting from the front port of the brake master cylinder to purge air from
the master cylinder port.
6. Tighten the front brake pipe fitting, then have the assistant slowly release the brake pedal.
7. Wait 15 seconds, then repeat steps 6.4-6.6 until all air is purged from the front brake pipe fitting of
the front port of the master cylinder.
8. After all air is purged from the front port of the brake master cylinder, tighten the front master
cylinder brake pipe fitting. Refer to Fastener Tightening Specifications.
9. With the front brake pipe fitting installed securely to the front port of the brake master cylinder,
loosen and separate the rear brake pipe fitting from the rear port of the brake master cylinder.
10. Repeat steps 6.2-6.7 for the rear port of the brake master cylinder.
11. After all air is purged from the rear port of the brake master cylinder, tighten the rear master
13. If the brake pedal feels spongy, proceed to step 7.
14. If the brake pedal feels firm, proceed to step 24.
7. If the brake pipes have been removed from the brake pressure modulator valve (BPMV) assembly, if
equipped, or the brake proportion valve assembly, if equipped, air must be purged from each port of the
respective assembly beginning with the feed pipes from the master cylinder.
1. Loosen and separate one of the master cylinder brake pipe fittings from the inlet port of the
assembly to be bled.
2. Allow a small amount of brake fluid to gravity bleed from the open port of the assembly. Capture
and properly dispose of the brake fluid in an approved container.
3. Install the brake pipe fitting and to the inlet port of the assembly and tighten securely.
5. Loosen the same brake pipe fitting to purge air from the open port of the assembly.
6. Tighten the brake pipe fitting, then have the assistant slowly release the brake pedal.
7. Wait 15 seconds, then repeat steps 7.4-7.6 until all air is purged from the brake pipe fitting of the
assembly.
8. Repeat steps 7.1-7.7 for all of the remaining ports of the assembly.
9. After bleeding each port of the assembly, tighten all of the brake pipe fittings on the assembly.
Refer to Fastener Tightening Specifications.
10. Fill the master cylinder reservoir to the maximum-full level with GM approved brake fluid from a


NOTE:
The pressure bleeding equipment must be the diaphragm type. The rubber
diaphragm between the air supply and the brake fluid prevents air,
moisture, oil, and other contaminants from entering the hydraulic system.
8. Following the brake pressure bleeder manufacturer's instructions, fill the brake pressure bleeder with GM
9. Install the appropriate master cylinder reservoir adapter and connect the brake pressure bleeder.
10. Charge the brake pressure bleeder air tank to 170-200 kPa/1.7-2.0 bar (25-30 psi), or as recommended by
the brake pressure bleeder manufacturer's instructions.
11. Open the brake pressure bleeder fluid tank valve to allow pressurized brake fluid to enter the brake
hydraulic system.
NOTE:
Any brake fluid leaks identified require repair prior to completing this
procedure.
12. Wait approximately 30 seconds, then inspect the entire hydraulic brake system for external brake fluid
leaks.
13. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve.
15. Submerge the open end of the transparent hose into a transparent container partially filled with GM
16. Have an assistant slowly press the brake pedal fully and maintain steady pressure on the brake pedal.
18. Tighten the bleeder valve, then have the assistant slowly release the brake pedal.
19. Wait 15 seconds, then repeat steps 11-13 until all air is purged from the wheel hydraulic circuit.
20. Tighten the RIGHT REAR hydraulic wheel circuit bleeder valve securely.
21. Install a proper box-end wrench onto the LEFT REAR wheel hydraulic circuit bleeder valve, then repeat
steps 9-14.
22. Install a proper box-end wrench onto the RIGHT FRONT wheel hydraulic circuit bleeder valve, then
repeat steps 9-14.
23. Install a proper box-end wrench onto the LEFT FRONT wheel hydraulic circuit bleeder valve, then repeat
steps 9-14.
24. After completing the final wheel hydraulic circuit bleeding procedure, tighten all of the wheel hydraulic
circuit bleeder valves and install the bleeder valve dust caps.
25. Close the brake pressure bleeder fluid tank valve.
NOTE:
The brake reservoir may have residual pressure after the bleeding

operation is complete. Wrap a clean shop towel around the bleeder

adapter and all hose connections before disconnecting the pressure
bleeding equipment to prevent brake fluid from contacting and damaging
vehicle components and painted surfaces.
26. Remove the brake pressure bleeding equipment from the vehicle.
29. If the brake pedal feels spongy, perform the following procedure.
1. If equipped with antilock brakes, install a scan tool and perform the Antilock Brake System
Automated Bleed to remove air which may be trapped in the BPMV.
2. Inspect the hydraulic brake system for external leaks. Refer to Brake System External Leak
Inspection.
3. Repeat the Bleeding the Complete Brake Hydraulic System procedure.
30. If the brake pedal still feels spongy, pressure bleed the hydraulic brake system. Refer to Hydraulic Brake
System Bleeding (Manual Bleeding), Hydraulic Brake System Bleeding (Pressure Bleeding).
31. Turn the ignition switch ON with the engine OFF. Check to see if the brake system warning lamp remains
illuminated.
NOTE:
DO NOT allow the vehicle to be driven until the brake system is diagnosed
and repaired.
HYDRAULIC BRAKE SYSTEM BLEEDING (MANUAL BLEEDING)
If hydraulic components were serviced on only one wheel hydraulic circuit, perform the following procedure.
Bleeding a Single Hydraulic Brake Circuit

diaphragm.
clean, sealed brake fluid container. Add brake fluid as needed to ensure that the brake master cylinder
reservoir remains at least half-full throughout the bleed procedure. The reservoir cap must be installed at
all times except when filling the reservoir. Refer to Fluid and Lubricant Recommendations .
5. Install a proper box-end wrench onto the wheel hydraulic circuit bleeder valve which has been serviced.
7. Submerge the open end of the transparent hose into a transparent container partially filled with brake fluid
from a clean, sealed brake fluid container.
10. Tighten the bleeder valve, then have the assistant slowly release the brake pedal.
11. Wait 15 seconds, then repeat steps 8-10 until all air is purged from the wheel hydraulic circuit.
12. After all air has been purged from the hydraulic circuit, tighten the bleeder valve and install the dust cap.
13. Fill the brake master cylinder reservoir to the maximum-fill level with GM approved brake fluid from a
15. If the brake pedal feels spongy, perform the Bleeding the Complete Brake Hydraulic System procedure:
16. Turn the ignition key ON, with the engine OFF. Check to see if the brake system warning lamp remains
illuminated.
NOTE:
DO NOT allow the vehicle to be driven until it is diagnosed and repaired.
Bleeding the Complete Brake Hydraulic System
diaphragm.
clean, sealed brake fluid container. Add brake fluid as needed to ensure that the brake master cylinder
reservoir remains at least half-full throughout the bleed procedure. The reservoir cap must be installed at
all times except when filling the reservoir. Refer to Fluid and Lubricant Recommendations .
5. If the master cylinder was replaced, the master cylinder must be bench bled. Refer to Master Cylinder
Bench Bleeding.

6. If the brake pipes have been removed from the master cylinder, the following steps must be performed.
1. With the rear brake pipe installed securely to the master cylinder, loosen and separate the front
brake pipe fitting from the front port of the brake master cylinder.
2. Allow a small amount of brake fluid to gravity bleed from the open port of the master cylinder.
Capture and properly dispose of the brake fluid in an approved container.
3. Install the front brake pipe fitting to the front port of the brake master cylinder and tighten the
fitting. Refer to Fastener Tightening Specifications.
5. Loosen the front brake pipe fitting from the front port of the brake master cylinder to purge air from
the master cylinder port.
6. Tighten the front brake pipe fitting, then have the assistant slowly release the brake pedal.
7. Wait 15 seconds, then repeat steps 6.4-6.6 until all air is purged from the front brake pipe fitting of
the front port of the master cylinder.
8. After all air is purged from the front port of the brake master cylinder, tighten the front master
9. With the front brake pipe fitting installed securely to the front port of the brake master cylinder,
loosen and separate the rear brake pipe fitting from the rear port of the brake master cylinder.
10. Repeat steps 6.2-6.7 for the rear port of the brake master cylinder.
11. After all air is purged from the rear port of the brake master cylinder, tighten the rear master
7. If the brake pipes have been removed from the brake pressure modulator valve (BPMV) assembly, if
equipped, or the brake proportion valve assembly, if equipped, air must be purged from each port of the
respective assembly beginning with the feed pipes from the master cylinder.
1. Loosen and separate one of the master cylinder brake pipe fittings from the inlet port of the
assembly to be bled.
2. Allow a small amount of brake fluid to gravity bleed from the open port of the assembly. Capture
and properly dispose of the brake fluid in an approved container.
3. Install the brake pipe fitting and to the inlet port of the assembly and tighten securely.
5. Loosen the same brake pipe fitting to purge air from the open port of the assembly.
6. Tighten the brake pipe fitting, then have the assistant slowly release the brake pedal.
7. Wait 15 seconds, then repeat steps 7.4-7.6 until all air is purged from the brake pipe fitting of the
assembly.
8. Repeat steps 7.1-7.7 for all of the remaining ports of the assembly.
9. After bleeding each port of the assembly, tighten all of the brake pipe fittings on the assembly.
Refer to Fastener Tightening Specifications.
10. Fill the master cylinder reservoir to the maximum-full level with GM approved brake fluid from a

8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve.
Install a transparent hose over the end of the bleeder valve.
Submerge the open end of the transparent hose into a transparent container partially filled with GM
Have an assistant slowly press the brake pedal fully and maintain steady pressure on the brake pedal.
Loosen the bleeder valve to purge air from the wheel hydraulic circuit.
Tighten the bleeder valve, then have the assistant slowly release the brake pedal.
Wait 15 seconds, then repeat steps 11-13 until all air is purged from the wheel hydraulic circuit.
Tighten the RIGHT REAR hydraulic wheel circuit bleeder valve securely.
Install a proper box-end wrench onto the LEFT REAR wheel hydraulic circuit bleeder valve, then repeat
steps 9-14..
Install a proper box-end wrench onto the RIGHT FRONT wheel hydraulic circuit bleeder valve, then
repeat steps 9-14..
Install a proper box-end wrench onto the LEFT FRONT wheel hydraulic circuit bleeder valve, then repeat
steps 9-14..
After completing the final wheel hydraulic circuit bleeding procedure, tighten all of the wheel hydraulic
circuit bleeder valves and install the bleeder valve dust caps.
Fill the master cylinder reservoir to the maximum-full level with GM approved brake fluid from a clean,
sealed brake fluid container.
Slowly press and release the brake pedal. Observe the brake pedal feel.
If the brake pedal feels spongy, perform the following procedure.
1. If equipped with antilock brakes, install a scan tool and perform the Antilock Brake System
Automated Bleed to remove air which may be trapped in the BPMV.
2. Inspect the hydraulic brake system for external leaks. Refer to Brake System External Leak
Inspection.
3. Repeat the Bleeding the Complete Brake Hydraulic System procedure.
If the brake pedal still feels spongy, pressure bleed the hydraulic brake system. Refer to Hydraulic Brake
System Bleeding (Manual Bleeding), Hydraulic Brake System Bleeding (Pressure Bleeding)
Turn the ignition switch ON with the engine OFF. Check to see if the brake system warning lamp remains
illuminated.
NOTE:
DO NOT allow the vehicle to be driven until the brake system is diagnosed
and repaired.
HYDRAULIC BRAKE SYSTEM FLUSHING

1. Inspect the brake fluid for the following conditions, indicating brake fluid contamination:
Fluid separation, indicating two types of fluid are present; a substance other than the recommended
brake fluid has been introduced into the brake hydraulic system:
Swirled appearance-oil-based substance
Layered appearance-silicone-based substance
Fluid discoloration, indicating the presence of moisture or particles that have been introduced into
the brake hydraulic system:
Cloudy appearance-moisture
Dark appearance/suspended particles in fluid-dirt, rust, corrosion, brake dust
2. Inspect the master cylinder reservoir cap diaphragm and the reservoir-to-master cylinder grommets for
swelling, indicating brake fluid contamination.
3. If the brake fluid WAS contaminated with an oil-based or a silicone-based substance, indicated by fluid
separation and/or a swollen master cylinder reservoir cap diaphragm and/or swollen reservoir-to-master
cylinder grommets, perform the following:
1. Remove ALL of the following components listed from the vehicle. Each component contains
internal rubber seals/linings which have been contaminated by the contaminated brake fluid in the
brake hydraulic system.
Refer to the procedures indicated:
Rear Brake Hose Replacement (Drum Brake), Rear Brake Hose Replacement (Disc
Brake)
Front Brake Caliper Replacement
Hydraulic Brake System Bleeding (Manual Bleeding), Hydraulic Brake System
Bleeding (Pressure Bleeding)
2. Clean out all the hydraulic brake pipes using denatured alcohol, or equivalent.
3. Dry the brake pipes using non-lubricated, filtered air.
4. Repair or replace ALL of the following components listed and install them to the vehicle. Each
component contains internal rubber seals/linings which have been contaminated by the
contaminated brake fluid in the brake hydraulic system.
Refer to the procedures indicated:

Master Cylinder Replacement ; also perform the following:

Clean the brake master cylinder reservoir using denatured alcohol, or equivalent, then dry the
reservoir using non-lubricated, filtered air. Inspect the reservoir for cracks and/or damage and
replace if necessary. Refer to Master Cylinder Reservoir Replacement.
Replace the brake master cylinder reservoir cap diaphragm.
Rear Brake Hose Replacement (Drum Brake), Rear Brake Hose Replacement (Disc
Brake)
Front Brake Caliper Overhaul , or Front Brake Caliper Replacement
4. If the brake fluid was NOT contaminated with an oil-based or a silicone-based substance, but WAS
contaminated with water or dirt, rust, corrosion, and/or brake dust, replace the brake master cylinder
reservoir cap diaphragm. The diaphragm may have allowed the moisture or particles to enter the
hydraulic system.
5. Fill the brake master cylinder reservoir to the maximum-fill level with GM recommended brake fluid.
Refer to Adhesives, Fluids, Lubricants, and Sealers for the recommended brake fluid.
6. Pressure bleed the hydraulic brake system. Begin the procedure with the pressure bleeder reservoir filled
to the maximum-fill level with the correct brake fluid as indicated. Refer to Hydraulic Brake System
Bleeding (Manual Bleeding), Hydraulic Brake System Bleeding (Pressure Bleeding).
POWER BRAKE BOOSTER VACUUM PIPE REPLACEMENT (WITHOUT ELECTRIC PUMP)
Fig. 62: Power Brake Booster Vacuum Pipe


Power Brake Booster Vacuum Pipe Replacement (without Electric Pump)
Callout
Component Name
Power Brake Booster Vacuum Pipe
1
Procedure
1. Disconnect quick fitting from inlet exhaust.
2. Disconnect vacuum pipe from power brake booster.
POWER BRAKE BOOSTER VACUUM PIPE REPLACEMENT (WITH ELECTRIC PUMP)
Fig. 63: Power Brake Booster Vacuum Pipe (With Electric Pump)
Power Brake Booster Vacuum Pipe Replacement (with Electric Pump)
Callout
Component Name
Power Brake Booster Vacuum Pipe
1
Procedure
1. Disconnect quick fitting from intake manifold.
2. Disconnect wiring harness plug.

3. Disconnect vacuum pipe from power brake booster.

4. Disconnect vacuum pipe from power brake booster pump.
POWER BRAKE BOOSTER REPLACEMENT
Removal Procedure

NOTE:



NOTE:

NOTE:
6. Disconnect the master cylinder secondary brake pipe fitting (1).


NOTE:
7. Disconnect the master cylinder primary brake pipe fitting (1).


8. Remove the BPMV bracket bolts (2).
10. Remove the brake master cylinder assembly from the booster. Refer to Master Cylinder Replacement.

Fig. 69: Brake Booster Vacuum Pipe

11. Remove the booster vacuum pipe (1) from the booster.


13. Replace the click fit connector between booster pushrod and brake pedal with a new part.


14. Remove the brake booster bolts (1).
15. Remove the booster from the vehicle.


1. Install the booster to the vehicle.
2. Install the brake booster bolts (1) and tighten to 19 N.m (15 lb ft).


3. Connect the brake pedal pushrod (1) to the brake pedal.


4. Install the booster vacuum pipe (1) to the booster.
5. Install the master cylinder assembly to the booster. Refer to Master Cylinder Replacement.








NOTE:
10. Install the 6 brake pipes (1, 2) to the BPMV and tighten to 18 N.m (14 lb ft).
11. Connect the electrical connector with to the EBCM/EBTCM.

12. Install the radiator surge tank (1).
13. Install the radiator surge tank clip (2).
POWER BRAKE BOOSTER PUMP REPLACEMENT
Removal Procedure

Fig. 80: Brake Booster Vacuum Pump

1.
2.
3.
4.
Disconnect electrical connector (4).

Disconnect the vacuum hose quick fitting (1) from power brake booster vacuum pump (2).
Remove the bolts (3, 5).
Remove the power brake booster vacuum pump (2) with bracket from the vehicle.

Fig. 81: Pump Screws And Nuts

5. Remove pump screws and nuts (1, 2) from the power brake booster pump (3).

Fig. 82: Pump Screws And Nuts

1. Install the pump screws and nuts (1, 2) to the power brake booster pump (3) and tighten to 7.5 N.m (66 lb
in).

Fig. 83: Brake Booster Vacuum Pump

2.
3.
4.
5.
6.
Disconnect electrical connector (4).

Remove the power brake booster vacuum pump (2) with bracket from the vehicle.
Install the bolts (3, 5) and tighten to 20 N.m (15 lb ft).
Connect the vacuum hose quick fitting (1) to the power brake booster vacuum pump (2).
Connect the electrical connector (4).

BRAKE ASSIST SYSTEM DESCRIPTION AND OPERATION
The brake assist system consists of the following:

Brake Pedal
Receives, multiplies and transfers brake system input force from driver.
Brake Pedal Pushrod
Transfers multiplied input force received from brake pedal to brake booster.
Vacuum Brake Booster
Uses source vacuum to decrease effort required by driver when applying brake system input force.
At rest, source vacuum is applied to both sides of the vacuum diaphragm for single boosters, or to both
sides of each of the diaphragms for tandem boosters. Return springs maintain the booster in a rest
position.
When brake system input force is applied, vacuum to the rear of the diaphragm(s) is cut off, and air at
atmospheric pressure is admitted in its place. This provides a decrease in brake pedal effort required.
When input force is removed, vacuum again replaces atmospheric pressure within the booster.
Vacuum Source
Supplies force used by vacuum brake booster to decrease brake pedal effort.
The primary source for vacuum is typically the vehicle's internal combustion engine. Some vehicles may
use a vacuum pump to ensure and adequate supply of vacuum under various operating conditions, such as
during cold start-up, heavy throttle, and high altitude.
Vacuum Pump Relay
Vehicles equipped with a vacuum pump will typically be equipped with a relay used to provide voltage to
the vacuum pump motor, when commanded by the powertrain controller.
Vacuum Monitoring System
Provides a feedback voltage signal relative to the amount of vacuum available for the vacuum power
brake booster.
This typically consists of a vacuum sensor mounted either into the power vacuum brake booster,
integrated with the vacuum check valve, or in-line within the vacuum hose. The sensor feedback is
typically monitored by the powertrain control module(s).
Vacuum Source Control
If equipped with a system to monitor available levels of vacuum for the brake assist system, the
powertrain control module(s) typically perform the primary monitoring function.
The powertrain controller will typically monitor the feedback signal of a vacuum sensor, as it relates to
available vacuum at the vacuum power brake booster. The powertrain controller uses the information to
make sure available vacuum remains above predetermined levels. If additional vacuum is required, the
powertrain controller may reactivate engine cylinders, if equipped, or command a vacuum pump ON, if
equipped, and/or may alter the operation of various other engine controls and devices, as necessary.

Vacuum Source Delivery System

Enables delivery and retention of source vacuum for vacuum brake booster.
This typically consists of a vacuum check valve and a vacuum hose or pipe. If a vacuum pump is used,
additional check valves may be used.
System Operation
Brake system input force from the driver is multiplied by the brake pedal and transferred by the pedal pushrod
to the hydraulic brake master cylinder. Effort required to apply the brake system is reduced by the operation of
the vacuum brake booster.
When brake system force is applied, vacuum to the rear of the diaphragm(s) is cut off, and air at atmospheric
pressure is admitted in its place. The vacuum acts to pull the diaphragm(s) forward, while the atmospheric
pressure acts to push from behind. As a result, the amount of effort required by the driver is reduced. When
input force is removed, vacuum again replaces atmospheric pressure within the vacuum power brake booster to
help return the booster to rest. Return springs maintain the system in a rest position.
If the vehicle is equipped with a vacuum monitoring system, the powertrain control module(s) typically will
alter powertrain functions and/or command the vacuum pump ON, if equipped, to provide for the vacuum needs
of the brake assist system, as operating conditions warrant.
BRAKE BOOSTER VACUUM ASSIST DESCRIPTION AND OPERATION
In order to assure that vacuum is available to the vacuum brake booster, the car can contain a vacuum pump
either in addition to the normal intake manifold vacuum source or as stand-alone. The pump provides negative
pressure when the engine cannot properly accommodate the requirement, e.g. cold start, heavy throttle, high
altitude and turbo pressure.
Mechanical
The mechanical vacuum pump is driven by a camshaft. The pump delivers maximum vacuum irrespective of
engine RPM. This means that the pump, in certain situations, delivers more negative pressure than the system
uses.
Electrical
A low vacuum switch controls the 12 V to the relay coil in the brake vacuum assist pump. When more vacuum
is needed the vacuum switch closes. The relay coil closes the relay contact and connects the electric motor to
ground. The electric motor is fed with 12 V. When sufficient vacuum is reached the switch opens and the pump
stops.
A venturi is connected between the intake manifold and the vacuum brake booster, amplifying the vacuum. This
reduces the on-time for the pump. To prevent air flowing in the wrong direction check valves are used.
BRAKE FLUID AND BRAKE FLUID HANDLING
WARNING: Brake fluid may irritate eyes and skin. In case of contact, take the

following actions:
Eye contact-rinse thoroughly with water.

Skin contact-wash with soap and water.
If ingested-consult a physician immediately.
CAUTION: Brake fluid will damage electrical connections and painted surfaces. Use
shop cloths, suitable containers, and fender covers to prevent brake fluid
from contacting these areas. Always re-seal and wipe off brake fluid
containers to prevent spills.
CAUTION: Avoid spilling brake fluid on any of the vehicle's painted surfaces, wiring,
cables or electrical connectors. Brake fluid will damage paint and
electrical connections. If any fluid is spilled on the vehicle, immediately
flush the area with water to minimize the potential for damage.
CAUTION: Power steering fluid, engine oil, brake fluid, or any mineral based fluids
cannot be mixed. If brake seals contact power steering fluid or steering
seals contact brake fluid, seal damage will result.
NOTE:
Do not reuse the brake fluid collected during the hydraulic brake system
bleeding.
Always store brake fluid in a closed container.
Reseal brake fluid containers immediately after use.
Do not use brake fluid left in an open container.
Do not use brake fluid left in an improperly sealed container.
Do not use the following fluids in the hydraulic brake system:
Power steering fluid
Automatic transmission fluid
DOT 5 silicone hydraulic brake fluid
BRAKE WARNING SYSTEM DESCRIPTION AND OPERATION

Brake Warning Indicator
The instrument cluster turns the brake warning indicator ON when the following occurs:

The instrument cluster performs the bulb check. The brake warning indicator illuminates for 5 s.
When the Electronic Brake Control Module (EBCM) detects low brake fluid level it sets DTC C0267 and
sends a serial data message to the instrument cluster, which will illuminate the red brake indicator.
The Body Control Module (BCM) detects that the parking brake is engaged. The instrument cluster
receives a serial data message from the BCM requesting illumination.
Driver Information Center Messages
When the Electronic Brake Control Module (EBCM) detects low brake fluid level it sets DTC C0267 and sends
a serial data message to the Driver Information Center, which will display Brake Fluid Low message.
HYDRAULIC BRAKE SYSTEM DESCRIPTION AND OPERATION
The hydraulic brake system consists of the following:

Hydraulic Brake Master Cylinder Fluid Reservoir
Contains supply of brake fluid for the hydraulic brake system.
Hydraulic Brake Master Cylinder
Converts mechanical input force into hydraulic output pressure.
Hydraulic output pressure is distributed from the master cylinder through two hydraulic circuits,
supplying diagonally-opposed wheel apply circuits.
Hydraulic Brake Pressure Balance Control System
Regulates brake fluid pressure delivered to hydraulic brake wheel circuits, in order to control the
distribution of braking force.
Pressure balance control is achieved through dynamic rear proportioning (DRP), which is a function of
the ABS modulator. Refer to ABS Description and Operation for specific information on the operation
of DRP.
Hydraulic Brake Pipes and Flexible Brake Hoses
Carries brake fluid to and from hydraulic brake system components.
Hydraulic Brake Wheel Apply Components
Converts hydraulic input pressure into mechanical output force.
System Operation
Mechanical force is converted into hydraulic pressure by the master cylinder, regulated to meet braking system
demands by the pressure balance control system, and delivered to the hydraulic brake wheel circuits by the

pipes and flexible hoses. The wheel apply components then convert the hydraulic pressure back into mechanical
force which presses linings against rotating brake system components.

SPECIAL TOOLS
Illustration

CH-28662
J-28662
Brake Pedal Effort Gauge
CH-29532-A
J-29532-A
Brake Pressure Bleeder
CH-35798
J-35798
Brake Bleeder Adapter
CH-45405
J-45405
Pipe Flaring Tool Kit
DT-6202-A
Pliers
DT-6202-B
Pliers
DT-6202-20
Adapter to DT-6202-A

DT-50894
Remover

2013 BRAKES Park Brake - Cruze
2013 BRAKES
Park Brake - Cruze
SPECIFICATIONS
Specification
Application
Park Brake Cable Guide Bolt
Parking Brake Cable Casing Retainer Bolt
Parking Brake Indicator Switch Bolt
Parking Brake Lever Nut
Metric
22 N.m
22 N.m
2.5 Y
9 N.m
English
16 lb ft
16 lb ft
23 lb in
80 lb in

SYMPTOMS - PARK BRAKE
NOTE:
Review the system operation in order to familiarize yourself with the system
functions.
Refer to Park Brake System Diagnosis (Drum Brakes), Park Brake System Diagnosis (Disc Brakes).
1. Inspect for aftermarket devices which could affect the operation of the park brake system.
2. Inspect the easily accessible or visible system components for obvious damage or conditions which could
cause the symptom.
PARK BRAKE WILL NOT HOLD OR RELEASE (DISC BRAKE)
Park Brake Will Not Hold or Release (Disc Brake)
Step
Action
Were you sent here from the Park Brake
1
Symptom table?
Inspect the disc brake system for proper
operation. Refer to Disc Brake System
2
Diagnosis .
Inspect the park brake system for proper
operation. Refer to Park Brake System
3
Diagnosis (Drum Brakes), Park Brake
System Diagnosis (Disc Brakes).
Yes
No
Go to Symptoms - Park
Go to Step 2 Brake
Go to Step 5
Go to Step 3


Inspect the hydraulic brake system for
proper operation. Refer to Hydraulic
Brake System Diagnosis .
Road test the vehicle in order to confirm
proper operation. Refer to Brake System
Vehicle Road Test .
Go to Step 5
Go to Step 4
Go to Step 5 Brake
Go to Step 2
System OK
PARK BRAKE WILL NOT HOLD OR RELEASE (DRUM BRAKE)

Park Brake Will Not Hold or Release (Drum Brake)
Step
Action
Were you sent here from the Park Brake
1
Symptom Table?
Inspect the park brake system for proper
operation. Refer to Park Brake System
2
Diagnosis (Drum Brakes), Park Brake
System Diagnosis (Disc Brakes).
Inspect the drum brake system for proper
operation. Refer to Drum Brake System
3
Diagnosis .
Inspect the disc brake system for proper
operation. Refer to Disc Brake System
4
Diagnosis .
Inspect the hydraulic brake system for
proper operation. Refer to Hydraulic
5
Brake System Diagnosis .
Road test the vehicle in order to confirm
proper operation. Refer to Brake System
6
Vehicle Road Test .
Yes
No
Go to Step 2 Brake
Go to Step 6
Go to Step 3
Go to Step 6
Go to Step 4
Go to Step 6
Go to Step 5
Go to Step 6 Brake
Go to Step 2
System OK
PARK BRAKE SYSTEM DIAGNOSIS (DISC BRAKES)

Park Brake System Diagnosis (Disc Brakes)
Step
Action
Yes
No
DEFINITION: This diagnostic table is designed to diagnose ONLY the mechanical components of the
PARK brake system in order to determine if the PARK brake system is operating properly. You will be
directed by the appropriate Symptom table to go to other brake system diagnostic tables as appropriate.

1
2
3
Were you sent here from a Hydraulic Brake

Go to Step 4
Go to Step 2
Symptom table?
Were you sent here from a Park Brake
Go to Step 4
Go to Step 3
Symptom table?
Is the symptom related to the ability of the Go to Symptoms - Park Go to Symptoms park brake system to hold and/or release? Brake
Hydraulic Brakes
1. Raise and support the vehicle with
the rear axle supported by jack
stands. Refer to Lifting and Jacking
the Vehicle .
2. With the park brake RELEASED,
attempt to rotate the rear wheels to
check the rear brakes for a significant
amount of drag.
Do the rear brakes have a significant
amount of drag?
Go to Step 8
Go to Step 5
Go to Step 13
Go to Step 6
Go to Step 7
Go to Step 8
1. Apply the park brake.

2. Attempt to rotate the rear wheels to
amount of drag.
Do the rear brakes have a significant
amount of drag?
Visually inspect the park brake cable
connections and the cables 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?
Reconnect or replace the park brake cables
as necessary. Refer to Parking Brake
Cable Replacement (Mechanical Parking
Brake).
Did you complete the repair and/or
replacement?
1. Disconnect the rear park brake cables
from the equalizer and from the
brake caliper piston apply levers.
Refer to Parking Brake Cable
Replacement (Mechanical Parking
Brake).
2. Have an assistant apply and maintain
the caliper piston apply lever to apply
the caliper piston.
Go to Step 13

10
11
12
13

amount of drag.
4. Release the caliper piston apply
lever.
5. Repeat steps 2, 3, and 4 for the other
side of the vehicle.
6. Rotate the rear wheels to check the
brake for a significant reduction of
drag.
Did the brake calipers apply and release
Go to Step 10
properly?
Replace the appropriate rear brake caliper.
Refer to Rear Brake Caliper
Replacement .
Go to Step 13
With the aid of an assistant, apply and
release the parking brake while observing
the cables for free movement.
Did the park brake cables move freely?
Go to Step 12
Replace any of the park brake cables
inspected that do not have free movement.
Refer to Parking Brake Cable
Replacement (Mechanical Parking
Brake).
Go to Step 13
Inspect the park brake pedal assembly for
proper operation and replace if necessary.
Refer to Parking Brake Lever
Replacement.
Go to Step 13
Install or connect any components that
Park Brake System OK
were removed or disconnected during
diagnosis.
Brake
Go to Step 9
-
Go to Step 11
PARK BRAKE SYSTEM DIAGNOSIS (DRUM BRAKES)

Park Brake System Diagnosis (Drum Brakes)
Step
Action
Yes
No
DEFINITION: This diagnostic table is designed to diagnose ONLY the components of the PARK brake
system in order to determine if the PARK brake system is operating properly. You will be directed by the
appropriate Symptom table to go to other brake system diagnostic tables as appropriate.
Were you sent here from a Hydraulic Brake
1

2
3
Symptom table?
Were you sent here from a Park Brake
Symptom table?
Is the symptom related to the ability of the
park brake system to hold and/or release?
Go to Step 3
Go to Symptoms Hydraulic Brakes
Go to Step 9
Go to Step 5
Go to Step 6
Go to Step 7
Go to Step 16
Go to Step 9
1. Release the park brake.

rear brakes for a significant reduction
in the amount of drag.
Did the rear brakes exhibit a significant
reduction in the amount of drag?
Go to Step 4
Go to Symptoms Park Brake

amount of drag.
Did the rear brakes exhibit a significant
reduction in the amount of drag?
Go to Step 2
1. Raise and support the vehicle with the

rear axle supported by jack stands.
Refer to Lifting and Jacking the
Vehicle .
2. With the park brake RELEASED,
attempt to rotate the rear wheels to
amount of drag.
Do the rear brakes have a significant amount
of drag?
Go to Step 4
1. Remove the brake drums. Refer to

Brake Drum Replacement .
2. Visually check the park brake cable
connections and the cables that are
accessible on the UNDERSIDE of the
vehicle for disconnections and/or
damage.
Were any or the park brake cables
disconnected and/or damaged?
Reconnect or replace the park brake cables as
necessary. Refer to Parking Brake Cable
Replacement (Mechanical Parking Brake).
Did you complete the repair?
Go to Step 8
Go to Step 11

CAUTION:
Do not depress the brake pedal with the
brake rotors and/or the brake drums
removed, or with the brake calipers
repositioned away from the brake rotors,
or damage to the brake system may result.

2. Inspect the park brake hardware for
loose, damaged, broken or missing
components.
3. Check the drum brake adjusters for a
condition.
Does the park brake hardware and/or the
park brake adjusters require replacement?
10
11
12
Go to Step 10
1. Replace park brake hardware

components as necessary. Refer to
Brake Shoe Replacement .
2. Replace the drum brake adjusting
hardware as necessary. Refer to Drum
Brake Adjusting Hardware
Replacement .
Have an assistant apply and release the park
brake, while you observe the park brake
cables for free movement.
Did the park brake cables move freely?
Go to Step 11
Go to Step 11
Go to Step 12
Go to Step 13
Go to Step 18
Return to Symptom
Table

amount of drag.
of drag.
Did the park brake apply and release
properly?
2. Disconnect the park brake cable

13
14
15
16
connections that are accessible on the

UNDERSIDE of the vehicle one at a
time and check each cable for free
movement.
Do any of the park brake cables accessible
on the underside of the vehicle require
replacement?
Replace any of the park brake cables that do
not have free movement - not releasing
properly. Refer to Parking Brake Cable
Replacement (Mechanical Parking Brake).
Replace the park brake lever assembly - not
releasing properly. Refer to Parking Brake
Lever Replacement.
18
Go to Step 15
Go to Step 17
Return to Symptom
Table
-
Go to Step 17

2. Check the drum brake adjusters for a
seized condition.
3. Replace the drum brake adjusting
hardware as necessary. Refer to Drum
Brake Adjusting Hardware
Replacement .
17
Go to Step 14
Go to Step 17

amount of drag.
of drag.
Did the park brake apply and release
properly?
Go to Step 18
Install or connect any components that were Park Brake System OK
Return to Symptom
Table
REPAIR INSTRUCTIONS
PARKING BRAKE LEVER REPLACEMENT
Return to Symptom
Table
Return to Symptom
Table

Removal Procedure
Fig. 1: Parking Brake Cable And Parking Brake Lever

2. Unhook the parking brake cable (1) from the parking brake lever (2).
3. Remove the parking brake indicator switch. Refer to Parking Brake Indicator Switch Replacement.

Fig. 2: Parking Brake Lever Nuts

4. Remove the parking brake lever nut (1).
5. Remove the parking brake lever (2).

Fig. 3: Parking Brake Lever Nuts

1. Install the parking brake lever (2).
2. Install the parking brake lever nut (1) and tighten to 9 N.m (80 lb in).
3. Install the parking brake indicator switch. Refer to Parking Brake Indicator Switch Replacement.


4. Hook in the parking brake cable (1) to the parking brake lever (2).
5. Remove the transit support (1).
6. Install the front floor console. Refer to Front Floor Console Replacement .
PARKING BRAKE LEVER BOOT REPLACEMENT

Fig. 5: Parking Brake Lever Boot

Parking Brake Lever Boot Replacement
Callout
Component Name
Parking Brake Lever Boot
Procedure
1
1. Pull down boot.

2. Apply bead of adhesive to upper surface of parking brake lever
(arrow).
3. Install parking brake lever boot carefully.
PARKING BRAKE INDICATOR SWITCH REPLACEMENT

Fig. 6: Parking Brake Indicator Switch

Parking Brake Indicator Switch Replacement
Callout
Component Name
Parking Brake Indicator Switch Bolt
2
3
CAUTION:
Tighten
2.5 N.m (22 lb in)
Wiring Harness Connector Parking Brake Indicator Switch
Parking Brake Indicator Switch
PARKING BRAKE CABLE REPLACEMENT (MECHANICAL PARKING BRAKE)

Removal Procedure

2. Remove the rear seat cushion. Refer to Rear Seat Cushion Removal and Installation .
3. Remove the center pillar lower garnish molding. Refer to Center Pillar Lower Garnish Molding
Replacement .
Fig. 7: Rear Floor Carpet

4. Partially remove the rear floor carpet (1).

Fig. 8: Parking Brake Cable And Parking Brake Cable Bracket

5. Remove the parking brake cable (2) from the parking brake lever (1).
6. Remove the parking brake cable (2) from the parking brake cable bracket (3).

Fig. 9: Parking Brake Cable Clip

7. Remove the parking brake cable clip (1).
8. Remove the parking brake cable grommet (2).

Fig. 10: Parking Brake Cable Casing Retainer Bolt

9. Remove the parking brake cable casing retainer bolt (1).
10. Unclip the parking brake cable.

Fig. 11: Parking Brake Cable At Rear Brake Caliper

11. Remove the parking brake cable (1) from the rear brake caliper.

Fig. 12: Parking Brake Cable At Rear Brake Caliper

1. Install the parking brake cable (1) to the rear brake caliper.

Fig. 13: Parking Brake Cable Casing Retainer Bolt

2. Clip in the parking brake cable (2).
3. Install the parking brake cable casing retainer bolt (1) and tighten to 22 N.m (16 lb ft).

Fig. 14: Parking Brake Cable Clip

4. Install the parking brake cable grommet (2).
5. Install the parking brake cable clip (1).

Fig. 15: Parking Brake Cable And Parking Brake Cable Bracket
6. Install the parking brake cable (2) to the parking brake cable bracket (3).
7. Install in the parking brake cable (2) to the parking brake lever (1).

Fig. 16: Rear Floor Carpet

8. Install the rear floor carpet (1).
9. Install the center pillar lower garnish molding. Refer to Center Pillar Lower Garnish Molding
Replacement .
10. Install the rear seat cushion. Refer to Rear Seat Cushion Removal and Installation .
11. Install the front floor console. Refer to Front Floor Console Replacement .
PARKING BRAKE REAR CABLE REPLACEMENT
Removal Procedure
2. Remove the rear tire and wheel assembly. Refer to Tire and Wheel Removal and Installation .

Fig. 17: Parking Brake Cable And Parking Brake Cable Retainer
3. Remove rear parking brake cable (1) from retainer (3).
4. Remove rear parking brake cable grommet (2) from rear backing plate.
5. Remove brake drum. Refer to Brake Drum Replacement .

Fig. 18: View Of Rear Park Brake Cable End Fitting

6. Using a flat-bladed screwdriver, depress the visible retaining tab (1) on the park brake cable fitting, then
tilt the released side of the cable end back into the backing plate.
7. Rotate the park brake cable to expose the other retaining tab.


8. Release rear parking brake cable (1) from parking brake lever (2), using a suitable tool.
9. Remove the rear parking brake cable (1) back through the opening in the backing plate.
1. Insert the park brake cable through the opening in the backing plate. Only install the cable return spring to
just rearward of the spring positioning tab on the backing plate.


2. Push the rear parking brake cable (1) toward the rear of the vehicle, along the outside of the trailing brake
shoe, until the cable end is positioned just past the slot on the parking brake lever (2).
3. While holding the rear parking brake cable (1) in position from front to rear, move the cable end to the
back of the parking brake lever (2).
4. Press the rear parking brake cable (1) into the slot on the lever (2), then pull the cable toward the front of
the vehicle to secure the cable end to the slot.
5. While continuing to pull the cable away from the lever, insert a flat-bladed screwdriver into the opening
on the lever to prevent the cable from lifting out of the slot on the lever.
6. Move the cable return spring through the opening in the backing plate.

Fig. 21: View Of Rear Park Brake Cable End Fitting

7. Secure the cable fitting to the backing plate. Attempt to pull the park brake cable free of the backing plate,
to ensure that the retaining tabs (1) on the fitting are properly secured.

Fig. 22: Parking Brake Cable And Parking Brake Cable Retainer
8.
9.
10.
11.
12.
13.
Install rear parking brake cable (1) to retainer (3).

Install rear parking brake cable grommet (2) onto rear backing plate.
Install brake drum. Refer to Brake Drum Replacement .
Adjust the rear drum brakes. Refer to Drum Brake Adjustment .
Install the rear tire and wheel assembly. Refer to Tire and Wheel Removal and Installation
Lower the vehicle.
PARKING BRAKE ADJUSTMENT (MECHANICAL PARKING BRAKE)


NOTE:
This vehicle utilizes a self-tensioning, or self-adjusting park brake cable system.

The park brake system does not require adjustment under normal operating
conditions. The tension on the park brake cables can be disabled and enabled
when necessary during service of the disc or drum brake and/or the park brake
system.
1. Apply and fully release the park brake several times. Verify that the park brake lever releases completely.
2. Turn ON the ignition. Verify the red BRAKE warning lamp is not illuminated.
3. If the red BRAKE warning lamp is illuminated, verify the following:
The park brake lever is in the fully released position and against the stop.
There is no slack in the park brake cables.
4. If the red BRAKE warning lamp remained illuminated and there were no other visible causes, refer to
Symptoms - Hydraulic Brakes .
7. With the park brake lever fully released, check the park brake levers on the rear calipers (only necessary
on vehicles equipped with disc brakes on the rear axle). The levers should be against the stops on the
caliper housings. If the levers are not against the stops, binding may exist.
8. Fully apply and release the park brake lever 3-5 times in order for the cable tensioner to take up any slack
in the park brake cables.
9. Fully apply the park brake lever, a firm lever should be obtained by depressing the lever less than one full
stroke.
10. Attempt to rotate the rear tire and wheel assemblies. There should be no rotation forward or rearward.
11. Fully release the park brake lever.
12. Verify the park brake is released by rotating the rear tire and wheel assemblies. The rear tire and wheel
assemblies should rotate freely and exhibit no brake drag.

PARK BRAKE SYSTEM DESCRIPTION AND OPERATION
Park Brake Cables
NOTE:
Plastic coated park brake cables do not need periodic lubrication.
Coated park brake cables are used to reduce apply effort and increase corrosion protection. The cables are
coated with plastic material which slides against nylon seals inside the conduit end fittings.
System Operation- Disc Brakes
Park brake apply input force is received by the park brake lever assembly being applied. The input force is
multiplied by the lever assembly, transferred and evenly distributed, through the park brake cables and the park

brake cable equalizer, to the left and right park brake apply levers. The park brake apply levers multiply and
transfer the apply input force to in turn apply the disc brake caliper pistons which compress the brake pads
against the friction surface of the brake rotors in order to prevent the rotation of the rear tire and wheel
assemblies. The park brake lever assembly releases an applied park brake system when it is released and
returned to the at-rest position.
System Operation- Drum Brakes
Park brake apply input force is received by the park brake lever assembly being applied. The input force is
multiplied by the lever assembly, transferred and evenly distributed, through the park brake cables and the park
brake cable equalizer, to the left and right park brake apply levers. The park brake apply levers multiply and
transfer the apply input force to the drum brake actuators/adjusters which expand the drum brake shoes toward
the friction surface of the brake drum in order to prevent the rotation of the rear tire and wheel assemblies. The
park brake lever assembly releases an applied park brake system when it is released and returned to the at-rest
position.
Self Adjusting Park Brake System

Fig. 23: Park Brake Jaws Pushed Apart In Released Position

If park brake is released, the jaws (1) are pushed apart (arrows) and will be retained by a locking mechanism.
Thus the conduit (2) is disengaged. Now the conduit can move free in longitudinal direction during regular
driving and braking.
Fig. 24: Park Brake Jaws In Applied Position

During engagement of park brake, the conduit (2) slides back to the limiting arrest given through the brake
pads. The jaws (1) are pushed back (arrows) and clamp the conduit (2).
Fading through wearing process is prevented because the conduit will be clamped at any position.

2013 DRIVELINE/AXLE Wheel Drive Shafts - Cruze
2013 DRIVELINE/AXLE
Wheel Drive Shafts - Cruze
SPECIFICATIONS
Specification
Application
Front Wheel Drive Intermediate Shaft Bearing Bolt
Intermediate Shaft Bracket Bolt
Retaining Clamp
Wheel Drive Shaft Nut (1)
First Pass
Release
Metric
22 N.m
58 N.m
25 N.m
English
16 lb ft
43 lb ft
18 lb ft
150 N.m
111 lb ft
45 Degrees
250 N.m
Third Pass
184 lb ft

Application
Wheel Drive Shaft Inner and Outer
Joint
Type of Material
Grease
GM Part Number
United States
Canada
1051344
993037

SYMPTOMS - WHEEL DRIVE SHAFTS
NOTE:
Complete the following steps prior to beginning the wheel drive shaft diagnosis.
1. Perform the Vibration Analysis - Road Testing in order to effectively diagnose the concern.
2. Review the system operation in order to become familiar with the system function. Refer to Wheel Drive
Shafts Description and Operation.
Inspect for aftermarket equipment and modifications which could affect the operation of the wheel drive
shafts or other rotating components.

cause the symptom.

Thoroughly inspect the entire wheel drive shaft for visible damage, leaking joint seals, and missing seal
clamps.
Inspect the wheel drive shaft seals for cuts, tears, or other damage which may allow the loss of lubricant
and the entry of contaminates.
Symptom List
After performing the Visual/Physical Inspection and no visual signs of damage or other interference impairing
the wheel drive shaft function is apparent, it may be necessary to remove the wheel drive shaft from the vehicle
and manipulate the joints manually. 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
Clunk Noise When Accelerating During Turns
CLICK NOISE IN TURNS

A click noise occuring during turns may be caused by a worn or damaged wheel drive shaft outer joint. This
may be more apparent while simultaneously turning and accelerating. This click is caused by wear and/or
damage to the constant velocity joint bearings and/or races. Commonly, this damage or wear is caused by the
loss of lubricating grease from the constant velocity joint and the entry of foreign material or contaminates.
Carefully inspect the wheel drive shaft seals for cuts, tears or other damage which may allow the lubricating
grease to escape. The loss of this grease will cause damage to the wheel drive shaft constant velocity joint in a
very short period of time.
If inspection reveals no visual evidence of wear or damage, it may be necessary to remove the wheel drive shaft
from the vehicle and manipulate the outer joint manually. Any binding or impeded movement of the joint may
indicate damage which could contribute to the concern.
CLUNK WHEN ACCELERATING FROM COAST
A clunk noise occurring when accelerating from coast or a standing start may be caused by a worn or damaged
wheel drive shaft inner joint. The common cause of wheel drive shaft inner joint damage is the loss of
lubricating grease and/or the presence of foreign material and contaminates in the joint. This usually occurs as a
result of a torn or damaged inner joint seal.
Carefully inspect the wheel drive shaft seal for cuts, tears or other damage that may allow the loss of the
lubricating grease and/or the entry of contaminates.
from the vehicle and manipulate the inner joint manually. Do not allow the joint to separate from the wheel
drive shaft bar. Any binding or impeded movement of the joint may indicate damage which could contribute to
the concern.

CLUNK NOISE WHEN ACCELERATING DURING TURNS

A clunk noise that occurs while accelerating during turns may be caused by wear and/or damage to the inboard
and the outboard joints in combination. The loss of lubricant and/or the presence of contaminates can cause
damage to the internal components of the joints.
Carefully inspect the joint seals for cuts, tears or other damage. Joint seals that are damaged may allow lubricant
leakage and the entry of contaminates.
from the vehicle and manipulate the joints manually. Do not allow the joints to separate from the wheel drive
shaft bar. Any binding or impeded movement of the joints may indicate damage which could contribute to the
concern.
SHUDDER OR VIBRATION DURING ACCELERATION
In order to diagnose a shudder or vibration during acceleration, refer to Symptoms - Vibration Diagnosis and
Correction .
REPAIR INSTRUCTIONS
FRONT WHEEL DRIVE INTERMEDIATE SHAFT REPLACEMENT
Fig. 1: Front Wheel Drive Intermediate Shaft


Front Wheel Drive Intermediate Shaft Replacement

Callout
Component Name
Remove the wheel drive shaft. Refer to Front Wheel Drive Shaft Replacement - Right Side.
Intermediate Shaft Bracket Bolt (Qty: 3)
CAUTION:
Tighten
58 N.m (43 lb ft)
Front Wheel Drive Intermediate Shaft and Bracket Assembly
Procedure
1. Remove and DISCARD the O-ring. DO NOT re-use, replace with

NEW only.
2. The DT-6332 protector must be installed into the differential output
shaft seal prior installation the intermediate shaft.
3. For vehicles with automatic transmission, check transmission fluid
level. Refer to Transmission Fluid Drain and Fill .
4. For vehicles with manual transmission, check transmission fluid
level. Refer to Transmission Fluid Drain and Fill .
Special Tools
DT-6332 Seal Protector
FRONT WHEEL DRIVE SHAFT REPLACEMENT - LEFT SIDE

Special Tools
CH-313 Slide Hammer

CH-6003 Axle Shaft Remover
DT-29794 Axle Shaft Remover Extension
CH-49400 Hub Spindle Remover

Removal Procedure

WARNING: To prevent personal injury and/or component damage, do not allow

the weight of the vehicle to load the front wheels, or attempt to
operate the vehicle, when the wheel drive shaft(s) or wheel drive
shaft nut(s) are removed. To do so may cause the inner bearing race
to separate, resulting in damage to brake and suspension
components and loss of vehicle control.
CAUTION: Wheel drive shaft boots, seals and clamps should be protected from
sharp objects any time service is performed on or near the wheel
drive shaft(s). Damage to the boot(s), the seal(s) or the clamp(s) may
cause lubricant to leak from the joint and lead to increased noise and
possible failure of the wheel drive shaft.
3. Drain the transmission.
For vehicles with manual transmission, refer to Transmission Fluid Drain and Fill .
For vehicles with automatic transmission, refer to Transmission Fluid Drain and Fill .

Fig. 2: Breaker Bar And Punch Or Drift Tools

4. Insert a drift or punch (2) in the cooling fins of the brake rotor.
5. Rotate the brake rotor until the drift or punch contacts the brake caliper mounting bracket.
6. Using a breaker bar (1), loosen the wheel drive shaft nut.

Fig. 3: Wheel Drive Shaft And Nut

7. Remove and DISCARD the wheel drive shaft nut (2) from the wheel drive shaft (1).

Fig. 4: Special Tool And Wheel Bearing/Hub Assembly

NOTE:
Do not hit the end of the wheel drive shaft with a hammer to separate it
from the wheel bearing/hub. Damage to the wheel bearing hub and/or
wheel drive shaft may result.
8. Using the CH-49400 remover (2) or equivalent, separate the brake rotor and wheel bearing/hub assembly
(1).
9. Remove the outer tie rod assembly from the steering knuckle. Refer to Steering Linkage Outer Tie Rod
Replacement .
10. Remove the ball joint from the steering knuckle. Refer to Lower Control Arm Replacement .

Fig. 5: Seal Protector

CAUTION: Wheel drive shaft seal protector must be installed into the differential
output shaft seal prior to removing and installing the wheel drive
shaft. Failure to install the wheel drive shaft seal protector as
indicated may cause the splines of the wheel drive shaft to cut the
differential output seal.
11. Install the DT-6332 protector into the differential output shaft seal.

Fig. 6: Special Tools And Wheel Drive Shaft

12. Using the CH-313 hammer (2) with CH-6003 remover (1) along with DT-29794 extension and remove
the wheel drive shaft (3) from the vehicle.

Fig. 7: Wheel Drive Shaft & Washer

NOTE:
If there is no washer on the wheel drive shaft, install a NEW washer.
13. Remove and discard the washer (1) from the wheel drive shaft (2). DO NOT re-use the washer, replace
with NEW only.


1. Install a NEW washer (1) to the wheel drive shaft (2).

Fig. 9: Output Shaft Protector Tool

NOTE:
In order to prevent lubricant leaks, use care when installing the wheel
drive shaft to the differential. Do not damage the oil seal. Replace the oil
seal if it becomes nicked, distorted, or otherwise damaged.
2. Carefully install the wheel drive shaft into the differential until the splines are past the DT-6332
protector.

Fig. 10: Special Output Shaft Protector Tool

3. Remove the DT-6332 protector from the differential output shaft seal.
4. Install the wheel drive shaft into the differential until the retaining ring is fully seated.
5. Confirm that the front wheel drive shaft retaining ring is properly seated by holding the inner housing and
pull the inner housing outward
6. Install the front wheel drive shaft into the front wheel bearing/hub.
7. Install the ball joint to the steering knuckle. Refer to Lower Control Arm Replacement .
8. Install the outer tie rod assembly at the steering knuckle. Refer to Steering Linkage Outer Tie Rod
Replacement .


9. Install the NEW wheel drive shaft nut (2) to the wheel drive shaft (1) tighten in 3 passes.

Fig. 12: Tightening Wheel Drive Shaft Nut

12. Using a torque wrench (1) and the appropriate size socket, tighten the wheel drive shaft nut to 150 N.m
(111 lb ft).
13. Release the wheel drive shaft nut (2) trough 45 degrees.
14. Retighten the wheel drive shaft nut (2) to 250 N.m (185 lb ft).
17. Refill the transmission.
FRONT WHEEL DRIVE SHAFT REPLACEMENT - RIGHT SIDE

Special Tools
CH-313 Slide Hammer

CH-6003 Axle Shaft Remover
DT-29794 Axle Shaft Remover Extension
CH-49400 Hub Spindle Remover

Removal Procedure
WARNING: To prevent personal injury and/or component damage, do not allow

the weight of the vehicle to load the front wheels, or attempt to
operate the vehicle, when the wheel drive shaft(s) or wheel drive
shaft nut(s) are removed. To do so may cause the inner bearing race
to separate, resulting in damage to brake and suspension
components and loss of vehicle control.
CAUTION: Wheel drive shaft boots, seals and clamps should be protected from
sharp objects any time service is performed on or near the wheel
drive shaft(s). Damage to the boot(s), the seal(s) or the clamp(s) may
cause lubricant to leak from the joint and lead to increased noise and
possible failure of the wheel drive shaft.
3. Drain the transmission.

Fig. 13: Breaker Bar And Punch Or Drift Tools

6. Using a breaker bar (1), loosen the wheel drive shaft nut.


7. Remove and DISCARD the wheel drive shaft nut (2) from the wheel drive shaft (1).

Fig. 15: Special Tool And Wheel Bearing/Hub Assembly

NOTE:
Do not hit the end of the wheel drive shaft with a hammer to separate it
from the wheel bearing/hub. Damage to the wheel bearing hub and/or
wheel drive shaft may result.
8. Using the CH-49400 remover (2) or equivalent, separate the brake rotor and wheel bearing/hub assembly
(1).

9. Remove the outer tie rod assembly from the steering knuckle. Refer to Steering Linkage Outer Tie Rod
Replacement .
10. Remove the ball joint from the steering knuckle. Refer to Lower Control Arm Replacement .
Fig. 16: Seal Protector

CAUTION: Wheel drive shaft seal protector must be installed into the differential
output shaft seal prior to removing and installing the wheel drive
shaft. Failure to install the wheel drive shaft seal protector as
indicated may cause the splines of the wheel drive shaft to cut the
differential output seal.
11. Install the DT-6332 protector into the differential output shaft seal.

Fig. 17: Special Tools And Wheel Drive Shaft

12. Using the CH-313 hammer (2) with CH-6003 remover (1) along with DT-29794 extension and remove
the wheel drive shaft (3) from the vehicle.


NOTE:
If there is no washer on the wheel drive shaft, install a NEW washer.
13. Remove and discard the washer (1) from the wheel drive shaft (2). DO NOT re-use the washer, replace
with NEW only.


1. Install a NEW washer (1) to the wheel drive shaft (2).

Fig. 20: Output Shaft Protector Tool

NOTE:
In order to prevent lubricant leaks, use care when installing the wheel
drive shaft to the differential. Do not damage the oil seal. Replace the oil
seal if it becomes nicked, distorted, or otherwise damaged.
2. Carefully install the wheel drive shaft into the differential until the splines are past the DT-6332
protector.

Fig. 21: Special Output Shaft Protector Tool

3. Remove the DT-6332 protector from the differential output shaft seal.
4. Install the wheel drive shaft into the differential until the retaining ring is fully seated.
5. Confirm that the front wheel drive shaft retaining ring is properly seated by holding the inner housing and
pull the inner housing outward.
6. Install the front wheel drive shaft into the front wheel bearing/hub.
7. Install the ball joint to the steering knuckle. Refer to Lower Control Arm Replacement .
8. Install the outer tie rod assembly at the steering knuckle. Refer to Steering Linkage Outer Tie Rod
Replacement .


9. Install the NEW wheel drive shaft nut (2) to the wheel drive shaft (1) tighten in 3 passes.

Fig. 23: Tightening Wheel Drive Shaft Nut

12. Using a torque wrench (1) and the appropriate size socket, tighten the wheel drive shaft nut to 150 N.m
(111 lb ft).
13. Release the wheel drive shaft nut (2) trough 45 degrees.
14. Retighten the wheel drive shaft nut (2) to 250 N.m (185 lb ft).
17. Refill the transmission.
FRONT WHEEL DRIVE SHAFT INNER JOINT AND BOOT REPLACEMENT

Special Tools
CH-804 Tensioner
GE-396 Snap Ring Pliers

Removal Procedure
1. Remove the left or right wheel drive shaft, refer to Front Wheel Drive Shaft Replacement - Left Side,
or Front Wheel Drive Shaft Replacement - Right Side
Fig. 24: Wheel Drive Shaft Inner Joint Components

CAUTION: Do not cut through the wheel drive shaft inboard or outboard boot

during service. Cutting through the boot may damage the sealing
surface of the housing and the tripot or the constant velocity joint
bushing. Damage to the sealing surface may lead to water and dirt
intrusion and premature wear of the constant velocity joint.
2. If equipped with a small swage ring, use a hand grinder to cut through the swage ring, taking care not to
damage the halfshaft bar, in order to remove the swage ring. Otherwise, remove the small seal retaining
clamp with a side cutter. Discard the retaining clamp.
3. Remove the large seal retaining clamp (2) from the tripot joint with side cutters. Discard the large seal
retaining clamp.
4. Separate the inboard seal from the trilobal tripot bushing (3) at the large diameter.
5. Slide the seal away from the joint along the halfshaft bar.
Fig. 25: View Of Housing, Tripot Joint Spider & Halfshaft Bar

6. Remove the housing (1) from the tripot joint spider and the halfshaft bar (2).
Fig. 26: View Of Spider Assembly, Rings & Tripot Boot

7. Remove the spacer ring (1), spider assembly (2), spacer ring (3) (if equipped) using GE-396 pliers, and
tripot boot (4). DISCARD the boot and rings.
8. Clean the halfshaft bar (5). Use a wire brush in order to remove any rust in the boot mounting area
(grooves).
9. Inspect the needle rollers, needle bearings, and trunnion. Check the tripot housing for unusual wear,
cracks, or other damage. Replace any damaged parts with the appropriate kit.

Fig. 27: View Of Outboard Seal, Seal Groove & Eared Clamp
NOTE:
Place a towel in the vise before inserting the halfshaft.
1. Mount the halfshaft into a vise.

2. Place the new small eared clamp (2) onto the small end of the joint seal (1). Slide the joint seal (1) and the
eared clamp (2) onto the halfshaft bar.
3. Position the small end of the joint seal (1) into the joint seal groove (3) on the halfshaft bar.

Fig. 28: Identifying Clamp And Special Tool CH-804

4. Crimp the eared clamp (1) using the CH-804 tensioner (1), and a torque wrench. Tighten the eared clamp
to 25 N.m (19 lb ft).

Fig. 29: View Of Spacer Ring

5. Install the spacer ring (2) into the groove of the halfshaft bar using

Fig. 30: Spider Assembly & Spacer Rings

6. Slide the tripot joint spider assembly (4) as far as it will go on the halfshaft bar.
7. Install the spacer ring (2) into the groove of the halfshaft bar, using GE-396 pliers.

Fig. 31: Seal Retaining Clamp, Tripot Bushing & Housing

8. Place approximately 150 grams of the lubricant on the boot and the remaining half of the tripod housing.
Refer to Adhesives, Fluids, Lubricants, and Sealers.
NOTE:
Ensure the trilobal tripot bushing (3) is flush with the face of the housing
(1).
9. Install the trilobal tripot bushing (3) to housing (1).

10. Position the larger new seal retaining clamp (2) on the halfshaft inboard seal.
11. Slide the housing (1) over the tripot joint spider assembly on the halfshaft bar.

Fig. 32: Identifying Axle Shaft/CV Joint Assembly Compontents And Installed Boot Measurement
Dimension
12. Slide the large diameter of the halfshaft inboard seal (2), with larger clamp (3) in place, over the outside
of the trilobal tripot bushing and locate the lip of the seal in the groove.
13. Position the joint assembly at the proper vehicle dimension, a = 106 mm (4.00 in).
14. Carefully insert a thin flat blunt tool, no sharp edges, between the large seal opening and the trilobal tripot
bushing in order to equalize the pressure. Remove the tool.

Fig. 33: Identifying Clamp And Special Tool CH-804

15. Crimp the eared clamp (1) using the CH-804 tensioner (1), and a torque wrench. Tighten the eared clamp
to 25 N.m (19 lb ft).
16. Fully stroke the joint several times to disperse the grease.
17. Install the left or right wheel drive shaft, refer to Front Wheel Drive Shaft Replacement - Left Side, or
Front Wheel Drive Shaft Replacement - Right Side.
FRONT WHEEL DRIVE SHAFT OUTER JOINT AND BOOT REPLACEMENT
Special Tools
GE-396 Snap Ring Pliers

CH-804 Tensioner

Removal Procedure
1. Remove the left or right wheel drive shaft, refer to Front Wheel Drive Shaft Replacement - Left Side,
or Front Wheel Drive Shaft Replacement - Right Side.
Fig. 34: View Of Front Wheel Drive Shaft Inner Joint

2. Clamp the drive axle shaft in a soft jawed vice.

Fig. 35: Identifying Boot Clamps

CAUTION: Do not cut through the wheel drive shaft inboard or outboard boot
during service. Cutting through the boot may damage the sealing
surface of the housing and the tripot or the constant velocity joint
bushing. Damage to the sealing surface may lead to water and dirt
intrusion and premature wear of the constant velocity joint.
3. Use a flat-bladed tool, remove the boot clamp (2) from the constant velocity (CV) joint (1) and the boot
(3).
4. Using a pair of side cutters, remove and discard the boot clamp (4) from the boot (3) and the wheel drive
shaft (5). Replace with NEW clamps.

Fig. 36: Separating CV Joint From Axle Shaft

5. Using a block of wood and a hammer, remove the CV joint (2) from the wheel drive shaft (1).

Fig. 37: Identifying Clamp & Wheel Drive Shaft

6. Remove the boot (1) from the wheel drive shaft (2).
7. Inspect the outer CV joint for damage and wear. Refer to Wheel Drive Shaft Outer Joint Inspection.

Fig. 38: Identifying Clamp & Wheel Drive Shaft

NOTE:
Position the inner boot clamp on the wheel drive shaft prior the boot
assemble.
1. Position the boot (1) on the wheel drive shaft (2).

Fig. 39: Identifying Groove In Wheel Drive Shaft

2. Ensure that the boot (1) is properly seated in the groove (2) in the wheel drive shaft (3).

Fig. 40: Lubricating Boot Of Tripot Housing

3. Place approximately 160 grams of lubricant (2) inside the outboard boot (1) and pack the CV joint (3)
with the remaining lubricant. Refer to Adhesives, Fluids, Lubricants, and Sealers.

Fig. 41: Installing CV Joint

4. Using a block of wood and a hammer, install the CV joint on the wheel drive shaft (1).

Fig. 42: Identifying Boot Clamps

5. Install the boot clamp (4) on the boot (3) and the wheel drive shaft (5).
6. Install the boot clamp (2) on the boot (3) and the CV joint housing (1).
7. Crimp the eared clamp using the CH-804 tensioner (1), and a torque wrench. Tighten the eared clamp to
25 N.m (19 lb ft).
8. Remove the wheel drive shaft from the bench vise.
9. Move the CV joint in a circular motion 4 to 5 times to distribute the lubricant.
10. Install the left or right wheel drive shaft, refer to Front Wheel Drive Shaft Replacement - Left Side, or
Front Wheel Drive Shaft Replacement - Right Side.
WHEEL DRIVE SHAFT OUTER JOINT INSPECTION

Disassembly Procedure
1. Remove the outer constant velocity (CV) joint and boot from the wheel drive shaft. Refer to Front Wheel
Drive Shaft Outer Joint and Boot Replacement.
2. Remove any lubricant from the CV joint.
Fig. 43: Taping Gently On Brass Drift With A Hammer In Order To Tilt Cage
NOTE:
Position the cage and the inner race so they are level.
3. Install the outer CV joint assembly in a soft jawed vise.

NOTE:
The following procedure will have to be repeated until all the ball bearing
are removed form the cage.

4. Using a brass drift (1), gentle tap the cage until the ball bearing can be removed from the cage.
Fig. 44: Ball Bearing & CV Joint

5. Using a small screwdriver, remove the ball bearings (1) from the CV joint (2).

Fig. 45: View Of Ball Removal/Installation Sequence

6. Remove the ball bearings from the CV joint in sequence.

Fig. 46: Positioning Cage & Inner Race 90 Degrees To Centerline Of Outer Race
NOTE:
Position the cage so that the larger radius corners of the cage windows
are facing up.
7. Position the cage (1) at a 90 degrees to the centerline of the outer race (2).
8. Align the cage windows with the lands of the outer race (2).
9. Lift and remove the cage (1) and the inner race from the outer race (2).

Fig. 47: Positioning Cage So Larger Radius Corners Of Cage Windows Are Up
10.
11.
12.
13.
14.
15.
Position the cage (2) and the inner race (1) so that the larger radius corners of the cage windows are up.
Rotate the inner race (1) 90 degrees to the center line of the cage (2).
Align the lands of the inner race (1) with the windows of the cage (2).
Move the inner race (1) land into the cage window (2).
Rotate the inner race (1) down and remove it from the cage (2).
Clean the following items thoroughly with the proper cleaning solvent:
The inner race
The outer race
The cage
The ball bearings
The exposed end of the wheel drive shaft
NOTE:
The internal parts of the CV joint are NOT SERVICED separately. The outer

CV joint is serviced as an assembly.

16. If any of the above items are found to have excessive wear or are damaged, replace the outer CV joint as
an assembly.
Assembly Procedure
Fig. 48: Positioning Cage So Larger Radius Corners Of Cage Windows Are Up
1.
2.
3.
4.
5.
6.
7.
Position the cage (2) so that the larger radius corners of the cage windows are up.
Position the inner race (1) 90 degrees to the centerline of the cage (2).
Insert the inner race (1) through the bottom of the cage (2).
Align the lands of the inner race (1) with the windows of the cage (2).
Move the inner race (1) land into the cage window (2).
Rotate the inner race (1) down and remove it from the cage (2).
Rotate the inner race (1) within the cage (2) so that the grooved surface of the inner race (1) is facing up.

8. Align the inner race (1) ball bearing tracks with the cage (2) windows.
Fig. 49: Positioning Cage & Inner Race 90 Degrees To Centerline Of Outer Race
9.
10.
11.
12.
Wrap a clean shop towel around the CV joint outer race splined shaft.
Place the outer race (2) vertically in a bench vise.
Position the cage (1) and the inner race at a 90 degrees to the centerline of the outer race (2).
With the inner race and the cage (1) assembly in a vertical position, insert the cage and the inner race into
the outer race (2).

Fig. 50: Ball Bearing & CV Joint

NOTE:
The larger radius corners of the cage windows should be positioned up

and the grooved surface of the inner race should be visible.
13. Position the cage (2) and the inner race so that they are level in the vise.
14. Rotate the appropriate component(s), and align the cage windows and the inner race ball bearing (1)
tracks with the outer race ball bearing tracks.
15. Position a cage window and the inner race ball bearing track for the ball bearing installation.
NOTE:
When performing the following procedure, the opposing cage (2) window
and the inner ball bearing (1) track will be accessible for the ball bearing
installation.
16. Press down on the cage following one of the outer race ball bearing (1) tracks.
17. Install the ball bearing through the cage window onto the inner race ball bearing (1) track.

NOTE:
The following service procedure will have to be performed after each ball
bearing (1) has been installed.
18. After the first ball bearing (1) has been installed, use a brass drift and a hammer and gently tap the cage in
order to drive the cage and the inner race down completely in the outer race.
NOTE:
After the ball bearing (1) has been installed, there should be NO GAP
between the ball bearing and the inner race.
19. Position the cage and the inner race so that they are level.
20. Using a plastic hammer, lightly tap the ball bearing (1) into place.
Fig. 51: View Of Ball Removal/Installation Sequence

21. Install the ball bearings in sequence.
22. Repeat steps 18 thru 20 until all the ball bearings are installed.

23. Install the outer CV joint and boot on the wheel drive shaft. Refer to Front Wheel Drive Shaft Outer
Joint and Boot Replacement.

WHEEL DRIVE SHAFTS DESCRIPTION AND OPERATION
Front wheel drive axles are flexible assemblies.
Front wheel drive axles consist of the following components:
A front wheel drive shaft tripot joint (inner joint)

A front wheel drive shaft constant velocity joint (outer joint)
A front wheel drive shaft
The front wheel drive shaft connects the front wheel drive shaft tripot joint and the front wheel drive shaft
constant velocity joint.
The front wheel drive shaft tripot joint is completely flexible. The front wheel drive shaft tripot joint can move
in and out.
The front wheel drive shaft constant velocity joint is flexible, but the front wheel drive shaft constant velocity
joint cannot move in and out.
Boots (Seals) And Clamps
The front wheel drive shaft constant velocity joint and the front wheel drive shaft tripot joint boots (seals) in the
front wheel drive axle are made of a thermoplastic material.
The clamps in the front wheel drive axle are made of stainless steel.
The boot (seal) provides the following functions:
Protection of the internal parts of the front wheel drive shaft constant velocity joint and the front wheel
drive shaft tripot joint
The boot (seal) protects the grease from the following sources of damage:
Harmful atmospheric conditions, such as extreme temperatures or ozone gas
Foreign material, such as dirt or water
Allows angular movement and the axial movement of the front wheel drive shaft tripot joint
Allows angular movement of the front wheel drive shaft constant velocity joint
NOTE:
Protect the boots (seals) from sharp tools and from the sharp edges of the
surrounding components.

Any damage to the boots (seals) or the clamps will result in leakage. Leakage
will allow water to leak into the front wheel drive shaft tripot joint and the front
wheel drive shaft constant velocity joints. Leakage will also allow grease to leak
out of the front wheel drive shaft tripot joints and the front wheel drive shaft
constant velocity joints.
Leakage may cause noisy front wheel drive axle operation and eventual failure
of the internal components.
The clamps provide a leak proof connection for the front wheel drive shaft tripot joint and the front wheel drive
shaft constant velocity joint at the following locations:
The housing
The front wheel drive shaft
The thermoplastic material performs well under normal conditions and normal operation. However, the material
is not strong enough to withstand the following conditions:
Abusive handling
Damage from sharp objects, such as sharp tools or any sharp edges of the surrounding components in the
vehicle
Front Wheel Drive Shaft Tripot Joint (Inner Joint)
The front wheel drive shaft tri-pot joint is made with the tripot design without an over-extension limitation
retainer.
The joint is constructed as follows for vehicles that are equipped with an automatic transmission:
The left front wheel drive axle has a female spline. The female spline installs over a stub shaft that
protrudes from the transaxle.
The right front wheel drive axle has a male spline. The right front wheel drive axle uses barrel type snap
rings in order to interlock with the transaxle gears.
Front Wheel Drive Shaft Constant Velocity Joint (Outer Joint)
The front wheel drive shaft constant velocity joint is made with the Rzeppa joint design.
The shaft end (which mates with the knuckle/hub) has a helical spline. The helical spline ensures a tight, presstype fit.
This design prevents end play between the hub bearing and the front wheel drive axle.

SPECIAL TOOLS

Illustration

GE-313
KM-313
J-2619-01
J-6125-1B
Slide Hammer
GE-396
GE-8059
J-8059
Snap Ring Pliers
CH-804
KM-804
J-35566
J-35910
J-42572, or equivalent
Boot Clamp Pliers
CH-6003
KM-6003
J-42943
Axle Shaft Remover
DT-6332
KM-6332
J-44396
J-44394-A
Seal Protector
DT-29794
J 29794
Axle Shaft Remover Extension
CH-49400
J-42129
J-45859
Hub Spindle Remover

2013 ELECTRICAL Power Outlets - Cruze
2013 ELECTRICAL
Power Outlets - Cruze

CIGAR LIGHTER/POWER OUTLET WIRING SCHEMATICS
Cigar Lighter and Power Outlet
Fig. 1: Cigar Lighter/Power Outlet Wiring Schematics

Callout
801
CAV_1
CAV 1
801_VT
801_VT
801_VT
801_VT
2150
Component Name
Retained Accessory Power Fuse Supply Voltage
1
1
801 VT
801 VT
801 VT
801 VT
Ground

2150_BK
CAV_3
1650
1650_BK
CAV_3
CAV_23
CAV_24
X300
CAV_5
CAV_19
F7DA
F6DA
X300
X80L
E32
KR76
X51A
2150 BK
3
Ground
1650 BK
3
23
24
X300
5
19
F7DA 20A
F6DA 20A
X300

SYMPTOMS - POWER OUTLETS
Inspect for aftermarket devices which can affect the operation of the power outlets. Refer to Checking
Aftermarket Accessories
Intermittent
Electrical connections or wiring may be the cause of intermittent conditions. Refer to Testing for Intermittent
Conditions and Poor Connections
Symptom List
Refer to Power Outlet Receptacle Malfunction in order to diagnose the system.

POWER OUTLET RECEPTACLE MALFUNCTION

Short to
Ground
Ignition
1
Ground
1. Accessory Power Receptacle Malfunction
Circuit
Open/High
Resistance
1
1
Short to
Voltage
-
Signal Performance
-
The vehicle is fitted with a 12 V accessory power receptacle. The accessory power outlets are controlled by an
ignition operated relay. The accessory power receptacle is operational when the ignition is turned to either the
On or the Accessories positions.
Diagnostic Aids
It may be helpful to discuss with the customer the usage of any device that may have drawn too much current
and caused an open fuse.
Schematic Reference
Cigar Lighter/Power Outlet Schematics
Power Outlets Description and Operation
Circuit Testing
Connector Repairs

Wiring Repairs
1. Ignition ON, connect an appropriate device to the X80 Accessory Power Receptacle.
2. Verify the device is powered by the X80 Accessory Power Receptacle.
If the device is not powered
If the device is powered
3. All OK.
1. Ignition OFF, disconnect the harness connector at the appropriate X80 Accessory Power Receptacle or
E32 Cigarette Lighter Receptacle.
1. Ignition OFF.
3. Ignition ON.
4. Verify that a test lamp illuminates between the control circuit terminal A and ground.
1. Ignition OFF.
If greater than 2 ohms, repair the open/high resistance in the circuit.
If less than 2 ohms, verify the fuse is not open and there is voltage at the fuse. Refer to
Retained Accessory Power Malfunction .
1. Ignition OFF.
2. Test for infinite resistance between the control circuit terminal A and ground.
If infinite resistance, replace the appropriate X80 Accessory Power Receptacle.
5. Replace the appropriate X80 Accessory Power Receptacle or E32 Cigarette Lighter Receptacle.
Repair Instructions


Accessory Power Receptacle Replacement
REPAIR INSTRUCTIONS
ACCESSORY POWER RECEPTACLE RETAINER REPLACEMENT
Fig. 2: Identifying Accessory Power Receptacle Retainers

Accessory Power Receptacle Retainer Replacement
Callout
Component Name
Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and
Connection .
Special Tools
BO-48871 Accessory Power Receptacle Remover
Fro equivalent regional tools, refer to Special Tools.
Accessory Power Receptacle Retainer
1
Procedure
2
ACCESSORY POWER RECEPTACLE REPLACEMENT

Fig. 3: Identifying Accessory Power Receptacle And Retainer

Accessory Power Receptacle Replacement
Callout
Component Name
Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and
Connection .
Special Tools
BO-48871 Accessory Power Receptacle Remover
1
Accessory Power Receptacle
2
Procedure

POWER OUTLETS DESCRIPTION AND OPERATION
12 Volt Power Outlet Receptacle Description and Operation
The 12 V accessory power receptacles are supplied with power by the accessory relay.
The vehicle is fitted with a cigarette lighter and/or with a 12 V accessory power receptacle. The cigarette lighter

and accessory power outlets are controlled by an ignition operated relay. The accessory power receptacle and
cigarette lighter are operational when the ignition is turned to either the On or the Accessories positions. To
operate the cigarette lighter, press in the lighter knob. When the element is hot, the lighter automatically pops
out and is ready for use.
110 Volt Power Outlet Receptacle System Description
The alternating current (AC) accessory power outlet system consists of the accessory DC/AC power inverter
module and the accessory power receptacle - 110 V AC. The accessory DC/AC power inverter module converts
12 V direct current (DC) battery power to 110 V at 60 Hertz (Hz) AC power to operate AC powered devices.
The accessory DC/AC power inverter module provides up to 150 watts of power. The accessory power
receptacle - 110 V AC provides the usual connection for AC powered devices.
110 Volt Power Outlet Receptacle System Operation
The accessory DC/AC power inverter module receives fuse protected battery voltage and is connected to the 12
V electrical system ground. The accessory power receptacle - 110 V AC has an internal switch, that detects
when an AC powered device is plugged into the outlet. When the ignition is ON, and an AC powered device is
plugged into the accessory power receptacle - 110 V AC, the normally open switch in the accessory power
receptacle - 110 V AC, closes. When the accessory DC/AC power inverter module detects the voltage from the
accessory power receptacle - 110 V AC switch, the inverter module begins to supply 110 V AC to the accessory
power receptacle - 110 V AC after a 1.5 s delay. The accessory AC power system is protected against circuit
overload and circuit shorts to ground.
110 Volt Power Outlet Receptacle Isolation Fault Protection
The accessory DC/AC power inverter module contains a ground fault circuit interrupter (GFCI). GFCI monitors
the 110 V circuit for a short to vehicle chassis ground. If a 110 V AC short to ground is detected, the accessory
DC/AC power inverter module will turn OFF. The module remains OFF, until the AC powered device is
unplugged from the outlet, and then plugged into the outlet after a 3 s delay.
110 Volt Power Outlet Receptacle Overload Shutdown
The accessory DC/AC power inverter module will turn OFF if the current in the 110 V circuit is greater than 3.8
A for 1 s, or 2.5 A for 10 s. The module will turn ON again, when the AC powered device is unplugged from
the outlet, and then plugged into the outlet after a 3 s delay.
110 Volt Power Outlet Receptacle Internal Shutdown
The accessory DC/AC power inverter module will turn OFF if the B+ supply voltage is greater than 16.5 V or
less than 11 V. The module will also turn OFF if the device temperature is greater than 85C (185F). The
module will turn ON again, after the shutdown condition is corrected, and the AC powered device is unplugged
from the outlet, and then plugged into the outlet.

SPECIAL TOOLS

Illustration

BO-48871
J-42059
Accessory Power Receptacle Remover

2013 ELECTRICAL Wiring Systems and Power Management - Component Locator - Door Component Views - Cruze
2013 ELECTRICAL
Wiring Systems and Power Management - Component Locator - Door Component Views Cruze
DOOR COMPONENT VIEWS

DRIVER DOOR COMPONENTS
Fig. 1: Driver Door Components

Items
1: A23D Door Latch Assembly - Driver A23D Door Latch Assembly - Driver
2: A9A Outside Rearview Mirror - Driver A9A Outside Rearview Mirror - Driver
3: S52 Outside Rearview Mirror Switch S52 Outside Rearview Mirror Switch
4: P19AG Speaker - Left Front Door P19AG Speaker - Left Front Door
5: S79D Window Switch - Driver S79D Window Switch - Driver (AEC) S79D Window Switch Driver (AXG)
6: M74D Window Motor - Driver M74D Window Motor - Driver (AEC) M74D Window Motor Driver (AXG)
PASSENGER DOOR COMPONENTS

Fig. 2: Passenger Door Components

Items
1: A9B Outside Rearview Mirror - Passenger A9B Outside Rearview Mirror - Passenger
2: A23P Door Latch Assembly - Passenger A23P Door Latch Assembly - Passenger
3: M74P Window Motor - Passenger M74P Window Motor - Passenger
4: P19AH Speaker - Right Front Door P19AH Speaker - Right Front Door
5: S79P Window Switch - Passenger S79P Window Switch - Passenger
LEFT REAR DOOR COMPONENTS

Fig. 3: Left Rear Door Components

Items
1: A23LR Door Latch Assembly - Left Rear A23LR Door Latch Assembly - Left Rear
2: S79LR Window Switch - Left Rear S79LR Window Switch - Left Rear
3: P19AL Speaker - Left Rear Door P19AL Speaker - Left Rear Door
4: M74LR Window Motor - Left Rear M74LR Window Motor - Left Rear
RIGHT REAR DOOR COMPONENTS

Fig. 4: Right Rear Door Components

Items
1: S79RR Window Switch - Right Rear S79RR Window Switch - Right Rear
2: A23RR Door Latch Assembly - Right Rear A23RR Door Latch Assembly - Right Rear
3: M74RR Window Motor - Right Rear M74RR Window Motor - Right Rear
4: P19AM Speaker - Right Rear Door P19AM Speaker - Right Rear Door

2013 ELECTRICAL Wiring Systems and Power Management - Component Locator - Electrical Center Identification
Views - Cruze
2013 ELECTRICAL
Wiring Systems and Power Management - Component Locator - Electrical Center Identification
Views - Cruze
ELECTRICAL CENTER IDENTIFICATION VIEWS

X50A FUSE BLOCK - UNDERHOOD LABEL
Fig. 1: X50A Fuse Block - Underhood Label

X50A FUSE BLOCK - UNDERHOOD TOP VIEW

Views - Cruze
Fig. 2: X50A Fuse Block - Underhood Top View

X50A Fuse Block - Underhood Usage
Device Label
Device Assigned
No.
Name
Name
Rating
F1UA: 1
F1UA: -
F1UA: F1UA Fuse
F1UA: 15A
F2UA: 2
F2UA: -
F2UA: F2UA Fuse
F2UA: 15A
F3UA: 3
F3UA: -
F3UA: F3UA Fuse
F3UA: -
F4UA: 4
F4UA: -
F4UA: F4UA Fuse
F4UA: 10A
F5UA: 5
F5UA: -
F5UA: F5UA Fuse
F5UA: 15A
Description
F1UA: Q8 Control Solenoid
Valve Assembly (MH8)
F2UA: K20 Engine Control
Module
F3UA: Not Used
F4UA: Q13 Evaporative
Emission Vent Solenoid
Valve
Module, Q8 Control
Solenoid Valve Assembly

Views - Cruze
F6UA: 6
F6UA: -
F6UA: F6UA Fuse
F7UA: 7
F8UA: 8
F7UA: F8UA: -
F7UA: F7UA Fuse

F8UA: F8UA Fuse
F9UA: 9
F9UA: -
F9UA: F9UA Fuse
F10UA: 10
F10UA: -
F10UA: F10UA Fuse
F11UA: 11
F11UA: -
F11UA: F11UA Fuse
F12UA: 12
F12UA: -
F12UA: F12UA Fuse
F13UA: 13
F14UA: 14
F15UA: 15
F13UA: F14UA: F15UA: -
F13UA: F13UA Fuse

F14UA: F14UA Fuse
F15UA: F15UA Fuse
F16UA: 16
F16UA: -
F16UA: F16UA Fuse
F17UA: 17
F17UA: -
F17UA: F17UA Fuse
F18UA: 18
F18UA: -
F18UA: F18UA Fuse
F19UA: 19
F20UA: 20
F19UA: F20UA: -
F19UA: F19UA Fuse

F20UA: F20UA Fuse
F21UA: 21
F21UA: -
F21UA: F21UA Fuse
F22UA: 22
F23UA: 23
F22UA: F23UA: -
F22UA: F22UA Fuse

F23UA: F23UA Fuse
F24UA: 24
F24UA: -
F24UA: F24UA Fuse
F25UA: 25
F25UA: -
F25UA: F25UA Fuse
(MH8)
F6UA: KR12B Windshield
Wiper Relay, KR12C
F6UA: 30A
Windshield Wiper Speed
Control Relay
F7UA: F7UA: Not Used
F8UA: 15A F8UA: Not Used
F9UA: Q17A Fuel Injector
1, Q17B Fuel Injector 2,
F9UA: 15A Q17C Fuel Injector 3, Q17D
Fuel injector 4, T8 Ignition
Coil
F10UA: 15A
Module
F11UA: B75B Mass Air
F11UA: 10A Flow/Intake Air Temperature
Sensor
F12UA: KR27 Starter Motor
F12UA: 30A
Relay
F13UA: 7.5A F13UA: Not Used
F16UA: B108 Air Quality
Sensor (C68), M96 Active
F16UA: 7.5A
Grille Air Shutter Actuator
(Y8X)
F17UA: K36 Inflatable
F17UA: 5A Restraint Sensing and
Diagnostic Module
F18UA: K27 Fuel Pump
F18UA: 10A
Control Module
F21UA: S79LR Window
F21UA: 30A Switch - Left Rear, S79RR
Window Switch - Right Rear
F24UA: M74D Window
Motor - Driver (AXG), S79D
F24UA: 30A Window Switch - Driver
(AEC), S79P Window
Switch - Passenger
F25UA: M9 Brake Booster
F25UA: Pump Motor

Views - Cruze
F26UA: 26
F26UA: -
F26UA: F26UA Fuse
F26UA: 40A
F27UA: 27
F27UA: -
F27UA: F27UA Fuse
F27UA: -
F28UA: 28
F28UA: -
F28UA: F28UA Fuse
F28UA: 40A
F29UA: 29
F29UA: -
F29UA: F29UA Fuse
F29UA: -
F30UA: 30
F30UA: -
F30UA: F30UA Fuse
F30UA: 15A
F31UA: 31
F31UA: -
F31UA: F31UA Fuse
F31UA: 20A
F32UA: 32
F32UA: -
F32UA: F32UA Fuse
F32UA: 20A
F33UA: 33
F33UA: -
F33UA: F33UA Fuse
F33UA: 30A
F34UA: 34
F34UA: -
F34UA: F34UA Fuse
F34UA: 25A
F35UA: 35
F35UA: -
F35UA: F35UA Fuse
F35UA: 30A
F36UA: 36
F36UA: -
F36UA: F36UA Fuse
F36UA: -
F37UA: 37
F37UA: -
F37UA: F37UA Fuse
F37UA: 10A
F38UA: 38
F38UA: -
F38UA: F38UA Fuse
F38UA: 10A
F39UA: 39
F40UA: 40
F41UA: 41
F39UA: F39UA Fuse

F40UA: F40UA Fuse
F41UA: F41UA Fuse
F42UA: 42
F42UA: -
F42UA: F42UA Fuse
F42UA: 30A
F43UA: 43
F44UA: 44
F43UA: F44UA: -
F43UA: F43UA Fuse

F44UA: F44UA Fuse
F45UA: 45
F45UA: -
F45UA: F45UA Fuse
F43UA: F44UA: F45UA:

40A/60A
F46UA: 46
F46UA: -
F46UA: F46UA Fuse
F46UA: 10A
F26UA: K17 Electronic

Brake Control Module
F27UA: Not Used
F28UA: E18 Rear Defogger
Grid
F29UA: Not Used
F30UA: K17 Electronic
Brake Control Module
F31UA: Body Control
Module
F32UA: K9 Body Control
Module
F33UA: K29 Seat Heating
Control Module (KA1)
F34UA: K61 Sunroof
Control Module (CF5)
F35UA: T3 Audio Amplifier
(UQA)
F36UA: Not Used
F37UA: E13R Headlamp Right
F38UA: E13L Headlamp Left
F39UA: Not Used
F40UA: Not Used
F41UA: Not Used
F42UA: KR20P Cooling Fan
Medium Speed Relay,
KR20C Cooling Fan Low
Speed Relay
F43UA: Not Used
F44UA: Not Used
F45UA: KR20D Cooling
Fan High Speed Relay
F46UA: KR20C Cooling
Fan Low Speed Relay,
KR20E Cooling Fan Speed
Control Relay, KR20F
Cooling Fan Relay
F47UA: B52A Heated
Oxygen Sensor 1, B52B
Heated Oxygen Sensor 2,
E41 Engine Coolant
Thermostat Heater, Q12

Views - Cruze
F47UA: 47
F47UA: -
F47UA: F47UA Fuse
F48UA: 48
F48UA: -
F48UA: F48UA Fuse
F49UA: 49
F50UA: 50
F51UA: 51
F49UA: F49UA Fuse

F50UA: F50UA Fuse
F51UA: F51UA Fuse
F52UA: 52
F52UA: -
F52UA: F52UA Fuse
F53UA: 53
F53UA: -
F53UA: F53UA Fuse
F54UA: 54
F54UA: -
F54UA: F54UA Fuse
F55UA: 55
F55UA: -
F55UA: F55UA Fuse
F56UA: 56
F56UA: -
F56UA: F56UA Fuse
F57UA: 57
F57UA: -
F57UA: F57UA Fuse
F58UA: 58
F59UA: 59
F58UA: F59UA: -
F58UA: F58UA Fuse

F59UA: F59UA Fuse
F60UA: 60
F60UA: -
F60UA: F60UA Fuse
F61UA: 61
F61UA: -
F61UA: F61UA Fuse
F62UA: 62
F62UA: -
F62UA: F62UA Fuse
F63UA: 63
F63UA: -
F63UA: F63UA Fuse
F64UA: 64
F64UA: -
F64UA: F64UA Fuse
Evaporative Emission Purge

Solenoid Valve, Q22 Intake
Manifold Tuning Solenoid
valve (LUW), Q40
F47UA: 10A
turbocharger Bypass
Solenoid Valve (LUJ), Q42
Turbocharger Wastegate
Solenoid Valve (LUJ)
F48UA: E29LF Fog Lamp Left Front (T3U), E29RF
F48UA: 15A
Fog Lamp - Right Front
(T3U)
F51UA: 15A F51UA: P12 Horn
F52UA: P16 Instrument
F52UA: 5A
Cluster
F53UA: A10 Inside
F53UA: 10A
Rearview Mirror (DD8)
F54UA: K33 HVAC Control
F54UA: 5A Module, P14 Passenger Air
Bag Disable Indicator
F55UA: S52 Outside
Rearview Mirror Switch,
F55UA: 7.5A
S79D Window Switch Driver (AXG)
F56UA: G24 Windshield
F56UA: 15A
Washer Pump
F57UA: K60 Steering
F57UA: 15A Column Lock Control
Module (ULS)
F60UA: A9A Outside
Rearview Mirror - Driver
F60UA: 7.5A (DWE), A9B Outside
Rearview Mirror - Passenger
(DWE)
F62UA: KR29 A/C
F62UA: 10A Compressor Clutch Relay
(LUW)
F64UA: K85 Passenger
F64UA: 5A
Presence Detection Module

Views - Cruze
F65UA: 65
F66UA: 66
F65UA: F66UA: -
F65UA: F65UA Fuse

F66UA: F66UA Fuse
F65UA: F66UA: -
F67UA: 67
F67UA: -
F67UA: F67UA Fuse
F67UA: 20A
F68UA: 68
F68UA: -
F68UA: F68UA Fuse
F68UA: -
F69UA: 69
F69UA: -
F69UA: F69UA Fuse
F69UA: 5A
F70UA: 70
F71UA: 71
Relays
F70UA: F71UA: -
F70UA: F70UA Fuse

F71UA: F71UA Fuse
F70UA: F71UA: -
KR29: 1
KR29: -
KR27: 2
KR27: -
KR20F: 3
KR20F: -
KR12C: 4
KR12C: -
KR29: KR29 A/C

Compressor Clutch
Relay
KR27: KR27 Starter
Relay
KR20F: KR20F
Cooling Fan Relay
KR12C: KR12C
Windshield Wiper
Speed Control Relay
KR29: -
KR29: Q2 A/C Compressor

Clutch (LUW)
KR27: -
KR27: M64 Starter Motor
KR20F: -
KR20F: KR20F Cooling

Fan Relay
KR12C: -
KR12C: M75 Windshield

Wiper Motor
KR12B: 5
KR12B: -
KR12B: KR12B
Windshield Wiper
Relay
KR75: 7
KR75: -
KR75: KR75 Engine

Controls Ignition
Relay
KR75: -
KR20P: 9
KR20P: -
KR20C: 10
KR20C: -
11
KR20E: 12
KR20E: -
KR20D: 13
KR20D: -
KR20P: KR20P
Cooling Fan Medium
Speed Relay
KR20C: KR20C
Cooling Fan Low
Speed Relay
KR20E: KR20E
Cooling Fan Speed
Control Relay
KR20D: KR20D
Cooling Fan High
F65UA: Not Used

F66UA: Not Used
F67UA: K27 Fuel Pump
Control Module
F68UA: Not Used
F69UA: K9 Body Control
Module
F70UA: Not Used
F71UA: Not Used
KR12B: -
KR12B: KR12C Windshield

Wiper Speed Control Relay,
M75 Windshield Wiper
Motor
Not Used
KR75: F9UA Fuse, F10UA
Fuse, F11UA Fuse, F46UA
Fuse, F47UA Fuse, KR20P
Cooling Fan Medium Speed
Relay, KR29 A/C
Compressor Clutch Relay
(LUW)
Not Used
KR20P: -
KR20P: Cooling Fan

Medium Speed Relay
KR20C: -
KR20C: Cooling Fan Low

Speed Relay
KR20E: KR20D: -
Not Used
KR20E: KR20E Cooling
Fan Speed Control Relay
KR20D: Cooling Fan High

Views - Cruze
14
KR73: 15
KR73: -
16
KR5: 17
KR5: -
Speed Relay
KR73: KR73 Ignition
Main Relay
KR5: KR5 Rear
Window Defogger
Relay
KR73: -
KR5: -
Speed Relay
Not Used
KR73: F5UA Fuse, F13UA
Fuse, F57UA Fuse
Not Used
KR5: F28UA Fuse
NOTE:
Relays listed below are non-serviceable Printed Circuit Board (PCB) relays and are internal to the
block
KR3 Horn Relay
KR114 Door Lock

Security Relay
KR46 Front Fog

Lamp Relay
KR48 Headlamp High
Beam Relay
KR11 Windshield
Washer Pump Relay
X50A FUSE BLOCK - UNDERHOOD BOTTOM VIEW
F51UA Fuse
A23D Door Latch Assembly
- Driver, A23P Door Latch
Assembly - Passenger,
A23LR Door Latch
Assembly - Left Rear,
A23RR Door Latch
Assembly - Right Rear
F48UA Fuse
F37UA Fuse, F38UA Fuse
F56UA Fuse

Views - Cruze
Fig. 3: X50A Fuse Block - Underhood Bottom View

X50A FUSE BLOCK - UNDERHOOD X1
Connector Part Information
Harness Type: Forward Lamp

OEM Connector: 13732286
Service Connector: 13580740
Description: 82-Way F DSQ 1.5 2.8 Metri-Pack 800 Series (BK)
Terminal Part Information

Terminal
Type ID
Terminated Diagnostic
Lead
Test Probe
13575760
II
13578869
Terminal
Removal
Tool
Service
Terminal
J-35616-35
J-38125-36 2-964284-1
(VT)
J-35616-14
J-38125-560 962943-5
(GN)
Tray
Core
Crimp
Insulation
Crimp
25
16

Views - Cruze
III
13575718
IV
13579931
13575491
J-35616-44
J-38125-558 12110127
(YE)
J-35616-2A
J-38125-560 965914-1
(GY)
J-35616-35
J-38125-36 4-965999-1
(VT)
19
32
25
X50A Fuse Block - Underhood X1

Pin
Color
Circuit
Function
1-10
11: 11 11: 1
12
-
11: BN/GY
-
11: 29
-
13: 13 13: 1.5
13: WH
13: 311
14: 14 14: 1.5
14: WH
14: 711
Not Occupied
11: Horn Control
Not Occupied
13: Right Headlamp High
Beam Control
14: Left Headlamp High
Beam Control
Not Occupied
20: Cooling Fan Motor
Supply Voltage (4)
Not Occupied
30: Windshield Washer
Pump Control
31: Front Fog Lamp
Control
Not Occupied
34: Cooling Fan Control
Relay Speed Signal
Not Occupied
43: Cooling Fan Control
Relay Speed Signal
Not Occupied
Control (2)
Control (1)
Not Occupied
Control (3)
Not Occupied
53: A/C Pressure Sensor 5
Volt Reference
15-19
Size
20: 20 20: 0.5 20: RD/WH

21-29
30: 30 30: 1
31: 31
32-33
31:
0.75
-
30: GY/VT
30: 228
31: VT/BN
31: 34
34: 34 34: 2.5 34: WH/BK

35-42
43: 43 43: 2.5 43: WH/BK

44-45
46: 46 46: 4
50: 50 50: 4
51-52
53: 53 53: 0.5
34: 2366
43: 2366
46: GY
46: 532
47: 47 47: 2.5 47: WH/D-BU

48-49
20: 999
47: 409
50: YE
50: 5358
53: BN/RD
53: 2700
54: 54 54: 0.5 54: BK/D-BU
54: 6813
54: Coolant Temperature
Terminal Type
ID
11: I
-
Option
11: -
13: II
13: -
14: II
14: -
20: II
20: -
30: II
30: -
31: II
31: -
34: -
34: -
43: III
43: -
46: III
46: -
47: III
47: -
50: III
50: -
53: II
53: -
54: II
54: -

Views - Cruze
55: 55 55: 0.5
55: BK/BN
55: 5514
56: 56 56: 0.5 56: D-GN/VT
56: 2032
57: 57 57: 0.5
57: D-GN
57: 380
58-64
Sensor 2 Low Reference

55: A/C Refrigerant
Pressure Sensor Low
Reference
Sensor Signal
57: A/C Refrigerant
Pressure Sensor Signal
Not Occupied
65: Run/Crank Ignition 1
Voltage
Supply Voltage (4)
Supply Voltage (4)
Supply Voltage (4)
Not Occupied
71: Ground
72: Windshield Wiper
Motor High Speed Control
Motor Low Speed Control
74: Ground
Not Occupied
65: 65 65: 0.5 65: VT/D-GN
65: 1339
66: 66 66: 0.5 66: RD/WH
66: 999
67: 67 67: 0.5
67: D-GN
67: 7625
68: 68 68: 0.5
68: D-GN
68: 7625
69-70
71: 71 71: 2.5
71: BK
71: 1150
72: 72 72: 2.5
72: WH
72: 92
73: 73 73: 2.5
73: YE/BN
73: 95
74: 74 74: 2.5

75-82
-
74: BK
-
74: 50
-
55: II
55: -
56: II
56: -
57: II
57: -
65: II
65: IV
65: C68
66: -
66: -
67: II
67: -
68: -
68: -
71: V
71: -
72: V
72: -
73: V
73: -
74: V
-
74: -
Harness Type: Body

Service: 13576544
Description: 74-Way F 1.5/2.8 DSQ Metri-Pack 800 Series (BK)

Terminal
Type ID
Lead
Test Probe
J-35616-35
Terminal
Removal
Tool
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp

Views - Cruze
13575760
II
13575718
III
13578869
IV
13575491
(VT)
J-35616-44
(YE)
J-35616-14
(GN)
J-35616-35
(VT)
J-38125-36 2-964284-1
25
J-38125-558
12110127
19
J-38125-560
962943-5
16
25
J-38125-36 4-965999-1

Pin
Size
Color
Circuit
Function
1-3
4: GY
4: 295
Not Occupied
4: Door Lock Actuator
Lock Control SAE
5: Child Security Lock
Motor Unlock Control SAE
Not Occupied
10: A/C Compressor
Clutch Control
Not Occupied
12: 3271
12: Door Lock Control (2)
4: 4 4: 0.75
5: 5 5: 0.75 5: WH/D-BU
6-9
10: 10 10: 0.5 10: BN/D-GN

11
12: 12
13: 13
14: 14
15: 15
16
12:
12: GY/D-GN
0.75
13:
13: VT/YE
0.75
14: 0.5 14: VT/D-GN
15: 0.5 15: VT/BK
-
17: 17 17: 0.5

18
10: 59
13: 3267
14: 3039
15: 739
-
17: BN/VT
17: 1594
19: 19 19: 0.5 19: BN/WH

20
5: 3266
21: 21 21: 0.5 21: D-BU/BN
19: 1317
21: 7573
22: 22 22: 0.5
22: GY
22: 91
23: 23 23: 0.5
23: RD/GY
23: 2840
24
25: 25 25: 0.5 25: BN/WH
26: 26 26: 0.5 26: VT/WH
27
-
25: 28
26: 239
-

Relay Control
14: Ignition Voltage
Not Occupied
17: Ignition 3 Relay
Control
Not Occupied
19: Fog Lamp Relay
Control
Not Occupied
21: Electric Variable
Displacement Supply
Motor Relay Coil Control
23: Battery Positive
Voltage
Not Occupied
25: Horn Relay Control
Not Occupied
Terminal Type
ID
-
Option
-
4: I
4: -
5: I
5: -
10: -
10: -
12: III
12: SAE
13: III
13: SAE
14: III
15: III
-
14: 15: -
17: III
17: -
19: III
19: -
21: III
21: -
22: III
22: -
23: III
23: -
25: III
26: III
-
25: 26: -

Views - Cruze
28: 0.5 28: RD/D-GN

28: 28
28: 0.5 28: RD/GY
28: 1540
28: 2840
29: 29 29: 0.5 29: VT/WH

30
31: 31 31: 0.5 31: VT/WH
32
-
29: 239
31: 2839
-
33: 33 33: 4
33: RD/BN
33: 2940
34-35
36: 36 36: 4 36: RD/D-GN

37-38
39: 39 39: 4
39: BN/VT
39: 293
40: 40 40: 2.5
40: RD/VT
40: 1940
41: 41 41: 4
41: RD/VT
41: 1640
42-55
36: 1540
56: 56 56: 1 56: RD/D-GN

57
56: 1840
58: BN/VT
58: 1969
60: 60 60: 0.5
60: BN/GY
60: 2268
61: 61 61: 0.5
61: BN/VT
61: 193
62: 62 62: 0.5
62: BN/YE
62: 2267
63: 63 63: 0.5
63: RD/GY
63: 402
58: 58 58: 0.5

59
64-66
67: 67 67: 1.5 67: RD/WH
67: 2740
68: 68 68: 1.5
68: RD/VT
68: 2640
69: 69 69: 2.5 69: RD/WH
69: 2040
70: 70 70: 2.5 70: RD/WH
70: 140

Voltage
Voltage
Not Occupied
Not Occupied
Voltage
Not Occupied
Voltage
Not Occupied
39: Rear Defog Element
Control
Voltage
Voltage
Not Occupied
Voltage
Not Occupied
58: Headlamp High Beam
Relay Control
Not Occupied
Relay Control
61: Rear Defog Relay
Control
62: Mirror Heating
Element Control
Voltage
Not Occupied
Voltage
Voltage
Voltage
Voltage
28: III
28: DWY or
DWE
29: III
31: III
-
29: 31: DD8

-
33: II
33: AEQ
36: II
36: -
39: II
39: -
40: II
40: -
41: II
41: -
56: III
56: -
58: III
58: -
60: III
60: -
61: III
61: -
62: III
62: -
63: III
63: -
67: IV
67: -
68: IV
68: -
69: IV
69: -
70: IV
70: -

Views - Cruze
71: 71 71: 2.5 71: RD/WH
71: 1040
72: 72 72: 0.5
72: 1440
72: RD/BN
73: 73 73: 0.5 73: D-BU/BN
73: 7573
74: 74 74: 2.5
74: 1740
74: RD/GY

Voltage
Voltage
Displacement Supply
Voltage
71: IV
71: UQG
72: I
72: -
73: -
73: -
74: IV
74: -
X50A FUSE BLOCK - UNDERHOOD X3 (LUV)

Harness Type: Engine

Terminal Terminated Diagnostic
Type ID
Lead
Test Probe
I
13575860
II
13578869
III
13575860
Terminal
Removal
Tool
Service
Terminal
J-35616-14
Not
J-38125-560
(GN)
Available
J-35616-14
J-38125-560 962943-5
(GN)
J-35616-35
J-38125-36 2-964284-1
(VT)
Tray
Core
Crimp
Insulation
Crimp
Not
Available
Not
Available
Not
Available
16
25
X50A Fuse Block - Underhood X3 (LUV)

Pin
Size
Color
Circuit
1: 1
1: 2.5
1: RD/D-BU
1: 5290
2: 2
2: 1
2: RD/D-BU
2: 5291
3-4
5: 5
5: 2.5
5: YE
5: 6
6: 6
6: 1
6: RD/WH
6: 5293
Function
1: Powertrain Main Relay
Fused Supply (1)
Fused Supply (2)
Not Occupied
5: Starter Solenoid Crank
Voltage
Terminal Type
ID
Option
1: I
1: -
2: I
2: -
5: I
5: -
6: II
6: -

Views - Cruze
30: 30 30: 0.5 30: BK/L-BU
30: 6813
31: 31 31: 0.5
31: YE/BK
31: 3000
32: 32 32: 0.5
32: L-GN
32: 380
34: WH/YE
34: 459
35: D-BU
35: 5372
37: RD/WH
37: 340
38: 38 38: 0.5
38: BN/RD
38: 2700
39: 39 39: 0.5
39: BK/BN
39: 5514
Fused Supply (4)

Fused Supply (5)
Not Occupied
9: Ground
Not Occupied
11: Starter Enable Relay
Control
Not Occupied
15: High Speed Cooling
Fan Relay Control
Not Occupied
17: Powertrain Relay Coil
Control
Not Occupied
Voltage
21: Ground
Not Occupied
Voltage
Not Occupied
Sensor #2 Low Reference
Sensor #2 Signal
32: A/C Refrigerant
Not Occupied
34: A/C Compressor
Clutch Relay Control
35: Canister Valve
Solenoid
Not Occupied
Voltage
38: A/C Pressure Sensor
5V Reference
39: A/C Refrigerant
Pressure Sensor Low
Reference
Not Occupied
46: BN/YE
46: 473
7: 7 7: 0.75
8
9: 9
10
9: 0.5
-
11: 11 11: 0.5

12-14
15: 15 15: 0.5

16
17: 17 17: 0.5

18-19
20: 20
21: 21
22-26
27: 27
28-29
7: 5294
9: BK
-
9: 150
-
11: YE/BK
11: 625
15: BN/YE
15: 473
17: YE
17: 5991
20:
20: VT/D-BU
0.75
21: 0.5
21: BK
27:
27: RD/WH
0.75
-
33
34:
34: 34
0.75
35:
35: 35
0.75
36
37:
37: 37
0.75
40-45
7: VT/BN
46: 46 46: 0.5
20: 139
21: 150
27: 140
-
7: II
7: -
9: II
-
9: -
11: II
11: -
15: II
15: -
17: II
17: -
20: II
20: -
21: II
-
21: -
27: III
27: -
30: II
30: -
31: II
31: -
32: II
32: -
34: II
34: -
35: II
35: -
37: -
37: MH8
38: II
38: -
39: II
39: -
46: III
46: -

Views - Cruze
47-48
49: 49 49: 0.5 49: L-GN/VT
49: 335
50: 50 50: 1 50: BN/D-GN
50: 59
Fan Relay Control

Not Occupied
49: Low Speed Cooling
Fan Relay Control
50: A/C Compressor
Clutch Supply Voltage
49: III
49: -
50: III
50: -
X50A FUSE BLOCK - UNDERHOOD X3 (LUW/LWE)


Terminal
Type ID
Lead
Test Probe
13575860
II
13578869
III
13578869
Terminal
Removal
Tool
Service
Terminal
J-35616-35
J-38125-36 2-964284-1
(VT)
J-35616-14
J-38125-560 962943-5
(GN)
J-35616-14
J-38125-560 962943-5
(GN)
Tray
Core
Crimp
Insulation
Crimp
25
16
16
X50A Fuse Block - Underhood X3 (LUW/LWE)

Pin
Size
Color
Circuit
1: 1 1: 0.75 1: VT/L-BU
1: 5290
2: 2
2: 1.5
2: VT/L-BU
2: 5291
3-4
5: 5
5: 2.5
5: BK/RD
5: 6
6: 6
6: 1.5
6: VT/L-BU
6: 5293
Function
Fused Supply (1)
Fused Supply (2)
Not Occupied
5: Starter Solenoid Crank
Voltage
Fused Supply (4)
Terminal Type
ID
Option
1: I
1: -
2: I
2: -
5: I
5: -
6: II
6: -

Views - Cruze
7: 7 7: 0.75 7: VT/D-BU
8
9: 9 9: 0.5
9: BK
10
11: 11 11: 0.5
12
11: YE/BK
11: 625
13: 13 13: 0.5 13: D-GN/GY

14
15: 15 15: 0.5

16
17: 17 17: 0.5

18-19
20: 20
21: 21
22-26
27: 27
28-29
7: 5294
9: 150
-
13: 465
15: BN/YE
15: 335
17: YE
17: 5991
20:
20: VT/GY
0.75
21: 0.5
21: BK
27:
27: RD/WH
0.75
-
20: 139
21: 150
27: 140
-
30: 30 30: 0.5 30: BK/L-BU
30: 6813
31: 31 31: 0.5
31: YE/BK
31: 3000
32: 32 32: 0.5
32: L-GN
32: 380
33
34: 34 34: 0.5 34: WH/GY

35:
0.75
36
37:
37: 37
0.75
35: 35
34: 459
35: L-BU
35: 5372
37: RD/WH
37: 1840
38: 38 38: 0.5
38: BN/RD
38: 2700
39: 39 39: 0.5
39: BK/BN
39: 5514
40-45
Fused Supply (5)

Not Occupied
9: Ground
Not Occupied
Control
Not Occupied
13: Fuel Pump Primary
Relay Control
Not Occupied
Fan Relay Control
Not Occupied
Control
Not Occupied
Voltage
21: Ground
Not Occupied
Voltage
Not Occupied
Sensor #2 Signal
32: A/C Refrigerant
Not Occupied
34: A/C Compressor
Clutch Relay Control
35: Canister Valve
Solenoid
Not Occupied
Voltage
38: A/C Pressure Sensor
5V Reference
39: A/C Refrigerant
Pressure Sensor Low
Reference
Not Occupied
7: III
9: III
-
7: 9: -
11: III
11: -
13: III
13: -
15: III
15: -
17: III
17: -
20: I
20: -
21: III
-
21: -
27: I
27: -
30: III
30: -
31: III
31: -
32: III
32: -
34: III
34: -
35: III
35: -
37: III
37: MH8
38: III
38: -
39: III
39: -

Views - Cruze
46: 46 46: 0.5

47-48
49: 49 49: 0.5

50
46: BN/YE
46: 473
49: GY/VT
49: 335

Fan Relay Control
Not Occupied
Fan Relay Control
Not Occupied
46: I
46: -
49: I
49: -
Harness Type: Fuse Block - Underhood

OEM Connector: Not Available
Service Connector: Service by Harness - See Part Catalog
Description: Ring Terminal

Type ID
Lead
Test Probe
Not
Available
No Tool
Required
Terminal
Removal
Tool
Tool
Required
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
Not
Available
Not
Available
Not
Available
Not
Available

Pin
Size
Color
Circuit
1: 1
1: 35
1: RD/WH
1: 4042
Terminal Type
ID
1: Battery Positive Voltage
1: I
X50D FUSE BLOCK - BATTERY TOP VIEW
Function
Option
1: -

Views - Cruze
Fig. 4: X50D Fuse Block - Battery Top View

X50D Fuse Block - Battery Usage
Device Label Device Assigned
No.
Name
Name
Rating
F1UD: 1
F1UD: -
F1UD: F1UD Fuse
F1UD: 100A
F2UD: 2
F2UD: -
F2UD: F2UD Fuse
F2UD: 100A
F3UD: 3
F3UD: -
F3UD: F3UD Fuse
F3UD: 80A
F4UD: 4
F5UD: 5
F4UD: F5UD: -
F4UD: F4UD Fuse

F5UD: F5UD Fuse
F4UD: F5UD: 250A
F6UD: 6
F6UD: -
F6UD: F6UD Fuse
F6UD: 250A
Description
F1UD: X51 Fuse Block Instrument Panel
F2UD: X51 Fuse Block Instrument Panel
F3UD: K43 Power Steering
Control Module
F4UD: Not Used
F5UD: Fuse Block - Underhood
F6UD: M64 Starter Motor, G13
Generator

Views - Cruze
X50D FUSE BLOCK - BATTERY X1
Harness Type: Body


Type ID
Lead
Test Probe
Not
Available
No Tool
Required
Terminal
Removal
Tool
Tool
Required
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
Not
Available
Not
Available
Not
Available
Not
Available
X50D Fuse Block - Battery X1

Pin
Size
Color
Circuit
1: 1
1: 10
1: RD/GN
1: 5140
Terminal Type
ID
1: I
Function
Option
1: -
Harness Type: Body


Type ID
Lead
Test Probe
I
Not
Available
No Tool
Required
Terminal
Removal
Tool
Tool
Required
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
Not
Available
Not
Available
Not
Available
Not
Available

Terminal Type

Views - Cruze
Pin
A: A
Size
A: 10
Color
A: RD/YE
Circuit
A: 5040
Function
A: Battery Positive Voltage
ID
A: I
Option
A: -
Harness Type: Power Steering


Type ID
Lead
Test Probe
Not
Available
No Tool
Required
Terminal
Removal
Tool
Tool
Required
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
Not
Available
Not
Available
Not
Available
Not
Available

Pin
Size
A: A A: 10
Color
Circuit
A: RD/WH
A: 140
Terminal Type
ID
A: I
Function
Option
A: -
Harness Type: Fuse Block - Underhood


Type ID
Lead
Test Probe
I
Not
No Tool
Terminal
Removal
Tool
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
Tool
Not
Not
Not
Not

Views - Cruze
Available
Required
Required
Available
Available
Available
Available

Pin
Size
Color
Circuit
1: 1
1: 10
1: RD/WH
1: 4042
Terminal Type
ID
1: I
Function
Option
1: -

Harness Type: Battery Positive

Type ID
Lead
Test Probe
Not
Available
No Tool
Required
Terminal
Removal
Tool
Tool
Required
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
Not
Available
Not
Available
Not
Available
Not
Available

Pin
Size
Color
Circuit
A: A
A: 20
A: RD
A: 2
Terminal Type
ID
A: I
Function
Harness Type: Battery

Option
A: -

Views - Cruze

Type ID
Lead
Test Probe
Not
Available
No Tool
Required
Terminal
Removal
Tool
Tool
Required
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
Not
Available
Not
Available
Not
Available
Not
Available

Pin
Size
Color
Circuit
1: 1
1: 10
1: RD/GN
1: 40
Terminal Type
ID
1: I
Function
Option
1: -
X51A FUSE BLOCK - INSTRUMENT PANEL TOP VIEW FUSES
Fig. 5: X51A Fuse Block -- Instrument Panel Top View Fuses

X51A Fuse Block - Instrument Panel Fuse Usage
Device Label Device Assigned
No.
Name
Name
Rating
F1DA: 1
F1DA: -
F1DA: F1DA Fuse
F1DA: 10A
F2DA: 2
F2DA: -
F2DA: F2DA Fuse
F2DA: -
Description
F1DA: K73 Telematics
Control Module (UE1)
F2DA: Not Used

Views - Cruze
F3DA: K9 Body Control

Module
F4DA: 20A F4DA: A11 Radio
F5DA: A22 Radio Controls,
K41 Parking Assist Control
Module (UD7), P17 Info
F5DA: 7.5A
Display Module, T11
Multimedia Player Interface
Module (KTA)
F6DA: E32 Cigarette Lighter
F6DA: 20A
Receptacle
F7DA: X80L Accessory Power
F7DA: 20A
Receptacle - Rear Console
F8DA: 30A
Module
F9DA: 30A
Module
F10DA: 30A
Module
F11DA: K8 Blower Motor
F11DA: 40A
Control Module
F3DA: 3
F3DA: -
F3DA: F3DA Fuse
F4DA: 4
F4DA: -
F4DA: F4DA Fuse
F5DA: 5
F5DA: -
F5DA: F5DA Fuse
F6DA: 6
F6DA: -
F6DA: F6DA Fuse
F7DA: 7
F7DA: -
F7DA: F7DA Fuse
F8DA: 8
F8DA: -
F8DA: F8DA Fuse
F9DA: 9
F9DA: -
F9DA: F9DA Fuse
F10DA: 10
F10DA: -
F11DA: 11
F11DA: -
F12DA: 12
F12DA: -
F13DA: 13
F13DA: -
F14DA: 14
F14DA: -
F15DA: 15
F15DA: -
F15DA: F15DA
Fuse
F15DA: 10A
F16DA: 16
F16DA: -
F16DA: F16DA
Fuse
F16DA: 10A
F17DA: 17
F17DA: -
F17DA: F17DA
Fuse
F17DA: 15A
F18DA: 18
F18DA: -
F19DA: 19
F19DA: -
F20DA: 20
F20DA: -
F21DA: 21
F21DA: -
F10DA: F10DA
Fuse
F11DA: F11DA
Fuse
F12DA: F12DA
Fuse
F13DA: F13DA
Fuse
F14DA: F14DA
Fuse
F18DA: F18DA
Fuse
F19DA: F19DA
Fuse
F20DA: F20DA
Fuse
F21DA: F21DA
Fuse
F22DA: F22DA
F3DA: 25A
F12DA: F13DA: 25A

F14DA: 7.5A
F12DA: Not Used

F13DA: S64D Seat Adjuster
Switch - Driver (ADS)
F14DA: X84 Data Link
Connector
F15DA: K36 Inflatable
Diagnostic Module
F16DA: KR95B Rear
Compartment Lid Release
Relay
F17DA: K33 HVAC Control
Module, S34 HVAC Controls
Switch Assembly
F18DA: -
F18DA: Not Used
F19DA: -
F19DA: Not Used
F20DA: -
F20DA: Not Used
F21DA: 15A F21DA: P16 Instrument Cluster

Views - Cruze
F22DA: 22
F22DA: -
F23DA: 23
F23DA: -
F24DA: 24
F24DA: -
F25DA: 25
F25DA: -
F26DA: 26
F26DA: -
Fuse
F23DA: F23DA
Fuse
F24DA: F24DA
Fuse
F25DA: F25DA
Fuse
F26DA: F26DA
Fuse
F22DA: 2A
F22DA: S39 Ignition Switch

F23DA: 20A
Module
F24DA: 20A
Module
F25DA: K60 Steering Column
F25DA: 20A
Lock Control Module (ULS)
F26DA: -
F26DA: Not Used
X51A FUSE BLOCK - INSTRUMENT PANEL TOP VIEW RELAYS
Fig. 6: X51A Fuse Block -- Instrument Panel Top View Relays (except CZ2)
X51A Fuse Block - Instrument Panel Relay Usage
Device Label
Device Assigned

Views - Cruze
No.
Name
KR95B: 1
KR95B: -
KR104A: 2
KR104A: -
KR76: 3
KR76: -
Name
KR95B: KR95B Rear
Compartment Lid
Unlatch Relay
KR104A: KR104A
Battery Saver Relay 1
KR76: KR76 Retained
Accessory Power Relay
Rating
Description
KR95B: -
KR95B: M40 Rear

Compartment Lid Unlatch
KR104A: KR76: -
KR104A: F1DA Fuse,

F4DA Fuse, F5DA Fuse
KR76: F6DA Fuse, F7DA
Fuse
X51A FUSE BLOCK - INSTRUMENT PANEL BOTTOM VIEW FUSES

Harness Type: Instrument Panel
Description: 26-Way Fuse Block (GY)

Type ID
Lead
Test Probe
I
13575780
II
13575781
III
13575730
IV
13327178
13575770
Terminal
Removal
Tool
Service
Terminal
J-35616-35
J-38125-38 2-964284-1
(VT)
J-35616-35
J-38125-38 4-965999-1
(VT)
J-35616-42 J-3812515396853
(RD)
11A
J-35616-43 J-3812515343823
(RD)
11A
J-35616-43 J-3812515343823
(RD)
11A
Tray
Core
Crimp
Insulation
Crimp
25
25
23
Not
Available
Not
Available
19
G/F/G
G/F/G
19
G/F/G
G/F/G
X51A Fuse Block - Instrument Panel Bottom View Fuses

Pin
Size
Color
16: 16 16: 0.5 16: RD/L-GN
Circuit
Function
Terminal Type
ID
Option
16: 3140

Voltage
16: I
16: -

Views - Cruze
17: 17 17: 0.5 17: RD/D-BU
17: 840
34: 34 34: 2.5 34: RD/D-GN
34: 2440
35: 35 35: 2.5
35: RD/GY
35: 2840
36: 36 36: 4
36: RD/BN
36: 440
Voltage
Voltage
Voltage
Voltage
Not Occupied
Voltage
23: Retained Accessory
Power Fuse Supply
Voltage
24: Retained Accessory
Power Fuse Supply
Voltage
Voltage
Voltage
Voltage
Voltage
29: Rear Closure Unlatch
Motor Unlatch Control
Voltage
Voltage
Voltage
Voltage
Voltage
Voltage
Voltage
Not Occupied
18: 18 18: 1.5 18: RD/D-GN
18: 40
19: 19 19: 6 19: RD/D-GN
19: 3140
20: 20 20: 0.5 20: RD/D-BU
20: 540
38: RD/BN
38: 702
21
22: 22 22: 2.5 22: RD/D-GN
22: 3140
23: 23 23: 1
23: VT
23: 801
24: 24 24: 1
24: VT
24: 801
25: RD/YE
25: 3040
25: 25
25:
0.75
26: 26 26: 1.5 26: RD/D-BU
26: 2540
27: 27 27: 1.5 27: RD/L-GN
27: 3140
28: 28 28: 0.5 28: RD/L-GN
28: 3140
29: 29 29: 1 29: D-BU/WH
29: 6128
30: 30 30: 1 30: D-BU/WH
30: 6128
31: 31 31: 0.5 31: RD/D-BU
31: 5240
32:
0.75
32: 32
32:
0.75
32: RD/YE
32: RD/YE
32: 240
32: 240
33: 33 33: 2.5
33: RD/YE
33: 2340
37
38: 38 38: 1.5
17: I
17: -
18: II
18: -
19: III
19: -
20: I
20: -
22: II
22: -
23: I
23: -
24: I
24: -
25: I
25: -
26: II
26: -
27: II
27: -
28: I
28: -
29: I
29: -
30: I
30: -
31: I
31: -
32: II
32: -
33: II
33: -
34: II
34: -
35: IV
35: -
36: V
36: -
38: II
38: -

Views - Cruze
39-41
42:
42: 42
0.75
42: RD/WH
42: 140
43: 43 43: 0.5
43: RD/VT
43: 340
44: 44 44: 1.5
44: RD/GY
44: 2140
45: 45 45: 1.5
45: RD/BN
45: 2240
46-47
Voltage
Not Occupied
Voltage
Voltage
Voltage
Voltage
Not Occupied
42: I
42: -
43: I
43: -
44: II
44: -
45: II
45: -
X51A FUSE BLOCK - INSTRUMENT PANEL BOTTOM VIEW RELAYS

Service Connector: Service by Component Assembly - See Part Catalog
Description: 15-Way Relay Block (BK)

Terminal
Type ID
Lead
Test Probe
13327158
II
13327158
J-35616-42
(RD)
J-35616-42
(RD)
Terminal
Removal
Tool
J-3812511A
J-3812511A
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
15344769
23
15344769
23
X51A Fuse Block - Instrument Panel Bottom View Relays

Pin
Size
Color
Circuit
Function
1: 1
2: 2
1: 0.5
2: 0.5
1: BK
2: BK
1: 1650
2: 1650
3: 3
3: 0.5
3: GY/YE
3: 6188
4: 4
4: 0.5
4: RD/D-BU
4: 5240
5: 5
5: 0.5
5: D-BU/YE
5: 6795
1: Ground
2: Ground
3: Lift Glass/Trunk Motor
Release Control
Release Control 2
6: Technology
Terminal Type
ID
1: I
2: I
Option
1: 2: -
3: I
3: -
4: I
4: -
5: I
5: -

Views - Cruze
6: 6
7: 7
8: 8
9: 9
6: 0.5 6: L-GN/BK
7: 0.5
7: BK
8: 0.5
8: YE
9: 2.5 9: RD/D-GN
6: 5103
7: 1650
8: 7546
9: 3140
10: 10 10: 2.5 10: RD/D-GN
10: 3140
11: 11 11: 0.5
11: VT/BK
11: 3
12
13: 13 13: 0.5
13: BK
13: 1650
14: 1 14: D-BU/WH

14: 1 14: D-BU/WH
14: 6128
14: 6128
15: 15 15: 2.5 15: RD/D-GN
15: 3140
14: 14
Identification
7: Ground
8: Logistics Relay Control
Voltage
Voltage
Not Occupied
13: Ground
Voltage
6: I
7: I
8: I
9: II
6: 7: 8: 9: -
10: II
10: -
11: I
11: -
13: I
13: -
14: II
14: -
15: II
15: -

2013 ELECTRICAL Wiring Systems and Power Management - Component Locator - Front of Vehicle/Engine
Compartment Component Views - Cruze
2013 ELECTRICAL
Wiring Systems and Power Management - Component Locator - Front of Vehicle/Engine
FRONT OF VEHICLE/ENGINE COMPARTMENT COMPONENT VIEWS

FRONT OF VEHICLE COMPONENTS
Fig. 1: Front Of Vehicle

Items
1: E4P Park/Turn Signal Lamp - Right E4P Park/Turn Signal Lamp - Right
2: E13R Headlamp - Right E13R Headlamp - Right
3: E13L Headlamp - Left E13L Headlamp - Left
4: E4N Park/Turn Signal Lamp - Left E4N Park/Turn Signal Lamp - Left

5: E29LF Fog Lamp - Left Front (T3U) E29LF Fog Lamp - Left Front (T3U)
6: B9 Ambient Air Temperature Sensor B9 Ambient Air Temperature Sensor
7: E2LF Side Marker Lamp - Left Front E2LF Side Marker Lamp - Left Front
8: E2RF Side Marker Lamp - Right Front E2RF Side Marker Lamp - Right Front
9: E29RF Fog Lamp - Right Front (T3U) E29RF Fog Lamp - Right Front (T3U)
BEHIND THE FRONT BUMPER FASCIA COMPONENTS (Y8X)
Fig. 2: Behind Front Bumper Fascia (Y8X)

Items
1: M96 Active Grille Air Shutter Actuator (Y8K) M96 Active Grille Air Shutter Actuator (Y8X)
FRONT OF ENGINE COMPARTMENT COMPONENTS

Fig. 3: Front Of Engine Compartment

Items
1: G24 Windshield Washer Pump G24 Windshield Washer Pump
2: B55 Hood Ajar Switch B55 Hood Ajar Switch
3: B59R Front Impact Sensor - Right B59R Front Impact Sensor - Right
4: B1 A/C Refrigerant Pressure Sensor B1 A/C Refrigerant Pressure Sensor
5: B34B Engine Coolant Temperature Sensor 2 B34B Engine Coolant Temperature Sensor 2
6: G10 Cooling Fan Motor G10 Cooling Fan Motor
LEFT SIDE OF ENGINE COMPARTMENT COMPONENTS

Fig. 4: Left Side Of Engine Compartment

Items
1: B108 Air Quality Sensor (C68) B108 Air Quality Sensor (C68)
2: B19B Brake Booster Vacuum Sensor B19B Brake Booster Vacuum Sensor
3: B20 Brake Fluid Level Switch B20 Brake Fluid Level Switch
4: M75 Windshield Wiper Motor M75 Windshield Wiper Motor
5: K17 Electronic Brake Control Module K17 Electronic Brake Control Module
6: X50D Fuse Block - Battery X50D Fuse Block - Battery X1 X50D Fuse Block - Battery X2 X50D
Fuse Block - Battery X3 X50D Fuse Block - Battery X5 X50D Fuse Block - Battery X6 X50D Fuse
Block - Battery X7
7: X50A Fuse Block - Underhood X50A Fuse Block - Underhood X1 X50A Fuse Block - Underhood
X2 X50A Fuse Block - Underhood X3 (LUV) X50A Fuse Block - Underhood X3 (LUW/LWE)
8: B18 Battery Current Sensor B18 Battery Current Sensor
9: P12 Horn P12 Horn

10: C1 Battery
11: B59L Front Impact Sensor - Left B59L Front Impact Sensor - Left
LOWER REAR OF ENGINE COMPARTMENT COMPONENTS
Fig. 5: Lower Rear Of Engine Compartment

Items
1: M9 Brake Booster Pump Motor
2: B137 Power Steering Shaft Torque Sensor (NJ1)
3: K43 Power Steering Control Module K43 Power Steering Control Module X1 K43 Power Steering
Control Module X2

2013 ELECTRICAL Wiring Systems and Power Management - Component Locator - Ground Views - Cruze
2013 ELECTRICAL
Wiring Systems and Power Management - Component Locator - Ground Views - Cruze
GROUND VIEWS
G100, G101, G103, G104, G105, G120, AND G121
Fig. 1: G100, G101, G103, G104, G105, G120 And G121 Ground Locations
Items
1: G104
2: G103
3: G121
4: G120
5: G101

6: G100
7: G105
G102
Fig. 2: G102 Ground Location

Items
1: G102
G112 (LUW/LWE)

Fig. 3: G112 Ground Location (LUW)

Items
1: G112
G114 (LUV)

Fig. 4: G112 And G114 Ground Locations (LUJ)

Items
1: G114
G114 (LUW/LWE)

Fig. 5: G114 Ground Location (LUW)

Items
1: G114
G201

Fig. 6: Identifying Behind the Left Side of the I/P Components

Items
1: G201
G202 AND G203

Fig. 7: G202 And G203 Ground Locations

Items
1: G202
2: G203
G204


Items
1: G204
G301


Items
1: G301
G305, G307, G308, AND G400

Fig. 10: G305, G307, And G308 And G400 Ground Locations (Notchback)
Items
1: G308
2: G400
3: G307
4: G305
G309

Fig. 11: G309 Ground Locations (Notchback)

Items
1: G309
G402

Fig. 12: G402 Ground Locations (Notchback)

Items
1: G402

2013 ELECTRICAL Wiring Systems and Power Management - Component Locator - Instrument Panel/Center Console
Component Views - Cruze
2013 ELECTRICAL
Wiring Systems and Power Management - Component Locator - Instrument Panel/Center
Console Component Views - Cruze
INSTRUMENT PANEL/CENTER CONSOLE COMPONENT VIEWS

BEHIND THE INSTRUMENT PANEL COMPONENTS
Fig. 1: Instrument Panel Components (Behind)

Items
1: T15 Navigation Antenna Signal Splitter (UE1 and UYS)
2: F101 Passenger Instrument Panel Air Bag F101 Passenger Instrument Panel Air Bag X1 F101
Passenger Instrument Panel Air Bag X2
3: A11 Radio A11 Radio X1 A11 Radio X2 (UDN) A11 Radio X3 (UEW)

4: B25B Clutch Pedal Position Sensor (MF3 or MZ0) B25B Clutch Pedal Position Sensor (MF3 or
MZ0)
5: K60 Steering Column Lock Module (ULS) K60 Steering Column Lock Control Module (ULS)
6: B22 Brake Pedal Position Sensor B22 Brake Pedal Position Sensor (MF3 or MZ0) B22 Brake
Pedal Position Sensor (MH8)
7: B107 Accelerator Pedal Position Sensor B107 Accelerator Pedal Position Sensor
8: K33 HVAC Control Module K33 HVAC Control Module X1 K33 HVAC Control Module X2 K33
HVAC Control Module X3
9: K73 Telematics Communication Interface Control Module (UE1) K73 Telematics Communications
Interface Control Module X1 (UE1) K73 Telematics Communications Interface Control Module
X2 (UE1)
INSTRUMENT PANEL AND CENTER CONSOLE COMPONENTS
Fig. 2: Instrument Panel and Center Console Components


Items
1: P16 Instrument Cluster P16 Instrument Cluster
2: B10B Ambient Light/Sunload Sensor B10B Ambient Light/Sunload Sensor
3: S82 Windshield Wiper/Washer Switch S82 Windshield Wiper/Washer Switch
4: P17 Info Display Module P17 Info Display Module (UAG) P17 Info Display Module X1 (UHQ)
P17 Info Display Module X2 (UHQ)
5: A22 Radio Controls A22 Radio Controls (UEW) A22 Radio Controls (UYC or UYE)
6: P14 Passenger Air Bag Disable Indicator P14 Passenger Air Bag Disable Indicator
7: S26 Hazard Warning Switch S26 Hazard Lamps Switch
8: A26 HVAC Controls A26 HVAC Controls
9: S3 Transmission Shift Lever (MH8/MH9) S3 Transmission Shift Lever (MH8)
10: S75 Traction Control Switch (FX3) S75 Traction Control Switch (FX3)
11: E32 Cigarette Lighter Receptacle E32 Cigarette Lighter Receptacle
12: X80L Accessory Power Receptacle - Rear Console X80L Accessory Power Receptacle - Rear
Console
13: X83 Auxiliary Audio Input X83 Auxiliary Audio Input
14: P2 Transmission Shift Lever Position Indicator (MH8/MH9) P2 Transmission Shift Lever Position
Indicator (MH8)
15: S13D Door Lock Switch - Driver S13D Door Lock Switch - Driver
16: S70R Steering Wheel Controls Switch - Right (W1Y) S70R Steering Wheel Controls Switch Right (W1Y)
17: F107 Steering Wheel Air Bag F107 Steering Wheel Air Bag X1 F107 Steering Wheel Air Bag X2
(Early Production)
18: S70L Steering Wheel Controls Switch - Left (K34) S70L Steering Wheel Controls Switch - Left
(K34)
19: X51A Fuse Block - Instrument Panel
20: X84 Data Link Connector X84 Data Link Connector
21: S30 Headlamp Switch S30 Headlamp Switch
22: S78 Turn Signal/Multifunction Switch S78 Turn Signal/Multi-Function Switch
INTERIOR HVAC COMPONENTS

Fig. 3: Interior HVAC Components

Items
1: M37 Mode Door Actuator M37 Mode Door Actuator
2: M6 Air Temperature Door Actuator M6 Air Temperature Door Actuator
3: M46 Air Recirculation Door Actuator M46 Air Recirculation Door Actuator
4: B39 A/C Evaporator Temperature Sensor B39 A/C Evaporator Temperature Sensor
5: K8 Blower Motor Control Module K8 Blower Motor Control Module X1 K8 Blower Motor
Control Module X2
6: M8 Blower Motor M8 Blower Motor

2013 ELECTRICAL Wiring Systems and Power Management - Component Locator - Luggage Compartment/Rear of
Vehicle Component Views - Cruze
2013 ELECTRICAL
Wiring Systems and Power Management - Component Locator - Luggage Compartment/Rear
of Vehicle Component Views - Cruze
LUGGAGE COMPARTMENT/REAR OF VEHICLE COMPONENT VIEWS

LUGGAGE COMPARTMENT COMPONENTS (NOTCHBACK)
Fig. 1: Luggage Compartment Components

Items
1: T3 Audio Amplifier (UQA) T3 Audio Amplifier X1 (UQA) T3 Audio Amplifier X2 (UQA) T3
Audio Amplifier X3 (UQA)
2: K27 Fuel Pump Control Module K27 Fuel Pump Control Module
3: P19N Speaker - Left Subwoofer P19N Speaker - Left Subwoofer

4: P19AA Speaker - Right Subwoofer P19AA Speaker - Right Subwoofer

5: E8S Rear Compartment Courtesy Lamp E8S Rear Compartment Courtesy Lamp
6: K41R Rear Parking Assist Control Module (UD7) K41R Rear Parking Assist Control Module X1
(UD7) K41R Rear Parking Assist Control Module X2 (UD7)
REAR COMPARTMENT LID COMPONENTS
Fig. 2: Rear Compartment Lid

Items
1: E5E Tail Lamp - Left E5E Tail Lamp - Left
2: M40 Rear Compartment Lid Latch M40 Rear Compartment Lid Latch
3: E5F Tail Lamp - Right E5F Tail Lamp - Right
REAR OF VEHICLE COMPONENTS

Fig. 3: Rear Of Vehicle Components (Notchback)

Items
1: E5AA Tail/Stop Lamp - Left E5AA Tail/Stop Lamp - Left
2: E5E Tail Lamp - Left E5E Tail Lamp - Left
3: E6 Center High Mounted Stop Lamp E6 Center High Mounted Stop Lamp
4: T4G Cellular Phone, Navigation and Digital Radio Antenna
5: E18 Rear Defogger Grid E18 Rear Defogger X1 E18 Rear Defogger X2
6: E5F Tail Lamp - Right E5F Tail Lamp - Right
7: E5AB Tail/Stop Lamp - Right E5AB Tail/Stop Lamp - Right
8: E4RR Turn Signal Lamp - Right Rear E4RR Turn Signal Lamp - Right Rear
9: E5B Backup Lamp - Right E5B Backup Lamp - Right
10: B78H Rear Object Sensor - Right Outer (UD7) B78H Rear Object Sensor - Right Outer (UD7)
11: B78F Rear Object Sensor - Right Middle (UD7) B78F Rear Object Sensor - Right Middle (UD7)
12: E7R License Plate Lamp - Right E7R License Plate Lamp - Right
13: S58A Rear Compartment Lid Unlatch Switch - Exterior

14: E7L License Plate Lamp - Left E7L License Plate Lamp - Left
15: B78E Rear Object Sensor - Left Middle (UD7) B78E Rear Object Sensor - Left Middle (UD7)
16: B78G Rear Object Sensor - Left Outer (UD7) B78G Rear Object Sensor - Left Outer (UD7)
17: E5A Backup Lamp - Left E5A Backup Lamp - Left
18: E4LR Turn Signal Lamp - Left Rear E4LR Turn Signal Lamp - Left Rear

2013 ELECTRICAL Wiring Systems and Power Management - Component Locator - Master Electrical Component List Cruze
2013 ELECTRICAL
Wiring Systems and Power Management - Component Locator - Master Electrical Component
List - Cruze
MASTER ELECTRICAL COMPONENT LIST

Master Electrical Component List
Code
Name
Option
A3L
Sunshade - Left
D6I
A3R
Sunshade - Right
D6I
A7
Fuel Pump and

Level Sensor
Assembly
A9A
Outside Rearview
Mirror - Driver
A9B
Outside Rearview
Mirror - Passenger
A10
Inside Rearview
Mirror
A11
Radio
DD8
Location
In the
passenger
compartment,
on the left
sunshade
In the
passenger
compartment,
on the right
sunshade
Under the
vehicle, at the
top of the fuel
tank, next to
the fuel tank
pressure sensor
Outside the
vehicle, at the
front of the
driver door
Outside the
vehicle, at the
front of the
passenger door
In the
passenger
compartment,
at the top
center of the
windshield
Locator View
Connector End View
Headliner
Components
A3L Sunshade - Left

(D61)
Headliner
Components
A3R Sunshade - Right

(D6I)
Fuel Tank
Components
A7 Fuel Pump and

Level Sensor Assembly
Driver Door
Components
A9A Outside Rearview

Mirror - Driver
Passenger Door
Components
A9B Outside Rearview

Mirror - Passenger
Headliner
Components
A10 Inside Rearview

Mirror
In the
passenger
compartment, Behind the
in the middle of Instrument Panel
the instrument Components
panel, behind
the radio
A11 Radio X1
A11 Radio X2
(UDN)
A11 Radio X3
(UEW)

A22
A23D
Radio Controls
Door Latch
Assembly - Driver
Door Latch
A23LR Assembly - Left
Rear
Door Latch
A23RR Assembly - Right
Rear
A23P
A24D
A24P
A26
Door Latch
Assembly Passenger
Door Handle
Assembly - Driver
Exterior
Door Handle
Assembly Passenger Exterior
HVAC Controls
controls
In the
passenger
Instrument Panel
compartment, and Center
in the center of Console
panel
In the
passenger
compartment, Driver Door
at the middle Components
rear of the
driver door
In the
passenger
compartment, Left Rear Door
rear of the left
rear door
In the
passenger
compartment, Right Rear Door
rear of the right
rear door
In the
passenger
compartment, Passenger Door
rear of the
passenger door
A22 Radio
Controls (UYC
or UYE)
A22 Radio
Controls (UEW)
A23D Door Latch

Assembly - Driver
A23LR Door Latch

Assembly - Left Rear
A23RR Door Latch

Assembly - Right Rear
A23P Door Latch

Assembly - Passenger
In the
passenger
compartment,
in the lower
center of the
instrument
panel
In the front of
the engine
Instrument Panel
and Center
Console
Components
A26 HVAC Controls

B1
A/C Refrigerant
Pressure Sensor
B5LF
Wheel Speed Sensor

- Left Front
B5LR
Wheel Speed Sensor

- Left Rear
B5RF
Wheel Speed Sensor

- Right Front
B5RR
Wheel Speed Sensor

- Right Rear
B7D
Air Temperature
Sensor - Duct Left
Lower
C68
B7H
Air Temperature
Sensor - Duct Left
Upper
C68
B9
Ambient Air
Temperature Sensor
Ambient
compartment,
Front of Engine
on the right
Compartment
side of the
radiator, in the Components
A/C line
Outside the
vehicle, part of Underbody
the left front
Components
hub assembly
Outside the
the left rear hub Components
assembly
Outside the
the right front Components
hub assembly
Outside the
the right rear Components
hub assembly
In the
passenger
compartment,
behind the
instrument
panel, on the
lower left side
of the HVAC
module
In the
passenger
compartment,
behind the
instrument
panel, on the
upper left side
of the HVAC
module
Left front of
the vehicle,
Front of Vehicle
behind the
Components
bumper fascia
In the
passenger
compartment,
at the top
Instrument Panel
B1 A/C Refrigerant
Pressure Sensor
B5LF Wheel Speed

Sensor - Left Front
B5LR Wheel Speed

Sensor - Left Rear
B5RF Wheel Speed

Sensor - Right Front
B5RR Wheel Speed

Sensor - Right Rear
B7H Air Temperature

Sensor - Duct Left
Upper (C68)
B9 Ambient Air
Temperature Sensor

Light/Sunload
Sensor
B10B
B12A
Transmission Fluid
Pressure Switch
B13
Transmission Fluid
MH8/MH9
Temperature Sensor
MH8/MH9
B14A
Transmission Output
MH8/MH9
Shaft Speed Sensor
B14C
Transmission Input
Shaft Speed Sensor
B15
Transmission
Internal Mode
Switch
MH8/MH9
B16
Backup Lamp
Switch
MF3 or
MZ0
B18
Battery Current
Sensor
MH8/MH9
center of the
instrument
panel, in the
defroster
deflector
In the engine
compartment,
internal to the
transmission
assembly
In the engine
compartment,
internal to the
transmission
assembly
In the engine
compartment,
internal to the
transmission
assembly
In the engine
compartment,
internal to the
transmission
assembly
In the engine
compartment,
mounted inside
the
transmission,
around shift
shaft
Left side of
engine
compartment,
lower rear of
engine block,
above the
transmission
In the engine
compartment,
near the
battery, on the
negative
battery cable
At the rear of
the engine
and Center
Console
Components
B10B Ambient
Light/Sunload Sensor
Automatic
Transmission
Electronic
Components
(MH8)
Automatic
Transmission
Electronic
Components
(MH8)
Automatic
Transmission
Electronic
Components
(MH8)
Transmission
B16 Backup Lamp
Components (MF3
Switch (MF3 or MZ0)
or MZ0)
Left Side of Engine

B18 Battery Current
Compartment
Sensor
Components

B19B
Brake Booster
Vacuum Sensor
B20
Brake Fluid Level

Switch
B22
Brake Pedal Position

Sensor
B23E
Camshaft Position
Sensor - Exhaust
B23E
Camshaft Position
Sensor - Exhaust
B23F
Camshaft Position
Sensor - Intake
B23F
Camshaft Position
Sensor - Intake
B24
Cellular Phone
Microphone
B25B
Clutch Pedal
Position Sensor
compartment,
right of the
brake fluid
reservoir
At the rear of
the engine
compartment,
on the brake
fluid reservoir
Left Side of Engine

B19B Brake Booster
Compartment
Vacuum Sensor
Components
Left Side of Engine
B20 Brake Fluid Level
Compartment
Switch
Components
In the
Behind the
passenger
compartment, Instrument Panel
on the brake
Components
pedal assembly
In the engine
Right Front of the
compartment,
Engine
LUV
at the front
Components
right side of the
(LUV)
engine
In the engine
Left Front of the
compartment,
Engine
LUW/LWE at the upper left
Components
side of the
(LUW/LWE)
engine
In the engine
Right Rear of the
compartment,
Engine
LUV
at the rear right
Components
side of the
(LUV)
engine
In the engine
Left Front of the
compartment,
Engine
LUW/LWE at the upper left
Components
side of the
(LUW/LWE)
engine
In the
passenger
compartment,
near the inside Headliner
UE1
Components
rearview
mirror, in the
overhead
console
MF3 or
MZ0
In the
passenger
compartment,
Behind the
Instrument Panel
B22 Brake Pedal

Position Sensor
(MF3 or MZ0)
B22 Brake Pedal
Position Sensor
(MH8)
B23E Camshaft
Position Sensor Exhaust (LUV)
B23E Camshaft
Position Sensor Exhaust (LUW/LWE)
B23F Camshaft
Position Sensor Intake (LUV)
B23F Camshaft
Position Sensor Intake (LUW/LWE)
B24 Cellular Phone

Microphone (UE1)
B25B Clutch Pedal

Position Sensor (MF3

on the clutch Components

pedal assembly
In the engine
Right Rear of the
compartment,
Crankshaft Position
Engine
B26
LUV
at the lower left
Components
Sensor
rear of the
(LUV)
engine
In the engine
compartment, Top of the Engine
Crankshaft Position
B26
LUW/LWE at the upper left Components
Sensor
rear of the
(LUW/LWE)
engine
In the driver
door, rear
middle,
Door Handle Switch
B27D
mounted to
- Driver Exterior
inside of outer
panel
In the
passenger door,
rear middle,
Door Handle Switch
B27P
- Passenger Exterior
mounted to
inside of outer
panel
In the left rear
door, rear
Door Handle Switch
middle,
B27LR
- Left Rear Exterior
mounted to
inside of outer
panel
In the right rear
door, rear
middle,
Door Handle Switch
B27RR
mounted to
- Right Rear Exterior
inside of outer
panel
B34A
Engine Coolant
Temperature Sensor
1
In the engine
compartment,
at the top left
front of engine,
in the
thermostat
housing
In the front of
Left Rear of
the Engine
Components
(LUV)
Left Front of
the Engine
Components
(LUW/LWE)
or MZ0)
B26 Crankshaft
Position Sensor (LUV)
B26 Crankshaft
Position Sensor
(LUW/LWE)
B34A Engine
Coolant
Temperature
Sensor 1 (LUV)
B34A Engine
Coolant
Temperature
Sensor 1
(LUW/LWE)

B34B
Engine Coolant
Temperature Sensor
2
B37
Engine Oil Pressure

Switch
B37
Engine Oil Pressure

Switch
B39
A/C Evaporator
Temperature Sensor
B46
Fuel Level Sensor
B47
the engine
compartment, Front of Engine
Compartment
on the right
side of the
Components
radiator
In the engine
Right Front of the
compartment,
Engine
LUV
at the front left
Components
side of the
(LUV)
engine
In the engine
Right Front of the
compartment,
Engine
LUW/LWE at the front
Components
right side of the
(LUW/LWE)
engine
In the
passenger
compartment,
Interior HVAC
part of HVAC
Components
module, behind
the instrument
panel
On the vehicle
underbody,
below rear
seats, part of
fuel pump and
level sensor
assembly,
mounted in fuel
tank
On the vehicle
underbody, on
Fuel Tank
the fuel line,
Components
below the right
rear seat
B52A
Heated Oxygen
Sensor 1
In the engine
compartment,
at the left front
of the engine
Right Front
of the Engine
Components
(LUV)
Top of the
Engine
Components
(LUW/LWE)
Right Rear
of the Engine
B34B Engine Coolant

Temperature Sensor 2
B37 Engine Oil

Pressure Switch
B37 Engine Oil

Pressure Switch
B39 A/C Evaporator

Temperature Sensor
B47 Fuel Pressure

Sensor
B52A Heated
Oxygen Sensor 1
(LUV)
B52A Heated
Oxygen Sensor 1
(LUW/LWE)

B52B
Heated Oxygen
Sensor 2
B55
Hood Ajar Switch
B59L
Front Impact Sensor

- Left
B59R
Front Impact Sensor

- Right
B60
Passenger Presence
Sensor
B63LF
Side Impact Sensor Left Front
B63LR
Side Impact Sensor Left Rear
Side Impact Sensor B63RF

Right Front
In the engine
compartment,
rear of the
engine, on the
exhaust pipe
Components
(LUV)
Right Rear B52B Heated Oxygen
of the Engine Sensor 2
Components
(LUW/LWE)
In the front of
the engine
Front of Engine
compartment, Compartment
on the hood
Components
latch
At the front of
the engine
Left Side of Engine
compartment,
Compartment
on the left side
Components
of the radiator
support
At the front of
the engine
Front of Engine
compartment,
Compartment
on the right
Components
side of the
radiator support
In the
passenger
compartment,
in the
passenger front
seat cushion,
under the
upholstery
In the
Left Side of
passenger
Passenger
compartment,
Compartment
at the bottom of
Components
the left B-pillar
In the
Left Side of
passenger
Passenger
compartment,
Compartment
at the bottom of
Components
the left C-pillar
In the
Right Side of
passenger
Passenger
at the bottom of Components
the right B-
B55 Hood Ajar Switch
B59L Front Impact

Sensor - Left
B59R Front Impact

Sensor - Right
B63LF Side Impact

Sensor - Left Front
B63LR Side Impact

Sensor - Left Rear
B63RF Side Impact

Sensor - Right Front

B63RR
Side Impact Sensor Right Rear
pillar
In the
passenger
Right Side of
compartment, Passenger
at the bottom of Compartment
Components
the right Cpillar
B68
Knock Sensor
B74
Manifold Absolute
Pressure Sensor
B74
Manifold Absolute
Pressure Sensor
B75C
Multifunction Intake
Air Sensor
B78E
Rear Object Sensor Left Middle
B78F
Rear Object Sensor Right Middle
B78G
Rear Object Sensor Left Outer
Rear Object Sensor -
In the engine
compartment,
at the center
rear of the
engine
Left Rear of
the Engine
Components
(LUV)
Right Rear
of the Engine
Components
(LUW/LWE)
In the engine
Right Rear of the
compartment,
Engine
LUV
at the upper
Components
right rear of the
(LUV)
engine
In the engine
compartment, Top of the Engine
LUW/LWE on the front
Components
(LUW/LWE)
center of the
intake manifold
Right side of
the engine
Top of the Engine
compartment, Components
in the air intake (LUW/LWE)
duct
At the rear of
the vehicle, in
Rear of Vehicle
UD7
the left center
Components
of rear bumper
fascia
At the rear of
the vehicle, in
Rear of Vehicle
UD7
the right center
Components
of rear bumper
fascia
At the rear of
the vehicle, in Rear of Vehicle
UD7
the left of rear Components
bumper fascia
At the rear of
the vehicle, in Rear of Vehicle
B63RR Side Impact

Sensor - Right Rear
B68 Knock
Sensor (LUV)
B68 Knock
Sensor
(LUW/LWE)
B74 Manifold Absolute

Pressure Sensor (LUV)
B74 Manifold Absolute

Pressure Sensor
(LUW/LWE)
B75C Multifunction
Air Intake Sensor
B78E Rear Object

Sensor - Left Middle
(UD7)
B78F Rear Object

Sensor - Right Middle
(UD7)
B78G Rear Object
Sensor - Left Outer
(UD7)
B78H Rear Object

B78H
B80
B81B
B87
B88D
B88P
B99
B107
Right Outer
the right of rear Components

bumper fascia
In the
passenger
compartment,
Park Brake Switch
under the rear
of the center
console
In the
passenger
compartment,
Park Position Switch MH8/MH9 center near
front, part of
transmission
shift lever
At the rear of
vehicle,
mounted to rear
Rearview Camera
UVC
compartment
lid trim above
license plate
In the
passenger
Driver Seat
Seat Belt Switch compartment,
Components (2 of
Driver
part of the
2)
driver seat belt
buckle
In the
passenger
Passenger Seat
Seat Belt Switch compartment,
Components (2 of
Passenger
part of the front
2)
passenger seat
belt buckle
In the
passenger
compartment,
Steering Wheel
near the top of
FX3
Angle Sensor
the steering
column, below
the SIR coil
In the
passenger
compartment, Behind the
Accelerator Pedal
attached to the Instrument Panel
Position Sensor
Components
top of the
accelerator
pedal assembly
UD7
Sensor - Right Outer

(UD7)
B80 Park Brake

Switch
B87 Rearview Camera

(UVC)
B88D Seat Belt Switch

- Driver
B88P Seat Belt Switch

- Passenger
B99 Steering Wheel

Angle Sensor (FX3)
B107 Accelerator
Pedal Position Sensor

B108
Air Quality Sensor
Intake Manifold
B111B Pressure and Air
Temperature Sensor
B115
Vehicle Speed
Sensor
C68
LUV
MF3 or
MZ0
B119
Multi-axis
Acceleration Sensor
B137
Power Steering Shaft

Torque Sensor
B150
Fuel Tank Pressure

Sensor
B153D
Seat Belt Buckle Driver
B153P
Seat Belt Buckle Passenger
FX3
NJ1
In the engine
compartment,
under the cowl
panel, at the
base of the
windshield
In the engine
compartment,
at the left front
of the engine,
on the air inlet
duct
In the engine
compartment,
at the front of
the
transmission
In the
passenger
compartment,
under the
center console
Under the
vehicle, on the
power steering
rack assembly,
part of the
power steering
control module
Under the
vehicle, at the
top of the fuel
tank, next to
the fuel pump
assembly
In the
passenger
compartment,
to the inside of
the driver seat
In the
passenger
compartment,
to the inside of
the passenger
seat
In the engine
Left Side of Engine

B108 Air Quality
Compartment
Sensor (C68)
Components
Left Rear of the

Engine
Components
(LUV)
B111B Turbocharger
Boost/Intake Air
Temperature (LUV)
Transmission
B115 Vehicle Speed
Components (MF3
Sensor (MF3 or MZ0)
or MZ0)
Right Side of
Passenger
Compartment
Components
Lower Rear of
Engine
Compartment
Components
Fuel Tank
Components
B119 Multi-Axis
Acceleration Sensor
(FX3)
B150 Fuel Tank

Pressure Sensor

B157
Secondary Air
Injection Pressure B
Sensor
B160
Windshield
Temperature and
Inside Moisture
Sensor
C68
Door Handle Touch

B210D Sensor - Driver
Exterior
Door Handle Touch

B210P Sensor - Passenger
Exterior
B218L
Side Object Sensor

Module - Left
UFT
B218R
Side Object Sensor

Module - Right
UFT
C1
Battery
E2LF
Side Marker Lamp Left Front
E2LR
Side Marker Lamp Left Rear
E2RF
Side Marker Lamp Right Front
compartment,
right rear of the
engine upper
position
In the
passenger
compartment,
at the top
center of the
windshield
On the driver
door, part of
exterior door
handle
On the
passenger door,
part of exterior
door handle
At the rear of
the vehicle,
mounted to the
fascia, left side
At the rear of
the vehicle,
mounted to the
fascia, right
side
In the engine
compartment,
Left Side of Engine
on the left side,
Compartment
near the
Components
underhood fuse
block
Outside the
vehicle, on the
Front of Vehicle
left front side
Components
of the bumper
fascia
Rear of vehicle,
on the left side,
part of tail
lamp assembly
Outside the
Front of Vehicle
vehicle, on the
Components
right front side
of the bumper
B160 Winshield
Temperature and
Inside Moisture Sensor
(C68)
E2LF Side Marker

Lamp - Left Front
E2RF Side Marker

Lamp - Right Front

E2RR
Side Marker Lamp Right Rear
E4LR
Turn Signal Lamp Left Rear
E4N
Park/Turn Signal
Lamp - Left
E4P
Park/Turn Signal
Lamp - Right
E4RR
Turn Signal Lamp Right Rear
E5A
Backup Lamp - Left
E5AA
Tail/Stop Lamp Left
E5AB
Tail/Stop Lamp Right
fascia
Rear of vehicle,
on the right
side, part of tail
lamp assembly
Outside the
vehicle, at the
left rear corner, Rear of Vehicle
part of the left Components
tail lamp
assembly
Outside the
vehicle, at the
left front corner
Front of Vehicle
of the vehicle,
Components
in the left
headlamp
assembly
Outside the
vehicle, at the
right front
Front of Vehicle
corner of the
Components
vehicle, in the
right headlamp
assembly
Outside the
vehicle, at the
right rear
Rear of Vehicle
corner, part of Components
the right tail
lamp assembly
Outside the
vehicle, at the
tail lamp
assembly
Outside the
vehicle, at the
tail lamp
assembly
Outside the
vehicle, at the Rear of Vehicle
Components
right rear
corner, part of
E4LR Turn Signal

Lamp - Left Rear
E4N Park/Turn Signal

Lamp - Left
E4P Park/Turn Signal

Lamp - Right
E4RR Turn Signal

Lamp - Right Rear
E5A Backup Lamp Left
E5AA Tail/Stop Lamp

- Left
E5AB Tail/Stop Lamp

- Right

E5B
Backup Lamp Right
E5E
Tail Lamp - Left
E5F
Tail Lamp - Right
E6
Center High
Mounted Stop Lamp
E7L
License Plate Lamp Left
E7R
License Plate Lamp Right
E8S
Rear Compartment
Courtesy Lamp
E13L
Headlamp - Left
the right tail

lamp assembly
Outside the
vehicle, at the
right rear
Rear of Vehicle
corner, part of Components
the right tail
lamp assembly
Outside the
vehicle, in the
rear
Rear
compartment Compartment Lid
lid, part of the Components
left inner tail
lamp assembly
Outside the
vehicle, in the
rear
Rear
compartment Compartment Lid
lid, part of the Components
right inner tail
lamp assembly
In the
passenger
compartment, Rear of Vehicle
at the top
Components
center of the
rear window
At the rear of
the vehicle, in
Rear of Vehicle
the center of
Components
the rear
compartment
lid
At the rear of
the vehicle, in
the center of
Rear of Vehicle
the rear
Components
compartment
lid
In the rear
Luggage
compartment,
Compartment
in the center of
Components
the rear
(Notchback)
window shelf
At the left front
corner of the Front of Vehicle
E5B Backup Lamp Right
E5E Tail Lamp - Left
E5F Tail Lamp - Right
E6 Center High
Mounted Stop Lamp
E7L License Plate

Lamp - Left
E7R License Plate

Lamp - Right
E8S Rear
Compartment
Courtesy Lamp
E13L Headlamp - Left

E13R
Headlamp - Right
E14A
Seat Heating
Element - Driver
Back
KA1
E14B
Seat Heating
Element - Driver
Cushion
KA1
E14C
Seat Heating
Element - Passenger
Back
KA1
E14D
Seat Heating
Element - Passenger
Cushion
KA1
E18
Rear Defogger Grid
E27
Instrument Panel
Compartment Lamp
E29LF
Fog Lamp - Left

Front
T3U
vehicle
At the right
front corner of
the vehicle
In the
passenger
compartment,
in the driver
seat back
In the
passenger
compartment,
part of the
driver seat
cushion
In the front
passenger
compartment,
in the
passenger seat
back
In the front
passenger
compartment,
part of the
passenger seat
cushion
In the
passenger
compartment,
on the inside of
the rear
window
In the
passenger
compartment,
inside the
instrument
panel
compartment
Outside the
vehicle, at the
left front
corner, below
the left
headlamp
assembly
Components
Front of Vehicle
Components
E13R Headlamp Right
Driver Seat
E14A Seat Heating
Components (2 of Element - Driver Back
2)
(KA1)
Driver Seat
E14B Seat Heating
Components (2 of Element - Driver
2)
Cushion (KA1)
Passenger Seat
E14C Seat Heating
Components (2 of Element - Passenger
2)
Back (KA1)
Passenger Seat
E14D Seat Heating
Components (2 of Element - Passenger
2)
Cushion (KA1)
Rear of Vehicle
Components
Front of Vehicle
Components
E18 Rear
Defogger X1
E18 Rear
Defogger X2
E27 Instrument Panel

Compartment Lamp
E29LF Fog Lamp Left Front (T3U)

E29RF
Fog Lamp - Right

Front
T3U
E32
Cigarette Lighter Receptacle
E37F
Dome/Reading
Lamps - Front
E37M
Dome/Reading
Lamps - Middle
Outside the
vehicle, at the
right front
Front of Vehicle
corner, below
Components
the right
headlamp
assembly
In the
Instrument Panel
passenger
Console
in the center
console, rear of Components
the shifter
In the
passenger
compartment,
Headliner
at the front of
Components
the headliner,
in the overhead
console
In the
passenger
Headliner
compartment,
Components
in the middle of
the headliner
E29RF Fog Lamp Right Front (T3U)
E32 Cigarette Lighter

Receptacle
E37F Dome/Reading
Lamps - Front
E37M Dome/Reading
Lamps - Middle
E41
F101
Engine Coolant
Thermostat Heater
Passenger
Instrument Panel Air
Bag
Roof Rail Air Bag F105L

Left
In the engine
compartment,
top left front of
engine, in the
thermostat
housing
In the
passenger
compartment,
Behind the
at the top of the
Instrument Panel
passenger side
Components
of the
instrument
panel
In the
passenger
compartment,
along the left
Left Front of the

Engine
Components
(LUW/LWE)
Left Side of
Passenger
Compartment
E41 Engine
Coolant
Thermostat
Heater (LUV)
E41 Engine
Coolant
Thermostat
Heater
(LUW/LWE)
F101 Passenger
Instrument
Panel Air Bag
X1
F101 Passenger
Instrument
Panel Air Bag
X2
F105L Roof Rail Air

Bag - Left

Roof Rail Air Bag F105R

Right
F106D
Seat Air Bag Driver
F106LR
Seat Air Bag - Left

Rear
F106P
Seat Air Bag Passenger
F106RR
Seat Air Bag - Right

Rear
F107
F112D
F112P
Steering Wheel Air

Bag
Seat Belt Retractor

Pretensioner - Driver
Seat Belt Retractor

Pretensioner -
roof rail
In the
passenger
compartment,
along the right
roof rail
In the
passenger
compartment,
on the left side
of the driver
seat back
In the
passenger
compartment,
on the left side
of the rear seat
back
In the
passenger
compartment,
on the right
side of the
passenger seat
back
In the
passenger
compartment,
on the right
side of the rear
seat back
Components
Right Side of
Passenger
Compartment
Components
F105R Roof Rail Air

Bag - Right
Driver Seat
F106D Seat Air Bag Components (1 of
Driver
2)
Rear Seat
Components
F106LR Seat Air Bag Left Rear
Passenger Seat
F106P Seat Air Bag Components (1 of
Passenger
2)
Rear Seat
Components
F106RR Seat Air Bag Right Rear
F107 Steering
Wheel Air Bag
X1
F107 Steering
Wheel Air Bag
X2 (Early
Production)
In the
passenger
compartment,
in the center of
the steering
wheel
Instrument Panel
and Center
Console
Components
In the
passenger
compartment,
at the base of
the left B-pillar
Left Side of
Passenger
Compartment
Components
F112D Seat Belt

Retractor Pretensioner
- Driver
In the
passenger
compartment,
Right Side of
Passenger
F112P Seat Belt

Retractor Pretensioner

Passenger
Seat Belt Anchor

F113D
Pretensioner - Driver
F113P
Seat Belt Anchor

Pretensioner Passenger
F114D
Knee Air Bag Driver
F114P
Knee Air Bag Passenger
G1
A/C Compressor
G10
Cooling Fan Motor
G12
Fuel Pump
at the base of Compartment

Components
the right Bpillar
In the
passenger
compartment,
Driver Seat
on the lower
Components (1 of
outside of the
2)
driver seat,
mounted to the
seat rack
In the
passenger
compartment,
Passenger Seat
on the lower
Components (1 of
outside of the
2)
passenger seat,
mounted to the
seat rack
In the
passenger
compartment,
at the bottom of
the driver side
of the
instrument
panel
In the
passenger
compartment,
at the bottom of
the passenger
side of the
instrument
panel
In the engine
compartment,
on the right
front of the
engine
At the front of
Front of Engine
the engine
rear of the
Components
radiator
Under the rear
of the vehicle, Fuel Tank
- Passenger
F113D Seat Belt

Anchor Prestensioner Driver
F113P Seat Belt

Anchor Pretensioner Passenger
F114D Knee Air Bag Driver
F114P Knee Air Bag Passenger
G10 Cooling Fan

Motor

in the fuel tank Components
G13
Generator
G21
Secondary Air
Injection Pump
G24
Windshield Washer
Pump
K8
Blower Motor
Control Module
In the engine
compartment,
at the lower
right rear side
of the engine
In the engine
compartment,
on the right
front of the
engine, above
the water pump
In the engine
compartment,
below the left
headlamp
assembly,
attached to the
washer fluid
reservoir
In the
passenger
compartment,
behind the
passenger side
of the
instrument
panel, on the
HVAC module
Right Rear
of the Engine
Components
(LUV)
G13 Generator X2
Right Rear
of the Engine
Components
(LUW/LWE)
Front of Engine
Compartment
Components
G24 Windshield
Washer Pump
Interior HVAC
Components
K9
Body Control
Module
In the
passenger
compartment,
at the bottom
center of the
instrument
panel
Right Side of
Passenger
Compartment
Components
K8 Blower
Motor Control
Module X1
K8 Blower
Motor Control
Module X2
K9 Body Control
Module X1
K9 Body Control
Module X2
K9 Body Control
Module X3
K9 Body Control
Module X4
K9 Body Control
Module X5
K9 Body Control
Module X6
K9 Body Control

Module X7
K17
Electronic Brake
Control Module
In the engine
compartment,
under the
radiator surge
tank
Left Side of Engine

K17 Electronic Brake
Compartment
Control Module
Components
K20
Engine Control
Module
In the engine Top of the Engine

compartment, Components
near the battery (LUW/LWE)
K27
Fuel Pump Control

Module
In the luggage
compartment,
on the rear of
the right rear
wheel well
Luggage
Compartment
Components
(Notchback)
K27 Fuel Pump

Control Module
K29
K33
Seat Heating Control

Module
HVAC Control
Module
KA1
In the
passenger
Driver Seat
compartment,
Components (1 of
under the front
2)
of the driver
seat
In the
Behind the
passenger
in the center of Components
the instrument
panel, behind
K20 Engine
Control Module
X1 (LUV)
K20 Engine
Control Module
X1 (LUW/LWE)
K20 Engine
Control Module
X2 (LUV)
K20 Engine
Control Module
X2 (LUW/LWE)
K20 Engine
Control Module
X3 (LUV)
K29 Seat
Heating Control
Module X1
(KA1)
K29 Seat
Heating Control
Module X2
(KA1)
K29 Seat
Heating Control
Module X3
(KA1)
K33 HVAC
Control Module
X1
K33 HVAC
Control Module
X2

the HVAC
controls
K35
Ignition Coil Module
In the engine Left Rear of the

compartment, Engine
at the top of the Components
engine
(LUV)
K35 Ignition Coil

Module
K36
Sensing and
Diagnostic Module
In the
passenger
compartment,
under the front
of the center
console
Right Side of
Passenger
Compartment
Components
K41R
Rear Parking Assist

Control Module
UD7
In the luggage
compartment,
on the rear of
the left rear
wheel well
Luggage
Compartment
Components
(Notchback)
K43
Power Steering
Control Module
K60
Steering Column
Lock Module
ULS
K61
Sunroof Control
Module
CF5
Under the
vehicle, on the
power steering
rack assembly
Lower Rear of
Engine
Compartment
Components
In the
passenger
Behind the
compartment,
Instrument Panel
behind and
Components
below the
steering wheel
In the
passenger
compartment,
at the front of
the headliner,
part of the
sunroof module
assembly
K33 HVAC
Control Module
X3
K36 Inflatable
Restraint
Sensing and
Diagnostic
Module X1
K36 Inflatable
Restraint
Sensing and
Diagnostic
Module X2
K41R Rear
Parking Assist
Control Module
X1 (UD7)
K41R Rear
Parking Assist
Control Module
X2 (UD7)
K43 Power
Steering Control
Module X1
K43 Power
Steering Control
Module X2
K60 Steering Column

Lock Control Module
(ULS)
K61 Sunroof Control

Module (CF5)

K71
Transmission
Control Module
In the engine
compartment,
mounted to the
valve body
inside the
MH8/MH9
transmission,
part of the
control
solenoid valve
assembly
K73
K77
Telematics
Communication
Interface Control
Module
Remote Control
Door Lock Receiver
UE1
In the
passenger
compartment,
Behind the
behind the
Instrument Panel
passenger side
Components
of the
instrument
panel
In the
passenger
compartment, Headliner
above the front Components
center of the
headliner
K77 Remote Control

Door Lock Receiver
K84
K85
Keyless Entry
Control Module
Passenger Presence
Detection Module
ATH
In the
passenger
compartment,
at the right
front A-pillar
trim panel
In the
passenger
compartment, Passenger Seat
under the front Components (1 of
of the front
2)
passenger seat
cushion
K73 Telematics
Communications
Interface
Control Module
X1 (UE1)
K73 Telematics
Communications
Interface
Control Module
X2 (UE1)
K84 Keyless
Entry Control
Module X1
(ATH)
K84 Keyless
Entry Control
Module X2
(ATH)
K84 Keyless
Entry Control
Module X4
(ATH)
K85 Passenger
Presence
Detection
Module X1
K85 Passenger
Presence
Detection

Module X2
K89
KR14
M6
M7
M8
M9
Immobilizer Control
Module
Brake Booster Pump

Motor Relay
In the
passenger
compartment,
on the driver
side, near the
ignition
cylinder
In the left rear

of the engine
compartment,
near the brake
booster
In the
passenger
compartment,
Air Temperature
behind the
Door Actuator
instrument
panel, part of
HVAC module
In the center of
the passenger
compartment,
Transmission Shift
in the floor
Lock Control
MH8/MH9
console, part of
Solenoid Actuator
the
transmission
shift lever
In the
passenger
compartment,
behind the
Blower Motor
passenger side
of the
instrument
panel
In the left rear
of the engine
Brake Booster Pump
compartment,
Motor
near the brake
booster
In the
passenger
compartment,
behind the left
K89 Immobilizer
Control Module
Interior HVAC
Components
Interior HVAC
Components
Lower Rear of
Engine
Compartment
Components
KR14 Brake
Booster Pump
Relay X1
KR14 Brake
Booster Pump
Relay X2
M6 Air Temperature
Door Actuator
M8 Blower Motor

M37
Mode Door Actuator
M38
Power Steering
Motor
M40
Rear Compartment
Lid Latch
M46
Air Recirculation
Door Actuator
M50D
Seat Front Vertical

Motor - Driver
ADS
M51D
Seat Horizontal
Motor - Driver
ADS
M55D
Seat Rear Vertical

Motor - Driver
ADS
side of the
instrument
panel, on the Interior HVAC
upper left side Components
of the HVAC
module
In the vehicle
underbody,
below rear of
engine
compartment,
mounted to
steering gear
At the rear of
the vehicle, in
Rear
the bottom
Compartment Lid
center of the
Components
rear
compartment
In the
passenger
compartment,
Interior HVAC
behind the
Components
instrument
panel, part of
HVAC module
In the
passenger
compartment, Driver Seat
under the front Components (1 of
2)
of the driver
seat, next to the
right seat track
In the
passenger
compartment,
Driver Seat
under the
Components (1 of
center of the
2)
driver seat,
between the
seat tracks
M37 Mode Door

Actuator
M40 Rear
Compartment Lid
Latch
M46 Air Recirculation

Door Actuator
M50D Seat Front

Vertical Motor Driver (ADS)
M51D Seat Horizontal

Motor - Driver (ADS)
In the
passenger
Driver Seat
M55D Seat Rear
compartment, Components (1 of Vertical Motor under the front 2)
Driver (ADS)
of the driver
seat, next to the

left seat track
M64
Starter Motor
M74D
Window Motor Driver
AEC
M74D
Window Motor Driver
AXG
M74LR
Window Motor Left Rear
M74P
Window Motor Passenger
Window Motor -
In the engine
compartment,
lower left rear
of the engine
Right Rear
of the Engine
Components
(LUV)
Right Rear
of the Engine
Components
(LUW/LWE)
In the
passenger
compartment,
behind the
Driver Door
driver door
Components
trim panel, at
the bottom
center of the
door
In the
passenger
compartment,
behind the
Driver Door
driver door
Components
trim panel, at
the bottom
center of the
door
In the
passenger
compartment,
Left Rear Door
center of the
Components
left rear door,
behind the door
trim panel
In the
passenger
compartment,
behind the
Passenger Door
front passenger
Components
door trim
panel, at the
bottom center
of the door
In the
passenger
compartment,
Right Rear Door
M74D Window Motor

- Driver (AEC)
M74D Window Motor

- Driver (AXG)
M74LR Window
Motor - Left Rear
M74P Window Motor

- Passenger
M74RR Window

Right Rear
M74RR
M75
Windshield Wiper
Motor
M93
Key Capture
Solenoid Actuator
M96
Active Grille Air

Shutter Actuator
P2
Transmission Shift
Lever Position
Indicator
P9
Driver Information
Center Display
P12
Horn
P14
Passenger Air Bag

Disable Indicator
center of the
Components
Motor - Right Rear
right rear door,
behind the door
trim panel
At the left rear
of the engine Left Side of Engine
M75 Windshield
Wiper Motor
near the
Components
windshield
In the
passenger
compartment,
M93 Ignition Cylinder
MH8/MH9 on the steering
Lock Control Solenoid
column, near
Actuator (MH8)
the ignition
switch
Outside the
vehicle, near
Behind the Front M96 Active Grille Air
the left front
Y8K
Bumper Fascia
Shutter Actuator
corner of the
Components (Y8X) (Y8X)
vehicle, behind
the fascia
In the
passenger
P2 Transmission Shift
behind and
and Center
MH8/MH9
Lever Position
below the
Console
Indicator (MH8)
center of the
Components
instrument
panel
In the
passenger
compartment,
in the center of
the instrument
cluster
In the left front
P12 Horn
mounted on the Components
frame rail
In the
passenger
Instrument Panel
P14 Passenger Air Bag
Disable Indicator
in the center of Console
panel

P16
P17
Instrument Cluster
Info Display Module
P19AA
Speaker - Right
Subwoofer
P19AG
Speaker - Left Front

Door
P19AH
Speaker - Right
Front Door
P19AL
Speaker - Left Rear

Door
In the
passenger
compartment,
Instrument Panel
at the top of the
and Center
driver side of
Console
the instrument
Components
panel, above
the steering
column
In the
passenger
compartment,
Instrument Panel
at the top
and Center
center of the
Console
instrument
Components
panel, above
the radio
controls
In the luggage Luggage
at the top right Components
side
(Notchback)
In the
passenger
compartment,
at the front of Driver Door
Components
the left front
door, behind
the door trim
panel
In the
passenger
compartment,
at the front of Passenger Door
the right front Components
door, behind
the door trim
panel
In the
passenger
compartment,
Left Rear Door
in the lower left
Components
rear door,
behind the door
panel
In the
passenger
P16 Instrument
Cluster
P17 Info Display

Module (UAG)
P17 Info Display
Module X1
(UHQ)
P17 Info Display
Module X2
(UHQ)
P19AA Speaker Right Subwoofer
P19AG Speaker - Left

Front Door
P19AH Speaker Right Front Door
P19AL Speaker - Left

Rear Door

Speaker - Right Rear

P19AM
Door
P19B
Speaker - Center
Instrument Panel
P19H
Speaker - Left Front

Tweeter
UQA
P19N
Speaker - Left
Subwoofer
P19V
Speaker - Right
Front Tweeter
Q2
A/C Compressor
Clutch
Q5
Brake Pressure
Modulator
compartment,
in the lower
right rear door
panel
In the
passenger
compartment,
in the center of
the instrument
panel upper
dash pad
In the
passenger
compartment,
at the base of
the left A-pillar
In the luggage
compartment,
at the top left
side
In the
passenger
compartment,
at the base of
the right Apillar
In the engine
compartment,
attached to
front of A/C
compressor
In the engine
compartment,
under the
radiator surge
tank, attached
to the brake
control module
Right Rear Door

Components
P19AM Speaker Right Rear Door
P19B Speaker - Center

Instrument Panel
(UQA)
Left Side of
Passenger
Compartment
Components
P19H Speaker - Left

Front Tweeter
Luggage
Compartment
Components
(Notchback)
P19N Speaker - Left

Subwoofer
Right Side of
Passenger
Compartment
Components
P19V Speaker - Right

Front Tweeter
Q6E
Camshaft Position
Actuator Solenoid
Valve - Exhaust
In the engine
compartment,
at the front
right side of the
engine
Right Front
of the Engine
Components
(LUV)
Top of the
Engine
Components
Q6E Camshaft
Position
Actuator
Solenoid Valve Exhaust (LUV)
Q6E Camshaft
Position
Actuator

(LUW/LWE)
Solenoid Valve Exhaust

(LUW/LWE)
Q6F
Camshaft Position
Actuator Solenoid
Valve - Intake
In the engine
compartment,
at the rear right
side of the
engine
Right Rear
of the Engine
Components
(LUV)
Top of the
Engine
Components
(LUW/LWE)
Q8
Control Solenoid
Valve Assembly
In the engine
compartment,
MH8/MH9 at the front of
the
transmission
Left Front of the

Engine
Components
(LUW/LWE)
Q12
Q13
Evaporative
Emission Purge
Solenoid Valve
Evaporative
Emission Vent
Solenoid Valve
In the engine
compartment,
at the top
middle rear of
the engine
Right Rear
of the Engine
Components
(LUV)
Top of the
Engine
Components
(LUW/LWE)
Under the
vehicle, at the Fuel Tank
top right side of Components
the fuel tank
In the engine
compartment,
Right Rear
of the Engine
Components
Q6F Camshaft
Position
Actuator
Solenoid Valve Intake (LUV)
Q6F Camshaft
Position
Actuator
Solenoid Valve Intake
(LUW/LWE)
Q8 Control
Solenoid Valve
Assembly X1
(MH8)
Q8 Control
Solenoid Valve
Assembly X2
(MH8)
Q8 Control
Solenoid Valve
Assembly X3
(MH8)
Q8 Control
Solenoid Valve
Assembly X4
(MH8)
Q12 Evaporative
Emission Purge
Solenoid Valve
(LUV)
Q12 Evaporative
Emission Purge
Solenoid Valve
(LUW/LWE)
Q13 Evaporative
Emission Vent
Solenoid Valve
Q17A Fuel

Q17A
Fuel Injector 1
at the top rear

of the engine,
at the cylinder
1 intake port
Q17B
Fuel Injector 2
In the engine
compartment,
at the top rear
of the engine,
at the cylinder
2 intake port
Q17C
Fuel Injector 3
In the engine
compartment,
at the top rear
of the engine,
at the cylinder
3 intake port
Q17D
Fuel Injector 4
Q22
Intake Manifold
Tuning Solenoid
Valve
Q27A
Pressure Control
Solenoid Valve 1
Q27B
Pressure Control
Solenoid Valve 2
In the engine
compartment,
at the top rear
of the engine,
at the cylinder
4 intake port
In the engine
compartment,
on the left side
LUW/LWE of the engine
block, under
the intake
manifold
In the engine
compartment,
MH8/MH9 internal to the
transmission
assembly
In the engine
MH8/MH9 compartment,
internal to the
transmission
(LUV)
Top of the
Engine
Components
(LUW/LWE)
Right Rear
of the Engine
Components
(LUV)
Top of the
Engine
Components
(LUW/LWE)
Right Rear
of the Engine
Components
(LUV)
Top of the
Engine
Components
(LUW/LWE)
Right Rear
of the Engine
Components
(LUV)
Top of the
Engine
Components
(LUW/LWE)
Right Rear of the

Engine
Components
(LUW/LWE)
Injector 1 (LUV)
Q17A Fuel
Injector 1
(LUW/LWE)
Q17B Fuel
Injector 2 (LUV)
Q17B Fuel
Injector 2
(LUW/LWE)
Q17C Fuel
Injector 3 (LUV)
Q17C Fuel
Injector 3
(LUW/LWE)
Q17D Fuel
Injector 4 (LUV)
Q17D Fuel
Injector 4
(LUW/LWE)
Q22 Intake Manifold

Tuning Solenoid Valve
(LUW/LWE)

Q27C
Q27D
Q27E
Q29
Q32A
Q38
Q38
Q39A
Q40
assembly
In the engine
compartment,
Pressure Control
Solenoid Valve 3
transmission
assembly
In the engine
compartment,
Pressure Control
Solenoid Valve 4
transmission
assembly
In the engine
compartment,
Pressure Control
Solenoid Valve 5
transmission
assembly
In the engine
compartment,
on the left side
Secondary Air
of the engine,
Injection Solenoid
on the left front
Valve
corner of the
cylinder head
In the engine
compartment,
1
transmission
assembly
In the engine Left Rear of the
compartment, Engine
Throttle Body
LUV
at the left rear Components
of the engine (LUV)
In the engine
Top of the Engine
compartment,
Throttle Body
LUW/LWE
Components
at the right rear
(LUW/LWE)
of the engine
In the engine
Torque Converter
compartment,
Clutch Pressure
Control Solenoid
transmission
Valve
assembly
In the engine
Turbocharger
compartment,
Bypass Solenoid
LUV
at the right rear
Valve
of the engine
In the engine
Q38 Throttle Body
Q38 Throttle Body
Q40 Turbocharger
Bypass Solenoid Valve
(LUV)

Q42
Turbocharger
Wastegate Solenoid
Valve
LUV
compartment,
at the right
front of the
engine, above
the A/C
compressor
At the front of
the engine
compartment,
part of the
compressor
assembly
Right Front of the

Q42 Turbocharger
Engine
Wastegate Solenoid
Components
Valve (LUV)
(LUV)
Q46
S2
S3
S13D
S26
S30
A/C Compressor
Solenoid Valve
In the
passenger
Transmission
compartment,
MH8/MH9
Manual Shift Switch
part of the
transmission
shift lever
In the
passenger
compartment,
under the
Transmission Shift
center console,
MH8/MH9
Lever
part of the
automatic
transmission
shift lever
assembly
In the
passenger
Door Lock Switch compartment,
Driver
in the center of
the instrument
panel
In the
passenger
Hazard Warning
compartment,
Switch
in the center of
the instrument
panel
Headlamp Switch
Right Front
of the Engine
Components
(LUV)
Q46 A/C Compressor
Right Front Solenoid Valve
of the Engine
Components
(LUW/LWE)
S2 Transmission
Manual Shift Switch
(MH8)
Instrument Panel
and Center
Console
Components
S3 Transmission Shift
Lever (MH8)
Instrument Panel
and Center
Console
Components
S13D Door Lock

Switch - Driver
Instrument Panel
and Center
Console
Components
S26 Hazard Lamps

Switch
In the
passenger
Instrument Panel
on the left side Console
S30 Headlamp Switch

S33
Horn Switch
S38
Ignition Mode
Switch
BTM
S39
Ignition Switch
without
BTM
S52
Outside Rearview
Mirror Switch
S58A
Rear Compartment
Lid Unlatch Switch Exterior
S64D
Seat Adjuster Switch

- Driver
ADS
of the steering Components

column
In the
passenger
compartment,
in the center of
the steering
wheel, behind
the driver side
air bag
In the
passenger
compartment,
behind the
steering wheel,
on the right
side of the
steering
column
In the
passenger
compartment,
behind the
steering wheel,
on the right
side of the
steering
column
In the
passenger
Driver Door
compartment,
Components
on the driver
door trim panel
At the rear of
the vehicle, in
the center of
the rear
Rear of Vehicle
compartment Components
lid, between the
license plate
lamps
S38 Igntion Mode

Switch (BTM)
S39 Ignition Switch
S52 Outside Rearview

Mirror Switch
In the
passenger
Driver Seat
compartment, Components (1 of S64D Seat Adjuster
Switch - Driver (ADS)
mounted to the 2)
outboard side
of the driver

S70L
Steering Wheel
Controls Switch Left
S70R
Steering Wheel
Controls Switch Right
W1Y
S72
Sunroof Switch
CF5
S75
Traction Control
Switch
S78
Turn
Signal/Multifunction
Switch
S79D
Window Switch Driver
S79D
Window Switch Driver
K34
FX3
AEC
AXG
seat cushion
In the
passenger
compartment,
on the left side
of the steering
wheel
In the
passenger
compartment,
on the right
side of the
steering wheel
In the
passenger
compartment,
at the front of
the headliner,
in the overhead
console
In the
passenger
compartment,
on the center
console trim
plate, right side
of the shifter
In the
passenger
compartment,
on the left side
of the steering
column
In the
passenger
compartment,
behind the
driver door
trim panel,
center of the
door
Instrument Panel
and Center
Console
Components
S70L Steering Wheel

Controls Switch - Left
(K34)
Instrument Panel
and Center
Console
Components
S70R Steering Wheel

Controls Switch Right (W1Y)
S72 Sunroof Switch

(CF5)
Instrument Panel
and Center
Console
Components
S75 Traction Control

Switch (FX3)
Instrument Panel
and Center
Console
Components
S78 Turn Signal/MultiFunction Switch
Driver Door
Components
S79D Window Switch Driver (AEC)
In the
passenger
compartment, Driver Door
on the driver Components
door trim
panel, center of
S79D Window Switch Driver (AXG)

S79LR
Window Switch Left Rear
S79P
Window Switch Passenger
S79RR
Window Switch Right Rear
S82
Windshield
Wiper/Washer
Switch
S88
Sunroof Tilt Switch
CF5
the door
In the
passenger
compartment,
at the center of
the left rear
door, on the
door trim panel
In the
passenger
compartment,
on the
passenger door
trim panel,
center of the
door
In the
passenger
compartment,
at the center of
the right rear
door, on the
door trim panel
In the
passenger
compartment,
on the right
side of the
steering
column
In the
passenger
compartment,
at the front of
the headliner,
in the overhead
console
Left Rear Door

Components
S79LR Window Switch

- Left Rear
Passenger Door
Components
S79P Window Switch Passenger
Right Rear Door

Components
S79RR Window
Switch - Right Rear
Instrument Panel
and Center
Console
Components
S82 Windshield
Wiper/Washer Switch
S88 Sunroof Tilt

Switch (CF5)
T3
Audio Amplifier
UQA
In the luggage
Luggage
compartment,
Compartment
mounted on the
Components
right rear wheel
(Notchback)
well
T3 Audio
Amplifier X1
(UQA)
T3 Audio
Amplifier X2
(UQA)
T3 Audio
Amplifier X3
(UQA)

T4G
Cellular Phone,
Navigation, and
Digital Radio
Antenna
T4S
Wireless
Communication
Antenna - Bluetooth
T10E
Keyless Entry
Antenna - Rear
Compartment
ATH
T10G
Keyless Entry
Antenna - Rear
Fascia
ATH
T10J
Keyless Entry
Antenna - Center
Console Front
ATH
T10K
Keyless Entry
Antenna - Center
Console Rear
ATH
T10M
Keyless Entry
Antenna - Driver
Door Handle
T10N
Keyless Entry
Antenna - Passenger
Door Handle
UPF
ATH
ATH
Outside the
vehicle, at the Rear of Vehicle
rear center of Components
the roof
In the
passenger
compartment,
in the
instrument
panel, attached
to the
telematics
communication
interface
module
In the rear
compartment,
in the center of
the metal floor
pan near the
seatback
On the vehicle
exterior, behind
the rear fascia
In the
passenger
compartment,
in the lower
instrument
panel near the
front of the
console
In the
passenger
compartment,
in the rear end
of the console
On the vehicle
exterior, inside
the driver door
handle
On the vehicle
exterior, inside
the passenger
door handle
In the
passenger
T10E Keyless Entry

Antenna - Rear
Compartment (ATH)
T10G Keyless Entry
Antenna - Rear Fascia
(ATH)
T10J Keyless Entry

Antenna - Center
Console Front (ATH)
T10K Keyless Entry

Antenna - Center
Console Rear (ATH)
T10M Keyless Entry
Antenna - Driver Door
Handle (ATH)
T10N Keyless Entry
Antenna - Passenger
Door Handle (ATH)

T11
T12
T15
W7
X50A
X50D
X51A
X80L
compartment,
behind the
center of the
Multimedia Player
KTA
instrument
Interface Module
panel, below
the HVAC
controls
In the engine
Automatic
compartment,
Transmission
MH8/MH9 toward the left
Assembly
side, attached
to the engine
In the
passenger
Behind the
Navigation Antenna UE1 and compartment,
Instrument Panel
Signal Splitter
UYS
near the bottom
Components
of the right
front A-pillar
On Instrument
panel harness
Blunt Cut - Shield
near X200
connector
In the left front
of the engine
Left Side of Engine
compartment,
Fuse Block Compartment
behind the
Underhood
Components
headlamp
assembly
In the left side
Fuse Block - Battery
on top of the Components
battery
In the
passenger
compartment,
to the left of
Instrument Panel
Fuse Block the steering
and Center
Instrument Panel
column, under Console
the left
Components
instrument
panel knee
bolster
Accessory Power
Receptacle - Rear
In the
passenger
compartment,
at the rear of
Instrument Panel
and Center
Console
T11 Multimedia Player

Interface Module
(KTA)
Electrical Center
Identification Views
Electrical Center
Electrical Center
X80L Accessory Power

Receptacle - Rear

Console
X83
Auxiliary Audio
Input
X84
Data Link Connector
the center
Components
console
In the
Instrument Panel
passenger
in the center
Console
console storage Components
compartment
In the
passenger
at the bottom of and Center
the driver side Console
Components
of the
instrument
panel
Console
X83 Auxiliary Audio

Input
X84 Data Link

Connector
X85
Steering Wheel Air

Bag Coil
X100
Body Harness to
Forward Lamp
Harness (40 cavities)
X102
Engine Cooling
Harness to Forward
Lamp Harness (4
cavities)
X104
Engine Cooling
Harness to Forward
Lamp Harness (5
cavities)
In the
passenger
compartment,
behind the
steering wheel
In the left front

of the engine
compartment,
under the front
of the battery
tray
In the left front
of the engine
compartment,
on the lower
left side of the
cooling fan
assembly
In the left front
of the engine
compartment,
on the lower
left side of the
cooling fan
assembly
In the engine
X85 Steering
Wheel Air Bag
Coil X1
X85 Steering
Wheel Air Bag
Coil X2
X85 Steering
Wheel Air Bag
Coil X3
Forward Lamp
Harness Routing
X100 Body Harness to

Forward Lamp
Harness
Forward Lamp
Harness Routing
X102 Engine Cooling

Harness to Forward
Lamp Harness
Forward Lamp
Harness Routing
X104 Engine Cooling

Harness to Forward
Lamp Harness

X105
X114
X190
X200
X203
X205
X206
X207
Engine Harness to
compartment, Engine Harness
LUW/LWE left side of
Routing - Right
Fuel Injectors
Rear (LUW/LWE)
engine
In the left front
of the engine
Power Steering
compartment,
Harness to Forward
Forward Lamp
on the lower
Lamp Harness (12
Harness Routing
left side of the
cavities)
cooling fan
assembly
In the left front
of the engine Engine Harness
Body Harness to
compartment, Routing - Left
Engine Harness (40
under the front Front
cavities)
of the battery (LUW/LWE)
tray
In the
Instrument Panel
passenger
Passenger
Harness to Body
compartment,
Compartment
Harness (102
near the bottom
Harness Routing
cavities)
of the left front
A-pillar
In the
Instrument Panel
passenger
Harness to Passenger
compartment,
Instrument Panel
behind
Harness Routing
Bag Harness (5
instrument
cavities)
panel
compartment
In the
passenger
Instrument Panel
Passenger
compartment,
Harness to Body
UQA
Compartment
near the bottom
Harness Routing
of the right
front A-pillar
In the
passenger
Instrument Panel
Passenger
compartment,
Harness to Body
Compartment
near the bottom
Harness (2 cavities Harness Routing
of the right
COAX)
front A-pillar
In the
Instrument Panel
passenger
Passenger
Harness to Body
compartment,
Compartment
Harness (2 cavities near the bottom
Harness Routing
COAX)
of the right
front A-pillar
X105 Engine Harness

to Fuel Injectors
Harness (LUW/LWE)
X114 Power Steering

Harness to Forward
Lamp Harness

Engine Harness
X200 Instrument Panel

Harness to Body
Harness

Harness to Passenger
Bag Harness

Harness to Body
Harness (UQA)

X210
Headliner Harness to
Body Harness (20
cavities)
X211
Headliner Harness to
Body Harness (20
cavities)
X212
Instrument Panel
Harness to HVAC
C68
X300
Console Harness to
Instrument Panel
X301
Console Harness to
Instrument Panel
Harness (5 cavities USB)
X310
Body Harness to
Driver Seat Harness
(20 cavities)
X320
Body Harness to
Passenger Seat
In the
passenger
compartment,
at the right
front A-pillar
In the
passenger
compartment,
at the right
front A-pillar
In the
passenger
compartment,
behind the
center of the
instrument
panel
In the
passenger
compartment,
under the
center of
instrument
panel, in front
of the shifter
In the
passenger
compartment,
under the
center of
instrument
panel, in front
of the shifter
In the
passenger
compartment,
under the right
side of the
driver seat
In the
passenger
compartment,
under the left
side of the
passenger seat
In the
passenger
Passenger
Compartment
Harness Routing
X210 Headliner
Harness to Body
Harness
Passenger
Compartment
Harness Routing
X211 Headliner
Harness to Body
Harness

Harness to HVAC
Harness (C68)
Center Console
Harness Routing
X300 Console Harness

to Instrument Panel
Harness
Center Console
Harness Routing
Driver Seat
Harness Routing

Driver Seat Harness
Passenger Seat
Harness Routing

Passenger Seat
Harness

X335
Body Harness to
Curtain Air Bag
Jumper Harness (2
cavities)
X345
Body Harness to
Curtain Air Bag
Jumper Harness (2
cavities)
X401
Fuel Tank Harness

to Body Harness (16
cavities)
X402
Rear Object Sensor

Harness to Body
UD7
X410
Left Tail Lamp

Harness to Body
X420
Right Tail Lamp

Harness to Body
X500
Driver Door Harness

to Body Harness (41
cavities)
X600
Passenger Door
Harness to Body
compartment,
above the
headliner,
between the
left B-pillar
and C-pillar
In the
passenger
compartment,
Passenger
above the
Compartment
headliner,
Harness Routing
between the
right B-pillar
and C-pillar
Under the
Body Harness
vehicle, at the
Routing - Under
front of the
the Rear of the
right rear wheel
Vehicle
well
At the rear of
the vehicle,
Body Harness
behind the
Routing - Under
inner left side the Rear of the
of the rear
Vehicle
fascia
In the luggage
Body Harness
compartment,
Routing - Left Side
near the left tail
of the Luggage
lamp, behind
Compartment
the trim panel
In the luggage
Body Harness
compartment,
Routing - Right
near the right
Side of the
tail lamp,
Luggage
behind the trim
Compartment
panel
In the
passenger
Driver Door
compartment,
Harness Routing
at the left front
A-pillar
In the
passenger
Passenger Door
compartment,
Harness Routing
at the right
front A-pillar
In the

Curtain Air Bag
Harness

Curtain Air Bag
Harness
X401 Fuel Tank

Harness to Body
Harness
X402 Rear Object

Sensor Harness to
Body Harness (UD7)
X410 Left Tail Lamp

Harness to Body
Harness
X420 Right Tail Lamp

Harness to Body
Harness
X500 Driver Door

Harness to Body
Harness
X600 Passenger Door

Harness to Body
Harness

X700
Left Rear Door

Harness to Body
X800
Right Rear Door

Harness to Body
X900
Rear Compartment
Lid Harness to Body
X910
Left Inner Tail Lamp

Jumper Harness to
Rear Compartment
Lid Harness (2
cavities)
X915
License Plate Lamp

Harness to Rear
Compartment Lid
X915
License Plate Lamp

Harness to Rear
Compartment Lid
X920
Right Inner Tail

Lamp Jumper
Harness to Rear
Compartment Lid
G100
Battery (-) Harness
G101
Forward Lamp
Harness
(-UVC)
(UVC)
passenger
compartment,
in the left Bpillar
In the
passenger
compartment,
in the right Bpillar
In the luggage
compartment,
on the left side,
behind the trim
panel
In the luggage
compartment,
near the left
inner tail lamp,
behind the trim
panel
At the rear of
the vehicle, in
the right center
of the rear
compartment
lid
At the rear of
the vehicle, in
the right center
of the rear
compartment
lid
In the luggage
compartment,
near the right
inner tail lamp,
behind the trim
panel
In the engine
compartment,
on the left side,
forward of the
battery
In the engine
compartment,
on the left side,
forward of the
Left Rear Door

Harness Routing
X700 Left Rear Door

Harness to Body
Harness
Right Rear Door

Harness Routing
X800 Right Rear Door

Harness to Body
Harness
Body Harness
Routing - Left Side
of the Luggage
Compartment
X900 Rear
Compartment Lid
Harness to Body
Harness
X910 Left Inner Tail

Rear
Lamp Harness to Rear
Compartment Lid
Compartment Lid
Harness Routing
Harness
X915 License Lamp

Rear
Harness to Rear
Compartment Lid
Compartment Lid
Harness Routing
Harness (-UVC)
X915 License Lamp

Rear
Harness to Rear
Compartment Lid
Compartment Lid
Harness Routing
Harness (UVC)
X920 Right Inner Tail

Rear
Lamp Harness to Rear
Compartment Lid
Compartment Lid
Harness Routing
Harness
G100, G101, G103,

G104, G105, G120,
and G121
G100, G101, G103,

G104, G105, G120,
and G121

G102
G103
G104
G105
G112
G114
G114
G120
battery
In the engine
compartment,
on the lower
rear of the
Battery (+) Harness
G102
engine, near the
starter
assembly
In the left rear
of the engine G100, G101, G103,
Forward Lamp
compartment, G104, G105, G120,
Harness
near the strut and G121
tower
In the right
front of the
G100, G101, G103,
Forward Lamp
engine
G104, G105, G120,
Harness
compartment,
and G121
near the right
engine mount
In the engine
Engine Cooling
on the left side, G104, G105, G120,
Harness
forward of the and G121
battery
In the engine
compartment,
top left side of
Engine Harness
G112 (LUW/LWE)
the engine,
above the
thermostat
housing
In the engine
compartment,
Engine Harness
LUV
on the left side, G114 (LUV)
forward of the
battery
In the engine
compartment,
Engine Harness
LUW/LWE on the left side, G114 (LUW/LWE)
forward of the
battery
In the left rear
Body Harness
tower

G121
Power Steering
Harness
G201
Instrument Panel
Harness
G202
Instrument Panel
Harness
G203
Instrument Panel
Harness
G204
Instrument Panel
Harness
G301
Body Harness
G305
Body Harness
G307
Body Harness
In the left rear

tower
In the
passenger
compartment,
behind the left G201
side of the
instrument
panel
In the
passenger
compartment,
G202 and G203
behind the
center of the
instrument
panel
In the
passenger
compartment,
behind the
G202 and G203
center of the
instrument
panel
In the
passenger
compartment,
behind the
G204
center of the
instrument
panel
In the
passenger
compartment, G301
below the
center console
In the
passenger
near the bottom and G400
of the left front
A-pillar
In the
passenger
compartment,
G305, G307, G308,

G308
Body Harness
G309
Body Harness
G400
Body Harness
G402
Body Harness
J101
Forward Lamp
Harness
J102
Forward Lamp
Harness
J108
Fuel Injector
Harness
under the
and G400
center console
In the
passenger
near the bottom and G400
of the right
front A-pillar
In the luggage
compartment,
on the rear of G309
the left rear
wheel well
In the
passenger
G305, G307, G308,
compartment,
and G400
on the right Dpillar
In the luggage
compartment,
on the right
rear wheel
G402
well, above the
fuel pump
control module
In the forward
lamp harness,
toward the left
front,
approximately
7 cm (2.76 in)
from the
breakout for
X114
In the forward
lamp harness,
approximately
17 cm (6.7 in)
from the
breakout for
the hood ajar
switch
In the fuel
injector
LUW/LWE harness,
approximately Engine Harness
5 cm (1.97 in) Routing - Right

J111
Engine Harness
J111
Engine Harness
J112
Engine Harness
J114
Engine Harness
J114
Engine Harness
from the
breakout for
fuel injector 4
In the engine
harness,
approximately
9 cm (3.54 in)
LUV
from the
throttle body
breakout
In the engine
harness,
approximately
18.5 cm (7.28
in) from the
LUW/LWE breakout for
the camshaft
position
actuator
solenoid valve
- intake
In the engine
harness,
approximately
30 cm (1.18 in)
LUV
from the
breakout for
the engine
control module
connectors
In the engine
harness
approximately
LUV
9 cm (3.54 in)
from the
throttle body
breakout
Rear (LUW/LWE)
Engine Harness
Routing - Left
Front (LUV)
Engine Harness
Routing - Right
Rear (LUW/LWE)
Engine Harness
Routing - Left
Front (LUV)
Engine Harness
Routing - Left
Front (LUV)
In the engine
harness,
approximately
24 cm (9.45 in) Engine Harness
LUWLWE from the
Routing - Right
breakout for
Rear (LUW/LWE)
the camshaft
position
actuator
solenoid valve

J116
Forward Lamp
Harness
J119
Engine Harness
J119
Engine Harness
J122
Engine Harness
J123
Engine Harness
- intake
In the forward
lamp harness,
approximately
5 cm (1.97 in)
from the main
T3U
bundle in the
breakout for
the underhood
fuse block
In the engine
harness
approximately
LUV with
0.5 cm (0.19
MH8
in) from the oil
pressure switch
breakout
In the engine
harness,
approximately
3 cm (1.18 in)
LUW or from the
LWE with breakout for
MH9
the camshaft
position
actuator
solenoid valve
- intake
In the engine
harness,
approximately
10 cm (3.98 in)
LUW or
from the
LWE with
breakout for
MH9
the intake
manifold
tuning solenoid
valve
In the engine
harness, in the
the underhood
fuse block
Forward Lamp
Harness Routing
Engine Harness
Routing - Left
Front (LUV)
Engine Harness
Routing - Right
Rear (LUW/LWE)
Engine Harness
Routing - Right
Rear (LUW/LWE)
In the engine
harness,
approximately
9 cm (3.5 in) Engine Harness

J127
Engine Harness
J127
Engine Harness
J128
Body Harness
J132
Engine Harness
J132
Engine Harness
J144
Engine Harness
from the
Routing - Left
Front (LUV)
breakout for
LUV
the engine
control module
In the engine
harness,
LUW/LWE 6 cm (2.4 in) Routing - Right
Rear (LUW/LWE)
from the
breakout for
G114
In the body
harness
approximately
8.0 cm (4.33
in) from the
body control
module ground
In the engine
harness
approximately
Engine Harness
2 cm (.79 in)
LUV
Routing - Left
from the fuse
Front (LUV)
block
underhood
breakout
In the engine
harness,
approximately
12.5 cm (4.92
Engine Harness
in) from the
Routing - Right
the camshaft Rear (LUW/LWE)
position
actuator
solenoid valve
- intake
In the engine
harness
LUV with
8 cm (4.33 in) Routing - Left
MH8
from the engine Front (LUV)
control module
breakout
In the engine
harness,
approximately

J144
Engine Harness
J200
Instrument Panel
Harness
J201
Instrument Panel
Harness
J202
Instrument Panel
Harness
J203
Instrument Panel
Harness
22.5 cm (8.86
in) from the
breakout for
LUW or
the camshaft
LWE with
position
MH9
actuator
solenoid valve
- intake
In the
instrument
panel harness,
approximately
9 cm (3.54 in)
from the
breakout for
the center
speaker
In the
instrument
panel harness,
in the breakout
to the
instrument
panel fuse
block,
approximately
10 cm (3.93
in.) from the
main harness
In the
instrument
panel harness,
approximately
23 cm (9.06 in)
from the
breakout for
the USB
connector and
the traction
control switch
Engine Harness
Routing - Right
Rear (LUW/LWE)
Instrument Panel
Harness Routing
Instrument Panel
Harness Routing
Instrument Panel
Harness Routing
In the
instrument
panel harness, Instrument Panel
approximately Harness Routing
10 cm (3.94 in)
from the
breakout for

J204
Instrument Panel
Harness
J206
Instrument Panel
Harness
J207
Instrument Panel
Harness
J209
Instrument Panel
Harness
J211
Instrument Panel
Harness
the instrument
panel cluster
In the
instrument
panel harness,
approximately
3 cm (1.18 in)
from the main
breakout for
center speaker
In the
instrument
panel harness,
in the breakout
to the relay
section of the
instrument
panel fuse
block
In the
instrument
panel harness,
in the breakout
to the relay
section of the
instrument
panel fuse
block
In the steering
column
breakout,
approximately
4 cm (1.57 in)
from the main
harness
In the
instrument
panel harness,
approximately
6 cm (2.36 in)
from the
breakout for
the hazard
switch and air
bag display
In the
instrument
Instrument Panel
Harness Routing
Instrument Panel
Harness Routing
Instrument Panel
Harness Routing
Instrument Panel
Harness Routing
Instrument Panel
Harness Routing

J212
Instrument Panel
Harness
J213
Instrument Panel
Harness
J214
Instrument Panel
Harness
J271
HVAC Harness
J272
HVAC Harness
J300
Body Harness
J301
Body Harness
panel harness,
approximately
6 cm (2.36 in)
from the
breakout for
the shift lever
In the
instrument
panel harness,
approximately
15 cm (5.91 in)
from the
instrument
cluster
breakout
In the
instrument
panel harness,
approximately
4 cm (1.57 in)
from the
breakout for
the radio
controls
In the HVAC
harness, behind
and below the
center of the
instrument
panel
In the HVAC
harness, behind
and below the
center of the
instrument
panel
In the body
harness,
approximately
7.5 cm (2.95
in) from the
G303 breakout
Center Console
Harness Routing
Instrument Panel
Harness Routing
Instrument Panel
Harness Routing
In the body
Passenger
harness,
approximately Compartment
8 cm (3.14 in) Harness Routing
from the X225

J302
Body Harness
J303
Body Harness
J305
Body Harness
J307
Body Harness
J308
Body Harness
J311
Body Harness
breakout
In the body
harness,
approximately
17 cm (6.69 in)
from the right
main bundle,
toward the
center console
In the body
harness,
approximately
15 cm (5.90 in)
from the X500
breakout
In the body
harness,
approximately
25 cm (9.84 in)
from the right
main bundle
In the body
harness,
approximately
16 cm (6.29 in)
from the park
brake switch
breakout
In the body
harness,
approximately
22 cm (8.66 in)
from the right
main bundle,
near the right
front side
impact sensor
breakout
In the body
harness,
approximately
7 cm (2.75 in)
from the G301
breakout
Passenger
Compartment
Harness Routing
Passenger
Compartment
Harness Routing
Passenger
Compartment
Harness Routing
Passenger
Compartment
Harness Routing
Passenger
Compartment
Harness Routing
Passenger
Compartment
Harness Routing
In the body
harness,
approximately Body Harness

J312
Body Harness
Y8X
J313
Body Harness
J314
Body Harness
J315
Body Harness
J316
Body Harness
J317
Passenger Seat
Harness
J319
Body Harness
9 cm (3.54 in) Routing - Right

from the right Side of the
Luggage
rear wheel
speed sensor Compartment
breakout
In the body
harness,
approximately
Passenger
17 cm (6.69 in)
Compartment
from the left
Harness Routing
main bundle
towards X320
breakout
In the body
harness,
Passenger
approximately
Compartment
21 cm (8.26 in)
Harness Routing
from the G301
breakout
In the body
harness,
approximately
Passenger
6.5 cm (2.55
Compartment
in) from the left
Harness Routing
front side
impact sensor
breakout
In the body
harness,
Passenger
approximately
Compartment
7 cm (2.75 in)
Harness Routing
from the X500
breakout
In the
passenger seat
Passenger Seat
harness, in the
Harness Routing
breakout to
X315
In the body
harness,
Passenger
approximately
Compartment
6.5 cm (2.55
Harness Routing
in) from the
X225 breakout
In the headliner
harness,
approximately

J332
Headliner Harness
J333
Headliner Harness
CF5
J334
Headliner Harness
J401
Body Harness
J402
Body Harness
J404
Body Harness
33 cm (13 in)
from the
Headliner Harness
breakout for
Routing
the left
sunshade
In the headliner
harness,
approximately
8.5 cm (3.35 Headliner Harness
in) from the
Routing
breakout for
the sunroof
control module
In the headliner
harness,
approximately
5 cm (1.97 in) Headliner Harness
from the
Routing
breakout for
the sunroof
control module
In the body
harness,
14.0 cm (5.51 Routing - Left Side
in) from the
of the Luggage
parking assist Compartment
control module
breakout
In the body
harness,
8.0 cm (3.14 Routing - Left Side
of the Luggage
in) from the
parking assist Compartment
control module
breakout
In the body
harness,
Body Harness
approximately
Routing - Right
13 cm (5.12 in)
Side of the
into the
Luggage
breakout for
Compartment
the fuel pump
control module
In the rear
object sensor

J498
Rear Object Sensor

Harness
UD7
J499
Rear Object Sensor

Harness
UD7
J501
Driver Door Harness
AXG
J502
Driver Door Harness
J605
Passenger Door
Harness
Left Rear Door
harness,
approximately
10 cm (3.94 in)
from the
breakout for
X402
In the rear
object sensor
harness,
approximately
8 cm (3.15 in)
from the
breakout to the
right middle
rear object
sensor
Inside the
driver door
harness,
approximately
Driver Door
9 cm (3.54 in)
Harness Routing
into the
breakout for
driver outside
rearview mirror
Inside the
driver door
harness,
approximately
Driver Door
10.5 cm (4.13
Harness Routing
in) from the
breakout for
driver window
motor
Inside the
passenger door
harness,
approximately
Passenger Door
9 cm (3.54 in)
Harness Routing
into the main
breakout for
the passenger
window switch
Inside the right
rear door
harness,
approximately

Harness
J701
J702
Left Rear Door

Harness
J704
Left Rear Door

Harness
J801
Right Rear Door

Harness
J803
Right Rear Door

Harness
J901
License Lamp
Harness
20.5 cm (8.07
in) from the
breakout for
the left rear
window switch
Inside the left
rear door
harness,
approximately
5 cm (1.97 in)
from the
breakout for
the left rear
window switch
Inside the left
rear door
harness,
approximately
2 cm (.78 in)
from the
breakout for
the left rear
window switch
Inside the right
rear door
harness,
approximately
20.5 cm (8.07
in) from the
breakout for
the right rear
window switch
Inside the right
rear door
harness,
approximately
27.5 cm (10.83
in) from the
breakout for
the right rear
window switch
Left Rear Door

Harness Routing
Left Rear Door

Harness Routing
Right Rear Door

Harness Routing
Right Rear Door

Harness Routing
In the license
lamp harness, Rear
at the takeout Compartment Lid
for the exterior Harness Routing
rear
compartment

J902
License Lamp
Harness
J903
Rear Compartment
Lid Harness
lid unlatch
switch
In the license
lamp harness,
at the takeout
for the exterior
rear
compartment
lid unlatch
switch
In the rear
compartment
lid harness,
approximately Rear
39 cm (15.35 Compartment Lid
Harness Routing
in) from the
breakout for
the left tail
lamp

2013 ELECTRICAL Wiring Systems and Power Management - Component Locator - Passenger Compartment/Roof
2013 ELECTRICAL
Wiring Systems and Power Management - Component Locator - Passenger Compartment/Roof
PASSENGER COMPARTMENT/ROOF COMPONENT VIEWS

LEFT SIDE OF PASSENGER COMPARTMENT COMPONENTS
Fig. 1: Left Side Of Passenger Compartment Components

Items
1: B63LR Side Impact Sensor - Left Rear B63LR Side Impact Sensor - Left Rear
2: F112D Seat Belt Retractor Pretensioner - Driver F112D Seat Belt Retractor Pretensioner - Driver
3: F105L Roof Rail Air Bag - Left F105L Roof Rail Air Bag - Left
4: B63LF Side Impact Sensor - Left Front B63LF Side Impact Sensor - Left Front

5: P19H Speaker - Left Front Tweeter P19H Speaker - Left Front Tweeter
RIGHT SIDE OF PASSENGER COMPARTMENT COMPONENTS
Fig. 2: Right Side Of Passenger Compartment Components

Items
1: K9 Body Control Module K9 Body Control Module X1 K9 Body Control Module X2 K9 Body
Control Module X3 K9 Body Control Module X4 K9 Body Control Module X5 K9 Body Control
Module X6 K9 Body Control Module X7
2: P19V Speaker - Right Front Tweeter P19V Speaker - Right Front Tweeter
3: B63RF Side Impact Sensor - Right Front B63RF Side Impact Sensor - Right Front
4: F105R Roof Rail Air Bag - Right F105R Roof Rail Air Bag - Right
5: F112P Seat Belt Retractor Pretensioner - Passenger F112P Seat Belt Retractor Pretensioner Passenger
6: B63RR Side Impact Sensor - Right Rear B63RR Side Impact Sensor - Right Rear

7: B119 Multi-axis Acceleration Sensor (FX3) B119 Multi-Axis Acceleration Sensor (FX3)
8: K36 Inflatable Restraint Sensing and Diagnostic Module K36 Inflatable Restraint Sensing and
Diagnostic Module X1 K36 Inflatable Restraint Sensing and Diagnostic Module X2
HEADLINER COMPONENTS
Fig. 3: Headliner Components

Items
1: E37M Dome/Reading Lamps - Middle E37M Dome/Reading Lamps - Middle
2: A3R Sunshade - Right (D6I) A3R Sunshade - Right (D6I)
3: E37F Dome/Reading Lamps - Front E37F Dome/Reading Lamps - Front
4: K77 Remote Control Door Lock Receiver K77 Remote Control Door Lock Receiver
5: A10 Inside Rearview Mirror (DD8) A10 Inside Rearview Mirror
6: B24 Cellular Phone Microphone (UE1) B24 Cellular Phone Microphone (UE1)
7: A3L Sunshade - Left (D6I) A3L Sunshade - Left (D61)
DRIVER SEAT COMPONENTS (1 OF 2)

Fig. 4: Driver Seat Components (1 of 2)

Items
1: M50D Seat Front Vertical Motor - Driver (ADS) M50D Seat Front Vertical Motor - Driver (ADS)
2: K29 Seat Heating Control Module (KA1) K29 Seat Heating Control Module X1 (KA1) K29 Seat
Heating Control Module X2 (KA1) K29 Seat Heating Control Module X3 (KA1)
3: S64D Seat Adjuster Switch - Driver (ADS) S64D Seat Adjuster Switch - Driver (ADS)
4: F106D Seat Side Air Bag - Driver F106D Seat Air Bag - Driver
5: F113D Seat Belt Anchor Pretensioner - Driver F113D Seat Belt Anchor Prestensioner - Driver
6: M55D Seat Rear Vertical Motor - Driver (ADS) M55D Seat Rear Vertical Motor - Driver (ADS)
7: M51D Seat Horizontal Motor - Driver (ADS) M51D Seat Horizontal Motor - Driver (ADS)
DRIVER SEAT COMPONENTS (2 OF 2)

Fig. 5: Driver Seat Components (2 Of 2)

Items
1: B88D Seat Belt Switch - Driver B88D Seat Belt Switch - Driver
2: E14A Seat Heating Element - Driver Back (KA1) E14A Seat Heating Element - Driver Back (KA1)
3: E14B Seat Heating Element - Driver Cushion (KA1) E14B Seat Heating Element - Driver Cushion
(KA1)
PASSENGER SEAT COMPONENTS (1 OF 2)

Fig. 6: Passenger Seat Components (1 Of 2)

Items
1: F106P Seat Side Air Bag - Passenger F106P Seat Air Bag - Passenger
2: K85 Passenger Presence Module K85 Passenger Presence Detection Module X1 K85 Passenger
Presence Detection Module X2
3: F113P Seat Belt Anchor Pretensioner - Passenger F113P Seat Belt Anchor Pretensioner - Passenger
PASSENGER SEAT COMPONENTS (2 OF 2)

Fig. 7: Passenger Seat Components (2 Of 2)

Items
1: E14D Seat Heating Element - Passenger Cushion (KA1) E14D Seat Heating Element - Passenger
Cushion (KA1)
2: E14C Seat Heating Element - Passenger Back (KA1) E14C Seat Heating Element - Passenger Back
(KA1)
3: B88P Seat Belt Switch - Passenger B88P Seat Belt Switch - Passenger
REAR SEAT COMPONENTS

Fig. 8: Rear Seat Components

Items
1: F106RR Seat Side Air Bag - Right Rear F106RR Seat Air Bag - Right Rear
2: F106LR Seat Side Air Bag - Left Rear F106LR Seat Air Bag - Left Rear

2013 ELECTRICAL Wiring Systems and Power Management - Component Locator - Powertrain Component Views Cruze
2013 ELECTRICAL
Wiring Systems and Power Management - Component Locator - Powertrain Component Views
- Cruze
POWERTRAIN COMPONENT VIEWS

TOP OF THE ENGINE COMPONENTS (LUW/LWE)
Fig. 1: Top Of Engine Components (LUW)

Items
1: K20 Engine Control Module K20 Engine Control Module X1 (LUV) K20 Engine Control Module
X1 (LUW/LWE) K20 Engine Control Module X2 (LUV) K20 Engine Control Module X2
(LUW/LWE) K20 Engine Control Module X3 (LUV)
2: B52A Heated Oxygen Sensor 1 B52A Heated Oxygen Sensor 1 (LUV) B52A Heated Oxygen
Sensor 1 (LUW/LWE)

3: K35 Ignition Coil Module K35 Ignition Coil Module

4: Q6E Camshaft Position Actuator Solenoid Valve - Exhaust Q6E Camshaft Position Actuator
Solenoid Valve - Exhaust (LUV) Q6E Camshaft Position Actuator Solenoid Valve - Exhaust
(LUW/LWE)
5: B75C Multifunction Intake Air Sensor B75C Multifunction Air Intake Sensor
6: Q6F Camshaft Position Actuator Solenoid Valve - Intake Q6F Camshaft Position Actuator Solenoid
Valve - Intake (LUV) Q6F Camshaft Position Actuator Solenoid Valve - Intake (LUW/LWE)
7: Q38 Throttle Body Q38 Throttle Body
8: Q17A Fuel Injector 1 Q17A Fuel Injector 1 (LUV) Q17A Fuel Injector 1 (LUW/LWE)
9: Q12 Evaporative Emission Purge Solenoid Valve Q12 Evaporative Emission Purge Solenoid Valve
(LUV) Q12 Evaporative Emission Purge Solenoid Valve (LUW/LWE)
10: Q17B Fuel Injector 2 Q17B Fuel Injector 2 (LUV) Q17B Fuel Injector 2 (LUW/LWE)
11: B74 Manifold Absolute Pressure Sensor B74 Manifold Absolute Pressure Sensor (LUV) B74
Manifold Absolute Pressure Sensor (LUW/LWE)
12: Q17C Fuel Injector 3 Q17C Fuel Injector 3 (LUV) Q17C Fuel Injector 3 (LUW/LWE)
13: Q17D Fuel Injector 4 Q17D Fuel Injector 4 (LUV) Q17D Fuel Injector 4 (LUW/LWE)
14: B26 Crankshaft Position Sensor B26 Crankshaft Position Sensor (LUV) B26 Crankshaft Position
Sensor (LUW/LWE)
LEFT FRONT OF THE ENGINE COMPONENTS (LUW/LWE)

Fig. 2: Left Front Of Engine Components (LUW)

Items
1: B23E Camshaft Position Sensor - Exhaust B23E Camshaft Position Sensor - Exhaust (LUV) B23E
Camshaft Position Sensor - Exhaust (LUW/LWE)
2: B23F Camshaft Position Sensor - Intake B23F Camshaft Position Sensor - Intake (LUV) B23F
Camshaft Position Sensor - Intake (LUW/LWE)
3: B34A Engine Coolant Temperature Sensor 1 B34A Engine Coolant Temperature Sensor 1 (LUV)
B34A Engine Coolant Temperature Sensor 1 (LUW/LWE)
4: Q8 Control Solenoid Valve Assembly (MH8/MH9) Q8 Control Solenoid Valve Assembly X1
(MH8) Q8 Control Solenoid Valve Assembly X2 (MH8) Q8 Control Solenoid Valve Assembly X3
(MH8) Q8 Control Solenoid Valve Assembly X4 (MH8)
5: E41 Engine Coolant Thermostat Heater E41 Engine Coolant Thermostat Heater (LUV) E41 Engine
Coolant Thermostat Heater (LUW/LWE)
RIGHT FRONT OF THE ENGINE COMPONENTS (LUW/LWE)

Fig. 3: Right Front Of Engine Components (LUW)

Items
1: B37 Engine Oil Pressure Switch B37 Engine Oil Pressure Switch
2: Q46 A/C Compressor Solenoid Valve Q46 A/C Compressor Solenoid Valve
RIGHT REAR OF THE ENGINE COMPONENTS (LUW/LWE)

Fig. 4: Right Rear Of Engine Components (LUW)

Items
1: Q22 Intake Manifold Tuning Solenoid Valve (LUW/LWE) Q22 Intake Manifold Tuning Solenoid
Valve (LUW/LWE)
2: G13 Generator G13 Generator X2
3: B68 Knock Sensor B68 Knock Sensor (LUV) B68 Knock Sensor (LUW/LWE)
4: B52B Heated Oxygen Sensor 2 B52B Heated Oxygen Sensor 2
5: M64 Starter Motor
LEFT REAR OF THE ENGINE COMPONENTS (LUV)

Fig. 5: Left Rear of the Engine Components (LUV)

Items
1: B111B Turbocharger Boost/Intake Air Temperature Sensor (LUV) B111B Turbocharger
Boost/Intake Air Temperature (LUV)
2: K35 Ignition Coil Module K35 Ignition Coil Module
3: B68 Knock Sensor B68 Knock Sensor (LUV) B68 Knock Sensor (LUW/LWE)
4: Q38 Throttle Body Q38 Throttle Body
5: B34A Engine Coolant Temperature Sensor 1 B34A Engine Coolant Temperature Sensor 1 (LUV)
RIGHT FRONT OF THE ENGINE COMPONENTS (LUV)

Fig. 6: Identifying Engine Components - Right Front (LUJ)

Items
1: Q6E Camshaft Position Actuator Solenoid Valve - Exhaust Q6E Camshaft Position Actuator
Solenoid Valve - Exhaust (LUV) Q6E Camshaft Position Actuator Solenoid Valve - Exhaust
(LUW/LWE)
2: B23E Camshaft Position Sensor - Exhaust B23E Camshaft Position Sensor - Exhaust (LUV) B23E
Camshaft Position Sensor - Exhaust (LUW/LWE)
3: B37 Engine Oil Pressure Switch B37 Engine Oil Pressure Switch
4: B52A Heated Oxygen Sensor 1 B52A Heated Oxygen Sensor 1 (LUV) B52A Heated Oxygen
Sensor 1 (LUW/LWE)
5: Q42 Turbocharger Wastegate Solenoid Valve (LUV) Q42 Turbocharger Wastegate Solenoid Valve
(LUV)
6: Q46 A/C Compressor Solenoid Valve Q46 A/C Compressor Solenoid Valve
RIGHT REAR OF THE ENGINE COMPONENTS (LUV)

Fig. 7: Right Rear of the Engine Components (LUV)

Items
1: Q12 Evaporative Emission Purge Solenoid Valve Q12 Evaporative Emission Purge Solenoid Valve
(LUV) Q12 Evaporative Emission Purge Solenoid Valve (LUW/LWE)
2: Q17D Fuel Injector 4 Q17D Fuel Injector 4 (LUV) Q17D Fuel Injector 4 (LUW/LWE)
3: B74 Manifold Absolute Pressure Sensor B74 Manifold Absolute Pressure Sensor (LUV) B74
Manifold Absolute Pressure Sensor (LUW/LWE)
4: Q17C Fuel Injector 3 Q17C Fuel Injector 3 (LUV) Q17C Fuel Injector 3 (LUW/LWE)
5: Q17B Fuel Injector 2 Q17B Fuel Injector 2 (LUV) Q17B Fuel Injector 2 (LUW/LWE)
6: Q17A Fuel Injector 1 Q17A Fuel Injector 1 (LUV) Q17A Fuel Injector 1 (LUW/LWE)
7: Q42 Turbocharger Wastegate Solenoid Valve (LUV) Q42 Turbocharger Wastegate Solenoid Valve
(LUV)
8: B23F Camshaft Position Sensor - Intake B23F Camshaft Position Sensor - Intake (LUV) B23F
Camshaft Position Sensor - Intake (LUW/LWE)
9: Q6F Camshaft Position Actuator Solenoid Valve - Intake Q6F Camshaft Position Actuator Solenoid

Valve - Intake (LUV) Q6F Camshaft Position Actuator Solenoid Valve - Intake (LUW/LWE)
10: G13 Generator G13 Generator X2
11: B52B Heated Oxygen Sensor 2 B52B Heated Oxygen Sensor 2
12: B26 Crankshaft Position Sensor B26 Crankshaft Position Sensor (LUV) B26 Crankshaft Position
Sensor (LUW/LWE)
13: M64 Starter Motor
TRANSMISSION COMPONENTS (MF3 OR MZ0)
Fig. 8: Transmission Components (MF3 Or MZ0)

Items
1: B115 Vehicle Speed Sensor (MF3 or MZ0) B115 Vehicle Speed Sensor (MF3 or MZ0)
2: B16 Backup Lamp Switch (MF3 or MZ0) B16 Backup Lamp Switch (MF3 or MZ0)
AUTOMATIC TRANSMISSION ELECTRONIC COMPONENTS (MH8)

Fig. 9: Automatic Transmission Electronic Components (MH7, MH8 Or MH9)

Items
1: B15 Transmission Internal Mode Switch (MH8/MH9)
2: B14A Transmission Output Shaft Speed Sensor (MH8/MH9)
3: B14C Transmission Input Shaft Speed Sensor (MH8/MH9)
4: Q8 Control Solenoid Valve Assembly (MH8/MH9) Q8 Control Solenoid Valve Assembly X1
(MH8) Q8 Control Solenoid Valve Assembly X2 (MH8) Q8 Control Solenoid Valve Assembly X3
(MH8) Q8 Control Solenoid Valve Assembly X4 (MH8)

2013 ELECTRICAL Wiring Systems and Power Management - Component Locator - Wheels/Vehicle Underbody
2013 ELECTRICAL
Wiring Systems and Power Management - Component Locator - Wheels/Vehicle Underbody
WHEELS/VEHICLE UNDERBODY COMPONENT VIEWS

UNDERBODY COMPONENTS
Fig. 1: Underbody Components

Items
1: B5RF Wheel Speed Sensor - Right Front B5RF Wheel Speed Sensor - Right Front
2: B5RR Wheel Speed Sensor - Right Rear B5RR Wheel Speed Sensor - Right Rear
3: B5LR Wheel Speed Sensor - Left Rear B5LR Wheel Speed Sensor - Left Rear
4: B5LF Wheel Speed Sensor - Left Front B5LF Wheel Speed Sensor - Left Front

2013 ELECTRICAL Wiring Systems and Power Management - Component Locator - Wheels/Vehicle Underbody
FUEL TANK COMPONENTS
Fig. 2: Fuel Tank Components

Items
1: B47 Fuel Pressure Sensor B47 Fuel Pressure Sensor
2: Q13 Evaporative Emission Vent Solenoid Valve Q13 Evaporative Emission Vent Solenoid Valve
3: A7 Fuel Pump and Level Sensor Assembly A7 Fuel Pump and Level Sensor Assembly
4: B150 Fuel Tank Pressure Sensor B150 Fuel Tank Pressure Sensor
5: G12 Fuel Pump

2013 ELECTRICAL Wiring Systems and Power Management - Component Locator - Component Connector End Views Cruze
2013 ELECTRICAL
Wiring Systems and Power Management - Component Locator - Component Connector End
Views - Cruze
COMPONENT CONNECTOR END VIEWS

A3L SUNSHADE - LEFT (D61)
Harness Type: Headliner

Description: 2-Way M Metri-Pack 150 Series (BK)

Terminal
Type ID
Lead
Test Probe
13575462
J-35616-3
(GY)
Terminal
Removal
Tool
J-3812512A
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
12047581
A3L Sunshade - Left (D61)

Pin
Size
Color
Circuit
A: A
A: 1
A: WH/BN
A: 6815
B: BK
B: 1550
B: B B: 0.5
A3R SUNSHADE - RIGHT (D6I)

Function
A: Inadvertent Power
Control
B: Ground
Terminal Type
ID
Option
A: I
A: -
B: I
B: -


Terminal
Type ID
Lead
Test Probe
J-35616-3
(GY)
13575462
Terminal
Removal
Tool
J-3812512A
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
12047581
A3R Sunshade - Right (D6I)

Pin
Size
Color
Circuit
A: A
A: 1
A: WH/BN
A: 6815
B: BK
B: 1550
B: B B: 0.5
Function
Terminal Type
ID
Option
A: I
A: -
B: I
B: -
A: Inadvertent Power
Control
B: Ground
A7 FUEL PUMP AND LEVEL SENSOR ASSEMBLY
Harness Type: Fuel Tank

Description: 4-Way F GT 280 Series, Sealed (NA)

Terminal
Type ID
Lead
Test Probe
13575392
II
13576356
Terminal
Removal
Tool
J-35616-4A
J-38125-553
(PU)
J-35616-4A
J-38125-553
(PU)
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
15304720
19
15304719
19
A7 Fuel Pump and Level Sensor Assembly

Pin
1: 1
2: 2
Size
Color
1: 2.5
1: GY
2: 2.5 2: BK/D-GN
Circuit
Function
1: 120
2: 1580
1: Fuel Pump Control

2: Low Reference
3: Fuel Level Sensor Low
Terminal Type
ID
1: I
2: I
Option
1: 2: -

3: 3
3: 0.5 3: BK/D-GN
3: 6281
4: 4
4: 0.5 4: D-BU/VT
4: 1589
Reference
4: Primary Fuel Level
Sensor Signal
3: II
3: -
4: II
4: -
A9A OUTSIDE REARVIEW MIRROR - DRIVER
Harness Type: Driver Door

Description: 8-Way F GT 150 Series, Sealed (BK)

Terminal
Type ID
Lead
Test Probe
13575735
Terminal
Removal
Tool
J-35616-2A
J-38125-553
(GY)
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
12191812
19
A9A Outside Rearview Mirror - Driver

Pin
Size
A: A A: 0.5
Color
Circuit
A: YE/BN
A: 3391
B: B B: 0.5 B: VT/D-BU
B: 3390
C: C C: 0.5
C: BN/BK
C: 3389
D-E
F: F
F: 0.5
F: BN/YE
F: 2267
G: BK
-
G: 1550
-
G: G G: 0.5
H
-
Function
A: Driver Mirror Motor
Common Control
B: Driver Mirror Motor Up
(+) Down (-) Control
C: Driver Mirror Motor
Right (+) Left (-) Control
Not Occupied
F: Mirror Heating Element
Control
G: Ground
Not Occupied
A9B OUTSIDE REARVIEW MIRROR - PASSENGER
Terminal Type
ID
Option
A: I
A: -
B: I
B: -
C: I
C: -
F: I
F: -
G: I
-
G: -

Harness Type: Passenger Door

Description: 8-Way F GT 150 Series (BK)

Terminal
Type ID
Lead
Test Probe
13575735
Terminal
Removal
Tool
J-35616-2A
J-38125-553
(GY)
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
12191812
19
A9B Outside Rearview Mirror - Passenger

Pin
Size
Color
Circuit
A: A A: 0.5
A: WH
A: 3398
B: B B: 0.5
B: YE/VT
B: 3397
C: C C: 0.5 C: D-GN/BK
C: 3396
D-E
F: F
F: 0.5
F: BN/YE
F: 2267
G: BK
-
G: 2050
-
G: G G: 0.5
H
-
A10 INSIDE REARVIEW MIRROR

Function
A: Co-Driver Mirror Motor
Common Control
B: Co-Driver Mirror Motor
Up (+) Down (-) Control
C: Co-Driver Mirror Motor
Not Occupied
F: Mirror Heating Element
Control
G: Ground
Not Occupied
Terminal Type
ID
Option
A: I
A: -
B: I
B: -
C: I
C: -
F: I
F: -
G: I
-
G: -

Description: 10-Way F Kaizen 0.64 Series (BK)

Terminal
Type ID
Terminal
Service
Removal
Terminal
Tool
J-35616-64B J-38125- SAIT-A03T13575866
(L-BU)
215A
M064
Lead
Test Probe
Tray
Core
Crimp
Insulation
Crimp
14
A10 Inside Rearview Mirror

Pin
Size
Color
Circuit
Function
1: 1 1: 0.35 1: D-GN/WH
2: 2 2: 0.5
2: VT/WH
3: 3 3: 0.5 3: D-GN/WH
4: 4 4: 0.5 4: D-GN/BK
5: 5 5: 0.5
5: BK
1: 1324
2: 2839
3: 2514
4: 2515
5: 1550
6: 6
6: 0.5
6: YE/VT
6: 2516
7: 7
8-10
7: 0.5
-
7: BN/WH
-
7: 2517
-
1: Backup Lamp Control

2: Ignition Voltage
3: Keypad Signal
4: Keypad Control
5: Ground
6: Keypad Green LED
Signal
7: Keypad Red LED Signal
Not Occupied
Terminal Type
ID
1: I
2: I
3: I
4: I
5: I
1: DD8
2: DD8
3: UE1
4: UE1
5: -
6: I
6: UE1
7: I
-
7: UE1
-
Option
A11 RADIO X1

Description: 44-Way F GT 150/280 64 Series (BK)

Terminal
Type ID
I
II
Terminal
Service
Removal
Terminal
Tool
J-35616-64B J-38125- SAIT-A03T13575866
(L-BU)
215A
M064
J-35616-2A
13575735
J-38125-553 12191812
(GY)
Lead
Test Probe
Tray
Core
Crimp
Insulation
Crimp
14
19

III
13575735
IV
13575753
J-35616-2A
J-38125-553
(GY)
J-35616-4A
J-38125-553
(PU)
12191812
19
15304713
19
A11 Radio X1
Pin
Size
Color
Circuit
Function
2: 2 2: 0.35
2: YE
2: 7459
3: 3 3: 0.35
3: BARE
3: 7460
Not Occupied
2: Integrated Center Stack
Serial Data Low
Serial Data Shield
Not Occupied
6: Low Reference
Not Occupied
10: Right Auxiliary Audio
Signal (2)
Signal (3)
11: Auxiliary Detection
Signal
Not Occupied
13: Integrated Center
Stack Wake Up Signal
14: Low Speed GMLAN
Serial Data
Not Occupied
16: Center Integrated
Center Stack Serial Data
High
17: Auxiliary Audio
Screen (2)
Not Occupied
20: Cellular Telephone
Voice Signal
Not Occupied
23: Auxiliary Audio
Common Signal
23: Auxiliary Audio
Common Signal (3)
4-5
6: 6
7-9
6: 0.5
6: BK/YE
10:
0.35
10: D-GN
10: 10
10:
10: BN
0.35
11:
11: 11
11: L-BU
0.35
12
13:
13: 13
13: GY/L-GN
0.35
14: 14 14: 0.5
6: 659
10: 5841
10: 3378
11: 2060
13: 3291
14: L-GN
14: 5060
15
16: 16
16:
0.35
16: VT
16: 7458
17: BARE
17: 5842
20: YE
20: 658
23: VT
23: D-GN
23: 5843
23: 3376
24: GY
24: VT
24: 5839
24: 3377
17: 17
18-19
17:
0.35
-
20: 20 20: 0.5

21-22
23:
0.35
23: 23
23:
0.35
24:
24: 24 0.35
24:
24: Left Auxiliary Audio

Signal (2)
Terminal Type
ID
-
Option
-
2: I
2: -
3: I
3: -
6: I
-
6: UE1
-
10: I
10: Without
KTA
10: KTA
11: Without
KTA
-
13: I
13: -
14: I
14: -
16: I
16: -
11: I
17: Without
KTA
-
20: I
20: UE1
23: I
23: Without
KTA
23: KTA
24: I
24: Without
KTA
24: KTA
17: I

Signal (3)
Not Occupied
27: Integrated Center
Stack Reset Signal
Not Occupied
29: Left Front Audio Drain
Wire
30: Left Rear Audio Drain
Wire
31: Front Low Level
Audio (-)
31: Right Front Speaker
Signal (-) (1)
32: Left Front Low Level
Audio (-)
32: Left Front Speaker
Signal (-) (1)
33: Right Rear Low Level
Audio (-)
33: Right Rear Speaker
Signal (-)
34: Left Rear Low Level
Audio (-)
34: Left Rear Speaker
Signal (-)
Not Occupied
37: 37 37: 0.5 37: VT/D-BU
37: 6978
37: Amplifier Control
38: 38 38: 1.5

38: BK
39:
0.35
39: YE
39: 39
39:
39: YE
0.75
40:
0.35
40: D-BU
40: 40
40:
40: D-BU
0.75
41:
0.35 41: BN/WH
41: 41
41:
41: WH
0.75
42:
0.35 42: L-GN/BK
42: 42
42:
42: D-GN
0.75
38: 1750
38: Ground
39: Right Front Low Level
Audio Signal
(+) (1)
Audio Signal
40: Left Front Speaker (+)
(1)
25-26
27: 27
28
29: 29
30: 30
31: 31
32: 32
33: 33
34: 34
35-36
0.35
27:
27: VT
0.35
29:
29: BARE
0.35
30:
30: BARE
0.35
31:
0.35 31: L-BU/OG
31:
31: YE/BK
0.75
32:
0.35 32: OG/D-BU
32: 32: BN/D-BU
0.75
33:
0.35 33: L-BU/BK
33: 33: D-BU/BK
0.75
34: 0.3
34: OG/VT
34:
34: D-GN/BK
0.75
-
27: 3290
29: 2011
30: 2099
31: 1546
31: 117
32: 1947
32: 118
33: 1946
33: 115
34: 1999
34: 116
39: 512
39: 200
40: 511
40: 201
27: I
27: -
29: II
29: KTA
30: II
30: KTA
31: II
31: III
31: UQA
31: Without
UQA
32: II
32: III
32: UQA
32: without
UQA
33: II
33: III
33: UQA
33: Without
UQA
34: II
34: III
34: UQA
34: Without
UQA
37: I
37: II
38: IV
37: UQA
39: II
39: III
39: UQA
39: WIthout
UQA
40: II
40: III
40: UQA
40: Without
UQA
38: -
41: 546
41: 46

Audio Signal
41: Right Rear Speaker (+)
41: II
41: III
41: UQA
41: Without
UQA
42: 599
42: 199

Audio Signal
42: Left Rear Speaker (+)
42: II
42: III
42: UQA
42: Without
UQA

43: 0.5
43: D-GN/YE
43: 43 43:
43: D-GN/YE
0.35
43: 7066
43: 7066
44: 44 44: 1.5 44: RD/D-GN
44: 40
43: Entertainment Remote

Enable Signal
Enable Signal
Voltage
43: II
43: III
43: UYS
43: UQA
44: IV
44: -
A11 RADIO X2 (UDN)

Description: 20-Way F USCAR 64 Series (GY)

Terminal
Type ID
Terminal
Service
Removal
Terminal
Tool
J-35616-64B J-38125- SAIT-A03T13575866
(L-BU)
215A
M064
Lead
Test Probe
Tray
Core
Crimp
Insulation
Crimp
14
A11 Radio X2 (UDN)

Pin
Size
Color
Circuit
Function
1-5
6: 6
7-9
6: 0.5
-
6: BK/GY
-
6: 5152
-
Not Occupied
6: Low Reference
Not Occupied
10: Navigation Display
Reset Signal
Not Occupied
Dimming Control
Not Occupied
16: Voice Recognition
Audio Signal
Not Occupied
20: AAS Wheel Speed
Sensor Signal Left Front
10: 10 10: 0.5 10: BN/L-GN

11-13
14: 14
15
14:
0.35
-
14: GY/VT
14: 3363
16: 16 16: 0.5 16: GY/YE

17-19
20: 20 20: 0.5
10: 3364
16: 5149
20: GY
20: 1903
Terminal Type
ID
6: I
-
Option
6: -
10: I
10: -
14: I
14: -
16: I
16: -
20: I
20: -

A11 RADIO X3 (UEW)
Harness Type: Instrument Panel TWINAX

Service Connector: Service by Cable Assembly - See Parts Catalog
Description: 3-Way F Sealed (L-BU)

Terminal Type
Terminated Lead
ID
Service by Cable Assembly
I
- See Parts Catalog
Diagnostic Test Probe
Terminal Removal Tool
No Tool Required
No Tool Required
A11 Radio X3 (UEW)

Pin
Size
Color
Circuit
Function
Terminal Type
ID
Option
1: 1-3
1: -
1: TWINAX
1: -
Signal
1: I
1: -
A22 RADIO CONTROLS (UYC OR UYE)

Description: 8-Way F Micro 64 Series (GY)

Terminal
Type ID
I
Terminal
Removal
Tool
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
J-35616-64B
J-38125-21
(L-BU)
15359541
Lead
Test Probe
13582245

A22 Radio Controls (UYC or UYE)

Pin
Size
Color
1: 1
1: 0.5
1: RD/LGN
2: 0.5
2: BK
4: L-GN/L4: 0.5
BU
-
2: 2
3
4: 4
5-8
Circuit
Function
Terminal Type
ID
Option
1: 3140
1: I
1: -
2: 1650
-
2: Ground
Not Occupied
4: Linear Interconnect
Network Bus 10
Not Occupied
2: I
-
2: -
4: I
4: -
4: 7532
-
A22 RADIO CONTROLS (UEW)


Terminal
Type ID
Terminal
Removal
Tool
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
J-35616-64B
J-38125-21
(L-BU)
15359541
Lead
Test Probe
13575867
A22 Radio Controls (UEW)

Color
Circuit
Function
Terminal Type
ID
Option
1: 3140
1: I
1: -
2: 1750
-
2: Ground
Not Occupied
4: Center Integrated Center
Serial Data Low
Serial Data Shield
2: I
-
2: -
4: I
4: -
5: I
5: -
6: I
6: -
Pin
Size
1: 1
1: 0.5
2: 2
3
2: 0.5
-
1: RD/LGN
2: BK
-
4: 4
4: 0.35
4: VT
4: 7458
5: 5
5: 0.35
5: YE
5: 7459
6: 6
6: 0.35
6: BARE
6: 7460

7: 7
7: 0.35
7: GY/LGN
7: 3291
8: 8
8: 0.35
8: VT
8: 3290

Wake Up Signal
Reset Signal
7: I
7: -
8: I
8: -
A23D DOOR LATCH ASSEMBLY - DRIVER

Description: 10-Way F Sealed (BK)

Terminal
Type ID
Lead
Test Probe
13575366
Terminal
Removal
Tool
J-35616-14
J-38125-560
(GN)
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
964274-2
16
A23D Door Latch Assembly - Driver

Pin
Size
Color
Circuit
Function
2: 2 2: 0.75
2: BN/YE
2: 294
3: 3 3: 0.75
3: GY
3: 5911
Not Occupied
Unlock Control
Lock Control 2
4: Driver Door Lock Motor
Status Control
Not Occupied
6: Left Front Door Ajar
Switch Signal
Not Occupied
8: Ground
Not Occupied
4: 4
4: 0.5
4: WH/VT
4: 3270
6: 6
6: 0.5
6: GY
6: 745
7
8: 8 8: 0.75
9-10
-
8: BK
-
8: 1550
-
A23LR DOOR LATCH ASSEMBLY - LEFT REAR
Terminal Type
ID
-
Option
-
2: I
2: -
3: I
3: -
4: I
4: -
6: I
6: -
8: I
-
8: -

Harness Type: Left Rear Door


Terminal
Type ID
Lead
Test Probe
13575366
Terminal
Removal
Tool
J-35616-14
J-38125-560
(GN)
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
964274-2
16
A23LR Door Latch Assembly - Left Rear

Pin
Size
Color
Circuit
Function
2: 2 2: 0.75
2: BN/YE
2: 294
3: 3 3: 0.75
3: GY
3: 295
4: 4 4: 0.75
4: BN/YE
4: 294
Not Occupied
Unlock Control
Lock Control
Unlock Control
Not Occupied
6: Left Rear Door Ajar
Switch Signal
Motor Unlock Control
8: Ground
Motor Status Signal Left
Rear
Not Occupied
6: 6
6: 0.5
6: GY
6: 747
7: 7 7: 0.75 7: WH/D-BU
7: 3266
8: 8 8: 0.75
8: BK
8: 2350
9: 9
9: 0.5
9: BN/WH
9: 3269
10
A23P DOOR LATCH ASSEMBLY - PASSENGER
Terminal Type
ID
-
Option
-
2: I
2: -
3: I
3: -
4: I
4: -
6: I
6: -
7: I
7: -
8: I
8: -
9: I
9: -



Terminal
Type ID
Lead
Test Probe
13575366
Terminal
Removal
Tool
J-35616-14
J-38125-560
(GN)
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
964274-2
16
A23P Door Latch Assembly - Passenger

Pin
Size
Color
Circuit
1: 1
1: 0.5
1: GY
1: 746
2
3: 3 3: 0.75
4-6
-
3: BK
-
3: 2050
-
7: 7 7: 0.75
7: BN/YE
7: 294
8: 8 8: 0.75
8: GY
8: 295
9-10
Function
1: Right Front Door Ajar
Switch Signal
Not Occupied
3: Ground
Not Occupied
Unlock Control
Lock Control
Not Occupied
Terminal Type
ID
Option
1: I
1: -
3: I
-
3: -
7: I
7: -
8: I
8: -
A23RR DOOR LATCH ASSEMBLY - RIGHT REAR
Harness Type: Right Rear Door


Terminal
Terminal
Service
Core
Insulation

Type ID
Lead
13575366
Test Probe
Removal
Tool
Terminal
J-35616-14
J-38125-560
(GN)
964274-2
Tray
Crimp
Crimp
16
A23RR Door Latch Assembly - Right Rear

Pin
Size
Color
Circuit
1: 1
1: 0.5
1: GY
1: 748
2: 2 2: 0.75 2: WH/D-BU
2: 3266
3: 3 3: 0.75
3: BK
3: 2050
4: 4
4: 0.5
4: GY/BK
4: 3268
5-6
7: 7 7: 0.75
7: BN/YE
7: 294
8: 8 8: 0.75
8: GY
8: 295
9: 9 9: 0.75
9: BN/YE
9: 294
10
Function
Terminal Type
ID
Option
1: I
1: -
2: I
2: -
3: I
3: -
4: I
4: -
7: I
7: -
8: I
8: -
9: I
9: -
1: Right Rear Door Ajar

Switch Signal
Motor Unlock Control
3: Ground
Motor Status Signal Right
Rear
Not Occupied
Unlock Control
Lock Control
Unlock Control
Not Occupied
B1 A/C REFRIGERANT PRESSURE SENSOR
Harness Type: Engine Cooling


Terminal
Type ID
I
Lead
Test Probe
13575400
Terminal
Removal
Tool
J-35616-2A
J-38125-553
(GY)
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
15326267
19

B1 A/C Refrigerant Pressure Sensor

Pin
Size
Color
Circuit
1: 1
1: 0.5
1: BK/BN
1: 5514
2: 2
2: 0.5
2: BN/RD
2: 2700
3: 3
3: 0.5
3: D-GN
3: 380
Function
Terminal Type
ID
Option
1: I
1: -
2: I
2: -
3: I
3: -
1: A/C Refrigerant Pressure

Volt Reference
Sensor Signal
B5LF WHEEL SPEED SENSOR - LEFT FRONT


Terminal
Type ID
Lead
Test Probe
13575412
Terminal
Removal
Tool
J-35616-2A
J-38125-553
(GY)
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
12191819
B5LF Wheel Speed Sensor - Left Front

Pin
Size
Color
Circuit
1: 1
1: 0.5
1: GY/WH
1: 7064
2: 2
2: 0.5
2: GY
2: 830
Function
1: Wheel Speed Sensor
Control Left Front
Signal Left Front
B5LR WHEEL SPEED SENSOR - LEFT REAR
Terminal Type
ID
Option
1: I
1: -
2: I
2: -

Harness Type: Body Harness


Terminal
Type ID
Lead
Test Probe
13575412
Terminal
Removal
Tool
J-35616-2A
J-38125-553
(GY)
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
12191819
B5LR Wheel Speed Sensor - Left Rear

Pin
Size
Color
Circuit
1: 1
1: 0.5
1: GY/BK
1: 7127
2: 2
2: 0.5
2: D-BU
2: 884
Function
Terminal Type
ID
Option
1: I
1: -
2: I
2: -

Control Left Rear
Signal Left Rear
B5RF WHEEL SPEED SENSOR - RIGHT FRONT


Terminal
Type ID
I
Lead
Test Probe
13575412
Terminal
Removal
Tool
J-35616-2A
J-38125-553
(GY)
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
12191819
B5RF Wheel Speed Sensor - Right Front

Pin
Size
Color
Circuit
Function
Terminal Type
ID
Option

1: 1
1: 0.5
1: GY/BN
1: 7065
2: 2
2: 0.5
2: YE
2: 872

Control Right Front
Signal Right Front
1: I
1: -
2: I
2: -
B5RR WHEEL SPEED SENSOR - RIGHT REAR
Harness Type: Body Harness


Terminal
Type ID
Lead
Test Probe
13575412
Terminal
Removal
Tool
J-35616-2A
J-38125-553
(GY)
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
12191819
B5RR Wheel Speed Sensor - Right Rear

Pin
Size
Color
Circuit
1: 1
1: 0.5
1: GY/YE
1: 7128
2: 2
2: 0.5
2: VT
2: 882
Function
Control Right Rear
Signal Right Rear
B7D AIR TEMPERATURE SENSOR - DUCT LEFT LOWER (C68)
Harness Type: HVAC

Terminal Type
ID
Option
1: I
1: -
2: I
2: -

Description: 2-Way F Metri-Pack 150 Series (BK)

Terminal
Type ID
Lead
Test Probe
Terminal
Removal
Tool
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
Service by
J-35616-14
Harness - See
(GN)
Part Catalog
J-3812512A
15326030
B7D Air Temperature Sensor - Duct Left Lower (C68)

Pin
Size
A: A A: 0.5
B: B
B: 0.5
Color
Circuit
A: D-BU
A: 404
B: BK
B: 407
Function
Terminal Type
ID
Option
A: I
A: -
B: I
B: -
A: Lower Air Temperature

Sensor Signal
B: Sensor Low Reference
B7H AIR TEMPERATURE SENSOR - DUCT LEFT UPPER (C68)
Harness Type: HVAC


Terminal
Type ID
Lead
Test Probe
Terminal
Removal
Tool
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
Service by
J-35616-14
Harness - See
(GN)
Part Catalog
J-3812512A
15326030
B7H Air Temperature Sensor - Duct Left Upper (C68)

Pin
Size
A: A A: BK/GY
Color
A: BK/GY
Circuit
Function
Terminal Type
ID
Option
A: 516
A: Upper Left Air

Temperature Sensor
Signal
A: I
A: -

B: B
B: BK
B: BK
B: 720
B: I
B: -
B9 AMBIENT AIR TEMPERATURE SENSOR


Terminal
Type ID
I
Lead
Test Probe
13575414
Terminal
Removal
Tool
J-35616-2A
J-38125-553
(GY)
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
12191819
B9 Ambient Air Temperature Sensor

Pin
Size
Color
Circuit
1: 1
1: 0.5 1: D-BU/GY
1: 636
2: 2
2: 0.5 2: BK/D-BU
2: 61
Function
1: Outside Ambient Air
Temperature Sensor Signal
2: Outside Ambient
Temperature Sensor Low
Reference
B10B AMBIENT LIGHT/SUNLOAD SENSOR

Description: 6-Way F 0.64 Micro Quadlok Series (BK)
Terminal Type
ID
Option
1: I
1: -
2: I
2: -


Terminal
Type ID
I
Terminal
Removal
Tool
J-35616-64B J-3812513575737
(L-BU)
12A
Lead
Test Probe
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
928999-5
15
B10B Ambient Light/Sunload Sensor

Pin
Size
Color
Circuit
Function
1: GY
2: GY
3: DBU/WH
1: 728
2: 590
4: 4 4: 0.35
4: D-BU
4: 1120
1: Security Indicator Control

2: Solar Sensor Driver Signal
3: Inside Air Temperature Sensor
Signal
4: Solar Sensor Pulsed Supply
Voltage
5: 5 5: 0.35
5: WH/LBU
5: 278
6: 7566
6: 1650
1: 1 1: 0.35
2: 2 2: 0.35
3: 3 3: 0.35
6: 6
3: 734
6: 0.35 6: BK/L-BU
6: 0.35
6: BK
Terminal
Type ID
1: I
2: I
Option
1: 2: C68
3: I
3: C68
4: I
4: C68
5: Ambient Light Sensor Signal
5: I
5: -
6: Humidity/Windscreen Temp
6: Ground
6: I
6: C68
6: Without
C68
B16 BACKUP LAMP SWITCH (MF3 OR MZ0)

Description: 2-Way F Metri-Pack 150 Series, Sealed (BK)

Terminal
Type ID
I
Lead
Test Probe
13575414
Terminal
Removal
Tool
J-35616-2A
J-38125-553
(GY)
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
12191819
B16 Backup Lamp Switch (MF3 or MZ0)

Pin
Size
Color
Circuit
Function
Terminal Type
Option

ID
1: 1
1: 0.5
1: GN/WH
1: 5007
2: 2
2: 0.5
2: BK
2: 150
1: Engine Reverse Gear

Switch Signal
2: Ground
1: I
1: -
2: I
2: -
B18 BATTERY CURRENT SENSOR
Harness Type: Body


Terminal
Type ID
Lead
Test Probe
13578912
Terminal
Removal
Tool
J-35616-2A
J-38125-553
(GY)
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
12191819
B18 Battery Current Sensor

Pin
Size
Color
Circuit
A: A A: 0.5 A: D-BU/VT
A: 5076
B: B B: 0.5
B: BK/VT
B: 5077
C: C C: 0.5
C: WH/YE
C: 5075
Function
A: Current Sensor Supply
Voltage
B: Current Sensor Low
Reference
C: Current Sensor Signal
B19B BRAKE BOOSTER VACUUM SENSOR
Harness Type: Body

Terminal Type
ID
Option
A: I
A: -
B: I
B: -
C: I
C: -

Service Connector: Pending

Description: 3-Way F 150 GT Series, Sealed (GY)

Type ID
Lead
Test Probe
I
Pending
Pending
Terminal
Removal
Tool
Pending
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
Pending
Pending
Pending
Pending
B19B Brake Booster Vacuum Sensor

Pin
Size
Color
Circuit
1: 1
1: 0.5
1: YE/VT
1: 6030
2: 2
2: 0.5
2: BK/YE
2: 6032
3: 3
3: 0.5
3: YE/RD
3: 6031
Function
Terminal Type
ID
Option
1: I
1: -
2: I
2: -
3: I
3: -
1: Brake Vacuum Sensor

Signal
Low Reference
3: Brake Vacuum Sensor 5
Volt Reference
B20 BRAKE FLUID LEVEL SWITCH
Harness Type: Body

Description: 2-Way F 1.2 Timer Series, Sealed (BK)

Terminal
Type ID
I
Lead
Test Probe
13578874
Terminal
Removal
Tool
J-35616-14
J-38125-560
(GN)
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
964274-2
16
B20 Brake Fluid Level Switch

Pin
1: 1
Size
Color
1: 0.5 1: D-GN/GY
Circuit
Function
Terminal Type
ID
Option
1: 333
1: Brake Fluid Level

Sensor Signal
1: I
1: -

2: 2
2: 0.5
2: BK
2: 1550
2: Ground
2: I
2: -
B22 BRAKE PEDAL POSITION SENSOR (MF3 OR MZ0)


Terminal
Type ID
Lead
Test Probe
13575735
Terminal
Removal
Tool
J-35616-2A
J-38125-553
(GY)
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
12191812
19
B22 Brake Pedal Position Sensor (MF3 or MZ0)

Pin
Size
A: A A: 0.5
Color
Circuit
A: BK/BN
A: 5360
B: B B: 0.5 B: D-BU/YE
B: 5361
C: C C: 0.5
C: 5359
C: WH
Function
A: Brake Apply Sensor
Low Reference
B: Brake Apply Sensor
Signal
C: Brake Apply Sensor
Supply Voltage
B22 BRAKE PEDAL POSITION SENSOR (MH8)

Description: 6-Way F AIT II Series (BK)
Terminal Type
ID
Option
A: I
A: -
B: I
B: -
C: I
C: -


Terminal
Type ID
Terminal
Service
Removal
Terminal
Tool
J-35616-64B J-38125- SAIT-A03T13575867
(L-BU)
215A
M064
Lead
Test Probe
Tray
Core
Crimp
Insulation
Crimp
14
B22 Brake Pedal Position Sensor (MH8)

Pin
Size
Color
Circuit
1: 1
1: 0.5
1: WH
1: 5359
2: 2
2: 0.5
2: BK/BN
2: 5360
3: 3
3: 0.5 3: D-BU/YE
3: 5361
4: 4
4: 0.5 4: D-BU/YE
4: 5361
5: 5
5: 0.5
5: WH
5: 5359
6: 6
6: 0.5
6: BK/BN
6: 5360
Function
Terminal Type
ID
Option
1: I
1: -
2: I
2: -
3: I
3: -
4: I
4: -
5: I
5: -
6: I
6: -
1: Brake Apply Sensor

Supply Voltage
2: Low Reference
Signal
Signal
Supply Voltage
6: Low Reference
B23E CAMSHAFT POSITION SENSOR - EXHAUST (LUV)

Description: 3-Way F MLK 1.2 Series, Sealed (BK)

Type ID
Lead
Test Probe
I
Pending
Pending
Terminal
Removal
Tool
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
Pending
Not
Available
Not
Available
Not
Available
Not
Available
B23E Camshaft Position Sensor - Exhaust (LUV)

Pin
Size
Color
Circuit
Function
Terminal Type
ID
Option

1: 1
1: 0.5
1: GY/YE
1: 6457
2: 2
2: 0.5
2: BK/GY
2: 6267
3: 3
3: 0.5
3: VT/BK
3: 6264
1: Camshaft CAM X
Supply Voltage
2: Camshaft CAM X
Ground
3: Camshaft CAM X Signal
1: I
1: -
2: I
2: -
3: I
3: -
B23E CAMSHAFT POSITION SENSOR - EXHAUST (LUW/LWE)


Type ID
Lead
Test Probe
I
Pending
Pending
Terminal
Removal
Tool
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
Pending
Not
Available
Not
Available
Not
Available
Not
Available
B23E Camshaft Position Sensor - Exhaust (LUW/LWE)

Pin
Size
Color
Circuit
1: 1
1: 0.5
1: GY/YE
1: 5297
2: 2
2: 0.5
2: BK/GY
2: 5296
3: 3
3: 0.5
3: VT/BK
3: 5273
Function
1: Camshaft Position
Exhaust Sensor Supply
Voltage (1)
2: Low Reference
Exhaust Sensor (1)
B23F CAMSHAFT POSITION SENSOR - INTAKE (LUV)
Terminal Type
ID
Option
1: I
1: -
2: I
2: -
3: I
3: -



Terminal
Type ID
Lead
Test Probe
13575575
Terminal
Removal
Tool
Service
Terminal
J-35616-64B
J-38125-213 33467-0005
(L-BU)
Tray
Core
Crimp
Insulation
Crimp
23
B23F Camshaft Position Sensor - Intake (LUV)

Pin
Size
Color
Circuit
1: 1
1: 0.5 1: GY/D-BU
1: 5300
2: 2
2: 0.5 2: BK/D-GN
2: 5301
3: 3
3: 0.5
3: 5275
3: YE/VT
Function
Terminal Type
ID
Option
1: I
1: -
2: I
2: -
3: I
3: -
1: Camshaft Position Intake

Sensor Supply Voltage (1)
Sensor Low Reference (1)
Sensor (1)
B23F CAMSHAFT POSITION SENSOR - INTAKE (LUW/LWE)

Description: 3-Way F, Sealed (BK)

Type ID
Lead
Test Probe
I
Pending
Pending
Terminal
Removal
Tool
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
Pending
Not
Available
Not
Available
Not
Available
Not
Available
B23F Camshaft Position Sensor - Intake (LUW/LWE)

Pin
Size
Color
Circuit
Function
Terminal Type
ID
Option

1: 1
1: 0.5 1: GY/D-BU
1: 5300
2: 2
2: 0.5 2: BK/L-GN
2: 5301
3: 3
3: 0.5
3: 5275
3: YE/VT

Sensor Supply Voltage (1)
Sensor Low Reference (1)
Sensor (1)
1: I
1: -
2: I
2: -
3: I
3: -
B24 CELLULAR PHONE MICROPHONE (UE1)


Terminal
Type ID
Lead
Test Probe
13575462
J-35616-3
(GY)
Terminal
Removal
Tool
J-3812512A
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
12047581
B24 Cellular Phone Microphone (UE1)

Pin
Size
A: A A: 0.5
B: B B: 0.5
Color
Circuit
A: BARE
B: YE
A: 5193
B: 5191
Terminal Type
ID
A: Microphone Low Signal
A: I
B: Microphone High Signal
B: I
Function
B25B CLUTCH PEDAL POSITION SENSOR (MF3 OR MZ0)

Option
A: B: -


Terminal
Type ID
Lead
Test Probe
13575735
Terminal
Removal
Tool
J-35616-2A
J-38125-553
(GY)
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
12191812
19
B25B Clutch Pedal Position Sensor (MF3 or MZ0)

Pin
Size
Color
Circuit
A: A A: 0.5
A: BK/GY
A: 6110
B: B B: 0.5
B: YE
B: 6111
C: C C: 0.5
C: GY/RD
C: 6109
Function
Terminal Type
ID
Option
A: I
A: -
B: I
B: -
C: I
C: -
A: Clutch Apply Sensor

Low Reference
B: Clutch Apply Sensor
Signal
C: Clutch Apply Sensor
Voltage Reference
B26 CRANKSHAFT POSITION SENSOR (LUV)


Terminal
Type ID
I
Lead
Test Probe
13575812
Terminal
Removal
Tool
Service
Terminal
J-35616-64B
J-38125-213 33467-0005
(L-BU)
Tray
Core
Crimp
Insulation
Crimp
23
B26 Crankshaft Position Sensor (LUV)

Pin
1: 1
Size
Color
1: 0.5 1: VT/L-BU
Circuit
Function
Terminal Type
ID
Option
1: 6270
1: Crankshaft 60X Sensor

Voltage
1: I
1: -

2: 2
2: 0.5
2: BK/VT
2: 6272
3: 3
3: 0.5
3: L-GN
3: 6271
2: Low Reference
Signal
2: I
2: -
3: I
3: -
B26 CRANKSHAFT POSITION SENSOR (LUW/LWE)

Description: 3-Way F (BK)

Terminal
Type ID
Lead
Test Probe
13575415
Terminal
Removal
Tool
Service
Terminal
J-35616-35
J-38125-36 4-964286-1
(VT)
Tray
Core
Crimp
Insulation
Crimp
16
B26 Crankshaft Position Sensor (LUW/LWE)

Pin
Size
Color
Circuit
1: 1
1: 0.5
1: GN
1: 6271
2: 2
2: 0.5
2: BK/VT
2: 6272
3: 3
3: 0.5
3: VT/BU
3: 6270
Function
Signal
2: Low Reference
Voltage
B34A ENGINE COOLANT TEMPERATURE SENSOR 1 (LUV)

Terminal Type
ID
Option
1: I
1: -
2: I
2: -
3: I
3: -

Description: 2-Way F 0.64 MQS Series, Sealed (BK)

Terminal
Type ID
Terminal
Removal
Tool
J-35616-64B J-3812513576394
(L-BU)
12A
Lead
Test Probe
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
962885-5
15
B34A Engine Coolant Temperature Sensor 1 (LUV)

Pin
Size
Color
Circuit
1: 1 1: 0.75
1: D-BU
1: 410
2: 2 2: 0.75
2: BK/BU
2: 2761
Function
Terminal Type
ID
Option
1: I
1: -
2: I
2: -
1: Engine Coolant
B34A ENGINE COOLANT TEMPERATURE SENSOR 1 (LUW/LWE)


Terminal
Type ID
Terminal
Removal
Tool
J-35616-64B J-3812513576394
(L-BU)
12A
Lead
Test Probe
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
962885-5
15

Pin
Size
Color
Circuit
1: 1
1: 0.5 1: L-GN/VT
1: 2032
2: 2
2: 0.5
2: 2761
2: BK/BN
Function
Sensor Signal
Terminal Type
ID
Option
1: I
1: -
2: I
2: -

B34B ENGINE COOLANT TEMPERATURE SENSOR 2

Description: 2-Way F MQS Series, Sealed (BK)

Terminal
Type ID
I
Terminal
Removal
Tool
J-35616-64B J-3812515376394
(L-BU)
12A
Lead
Test Probe
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
962885-5
15
B34B Engine Coolant Temperature Sensor 2

Pin
Size
Color
Circuit
1: 1
1: 0.5 1: BK/D-BU
1: 6813
2: 2
2: 0.5 2: D-GN/VT
2: 2032
Function
Terminal Type
ID
Option
1: I
1: -
2: I
2: -
Sensor 2 Low Reference
Sensor Signal
B37 ENGINE OIL PRESSURE SWITCH

Description: 1-Way F DCS2 Series, Sealed (BK)

Terminal
Type ID
Lead
Test Probe
Terminal
Removal
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp

13575400
Tool
J-35616-2A
J-38125-553
(GY)
15326267
19
B37 Engine Oil Pressure Switch

Pin
Size
Color
Circuit
Function
Terminal Type
ID
Option
1: 1
1: 0.5
1: YE/BU
1: 231
1: Oil Pressure Switch

Signal
1: I
1: -
B39 A/C EVAPORATOR TEMPERATURE SENSOR
Harness Type: HVAC


Terminal
Type ID
Lead
Test Probe
Terminal
Removal
Tool
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
Service by
J-35616-14
Harness - See
(GN)
Part Catalog
J-3812512A
15326030
B39 A/C Evaporator Temperature Sensor

Pin
Size
A: A A: BK/GY
B: B
B: BK
Color
Circuit
A: BK/GY
A: 6137
B: BK
B: 720
B47 FUEL PRESSURE SENSOR
Function
A: EVAP Core
Temperature Sensor
Signal
Terminal Type
ID
Option
A: I
A: -
B: I
B: -


Description: 3-Way F GT 150 Series Sealed (BK)

Terminal
Type ID
Lead
Test Probe
13575412
Terminal
Removal
Tool
J-35616-2A
J-38125-553
(GY)
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
12191819
B47 Fuel Pressure Sensor

Pin
Size
Color
Circuit
1: 1
1: 0.5 1: D-BU/BN
1: 7446
2: 2
3: 3
2: 0.5
3: 0.5
2: 7447
3: 7445
2: BK/YE
3: BN/RD
Function
Terminal Type
ID
Option
1: I
1: -
2: I
3: I
2: 3: -
1: Fuel Line Pressure

Sensor Signal
2: Low Reference
3: 5-Volt Reference
B52A HEATED OXYGEN SENSOR 1 (LUV)


Terminal
Type ID
I
Lead
Test Probe
13581346
Terminal
Removal
Tool
Service
Terminal
J-35616-35
J-38125-36 4-964286-1
(VT)
B52A Heated Oxygen Sensor 1 (LUV)
Tray
Core
Crimp
Insulation
Crimp
16

Pin
Size
Color
Circuit
1: 1 1: 0.75
1: RD/WH
1: 5293
2: 2 2: 0.75
2: GY/WH
2: 3113
3: 3
3: 0.5
3: BK/GN
3: 1664
4: 4
4: 0.5
4: GN
4: 1665
Function
Terminal Type
ID
Option
1: I
1: -
2: I
2: -
3: I
3: -
4: I
4: -

Fused Supply (4)
2: Heated Oxygen Sensor
Heater Low Control Bank
1 Sensor (1)
Low Signal Bank 1 Sensor
(1)
High Signal Bank 1 Sensor
(1)
B52A HEATED OXYGEN SENSOR 1 (LUW/LWE)

Description: 4-Way M 2.8 Series, Sealed (BK)

Terminal
Type ID
Lead
Test Probe
13582181
J-35616-5
(PU)
Terminal
Removal
Tool
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
15
J-38125-36 1-962915-3
B52A Heated Oxygen Sensor 1 (LUW/LWE)

Pin
Size
Color
Circuit
1: 1 1: 0.75
1: VT/BU
1: 5293
2: 2 2: 0.75
2: GY/WH
2: 3113
3: 3
3: YE/BN
3: 1664
3: 0.5
Function
Fused Supply (4)
1 Sensor (1)
(1)
Terminal Type
ID
Option
1: I
1: -
2: I
2: -
3: I
3: -

4: 4
4: 0.5
4: GN
4: 1665

(1)
4: I
4: -
B52B HEATED OXYGEN SENSOR 2


Terminal
Type ID
Lead
Test Probe
13575350
J-35616-5
(PU)
Terminal
Removal
Tool
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
15
J-38125-36 1-962915-3
B52B Heated Oxygen Sensor 2

Pin
Size
1: 1 1: 0.75
Color
Circuit
1: VT/BU
1: 5293
2: 2 2: 0.75 2: L-GN/VT
2: 1423
3: 3
3: 0.5
3: YE/WH
3: 1669
4: 4
4: 0.5
4: L-GN
4: 1668
B55 HOOD AJAR SWITCH
Function
Fused Supply (4)
Heater Low Control Bank 1
Sensor (2)
(2)
(2)
Terminal Type
ID
Option
1: I
1: -
2: I
2: -
3: I
3: -
4: I
4: -



Terminal
Type ID
Lead
Test Probe
13575412
Terminal
Removal
Tool
J-35616-2A
J-38125-553
(GY)
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
12191819

Pin
Size
Color
Circuit
Function
B: BN/DGN
C: BK
Not Occupied
Terminal Type
ID
-
B: 109
B: Hood Ajar Switch Signal
B: I
B: -
C: 1350
C: Ground
C: I
C: -
B: B B: 0.5
C: C C: 0.5
Option
-
B59L FRONT IMPACT SENSOR - LEFT

Description: 2-Way F Kaizen 0.64 Series, Sealed (D-GY)

Terminal
Type ID
Lead
Test Probe
Terminal
Removal
Tool
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
Service by
Connector J-35616-64B
Assembly (L-BU)
13314084
N/A

B59L Front Impact Sensor - Left

Pin
Size
Color
Circuit
1: 1
1: 0.5
1: OG/YE
1: 354
2: 2
2: 0.5
2: BK/OG
2: 5045
Function
Terminal Type
ID
Option
1: I
1: -
2: I
2: -
1: Left Front
Discriminating Sensor
Signal
2: Left Front
Discriminating Sensor Low
Reference
B59R FRONT IMPACT SENSOR - RIGHT


Terminal
Type ID
Lead
Test Probe
Terminal
Removal
Tool
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
Service by
(L-BU)
Assembly 13314084
N/A
B59R Front Impact Sensor - Right

Pin
Size
Color
Circuit
1: 1
1: 0.5 1: OG/D-GN
1: 1409
2: 2
2: 0.5
2: 5600
2: BK/OG
Function
1: Right Front
Discriminating Sensor
Signal
2: Right Front
Discriminating Sensor Low
Reference
B63LF SIDE IMPACT SENSOR - LEFT FRONT
Terminal Type
ID
Option
1: I
1: -
2: I
2: -

Harness Type: Body


Terminal
Type ID
Lead
Test Probe
Terminal
Removal
Tool
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
Service by
Assembly (L-BU)
13314084
N/A
B63LF Side Impact Sensor - Left Front

Pin
Size
Color
Circuit
1: 1
1: 0.5 1: OG/D-GN
1: 2132
2: 2
2: 0.5
2: 6628
2: BK/OG
Function
1: Left Front Side Impact
Sensing Module Signal
Sensing Module Low
Reference
Terminal Type
ID
Option
1: I
1: -
2: I
2: -
B63LR SIDE IMPACT SENSOR - LEFT REAR
Harness Type: Body


Terminal
Terminal
Service
Core
Insulation

Type ID
Lead
Test Probe
Service by
(L-BU)
Assembly 13314084
Removal
Tool
Terminal
N/A
Tray
Crimp
Crimp
B63LR Side Impact Sensor - Left Rear

Pin
Size
Color
Circuit
1: 1
1: 0.5 1: OG/D-BU
1: 6620
2: 2
2: 0.5
2: 6621
2: BK/OG
Function
Terminal Type
ID
Option
1: I
1: -
2: I
2: -
1: Left Middle Side Impact

2: Left Middle Side Impact
Sensing Module Low
Reference
B63RF SIDE IMPACT SENSOR - RIGHT FRONT
Harness Type: Body


Terminal
Type ID
Lead
Test Probe
Terminal
Removal
Tool
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
Service by
Assembly (L-BU)
13314084
N/A
B63RF Side Impact Sensor - Right Front

Pin
Size
Color
Circuit
1: 1
1: 0.5
1: BN/OG
1: 2134
2: 2
2: 0.5
2: BK/OG
2: 6629
Function
1: Right Front Side Impact
Sensing Module Low
Terminal Type
ID
Option
1: I
1: -
2: I
2: -

Reference
B63RR SIDE IMPACT SENSOR - RIGHT REAR
Harness Type: Body


Terminal
Type ID
Lead
Test Probe
Terminal
Removal
Tool
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
Service by
Assembly (L-BU)
13314084
N/A
B63RR Side Impact Sensor - Right Rear

Pin
Size
Color
Circuit
1: 1
1: 0.5
1: OG/VT
1: 6624
2: 2
2: 0.5
2: BK/OG
2: 6625
Function
1: Right Middle Side
Impact Sensing Module
Signal
2: Right Middle Side
Low Reference
Terminal Type
ID
Option
1: I
1: -
2: I
2: -
B111B TURBOCHARGER BOOST/INTAKE AIR TEMPERATURE (LUV)



Type ID
Lead
Test Probe
I
Terminal
Removal
Tool
Service
Terminal
J-35616-35
J-38125-561 1928498056
(VT)
13576381
Tray
Core
Crimp
Insulation
Crimp
B111B Turbocharger Boost/Intake Air Temperature (LUV)

Pin
Size
Color
Circuit
Function
1: Low Reference
2: Pre-Throttle Air Temp
and Press (TMAP)
Temperature Signal
3: 5 Volt Reference
4: Pre Throttle Air Temp
and Press (TMAP) Air
Pressure Signal
1: 1
1: 0.5 1: BK/D-GN
1: 7332
2: 2
2: 0.5
2: GY
2: 7329
3: 3
3: 0.5
3: BN/RD
3: 7331
4: 4
4: 0.5
4: D-GN
4: 7330
Terminal Type
ID
1: I
Option
1: -
2: I
2: -
3: I
3: -
4: I
4: -
B68 KNOCK SENSOR (LUV)

Description: 2-Way F 2.8 DCS Series, Sealed (BK)

Terminal
Type ID
I
Lead
Test Probe
13575575
Terminal
Removal
Tool
Service
Terminal
J-35616-64B
J-38125-213 33467-0005
(L-BU)
Tray
Core
Crimp
Insulation
Crimp
23
B68 Knock Sensor (LUV)

Pin
Size
Color
Circuit
Function
Terminal Type
ID
Option

1: 1
2: 2
1: 0.5
2: 0.5
1: VT/GY
2: BK/YE
1: 496
2: 1716
1: Knock Sensor Signal (1)

1: I
2: I
1: 2: -
B68 KNOCK SENSOR (LUW/LWE)

Description: 2-Way F 2.8 Timer Series, Sealed (NA)

Terminal
Type ID
Lead
Test Probe
13581346
Terminal
Removal
Tool
Service
Terminal
J-35616-35
J-38125-36 4-964286-1
(VT)
Tray
Core
Crimp
Insulation
Crimp
16
B68 Knock Sensor (LUW/LWE)

Pin
Size
Color
Circuit
1: 1
2: 2
1: 0.5
2: 0.5
1: VT/GY
2: BK/YE
1: 496
2: 1716
Terminal Type
ID
1: I
2: I
Function
B74 MANIFOLD ABSOLUTE PRESSURE SENSOR (LUV)


Terminal
Option
1: 2: -


Type ID
Lead
Test Probe
I
Pending
Pending
Removal
Tool
Pending
Service
Terminal
Not
Available
Tray
Not
Available
Core
Insulation
Crimp
Crimp
Not
Not
Available Available
B74 Manifold Absolute Pressure Sensor (LUV)

Pin
Size
Color
Circuit
Function
1: 1
2: 2
1: 0.5
2: 0.5
1: BN/RD
2: BK/L-GN
1: 2704
2: 469
3: 3
3: 0.5 3: L-GN/WH
3: 432
1: 5 Volt Reference
2: Low Reference
3: Manifold Absolute
Terminal Type
ID
1: I
2: I
3: I
Option
1: 2: 3: -
B74 MANIFOLD ABSOLUTE PRESSURE SENSOR (LUW/LWE)


Terminal
Type ID
Lead
Test Probe
13581346
Terminal
Removal
Tool
Service
Terminal
J-35616-35
J-38125-36 4-964286-1
(VT)
Tray
Core
Crimp
Insulation
Crimp
16
B74 Manifold Absolute Pressure Sensor (LUW/LWE)

Pin
Size
Color
Circuit
1: 1
1: 0.5
1: GY/RD
1: 2704
2: 2
2: 0.5
2: BK/L-GN
2: 469
3: 3
3: 0.5 3: L-GN/WH
3: 432
Function
Pressure Sensor 5 Volt
Reference
Pressure Sensor Low
Reference
Terminal Type
ID
Option
1: I
1: -
2: I
2: -
3: I
3: -

B75C MULTIFUNCTION AIR INTAKE SENSOR

Description: 8-Way F 064 Series, Sealed (BK)

Type ID
Lead
Test Probe
I
Pending
Pending
Terminal
Removal
Tool
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
Pending
Not
Available
Not
Available
Not
Available
Not
Available
B75C Multifunction Air Intake Sensor

Pin
Color
Circuit
1: 1 1: 0.5
1: BN/GY
1: 4008
2: 0.5
2: 0.5
2: WH/RD
2: WH/YE
2: 3201
2: 3202
3: 3 3: 0.5
3: GN/WH
3: 492
4: 4 4: 0.5
4: BK
4: 150
5: 5 5: 0.75
5: VT/BU
5: 5294
6: 6 6: 0.5
6: YE/WH
6: 3200
7: 7 7: 0.5
7: BK/VT
7: 2760
8: 8 8: 0.5
8: BN/VT
8: 472
2: 2
Size
Function
1: Humidity Sensor
Signal
2: Throttle Inlet Absolute
Reference
Reference
3: Mass Air Flow Sensor
Signal
4: Ground
5: Powertrain Main
Relay Fused Supply (5)
7: Intake Air
Reference
8: Induction Air
Temperature Sensor
Signal
Terminal Type
ID
Option
1: I
1: -
2: I
2: LUV
2: LUW/LWE
3: I
3: -
4: I
4: -
5: I
5: -
6: I
6: -
7: I
7: -
8: I
8: -

B78E REAR OBJECT SENSOR - LEFT MIDDLE (UD7)
Harness Type: Rear Object Sensor

OEM Connector: 31404-3700

Terminal
Type ID
Terminal
Service
Removal
Terminal
Tool
J-35616-64B J-38125- SAIT-A03T13575845
(L-BU)
215A
M064
Lead
Test Probe
Tray
Core
Crimp
Insulation
Crimp
14
B78E Rear Object Sensor - Left Middle (UD7)

Pin
Size
Color
Circuit
Function
1: 1
1: 0.5
1: BN/WH
1: 2374
2: 2
2: 0.5
2: BK/GY
2: 2379
3: 3
3: 0.5
3: YE/D-BU
3: 2376
1: Object Sensor Control

2: Object Sensor Low
Reference
3: Left Rear Middle Object
Sensor Signal
Terminal Type
ID
1: I
Option
1: -
2: I
2: -
3: I
3: -
B78F REAR OBJECT SENSOR - RIGHT MIDDLE (UD7)


Terminal
Terminal
Service
Core
Insulation

Type ID
Lead
Removal
Tool
J-35616-64B J-3812513575845
(L-BU)
215A
Test Probe
Terminal
SAIT-A03TM064
Tray
Crimp
Crimp
14
B78F Rear Object Sensor - Right Middle (UD7)

Pin
Size
Color
Circuit
Function
1: 1
1: 0.5
1: BN/WH
1: 2374
2: 2
2: 0.5
2: BK/GY
2: 2379
3: 3
3: 0.5
3: YE/WH
3: 2377

Reference
3: Right Rear Middle
Object Sensor Signal
Terminal Type
ID
1: I
Option
1: -
2: I
2: -
3: I
3: -
B78G REAR OBJECT SENSOR - LEFT OUTER (UD7)


Terminal
Type ID
Terminal
Service
Removal
Terminal
Tool
J-35616-64B J-38125- SAIT-A03T13575845
(L-BU)
215A
M064
Lead
Test Probe
Tray
Core
Crimp
Insulation
Crimp
14
B78G Rear Object Sensor - Left Outer (UD7)

Pin
Size
Color
Circuit
Function
1: 1
1: 0.5
1: BN/WH
1: 2374
2: 2
2: 0.5
2: BK/GY
2: 2379
3: 3
3: 0.5
3: YE
3: 2375

Reference
3: Left Rear Corner Object
Sensor Signal
B78H REAR OBJECT SENSOR - RIGHT OUTER (UD7)
Terminal Type
ID
1: I
Option
1: -
2: I
2: -
3: I
3: -



Terminal
Type ID
Terminal
Service
Removal
Terminal
Tool
J-35616-64B J-38125- SAIT-A03T13575845
(L-BU)
215A
M064
Lead
Test Probe
Tray
Core
Crimp
Insulation
Crimp
14
B78H Rear Object Sensor - Right Outer (UD7)

Pin
Size
Color
Circuit
Function
1: 1
1: 0.5
1: BN/WH
1: 2374
2: 2
2: 0.5
2: BK/GY
2: 2379
3: 3
3: 0.5
3: YE/VT
3: 2378

Reference
3: Right Rear Corner
Terminal Type
ID
1: I
Option
1: -
2: I
2: -
3: I
3: -
B80 PARK BRAKE SWITCH
Harness Type: Body

Description: 1-Way Female (BK)

Terminal
Type ID
Lead
Test Probe
Terminal
Removal
Tool
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp

J-35616-14
(GN)
13575464
J-3812512A
15326030
B80 Park Brake Switch

Pin
Size
Color
A: A A: 0.5 A: D-BU/VT
Circuit
Function
Terminal Type
ID
Option
A: 1134
A: Park Brake Switch

Signal
A: I
A: -
B87 REARVIEW CAMERA (UVC)
Harness Type: License Lamp

Description: 6-Way F 0.64 Series, Sealed (GY)

Terminal
Type ID
Lead
Test Probe
13327120
J-35616-64B
(L-BU)
Terminal
Removal
Tool
J-38125215A
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
SAIT-A03T M064
23
B87 Rearview Camera (UVC)

Pin
Size
1: 1 1: 0.35
2: 2
2: 0.5
Color
Circuit
1: GY/YE
1: 6972
2: GY
2: 7069
3: 3 3: 0.35 3: L-GN/WH
3: 24
4: 4 4: 0.35
5: 5 5: 0.35
4: WH/BU
5: BK
4: 6973
5: 2350
6: 6 6: 0.35
6: VT/BK
6: 339
B88D SEAT BELT SWITCH - DRIVER
Function
1: Camera Signal #2 +
2: Camera Shield
Extension
3: Backup Lamp Supply
Voltage
4: Camera Signal #2
5: Ground
Voltage
Terminal Type
ID
1: I
Option
1: -
2: I
2: -
3: I
3: -
4: I
5: I
4: 5: -
6: I
6: -

Harness Type: Driver Seat

Description: 2-Way F 0.64 Series (BK)

Terminal
Type ID
Lead
Test Probe
13575855
Terminal
Removal
Tool
Service
Terminal
J-35616-2A
J-38125-553 8240-0127
(GY)
Tray
Core
Crimp
Insulation
Crimp
22
B88D Seat Belt Switch - Driver

Pin
Size
Color
Circuit
1: 1
1: 0.5
1: RD
1: 238
2: 2
2: 0.5
2: BK
2: 1363
Function
Terminal Type
ID
Option
1: I
1: -
2: I
2: -
1: Driver Seat Belt Switch

Signal
2: Driver Seat Belt Switch
Low Reference
B88P SEAT BELT SWITCH - PASSENGER


Terminal
Type ID
I
Lead
Test Probe
13575855
Terminal
Removal
Tool
Service
Terminal
J-35616-2A J-38125-553 8240-0127
Tray
Core
Crimp
Insulation
Crimp
22

(GY)
B88P Seat Belt Switch - Passenger
Pin
Size
Color
Circuit
1: 1
1: 0.5
1: RD
1: 1362
2: 2
2: 0.5
2: BK
2: 1361
Function
Terminal Type
ID
Option
1: I
1: -
2: I
2: -
1: Passenger Seat Belt

Switch Signal
Switch Low Reference
B99 STEERING WHEEL ANGLE SENSOR (FX3)

OEM Connector: 1-1241370-3
Description: 6-Way F 0.64 MQS Series (BK)

Terminal
Type ID
Terminal
Removal
Tool
J-35616-64B J-3812513575737
(L-BU)
12A
Lead
Test Probe
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
928999-5
15
B99 Steering Wheel Angle Sensor (FX3)

Pin
Size
Color
Circuit
1: 1
1: 0.5
1: WH
1: 6106
2: 2
2: 0.5
2: WH
2: 6106
3: 3
3: 0.5 3: D-BU/YE
3: 6105
4: 4
4: 0.5 4: D-BU/YE
4: 6105
5: 5
6: 6
5: 0.5 5: L-GN/BN
6: 0.5
6: BK
5: 2087
6: 1650
Function
1: High Speed GMLAN
Serial Data 2: High Speed GMLAN
Serial Data 3: High Speed GMLAN
Serial Data +
4: High Speed GMLAN
Serial Data +
5: 12 Volt Reference
6: Ground
Terminal Type
ID
Option
1: I
1: -
2: I
2: -
3: I
3: -
4: I
4: -
5: I
6: I
5: 6: -

B107 ACCELERATOR PEDAL POSITION SENSOR

Description: 6-Way F 1.2 Micro Timer Series, Sealed (BK)

Terminal
Type ID
Lead
Test Probe
13576269
Terminal
Removal
Tool
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
16
J-35616-14
J-38125-560 4-969005-1
(GN)
B107 Accelerator Pedal Position Sensor

Pin
Size
Color
Circuit
1: 1
1: 0.5
1: BN/RD
1: 1274
2: 2
2: 0.5
2: WH/RD
2: 1164
3: 3
3: 0.5
3: YE/WH
3: 1161
4: 4
4: 0.5
4: BK/D-BU
4: 1271
5: 5
5: 0.5
5: BK/VT
5: 1272
6: 6
6: 0.5 6: L-GN/WH
6: 1162
B108 AIR QUALITY SENSOR (C68)
Function
1: Accelerator Pedal
Position 5 Volt Reference
(2)
Position 5 Volt Reference
(1)
Position Signal (1)
Position Low Reference (1)
Position Signal (2)
Terminal Type
ID
Option
1: I
1: -
2: I
2: -
3: I
3: -
4: I
4: -
5: I
5: -
6: I
6: -



Terminal
Type ID
Terminal
Removal
Tool
J-35616-64B J-3812513576395
(L-BU)
12A
Lead
Test Probe
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
962885-5
15
B108 Air Quality Sensor (C68)

Pin
Size
Color
Circuit
Function
1: Ignition Voltage
2: Ground
3: Air Quality Sensor
Signal
1: 1
2: 2
1: 0.5 1: VT/D-GN
2: 0.5
2: BK
1: 1339
2: 1350
3: 3
3: 0.5
3: 5203
3: VT/WH
Terminal Type
ID
1: I
2: I
3: I
Option
1: 2: 3: -
B115 VEHICLE SPEED SENSOR (MF3 OR MZ0)


Terminal
Removal
Tool
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
Not Stocked J-35616-16

J-38125-21
in Kit
(L-GN)
Not
Available
Not
Available
Not
Available
Not
Available

Type ID
Lead
Test Probe
I
B115 Vehicle Speed Sensor (MF3 or MZ0)

Pin
Size
Color
Circuit
Function
Terminal Type
ID
Option

1: 1
2: 2
3: 3
1: 0.5
1: 0.5
2: 0.5
2: 1
1: GY/BK
1: WH/BK
2: WH/BK
2: GY/BK
1: 3096
1: 3096
2: 3097
2: 3097
1: 5 Volt Reference
1: 5 Volt Reference
2: Low Reference
2: Low Reference
3: 0.5
3: 0.5
3: D-GN
3: L-GN
3: 3098
3: 3098
3: Output Speed
3: Output Speed
1: LUJ
1: LUW
2: LUJ
2: LUW
3: Digital)
Signal (LUJ
3: Digital)
Signal (LUW
1: I
2: I
3: I
B119 MULTI-AXIS ACCELERATION SENSOR (FX3)
Harness Type: Body

Description: 6-Way F Micro 064 Series, Sealed (BK)

Terminal
Type ID
Terminal
Removal
Tool
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
J-35616-64B
J-38125-21
(L-BU)
15359541
Lead
Test Probe
13575528
B119 Multi-Axis Acceleration Sensor (FX3)

Pin
Size
Color
Circuit
1: 1
1: 0.5
1: WH
1: 6106
3: 3
4
3: 0.5 3: D-BU/YE
-
3: 6105
-
5: 5
5: 0.5 5: D-GN/BN
5: 2087
6: 6
6: 0.5
6: 1337
6: GY/RD
B150 FUEL TANK PRESSURE SENSOR
Function
1: High Speed GMLAN
Serial Data (-) (2)
Not Occupied
3: High Speed GMLAN
Serial Data (+) (2)
Not Occupied
5: Combined Vehicle
Inertial Sensor Supply
Voltage
6: Ground
Terminal Type
ID
Option
1: I
1: -
3: I
3: -
5: I
5: -
6: I
6: -


Description: 3-Way F GT 150 Series, Sealed (GY)

Terminal
Type ID
Lead
Test Probe
13575412
Terminal
Removal
Tool
J-35616-2A
J-38125-553
(GY)
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
12191819
B150 Fuel Tank Pressure Sensor

Pin
Size
Color
Circuit
1: 1
1: 0.5 1: D-BU/WH
1: 890
2: 2
3: 3
2: 0.5
3: 0.5
2: 6281
3: 2709
2: BK/WH
3: BN/RD
Function
Terminal Type
ID
Option
1: I
1: -
2: I
3: I
2: 3: -
1: Fuel Tank Pressure

Sensor Signal
2: Low Reference
3: 5 Volt Reference
B160 WINSHIELD TEMPERATURE AND INSIDE MOISTURE SENSOR (C68)


Terminal
Type ID
I
Lead
Test Probe
Terminal
Removal
Tool
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
13575782 J-35616-64B
J-38125-
928999-5
15

(L-BU)
12A
B160 Winshield Temperature and Inside Moisture Sensor (C68)

Pin
Size
Color
Circuit
1: 1 1: 0.35 1: YE/RD
2: 2 2: 0.35 2: GY/D-BU
3: 3 3: 0.35 3: BK/D-BU
1: 597
2: 7564
3: 7566
4: 4 4: 0.35 4: GY/D-GN
4: 7565
5: 5 5: 0.35 5: YE/D-BU
5: 3197
Terminal Type
ID
1: 5 Volt Reference
1: I
2: Humidity Sensor Signal
2: I
3: Ground
3: I
4: Windscreen Temp
4: I
Sensor Signal
5: Humidity Temperature
5: I
Sensor Signal
Not Occupied
Function
Option
1: 2: 3: 4: 5: -
E2LF SIDE MARKER LAMP - LEFT FRONT

Description: 2-Way F Bulb Socket (L-GY)

Terminal
Type ID
Lead
Test Probe
13576389
J-35616-2A
(GY)
Terminal
Removal
Tool
J-3812511A
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
7116-410208
E2LF Side Marker Lamp - Left Front

Pin
Size
Color
Circuit
1: 1
2: 2
1: 0.5
2: 0.5
1: VT/GY
2: BK
1: 709
2: 1150
Terminal Type
ID
1: Left Park Lamp Control
1: I
2: Ground
2: I
E2RF SIDE MARKER LAMP - RIGHT FRONT
Function
Option
1: 2: -


Description: 2-Way F Bulb Socket (L-GY)

Terminal
Type ID
Lead
Test Probe
13576389
J-35616-2A
(GY)
Terminal
Removal
Tool
J-3812511A
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
7116-410208
E2RF Side Marker Lamp - Right Front

Pin
Size
Color
Circuit
1: 1
2: 2
1: 0.5
2: 0.5
1: GY/BN
2: BK
1: 309
2: 1050
Terminal Type
ID
1: Right Park Lamp Control
1: I
2: Ground
2: I
Function
Option
1: 2: -
E4LR TURN SIGNAL LAMP - LEFT REAR
Harness Type: Left Tail Lamp

OEM Connector: Pending
Description: 3-Way F Bulb Socket Sealed (NA)

Type ID
Lead
Test Probe
Terminal
Removal
Tool
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
Service by
Harness See Part
Not
Available
Service by
Harness See Part
Service by
Harness See Part
Not
Available
Not
Available
Pending

Catalog
Catalog
Catalog
E4LR Turn Signal Lamp - Left Rear

Pin
Size
Color
Circuit
Function
2: 2
2: 0.5
2: YE
2: 1334
3: 3
3: 0.5
3: BK/WH
3: 2550
Not Occupied
2: Left Rear Turn Signal
Lamp Control
3: Ground
Terminal Type
ID
-
Option
-
2: I
2: -
3: I
3: -
E4RR TURN SIGNAL LAMP - RIGHT REAR
Harness Type: Right Tail Lamp

Description: 3-Way F Bulb Socket, Sealed (NA)

Type ID
Lead
Test Probe
Terminal
Removal
Tool
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
Service by
Harness See Part
Catalog
Not
Available
Service by
Harness See Part
Catalog
Service by
Harness See Part
Catalog
Not
Available
Not
Available
Pending
E4RR Turn Signal Lamp - Right Rear

Pin
Size
Color
Circuit
Function
2: 2
2: 0.5
2: YE
2: 1335
3: 3
3: 0.5
3: BK/WH
3: 2550
Not Occupied
2: Right Rear Turn Signal
Lamp Control
3: Ground
E4N PARK/TURN SIGNAL LAMP - LEFT
Terminal Type
ID
-
Option
-
2: I
2: -
3: I
3: -

Harness: Forward Lamp

OEM: 13597525
Service: Pending
Description: 3-Way F (WH/BK)

Terminal Type
Terminated Lead
ID
Service by Harness - See
I
Part Catalog
J-35616-18 (BK)
J-38125-553
E4N Park/Turn Signal Lamp - Left

Pin
Size
Color
Circuit
1: 1
1: 0.5 1: D-BU/WH
1: 1314
2: 2
3: 3
2: 0.5
3: 0.5
2: 50
3: 709
2: BK
3: VT/GY
Function
1: Left Front Turn Signal
Lamp Control
2: Ground
Terminal Type
ID
Option
1: I
1: -
2: I
3: I
2: 3: -
E4P PARK/TURN SIGNAL LAMP - RIGHT
Harness: Forward Lamp

OEM: 13597525
Service: Pending
Description: 3-Way F (WH/BK)

Terminal Type
Terminated Lead
ID
I
Part Catalog
J-35616-18 (BK)
J-38125-553

E4P Park/Turn Signal Lamp - Right

Pin
Size
Color
Circuit
1: 1
1: 0.5 1: D-GN/VT
1: 1315
2: 2
3: 3
2: 0.5
3: 0.5
2: 50
3: 309
2: BK
3: GY/BN
Function
Terminal Type
ID
Option
1: I
1: -
2: I
3: I
2: 3: -
1: Right Front Turn Signal

Lamp Control
2: Ground
E5A BACKUP LAMP - LEFT

Description: 2-Way F Bulb Socket, Sealed (GY)

Type ID
Lead
Test Probe
Terminal
Removal
Tool
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
Service by
Harness See Part
Catalog
Not
Available
Service by
Harness See Part
Catalog
Service by
Harness See Part
Catalog
Not
Available
Not
Available
Pending
E5A Backup Lamp - Left

Pin
Size
Color
Circuit
Function
1: 1
2: 2
1: 0.5
2: 0.5
1: WH
2: BK/WH
1: 1324
2: 2550

2: Ground
Terminal Type
ID
1: I
2: I
Option
1: 2: -

2013 ELECTRICAL
Views - Cruze

E5AA TAIL/STOP LAMP - LEFT

OEM Connector: 3235
Description: 3-Way F Bulb Socket, Sealed (BK)

Type ID
Lead
Test Probe
Terminal
Removal
Tool
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
Service by
Harness See Part
Catalog
Not
Available
Service by
Harness See Part
Catalog
Service by
Harness See Part
Catalog
Not
Available
Not
Available
Pending
E5AA Tail/Stop Lamp - Left

Pin
Size
Color
Circuit
1: 1
1: 0.5
1: RD
1: 7542
2: 2
3: 3
2: 0.5
3: 1
2: D-BU
3: BK
2: 709
3: 2550
E5AB TAIL/STOP LAMP - RIGHT
Function
1: Left Rear Stop Lamp
Supply Voltage
3: Ground
Terminal Type
ID
Option
1: I
1: -
2: I
3: I
2: 3: -


OEM Connector: 3235
Description: 3-Way F Bulb Socket, Sealed (BK)

Type ID
Lead
Test Probe
Terminal
Removal
Tool
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
Service by
Harness See Part
Catalog
Not
Available
Service by
Harness See Part
Catalog
Service by
Harness See Part
Catalog
Not
Available
Not
Available
Pending
E5AB Tail/Stop Lamp - Right

Pin
Size
Color
Circuit
1: 1
1: 0.5
1: RD
1: 7541
2: 2
3: 3
2: 0.5
3: 1
2: D-BU
3: BK
2: 309
3: 2550
Function
Terminal Type
ID
Option
1: I
1: -
2: I
3: I
2: 3: -
1: Right Rear Stop Lamp

Supply Voltage
3: Ground
E5B BACKUP LAMP - RIGHT


Type ID
Lead
Test Probe
Service by
Harness See Part
Catalog
Pending
Terminal
Removal
Tool
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
Not
Available
Service by
Harness See Part
Catalog
Service by
Harness See Part
Catalog
Not
Available
Not
Available

E5B Backup Lamp - Right

Pin
Size
Color
Circuit
Function
1: 1
2: 2
1: 0.5
2: 0.5
1: WH
2: BK
1: 1324
2: 2550

2: Ground
Terminal Type
ID
1: I
2: I
Option
1: 2: -
E5E TAIL LAMP - LEFT
Harness Type: Left Inner Tail Lamp

OEM Connector: 3233
Description: 3-Way F Bulb Socket, Sealed (GN)

Type ID
Lead
Test Probe
Terminal
Removal
Tool
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
Service by
Harness See Part
Catalog
Not
Available
Service by
Harness See Part
Catalog
Service by
Harness See Part
Catalog
Not
Available
Not
Available
Pending

Pin
Size
Color
Circuit
Function
1
2: 2
3: 3
2: 0.5
3: 0.5
2: D-BU
3: BK
2: 709
3: 2550
Not Occupied
3: Ground
E5F TAIL LAMP - RIGHT
Harness Type: Right Inner Tail Lamp
Terminal Type
ID
2: I
3: I
Option
2: 3: -

OEM Connector: 3233

Description: 3-Way F Bulb Socket, Sealed (GN)

Type ID
Lead
Test Probe
Terminal
Removal
Tool
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
Service by
Harness See Part
Catalog
Not
Available
Service by
Harness See Part
Catalog
Service by
Harness See Part
Catalog
Not
Available
Not
Available
Pending

Pin
Size
Color
Circuit
1
2: 2
3: 3
2: 0.5
3: 0.5
2: D-BU
3: BK
2: 309
3: 2550
Terminal Type
ID
Not Occupied
2: I
3: Ground
3: I
Function
Option
2: 3: -
E6 CENTER HIGH MOUNTED STOP LAMP
Harness Type: Body


Terminal
Type ID
I
Lead
Test Probe
13575735
Terminal
Removal
Tool
J-35616-2A
J-38125-553
(GY)
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
12191812
19
E6 Center High Mounted Stop Lamp

Pin
Size
Color
Circuit
Function
Terminal Type
ID
Option

A: A A: 0.5
A: VT/WH
A: 5065
B: B B: 0.5
B: BK
B: 650
A: Stop Lamp Relay Coil

Control
B: Ground
A: I
A: -
B: I
B: -
E7L LICENSE PLATE LAMP - LEFT

Service Connector: Service By Harness

Type ID
Lead
Test Probe
Service by
Harness See Part
Catalog
Pending
Terminal
Removal
Tool
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
Not
Available
Service by
Harness See Part
Catalog
Service by
Harness See Part
Catalog
Not
Available
Not
Available
E7L License Plate Lamp - Left

Pin
Size
Color
Circuit
Function
1: 1
1: 0.5
1: BK/WH
1: 2550
2: 2
2: 0.5
2: WH
2: 6846
1: Ground
2: Rear License Lamp
Supply Voltage
E7R LICENSE PLATE LAMP - RIGHT

Service Connector: Service By Harness
Terminal Type
ID
1: I
2: I
Option
1: 2: -


Type ID
Lead
Test Probe
Service by
Harness See Part
Catalog
Pending
Terminal
Removal
Tool
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
Not
Available
Service by
Harness See Part
Catalog
Service by
Harness See Part
Catalog
Not
Available
Not
Available
E7R License Plate Lamp - Right

Pin
Size
Color
Circuit
Function
1: 1
1: 0.5
1: BK/WH
1: 2550
2: 2
2: 0.5
2: WH
2: 6846
1: Ground
Supply Voltage
Terminal Type
ID
1: I
2: I
Option
1: 2: -
E8S REAR COMPARTMENT COURTESY LAMP
Harness Type: Body


Terminal
Type ID
I
Lead
Test Probe
13575855
Terminal
Removal
Tool
Service
Terminal
J-35616-2A
J-38125-553 8240-0127
(GY)
Tray
Core
Crimp
Insulation
Crimp
22
E8S Rear Compartment Courtesy Lamp

Pin
1: 1
2: 2
Size
Color
1: 0.5 1: D-GN/GY
2: 0.5
2: BK
Circuit
Function
1: 737
2: 2350
1: Trunk Lamp Control

2: Ground
Terminal Type
ID
1: I
2: I
Option
1: 2: -

E13L HEADLAMP - LEFT

Description: 3-Way F GT 150 Series, Sealed (GN)

Terminal
Type ID
Lead
Test Probe
13578879
II
13578879
Terminal
Removal
Tool
J-35616-2A
J-38125-553
(GY)
J-35616-2A
J-38125-553
(GY)
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
12191819
12191819

Pin
Size
Color
Circuit
1: 1
1: 1
1: YE
1: 712
2: 2
2: 1.5
2: BK
2: 1150
3: 3
3: 1.5
3: WH
3: 711
Function
1: Left Headlamp Low
Beam Control
2: Ground
3: Left Headlamp High
Beam Control
E13R HEADLAMP - RIGHT

Description: 3-Way F GT 150 Series, Sealed (GN)
Terminal Type
ID
Option
1: I
1: -
2: II
2: -
3: II
3: -


Terminal
Type ID
Lead
Test Probe
13578879
II
13578879
Terminal
Removal
Tool
J-35616-2A
J-38125-553
(GY)
J-35616-2A
J-38125-553
(GY)
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
12191819
12191819
E13R Headlamp - Right

Pin
Size
Color
Circuit
1: 1
1: 1
1: YE
1: 312
2: 2
2: 1.5
2: BK
2: 1050
3: 3
3: 1.5
3: WH
3: 311
Function
Terminal Type
ID
Option
1: I
1: -
2: II
2: -
3: II
3: -
1: Right Headlamp Low

Beam Control
2: Ground
3: Right Headlamp High
Beam Control
E14A SEAT HEATING ELEMENT - DRIVER BACK (KA1)
Harness: Driver Seat Cushion Heater

OEM: Pending
Description: 2-Way M (BK)

Terminal Type
Terminated Lead
ID
I
Pending
Pending
Pending
E14A Seat Heating Element - Driver Back (KA1)

Pin
Size
Color
Circuit
1: 1
1: 1
1: GN
1: 2020
2: 2
2: 1
2: BK
2: 2424
Function
1: Driver Heated Back
Element Return
2: Driver Heated Seat
Element Control
Terminal Type
ID
Option
1: I
1: -
2: I
2: -

E14B SEAT HEATING ELEMENT - DRIVER CUSHION (KA1)

OEM Connector: MG620397
Service Connector: Service by Harness- See Part Catalog
Description: 4-Way M 090-II Series (NA)

Type ID
Lead
Test Probe
I
Service by
Harness- See
Part Catalog
Pending
Terminal
Removal
Tool
Service
Terminal
Core
Crimp
Tray
Service by Service by
Not
Not
Harness- See Harness- See
Available
Available
Part Catalog Part Catalog
Insulation
Crimp
Not
Available
E14B Seat Heating Element - Driver Cushion (KA1)

Pin
Size
Color
Circuit
1: 1
1: 2.5
1: YE
1: 2077
2: 2
2: 0.5
2: RD
2: 2079
3: 3
3: 0.5
3: BK
3: 2080
4: 4
4: 0.5
4: BK
4: 2078
Function
2: Driver Heated Seat NTC
Signal
Low Reference
Element Return
E14C SEAT HEATING ELEMENT - PASSENGER BACK (KA1)
Harness: Passenger Seat Cushion Heater

OEM: Pending
Terminal Type
ID
Option
1: I
1: -
2: I
2: -
3: I
3: -
4: I
4: -

Description: Pending

Terminal Type
Terminated Lead
ID
I
Pending
Pending
Pending
E14C Seat Heating Element - Passenger Back (KA1)

Pin
Size
Color
Circuit
1: 1
1: 1
1: GN
1: 2019
2: 2
2: 1
2: BK
2: 2433
Function
Terminal Type
ID
Option
1: I
1: -
2: I
2: -
1: Passenger Heated Back

Element Return
2: Passenger Heated Seat
Element Control
E14D SEAT HEATING ELEMENT - PASSENGER CUSHION (KA1)
Harness Type: Passenger Seat

OEM Connector: MG620397
Description: 4-Way M 090-II Series (NA)

Type ID
Lead
Test Probe
Service by
Harness- See
Part Catalog
Pending
Terminal
Removal
Tool
Service
Terminal
Tray
Core
Crimp
Not
Not
Available
Available
Insulation
Crimp
Not
Available
E14D Seat Heating Element - Passenger Cushion (KA1)

Pin
Size
Color
Circuit
1: 1
1: 2.5
1: BN/BU
1: 2479
2: 2
2: 0.5
2: BK/VT
2: 2480
Function
Element Return
Terminal Type
ID
Option
1: I
1: -
2: I
2: -

3: 3
3: 0.5
3: BK/GY
3: 2435
4: 4
4: 0.5
4: WT/GY
4: 2434
Low Reference
NTC Signal
3: I
3: -
4: I
4: -
E18 REAR DEFOGGER X1
Harness Type: Body


Type ID
Lead
Test Probe
Terminal
Removal
Tool
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
Service by
Connector
Assembly 13580102
J-35616-42
(RD)
Not
Available
Not
Available
Not
Available
Not
Available
J-3812512A
E18 Rear Defogger X1

Pin
Size
Color
Circuit
Function
Terminal Type
ID
Option
1: 1
1: 4
1: BN/VT
1: 293
1: Rear Defog Element

Supply Voltage
1: I
1: -
E18 REAR DEFOGGER X2
Harness Type: Body



Type ID
Lead
Test Probe
Terminal
Removal
Tool
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
Service by
Connector
Assembly 13580102
J-35616-42
(RD)
Not
Available
Not
Available
Not
Available
Not
Available
J-3812512A

Pin
Size
Color
Circuit
Function
1: 1
1: 4
1: BK
1: 1650
1: Ground
Terminal Type
ID
1: I
Option
1: -
E27 INSTRUMENT PANEL COMPARTMENT LAMP

Description: 2-Way F 1.6 Timer Series (BK)

Terminal
Type ID
Lead
Test Probe
13575760
Terminal
Removal
Tool
J-35616-14
J-38125-560
(GN)
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
964274-2
16
E27 Instrument Panel Compartment Lamp

Pin
Size
Color
Circuit
1: 1
1: 0.5
1: WH/BN
1: 6815
2: 2
2: 0.5
2: BK
2: 1650
E29LF FOG LAMP - LEFT FRONT (T3U)
Function
1: Inadvertent Power
Control
2: Ground
Terminal Type
ID
Option
1: I
1: -
2: I
2: -



Terminal
Type ID
Lead
Test Probe
13575418
J-35616-4A
(PU)
Terminal
Removal
Tool
J-3812511A
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
12077411
E29LF Fog Lamp - Left Front (T3U)

Pin
Size
A: A A: 0.75
Color
Circuit
Function
A: BK
A: 1150
A: Ground
B: Left Front Fog Lamp
Supply Voltage
B: B B: 0.75 B: BN/GY
B: 5061
Terminal Type
ID
A: I
B: I
Option
A: B: -
E29RF FOG LAMP - RIGHT FRONT (T3U)


Terminal
Type ID
I
Lead
Test Probe
13575418
J-35616-4A
(PU)
Terminal
Removal
Tool
J-3812511A
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
12077411

E29RF Fog Lamp - Right Front (T3U)

Pin
Size
Color
A: A A: 0.75
A: BK
B: BN/DB: B B: 0.75
GN
Circuit
Function
A: 1050
A: Ground
B: Right Front Fog Lamp
Supply Voltage
B: 5062
Terminal Type
ID
A: I
B: I
Option
A: B: -
E32 CIGARETTE LIGHTER RECEPTACLE
Harness Type: Console

Description: 3-Way F Metri-Pack 280 Series (GY)

Terminal
Type ID
I
Lead
Test Probe
13575721
Terminal
Removal
Tool
J-35616-4A
J-38125-553
(PU)
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
12110844
E32 Cigarette Lighter Receptacle

Pin
Size
Color
Circuit
A: A
A: 1
A: VT
A: 801
B
C: C
C: 1
C: BK
C: 1650
Function
A: Retained Accessory
Power Fuse Supply Voltage
Not Occupied
C: Ground
E37F DOME/READING LAMPS - FRONT
Terminal Type
ID
Option
A: I
A: -
C: I
C: -



Terminal
Type ID
Lead
Test Probe
13575790
Terminal
Removal
Tool
J-35616-2A
J-38125-553
(GY)
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
15496302
E37F Dome/Reading Lamps - Front

Pin
Size
Color
Circuit
1: 1
1: 0.5
1: WH/BN
1: 6815
2-5
6: 6
6: 0.5
6: BK
6: 1550
Function
Terminal Type
ID
Option
1: I
1: -
6: I
6: -
Control
Not Occupied
6: Ground
E37M DOME/READING LAMPS - MIDDLE


Terminal
Type ID
I
Lead
Test Probe
13575790
Terminal
Removal
Tool
J-35616-2A
J-38125-553
(GY)
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
15496302
E37M Dome/Reading Lamps - Middle

Pin
Size
Color
Circuit
Function
Not Occupied
Terminal Type
ID
-
Option
-

2: 2
3
2: 0.5
-
2: GY
-
2: 157
-
4: 4
4: 0.5 4: GY/D-GN
4: 328
5: 5
5: 0.5 5: D-GN/BN
5: 6998
6: 6
6: 0.5
6: 1550
6: BK
2: Interior Lamp Control

Not Occupied
4: Interior Lamp Defeat
Switch Signal
5: Inadvertent Load 1
Supply Voltage
6: Ground
2: I
-
2: -
4: I
4: -
5: I
5: -
6: I
6: -
E41 ENGINE COOLANT THERMOSTAT HEATER (LUV)


Terminal
Type ID
Lead
Test Probe
13575812
Terminal
Removal
Tool
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
23
J-35616-64B
J-38125-213 33467-0005
(L-BU)
E41 Engine Coolant Thermostat Heater (LUV)

Pin
Size
Color
Circuit
1: 1
1: 0.5
1: RD/WH
1: 5293
2: 2
2: 0.5
2: L-BU
2: 6814
Function
Fused Supply (4)
2: Thermostat Engine Cool
Control
E41 ENGINE COOLANT THERMOSTAT HEATER (LUW/LWE)
Terminal Type
ID
Option
1: I
1: -
2: I
2: -


Description: 2-Way F 2.8 Junior Power Timer Series (GY)

Terminal
Type ID
Lead
Test Probe
13581346
Terminal
Removal
Tool
Service
Terminal
J-35616-35
J-38125-36 4-964286-1
(VT)
Tray
Core
Crimp
Insulation
Crimp
16
E41 Engine Coolant Thermostat Heater (LUW/LWE)

Pin
Size
Color
Circuit
1: 1
1: 0.5
1: D-BU
1: 6814
2: 2
2: 0.5
2: VT/DBU
2: 5293
Function
Terminal Type
ID
Option
1: I
1: -
2: I
2: -

Control
Fused Supply (4)
F101 PASSENGER INSTRUMENT PANEL AIR BAG X1
Harness Type: Passenger Instrument Panel Air Bag

Description: 2-Way F (L-BU With YE Case)

Terminal
Removal
Tool
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
Service by
Not
(L-BU)
Available
Assembly 19118659
Service by
Harness See Part
Catalog
Service by
Harness See Part
Catalog
Not
Available
Not
Available

Type ID
Lead
Test Probe
F101 Passenger Instrument Panel Air Bag X1

Pin
Size
Color
Circuit
Function
Terminal Type
ID
Option

1: 1
1: 0.5
1: YE
1: 3025
2: 2
2: 0.5
2: OG
2: 3024
1: Passenger Instrument
Panel Module Stage 1 High
Control
Panel Module Stage 1 Low
Control
1: I
1: -
2: I
2: -
F101 PASSENGER INSTRUMENT PANEL AIR BAG X2
Harness Type: Passenger Instrument Panel Air Bag

Description: 2-Way F (YE with YE case)

Type ID
Lead
Test Probe
I
Terminal
Removal
Tool
Service
Terminal
Core
Crimp
Tray
Service by
J-35616-64B
Not
Not
Harness- See
(L-BU)
Available
Available
Part Catalog
Insulation
Crimp
Not
Available

Pin
Size
Color
Circuit
1: 1
1: 0.5
1: GY
1: 3027
2: 2
2: 0.5
2: PU
2: 3026
F105L ROOF RAIL AIR BAG - LEFT
Harness Type: Curtain Airbag
Function
1: Passenger IP Module
Stage 2 High Control
2: Passenger IP Module
Stage 2 Low Control
Terminal Type
ID
Option
1: I
1: -
2: I
2: -


Description: 2-Way F FPB90-1 Series (BK with YE cover)

Terminal
Removal
Tool
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
Service by
Not
(L-BU)
Available
Assembly 19180245
Service by
Harness See Part
Catalog
Service by
Harness See Part
Catalog
Not
Available
Not
Available

Type ID
Lead
Test Probe
F105L Roof Rail Air Bag - Left

Pin
Size
Color
Circuit
1: 1
1: 0.5 1: OG/L-GN
1: 5019
2: 2
2: 0.5
2: 5020
2: VT/OG
Function
Terminal Type
ID
Option
1: I
1: -
2: I
2: -
1: Left Front Head Curtain

Module High Control
2: Left Front Head Curtain
Module Low Control
F105R ROOF RAIL AIR BAG - RIGHT
Harness Type: Curtain Airbag


Terminal
Removal
Tool
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
Service by
Not
Assembly (L-BU)
Available
19180245
Service by
Harness See Part
Catalog
Service by
Harness See Part
Catalog
Not
Available
Not
Available

Type ID
Lead
Test Probe
F105R Roof Rail Air Bag - Right

Pin
Size
Color
Circuit
1: 1
1: 0.5
1: OG/GY
1: 5021
2: 2
2: 0.5
2: WH/OG
2: 5022
Function
Terminal Type
ID
Option
1: I
1: -
2: I
2: -
1: Right Front Head

Curtain Module High
Control
2: Right Front Head
Curtain Module Low
Control
F106D SEAT AIR BAG - DRIVER

Description: 2-Way F (YE/OG)

Terminal
Removal
Tool
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
Service by
J-35616-64B
Not
Harness (L-BU)
Available
19258830
Service by
Harness See Part
Catalog
Service by
Harness See Part
Catalog
Not
Available
Not
Available

Type ID
Lead
Test Probe
F106D Seat Air Bag - Driver

Pin
Size
Color
Circuit
1: 1
1: 0.5 1: OG/D-BU
1: 2137
2: 2
2: 0.5
2: 2138
2: YE/OG
F106LR SEAT AIR BAG - LEFT REAR
Function
Module High Control
Module Low Control
Terminal Type
ID
Option
1: I
1: -
2: I
2: -

Harness Type: Body


Terminal
Removal
Tool
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
Service by
J-35616-64B
Not
Harness (L-BU)
Available
19258830
Service by
Harness See Part
Catalog
Service by
Harness See Part
Catalog
Not
Available
Not
Available

Type ID
Lead
Test Probe
F106LR Seat Air Bag - Left Rear

Pin
Size
Color
Circuit
1: 1
1: 0.5
1: OG/GY
1: 5223
2: 2
2: 0.5
2: BK/OG
2: 5224
Function
Terminal Type
ID
Option
1: I
1: -
2: I
2: -
1: Left Rear Side Impact

SIR Inflator Supply
Voltage
SIR Inflator Control
F106P SEAT AIR BAG - PASSENGER


Type ID
Lead
Test Probe
I
Service by
Harness - J-35616-64B
Terminal
Removal
Tool
Not
Service
Terminal
Tray
Service by
Harness -
Service by
Harness -
Core
Crimp
Insulation
Crimp
Not
Not

19258830
(L-BU)
Available
See Part
Catalog
See Part
Catalog
Available
Available
F106P Seat Air Bag - Passenger

Pin
Size
Color
Circuit
1: 1
1: 0.5
1: OG/YE
1: 2135
2: 2
2: 0.5 2: D-GN/OG
Function
Terminal Type
ID
Option
1: I
1: -
2: I
2: -

Module High Control
Module Low Control
2: 2136
F106RR SEAT AIR BAG - RIGHT REAR


Terminal
Removal
Tool
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
Service by
J-35616-64B
Not
Harness (L-BU)
Available
19258830
Service by
Harness See Part
Catalog
Service by
Harness See Part
Catalog
Not
Available
Not
Available

Type ID
Lead
Test Probe
F106RR Seat Air Bag - Right Rear

Pin
Size
Color
Circuit
1: 1
1: VT/OG
1: VT/OG
1: 5225
2: 2
2: OG/GY
2: OG/GY
2: 5226
F107 STEERING WHEEL AIR BAG X1
Function
1: Right Rear Side Impact
SIR Inflator Supply
Voltage
Terminal Type
ID
Option
1: I
1: -
2: I
2: -

Harness Type: Steering Column

Description: 2-Way F (L-GN with YE Case)

Terminal
Removal
Tool
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
Service by
Not
Assembly (L-BU)
Available
19118659
Service by
Harness See Part
Catalog
Service by
Harness See Part
Catalog
Not
Available
Not
Available

Type ID
Lead
Test Probe
F107 Steering Wheel Air Bag X1

Pin
Size
Color
Circuit
1: 1
1: 0.5
1: TN
1: 3021
2: 2
2: 0.5
2: BN
2: 3020
Function
Terminal Type
ID
Option
1: I
1: -
2: I
2: -
1: Steering Wheel Module

Stage 1 Low Control
F107 STEERING WHEEL AIR BAG X2 (EARLY PRODUCTION)
Harness Type: Steering Column

Description: 2-Way F (YE with YE case)

Type ID
Lead
Test Probe
Terminal
Removal
Tool
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp

Service by
Not
(L-BU)
Available
See Part
Catalog
Service by
Harness See Part
Catalog
Service by
Harness See Part
Catalog
Not
Available
Not
Available
F107 Steering Wheel Air Bag X2 (Early Production)

Pin
Size
Color
Circuit
1: 1
1: 0.5
1: WH
1: 3023
2: 2
2: 0.5
2: PK
2: 3022
Function
Terminal Type
ID
Option
1: I
1: -
2: I
2: -

Stage 2 Low Control
F112D SEAT BELT RETRACTOR PRETENSIONER - DRIVER
Harness Type: Body


Terminal
Removal
Tool
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
Service by
Not
(L-BU)
Available
Assembly 19180245
Service by
Harness See Part
Catalog
Service by
Harness See Part
Catalog
Not
Available
Not
Available

Type ID
Lead
Test Probe
F112D Seat Belt Retractor Pretensioner - Driver

Pin
Size
Color
Circuit
1: 1
1: 0.5 1: BN/D-BU
1: 2118
2: 2
2: 0.5
2: 2119
2: OG/RD
Function
Terminal Type
ID
Option
1: I
1: -
2: I
2: -
1: Driver Seat Belt

Pretensioner High Control
2: Driver Seat Belt
Pretensioner Low Control
F112P SEAT BELT RETRACTOR PRETENSIONER - PASSENGER

Harness Type: Body


Terminal
Removal
Tool
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
Service by
Not
Assembly (L-BU)
Available
19180245
Service by
Harness See Part
Catalog
Service by
Harness See Part
Catalog
Not
Available
Not
Available

Type ID
Lead
Test Probe
F112P Seat Belt Retractor Pretensioner - Passenger

Pin
Size
Color
Circuit
1: 1
1: 0.5
1: OG/GY
1: 2116
2: 2
2: 0.5 2: D-BU/BN
2: 2117
Function
Terminal Type
ID
Option
1: I
1: -
2: I
2: -

F113D SEAT BELT ANCHOR PRESTENSIONER - DRIVER

Description: 2-Way F 0.64 Series Unsealed (YE)

Type ID
Lead
Test Probe
Terminal
Removal
Tool
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp

Service by
Not
(L-BU)
Available
Assembly 19208396
Service by
Harness See Part
Catalog
Service by
Harness See Part
Catalog
Not
Available
Not
Available
F113D Seat Belt Anchor Prestensioner - Driver

Pin
Size
Color
1: 1
1: 0.5
1: RD
2: 2
2: 0.5
2: BK
Circuit
Function
Terminal Type
ID
Option
1: I
1: -
2: I
2: -
1: Driver Seat Belt

Pretensioner - High Control
2: Driver Seat Belt
Pretensioner - Low Control
F113P SEAT BELT ANCHOR PRETENSIONER - PASSENGER

Description: 2-Way F 0.64 Series Unsealed (YE)

Terminal
Removal
Tool
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
Service by
Not
(L-BU)
Available
Assembly 19208396
Service by
Harness See Part
Catalog
Service by
Harness See Part
Catalog
Not
Available
Not
Available

Type ID
Lead
Test Probe
F113P Seat Belt Anchor Pretensioner - Passenger

Pin
Size
Color
Circuit
1: 1
1: 0.5
1: RD
1: 3479
2: 2
2: 0.5
2: BK
2: 3480
F114D KNEE AIR BAG - DRIVER
Function
Pretensioner - High Control
Pretensioner - Low Control
Terminal Type
ID
Option
1: I
1: -
2: I
2: -


OEM: 13863037
Description: 2-Way F 1.2 MCP Series, Sealed (YE with BK Inner Connector)

Terminal
Removal
Tool
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
Service By
Not
Assembly (L-BU)
Available
19178096
Not
Available
Not
Available
Not
Available
Not
Available

Type ID
Lead
Test Probe
F114D Knee Air Bag - Driver

Pin
Size
Color
Circuit
1: 1
1: 0.5
1: OG/BU
1: 3078
2: 2
2: 0.5
2: GY/OG
2: 3079
Function
Terminal Type
ID
Option
1: I
1: -
2: I
2: -
1: Driver Knee Module

High Control
Low Control
F114P KNEE AIR BAG - PASSENGER

OEM: 13863037
Description: 2-Way F 1.2 MCP Series, Sealed (YE with BK Inner Connector)

Type ID
Lead
Test Probe
Terminal
Removal
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp

Tool
Service By
Not
Assembly (L-BU)
Available
19178096
Not
Available
Not
Available
Not
Available
Not
Available
F114P Knee Air Bag - Passenger

Pin
Size
Color
Circuit
1: 1
1: 0.5 1: OG/D-BU
1: 3076
2: 2
2: 0.5
2: 3077
2: GY/OG
Function
Terminal Type
ID
Option
1: I
1: -
2: I
2: -
1: Passenger Knee Module

High Control
2: Passenger Knee Module
Low Control
G10 COOLING FAN MOTOR

Description: 4-Way F 4.8 9.5 Series, Sealed (BK)

Type ID
Lead
Test Probe
I
13582260
II
Pending
Terminal
Removal
Tool
J-3812511A
J-35616-22
(RD)
J-35616-40
J-38125-556
(BU)
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
60070461
29
60040441
21
Not
Available
Not
Available
G10 Cooling Fan Motor

Pin
1: 1
Size
1: 4
1: 6
Color
1: BK
1: BK
Circuit
1: 1250
1: 1250
Function
1: Ground
1: Ground
Terminal Type
ID
Option
1: -
1: Except
LUJ with
MH8
1: LUJ with
MH8

2: 2.5 2: WH/D-BU
2: 4 2: WH/D-BU
2: 2
2: 409
2: 409

Control (1)
Control (1)
2: II
3: II
4: -
3: 3
3: 2.5
3: 4
3: GY
3: GY
3: 532
3: 532

Control (2)
Control (2)
4: 4
4: 4
4: 6
4: YE
4: YE
4: 5358
4: 5358

Control (3)
Control (3)
2: Except
LUJ with
MH8
2: LUJ with
MH8
3: Except
LUJ with
MH8
3: LUJ with
MH8
4: Except
LUJ with
MH8
4: LUJ with
MH8
G13 GENERATOR X2

Description: 2-Way F Junior Power Timer 2.8 Series, Sealed (BK)

Terminal
Type ID
I
Lead
Test Probe
13580821
Terminal
Removal
Tool
Service
Terminal
J-35616-35
J-38125-36 4-964273-1
(VT)
Tray
Core
Crimp
Insulation
Crimp
15
G13 Generator X2
Pin
Size
Color
Circuit
1: 0.5 1: BU/WH
1: 1
1: 0.75
1: BN
1: 25
1: 25
2: 2 2: 0.75
2: 23
2: GY
Function
1: Charge Indicator
Control
1: Charge Indicator
Control
2: Generator Field Duty
Cycle Signal
Terminal Type
ID
Option
1: I
1: LUV
1: LUW/LWE
2: I
2: -

G24 WINDSHIELD WASHER PUMP

Description: 2-Way F MCP 2.8 Series, Sealed (BK)

Terminal
Type ID
I
Lead
Test Probe
13575435
Terminal
Removal
Tool
Service
Terminal
J-35616-35
J-38125-557 1-968857-3
(VT)
Tray
Core
Crimp
Insulation
Crimp
G24 Windshield Washer Pump

Pin
Size
Color
Circuit
1: 1
1: 1
1: GY/VT
1: 228
2: 2
2: 1
2: BK
2: 1350
Function
Terminal Type
ID
Option
1: I
1: -
2: I
2: -
Pump Control
2: Ground
K8 BLOWER MOTOR CONTROL MODULE X1

Description: 6-Way F GT 150 6.3 Series (BK)

Terminal
Type ID
Lead
Test Probe
Terminal
Removal
Tool
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp

13575735
II
13575835
J-35616-2A
J-38125-553 12191812
(GY)
J-35616-42 J-38125- 7116-4122(RD)
11A
02
19
10
K8 Blower Motor Control Module X1

Pin
Size
Color
Circuit
Function
1-2
Not Occupied
3: Blower Motor Speed
Control
Not Occupied
5: Ground
3: 3
3: 0.5 3: D-BU/GY
4
5: 5
6: 6
5: 4
6: 4
5: BK
6: RD/BN
3: 754
5: 1850
6: 440
Terminal Type
ID
-
Option
-
3: I
3: -
5: II
6: II
5: 6: -
K8 BLOWER MOTOR CONTROL MODULE X2
Harness Type: HVAC

Description: 2-Way F (GY)

Type ID
Lead
Test Probe
I
13575835
J-35616-42
(RD)
Terminal
Removal
Tool
J-3812511A
Service
Terminal
Tray
7116-4122- 7116-412202
02
Core
Crimp
Insulation
Crimp

Pin
Size
Color
Circuit
1: 1
1: 4
1: RD
1: 65
2: 2
2: 4
2: BK
2: 374
K9 BODY CONTROL MODULE X1
Function
1: Blower Motor Supply
Voltage
2: Blower Motor Fan
Control
Terminal Type
ID
Option
1: I
1: -
2: I
2: -


Description: 26-Way F 0.64 2.8 Series (WH)

Terminal
Service
Removal
Terminal
Tool
J-35616-35 J-38125SNAC13575560
(VT)
12A
A081T-M2.8
J-35616-64B J-38125SNAC313575870
(L-BU)
12A
A021T-M064
Terminal
Type ID
Lead
Test Probe
I
II
Tray
Core
Crimp
Insulation
Crimp
20
20
K9 Body Control Module X1

Pin
Size
Color
Circuit
Function
1: 1
1: 2.5
1: BK
1: 1650
2: 2
2: 2.5
2: RD/D-GN
2: 2440
3: 3
3: 2.5
3: RD/YE
3: 2340
4: 4
4: 1.5
4: RD/BN
4: 2240
5-8
9: 9
9: 0.5
9: WH/BN
9: 7555
10
11:
11
11: 0.35
11: DGN/BN
11: 306
14: 0.5
14: GY/L-GN
14: 328
16: 0.35
16: WH/VT
16: 103
1: Ground
2: Battery Positive
Voltage
3: Battery Positive
Voltage
4: Battery Positive
Voltage
Not Occupied
9: Lighting Control
Switch Signal
Not Occupied
11: Headlamp Switch
Headlamps Off Signal
Control
Not Occupied
14: Interior Lamp Defeat
Switch Signal
Not Occupied
16: Headlamp Switch On
Signal
12-13
14:
14
15
16:
16
17:
17: Hazard Switch Turn
Terminal Type
ID
1: I
Option
1: -
2: I
2: -
3: I
3: -
4: I
4: -
9: II
9: -
11: II
11: -
14: II
14: -
16: II
16: -

17
18:
18
19:
19
20
21:
21
22:
22
23
24:
24
25:
25
26:
26
17: 0.35
18: DBU/VT
17: L-BU/VT
17: 1717
18: D-BU/VT
18: 5904
19: 0.5
19: BK/BN
19: 5360
21: 0.35
21: GY
21: 728
22: DGN/GY
-
24: 0.5
24: WH
24: 2501
25: 0.5
25: D-BU
25: 2500
26: 0.5
26: YE/L-GN
26: 3274
22: 0.35
22: 13
-
Flasher Control
18: Steering Column
Lock Status Signal
Low Reference
Not Occupied
21: Security Indicator
Control
22: Headlamp Switch
Park Lamp Signal
Not Occupied
24: High Speed GMLAN
Serial Data (-) (1)
Serial Data (+) (1)
26: Remote Function
Actuator Transmit Signal
17: II
17: -
18: -
18: ULS
19: II
19: -
21: II
21: -
22: II
22: -
24: II
24: -
25: II
25: -
26: II
26: -

Description: 27-Way F 0.64 2.8 Series (L-BU)

Terminal
Type ID
I
II
III
Terminal
Service
Removal
Terminal
Tool
J-35616-35 J-38125SNAC13575560
(VT)
12A
A081T-M028
J-35616-64B J-38125SNAC313575870
(L-BU)
12A
A021T-M064
J-35616-64B J-38125SNAC313575870
(L-BU)
12A
A021T-M064
Lead
Test Probe
Tray
Core
Crimp
Insulation
Crimp
20
20
20

Terminal Type

Pin
1: 1
2: 2
3: 3
4: 4
5-6
Size
1: 1.5
2: 2.5
3: 1.5
4: 2.5
-
Color
1: RD/GY
2: BK
3: RD/D-BU
4: RD/GY
-
Circuit
1: 2140
2: 850
3: 2540
4: 2840
-
7: 7
7: 0.5
7: D-BU/YE
7: 5361
8: 8
8: 0.5
8: YE
8: 6817
10: WH/L-BU
10: 278
11: YE
11: 7554
13: WH
13: 5359
10:
10: 10
0.35
11: 11 11: 0.5
12
13: 13 13: 0.5
14: 14 14: 0.5 14: D-BU/VT
14: 1788
15: 15 15: 0.5 15: OG/WH
15: 781
16: 16 16: 0.5
16: GY
16: 3273
19: OG/YE
19: 780
17-18
19: 19 19: 0.5

20
21: 21 21: 0.5 21: L-GN/GY
21: 6135
22: 22 22: 0.5
22: L-GN
22: 5060
23: 23 23: 0.5
23: WH
23: 2501
24: 24 24: 0.5
24: D-BU
24: 2500
25: 25 25: 0.5 25: GY/WH
25: 3272
Function
2: Ground
Not Occupied
Signal
8: LED Backlight
Dimming Control
Not Occupied
10: Ambient Light Sensor
Signal
11: Park Lock Solenoid
Soft Control
Not Occupied
Supply Voltage
14: Traction Control
Switch Signal (1)
15: Driver Door Lock
Switch Unlock Signal
16: Remote Function
Actuator Return
Not Occupied
19: Driver Door Lock
Switch Lock Signal
Not Occupied
Network Bus 4
22: Low Speed GMLAN
Serial Data
Serial Data (-) (1)
Serial Data (+) (1)
25: Remote Function
Actuator Supply Voltage
ID
1: I
2: I
3: I
4: I
-
Option
1: 2: 3: 4: -
7: II
7: -
8: II
8: -
10: III
10: -
11: II
11: MH8
13: II
13: -
14: II
14: -
15: II
15: -
16: II
16: -
19: II
19: -
21: II
21: -
22: II
22: -
23: II
23: -
24: II
24: -
25: II
25: -
26:
26: D-GN/WH
0.35
26: 111
26: Hazard Switch Signal
26: III
26: -
27: 27 27: 0.5 27: D-BU/WH
27: 3275
27: Remote Function

Actuator Receive Signal
27: II
27: -
26: 26


Description: 25-Way F 0.64 Series (L-GN)

Terminal
Type ID
Terminal
Service
Removal
Terminal
Tool
J-35616-64B J-38125SNAC313575870
(L-BU)
12A
A021T-M064
Lead
Test Probe
Tray
Core
Crimp
Insulation
Crimp
20

Pin
Size
Color
Circuit
1: 1
1: 0.5
1: L-GN/GY
1: 3277
2: 2
2: 0.5
2: L-GN/VT
2: 7533
3: 3
3: 0.5
3: GY/BK
3: 3276
4: 4
4: 0.5
4: YE
4: 7556
5: 5
6: 6
7: 7
5: 0.5
6: 0.5
7: 0.5
5: VT/YE
6: VT/BK
7: VT/YE
5: 4
6: 3
7: 143
8: 8
8: 0.5 8: L-GN/WH
8: 6819
9: 9
9: 0.5
9: GY/L-GN
9: 5737
10: 10 10: 0.5
10: BK/GY
10: 6009
11: 11 11: 0.5
11: WH
11: 524
12: 12 12: 0.5 12: WH/L-GN
12: 663
Function
1: Vehicle Anti-Theft
System Immobilizer Return
Network Bus 11
System Immobilizer
Supply Voltage
4: Lighting Control Switch
Reference
5: Ignition Voltage
6: Ignition Voltage
7: Ignition Voltage
8: Steering Wheel Resistor
Ladder Signal #2
9: Adaptive Cruise Control
Gap Up/Down Switch
Signal
11: Headlamp Dimmer
Switch High Beam Signal
12: Hazard Switch Left
Turn Signal
Terminal Type
ID
Option
1: I
1: -
2: I
2: -
3: I
3: -
4: I
4: -
5: I
6: I
7: I
5: 6: 7: -
8: I
8: -
9: I
9: -
10: I
10: -
11: I
11: -
12: I
12: -

13: 13 13: 0.5
13: YE/BK
13: 1714
14
15: 15 15: 0.5 15: WH/VT
16
-
15: 1020
-
17: 17 17: 0.5
17: 307
17: YE/BN
18: 18 18: 0.5 18: L-GN/WH

19
-
18: 3287
-
20: 20 20: 0.5
20: GY
20: 1715
21
22: 22 22: 0.5 22: WH/BK

23
22: 1073
-
24: 24 24: 0.5 24: VT/D-BU
24: 664
25: 25 25: 0.5 25: WH/BK
25: 94

Switch Low Signal
Not Occupied
Not Occupied
17: Headlamp Switch Flash
To Pass Signal
18: Horn Switch Signal
Not Occupied
Switch High Signal
Not Occupied
22: Ignition Key Resistor
Signal
Not Occupied
24: Hazard Switch Right
Turn Signal
Switch Signal
13: I
13: -
15: I
-
15: -
17: I
17: -
18: I
-
18: -
20: I
20: -
22: I
22: -
24: I
24: -
25: I
25: -
Harness Type: Body

Description: 26-Way F 0.64 2.8 Series (BK)

Terminal
Type ID
I
II
Terminal
Service
Removal
Terminal
Tool
J-35616-35 J-38125SNAC13575560
(VT)
12A
A081T-M28
J-35616-64B J-38125SNAC313575870
(L-BU)
12A
A021T-M064
Lead
Test Probe
Tray
Core
Crimp
Insulation
Crimp
20
20

Terminal Type

Pin
Size
Color
Circuit
1: 1
1: 1
1: YE
1: 312
2: 2
2: 1
2: YE
2: 712
3: 3
3: 0.5
3: D-GN/VT
3: 1315
4: 4
4: 0.5
4: D-BU/VT
4: 1335
5: 5
5: 0.5
5: GY/BN
5: 309
6: 6
6: 0.5
6: VT/GY
6: 709
7: 7
7: 0.5
7: GY/YE
7: 7542
8: 8 8: .5 VT/YE 8: .5 VT/YE
8: 3267
9: 9
10
11:
11
12:
12
13:
13
14:
14
15:
15
16:
16
17:
17
18:
18
19
20:
20
21:
21
22:
22
23:
23
24:
Function
1: Right Headlamp Low
Beam Control
2: Left Headlamp Low
Beam Control
3: Right Front Turn Signal
Lamp Control
4: Right Rear Turn Signal
Lamp Control
5: Right Park Lamp
Control
7: Left Rear Stop Lamp
Supply Voltage
Relay Control
9: Logistics Relay Control
Not Occupied
11: Stop Lamp Relay Coil
Control
ID
Option
1: I
1: -
2: I
2: -
3: I
3: -
4: I
4: -
5: II
5: -
6: II
6: -
7: II
7: -
8: II
8: -
9: II
-
9: -
11: II
11: -
12: II
12: -
13: II
13: -
14: II
14: -
15: II
15: -
16: II
16: -
17: II
17: -
9: 0.5
-
9: YE
-
9: 7546
-
11: 0.5
11: VT/WH
11: 5065
12: 0.5
12: VT/BK
12: 3
13: 0.5
13: DGN/YE
13: 6846
14: 0.5
14: BN/GY
14: 2268
15: 0.5
15: BN/VT
15: 1594
16: 0.5
16: GY
16: 91
17: 0.5
17: BN/DGN
17: 196
18: 0.5
18: WH/YE
18: 5075
18: Current Sensor Signal
18: II
18: -
20: 0.5
20: RD/BN
20: 1440
20: II
20: -
21: 0.5
21: DBU/VT
21: 5076
21: II
21: -
22: 0.5
22: VT/YE
22: 5985
22: II
22: -
23: 0.5
23: WH/DBU
23: 5986
Not Occupied
Voltage
21: Current Sensor Supply
Voltage
22: Accessory Wakeup
Serial Data
23: Serial Data
Communication Enable
23: II
23: -
24: BN/D-

Control
Relay Control
15: Ignition 3 Relay
Control
Motor Relay Coil Control
Motor Park Switch Signal
24: Hood Ajar Switch

24
25
26:
26
24: 0.5
-
GN
-
24: 109
-
Signal
Not Occupied
24: II
-
24: -
26: 0.5
26: BK
26: 981
26: Ground
26: II
26: -
Harness Type: Body

Description: 26-Way F 0.64 2.8 Series (BN)

Terminal
Type ID
I
II
Terminal
Service
Removal
Terminal
Tool
J-35616-35 J-38125SNAC13575560
(VT)
12A
A081T-M28
J-35616-64B J-38125SNAC313575870
(L-BU)
12A
A021T-M064
Lead
Test Probe
Tray
Core
Crimp
Insulation
Crimp
20
20

Pin
Size
Color
Circuit
1: 1
1: 0.5 1: D-BU/WH
1: 1334
2: 2
2: 0.5 2: D-BU/WH
2: 1314
3: 3
4: 4
5
3: 1.5
4: 1.5
-
3: RD/WH
4: RD/VT
-
3: 2740
4: 2640
-
6: 6
6: 0.5
6: BK/VT
6: 5077
7: 7
7: 0.5
7: WH/YE
7: 7541
11: GY/YE
11: 6188
8-10
11:
11: 11
0.75
Function
1: Left Rear Turn Signal
Lamp Control
2: Left Front Turn Signal
Lamp Control
Not Occupied
6: Current Sensor Low
Reference
7: Right Rear Stop Lamp
Supply Voltage
Not Occupied
Release Control
Terminal Type
ID
Option
1: I
1: -
2: I
2: -
3: I
4: I
-
3: 4: -
6: II
6: -
7: II
7: -
11: II
11: -

12: 12 12: 0.5 12: WH/BU
12: 6311
13: 13 13: 0.5 13: BN/WH

14-17
-
13: 1317
-
18: 18 18: 0.5 18: BN/VT
18: 1969
19: 19 19: 0.5 19: BN/WH

20-23
-
19: 28
-
24: 24 24: 0.5 24: WH/VT
24: 860
25-26
12: Cruise/ETC/TCC Brake

Signal
13: Fog Lamp Relay Control
Not Occupied
18: Headlamp High Beam
Relay Control
19: Horn Relay Control
Not Occupied
24: Front Windshield Wiper
Switch High Signal
Not Occupied
12: II
12: K34
13: II
-
13: -
18: II
18: -
19: II
-
19: -
24: II
24: -
Harness Type: Body

Description: 27-Way F 0.64 2.8 Series (PK)

Terminal
Type ID
Terminal
Service
Removal
Terminal
Tool
J-35616-35 J-38125SNAC13575560
(VT)
12A
A081T-M28
J-35616-64B J-38125SNAC313575870
(L-BU)
12A
A021T-M064
Lead
Test Probe
I
II
Tray
Core
Crimp
Insulation
Crimp
20
20

Pin
Size
1: 1 1: 0.75
Color
Circuit
1: GY
1: 5911
2: 2 2: 0.75 2: GY/D-GN
3: 3 3: 0.5
3: BK
2: 3271
3: 1650
4: 4 4: 0.75
4: 294
4: BN/YE
Function
Lock Control
2: Door Lock Control (2)
3: Ground
Unlock Control
5: Lift Gate Ajar Switch
Terminal Type
ID
Option
1: I
1: -
2: I
3: I
2: 3: -
4: I
4: 5: without

5: 5
6: 6
7-9
5: 0.5 5: VT/GY
6: 0.5 6: BN/D-GN
10: D10: 10 10: 0.5
GN/YE
11-14
15: 15 15: 0.5 15: YE/D-BU
16: 16 16: 0.5
17
16: DGN/BN
-
5: 1303
6: 109
10: 6134
15: 5797
16: 6132
-
18: 18 18: 0.5
18: D-BU
18: 2500
19: 19 19: 0.5
19: WH
19: 2501
24: 24 24: 0.5
24: D-BU
24: 2500
25: 25 25: 0.5
25: WH
25: 2501
27: GY
27: 747
20-23
26
27: 27 27: 0.5
Signal (1)
6: Hood Ajar Switch Signal
Not Occupied
Network Bus 3
Not Occupied
15: Rear Closure Handle
Switch Open Signal
Network Bus 1
Not Occupied
Serial Data (+) (1)
Serial Data (-) (1)
Not Occupied
Serial Data (+) (1)
Serial Data (-) (1)
Not Occupied
Switch Signal
5: II
6: II
-
BTV
6: -
10: II
10: -
15: II
15: -
16: II
16: -
18: II
18: -
19: II
19: -
24: II
24: -
25: II
25: -
27: II
27: -
Harness Type: Body

Description: 26-Way F 0.64 2.8 Series (GY)

Terminal
Type ID
I
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
J-35616-35
(VT)
Terminal
Removal
Tool
J-3812512A
SNACA081T-M28
20
J-35616-64B
J-38125-
SNAC3-
Lead
Test Probe
13575560

II
13575870
(L-BU)
12A
A021T-M064
20

Pin
Size
Color
Circuit
Function
1: 1
1: 0.5
1: GY
1: 157
2: 2
2: 1
2: WH/BN
2: 6815
1: Interior Lamp Control

Control
Not Occupied
Control
7: Trunk Lamp Control
Not Occupied
9: LED Backlight
Dimming Control
Not Occupied
Switch Signal
Motor Status Signal Left
Rear
Not Occupied
Switch Signal
15: Park Brake Switch
Signal
16: Technology
Identification
Not Occupied
Motor Status Signal Right
Rear
19: Inadvertent Load 1
Supply Voltage
Not Occupied
23: Low Speed GMLAN
Serial Data
Not Occupied
Switch Signal
Not Occupied
3: 3
4-5
3: 0.5 3: D-GN/WH
-
3: 1324
-
6: 6
6: 0.5
6: VT/BK
6: 7553
7: 7
8
7: 0.5
-
7: D-GN/GY
-
7: 737
-
9: 9
9: 0.5
9: YE
9: 6817
10
11: GY
11: 748
11: 11 11: 0.5
12: 12 12: 0.5 12: BN/WH

13
14: 14 14: 0.5
12: 3269
14: GY
14: 746
15: 15 15: 0.5 15: D-BU/VT
15: 1134
16: 16 16: 0.5 16: D-GN/BK
16: 5103
17
18: 18 18: 0.5
18: GY/BK
18: 3268
19: 19 19: 0.5 19: D-GN/BN

20-22
23: 23 23: 0.5

24
25: 25 25: 0.5

26
19: 6998
23: D-GN
23: 5060
25: GY
25: 745
KR14 BRAKE BOOSTER PUMP RELAY X1
Terminal Type
ID
1: I
Option
1: -
2: I
2: -
3: I
-
3: -
6: II
6: MH8
7: II
-
7: -
9: II
9: -
11: II
11: -
12: II
12: -
14: II
14: -
15: II
15: -
16: II
16: -
18: II
18: -
19: II
19: -
23: II
23: -
25: II
25: -

Harness Type: Body

Description: 6-Way F 2.8 Series, Sealed (BK)

Type ID
Lead
Test Probe
I
Pending
II
Pending
Terminal
Removal
Tool
Pending
Pending
J-35616-4A
J-38125-556
(PU)
Service
Terminal
Pending
2 21 40
49206 0
Tray
Pending
27
Core
Crimp
Insulation
Crimp
Pending
Not
Available
Pending
Not
Available
KR14 Brake Booster Pump Relay X1

Pin
Size
Color
Circuit
Function
1: 1
1: 2.5
1: BK
1: 1050
2: 2
2: 0.5
2: BN
2: 6305
3-4
5: 5
6
5: 2.5
-
5: RD/VT
-
5: 1940
-
1: Ground
2: Brake Vacuum Switch
Signal
Not Occupied
Not Occupied
KR14 BRAKE BOOSTER PUMP RELAY X2
Harness Type: Brake Booster Pump Motor Relay

Description: 2-Way F 2.8 Series, Sealed (D-GY)

Terminal Type
Terminal Type
ID
1: I
Option
1: -
2: II
2: -
5: I
-
5: -

ID
Terminated Lead
Part Catalog
Pending
Pending

Pin
Size
Color
Circuit
1: 1
1: 1.5
1: RD
1: 1470
2: 2
2: 1.5
2: WH
2: 1809
Function
Terminal Type
ID
Option
1: I
1: -
2: I
2: -
1: Brake Booster Pump

Motor Supply Voltage
2: Brake Booster Vacuum
Sensor Signal
K17 ELECTRONIC BRAKE CONTROL MODULE

Harness Type: Body
Description: 38-Way F 0.64, 2.8, 5.8 Series, Sealed (BK)

Type ID
Lead
Test Probe
Terminal
Removal
Tool
Service
Terminal
J-35616-42
J-38125-36 1241818-1
(RD)
J-35616-35
Not
13578854
J-38125-36
(VT)
Available
J-35616-64B J-38125SAITS13575264
(L-BU)
215A
A03T-M064
Tray
Core
Crimp
Insulation
Crimp
Not
Available
14
13575437
II
III

Pin
Size
Color
Circuit
1: 1
1: 4
1: RD/VT
1: 1640
2: 2
2: 0.5
2: GY
2: 1903
3-4
Terminal Type
ID
1: I
2: AAS Wheel Speed
2: III
Sensor Signal Left Front
Not Occupied
Function
5: High Speed GMLAN
Option
1: 2: -

5: 5
5: 0.5
5: D-BU/YE
5: 6105
6: 6
6: 0.5
6: WH
6: 6106
8: 8
8: 0.5 8: WH/D-BU
8: 5986
9: 9
9: 0.5
9: WH
9: 2501
10: 10 10: 0.5
10: WH
10: 2501
11: 11 11: 0.5
11: D-BU
11: 2500
12: 12 12: 0.5
12: D-BU
12: 2500
13: 13 13: 4
14
-
13: BK
-
13: 1450
-
15: 15 15: 0.5 15: D-GN/BN

16
17: 17 17: 0.5

18-21
22: 22 22: 0.5

23
24: 24 24: 0.5
15: 2087
17: YE/RD
17: 6031
22: YE/VT
22: 6030
24: BK/YE
24: 6032
25: 25 25: 1 25: RD/D-GN
25: 1840
26: 26 26: 0.5
26: YE
26: 872
27: 27 27: 0.5
27: GY/BN
27: 7065
28: 28 28: 0.5 28: D-GN/GY
28: 333
29: 29 29: 0.5
29: GY/BK
29: 7127
30: 30 30: 0.5
30: D-BU
30: 884
33: VT
33: 882
31-32
33: 33 33: 0.5
Serial Data (+) (2)

6: High Speed GMLAN
Serial Data (-) (2)
Not Occupied
8: Serial Data
9: High Speed GMLAN
Serial Data (-) (1)
Serial Data (-) (1)
Serial Data (+) (1)
Serial Data (+) (1)
13: Ground
Not Occupied
15: Combined Vehicle
Inertial Sensor Supply
Voltage
Not Occupied
17: Brake Vacuum Sensor 5
Volt Reference
Not Occupied
Signal
Not Occupied
Low Reference
Voltage
Signal Right Front
Control Right Front
28: Brake Fluid Level
Sensor Signal
Control Left Rear
Signal Left Rear
Not Occupied
Signal Right Rear
5: III
5: -
6: III
6: -
8: III
8: -
9: III
9: -
10: III
10: -
11: III
11: NJ1
12: III
12: -
13: I
-
13: -
15: III
15: -
17: III
17: -
22: III
22: -
24: III
24: -
25: II
25: -
26: III
26: -
27: III
27: -
28: III
28: -
29: III
29: -
30: III
30: -
33: III
33: -

34: 34 34: 0.5

35
-
34: GY/YE
-
34: 7128
-
36: 36 36: 0.5 36: GY/WH
36: 7064
37: 37 37: 0.5
37: GY
37: 830
38
Control Right Rear

Not Occupied
Control Left Front
Signal Left Front
Not Occupied
34: III
-
34: -
36: III
36: -
37: III
37: -
K20 ENGINE CONTROL MODULE X1 (LUW/LWE)


Terminal
Type ID
I
II
Terminal
Removal
Tool
J-35616-64B J-3812513582274
(L-BU)
12A
J-35616-64B J-3812513582275
(L-BU)
12A
Lead
Test Probe
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
928999-5
15
1719532-5
K20 Engine Control Module X1 (LUW/LWE)

Pin
Size
Color
Circuit
1: 1
1: 0.5
1: BN/WH
1: 419
2: 2
2: 0.5 2: D-GN/GY
2: 465
3: 3 3: 0.75 3: VT/L-BU
3: 5290
4: 4
4: 0.5
4: WH/GY
4: 459
5: 5
5: 0.5
5: WH/RD
5: 1164
Function
1: Check Engine Indicator
Control
2: Fuel Pump Primary Relay
Control
Fused Supply (1)
4: A/C Compressor Clutch
Relay Control
5: Accelerator Pedal Position
5 Volt Reference (1)
6: EVAP Canister Vent
Terminal Type
ID
Option
1: I
1: -
2: I
2: -
3: II
3: -
4: I
4: -
5: I
5: -

6: 6 6: 0.75
7: 7 7: 0.5
8-9
-
6: WH
7: GY/BK
-
6: 1310
7: 3097
-
10: 10 10: 0.5
10: D-BU
10: 2500
11: 11 11: 0.5
11: WH
11: 2501
12: RD/WH
12: 140
14: VT/GY
14: 139
15: 15 15: 0.5 15: BN/YE
15: 473
16: 16 16: 0.5
16: YE
16: 5991
12:
0.75
13
14:
14: 14
0.75
12: 12
17-18
19: 19 19: 0.5 19: BN/RD
19: 1274
20: 20 20: 0.5 20: BK/L-BU
20: 1271
21: 21 21: 0.5 21: BK/VT
21: 1272
22
Solenoid Control
7: 5 Volt Reference
Not Occupied
Serial Data (+) (1)
Serial Data (-) (1)
6: II
7: I
-
6: 7: MZ0
-
10: I
10: -
11: I
11: -
12: II
12: -
Not Occupied
Voltage
15: High Speed Cooling Fan
Relay Control
Control
Not Occupied
Position 5 Volt Reference (2)
Not Occupied
23: Clutch Apply Sensor
Low Reference
24: Intake Air Temperature
Signal
26: Park Neutral Position
Switch Park Signal
14: II
14: -
15: I
15: -
16: I
16: -
19: I
19: -
20: I
20: -
21: I
21: -
23: I
23: MZ0
24: I
24: -
25: I
25: -
26: I
26: MH8
23: 23 23: 0.5 23: BK/GY
23: 6110
24: 24 24: 0.5 24: BK/VT
24: 2760
25: 25 25: 0.5
25: WH/DBU
25: 6311
26: 26 26: 0.5
26: D-GN
26: 275
27: 27 27: 0.5
27: L-GN
27: 3098
27: Output Speed
27: I
27: Digital)
Signal (MZ0
28: 28 28: 0.5
28: LGN/WH
28: 5007
28: Reverse Switch Signal
28: I
28: MZ0
29: I
29: -
32: I
32: MZ0
33: I
33: -
29: 29 29: 0.5 29: YE/BK

30-31
29: 625
-
32: 32 32: 0.5 32: GY/RD
32: 6109
33: 33 33: 0.5 33: BN/RD
33: 2700

Control
Not Occupied
Voltage Reference
Volt Reference

34: 34 34: 0.5 34: YE/RD

35
-
34: 2709
-
36: 36 36: 0.5
36: VT/YE
36: 5985
37
38: 38 38: 0.5 38: BK/D-GN

39
38: 6281
-
40: 40 40: 0.5 40: YE/WH
40: 1161
41: 41 41: 0.5
41: D-GN
41: 380
42: 42 42: 0.5
42: DGN/WH
42: 1162
43: 43 43: 0.5
43: D-BU
43: 6814
44: 44 44: 0.5 44: D-GN/VT
44: 335
45: 45 45: 0.5 45: BK/BN
45: 5514
46: 46 46: 0.5 46: BK/D-BU
46: 6813
47: 47 47: 0.5 47: WH/BK

48-50
51: L51: 51 51: 0.5
GN/WH
47: 3096
-
52: 52 52: 0.5 52: D-BU/VT
52: 1589
53: 53 53: 0.5 53: YE/BK
53: 3000
54: 54 54: 0.5 54: BN/VT
54: 472
51: 492
55: 55 55: 0.5
55: DBU/WH
55: 890
56: 56 56: 0.5
56: YE
56: 6111
Sensor 5 Volt Reference

Not Occupied
36: Accessory Wakeup Serial
Data
Not Occupied
38: Fuel Level Sensor Low
Reference
Not Occupied
Position Signal (1)
Sensor Signal
Position Signal (2)
Control
44: Low Speed Cooling Fan
Relay Control
Not Occupied
Signal
Sensor Signal
Sensor #2 Signal
Sensor Signal
Sensor Signal
Signal
K20 ENGINE CONTROL MODULE X2 (LUW/LWE)
34: I
-
34: -
36: I
36: -
38: I
38: -
40: I
40: -
41: I
41: -
42: I
42: -
43: I
43: -
44: I
44: -
45: I
45: -
46: I
46: -
47: I
-
47: MZ0
-
51: I
51: -
52: I
52: -
53: I
53: -
54: I
54: -
55: I
55: -
56: I
56: MZ0


OEM Connector: PPI0001016
Description: 73-Way F 0.64, 2.8 Series, Sealed (BK)

Terminal
Removal
Tool
J-35616-64B J-3812513582274
(L-BU)
12A
J-35616-64B J-3812513582275
(L-BU)
12A

Type ID
Lead
Test Probe
I
II
III
13581360
Pending
Pending
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
928999-5
15
1719532-5
Not
Available
Not
Available
Not
Available
Not
Available

Pin
Size
Color
Circuit
1: 1
2
1: 0.5
-
1: BN
-
1: 25
-
3: 3
3: 0.5
3: L-GN
3: 1668
4: 4
4: 0.5
4: L-GN
4: 1665
5: 5
5: 0.5
5: BN/D-GN
5: 485
6-7
8: 8
8: 0.5 8: L-GN/WH
8: 432
9: 9
9: 0.5
9: BN/D-BU
9: 486
10: 10 10: 0.5
10: YE/WH
10: 1669
11: 11 11: 0.5
11: VT/BK
11: 5273
12: 12 12: 0.5
12: BN/YE
12: 844
13: 13 13: 0.5
13: BK/VT
13: 6754
Terminal Type
ID
1: Charge Indicator Control
1: I
Not Occupied
3: I
(2)
4: I
(1)
5: Throttle Position Sensor
5: I
Signal (1)
Not Occupied
8: I
9: Throttle Position Sensor
9: I
Signal (2)
10: I
(2)
11: I
Exhaust Sensor (1)
12: Fuel Injector Control
12: I
(4)
13: Cam Phaser X Return
13: I
Low Reference
Function
Option
1: 3: -
4: 5: 8: 9: 10: 11: 12: 13: -

14: 14 14: 0.5 14: GY/D-BU
14: 5282
15: 15 15: 0.5
15: BK/BN
15: 6753
16: 16 16: 0.5
16: YE/WH
16: 1745
17
18: 18 18: 0.5 18: VT/D-BU

19
20: 20 20: 0.5
20: YE/BN
20: 1664
21: 21 21: 0.5
21: GY
21: 23
22-23
18: 6270
24: 24 24: 0.5 24: YE/L-BU
24: 231
25: 25 25: 0.5 25: L-GN/VT
25: 2032
26: 26 26: 0.5
26: L-GN
26: 6271
27: 27 27: 0.5
27: YE/VT
27: 5275
28
29: 29 29: 0.5 29: GY/L-GN

30-31
32: 32 32: 0.5
32: VT/BN
32: 5284
33: 33 33: 0.5
33: GY/YE
33: 5297
35: 35 35: 0.5
35: VT/GY
35: 496
36: 36 36: 0.5
36: GY/RD
36: 2704
39: BK/GY
39: 5296
34
37-38
29: 7303
39: 39 39: 0.5
14: Camshaft Phaser

Exhaust Solenoid (1)
15: Cam Phaser W Return
Low Reference
(2)
Not Occupied
Voltage
Not Occupied
(1)
Cycle Signal
Not Occupied
Signal
Sensor Signal
Signal
Intake Sensor (1)
Not Occupied
29: Intake Manifold
Tuning Valve (IMTV)
Position - Signal
Not Occupied
32: Camshaft Phaser Intake
Solenoid (1)
Exhaust Sensor Supply
Voltage (1)
Not Occupied
35: Knock Sensor Signal
(1)
Reference
Not Occupied
Exhaust Sensor Low
Reference (1)
14: I
14: -
15: I
15: -
16: I
16: -
18: I
18: -
20: I
20: -
21: I
21: -
24: I
24: -
25: I
25: -
26: I
26: -
27: I
27: -
29: I
29: -
32: I
32: -
33: I
33: -
35: I
35: -
36: I
36: -
39: I
39: -

40: 40 40: 0.5 40: BK/L-GN

41-43
40: 5301

Intake Sensor Low
Reference (1)
Not Occupied
44: Intake Manifold
Tuning Valve (IMTV)
Control - Signal
Low Reference
40: I
40: -
44: I
44: -
45: I
45: -
44: 44 44: 0.5
44: D-BU
44: 7302
45: 45 45: 0.5
45: BK/VT
45: 6272
46: YE/D-BU
46: 2124
46: Ignition Control (4)
46: I
46: -
47: L-BU/WH
47: 2122
47: I
47: -
Not Occupied
49: BK/D-BU
49: 2129
49: Low Reference
49: II
49: -
50: 50 50: 0.5
50: BN/VT
50: 1744
50: I
50: -
51: 51 51: 0.5
51: BN/VT
51: 1746
51: I
51: -
52: II
52: -
54: I
54: -
55: I
55: -
56: I
56: -
60: I
60: -
62: I
62: -
64: I
64: -
66: II
66: -
46:
0.75
47:
47: 47
0.75
48
49:
49: 49
0.75
46: 46
52: 52
52:
0.75
52: L-GN/VT
52: 1423
53
54: 54 54: 0.5 54: GY/D-BU
54: 5300
55: 55 55: 0.5
55: BK/YE
55: 1716
56: 56 56: 0.5
56: BN/RD
56: 2701
60: BK/BN
60: 2752
57-59
60: 60 60: 0.5

61
62: 62 62: 0.5 62: BK/L-GN

63
64: 64 64: 0.5

65
66:
66: 66
0.75
62: 469
64: BK/BN
64: 2761
66: L-GN/DBU
66: 428

(1)
(3)
1 Sensor (2)
Not Occupied
Intake Sensor Supply
Voltage (1)
55: Knock Sensor Low
Reference (1)
56: Throttle Position
Sensor 5 Volt Reference
Not Occupied
Not Occupied
Pressure Sensor Low
Reference
Not Occupied
Not Occupied
66: EVAP Canister Purge
Solenoid Control

67
68: 68
69: 69
70: 70
71: 71
68:
0.75
69:
0.75
70:
0.75
71:
0.75
68: BN/WH
68: 582
69: YE
69: 581
70: BU/VT
70: 2121
71: L-GN/DBU
71: 2123
72:
72: 72
0.75
72: GY/WH
72: 3113
73: 73 73: 2.5
73: BK
73: 450
Not Occupied
68: Throttle Actuator
Control Close
Control Open
68: II
68: -
69: II
69: -
70: II
70: -
71: II
71: -
72: II
72: -
73: III
73: -

1 Sensor (1)
73: Ground

2013 ELECTRICAL
Views - Cruze

K20 ENGINE CONTROL MODULE X1 (LUV)

Description: 56-Way F MX123 34576 Series, Sealed (BU)

Terminal
Type ID
Lead
Test Probe
Terminal
Removal
Tool
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
23
23
J-35616-64B
J-38125-213 33467-0005
(L-BU)
J-35616-64B
13575812
J-38125-213 33467-0005
(L-BU)
13575812
II
K20 Engine Control Module X1 (LUV)

Pin
Size
Color
Circuit
Function
2: 2
2: 0.5
2: L-GN/WH
2: 1162
3: 3
3: 0.5
3: GN/WH
3: 492
4-7
8: 8
8: 0.5
8: BN/GY
8: 4008
9: 9
9: 0.5
9: YE/WH
9: 3200
10:
10
10: 0.5
10: YE/WH
10: 1161
Not Occupied
Position Signal (2)
Signal
Not Occupied
8: Humidity Sensor Signal
Position Signal (1)
11:
11: Pre Throttle Air Temp
Terminal Type
ID
-
Option
-
2: I
2: -
3: I
3: -
8: -
8: -
9: I
9: -
10: I
10: -

11
11: 0.5
11: L-GN
12:
12: 0.5
12: L-GN
12
13:
13: 0.5
13: BK/BN
13
14-15
16:
16: 0.5
16: BN/RD
16
17
18:
18: 0.5
18: BU
18
19:
19: 0.75 19: VT/D-BU
19
20:
20: 0.75 20: RD/WH
20
21-22
23:
23: 0.5 23: WH/RD
23
24:
24: 0.5
24: BN/RD
24
25:
25: 0.5
25: BN/RD
25
26:
26: 0.5
26: BN/RD
26
27:
27: 0.5
27: YE/BK
27
28:
28: 0.5 28: L-GN/GY
28
29:
29: 0.5
29: L-BU
29
30:
30: 0.5
30: BN/VT
30
31:
31: 0.5
31: BK/VT
31
32: 32: BK/L32: BK/L-BU
32
BU
33:
33: WH/D33: 0.5
33
BU
34:
34: 0.5
34: L-GN
34
35-36
37:
37: 0.5
37: BK/YE
37
11: 7330
12: 380
and Press (TMAP) Air

Pressure Signal
12: A/C Refrigerant
11: I
11: -
12: I
12: -
13: 5514
13: Low Reference
13: I
13: -
Not Occupied
16: 1274
16: I
16: -
Not Occupied
18: Accessory Wakeup
Serial Data
Voltage
18: I
18: -
19: II
19: -
18: 5985
19: 139
20: 140
20: II
20: -
Not Occupied
23: 3201
23: I
23: -
24: 1164
24: I
24: -
25: 7331
25: I
25: -
26: 2700
26: I
26: -
27: I
27: -
28: I
28: -
29: I
29: -
27: 625
28: 465
29: 2500

Control
28: Fuel Pump Primary
Relay Control
Serial Data (+) (1)
30: 1272
30: Low Reference
30: I
30: -
31: 2760
31: Low Reference
31: II
31: -
32: 6813
32: Low Reference
32: I
32: -
33: I
33: -
34: I
34: MH8
37: I
37: -

Signal
34: Park Neutral Position
Switch Park Signal
Not Occupied
37: 6014
37: Low Reference
33: 6311
34: 275

38:
38
39:
39
40:
40
41:
41
42
43:
43
44
45:
45
46:
46
47:
47
48-51
52:
52
53
54:
54
55
56:
56
38: 0.5
38: BK/VT
38: 1271
38: Low Reference
38: I
38: -
39: 0.5
39: BK/L-GN
39: 7332
39: Low Reference
39: I
39: -
40: 0.5
40: YE
40: 5991
40: I
40: -
41: 0.5
41: L-GN/VT
41: 335
41: I
41: -
43: 0.5
43: WH
43: 2501
43: I
43: -
45: 0.5
45: BN/VT
45: 472
45: I
45: -
46: 0.5
46: YE/BK
46: 3000
46: I
46: -
47: LBU/WH
-
52: 0.5
52: BN/WH
52: 419
54: 0.5
54: BN/YE
54: 473
56: 0.5
56: WH
56: 1310
47: 0.5

Control
41: Low Speed Cooling Fan
Relay Control
Not Occupied
Serial Data (-) (1)
Not Occupied
Sensor Signal
Sensor #2 Signal
47: 25
47: Charge Indicator Control
47: I
47: -
Not Occupied
Control
Not Occupied
54: High Speed Cooling Fan
Relay Control
Not Occupied
56: EVAP Canister Vent
Solenoid Control
52: I
52: -
54: I
54: -
56: I
56: -

Description: 73-Way F 0.64 2.8 Series, Sealed (BK)

Terminal
Terminal
Removal
Service
Tray
Core
Insulation

Type ID
I
II
III
Lead
Test Probe
Tool
Terminal
J-35616-64B
13575812
J-38125-213 33467-0005
(L-BU)
J-35616-64B
13575812
J-38125-213 33467-0005
(L-BU)
J-35616-35 J-38125- 7116-415213575291
(VT)
11A
02
Crimp
Crimp
23
23

Pin
Size
Color
1: 1
2: 2
3: 3
4: 4
5: 5
6-9
1: 0.5 1: L-BU/VT
2: 0.5
2: BN/VT
3: 0.5
3: BN/YE
4: 0.5
4: BN
5: 0.5
5: YE/WH
10:
10: 10
10: GY/D-BU
0.75
11:
11: 11
11: VT/BN
0.75
12
13:
13: 13
13: RD/D-BU
0.75
Circuit
Function
1: 2121
2: 1744
3: 1746
4: 844
5: 1745
-

2: Fuel Injector Control (1)
Not Occupied
10: Camshaft Phaser
Exhaust Solenoid (1)
Solenoid (1)
Not Occupied
Fused Supply (1)
14: Thermostat Engine
Cool Control
Control Open
Control Close
10: 5282
11: 5284
13: 5290
14: 14 14: 0.5
14: L-BU
14: 6814
15: 15 15: 0.5
15: BN/RD
15: 581
16: 16 16: 0.5 16: BN/WH
16: 582
17: L-GN/LBU
18-19
20: 20 20: 0.5 20: BK/VT
17: 17 17: 0.5
21: 21 21: 0.5

22-23
25-27
28:
28: 28
0.75
29: 29
29:
Option
1: 2: 3: 4: 5: -
10: II
10: -
11: II
11: -
13: II
13: -
14: I
14: -
15: I
15: -
16: I
16: -
17: 2123
17: I
17: -
20: 6272
Not Occupied
20: Low Reference
21: Camshaft CAM X
Ground
Not Occupied
24: Camshaft CAM W
Ground
Not Occupied
Fused Supply (1)
20: I
20: -
21: I
21: -
24: I
24: -
28: II
28: -
29: II
29: -
21: BK/GY
21: 6267
24: 24 24: 0.5 24: BK/L-GN
Terminal Type
ID
1: I
2: I
3: I
4: I
5: I
-
24: 6266
28: RD/D-BU
28: 5290
29: BN/WH
29: 6783
29: Low Reference

30: 30
31: 31
32
33: 33
34
35: 35
0.75
30:
30: BK/VT
0.75
31:
31: YE/D-BU
0.75
33: 0.5 33: YE/D-BU
35: 0.5 35: BK/L-BU
30: 6754
40: I
40: -
44: II
44: -
46: GY
46: 5641
Not Occupied
46: Turbo Boost Pressure
Sensor Temperature Signal
(1)
Not Occupied
49: Low Reference
Not Occupied
Not Occupied
Signal
57: Camshaft CAM X
Signal
Not Occupied
60: Camshaft CAM W
Signal
Not Occupied
Sensor Signal (1)
Not Occupied
46: I
46: -
47: I
47: -
49: I
53: I
-
49: 53: -
56: I
56: -
57: I
57: -
60: I
60: -
63: I
63: -
49: 1716
53: 2122
-
56: 56 56: 0.5
56: L-GN
56: 6271
57: 57 57: 0.5
57: VT/BK
57: 6264
60: YE/VT
60: 6265
63: 63 63: 0.5 63: BN/L-GN

-
44: Low Reference
48
49: 49 49: 0.5 49: BK/YE
50-52
53: 53 53: 0.5 53: L-BU/WH
54-55
-
64
37: -
44: 2752
47: 1664
37: I
44: BK/YE
40: 6259
47: 47 47: 0.5 47: BK/L-GN
61-62
36: -
43: -
40: 40 40: 0.5 40: GY/L-BU
60: 60 60: 0.5
36: I
43: II
33: 35: -
58-59
33: I
35: I
43: 416
37: 6457
46: 46 46: 0.5
31: -
43: BN/RD
37: GY/YE
43:
43: 43
0.75
44:
44: 44
0.75
45
-
31: II
37: 37 37: 0.5
41-42
30: -
33: 2124
35: 2129
36: 6270
30: II

Signal
Not Occupied
Not Occupied
35: Low Reference
Voltage
37: Camshaft CAM X
Supply Voltage
Not Occupied
40: Camshaft CAM W
Supply Voltage
Not Occupied
31: 231
36: 36 36: 0.5 36: VT/L-BU
38-39
30: Low Reference
63: 485
-

65: 65 65: 0.5 65: BN/D-BU

66
67: 67 67: 0.5

68
69: 69 69: 0.5
65: 486
67: L-GN
67: 1665
69: VT/GY
69: 496
70-71
72: 72
72:
0.75
72: GY/WH
72: 3113
73: BK
73: 450
73: 73 73: 2.5

Sensor Signal (2)
Not Occupied
(1)
Not Occupied
69: Knock Sensor Signal
(1)
Not Occupied
1 Sensor (1)
73: Ground
65: I
65: -
67: I
67: -
69: I
69: -
72: II
72: -
73: III
73: -

Description: 73-Way F 0.64 2.8 Series, Sealed (BK with GY Terminal Position Assurance Lock)

Terminal
Type ID
Lead
Test Probe
Terminal
Removal
Tool
Service
Terminal
J-35616-64B
J-38125-213 33467-0005
(L-BU)
J-35616-64B
13575812
J-38125-213 33467-0005
(L-BU)
13575812
II
Tray
Core
Crimp
Insulation
Crimp
23
23

Pin
Size
1: 1
2-9
1: 0.5
-
Color
1: GN/WH
10: L-GN/L10: 10 10: 0.5
BU
Circuit
Function
1: 5007
-
1: Reverse Switch Signal

Not Occupied
Solenoid Control
10: 428
Terminal Type
ID
1: I
-
1: MF3
-
10: I
10: -
Option

11-12
13: BN/YE
13: 5268
15: BN/RD
15: 258
17: GY
17: 23
19: WH/BK
22: BK/GY
22: BK/BN
27: BN/D-GN
28: BN/RD
29: BK/L-GN
19: 3097
22: 6110
22: 5382
27: 6281
28: 2704
29: 469
Not Occupied
13: Overrun Air Valve
Solenoid
Not Occupied
15: Waste Gate Solenoid
Control
Not Occupied
Cycle Signal
Not Occupied
19: Low Reference
Not Occupied
22: Low Reference
22: Low Reference
Not Occupied
27: Low Reference
29: Low Reference
30: BK/D-BU
30: 2761
32: BN/GY
32: 5035
33-34
35: 35 35: 0.5
36-37
-
35: GY/BK
-
35: 3096
-
38: 0.5
38: 0.5
38: GY/RD
38: WH
38: 6109
38: 5381
39-42
43: 43 43: 0.5
44
-
43: YE/RD
-
43: 2709
-
13: 13 13: 0.5

14
15: 15
16
17: 17
18
19: 19
20-21
22: 22
23-26
27: 27
28: 28
29: 29
30: 30
31
32: 32
38: 38
15:
0.75
17:
0.75
19: 0.5
22: 0.5
22: 0.5
27: 0.5
28: 0.5
29: 0.5
30:
0.75
-
47-54
58: 58
13: I
13: -
15: II
15: -
17: II
17: -
19: I
-
27: I
28: I
29: I
19: MF3
22: MF3
22: MH8
27: 28: 29: -
30: Low Reference
30: II
30: -
32: II
32: -
35: I
-
35: MF3
-
38: I
38: MF3
38: MH8
43: I
-
43: -
45: I
45: -
46: II
46: -
55: Digital)
Signal (MF3
-
22: I
46: D-BU
46: 410
55: GN
55: 3098
55: Output Speed
55: I
Not Occupied
58: 0.5
58: YE
58: 6111

Signal
58: I
32:
0.75
46:
0.75
-
55: 55 55: 0.5

56-57
Not Occupied
Heater High Control Bank
1 Sensor (2)
Not Occupied
Not Occupied
Voltage Reference
Not Occupied
Not Occupied
46: Engine Coolant
Not Occupied
45: 45 45: 0.5 45: L-GN/WH

46: 46
45: 432
58: MF3

58: 0.5 58: L-BU/YE

59-62
58: 5380
63: 63 63: 0.5 63: L-BU/WH
63: 890
64: 64 64: 0.5 64: L-BU/VT
64: 1589
65-66
67: 67 67: 0.5
67: L-GN
67: 1668
68: 68 68: 0.5 68: BK/L-GN

69-73
58: Brake Position Sensor

Signal
Not Occupied
Sensor Signal
Sensor Signal
Not Occupied
(2)
(2)
Not Occupied
68: 1669
58: MH8
-
63: I
63: -
64: I
64: -
67: I
67: -
68: I
68: -
K27 FUEL PUMP CONTROL MODULE
Harness Type: Body

Description: 38-Way F, Sealed (BK/GY)

Terminal
Type ID
Lead
Test Probe
Terminal
Removal
Tool
Service
Terminal
J-35616-4A
J-38125-553 15304720
(PU)
J-35616-64B J-38125SAITS13578883
(L-BU)
215A
A03T-M064
13576407
II
Tray
Core
Crimp
Insulation
Crimp
19
14
K27 Fuel Pump Control Module

Pin
Size
Color
Circuit
1: 1
2
1: 2.5
-
1: RD/GY
-
1: 1740
-
Terminal Type
ID
1: I
Not Occupied
Function
3: Shutter Actuator
Option
1: -

3: 3
4
3: 0.5
-
3: GY/BK
-
3: 3437
-
5: 5
5: 0.5
5: D-BU
5: 2500
6: 6
6: 0.5
6: D-BU
6: 2500
8: 8
8: 0.5 8: WH/D-BU
10: 10 10: 0.5 10: D-BU/WH

11
8: 5986
10: 7446
12: 12 12: 0.5 12: GY/BK
12: 3437
13: 13 13: 2.5

14-16
-
13: GY
-
13: 120
-
17: 17 17: 0.5
17: WH
17: 2501
18: 18 18: 0.5
18: WH
18: 2501
19
20: 20 20: 0.5 20: D-GN/GY
20: 465
21: 21 21: 0.5
21: VT/BK
21: 739
22: 22 22: 0.5 22: OG/RD
22: 7445
23: 23
24: 24
25: 25
26-37
38: 38
23: 7447
24: 120
25: 2350
38: 1580
23: 0.5 23: BK/YE

24: 0.5
24: BK
25: 2.5
25: BK
38: 2.5 38: BK/D-GN
Solenoid Control
Not Occupied
5: High Speed GMLAN
Serial Data Bus (+)
6: High Speed GMLAN
Serial Data Bus (+)
Not Occupied
8: Serial Data
Not Occupied
10: Fuel Pressure Sensor
Signal
Not Occupied
12: Shutter Actuator
Solenoid Control
13: Fuel Pump Control
Not Occupied
Serial Data Bus (-)
Serial Data Bus (-)
Not Occupied
20: Fuel Pump Relay
Control
22: Fuel Line Pressure
Sensor 5V Reference
23: Low reference
24: Shield
25: Ground
Not Occupied
38: Low reference
K29 SEAT HEATING CONTROL MODULE X1 (KA1)

3: II
-
3: -
5: II
5: -
6: II
6: -
8: II
8: -
10: II
10: -
12: II
12: -
13: I
-
13: -
17: II
17: -
18: II
18: -
20: II
20: -
21: II
21: -
22: II
22: -
23: II
24: II
25: I
38: I
23: 24: 25: 38: -



Type ID
Lead
Test Probe
I
Service by
Harness- See
Part Catalog
Pending
Terminal
Removal
Tool
Service
Terminal
Core
Crimp
Tray
Not
Not
Available
Available
Insulation
Crimp
Not
Available
K29 Seat Heating Control Module X1 (KA1)

Pin
Size
A: A A: 2.5
B: B B: 2.5
Color
Circuit
A: BK
B: RD
A: 2150
B: 2040
Terminal Type
ID
A: Ground
A: I
B: Battery Positive Voltage
B: I
Function
Option
A: B: -

Description: 16-Way F GT FBT 150 Series (BK)

Type ID
Lead
Test Probe
Terminal
Removal
Tool
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
Service by
Harness See Part
Catalog
Not
Available
Not
Available
Not
Available
Not
Available
Not
Available
Not
Available

Pin
Size
Color
Circuit
Function
Terminal Type
ID
Option
1: 1
1: 1
1: BK
1: 2424
1: Driver Heated Back

Element Return
1: I
1: -

2: 2
2: 1
2: BK
2: 2433
3: 3
3: 1
3: YE
3: 2077
5: 5
5: 1
5: YE
5: 2479
6-12
13: 13 13: 0.5
13: BK
13: 2080
14: 14 14: 0.5
14: BK
14: 2435
15: 15 15: 0.5

16
-
15: YE
-
15: 7018
-
2: Passenger Heated Back

Element Return
Element Control
Not Occupied
Element Control
Not Occupied
Low Reference
NTC Low Reference
15: Cushion NTC Signal
Not Occupied
2: I
2: -
3: I
3: -
5: I
5: -
13: I
13: -
14: I
14: -
15: I
-
15: -

Description: 12-Way F Micro HVT Series (BK)

Terminal
Type ID
Lead
Test Probe
13575550
Terminal
Removal
Tool
J-35616-16
J-38125-559
(L-GN)
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
15445905
23

Pin
Size
Color
Circuit
Function
1-2
3: 3
3: 0.5
3: RD
3: 2079
4: 4
4: 0.5
4: RD
4: 2434
5-10
Not Occupied
Signal
NTC Signal
Not Occupied
Terminal Type
ID
-
Option
-
3: I
3: -
4: I
4: -

11: 11 11: 0.5 11: D-BU

12
11: 5060
11: Low Speed GMLAN

Serial Data
Not Occupied
11: I
11: -
K33 HVAC CONTROL MODULE X1

Description: 20-Way F 0.64 Series (GN)

Terminal
Type ID
Lead
Test Probe
13582250
Terminal
Removal
Tool
J-35616-16
J-38125-559
(L-GN)
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
15445905
23
K33 HVAC Control Module X1

Pin
Size
Color
Circuit
Function
Not Occupied
2: Windscreen Temp
Sensor Signal
3: Air Quality Sensor
Signal
4: Inside Air Temperature
Sensor Signal
5: Humidity Temperature
Sensor Signal
6: 5V Reference
7: Low Reference
Not Occupied
12: Humidity Sensor
Signal
13: Solar Sensor Pulsed
Supply Voltage
Not Occupied
2: 2 2: 0.35 2: GY/D-GN
2: 7565
3: 3
3: 5203
3: 0.5
3: VT/WH
4: 4 4: 0.35 4: D-BU/WH
4: 734
5: 5 5: 0.35 5: YE/D-BU
5: 3197
6: 6 6: 0.35 6: YE/RD
7: 7 7: 0.35 7: BK/D-BU
8-11
12:
12: 12
12: GY/D-BU
0.35
13:
13: 13
13: D-BU
0.35
14-15
-
6: 597
7: 7566
12: 7564
13: 1120
-
Terminal Type
ID
-
Option
-
2: I
2: -
3: I
3: -
4: I
4: -
5: I
5: -
6: I
7: I
-
6: 7: -
12: I
12: -
13: I
13: -

16: 16
17
16:
0.75
-
18: 18 18: 0.5

19
20:
20: 20
0.35
16: BK
16: 1650
16: Ground
16: I
16: -
18: BN
18: 404
18: I
18: -
20: GY
20: 590
Not Occupied
18: Upper Air Temperature
Sensor Signal
Not Occupied
20: Solar Sensor Driver
Signal
20: I
20: -

Description: 20-Way F USCAR 64 Series (BN)

Terminal
Service
Removal
Terminal
Tool
J-35616-64B J-38125- SAIT-A03T13575867
(L-BU)
215A
M064
Terminal
Type ID
Lead
Test Probe
Tray
Core
Crimp
Insulation
Crimp
14

Pin
Size
Color
Circuit
1: 1
1: 0.75
1: RD/YE
1: 240
3: 3
3: 0.5
3: L-GN
3: 5060
4: 4
4: 0.5
4: L-GN/YE
4: 7531
5-7
8: 8
9: 9
10:
10
8: 0.75
9: 0.5
10: .5 DBU/YE
8: BK
9: VT/WH
10: .5 DBU/YE
8: 1650
9: 239
10: 7574
Function
1: Battery Positive
Voltage
Not Occupied
3: Low Speed GMLAN
Serial Data
Network Bus 9
Not Occupied
8: Ground
9: Ignition Voltage
Displacement Control
Terminal Type
ID
Option
1: I
1: -
3: I
3: -
4: I
4: -
8: I
9: I
8: 9: -
10: I
10: -

11:
11
12-14
15:
15
16-18
19:
19
20
11: .5 LBU/BN
-
11: .5 LBU/BN
15: DBU/GY
-
19: 0.5
19: BN/VT
19: 193
15: 0.5
11: 7573
15: 754
-

Displacement Supply
Not Occupied
15: Blower Motor Speed
Control
Not Occupied
19: Rear Defog Relay
Control
Not Occupied
11: I
11: -
15: I
15: -
19: I
19: -
Harness Type: HVAC

Description: 20-Way F 64 Series (BK)

Terminal
Type ID
Terminal
Service
Removal
Terminal
Tool
J-35616-64B J-38125- SAIT-A03T13575867
(L-BU)
215A
M064
Lead
Test Probe
Tray
Core
Crimp
Insulation
Crimp
14

Pin
Size
Color
Circuit
1: 1
1: 0.5
1: GY/D-GN
1: 516
2: 2
2: 0.5
2: YE
2: 936
3: 3
3: 0.5
3: WH/RD
3: 931
4: 4
4: 0.5
4: GY/BN
4: 926
5: 5
5: 0.5 5: D-GN/WH
6-8
5: 925
-
Function
1: Upper Left Air
2: Mode Door Stepper
Motor Control
Motor Control
Motor Control
Motor Control
Not Occupied
Terminal Type
ID
Option
1: I
1: C68
2: I
2: -
3: I
3: -
4: I
4: -
5: I
5: -

9: 9
10
9: 0.5
-
11: 11 11: 0.5
9: BK
-
9: 720
-
11: D-GN
11: 933
12: 12 12: 0.5 12: WH/RD
12: 932
13: 13 13: 0.5
13: GY/RD
13: 930
14: 14 14: 0.5
14: RD/BK
14: 929
15: 15 15: 0.5
15: OG
15: 943
16: 16 16: 0.5
16: GY
16: 929
17: 17 17: 0.5 17: D-BU/WH
17: 929
18: 18 18: 0.5 18: BN/D-GN
18: 929
19: 19 19: 0.5 19: RD/D-GN
19: 929
20: 20 20: 0.5
20: 6137
20: BK/GY
9: Sensor Low Reference

Not Occupied
11: Air Temperature Door
Control
Control
Control
Control
15: 5-Volt Reference
16: Recirculation Door
Control
Control
Control
Control
20: EVAP Core
9: I
-
9: -
11: I
11: -
12: I
12: -
13: I
13: -
14: I
14: -
15: I
15: -
16: I
16: -
17: I
17: -
18: I
18: -
19: I
19: -
20: I
20: -
K35 IGNITION COIL MODULE


Type ID
Lead
Test Probe
I
Pending
Pending
Terminal
Removal
Tool
Not
Available
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
Not
Available
Not
Available
Not
Available
Not
Available
K35 Ignition Coil Module

Terminal Type

Pin
Size
Color
Circuit
A: A
A: 1
A: VT/D-BU
A: 5291
B: 0.75
B: BK
C: 0.5 C: BK/D-BU
D: 0.75 D: D-BU/VT
E: 0.75 E: D-BU/WH
F: L-GN/LF: F F: 0.75
BU
G: G G: 0.75 G: YE/D-BU
B: 250
C: 2129
D: 2121
E: 2122
Function
A: Powertrain Main Relay
Fused Supply (1)
B: Ground
C: Low Reference
D: Ignition Control (1)
E: Ignition Control (2)
F: 2123
G: 2124
B: B
C: C
D: D
E: E
ID
Option
A: I
A: -
B: I
C: I
D: I
E: I
B: C: D: E: -
F: Ignition Control (3)
F: I
F: -
G: Ignition Control (4)
G: I
G: -
K36 INFLATABLE RESTRAINT SENSING AND DIAGNOSTIC MODULE X1

Description: 24-Way F Kaizen 0.64 Series, Sealed (YE)

Terminal
Type ID
I
Terminal
Service
Removal
Terminal
Tool
J-35616-64B J-38125SAIT13575846
(L-BU)
215A
A036F-M064
Lead
Test Probe
Tray
Core
Crimp
Insulation
Crimp
14
K36 Inflatable Restraint Sensing and Diagnostic Module X1

Pin
Size
Color
Circuit
1: 1
1: 0.5 1: OG/D-GN
1: 3023
2: 2
2: 0.5 2: WH/D-GN
2: 3022
3: 3
3: 0.5
3: 3020
3: BN/OG
Function
1: Steering Wheel
Module Stage 2 High
Control
2: Steering Wheel
Module Stage 2 Low
Control
3: Steering Wheel
Module Stage 1 Low
Control
4: Steering Wheel
Terminal Type
ID
Option
1: I
1: Early
Production
2: I
2: Early
Production
3: I
3: -

4: 4
4: 0.5
4: OG/VT
4: 3021
5: 5
5: 0.5
5: YE/OG
5: 3025
6: 6
6: 0.5
6: OG/WH
6: 3024
7: 7
7: 0.5
7: OG/VT
7: 3026
8: 8
8: 0.5
8: GY/OG
8: 3027
9: 9 9: 0.75
9: RD/YE
9: 3040
10: VT/WH
10: 5234
11: D-BU
11: 2307
12: D-GN
12: 2308
15: 0.5
15: D-GN
15: 5060
Module Stage 1 High

Control
Panel Module Stage 1
High Control
Low Control
Low Control
High Control
9: Battery Positive
Voltage
Indicator
11: Passenger Air Bag On
Indicator Control
12: Passenger Air Bag
Off Indicator Control
Not Occupied
15: Low Speed GMLAN
Serial Data
Not Occupied
17: 3039
10:
10
11:
11
12:
12
13-14
15:
15
16
17:
17
18
19:
19
20
21:
21
22:
22
23:
23
24:
24
10:
0.35
11:
0.35
12:
0.35
-
17: 0.5 17: VT/D-GN
4: I
4: -
5: I
5: -
6: I
6: -
7: I
7: -
8: I
8: -
9: I
9: -
10: I
10: -
11: I
11: -
12: I
12: -
15: I
15: -
17: I
17: -
Not Occupied
19: 0.5
19: BK
19: 2450
19: Ground
19: I
19: -
Not Occupied
High Control
Low Control
23: Passenger Knee
Module Low Control
24: Passenger Knee
Module High Control
21: I
21: -
22: I
22: -
23: I
23: -
24: I
24: -
21: 0.5 21: OG/D-BU
21: 3078
22: 0.5 22: GY/OG
22: 3079
23: 0.5 23: WH/OG
23: 3077
24: 0.5 24: OG/D-BU
24: 3076
K36 INFLATABLE RESTRAINT SENSING AND DIAGNOSTIC MODULE X2

Harness Type: Body

Description: 54-Way F 0.64 Series, Sealed (RD w/ YE cover)

Terminal
Type ID
Terminal
Service
Removal
Terminal
Tool
J-35616-64B J-38125SAIT13575846
(L-BU)
215A
A036F-M064
Lead
Test Probe
Tray
Core
Crimp
Insulation
Crimp
14

Pin
Size
Color
Circuit
Function
1-2
3: 3
3: 0.5
3: OG/GY
3: 5226
4: 4
4: 0.5
4: VT/OG
4: 5225
5-6
7: 7
7: 0.5
7: BN/OG
7: 5224
8: 8
8: 0.5
8: OG/GY
8: 5223
9: 9
9: 0.5
9: OG/YE
9: 3481
10: 10 10: 0.5
10: YE/OG
10: 3482
11: 11 11: 0.5 11: GY/OG
11: 3480
12: 12 12: 0.5
12: 3479
Not Occupied
SIR Inflator Supply
Voltage
Not Occupied
SIR Inflator Supply
Voltage
9: Driver Seat Belt Anchor
Pretensioner +
10: Driver Seat Belt
Anchor Pretensioner 11: Passenger Seat Belt
Anchor Pretensioner 12: Passenger Seat Belt
Anchor Pretensioner +
Module High Control
12: OG/BN
13: 13 13: 0.5 13: OG/D-BU
13: 2137
14: 14 14: 0.5
14: 2138
14: YE/OG
Terminal Type
ID
-
Option
-
3: I
3: -
4: I
4: -
7: I
7: -
8: I
8: -
9: I
9: -
10: I
10: -
11: I
11: -
12: I
12: -
13: I
13: -
14: I
14: -

15: 15 15: 0.5 15: D-GN/OG
15: 2136
16: 16 16: 0.5
16: 2135
16: OG/YE
17: 17 17: 0.5 17: OG/D-GN
17: 5019
18: 18 18: 0.5
18: 5020
18: VT/OG
19: 19 19: 0.5 19: OG/D-GN
19: 2132
20: 20 20: 0.5

21: 21 21: 0.5
20: BK/OG
21: BK/OG
20: 6628
21: 6629
22: 22 22: 0.5
22: BN/OG
22: 2134
23: 23 23: 0.5
23: OG/YE
23: 354
24: 24 24: 0.5

25: 25 25: 0.5
24: BK/OG
25: BK/OG
24: 5045
25: 5600
26: 26 26: 0.5 26: OG/D-GN
26: 1409
27: 27 27: 0.5 27: OG/D-BU
27: 6620
28: 28 28: 0.5

29: 29 29: 0.5
28: BK/OG
29: BK/OG
28: 6621
29: 6625
30: 30 30: 0.5
30: OG/VT
30: 6624
31-32
33-36
37: 37 37: 0.5 37: BK/D-BU
37: 2118
38: 38 38: 0.5
38: 2119
38: OG/RD
39: 39 39: 0.5 39: D-BU/BN
39: 2117
40: 40 40: 0.5 40: OG/GY
40: 2116
41: 41 41: 0.5

42
-
41: OG/BN
-
41: 238
-
43: 43 43: 0.5
43: BK/OG
43: 1363
Module Low Control

15: Right Front Side
Impact Module Low
Control
Impact Module High
Control
17: Roof Rail Module Left - High Control
18: Roof Rail Module Left - Low Control
19: Side Impact Sensing
Module - Left - Signal
20: Low Reference
21: Low Reference
Signal
23: Front End Sensor - Left
- Signal
24: Low Reference
25: Low Reference
26: Front End Sensor Right - Signal
28: Low Reference
29: Low Reference
Not Occupied
Not Occupied
41: Seat Belt Switch - Left
Not Occupied
43: Seat Belt Switch - Left
- Low Reference
15: I
15: -
16: I
16: -
17: I
17: -
18: I
18: -
19: I
19: -
20: I
21: I
20: 21: -
22: I
22: -
23: I
23: -
24: I
25: I
24: 25: -
26: I
26: -
27: I
27: -
28: I
29: I
28: 29: -
30: I
30: -
37: I
37: -
38: I
38: -
39: I
39: -
40: I
40: -
41: I
-
41: -
43: I
43: -

44: 44 44: 0.5
44: BK/OG
44: 1361
45: 45 45: 0.5
45: OG/VT
45: 1362
47: OG/BN
47: 7571
46
47: 47 47: 0.5

48-52
53: 53 53: 0.5 53: OG/D-BU
53: 5021
54: 54 54: 0.5 54: WH/BK
54: 5022
44: Seat Belt Switch Right - Low Reference

45: Seat Belt Switch Right - Signal
Not Occupied
Reminder Signal
Not Occupied
53: Roof Rail Module Right - High Control
54: Roof Rail Module Right - Low Control
44: I
44: -
45: I
45: -
47: I
47: -
53: I
53: -
54: I
54: -
K41R REAR PARKING ASSIST CONTROL MODULE X1 (UD7)
Harness Type: Body


Terminal
Type ID
Terminal
Service
Removal
Terminal
Tool
J-35616-64B J-38125- SAIT-A03T13575867
(L-BU)
215A
M064
Lead
Test Probe
Tray
Core
Crimp
Insulation
Crimp
14
K41R Rear Parking Assist Control Module X1 (UD7)

Color
Circuit
Function
Terminal Type
ID
Option
1: 40
1: I
1: -
Not Occupied
6: Low Speed GMLAN
Serial Data
7: Ground
Not Occupied
6: I
6: -
7: I
-
7: -
Pin
Size
1: 1
1: 0.5
2-5
1: RD/DGN
-
6: 6
6: 0.5
6: D-GN
6: 5060
7: 7
8-12
7: 0.5
-
7: BK
-
7: 50
-

K41R REAR PARKING ASSIST CONTROL MODULE X2 (UD7)
Harness Type: Body

Description: 8-Way F YESC Kaizen Series (L-GY)

Terminal
Type ID
Terminal
Service
Removal
Terminal
Tool
J-35616-64B J-38125- SAIT-A03T13575867
(L-BU)
215A
M064
Lead
Test Probe
Tray
Core
Crimp
Insulation
Crimp
14

Pin
Size
Color
Circuit
1: 1
1: 0.5
1: YE/VT
1: 2378
2: 2
2: 0.5
2: YE/WH
2: 2377
3: 3
3: 0.5
3: YE/D-BU
3: 2376
4: 4
4: 0.5
4: BN/WH
4: 2374
5: 5
5: 0.5
5: YE
5: 2375
6-7
8: 8
8: 0.5
8: BK/GY
8: 2379
Function
1: Right Rear Corner
2: Right Rear Middle
3: Left Rear Middle Object
Sensor Signal
5: Left Rear Corner Object
Sensor Signal
Not Occupied
Reference
K43 POWER STEERING CONTROL MODULE X1
Terminal Type
ID
Option
1: I
1: -
2: I
2: -
3: I
3: -
4: I
4: -
5: I
5: -
8: I
8: -


Description: 5-Way F Micro II Timer Series, Sealed (BK)

Terminal
Type ID
Terminal
Removal
Tool
Lead
Test Probe
J-35616-14
J-38125-560
(GN)
13578884
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
964274-2
16
K43 Power Steering Control Module X1

Pin
Size
Color
Circuit
1: 1
1: 0.5 1: WH/D-BU
1: 5986
2: 2
2: 0.5
2: D-BU
2: 2500
3: 3
3: 0.5
3: D-BU
3: 2500
4: 4
4: 0.5
4: WH
4: 2501
5: 5
5: 0.5
5: WH
5: 2501
Function
Terminal Type
ID
Option
1: I
1: -
2: I
2: -
3: I
3: -
4: I
4: -
5: I
5: -
1: Serial Data
2: High Speed GMLAN
Serial Data (+) (1)
3: High Speed GMLAN
Serial Data (+) (1)
4: High Speed GMLAN
Serial Data (-) (1)
5: High Speed GMLAN
Serial Data (-) (1)
K43 POWER STEERING CONTROL MODULE X2

Description: 2-Way F ASM CONN 2 F DUCON 9.5 BLK SLD (BK)

Type ID
Lead
Test Probe
Service by
Harness -
J-35616-22
Terminal
Removal
Tool
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
J-38125-
Not
Not
Not
Not

See Part
Catalog
(RD)
11A
Available
Available
Available
Available

Pin
Size
1: 1 1: 10.0
2: 2 2: 10.0
Color
Circuit
1: BK
2: RD/WH
1: 350
2: 140
Terminal Type
ID
1: Ground
1: I
2: I
Function
Option
1: 2: -
K60 STEERING COLUMN LOCK CONTROL MODULE (ULS)

Description: 8-Way F 1.6 Micro Timer Series (BK)

Terminal
Type ID
Lead
Test Probe
13575538
Terminal
Removal
Tool
J-35616-14
J-38125-560
(GN)
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
962943-5
16
K60 Steering Column Lock Control Module (ULS)

Pin
Size
Color
Circuit
Function
2: 2
2: 0.5
2: BU/VT
2: 5904
3: 3
3: 1
3: BU/VT
3: 807
4: GN/VT
4: 1601
Not Occupied
2: Steering Column Lock
Status Signal
3: OFF /Accessory Voltage
Signal
6: Ground
7: Ground
8: Low Speed GMLAN
Serial Data
4: 4 4: 0.75
5: 5
6: 6
7: 7
5: 1
6: 0.5
7: 0.5
5: BN
6: BK
7: BK
5: 40
6: 50
7: 50
8: 8
8: 0.5
8: GN
8: 5060
Terminal Type
ID
-
Option
-
2: I
2: -
3: I
3: -
4: I
4: -
5: I
6: I
7: I
5: 6: 7: -
8: I
8: -

K61 SUNROOF CONTROL MODULE (CF5)

Description: 12-Way F 2.8 Junior Power Timer Series (BK)

Terminal
Type ID
Lead
Test Probe
13575472
II
13575490
Terminal
Removal
Tool
Service
Terminal
J-35616-35
J-38125-36 4-965999-1
(VT)
J-35616-35
J-38125-36 2-964284-1
(VT)
Tray
Core
Crimp
Insulation
Crimp
25
25
K61 Sunroof Control Module (CF5)

Pin
Size
Color
Circuit
1: 1
2: 2
1: 2.5
2: 2.5
1: RD/WH
2: BK
1: 140
2: 2050
3: 3
3: 0.5
3: 0.5
3: BK/BN
3: BK/GY
3: 3030
3: 128
4: 4
4: 0.5 4: D-GN/BN
4: 6132
5: 5
5: 0.5
5: D-BU/VT
5: 5027
6: 6
6: 0.5 6: WH/D-GN
6: 3031
7-12
Terminal Type
ID
1: I
2: Ground
2: I
3: Sunroof Vent Switch
Low Reference
3: II
3: Sunroof Switch Low
Reference
4: II
Network Bus 1
5: Sunroof Switch Data (1)
5: II
6: II
Signal
Not Occupied
Function
Option
1: 2: 3: -
4: 5: 6: -
K73 TELEMATICS COMMUNICATIONS INTERFACE CONTROL MODULE X1 (UE1)


Description: 16-Way F Micro-Pack 100A Series (NA)

Terminal
Type ID
Lead
Test Probe
13575548
Terminal
Removal
Tool
J-35616-16
J-38125-559
(L-GN)
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
15445905
23
K73 Telematics Communications Interface Control Module X1 (UE1)

Pin
Size
Color
Circuit
1: 1
1: 0.5
1: L-GN
1: 5060
2: 2
3: 3
4-5
6: 6
7: 7
8-9
2: 0.5
3: 0.5
6: 0.5
7: 0.5
-
2: BN/WH
3: YE/VT
6: L-GN/BK
7: BK
-
2: 2517
3: 2516
6: 2515
7: 1750
-
10: D-BU
10: 2500
10: 10 10: 0.5
11: 11 11: 0.5 11: L-GN/WH
11: 2514
12: 12 12: 0.5
12: WH
12: 2501
13: 13 13: 0.5
13: BK/VT
13: 5167
14: 14 14: 0.5
14: YE/VT
14: 5235
15: 15 15: 0.5 15: RD/D-BU

16
15: 840
-
Function
1: Low Speed GMLAN
Serial Data
2: Keypad Red LED
3: Keypad Green LED
Not Occupied
6: Keypad Supply Voltage
7: Ground
Not Occupied
Serial Data (+) (1)
11: Keypad Signal
Serial Data (-) (1)
13: Low Reference
14: Battery Backup Supply
Voltage
Voltage
Not Occupied
Terminal Type
ID
Option
1: I
1: -
2: I
3: I
6: I
7: I
-
2: 3: 6: 7: -
10: I
10: -
11: I
11: -
12: I
12: -
13: I
13: -
14: I
14: -
15: I
15: -
K73 TELEMATICS COMMUNICATIONS INTERFACE CONTROL MODULE X2 (UE1)


Description: 12-Way F Micro-Pack 100A Series (NA)

Terminal
Type ID
Lead
Test Probe
13575548
Terminal
Removal
Tool
J-35616-16
J-38125-559
(L-GN)
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
15445905
23

Pin
Size
Color
Circuit
1: 1
1: 0.5
1: YE
1: 658
2: 2
2: 0.5
2: BK/YE
2: 659
3: 3
3: 0.5
3: D-BU
3: 2500
4: 4
4: 0.5
4: WH
4: 2501
5: 5
5: 0.5
5: BARE
5: 5149
6: 6
6: 0.5
6: BK/GY
6: 5152
7: 7
7: 0.5 7: WH/D-BU
8: 8 8: 0.5
9: 9 9: 0.5
10: 10 10: 0.5
11
-
7: 5986
8: BARE
9: YE
10: BARE
-
8: 1782
9: 5191
10: 5193
-
12: 12 12: 0.5 12: GY/YE
12: 5149
Function
1: Cellular Telephone Voice
Signal
2: Cellular Telephone Voice
Low Reference
3: High Speed GMLAN
Serial Data Bus+
4: High Speed GMLAN
Serial Data Bus 5: Voice Recognition Audio
Signal
6: Low Reference
7: Serial Data
8: Drain Wire
9: Microphone High Signal
10: Microphone Low Signal
Not Occupied
12: Voice Recognition
Audio Signal
K77 REMOTE CONTROL DOOR LOCK RECEIVER
Terminal Type
ID
Option
1: I
1: -
2: I
2: -
3: I
3: -
4: I
4: -
5: I
5: UYS
6: I
6: UYS
7: I
7: -
8: I
9: I
10: I
-
8: 9: 10: -
12: I
12: UYS


Description: 4-Way F 64 MQS Series (BK)

Terminal
Type ID
Terminal
Removal
Tool
J-35616-64B J-3812513575587
(L-BU)
12A
Lead
Test Probe
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
928999-5
15
K77 Remote Control Door Lock Receiver

Pin
Size
Color
Circuit
1: 1
1: 0.5
1: GY
1: 3273
2: 2
2: 0.5
2: BU/WH
2: 3275
3: 3
3: 0.5
3: YE/GN
3: 3274
4: 4
4: 0.5
4: GY/WH
4: 3272
Function
Terminal Type
ID
Option
1: I
1: -
2: I
2: -
3: I
3: -
4: I
4: -
1: Remote Function
Actuator Return
2: Remote Function
Actuator Receive Signal
3: Remote Function
Actuator Transmit Signal
4: Remote Function
Actuator Supply Voltage
K84 KEYLESS ENTRY CONTROL MODULE X1 (ATH)
Harness Type: Body

Description: 20-Way Female (BK)

Terminal
Type ID
I
Terminal
Service
Removal
Terminal
Tool
J-35616-64B J-38125- SAIT-A03T13575867
(L-BU)
215A
M064
Lead
Test Probe
K84 Keyless Entry Control Module X1 (ATH)
Tray
Core
Crimp
Insulation
Crimp
14

Pin
Size
Color
1: 1 1: 0.75 1: D-GN/VT
Circuit
1: 1601
3: 3
3: 0.5
3: D-GN
3: 5060
4-8
9: 9
9: 0.5
9: WH/YE
9: 3574
10: 10 10: 0.5 10: GY/D-GN
10: 3575
11: 11
11: 0.5 11: D-GN/BK

11: 0.5 11: D-GN/BK
11: 3558
11: 3358
12: 12
12: 0.5
12: 0.5
12: BK/GY
12: BK/GY
12: 3359
12: 3559
13-14
15: 15 15: 0.5
15: GY/BK
15: 3555
16: 16 16: 0.5
16: BN/BK
16: 3552
17: 17 17: 0.5
17: WH
17: 3553
18: 18 18: 0.5
18: WH/DGN
18: 3556
19: 19 19: 0.5
19: D-GN
19: 3557
20: 20 20: 0.5
20: D-BU
20: 3554
Function
Signal
Not Occupied
3: Low Speed GMLAN
Serial Data
Not Occupied
9: Driver Door Open
Switch Signal
10: Co-Driver Door Open
Switch Signal
11: Passive Start Switch
Signal 2
11: Left TV Audio Return
12: Right TV Audio Return
12: Passive Start Switch 2
Low Reference
Not Occupied
15: Passive Start Interior
Antenna 2 Signal Lo
Antenna 1 Signal Hi
Antenna 1 Signal Lo
Antenna 3 Signal Hi
Antenna 3 Signal Lo
Antenna 2 Signal Hi
Harness Type: Body

Description: 6-Way F YESC Kaizen Series (BK)
Terminal Type
ID
Option
1: I
1: -
3: I
3: -
9: I
9: ATH
10: I
10: ATH
11: I
11: ATH
11: ATH
12: I
12: ATH
12: ATH
15: I
15: -
16: I
16: -
17: I
17: -
18: I
18: -
19: I
19: -
20: I
20: -


Terminal
Type ID
Lead
Test Probe
J-35616-42
(RD)
13575289
Terminal
Removal
Tool
J-3812511A
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
7116-412202
10

Pin
Size
Color
Circuit
1: 1
2: 2
3: 3
4: 4
5: 5
6: 6
1: 0.5
2: 0.5
3: 0.5
4: 0.5
5: 4
6: 4
1: RD/BN
2: BK
3: VT/YE
4: VT/BK
5: RD/GN
6: BK
1: 1140
2: 350
3: 4
4: 3
5: 3140
6: 1050
Terminal Type
ID
1: I
2: Ground
2: I
3: Ignition Voltage
3: I
4: Ignition Voltage
4: I
5: I
6: Ground
6: I
Function
Option
1: 2: 3: 4: 5: 6: -
Harness Type: Body

Description: 20-Way F USCAR 64 Series (GY)

Terminal
Removal
Tool
J-35616-64B -38125(L-BU)
215A

Type ID
Lead
Test Probe
I
Pending
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
Pending
Pending
Pending
Pending

Pin
Size
Color
Circuit
1: 1
1: 0.5
1: YE/GY
1: 6158
2: 2
2: 0.5
2: BN/YE
2: 6157
Function
1: Right Rear Door Handle
Switch Signal
2: Left Rear Door Handle
Switch Signal
Terminal Type
ID
Option
1: I
1: -
2: I
2: -

3: 3
3: 0.5
3: WH/BN
3: 3572
5: GY/BU
5: 3576
5: 5 5: 0.75
6: 6
6: 0.5
6: VT
6: 3560
7: 7
7: 0.5
7: VT/GY
7: 3561
9: 9
9: 0.5
9: GN/BK
9: 3563
10
11: VT/WH
11: 3571
12: 12 12: 0.5 12: GN/WH
12: 3570
11: 11 11: 0.5
13
14: 14 14: 0.5
14: BU
14: 3573
15: 15 15: 0.5 15: GN/WH
15: 6655
16: 16 16: 0.5
16: BN/GN
16: 3568
18: GN/GY
18: 3569
20: GN/YE
20: 3562
17
18: 18 18: 0.5

19
20: 20 20: 0.5
3: Driver Door Unlatch

Enable Signal
Not Occupied
5: Co-Driver Door Exterior
Switch Lock Signal
6: Passive Entry Driver
Door Antenna Signal Hi
Door Antenna Signal Lo
Not Occupied
9: Passive Entry Co Driver
Not Occupied
11: Co Driver Door Handle
Switch Signal
12: Driver Door Handle
Switch Signal
Not Occupied
14: Non Driver Door
Unlatch Enable Signal
Switch Signal
16: Passive Entry Rear
Closure Antenna Signal Hi
Not Occupied
Closure Antenna Signal Lo
Not Occupied
20: Passive Entry Co
Driver Door Antenna
Signal Hi
K85 PASSENGER PRESENCE DETECTION MODULE X1

Description: 6-Way F Micro-Pack HVT Series (BK)
3: I
3: ATH
5: I
5: -
6: I
6: -
7: I
7: -
9: I
9: -
11: I
11: -
12: I
12: -
14: I
14: ATH
15: I
15: -
16: I
16: -
18: I
18: -
20: I
20: -


Terminal
Type ID
Lead
Test Probe
13575550
Terminal
Removal
Tool
J-35616-16
J-38125-559
(L-GN)
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
15445905
23
K85 Passenger Presence Detection Module X1

Pin
Size
Color
Circuit
Function
1: 1
1: 0.5
1: D-BU
1: 402
2: 2
2: 0.5
2: WH
2: 5060
3: 3
3: 0.5
3: WH
3: 5060
4: 4
5-6
4: 0.5
-
4: BK
-
4: 2450
-

2: Low Speed GMLAN
Serial Data
3: Low Speed GMLAN
Serial Data
4: Ground
Not Occupied
Terminal Type
ID
1: I
Option
1: -
2: I
2: -
3: I
3: -
4: I
-
4: -
K85 PASSENGER PRESENCE DETECTION MODULE X2
Harness Type: Passenger Presence Detection Sensor

Service Connector: Service by Component Assembly - See Part Catalog
Description: 18-Way F Flexible Printed Circuit Series (BK)

Type ID
Lead
Test Probe
Terminal
Removal
Tool
Service
Terminal
Service
Connector:
Service by
J-35616-6B
Component
(L-BU)
Assembly See Part
Catalog
Tray
Core
Crimp
Insulation
Crimp
Service
Connector:
Service by
Not
Not
Component
Available Available
Assembly See Part
Catalog

Pin
Size
Color
Circuit
Function
1: 1
2: 2
3: 3
4: 4
5: 5
6: 6
7: 7
8: 8
9: 9
10: 10
11: 11
12: 12
13: 13
14: 14
15: 15
16: 16
17: 17
18: 18
1: FW
2: FW
3: FW
4: FW
5: FW
6: FW
7: FW
8: FW
9: FW
10: FW
11: FW
12: FW
13: FW
14: FW
15: FW
16: FW
17: FW
18: FW
1: FW
2: FW
3: FW
4: FW
5: FW
6: FW
7: FW
8: FW
9: FW
10: FW
11: FW
12: FW
13: FW
14: FW
15: FW
16: FW
17: FW
18: FW
1: 2: 3: 4: 5: 6: 7: 8: 9: 10: 11: 12: 13: 14: 15: 16: 17: 18: -
1: 2: 3: 4: 5: 6: 7: 8: 9: 10: 11: 12: 13: 14: 15: 16: 17: 18: -
Terminal Type
ID
1: I
2: I
3: I
4: I
5: I
6: I
7: I
8: I
9: I
10: I
11: I
12: I
13: I
14: I
15: I
16: I
17: I
18: I
Option
1: 2: 3: 4: 5: 6: 7: 8: 9: 10: 11: 12: 13: 14: 15: 16: 17: 18: -
K89 IMMOBILIZER CONTROL MODULE

Description: 3-Way F Micro Quadlok Series (PU)

Terminal
Type ID
I
Terminal
Removal
Tool
J-35616-64B J-3812513575587
(L-BU)
12A
Lead
Test Probe
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
928999-5
15
K89 Immobilizer Control Module

Terminal Type

Pin
Size
Color
Circuit
1: 1
1: 0.5 1: D-GN/GY
1: 3277
2: 2
2: 0.5 2: D-GN/VT
2: 7533
3: 3
3: 0.5
3: 3276
3: GY/BK
Function
System Immobilizer Return
Network Bus 11
System Immobilizer Supply
Voltage
ID
Option
1: I
1: -
2: I
2: -
3: I
3: -
M6 AIR TEMPERATURE DOOR ACTUATOR
Harness Type: HVAC


Terminal
Type ID
Terminal
Removal
Tool
J-35616-64B J-3812513575737
(L-BU)
12A
Lead
Test Probe
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
928999-5
15
M6 Air Temperature Door Actuator

Pin
Size
Color
Circuit
1: 1
1: 0.5
1: D-GN
1: 933
2: 2
2: 0.5
2: OG
2: 943
3: 3
3: 0.5
3: WH/RD
3: 932
4: 4
4: 0.5
4: GY/RD
4: 930
6: 6
6: 0.5
6: RD/BK
6: 929
Function
1: Temp Door Stepper
Motor Control (1)
2: HVAC Motor Supply
Voltage
Motor Control (2)
Motor Control (3)
Not Occupied
Motor Control (4)
Terminal Type
ID
Option
1: I
1: -
2: I
2: -
3: I
3: -
4: I
4: -
6: I
6: -

M8 BLOWER MOTOR
Harness Type: HVAC


Terminal
Type ID
Lead
Test Probe
Terminal
Removal
Tool
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
Service by
J-35616-40
Harness - See
(BU)
Part Catalog
J-3812511A
12084595
M8 Blower Motor
Pin
Size
Color
Circuit
A: A
A: 4
A: RD
A: 65
B: B
B: 4
B: BK
B: 374
Function
A: Blower Motor Supply
Voltage
B: Blower Motor Fan
Control
Terminal Type
ID
Option
A: I
A: -
B: I
B: -
M37 MODE DOOR ACTUATOR
Harness Type: HVAC


Terminal
Terminal
Service
Core
Insulation

Type ID
Lead
Removal
Tool
J-35616-64B J-3812513575737
(L-BU)
12A
Test Probe
Terminal
928999-5
Tray
Crimp
Crimp
15
M37 Mode Door Actuator

Pin
Size
Color
Circuit
1: 1
1: 0.5
1: YE
1: 936
2: 2
2: 0.5
2: OG
2: 943
3: 3
3: 0.5
3: WH/RD
3: 931
4: 4
4: 0.5
4: GY/BN
4: 926
6: 6
6: 0.5 6: D-GN/WH
6: 925
Function
Terminal Type
ID
Option
1: I
1: -
2: I
2: -
3: I
3: -
4: I
4: -
6: I
6: -

Motor Control (1)
Voltage
Motor Control (2)
Motor Control (3)
Not Occupied
Motor Control (4)
M40 REAR COMPARTMENT LID LATCH
Harness Type: Rear Compartment Lid

Description: 4-Way F Timer Micro-Pack Series (BK)

Terminal
Type ID
I
Lead
Test Probe
13575538
Terminal
Removal
Tool
J-35616-14
J-38125-560
(GN)
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
962943-5
16
M40 Rear Compartment Lid Latch

Pin
1: 1
Size
Color
1: 0.5 1: D-BU/YE
Circuit
Function
Terminal Type
ID
Option
1: 6795
1: I
1: -

2: 2
3
2: 0.5
-
2: BK
-
2: 650
-
4: 4
4: 0.5
4: VT/BK
4: 1303
Release Control 2
2: Ground
Not Occupied
4: Lift Gate Ajar Switch
Signal (1)
2: I
-
2: -
4: I
4: -
M46 AIR RECIRCULATION DOOR ACTUATOR
Harness Type: HVAC


Terminal
Type ID
Terminal
Removal
Tool
J-35616-64B J-3812513575737
(L-BU)
12A
Lead
Test Probe
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
928999-5
15
Pin: 2: J
M46 Air Recirculation Door Actuator

Pin
Size
Color
Circuit
1: 1
1: 0.5
1: GY
1: 929
2: 2
2: 0.5
2: OG
2: 943
3: 3
3: 0.5 3: D-BU/WH
3: 929
4: 4
4: 0.5 4: BN/D-GN
4: 929
5
6: 6
6: 0.5 6: RD/D-GN
6: 929
Function
1: Air Inlet Door Stepper
Motor Control (1)
Voltage
Motor Control (2)
Motor Control (3)
Not Occupied
Motor Control (4)
M50D SEAT FRONT VERTICAL MOTOR - DRIVER (ADS)
Terminal Type
ID
Option
1: I
1: -
2: I
2: -
3: I
3: -
4: I
4: -
6: I
6: -


Description: 5-Way F MQS/MCP Mixed Series (BK)

Type ID
Lead
Test Probe
Terminal
Removal
Tool
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
Service by
Harness See Part
Catalog
Not
Available
Not
Available
Not
Available
Not
Available
Not
Available
J-35616-4A
(PU)
M50D Seat Front Vertical Motor - Driver (ADS)

Pin
Size
Color
Circuit
1: 1
1: 1.5
1: GY
1: 287
2-4
5: 5
5: 1.5
5: BU
5: 286
Function
1: Driver Power Seat Front
Vertical Motor Down
Control
Not Occupied
5: Driver Power Seat Front
Vertical Motor Up Control
M51D SEAT HORIZONTAL MOTOR - DRIVER (ADS)

Terminal Type
ID
Option
1: I
1: -
5: I
5: -


Type ID
Lead
Test Probe
Terminal
Removal
Tool
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
Service by
Harness See Part
Catalog
Not
Available
Not
Available
Not
Available
Not
Available
Not
Available
J-35616-4A
(PU)
M51D Seat Horizontal Motor - Driver (ADS)

Pin
Size
Color
Circuit
1: 1
1: 1.5
1: YE
1: 285
2-4
5: 5
5: 1.5
5: BN
5: 284
Function
Terminal Type
ID
Option
1: I
1: -
5: I
5: -
1: Driver Power Seat

Control
Not Occupied
5: Driver Power Seat
Control
M55D SEAT REAR VERTICAL MOTOR - DRIVER (ADS)


Type ID
Lead
Test Probe
Terminal
Removal
Tool
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
Service by
Harness See Part
Catalog
Not
Available
Not
Available
Not
Available
Not
Available
Not
Available
J-35616-4A
(PU)
M55D Seat Rear Vertical Motor - Driver (ADS)

Pin
Size
Color
Circuit
Function
1: Driver Power Seat Rear
Terminal Type
ID
Option

1: 1
2-4
1: 1.5
-
1: WH
-
1: 282
-
5: 5
5: 1.5
5: GN
5: 283

Not Occupied
5: Driver Power Seat Rear
Vertical Motor Down
Control
1: I
-
1: -
5: I
5: -
M74D WINDOW MOTOR - DRIVER (AEC)

Description: 2-Way F Metri-Pack 280 Series, Flexlock, Sealed (GY)

Terminal
Type ID
Lead
Test Probe
Pending
Terminal
Removal
Tool
J-35616-4A
J-38125-553
(PU)
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
12110845
M74D Window Motor - Driver (AEC)

Pin
Size
Color
Circuit
A: A A: 2.5 A: D-GN/GY
A: 3382
B: B B: 2.5
B: 3383
B: YE/VT
Function
A: Power Window Motor
Driver Up Control
B: Power Window Motor
Driver Down Control
M74D WINDOW MOTOR - DRIVER (AXG)

Terminal Type
ID
Option
A: I
A: -
B: I
B: -


Description: 7-Way F Kaizen 0.64 2.8 Timer Series, Sealed (BK)

Terminal
Type ID
Lead
Test Probe
Terminal
Removal
Tool
Service
Terminal
J-35616-35
J-38125-36 4-964273-1
(VT)
J-35616-64B J-38125- SAIT-A03T13575867
(L-BU)
215A
M064
13580821
II
Tray
Core
Crimp
Insulation
Crimp
15
14
M74D Window Motor - Driver (AXG)

Pin
Size
Color
Circuit
1: 1
2: 2
1: 2.5
2: 2.5
1: BK
2: RD/GN
1: 1550
2: 1540
3: 3
3: 0.5
3: GN/WH
3: 3379
4: 4
4: 0.5
4: GN/YE
4: 6134
5: 5
5: 0.5
5: GN
5: 3381
6: 6
6: 0.5
6: GY
6: 745
7: 7
7: 0.5
7: GY
7: 3380
Terminal Type
ID
1: Ground
1: I
2: I
3: Power Window Switch
3: II
Driver Up Signal
4: II
Network Bus 3
5: II
6: II
Switch Signal
7: II
Driver Down Signal
Function
Option
1: 2: 3: 4: 5: 6: 7: -
M74LR WINDOW MOTOR - LEFT REAR


Terminal
Terminal
Removal
Service
Tray
Core
Insulation

Type ID
I
Lead
Test Probe
Tool
Service by
J-35616-4A
Harness - See
J-38125-553
(PU)
Part Catalog
Terminal
12110845
Crimp
Crimp
M74LR Window Motor - Left Rear

Pin
Size
Color
Circuit
A: A A: 2.5 A: D-BU/GY
A: 668
B: B B: 2.5 B: D-GN/BK
B: 669
Function
Terminal Type
ID
Option
A: I
A: AEQ
B: I
B: AEQ

Left Rear Up Control
Left Rear Down Control
M74P WINDOW MOTOR - PASSENGER


Terminal
Type ID
Lead
Test Probe
Terminal
Removal
Tool
Service by
J-35616-4A
J-38125-553
Harness - See
(PU)
Part Catalog
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
12110845
M74P Window Motor - Passenger

Pin
Size
Color
Circuit
A: A A: 2.5 A: D-GN/GY
A: 3387
B: B B: 2.5 B: YE/D-BU
B: 3388
Function
Co-Driver Up Control
Co-Driver Down Control
M74RR WINDOW MOTOR - RIGHT REAR
Terminal Type
ID
Option
A: I
A: -
B: I
B: -



Terminal
Type ID
Lead
Test Probe
Terminal
Removal
Tool
Service by
J-35616-4A
Harness - See
J-38125-553
(PU)
Part Catalog
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
12110845
M74RR Window Motor - Right Rear

Pin
Size
Color
Circuit
A: A A: 2.5 A: D-BU/GY
A: 670
B: B B: 2.5 B: D-GN/BK
B: 671
Function
Terminal Type
ID
Option
A: I
A: AEQ
B: I
B: AEQ

Right Rear Up Control
Right Rear Down Control
M75 WINDSHIELD WIPER MOTOR

Description: 4-Way F GT 280 5.8 Series, Sealed (BK)

Type ID
Lead
Test Probe
Terminal
Removal
Tool
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp

13575392
II
13575392
J-35616-4A
J-38125-553
(PU)
J-35616-4A
J-38125-553
(PU)
15304720
19
Not
Available
Not
Available
15304720
19
M75 Windshield Wiper Motor

Pin
Size
Color
Circuit
A: A A: 0.5
A: BN/GN
A: 196
B: B B: 2.5
B: YE/BN
B: 95
C: C C: 2.5
C: BK
C: 1350
D: D D: 2.5
D: WH
D: 92
Function
Terminal Type
ID
Option
A: I
A: -
B: II
B: -
C: II
C: -
D: II
D: -
A: Windshield Wiper
Motor Park Switch Signal
B: Windshield Wiper
Motor Low Speed Control
C: Ground
D: Windshield Wiper
Motor High Speed Control
M93 IGNITION CYLINDER LOCK CONTROL SOLENOID ACTUATOR (MH8)

Description: 2-Way F Kaizen 64 Series (BK)

Terminal
Type ID
I
Terminal
Service
Removal
Terminal
Tool
J-35616-64B J-38125- SAIT-A03T13575867
(L-BU)
215A
M064
Lead
Test Probe
Tray
Core
Crimp
Insulation
Crimp
14
M93 Ignition Cylinder Lock Control Solenoid Actuator (MH8)

Pin
Size
Color
Circuit
Function
1: 1
1: 0.5
1: VT/YE
1: 143
2: 2
2: 0.5
2: WH/VT
2: 5905
1: Ignition Voltage
2: Key Capture/Column
Lock Shift Position Signal
M96 ACTIVE GRILLE AIR SHUTTER ACTUATOR (Y8X)
Terminal Type
ID
1: I
2: I
Option
1: 2: -



Type ID
Lead
Test Probe
I
Pending
Pending
Terminal
Removal
Tool
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
Pending
Pending
Pending
Not
Available
Not
Available
M96 Active Grille Air Shutter Actuator (Y8X)

Pin
Size
Color
Circuit
1: 1 1: 0.75
1: GY/BK
1: 3437
2: 2 2: 0.75
2: BK
2: 1150
3: 3
3: 0.5
3: VT/GY
3: 1039
Function
Terminal Type
ID
Option
1: I
1: -
2: I
2: -
3: I
3: -
1: Shutter Valve Solenoid

Control
2: Ground
Voltage
Not Occupied
P2 TRANSMISSION SHIFT LEVER POSITION INDICATOR (MH8)


Terminal
Type ID
Lead
Test Probe
Terminal
Removal
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp

13575735
Tool
J-35616-2A
J-38125-553
(GY)
12191812
19
P2 Transmission Shift Lever Position Indicator (MH8)

Pin
Size
Color
Circuit
A: A A: 0.5
A: YE
A: 6817
B: B
B: BK
B: 1750
B: 0.5
Function
Terminal Type
ID
Option
A: I
A: -
B: I
B: -
A: LED Backlight Dimming

Control
B: Ground
P12 HORN


Terminal
Type ID
I
Lead
Test Probe
13575412
Terminal
Removal
Tool
J-35616-2A
J-38125-553
(GY)
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
12191819
P12 Horn
Pin
Size
Color
Circuit
Function
1: 1
2: 2
1: 1
2: 1
1: BK
2: BN/GY
1: 1050
2: 29
1: Ground
2: Horn Control
P14 PASSENGER AIR BAG DISABLE INDICATOR
Terminal Type
ID
1: I
2: I
Option
1: 2: -


Description: 6-Way F MTS 0.64 Series (GY)

Terminal
Type ID
Terminal
Removal
Tool
J-35616-64B J-3812513575782
(L-BU)
12A
Lead
Test Probe
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
928999-5
15
P14 Passenger Air Bag Disable Indicator

Pin
Size
Color
Circuit
1: 1
1: 0.5
1: VT/WH
1: 239
2: L-BU
2: 2307
3: BK
4: BK
3: 1650
4: 1650
5: 5 5: 0.35
5: D-GN
5: 2308
6: 6 6: 0.35
6: VT/WH
6: 5234
2: 2 2: 0.35
3: 3
4: 4
3: 0.5
4: 0.5
Function
Terminal Type
ID
Option
1: I
1: -
2: I
2: -
3: I
4: I
3: 4: -
5: I
5: -
6: I
6: -
Voltage
2: Passenger Air Bag On
Indicator Control
3: Ground
4: Ground
5: Passenger Air Bag Off
Indicator Control
Indicator
P16 INSTRUMENT CLUSTER

Description: 32-Way F 64 Quadlock Series (BK)

Terminal
Type ID
Lead
Test Probe
Terminal
Removal
Tool
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp

13575737
J-35616-64B
(L-BU)
J-3812512A
928999-5
15

Pin
Size
Color
Circuit
Function
1-8
9: BK/BN
9: 897
Terminal Type
ID
-
Option
16:
16: 16
0.75
17-23
-
Not Occupied
9: Driver Information
Center Switch Low
Reference
Center Switch Signal
11: Outside Ambient
Reference
12: Outside Ambient Air
Not Occupied
16: BK
16: 50
16: Ground
16: I
16: -
24: 24 24: 0.5
24: D-BU
24: 507
Not Occupied
24: Wait To Start Indicator
Control
Control
26: Low Speed GMLAN
Serial Data
Not Occupied
Center Select Menu Switch
Signal
Not Occupied
Voltage
24: I
24: -
25: I
25: -
26: I
26: -
28: I
28: -
31: I
31: -
32: I
32: -
9: 9 9: 0.35
10: 10
10:
10: D-GN/WH
0.35
10: 1358
11: 11 11: 0.5 11: BK/D-BU
11: 61
12: 12 12: 0.5 12: D-BU/GY
12: 636
13-15
25: 25 25: 0.5 25: BN/WH
25: 419
26: 26 26: 0.5
26: D-GN
26: 5060
27
28: 28
28:
0.35
28: GY/D-BU
28: 893
29-30
31: 31 31: 0.5 31: VT/WH
32:
32: 32
32: RD/WH
0.75
31: 239
32: 140
P17 INFO DISPLAY MODULE (UAG)
9: I
9: -
10: I
10: -
11: I
11: -
12: I
12: -



Terminal
Type ID
Terminal
Removal
Tool
J-35616-64B J-3812513575230
(L-BU)
215A
J-35616-64B J-3812513575299
(L-BU)
215A
Lead
Test Probe
I
II
Service
Terminal
Not Stocked
in Kit
Not Stocked
in Kit
Tray
Core
Crimp
Insulation
Crimp
le
le
P17 Info Display Module (UAG)

Pin
Size
Color
Circuit
1: 1
2: 2
1: 0.5
2: 0.5
1: RD/GN
2: BK
1: 3140
2: 1750
3: 3
3: 0.5
3: GN/BU
3: 7532
4: 4 4: 0.35
4: GY/GN
4: 3291
5: 5 5: 0.35
5: VT
5: 3290
6: 6 6: 0.35
6: BARE
6: 7460
7: 7 7: 0.35
7: VT
7: 7458
8: 8 8: 0.35
8: YE
8: 7459
Terminal Type
ID
1: I
2: Ground
2: I
3: I
Network Bus 10
4: II
Wake Up Signal
5: II
Reset Signal
6: II
Serial Data Shield
7: Center Integrated Center
7: II
8: II
Serial Data Low
Function
Option
1: 2: 3: 4: 5: 6: 7: 8: -

2013 ELECTRICAL
Views - Cruze

P17 INFO DISPLAY MODULE X1 (UHQ)


Type ID
Lead
Test Probe
Terminal
Removal
Tool
13579944
Pending
Pending
II
Pending
Pending
Pending
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
Not
Available
Not
Available
Not
Available
Not
Available
Not
Available
Not
Available
Not
Available
Not
Available

Pin
Size
Color
Circuit
1: 1
2: 2
3
1: 0.5
2: 0.5
-
1: RD/GN
2: BK
-
1: 3140
2: 1750
-
4: GY
4: 3369
4: 4 4: 0.35
5: 5
5: 0.5
5: BN/GN
5: 3364
6: 6
6: 0.5
6: GN/YE
6: 7066
7: 7 7: 0.35
7: BARE
7: 3368
8: VT
8: 3370
8: 8
8: 0.5
Terminal Type
ID
1: 2: Ground
2: Not Occupied
4: Touch Screen Display
4: II
Signal (+)
5: II
Reset Signal
6: II
Enable Signal
7: II
Drain Wire
Function
8: II
Option
1: 2: 4: 5: 6: 7: 8: -

Signal (-)


Terminal Type
Terminated Lead
ID
I
- See Parts Catalog
No Tool Required
No Tool Required

Pin
Size
Color
Circuit
1: 1
1: 0.35
1: BN
1: 3367
2: 2
2: 0.35
2: BU
2: 3366
3: 3
3: 0.35
3: BARE
3: 3365
Function
Signal (-)
Signal (+)
3: Navigation Display Drain
Wire
P19AA SPEAKER - RIGHT SUBWOOFER
Harness Type: Body

Terminal Type
ID
Option
1: I
1: -
2: I
2: -
3: I
3: -


Terminal
Type ID
Terminal
Removal
Tool
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
J-35616-2A
J-38125-29
(GY)
13526678
PO
Lead
Test Probe
13575480
P19AA Speaker - Right Subwoofer

Pin
Size
Color
Circuit
1: 1
1: 1
1: GY/BK
1: 315
2: 2
2: 1
2: D-GN/VT
2: 1795
Function
Terminal Type
ID
Option
1: I
1: UQA
2: I
2: UQA
1: Right Subwoofer
Speaker (-)
2: Right Subwoofer
Speaker (+)
P19AG SPEAKER - LEFT FRONT DOOR


Terminal
Type ID
Terminal
Removal
Tool
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
J-35616-2A
J-38125-29
(GY)
13526678
PO
Lead
Test Probe
13575480
P19AG Speaker - Left Front Door

Pin
Size
Color
Circuit
1: 1
1: 0.75
1: BN/DBU
1: 118
2: 2
2: 0.75
2: D-BU
2: 201
Function
1: Left Front Speaker Signal
(-) (1)
(1)
P19AH SPEAKER - RIGHT FRONT DOOR
Terminal Type
ID
Option
1: I
1: -
2: I
2: -



Terminal
Type ID
Terminal
Removal
Tool
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
J-35616-2A
J-38125-29
(GY)
13526678
PO
Lead
Test Probe
13575480
P19AH Speaker - Right Front Door

Pin
Size
Color
Circuit
1: 1 1: 0.75
1: YE/BK
1: 117
2: 2 2: 0.75
2: YE
2: 200
Function
Terminal Type
ID
Option
1: I
1: -
2: I
2: -

Signal (-) (1)
2: Right Front Speaker (+)
(1)
P19AL SPEAKER - LEFT REAR DOOR


Terminal
Type ID
I
Terminal
Removal
Tool
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
J-35616-2A J-38125-29
13526678
PO
Lead
Test Probe
13575480

(GY)
P19AL Speaker - Left Rear Door
Pin
Size
Color
Circuit
1: 1 1: 0.75 1: D-GN/BK
1: 116
2: 2 2: 0.75
2: 199
2: D-GN
Function
Terminal Type
ID
Option
1: I
1: -
2: I
2: -
1: Left Rear Speaker Signal

(-)
P19AM SPEAKER - RIGHT REAR DOOR


Terminal
Type ID
Terminal
Removal
Tool
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
J-35616-2A
J-38125-29
(GY)
13526678
PO
Lead
Test Probe
13575480
P19AM Speaker - Right Rear Door

Pin
Size
Color
Circuit
1: 1 1: 0.75 1: D-BU/BK
1: 115
2: 2 2: 0.75
2: 46
2: WH
Function
Signal (-)
P19B SPEAKER - CENTER INSTRUMENT PANEL (UQA)
Terminal Type
ID
Option
1: I
1: -
2: I
2: -



Terminal
Type ID
Lead
Test Probe
13327201
Terminal
Removal
Tool
Service
Terminal
J-35616-2A
J-38125-553 8240-0128
(GY)
Tray
Core
Crimp
Insulation
Crimp
22
P19B Speaker - Center Instrument Panel (UQA)

Pin
Size
Color
1: 1 1: 0.75 1: D-BU/YE
2: 2 2: 0.75 2: YE/WH
Circuit
1: 1960
2: 1860
Terminal Type
ID
1: Front Center Speaker (-)
1: I
2: Front Center Speaker (+)
2: I
Function
Option
1: UQA
2: UQA
P19H SPEAKER - LEFT FRONT TWEETER


Terminal
Removal
Tool
J-35616-64B J-3812513575867
(L-BU)
215A

Type ID
Lead
Test Probe
I
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
Not
Available
Not
Available
Not
Available
Not
Available
P19H Speaker - Left Front Tweeter

Pin
Size
1: 1
1: 0.75
2: 2
2: 0.75
Color
1: BN/DBU
2: D-BU
Circuit
1: 118
2: 201
Function
(-)
Terminal Type
ID
Option
1: I
1: -
2: I
2: -

P19N SPEAKER - LEFT SUBWOOFER
Harness Type: Body


Terminal
Type ID
I
Terminal
Removal
Tool
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
J-35616-2A
J-38125-29
(GY)
13526678
PO
Lead
Test Probe
13575480
P19N Speaker - Left Subwoofer

Pin
Size
Color
Circuit
1: 1
1: 1
1: D-GN/BK
1: 1794
2: 2
2: 1
2: D-BU/GY
2: 346
Function
Terminal Type
ID
Option
1: I
1: UQA
2: I
2: UQA
1: Left/Rear Subwoofer
Speaker (-)
Speaker (+)
P19V SPEAKER - RIGHT FRONT TWEETER


Type ID
Lead
Test Probe
Terminal
Removal
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp

Tool
J-35616-64B J-3812513575867
(L-BU)
215A
Not
Available
Not
Available
Not
Available
Not
Available
P19V Speaker - Right Front Tweeter

Pin
Size
Color
Circuit
1: 1 1: 0.75
1: YE/BK
1: 117
2: 2 2: 0.75
2: YE
2: 200
Function
Terminal Type
ID
Option
1: I
1: -
2: I
2: -

Signal (-) (1)
(1)
Q6E CAMSHAFT POSITION ACTUATOR SOLENOID VALVE - EXHAUST (LUV)

Description: 2-Way F 1.2 MLK Series, Sealed (BK)

Type ID
Lead
Test Probe
I
13576385
Pending
Terminal
Removal
Tool
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
Pending
Not
Available
Not
Available
Not
Available
Not
Available
Q6E Camshaft Position Actuator Solenoid Valve - Exhaust (LUV)

Pin
Size
Color
Circuit
Function
1: 1
1: 0.5
1: BK/VT
1: 6754
2: 2
2: 0.5 2: GY/D-BU
1: Low Reference
2: Camshaft Phaser Exhaust
Solenoid (1)
2: 5282
Terminal Type
ID
1: I
2: I
Option
1: 2: -
Q6E CAMSHAFT POSITION ACTUATOR SOLENOID VALVE - EXHAUST (LUW/LWE)



Terminal
Type ID
I
Terminal
Removal
Tool
J-35616-64B J-3812513582274
(L-BU)
12A
Lead
Test Probe
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
928999-5
15
Q6E Camshaft Position Actuator Solenoid Valve - Exhaust (LUW/LWE)

Terminal Type
Pin
Size
Color
Circuit
Function
ID
1: 1 1: 0.5 1: BK/VT
1: 6754
1: Low Reference
1: I
2: 2 2: 0.5 2: GY/D-BU
2: 5282
2: I
Solenoid (1)
Option
1: 2: -
Q6F CAMSHAFT POSITION ACTUATOR SOLENOID VALVE - INTAKE (LUV)


Type ID
Lead
Test Probe
I
13576385
Pending
Terminal
Removal
Tool
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
Pending
Not
Available
Not
Available
Not
Available
Not
Available
Q6F Camshaft Position Actuator Solenoid Valve - Intake (LUV)

Pin
Size
Color
Circuit
Function
Terminal Type
ID
Option

1: 1
1: 0.5
1: BN/WH
1: 6753
2: 2
2: 0.5
2: VT/BN
2: 5284
1: Low Reference
Solenoid (1)
1: I
1: -
2: I
2: -
Q6F CAMSHAFT POSITION ACTUATOR SOLENOID VALVE - INTAKE (LUW/LWE)


Terminal
Type ID
I
Terminal
Removal
Tool
J-35616-64B J-3812513582274
(L-BU)
12A
Lead
Test Probe
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
928999-5
15
Q6F Camshaft Position Actuator Solenoid Valve - Intake (LUW/LWE)

Terminal Type
Pin
Size
Color
Circuit
Function
ID
1: 1 1: 0.5 1: BK/BN
1: 6753
1: Low Reference
1: I
2: 2 2: 0.5 2: VT/BN
2: 5284
2: I
Solenoid (1)
Q8 CONTROL SOLENOID VALVE ASSEMBLY X1 (MH8)

Description: 14-Way F GT 150 280 Series, Sealed (L-GY)
Option
1: 2: -


Terminal
Type ID
Lead
Test Probe
13575392
II
13575400
Terminal
Removal
Tool
J-35616-4A
J-38125-553
(PU)
J-35616-2A
J-38125-553
(GY)
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
15304720
19
15326267
19
Q8 Control Solenoid Valve Assembly X1 (MH8)

Pin
Size
Color
Circuit
Function
1: 0.75
1: 0.75
2: 2 2: 0.75
1: RD/WH
1: RD/WH
2: BK
1: 340
1: 1840
2: 150
3: 3
3: 0.5
3: 0.5
3: L-GN
3: WH/GY
3: 275
3: 1786
4-5
6: 6
6: 0.5
6: D-BU
6: 2500
7: 7
7: 0.5
7: D-BU
7: 2500
8: 8
8: 0.5
8: WH
8: 2501

2: Ground
3: Transmission Park/Neutral
Signal (1)
Signal (1)
Not Occupied
6: High Speed GMLAN
Serial Data (+) (1)
7: High Speed GMLAN
Serial Data (+) (1)
8: High Speed GMLAN
Serial Data (-) (1)
Not Occupied
Signal
Not Occupied
Data
Data
Serial Data (-) (1)
1: 1
10: WH/D10: 10 10: 0.5

BU
11
12: 0.5 12: VT/D-BU
12: 12
12: 0.5 12: VT/GY
13: 13
13: 0.5
13: 0.5
14: 14 14: 0.5
10: 6311
12: 139
12: 139
13: BU
13: VT/YE
13: 5985
13: 5985
14: WH
14: 2501
Terminal Type
ID
1: I
2: I
Option
1: LUJ
1: LUW
2: -
3: II
3: LUJ
3: LUW
6: II
6: -
7: II
7: -
8: II
8: -
10: -
10: LUW
12: LUJ
12: LUW
12: II
13: II
13: LUJ
13: LUW
14: II
14: -

Harness Type: Automatic Transmission

Description: 6-Way F Micro-Pack 150.2 Series Sealed (BU)

Type ID
Lead
Test Probe
Terminal
Removal
Tool
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
Service by
J-35616-14
Component
(GN)
Assembly
Not
Available
Not
Available
Not
Available
Not
Available
Not
Available

Pin
Size
Color
Circuit
A: A A: 0.5
A: BU
A: -
B: B
B: 0.5
B: GN
B: -
C: C C: 0.5
C: GY
C: -
D: D D: 0.5
D: YE
D: -
E: E
E: 0.5
E: RD
E: -
F: F
F: 0.5
F: BK
F: -
Function
A: Park/Neutral Switch
Signal
B: Transmission Range
Switch Signal A
C: Transmission Range
Switch Signal B
D: Transmission Range
Switch Signal C
E: Transmission Range
Switch Signal P
F: Low Reference

Description: 2-Way F Metri-Pack 150.2 Series (L-GY)
Terminal Type
ID
Option
A: I
A: -
B: I
B: -
C: I
C: -
D: I
D: -
E: I
E: -
F: I
F: -


Type ID
Lead
Test Probe
Terminal
Removal
Tool
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
Service by
J-35616-14
Component
(GN)
Assembly
Not
Available
Not
Available
Not
Available
Not
Available
Not
Available

Pin
Size
A: A A: 0.5
B: B B: 0.5
Color
Circuit
Function
A: WH
B: BK
A: B: -
A: ISS High Signal

B: ISS Low Signal
Terminal Type
ID
A: I
B: I
Option
A: B: -


Type ID
Lead
Test Probe
Terminal
Removal
Tool
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
Service by
J-35616-14
Component
(GN)
Assembly
Not
Available
Not
Available
Not
Available
Not
Available
Not
Available

Pin
Size
A: A A: 0.5
B: B B: 0.5
Color
Circuit
Function
A: WH
B: BK
A: B: -
A: OSS High Signal

B: OSS Low Signal
Terminal Type
ID
A: I
B: I
Q12 EVAPORATIVE EMISSION PURGE SOLENOID VALVE (LUV)
Option
A: B: -



Type ID
Lead
Test Probe
I
Not
Available
Terminal
Removal
Tool
Service
Terminal
J-35616-35
J-38125-561 1928498056
(VT)
Tray
Core
Crimp
Insulation
Crimp
Q12 Evaporative Emission Purge Solenoid Valve (LUV)

Pin
Size
Color
Circuit
1: 1
1: 0.5
1: GN/D-BU
1: 428
2: 2
2: RD/WH
2: RD/WH
2: 5293
Function
Terminal Type
ID
Option
1: I
1: -
2: I
2: -

Solenoid Control
Fused Supply (4)
Q12 EVAPORATIVE EMISSION PURGE SOLENOID VALVE (LUW/LWE)


Type ID
Lead
Test Probe
I
Not
Terminal
Removal
Tool
Service
Terminal
J-35616-35 J-38125-561 1928498056
Tray
Core
Crimp
Insulation
Crimp

Available
(VT)
Q12 Evaporative Emission Purge Solenoid Valve (LUW/LWE)

Pin
Size
Color
Circuit
1: 1
1: 0.75
1: L-GN/DBU
1: 428
2: 2
2: 0.75 2: VT/D-BU
2: 5293
Function
Terminal Type
ID
Option
1: I
1: -
2: I
2: -

Solenoid Control
Fused Supply (4)
Q13 EVAPORATIVE EMISSION VENT SOLENOID VALVE

Description: 2-Way F Metri-Pack 150 Series, Sealed (RD)

Terminal
Type ID
Lead
Test Probe
13575427
J-35616-14
(GN)
Terminal
Removal
Tool
J-3812512A
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
12048074
Q13 Evaporative Emission Vent Solenoid Valve

Color
Circuit
Function
Terminal Type
ID
Option
A: A A: 0.75
A: RD/DBU
A: 5372
A: Canister Valve Solenoid
A: I
A: -
B: B B: 0.75
B: WH
B: 1310
B: EVAP Canister Vent

Solenoid Control
B: I
B: -
Pin
Size
Q17A FUEL INJECTOR 1 (LUV)



Terminal
Type ID
Lead
Test Probe
13327154
Terminal
Removal
Tool
Service
Terminal
J-35616-35
J-38125-36 4-964286-1
(VT)
Tray
Core
Crimp
Insulation
Crimp
16
Q17A Fuel Injector 1 (LUV)

Pin
Size
Color
Circuit
1: 1
1: 0.5
1: RD/BU
1: 5291
2: 2
2: 0.5
2: BN/VT
2: 1744
Function
Terminal Type
ID
Option
1: I
1: -
2: I
2: -

Fused Supply (2)
Q17A FUEL INJECTOR 1 (LUW/LWE)
Harness Type: Fuel Injector


Terminal
Type ID
I
Lead
Test Probe
13581346
Terminal
Removal
Tool
Service
Terminal
J-35616-35
J-38125-36 4-964286-1
(VT)
Tray
Core
Crimp
Insulation
Crimp
16
Q17A Fuel Injector 1 (LUW/LWE)

Pin
Size
Color
Circuit
Function
Terminal Type
ID
Option

1: 1
2: 2
1: 0.5
2: 0.5
1: PK/BK
2: BN
1: 5291
2: 1744
Fused Supply (2)

1: I
2: I
1: 2: -
Q17B FUEL INJECTOR 2 (LUV)


Terminal
Type ID
Lead
Test Probe
13327154
Terminal
Removal
Tool
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
16
J-35616-35
J-38125-36 4-964286-1
(VT)
Q17B Fuel Injector 2 (LUV)

Pin
Size
Color
Circuit
1: 1
1: 0.5
1: RD/BU
1: 5291
2: 2
2: 0.5
2: YE/WH
2: 1745
Function
Fused Supply (2)
Q17B FUEL INJECTOR 2 (LUW/LWE)

Terminal Type
ID
Option
1: I
1: -
2: I
2: -

Terminal
Type ID
Lead
Test Probe
13581346
Terminal
Removal
Tool
Service
Terminal
J-35616-35
J-38125-36 4-964286-1
(VT)
Tray
Core
Crimp
Insulation
Crimp
16
Q17B Fuel Injector 2 (LUW/LWE)

Pin
Size
Color
Circuit
1: 1
1: 0.5
1: PK/WH
1: 5291
2: 2
2: 0.5 2: L-GN/BK
Function
Terminal Type
ID
Option
1: I
1: -
2: I
2: -

Fused Supply (2)
2: 1745
Q17C FUEL INJECTOR 3 (LUV)


Terminal
Type ID
Lead
Test Probe
13327154
Terminal
Removal
Tool
Service
Terminal
J-35616-35
J-38125-36 4-964286-1
(VT)
Tray
Core
Crimp
Insulation
Crimp
16
Q17C Fuel Injector 3 (LUV)

Pin
Size
Color
Circuit
1: 1
1: 0.5
1: RD/BU
1: 5291
2: 2
2: 0.5
2: BN/YE
2: 1746
Q17C FUEL INJECTOR 3 (LUW/LWE)
Function
Fused Supply (2)
Terminal Type
ID
Option
1: I
1: -
2: I
2: -



Terminal
Type ID
Lead
Test Probe
13581346
Terminal
Removal
Tool
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
16
J-35616-35
J-38125-36 4-964286-1
(VT)
Q17C Fuel Injector 3 (LUW/LWE)

Pin
Size
Color
Circuit
1: 1
1: 0.5
1: PK/BK
1: 5291
2: 2
2: 0.5
2: WH/BK
2: 1746
Function
Terminal Type
ID
Option
1: I
1: -
2: I
2: -

Fused Supply (2)
Q17D FUEL INJECTOR 4 (LUV)


Terminal
Type ID
I
Lead
Test Probe
13327154
Terminal
Removal
Tool
Service
Terminal
J-35616-35
J-38125-36 4-964286-1
(VT)
Tray
Core
Crimp
Insulation
Crimp
16

Q17D Fuel Injector 4 (LUV)

Pin
Size
Color
Circuit
1: 1
1: 0.5
1: RD/BU
1: 5291
2: 2
2: 0.5
2: BN
2: 844
Function
Terminal Type
ID
Option
1: I
1: -
2: I
2: -

Fused Supply (2)
Q17D FUEL INJECTOR 4 (LUW/LWE)


Terminal
Type ID
Lead
Test Probe
13581346
Terminal
Removal
Tool
Service
Terminal
J-35616-35
J-38125-36 4-964286-1
(VT)
Tray
Core
Crimp
Insulation
Crimp
16
Q17D Fuel Injector 4 (LUW/LWE)

Pin
Size
Color
Circuit
1: 1
1: 0.5
1: PK/BK
1: 5291
2: 2
2: 0.5 2: D-BU/BK
2: 844
Function
Terminal Type
ID
Option
1: I
1: -
2: I
2: -

Fused Supply (2)
Q22 INTAKE MANIFOLD TUNING SOLENOID VALVE (LUW/LWE)




Terminal
Type ID
Terminal
Removal
Tool
J-35616-64B J-3812513576394
(L-BU)
12A
Lead
Test Probe
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
962885-5
15
Q22 Intake Manifold Tuning Solenoid Valve (LUW/LWE)

Pin
Size
Color
Circuit
1: 1
1: 0.5
2: 2
2: 0.5
1: VT/DBU
2: BK
3: 3
3: 0.5
3: D-BU
3: 7302
4: 4
4: 0.5
4: GY/LGN
4: 7303
1: 5293
2: 150
Function
Terminal Type
ID
Option
1: I
1: -
2: I
2: -
3: I
3: -
4: I
4: -

Fused Supply (4)
2: Ground
3: Intake Manifold Tuning
Valve (IMTV) Control Signal
Valve (IMTV) Position Signal
Q38 THROTTLE BODY

Description: 6-Way Sealed (BK)

Terminal
Type ID
I
Lead
Test Probe
13575396
Q38 Throttle Body
Terminal
Removal
Tool
J-35616-2A
J-38125-553
(GY)
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
15326427

Pin
Size
Color
Circuit
A: A A: 0.5
A: BN/WH
A: 582
B: B B: 0.5
B: BN/RD
B: 581
C: C C: 0.5
C: BK/YE
C: 2752
D: D D: 0.5
D: BN/GN
D: 485
E: E E: 0.5
E: BN/RD
E: 2701
F: F
F: BN/BU
F: 486
F: 0.5
Function
Terminal Type
ID
Option
A: I
A: -
B: I
B: -
C: I
C: -
D: I
D: -
E: I
E: -
F: I
F: -
A: Throttle Actuator
Control Close
B: Throttle Actuator
Control Open
C: Throttle Position Sensor
Low Reference
D: Throttle Position Sensor
Signal (1)
E: 5 Volt Reference
F: Throttle Position Sensor
Signal (2)
Q40 TURBOCHARGER BYPASS SOLENOID VALVE (LUV)

Description: 2-Way F 2.8 Junior Power Timer Series, Sealed (BK)

Terminal
Type ID
Lead
Test Probe
13575438
Terminal
Removal
Tool
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
16
J-35616-35
J-38125-36 4-964286-1
(VT)
Q40 Turbocharger Bypass Solenoid Valve (LUV)

Pin
Size
Color
Circuit
1: 1
1: 0.5
1: BN/WH
1: 3060
2: 2
2: 0.5
2: RD/WH
2: 5293
Function
1: Turbo Bypass Solenoid
Control Bank (1)
Fused Supply (4)
Q42 TURBOCHARGER WASTEGATE SOLENOID VALVE (LUV)
Terminal Type
ID
Option
1: I
1: -
2: I
2: -



Terminal
Type ID
Lead
Test Probe
13575438
Terminal
Removal
Tool
Service
Terminal
J-35616-35
J-38125-36 4-964286-1
(VT)
Tray
Core
Crimp
Insulation
Crimp
16
Q42 Turbocharger Wastegate Solenoid Valve (LUV)

Pin
Size
Color
Circuit
1: 1 1: 0.75
1: BN/RD
1: 3058
2: 2 2: 0.75
2: RD/WH
2: 5293
Function
Terminal Type
ID
Option
1: I
1: -
2: I
2: -
1: Turbo Waste Gate

Solenoid Control Bank (1)
Fused Supply (4)
Q46 A/C COMPRESSOR SOLENOID VALVE

Description: 2-Way F 1.2 MCP Series, Sealed (BK with NA Inner Connector)

Type ID
Lead
Test Probe
I
Pending
Pending
Terminal
Removal
Tool
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
Pending
Not
Not
Pending
Pending

Available
Available
Q46 A/C Compressor Solenoid Valve

Pin
Size
Color
Circuit
1: 1 1: 0.50
1: BU/BN
1: 7573
2: 2 2: 0.50
2: BU/YE
2: 7574
Function
Terminal Type
ID
Option
1: I
1: -
2: I
2: -
Displacement Supply
S2 TRANSMISSION MANUAL SHIFT SWITCH (MH8)
Harness Type: Shift Lever

Service Connector: Service By Component - See Part Catalog
Description: 4-Way F (WH)

Type ID
Lead
Test Probe
Service By
Not
Component Available
See Part
Catalog
Terminal
Removal
Tool
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
Service By Service By
Not
Not
Not
Component - Component Available
Available Available
See Part
See Part
Catalog
Catalog
S2 Transmission Manual Shift Switch (MH8)

Pin
Size
Color
Circuit
1: 1
1: VT/WH
1: VT/WH
1: -
2: 2
2: BK
2: BK
2: -
3: 3
3: RD/WH
3: RD/WH
3: -
4: 4
4: BK
4: BK
4: -
S3 TRANSMISSION SHIFT LEVER (MH8)
Function
1: Battery Positive
Voltage
Control
Soft Control
4: Ground
Terminal Type
ID
Option
1: I
1: -
2: I
2: -
3: I
3: -
4: I
4: -



Type ID
Lead
Test Probe
Terminal
Removal
Tool
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
Service by
J-35616-64B
Connector
(L-BU)
Assembly
J-38125215A
Pending
Pending
Pending
Pending
S3 Transmission Shift Lever (MH8)

Pin
Size
Color
Circuit
1: 1
2: 2
1: 0.5
2: 0.5
1: RD/BN
2: BK
1: 202
2: 2150
3: 3
3: 0.5
3: YE
3: 7554
4: 4
4: 0.5
4: VT/BK
4: 7553
6: 6
6: 0.5
6: WH/VT
6: 5905
S13D DOOR LOCK SWITCH - DRIVER

Terminal Type
ID
1: I
2: Ground
2: I
3: Park Lock Solenoid Soft
3: I
Control
4: I
Control
Not Occupied
6: I
Function
Option
1: 2: 3: 4: 6: -


Terminal
Type ID
Terminal
Removal
Tool
J-35616-64B J-3812513575782
(L-BU)
12A
Lead
Test Probe
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
928999-5
15
S13D Door Lock Switch - Driver

Pin
Size
Color
Circuit
Function
1: 1
1: 0.5
1: BK
1: 50
2: 2
2: 0.5
2: YE
2: 6817
3: 3
3: 0.5
3: BN/WH
3: 781
4: 4
4: 0.5
4: BN/YE
4: 780
1: Ground
2: LED Backlight
Dimming Control
3: Driver Door Lock
4: Driver Door Lock
Switch Lock Signal
Terminal Type
ID
1: I
Option
1: -
2: I
2: -
3: I
3: -
4: I
4: -
S26 HAZARD LAMPS SWITCH

Description: 4-Way F (BU)

Terminal
Type ID
I
Terminal
Removal
Tool
J-35616-64B J-3812513575782
(L-BU)
12A
Lead
Test Probe
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
928999-5
15
S26 Hazard Lamps Switch

Pin
Size
Color
Circuit
Function
1: 1 1: 0.35 1: D-GN/WH
1: 111
2: 2 2: 0.35 2: L-BU/VT
2: 1717

Flasher Control
Terminal Type
ID
1: I
2: I
Option
1: 2: -

3: 3
4
3: 0.5
-
3: BK
-
3: 50
-
3: Ground
Not Occupied
3: I
-
3: -
S30 HEADLAMP SWITCH

Description: 12-Way F Micro HVT (BK)

Terminal
Type ID
Lead
Test Probe
13575550
Terminal
Removal
Tool
J-35616-16
J-38125-559
(L-GN)
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
15445905
23
S30 Headlamp Switch

Pin
Size
Color
Circuit
1: 1
1: 0.5
1: YE
1: 7556
3: 3 3: 0.35 3: D-GN/GY
3: 13
4: 4 4: 0.35
4: 103
4: WH/VT
5: 5 5: 0.35 5: D-GN/BN
5: 306
6: 6
6: 0.5
6: BK
6: 1650
7: 7
7: 0.5
7: YE
7: 6817
8-11
12: 12 12: 0.5 12: WH/BN

A26 HVAC CONTROLS
12: 7555
Function
Reference
Not Occupied
3: Headlamp Switch Park
Lamp Signal
Signal
5: Headlamp Switch
Control
6: Ground
7: LED Backlight
Dimming Control
Not Occupied
12: Lighting Control
Switch Signal
Terminal Type
ID
Option
1: I
1: -
3: I
3: -
4: I
4: -
5: I
5: -
6: I
6: -
7: I
7: -
12: I
12: -



Terminal
Type ID
Lead
Test Probe
13579977
Terminal
Removal
Tool
Service
Terminal
J-35616-64B
J-38125-553 1393366-1
(L-BU)
Tray
Core
Crimp
Insulation
Crimp
16
A26 HVAC Controls

Pin
1: 1
Size
Color
1: 0.5 1: L-GN/YE
2: 2 2: 0.75
3: 3 3: 0.75
4-6
-
2: BK
3: RD/YE
-
Circuit
1: 7531
2: 1650
3: 240
-
Function
Terminal Type
ID
Option
1: I
1: -
2: I
3: I
-
2: 3: -
Network Bus 9
2: Ground
Not Occupied
S38 IGNTION MODE SWITCH (BTM)


Terminal
Type ID
Lead
Test Probe
Terminal
Removal
Tool
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp

13579976
J-35616-64B
J-38125-21
(L-BU)
15359541
S38 Igntion Mode Switch (BTM)

Pin
Size
Color
Circuit
Function
2: 2
2: 0.5
2: BN/BK
2: 5720
3: 3
3: 0.5 3: D-GN/BK
3: 3558
4: 4
4: 0.5
4: 1650
5: 5
5: 0.5 5: D-BU/BK
5: 5719
6: 6
6: 0.5
6: D-BU/DGN
6: 5723
7: 7
7: 0.5
7: BK/GY
7: 3559
8: 8
8: 0.5
8: YE
8: 6817
Not Occupied
2: Ignition Mode Switch
Accessory LED Signal
Signal 2
4: Ground
Start LED Signal
Mode Voltage
Low Reference
8: LED Backlight Dimming
Control
4: BK
Terminal Type
ID
-
Option
-
2: I
2: -
3: I
3: -
4: I
4: -
5: I
5: -
6: I
6: -
7: I
7: -
8: I
8: -
S39 IGNITION SWITCH

Description: 6-Way F 1.2 HCM Series (NA)

Terminal
Type ID
I
Terminal
Removal
Tool
J-35616-64B J-3812513575868
(L-BU)
12A
Lead
Test Probe
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
SHCMA03T-P025
20
S39 Ignition Switch

Pin
Size
Color
Circuit
Function
Terminal Type
ID
Option

1: 1
1: 0.5
1: VT/BK
1: 3
2: 2
3: 3
4: 4
5
2: 0.5
3: 0.5
4: 0.5
-
2: RD/VT
3: VT/YE
4: WH/VT
-
2: 340
3: 4
4: 1020
-
6: 6
6: 0.5
6: WH/BK
6: 1073
Voltage
3: Accessory Voltage
4: Off/Run/Crank Voltage
Not Occupied
Signal
1: I
1: -
2: I
3: I
4: I
-
2: 3: 4: -
6: I
6: -
S52 OUTSIDE REARVIEW MIRROR SWITCH


Terminal
Type ID
Terminal
Service
Removal
Terminal
Tool
J-35616-64B J-38125- SAIT-A03T13575867
(L-BU)
215A
M064
Lead
Test Probe
Tray
Core
Crimp
Insulation
Crimp
14
S52 Outside Rearview Mirror Switch

Pin
Size
Color
Circuit
1: 1
1: 0.5 1: VT/D-BU
1: 3390
2: 2
2: 0.5
2: YE/BN
2: 3391
3: 3
3: 0.5
3: BN/BK
3: 3389
4: 4
5: 5
4: 0.5
5: 0.5
4: RD/GY
5: BK
4: 2840
5: 50
7: 7
7: 0.5
7: YE/VT
7: 3397
8: 8
8: 0.5
8: WH
8: 3398
Function
1: Driver Mirror Motor Up
2: Driver Mirror Motor
Common Control
5: Ground
7: Co-Driver Mirror Motor
Common Control
Terminal Type
ID
Option
1: I
1: -
2: I
2: -
3: I
3: -
4: I
5: I
4: 5: -
7: I
7: -
8: I
8: -

9: 9
9: 0.5 9: D-GN/BK
10: 10 10: 0.5

11-12

10: LED Backlight
Dimming Control
Not Occupied
9: 3396
10: YE
10: 6817
9: I
9: -
10: I
10: -
S64D SEAT ADJUSTER SWITCH - DRIVER (ADS)


Terminal
Type ID
Lead
Test Probe
13575756
Terminal
Removal
Tool
J-35616-4A
J-38125-553
(PU)
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
15304713
19
S64D Seat Adjuster Switch - Driver (ADS)

Pin
Size
Color
Circuit
A: D-BU
A: 286
B: 1.5
B: BK
B: 2150
C: C C: 1.5
C: YE
C: 285
D: D D: 1.5
D: RD
D: 702
E: E
E: 1.5
E: WH
E: 282
F: F
F: 1.5
F: BN
F: 284
A: A A: 1.5
B: B
G: G G: 1.5 G: D-GN
G: 283
Function
A: Driver Power Seat Front
B: Ground
C: Driver Power Seat
Control
D: Battery Positive Voltage
E: Driver Power Seat Rear
F: Driver Power Seat
Control
G: Driver Power Seat Rear
Vertical Motor Down
Control
Terminal Type
ID
Option
A: I
A: -
B: I
B: -
C: I
C: -
D: I
D: -
E: I
E: -
F: I
F: -
G: I
G: -

H: H H: 1.5
H: GY
H: Driver Power Seat Front

Vertical Motor Down
Control
H: 287
H: I
H: -
S70L STEERING WHEEL CONTROLS SWITCH - LEFT (K34)
Harness Type: Steering Wheel

OEM Connector: AIT2PB-7-1FS
Description: 7-way F (WH)

Terminal
Removal
Tool
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
Service by
Not
See Parts
(L-BU)
Available
Catalog
Service by
Harness See Parts
Catalog
Service by
Harness See Parts
Catalog
Not
Available
Not
Available

Type ID
Lead
Test Probe
S70L Steering Wheel Controls Switch - Left (K34)

Pin Size
1: 1
2
3: 3
4-5
Color
1:
1: WH/RD
0.35
3:
0.35
6:
6: 6
0.35
7:
7: 7
0.35
Circuit
Function
Terminal
Type ID
Option
1: 1444
1: I
1: -
3: I
3: -
3: BN/DGN
3: 1884
Not Occupied
3: Cruise Control
Set/Coast/Resume/Accelerate Switch
Signal
Not Occupied
6: YE
6: 6817
6: LED Backlight Dimming Control
6: I
6: -
7: BK
7: 1650
7: Ground
7: I
7: -
S70R STEERING WHEEL CONTROLS SWITCH - RIGHT (W1Y)


OEM Connector: AIT2PB-6-1AK

Terminal
Removal
Tool
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
Service by
Not
See Parts
(L-BU)
Available
Catalog
Service by
Harness See Parts
Catalog
Service by
Harness See Parts
Catalog
Not
Available
Not
Available

Type ID
Lead
Test Probe
S70R Steering Wheel Controls Switch - Right (W1Y)

Pin
Size
Color
Circuit
Function
1: 1
1: 0.5
1: WH/RD
1: 1444
2: 2
2: 0.5 2: D-GN/WH
1: 12V Reference
Ladder Signal #2
Not Occupied
4: LED Backlight
Dimming Control
5: Ground
Not Occupied
2: 6819
4: 4
4: 0.5
4: YE
4: 6817
5: 5
6
5: 0.5
-
5: BK
-
5: 50
-
S72 SUNROOF SWITCH (CF5)

Terminal Type
ID
1: I
Option
1: -
2: I
2: -
4: I
4: -
5: I
-
5: -


Terminal
Type ID
Terminal
Removal
Tool
J-35616-64B J-3812513575782
(L-BU)
12A
Lead
Test Probe
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
928999-5
15
S72 Sunroof Switch (CF5)

Pin
Size
Color
Circuit
1: 1
1: 0.5
1: BK/GY
1: 128
2: 2
2: 0.5
2: YE
2: 6817
3: 3
4: 4
3: 0.5
3: BK
4: 0.5 4: D-BU/VT
3: 50
4: 5027
Function
Terminal Type
ID
Option
1: I
1: -
2: I
2: -
3: I
4: I
3: 4: -

Reference
Control
3: Ground
S75 TRACTION CONTROL SWITCH (FX3)

Description: 6-Way F 0.64 MTS Series (BK)

Terminal
Type ID
I
Terminal
Removal
Tool
J-35616-64B J-3812513575782
(L-BU)
12A
Lead
Test Probe
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
928999-5
15
S75 Traction Control Switch (FX3)

Pin
Size
Color
Circuit
Function
1
2
Not Occupied
Not Occupied
3: 6817
3: Cruise Control
3: 3 3: 0.5 3: YE
Terminal
Type ID
3: I
Option
3: -

Signal
4: 0.5 4: BK
4: 4
4: 0.5 4: BK
5-6
4: 1750
4: 1650
4: Ground
4: Ground
4: I
Not Occupied
4: MF3 or
MZ0
4: MH8
-
S78 TURN SIGNAL/MULTI-FUNCTION SWITCH


Terminal
Type ID
Terminal
Service
Removal
Terminal
Tool
J-35616-64B J-38125SNAC313575870
(L-BU)
12A
A021T-M064
Lead
Test Probe
Tray
Core
Crimp
Insulation
Crimp
20
S78 Turn Signal/Multi-Function Switch

Pin
Size
Color
Circuit
1: 1
1: 0.5 1: WH/L-GN
1: 663
2: 2
2: 0.5
2: WH
2: 524
3: 3
3: 0.5
3: BK
3: 1650
4: 4
4: 0.5
4: YE/BN
4: 307
5: 5 5: 0.35 5: GY/L-BU
5: 893
6: 6 6: 0.35
6: BK/BN
6: 897
7: VT/D-BU
7: 664
7: 7
7: 0.5
Function
1: Hazard Switch Left Turn
Signal
2: Headlamp Dimmer
3: Ground
To Pass Signal
Signal
Center Switch Low
Reference
Turn Signal
Terminal Type
ID
Option
1: I
1: -
2: I
2: -
3: I
3: -
4: I
4: -
5: I
5: -
6: I
6: -
7: I
7: -

8-11
12:
12: 12
12: D-GN/WH
0.35
Not Occupied
12: 1358
12: I
12: -
S79D WINDOW SWITCH - DRIVER (AEC)


Type ID
Lead
Test Probe
Terminal
Removal
Tool
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
Service by
Harness See Part
Catalog
Pending
Not
Available
Not
Available
Not
Available
Not
Available
Pending
S79D Window Switch - Driver (AEC)

Pin
Size
Color
Circuit
Function
1: 1
1: 2.5
1: BK
1: 2050
2: 2
2: 0.5 2: D-GN/GY
2: 3382
3: 3
3: 0.5
3: 3383
4: 4
4: 2.5 4: RD/D-GN
4: 1540
5: 5
5: 0.5 5: D-GN/YE
5: 6134
6: 6
6: 0.5
6: GY
6: 745
7: 7
7: 0.5
7: WH/VT
7: 3270
1: Ground
2: Power Window Motor
Driver Up Control
Driver Down Control
Network Bus 3
Switch Signal
Status Control
Not Occupied
3: YE/VT
S79D WINDOW SWITCH - DRIVER (AXG)
Terminal Type
ID
1: I
Option
1: -
2: I
2: -
3: I
3: -
4: I
4: -
5: I
5: -
6: I
6: -
7: I
7: -



Terminal
Type ID
Terminal
Removal
Tool
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
J-35616-64B
J-38125-21
(L-BU)
15359541
Lead
Test Probe
13579976
S79D Window Switch - Driver (AXG)

Pin
Size
Color
Circuit
Function
1: 1
1: 0.5
1: BK
1: 1550
2: 2
2: 0.5
2: D-GN
2: 3381
3: 3
3: 0.5
3: GY
3: 3380
4: 4
4: 0.5
4: RD/D-GN
4: 1540
5: 5
5: 0.5
5: D-GN/YE
5: 6134
6: 6
6: 0.5 6: D-GN/WH
6: 3379
7: 7
7: 0.5
7: WH/VT
7: 3270
1: Ground
Driver Down Signal
Network Bus 3
Driver Up Signal
Status Control
Not Occupied
S79LR WINDOW SWITCH - LEFT REAR
Terminal Type
ID
1: I
Option
1: -
2: I
2: -
3: I
3: -
4: I
4: -
5: I
5: -
6: I
6: -
7: I
7: -



Type ID
Lead
Test Probe
Terminal
Removal
Tool
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
Service by
Connector
Assembly
Not
Available
Not
Available
Not
Available
Not
Available
Not
Available
J-35616-35
(VT)
S79LR Window Switch - Left Rear

Pin
Size
Color
Circuit
1: 1
1: 0.5 1: D-GN/GY
1: 6135
2: 2
2: 0.5
2: GY
2: 747
3: 3
4
5: 5
3: 0.5
5: 2.5
3: BK
5: BK
3: 2350
5: 2350
6: 6
6: 2.5 6: D-BU/GY
6: 668
7: 7
7: 2.5 7: D-GN/BK
7: 669
8: 8
8: 2.5
8: 2940
8: RD/BN
Function
Network Bus 4
Switch Signal
3: Ground
Not Occupied
5: Ground
Terminal Type
ID
Option
1: I
1: -
2: I
2: -
3: I
5: I
3: 5: -
6: I
6: -
7: I
7: -
8: I
8: -
S79P WINDOW SWITCH - PASSENGER


Terminal
Service
Core
Insulation

Type ID
Lead
Test Probe
Removal
Tool
Terminal
Service by
Connector
Assembly
J-35616-35
(VT)
Not
Available
Not
Available
Crimp
Crimp
Not
Available
Not
Available
Tray
Not
Available
S79P Window Switch - Passenger

Pin
Size
Color
Circuit
Function
1: 1
1: 2.5
1: BK
1: 2050
2: 2
2: 2.5 2: D-GN/GY
2: 3387
3: 3
3: 2.5 3: YE/D-BU
3: 3388
4: 4
4: 2.5 4: RD/D-GN
4: 1540
5: 5
5: 0.5 5: D-GN/YE
5: 6134
6: 6
6: 0.5
6: GY
6: 746
7-8
1: Ground
Network Bus 3
Switch Signal
Not Occupied
Terminal Type
ID
1: I
Option
1: -
2: I
2: -
3: I
3: -
4: I
4: -
5: I
5: -
6: I
6: -
S79RR WINDOW SWITCH - RIGHT REAR


Type ID
Lead
Test Probe
Terminal
Removal
Tool
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
Service by
Connector
Assembly
15315247
Not
Available
Not
Available
Not
Available
Not
Available
J-35616-35
(VT)
S79RR Window Switch - Right Rear

Pin
Size
Color
Circuit
Function
Terminal Type
Option

ID
1: 1
1: 0.5
1: D-GN/GY
1: 6135
2: 2
2: 0.5
2: GY
2: 748
3-4
5: 5
5: 2.5
5: BK
5: 2350
6: 6
6: 2.5
6: D-BU/GY
6: 670
7: 7
7: 2.5 7: D-GN/BKk
7: 671
8: 8
8: 2.5
8: 2940
8: RD/BN
Network Bus 4
Switch Signal
Not Occupied
5: Ground
1: I
1: -
2: I
2: -
5: I
5: -
6: I
6: -
7: I
7: -
8: I
8: -
S82 WINDSHIELD WIPER/WASHER SWITCH

Description: 8-Way F 1.2 HCM Series (BK)

Terminal
Type ID
Terminal
Removal
Tool
J-35616-64B J-3812513575868
(L-BU)
12A
Lead
Test Probe
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
SHCMA03T-P025
20
S82 Windshield Wiper/Washer Switch

Pin
Size
Color
Circuit
1: 1
1: 0.5
1: GY
1: 1715
2: 2
2: 0.5
2: BK/GY
2: 6009
3: 3
3: 0.5
3: YE/D-BU
3: 1714
Function
1: Windshield Wiper
Switch High Signal
2: Windshield Wiper
3: Windshield Wiper
Switch Low Signal
Not Occupied
Terminal Type
ID
Option
1: I
1: -
2: I
2: -
3: I
3: -

5: 5
6-8
5: 0.5
-
5: WH/BK
-
5: 94
-
Switch Signal
Not Occupied
5: I
-
5: -
S88 SUNROOF TILT SWITCH (CF5)

Description: 4-Way F 0.64 Micro Quadlok Series (WH)

Terminal
Type ID
Terminal
Removal
Tool
J-35616-64B J-3812513575782
(L-BU)
12A
Lead
Test Probe
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
928999-5
15
S88 Sunroof Tilt Switch (CF5)

Pin
Size
Color
Circuit
1: 1
1: 0.5
1: BK/BN
1: 128
2: 2
2: 0.5
2: YE
2: 6817
3: 3
3: 0.5
3: BK
3: 50
4: 4
4: 0.5 4: WH/D-GN
4: 3031
T3 AUDIO AMPLIFIER X1 (UQA)
Harness Type: Body

Function
Reference
Control
3: Ground
Signal
Terminal Type
ID
Option
1: I
1: -
2: I
2: -
3: I
3: -
4: I
4: -



Terminal
Type ID
Lead
Test Probe
13575578
II
13575577
Terminal
Removal
Tool
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
22
22
J-35616-35
J-38125-553 8100-4444
(VT)
J-35616-35
J-38125-553 8100-4445
(VT)
T3 Audio Amplifier X1 (UQA)

Pin
Size
Color
Circuit
1: 1
1: 1
1: L-GN/VT
1: 1795
2: 2
2: 1
2: D-GN/BK
2: 1794
3: 3
3: 1
3: D-BU/GY
3: 346
4: 4
4: 2.5
4: RD/WH
4: 1040
5: 5
5: 1
5: GY/BK
5: 315
6-7
8: 8
8: 2.5
8: BK
8: 450
Function
Terminal Type
ID
Option
1: I
1: -
2: I
2: -
3: I
3: -
4: II
4: -
5: I
5: -
8: II
8: -
1: Right Subwoofer
Speaker (+)
Speaker (-)
Speaker (+)
5: Right Subwoofer
Speaker (-)
Not Occupied
8: Ground
Harness Type: Body


Terminal
Type ID
Lead
Test Probe
Terminal
Removal
Tool
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp

13327201
J-35616-2A
J-38125-553 8240-0128
(GY)
22

Pin
Size
1: 1 1: 0.75
Color
Circuit
1: D-BU
1: 201
2: 2 2: 0.75 2: BN/D-BU
2: 118
3: 3 3: 0.75
3: 199
3: D-GN
4: 4 4: 0.75 4: D-GN/BK
4: 116
5-6
7: 7 7: 0.75 7: YE/WH
8: 8 8: 0.75 8: D-BU/YE
7: 1860
8: 1960
9: 9 9: 0.75 9: D-BU/BK
9: 115
10:
0.75
11:
11: 11
0.75
12:
12: 12
0.75
13-16
10: 10
10: WH
10: 46
11: YE
11: 200
12: YE/BK
12: 117
Function
Terminal Type
ID
Option
1: I
1: -
2: I
2: -
3: I
3: -
4: I
4: -
7: I
8: I
7: 8: -
9: I
9: -
10: I
10: -
11: I
11: -
12: I
12: -

(1)
Signal (-) (1)
(-)
Not Occupied
Signal (-)
(1)
Signal (-) (1)
Not Occupied
Harness Type: Body

Description: 16-Way F Micro-Pack 064 Series (BK)

Terminal
Type ID
Lead
Test Probe
J-35616-64B
Terminal
Removal
Tool
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp

13575528
(L-BU)
J-38125-21
15359541

Pin
Size
Color
Circuit
1: 1 1: 0.35 1: D-GN/BK
1: 599
2: 2 2: 0.35
2: 1999
2: BN/VT
3: 3 3: 0.35 3: D-BU/BK
3: 1946
4: 4 4: 0.35
4: BN/WH
4: 546
5-7
8: 8 8: 0.35 8: D-GN/YE
8: 7066
9: 9 9: 0.35
9: 512
10: 10
11: 11
12: 12
13-15
16: 16
9: YE
10:
10: D-BU/BN
0.35
11:
11: BN/D-BU
0.35
12:
12: D-BU
0.35
16: 0.5 16: VT/D-BU
10: 1546
11: 1947
12: 511
16: 6978
Function
Terminal Type
ID
Option
1: I
1: -
2: I
2: -
3: I
3: -
4: I
4: -
8: I
8: -
9: I
9: -
10: I
10: -
11: I
11: -
12: I
12: -
16: I
16: -

Audio Signal
Audio (-)
Audio (-)
Audio Signal
Not Occupied
Enable Signal
Audio Signal
10: Front Low Level Audio
(-)
Audio (-)
Audio Signal
Not Occupied
T10E KEYLESS ENTRY ANTENNA - REAR COMPARTMENT (ATH)
Harness: Body
OEM: 24414929
Service: 24414929
Description: 4-Way F 64 MQS Series (GY)

Terminal Type
Terminated Lead
ID

Part Catalog
J-35616-65B (L-BU)
J-38125-215A
T10E Keyless Entry Antenna - Rear Compartment (ATH)

Pin
Size
Color
Circuit
1: 1
1: 0.5
1: WH/DGN
1: 3556
2: 2
2: 0.5
2: D-GN
2: 3557
3-4
Function
Antenna 3 Signal Hi
Antenna 3 Signal Lo
Not Occupied
Terminal Type
ID
Option
1: I
1: -
2: I
2: -
T10G KEYLESS ENTRY ANTENNA - REAR FASCIA (ATH)
Harness: Body
OEM: 24461693

Terminal Type
Terminated Lead
ID
I
13575569
J-35616-65B (L-BU)
J-38125-12A
T10G Keyless Entry Antenna - Rear Fascia (ATH)

Pin
Size
Color
Circuit
1: 1
1: 0.5 1: BN/D-GN
1: 3568
2: 2
2: 0.5 2: D-GN/GY
2: 3569
Function
Terminal Type
ID
Option
1: I
1: -
2: I
2: -
T10J KEYLESS ENTRY ANTENNA - CENTER CONSOLE FRONT (ATH)

Harness: Console
OEM: 24461693

Terminal Type
Terminated Lead
ID
Service by Harness- See
I
Part Catalog
J-35616-14 (GN)
J-38125-560
T10J Keyless Entry Antenna - Center Console Front (ATH)

Pin
Size
Color
Circuit
1: 1
1: 0.5
1: BN/BK
1: 3552
2: 2
2: 0.5
2: WH
2: 3553
Function
Antenna 1 Signal Hi
Antenna 1 Signal Lo
Terminal Type
ID
Option
1: I
1: -
2: I
2: -
T10K KEYLESS ENTRY ANTENNA - CENTER CONSOLE REAR (ATH)


Terminal Type
Terminated Lead
ID
I
13576395
J-35616-64B (L-BU)
J-38125-12A
T10K Keyless Entry Antenna - Center Console Rear (ATH)

Pin
Size
Color
Circuit
Function
Terminal Type
ID
Option
1: 1
1: 0.5
1: D-BU
1: 3554

Antenna 2 Signal Hi
1: I
1: -
2: 2
2: 0.5
2: GY/BK
2: 3555
2: I
2: -

Antenna 2 Signal Lo
T10M KEYLESS ENTRY ANTENNA - DRIVER DOOR HANDLE (ATH)
Harness: Driver Door

OEM: 19153433

Terminal Type
Terminated Lead
ID
I
Part Catalog
J-35616-14 (GN)
J-38125-560
T10M Keyless Entry Antenna - Driver Door Handle (ATH)

Pin
Size
Color
Circuit
1: 1
1: 0.5
1: VT
1: 3560
2: 2
2: 0.5
2: VT/GY
2: 3561
3: 3
3: 0.5
3: GN/WH
3: 6655
4: 4
4: 0.5
4: BK
4: 350
Function
Switch Signal
4: Ground
Terminal Type
ID
Option
1: I
1: -
2: I
2: -
3: I
3: -
4: I
4: -
T10N KEYLESS ENTRY ANTENNA - PASSENGER DOOR HANDLE (ATH)
Harness: Passenger Door

OEM: 19153433


Terminal Type
Terminated Lead
ID
I
Part Catalog
J-35616-14 (GN)
J-38125-560
T10N Keyless Entry Antenna - Passenger Door Handle (ATH)

Pin
Size
Color
Circuit
1: 1
1: 0.5
1: GN/YE
1: 3562
2: 2
2: 0.5 2: D-GN/BK
3: 3 3: 0.75
4: 4
4: 0.5
Function
3: 3576
4: BK
4: 350
Option
1: I
1: -
2: I
2: -
3: I
3: -
4: I
4: -
1: Passive Entry Co-Driver

Switch Lock Signal
4: Ground
2: 3563
3: GY/BU
Terminal Type
ID
T11 MULTIMEDIA PLAYER INTERFACE MODULE (KTA)


Type ID
Lead
Test Probe
I
13579944
Pending
Terminal
Removal
Tool
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
Pending
Not
Available
Not
Available
Not
Available
Not
Available
T11 Multimedia Player Interface Module (KTA)

Pin
Size
Color
Circuit
Function
Terminal Type
ID
Option
1: 1
1: 0.5
1: RD/DGN
1: 3140
1: I
1: -
2: 2
2: 0.35
2: D-BU
2: 2060
Signal
2: I
2: -

3: 3
3: 0.35
3: VT
3: 5843
4: 4
4: 0.35
4: D-GN
4: 3376
5: 5
5: 0.35
5: BARE
5: 3375
6-7
8: 8
8: 0.5
8: D-GN
8: 5060
9-10
11: 11 11: 0.5 11: BK
12:
12: 12
12: GY
0.35
13:
13: 13
13: D-GN
0.35
14:
14: 14
14: VT
0.35
15:
15: 15
15: BN
0.35
16-17
18:
18: 18
18: BARE
0.35
19-20
-
11: 1750
12: 5839
13: 5841
14: 3377
15: 3378
18: 5842
-
3: Auxiliary Audio
Common Signal
4: Auxiliary Audio
Common Signal (3)
5: Auxiliary Audio Drain
Wire (3)
Not Occupied
8: Low Speed GMLAN
Serial Data
Not Occupied
11: Ground
Signal (2)
Signal (2)
Signal (3)
Signal (3)
Not Occupied
18: Auxiliary Audio Screen
(2)
Not Occupied
3: I
3: -
4: I
4: -
5: I
5: -
8: I
8: -
11: I
11: -
12: I
12: -
13: I
13: -
14: I
14: -
15: I
15: -
18: I
18: -
X80L ACCESSORY POWER RECEPTACLE - REAR CONSOLE


Terminal
Type ID
I
Lead
Test Probe
13575721
Terminal
Removal
Tool
J-35616-4A
J-38125-553
(PU)
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
12110844

X80L Accessory Power Receptacle - Rear Console

Pin
Size
Color
Circuit
A: A A: 1.0
A: VT
A: 801
B
C: C C: 1.0
C: BK
C: 2150
Function
Terminal Type
ID
Option
A: I
A: -
C: I
C: -
Not Occupied
C: Ground
X83 AUXILIARY AUDIO INPUT


Terminal
Type ID
Terminal
Removal
Tool
J-35616-64B J-3812513575782
(L-BU)
12A
Lead
Test Probe
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
928999-5
15
X83 Auxiliary Audio Input

Pin
Size
Color
Circuit
1: 1
1: 0.35
1: D-BU
1: 2060
2: 2
2: 0.35
2: GY
2: 5839
3: 3
3: 0.35
3: BARE
3: 5842
4: 4
4: 0.35
4: L-GN
4: 5841
5: 5
5: 0.35
5: VT
5: 5843
X84 DATA LINK CONNECTOR
Function
Signal
Signal (2)
(2)
Signal (2)
5: Auxiliary Audio
Common Signal
Terminal Type
ID
Option
1: I
1: -
2: I
2: -
3: I
3: -
4: I
4: -
5: I
5: -


Description: 16-Way F Metri-Pack/150 Series (BK)

Terminal
Type ID
Lead
Test Probe
13575725
J-35616-14
(GN)
Terminal
Removal
Tool
J-3812512A
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
12129484
19
X84 Data Link Connector

Pin
Size
Color
Circuit
1: 1
1: 0.5
1: L-GN
1: 5060
2-3
4: 4
5: 5
4: 0.5
5: 0.5
4: BK
5: BK
4: 2150
5: 2150
6: 6
6: 0.5
6: D-BU
6: 2500
7: 7
7: 0.5
7: BN/WH
7: 5043
8-11
12: 12 12: 0.5 12: D-BU/YE
12: 6105
13: 13 13: 0.5
13: WH
13: 6106
14: 14 14: 0.5
14: WH
14: 2501
15
16: 16
16: 0.5 16: RD/D-BU

16: 0.5 16: RD/D-BU
16: 540
16: 540
Function
1: Low Speed GMLAN
Serial Data
Not Occupied
4: Ground
5: Ground
6: High Speed GMLAN
Serial Data (+) (1)
7: Keyword 2000 Serial
Data
Not Occupied
Serial Data (+) (2)
Serial Data (-) (2)
Serial Data (-) (1)
Not Occupied
Voltage
Voltage
X85 STEERING WHEEL AIR BAG COIL X1
Terminal Type
ID
Option
1: I
1: -
4: I
5: I
4: 5: -
6: I
6: -
7: I
7: -
12: I
12: -
13: I
13: -
14: I
14: -
16: I
16: -



Terminal
Type ID
Terminal
Service
Removal
Terminal
Tool
J-35616-64B J-38125- SAIT-A03T13575867
(L-BU)
215A
M064
Lead
Test Probe
Tray
Core
Crimp
Insulation
Crimp
14
X85 Steering Wheel Air Bag Coil X1

Pin
Size
Color
Circuit
Function
2: Ground
Gap Up/Down Switch
Signal
Ladder Signal 2
6: LED Backlight
Dimming Control
Not Occupied
1: 1
2: 2
1: 0.5 1: L-GN/WH
2: 0.5
2: BK
1: 3287
2: 50
3: 3
3: 0.5
3: GY/D-GN
3: 5737
4: 4
4: 0.5 4: L-GN/WH
4: 6819
5: 5
5: 0.5
5: WH/RD
5: 1444
6: 6
6: 0.5
6: YE
6: 6817
7-10

Terminal Type
ID
1: I
2: I
Option
1: 2: -
3: I
3: -
4: I
4: -
5: I
5: -
6: I
6: -

Description: 4-Way F Micro-Pack 064 Series (YE)

Terminal
Removal
Tool
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
Service by
Not
(L-BU)
Available
Assembly 13580115
Not
Available
Not
Available
Not
Available
Not
Available

Type ID
Lead
Test Probe

Pin
Size
Color
Circuit
1: 1
1: 0.5
1: OG/VT
1: 3021
2: 2
2: 0.5
2: BN/OG
2: 3020
3: 3
3: 0.5 3: OG/D-GN
4: 4
4: 0.5
4: WH/DGN
3: 3023
4: 3022
Function
Stage 1 Low Control
Stage 2 Low Control
Terminal Type
ID
Option
1: I
1: -
2: I
2: 3: Early
Production
4: Early
Production
3: I
4: I


Terminal
Type ID
I
Terminal
Service
Removal
Terminal
Tool
J-35616-64B J-38125- SAIT-A03T13575867
(L-BU)
215A
M064
Lead
Test Probe
Tray
Core
Crimp
Insulation
Crimp
14

Pin Size
Color
1-4
5: 5 5: 0.5
5: YE
6: 6 6: 0.5 6: WH/RD
7: D7: 7 7: 0.5
GN/WH
8: 8 8: 0.5
8: BN/DGN
Circuit
Function
5: 6817
6: 1444
Not Occupied
7: Steering Wheel Resistor Ladder Signal
2
8: Cruise Control
Signal
9: Ground
7: 6819
8: 1884
9: 9 9: 0.5
9: BK
9: 50
10: 10:
10: BN/WH 10: 3287
10 0.5
Terminal
Type ID
5: I
6: I
Option
5: 6: -
7: I
7: -
8: I
8: -
9: I
9: -
10: I
10: -

2013 ELECTRICAL
Views - Cruze



Type ID
Lead
Test Probe
Terminal
Removal
Tool
13579944
Pending
Pending
II
Pending
Pending
Pending
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
Not
Available
Not
Available
Not
Available
Not
Available
Not
Available
Not
Available
Not
Available
Not
Available

Pin
Size
Color
Circuit
1: 1
2: 2
3
1: 0.5
2: 0.5
-
1: RD/GN
2: BK
-
1: 3140
2: 1750
-
4: GY
4: 3369
4: 4 4: 0.35
5: 5
5: 0.5
5: BN/GN
5: 3364
6: 6
6: 0.5
6: GN/YE
6: 7066
7: 7 7: 0.35
7: BARE
7: 3368
8: VT
8: 3370
8: 8
8: 0.5
Terminal Type
ID
1: 2: Ground
2: Not Occupied
4: II
Signal (+)
5: II
Reset Signal
6: II
Enable Signal
7: II
Drain Wire
Function
8: II
Option
1: 2: 4: 5: 6: 7: 8: -

Signal (-)


Terminal Type
Terminated Lead
ID
I
- See Parts Catalog
No Tool Required
No Tool Required

Pin
Size
Color
Circuit
1: 1
1: 0.35
1: BN
1: 3367
2: 2
2: 0.35
2: BU
2: 3366
3: 3
3: 0.35
3: BARE
3: 3365
Function
Signal (-)
Signal (+)
3: Navigation Display Drain
Wire
P19AA SPEAKER - RIGHT SUBWOOFER
Harness Type: Body

Terminal Type
ID
Option
1: I
1: -
2: I
2: -
3: I
3: -


Terminal
Type ID
Terminal
Removal
Tool
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
J-35616-2A
J-38125-29
(GY)
13526678
PO
Lead
Test Probe
13575480

Pin
Size
Color
Circuit
1: 1
1: 1
1: GY/BK
1: 315
2: 2
2: 1
2: D-GN/VT
2: 1795
Function
Terminal Type
ID
Option
1: I
1: UQA
2: I
2: UQA
1: Right Subwoofer
Speaker (-)
2: Right Subwoofer
Speaker (+)
P19AG SPEAKER - LEFT FRONT DOOR


Terminal
Type ID
Terminal
Removal
Tool
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
J-35616-2A
J-38125-29
(GY)
13526678
PO
Lead
Test Probe
13575480

Pin
Size
Color
Circuit
1: 1
1: 0.75
1: BN/DBU
1: 118
2: 2
2: 0.75
2: D-BU
2: 201
Function
(-) (1)
(1)
P19AH SPEAKER - RIGHT FRONT DOOR
Terminal Type
ID
Option
1: I
1: -
2: I
2: -



Terminal
Type ID
Terminal
Removal
Tool
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
J-35616-2A
J-38125-29
(GY)
13526678
PO
Lead
Test Probe
13575480

Pin
Size
Color
Circuit
1: 1 1: 0.75
1: YE/BK
1: 117
2: 2 2: 0.75
2: YE
2: 200
Function
Terminal Type
ID
Option
1: I
1: -
2: I
2: -

Signal (-) (1)
(1)
P19AL SPEAKER - LEFT REAR DOOR


Terminal
Type ID
I
Terminal
Removal
Tool
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
J-35616-2A J-38125-29
13526678
PO
Lead
Test Probe
13575480

(GY)
Pin
Size
Color
Circuit
1: 1 1: 0.75 1: D-GN/BK
1: 116
2: 2 2: 0.75
2: 199
2: D-GN
Function
Terminal Type
ID
Option
1: I
1: -
2: I
2: -

(-)
P19AM SPEAKER - RIGHT REAR DOOR


Terminal
Type ID
Terminal
Removal
Tool
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
J-35616-2A
J-38125-29
(GY)
13526678
PO
Lead
Test Probe
13575480
P19AM Speaker - Right Rear Door

Pin
Size
Color
Circuit
1: 1 1: 0.75 1: D-BU/BK
1: 115
2: 2 2: 0.75
2: 46
2: WH
Function
Signal (-)
P19B SPEAKER - CENTER INSTRUMENT PANEL (UQA)
Terminal Type
ID
Option
1: I
1: -
2: I
2: -



Terminal
Type ID
Lead
Test Probe
13327201
Terminal
Removal
Tool
Service
Terminal
J-35616-2A
J-38125-553 8240-0128
(GY)
Tray
Core
Crimp
Insulation
Crimp
22

Pin
Size
Color
1: 1 1: 0.75 1: D-BU/YE
2: 2 2: 0.75 2: YE/WH
Circuit
1: 1960
2: 1860
Terminal Type
ID
1: I
2: I
Function
Option
1: UQA
2: UQA
P19H SPEAKER - LEFT FRONT TWEETER


Terminal
Removal
Tool
J-35616-64B J-3812513575867
(L-BU)
215A

Type ID
Lead
Test Probe
I
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
Not
Available
Not
Available
Not
Available
Not
Available

Pin
Size
1: 1
1: 0.75
2: 2
2: 0.75
Color
1: BN/DBU
2: D-BU
Circuit
1: 118
2: 201
Function
(-)
Terminal Type
ID
Option
1: I
1: -
2: I
2: -

P19N SPEAKER - LEFT SUBWOOFER
Harness Type: Body


Terminal
Type ID
I
Terminal
Removal
Tool
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
J-35616-2A
J-38125-29
(GY)
13526678
PO
Lead
Test Probe
13575480

Pin
Size
Color
Circuit
1: 1
1: 1
1: D-GN/BK
1: 1794
2: 2
2: 1
2: D-BU/GY
2: 346
Function
Terminal Type
ID
Option
1: I
1: UQA
2: I
2: UQA
Speaker (-)
Speaker (+)
P19V SPEAKER - RIGHT FRONT TWEETER


Type ID
Lead
Test Probe
Terminal
Removal
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp

Tool
J-35616-64B J-3812513575867
(L-BU)
215A
Not
Available
Not
Available
Not
Available
Not
Available

Pin
Size
Color
Circuit
1: 1 1: 0.75
1: YE/BK
1: 117
2: 2 2: 0.75
2: YE
2: 200
Function
Terminal Type
ID
Option
1: I
1: -
2: I
2: -

Signal (-) (1)
(1)
Q6E CAMSHAFT POSITION ACTUATOR SOLENOID VALVE - EXHAUST (LUV)


Type ID
Lead
Test Probe
I
13576385
Pending
Terminal
Removal
Tool
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
Pending
Not
Available
Not
Available
Not
Available
Not
Available

Pin
Size
Color
Circuit
Function
1: 1
1: 0.5
1: BK/VT
1: 6754
2: 2
2: 0.5 2: GY/D-BU
1: Low Reference
Solenoid (1)
2: 5282
Terminal Type
ID
1: I
2: I
Option
1: 2: -
Q6E CAMSHAFT POSITION ACTUATOR SOLENOID VALVE - EXHAUST (LUW/LWE)



Terminal
Type ID
I
Terminal
Removal
Tool
J-35616-64B J-3812513582274
(L-BU)
12A
Lead
Test Probe
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
928999-5
15

Terminal Type
Pin
Size
Color
Circuit
Function
ID
1: 1 1: 0.5 1: BK/VT
1: 6754
1: Low Reference
1: I
2: 2 2: 0.5 2: GY/D-BU
2: 5282
2: I
Solenoid (1)
Option
1: 2: -
Q6F CAMSHAFT POSITION ACTUATOR SOLENOID VALVE - INTAKE (LUV)


Type ID
Lead
Test Probe
I
13576385
Pending
Terminal
Removal
Tool
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
Pending
Not
Available
Not
Available
Not
Available
Not
Available

Pin
Size
Color
Circuit
Function
Terminal Type
ID
Option

1: 1
1: 0.5
1: BN/WH
1: 6753
2: 2
2: 0.5
2: VT/BN
2: 5284
1: Low Reference
Solenoid (1)
1: I
1: -
2: I
2: -
Q6F CAMSHAFT POSITION ACTUATOR SOLENOID VALVE - INTAKE (LUW/LWE)


Terminal
Type ID
I
Terminal
Removal
Tool
J-35616-64B J-3812513582274
(L-BU)
12A
Lead
Test Probe
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
928999-5
15

Terminal Type
Pin
Size
Color
Circuit
Function
ID
1: 1 1: 0.5 1: BK/BN
1: 6753
1: Low Reference
1: I
2: 2 2: 0.5 2: VT/BN
2: 5284
2: I
Solenoid (1)

Description: 14-Way F GT 150 280 Series, Sealed (L-GY)
Option
1: 2: -


Terminal
Type ID
Lead
Test Probe
13575392
II
13575400
Terminal
Removal
Tool
J-35616-4A
J-38125-553
(PU)
J-35616-2A
J-38125-553
(GY)
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
15304720
19
15326267
19

Pin
Size
Color
Circuit
Function
1: 0.75
1: 0.75
2: 2 2: 0.75
1: RD/WH
1: RD/WH
2: BK
1: 340
1: 1840
2: 150
3: 3
3: 0.5
3: 0.5
3: L-GN
3: WH/GY
3: 275
3: 1786
4-5
6: 6
6: 0.5
6: D-BU
6: 2500
7: 7
7: 0.5
7: D-BU
7: 2500
8: 8
8: 0.5
8: WH
8: 2501

2: Ground
Signal (1)
Signal (1)
Not Occupied
6: High Speed GMLAN
Serial Data (+) (1)
7: High Speed GMLAN
Serial Data (+) (1)
8: High Speed GMLAN
Serial Data (-) (1)
Not Occupied
Signal
Not Occupied
Data
Data
Serial Data (-) (1)
1: 1
10: WH/D10: 10 10: 0.5

BU
11
12: 0.5 12: VT/D-BU
12: 12
12: 0.5 12: VT/GY
13: 13
13: 0.5
13: 0.5
14: 14 14: 0.5
10: 6311
12: 139
12: 139
13: BU
13: VT/YE
13: 5985
13: 5985
14: WH
14: 2501
Terminal Type
ID
1: I
2: I
Option
1: LUJ
1: LUW
2: -
3: II
3: LUJ
3: LUW
6: II
6: -
7: II
7: -
8: II
8: -
10: -
10: LUW
12: LUJ
12: LUW
12: II
13: II
13: LUJ
13: LUW
14: II
14: -


Description: 6-Way F Micro-Pack 150.2 Series Sealed (BU)

Type ID
Lead
Test Probe
Terminal
Removal
Tool
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
Service by
J-35616-14
Component
(GN)
Assembly
Not
Available
Not
Available
Not
Available
Not
Available
Not
Available

Pin
Size
Color
Circuit
A: A A: 0.5
A: BU
A: -
B: B
B: 0.5
B: GN
B: -
C: C C: 0.5
C: GY
C: -
D: D D: 0.5
D: YE
D: -
E: E
E: 0.5
E: RD
E: -
F: F
F: 0.5
F: BK
F: -
Function
A: Park/Neutral Switch
Signal
B: Transmission Range
Switch Signal A
C: Transmission Range
Switch Signal B
D: Transmission Range
Switch Signal C
E: Transmission Range
Switch Signal P
F: Low Reference

Terminal Type
ID
Option
A: I
A: -
B: I
B: -
C: I
C: -
D: I
D: -
E: I
E: -
F: I
F: -


Type ID
Lead
Test Probe
Terminal
Removal
Tool
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
Service by
J-35616-14
Component
(GN)
Assembly
Not
Available
Not
Available
Not
Available
Not
Available
Not
Available

Pin
Size
A: A A: 0.5
B: B B: 0.5
Color
Circuit
Function
A: WH
B: BK
A: B: -
A: ISS High Signal

B: ISS Low Signal
Terminal Type
ID
A: I
B: I
Option
A: B: -


Type ID
Lead
Test Probe
Terminal
Removal
Tool
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
Service by
J-35616-14
Component
(GN)
Assembly
Not
Available
Not
Available
Not
Available
Not
Available
Not
Available

Pin
Size
A: A A: 0.5
B: B B: 0.5
Color
Circuit
Function
A: WH
B: BK
A: B: -
A: OSS High Signal

B: OSS Low Signal
Terminal Type
ID
A: I
B: I
Q12 EVAPORATIVE EMISSION PURGE SOLENOID VALVE (LUV)
Option
A: B: -



Type ID
Lead
Test Probe
I
Not
Available
Terminal
Removal
Tool
Service
Terminal
J-35616-35
J-38125-561 1928498056
(VT)
Tray
Core
Crimp
Insulation
Crimp

Pin
Size
Color
Circuit
1: 1
1: 0.5
1: GN/D-BU
1: 428
2: 2
2: RD/WH
2: RD/WH
2: 5293
Function
Terminal Type
ID
Option
1: I
1: -
2: I
2: -

Solenoid Control
Fused Supply (4)
Q12 EVAPORATIVE EMISSION PURGE SOLENOID VALVE (LUW/LWE)


Type ID
Lead
Test Probe
I
Not
Terminal
Removal
Tool
Service
Terminal
J-35616-35 J-38125-561 1928498056
Tray
Core
Crimp
Insulation
Crimp

Available
(VT)

Pin
Size
Color
Circuit
1: 1
1: 0.75
1: L-GN/DBU
1: 428
2: 2
2: 0.75 2: VT/D-BU
2: 5293
Function
Terminal Type
ID
Option
1: I
1: -
2: I
2: -

Solenoid Control
Fused Supply (4)
Q13 EVAPORATIVE EMISSION VENT SOLENOID VALVE

Description: 2-Way F Metri-Pack 150 Series, Sealed (RD)

Terminal
Type ID
Lead
Test Probe
13575427
J-35616-14
(GN)
Terminal
Removal
Tool
J-3812512A
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
12048074

Color
Circuit
Function
Terminal Type
ID
Option
A: A A: 0.75
A: RD/DBU
A: 5372
A: Canister Valve Solenoid
A: I
A: -
B: B B: 0.75
B: WH
B: 1310
B: EVAP Canister Vent

Solenoid Control
B: I
B: -
Pin
Size
Q17A FUEL INJECTOR 1 (LUV)



Terminal
Type ID
Lead
Test Probe
13327154
Terminal
Removal
Tool
Service
Terminal
J-35616-35
J-38125-36 4-964286-1
(VT)
Tray
Core
Crimp
Insulation
Crimp
16

Pin
Size
Color
Circuit
1: 1
1: 0.5
1: RD/BU
1: 5291
2: 2
2: 0.5
2: BN/VT
2: 1744
Function
Terminal Type
ID
Option
1: I
1: -
2: I
2: -

Fused Supply (2)
Q17A FUEL INJECTOR 1 (LUW/LWE)


Terminal
Type ID
I
Lead
Test Probe
13581346
Terminal
Removal
Tool
Service
Terminal
J-35616-35
J-38125-36 4-964286-1
(VT)
Tray
Core
Crimp
Insulation
Crimp
16

Pin
Size
Color
Circuit
Function
Terminal Type
ID
Option

1: 1
2: 2
1: 0.5
2: 0.5
1: PK/BK
2: BN
1: 5291
2: 1744
Fused Supply (2)

1: I
2: I
1: 2: -
Q17B FUEL INJECTOR 2 (LUV)


Terminal
Type ID
Lead
Test Probe
13327154
Terminal
Removal
Tool
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
16
J-35616-35
J-38125-36 4-964286-1
(VT)

Pin
Size
Color
Circuit
1: 1
1: 0.5
1: RD/BU
1: 5291
2: 2
2: 0.5
2: YE/WH
2: 1745
Function
Fused Supply (2)
Q17B FUEL INJECTOR 2 (LUW/LWE)

Terminal Type
ID
Option
1: I
1: -
2: I
2: -

Terminal
Type ID
Lead
Test Probe
13581346
Terminal
Removal
Tool
Service
Terminal
J-35616-35
J-38125-36 4-964286-1
(VT)
Tray
Core
Crimp
Insulation
Crimp
16

Pin
Size
Color
Circuit
1: 1
1: 0.5
1: PK/WH
1: 5291
2: 2
2: 0.5 2: L-GN/BK
Function
Terminal Type
ID
Option
1: I
1: -
2: I
2: -

Fused Supply (2)
2: 1745
Q17C FUEL INJECTOR 3 (LUV)


Terminal
Type ID
Lead
Test Probe
13327154
Terminal
Removal
Tool
Service
Terminal
J-35616-35
J-38125-36 4-964286-1
(VT)
Tray
Core
Crimp
Insulation
Crimp
16

Pin
Size
Color
Circuit
1: 1
1: 0.5
1: RD/BU
1: 5291
2: 2
2: 0.5
2: BN/YE
2: 1746
Q17C FUEL INJECTOR 3 (LUW/LWE)
Function
Fused Supply (2)
Terminal Type
ID
Option
1: I
1: -
2: I
2: -



Terminal
Type ID
Lead
Test Probe
13581346
Terminal
Removal
Tool
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
16
J-35616-35
J-38125-36 4-964286-1
(VT)

Pin
Size
Color
Circuit
1: 1
1: 0.5
1: PK/BK
1: 5291
2: 2
2: 0.5
2: WH/BK
2: 1746
Function
Terminal Type
ID
Option
1: I
1: -
2: I
2: -

Fused Supply (2)
Q17D FUEL INJECTOR 4 (LUV)


Terminal
Type ID
I
Lead
Test Probe
13327154
Terminal
Removal
Tool
Service
Terminal
J-35616-35
J-38125-36 4-964286-1
(VT)
Tray
Core
Crimp
Insulation
Crimp
16


Pin
Size
Color
Circuit
1: 1
1: 0.5
1: RD/BU
1: 5291
2: 2
2: 0.5
2: BN
2: 844
Function
Terminal Type
ID
Option
1: I
1: -
2: I
2: -

Fused Supply (2)
Q17D FUEL INJECTOR 4 (LUW/LWE)


Terminal
Type ID
Lead
Test Probe
13581346
Terminal
Removal
Tool
Service
Terminal
J-35616-35
J-38125-36 4-964286-1
(VT)
Tray
Core
Crimp
Insulation
Crimp
16

Pin
Size
Color
Circuit
1: 1
1: 0.5
1: PK/BK
1: 5291
2: 2
2: 0.5 2: D-BU/BK
2: 844
Function
Terminal Type
ID
Option
1: I
1: -
2: I
2: -

Fused Supply (2)
Q22 INTAKE MANIFOLD TUNING SOLENOID VALVE (LUW/LWE)




Terminal
Type ID
Terminal
Removal
Tool
J-35616-64B J-3812513576394
(L-BU)
12A
Lead
Test Probe
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
962885-5
15

Pin
Size
Color
Circuit
1: 1
1: 0.5
2: 2
2: 0.5
1: VT/DBU
2: BK
3: 3
3: 0.5
3: D-BU
3: 7302
4: 4
4: 0.5
4: GY/LGN
4: 7303
1: 5293
2: 150
Function
Terminal Type
ID
Option
1: I
1: -
2: I
2: -
3: I
3: -
4: I
4: -

Fused Supply (4)
2: Ground
Valve (IMTV) Control Signal
Valve (IMTV) Position Signal
Q38 THROTTLE BODY

Description: 6-Way Sealed (BK)

Terminal
Type ID
I
Lead
Test Probe
13575396
Q38 Throttle Body
Terminal
Removal
Tool
J-35616-2A
J-38125-553
(GY)
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
15326427

Pin
Size
Color
Circuit
A: A A: 0.5
A: BN/WH
A: 582
B: B B: 0.5
B: BN/RD
B: 581
C: C C: 0.5
C: BK/YE
C: 2752
D: D D: 0.5
D: BN/GN
D: 485
E: E E: 0.5
E: BN/RD
E: 2701
F: F
F: BN/BU
F: 486
F: 0.5
Function
Terminal Type
ID
Option
A: I
A: -
B: I
B: -
C: I
C: -
D: I
D: -
E: I
E: -
F: I
F: -
A: Throttle Actuator
Control Close
B: Throttle Actuator
Control Open
C: Throttle Position Sensor
Low Reference
D: Throttle Position Sensor
Signal (1)
E: 5 Volt Reference
F: Throttle Position Sensor
Signal (2)
Q40 TURBOCHARGER BYPASS SOLENOID VALVE (LUV)

Description: 2-Way F 2.8 Junior Power Timer Series, Sealed (BK)

Terminal
Type ID
Lead
Test Probe
13575438
Terminal
Removal
Tool
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
16
J-35616-35
J-38125-36 4-964286-1
(VT)

Pin
Size
Color
Circuit
1: 1
1: 0.5
1: BN/WH
1: 3060
2: 2
2: 0.5
2: RD/WH
2: 5293
Function
1: Turbo Bypass Solenoid
Control Bank (1)
Fused Supply (4)
Q42 TURBOCHARGER WASTEGATE SOLENOID VALVE (LUV)
Terminal Type
ID
Option
1: I
1: -
2: I
2: -



Terminal
Type ID
Lead
Test Probe
13575438
Terminal
Removal
Tool
Service
Terminal
J-35616-35
J-38125-36 4-964286-1
(VT)
Tray
Core
Crimp
Insulation
Crimp
16

Pin
Size
Color
Circuit
1: 1 1: 0.75
1: BN/RD
1: 3058
2: 2 2: 0.75
2: RD/WH
2: 5293
Function
Terminal Type
ID
Option
1: I
1: -
2: I
2: -
1: Turbo Waste Gate

Solenoid Control Bank (1)
Fused Supply (4)
Q46 A/C COMPRESSOR SOLENOID VALVE

Description: 2-Way F 1.2 MCP Series, Sealed (BK with NA Inner Connector)

Type ID
Lead
Test Probe
I
Pending
Pending
Terminal
Removal
Tool
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
Pending
Not
Not
Pending
Pending

Available
Available

Pin
Size
Color
Circuit
1: 1 1: 0.50
1: BU/BN
1: 7573
2: 2 2: 0.50
2: BU/YE
2: 7574
Function
Terminal Type
ID
Option
1: I
1: -
2: I
2: -
Displacement Supply
S2 TRANSMISSION MANUAL SHIFT SWITCH (MH8)
Harness Type: Shift Lever

Service Connector: Service By Component - See Part Catalog

Type ID
Lead
Test Probe
Service By
Not
Component Available
See Part
Catalog
Terminal
Removal
Tool
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
Service By Service By
Not
Not
Not
Component - Component Available
Available Available
See Part
See Part
Catalog
Catalog

Pin
Size
Color
Circuit
1: 1
1: VT/WH
1: VT/WH
1: -
2: 2
2: BK
2: BK
2: -
3: 3
3: RD/WH
3: RD/WH
3: -
4: 4
4: BK
4: BK
4: -
S3 TRANSMISSION SHIFT LEVER (MH8)
Function
1: Battery Positive
Voltage
Control
Soft Control
4: Ground
Terminal Type
ID
Option
1: I
1: -
2: I
2: -
3: I
3: -
4: I
4: -



Type ID
Lead
Test Probe
Terminal
Removal
Tool
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
Service by
J-35616-64B
Connector
(L-BU)
Assembly
J-38125215A
Pending
Pending
Pending
Pending

Pin
Size
Color
Circuit
1: 1
2: 2
1: 0.5
2: 0.5
1: RD/BN
2: BK
1: 202
2: 2150
3: 3
3: 0.5
3: YE
3: 7554
4: 4
4: 0.5
4: VT/BK
4: 7553
6: 6
6: 0.5
6: WH/VT
6: 5905
S13D DOOR LOCK SWITCH - DRIVER

Terminal Type
ID
1: I
2: Ground
2: I
3: Park Lock Solenoid Soft
3: I
Control
4: I
Control
Not Occupied
6: I
Function
Option
1: 2: 3: 4: 6: -


Terminal
Type ID
Terminal
Removal
Tool
J-35616-64B J-3812513575782
(L-BU)
12A
Lead
Test Probe
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
928999-5
15

Pin
Size
Color
Circuit
Function
1: 1
1: 0.5
1: BK
1: 50
2: 2
2: 0.5
2: YE
2: 6817
3: 3
3: 0.5
3: BN/WH
3: 781
4: 4
4: 0.5
4: BN/YE
4: 780
1: Ground
2: LED Backlight
Dimming Control
3: Driver Door Lock
4: Driver Door Lock
Switch Lock Signal
Terminal Type
ID
1: I
Option
1: -
2: I
2: -
3: I
3: -
4: I
4: -
S26 HAZARD LAMPS SWITCH

Description: 4-Way F (BU)

Terminal
Type ID
I
Terminal
Removal
Tool
J-35616-64B J-3812513575782
(L-BU)
12A
Lead
Test Probe
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
928999-5
15

Pin
Size
Color
Circuit
Function
1: 1 1: 0.35 1: D-GN/WH
1: 111
2: 2 2: 0.35 2: L-BU/VT
2: 1717

Flasher Control
Terminal Type
ID
1: I
2: I
Option
1: 2: -

3: 3
4
3: 0.5
-
3: BK
-
3: 50
-
3: Ground
Not Occupied
3: I
-
3: -
S30 HEADLAMP SWITCH

Description: 12-Way F Micro HVT (BK)

Terminal
Type ID
Lead
Test Probe
13575550
Terminal
Removal
Tool
J-35616-16
J-38125-559
(L-GN)
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
15445905
23
S30 Headlamp Switch

Pin
Size
Color
Circuit
1: 1
1: 0.5
1: YE
1: 7556
3: 3 3: 0.35 3: D-GN/GY
3: 13
4: 4 4: 0.35
4: 103
4: WH/VT
5: 5 5: 0.35 5: D-GN/BN
5: 306
6: 6
6: 0.5
6: BK
6: 1650
7: 7
7: 0.5
7: YE
7: 6817
8-11
12: 12 12: 0.5 12: WH/BN

A26 HVAC CONTROLS
12: 7555
Function
Reference
Not Occupied
3: Headlamp Switch Park
Lamp Signal
Signal
5: Headlamp Switch
Control
6: Ground
7: LED Backlight
Dimming Control
Not Occupied
12: Lighting Control
Switch Signal
Terminal Type
ID
Option
1: I
1: -
3: I
3: -
4: I
4: -
5: I
5: -
6: I
6: -
7: I
7: -
12: I
12: -



Terminal
Type ID
Lead
Test Probe
13579977
Terminal
Removal
Tool
Service
Terminal
J-35616-64B
J-38125-553 1393366-1
(L-BU)
Tray
Core
Crimp
Insulation
Crimp
16
A26 HVAC Controls

Pin
1: 1
Size
Color
1: 0.5 1: L-GN/YE
2: 2 2: 0.75
3: 3 3: 0.75
4-6
-
2: BK
3: RD/YE
-
Circuit
1: 7531
2: 1650
3: 240
-
Function
Terminal Type
ID
Option
1: I
1: -
2: I
3: I
-
2: 3: -
Network Bus 9
2: Ground
Not Occupied
S38 IGNTION MODE SWITCH (BTM)


Terminal
Type ID
Lead
Test Probe
Terminal
Removal
Tool
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp

13579976
J-35616-64B
J-38125-21
(L-BU)
15359541

Pin
Size
Color
Circuit
Function
2: 2
2: 0.5
2: BN/BK
2: 5720
3: 3
3: 0.5 3: D-GN/BK
3: 3558
4: 4
4: 0.5
4: 1650
5: 5
5: 0.5 5: D-BU/BK
5: 5719
6: 6
6: 0.5
6: D-BU/DGN
6: 5723
7: 7
7: 0.5
7: BK/GY
7: 3559
8: 8
8: 0.5
8: YE
8: 6817
Not Occupied
Accessory LED Signal
Signal 2
4: Ground
Start LED Signal
Mode Voltage
Low Reference
Control
4: BK
Terminal Type
ID
-
Option
-
2: I
2: -
3: I
3: -
4: I
4: -
5: I
5: -
6: I
6: -
7: I
7: -
8: I
8: -
S39 IGNITION SWITCH

Description: 6-Way F 1.2 HCM Series (NA)

Terminal
Type ID
I
Terminal
Removal
Tool
J-35616-64B J-3812513575868
(L-BU)
12A
Lead
Test Probe
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
SHCMA03T-P025
20
S39 Ignition Switch

Pin
Size
Color
Circuit
Function
Terminal Type
ID
Option

1: 1
1: 0.5
1: VT/BK
1: 3
2: 2
3: 3
4: 4
5
2: 0.5
3: 0.5
4: 0.5
-
2: RD/VT
3: VT/YE
4: WH/VT
-
2: 340
3: 4
4: 1020
-
6: 6
6: 0.5
6: WH/BK
6: 1073
Voltage
3: Accessory Voltage
4: Off/Run/Crank Voltage
Not Occupied
Signal
1: I
1: -
2: I
3: I
4: I
-
2: 3: 4: -
6: I
6: -
S52 OUTSIDE REARVIEW MIRROR SWITCH


Terminal
Type ID
Terminal
Service
Removal
Terminal
Tool
J-35616-64B J-38125- SAIT-A03T13575867
(L-BU)
215A
M064
Lead
Test Probe
Tray
Core
Crimp
Insulation
Crimp
14

Pin
Size
Color
Circuit
1: 1
1: 0.5 1: VT/D-BU
1: 3390
2: 2
2: 0.5
2: YE/BN
2: 3391
3: 3
3: 0.5
3: BN/BK
3: 3389
4: 4
5: 5
4: 0.5
5: 0.5
4: RD/GY
5: BK
4: 2840
5: 50
7: 7
7: 0.5
7: YE/VT
7: 3397
8: 8
8: 0.5
8: WH
8: 3398
Function
1: Driver Mirror Motor Up
Common Control
5: Ground
Common Control
Terminal Type
ID
Option
1: I
1: -
2: I
2: -
3: I
3: -
4: I
5: I
4: 5: -
7: I
7: -
8: I
8: -

9: 9
9: 0.5 9: D-GN/BK
10: 10 10: 0.5

11-12

10: LED Backlight
Dimming Control
Not Occupied
9: 3396
10: YE
10: 6817
9: I
9: -
10: I
10: -
S64D SEAT ADJUSTER SWITCH - DRIVER (ADS)


Terminal
Type ID
Lead
Test Probe
13575756
Terminal
Removal
Tool
J-35616-4A
J-38125-553
(PU)
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
15304713
19

Pin
Size
Color
Circuit
A: D-BU
A: 286
B: 1.5
B: BK
B: 2150
C: C C: 1.5
C: YE
C: 285
D: D D: 1.5
D: RD
D: 702
E: E
E: 1.5
E: WH
E: 282
F: F
F: 1.5
F: BN
F: 284
A: A A: 1.5
B: B
G: G G: 1.5 G: D-GN
G: 283
Function
A: Driver Power Seat Front
B: Ground
C: Driver Power Seat
Control
D: Battery Positive Voltage
E: Driver Power Seat Rear
F: Driver Power Seat
Control
G: Driver Power Seat Rear
Vertical Motor Down
Control
Terminal Type
ID
Option
A: I
A: -
B: I
B: -
C: I
C: -
D: I
D: -
E: I
E: -
F: I
F: -
G: I
G: -

H: H H: 1.5
H: GY
H: Driver Power Seat Front

Vertical Motor Down
Control
H: 287
H: I
H: -
S70L STEERING WHEEL CONTROLS SWITCH - LEFT (K34)

OEM Connector: AIT2PB-7-1FS

Terminal
Removal
Tool
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
Service by
Not
See Parts
(L-BU)
Available
Catalog
Service by
Harness See Parts
Catalog
Service by
Harness See Parts
Catalog
Not
Available
Not
Available

Type ID
Lead
Test Probe

Pin Size
1: 1
2
3: 3
4-5
Color
1:
1: WH/RD
0.35
3:
0.35
6:
6: 6
0.35
7:
7: 7
0.35
Circuit
Function
Terminal
Type ID
Option
1: 1444
1: I
1: -
3: I
3: -
3: BN/DGN
3: 1884
Not Occupied
3: Cruise Control
Signal
Not Occupied
6: YE
6: 6817
6: I
6: -
7: BK
7: 1650
7: Ground
7: I
7: -
S70R STEERING WHEEL CONTROLS SWITCH - RIGHT (W1Y)


OEM Connector: AIT2PB-6-1AK

Terminal
Removal
Tool
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
Service by
Not
See Parts
(L-BU)
Available
Catalog
Service by
Harness See Parts
Catalog
Service by
Harness See Parts
Catalog
Not
Available
Not
Available

Type ID
Lead
Test Probe

Pin
Size
Color
Circuit
Function
1: 1
1: 0.5
1: WH/RD
1: 1444
2: 2
2: 0.5 2: D-GN/WH
1: 12V Reference
Ladder Signal #2
Not Occupied
4: LED Backlight
Dimming Control
5: Ground
Not Occupied
2: 6819
4: 4
4: 0.5
4: YE
4: 6817
5: 5
6
5: 0.5
-
5: BK
-
5: 50
-
S72 SUNROOF SWITCH (CF5)

Terminal Type
ID
1: I
Option
1: -
2: I
2: -
4: I
4: -
5: I
-
5: -


Terminal
Type ID
Terminal
Removal
Tool
J-35616-64B J-3812513575782
(L-BU)
12A
Lead
Test Probe
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
928999-5
15

Pin
Size
Color
Circuit
1: 1
1: 0.5
1: BK/GY
1: 128
2: 2
2: 0.5
2: YE
2: 6817
3: 3
4: 4
3: 0.5
3: BK
4: 0.5 4: D-BU/VT
3: 50
4: 5027
Function
Terminal Type
ID
Option
1: I
1: -
2: I
2: -
3: I
4: I
3: 4: -

Reference
Control
3: Ground
S75 TRACTION CONTROL SWITCH (FX3)

Description: 6-Way F 0.64 MTS Series (BK)

Terminal
Type ID
I
Terminal
Removal
Tool
J-35616-64B J-3812513575782
(L-BU)
12A
Lead
Test Probe
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
928999-5
15

Pin
Size
Color
Circuit
Function
1
2
Not Occupied
Not Occupied
3: 6817
3: Cruise Control
3: 3 3: 0.5 3: YE
Terminal
Type ID
3: I
Option
3: -

Signal
4: 0.5 4: BK
4: 4
4: 0.5 4: BK
5-6
4: 1750
4: 1650
4: Ground
4: Ground
4: I
Not Occupied
4: MF3 or
MZ0
4: MH8
-
S78 TURN SIGNAL/MULTI-FUNCTION SWITCH


Terminal
Type ID
Terminal
Service
Removal
Terminal
Tool
J-35616-64B J-38125SNAC313575870
(L-BU)
12A
A021T-M064
Lead
Test Probe
Tray
Core
Crimp
Insulation
Crimp
20

Pin
Size
Color
Circuit
1: 1
1: 0.5 1: WH/L-GN
1: 663
2: 2
2: 0.5
2: WH
2: 524
3: 3
3: 0.5
3: BK
3: 1650
4: 4
4: 0.5
4: YE/BN
4: 307
5: 5 5: 0.35 5: GY/L-BU
5: 893
6: 6 6: 0.35
6: BK/BN
6: 897
7: VT/D-BU
7: 664
7: 7
7: 0.5
Function
1: Hazard Switch Left Turn
Signal
2: Headlamp Dimmer
3: Ground
To Pass Signal
Signal
Center Switch Low
Reference
Turn Signal
Terminal Type
ID
Option
1: I
1: -
2: I
2: -
3: I
3: -
4: I
4: -
5: I
5: -
6: I
6: -
7: I
7: -

8-11
12:
12: 12
12: D-GN/WH
0.35
Not Occupied
12: 1358
12: I
12: -
S79D WINDOW SWITCH - DRIVER (AEC)


Type ID
Lead
Test Probe
Terminal
Removal
Tool
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
Service by
Harness See Part
Catalog
Pending
Not
Available
Not
Available
Not
Available
Not
Available
Pending

Pin
Size
Color
Circuit
Function
1: 1
1: 2.5
1: BK
1: 2050
2: 2
2: 0.5 2: D-GN/GY
2: 3382
3: 3
3: 0.5
3: 3383
4: 4
4: 2.5 4: RD/D-GN
4: 1540
5: 5
5: 0.5 5: D-GN/YE
5: 6134
6: 6
6: 0.5
6: GY
6: 745
7: 7
7: 0.5
7: WH/VT
7: 3270
1: Ground
Driver Up Control
Driver Down Control
Network Bus 3
Switch Signal
Status Control
Not Occupied
3: YE/VT
S79D WINDOW SWITCH - DRIVER (AXG)
Terminal Type
ID
1: I
Option
1: -
2: I
2: -
3: I
3: -
4: I
4: -
5: I
5: -
6: I
6: -
7: I
7: -



Terminal
Type ID
Terminal
Removal
Tool
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
J-35616-64B
J-38125-21
(L-BU)
15359541
Lead
Test Probe
13579976

Pin
Size
Color
Circuit
Function
1: 1
1: 0.5
1: BK
1: 1550
2: 2
2: 0.5
2: D-GN
2: 3381
3: 3
3: 0.5
3: GY
3: 3380
4: 4
4: 0.5
4: RD/D-GN
4: 1540
5: 5
5: 0.5
5: D-GN/YE
5: 6134
6: 6
6: 0.5 6: D-GN/WH
6: 3379
7: 7
7: 0.5
7: WH/VT
7: 3270
1: Ground
Driver Down Signal
Network Bus 3
Driver Up Signal
Status Control
Not Occupied
S79LR WINDOW SWITCH - LEFT REAR
Terminal Type
ID
1: I
Option
1: -
2: I
2: -
3: I
3: -
4: I
4: -
5: I
5: -
6: I
6: -
7: I
7: -



Type ID
Lead
Test Probe
Terminal
Removal
Tool
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
Service by
Connector
Assembly
Not
Available
Not
Available
Not
Available
Not
Available
Not
Available
J-35616-35
(VT)

Pin
Size
Color
Circuit
1: 1
1: 0.5 1: D-GN/GY
1: 6135
2: 2
2: 0.5
2: GY
2: 747
3: 3
4
5: 5
3: 0.5
5: 2.5
3: BK
5: BK
3: 2350
5: 2350
6: 6
6: 2.5 6: D-BU/GY
6: 668
7: 7
7: 2.5 7: D-GN/BK
7: 669
8: 8
8: 2.5
8: 2940
8: RD/BN
Function
Network Bus 4
Switch Signal
3: Ground
Not Occupied
5: Ground
Terminal Type
ID
Option
1: I
1: -
2: I
2: -
3: I
5: I
3: 5: -
6: I
6: -
7: I
7: -
8: I
8: -
S79P WINDOW SWITCH - PASSENGER


Terminal
Service
Core
Insulation

Type ID
Lead
Test Probe
Removal
Tool
Terminal
Service by
Connector
Assembly
J-35616-35
(VT)
Not
Available
Not
Available
Crimp
Crimp
Not
Available
Not
Available
Tray
Not
Available

Pin
Size
Color
Circuit
Function
1: 1
1: 2.5
1: BK
1: 2050
2: 2
2: 2.5 2: D-GN/GY
2: 3387
3: 3
3: 2.5 3: YE/D-BU
3: 3388
4: 4
4: 2.5 4: RD/D-GN
4: 1540
5: 5
5: 0.5 5: D-GN/YE
5: 6134
6: 6
6: 0.5
6: GY
6: 746
7-8
1: Ground
Network Bus 3
Switch Signal
Not Occupied
Terminal Type
ID
1: I
Option
1: -
2: I
2: -
3: I
3: -
4: I
4: -
5: I
5: -
6: I
6: -
S79RR WINDOW SWITCH - RIGHT REAR


Type ID
Lead
Test Probe
Terminal
Removal
Tool
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
Service by
Connector
Assembly
15315247
Not
Available
Not
Available
Not
Available
Not
Available
J-35616-35
(VT)

Pin
Size
Color
Circuit
Function
Terminal Type
Option

ID
1: 1
1: 0.5
1: D-GN/GY
1: 6135
2: 2
2: 0.5
2: GY
2: 748
3-4
5: 5
5: 2.5
5: BK
5: 2350
6: 6
6: 2.5
6: D-BU/GY
6: 670
7: 7
7: 2.5 7: D-GN/BKk
7: 671
8: 8
8: 2.5
8: 2940
8: RD/BN
Network Bus 4
Switch Signal
Not Occupied
5: Ground
1: I
1: -
2: I
2: -
5: I
5: -
6: I
6: -
7: I
7: -
8: I
8: -
S82 WINDSHIELD WIPER/WASHER SWITCH

Description: 8-Way F 1.2 HCM Series (BK)

Terminal
Type ID
Terminal
Removal
Tool
J-35616-64B J-3812513575868
(L-BU)
12A
Lead
Test Probe
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
SHCMA03T-P025
20

Pin
Size
Color
Circuit
1: 1
1: 0.5
1: GY
1: 1715
2: 2
2: 0.5
2: BK/GY
2: 6009
3: 3
3: 0.5
3: YE/D-BU
3: 1714
Function
1: Windshield Wiper
Switch High Signal
2: Windshield Wiper
3: Windshield Wiper
Switch Low Signal
Not Occupied
Terminal Type
ID
Option
1: I
1: -
2: I
2: -
3: I
3: -

5: 5
6-8
5: 0.5
-
5: WH/BK
-
5: 94
-
Switch Signal
Not Occupied
5: I
-
5: -
S88 SUNROOF TILT SWITCH (CF5)

Description: 4-Way F 0.64 Micro Quadlok Series (WH)

Terminal
Type ID
Terminal
Removal
Tool
J-35616-64B J-3812513575782
(L-BU)
12A
Lead
Test Probe
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
928999-5
15

Pin
Size
Color
Circuit
1: 1
1: 0.5
1: BK/BN
1: 128
2: 2
2: 0.5
2: YE
2: 6817
3: 3
3: 0.5
3: BK
3: 50
4: 4
4: 0.5 4: WH/D-GN
4: 3031
Harness Type: Body

Function
Reference
Control
3: Ground
Signal
Terminal Type
ID
Option
1: I
1: -
2: I
2: -
3: I
3: -
4: I
4: -



Terminal
Type ID
Lead
Test Probe
13575578
II
13575577
Terminal
Removal
Tool
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
22
22
J-35616-35
J-38125-553 8100-4444
(VT)
J-35616-35
J-38125-553 8100-4445
(VT)

Pin
Size
Color
Circuit
1: 1
1: 1
1: L-GN/VT
1: 1795
2: 2
2: 1
2: D-GN/BK
2: 1794
3: 3
3: 1
3: D-BU/GY
3: 346
4: 4
4: 2.5
4: RD/WH
4: 1040
5: 5
5: 1
5: GY/BK
5: 315
6-7
8: 8
8: 2.5
8: BK
8: 450
Function
Terminal Type
ID
Option
1: I
1: -
2: I
2: -
3: I
3: -
4: II
4: -
5: I
5: -
8: II
8: -
1: Right Subwoofer
Speaker (+)
Speaker (-)
Speaker (+)
5: Right Subwoofer
Speaker (-)
Not Occupied
8: Ground
Harness Type: Body


Terminal
Type ID
Lead
Test Probe
Terminal
Removal
Tool
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp

13327201
J-35616-2A
J-38125-553 8240-0128
(GY)
22

Pin
Size
1: 1 1: 0.75
Color
Circuit
1: D-BU
1: 201
2: 2 2: 0.75 2: BN/D-BU
2: 118
3: 3 3: 0.75
3: 199
3: D-GN
4: 4 4: 0.75 4: D-GN/BK
4: 116
5-6
7: 7 7: 0.75 7: YE/WH
8: 8 8: 0.75 8: D-BU/YE
7: 1860
8: 1960
9: 9 9: 0.75 9: D-BU/BK
9: 115
10:
0.75
11:
11: 11
0.75
12:
12: 12
0.75
13-16
10: 10
10: WH
10: 46
11: YE
11: 200
12: YE/BK
12: 117
Function
Terminal Type
ID
Option
1: I
1: -
2: I
2: -
3: I
3: -
4: I
4: -
7: I
8: I
7: 8: -
9: I
9: -
10: I
10: -
11: I
11: -
12: I
12: -

(1)
Signal (-) (1)
(-)
Not Occupied
Signal (-)
(1)
Signal (-) (1)
Not Occupied
Harness Type: Body

Description: 16-Way F Micro-Pack 064 Series (BK)

Terminal
Type ID
Lead
Test Probe
J-35616-64B
Terminal
Removal
Tool
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp

13575528
(L-BU)
J-38125-21
15359541

Pin
Size
Color
Circuit
1: 1 1: 0.35 1: D-GN/BK
1: 599
2: 2 2: 0.35
2: 1999
2: BN/VT
3: 3 3: 0.35 3: D-BU/BK
3: 1946
4: 4 4: 0.35
4: BN/WH
4: 546
5-7
8: 8 8: 0.35 8: D-GN/YE
8: 7066
9: 9 9: 0.35
9: 512
10: 10
11: 11
12: 12
13-15
16: 16
9: YE
10:
10: D-BU/BN
0.35
11:
11: BN/D-BU
0.35
12:
12: D-BU
0.35
16: 0.5 16: VT/D-BU
10: 1546
11: 1947
12: 511
16: 6978
Function
Terminal Type
ID
Option
1: I
1: -
2: I
2: -
3: I
3: -
4: I
4: -
8: I
8: -
9: I
9: -
10: I
10: -
11: I
11: -
12: I
12: -
16: I
16: -

Audio Signal
Audio (-)
Audio (-)
Audio Signal
Not Occupied
Enable Signal
Audio Signal
10: Front Low Level Audio
(-)
Audio (-)
Audio Signal
Not Occupied
T10E KEYLESS ENTRY ANTENNA - REAR COMPARTMENT (ATH)
Harness: Body
OEM: 24414929
Service: 24414929
Description: 4-Way F 64 MQS Series (GY)

Terminal Type
Terminated Lead
ID

Part Catalog
J-35616-65B (L-BU)
J-38125-215A

Pin
Size
Color
Circuit
1: 1
1: 0.5
1: WH/DGN
1: 3556
2: 2
2: 0.5
2: D-GN
2: 3557
3-4
Function
Antenna 3 Signal Hi
Antenna 3 Signal Lo
Not Occupied
Terminal Type
ID
Option
1: I
1: -
2: I
2: -
T10G KEYLESS ENTRY ANTENNA - REAR FASCIA (ATH)
Harness: Body
OEM: 24461693

Terminal Type
Terminated Lead
ID
I
13575569
J-35616-65B (L-BU)
J-38125-12A

Pin
Size
Color
Circuit
1: 1
1: 0.5 1: BN/D-GN
1: 3568
2: 2
2: 0.5 2: D-GN/GY
2: 3569
Function
Terminal Type
ID
Option
1: I
1: -
2: I
2: -
T10J KEYLESS ENTRY ANTENNA - CENTER CONSOLE FRONT (ATH)

Harness: Console
OEM: 24461693

Terminal Type
Terminated Lead
ID
I
Part Catalog
J-35616-14 (GN)
J-38125-560

Pin
Size
Color
Circuit
1: 1
1: 0.5
1: BN/BK
1: 3552
2: 2
2: 0.5
2: WH
2: 3553
Function
Antenna 1 Signal Hi
Antenna 1 Signal Lo
Terminal Type
ID
Option
1: I
1: -
2: I
2: -
T10K KEYLESS ENTRY ANTENNA - CENTER CONSOLE REAR (ATH)


Terminal Type
Terminated Lead
ID
I
13576395
J-35616-64B (L-BU)
J-38125-12A

Pin
Size
Color
Circuit
Function
Terminal Type
ID
Option
1: 1
1: 0.5
1: D-BU
1: 3554

Antenna 2 Signal Hi
1: I
1: -
2: 2
2: 0.5
2: GY/BK
2: 3555
2: I
2: -

Antenna 2 Signal Lo
T10M KEYLESS ENTRY ANTENNA - DRIVER DOOR HANDLE (ATH)
Harness: Driver Door

OEM: 19153433

Terminal Type
Terminated Lead
ID
I
Part Catalog
J-35616-14 (GN)
J-38125-560

Pin
Size
Color
Circuit
1: 1
1: 0.5
1: VT
1: 3560
2: 2
2: 0.5
2: VT/GY
2: 3561
3: 3
3: 0.5
3: GN/WH
3: 6655
4: 4
4: 0.5
4: BK
4: 350
Function
Switch Signal
4: Ground
Terminal Type
ID
Option
1: I
1: -
2: I
2: -
3: I
3: -
4: I
4: -
T10N KEYLESS ENTRY ANTENNA - PASSENGER DOOR HANDLE (ATH)
Harness: Passenger Door

OEM: 19153433


Terminal Type
Terminated Lead
ID
I
Part Catalog
J-35616-14 (GN)
J-38125-560

Pin
Size
Color
Circuit
1: 1
1: 0.5
1: GN/YE
1: 3562
2: 2
2: 0.5 2: D-GN/BK
3: 3 3: 0.75
4: 4
4: 0.5
Function
3: 3576
4: BK
4: 350
Option
1: I
1: -
2: I
2: -
3: I
3: -
4: I
4: -

Switch Lock Signal
4: Ground
2: 3563
3: GY/BU
Terminal Type
ID
T11 MULTIMEDIA PLAYER INTERFACE MODULE (KTA)


Type ID
Lead
Test Probe
I
13579944
Pending
Terminal
Removal
Tool
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
Pending
Not
Available
Not
Available
Not
Available
Not
Available

Pin
Size
Color
Circuit
Function
Terminal Type
ID
Option
1: 1
1: 0.5
1: RD/DGN
1: 3140
1: I
1: -
2: 2
2: 0.35
2: D-BU
2: 2060
Signal
2: I
2: -

3: 3
3: 0.35
3: VT
3: 5843
4: 4
4: 0.35
4: D-GN
4: 3376
5: 5
5: 0.35
5: BARE
5: 3375
6-7
8: 8
8: 0.5
8: D-GN
8: 5060
9-10
11: 11 11: 0.5 11: BK
12:
12: 12
12: GY
0.35
13:
13: 13
13: D-GN
0.35
14:
14: 14
14: VT
0.35
15:
15: 15
15: BN
0.35
16-17
18:
18: 18
18: BARE
0.35
19-20
-
11: 1750
12: 5839
13: 5841
14: 3377
15: 3378
18: 5842
-
3: Auxiliary Audio
Common Signal
4: Auxiliary Audio
Common Signal (3)
5: Auxiliary Audio Drain
Wire (3)
Not Occupied
8: Low Speed GMLAN
Serial Data
Not Occupied
11: Ground
Signal (2)
Signal (2)
Signal (3)
Signal (3)
Not Occupied
(2)
Not Occupied
3: I
3: -
4: I
4: -
5: I
5: -
8: I
8: -
11: I
11: -
12: I
12: -
13: I
13: -
14: I
14: -
15: I
15: -
18: I
18: -
X80L ACCESSORY POWER RECEPTACLE - REAR CONSOLE


Terminal
Type ID
I
Lead
Test Probe
13575721
Terminal
Removal
Tool
J-35616-4A
J-38125-553
(PU)
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
12110844


Pin
Size
Color
Circuit
A: A A: 1.0
A: VT
A: 801
B
C: C C: 1.0
C: BK
C: 2150
Function
Terminal Type
ID
Option
A: I
A: -
C: I
C: -
Not Occupied
C: Ground
X83 AUXILIARY AUDIO INPUT


Terminal
Type ID
Terminal
Removal
Tool
J-35616-64B J-3812513575782
(L-BU)
12A
Lead
Test Probe
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
928999-5
15

Pin
Size
Color
Circuit
1: 1
1: 0.35
1: D-BU
1: 2060
2: 2
2: 0.35
2: GY
2: 5839
3: 3
3: 0.35
3: BARE
3: 5842
4: 4
4: 0.35
4: L-GN
4: 5841
5: 5
5: 0.35
5: VT
5: 5843
X84 DATA LINK CONNECTOR
Function
Signal
Signal (2)
(2)
Signal (2)
5: Auxiliary Audio
Common Signal
Terminal Type
ID
Option
1: I
1: -
2: I
2: -
3: I
3: -
4: I
4: -
5: I
5: -


Description: 16-Way F Metri-Pack/150 Series (BK)

Terminal
Type ID
Lead
Test Probe
13575725
J-35616-14
(GN)
Terminal
Removal
Tool
J-3812512A
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
12129484
19

Pin
Size
Color
Circuit
1: 1
1: 0.5
1: L-GN
1: 5060
2-3
4: 4
5: 5
4: 0.5
5: 0.5
4: BK
5: BK
4: 2150
5: 2150
6: 6
6: 0.5
6: D-BU
6: 2500
7: 7
7: 0.5
7: BN/WH
7: 5043
8-11
12: 12 12: 0.5 12: D-BU/YE
12: 6105
13: 13 13: 0.5
13: WH
13: 6106
14: 14 14: 0.5
14: WH
14: 2501
15
16: 16
16: 0.5 16: RD/D-BU

16: 0.5 16: RD/D-BU
16: 540
16: 540
Function
1: Low Speed GMLAN
Serial Data
Not Occupied
4: Ground
5: Ground
6: High Speed GMLAN
Serial Data (+) (1)
7: Keyword 2000 Serial
Data
Not Occupied
Serial Data (+) (2)
Serial Data (-) (2)
Serial Data (-) (1)
Not Occupied
Voltage
Voltage
Terminal Type
ID
Option
1: I
1: -
4: I
5: I
4: 5: -
6: I
6: -
7: I
7: -
12: I
12: -
13: I
13: -
14: I
14: -
16: I
16: -



Terminal
Type ID
Terminal
Service
Removal
Terminal
Tool
J-35616-64B J-38125- SAIT-A03T13575867
(L-BU)
215A
M064
Lead
Test Probe
Tray
Core
Crimp
Insulation
Crimp
14

Pin
Size
Color
Circuit
Function
2: Ground
Gap Up/Down Switch
Signal
Ladder Signal 2
6: LED Backlight
Dimming Control
Not Occupied
1: 1
2: 2
1: 0.5 1: L-GN/WH
2: 0.5
2: BK
1: 3287
2: 50
3: 3
3: 0.5
3: GY/D-GN
3: 5737
4: 4
4: 0.5 4: L-GN/WH
4: 6819
5: 5
5: 0.5
5: WH/RD
5: 1444
6: 6
6: 0.5
6: YE
6: 6817
7-10

Terminal Type
ID
1: I
2: I
Option
1: 2: -
3: I
3: -
4: I
4: -
5: I
5: -
6: I
6: -

Description: 4-Way F Micro-Pack 064 Series (YE)

Terminal
Removal
Tool
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
Service by
Not
(L-BU)
Available
Assembly 13580115
Not
Available
Not
Available
Not
Available
Not
Available

Type ID
Lead
Test Probe

Pin
Size
Color
Circuit
1: 1
1: 0.5
1: OG/VT
1: 3021
2: 2
2: 0.5
2: BN/OG
2: 3020
3: 3
3: 0.5 3: OG/D-GN
4: 4
4: 0.5
4: WH/DGN
3: 3023
4: 3022
Function
Stage 1 Low Control
Stage 2 Low Control
Terminal Type
ID
Option
1: I
1: -
2: I
2: 3: Early
Production
4: Early
Production
3: I
4: I


Terminal
Type ID
I
Terminal
Service
Removal
Terminal
Tool
J-35616-64B J-38125- SAIT-A03T13575867
(L-BU)
215A
M064
Lead
Test Probe
Tray
Core
Crimp
Insulation
Crimp
14

Pin Size
Color
1-4
5: 5 5: 0.5
5: YE
6: 6 6: 0.5 6: WH/RD
7: D7: 7 7: 0.5
GN/WH
8: 8 8: 0.5
8: BN/DGN
Circuit
Function
5: 6817
6: 1444
Not Occupied
7: Steering Wheel Resistor Ladder Signal
2
8: Cruise Control
Signal
9: Ground
7: 6819
8: 1884
9: 9 9: 0.5
9: BK
9: 50
10: 10:
10: BN/WH 10: 3287
10 0.5
Terminal
Type ID
5: I
6: I
Option
5: 6: -
7: I
7: -
8: I
8: -
9: I
9: -
10: I
10: -

2013 ELECTRICAL Wiring Systems And Power Management - Inline Harness Connector End Views - Index
2013 ELECTRICAL
Wiring Systems And Power Management - Inline Harness Connector End Views - Index
INLINE HARNESS CONNECTOR END VIEWS - INDEX

NOTE:
Inline Harness Connector end views are sorted in alpha/Numeric sequence

based upon connector ID (Code), NOT component name. If you do not know the
connector ID, a search using the relevant component may help locate the
desired connector link.

Description
X100 Body Harness to Forward Lamp Harness
X102 Engine Cooling Harness to Forward Lamp Harness
X105 Engine Harness to Fuel Injectors Harness (LUW/LWE)
X190 Body Harness to Engine Harness
X114 Power Steering Harness to Forward Lamp Harness
X200 Instrument Panel Harness to Body Harness
X203 Instrument Panel Harness to Passenger Instrument Panel Air Bag Harness
X205 Instrument Panel Harness to Body Harness (UQA)
X210 Headliner Harness to Body Harness
X212 Instrument Panel Harness to HVAC Harness (C68)
X300 Console Harness to Instrument Panel Harness
X310 Body Harness to Driver Seat Harness
X320 Body Harness to Passenger Seat Harness
X335 Body Harness to Curtain Air Bag Harness
X401 Fuel Tank Harness to Body Harness
X402 Rear Object Sensor Harness to Body Harness (UD7)
X410 Left Tail Lamp Harness to Body Harness
X420 Right Tail Lamp Harness to Body Harness
X500 Driver Door Harness to Body Harness
X600 Passenger Door Harness to Body Harness
X700 Left Rear Door Harness to Body Harness
X800 Right Rear Door Harness to Body Harness
X900 Rear Compartment Lid Harness to Body Harness
X910 Left Inner Tail Lamp Harness to Rear Compartment Lid Harness
X920 Right Inner Tail Lamp Harness to Rear Compartment Lid Harness
X915 License Lamp Harness to Rear Compartment Lid Harness (-UVC)

2013 ELECTRICAL Wiring Systems And Power Management - Inline Harness Connector End Views - Index
X915 License Lamp Harness to Rear Compartment Lid Harness (UVC)

2013 ELECTRICAL Wiring Systems and Power Management - Component Locator - Inline Harness Connector End
Views - Cruze
2013 ELECTRICAL
Wiring Systems and Power Management - Component Locator - Inline Harness Connector End
Views - Cruze
INLINE HARNESS CONNECTOR END VIEWS

X100 BODY HARNESS TO FORWARD LAMP HARNESS
Harness Type: Body

Description: 40-Way F 1.5/2.8 Series, Sealed
(BK)

Description: 40-Way M 1.5/2.8 Series, Sealed
(BK)

Terminal
Type ID
Lead
Test Probe
13575393
II
13578874
III
13575356
IV
13327146
J-35616-35
(VT)
J-35616-14
(GN)
J-35616-3
(GY)
J-35616-5
(PU)
Terminal
Removal
Tool
Tray
Core
Crimp
Insulation
Crimp
J-38125-36 4-964286-1
16
J-38125-560
964274-2
16
J-38125-560
964269-3
32
15
32
J-38125-36 1-962915-3
SEALED:
13575387
J-35616-3
J-38125-560
UNSEALED:
(GY)
13327171
X100 Body Harness to Forward Lamp Harness

Terminal
Pin
Size
Color Circuit
Option
Type ID
1:
1
Service
Terminal
1: 1
1: YE
1: 712
1: I
1: -
969079-2
Function
Pin
1: Left
1:
Headlamp Low
1
Beam Control
2: Shutter
Size
Color
Circuit
Termin
Type I
1: 1
1: YE
1: 712
1: IV

Views - Cruze
2:
2
3-7
8:
8
2: 0.75
8: 0.5
2: GY/BK
2:
3437
-
8: BN/D8: 109
GN
2: 8: -
9:
9
9: 0.5
9: D-BU
9:
2500
9: -
10:
10
10: 0.5
10: WH
10:
2501
10: -
11:
11
11: 0.5
11: D-BU
11:
2500
11: -
12:
12
12: 0.5
12: WH
12:
2501
12: -
13:
13
13: 0.5
13:
WH/DBU
13:
5986
13: -
1416
17:
17
17: 1
17: YE
17:
312
17: -
18:
18
18: 0.5
18: DBU/WH
18:
1314
18: -
19:
19
19: 0.5
19: DGN/VT
19:
1315
19: -
20:
20
20: 0.5
20:
VT/WH
20:
5203
20: -
21:
21
21: 0.5
21: DBU/GY
21:
636
21: -
22:
22
22: 0.5
2324
22: BK/D22: 61
BU
22: -
2: Valve Solenoid 2:
WA7
Control
2
Not Occupied 3-7
8: Hood Ajar 8:
8: Switch Signal 8
9: High Speed
9:
9: - GMLAN Serial
9
Data (+) (1)
10: High Speed
10:
10: - GMLAN Serial
10
Data (-) (1)
11: High Speed
11:
11: - GMLAN Serial
11
Data (+) (1)
12: High Speed
12:
12: - GMLAN Serial
12
Data (-) (1)
13: Serial Data
13:
13: - Communication
13
Enable
14Not Occupied
16
17: Right
17:
17: - Headlamp Low
17
Beam Control
18: Left Front
18:
Turn Signal
18: 18
Lamp Control
19: Right Front
19:
19: Turn Signal
19
Lamp Control
20: Air Quality 20:
20: Sensor Signal 20
21: Outside
Ambient Air 21:
21: Temperature 21
Sensor Signal
22: Outside
Ambient
22:
22: - Temperature
22
Sensor Low
Reference
23Not Occupied
24
25: Right Front
2: 0.75
8: 0.5
2: GY/BK
2:
3437
-
8: BN/D8: 109
GN
2: III
8: -
9: 0.5
9: D-BU
9:
2500
9: -
10: 0.5
10: WH
10:
2501
10: -
11: 0.5
11: D-BU
11:
2500
11: -
12: 0.5
12: WH
12:
2501
12: -
13: 0.5
13:
WH/DBU
13:
5986
13: -
17: 1
17: YE
17:
312
17: -
18: 0.5
18: LBU/WH
18:
1314
18: -
19: 0.5
19: DGN/VT
19:
1315
19: -
20: 0.5
20:
VT/WH
20:
5203
20: -
21: 0.5
21: DBU/GY
21:
636
21: -
22: 0.5
22: BK/D22: 61
BU
22: -

Views - Cruze
25:
25:
25:
25:
25 0.5BK/OG 0.5BK/OG 5600
25: -
26:
26
26: 0.5
26: OG/D- 26:

GN
1409
26: -
27:
27
27: 0.5
27: BN/D- 27:

GN
109
27: -
28:
28
28: 0.5
28: BN/D28: 59
GN
28: -
29
30:
30
31:
31
3233
30: 0.5
31: 0.5
-
30:
VT/GY
31:
GY/BN
30:
709
31:
309
34: BN/D- 34:

GN
196
30: 31: -
Discriminating
Sensor Low
Reference
26: Right Front
26: - Discriminating
Sensor Signal
27: Hood Ajar
27: Switch Signal
28:
28: A/C
LXT,
Compressor
LXV
Clutch Control
or 2H0
Not Occupied
30: Left Park
30: Lamp Control
31: Right Park
31: Lamp Control
25: -
34: -
34: -
34:
34
34: 0.5
35:
35
35: 0.5
35:
GY/WH
35:
7064
35: -
35: -
36:
36
36: 0.5
36: GY
36:
830
36: -
36: -
37:
37
37: 0.5
37:
GY/BN
37:
7065
37: -
37: -
38:
38
38: 0.5
38: YE
38:
872
38: -
38: -
39:
39
39: 0.5
39:
OG/YE
39:
354
39: -
39: -
40:
40
40: 0.5
40:
BK/OG
40:
5045
40: -
40: -
25:
25:
25:
25:
25 0.5BK/OG 0.5BK/OG 5600
25: -
26:
26
26: 0.5
26: -
27:
27
27: -
28:
28
28: 0.5
29
30:
30
31:
31
32Not Occupied
33
34: Windshield
Wiper Motor 34:
Park Switch 34
Signal
35: Wheel
Speed Sensor 35:
Control Left 35
Front
36: Wheel
Speed Sensor 36:
Signal Left 36
Front
37: Wheel
Speed Sensor 37:
Control Right 37
Front
38: Wheel
Speed Sensor 38:
Signal Right 38
Front
39: Left Front
39:
Discriminating
39
Sensor Signal
40: Left Front
Discriminating 40:
Sensor Low 40
Reference
30: 0.5
31: 0.5
-
34: 0.5
26: OG/D- 26:

GN
1409
27: -
27: -
28: BN/D28: 59
GN
30:
VT/GY
31:
GY/BN
30:
709
31:
309
34: BN/D- 34:

GN
196
27: -
28: 30: 31: -
34: -
35: 0.5
35:
GY/WH
35:
7064
35: -
36: 0.5
36: GY
36:
830
36: -
37: 0.5
37:
GY/BN
37:
7065
37: -
38: 0.5
38: YE
38:
872
38: -
39: 0.5
39:
OG/YE
39:
354
39: -
40: 0.5
40:
BK/OG
40:
5045
40: -

Views - Cruze
X102 ENGINE COOLING HARNESS TO FORWARD LAMP HARNESS


Service Connector: Service by Harness - See
Part Catalog
Description: 4-Way F 2.8 6.3 MCP Series,
Sealed (BK)


Type ID
Lead
Test Probe
Terminal
Removal
Tool
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
Not
Available
Not
Available
Not
Available
Not
Available
15
Not
Available
Not
Available
Not
Available
Pending
Pending
Pending
Pending
Pending
II
Pending
Pending
Pending
Pending
Pending
III
13327146
IV
13578881
J-35616-5
(PU)
Not
Available
J-38125-36 1-962915-3
Not
Available
Not
Available

Terminal
Pin Size Color Circuit
Option Function Pin
Type ID
1: Cooling
1:
Fan Motor 1: 1
1: 1 1: 4 1: YE
1: I
1: 5358
Control (3)
2: Cooling
2:
2: 2
2: GY 2: 532
2: I
2: Fan Motor 2: 2
2.5
Control (2)
3:
3: Cooling
3:
3: 3
WH/D- 3: 409
3: I
3: Fan Motor 3: 3
2.5
BU
Control (1)
4
Not Occupied 4
Size Color Circuit
Terminal
Option
Type ID
1:
5358
1: II
1: -
2:
2: GY 2: 532
2.5
2: IV
2: -
3: II
3: -
1: 4 1: YE
3:
3:
WH/D- 3: 409
2.5
BU
-
X104 ENGINE COOLING HARNESS TO FORWARD LAMP HARNESS

Views - Cruze


Service Connector: Service by Harness- See
Part Catalog
Description: 5-Way F 1.5 MCP Series, Sealed
(BK)


Terminal
Type ID
Lead
Test Probe
II
Pending
No Tool
Reqd
Terminal
Removal
Tool
No Tool
Reqd
SEALED:
13575387
J-35616-3
J-38125-560
UNSEALED:
(GY)
13327171
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
15366022
20
Not
Available
Not
Available
969079-2
32

Terminal
Option Function Pin
Type ID
1: A/C
1: 1: DRefrigerant
1: 1
1: 380
1: I
1: 1: 1
0.5 GN
Pressure
Sensor Signal
2: A/C
2:
2:
2:
Pressure
2: 2
2: I
2: 2: 2
0.5 BN/RD 2700
Sensor 5V
Reference
3: A/C
Refrigerant
3:
3:
3:
3: 3
3: I
3: Pressure
3: 3
0.5 BK/BN 5514
Sensor Low
Reference
4: Coolant
4: 4: D4:
4: 4
4: I
4: - Temperature 4: 4
0.5 GN/VT 2032
Sensor Signal
5:
5:
5:
5: Coolant
Temperature
Size Color Circuit

1:
0.5
Terminal
Option
Type ID
1: D1: 380
GN
1: II
1: -
2:
2:
2:
0.5 BN/RD 2700
2: II
2: -
3:
3:
3:
0.5 BK/BN 5514
3: II
3: -
4: 4: D4:
0.5 GN/VT 2032
4: II
4: -
5:
5:
5:

Views - Cruze
5: 5
0.5 BK/D- 6813

BU
5: I
5: -
Sensor #2
Low
Reference
0.5 BK/D- 6813

BU
5: 5
5: II
5: -
X105 ENGINE HARNESS TO FUEL INJECTORS HARNESS (LUW/LWE)



Part Catalog
Description: 7-Way M 1.6 Series, Sealed
(BK)

Type ID
Lead
Test Probe
I
Pending
II
Pending
Terminal
Removal
Tool
J-35616-14
J-38125-560
(GN)
Pending
Pending
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
964274-2
16
Pending
Pending
Not
Available
Not
Available
X105 Engine Harness to Fuel Injectors Harness (LUW/LWE)

Terminal
Option Function Pin
Type ID
1: Fuel
1:
1:
1:
1: 1
1: I
1: Injector
1: 1
0.5 BN/VT 1744
Control (1)
2: Fuel
2:
2:
2:
Injector
2: 2
2: I
2: 2: 2
0.5 YE/WH 1745
Control (2)
3: Fuel
3:
3:
3:
3: 3
3: I
3: 3: 3
Injector
0.5 BN/VT 1746
Control (3)
4: Fuel
4:
4:
Injector
4: 4
4: 844
4: I
4: 4: 4
0.5 BN/YE
Control (4)
5:
5:
5:
5: Powertrain
Main Relay
Size Color Circuit

1:
0.5
Terminal
Option
Type ID
1:
1744
1: II
1: -
2: 2: L2:
0.5 GN/BK 1745
2: II
2: -
3:
3:
3:
0.5 WH/BK 1746
3: II
3: -
4: 4: D4: 844
0.5 BU/BK
4: II
4: -
5:
1: BN
5:
5:

Views - Cruze
0.5 VT/DBU
6-7 -
5: 5
5291
-
5: I
5: -
Fused Supply
0.5 PK/BK 5291
5: 5
(2)
Not Occupied 6-7 -
5: II
5: -
X190 BODY HARNESS TO ENGINE HARNESS
Harness Type: Body

Description: 40-Way F 1.5/2.8 Series, Sealed
(GY)

Description: 40-Way M 1.5/2.8 Series, Sealed
(GY)

Type ID
Lead
Test Probe
I
13327156
II
Pending
III
Pending
IV
13575380
Terminal
Removal
Tool
Service
Terminal
J-35616-35
J-38125-36 4-964286-1
(VT)
J-35616-14
J-38125-560 964274-2
(GN)
Service by
Harness Not
Pending
See Part
Available
Catalog
J-35616-3
J-38125-560 964265-2
(GY)
Tray
Core
Crimp
Insulation
Crimp
16
16
Service by
Harness See Part
Catalog
Not
Available
Not
Available
28
X190 Body Harness to Engine Harness

Terminal
Terminal
Option
Function
Option
Type ID
Type ID
1 Not Occupied 1 2: LUJ 2: Brake Apply
2: LUJ
2: 2:
2:
2: 2:
2:
2: WH
2: with Sensor Supply
2: WH
2: with
2 0.5
5359
2 0.5
5381
MH8
Voltage
MH8
3: LUJ
3: LUJ
3: 3:
3:
3:
3: Low
3: 3:
3:
3:
3: with
3: with
3 0.5 BK/BN 5360
Reference
3 0.5 BK/BN 5382
MH8
MH8
4: 4:
4: D-
4:
4: LUJ 4: Brake Apply 4: 4:
4: L-
4:
4: LUJ

Views - Cruze
4 0.5 BU/YE 5361

5
6: 6: 6: D6:
6 0.5 BU/VT 1589
7 8: 8:
8: YE
8 0.5
8:
6111
4: -
with
MH8
-
6: -
6: -
8: -
9: 9:
9:
9:
9 0.5 GY/RD 6109
9: -
10:
10: 10:
10:
WH/D10 0.5
6311
BU
10: -
11: -
11: -
12: 12: 12:

12:
12 0.5 BN/WH 419
12: -
12: -
13: 13:
13:
13: WH
13 0.5
2501
13: -
13: -
14: 14: 14: D14 0.5 BU
14:
2500
14: -
14: -
15: 15: 15: D15 0.5 GN/GY
15:
465
15: -
15: -
18:
6281
18: -
18: -
19: 19: 19: D- 19:

19 0.5 BU/WH 890
19: -
19: -
20: 20: 20:

20:
20 0.5 YE/RD 2709
20: -
20: -
21: 21:
21:
21: WH
21 0.75
1310
21: -
21: -
18:
18: 18:
BK/D18 0.5
GN
4 0.5 BU/YE 5380
Not Occupied
6: Primary Fuel
6:
Level Sensor
6
Signal
Not Occupied 7
8: Clutch Apply 8:
8: Sensor Signal 8
9: Clutch Apply
9:
9: - Sensor Voltage
9
Reference
10:
10:
10: - Cruise/ETC/TCC
10
Brake Signal
11: 11: 11:

11:
11 0.5 VT/YE 5985
1617
Sensor Signal
6: 6: D6:
0.5 BU/VT 1589
6: 6: L6:
0.5 BU/VT 1589
8:
8:
8: YE
0.5
6111
9:
9:
9:
0.5 GY/RD 6109
10:
10:
10:
WH/L0.5
6311
BU
11: 11: L- 11:
11: Accessory
11: 0.5 BU
5985
Wakeup Serial
11 11: 11:
11:
Data
0.5 VT/YE 5985
12: Check
12: 12: 12:
12:
Engine Indicator
12 0.5 BN/WH 419
Control
13: High Speed
13: 13:
13:
GMLAN Serial
13: WH
13 0.5
2501
Data (-) (1)
14: High Speed
14: 14: 14: L- 14:
GMLAN Serial
14 0.5 BU
2500
Data (+) (1)
15: 15: L- 15:
15: Fuel Pump
15: 0.5 GN/GY 465
Primary Relay
15 15: 15: D- 15:
Control
0.5 GN/GY 465
16Not Occupied
17
18:
18: Low
18: 18:
18:
BK/DReference
18 0.5
6281
GN
19: Fuel Tank
19: 19: 19: L- 19:
Pressure Sensor
19 0.5 BU/WH 890
Signal
20: 5 Volt
20: 20: 20:
20:
Reference
20 0.5 YE/RD 2709
21: 21:
21:
21: EVAP
21: WH
21
0.75
1310
Canister Vent
4: 6: 8: -
with
MH8
6: LUJ
6:
LUW
8:
MF3
9: -
9:
MF3
10: -
10: -
11: -
11:
LUJ
11:
LUW
12: -
12: -
13: -
13: -
14: -
14: -
15: -
15:
LUJ
15:
LUW
18: -
18: -
19: -
19: -
20: -
20: -
21: -
21: -

Views - Cruze
Solenoid Control
22:
22: 22:
BK/D22 0.5
GN
22:
6281
22: -
22: -
23: 23: 23:

23:
23 0.5 BK/GY 6110
23: -
23: -
24:
24: 24:
BK/D24 0.5
BU
24:
1271
24: -
24: -
25: 25: 25:

25:
25 0.5 YE/WH 1161
25: -
25: -
26: 26: 26:

26:
26 0.5 WH/RD 1164
27:
27:
27: BK
27: 0.5
1272
27:
27 27:
27:
BK/VT
0.5
1272
26: -
26: -
27: -
27:
LUJ
27:
LUW
28: 28: 28: D- 28:

28 0.5 GN/WH 1162
28: -
28: -
29: 29: 29:

29:
29 0.5 BN/RD 1274
29: -
29: -
30: -
30: -
32: I
32: -
30: 30: 30: D30 0.75 BU

31 -
30:
5372
-
32: 32: 32: D- 32:

32 0.75 BU/BN 7573
22: Low
Reference
22:
22: 0.5
22 22:
0.5
22:
BN/DGN
22:
BK/DGN
23: Clutch Apply

23: 23: 23:
Sensor Low
23 0.5 BK/GY
Reference
24:
24: Accelerator
24:
BK/VT
Pedal Position 24: 0.5
24:
Low Reference 24 24:
BK/L(1)
0.5
BU
25: Accelerator
25: 25: 25:
Pedal Position
25 0.5 YE/WH
Signal (1)
26: 26:
26: Accelerator
26: 0.5 BN/RD
Pedal Position
26 26: 26:
5V Reference (1)
0.5 WH/RD
27: Accelerator
Pedal Position
Low Reference
27: 27:
(2)
27: 0.5 BN/VT
27: Accelerator 27 27: 27:
Pedal Position
0.5 BK/VT
Low Reference
(2)
28: 28: L28: Accelerator
28: 0.5 GN/WH
Pedal Position
28 28: 28: DSignal (2)
0.5 GN/WH
29: Accelerator
29: 29: 29:
Pedal Position
29 0.5 BN/RD
Signal (2)
30: Canister 30: 30: 30: DValve Solenoid 30 0.75 BU
Not Occupied 31 32: Electric
32: 32:
Variable
32: 0.75 BN/BK
Displacement 32 32: 32: LSupply
0.75 BU/BN
33: Electric
33:
33: BK/D-
22:
6281
22:
6281
22: -
22:
LUJ
22:
LUW
23:
6110
23: -
23: -
24:
1271
24:
1271
24: -
24:
LUJ
24:
LUW
25:
1161
25: -
25: -
26: -
26:
LUJ
26:
LUW
27: -
27:
LUJ
27:
LUW
28:
1162
28:
1162
28: -
28:
LUJ
28:
LUW
29:
1274
29: -
29: -
30: -
30: -
32:
LUJ
32:
LUW
26:
1164
26:
1164
27:
1272
27:
1272
30:
5372
32:
7573
32:
7573
33:
32: III
33:

Views - Cruze
33: 33: 33: D- 33:

33 0.75 BU/YE 7574
3440
33: I
33: -
Variable
0.75 BU
7574
33:
Displacement
33: 33: L- 33:
33
Control
0.75 BU/YE 7574
34Not Occupied
40
33: III
LUJ
33:
LUW
X114 POWER STEERING HARNESS TO FORWARD LAMP HARNESS

Description: 12-Way F GT 150 Series, Sealed
(BK/VT)

Description: 12-Way M (BK/VT)

Terminal
Type ID
Lead
Test Probe
13578912
II
Pending
Terminal
Removal
Tool
J-35616-2A
J-38125-553
(GY)
J-35616-3
J-38125-553
(GY)
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
12191819
15326269
19
X114 Power Steering Harness to Forward Lamp Harness

Terminal
Option Function
Type ID
A: High Speed
A: A: A: DA:
A: I
A: - GMLAN Serial
A 0.5 BU
2500
Data (+)
B: High Speed
B: B:
B:
B: WH
B: I
B: - GMLAN Serial
B 0.5
2501
Data (-) (1)
C: High Speed
C: C: C: DC:
C: I
C: - GMLAN Serial
C 0.5 BU
2500
Data (+)
D: High Speed
D: D:
D:
D: WH
D: I
D: - GMLAN Serial
D 0.5
2501
Data (-) (1)
E-K Not Occupied

A: A: A: DA 0.5 BU
Terminal
Option
Type ID
A:
2500
A: II
A: -
B: B:
B:
B: WH
B 0.5
2501
B: II
B: -
C: C: C: DC 0.5 BU
C:
2500
C: II
C: -
D: D:
D:
D: WH
D 0.5
2501
D: II
D: -
E-K

Views - Cruze
L:
L: L:
L:
WH/DL 0.5
5986
BU
M -
L: I
-
L: Serial Data
L:
L: L:
L:
L: - Communication
WH/DL 0.5
5986
Enable
BU
Not Occupied M -
L: II
L: -
X200 INSTRUMENT PANEL HARNESS TO BODY HARNESS

Description: 102-Way F 1.6/2.8/8.0 Timer
Series (BK)
Harness Type: Body

Description: 102-Way M 1.6/2.8/8.0 Timer
Series (BK)

Type ID
Lead
Test Probe
I
Pending
II
13575472
III
13575760
IV
13575591
Pending
VI
Pending
VII
13575574
VIII
13575593
J-35616-44
(YE)
J-35616-35
(VT)
J-35616-14
(GN)
J-35616-14
(GN)
J-35616-3
(GY)
J-35616-21
(RD)
J-35616-5
(PU)
J-35616-14
(GN)
Terminal
Removal
Tool
N/A
1: D-
1:
1: -
Tray
962932-1//A 962932-1//A
Core
Crimp
Insulation
Crimp
Not
Available
Not
Available
J-38125-36 4-965999-1
25
J-38125-560
964274-2
16
J-38125-560
964265-2
28
J-38125-560
969079-2
32
Not
Available
Not
Available
J-38125-221 963768-2//A 963768-2//A

J-38125-36 2-964296-1
31
J-38125-560
28
X200 Instrument Panel Harness to Body Harness

Terminal
Option
Type ID
1: 1: 0.75
Service
Terminal
1: UQA
964265-2
Function
1: Front Center

1: 1:
1: D-
1:
Terminal
Op
Type ID
1: -
1: U

Views - Cruze
BU/YE
2: 0.75 2: 0.75
2:
1860
1860
2
YE/WH YE/WH
3
4:
4: L4: 0.75
4
BU/BN
5:
5: D5: 0.75
5
BU/YE
6-7
-
1960
2:
1860
4:
7573
5:
7574
-
2: -
2: UQA
4: 5: -
8:
8:
8:
8: 0.5
8
BN/BK 3552
8: -
9:
9: 0.5
9
9:
3554
9: -
10:
10:
10:
10: 0.5
10
GY/BK 3555
10: -
11:
11:
11: 0.5 11: WH
11
3553
11: -
9: DBU
12:
12
12:
0.75
12:
BN/DBU
12:
118
12: -
13:
13
13:
0.75
13:
YE/BK
13:
117
13: -
14:
14
14:
0.75
14: DGN/BK
14:
116
14: -
15: 15:
15: D- 15:
15 0.75 BU/BK 115
16:
16:
16:
16: 0.5
16
VT/BK 7553
1718
15: 16: -
19:
19: D- 19:
19: 0.5
19
BU/YE 6105
19: -
20:
20:
20: 0.5 20: WH
20
6106
20: -
21:
21:
21: 0.5
21: 40
21
RD/WH
21: -
Speaker (-)
1 0.75 BU/YE 1960
2: Front Center
Speaker (+)
2: 2:
2:
2:
2 0.75 YE/WH 1860
Not Occupied
3 4: Electric Variable 4: 4: 4: D4: Displacement Supply 4 0.75 BU/BN
5: Electric Variable 5: 5: 5: D5: Displacement Control 5 0.75 BU/YE
Not Occupied
6-7 8: Passive Start
8: 8:
8:
8: Interior Antenna 1
8 0.5 BN/BK
Signal Hi
9: Passive Start
9: 9: 9: D9: Interior Antenna 2
9 0.5 BU
Signal Hi
10: Passive Start
10: 10: 10:
Interior Antenna 2
10: 10 0.5 GY/BK
Signal Lo
11: Passive Start
11: 11:
11: Interior Antenna 1
11: WH
11 0.5
Signal Lo
12:
12:
12: Left Front
12: 12:
WIthout
BN/DSpeaker Signal (-) 12 0.75
UQA
BU
13:
13: Right Front
13: 13: 13:
WIthout
Speaker Signal (-) 13 0.75 YE/BK
UQA
14:
14: Left Rear Speaker 14: 14: 14: DWIthout
Signal (-)
14 0.75 GN
UQA
15: Right Rear
15: 15: 15: D15: Speaker Signal (-) 15 0.75 BU
16: Park Lock
16: 16: 16:
16: Solenoid Control 16 0.5 VT/BK
17Not Occupied
18
19: High Speed
19: 19: 19: D19: - GMLAN Serial Data
19 0.5 BU/YE
(+) (2)
20: High Speed
20: 20:
20: - GMLAN Serial Data
20: WH
20 0.5
(-) (2)
21: Battery Positive 21: 21: 21:
21: Voltage
21 0.5 RD/WH
4:
7573
5:
7574
-
2: -
2: U
4: -
5: -
8:
3552
8: -
9:
3554
9: -
10:
3555
10: -
10
11:
3553
11: -
11
12:
118
12: -
13:
117
13: -
14:
116
14: -
15:
115
16:
7553
1
WIt
UQ
1
WIt
UQ
1
WIt
UQ
15: -
15
16: -
16
19:
6105
19: -
19
20:
6106
20: -
20
21: 40
21: -
21

Views - Cruze
22:
22: 0.5 22: YE 22: 40
22
22: -
23:
23
23:
0.75
23: DBU
23:
201
23: -
24:
24
24:
0.75
24: YE
24:
200
24: -
25:
25
25:
0.75
25: DGN
25:
199
25: -
26:
26
26:
0.75
26: WH 26: 46
27:
27: D27: 1
27
BU/VT
28
-
27:
807
-
26: 27: -
29:
29:
29:
29: 0.5
29
BK/GY 6110
29: -
30:
30:
30: 0.5 30: YE
30
6111
30: -
31:
31:
31:
31: 0.5
31
GY/RD 6109
31: -
32:
32: 0.5 32: YE
32
33:
33: 33:
GY/D33 0.35
GN
34
35:
35: L35: 0.5
35
GN/BK
36:
36:
36: 0.5 YE/D36
GN
32:
7546
32: -
33:
7565
33: -
35:
5103
35: -
36:
3274
36: -
37:
37: D- 37:
37: 0.5
37
BU/WH 3275
37: -
38:
38:
38:
38: 0.5
38
GY/WH 3272
38: -
39:
39:
39: 0.5 39: GY
39
3273
39: -
40:
40:
40: D-
40:
22: -
22: Battery Positive 22: 22:

22: YE 22: 40
Voltage
22 0.5
23:
23: Left Front
23: 23: 23: DWithout
Speaker (+)
23 0.75 BU
UQA
24:
24: Right Front
24: 24:
24: YE
WIthout
Speaker (+)
24 0.75
UQA
25:
25: Left Rear Speaker 25: 25: 25: DWIthout
(+)
25 0.75 GN
UQA
26:
26: Right Rear
26: 26:
WIthout
26: WH
Speaker (+)
26 0.75
UQA
27: OFF/Accessory 27: 27: 27: D27: Voltage
27 1 BU/VT
Not Occupied
28 29: Clutch Apply
29: 29: 29:
29: Sensor Low
29 0.5 BK/GY
Reference
30: Clutch Apply 30: 30:
30: 30: YE
Sensor Signal
30 0.5
31: Clutch Apply
31: 31: 31:
31: Sensor Voltage
31 0.5 GY/RD
Reference
32: Logistics Relay 32: 32:
32: 32: YE
Control
32 0.5
33:
33: Windscreen
33: 33:
33: C68
GY/DTemp Sensor Signal 33 0.35
GN
Not Occupied
34 35: Technology
35: 35: 35: D35: Identification
35 0.5 GN/BK
36: Remote Function
36:
36: 36:
Actuator Transmit
YE/D36: 36 0.5
Signal
GN
37: Remote Function
37: 37: 37: D37: Actuator Receive
37 0.5 BU/WH
Signal
38: Remote Function
38: 38: 38:
38: Actuator Supply
38 0.5 GY/WH
Voltage
39: Remote Function 39: 39:
39: 39: GY
Actuator Return
39 0.5
40: Steering Column 40: 40: 40: D-
22: -
23:
201
23: -
24:
200
24: -
25:
199
25: -
26: 46
26: -
27:
807
-
27: -
22
2
Wit
UQ
2
WIt
UQ
2
WIt
UQ
2
WIt
UQ
27
29:
6110
29: -
29
30:
6111
30: -
30
31:
6109
31: -
31
32:
7546
32: -
32
33:
7565
35:
5103
33: IV 33:
35: -
35
36:
3274
36: -
36
37:
3275
37: -
37
38:
3272
38: -
38
39:
3273
39: -
39
40:

Views - Cruze
40
0.75
GN/VT 1601
41:
41: D41: 0.5
41
BU/GY
4243
41:
636
41: -
44:
44:
YE/D3197
BU
45:
45:
45:
45: 0.5
45
YE/WH 1161
46:
46:
46:
46: 0.5 BK/D46
1271
BU
44:
44
40: -
44:
0.35
47:
47:
47:
47: 0.5
47
BK/VT 1272
48:
48: L- 48:
48: 0.5
48
GN/WH 1162
49:
49:
49: 0.5 BK/D- 49: 61
49
BU
50: 50:
50:
50:
50 0.35 VT/WH 5203
44: 45: 46: -
47: 48: 49: 50: -
51:
51: L- 51:
51: 0.5
51
GN/GY 6135
51: -
52:
52:
52: 0.5 52: WH
52
5359
52: -
53:
53:
53: 0.5 VT/L- 53: 39
53
GN
54:
54:
54: 0.5 RD/L- 54: 40
54
GN
55:
55:
55:
55: 0.5 RD/D55
840
BU
56:
56: L- 56:
56: 0.5
56
GN/BK 2515
57:
57:
57: 0.5
57: 39
57
BN/YE
58:
58:
58:
58:
53: -
54: -
40: -
Lock Signal
40 0.75 GN/VT
41: Outside Ambient
41: 41: 41: DAir Temperature
41: 41 0.5 BU/GY
Sensor Signal 45
42Not Occupied
43
44: Humidity
44:
44: 44:
44: C68 Temperature Sensor
YE/D44 0.35
Signal
BU
45: Accelerator Pedal 45: 45: 45:
45: Position Signal (1) 45 0.5 YE/WH
46:
46: 46:
46: Position Low
BK/D46 0.5
Reference (1)
BU
47: 47: 47:
47: Position Low
47 0.5 BK/VT
Reference (2)
48: Accelerator Pedal 48: 48: 48: D48: Position Signal (2) 48 0.5 GN/WH
49: Outside Ambient
49:
49: 49:
49: - Temperature Sensor
BK/D49 0.5
Low Reference
BU
50: Air Quality
50: 50: 50:
50: Sensor Signal
50 0.5 VT/WH
51: Linear
51: 51: 51: D51: - Interconnect Network
51 0.5 GN/GY
Bus 4
52: Brake Apply
52: 52:
52: Sensor Supply
52: WH
52 0.5
Voltage
53:
53: 53:
VT/D53: - 53: Ignition Voltage
53 0.5
GN
54:
RD/D54: Voltage
54 0.5
GN
55: -
55: -
56: -
56: -
57: -
57: -

Voltage
55 -
55: -
1601
40: -
40
41:
636
41: -
41
44:
3197
45:
1161
45: -
45
46:
1271
46: -
46
47:
1272
47: -
47
48:
1162
48: -
48
49: 61
49: -
49
50:
5203
50: -
50
51:
6135
51: -
51
52:
5359
52: -
52
53: 39
53: -
53
54: 40
54: -
54
55: -
55: -
55
56: -
56
57: -
57
56: Keypad Supply 56: 56: 56: L- 56:

Voltage
56 0.5 GN/BK 2515
57:
57: 57:
RD/D- 57: 39
57 0.5
GN
58: Lift Glass/Trunk 58: 58:
58:
44: IV 44:
58:

Views - Cruze
58
0.75
GY/YE 6188
59:
59:
59:
59: 1
59
WH/BN 6815
60
61:
61:
61:
61: 0.5
61
BN/VT 193
62:
62
62:
0.35
63:
63
63:
0.35
64:
64
64:
0.35
62:
BK/DBU
62:
7566
63:
63:
GY/D7564
BU
64:
64:
YE/RD 597
58: 59: 61: -
62: -
63: 64: -
65:
65:
65:
65: 0.5
65
BN/RD 1274
65: -
66:
66:
66:
66: 0.5
66
WH/RD 1164
66: -
67:
67:
67:
67: 0.5
67
WH/VT 5905
67: -
68:
68: L- 68:
68: 0.5
68
GN/BN 2087
68: -
69:
69: D- 69:
69: 0.5
69
BU/YE 6795
69: -
70:
70:
70:
70: 0.5
70
VT/WH 239
71:
71: 71: 0.5 VT/WH 71: 39
71 71: 0.5 71: 71: 39
VT/WH
72:
72:
72:
72: 0.5 GY/L72
328
GN
73:
73:
73: 0.5 73: YE
73
5191
74: 74: 0.5
74:
74:
70: -
Motor Release
58 0.75 GY/YE
Control
59: Inadvertent
59: 59: 59:
59: Power Control
59 0.5 WH/BN
Not Occupied
60 61: Rear Defog Relay 61: 61: 61:
61: Control
61 0.5 BN/VT
62:
62:
Humidity/Windscreen 62: 62:
62: C68
BK/DTemp Sensor Low 62 0.35
BU
Reference
63:
63: Humidity Sensor 63: 63:
63: C68
GY/DSignal
63 0.35
BU
64: 64: 64:
64: C68 64: 5V Reference
64 0.35 YE/RD
65: 65: 65:
65: Position 5V
65 0.5 BN/RD
Reference (2)
66: 66: 66:
66: Position 5V
66 0.5 WH/RD
Reference (1)
67: Key
Capture/Column 67: 67: 67:
67: Lock Shift Position 67 0.5 WH/VT
Signal
68: Combined
68: 68: DVehicle Inertial
68: 0.5 GN/BN
68: Sensor Supply
68 68: 68: DVoltage
0.5 GN/BN
69: Lift Glass/Trunk
69: 69: 69: D69: Motor Release
69 0.5 BU/YE
Control 2
70: 70: 70:
70: - 70: Ignition Voltage
70 0.5 VT/WH
58: -
71: -
71: -
72: -
72: -
73: 74: -
6188
59:
6815
61:
193
74:
59: -
59
61: -
61
62: -
62:
63:
7564
63: -
63:
64:
597
64: -
64:
65:
1274
65: -
65
66:
1164
66: -
66
67:
5905
67: -
67
68:
2087
68:
2087
68: V
68
69:
6795
69: -
69
70:
239
70: -
70
71: -
71
72: -
72
73: -
73
74: -
74
71: Ignition Voltage 71: 71: 71:

71: 39
71: Ignition Voltage 71 0.5 VT/WH
74: Microphone Low 74: 74:
58
62:
7566
72:
72: Interior Lamp 72: 72:
72:
GY/DDefeat Switch Signal 72 0.5
328
GN
73: Microphone High 73: 73:
73:
73: 73: YE
Signal
73 0.5
5191
74: -
58: -
74:

Views - Cruze
74
75:
75
76:
76
77:
77
78:
78
79:
79
75: 0.5
76: 0.5
77: 0.5
78: 0.5
79: 0.5
80:
80: 0.5
80
BARE
75:
BN/WH
76:
YE/VT
77: LGN/WH
78:
BN/WH
79:
BN/WH
80:
WH/DBU
81: D81: 81: 0.5 BU

81 81: 0.5 81: DBU
5193
75:
2517
76:
2516
77:
2514
78:
5043
79:
419
80:
507
Signal
75: -
75: -
76: -
76: -
77: -
77: -
78: -
78: -
79: -
79: -
80: -
80: -
81:
6105
81:
6105
81: -
81: -
82:
82: 82: 0.5 82: WH 6106
82 82: 0.5 82: WH 82:
6106
82: -
82: -
83: -
83: -
84: -
84: -
85:
85:
85: 0.5 85: GY
85
1903
85: -
85:
UDN
86:
86:
86:
86: 0.5
86
BK/BN 5360
86: -
86: -
87:
87: D87: 0.5
87
BU
87:
2500
87: -
87: -
88:
88:
88: 0.5 88: WH
88
2501
88: -
88: -
89:
89:
89: 10
89: 40
89
RD/YE
89: I
89: -
83:
83: D- 83:
83: 0.5
83
BU/YE 5361
84:
84:
84: 0.5
84: 3
84
VT/BK
90:
90:
74
75:
75: Keypad Red LED
75
76: Keypad Green 76:
LED
76
77:
77: Keypad Signal
77
78: Keyword 2000 78:
Serial Data
78
79: Check Engine 79:
Indicator Control 79
80: Wait To Start
Indicator Control
81: High Speed
GMLAN Serial Data
(+) (2)
81: High Speed
GMLAN Serial Data
(+) (2)
82: High Speed
GMLAN Serial Data
(-) (2)
82: High Speed
GMLAN Serial Data
(-) (2)
83: Brake Apply
Sensor Signal
0.5
75:
0.5
76:
0.5
77:
0.5
78:
0.5
79:
0.5
BARE 5193
75:
75:
OG/WH 2517
76:
76: YE
2516
77: D- 77:
GN/WH 2514
78:
78:
BN/WH 5043
79:
79:
BN/WH 419
80:
80: 80:
80:
WH/D80 0.5
507
BU
75: -
75
76: -
76
77: -
77
78: -
78
79: -
79
80: -
80
81: 81: 81: D- 81:

81 0.5 BU/YE 6105
81: -
81
82: 82:
82:
82: WH
82 0.5
6106
82: -
82
83: -
83
84: -
84
85:
85:
85: GY
0.5
1903
85: -
8
UD
86: 86:
86:
0.5 BK/BN 5360
86: -
86
87: 87: D0.5 BU
87:
2500
87: -
87
88:
88:
88: WH
0.5
2501
88: -
88
89: 89:
89: 40
10 RD/YE
89: VI
89
83:
83
84:
84
85: AAS Wheel
85:
Speed Sensor Signal
85
Left Front
86: Brake Apply
86:
Sensor Low
86
Reference
87: High Speed
87:
GMLAN Serial Data
87
(+) (1)
88: High Speed
88:
GMLAN Serial Data
88
(-) (1)
89: Battery Positive 89:
Voltage
89
83: 83: D- 83:

0.5 BU/YE 5361
84: 84:
84: 3
0.5 VT/BK
90:

Views - Cruze
90
RD/D90: 40
GN
91:
91:
91:
91: 1.5
91
RD/BN 702
92102
90: 10
90: I
90: -
91: II
91: -
Voltage
90 10 RD/D90: 40 90: VI
GN
91: Battery Positive 91: 91: 91:
91:
91: VII
Voltage
91 1.5 RD/BN 702
92Not Occupied
102
X203 INSTRUMENT PANEL HARNESS TO PASSENGER INSTRUMENT PANEL AIR BAG

HARNESS

Description: 5-Way F 0.64 Series Unsealed
(YE)
Harness Type: Passenger Instrument Panel

Air Bag
Description: 5-Way M 0.64 Series Unsealed
(YE)

Type ID
Lead
Test Probe
II
Terminal
Removal
Tool
Service by
Connector J-35616-64B J-38125Assembly(L-BU)
215A
13601511
Service by
J-35616-65B J-38125Harness- See
(L-BU)
215A
Part Catalog
Service
Terminal
Service by
Connector
Assembly13601511
Service by
Harness- See
Part Catalog
Tray
Core
Crimp
Insulation
Crimp
Service by
Connector
Not
Not
Assembly- Available Available
13601511
Service by
Not
Not
Harness- See
Available Available
Part Catalog
X203 Instrument Panel Harness to Passenger Instrument Panel Air Bag Harness
Terminal
Terminal
Option Function
Option
Type ID
Type ID
1: Passenger IP
1:
1:
1:
1:
1: 1
1: YE
1: I
1: - Module Stage 1: 1
1: YE
1: II
1: YE
3025
0.5
3025
1 High Control
2: Passenger IP
2:
2:
2:
2:
2: 2
2: OG
2: I
2: - Module Stage 2: 2
2: OG
2: II
2: 0.5
3024
0.5
3024
1 Low Control
3:
3:
3:
3:
90
91

Views - Cruze
3: 3 0.5 3: BN 3050
3: I
3: -
4: 4
4:
4:
4: GY
0.5
3027
4: I
4: -
5: 5
5:
5:
5: PU
0.5
3026
5: I
5: -
3: Ground 3: 3 0.5 3: BN 3050

4: Passenger IP
4:
4:
Module Stage 4: 4
4: GY
0.5
3027
2 High Control
5: Passenger IP
5:
5:
Module Stage 5: 5
5: PU
0.5
3026
2 Low Control
3: II
3: -
4: II
4: -
5: II
5: -
X205 INSTRUMENT PANEL HARNESS TO BODY HARNESS (UQA)

Description: 12-Way F 1.2 Micro II Timer
Series (BU)
Harness Type: Body

Description: 12-Way M 1.2 Micro II Timer
Series (BU)

Terminal
Type ID
Lead
Test Probe
13575538
II
13575593
III
13575591
Terminal
Removal
Tool
J-35616-14
J-38125-560
(GN)
J-35616-14
J-38125-560
(GN)
J-35616-14
J-38125-560
(GN)
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
962943-5
16
964265-2
28
964265-2
28
X205 Instrument Panel Harness to Body Harness (UQA)

Terminal
Option Function
Type ID
1: Right Rear
1: 1: L1:
Low Level
1: 1
1: I
1: 0.35 BU/BK 1946
Audio (-)
2: Left Rear
2:
2:
2: 2
2: Bare
2: I
2: - Audio Drain
0.35
2099
Wire
3: Right Front
3: 3: L3:
3: 3
3: I
3: Low Level
0.35 BU/OG 1546
Audio (-)
Terminal
Option
Type ID
1: 1
1: 1: D1:
0.35 BU/BK 1946
1: -
1: -
2: 2
2:
2:
2: Bare
0.35
2099
2: -
2: -
3: 3
3: 3: D3:
0.35 BU/BN 1546
3: -
3: -

Views - Cruze
4: 4
4:
4:
4:
0.35 OG/VT 1999
4: I
4: -
5: 5
5:
5:
5:
0.5 GN/YE 7066
5: I
5: -
6: 6
6:
6: YE 6: 512
0.35
6: I
6: -
7: 7
7:
7:
7: 546
0.35 BN/WH
7: I
7: -
8:
8:
8:
OG/D0.5
6978
BU
9:
9:
9:
9: 9
BN/D0.35
1947
BU
8: 8
8: I
9: I
10: 10: 10: D10 0.35 GN/BK
10:
599
10: I
11: 11:
11:
11 0.35 BARE
11:
2011
11: I
12: 12: 12: D12 0.35 BU
12:
511
12: I
4: Left Rear
Low Level
Audio (-)
5:
Entertainment
Remote
Enable Signal
6: Right Front
Audio Signal
(+)
7: Right Rear
Audio Signal
(+)
4: 4
4:
4:
4:
0.35 BN/VT 1999
4: -
4: -
5: 5
5: 5: D5:
0.5 GN/YE 7066
5: -
5: -
6: 6
6:
6: YE 6: 512
0.35
6: -
6: -
7: 7
7:
7:
7: 546
0.35 BN/WH
7: -
7: -
8: II
8: -
9: -
9: -
10: -
10: -
11: -
11: -
12: -
12: -
8:
8: Amplifier
8:
8:
VT/D8: 8
Control
0.5
6978
BU
9: Left Front
9:
9:
9:
9: Low Level 9: 9
BN/D0.35
1947
Audio (-)
BU
10: Left Front
10: 10: 10: D- 10:
10: - Audio Signal
10 0.35 GN/BK 599
(+)
11: Left Front
11: 11:
11:
11:
11: - Audio Drain
11 0.35 BARE 2011
Wire
12: Left Front
12: 12: 12: D- 12:
12: - Audio Signal
12 0.35 BU
511
(+)
8: -
X210 HEADLINER HARNESS TO BODY HARNESS

Harness Type: Body

Description: 20-Way M (GY)

Type ID
Lead
Test Probe
Terminal
Removal
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp

Views - Cruze
Tool
I
Pending
Pending
Pending
Pending
Pending
II
Pending
Pending
Pending
Pending
Pending

Terminal
Option
Type ID
1: 1 1: 1 1: BK 1: 50
1: I
1: -
Function
1: Ground
2: Remote
Function
Actuator
Return
3: Remote
Function
Actuator
Supply
Voltage
4: Remote
Function
Actuator
Receive
Signal
5: Remote
Function
Actuator
Transmit
Signal
6: Inadvertent
Power
Control
7: Interior
Lamp Control
8: Interior
Lamp Defeat
Switch Signal
1: 1 1: 1 1: BK
2:
2: GY
0.5
2:
3273
2: I
2: -
3: 3
3:
3:
3:
0.5 GY/WH 3272
3: I
3: -
4: 4
4: 4: D4:
0.5 BU/WH 3275
4: I
4: -
5: 5
5:
5:
YE/D0.5
GN
5:
3274
5: I
5: -
6:
6:
WH/BN 6815
6: I
6: -
7: I
7: -
8: I
8: -
9: I
9: C68
9: Humidity
9: 9
Sensor Signal
10: I
10:
UZ6
10: Left Front

10:
Speaker
10
Signal (-) (1)
11: I
11: 11: Left Front 11: 11: 11: DUZ6 Speaker (+) 11 0.75 BU
7: 7
8: 8
9: 9
10:
10
7:
7: GY 7: 157
0.5
8:
8:
GY/D- 8: 328
0.5
GN
9:
9:
9:
GY/D0.35
7564
BU
10:
10:
10:
BN/D0.75
118
BU
11: 11: 11: D11 0.75 BU
11:
201
Not
Available
Not
Available
Terminal
Option
Type ID
1: 50
1: II
1: -
2: 2
6: 6 6: 1
Not
Available
Not
Available
2: 2
2:
2: GY
0.5
2:
3273
2: II
2: -
3: 3
3:
3:
3:
0.5 GY/WH 3272
3: II
3: -
4: 4
4: 4: D4:
0.5 BU/WH 3275
4: II
4: -
5: 5
5:
5:
YE/D0.5
GN
5:
3274
5: II
5: -
6:
6:
WH/BN 6815
6: II
6: -
7: II
7: -
8: II
8: -
9: II
9: C68
10: II
10:
UZ6
11: II
11:
UZ6
6: 6 6: 1
7: 7
8: 8
7:
7: GY 7: 157
0.5
8:
8:
GY/D- 8: 328
0.5
GN
9:
9:
9:
GY/D0.35
7564
BU
10:
10:
10:
BN/D0.75
118
BU
11:
201

Views - Cruze
12: 12:
12: YE
12 0.75
12:
200
12: I
12:
UZ6
13: 13:
13:
13 0.75 YE/BK
13:
117
13: I
13:
UZ6
14: 14:
14:
14:
14 0.5 WH/BN 6815
14: I
14: -
15: 15:
15:
15:
15 0.5 WH/BN 6815
15: I
15: -
16:
16: 16:
BK/D- 16: 50
16 0.35
BU
16: I
17:
17: 17:
GY/D17 0.35
GN
17: I
17:
7565
18:
18: 18:
18:
YE/D18 0.35
3197
BU
19: 19:
19:
19:
19 0.35 YE/RD 597
20: 20: 20: D- 20:
20 0.5 GN/BN 6998
18: I
19: I
20: I
(1)
12: Right
Front Speaker
(+) (1)
13: Right
Front Speaker
Signal (-) (1)
14:
Inadvertent
Power
Control
15:
Inadvertent
Power
Control
12: 12:
12: YE
12 0.75
12:
200
12: II
12:
UZ6
13: 13:
13:
13 0.75 YE/BK
13:
117
13: II
13:
UZ6
14: 14:
14:
14:
14 0.5 WH/BN 6815
14: II
14: -
15: 15:
15:
15:
15 0.5 WH/BN 6815
15: II
15: -
16: 50
16: II
16:
C68
17:
7565
17: II
17:
C68
18:
3197
18: II
18:
C68
19:
597
19: II
19:
CJ2
20:
6998
20: II
20: -
16:
16: 16:
16: Ground
BK/D16 0.35
BU
17:
17:
Windscreen 17: 17:
17:
GY/DC68 Temp Sensor 17 0.35
GN
Signal
18: Humidity
18:
18:
18: 18:
Temperature
YE/DC68
18 0.35
Sensor Signal
BU
19:
19: 5V
19: 19:
19:
CJ2
Reference 19 0.35 YE/RD
20:
Inadvertent
20: 20: 20: D20: Load 1
20 0.5 GN/BN
Supply
Voltage
16:
C68

Views - Cruze
2013 ELECTRICAL
Wiring Systems and Power Management - Component Locator - Inline Harness Connector End
Views - Cruze
INLINE HARNESS CONNECTOR END VIEWS

X211 HEADLINER HARNESS TO BODY HARNESS

Harness Type: Body

Description: 20-Way M (WH)

Type ID
Lead
Test Probe
Terminal
Removal
Tool
Service
Terminal
Tray
Pending
Pending
Pending
Pending
Pending
II
Pending
Pending
Pending
Pending
Pending

Terminal
Option Function
Type ID
1:
1:
1: 1
1: BK
1: I
1: 1: Ground
2.5
2050
2:
2:
2: 2
2: BK
2: I
2: 2: Ground
0.5
2050
3: LED
Backlight
3:
3:
3: 3
3: YE
3: I
3: CF5
Dimming
0.5
6817
Control
4: Linear
Interconnect
4: 4: D4:
4: 4
4: I
4: Network Bus
0.5 GN/BN 6132
1
5:
5:
5: Ignition
Core
Crimp
Insulation
Crimp
Not
Available
Not
Available
Not
Available
Not
Available

1:
2.5
2:
2: 2
0.5
1: 1
1: BK
2: BK
1:
2050
2:
2050
Terminal
Option
Type ID
1: II
1: -
2: II
2: -
3: 3
3:
0.5
3:
6817
3: II
3: CF5
4: 4
4: 4: D4:
0.5 GN/BN 6132
4: II
4: -
5:
3: YE
5:

Views - Cruze
5: 5 0.5 VT/WH 5: 39
6: 6: D6:
6: 6
0.35 GN/WH 1324
5: I
6: I
7: 7
7:
0.5
7: YE
7:
5191
7: I
8: 8
8:
8:
0.5 BARE
8:
5193
8: I
9: 9
9:
9:
9:
0.5 YE/VT 2516
9: I
10: 10: 10: L- 10:

10 0.5 GN/BK 2515
10: I
11:
11
12:
12
1319
11:
11:
11:
0.5 GN/WH 2514
12:
12:
12:
0.5 BN/WH 2517
-
11: I
12: I
20: 20:
20:
20: 40
20 2.5 RD/WH
20: I
5: -
Voltage
6: Backup
6: Lamp Control
7:
7: - Microphone
High Signal
8:
8: - Microphone
Low Signal
9: Keypad
9: Green LED
10: Keypad
10: Supply
Voltage
11: Keypad
11: Signal
12: Keypad
12: Red LED
5: 5 0.5 VT/WH 5: 39
6: 6: D6:
6: 6
0.35 GN/WH 1324
5: II
5: -
6: II
6: -
7: 7
7:
0.5
7: YE
7:
5191
7: II
7: -
8: 8
8:
8:
0.5 BARE
8:
5193
8: II
8: -
9: 9
9:
9:
9:
0.5 YE/VT 2516
9: II
9: -
10: 10: 10: L- 10:

10 0.5 GN/BK 2515
10: II
10: -
11: II
11: -
12: II
12: -
20: II
20: -
11:
11
12:
12
14Not Occupied
19
20: Battery
20:
20: Positive
20
Voltage
11: 11: D- 11:

0.5 GN/WH 2514
12:
12:
12:
0.5 BN/WH 2517
-
20:
20:
20: 40
2.5 RD/WH
X212 INSTRUMENT PANEL HARNESS TO HVAC HARNESS (C68)

Harness Type: HVAC

Description: 2-Way M GT 150 Series (BK)

Type ID
Lead
Test Probe
I
13575735
II
Pending
Terminal
Removal
Tool
Service
Terminal
J-35616-2A
J-38125-553 12191812
(GY)
Pending
Pending
Pending
Tray
Core
Crimp
Insulation
Crimp
19
Not
Not
Pending

Views - Cruze
Available
Available
X212 Instrument Panel Harness to HVAC Harness (C68)

Terminal
Terminal
Option Function
Option
Type ID
Type ID
A
Not Occupied A
B: Upper Air
B:
B: B: DB: B
B: BN B: 404
B: I
B: - Temperature B: B
B: 404 B: II
B: 0.5
0.5 BU
Sensor Signal
X300 CONSOLE HARNESS TO INSTRUMENT PANEL HARNESS


Part Catalog
Description: 22-Way F MQS/MCP 2.8 Series
(BK)


Terminal
Type ID
Terminal
Removal
Tool
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
SEALED:
13575390 J-35616-64B J-38125UNSEALED: (L-BU)
12A
13575522
928999-5
15
Pending
Pending
Not
Available
Not
Available
31
Lead
Test Probe
II
Pending
III
13327167
IV
13575574
Pending
Pending
J-35616-65B J-38125963716-2
(L-BU)
12A
J-35616-5
J-38125-36 2-964296-1
(PU)
X300 Console Harness to Instrument Panel Harness

Terminal
Terminal
Option Function
Option
Type ID
Type ID
1-3 Not Occupied 1-3 -

Views - Cruze
4: 4 4: 1 4: BK 4: 50
4: -
5: 5 5: 1 5: VT 5: 801
5: -
6: 6: D6:
0.5 BU 3554
6: -
6: 6
7
4: Ground
5: Retained
Accessory
5: Power Fuse
Supply Voltage
6: Passive Start
Interior
6: Antenna 2
Signal Hi
Not Occupied
4: 4 4: 1 4: BK 4: 50
4: -
4: -
5: 5 5: 1 5: VT 5: 801
5: -
5: -
6: -
6: -
8: -
8: -
12: III
12: -
13: III
13: -
14: III
14: -
18:
18:
18: 1
18
BK
18: 50
18: -
18: -
19:
19:
19: 1
19
VT
19:
801
19: -
19: -
21: 21: 21:

21:
21 0.35 BARE 5842
21: -
21: -
22: 22: 22: L- 22:

22 0.35 BU 2060
22: -
22: -
6: 6
6: 6: D0.5 BU
6:
3554
8:
8: 8
8: BK 8: 50
0.5
9-11 -
8: -
8: -
12: 12: 12: L- 12:

12 0.35 GN 5841
12: I
12: -
13: 13:
13 0.35
13:
VT
13:
5843
13: I
13: -
14: 14:
14 0.35
14:
GY
14:
5839
14: I
14: -
8:
8: Ground 8: 8
8: BK 8: 50
0.5
Not Occupied 9-11 12: Right
Auxiliary
12: 12: 12: D- 12:
Audio Signal 12 0.35 GN 5841
(2)
13: Auxiliary
Audio
13: 13: 13:
13:
Common
13 0.35 VT 5843
Signal
14: Left
Auxiliary
14: 14: 14:
14:
Audio Signal 14 0.35 GY 5839
(2)
Not Occupied 15
-
Not Occupied
18: 50
18: -
18: -
18: Ground
15
1617
18:
18:
18: 1
18
BK
19:
19:
19: 1
19
VT
4: -
19:
801
19: -
21:
BK
21:
5842
21: -
22: 22: 22: D- 22:

22 0.35 BU 2060
22: -
20
21: 21:
21 0.35
19: Retained
Accessory
19: Power Fuse
Supply Voltage
Not Occupied
21: Auxiliary
21: - Audio Screen
(2)
22: Auxiliary
22: Detection
Signal
X310 BODY HARNESS TO DRIVER SEAT HARNESS
17
20

Views - Cruze
Harness Type: Body

Description: 20-Way F, 1.6 2.8 Series (BK)

Description: 20-Way M, 1.6 2.8 Timer Series
(BK)

Type ID
Lead
Test Probe
I
II
III
Pending
J-35616-35
(VT)
Terminal
Removal
Tool
J-3812512A
1:
1:
1: 702
1.5 RD/BN
1: I
1: -
2:
2479
2: I
2:
KA1
3:
3:
3: 40
2.5 RD/WH
3: I
3: -
4: D4:
BU/BK 2433
4: I
4:
KA1
5: II
5: -
2:
2: 2 2: 1 BN/DBU
3: 3
4: 4 4: 1
5: 5
5:
Tray
Core
Crimp
Insulation
Crimp
54001400
29
Not
Available
Not
Available
Not
Available
Not
Available
Not
Available
Service by
Harness See Part
Catalog
Not
Available
Not
Available
Pins: 5-7, 12,

J-35616-3
Not
15, 18:
J-38125-560
(GY)
Available
13579989
Service by Service by Service by Service by
Harness Harness Harness Harness See Part
See Part
See Part
See Part
Catalog
Catalog
Catalog
Catalog
X310 Body Harness to Driver Seat Harness

Terminal
Option
Type ID
1: 1
Service
Terminal
5:
5:
Function
1: Battery
Positive
Voltage
2: Passenger
Heated Seat
Element
Control
3: Battery
Positive
Voltage
4: Passenger
Heated Back
Element
Return

1: 1
1:
1.5
Terminal
Option
Type ID
1: RD 1: 702
1: III
1: -
2:
2479
2: III
2:
KA1
3: RD
3: 40
3: III
3: -
4: 4 4: 1 4: BK
4:
2433
4: III
4:
KA1
5: III
5: -
2: 2 2: 1 2: YE
3: 3
3:
2.5
5: Driver Seat 5: 5
Belt Switch
5:
5: BK
5:

Views - Cruze
0.5 BK/OG 1363
6: 6
6:
6:
6:
0.5 BK/GY 2435
6: II
7: 7
7:
7:
7:
0.5 WH/GY 2434
7: II
8: 8
8:
8:
8:
0.5 YE/OG 2138
8: II
9: 9
9:
9:
OG/D0.5
BU
9:
2137
9: II
12:
238
12: II
13: 13:
13:
13:
13 0.5 YE/OG 3482
13: II
14: 14:
14:
14:
14 0.5 OG/YE 3481
14: II
1011
12: 12:
12:
12 0.5 OG/BN
15: 15:
15:
15:
15 0.5 WH/BK 7018
1617
18: 18: 18: D18 0.5
GN
19:
19
20:
20
18:
5060
19:
19: BK 19: 50
1.5
20:
20: BK 20: 50
2.5
15: II
-
18: II
19: I
20: -
Low
Reference
6: Passenger
6:
Heated Seat
KA1
NTC Low
Reference
7: Passenger
7:
Heated Seat
KA1
NTC Signal
8: Left Front
Side Impact
8: Module Low
Control
9: Left Front
Side Impact
9: Module High
Control
-
Not Occupied
12: Driver
Seat Belt
Switch Signal
13: Driver
Seat Belt
13: Anchor
Pretensioner
Low Control
14: Driver
Seat Belt
14: Anchor
Pretensioner
High Control
15: 15: Cushion
KA1 NTC Signal
12: -
0.5
1363
6: 6
6:
0.5
6: BK
6:
2435
6: III
6:
KA1
7: 7
7:
0.5
7: RD
7:
2434
7: III
7:
KA1
8: 8
8:
8:
8:
0.5 WH/BK 2138
8: III
8: -
9: 9
9: 9: L9:
0.5 GN/WH 2137
9: III
9: -
12:
238
12: III
12: -
13: 13:
13:
13: BK
13 0.5
3482
13: III
13: -
14: 14:
14:
14: RD
14 0.5
3481
14: III
14: -
15:
7018
15: III
15:
KA1
18:
5060
18: III
18: -
19: 50
19: III
19: -
20: 50
20: III
20: -
1011
12: 12:
12: RD
12 0.5
15: 15:
15: YE
15 0.5
16Not Occupied
17
18: Low
18: 18: 18: DSpeed
18: 18 0.5
BU
GMLAN
Serial Data
19: 19:
19: - 19: Ground
19: BK
19 1.5
20: 20:
20: - 20: Ground
20: BK
20 2.5
X320 BODY HARNESS TO PASSENGER SEAT HARNESS

Views - Cruze
Harness Type: Body

Description: 20-Way F, 1.6 2.8 Series (BK)

Description: 20-Way M, 1.6 2.8 Timer Series
(BK)

Type ID
Lead
Test Probe
I
II
III
Pending
J-35616-35
(VT)
Terminal
Removal
Tool
J-3812512A
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
54001400
29
Not
Available
Not
Available
Not
Available
Not
Available
Not
Available
Service by
Harness See Part
Catalog
Not
Available
Not
Available
Pins: 5-7, 12,

J-35616-3
Not
15, 18:
J-38125-560
(GY)
Available
13579989
Service by Service by Service by Service by
Harness Harness Harness Harness See Part
See Part
See Part
See Part
Catalog
Catalog
Catalog
Catalog
X320 Body Harness to Passenger Seat Harness

Terminal
Option Function
Type ID
1
Not Occupied
2: Passenger
2:
2:
2:
Heated Seat
2: 2 2: 1 BN/D2: I
2479
KA1
Element
BU
Control
3
Not Occupied
4: Passenger
Heated Back
4: D4:
4:
4: 4 4: 1
4: Element
BU/BK 2433
KA1
Return
5: Passenger
5:
5:
5:
Seat Belt
5: 5
5: II
5: 0.5 BK/OG 1361
Switch Low
Reference
6:
6:
6:
6:
6: Passenger
Heated Seat

1
2:
2479
2: III
2:
KA1
4:
2433
4: III
4:
KA1
5:
5:
5: BK
0.5
1361
5: III
5: -
2: 2 2: 1 2: YE
3
4: 4 4: 1 4: BK
5: 5
Terminal
Option
Type ID
-
6:
6:
6:

Views - Cruze
6: 6
0.5 BK/GY 2435
15:
KA1
-
NTC Low
Reference
7: Passenger
Heated Seat
NTC Signal
8: Right Front
Side Impact
Module Low
Control
9: Right Front
Side Impact
Module High
Control
10: Battery
Positive
Voltage
11: Low
Speed
GMLAN
Serial Data
12: Passenger
Seat Belt
Switch Signal
13: Passenger
Seat Belt
Anchor
Pretensioner
Low Control
14: Passenger
Seat Belt
Anchor
Pretensioner
High Control
15: Cushion
NTC Signal
Not Occupied
17: II
17: -
17: Ground
6: II
KA1
7: 7
7:
7:
7:
0.5 WH/GY 2434
7: II
7:
KA1
8: 8
8: 8: D8:
0.5 GN/OG 2136
8: II
8: -
9: 9
9:
9:
9:
0.5 OG/YE 2135
9: II
9: -
10: 10:
10:
10 0.5 RD/GY
10:
402
10: II
10: -
11: 11: 11: D11 0.5

GN
11:
5060
11: II
11: -
12: 12:
12:
12:
12 0.5 OG/VT 1362
12: II
12: -
13: 13:
13:
13:
13 0.5 GY/OG 3480
13: II
13: -
14: 14:
14:
14:
14 0.5 OG/BN 3479
14: II
14: -
15:
15
16
17:
17
1920
15:
15:
15:
0.5 WH/BK 7018
17:
17: BK 17: 50
0.5
-
15: II
6: 6
0.5
6: BK
2435
6: III
KA1
7: 7
7:
7:
7: RD
0.5
2434
7: III
7:
KA1
8: 8
8: 8: L0.5 GN
8:
2136
8: III
8: -
9: 9
9:
0.5
9:
2135
9: III
9: -
10: 10: 10: D- 10:

10 0.5 BU
402
10: III
10: -
11: 11:
11 0.5
11:
WH
11:
5060
11: III
11: -
12: 12:
12 0.5
12:
RD
12:
1362
12: III
12: -
13: 13:
13 0.5
13:
BK
13:
3480
13: III
13: -
14: 14:
14 0.5
14:
RD
14:
3479
14: III
14: -
15:
15
16
17:
17
15:
0.5
17:
0.5
15:
YE
17:
BK
15:
7018
-
Passenger Seat
Belt Reminder 18Signal
20
Not Occupied
X335 BODY HARNESS TO CURTAIN AIR BAG HARNESS
9:
WH
15:
KA1
-
17: 50
17: III
17: -
15: III

Views - Cruze
Harness Type: Body

Description: 2-Way F Metri-Pack 150 Series
(YE)
Harness Type: Curtain Air Bag

Part Catalog
Description: 2-Way M, Metri-Pack 150 Series
(YE)
13575524
J-35616-14
(GN)
Terminal
Removal
Tool
J-3812512A
II
Pending
Pending
Pending

Type ID
Lead
Test Probe
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
15326030
Pending
Pending
Not
Available
Not
Available

Terminal
Option Function
Type ID
A: Left Front
A:
Head Curtain
A: A:
A:
OG/DA: I
A: Module High
A 0.5
5019
GN
Control
B: Left Front
B: B:
B:
B:
Head Curtain
B: I
B: B 0.5 VT/OG 5020
Module Low
Control
Terminal
Option
Type ID
A:
A
A:
A:
A:
0.5 OG/GY 5019
A: II
A: -
B:
B
B:
B:
B:
0.5 VT/OG 5020
B: II
B: -
X345 BODY HARNESS TO CURTAIN AIR BAG HARNESS

Harness Type: Body

Harness Type: Curtain Air Bag


Views - Cruze

Description: 2-Way F Metri-Pack 150 Series
(YE)
Part Catalog
Description: 2-Way M, Metri-Pack 150 Series
(YE)
13575524
J-35616-14
(GN)
Terminal
Removal
Tool
J-3812512A
II
Pending
Pending
Pending

Type ID
Lead
Test Probe
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
15326030
Pending
Pending
Not
Available
Not
Available

Terminal
Option Function
Type ID
A: Right
A:
Front Head
A: A:
A:
OG/DA: I
A: Curtain
A 0.5
5021
BU
Module High
Control
B: Right
Front Head
B: B:
B:
B:
B: I
B: Curtain
B 0.5 WH/BK 5022
Module Low
Control
Terminal
Option
Type ID
A: A:
A:
A:
A 0.5 OG/GY 5021
A: II
A: -
B: B:
B:
B:
B 0.5 WH/OG 5022
B: II
B: -
X401 FUEL TANK HARNESS TO BODY HARNESS

Description: 16-Way F GT 150 280 Sealed
4.0 5.8 (BK)
Harness Type: Body

Description: 16-Way M GT 150 280 Sealed
4.0 5.8 (BK)

Terminal
Type ID
Lead
Test Probe
Terminal
Removal
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp

Views - Cruze
Tool
I
Pending
II
III
IV
V
Pending
Pending
SEALED:
13575443
J-35616-5
J-38125-553
UNSEALED:
(PU)
13579955
J-35616-5
13327134
J-38125-553
(PU)
J-35616-3
Pending
J-38125-553
(GY)
J-35616-3
Pending
J-38125-553
(GY)
X401 Fuel Tank Harness to Body Harness

Terminal
Option
Type ID
A: A:
A: GY A: 120
A 2.5
A: I
A: -
B: B: B: DB:
B 0.5 BU/VT 1589
B: I
B: -
D: D:
D:
D:
D 0.5 BN/RD 2709
D: I
D: -
E: E: E: DE: 890
E 0.5 BU/WH
E: I
E: -
F: I
F: -
H: I
H: -
K: I
K: -
F: F
G
F:
F:
F:
0.5 BK/WH 6281
-
H: H:
H:
H:
H 0.5 BN/RD 7445
I-J
K: K: K: DK:
K 0.5 BU/VT 7446
L:
L:
L:
L:
Pending
Pending
Not
Available
Not
Available
15304732
15304731
19
15326269
19
15326269
19
Function
A: Fuel
A:
Pump
A
Control
B: Primary
B:
Fuel Level
B
Sensor Signal
Not Occupied C
D: Fuel Tank
Pressure
D:
Sensor 5V D
Reference
E: Fuel Tank
E:
Pressure
E
Sensor Signal
F: Fuel Level
Sensor Low F: F
Reference
Not Occupied G
H: Fuel Line
Pressure
H:
Sensor 5V H
Reference
Not Occupied I-J
K: Fuel Line
K:
Pressure
K
Sensor Signal
L: Fuel Line
Pressure
L:
Terminal
Option
Type ID
A:
A: GY A: 120
2.5
A: II
A: -
B: B: DB:
0.5 BU/VT 1589
B: IV
B: -
D:
D:
D:
0.5 YE/RD 2709
D: IV
D: -
E: E: DE: 890
0.5 BU/WH
E: IV
E: -
F:
6281
F: IV
F: -
H: III
H: -
K: IV
K: -
F:
F:
BK/D0.5
GN
-
H:
H:
H:
0.5 BN/RD 7445
-
K: K: DK:
0.5 BU/WH 7446
L:
L:
L:

Views - Cruze
0.5 BK/YE 7447
M:
M: M:
RD/DM 0.75
BU
L: I
M:
5372
M: I
N: N:
N:
N: WH
N 0.75
1310
N: I
O-Q
R:
R: R:
BK/DR 0.5
GN
S:
S:
S: S
BK/D2.5
GN
R:
6281
R: I
S:
2350
S: I
Sensor Low L
Reference
M: Canister
M:
M: Valve
M
Solenoid
N: EVAP
Canister Vent N:
N: N
Solenoid
Control
Not Occupied O-Q
R: Fuel Level
R:
R: - Sensor Low
R
Reference
0.5 BK/YE 7447
L: -
S: -
L: IV
L: -
M:
5372
M: -
M: -
N:
N:
N: WH
0.75
1310
N: -
N: -
R:
6281
R: -
R: -
S:
2350
S: -
S: -
M:
M:
RD/D0.75
BU
R:
R:
BK/D0.5
GN
S:
S:
S: Ground S: S
BK/D2.5
GN
X402 REAR OBJECT SENSOR HARNESS TO BODY HARNESS (UD7)

Description: 12-Way F 150 GT Series, Sealed
(BK)
Harness Type: Body

Description: 12-Way M 150 GT Series Sealed
(BK)

Type ID
Lead
Test Probe
I
Pending
II
Pending
Pending
Terminal
Removal
Tool
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
Pending
Pending
Pending
Not
Available
Not
Available
19
J-35616-3
J-38125-553 15326269
(GY)
X402 Rear Object Sensor Harness to Body Harness (UD7)

Terminal
Terminal
Option Function Pin Size Color Circuit
Option
Type ID
Type ID
A: Right
Rear Corner A: A:
A: A:
A:
A:
A:
A:

Views - Cruze
0.5 YE/VT 2378
B: B:
B:
B:
B 0.5 YE/WH 2377
C:
C: C:
YE/DC 0.5
BU
A: I
A: -
B: I
B: -
C:
2376
C: I
C: -
D: D:
D:
D:
D 0.5 BN/WH 2374
D: I
D: -
E: E:
E: YE
E 0.5
E:
2375
E: I
E: -
F:
F:
F:
0.5 BK/GY 2379
F: I
F: -
G: G:
G:
G:
G 0.5 RD/GN 3140
G: I
G: -
H: H:
H: BK
H 0.5
H:
2350
H: I
H: -
J:
J: GN
0.5
J:
5060
J: I
J: -
K: K:
K:
K:
K 0.5 GY/YE 5853
K: I
K: -
L: L:
L: GY
L 0.5
L:
5861
L: I
L: -
F: F
J: J
Object Sensor A
Signal
B: Right Rear
B:
Middle
Object Sensor B
Signal
C: Left Rear
Middle
C:
Object Sensor C
Signal
D: Object
D:
Sensor
D
Control
E: Left Rear
Corner
E:
Object Sensor E
Signal
F: Object
Sensor Low F: F
Reference
G: Battery
G:
Positive
G
Voltage
H:
H: Ground
H
J: Low Speed
GMLAN J: J
Serial Data
K: Driver
Side Object
K:
Detection
K
LED Signal
(1)
L: Passenger
Side Object
L:
Detection
L
LED Signal
(1)
Not Occupied M
X410 LEFT TAIL LAMP HARNESS TO BODY HARNESS
0.5 YE/VT 2378
A: II
A: -
B:
B:
B:
0.5 YE/WH 2377
B: II
B: -
C:
C:
YE/D0.5
BU
C:
2376
C: II
C: -
D:
D:
D:
0.5 BN/WH 2374
D: II
D: -
E:
E: YE
0.5
E:
2375
E: II
E: -
F:
F:
F:
0.5 BK/GY 2379
F: II
F: -
G:
G:
G:
0.5 RD/GN 3140
G: II
G: -
H:
H: BK
0.5
H:
2350
H: II
H: -
J:
J: GN
0.5
J:
5060
J: II
J: -
K:
K:
K:
0.5 GY/YE 5853
K: II
K: -
L:
L: GY
0.5
L:
5861
L: II
L: -

Views - Cruze

Harness Type: Body


Type ID
Lead
Test Probe
I
Pending
II
13575502
Pending
Terminal
Removal
Tool
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
Pending
Pending
Pending
Not
Available
Not
Available
19
J-35616-3
J-38125-553 15304702
(GY)
X410 Left Tail Lamp Harness to Body Harness

Terminal
Option Function Pin
Type ID
A: Left Rear
Stop Lamp A:
A: A:
A:
A: RD
A: I
A: Supply
A 0.5
7542
A
Voltage
B: Left Park
B: B: B: DB:
B: 709
B: I
B: Lamp
B 0.5
GN
B
Control
C
Not Occupied C
D:
D:
D:
D: 1 D: BK
D: I
D: - D: Ground
D
2550
D
E: Left Rear
E: E:
E:
Turn Signal E:
E: YE
E: I
E: E 0.5
1334
E
Lamp
Control
F: Backup
F:
F:
F: F
F: WH
F: I
F: Lamp
F: F
0.5
1324
Control
G
Not Occupied G
H: H:
H:
H:
H:
H: I
H: - H: Ground
H 0.5 BK/WH 2550
H
Size Color Circuit

A:
A:
A:
0.5 GY/YE 7542
A: II
A: -
B:
B:
B: 709
0.5 VT/GY
B: II
B: -
D: II
D: -
E: E: DE:
0.5 BU/WH 1334
E: II
E: -
F: F: DF:
0.5 GN/WH 1324
F: II
F: -
H: II
H: -
D: 1 D: BK
X420 RIGHT TAIL LAMP HARNESS TO BODY HARNESS
Terminal
Option
Type ID
H:
H: BK
0.5
D:
2550
H:
2550

Views - Cruze

Harness Type: Body


Type ID
Lead
Test Probe
I
Pending
II
13575502
Pending
Terminal
Removal
Tool
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
Pending
Pending
Pending
Not
Available
Not
Available
19
J-35616-3
J-38125-553 15304702
(GY)
X420 Right Tail Lamp Harness to Body Harness

Terminal
Option Function Pin
Type ID
A: Right
Rear Stop A:
A: A:
A:
A: RD
A: I
A: Lamp Supply A
A 0.5
7541
Voltage
B: Right Park
B: B: B: DB:
B: 309
B: I
B: Lamp
B 0.5
GN
B
Control
C
Not Occupied C
D:
D:
D:
D: 1 D: BK
D: I
D: - D: Ground
D
2550
D
E: Right
Rear Turn E:
E: E:
E:
E: YE
E: I
E: Signal Lamp E
E 0.5
1335
Control
F: Backup
F:
F:
Lamp
F: F
F: WH
F: I
F: F: F
0.5
1324
Control
G
Not Occupied G
H: H:
H:
H:
H:
H: I
H: - H: Ground
H 0.5 BK/WH 2550
H
X500 DRIVER DOOR HARNESS TO BODY HARNESS
Size Color Circuit
Terminal
Option
Type ID
A:
A:
A:
0.5 WH/YE 7541
A: II
A: -
B:
B:
B: 309
0.5 GY/BN
B: II
B: -
D: II
D: -
E: E: DE:
0.5 BU/VT 1335
E: II
E: -
F: F: DF:
0.5 GN/WH 1324
F: II
F: -
H: II
H: -
D: 1 D: BK
H:
H: BK
0.5
D:
2550
H:
2550

Views - Cruze

Part Catalog
Description: 41-Way F 4.8 TIMER/DSQ 1.5
Series (GY)
Harness Type: Body

Description: 41-Way M DSQ 1.5 2.8 Series
(GY)

Type ID
Lead
Test Probe
I
13575858
II
13575539
III
13575538
IV
13582220
13579964
VI
13580818
Terminal
Removal
Tool
Service
Terminal
J-35616-42
J-38125-36 927837-1
(RD)
J-35616-14
J-38125-560 962943-5
(GN)
J-35616-14
J-38125-560 962943-5
(GN)
Not
Pending
Pending
Available
J-35616-3
J-38125-560 969079-2
(GY)
Not
Pending
Pending
Available
X500 Driver Door Harness to Body Harness

Terminal
Option Function
Type ID
1:
1: Battery
1:
1:
RD/DPositive
1: 1
1: 1: 2.5
1540
GN
Voltage
2:
2:
2: 2
2: BK
2: 2: 2: Ground
2.5
1550
3:
3:
3: 3
3: BK
3: II
3: 3: Ground
1.25
1550
4:
4: Battery
4:
4:
4:
RD/DPositive
4: 4
4: 2.5
1540
AXG
GN
Voltage
5-8 Not Occupied
Tray
Core
Crimp
Insulation
Crimp
25
16
16
Not
Available
Not
Available
Not
Available
32
Not
Available
Not
Available
Not
Available

1: 1
2: 2
3: 3
4: 4
5-8
1:
1:
1:
RD/D2.5
1540
GN
2:
2:
2: BK
2.5
1550
3:
3: 1 3: BK
1550
4:
4:
4:
RD/D2.5
1540
GN
-
Terminal
Option
Type ID
1: -
1: -
2: -
2: -
3: -
3: -
4: -
4: -

Views - Cruze
9: 9
9:
9: GY 9: 295
0.75
10: 10: 10:

10 0.75 BN/YE
1113
14: 14: 14: D14 0.75 BU
15:
15: 15:
BN/D15 0.75
BU
1617
10:
294
10: II
14:
201
14: II
15:
118
15: II
18: 18: 18: D- 18:

18 0.5 GN/YE 6134
1920
9: II
18: -
21: 21:
21:
21: YE
21 0.5
6817
21: -
22: 22: 22: D- 22:

22 0.5 GN/BK 3396
22: -
23: 23:
23 0.5
23:
3398
23: -
24: 24: 24:

24:
24 0.5 YE/VT 3397
24: -
25: 25:
25:
25: BK
25 0.75
1550
25: II
23:
WH
9: Door Lock
Actuator Lock 9: 9
Control
10: Door Lock
Actuator
10:
10: Unlock
10
Control
11Not Occupied
13
9: -
9:
9: GY 9: 295
0.75
9: -
9: -
10: 10:
0.75 BN/YE
10:
294
10: -
10: -
14:
201
14:
201
14: -
14: -
15:
118
15:
118
15: -
15: -
18:
6134
18: -
18: -
21:
6817
21: -
21: -
22:
3396
22: -
22: -
23:
3398
23: -
23: -
24:
3397
24: -
24: -
25:
1550
25: -
25: -
14: 14: D14: Left Front

14: 0.75 BU
14: Speaker
14 14: 14: DSignal (+) (1)
0.75 BU
15:
15: BN/D15: Left Front
15: 0.75 BU
Speaker
15: 15 15: 15:
Signal (-) (1)
0.75 BN/DBU
16Not Occupied
17
18: Linear
Interconnect 18: 18: 18: D18: Network Bus 18 0.5 GN/YE
3
19Not Occupied
20
21: LED
Backlight 21: 21:
21: 21: YE
Dimming
21 0.5
Control
22: Co-Driver
Mirror Motor 22: 22: 22: D22: Right (+) Left 22 0.5 GN/BK
(-) Control
23: Co-Driver
Mirror Motor 23: 23: 23:
23: Common
23 0.5 WH
Control
24: Co-Driver
24: Up (+) Down 24 0.5 YE/VT
(-) Control
25: 25:
25: - 25: Ground
25: BK
25 0.75
26: Battery

Views - Cruze
26: 26: 26:

26:
26 0.5 RD/GY 2840
27 -
26: -
28: 28: 28:

28:
28 0.5 BN/YE 2267
2941
28: -
Positive
Voltage
Not Occupied
28: Mirror
Heating
28: Element
Control
26: -
Not Occupied
26: 26: 26:

26:
26 0.5 RD/GY 2840
27 28: 28: 28:
28:
28 0.5 BN/YE 2267
2941
26: -
26: -
28: -
28: -
X600 PASSENGER DOOR HARNESS TO BODY HARNESS

Part Catalog
Description: 41-Way F 4.8 TIMER/DSQ 1.5
Series (GY)
Harness Type: Body

Description: 41-Way M DSQ 1.5 2.8 Series
(GY)

Type ID
Lead
Test Probe
I
13575858
II
13575539
III
13582220
IV
13579964
13580818
Terminal
Removal
Tool
Service
Terminal
J-35616-42
J-38125-36 927837-1
(RD)
J-35616-14
J-38125-560 962943-5
(GN)
Not
Pending
Pending
Available
J-35616-3
J-38125-560 969079-2
(GY)
Not
Pending
Pending
Available
X600 Passenger Door Harness to Body Harness

Terminal
Option Function
Type ID
1:
1:
1:
1: Battery
Tray
Core
Crimp
Insulation
Crimp
25
16
Not
Available
Not
Available
Not
Available
32
Not
Available
Not
Available
Not
Available

1:
1:
1:
Terminal
Option
Type ID

Views - Cruze
2.5 RD/D- 1540

GN
2:
2:
2: 2
2: BK
2.5
2050
3:
3: 3 3: 1 3: BK
2050
4
1: 1
1: -
1: -
2: -
2: -
3: -
3: -
5: -
5: -
9: -
9: -
11: -
11: -
13: 13: 13: D- 13:

13 0.5 GN/BK 3396
13: -
13: -
14: 14:
14 0.5
14:
3398
14: -
14: -
15: 15: 15: D- 15:

15 0.5 GN/YE 6134
15: -
15: -
17: 17: 17:

17 0.75 YE/BK
17:
117
17: -
17: -
18: 18:
18: YE
18 0.75
18:
200
18: -
18: -
5: 5
6-8
9: 9
10
5:
5:
5: 294
0.75 BN/YE
-
9:
9: GY 9: 295
0.75
-
11: 11: 11:

11:
11 0.5 YE/VT 3397
12
16
1922
14:
WH
Positive
Voltage
2.5 RD/D- 1540

GN
2:
2:
2: Ground 2: 2
2: BK
2.5
2050
3:
3: Ground 3: 3 3: 1 3: BK
2050
Not Occupied 4
5: Door Lock
5:
5:
Actuator
5: 5
5: 294
0.75 BN/YE
Unlock
Control
Not Occupied 6-8 9: Door Lock
9:
9:
9: 295
Actuator Lock 9: 9
0.75 GY/BK
Control
Not Occupied 10 11: Co-Driver
11:
Up (+) Down 11 0.5 YE/VT 3397
(-) Control
Not Occupied 12 13: Co-Driver
Mirror Motor 13: 13: 13: D- 13:
Right (+) Left 13 0.5 GN/BK 3396
(-) Control
14: Co-Driver
14:
Common
14 0.5 WH 3398
Control
15: Linear
Interconnect 15: 15: 15: D- 15:
Network Bus 15 0.5 GN/YE 6134
3
Not Occupied 16 17: 17:
17:
17: Right
17: 0.75 YE/BK 117
Front Speaker
17 17: 17:
17:
Signal (-) (1)
0.75 YE/BK 117
18:
18:
18: Right
18: 0.75 18: YE 200
Front Speaker
18 18: 18: YE 18:
(+) (1)
0.75
200
19Not Occupied
22
23: Mirror
1: 1
1: -
1: -
2: -
2: -
3: -
3: -
5: -
5: -
9: -
9: -
11: -
11: -
13: -
13: -
14: -
14: -
15: -
15: -
17: -
17: -
18: -
18: -

Views - Cruze
23: 23: 23:

23:
23 0.5 BN/YE 2267
2441
23: -
23: -
Heating
Element
Control
Not Occupied
23: 23: 23:

23:
23 0.5 BN/YE 2267
2841
23: -
23: -
X700 LEFT REAR DOOR HARNESS TO BODY HARNESS

Part Catalog
Harness Type: Body

Description: 20-Way M 5.8 TTS 1.5 Series
(GY)

Type ID
Lead
Test Probe
I
13575858
II
13575538
III
13575539
IV
13575706
13575593
VI
13575593
Terminal
Removal
Tool
J-35616-42
J-38125-36
(RD)
J-35616-14
J-38125-560
(GN)
J-35616-14
J-38125-560
(GN)
Pending
J-38125-36
J-35616-14
J-38125-560
(GN)
J-35616-14
J-38125-560
(GN)
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
927837-1
25
962943-5
16
962943-5
16
964308-1
NA
Not
Available
Not
Available
964265-2
28
964265-2
28
X700 Left Rear Door Harness to Body Harness

Terminal
Option Function
Type ID
1:
1:
1: 1
1: BK
1: 1: 1: Ground
2.5
2350
2: 2
2:
2:
2:
2.5 RD/BN 2940
2: -
2: -
2: Battery
Positive
Terminal
Option
Type ID
1: 1
1:
2.5
1:
2350
1: -
1: -
2: 2
2:
2:
2:
2.5 RD/BN 2940
2: -
2: -
1: BK

Views - Cruze
3: 3
3:
3:
3: 294
0.75 BN/YE
3: -
3: -
4: 4
4:
4: GY 4: 295
0.75
4: -
4: -
9: -
9: -
5-8
9: 9
1016
9: 9: D9:
0.5 GN/GY 6135
-
17: 17:
17:
17:
17 0.5 BN/WH 3269
17: -
17: -
18:
18: 18:
18:
WH/D18 0.75
3266
BU
18: -
18: -
19: 19: 19: D19 0.75 GN
19:
199
19: -
19: -
20: 20: 20: D20 0.75 GN/BK
20:
116
20: -
20: -
Voltage
3: Door Lock
Actuator
Unlock
Control
4: Door Lock
Actuator
Lock Control
Not Occupied
9: Linear
Interconnect
Network Bus
4
Not Occupied
17: Child
Security Lock
Motor Status
Signal Left
Rear
18: Child
Security Lock
Motor Unlock
Control
19: Left Rear
Speaker (+)
20: Left Rear
Speaker
Signal (-)
3: 3
3:
3:
3: 294
0.75 BN/YE
3: -
3: -
4: 4
4:
4: GY 4: 295
0.75
4: -
4: -
9: -
9: -
17: 17:
17:
17:
17 0.5 BN/WH 3269
17: -
17: -
18:
18: 18:
18:
WH/D18 0.75
3266
BU
18: -
18: -
19: 19: 19: D19 0.75 GN
19:
199
19: -
19: -
20: 20: 20: D20 0.75 GN/BK
20:
116
20: -
20: -
5-8
9: 9
9: 9: D9:
0.5 GN/GY 6135
1216
X800 RIGHT REAR DOOR HARNESS TO BODY HARNESS

Part Catalog
Harness Type: Body

Description: 20-Way M 5.8 TTS 1.5 Series
(GY)

Views - Cruze

Type ID
Lead
Test Probe
I
13575858
II
13575538
III
13575539
IV
13575706
13575593
VI
13575593
Terminal
Removal
Tool
J-35616-42
J-38125-36
(RD)
J-35616-14
J-38125-560
(GN)
J-35616-14
J-38125-560
(GN)
Pending
J-38125-36
J-35616-14
J-38125-560
(GN)
J-35616-14
J-38125-560
(GN)
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
927837-1
25
962943-5
16
962943-5
16
964308-1
NA
Not
Available
Not
Available
964265-2
28
964265-2
28
X800 Right Rear Door Harness to Body Harness

Terminal
Option Function
Type ID
1:
1:
1: 1
1: BK
1: 1: 1: Ground
2.5
2050
2: Battery
2:
2:
2:
2: 2
2: 2: Positive
2.5 RD/BN 2940
Voltage
3: Door Lock
Actuator
3:
3:
3: 3
3: 294
3: 3: Unlock
0.75 BN/YE
Control
4: Door Lock
4:
4: 4
4: GY 4: 295
4: 4: - Actuator Lock
0.75
Control
5-8 Not Occupied
9: Linear
9: 9: D9:
Interconnect
9: 9
9: 9: 0.5 GN/GY 6135
Network Bus
4
10 Not Occupied
11: Front
11: 11:
11:
Passenger
11: GY
11: 11: 11 0.5
748
Door Ajar
Switch Signal
12Not Occupied
16
17: Child
Security Lock
Terminal
Option
Type ID
1: 1
1:
1: BK
2.5
1:
2050
1: -
1: -
2: 2
2:
2:
2:
2.5 RD/BN 2940
2: -
2: -
3: 3
3:
3:
3: 294
0.75 BN/YE
3: -
3: -
4: 4
4:
4: GY 4: 295
0.75
4: -
4: -
9: -
9: -
11:
748
11: V
11: -
5-8
9: 9
10
9: 9: D9:
0.5 GN/GY 6135
-
11: 11:
11: GY
11 0.5
1216

Views - Cruze
17: 17: 17:

17:
17 0.5 GY/BK 3268
17: -
18:
18: 18:
18:
WH/D18 0.75
3266
BU
18: -
19: 19:
19 0.75
19: 46
19: -
20:
115
20: -
19:
WH
20: 20: 20: D20 0.75 BU/BK
Motor Status
Signal Right
Rear
18: Child
Security Lock
18: Motor Unlock
Control
19: Right
19: - Rear Speaker
(+)
20: Right
20: - Rear Speaker
Signal (-)
17: -
17: 17: 17:

17:
17 0.5 GY/BK 3268
17: -
17: -
18:
18: 18:
18:
WH/D18 0.75
3266
BU
18: -
18: -
19: 19:
19 0.75
19: 46
19: -
19: -
20:
115
20: -
20: -
19:
WH
20: 20: 20: D20 0.75 BU/BK
X900 REAR COMPARTMENT LID HARNESS TO BODY HARNESS

Description: 22-Way F MQS/MCP 2.8 Series
(BK)
Harness Type: Body

Description: 22-Way M MQS/MCP 2.8
Series (BK)

Type ID
Lead
Test Probe
Terminal
Removal
Tool
Service
Terminal
Tray
Pending
Pending
Pending
Pending
Pending
II
Pending
Pending
Pending
Pending
Pending
Core
Crimp
Insulation
Crimp
Not
Available
Not
Available
Not
Available
Not
Available
X900 Rear Compartment Lid Harness to Body Harness

Terminal
Terminal
Option
Type ID
Type ID
1: Lift
Glass/Trunk
1:
1:
1:
1:
1:
1:
Motor
1: 1
1: I
1: 1: 1
1: II
1: 0.5 BU/YE 6795
0.5 BU/YE 6795
Release
Control 2

Views - Cruze
2: 2
2:
2:
2:
0.5 VT/GY 1303
2: I
2: -
3: 3
3:
3:
3:
0.5 GN/YE 6846
3: I
3: -
2: Lift Gate
Ajar Switch
Signal (1)
3: Rear
License Lamp
Control
Not Occupied
Not Occupied
Not Occupied
7: Lift Gate
Ajar Switch
Signal (1)
4
5
6
7: 7
7:
0.5
7: BK
7:
2550
7: I
7: -
8: BK 8: 650
8: I
8: -
8: Ground
9:
1650
9: I
9: -
9: Ground
8:
0.5
9:
9: 9
0.5
8: 8
9: BK
10: 10:
10:
10:
10 0.5 YE/BU 5797
10: I
10: -
13: 13:
13:
13 0.5 VT/GY
13:
709
13: I
13: -
14: 14:
14:
14 0.5 GY/BN
14:
309
14: I
14: -
15: I
15: -
16: I
16: -
17: I
17: -
20: 20:
20:
20: BK
20 0.5
1324
20: I
20: -
21: 21:
21:
21 0.5 VT/BK
21:
339
21: I
21: -
11
12
15:
15
16:
16
17:
17
18
19
22
15:
15:
15:
0.5 BARE 6974
16:
16:
16:
0.5 WH/BU 6973
17:
17:
17:
0.5 GY/YE 6972
-
10: Rear
Closure
Handle
Switch Open
Signal
Not Occupied
Not Occupied
13: Left Park
Lamp Supply
Voltage
14: Right
Park Lamp
Control
15: Camera
Drain Wire
16: Camera
Signal #2
17: Camera
Signal #2 +
Not Occupied
Not Occupied
20: Backup
Lamp Supply
Voltage
21:
Run/Crank
Ignition 1
Voltage
Not Occupied
2: 2
2:
2:
2:
0.5 VT/GY 1303
2: II
2: -
3: 3
3:
3:
3:
0.5 GN/YE 6846
3: II
3: -
4
5
6
7: 7
7:
0.5
7: BK
7:
2550
7: II
7: -
8: BK 8: 650
8: II
8: -
9:
1650
9: II
9: -
10: 10:
10:
10:
10 0.5 YE/BU 5797
10: II
10: -
13: 13:
13:
13 0.5 VT/GY
13:
709
13: II
13: -
14: 14:
14:
14 0.5 GY/BN
14:
309
14: II
14: -
15: II
15: -
16: II
16: -
17: II
17: -
20: 20:
20:
20: BK
20 0.5
1324
20: II
20: -
21: 21:
21:
21 0.5 VT/BK
21:
339
21: II
21: -
8:
0.5
9:
9: 9
0.5
8: 8
11
12
15:
15
16:
16
17:
17
18
19
22
9: BK
15:
15:
15:
0.5 BARE 6974
16:
16:
16:
0.5 WH/BU 6973
17:
17:
17:
0.5 GY/YE 6972
-

Views - Cruze
X910 LEFT INNER TAIL LAMP HARNESS TO REAR COMPARTMENT LID HARNESS
Harness Type: Left Inner Tail Lamp



Type ID
Lead
Test Probe
Terminal
Removal
Tool
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
Service by
Connector
Assembly 15306425
Not
Available
Not
Available
Not
Available
Not
Available
Not
Available
II
13575502
19
Pending
J-35616-3
J-38125-553 15304702
(GY)
X910 Left Inner Tail Lamp Harness to Rear Compartment Lid Harness
Terminal
Terminal
Option Function
Option
Type ID
Type ID
A: Left Park
A: A:
A:
A: A:
A:
A: 709 A: I
A: - Lamp Supply
A: 709 A: II
A: A 0.5 BK
A 0.5 VT/GY
Voltage
B: B: D- B:
B:
B:
B: B
B: I
B: B: Ground B: B
B: BK
B: II
B: 0.5 BU 2550
0.5
2550
X920 RIGHT INNER TAIL LAMP HARNESS TO REAR COMPARTMENT LID HARNESS
Harness Type: Right Inner Tail Lamp



Views - Cruze

Type ID
Lead
Test Probe
Terminal
Removal
Tool
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
Service by
Connector
Assembly 15306425
Not
Available
Not
Available
Not
Available
Not
Available
Not
Available
II
13575502
19
Pending
J-35616-3
J-38125-553 15304702
(GY)
X920 Right Inner Tail Lamp Harness to Rear Compartment Lid Harness
Terminal
Terminal
Option Function
Option
Type ID
Type ID
A: Right Park
A: A:
A:
A: A:
A:
A: 309 A: I
A: - Lamp Supply
A: 309 A: II
A: A 0.5 BK
A 0.5 GY/BN
Voltage
B: B: B: D- B:
B: B:
B:
B: I
B: B: Ground
B: BK
B: II
B: B 0.5 BU 2550
B 0.5
2550
X915 LICENSE LAMP HARNESS TO REAR COMPARTMENT LID HARNESS (-UVC)

Service Connector: Service by Harness- See
Part Catalog

Part Catalog

Terminal
Type ID
I
II
Terminal
Removal
Tool
J-35616-64B J-3812513575585
(L-BU)
12A
J-35616-65B J-3812513327167
(L-BU)
12A
Lead
Test Probe
Service
Terminal
Tray
Core
Crimp
Insulation
Crimp
928999-5
15
963716-2

Views - Cruze
X915 License Lamp Harness to Rear Compartment Lid Harness (-UVC)

Terminal
Terminal
Option
Type ID
Type ID
1:
1:
1:
1:
1:
1: 1
1: I
1: 1: Ground 1: 1
1: BK
1: II
1: 0.5 BK/WH 2550
0.5
2550
2: Rear
2:
2:
2:
2:
2:
2: 2
2: WH
2: I
2: - License Lamp 2: 2
2: II
2: 0.5
6846
0.5 GN/YE 6846
Control
3:
3:
3:
3:
3: 3
3: BK
3: I
3: 3: Ground 3: 3
3: BK
3: II
3: 0.5
1650
0.5
1650
4: Rear
Closure
4:
4:
4:
4:
4:
4: 4
4: BK
4: I
4: Handle
4: 4
YE/D4: II
4: 0.5
5797
0.5
5797
Switch Open
BU
Signal
X915 LICENSE LAMP HARNESS TO REAR COMPARTMENT LID HARNESS (UVC)

Description: 10-Way F Kaisen 0.64 Series
(BK)

Description: 10-Way M Kaisen 0.64 Series
(BK)

Terminal
Removal
Tool
J-35616-64B J-38125(L-BU)
215A
J-35616-65B J-38125(L-BU)
215A

Type ID
Lead
Test Probe
I
Pending
II
Pending
Service
Terminal
Tray
Not
Available
Not
Available
18
18
Core
Crimp
Insulation
Crimp
Not
Available
Not
Available
Not
Available
Not
Available
X915 License Lamp Harness to Rear Compartment Lid Harness (UVC)

Terminal
Terminal
Option
Type ID
Type ID
1:
1:
1:
1:
1: 1
1: BK
1: I
1: 1: Ground 1: 1
1: BK
1: II
1: 0.5
2550
0.5
2550
2:
2:
2:
2:

Views - Cruze
2: 2 0.5 2: BK 1650
3:
3:
3:
3: 3
0.5 GY/YE 6972
4:
4:
4:
4: 4
0.5 BARE 6974
2: I
2: -
3: I
3: -
4: I
4: -
2: Ground
3: Camera
Signal #2 +
4: Camera
Drain Wire
5: Backup
Lamp Supply
Voltage
6: Rear
License
Lamp Supply
Voltage
7: Rear
Closure
Handle
Switch Open
Signal
8: Camera
Signal #2
5: 5
5:
5:
5:
0.5 GN/WH 1324
5: I
5: -
6: 6
6:
6:
6:
0.5 GN/YE 6846
6: I
6: -
7: 7
7:
7:
7:
0.5 YE/BU 5797
7: I
7: -
8: I
8: -
9: I
9: -
9: Ground
10: -
10:
Run/Crank
Ignition 1
Voltage
8:
8:
8:
0.5 WH/BU 6973
9:
9:
9: 9
9: BK
0.5
2350
8: 8
10: 10:
10:
10 0.5 VT/BK
10:
339
10: I
2: 2 0.5 2: BK 1650
3:
3:
3:
3: 3
0.5 GY/YE 6972
4:
4:
4:
4: 4
0.5 BARE 6974
2: II
2: -
3: II
3: -
4: II
4: -
5: 5
5:
5:
5:
0.5 GN/WH 1324
5: II
5: -
6: 6
6:
6:
6:
0.5 GN/YE 6846
6: II
6: -
7: 7
7:
7:
7:
0.5 YE/BU 5797
7: II
7: -
8: II
8: -
9: II
9: -
10: II
10: -
8:
8:
8:
0.5 WH/BU 6973
9:
9:
9: 9
9: BK
0.5
2350
8: 8
10: 10:
10:
10 0.5 VT/BK
10:
339

2013 ELECTRICAL Wiring Systems and Power Management - Schematic and Routing Diagrams - Cruze
2013 ELECTRICAL
Wiring Systems and Power Management - Schematic and Routing Diagrams - Cruze
WIRING SCHEMATICS AND WIRING HARNESS ROUTING DIAGRAMS

HARNESS ROUTING VIEWS
Forward Lamp Harness Routing
Fig. 1: Foward Lamp Harness Routing

Items
1: X100 X100 Body Harness to Forward Lamp Harness
2: J116 (T3U)
3: X102 X102 Engine Cooling Harness to Forward Lamp Harness

4: X104 X104 Engine Cooling Harness to Forward Lamp Harness

5: X114 X114 Power Steering Harness to Forward Lamp Harness
Engine Harness Routing - Left Front (LUV)
Fig. 2: Engine Harness Routing -- Left Front (LUJ)

Items
1: J114
2: J111
3: J127
4: J144
5: J112 (LUV)
6: J119
7: J132
Engine Harness Routing - Left Front (LUW/LWE)

Fig. 3: Engine Harness Routing -- Left Front (LUW)

Items
1: X190 X190 Body Harness to Engine Harness
Engine Harness Routing - Right Rear (LUW/LWE)

Fig. 4: Engine Harness Routing -- Right Rear (LUW)

Items
1: X105 (LUW/LWE) X105 Engine Harness to Fuel Injectors Harness (LUW/LWE)
2: J114
3: J144
4: J127
5: J111
6: J132
7: J119
8: J122 (LUW or LWE with MH9)
9: J108 (LUW/LWE)
Instrument Panel Harness Routing

Fig. 5: Instrument Panel Harness Routing

Items
1: J202
2: J214
3: J204
4: J200
5: J213
6: J203
7: J209
8: J207
9: J206
10: J201
11: J211
12: X203 X203 Instrument Panel Harness to Passenger Instrument Panel Air Bag Harness

Center Console Harness Routing
Fig. 6: Center Console Harness Routing

Items
1: X300 X300 Console Harness to Instrument Panel Harness
2: J212
3: X301
Passenger Compartment Harness Routing

Fig. 7: Passenger Compartment Harness Routing

Items
1: X205 (UQA) X205 Instrument Panel Harness to Body Harness (UQA)
2: X211 X211 Headliner Harness to Body Harness
3: X210 X210 Headliner Harness to Body Harness
4: X206
5: X207
6: J302
7: J308
8: X800 X800 Right Rear Door Harness to Body Harness
9: X345 X345 Body Harness to Curtain Air Bag Harness
10: J402
11: J401
12: J305
13: J307

14: J315
15: J313
16: J314
17: J311
18: J319
19: J301
20: J303
21: J316
22: X200 X200 Instrument Panel Harness to Body Harness
Driver Seat Harness Routing
Fig. 8: Driver Seat Harness Routing

Items
1: X310 X310 Body Harness to Driver Seat Harness
Passenger Seat Harness Routing

Fig. 9: Passenger Seat Harness Routing

Items
1: X320 X320 Body Harness to Passenger Seat Harness
2: J317
Driver Door Harness Routing

Fig. 10: Driver Door Harness Routing

Items
1: J501 (AXG)
2: X500 X500 Driver Door Harness to Body Harness
3: J502
Passenger Door Harness Routing

Fig. 11: Passenger Door Harness Routing

Items
1: X600 X600 Passenger Door Harness to Body Harness
2: J605
Left Rear Door Harness Routing

Fig. 12: Left Rear Door Harness Routing

Items
1: J704
2: X700 X700 Left Rear Door Harness to Body Harness
3: J702
Right Rear Door Harness Routing

Fig. 13: Right Rear Door Harness Routing

Items
1: X800 X800 Right Rear Door Harness to Body Harness
2: J803
3: J801
Headliner Harness Routing

Fig. 14: Headliner Harness Routing

Items
1: J334
2: J333 (CF5)
3: J332
Rear Compartment Lid Harness Routing

Fig. 15: Rear Compartment Lid Harness Routing

Items
1: J903
2: X910 X910 Left Inner Tail Lamp Harness to Rear Compartment Lid Harness
3: X915 X915 License Lamp Harness to Rear Compartment Lid Harness (-UVC) X915 License
Lamp Harness to Rear Compartment Lid Harness (UVC)
4: J901
5: X920 X920 Right Inner Tail Lamp Harness to Rear Compartment Lid Harness
Body Harness Routing - Left Side of the Luggage Compartment

Fig. 16: Body Harness Routing -- Left Side of the Luggage Compartment
Items
1: X410 X410 Left Tail Lamp Harness to Body Harness
2: X900 X900 Rear Compartment Lid Harness to Body Harness
3: J401
4: J402
Body Harness Routing - Right Side of the Luggage Compartment

Fig. 17: Body Harness Routing - Right Side of the Luggage Compartment
Items
1: J312 (Y8X)
2: X420 X420 Right Tail Lamp Harness to Body Harness
3: J404
Body Harness Routing - Under the Rear of the Vehicle

Fig. 18: Body Harness Routing -- Under the Rear of the Vehicle
Items
1: X401 X401 Fuel Tank Harness to Body Harness
2: X402 (UD7) X402 Rear Object Sensor Harness to Body Harness (UD7)
ELECTRICAL SCHEMATIC SYMBOLS
Voltage Indicators
Symbol
Description
Battery Voltage

Ignition Switch- Off Position
Ignition Switch- Accessory Position
Ignition Switch- Run Position
Ignition Switch- Start Position
General Icons
Symbol
Description
Master Component List Icon
This icon is used on the schematic to link to the Master
Electrical Component List.
Description and Operation Icon

This icon is used on the schematic to link to the
Description and Operation of that particular system.
Computer Programming Icon

This icon is used on the schematic to link to Control
Module References, which identifies which components
need programming upon replacement.
Next Schematic Page Icon
This icon is used on the schematic to navigate to the
next schematic in the subsystem.

Previous Schematic Page Icon

This icon is used on the schematic to navigate to the
previous schematic in the subsystem.
Supplemental Inflatable Restraint (SIR) or
Supplemental Restraint System (SRS) Icon
This icon is used to alert the technician that the system
contains SIR/SRS components that require certain
precautions before servicing.
Information Icon
This icon is used to alert the technician that there is
additional information that will aid in servicing a
system.
Danger Icon
This icon is intended to alert the technician that a
component within the system contains labeling with the
same icon.
This icon is used when a source component has
potential for 60 volts DC or greater or has potential for
42 volts AC or greater.
High Voltage Icon
This icon is intended to alert the technician that a
component within the system contains labeling with the
same icon.
This icon is used when a component/circuit has
potential for 60 volts DC or greater or has potential for
42 volts AC or greater.
Caution Icon
This icon is used to advise the technician to use caution
when servicing this component.
This icon may be used when a component/circuit has a
voltage range potential between 30-60 volts DC or 1542 volts AC.
Functional Serial Data Communication
This icon is used to show the technician that the serial
data circuit detail is shown incomplete. It also provides
an active link to the Data Communication Schematics

were the circuit is shown complete.
Switch Position Icons

Symbol
Description
Generic Up Arrows
Generic Down Arrows
Generic Left Arrows
Generic Right Arrows
Generic Express Down Arrows
On/Off Icon
Generic Lock Icon

Generic Unlock Icon
Generic Window Switch Positions- 4 Door
Generic Window Switch Positions- 2 Door
Module Circuit Function Icons

Symbol
Description
I/O Pull-Down Resistors (-)
I/O Pull-Up Resistors (+)
I/O High-Side Drive Switch (+)
I/O Low-Side Drive Switch (+)

I/O Bidirectional Switch (+/-)
Pulse-Width Modulation Symbol
Battery Voltage
Ignition Voltage
Voltage Reference
A/C Voltage
Low Reference

Ground
Serial Data
Antenna Signal- In
Antenna Signal- Out
Brake Apply
Harness Components
Symbol
Description
Fuse
Fuse Supplied by a Relay
Circuit Breaker

Fusible Link
Ground
Case Ground
Inline Harness Connector
Inline Harness Connector
Pigtail Connection
Pigtail Connection

Provisional or Diagnostic Connector
Blunt Cut Wire
Incomplete Physical Splice
Complete Physical Splice- 2 Wires
Complete Physical Splice- 3 or more wires
Wire Crosses
Twisted Wires
Shield

Circuit References
Circuit Continuation Arrowheads
Option Breakpoint
Ground Circuit Connection
Connector Shorting Clip
Component Parts
Symbol
Description
Partial Component
When a component is represented 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.
Connector Directly Attached to Component

Pigtail Connector
Switches and Relays

Symbol
Description
Accessory Power Outlet
Cigar Lighter
Switch- 2 Position Normally Open
Switch- 2 Position Normally Closed
Switch- Rocker
Switch- Contact Plate (1 Wire)

Switch- Contact Plate (2 Wire)
Switch- 3 Position
Switch- 4 Position
Switch- 5 Position
Switch- 6 Position
Switch Actuator- Push (Momentary)
Switch Actuator- Push (Latching)

Switch Actuator- Pull (Momentary)
Switch Actuator- Pull (Latching)
Switch Actuator- Rotate (Momentary)
Switch Actuator- Rotate (Latching)
Switch Actuator- Slide (Momentary)
Switch Actuator- Slide (Latching)
Switch Actuator- Pressure (Momentary)
Switch Actuator- Temperature (Momentary)

Switch Actuator- Volume (Latching)
4-Pin Single Pole/Throw Relay- Normally Open
5-Pin Relay- Normally Closed
Devices and Sensors

Symbol
Description
Battery
Battery Assembly- Hybrid
Single Filament Light Bulb
Double Filament Light Bulb
Light Emitting Diode (LED)

Photo Sensor
Gauge
Diode
Capacitor
Resistor
Variable Resistor
Variable Resistor- NTC

Breakable Wire
Heating Element
Position Sensor
Pressure Sensor
Knock Sensor
Inductive Type Sensor- 2-Wire
Inductive Type Sensor- 3-Wire
Hall Effect Sensor- 2-Wire

Hall Effect Sensor- 3-Wire
Oxygen Sensor- 2-Wire
Heated Oxygen Sensor- 4-Wire
Solenoid- Actuator
Solenoid- Valve
Clutch
Motor
Motor with PTC

Antenna
Speaker
Horn
Microphone
Airbag
SIR Coil
SIR Impact Sensor
VEHICLE ZONING STRATEGY

All grounds, in-line connectors, and splices have identifying numbers that correspond to where they are located
in the vehicle. The following table explains the numbering system.

Fig. 19: Passenger Car Zoning View

Vehicle Zoning Strategy
Callout Numbers
100-199
200-299
300-399
400-499
500-599
600-699
700-799
800-899
900-999
Zone Description
Engine compartment (all forward of the instrument
panel)
Within the instrument panel area (between the
bulkhead and the front plane of the instrument
panel)
Passenger compartment (from instrument panel to
the back of the rear seats)
Luggage compartment (from the back of the rear
seats to the rear of the vehicle)
Inline harness connectors to or within the driver
door
Inline harness connectors to or within the front
passenger door
Inline harness connectors to or within the left rear
door
Inline harness connectors to or within the right rear
door
Inline harness connectors to or within the luggage
compartment lid or hatch

SCHEMATICS RPO CODE LIST

Schematics RPO Code List
RPO
2H0
A69
ADS
AEC
Option Name
ENGINE-GAS, 4 CYL, 1.8L, MFI, 103KW,
DOHC
RESTRAINT-SEAT BELT TENSIONER,
FRT, VAR. 2
ADJUSTER FRT ST-POWER, MULTIDIRECTIONAL, RECLINER MANUAL,
DRIVER
WINDOW-POWER OPERATED, DRIVER
EXPRESS DOWN
AED
PASSENGER, EXPRESS DOWN
AEF
PASSENGER, EXPRESS UP/DOWN
AEQ
AJG
ATH
AU3
AXG
AYC
BLUETOOTH
C25
C32
C67
C68
WINDOW-POWER OPERATED, RR DRS,

EXPRESS DOWN
Country Group
S America2 - Andean
(MAY), All Europe (MAE)
All Europe (MAE)
All Europe (MAE),

VietNam (MBL)
India (MBF), S America2 Andean (MAY), All Europe
(MAE), VietNam (MBL)
ASEAN (-VietNam) (MBJ),

India (MBF), S America2 Andean (MAY), VietNam
(MBL)
RESTRAINT SYSTEM-SEAT,
INFLATABLE, DRIVER and PASS, FRT and
SEAT SIDE, SINGLE STAGE
LOCK CONTROL, ENTRY-REMOTE
ENTRY, EXTENDED RANGE, PASSIVE
ENTRY, ALL DOORS
LOCK CONTROL-SIDE DR, ELEC
WINDOW-POWER OPERATED-EXPRESS
India (MBF), S America2 DRIVER UP/DOWN
Andean (MAY)
RESTRAINT SYSTEM-SEAT,
All Europe (MAE)
INFLATABLE, DRIVER and PASS FRT,
SEAT SIDE, ROOF SIDE, SINGLE STAGE
Bluetooth
WIPER SYS RR WINDOWS America2 - Andean
INTERMITTENT
HEATER-HEATING/DEFROSTER
All Europe (MAE)
SYSTEM, REINFORCED, ELECTRIC
HVAC SYSTEM-AIR CONDITIONER FRT, S America2 - Andean
(MAY), All Europe (MAE),
ELECTRONIC CONTROLS
VietNam (MBL)
HVAC SYSTEM-AIR CONDITIONER FRT,

CE1
CF5
CV8
CX5
D61
DD8
DMH
DT4
DWE
DWF
DWY
E30
E83
FX3
GENHATCH
GENSEDAN
HATCHBACK
J94
K27
K34
KA1
KC5
KC7
AUTO, ELECTRONIC CONTROLS

WIPER SYS WINDSHIELD-PULSE,
MOISTURE SENSITIVE
COUNTRY-IRAQ
COUNTRY-AUSTRALIA
MIRROR I/S FRT VAN-SUNSHADE,
DRIVER, W/MIRROR, COVER, ILLUM,
PASS, W/MIRROR, COVER, ILLUM
MIRROR I/S R/V-LT SENSITIVE
MIRROR I/S FRT VAN-SUNSHADE,
DRIVER, W/MIRROR, COVER, ILLUM,
PASS, W/MIRROR, COVER
ASHTRAY-CIGARETTE LIGHTER
S America2 - Andean
VietNam (MBL)
MIRROR O/S-LH and RH, RC, ELEC, HEAT,

S America2 - Andean
AUX WFOV/DRVR, MANFOLD,
CNVX/PASS
MIRROR O/S-LH and RH, RC, ELEC, HEAT,
AUX WFOV/DRVR, PWRFOLD,
CNVX/PASS
MIRROR O/S-LH and RH, RC, ELEC,
India (MBF), S America2 MANFOLD, AUX WFOV/DRVR,
Andean (MAY), VietNam
CNVX/PASS
(MBL)
ECM CONTROL MODULE WITH EDGE
MOUNTED CONNECTORS
ECM CONTROL MODULE WITH FACE
MOUNTED CONNECTORS
RIDE AND HANDLING-AUTOMATIC
S America2 - Andean
ELECTRONIC CONTROLLED
Hatchback
Notchback
HATCHBACK
BRAKE SYSTEM-POWER, FRT DISC, RR
VietNam (MBL)
DRUM, 15"
Fuel Pump Control Module
CRUISE CONTROL-AUTOMATIC,
S America2 - Andean
ELECTRONIC
(MAY)
RECEPTACLE-ELECTRICAL,
ACCESSORY
All Europe (MAE),
RECEPTACLE-ELECTRICAL, RR SEAT
VietNam (MBL)

KL9
ENG CONTROL-STOP/START SYS
KRE
FUEL RATING-OCTANE NO. 95
KTA
KTB
AUDIO INTERFACEAUDIO INTERFACE-WIRELESS

ENGINE-GAS, 4 CYL, 1.6L, MFI, L4,
DOHC, FAM 1, GEN S200, 80 KW, E20
MAX
TBD
TBD
ENGINE-GAS, 4 CYL, 1.6L, MFI, DOHC,
VVT, VARIABLE CAMSHAFT PHASING,
VARIABLE INTAKE MODULE (VIM)
ENGINE-GAS, 4 CYL, 1.8L, MFI, E100
MAX
L2W
LAM
LDD
LDE
LFH
LHD
VEHICLE DRIVE-LEFTHAND DRIVE
LKR
TBD
TURBO, PT-JV, 132KW
LLU
LNP
LUD
LUJ
LUW
LXT
LXV
M26
MF3
ENGINE-DIESEL, 4 CYL, L4, 2.0L, CRI,

DOHC, TURBO, 120 KW,
S America2 - Andean
India (MBF)
All Europe (MAE)
All Europe (MAE),

VietNam (MBL)

(MAE)
ENGINE-DIESEL, 4 CYL, 1.7L, L4, CRI,

DOHC, VGT, 96KW
ENGINE-GAS, 4 CYL, L4, 1.4L, MFI,
DOHC, TURBO HO, ALUM, GME
ENGINE-GAS, 4 CYL, 1.8L, MFI, 103KW,
DOHC, E85 MAX
80KW (GMDAT)
TBD
TBD
TRANSMISSION-MAN 6 SPD, OPEL, 76.5
MM, 4.273 1ST, 2.158 2ND, 1.302 3RD, 0.959
4TH, 0.744 5TH, 0.614 6TH, M32-6 WR
S America2 - Andean
VietNam (MBL)
MFH
TRANSMISSION-MAN 5 SPD, D16 M/CR
MFV
TBD
TRANSMISSION-AUTO 6 SPD, HMD,
S America2 - Andean
X23FHD
(MAY)
MH7
MH8

MH9
MSA
MYH
MYJ
MZ0
MZ4
NJ1
NOTCHBACK
OJP

TRANSMISSION-MAN 5 SPD, D20 M/CR,
1ST 3.818, 5TH 0.868
TRANSMISSION-MAN 6 SPD, 4.167 1ST,
2.208 2ND, 1.321 3RD, 0, 954 4TH, 0.755
5TH, 0.623 6TH F40-6 WR
TRANSMISSION-MAN 6 SPD, (F40-6,
FWD) 1ST 4.167, SIXTH 0.623
MM, 3.82 1ST, 0.74 6TH, (M32 WR)
MM, 3.82 1ST, 0.615 6TH, (M32 WR)
STEERING-POWER, NON-VARIABLE
RATIO, ELECTRIC
NOTCHBACK
Outside Ambient Air Temperature Sensor
RHD
VEHICLE DRIVE-RIGHTHAND DRIVE
SPO
T39
Special Part Option

LAMP-TURN SIGNAL, AUX
T79
LAMP-FOG, RR
T83
TR6
TRAILER
TS6
U05
CONTROL, HEADLAMPS-AUTOMATIC
ON-OFF
CONTROL, HEADLAMPS-LEVELING
SYSTEM, MANUAL
Trailer
LAMP-STOP, HIGH LEVEL
TBD
UAG
INFOTAINMENT DISPLAY-GRAPHIC
INFO DISPLAY (GID), VAR 1
UD7
PARK ASSIST-REAR
UEC
UFD
UH0
SENSOR INDICATOR-AUTOMATIC AIR

RECIRCULATION
INFOTAINMENT DISPLAY-TIME,
EXTERNAL TEMP, RADIO
INDICATOR-SEAT BELT WARNING, LH
S America2 - Andean
S America2 - Andean
All Europe (MAE)

All Europe (MAE)

(MAE)
S America2 - Andean
All Europe (MAE)

India (MBF), All Europe
(MAE)
S America2 - Andean
(MAY)
All Europe (MAE),

VietNam (MBL)
S America2 - Andean
VietNam (MBL)

UH1
INDICATOR-SEAT BELT WARNING, RH
ULS
LOCK CONTROL-STEERING COLUMN
UQG
UTU
UVC
TBD
THEFT DETERENT-ELECTRICAL,
UNAUTHORIZED ENTRY
ALARM, HORN-CONTENT THEFT
DETERENT, SELF POWERED
SENSOR, VEHICLE-INCLINATION
VISION-REAR VIEW
UW6
SPEAKER SYSTEM-6, CUSTOM
UTJ
UTR
UZZ
UDY
UDK

(MAE)
S America2 - Andean
VietNam (MBL)
S America2 - Andean
RADIO-AM/FM STEREO, CD-ROM, CAF,

RSA, MUSIC NAVIGATOR
(GME/ME/TAIWAN VERSION)
INFOTAINMENT DISPLAY-COLOR INFO
DISPLAY (CID) 7", WVGA, TOUCH
SCREEN
INFOTAINMENT DISPLAY-COLOR INFO
DISPLAY (CID) 7", QVGA
MASTER ELECTRICAL SCHEMATIC ICONS

Icon
Icon Definition
WARNING:
This vehicle is equipped with a Supplemental Inflatable Restraint
(SIR) System. Failure to follow the correct procedure could cause
Air bag deployment

Personal injury
Unnecessary SIR system repairs
In order to avoid the above conditions, observe the following

guidelines:
Refer to SIR Component Views in order to determine if you

are performing service on or near the SIR components or
the SIR wiring.
If you are performing service on or near the SIR
components or the SIR wiring, disable the SIR system.

Refer to Disabling the SIR System.

NOTE:
Twisted wires provide an effective shield that helps protect
sensitive electronic components from electrical interference.
In order to prevent electrical interference from degrading the
performance of the connected components, you must maintain
the proper specification when making any repairs to the twisted
wires shown
The wires must be twisted a minimum of 10 turns per 31

cm (12 in) as measured anywhere along the length of the
wires.
The outside diameter of the twisted wires must not exceed
6.0 mm (0.25 in).
POWER DISTRIBUTION WIRING SCHEMATICS

B+ Bus (1 of 3)
Fig. 20: B+ Bus (1 of 3)

Callout
Component Name

4042
4042_RD/WH
CAV_1
CONN_X4
CAV_1
CONN_X2
40
40_RD/GN
CAV_1
CONN_X1
4040
4040_RD/VT
CAV 20
CONN_X2
CAV_9
CONN_X2
CAV_87
CAV_85
CAV_30
CAV_87
CAV_5
CAV_30
CAV_3
CAV_5
A_REF
F5UD
F2UA
F64UA
F31UA
F62UA
F30UA
F21UA
F24UA
F27UA
F26UA
F33UA
F1UA
F69UA
F34UA
F35UA
F32UA
F67U

4042 RD/WH
1
X4
1
X2
40 RD/GN
1
X1
4040 RD/VT
20
X2
9
X2
87
85
30
87
5
30
3
5
A
F5UD 250A
F2UA 15A
F64UA 5A
F31UA 20A
F62UA 10A
F30UA 15A
F21UA 30A
F24UA 30A
F27UA 30A
F26UA 40A
F33UA 30A
F1UA 15A
F69UA 5A
F34UA 25A
F35UA 30A
F32UA 20A

F14UA
F55UA
F6UA
F12UA
F59UA
F45UA
F56UA
F51UA
F28UA
F60UA
F37UA
F38UA
F48UA
C1
KR11
KR27
KR3
KR5
KR48
KR46
X50A
X50A
KR20D
KR12B
KR12C
X50D
X50D
KR25
KR26
B+ Bus (2 of 3)
F67UA 20A
F14UA 10A
F55UA 7.5A
F6UA 30A
F12UA 30A
F59UA 30A
F45UA 60A
F56UA 15A
F51UA 15A
F28UA 40A
F60UA 7.5A
F37UA 10A
F38UA 10A
F48UA 15A

Fig. 21: B+ Bus (2 of 3)

Callout
CAV_86
CAV 86
CAV_86
CAV_87A
CAV_87
CAV_30
CAV_5
CAV_1
CAV_5
CAV_2
CAV_3
F42UA
F47UA
F11UA
F10UA
F9UA
F8UA
Component Name
86
86
86
87A
87
30
5
1
5
2
3
F42UA 60A
F47UA 10A
F11UA 10A
F10UA 15A
F9UA 15A
F8UA 15A

F46UA
F57UA
F53UA
F52UA
F16UA
F5UA
F17UA
F18UA
F13UA
F54UA
F4UA
B_REF
X50A
X50A
KR73
KR20E
KR20F
KR20P
KR20C
KR75
B+ Bus (3 of 3)
F46UA 10A
F57UA 15A
F53UA 10A
F52UA 5A
F16UA 7.5A
F5UA 15A
F17UA 5A
F18UA 10A
F13UA 7.5
F54UA 5A
F4UA 10A
B

Fig. 22: B+ Bus (3 of 3)

Callout
5040
5040 RD/YE
CAV_1
CONN_X3
5040_RD/YE
5140
5140_RD/GN
CAV_1
CONN_X4
5140_RD/GN
3140
3140_RD/GN
3140_RD/GN
CAV_19
3140_RD/GN
CAV_10
CAV_49
Component Name
5040 RD/YE
1
X3
5040 RD/YE
5140 RD/GN
1
X4
5140 RD/GN
3140 RD/GN
3140 RD/GN
19
3140 RD/GN
10
49

CAV_15
X200
CAV_89
CAV_90
A_REF
F1UD
F3UD
F6UD
F2UD
F23DA
F15DA
F24DA
F14DA
F21DA
F22DA
F25DA
F16DA
F17DA
F8DA
F9DA
F3DA
F10DA
F11DA
F13DA
F12DA
X200
X51A
X50D
X50D
KR104A
KR76
15
X200
89
90
A
F1UD 100A
F3UD 60A
F6UD 250A
F2UD 100A
F23DA 20A
F15DA 10A
F24DA 20A
F14DA 7.5A
F21DA 15A
F22DA 2A
F25DA 20A
F16DA 10A
F17DA 15A
F8DA 30A
F9DA 30A
F3DA 25A
F10DA 30A
F11DA 40A
F13DA 25A
F12DA 25A
X200
F2UA, F21UA, F25UA, F27UA, F31UA, F32UA, F34UA, F35UA, F69UA, and F70UA Fuses

Fig. 23: F2UA, F21UA, F25UA, F27UA, F31UA, F32UA, F34UA, F35UA, F69UA, and F70UA Fuses
Callout
1040
1040 RD/WH
CAV_4
CONN_X1
CAV_71
CONN_X2
1940
1940_RD/GN
CAV_5
CAV_40
3140
3140_RD/GN
CAV_5
CONN_X2
CAV_42
2940
2940_RD/BN
Component Name
1040 RD/WH
4
X1
71
X2
1940 RD/GN
5
40
3140 RD/GN
5
X2
42
2940 RD/BN

CAV_8
CAV_33
CAV_8
140
140_RD/WH
CAV_1
CAV_70
2740
2740_RD/WH
CAV_3
CONN_X5
CAV_67
1440
1440_RD/BN
CAV_20
CONN_X4
CAV_72
2640
2640_RD/VT
CAV_4
CONN_X5
CAV_68
140_RD/WH
CAV_20
CONN_X1
CAV_27
CONN_X3
2940 RD/BN
2940_RD/BN
2940 RD/BN
2940_RD/BN
140_RD/WH
UQA
ATH
CF5
CAV_2
CAV_2
CAV_20
J301
8
33
8
140 RD/WH
1
70
2740 RD/WH
3
X5
67
1440 RD/BN
20
X4
72
2640 RD/VT
4
X5
68
140 RD/WH
20
X1
27
X3
2940 RD/BN
2940 RD/BN
2940 RD/BN
2940 RD/BN
140 RD/WH
SPEAKER SYSTEM-PREMIUM AUDIO
BRANDED WITH AMPLIFIER
DOORS
2
2
20
J301

X700
X800
X211
F70UA
F35UA
F25UA
F27UA
F21UA
F34UA
F31UA
F69UA
F32UA
F2UA
S79LR
S79RR
K61
K20
K9
T3
M9
X50A
K84
X700
X800
X211
F70UA 5A
F35UA 30A
F25UA 20A
F27UA 30A
F21UA 30A
F34UA 20A
F31UA 20A
F69UA 5A
F32UA 20A
F2UA 15A
(CF5)
(UQA)
(ATH)
F1UA, F26UA, F30UA, F33UA, F55UA, F64UA, and F67UA Fuses

Fig. 24: F1UA, F26UA, F30UA, F33UA, F55UA, F64UA, and F67UA Fuses
Callout
140
140 RD/WH
CAV_37
CONN_X3
CAV_1
CONN_X1
1840
1840_RD/GN
CAV_25
CAV_56
CONN_X2
1640
1640_RD/VT
CAV_1
CAV_41
2040
2040_RD/WH
Component Name
140 RD/WH
37
X3
1
X1
1840 RD/GN
25
56
X2
1640 RD/VT
1
41
2040 RD/WH

CAV_69
2040_RD
CAV_B
CONN_X1
1540
1540_RD/GN
CAV_4
2840
2840_RD/GY
CAV_4
CAV_28
402
402 RD/GY
CAV_63
402_BU
CAV_1
CONN_X1
1740
1740_RD/GY
CAV_1
CAV_74
1540_RD/GN
2840_RD/GY
340_RD/VT
LUV
LUV
LWE
MH8
MH9
KA1
AXG
CAV_3
CAV_10
X500
CAV_26
CAV_4
F1UA
F30UA
69
2040 RD
B
X1
1540 RD/GN
4
2840 RD/GY
4
28
402 RD/GY
63
402 BU
1
X1
1740 RD/GY
1
74
1540 RD/GN
2840 RD/GY
340 RD/VT
ALUM, GME, E85 MAX
ALUM, GME, E85 MAX
KW, GME
UP/DOWN
3
10
X500
26
4
F1UA 15A
F30UA 15A

F26UA
F33UA
F55UA
F64UA
F67UA
X310
X320
X500
X50A
S79D
S52
K29
K17
K27
Q8
T12
K85
F26UA 40A
F33UA 30A
F55UA 7.5A
F64UA 5A
F67UA 20A
X310
X320
X500
(KA1)
(MH8/MH9)
(MH8/MH9)
F5UB, F6UB, F14UA, F24UA, F45UA, and F48UA Fuses
Fig. 25: F5UB, F6UB, F14UA, F24UA, F45UA, and F48UA Fuses


Callout
4040
4040 RD/VT
CAV_9
CAV 20
CONN_X2
1540
CAV_4
CAV_36
1540_RD/GN
CAV_4
CAV_2
1540_RD/GN
1540_RD/GN
1540_RD/GN
1540_RD/GN
34
34_VT/BN
CAV_31
CONN X1
5061
5061_BN/GY
CAV_B
5062
5062_BN/GN
CAV_B
CAV_30
CAV_5
AEC
AXG
LWE
CAV_1
CAV_1
J129
J116
F14UA
F24UA
Component Name
4040 RD/VT
9
20
X2
4
36
1540 RD/GN
4
2
1540 RD/GN
1540 RD/GN
1540 RD/GN
1540 RD/GN
Front Fog Lamp Supply Voltage
34 VT/BN
31
X1
Left Front Fog Lamp Supply Voltage
5061 BN/GY
B
Right Front Fog Lamp Supply Voltage
5062 BN/GN
B
30
5
WINDOW-POWER OPERATED, DRIVER
EXPRESS DOWN
WINDOW-POWER OPERATED-EXPRESS
DRIVER UP/DOWN
KW, GME
1
1
J129
J116
F14UA 10A
F24UA 30A

F45UA
F48UA
X500
X600
S79D
M74D
E29LF
E29RF
KR46
X50A
KR26
S79P
KR20D
F45UA 60A
F48UA 15A
X500
X600
(T3U)
(T3U)
F3DA, F3UD, F6UD, F8DA, F9DA, F10DA, F11DA, and F16DA Fuses
Fig. 26: F3DA, F3UD, F6UD, F8DA, F9DA, F10DA, F11DA, and F16DA Fuses
Callout
CAV_33
Component Name
33

CAV_34
CAV_26
CAV_35
CAV_31
CAV_36
140
140_RD/WH
CAV_2
CONN_X2
CAV_1
CONN_X6
2
2 RD/YE
CAV_1
CONN_X2
CAV_1
CONN_X5
2340
2340_RD/YE
CAV_3
CONN_X1
2440
2440_RD/GN
CAV_2
2540
2540_RD/BU
CAV_3
CONN X2
2840
2840 RD/GY
CAV_4
5240
5240_RD/BU
440
440_RD/BN
CAV_6
CONN_X1
2_RD/YE
CAV_A
CONN_X1
CAV_4
F3UD
34
26
35
31
36
140 RD/WH
2
X2
1
X6
TBD
2 RD/YE
1
X2
1
X5
2340 RD/YE
3
X1
2440 RD/GN
2
2540 RD/BU
3
X2
2840 RD/GY
4
5240 RD/BU
440 RD/BN
6
X1
2 RD/YE
A
X1
4

F6UD
F8DA
F9DA
F3DA
F10DA
F16DA
F11DA
G13
M64
K8
K43
X51A
X51A
X50D
K9
KR95B
F3UD 80A
F6UD 250A
F8DA 30A
F9DA 30A
F3DA 25A
F10DA 30A
F16DA 10A
F11DA 40A
F12DA and F13DA Circuit Breakers, and F14DA, F15DA, F17DA, F21DA, F23DA, F24DA, and F25DA Fuses
Fig. 27: F12DA and F13DA Circuit Breakers, and F14DA, F15DA, F17DA, F21DA, F23DA, F24DA, and

F25DA Fuses
Callout
940_RD/BN
CAV_5
3040
3040_RD/YE
CAV_9
CONN_X1
2140
2140_RD/GY
CAV 1
CONN_X2
2240
2240_RD/BN
CAV_4
CONN_X1
540
540_RD/BU
840
840_RD/BU
140
140_RD/WH
CAV_32
240
240_RD/YE
CAV_1
CONN_X2
240 RD/YE
CAV_3
702
702_RD/BN
CAV_D
702_RD/BN
702_RD
CAV_91
CAV_1
CAV_32
CAV_42
CAV_20
Component Name
940 RD/BN
5
3040 RD/YE
9
X1
2140 RD/GY
1
X2
2240 RD/BN
4
X1
540 RD/BU
840 RD/BU
140 RD/WH
32
240 RD/YE
1
X2
240 RD/YE
3
702 RD/BN
D
702 RD/BN
702 RD
91
1
32
42
20

CAV_45
CAV_44
CAV_25
CAV_46
ULS
ADS
CAV_38
CAV_37
CAV_16
CAV_55
X200
X310
F13DA
F12DA
F17DA
F21DA
F14DA
F24DA
F23DA
F15DA
F25DA
X200
K36
K9
P16
K33
X51A
S64D
X84
K60
A26
Ignition Switch and Fuse F22DA (without BTM)
45
44
25
46
STEERING COLUMN LOCK-MECHANICAL
ADJUSTER FRT ST-POWER, MULTI-DIRECTIONAL,
RECLINER MANUAL, DRIVER
38
37
16
55
X200
X310
F13DA 25A
F12DA 25A
F17DA 10A
F21DA 15A
F14DA 7.5A
F24DA 20A
F23DA 20A
F15DA 10A
F25DA 20A
X200
(ADS)
(ULS)

Fig. 28: Ignition Switch and Fuse F22DA (without BTM)

Callout
CAV_43
340
340_RD/VT
CAV_2
1073
1073_WH/BK
CAV_22
CONN_X3
CAV_6
1020
1020_WH/VT
CAV_15
CAV_4
4
4_VT/YE
CAV_5
CAV_3
Component Name
43
340 RD/VT
2
Ignition Key Resistor Signal
1073 WH/BK
22
X3
6
1020 WH/VT
15
4
Accessory Voltage
4 VT/YE
5
3

3
3_VT/BK
CAV_6
CAV_1
1594
1594_BN/VT
CAV_17
CONN_X2
CAV_15
CAV_86
5985
5985_VT/YE
CAV 18
CONN_X1
CAV_22
CONN_X4
5985_VT/YE
CAV_11
5985_VT/YE
5985_VT/YE
CAV_13
CONN_X1
MF3
MZ0
MH8
MH9
F22DA
X190
J119
S39
KR73
X50A
K9
X51A
K20
T12
Q8
Ignition Switch and Fuse F22DA (BTM)

3 VT/BK
6
1
1594 BN/VT
17
X2
15
86
5985 VT/YE
18
X1
22
X4
5985 VT/YE
11
5985 VT/YE
5985 VT/YE
13
X1
1ST, 2.158 2ND, 1.302 3RD, 0.959 4TH, 0.744 5TH, 0.614
6TH, M32-6 WR
1ST, 0.74 6TH, (M32 WR)
F22DA 2A
X190
J119
(without BTM)
(MH8/MH9)
(MH8/MH9)

Fig. 29: Ignition Switch and Fuse F22DA (BTM)

Callout
CAV_43
1140
1140_RD/BN
CAV_1
CONN_X2
3
3_VT/BK
CAV_6
CONN_X3
CAV_4
CONN_X2
4
4_VT/YE
CAV_5
CAV_3
3558
3558_GN/BK
Component Name
43
1140 RD/BN
1
X2
3 VT/BK
6
X3
4
X2
Accessory Voltage
4 VT/YE
5
3
Passive Start Switch Signal 2
3558 GN/BK

CAV_3
CAV_11
CONN_X1
3559
3559_BK/GY
CAV_7
CAV_12
5723
5723_BU/GN
CAV_6
CAV_17
CONN_X2
5720
5720_BN/BK
CAV_2
CAV_8
5719
5719_BU/BK
CAV_5
CAV_20
CONN_X1
1594
1594_BN/VT
CAV_17
CONN_X2
CAV_15
CONN_X4
5985
5985_VT/YE
CAV 18
CONN_X1
CAV_22
5985_VT/YE
CAV_13
CONN_X1
1650
1650_BK
CAV_4
1140_RD/BN
CAV_34
3_VT/BK
4 VT/YE
3
11
X1
Passive Start Switch 2 Low Reference
3559 BK/GY
7
12
Ignition Mode Switch Mode Voltage
5723 BU/GN
6
17
X2
Ignition Mode Switch Accessory LED Signal
5720 BN/BK
2
8
Ignition Mode Switch Start LED Signal
5719 BU/BK
5
20
X1
1594 BN/VT
17
X2
15
X4
5985 VT/YE
18
X1
22
5985 VT/YE
13
X1
Ground
1650 BK
4
1140 RD/BN
34
3 VT/BK

3558_GN/BK
3559_BK/GY
5985_VT/YE
5985_VT/YE
CAV_11
CAV_86
X200
CAV_17
CAV_28
CAV_42
CAV_43
G201
F22DA
F3DA
F3DA
X200
X190
J119
X200
X51A
K84
K9
KR73
X50A
S38
Q8
T12
K20
F47UA, F59UA, and F62UA Fuses
4 VT/YE
3558 GN/BK
3559 BK/GY
5985 VT/YE
5985 VT/YE
11
86
X200
17
28
42
43
G201
F22DA 2A
F3DA
F3DA
X200
X190
J119
X200
(ATH)
(BTM)
(MH8/MH9)
(MH8/MH9)

Fig. 30: F47UA, F59UA, and F62UA Fuses

Callout
CAV_87
CAV 86
CAV_30
CAV_30
CAV_85
CAV_5
CAV_3
CAV_2
78
78_BN/YE
CAV_A
CAV_37
CONN_X2
7573
7573_BU/BN
CAV_21
CAV_73
Component Name
87
86
30
30
85
5
3
2
Air Injection Reaction Pump Supply Voltage
78 BN/YE
A
37
X2
Electric Variable Displacement Supply
7573 BU/BN
21
73

5293
5293_RD/WH
CAV_6
CONN_X3
5293_RD/WH
CAV_2
5293_RD/WH
CAV_1
5293_RD/WH
CAV_2
5293_RD/WH
CAV_2
5293 RD/WH
5293_VT/BU
CAV_1
5293_VT/BU
5293_VT/BU
5293_VT/BU
5293_VT/BU
CAV_1
CAV_1
CAV_1
CAV_1
LUV
LUV
LUV
LUW
LWE
LUV
LUV
LUV
LUV
LUW
Powertrain Main Relay Fused Supply (4)

5293 RD/WH
6
X3
5293 RD/WH
2
5293 RD/WH
1
5293 RD/WH
2
5293 RD/WH
2
5293 RD/WH
5293 VT/BU
1
5293 VT/BU
5293 VT/BU
5293 VT/BU
5293 VT/BU
1
1
1
1
ENGINE-GAS, 4 CYL, 1.4L, MFI, DOHC, TURBO,
VVT, ALUM, GME, E85 MAX
ENGINE-GAS, 4 CYL, 1.8L, MFI, 103KW, DOHC,
E85 MAX
ENGINE-GAS, 4 CYL, 1.8L, MFI, DOHC, VVT,
103 KW, GME
E85 MAX

LWE
LUW
LWE
LUW
LWE
LUW
LWE
5293_RD/WH
5293_VT/BU
78_BN/YE
CAV 16
LWE
LUV
LUW
LWE
LUW
LWE
F59UA
F62UA
F47UA
X190
J111
C_REF
KR29
X50A
X50A
B52A
B52B
Q12
Q22

103 KW, GME
E85 MAX
103 KW, GME
E85 MAX
103 KW, GME
E85 MAX
103 KW, GME
5293 RD/WH
5293 VT/BU
78 BN/YE
16
103 KW, GME
E85 MAX
103 KW, GME
E85 MAX
103 KW, GME
F59UA 30A
F62UA 10A
F47UA 10A
X190
J111
C
(LUW/LWE)

E41
Q42
Q40
G21
KR25
KR75
(LUV)
(LUV)
F8UA, F9UA, F10UA, and F11UA Fuses
Fig. 31: F8UA, F9UA, F10UA, and F11UA Fuses

Callout
X3_-_3
5291
5291_VT/BU
CAV_A
CAV_2
CONN_X3
5291_VT/BU
LWE
Component Name
X3 - 3
5291 VT/BU
A
2
X3
5291 VT/BU

LUW
RD/BU
LUV
LWE
LUW
5290
5290_VT/BU
CAV_28
CONN_X2
5290_VT/BU
RD/BU
LUV
RD/BU
LUV
LWE
LUW
LWE
LUW
CAV_1
5290_VT/BU
CAV_13
LWE
LUW
RD/BU
LUV
5294
5294_VT/BU
CAV_16
CONN_X2
KW, GME
E85 MAX
RD/BU
KW, GME
E85 MAX
5290 VT/BU
28
X2
5290 VT/BU
RD/BU
RD/BU
KW, GME
E85 MAX
KW, GME
E85 MAX
1
5290 VT/BU
13
KW, GME
E85 MAX
RD/BU
5294 VT/BU
16
X2

CAV_47
LWE
5294 VT/BU
CAV_5
CAV_86
5291_VT/BU
CAV_1
5291_VT/BU
5291_PK/BK
5291_PK/BK
CAV_1
5291_PK/BK
CAV_1
5291_PK/BK
CAV_1
CAV_5
LWE
LUW
5291 RD/BU
CAV_1
5291_RD/BU
CAV_1
5291_RD/BU
CAV_1
5291_RD/BU
CAV_1
LUV
LUV
LUV
LUV
CAV_7
C_REF
D_REF
F8UA
F9UA
47
KW, GME
5294 VT/BU
5
86
5291 VT/BU
1
5291 VT/BU
5291 PK/BK
5291 PK/BK
1
5291 PK/BK
1
5291 PK/BK
1
5
KW, GME
E85 MAX
5291 RD/BU
1
5291 RD/BU
1
5291 RD/BU
1
5291 RD/BU
1
7
C
D
F8UA 15A
F9UA 15A

J112
F11UA
F10UA
X160
J114
J108
X50A
K20
Q17A
Q17B
Q17C
Q17D
X50A
X50A
Q17A
Q17B
Q17C
Q17D
K35
KR26
B75C
F42UA and F46UA Fuses
J112
F11UA 10A
F10UA 15A
X160
J114
J108

Fig. 32: F42UA and F46UA Fuses

Callout
2366
CAV 43
CAV_34
CONN_X1
999_WH/D-BU
CAV_66
CAV_20
2366_WH/BK
CAV_1
CAV_5
CAV_30
CAV_86
CAV_30
CAV_86
CAV_86
F42UA
F46UA
Component Name
Cooling Fan Control Relay Speed Signal
43
34
X1
999 WH/D-BU
66
20
2366 WH/BK
1
5
30
86
30
86
86
F42UA 60A
F46UA 10A

D_REF
X50A
KR20F
X50A
KR20P
KR20C
KR20E
F16UA, F17UA, F18UA, F20UA, F52UA, F54UA, and F57UA Fuses
Fig. 33: F16UA, F17UA, F18UA, F20UA, F52UA, F54UA, and F57UA Fuses
Callout
739
739_VT/BK
CAV_21
CAV_15
CONN_X2
1339
1339_VT/GN
Component Name
739 VT/BK
21
15
X2
1339 VT/GN

CAV_1
CAV_65
CONN_X1
1039
1039_VT/GY
CAV_3
339
339_VT/BK
CAV_1
339_VT/BK
339_VT/BK
239
239 VT/WH
CAV_9
CONN_X2
CAV_29
239_VT/WH
239_VT/WH
239_VT/WH
CAV_1
CAV_21
CAV_10
239_VT/WH
CAV_31
CAV_26
239_VT/WH
3039
3039 VT/GN
CAV_17
CONN X1
CAV_14
3039_VT/GN
807
807_BU/VT
CAV_3
CAV_32
CONN_X2
807_BU/VT
CAV_37A
CAV_87
CAV_30
ULS
1
65
X1
1039 VT/GY
3
339 VT/BK
1
339 VT/BK
339 VT/BK
239 VT/WH
9
X2
29
239 VT/WH
239 VT/WH
239 VT/WH
1
21
10
239 VT/WH
31
26
239 VT/WH
3039 VT/GN
17
X1
14
3039 VT/GN
OFF /Accessory Voltage
807 BU/VT
3
32
X2
807 BU/VT
37A
87
30

C68
Y8X
X200
CAV_70
CAV_53
CAV_27
CAV_71
E_REF
X900
X915
F57UA
F17UA
F52UA
F54UA
F16UA
F18UA
J309
X200
B108
K33
P16
X50A
KR73
X50A
K27
K36
P14
M96
K60
B87
F5UA, F13UA, F53UA, and F65UA Fuses
STEERING COLUMN LOCK-MECHANICAL

ELECTRONIC CONTROLS
MODEL CONVERSION-ENGINE IMPROVEMENT
X200
70
53
27
71
E
X900
X915
F57UA 15A
F17UA 5A
F52UA 5A
F54UA 5A
F16UA 7.5A
F18UA 10A
J309
X200
(C68)
(Y8K)
(ULS)
(UVC)

Fig. 34: F5UA, F13UA, F53UA, and F65UA Fuses

Callout
2839
CAV 2
CAV_31
CONN_X2
5372
CAV_35
CONN_X3
5372_RD/BU
CAV_1
139
139_VT/GY
CAV_19
CONN_X1
CAV_20
139_VT/GY
CAV_19
CONN_X1
Component Name
2
31
X2
Canister Valve Solenoid
35
X3
5372 RD/BU
1
139 VT/GY
19
X1
20
139 VT/GY
19
X1

139_VT/GY
CAV_12
CONN_X1
5372_BU
5372_BU
2839_VT/WH
2839_VT/WH
VT/BU
LUV
LUW
LWE
VT/BU
LUV
LUW
LWE
VT/BU
LUV
LUW
LWE
MH8
MH9
MF3
MZ0
DD8
CAV_M
CAV_30
CAV_5
J144
F13UA
F53UA
F4UA
139 VT/GY
12
X1
5372 BU
5372 BU
2839 VT/WH
2839 VT/WH
VT/BU
ALUM, GME, E85 MAX
MAX
ENGINE-GAS, 4 CYL, 1.8L, MFI, DOHC, VVT, 103 KW,
GME
VT/BU
ALUM, GME, E85 MAX
MAX
GME
VT/BU
ALUM, GME, E85 MAX
MAX
GME
1ST, 2.158 2ND, 1.302 3RD, 0.959 4TH, 0.744 5TH, 0.614
6TH, M32-6 WR
1ST, 0.74 6TH, (M32 WR)
MIRROR I/S R/V-LT SENSITIVE
M
30
5
J144
F13UA 7.5A
F53UA 10A
F4UA 10A

F5UA
E_REF
X401
X190
X211
X50A
X50A
A10
Q13
K20
Q8
T12
F5UA 15A
E
X401
X190
X211
(DD8)
(MH8/MH9)
(MH8/MH9)
F28UA, F37UA, F38UA, F51UA, F56UA, and F60UA Fuses
Fig. 35: F28UA, F37UA, F38UA, F51UA, F56UA, and F60UA Fuses
Callout
2267
CAV_F
Component Name
Mirror Heating Element Supply Voltage
F

CAV_62
CONN_X2
CAV_F
293
293_BN/VT
CAV_1
CONN_X1
CAV_39
228
228_GY/VT
CAV_1
CAV_30
CONN X1
29
29_BN/GY
CAV_2
CAV_11
711
711_WH
CAV_3
CAV_14
311
311_WH
CAV_3
CAV_13
2267_BN/YE
2267_BN/YE
2267 BN/YE
2267_BN/YE
2267 BN/YE
DWE
CAV_87
CAV_30
CAV_28
CAV 23
J316
F60UA
F28UA
F56UA
F51UA
62
X2
F
Rear Defog Element Supply Voltage
293 BN/VT
1
X1
39
Windshield Washer Pump Control
228 GY/VT
1
30
X1
Horn Control
29 BN/GY
2
11
Left Headlamp High Beam Supply Voltage
711 WH
3
14
Right Headlamp High Beam Supply Voltage
311 WH
3
13
2267 BN/YE
2267 BN/YE
2267 BN/YE
2267 BN/YE
2267 BN/YE
MIRROR O/S-LH and RH, RC, ELEC, HEAT, AUX
WFOV/DRVR, MANFOLD, CNVX/PASS
87
30
28
23
J316
F60UA 7.5A
F28UA 40A
F56UA 15A
F51UA 15A

F38UA
F37UA
X500
X600
KR5
KR3
KR48
X50A
A9B
G24
KR11
E18
A9A
E13R
E13L
P12
F38UA 7.5A
F37UA 10A
X500
X600
F1DA, F4DA, F5DA, F6DA, and F7DA Fuses
Fig. 36: F1DA, F4DA, F5DA, F6DA, and F7DA Fuses


Callout
6128
6128_BU/WH
CAV_14
6128_BU/WH
801
CAV_1
CAV_1
40
CAV_44
CONN_X1
840
CAV 15
CONN_X1
3140
3140_RD/GN
CAV_1
3140_RD/GN
CAV_1
3140_RD/GN
CAV_1
3140_RD/GN
CAV_1
CONN_X1
3140_RD/GN
3140_RD/GN
CAV_5
3140 RD/GN
CAV_5
3140 RD/GN
3140_RD/GN
3140_RD/GN
3140_RD/GN
CAV_9
CAV_10
CAV_15
801_VT
801_VT
801_VT
801_VT
40_RD/GN
840 RD/BU
Component Name
Rear Closure Unlatch Motor Unlatch Control
6128 BU/WH
14
6128 BU/WH
Retained Accessory Power Fuse Supply Voltage
1
1
44
X1
15
X1
3140 RD/GN
1
3140 RD/GN
1
3140 RD/GN
1
3140 RD/GN
1
X1
3140 RD/GN
3140 RD/GN
5
3140 RD/GN
5
3140 RD/GN
3140 RD/GN
3140 RD/GN
3140 RD/GN
9
10
15
801 VT
801 VT
801 VT
801 VT
40 RD/GN

3140_RD/GN
3140_RD/GN
3140_RD/GN
3140_RD/GN
CAV_29
CAV_23
CAV_30
CAV_24
CAV_22
CAV_18
CAV_16
CAV 17
CAV_27
CAV_28
KTA
UD7
UFT
CAV_54
CAV_G
X300
CAV_5
CAV_19
F7DA
F6DA
F4DA
F1DA
F5DA
X200
X402
J320
J203
X300
A22
P17
T11
A11
X80L
E32
X51A
K73
KR104
840 RD/BU
3140 RD/GN
3140 RD/GN
3140 RD/GN
3140 RD/GN
29
23
30
24
22
18
16
17
27
28
AUDIO INTERFACEPARK ASSIST-REAR
SIDE ACTIVE SAFETY-OBSTACLE DETECTION
54
G
X300
5
19
F7DA 20A
F6DA 20A
F4DA 20A
F1DA 10A
F5DA 7.5A
X200
X402
J320
J203
X300
(KTA)
(UE1)

K41R
B218L
B218R
KR76
(UD7)
POWER MODING WIRING SCHEMATICS

Ignition Main Relay Wiring Schematics
Fig. 37: Ignition Main Relay Wiring Schematics

Callout
340
340_RD/VT
CAV_2
1594
1594_BN/VT
CAV_15
CONN_X4
Component Name
340 RD/VT
2
1594 BN/VT
15
X4

CAV_17
CONN_X2
3
3_VT/BK
CAV_6
CONN_X3
CAV_1
1150
1150_BK
CAV_71
CONN_X1
CAV_43
CAV 2
CAV_3
CAV_1
CAV_5
CAV_4
G101
F22DA
F52UA
F57UA
F13UA
F5UA
F54UA
F53UA
F16UA
F17UA
F18UA
S39
K9
KR73
X51A
X50A
Retained Accessory Power Relay Wiring Schematics
17
X2
3 VT/BK
6
X3
1
Ground
1150 BK
71
X1
43
2
3
1
5
4
G101
F22DA 2A
F52UA 5A
F57UA 15A
F13UA 7.5A
F5UA 15A
F54UA 5A
F53UA 10A
F16UA 7.5A
F17UA 5A
F18UA 10A
(without BTM)

Fig. 38: Retained Accessory Power Relay Wiring Schematics

Callout
202
2540
2540_RD/BU
CAV_3
CONN_X2
3
3_VT/BK
CAV_12
CONN_X4
202_RD/BN
CAV_1
3_VT/BK
CAV_84
1650
1650_BK
6128
6128_BU/WH
Component Name
2540 RD/BU
3
X2
3 VT/BK
12
X4
202 RD/BN
1
3 VT/BK
84
Ground
1650 BK
Rear Closure Unlatch Motor Unlatch Control
6128 BU/WH

6128_BU/WH
CAV_29
CAV_23
CAV_30
CAV_24
CAV_11
CAV_15
CAV_13
CAV_14
CAV_26
MH8
MH9
G201
X200
F6DA
F7DA
F3DA
S3
X51A
K9
X51A
KR76
Battery Saver Relay Wiring Schematics
6128 BU/WH
29
23
30
24
11
15
13
14
26
G201
X200
F6DA 20A
F7DA 20A
F3DA 25A
(MH8/MH9)

Fig. 39: Battery Saver Relay Wiring Schematics

IGNITION LOCK WIRING SCHEMATICS
Ignition Lock Wiring Schematics

Fig. 40: Ignition Lock Wiring Schematics

Callout
5905
5905 WH/VT
CAV_6
CAV_13
CONN_X7
143
143_VT/YE
CAV_1
CAV_7
CONN_X3
5905_WH/VT
CAV_2
CAV_67
ATH
Component Name
Key Capture/Column Lock Shift Position Signal
5905 WH/VT
6
13
X7
Accessory Voltage
143 VT/YE
1
7
X3
5905 WH/VT
2
67
DOORS


DOORS
Ground
2150 BK
2
G202
X200
ATH
2150
2150 BK
CAV_2
G202
X200
K9
B81B
S3
M93
(MH8/MH9)
(MH8/MH9)
(MH8/MH9)
GROUND DISTRIBUTION WIRING SCHEMATICS

G100, G101, and G102 Wiring Schematics
Fig. 41: G100, G101, and G102

Callout
50
CAV_85
Component Name
Ground
85

CAV_87
CAV_2
981_BK
CAV_26
CONN_X4
50_BK
50_BK
1150
1150_BK
CAV_71
1150_BK
CAV_2
1150 BK
CAV_A
1150_BK
CAV_2
1150_BK
CAV_C
1150_BK
CAV_2
Y8X
G101
G100
G102
C1
E29LF
KR73
E13L
E2LF
E4N
K9
KR5
X50A
M96
KR20F
KR114
87
2
981 BK
26
X4
50 BK
50 BK
Ground
1150 BK
71
1150 BK
2
1150 BK
A
1150 BK
2
1150 BK
C
1150 BK
2
MODEL CONVERSION-ENGINE IMPROVEMENT
G101
G100
G102
(T3U)
(Y8K)

Fig. 42: G103, G104, and G105

Callout
CAV_87A
CAV 30
CAV_30
CAV_85
CAV_87A
1350
1350_BK
CAV_C
CAV_2
95
95_YE/BN
CAV_73
CONN_X1
CAV_B
CAV_1
1050
1050_BK
Component Name
87A
30
30
85
87A
Ground
1350 BK
C
2
Windshield Wiper Motor Low Speed Control
95 YE/BN
73
X1
B
1
Ground
1050 BK

1050_BK
CAV_2
1350_BK
CAV_2
1050_BK
CAV_A
1050_BK
CAV_2
1050_BK
CAV_C
1350_BK
CAV_C
1250
1250_BK
CAV_1
1350_BK
CAV_74
CONN_X1
1350_BK
C68
BTV
G103
G104
G105
M75
G24
B108
E29RF
B55
E13R
G10
E2RF
E4P
KR12B
KR12C
X50A
M75
P12
G112 and G114 Wiring Schematics
1050 BK
2
1350 BK
2
1050 BK
A
1050 BK
2
1050 BK
C
1350 BK
C
Ground
1250 BK
1
1350 BK
74
X1
1350 BK
ELECTRONIC CONTROLS
REMOTE START-ENGINE
G103
G104
G105
(C68)
(T3U)

Fig. 43: G112 and G114

Callout
CAV_86
CAV 86
150
150_BK
CAV_9
CONN_X3
150_BK
CAV_21
150_BK
CAV_4
150_BK
CAV_2
CONN_X1
150_BK
CAV_2
150_BK
CAV_B
Component Name
86
86
Ground
150 BK
9
X3
150 BK
21
150 BK
4
150 BK
2
X1
150 BK
2
150 BK
B

150_BK
CAV_4
150_BK
CAV_2
150_BK
CAV_2
450
450_BK
CAV_73
CONN_X2
250
250_BK
CAV B
C68
MH8
MH9
MF3
MZ0
LWE
LWE
LUW
LWE
G112
G114
J124
KR27
X50A
B16
Q22
K20
Q8
T12
G21
Q29
B75C
150 BK
4
150 BK
2
150 BK
2
Ground
450 BK
73
X2
Ground
250 BK
B
ELECTRONIC CONTROLS
2.158 2ND, 1.302 3RD, 0.959 4TH, 0.744 5TH, 0.614 6TH,
M32-6 WR
0.74 6TH, (M32 WR)
GME
GME
ENGINE-GAS, 4 CYL, 1.8L, MFI, 103KW, DOHC, E85 MAX
GME
G112
G114
J124
(MF3 or MZ0)
(LUW/LWE)
(MH8/MH9)
(MH8/MH9)

KR23A
Q2
K35
Fig. 44: G120, G121, and G201

Callout
1050
1050_BK
CAV_1
CONN_X1
1450
1450_BK
CAV_13
350
350 BK
CAV_1
CONN_X2
Component Name
Ground
1050 BK
1
X1
Ground
1450 BK
13
Ground
350 BK
1
X2

1650
1650_BK
CAV_6
1650_BK
CAV_7
1650_BK
CAV_4
1650_BK
CAV_6
2150
2150_BK
2150_BK
1650 BK
CAV_16
1650_BK
1650_BK
1650_BK
1650_BK
1750
1750_BK
CAV_7
CAV_1
CAV_2
CAV_13
BTM
CAV_4
CAV_5
G120
G121
G201
J210
J201
S30
X84
K17
K43
P16
X51A
K60
KR104A
KR95B
KR76
Ground
1650 BK
6
1650 BK
7
1650 BK
4
1650 BK
6
Ground
2150 BK
2150 BK
1650 BK
16
1650 BK
1650 BK
1650 BK
1650 BK
Ground
1750 BK
7
1
2
13
SWITCH-ENGINE START, KEYLESS
4
5
G120
G121
G201
J210
J201
(ULS)

S38
KR14
(BTM)
G202 Wiring Schematics
Fig. 45: G202

Callout
1650
1650_BK
CAV 3
1650_BK
CAV 6
1650_BK
CAV_7
1650_BK
CAV_9
CONN_X3
CAV_5
Component Name
Ground
1650 BK
3
1650 BK
6
1650 BK
7
1650 BK
9
X3
5

1750
1750_BK
CAV_2
CONN_X1
1650_BK
CAV_3
1650_BK
CAV_1
1650_BK
CAV_3
1750_BK
CAV_4
1850
1850_BK
CAV_5
CONN_X1
1650_BK
CAV_2
1650_BK
CAV_8
CONN_X2
1650_BK
CAV_16
CONN_X1
1750_BK
CAV_B
1750_BK
CAV 2
1650_BK
CAV 1
CONN_X1
850
850_BK
CAV_2
CONN_X2
MH8
1650_BK
C68
1650_BK
2150
Ground
1750 BK
2
X1
1650 BK
3
1650 BK
1
1650 BK
3
1750 BK
4
Ground
1850 BK
5
X1
1650 BK
2
1650 BK
8
X2
1650 BK
16
X1
1750 BK
B
1750 BK
2
1650 BK
1
X1
Ground
850 BK
2
X2
1650 BK
ELECTRONIC CONTROLS
1650 BK
Ground

2150_BK
J209
J211
J212
X85
B99
S70L
S70R
K8
S13D
S3
K9
P2
P14
S78
S26
A26
K33
2150 BK
J209
J211
J212
(FX3)
(K34)
(W1Y)
(MH8/MH9)
(MH8/MH9)

Fig. 46: G203

Callout
1650
1750
1850
1750_BK
CAV_20
CONN_X2
1750_BK
CAV_38
CONN X1
1750_BK
CAV 7
CONN_X1
1650_BK
CAV_2
1750_BK
1750_BK
CAV_2
1750_BK
1750_BK
1750_BK
CAV_4
1650_BK
CAV_C
2150
2150_BK
CAV C
1650_BK
CAV_2
1650_BK
CAV_6
1650_BK
CAV_4
1750_BK
1750_BK
CAV_11
CONN_X1
1850_BK
Component Name
Ground
Ground
Ground
1750 BK
20
X2
1750 BK
38
X1
1750 BK
7
X1
1650 BK
2
1750 BK
1750 BK
2
1750 BK
1750 BK
1750 BK
4
1650 BK
C
Ground
2150 BK
C
1650 BK
2
1650 BK
6
1650 BK
4
1750 BK
1750 BK
11
X1
1850 BK

1750_BK
MF3
MZ0
MH8
MH9
UAG
UDY
X300
CAV_7
CAV_4
CAV_18
J214
G301
X300
A22
P17
A11
E32
X80L
E27
B10B
S75
T11
K73
X83
1750 BK
2.158 2ND, 1.302 3RD, 0.959 4TH, 0.744 5TH, 0.614 6TH, M326 WR
6TH, (M32 WR)
INFOTAINMENT DISPLAY-GRAPHIC INFO DISPLAY
(GID), VAR 1
"INFOTAINMENT DISPLAY-COLOR INFO DISPLAY (CID)
7"", WVGA, TOUCH SCREEN"
X300
7
4
18
J214
G301
X300
(FX3)
(KTA)
(UE1)

Fig. 47: G204 and G305 Wiring Schematics

Callout
2450
2450 BK
CAV_19
CONN_X1
3050
3050_BK
CAV_1
CONN_X3
3050_BK
CAV_3
1550
1550_BK
CAV_G
1550_BK
1550_BK
1550_BK
CAV_1
Component Name
Ground
2450 BK
19
X1
Ground
3050 BK
1
X3
3050 BK
3
Ground
1550 BK
G
1550 BK
1550 BK
1550 BK
1

1550_BK
CAV_5
1550_BK
CAV_8
1550_BK
350
350_BK
CAV_1
350_BK
CAV_4
1550_BK
1550_BK
CAV 1
1550_BK
1550_BK
CAV_5
1550_BK
1550_BK
1550_BK
CAV_2
1550_BK
CAV_B
1550_BK
CAV_B
1550_BK
CAV_6
1550_BK
CAV 6
CAV_1
AXG
AXG
2050
2050_BK
CAV_1
AEC
X500
CAV_25
CAV_8
CAV_3
1550 BK
5
1550 BK
8
1550 BK
Ground
350 BK
1
350 BK
4
1550 BK
1550 BK
1
1550 BK
1550 BK
5
1550 BK
1550 BK
1550 BK
2
1550 BK
B
1550 BK
B
1550 BK
6
1550 BK
6
1
UP/DOWN
UP/DOWN
Ground
2050 BK
1
WINDOW-POWER OPERATED, DRIVER EXPRESS
DOWN
X500
25
8
3

CAV_2
X203
J502
J332
X210
X500
A23D
S52
S79D
A9A
S79D
M74D
A3L
A3R
A10
B20
E37M
E37F
B27D
B210D
F101
K36
2
X203
J502
J332
X210
X500
(D6I)
(D6I)
(DD8)

Fig. 48: G307 and G308

Callout
2150
2050
350
2450
2450_BK
CAV_4
1337
1337_GY/RD
CAV_6
2150_BK
CAV_B
2150_BK
CAV_A
CONN_X1
1650
1650_BK
CAV_3
Component Name
Ground
Ground
Ground
Ground
2450 BK
4
Yaw Rate Sensor Volt Reference
1337 GY/RD
6
2150 BK
B
2150 BK
A
X1
Ground
1650 BK
3

CONN_X6
2050_BK
CAV_G
2050_BK
CAV_3
2050_BK
CAV_1
350_BK
CAV_4
2050_BK
CAV_1
2050_BK
CAV 3
2050_BK
CAV_3
2050_BK
CAV_2
350_BK
CAV_2
CONN_X2
1050
1050_BK
CAV_6
2050_BK
2050_BK
2050_BK
2050_BK
2050 BK
2050_BK
350 BK
2450_BK
2150_BK
2150_BK
CAV_17
CF5
CF5
KA1
ATH
ATH
X6
2050 BK
G
2050 BK
3
2050 BK
1
350 BK
4
2050 BK
1
2050 BK
3
2050 BK
3
2050 BK
2
350 BK
2
X2
Ground
1050 BK
6
2050 BK
2050 BK
2050 BK
2050 BK
2050 BK
2050 BK
350 BK
2450 BK
2150 BK
2150 BK
17
DOORS

ATH
X310
CAV_19
CAV_20
X600
CAV_3
CAV_2
CAV_8
X211
CAV_2
CAV 1
G307
G308
X320
J333
J605
X310
X600
X211
B119
A9B
A23P
S79P
S88
S72
K61
K29
S64D
K9
K84
B210P
B27P
K85
DOORS
DOORS
X310
19
20
X600
3
2
8
X211
2
1
G307
G308
X320
J333
J605
X310
X600
X211
(FX3)
(CF5)
(CF5)
(CF5)
(KA1)
(ADS)
(ATH)

Fig. 49: G309

Callout
1650
1650 BK
2350_BK
BK
1650_BK
1650_BK
1650_BK
1650_BK
2550
2550_BK
CAV_1
2550_BK
2550_BK
2550_BK
2550_BK/WH
2550_BK
CAV_1
Component Name
Ground
1650 BK
2350 BK
BK
1650 BK
1650 BK
1650 BK
1650 BK
Ground
2550 BK
1
2550 BK
2550 BK
2550 BK
2550 BK/WH
2550 BK
1

650
650_BK
CAV_2
650_BK
CAV_5
2550_BK
CAV_7
2550_BK
CAV_3
2550_BK
2550_BK
CAV_3
2550 BK
CAV_B
CAV_B
2350
2350_BK
CAV_2
650_BK
CAV_B
2550_BK
CAV_7
CONN_X1
2550_BK
CAV_3
2550_BK/WH
2550_BK
CAV 3
2550_BK
2350 BK
CAV_5
2350_BK
2350_BK
2350_BK
CAV_3
2350_BK
CAV_8
2350_BK
CAV_8
2350_BK
2350_BK
2350 BK
Ground
650 BK
2
650 BK
5
2550 BK
7
2550 BK
3
2550 BK
2550 BK
3
2550 BK
B
B
Ground
2350 BK
2
650 BK
B
2550 BK
7
X1
2550 BK
3
2550 BK/WH
2550 BK
3
2550 BK
2350 BK
5
2350 BK
2350 BK
2350 BK
3
2350 BK
8
2350 BK
8
2350 BK
2350 BK

CAV_3
2350_BK
CAV_8
CAV_1
CAV_H
UVC
UVC
ATH
UD7
X900
CAV 9
CAV_8
CAV_7
X915
CAV_9
CAV_2
CAV_3
CAV_1
X410
CAV_D
CAV_H
G309
J904
J902
X920
X910
J903
J701
J496
X700
X402
X900
X915
X410
S58A
E5E
E5F
S79LR
2350 BK
3
2350 BK
8
1
H
DOORS
PARK ASSIST-REAR
X900
9
8
7
X915
9
2
3
1
X410
D
H
G309
J904
J902
X920
X910
J903
J701
J496
X700
X402
X900
X915
X410

A23LR
E8S
E6
E5AA
E4LR
E7L
E7R
K41R
M40
B87
T10E
B218R
B218L
(UD7)
(UVC)
(ATH)
Fig. 50: G400 and G402

Callout
2050
Component Name
Ground

1650
1650_BK
CAV_1
CONN_X2
2350
2350_BK
CAV_25
450
450_BK
CAV_8
2050_BK
CAV_3
2350 BK
CAV_5
2050_BK
2550
2550_BK/WH
CAV_3
2550_BK
2550_BK
CAV_3
2350_BK
2550_BK
UQA
CAV_1
X420
CAV_H
CAV_D
G402
G400
X800
J801
X420
A23RR
S79RR
E4RR
E5AB
T3
E18
K27
Ground
1650 BK
1
X2
Ground
2350 BK
25
Ground
450 BK
8
2050 BK
3
2350 BK
5
2050 BK
Ground
2550 BK/WH
3
2550 BK
2550 BK
3
2350 BK
2550 BK
SPEAKER SYSTEM-PREMIUM AUDIO
BRANDED WITH AMPLIFIER
1
X420
H
D
G402
G400
X800
J801
X420
(UQA)

2013 ELECTRICAL Wiring Systems And Power Management - Component Connector End Views - Index - Cruz
2013 ELECTRICAL
Wiring Systems And Power Management - Component Connector End Views - Index - Cruz

NOTE:
Component Connector end views are sorted in alpha/Numeric sequence based

upon connector ID (Code), NOT component name. If you do not know the
connector ID, a search using the relevant component may help locate the
desired connector link.

Description
A3L Sunshade - Left (D61)
A3R Sunshade - Right (D6I)
A7 Fuel Pump and Level Sensor Assembly
A9A Outside Rearview Mirror - Driver
A9B Outside Rearview Mirror - Passenger
A10 Inside Rearview Mirror
A11 Radio X1
A11 Radio X2 (UDN)
A11 Radio X3 (UEW)
A22 Radio Controls (UYC or UYE)
A22 Radio Controls (UEW)
A23D Door Latch Assembly - Driver
A23LR Door Latch Assembly - Left Rear
A23P Door Latch Assembly - Passenger
A23RR Door Latch Assembly - Right Rear
B1 A/C Refrigerant Pressure Sensor
B5LF Wheel Speed Sensor - Left Front
B5LR Wheel Speed Sensor - Left Rear
B5RF Wheel Speed Sensor - Right Front
B5RR Wheel Speed Sensor - Right Rear
B7D Air Temperature Sensor - Duct Left Lower (C68)
B7H Air Temperature Sensor - Duct Left Upper (C68)
B9 Ambient Air Temperature Sensor
B10B Ambient Light/Sunload Sensor
B16 Backup Lamp Switch (MF3 or MZ0)
B18 Battery Current Sensor
B19B Brake Booster Vacuum Sensor
B20 Brake Fluid Level Switch
B22 Brake Pedal Position Sensor (MF3 or MZ0)

B22 Brake Pedal Position Sensor (MH8)

B23E Camshaft Position Sensor - Exhaust (LUV)
B23E Camshaft Position Sensor - Exhaust (LUW/LWE)
B23F Camshaft Position Sensor - Intake (LUV)
B23F Camshaft Position Sensor - Intake (LUW/LWE)
B24 Cellular Phone Microphone (UE1)
B25B Clutch Pedal Position Sensor (MF3 or MZ0)
B26 Crankshaft Position Sensor (LUV)
B26 Crankshaft Position Sensor (LUW/LWE)
B34A Engine Coolant Temperature Sensor 1 (LUV)
B34B Engine Coolant Temperature Sensor 2
B37 Engine Oil Pressure Switch
B39 A/C Evaporator Temperature Sensor
B47 Fuel Pressure Sensor
B52A Heated Oxygen Sensor 1 (LUV)
B52A Heated Oxygen Sensor 1 (LUW/LWE)
B52B Heated Oxygen Sensor 2
B59L Front Impact Sensor - Left
B59R Front Impact Sensor - Right
B63LF Side Impact Sensor - Left Front
B63LR Side Impact Sensor - Left Rear
B63RF Side Impact Sensor - Right Front
B63RR Side Impact Sensor - Right Rear
B111B Turbocharger Boost/Intake Air Temperature (LUV)
B68 Knock Sensor (LUV)
B68 Knock Sensor (LUW/LWE)
B74 Manifold Absolute Pressure Sensor (LUV)
B74 Manifold Absolute Pressure Sensor (LUW/LWE)
B75C Multifunction Air Intake Sensor
B78E Rear Object Sensor - Left Middle (UD7)
B78F Rear Object Sensor - Right Middle (UD7)
B78G Rear Object Sensor - Left Outer (UD7)
B78H Rear Object Sensor - Right Outer (UD7)
B80 Park Brake Switch
B87 Rearview Camera (UVC)
B88D Seat Belt Switch - Driver
B88P Seat Belt Switch - Passenger
B99 Steering Wheel Angle Sensor (FX3)
B107 Accelerator Pedal Position Sensor
B108 Air Quality Sensor (C68)

B115 Vehicle Speed Sensor (MF3 or MZ0)

B119 Multi-Axis Acceleration Sensor (FX3)
B150 Fuel Tank Pressure Sensor
B160 Winshield Temperature and Inside Moisture Sensor (C68)
E2LF Side Marker Lamp - Left Front
E2RF Side Marker Lamp - Right Front
E4LR Turn Signal Lamp - Left Rear
E4RR Turn Signal Lamp - Right Rear
E4N Park/Turn Signal Lamp - Left
E4P Park/Turn Signal Lamp - Right
E5A Backup Lamp - Left
E5AA Tail/Stop Lamp - Left
E5AB Tail/Stop Lamp - Right
E5B Backup Lamp - Right
E6 Center High Mounted Stop Lamp
E7L License Plate Lamp - Left
E7R License Plate Lamp - Right
E8S Rear Compartment Courtesy Lamp
E13R Headlamp - Right
E14A Seat Heating Element - Driver Back (KA1)
E14B Seat Heating Element - Driver Cushion (KA1)
E14C Seat Heating Element - Passenger Back (KA1)
E14D Seat Heating Element - Passenger Cushion (KA1)
E27 Instrument Panel Compartment Lamp
E29LF Fog Lamp - Left Front (T3U)
E29RF Fog Lamp - Right Front (T3U)
E32 Cigarette Lighter Receptacle
E37F Dome/Reading Lamps - Front
E37M Dome/Reading Lamps - Middle
E41 Engine Coolant Thermostat Heater (LUV)
E41 Engine Coolant Thermostat Heater (LUW/LWE)
F105L Roof Rail Air Bag - Left
F105R Roof Rail Air Bag - Right
F106D Seat Air Bag - Driver

F106P Seat Air Bag - Passenger

F106RR Seat Air Bag - Right Rear
F107 Steering Wheel Air Bag X1
F107 Steering Wheel Air Bag X2 (Early Production)
F112D Seat Belt Retractor Pretensioner - Driver
F112P Seat Belt Retractor Pretensioner - Passenger
F113D Seat Belt Anchor Prestensioner - Driver
F113P Seat Belt Anchor Pretensioner - Passenger
F114D Knee Air Bag - Driver
F114P Knee Air Bag - Passenger
G10 Cooling Fan Motor
G13 Generator X2
G24 Windshield Washer Pump
K27 Fuel Pump Control Module
K35 Ignition Coil Module


K60 Steering Column Lock Control Module (ULS)
K61 Sunroof Control Module (CF5)
K77 Remote Control Door Lock Receiver
K89 Immobilizer Control Module
M6 Air Temperature Door Actuator
M8 Blower Motor
M37 Mode Door Actuator
M40 Rear Compartment Lid Latch
M46 Air Recirculation Door Actuator
M50D Seat Front Vertical Motor - Driver (ADS)
M51D Seat Horizontal Motor - Driver (ADS)
M55D Seat Rear Vertical Motor - Driver (ADS)
M74D Window Motor - Driver (AEC)
M74D Window Motor - Driver (AXG)
M74LR Window Motor - Left Rear
M74P Window Motor - Passenger
M74RR Window Motor - Right Rear
M75 Windshield Wiper Motor
M93 Ignition Cylinder Lock Control Solenoid Actuator (MH8)
M96 Active Grille Air Shutter Actuator (Y8X)
P2 Transmission Shift Lever Position Indicator (MH8)
P12 Horn
P14 Passenger Air Bag Disable Indicator
P17 Info Display Module (UAG)
P19AM S k
Ri h R
D


Q38 Throttle Body
S30 Headlamp Switch
A26 HVAC Controls
S39 Ignition Switch



2013 ELECTRICAL Wiring Systems and Power Management - Description and Operation - Cruze
2013 ELECTRICAL
Wiring Systems and Power Management - Description and Operation - Cruze

ELECTRONIC PARK LOCK DESCRIPTION AND OPERATION
Without ATH or BTM
If the vehicle is equipped with automatic transmission and a floor mounted console gear shift, it has an
electronic park lock system (EPL). The EPL system purpose is to prevent the ignition key from being turned to
the OFF position when the transmission is in any position other than PARK and the vehicle may still be
moving. The EPL system consists of an ignition lock cylinder solenoid, and a park position switch that is
located in the A/T shift lock control switch. The ignition lock cylinder solenoid contains a pin that is spring
loaded to mechanically prevent the ignition key cylinder from being turned to the lock position when the
vehicle transmission is not in the PARK position. If vehicle power is lost, and/or the transmission is not in the
Park position the operator will not be able to turn the ignition key to the lock position and will not be able to
remove the ignition key from the column.
With ATH or BTM
If the vehicle is equipped with automatic transmission and a floor mounted console gear shift, it has an
electronic park lock system. The electronic park lock system purpose is to prevent the ignition from being
switched to the OFF position when the transmission is in any position other than PARK and the vehicle may
still be moving. The electronic park lock system incorporates the park position switch that located in the A/T
shift lock control switch. When the transmission shift selector is in PARK, the park position switch closes and
the BCM allows the ignition to be turned OFF.
If the vehicle is not in PARK, the ignition will return to ACC/ACCESSORY and display the message SHIFT
TO PARK in the Driver Information Center. When the vehicle is shifted into PARK, the ignition system will
switch to OFF.
POWER MODE DESCRIPTION AND OPERATION
Serial Data Power Mode Master
Power to many of this vehicles circuits is controlled by the module that is designated the power mode master.
This vehicles power mode master is the body control module (BCM). The BCM has multiple B+ circuits that
feed into it. Each of those circuits are partitioned within the controller to drive certain outputs of the vehicle's
body functions. An open or short in any one of the B+ circuits may induce multiple codes/or a section of nonfunctionality within the BCM with the rest of the BCM functioning normally. In this case it is useful to refer to
the power distribution schematics to determine if the non-functional partition of the controller shares a common
B+ circuit. The ignition switch is a low current switch with multiple discrete ignition switch signals to the
power mode master for determination of the power mode that will be sent over the serial data circuits to the
other modules that need this information. The power mode master will also activate relays and other direct
outputs of the power mode master as needed. The power mode master determines which power mode (Off,
Accessory, Run, Crank Request) is required, and reports this information to other modules via serial data.

Modules which have switched voltage inputs may operate in a default mode if the power mode serial data
message does not match what the individual module can see from its own connections.
The power mode master receives ignition switch signals to identify the operators desired power mode. The
Power Mode Parameters table below illustrates the correct state of these input parameters (circuits) in
correspondence to the ignition switch position:
Power Mode Parameters
Ignition Switch
Position
Power Mode
Transmitted
Off Key Out

Off Key IN
Accessory
Run
Start
Off
Off
Accessory
Run
Crank Request
Ignition
Ignition
Ign. Off/Run/Crank
Accessory/Run
Run/Crank
(Off/Run Crank
(Accessory Voltage (Ignition 1 Voltage
Voltage Circuit)
Circuit)
Circuit)
Key Out / ACC
Inactive
Inactive
Key In / Off
Inactive
Inactive
Key Out / ACC
Active
Inactive
Run
Active
Active
Crank
Inactive
Active
Relay Controlled Power Mode
The BCM uses the discrete ignition switch inputs Off/Run/Crank Voltage, Accessory Voltage, and Ignition 1
Voltage, to distinguish the correct power mode. The BCM, after determining the desired power mode, will
activate the appropriate relays for that power mode.
The retained accessory power relay remains on for a timed period after the Ignition key is removed. Refer to
Retained Accessory Power Description and Operation for more information on the retained accessory power
function.
Push Button Start (If Equipped)
The ignition mode switch has 2 LEDs that indicate the vehicle power mode. When the vehicle is in the off
mode, both LED's will be off. Pressing the ignition mode switch button once (without the brake pedal applied),
the vehicle enters the accessory mode and the amber LED (ACC) will illuminate. The accessory mode has a 5
minute timeout to reduce battery drain. Pressing the ignition mode switch button a second time (without the
brake pedal applied), the vehicle enters the run/start mode (without the engine running) and the green LED
(Run/Start) will illuminate. With the ignition off (without the brake pedal applied) and pressing and holding the
push button start switch for up to 10 seconds will place the vehicle in run/start mode (without the vehicle
running) and the green LED (Run/Start) will illuminate. With the ignition off (with the brake pedal applied),
pressing the ignition mode switch button once, the vehicle will enter run/start mode and the green LED
(run/start) will illuminate. This will start the engine. Both LED's have the voltage supplied from the body
control module (BCM). The ignition mode switch sends the ignition mode switch status to the passive entry
passive start module (PEPS) and to the BCM. The PEPS module sends a redundant signal to the BCM with the
ignition mode switch status.
Battery Saver Mode (Transport Mode) (If Equipped)
The battery saver mode (transport mode) reduces the parasitic load of some modules during overseas shipment

or during vehicle storage conditions. This improves the drain time on the battery (up to 70 days without the
battery going dead). When the vehicle is in transport/storage, some features may have reduced functionality
while in the battery saver mode (transport mode), such as disabling the Remote Function Actuator or content
theft features.
The battery saver mode (transport mode) incorporates a latching relay that when enabled disconnects some
modules from their ignition power or memory power sources. Battery saver mode (transport mode) is initiated
by turning on the hazard flashers and then turning the ignition key into the crank position or pushing the push
button start switch (if equipped) for greater than 15 seconds. The mode is disengaged by repeating the previous
process causing the relay to latch in the other direction. After battery saver mode (transport mode) has been
enabled, the BCM may not send the command to unlatch the relay until after the ignition has been switched to
the off position for up to 1 minute. In battery saver mode (transport mode) the BCM will send a command to
latch the relay for operation of those modules while the ignition is in the run position and then again unlatching
the relay after the ignition is turned off. The DIC (if equipped) will display Transport Mode is On when the
transport mode is enabled and Transport Mode is Off when the transport mode is disabled. For vehicles not
equipped with a DIC, the battery indicator light will constantly flash on the Instrument Cluster when transport
mode is enabled. Once the vehicle is running and the hazard flashers are on, turning the ignition key into the
crank position or pushing the push button start switch (if equipped) for greater than 15 seconds will latch the
relay in the other direction. This feature can be used as many times as necessary if the vehicle is to be stored for
an extended period of time.
BCM Awake/Sleep States
The BCM is able to control or perform all of the BCM functions in the awake state. The BCM enters the sleep
state when active control or normal monitoring of system functions has stopped and a time limit has passed. The
BCM must detect certain wake-up inputs before entering the awake state. The BCM monitors for these inputs
during the sleep state.
The BCM will enter the awake state if any of the following wake-up inputs are detected:
Activity on the serial data line

Detection of a battery reconnect
Any door open signal
Headlamps ON
Key-in-ignition
Ignition ON
Park lamps ON
Keyless entry or remote start message
The BCM will enter a sleep state when all of the following conditions exist:
The ignition switch is OFF, key out.

No activity exists on the serial data line.
No outputs are commanded.
No delay timers are actively counting.

No wake-up inputs are present.
If all these conditions are met, the BCM will enter a low power or sleep condition.
RETAINED ACCESSORY POWER DESCRIPTION AND OPERATION
Retained Accessory Power
The body control module (BCM) monitors the ignition switch position, battery condition, and each door
ajar/open switch status to determine whether the retained accessory power should be initiated or terminated.
Retained accessory power is controlled by two different methods; relay control and serial data. Some modules
receive a retained accessory power message from the BCM over the serial data circuits. Serial data controlled
retained accessory power is deactivated as required by their modules retained accessory power mode operation.
Other subsystems are activated directly by the BCM through a relay. Components and systems that are active in
retained accessory power are also activated anytime the ignition is any position other than OFF regardless of the
door switch signals.
Relay Controlled Retained Accessory Power
The BCM keeps the relay energized during all power modes, except Off-Awake and Crank. The relay is also
energized for approximately 10 minutes after shutting the ignition OFF and removing the key, providing no
door is opened.
Relay controlled retained accessory power will end when one of the following conditions is met:
The BCM receives an input from any door ajar or open switch indicating the opening of any door after
the ignition key is out of the ignition.
NOTE:
If the BCM is receiving any door ajar or open signal from those switches
when the ignition key is turned OFF, retained accessory power will not
initiate.
The BCM internal timer for the retained accessory power expires after approximately 10 minutes.
The BCM detects a decrease in battery capacity below a prescribed limit.
Systems powered by the retained accessory power relay during the retained accessory power mode are as
follows:
NOTE:
The vehicle may not be equipped with all components as listed below.
Accessory Power Receptacle

Cigarette Lighter Receptacle
Window Switches

Sunroof Switch
Mobile Device Wireless Charger Module
Mobile Telephone Control Module
Traffic Data Receiver
Transmission Shift Lever Position Indicator (w/floor mounted console gear shift)
Seat Heating Control Module
Serial Data Controlled Retained Accessory Power
Retained accessory power systems controlled by serial data are as follows:

Radio
Radio retained accessory power activation / termination is the same as relay operation with one exception; the
only door switch that will turn off the radio during retained accessory power is the driver door open switch.
Vehicle Communication Interface Module (VCIM) (Onstar) (If Equipped)
VCIM RAP activation/termination is the same as radio operation with 1 exception; if there is an active call
when the ignition key is turned off the VCIM will remain in RAP mode, and keep the radio in RAP mode until
the call is terminated.


Wiring Systems and Power Management - Repair Instructions - Cruze
REPAIR INSTRUCTIONS
GMLAN AND MEDIA ORIENTED SYSTEMS TRANSPORT (MOST) WIRING REPAIRS
Special Tools
EL-38125-10 Splice Sleeve Crimping Tool

DuraSeal splice sleeves
A wire stripping tool

The DuraSeal splice sleeves have the following 2 critical features:
A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing
adhesive inside.
A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy
circuits.
The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive
nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors
and terminals.
GMLAN Repairs
NOTE:
When making a repair to any GMLAN network, the original wire length after the
repair must be the same length as before the repair. If the network is a twisted
pair, the twist must be maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works
at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more
information on GMLAN, refer to Data Link Communications Description and Operation .
GMLAN Connector Terminal Repair
NOTE:
A terminated lead can be used to replace damaged connector terminals for both
high speed and low speed GMLAN systems. When making a connector terminal
repair on a GMLAN high speed system with twisted pair wires, do not untwist
the wires more than necessary to make the repair.
If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair
procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair

procedure.
GMLAN Wire Repair
NOTE:
Refer to Wiring Repairs in the service information connector end views or the
vehicle schematics in order to determine the correct wire size for the circuit you
are repairing. You must obtain this information in order to ensure circuit
integrity.
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge
size (0.5 mm2 , 0.8 mm2 , 1.0 mm2 etc.). Use the DuraSeal splice sleeves and EL-38125-10 tool. For wiring
repair, refer to Splicing Copper Wire Using Splice Sleeves .
INSTRUMENT PANEL WIRING HARNESS FUSE BLOCK DISASSEMBLE
NOTE:
To remove wires from the top part using terminal release tools, only steps 1, 3,
8, 9, 10, 11, 12 and 13 are required. Use release tool J-38125-38 for cavities 1618, 20-34, 37-47.
Fuse Block Disassemble Procedure

Fig. 1: Fuse Block & Locking Arms

1. Push the locking arms (1) and unlock the fuse block (2).

Fig. 2: Fuse Block In Unlocked Position

2. Fuse block unlocked.

Fig. 3: Fuse Block & Bracket

3. Pull out and remove the fuse block from bracket.

Fig. 4: Fuse Block & Brackets

4. Fuse block after removed from bracket.

Fig. 5: Fuse Block & Relay Protection Cover

5. Push and open the relay protection cover.

Fig. 6: Fuse Block Micro Relays

6. Remove micro relays (3x).

Fig. 7: Micro Relays

7. Fuse block with relays removed.

Fig. 8: Fuse Block Components

8. Remove mini fuses (22x), J-case fuses (2x), and circuit breakers (2x) from fuse block.

Fig. 9: View Of Fuse Block Components

9. Fuse block with all fuses and circuit breakers removed.

Fig. 10: Fuse Block Cover

10. Unlock (6 locking points) and remove bottom protection cover from fuse block.

Fig. 11: Fuse Block Wires & Straps

11. Remove straps (4x) from wires.

Fig. 12: Fuse Block Locking Arm Components

12. To place the top part (1) in pre-assembled position, press together locking arms on both sides of the
bottom part (2), insert a pry tool into an appropriate hole in the top part and lever the top part upward
until it remains in the pre-assembled position. Release the locking arms.

Fig. 13: Fuse Block Tabs

13. When the top part is in the pre-assembled position (required to release wire terminals), the tabs of the top
part are on top of the tabs of the bottom part (left close-up view).
When the top part is in the end-locking position (required after wires are inserted), the tabs of the bottom
part are on top of the tabs of the top part (right close-up view).

Fig. 14: Fuse Block Relays

14. Unlock and remove relay socket from fuse block.

Fig. 15: Fuse Block Relay Socket & Locking Caps

15. Unlock (6 locking points) and remove locking caps (3x) from relay socket.

Fig. 16: Relay Socket & Locking Caps

16. Relay socket with locking caps removed.
RELAY REPLACEMENT (ATTACHED TO WIRE HARNESS)
Removal Procedure


1. Locate the relay. Refer to the Master Electrical Component List to locate the relay in the vehicle.
2. Remove any 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 fasteners or tape.
4. Separate the relay (1) from the wire harness connector (2).


1. Connect the relay (1) to the wire harness connector (2).
2. Install any connector position assurance (CPA) devices or secondary locks.
3. Install the relay using any fasteners or tape that originally held the relay in place.
RELAY REPLACEMENT (WITHIN AN ELECTRICAL CENTER)
Special Tools
EL-43244 Relay Puller Pliers

Removal Procedure
1. Remove the electrical center cover.

NOTE:
Always note the orientation of the relay.

If equipped with a notch style relay; observe the location of the notch
on the old relay to verify the new relay is installed with the notch in
the same location.
Ensure that the electrical center is secure, as not to put added stress
on the wires or terminals.
2. Locate the relay. Refer to Electrical Center Identification Views to locate the electrical center where the
relay exists.


3. Using the EL-43244 (1) position the tool on opposing corners of the relay (2).

CAUTION: Use EL-43244 to pull the relay straight out from the electrical center
terminals. The use of pliers or a flat bladed tool could damage the
electrical center.
4. Remove the relay (2) from the electrical center.


1. Install the relay (2) in the same position as removed.
2. Install the electrical center cover.

GROUND REPAIR
Electrical Grounds
Proper electrical system function relies on secure, positive, corrosion-free ground connections. Loose, stripped,
or corroded connections increase the possibility of improper system function and loss of module
communication. These conditions may also lead to unnecessary repairs and component replacements.
In general, electrical ground connections are accomplished using one, or a combination of, three attachment
methods:
Welded M6 stud and nut

Determine which attachment method is used, and carry out the appropriate repair.
M6 Weld Stud Replacement
1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance
behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 rivet stud flange.
to dry.
NOTE:

drilled.

visible.
5. Select a replacement conductive M6 rivet stud. Refer to GM parts catalog for the correct part number and
application.
NOTE:

Repair .
rivet stud threads.
15. Install the ground terminal to the new rivet stud.
16. Select a new, conductive M6 nut. Refer to GM parts catalog for the correct part number and application.
17. Install the M6 nut and tighten to 8 N.m (71 lb in).

M6 Weld Nut
1. If the M6 weld nut at the electrical ground location is damaged or stripped, a new, conductive selfthreading M7 bolt may be used to secure the ground terminal. Refer to GM parts catalog for the correct
part number and application.
the weld nut and allow to dry.
3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush.
conductive, self-threading M7 bolt threads.
6. Install the electrical ground terminal to the new, conductive M7 bolt.

7. Install the M7 bolt and tighten to 9 N.m (80 lb in).

1. If the electrical ground location is accessible from both sides of the panel, a conductive M6 bolt and a
conductive M6 nut may be used to secure the electrical ground terminal. Refer to GM parts catalog for
the correct part number and application.
2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79) clearance behind the panel
surface and 20 mm (0.79) clearance surrounding the new electrical ground site.
NOTE:

drilled.

visible.

NOTE:

grounding.
Repair .
M8 Weld Nut


1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a conductive M8
bolt and a conductive M8 nut may be used to secure the ground terminal. Refer to GM parts catalog for
the correct part numbers and application.
2. Select a location adjacent to M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and
20 mm (0.79 in) clearance surrounding the new electrical ground site.
NOTE:

drilled.

visible.
9. Install the conductive M8 nut and tighten to 22 N.m (16 lb ft).

NOTE:

grounding.
Repair .
1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a conductive
M6 rivet stud and a conductive M6 nut may be used to secure the ground terminal. Refer to GM parts
catalog for the correct part numbers and application.

2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel
surface and 20 mm (0.79 in) clearance surrounding the new, conductive M6 rivet stud flange.
to dry.
NOTE:

drilled.

visible.
NOTE:
Repair .
rivet stud threads.
15. Install the ground terminal to the new, conductive M6 rivet stud.
FUSE BLOCK REPLACEMENT
Removal Procedure



NOTE:
4.
5.
6.
7.
Open the battery fuse box cover (1).

Remove the positive battery cable to starter nut (2).
Remove the positive battery cable to starter (3) from the battery.
Remove the positive battery cable. Refer to Battery Positive Cable Replacement .

Fig. 23: Identifying Fuse Block, Body Wiring Harness And Nuts
8. Remove 2 body wiring harness nuts (1) and body wiring harness.
9. Remove fuse block (2).
1. Install fuse block.

2. Install body wiring harness and 2 body wiring harness nuts and tighten to 4.7 N.m (42 lb in).
3. Install the positive battery cable. Refer to Battery Positive Cable Replacement .

4. Install the positive battery cable to starter (3).
5. Install the positive battery cable to starter nut (2) and tighten to 9 N.m (80 lb in).


FRONT COMPARTMENT FUSE BLOCK REPLACEMENT
Removal Procedure
2. Remove the front compartment fuse block cover. Refer to Front Compartment Fuse Block Cover
Replacement.

Fig. 26: View Of Front Compartment Fuse Block, Wiring Harness Supply And Fuse Block Bolt
NOTE:
Bolts (1) are encapsulated on the end of threads so that they can not be
removed from the fuse block. The fuse block must be pulled out to expose
the positive cable lug.
3. Remove the 3 front compartment fuse block bolts (1).

4. Unlock retaining tabs and remove the front compartment fuse block (3).
5. Remove the front compartment fuse block wiring harness supply (2).

Fig. 27: Wiring Harness Supply, Front Compartment Fuse Block And Electrical Connectors
1. Install front compartment fuse block wiring harness supply (1) and tighten to 12 N.m (106 lb in).
2. Push down the 3 electrical connectors (3) before installation of the front compartment fuse block (2).

Fig. 28: Identifying Front Compartment Fuse Block Bolt

3. Install 3 front compartment fuse block bolts (1) and tighten to 6 N.m (53 lb in).
4. Install the front compartment fuse block cover. Refer to Front Compartment Fuse Block Cover
Replacement.
FRONT COMPARTMENT FUSE BLOCK HOUSING REPLACEMENT

Fig. 29: Identifying Front Compartment Fuse Block Housing And Nut
Front Compartment Fuse Block Housing Replacement
Callout
Component Name
Connection .
Container Filler Tube Replacement .
3. Remove front compartment fuse block. Refer to Front Compartment Fuse Block Replacement.
Front Compartment Fuse Block Housing Nut
CAUTION:
Tighten
22 N.m(16 lb ft)
Front Compartment Fuse Block Housing

Procedure

1. Remove 3 electrical connectors from front compartment fuse block

housing.
2. Remove attaching parts and unclip wiring harnesses from front
compartment fuse block housing.
FRONT COMPARTMENT FUSE BLOCK COVER REPLACEMENT
Fig. 30: Identifying Front Compartment Fuse Block Cover

Front Compartment Fuse Block Cover Replacement
Callout
Component Name
Front Compartment Fuse Block Cover
Procedure
1
Squeeze 3 tabs to release cover.
IGNITION LOCK CYLINDER REPLACEMENT
Removal Procedure
Connection .
Replacement .


3. Insert the key into the ignition lock cylinder and turn the key to the RUN position.

Fig. 32: Access Hole

4. Depress the retainer through the lock housing access hole (1) with a small Allen wrench or similar picktype tool.
5. Remove the ignition lock cylinder from the lock housing.
1. If you are installing a new ignition lock cylinder, code the lock cylinder. Refer to Key and Lock
Cylinder Coding .


2. Turn the key to the RUN position and insert ignition lock cylinder into the lock housing.
3. Turn the key to the LOCK position and remove the key from the ignition lock cylinder.
4. Install the steering column lower trim cover. Refer to Steering Column Lower Trim Cover
Replacement .
IGNITION AND START SWITCH REPLACEMENT

Fig. 34: Ignition Switch And Bolts

Ignition and Start Switch Replacement
Callout
Component Name
Connection .
Replacement
Ignition and Start Switch Bolt (Qty: 2)
CAUTION:
Procedure
Reposition the steering column wiring harness retainers in order to
gain access to the switch bolts.
Ignition and Start Switch
ENGINE STOP/START MODE CONTROL SWITCH REPLACEMENT

Fig. 35: Engine Stop/Start Mode Control Switch

Engine Stop/Start Mode Control Switch Replacement
Callout
Component Name
Remove the instrument panel lower trim pad cover. Refer to Instrument Panel Lower Trim Pad Cover
Knee Airbag) .
Engine Stop/Start Mode Control Switch
Procedure
1
Unlock the retaining tabs.
IGNITION AND START SWITCH HOUSING REPLACEMENT

Fig. 36: Ignition And Start Switch Housing

Ignition and Start Switch Housing Replacement
Callout
Component Name
1. Remove the ignition lock cylinder. Refer to Ignition Lock Cylinder Replacement
2. Remove the turn signal switch bracket. Refer to Turn Signal Switch Bracket Replacement
Ignition Lock Cylinder Bolt
CAUTION:
1
Procedure
1. Use a suitable chisel to remove bolt.
2. Install NEW bolt and tighten until head tears off.
Ignition and Start Switch Housing
2
Procedure
2. Remove ignition and start switch. Refer to Ignition and Start

Switch Replacement.

2013 ELECTRICAL Wiring Systems and Power Management - Cruze
2013 ELECTRICAL
Wiring Systems and Power Management - Cruze

DTC
DTC B097B
DTC B097C
DTC B1370 (Instrument Cluster)
DTC B1370-B1379, B1380-B1389, or B1440B1443
DTC B1448
DTC B144B
DTC B1451
DTC B147E or B147F
DTC P2537
Description
DTC B097B Power Mode Start Switch Circuit
DTC B097C Power Mode Run/Start Indicator
Circuit
DTC B1370 Control Module Ignition On and Start
Circuit
DTC B1370 Control Module Ignition ON and Start
Circuit
DTC B1380 Control Module Ignition Accessory
Circuit
DTC B1441 Control Module Ignition OFF, Run,
and Start Circuit
DTC B1448 01 Accessory Power Relay Circuit
Short to Battery
Short to Ground
Open
DTC B144B 01 Run/Crank Power Relay Circuit
Short to Battery
Short to Ground
Open
DTC B1451 Accessory Power Circuit
DTC B147E 01 Battery Saver Relay Set Secondary
Circuit Short to Battery
Circuit Open
DTC B147F 01 Battery Saver Relay Reset
Secondary Circuit Short to Battery
Secondary Circuit Short to Ground
Secondary Circuit Open
DTC P2537 Ignition Accessory Switch Circuit Low
Voltage

2013 ENGINE Engine Cooling - Cruze
2013 ENGINE
Engine Cooling - Cruze
SPECIFICATIONS
TEMPERATURE VERSUS RESISTANCE
Temperature Versus Resistance
C
Temperature vs Resistance Values (Approximate)
100
90
80
70
60
50
45
40
35
30
25
20
15
10
5
0
-5
-10
-15
-20
-30
-40
Sensor Resistance
212
194
176
158
140
122
113
104
95
86
77
68
59
50
41
32
23
14
5
-4
-22
-40
155
208
283
392
552
793
958
1165
1425
1755
2176
2717
3428
4356
5578
7198
9362
12278
16229
21653
39631
75532
FASTENER TIGHTENING SPECIFICATIONS (1.4L LUV)

Fastener Tightening Specifications (1.4L LUV)
Specification
Application
Air Conditioning Compressor And Condenser Hose Bolt
Air Conditioning Compressor And Condenser Hose Nut
Air Conditioning Evaporator Hose Nut
Metric
9 N.m
19 N.m
19 N.m
English
80 lb in
14 lb ft
14 lb ft

Engine Coolant Thermostat Housing Bolt

Engine Oil Cooler Bolt
Engine Oil Cooler Inlet Pipe Bolt
Engine Oil Cooler Outlet Pipe Bolt
Ground Cable Nut - Coolant Fan Wiring Harness
Oil Pressure Indicator Switch
Radiator Lower Bracket Bolt
Radiator Upper Bracket Bolt
Turbocharger Coolant Return Pipe Bolt
Water Outlet Bolt
Water Pump Bolt
Water Pump Pulley Bolt
8 N.m
20 N.m
10 N.m
10 N.m
10 N.m
20 N.m
22 N.m
22 N.m
10 N.m
8 N.m
8 N.m
22 N.m
71 lb in
15 lb ft
89 lb in
89 lb in
89 lb in
15 lb ft
16 lb ft
16 lb ft
89 lb in
71 lb in
71 lb in
16 lb ft
FASTENER TIGHTENING SPECIFICATIONS (1.8L LUW AND LWE)

Fastener Tightening Specifications (1.8L LUW and LWE)
Specification
Application
Metric
English
Engine Coolant Fan Motor Bolt
4 N.m
36 lb in
Engine Coolant Fan Resistor Bolt
4 N.m
36 lb in
Engine Coolant Thermostat Bolt
8 N.m
71 lb in
Engine Coolant Thermostat Bypass Pipe Bolt
8 N.m
71 lb in
Engine Coolant Thermostat Housing Bolt
8 N.m
71 lb in
Engine Coolant Thermostat Housing Retainer Nut
9 N.m
80 lb in
Engine Oil Cooler Bolt
8 N.m
71 lb in
Engine Oil Cooler Housing Bolt
25 N.m
19 lb ft
Engine Oil Cooler Pipe Bolt
8 N.m
71 lb in
Hood Hold Open Rod Retainer Bracket Bolt
22 N.m
17 lb ft
Radiator Bracket Bolt
25 N.m
18 lb ft
Radiator Support Bracket Bolt
22 N.m
17 lb ft
Water Pump Housing Bolt
8 N.m
71 lb in
20 N.m (1)
15 lb ft (1)
(1) Recut threads before re-use and insert bolts with screw locking compound. The installation time,
including torque inspection, is a maximum of 10 minutes.
ENGINE COOLING SYSTEM SPECIFICATIONS (1.4L LUV)
Engine Cooling System Specifications (1.4L LUV)
Specification
Application
Metric
English
Cooling System
Water Pump Design
Rotary Pump

Cooling Filling Quantity

Thermostat (Grid Controlled)
6.2 L
6.6 quart
Thermostat Opening 0V
103C
217F
Thermostat Opening 12V
80C
176F
ENGINE COOLING SYSTEM SPECIFICATIONS (1.8L LUW AND LWE)

Engine Cooling System Specifications (1.8L LUW and LWE)
Specification
Application
Metric
Cooling System
Water Pump Design
Flow (engine outlet 6000 min -1 , Thermostat fully
open)
Coolant filling quantity
Thermostat
Thermostat Opening- Electrical
Thermostat Opening- Thermic
Rotary Pump
165 l/min
43.588 US gal
5.9L
5.917 quart
90C
105C
194F
221F

ENGINE HEATING/COOLING WIRING SCHEMATICS
Engine Cooling Wiring Schematics
English

Fig. 1: Engine Cooling Wiring Schematics

Callout
CAV_86
CAV 87
CAV_30
CAV_85
CAV_86
CAV_87
CAV_30
CAV_85
CAV_30
CAV_85
CAV_86
CAV_87
CAV_30
CAV_85
CAV_86
CAV_87
CAV_86
Component Name
86
87
30
85
86
87
30
85
30
85
86
87
30
85
86
87
86

CAV_30
CAV_87
CAV_85
7625
7625_GN
CAV_67
CAV_68
CONN_X1
999_RD/WH
CAV_66
CAV_20
CONN_X1
MH8
MH9
MF3
MZ0
473
473_BN/YE
CAV 15
CONN_X3
473_BN/YE
CAV_54
CONN_X1
CAV_46
5358
5358_YE
CAV_4
CAV_50
CONN_X1
532
532_GY
CAV_3
CAV_46
2366
2366_WH/BK
CAV_43
CAV_34
409
409_WH/BU
30
87
85
Cooling Fan Motor Supply Voltage (4)
7625 GN
67
68
X1
999 RD/WH
66
20
X1
1ST, 2.158 2ND, 1.302 3RD, 0.959 4TH, 0.744 5TH, 0.614
6TH, M32-6 WR
1ST, 0.74 6TH, (M32 WR)
High Speed Cooling Fan Relay Control
473 BN/YE
15
X3
473 BN/YE
54
X1
46
5358 YE
4
50
X1
532 GY
3
46
Cooling Fan Control Relay Speed Signal
2366 WH/BK
43
34
409 WH/BU

CAV_2
CAV_47
5358_YE
532_GY
409_WH/BU
1150
1150_BK
CAV_71
335
335_GN/VT
CAV_41
CONN_X1
CAV 49
CONN_X3
1250
1250_BK
CAV_1
X102
CAV_1
CAV_2
CAV_3
G101
G105
F45UA
F45UA
F42UA
F46UA
X102
KR20E
KR20F
K20
X50A
G10
KR20C
KR20P
KR75
K20
KR20D
2
47
5358 YE
532 GY
409 WH/BU
Ground
1150 BK
71
Low Speed Cooling Fan Relay Control
335 GN/VT
41
X1
49
X3
Ground
1250 BK
1
X102
1
2
3
G101
G105
F45UA 60A
F45UA 40A
F42UA 30A
F46UA 10A
X102


DTC
DTC P00B3 or P00B4
DTC P00B6
DTC P00B7
DTC P0480, P0481, P0691, P0692, P0693, or

P0694
DTC P0597-P0599
DTC P2181
Description
DTC P00B3 Radiator Coolant Temperature (RCT)
Sensor Circuit Low Voltage
DTC P00B4 Radiator Coolant Temperature (RCT)
Sensor Circuit High Voltage
DTC P00B6 Radiator Coolant Temperature (RCT)Engine Coolant Temperature (ECT) Not Plausible
DTC P00B7 Engine Coolant Flow Insufficient
DTC P0481 Cooling Fan Relays 2 and 3 Control
Circuit
Low Voltage
High Voltage
Circuit Low Voltage
DTC P0597 Engine Coolant Thermostat Heater
Control Circuit
Control Circuit Low Voltage
Control Circuit High Voltage
DTC P2181 Engine Cooling System Performance
DTC P00B3 OR P00B4

DTC Descriptors
DTC P00B3
Radiator Coolant Temperature (RCT) Sensor Circuit Low Voltage
DTC P00B4

Radiator Coolant Temperature (RCT) Sensor Circuit High Voltage

Short to
Open/High
Short to
Ground
Resistance
Voltage
Signal
P00B3
P00B4
P00B4*
Low Reference
P00B4
* Internal ECM or sensor damage may occur if the circuit is shorted to B+.
Circuit
Signal Performance
P00B6
P00B6
Radiator Coolant Temperature Sensor

Circuit
Short to Ground
Open
Parameter Normal Range: Varies with ambient temperature
Signal
140C (284F)
-40C (-40F)
Low Reference
-40C (-40F)
Short to Voltage
-40C (-40F)*
-
NOTE:
The radiator coolant temperature sensor is referred to as B34B Engine Coolant

Temperature Sensor 2 in schematics and other areas.
The radiator coolant temperature (RCT) sensor is a variable resistor that measures the temperature of the engine
coolant in the radiator. This diagnostic checks for an open, short to ground or an intermittent circuit condition
between the engine control module (ECM) and RCT sensor.
The following table illustrates the difference between temperature, resistance, and voltage:
RCT
Cold
Warm
RCT Resistance
High
Low
P00B3
The engine run time is greater than 10 s.

The intake air temperature (IAT) is colder than 70C (158F).
P00B4
RCT Signal Voltage

High
Low

The engine run time is greater than 60 s.

The intake air temperature (IAT) is warmer than -7C (19F).
P00B3
The ECM detects that the RCT sensor is warmer than 149C (300F) for greater than 10 s.
P00B4
NOTE:
The scan tool only displays to -40C (-40F).
The ECM detects that the RCT sensor is colder than -60C (-76F) for greater than 10 s.
DTC P00B3 and P00B4 are Type B DTCs.

Conditions for Clearing the MIL/DTC
DTC P00B3 and P00B4 are Type B DTCs.

Diagnostic Aids
NOTE:
The engine coolant temperature (ECT) sensor is mounted on the engine and the
radiator coolant temperature (RCT) sensor is mounted on the radiator.
As the thermostat opens, the RCT sensor temperature should rise steadily, then stabilize once the
thermostat opens completely.
Test the RCT sensor at various temperature levels in order to evaluate the possibility of a skewed sensor.
If the vehicle has sat for greater than 8 hours, the ECT sensor and the RCT sensor values should display
within 3C (5F).
Schematic Reference

Circuit Testing
Connector Repairs
Wiring Repairs
DTC Type Reference

Scan Tool Reference
1. Ignition ON.
2. Verify the scan tool Radiator Coolant Temperature Sensor parameter is between -39 to + 120C (-38 to
+248F) and changes with engine run time.
If not between -39 to + 120C (-38 to +248F) or does not change
If between -39 to + 120C (-38 to +248F) and changes
3. Operate the vehicle within the Conditions for Running the DTC. You may also operate the vehicle within
the conditions that you observed from the Freeze Frame/Failure Records data.
If the DTC sets

5. All OK.
1. Ignition OFF and all vehicle systems OFF, disconnect the harness connector at the B34B Engine Coolant
Temperature Sensor. It may take up to 2 min for all vehicle systems to power down.

If less than 5 ohms

Ignition ON.
Verify the scan tool Radiator Coolant Temperature Sensor parameter is colder than -39C (-38F).
If warmer than -39C (-38F)
If colder than -39C (-38F)
terminal 1.
Verify the scan tool Radiator Coolant Temperature sensor parameter is warmer than 137C (280F).
If colder than 137C (280F)
1. Ignition OFF, remove the jumper wire, disconnect the harness connector at the K20 Engine Control
Module.
If less than 1 V
3. Ignition OFF.
If warmer than 137C (280F)
Test or replace the B34B Engine Coolant Temperature Sensor.
3.
4.
5.
6.
7.
Component Testing
1. Ignition OFF, disconnect the harness connector at the B34B Engine Coolant Temperature Sensor.
2. Test the RCT sensor by varying the sensor temperature while monitoring the sensor resistance. Compare
the readings with the Temperature Versus Resistance table. The resistance values should be in range of
the table values.
Replace the B34B Engine Coolant Temperature Sensor.
3. Test for infinite resistance between each terminal and the sensor housing.
Replace the B34B Engine Coolant Temperature Sensor.

4. All OK.
Repair Instructions
Engine Coolant Temperature Sensor Replacement (Radiator) , Engine Coolant Temperature

Sensor Replacement (Water Outlet) for radiator coolant temperature sensor replacement.
Engine Control Module Replacement for engine control module replacement, setup, and programming.
DTC P00B6
DTC Descriptor
DTC P00B6
Radiator Coolant Temperature (RCT)-Engine Coolant Temperature (ECT) Not Plausible
Short to
Open/High
Short to
Ground
Resistance
Voltage
Circuit
Coolant Temperature
P00B3
P00B4
P00B4*
Sensor Signal
Low Reference
P00B4
Signal Performance
P00B6
P00B6

Circuit
Short to Ground
Open
Operating Conditions: Engine Running in Closed Loop
Coolant Temperature Sensor Signal
140C (284F)
-40C (-40F)
Low Reference
-40C (-40F)
Circuit Description
Short to Voltage
-40C (-40F)*
-40C (-40F)*

The engine coolant temperature sensor is a variable resistor that measures the temperature of the engine coolant
in the radiator. The engine control module (ECM) supplies 5 volts to the engine coolant temperature signal
circuit and supplies a ground to the low reference circuit. The purpose of this diagnostic is to determine if the
input from the RCT sensor is skewed warmer than normal. The internal clock of the ECM will record the
amount of time the engine is OFF. If the required engine OFF time is met at start-up, the ECM will compare the
temperature difference between the actual measured RCT and ECT sensors.
The following table illustrates the difference between temperature, resistance, and voltage:
RCT
Cold
Warm
RCT Resistance
High
Low
RCT Signal Voltage

High
Low
DTCs P00B3, P00B4, P00B6, P0112, P0113, P0117, P0118, P0502, P0503 or P2610 are not set.
The vehicle has been OFF for greater than 8 hours before vehicle ON.
The vehicle is ON, or the engine is running.
The intake air temperature (IAT) is warmer than -7C (19F).
The fuel level is greater than 10 percent.
The DTC runs once per ignition cycle when the above conditions are met.
The ECM determines the absolute difference of temperature between the RCT start up temperature and ECT
start up temperature is greater than 20C (68F).
DTC P00B6 is a Type B DTC.


Diagnostic Aids
As the thermostat opens, the radiator coolant temperature sensor signal should rise steadily, then stabilize
once the thermostat opens completely.
Inspect for the correct operation of the engine cooling system and verify the correct coolant level.
Schematic Reference


Circuit Testing
Connector Repairs
Wiring Repairs
DTC Type Reference

Scan Tool Reference
1. Engine running, observe the DTC information with a scan tool. DTC P00B3, P00B4, P0117, P0118,
P0597, P0598, or P0599 should not be set.
If a DTC is set, refer to Diagnostic Trouble Code (DTC) List - Vehicle for further diagnosis.
2. Verify the coolant in the radiator surge tank is at the correct level and there are no engine coolant leaks.
Refer to Cooling System Draining and Filling (Static Fill), Cooling System Draining and Filling
(GE-47716 Fill), and Loss of Coolant.
3. Engine idling for 15 minutes with the A/C OFF.
NOTE:
Depending on ambient temperature, it may take up to 4 minutes for the

temperatures to equalize.
4. Command the engine coolant thermostat heater to 100 percent with a scan tool. Increase the engine speed
to 3, 000 RPM. Observe the scan tool radiator coolant temperature sensor and ECT sensor parameters.
The radiator coolant temperature sensor and the ECT sensor parameters should be within 20C (68F).
5. Operate the vehicle within the conditions for running the DTC to verify the DTC does not reset. You may
also operate the vehicle within the conditions that you observed from the freeze frame/failure records
data.
1. Vehicle OFF, disconnect the harness connector at the B34B engine coolant temperature sensor.
2. Vehicle OFF, all systems OFF. This may take up to 2 minutes for all vehicle systems to power down. Test
for less than 5 ohms between the low reference circuit terminal 1 and ground.
If greater than the specified range, test the low reference circuit for an open/high resistance. If the

circuit tests normal, replace the K20 engine control module.

3. Vehicle ON, verify the scan tool Radiator Coolant Temperature Sensor parameter is at -40C (-40F).
If warmer than the specified range, test the signal circuit terminal 2 for a short to ground. If the
circuit tests normal, replace the K20 engine control module.
NOTE:
If the fuse in the jumper wire opens, the signal circuit is shorted to a
voltage and the sensor may be damaged.
terminal 1. Verify the scan tool Radiator Coolant Temperature Sensor parameter is at 140C (284F).
If less than specified range, test the signal circuit for a short to voltage or an open/high resistance. If
the circuit tests normal, replace the K20 engine control module.
5. If all circuits test normal, test or replace the B34B engine coolant temperature sensor.
Component Testing
1. Vehicle OFF, remove the B34B engine coolant temperature sensor.

NOTE:
A thermometer can be used to the used to test the sensor off the vehicle.
2. Test the engine coolant temperature sensor by varying the sensor temperature while monitoring the sensor
resistance. Compare the readings with the Temperature Versus Resistance table and verify that the
resistance is within 5 percent of the specification.
If not within the specified range, replace the B34B engine coolant temperature sensor.
Repair Instructions

Sensor Replacement (Water Outlet)
Engine Control Module Replacement for ECM replacement, setup, and programming
DTC P00B7
DTC Descriptors
DTC P00B7

Engine Coolant Flow Insufficient

Short to
Open/High
Short to
Circuit
Ground
Resistance
Voltage
Coolant Temperature
P00B3
P00B4
P00B4*
Sensor Signal
Low Reference
P00B4
P00B4*
Signal Performance
P00B6
P00B6

Circuit
Short to Ground
Open
Operating Conditions: Engine Running in Closed Loop
140C (284F)
-40C (-40F)
Signal
Low Reference
-40C (-40F)
Short to Voltage
-40C (-40F)*
-40C (-40F)*
Circuit Description
The engine control module (ECM) monitors the temperature of the engine radiator coolant. The ECM controls
the thermostat with a pulse width modulated (PWM) signal. The ECM compares the radiator coolant
temperature to the engine coolant temperature in order to determine if there sufficient coolant flow through the
thermostat.
DTCs P00B3, P00B4, P00B6, P0116, P0117, and P0118 are not set.
The engine run time is greater than 5 m.
OR
The engine coolant temperature is greater than 105C (221F).

NOTE:
The scan tool display range is between -40 and + 150C (-40 and +302F).
The ECM detects the difference between the RCT sensor and the ECT sensor is greater than 30C (86F) when
the ECT sensor is warmer than 117C (242F) for greater than 5 s.



Diagnostic Aids
The thermostat has a mechanical fail-safe in case of an electrical condition with the thermostat heater.
The mechanical thermostat will open at approximately 80C (176F). The mechanical thermostat will
cycle from approximately 85C (185F) to approximately 102C (215F).
A resistance condition in the RCT sensor circuits may cause this DTC. This condition results in a greater
voltage on the RCT sensor signal circuit, which is interpreted by the ECM as a colder RCT.
Schematic Reference
Circuit Testing
Connector Repairs
Wiring Repairs
DTC Type Reference

Scan Tool Reference
1. Engine Running, observe the DTC information with a scan tool. DTC P00B3, P00B4, P00B6, P0117,
P0118, P0597, P0598, and P0599 should not be set.
3. Verify the engine cooling fan operates. Refer to Cooling Fan Inoperative.

4. Engine idling for 15 minutes with the A/C OFF.

NOTE:
Depending on ambient temperature, it may take up to 4 minutes for the

temperature to decrease less than the specified value.
5. Command the Engine Coolant Thermostat Heater to 100 percent with a scan tool. Increase the engine
speed to 3, 000 RPM. Observe the scan tool ECT sensor parameter. The temperature should decrease to
less than 85C (185F).
6. Operate the vehicle within the conditions for running the DTC. You may also operate the vehicle within
the conditions that you observed from the freeze frame/failure records data.
1. Vehicle OFF, inspect the cooling system for the conditions below. Refer to Symptoms - Engine Cooling.
Weak coolant solution
Obstructed radiator air flow or bent radiator fins
Blocked cooling system passages
Radiator hoses that are restricted, collapsed, or deteriorated
Damaged water pump and or belt
Loss of cooling system pressure
Leaking surge tank cap
Radiator hoses
Cylinder head or an engine block that is cracked or plugged
If you find any of the above conditions, repair as necessary.
2. If all conditions test normal, replace the E41 engine coolant thermostat heater.
Repair Instructions
Engine Coolant Thermostat Replacement
DTC P0480, P0481, P0691, P0692, P0693, OR P0694
DTC Descriptors
DTC P0480

Cooling Fan Relay 1 Control Circuit

DTC P0481
Cooling Fan Relays 2 and 3 Control Circuit
DTC P0691
Cooling Fan Relay 1 Control Circuit Low Voltage
DTC P0692
Cooling Fan Relay 1 Control Circuit High Voltage
DTC P0693
Cooling Fan Relays 2 and 3 Control Circuit Low Voltage
DTC P0694
Cooling Fan Relays 2 and 3 Control Circuit High Voltage
KR20C Cooling Fan Low Speed Relay

Short to
Circuit
Ground
Relay Coil Ignition
P0480, P0691
Relay Switch B+
1
Relay Coil Control
3
Relay Controlled Output
1
1.
2.
3.
4.
Open/High
Resistance
2
2
2
2
Short to
Voltage
4
3
Signal Performance
-
Low and medium speed fan inoperative without a DTC.

Low speed fan inoperative without a DTC.
Low speed fan always ON without a DTC.
Low and high speed fan inoperative without a DTC.
KR20D Cooling Fan High Speed Relay

Short to
Ground
Circuit
Relay Coil Ignition
P0480, P0691
Relay Switch B+
2
P0481 or
Relay Control
P0693
2
Open/High
Resistance
2
2
P0481
2
Short to
Voltage
1
P0481 or
P0694
3
Signal Performance
-

1. Medium speed fan replaced by high speed fan without a DTC.

2. High speed fan inoperative without a DTC.
3. High speed fan always ON without a DTC.
KR20E Cooling Fan Speed Control Relay
Short to
Circuit
Ground
Relay Coil Ignition
P0480, P0691
Relay Switch Ignition
P0480, P0691
Relay Coil Control
2
1
1.
2.
3.
4.
Open/High
Resistance
1
1
1
1
Short to
Voltage
3
4
Signal Performance
-
High speed fan inoperative without a DTC.

Low speed fan always ON without a DTC.
Low and high speed fan inoperative without a DTC.
Medium speed fan inoperative without a DTC.
KR20F Cooling Fan Relay

Circuit
Relay Coil Ignition
Relay Switch Ignition
Relay Control
Short to
Ground
P0480, P0691
1
P0480 or
P0691
-
Open/High
Resistance
P0480
2
P0480
2
Short to
Voltage
P0480 or
P0692
-
Signal Performance
-
1. Low speed fan always ON without a DTC.

2. Low speed fan and high speed fan inoperative.
KR20P Cooling Fan Medium Speed Relay
Short to
Circuit
Ground
Relay Coil Ignition
Relay Switch B+
1
P0481 or
Relay Control
P0693
1
Open/High
Resistance
P0481
2
P0481
2
1. Low and medium speed fan inoperative without a DTC.

2. Medium speed fan inoperative without a DTC.
3. Medium speed fan always ON without a DTC.
Short to
Voltage
P0481 or
P0694
3
Signal Performance
-

The engine cooling fan system is composed of one cooling fan, a series of 5 relays, the engine control module
(ECM), and the associated wiring. The cooling fan assembly includes two resistors. This combination of
components enables the ECM to operate the cooling fan at 3 speeds using two fan control circuits.
The ignition voltage is greater 11 volts.

The ECM has commanded the output driver ON and OFF at least once during the ignition cycle.
The DTCs run continuously when the conditions above are met.
The commanded state of the ECM driver and the actual state of the control circuit do not match for greater than
5 seconds.
DTCs P0480 P0481, P0691, P0692, P0693, and P0694 are Type B DTCs.
DTCs P0480 P0481, P0691, P0692, P0693, and P0694 are Type B DTCs.
Diagnostic Aids
The ECM has the capability of providing command to the fan relays even when a scan tool output control
is being used. Always refer to the scan tool Cooling Fan Relay Command parameters to know which fans
are being commanded ON by the ECM.
The scan tool cooling fan output control operates as follows:
Cooling Fan Relay 1 operates the fan at a low speed
Cooling Fan Relay 2 and 3 operates the fan at a medium speed
Cooling Fan Relay 1, 2 and 3 operates the fan at a high speed
When disconnecting or removing fuses and relays from a fuse block, always inspect the component
electrical terminals for corrosion and the correct orientation in the fuse block. Test the mating electrical
terminals for tightness.
Schematic Reference
Engine Heating/Cooling Schematics

Electrical Center Identification Views


Cooling Fan Description and Operation
Circuit Testing
Connector Repairs
Wiring Repairs
DTC Type Reference

Scan Tool Reference
1. Ignition ON.
2. Verify an audible click is heard or felt from each cooling fan relay when commanding the cooling fan ON
If a click is not heard or felt at each of the relays
If a click is heard or felt at each of the relays
3. Operate the vehicle within the Conditions for Running the DTC to verify the DTC does not reset. You
may also operate the vehicle within the conditions that you observed from the Freeze Frame/Failure
Records data.
If the DTC sets

5. All OK.
1. Ignition OFF, disconnect the KR20 cooling fan relays listed below:

NOTE:
The following test must be performed on each of the relay coil ignition
circuits.
2. Ignition ON, verify that a test lamp illuminates between ground and the relay coil ignition circuit terminal
listed below:
KR20F Cooling Fan Relay terminal 85
KR20P Cooling Fan Medium Speed Relay terminal 1
If the test lamp does not illuminate and the fuse is good
1. Ignition OFF, and all vehicle systems OFF, it may take up to 2 minutes for all vehicle systems to
power down.
2. Test for less than 2 ohms in the ignition circuit of the appropriate KR20 Cooling Fan Relay, end to
end.
power down.
2. Test for infinite resistance between the relay coil ignition circuits listed below and ground:
KR20D Cooling Fan High Speed Relay terminal 1
If infinite resistance, test all of the appropriate KR20 Cooling Fan Relays for a short and
replace as necessary.
3. Ignition OFF, remove the test lamp, ignition ON.
NOTE:
The following tests must be performed on all three fan relay control
circuits.
4. Connect a DMM, set on the diode setting, between a control circuit terminal listed below and ground:
5. Verify the DMM reading is greater than 2.5 V or displays O.L.
If 2.5 V or less
power down. Disconnect the X1 harness connector at the K20 Engine Control Module.
2. Test for infinite resistance between the appropriate relay coil control circuit and ground.

If greater than 2.5 V or displays O.L.
NOTE:
The following test must be performed on all three fan relay circuits.
6. Verify the DMM reading is less than 1 V when commanding the Cooling Fan Relays ON with a scan tool.
If 1 V or greater
1. Ignition OFF, disconnect the X1 harness connector at the K20 Engine Control Module, ignition
ON.
2. Test for less than 1 V between the appropriate KR20 Cooling Fan Relay control circuit and ground.
If less than 1 V.
3. Ignition OFF.
4. Test for less than 2 ohms in the appropriate KR20 Cooling Fan Relay control circuit end to end.
If less than 1 V
7. Test or replace the appropriate KR20 Cooling Fan Relay.
Component Testing
1. Ignition OFF.
2. Disconnect a KR20 Cooling Fan Relay.
3. Test for 70-110 ohms between terminals 85/2 and 86/1. 95-135 ohms for the KR20F Cooling Fan Relay.
If less than or greater than the specified range
Replace the KR20 Cooling Fan Relay.
4. Test for infinite resistance between the following terminals:
30/3 and 86/1
30/3 and 87/5
30/3 and 85/2
85/2 and 87/5

5. Install a 20 A fused jumper wire between relay terminal 85/2 and 12 V.

6. Install a jumper wire between relay terminal 86/1 and ground.

7. Test for less than 2 ohms between terminals 30/3 and 87/5.
If less than 2 ohms
8. All OK.
Repair Instructions
Control Module References for ECM replacement, setup, and programming
DTC P0597-P0599
DTC Descriptor
DTC P0597
Engine Coolant Thermostat Heater Control Circuit
DTC P0598
Engine Coolant Thermostat Heater Control Circuit Low Voltage
DTC P0599
Engine Coolant Thermostat Heater Control Circuit High Voltage
Circuit
Voltage
Short to
Ground
Open/High
Resistance
Short to
Voltage
Signal Performance
P0031, P0037,
P0135, P0141,
P0443, P0597,
P0031, P0037,
P0135, P0141,
P0443, P0597,

P0598*,
P0598, P0660,
P0660, P0661
P0661
Thermostat Control Circuit P0458, P0598
P0597
P0599
*Opens the fuse that supplies voltage to the engine coolant thermostat
The engine control module (ECM) controls the pulse width modulated (PWM) thermostat. The thermostat
controls coolant flow and regulates the engine operating temperature. Ignition voltage is supplied directly to the
thermostat through a fuse. The ECM controls the thermostat by grounding the control circuit with a solid state
device called a driver. The driver is equipped with a feedback circuit that is pulled-up to a voltage. The ECM
can determine if the control circuit is open, shorted to ground, or shorted to a voltage by monitoring the
feedback voltage.
The ignition is ON, or the engine is running.

The DTCs run continuously once the above condition is met
The ECM detects that the commanded state of the driver and the actual state of the control circuit do not match
for greater than 15 seconds.
DTCs P0597, P0598, and P0599 are Type B DTCs.

The engine control module commands the engine cooling fans ON.

Diagnostic Aids
A low engine coolant level could cause the thermostat heater to overheat and set a DTC.
The thermostat has a mechanical fail-safe in case of an electrical condition with the thermostat heater.
The mechanical thermostat will open at approximately 80C (176F). The mechanical thermostat will
cycle from approximately 85C (185F) to approximately 102C (215F).
Schematic Reference


Circuit Testing
Connector Repairs
Wiring Repairs
DTC Type Reference

Scan Tool Reference
Loss of Coolant, and Cooling System Draining and Filling (Static Fill), Cooling System Draining
and Filling (GE-47716 Fill)
If the coolant level is not correct
Repair as necessary.
If the coolant level is correct
2. Ignition ON.
3. Verify the parameters listed below do not display Malfunction when commanding the Engine Coolant
Thermostat Heater ON and OFF with a scan tool.
Engine Coolant Thermostat Heater Control Circuit Low Voltage Test Status
Engine Coolant Thermostat Heater Control Circuit Open Test Status
Engine Coolant Thermostat Heater Control Circuit High Voltage Test Status
If Malfunction is displayed

If Malfunction is not displayed
If any DTC sets


6. All OK.
1. Ignition OFF, disconnect the harness connector at the E41 Engine Coolant Thermostat Heater, Ignition
ON.
2. Verify that a test lamp illuminates between the ignition circuit terminal 2 and ground.
1. Ignition OFF, remove the test lamp.
If less than 2 ohms verify the fuse is not open and there is voltage at the fuse.
If infinite resistance, test all the components connected to fuse and replace as necessary.
3. Verify that a test lamp does not illuminate between the ignition circuit terminal 2 and the control circuit
terminal 1.
4. Remove the test lamp, command the E41 Engine Coolant Thermostat Heater ON with a scan tool.
5. Verify the scan tool E41 Engine Coolant Thermostat Heater Control Circuit High Voltage Test Status
parameter displays OK.
If OK is not displayed
If less than 1 V, replace the K20 Engine Control Module.
If OK is displayed
6. Install a 3 A fused jumper wire between the control circuit terminal 1 and the ignition circuit terminal 2.
7. Verify the scan tool Engine Coolant Thermostat Heater Circuit High Voltage Test Status parameter is
displaying Malfunction when commanding the E41 Engine Coolant Thermostat Heater ON with a scan
tool.


Module.
If less than 2 ohms replace the K20 Engine Control Module.
8. Test or replace the E41 Engine Coolant Thermostat Heater.
Repair Instructions
Engine Coolant Thermostat Replacement for E41 engine coolant thermostat heater replacement.
Control Module References for engine control module, replacement, programming, and setup.
DTC P2181
DTC Descriptor
DTC P2181
Engine Cooling System Performance
The engine control module (ECM) monitors temperature difference between the engine coolant temperature
(ECT) sensor and the radiator coolant temperature (RCT) sensor during a cold start-up. The purpose of this
diagnostic is to analyze the engine coolant thermostat for being stuck open.
DTCs P00B3, P00B4, P00B6, P0101, P0102, P0103, P0111, P0112, P0113, P0114, P0116, P0117, or
P0118 are not set.
The engine run time is between 70 s and 30 min.
The engine coolant temperature (ECT) sensor at start-up is between -10C to +59C (14F to 138F).
The intake air temperature (IAT) sensor is between -7C to +60C (-4F to +140F).
The airflow into the engine is between 1 to 100 g/s.

The DTC runs once per ignition cycle when the above conditions are met.
The ECM detects the engine coolant thermostat is stuck open for at least 2.5 min.
DTC P2181 is a Type B DTC

DTC P2181 is a Type B DTC

Diagnostic Aids
Insufficient vehicle interior heating is an indication of improper thermostat operation.

The scan tool Desired ECT Sensor and the ECT Sensor parameters should be within 5C (9F) when the
engine is at operating temperature.
A resistance condition in the ECT sensor circuits may cause this DTC. This condition results in a greater
voltage on the ECT sensor signal circuit, which is interpreted by the ECM as a colder ECT.
Schematic Reference
Cooling System Description and Operation (1.4L LUV), Cooling System Description and Operation (1.8L
LUW and LWE)
Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference


1. Engine running, observe the DTC information with a scan tool. DTC P00B3, P00B4, P00B6, P0117, or
P0118 should not be set.
NOTE:
Depending on ambient temperature, it may take up to 4 min for the

temperature to increase greater than the specified value.
3. Engine idling for 15 min with the A/C OFF. Verify the engine cooling fan is not ON at all times.
4. Command the Engine Coolant Thermostat Heater to 0 % with a scan tool. Increase the engine speed to 3,
000 RPM. Observe the scan tool ECT sensor parameter. The temperature should increase to greater than
102C (215F).
If less than the specified value, replace the E41 engine coolant thermostat heater.
data.
Repair Instructions
Engine Coolant Thermostat Replacement
SYMPTOMS - ENGINE COOLING
Important Preliminary Inspections Before Starting
Before using the Symptom diagnosis, perform the following:
Perform Diagnostic System Check - Vehicle and verify all of the following items:
Engine control module (ECM) and malfunction indicator lamp (MIL) are operating correctly.
There are no diagnostic trouble codes (DTCs) stored.
Scan tool data is within a normal operating range.
Verify the customer concern.
Perform the Visual/Physical Inspection in this section. The visual/physical inspection is extremely
important, and can lead to correcting a condition without additional testing. It may also help reveal the
cause of an intermittent condition.
Locate the correct symptom. Perform the tests and inspections associated with the symptom.

Review the entire cooling system operation in order to familiarize yourself with the system functions. Refer to
Cooling Fan Description and Operation, and Cooling System Description and Operation (1.4L LUV),
Cooling System Description and Operation (1.8L LUW and LWE).
CAUTION: Use the connector test adapter kit EL-35616-F for any test that requires
probing the following items:
The control module harness connectors

The electrical center fuse/relay cavities
The component terminals
The component harness connector
Using this kit will prevent damage caused by the improper probing of
connector terminals.
Several of the symptom procedures call for a careful visual and physical inspection. This can lead to correcting
a condition without further tests and can save time. This inspection should include the following:
Ensure that the control module grounds are clean, tight, and correctly located.
Inspect cooling system hoses and pipes for splits, kinks, and improper connections. Inspect thoroughly for
any type of leak or restriction.
Inspect for a dirty or restricted radiator or HVAC condenser.
Inspect for aftermarket devices which could affect the operation of the cooling system.
cause the symptom.
Inspect the surge tank reservoir for proper coolant level.
Identifying Intermittent Conditions
Many intermittent conditions occur with harness or connector movement due to engine torque, rough pavement,
vibration or physical movement of a component. Refer to the following for a list to help isolate an intermittent
condition:
Water intrusion in connectors, terminals, or components

Poor connector mating
Terminal contact
High circuit or component resistance-High resistance can include any resistance, regardless of the
amount, which can interrupt the operation of the component.
Harness' that are routed too tight, or chaffed circuits
High or low ambient temperatures
High or low engine coolant temperatures

High underhood temperatures

Heat build up in components or circuits due to circuit resistance, poor terminal contact, or high electrical
load
High or low system voltage
High vehicle load conditions
Rough road surface
Electro-magnetic interference (EMI)/circuit interference from relays, solenoids or other electrical surge
Incorrect installation of non-factory, aftermarket, or after factory add on accessories
If an intermittent is detected, refer to Testing for Intermittent Conditions and Poor Connections for specific
strategies in diagnosing intermittent conditions.
Symptom List
Cooling Fan Always On

Cooling Fan Inoperative
Engine Overheating
Loss of Coolant
Thermostat Diagnosis (1.8L LUW and LWE), Thermostat Diagnosis (1.4L LUV)
Engine Fails To Reach Normal Operating Temperature
COOLING FAN ALWAYS ON

Diagnostic Procedure Instructions provides an overview of the diagnostic category.
Diagnostic Aids


Certain resistance conditions with IAT or ECT sensors may cause unwarranted cooling fan activation. If
the ECM is commanding the cooling fans ON for no apparent reason and without any component or
system DTCs set, the IAT or ECT sensor may be skewed. If this condition is suspected, refer to the
Temperature Versus Resistance tables in the appropriate engine controls subsection.
If the cooling fan operates at high speed when the ECM is requesting medium speed operation, test or
replace the KR20E Cooling Fan Speed Control Relay.
Schematic Reference


Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference

1. Ignition ON.
2. Verify that there are no cooling system DTCs set.
If any DTCs are set
If no DTCs are set
3. Verify the scan tool parameters listed below display OFF.
Cooling Fan Relay 1 Command
Cooling Fan Relays 2 and 3 Command

If a scan tool parameter displays ON

Refer to Diagnostic Aids and Symptoms - Engine Cooling for further diagnosis.
If both scan tool parameters display OFF

4. Verify that the fan is not activated.
If the fan is operating

If the fan is OFF
5. All OK.
NOTE:
The following tests must be performed on each cooling fan relay.
1. Ignition OFF, disconnect each KR20 cooling fan relay one at a time, in the order listed below, ignition
ON:
2. Verify that the cooling fan is not activated after each relay is removed.
If the cooling fan is ON with all of the listed relays removed
1. Ignition OFF, disconnect the harness connector at the G10 Cooling Fan Motor, ignition ON.
2. Test for less than 1 V between ground and the relay controlled output circuit terminal listed below:
KR20C Cooling Fan Low Speed Relay terminal 87
If 1 V or greater, repair the short to voltage in the appropriate circuit.
If the cooling fan is OFF after a listed relay is removed
3. Replace the appropriate KR20 Cooling Fan Relay.
Component Testing
1. Ignition OFF.


30/3 and 86/1
30/3 and 87/5
30/3 and 85/2
85/2 and 87/5


If less than 2 ohms
8. All OK.
Repair Instructions
COOLING FAN INOPERATIVE
Diagnostic Aids


When disconnecting or removing fuses and relays from a fuse block, always inspect the component
electrical terminals for corrosion and the correct orientation in the fuse block. Test the mating electrical
terminals for tightness.
Schematic Reference


Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference

1. Ignition ON.
2. Verify that DTC P0480, P0481, P0691, P0692, P0693, or P0694 is not set.
If a DTC is set
Refer to DTC P0480, P0481, P0691, P0692, P0693, or P0694.
If no DTC is set
3. Verify that the cooling fan operates at low, medium, and high speed, when commanding the appropriate
cooling fan relays ON and OFF with a scan tool.

If the cooling fan does not operate at all speeds

If the cooling fan operates at all speeds

4. All OK.
Inoperative in All Speeds

1. Ignition OFF, disconnect the harness connector at the G10 Cooling Fan Motor.
2. Verify a test lamp illuminates between the ground circuit terminal 1 and B+
3. Test or replace the G10 Cooling Fan Motor. Replace the cooling fan fuses if necessary.
Low, Medium or High Speed Inoperative
1. Disconnect the following cooling fan relays, ignition ON:
KR20E Cooling Fan Speed Control Relay
2. Verify a test lamp illuminates between ground and each of the cooling fan relay B+ circuit terminals
listed below:
2. Test for less than 2 ohms in the appropriate relay B+ circuit, end to end.
1. Ignition OFF, disconnect the harness connector at the G10 Cooling Fan Motor.

3.
4.
5.
6.
7.
2. Test for infinite resistance between the appropriate relay controlled output circuit terminal listed
below and ground:
If infinite resistance, test or replace the G10 Cooling Fan Motor, replace the fuse as
necessary.
Verify a test lamp illuminates between the KR20F Cooling Fan Relay output circuit terminal 87 and B+.
2. Test for less than 2 ohms in the ground circuit, end to end.
Ignition OFF, Install the KR20F Cooling Fan Relay, ignition ON.
Verify a test lamp illuminates between ground and each of the cooling fan relay terminals listed below:
KR20E Cooling Fan Speed Control Relay terminal 86 and 30
If the test lamp does not illuminate at each terminal
2. Test for less than 2 ohms in the appropriate relay ignition circuit, end to end.
If the test lamp illuminates at each terminal
Command the cooling fan ON at low speed with a scan tool.
Verify a test lamp illuminates between B+ and each of the KR20 Cooling Fan Relay terminals listed
below:
KR20E Cooling Fan Speed Control Relay terminal 85
1. Ignition OFF, remove the test lamp and disconnect the KR20F Cooling Fan Relay.
2. Test for less than 2 ohms between the KR20F Cooling Fan Relay terminal 30 and the relay control
circuit terminals listed below:
KR20E Cooling Fan Speed Control Relay terminal 85

If less than 2 ohms, replace the KR20F Cooling Fan Relay.

Ignition OFF, install the KR20E Cooling Fan Speed Control Relay, Ignition ON.
Command the cooling fan ON at low speed with a scan tool.
Verify a test lamp illuminates between ground and the KR20D High Speed Relay ignition circuit terminal
1.
1. Ignition OFF, remove the test lamp and disconnect the KR20E Cooling Fan Speed Control Relay.
2. Test for less than 2 ohms between the KR20D High Speed Relay terminal 1 and KR20E Cooling
Fan Speed Control Relay 87
If less than 2 ohms, replace the KR20E Cooling Fan Speed Control Relay.
Ignition OFF, install all of the previously removed KR20 Cooling Fan Relays. Disconnect the harness
connector at the G10 Cooling Fan Motor, ignition ON.
Command the cooling fan ON at high speed with a scan tool.
Verify a test lamp illuminates between ground and each of the G10 Cooling Fan Motor circuit terminals
listed below:
G10 Cooling Fan low speed circuit terminal 2
G10 Cooling Fan medium speed circuit terminal 3
G10 Cooling Fan high speed circuit terminal 4
If the test lamp does not illuminate at each terminal
2. Disconnect the appropriate relay from the list below:
3. Test for less than 2 ohms in the relay controlled output circuit, end to end.
If less than 2 ohms, test or replace the relay.
If the test lamp illuminate at each terminal
Test or replace the G10 Cooling Fan Motor.
8.
9.
10.
11.
12.
13.
14.
Component Testing
1. Ignition OFF.


30/3 and 86/1
30/3 and 87/5
30/3 and 85/2
85/2 and 87/5


If less than 2 ohms
8. All OK.
Repair Instructions
Engine Coolant Fan Replacement
ENGINE OVERHEATING
Engine Overheating
Step
Action
Yes
No
DEFINITION: Either of the following conditions indicate a probable engine overheat condition.
The engine temperature gauge is in the red (overheat) zone and/or the engine temperature indicator
is ON.
Hot engine coolant overflows from the coolant recovery reservoir and/or radiator cap onto the
ground while the engine is running.
1. Inspect and fill the cooling system, as
necessary. Refer to Cooling System
Draining and Filling (Static Fill), Cooling

System Draining and Filling (GE-47716

Fill).
2. Inspect the cooling system for leaks, as
necessary.
3. Repair the cooling system leaks, as
necessary.
Has the inspection/repair been performed?
1. Start the engine and allow the engine to run

at approximately 1, 200 RPM.
2. Use the Scan Tool in order to verify the
overheat condition.
Does the Scan Tool verify the engine overheat
condition?
Go to Diagnostic System
Go to Step 3 Check - Vehicle
1. Verify that the cooling fans are operating

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

cooling fins for debris or any other
obstruction.
Inspect the drive belt system and the drive
belt tensioner for proper operation in order
to ensure that the coolant pump is rotating
properly.
Inspect for loose, damaged and/or missing
air deflector(s).
Check for a pinched or kinked cooling
system hose.
Repair the systems as necessary.

Inspect the thermostat for proper operation. Refer
to Thermostat Diagnosis (1.8L LUW and
LWE), Thermostat Diagnosis (1.4L LUV).
Is the thermostat operating properly?
Go to Step 7 Go to Step 6
Replace the thermostat. Refer to Engine Coolant
Thermostat Replacement.

NOTE:
Excessive coolant freeze point protection MAY
cause the coolant to boil at low temperatures.
1. Inspect for the proper coolant concentration

(mixture). Correct the coolant concentration
as necessary.
2. Remove the radiator cap.
3. Start the engine and inspect for a constant
flow of air bubbles in the engine coolant.
Is there a constant flow of air bubbles in the
engine coolant?
The probable cause of the engine overheat is
combustion chamber gasses leaking into the
cooling system. This condition is usually caused
by the following:
Go to Step 8 Go to Step 9
A worn or damaged cylinder head gasket

A worn or damaged cylinder head
A worn and/or damaged engine block
Verify this condition by inspecting the spark plug

electrodes and porcelain surrounding the spark
plug electrode for signs of coolant. Replace
and/or repair the engine internal component(s), as
necessary, in order to repair the engine internal
coolant leak.
The engine overheat may be caused by a cooling
system blockage. Flush the cooling system. Refer
to Coolant System Flushing
NOTE:
It is unlikely that the water pump is the cause
of the overheat condition.
10
If NONE of the cooling system passages are

restricted, replace the coolant pump. Refer to
Water Pump Replacement (1.8L LUW and
LWE), Water Pump Replacement (1.4L LUV)
LOSS OF COOLANT

Loss of Coolant
Step
Action
Yes
No
DEFINITION: The cooling system is losing coolant either internally or externally.
Special Tools
BO-42220 Universal 12V Leak Detection Lamp
Are you sent here from Symptoms?
Go to Symptoms 1
Go to Step 2 Engine Cooling
Repair any present DTCs. Refer to Diagnostic
2
System Check - Vehicle .
Go to Step 3
Is the action complete?
Inspect the coolant level.
3
Is the coolant at the proper level?
Go to Step 5
Go to Step 4
Fill the cooling system to the proper level. Refer
to Cooling System Draining and Filling (Static
4
Fill), Cooling System Draining and Filling
(GE-47716 Fill).
Go to Step 5
If the engine is suspected to have a coolant leak
into a cylinder, the coolant can hydraulically lock
5
the engine.
Does the engine crankshaft rotate?
Go to Step 6
Go to Step 25
Engine overheating can cause a loss of coolant.
6
Is the engine overheating?
Go to Step 28
Go to Step 7
Extended operation with a low coolant level can
7
cause engine internal component failure.
Is the engine knocking?
Go to Step 30
Go to Step 8
10
1. Idle the engine at normal operating

temperature.
2. Inspect for heavy white smoke coming out
of the exhaust pipe.
Is a heavy white smoke present from the exhaust
pipe?
Coolant in the exhaust system creates a
distinctive, burning coolant odor in the exhaust.
Condensation in the exhaust system can cause an
odorless white smoke during engine warm up.
Does the white smoke have a burning coolant
type odor?
WARNING:
Refer to Moving Parts and Hot Surfaces
Warning .
With the engine idling, inspect the coolant
Go to Step 9
Go to Step 10
Go to Step 29
Go to Step 10

recovery system.Does the coolant recovery

system discharge coolant while the engine is
idling?
Visually inspect the hoses, pipes and hose clamps
at the following locations:
11
12
14
Go to Step 12
Go to Step 21
Go to Step 13
Go to Step 21
Go to Step 14
Go to Step 15
Go to Step 22
Go to Step 23
Go to Step 16
1. Pressure test the cooling system. Refer to

Cooling System Leak Testing.
2. With the cooling system pressurized,
visually inspect the components listed in
steps 11 and 12.
Are any leaks present?
Pressure test the coolant pressure cap.
Does the coolant pressure cap hold pressure?
Inspect for the following conditions:
15
Go to Step 21
The coolant pressure cap

The core plugs
The cylinder head gaskets
The engine block
The intake manifold
The radiator
The thermostat housing
The water pump
Are any of the listed components leaking?
13
Go to Step 11
The coolant surge tank

The heater core
The radiator
Are any of the hoses, clamps or pipes leaking?

Visually inspect the following components:
Go to Step 15
A coolant smell inside of the vehicle

Coolant in the HVAC module drain tube
Coolant on the vehicle floor covering near
the HVAC module
Is coolant present?

16
1. Add 30 ml (1 oz) of Extended Life Coolant

Leak Detection Dye to the cooling system
for each 15 L (4 gal) of coolant. Refer to
Approximate Fluid Capacities .
2. Start the vehicle and allow the engine to
reach normal operating temperature.
3. Shut the engine off.
4. Use BO 42220 detection lamp to visually
inspect the components listed in steps 11
and 12.
Are any leaks present?
Use BO 42220 detection lamp to inspect for the
17
18
19
20
21
22
23
Go to Step 21
Go to Step 17
Go to Step 23
Go to Step 18
Go to Step 19
Go to Step 20
Go to Step 29
Go to Step 20
Go to Step 24
Go to Step 32
Coolant dye in the HVAC module drain

tube
Coolant dye on the vehicle floor covering
near the HVAC module
Is coolant dye present?

Inspect the underside of the engine oil fill cap for
a gray/white milky substance.
Is a milky substance under the oil fill cap?
Inspect the engine oil fluid level indicator for a
gray/white milky substance.
Is a milky substance on the engine oil fluid level
indicator?
Inspect the automatic transmission oil fluid level
indicator, if equipped, for a gray/white milky
substance.
Is there a milky substance on the automatic
transmission fluid level indicator?
Repair or replace the leaking component. Refer to
the appropriate repair.
Is the repair complete?
Replace the coolant pressure cap.
Replace the heater core. Refer to Heater Core
Replacement .
1. Remove the transmission oil cooler lines
from the radiator.
Go to Step 32
Go to Step 32
Go to Step 32

24
2. Pressure test the cooling system. Refer to

Cooling System Leak Testing.
3. Inspect the transmission oil cooler for
coolant.
Go to Step 25
Is coolant present?
25
26
27
28
29
30
31
32
Go to Step 26
1. Replace the radiator. Refer to Radiator

Replacement (1.4L LUV with Automatic
Transmission), Radiator Replacement
(1.8L LUW and LWE), Radiator
Replacement (1.4L LUV with Manual
Transmission).
2. Service the automatic transmission.
Install the cooler lines to the radiator.
Repair the engine no crank condition.
Repair the engine overheating condition.
Repair the engine internal coolant leak.
Repair the engine knock.
Repair the combustion pressure in the cooling
system problem.
Operate the system in order to verify the repair.
Did you find and correct the condition?
Go to Step 32
-
Go to Step 32
Go to Step 32
Go to Step 32
Go to Step 32
Go to Step 32
Go to Step 32
System OK
Go to Step 2
THERMOSTAT DIAGNOSIS (1.4L LUV)

Thermostat Diagnosis (1.4L LUV)
Step
Action
1. Pressure test the cooling system and the

cap for leaks.
2. Repair any leaks before proceeding.
These engines use a 105C (221F)
thermostat. The ambient temperatures
should be within the specified range
given.
3. Set the HVAC controls in the OFF
position.
Values
13-38C (55-
Yes
No

4. Run the cold engine at idle 20C-21C

(68-70F) for 15-20 minutes before
checking the engine temperature.
5. Check the engine coolant temperature
at idle with the scan tool.
4
5
Is the engine coolant temperature (ECT)

between 105-120C (221-248F)?
Is the ECT below 105C (221F)?
The thermostat is opening early, or the
thermostat seal is leaking.
Replace the thermostat and the thermostat
seal.
Is the ECT over 120C (248F)?
Is the radiator inlet hot?
1. Turn ON the heater.
2. Check if hot air is coming from the
heater outlets.
100F)
System OK
-
The cylinder head

The radiator
The radiator hoses
Is there a blockage?
1. Repair the blockage.
2. Recheck the coolant temperature with
Go to Step 6
Go to Step
7
Go to Step 11
Go to Step
12
Go to Step 6
Go to Step
8
Go to Step 9
Go to Step
10
Is the inlet hose hot?

Inspect for blockage in the following areas:
System OK
Go to Step 5
Is the air hot?

There may be air in the system.
1. Add coolant to the surge tank if the
coolant level is low. Refer to Cooling
System Draining and Filling (Static
Fill), Cooling System Draining and
Filling (GE-47716 Fill).
2. Recheck the radiator inlet hose.
Go to Step 3
Go to Step
2
Go to Step
4

the scan tool.

9
10
11
12
13
1. Replace the thermostat housing. Refer

to Engine Coolant Thermostat
Housing Replacement (1.4L LUV),
Engine Coolant Thermostat Housing
Replacement (1.8L LUW and LWE).
the scan tool.
Inspect for blockage in the radiator.
Is there any blockage?
1. Accelerate the engine several times in
order to remove any air from the
system.
2. Inspect for blockage in the heater
circuit.
3. Inspect for any pinched or buckled
hoses.
System OK
System OK
Go to Step 9
Go to Step
10
Go to Step 9
System OK
Go to Step
13
-
Yes
No

THERMOSTAT DIAGNOSIS (1.8L LUW AND LWE)

Thermostat Diagnosis (1.8L LUW and LWE)
Step
Action
Values
1. Pressure test the cooling system and the

cap for leaks.
2. Repair any leaks before proceeding.
These engines use a 90C (194F)
thermostat. The ambient temperatures
should be within the specified range
given.
13-38C (553. Set the HVAC controls in the OFF
100F)
position.
4. Run the cold engine at idle (68-70F) for
15-20 minutes before checking the
engine temperature.
5. Check the engine coolant temperature at
idle with the scan tool.

3
4
5
Is the engine coolant temperature (ECT)

between 90-105C (194-221F)?
Is the ECT below 90C (194F)?
The thermostat is opening early, or the
thermostat seal is leaking.
Replace the thermostat and the thermostat seal.
Is the ECT over 105C (221F)?
Is the radiator inlet hot?
1. Turn ON the heater.
2. Check if hot air is coming from the
heater outlets.
System OK
-
The cylinder head

The radiator
The radiator hoses
10
Go to Step
12
Go to Step 6
Go to Step
8
Go to Step 9
Go to Step
10
System OK

1. Replace the thermostat. Refer to Engine
Coolant Thermostat Replacement.
the scan tool.
Go to Step 11
Is there a blockage?
1. Repair the blockage.
the the scan tool.
Go to Step 6
Go to Step
7
Is the inlet hose hot?

Inspect for blockage in the following areas:
System OK
Go to Step 5
Is the air hot?

There may be air in the system.
1. Add coolant to the surge tank if the
coolant level is low. Refer to Cooling
System Draining and Filling (Static
Fill), Cooling System Draining and
Filling (GE-47716 Fill).
2. Recheck the radiator inlet hose.
Go to Step 3
Go to Step
2
Go to Step
4


System OK
11
12
13
Inspect for blockage in the radiator.

1. Accelerate the engine several times in
order to remove any air from the system.
2. Inspect for blockage in the heater
circuit.
3. Inspect for any pinched or buckled
hoses.
Go to Step 9
Go to Step
10
Go to Step 9
System OK
Go to Step
13
-

ENGINE FAILS TO REACH NORMAL OPERATING TEMPERATURE

Engine Fails To Reach Normal Operating Temperature
Step
Action
Check the coolant level in the radiator surge
tank. Refer to Cooling System Draining and
1
Filling (Static Fill), Cooling System
Draining and Filling (GE-47716 Fill).
Is the coolant at the proper level?
Add coolant to the radiator surge tank as
necessary.
2
Does the engine still fail to reach normal
operating temperatures?
Check for a blockage in the coolant passages.
3
Are there any blockages in the coolant
passages?
Flush the cooling system or flow check the
radiator.
4
operating temperatures?
Check to see if the incorrect thermostat was
installed or if it is stuck or sticks in the open
5
position.
Was the incorrect thermostat installed, or is it
stuck or does it stick in the open position?
Replace the thermostat. Refer to Engine
Coolant Thermostat Replacement.
6
operating temperature?
COOLING SYSTEM LEAK TESTING
Yes
No
Go to Step 3
Go to Step 2
Go to Step 3
System OK
Go to Step 4
Go to Step 5
Go to Step 5
System OK
Go to Step 6
System OK

Special Tools
EN-471 Adapter
EN-6327-A Cooling System Test Adapter

WARNING: Under pressure, the temperature of the solution in the radiator can
be considerably higher, without boiling. Removing the radiator cap
while the engine is hot (pressure is high), will cause the solution to
boil instantaneously, with explosive force. The solution will spew 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
cause a serious fire.
WARNING: In order to help avoid being burned, do not remove the radiator cap
while the engine and the radiator are hot. Scalding fluid and steam
can be blown out under pressure if the cap is removed too soon.
1. Detach the coolant expansion tank closure cap.

Fig. 2: View Of Coolant System Tester, KM-471 And KM-6327

2. Check the coolant level.
Top up the coolant to the COLD mark if necessary.
3. Pull the coolant expansion tank from the bracket in the direction of the battery.
NOTE:
Follow manufacturer instructions.
4. Attach the coolant system tester (1) with EN-471 adapter (2) and EN-6327-A adapter (3) to the coolant
expansion tank.
5. Apply approximately 100 kPa (15 psi) to the cooling system.
6. Cooling system, check for leaks.
7. Detach the cooling system tester.
Release the pressure

Detach the cooling system tester with EN-471 adapter.

8. Attach the coolant expansion tank closure cap.
9. Slide the coolant expansion tank onto the bracket.
REPAIR INSTRUCTIONS
COOLING SYSTEM DRAINING AND FILLING (GE-47716 FILL)
Special Tools
GE-26568 Coolant and Battery Fluid Tester

GE-42401-A Radiator Pressure Adapter
GE-47716 Vac N Fill Coolant Refill Tool

Draining Procedure
WARNING: With a pressurized cooling system, the coolant temperature in the

radiator can be considerably higher than the boiling point of the solution
at atmospheric pressure. Removal of the surge tank cap, while the
cooling system is hot and under high pressure, causes the solution to
boil instantaneously with explosive force. This will cause the solution to
spew out over the engine, the fenders, and the person removing the cap.
Serious bodily injury may result.

Fig. 3: Radiator Drain Plug

1.
2.
3.
4.
5.
Unscrew the surge tank cap to remove vacuum when draining coolant.
Place a container under the radiator drain.
Unscrew the radiator drain plug (1) until coolant flows out the radiator drain.
Follow the appropriate procedure based on the condition of the coolant:
Normal in appearance-Follow the filling procedure.
Discolored-Follow the flush procedure. Refer to Coolant System Flushing.
Vac-N-Fill Procedure


CAUTION: The procedure below must be followed. Improper coolant level could
result in a low or high coolant level condition, causing engine
damage.
1. Close the radiator drain cock by hand.

Fig. 5: Identifying Vac-N-Fill Cap

NOTE:
To prevent boiling of the coolant/water mixture in the vehicle's cooling

system, do not apply vacuum to a cooling system above 49 C (120 F).
The tool will not operate properly when the coolant is boiling.
2. Install GE-42401-2 adapter into the surge tank fill neck.

3. Install GE-42401-3 adapter to the surge tank fill neck.
4. Attach the Vac N Fill cap to the GE-42401-3 adapter.

Fig. 6: Vacuum Gage & Vac N Fill cap

5. Attach the vacuum gauge assembly to the Vac N Fill cap.

Fig. 7: View Of Fill Hose & Vacuum Gage Assembly

6. Attach the fill hose to the barb fitting on the vacuum gauge assembly.
Ensure that the valve is closed.

Fig. 8: View Of Graduated Reservoir & Hose

NOTE:
Use a 50/50 mixture of DEX-COOL antifreeze and clean, drinkable water.

Always use more coolant than necessary. This will eliminate air from being
drawn into the cooling system.
7. Pour the coolant mixture into the graduated reservoir.

8. Place the fill hose in the graduated reservoir.
NOTE:
Prior to installing the vacuum tank onto the graduated reservoir, ensure
that the drain valve located on the bottom of the tank is closed.
9. Install the vacuum tank on the graduated reservoir with the fill hose routed through the cut-out area in the
vacuum tank.

Fig. 9: View Of Venturi Assembly & Vacuum Tank

10. Attach the venturi assembly to the vacuum tank.

Fig. 10: View Of Shop Air Hose & Venturi Assembly

11. Attach a shop air hose to the venturi assembly.
Ensure the valve on the venturi assembly is closed.

Fig. 11: Vacuum Gage Assembly And Vacuum Tank

12. Attach the vacuum hose to the vacuum gauge assembly and the vacuum tank.

Fig. 12: Identifying Valve On Venturi Assembly

13. Open the valve on the venturi assembly. The vacuum gauge will begin to rise and a hissing noise will be
present.

Fig. 13: View Of Vacuum Gauge

14. Continue to draw vacuum until the needle stops rising. This should be 610-660 mm Hg (24-26 in Hg).
Cooling hoses may start to collapse. This is normal due to vacuum draw.
15. To aid in the fill process, position the graduated reservoir above the coolant fill port.

Fig. 14: Identifying Valve On Vacuum Gage Assembly

16. Slowly open the valve on the vacuum gauge assembly. When the coolant reaches the top of the fill hose,
close the valve. This will eliminate air from the fill hose.
17. Close the valve on the venturi assembly.
18. If there is a suspected leak in the cooling system, allow the system to stabilize under vacuum and monitor
for vacuum loss.
If vacuum loss is observed, refer to Loss of Coolant.
19. Open the valve on the vacuum gauge assembly. The vacuum gauge will drop as coolant is drawn into the
system.

Fig. 15: View Of Vacuum Gauge & Radiator

20. Once the vacuum gauge reaches zero, close the valve on the vacuum gauge assembly and repeat steps 1016.
21. Detach the Vac N Fill cap from the vehicle's coolant fill port.
22. Add coolant to the system as necessary.
23. Inspect the concentration of the coolant mixture, using the GE-26568 tester.
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.

Fig. 16: Extraction Hose And Vacuum Hose

25. Attach the extraction hose to the vacuum hose.

Fig. 17: Identifying Valve On Venturi Assembly

26. Open the valve on the venturi assembly to start a vacuum draw.

Fig. 18: Using Extraction Hose To Draw Out Coolant

27. Use the extraction hose to draw out coolant to the proper level.
28. The vacuum tank has a drain valve on the bottom of the tank. Open the valve to drain coolant from the
vacuum tank into a suitable container for disposal.
COOLING SYSTEM DRAINING AND FILLING (STATIC FILL)
Special Tools
GE-26568 Coolant and Battery Fluid Tester

Draining Procedure




1.
2.
3.
4.
5.
Unscrew the surge tank cap to remove vacuum when draining coolant.
Place a container under the radiator drain.
Unscrew the radiator drain plug (1) until coolant flows out the radiator drain.
Follow the appropriate procedure based on the condition of the coolant:
Normal in appearance-Follow the filling procedure.

Discolored-Follow the flush procedure. Refer to Coolant System Flushing.
Fill Procedure
1. Close the radiator drain plug.

3. Vehicle should be level.
Fig. 20: Radiator Vent Screw

NOTE:
Close vent screw when coolant begins to flow from the vent screw.
4. Loosen the vent screw (1) on the radiator.

Fig. 21: Radiator Coolant Surge Tank

5. Add a mixture of 50/50 DEX-COOL antifreeze and clean drinkable water to the bottom line of the
bleed nozzle on the coolant surge tank (1).
When the coolant level stabilizes, add enough coolant to reach the bottom line of the down pipe hole
(black arrow).
6. Start the engine. After the engine starts, verify that the coolant level reaches the bottom line of the down
pipe hole (black arrow).
7. Install the surge tank cap.
8. Warm up the engine.
NOTE:
If the heater core has been replaced, let the engine run for 2 minutes at
2.000-2.500 RPM. This ensures complete venting of the cooling system.

Run at 2, 500 RPM until the engine cooling fan turns ON.
9. Turn the engine OFF and allow the engine to cool down.
10. Remove the surge tank cap.
Fig. 22: Identifying Coolant Level Mark

NOTE:
11.
12.
13.
14.
After a test drive let the engine cool down and check the coolant level
again. Adjust the coolant level to the "COLD" mark if necessary.
Check the coolant level and fill to the "COLD" mark if necessary (1).
Inspect the concentration of the engine coolant, using GE-26568 tester.
Install the surge tank cap.
Rinse away any excess coolant from the engine and the engine compartment.

COOLANT SYSTEM FLUSHING

NOTE:
Do not use a chemical flush.

Store used coolant in the proper manner, such as in a used engine coolant
holding tank.
Do not pour used coolant down a drain. Ethylene glycol antifreeze is a very
toxic chemical.
Do not dispose of coolant into the sewer system or ground water. This is illegal
and ecologically unsound.
Various methods and equipment can be used to flush the cooling system. If
special equipment is used, such as a back flusher, follow the manufactures
instruction. However, always remove the thermostat before back flushing the
system.

2. Drain the coolant. Refer to Cooling System Draining and Filling (Static Fill), Cooling System
3. Fill the coolant system with clean drinkable water. Refer to Cooling System Draining and Filling
(Static Fill), Cooling System Draining and Filling (GE-47716 Fill).
4. Start the engine and run at 2.000 RPM until the thermostat opens.
5. Turn OFF the engine.
6. Drain the coolant system. Refer to Cooling System Draining and Filling (Static Fill), Cooling System
7. Repeat the above procedure until the water from the coolant system is colorless.
8. Drain the coolant system. Refer to Cooling System Draining and Filling (Static Fill), Cooling System
9. Add 3.8 liters (1.0 gal) of concentrated antifreeze since there will be some water in the system.
10. Add a mixture of 50/50 antifreeze and clean drinkable water until the level stabilizes at the weld seam on
the surge tank. Refer to Cooling System Draining and Filling (Static Fill), Cooling System Draining
and Filling (GE-47716 Fill).
RADIATOR CLEANING
WARNING: NEVER spray water on a hot heat exchanger. The resulting steam could
cause personal injury.
CAUTION: The heat exchanger fins are necessary for good heat transfer. Do not
brush the fins. This may cause damage to the fins, reducing heat transfer.

NOTE:
Remove bugs, leaves, dirt and other debris by blowing compressed air
through the engine side of the radiator.
Some conditions may require the use of warm water and a mild detergent.
Clean the A/C condenser fins.
Clean between the A/C condenser and radiator.
Clean the radiator cooling fins.
Straighten any damaged cooling fins.
RADIATOR SURGE TANK REPLACEMENT

Removal Procedure

NOTE:
Use only a GM released anti-freeze mixture and ensure a concentration of 50

percent water to 50 percent antifreeze. Antifreeze does not just prevent the
cooling system from freezing up, it also protects all the components that are in
contact with coolant from rust/limescale deposits. As a result, antifreeze should
always be added, even in tropical countries.
In addition to the anti-freeze mixture, water quality also plays an important role.
Potable tap water should normally suffice to fulfil this requirement. The quality
of regenerated sea water is not suitable.
1. Open the cooling system by removing the radiator surge tank cap.

Fig. 23: Surge Tank Drain Screw

NOTE:
Do NOT drain more than 1.5 liter (1.36 quarts) of coolant fluid to avoid
necessity of the coolant system bleeding procedure.
3. Install a drain hose, slowly open the drain screw (1) and allow the to drain out max. 1.5 liter (1.36 quarts)
coolant fluid into a clean measuring pincher.

Fig. 24: Surge Tank And Components

5.
6.
7.
8.
9.
Remove the engine coolant air bleed hose (6), remove the clamp.
Remove the radiator surge tank engine hose (5), remove the clamp.
Remove radiator surge tank clip (2).
Disconnect coolant level sensor wiring harness plug (4).
Remove the radiator surge tank (1), unclip from the bracket (3).

Fig. 25: Surge Tank And Components

1.
2.
3.
4.
5.
6.
Install the radiator surge tank (1) and clip into the bracket (3).
Connect coolant level sensor wiring harness plug (4).
Install radiator surge tank clip (2).
Install the radiator surge tank engine hose (5), install the clamp.
Install the engine coolant air bleed hose (6), install the clamp.
Refill the radiator surge tank with the coolant fluid, which has been drained out before.
RADIATOR SURGE TANK OUTLET HOSE REPLACEMENT

Removal Procedure
1. Drain the cooling system. Refer to Cooling System Draining and Filling (Static Fill), Cooling System

Fig. 26: Radiator Surge Tank, Hoses And Clamps

2.
3.
4.
5.
Loosen the hose clamp (4).

Remove the radiator surge tank hose (3) from the surge tank (5).
Loosen the clamp (2).
Remove the radiator surge tank hose (3) from the radiator outlet hose (1).

Fig. 27: Radiator Surge Tank, Hoses And Clamps

1.
2.
3.
4.
5.
Install the radiator surge tank outlet hose (3) to the radiator outlet hose (1).
Install the clamp (2).
Install the radiator surge tank outlet hose (3) to the surge tank (5).
Install the clamp (4).
Fill the cooling system. Refer to Cooling System Draining and Filling (Static Fill), Cooling System
RADIATOR INLET HOSE REPLACEMENT (1.4L LUV)

Fig. 28: Radiator Inlet Hose

Radiator Inlet Hose Replacement (1.4L LUV)
Callout
Component Name
Drain the cooling system. Refer to Cooling System Draining and Filling (Static Fill), Cooling System
Radiator Inlet Hose Clamp
Procedure
1
Place a drain pan below the vehicle.
2
Radiator Inlet Hose Clamp
3
Radiator Inlet Hose
RADIATOR INLET HOSE REPLACEMENT (1.8L LUW AND LWE)
Removal Procedure
1.
2.
3.
4.
5.
Disconnect the battery. Refer to Battery Negative Cable Disconnection and Connection .
Unclip the engine control module, if necessary.


6.
7.
8.
9.
Loosen the radiator inlet hose clamp (2).

Remove the radiator inlet hose (3) from the radiator (1).
Loosen the radiator inlet hose clamp (4).
Remove the radiator inlet hose (3) from the thermostat housing (5).


1.
2.
3.
4.
5.
6.
Install the radiator inlet hose (3) to the thermostat housing (5).
Install the radiator inlet hose clamp (4).
Install the radiator inlet hose (3) to the radiator (1).
Install the radiator inlet hose clamp (2).
Lower the vehicle.
7. Clip in the engine control module, if necessary.
8. Connect the battery. Refer to Battery Negative Cable Disconnection and Connection .
RADIATOR OUTLET HOSE REPLACEMENT (1.4L LUV)

Fig. 31: Radiator Outlet Hose

Radiator Outlet Hose Replacement (1.4L LUV)
Callout
Component Name
Radiator Outlet Hose Connector
1
2
3
Procedure
1. Place a drain pan below the vehicle.
2. Unlock radiator outlet hose connector.
Radiator Outlet Hose Connector
Procedure
Unlock the radiator outlet hose connector.
Radiator Outlet Hose
RADIATOR OUTLET HOSE REPLACEMENT (1.8L LUW AND LWE)

Removal Procedure
Draining and Filling (GE-47716 Fill)

Fig. 32: Radiator Outlet Hose Assembly

2.
3.
4.
5.
Loosen the hose clamp (1).

Remove the radiator outlet hose assembly (3) from the water pump.
Unclip the clamp (2).
Remove the radiator outlet hose assembly (3) from the radiator.

Fig. 33: Radiator Surge Tank Outlet Hose

6. Loosen the clamp (3).
7. Remove the radiator outlet hose (1) from the radiator surge tank outlet hose (2).
8. Unclip the radiator outlet hose (1) from the 2 clips (4).

Fig. 34: Radiator Surge Tank Outlet Hose

1. Clip in the radiator outlet hose (1) into the 2 clips (4).
2. Install the radiator outlet hose (1) to the radiator surge tank outlet hose (2).
3. Install the clamp (3).

Fig. 35: Radiator Outlet Hose Assembly

4.
5.
6.
7.
8.
Install the radiator surge tank outlet hose assembly (3) to the radiator.
Clip in the clamp (2).
Install the radiator surge tank outlet hose assembly (3) to the water pump.
Install the hose clamp (1).
RADIATOR MOUNTING STUD REPAIR

Repair Procedure
1. Pressure test the cooling system. Refer to Cooling System Leak Testing. If the radiator is not leaky,
perform the following procedure.

2. Remove the radiator. Refer to Radiator Replacement (1.4L LUV with Automatic Transmission),
Radiator Replacement (1.8L LUW and LWE), Radiator Replacement (1.4L LUV with Manual
Transmission).
Fig. 36: Identifying Fracture Surface

3. Grind the fracture surface (1) with a proper tool.
4. Drill a hole in the center of the fractured surface, using a 6 mm (0.24 in) drill.

Fig. 37: Radiator Mounting Pin, Nut And Bolt

5. Install the new radiator mounting pin (2).
Install the nut (3).
NOTE:
The bolt should not be longer than 35 mm (1.38 in).
Install the radiator mounting pin (2) with the bolt (1).
6. Tighten the bolt 5 N.m (44 lb in).

7. Install the radiator. Refer to Radiator Replacement (1.4L LUV with Automatic Transmission),

Transmission).
CHARGE AIR COOLER REPLACEMENT (AUTOMATIC TRANSMISSION)
Removal Procedure
1.
2.
3.
4.
5.
Disconnect battery negative cable. Refer to Battery Negative Cable Disconnection and Connection .
Remove the radiator upper air seal.
Remove the left and right side radiator air baffles.
Remove the charge air cooler inlet air hose from the charge air cooler. Refer to Charge Air Cooler Inlet
Air Hose Replacement .
6. Remove the charge air cooler outlet air hose from the charge air cooler. Refer to Charge Air Cooler
Outlet Air Hose Replacement (Automatic Transmission) , Charge Air Cooler Outlet Air Hose
Replacement (Manual Transmission) .

Fig. 38: Transmission Fluid Cooler

7. Unclip the transmission fluid cooler (1) from the radiator.
8. Reposition the transmission fluid cooler (1) away from the radiator and secure.
Fig. 39: Identifying Air Conditioning Condenser And Charge Air Cooler
9. Unclip the air conditioning condenser (2) from the charge air cooler (1).
10. Reposition the air conditioning condenser (2) forward and below the front bumper impact bar.

Fig. 40: Identifying Charge Air Cooler And Radiator

11. Unclip the charge air cooler (2) from the radiator (1).
12. Lift the charge air cooler (2) up and away from the radiator (1).


1. Clip the charge air cooler (2) to the radiator (1).

2. Clip the air conditioning condenser (2) to the charge air cooler (1).

Fig. 43: Transmission Fluid Cooler

3. Clip the transmission fluid cooler (1) to the radiator.
4. Install the charge air cooler inlet air hose to the charge air cooler. Refer to Charge Air Cooler Inlet Air
Hose Replacement .
5. Install the charge air cooler outlet air hose to the charge air cooler. Refer to Charge Air Cooler Outlet
Air Hose Replacement (Automatic Transmission) , Charge Air Cooler Outlet Air Hose
6. Install the left and right side radiator air baffles.
7. Install the radiator upper air seal.
8. Install the front bumper fascia. Refer to Front Bumper Fascia Replacement .
CHARGE AIR COOLER REPLACEMENT (MANUAL TRANSMISSION)

Removal Procedure
Connection .
3. Remove the radiator upper air seal.
4. Remove the left and right side radiator air baffles.
5. Remove the charge air cooler inlet air hose from the charge air cooler. Refer to Charge Air Cooler Inlet
Air Hose Replacement .
6. Remove the charge air cooler outlet air hose from the charge air cooler. Refer to Charge Air Cooler
Outlet Air Hose Replacement (Automatic Transmission) , Charge Air Cooler Outlet Air Hose

7. Unclip the air conditioning condenser (2) from the charge air cooler (1).
8. Reposition the air conditioning condenser (2) forward and below the front bumper impact bar.

9. Unclip the charge air cooler (2) from the radiator (1).
10. Lift the charge air cooler (2) up and away from the radiator (1).


1. Clip the charge air cooler (2) to the radiator (1).

2. Clip the air conditioning condenser (2) to the charge air cooler (1).
3. Install the charge air cooler inlet air hose to the charge air cooler. Refer to Charge Air Cooler Inlet Air
Hose Replacement .
4. Install the charge air cooler outlet air hose to the charge air cooler. Refer to Charge Air Cooler Outlet
5. Install the left and right side radiator air baffles.
6. Install the radiator upper air seal.
7. Install the front bumper fascia. Refer to Front Bumper Fascia Replacement .
RADIATOR AND CHARGE AIR COOLER BRACKET REPAIR

1. Remove the radiator. Refer to Radiator Replacement (1.4L LUV with Automatic Transmission),
Transmission).
Fig. 48: Radiator Mounting Components

2. Drill hole in the charge air cooler bracket and radiator bracket (2) using a 7 mm (0.28 in) drill.
3. Install the j-clip (3) to the radiator.
4. Install the radiator. Refer to Radiator Replacement (1.4L LUV with Automatic Transmission),
Transmission).

5. Install the repair bolt (1) with locking compound and tighten to 5 N.m (45 lb in).
RADIATOR LOWER BRACKET REPLACEMENT
Fig. 49: Radiator Lower Bracket

Radiator Lower Bracket Replacement
Callout
Component Name
Radiator Lower Bracket Bolt (Qty: 2)
CAUTION:
Procedure
Secure the radiator.
Tighten
22 N.m (16 lb ft)
Radiator Lower Bracket
ENGINE COOLANT FAN RESISTOR MOUNT REPAIR

Fig. 50: Engine Coolant Fan Resistor Mount (Single Coolant Fan)
Engine Coolant Fan Resistor Mount Repair
Callout
Component Name
Remove the engine cooling fan shroud. Refer to Engine Coolant Fan Replacement.
1
Engine Coolant Fan Resistor Mount
Engine Coolant Fan Resistor Mount Bolt
CAUTION:
2
Procedure
In case of a broken engine coolant fan resistor mount use this repair
procedure.
Tighten
5 N.m (44 lb in)
THROTTLE BODY HEATER INLET HOSE REPLACEMENT
Removal Procedure
1. Open the hood.

2. Place a collection basin under the vehicle.
Fig. 51: Identifying Engine Coolant Thermostat Housing

3. Disconnect the throttle body heater inlet hose connector from the engine coolant thermostat housing (1).
4. Loosen the clamp and disconnect the throttle body heater inlet hose connector from the throttle body (3).
5. Remove the throttle body heater inlet hose (2).


1. Install the throttle body heater inlet hose (2).
2. Connect the throttle body heater inlet hose to the throttle body (3) and install the clamp.
3. Connect the throttle body heater inlet hose (2) to the engine coolant thermostat housing (1).


4. Top off the coolant by filling to the bottom line (black arrow) on the coolant surge tank (1) if necessary.
5. Close the hood.
THROTTLE BODY HEATER OUTLET HOSE REPLACEMENT
Removal Procedure
1. Open the hood.

2. Place a collection basin under the vehicle.

Fig. 54: Radiator Surge Tank, Throttle Body And Throttle Body Heater Outlet Hose
3.
4.
5.
6.
Clip out the throttle body heater outlet hose from the intake manifold.
Loosen the clamp and disconnect the throttle body heater outlet hose (2) from the radiator surge tank (1).
Disconnect the throttle body heater outlet hose connector from the throttle body (3).
Remove the throttle body heater outlet hose (2).

Fig. 55: Radiator Surge Tank, Throttle Body And Throttle Body Heater Outlet Hose
1.
2.
3.
4.
Install the throttle body heater outlet hose (2).

Connect the throttle body heater outlet hose connector to the throttle body (3)
Connect the throttle body heater outlet hose (2) to the radiator surge tank (1) and install the clamp.
Clip in the throttle body heater outlet hose to the intake manifold


5. Top off the coolant by filling to the bottom line (black arrow) on the coolant surge tank (1), if necessary.
6. Close the hood.
ENGINE OIL COOLER REPLACEMENT (1.4L LUV)
Removal Procedure
2. Drain engine coolant. Refer to Cooling System Draining and Filling (Static Fill), Cooling System
3. Remove the turbocharger oil feed pipe. Refer to Turbocharger Oil Feed Pipe Replacement .
4. Remove the warm up three way catalytic converter. Refer to Warm Up Three-Way Catalytic
Converter Replacement .

5. Lower vehicle.
6. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement .
Fig. 57: Thermostat Housing And Oil Cooler Outlet Hose

7. Remove the oil cooler outlet hose clamp (2).
8. Remove the oil cooler outlet hose (3) from the thermostat housing (1).

Fig. 58: Turbocharger Coolant Return Pipe Clamp And Bolt

9. Remove the turbocharger coolant return pipe bolt (1) from the oil cooler housing.
10. Remove the turbocharger coolant return pipe clamp (2).
NOTE:
Do not move the turbocharger coolant return pipe too much. An excessive
moving of the turbocharger coolant return pipe could cause leakage.
11. Remove the turbocharger coolant return pipe (3) from the oil cooler inlet pipe.
12. Disconnect the oil pressure indicator switch wiring harness plug.

Fig. 59: Oil Cooler Inlet Pipe

13.
14.
15.
16.
17.
Remove the oil cooler inlet hose clamp (1) and remove the oil cooler inlet hose from the water outlet.
Remove the engine oil cooler bolt (5).
Remove the engine oil cooler inlet pipe bolt (4).
Remove the engine oil cooler inlet pipe (2) and the seal ring (3).
Raise vehicle.

Fig. 60: Oil Cooler Outlet Pipe

18. Remove the oil cooler outlet pipe bolt (1) from the engine block.
19. Remove the oil cooler outlet pipe (2) in compound with the oil cooler outlet hose.
20. Lower vehicle.

Fig. 61: Oil Cooler Bolts

21. Remove the 2 oil cooler bolts (1).
22. Raise vehicle.

Fig. 62: Oil Cooler And Oil Cooler Gasket

23. Remove the oil cooler (1) in compound with the oil cooler gasket (2) and the seal ring (3).
24. Remove the oil pressure indicator switch from the oil cooler.
1. Install the oil pressure indicator switch to the oil cooler. Use a NEW seal ring.
2. Tighten the oil pressure indicator switch to 20 N.m (15 lb ft).

Fig. 63: Oil Cooler And Oil Cooler Gasket

3. Clean the sealing surfaces.
4. Install the oil cooler (1) in compound with a NEW oil cooler gasket (2) and a NEW seal ring (3).
5. Lower vehicle.

Fig. 64: Oil Cooler Bolts

6. Install the 2 oil cooler bolts (1) and hand tighten.

Fig. 65: Oil Cooler Inlet Pipe

7.
8.
9.
10.
11.
Install the engine oil cooler inlet pipe (2) in compound with a NEW seal ring (3).
Install the oil cooler inlet hose to the water outlet and install the oil cooler inlet hose clamp (1).
Install the engine oil cooler bolt (5).
Install the engine oil cooler inlet pipe bolt (4) and tighten to 10 N.m (89 lb in).
Tighten the 3 engine oil cooler bolts to 20 N.m (15 lb ft).

Fig. 66: Turbocharger Coolant Return Pipe Clamp And Bolt

12.
13.
14.
15.
16.
Install the turbocharger coolant return pipe (3) to the oil cooler inlet pipe.
Install the turbocharger coolant return pipe clamp (2).
Install turbocharger coolant return pipe bolt (1) and tighten to 10 N.m (89 lb in).
Connect the oil pressure indicator switch wiring harness plug.
Raise vehicle.


17. Install the oil cooler outlet pipe (2) in compound with the oil cooler outlet hose to the oil cooler.
18. Install the oil cooler outlet pipe bolt (1) to the engine block and tighten to 10 N.m (89 lb in).
19. Install the warm up three way catalytic converter. Refer to Warm Up Three-Way Catalytic Converter
Replacement .


20.
21.
22.
23.
Install the oil cooler outlet hose (3) to the thermostat housing (1).
Install the oil cooler outlet hose clamp (2).
Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement .
Install the turbocharger oil feed pipe and the exhaust manifold heat shield. Refer to Turbocharger Oil
Feed Pipe Replacement .
25. Fill engine coolant. Refer to Cooling System Draining and Filling (Static Fill), Cooling System
ENGINE OIL COOLER REPLACEMENT (1.8L LUW AND LWE)
1. Remove the exhaust manifold. Refer to Exhaust Manifold Replacement .

Fig. 69: Identifying Engine Oil Cooler Outlet Pipe And Bolts
3. Remove the 2 engine oil cooler outlet pipe bolts (1).
4. Remove the engine oil cooler outlet pipe (2) from the engine oil cooler housing and the engine coolant
thermostat housing.
5. Remove the 2 engine oil cooler outlet pipe gaskets.

Fig. 70: Identifying Engine Oil Cooler Housing, Bolts And Engine Oil Cooler Inlet Pipe
6.
7.
8.
9.
10.
Remove the 5 engine oil cooler housing bolts (2).

Remove the engine oil cooler housing (1).
Remove the 2 engine oil cooler housing gaskets.
Remove the engine oil cooler inlet pipe (3).
Remove the 2 engine oil cooler inlet pipe gaskets.

Fig. 71: Identifying Engine Oil Cooler And Bolts

11. Remove the 6 engine oil cooler bolts (2) and the engine oil cooler (1) from the engine oil cooler housing.
12. Remove the engine oil cooler gasket.
1. Clean the engine oil cooler to engine oil cooler housing sealing surfaces.
2. Install a NEW engine oil cooler gasket.

Fig. 72: Identifying Engine Oil Cooler And Bolts

3. Install the engine oil cooler (1) to the engine oil cooler housing.
4. Install the 6 engine oil cooler bolts (2) and tighten to 8 N.m (71 lb in).

5.
6.
7.
8.
9.
Install the 2 NEW engine oil cooler inlet pipe gaskets.

Install the engine oil cooler inlet pipe (3).
Install the 2 NEW engine oil cooler housing gaskets.
Install the engine oil cooler housing (1).
Install the 5 engine oil cooler housing bolts (2) and tighten to 25 N.m (19 lb ft).

10. Clean the engine oil cooler outlet pipe sealing surfaces.
11. Install the 2 NEW engine oil cooler outlet pipe gaskets.
12. Install the engine oil cooler outlet pipe (2) to the engine oil cooler housing and the engine coolant
thermostat housing.
13. Install the 2 engine oil cooler outlet pipe bolts (1) and tighten to 8 N.m (71 lb in).
14. Fill the cooling system. Refer to Cooling System Draining and Filling (Static Fill), Cooling System
15. Install the exhaust manifold. Refer to Exhaust Manifold Replacement .
ENGINE OIL COOLER OUTLET HOSE REPLACEMENT
Removal Procedure

1. Disconnect battery negative cable. Refer to Battery Negative Cable Disconnection and Connection
2. Drain engine coolant. Refer to Cooling System Draining and Filling (Static Fill), Cooling System
3. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement

4. Remove the oil cooler outlet hose clamp (2).
5. Remove the oil cooler outlet hose (3) from the thermostat housing (1).
Converter Replacement


7.
8.
9.
10.
Remove the oil cooler outlet pipe bolt (1) from the engine block.
Remove the oil cooler outlet pipe (2) in compound with the oil cooler outlet hose.
Remove the oil cooler outlet hose clamp.
Remove the oil cooler outlet hose from the oil cooler outlet pipe.
1. Install the oil cooler outlet hose to the oil cooler outlet pipe.
2. Install the oil cooler outlet hose clamp.


3. Install the oil cooler outlet pipe (2) in compound with the oil cooler outlet hose to the oil cooler.
4. Install the oil cooler outlet pipe bolt (1) to the engine block and tighten to 10 N.m (89 lb in).
Replacement


6.
7.
8.
9.
Install the oil cooler outlet hose (3) to the thermostat housing (1).
Install the oil cooler outlet hose clamp (2).
Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement
Install the turbocharger oil feed pipe and the exhaust manifold heat shield. Refer to Turbocharger Oil
Feed Pipe Replacement
10. Connect battery negative cable. Refer to Battery Negative Cable Disconnection and Connection
11. Fill engine coolant. Refer to Cooling System Draining and Filling (Static Fill), Cooling System
ENGINE OIL COOLER INLET HOSE REPLACEMENT

Fig. 79: Identifying Engine Oil Cooler Inlet Hose

Engine Oil Cooler Inlet Hose Replacement
Callout
Component Name
1. Open the hood.

2. Drain the cooling system. Refer to Cooling System Draining and Filling (Static Fill), Cooling
System Draining and Filling (GE-47716 Fill).
Oil Cooler Inlet Hose Clamp
1
Procedure
2. Remove / install engine coolant air bleed hose clamp.
Oil Cooler Inlet Hose Clamp
Procedure
Oil Cooler Inlet Hose

ENGINE OIL COOLER INLET PIPE REPLACEMENT (1.4L LUV)

Removal Procedure
1. Drain coolant fluid. Refer to Cooling System Draining and Filling (Static Fill), Cooling System
3. Remove the engine oil cooler inlet hose from the engine oil cooler inlet pipe. Refer to Engine Oil Cooler
Inlet Hose Replacement.
Fig. 80: Turbocharger Coolant Return Pipe Hose, Clamp And Bolt
4. Remove the turbocharger coolant return pipe hose clamp (3).
5. Remove the turbocharger coolant return pipe hose (2) from the engine oil cooler inlet pipe.

NOTE:
Do not move the turbocharger coolant return pipe too much. An excessive
moving of the turbocharger coolant return pipe could cause leakage.
6. Remove the turbocharger coolant return pipe bolt (1).
Fig. 81: Identifying Engine Oil Cooler Inlet Pipe

7. Remove the engine oil cooler bolt (1).
8. Remove the engine oil cooler inlet pipe bolt (4).
9. Remove the engine oil cooler inlet pipe (2) and the seal ring (3).


1. Install the engine oil cooler inlet pipe (2) in compound with a NEW seal ring (3).
2. Install the engine oil cooler bolt (1).
3. Install the engine oil cooler inlet pipe bolt (4) and tighten to 10 N.m (89 lb in).
4. Tighten the engine oil cooler bolt (1) to 20 N.m (15 lb ft).

Fig. 83: Turbocharger Coolant Return Pipe Hose, Clamp And Bolt
5.
6.
7.
8.
Install the turbocharger coolant return pipe hose (2) to the engine oil cooler inlet pipe.
Install the turbocharger coolant return pipe hose clamp (3).
Install turbocharger coolant return pipe bolt (1) and tighten to 10 N.m (89 lb in).
Install the engine oil cooler inlet hose to the engine oil cooler inlet pipe. Refer to Engine Oil Cooler Inlet
Hose Replacement.
Replacement .
10. Fill up coolant fluid. Refer to Cooling System Draining and Filling (Static Fill), Cooling System
ENGINE OIL COOLER INLET PIPE REPLACEMENT (1.8L LUW AND LWE)


Engine Oil Cooler Inlet Pipe Replacement (1.8L LUW and LWE)
Callout
Component Name
Remove the engine oil cooler housing. Refer to Engine Oil Cooler Replacement (1.8L LUW and
LWE), Engine Oil Cooler Replacement (1.4L LUV).
1
Engine Oil Cooler Inlet Pipe
ENGINE OIL COOLER OUTLET PIPE REPLACEMENT
Removal Procedure


3. Remove the 2 engine oil cooler outlet pipe bolts (1).
4. Remove the engine oil cooler outlet pipe (2) from the engine oil cooler housing and the engine coolant
thermostat housing.
5. Remove the 2 engine oil cooler outlet pipe gaskets.
1. Clean the engine oil cooler outlet pipe sealing surfaces.

2. Install the 2 NEW engine oil cooler outlet pipe gaskets.

3. Install the engine oil cooler outlet pipe (2) to the engine oil cooler housing and the engine coolant
thermostat housing.
4. Install the 2 engine oil cooler outlet pipe bolts (1) and tighten to 8 N.m (71 lb in).
ENGINE COOLANT FAN REPLACEMENT

Removal Procedure
NOTE:
It is not necessary to remove the hood latches and wiring clips from the
front end upper tie bar for this procedure.
1. Remove and reposition the front end upper tie bar rearward. Refer to Front End Upper Tie Bar
Replacement .
5. Position the radiator assembly forward for engine coolant fan shroud access.
Fig. 87: Identifying Engine Coolant Fan Resistor Wiring Harness Connector
6. Disconnect the engine coolant fan resistor wiring harness connector (1) and remove the ground cable nut.

7. Remove the wiring harness (3) and clips.
Fig. 88: Identifying Engine Coolant Fan Shroud

8. Unclip the engine coolant fan shroud (1) from the four mounting points shown.
9. Remove the engine coolant fan shroud (1).
1. Slide the engine coolant fan shroud (1) toward the right side of the vehicle.
2. Lift the left hand side of the engine coolant fan shroud (1) up.
3. Remove the engine coolant fan shroud (1) from the vehicle.

Fig. 89: Identifying Engine Coolant Fan Resistor

10.
11.
12.
13.
Remove the engine coolant fan resistor (1) by uncliping the retainer clip (2).
Unclip the engine coolant fan resistor wiring harness (arrows) from the shroud.
Remove the 3 engine coolant fan engine bolts (3) from the engine coolant fan.
Remove the engine coolant fan.

Fig. 90: Identifying Engine Coolant Fan Resistor

1. Install the engine coolant fan.
2. Install the 3 engine coolant fan engine bolts (3) to the engine coolant fan and tighten.
3. Clip in the engine coolant fan resistor wiring harness (arrows) to the shroud.
4. Install the engine coolant fan resistor (1) by clipping the retainer clip (2).


5. Install the engine coolant fan shroud (1).
1. Lower the right hand side of the engine coolant fan shroud (1) behind the radiator.
2. Slide the engine coolant fan shroud (1) toward the left side of the vehicle.
6. Clip in the engine coolant fan shroud (1) to the four mounting points shown.

7.
8.
9.
10.
11.
12.
Connect the engine coolant fan resistor wiring harness connector (1).
Install the wiring harness (3) and clips.
Install the front end upper tie bar. Refer to Front End Upper Tie Bar Replacement .
Install the left and right side radiator air baffles.
Install the radiator upper air seal.
Connect battery negative cable. Refer to Battery Negative Cable Disconnection and Connection .
ENGINE COOLANT FAN RESISTOR REPLACEMENT

Removal Procedure
1. Disconnect the negative cable from the battery. Refer to Battery Negative Cable Disconnection and
Connection .

2. Disconnect the engine coolant fan resistor wiring harness plug.
3. Remove the engine coolant fan resistor bolt (2).
4. Remove the engine coolant fan resistor (1).

1. Install the engine coolant fan resistor (1).
2. Install the engine coolant fan resistor bolt (2) and tighten to 4 N.m (36 lb in).
3. Connect the engine coolant fan resistor wiring harness plug.
4. Connect the negative cable to the battery. Refer to Battery Negative Cable Disconnection and
Connection .
ENGINE COOLANT LEVEL INDICATOR MODULE REPLACEMENT

Fig. 95: Identifying Engine Coolant Level Indicator Module

Engine Coolant Level Indicator Module Replacement
Callout
Component Name
1. Drain the cooling system. Refer to Cooling System Draining and Filling (Static Fill), Cooling
2. Remove the fuse block. Refer to Fuse Block Replacement .
1
Coolant Hose (Qty: 2)
2
Radiator Surge Tank Clip
3
Radiator Surge Tank
Engine Coolant Level Indicator Module
4
Procedure
TURBOCHARGER COOLANT FEED PIPE REPLACEMENT
Removal Procedure
1. Remove the turbocharger. Refer to Turbocharger Replacement .

2. Remove the turbocharger coolant feed pipe from quick fitting connector. Refer to Turbocharger
Disassemble .

1. Install the turbocharger coolant feed pipe to the quick fitting connector. Refer to Turbocharger
Assemble .
2. Install the turbocharger. Refer to Turbocharger Replacement .
TURBOCHARGER COOLANT RETURN PIPE REPLACEMENT
Removal Procedure
1. Remove the turbocharger. Refer to Turbocharger Replacement .

2. Remove the turbocharger coolant return pipe from quick fitting connector. Refer to Turbocharger
Disassemble .
3. Replace the quick fitting connector. Refer to Turbocharger Disassemble .
1. Install the turbocharger coolant return pipe to the quick fitting connector. Refer to Turbocharger
Disassemble .
2. Install the turbocharger. Refer to Turbocharger Replacement .
ENGINE COOLANT THERMOSTAT HOUSING REPLACEMENT (1.4L LUV)
Removal Procedure
3. Disconnect the positive crankcase ventilation pipe from the turbocharger. Refer to Positive Crankcase
Ventilation Hose/Pipe/Tube Replacement .
4. Remove the radiator outlet hose from the engine coolant thermostat housing. Refer to Radiator Outlet
Hose Replacement (1.8L LUW and LWE), Radiator Outlet Hose Replacement (1.4L LUV).
5. Disconnect the engine coolant temperature sensor wiring harness connector.

Fig. 96: Identifying Engine Coolant Thermostat Housing And Engine Oil Cooler Outlet Hose
6.
7.
8.
9.
Remove the engine oil cooler outlet hose clamp (2).

Remove the engine oil cooler outlet hose (3) from the engine coolant thermostat housing.
Remove the 3 engine coolant thermostat housing bolts (4).
Remove the engine coolant thermostat housing (5) and the seal ring (1).

Fig. 97: Identifying Engine Coolant Thermostat Housing And Engine Oil Cooler Outlet Hose
2. Install the engine coolant thermostat housing (5) along with a NEW seal ring (1).
3.
4.
5.
6.
7.
Install the 3 engine coolant thermostat housing bolts (4) and tighten to 8 N.m(71 lb in).
Install the engine oil cooler outlet hose (3) to the engine coolant thermostat housing.
Install the engine oil cooler outlet hose clamp (2).
Connect the engine coolant temperature sensor wiring harness connector.
Install the radiator outlet hose to the engine coolant thermostat housing. Refer to Radiator Outlet Hose
Replacement (1.8L LUW and LWE), Radiator Outlet Hose Replacement (1.4L LUV).
8. Connect the positive crankcase ventilation pipe to the turbocharger. Refer to Positive Crankcase

Ventilation Hose/Pipe/Tube Replacement .

9. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement .
ENGINE COOLANT THERMOSTAT HOUSING REPLACEMENT (1.8L LUW AND LWE)
Removal Procedure
CAUTION: Refer to Engine Coolant Thermostat Housing Caution .
1.
2.
3.
4.
Open the hood.


Fig. 98: Radiator Inlet Hose And Clamp

5. Loosen the radiator inlet hose clamp (2).
6. Remove the radiator inlet hose (3) from the engine coolant thermostat (1).


7. Remove the throttle body heater inlet hose (2) from the engine coolant thermostat (1).
8. Remove the heater outlet hose from the engine coolant thermostat housing. Refer to Heater Outlet Hose
Replacement (1.8L LUW) , Heater Outlet Hose Replacement (1.4L LUV) , Heater Outlet Hose
Replacement (1.8L LWE) .
9. Remove the heater inlet hose from the engine coolant thermostat housing. Refer to Heater Inlet Hose
Replacement (1.8L LUW and LWE) , Heater Inlet Hose Replacement (1.4L LUV) .
10. Remove the thermostat housing bracket nut.
11. Remove the thermostat housing bracket.

Fig. 100: Identifying Engine Coolant Temperature Sensor Connector, Engine Oil Cooler Pipe And
Thermostat Housing
12. Disconnect the engine coolant temperature sensor connector (1).
13. Remove the 2 engine oil cooler pipe bolts (6).
NOTE:
14.
15.
16.
17.
18.
Pull the engine oil cooler pipe out of the engine oil cooler.
Remove the engine oil cooler pipe (5).

Remove the engine oil cooler pipe seals (4, 7).
Remove the thermostat housing (2).
Remove the thermostat housing seal (8).

1. Clean sealing surface.
Thermostat Housing
2. Install a NEW engine coolant thermostat housing seal (8).
3. Install the engine coolant thermostat housing (2).
NOTE:
Partially install the 4 bolts until the engine coolant thermostat housing is
in contact with the cylinder head.
4. Install the 4 engine coolant thermostat housing bolts (3) and tighten to 2 N.m (18 lb in).

Fig. 102: Identifying Engine Coolant Thermostat Housing Bolts Tightening Sequence
CAUTION: Following the proper fastener tightening sequence and torque is
essential. Failure to do so may fracture the thermostat housing.
5. Tighten the 4 engine coolant thermostat housing bolts to 8 N.m (71 lb in) in sequence (1-2-3-4).

Thermostat Housing
6. Install NEW engine oil cooler pipe seals (4, 7).
NOTE:
Push the engine oil cooler pipe into the engine oil cooler.
7. Install the engine oil cooler pipe (5).

8. Install the 2 engine oil cooler pipe bolts (6) and tighten to 8 N.m (71 lb in).
9. Install the heater inlet hose to the engine coolant thermostat housing. Refer to Heater Inlet Hose
Replacement (1.8L LUW and LWE) , Heater Inlet Hose Replacement (1.4L LUV) .
10. Install the heater outlet hose to the engine coolant thermostat housing. Refer to Heater Outlet Hose
Replacement (1.8L LUW) , Heater Outlet Hose Replacement (1.4L LUV) , Heater Outlet Hose
Replacement (1.8L LWE) .
11. Connect the engine coolant temperature sensor connector (1).

12. Install the engine coolant thermostat housing bracket.

13. Install the engine coolant thermostat housing bracket nut and tighten to 6 N.m (53 lb in).

14. Install the throttle body heater inlet hose (2) to the engine coolant thermostat housing (1).


15. Install the radiator inlet hose (3) with the radiator inlet hose clamp (2) to the engine coolant thermostat
(1).
ENGINE COOLANT THERMOSTAT REPLACEMENT
Removal Procedure



Fig. 107: Identifying Engine Coolant Thermostat Assembly

6. Remove the 4 engine coolant thermostat bolts (3).
7. Remove the engine coolant thermostat assembly (2).
8. Remove the engine coolant seal (1).
1. Clean the engine coolant sealing surfaces.


2. Install the engine coolant seal (1).
3. Install the engine coolant thermostat assembly (2).
4. Install the 4 engine coolant thermostat bolts (3) and tighten to 8 N.m (71 lb in).


(1).
ENGINE COOLANT AIR BLEED HOSE REPLACEMENT (1.4L LUV)

Fig. 110: Identifying Engine Coolant Air Bleed Hose

Engine Coolant Air Bleed Hose Replacement (1.4L LUV)
Callout
Component Name
Engine Coolant Air Bleed Hose Clamp
1
2
3
Procedure
Engine Coolant Air Bleed Hose Connector
Procedure
Unlock / lock engine coolant air bleed hose connector.
Engine Coolant Air Bleed Hose
ENGINE COOLANT AIR BLEED HOSE REPLACEMENT (1.8L LUW AND LWE)
NOTE:
The engine coolant air bleed hose is the same part like the throttle body heater
outlet hose.
Remove and install the engine coolant air bleed hose. Refer to Throttle Body Heater Outlet Hose
Replacement.

WATER OUTLET REPLACEMENT

Removal Procedure
2. Remove the charge air cooler outlet air hose from the throttle body. Refer to Charge Air Cooler Outlet
3. Remove the engine coolant air bleed hose from the water outlet. Refer to Engine Coolant Air Bleed
Hose Replacement (1.8L LUW and LWE), Engine Coolant Air Bleed Hose Replacement (1.4L
LUV).
4. Remove the heater inlet hose from the water outlet. Refer to Heater Inlet Hose Replacement (1.8L
LUW and LWE) , Heater Inlet Hose Replacement (1.4L LUV) .
5. Remove the radiator inlet hose from the water outlet. Refer to Radiator Inlet Hose Replacement (1.4L
LUV), Radiator Inlet Hose Replacement (1.8L LUW and LWE).
6. Remove the engine oil cooler inlet hose from the water outlet. Refer to Engine Oil Cooler Inlet Hose
Replacement.
7. Disconnect the engine coolant temperature sensor (water outlet) wiring harness connector.

Fig. 111: Water Outlet

8. Remove the 3 water outlet bolts (3).
9. Remove the water outlet (2) and the water outlet seal ring (1).

Fig. 112: Water Outlet

2. Install the water outlet (2) and a NEW water outlet seal ring (1).
3. Install the 3 water outlet bolts (3) and tighten to 8 N.m (71 lb in).
4. Connect the engine coolant temperature sensor (water outlet) wiring harness connector.
5. Install the engine oil cooler inlet hose to the water outlet. Refer to Engine Oil Cooler Inlet Hose
Replacement.
6. Install the radiator inlet hose to the water outlet. Refer to Radiator Inlet Hose Replacement (1.4L
LUV), Radiator Inlet Hose Replacement (1.8L LUW and LWE).
7. Install the heater inlet hose to the water outlet. Refer to Heater Inlet Hose Replacement (1.8L LUW
and LWE) , Heater Inlet Hose Replacement (1.4L LUV) .

8. Install the engine coolant air bleed hose to the water outlet. Refer to Engine Coolant Air Bleed Hose
Replacement (1.8L LUW and LWE), Engine Coolant Air Bleed Hose Replacement (1.4L LUV).
9. Install the charge air cooler outlet air hose to the throttle body. Refer to Charge Air Cooler Outlet Air
Hose Replacement (Automatic Transmission) , Charge Air Cooler Outlet Air Hose Replacement
(Manual Transmission) .
WATER PUMP PULLEY REPLACEMENT (1.4L LUV)
Removal Procedure
1. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement .
2. Remove the engine mount bracket. Refer to Engine Mount Bracket Replacement - Right Side .
3. Remove the drive belt. Refer to Drive Belt Replacement .

Fig. 113: Water Pump Pulley

4. Loosen the 3 water pump pulley bolts (2) while holding the water pump pulley hub with a wrench.
5. Remove the 3 water pump pulley bolts (2).
6. Remove the water pump pulley (1).

1. Install the water pump pulley (1).
2. Install the 3 water pump pulley bolts (2).

3. Tighten the 3 water pump pulley bolts to 22 N.m (16 lb ft) while holding the water pump pulley hub with
a wrench.
4. Install the drive belt. Refer to Drive Belt Replacement .
5. Install the engine mount bracket. Refer to Engine Mount Bracket Replacement - Right Side .
6. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement .
WATER PUMP PULLEY REPLACEMENT (1.8L LUW AND LWE)
Removal Procedure
1. Remove the air cleaner housing. Refer to Air Cleaner Assembly Replacement (1.8L LWE) , Air
Cleaner Assembly Replacement (1.8L LUW) .
Fig. 115: Water Pump And Water Pump Pulley


NOTE:
2.
3.
4.
5.
Counterhold against crankshaft balancer bolt.
Loosen the 3 water pump pulley bolts (1).

Remove the drive belt. Refer to Drive Belt Replacement .
Remove the 3 water pump pulley bolts (1).
Remove the water pump pulley (2) from the water pump (3).

1. Install the water pump pulley (2) to the water pump (3).
3. Install the drive belt. Refer to Drive Belt Replacement .

NOTE:
Counterhold against crankshaft balancer bolt.
4. Tighten the 3 water pump pulley bolts (1) to 20 N.m (15 lb ft).
5. Install the air cleaner housing. Refer to Air Cleaner Assembly Replacement (1.8L LWE) , Air Cleaner
Assembly Replacement (1.8L LUW) .
WATER PUMP REPLACEMENT (1.4L LUV)
Removal Procedure
2. Remove the engine coolant thermostat housing from water pump. Refer to Engine Coolant Thermostat
Housing Replacement (1.4L LUV), Engine Coolant Thermostat Housing Replacement (1.8L LUW
and LWE).
3. Remove the water pump pulley. Refer to Water Pump Pulley Replacement (1.8L LUW and LWE),
Water Pump Pulley Replacement (1.4L LUV)
4. Remove the heater outlet hose from the water pump. Refer to Heater Outlet Hose Replacement (1.8L
LUW) , Heater Outlet Hose Replacement (1.4L LUV) , Heater Outlet Hose Replacement (1.8L
LWE) .

Fig. 117: Water Pump, Bolts And Gasket

5. Remove the 5 water pump bolts (4) and the 5 long engine front cover bolts (3).
6. Remove the water pump (2).
7. Remove and DISCARD the water pump gasket (1).

Fig. 118: Water Pump And Engine Front Cover Bolts

2. The water pump and engine front cover bolts are located as followed:
Engine front cover special bolt without cone end 60 mm (2.362 in) (1).
Engine front cover standard bolt with cone end 52 mm (2.047 in) (2).
Water pump bolt 25 mm (0.984 in) (3).


3. Install the water pump (2) and a NEW water pump gasket (1).
4. Install the 5 water pump bolts (4) and the 5 engine front cover bolts (3) and tighten in a cross sequence to
8 N.m (71 lb in).
5. Install the heater outlet hose from the water pump. Refer to Heater Outlet Hose Replacement (1.8L
LUW) , Heater Outlet Hose Replacement (1.4L LUV) , Heater Outlet Hose Replacement (1.8L
LWE) .
6. Install the water pump pulley. Refer to Water Pump Pulley Replacement (1.8L LUW and LWE),
Water Pump Pulley Replacement (1.4L LUV).
7. Install the engine coolant thermostat housing to the water pump. Refer to Engine Coolant Thermostat

Housing Replacement (1.4L LUV), Engine Coolant Thermostat Housing Replacement (1.8L LUW
and LWE).
WATER PUMP REPLACEMENT (1.8L LUW AND LWE)
Removal Procedure
2. Remove the water pump pulley. Refer to Water Pump Pulley Replacement (1.8L LUW and LWE),
Fig. 120: Water Pump And Bolts


3. Remove the 5 water pump bolts (2).

5. Remove and DISCARD the water pump seal ring.
1. Clean the 5 water pump threads.

2. Clean the water pump sealing surface.
3. Insert a NEW water pump seal ring.

4. Install the water pump (1).

5. Install the 5 water pump bolts (2) and tighten to 8 N.m (71 lb in).
6. Install the water pump pulley. Refer to Water Pump Pulley Replacement (1.8L LUW and LWE),
7. Refill the cooling system. Refer to Cooling System Draining and Filling (Static Fill), Cooling System
ENGINE COOLANT FAN SHROUD REPLACEMENT
Removal Procedure
NOTE:
It is not necessary to remove the hood latches and wiring clips from the
front end upper tie bar for this procedure.
1. Remove and reposition the front end upper tie bar rearward. Refer to Front End Upper Tie Bar
Replacement .
5. Position the radiator assembly forward for engine coolant fan shroud access.

6. Disconnect the engine coolant fan resistor wiring harness plug (1) and remove the ground cable nut.
7. Remove the wiring harness (3) and clips.


8. Unclip the engine coolant fan shroud (1) at the four mounting points shown.
9. Remove the engine coolant fan shroud (1).
1. Slide the engine coolant fan shroud (1) toward the right side of the vehicle.
2. Lift the left hand side of the engine coolant fan shroud (1) up.
3. Remove the engine coolant fan shroud (1) from the vehicle.


1. Install the engine coolant fan shroud (1).
1. Lower the right hand side of the engine coolant fan shroud (1) behind the radiator.
2. Slide the engine coolant fan shroud (1) toward the left side of the vehicle.
2. Clip in the engine coolant fan shroud (1) at the four mounting points shown.

3. Connect the engine coolant fan resistor wiring harness connector (1).
4. Install the wiring harness (3) and clips.
5.
6.
7.
8.
Install the front end upper tie bar. Refer to Front End Upper Tie Bar Replacement .
Install the left and right side radiator air baffles.
Install the radiator upper air seal.
Connect battery negative cable. Refer to Battery Negative Cable Disconnection and Connection .
RADIATOR REPLACEMENT (1.4L LUV WITH AUTOMATIC TRANSMISSION)

Removal Procedure
1. Remove the charge air cooler. Refer to Charge Air Cooler Replacement (Automatic Transmission),
Charge Air Cooler Replacement (Manual Transmission).
3. Disconnect the radiator outlet hose and the radiator inlet hose from the radiator. Refer to Radiator Outlet
Hose Replacement (1.8L LUW and LWE), Radiator Outlet Hose Replacement (1.4L LUV), and
Radiator Inlet Hose Replacement (1.4L LUV), Radiator Inlet Hose Replacement (1.8L LUW and
LWE).
4. Remove the transmission fluid cooler inlet pipe from the radiator. Refer to Transmission Fluid Cooler
Inlet Pipe Replacement (1.4L LUV) .
5. Remove the transmission fluid auxiliary cooler pipe. Refer to Transmission Fluid Cooler Hose/Pipe
Replacement .
6. Use care and lay the transmission fluid cooler aside. Fix it in a suitable position so that the radiator is easy
accessible.
7. Unclip the engine coolant fan shroud from the radiator.

Fig. 126: Radiator Upper Bracket And Bolts

8. Remove the 2 radiator upper bracket bolts (1) and the 2 radiator upper brackets (2).

Fig. 127: Radiator And Lower Bracket

9. Remove the radiator (1) from the 2 lower brackets (2).
10. Use care and rotate the radiator in order to gain more access for the removal.
11. Use care and lift the radiator up and away from the vehicle.


1. Use care and install the radiator (1).
2. Use care and rotate the radiator in order to get more access for the installation.
3. Install the radiator (1) to the 2 lower brackets (2).


4. Install the 2 radiator upper brackets (2).
5. Install the 2 radiator upper bracket bolts (1) and tighten to 22 N.m (16 lb ft).
6. Clip the engine coolant fan shroud to the radiator.
7. Install the transmission fluid auxiliary cooler pipe. Refer to Transmission Fluid Cooler Hose/Pipe
Replacement .
8. Install the transmission fluid cooler inlet pipe to the radiator. Refer to Transmission Fluid Cooler Inlet
Pipe Replacement (1.4L LUV) .
9. Connect the radiator outlet hose and the radiator inlet hose to the radiator. Refer to Radiator Outlet Hose
Replacement (1.8L LUW and LWE), Radiator Outlet Hose Replacement (1.4L LUV), and Radiator

Inlet Hose Replacement (1.4L LUV), Radiator Inlet Hose Replacement (1.8L LUW and LWE).
10. Fill and bleed the cooling system. Refer to Cooling System Draining and Filling (Static Fill), Cooling
11. Install the charge air cooler. Refer to Charge Air Cooler Replacement (Automatic Transmission),
RADIATOR REPLACEMENT (1.4L LUV WITH MANUAL TRANSMISSION)
Removal Procedure
1. Remove the charge air cooler. Refer to Charge Air Cooler Replacement (Automatic Transmission),
LWE).








8. Fill and bleed the cooling system. Refer to Cooling System Draining and Filling (Static Fill), Cooling
9. Install the charge air cooler. Refer to Charge Air Cooler Replacement (Automatic Transmission),


RADIATOR REPLACEMENT (1.8L LUW AND LWE)
Removal Procedure
Connection .
4. Remove the front intake air duct deflector.
Fig. 134: Intake Air Duct And Bolt

5. Remove the front intake air duct bolt (2).

6. Remove the front intake air duct (1).

7. Remove the radiator grill support. Refer to Front Grille Support Replacement .
Fig. 135: A/C Pressure Sensor Wiring Harness

8. Disconnect and unclip the A/C pressure sensor wiring harness (1).

Fig. 136: Radiator Protector Fenders

9. Remove the 2 protector fenders (2) from the charge air cooler (1).
LWE).
11. If equipped, remove the transmission fluid cooler inlet pipe from the radiator. Refer to Transmission
Fluid Cooler Inlet Pipe Replacement (1.4L LUV) .
12. If equipped, remove the transmission fluid cooler outlet pipe from the radiator. Refer to Transmission
Fluid Cooler Outlet Pipe Replacement (1.4L LUV) .






NOTE:
Handle the radiator with care.



8. If equipped, install the transmission fluid cooler inlet pipe to the radiator. Refer to Transmission Fluid
Cooler Inlet Pipe Replacement (1.4L LUV) .
9. If equipped, install the transmission fluid cooler outlet pipe to the radiator. Refer to Transmission Fluid

Cooler Outlet Pipe Replacement (1.4L LUV) .
Fig. 141: Radiator Protector Fenders

10. Install the 2 protector fenders (2) to the charge air cooler (1).

Fig. 142: A/C Pressure Sensor Wiring Harness

11. Connect and clip in the A/C pressure sensor wiring harness (1).
12. Install the radiator grill support. Refer to Front Grille Support Replacement .

Fig. 143: Intake Air Duct And Bolt

13.
14.
15.
16.
17.
18.
Install the front intake air duct (1).

Install the front intake air duct bolt (2).
Install the front intake air duct deflector.
Install the front bumper fascia. Refer to Front Bumper Fascia Replacement .
Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection .
Fill and bleed the cooling system. Refer to Cooling System Draining and Filling (Static Fill), Cooling
RADIATOR SUPPORT BRACKET REPLACEMENT

Fig. 144: Radiator Support Bracket

Radiator Support Bracket Replacement
Callout
Component Name
Radiator Support Bracket Bolt
CAUTION:
Tighten
22 N.m (17 lb ft)
Radiator Support Bracket
Procedure
Pull the radiator forward until the bracket is reachable.

COOLING FAN DESCRIPTION AND OPERATION

Low Speed Operation
The ECM applies ground at the FAN 1 control circuit for the coil side of the cooling fan relay. The energized
cooling fan relay completes a ground, through the switch side of the relay, for the coils of the cooling fan low
speed relay and the cooling fan speed control relay. The speed control relay activates and supplies B+ to the coil
side of the cooling fan high speed relay. The high speed relay remains inactive because the ECM is not
commanding the FAN 2 control circuit ON. The energized low speed relay switch closes to supply B+ through
the internal low speed resistor of the engine cooling fan motor. The result is cooling fan operation at a reduced
speed.
Medium Speed Operation
The ECM applies ground at the FAN 2 control circuit for the coil side of the cooling fan high speed, and
medium speed relays. The high speed relay remains inactive because the ECM is not commanding the FAN 1
control circuit ON. The energized medium speed relay switch closes to supply B+ through the internal medium
speed resistor of the engine cooling fan motor. The result is cooling fan operation at a medium speed.
High Speed Operation
The ECM applies ground at the FAN 1 control circuit for the coil side of the cooling fan relay. The energized
cooling fan relay completes a ground, through the switch side of the relay, for the coil of the cooling fan speed
control relay. The energized speed control relay switch closes to supply B+ to the coil side of cooling fan high
speed relay. Simultaneously, the ECM applies ground at the FAN 2 control circuit for the coil side of the
cooling fan high speed relay. The energized high speed relay switch closes to supply B+ directly to the engine
cooling fan motor, by-passing the fans internal resistors. The result is cooling fan operation at full speed.
COOLING SYSTEM DESCRIPTION AND OPERATION (1.4L LUV)
Cooling System
The cooling systems function is to maintain an efficient engine operating temperature during all engine speeds
and operating conditions. The cooling system is designed to remove approximately one-third of the heat
produced by the burning of the air-fuel mixture. When the engine is cold, the coolant does not flow to the
radiator until the thermostat opens. This allows the engine to warm quickly. Refer to the following illustration
for the components in the system and the basic flow path of the coolant.

Fig. 145: Cooling System Flow Operation

NOTE:
See arrows for coolant flow order.
The cooling system consists of the following components:
Heater (1)
Surge Tank (2)
Water Outlet (3)
Engine Oil Cooler (4)
Cooling Fan (5)
Radiator (6)
Turbocharger (7)
Engine Coolant Thermostat (8)

Engine Block (9)

Water Pump (10)
Water Pump
Fig. 146: Water Pump (1.4L LUJ)

Water pump is a component of the engine cooling system and circulated the coolant from each cooling circuit
components. This water pump consists of sealing, bearing, pulley (1) and housing (2) and is driven by the drive
belt to loose noise to water pump pulley. Water pump apply drain hole cup to cap to prevent coolant leakage for
customers. Water pump is not open impeller type but closed plastic impeller type (3) to increase the cooling
efficiency.
Thermostat

Fig. 147: Thermostat (1.4L LUJ)

The Thermostat is a regular part of the Thermostat Housing (1). The thermostat controls coolant flowing. It is a
grid controlled electronic wax pellet type. By coolant temperature and / or applying current, the wax-pellet of
the thermostat is molten what leads to the opening of the thermostat. That allows the coolant to flow through the
radiator. The electronic heating of the thermostat is controlled by the engine control unit. The thermostat begins
to open with 0V at 103C (217F) and with 12V at 80C (176F). It is fully open at 117C (243F). Whether the
thermostat opening is supported by the electronic heating or not depends on load conditions which are defined
as parameters in the grid.
Radiator
The radiator is a heat exchanger. It consists of a core and 2 tanks. The aluminum core is a tube and fin crossflow design that extends from the inlet tank to the outlet tank. Fins are placed around the outside of the tubes to
improve heat transfer to the atmosphere. The inlet and outlet tanks are a molded, high temperature, nylon
reinforced plastic material. A high temperature rubber gasket seals the tank flange edge to the aluminum core.
The tanks are clamped to the core with clinch tabs. The tabs are part of the aluminum header at each end of the

core. The radiator also has a drain cock located in the bottom of the left hand tank. The drain cock unit includes
the drain cock and drain cock seal. The radiator removes heat from the coolant passing through it. The fins on
the core transfer heat from the coolant passing through the tubes. As air passes between the fins, it absorbs heat
and cools the coolant.
Surge Tank
The surge tank is a plastic tank with a threaded pressure cap. The tank is mounted at a point higher than all
other coolant passages. The surge tank provides an air space in the cooling system that allows the coolant to
expand and contract. The surge tank provides a coolant fill point and a central air bleed location. During vehicle
use, the coolant heats and expands. The increased coolant volume flows into the surge tank. As the coolant
circulates, any air is allowed to bubble out. Coolant without air bubbles absorbs heat much better than coolant
with bubbles.
Cooling Fan
The cooling fan is mounted behind the radiator in the engine compartment. The engine cooling fan is driven by
electric power. The cooling fan draws air through the radiator to improve the transfer of heat from the coolant to
the atmosphere. As the fan blades spin, they increase the flow of air across the radiator core and across the
condenser on air condition (A/C) equipped vehicles. This helps to speed cooling when the vehicle is at idle or
moving at low speeds.
COOLING SYSTEM DESCRIPTION AND OPERATION (1.8L LUW AND LWE)
Cooling System
The cooling system's function is to maintain an efficient engine operating temperature during all engine speeds
and operating conditions. The cooling system is designed to remove approximately one-third of the heat
produced by the burning of the air-fuel mixture. When the engine is cold, the coolant does not flow to the
radiator until the thermostat opens. This allows the engine to warm quickly.

Fig. 148: Cooling System Flow Operation Diagram

NOTE:
See arrows for coolant flow order. Notice the port between cylinder head and
thermostat housing, as well as the port between cylinder block and water pump.
The cooling system consists of the following components:
Throttle Body (1)

Heater (2)
Surge Tank (3)
Engine Coolant Thermostat Housing (4)
Radiator (5)
Cooling Fan (6)
Engine Oil Cooler Housing (7)
Water Pump (8)
Cylinder Head / Cylinder Block (9)
Water Pump

Fig. 149: Water Pump And Components

Water pump is a component of the engine cooling system and circulated the coolant from each cooling circuit
components. This water pump consists of sealing, bearing, pulley (3) and housing (2) and is driven by the
crankshaft with the back of timing belt to loose noise to water pump pulley. Water pump apply drain hole cup to
cap to prevent coolant leakage for customers. Water pump is not open impeller type but closed plastic impeller
type to increase the cooling efficiency.
Thermostat

Fig. 150: View Of Thermostat And Components

Thermostat controls the flow of coolant and is mounted to the cylinder head. The thermostat contains a wax
pellet (7) that expands and contracts based on the coolant temperature, which will mechanically move the main
spring and a sealing disc to control the flow of coolant. The thermostat will begins to open electrically at 90C
(194F) and will fully open mechanically at 105C (221F).
Radiator
The radiator is a heat exchanger. It consists of a core and 2 tanks. The aluminum core is a tube and fin crossflow design that extends from the inlet tank to the outlet tank. Fins are placed around the outside of the tubes to
improve heat transfer to the atmosphere. The inlet and outlet tanks are a molded, high temperature, nylon
reinforced plastic material. A high temperature rubber gasket seals the tank flange edge to the aluminum core.
The tanks are clamped to the core with clinch tabs. The tabs are part of the aluminum header at each end of the
core. The radiator also has a drain cock located in the bottom of the left hand tank. The drain cock unit includes
the drain cock and drain cock seal. The radiator removes heat from the coolant passing through it. The fins on
the core transfer heat from the coolant passing through the tubes. As air passes between the fins, it absorbs heat
and cools the coolant.

Surge Tank
The surge tank is a plastic tank with a threaded pressure cap. The tank is mounted at a point higher than all
other coolant passages. The surge tank provides an air space in the cooling system that allows the coolant to
expand and contract. The surge tank provides a coolant fill point and a central air bleed location. During vehicle
use, the coolant heats and expands. The increased coolant volume flows into the surge tank. As the coolant
circulates, any air is allowed to bubble out. Coolant without air bubbles absorbs heat much better than coolant
with bubbles.
Cooling Fan
The cooling fans are mounted behind the radiator in the engine compartment. The engine cooling fan is driven
by electric power. The cooling fan draws air through the radiator to improve the transfer of heat from the
coolant to the atmosphere. As the fan blades spin, they increase the flow of air across the radiator core and
across the condenser on air condition (A/C) equipped vehicles. This helps to speed cooling when the vehicle is
at idle or moving at low speeds.

SPECIAL TOOLS
Illustration

EN-471
KM-471
GE-42401-A
Adapter
GE-26568
J 26568
Coolant and Battery Fluid Tester
BO-42220
J-42220
Universal 12V Leak Detection Lamp
GE-42401-A
J 42401
Radiator Cap/Surge Tank Tester Adapter

GE 47716
Vac N Fill Coolant Refill Tool
EN-6327-A
KM-6327-A
GE-42401-A
Cooling System Test Adapter

2013 ELECTRICAL Engine Electrical - Cruze
2013 ELECTRICAL
Engine Electrical - Cruze
SPECIFICATIONS
Specification
Application
Battery Ground Cable Nut
Battery Ground Cable To Battery Negative Cable
Nut
Battery Hold Down Retainer Nut
Battery Negative Cable Nut
Battery Positive Cable Nut
Battery Positive Cable To Fuse Box Nut
Battery Positive Cable Nut To Starter Cable Nut
Battery Positive Plate Nut
Battery Sensor Wiring Harness Ground Cable Bolt
Battery Sensor Wiring Harness Ground Cable Nut
Battery Tray Bolt
Generator Bolt
Generator Positive Cable Nut
Generator Wiring Harness Nut
Starter Bolt
Starter Stud
Starter Ground Cable Nut
Starter And Generator Positive Cable Nut
Starter Positive Cable Nut
Metric
9 N.m
English
80 lb in
9 N.m
80 lb in
12 N.m
4.5 N.m
4.5 N.m
9 N.m
12 N.m
12 N.m
5 N.m
11 N.m
15 N.m
35 N.m
20 N.m
7 N.m
25 N.m
25 N.m
12.5 N.m
12.5 N.m
12.5 N.m
106 lb in
40 lb in
40 lb in
80 lb in
106 lb in
106 lb in
44 lb in
97 lb in
11 lb ft
26 lb ft
15 lb ft
62 lb in
18 lb ft
18 lb ft
111 lb in
111 lb in
111 lb in

Specification
Application
Battery Ground Cable Nut
Battery Ground Cable to Battery Negative Cable
Nut
Battery Hold Down Retainer Nut
Battery Negative Cable Nut
Battery Positive Cable Nut
Metric
English
9 N.m
80 lb in
9 N.m
80 lb in
12 N.m
4.5 N.m
4.5 N.m
106 lb in
40 lb in
40 lb in

Battery Positive Cable to Fuse Box Nut

Battery Positive Cable Nut to Starter Cable Nut
Battery Positive Plate Nut
Battery Sensor Wiring Harness Ground Cable Bolt
Battery Sensor Wiring Harness Ground Cable Nut
Battery Tray Bolt
Generator Bolt
Generator Positive Cable Nut
Generator Wiring Harness Nut
Starter Bolt
Starter Stud
Starter And Generator Positive Cable Nut
9 N.m
12 N.m
12 N.m
5 N.m
11 N.m
15 N.m
35 N.m
12.5 N.m
7 N.m
25 N.m
25 N.m
20 N.m
12.5 N.m
12.5 N.m
80 lb in
106 lb in
106 lb in
44 lb in
97 lb in
11 lb ft
26 lb ft
111 lb in
62 lb in
18 lb ft
18 lb ft
15 lb ft
111 lb in
111 lb in
BATTERY USAGE
Battery Usage
Application
Cold Cranking Amperage (CCA)
Amp Hour Rating
Specification
438 A
60 Ah
GENERATOR USAGE
Generator Usage
Description
Rated Output
Load Test Output

STARTING AND CHARGING WIRING SCHEMATICS
Starting Wiring Schematics
Specification
130A (KL9)
92 A (KL9)

Fig. 1: Starting Wiring Schematics

Callout
40
40 RD/GN
CAV_1
CONN_X1
50
50_BK
2
2_RD/YE
CAV_1
CONN_X2
2_RD/YE
CAV_1
CONN_X5
625
625_YE/BK
CAV_11
Component Name
40 RD/GN
1
X1
Ground
50 BK
TBD
2 RD/YE
1
X2
2 RD/YE
1
X5
Starter Enable Relay
Control
625 YE/BK
11

CONN_X3
CAV_27
CONN_X1
139
139_VT/GY
CAV_19
VT/BU
LUV
LUV
139_VT/GY
CAV 20
VT/BU
LUV
LUV
6
6_YE
CAV_1
CONN_X1
CAV_5
CONN_X3
BK/RD
LUV
LUV
CAV_30
X3
27
X1
Run/Crank Ignition 1
Voltage
139 VT/GY
19
VT/BU
ENGINE-GAS, 4 CYL,
1.4L, MFI, DOHC,
TURBO, VVT, ALUM,
GME, E85 MAX
ENGINE-GAS, 4 CYL,
1.4L, MFI, DOHC,
TURBO, VVT, ALUM,
GME, E85 MAX
139 VT/GY
20
VT/BU
ENGINE-GAS, 4 CYL,
1.4L, MFI, DOHC,
TURBO, VVT, ALUM,
GME, E85 MAX
ENGINE-GAS, 4 CYL,
1.4L, MFI, DOHC,
TURBO, VVT, ALUM,
GME, E85 MAX
Starter Solenoid Crank
Voltage
6 YE
1
X1
5
X3
BK/RD
ENGINE-GAS, 4 CYL,
1.4L, MFI, DOHC,
TURBO, VVT, ALUM,
GME, E85 MAX
ENGINE-GAS, 4 CYL,
1.4L, MFI, DOHC,
TURBO, VVT, ALUM,
GME, E85 MAX
30

CAV_85
CAV_87
CAV_86
SD
1020
1020_WH/VT
CAV_15
CAV_4
1073
1073_WH/BK
CAV 22
CONN_X3
CAV_6
6109
6109_GY/RD
CAV 38
CONN_X3
6111
6111_YE
CAV_58
6110
6110_BK/GY
CAV 22
275
275_GN
CAV_3
CONN_X1
CAV_34
CONN_X1
1786 WH/GY
LUV
LUV
85
87
86
Serial Data
Data Communication
Schematics
1020 WH/VT
15
4
Ignition Key Resistor
Signal
1073 WH/BK
22
X3
6
Clutch Apply Sensor
Voltage Reference
6109 GY/RD
38
X3
Clutch Apply Sensor Signal
6111 YE
58
Clutch Apply Sensor Low
Reference
6110 BK/GY
22
Park Neutral Position
Switch Park Signal
275 GN
3
X1
34
X1
1786 WH/GY
ENGINE-GAS, 4 CYL,
1.4L, MFI, DOHC,
TURBO, VVT, ALUM,
GME, E85 MAX
ENGINE-GAS, 4 CYL,
1.4L, MFI, DOHC,
TURBO, VVT, ALUM,

150
150_BK
CAV_2
CONN_X1
150_BK
CAV_21
CAV_A
CONN_X2
CAV_F
CONN_X2
MF3
MZ0
MF3
MZ0
MF3
MZ0
MH8
MH8
GME, E85 MAX

Ground
150 BK
2
X1
150 BK
21
A
X2
F
X2
TRANSMISSION-MAN 6
SPD, OPEL, 76.5 MM,
4.273 1ST, 2.158 2ND,
1.302 3RD, 0.959 4TH,
0.744 5TH, 0.614 6TH,
M32-6 WR
TRANSMISSION-MAN 6
SPD, OPEL, 76.5 MM,
3.82 1ST, 0.74 6TH, (M32
WR)
TRANSMISSION-MAN 6
SPD, OPEL, 76.5 MM,
4.273 1ST, 2.158 2ND,
1.302 3RD, 0.959 4TH,
0.744 5TH, 0.614 6TH,
M32-6 WR
TRANSMISSION-MAN 6
SPD, OPEL, 76.5 MM,
3.82 1ST, 0.74 6TH, (M32
WR)
TRANSMISSION-MAN 6
SPD, OPEL, 76.5 MM,
4.273 1ST, 2.158 2ND,
1.302 3RD, 0.959 4TH,
0.744 5TH, 0.614 6TH,
M32-6 WR
TRANSMISSION-MAN 6
SPD, OPEL, 76.5 MM,
3.82 1ST, 0.74 6TH, (M32
WR)
TRANSMISSION-AUTO
6 SPD, HMD, X23F
TRANSMISSION-AUTO
6 SPD, HMD, X23F

MH9
MF3
MZ0
_WH
_GY
G100
G114
F6UD
F12UA
F5UA
C1
B15
Q8
K9
Automatic_Transmission_Controls_Schematics_REF
K71
K20
KR27
X50D
T12
M64
Power_Distribution_Schematics_REF
X50A
S39
KR73
Manual_Transmission_Schematics_REF
Charging Wiring Schematics
TRANSMISSION-AUTO
6 SPD, HMD, X24F
TRANSMISSION-MAN 6
SPD, OPEL, 76.5 MM,
4.273 1ST, 2.158 2ND,
1.302 3RD, 0.959 4TH,
0.744 5TH, 0.614 6TH,
M32-6 WR
TRANSMISSION-MAN 6
SPD, OPEL, 76.5 MM,
3.82 1ST, 0.74 6TH, (M32
WR)
WH
GY
G100
G114
F6UD 250A
F12UA 30A
F5UA 15A
(MH8/MH9)
(MH8/MH9)
Automatic Transmission
Controls Schematics
(MH8/MH9)
(MH8/MH9)
Power Distribution
Schematics
(without BTM)
Manual Transmission
Schematics

Fig. 2: Charging Wiring Schematics

Callout
50
1440
1440_RD/BN
CAV_20
CONN_X4
CAV 72
CONN_X2
5077
5077_BK/VT
CAV_B
CAV 6
CONN_X5
5075
5075_WH/YE
CAV_C
CAV_18
Component Name
Ground
1440 RD/BN
20
X4
72
X2
Current Sensor Low
Reference
5077 BK/VT
B
6
X5
Current Sensor Signal
5075 WH/YE
C
18

CONN_X4
5076
5076 BU/VT
CAV_A
CAV_21
981_BK
CAV_26
981_BK
50_BK
40
40_RD/GN
CAV_1
CONN_X1
2
2_RD/YE
CAV_1
CONN_X2
CAV 1
CONN_X5
8
8_RD/YE
CAV_A
CONN_X1
23
23_GY
CAV_2
CONN_X2
CAV_17
CONN_X3
25
25_BU/WH
CAV_1
CAV_47
CONN X1
BN
LUV
X4
Current Sensor Supply
Voltage
5076 BU/VT
A
21
981 BK
26
981 BK
50 BK
40 RD/GN
1
X1
TBD
2 RD/YE
1
X2
1
X5
Instrument Panel Lamp
Supply Voltage (1)
8 RD/YE
A
X1
Generator Field Duty Cycle
Signal
23 GY
2
X2
17
X3
Charge Indicator Control
25 BU/WH
1
47
X1
BN
ENGINE-GAS, 4 CYL, 1.4L,
MFI, DOHC, TURBO, VVT,
ALUM, GME, E85 MAX

LUW
LWE
SD
G100
F69UA
J128
F6UD
B18
G13
A90
C1
X50A
M64
K9
X50D
K20
P16
MFI, 103KW, DOHC, E85

MAX
MFI, DOHC, VVT, 103 KW,
GME
Serial Data
Data Communication
Schematics
G100
F69UA 5A
J128
F6UD 250A
Logic

DTC
Description
DTC B1325 03 Control Module Power Circuit Low

Voltage
DTC B1325 07 Control Module Power Circuit High
Voltage
DTC B1330 03 Device Power 2 Circuit Low
Voltage
DTC B1325, B1330, B1517, C0800, P0560, P0562, DTC B1517 03 Battery Voltage Low Voltage
DTC B1517 07 Battery Voltage High Voltage
or P0563
DTC B1517 5A Battery Voltage Plausibility Failure
DTC C0800 03 Control Module Power Circuit Low
Voltage
DTC C0800 07 Control Module Power Circuit High
Voltage
DTC C0800 08 Control Module Power Circuit
Voltage Signal Invalid

DTC B1516
DTC B151A
DTC B1527
DTC P0615, P0616, or P0617
DTC P0621
DTC P0622
DTC C0800 11 Control Module Power Circuit High

Input
DTC C0800 12 Control Module Power Circuit Low
Input
DTC C0800 0D Control Module Power Circuit
High Resistance
DTC P0560 System Voltage
DTC B1516 08 Battery Current Sensor Performance
- Signal Invalid
DTC B1516 66 Battery Current Sensor Incorrect
Mounting
DTC B151A 58 Battery Capacity Performance
DTC B1527 00 Parasitic Load
DTC P0615 Starter Relay Control Circuit
DTC P0616 Starter Relay Control Circuit Low
Voltage
DTC P0617 Starter Relay Control Circuit High
Voltage
DTC P0621 Generator L-Terminal Circuit
DTC P0622 Generator F-Terminal Circuit
DTC B1325, B1330, B1517, C0800, P0560, P0562, OR P0563

DTC Descriptors
DTC B1325 03
Control Module Power Circuit Low Voltage
DTC B1325 07
Control Module Power Circuit High Voltage
DTC B1330 03
Device Power 2 Circuit Low Voltage
DTC B1517 03

Battery Voltage Low Voltage

DTC B1517 07
Battery Voltage High Voltage
DTC B1517 5A
Battery Voltage Plausibility Failure
DTC C0800 03
Control Module Power Circuit Low Voltage
DTC C0800 07
Control Module Power Circuit High Voltage
DTC C0800 08
Control Module Power Circuit Voltage Signal Invalid
DTC C0800 11
Control Module Power Circuit High Input
DTC C0800 12
Control Module Power Circuit Low Input
DTC C0800 0D
Control Module Power Circuit High Resistance
DTC P0560
System Voltage
DTC P0562
System Voltage Low Voltage
DTC P0563
System Voltage High Voltage

The vehicle control modules or sensors monitor the system voltage to verify the system voltage is within the
normal operating range.

The control module or sensor detects a system voltage of less than approximately 9 V or greater than 18 V for
approximately 5 s.
A driver information center message and/or warning indicator may be displayed.

The control module may be temporarily disabled.
The system voltage returns to normal operating range.

Diagnostic Aids
A high or low voltage DTC set or voltage value in multiple modules/sensors indicates a concern in the
charging system.
A possible cause of this DTC could be overcharging with a battery charger or jump starting.
Schematic Reference


Charging System Description and Operation
Circuit Testing
Connector Repairs

Wiring Repairs
DTC Type Reference

Scan Tool Reference
Special Tools
1. Ignition OFF, measure and record the battery voltage at the battery terminals.
2. Verify the battery voltage stabilizes between 12.4 and 12.8 V within a few minutes of turning the ignition
OFF.
If battery voltage is less than 12.4 V or more than 12.8 V
Refer to Battery Inspection/Test.
If battery voltage is between 12.4 and 12.8 V
3. Engine running, headlights ON, measure and record the battery voltage at the battery terminals.
4. Verify the voltage is at least 1 V greater than the voltage measured in step 1, but less than 15 V.
If the voltage is not at least 1 V greater than the voltage measured in step 1 or is greater than
15 V.
Refer to Charging System Test.

If the voltage is at least 1 V greater than the voltage measured in step 1, but less than 15 V.
5. Verify the appropriate control module scan tool battery voltage and ignition voltage parameters are within
1 V of the battery voltage.
If not within 1 V of the battery voltage

If within 1 V of the battery voltage
6. All OK.
NOTE:

NOTE:
Control modules the vehicle is equipped with

The control module's ground, B+, and Ignition circuit terminal IDs and
connectors
Some control module ground circuits may require up to 20 min after the ignition
is turned off before achieving a resistance reading of less than 5 ohms. In most
cases the readings will drop below 20 ohms within 1 min indicating the control
module is going to sleep.
1. Ignition OFF and all vehicle systems OFF, disconnect the harness connectors at the appropriate control
module. It may take up to 2 min for all vehicle systems to power down.
1. Ignition OFF.
1. Ignition OFF.
1. Ignition OFF.
If infinite resistance, replace the appropriate control module.
4. Ignition ON.
5. If equipped, verify a test lamp illuminates between each ignition circuit terminal and ground.
1. Ignition OFF.
1. Ignition OFF.

If infinite resistance, replace the appropriate control module.
6. Replace the control module.
Repair Instructions

Control Module References for control module replacement, programming and setup
DTC B1516
DTC Descriptors
DTC B1516 08
Battery Current Sensor Performance - Signal Invalid
DTC B1516 66
Battery Current Sensor Incorrect Mounting
Circuit
5 V Reference
Signal
Low Reference
Short to
Ground
B1516 08
B1516 08
-
Open/High
Resistance
B1516 08
B1516 08
B1516 08
Short to
Voltage
B1516 08
B1516 08
-
Signal Performance
B1516 08, B1516 66
-
The battery current sensor is a 3-wire hall effect current sensor. The body control module (BCM) supplies 5 V
and ground to the battery current sensor. The battery current sensor measures the amount of current flowing to
or from the battery, and supplies a pulse width modulation (PWM) signal to the BCM.

B1516 08
The BCM is awake.
B1516 66
The BCM is awake.

The engine is OFF.
B1516 08
The battery current signal is less than 4 percent or greater than 96 percent duty cycle for 2 minutes.
B1516 66
The battery current polarity is positive for 2 minutes.
The regulated voltage control is disabled.

The DTC passes when the battery current returns to the normal range for 15 seconds.
Diagnostic Aids
DTC B1516 08 could be set by overcharging with a battery charger or jump starting.
Schematic Reference
Starting and Charging Schematics

Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference

B1516 08
1. Ignition OFF and all vehicle systems OFF, disconnect the harness connector at the B18 Battery Current
Sensor. It may take up to 2 minutes for all vehicle systems to power down.
2. Test for less than 30 ohms between the low reference circuit terminal B and ground.
3. Ignition ON.
4. Test for 4.8-5.2 V between the 5 V reference circuit terminal A and ground.
If less than 4.8 V
3. Test for less than 2 ohms in the 5V reference circuit end to end.
5. Test for 4.8-5.2 V between the signal circuit terminal C and ground.
If less than 4.8 V

6. Test or replace the B18 Battery Current Sensor.
B1516 66
1. Verify that the B18 Battery Current Sensor is installed securely around the negative battery cable, with
the tape tab pointing away from the negative terminal on the C1 Battery.
If the B18 Battery Current Sensor is not installed correctly
Remove and reinstall the B18 Battery Current Sensor properly.
If the B18 Battery Current Sensor is installed correctly
2. Replace the B18 Battery Current Sensor.
Repair Instructions
Battery Positive and Negative Cable Replacement

Control Module References for BCM replacement, programming, and setup.
DTC B151A
DTC Descriptor

DTC B151A 58
Battery Capacity Performance
The body control module (BCM) monitors the battery voltage level during an engine crank event to detect a low
battery voltage condition.
The vehicle is ON
A minimum crank battery voltage is less than the minimum crank battery voltage threshold for 16 consecutive
crank events.
A driver information center message is displayed.

The DTC will clear if the minimum crank voltage is greater than the minimum crank voltage threshold during a
crank event.
Schematic Reference
Circuit Testing
Connector Repairs
Wiring Repairs

Scan Tool Reference

1. Verify DTC P0621 or P0622 is not set.

If DTC P0621 or P0622 is set
Refer to DTC P0621, or DTC P0622
If DTC P0621 or P0622 is not set
2. Perform the Battery Inspection/Test.
DTC B1527
DTC Descriptor
DTC B1527 00
Parasitic Load
The body control module (BCM) monitors the state of charge of the electrical system.
The ignition is in Accessory or Run mode.

The state of charge at ignition ON is 30% lower than when the engine was running and battery drain is more
than 2 A.
There is no battery telltale illuminated or DIC message displayed.


The DTC will clear if the fault does not return after 50 consecutive ignition cycles.
The DTC will clear when run state of charge is greater than or equal to 80%.
Schematic Reference
Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference

Refer to Battery Electrical Drain/Parasitic Load Test.

DTC P0615, P0616, OR P0617
DTC Descriptors
DTC P0615
Starter Relay Control Circuit

DTC P0616
Starter Relay Control Circuit Low Voltage
DTC P0617
Starter Relay Control Circuit High Voltage
Circuit
Control
Ground
Short to
Ground
P0616
-
Open/High
Resistance
P0615
P0615
Short to
Voltage
P0617
-
Signal Performance
-
When the ignition switch is placed in the CRANK position, a discrete signal is supplied to the body control
module (BCM) notifying it that the ignition is in the CRANK position. The BCM then sends a message to the
engine control module (ECM) that crank has been requested. The ECM then verifies that the clutch pedal is
depressed or the transmission is in Park/Neutral. If it is, the ECM then supplies 12 V to the control circuit of the
starter relay. When this occurs, battery voltage is supplied through the switch of the starter relay to the starter
motor.
The ignition is in the CRANK position.

The system voltage is between 9.5-18 V.
The ECM detects improper voltage on the control circuit of the starter relay.
DTC P0615, P0616, and P0617 are C type DTCs.

DTC P0615, P0616, and P0617 are C type DTCs.

Schematic Reference


Starting System Description and Operation
Circuit Testing
Connector Repairs
Wiring Repairs
DTC Type Reference

Scan Tool Reference
1. Ignition OFF and all vehicle systems OFF, disconnect the KR27 Starter Relay. It may take up to 2
1. Ignition OFF.
3. Ignition ON.
1. Ignition OFF.
If less than 2 ohms, verify the fuse is good and there is voltage at the fuse.

5.
6.
7.
8.
9.
1. Ignition OFF.
If infinite resistance, replace the KR27 Starter Relay.
Connect a test lamp between the control circuit terminal 85 and the ground circuit terminal 86.
Verify the test lamp turns ON and OFF when commanding the KR27 Starter Relay ON and OFF with a
scan tool.
terminal 87.
Verify the M64 starter motor is activated.
If the M64 starter motor does not activate
1. Ignition OFF, disconnect the X1 harness connector at the M64 starter motor.
2. Test for infinite resistance between the control circuit terminal X1 1 and ground.
If less than 2 ohms, replace the M64 starter motor.
If the M64 starter motor activates
Test or replace the KR27 Starter Relay.

Component Testing
Relay Test
1. Ignition OFF, disconnect the KR27 Starter Relay.
If less than 60 or greater than 180 ohms
Replace the relay.
30 and 86
30 and 87
30 and 85
85 and 87
Replace the relay.

Replace the relay.

If less than 2 ohms
6. All OK
Repair Instructions
Starter Replacement (1.4L LUV), Starter Replacement (1.8L LUW and LWE)
Control Module References for ECM replacement, programming, and setup.
DTC P0621


DTC Descriptor
DTC P0621
Generator L-Terminal Circuit
Circuit
B+
Control - L Terminal
Signal - F Terminal
Short to
Ground
P0622
P0621
P0622
Open/High
Resistance
P0621
P0621
P0622
Short to
Voltage
P0621
P0622
Signal Performance
P0622
The engine control module (ECM) uses the generator turn ON control circuit to control the load of the generator
on the engine. A high side driver in the ECM applies a duty cycled voltage to the voltage regulator. The duty
cycle controls the voltage regulator to turn the field circuit ON and OFF. The ECM monitors the state of the
generator turn ON control circuit. The ECM should detect low voltage on the generator turn on control circuit
when the ignition is ON and the engine is OFF, or when the charging system malfunctions. With the engine
running, the ECM should detect high voltage when the duty cycle voltage is commanded high and a low voltage
when the duty cycle voltage is commanded low. on the generator turn on control circuit.
Ignition ON, engine OFF (Prior to Ignition ON, the ignition must have been OFF for at least 5 seconds)
The engine is running for the run test
Ignition ON, engine OFF - The ECM detects greater than 3.5 V on the generator control circuit for 5
seconds
Engine running - The ECM detects a low voltage for 15 seconds on the generator control circuit when the
duty cycle voltage is commanded high
Engine running - The ECM detects a high voltage for 15 seconds on the generator control circuit when
the duty cycle voltage is commanded low
DTC P0621 is a C type DTC


Ignition ON, engine OFF- Low voltage

Engine running - A control signal duty cycle is detected
Schematic Reference
Circuit Testing
Connector Repairs
Wiring Repairs
DTC Type Reference

Scan Tool Reference
If the DTC sets
3. All OK.

1. Verify a test lamp illuminates between the G13 Generator B+ circuit terminal A X1 and ground.
1. Remove the test lamp and disconnect the B+ cable at the G13 Generator.
1. Remove the test lamp, disconnect the battery negative cable, and disconnect the G13 Generator B+
cable.
2. Disconnect the X2 harness connector at the G13 Generator, ignition ON.
3. Test for 3.0- 5.5 V between the control circuit terminal 1 and ground.
If less than 3.0 V
1. Ignition OFF, disconnect the harness connectors at the K20 Engine Control Module.
If greater the 2 ohms, repair the open/high resistance in the circuit.
1. Ignition OFF, disconnect the harness connectors at the K20 Engine Control Module, Ignition ON.
If greater than 1 V, repair the short to voltage on the circuit.
4. Test or replace the G13 Generator.
Repair Instructions
Generator Replacement (1.4L LUV), Generator Replacement (1.8L LUW and LWE)
Control Module References for Engine Control Module replacement, programming, and setup
DTC P0622

DTC Descriptor
DTC P0622
Generator F-Terminal Circuit
Circuit
B+
Signal - F Terminal
Short to
Ground
P0622
P0621
P0622
Open/High
Resistance
P0621
P0621
P0622
Short to
Voltage
P0621
P0622
Signal Performance
P0622
The engine control module (ECM) uses the generator field duty cycle signal circuit, or F-terminal circuit, to
monitor the duty cycle of the generator. The generator field duty cycle signal circuit connects to high side of the
field windings in the generator. A pulse width modulated (PWM) high side driver in the voltage regulator turns
the field windings ON and OFF. The ECM uses the PWM signal input to determine the generator load on the
engine. This allows the ECM to adjust the idle speed to compensate for high electrical loads. The ECM
monitors the status of the generator field duty cycle signal circuit. When the ignition is ON and the engine is
OFF, the ECM should detect a duty cycle near 0%. When the engine is running, the duty cycle should be
between 5-99%.
Ignition ON, engine OFF (Prior to Ignition ON, the ignition must have been OFF for at least 5 seconds)
Engine running at less than 3, 000 RPM
DTC P0621 is not set.

Ignition ON, engine OFF (Prior to Ignition ON, the ignition must have been OFF for at least 5 seconds),
the ECM detects a PWM signal that is greater than 65% for 5 seconds
Engine running at less than 3, 000 RPM - The ECM detects a PWM signal that is less than 5% for 30
seconds
DTC P0622 is a C type DTC

Ignition ON, Engine OFF - Low / no PWM signal detected

Engine running - A 5-90% duty cycle is detected
Schematic Reference
Circuit Testing
Connector Repairs
Wiring Repairs
DTC Type Reference

Scan Tool Reference
NOTE:
Do not have a battery charger connected during the generator testing.
1. Engine running.
2. Verify the scan tool Engine Control Module Generator F-Terminal Signal parameter is between 5-90%.
If not between 5-90%
If between 5-90%

3. Verify the scan tool Engine Control Module Generator F-Terminal Signal parameter changes when
commanding the headlamps ON and OFF.
If the DTC sets

6. All OK.
cable.
If infinite resistance, test or replace the G13 Generator.
2. Disconnect the X2 harness connector at the G13 Generator, engine running.
3. Verify the scan tool Engine Control Module Generator F-Terminal Signal parameter is less than 5%.
If 5% or greater
If less than 5%
4. Install a 3 A fused jumper wire between the signal circuit terminal 2 and B+, engine running.

5. Verify the scan tool Engine Control Module Generator F-Terminal Signal parameter is greater than 95%.
If 95% or less
Module.
If 2 ohms or greater, repair the open/high resistance in the circuit
If greater than 95%
Repair Instructions
SYMPTOMS - ENGINE ELECTRICAL

NOTE:
Perform Diagnostic System Check - Vehicle before using the Symptom Tables in order to verify that all
of the following are true:
Review the system descriptions and operations in order to familiarize yourself with the system functions.
Refer to one of the following system operations:
Battery Description and Operation
Electrical Power Management Description and Operation
Inspect for aftermarket devices which could affect the operation of the starting and charging systems.
Refer to Checking Aftermarket Accessories .
cause the symptom.

Intermittent
Symptom List
Battery Inspection/Test
Battery Electrical Drain/Parasitic Load Test
Charging System Test
Generator Noise Diagnosis
Starter Solenoid Does Not Click
Starter Solenoid Clicks, Engine Does Not Crank
Engine Cranks Slowly
Starter Noise Diagnosis
BATTERY INSPECTION/TEST
Diagnostic Aids
NOTE:
For Warranty repairs You must use regionally required battery test equipment for warranty repairs.
For accurate test results the battery must be disconnected from the vehicle and
the equipment connected directly to the battery posts. When setting up the
equipment, select "Out of Vehicle" and then the correct battery type (Flooded or
AGM) and rated CCA (both from the battery label) must be entered.
Failure to obtain the correct connections during the test may result in a
failed test on a good battery.
Use the Out of Vehicle test (both batteries disconnected with test
equipment connected directly to the post) test for each battery when
testing a vehicle with dual batteries.
Follow these instructions in order to avoid an incorrect diagnosis because of connections:

If testing the vehicle with the battery cables still connected, wiggle the battery tester clips on the terminal.
This may cut through any coating or through any oxidation that may be present on the terminal.
If correct connections to the battery terminals in the vehicle are in doubt, perform the following steps:
1. Disconnect the negative battery cable.
2. Disconnect the positive battery cable.
3. Follow the instructions for testing a removed battery.
If the tester displays a REPLACE BATTERY or BAD CELL-REPLACE result for a battery tested in the
vehicle with the battery cables connected, perform the following steps:
1. Disconnect the negative battery cable.
2. Disconnect the positive battery cable.
NOTE:
Always write the test code displayed by the tester on the repair order
for any warranty purposes. The number is a unique code that
describes the test data for a particular battery at a particular time.
The test code may occasionally repeat when you retest the same
battery. More often, each test will result in a different code. Use the
test code from the second, or Out of Vehicle test.
3. Follow the instructions for testing a removed battery.

4. Replace the battery only if the second test shows a REPLACE BATTERY or BAD CELLREPLACE result.
Use the test code from the second test for any warranty purposes.
Schematic Reference
Circuit Testing
Connector Repairs
Wiring Repairs

Scan Tool Reference

Special Tools
Battery Tester, for regionally available devices, refer to Special Tools.
WARNING: Unless directed otherwise, the ignition and start switch must be in the
OFF or LOCK position, and all electrical loads must be OFF before
servicing any electrical component. Disconnect the negative battery cable
to prevent an electrical spark should a tool or equipment come in contact
with an exposed electrical terminal. Failure to follow these precautions
may result in personal injury and/or damage to the vehicle or its
components.
For Vehicles equipped with OnStar (UE1) with Back Up Battery:
The Back Up Battery is a redundant power supply to allow limited
OnStar functionality in the event of a main vehicle battery power
disruption to the VCIM (OnStarmodule). Do not disconnect the main
vehicle battery or remove the OnStar fuse with the ignition key in any
position other than OFF. Retained accessory power should be allowed to
time out or be disabled (simply opening the driver door should disable
retained accessory power) before disconnecting power. Disconnecting
power to the OnStar module in any way while the ignition is On or with
retained accessory power activated may cause activation of the OnStar
Back-Up Battery system and will discharge and permanently damage the
back-up battery. Once the Back-Up Battery is activated it will stay on until
it has completely discharged. The back-up battery is not rechargeable and
once activated the back-up battery must be replaced.
1. Verify the C1 Battery case is not cracked, broken, or damaged, which may be indicated by battery acid
leakage.
If there is any apparent damage
Replace the C1 Battery.
If there is no damage
2. Verify the cold cranking amperage and amperage hour rating of the C1 Battery. Refer to the manufacturer
specifications on the battery label.
If the C1 Battery does not meet specifications
Replace the C1 Battery.

If the C1 Battery meets specifications

3. Verify that the battery cables are clean and tight. The battery terminal bolts should be torqued as specified
in Fastener Tightening Specifications (1.8L LUW and LWE), Fastener Tightening Specifications
(1.4L LUV).
If the battery cables need to be cleaned or tightened
Clean as required and tighten as specified.

If the battery cables are clean and tight
4. Install the battery tester and follow directions supplied by the tester.
Repair Instructions

Battery Replacement
BATTERY CHARGING
Special Tools
EL 50313 Battery Tester

Diagnostic Aids
For best results, use an automatic taper-rate battery charger with a voltage capability of 16 V.
The charging area should be well ventilated.
Do not charge a battery that appears to be frozen. Allow the battery to warm to room temperature and test
it using the EL 50313 before charging.
Battery State of Charge
NOTE:
Using voltage to determine the batteries state of charge is only accurate after
the battery has been at rest for 24 hours. This is enough time for the acid in
each cell to equalize. If the battery has been charged or discharged in the past
24 hours, the battery state of charge will only be an estimate.
The maintenance-free batteries state of charge is estimated by reading the voltage of the battery across the
battery terminals. Because the voltage is affected by current flow into or out of the battery, the engine must be
stopped and all electrical loads turned OFF, including parasitic loads, when checking the voltage. The voltage
can also be affected if the battery has just been charged or discharged, so it is important to consider what has
happened to the battery in the time just before testing. Use the following procedure to determine the battery's
state of charge:

1. Be sure all electrical loads are turned OFF.

2. Determine whether the battery has been used in a vehicle or charged within the past 12 hours.
If the answer is no, the terminal voltage will be stabilized and no action is necessary before reading
the voltage. Skip to step 3.
If the answer is yes, terminal voltage will not be stabilized 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 past 12 hours.
NOTE:
The table is accurate to 10 % only after the battery has been at rest for 12
hours.
4. Measure the battery voltage at the battery terminals. Refer to the following table to determine the state of
charge according to the estimated battery temperature:
Battery Voltage
12.75 V
12.7 V
12.6 V
12.45 V
12.2 V
12.0 V
% Charge at 0C (32F)
100%
100%
90%
75%
65%
40%
% Charge at 25C (75F)

100%
90%
75%
65%
45%
20%
Use the state of charge information as follows:
A battery with a state of charge that is below 65% must always be recharged before returning it to service
or continuing storage.
A battery with a state of charge that is 65% or greater is generally considered to be charged enough in
order to be returned to normal service or in order to continue storage. However, if the battery is being
used in slow traffic or with short drive times, or if the temperature is very hot or very cold, the battery
should be fully charged, to at least 90%, before returning it to service or continuing storage.
Charging Time Required
The time required to charge a battery will vary depending upon the following factors:
The battery charger capacity-The higher the charger amperage, the less time it will take to charge the
battery.
The state of charge of the battery-A completely discharged battery requires more than twice as much
charging time as a half charged battery. In a discharged battery with a voltage below 11 V, the battery has
a very high internal resistance and may only accept a very low current at first. Later, as the charging
current causes the acid content to increase in the electrolyte, the charging current will increase. Extremely
discharged batteries may not activate the reversed voltage protection in some chargers. Refer to the
manufacturer's instructions for operating this circuitry.

The temperature of the battery-The colder the battery is, the more time it takes to recharge the battery.
The charging current accepted by a cold battery is very low at first. As the battery warms, the charging
current will increase.
Charging Procedure
CAUTION: Turn OFF the ignition when connecting or disconnecting the battery
cables, the battery charger or the jumper cables. Failure to do so may
damage the ECM/PCM or other electronic components.
When charging side-terminal batteries with the battery cables connected, connect the charger to the positive
cable bolt and to a ground located away from the battery. When charging side-terminal batteries with the battery
cables disconnected, install the battery side terminal adapters and connect the charger to the adapters.
Tighten
Tighten the battery side terminal adapters to 15 (11 lb ft).
Use the following procedure to charge the battery:
1. Turn OFF the charger.
2. Ensure that all of the battery terminal connections are clean and tight.
3. Connect the charger positive lead to the battery positive terminal on the battery or the remote jumper stud
underhood.
CAUTION: Do not connect the negative charger lead to the housings of other
vehicle electrical accessories or equipment. The action of the battery
charger may damage such equipment.
4. Connect the negative charger lead to a solid engine ground or to a ground stud in the engine compartment
that is connected directly to the battery negative terminal, but away from the battery. If the negative
battery cable is disconnected and a terminal adapter is being used, connect directly 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-rate charger indicates that the battery is fully charged.
Estimate the battery temperature by feeling the side of the battery. If it feels hot to the touch or its
temperature is over 45C (125F), discontinue charging and allow the battery to cool before
resuming charging.
7. After charging, test the battery. Refer to Battery Inspection/Test.
BATTERY ELECTRICAL DRAIN/PARASITIC LOAD TEST

12 V Battery
The following procedure is for the 12 V battery only.

Components most likely to cause a parasitic draw on the vehicles battery are switches, relays, and control
modules. After the ignition is turned OFF the control modules will begin to go to sleep shut OFF). All control
modules do not go to sleep at the same time, some may take up to 30 min or longer after turning the ignition off
before going to sleep, like the HVAC and body control modules. Others such as the ON Star and keyless entry
control modules may periodically wake up then go back to sleep. These are all normal conditions.
Diagnostic Aids
Rule out any possible aftermarket equipment causing an unacceptable parasitic current drain. Aftermarket
accessories installed into the courtesy lamp circuit can cause the inadvertent power timer in the body
control module (BCM) to keep resetting. This may cause the BCM to remain awake and cause a current
drain on the battery.
Rule out customer driving habits such as regular short trips that do not allow enough time to properly
charge the battery. Refer to Battery Description and Operation.
Verify that the battery and charging system are in proper working order. Refer to Battery Charging, and
Charging System Test.
A battery discharging for no apparent reason while the vehicle is parked can be caused by an intermittent
draw, such as a module waking up, or a continuous draw, such as a dome light or stuck relay.
Some systems and modules such as OnStar, and regulated voltage control, if equipped, are designed to
wake up, perform a task, and go back asleep at regular intervals. Refer to Body Control System
Description and Operation for the system or modules description and operation.
An engine off natural vacuum evaporative test can occur if the engine control module ECM) determines
the drive cycle has met the appropriate criteria immediately after key off. The ECM will stay awake and
the vent solenoid will stay energized for as long as 45 min. The typical current draw for this is about 1 A.
Digital OnStar generation 6 and later vehicle communication interface module do not "wake up" every 10
min for the first 48 h as the generation 5 and prior. generation 6 and later vehicle communication interface
module current draw is very low, less than 40 mA, so the OnStar system is left in that state for up to the
first 48 h. Parasitic draw of up to 40 mA with an occasional spike as high as 80 mA through the vehicle
communication interface module for the first 48 h is normal.
Some automatic climate control systems can remain in a semi awake state for up to three hours, actual
draw amounts vary by vehicle platform but are typically not greater than 50 mA.
An extremely low mA current level is consumed by the remote keyless entry receiver for monitoring
purposes, actual system wake up only occurs when the fobs for the vehicle are used. When other devices
on the same remote keyless entry operating frequency are activated, such as the 4 tire pressure monitoring

sensors and other vehicle FOBs in the vicinity, the remote keyless entry receiver will have a 100 mA
spike. These spikes are normal and occur too briefly to have a significant effect on battery drain.
Competing signals may cause remote keyless entry performance issues such as jamming but should not
cause excessive battery draw.
If an excessive current draw is not present during initial testing, continue periodic testing over a 1-2 hour
period to see if the current draw increases and stays above an unacceptable level.
NOTE:
The battery specification listed below is a generic specification. Refer to

the label on the original battery when testing the battery.
The battery run down time will vary depending on the batteries reserve capacity. If the reserve capacity is
higher, then the battery run down time may be longer. If the reserve capacity is lower, then the battery run
down time may be shorter. The graph below indicates roughly how many days a 690 cold cranking
amperage battery with a 110 min reserve capacity starting at 80% state of charge will last with a constant
current draw until it reaches 50% state of charge. Differences in battery reserve capacity and temperature
will affect the results.
Current Drain
25 mA
50 mA
75 mA
100 mA
250 mA
500 mA
750 mA
1A
2A
Schematic Reference
Circuit Testing
Connector Repairs
Wiring Repairs
Days
33
16.5
11
8.25
3.3
1.65
1
0.8
0.4

Scan Tool Reference

Special Tools
EL 38758 Parasitic Draw Test Switch
NOTE:
Most vehicle systems will go to sleep within 30 min but it can take up to 2
h before all systems power down allowing the parasitic draw test to pass.
An occasional increase in the parasitic draw is normal as long as it returns
within 1 s.
Closing the door latches/ajar switch while leaving the doors open is
recommended, this allows the vehicle systems to perform in a "doors
closed" mode while allowing vehicle interior access that may be needed to
complete the diagnostic steps.
Locking doors will arm the vehicle content theft deterrent system if
equipped. Failure to arm the system may cause a theft system fault to not
be present during testing.
There are many things that can prevent the vehicle from completely going
to sleep and passing the parasitic draw test. Make sure all the conditions
listed below are met before performing the parasitic current draw test.
Ignition OFF
Key out of the ignition switch - when not equipped with keyless
access and start
Retained Accessory Power OFF - open and close the driver door after
ignition OFF
Scan tool not communicating with a vehicle control module - in some
cases it may need to be disconnected from the DLC
All access doors closed
Headlamps OFF - auto headlamps disabled
Any delay lighting OFF
If equipped with an under hood lamp disable it
HVAC after blow OFF
Any accessory that can work with ignition OFF inactive or OFF
Wait up to 2 min or longer, after all other listed conditions are met
Using an Inductive Pickup Probe

1. Connect an inductive pickup probe to the negative battery cable that can read down to 1 mA.
2. Ignition OFF, as the vehicle systems shut down test for less than 30 mA of parasitic current drain.
If greater than the specified range, refer to Circuit/System Testing below.
Using the EL 38758 Parasitic Draw Test Switch
WARNING: Refer to Battery Disconnect Warning .
CAUTION: When a fused jumper wire or digital multimeter is connected to the

test switch terminals, always turn the test switch ON before opening
any access door, turning the ignition on, or turning any accessory
on. This is to prevent damaging the jumper wire or digital multimeter
fuse.
NOTE:
The switch knob on the EL 38758 switch is marked ON and OFF. When the
switch knob is in the ON position, the circuit is closed and electrical
current will pass through the switch. When the switch knob is in the OFF
position, the circuit is open and electrical current will not pass through the
switch.
1. Ignition OFF, disconnect the battery negative cable from the battery. Refer to Battery Negative Cable
Disconnection and Connection.
2. Turn the EL 38758 switch knob to the OFF position.
3. Install the male end of the EL 38758 switch to the battery ground terminal.
4. Install the battery negative cable to the female end of the EL 38758 switch.
5. Turn the EL 38758 switch knob to the ON position.
6. Road test the vehicle and activate all of the accessories such as the radio and air conditioning.
7. Ignition OFF, connect a 10 A fused jumper wire to the test switch tool terminals.
8. Turn the EL 38758 switch knob to the OFF position. The current now flows through the jumper wire.
9. Check the fuse in the jumper wire. The fuse should be OK.
Failed: If the jumper wire fuse is blown, refer to Circuit/System Testing below.
Passed
10. Turn the EL 38758 switch knob to the ON position. Remove the fused jumper wire.
11. Connect a DMM set to the 10 A DC scale between the test switch tool terminals.
12. Turn the EL 38758 switch knob to the OFF position. The current now flows through the DMM.
13. As the vehicle systems shut down test for less than 30 mA of parasitic current drain.
If greater than the specified range, refer to Circuit/System Testing below.

NOTE:
Removing or installing a fuse, relay, or connector, to determine the area

causing high parasitic draw may wake up control modules. You must wait
for the control modules to go back to sleep before retesting. It is best to
install any removed or disconnected components after the diagnosis is
completed.
Fuses for power mode master components such as the BCM should be
removed last to avoid misdiagnosis.
If a scan tool is connected to the DLC, either disconnect it or subtract the
scan tool current draw from the DMM reading to get the actual vehicle
parasitic current draw.
If the vehicle has an unacceptable amount of parasitic current draw, remove each fuse one at a time until the
current draw falls to an acceptable level. A drop of more than 10-20 mA, when disabling a single system or
circuit, is an indication of an overly high current draw that could be causing the battery drain. Refer to Power
Distribution Schematics to diagnose exactly which circuit of the suspect system is causing the high parasitic
drain. The following is a list of common components that could cause a high current draw:
Stuck switch
Stuck relay
Control module
Repair Instructions
Control Module References for control module replacement, programming and setup
CHARGING SYSTEM TEST
Circuit
B+
Signal - F Terminal
Short to
Ground
P0622
P0621
P0622
Open/High
Resistance
P0621
P0621
P0622
Short to
Voltage
P0621
P0622
Signal Performance
P0622

The engine control module (ECM) uses the generator turn ON control circuit to control the load of the generator
on the engine. A high side driver in the ECM applies a duty cycled voltage to the voltage regulator. The duty
cycle controls the voltage regulator to turn the field circuit ON and OFF. The ECM monitors the state of the
generator turn ON control circuit. The ECM should detect low voltage on the generator turn on control circuit
when the ignition is ON and the engine is OFF, or when the charging system malfunctions. With the engine
running, the ECM should detect high voltage when the duty cycle voltage is commanded high and a low voltage
when the duty cycle voltage is commanded low on the generator turn on control circuit.
The engine control module (ECM) uses the generator field duty cycle signal circuit, or F-terminal circuit, to
monitor the duty cycle of the generator. The generator field duty cycle signal circuit connects to high side of the
field windings in the generator. A pulse width modulated (PWM) high side driver in the voltage regulator turns
the field windings on and off. The ECM uses the PWM signal input to determine the generator load on the
engine. This allows the ECM to adjust the idle speed to compensate for high electrical loads. The ECM
monitors the status of the generator field duty cycle signal circuit. When the ignition is ON and the engine is
off, the ECM should detect a duty cycle near 0%. When the engine is running, the duty cycle should be between
5-99%.
Schematic Reference
Circuit Testing
Connector Repairs
Wiring Repairs
NOTE:
Do not have a battery charger connected during the generator testing.
1. Ignition ON.
2. Verify that no G13 Generator or B18 Battery Current Sensor DTCs are set that would cause a charging
system concern.
If DTCs are set


If no DTCs are set
3. Verify the scan tool Body Control Module Battery Voltage parameter is 12 V or greater.
If less than 12 V

If 12 V or greater
4. Engine running, all accessories OFF.
5. Verify the scan tool Body Control Module Battery Voltage parameter continually increases when
controlling the Body Control Module Generator Regulator Setpoint from 10% to 80% with a scan tool. It
may take up to 10 seconds for the battery voltage to stabilize between each setpoint change.
If the battery voltage does not continually increase

If the battery voltage continually increases
6. All OK.
NOTE:
You must perform the Circuit/System Verification before proceeding with

Circuit/System Testing.
1. Ignition OFF.
2. Test for less than 2 ohms between the G13 Generator housing and battery negative terminal.
If less than 2 ohms
cable.

If infinite resistance, test or replace the G13 Generator.
Repair Instructions

GENERATOR NOISE DIAGNOSIS
Diagnostic Aids
Noise from a generator may be due to electrical or mechanical noise. Electrical noise or magnetic whine usually
varies with the electrical load placed on the generator and is a normal operating characteristic of all generators.
When diagnosing a noisy generator, it is important to remember that loose or misaligned components around
the generator may transmit the noise into the passenger compartment and that replacing the generator may not
solve the problem.
1. Start the engine. Verify the noise can be heard. Compare the concern to a similar vehicle.
2. Perform a charging system test. Verify that the generator is charging properly.
3. Inspect the generator, generator mounting, wiring harness, heater hoses, A/C lines, or other accessory
equipment that may be misrouted or be the cause of noise being transmitted into the passenger
compartment.
4. Ignition OFF, remove the engine drive belt.
5. Verify the generator, A/C compressor, water pump pulley, power steering pump, idler pulley, and
tensioner pulley spin freely.
If any of the pulleys do not spin freely
Replace the affected component.
If all belt driven components spin freely
6. Start the engine. Operate the engine for no longer than 30-40 seconds.
7. Verify that the noise goes away.

If the noise is still present

The generator is not the cause of the noise. Refer to Symptoms - Engine Mechanical , for 1.4L
engine or Symptoms - Engine Mechanical for 1.6L or 1.8L engine.
If noise is no longer present

8. Inspect for worn accessory drive components or abnormalities such as severe cracking, bumps, or missing
areas in the accessory drive belt and/or misalignment of system components
Repair Instructions
STARTER SOLENOID DOES NOT CLICK
Short to
Ground
Circuit
B+ (relay terminal 30)
1
Relay Coil Control (relay
P0615
terminal 85)
Starter Control (relay
1
terminal 87)
Ground (relay terminal 86)
1. Starter Solenoid Does Not Click
2. Cranks All The Time
Open/High
Resistance
1
Short to
Voltage
-
Signal Performance
-
P0615
P0615
When the ignition mode switch is placed in the START position, a discrete signal is supplied to the body
control module (BCM) notifying it that the ignition is in the START position. The BCM then sends a serial data
message to the engine control module (ECM) that crank has been requested. The ECM then verifies that the
clutch is fully depressed or the automatic transmission is in Park/Neutral. If it is, the ECM then supplies 12 V to
the control circuit of the starter relay. When this occurs, battery voltage is supplied through the switch of the
starter relay to the starter solenoid.
Schematic Reference


Automatic Transmission Controls Schematics
Manual Transmission Schematics

Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference

1. Ignition ON.
2. Verify that no ignition, starter relay, brake pedal position sensor, immobilizer, or automatic transmission
DTCs are set that would cause the ECM to disable engine starting.
If DTCs are set
If no DTCs are set
3. Verify the scan tool BCM 5 V Ignition Switch parameter is Crank Request when the ignition switch is in
the crank position.
If Crank Request not displayed

4. Verify the scan tool TCM Internal Mode Switch parameter displays Park with the transmission range
selector in park.
If the TCM Internal Mode Switch parameter does not indicate Park
Refer to Transmission Internal Mode Switch Logic for the M32 transmission.

If the TCM Internal Mode Switch parameter indicates Park

5. Verify the scan tool ECM Crankshaft Position Active Counter parameter is not incrementing.
If the counter increments
Replace the B26 Crankshaft Position Sensor.

If the counter does not increment
6. Verify the crank relay clicks and the engine begins cranking with the ignition in the Crank position.
If the KR27 starter relay does not click

If the KR27 starter relay clicks
7. All OK.
1. Ignition ON.
2. Verify the scan tool ECM Ignition 1 Signal parameter is greater than 10 V.
If 10 V or less
2. Test for infinite resistance between the ignition voltage circuits and ground.
3. Ignition OFF, disconnect the KR27 starter relay, ignition ON.
1. Ignition OFF.
1. Ignition OFF.
If infinite resistance,

3. Disconnect X1 harness connector at the M64 starter motor.

If infinite resistance, replace the M64 starter motor.
5. Ensure the parking brake is applied and the T12 transmission is in PARK. Momentarily install a 30 A
fused jumper wire between the B+ circuit terminal 30 and the control circuit terminal 87.
6. Verify the M64 starter motor is activated.
If the M64 starter motor does not activate
1. Disconnect the X1 harness connector at the M64 starter motor.
If greater the 2 ohms, repair the open/high resistance in the circuit.
If less than 2 ohms, replace the M64 starter motor.
If the M64 starter motor activates
7. Test or replace the KR27 starter relay.
Component Testing
Relay Test
1. Ignition OFF, disconnect the KR27 starter relay.
If less than 60 or greater than 180 ohms
Replace the relay.
30 and 86
30 and 87
30 and 85
85 and 87
Replace the relay.


Replace the relay.

If less than 2 ohms
6. All OK
Repair Instructions
Manual Shift Detent Lever with Shaft Position Switch Assembly Replacement
Crankshaft Position Sensor Replacement for the 1.4L engine
Crankshaft Position Sensor Replacement for the 1.8L engine
Control Module References for ECM replacement, programming, and setup.
STARTER SOLENOID CLICKS, ENGINE DOES NOT CRANK

Schematic Reference
Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference


1. Ignition OFF, measure and record the battery voltage at the C1 terminals.
2. Verify the measured voltage is between 12-15 V.
If voltage is less than 12 V or greater than 15 V
If voltage is between 12-15V
3. Remove the drive belts. Refer to Drive Belt Replacement , for the 1.4L LUV engine or Drive Belt
Replacement for the 1.8L LUW and LWE engines.
4. Verify the crankshaft rotates rotate the crankshaft by hand using the appropriate tools.
If the crankshaft does not rotate
Refer to Engine Will Not Crank - Crankshaft Will Not Rotate , for the 1.4L LUV engine or
Engine Will Not Crank - Crankshaft Will Not Rotate for the 1.8L LUW and LWE engines.
If the crankshaft rotates
5. Verify the engine does not crank when attempting to start the vehicle.
If the engine cranks
Inspect the engine and belt drive system for mechanical binding, seized engine, or seized generator.
If the engine does not crank
6. Verify that a test lamp illuminates between the M64 starter motor B+ terminal 1 X2 and ground.
1. Ignition OFF.
1. Ignition OFF.
2. Test for greater than 100 ohms between the B+ circuit and ground.
If 100 ohms or less, repair the short to ground on the circuit.
If greater than 100 ohms, replace the M64 starter motor.
7. Test for less than 0.5 V between the positive battery cable and M64 Starter Motor B+ terminal 1 X2 with
the ignition in the START position.
If 0.5 V or greater

Replace the positive battery cable.

If less than 0.5 V
8. Test for less than 0.5 V between the negative battery cable and the M64 starter motor case with the
ignition in the START position.
If 0.5 V or greater
Replace the negative battery cable.

less than 0.5 V
9. Replace the M64 starter motor.
Repair Instructions

ENGINE CRANKS SLOWLY

Schematic Reference
Circuit Testing
Connector Repairs


Wiring Repairs
Scan Tool Reference

1. Ignition OFF, measure and record the battery voltage at the C1 terminals.
2. Verify the measured voltage is between 12 -15.0 V.
If voltage is less than 12 V or greater than 15 V
If voltage is between 12-15 V
3. Remove the drive belts. Refer to Drive Belt Replacement , for the 1.4Lengine or Drive Belt
Replacement for the 1.8L engine.
4. Verify the engine cranks slowly when attempting to start the vehicle.
If the engine cranks at normal speed
Inspect the engine and belt drive system for mechanical binding, seized engine, or seized generator.
If the engine cranks slowly
5. Verify that a test lamp illuminates between the M64 starter motor B+ terminal 1 X2 and ground.
1. Ignition OFF.
6. Test for less than 0.5 V between the positive battery cable and terminal 1 X2 at the M64 starter motor
with the ignition in the START position.
If 0.5 V or greater
Replace the positive battery cable.

If less than 0.5 V
7. Test for less than 0.5 V between the negative battery cable and the M64 starter motor case with the
ignition in the START position.
If 0.5 V or greater
Replace the negative battery cable.

If less than 0.5 V

8. Replace the M64 starter motor.
Repair Instructions

STARTER NOISE DIAGNOSIS

The starter motors are non-repairable. They have pole pieces that are arranged around the armature. Both
solenoid windings are energized. The pull-in winding circuit is completed to the ground through the starter
motor. The windings work together magnetically to pull and hold in the plunger. The plunger moves the shift
lever. This action causes the starter drive assembly to rotate on the armature shaft spline as it engages with the
flywheel ring gear on the engine. Moving at the same time, the plunger also closes the solenoid switch contacts
in the starter solenoid. Full battery voltage is applied directly to the starter motor and it cranks the engine.

Start the engine. Listen to the starter noise, while the engine is cranking. Compare the concern to a similar
vehicle.
1. Remove the flywheel inspection cover.

2. Inspect the flywheel for the following:
Loose flywheel bolts
Chipped gear teeth
Missing gear teeth

Bent flywheel
Debris in the bell housing
If not within specifications, remove the debris, tighten the flywheel bolts, or repair or replace the
flywheel.
3. If all inspections were within specification, replace the starter motor.
Repair Instructions
Fastener Tightening Specifications for the 1.8L LUW

Engine Flywheel Replacement for the 1.8L LUW
Fastener Tightening Specifications for the 1.4L LUJ
Engine Flywheel Replacement for the 1.4L LUJ
REPAIR INSTRUCTIONS
BATTERY NEGATIVE CABLE DISCONNECTION AND CONNECTION
Removal Procedure
1. Turn on the radio and record all of the customer radio station presets.
2. Ensure that all lamps and accessories are turned off.
3. Turn the ignition OFF and remove the ignition key.

Fig. 3: Battery Negative Cable And Nut

4. Loosen the battery negative cable nut (2).

5. Remove the battery negative cable (1) from the battery.

Fig. 4: Battery Negative Cable And Nut

1. Install the battery negative cable (1) to the battery.
2.
3.
4.
5.
Fasten the battery negative cable nut (2) and tighten the nut to 4.5 N.m (40 lb in).
Insert the ignition key and turn the ignition to the ON position.
Program volatile memory. Refer to Volatile Memory Programming .
Program all of the customer's radio station presets and set the radio clock to the current time.
BATTERY CURRENT SENSOR REPLACEMENT

Removal Procedure

1. Open the hood.

2. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection.
Fig. 5: Battery Negative Cable And Battery Ground Cable Nut

3. Remove the battery ground cable nut (1).
4. Remove the battery negative cable (2).

Fig. 6: Wiring Harness Current Sensor Plug

5. Disconnect the wiring harness current sensor plug (4).
6. Remove the current sensor (5) from the battery tray.

Fig. 7: Battery Negative Cable And Current Sensor

7. Remove the current sensor (2) from the battery negative cable (1).


1. Install the current sensor (2) to the battery negative cable (1).


2. Install the current sensor (5) to the battery tray.
3. Connect the wiring harness current sensor plug (4).

4. Install the battery negative cable (2).
5. Install the battery ground cable nut (1) and tighten to 9 N.m (80 lb in).
6. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection.
7. Close the hood.
BATTERY POSITIVE AND NEGATIVE CABLE REPLACEMENT
Removal Procedure


3. Use a suitable screw driver (2) to unlock the clip (4) through the window (3).

NOTE:
4. Open the battery fuse box cover (1).

5. Remove the battery positive cable to starter nut (2).
6. Remove the battery positive cable to starter (3) from the battery.


Fig. 14: Starter Motor, Negative Cable And Positive Cables

9.
10.
11.
12.
Remove the starter ground cable nut (2) from the starter motor (7).
Remove the negative cable (1).
Remove the starter and generator positive cable nut (5) and the starter positive cable nut (4).
Remove the 2 positive cables (3, 6).

Fig. 15: Generator And Generator Positive Cable

13. Remove the rubber cap from the positive cable generator connector.
14. Remove the positive cable nut (1) from the generator (3).
15. Remove the generator positive cable (2) from the generator (3).

Fig. 16: Generator And Generator Positive Cable

1. Install the positive cable (2) to the generator (3).
2. Install the generator positive cable nut (1) to the generator (3) and tighten to 20 N.m (15 lb ft).
3. Install the rubber cap to the positive cable generator connector.

Fig. 17: Starter Motor, Negative Cable And Positive Cables

4. Install the 2 positive cables (3, 6).
5. Install the starter and generator positive cable nut (5) and the starter positive cable nut (4) and tighten to
12.5 N.m (111 lb in).
6. Install the negative cable (1).
7. Install the starter ground cable nut (2) to the starter motor (7) and tighten to 12.5 N.m (111 lb in).

8. Install the battery ground cable (2).
9. Install the battery negative cable nut (1) and tighten to 9 N.m (80 lb in).

10. Install the battery positive cable to starter (3) at the battery.
11. Install the battery positive cable to starter nut (2) and tighten to 12 N.m (106 lb in).


BATTERY NEGATIVE CABLE REPLACEMENT
Removal Procedure



4.
5.
6.
7.
8.
Disconnect the wiring harness current sensor plug (4).

Remove the current sensor (5) from the battery tray.
Remove battery ground cable from the battery negative cable nut (2).
Remove the ground cable (3).
Remove the battery negative cable (1).


9. Remove the current sensor (2) from the battery negative cable (1).


1. Install the current sensor (2) to the battery negative cable (1).


3. Install the ground cable (3).
4. Install the battery ground cable to the battery negative cable nut (2) and tighten to 9 N.m (80 lb in).
5. Install the current sensor (5) at the battery tray.
6. Connect the wiring harness current sensor plug (4).

8. Install the battery ground cable nut (1) and tighten to 9 N.m (80 lb in).
BATTERY POSITIVE CABLE REPLACEMENT
Removal Procedure


NOTE:
Pull the battery fuse box housing, DO NOT pull the flap.
4. Open the battery fuse box cover.

Fig. 28: Battery Positive Cable-To-Fuse Box Nut

5. Remove the battery positive cable to fuse box nut (1).
6. Remove the battery positive cable to battery nut (2).
7. Remove the battery positive cable to fuse box cable (3).

Fig. 29: Battery Positive Cable-To-Fuse Box Nut

1. Install the battery positive cable to fuse box cable (3).
2. Install the battery positive cable to battery nut (2) and tighten to 4.5 N.m (40 lb in).
3. Install the battery positive cable to fuse box nut (1) and tighten to 9 N.m (80 lb in).


BATTERY REPLACEMENT
Removal Procedure
1. Open the hood.




NOTE:
5. Open the battery fuse box cover (1).

Fig. 33: Starter Cable, Battery Positive Cable And Retainer

6.
7.
8.
9.
10.
11.
12.
Remove the battery hold down retainer nut (5).

Remove the battery hold down retainer (6).
Remove the battery positive cable to starter cable nut (1).
Remove the battery positive cable to starter cable (7).
Loosen the 2 battery positive plate nuts (2).
Loosen the battery positive cable nut (3).
Remove the battery positive cable (4).

Fig. 34: Fuse Block Retainer Clips

13. Unclip the battery fuse block retainer clips (1) from the battery and reposition the battery fuse block along
with the battery positive cable.

Fig. 35: Battery Tray Protector And Battery Tray Protector Retainer
NOTE:
Only necessary if vehicle is equipped with a short battery.
14. Unclip the battery tray protector retainer (2) from battery tray.
15. Remove the battery tray protector (1) by moving rearward, in the direction of the arrow.

Fig. 36: Battery Position

16. Move the battery (1) forward, in the direction of the arrow and lift to remove.

Fig. 37: Battery Position

1. Install battery (1) and move rearward, in direction of the arrow until it rests against the battery tray.

Fig. 38: Battery Tray Protector And Retainer

2. Install the battery tray protector (1) to battery tray and move forward, in the direction of the arrow until
the retainer (2) engages with the battery tray.

Fig. 39: Battery And Battery Fuse Box

3. Align the rear side of the battery fuse box (1) exactly to the rear side of the battery (2).

Fig. 40: Starter Cable, Battery Positive Cable And Retainer

4. Install the battery positive cable (4) to the battery.
5.
6.
7.
8.
9.
10.
Tighten the battery positive cable nut (3) to 4.5 N.m (40 lb in).
Tighten the 2 battery positive plate nuts (2) to 12 N.m (106 lb in).
Install the battery positive cable to starter cable (7).
Install the battery positive cable to starter cable nut (1) and tighten to 12 N.m (106 lb in).
Install the battery hold down retainer (6).
Install the battery hold down retainer nut (5) and tighten to 9 N.m (80 lb in).


NOTE:
Pull the battery fuse box housing, not the flap.
11. Close the battery fuse box cover and lock the retaining tabs (1, 4).
13. Close the hood.
BATTERY TRAY REPLACEMENT
Removal Procedure
1. Open the hood.

2. Remove the battery. Refer to Battery Replacement.
3. Unclip all wiring harness from the battery tray.

4. Unclip the engine control module bracket from the battery tray.
5. If equipped, unclip the radiator surge tank engine hose from the battery tray.
Fig. 42: Battery Current Sensor And Battery Tray

6. Unclip the battery current sensor (1) from the battery tray.

Fig. 43: Battery Tray Bolts

7. Remove the 3 battery tray bolts (1).
8. Remove the battery tray (2).

Fig. 44: Battery Tray Bolts

1. Install the battery tray (2).
2. Install the 3 battery tray bolts (1) and tighten to 15 N.m (11 lb ft).

Fig. 45: Battery Current Sensor And Battery Tray

3.
4.
5.
6.
7.
8.
Clip in the battery current sensor (1) to the battery tray.

If equipped, clip in the radiator surge tank engine hose to the battery tray.
Install battery. Refer to Battery Replacement.
Clip in all wiring harness at the battery tray.
Clip in the engine control module bracket to the battery tray.
Close the hood.
STARTER REPLACEMENT (1.4L LUV)

Removal Procedure

3. If equipped, remove the front compartment splash shield. Refer to Front Compartment Insulator
Replacement .
4. If equipped, remove the engine shield. Refer to Engine Shield Replacement .
Fig. 46: Generator Positive Cable, Starter Positive Cable And Ground Cable
5.
6.
7.
8.
9.
10.
Remove the starter and generator positive cable nut (2).

Remove the starter and generator positive cable (1).
Remove the starter positive cable nut (3).
Remove the starter positive cable (4) from the starter.
Remove the starter ground cable nut (5).
Remove the ground cable (6).

Fig. 47: Starter And Components

11. Remove the upper starter bolt (2) and the washer (1).
12. Remove the starter bolt stud (4) and the washer (5).
13. Remove the starter (3).

Fig. 48: Starter And Components

1. Install the starter (3).
2. Install the washer (5) and the starter bolt stud (4) and tighten to 25 N.m (18 lb ft).
3. Install the upper starter bolt (2) and the washer (1) and tighten to 25 N.m (18 lb ft).

Fig. 49: Generator Positive Cable, Starter Positive Cable And Ground Cable
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
Install the ground cable (6).

Install the starter ground cable nut (5) and tighten to 12.5 N.m (111 lb in).
Install the starter positive cable (4) to starter.
Install the starter positive cable nut (3) and tighten.
Install the starter and generator positive cable (1).
Remove the starter and generator positive cable nut (2) and tighten to 12.5 N.m (111 lb in).
If equipped, remove the front compartment splash shield. Refer to Front Compartment Insulator
Replacement .
If equipped, remove the engine shield. Refer to Engine Shield Replacement .
Lower the vehicle.
Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection.
Close the hood.

STARTER REPLACEMENT (1.8L LUW AND LWE)
Fig. 50: Starter (LUW)

Starter Replacement (1.8L LUW and LWE)
Callout
Component Name
1. Disconnect the negative cable from the battery. Refer to Battery Negative Cable Disconnection
and Connection.
2. Remove the intake manifold brace. Refer to Intake Manifold Replacement .
Starter and Generator Positive Cable Nut
2
3
CAUTION:
Tighten
12.5 N.m (111 lb in)
Starter and Generator Positive Cable
Tighten
12.5 N.m (111 lb in)

4
5
6
7
8
9
Starter Positive Cable

Tighten
20 N.m (15 lb ft)
Starter Ground Cable
Starter Stud
Tighten
25 N.m (18 lb ft)
Starter Bolt
Tighten
25 N.m (18 lb ft)
Starter
GENERATOR REPLACEMENT (1.4L LUV)

Removal Procedure
1.
2.
3.
4.
Open the hood.

Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection.
If equipped, remove the front compartment splash shield. Refer to Front Compartment Insulator
Replacement .
5. If equipped, remove the engine shield. Refer to Engine Shield Replacement .

Fig. 51: Generator Positive Cable And Generator Wiring Harness Connector
6.
7.
8.
9.
Disconnect the generator wiring harness connector (3).

Remove the generator positive cable nut (1).
Remove the generator positive cable (2).
Remove the lower bolt and loosen the upper bolt of the drive belt tensioner. Refer to Drive Belt
Tensioner Replacement .

Fig. 52: Generator And Bolts

11. Remove the 2 generator bolts (2).
12. Remove the generator (1) from above.


1. Install the generator (1) from above.
2. Install the 2 generator bolts (2) and tighten to 35 N.m (26 lb ft).
3. Raise the vehicle.
4. Fasten the drive belt tensioner. Refer to Drive Belt Tensioner Replacement .

Fig. 54: Generator Positive Cable And Generator Wiring Harness Connector
5.
6.
7.
8.
9.
10.
11.
12.
Connect the generator wiring harness connector (3).

Install the generator positive cable (2).
Install the generator positive cable nut (1) and tighten to 17 N.m (13 lb ft).
If equipped, install the front compartment splash shield. Refer to Front Compartment Insulator
Replacement .
If equipped, remove the engine shield. Refer to Engine Shield Replacement .
Lower the vehicle.
Close the hood.
GENERATOR REPLACEMENT (1.8L LUW AND LWE)

Removal Procedure

2. Remove the generator and air conditioning compressor belt. Refer to Drive Belt Replacement .
Fig. 55: Generator Positive Cable Nut And Generator Wiring Harness Nut
3. Remove the generator wiring harness nut (2).
4. Remove the generator positive cable nut (1).

Fig. 56: Generator Positive Cable Nut And Nut

5. If equipped, remove the generator positive cable nut (1) and the generator positive cable (3).
6. If equipped, disconnect the generator wiring harness plug (2).

Fig. 57: Generator Bolts

8. Remove the generator (1).

Fig. 58: Generator Bolts

1. Install the generator (1).

Fig. 59: Generator Positive Cable Nut And Nut

3. If equipped, install the generator positive cable (3) and the generator positive cable nut (1). Tighten the
nut to 12.5 N.m (111 lb in).
4. If equipped, connect the generator wiring harness plug (2).

Fig. 60: Generator Positive Cable Nut And Generator Wiring Harness Nut
5.
6.
7.
8.
9.
Install the generator wiring harness nut and tighten to 12.5 N.m (111 lb in).
Install the generator positive cable nut (1) and tighten to 7 N.m (62 lb in).
Install the generator and air conditioning compressor belt. Refer to Drive Belt Replacement .
Close the hood.

BATTERY DESCRIPTION AND OPERATION
WARNING: Batteries produce explosive gases, contain corrosive acid, and supply
levels of electrical current high enough to cause burns. Therefore, to
reduce the risk of personal injury when working near a battery:

NOTE:
Always shield your eyes and avoid leaning over the battery
whenever possible.
Do not expose the battery to open flames or sparks.
Do not allow the battery electrolyte to contact the eyes or the skin.
Flush immediately and thoroughly any contacted areas with water
and get medical help.
Follow each step of the jump starting procedure in order.
Treat both the booster and the discharged batteries carefully when
using the jumper cables.
Because of the materials used in the manufacture of automotive lead acid

batteries, dealers and service shops that handle them are subject to various
regulations 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 are no longer wanted must be disposed of by an approved battery recycler and must never be
thrown in the trash or sent to a landfill.
Batteries that are not part of the vehicle itself, not the battery under the hood, must only be transported on public
streets for business purposes via approved hazardous material transportation procedures.
Battery storage, charging and testing facilities in repair shops must meet various requirements for ventilation,
safety equipment, material segregation, etc.
The maintenance free battery is standard. There are no vent plugs in the cover. The battery is completely sealed
except for 2 small vent holes in the side. These vent holes allow the small amount of gas that is produced in the
battery to escape.
The battery has 3 functions as a major source of energy:
Engine cranking
Voltage stabilizer
Alternate source of energy with generator overload
Battery Low Start Vehicle Message
The body control module (BCM) monitors battery positive voltage to determine battery state of charge. If one
or more of the BCM battery positive voltage terminals measure less than approximately 11.6V compared to the
BCM ground circuits, this message will display and four chimes may sound. Start the vehicle immediately. If
the vehicle is not started and the battery continues to discharge, the climate controls, heated seats, and audio
systems will shut off and the vehicle may require a jump start. These systems will function again after the
vehicle is started.
Battery Ratings

A battery has 2 ratings:
Cold cranking amperage

Amperage hours
When a battery is replaced use a battery with similar ratings. See battery specification label on the original
battery.
Amperage Hours
The amperage hour rating tells you how much amperage is available when discharged evenly over a 20 hour
period. The amperage hour rating is cumulative, so in order to know how many constant amperage the battery
will output for 20 h, you have to divide the amperage hour rating by 20. Example: If a battery has an amperage
hour rating of 74, dividing by 20 = 3.75. Such a battery can carry a 3.75 A load for 20 hours before dropping to
10.5 V. (10.5 V is the fully discharged level, at which point the battery needs to be recharged.) A battery with
an amperage hour rating of 55 will carry a 2.75 A load for 20 hours before dropping to 10.5 V.
Cold Cranking Amperage
The cold cranking amperage is an indication of the ability of the battery to crank the engine at cold
temperatures. The cold cranking amperage rating is the minimum amperage the battery must maintain for 30
seconds at -18C (0F) while maintaining at least 7.2 V. See battery label for the cold cranking amperage rating
of this battery.
CHARGING SYSTEM DESCRIPTION AND OPERATION
Electrical Power Management Overview
The electrical power management system is designed to monitor and control the charging system and send
diagnostic messages to alert the driver of possible problems with the battery and generator. This electrical
power management system primarily utilizes existing on-board computer capability to maximize the
effectiveness of the generator, to manage the load, improve battery state-of-charge and life, and minimize the
system's impact on fuel economy. The electrical power management system performs 3 functions:
It monitors the battery voltage and estimates the battery condition.

It takes corrective actions by boosting idle speeds, and adjusting the regulated voltage.
It performs diagnostics and driver notification.
The battery condition is estimated during ignition-off and during ignition-on. During ignition-off the state-ofcharge of the battery is determined by measuring the open-circuit voltage. The state-of-charge is a function of
the acid concentration and the internal resistance of the battery, and is estimated by reading the battery open
circuit voltage when the battery has been at rest for several hours.
The state-of-charge can be used as a diagnostic tool to tell the customer or the dealer the condition of the
battery. Throughout ignition-on, the algorithm continuously estimates state-of-charge based on adjusted net amp
hours, battery capacity, initial state-of-charge, and temperature.

While running, the battery degree of discharge is primarily determined by a battery current sensor, which is
integrated to obtain net amp hours.
In addition, the electrical power management function is designed to perform regulated voltage control to
improve battery state-of-charge, battery life, and fuel economy. This is accomplished by using knowledge of the
battery state-of-charge and temperature to set the charging voltage to an optimum battery voltage level for
recharging without detriment to battery life.
The Charging System Description and Operation is divided into 3 sections. The first section describes the
charging system components and their integration into the electrical power management. The second section
describes charging system operation. The third section describes the instrument panel cluster operation of the
charge indicator, driver information center messages, and voltmeter operation.
Charging System Components
Generator
The generator is a serviceable component. If there is a diagnosed failure of the generator it must be replaced as
an assembly. The engine drive belt drives the generator. When the rotor is spun it induces an alternating current
(AC) into the stator windings. The AC voltage is then sent through a series of diodes for rectification. The
rectified voltage has been converted into a direct current (DC) for use by the vehicles electrical system to
maintain electrical loads and the battery charge. The voltage regulator integral to the generator controls the
output of the generator. It is not serviceable. The voltage regulator controls the amount of current provided to
the rotor. If the generator has field control circuit failure, the generator defaults to an output voltage of 13.8 V.
The body control module (BCM) is a GMLAN device. It communicates with the engine control module (ECM)
and the instrument panel cluster for electrical power management (electrical power management) operation. The
BCM determines the output of the generator and sends the information to the ECM for control of the generator
turn on signal circuit. It monitors the generator field duty cycle signal circuit information sent from the ECM for
control of the generator. It monitors a battery current sensor, the battery positive voltage circuit, and estimated
battery temperature to determine battery state of charge. The BCM performs idle boost.
Battery Current Sensor
The battery current sensor is a serviceable component that is connected to either the negative or positive battery
cable at the battery. The battery current sensor is a 3-wire hall effect current sensor. The battery current sensor
monitors the battery current. It directly inputs to the BCM. It creates a 5-volt pulse width modulation (PWM)
signal of 128 Hz with a duty cycle of 0-100 percent. Normal duty cycle is between 5-95 percent. Between 0-5
percent and 95-100 percent are for diagnostic purposes.
When the engine is running, the generator turn-on signal is sent to the generator from the ECM, turning on the
regulator. The generator's voltage regulator controls current to the rotor, thereby controlling the output voltage.
The rotor current is proportional to the electrical pulse width supplied by the regulator. When the engine is
started, the regulator senses generator rotation by detecting AC voltage at the stator through an internal wire.

Once the engine is running, the regulator varies the field current by controlling the pulse width. This regulates
the generator output voltage for proper battery charging and electrical system operation. The generator field
duty terminal is connected internally to the voltage regulator and externally to the ECM. When the voltage
regulator detects a charging system problem, it grounds this circuit to signal the ECM that a problem exists. The
ECM monitors the generator field duty cycle signal circuit, and receives control decisions based on information
from the BCM.
Instrument Panel Cluster
The instrument panel cluster provides the customer notification in case a concern with the charging system.
There are 2 means of notification, a charge indicator and a driver information center message of SERVICE
BATTERY CHARGING SYSTEM if equipped.
Charging System Operation
The purpose of the charging system is to maintain the battery charge and vehicle loads. There are 6 modes of
operation and they include:
Battery Sulfation Mode

Charge Mode
Fuel Economy Mode
Headlamp Mode
Start Up Mode
Voltage Reduction Mode
The engine control module (ECM) controls the generator through the generator turn ON signal circuit. The
ECM monitors the generator performance though the generator field duty cycle signal circuit. The signal is a
pulse width modulation (PWM) signal of 128 Hz with a duty cycle of 0-100 percent. Normal duty cycle is
between 5-95 percent. Between 0-5 percent and 95-100 percent are for diagnostic purposes. The following table
shows the commanded duty cycle and output voltage of the generator:
Commanded Duty Cycle
10%
20%
30%
40%
50%
60%
70%
80%
90%
Generator Output Voltage

11 V
11.56 V
12.12 V
12.68 V
13.25 V
13.81 V
14.37 V
14.94 V
15.5 V
The generator provides a feedback signal of the generator voltage output through the generator field duty cycle
signal circuit to the ECM. This information is sent to the body control module (BCM). The signal is PWM
signal of 128 Hz with a duty cycle of 0-100 percent. Normal duty cycle is between 5-99 percent. Between 0-5

percent and 100 percent are for diagnostic purposes.

Battery Sulfation Mode
The BCM will enter this mode when the interpreted generator output voltage is less than 13.2 V for 45 minutes.
When this condition exists the BCM will enter Charge Mode for 2-3 minutes. The BCM will then determine
which mode to enter depending on voltage requirements.
Charge Mode
The BCM will enter Charge Mode when ever one of the following conditions are met.
The wipers are ON for more than 3 seconds.

GMLAN (Climate Control Voltage Boost Mode Request) is true, as sensed by the HVAC control head.
High speed cooling fan, rear defogger and HVAC high speed blower operation can cause the BCM to
enter the Charge Mode.
The estimated battery temperature is less than 0C (32F).
Battery State of Charge is less than 80 percent.
Vehicle speed is greater than 145 km/h (90 mph)
Current sensor fault exists.
System voltage was determined to be below 12.56 V
When any one of these conditions is met, the system will set targeted generator output voltage to a charging
voltage between 13.9-15.5 V, depending on the battery state of charge and estimated battery temperature.
Fuel Economy Mode
The BCM will enter Fuel Economy Mode when the estimated battery temperature is at least 0C (32F) but less
than or equal to 80C (176F), the calculated battery current is less than 15 amperes and greater than -8
amperes, and the battery state-of-charge is greater than or equal to 80 percent. Its targeted generator output
voltage is the open circuit voltage of the battery and can be between 12.5-13.1 V. The BCM will exit this mode
and enter Charge Mode when any of the conditions described above are present.
Headlamp Mode
The BCM will enter Headlamp Mode when ever the headlamps are ON (high or low beams). Voltage will be
regulated between 13.9-14.5 V.
Start Up Mode
When the engine is started the BCM sets a targeted generator output voltage of 14.5 V for 30 seconds.
Voltage Reduction Mode
The BCM will enter Voltage Reduction Mode when the calculated ambient air temperature is above 0C (32F).
The calculated battery current is less than 1 ampere and greater than -7 amperes, and the generator field duty
cycle is less than 99 percent. Its targeted generator output voltage is 12.9 V. The BCM will exit this mode once

the criteria are met for Charge Mode.

Instrument Panel Cluster Operation
Charge Indicator Operation

The instrument panel cluster illuminates the charge indicator and displays a warning message in the driver
information center if equipped, when the one or more of the following occurs:
The engine control module (ECM) detects that the generator output is less than 11 V or greater than 16 V.
The instrument panel cluster receives a GMLAN message from the ECM requesting illumination.
The instrument panel cluster determines that the system voltage is less than 11 V or greater than 16 V for
more than 30 seconds. The instrument panel cluster receives a GMLAN message from the body control
module (BCM) indicating there is a system voltage range concern.
The instrument panel cluster performs the displays test at the start of each ignition cycle. The indicator
illuminates for approximately 3 seconds.
Display Message: BATTERY NOT CHARGING SERVICE CHARGING SYSTEM or SERVICE

BATTERY CHARGING SYSTEM
The BCM and the ECM will send a serial data message to the driver information center for the BATTERY
NOT CHARGING SERVICE CHARGING SYSTEM or SERVICE BATTERY CHARGING SYSTEM
message to be displayed. It is commanded ON when a charging system DTC is a current DTC. The message is
turned OFF when the conditions for clearing the DTC have been met.
ELECTRICAL POWER MANAGEMENT DESCRIPTION AND OPERATION
Electrical Power Management
The electrical power management is used to monitor and control the charging system and alert the driver of
possible problems within the charging system. The electrical power management system makes the most
efficient use of the generator output, improves the battery state-of-charge, extends battery life, and manages
system electrical loads.
The load shed operation is a means of reducing electrical loads during a low voltage or low battery state-ofcharge condition.
The idle boost operation is a means of improving generator performance during a low voltage or low battery
state-of-charge condition.
Each electrical power management function, either idle boost or load shed, is discrete. No two functions are
active at the same time. Idle boost is activated in incremental steps, idle boost 1 must be active before idle boost
2 can be active. The criteria used by the body control module (BCM) to regulate electrical power management
are outlined below:
Battery
Temperature
Battery Voltage
Amp-Hour

Function
Calculation
Less Than -15C (5
Idle Boost 1 Start
F)
Calculation
Calculation
Less Than 13 V
Idle Boost 1 Start
Idle Boost 1 Start
Less Than 10.9 V
Idle Boost 1 End
Greater Than -15C

Greater Than -12 V
(5F)
Load Shed 1 Start
Load Shed 1 Start
Less Than 10.9 V
Load Shed 1 End
Greater Than 12 V
Idle Boost 2 Start
Idle Boost 2 Start
Less Than 10.9 V
Idle Boost 2 End
Greater Than 12 V
Idle Boost 3 Start
Idle Boost 3 Start
Less Than 10.9 V
Idle Boost 3 End
Greater Than 12 V
Load Shed 2 Start
Less Than 10 V
Action Taken
First level Idle boost
requested
Battery has a net

loss greater than 0.6
requested
Ah
requested
Battery has a net First level Idle boost
loss less than 0.2 Ah request cancelled
Rear Defrost,
Heated Mirrors,
Battery has a net
Heated Seats cycled
loss of 4 Ah
OFF for 20% of
their cycle
Rear Defrost,
Heated Mirrors,
Heated Seats cycled
OFF for 20% of
their cycle
Battery has a net
loss of less than 2 Clear Load Shed 1
Ah
Battery has a net
Second level Idle
loss greater than 1.6
boost requested
Ah
Second level Idle
boost requested
Second level Idle
Battery has a net
boost request
loss less than 0.8 Ah
cancelled
Battery has a net
Third level Idle
loss of 10 Ah
boost requested
Third level Idle
boost requested
Battery has a net
Third level Idle
loss of less than 6.0
boost request
Ah
cancelled
Rear Defrost,
Heated Mirrors,
Heated Seats cycled
Battery has a net
OFF for 50% of
loss greater than 12
their cycle. The
Ah
BATTERY SAVER
ACTIVE message
will be displayed on

Load Shed 2 Start
Less Than 10.9 V
Load Shed 2 End
Greater Than 12.6 V
Battery has a net

loss of less than
10.5 Ah
Load Shed 3 Start
Load Shed 3 End
the DIC
Rear Defrost,
Heated Mirrors,
Heated Seats cycled
OFF for 50% of
their cycle. The
BATTERY SAVER
ACTIVE message
the DIC
Clear Load Shed 2
Rear Defrost,
Heated Mirrors,
Heated Seats cycled
Battery has a net
OFF for 100% of
Less Than 11.9 V loss greater than 20 their cycle. The
Ah
BATTERY SAVER
ACTIVE message
the DIC
Battery has a net
Greater Than 12.6 V loss of less than 15 Clear Load Shed 3
Ah
STARTING SYSTEM DESCRIPTION AND OPERATION

The starter motors are non-repairable starter motors. They have pole pieces that are arranged around the
armature. Both solenoid windings are energized. The pull-in winding circuit is completed to the ground through
the starter motor. The windings work together magnetically to pull and hold in the plunger. The plunger moves
the shift lever. This action causes the starter drive assembly to rotate on the armature shaft spline as it engages
with the flywheel ring gear on the engine. Moving at the same time, the plunger also closes the solenoid switch
contacts in the starter solenoid. Full battery voltage is applied directly to the starter motor and it cranks the
engine.
As soon as the solenoid switch contacts close, current stops flowing thorough the pull-in winding because
battery voltage is applied to both ends of the windings. The hold-in winding remains energized. Its magnetic
field is strong enough to hold the plunger, shift lever, starter drive assembly, and solenoid switch contacts in
place to continue cranking the engine. When the engine starts, pinion overrun protects the armature from
excessive speed until 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 motor contacts through both windings to
the ground at the end of the hold-in winding. However, the direction of the current flow through the pull-in
winding is now opposite the direction of the current flow when the winding was first energized.

The magnetic fields of the pull-in and hold-in windings now oppose one another. This action of the windings,
along with the help of the return spring, causes the starter drive assembly to disengage and the solenoid switch
contacts to open simultaneously. As soon as the contacts open, the starter circuit is turned off.
Circuit Description (Key Start)
When the ignition switch is placed in the Start position, a discrete signal is supplied to the body control module
(BCM) notifying it that the ignition is in the Start position. The BCM then sends a message to the engine
control module (ECM) notifying it that CRANK has been requested. The ECM verifies that the transmission is
in Park or Neutral. If it is, the ECM then supplies 12 V to the control circuit of the crank relay. When this
occurs, battery positive voltage is supplied through the switch side of the crank relay to the S terminal of the
starter solenoid.

SPECIAL TOOLS
Illustration
EL 38758
EL 50074
J 38758
Parasitic Draw Test Switch
EL 50313
EL 42000
EL 50076
J 42000
Battery Tester

2013 ENGINE Engine Exhaust - Cruze
2013 ENGINE
Engine Exhaust - Cruze
SPECIFICATIONS
Specification
Application
Catalytic Converter to Warm Up Three Way Catalytic
Converter (LUJ, LUH)
Exhaust Front Hanger Bracket Bolt M8
Exhaust Front Hanger Bracket Nut
Exhaust Manifold/Catalytic Converter to Bracket (LDD)
Exhaust Front Pipe to Exhaust Manifold/Catalytic Converter
Flange Nut (LDD)
Exhaust Front Pipe to Exhaust Muffler Flange Nut (LDD)
Exhaust Manifold to Cylinder Head (LDD)
Exhaust Manifold Heat Shield Bolts (LUJ, LUH)
Turbocharger to Cylinder Head
Warm Up Three Way Catalytic Converter Heat Shield Bolts
Warm Up Three Way Catalytic Converter Bracket to
Cylinder Block (LUJ, LUH)
Warm Up Three Way Catalytic Converter to Bracket LUJ,
LUH)
Warm Up Three Way Catalytic Converter to Turbocharger
(V-Clamp) LUJ, LUH
Metric
English
22 N.m
16 lb ft
20 N.m
15 lb ft
60 N.m +30 - 45
44 lb ft +30 - 45 (1)
(1)
20 N.m
15 lb ft
10 N.m
89 lb in
17 N.m (1)
13 lb ft (1)
17 N.m (1)
22 N.m
8 N.m
8 N.m
10 N.m
13 lb ft (1)
16 lb ft
71 lb in
71 lb in
89 lb in
22 N.m
16 lb ft
22 N.m
16 lb ft
13 N.m
115 lb in

Specification
Application
Catalytic Converter to Cylinder Head Nut
Catalytic Converter to Exhaust Front Pipe Nut
Engine Lift Bracket Bolt
Engine Lift Bracket Stud and Nut
Metric
20
22
25
25
22
English
15 lb ft
16 lb ft
19 lb ft
19 lb ft
16 lb ft

Exhaust Front Hanger Bracket Bolt M10 (1)

First Pass
Final Pass
Exhaust Front Hanger Insulator Nut
Exhaust Front Pipe to Exhaust Muffler Nut
Exhaust Front Pipe-to-Underbody Shield Nut
Exhaust Front/Rear Muffler Shield Nut
Exhaust Manifold Brace Bolt (Catalytic Converter
To Brace)
Exhaust Manifold Brace Bolt (Brace To Engine Block) (1)
First Pass
Final Pass
Exhaust Manifold Heat Shield Bolt (bottom)
Exhaust Manifold Heat Shield Bolt (top)
Exhaust Manifold Nut (1)
Exhaust Pipe Clamp
Heated Oxygen Sensor (2)
Tank Heat Shield Bolt
Wiring Harness Bracket Bolt
2 = Use assembly paste (refer to Electronic Parts Catalog).
60
44 lb ft
30-45 Degrees
17
17
2.5
2.5
13 lb ft
13 lb ft
22 lb in
22 lb in
20
15 lb ft
20
15 lb ft
30 - 45 Degrees
8
15
20
30
42
2.5
15
71 lb in
11 lb ft
15 lb ft
22 lb ft
31 lb ft
22 lb in
11 lb ft

SYMPTOMS - ENGINE EXHAUST
Review the Exhaust System Description and Operation in order to familiarize yourself with the system
functions. Refer to Exhaust System Description (1.8L LUW and LWE).
All diagnostics on a vehicle should follow a logical process. Strategy Based Diagnostics is a uniform
approach for repairing all systems. The diagnostic flow is the place to start when repairs are necessary
and may always be used in order to resolve a system problem.
Inspect for aftermarket or non-OEM devices such as, but not including; tailpipe extensions, headers, and
exhaust cutouts. This could affect the operation and proper performance of the exhaust system.
Verify the exact operating conditions under which the concern exists. Note factors such as engine RPM,
engine temperature, engine load, and frequency of concern.
Inspect the easily accessible or visible system components for obvious damage or conditions, which could
cause any symptom.
Intermittents
Test the vehicle under the same conditions that the customer reported in order to verify the system is operating

as designed.
Symptom List
Loss of power-Refer to Restricted Exhaust.

Poor acceleration-Refer to Restricted Exhaust.
Poor fuel economy-Refer to Restricted Exhaust.
Excessive smoke-diesel-Refer to Restricted Exhaust.
Exhaust hissing noise-Refer to Exhaust Leakage.
Exhaust popping noise-Refer to Exhaust Leakage.
Exhaust rattle noise-Refer to Exhaust Noise.
Loud Exhaust noise-Refer to Exhaust Noise.
Exhaust buzz, groan, hum noise-Refer to Exhaust Noise.
RESTRICTED EXHAUST
Special Tools
EN-35314-A Exhaust Back Pressure Gage

For equivalent regional tools. Refer to Special Tools.
Diagnostic Aids
A quick check of exhaust flow will help determine for gasoline engines.
Test Description
3
The exhaust system has very low back pressure under normal conditions. If the exhaust system is
restricted, a significant increase in the exhaust pressure is noticed on the EN-35314-A gauge.
Removing the heated oxygen sensor may set a DTC. When finishing this diagnostic table, be sure to clear
all codes.
4
This step will isolate the catalytic converter from the remainder of the exhaust system.
7
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 exhaust pipe.

Restricted Exhaust
Step
Action
1
Did you verify the customers complaint?
Did you review the exhaust symptoms
2
diagnostic information and perform the
necessary inspections?
Value(s)
Yes
Go to Step 2
-
Go to Symptoms Go to Step 3 Engine Exhaust
1. Remove the heated oxygen sensor 1.

Refer to:
1.4L LUJ Heated Oxygen Sensor
Replacement - Sensor 1
1.8L LUW Heated Oxygen Sensor
2. Install the EN-35314-A gauge in place of 14 kPa (2
the heated oxygen sensor 1.
psi)
4. Increase and monitor the engine speed at
2, 000 RPM.
5. Observe the exhaust system back pressure
reading on the gauge.
Go to Step 4
Does the reading exceed the specified value?
No
-
1. Turn the engine off and place the ignition

in the lock position.
2. Remove the EN-35314-A gauge.
3. Install the heated oxygen sensor 1. Refer
to:
4. Remove the heated oxygen sensor 2.
Refer to:
5. Install the EN-35314-A gauge in place of
the heated oxygen sensor 2.
7. Increase and monitor the engine speed at
2, 000 RPM.
8. Observe the exhaust system back pressure
Go to Step 7

reading on the gauge.

Does the reading exceed the specified value?
Inspect the exhaust system for the following
conditions:
Damage in the exhaust pipe.

Debris in the exhaust pipe.
Muffler or resonator internal failure.
Two-layer exhaust pipe separation.

Replace the catalytic converter. Refer to
Catalytic Converter Replacement (1.4L
LUV), Catalytic Converter Replacement
(1.8L LUW and LWE).
1. Remove the EN-35314-A gauge.
2. Install the heated oxygen sensor 2. Refer
to:
3. Clear any DTCs.
4. Road test the vehicle in order to verify the
repair.
Did you correct the condition?
Go to Step 5
Go to Step 6
Go to Step 7
Go to Step 7
System OK
Go to Step 2
EXHAUST LEAKAGE
Exhaust Leakage
Problem
Action
WARNING:
While engine is operating, the exhaust system will become extremely hot. To prevent burns avoid
contacting a hot exhaust system.
DEFINITION: An exhaust leak may show stains at the area of the leak. The leak may be felt by holding a
hand close to the suspected areas or using a smoke pencil. The leak may make a popping or hissing
noise.Refer to Symptoms - Engine Exhaust prior to beginning this table.
Misaligned or improperly installed exhaust system
Align and tighten the components to the
components
specifications. Refer to Fastener Tightening

Exhaust leaks at the following connections:

Exhaust manifold to pipe
Flanges
Pipe clamps
Seals or gaskets leaking.
Specifications (1.4L LUV), Fastener

Tightening Specifications (1.8L LUW and
LWE).
Tighten the components to the specifications.
Refer to Fastener Tightening Specifications
(1.4L LUV), Fastener Tightening
Specifications (1.8L LUW and LWE).
Replace the leaking seal or gasket. Refer to the
affected components procedure for service.
Exhaust manifold to cylinder head

Exhaust pipes to exhaust manifold
Catalytic converter connection
AIR connections to the exhaust manifold or
cylinder head
Irregularities at the mating surfaces on the flange
connections
Exhaust manifold cracked or broken

Exhaust system component connection welds leaking
Repair as required or replace the affected

component. Refer to the affected components
procedure for service.
Replace the exhaust manifold. Refer to Exhaust
Manifold Replacement.
Replace the leaking component. Refer to the
affected component's procedure for service.
EXHAUST NOISE
Exhaust Noise
Conditions
Action
DEFINITION: An audible or physical noise due to a faulty component or damaged components causing a
loose or misaligned exhaust system resulting in a rattle or vibration noise, i.e. buzz, groan, hum. Refer to
Symptoms - Engine Exhaust prior to beginning this table.
Popping or hissing noise
Exhaust leak. Refer to Exhaust Leakage.
Loud exhaust
1. Compare to a known good vehicle.

2. Inspect for a damaged or failed muffler.
3. Replace the faulty muffler. Refer to Exhaust System
Replacement.
External rattle or vibration noise
1. Inspect for a bent or loose hanger, loose heat shield, or loose

clamp.
2. Inspect for an exhaust pipe causing interference.
3. Repair or replace the affected component. Refer to the affected
component's service procedure.
1. Test the components by tapping with a rubber mallet to confirm a
rattle.

Internal rattle
2. Replace the faulty catalytic converter, or muffler. Refer to one of

the following procedures:
Catalytic Converter Replacement (1.4L LUV), Catalytic
Converter Replacement (1.8L LUW and LWE)
Exhaust System Replacement
REPAIR INSTRUCTIONS
EXHAUST MANIFOLD REPLACEMENT
Fig. 1: Exhaust Manifold Replacement Components

Exhaust Manifold Replacement
Callout
Component Name
WARNING:
Refer to Exhaust Service Warning .
WARNING:
Refer to Protective Goggles and Glove Warning .
Preliminary Procedure Remove the catalytic converter heat shield. Refer to Catalytic Converter Heat
Shield Replacement (1.4L LUV), Catalytic Converter Heat Shield Replacement (1.8L LUW and

LWE).
Catalytic Converter to Flexible Exhaust Pipe Nut (Qty: 3)
2
3
4
7
8
9
CAUTION:
Tighten
22 (16 lb ft)
Flexible Exhaust Pipe
Catalytic Converter to Flexible Exhaust Pipe Gasket
Exhaust Manifold Brace Bolt (Catalytic Converter To Brace) (Qty:
2)
Tighten
20 (15 lb ft)
Exhaust Manifold Brace Bolt (Brace To Engine Block) (Qty: 2)
Procedure
NOTE:
NOT necessary to remove the brace.
Loosen the exhaust manifold brace bolts.

Tighten
20 (15 lb ft) + 30 degrees + 15 degrees
Tighten
42 (31 lb ft)
Catalytic Converter to Cylinder Head Nut (Qty: 9)
Tighten
20 (15 lb ft)
Catalytic Converter
Catalytic Converter To Cylinder Head Gasket
EXHAUST FRONT PIPE REPLACEMENT

Fig. 2: Exhaust Front Pipe

Exhaust Front Pipe Replacement
Callout
Component Name
WARNING:
WARNING:
2. Disconnect the heated oxygen sensor.
Exhaust Front Pipe to Exhaust Muffler Nut (Qty: 2)
CAUTION:
Tighten
17 N.m (13 lb ft)
Exhaust Front Pipe Gasket to Exhaust Muffler

3
4
Catalytic Converter to Exhaust Front Pipe Nut (Qty: 3)

Tighten
22 N.m (16 lb ft)
Catalytic Converter to Exhaust Front Pipe Gasket
Drivetrain and Front Suspension Frame Support Bolts - M10 (Qty: 2)
CAUTION:
Refer to Torque-to-Yield Fastener Caution .
7
8
9
10
11
Procedure
Install NEW support bolts, do NOT reuse old bolts.
Tighten
60 N.m (44 lb ft) +30-45
Exhaust Pipe Front Hanger Bracket Bolt - M8 (Qty: 2)
Tighten
22 N.m (16 lb ft)
Exhaust Pipe Front Hanger Insulator Nut (Qty: 2)
Tighten
17 N.m (13 lb ft)
Exhaust Pipe Front Hanger Bracket
Exhaust Muffler Insulator (Qty: 2)
Exhaust Front Pipe
Tighten
42 N.m (31 lb ft)
EXHAUST SYSTEM REPLACEMENT

Removal Procedure
WARNING: In order to avoid being burned, do not service the exhaust system
while it is still hot. Service the system when it is cool.
WARNING: Always wear protective goggles and gloves when removing exhaust
parts as falling rust and sharp edges from worn exhaust
components could result in serious personal injury.
1. Read the exhaust system cutting instructions. .
2. Remove the exhaust rear muffler. Refer to Exhaust Rear Muffler Replacement.

Fig. 3: Exhaust Pipe Front Hanger Bracket, Insulators, Nuts And Bolts
NOTE:
3.
4.
5.
6.
A second technician is required.
Remove the 4 exhaust pipe front hanger bracket bolts (4, 5).
Remove the 2 exhaust pipe front hanger bracket insulator nuts (3).
Remove the exhaust pipe front hanger bracket (2).
Remove the 2 exhaust pipe front hanger bracket insulators (1).

Fig. 4: Heated Oxygen Sensor

NOTE:
7.
8.
9.
10.
Remove the heated oxygen sensor (1).

Remove and DISCARD the 3 catalytic converter nuts (3).
Remove the exhaust front pipe gasket (4) from the catalytic converter and exhaust front pipe (2).
Remove the exhaust system.
NOTE:
1. Install the exhaust system.

Fig. 5: Heated Oxygen Sensor

2. Install the NEW exhaust front pipe gasket (4).
3. Install the 3 NEW catalytic converter nuts (3) to the exhaust front pipe (2) and tighten to 22 N.m (16 lb
ft).
4. Install the heated oxygen sensor (1) and tighten to 42 N.m (31 lb ft).

Fig. 6: Exhaust Pipe Front Hanger Bracket, Insulators, Nuts And Bolts
5.
6.
7.
8.
9.
10.
Install the 2 exhaust pipe front hanger bracket insulators (1).

Install the exhaust pipe front hanger bracket (2).
Install the 2 exhaust pipe front hanger bracket insulator nuts (3) and tighten to 17 N.m (13 lb ft).
Install the 4 exhaust pipe front hanger bracket bolts (4, 5) and tighten to 22 N.m (16 lb ft).
Install the 2 exhaust pipe front hanger bolts (5) - M10 and tighten to 60 N.m (44 lb ft).
Install the exhaust rear muffler. Refer to Exhaust Rear Muffler Replacement.
CATALYTIC CONVERTER REPLACEMENT (1.4L LUV)

Fig. 7: Catalytic Converter (1.4L LUV)

Catalytic Converter Replacement (1.4L LUV)
Callout
Component Name
WARNING:
In order to avoid being burned, do not service the exhaust system while it is still hot. Service the
system when it is cool.
WARNING:
Always wear protective goggles and gloves when removing exhaust parts as falling rust and sharp
edges from worn exhaust components could result in serious personal injury.
CAUTION:
Do not bend the exhaust flex pipe more than 10 degrees in any direction. Bending of more than 10
degrees or twisting in a range of 0.5 degrees will damage the exhaust flex decoupler.
2. Disconnect the heated oxygen sensor wiring harness plug.
Exhaust Front Pipe to Exhaust Muffler Nut (Qty: 2)
CAUTION:


CAUTION:
Procedure
1
1. Support exhaust muffler with a jack.
2. Install NEW nuts, do NOT reuse old nuts.
7
8
9
10
11
Tighten
17 N.m (13 lb ft)
Exhaust Front Pipe Gasket to Exhaust Muffler
Catalytic Converter to Exhaust Front Pipe Nuts (Qty: 3)
Procedure
Install NEW nuts, do NOT reuse old nuts.
Tighten
22 N.m (16 lb ft)
Catalytic Converter to Exhaust Front Pipe Gasket
Drivetrain and Front Suspension Frame Support Bolts - M10 (Qty: 2)
Procedure
Install NEW bolts, do NOT reuse old bolts.
Tighten
60 N.m (44 lb ft) +30-45
Exhaust Pipe Front Hanger Bracket Bolts - M8 (Qty: 2)
Tighten
22 N.m (16 lb ft)
Exhaust Pipe Front Hanger Insulator Nuts (Qty: 2)
Tighten
17 N.m (13 lb ft)
Exhaust Muffler Insulator (Qty: 2)
Exhaust Front Pipe Assembly
Tighten
42 N.m (31 lb ft)
CATALYTIC CONVERTER REPLACEMENT (1.8L LUW AND LWE)

Fig. 8: Catalytic Converter (1.8L LUW and LWE)

Catalytic Converter Replacement (1.8L LUW and LWE)
Callout
Component Name
WARNING:
WARNING:
Preliminary Procedure Remove the catalytic converter heat shield. Refer to Catalytic Converter Heat
Shield Replacement (1.4L LUV), Catalytic Converter Heat Shield Replacement (1.8L LUW and
LWE)
Catalytic Converter to Flexible Exhaust Pipe Nut (Qty: 3)
2
3
CAUTION:
Tighten
22 N.m (16 lb ft)
Flexible Exhaust Pipe
Catalytic Converter to Flexible Exhaust Pipe Gasket

4
5
6
7
8
9
Exhaust Manifold Brace Bolt (Qty: 4)

Tighten
20 N.m (15 lb ft)
Catalytic Converter
Exhaust Manifold Brace
Tighten
42 N.m (31 lb ft)
Catalytic Converter to Cylinder Head Nut (Qty: 9)
Tighten
20 N.m (15 lb ft)
Catalytic Converter to Cylinder Head Gasket
WARM UP THREE-WAY CATALYTIC CONVERTER REPLACEMENT

Removal Procedure
2. Disconnect the heated oxygen sensor 1 wiring harness connector. Refer to Heated Oxygen Sensor
Replacement - Sensor 1 .
3. Remove the exhaust manifold heat shield. Refer to Exhaust Manifold Heat Shield Replacement (1.4L
LUV), Exhaust Manifold Heat Shield Replacement (1.8L LUW and LWE).

Fig. 9: V-Clamp And Bolt

4. Loosen the three way warm up catalytic converter V-clamp bolt (2) so that the three way warm up
catalytic converter V-clamp (1) can be removed from catalytic converter to turbocharger flange.
6. Remove the engine front compartment insulator if equipped. Refer to Front Compartment Insulator
Replacement

Fig. 10: Catalytic Converter

WARNING: Always wear protective goggles and gloves when removing exhaust
parts as falling rust and sharp edges from worn exhaust
components could result in serious personal injury.
CAUTION: Do not bend the exhaust flex pipe more than 10 degrees in any
direction. Bending of more than 10 degrees or twisting in a range of
0.5 degrees will damage the exhaust flex decoupler.
7. Remove and DISCARD the 3 catalytic converter flange nuts (2).
8. Remove the catalytic converter (3) from the three way warm up catalytic converter and hang aside.
9. Remove the catalytic converter gasket (1).

Fig. 11: Catalytic Converter Bracket Nuts

10. Remove the 2 three way warm up catalytic converter bracket nuts (1) and (2).
11. Remove the three way warm up catalytic converter and the three way warm up catalytic converter to
turbocharger seal ring.
12. Remove the heated oxygen sensor 1 from the three way warm up catalytic converter. Refer to Heated
Oxygen Sensor Replacement - Sensor 1 .
1. Install the heated oxygen sensor 1 to the three way warm up catalytic converter. Refer to Heated Oxygen
Sensor Replacement - Sensor 1 .
NOTE:
Never re-use the V-clamp.
2. Pre-install a NEW three way warm up catalytic converter V-clamp.

3. Install the three way warm up catalytic converter to the turbocharger and the three way warm up catalytic
converter brackets. Install a NEW three way warm up catalytic converter to turbocharger seal ring.
Fig. 12: Catalytic Converter Bracket Nuts

4. Install and hand-tighten the 2 three way warm up catalytic converter bracket nuts (1) and (2).
6. Install the three way warm up catalytic converter V-clamp to the catalytic converter to turbocharger
flange.

Fig. 13: Catalytic Converter V-Clamp

7. The three way warm up catalytic converter V-clamp (1) should be installed in the shown position.
8. Hand-tighten the three way warm up catalytic converter V-clamp.
10. Tighten the 2 three way catalytic converter bracket nuts to 22 (16 lb ft).

Fig. 14: Catalytic Converter

11. Install the catalytic converter (3) and a NEW catalytic converter gasket (1) to the three way warm up
catalytic converter.
12. Install the 3 NEW catalytic converter flange nuts (2) and tighten to 22 (16 lb ft).
13. Install the engine front compartment insulator if equipped. Refer to Front Compartment Insulator
Replacement
15. Tighten the three way catalytic converter V-clamp bolt to 13 (115 lb in).
16. Install the exhaust manifold heat shield. Refer to Exhaust Manifold Heat Shield Replacement (1.4L
LUV), Exhaust Manifold Heat Shield Replacement (1.8L LUW and LWE).
17. Connect the heated oxygen sensor 1 wiring harness plug. Refer to Heated Oxygen Sensor Replacement
- Sensor 1 .

19. Close the hood.

EXHAUST PIPE FRONT HANGER BRACKET REPLACEMENT
Fig. 15: Exhaust Pipe Front Hanger Bracket

Exhaust Pipe Front Hanger Bracket Replacement
Callout
Component Name
WARNING:
WARNING:
Preliminary Procedure Raise and support the vehicle. Refer to Lifting and Jacking the
Vehicle .Special Tools EN-45059 Angle MeterFor equivalent regional tools, refer to Special Tools.
Exhaust Pipe Front Hanger Insulator Nut (Qty: 2)
1
CAUTION:
Tighten

17 N.m (13 lb ft)

Exhaust Pipe Front Hanger Bracket Bolt (Qty: 2)
CAUTION:
Procedure
Tighten
First Pass: 22 N.m (16 lb ft).
Final Pass: 30-45 degrees, using the EN-45059 meter.
Drivetrain and Front Suspension Frame Support Bolt (Qty: 2)
Procedure
Tighten
First Pass: 60 N.m (44 lb ft).

Final Pass: 30-45 degrees, using the EN-45059 meter.
CATALYTIC CONVERTER HEAT SHIELD REPLACEMENT (1.4L LUV)

Fig. 16: Catalytic Converter Heat Shield (1.4L LUV)

Catalytic Converter Heat Shield Replacement (1.4L LUV)
Callout
Component Name
WARNING:
WARNING:
1. Open the hood.
2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle
Catalytic Converter Heat Shield Bolt (Qty: 4)
CAUTION:
Tighten:
10 N.m (89 lb in)

Catalytic Converter Heat Shield
CATALYTIC CONVERTER HEAT SHIELD REPLACEMENT (1.8L LUW AND LWE)

Removal Procedure
WARNING: Refer to Exhaust Service Warning .
WARNING: Refer to Protective Goggles and Glove Warning .
1. Open the hood.

Connection .
4. Remove the oil level indicator tube. Refer to Oil Level Indicator Tube Replacement .

Fig. 17: Wiring Harness Bracket

5. Remove the wiring harness bracket bolt (2) and the wiring harness bracket (1).
6. Remove the 2 exhaust manifold heat shield bolts (4).
7. Remove the exhaust manifold heat shield (3).


1. Install the exhaust manifold heat shield (3).
2. Install the 2 exhaust manifold heat shield bolts (4) and tighten to 8 N.m (71 lb in).
3. Install the wiring harness bracket (1) and the wiring harness bracket bolt (2) and tighten to 15 N.m (11 lb
ft).
4. Install the oil level indicator tube. Refer to Oil Level Indicator Tube Replacement .
5. Connect the heated oxygen sensor wiring harness plug.
7. Close the hood.

EXHAUST HEAT SHIELD REPLACEMENT
Fig. 19: Exhaust Heat Shield And Retainers

Exhaust Heat Shield Replacement
Callout
Component Name
WARNING:
WARNING:
Preliminary Procedure Remove the exhaust front pipe. Refer to Exhaust Front Pipe Replacement.
1
Heat Shield Retainer (Qty: 7)
2
Heat Shield
FUEL TANK HEAT SHIELD REPLACEMENT

Fig. 20: Fuel Tank Heat Shield (Gasoline)

Fuel Tank Heat Shield Replacement
Callout
Component Name
WARNING:
Refer to Safety Goggles and Fuel Warning .
WARNING:
Refer to Actions to Take When Working with Fuel Warning .
Preliminary Procedure Remove the fuel tank. Refer to Fuel Tank Replacement .
1
Fuel Tank Heat Shield Retaining Clamp (Qty: 3)
2
Fuel Tank Heat Shield
EXHAUST MANIFOLD HEAT SHIELD REPLACEMENT (1.4L LUV)

Fig. 21: Exhaust Manifold Heat Shield (1.4L LUV)

Exhaust Manifold Heat Shield Replacement (1.4L LUV)
Callout
Component Name
WARNING:
Exhaust Manifold Heat Shield Bolts (Qty: 3)
CAUTION:
Tighten
8 N.m (71 lb in)
Exhaust Manifold Heat Shield
EXHAUST MANIFOLD HEAT SHIELD REPLACEMENT (1.8L LUW AND LWE)

Removal Procedure

1. Open the hood.

Connection .
4. Remove the oil level indicator tube. Refer to Oil Level Indicator Tube Replacement .

5. Remove the wiring harness bracket bolt (2) and the wiring harness bracket (1).
6. Remove the 2 exhaust manifold heat shield bolts (4).


2. Install the 2 exhaust manifold heat shield bolts (4) and tighten to 8 N.m (71 lb in).
3. Install the wiring harness bracket (1) and the wiring harness bracket bolt (2) and tighten to 15 N.m (11 lb
ft).
4. Install the oil level indicator tube. Refer to Oil Level Indicator Tube Replacement .
5. Connect the heated oxygen sensor wiring harness plug.

7. Close the hood.

EXHAUST REAR MUFFLER HEAT SHIELD REPLACEMENT
Fig. 24: Exhaust Rear Muffler Heat Shield

Exhaust Rear Muffler Heat Shield Replacement
Callout
Component Name
WARNING:
WARNING:
2. Separate the exhaust rear muffler from the underbody and support the exhaust system.
1
Heat Shield Retainer (Qty: 4)
2
Exhaust Rear Muffler Heat Shield
EXHAUST REAR MUFFLER REPLACEMENT

Removal Procedure
2. Read the exhaust system cutting instructions before cutting the exhaust system. .
Fig. 25: Exhaust Rear Muffler, Exhaust Rear Muffler Hanger Insulators, Exhaust Rear Muffler
End Pipe Bracket And Bolt
3. Remove the 2 exhaust rear muffler hanger insulators (3) from the exhaust rear muffler (4).

4. Remove the exhaust rear muffler end pipe bracket bolt (1) from the exhaust rear muffler end pipe bracket
(2).
5. Remove the exhaust rear muffler end pipe bracket (2).
Fig. 26: Exhaust Rear Muffler Cutting Positions

NOTE:
Support the exhaust rear muffler with a jack.
NOTE:
The follow step is only necessary if the new exhaust rear muffler is not
equipped with the exhaust rear muffler end pipe.
6. Cut the exhaust rear muffler at position (2) and remove the exhaust rear muffler end pipe.
7. Cut the exhaust rear muffler at position (1).
8. Remove the exhaust rear muffler.

Fig. 27: Exhaust Rear Muffler Components

1. Install the exhaust rear muffler (6) and hang in the 2 exhaust rear muffler hanger insulators (5).
2. Install the exhaust pipe clamp (1) and loosely tighten.
3. Install the exhaust rear muffler end pipe bracket (3) to the exhaust rear muffler end pipe.
NOTE:
The follow step is only necessary if the new exhaust rear muffler is not
equipped with the exhaust rear muffler end pipe.
4. Install the exhaust rear muffler end pipe.


5. Install the exhaust rear muffler end pipe bracket bolt (4) to the exhaust rear muffler end pipe bracket (3)
and tighten to 22 N.m (16 lb ft).
6. Install the exhaust pipe clamp (2) and loosely tighten.
7. Position the exhaust rear muffler.
8. Tighten the exhaust pipe clamp (1) to 20 N.m (15 lb ft).
9. Position the exhaust rear muffler end pipe.
10. Tighten the exhaust pipe clamp (2) to 20 N.m (15 lb ft).

EXHAUST SYSTEM DESCRIPTION (1.8L LUW AND LWE)
Catalytic Converter
Fig. 28: View Of Pre-Catalyst


The catalytic converter is an emission control device added to the engine exhaust system in order to reduce
hydrocarbons (HC), carbon 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 shell. The substrate may be washcoated with 3 noble metals, Platium (Pt), Palladium (Pd) and
Rhodium (Rh). The catalyst in the converter is not serviceable.
Exhaust Rear Muffler
Fig. 29: Exhaust Rear Muffler

The rear muffler is to reduce broad band engine exhaust noise. It is comprised of a series of perforated tubes
and baffles to break up the sound waves and reflect them.
It is made of stainless steel to protect the front muffler from corrosion.
It is mounted behind the rear wheel.


SPECIAL TOOLS
Special Tools
Illustration
EN-35314-A
J-35314-A
Exhaust Back Pressure Gauge
EN-45059
J 45059
Angle Meter
EN-6179
KM-6179
J-39174-C
Heated Oxygen Sensor Remover/Installer

2013 ENGINE Engine Mechanical - 1.4L LUV - Cruze
SPECIFICATIONS
Specification
Application
Air Conditioning Compressor Bracket Bolts
Camshaft Actuator
Camshaft Bearing Cap Bolts
Camshaft Cover Bolts
Camshaft Position Actuator Solenoid Valve
Camshaft Position Sensor Bolt
Camshaft Sprocket Bolt
Catalytic Converter Bracket to Cylinder Block
Catalytic Converter to Bracket
Catalytic Converter to Turbocharger (V-clamp)
Connecting Rod Bearing Cap
Metric
English
22 N.m
16 lb ft
50 N.m + 60 degrees
37 lb ft + 60 degrees
8 N.m
71 lb in
8 N.m
71 lb in
8 N.m
71 lb in
6 N.m
53 lb in
50 N.m + 60 degrees (1) 37 lb ft + 60 degrees (1)
22 N.m
16 lb ft
22 N.m
16 lb ft
13 N.m
115 lb in
150 N.m + 45 degrees + 111 lb ft + 45 degrees + 15
Crankshaft Balancer Bolt
15 degrees (1)
degrees (1)
10 N.m + 60 degrees + 89 lb in + 60 degrees + 15
Crankshaft Bearing Tie Plate Bolts (M6)
15 degrees (1)
degrees (1)
Crankshaft Bearing Tie Plate Bolts (M8)
15 degrees (1)
degrees (1)
Crankshaft Position Sensor Bolt
8 N.m
71 lb in
Cylinder Head Bolts
Drive Belt Tensioner Bolt M8
22 N.m
16 lb ft
Drive Belt Tensioner Bolt M10
55 N.m
41 lb ft
Engine Cooling Thermostat Housing Bolts
8 N.m
71 lb in
Engine Front Cover Bolts M10
35 N.m
26 lb ft
Engine Front Cover Bolts M6
8 N.m
71 lb in
60 N.m + 45-60 degrees 44 lb ft + 45-60 degrees
Engine Mount Bracket Bolts
(1)
(1)
Engine Mount Right Side to Body
62 N.m
46 lb ft
50 N.m + 60-75 degrees 37 lb ft + 60-75 degrees
Engine Mount Right Side to Engine Mount Bracket
(1)
(1)
Engine Oil Filter Cap
25 N.m
18 lb ft
Exhaust Manifold Heat Shield Bolts
8 N.m
71 lb in
Flywheel Bolts (Two-Mass)
15 degrees (1)
degrees (1)
Fuel Injection Rail to Intake Manifold
6 N.m
53 lb in
Generator to Cylinder Block and Engine Cover
35 N.m
26 lb ft

Ignition Coil Bolts

Intake Manifold Bolt
Knock Sensor
Oil Cooler Coolant Inlet Pipe to Oil Cooler
Oil Cooler to Engine Block
Oil Cooler to Oil Filter Assembly (only bolts
serviceable)
Oil Filler Plug to Engine Front Cover (M18)
Oil Filter Assembly to Block
Oil Gallery Plug in Engine Front Cover (M22)
Oil Pan Bolt
Oil Pan Drain Plug
Oil Pressure Indicator
Oil Pressure Relief Valve
Oil Pump Cover Bolts
Oil Pump Housing Plug (M10)
Oxygen Sensor to Exhaust Manifold
Oxygen Sensor to Exhaust Front Pipe
Piston Oil Nozzles to Block
Spark Plugs
Starter Bolts
Throttle Body Bolts
Timing Chain Guide
Timing Chain Tensioner
Timing Chain Tensioner Shoe
Turbocharger Coolant Feed Pipe to Engine Block
Turbocharger Coolant Feed Pipe to Turbocharger
(Quick Fitting)
Turbocharger Coolant Return Pipe to Turbocharger
(Quick Fitting)
Turbocharger Oil Feed Pipe to Oil Cooler/Filter
Turbocharger Oil Feed Pipe to Turbocharger
Turbocharger Oil Return Pipe to Turbocharger
Turbocharger to Cylinder Head
Water Outlet
Water Pump Housing Bolts
Water Pump Drain Plug
Water Pump Pulley Bolts
ENGINE MECHANICAL SPECIFICATIONS
8 N.m
20 N.m
20 N.m
10 N.m
20 N.m
71 lb in
15 lb ft
15 lb ft
89 lb in
15 lb ft
10 N.m
89 lb in
30 N.m
20 N.m
60 N.m
10 N.m
14 N.m
20 N.m
50 N.m
8 N.m
10 N.m
42 N.m
42 N.m
25 N.m
25 N.m
25 N.m
9 N.m
8 N.m
8 N.m
20 N.m
30 N.m
22 lb ft
15 lb ft
44 lb ft
89 lb in
124 lb in
15 lb ft
37 lb ft
71 lb in
89 lb in
31 lb ft
31 lb ft
18 lb ft
18 lb ft
18 lb ft
80 lb in
71 lb in
71 lb in
15 lb ft
22 lb ft
20 N.m
15 lb ft
20 N.m
15 lb ft
8 N.m
30 N.m
8 N.m
8 N.m (1)
8 N.m
8 N.m
15 N.m
22 N.m
71 lb in
22 lb ft
71 lb in
71 lb in (1)
71 lb in
71 lb in
11 lb ft
16 lb ft

Engine Mechanical Specifications

Specification
Application
Metric
English
General Data
4-Cylinder Inline
Engine Type
Displacement
1364 ccm
83.24 cu in
Bore
72.5 mm
2.854 in
Stroke
82.6 mm
3.3 in
Compression Ratio
9.5:1
Number of Valves
16
Maximum Power @ engine speed KW/RPM
Maximum Torque @ engine speed / RPM / lb ft /

RPM
Engine Block
Cylinder Bore Diameter Standard
Cylinder Bore Diameter Oversize 0.5
105 KW /4900
200 / 1850
72.492 mm - 72.508
mm
72.992 mm - 73.008
mm
148 lb ft / 4000
2.8540 in - 2.8546 in
2.8737 in - 2.8743 in
Piston, Piston Rings and Piston Pins
Piston Diameter Standard
Piston Diameter Oversize 0.5
Piston Clearance to Bore
Piston - Upper Compression Ring Thickness
Piston - Upper Compression Ring Ring Gap
72.453 mm - 72.467
2.8525 in - 2.8530 in
mm
72.953 mm - 72.967
2.8722 in - 2.8727 in
mm
0.025 mm -0.055
0.001 in - 0.0022 in
mm
1.17 mm - 1.195 mm 0.0461 in 0.047 in
0.25 mm - 0.4 mm
0.0098 in - 0.0157 in
Piston - Upper Compression Ring Side Clearance
0.025 mm - 0.07 mm
0.001 in - 0.0028 in
Piston - Lower Compression Ring Thickness
1.17 mm - 1.195 mm
0.0461 in 0.047 in
Piston - Lower Compression Ring Ring Gap
0.4 mm - 0.6 mm
0.0157 in - 0.0236 in
Piston - Lower Compression Ring Side Clearance
0.025 mm - 0.07 mm
0.001 in - 0.0028 in
Piston - Oil Ring Thickness
1.92 mm - 2 mm
0.0756 in - 0.0787 in
Piston - Oil Ring Ring Gap
0.25 mm - 0.75 mm
0.0098 in - 0.0295 in
Piston - Oil Ring Side Clearance
Piston Pin Bore Diameter
Piston Pin Outer Diameter
0.04 mm - 0.12 mm 0.0016 in - 0.0047 in

18.006 mm - 18.012
0.7089 in - 0.7091 in
mm
17.995 mm - 18 mm 0.7085 in - 0.7087 in
Piston Pin Length
48 mm
1.8898 in

Piston Pin Clearance to Piston Bore
Piston Pin Clearance to Conrod Bore
0.005 mm - 0.010
mm
0.010 mm - 0.018
mm
0.0002 in - 0.00039 in
0.0039 in - 0.00070 in
Crankshaft
Crankshaft Bearing Journal Standard Diameter

(brown or green)
50.004 mm -50.017
mm
Crankshaft Bearing Journal Undersize 0.25 Diameter 49.754 mm -49.767

mm
(brown/blue or green/blue)
Crankshaft Bearing Journal Undersize 0.5 Diameter 49.504 mm -49.517
mm
(brown/white or green/white)
23.000 mm -23.052
Crankshaft Bearing Journal Width Standard
mm
23.200 mm -23.252
Crankshaft Bearing Journal Width Undersize 0.25
mm
23.400 mm -23.452
Crankshaft Bearing Journal Width Undersize 0.4
mm
1.989 mm -1.995
Crankshaft Bearing Mark 328N (brown) - Thickness
mm
1.995 mm -2.001
Crankshaft Bearing Mark 329N (green) - Thickness
mm
2.114 mm - 2.120
Crankshaft Bearing Mark 330N - Thickness
mm
Undersize 0.25 (brown/blue)
Crankshaft Bearing Mark 331 - Thickness Undersize 2.120 mm - 2.126
mm
0.25 (green/blue)
mm
0.5 (brown/white)
mm
0.5 (green/white)
0.007 mm - 0.031
Crankshaft Bearing Clearance
mm
0.100 mm - 0.202
Crankshaft Bearing Clearance Axial
mm
0.03 mm
Crankshaft Bearing Out Of Round
42.971 mm - 42.987
Connecting Rod Bearing Journal Diameter Standard
mm
42.721 mm -42.737
Connecting Rod Bearing Journal Diameter
mm
Undersize 0.25 (blue)
42.471 mm -42.487
Connecting Rod Bearing Journal Diameter
mm
Undersize 0.5 (white)
1.490 mm - 1.500
Connecting Rod Bearing Thickness Standard
mm
1.9687 in - 1.9692 in
1.9588 in - 1.9593 in
1.949 in - 1.9495 in
0.9055 in - 0.9076 in
0.9134 in - 0.9154 in
0.9213 in - 0.9233 in
0.0783 in - 0.0785 in
0.0785 in - 0.0788 in
0.0832 in - 0.0835 in
0.0835 in - 0.0837 in
0.0881 in - 0.0884 in
0.0884 in - 0.0886 in
0.0003 in - 0.0012 in
0.0039 in - 0.008 in
0.0012 in
1.6918 in - 1.6924 in
1.6819 in - 1.6826 in
1.6721 in - 1.6727 in
0.0587 in - 0.0591 in

0.0685 in - 0.0689 in
Connecting Rod Bearing Diameter Standard (upper

and lower)
1.615 mm - 1.625
mm
1.740 mm - 1.750
mm
1.490 mm - 1.500
mm
Connecting Rod Bearing Diameter Undersize 0.25

(upper and lower)
1.615 mm - 1.625
mm
0.0636 in - 0.064 in
Connecting Rod Bearing Diameter Undersize 0.5

(upper and lower)
Connecting Rod Bearing Clearance
1.740 mm - 1.750
mm
0.013 mm - 0.061
mm
Connecting Rod Bearing Thickness Undersize 0.25
Connecting Rod Bearing Thickness Undersize 0.5
0.0636 in - 0.064 in
0.0587 in - 0.0591 in
0.0685 in - 0.0689 in
0.0005 in - 0.0024 in
Cylinder Head
1.4 mm - 1.8 mm
0.0551 in - 0.0709 in
1 mm -1.4 mm
0.0394 in - 0.0551 in
Cylinder Head - Intake Valve Seat Width
Cylinder Head - Exhaust Valve Seat Width
Cylinder Head - Valve Seat Angle
Cylinder Head - Valve Seat Angle Adjustment

Upper
110
Cylinder Head - Valve Seat Angle Adjustment

Lower
60
Cylinder Head - Intake Valve Guide Inner Diameter

Standard
4.991 mm - 5.007
mm
0.1965 in - 0.1971 in

+ 0.075
5.066 mm - 5.082
mm
0.1994 in - 0.2001 in

0.150
5.141 mm -5.157
mm
0.2024 in - 0.203 in
Cylinder Head - Exhaust Valve Guide Inner

Diameter Standard
4.991 mm - 5.007
mm
0.1965 in - 0.1971 in

Diameter + 0.075
5.066 mm - 5.082
mm
0.1994 in - 0.2001 in

Diameter + 0.150
5.141 mm - 5.157
mm
0.2024 in - 0.203 in
Cylinder Head - Valve Guide Length
38.7 mm - 39.3 mm
1.5236 in - 1.5472 in
Cylinder Head - Surface Flatness (max) - Block

Deck - longitude
0.05 mm
0.00197 in
Cylinder Head - Surface Flatness (max) - Block

Deck - transverse
Valve Train
0.03 mm
0.00118 in
92.9 mm
3.6575 in
Intake Valve Length Standard
90 30`

Exhaust Valve Length Standard
Intake Valve Stem Diameter Standard
Exhaust Valve Stem Diameter Standard
Intake Valve Stem Diameter + 0.075
Exhaust Valve Stem Diameter + 0.075
Intake Valve Stem Diameter + 0.150
Exhaust Valve Stem Diameter + 0.150
Intake Valve Disc Diameter
Exhaust Valve Disc Diameter
Valve Spring Height Free
Valve Spring Height Under Load - Valve open
Valve Spring Height Under Load - Valve closed
Valve Clearance to Guide Intake
Valve Clearance to Guide Exhaust
92.7 mm
4.950 mm - 4.965
mm
4.930 mm - 4.945
mm
5.025 mm - 5.040
mm
5.005 mm - 5.020
mm
5.100 mm - 5.115
mm
5.080 mm - 5.095
mm
27.9 mm - 28.1 mm
3.6496 in
0.1949 in - 0.1955 in
0.1941 in - 0.1947 in
0.1978 in - 0.1984 in
0.197 in - 0.1976 in
0.2008 in - 0.2014 in
0.2 in - 0.2006 in
1.0984 in - 1.1063 in
24.9 mm - 25.1
0.9803 in - 0.9882 in
40 mm
1.5748 in
21.5 mm
0.8465 in
30 mm
0.026 mm - 0.057
mm
0.046 mm - 0.077
mm
1.1811 in
0.001 in - 0.0022 in
0.0015 in - 0.003 in
Engine Oil
Quality
Filling - With New Oil Filter
Viscosity
Oil Pressure @ Idle Speed
Oil Pressure @ 3000 rpm - 3500 rpm

Oil Pump
Dexos I
4L
4.25 Quarts
5W-30
150 kpa
22 psi
380 kpa - 650 kpa
55 psi - 94 psi
Axial Clearance Vane Rotor to Cover
0.01 mm
0.0004 in
Axial Clearance Vane to Cover
0.09 mm
0.0036 in
Axial Clearance Vane Ring to Cover
0.04 mm
0.0016 in
Axial Clearance Slide to Cover
0.08 mm
0.0031 in
Axial Clearance Slide Seal to Cover
0.09 mm
0.0036 in
Radial Clearance Vane to Vane Rotor
0.05 mm
0.002 in
Radial Clearance Vane to Slide
0.2 mm
0.008 in


Application
Bolt Connections
Camshaft Bearings
Camshaft Cover Bolt
Camshaft Front Oil Seal
Camshafts
Crankshaft Bearing Lubricant
Engine Block Oil Gallery Plugs
Engine Oil
Intake and Exhaust Valves
Oil Pan
Oxygen Sensor
Oxygen Sensor Threads
Rear Crankshaft Main Bearing
Cap
Rear Crankshaft Oil Seal
Rod Bearing - Rod Pins of
Crankshaft
Seal Rings
Turbo Heat Shield Fastener
Water Pump Bearing
Type of Material
Screw Locking
Compound
Dexos1 Engine Oil
Pipe Sealant
Sealant
Dexos1 Engine Oil
Dexos1 Engine Oil
Sealant
Dexos1 Engine Oil
Dexos1 Engine Oil
Sealant
Assembly Paste - White
Anti-seize
12345382
10953489
19293000
12346004
1052943
19293000
19293000
1052943
19293000
19293000
12378521
88862477
12397953
19286321
10953480
10953491
19286321
19286321
10953491
19286321
19286321
88901148
88862478
NA
Sealant
12378521
88901148
Dexos1 Engine Oil
19293000
19286321
Dexos1 Engine Oil
19293000
19286321
Silicone Grease - White

Lubricant
Sealant
12345579
12345996
1052943
10953481
10953501
10953491
COMPONENT LOCATOR
DISASSEMBLED VIEWS
Accessory Drive Components
GM Part Number
United States
Canada

Fig. 1: Accessory Drive Components

Callout
1
2
3
4
5
6
7
8
9
10
11
12
Component Name
Generator And Air Conditioning Compressor Belt
Drive Belt Tensioner Bolt (short)
Drive Belt Tensioner Bolt (long)
Drive Belt Tensioner
Upper Generator Bolt
Water Pump Pulley
Water Pump Bolt (Long)
Water Pump Bolt (Short)
Water Pump
Generator
Air Conditioning Compressor Bolt

13
14
15
16
17
18
Air Conditioning Compressor

Air Conditioning Compressor Bracket Bolt
Air Conditioning Compressor Bracket
Lower Generator Bolt
Crankshaft Balancer
Crankshaft Balancer Bolt
Engine Front Cover And Oil Pump Assembly (1 of 2)
Fig. 2: Engine Front Cover And Oil Pump Assembly Components (1 Of 2)

Callout
1
2
3
4
Component Name
Camshaft Position Actuator Solenoid Valve Bolt
Intake Camshaft Position Actuator Solenoid Valve
Exhaust Camshaft Position Actuator Solenoid Valve
Intake Camshaft Position Sensor Bolt

5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
Intake Camshaft Position Sensor

Intake Camshaft Position Sensor Seal Ring
Engine Front Cover
Engine Front Cover Gasket
Exhaust Camshaft Position Sensor Seal Ring
Exhaust Camshaft Position Sensor
Exhaust Camshaft Position Sensor Bolt
Engine Front Cover Oil Gallery Plug
Engine Front Cover Oil Gallery Plug Seal Ring
Oil Pressure Relief Valve Piston
Oil Pressure Relief Valve Spring
Oil Pressure Relief Valve Plug
Engine Front Cover Bolt (M10)
Crankshaft Front Oil Seal
Engine Front Cover Bolt (M6)
Water Drain Plug Seal Ring
Water Drain Plug
Exhaust Camshaft Position Actuator Solenoid Valve Bolt
Engine Front Cover And Oil Pump Assembly (2 of 2)

Fig. 3: Engine Front Cover And Oil Pump Assembly (2 of 2)

Callout
1
2
3
4
5
6
7
8
9
10
11
12
Component Name
Oil Pump Cover Bolt
Oil Pump Cover
Oil Pump Vane Ring
Oil Pump Vane Rotor
Oil Pump Vane
Oil Pump Slide Spring Pin
Oil Pump Slide Spring
Oil Pump Slide Pivot Pin
Oil Pump Slide Seal
Oil Pump Slide Seal Spring
Oil Pump Slide
Oil Pump Vane Ring

Timing Chain Components
Fig. 4: Timing Chain Components

Callout
1
2
3
4
5
6
7
8
9
10
11
Component Name
Timing Chain Tensioner Bolt
Timing Chain Tensioner
Timing Chain Tensioner Shoe
Camshaft Timing Chain
Intake Camshaft Sprocket Bolt (With Actuator)
Intake Camshaft Position Sensor Exciter Wheel
Intake Camshaft Sprocket (With Position Actuator)
Upper Timing Chain Guide Bolt
Upper Timing Chain Guide
Exhaust Camshaft Sprocket (With Position Actuator)
Exhaust Camshaft Position Sensor Exciter Wheel

12
13
14
15
16
17
Exhaust Camshaft Sprocket Bolt (With Actuator)

Timing Chain Guide Pivot Pin
Crankshaft Sprocket
Timing Chain Guide Right Side
Timing Chain Guide Bolt
Timing Chain Tensioner Shoe Bolt
Intake Manifold Assembly- 1.4L LDD
Fig. 5: Identifying Intake Manifold Assembly Components - 1.4L LDD

Callout
1
2
3
Component Name
Intake Manifold Sealings
Intake Manifold (With Intake Manifold Runner and Intake Manifold
Runner Valve)
Throttle Body Bolt

4
5
6
7
8
9
10
11
12
13
14
15
16
Throttle Body
Throttle Body Seal Ring
Fuel Injection Fuel Rail Bolt
Evaporative Emission Canister Purge Solenoid Valve
Evaporative Emission Canister Purge Solenoid Valve Rubber
Evaporative Emission Canister Purge Solenoid Valve Bracket Bolt
Evaporative Emission Canister Purge Solenoid Valve Bracket
Fuel Injection Fuel Rail
Fuel Injector Retainer Clamp
Fuel Injector
Manifold Absolute Pressure Sensor Bolt
Manifold Absolute Pressure Sensor
Manifold Absolute Pressure Sensor Seal Ring
Cylinder Head Assembly
Fig. 6: Identifying Cylinder Head Assembly Components


Callout
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
Engine Block Assembly- 1.4L LDD
Component Name
Camshaft Cover
Oil Level Indicator
Camshaft Cover Bolt
Oil Filler Cap
Oil Filler Cap Seal Ring
Camshaft Cover Gasket
Camshaft Bearing Cap Bolt
Camshaft Bearing Cap
Cylinder Head Bolt
Valve Keys
Valve Spring Retainer
Valve Spring
Engine Lift Bracket Left Side
Cylinder Head
Intake Valve
Exhaust Valve
Engine Lift Bracket
Engine Lift Bracket
Oil Pressure Indicator Switch (only for 1.4L LDD)
Oil Pressure Indicator Switch Seal Ring (only for 1.4L LDD)
Hydraulic Valve Lash Adjuster
Hydraulic Valve Lash Adjuster Arm
Exhaust Camshaft
Intake Camshaft

Fig. 7: Identifying Engine Block Assembly Components - 1.4L LDD

Callout
1
2
3
4
5
6
7
8
9
10
11
12
Component Name
Transmission Guide Sleeve
Cylinder Head Guide Sleeve
Engine Block
Knock Sensor
Knock Sensor Bolt
Upper Crankshaft Thrust Bearing
Upper Crankshaft Bearing
Crankshaft
Lower Crankshaft Bearing
Lower Crankshaft Thrust Bearing

13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
Crankshaft Bearing Cap Tie Plate

Crankshaft Bearing Cap Tie Plate Bolt (M10)
Oil Pan
Oil Pan Bolt
Oil Pan Drain Plug Seal Ring
Oil Pan Drain Plug
Crankshaft Position Sensor
Crankshaft Position Sensor Seal Ring
Crankshaft Position Sensor Reluctor Ring
Flywheel Bolt
Engine Flywheel
Crankshaft Rear Oil Seal
Crankshaft Position Sensor Reluctor Ring Bolt
Connecting Rod Bearing Cap Bolt
Lower Connecting Rod Bearing
Upper Connecting Rod Bearing
Connecting Rod
Piston Pin
Piston
Piston Oil Ring (With oil Ring Spacer)
Lower Compression Ring
Upper Compression Ring
Engine Block Assembly- 1.4L LUH and LUJ

Fig. 8: Identifying Engine Block Assembly Components - 1.4L LUH and LUJ
Callout
1
2
3
4
5
6
7
8
9
10
11
12
Component Name
Cylinder Head
Knock Sensor
Knock Sensor Bolt
Upper Crankshaft Thrust Bearing
Upper Crankshaft Bearing
Crankshaft
Lower Crankshaft Bearing
Lower Crankshaft Thrust Bearing

13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
Crankshaft Bearing Cap Tie Plate

Oil Pan Baffle
Oil Pan Baffle Bolt
Oil Pan
Oil Pan Bolt
Oil Pan Drain Plug
Crankshaft Position Sensor Seal Ring
Piston Oil Nozzle
Crankshaft Position Sensor Reluctor Ring
Crankshaft Position Sensor Reluctor Ring Bolt
Crankshaft Rear Oil Seal
Engine Flywheel (Two-Mass)
Engine Flywheel Bolt
Connecting Rod Bearing Cap Bolt
Lower Connecting Rod Bearing
Upper Connecting Rod Bearing
Connecting Rod
Piston Pin
Piston Pin Retainer
Piston Pin Retainer
Piston
Piston Oil Ring (With Oil Ring Spacer)
Lower Compression Ring
Upper Compression Ring
Intake Manifold Assembly- 1.4L LUH and LUJ

Fig. 9: Intake Manifold Assembly - 1.4L LUH and LUJ

Callout
1
2
3
4
5
6
7
8
9
10
Exhaust Side- 1.4L LUH and LUJ
Component Name
Fuel Injector Fuel Rail
Fuel Injector Fuel Rail Bolt
Manifold Absolute Pressure Sensor
Manifold Absolute Pressure Sensor Bolt
Evaporative Emission Canister Purge Solenoid Valve
Intake Manifold
Throttle Body Seal Ring
Throttle Body
Throttle Body Bolt
Intake Manifold Gasket

Fig. 10: Identifying Exhaust Side Components - 1.4L LUH and LUJ
Callout
1
2
3
4
5
6
7
8
9
10
11
12
Component Name
Positive Crankcase Ventilation Pipe Assembly
Exhaust Manifold Gasket
Turbo Charger Oil Feed Pipe Hollow Screw
Turbo Charger Oil Feed Pipe
Turbo Charger Oil Feed Pipe Bolt
Oil Cooler Coolant Outlet Hose
Oil Cooler Coolant Outlet Hose Clamp
Oil Cooler Coolant Feed Pipe Bolt
Oil Cooler Coolant Feed Pipe
Engine Oil Cooler Assembly
Catalytic Converter Bracket
Catalytic Converter to Catalytic Converter Bracket Nut

13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
ENGINE IDENTIFICATION
Engine Number
Turbocharger Coolant Return Pipe

Turbocharger Coolant Feed Pipe
Turbocharger Coolant Feed Pipe Hollow Screw
Heated Oxygen Sensor 1
Catalytic Converter
Catalytic Converter Heat Shield
Catalytic Converter Heat Shield Bolt
Catalytic Converter Seal
Catalytic Converter V-Clamp
Turbocharger Oil Return Pipe
Turbocharger Oil Return Pipe Bolt
Exhaust Manifold Heat Shield
Exhaust Manifold Heat Shield Bolt
Turbocharger (with Exhaust Manifold)
Engine Oil Pressure Switch

Fig. 11: Engine Number

NOTE:
The engine identification number must be stamped to the cylinder block in case
of engine replacement.
The engine number is stamped to the engine block (1).

SYMPTOMS - ENGINE MECHANICAL
Strategy Based Diagnostics
Perform a Diagnostic System Check - Vehicle .

All diagnosis on a vehicle should follow a logical process. Strategy based diagnostics is a uniform approach for

repairing all systems. The diagnostic flow may always be used in order to resolve a system condition. The
diagnostic flow is the place to start when repairs are necessary.
Inspect for aftermarket devices which could affect the operation of the engine.
cause the symptom.
Inspect for the correct oil level, proper oil viscosity, and correct filter application.
ambient temperature, engine temperature, amount of engine warm-up time, and other specifics.
Compare the engine sounds, if applicable, to a known good engine and make sure you are not trying to
correct a normal condition.
Intermittent
properly.
Symptom List
Base Engine Misfire without Internal Engine Noises

Base Engine Misfire with Abnormal Internal Lower Engine Noises
Base Engine Misfire with Abnormal Valve Train Noise
Base Engine Misfire with Coolant Consumption
Base Engine Misfire with Excessive Oil Consumption
Engine Noise on Start-Up, but Only Lasting a Few Seconds
Upper Engine Noise, Regardless of Engine Speed
Lower Engine Noise, Regardless of Engine Speed
Engine Noise Under Load
Engine Will Not Crank - Crankshaft Will Not Rotate
Engine Compression Test
Oil Consumption Diagnosis
Oil Pressure Diagnosis and Testing
Drive Belt Chirping, Squeal, and Whine Diagnosis
Drive Belt Rumbling and Vibration Diagnosis
Drive Belt Falls Off and Excessive Wear Diagnosis
OIL PRESSURE DIAGNOSIS AND TESTING

Special Tools

EN-498-B Oil Pressure Gauge

EN-498-3 Adapter

Removal Procedure
1. Disconnect the oil pressure indicator switch wiring harness plug.
Fig. 12: Engine Oil Pressure Indicator Switch

2. Remove the oil pressure indicator switch (1) and the oil pressure indicator switch seal ring (2).
Measuring Procedure

Fig. 13: Gauge And Adapter

1. Install EN-498-B gauge (1) along with EN-498-3 adapter (2).
2. Start Engine.
NOTE:
The oil temperature should be between 80C (176F)and 100C (212).
3. Measure the oil pressure:

The oil pressure at idle speed should be 150 kpa (22 psi).
The oil pressure between 3000 - 3500 rpmshould be 380 - 650 kpa (55 - 94 psi).
4. Stop engine.
5. If the engine oil pressure is below specifications, inspect the engine for 1 or more of the following
conditions:
Oil pump worn or dirty. Refer to Oil Pump Replacement, and Engine Front Cover and Oil

Pump Cleaning and Inspection.

Oil suction gallery clogged or dirty. Refer to Oil Pan Cleaning and Inspection
Cracked, porous, or restricted oil galleries.
Oil pressure relief valve malfunction.
6. Remove EN-498-B gauge and EN-498-3 adapter.
Fig. 14: Engine Oil Pressure Indicator Switch

1. Install the oil pressure indicator switch (1) and a NEW oil pressure indicator switch seal ring (2).

2. Tighten the oil pressure indicator switch to 20 N.m (15 lb ft).

OIL LEAK DIAGNOSIS
Oil Leak Diagnosis
Step
Action
Yes
No
DEFINITION: You can repair most fluid leaks by first, visually locating the leak, repairing or replacing
the component, or by resealing the gasket surface. Once the leak is identified, determine the cause of the
leak. Repair the leak and the cause of the leak.
1. Operate the vehicle until it reaches normal operating

temperature. Refer to Engine Mechanical
Specifications.
2. Park the vehicle on a level surface over a large sheet of
paper or other clean surface.
3. Wait 15 minutes.
4. Inspect for drippings.
Are drippings present?
Can you identify the type of fluid and the approximate
location of the leak?
System OK
Go to Step 3
Go to Step
10
Go to Step 4
Go to Step
10
Go to Step 5
1. Visually inspect the suspected area. Use a small mirror

to assist in looking at hard to see areas.
2. Inspect for leaks at the following locations:
Sealing surfaces
Fittings
Cracked or damaged components
Go to Step 2
Go to Step
10
1. Completely clean the entire engine and surrounding

components.
2. Operate the vehicle for several miles at normal
operating temperature and at varying speeds.
4. Wait 15 minutes.
5. Identify the type of fluid and the approximate location
of the leak.


Sealing surfaces
Fittings
Go to Step 6
Go to Step
10
Go to Step 7
Go to Step
10
Go to Step 8
Go to Step
10
Go to Step 9
Go to Step
10
System OK

components.
2. Apply an aerosol-type powder, for example, baby
powder or foot powder, to the suspected area.
of the leak from the discolorations in the powder
surface.
Go to Step
10

Sealing surfaces
Fittings
Identify the type of fluid and the approximate location of the
leak.
Sealing surfaces
Fittings

10
11
1. Inspect the engine for mechanical damage. Special

interest should be shown to the following areas:
Higher than recommended fluid levels
Higher than recommended fluid pressures
Plugged or malfunctioning fluid filters or pressure
bypass valves
Plugged or malfunctioning engine ventilation
system
Improperly tightened or damaged fasteners
Cracked or porous components
Improper sealants or gaskets, where required
Improper sealant or gasket installation
Damaged or worn gaskets or seals
Damaged or worn sealing surfaces
2. Inspect the engine for customer modifications.
Is there mechanical damage or customer modifications to the
engine?
Repair or replace all damaged or modified components.
Go to Step
11
Go to Step 1
System OK
-
OIL CONSUMPTION DIAGNOSIS

Checks
Causes
The causes of excessive oil consumption may include the following conditions:
Preliminary
External oil leaks.
Incorrect oil level or improper reading of the oil level

indicator.
With the vehicle on a level surface, run the engine for a few
minutes, allow adequate drain down time (2-3 minutes) and
check for the correct engine oil level.
Improper oil viscosity.

Refer to the vehicle owners manual and use the
recommended SAE grade and viscosity for the prevailing
temperatures.
Continuous high speed driving and/or severe usage.

Crankcase ventilation system restrictions or malfunctioning

components.
Worn valve guides and/or valve stems.
Worn, missing or improperly installed valve stem oil seals.
Piston rings broken, worn, not seated properly.
Allow adequate time for the rings to seat.
Replace worn piston rings as necessary.
Piston and rings improperly installed or miss-fitted to the

cylinder bore.
ENGINE NOISE UNDER LOAD

Cause
Low oil pressure
Correction
Insufficient or poor oil supply to components.
1. Perform oil pressure test.
2. Repair or replace all damaged components.
Loose torque converter bolts
1. Inspect the torque converter bolts and flywheel.

Loose and/or damaged flywheel
1. Inspect the flywheel and flywheel attaching bolts.

Excessive piston-to-cylinder bore

clearance
1. Inspect the piston rings for low ring tension, broken or worn
rings, inspect cylinder bore.
Excessive crankshaft thrust bearing

clearance
1. Inspect the crankshaft end play and crankshaft thrust

bearings.
Excessive crankshaft bearing

clearance
1. Inspect the crankshaft bearings and crankshaft journals.

ENGINE NOISE ON START-UP, BUT ONLY LASTING A FEW SECONDS

Cause
Correction
Incorrect oil filter without anti-drainback feature Install the correct oil filter.
Incorrect oil viscosity
Drain the engine oil and replace with the correct
viscosity oil.
High stationary hydraulic lash adjuster (SHLA), Replace the SHLAs, valve lifters, as required.

valve lifter, leak down rate

Worn crankshaft thrust bearing
Damaged or faulty oil filter by-pass valve
Inspect the thrust bearing and crankshaft.

Repair or replace as required.
Inspect the oil filter by-pass valve for proper
operation.
BASE ENGINE MISFIRE WITHOUT INTERNAL ENGINE NOISES

Condition
Action
Abnormalities in the accessory drive belt and/or
components may cause engine RPM variations, noises
Abnormalities (severe cracking, bumps or
similar to a faulty lower engine and also lead to a misfire
missing areas) in the accessory drive belt.
condition. A misfire code may be present without an actual
Also worn, damaged, or misaligned
misfire condition.
accessory drive components or excessive
pulley runout.
1. Inspect the accessory drive components.
A misfire code may be present without an actual misfire
condition.
Loose and/or damaged crankshaft pulley
1. Inspect crankshaft pulley and pulley bolt.
condition.
1. Inspect torque converter bolts and flywheel.
condition.
Restricted exhaust system
1. Inspect flywheel and flywheel attaching bolts.

A severe restriction in the exhaust flow can cause
significant loss of engine performance and may set a
misfire code. Possible causes of restrictions include
collapsed or dented pipes, plugged mufflers and/or catalytic
converters. Repair or replace all damaged components.
Air in fuel system
1. Inspect fuel filter, fuel system for leaks and/or

restrictions.
Bent and/or worn valve bridge and finger-
1. Inspect valve bridge and valve finger-follower.

follower

Carbon on the valve stem or valve seat may cause the valve
to stick.
Sticking valve
1. Inspect valves and valve guides.
Damaged or misaligned timing gears
1. Inspect timing gears.

2. Replace all damaged components.
Worn or faulty camshaft lobes
1. Inspect camshaft lobes.

Excessive piston-to-cylinder bore clearance
1. Perform compression tests.

2. Inspect the piston, piston rings and cylinder bore.
Faulty cylinder head gaskets and/or cracking

or other damage to the cylinder heads and
engine block cooling system passages.
(Coolant consumption may or may not cause
the engine to overheat.)
1. Perform compression tests.

BASE ENGINE MISFIRE WITH ABNORMAL INTERNAL LOWER ENGINE NOISES

Condition
Actions
Abnormalities (server cracking, bumps or
Abnormalities in the accessory drive belt and/or
missing areas) in the accessory drive belt
components may cause engine RPM variations, noises
similar to faulty lower engine and also lead to a misfire
condition. A misfire code may be present without an actual
misfire condition.
Worn, damaged, or misaligned accessory

drive components or excessive pulley runout

condition.
2. Repair or replace all damage components.
condition.


condition.

condition.

1. Inspect flywheel and flywheel attaching bolts.
1. Perform cylinder leak down and compression tests.
Severely worn thrust surfaces on the crankshaft and/or
thrust bearing may permit for and aft movement of the
crankshaft and create a misfire code without an actual
misfire condition.
Excessive crankshaft thrust bearing
clearance
1. Inspect the crankshaft end play and crankshaft thrust
bearings.
2. Repair or replace all damaged.
BASE ENGINE MISFIRE WITH ABNORMAL VALVE TRAIN NOISE
Condition
Loose, worn or damaged valve bridge
and finger-follower
Broken valve springs
Action
1. Inspect valve bridge and finger-follower.

1. Inspect valve springs.
Carbon on the valve stem or valve seat may cause the valve to
stick.
Sticking valve

BASE ENGINE MISFIRE WITH COOLANT CONSUMPTION

Inspection
DEFINITION: Base engine misfire with coolant consumption
Action

Preliminary Inspection
Verify that there are no external coolant leaks.
Isolate Affected Cylinders
EGR System Inspection
Cylinder Head Gasket Leakage
Cylinder Head or Engine Block

Damage
Cylinder balance test with scan tool

Cooling system pressurization
Inspection of glow plugs
Compression test
Inspect EGR valve and intake system for evidence of
coolant leakage.
Replace the EGR cooler if any problem is found.
Remove cylinder heads of the affected cylinder bank and
inspect for damage.
Replace components as necessary.
Inspect the cylinder head for cracks.
Inspect the cylinder block for damage.
Inspect the cylinder block to head mating surface for
straightness.
Replace components as necessary.
BASE ENGINE MISFIRE WITH EXCESSIVE OIL CONSUMPTION

Condition
Action
Worn valve guides
1. Inspect the valves and valve guides.

Worn valve stem oil seals
1. Inspect the valve stem oil seals.

Excessive piston-to-cylinder bore

clearance
1. Perform compression tests to determine the cause.

2. Inspect the piston rings for low ring tension, broken or worn
rings.
3. Inspect cylinder bore.
UPPER ENGINE NOISE, REGARDLESS OF ENGINE SPEED

Condition
Action
Insufficient or poor oil supply to valve train.
Low oil pressure


1. Inspect valve finger-follower, valve bridge, valve finger

follower lifter, oil pump and engine block oil galleries.
Improper lubrication to the valve

finger-follower
Worn or damaged valve fingerfollower
1. Inspect valve bridge and finger-follower.

Carbon on the valve stem or valve seat may cause the valve to
stick.
Sticking valve

2. If damaged replace camshaft and all valve finger-followers.
Damaged or misaligned timing gears
1. Inspect timing gears.

2. Replace all damaged components.
LOWER ENGINE NOISE, REGARDLESS OF ENGINE SPEED

Condition
Action
Worn accessory drive components
(abnormalities such as severe cracking,
bumps or missing areas in the accessory
drive belt and/or misalignment of the system
components.)
Insufficient or poor oil supply to crankshaft and connecting
rod bearings.
Low oil pressure
Leaking and/or sticking fuel injection nozzle

(A stuck fuel injection nozzle can cause a
noise similar to a damaged piston, rod or rod
bearing.)
1. Inspect the cylinder balance with scan tool to help

locate the cylinder that is the source of the noise.
2. If you cannot locate the cylinder that is the source of
the noise, diagnose the engine for mechanical
damage.
3. If it has been determined that the fuel injection
nozzle is causing the noise, replace the fuel injection
nozzle.



1. Inspect flywheel and flyweel attaching bolts.

Excessive piston pin-to-bore clearance
1. Inspect the piston, piston pin, and the connecting

rod.
Misaligned or bent connecting rod
1. Inspect connecting rod and connecting rod bearings.

Excessive connecting rod bearing clearance
1. Inspect the connecting rod bearings, connecting rods,

crankshaft and crankshaft journals.
Excessive crankshaft bearing clearance
1. Inspect the crankshaft bearings and crankshaft

journals.
ENGINE WILL NOT CRANK - CRANKSHAFT WILL NOT ROTATE

Cause
Seized accessory drive system component
Hydraulically locked cylinder
Coolant/antifreeze in cylinder
Oil in cylinder
Fuel in cylinder
Correction
1. Inspect the accessory drive system
components.
2. Repair or replace all damaged
components.
1. Inspect for broken head gasket(s).
2. Inspect for cracked engine block or
cylinder head.
3. Inspect for a sticking fuel injector.
Seized automatic transmission torque converter
1. Remove the engine assembly. The

torque converter bolts are not accessible
with the engine installed to the
transmission.
2. Rotate the crankshaft at the pulley.
Seized manual transmission
1. Disengage the clutch.

2. Rotate crankshaft at the pulley.
Material in cylinder
Broken valve
Piston material
Foreign material
1. Inspect the cylinder for damaged

components and/or foreign materials.
2. Repair or replace as required.
1. Inspect the crankshaft and connecting

Seized crankshaft or connecting rod bearing
rod bearings.
2. Repair as required.
Bent or broken connecting rod
1. Inspect the connecting rods.

Broken crankshaft
1. Inspect the crankshaft.

ENGINE COMPRESSION TEST

Special Tools
EN-48248 Cylinder Compression Pressure Gauge

Removal Procedure
1.
2.
3.
4.
Remove the throttle body assembly. Refer to Throttle Body Assembly Replacement .
Remove the spark plugs. Refer to Spark Plug Replacement .
Remove the relay holder cover.
Remove the fuel pump relay.
NOTE:
The engine cranking time for the compression test should be less then 10
seconds and at 30 second intervals.
5. Crank the engine with the starter motor for 5 seconds to remove any foreign substances from the
cylinders.
6. Prior to taking a compression reading, verify the cranking speed is greater than 300 RPM. If the cranking
speed is below 300 RPM, repair the slow cranking speed condition before continuing with the
compression test.
7. Install EN-48248 gauge in the spark plug bore for the cylinder that is being checked.
8. Using the vehicle's starter motor, rotate or crank the engine for 4 compression strokes, puffs, for the
cylinder being tested.
9. Observe the compression gauge and note the reading as the compression test is being performed. A
normal cylinder reading will be indicated if compression builds up quickly and evenly to the specified
level. An abnormal reading will be indicated if compression is low on the first compression stroke, starts
increasing on the following compression strokes but does not reach the specified level.
10. Record the compression reading for the cylinder just tested.
11. Repeat steps for all remaining cylinders. All 4 cylinders must be tested to obtain valid test results. Record
the readings.
12. The maximum pressure differential should not exceed 100 kPa (14.5 psi).
13. The nominal cylinder compression value is

for natural aspirated engines 1300 kPa - 1500 kPa (188.5 psi - 217.6 psi).
for turbo engines 1200 kPa - 1400 kPa (174 psi - 203.1 psi).
1.
2.
3.
4.
Install the fuel pump relay.

Install the relay holder cover.
Install the spark plugs. Refer to Spark Plug Replacement .
Install the throttle body assembly. Refer to Throttle Body Assembly Replacement .
DRIVE BELT CHIRPING, SQUEAL, AND WHINE DIAGNOSIS

Diagnostic Aids
A chirping or squeal noise may be intermittent due to moisture on the drive belts or the pulleys. It may be
necessary to spray a small amount of water on the drive belts in order to duplicate the customers concern.
If spraying water on the drive belt duplicates the symptom, cleaning the belt pulleys may be the probable
solution.
If the noise is intermittent, verify the accessory drive components by varying their loads making sure they
are operated to their maximum capacity. An overcharged A/C system, power steering system with a
pinched hose or wrong fluid, or a generator failing are suggested items to inspect.
A chirping, squeal or whine noise may be caused by a loose or improper installation of a body or
suspension component. Other items of the vehicle may also cause the noise.
The drive belts will not cause a whine noise.
Test Description
2
The noise may not be engine related. This step is to verify that the engine is making the noise. If the
engine is not making the noise do not proceed further with this table.
3
The noise may be an internal engine noise. Removing the drive belts one at a time and operating the
engine for a brief period will verify the noise is related to the drive belt. When removing the drive belt the
water pump may not be operating and the engine may overheat. Also DTCs may set when the engine is
operating with the drive belts removed.
4
Inspect all drive belt pulleys for pilling. Pilling is the small balls or pills or it can be strings in the drive
belt grooves from the accumulation of rubber dust.

6
Misalignment of the pulleys may be caused from improper mounting of the accessory drive component,
incorrect installation of the accessory drive component pulley, or the pulley bent inward or outward from
a previous repair. Test for a misaligned pulley using a straight edge in the pulley grooves across two or
three pulleys. If a misaligned pulley is found refer to that accessory drive component for the proper
installation procedure for that pulley.
10
Inspecting of the fasteners can eliminate the possibility that a wrong bolt, nut, spacer, or washer was
installed.
12
Inspecting the pulleys for being bent should include inspecting for a dent or other damage to the pulleys
that would prevent the drive belt from not seating properly in all of the pulley grooves or on the smooth
surface of a pulley when the back side of the belt is used to drive the pulley.
14
This test is to verify that the drive belt tensioner operates properly. If the drive belt tensioner is not
operating properly, proper belt tension may not be achieved to keep the drive belt from slipping which
could cause a squeal noise.
15
This test is to verify that the drive belt is not too long, which would prevent the drive belt tensioner from
working properly. Also if an incorrect length drive belt was installed, it may not be routed properly and
may be turning an accessory drive component in the wrong direction.
16
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 it is not damaged or there is not excessive pilling will only be a temporary

repair.
Step
Action
Yes
No
CAUTION:
Do not use belt dressing on the drive belt. Belt dressing causes the breakdown of the composition
of the drive belt. Failure to follow this recommendation will damage the drive belt.
DEFINITION: The following items are indications of chirping:
A high pitched noise that is heard once per revolution of the drive belt or a pulley.
Chirping may occur on cold damp start-ups and will subside once the vehicle reaches normal
operating temp.
DEFINITION: The following items are indications of drive belt squeal:
A loud screeching noise that is caused by a slipping drive belt. This is unusual for a drive belt with
multiple ribs.
The noise occurs when a heavy load is applied to the drive belt, such as an air conditioning
compressor engagement snapping the throttle, or slipping on a seized pulley or a faulty accessory
drive component.
DEFINITION: The following items are indications of drive belt whine:

A high pitched continuous noise.
The noise may be caused by an accessory drive component failed bearing.
Did you review the Drive Belt Symptom
1
operation and perform the necessary
Go to Symptoms Go to Step 2
inspections?
Engine Mechanical
Verify that there is a chirping, squeal or
whine noise.
2
Does the engine make the chirping squeal
or whine noise?
Go to Step 3
Go to Diagnostic Aids
1. Remove the drive belt.

If the engine has multiple drive belts,
remove the belts one at a time and
perform the test below each time a
belt is removed.
3
2. Operate the engine for no longer than
30-40 seconds.
3. Repeat this test if necessary by
removing the remaining belt(s).

5
6
7
8
9
10
Does the chirping, squeal or whine noise Go to Symptoms still exist?

Engine Mechanical
If diagnosing a chirping noise, inspect for
severe pilling exceeding 1/3 of the belt
groove depth.
If diagnosing a squeal or whine noise,
proceed to Step 13 .
Do the belt grooves have pilling?
Go to Step 5
Clean the drive belt pulleys with a suitable
wire brush.
Go to Step 20
Inspect for misalignment of the pulleys.
Go to Step 7
Are any of the pulleys misaligned?
Replace or repair any misaligned pulleys.
Go to Step 20
Inspect for bent or cracked brackets.
Did you find any bent or cracked brackets?
Go to Step 9
Replace any bent or cracked brackets.
Go to Step 20
Inspect for improper, loose or missing
fasteners.
Did you find the condition?
Go to Step 11
Go to Step 4
Go to Step 6
Go to Step 6
Go to Step 8
Go to Step 8
Go to Step 10
Go to Step 10
Go to Step 12
CAUTION:
11
12
13
14
15
1. Tighten any loose fasteners. Refer to

Fastener Tightening Specifications.
2. Replace any improper or missing
fasteners.
Inspect for a bent pulley.
Inspect for an accessory drive component
seized bearing or a faulty accessory drive
component.
If diagnosing a whine noise and the
condition still exist, proceed to Diagnostic
Aids.
Test the drive belt tensioner for proper
operation.
Inspect for the correct drive belt length.
Go to Step 20
Go to Step 12
Go to Step 18
Go to Step 19
Go to Step 20
Go to Step 14
Go to Step 20
Go to Step 15
Go to Step 20
Go to Step 16

16
17
18
19
20
Inspect for misalignment of a pulley.

Inspect for the correct pulley size.
Replace the bent pulley.
Replace the drive belt. Refer to Symptoms
- Engine Mechanical.
Operate the system in order to verify the
repair.
Go to Step 20
Go to Step 20
Go to Step 20
Go to Step 20
System OK
Go to Step 17
Go to Step 19
Go to Step 3
DRIVE BELT RUMBLING AND VIBRATION DIAGNOSIS

Diagnostic Aids
The accessory drive components can have an affect on engine vibration. Vibration from the engine operating
may cause a body component or another part of the vehicle to make rumbling noise. Vibration can be caused
by, but not limited to the A/C system over charged, the power steering system restricted or the incorrect fluid, or
an extra load on the generator. To help identify an intermittent or an improper condition, vary the loads on the
accessory drive components.
The drive belt may have a rumbling condition that can not be seen or felt. Sometimes replacing the drive belt
may be the only repair for the symptom.
If replacing the drive belt, completing the diagnostic table, and the noise is only heard when the drive belts are
installed, there might be an accessory drive component with a failure. Varying the load on the different
accessory drive components may aid in identifying which component is causing the rumbling noise.
Test Description
2
This test is to verify that the symptom is present during diagnosing. Other vehicle components may cause
a similar symptom.
3
This test is to verify that one of the drive belts is causing the rumbling noise or vibration. Rumbling noise
may be confused with an internal engine noise due to the similarity in the description. Remove only one
drive belt at a time if the vehicle has multiple drive belts. When removing the drive belts the water pump
may not be operating and the engine may overheat. Also DTCs may set when the engine is operating with
the drive belts removed.

4
Inspecting 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 can be recognized at the edge of the belt or felt as a
lump in the belt.
5
Small amounts of pilling is normal condition and acceptable. When the pilling is severe the drive belt
does not have a smooth surface for proper operation.
9
Inspecting of the fasteners can eliminate the possibility that the wrong bolt, nut, spacer, or washer was
installed.
11
This step should only be performed if the water pump is driven by the drive belt. Inspect the water pump
shaft for being bent. Also inspect the water pump bearings for smooth operation and excessive play.
Compare the water pump with a known good water pump.
12
Accessory drive component brackets that are bent, cracked, or loose may put extra strain on that
accessory component causing it to vibrate.
Step
Action
Yes
DEFINITION: The following items are indications of drive belt rumbling:
A low pitch tapping, knocking, or thumping noise heard at or just above idle.
Heard once per revolution of the drive belt or a pulley.
Rumbling may be caused from:
Pilling, the accumulation of rubber dust that forms small balls (pills) or strings in the drive
belt pulley groove
The separation of the drive belt
A damaged drive belt.
DEFINITION: The following items are indications of drive belt vibration:
No
The vibration is engine-speed related.

The vibration may be sensitive to accessory load.


inspections?
Verify that there is a rumbling noise or that
the vibration is engine related.
Does the engine make the rumbling noise
or vibration?
Go to Step 2
Go to Symptoms Engine Mechanical
Go to Step 3

belt is removed.
3
30-40 seconds.
7
8
Go to Symptoms Does the rumbling or vibration still exist? Engine Mechanical

Inspect the drive belts for wear, damage,
separation, sections of missing ribs, and
debris build-up.
Did you find any of these conditions?
Go to Step 7
Inspect for severe pilling of more than 1/3
of the drive belt pulley grooves.
Did you find severe pilling?
Go to Step 6
Go to Step 5
Go to Step 7
1. Clean the drive belt pulleys using a

suitable wire brush.
2. Reinstall the drive belts.
Install a new drive belt.
repair.
fasteners.
CAUTION:
10
Go to Step 4

Go to Step 8
Go to Step 7
Go to Step 8
Go to Step 9
System OK
Go to Step 9
Go to Step 10
Go to Step 11

2. Replace improper or missing

fasteners.
11
12

repair.
Go to Step 12
Go to Step 12
System OK
Go to Step 11
Go to Step 3
DRIVE BELT FALLS OFF AND EXCESSIVE WEAR DIAGNOSIS

Diagnostic Aids
If the drive belt repeatedly falls off the drive belt pulleys, this is because of pulley misalignment.
An extra load that is quickly applied on released by an accessory drive component may cause the drive belt to
fall off the pulleys. Verify the accessory drive components operate properly.
If the drive belt is the incorrect length, the drive belt tensioner may not keep the proper tension on the drive belt.
Excessive wear on a drive belt is usually caused by an incorrect installation or the wrong drive belt for the
application.
Minor misalignment of the drive belt pulleys will not cause excessive wear, but will probably cause the drive
belt to make a noise or to fall off.
Excessive misalignment of the drive belt pulleys will cause excessive wear but may also make the drive belt fall
off.
Test Description
2
This inspection is to verify the condition of the drive belt. Damage may of occurred to the drive belt when
the drive belt fell off. The drive belt may of been damaged, which caused the drive belt to fall off. Inspect
the belt for cuts, tears or sections of ribs missing.
4
installation procedure of that pulley.

5
6
Accessory drive component brackets that are bent or cracked will let the drive belt fall off.
7
installed. Missing. loose, or the wrong fasteners may cause pulley misalignment from the bracket moving
under load. Over tightening of the fasteners may cause misalignment of the accessory component bracket.
13
The inspection is to verify the drive belt is correctly installed on all of the drive belt pulleys. Wear on the
drive belt may be caused by mis-positioning the drive belt by one groove on a pulley.
14
The installation of a drive belt that is two wide or two narrow will cause wear on the drive belt. The drive
belt ribs should match all of the grooves on all of the pulleys.
15
This inspection is to verify the drive belt is not contacting any parts of the engine or body while the
engine is operating. There should be sufficient clearance when the drive belt accessory drive components
load varies. The drive belt should not come in contact with an engine or a body component when
snapping the throttle.
Step
Action
Yes
No
DEFINITION: The drive belt falls off the pulleys or may not ride correctly on the pulleys.
DEFINITION: Wear at the outside ribs of the drive belt due to an incorrectly installed drive belt.
1
Go to Symptoms - Engine
inspections?
Go to Step 2 Mechanical
If diagnosing high wear, proceed to Step 13 .
If diagnosing a drive belt that falls off, inspect
2
for a damaged drive belt.
Go to Step 3
Go to Step 4
Install a new drive belt. Refer to Drive Belt
3
Replacement.

4
5
6
7
Does the drive belt continue to fall off?

Go to Step 4
Did you find and repair the condition?
Go to Step 12
Inspect for a bent or dented pulley.
Go to Step 12
Inspect for a bent or a cracked bracket.
Go to Step 12
Inspect for improper, loose or missing fasteners.
Go to Step 8
Did you find loose or missing fasteners?
System OK
Go to Step 5
Go to Step 6
Go to Step 7
Go to Step 9
CAUTION:

2. Replace improper or missing fasteners.
10
11
12
13
14
15
16
17

Test the drive belt tensioner for operating
correctly.
Does the drive belt tensioner operate correctly?
Replace the drive belt tensioner. Refer to Drive
Belt Tensioner Replacement.
Inspect for failed drive belt idler and drive belt
tensioner pulley bearings.
Inspect the drive belt for the proper installation.
Refer to Drive Belt Replacement.
Did you find this condition?
Inspect for the proper drive belt.
Inspect for the drive belt rubbing against a
bracket, hose, or wiring harness.
Replace the drive belt. Refer to Drive Belt
Replacement.
DRIVE BELT TENSIONER DIAGNOSIS

Special Tools
Go to Step 9
System OK
Go to Step 11
Go to Step 10
Go to Step 11
System OK
Go to Step 12 Go to Diagnostic Aids

System OK
Go to Step 2
Go to Step 16
Go to Step 14
Go to Step 16
Go to Step 15
Go to Step 17
System OK

EN-48488 Holding Wrench

1. Diagnosis consists of a function check on the automatic belt tensioner and a visual check on the belt and
the components linked to the belt.
Fig. 15: Drive Belt Tensioner Spring, Drive Belt Tensioner Pulley Bolt And Wrench
2. Install the EN-48488 wrench (2) to the drive belt tensioner pulley bolt (1).
3. Apply tension to the drive belt tensioner spring (3) by moving the drive belt tensioner pulley clockwise.
4. Allow the drive belt tensioner to slide back slowly and thereby inspect the drive belt tensioner mechanism
for practicability.
DUAL MASS FLYWHEEL DIAGNOSIS

Check for Thermal Overload
NOTE:
These quick information shall help to carry out a correct diagnosis in case of a
customer complaint.
Through friction of clutch plate on the friction surface of the dual mass flywheel temperatures up to 200 C can
arise during normal driving. At sliding clutch or through operating errors much higher temperatures can arise.
These temperatures must not cause mandatory a reduced lifetime of the dual mass flywheel.
Possible indications for a high thermal load are:
Tarnish (bluish) as well as local hotspots on friction surface

Tarnish (bluish) near of mounting area and riveting area of clutch
If all other checkable features are well, the dual mass flywheel can stay in the vehicle.
Possible indications for a too high thermal load are:
Cracks
Fusion zones on friction surface (material smear)
Scores in friction surface (for example through clutch lining riveting at destroyed or worn clutch plate)
Tarnish (bluish) which reaches up to bearing area of dual mass flywheel
Bluish discoloration of locating pins (3 locating pins in outer zone of dual mass flywheel)
In these cases the dual mass flywheel has to be replaced.

Overview Dual Mass Flywheel

Fig. 16: Overview Dual Mass Flywheel

Callout
1
2
3
4
5
Component Name
Bearing Area
Mounting Area Pressure Plate
Locating Pins
Friction Surface
Riveting Area
Exploded View Dual Mass Flywheel with Additional Mass

Fig. 17: Exploded View Dual Mass Flywheel with Additional Mass
Callout
1
2
3
4
5
Component Name
Secondary Flywheel Mass
Additional Mass, Coupled with Cover and Pulse-Generator Ring
Flange
Primary Flywheel Mass with Bowed Springs and Plain
Bearing/Bearing Bolt
Toothed Ring
Check for Damaged Components
All following checking procedures have to be carried out at installed dual mass flywheel. For visual check at
vehicle very bright light and a additional bright and small pocket lamp is necessary. Damages like grease on
primary flywheel and loose ore missing balance weights cannot be checked at installed condition. During visual

check material alteration can be stated which eliminate a further operating suitability.
For comparison different damages at dual mass flywheel with the corresponding further procedure are presented
here.
Fig. 18: Plain Bearing

NOTE:
In case of mechanical damages at plain bearing the dual mass flywheel

has to be replaced.
1. Inspect plain bearing (1) for damages.

Dependent of the manufacturer damages can be detected through ventilation openings of secondary
flywheel. Parts of the bearing (1) are detached or lie loose around the bearing bolt.

Fig. 19: Toothed Ring

NOTE:
Light abrasion on frontal areas of teeth is allowed. If problems occur

during starting the engine the dual mass flywheel has to be replaced.
2. Inspect toothed ring (1) for damages.

The toothed ring is needed to start the engine. Through a lot of starting procedures and/or an incorrect
engaging starter signs of abrasion can occur on teeth of the toothed ring. The profile of damages can reach
from only low signs of abrasion up to heavy material removal. The installation of a pulse-generator ring
depends on the manufacturer.
The image shows signs of abrasion and mechanical damages at toothed ring (1), they occur through
abrasion due to a lot of starting procedures. In this case the dual mass flywheel has to be replaced.

Fig. 20: Inspecting Tilt Clearance

NOTE:
The check must be carried out only by hand without any tools.
3. Inspect tilt clearance.

At dual mass flywheel the additional-mass ring looms over the gap between primary and secondary
flywheel. It is not possible to carry out just a visual check.

Fig. 21: Tilt Clearance Height

NOTE:
An absolute clear measurement is not possible with this check due to the
different applied forces of the several workshop employees during the
check.
4. Embrace dual mass flywheel and apply thumbs onto the outer radius of secondary flywheel.
5. Apply pressure onto the secondary flywheel alternating on upper, lower, left and right side
During the tilt clearance check a functional metal rattling noise may occur.
If tilt clearance is higher than 3 mm (MUST be measured, DO NOT make an estimation) (1) the dual
mass flywheel has to be replaced.

Fig. 22: Tilt Clearance Angle


Fig. 23: Rotating Secondary Flywheel Anticlockwise


Fig. 24: Releasing Secondary Flywheel


Fig. 25: Mark On Flywheel And Toothed Ring For Starter

6. Inspect clearance angle (1).
Before the inspection of the clearance angle the dual mass flywheel should be rotated several times
clockwise and anticlockwise to receive a feeling for the resistance of the springs. In addition unusual loud
clicking noise or possible rattle, crunch, grinding noise can be sounded out during rotating the dual mass
flywheel.
If the rotation of the flywheel is impossible the flywheel is defective and has to be replaced.
The clearance angle is the angle (1) about the secondary and the primary flywheel can be turned light
against each other. Thereby the flange wings are moved in the duct of the bowed springs without
adjoining the bowed springs. Dictated by functional factors the clearance angle is up to 8 teeth.
Is the secondary flywheel rotated beyond this point the bowed springs in the duct are moved to spring

arrestor in the primary flywheel/cover. Now the both spring are tensioned.
Rotate secondary flywheel anticlockwise (arrow) until the elastic counterforce (spring force) is
clear noticeable.
Release secondary flywheel slowly until the bowed springs are relaxed, so no counterforce acts
onto the springs.
Mark position with a vertical line by a white pencil on secondary flywheel (1) and on toothed ring
for starter (2).
Rotate secondary flywheel clockwise until the elastic counterforce is clear noticeable.
Release secondary flywheel slowly until the bowed springs are relaxed.
Apply new marking on secondary flywheel (1) on the height of the marking on the toothed ring for
starter (3).
Count amount of teeth on toothed ring for starter from marked tooth up to the height of the first
marking on secondary flywheel (2). Dictated by functional factors up to 8 teeth are allowed.
7. ALWAYS replace the engine flywheel if following conditions are given:
The difference exceeds the amount of 8 teeth.
The dual mass flywheel cannot be rotated.
During rotating the dual mass flywheel a hard metallic arrestor is audible or noticeable.
REPAIR INSTRUCTIONS - ON VEHICLE

DRIVE BELT REPLACEMENT
Removal Procedure
2. Remove the right front wheelhouse liner. Refer to Front Wheelhouse Liner Replacement .

Fig. 26: Drive Belt Tensioner Pulley And Bolt

3. Rotate the drive belt tensioner pulley bolt (1) in the direction shown until the bore (2) aligns with the bore
in the engine front cover, using a TORX wrench and hold in position.

Fig. 27: Punch Inserted In Drive Belt Tensioner Bore

4. Install a suitable punch (1) through the drive belt tensioner bore (2) to the engine front cover bore to fix
the tensioner in position.
6. Remove the right engine mount. Refer to Engine Mount Replacement - Right Side.

Fig. 28: Drive Belt Routing

7. Remove the drive belt (1).


1. Install the drive belt (1) according to the shown routing.
2. Install the right engine mount. Refer to Engine Mount Replacement - Right Side.


4. Rotate the drive belt tensioner pulley bolt (1) in the direction shown until the punch can be removed,
using a TORX wrench and hold in position.


5.
6.
7.
8.
Remove the punch (1) from the engine front cover bore and the drive belt tensioner bore (2).
Allow the tensioner to slide back slowly.
Install the right front wheelhouse liner. Refer to Front Wheelhouse Liner Replacement .
Lower the vehicle.
DRIVE BELT TENSIONER REPLACEMENT

Removal Procedure
1. Remove the engine mount bracket. Refer to Engine Mount Bracket Replacement - Right Side.






5. Move the drive belt tensioner until the punch can be removed and remove the punch from the engine front
cover bore and drive belt tensioner bore.

Fig. 35: Drive Belt Tensioner And Bolts

6. Remove the upper drive belt tensioner bolt (2).
7. Remove the lower drive belt tensioner bolt (3).
8. Remove the drive belt tensioner (1).


1. Install the drive belt tensioner (1).
2. Install the lower drive belt tensioner bolt (3).
3. Install the upper drive belt tensioner bolt (2).
4. Tighten the lower drive belt tensioner bolt to 22 N.m (16 lb ft).
5. Tighten the upper drive belt tensioner bolt to 55 N.m (41 lb ft).






8. Install the drive belt (1) according to the shown routing.
9. Move the drive belt tensioner until the punch can be removed (see step 6) and remove the punch from the
engine front cover bore and drive belt tensioner bore.
10. Allow the tensioner to slide back slowly.
11. Install the engine mount bracket. Refer to Engine Mount Bracket Replacement - Right Side.
POWERTRAIN MOUNT BALANCING
NOTE:
Follow the balance procedure steps listed below when no starting point has
been established such as in a collision repair.

Fig. 40: Front Transaxle Mount Through Bolt

2. Loosen the front transaxle mount through bolt (1) until it is finger tight.

Fig. 41: Rear Transaxle Mount Through Bolt

3. Loosen the rear transaxle mount (1) through bolt until it is finger tight.

Fig. 42: Supporting Engine/Transmission With Hydraulic Floor Jack

5. Position two floor jacks with wood blocks under the engine and transaxle in order to support the
powertrain assembly.

Fig. 43: Transaxle Bolts

6. Loosen the transaxle adapter to transaxle bolts (1).

Fig. 44: Engine Mount And Bracket Bolts

7. Loosen the engine mount (1) to bracket bolts (2).
8. Lower the floor jacks in order to allow a 1/4 inch (6 mm) gap between the upper engine mount and engine
mount bracket, and also between the transmission and left transmission mount.

Fig. 45: Front And Rear Powertrain Mounts

9. Check that the front and rear mounts are centered (1) in the mount brackets, adjust if necessary.
10. Tighten the left hand (transaxle side) mount bolts, starting with the bolt nearest to the center of the mount.
See the appropriate transmission mount replacement procedure for the fastener tightening specifications.


11. Tighten the right hand (engine side) mount bolts (1), starting with the bolt nearest to the center of the
mount. See the appropriate engine mount replacement procedure for the fastener tightening specifications.
12. Remove the floor jacks from under the oil pan and transmission.
14. Shake the powertrain from front to rear and allow the powertrain to settle.


NOTE:
It is essential that the lower mount through bolts should be as close to

centered as possible in the oversized mount insert holes before tightening
to specification.
15. Tighten the rear transaxle mount through bolt (1). See the appropriate transmission mount replacement
procedure for the fastener tightening specifications.


16. Tighten the front transaxle mount through bolt (1). See the appropriate transmission mount replacement
POWERTRAIN MOUNT BALANCING - LOWER
NOTE:
Follow the balance procedure steps listed below when front or rear
mounts through bolts are loosened or removed during a repair procedure.


2. Loosen the front transaxle mount through bolt (1).


3. Loosen the rear transaxle mount through bolt (1).
NOTE:
It is essential that the through bolts are as close to centered as possible in

the oversized mount insert holes before tightening to specification.


ENGINE MOUNT REPLACEMENT - RIGHT SIDE
Removal Procedure
1. Open the hood.


Fig. 52: Engine Lifter

3. Install an engine lifter (1) to the right engine lift bracket and apply tension to the engine lifter chain in
order to support the engine.

Fig. 53: Engine Mount, Bracket Bolts, Body Bolts, Mount Nuts And Washers
4. Remove and DISCARD the 3 engine mount to engine mount bracket bolts (3) and the 3 washers (4).
5. Remove the 2 engine mount to body bolts (2) and the engine mount nut (1).
6. Remove the engine mount (5).

Fig. 54: Engine Mount, Bracket Bolts, Body Bolts, Mount Nuts And Washers
1.
2.
3.
4.
Install the engine mount (5).

Install the 2 engine mount to body bolts (2).
Install the engine mount nut (1).
Install the 3 NEW engine mount to engine mount bracket bolts (3) and the 3 washers (4).
5. Tighten the 2 engine mount to body bolts (2) and the engine mount nut (1) to 62 N.m (46 lb ft).

6.
7.
8.
9.
Tighten the 3 engine mount to engine mount bracket bolts (3) to 50 N.m (37 lb ft) + 60-70.
Remove the engine lifter from right engine lift bracket.
Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement .
Close the hood.
ENGINE MOUNT INSPECTION

1. Install the engine support fixture. Refer to Engine Support Fixture.
2. Observe the engine mount while raising the engine. Raising the engine removes the weight from the
engine mount and creates slight tension on the rubber.
3. Replace the engine mount if the engine mount exhibits any of the following conditions:
The hard rubber is covered with heat check cracks.
The rubber is separated from the metal plate of the engine mount.
The rubber is split through the center of the engine mount.
4. For engine mount replacement, refer to Engine Mount Replacement - Right Side.
5. For rear transmission mount replacement, refer to:
Automatic transmission, refer to Transmission Rear Mount Replacement .
Manual transmission, refer to Transmission Rear Mount Replacement .
6. For left transmission mount replacement, refer to:
Automatic transmission, refer to Transmission Mount Replacement - Left Side .
Manual transmission, refer to Transmission Mount Bracket Replacement - Left Side .
ENGINE MOUNT BRACKET REPLACEMENT - RIGHT SIDE
Removal Procedure
1. Open the hood.

3. Remove the engine mount. Refer to Engine Mount Replacement - Right Side.

Fig. 55: Engine Mount Bracket And Bolts

4. Remove and DISCARD the 3 engine mount bracket bolts (1).
5. Remove the engine mount bracket (2).


1. Install the engine mount bracket (2).
2.
3.
4.
5.
Install the 3 NEW engine mount bracket bolts (1) and tighten to 60 N.m (45 lb ft) + 45-60.
Install the engine mount. Refer to Engine Mount Replacement - Right Side.
Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement .
Close the hood.

AIR CONDITIONING COMPRESSOR BRACKET REPLACEMENT

Removal Procedure
1.
2.
3.
4.
Open the hood.

Remove the right front wheelhouse liner. Refer to Front Wheelhouse Liner Replacement .
Remove the drive belt from crankshaft balancer, drive belt tensioner and air conditioning compressor.
Fig. 57: Wiring Harness Retainer Clips And Plug

5. Disconnect the air conditioning compressor wiring harness plug (3).
6. Unclip the air conditioning compressor wiring harness from the 2 retainer clips (1) and (2).

NOTE:
Do not remove the air conditioning compressor and condenser hose from
air conditioning compressor.
7. Remove the air conditioning compressor from the air conditioning compressor bracket and hang aside.
Refer to Air Conditioning Compressor Replacement (1.8L LUW and LWE) , Air Conditioning
Compressor Replacement (1.4L LUV) .
Fig. 58: Power Steering Pump Bracket/Air Conditioning Compressor Bracket And Bolts
8. Remove the 3 air conditioning compressor bracket bolts (1).
9. Remove the air conditioning compressor bracket (2).

1. Install the air conditioning compressor and power steering pump bracket (2).
2. Install the 3 air conditioning compressor bracket bolts (1) and tighten to 22 N.m (16 lb ft).
3. Install the air conditioning compressor to air conditioning compressor bracket. Refer to Air Conditioning
Compressor Replacement (1.4L LUV) .
4. Install the drive belt to crankshaft balancer, drive belt tensioner and air conditioning compressor. Refer to
Drive Belt Replacement.
5. Install the right front wheelhouse liner. Refer to Front Wheelhouse Liner Replacement .

7. Close the hood.

INTAKE MANIFOLD REPLACEMENT
Special Tools
EN-34730-91 Pressure Tester

Removal Procedure
1. Open hood.
3. Remove engine sight shield.
Fig. 60: Heater Outlet Hose And ECM Wiring Harness Retainer Clips


4. Unclip the heater outlet hose from retainer clip (1).
5. Unclip the engine control module wiring harness from 2 retainer clips (2).
6. Remove the charge air cooler outlet air hose from the throttle body. Refer to Charge Air Cooler Outlet
Fig. 61: Throttle Body Wiring Harness Plug

7. Disconnect the throttle body wiring harness plug (1).

Fig. 62: Wiring Harness Plugs

8. Disconnect the evaporative emission canister purge solenoid valve wiring harness plug (3).
NOTE:
Make note of the installed position of the manifold absolute pressure

sensor wiring harness plugs to ensure they will be connected in their
original position.
9. Disconnect the 2 manifold absolute pressure sensor wiring harness plugs (1) and (2).
10. Disconnect the 4 fuel injector wiring harness plugs (4).
11. Unclip the engine control module wiring harness from the camshaft cover.

Fig. 63: Turbocharger Wastegate Regulator Solenoid Valve Wiring Harness Plug, Intake Manifold
And Fuel Injection Rail Retainer Clips
12. Disconnect the turbocharger wastegate regulator solenoid valve wiring harness plug (3).
13. Unclip the engine control module wiring harness from 2 intake manifold retainer clips (2) and from 2 fuel
injection rail retainer clips (1).
WARNING: Gasoline or gasoline vapors are highly flammable. A fire could occur
if an ignition source is present. Never drain or store gasoline or
diesel fuel in an open container, due to the possibility of fire or
explosion. Have a dry chemical (Class B) fire extinguisher nearby.

Fig. 64: Fuel Injector Rail Cap

14. Remove fuel injector rail cap (1).

Fig. 65: Pressure Tester

15. Relieve the fuel system pressure. Use EN-34730-91 pressure tester (1).

Fig. 66: Fuel Feed Pipe

16. Disconnect the fuel feed pipe (1) from the fuel rail. Refer to Metal Collar Quick Connect Fitting
Service .
17. Unclip fuel feed pipe from the retainer clip.
18. Disconnect the positive crankcase ventilation pipe from the intake manifold. Refer to Positive Crankcase
Ventilation Hose/Pipe/Tube Replacement

Fig. 67: Fuel Ventilation Pipe

19. Disconnect the fuel ventilation pipe (1) from the evaporative emission canister purge solenoid valve.
20. Unclip the fuel ventilation pipe from the retainer clip.


21. Disconnect the brake booster vacuum pipe (1) from intake manifold.

Fig. 69: Intake Manifold Bolts

NOTE:
Intake manifold bolts remain in intake manifold. Note the installation of the
fuel rail ground strap for proper installation.
22. Remove the 6 intake manifold bolts (1).

Fig. 70: Intake Manifold

23. Remove the intake manifold (1).
24. Remove and DISCARD the intake manifold gasket.
25. Remove the assembly parts from the intake manifold as necessary. Refer to Intake Manifold
Disassemble.
1. Install the assembly parts to the intake manifold as necessary. Refer to Intake Manifold Assemble.


3. Install the intake manifold (1) along with a NEW intake manifold gasket.


NOTE:
Install the fuel rail ground strap to the appropriate intake manifold bolt.
4. Install the 6 intake manifold bolts (1) and tighten to 20 N.m(15 lb ft).


5. Connect the fuel ventilation pipe (1) to the evaporative emission canister purge solenoid valve.
6. Clip in the fuel ventilation pipe to retainer clip.
7. Connect the positive crankcase ventilation pipe to the intake manifold. Refer to Positive Crankcase
Ventilation Hose/Pipe/Tube Replacement


8. Connect the fuel feed pipe (1) to the fuel rail. Refer to Metal Collar Quick Connect Fitting Service .
9. Clip in the fuel feed pipe to retainer clip.


10. Connect the brake booster vacuum pipe (1) to the intake manifold.

Fig. 76: Fuel Injector Rail Cap

11. Install fuel injector rail cap (1).

Fig. 77: Turbocharger Wastegate Regulator Solenoid Valve Wiring Harness Plug, Intake Manifold
And Fuel Injection Rail Retainer Clips
12. Connect the turbocharger wastegate regulator solenoid valve wiring harness plug (3).
13. Clip in the engine control module wiring harness to 2 intake manifold retainer clips (2) and from 2 fuel
injection rail retainer clips (1).

Fig. 78: Wiring Harness Plugs

14.
15.
16.
17.
Clip in the engine control module wiring harness to the camshaft cover.
Connect the 4 fuel injector wiring harness plugs (4).
Connect the 2 manifold absolute pressure sensor wiring harness plugs (1) and (2).
Disconnect the evaporative emission canister purge solenoid valve wiring harness plug (3).

Fig. 79: Throttle Body Wiring Harness Plug

18. Connect the throttle body wiring harness plug (1).
19. Install the charge air cooler outlet air hose to the throttle body. Refer to Charge Air Cooler Outlet Air
Hose Replacement (Automatic Transmission) , Charge Air Cooler Outlet Air Hose Replacement
(Manual Transmission) .

Fig. 80: Heater Outlet Hose And ECM Wiring Harness Retainer Clips
20.
21.
22.
23.
24.
Clip in the heater outlet hose to retainer clip (1).

Clip in the engine control module wiring harness to 2 retainer clips (2).
Install the engine sight shield.
Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection .
Close the hood.
CAMSHAFT TIMING CHAIN REPLACEMENT

Special Tools
EN-955-10 Fixing Pin from EN-955 Kit


Removal Procedure
1. Open the hood.

2. Remove the engine front cover with oil pump. Refer to Engine Front Cover with Oil Pump
Replacement.
Fig. 81: Timing Chain And Timing Chain Tensioner

NOTE:
If EN-955-10 fixing pin can not be inserted, compress the timing chain
tensioner further with the aid of a flat bladed tool to allow complete
insertion of the pin.
3. Push the timing chain (2) in direction to the timing chain tensioner (1) and secure the tensioner with EN955-10 fixing pin (3).

Fig. 82: Upper Timing Chain Guide And Bolts

4. Remove the 2 upper timing chain guide bolts (1).
5. Remove the upper timing chain guide (2).

Fig. 83: Timing Chain Guide Right Side

6. Remove the 2 timing chain guide right side bolts (2).
7. Remove the timing chain guide right side (1).

Fig. 84: Timing Chain Tensioner Shoe And Bolt

8. Remove the timing chain tensioner shoe bolt (2).
9. Remove the timing chain tensioner shoe (1).

Fig. 85: Timing Chain And Crankshaft Sprocket

10. Remove the timing chain (1) along with the crankshaft sprocket (2).

Fig. 86: Engine Front Cover Gasket

11. Remove the engine front cover gasket (1).
1. Clean the engine front cover sealing surfaces on the engine block and the cylinder head.

Fig. 87: Sealing Compound Application Areas

NOTE:
The thickness of the sealing bead should be 2 mm (0.0787 in).
2. Apply sealing compound to the shown areas (1) and (2). Refer to Adhesives, Fluids, Lubricants, and
Sealers.


NOTE:
Mind the guide sleeves.
3. Install the engine front cover gasket (1).


4. Install the timing chain (1) along with the crankshaft sprocket (2).


5. Install the timing chain tensioner shoe (1).
6. Install the timing chain tensioner shoe bolt (2) and tighten to 20 N.m (15 lb ft).


7. Install the timing chain guide right side (1).
8. Install the 2 timing chain guide right side bolts (2) and tighten to 8 N.m (71 lb in).


9. Push the timing chain (2) in direction to the timing chain tensioner (1) and remove EN-955-10 fixing pin
(3).
10. Install the engine front cover with oil pump. Refer to Engine Front Cover with Oil Pump
Replacement.
11. Close the hood.
TIMING CHAIN TENSIONER REPLACEMENT
Special Tools


Removal Procedure
1. Remove the engine front cover with oil pump. Refer to Engine Front Cover with Oil Pump
Replacement.
NOTE:
Removal of timing chain is necessary to get access to the engine front

cover gasket.
2. Remove the camshaft timing chain. Refer to Camshaft Timing Chain Replacement.
Fig. 93: Timing Chain Tensioner, Bolts And Pin

3. Remove the EN-955-10 pin (1) from timing chain tensioner.
4. Remove the 2 timing chain tensioner bolts (2).
5. Remove the timing chain tensioner (3).

Fig. 94: Timing Chain Tensioner, Bolts And Pin

1. Install the timing chain tensioner (3).
2. Install the 2 timing chain tensioner bolts (2) and tighten to 8 (71 lb in).
3. Fix the timing chain tensioner with EN-955-10 pin (1)
4. Install the engine front cover gasket and the camshaft timing chain. Refer to Camshaft Timing Chain
Replacement.
5. Install the engine front cover with oil pump. Refer to Engine Front Cover with Oil Pump
Replacement.

HYDRAULIC VALVE LASH ADJUSTER ARM REPLACEMENT

Removal Procedure
1. Remove the intake camshaft. Refer to Intake Camshaft Replacement.

2. Remove the exhaust camshaft. Refer to Exhaust Camshaft Replacement.
Fig. 95: Hydraulic Valve Lash Adjuster Arms

NOTE:
Mind the installation position of the hydraulic valve lash adjuster arms.
3. Remove the 16 hydraulic valve lash adjuster arms (1).



NOTE:
1.
2.
3.
4.
Hydraulic valve lash adjuster arms should be installed in their original

position
Lubricate the hydraulic valve lash adjuster arms with engine oil.
Install the 16 hydraulic valve lash adjuster arms (1).
Install the exhaust camshaft. Refer to Exhaust Camshaft Replacement.
Install the intake camshaft. Refer to Intake Camshaft Replacement.
HYDRAULIC VALVE LASH ADJUSTER REPLACEMENT

Removal Procedure
1. Remove the 16 hydraulic valve lash adjuster arms. Refer to Hydraulic Valve Lash Adjuster Arm

Replacement.
Fig. 97: Hydraulic Valve Lash Adjusters

NOTE:
Mind the installation position of the hydraulic valve lash adjusters.
2. Remove the 16 hydraulic valve lash adjusters (1).



NOTE:
1. Lubricate the hydraulic valve lash adjusters with engine oil.

2. Install the 16 hydraulic valve lash adjusters (1).
3. Install the 16 hydraulic valve lash adjuster arms. Refer to Hydraulic Valve Lash Adjuster Arm
Replacement.
CAMSHAFT INTAKE SPROCKET REPLACEMENT
Special Tool


Removal Procedure
1.
2.
3.
4.
Open the hood.

Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement .
Remove the camshaft cover. Refer to Camshaft Cover Replacement.
Remove the 2 camshaft position actuator solenoid valves. Refer to Camshaft Position Actuator
Solenoid Valve Removal.
5. Adjust the engine to TDC. Refer to Camshaft Timing Chain Inspection.
Fig. 99: Timing Chain Tensioner Plug

6. Remove the timing chain tensioner plug (1) from the engine front cover.

Fig. 100: Hexagonal Wrench Rotation Direction

7. Install a wrench (1) to the hexagon of the intake camshaft and rotate it in direction of the arrow in order to
apply tension to the timing chain and hold.

Fig. 101: Timing Chain Tensioner Bore And Pin

8. Install the EN-955-10 pin (2) to the timing chain tensioner bore (1) to secure it in place.
9. Remove the wrench from the intake camshaft.



Fig. 103: Intake Camshaft Sprocket Bolt And Hexagonal Wrench

12. Loosen the intake camshaft sprocket bolt (2) while holding the hexagon of the intake camshaft with a
wrench (1).
13. Loosen the exhaust camshaft sprocket bolt while holding the hexagon of the exhaust camshaft with a
wrench.

Fig. 104: Camshaft Position Exciter Wheels And Camshaft Sprocket Bolts
14. Remove the 2 camshaft sprocket bolts (2) and the 2 camshaft position exciter wheels (1).

Fig. 105: Timing Chain And Camshaft Sprockets

15. Remove the 2 camshaft sprockets (2) along with the timing chain (1) and place it in the engine front
cover.
16. Remove the intake camshaft sprocket.
1. Insert the intake camshaft sprocket to the engine to engine front cover and timing chain.


2. Install the 2 camshaft sprockets (2) along with the timing chain (1) to the camshafts.

3. Install the 2 camshaft sprocket bolts (2) and the 2 camshaft position exciter wheels (1).
4. Remove EN-955-10 pin to apply tension to the timing chain.
NOTE:
Engine must be adjusted to TDC.
5. Tighten the 2 camshaft sprockets. Refer to Camshaft Timing Chain Adjustment.

6. Remove all special tools for timing chain adjustment. Refer to Camshaft Timing Chain Adjustment.


7. Install the upper timing chain guide (2).
8. Install the 2 upper timing chain guide bolts (1) and tighten to 8 N.m (71 lb in).
9. Install the 2 camshaft position actuator solenoid valves. Refer to Camshaft Position Actuator Solenoid
Valve Installation.
10. Install the camshaft cover. Refer to Camshaft Cover Replacement.
11. Install the timing chain tensioner plug and tighten to 50 N.m (37 lb ft).
13. Check and correct engine oil level.

14. Close the hood.

CAMSHAFT EXHAUST SPROCKET REPLACEMENT
Special Tool

Removal Procedure
1.
2.
3.
4.
Open the hood.

Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement .
5. Adjust the engine to TDC. Refer to Camshaft Timing Chain Inspection.




7. Install a wrench (1) to the hexagon of the intake camshaft and rotate it in direction of the arrow in order to
apply tension to the timing chain and hold.


8. Install the EN-955-10 pin (2) to the timing chain tensioner bore (1) to secure it in place.




wrench (1).
wrench.



cover.
16. Remove the exhaust camshaft sprocket.
1. Insert the exhaust camshaft sprocket to the engine front cover and timing chain.


2. Install the 2 camshaft sprockets (2) along with the timing chain (1) to the camshafts.

3. Install the 2 camshaft sprocket bolts (2) and the 2 camshaft position exciter wheels (1).
4. Remove the EN-955-10 pin to apply tension to the timing chain.
NOTE:
Engine must be adjusted to TDC.
5. Tighten the 2 camshaft sprockets. Refer to Camshaft Timing Chain Adjustment.

6. Remove all special tools for timing chain adjustment. Refer to Camshaft Timing Chain Adjustment.


Valve Installation.
11. Install the timing chain tensioner plug and tighten to 50 N.m (37 lb ft).

14. Close the hood.

CYLINDER HEAD REPLACEMENT
Special Tools
EN-470-B Angular Torque Wrench

EN-953-A Fixing Tool

Removal Procedure
Connection .
2. Remove the engine sight shield.
3. Remove the air cleaner assembly along with the air cleaner outlet duct. Refer to Air Cleaner Assembly
Replacement , and Air Cleaner Outlet Duct Replacement .
4. Remove the positive crankcase ventilation pipe. Refer to Positive Crankcase Ventilation
Hose/Pipe/Tube Replacement.
5. Remove the intake manifold. Refer to Intake Manifold Replacement.
6. Remove the turbocharger. Refer to Turbocharger Replacement.

Fig. 119: Wiring Harnesses And Plugs

7. Remove the engine control module wiring harness (1) from camshaft cover:
Disconnect the intake camshaft position sensor wiring harness plug (7).
Disconnect the intake camshaft position actuator solenoid valve wiring harness plug (6).
Disconnect the exhaust camshaft position sensor wiring harness plug (4).
Disconnect the exhaust camshaft position actuator solenoid valve wiring harness plug (5).
Disconnect the engine coolant temperature sensor wiring harness plug (3).

Fig. 120: Oil Cooler Inlet Hose, Engine Coolant Air Bleed Hose, Temperature Sensor Wiring
Harness Plug And Radiator Inlet Hose
8.
9.
10.
11.
12.
13.
Place a drain pan underneath the vehicle.

Remove the oil cooler inlet hose clamp and the oil cooler inlet hose (1).
Remove the radiator inlet hose clamp and the radiator inlet hose (4).
Remove the engine coolant air bleed hose (2).
Disconnect the engine coolant temperature sensor wiring harness plug (3).
Remove the heater inlet hose from the water outlet. Refer to Heater Inlet Hose Replacement (1.8L
LUW and LWE) , Heater Inlet Hose Replacement (1.4L LUV) .

Fig. 121: Ground Cable And Bolt

14. Remove the ground cable bolt (2) and the ground cable (1).

Fig. 122: Engine Coolant Thermostat Housing, Radiator Outlet House And Quick Connector
Clamp
15.
16.
17.
18.
19.
Unclip the radiator outlet hose quick connector clamp (2).

Remove the radiator outlet hose (3) from the engine coolant thermostat housing (1).
Remove the engine mount bracket. Refer to Engine Mount Bracket Replacement - Right Side.
Remove the drive belt. Refer to Drive Belt Replacement.
Remove the water pump pulley. Refer to Water Pump Pulley Removal.

Fig. 123: Drain Plug And Seal Ring

20. Remove the drain plug (1) and the seal ring (2) and allow the remaining coolant fluid to drain out of the
engine block. DISCARD the seal ring.
21. Install the drain plug (1) and a NEW seal ring (2) and tighten the plug to 15 N.m (11 lb ft).

Fig. 124: Engine Front Cover Bolts And Water Pump Bolts
22.
23.
24.
25.
26.
27.
28.
29.
Remove 5 engine front cover bolts (1, 2).

Remove 3 water pump bolts (3).
Install the engine mount bracket. Refer to Engine Mount Bracket Replacement - Right Side.
Remove the ignition coil. Refer to Ignition Coil Replacement .
Set engine to TDC. Refer to Camshaft Timing Chain Adjustment.




NOTE:
Remove and reinstall the EN-953-A fixing tool for this step.
31. Install a wrench (1) to the hexagon of the intake camshaft and rotate it in direction of the arrow to apply
tension to the timing chain and hold.


32. Install EN-955-10 pin (2) to the timing chain tensioner bore (1) to secure it in place.


34. Remove 2 upper timing chain guide bolts (1).
35. Remove upper timing chain guide (2).


36. Loosen the intake camshaft sprocket bolt (2) while holding the hexagon of intake camshaft sprocket with
a wrench (1).
37. Loosen the exhaust camshaft sprocket bolt while holding with a wrench.



cover.

Fig. 132: Cylinder Head Bolts Loosening Sequence

40. Loosen the 12 cylinder head bolts in the sequence as shown. Use the following procedure:
1. Loosen the cylinder head bolts 90.
2. Loosen the cylinder head bolts 180.
41. Remove and DISCARD the 12 cylinder head bolts.
42. Move the cylinder head assembly slightly in direction of the transmission.
NOTE:
Mind the timing chain tensioner and the timing chain guide pin.
NOTE:
43. Remove the cylinder head assembly.

44. Remove the cylinder head gasket.

45. Remove the assembly parts from cylinder head:

Remove the EN-953-A fixing tool.
Remove the engine coolant thermostat housing. Refer to Engine Coolant Thermostat Housing
Removal.
Remove the water outlet. Refer to Water Outlet Removal.
Remove the intake camshaft. Refer to Intake Camshaft Removal.
Remove exhaust camshaft. Refer to Exhaust Camshaft Removal.
Remove the hydraulic valve lash adjuster arms. Refer to Hydraulic Valve Lash Adjuster Arm
Removal.
Remove the hydraulic valve lash adjusters. Refer to Hydraulic Valve Lash Adjuster Removal.
Remove the 3 engine lift brackets.
1. Install the cylinder head assembly parts:

Install the 3 engine lift brackets.
Install the 3 engine lift bracket bolts and tighten to 22 N.m (16 lb ft).
Install the hydraulic valve lash adjusters. Refer to Hydraulic Valve Lash Adjuster Installation.
Install the hydraulic valve lash adjuster arms. Refer to Hydraulic Valve Lash Adjuster Arm
Installation.
Install the exhaust camshaft. Refer to Exhaust Camshaft Installation.
Install the intake camshaft. Refer to Intake Camshaft Installation.
Install the water outlet. Refer to Water Outlet Installation.
Install the engine coolant thermostat housing. Refer to Engine Coolant Thermostat Housing
Installation.
NOTE:
Adjust the camshafts using the hexagon and a wrench.
Install the EN-953-A fixing tool.

Fig. 133: Elastomer Sealing Strips

2.
3.
4.
5.
Cut the 2 elastomer sealing lips (1) from engine front cover gasket.
Bend down the engine front cover gasket at the predetermined breaking points (arrows).
Clean sealing surfaces of engine front cover and engine block from grease and old gasket material.
Inspect cylinder block and cylinder head for flatness. Refer to Cylinder Head Cleaning and Inspection,
and Engine Block Cleaning and Inspection.

Fig. 134: Sealing Compound Application Area

NOTE:
6. Apply sealing compound to the shown areas (1). Refer to Adhesives, Fluids, Lubricants, and Sealers.
NOTE:
Mind the marking on the cylinder head gasket for top side.
7. Install the cylinder head gasket to engine block.

Fig. 135: Engine Front Cover Bolts And Sealing Compound Application Areas
8. Install 2 engine front cover bolts (1) in order to guide the NEW upper engine front cover gasket.
9. Install the NEW upper engine front cover gasket.
10. Apply sealing compound to the shown areas (2). The thickness of the sealing bead should be 2 mm
(0.0787 in).

Fig. 136: Timing Chain Tensioner, Guide Pin And Cylinder Head
NOTE:
A second technician is required. Guide the timing chain guide pin (2) to
the timing chain guide and the timing chain tensioner (1) with the installed
fixing pin through the timing chain tensioner plug bore in engine front
cover.
11. Install the cylinder head (3).

12. Loosely install 12 NEW cylinder head bolts.

Fig. 137: Engine Front Cover Bolts

13. Adjust the cylinder head to the engine front cover. Use a rubber mallet.
14. Locate the engine front cover to cylinder head by installing 3 bolts (1).
15. Tighten the 3 bolts (1) to 8 N.m (71 lb in).

Fig. 138: Cylinder Head Bolts Tightening Sequence

16. Tighten the cylinder head bolts in the sequence as shown and in the following order:
1. Tighten the cylinder head bolts a first pass to 35 N.m (26 lb ft).
2. Tighten the cylinder head bolts a final pass to an additional 180, using EN-470-B wrench.
17. Loosen the 3 bolts from engine front cover.

Fig. 139: Engine Front Cover Bolts And Water Pump Bolts
18.
19.
20.
21.
22.
23.
24.
25.
Install the 5 remaining bolts to engine front cover and water pump.
Tighten the 5 engine front cover bolts (1, 2) to 8 N.m (71 lb in).
Tighten the 3 water pump bolts (3) to 8 N.m (71 lb in).
Install the water pump pulley. Refer to Water Pump Pulley Installation.
Install the drive belt. Refer to Drive Belt Replacement.
Install engine mount bracket. Refer to Engine Mount Bracket Replacement - Right Side.


26. Install the 2 camshaft sprockets (2) along with the timing chain (1).

NOTE:
Camshaft position exciter wheels should stay rotatable.
27. Install the 2 camshaft position exciter wheels (1) and the 2 camshaft sprocket bolts (2).
28. Adjust engine to TDC and tighten the camshaft sprockets and install upper timing chain tensioner guide.
Refer to Camshaft Timing Chain Adjustment.
29. Rotate the crankshaft for 720 and check the engine timing again. Repeat the adjustment procedure if
necessary.
30. Remove all special tools for timing chain adjustment and install and tighten the timing chain tensioner
plug. Refer to Camshaft Timing Chain Adjustment.
Valve Installation.
33. Install the ignition coil and connect the ignition coil wiring harness plug. Refer to Ignition Coil

Replacement .
Fig. 142: Engine Coolant Thermostat Housing, Radiator Outlet House And Quick Connector
Clamp
34. Connect radiator outlet hose (3) to engine coolant thermostat housing (1). Clip quick connector (2).

Fig. 143: Ground Cable And Bolt

35. Install the ground cable (1) and the ground cable bolt (2) and tighten to 20 N.m (15 lb ft).

Fig. 144: Oil Cooler Inlet Hose, Engine Coolant Air Bleed Hose, Temperature Sensor Wiring
Harness Plug And Radiator Inlet Hose
36.
37.
38.
39.
40.
Install the radiator inlet hose (4) and the radiator inlet hose clamp to the water outlet.
Install the oil cooler inlet hose (1) and the oil cooler inlet hose clamp to the water outlet.
Connect the engine coolant air bleed hose (2) to the water outlet.
Connect the engine coolant temperature sensor wiring harness plug (3).
Install the heater inlet hose to the water outlet. Refer to Heater Inlet Hose Replacement (1.4L LUV) .


41. Install the engine control module wiring harness to the camshaft cover:
Connect the engine coolant temperature sensor wiring harness plug (3).
Connect the exhaust camshaft position actuator solenoid valve wiring harness plug (5).
Connect the exhaust camshaft position sensor wiring harness plug (4).
Connect the intake camshaft position actuator solenoid valve wiring harness plug (6).
Connect the intake camshaft position sensor wiring harness plug (7).
42. Install the turbocharger. Refer to Turbocharger Replacement.
43. Install the intake manifold. Refer to Intake Manifold Replacement.
44. Install the air cleaner assembly in compound with the air cleaner outlet duct. Refer to Air Cleaner
Assembly Replacement , and Air Cleaner Outlet Duct Replacement .
45. Install the engine sight shield.

47. Fill coolant fluid. Refer to Cooling System Draining and Filling (Static Fill) , Cooling System
Draining and Filling (GE-47716 Fill) .
48. Check and correct engine oil.
49. Close the hood.
OIL PAN REPLACEMENT
Special Tools
EN-49980 Guidance Pins

Removal Procedure
1.
2.
3.
4.
Drain engine oil. Refer to Engine Oil and Oil Filter Replacement.
Remove the catalytic converter. Refer to Catalytic Converter Replacement (1.4L LUV) .
Remove the warm up three way catalytic converter. Refer to Warm Up Three-Way Catalytic
5. Remove the engine oil heater, if equipped. Refer to Engine Oil Heater Replacement

Fig. 146: Transmission-To-Oil Pan Bolts

6. Remove the transmission to oil pan bolts (1).
For vehicles with manual transmission remove 3 bolts.
For vehicles with automatic transmission remove 2 bolts.

Fig. 147: Oil Pan Bolts

7. Remove the 16 oil pan bolts (1).

Fig. 148: Oil Pan Prying Area

CAUTION: Pry the oil pan carefully in order to prevent damage to the transaxle
case or the oil pan sealing surfaces.
8. Position a prying tool to the area (1) shown, and gently pry the oil pan loose.

Fig. 149: Oil Pan

9. Remove the oil pan (1).
1. Clean the sealing surface of the crankshaft bearing cap tie plate and the groove in the engine front cover
from old gasket material, oil, dirt and grease.
2. If the oil pan is being reused, refer to Oil Pan Cleaning and Inspection.

Fig. 150: Oil Pan Pins

3. Install the 2 EN-49980 pins (1) to the shown oil pan screw bores.

Fig. 151: Engine Front Cover, Oil Suction Gallery And Screw Bore
NOTE:
The sealing bead should be applied close to the inner edge of the oil pan.
Take care that the oil suction gallery (4) will not get contaminated with
sealing compound or dirt. The thickness of the sealing bead (3) should be
2 mm (0.0787 in).
4. Apply sealing compound to the oil pan. Refer to Adhesives, Fluids, Lubricants, and Sealers.
5. Apply sealing compound to the groove of the engine front cover (1).
NOTE:
The complete installation procedure of the oil pan should not take longer
than 10 minutes.
6. Apply sealing compound around the screw bore (2) of the crankshaft bearing cap tie plate.

Fig. 152: Oil Pan Pins

CAUTION: Use care when installing the oil pan to prevent disruption of the
sealing bead. The sealing bead should remain consistent until the oil
pan is mated with the engine. An inconsistent sealing bead can
cause an insufficient seal and result in engine damage.
7. Carefully install the oil pan. Use the following procedure:
1. Lay the oil pan on drive train and front suspension frame.
2. Hang in the oil pan to crankshaft balancer (1).
3. Guide the oil pan with the 2 EN-49980 pins (2) and the equivalent screw bores to the engine.
4. Secure the oil pan with 4 oil pan bolts.
5. Remove the 2 EN-49980 pins.


6. Install the remaining 12 oil pan bolts and hand tighten to approximately 2 (18 lb in).
Fig. 153: Transmission-To-Oil Pan Bolts

7. Install the transmission to oil pan bolts (1).
For vehicles with manual transmission tighten 3 bolts to 40 (30 lb ft).
For vehicles with automatic transmission tighten 2 bolts to 58 (43 lb ft).
8. Tighten the 16 oil pan bolts to 10 (89 lb in).
8. Install the engine oil heater, if equipped. Refer to Engine Oil Heater Replacement.
Replacement .
10. Install the catalytic converter. Refer to Catalytic Converter Replacement (1.4L LUV) .


12. Fill engine oil. Refer to Engine Oil and Oil Filter Replacement.
AUTOMATIC TRANSMISSION FLEX PLATE REPLACEMENT
Special Tools

EN-652 Flywheel Holder

Removal Procedure
1. Open hood.
2. Remove the automatic transmission. Refer to Transmission Replacement .

Fig. 154: Automatic Transmission Flex Plate

3. Install EN-652 flywheel holder (1) in order to fix the automatic transmission flex plate (2).
Fig. 155: Automatic Transmission Flex Plate And Bolts

4. Remove and DISCARD the 6 automatic transmission flex plate bolts (2).
5. Remove the automatic transmission flex plate (1).
1. Clean the 6 screw bores. Rework if necessary.


2. Install the automatic transmission flex plate (1).
3. Install 6 NEW automatic transmission flex plate bolts (2).


5. Tighten the 6 automatic transmission flex plate bolts in a cross sequence to 35 N.m(26 lb ft).
6. Tighten the 6 automatic transmission flex plate bolts in a cross sequence to an additional 30.Use EN470-B wrench.
7. Tighten the 6 automatic transmission flex plate bolts in a cross sequence to an additional 15.Use EN-

470-B wrench.
8. Install automatic transmission. Refer to Transmission Replacement .
9. Close the hood.
ENGINE FLYWHEEL REPLACEMENT
Special Tools


Removal Procedure
1. Remove clutch pressure and driven plate from engine flywheel. Refer to Clutch Pressure and Driven
Plate Replacement (1.8L LUW and LWE) .

Fig. 158: Engine Flywheel And Holder

2. Install EN-652 flywheel holder (1) in order to fix the engine flywheel (2).

Fig. 159: Engine Flywheel And Bolts

3. Remove and DISCARD the 6 engine flywheel bolts (2).
4. Remove the engine flywheel (1).


2. Install the engine flywheel (1).
3. Install 6 NEW engine flywheel bolts (2).


4. Install EN-652 flywheel holder (1) in order to fix the engine flywheel (2).
5. Tighten the 6 engine flywheel bolts in a cross sequence a first pass to 60 N.m (44 lb ft).
6. Tighten the 6 engine flywheel bolts in a cross sequence a second pass to an additional 45, using EN-470B wrench.
7. Tighten the 6 engine flywheel bolts in a cross sequence a final pass to an additional 15, using EN-470-B

wrench.
8. Install clutch pressure and driven plate. Refer to Clutch Pressure and Driven Plate Replacement (1.4L
LUV) .
9. Install transmission. Refer to Transmission Replacement .
CRANKSHAFT BALANCER REPLACEMENT
Special Tools

EN-956-1 Extension
EN-49979 Crankshaft Shock Mount Retainer

Removal Procedure
2. Remove the right wheelhouse liner. Refer to Front Wheelhouse Liner Replacement .
3. Fix the drive belt tensioner, remove the drive belt from crankshaft balancer and lay aside. Refer to Drive
Belt Replacement.

Fig. 162: Bore And Mark

NOTE:
The crankshaft balancer can be incorrectly installed 180 from the required
position. Be sure to note the location of the alignment hole on the
crankshaft balancer prior to removing the crankshaft balancer from the
engine.
4. Rotate the engine clockwise until the bore (2) in the crankshaft balancer aligns with the mark (1) on the
engine front cover.
5. Install EN-49979 crankshaft shock mount retainer to EN-956-1 extension.

Fig. 163: Crankshaft Balancer, Retainer And Extension

6. Loosen the crankshaft balancer bolt (4) while fixing the crankshaft balancer (3) with EN-49979
crankshaft shock mount retainer (1) and EN-956-1 extension (2).

Fig. 164: Crankshaft Balancer And Bolt

7. Remove and DISCARD the crankshaft balancer bolt (2).
8. Remove the crankshaft balancer (1).

Fig. 165: Engine Oil Pump Rotor And Crankshaft

NOTE:
The crankshaft balancer flange must fit to the hexagon of the oil pump
rotor (2) and to the two-flat of the crankshaft (1). The TDC markings on
crankshaft balancer and engine front cover must match.
1. Install the crankshaft balancer carefully by pressing into position.

Fig. 166: Engine Front Cover And Crankshaft Balancer

2. Measure the distance (a) between the crankshaft balancer (2) and the mark on the engine front cover (1).
The distance (a) should be 5.5 mm (0.21654 in).
NOTE:
Never re-use the crankshaft balancer bolt.
3. Install a NEW crankshaft balancer bolt.


4. Tighten the crankshaft balancer bolt (4) to 150 N.m (111 lb ft) while fixing the crankshaft balancer (3)
with EN-49979 crankshaft shock mount retainer (1) and EN-956-1 extension (2). Use EN-470-B wrench.
5. Tighten the crankshaft balancer bolt to an additional 60 while fixing the crankshaft balancer (3) with
EN-49979 crankshaft shock mount retainer (1) and EN-956-1 extension (2).
6. Install the drive belt to the crankshaft balancer and remove the fixing pin. Refer to Drive Belt
Replacement.

7. Install the right wheelhouse liner. Refer to Front Wheelhouse Liner Replacement .
CRANKSHAFT FRONT OIL SEAL REPLACEMENT
Special Tools
EN-960 Installer
Removal Procedure
1. Remove the crankshaft balancer. Refer to Crankshaft Balancer Replacement.

2. Place collecting basin underneath.

Fig. 168: Crankshaft Front Oil Seal And Remover

3. Remove the crankshaft front oil seal (1) from the engine front cover.
Fig. 169: Crankshaft Front Oil Seal And Installer

1. Install NEW crankshaft front oil seal (1) to EN-960 installer (2).

Fig. 170: Crankshaft Front Oil Seal Installer And Engine Front Cover
2. Install crankshaft front oil seal by means of EN-960 installer (1) to engine front cover (2).

Fig. 171: Engine Front Cover And Crankshaft Front Oil Seal
3.
4.
5.
6.
Ensure that the crankshaft front oil seal (2) is flush with the engine front cover (1).
Install the crankshaft balancer. Refer to Crankshaft Balancer Replacement.
Remove the collecting basin.
Check and correct the engine oil level.
CRANKSHAFT REAR OIL SEAL REPLACEMENT (AUTOMATIC TRANSMISSION)

Special Tools
EN-235-6 Installer
EN-658-1 Installer

Removal Procedure
1. Remove the automatic transmission flex plate. Refer to Automatic Transmission Flex Plate
Replacement.
2. Place the collecting basin underneath.
3. Remove the crankshaft rear oil seal.
Fig. 172: Crankshaft Rear Oil Seal

1. Slide the crankshaft rear oil seal (2) across the EN-235-6 installer (1).

Fig. 173: Crankshaft Rear Oil Seal And Installer

2. Install the crankshaft rear oil seal (1) with EN-235-6 installer (2) to the crankshaft.

Fig. 174: Oil Seal Installer

NOTE:
Ensure that the crankshaft rear oil seal fits proper.
3. Use EN-658-1 installer (2) to strike the crankshaft rear oil seal (1)
4. Remove the collecting basin.
5. Install the automatic transmission flex plate. Refer to Automatic Transmission Flex Plate
Replacement.
CRANKSHAFT REAR OIL SEAL REPLACEMENT (MANUAL TRANSMISSION)
Special Tools
EN-235-6 Installer
EN-658-1 Installer


Removal Procedure
1. Remove the engine flywheel. Refer to Engine Flywheel Replacement.

3. Remove the crankshaft rear oil seal.





NOTE:
Ensure that the crankshaft rear oil seal fits proper.
5. Install the engine flywheel. Refer to Engine Flywheel Replacement.
POSITIVE CRANKCASE VENTILATION HOSE/PIPE/TUBE REPLACEMENT
Removal Procedure
1. Open the hood.


Fig. 178: Positive Crankcase Ventilation Pipe Retainer Clips And Clamp
3. Open the 2 positive crankcase ventilation pipe retainer clips (2) and (3).
NOTE:
Move retainer clamp (1) in direction of the arrow.
4. Remove the positive crankcase ventilation pipe from the intake manifold.

Fig. 179: Positive Crankcase Ventilation Pipe, Charger Air Bypass Valve Pipe And Clamp
5.
6.
7.
8.
9.
Loosen the charger air bypass valve pipe clamp (3).

Remove the charger air bypass valve pipe from turbocharger.
Remove the charger air bypass valve pipe (2) from turbo charger wastegate regulator solenoid valve.
Disconnect the positive crankcase ventilation pipe from turbocharger.
Unclip and remove the positive crankcase ventilation pipe assembly (1) from the camshaft cover retainer
clips.

Fig. 180: Positive Crankcase Ventilation Pipe, Charger Air Bypass Valve Pipe And Clamp
1.
2.
3.
4.
5.
Install the positive crankcase ventilation pipe assembly (1) to the camshaft cover retainer clips.
Connect the positive crankcase ventilation pipe to turbocharger.
Install the charger air bypass valve pipe (2) to turbo charger wastegate regulator solenoid valve.
Install the charger air bypass valve pipe to turbocharger.
Fasten the charger air bypass valve pipe clamp (3).

Fig. 181: Positive Crankcase Ventilation Pipe Retainer Clips And Clamp
6. Install the positive crankcase ventilation pipe to the intake manifold and fix with retainer clamp (1).
7. Clip in the positive crankcase ventilation pipe to the 2 retainer clips (2) and (3).
ENGINE OIL HEATER REPLACEMENT

Fig. 182: Engine Oil Heater And Bolt

Engine Oil Heater Replacement
Callout
Component Name
Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle
Engine Oil Heater Bolt
CAUTION:
Tighten
40 Y (30 lb ft)
Engine Oil Heater
Procedure
ENGINE FRONT COVER WITH OIL PUMP REPLACEMENT

Removal Procedure
1. Open the hood.


3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
Connection .
Set the engine to TDC. Refer to Camshaft Timing Chain Inspection.
Remove the front compartment insulator. Refer to Front Compartment Insulator Replacement .
Disconnect all electrical connectors from the generator. Refer to Generator Replacement (1.4L LUV) .
Fix the drive belt tensioner and remove the drive belt from crankshaft balancer, drive belt tensioner and
air conditioning compressor. Refer to Drive Belt Replacement.
Remove the air conditioning compressor bracket. Refer to Air Conditioning Compressor Bracket
Replacement.
Place a collecting basin underneath.
Remove the crankshaft balancer. Refer to Crankshaft Balancer Replacement.
Remove the oil pan. Refer to Oil Pan Replacement.
Lower vehicle.
Remove the drive belt tensioner. Refer to Drive Belt Tensioner Replacement.
Remove the generator from above. Refer to Generator Replacement (1.4L LUV) .
Remove the water pump pulley and the water pump. Refer to Water Pump Replacement (1.4L LUV) .
Remove the camshaft position actuator solenoid valves and disconnect electrical connectors. Refer to
Camshaft Position Actuator Solenoid Valve Removal.
Remove the camshaft position sensors. Refer to Camshaft Position Sensor Replacement .
Loosen the camshaft sprocket bolts until the camshaft position exciter wheels are free rotatable. Refer to
Camshaft Timing Chain Adjustment.

Fig. 183: M6, M10 Front Cover Bolts And Engine Front Cover
21. Remove the 13 engine front cover bolts M6 (1).
23. Remove the engine front cover (3).
NOTE:
Removal of timing chain is necessary to get access to engine front cover

gasket.
24. Remove the camshaft timing chain. Refer to Camshaft Timing Chain Replacement.


25. Remove the engine front cover gasket (1).
26. Remove the intake and exhaust camshaft position sensors from the engine front cover. Refer to Engine
Front Cover and Oil Pump Disassemble.
1. Install the intake and exhaust camshaft position sensors to the engine front cover. Refer to Engine Front
Cover and Oil Pump Assemble.
2. Clean the engine front cover sealing surfaces on engine block and cylinder head.


NOTE:
Sealers.


NOTE:
4. Install a NEW engine front cover gasket (1).

5. Install the timing chain. Refer to Camshaft Timing Chain Replacement.

NOTE:
Mind the guide sleeves when installing the engine front cover. The
complete installation procedure of the engine front cover should not take
longer than 10 minutes.
6. Install the engine front cover (3).

7. Install the 13 engine front cover bolts M6 (1).
9. Tighten the 13 engine front cover bolts M6 to 8 N.m (71 lb in).

10. Tighten the 2 engine front cover bolts M10 to 35 N.m (26 lb ft).
NOTE:
Engine should be adjusted and fixed in TDC position.
11. Tighten the camshaft sprockets, install the upper timing chain guide and remove all special tools. Refer to
12. Install the camshaft position sensors. Refer to Camshaft Position Sensor Replacement .
13. Install the 2 camshaft position actuator solenoid valves and connect electrical connectors. Refer to
Camshaft Position Actuator Solenoid Valve Replacement .
14. Install the water pump and the water pump pulley. Refer to Water Pump Replacement (1.4L LUV) .
15. Install the generator from above. Refer to Generator Replacement (1.4L LUV) .
16. Install the drive belt tensioner. Refer to Drive Belt Tensioner Replacement.
17. Install the engine mount bracket. Refer to Engine Mount Bracket Replacement - Right Side.
18. Loosely install the drive belt to water pump pulley and generator pulley.
19. Install the engine mount. Refer to Engine Mount Replacement - Right Side.
20. Remove engine lifter from engine lift bracket.
24. Install the crankshaft balancer. Refer to Crankshaft Balancer Replacement.
25. Install the oil pan. Refer to Oil Pan Replacement.
26. Install the air conditioning compressor bracket. Refer to Air Conditioning Compressor Bracket
Replacement.
27. Install the drive belt to crankshaft balancer, drive belt tensioner and air conditioning compressor. Refer to
28. Connect all electrical connectors to the generator. Refer to Generator Replacement (1.4L LUV) .
29. Install the right front wheelhouse liner. Refer to Front Wheelhouse Liner Replacement .
30. Install the front compartment insulator. Refer to Front Compartment Insulator Replacement .
31. Lower the vehicle
33. Fill up engine oil. Refer to Engine Oil and Oil Filter Replacement.
34. Close the hood.
OIL PUMP REPLACEMENT
Removal Procedure
1. Measure the oil pressure and compare with the specified values. Refer to Oil Pressure Diagnosis and
Testing.
2. Remove the engine front cover. Refer to Engine Front Cover with Oil Pump Replacement.

Fig. 188: Engine Oil Pump Cover And Bolts

3. Remove the 8 oil pump cover bolts (1).
4. Remove the oil pump cover (2).

Fig. 189: Oil Pump Slide Spring Windings And Engine Front Cover Edge
WARNING: Before removing the spring, cover the spring with a towel to prevent
the spring from flying and possibly causing damage or personal
injury.
NOTE:
Add the screw driver between the oil pump slide spring windings (2).
5. Protect the engine front cover edge (1) with a suitable piece of plastics.
6. Compress the oil pump slide spring with a screw driver and remove the oil pump slide spring in
compound with the oil pump slide spring pin.

Fig. 190: Engine Oil Pump Components

NOTE:
Mind the installation position of the oil pump components.
7. Remove the oil pump components in the following order:

1. Outer oil pump vane ring (1).
2. Oil pump vane rotor (3) and the 7 oil pump vanes (2).
3. Inner oil pump vane ring (6).
4. Oil pump slide (4) and the 2 oil pump slide seals with the 2 oil pump slide seal springs (5).
Cleaning And Inspection Procedure
1. Inspect the engine front cover for cracks, scratches and damage.
2. Inspect the oil pump cover and the engine front cover for flatness.
3. Inspect the oil pump vanes, the oil pump vane rotor, the oil pump vane rings and the oil pump slide for

localized flatting.
4. Inspect the oil pump slide pivot pin for firm seat.
Fig. 191: Oil Gallery Bores

WARNING: Wear safety glasses when using compressed air in order to prevent
eye injury.
CAUTION: To ensure proper engine lubrication, clean clogged or contaminated
oil galleries in an approved solvent and with compressed air. Failure
to clean oil galleries may cause engine damage.
5. Clean the oil galleries with solvent and compressed air. Blow compressed air from bore (2) to bore (1).

Fig. 192: Oil Pump Components

NOTE:
Oil pump slide spring pin and oil pump slide spring, as well as slide seal
and slide seal spring can be ordered as single parts. All other oil pump
components can only be ordered as a replacement kit.
1. Install the oil pan components in the following order:

NOTE:
The bore (8) in the oil pump slide must fit smooth-running and
without clearance to the oil pump slide pivot pin (7).
1. Install the oil pump slide (6).

2. Install the inner oil pump vane ring (5).
NOTE:
Mind the installation position of the oil pump vane rotor (4). The mark

(9) must point to direction of the oil pump cover.

3. Install the oil pump vane rotor (4).
NOTE:
Mind the localized flattings (3) on the oil pump vanes (2) caused by
the oil pump vane rings. The localized flattings must point to the oil
pump vane rotor.
4. Install the 7 oil pump vanes (2).

5. Install the outer oil pump vane ring (1).
Fig. 193: Oil Pump Slide Seal Springs And Grooves

2. Install the 2 oil pump slide seals and the 2 oil pump slide seal springs (2) in the position as shown to the 2
grooves (1) of the oil pump slide.

Fig. 194: Oil Pump Slide Spring, Pin, Chambers And Front Cover Edge
3. Protect the engine front cover edge (5) with a suitable piece of plastics.
NOTE:
The length of the removed oil pump slide spring (2) should be 76.5 mm
(3.0118 in) for suction engines and 61 mm (2.4016 in) for turbo engines.
4. Install the oil pump slide spring pin (1) in compound with the oil pump slide spring (4). Use a scewdriver
to compress the oil pump slide spring. The flat side of oil pump slide spring pin must face upwards.
5. Lubricate the oil pump vanes, the oil pump vane rotor, the oil pump slide spring and the chambers (3)
with engine oil.
6. Inspect the oil pump slide spring mechanism for practicability.
7. Measure the oil pump axial and radial clearances and compare with the specified values. Refer to Engine
Front Cover and Oil Pump Cleaning and Inspection


8. Install the oil pump cover (2) and the 8 oil pump cover bolts (1).

Fig. 196: Oil Pump Cover Bolts Tightening Sequence

9. Tighten the oil pump cover bolts in a sequence as shown to 8 N.m (71 lb in).

Fig. 197: Crankshaft Balancer

10. Install the crankshaft balancer (1) and rotate in shown direction (2) in order to inspect the function of the
oil pump mechanism. Crankshaft balancer should rotate easily.
11. Remove the timing chain and replace the engine front cover gasket. Refer to Camshaft Timing Chain
Replacement.
12. Install the timing chain. Refer to Camshaft Timing Chain Replacement.
13. Install the engine front cover. Refer to Engine Front Cover with Oil Pump Replacement.
14. Measure the oil pressure and compare with the specified values. Refer to Oil Pressure Diagnosis and
Testing.
ENGINE REPLACEMENT
Removal Procedure

1. Disconnect the negative battery cable from the battery. Refer to Battery Negative Cable Disconnection
and Connection .
2. Drain the engine cooling system. Refer to Cooling System Draining and Filling (Static Fill) , Cooling
System Draining and Filling (GE-47716 Fill) .
3. Recover the air conditioning refrigerant. Refer to Refrigerant Recovery and Recharging .
Fig. 198: Air Cleaner Assembly, Electrical Connector And Clamp

5. Loosen the clamp (2) and remove air cleaner from air cleaner assembly (3).

Fig. 199: Air Cleaner Outlet Duct And Clamp

6. Loosen the clamp (1) and remove the outlet duct (2).
7. Remove the charge air cooler inlet air hose. Refer to Charge Air Cooler Inlet Air Hose Replacement .
8. Remove the charge air cooler outlet air hose. Refer to Charge Air Cooler Outlet Air Hose
Replacement (Automatic Transmission) , Charge Air Cooler Outlet Air Hose Replacement (Manual
Transmission) .

Fig. 200: Refrigerant Hose And Nut

9. Remove refrigerant hose nut (1) from refrigerant hose (2).


10. Disconnect the fuel feed line (1) and reposition away from the engine. Refer to Fuel Pressure Relief .


11. Disconnect the EVAP hose (1). Refer to Plastic Collar Quick Connect Fitting Service .


12. Disconnect the power brake booster vacuum pipe (1).

Fig. 204: Radiator Surge Tank Outlet Hose Clamp

13. Reposition the hose clamp (1) and remove the radiator surge tank outlet hose.

Fig. 205: Heater Core Inlet And Outlet Hoses

14. Disconnect inlet (2) and outlet (1) heater core hoses.

Fig. 206: View Of Transmission Range Selector Lever & Cable Connection
15. On vehicles equipped with a automatic transmission, disconnect the transmission range selector lever
cable terminal (1) from the transmission manual shift lever pin.
16. On vehicles equipped with a automatic transmission, press the locking tabs inward in order to release the
transmission range selector lever cable (2) from the cable bracket.

Fig. 207: Selector Lever Cable, Bracket And Transmission Control Housing
17. On vehicles equipped with a manual transmission, using a suitable pry tool, disconnect the shift lever
cables (2) from the shift levers (3)
18. On vehicles equipped with a manual transmission, remove the shift lever cables (2) from the cable bracket
(1).

Fig. 208: Ground Strap And Bolt

19. Remove the ground strap bolt (1) from the battery cable and reposition the strap (2) a side.

Fig. 209: Wiring Harnesses And Ground Nuts

21. Remove the ground nuts (1) and put the wiring harness (2) aside.
22. Disconnect the electrical connectors from the engine control module (ECM). Refer to Engine Control
Module Replacement .
23. Disconnect the wiring harness from the accessory wiring junction block.

Fig. 210: Junction Connector

24. Disconnect the wiring harness from the junction connector (1).
25. Place the ECM, transmission and the accessory wiring junction block wiring harnesses on the top of
engine assembly.
26. Install the engine support fixture.

Fig. 211: Lower Steering Intermediate Shaft Bolt

27. Remove and DISCARD the lower steering intermediate shaft bolt (1).

NOTE:
Do Not disconnect the brake hoses from the calipers.
28. Remove the front brake calipers (1) and caliper bolts (2) from the caliper brackets, and then suspend the
calipers with mechanics wire to the body.
29. Remove the exhaust system. Refer to Exhaust System Replacement .


30. Remove and DISCARD the stabilizer link nut (1) from the strut assemblies. Refer to Stabilizer Shaft
Link Replacement .
31. Disconnect the right wheel drive shaft from the intermediate shaft.
32. Disconnect the front steering knuckles from the strut assemblies. Refer to Steering Knuckle
Replacement .
33. Disconnect the electronic power steering connectors from the electronic power steering assembly. Refer
to FEP Connectors (Steering Gear) .

Fig. 214: Transmission Bracket Mount To Mount Through Bolt

34. Remove the rear transmission mount bracket to rear mount through bolt (1).

Fig. 215: Front Transmission Mount Through Bolt

35. Remove the transmission front mount through bolt (1).
36. Using suitable straps or chains, secure the front of vehicle to the hoist arms.
NOTE:
Use the engine support fixture to slightly raise the powertrain assembly to
aid in the removal of the engine and transmission mount bolts.
37. Use the engine support fixture to slightly raise the powertrain assembly to aid in the removal of the
engine and transmission mount bolts.

Fig. 216: Left Transmission Mount Bolts

38. Remove and DISCARD the left transmission mount to bracket bolts (1).

Fig. 217: Engine Mount Bracket Bolts And Washers

39. Remove the engine mount to engine mount bracket bolts (1) and the washers (2).
40. Using a suitable engine support table, lower the vehicle until the drivetrain and front suspension frame
contacts the engine support table.
41. Position blocks of wood below the oil pan and transmission to stabilize the powertrain on the support
table.
42. Using the engine support fixture, lower the powertrain down until it is resting on the engine support table.

Fig. 218: Power Steering Gear, Inlet And Outlet Hose And Bolts
43. Remove the power steering gear inlet and outlet hose bolts (1). Remove the inlet and outlet hose (2) from
the steering gear (3).
44. Remove the engine support fixture.
45. Remove the drivetrain and front suspension frame reinforcements from the rear of the frame.
46. Remove the front drivetrain and front suspension frame retaining bolts.
47. Slowly and carefully raise the vehicle, ensure the engine, transmission, radiator assembly and drivetrain
suspension frame are free from wiring, hoses and other engine compartment components.
48. Separate the transmission from the engine assembly.
49. Disconnect engine coolant hoses as necessary.
50. Disconnect electrical connectors as necessary.

1. Position the engine to the transmission assembly.

2. Position the engine, transmission, radiator assembly and drivetrain suspension frame under the vehicle.
3. Slowly and carefully lower the vehicle, ensure the engine, transmission, radiator assembly and drivetrain
4. Install the four front drivetrain and front suspension frame retaining bolts, then tighten to the fasteners to
160 N.m (118 lb ft).
5. Install the drivetrain and front suspension frame reinforcements to the rear of the frame, then tighten the
reinforcement fasteners to 22 N.m (16 lb ft).
NOTE:
aid in the installation of the engine and transmission mount bolts.

Fig. 219: Transmission Bracket Mounting Bolts

7. Install the transmission bracket mount to mount through bolt (1) and tighten to 100 N.m (74 lb ft).

Fig. 220: Front Transmission Mounting Bolts

8. Install the transmission mount through bolt (1) and tighten to 58 N.m (43 lb ft).
9. Install the engine mount. Refer to Engine Mount Replacement - Right Side.


10. Install the NEW left transmission mount to transmission bolts (1) and tighten to 50 N.m (37 lb ft) plus 6075 degrees.

11. Install the inlet and outlet hose (2) to the steering gear (3).
12. Install power steering gear inlet and outlet hose bolts (1) and tighten to 11 N.m (97 lb in).


13. Instal NEW the lower steering intermediate shaft (1) bolt and tighten to 34 N.m (25 lb ft).
14. Connect the front steering knuckles to the strut assemblies. Refer to Steering Knuckle Replacement .


15. Install NEW the stabilizer link nut (1) to the strut assemblies. Refer to Stabilizer Shaft Link
Replacement .
16. Connect the right wheel drive shaft from the intermediate shaft.

17.
18.
19.
20.
21.
22.
23.
Install the front brake caliper (1) and tighten the brake caliper guide pin bolt (2) to 28 N.m (21 lb ft).
Install the exhaust system. Refer to Exhaust System Replacement .
Connect the wheel speed connectors to the steering knuckles.
Remove the engine support fixture.
Connect the wiring connectors and ground strap to the transmission.
Connect the wiring harness to the accessory wiring junction block.
Connect the electrical connectors to the ECM. Refer to Engine Control Module Replacement .


24. Install the wiring harnesses (2).
25. Install the ground nuts (1) and tighten to 9 N.m (80 lb in).


26. Connect the wiring harness plugs (1).

27. On vehicles equipped with a automatic transmission, connect the transmission range selector lever cable
terminal (1) to the transmission manual shift lever pin.
28. On vehicles equipped with a automatic transmission, press the locking tabs outward in order to lock the
transmission range selector lever cable (2) to the cable bracket.

29. On vehicles equipped with a manual transmission, connect the shift lever cables (2) to the shift levers (3)
30. On vehicles equipped with a manual transmission, install the shift lever cables (2) to the cable bracket (1).
31. Install the battery tray. Refer to Battery Tray Replacement .


32. Connect inlet (2) and outlet (1) heater core hoses.


33. Connect the power brake booster vacuum pipe (1).


34. Connect the coolant hose and reposition the clamp (1).


35. Connect the fuel feed line (1) and reposition away from the engine. Refer to Fuel Pressure Relief .


36. Connect the EVAP hose (1). Refer to Plastic Collar Quick Connect Fitting Service .


NOTE:
Use NEW O-ring seals. Refer to Air Conditioning O-Ring Seal

Replacement .
37. Install refrigerant hose (2) and tighten the nut (1) to 19 N.m (14 lb ft).
38. Install the charge air cooler inlet air hose. Refer to Charge Air Cooler Inlet Air Hose Replacement .
39. Install the charge air cooler outlet air hose. Refer to Charge Air Cooler Outlet Air Hose Replacement
(Automatic Transmission) , Charge Air Cooler Outlet Air Hose Replacement (Manual
Transmission) .
40. Connect engine coolant hoses as necessary.
41. Connect electrical connectors as necessary.
42. Install the front fascia.
43. Install the front wheelhouse front liners.
45. Fill the engine cooling system. Refer to Cooling System Draining and Filling (Static Fill) , Cooling


46. Charge the air conditioning system. Refer to Refrigerant Recovery and Recharging .
47. Check engine oil level. Refer to Engine Oil and Oil Filter Replacement.
48. Connect the negative battery cable to the battery. Refer to Battery Negative Cable Disconnection and
Connection .
ENGINE OIL AND OIL FILTER REPLACEMENT
Removal Procedure
1. Open hood.
CAUTION: To prevent damage to oil filter cap ensure proper tool is used. Do not
use an open end wrench which may cause damage to filter cap.
3. Using a 24mm socket or closed end wrench loosen oil filter cap. Unscrew filter cap 3 turns and let oil
filter and cap assembly drain in housing for 30 seconds.

Fig. 236: Engine Oil Filter Cap, Cap Seal Ring And Oil Filter Element
NOTE:
Use care when removing engine oil filter cap and filter to minimize fluid
spillage. If fluid spillage occurs it must be cleaned with appropriate
cleaner.
NOTE:
Inspect oil filter cap for any cracks or damage. If oil filter cap is damaged it
must be replaced.
4. Remove the engine oil filter cap (2) with the engine oil filter cap seal ring (3) and the oil filter element
(1).
6. Remove the oil pan drain plug and allow the oil to drain into the drain pan.
1. Clean the oil pan drain plug thread in the oil pan.

2. Install a NEW seal ring to the oil pan drain plug.

CAUTION: Refer to Component Fastener Tightening Caution .
3. Install the oil pan drain plug and tighten to 14 N.m (10 lb ft).
Fig. 237: Oil Filter Cap Seal Ring

NOTE:
Clean oil filter cap and lubricate the NEW oil filter cap seal ring with clean
engine oil. Ensure oil filter cap seal ring is in proper position as shown.
5. Install a NEW oil filter cap seal ring (1).

6. Install the engine oil filter cap (2) with NEW engine oil filter cap seal ring (3) and NEW oil filter element
(1) hand tight.


CAUTION: Ensure oil filter cap is completely seated on oil filter housing. If not
completely seated an oil leak may occur.
CAUTION: Over torquing the oil filter cap may cause damage to the oil filter cap
resulting in an oil leak.
7. Using a 24mm socket or closed end wrench tighten the engine oil filter cap to 25 N.m (18 lb ft).
CAUTION: Using engine oils of any viscosity other than those viscosities
recommended could result in engine damage.
NOTE:
Do not overfill the engine with engine oil.
NOTE:
Anytime engine oil is added (top off or oil changes) ensure all engine
surfaces are completely free of residual oil. If there is oil on any engine
surface clean as necessary.
8. Fill engine with NEW oil using Dexos1 5W-30 specification.

Fig. 240: Proper Oil Filler Cap Seating

NOTE:
Oil fill cap must be properly seated and tightened during installation.
9. Install oil fill cap.

10. Start the engine and allow it to run until the oil pressure control indicator goes off. Inspect for any oil
leaks around the drain plug, oil filter and oil fill cap.

Fig. 241: Engine Oil Level Indicator

11. Inspect the engine oil level. The oil level should be in the cross-hatched section of the oil level indicator
as shown.
12. Close hood.
13. Reset the engine oil life system monitor.
ENGINE SIGHT SHIELD REPLACEMENT
Removal Procedure

Fig. 242: Engine Sight Shield

1. Using a screwdriver or similar tool, unclip the engine sight shield (1) at the shown positions (arrows).

Fig. 243: Engine Sight Shield

2. Rotate the engine sight shield in arrow direction and unclip it from the camshaft cover.

Fig. 244: Rear Clips And Camshaft Cover

1. Clip the rear clips (1) to the camshaft cover.

Fig. 245: Rear Clips And Camshaft Cover

2. Rotate the engine sight shield as shown until the clips (1) engage audible in the camshaft cover.
TURBOCHARGER REPLACEMENT
Special Tools

Removal Procedure
1. Open the hood.


3. Drain the cooling system. Refer to Cooling System Draining and Filling (Static Fill) , Cooling System
5. Disconnect the positive crankcase ventilation pipe from turbocharger. Refer to Positive Crankcase
Ventilation Hose/Pipe/Tube Replacement.
LUV) .
Fig. 246: Turbocharger Wastegate Regulator Solenoid Valve Wiring Harness Connector And
Retaining Clip
7. Disconnect the turbocharger wastegate regulator solenoid valve wiring harness connector (1) and unclip
wiring harness from retainer clip (2).

Fig. 247: Turbocharger Oil Feed Pipe Components

8. Remove the turbocharger oil feed pipe hollow screw (4).
9. Remove and DISCARD the 2 seal rings (1) and (3).
10. Remove the turbocharger oil feed pipe bolt (5).
NOTE:
Close the screw bore in the turbocharger in order to avoid contamination.
11. Remove the turbocharger oil feed pipe (2).

12. Loosen the turbocharger coolant return hose clamp and remove the turbocharger coolant return hose (6)
from the oil cooler inlet pipe.
13. Remove the turbocharger coolant return pipe bolt (7).
14. Remove the charge air cooler inlet air hose from the turbocharger. Refer to Charge Air Cooler Inlet Air
Hose Replacement .

Fig. 248: Ratchet Wrench And Holding Wrench

15. Install the EN-49942 holding wrench (2) to the turbocharger coolant feed pipe. Guide a ratchet wrench
(1) along with an extension through EN-49942 holding wrench to the turbocharger coolant feed pipe
hollow screw.

Fig. 249: Ratchet Wrench, Holding Wrench And Coolant Feed Pipe
NOTE:
16.
17.
18.
19.
EN-49942 holding wrench (2) should be installed to turbocharger coolant

feed pipe as shown. The holding wrench should be installed to avoid twist
of the turbocharger coolant feed pipe during the loosening procedure.
Loosen the turbocharger coolant feed pipe hollow screw with ratchet wrench and extension (1).
Remove the turbocharger coolant feed pipe hollow screw.
Remove and DISCARD the 2 seal rings.
Remove the three way warm catalytic converter. Refer to Warm Up Three-Way Catalytic Converter
Replacement .

Fig. 250: Turbocharger Oil Return Pipe Bolts

20. Remove the 2 turbocharger oil return pipe bolts (1) from turbocharger.
21. Remove the turbocharger oil return pipe from the turbocharger.
22. Remove and DISCARD the gasket.

Fig. 251: Turbocharger Nuts

23. Remove and DISCARD the 8 turbocharger nuts (1).

Fig. 252: Turbocharger Assembly And Gasket

24.
25.
26.
27.
Remove the turbocharger assembly (1).

Remove and DISCARD the turbocharger gasket (2).
Remove the assembly parts from the turbocharger as necessary. Refer to Turbocharger Disassemble.
If the turbocharger is being reused, refer to Turbocharger Cleaning and Inspection.
1. Install the assembly parts to the turbocharger as necessary. Refer to Turbocharger Assemble.

Fig. 253: Turbocharger Assembly And Gasket

3. Install a NEW turbocharger gasket.
4. Install the turbocharger assembly (1).


5. Install the 8 NEW turbocharger nuts (1).

Fig. 255: Turbocharger Nuts Tightening Sequence

6. Tighten the 8 turbocharger nuts in a sequence as shown to 8 N.m (71 lb in).

7. Repeat the tightening procedure to ensure a proper fastening of the turbocharger nuts.

Fig. 256: Turbocharger Oil Return Pipe Bolts

8. Install a NEW gasket and the 2 turbocharger oil return pipe bolts (1) and tighten to 8 N.m (71 lb in).
9. Install the three way warm up catalytic converter. Refer to Warm Up Three-Way Catalytic Converter
Replacement .

Fig. 257: Turbocharger Coolant Feed Pipe Components

10. Install the turbocharger coolant feed pipe to the engine block. Use the following procedure:
Install a NEW seal ring (3) to the turbocharger coolant feed pipe hollow screw (4).
Install the turbocharger coolant feed pipe hollow screw along with the seal ring to the turbocharger
coolant feed pipe (2).
Install a NEW seal ring (1) to the turbocharger coolant feed pipe hollow screw.
Install the turbocharger coolant feed pipe hollow screw along with the turbocharger coolant feed
pipe and the 2 seal rings to the engine.

Fig. 258: Ratchet Wrench And Holding Wrench

NOTE:
The EN-49942 holding wrench should be installed in a perpendicular

position as shown to ensure a proper installation position of the
turbocharger coolant feed pipe.
hollow screw.

NOTE:
EN-49942 holding wrench (2) should be installed to the turbocharger

coolant feed pipe as shown. The holding wrench should be installed to
avoid twist of the turbocharger coolant feed pipe during the fastening
procedure.
12. Tighten the turbocharger coolant feed pipe hollow screw with ratchet wrench and extension (1) to 30 N.m
(22 lb ft).
13. Install the charge air cooler inlet air hose to the turbocharger. Refer to Charge Air Cooler Inlet Air
Hose Replacement .


14.
15.
16.
17.
18.
19.
Install the turbocharger coolant return pipe bolt (7) and tighten to 8 N.m (71 lb in).
Install the turbocharger coolant return hose (6) to the oil cooler inlet pipe.
Install the turbocharger coolant return hose clamp.
Install the turbocharger oil feed pipe (2) to the oil cooler and the turbocharger.
Install the turbocharger oil feed pipe bolt (5).
Install the turbocharger oil feed pipe hollow screw (4) along with the 2 NEW seal rings (1) and (3) and
tighten to 30 N.m (22 lb ft).
20. Tighten the turbocharger oil feed pipe bolt to 10 N.m (89 lb in).

Fig. 261: Turbocharger Wastegate Regulator Solenoid Valve Wiring Harness Connector And
Retaining Clip
21. Connect the turbocharger wastegate regulator solenoid valve wiring harness connector (1) and clip in
wiring harness to retainer clip (2).
LUV) .
23. Connect the positive crankcase ventilation pipe to the turbocharger. Refer to Positive Crankcase
26. Fill the cooling system. Refer to Cooling System Draining and Filling (Static Fill) , Cooling System
27. Close the hood.

TURBOCHARGER OIL FEED PIPE REPLACEMENT

Removal Procedure
1. Disconnect the battery negative cable. Battery Negative Cable Disconnection and Connection .
LUV) .

3.
4.
5.
6.
Remove the turbocharger oil feed pipe bolt (5).

Remove the turbocharger oil feed pipe hollow screw (4) and the 2 seal rings (1, 3).
Remove the turbocharger oil feed pipe (2) and the rubber seal ring.
Inspect the turbocharger oil feed pipe for damage or restriction. Do NOT attempt to clean or repair the
pipe. Replace the pipe if it has damage or a restriction.

1. Clean all sealing surfaces.

2. Install the turbocharger oil feed pipe (2) along with a NEW rubber seal ring.
3. Install the turbocharger oil feed pipe hollow screw (4) and 2 NEW seal rings (1, 3).
4. Install the turbocharger oil feed pipe bolt (5) and tighten to 10 N.m (89 lb in).
5. Tighten the turbocharger oil feed pipe hollow screw (4) to 30 N.m (22 lb ft).

LUV) .
7. Connect the battery negative cable. Battery Negative Cable Disconnection and Connection .
TURBOCHARGER OIL RETURN PIPE REPLACEMENT
Removal procedure
1. Raise and support the vehicle. Lifting and Jacking the Vehicle .
Fig. 264: Turbocharger Oil Return Pipe Components

NOTE:
Simplified Graphic. DO NOT remove the warm up three way catalytic

converter.
2. Remove the 2 turbocharger oil return pipe bolts (1).


4. Release the turbocharger oil return pipe connector (4) and disconnect the turbocharger oil return pipe
from the engine block.
5. Remove the turbocharger oil return pipe (2) and the gasket (3).
6. Inspect the turbocharger oil return pipe for damage or restriction. Do NOT attempt to clean or repair the
pipe. Replace the pipe if it has damage or a restriction.
Fig. 265: Turbocharger Oil Return Pipe Components

2. Install the turbocharger oil return pipe (2) in compound with a NEW gasket (3) and connect to the engine
block.


3. Install the 2 turbocharger oil return pipe bolts (1) and tighten to 8 N.m (71 lb in).
4. Lower and unsupport the vehicle. Refer to Lifting and Jacking the Vehicle .
5. Check engine oil level.
PISTON, CONNECTING ROD, AND BEARING REPLACEMENT
Special Tools

Removal Procedure
1.
2.
3.
4.
Open the hood.

Remove the cylinder head. Refer to Cylinder Head Replacement.
Remove the oil pan. Refer to Oil Pan Replacement.

Fig. 266: Rod Bearing Caps And Bolts

NOTE:
Mark the installation position of the connecting rod bearing caps. The
connecting rod bearings and bearing caps must not be interchanged with
other connecting rods.
5. Remove and DISCARD the 4 connecting rod bearing cap bolts (1) of cylinder 2 and 3.
6. Remove the 2 connecting rod bearing caps (2) and the 2 connecting rod bearings of cylinder 2 and 3.
7. Rotate the crankshaft 180 degrees.


8. Remove and DISCARD the 4 connecting rod bearing cap bolts (1) of cylinder 1 and 4.

Fig. 268: Pistons, Connecting Rods And Bearings

10. Remove the 4 pistons (1) and connecting rods (2) and the 4 upper connecting rod bearings (3) from the
cylinder block.
1. For cleaning and inspection procedure, refer to Piston, Connecting Rod, and Bearing Cleaning and
Inspection.
2. Assemble the NEW piston and connecting rod. Refer to Piston and Connecting Rod Assemble.

Fig. 269: Piston Ring Joint Adjustment Points

3. Adjust the piston ring joints as followed:
1. Upper compression ring (1)
2. Lower compression ring (4)
3. Oilring (2) or (3)
4. Oilring spacer (5)

Fig. 270: Rods And Arrow On Piston Head

4. The arrow (1) on the piston head must point to the timing side.
5. The markings on the connecting rods (2) must point to the transmission side.


6. Lubricate the piston rings, piston, inner cylinder bore surface and a piston ring compressor with clean
engine oil.
7. Install the piston ring compressor in order to compress the piston rings.
8. Install the pistons (1) in compound with connecting rods (2) and upper connecting rod bearings (3) to the
engine block and to the crankshaft.


NOTE:
The flarings (arrows) on the connecting rod bearing caps must point to the
transmission side. The connecting rod bearing caps must be installed in
their original position.
9. Install the 2 connecting rod bearings and the 2 connecting rod bearing caps (2) of cylinder 1 and 4.
10. Install the 4 NEW connecting rod bearing cap bolts (1) and tighten in the following sequence:

1. Tighten the connecting rod bearing cap bolts to 25 N.m (18 lb ft).
2. Tighten the connecting rod bearing cap bolts an additional 45 degrees. Use EN-470-B wrench.

NOTE:

14. Install the oil pan. Refer to Oil Pan Replacement.
16. Install the cylinder head. Refer to Cylinder Head Replacement.
17. Close the hood.
CAMSHAFT COVER REPLACEMENT
Removal Procedure
1. Open the hood.

2. Remove ignition coil. Refer to Ignition Coil Replacement .
3. Remove the positive crankcase ventilation pipe from camshaft cover. Refer to Positive Crankcase


4. Remove engine control module wiring harness (1) from camshaft cover.
Disconnect intake camshaft position sensor wiring harness plug (7).
Disconnect intake camshaft position actuator solenoid valve wiring harness plug (6).
Disconnect exhaust camshaft position sensor wiring harness plug (4).
Disconnect exhaust camshaft position actuator solenoid valve wiring harness plug (5).
Disconnect engine coolant temperature sensor wiring harness plug (3).
Disconnect engine oil pressure indicator switch wiring harness plug (2).
Unclip engine control module wiring harness plug from camshaft cover and lay aside.


5. Remove the oil level indicator (1).

Fig. 276: Camshaft Cover And Gasket

6. Remove the 15 camshaft cover bolts (1).
7. Remove the camshaft cover (2) and the camshaft cover gasket (3).


NOTE:
2. Apply sealing compound to areas (1) and (2). Refer to Adhesives, Fluids, Lubricants, and Sealers.


NOTE:
The installation procedure should not take longer than 10 minutes.
3. Install the camshaft cover (2) and a NEW gasket (3).

4. Install the 15 camshaft cover bolts (1).

Fig. 279: Camshaft Cover Bolts Tightening Sequence

5. Tighten the 15 camshaft cover bolts in a sequence as shown to 8 N.m (71 lb in).


6. Install engine control module wiring harness (1) to camshaft cover.
Clip engine control module wiring harness plug to camshaft cover.
Connect intake camshaft position sensor wiring harness plug (7).
Connect intake camshaft position actuator solenoid valve wiring harness plug (6).
Connect exhaust camshaft position sensor wiring harness plug (4).
Connect exhaust camshaft position actuator solenoid valve wiring harness plug (5).
Connect engine coolant temperature sensor wiring harness plug (3).
Connect engine oil pressure indicator switch wiring harness plug (2).
7. Install ignition coil. Refer to Ignition Coil Replacement .
8. Install the positive crankcase ventilation pipe to camshaft cover. Refer to Positive Crankcase

10. Close the hood.

INTAKE CAMSHAFT REPLACEMENT
Removal Procedure
1. Remove the camshaft intake sprocket. Refer to Camshaft Intake Sprocket Replacement.
Fig. 281: Intake Camshaft Bearing Cap Bolts Removal Sequence

2. Remove the camshaft bearing cap bolts in a spiral sequence as shown one turn at a time until there is no
spring tension pushing on the camshaft.

Fig. 282: Intake Camshaft, Camshaft Bearing Caps And Bolts

NOTE:
Mind the markings on the camshaft bearing caps to ensure they will be
installed in the same position.
3. Remove the 10 camshaft bearing cap bolts (1).

4. Remove the 5 camshaft bearing caps (2).
5. Remove the intake camshaft (3).


NOTE:
1.
2.
3.
4.
Mind the markings on the camshaft bearing caps. Camshaft bearing caps
should be installed in their original position.
Lubricate camshaft and camshaft bearing caps with engine oil.

Install the intake camshaft (3).
Install the 5 camshaft bearing caps (2).
Install the 10 camshaft bearing cap bolts (1) and handtighten.

Fig. 284: Intake Camshaft Bearing Cap Bolts Tightening Sequence

NOTE:
Tighten the camshaft bearing cap bolts one turn a time to avoid shape
distortion of the camshaft.
5. Tighten the camshaft bearing cap bolts one turn at a time in a spiral sequence as shown to 8 N.m (71 lb
in).
6. Install camshaft intake sprocket. Refer to Camshaft Intake Sprocket Replacement.
EXHAUST CAMSHAFT REPLACEMENT
Removal Procedure

1. Remove the camshaft exhaust sprocket. Refer to Camshaft Exhaust Sprocket Replacement.
Fig. 285: Exhaust Camshaft Bearing Cap Bolts Removal Sequence


Fig. 286: Exhaust Camshaft, Camshaft Bearing Caps And Bolts

NOTE:

5. Remove the exhaust camshaft (3).


NOTE:
1.
2.
3.
4.

Install the exhaust camshaft (3).

Fig. 288: Exhaust Camshaft Bearing Cap Bolts Tightening Sequence

NOTE:
Tighten the camshaft bearing cap bolts one turn a time to avoid shape
distortion of the camshaft.
5. Tighten the camshaft bearing cap bolts one turn at a time in a spiral sequence as shown to 8 N.m (71 lb
in).
6. Install the camshaft exhaust sprocket. Refer to Camshaft Exhaust Sprocket Replacement.
VALVE STEM OIL SEAL AND VALVE SPRING REPLACEMENT
Special Tools

207649 Rod Hairpin Clips

547324 Flange Screws
EN-958 Installer
EN-840 Pliers / Remover
EN-952 Fixing Pin
EN-50717 Kit
J-43649-2 Rods

Removal Procedure
1.
2.
3.
4.
Remove the right front wheel house liner. Refer to Front Wheelhouse Liner Replacement .
Lower the vehicle.
Remove the hydraulic valve lash adjuster arms. Refer to Hydraulic Valve Lash Adjuster Arm
Replacement.
5. Remove the spark plugs. Refer to Spark Plug Replacement .
6. Adjust the engine to TDC of cylinder 1 and fix the crankshaft. Refer to Camshaft Timing Chain
Adjustment.
NOTE:
Wheels must contact the ground.
7. Shift to 5. gear (MT) or park position (AT) and apply the park brake.
Valve Stem Oil Seal Removal

Fig. 289: Special Seal Removal Tools

1. Install the 2 EN-50717-1 stands (1) to the cylinder head and fix them with the 547324 screws.
2. Install the 2 J-43649-2 rods (2) and the EN-51717-2 compressor (3) to the EN-50717-1 stands. Secure
the rods with the 207649 clips then.
3. Install an suitable air pressure adapter (4) to the spark plug hole.
4. Apply air pressure to the corresponding cylinder.
5. Position the EN-51717-2 compressor (3) so that its adapter proper contacts the valve spring retainer and
pretension the compressor.

Fig. 290: Valve Spring Retainer And Valve Spring

WARNING: Valve springs can be tightly compressed. Use care when removing
the retainers and plugs. Personal injury could result.
6. Apply pressure to the EN-50717-2 compressor to push down the vale spring retainer (1) and compress the
valve spring (3) until the valve keys (2) are free from tension. Carefully remove the valve keys then.
7. Release the tension from the EN-50717-2 compressor.
8. Remove the valve spring retainer (1) and the valve spring (3).

Fig. 291: Pliers And Intake Valve Stem Oil Seals

9. Remove and DISCARD the valve stem oil seal (2), using the EN-840 pliers (1).
Valve Stem Oil Seal Installation

Fig. 292: Intake Valve Stem Oil Seal Installation Tool

NOTE:
Lubricate the NEW valve stem oil seal with clean engine oil.
1. Install the NEW valve stem oil seal, using the EN-958 installer (1).
2. Loosely install the valve spring and the valve spring retainer.

Fig. 293: Special Valve Spring Compression Tool

CAUTION: The valve stem keys must correctly seat in the valve spring cap.
Engine damage may occur by not installing properly.
3. Using the EN-51717-2 compressor (4), push down the valve spring retainer (1) and compress the valve
spring (3) until the valve keys (2) can be inserted. Carefully insert the valve keys then, so that they are
proper installed to the valve stem grooves.
4. Carefully release the tension from the EN-50717-2 compressor.
5. Inspect the valve keys and valve spring retainer for proper seat.
6. Repeat the procedure with the remaining valves and cylinders. Transfer the EN-50717-1 stands and the
EN-51717-2 compressor as needed.
7. Take care that air pressure is always applied to the combustion chamber of the treated cylinder.

1.
2.
3.
4.
5.
6.
7.
8.
9.
Remove the tools from the cylinder head.

Release the air pressure and remove the air pressure adapter form the spark plug hole.
Shift to neutral gear and release the park brake.
Install the hydraulic valve lash adjuster arms. Refer to Hydraulic Valve Lash Adjuster Arm
Replacement.
Raise the vehicle.
Remove the EN-952 fixing pin and install the crankshaft bearing cap tie plate hole plug. Refer to
Lower the vehicle.

REPAIR INSTRUCTIONS - OFF VEHICLE

ENGINE SUPPORT FIXTURE
Fig. 294: Engine Support Fixture

Engine Support Fixture
Callous
Component Name
Remove the front fender shipping cover. Refer to Front Fender Shipping Cover Replacement .
Special Tools
J-28467-1A Cross Bracket

J-28467-2A Radiator Tube Shelf Assembly
J-28467-5A Strut Tower Support Assembly
J-28467-8A Hook Assembly
J-28467-518 Main Support Beam
J-36857 Engine Lift Bracket
J-43405 Engine Support Fixture Adapter

1
2
3
4
5
Engine Support Fixture Adapter Leg (Qty: 2)

Procedure
Install the bracket to fender frame. Do not install on top of fender
lip.
Main Support Beam
Cross Bracket (Qty: 2)
Strut Tower Support Assembly (Qty: 2)
Procedure
Adjust the length of the strut tower support assembly.
Radiator Tube Shelf Assembly (Qty: 2)
Engine Lift Bracket
Procedure
Use a grade 10.9 bolt to install the engine lift bracket.
TIP: If the engine is not equipped with engine lift bracket, install J36857 bracket in place.
ENGINE MOUNT BRACKET REMOVAL


1. Remove the 3 engine mount bracket bolts (1).
CAMSHAFT TIMING CHAIN INSPECTION
Special Tools
EN-952 Fixing Pin

EN-49977-100 Transmitter Disc Fixation

1. Remove the ignition coil. Refer to Ignition Coil Replacement .

2. Remove the camshaft cover. Refer to Camshaft Cover Replacement.

3. Remove the right front wheelhouse liner. Refer to Front Wheelhouse Liner Replacement
4. Remove the front compartment insulator. Refer to Front Compartment Insulator Replacement
engine front cover.

Fig. 297: Camshaft Grooves

6. Examine that the camshaft grooves (1) are visible as shown. If the camshaft grooves are not visible rotate
the crankshaft 360.

Fig. 298: Crankshaft Bearing Cap Tie Plate Hole Plug And Seal Ring
7. Remove the crankshaft bearing cap tie plate hole plug (2) and the seal ring (1).

Fig. 299: Fixing Pin

CAUTION: To ensure proper crankshaft top dead center (TDC) alignment, the
retention pin should fit easily through the bore in the crankshaft tie
plate and into the crankshaft. Binding of the retention pin could affect
proper engine timing.
8. Install EN-952 fixing pin (1) to hold the crankshaft in TDC position.

Fig. 300: Fixing Tool

NOTE:
The fixing tool should be installed completely to both camshaft grooves

without high effort.
9. Install EN-953-A fixing tool (1) to the camshafts.

Fig. 301: Transmitter Disc Fixation And Bolts

NOTE:
A wrong installation position is possible. Make sure that the fixation tool is
installed without clearance to the cylinder head in areas (3) and (4).
10. Install EN-49977-100 transmitter disc fixation (1) to inspect the correct position of the camshaft position
exciter wheels.
11. Tighten the bolts (2) of EN-49977-100 transmitter disc fixation.
12. If EN-953-A fixing tool or EN-49977-100 transmitter disc fixation can not be installed, refer to
13. Remove EN-49977-100 transmitter disc fixation.
14. Remove EN-953-A fixing tool.
15. Remove EN-952 fixing pin.


16.
17.
18.
19.
20.
Install crankshaft bearing cap tie plate hole plug and seal ring and tighten to 40 N.m (30 lb ft).
Install the front compartment insulator. Refer to Front Compartment Insulator Replacement
Install the right front wheelhouse liner. Refer to Front Wheelhouse Liner Replacement
Install the camshaft cover. Refer to Camshaft Cover Installation.
Install the ignition coil. Refer to Ignition Coil Installation.
CAMSHAFT TIMING CHAIN ADJUSTMENT

Special Tools
EN-952 Fixing Pin

EN-49977-100 Fixation Sensor Discs

2. Remove the camshaft cover. Refer to Camshaft Cover Replacement.
3. Remove the camshaft position actuator solenoid valves. Refer to Camshaft Position Actuator Solenoid
Valve Replacement .
5. Remove the front compartment insulator. Refer to Front Compartment Insulator Replacement .


engine front cover.

Fig. 303: Crankshaft Bearing Cap Tie Plate Hole Plug And Seal Ring
7. Remove the crankshaft bearing cap tie plate hole plug (2) and the seal ring (1).

Fig. 304: Fixing Pin

CAUTION: To ensure proper crankshaft top dead center (TDC) alignment, the
retention pin should fit easily through the bore in the crankshaft tie
plate and into the crankshaft. Binding of the retention pin could affect
proper engine timing.
8. Install the EN-952 fixing pin (1) to hold the crankshaft in TDC position.

Fig. 305: Intake Camshaft Sprocket Bolt And Wrench

wrench (1) until the camshaft position exciter wheel is clearly rotatable.
wrench until the camshaft position exciter wheel is clearly rotatable.

Fig. 306: Fixing Tool

NOTE:
The fixing tool should be installed completely to both camshaft grooves

without high effort.
11. Adjust the camshafts so that the EN-953-A fixing tool (1) can be installed.



Fig. 308: Intake Camshaft Sprocket Gearing And Special Tool

NOTE:
Push the fixing tool in the direction of the arrow to ensure it engages
without clearance.
14. Install the EN-49977-200 fixing tool (2) and adjust the gearing of the fixing tool so it engages with the
intake camshaft sprocket gearing (1).

Fig. 309: Adjuster Bolt And Fastening Bolts

15. Tighten the 2 fastening bolts (1) of the EN-49977-200 fixing tool while pushing the fixing tool in
direction of the arrow.
16. Tighten the adjuster bolt (2).

Fig. 310: Fastening Bolts And Fixation Tool

NOTE:
A wrong installation position is possible. Make sure that the fixation tool is
installed without clearance to the cylinder head in areas (3) and (5).
17. Install the EN-49977-100 fixation (2) to find and hold the camshaft position exciter wheels in the correct
position.
18. Tighten the 2 fastening bolts (6) of the EN-49977-100 fixation.
19. Tighten the intake camshaft sprocket bolt (4) while holding the hexagon (1) of the intake camshaft to 50
N.m (37 lb ft).
20. Tighten the intake camshaft sprocket bolt (4) while holding the hexagon (1) of the intake camshaft an

additional 60.
21. Tighten the exhaust camshaft sprocket bolt while holding the hexagon of the exhaust camshaft to 50 N.m
(37 lb ft).
22. Tighten the exhaust camshaft sprocket bolt while holding the hexagon of the exhaust camshaft an
additional 60.
23. Remove the EN-49977-100 fixation and the EN-49977-200 fixing tool.

24.
25.
26.
27.
28.
Install the upper timing chain guide (2).

Install the 2 upper timing chain guide bolts (1) and tighten to 8 N.m (71 lb in).
Remove the EN-953-A fixing tool.
Remove the EN-952 fixing pin.
Rotate the crankshaft for 720 and check the engine timing again. Repeat the adjustment procedure if
necessary.

29.
30.
31.
32.
Install the crankshaft bearing cap tie plate hole plug and seal ring and tighten to 40 N.m (30 lb ft).
Install the front compartment insulator. Refer to Front Compartment Insulator Replacement
Install the camshaft position actuator solenoid valves. Refer to Camshaft Position Actuator Solenoid
Valve Replacement .
34. Install the ignition coil. Refer to Ignition Coil Replacement .
DRAINING FLUIDS AND OIL FILTER REMOVAL
Fig. 312: Engine Oil Filter Element, Cap And Seal Ring
1. Remove the engine oil filter cap (2) along with the engine oil filter cap seal ring (3) and the oil filter
element (1).
2. Remove the oil pan drain plug and allow the oil to drain out.

3. Install the oil pan drain plug and a NEW seal ring and tighten to 14 N.m (124 lb in).
4. Install the engine oil filter cap along with a NEW engine oil filter cap seal ring and a NEW oil filter
element.
5. Tighten the engine oil filter cap to 25 N.m (18 lb ft).
Fig. 313: Water Pump Drain Plug And Seal Ring

6. Remove the water pump drain plug (1) and the water pump drain plug seal ring (2) and allow the
remaining coolant to drain out.
7. Install the water pump drain plug and a NEW seal ring and tighten to 15 N.m (11 lb ft).
POSITIVE CRANKCASE VENTILATION PIPE REMOVAL

Fig. 314: Positive Crankcase Ventilation Pipe Retainer Clips And Retainer Clamp
1. Open the 2 positive crankcase ventilation pipe retainer clips (2) and (3).
NOTE:
Move retainer clamp (1) in direction of the arrow.
2. Remove the positive crankcase ventilation pipe from the intake manifold.

Fig. 315: Turbocharger, Positive Crankcase Ventilation Pipe Assembly And Charger Air Bypass
Valve Pipe
3.
4.
5.
6.
7.
Loosen the charger air bypass valve pipe clamp (4).

Remove the charger air bypass valve pipe from turbocharger.
Remove the charger air bypass valve pipe (2) from turbo charger waste regulator solenoid valve.
Disconnect the positive crankcase ventilation pipe from turbocharger (3).
Unclip and remove the positive crankcase ventilation pipe assembly (1) from the camshaft cover retainer
clips.
EXHAUST MANIFOLD HEAT SHIELD REMOVAL

Fig. 316: Exhaust Manifold Heat Shield

1. Remove the 3 exhaust manifold heat shield bolts (1) and the washers.
WARM UP THREE-WAY CATALYTIC CONVERTER REMOVAL

Fig. 317: Catalytic Converter Components

1.
2.
3.
4.
Disconnect the heated oxygen sensor wiring harness (3) from retainer clip.
Remove the 2 catalytic converter to catalytic converter bracket nuts (4) and (6).
Loosen the three way warm up catalytic converter V-clamp (1).
Remove the three way warm up catalytic converter (5) and the catalytic converter seal (2).
TURBOCHARGER REMOVAL
Special Tool

Fig. 318: Holding Wrench And Ratchet Wrench

hollow screw.

NOTE:

of the turbocharger coolant feed pipe during the loosening procedure.
2. Loosen the turbocharger coolant feed pipe hollow screw with ratchet wrench and extension (1).

Fig. 320: Turbocharger Oil Return Pipe

3. Remove the turbocharger coolant feed pipe hollow screw (3) and the 2 seal rings (1) and (2).
4. Disconnect the turbocharger oil return pipe (4) from the engine block.


5. Remove the turbocharger oil feed pipe bolt (5) from the oil cooler.
6. Remove the turbocharger oil feed pipe hollow screw (4) and the 2 seal rings (1) and (3) and close the
screw bore in the turbocharger.
7. Remove the turbocharger oil feed pipe (2) and the rubber seal ring.
8. Disconnect the turbocharger coolant return hose (6) from the oil cooler coolant inlet pipe and remove the
turbocharger coolant return pipe bolt (7) from the oil cooler.


9. Remove the 8 turbocharger nuts (1).

Fig. 323: Turbocharger Assembly And Turbocharger Gasket

10. Remove the turbocharger assembly (1) and the turbocharger gasket (2).
ENGINE OIL COOLER REMOVAL

Fig. 324: Engine Oil Cooler

1.
2.
3.
4.
5.
6.
7.
Remove the oil cooler coolant outlet hose clamp (1).

Remove the oil cooler coolant outlet hose (2) from engine coolant thermostat housing.
Remove the oil cooler coolant inlet hose clamp (3).
Remove the oil cooler coolant inlet hose (4) from water outlet.
Remove the oil cooler coolant outlet pipe bolt (7).
Remove the 3 oil cooler bolts (5).
Remove the engine oil cooler assembly (6) and the 2 oil cooler sealings (8) and (9).
ENGINE COOLANT THERMOSTAT HOUSING REMOVAL

Fig. 325: Engine Coolant Thermostat Housing

1. Remove the 3 engine coolant thermostat housing bolts (1).
2. Remove the engine coolant thermostat housing (2) and the engine coolant thermostat housing seal ring
(3).
WATER OUTLET REMOVAL

Fig. 326: Water Outlet, Bolts And Seal Ring

1. Remove the 3 water outlet bolts (3).
2. Remove the water outlet (2) and the water outlet seal ring (1).
DRIVE BELT TENSIONER REMOVAL


CAUTION: The drive belt tensioner must always be in a pre-tensioned state and
must never be free from tension. If the drive belt tensioner is free
from the belt tension, it must always stay fixed with an appropriate
locking pin. Failure to follow this instruction will lead to a damage of
the drive belt tensioner.
1. Remove the upper drive belt tensioner bolt (2).
2. Remove the lower drive belt tensioner bolt (3).
AIR CONDITIONING COMPRESSOR BRACKET REMOVAL

1. Remove the 3 air conditioning compressor bracket bolts (1).
2. Remove the air conditioning compressor bracket (2).
WATER PUMP PULLEY REMOVAL


1. Loosen the 3 water pump pulley bolts (2) while holding up the water pump pulley hub with a wrench.
3. Remove the water pump pulley (1).
CRANKSHAFT BALANCER REMOVAL
Special Tools
EN-956-1 Extension

1. Install EN-49979 retainer to EN-956-1 extension.

NOTE:
The crankshaft balancer can be incorrectly installed 180 from the required
position. Be sure to note the location of the alignment hole on the
crankshaft balancer prior to removing the crankshaft balancer from the
engine.
2. Loosen the crankshaft balancer bolt (4) while fixing the crankshaft balancer (3) with EN-49979 retainer
(1) and EN-956-1 extension (2).


WATER PUMP REMOVAL

Fig. 332: Water Pump, Gasket And Bolts

1. Remove the 5 short water pump bolts (4) and the 5 long water pump bolts (3).
3. Remove the water pump gasket (1).
THROTTLE BODY REMOVAL

Fig. 333: Throttle Body And Bolts

1. Remove the 4 throttle body bolts (3).
2. Remove the throttle body (2) and the throttle body seal ring (1).
INTAKE MANIFOLD REMOVAL


NOTE:
Intake manifold bolts remain in intake manifold screw bores.


2. Remove the intake manifold (1) along with the intake manifold gasket.
GENERATOR REMOVAL


2. Remove the generator (1).
STARTER REMOVAL

Fig. 337: Starter, Bolt, Stud And Washer

1. Remove the upper starter bolt (2) and if equipped the washer (1).
2. Remove the lower starter bolt stud (3) and if equipped the washer.
3. Remove the starter (4).
ENGINE FLYWHEEL REMOVAL
Special Tools


1. Install EN-652 holder (1) to hold the engine flywheel (2).


2. Remove and DISCARD the 6 engine flywheel bolts (2).
3. Remove the engine flywheel (1).
IGNITION COIL REMOVAL
Special Tools
EN-6009 Remover and Installer Ignition Module

Fig. 340: Ignition Coil Bolts

1. Remove the 2 ignition coil bolts (1).

Fig. 341: Ignition Coil And Remover/Installer

2. Install EN-6009 remover and installer (2) and remove the ignition coil (1).
CAMSHAFT COVER REMOVAL


1. Remove the oil level indicator (1).


2. Remove the 15 camshaft cover bolts (1).
3. Remove the camshaft cover (2) and the camshaft cover gasket (3).
CAMSHAFT POSITION ACTUATOR SOLENOID VALVE REMOVAL

Fig. 344: Camshaft Position Actuator Solenoid Valve Bolts

1. Remove the 4 camshaft position actuator solenoid valve bolts (1).

Fig. 345: Intake Camshaft Position Actuator Solenoid Valve And Exhaust Camshaft Position
Actuator Solenoid Valve
2. Move the intake camshaft position actuator solenoid valve (1) carefully counter clockwise in the position
shown.
3. Move the exhaust camshaft position actuator solenoid valve (2) carefully clockwise in the position shown
in the graphic.

Fig. 346: Camshaft Position Actuator Solenoid Valves And Seal Rings
CAUTION: The camshaft position actuator solenoid valves must be kept parallel
to the engine front cover during removal and installation. The
camshaft position actuator solenoid valves can be damaged if they
become wedged or stuck during this process.
4. Carefully remove the 2 camshaft position actuator solenoid valves (2) and the seal rings (1).
ENGINE OIL HEATER REMOVAL

Fig. 347: Engine Oil Heater

1. Remove the engine oil heater bolt (1).
2. Remove the engine oil heater (2).
OIL PAN REMOVAL


1. Remove the 16 oil pan bolts (1).

Fig. 349: Oil Pan Prying Area

CAUTION: Pry the oil pan carefully in order to prevent damage to the transaxle
case or the oil pan sealing surfaces.
2. Place a suitable prying tool to the area shown (1) and carefully pry the oil pan loose.

Fig. 350: Oil Pan

3. Remove the oil pan (1).
ENGINE FRONT COVER AND OIL PUMP REMOVAL
1. Set engine to TDC. Refer to Camshaft Timing Chain Inspection.

4. Remove the engine front cover.
CAMSHAFT TIMING CHAIN REMOVAL
Special Tools
EN-952 Fixing Pin


1. The engine should be adjusted to TDC.

2. The crankshaft should be fixed with EN-952 fixing pin.
3. The camshaft should be fixed with EN-953-A fixing tool.

4. Push the timing chain (2) in direction to the timing chain tensioner (1) and fix the tensioner with EN-95510 fixing pin (3).




7. Remove the 2 timing chain guide right side bolts (2).
8. Remove the timing chain guide right side (1).


9. Remove the timing chain tensioner shoe bolt (2).
10. Remove the timing chain tensioner shoe (1).


11. Remove the timing chain (1) in compound with the crankshaft sprocket (2).
TIMING CHAIN TENSIONER REMOVAL

Fig. 357: Timing Chain Tensioner And Bolts

1. Remove the 2 timing chain tensioner bolts (1).
2. Remove the timing chain tensioner (2).
ENGINE FRONT COVER GASKET REMOVAL


Remove and DISCARD the engine front cover gasket (1).
CAMSHAFT SPROCKET REMOVAL

Fig. 359: Intake Camshaft And Intake Camshaft Sprocket Bolt

1. Loosen the intake camshaft sprocket bolt (1) while holding the hexagon of intake camshaft (2) with a
wrench.

Fig. 360: Intake Camshaft Sprocket, Bolt And Intake Camshaft Position Exciter Wheel
2.
3.
4.
5.
6.
Remove the intake camshaft sprocket bolt (1) and the intake camshaft position exciter wheel (2).
Remove the intake camshaft sprocket (3).
Loosen the exhaust camshaft sprocket bolt while holding the hexagon of exhaust camshaft with a wrench.
Remove the exhaust camshaft sprocket bolt and the exhaust camshaft position exciter wheel.
Remove the exhaust camshaft sprocket.
INTAKE CAMSHAFT REMOVAL

Fig. 361: Intake Camshaft Bearing Cap Bolts Removal Sequence



NOTE:

EXHAUST CAMSHAFT REMOVAL

Fig. 363: Exhaust Camshaft Bearing Cap Bolts Removal Sequence



NOTE:

HYDRAULIC VALVE LASH ADJUSTER ARM REMOVAL


NOTE:
Mind the installation position of the hydraulic valve lash adjuster arms.
Remove the 16 hydraulic valve lash adjuster arms (1).

HYDRAULIC VALVE LASH ADJUSTER REMOVAL


NOTE:
Remove the 16 hydraulic valve lash adjusters (1).

CYLINDER HEAD REMOVAL

Fig. 367: Cylinder Head Bolts Loosening Sequence

1. Loosen the 12 cylinder head bolts in the sequence as shown. Use the following procedure:
1. Loosen the cylinder head bolts 90 degrees.
2. Loosen the cylinder head bolts 180 degrees.

Fig. 368: Cylinder Head, Gasket, Bolts And Guide Sleeves

NOTE:
Do not damage the guide sleeves (4) and (5).
2. Remove the 12 cylinder head bolts (1).

3. Remove the cylinder head (2).
4. Remove the cylinder head gasket (3).
PISTON, CONNECTING ROD, AND BEARING REMOVAL


NOTE:
Mark the installation position of the connecting rod bearing caps. The
connecting rod bearings and bearing caps must not be interchanged with
other connecting rods.
1. Remove the 4 connecting rod bearing cap bolts (1) of cylinder 2 and 3.


4. Remove the 4 connecting rod bearing cap bolts (1) of cylinder 1 and 4.


6. Remove the 4 pistons (1) and connecting rods (2) and the 4 upper connecting rod bearings (3) from the
cylinder block.
CRANKSHAFT AND BEARING REMOVAL

Fig. 372: Crankshaft Position Sensor, Bolt And Seal Ring

1. Remove the crankshaft position sensor bolt (3).
2. Remove the crankshaft position sensor (1) and the crankshaft position sensor seal ring (2).

Fig. 373: Outer Crankshaft Bearing Cap Tie Plate Bolts

3. Remove the 12 outer crankshaft bearing cap tie plate bolts (1).

Fig. 374: Inner Crankshaft Bearing Cap Tie Plate Bolts Loosening Sequence
4. Loosen the 10 inner crankshaft bearing cap tie plate bolts in a sequence as shown.

Fig. 375: Crankshaft Bearing Cap Tie Plate, Bolts, Lower Crankshaft Bearings, Lower Crankshaft
Thrust Bearing And Crankshaft Rear Oil Seal
5. Remove and DISCARD the 10 crankshaft bearing cap tie plate bolts (1)
Remove the crankshaft bearing cap tie plate (2).
6. Remove the 4 lower crankshaft bearings (3) an the lower crankshaft thrust bearing (4).
7. Remove the crankshaft rear oil seal (5).

Fig. 376: Crankshaft, Upper Crankshaft Bearings And Upper Crankshaft Thrust Bearing
8. Remove the crankshaft (1), the 4 upper crankshaft bearings (2) and the upper crankshaft thrust bearing
(3).
CYLINDER HEAD DISASSEMBLE
Special Tools
EN-840 Pliers/Remover
EN-8062 Valve Spring Compressor
EN-8062-5 Adapter
EN-50717-2 Compressor Assembly of EN-50717 Kit

Fig. 377: Valve Spring Compressor And Adapter Assembly

1. Install the EN-50717-2 assembly (1) to the EN-8062 compressor (4).
2. Install the EN-8062-5 adapter (3) to the EN-8062 compressor.
3. Install the compressor assembly to the cylinder head, so that the adapter (5) of the EN-50717-2 assembly
(1) contacts the valve spring retainer properly and the EN-8062-5 adapter (3) contacts the valve disc (2).
Prefix the EN-8062 compressor (4).


4. Apply pressure to the EN-50717-2 assembly to push down the vale spring retainer (1) and compress the
valve spring (3) until the valve keys (2) are free from tension. Carefully remove the valve keys.

Fig. 379: Spring Compressor

5.
6.
7.
8.
9.
Slowly and carefully loosen the EN-50717-2 assembly until the valve spring is entirely expanded.
Remove the compressor assembly from the cylinder head.
Remove the valve spring retainer (1) and the valve spring (3).
Remove and DISCARD the valve stem oil seal (4), using the EN-840 pliers (2).
Remove the valve (5).
NOTE:
Ensure that the valve train components are kept together and identified in
order for proper installation in their original position.
10. Repeat the procedure with the remaining valves.

11. In case of re-using the cylinder head, refer to Cylinder Head Cleaning and Inspection.
CYLINDER HEAD CLEANING AND INSPECTION

Cleaning Procedure
1. Remove any old thread sealant, gasket material or sealant.

2. Clean all cylinder head surfaces with non-corrosive sealant.
3. Blow out all the oil galleries using compressed air.

4. Remove any carbon deposits from the combustion chamber.
Visual Inspection
1. Inspect the cylinder head camshaft bearing surfaces for the following conditions:
Excessive scoring or pitting
Discoloration from overheating
Deformation from excessive wear
If the camshaft bearing journals appear to be scored or damaged, you must replace the cylinder
head. DO NOT machine the camshaft bearing journals.
2. If any of the above conditions exist on the camshaft bearing surfaces, replace the cylinder head.
3. Inspect the cylinder head for the following:
Cracks, damage or pitting in the combustion chambers.
Debris in the oil galleries - Continue to clean the galleries until all debris is removed.
Coolant leaks or damage to the deck face sealing surface - If coolant leaks are present, measure the
surface war page as described under cylinder head measurement - deck flatness inspection.
Damage to any gasket surfaces.
Burnt or eroded areas in the combustion chamber.
Cracks in the exhaust ports and combustion chambers.
External cracks in the water passages.
Restrictions in the intake or exhaust passages.
Restrictions in the cooling system passages.
Rusted, damaged or leaking core plugs.
4. If the cylinder head is cracked or damaged, it must be replaced. No welding or patching of the cylinder
head is allowed.
Valve Inspection And Measurement

Fig. 380: Valve Inspection And Measurement

1. Clean the valves of carbon and oil. Carbon can be removed with a wire brush.
2. Inspect the valves for the following conditions:
1. Inspect the valve faces for burning and cracking (1). If pieces are broken, replace the valve and
inspect the corresponding piston and cylinder head area for damage.
2. Inspect the valve for straightness and distortion (2). Distorted valve must be replaced.
3. Inspect the valve stem for wear (3).
4. Inspect the valve key grooves for chipping and wear (5). Replace the valve if chipped or worn.

Fig. 381: Measuring Valve Length Using Slide Gauge

3. Measure the valve length (2). Use a slide gauge (1). Refer to Engine Mechanical Specifications to find
the permitted values.

Fig. 382: Measuring Valve Stem Diameter Using Micrometer Gauge

4. Measure the valve stem diameter. Use a micrometer gauge (2). Refer to Engine Mechanical
Specifications to find the permitted values. Note the measurement results.
Cylinder Head Measurement

Fig. 383: Using Straightedge To Inspect Cylinder Head Sealing Surface For Flatness
1. Inspect the cylinder head sealing surface for flatness. Use a straightedge (1). Refer to Engine Mechanical
Specifications to find the permitted values. If the measurement does not show the permitted value,
replace the cylinder head. Machining is NOT allowed.
2. Measure the valve guide inner diameter. Note the measurement results. Refer to Engine Mechanical
Specifications to find the permitted values.
3. Substract the valve stem diameter from valve guide inner diameter to calculate the valve stem to guide
clearance. Refer to Engine Mechanical Specifications to find the permitted values.
4. Turn the cylinder head upside down.
CYLINDER HEAD ASSEMBLE
Special Tools
EN-958 Valve Stem Seal Installer


EN-8062-5 Adapter
Fig. 384: Valve Stem Oil Seal And Installer

1. Lubricate the valve stem and the valve guide with clean engine oil.
NOTE:
Ensure all valve train components will be installed in their original

position.
2. Install the valve (5).

3. Install the NEW valve stem oil seal (4), using the EN-958 installer (2).

4. Loosely install the valve spring (3) and the valve spring retainer (1).



valve spring (3) until the valve keys (2) can be inserted. Carefully insert the valve keys then, so that they
are proper installed to the valve stem grooves.
9. Carefully release the tension from the EN-50717-2 assembly.
10. Inspect the valve keys and valve spring retainers for proper seat.
11. Remove the compressor assembly from the cylinder head.
ENGINE BLOCK DISASSEMBLE

Fig. 387: Knock Sensor, Bolt, Cylinder Head Guide Sleeves And Transmission Guide Sleeves
1.
2.
3.
4.
Remove the knock sensor bolt (3).

Remove the knock sensor (2).
Remove the 2 cylinder head guide sleeves (1). Use suitable pliers.
Remove the 2 transmission guide sleeves (4) and (5). Use suitable pliers.

Fig. 388: Piston Oil Nozzles And Bolts

5. Remove the 4 piston oil nozzle bolts (2).
6. Remove the 4 piston oil nozzles (1).
ENGINE BLOCK ASSEMBLE

Fig. 389: Piston Oil Nozzles And Bolts

1. Install the 4 piston oil nozzles (1).
2. Install the 4 piston oil nozzle bolts (2) and tighten to 25 N.m (18 lb ft).

Fig. 390: Knock Sensor, Bolt, Cylinder Head Guide Sleeves And Transmission Guide Sleeves
3.
4.
5.
6.
Install the knock sensor (2).

Install the knock sensor bolt (3) and tighten to 20 N.m (15 lb ft).
Install the 2 cylinder head guide sleeves (1). Use a rubber mallet.
Install the 2 transmission guide sleeves (4) and (5). Use a rubber mallet.
PISTON AND CONNECTING ROD DISASSEMBLE

Special Tool
EN-49941 Remover / Installer Piston Retainer Ring

Fig. 391: Using Piston Ring Pliers

WARNING: Handle the piston carefully. Worn piston rings are sharp and may
cause bodily injury.
1. Remove the piston rings. Use piston ring pliers (1)

Fig. 392: Upper Compression Ring, Lower Compression Ring, Oil Rings And Oil Ring Spacer
2. The piston rings are ordered as followed:
Upper compression ring (1)
Lower compression ring (2)
Oil rings and oil ring spacer (3) and (4)
3. Install the piston and connecting rod assembly to a bench vise. Use aluminium braces

Fig. 393: Piston Pin Retainer, Remover And Notch

WARNING: Use extreme care when removing snap rings. Always wear adequate
eye protection in order to avoid personal injury.
4. Apply the EN-49941 remover (1) in the notch (3) to the piston pin retainer (2) and remove it.

Fig. 394: Connecting Rod, Piston And Piston Pin

5. Remove the piston pin (2) and the connecting rod (3) from the piston (1).
PISTON, CONNECTING ROD, AND BEARING CLEANING AND INSPECTION
Special Tools

Visual Inspection And Cleaning Procedure
Connecting Rod

eye injury.
1. Clean the connecting rods in solvent and dry with compressed air.
2. Inspect the connecting rod for the following:
Signs of being twisted, bent, nicked or cracked
Scratches or abrasion on the connecting rod bearing seating surfaces
Piston
Fig. 395: Identifying Piston Damage Inspection Areas

1. Clean the piston with a cleaning solvent. DO NOT wire brush any parts of the piston.
2. Clean the piston ring grooves.
3. Inspect the piston on the following:

Cracked ring lands, skirts or pin bosses

Ring grooves for nicks
Eroded areas on the top of the piston (1)
Scuffed or damaged skirts (2)
Worn piston pin bores (3)
4. If there is any excessive wear, replace the piston.
5. Measure the clearance between piston pin and piston bore.
Piston And Connecting Rod Measurement Procedure
Piston Ring Clearance
Fig. 396: Measuring Piston Ring End Clearance

1. Install the piston rings to the cylinder as shown (1) and measure the piston ring end gap. Compare the

measurements with those provided below:

The upper compression ring end gap should be 0.4-0.6 mm (0.0157-0.0236 in).
The lower compression ring end gap should be 0.4-0.6 mm (0.0157-0.0236 in).
The oil ring end gap should be 0.2-0.9 mm (0.0079-0.0354 in).
2. If the clearance is greater than the provided specifications, the piston rings must be replaced.
Fig. 397: Measuring Piston Ring Side Clearance

3. Measure the piston ring side clearance as shown (1). Compare the measurements with those provided
below:
The upper compression ring side clearance should be 0.025-0.07 mm (0.001-0.0028 in).
The lower compression ring side clearance should be 0.025-0.07 mm (0.001-0.0028 in).
The oil ring side clearance should be 0.04-0.12 mm (0.0016-0.0047 in).
4. If the clearance is greater than the provided specifications, replace the piston rings.

5. If the clearance is still to great, replace the pistons.

Connecting Rod Bearing Clearance (With Micrometer Gauge Internal Measuring Device)
1. Install the connecting bearings and the connecting rod bearing caps.
2. Tighten the connecting rod bearing cap bolts in the following sequence:
NOTE:
The old bolts can be reused for the measuring procedure.
1. Tighten the connecting rod bearing cap bolts to 10 N.m (89 lb in).
2. Tighten the bolts to an additional 60 degrees using EN-470-B wrench.
3. Tighten the bolts to an additional 15 degrees using EN-470-B wrench.

Fig. 398: Measuring Connecting Rod Bearing Diameters

3. Measure the connecting rod bearing diameters at 3 points as shown (1). Use a internal measuring device.
4. Calculate the average connecting rod inner diameter.
Formula: 1. result + 2. result + 3. result / 3

Fig. 399: Connecting Rod Journal Diameter Points

5. Measure the connecting rod journal diameter at 2 points between (1) and (3) and between (2) and (4). Use
a micrometer gauge.
6. Calculate the average connecting rod journal diameter.
Formula: 1. result + 2. result / 2.
7. Substract the average connecting rod journal diameter from the average connecting rod bearing diameter
in order to determine the connecting rod bearing clearance.
The clearance should be 0.013-0.061 mm (0.0005-0.0024 in).
PISTON AND CONNECTING ROD ASSEMBLE
Special Tools

EN-49941 Remover / Installer Piston Retainer Ring

Fig. 400: Connecting Rod, Piston And Piston Pin

NOTE:
Lubricate the piston pin with clean engine oil.
1. Install the connecting rod (3) and the piston pin (2) to the piston (1).
2. Install the piston and connecting rod assembly to a bench vise. Use aluminium braces.

Fig. 401: Pushing Piston Pin Retainer Down With Thumb

WARNING: Use extreme care when removing snap rings. Always wear adequate
eye protection in order to avoid personal injury.
WARNING: Use care when removing or installing the piston retainer ring.
Ensure the EN-49941 remover/installer is installed properly onto the
retainer ring and that hands and fingers are kept clear from the front
of the tool. Otherwise, bodily injury may occur.
NOTE:
Notch (2) on right side.
3. Place the piston pin retainer in the piston pin retainer groove so that the ring gap lays on the notch (2).
4. Push the piston pin retainer down with the thumb in the shown position (1) and hold.

NOTE:
The EN-49941 installer should be applied in a perpendicular position to the

piston pin retainer.
5. Apply the EN-49941 installer (4) to the piston pin retainer in the position shown (3) and push in direction
of the arrow while pushing down with the thumb.
Fig. 402: Pushing Piston Pin Retainer Down

NOTE:
Push the piston pin retainer down in the position shown (2).
6. Move the EN-49941 installer (1) carefully to the position shown while pushing in direction of the arrow
until the piston pin retainer engages in the piston pin retainer groove.
7. Push down the piston ring retainer to get a proper seat in the groove.

Fig. 403: Pushing Piston Pin Retainer Down With Thumb

NOTE:
Notch (4) on left side. EN-49941 installer should be used with left hand.
8. Place the piston pin retainer in the piston pin retainer groove so that the ring gap lays on the notch (4).
9. Push the piston pin retainer down with the thumb in the position shown (1) and hold.
NOTE:
The EN-49941 installer should be applied in a perpendicular position to the

piston pin retainer.
10. Apply the EN-49941 installer (3) to the piston pin retainer in the position shown (2) and push in direction
of the arrow while pushing down with the thumb.

Fig. 404: Pushing Piston Pin Retainer Down

NOTE:
Push the piston pin retainer down in the position shown (1).
11. Move the EN-49941 installer (2) carefully to the position shown while pushing in direction of the arrow
until the piston pin retainer engages in the piston pin retainer groove.
12. Push down the piston ring retainer to get a proper seat in the groove.
13. Remove the piston and connecting rod assembly from the bench vise.

Fig. 405: Using Piston Ring Pliers

14. Install the piston rings. Use piston ring pliers (1).

Fig. 406: Upper Compression Ring, Lower Compression Ring, Oil Rings And Oil Ring Spacer
NOTE:
Mind the TOP marking on the piston rings.
15. The piston rings must be ordered as followed:

Upper compression ring (1)
Lower compression ring (2)
Piston oil ring with spacer (3), (4)

Fig. 407: Oil Ring Joints, Lower Compression Ring Joint, Upper Compression Ring Joint And Oil
Ring Spacer Joint
16. The piston ring joints must be positioned 90 degrees to each other.
Upper compression ring joint (2)
Lower compression ring joint (5)
Oil ring joint, upper part (1)
Oil ring joint, lower part (4)
Oil ring spacer joint (3)
INTAKE MANIFOLD DISASSEMBLE

Fig. 408: Fuel Injection Fuel Rail Assembly And Intake Manifold Gasket
1.
2.
3.
4.
Remove the fuel injection rail ground cable nut (1).

Remove the 2 fuel injection rail bolts (2).
Remove the fuel injection fuel rail assembly (3).
Remove the intake manifold gasket (4).

Fig. 409: Evaporative Emission Canister Purge Solenoid Valve And Manifold Absolute Pressure
Sensors
5. Remove the 2 manifold absolute pressure sensor bolts (1).
6. Remove the 2 manifold absolute pressure sensors (2).
7. Remove the evaporative emission canister purge solenoid valve (3).
INTAKE MANIFOLD CLEANING AND INSPECTION

Fig. 410: Sealing Surfaces

1. Clean the sealing surfaces (1) and (2).
2. Inspect the intake manifold for cracks and fractures.
INTAKE MANIFOLD ASSEMBLE

Fig. 411: Evaporative Emission Canister Purge Solenoid Valve And Manifold Absolute Pressure
Sensors
1. Install the evaporative emission canister purge solenoid valve (3).
2. Install the 2 manifold absolute pressure sensors (2).
3. Install the 2 manifold absolute pressure sensor bolts (1) and tighten.

Fig. 412: Fuel Injection Fuel Rail Assembly And Intake Manifold Gasket
4. Install the fuel injection fuel rail assembly (3).
5. Install the 2 fuel injection rail bolts (2) and tighten to 8 N.m (71 lb in).
6. Install the fuel injection rail ground cable nut (1) and tighten.
7. Install a NEW intake manifold gasket (4).
CRANKSHAFT AND BEARING CLEANING AND INSPECTION
Special Tools


GE-571-B Dial Gauge

Crankshaft End Play, Check
Fig. 413: Gauge Tool

NOTE:
Crankshaft attached with crankshaft bearing caps.
1. Install the GE-571-B gauge (1).

Install the holder on the front of the engine block.
Place the dial gauge plunger against the crankshaft and adjust.
2. Measure the longitudinal play of the crankshaft.

Move the crankshaft in the longitudinal direction.

Permissible crankshaft end play 0.100-0.202 mm (0.0039-0.0080 in).
3. Remove the GE-571-B gauge.
Crankshaft Out-of-Round, Check

NOTE:
Crankshaft removed.
1. Insert the crankshaft in the engine block.

Attach holder to the engine block.
Place the dial gauge plunger against the crankshaft bearing journal and adjust.

3. Check the rotational play of the crankshaft.

Turn the crankshaft evenly.
Maximum permissible rotational play 0.03 mm (0.001 in).
Check Crankshaft Bearing Clearance (With Plastigage)
Fig. 415: Plastigage On Bearing Journal

NOTE:
1. Lay out plastigage.
Crankshaft removed.
Do not rotate the crankshaft.

Lay out plastigage (flexible plastic thread) around the entire width of the crankshaft bearing journal (1).
Fig. 416: Crankshaft Bearing Cap Tie Plate

NOTE:
The bolts can be reused for checking the crankshaft bearing play.
2. Install the 4 lower crankshaft bearings (3) and the lower crankshaft thrust bearing (4).
3. Install the crankshaft bearing cap tie plate (2).
4. Install the 10 inner crankshaft bearing cap tie plate bolts (1).

Fig. 417: Inner Crankshaft Bearing Cap Tie Plate Bolts Tightening Sequence
5. Tighten the 10 inner crankshaft bearing cap tie plate bolts in a sequence as shown and in the following
order:
1. Tighten the inner crankshaft bearing cap tie plate bolts to 25 N.m (18 lb ft).
2. Tighten the inner crankshaft bearing cap tie plate bolts an additional 60. Use EN-470-B wrench.
6. Remove the crankshaft bearing cap tie plate bolts and the crankshaft bearing cap tie plate.

Fig. 418: Measuring Crankshaft Bearing Play Using Measuring Scale

NOTE:
When reading the value, do not confuse millimeters and inches on the
measuring scale.
7. Measure the crankshaft bearing play.

Compare the width of the flattened plastic thread (arrow) to the measuring scale (1).
The crankshaft bearing play should be 0.007-0.031 mm (0.00028-0.00122 in).
Check Crankshaft Bearing Clearance (With Micrometer Gauge Internal Measuring Device)
NOTE:
1. Install and tighten the crankshaft bearing cap tie plate and the crankshaft bearings as shown above.

Fig. 419: Crankshaft Bearing Diameter Measuring Points

2. Measure the crankshaft bearing diameter at 3 points.
Measure in areas as shown (1) with an internal measuring device.
Calculate the average crankshaft bearing diameter.
Formula: 1. result + 2. result + 3. result / 3.

Fig. 420: Connecting Rod Journal Diameter Points

3. Measure the crankshaft bearing journal diameter at 2 points between (1) and (3) and between (2) and (4)
with the micrometer gauge.
4. Calculate the average crankshaft bearing journal diameter.
Formula: 1. result + 2. result / 2.
5. Determine the crankshaft bearing play.
Calculation formula: average crankshaft bearing diameter minus average crankshaft bearing journal
diameter.
6. The crankshaft bearing play should be 0.007-0.031 mm (0.00028-0.00122 in).
ENGINE FRONT COVER AND OIL PUMP CLEANING AND INSPECTION

Engine Front Cover Cleaning Procedure
1. Clean the engine front cover sealing surface.
Fig. 421: Oil Gallery Bores

eye injury.
2. Clean the shown oil gallery with solvent and compressed air. Blow compressed air from bore (2) to bore
(1).

Engine Front Cover Visual Inspection
Inspect the engine front cover for cracks, scratches and damage.
Oil Pump Visual Inspection and Measurement
1. Inspect the oil pump cover and the engine front cover for flatness.
2. Inspect the oil pump vanes, the oil pump vane rotor, the oil pump vane rings and the oil pump slide for
localized flatting.
3. Inspect the oil pump slide pivot pin for firm seat.
Fig. 422: Straight Edge Tool

NOTE:
Oil pump components are installed.
4. Measure the oil pump axial clearances. Use a straight edge (1) and a feeler gauge.

1. The maximal axial clearance between engine front cover and oil pump vane rotor should be 0.1 mm
(0.004 in).
2. The maximal axial clearance between engine front cover and oil pump vane should be 0.09 mm
(0.0035 in).
3. The maximal axial clearance between engine front cover and oil pump vane ring should be 0.4 mm
(0.016 in).
4. The maximal axial clearance between engine front cover and oil pump slide should be 0.08 mm
(0.0031 in).
5. The maximal axial clearance between engine front cover and oil pump slide seal should be 0.09
mm (0.0035 in).
Fig. 423: Feeler Gauge, Oil Pump Slide And Oil Pump Vane
5. Measure the oil pump radial clearance. Use a feeler gauge (1). Measure the clearance between oil pump
vane rotor and oil pump vane (3).

The maximal clearance should be 0.05 mm (0.002 in).

6. Measure the clearance between oil pump vane and oil pump slide (2).
The maximal clearance should be 0.2 mm (0.008 in).
ENGINE FRONT COVER AND OIL PUMP DISASSEMBLE
Engine Front Cover Disassemble
Fig. 424: Engine Front Cover Components

1.
2.
3.
4.
Remove the intake camshaft position sensor bolt (1).

Remove the intake camshaft position sensor (2) and the seal ring (3).
Remove the exhaust camshaft position sensor bolt (6).
Remove the exhaust camshaft position sensor (5) and the seal ring (4).

5. Remove the oil pressure relief valve (7, 8 and 9)

6. Remove the crankshaft front oil seal (10).
Oil Pump Removal

1. Remove the 8 oil pump cover bolts (1).
2. Remove the oil pump cover (2).

Fig. 426: Oil Pump Slide Spring Windings And Engine Front Cover Edge
WARNING: Before removing the spring, cover the spring with a towel to prevent
the spring from flying and possibly causing damage or personal
injury.
NOTE:
Position a screw driver between the oil pump slide spring windings (2).
3. Protect the engine front cover edge (1) with a suitable piece of plastic.
4. Compress the oil pump slide spring with a screw driver and remove the oil pump slide spring along with
the oil pump slide spring pin.

Fig. 427: Engine Oil Pump Components

NOTE:
Mind the installation position of the oil pump components.
5. Remove the oil pump components in the following order:

1. Outer oil pump vane ring (1).
2. Oil pump vane rotor (3) and the 7 oil pump vanes (2).
3. Inner oil pump vane ring (6).
4. Oil pump slide (4) and the 2 oil pump slide seals with the 2 oil pump slide seal springs (5).
TURBOCHARGER DISASSEMBLE
Special Tool
EN-49940 Remover Quick Connector


1. Remove the 2 turbocharger oil return pipe bolts (2).
2. Remove the turbocharger oil return pipe (1) and the sealing (3) from the turbocharger.

Fig. 429: Turbocharger Coolant Feed Pipe

NOTE:
The quick fitting connectors should be always replaced when the

turbocharger coolant pipes are removed
3. Install the EN-49940 remover (2) to the turbocharger coolant feed pipe (1) and the quick fitting connector
as shown.
4. Compress the EN-49940 remover and remove the turbocharger coolant feed pipe direction of the arrow.

Fig. 430: Quick Fitting Connector And Seal Ring

5. Remove the quick fitting connector (2) and the seal ring (1).
6. Use the same procedure for the turbocharger coolant return pipe and the turbocharger coolant return pipe
quick fitting connector.
TURBOCHARGER CLEANING AND INSPECTION
Cleaning Procedure

2. Clean all threads if necessary.
Inspection Procedure

Fig. 431: Wastegate Regulator Mechanism

1.
2.
3.
4.
5.
6.
Inspect the wastegate regulator mechanism (1) for functionality.

Inspect the turbine blades for damage or foreign material.
Inspect the turbocharger wastegate regulator vacuum hoses for damage.
Inspect the exhaust manifold and the turbocharger for cracks or other damage.
Inspect the exhaust manifold mating surface for flatness.
Inspect the turbocharger oil feed and return pipes for damage or restriction. Do NOT attempt to clean or
repair the pipes. Replace any pipe that has damage or a restriction.
TURBOCHARGER ASSEMBLE

Fig. 432: Quick Fitting Connector And Seal Ring

1. Install the NEW quick fitting connector (2) and a NEW seal ring (1) to the turbocharger and tighten to 20
N.m (15 lb ft).

Fig. 433: Turbocharger Coolant Feed Pipe And Quick Fitting Connector
2. Inspect the turbocharger coolant pipes for ridges and damage.
3. Install the turbocharger coolant feed pipe (1) to the quick fitting connector (2) by pushing in direction of
the arrow until an audible click is heard.
4. Use the same procedure for the turbocharger coolant return pipe and the turbocharger coolant return pipe
quick fitting connector.


5. Install the turbocharger oil return pipe (1) and a NEW sealing (3) to the turbocharger.
6. Install the 2 turbocharger oil return pipe bolts (2) and tighten to 8 N.m (71 lb in).
ENGINE OIL COOLER DISASSEMBLE

Fig. 435: Engine Oil Cooler Components

1.
2.
3.
4.
5.
6.
Remove the oil cooler coolant inlet hose clamp (2).

Remove the oil cooler coolant inlet hose (1).
Remove the oil cooler coolant inlet pipe bolt (7)
Remove the oil cooler coolant inlet pipe (3) and the seal ring (6).
Remove the oil cooler coolant outlet hose clamp (4).
Remove the oil cooler coolant outlet hose (5).

Fig. 436: Engine Oil Pressure Indicator Switch, Oil Filter Cap And Oil Filter Element
7. Remove the engine oil pressure indicator switch (5) and the seal ring (4).
8. Remove the engine oil filter cap (1) along with the seal ring (2) and the oil filter element (3).
ENGINE OIL COOLER ASSEMBLE

Fig. 437: Engine Oil Pressure Indicator Switch, Oil Filter Cap And Oil Filter Element
1. Install the engine oil filter cap (1) along with a NEW seal ring (2) and a NEW oil filter element (3) and
tighten to 25 N.m (18 lb ft).
2. Install the engine oil pressure indicator switch (5) and NEW seal ring (4) and tighten to 20 N.m (15 lb ft).

Fig. 438: Engine Oil Cooler Components

3.
4.
5.
6.
7.
8.
Install the oil cooler coolant outlet hose (5)

Install the oil cooler coolant outlet hose clamp (4).
Install the oil cooler coolant inlet pipe (3) and a NEW seal ring (6).
Install the oil cooler coolant inlet pipe bolt (7) and tighten to 10 N.m (89 lb in).
Install the oil cooler coolant inlet hose (1).
Install oil cooler coolant inlet hose clamp (2).
OIL PAN CLEANING AND INSPECTION

Fig. 439: Oil Suction Gallery, Sealing Surface And Screw Bores
eye injury.
1. Clean the oil suction gallery (2) with compressed air. Be sure to remove all dirt and old gasket material
from the suction gallery (2).
2. Remove all remaining old gasket material from sealing surface (1) and screw bores (3).
3. Clean the sealing surfaces from dirt and grease.
4. Inspect the sealing surface for cracks and damage.

CRANKSHAFT AND BEARING INSTALLATION

Special Tools
EN-235-6 Installer
EN-658-1 Installer

1. Lubricate crankshaft, crankshaft bearings and crankshaft bearing cap tie plate with engine oil.
Fig. 440: Crankshaft, Upper Crankshaft Bearings And Upper Crankshaft Thrust Bearing
2. Install the 4 upper crankshaft bearings (2) and the crankshaft thrust bearing (3).

3. Install the crankshaft (1).
Fig. 441: Sealing Compound Application Area

NOTE:
4. Apply sealing compound (1) to the outer rim of the groove on the crankshaft bearing cap tie plate. Refer
to Adhesives, Fluids, Lubricants, and Sealers.

Fig. 442: Crankshaft Bearing Cap Tie Plate

NOTE:
The complete installation procedure should not take longer than 10

minutes.
5. Install the 4 lower crankshaft bearings (3) and the lower crankshaft thrust bearing (4).
6. Install the crankshaft bearing cap tie plate (2).
NOTE:
Do not reuse the old bolts.
7. Install the 10 NEW inner crankshaft bearing cap tie plate bolts (1).

Fig. 443: Inner Crankshaft Bearing Cap Tie Plate Bolts Tightening Sequence
8. Tighten the 10 inner crankshaft bearing cap tie plate bolts in the sequence shown and to the following
specifications:
1. Tighten the inner crankshaft bearing cap tie plate bolts to 25 N.m (18 lb ft).

Fig. 444: Outer Crankshaft Bearing Cap Tie Plate Bolts

NOTE:
9. Install the 12 NEW outer crankshaft bearing cap tie plate bolts (1) and tighten to the following
specification:
1. Tighten the outer crankshaft bearing cap tie plate bolts to 10 N.m (89 lb in).
2. Tighten the outer crankshaft bearing cap tie plate bolts an additional 60. Use EN-470-B wrench.
3. Tighten the outer crankshaft bearing cap tie plate bolts an additional 15. Use EN-470-B wrench.

Fig. 445: Crankshaft Position Sensor, Bolt And Seal Ring

10. Install the crankshaft position sensor (1) and a NEW crankshaft position sensor seal ring (2).
11. Install the crankshaft position sensor bolt (3) and tighten to 8 N.m (71 lb in).


NOTE:
Lubricate the crankshaft rear oil seal.
12. Install the crankshaft rear oil seal (1) with EN-235-6 installer (2).

Fig. 447: Crankshaft Rear Oil Seal Installer

13. Use EN-658-1 installer (1) to strike the crankshaft rear oil seal.
PISTON, CONNECTING ROD, AND BEARING INSTALLATION
Special Tools

Fig. 448: Piston Ring Joint Adjustment Points

1. Adjust the piston ring joints as follows:
1. Upper compression ring (1).
2. Lower compression ring (4).
3. Oil rings (2) or (3).
4. Oil ring spacer (5).

Fig. 449: Rods And Arrow On Piston Head

2. The arrow (1) on the piston head must point to the timing side.
3. The markings on the connecting rods (2) must point to the transmission side.


4. Install a piston ring compressor to compress the piston rings.
5. Install the pistons (1) in along with connecting rods (2) and upper connecting rod bearings (3) to the
engine block and to the crankshaft.


NOTE:

NOTE:
2. Tighten the connecting rod bearing cap bolts an additional 45 degrees. Use EN-470 B wrench.

NOTE:

NOTE:
CYLINDER HEAD INSTALLATION
Special Tools
EN-470-B Angular Torque Wrench.
eye injury.
1. Clean the sealing surfaces and remove dirt and old gasket material from thread bores, water galleries and
oil galleries.

Fig. 453: Cylinder Head, Gasket, Bolts And Guide Sleeves

NOTE:
Mind the guide sleeves (4) and (5).
2. Install a NEW cylinder head gasket (3). The marking "Top" should point to the cylinder head.
4. Install 12 NEW cylinder head bolts (1) and hand tighten.


5. Lay a straight edge (1) against the engine block and cylinder head. Adjust the transition in area (2) until
there is no clearance between cylinder head and straight edge, using a rubber mallet.


6. Tighten the cylinder head bolts in the sequence shown and to the following specifications:
1. Tighten the cylinder head bolts to 35 N.m (26 lb ft).
2. Tighten the cylinder head bolts an additional 180 degrees. Use EN-470-B wrench.
HYDRAULIC VALVE LASH ADJUSTER INSTALLATION


NOTE:
1. Lubricate the hydraulic valve lash adjusters with engine oil.

2. Install the 16 hydraulic valve lash adjusters (1).
HYDRAULIC VALVE LASH ADJUSTER ARM INSTALLATION


NOTE:
Hydraulic valve lash adjuster arms should be installed in their original

position.
1. Lubricate the hydraulic valve lash adjuster arms with engine oil.
2. Install the 16 hydraulic valve lash adjuster arms (1).
INTAKE CAMSHAFT INSTALLATION


NOTE:
1.
2.
3.
4.

Install the intake camshaft (3).

Fig. 459: Intake Camshaft Bearing Cap Bolts Tightening Sequence

NOTE:
Tighten the camshaft bearing cap bolts one turn at a time in order to avoid
shape distortion of the camshaft.
5. Tighten the camshaft bearing cap bolts one turn at a time and in a spiral sequence as shown to 8 N.m (71
lb in).
EXHAUST CAMSHAFT INSTALLATION


NOTE:
1.
2.
3.
4.

Install the exhaust camshaft (3).

Fig. 461: Exhaust Camshaft Bearing Cap Bolts Tightening Sequence

NOTE:
Tighten the camshaft bearing cap bolts one turn at a time in order to avoid
shape distortion of the camshaft.
5. Tighten the camshaft bearing cap bolts one turn at a time and in a spiral sequence as shown to 8 N.m (71
lb in).
CAMSHAFT SPROCKET INSTALLATION

Fig. 462: Intake Camshaft Sprocket, Bolt And Intake Camshaft Position Exciter Wheel
1. Install the intake camshaft sprocket (3).
2. Install the intake camshaft position sensor exciter wheel (2) and the intake camshaft sprocket bolt (1), but
do not tighten yet.
3. Install the exhaust camshaft sprocket.
NOTE:
Tightening of camshaft sprocket bolts will be done after the engine front
cover installation.
4. Install the exhaust camshaft position sensor exciter wheel and the exhaust camshaft sprocket bolt, but do
not tighten yet.
TIMING CHAIN TENSIONER INSTALLATION

Fig. 463: Timing Chain Tensioner And Bolts

1. Install the timing chain tensioner (2).
2. Install the 2 timing chain tensioner bolts (1) and tighten to 8 N.m (71 lb in).
ENGINE FRONT COVER GASKET INSTALLATION
1. Clean the sealing surfaces and remove all remains of old sealing compound material.


NOTE:
Sealers.


NOTE:
3. Install the NEW engine front cover gasket (1).

4. Install the timing chain. Refer to Camshaft Timing Chain Installation.
NOTE:
The complete installation procedure should not take longer than 10

minutes.
5. Install the engine front cover. Refer to Engine Front Cover and Oil Pump Installation.
CAMSHAFT TIMING CHAIN INSTALLATION
Special Tools

EN-952 Fixing Pin


1. The engine should be adjusted to TDC.
2. The crankshaft should be locked with EN-952 fixing pin.
3. The camshaft should be locked with EN-953-A fixing tool.

4. Install the timing chain (1) along with the crankshaft sprocket (2).


5. Install the timing chain tensioner shoe (1).
6. Install the timing chain tensioner shoe bolt (2) and tighten to 20 N.m (15 lb ft).


7. Install the timing chain guide right side (1).
8. Install the 2 timing chain guide right side bolts (2) and tighten to 8 N.m (71 lb in).


9. Push the timing chain (2) in direction to the timing chain tensioner (1) and remove the EN-955-10 fixing
pin (3).
The upper timing chain guide will be installed after the installation of the engine front cover and the fastening
of the camshaft sprockets.
ENGINE FRONT COVER AND OIL PUMP INSTALLATION
Special Tools
EN-952 Fixing Pin

EN-49977-100 Transmitter Disc Fixation
EN-49977-200 Fixing Tool

NOTE:
Mind the guide sleeves when installing engine front cover.

4. Tighten the 13 engine front cover bolts M6 to 8 N.m (71 lb in).

5. Tighten the 2 engine front cover bolts M10 to 35 N.m (26 lb ft).
Camshaft Sprocket Fastening
Fig. 471: Intake Camshaft Sprocket Gearing And Special Tool

NOTE:
Push the fixing tool in the direction of the arrow to ensure it fully engages.
1. Install EN-49977-200 fixing tool (2) and ensure that the gearing of the fixing tool engages with the intake
camshaft sprocket gearing (1).

Fig. 472: Adjuster Bolt And Fastening Bolts

2. Tighten the 2 fastening bolts (1) of EN-49977-200 fixing tool while pushing the fixing tool in direction of
the arrow.
3. Tighten the adjuster bolt (2).

Fig. 473: Fastening Bolts And Fixation Tool

NOTE:
A wrong installation position is possible. Make sure that the holding tool is
fully installed to the cylinder head in areas (3) and (5).
4. Install EN-49977-100 transmitter disc holder (2) to find and hold the correct position of the camshaft
position exciter wheels.
5. Tighten the fastening bolts (6) of EN-49977-100 transmitter disc holder.

6. Tighten the NEW intake camshaft sprocket bolt (4) while holding the hexagon (1) of the intake camshaft
to 50 N.m (37 lb ft).
7. Tighten the intake camshaft sprocket bolt (4) while holding the hexagon (1) of the intake camshaft to an
additional 60 degrees.
8. Tighten the NEW exhaust camshaft sprocket bolt while holding the hexagon of the exhaust camshaft to
50 N.m (37 lb ft).
9. Tighten the exhaust camshaft sprocket bolt while holding the hexagon of the exhaust camshaft to an
additional 60 degrees.
10. Remove EN-49977-100 transmitter disc holder and EN-49977-200 fixing tool.
Upper Timing Chain Guide Installation


3. Remove EN-953-A fixing tool and EN-952 fixing pin.
4. Install crankshaft bearing cap tie plate hole plug and seal ring and tighten to 50 N.m (37 lb ft).
OIL PAN INSTALLATION
Special Tools
EN-49980 Guidance Pins
1. Clean the sealing surfaces from old sealing material, dirt, oil and grease.
Fig. 475: Engine Front Cover, Oil Suction Gallery And Screw Bore

NOTE:
The sealing bead should be applied close to the inner edge of the oil pan.
Take care that the oil suction gallery (4) will not get contaminated with
sealing compound or dirt. The thickness of the sealing bead (3) should be
2 mm (0.0787 in).
2. Apply sealing compound to the oil pan. Refer to Adhesives, Fluids, Lubricants, and Sealers.
3. Apply sealing compound to the groove of the engine front cover (1). Refer to Adhesives, Fluids,
Lubricants, and Sealers.
4. Apply sealing compound around the screw bore (2) of the crankshaft bearing cap tie plate.
Fig. 476: Engine Oil Pan Pins

NOTE:
The complete installation procedure of the oil pan should not take longer
than 10 minutes.

5. Install the 2 EN-49980 pins (1) and (2) to the shown oil pan screw bores.
Fig. 477: Engine Oil Pan Pins And Screw Bores

CAUTION: Use care when installing the oil pan to prevent disruption of the
sealing bead. The sealing bead should remain consistent until the oil
pan is mated with the engine. An inconsistent sealing bead can
cause an insufficient seal and result in engine damage.
6.
7.
8.
9.
Carefully install the oil pan. Guide the oil pan with EN-49980 pins (2) and the equivalent screw bores (1).
Hold the oil pan with 4 oil pan bolts.
Remove EN-49980 pins.
Install the remaining 12 oil pan bolts and hand tighten.


10. Lay a straight edge (1) against the oil pan and engine block. Using a rubber mallet, adjust the transition in
area (2) until there is no clearance between oil pan and the straight edge.
11. Tighten the 16 oil pan bolts to 10 N.m (89 lb in).

ENGINE OIL HEATER INSTALLATION


1. Install the engine oil heater (2).
2. Install the engine oil heater bolt (1) and tighten to 40 N.m (30 lb ft).
CAMSHAFT POSITION ACTUATOR SOLENOID VALVE INSTALLATION

Fig. 480: Camshaft Position Actuator Solenoid Valves And Seal Rings
CAUTION: The camshaft position actuator solenoid valves must be kept parallel
to the engine front cover during removal and installation. The
camshaft position actuator solenoid valves can be damaged if they
become wedged or stuck during this process.
1. Install the 2 camshaft position actuator solenoid valves (2) and the 2 seal rings (1) by carefully and evenly
pressing.

Fig. 481: Camshaft Position Actuator Solenoid Valve Bolts

2. Install the 4 camshaft position actuator solenoid valve bolts (1) and tighten to 8 N.m (71 lb in).

Fig. 482: Camshaft Position Actuator Solenoid Valves Proper Position

3. The 2 camshaft position actuator solenoid valves should be installed in the position as shown (1) and (2).
CAMSHAFT COVER INSTALLATION


NOTE:
2. Apply sealing compound to areas (1) and (2). Refer to Adhesives, Fluids, Lubricants, and Sealers.


NOTE:
The installation procedure should not take longer than 10 minutes.
3. Install the camshaft cover (2) and a NEW gasket (3).

4. Install the 15 camshaft cover bolts (1).

Fig. 485: Camshaft Cover Bolts Tightening Sequence

5. Tighten the 15 camshaft cover bolts in a sequence as shown to 8 N.m (71 lb in).


6. Install the oil level indicator (1).
IGNITION COIL INSTALLATION
Special Tools
EN-6009 Remover and Installer Ignition Module

Fig. 487: Ignition Coil And Remover/Installer

1. Install the ignition coil (1) and remove EN-6009 remover and installer (2).

Fig. 488: Ignition Coil Bolts

2. Install the 2 ignition coil bolts (1) and tighten to 8 N.m (71 lb in).
ENGINE FLYWHEEL INSTALLATION
Special Tools



1. Install the engine flywheel (1).
2. Install the 6 NEW engine flywheel bolts (2).


3. Install EN-652 holder (1) to hold the engine flywheel (2).
4. Tighten the 6 engine flywheel bolts in a cross sequence to 60 N.m (44 lb ft).
1. Tighten the 6 engine flywheel bolts in a cross sequence to an additional 45 degrees. Use EN-470-B
wrench.
2. Tighten the 6 engine flywheel bolts in a cross sequence to an additional 15 degrees. Use EN-470-B

wrench.
5. Remove EN-652 holder.
GENERATOR INSTALLATION

1. Install the generator (1).
STARTER INSTALLATION

Fig. 492: Starter, Bolt, Stud And Washer

1. Install the starter (4).
2. Install the lower starter bolt stud (3) and if equipped the washer.
3. Install the upper starter bolt (2) and if equipped the washer (1).
4. Tighten the starter bolt and starter bolt stud to 25 N.m (18 lb ft).
INTAKE MANIFOLD INSTALLATION


2. Install the intake manifold (1) along with a NEW intake manifold gasket.


3. Install the 6 intake manifold bolts (1) and tighten to 20 N.m (15 lb ft).
THROTTLE BODY INSTALLATION


1. Install the throttle body (2) and a NEW throttle body seal ring (1).
2. Install the 4 throttle body bolts (3) and tighten to 8 N.m (71 lb in).
WATER PUMP INSTALLATION

Fig. 496: Water Pump And Engine Front Cover Bolts

2. The water pump and engine front cover bolts are located as followed:
Engine front cover special bolt without cone end 60 mm (2.362 in) (1).
Engine front cover standard bolt with cone end 52 mm (2.047 in) (2).
Water pump bolt 25 mm (0.984 in) (3).


3. Install the water pump (2) and a NEW water pump gasket (1).
4. Install the 5 water pump bolts (4) and the 5 long engine front cover bolts (3) and tighten in a cross
sequence to 8 N.m (71 lb in).
CRANKSHAFT BALANCER INSTALLATION
Special Tools

EN-956-1 Extension
Fig. 498: Engine Oil Pump Rotor And Crankshaft

NOTE:
The crankshaft balancer flange must fit to the hexagon of the oil pump
rotor (2) and to the two-flat of the crankshaft (1).
1. Install the crankshaft balancer by carefully pressing into position.

Fig. 499: Engine Front Cover And Crankshaft Balancer

2. Measure the distance a between the crankshaft balancer (2) and the engine front cover (1). The distance a
should be 5.5 mm (0.21654 in).
NOTE:
Never re-use the crankshaft balancer bolt.
3. Install a NEW crankshaft balancer bolt.


4. Tighten the crankshaft balancer bolt (4) while holding the crankshaft balancer (3) with EN-49979 retainer
(1) and EN-956-1 extension (2) in the following order:
1. Tighten the crankshaft balancer bolt to 150 N.m (111 lb ft).
2. Tighten the crankshaft balancer bolt to an additional 60 degrees, using EN-470-B wrench.
WATER PUMP PULLEY INSTALLATION


1. Install the water pump pulley (1).
3. Tighten the 3 water pump pulley bolts (2) to 22 N.m (16 lb ft) while holding up the water pump pulley
hub with a wrench.
AIR CONDITIONING COMPRESSOR BRACKET INSTALLATION

1. Install the air conditioning compressor bracket (2).
2. Install the 3 air conditioning compressor bracket bolts (1) and tighten to 22 N.m (16 lb ft).
DRIVE BELT TENSIONER INSTALLATION


1. Install the drive belt tensioner (1).
2. Install the upper drive belt tensioner bolt (2).
3. Install the lower drive belt tensioner bolt (3).
4. Tighten the lower drive belt tensioner bolt (M8) to 22 N.m (16 lb ft).
5. Tighten the upper drive belt tensioner bolt to 55 N.m (41 lb ft).
DRIVE BELT INSTALLATION
Special Tools

EN-955 Locking Pins


NOTE:
Ensure that the drive belt tensioner is held with EN-955-2 locking pin.
1. Install the drive belt.
Fig. 504: Locking Pin And Wrench

2. Move the drive belt tensioner clockwise until EN-955-20 locking pin (2) can be removed. Use EN-48488
wrench (1).
3. Remove EN-955-20 locking pin (2) from the drive belt tensioner while holding with EN-48488 wrench
(1).

4. Release tension from drive belt tensioner and remove EN-48488 wrench (1).
ENGINE OIL COOLER INSTALLATION

NOTE:
1.
2.
3.
4.
5.
6.
Lubricate the oil cooler seal (8) with clean engine oil.
Install the engine oil cooler assembly (6) along with 2 NEW sealings (8) and (9).
Install the 3 oil cooler bolts (5) and tighten to 10 N.m (89 lb in).
Install the oil cooler coolant outlet pipe bolt (7) and tighten to 10 N.m (89 lb in).
Install the oil cooler coolant outlet hose (2) to the engine coolant thermostat housing.
Install the oil cooler coolant outlet hose clamp (1).
Install the oil cooler coolant inlet hose (4) to the water outlet.

7. Install the oil cooler coolant inlet hose clamp (3).

WATER OUTLET INSTALLATION
Fig. 506: Water Outlet, Bolts And Seal Ring

2. Install the water outlet (2) and a NEW water outlet seal ring (1).
3. Install the 3 water outlet bolts (3) and tighten to 8 N.m (71 lb in).

ENGINE COOLANT THERMOSTAT HOUSING INSTALLATION


2. Install the engine coolant thermostat housing (2) and a NEW engine coolant thermostat housing seal ring
(3).
TURBOCHARGER INSTALLATION

Special Tool
2. Replace the connect fittings on the turbocharger coolant feed pipe and the turbocharger coolant return
pipe. Refer to Turbocharger Disassemble, and Turbocharger Assemble.
Fig. 508: Turbocharger Assembly And Turbocharger Gasket

NOTE:
Mind the turbocharger oil return pipe.
3. Install the turbocharger assembly (1) and a NEW turbocharger gasket (2).


4. Connect the turbocharger oil return pipe to the engine while installing the turbocharger.
5. Install the turbocharger coolant feed pipe hollow screw along with 2 NEW seal rings (1) and (2).


6. Install the 8 NEW turbocharger nuts (1).

Fig. 511: Turbocharger Nuts Tightening Sequence

7. Tighten the 8 turbocharger nuts in a sequence as shown to 8 N.m (71 lb in).

8. Repeat the tightening procedure to ensure a proper fastening of the turbocharger nuts.


9. Connect the turbocharger coolant return hose (6) to the oil cooler coolant inlet pipe and install the
turbocharger coolant return pipe bolt (7) to the oil cooler. Tighten the turbocharger coolant return pipe
bolt to 8 N.m (71 lb in).
10. Install the turbocharger oil feed pipe (2) along with a NEW rubber seal ring.
11. Install the turbocharger oil feed pipe hollow screw (4) in compound with 2 NEW seal rings (1) and (3).
12. Install the turbocharger oil feed pipe bolt (5) to the oil cooler and tighten to 10 N.m (89 lb in).
13. Tighten the turbocharger oil feed pipe hollow screw to 30 N.m (22 lb ft).

Fig. 513: Holding Wrench And Ratchet Wrench

NOTE:
The EN-49942 holding wrench (2) should be installed to turbocharger

coolant feed pipe as shown. The holding wrench should be installed to
avoid twisting of the turbocharger coolant feed pipe during the fastening
procedure.
hollow screw.

NOTE:

of the turbocharger coolant feed pipe while the fastening procedure.
15. Tighten the turbocharger coolant feed pipe hollow screw with ratchet wrench and extension (1) to 30 N.m
(22 lb ft).
EXHAUST MANIFOLD HEAT SHIELD INSTALLATION

Fig. 515: Exhaust Manifold Heat Shield

2. Install the 3 exhaust manifold heat shield bolts (1) and the washers and tighten to 8 N.m (71 lb in).
WARM UP THREE-WAY CATALYTIC CONVERTER INSTALLATION

Fig. 516: Catalytic Converter Components

1. Install the warm up three way catalytic converter (5) to the brackets and the turbocharger. Use a NEW
warm up three way catalytic converter seal (2).
NOTE:
2.
3.
4.
5.
Never re-use the V-clamp.
Install a NEW warm up three way catalytic converter V-clamp (1).

Install the 2 catalytic converter to catalytic converter bracket nuts (4) and (6) and hand tighten.
Hand tighten the catalytic converter V-clamp.
Connect the heated oxygen sensor wiring harness (3) to retainer clip.

Fig. 517: Catalytic Converter V-Clamp

6. The catalytic converter V-clamp (1) should be installed in the shown position.
7. Tighten the catalytic converter to catalytic converter bracket nuts to 22 N.m (16 lb ft).
8. Tighten the catalytic converter V-clamp to 13 N.m (115 lb in).
POSITIVE CRANKCASE VENTILATION PIPE INSTALLATION

Fig. 518: Turbocharger, Positive Crankcase Ventilation Pipe Assembly And Charger Air Bypass
Valve Pipe
1.
2.
3.
4.
5.
Install the positive crankcase ventilation pipe assembly (1) to the camshaft cover retainer clips.
Connect the positive crankcase ventilation pipe to turbocharger (3).
Install the charger air bypass valve pipe (2) to turbo charger waste regulator solenoid valve.
Install the charger air bypass valve pipe to turbocharger.
Fasten the charger air bypass valve pipe clamp (4).

Fig. 519: Positive Crankcase Ventilation Pipe Retainer Clips And Retainer Clamp
6. Install the positive crankcase ventilation pipe to the intake manifold and fix with retainer clamp (1).
7. Clip in the positive crankcase ventilation pipe to the 2 retainer clips (2) and (3).
ENGINE MOUNT BRACKET INSTALLATION


2. Install the 3 engine mount bracket bolts and tighten to 60 N.m (45 lb ft) + 45-60.
ENGINE FRONT COVER AND OIL PUMP ASSEMBLE
Oil Pump Installation

Fig. 521: Oil Pump Components

NOTE:
The oil pump slide spring and pin, as well as the slide seal and slide seal
spring can be ordered as single parts. All other oil pump components can
only be ordered as a replacement kit.
1. Install the oil pump components in the following order:

NOTE:
The bore (8) in the oil pump slide must fit smooth-running and
without clearance to the oil pump slide pivot pin (7).
1. Install the oil pump slide (6).

2. Install the inner oil pump vane ring (5).
NOTE:
Mind the installation position of the oil pump vane rotor (4). The mark

(9) must point to direction of the oil pump cover.

3. Install the oil pump vane rotor (4).
NOTE:
Mind the localized flats (3) on the oil pump vanes (2) caused by the
oil pump vane rings. The localized flats must point to the oil pump
vane rotor.
4. Install the 6 oil pump vanes (2).

5. Install the outer oil pump vane ring (1).
Fig. 522: Oil Pump Slide Seal Springs And Grooves

2. Install the 2 oil pump slide seals and the 2 oil pump slide seal springs (2) in the position as shown to the 2
grooves (1) of the oil pump slide.

Fig. 523: Oil Pump Slide Spring, Pin, Chambers And Front Cover Edge
3. Protect the engine front cover edge (5) with a suitable piece of plastic.
NOTE:
The length of the removed oil pump slide spring (2) should be 76.5 mm
(3.0118 in) for suction engines and 61 mm (2.4016 in) for turbo engines.
4. Install the oil pump slide spring pin along with the oil pump slide spring (4). Use a screwdriver to
compress the oil pump slide spring. The flat side of oil pump slide spring pin must face upwards.
5. Measure the oil pump clearances to ensure a correct installation of the oil pump components. Refer to
Engine Front Cover and Oil Pump Cleaning and Inspection.
6. Lubricate the oil pump vanes, the oil pump vane rotor, the oil pump slide spring and the area (3) with
engine oil.
7. Inspect the oil pump slide spring mechanism for functionality.


8. Install the oil pump cover (2) and the 8 oil pump cover bolts (1).

Fig. 525: Oil Pump Cover Bolts Tightening Sequence

9. Tighten the oil pump cover bolts in a sequence as shown to 8 N.m (71 lb in).

Fig. 526: Crankshaft Balancer

10. Install the crankshaft balancer (1) and rotate in the direction shown (2) in order to inspect the function of
the oil pump mechanism. The crankshaft balancer should rotate easily.
Engine Front Cover Assemble

Fig. 527: Engine Front Cover Components

1.
2.
3.
4.
5.
6.
Install the crankshaft front oil seal (10).

Install the oil pressure relief valve (7), (8) and (9) and tighten to 50 N.m (37 lb ft).
Install the exhaust camshaft position sensor (5) and the seal ring (4).
Install the exhaust camshaft sensor bolt (6) and tighten to 6 N.m (53 lb in).
Install the intake camshaft position sensor (2) and the seal ring (3).
Install the intake camshaft sensor bolt (1) and tighten to 6 N.m (53 lb in).
DRIVE BELT REMOVAL

Special Tools
EN-955 Locking Pins


Fig. 528: Locking Pin And Wrench

1. Install EN-48488 wrench (1) to the drive belt tensioner.
NOTE:
The drive belt tensioner must always be in a pre-tensioned state.
2. Move the drive belt tensioner clockwise until the drive belt tensioner can be fixed with the EN-955-20
locking pin (2).
AUTOMATIC TRANSMISSION FLEX PLATE REMOVAL
Special Tools



1. Install the EN-652 flywheel holder (1) in order to fix the automatic transmission flex plate (2).


2. Remove and DISCARD the 6 automatic transmission flex plate bolts (2).
ENGINE BLOCK CLEANING AND INSPECTION
Special Tools
EN-8087 Cylinder Bore Gauge

Cleaning Procedure
1. Remove any old thread sealant, gasket material or sealant.

2. Clean all the following areas with solvent:

Sealing surfaces
Cooling passages
Oil passages
3. Clean all threaded and through holes with solvent.
eye injury.
4. Dry the engine block with compressed air.
Visual Inspection
1. Inspect the crankshaft bearings journals for damage or spun bearings. The crankshaft bearing journals are
not repairable, if the crankshaft bearing journals are damaged the engine block assembly must be
replaced.
2. Inspect all sealing and mating surfaces for damage, repair or replace the engine block assembly if
necessary.
3. Inspect all threaded and through holes for damage or excessive debris.
4. Inspect all bolts for damage, if damaged replace with NEW bolts only.
5. Inspect the cylinder walls for cracks or damage. The cylinder sleeves are not serviced separately, if the
cylinders are damaged the cylinder block assembly must be replaced.
6. Inspect the engine block for cracks. Do not repair any cracks. If cracks are found, the cylinder block
assembly must be replaced.
Measuring Procedure
Engine Block Flatness Inspection

Fig. 531: Inspecting Engine Block For Distortion Using Straight Edge
1. Inspect the engine block as shown for distortion. Use a straightedge (1).

Fig. 532: Inspecting Engine Block For Deflection Using Straight Edge
2. Inspect the engine block as shown for deflection. Use a straightedge (1).
Cylinder bore and crankshaft bearing bore
NOTE:
Old bolts can be used for the measuring procedure.
1. Install the crankshaft bearing cap tie plate and tighten.

Fig. 533: Measuring Bearing Bore Concentricity And Alignment Using Gauge Tool
2. Inspect the crankshaft main bearing bores. Use the EN-8087 gauge (1) to measure the bearing bore
concentricity and alignment. Refer to Engine Mechanical Specifications to find the permitted values.
3. Replace the engine block and crankshaft bearing cap tie plate if the crankshaft bearing bores are out of
specification.

Fig. 534: Inspecting Cylinder Bore

4. Inspect the cylinder bores using the EN-8087 gauge (1). Inspect for the following items:
Wear
Taper
Runout
Ridging
5. Refer to Engine Mechanical Specifications to find the permitted values.
6. If the cylinder bores are out of specification, replace the engine block.
7. Remove the crankshaft bearing cap tie plate.
AUTOMATIC TRANSMISSION FLEX PLATE INSTALLATION
Special Tools



2. Install the automatic transmission flex plate (1).
3. Install 6 NEW automatic transmission flex plate bolts (2).


5. Tighten the 6 automatic transmission flex plate bolts in a cross sequence to 35 N.m(26 lb ft).
6. Tighten the 6 automatic transmission flex plate bolts in a cross sequence to an additional 30.
7. Tighten the 6 automatic transmission flex plate bolts in a cross sequence to an additional 15.


ENGINE COMPONENT DESCRIPTION
Cylinder Block
The cylinder hollow frame structured in-line 4 cylinder. The block has 5 crankshaft bearings with the thrust
bearing located on the third bearing from the front of the engine.
Crankshaft
The crankshaft is a steel crankshaft. It is supported in 5 main journals with main bearings which have oil
clearance for lubrication. The 3rd bearing is the thrust bearing which controls the proper axial end play of the
crankshaft. A harmonic damper is used to control torsional vibration.
Oil Pump
The engine is equipped with a variable oil pump. The oil pump is integrated into the engine front cover and
provides different oil pressure values depending on the engine speed.
Oil Pan
The oil pan is a structural aluminum oil pan with transmission attachment points. The oil suction gallery for the
oil pump is integrated into the oil pan.
Piston and Connecting Rod
The pistons are aluminum pistons. The connecting rods are made of fractured steel. The piston pin is floating in
piston bore and shrinked in connecting rod.
Cylinder Head
This cylinder head is a double over head camshaft (DOHC) type and has 2 camshafts that open 4 valves per
cylinder with hydraulic valve lash adjusters and hydraulic valve lash adjuster arms. The cylinder head is made
of cast aluminum alloy for better strength and hardness while remaining light weight. The combustion chamber
of the cylinder head is designed for increasing of squish and swirl efficiency to help maximize gasoline
combustion efficiency.
Camshaft Drive with Variable Camshaft Timing
A timing chain is used for camshaft drive. There is a tensioner to control the tension of the chain. The engine is
equipped with a variable camshaft timing system. The camshaft adjuster will readjust itself depending on the
engine speed. The valve timing readjusts to reduce fuel consumption and provide optimal power and torque.
Intake Manifold
The intake manifold provides the air flow passage to the combustion chambers through the throttle body. The
intake manifold along with the throttle body have an effect on engine torque, power, noise, driveability,

emission, fuel economy and performance. The intake manifold is made of plastic for better strength with
maintaining a light weight.
Turbocharger
The turbocharger consists of turbine and compressor on a common shaft. The shaft bearing is constructed to
higher rotation speed and lubricated by engine oil. The turbocharger is water cooled for improved durability.
The turbine wheel is driven by exhaust emissions. The compressor wheel compresses the intake air. A bypass
valve (Wastegate) regulates the charging pressure for generating a high pressure at low speed as well. At a
defined charging pressure it regulates the way of the exhaust emission on bypassing the turbine wheel. The
Wastegate valve is controlled pneumatic and electric from the pressure in the intake manifold. The pressure of
exhaust emission is reduced by opening the Wastegate thereby reducing the intake pressure.
CRANKCASE VENTILATION SYSTEM DESCRIPTION
Positive Crankcase Ventilation
The crankcase ventilation system is used to consume crankcase vapors in the combustion process instead of
venting vapors to the atmosphere. Fresh air from the intake system is supplied to the crankcase, mixed with
blow-by gases and then passed through a calibrated orifice into the intake manifold. The primary control is
through the positive crankcase ventilation (PCV) orifice which meters the flow at a rate depending on inlet
vacuum. The PCV orifice is an integral part of the camshaft cover. If abnormal operating conditions occur, the
system is designed to allow excessive amounts of blow-by gases to back flow through the crankcase vent into
the intake system to be consumed by normal combustion.

Fig. 537: Positive Crankcase Ventilation System Description Graph

The blow-by system is designed as a closed crankcase ventilation system (CCV) evacuating the combustion gas
from the crankcase (8), separating the oil with an oil separator (1), regulating the pressure in the cylinder head
cover (2) over an pressure regulation valve (3) and feed the cleaned gas through the cylinder head (7) into the
intake manifold (6). The primary blow-by system leads the gas through a non-return valve (NRV) directly into
the plenum; the secondary blow-by pipe assembly (4) routes the cleaned blow-by gas from the intake manifold
to the air intake of the turbo charger (9). Deviations from recommended materials have to be indicated and
agreed. The blow-by pipe assembly carries the ventilation gas and prevents a leakage or a back-flow of the
blow-by gas. It incorporates a quick connector to the manifold, the non-return valve (5) and a quick connector
to the turbo charger as well as brackets to hold the pipe assembly. A combined quick connector with a nonreturn valve (10) at the turbo charger is installed, also.
Results of Incorrect Operation
A plugged positive crankcase ventilation (PCV) orifice or hose may cause the following conditions:

Rough idle
Stalling or slow idle speed
Oil leaks
Oil in the throttle body
Sludge in the engine
Functional Check
With these systems, any blow-by in excess of the system capacity, from a badly worn engine, sustained heavy
load, etc., is exhausted into the air cleaner and is drawn into the engine.
Proper operation of the crankcase ventilation system depends upon a sealed engine. If oil slugging or dilution is
noted and the crankcase ventilation system is functioning properly, check the engine for a possible cause.
Correct any problems.
If an engine is idling rough, inspect for a clogged PCV orifice, a dirty vent filter, air cleaner element, or plugged
hose. Replace as required. Use the following procedure:
Remove the PCV hose from the cylinder head cover.

Operate the engine at idle.
Place your thumb over the end of the hose in order to check for a vacuum. If there is no vacuum at the
hose, inspect for the following items:
Plugged hoses
The manifold port
Turn OFF the engine.
Inspect the PCV orifice in the cylinder head cover for debris or blockage.
LUBRICATION DESCRIPTION
General Lubrication Description

Fig. 538: Lubrication System Components

Oil is applied under pressure to the crankshaft bearings (6), connecting rod bearings (7), camshaft bearings (2)
and hydraulic lash adjusters (3). In addition the variable oil pump (9), variable camshaft phaser (1), and
hydraulic chain tensioner (14) are supplied with pressurized oil. Oil is sucked from the oil pan through the fixed
screen into the variable vane type oil pump. The pump is integrated in the front cover and directly driven by the
crankshaft. Also integrated into the front cover is a pressure relieve valve (8) that opens when the oil pressure is
too high at a cold start. When that valve is open some oil flows directly into the oil pan. Normally the
pressurized oil passes into the engine oil gallery leading through the oil cooler (5) to the oil filter assembly (4).
The oil is cleaned by passing the filter from the outer to the inner side of the filter. Then the oil flows into the
main oil gallery. A filter by-pass valve in the oil filter ensures continues oil flow in case the oil filter should be
restricted by more than 1.7 bar. From the oil filter the oil is distributed to the crankshaft bearings, oil pump
displacement control chamber (10) and cylinder head feed (11). The connecting rod bearings are supplied by oil
flow passages through the crankshaft connecting the main journals to the rod journals. A groove around each
upper main bearing furnishes oil to the drilled crankshaft passages. In the cylinder head the oil is distributed to
the variable camshaft phasers, chain tensioner, oil pressure switch (12) and through the restrictor orifice (13)
into the camshaft feed oil gallery. From there the hydraulic valve lifters and camshaft bearings are supplied with
oil.

Variable Oil Pump Description
The engine is equipped with a variable displacement vane oil pump. It is indirect regulated by the oil pressure
out of the main oil gallery. The purpose of this indirect regulation is to keep a defined maximum pressure in the
main oil gallery independent of the individual pressure drop between the pump outlet, the main gallery inlet,
and the various engine components. The purpose of the variable displacement is to reduce the power
consumption of the pump to reduce the overall fuel consumption of the engine. The oil flow of a static
displacement oil pump is linear to the speed of the pump. This would lead to a too high oil pressure after a
certain engine speed (ca. 1000 rpm at cold oil temperature, ca. 3000 rpm at hot oil temperatures). To reduce that
high oil pressure normal pumps have a relieve valve: a portion of the pressurized, already pumped oil is fed
back to the intake of the pump. This is waste of power. The oil flow of a Variable Displacement Vane Pump
(VDVP) as used in Fam 0 Gen 3 is linear to the speed and to the excentricity of the rotor to the slide. The slide
is moveable, so it is possible to reduce the oil flow for a given speed by reducing the excentricity. With a lower
flow the oil pressure is reduced; pump oil flow equals now engine oil flow.
CLEANLINESS AND CARE
An automobile engine is a combination of many of the following surfaces:
Machined
Honed
Polished
Lapped
The tolerances of these surfaces are measured in the ten-thousandths of an inch. When you service any internal
engine part, cleanliness and care are important. Apply a liberal coating of engine oil to the friction areas during
assembly in order to protect and lubricate the surfaces on initial operation. Throughout this section, practice
proper cleaning and protection procedures to the machined surfaces and to the friction areas.
Whenever you remove the valve train components, keep the components in order. Follow this procedure in
order to install the components in the same locations and with the same mating surfaces as when removed.
Disconnect the negative battery cables before you perform any major work on the engine.
USE OF ROOM TEMPERATURE VULCANIZING (RTV) AND ANAEROBIC SEALANT
Pipe Joint Compound
NOTE:
Three types of sealer are commonly used in engines. These are RTV sealer,
anaerobic gasket eliminator sealer, and pipe joint compound. The correct sealer
and amount must be used in the proper location to prevent oil leaks. DO NOT
interchange the 3 types of sealers. Use only the specific sealer or the equivalent
as recommended in the service procedure.

Pipe joint compound is a pliable sealer that does not completely harden. This type sealer is used where 2
non-rigid parts, such as the oil pan and the engine block, are assembled together.
Do not use pipe joint compound in areas where extreme temperatures are expected. These areas include:
exhaust manifold, head gasket, or other surfaces where gasket eliminator is specified.
Follow all safety recommendations and directions that are on the container. To remove the sealant or the
gasket material.
Apply the pipe joint compound to a clean surface. Use a bead size or quantity as specified in the
procedure. Run the bead to the inside of any bolt holes. Do not allow the sealer to enter any blind
threaded holes, as it may prevent the bolt from clamping properly.
Apply a continuous bead of pipe joint compound to one sealing surface. Sealing surfaces to be resealed
must be clean and dry.
Tighten the bolts to specifications. Do not overtighten.

SPECIAL TOOLS
Illustration
207649
Rod Hairpins
547324
Flange Screws
CH-807
KM-807
Plugs
EN-194-E
KM-194-E
Spark Plug Key
EN-235-6
KM-235-6
Installer

EN-301
KM-301
Measuring Bridge
EN-470-B
KM-470-B
J-45059
Angular Torque Wrench
EN-498-B
KM-498-B
CH-48027
J-21867-L40
Pressure Gauge
EN-652
DT-652
KM-652
Flywheel Holder
EN-658-1
KM-658-1
J-35264
Installer
EN-663
KM-663
Installer
EN-796-A
KM-796-A
Remover Quick Fitting

EN-835-A
KM-835-A
Plugs
EN-840
KM-840
J-36017
Pliers / Remover
EN-849
KM-849
Assembly Tray
EN-952
KM-952
Fixing Tool Crankshaft
EN-953-A
KM-953-A
Fixing Tool Camshaft
EN-955
KM-955
Locking Pins
EN-956-1
KM-956-1
Extension
EN-958
KM-958
Valve Stem Seal Installer

EN-960
KM-960
Installer
EN-6009
KM-6009
J-43301
Remover / Installer
EN-6086
MKM-6086
Basic Kit, Spring and Wedge Replacer
EN-6167
KM-6167
Adapter Kit
EN-6171
KM-6171
Release Tool
EN-6179
KM-6179
Installer / Remover
EN-28467-B
J-28467-B
Universal Engine Support Fixture
EN-36857
J-36857
Engine Lift Bracket
EN-34730-91

KM-34730-91
J-34730-91
CH-48027
Pressure Tester
EN-43405
J-43405
Support Foot Set
EN-45000
KM-J45000
J-45000
Remover Oil Seal
EN-48248
Cylinder Compression Pressure Gauge
EN-48488
KM-956
Holding Wrench
EN-49940
Remover Quick Connector
EN-49941
Remover / Installer Piston Retainer Ring
EN-49942
Holding Wrench

EN-49977-100
Fixation Sensor Disks and Camshafts
EN-49977-200
Fixing Tool
EN-49979
Retainer Shock Mount Crankshaft
EN-49980
EN-46109
Guidance Pins Oil Pan
EN-50717-1
Stands
EN-50717-2
Compressor
EN-8062
J-8062
Valve Spring Compressor
GE-571-B
MKM-571-B
GE-8001
Dial Gauge

2013 ENGINE Engine Mechanical - 1.8L LUW and LWE - Cruze
SPECIFICATIONS
Specification
Application
AC Compressor Bolt
AC Compressor and Condenser Hose Nut
AC Evaporator Hose Assembly Nut
Air Intake Hose Clamps
Automatic Transmission Flex Plate Bolt (2)
Camshaft Adjuster Bolt (1)
First Pass
Second Pass
Final Pass
Camshaft Adjuster Closure Plug
Camshaft Bearing Cap Bolt
Camshaft Closure Bolt
Camshaft Cover Bolt
Camshaft Position Actuator Solenoid Valve Bolt
Camshaft Position Sensor Bolt
Cold Start Rail Bolt
Connecting Rod Bearing Cap Bolt (1)
Metric
22
19
19
3.5
60
English
16 lb ft
14 lb ft
14 lb ft
31 lb in
44 lb ft
50
37 lb ft
150 degrees
15 degrees
First Pass
Second Pass
Final Pass
Coolant Pipe Pump Module Bolt
Coolant Pipe Thermostat Housing Bolt
Crankshaft Balancer Bolt (1)
30
8
30
8
6
6
4
22 lb ft
71 lb in
22 lb ft
71 lb in
53 lb in
53 lb in
35 lb in
35
26 lb ft
45 degrees
15 degrees
First Pass
Second Pass
8
8
71 lb in
71 lb in
95
70 lb ft
45 degrees
15 degrees
Final Pass
Crankshaft Bearing Cap Bolt (1)
First Pass
Second Pass
Final Pass
Cylinder Head Bolt (1)
50
37 lb ft
45 degrees
15 degrees
44 lb in

25
18 lb ft
First Pass
Second Pass
90 degrees
Third Pass
90 degrees
Fourth Pass
90 degrees
Final Pass
Drive Belt Tensioner Bolt
Engine Coolant Pipe Bolts
Engine Coolant Thermostat
Engine Coolant Thermostat Housing
Engine Coolant Thermostat Housing Coolant Pipe
Bolt
Engine Flywheel Bolt (1)
45 degrees
First Pass
Second Pass
Final Pass
Engine Front Cover (Oil Pump Housing)
Engine Lift Front Bracket
Engine Mount Bolt to Engine Mount Bracket - M10 (1)
55
9
8
8
41 lb ft
80 lb in
71 lb in
71 lb in
71 lb in
60
44 lb ft
45 degrees
15 degrees
First Pass
Second Pass
Final Pass
Engine Mount Bolt
Engine Mount Bracket to Engine Block/Cylinder Head (1)
20
25
15 lb ft
18 lb ft
50
37 lb ft
60 degrees
75 degrees
First Pass
Second Pass
62
46 lb ft
60
46 lb ft
45 degrees
60 degrees
Final Pass
Engine Mount Bracket Bolt to Engine Mount (1)
First Pass
Second Pass
Final Pass
Engine Mount Nut
Engine Oil Cooler Bolts
Engine Oil Cooler Housing Bolt
Engine Oil Cooler Inlet Pipe Bolt
Engine Oil Cooler Outlet Pipe Bolt
Engine Oil Pressure Indicator Switch
50
37 lb ft
60 degrees
75 degrees
62
8
25
8
8
40
20
46 lb ft
71 lb ft
18 lb ft
71 lb in
71 lb in
30 lb ft
15 lb ft

Engine Oil Level Indicator Bolt

Engine Support Fixture (Front) Bolt
Engine Support Fixture (Rear Left Side) Bolt
Engine Support Fixture (Rear Right Side) Bolt
Evaporative Emission Canister Purge Solenoid
Valve Bracket Bolt
Exhaust Manifold Bracket Bolt
Exhaust Manifold Nut (1)
Fuel Injection Fuel Rail Bolt
Front Compartment Fuse Block Bolt
Front Exhaust Pipe Bolt
Generator Bolt
Heat Shield Exhaust Manifold Bolt
Knock Sensor Bolt
Ignition Module Bolt
Intake Manifold Absolute Pressure Sensor Bolt
Intake Manifold Bolt
Intake Manifold Bracket to Engine Block Bolt
Intake Manifold Bracket Bolt
Intake Manifold Grommet Bolt
Oil Filter Cap
Oil Flow Check Valve Bore Plug
Oil Level Indicator Tube Bolt
Oil Pan Bolt
Oil Pan Drain Plug
Oil Pan Baffle Bolt
Oil Pan Transmission Housing Bolt M10 (M32,
F17)
Oil Pan Transmission Housing Bolt M12 (M32,
F17)
Oil Pan Transmission Housing Bolt M10 (D16,
D20)
Oil Pan Transmission Housing Bolt M12 (D16,
D20)
Oil Pan Transmission Housing Bolt (GF6)
Oil Pressure Measurement Closure Bolt Cylinder
Head
Oil Pressure Switch
Oil Pressure Relief Valve Closure Bolt
Oil Pump Cover Bolt
Secondary Air Injection Check Valve Bolt
10
65
65
65
89 lb in
48 lb ft
48 lb ft
48 lb ft
62 lb in
20
20
7
22
20
35
42
8
20
8
6
20
8
8
7
25
21
15
10
14
10
15 lb ft
15 lb ft
62 lb in
16 lb ft
15 lb ft
26 lb ft
31 lb ft
71 lb in
15 lb ft
71 lb in
53 lb in
15 lb ft
71 lb in
71 lb in
62 lb in
18 lb ft
15 lb ft
11 lb ft
89 lb in
124 lb in
89 lb in
40
30 lb ft
60
44 lb ft
45
33 lb ft
75
55 lb ft
58
43 lb ft
15
11 lb ft
20
21
8
22
15 lb ft
15 lb ft
71 lb in
16 lb ft

Secondary Air Injection Pump Bolt

Spark Plugs
Throttle Body Bolt
Timing Belt Idler Pulley Bolt (1)
First Pass
Second Pass
Final Pass
Timing Belt Lower Front Cover Bolt
Timing Belt Rear Cover Bolt (2)
Timing Belt Tensioner Bolt (1)
First Pass
Second Pass
22
25
8
16 lb ft
18 lb ft
71 lb in
20
15 lb ft
120 degrees
15 degrees
6
6
53 lb in
53 lb in
20
15 lb ft
120 degrees
Final Pass
Timing Belt Upper Front Cover Bolt
6
Transmission to Cylinder Block Bolt (M32, F17)
60
Transmission to Cylinder Block Nut (M32, F17)
40
Transmission to Cylinder Block Bolt (D16, D20)
75
Transmission to Cylinder Block Bolt (GF6)
58
Transmission to Cylinder Block Nut (GF6)
58
Water Pump Bolt
8
Water Pump Pulley Bolt (2)
20
Wiring Harness Ground Nut
9
1 = Use NEW fastener
2 = Recut threads and insert NEW bolts with screw locking compound.
For screw locking compound, refer to Electronic Parts Catalogue.
15 degrees
53 lb in
44 lb ft
30 lb ft
55 lb ft
43 lb ft
43 lb ft
71 lb in
15 lb ft
80 lb in
ENGINE MECHANICAL SPECIFICATIONS

Engine Mechanical Specifications
Application
Metric
Specification
English
General Data
Engine Type
Valves
Displacement
Bore
Bore Distance
Stroke
Compression Ratio
4-Cylinder Inline
16
1.796 l
109.59 cu in
80.5 mm
3.169 in
86 mm
3.386 in
88.2 mm
3.472 in
10.5:1

Maximum Power / Engine Speed kW/RPM Gasoline

Maximum Power / Engine Speed kW/RPM E85 Ethanol
Maximum Torque / Engine Speed - Gasoline
Y/RPM/lb ft/RPM
Maximum Torque / Engine Speed - E85 Ethanol
Y/RPM/lb ft/RPM
103 KW/6300
106 KW/6300
170 N.m/ 3800

183 N.m/ 3800
125 lb ft/3800
135 lb ft/3800
Idle Speed RPM
700-780
Overspeed RPM
6500
Firing Order
Engine Length - RFB to Front of Poly V Belt
513 mm
20 in
Engine Height - Crank Center to Top
420 mm
17 in
Engine Weight - MT Version
120.5 kg
266 lb
Cylinder Block Height
198.5 mm
8 in
Cylinder Bore Diameter - Standard Size

Guiding Value 00
80.492-80.508 mm
3.169-3.1694 in
Cylinder Bore Diameter - Standard Size

Guiding Value 05
80.542-80.558 mm
3.171-3.1716 in
80.992-81.008 mm
3.188-3.1893 in
1-3-4-2
Block
Cylinder Bore Diameter - Oversize Guiding

Value 00+05
Crankshaft
Crankshaft Main Bearing Journal 1-5 Diameter

- Standard Size (brown/green)
54.980-54.997 mm
2.165-2.166 in

- Undersize 0.25 (brown/green)
54.730-54.747 mm
2.155-2.156 in

- Undersize 0.50 (brown/green)
54.482-54.495 mm
2.145-2.146 in
Crankshaft Main Bearing Journal 3 Width Standard Size
26.000-26.052 mm
1.024-1.026 in
Crankshaft Main Bearing Journal 3 Width Undersize 0.25
26.200-26.252 mm
1.032-1.034 in
Crankshaft Main Bearing Journal 3 Width Undersize 0.50
26.400-26.452 mm
1.040-1.042 in
Con-Rod Bearing Journal - Standard Size
42.971-42.987 mm
1.692-1.693 in
Con-Rod Bearing Journal - Undersize 0.25

(blue)
42.721-42.737 mm
1.682-1.683 in

Con-Rod Bearing Journal - Undersize 0.50

(white)
42.471-42.487 mm
1.672-1.673 in
Crankshaft Main Bearing 1-5 - Bearing Shell

Thickness - Standard Size (brown)
1.987-1.993 mm
0.0783-0.0785 in

Thickness - Standard Size (green)
1.993-1.999 mm
0.0785-0.0787 in

Thickness - Undersize 0.25 (brown/blue)
2.112-2.118 mm
0.0832-0.0834 in

Thickness - Undersize 0.25 (green/blue)
2.118-2.124 mm
0.0834-0.0836 in

Thickness - Undersize 0.50 (brown/blue)
Thickness - Undersize 0.50 (green/blue)
Crankshaft Bearing Allowable Clearance
Crankshaft Bearing Allowable End Clearance
Crankshaft Main Bearing 3 Width - Standard Size
Crankshaft Main Bearing 3 Width - Undersize 0.25
Crankshaft Main Bearing 3 Width - Undersize 0.50
Con-Rod Bearing Shell Thickness - Standard Size
Con-Rod Bearing Shell Thickness - Undersize 0.25
Con-Rod Bearing Shell Thickness - Undersize 0.50
Con-Rod Bearing Allowable Clearance
Pistons and Pins
2.237-2.243 mm
0.0842-0.0844 in
2.243-2.249 mm
0.0884-0.0886 in
0.005-0.059 mm
0.100-0.202 mm
25.85-25.90 mm
26.05-26.10 mm
26.25-26.30 mm
1.485-1.497 mm
1.610-1.622 mm
1.735-1.747 mm
0.019-0.071 mm
0.0002-0.0024 in
0.004-0.008 in
1.018-1.020 in
1.026-1.028 in
1.034-1.036 in
0.0585-0.0590 in
0.0634-0.0639 in
0.0684-0.0688 in
0.0007-0.0028 in
Piston Diameter - Standard Size Guiding Value

00
80.455-80.465 mm
3.1676-3.1680 in
Piston Diameter - Standard Size Guiding Value

00
80-505-80.51 mm
3.1695-3.1697 in
Piston Diameter - Oversize Guiding Value

00+05
80.955-80.965 mm
3.1872-3.1876 in
Piston Clearance
0.027-0.053 mm
0.0011-0.0021 in
Pin Diameter
19 mm
0.748 in
Pin Longitude
49.84 mm
1.962 in
Pin to Piston Clearance
0.020-0.060 mm
0.0008-0.0024 in
0.015-0.021 mm
0.0006-0.0009 in
Pin to Con-Rod Clearance

Piston Rings
Piston Ring Thickness - First Compression Ring
1.170-1.190 mm
0.0461-0.0469 in
Piston Ring Thickness - Second Compression

Ring
1.170-1.190 mm
0.0461-0.0469 in

1.900-1.980 mm
0.0749-0.0780 in
Piston Ring End Gap - First Compression Ring
0.20-0.40 mm
0.0079-0.0158 in
Piston Ring End Gap - Second Compression

Ring
0.40-0.60 mm
0.0158-0.0237 in
Piston Ring End Gap - Oil Control Ring
0.25-0.75 mm
0.0098-0.0295 in
Piston Ring to Groove Clearance - First

Compression Ring
0.040-0.080 mm
0.0016-0.0032 in
Piston Ring to groove Clearance - Second

Compression Ring
0.030-0.070 mm
0.0012-0.0028 in
0.030-0.130 mm
0.0012-0.051 in
Piston Ring Thickness - Oil Control Ring
Piston Ring to Groove Clearance - Oil Control

Ring
Cylinder Head
Surface Flatness - Block Deck - Longitude
Surface Flatness - Block Deck - Transverse
Valve Seat Width - Intake

Valve Seat Width - Exhaust
Valve Seat Angle
Valve Seat Angle Adjustment - Upper
Valve Seat Angle Adjustment - Lower
Valve Guide Bore Norm Size
Valve Guide Bore Oversize 0.075
Valve Guide Bore Oversize 0.150
Valve Guide Assembly Height
Valve Guide Longitude
Valve Assembly Height - Intake
Valve Assembly Height - Exhaust
Camshaft
Cam Stroke Intake
Cam Stroke Exhaust

Valve System
0.05 mm
0.00197 in
If the deck surface is out of specification, replace
the cylinder head. Do not machine the cylinder
head.
0.03 mm
0.00118 in
If the deck surface is out of specification, replace
the cylinder head. Do not machine the cylinder
head.
1.0-1.4 mm
0.040-0.056 in
1.4-1.8 mm
0.056-0.071 in
45 degrees (- 0.25 degrees)
30 degrees (+/- 0.5 degrees)
60 degrees (+/- 0.5 degrees)
5.000-5.016 mm
0.1969-0.1975 in
5.075-5.091 mm
0.1999-0.2005 in
5.150-5.166 mm
0.2028-0.2034 in
10.70-11.00 mm
0.422-0.434 in
36.70-37.30 mm
1.445-1.468 in
36.33 mm
1.430 in
36.33 mm
1.430 in
10 mm
0.394 in
9 mm
0.354 in
Valves Norm Longitude - Intake
101.10-101.30 mm
3.980-3.988 in
Valves Norm Longitude - Exhaust
100.40-100.60 mm
3.953-3.961 in
Valves Oversize Longitude 0.075 - Intake
100.70-100.90 mm
3.965-3.972 in

100.00-100.20 mm
3.937-3.945 in
Valves - Valve Stem Norm Diameter - Intake
4.965-4.980 mm
0.1955-0.1961 in
Valves - Valve Stem Norm Diameter - Exhaust
4.950-4.965 mm
0.1949-0.1955 in
Valves - Valve Stem Oversize Diameter 0.075 Intake
5.040-5.055 mm
0.1985-0.1991 in
Valves - Valve Stem Oversize Diameter 0.075 Exhaust
5.025-5.050 mm
0.1979-0.1989 in
Valves - Valve Stem to Guide Clearance Intake
0.020-0.051 mm
0.0008-0.0021 in
Valves - Valve Stem to Guide Clearance Exhaust
0.035-0.066 mm
0.0014-0.0026 in
Valves - Valve Stem allowable Run-Out
0.05 mm
0.0019 in
Valves - Valve Disk Diameter - Intake
31.1-31.3 mm
1.225-1.233 in
Valves - Valve Disk Diameter - Exhaust
27.4-27.6 mm
1.079-1.087 in
Valves - Valve Seat Angle on Valve Disk
Valve Springs Longitude
Valves Oversize Longitude 0.075 - Exhaust
9040' (+/-15')
42 mm
1.65 in
Valve Springs Longitude Under Load - Open
35.0 mm
1.38 in
Valve Springs Longitude Under Load - Close

Engine Oil
25.0 mm
0.98 in
Viscosity
SAE 0-W30, 0-W40, 5-W30 and 5-W40

Dexos 1
Quality
Quantity
Oil Change Incl. Filter
Oil Consumption Liter/1 000 km (1.057

quarts/621 miles)
Cooling System
4.5 l
4.76 quarts
max. 0.6 l
max. 0.634 quarts
Coolant Specification
Refer to Electronic Parts Catalog
Water Pump Design
Rotary Pump
Cooling System Capacity
5, 6 l
5.92 quarts
Flow (Engine Outlet 6000 min -1 , Thermostat

Fully Open)
160 l/min
42.27 US gal/min
Flow (Radiator 6000 min -1 , Thermostat Fully

Open)
165 l/min
174.4 quarts/min
Thermostat Opening - Electrical
90C
194F
Thermostat Opening - Thermic
105C
221F


Application
Bolt Connections
Camshaft Bearings
Camshaft Cover Bolt
Camshaft Front Oil Seal
Camshafts
Crankshaft Bearing Lubricant
Engine Block Oil Gallery Plugs
Engine Oil
Intake and Exhaust Valves
Oil Pan
Oxygen Sensor
Oxygen Sensor Threads
Rear Crankshaft Main Bearing
Cap
Rear Crankshaft Oil Seal
Rod Bearing - Rod Pins of
Crankshaft
Seal Rings
Turbo Heat Shield Fastener
Water Pump Bearing
Type of Material
Screw Locking
Compound
Dexos1 Engine Oil
Pipe Sealant
Sealant
Dexos1 Engine Oil
Dexos1 Engine Oil
Sealant
Dexos1 Engine Oil
Dexos1 Engine Oil
Sealant
Assembly Paste - White
Anti-seize
12345382
10953489
19293000
12346004
1052943
19293000
19293000
1052943
19293000
19293000
12378521
88862477
12397953
19286321
10953480
10953491
19286321
19286321
10953491
19286321
19286321
88901148
88862478
NA
Sealant
12378521
88901148
Dexos1 Engine Oil
19293000
19286321
Dexos1 Engine Oil
19293000
19286321
Silicone Grease - White

Lubricant
Sealant
12345579
12345996
1052943
10953481
10953501
10953491
COMPONENT LOCATOR
ENGINE IDENTIFICATION
GM Part Number
United States
Canada

Fig. 1: View Of Engine Identification Code On Cylinder Block

IMPORTANT: When a short block engine is installed, the engine number must be marked on
the cylinder block before installing the engine.
The engine identification code is embossed on the flattened area of the cylinder block, arrow, at the
transmission side.

SYMPTOMS - ENGINE MECHANICAL
Strategy Based Diagnostics
Perform the Diagnostic System Check - Vehicle .

All diagnosis on a vehicle should follow a logical process. Strategy based diagnostics is a uniform approach for

repairing all systems. The diagnostic flow may always be used in order to resolve a system condition. The
diagnostic flow is the place to start when repairs are necessary.
Inspect for aftermarket devices which could affect the operation of the engine.
cause the symptom.
Inspect for the correct oil level, proper oil viscosity, and correct filter application.
ambient temperature, engine temperature, amount of engine warm-up time, and other specifics.
Compare the engine sounds, if applicable, to a known good engine and make sure you are not trying to
correct a normal condition.
Intermittent
properly.
Symptom List

Coolant in Engine Oil
Engine Compression Test
Cylinder Leakage Test
Oil Pressure Diagnosis and Testing
Oil Leak Diagnosis
Crankcase Ventilation System Inspection/Diagnosis


Drive Belt Tensioner Diagnosis
OIL PRESSURE DIAGNOSIS AND TESTING

Special Tools
EN-498-B Oil Pressure Gauge

EN-232 Adapter Oil Pressure Check

Removal Procedure
1. If necessary, remove the exhaust manifold heat shield. Refer to Exhaust Manifold Heat Shield
Replacement (1.8L LUW and LWE) .
Fig. 2: View Of Closure Bolt


2. Remove the closure bolt (1).
3. Clean the thread.
Measurement Procedure
Fig. 3: Oil Pressure Test Gauge

1.
2.
3.
4.
Install the EN-498-B gauge (2).

Install the EN-232 adapter (1).
Start the engine.
Check oil pressure.
At idling speed, the oil pressure must be at least 130 kPa (18.85 psi) and the oil temperature must be 80C

(170F) or more.
1.
2.
3.
4.
Switch off the engine.

Remove the EN-232 adapter.
Remove the EN-498-B gauge.
Install new closure bolt in the cylinder head.
5. Tighten the closure bolt to 15 N.m (11 lb ft).

6. If necessary, install the exhaust manifold heat shield. Refer to Exhaust Manifold Heat Shield
7. Check the engine oil level.
OIL LEAK DIAGNOSIS
Oil Leak Diagnosis
Step
Action
Yes
No
DEFINITION: You can repair most fluid leaks by first, visually locating the leak, repairing or replacing
the component, or by resealing the gasket surface. Once the leak is identified, determine the cause of the
leak. Repair the leak and the cause of the leak.
1. Operate the vehicle until it reaches normal operating

temperature. Refer to Engine Mechanical
Specifications.
3. Wait 15 minutes.
4. Inspect for drippings.
Are drippings present?
Sealing surfaces
Fittings
Go to Step 2
Go to Step
10
System OK
Go to Step 3


Go to Step 5
Go to Step
10
Go to Step 6
Go to Step
10
Go to Step 7

components.
2. Apply an aerosol-type powder, for example, baby
powder or foot powder, to the suspected area.
of the leak from the discolorations in the powder
surface.
Go to Step
10

Sealing surfaces
Fittings
Go to Step 4

components.
4. Wait 15 minutes.
of the leak.
Go to Step
10

Sealing surfaces
Fittings


Identify the type of fluid and the approximate location of the
leak.
11
Go to Step 8
Go to Step
10
Go to Step 9
Go to Step
10
System OK
Go to Step
11
System OK

Sealing surfaces
Fittings
10
Go to Step
10
1. Inspect the engine for mechanical damage. Special

interest should be shown to the following areas:
Higher than recommended fluid levels
Higher than recommended fluid pressures
Plugged or malfunctioning fluid filters or pressure
bypass valves
Plugged or malfunctioning engine ventilation
system
Improperly tightened or damaged fasteners
Cracked or porous components
Improper sealants or gaskets, where required
Improper sealant or gasket installation
Damaged or worn gaskets or seals
Damaged or worn sealing surfaces
2. Inspect the engine for customer modifications.
Is there mechanical damage or customer modifications to the
engine?
Repair or replace all damaged or modified components.
Go to Step 1
OIL CONSUMPTION DIAGNOSIS

Excessive oil consumption, not due to leaks, is the use of 0.6 L (0.14 gallon) engine oil within 1000 kilometers
(622 miles). The causes of excessive oil consumption include the following conditions:
External oil leaks

Tighten bolts and/or replace gaskets and oil seals as necessary.
Incorrect oil level or improper reading of oil level indicator

With the vehicle on a level surface, allow adequate drain down time and inspect for the correct oil level.
Improper oil viscosity

Use recommended SAE viscosity for the prevailing temperatures.
Continuous high speed driving and/or severe usage

Crankcase ventilation system restrictions or malfunctioning components
Valve guides and/or valve stem oil seals worn, or the seal omitted
Ream guides and install oversize service valves and/or new valve stem oil seals.
Piston rings broken, improperly installed, worn, or not seated properly

Allow adequate time for rings to seat. Replace broken or worn rings, as necessary.
Piston improperly installed or mis-fitted.
COOLANT IN COMBUSTION CHAMBER

Coolant in Combustion Chamber
Cause
Correction
DEFINITION: Excessive white smoke and/or coolant type odor coming from the exhaust pipe may
indicate coolant in the combustion chamber. Low coolant levels, an inoperative cooling fan, or a faulty
thermostat may lead to an overtemperature condition which may cause engine component damage.
1. A slower than normal cranking speed may indicate coolant entering the combustion chamber. Refer
to Engine Will Not Crank - Crankshaft Will Not Rotate.
2. Remove the spark plugs and inspect for spark plugs saturated by coolant or coolant in the cylinder
bore.
3. Inspect by performing a cylinder leak-down test. During this test, excessive air bubbles within the
coolant may indicate a faulty gasket or damaged component.
4. Inspect by performing a cylinder compression test. Two cylinders side-by-side on the engine block,
with low compression, may indicate a failed cylinder head gasket. Refer to Engine Compression
Test.
Faulty cylinder head gasket
Replace the head gasket and components as
required. Refer to Cylinder Head Cleaning and
Inspection, and Cylinder Head Replacement.
Warped cylinder head
Replace the cylinder head and gasket. Refer to
Cylinder Head Replacement.
Cracked cylinder head
Replace the cylinder head and gasket. Cylinder

Cracked cylinder liner

Cylinder head or block porosity
Head Replacement
Replace the components as required.
COOLANT IN ENGINE OIL

Coolant in Engine Oil
Cause
Correction
DEFINITION: Foamy or discolored oil or an engine oil overfill condition may indicate coolant entering
the engine crankcase. Low coolant levels, an inoperative cooling fan, or a faulty thermostat may lead to
an overtemperature condition which may cause engine component damage. Contaminated engine oil and
oil filter should be changed.
1. Inspect the oil for excessive foaming or an overfill condition. Oil diluted by coolant may not
properly lubricate the crankshaft bearings and may lead to component damage. Refer to Lower
Engine Noise, Regardless of Engine Speed.
2. Inspect by performing a cylinder leak-down test. During this test, excessive air bubbles within the
cooling system may indicate a faulty gasket or damaged component.
3. Inspect by performing a cylinder compression test. Two cylinders side-by-side on the engine block
with low compression may indicate a failed cylinder head gasket. Refer to Engine Compression
Test.
Faulty cylinder head gasket
Replace the head gasket and components as
required. Refer to Cylinder Head Replacement.
Warped cylinder head
Replace the cylinder head and gasket. Refer to
Cylinder Head Replacement.
Cracked cylinder head
Replace the cylinder head and gasket. Cylinder
Head Replacement
Cracked cylinder liner
Cylinder head or block porosity
ENGINE NOISE UNDER LOAD
Cause
Low oil pressure
Detonation or spark knock
Correction
1. Perform an oil pressure test. Refer to Oil
Pressure Diagnosis and Testing.
Verify the correct operation of the ignition. Refer to
Symptoms - Engine Controls .

Cracked flywheel- automatic transmission
1. Inspect the flywheel bolts and flywheel.


Inspect the following components and repair as

required:
The connecting rod bearings
The connecting rods
The crankshaft
required:
The crankshaft bearings

The crankshaft journals
The cylinder block crankshaft bearing bore
ENGINE NOISE ON START-UP, BUT ONLY LASTING A FEW SECONDS

Cause
Correction
Incorrect oil filter without anti-drainback feature Install the correct oil filter.
Incorrect oil viscosity
1. Drain the oil.
High valve lash adjuster leak down rate
Worn crankshaft thrust bearing
Damaged or faulty oil filter by-pass valve
Malfunctioning camshaft position actuators improper oil viscosity or contamination. The

result is camshaft actuator locking pin does not
lock
2. Install the correct viscosity oil.

Replace the lash adjusters as required.
1. Inspect the thrust bearing and crankshaft.
1. Inspect the oil filter by-pass valve for proper
operation.
1. Verify correct engine oil viscosity by changing
the engine oil and filter. Reevaluate the concern.
2. Isolate the noise to a specific camshaft position
actuator.
3. Replace the camshaft actuator, oil and filter.
BASE ENGINE MISFIRE WITHOUT INTERNAL ENGINE NOISES

Cause
Correction
Abnormalities, severe cracking, bumps, or missing
Replace the drive belt.
areas in the accessory drive belt
Abnormalities in the accessory drive system and/or
components may cause engine revolutions per minute
(RPM) variations and lead to a misfire diagnostic
trouble code (DTC). A misfire code may be present

without an actual misfire condition.

Worn, damaged, or mis-aligned accessory drive
components or excessive pulley runout may lead to a
misfire DTC.
condition.
A loose or improperly installed engine flywheel or
crankshaft balancer
condition.
Restricted exhaust system
A severe restriction in the exhaust flow can cause
significant loss of engine performance and may set a
DTC. Possible causes of restrictions include collapsed
or dented pipes or plugged mufflers and/or catalytic
converters.
Improperly installed or damaged vacuum hoses
Improper sealing between the intake manifold and
cylinder heads or throttle body
Improperly installed or damaged manifold absolute
pressure (MAP) sensor
The sealing grommet of the MAP sensor should not be
torn or damaged.
Damage to the MAP sensor housing
Worn or loose rocker arms
The rocker arm bearing end caps and/or needle bearings
should be intact and in the proper position.
Stuck valves
Carbon buildup on the valve stem can cause the valve
not to close properly.
Excessively worn or mis-aligned timing chain
Worn camshaft lobes
Excessive oil pressure
A lubrication system with excessive oil pressure may
lead to excessive valve lifter pump up and loss of
compression.
Faulty cylinder head gaskets and/or cracking or other
damage to the cylinder heads and engine block cooling
system passages
Coolant consumption may or may not cause the engine
to overheat.
Inspect the components, and repair or replace as

required.
Repair or replace the flywheel and/or balancer

as required.

Replace the intake manifold, gaskets, cylinder
heads, and/or throttle body as required.
Repair or replace the MAP sensor as required.
Replace the intake manifold.

Replace the valve rocker arms as required.
Replace the timing chain and sprockets as

required.
Replace the camshaft and valve lifters.
Worn piston rings

Oil consumption may or may not cause the engine to
misfire.
Perform an oil pressure test. Refer to Oil

Repair or replace the oil pump as required.
Inspect for spark plugs saturated by
coolant.
Inspect the cylinder heads, engine block,
and/or head gaskets.
Inspect the spark plugs for oil deposits.
Inspect the cylinders for a loss of

A damaged crankshaft reluctor wheel

A damaged crankshaft reluctor wheel can result in
different symptoms depending on the severity and
location of the damage.
compression. Refer to Engine

Compression Test.
Perform cylinder leak down and
compression testing to identify the cause.
Replace the sensor and/or crankshaft as
required.
Systems with electronic communications, DIS or

coil per cylinder, and severe reluctor ring damage
may exhibit periodic loss of crankshaft position,
stop delivering a signal, and then re-sync the
crankshaft position.
Systems with electronic communication, DIS or
coil per cylinder, and slight reluctor ring damage
may exhibit no loss of crankshaft position and no
misfire may occur. However, a DTC P0300 may
be set.
Systems with mechanical communications, high
voltage switch, and severe reluctor ring damage
may cause additional pulses and effect fuel and
spark delivery to the point of generating a DTC
P0300 or P0336.
BASE ENGINE MISFIRE WITH ABNORMAL INTERNAL LOWER ENGINE NOISES

Cause
Correction
Abnormalities, severe cracking, bumps or
Replace the drive belt.
missing areas in the accessory drive belt
Abnormalities in the accessory drive system
and/or components may cause engine
revolutions per minute (RPM) variations,
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.
Worn, damaged, or mis-aligned accessory
Inspect the components, repair or replace as required.
drive components or excessive pulley runout
A misfire code may be present without an
actual misfire condition.
Loose or improperly installed engine
Repair or replace the flywheel and/or balancer as required.
flywheel or crankshaft balancer
A misfire code may be present without an

actual misfire condition.

Worn piston rings
Oil consumption may or may not cause the
engine to misfire.
Worn crankshaft thrust bearings

Severely worn thrust surfaces on the
crankshaft and/or thrust bearing may permit
fore and aft movement of the crankshaft, and
create a diagnostic trouble code (DTC)
without an actual misfire condition.

Inspect the cylinders for a loss of compression.
Refer to Engine Compression Test.
Perform cylinder leak down and compression testing
to determine the cause.
Replace the crankshaft and bearings as required.
BASE ENGINE MISFIRE WITH ABNORMAL VALVE TRAIN NOISE

Cause
Correction
Worn or loose rocker arms
Replace the valve rocker arms as required.
The rocker arm bearing end caps and/or needle
bearings should intact within the rocker arm
assembly.
Stuck valves
Carbon buildup on the valve stem can cause the
valve to not close properly.
Excessively worn or mis-aligned timing chain
Replace the timing chain and sprockets as required.
Worn camshaft lobes
Replace the camshaft and valve lash adjusters.
Sticking lifters
Replace as required.
BASE ENGINE MISFIRE WITH COOLANT CONSUMPTION
Cause
Faulty cylinder head gasket and/or cracking, or
other damage to the cylinder head and engine block
cooling system passages.
Coolant consumption may or may not cause the
engine to overheat.
Correction
Inspect for spark plugs saturated by coolant.

Perform a cylinder leak down test.
Inspect the cylinder head and engine block for
damage to the coolant passages and/or a
faulty head gasket.
BASE ENGINE MISFIRE WITH EXCESSIVE OIL CONSUMPTION


Cause
Worn valves, valve guides, and/or valve stem
oil seals
Worn piston rings
Oil consumption may or may not cause the
engine to misfire.
Correction

Inspect the cylinders for a loss of compression.
Refer to Engine Compression Test.
Perform cylinder leak down and compression testing
to determine the cause.
UPPER ENGINE NOISE, REGARDLESS OF ENGINE SPEED

Cause
Low oil pressure
Correction
Loose and/or worn valve rocker arm attachments

Worn valve rocker arm
Improper lubrication to the valve rocker arms

Inspect the valve rocker arm stud, nut, or bolt.

Replace the valve rocker arm.
Inspect the following components and repair or
replace as required:
The valve rocker arm

The valve lifter
The oil filter bypass valve
The oil pump and pump screen
The engine block oil galleries
Replace the valve spring.
Replace the valve lifters.
Replace the timing belt and sprockets.
Broken valve spring

Worn or dirty valve lifters
Stretched or broken timing belt and/or damaged
sprocket teeth
Worn, damaged, or faulty timing belt tensioners
Worn engine camshaft lobes
Worn valve guides or valve stems
Replace tensioners
Inspect the engine camshaft lobes.
Replace the camshaft and valve lifters as
required.
Inspect the following components, and repair as
required:
The valves
The valve guides

Stuck valves
Carbon on the valve stem or valve seat may cause required:
the valve to stay open.
The valves
The valve guides
LOWER ENGINE NOISE, REGARDLESS OF ENGINE SPEED
Cause
Low oil pressure
Correction
Worn accessory drive componentsabnormalities, such as severe cracking, bumps,

or missing areas in the accessory drive belt
and/or misalignment of system components
Loose or damaged crankshaft balancer
Detonation or spark knock
Loose or damaged flywheel
Damaged oil pan, contacting the oil pump
screen
An oil pan that has been damaged, may
improperly position the oil pump screen,
preventing proper oil flow to the oil pump.
Oil pump screen loose, damaged or restricted
Excessive piston pin-to-bore clearance

Repair or replace damaged components as
required.
1. Inspect the accessory drive system.

1. Inspect the crankshaft balancer.
Verify the correct operation of the ignition system.
Refer to Symptoms - Engine Controls .
Repair or replace the flywheel.
1. Inspect the oil pan.
2. Inspect the oil pump screen.
1. Inspect the oil pump screen.
1. Inspect the piston and cylinder bore.
1. Inspect the piston, piston pin, and the connecting
rod.
required:
The connecting rod bearings

The connecting rods

The crankshaft
required:
Incorrect piston, piston pin, and connecting rod

installation
Pistons must be installed with the mark, or
dimple, on the top of the piston, facing the front
of the engine. Piston pins must be centered in
the connecting rod pin bore.
The crankshaft bearings

1. Verify the pistons, piston pins and connecting

rods are installed correctly.
ENGINE WILL NOT CRANK - CRANKSHAFT WILL NOT ROTATE

Cause
Seized accessory drive system component
Hydraulically locked cylinder
Coolant/antifreeze in cylinder
Oil in cylinder
Fuel in cylinder
Correction
1. Remove accessory drive belts.
2. Rotate crankshaft by hand at the
balancer or flywheel location.
1. Remove spark plugs and check for
fluid.
2. Inspect for broken head gasket.
3. Inspect for cracked engine block or
cylinder head.
4. Inspect for a sticking fuel injector.
5. Inspect for cracked cylinder wall.
Seized automatic transmission torque converter
1. Remove the torque converter bolts.

Seized manual transmission
1. Disengage the clutch.

Broken timing chain and/or gears
Seized balance shaft
Material in cylinder
Broken valve
Inspect timing chain and gears.

Repair as required.
Inspect balance shaft.
Repair as required.
Inspect cylinder for damaged
components and/or foreign materials.

Piston material
Foreign material
Cracked cylinder wall
Seized crankshaft or connecting rod bearings
Bent or broken connecting rod
Broken crankshaft
Inspect for fallen cylinder wall.

Inspect crankshaft and connecting rod
bearings.
Inspect for fallen cylinder wall.
Repair as required.
Inspect connecting rods.
Repair as required.
Inspect crankshaft.
Repair as required.
ENGINE COMPRESSION TEST

Removal Procedure
1.
2.
3.
4.
Remove the throttle body. Refer to Throttle Body Assembly Replacement .

Remove the relay holder cover.
Remove the fuel pump relay.
Check Compression for all cylinders:

NOTE:
Engine revs at least 300/min.
1. Start the engine (approx. 4 seconds).

2. Compare the compression values.
Maximum pressure differential 100 kPa (14.5 psi)
1. Install the fuel pump relay.

Place into the socket.
Ensure the plug contacts are sound.
2. Install the relay carrier cover.
3. Install the spark plugs. Refer to Spark Plug Replacement .
4. Install the throttle body. Refer to Throttle Body Assembly Replacement .
DRIVE BELT CHIRPING, SQUEAL, AND WHINE DIAGNOSIS

Diagnostic Aids
A chirping or squeal noise may be intermittent due to moisture on the drive belts or the pulleys. It may be
necessary to spray a small amount of water on the drive belts in order to duplicate the customers concern.
If spraying water on the drive belt duplicates the symptom, cleaning the belt pulleys may be the probable
solution.
If the noise is intermittent, verify the accessory drive components by varying their loads making sure they
are operated to their maximum capacity. An overcharged A/C system, power steering system with a
pinched hose or wrong fluid, or a generator failing are suggested items to inspect.
A chirping, squeal or whine noise may be caused by a loose or improper installation of a body or
suspension component. Other items of the vehicle may also cause the noise.
The drive belts will not cause a whine noise.
Test Description
2
The noise may not be engine related. This step is to verify that the engine is making the noise. If the
engine is not making the noise do not proceed further with this table.
3
The noise may be an internal engine noise. Removing the drive belts one at a time and operating the
engine for a brief period will verify the noise is related to the drive belt. When removing the drive belt the
water pump may not be operating and the engine may overheat. Also DTCs may set when the engine is
operating with the drive belts removed.
4
Inspect all drive belt pulleys for pilling. Pilling is the small balls or pills or it can be strings in the drive
belt grooves from the accumulation of rubber dust.
6
10
installed.

12
14
This test is to verify that the drive belt tensioner operates properly. If the drive belt tensioner is not
operating properly, proper belt tension may not be achieved to keep the drive belt from slipping which
could cause a squeal noise.
15
This test is to verify that the drive belt is not too long, which would prevent the drive belt tensioner from
working properly. Also if an incorrect length drive belt was installed, it may not be routed properly and
may be turning an accessory drive component in the wrong direction.
16
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 it is not damaged or there is not excessive pilling will only be a temporary
repair.
Step
Action
Yes
No
CAUTION:
Refer to Belt Dressing Caution .
DEFINITION: The following items are indications of chirping:
A high pitched noise that is heard once per revolution of the drive belt or a pulley.
Chirping may occur on cold damp start-ups and will subside once the vehicle reaches normal
operating temp.

DEFINITION: The following items are indications of drive belt squeal:
A loud screeching noise that is caused by a slipping drive belt. This is unusual for a drive belt with
multiple ribs.
The noise occurs when a heavy load is applied to the drive belt, such as an air conditioning
compressor engagement snapping the throttle, or slipping on a seized pulley or a faulty accessory
drive component.
DEFINITION: The following items are indications of drive belt whine:
A high pitched continuous noise.

The noise may be caused by an accessory drive component failed bearing.
inspections?
Verify that there is a chirping, squeal or
whine noise.
Does the engine make the chirping squeal
or whine noise?
Go to Step 2
Go to Step 3

belt is removed.
3
5
6
7

30-40 seconds.
Does the chirping, squeal or whine noise Go to Symptoms Engine Mechanical
still exist?
If diagnosing a chirping noise, inspect for
severe pilling exceeding 1/3 of the belt
groove depth.
If diagnosing a squeal or whine noise,
proceed to step 13.
Do the belt grooves have pilling?
Go to Step 5
Clean the drive belt pulleys with a suitable
wire brush.
Go to Step 20
Are any of the pulleys misaligned?
Go to Step 7
Replace or repair any misaligned pulleys.
Go to Step 4
Go to Step 6
Go to Step 6
Go to Step 8

8
9
10

Did you find any bent or cracked brackets?
Replace any bent or cracked brackets.
fasteners.
Go to Step 20
Go to Step 8
Go to Step 9
Go to Step 10
Go to Step 20
Go to Step 10
Go to Step 11
Go to Step 12
Go to Step 20
Go to Step 12
Go to Step 18
Go to Step 19
Go to Step 20
Go to Step 14
Go to Step 20
Go to Step 15
Go to Step 20
Go to Step 16
Go to Step 20
Go to Step 17
CAUTION:
11
12
13
14
15
16
17
18
19
20

2. Replace any improper or missing
fasteners.
Inspect for a bent pulley.
Inspect for an accessory drive component
seized bearing or a faulty accessory drive
component.
If diagnosing a whine noise and the
condition still exist, proceed to Diagnostic
Aids.
Test the drive belt tensioner for proper
operation. Refer to Drive Belt Tensioner
Diagnosis.
Inspect for the correct drive belt length.
Inspect for misalignment of a pulley.
Inspect for the correct pulley size.
Replace the bent pulley.
Replacement.
repair.
Go to Step 20
Go to Step 20
Go to Step 20
System OK
Go to Step 19
Go to Step 3

DRIVE BELT RUMBLING AND VIBRATION DIAGNOSIS

Diagnostic Aids
The accessory drive components can have an affect on engine vibration. Vibration from the engine operating
may cause a body component or another part of the vehicle to make rumbling noise. Vibration can be caused
by, but not limited to the A/C system over charged, the power steering system restricted or the incorrect fluid, or
an extra load on the generator. To help identify an intermittent or an improper condition, vary the loads on the
accessory drive components.
The drive belt may have a rumbling condition that can not be seen or felt. Sometimes replacing the drive belt
may be the only repair for the symptom.
If replacing the drive belt, completing the diagnostic table, and the noise is only heard when the drive belts are
installed, there might be an accessory drive component with a failure. Varying the load on the different
accessory drive components may aid in identifying which component is causing the rumbling noise.
Test Description
2
This test is to verify that the symptom is present during diagnosing. Other vehicle components may cause
a similar symptom.
3
This test is to verify that one of the drive belts is causing the rumbling noise or vibration. Rumbling noise
may be confused with an internal engine noise due to the similarity in the description. Remove only one
drive belt at a time if the vehicle has multiple drive belts. When removing the drive belts the water pump
may not be operating and the engine may overheat. Also DTCs may set when the engine is operating with
the drive belts removed.
4
Inspecting 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 separating and
may be seen at the edge of the belt or felt as a lump in the belt.
5
Small amounts of pilling is normal condition and acceptable. When the pilling is severe the drive belt
does not have a smooth surface for proper operation.
9
Inspecting of the fasteners can eliminate the possibility that the wrong bolt, nut, spacer, or washer was

installed.
11
This step should only be performed if the water pump is driven by the drive belt. Inspect the water pump
shaft for being bent. Also inspect the water pump bearings for smooth operation and excessive play.
Compare the water pump with a known good water pump.
12
Accessory drive component brackets that are bent, cracked, or loose may put extra strain on that
accessory component causing it to vibrate.
Step
Action
Yes
No
CAUTION:
DEFINITION: The following items are indications of drive belt rumbling:
A low pitch tapping, knocking, or thumping noise heard at or just above idle.
Heard once per revolution of the drive belt or a pulley.
Rumbling may be caused from:
Pilling, the accumulation of rubber dust that forms small balls (pills) or strings in the drive
belt pulley groove
The separation of the drive belt
A damaged drive belt
A worn drive belt idler pulley
DEFINITION: The following items are indications of drive belt vibration:

The vibration is engine-speed related.
The vibration may be sensitive to accessory load.
1
inspections?
Verify that there is a rumbling noise or that
the vibration is engine related.
2
Does the engine make the rumbling noise
or vibration?

Go to Step 2
Go to Step 3


belt is removed.

30-40 seconds.
Go to Symptoms Does the rumbling or vibration still exist? Engine Mechanical
Inspect the drive belts for wear, damage,
separation, sections of missing ribs, and
debris build-up.
Go to Step 7
Inspect for severe pilling of more than 1/3
of the drive belt pulley grooves.
Go to Step 6
Did you find severe pilling?
Go to Step 4
Go to Step 5
Go to Step 7
1. Clean the drive belt pulleys using a

suitable wire brush.
2. Reinstall the drive belts. Refer to
Replacement.
repair.
fasteners.
Go to Step 8
Go to Step 7
Go to Step 8
Go to Step 9
System OK
Go to Step 9
Go to Step 10
Go to Step 11
Go to Step 13
Go to Step 11
Go to Step 13
Go to Step 12
CAUTION:
10
11

2. Replace improper or missing
fasteners.
Inspect for a bent water pump shaft. Refer
to Water Pump Replacement (1.8L LUW
and LWE) .

12
13

repair.
Go to Step 13
System OK
Go to Step 3
CYLINDER LEAKAGE TEST

Removal Procedure
1.
2.
3.
4.
5.
6.
7.
Open the hood.

Remove the right front wheelhouse liner. Refer to Front Wheelhouse Liner Replacement
Lower the vehicle.
Remove the timing belt upper front cover. Refer to Timing Belt Upper Front Cover Removal.
Detach the engine wiring harness from intake manifold, cylinder head cover and engine wiring harness
bracket.
8. Remove the coolant expansion tank closure cap.
9. Remove the oil dipstick.

Fig. 4: View Of Crankshaft TDC Position

10. Set up the crankshaft.
11. Move the crankshaft in the direction of the engine rotation to the first cylinder TDC position (mark 1).

Fig. 5: View Of Guidance Marks

12. Apply guidance marks.
13. Attach 3 markings (2) as an aid to one of the camshaft adjusters, each one offset by 90 to the marking
applied (1).
Test Procedure
NOTE:
Follow manufacturer instructions.
1. Calibrate the pressure loss tester and connect to the compressed air system.

Fig. 6: View Of Pressure Loss Tester

2. Install the pressure loss tester.
NOTE:
Wheels must be in contact with the ground.
Engage first gear and apply the parking brake.

Install the connecting piece into the spark plug thread of cylinder number 1.
Apply compressed air to cylinder number 1.
3. Inspect for Pressure Loss
Take pressure loss reading.
The maximum permissible pressure differential between cylinders is approximately 10
percent.
Maximum pressure loss of a cylinder is 25 percent.
Take note of any visible escape of compressed air.

Intake manifold, exhaust manifold, crankcase

Take note of any bubble formation in the coolant compensation tank.
4. Perform pressure loss test by analogy on cylinders 3, 4 and 2.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
Remove the pressure loss tester.

Remove the connection piece from the spark plug thread.
Put the vehicle in neutral.
Insert the oil dipstick.
Install the coolant expansion tank closure cap.
Install the engine wiring harness to the intake manifold.
Install the timing belt upper front cover. Refer to Timing Belt Upper Front Cover Installation.
Raise and support the vehicle.
Lower the vehicle.
Close the hood.
CRANKCASE VENTILATION SYSTEM INSPECTION/DIAGNOSIS

Results of Incorrect Operation
A plugged positive crankcase ventilation (PCV) orifice or hose may cause the following conditions:
Rough idle
Stalling or slow idle speed
Oil leaks
Oil in the throttle body
Sludge in the engine
Functional Check
With these systems, any blow-by in excess of the system capacity, from a badly worn engine, sustained heavy
load, etc., is exhausted into the throttle body and is drawn into the engine.
Proper operation of the crankcase ventilation system depends upon a sealed engine. If oil slugging or dilution is
noted and the crankcase ventilation system is functioning properly, check the engine for a possible cause.
Correct any problems.
If an engine is idling rough, inspect for a clogged PCV orifice, a dirty vent filter, air cleaner element, or plugged
hose. Replace as required. Use the following procedure:

1. Remove the PCV hose from the cylinder head cover.

2. Operate the engine at idle.
3. Place your thumb over the end of the hose in order to check for a vacuum. If there is no vacuum at the
hose, inspect for the following items:
Plugged hoses
The manifold port
4. Turn OFF the engine.
5. Inspect the PCV orifice in the cylinder head cover for debris or blockage.
DRIVE BELT FALLS OFF AND EXCESSIVE WEAR DIAGNOSIS
Diagnostic Aids
If the drive belt repeatedly falls off the drive belt pulleys, this is because of pulley misalignment.
An extra load that is quickly applied on released by an accessory drive component may cause the drive belt to
fall off the pulleys. Verify the accessory drive components operate properly.
If the drive belt is the incorrect length, the drive belt tensioner may not keep the proper tension on the drive belt.
Excessive wear on a drive belt is usually caused by an incorrect installation or the wrong drive belt for the
application.
Minor misalignment of the drive belt pulleys will not cause excessive wear, but will probably cause the drive
belt to make a noise or to fall off.
Excessive misalignment of the drive belt pulleys will cause excessive wear but may also make the drive belt fall
off.
Test Description
2
This inspection is to verify the condition of the drive belt. Damage may of occurred to the drive belt when
the drive belt fell off. The drive belt may of been damaged, which caused the drive belt to fall off. Inspect
the belt for cuts, tears, sections of ribs missing, or damaged belt plys.
4
installation procedure of that pulley.

5
6
Accessory drive component brackets that are bent or cracked will let the drive belt fall off.
7
installed. Missing. loose, or the wrong fasteners may cause pulley misalignment from the bracket moving
under load. Over tightening of the fasteners may cause misalignment of the accessory component bracket.
13
The inspection is to verify the drive belt is correctly installed on all of the drive belt pulleys. Wear on the
drive belt may be caused by mis-positioning the drive belt by one groove on a pulley.
14
The installation of a drive belt that is too wide or too narrow will cause wear on the drive belt. The drive
belt ribs should match all of the grooves on all of the pulleys.
15
This inspection is to verify the drive belt is not contacting any parts of the engine or body while the
engine is operating. There should be sufficient clearance when the drive belt accessory drive components
load varies. The drive belt should not come in contact with an engine or a body component when
snapping the throttle.
Step
Action
Yes
No
CAUTION:
DEFINITION: The drive belt falls off the pulleys or may not ride correctly on the pulleys.DEFINITION:
Wear at the outside ribs of the drive belt due to an incorrectly installed drive belt.
1
Go to Symptoms - Engine
inspections?
Go to Step 2 Mechanical
If diagnosing excessive wear, proceed to step
13.
2
If diagnosing a drive belt that falls off, inspect

3
4
5
6
7
for a damaged drive belt.

Go to Step 3
Replacement.
Go to Step 4
Go to Step 12
Inspect for a bent or dented pulley.
Go to Step 12
Inspect for a bent or a cracked bracket.
Go to Step 12
Inspect for improper, loose or missing fasteners.
Go to Step 8
Did you find loose or missing fasteners?
Go to Step 4
System OK
Go to Step 5
Go to Step 6
Go to Step 7
Go to Step 9
CAUTION:
10
11
12
13
14
15
16

2. Replace improper or missing fasteners.
Test the drive belt tensioner for operating
correctly. Refer to Drive Belt Tensioner
Diagnosis.
Does the drive belt tensioner operate correctly?
Replace the drive belt tensioner. Refer to Drive
Belt Tensioner Replacement.
Inspect for failed drive belt idler and drive belt
tensioner pulley bearings.
Inspect the drive belt for the proper installation.
Inspect for the proper drive belt.
Inspect for the drive belt rubbing against a
bracket, hose, or wiring harness.
Replacement.
Go to Step 9
System OK
Go to Step 11
Go to Step 10
Go to Step 11
System OK

System OK
Go to Step 2
Go to Step 16
Go to Step 14
Go to Step 16
Go to Step 15

Go to Step 17

17
System OK
DRIVE BELT TENSIONER DIAGNOSIS

Diagnosis consists of a function check on the automatic belt tensioner and a visual check on the belt and the
components linked to the belt.
Fig. 7: Drive Belt Tensioner

Apply tension to the belt tensioner via the cast projection (1) in the direction of the arrow,
counterclockwise, and allow to slide back slowly.
The tensioner must slide back to the initial position.
DUAL MASS FLYWHEEL DIAGNOSIS

Check for Thermal Overload

NOTE:
These quick information shall help to carry out a correct diagnosis in case of a
customer complaint.
Through friction of clutch plate on the friction surface of the dual mass flywheel temperatures up to 200 C can
arise during normal driving. At sliding clutch or through operating errors much higher temperatures can arise.
These temperatures must not cause mandatory a reduced lifetime of the dual mass flywheel.
Possible indications for a high thermal load are:
Tarnish (bluish) as well as local hotspots on friction surface

Tarnish (bluish) near of mounting area and riveting area of clutch
If all other checkable features are well, the dual mass flywheel can stay in the vehicle.
Possible indications for a too high thermal load are:
Cracks
Fusion zones on friction surface (material smear)
Scores in friction surface (for example through clutch lining riveting at destroyed or worn clutch plate)
Tarnish (bluish) which reaches up to bearing area of dual mass flywheel
Bluish discoloration of locating pins (3 locating pins in outer zone of dual mass flywheel)
In these cases the dual mass flywheel has to be replaced.

Overview Dual Mass Flywheel

Fig. 8: Overview Dual Mass Flywheel

Callout
1
2
3
4
5
Component Name
Bearing Area
Mounting Area Pressure Plate
Locating Pins
Friction Surface
Riveting Area
Exploded View Dual Mass Flywheel with Additional Mass

Fig. 9: Exploded View Dual Mass Flywheel with Additional Mass

Callout
1
2
3
4
5
Component Name
Secondary Flywheel Mass
Additional Mass, Coupled with Cover and Pulse-Generator Ring
Flange
Primary Flywheel Mass with Bowed Springs and Plain
Bearing/Bearing Bolt
Toothed Ring
Check for Damaged Components
All following checking procedures have to be carried out at installed dual mass flywheel. For visual check at
vehicle very bright light and a additional bright and small pocket lamp is necessary. Damages like grease on
primary flywheel and loose ore missing balance weights cannot be checked at installed condition. During visual

check material alteration can be stated which eliminate a further operating suitability.
For comparison different damages at dual mass flywheel with the corresponding further procedure are presented
here.
Fig. 10: Plain Bearing

NOTE:
In case of mechanical damages at plain bearing the dual mass flywheel

has to be replaced.
1. Inspect plain bearing (1) for damages.

Dependent of the manufacturer damages can be detected through ventilation openings of secondary
flywheel. Parts of the bearing (1) are detached or lie loose around the bearing bolt.

Fig. 11: Toothed Ring

NOTE:
Light abrasion on frontal areas of teeth is allowed. If problems occur

during starting the engine the dual mass flywheel has to be replaced.
2. Inspect toothed ring (1) for damages.

The toothed ring is needed to start the engine. Through a lot of starting procedures and/or an incorrect
engaging starter signs of abrasion can occur on teeth of the toothed ring. The profile of damages can reach
from only low signs of abrasion up to heavy material removal. The installation of a pulse-generator ring
depends on the manufacturer.
The image shows signs of abrasion and mechanical damages at toothed ring (1), they occur through
abrasion due to a lot of starting procedures. In this case the dual mass flywheel has to be replaced.

Fig. 12: Inspecting Tilt Clearance

NOTE:
The check must be carried out only by hand without any tools.
3. Inspect tilt clearance.

At dual mass flywheel the additional-mass ring looms over the gap between primary and secondary
flywheel. It is not possible to carry out just a visual check.

Fig. 13: Tilt Clearance Height

NOTE:
An absolute clear measurement is not possible with this check due to the
different applied forces of the several workshop employees during the
check.
4. Embrace dual mass flywheel and apply thumbs onto the outer radius of secondary flywheel.
5. Apply pressure onto the secondary flywheel alternating on upper, lower, left and right side
During the tilt clearance check a functional metal rattling noise may occur.
If tilt clearance is higher than 3 mm (MUST be measured, DO NOT make an estimation) (1) the dual
mass flywheel has to be replaced.

Fig. 14: Tilt Clearance Angle


Fig. 15: Rotating Secondary Flywheel Anticlockwise


Fig. 16: Releasing Secondary Flywheel


Fig. 17: Mark On Flywheel And Toothed Ring For Starter

6. Inspect clearance angle (1).
Before the inspection of the clearance angle the dual mass flywheel should be rotated several times
clockwise and anticlockwise to receive a feeling for the resistance of the springs. In addition unusual loud
clicking noise or possible rattle, crunch, grinding noise can be sounded out during rotating the dual mass
flywheel.
If the rotation of the flywheel is impossible the flywheel is defective and has to be replaced.
The clearance angle is the angle (1) about the secondary and the primary flywheel can be turned light
against each other. Thereby the flange wings are moved in the duct of the bowed springs without
adjoining the bowed springs. Dictated by functional factors the clearance angle is up to 8 teeth.
Is the secondary flywheel rotated beyond this point the bowed springs in the duct are moved to spring

arrestor in the primary flywheel/cover. Now the both spring are tensioned.
Rotate secondary flywheel anticlockwise (arrow) until the elastic counterforce (spring force) is
clear noticeable.
Release secondary flywheel slowly until the bowed springs are relaxed, so no counterforce acts
onto the springs.
Mark position with a vertical line by a white pencil on secondary flywheel (1) and on toothed ring
for starter (2).
Rotate secondary flywheel clockwise until the elastic counterforce is clear noticeable.
Release secondary flywheel slowly until the bowed springs are relaxed.
Apply new marking on secondary flywheel (1) on the height of the marking on the toothed ring for
starter (3).
Count amount of teeth on toothed ring for starter from marked tooth up to the height of the first
marking on secondary flywheel (2). Dictated by functional factors up to 8 teeth are allowed.
7. ALWAYS replace the engine flywheel if following conditions are given:
The difference exceeds the amount of 8 teeth.
The dual mass flywheel cannot be rotated.
During rotating the dual mass flywheel a hard metallic arrestor is audible or noticeable.
REPAIR INSTRUCTIONS - ON VEHICLE

DRIVE BELT REPLACEMENT
Special Tools
EN 6349 Locking Pin

Removal Procedure
1. Open the hood.

2. Raise the vehicle. Refer to Lifting and Jacking the Vehicle .

Fig. 18: Drive Belt Tensioner And Special Tool

4. Release tension to the drive belt tensioner by rotating counterclockwise (1) and lock with EN 6349 pin
(2).




1. Install the drive belt (1).

Fig. 21: Checking Drive Belt Position

NOTE:
Ensure that the drive belt is aligned on the generator pulley (4), crankshaft
balancer (5), drive belt tensioner (6) water pump pulley (7), and A/C
compressor. The drive belt must lie on the water pump pulley between the
flange (1) and (2).
2. Check the position of the drive belt (3).


3. Release tension to the tensioner by rotating counterclockwise (1).
NOTE:
4.
5.
6.
7.
8.
Allow tensioner to slide back slowly.
Remove EN 6349 pin (2).

Apply tension to the tensioner clockwise (1).
Lower the vehicle.
Close the hood.
DRIVE BELT TENSIONER REPLACEMENT

Removal Procedure

1. Remove the generator and air conditioning compressor belt. Refer to Drive Belt Replacement.
Fig. 23: Drive Belt Tensioner Bolt

2. Remove the drive belt tensioner bolt (1).
1. Clean the drive belt tensioner thread.


2. Install drive belt tensioner (2).
3. Install the drive belt tensioner bolt (1) and tighten to 55 N.m (41 lb ft).
4. Install the generator and air conditioning compressor belt. Refer to Drive Belt Replacement.
ENGINE MOUNT REPLACEMENT

Fig. 25: Engine Mount And Bolts

Engine Mount Replacement
Callout
Component Name
1. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement (1.8L LWE) ,
Air Cleaner Assembly Replacement (1.8L LUW) .
2. Support the engine. Install a suitable engine lifting device. Install a suitable cable at the 3 engine
lift brackets and at the engine lifting device.
Engine Mount Bolt (Qty: 2)
CAUTION:
Tighten
62 N.m (46 lb ft)
Engine Mount Bracket Bolt (Qty: 3)

CAUTION:

3
4
Procedure
Install NEW bolts, do NOT reuse old bolts
Tighten
50 N.m + 60-75 (37 lb ft + 60-75)
Engine Mount Nut
Tighten
62 N.m (46 lb ft)
Engine Mount
POWERTRAIN MOUNT BALANCING

NOTE:
Follow the balance procedure steps listed below when no starting point has
been established such as in a collision repair.


2. Loosen the front transaxle mount through bolt (1) until it is finger tight.

3. Loosen the rear transaxle mount (1) through bolt until it is finger tight.

Fig. 28: Supporting Engine/Transmission With Hydraulic Floor Jack

5. Position two floor jacks with wood blocks under the engine and transaxle in order to support the
powertrain assembly.


6. Loosen the transaxle adapter to transaxle bolts (1).

Fig. 30: Engine Mount And Bracket Bolts

7. Loosen the engine mount (1) to bracket bolts (2).
8. Lower the floor jacks in order to allow a 1/4 inch (6 mm) gap between the upper engine mount and engine
mount bracket, and also between the transmission and left transmission mount.

Fig. 31: Front And Rear Powertrain Mounts

9. Check that the front and rear mounts are centered (1) in the mount brackets, adjust if necessary.
10. Tighten the left hand (transaxle side) mount bolts, starting with the bolt nearest to the center of the mount.
See the appropriate transmission mount replacement procedure for the fastener tightening specifications.


11. Tighten the right hand (engine side) mount bolts (1), starting with the bolt nearest to the center of the
mount. See the appropriate engine mount replacement procedure for the fastener tightening specifications.
12. Remove the floor jacks from under the oil pan and transmission.


NOTE:
It is essential that the lower mount through bolts should be as close to

centered as possible in the oversized mount insert holes before tightening
to specification.


POWERTRAIN MOUNT BALANCING - LOWER
NOTE:
Follow the balance procedure steps listed below when front or rear
mounts through bolts are loosened or removed during a repair procedure.


2. Loosen the front transaxle mount through bolt (1).


3. Loosen the rear transaxle mount through bolt (1).
NOTE:
It is essential that the through bolts are as close to centered as possible in

the oversized mount insert holes before tightening to specification.


ENGINE MOUNT REPLACEMENT - RIGHT SIDE


Engine Mount Replacement - Right Side
Callout
Component Name
1. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement (1.8L LWE) ,
Air Cleaner Assembly Replacement (1.8L LUW) .
2. Support the engine. Install a suitable engine lifting device. Install a suitable cable at the 3 engine
lift brackets and at the engine lifting device.
Engine Mount Bolt (Qty: 2)
CAUTION:
Tighten
62 N.m (46 lb ft)

CAUTION:

3
4
Procedure
Use NEW bolts, do NOT reuse old bolts.
Tighten
50 N.m + 60-75 (37 lb ft + 60-75)
Engine Mount Nut
Tighten
62 N.m (46 lb ft)
Engine Mount
ENGINE MOUNT INSPECTION

2. Observe the engine mount while raising the engine. Raising the engine removes the weight from the
engine mount and creates slight tension on the rubber.
3. Replace the engine mount if the engine mount exhibits any of the following conditions:
The hard rubber is covered with heat check cracks.
The rubber is separated from the metal plate of the engine mount.
The rubber is split through the center of the engine mount.
4. For engine mount replacement, refer to Engine Mount Replacement - Right Side.
5. For rear transmission mount replacement, refer to:
Automatic transmission, refer to Transmission Rear Mount Replacement .
Manual transmission, refer to Transmission Rear Mount Replacement .
6. For left transmission mount replacement, refer to:
Automatic transmission, refer to Transmission Mount Replacement - Left Side .
Manual transmission, refer to Transmission Mount Bracket Replacement - Left Side .
ENGINE MOUNT BRACKET REPLACEMENT

Fig. 39: Engine Mount Bracket

Engine Mount Bracket Replacement
Callout
Component Name
Remove the engine mount. Refer to Engine Mount Replacement.
CAUTION:
Tighten
60 N.m (45 lb ft) + 45-60
Engine Mount Bracket
INTAKE MANIFOLD REPLACEMENT

Removal Procedure
WARNING: Refer to Gasoline/Gasoline Vapors Warning .

WARNING: Refer to Safety Goggles and Fuel Warning .
WARNING: In order to reduce the risk of fire and personal injury observe the
following items:
1.
2.
3.
4.
Replace all nylon fuel pipes that are nicked, scratched or damaged
during installation, do not attempt to repair the sections of the nylon
fuel pipes
Do not hammer directly on the fuel harness body clips when
installing new fuel pipes. Damage to the nylon pipes may result in a
fuel leak.
Always cover nylon vapor pipes with a wet towel before using a
torch near them. Also, never expose the vehicle to temperatures
higher than 115C (239F) for more than one hour, or more than 90C
(194F) for any extended period.
Apply a few drops of clean engine oil to the male pipe ends before
connecting fuel pipe fittings. This will ensure proper reconnection
and prevent a possible fuel leak. (During normal operation, the Orings located in the female connector will swell and may prevent
proper reconnection if not lubricated.)
Open the hood.

Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement .
Place a drain pan underneath the vehicle.

Fig. 40: Intake Manifold Bracket

5.
6.
7.
8.
Remove the 2 intake manifold brace bolts (2, 3).

Remove and disconnect the wiring harness plug from the heated oxygen sensor 1.
Remove the intake manifold brace (1).
Remove the evaporative emission canister purge solenoid valve. Refer to Evaporative Emission
Canister Purge Solenoid Valve Replacement


9. Unclip the fuel feed pipe (2) from the fuel feed pipe clip (3).
10. Release the fuel feed pipe (2) from the multiport fuel injection fuel rail (1) and remove the fuel feed pipe.
11. Close the fuel feed pipe with a suitable cap.

Fig. 42: Throttle Body And Positive Crankcase Ventilation Tube

12. Remove the positive crankcase ventilation tube (1) from throttle body (3) and the camshaft cover (2).
13. Remove the throttle body assembly. Refer to Throttle Body Assembly Replacement .

Fig. 43: Throttle Body, Throttle Body Heater Inlet Hose And Throttle Body Heater Outlet Hose
14.
15.
16.
17.
Disconnect the manifold absolute pressure sensor wiring harness plug (5).
Remove the clamp (2) and remove the throttle body heater inlet hose (1) from throttle body (3).
Disconnect the throttle body heater outlet hose (4) from the throttle body (3).
Remove the engine management wiring harness and the fuel injectors wiring harness.

Fig. 44: Intake Manifold, Multiport Fuel Injection Fuel Rail, Fuel Injectors, Seals And Bolts
18. Remove the 2 multiport fuel injection fuel rail bolts (1).
19. Remove the multiport fuel injection fuel rail (2) and the fuel injectors (3) from the intake manifold (5).
20. Remove the 4 multiport fuel injector seals (4).

Fig. 45: View Of Brake Servo Vacuum Line

21. Disconnect the booster vacuum pipe (1) from the intake manifold.

Fig. 46: Intake Manifold And Bolts

23. Remove the intake manifold (2).

Fig. 47: Intake Manifold, Seal And Throttle Body Seal

24. Remove the intake manifold gaskets (1, 3) from the intake manifold (2).

Fig. 48: Intake Manifold, Manifold Absolute Pressure Sensor And Bolt
25. Remove the manifold absolute pressure sensor bolt (1).
26. Remove the manifold absolute pressure sensor (2) from the intake manifold (3).

Fig. 49: Intake Manifold And Mount

27. Remove the rubber bracket (2) from intake manifold (1).
Cleaning and Inspection Procedure
Clean and inspect the intake manifold. Refer to Intake Manifold Cleaning and Inspection.


2. Install the rubber bracket (2) to intake manifold (1).

3. Install the manifold absolute pressure sensor (2) to the intake manifold (3).
4. Install the manifold absolute pressure sensor bolt (1) and tighten to 6 N.m (53 lb in).


5. Install the NEW gaskets (1, 3) to the intake manifold (2).


6. Install the intake manifold (2) and the 7 intake manifold bolts (1) and tighten to 20 N.m (15 lb ft).

Fig. 54: View Of Brake Servo Vacuum Line

7. Connect the booster vacuum pipe (1) to the intake manifold.

8. Install the 4 multiport fuel injector seals (4).
9. Install the multiport fuel injection fuel rail (2) and the fuel injectors (3) to the intake manifold (5).
10. Install the 2 multiport fuel injection fuel rail bolts (1) and tighten to 8 N.m (71 lb in).

Fig. 56: Throttle Body, Throttle Body Heater Inlet Hose And Throttle Body Heater Outlet Hose
11.
12.
13.
14.
Connect the throttle body heater outlet hose (4) to the throttle body (3).
Install the throttle body heater inlet hose (1) to the throttle body (3) and install the clamp (2).
Connect the manifold absolute pressure sensor wiring harness plug (5).
Install the engine management wiring harness and the fuel injectors wiring harness.

Fig. 57: Throttle Body And Positive Crankcase Ventilation Tube

15. Install the positive crankcase ventilation tube (1) the to throttle body (3) and to the camshaft cover (2).
16. Install the throttle body assembly. Refer to Throttle Body Assembly Replacement .
17. Install the evaporative emission canister purge solenoid valve. Refer to Evaporative Emission Canister
Purge Solenoid Valve Replacement


18. Remove the cap from fuel feed pipe (2).
19. Install the fuel feed pipe (2) to the multiport fuel injection fuel rail (1).
20. Clip the fuel feed pipe (2) to the fuel feed pipe clip (3).


21.
22.
23.
24.
25.
26.
Install the intake manifold brace (1).

Install and connect the wiring harness plug to the heated oxygen sensor 1.
Install the 2 intake manifold brace bolts (2, 3) and tighten to 8 N.m (71 lb in).
Lower the vehicle.
Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement .
Close the hood.
TIMING BELT REPLACEMENT

Special Tools
EN-6333 Timing Belt Tensioner Locking Pin

EN-6340 Camshaft Locking Tool

EN-6625 Crankshaft Locking Device


Removal Procedure
NOTE:
If the timing belt is being replaced due to the maintenance schedule

interval, then the timing belt tensioner and idler pulley must also be
replaced.
1. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement (1.8L LWE) , Air
2. Remove the timing belt upper front cover. Refer to Timing Belt Upper Front Cover Removal.
5. Remove the drive belt tensioner. Refer to Drive Belt Tensioner Replacement.
7. Set the engine to top dead center (TDC).
8. For vehicle with manual transmission: Remove the transmission front mount. Refer to Transmission
Front Mount Replacement .

Fig. 60: Connection Bolt

9. For vehicle with manual transmission: Remove the bolted connection (1).

Fig. 61: Automatic Transmission Bracket Bolt

10. For vehicle with automatic transmission: Remove the bolt (1).

Fig. 62: Locking Device And Bolt

11. Install EN-6625 locking device (2) to block the crankshaft.
12. Install the bolt or bolted connection (1).



Fig. 64: Timing Belt Lower Front Cover

14. Remove the 4 lower timing belt cover bolts (2).
15. Remove the lower timing belt cover (1).

Fig. 65: Locking Tool

NOTE:
The left half of the EN-6340 locking tool can be recognized by the lettering
"left", arrow, on the tool.
17. Prepare the left half of the EN-6340 locking tool.

1. Remove the 2 bolts (2)
2. Remove the front panel (1) from the EN-6340 locking tool - left.

Fig. 66: Camshaft Adjuster Locking Tool

18. Install the EN-6340 locking tool into the camshaft adjusters.
NOTE:
The spot type marking (4) on the intake camshaft adjuster does not
correspond to the groove of EN-6340 locking tool - left during this
process but must be somewhat above as shown.
1. Install the EN-6340 locking tool - left (1) in the camshaft adjusters as shown.
NOTE:
The spot type marking (3) on the exhaust camshaft adjuster must
correspond to the groove on EN-6340 locking tool - right.
2. Install EN-6340 locking tool - right (2) in the camshaft adjusters as shown.

Fig. 67: View Of Drive Belt Tensioner, Allen Key And KM-6333
20. Apply tension to the drive belt tensioner (2) in the direction of the arrow, using an allen key (1).
21. Install the EN-6333 locking pin (3).
22. Remove the timing belt idler pulley. Refer to Timing Belt Idler Pulley Replacement.


23. Remove the timing belt (1).

Fig. 69: Timing Belt And Assembly Tool

NOTE:
Threading the timing belt through the engine mount bracket is only
permissible in conjunction with the assembly tool supplied with NEW
timing belts or otherwise it is possible to damage the toothed belt at this
stage by kinking it.
NOTE:
If the toothed belt has been used, observe the direction of rotation.
1. Install the timing belt (1) in the enclosed assembly tool (2).
2. Guide the timing belt through the engine mount bracket with the assembly tool.
3. Remove the assembly tool.


4.
5.
6.
7.
8.
Install the timing belt (1).

Guide the timing belt past the tensioner and place it on the crankshaft sprocket wheel.
Place the timing belt on the exhaust and intake camshaft position actuator adjusters.
Raise and support the vehicle.
Install the timing belt idler pulley. Refer to Timing Belt Idler Pulley Replacement.

10. Remove the EN-6333 locking pin (3).
NOTE:
The timing belt tensioner moves automatically to the correct position.
11. Release tension on timing belt tensioner.


12.
13.
14.
15.
Remove bolt or bolted connection (1).

Remove EN-6625 locking device (2).
Lower the vehicle.
Remove the EN-6340 locking tool.


16. Check the timing
NOTE:
Note the marking at the camshaft sprockets.
1. Turn the crankshaft 720 degrees in the direction of engine rotation by the crankshaft balancer bolt.
NOTE:
2. Install EN-6340 locking tool - left (1) into the camshaft adjusters as shown.
NOTE:


3. Install EN-6340 locking tool - right (2) into the camshaft adjusters as shown.
17. Remove the EN-6340 locking tool.
Fig. 74: Aligning Timing Belt Drive Gear And Oil Pump Housing
NOTE:
The timing belt drive gear and oil pump housing must align.
19. Control the crankshaft balancer position.




22. Install the lower timing belt cover (1).
23. Install the 4 lower timing belt cover bolts (2) and tighten to 6 N.m (53 lb in).


24. Install the crankshaft balancer (2).
25. Install a NEW crankshaft balancer bolt (1) and tighten a first pass to 95 N.m (70 lb ft).
26. Tighten the NEW crankshaft balancer bolt a second pass to an additional 45 degrees. using the EN-45059
meter.
27. Tighten the NEW crankshaft balancer bolt a final pass to an additional 15 degrees. using the EN-45059
meter.


28. Remove bolt or bolted connection (1).
29. Remove EN-6625 locking device (2).


30. For vehicle with automatic transmission: Install the bolt (1) and tighten to 45 N.m (33 lb ft).


31.
32.
33.
34.
35.
36.
37.
For vehicle with manual transmission: Install the bolt (1) and tighten to 40 N.m (32 lb ft).
Install the drive belt tensioner. Refer to Drive Belt Tensioner Replacement.
Lower the vehicle.
Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement (1.8L LWE) , Air
38. Reset the CHANGE TIMING BELT message. Refer to Indicator/Warning Message Description and
Operation .
TIMING BELT IDLER PULLEY REPLACEMENT

Special Tools

For equivalent tools, refer to Special Tools.
Removal Procedure
1. Remove the timing belt. Refer to Timing Belt Replacement.
Fig. 81: Timing Belt Idler Pulley Bolt

2. Remove and DISCARD the timing belt idler pulley bolt (2).
3. Remove the timing belt idler pulley (1).


1. Install the timing belt idler pulley (1) and tighten the NEW bolt (2) in three passes use the EN-45059
meter :
1. First pass tighten to 20 N.m (15 lb ft).
2. Second pass to 120 degrees.
3. Final pass to 15 degrees.
2. Install the timing belt. Refer to Timing Belt Replacement.

TIMING BELT TENSIONER REPLACEMENT

Special Tools

EN-6340 Camshaft Locking Tool
EN-45059 Torque Angle Sensor Kit

Removal Procedure
1. Open the hood.

8. Set the engine to top dead center (TDC).
9. For vehicle with manual transmission: Remove the transmission front mount. Refer to Transmission
Front Mount Replacement .


10. For vehicle with manual transmission: Remove the bolted connection (1).


11. For vehicle with automatic transmission: Remove the bolt (1).








NOTE:
The left half of the EN-6340 locking tool can be recognized by the lettering
"left", arrow, on the tool.
18. Prepare the left half of the EN-6340 locking tool.

1. Remove the 2 bolts (2)
2. Remove the front panel (1) from the EN-6340 locking tool - left.


NOTE:
correspond to the groove of EN-6340-left during this process but
must be somewhat above as shown.
1. Install the EN-6340 locking tool - left (1) in the camshaft adjusters as shown.
NOTE:
correspond to the groove on EN-6340-right.
2. Install EN-6340 locking tool - right (2) in the camshaft adjusters as shown.
20. Remove EN-6340 locking tool.

22.
23.
24.
25.
26.
Apply tension to the drive belt tensioner (2) in the direction of the arrow, using an allen key (1).
Install the EN-6333 locking pin (3).
Lower the vehicle.
Remove the engine mount bracket. Refer to Engine Mount Bracket Replacement.
Remove the timing belt center front cover. Refer to Timing Belt Center Front Cover Removal.

Fig. 91: Timing Belt, Timing Belt Tensioner

NOTE:
Note the direction of the belt, if the timing belt will be reused.

28. Remove and DISCARD the timing belt tensioner bolt (3).
29. Remove the timing belt tensioner (2).
1. Re-cut the timing belt tensioner thread.


2. Install the timing belt tensioner (2).
NOTE:
Service may offer bolts that are not microencapsulated. If this is the case
apply thread lock agent to the bolt.
3. If fastener is microencapsulated, install a NEW timing belt tensioner bolt (3). DO NOT reuse the old bolt.
4. Tighten the timing belt tensioner bolt to 20 N.m (15 lb ft).

5. Install the timing belt (1).
6. Guide the timing belt past the tensioner and place it on the crankshaft sprocket wheel.

7.
8.
9.
10.
Place the timing belt on the exhaust and intake camshaft position actuator adjusters.
Install the engine mount bracket. Refer to Engine Mount Bracket Replacement.
Install the timing belt center front cover. Refer to Timing Belt Center Front Cover Installation.
Raise the vehicle.
NOTE:


14.
15.
16.
17.
Remove bolt or bolted connection (1).

Remove EN-6625 locking device (2).
Lower the vehicle.


NOTE:
1. Turn the crankshaft 720 in the direction of engine rotation by the crankshaft balancer bolt.
NOTE:
correspond to the groove of EN-6340-left during this process but
must be somewhat above as shown.
2. Install EN-6340-left locking tool (1) into the camshaft adjusters as shown.
NOTE:

correspond to the groove on EN-6340-right.

3. Install EN-6340-right locking tool (2) into the camshaft adjusters as shown.
NOTE:
21. Control the crankshaft balancer position.






CAUTION: Refer to Torque-to-Yield Fastener Caution in the Preface section.

27. Install a NEW crankshaft balancer bolt (1) and tighten in 3 passes using the EN-45059 sensor kit :
1. First pass to 95 N.m (70 lb ft).
2. Second pass to 45.
3. Third pass to 15.


28. Remove bolt or bolted connection (1).
29. Remove EN-6625 locking device (2).


30. For vehicle with automatic transmission: Install the bolt (1) and tighten to 45 N.m (33 lb ft).


31.
32.
33.
34.
35.
36.
37.
For vehicle with manual transmission: Install the bolted connection (1) and tighten to 40 N.m (32 lb ft).
Install the drive belt tensioner. Refer to Drive Belt Tensioner Replacement.
Lower the vehicle.
38. Close the hood.
TIMING BELT CENTER FRONT COVER REPLACEMENT

Fig. 103: Timing Belt Center Front Cover

Timing Belt Center Front Cover Replacement
Callout
Component Name
1. Remove the timing belt upper front cover. Refer to Timing Belt Upper Front Cover
Replacement.
2. Remove the engine mount bracket. Refer to Engine Mount Bracket Replacement.
1
Timing Belt Center Front Cover
TIMING BELT UPPER FRONT COVER REPLACEMENT
Removal Procedure

Fig. 104: Air Cleaner

1. Disconnect the wiring harness plug (2).
2. Unclip the wiring harness from the air cleaner (1).

Fig. 105: Timing Belt Upper Front Cover

3. Remove the 2 timing belt upper front cover bolts (2).
4. Remove the timing belt upper front cover (1).


1. Install the timing belt upper front cover (1).
2. Install the 2 timing belt upper front cover bolts (2) and tighten to 6 N.m (53 lb in).

Fig. 107: Air Cleaner

3. Connect the wiring harness plug (2).
4. Clip in the wiring harness to the air cleaner (1).
TIMING BELT LOWER FRONT COVER REPLACEMENT
Removal Procedure
2. Remove the crankshaft balancer. Refer to Crankshaft Balancer Replacement (Manual Transmission),
Crankshaft Balancer Replacement (Automatic Transmission).





3. Install the crankshaft balancer. Refer to Crankshaft Balancer Replacement (Manual Transmission),
TIMING BELT REAR COVER REPLACEMENT
Removal Procedure

1. Remove the camshaft position actuator adjuster. Refer to Camshaft Position Actuator Adjuster
Replacement.
2. Remove the timing belt tensioner. Refer to Timing Belt Tensioner Replacement.
Fig. 110: Timing Belt Rear Cover And Bolts

3. Remove and DISCARD the 4 timing belt rear cover bolts (2).
NOTE:
Oil can escape. Use a cloth, rag or paper to take the oil drain away from all
timing components.
4. Remove the timing belt rear cover (1).

1. Re-cut the 4 timing belt rear cover threads.


NOTE:
If the cover is contaminated with oil. You have to clean it close.
2. Install the timing belt rear cover (1).

NOTE:
apply thread lock agent to the bolt. If fastener is microencapsulated, install
a NEW 4 timing belt rear cover bolts. DO NOT reuse the old bolt.
3. Install the 4 NEW timing belt rear cover bolts (2) and tighten to 6 N.m (53 lb in).
4. Install the timing belt tensioner. Refer to Timing Belt Tensioner Replacement.

5. Install the camshaft position actuator adjuster. Refer to Camshaft Position Actuator Adjuster
Replacement.
VALVE LIFTER REPLACEMENT
Special Tools
EN-845 Suction Device

Removal Procedure
1. Remove the camshafts. Refer to Camshaft Replacement.
Fig. 112: Valve Lifters


NOTE:
Mark the assignments.
2. Remove the 16 valve lifters (1), using the EN-845 suction device.

NOTE:
Observe the correct assignment.
NOTE:
Coat the sliding surfaces with NEW engine oil.
1. Install the 16 valve lifters (1), using the EN-845 suction device.
2. Install the camshafts. Refer to Camshaft Replacement.

CYLINDER HEAD REPLACEMENT

Special Tools

EN-6340 Camshaft Adjuster Locking Tool
EN-6628-A Camshaft Locking Tool

Removal Procedure
Connection .
5. Drain the engine oil. Refer to Engine Oil and Oil Filter Replacement.
6. Remove the intake manifold. Refer to Intake Manifold Replacement.


9. Remove the heater outlet hose from the engine coolant thermostat housing. Refer to Heater Outlet Hose
Replacement (1.8L LUW) , Heater Outlet Hose Replacement (1.8L LWE) .
10. Remove the heater inlet hose from the engine coolant thermostat housing. Refer to Heater Inlet Hose

Fig. 115: Thermostat Housing Bracket, Bolts And Wiring Harness

11.
12.
13.
14.
Disconnect the thermostat wiring harness plug (1).

Remove the thermostat housing bracket nut (3).
Hang the thermostat housing bracket (2) with attached wiring harness aside.
Remove the exhaust manifold. Refer to Exhaust Manifold Replacement .


15.
16.
17.
18.
19.
Remove the 2 timing belt upper front cover bolts (2).

Remove the timing belt upper front cover (1).
Remove the 2 camshaft position sensor. Refer to Camshaft Position Sensor Replacement .
Remove the 2 camshaft position actuator solenoid valve. Refer to Camshaft Position Actuator Solenoid
Valve Replacement.


21. Set the crankshaft balancer in direction of engine rotation until the markings (1) line up with the cylinder
1 at TDC.


23.
24.
25.
26.
Remove the 4 lower timing belt cover bolts (2).

Remove the lower timing belt cover (1).
Lower the vehicle.
Support the engine under the oil pan.


27. Remove the engine mount nut (3).
28. Remove the 5 engine mount bolts (1, 2).
29. Remove the engine mount (4).


30. Remove the 3 engine mount bracket bolts (1).

Fig. 121: View Of Toothed Belt Cover

32. Remove the center front timing belt cover from the rear timing belt cover at 2 locations.
33. Remove the center front timing belt cover (1).

Fig. 122: Spot Type Markings And Special Tool

NOTE:
Install the EN-6340 locking tool - left (1) in the camshaft adjusters as shown.
NOTE:
Install EN-6340 locking tool - right (2) in the camshaft adjusters as shown.

35. Apply tension to the timing belt tensioner (2) in the direction of the arrow, using an allen key (1).
36. Install the EN-6333 pin (3).


NOTE:
37.
38.
39.
40.
Remove the timing belt (1).

Remove and DISCARD the timing belt tensioner bolt (3).
Remove the timing belt tensioner (2).
Raise the vehicle.


41. Remove the timing belt idler pulley bolt (1).
43. Remove the EN-6625 locking device.

Fig. 126: Turning Crankshaft Against Direction Of Engine Rotation

44. Set the crankshaft in direction of engine rotation to 60 degrees (a) before TDC. Use the EN-45059 meter
and the crankshaft balancer bolt.

Fig. 127: Crankshaft Sprocket

NOTE:
Some engine oil will run out of the camshaft and the camshaft position
actuator adjuster. That is the reason for the removal of the whole timing
assembly.
45. Remove the crankshaft sprocket (1).


Fig. 128: Aligning Camshafts Horizontally

NOTE:
Note the arrows.
48. Turn the camshaft by the camshaft position actuator adjuster until the groove on the end of the camshafts
is horizontal.


49. Install the EN-6628-A locking tool (1).
50. Place a collecting basin underneath the vehicle.

Fig. 130: Camshaft Position Actuator Adjuster Closure Bolt

51. Remove the camshaft position actuator adjuster closure bolt (1) of the intake camshaft position actuator
adjuster and the exhaust camshaft position actuator adjuster (3).
NOTE:
NOTE:
Use an appropriate open-end wrench in order to counterhold the camshaft

hexagon. A thin cross-section wrench is required for a better fit. The
usage of EN-6628-A locking tool is for the camshaft adjustment to prevent
misalignment of the camshafts. The wrench is required to counterhold the
camshafts during bolt torque procedure.
52. Remove and DISCARD the intake camshaft position actuator adjuster bolt and/or the exhaust camshaft
position actuator adjuster bolt (2).

53. Remove the intake camshaft position actuator adjuster and the exhaust camshaft position actuator adjuster
(3).
54. Remove the timing belt rear cover. Refer to Timing Belt Rear Cover Removal.

55. Loosen the 10 cylinder head bolts in sequence as shown.
1. Loosen the 10 bolts 90 degrees.
2. Loosen the 10 bolts 180 degrees.

Fig. 132: Cylinder Head And Bolts

56.
57.
58.
59.
60.
61.
62.
63.
Remove and DISCARD the 10 cylinder head bolts (1).

Remove the cylinder head (2).
Remove and DISCARD the cylinder head gasket (3).
In case of re-use, then clean and inspect the cylinder head. Refer to Cylinder Head Cleaning and
Inspection.
Remove the thermostat housing. Refer to Engine Coolant Thermostat Housing Removal.
Remove the camshafts. Refer to Camshaft Removal.
Remove the valve lifter. Refer to Valve Lifter Removal.
Disassemble the cylinder head. Refer to Cylinder Head Disassemble.
1. Assemble the cylinder head. Refer to Cylinder Head Assemble.

2.
3.
4.
5.
6.
Install the valve lifter. Refer to Valve Lifter Installation.

Install the camshafts. Refer to Camshaft Installation.
Install the thermostat housing. Refer to Engine Coolant Thermostat Housing Installation.
Clean the sealing surfaces.
Inspect for plane surface.
Cylinder block, cylinder head
Straight-edge, feeler gauge
Fig. 133: Cylinder Head And Bolts

7. Install a NEW cylinder head gasket (3).


9. Install 10 NEW cylinder head bolts (1).

10. Tighten the bolts as shown in sequence in 5 passes, using the EN-45059 meter :
1. First pass to 25 (18 lb ft)
2. Second pass to 90 degrees
3. Third pass to 90 degrees
4. Fourth pass to 90 degrees

5. Final pass to 45 degrees

11. Install the timing belt rear cover. Refer to Timing Belt Rear Cover Installation.

12. Align the camshafts horizontally by the hexagon arrows, until the EN-6628-A locking tool can be
inserted in both camshafts.


13. Insert the EN-6628-A locking tool (1) into the camshafts.


NOTE:
If the cover is contaminated with oil, you have to clean it close.
NOTE:
A second person is required. Counterhold against the hexagon of

corresponding camshaft with an open-ended wrench.
14. Install intake camshaft position actuator adjuster and/or the exhaust camshaft position actuator adjuster
(3).
15. Install a NEW intake camshaft position actuator adjuster bolt and/or a NEW exhaust camshaft position
actuator adjuster bolt (2).


16. Install the EN-6340 locking tool into the camshaft position actuator adjusters.
NOTE:
The spot type marking (4) on the intake camshaft position actuator
adjuster does not correspond to the groove of EN-6340 locking tool left during this process but must be somewhat above as shown.
1. Install the EN-6340 locking tool - left (1) in the camshaft position actuator adjusters as shown.
NOTE:
The spot type marking (3) on the exhaust camshaft position actuator
adjuster must correspond to the groove on EN-6340 locking tool right.
2. Install the EN-6340 locking tool - right (2) in the camshaft position actuator adjusters as shown.

NOTE:
NOTE:
NOTE:

hexagon. A thin cross-section wrench is required for a better fit. The Use
of EN-6628-A locking tool is for the camshaft adjustment to prevent
17. Tighten the camshaft position actuator adjuster bolts (2) in three passes use the EN-45059 meter :
Hold at the appropriate camshaft hexagon.
1. First pass tighten to 50 (37 lb ft).
NOTE:
Check the closure bolt seal ring.
18. Install the 2 camshaft position actuator adjuster closure plugs (1) and tighten to 30 (22 lb ft).
19. Remove the EN-6628-A locking tool.


NOTE:
When installing the crankshaft sprocket, the cam and the groove must
align (2).
20. Install the crankshaft sprocket (1).

NOTE:
The crankshaft sprocket and oil pump housing must align.
21. Set the crankshaft in the direction of engine rotation to TDC. Use the crankshaft balancer bolt.

Fig. 141: Timing Belt Tensioner

22. Install the timing belt tensioner (2) and tighten the NEW timing belt tensioner bolt (1) in three passes use
the EN-45059 meter :
3. Third pass to 15 degrees.


meter :


26. Place the timing belt on the exhaust and intake camshaft position actuator adjusters.

28. Remove the EN-6333 pin (3).
NOTE:



32. Install the 3 engine mount bracket bolts (1) tighten to 62 (46 lb ft).


33. Install the engine mount (4).
34. Install the 2 engine mount bolts (1) and tighten to 62 (46 lb ft).
35. Install the 3 engine mount bolts (2) and tighten in three passes use the EN-45059 meter.
36. Unsupport the engine.
37. Remove EN-6340 locking tool.


NOTE:
Turn the crankshaft 720 degrees in the direction of engine rotation by the bolt on the crankshaft
balancer.
NOTE:
Install EN-6340 locking tool - left (1) into the camshaft adjusters as shown.

NOTE:
Install EN-6340 locking tool - right (2) into the camshaft adjusters as shown.
Raise the vehicle.
NOTE:
39. Check the crankshaft position.


41. Install the 4 lower timing belt cover bolts (2) and tighten to 6 (53 lb in).
45. Install the camshaft position actuator solenoid valve. Refer to Camshaft Position Actuator Solenoid
Valve Replacement.

46. Install the 2 camshaft position sensors. Refer to Camshaft Position Sensor Replacement .

49. Install the 2 timing belt upper front cover bolts (2) and tighten to 6 (53 lb in).


(1).
52. Install the heater inlet hose to the engine coolant thermostat housing. Refer to Heater Inlet Hose
53. Install the heater outlet hose to the engine coolant thermostat housing. Refer to Heater Outlet Hose
Replacement (1.8L LUW) , Heater Outlet Hose Replacement (1.8L LWE) .

Fig. 152: Thermostat Housing Bracket, Bolts And Wiring Harness

54.
55.
56.
57.
58.
Install the engine coolant thermostat housing bracket (2).

Install the engine coolant thermostat housing bracket nut (3) and tighten to 6 (53 lb in).
Connect the thermostat wiring harness plug (1).
Install the intake manifold. Refer to Intake Manifold Replacement.
59. Fill engine oil. Refer to Engine Mechanical Specifications.
OIL PAN REPLACEMENT (MANUAL TRANSMISSION)

Removal Procedure
1.
2.
3.
4.
5.
Open the hood.

Place collecting basin underneath.
Remove the oil drain bolt.
Collect the engine oil.
6.
7.
8.
9.
10.
11.
12.
Install the NEW seal ring and the oil drain bolt, tighten to 14 N.m (124 lb in).
Lower the vehicle.
Remove the oil level indicator tube. Refer to Oil Level Indicator Tube Replacement.
Raise the vehicle.
Remove the engine oil heater. Refer to Engine Oil Heater Replacement.


13. Remove the 3 oil pan bolts (1, 2) from the transmission.

Fig. 154: Oil Pan And Bolts

NOTE:
Remove the oil pan evenly all the way around with a suitable tool.
14. Remove the 15 oil pan bolts (1) and remove the oil pan (2).

Fig. 155: Protecting Oil Screen From Damage

NOTE:
Use a screwdriver or another suitable tool.
15. To prevent damage to the oil screen, ensure that the oil screen (2) remains in the oil pan (3). If the oil
screen gets caught on the cylinder block (1), push it into the oil pan.
16. Remove the oil pan.

Fig. 156: View Of Joints For Sealant

2. Apply an approximately 3.5 mm (0.14 in) thick bead of oil pan sealant to the joints (arrows).

Fig. 157: Sealant Application Area

NOTE:
The assembly time including torque check must take no longer than 10
minutes.
3. Apply an approximately 3.5 mm (0.14 in) thick bead of oil pan sealant (1) as illustrated.


4. Install the 15 oil pan bolts (1) to the oil pan (2) and tighten to 10 N.m (89 lb in).


5.
6.
7.
8.
9.
10.
Install the 3 oil pan bolts (1, 2) to the transmission and tighten to 40 N.m (30 lb ft).
Install the exhaust front pipe. Refer to Exhaust Front Pipe Replacement .
Install the engine oil heater. Refer to Engine Oil Heater Replacement.
Lower the vehicle.
Install the oil level indicator tube. Refer to Oil Level Indicator Tube Replacement.
NOTE:
Inspect the engine oil level and correct if necessary.
11. Refill the collected engine oil.

12. Close the hood.

OIL PAN REPLACEMENT (AUTOMATIC TRANSMISSION)

Removal Procedure
1.
2.
3.
4.
Place collecting basin underneath.
Collect the engine oil.
5.
6.
7.
8.
9.
10.
11.
Install the NEW seal ring and the oil drain bolt, tighten to 14 N.m (124 lb in).
Lower the vehicle.
Remove the oil level indicator tube. Refer to Oil Level Indicator Tube Replacement.
Raise the vehicle.
Remove the engine oil heater. Refer to Engine Oil Heater Replacement.


12. Remove the 2 oil pan bolts (1) from the transmission.


NOTE:
Remove the oil pan evenly all the way around with a suitable tool.
13. Remove the 15 oil pan bolts (1) and remove the oil pan (2).

Fig. 162: Protecting Oil Screen From Damage

NOTE:
Use a screwdriver or another suitable tool.
14. To prevent damage to the oil screen, ensure that the oil screen (2) remains in the oil pan (3). If the oil
screen gets caught on the cylinder block (1), push it into the oil pan.
15. Remove the oil pan.


2. Apply an approximately 3.5 mm (0.14 in) thick bead of oil pan sealant to the joints (arrows).


NOTE:
The assembly time including torque check must take no longer than 10
minutes.
3. Apply an approximately 3.5 mm (0.14 in) thick bead of oil pan sealant (1) as illustrated.


4. Install the 15 oil pan bolts (1) to the oil pan (2) and tighten to 10 N.m (89 lb in).


5.
6.
7.
8.
9.
10.
Install the 2 oil pan bolts (1) to the transmission and tighten to 58 N.m (43 lb ft).
Install the exhaust front pipe. Refer to Exhaust Front Pipe Replacement .
Install the engine oil heater. Refer to Engine Oil Heater Replacement.
Lower the vehicle.
Install the oil level indicator tube. Refer to Oil Level Indicator Tube Replacement.
NOTE:
Inspect the engine oil level and correct if necessary.
11. Refill the collected engine oil.

AUTOMATIC TRANSMISSION FLEX PLATE REPLACEMENT

Special Tools
EN-652 Automatic Transmission Flex Plate Holder

Removal Procedure
1. Remove the automatic transmission. Refer to Transmission Replacement .
Fig. 167: Automatic Transmission Flex Plate And Holder

2. Install the EN-652 holder (1) to hold the automatic transmission flex plate (2).
3. Loosen the 6 automatic transmission flex plate bolts.
4. Remove the EN-652 holder (1).


5. Remove the 6 automatic transmission flex plate bolts (2).
1. Clean the automatic transmission flex plate bolt threads.


2. Install the automatic transmission flex plate (2) and the EN-652 holder to hold the automatic transmission
flex plate (2).


3. Install the 6 NEW automatic transmission flex plate bolts (2) and tighten the bolts to 60 N.m (44 lb ft)
5.
4. Remove the EN-652 holder.
5. Install the automatic transmission. Refer to Transmission Replacement .
ENGINE FLYWHEEL REPLACEMENT

Removal Procedure
1. Remove the manual transmission. Refer to Transmission Replacement .

2. Remove the clutch pressure and driven plate. Refer to Clutch Pressure and Driven Plate Replacement
(1.8L LUW and LWE) .
3. Remove the engine flywheel. Refer to Engine Flywheel Removal.
1. Install the engine flywheel. Refer to Engine Flywheel Installation

2. Install the clutch pressure and driven plate. Refer to Clutch Pressure and Driven Plate Replacement
3. Install the manual transmission. Refer to Transmission Replacement .
CRANKSHAFT BALANCER REPLACEMENT (AUTOMATIC TRANSMISSION)
Special Tools


Removal Procedure
3. Remove the drive belt. Refer to Drive Belt Replacement.


4. Remove the bolt (1).


5. Install the EN-6625 locking device (2) to lock the crankshaft.
6. Install the bolt (1).




2. Install a NEW crankshaft balancer bolt (1) and tighten a first pass to 95 (70 lb ft).
3. Tighten the NEW crankshaft balancer bolt a second pass to an additional 45 degrees, using the EN-45059
meter.
4. Tighten the NEW crankshaft balancer bolt a final pass to an additional 15 degrees, using the EN-45059

meter.

5. Remove the bolt (1).
6. Remove EN-6625 locking device (2) to unlock the crankshaft.


7.
8.
9.
10.
Install the bolt (1) and tighten to 45 (33 lb ft).

Lower the vehicle.
CRANKSHAFT BALANCER REPLACEMENT (MANUAL TRANSMISSION)

Special Tools


Removal Procedure
1.
2.
3.
4.
Remove the drive belt. Refer to Drive Belt Replacement.
Remove the transmission front mount. Refer to Transmission Front Mount Replacement .

5. Remove the bolted connection (1).

Fig. 178: Locking Device

6. Install the EN-6625 locking device (2) to lock the crankshaft.
7. Install the bolted connection (1).




2. Install a NEW crankshaft balancer bolt (1) and tighten a first pass to 95 (70 lb ft).
3. Tighten the NEW crankshaft balancer bolt a second pass to an additional 45 degrees, using the EN-45059
meter.
4. Tighten the NEW crankshaft balancer bolt a final pass to an additional 15 degrees, using the EN-45059

meter.
Fig. 181: Locking Device

5. Remove the bolted connection (1).
6. Remove EN-6625 locking device (2) to unlock the crankshaft.


7.
8.
9.
10.
11.
Install the bolted connection (1) and tighten to 40 (30 lb ft).

Install the transmission front mount. Refer to Transmission Front Mount Replacement .
Lower the vehicle.
CRANKSHAFT FRONT OIL SEAL REPLACEMENT

IMPORTANT: Special Tools
EN-6351 Mounting Sleeves

EN-45000 Remover


Removal Procedure
1. Replace the timing belt. Refer to Timing Belt Replacement.


Fig. 184: Crankshaft Front Oil Seal Removal Tool

CAUTION: Clean the crankshaft sealing surface with a clean, lint-free towel.
Inspect lead-in edge of crankshaft for burrs/sharp edges that could
damage the rear main oil seal. Remove burrs/sharp edges with
crocus cloth before proceeding.
3. Using the EN-45000 remover (3), remove the crankshaft front oil seal (1) from the crankshaft (2).

Fig. 185: Crankshaft And Crankshaft Front Oil Seal

2. Slide the EN-6351 mounting sleeves (2) protective sleeve onto the crankshaft journal.
3. Slide the crankshaft front oil seal (1) over the protective sleeve on the crankshaft journal.

Fig. 186: Crankshaft Drive Gear Bolt, Washer And Sleeves

4. Remove the protective sleeve, and using the EN-6351 mounting sleeves (3), press the seal ring into the
pump housing.
5. Use the crankshaft drive gear bolt (1) and washer (2) to press in the crankshaft front oil seal.


NOTE:
align (2).

CRANKSHAFT REAR OIL SEAL REPLACEMENT
Special Tools
EN-235-6 Installer
EN-328-B Pin Remover
EN-658-1 Installer

EN-6624 Remover

Removal Procedure
1. For vehicle with automatic transmission: remove the automatic transmission flex plate. Refer to
Automatic Transmission Flex Plate Replacement.
2. For vehicle with manual transmission: remove the engine flywheel. Refer to Engine Flywheel
Replacement.
Fig. 188: Crankshaft Position Sensor And Bolt


5. Remove the crankshaft position sensor (3) from the crankshaft rear oil seal housing (1).
Fig. 189: Crankshaft Position Sensor Reluctor Ring And Oil Seal Housing
CAUTION: Do not allow the crankshaft encoder wheel to come into contact with
external magnetic fields or sharp metal objects. Do not drop the
crankshaft encoder wheel. Do not damage the rubberized encoder
track. Failure to follow these precautions may cause damage to the
component.
6. Remove the crankshaft rear oil seal housing (1).
7. Remove the crankshaft position sensor reluctor ring (2).

Fig. 190: Holes At 5 O'clock And 7 O'clock Positions

NOTE:
The diameter of the hole must not exceed 2 mm (0.0787 in). If the diameter
of the hole exceeds 2 mm (0.0787 in), the bolt of EN-6624 remover will not
be able to grip.
8. Only make a hole at the 5 o'clock and 7 o'clock positions (1), these are the only positions where is a
cavity behind the seal ring.

Fig. 191: Scribe Tool

9. Using a suitable tool, such as a scribe (1), make a hole in the crankshaft rear oil seal.
Position the scribe (1) at the outer edge of the crankshaft rear oil seal.
10. Remove the seal ring.

Fig. 192: crankshaft Rear Oil Seal Removal Tool

11. Install EN-6624 remover (1) to the crankshaft rear oil seal and tighten the bolt.

Fig. 193: Special Removal Tools

12. Install the EN-328-B remover (1) to EN-6624 remover (2) and remove the crankshaft rear oil seal.







Fig. 197: Check Crankshaft Rear Oil Seal For Proper Seat
4. Check the crankshaft rear oil seal for proper seat, the EN-658-1 installer must be flush with the cylinder
block at the position (1).

5. Install the crankshaft position sensor reluctor ring (2).
component.
6. Install the crankshaft rear oil seal housing (1).


7. Install the crankshaft position sensor (3) to the crankshaft rear oil seal housing (1).
8. Install the crankshaft position sensor bolt (2) and tighten to 4.5 N.m (40 lb in).
10. For vehicle with manual transmission: install the engine flywheel. Refer to Engine Flywheel
Replacement.
11. For vehicle with automatic transmission: install the automatic transmission flex plate. Refer to Automatic
Transmission Flex Plate Replacement.
POSITIVE CRANKCASE VENTILATION HOSE/PIPE/TUBE REPLACEMENT

Removal Procedure
1. Open the hood.
Fig. 200: Positive Crankcase Ventilation Tube, Connectors And ECM Wiring Harness Guide
2. Unclip the ECM wiring harness guide (3) from the cylinder head cover.
3. Disconnect the 2 positive crankcase ventilation tube connectors (1).
4. Remove the positive crankcase ventilation tube (2).

1.
2.
3.
4.
Install the positive crankcase ventilation tube (2).

Connect the 2 positive crankcase ventilation tube connectors (1).
Clip in the ECM wiring harness guide (3) to the cylinder head cover.
Close the hood.
ENGINE OIL HEATER REPLACEMENT

Fig. 202: Engine Oil Heater And Bolt

Engine Oil Heater Replacement
Callout
Component Name
WARNING:
While engine is operating, the exhaust system will become extremely hot. To prevent burns avoid
contacting a hot exhaust system.
Preliminary Procedures Disconnect the battery negative cable. Refer to Battery Negative Cable
CAUTION:
Tighten
40 N.m (30 lb ft)
Engine Oil Heater
Procedure
Disconnect the wiring harness plug.
ENGINE FRONT COVER WITH OIL PUMP REPLACEMENT

Removal Procedure
1. Open the hood.

Connection .
5. Remove the air conditioning compressor. Refer to Air Conditioning Compressor Replacement (1.8L
LUW and LWE) .
6. Remove the generator. Refer to Generator Replacement (1.8L LUW and LWE) .
7. Remove the timing belt rear cover. Refer to Timing Belt Rear Cover Replacement.
8. Remove the oil pan. Refer to Oil Pan Replacement (Manual Transmission), Oil Pan Replacement
(Automatic Transmission).
9. Remove the radiator outlet hose from the water pump. Refer to Radiator Outlet Hose Replacement

Fig. 203: Engine Oil Cooler Outlet Pipe And Bolts

10.
11.
12.
13.
Remove the engine oil cooler inlet pipe bolt (4).

Push the engine oil cooler inlet pipe (1) into the engine oil cooler housing (2).
Remove the 2 engine oil cooler outlet pipe bolts (5) from the water pump.
Push the engine oil cooler outlet pipe (3) into the engine oil cooler housing (2).

Fig. 204: Engine Front Cover, Seal And Bolts

14. Remove the 8 engine front cover bolts (2, 3).
15. Remove the engine front cover (4).
16. Remove the engine front cover seal (1).

Fig. 205: Engine Front Cover, Seal And Bolts

2. Install a NEW engine front cover seal (1).
4. Install the 8 engine front cover bolts (2, 3) and tighten to 20 N.m (15 lb ft).

Fig. 206: Engine Oil Cooler Outlet Pipe And Bolts

5.
6.
7.
8.
9.
10.
11.
12.
13.
Push the engine oil cooler outlet pipe (3) to the water pump (6).
Install the engine oil cooler outlet pipe bolts (5) and tighten to 8 N.m (71 lb in).
Push the engine oil cooler inlet pipe (1) into the water pump (6).
Install the engine oil cooler inlet pipe bolt (4) and tighten to 8 N.m (71 lb in).
Install the radiator outlet hose to the water pump. Refer to Radiator Outlet Hose Replacement (1.8L
LUW and LWE) .
Install the oil pan. Refer to Oil Pan Replacement (Manual Transmission), Oil Pan Replacement
Install the timing belt rear cover. Refer to Timing Belt Rear Cover Replacement.
Install the generator. Refer to Generator Replacement (1.8L LUW and LWE) .
Install the air conditioning compressor. Refer to Air Conditioning Compressor Replacement (1.8L
LUW and LWE) .


17. Close the hood.
OIL PRESSURE RELIEF VALVE REPLACEMENT
Removal Procedure
1. Remove the oil pan. Refer to Oil Pan Replacement (Manual Transmission), Oil Pan Replacement
Fig. 207: Oil Pressure Relief Valve Assembly


2. Remove the oil pressure relief valve closure bolt (1).

3. Remove the oil pressure relief valve assembly (2).
4. Remove the piston (3) and the spring (4).
WARNING: Bodily injury may occur if the cleaning solvent is inhaled or exposed
to the skin.
WARNING: To avoid eye injury, use approved safety lenses, goggles, or face
shield when using buffing and cleaning equipment.
5. Clean the parts.
6. Inspect the parts.

Fig. 208: Oil Pressure Relief Valve Assembly

1. Install the piston (3) and the spring (4).
2. Install the oil pressure relief valve assembly (2).
3. Install the oil pressure relief valve closure bolt (1) and tighten to 21 N.m (16 lb ft).
4. Install the oil pan. Refer to Oil Pan Replacement (Manual Transmission), Oil Pan Replacement
ENGINE OIL COOLER HOUSING REPLACEMENT
Refer to Engine Oil Cooler Replacement (1.8L LUW and LWE) , it is the same procedure.

OIL FLOW CHECK VALVE REPLACEMENT
Fig. 209: Oil Flow Check Valve

Oil Flow Check Valve Replacement
Callout
Component Name
Remove the generator. Refer to Generator Replacement (1.8L LUW and LWE) .
Oil Flow Check Valve Bore Plug
CAUTION:
Tighten
21 N.m (16 lb ft)
Oil Flow Check Valve
OIL LEVEL INDICATOR TUBE REPLACEMENT

Removal Procedure
1. Open the hood.


NOTE:
If the engine oil level is at maximum, some oil may emerge when drawing
out the oil dipstick guide tube.
3. Place collecting basin underneath.
Fig. 210: Oil Level Indicator Tube And Bolt

4. Remove the oil level indicator tube bolt (1).
5. Remove the oil level indicator tube (2) and the oil level indicator seal.


1. Install the oil level indicator tube (2).
2. Install a NEW oil level indicator tube gasket.
3. Install the oil level indicator tube bolt (1) and tighten to 15 N.m (11 lb ft).
4. Install the oil dipstick.
5. Close the hood.
ENGINE REPLACEMENT
Removal Procedure

1. Disconnect the negative battery cable from the battery. Refer to Battery Negative Cable Disconnection
and Connection .
2. Drain the engine cooling system. Refer to Cooling System Draining and Filling (Static Fill) , Cooling
3. Recover the air conditioning refrigerant. Refer to Refrigerant Recovery and Recharging .
Fig. 212: Air Cleaner Assembly, Electrical Connector And Clamp

5. Loosen the clamp (2) and remove air cleaner from air cleaner assembly (3).

Fig. 213: Air Cleaner Outlet Duct And Clamp

6. Loosen the clamp (1) and remove the outlet duct (2).
7. Remove the charge air cooler inlet air hose. Refer to Charge Air Cooler Inlet Air Hose Replacement .
8. Remove the charge air cooler outlet air hose. Refer to Charge Air Cooler Outlet Air Hose
Replacement (Automatic Transmission) , Charge Air Cooler Outlet Air Hose Replacement (Manual
Transmission) .


9. Remove refrigerant hose nut (1) from refrigerant hose (2).


10. Disconnect the fuel feed line (1) and reposition away from the engine. Refer to Fuel Pressure Relief .


11. Disconnect the EVAP hose (1). Refer to Plastic Collar Quick Connect Fitting Service .


12. Disconnect the power brake booster vacuum pipe (1).


13. Reposition the hose clamp (1) and remove the radiator surge tank outlet hose.


14. Disconnect inlet (2) and outlet (1) heater core hoses.

15. On vehicles equipped with a automatic transmission, disconnect the transmission range selector lever
cable terminal (1) from the transmission manual shift lever pin.
16. On vehicles equipped with a automatic transmission, press the locking tabs inward in order to release the
transmission range selector lever cable (2) from the cable bracket.

17. On vehicles equipped with a manual transmission, using a suitable pry tool, disconnect the shift lever
cables (2) from the shift levers (3)
18. On vehicles equipped with a manual transmission, remove the shift lever cables (2) from the cable bracket
(1).

Fig. 222: Ground Strap And Bolt

19. Remove the ground strap bolt (1) from the battery cable and reposition the strap (2) a side.


21. Remove the ground nuts (1) and put the wiring harness (2) aside.
22. Disconnect the electrical connectors from the engine control module (ECM). Refer to Engine Control
Module Replacement .
23. Disconnect the wiring harness from the accessory wiring junction block.


24. Disconnect the wiring harness from the junction connector (1).
25. Place the ECM, transmission and the accessory wiring junction block wiring harnesses on the top of
engine assembly.
26. Install the engine support fixture.


27. Remove and DISCARD the lower steering intermediate shaft bolt (1).

NOTE:
Do Not disconnect the brake hoses from the calipers.
28. Remove the front brake calipers (1) and caliper bolts (2) from the caliper brackets, and then suspend the
calipers with mechanics wire to the body.
29. Remove the exhaust system. Refer to Exhaust System Replacement .


30. Remove and DISCARD the stabilizer link nut (1) from the strut assemblies. Refer to Stabilizer Shaft
Link Replacement .
31. Disconnect the right wheel drive shaft from the intermediate shaft.
32. Disconnect the front steering knuckles from the strut assemblies. Refer to Steering Knuckle
Replacement .
33. Disconnect the electronic power steering connectors from the electronic power steering assembly. Refer
to FEP Connectors (Steering Gear) .


34. Remove the rear transmission mount bracket to rear mount through bolt (1).


35. Remove the transmission front mount through bolt (1).
36. Using suitable straps or chains, secure the front of vehicle to the hoist arms.
NOTE:
aid in the removal of the engine and transmission mount bolts.
37. Use the engine support fixture to slightly raise the powertrain assembly to aid in the removal of the
engine and transmission mount bolts.


38. Remove and DISCARD the left transmission mount to bracket bolts (1).

Fig. 231: Engine Mount Bracket Bolts And Washers

39. Remove the engine mount to engine mount bracket bolts (1) and the washers (2).
40. Using a suitable engine support table, lower the vehicle until the drivetrain and front suspension frame
contacts the engine support table.
41. Position blocks of wood below the oil pan and transmission to stabilize the powertrain on the support
table.
42. Using the engine support fixture, lower the powertrain down until it is resting on the engine support table.

43. Remove the power steering gear inlet and outlet hose bolts (1). Remove the inlet and outlet hose (2) from
the steering gear (3).
44. Remove the engine support fixture.
45. Remove the drivetrain and front suspension frame reinforcements from the rear of the frame.
46. Remove the front drivetrain and front suspension frame retaining bolts.
47. Slowly and carefully raise the vehicle, ensure the engine, transmission, radiator assembly and drivetrain
48. Separate the transmission from the engine assembly.
49. Disconnect engine coolant hoses as necessary.
50. Disconnect electrical connectors as necessary.

1. Position the engine to the transmission assembly.

2. Position the engine, transmission, radiator assembly and drivetrain suspension frame under the vehicle.
3. Slowly and carefully lower the vehicle, ensure the engine, transmission, radiator assembly and drivetrain
4. Install the four front drivetrain and front suspension frame retaining bolts, then tighten to the fasteners to
160 N.m (118 lb ft).
5. Install the drivetrain and front suspension frame reinforcements to the rear of the frame, then tighten the
reinforcement fasteners to 22 N.m (16 lb ft).
NOTE:
aid in the installation of the engine and transmission mount bolts.
6. Install the engine support fixture. Refer to Engine Support Fixture .


7. Install the transmission bracket mount to mount through bolt (1) and tighten to 100 N.m (74 lb ft).


8. Install the transmission mount through bolt (1) and tighten to 58 N.m (43 lb ft).
9. Install the engine mount. Refer to Engine Mount Replacement - Right Side .


10. Install the NEW left transmission mount to transmission bolts (1) and tighten to 50 N.m (37 lb ft) plus 6075 degrees.

11. Install the inlet and outlet hose (2) to the steering gear (3).
12. Install power steering gear inlet and outlet hose bolts (1) and tighten to 11 N.m (97 lb in).


13. Instal NEW the lower steering intermediate shaft (1) bolt and tighten to 34 N.m (25 lb ft).
14. Connect the front steering knuckles to the strut assemblies. Refer to Steering Knuckle Replacement .


15. Install NEW the stabilizer link nut (1) to the strut assemblies. Refer to Stabilizer Shaft Link
Replacement .
16. Connect the right wheel drive shaft from the intermediate shaft.

17.
18.
19.
20.
21.
22.
23.
Install the front brake caliper (1) and tighten the brake caliper guide pin bolt (2) to 28 N.m (21 lb ft).
Install the exhaust system. Refer to Exhaust System Replacement .
Connect the wheel speed connectors to the steering knuckles.
Remove the engine support fixture.
Connect the wiring connectors and ground strap to the transmission.
Connect the wiring harness to the accessory wiring junction block.
Connect the electrical connectors to the ECM. Refer to Engine Control Module Replacement .


24. Install the wiring harnesses (2).
25. Install the ground nuts (1) and tighten to 9 N.m (80 lb in).


26. Connect the wiring harness plugs (1).

27. On vehicles equipped with a automatic transmission, connect the transmission range selector lever cable
terminal (1) to the transmission manual shift lever pin.
28. On vehicles equipped with a automatic transmission, press the locking tabs outward in order to lock the
transmission range selector lever cable (2) to the cable bracket.

29. On vehicles equipped with a manual transmission, connect the shift lever cables (2) to the shift levers (3)
30. On vehicles equipped with a manual transmission, install the shift lever cables (2) to the cable bracket (1).
31. Install the battery tray. Refer to Battery Tray Replacement .


32. Connect inlet (2) and outlet (1) heater core hoses.


33. Connect the power brake booster vacuum pipe (1).


34. Connect the coolant hose and reposition the clamp (1).


35. Connect the fuel feed line (1) and reposition away from the engine. Refer to Fuel Pressure Relief .


36. Connect the EVAP hose (1). Refer to Plastic Collar Quick Connect Fitting Service .


NOTE:
Use NEW O-ring seals. Refer to Air Conditioning O-Ring Seal

Replacement .
37. Install refrigerant hose (2) and tighten the nut (1) to 19 N.m (14 lb ft).
38. Install the charge air cooler inlet air hose. Refer to Charge Air Cooler Inlet Air Hose Replacement .
39. Install the charge air cooler outlet air hose. Refer to Charge Air Cooler Outlet Air Hose Replacement
(Automatic Transmission) , Charge Air Cooler Outlet Air Hose Replacement (Manual
Transmission) .
40. Connect engine coolant hoses as necessary.
41. Connect electrical connectors as necessary.
42. Install the front fascia.
43. Install the front wheelhouse front liners.
45. Fill the engine cooling system. Refer to Cooling System Draining and Filling (Static Fill) , Cooling


46. Charge the air conditioning system. Refer to Refrigerant Recovery and Recharging .
47. Check engine oil level. Refer to Engine Oil and Oil Filter Replacement .
48. Connect the negative battery cable to the battery. Refer to Battery Negative Cable Disconnection and
Connection .
ENGINE OIL AND OIL FILTER REPLACEMENT
Removal Procedure
1. Open hood.
CAUTION: To prevent damage to oil filter cap ensure proper tool is used. Do not
use an open end wrench which may cause damage to filter cap.
3. Using a 24mm socket or closed end wrench loosen oil filter cap. Unscrew filter cap 3 turns and let oil
filter and cap assembly drain in housing for 30 seconds.

NOTE:
Use care when removing engine oil filter cap and filter to minimize fluid
spillage. If fluid spillage occurs it must be cleaned with appropriate
cleaner.
NOTE:
Inspect oil filter cap for any cracks or damage. If oil filter cap is damaged it
must be replaced.
4. Remove the engine oil filter cap (2) with the engine oil filter cap seal ring (3) and the oil filter element
(1).
6. Remove the oil pan drain plug and allow the oil to drain into the drain pan.
1. Clean the oil pan drain plug thread in the oil pan.

2. Install a NEW seal ring to the oil pan drain plug.

CAUTION: Refer to Component Fastener Tightening Caution .
3. Install the oil pan drain plug and tighten to 14 N.m (10 lb ft).

NOTE:
Clean oil filter cap and lubricate the NEW oil filter cap seal ring with clean
engine oil. Ensure oil filter cap seal ring is in proper position as shown.
5. Install a NEW oil filter cap seal ring (1).

6. Install the engine oil filter cap (2) with NEW engine oil filter cap seal ring (3) and NEW oil filter element
(1) hand tight.


CAUTION: Ensure oil filter cap is completely seated on oil filter housing. If not
completely seated an oil leak may occur.
CAUTION: Over torquing the oil filter cap may cause damage to the oil filter cap
resulting in an oil leak.
7. Using a 24mm socket or closed end wrench tighten the engine oil filter cap to 25 N.m (18 lb ft).
CAUTION: Using engine oils of any viscosity other than those viscosities
recommended could result in engine damage.
NOTE:
Do not overfill the engine with engine oil.
NOTE:
Anytime engine oil is added (top off or oil changes) ensure all engine
surfaces are completely free of residual oil. If there is oil on any engine
surface clean as necessary.
8. Fill engine with NEW oil using Dexos1 5W-30 specification.

Fig. 254: Proper Oil Filler Cap Seating

NOTE:
Oil fill cap must be properly seated and tightened during installation.
9. Install oil fill cap.

10. Start the engine and allow it to run until the oil pressure control indicator goes off. Inspect for any oil
leaks around the drain plug, oil filter and oil fill cap.


11. Inspect the engine oil level. The oil level should be in the cross-hatched section of the oil level indicator
as shown.
12. Close hood.
13. Reset the engine oil life system monitor.
CAMSHAFT SEAL REPLACEMENT
Special Tools
EN-422 Installer
EN-45000 Remover

Removal Procedure

Replacement.
Fig. 256: Camshaft Front Oil Seals And Tool

NOTE:
Do not damage the sealing surfaces.
2. Use the EN-45000 remover to loosen the camshaft front oil seals (1).

Fig. 257: Camshaft Front Oil Seals

3. Remove the camshaft front oil seals (1).

Fig. 258: Camshaft Front Oil Seals

1. Insert 2 NEW camshaft front oil seals (1).

Fig. 259: Camshaft Sprocket Bolt, Shims And Tool

2. Tighten the seal ring with EN-422 installer (3) on the camshaft until this is in contact with the cylinder
head.
3. To install, use camshaft sprocket bolt (1) in conjunction with shims (2) with a total thickness of
approximately 10 mm (0.393 in).
Replacement.
CAMSHAFT COVER REPLACEMENT
Removal Procedure

Fig. 260: Wiring Harness Guide And Cylinder Head Cover

3. Disconnect the wiring guide (2).
4. Remove the positive crankcase ventilation tube. Refer to Positive Crankcase Ventilation
Hose/Pipe/Tube Replacement.

Fig. 261: Camshaft Cover And Bolts

5. Remove the 11 bolts (2, 3).
6. Remove the camshaft cover (1).

Fig. 262: Camshaft Cover Bolt

1.
2.
3.
4.
Clean the bolt and the camshaft cover bolt (4) thread.
Apply sealant to the camshaft cover bolt (4). Refer to Adhesives, Fluids, Lubricants, and Sealers
Insert a NEW gasket in the cylinder head cover.
Install the camshaft cover (1).
5. Install the 11 bolts (2, 3, 4) and tighten to 8 N.m (71 lb in).

6. Install the positive crankcase ventilation tube. Refer to Positive Crankcase Ventilation Hose/Pipe/Tube
Replacement.

Fig. 263: Wiring Harness Guide And Cylinder Head Cover

7. Clip in the ECM wiring harness guide (1) to the cylinder head cover.
8. Connect the wiring guide (2).
9. Install the ignition coil. Refer to Ignition Coil Replacement .
CAMSHAFT POSITION ACTUATOR ADJUSTER REPLACEMENT
Special Tools


Removal Procedure
1. Remove the air cleaner housing. Refer to Air Cleaner Assembly Replacement (1.8L LWE) , Air

2.
3.
4.
5.
Remove the 2 timing belt upper front cover bolts (2).

Remove the timing belt upper front cover (1).
Remove the 2 camshaft position actuator solenoid valve. Refer to Camshaft Position Actuator Solenoid
Valve Replacement.
6. Remove the drive belt. Refer to Drive Belt Replacement.


8. Set the crankshaft balancer in direction of engine rotation until the markings (1) line up with the cylinder
1 at TDC.
10. Remove the EN-6625 locking device.



Fig. 267: View Of Front Panel And Bolts

NOTE:
The right half of the EN-6340 locking tool can be recognized by the
lettering "right", arrow, on the tool.
14. Prepare the right half of the EN-6340 locking tool.

1. Remove the 2 bolts (2).
2. Remove the front panel (1) from the EN-6340 locking tool - right.


NOTE:
Install the EN-6340 locking tool - left (1) into the camshaft adjusters as shown.
NOTE:

17. Install the EN-6333 pin (3).


18. Remove and DISCARD the timing belt idler pulley bolt (1).


NOTE:

21. Remove and DISCARD the timing belt tensioner bolt (3).




NOTE:
Some engine oil will run out of the camshaft and the camshaft position
actuator adjuster. That is the reason for the removal of the whole timing
assembly.



NOTE:
Note the arrows.
26. Turn the camshaft by the hexagon until the groove on the end of the camshafts is horizontal.


29. Place a collecting basin underneath the vehicle.


adjuster and/or the exhaust camshaft position actuator adjuster (3).
NOTE:
NOTE:


32. Remove the intake camshaft position actuator adjuster and/or the exhaust camshaft position actuator
adjuster (3).

NOTE:
(3).
actuator adjuster bolt (2). DO NOT tighten the bolts yet.


NOTE:
adjuster does not correspond to the groove of EN-6340-left locking
tool - left during this process but must be somewhat above as
shown.
1. Install the EN-6340-left locking tool (1) in the camshaft position actuator adjusters as shown.
NOTE:
adjuster must correspond to the groove on EN-6340-left locking tool right.
2. Install the EN-6340-right locking tool (2) in the camshaft position actuator adjusters as shown.


NOTE:
NOTE:



4. Tighten the camshaft position actuator adjuster bolts (2) in three passes use the EN-45059 meter :
NOTE:
5. Install the 2 camshaft position actuator adjuster closure plugs (1) and tighten to 30 N.m (22 lb ft).


8. Install the timing belt tensioner (2) and tighten the NEW timing belt tensioner bolt (1) in three passes use
the EN-45059 meter :


meter :

NOTE:
align (2).

11. Set the crankshaft in the direction of engine rotation to TDC. Use the crankshaft balancer bolt.


14. Place the timing belt on the exhaust and intake camshaft position actuator adjusters.

16. Remove the EN-6333 pin (3).
NOTE:

18. Check position of the camshaft and camshaft position actuator adjuster.
1. Turn crankshaft 720 degrees in the direction of engine rotation by the crankshaft balancer bolt.
NOTE:
Note marking, camshaft position actuator adjuster.
2. Insert EN-6340 locking tool into camshaft position actuator adjuster.


20. Align camshafts by hexagon until EN-6628-A locking tool can be inserted in both camshafts.

NOTE:



23. Install the lower front timing belt cover (1) and tighten the 4 bolts (2) to 6 N.m (53 lb in).
25. Install the drive belt tensioner. Refer to Drive Belt Tensioner Replacement.
26. Install the drive belt. Refer to Drive Belt Replacement.
28. Install the camshaft position actuator solenoid valve. Refer to Camshaft Position Actuator Solenoid
Valve Replacement.


31. Install the 2 timing belt upper front cover bolts (2) and tighten to 6 N.m (53 lb in).
32. Install the air cleaner housing. Refer to Air Cleaner Assembly Replacement (1.8L LWE) , Air Cleaner
Assembly Replacement (1.8L LUW) .
CAMSHAFT POSITION ACTUATOR SOLENOID VALVE REPLACEMENT

Fig. 290: Camshaft Position Actuator Solenoid Valve

Camshaft Position Actuator Solenoid Valve Replacement
Callout
Component Name
Camshaft Position Actuator Solenoid Valve Bolt (Qty: 2)
2
3
CAMSHAFT REPLACEMENT
Special Tools
EN-422 Installer
EN-6628-A Locking Tool
CAUTION:
Tighten
6 N.m (53 lb in)
Camshaft Position Actuator Solenoid Valve (Qty: 2)
Camshaft Position Actuator Solenoid Valve Seal (Qty: 2)
TIP: Coat the camshaft position actuator solenoid valve seals with
NEW engine oil.


Removal Procedure
1.
2.
3.
4.
5.
Remove the camshaft adjuster. Refer to Camshaft Position Actuator Adjuster Replacement.
Remove the rear timing belt cover. Refer to Timing Belt Rear Cover Replacement.
Remove intake camshaft position sensor. Refer to Camshaft Position Sensor Replacement .
Remove exhaust camshaft position sensor. Refer to Camshaft Position Sensor Replacement .
Remove EN-6628-A locking tool.
Counterhold at hexagon of camshaft.
Fig. 291: Camshaft Bearing Cap And Camshaft Bearing Cap Bolts Removal Sequence
NOTE:
Note removal sequence 1-4.

6. Remove the 4 camshaft bearing cap bolts.

NOTE:
Release the bearing support by striking it gently with a plastic hammer.
7. Remove the first camshaft bearing cap (1).
Fig. 292: Exhaust Camshaft Bearing Cap Bolts Loosening Sequence

8. Loosen the 8 exhaust camshaft bearing cap bolts working from outside to inside in a spiral in steps of 1/2
up to 1 turn.
9. Remove the 8 exhaust camshaft bearing cap bolts.
NOTE:
Mark camshaft bearing caps before removal.
10. Remove the 4 exhaust camshaft bearing caps Numbers 6-9 from the cylinder head.

Fig. 293: Intake Camshaft Bearing Cap Bolts Loosening Sequence

12. Loosen the 8 intake camshaft bearing cap bolts working from outside to inside in a spiral in steps of 1/2
up to 1 turn.
13. Remove the 8 intake camshaft bearing cap bolts.
NOTE:
14. Remove the 4 intake camshaft bearing caps Numbers 2-5 from the cylinder head.
16. Detach the seal rings from the camshafts.

Fig. 294: Intake Camshaft Bearing Cover Bolts Tightening Sequence

NOTE:
Lubricate with clean engine oil.
1. Install the intake camshaft (1).

NOTE:
Note the identification marking on the camshaft bearing cover.
2. Install the 4 intake camshaft bearing cover Numbers 2-5.

3. Install the 8 intake camshaft bearing cover bolts and tighten in a spiral from the inside to the outside to 8
N.m (71 lb in).

Fig. 295: Exhaust Camshaft Bearing Cover Bolts Tightening Sequence

NOTE:
Lubricate with clean engine oil.
4. Install the exhaust camshaft (1).

NOTE:
5. Install the 4 exhaust camshaft bearing cover Numbers 6-9.

6. Install the 8 exhaust camshaft bearing cover bolts and tighten in a spiral from the inside to the outside to 8
N.m (71 lb in).

Fig. 296: View Of Oil Duct

NOTE:
Sealing surfaces must be free from oil and grease.
7. Clean sealing surfaces of the first camshaft bearing support and the cylinder head with a suitable tool.
Clean oil duct from any sealant residue.

Fig. 297: View Of Sealing Surfaces And Grooves

NOTE:

It is essential to ensure that no sealant is applied outside the marked
sealing areas.
The grooves adjacent to the sealing surfaces must remain free from
sealant.
8. Apply surface sealant to sealing surfaces (1) of the first camshaft bearing cap thinly and evenly.
9. Position the first camshaft bearing cap on the cylinder block and tighten the bolts approximately to 2 N.m
(18 lb in).

Fig. 298: Camshaft Bearing Cap

NOTE:
No sealant may reach the camshafts.
10. Install the first camshaft bearing cap (1).

NOTE:
Note installation sequence 1-4.
11. Install the first camshaft bearing cap bolts and tighten to 8 N.m (71 lb in).


12. Install 2 NEW sealing rings to the camshafts.
head.
approximately 10 mm (0.394 in).
15. Remove the EN-422 installer (3).
16. Turn the intake camshaft against the direction of engine rotation.
17. Install EN-6628-A locking tool.
18. Turn the exhaust camshaft in the direction of rotation of the engine.
19. Install EN-6628-A locking tool.
20. Install exhaust camshaft position sensor. Refer to Camshaft Position Sensor Replacement .
21. Install intake camshaft position sensor. Refer to Camshaft Position Sensor Replacement .

22. Install the rear timing belt cover. Refer to Timing Belt Rear Cover Replacement.
23. Install the camshaft adjuster. Refer to Camshaft Position Actuator Adjuster Replacement.
VALVE STEM OIL SEAL AND VALVE SPRING REPLACEMENT
Special Tools
207649 Rod Hairpin Clips

547324 Flange Screws
EN-840 Pliers / Remover
EN-958 Installer
EN-50717 Kit
J-43649-2 Rods

Removal Procedure

Replacement.
3. Remove both camshafts. Refer to Camshaft Replacement.
4. Remove the valve lifter. Refer to Valve Lifter Replacement.

5. For cylinder 1 and 4 set the crankshaft to TDC marking, cylinder number 1. Use the crankshaft balancer
bolt.
6. For cylinder 2 and 3, set the crankshaft BDC (180 degrees from TDC marking). Use the crankshaft
balancer bolt.
NOTE:
Wheels must contact the ground.
7. Shift to 1. gear (MT) or park position (AT) and apply the park brake.
Valve Stem Oil Seal Removal

Fig. 301: Valve Stem Oil Seal Removal Tools

1. Install the 2 EN-50717-1 stands (1) to the cylinder head and fix them with the 547324 screws.
2. Install the 2 J-43649-2 rods (2) and the EN-51717-2 compressor (3) to the B-side of the EN-50717-1
stands. Secure the rods with the 207649 clips then.
3. Install an suitable air pressure adapter (4) to the spark plug hole.
4. Apply air pressure to the corresponding cylinder.
5. Position the EN-51717-2 compressor (3) so that its adapter proper contacts the valve spring retainer and
pretension the compressor.


6. Apply pressure to the EN-50717-2 compressor to push down the vale spring retainer (1) and compress the
valve spring (3) until the valve keys (2) are free from tension. Carefully remove the valve keys then.
7. Release the tension from the EN-50717-2 compressor.
8. Remove the valve spring retainer (1) and the valve spring (3).

Fig. 303: Valve Stem Seal Removal Tool

9. Remove and DISCARD the valve stem oil seal, using the EN-840 pliers (1).
Valve Stem Oil Seal Installation

Fig. 304: Intake Valve Stem Oil Seal Installation Tool

NOTE:
Lubricate the NEW valve stem oil seal with clean engine oil.
1. Install the NEW valve stem oil seal, using the EN-958 installer (1).
2. Loosely install the valve spring and the valve spring retainer.

Fig. 305: Valve Spring Compressor

3. Using the EN-51717-2 compressor (4), push down the valve spring retainer (1) and compress the valve
spring (3) until the valve keys (2) can be inserted. Carefully insert the valve keys then, so that they are
proper installed to the valve stem grooves.
4. Carefully release the tension from the EN-50717-2 compressor.
5. Inspect the valve keys and valve spring retainer for proper seat.
6. Repeat the procedure with the remaining valves and cylinders. Transfer the EN-50717-1 stands and the
EN-51717-2 compressor as needed.
7. Take care that air pressure is always applied to the combustion chamber of the treated cylinder.


2. Install the valve lifter. Refer to Valve Lifter Replacement.
3. Install both camshafts. Refer to Camshaft Replacement.
Replacement.
5. Install the spark plugs. Refer to Spark Plug Replacement .
VALVE GUIDE REAMING, AND VALVE AND SEAT GRINDING
Valve Cleaning Procedure
1. Use soft bristle wire brush to clean any carbon build-up from the valve head. DO NOT use a wire brush

on any part of the valve stem. The valve stem is chrome plated to provide enhanced wear characteristics.
Wire brushing the stem could remove the chrome plating.
2. Thoroughly clean the valve with solvent and wipe dry.
Valve Visual Inspection Procedure
Fig. 307: Identifying Inspection Points For Valves Damage

1. Inspect the valve for damage from the head to tip for the following conditions:
Pitting in the valve seat area (1)
Lack of valve margin (2)
Bending in the valve stem (3)
Pitting or excessive wear in the stem (4)
Worn valve key grooves (5)
Worn valve tip (6)

2. Replace the valve if any of these conditions exist.

Valve Measurement and Reconditioning Overview
NOTE:
Proper valve service is critical to engine performance. Therefore, all

detailed measurement procedures must be followed to identify
components that are out of specification.
If the measurement procedures reveal that the valve or valve seat must be
reconditioned, it is critical to perform the measurement procedures after
reconditioning.
Valve Seat Width Measurement Procedure
Fig. 308: Checking Valve Seat Width

1. Measure the valve seat width in the cylinder head using a proper scale.

Fig. 309: Measuring Seat Width On Valve Face

2. Measure the seat width on the valve face (1) using a proper scale.
NOTE:
The seat contact area must be at least 0.5 mm (0.020 in) from the outer
diameter (margin) of the valve. If the contact area is too close to the
margins, the seat must be reconditioned to move the contact area away
from the margin.
3. Compare your measurements with the specifications, refer to Engine 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 grind the valve seat using the Valve and Seat Reconditioning
Procedure to bring the width back into specification. Proper valve seat width is critical to providing the
correct amount of valve heat dissipation.

Valve Seat Roundness Measurement Procedure
1. Measure the valve seat roundness using a dial indicator attached to a tapered pilot installed in the guide.
The pilot should have a slight bind when installed in the guide.
CAUTION: The correct size pilot must be used. Do not use adjustable diameter
pilots. Adjustable pilots may damage the valve guides.
2. Compare your measurements with the specifications, refer to Engine Mechanical Specifications.
3. If the valve seat exceeds the roundness specification, you must grind the valve and valve seat using the
Valve and Seat Reconditioning Procedure.
4. If new valves are being used, the valve seat roundness must be within 0.05 mm (0.002 in).
Valve Margin Measurement Procedure

Fig. 310: View Of Valve Margin Measurement

1. Measure the valve margin using an appropriate scale.
2. Reference the specifications in this section for minimum valve margin and compare them to your
measurements.
3. If the valve margins are beyond specification, replace the valves.
4. If the valve margins are within specification and do not require refacing, test the valve for seat
concentricity using the Valve-to-Seat Concentricity Measurement Procedure.
Valve-to-Seat Concentricity Measurement Procedure
Fig. 311: View Of Valve Contact Face Measurements


NOTE:
1.
2.
3.
4.
5.
Checking the valve-to-seat concentricity determines whether the

valve and seat are sealing properly.
You must measure the valve face and the valve seat to ensure proper
valve sealing.
Coat the valve face lightly with blue dye (3).

Install the valve in the cylinder head.
Turn the valve against the seat with enough pressure to wear off the dye.
Remove the valve from the cylinder head.
Inspect the valve face.
If the valve face is concentric, providing a proper seal, with the valve stem, a continuous mark will
be made around the entire face (1).
NOTE:
The wear mark MUST be at least 0.5 mm (0.020 in) from the outer
diameter, the margin, of the valve. If the wear mark is too close to the
margin, the seat must be reconditioned to move the contact area
away from the margin.
If the face is not concentric with the stem, the mark will NOT be continuous around the valve face.
The valve should be refaced or replaced and the seat must be reconditioned using the Valve and
Seat Reconditioning Procedure.
Valve and Seat Reconditioning Procedure

Fig. 312: View Of Valve Seat Proper Angles

NOTE:
If the valve seat width, roundness or concentricity is beyond

specifications, you must grind the seats in order to ensure proper
heat dissipation and prevent the build up of carbon on the seats.
It is necessary to reface the valve if seat reconditioning is required
unless a new valve is used.
1. Grind the valve seats (2) to the proper angle specification, refer to Engine Mechanical Specifications.
2. Using the proper angle specification, refer to Engine Mechanical Specifications, grind, relieve, the valve
seats (1) to correctly position the valve seating surface (2) to the valve.
3. Using the proper angle specification listed in engine mechanical specifications, refer to Engine
Mechanical Specifications,, grind, undercut, the valve seats (3) to narrow the valve seat widths to the
specifications, refer to Engine Mechanical Specifications.
4. If the original valve is being used, grind the valve to the specifications, refer to Engine Mechanical

Specifications. Measure the valve margin again after grinding using the Valve Margin Measurement
Procedure. Replace the valve if the margin is out of specification. New valves do not require grinding.
5. When grinding the valves and seats, grind off as little 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 fine grinding compound. The
refacing and reseating operations should leave the refinished surfaces smooth and true so that
minimal lapping is required. Excessive lapping will groove the valve face and prevent a good seat
when hot.
NOTE:
Be sure to clean any remaining lapping compound from the valve and
seat with solvent and compressed air prior to final assembly.
If you are using new valves, do not lap the valves under any condition.
7. After obtaining the proper valve seat width in the cylinder head, you must re-measure the valve stem
height using the Valve Stem Height Measurement Procedure.
8. If the valve stem height is acceptable, test the seats for concentricity using the Valve-to-Seat
Concentricity Measurement Procedure.
Valve Stem Height Measurement Procedure

Fig. 313: Measuring Valve Stem Height

NOTE:
To determine the valve stem height measurement, measure from the valve
spring seat to the valve spring retainer.
1.
2.
3.
4.
5.
Install the valve into the valve guide.

Ensure the valve is seated to the cylinder head valve seat.
Install the valve stem oil seal.
Install the valve spring retainer and valve stem locks.
Measure the distance (1) between the cylinder head to the bottom of the valve spring retainer. Refer to
Engine Mechanical Specifications.
6. If the maximum height specification is exceeded, a new valve should be installed and the valve stem
height re-measured.
CAUTION: DO NOT grind the valve stem tip. The tip of the valve is hardened and
grinding the tip will eliminate the hardened surface causing

premature wear and possible engine damage.

CAUTION: DO NOT use shims in order to adjust valve stem height. The use of
shims will cause the valve spring to bottom out before the camshaft
lobe is at peak lift and engine damage could result.
7. If the valve stem height still exceeds the maximum height specification, the cylinder head must be
replaced.
VALVE SPRING INSPECTION AND MEASUREMENT
Special Tool
GE-22738-B Valve Spring Tester

Inspection Procedure
1. Clean the valve springs in solvent.

2. Dry the valve springs with compressed air.

3. Inspect the valve springs for broken coils or coil ends.
1. Measure the tension of the valve spring using the GE-22738-B tester. Refer to Engine Mechanical
Specifications.
2. If low valve spring load is found, replace the valve springs. DO NOT use shims to increase spring load.
The use of shims can cause the valve spring to bottom out before the camshaft lobe is at peak lift.

REPAIR INSTRUCTIONS - OFF VEHICLE

ENGINE SUPPORT FIXTURE
Fig. 314: Locating Engine Support Components

Engine Support Fixture
Callout
Component Name
Remove the Front Fender Shipping Cover. Refer to Front Fender Shipping Cover Replacement .
Special Tools
J-43405 Engine Support Fixture Adapter

J-28467-518 Main Support Beam
J-28467-1A Cross Bracket
J-28467-5A Strut Tower Support Assembly
J-28467-2A Radiator Tube Shelf Assembly
J-36857 Engine Lift Bracket
J-28467-8A Hook Assembly

1
2
3
4
5
Engine Support Fixture Adapter Leg (Qty: 2)

Procedure
Install the bracket to fender frame. Do not install on top of fender lip.
Main Support Beam
Cross Bracket
Strut Tower Support Assembly
Procedure
Adjust the length of the strut tower support assembly.
Radiator Tube Shelf Assembly
Hook Assembly
Procedure
Use a grade 10.9 bolt to install the engine lift bracket.
TIP: If the engine is not equipped with engine lift bracket, install J36857 in place.
TIMING BELT INSPECTION

Special Tools
EN-6340 Locking Tool


Removal Procedure


2. Set the crankshaft balancer in the direction of the engine rotation to "1st cylinder TDC" (mark 1).
3. Remove the camshaft cover. Refer to Camshaft Cover Removal.

Fig. 316: Front Panel And Bolts

NOTE:

2. Remove the front panel (1) from the EN-6340 locking tool -right.


NOTE:
adjuster does not correspond to the groove of the EN-6340 locking
tool - left (1) during this process, but must be somewhat above.
adjuster must correspond to the groove on EN-6340 locking tool right (2).
5. Insert the EN-6340 locking tool - left (1) and the EN-6340 locking tool - right (2) in the camshaft
position actuator adjuster.


NOTE:
If the EN-6628-A locking tool cannot be inserted, the timing must be set.
6. Align the camshafts horizontally by the hexagon (arrows) until the EN-6628-A locking tool can be


1.
2.
3.
4.
Remove the EN-6628-A locking tool.

TIMING BELT ADJUSTMENT

Special Tools

EN-6333 Locking Pin


Removal Procedure

2. Set the crankshaft balancer in the direction of the engine rotation to "1st cylinder TDC" (mark 1).
3. Remove the camshaft cover. Refer to Camshaft Cover Removal.


NOTE:


Fig. 322: View Of Camshaft Holder And Markings

NOTE:
adjuster does not correspond to the groove of the EN-6340 locking
tool - left (1) during this process, but must be somewhat above.
adjuster must correspond to the groove on EN-6340 locking tool right (2).
position actuator adjuster.

Fig. 323: View Of Tooth Belt Tensioner Components

6. Install the EN-6333 locking pin (1), apply tension to the timing belt tension roller (2) in the direction of
the arrow. Install the EN-6333 locking pin (3).
7. Mark timing belt in direction of rotation.

Fig. 324: Flywheel And Flywheel Holder

8. Install the EN-652 flywheel holder (1), lock the flywheel (2) (or automatic transmission flex respectively)
via the starter ring gear.




11. Remove the 4 timing belt lower front cover bolts (2).
12. Remove the timing belt lower front cover (1).




15. Remove the tensioner bolt (1).


18. Stop the timing belt tensioner (2).
19. Remove the EN-652 flywheel holder to unlock the crankshaft.


20. Turn the crankshaft 60 (A) against the direction of engine rotation.


21. Remove the 2 camshaft position actuator adjuster closure bolts (1).
NOTE:
22. Loosen the camshaft position actuator adjuster bolts (2).

23. Remove and DISCARD the camshaft position actuator adjuster bolts (2) and the camshaft position
actuator adjuster (3).


24. Align the camshafts horizontally by the hexagon arrows, until the EN-6628-A locking tool can be




NOTE:
Do not tighten the camshaft adjuster bolts.
1. Install the camshaft position actuator adjuster (3).

2. Install NEW camshaft position actuator adjuster bolts (2).
NOTE:

3. Tighten the camshaft position actuator adjuster bolts (2) in three passes:
4. Replace the camshaft position actuator adjuster seal rings.

7. Clean the timing belt tensioner thread.

8. Install the timing belt tensioner (2) and tighten the NEW timing belt tensioner bolt (1) to 20 N.m (15 lb
ft).
9. Clean the timing belt idler pulley thread.

10. Install the timing belt idler pulley (2) and tighten the NEW bolt (1) to 25 N.m (18 lb ft).

NOTE:
11. Turn the crankshaft in the direction of engine rotation, by the crankshaft balancer bolt, to cylinder 1 TDC
of combustion stroke.


12. Install the EN-652 flywheel holder (1), lock the flywheel (2) (or automatic transmission flex respectively)
via the starter ring gear.


NOTE:
13.
14.
15.
16.
Observe direction of rotation.
Insert the timing belt (1).

Apply preliminary tension clockwise to the timing belt tension roller.
Remove the EN-6333 locking pin.
Release the tension on the timing belt tensioner.


17. Install the lower front timing belt cover (1) and tighten the 4 bolts (2) to 6 N.m (53 lb in).


18. Install the crankshaft balancer (2) and NEW bolt (1) and tighten in 3 passes using the EN-45059 sensor
kit :
19. Remove the EN-652 flywheel holder to unlock the crankshaft.
21. Check position of the camshaft position actuator adjuster.
1. Turn crankshaft 720 in the direction of engine rotation by the crankshaft balancer bolt.
NOTE:
Note marking, camshaft position actuator adjuster.

2. Insert EN-6340 locking tool into camshaft timing gears.

23. Align camshafts by hexagon until EN-6628-A locking tool can be inserted in both camshafts.


24.
25.
26.
27.
28.
Check the crankshaft position.

Marking on crankshaft balancer must align with marking on timing belt lower cover, see mark (1).
Remove the EN-6628-A locking tool.
DRAINING FLUIDS AND OIL FILTER REMOVAL

Fig. 344: Oil Filter Cap, Oil Filter Seal And Oil Filter Insert
1.
2.
3.
4.
5.
6.
7.
Place a drip pan underneath.

Remove the oil filter cap (1).
Remove the oil filter cap seal (2).
Remove and properly dispose of the oil filter insert (3).
Re-install the oil filter cap.
Drain the engine oil into the drip pan.
AUTOMATIC TRANSMISSION FLEX PLATE REMOVAL

Special Tools


1. Install the EN-652 holder (1) to hold the automatic transmission flex plate (2).
2. Loosen the 6 automatic transmission flex plate bolts.


4. Remove the 6 automatic transmission flex plate bolts (2).
ENGINE FLYWHEEL REMOVAL
Special Tools


1. Install the EN-652 holder (1), lock the flywheel via the starter ring gear.
2. Loosen the 6 flywheel bolts.

Fig. 348: Flywheel And Bolts

4. Remove and DISCARD the 6 flywheel bolts (1, 2).
5. Remove the flywheel (3).

Fig. 349: Crankshaft Position Reluctor Ring

6. Remove the crankshaft position reluctor ring (1).
CRANKSHAFT REAR OIL SEAL REMOVAL
Special Tools
EN-328-B Pin Remover

EN-6624 Remover


2. Remove the crankshaft position sensor (3) from the crankshaft rear oil seal housing (1).

component.
3. Remove the crankshaft rear oil seal housing (1).
4. Remove the crankshaft position sensor reluctor ring (2).

Fig. 352: Holes At 5 O'clock And 7 O'clock Positions

NOTE:
The diameter of the hole must not exceed 2 mm (0.0787 in). If the diameter
of the hole exceeds 2 mm (0.0787 in), the bolt of EN-6624 remover will not
be able to grip.
5. Only make a hole at the 5 o'clock and 7 o'clock positions (1), these are the only positions where is a
cavity behind the seal ring.

Fig. 353: Scribe Tool

6. Using a suitable tool, such as a scribe (1), make a hole in the crankshaft rear oil seal.
Position the scribe (1) at the outer edge of the crankshaft rear oil seal.
7. Remove the seal ring.

Fig. 354: crankshaft Rear Oil Seal Removal Tool

8. Install EN-6624 remover (1) to the crankshaft rear oil seal and tighten the bolt.

Fig. 355: Special Removal Tools

9. Install the EN-328-B remover (1) to EN-6624 remover (2) and remove the crankshaft rear oil seal.
POSITIVE CRANKCASE VENTILATION PIPE REMOVAL

2. Disconnect the 2 positive crankcase ventilation tube connectors (1).
3. Remove the positive crankcase ventilation tube (2).
SECONDARY AIR INJECTION PUMP PIPE REMOVAL

Fig. 357: Secondary Air Injection Pump Pipe

1. Disconnect the secondary air injection pump pipe (3) from the secondary air injection check valve. Refer
to Plastic Collar Quick Connect Fitting Service .
SECONDARY AIR INJECTION PUMP REMOVAL


1. Disconnect the secondary air injection pump pipe (3). Refer to Plastic Collar Quick Connect Fitting
Service .
2. Remove the secondary air injection pump nut (2) and the 2 secondary air injection pump bolts (4).
3. Remove the secondary air injection pump (1).
SECONDARY AIR INJECTION CHECK VALVE REMOVAL

Fig. 359: Secondary Air Injection Check Valve Bolts

1. Remove the 3 secondary air injection check valve bolts (3).
2. Remove the secondary air injection check valve (2).
3. Remove and DISCARD the secondary air injection check valve gasket (1).
DRIVE BELT REMOVAL
Special Tools
EN-6349 Locking Pin


1. Release tension to the drive belt tensioner counterclockwise (1) and lock with EN-6349 pin (2).


DRIVE BELT TENSIONER REMOVAL


1. Remove the drive belt tensioner bolt (1).
TIMING BELT UPPER FRONT COVER REMOVAL


1. Remove the 2 timing belt upper front cover bolts (2).
2. Remove the timing belt upper front cover (1).
TIMING BELT CENTER FRONT COVER REMOVAL

Fig. 364: View Of Toothed Belt Cover

1. Remove the center front timing belt cover from the rear timing belt cover at 2 locations.
2. Remove the center front timing belt cover (1).
CRANKSHAFT BALANCER REMOVAL
Special Tools


1. Install the EN-652 holder (1). Lock the flywheel (2) or the automatic transmission flex plate via the
starter ring gear.

Fig. 366: Crankshaft Balancer, Washer And Bolt

3. Remove the crankshaft balancer washer (3).
TIMING BELT LOWER FRONT COVER REMOVAL


1. Remove the 4 timing belt lower front cover bolts (2).
2. Remove the timing belt lower front cover (1).
TIMING BELT REMOVAL
Special Tools
EN-6333 Locking Pin


NOTE:


NOTE:
lettering right, arrow, on the tool.

2. Detach the front panel (1) from the EN-6340 locking tool - right.


NOTE:
correspond to the groove of the EN-6340 locking tool - left (1) during
this process, but must be somewhat above.
correspond to the groove on EN-6340 locking tool - right (2).
adjuster.

4. Install the EN-6333 locking pin (3), apply tension to the timing belt tension roller (2) in the direction of
the arrow, using an Allen key (1).
5. Stop the timing belt tensioner.


NOTE:

TIMING BELT TENSIONER REMOVAL


1. Remove the tensioner bolt (1).
TIMING BELT IDLER PULLEY REMOVAL


CRANKSHAFT SPROCKET REMOVAL


Remove the crankshaft sprocket (1).
CAMSHAFT POSITION ACTUATOR SOLENOID VALVE REMOVAL

Fig. 376: Camshaft Position Actuator Solenoid Valves, Bolts And Seals
1. Remove the camshaft position actuator solenoid valve bolts (1).
2. Remove the camshaft position actuator solenoid valves (2).
3. Remove the camshaft position actuator solenoid valve seals (3).
CAMSHAFT POSITION ACTUATOR ADJUSTER REMOVAL
Special Tools



NOTE:



NOTE:
Install the EN-6340 locking tool - left (1) into the camshaft adjusters as shown.
NOTE:


NOTE:
Note the arrows.




adjuster and/or the exhaust camshaft position actuator adjuster (3).
NOTE:
NOTE:


7. Remove the intake camshaft position actuator adjuster and/or the exhaust camshaft position actuator
adjuster (3).
CRANKSHAFT FRONT OIL SEAL REMOVAL
Special Tools
EN-45000 Remover
Fig. 382: Crankshaft Front Oil Seal Removal Tool

CAUTION: Clean the crankshaft sealing surface with a clean, lint-free towel. Inspect
lead-in edge of crankshaft for burrs/sharp edges that could damage the
rear main oil seal. Remove burrs/sharp edges with crocus cloth before

proceeding.
Using the EN-45000 remover (3), remove the crankshaft front oil seal (1) from the crankshaft (2).
TIMING BELT REAR COVER REMOVAL

1. Remove and DISCARD the 4 timing belt rear cover bolts (2).
2. Remove the timing belt rear cover (1).
THROTTLE BODY ASSEMBLY REMOVAL


1. Remove the 4 throttle body bolts (2).
2. Remove the throttle body (1).
3. Remove the throttle body seal.
INTAKE MANIFOLD REMOVAL


1. Remove the 2 intake manifold brace bolts (2, 3).
2. Remove the intake manifold brace (1).


4. Remove the intake manifold (2) and the 4 intake manifold gaskets.
OIL LEVEL INDICATOR AND TUBE REMOVAL


2. Remove the oil level indicator tube bolt (1).
NOTE:
If the engine oil level is at the maximum level, oil may emerge while
removing the oil dipstick guide tube.
3. Remove the oil level indicator tube (2) and oil level indicator seal.
EXHAUST MANIFOLD REMOVAL

Fig. 388: Exhaust Manifold And Bolts

1.
2.
3.
4.
Remove the 9 exhaust manifold nuts (4).

Remove the 2 exhaust manifold bolts (2)
Remove the exhaust manifold (3) and gasket (1).
Clean all of the gasket surfaces.
ENGINE COOLANT THERMOSTAT REMOVAL


1. Remove the 4 engine coolant thermostat bolts (3).

2. Remove the engine coolant thermostat assembly (2).
3. Remove the engine coolant seal (1).
ENGINE COOLANT THERMOSTAT HOUSING REMOVAL


1.
2.
3.
4.
Remove the engine coolant thermostat housing retainer nut (4).

Remove the engine coolant thermostat housing retainer (1).
Remove the engine coolant thermostat housing (2).
ENGINE OIL COOLER HOUSING REMOVAL

1. Remove the 2 engine oil cooler pipe bolts (1).
2. Remove the oil cooler pipe (2).

3. Remove the 5 engine oil cooler housing bolts (2).
4. Remove the engine oil cooler housing (1).
5. Remove the engine oil cooler inlet pipe (3).
ENGINE OIL COOLER REMOVAL


Remove the 6 engine oil cooler bolts (3), the engine oil cooler (1) and the engine oil cooler gasket (2) from the
engine oil cooler housing.
WATER PUMP PULLEY REMOVAL


NOTE:
Counterhold the crankshaft balancer. For this procedure the drive belt has
to be installed.
1. Loosen the 3 water pump pulley bolts (1).

3. Remove the water pump pulley (2) from the water pump (3).
WATER PUMP REMOVAL


1. Remove the 5 water pump bolts (2).
3. Remove the water pump seal.
ENGINE OIL HEATER REMOVAL


1. Remove the engine oil heater bolt (1).
2. Remove the engine oil heater (2).
OIL PAN REMOVAL


1. Remove the 15 oil pan bolts (1) from the engine block.
2. Use a suitable tool to remove the oil pan (2) evenly all the way around.
ENGINE FRONT COVER AND OIL PUMP REMOVAL

Fig. 398: Engine Oil Pump

NOTE:
Note the different screw lengths.

2. Remove the engine front cover with the included oil pump (4).
3. Remove the gasket (1).
NOTE:
Do not damage the sealing surfaces.
4. Clean the sealing surface.

IGNITION COIL REMOVAL
Special Tools

EN-6009 Remover/Installer Ignition Module

NOTE:
Note the arrow on the cover.
1. Remove the cover of the DIS ignition coil in the direction of the arrow.
2. Remove the 2 ignition coil bolts.
Fig. 399: View Of KM-6009

3. Install the EN-6009 remover/installer (1).

Fig. 400: Ignition Coil Module And Special Tool

4. Remove the ignition coil module (2) with the EN-6009 remover/installer (1).
CAMSHAFT COVER REMOVAL

Fig. 401: Camshaft Cover And Bolts

2. Remove the camshaft cover (1).
CAMSHAFT REMOVAL

Fig. 402: Camshaft Bearing Cap And Camshaft Bearing Cap Bolts Removal Sequence
NOTE:
Note removal sequence 1-4.
1. Remove the 4 camshaft bearing cap bolts.

NOTE:
Release the bearing support by striking it gently with a plastic hammer.
2. Remove the first camshaft bearing cap (1).

Fig. 403: Exhaust Camshaft Bearing Cap Bolts Loosening Sequence

3. Loosen the 8 exhaust camshaft bearing cap bolts working from outside to inside in a spiral in steps of 1/2
up to 1 turn.
4. Remove the 8 exhaust camshaft bearing cap bolts.
NOTE:
5. Remove the 4 exhaust camshaft bearing caps numbers 6-9 from the cylinder head.

Fig. 404: Intake Camshaft Bearing Cap Bolts Loosening Sequence

7. Loosen the 8 intake camshaft bearing cap bolts working from outside to inside in a spiral in steps of 1/2
up to 1 turn.
8. Remove the 8 intake camshaft bearing cap bolts.
NOTE:
9. Remove the 4 intake camshaft bearing caps numbers 2-5 from the cylinder head.
11. Remove the camshaft seal rings.
VALVE LIFTER REMOVAL
Special Tools



NOTE:
Mark the locations.
Remove the 16 valve lifter (1) use the EN-845 suction device.
CYLINDER HEAD REMOVAL


1. Remove the 10 cylinder head bolts in sequence as shown.
1. Loosen the 10 bolts 90.
2. Loosen the 10 bolts 180.
2. Remove the cylinder head and place on a suitable base.
3. Remove the cylinder head gasket.
PISTON, CONNECTING ROD, AND BEARING REMOVAL
1. Install the crankshaft balancer bolt.
2. Set the pistons 1 and 4 to TDC in direction of engine rotation.

Fig. 407: View Of Con-Rod Bearing Caps

NOTE:
Note cylinder sequence.
3. Mark the connecting rod with the connecting rod bearing cover (1).

Fig. 408: Connecting Rod Bearing, Connecting Rod Bearing Caps And Bolts
4. Remove the 4 connecting rod bearing caps bolts (2) of cylinder 1 and 4.
5. Remove the connecting rod bearing caps (1) and the connecting rod bearing (3).

Fig. 409: Pistons 1, 4 And Cylinder Bore

6. Push the pistons 1 and 4 (1) out of the cylinder bore (2).
NOTE:
The shear surfaces of the con-rod and the con-rod bearing cover form a
unique fit and must not be swapped or damaged. Do not lay down on the
shear surfaces.
7. Remove the pistons 1 and 4 (1).

8. Turn crankshaft on crankshaft balancer through 180 in direction of rotation of engine.


NOTE:
Note cylinder sequence.
9. Mark the connecting rod with the connecting rod bearing cover (1).

Fig. 411: Connecting Rod Bearing, Connecting Rod Bearing Caps And Bolts
10. Remove the 4 connecting rod bearing caps bolts (2) of cylinder 2 and 3.
11. Remove the connecting rod bearing caps (1) and the connecting rod bearing (3).

Fig. 412: Pistons 2, 3 And Cylinder Bore

12. Push the pistons 2 and 3 (1) out of the cylinder bore (2).
NOTE:
The shear surfaces of the con-rod and the con-rod bearing cover form a
unique fit and must not be swapped or damaged. Do not lay down on the
shear surfaces.
13. Remove the pistons 2 and 3 (1).

Fig. 413: Connecting Rod Bearing

NOTE:
Observe correct fitting position, observe alignment.
14. Remove the connecting rod bearing (1, 2).

15. Check the components. Refer to Piston, Connecting Rod, and Bearing Cleaning and Inspection.
CRANKSHAFT AND BEARING REMOVAL


1. Identify all the connecting rod bearing caps (1).


2. Remove the 4 bolts.
3. Remove the connecting rod bearing caps 1 and 4 (1).
4. Turn the crankshaft through 180.


6. Remove the connecting rod bearing caps 2 and 3 (1).
7. Identify the crankshaft bearing caps.

Fig. 417: View Of Crankshaft Bearing Cap Bolts

8.
9.
10.
11.
Remove the crankshaft bearing caps (1).

Remove the 10 bolts.
Remove the crankshaft (2).
Remove the crankshaft bearing clips.
INTAKE MANIFOLD DISASSEMBLE

1. Remove the intake manifold absolute pressure sensor bolt (1).
2. Remove the manifold absolute pressure sensor (2) from the intake manifold (3).


3. Remove the intake manifold mount (2) from the intake manifold (1).


4. Remove the throttle body seal (1).
5. Remove the intake manifold seal (3) from the intake manifold (2).

Fig. 421: Intake Manifold, Evaporative Emission Canister Purge Solenoid Valve Bracket And Bolts
6. Remove the 2 evaporative emission canister purge solenoid valve bracket bolts (2).
7. Remove the evaporative emission canister purge solenoid valve bracket (1) from the intake manifold (3).

8. Remove the 2 multiport fuel injection fuel rail bolts (1).
9. Remove the multiport fuel injection fuel rail (2) and the fuel injectors (3) from the intake manifold (5).
10. Remove the 4 multiport fuel injector seals (4).
CYLINDER HEAD DISASSEMBLE
Special Tools
EN-840 Pliers/Remover
EN-8062-5 Adapter




valve spring (3) until the valve keys (2) are free from tension. Carefully remove the valve keys.

Fig. 425: Spring Compressor

5.
6.
7.
8.
9.
Slowly and carefully loosen the EN-50717-2 assembly until the valve spring is entirely expanded.
Remove the compressor assembly from the cylinder head.
Remove the valve spring retainer (1) and the valve spring (3).
Remove and DISCARD the valve stem oil seal (4), using the EN-840 pliers (2).
Remove the valve (5).
NOTE:
Ensure that the valve train components are kept together and identified in
order for proper installation in their original position.

11. In case of re-using the cylinder head, refer to Cylinder Head Cleaning and Inspection.
PISTON AND CONNECTING ROD DISASSEMBLE

1. Remove the piston with connection rod. Refer to Piston, Connecting Rod, and Bearing Removal.
Fig. 426: Detaching Piston From Connecting Rod

NOTE:
Note installation position of the piston in respect of the connection rod.
2. Detach the piston from the connection rod.

NOTE:
Do not damage the bore.
3. Remove the retainer (1) from the piston eye.

4. Press the piston pin out of the piston.

Fig. 427: Removing Piston Rings Using Piston Ring Pliers

5. Remove the piston rings, using piston ring pliers (1).
Remove oil carbon from the groove with a split piston ring, filed to a wedge-shape.

Fig. 428: Rectangular Compression Ring, Tapered Compression Ring And Oil Scraper Ring
6. Measure the piston ring gap.
Tension the piston ring in the cylinder and measure the gap with a feeler gauge.
Permissible ring gap:
Rectangular compression ring (1): 0.20-0.40 mm (0.007-0.015 in)
Tapered compression ring (2): 0.40-0.60 mm (0.015-0.023 in)
Oil scraper ring (3): 0.25-0.75 mm (0.009-0.029 in)

Fig. 429: Checking Piston Ring Vertical Play With Feeler Gauge

Fig. 430: Rectangular Compression Ring, Tapered Compression Ring And Oil Scraper Ring
7. Check piston ring vertical play with a feeler gauge (1) in the piston ring groove.
Permissible vertical play:
Rectangular compression ring (1): 0.04-0.08 mm (0.001-0.003 in)

Tapered compression ring (2): 0.03-0.07 mm (0.001-0.002 in)
Oil scraper ring (3): 0.03-0.13 mm (0.001-0.005 in)
ENGINE BLOCK DISASSEMBLE

Fig. 431: Cylinder Head Locating Pins

1. Remove the cylinder head locating (1, 2).

Fig. 432: Oil Pressure Switch

2. Remove the oil pressure switch (1).

Fig. 433: Knock Sensor And Bolt

3. Remove the knock sensor bolt (2) and the knock sensor (1).


5. Remove the oil flow check valve (1).

Fig. 435: Oil Pressure Relief Valve Closure Bolt

6. Remove the oil pressure relief valve closure bolt (1) and the oil pressure relief valve.

Fig. 436: Piston, Spring And Oil Pressure Relief Valve Closure Bolt
7. Remove the piston (1) and spring (2) from the oil pressure relief valve closure bolt (3).
8. Clean and inspect the components. Refer to Engine Block Cleaning and Inspection.

Fig. 437: Piston Oil Nozzles

10. Remove the 4 piston oil nozzles (1).
INTAKE MANIFOLD CLEANING AND INSPECTION

Fig. 438: Intake Manifold And Sealing Surfaces

1.
2.
3.
4.
Clean the intake manifold mating surfaces.

Inspect the intake manifold (2) for damage.
Inspect the intake manifold for cracks near metallic inserts.
Inspect the crankcase ventilation passages in the intake manifold face for blockage.
5. Clean the crankcase ventilation passages with compressed air if necessary. Use a maximum of 172 kPa
(25 psi) of air pressure.
6. Clean the throttle body sealing surface (1).
7. Clean the intake manifold to cylinder head sealing surface (3).

8. Replace the intake manifold as necessary.

EXHAUST MANIFOLD CLEANING AND INSPECTION
Fig. 439: Exhaust Manifold

1. Clean the exhaust manifold (1) in solvent.
2. Dry the exhaust manifold (1) with compressed air.

3. An exhaust manifold leak or damage may cause an exhaust leak and may effect OBD II system
performance. A damaged exhaust must be replaced.

OIL PAN CLEANING AND INSPECTION
Fig. 440: Oil Pan Components

1.
2.
3.
4.
5.
6.
7.
8.
9.
Remove the 2 oil pan baffle bolts (1) and the oil pan baffle (2).
Remove the oil pump screen (3).
Clean the oil pan (4). Remove all the sludge and the oil deposits.
Remove the oil pan drain plug (5) and the oil pan drain plug seal (6).
Inspect the thread of the oil pan drain plug.
Inspect the oil pan for cracking near the pan rail and the transmission mounting points.
Inspect the oil pan for cracking resulting from impact or flying road debris.
Inspect the oil pan baffle and oil pump screen.
Repair or replace the oil pan as necessary.

OIL PUMP CLEANING AND INSPECTION
Fig. 441: Inspecting Axial Clearance

1.
2.
3.
4.
Remove the external rotor with the internal rotor.

Visually inspect the components.
Install the external and the internal rotors.
Inspect the axial clearance of the rotors in respect to the control unit housing upper edge.
Specifications
Permissible measurement is 0.02-0.058 mm (0.00079-0.00228 in).
CYLINDER HEAD CLEANING AND INSPECTION

Valve Cleaning and Inspection

Fig. 442: Identifying Inspection Points For Valves Damage

WARNING: Bodily injury may occur if the cleaning solvent is inhaled or exposed
to the skin.
NOTE:
Do not scratch the valve stem with the wire brush.
1. Clean the valves of carbon, oil and varnish. Carbon can be removed with a wire brush. Varnish can be
removed by soaking in Parts Immersion Solvent.
2. Clean the valve guides.
3. Inspect the valve stem for wear (4).
4. Inspect the valve key groove for chipping or wear (5). Replace the valve if chipped or worn.
5. Inspect the valve face for burning or cracking (1). If pieces are broken off, inspect the corresponding
piston and cylinder head area for damage.

6. Inspect the valve stem for burrs and scratches. Burrs and minor scratches may be removed with an oil
stone.
7. Inspect the valve stem for straightness and the valve head for bending or distortion (3) using V blocks.
Bent or distorted valves must be replaced.
8. Clean the deposits from the valve face. Inspect the valve face for grooving.
9. Replace the valve if the face is grooved. Valve faces cannot be machined. If worn, or damaged, the valves
must be replaced.
10. The valves may be lightly lapped to the valve seats.
Cylinder Head and Gasket Surface Cleaning and Inspection

2. Inspect the cylinder head gasket and mating surfaces for leaks, corrosion and blow-by. If the gasket has
failed, use the following faults to determine the cause:
1. Improper installation.
2. Loose or warped cylinder head.
3. Missing, off location or not fully seated dowel pins.
4. Corrosion in the seal area around the coolant passages.
5. Chips or debris in the cylinder head bolt holes.
6. Bolt holes in the cylinder block not drilled or tapped deep enough.

Fig. 443: Combustion Chambers

3. Inspect the cylinder head gasket surface.
Cylinder head may be reused if corrosion is found only outside a 4 mm (0.375 in) band around each
combustion chamber (1).
Replace the cylinder head if the area between the valve seats is cracked (2).
Replace the cylinder head if corrosion has been found inside a 4 mm (0.375 in) band around each
combustion chamber (3).
4. Clean the cylinder head bolts.
NOTE:
Do not use a wire brush on any gasket sealing surface.
5. Clean the cylinder head. Remove all varnish, soot and carbon to the bare metal.

6.
7.
8.
9.
Clean the valve guides.

Clean the threaded holes. Use a nylon bristle brush.
Clean the remains of the sealer from the plug holes.
Inspect the cylinder head bolts for damaged threads or stretching and damaged heads caused by improper
use of tools.
10. Replace all suspect bolts.
11. Inspect the cylinder head for cracks. Check between the valve seats and in the exhaust ports.
NOTE:
Do not attempt to weld the cylinder head, replace it.
12. Inspect the cylinder head deck for corrosion, sand inclusions and blow holes.
Fig. 444: Inspecting Cylinder Head Surfaces For Flatness


13. Inspect the cylinder head deck surface for flatness. Refer to Engine Mechanical Specifications. If the
cylinder head is out of specification, replace the cylinder head. Do not machine the cylinder head.
14. Inspect all the threaded holes for damage. Threads may be reconditioned with thread inserts.
15. Inspect the sealing surfaces.
16. Inspect the cylinder head plugs.
PISTON, CONNECTING ROD, AND BEARING CLEANING AND INSPECTION
Special Tools
1. Remove the oil pan. Refer to Oil Pan Removal.

Fig. 445: Connecting Rod Bearing Cap

Fig. 446: Marking Position On Connecting Rod Bearing Cap

2. Remove the connecting rod bearing cap (1).
1. Mark the installation position (1) of the connecting rod bearing cap.
3. Degrease the connecting rod bearing cap and wet the connecting rod bearing clip with engine oil.
NOTE:
3. Lay on plastigage. Refer to Adhesives, Fluids, Lubricants, and Sealers.

Lay plastigage (flexible plastic thread) over the entire width of the connecting rod bearing journal.

4. Install the connecting rod bearing cap.

5. Tighten the 2 bolts in three passes using the EN-45059 sensor kit :
2. Second pass tighten to an additional 45
3. Third pass tighten to an additional 15
Fig. 447: Connecting Rod Bearing Cap

7. Remove the connecting rod bearing cap (1).

Fig. 448: Measuring Connecting Rod Bearing Play Using Measuring Scale
NOTE:
measuring scale (1).
8. Measure the connecting rod bearing play.

Compare the width of the flattened plastic thread with the measuring scale.
Permissible connecting rod bearing play: 0.019-0.071 mm (0.0007-0.0028 in).
NOTE:
Check markings on parts.
9. Install the connecting rod bearing cap.

Wet the connecting rod bearing journal and con-rod bearing clips with engine oil.
Renew the bolts.

10. Tighten the 2 bolts in three passes using the EN-45059 sensor kit :
1. First pass tighten to 35 N.m (26 lb ft)
2. Second pass tighten to an additional 45
3. Third pass tighten to an additional 15
11. Install the oil pan. Refer to Oil Pan Installation.
CRANKSHAFT AND BEARING CLEANING AND INSPECTION
Special Tools

GE-571-B Dial Gauge

Crankshaft End Play, Check


NOTE:
Crankshaft attached with crankshaft bearing caps.

1. Install in the holder on the front of the engine block.
2. Place the dial gauge plunger against the crankshaft and adjust.
2. Measure the longitudinal play of the crankshaft.
1. Move the crankshaft in the longitudinal direction.
2. Permissible crankshaft end play: 0.100-0.202 mm (0.0039-0.0080 in)
Crankshaft Out-of-Round, Check


NOTE:
Crankshaft removed.
1. Insert the crankshaft in the engine block.

2. Install the GE-571-B gauge.
1. Attach to the bracket on the engine block.
2. Place the dial gauge plunger against the crankshaft bearing journal and adjust.
3. Check the rotational play of the crankshaft.
1. Turn the crankshaft evenly.
2. Maximum permissible rotational play: 0.03 mm (0.001 in).
4. Remove the GE-571-B gauge (1).
Check Crankshaft Bearing Clearance (With Plastigage)

Fig. 451: Plastigage On Bearing Journal

NOTE:
Crankshaft removed.
1. Lay on plastigage.
Lay out plastigage (flexible plastic thread) around the entire width of the con-rod bearing journal (1).
NOTE:
Note the correct tightening sequence.


2. Install the crankshaft bearing cap. Tighten the 2 crankshaft bearing cap bolts in 3 passes. Use the EN45059 sensor kit :
1. First pass to 50 N.m (37 lb ft)
2. Second pass to 45
3. Third pass to 15
3. Remove the 2 crankshaft bearing cap bolts.
Fig. 452: Measuring Crankshaft Bearing Play Using Measuring Scale

NOTE:
measuring scale (1).
4. Measure the crankshaft bearing play.

1. Compare the width of the flattened plastic thread (arrow) to the measuring scale.

2. Permissible crankshaft bearing play: 0.005-0.059 mm (0.0002-0.0023 in).

Check Crankshaft Bearing Clearance (With Micrometer Gauge Internal Measuring Device)
NOTE:

1. Install the crankshaft bearing cap with the crankshaft bearing clips to the cylinder block.
Tighten the 2 crankshaft bearing cap bolts in 3 passes. Use the EN-45059 sensor kit :
2. Second pass to 45
3. Third pass to 15
Fig. 453: Micrometer Gauge


2. Install the inner plunger and calibrate with the micrometer gauge (1).
Fig. 454: Measuring Crankshaft Bearing Diameter At Points

3. Measure the crankshaft bearing diameter at 3 points.
Measure at points A, B and C with the internal measuring device.
Calculate the average crankshaft bearing diameter.
Formula: A + B + C /3.

Fig. 455: Measuring Crankshaft Bearing Journal Diameter At 2 Points

4. Measure the crankshaft bearing journal diameter at 2 points.
Measure at points I and II with the micrometer gauge.
5. Calculate the average crankshaft bearing journal diameter.
Formula: I + II/2.
6. Determine the crankshaft bearing play.
Calculation formula: average crankshaft bearing diameter minus average crankshaft bearing journal
diameter.
7. Nominal-Actual comparison.
Permissible crankshaft bearing play: 0.005-0.059 mm (0.0002-0.0023 in).

ENGINE BLOCK CLEANING AND INSPECTION

Special Tools
EN-8087 Cylinder Gauge
Fig. 456: Engine Block

1. Clean the sealing material from the gasket mating surfaces (2).
2. Clean the engine block (1) and lower crankcase in a cleaning tank with solvent appropriate for aluminum.
Refer to Adhesives, Fluids, Lubricants, and Sealers for the recommended solvent.
3. Flush the engine block with clean water or steam.
4. Clean the oil passages.

5. Clean the blind holes.

6. Spray the cylinder bores and the machined surfaces with engine oil.
7. Inspect the threaded holes. Clean the threaded holes with a rifle brush. If necessary, drill out the holes and
install thread inserts. Refer to Thread Inserts .
Fig. 457: Inspecting Engine Block For Sag In Length And Width On Sealing Surfaces
NOTE:
Do not attempt to machine the lower crankcase to engine block surfaces.
8. Inspect the engine block for sag in length and width on the sealing surfaces.

Fig. 458: Inspecting Engine Block For Distortion Along Diagonals

9. Inspect the engine block for distortion along the diagonals.
If the deck surface is out of specification, replace the block. Do not machine the block.

Fig. 459: Gasket Mating Surfaces

10. Clean the sealing material from the gasket mating surfaces (1) on the lower crankcase oil pan side.

Fig. 460: Measuring Bearing Bore Concentricity And Alignment Using Gauge Tool
11. Inspect the crankshaft main bearing bores. Use the EN-8087 gauge (1) to measure the bearing bore
concentricity and alignment.
12. Replace the engine block and bed plate if the crankshaft bearing bores are out of specification.

Fig. 461: Inspecting Cylinder Bore

13. Inspect the cylinder bores using the EN-8087 gauge (1). Inspect for the following items:
Wear
Taper
Runout
Ridging
14. Check the cylinder bores specifications. Refer to Engine Mechanical Specifications.
15. If the cylinder bores are out of specification, replace the engine block.
SERVICE PRIOR TO ASSEMBLY
The importance of cleanliness during assembly cannot be overstated. Dirt or debris will cause engine damage.
An automobile engine is a combination of many machined, honed, polished and lapped surfaces with minor
tolerances. When any internal engine parts are serviced, care and cleanliness are important. A liberal coating of

engine oil should be applied to friction areas during assembly in order to protect and lubricate the surfaces on
initial operation. Throughout this section, it should be understood that proper cleaning and protection of
machined surfaces and friction areas are part of the repair procedure. This is considered standard shop practice
even if not specifically stated.
Use the proper tools to measure the components when checking for excessive wear. Components not within the
manufacturer's specification must be repaired or replaced.
Lubricate all moving parts with engine oil or a specified assembly lubricant. This will provide lubrication for
initial start up.
When the components are reinstalled into an engine, return the components to their original location, position,
and direction.
ENGINE BLOCK ASSEMBLE
Fig. 462: Piston Oil Nozzles


1. Install the 4 piston oil nozzles (1).
Fig. 463: Piston, Spring And Oil Pressure Relief Valve Closure Bolt
2. Install the piston (1) and spring (2) to the oil pressure relief valve closure bolt (3).

Fig. 464: Oil Pressure Relief Valve Closure Bolt

3. Install the oil pressure relief valve and the oil pressure relief valve closure bolt (1) and tighten to 21 N.m
(16 lb ft).

Fig. 465: Knock Sensor And Bolt

4. Install the knock sensor (1) and the knock sensor bolt (2) and tighten to 20 N.m (15 lb ft).


5. Install the oil flow check valve (1).

Fig. 467: Oil Pressure Switch

6. Install the oil pressure switch (1) and tighten to 20 N.m (15 lb ft).

Fig. 468: Cylinder Head Locating Pins

7. Install the cylinder head locating (1, 2).
PISTON AND CONNECTING ROD ASSEMBLE

Fig. 469: View Of Piston Ring Joint Positions

1. Install the piston rings.
Insert into the pistons with piston ring wrench and "TOP" pointing upwards.
Set the piston ring gap.
First piston ring (right-hand ring) in position (1)
Second piston ring (minute ring) in position (2)
Interim ring of oil scraper ring in position (3), steel band rings of oil scraper ring in position
(4 and/or 5)
NOTE:
Note installation position of the piston in respect of the connection rod.
2. Attach the piston to the connection rod.

1. Press the piston pin into the piston and the connection rod by hand.
2. Insert the retainer in the annular groove on the piston.
3. Ensure the retainer is firmly seated in the groove.

3. Install the piston with connection rod. Refer to Piston, Connecting Rod, and Bearing Installation.
CYLINDER HEAD ASSEMBLE
Special Tools
EN-958 Valve Stem Seal Installer

EN-8062-5 Adapter
Fig. 470: Valve Stem Oil Seal And Installer


1. Lubricate the valve stem and the valve guide with clean engine oil.
NOTE:
Ensure all valve train components will be installed in their original

position.
2. Install the valve (5).

3. Install the NEW valve stem oil seal (4), using the EN-958 installer (2).
4. Loosely install the valve spring (3) and the valve spring retainer (1).



valve spring (3) until the valve keys (2) can be inserted. Carefully insert the valve keys then, so that they
are proper installed to the valve stem grooves.
9. Carefully release the tension from the EN-50717-2 assembly.
10. Inspect the valve keys and valve spring retainers for proper seat.
11. Remove the compressor assembly from the cylinder head.
INTAKE MANIFOLD ASSEMBLE

1. Install the 4 NEW multiport fuel injector seals (4).
2. Install the multiport fuel injection fuel rail (2) and the fuel injectors (3) to the intake manifold (5).
3. Install the 2 multiport fuel injection fuel rail bolts (1) and tighten to 8 N.m (71 lb in).

Fig. 474: Intake Manifold, Evaporative Emission Canister Purge Solenoid Valve Bracket And Bolts
4. Install the evaporative emission canister purge solenoid valve bracket (1) to the intake manifold (3).
5. Install the 2 evaporative emission canister purge solenoid valve bracket bolts (2) and tighten to 7 N.m (62
lb in).


6. Install the NEW intake manifold seal (3) to the intake manifold (2).
7. Install the NEW throttle body seal (1).


8. Install the intake manifold mount (2) to the intake manifold (1) and tighten to 8 N.m (71 lb in).

9. Install the manifold absolute pressure sensor (2) to the intake manifold (3).
10. Install the intake manifold absolute pressure sensor bolt (1) and tighten to 6 N.m (53 lb in).
CRANKSHAFT AND BEARING INSTALLATION
Special Tools

Fig. 478: View Of Crankshaft Bearing Clip

NOTE:
Inspect the installation position.
1. Install the crankshaft bearing clips, oil bearing clips.

2. Install the crankshaft.
NOTE:
3. Install the crankshaft bearing caps 1-4.

Oil bearing clips.
Install the 8 NEW crankshaft bearing cap bolts.
NOTE:
4. Install the crankshaft bearing cap.

1. Apply black adhesive sealing compound to the grooves of the rear crankshaft bearing cap.
2. Install the 2 NEW crankshaft bearing cap bolts.
Fig. 479: View Of Crankshaft Bearing Cap Bolts

5. Tighten the bolts for the crankshaft bearing caps (1) in 3 passes using the EN-45059 sensor kit:
First pass to 50 N.m (37 lb ft)
Second pass to 45
Third pass to 15


NOTE:
6. Install the connecting rod bearing caps 2 and 3 (1) and oil the bearing clips.
7. Install 4 NEW connecting rod bearing cap bolts and tighten in 3 passes use the EN-45059 sensor kit:
Second pass to 45
Third pass to 15


8. Turn the crankshaft through 180.
NOTE:
9. Install the connecting rod bearing caps 1 and 4 (1) and oil the bearing clips.
10. Install 4 NEW connecting rod bearing cap bolts and tighten in 3 passes use the EN-45059 sensor kit:
Second pass to 45
Third pass to 15
PISTON, CONNECTING ROD, AND BEARING INSTALLATION
Special Tools


1. Lubricate the piston rings, piston, inner cylinder bore surface and a piston ring compressor with clean
engine oil.
2. Install the piston ring compressor in order to compress the piston rings.
Fig. 482: Connecting Rod Assembly, Connecting Rod Bearing And Connecting Rod Cap
3. Install the piston and connecting rod assembly (4).
4. Install the connecting rod bearing (3).
5. Install the connecting rod cap (1).

6. Install NEW connecting rod bolts (2) and tighten a first pass to 35 N.m (26 lb ft).
7. Tighten the NEW connecting rod bolts a second pass to an additional 45 degrees, using the EN-45059
meter.
8. Tighten the NEW connecting rod bolts a final pass to an additional 15 degrees, using the EN-45059
meter.
9. Assemble the caps and connecting rods in the marked position.
10. Rotate the crankshaft to a position where the connecting rod bolts are easy accessible.
CYLINDER HEAD INSTALLATION
Special Tools
2. Inspect for plane surface.
Cylinder block, cylinder head
Straight-edge, feeler gauge
3. Install the cylinder head gasket.
4. Install the cylinder head.


NOTE:
5. Install NEW cylinder head bolts.

6. Tighten the bolts (1) in 5 passes. Use the EN-45059 sensor kit :
Second pass to 90

Third pass to 90
Fourth pass to 90
Fifth pass to 45
VALVE LIFTER INSTALLATION

Special Tool

NOTE:
Observe the correct locations.

NOTE:
Coat the sliding surfaces with NEW engine oil.
Install the 16 valve lifter (1), using the EN-845 suction device.
CAMSHAFT INSTALLATION
Special Tools
EN-422 Installer
Fig. 485: Intake Camshaft Bearing Cover Bolts Tightening Sequence

NOTE:
Coat with MoS 2 lubricating paste. Refer to Adhesives, Fluids, Lubricants,

and Sealers.

1. Install the intake camshaft (1).

NOTE:
2. Install the 4 intake camshaft bearing cover number 2-5.

3. Install the 8 intake camshaft bearing cover bolts and tighten in a spiral from the inside to the outside to 8
N.m (71 lb in).
Fig. 486: Exhaust Camshaft Bearing Cover Bolts Tightening Sequence

NOTE:
Coat with MoS 2 lubricating paste. Refer to Adhesives, Fluids, Lubricants,

and Sealers.
4. Install the exhaust camshaft (1).
NOTE:
5. Install the 4 exhaust camshaft bearing cover number 6-9.

6. Install the 8 exhaust camshaft bearing cover bolts and tighten in a spiral from the inside to the outside to 8
N.m (71 lb in).
Fig. 487: View Of Oil Duct

NOTE:

Fig. 488: View Of Sealing Surfaces And Grooves

NOTE:
Sealing surfaces (arrows) must be free from oil and grease.

It is essential to ensure that no sealant is applied outside the marked
sealing areas (1).
The grooves adjacent to the sealing surfaces must remain free from
sealant.
7. Clean sealing surfaces of the first camshaft bearing support and the cylinder head with a suitable tool.
Clean oil duct from any sealant residue.
8. Apply surface sealant to sealing surfaces of the first camshaft bearing cap thinly and evenly.
9. Position the first camshaft bearing cap on the cylinder block and tighten the bolts approximately to 2 N.m
(18 lb in).

Fig. 489: Camshaft Bearing Cap

NOTE:
No sealant may reach the camshafts.
10. Install the first camshaft bearing cap.

NOTE:
Note installation sequence 1-4.
11. Install the first camshaft bearing cap (1) bolts and tighten to 8 N.m (71 lb in).


12. Install 2 NEW sealing rings to the camshafts.
head.
approximately 10 mm.
15. Remove the EN-422 installer (3).
CAMSHAFT COVER INSTALLATION

Fig. 491: Camshaft Cover Bolt

1.
2.
3.
4.
Clean the bolt and the camshaft cover bolt (4) thread.
Apply sealant to the camshaft cover bolt (4). Refer to Adhesives, Fluids, Lubricants, and Sealers.
Insert a NEW gasket in the camshaft cover.
Install the camshaft cover (1).
5. Install the 11 bolts (2, 3, 4) and tighten to 8 N.m (71 lb in).

IGNITION COIL INSTALLATION
Special Tools

EN-6009 Remover/Installer Ignition Module

Fig. 492: Ignition Coil Module And Special Tool

1. Install the ignition coil module (2) with the EN-6009 remover/installer (1).
2. Remove the EN-6009 remover/installer (1).
NOTE:
3. Install the 2 ignition coil bolts and tighten to 8 N.m (71 lb in).

NOTE:
4. Install the cover of the DIS ignition coil against the direction of the arrow.
ENGINE FRONT COVER AND OIL PUMP INSTALLATION
Fig. 493: Engine Oil Pump

1. Install the NEW engine cover gasket (1).
2. Install the engine cover with the included oil pump (4).
3. Install the 8 engine cover bolts (2, 3) and tighten to 20 N.m (15 lb ft).

OIL PAN INSTALLATION

2. Apply approximately a 3.5 mm (0.138 in) thick bead of oil pan sealant to the joints (arrows). Refer to
Adhesives, Fluids, Lubricants, and Sealers for the recommended sealant.


NOTE:
The assembly time, including torque check, must take no longer than 10
minutes.
3. Apply approximately a 3.5 mm (0.138 in) thick bead of oil pan sealant (1) to the oil pan. Refer to
Adhesives, Fluids, Lubricants, and Sealers for the recommended sealant.


4. Install the oil pan (2).
5. Install the 15 oil pan bolts (1) on the cylinder block and tighten to10 N.m (89 lb in).
ENGINE OIL HEATER INSTALLATION


1. Install the engine oil heater (2).
2. Install the engine oil heater bolt (1) and tighten to 40 N.m (30 lb ft).
WATER PUMP INSTALLATION


1. Clean the sealing surfaces and the 3 coolant pump threads.
2. Install NEW gasket.
3. Install the coolant pump (1).

4. Install 5 NEW bolts (2) and tighten to 8 N.m (71 lb in).

WATER PUMP PULLEY INSTALLATION

NOTE:
Counterhold the crankshaft balancer. The belt has to be installed for this
procedure.
1. Install the water pump pulley (2) to the water pump (3).
2. Install the 3 water pump pulley bolts (1) with locking compound and tighten to 20 N.m (15 lb ft).
Refer to Adhesives, Fluids, Lubricants, and Sealers.

ENGINE OIL COOLER INSTALLATION

1. Clean the engine oil cooler to the oil filter housing sealing surfaces.

2. Install the NEW engine oil cooler gasket (2) and the engine oil cooler (1) to the engine oil cooler housing.
3. Install the 6 engine oil cooler bolts (3) and tighten to 8 N.m (71 lb in).
ENGINE OIL COOLER HOUSING INSTALLATION
1. Clean the engine oil cooler housing to thermostat housing sealing surfaces.

2. Install 2 NEW gaskets.
3. Install the engine oil cooler inlet pipe (3).
4. Install the engine oil cooler housing (1) and the 5 engine oil cooler bolts (2) and tighten to 25 N.m (18 lb
ft).

5. Install the thermostat housing coolant pipe (2) to the engine oil cooler housing.
6. Install the 2 thermostat housing coolant pipe bolts (1) and tighten to 8 N.m (71 lb in).
ENGINE COOLANT THERMOSTAT HOUSING INSTALLATION

2. Install a NEW engine coolant thermostat housing seal.


3. Install the engine coolant thermostat housing (2).
NOTE:
Screw in the 4 bolts until the engine coolant thermostat housing is in

contact with the cylinder head.

Fig. 504: Identifying Engine Coolant Thermostat Housing Bolts Tightening Sequence
CAUTION: Following the proper fastener tightening sequence and torque is
essential. Failure to do so may fracture the thermostat housing.
5. Tighten the 4 engine coolant thermostat housing bolts to 8 N.m (71 lb in) in sequence (1-2-3-4).


6. Install the engine coolant thermostat housing retainer (1).
7. Install the engine coolant thermostat housing retainer nut (4) and tighten to 6 N.m (53 lb in).
ENGINE COOLANT THERMOSTAT INSTALLATION
1. Clean the engine coolant sealing surfaces.


2. Install the engine coolant seal (1).
3. Install the engine coolant thermostat assembly (2).
4. Install the 4 engine coolant thermostat bolts (3) and tighten to 8 N.m (71 lb in).
EXHAUST MANIFOLD INSTALLATION

Fig. 507: Exhaust Manifold And Bolts

1. Clean the exhaust manifold sealing surface.
2. Install a NEW exhaust manifold gasket (1) to the cylinder head.
3. Install the exhaust manifold (3) and tighten the NEW nuts (4) to 20 N.m (15 lb ft).
4. Install the 2 exhaust manifold bracket bolts (2) to 20 N.m (15 lb ft).

OIL LEVEL INDICATOR AND TUBE INSTALLATION

1. Install a NEW oil level indicator tube gasket.
2. Install the oil level indicator tube (2).
3. Install the oil level indicator tube bolt (1) and tighten to 15 N.m (11 lb ft).
4. Install the oil dipstick.
INTAKE MANIFOLD INSTALLATION


2. Install 4 NEW gaskets.

3. Install the intake manifold (2) and the 7 intake manifold bolts (1) and tighten to 20 N.m (15 lb ft).


4. Install the intake manifold brace (1).
5. Install the 2 intake manifold brace bolts (2, 3) and tighten to 8 N.m (71 lb in).
THROTTLE BODY ASSEMBLY INSTALLATION


1. Install a NEW throttle body seal.
2. Install the throttle body (1).
3. Install the 4 throttle body bolts (2) and tighten to 8 N.m (71 lb in).
CRANKSHAFT FRONT OIL SEAL INSTALLATION
Special Tools
EN-6351 Mounting Sleeves

Fig. 512: Crankshaft And Crankshaft Front Oil Seal

2. Slide the EN-6351 sleeves (2) protective sleeve onto the crankshaft journal.
3. Slide the crankshaft front oil seal (1) over the protective sleeve on the crankshaft journal.

Fig. 513: Crankshaft Drive Gear Bolt, Washer And Sleeves

4. Remove the protective sleeve, and using the EN-6351 sleeves (3), press the seal ring into the pump
housing.
5. Use the crankshaft drive gear bolt (1) and washer (2) to press in the crankshaft front oil seal.
TIMING BELT REAR COVER INSTALLATION
1. Re-cut the 4 rear timing belt cover threads.


2. Install the timing belt rear cover (1).
NOTE:
apply thread lock agent to the bolt. If fastener is microencapsulated, install
a NEW 4 timing belt rear cover bolts. DO NOT reuse the old bolt.
3. Install the 4 NEW timing belt rear cover bolts (2) and tighten to 6 N.m (53 lb in).
CAMSHAFT POSITION ACTUATOR ADJUSTER INSTALLATION

Special Tools


NOTE:
Note the arrows.




NOTE:
(3).
actuator adjuster bolt (2). DO NOT tighten the bolts yet.


NOTE:
adjuster does not correspond to the groove of EN-6340-left locking
tool - left during this process but must be somewhat above as
shown.
1. Install the EN-6340-left locking tool (1) in the camshaft position actuator adjusters as shown.
NOTE:
adjuster must correspond to the groove on EN-6340-left locking tool right.
2. Install the EN-6340-right locking tool (2) in the camshaft position actuator adjusters as shown.


NOTE:
NOTE:



6. Install the camshaft position actuator adjuster bolts (2) and tighten the bolts in 3 passes using the EN45059 meter.
2. Second pass to an additional 150 degrees
3. Final pass to an additional 15 degrees
NOTE:
9. After the installation of the timing belt, rotate the engine 720 degrees and check the position of the
crankshaft and camshafts, again. Refer to Timing Belt Adjustment.
CAMSHAFT POSITION ACTUATOR SOLENOID VALVE INSTALLATION

Fig. 520: Camshaft Position Actuator Solenoid Valves, Bolts And Seals
NOTE:
Lubricate the NEW camshaft position actuator solenoid valve seals with
NEW engine oil. Refer to Adhesives, Fluids, Lubricants, and Sealers.
1. Install NEW camshaft position actuator solenoid valve seals (3).

2. Install the camshaft position actuator solenoid valves (2).
3. Install the camshaft position actuator solenoid valve bolts (1) and tighten to 6 N.m (53 lb in).
CRANKSHAFT SPROCKET INSTALLATION


NOTE:
When installing the crankshaft sprocket, the cam and the groove must align (2).
Install the crankshaft sprocket (1).

TIMING BELT IDLER PULLEY INSTALLATION
Special Tools
For equivalent tools, refer to Special Tools.


meter :

TIMING BELT TENSIONER INSTALLATION

Special Tools

1. Clean the timing belt tensioner thread.
2. Install the timing belt tensioner (2).

3. Install a NEW timing belt tensioner bolt (1) and tighten the bolt in 3 passes using the EN-45059 meter.
2. Second pass to an additional 120 degrees.
3. Final pass to an additional 15 degrees.
TIMING BELT INSTALLATION
Special Tools
EN-6333 Locking Pin


NOTE:

NOTE:
lettering right, arrow, on the tool.


2. Detach the front panel (1) from the EN-6340 locking tool - right.

NOTE:
correspond to the groove of the EN-6340 locking tool - left (1) during
this process, but must be somewhat above.
correspond to the groove on EN-6340 locking tool - right (2).
adjuster.


NOTE:
4. Insert the timing belt (1).

5. Apply tension to the timing belt tensioner (2) in the direction of the arrow, using an Allen key (1).
NOTE:

9. Check position of the camshaft sprocket.
1. Turn crankshaft 720 in the direction of engine rotation by the crankshaft balancer bolt.
NOTE:
Note the marking on the camshaft sprocket.
2. Insert EN-6340 locking tool into camshaft sprockets.

NOTE:

TIMING BELT LOWER FRONT COVER INSTALLATION


Install the timing belt cover (1) and tighten the 4 timing belt lower front cover bolts (2) to 6 N.m (53 lb in).
CRANKSHAFT BALANCER INSTALLATION
Special Tools



1. Install the EN-652 holder (1), lock the flywheel (2) or the automatic transmission flex plate via the starter
ring gear.

Fig. 532: Crankshaft Balancer, Washer And Bolt

NOTE:
Use care that the height (1) of the washer is facing towards the bolt.
2. Install the crankshaft balancer (2) and the washer (3).

3. Install a NEW crankshaft balancer bolt (4) and tighten the bolt in 3 passes using the EN-45059 meter

2. Second pass to an additional 45,

3. Final pass to an additional 15.
TIMING BELT CENTER FRONT COVER INSTALLATION
Fig. 533: Timing Belt Center Front Cover

Install the timing belt center front cover (1) to the timing belt rear cover at 2 locations.
TIMING BELT UPPER FRONT COVER INSTALLATION


2. Install the 2 timing belt upper front cover bolts (2) and tighten to 6 N.m(53 lb in).
DRIVE BELT INSTALLATION
Special Tools
EN-6349 Locking Pin


1. Install the drive belt (1).

Fig. 536: Checking Drive Belt Position

NOTE:
Make sure that the drive belt is aligned on the generator pulley (4),
crankshaft balancer (5), drive belt tensioner (6) and water pump pulley (7).
The drive belt must lie on the water pump pulley between the flange (1)
and (2).
2. Check the position of the drive belt (3).


3. Release tension to the tensioner counterclockwise (1).
NOTE:
Allow tensioner to slide back slowly.
4. Remove EN-6349 pin (2).

5. Apply tension to the tensioner at projection (1) clockwise.
DRIVE BELT TENSIONER INSTALLATION
1. Clean the drive belt tensioner thread.


2. Install drive belt tensioner (2).
3. Install drive belt tensioner bolt (1) and tighten to 55 N.m (41 lb ft).
SECONDARY AIR INJECTION CHECK VALVE INSTALLATION

Fig. 539: Secondary Air Injection Check Valve Bolts

1. Install a NEW secondary air injection check valve gasket (1).
2. Install the secondary air injection check valve (2).
3. Install the 3 secondary air injection check valve bolts (3) and tighten to 22 N.m (16 lb ft).
SECONDARY AIR INJECTION PUMP INSTALLATION


1. Install the secondary air injection pump (1).
2. Loosely install the secondary air injection pump nut (2) and the 2 secondary air injection pump bolts (4).
3. Tighten the secondary air injection pump nut (2) and the 2 secondary air injection pump bolts (4) to 22
N.m (16 lb ft).
4. Connect the secondary air injection pump pipe (3). Refer to Plastic Collar Quick Connect Fitting
Service .
SECONDARY AIR INJECTION PUMP PIPE INSTALLATION


1. Connect the secondary air injection pump pipe (3) to the secondary air injection check valve. Refer to
Plastic Collar Quick Connect Fitting Service .
POSITIVE CRANKCASE VENTILATION PIPE INSTALLATION

1. Install the positive crankcase ventilation tube (2).
2. Connect the 2 positive crankcase ventilation tube connectors (1).
3. Clip in the ECM wiring harness guide (3) to the cylinder head cover.
ENGINE FLYWHEEL INSTALLATION
Special Tools


Fig. 543: Crankshaft Position Reluctor Ring

1. Install the crankshaft position reluctor ring (1).


2. Install the flywheel (2).
3. Install the EN-652 holder (1).

Fig. 545: Flywheel And Bolts

4. Install the 6 NEW flywheel bolts (1, 2) and tighten the bolts in 3 passes using the EN-45059 sensor kit :
2. Second pass to additional 45.
3. Third pass to an additional 15.

AUTOMATIC TRANSMISSION FLEX PLATE INSTALLATION

Special Tools
1. Clean the automatic transmission flex plate bolt threads.

2. Install the automatic transmission flex plate (2) and the EN-652 holder to hold the automatic transmission
flex plate (2).


3. Install the 6 NEW automatic transmission flex plate bolts (2) and tighten the bolts to 60 N.m (44 lb ft)
5.
CRANKSHAFT REAR OIL SEAL INSTALLATION
Special Tools

EN-658-1 Installer
EN-235-6 Installer






Fig. 551: Check Crankshaft Rear Oil Seal For Proper Seat
4. Check the crankshaft rear oil seal for proper seat, the EN-658-1 installer must be flush with the cylinder
block at the position (1).

5. Install the reluctor ring (2).
6. Install the crankshaft rear oil seal housing (1).


7. Install the crankshaft position sensor (3) to the crankshaft rear oil seal housing (1).
8. Install the crankshaft position sensor bolt (2) and tighten to 4.5 N.m (40 lb in).

CLEANLINESS AND CARE
An automobile engine is a combination of many machined, honed, polished, and lapped surfaces with tolerances
that are measured in ten thousandths of an inch. When any internal engine parts are serviced, care and

cleanliness are important. A liberal coating of engine oil should be applied to friction areas during assembly to
protect and lubricate the surfaces during initial operation. Throughout this section, it should be understood that
proper cleaning and protection of machined surfaces and friction areas are part of the repair procedure. This is
considered standard shop practice even if not specifically stated.
When valve train components are removed for service, they should be retained in order. At the time of
installation, they should be installed in the same locations and with the same mating surfaces as when removed.
ENGINE COMPONENT DESCRIPTION
Cylinder Block
The cylinder hollow frame structured 4 cylinder in-line. The block has 5 crankshaft bearings with the thrust
bearing located on the third bearing from the front of the engine.
Crankshaft
The crankshaft is a steel crankshaft. It is supported in 5 main journals with main bearings which have oil
clearance for lubricating. The 3rd bearing of the 5 main bearing is the thrust bearing whose the crankshaft has
properly axial end play. A harmonic damper is used to control torsional vibration.
Oil Pump
The oil pump is a crankshaft driven oil pump integrated in pump module. The oil pump draws engine oil from
the oil pan and feeds it under pressure to the various parts of the engine. An oil strainer is mounted before the
inlet of the oil pump to remove impurities which could clog or damage the oil pump or other engine
components. When the crankshaft rotates, the oil pump driven gear rotates. This causes the space between the
gears to constantly open and narrow, pulling oil in from the oil pan when the space opens and pumping the oil
out to the engine as it narrows. At high engine speeds, the oil pump supplies a much higher amount of oil than
required for lubrication of the engine. The oil pressure regulator prevents too much oil from entering the engine
lubrication passages.
Oil Pan
The oil pan is a structural aluminum oil pan with transmission attachment. It includes the oil suction pipe, this
pipe is connected with the oil pump. The oil pan is attached at the engine block.
Piston and Connecting Rod
The Pistons are aluminum pistons with top land and floating pin. The connecting rods are fractured steel
connecting rods with bushing.
Cylinder Head
This cylinder head is double over head camshaft (DOHC) type and has 2 camshafts that open 4 valves per
cylinder with tappets. The camshaft sprocket wheels are installed in front of the camshafts. The cylinder head is
made of cast aluminum alloy for better strength in hardness with light weight. The combustion chamber of the
cylinder head is designed for increasing of squish and swirl efficiency and then this is maximized to gasoline

combustion efficiency.
Valves
There are 2 intake and 2 exhaust valves with tappets per cylinder.
Camshaft
Two camshafts are used, one for all intake valves, the other for all exhaust valves. The camshafts are cast iron.
The camshafts are driven by the crankshaft over the timing belt.
Camshaft Drive
A timing belt is used for camshaft drive. There is a tensioner to control the tension of the belt. Instead of
camshaft gears or camshaft sprockets the engine is equipped with camshaft adjuster. The camshaft adjuster
readjust itself at the engine speed. So the valve timing is adjusted for a low consumption, optimal power and
torque.
Intake Manifold
The intake manifold is the air flow passage to the cylinder combustion chamber through the throttle body and
has an effect on engine torque, power, noise, drivability, emission, fuel economy and performance. It is made of
plastic for better strength in hardness with little weight.
Exhaust Manifold
The exhaust manifold is located to the cylinder head and channels the exhaust gas out of the combustion
chamber. It is designed to endure on high pressure and high temperature. The exhaust manifold includes the
catalytic converter.
Positive Crankcase Ventilation System
The crankcase ventilation system is used to consume crankcase vapors in the combustion process instead of
venting vapors to the atmosphere. Fresh air from the intake system is supplied to the crankcase, mixed with
blow-by gases and then passed through a calibrated orifice into the throttle body. The primary control is through
the positive crankcase ventilation (PCV) orifice which meters the flow at a rate depending on inlet vacuum. The
PCV orifice is an integral part of the camshaft cover. If abnormal operating conditions occur, the system is
designed to allow excessive amounts of blow-by gases to back flow through the crankcase vent into the intake
system to be consumed by normal combustion.
LUBRICATION DESCRIPTION

Fig. 554: Engine Lubrication System

Oil is applied under pressure to the crankshaft (8), connecting rods (5), camshaft adjuster (1), camshaft bearing
surfaces (3) and valve tappets (4). All other moving parts are lubricated by gravity flow or splash. Oil enters the
rotor type oil pump (10) through a fixed inlet screen (9). The oil pump is driven by the crankshaft. The oil pump
body is within the engine front cover (11). The pressurized oil from the pump passes through the oil cooling
system and the oil filter (6). The oil filter is integrated with the oil cooling system housing (7) that is connected
to the front of the engine block. The oil filter is a disposable cartridge type. A by-pass valve in the filter cap
allows continuous oil flow in case the oil filter should become restricted. The connecting rod bearings are oiled
by constant oil flow passages through the crankshaft connecting the main journals to the rod journals. A groove
around each upper main bearing furnishes oil to the drilled crankshaft passages. The pressurized oil passes
through the cylinder head restrictor orifice into the cylinder head and then into each camshaft feed gallery. An
engine oil pressure switch or sensor is installed at the end. Oil returns to the oil pan through passages cast into
the cylinder head. The crankcase ventilation system does not contain to the lubrication system, but to the oil
circuit. It is used to consume crankcase vapors in the combustion process instead of venting them to
atmosphere. Fresh air from the intake system is supplied to the crankcase, mixed with blow by gases and then
passed through a calibrated orifice of the crankcase ventilation tube (2) into the intake manifold.

REPLACING ENGINE GASKETS

Gasket Reuse and Applying Sealants
Do not reuse any gasket unless specified.

Gaskets that can be reused will be identified in the service procedure.
Do not apply sealant to any gasket or sealing surface unless called out in the service information.
Separating Components
Use a rubber mallet to separate components.

Bump the part sideways to loosen the components.
Bumping should be done at bends or reinforced areas to prevent distortion of parts.
Cleaning Gasket Surfaces
Remove all gasket and sealing material from the part using a scraping tool.
Care must be used to avoid gouging or scraping the sealing surfaces.
Do not use any other method or technique to remove sealant or gasket material from a part.
Do not use abrasive pads, sand paper, or power tools to clean the gasket surfaces.
These methods of cleaning can cause damage to the component sealing surfaces.
Abrasive pads also produce a fine grit that the oil filter cannot remove from the oil.
This grit is abrasive and has been known to cause internal engine damage.
Assembling Components
When assembling components, use only the sealant specified or equivalent in the service procedure.
Sealing surfaces should be clean and free of debris or oil.
Specific components such as crankshaft oil seals or valve stem oil seals may require lubrication during
assembly.
Components requiring lubrication will be identified in the service procedure.
When applying sealant to a component, apply the amount specified in the service procedure.
Do not allow the sealant to enter into any blind threaded holes, as it may prevent the bolt from clamping
properly or cause component damage when tightened.
Tighten bolts to specifications. Do not overtighten.
SEPARATING PARTS
NOTE:
Disassembly of the piston, press fit design piston pin, and connecting rod
may create scoring or damage to the piston pin and piston pin bore. If the
piston, pin, and connecting rod have been disassembled, replace the
components as an assembly.
Many internal engine components will develop specific wear patterns on

their friction surfaces.

When disassembling the engine, internal components MUST be separated,
marked, or organized in a way to ensure installation to their original
location and position.
Separate, mark, or organize the following components:
Piston and the piston pin

Piston to the specific cylinder bore
Piston rings to the piston
Connecting rod to the crankshaft journal
Connecting rod to the bearing cap-A paint stick or etching/engraving type tool are recommended.
Stamping the connecting rod or cap near the bearing bore may affect component geometry.
Crankshaft main and connecting rod bearings
Camshaft and valve tappets
Valve to the valve guide
Valve spring and shim to the cylinder head location
Engine block main bearing cap location and direction
Oil pump drive and driven gears
TOOLS AND EQUIPMENT

Special tools are listed and illustrated throughout this section with a complete listing at the end of the section.
These tools, or their equivalents, are specially designed to quickly and safely accomplish the operations for
which they are intended. The use of these special tools will also minimize possible damage to engine
components. Some precision measuring tools are required for inspection of certain critical components. Torque
wrenches and a torque angle meter are necessary for the proper 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 suitable parts cleaning tank
A compressed air supply
Trays or storage containers to keep parts and fasteners organized
An adequate set of hand tools
Approved engine repair stand
An approved engine lifting device that will adequately support the weight of the components
USE OF ROOM TEMPERATURE VULCANIZING (RTV) AND ANAEROBIC SEALANT

Pipe Joint Compound

NOTE:
Three types of sealer are commonly used in engines. These are RTV sealer,
anaerobic gasket eliminator sealer, and pipe joint compound. The correct sealer
and amount must be used in the proper location to prevent oil leaks. DO NOT
interchange the 3 types of sealers. Use only the specific sealer or the equivalent
as recommended in the service procedure.
Pipe joint compound is a pliable sealer that does not completely harden. This type sealer is used where 2
non-rigid parts, such as the oil pan and the engine block, are assembled together.
Do not use pipe joint compound in areas where extreme temperatures are expected. These areas include:
exhaust manifold, head gasket, or other surfaces where gasket eliminator is specified.
Follow all safety recommendations and directions that are on the container.
To remove the sealant or the gasket material.
Apply the pipe joint compound to a clean surface. Use a bead size or quantity as specified in the
procedure. Run the bead to the inside of any bolt holes. Do not allow the sealer to enter any blind
threaded holes, as it may prevent the bolt from clamping properly or cause component damage when the
bolt is tightened.
Apply a continuous bead of pipe joint compound to one sealing surface. Sealing surfaces to be resealed
must be clean and dry.
Tighten the bolts to specifications. Do not overtighten.

SPECIAL TOOLS
Illustration
207649
Rod Hairpins
547324
Flange Screws
EN-232
KM-232
J-21867-L40
Oil Pressure Check Adapter

EN-235-6
KM-235-6
Installer
EN-328-B
GE-328-B
KM-328-B
GE-6125-1B
Remover
EN-422
KM-422
83 94 959
Installer
EN-498-B
GE-21867-A
J-21867-A
KM-498-B
CH-48027
Pressure Gauge and Adapter Set
EN-652
KM-652
Flywheel Holder
EN-658-1
KM-658-1
J-35264
Installer
EN-796
KM-796-A
Dismantler
CH-807
KM-807
Closure Plugs
EN-840

KM-840
J-36017
83 94 157
Remover
EN-845
KM-845
Suction Device
EN-849
KM-849
Assembly Tray
EN-958
KM-958
Valve Stem Seal Installer
EN-6009
KM-6009
83 96 335
J-43301
Remover/Installer
EN-6333
KM-6333
Locking Pin
EN-6340
KM-6340
Locking Tool
EN-6349
KM-6349
Locking Pin

EN-6351
KM-6351
Assembly Sleeves
EN-6361
KM-6361
Feeler Gauge Set
EN-6624
KM-6624
Remover
EN-6625
KM-6625
Flywheel Locking Device
EN-6628-A
KM-6628-A
Locking Tool
EN-8087
J-8087
Cylinder Bore Gauge
EN-28467-B
J-28467-B
Universal Engine Support Fixture
EN-34730-91
KM-34730-91
Pressure Tester

EN-36857
J-36857
Engine Lift Bracket
EN-43405
J-43405
Support Foot Set
EN-45000
KM-45000
J-45000
Seal Remover
EN-45059
J-45059
Angle Meter
GE-571-B
MKM-571-B
GE-8001
J-8001
Dial Gauge
GE-22738-B
J-22738-B
Valve Spring Tester
J-37088-A
KM-37088A
Fuel Line Disconnect Tool Set
EN-50717-1
Stands

EN-50717-2
Compressor
EN-8062
J-8062
Valve Spring Compressor

2013 ENGINE PERFORMANCE Engine Controls and Fuel - 1.4L LUV - Description and Operation - Cruze
2013 ENGINE PERFORMANCE

Engine Controls and Fuel - 1.4L LUV - Description and Operation - Cruze

CAMSHAFT ACTUATOR SYSTEM DESCRIPTION
Camshaft Actuator System Overview
Fig. 1: Identifying Camshaft Actuator System Components

Callout
1
2
3
4
5
6
7
8
9
10
11
Component Name
Camshaft Actuator Vane
Timing Chain Sprocket
Engine Oil Pressure-For retarding the camshaft
Camshaft
Input Signals from Engine Sensors
Camshaft Actuator Solenoid
Engine Oil Pump
Engine Oil Pressure Supply
Engine Oil Drain
Engine Oil Pressure-For advancing the camshaft

12
13
14
15
Camshaft Actuator Rotor

Camshaft Position Sensor Reluctor
Camshaft Actuator Lock Pin
Camshaft Actuator Housing
The camshaft actuator system enables the engine control module (ECM) to change camshaft timing of all 4
camshafts while the engine is operating. The camshaft position (CMP) actuator assembly (15) varies the
camshaft position in response to directional changes in oil pressure. The CMP actuator solenoid valve controls
the oil pressure that is applied to advance or retard a camshaft. Modifying camshaft timing under changing
engine demand provides better balance between the following performance concerns:
Engine power output

Fuel economy
Tailpipe emissions
The CMP actuator solenoid valve (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 desired camshaft positions:
Engine coolant temperature

Calculated engine oil temperature (EOT)
Mass air flow (MAF)
Throttle position (TP)
Vehicle speed
Volumetric efficiency
Operation
The CMP actuator assembly has an outer housing that is driven by an engine timing chain. Inside the assembly
is a rotor with fixed vanes that is attached to the camshaft. Oil pressure that is applied to the fixed vanes will
rotate a specific camshaft in relationship to the crankshaft. The movement of the intake camshafts will advance
the intake valve timing. The movement of the exhaust camshafts will retard the exhaust valve timing. When oil
pressure is applied to the return side of the vanes, the camshafts will return to 0 crankshaft degrees, or top dead
center (TDC). The CMP actuator solenoid valve directs the oil flow that controls the camshaft movement. The
ECM commands the CMP solenoid to move the solenoid plunger and spool valve until oil flows from the
advance passage (11). Oil flowing thru the CMP actuator assembly from the CMP solenoid advance passage
applies pressure to the advance side of the vanes in the CMP actuator assembly. When the camshaft position is
retarded, the CMP actuator solenoid valve directs oil to flow into the CMP actuator assembly from the retard
passage (3). The ECM can also command the CMP actuator solenoid valve to stop oil flow from both passages
in order to hold the current camshaft position.
The ECM operates the CMP actuator solenoid valve by pulse width modulation (PWM) of the solenoid coil.
The higher the PWM duty cycle, the larger the change in camshaft timing. The CMP actuator assembly also
contains a lock pin (14) that prevents movement between the outer housing and the rotor vane assembly. The
lock pin is released by oil pressure before any movement in the CMP actuator assembly takes place. The ECM

is continuously comparing CMP sensor inputs with CKP sensor input in order to monitor camshaft position and
detect any system malfunctions. 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 Operation
Change in Camshaft
Position
Driving Condition
Objective
Idle
No Change
Minimize Valve Overlap
Light Engine Load
Retarded Valve Timing Decrease Valve Overlap
Medium Engine Load
Low to Medium RPM
with Heavy Load
High RPM with Heavy
Load
Advanced Valve Timing Increase Valve Overlap

Advanced Valve Timing
Retarded Valve Timing
Advance Intake Valve

Closing
Retard Intake Valve
Closing
Result
Stabilized Idle Speed
Stabled Engine Output
Better Fuel Economy
with Lower Emissions
Improved Low to Midrange Torque
Improved Engine Output
ELECTRONIC IGNITION SYSTEM DESCRIPTION

Electronic Ignition System Operation
The electronic ignition system produces and controls the high energy secondary spark. This spark ignites the
compressed air/fuel mixture at precisely the correct time, providing optimal performance, fuel economy, and
control of exhaust emissions. The engine control module (ECM) collects information from the crankshaft
position sensor and the intake/exhaust camshaft position sensors to determine the sequence, dwell, and timing
of the spark for each cylinder. The ECM transmits a frequency signal to the ignition coil module on the
individual ignition control circuits to fire the spark plugs.
The crankshaft position sensor is an externally magnetically biased digital output integrated circuit sensing
device. The sensor provides a pulse for each magnetic pole of the encoder wheel on the crankshaft. The sensor
produces an ON/OFF DC voltage of varying frequency, with 58 output pulses per crankshaft revolution. The
frequency of the sensor output depends on the velocity of the crankshaft. The ECM uses sensor signal pulse to
determine crankshaft speed and position to calculate the best timing for ignition and fuel injection. The ECM
also uses the crankshaft position sensor information to control camshaft phasing and to detect cylinder misfire.
The ECM also has a dedicated replicated crankshaft position sensor signal output circuit that may be used as an
input signal to other modules for monitoring engine RPM.
The crankshaft position sensor is connected to the engine control module by the circuits listed below:
A 5 V reference circuit
A low reference circuit
A signal circuit
Crankshaft Encoder Wheel

The crankshaft encoder wheel is part of the crankshaft. The encoder wheel consists of 58 tooth and a reference
gap. Each tooth on the encoder wheel is spaced 6 apart with a 12 space for the reference gap. The pulse from
the reference gap is known as the sync pulse. The sync pulse is used to synchronize the ignition coil module
firing sequence with the crankshaft position while the other tooth provides cylinder location during a revolution.
Camshaft Position Sensors
The intake and exhaust camshaft position sensors are each triggered by a notched reluctor wheel built onto the
camshaft sprockets. The four signal pulses occur every camshaft revolution. Each notch is a different size which
is used to identify the compression stroke of each cylinder and to enable sequential fuel injection. The camshaft
position sensors are connected to the ECM by the circuits listed below:
A 5 V reference circuit
A signal circuit
Ignition Coil Module
The ignition coil module integrates the 4 coils and the ignition control module within a single sealed
component.
The ignition coil module has the following circuits:
An ignition voltage circuit

A ground
4 ignition coil control circuits
The ECM controls the individual coils by transmitting timing pulses on the ignition coil control circuit to each
ignition coil to enable a spark event.
The spark plugs are connected to each coil by a short boot. The boot contains a spring that conducts the spark
energy from the coil to the spark plug. The spark plug electrode is coated with platinum for long wear and
higher efficiency.
The ECM controls all ignition system functions and constantly adjusts the spark timing. The ECM monitors
information from various sensor inputs that include the following:
The crankshaft position sensor

The accelerator pedal position (APP)
The manifold absolute pressure (MAP) sensor
The intake air temperature (IAT) sensor
The vehicle speed sensor (VSS)

The engine knock sensor

The engine coolant temperature (ECT) sensor
The mass airflow (MAF) sensor
The camshaft position sensors
ENGINE CONTROL MODULE DESCRIPTION

The Engine Control Module (ECM) interacts with many emission related components and systems, and
monitors emission related components and systems for deterioration. OBD II diagnostics monitor the system
performance and a diagnostic trouble code (DTC) sets if the system performance degrades. The ECM is part of
a network and communicates with various other vehicle control modules.
Malfunction indicator lamp (MIL) operation and DTC storage are dictated by the DTC type. A DTC is ranked
as a Type A or Type B if the DTC is emissions related. Type C is a non-emissions related DTC.
The ECM is the control center of the engine controls system. Review the components and wiring diagrams in
order to determine which systems are controlled by the ECM.
The ECM constantly monitors the information from various sensors and other inputs, and controls the systems
that affect engine performance and emissions. The ECM also performs diagnostic tests on various parts of the
system and can turn on the MIL when it recognizes an operational problem that affects emissions. When the
ECM detects a malfunction, the ECM stores a DTC. The condition area is identified by the particular DTC that
is set. This aids the technician in making repairs.
ECM Function
The ECM can supply 5 V or 12 V to various sensors or switches. This is done through pull-up resistors to
regulated power supplies within the ECM. In some cases, even an ordinary shop voltmeter will not give an
accurate reading due to low input resistance. Therefore, a digital multimeter (DMM) with at least 10 megaohms
input impedance is required in order to ensure accurate voltage readings.
The ECM controls the output circuits by controlling the ground or the power feed circuit through transistors or a
device called an output driver module.
EEPROM
The electronically erasable programmable read only memory (EEPROM) is an integral part of the ECM. The
EEPROM contains program and calibration information that the ECM needs in order to control engine
operation.
Special equipment, as well as the correct program and calibration for the vehicle, are required in order to
reprogram the ECM.
Data Link Connector (DLC)
The data link connector (DLC) provides serial data communication for ECM diagnosis. This connector allows
the technician to use a scan tool in order to monitor various serial data parameters, and display DTC

information. The DLC is located inside the driver's compartment, underneath the instrument panel.
Malfunction Indicator Lamp (MIL)
The malfunction indicator lamp (MIL) is inside the instrument panel cluster (IPC). The MIL is controlled by the
ECM and illuminates when the ECM detects a condition that affects vehicle emissions.
ECM Service Precautions
The ECM, by design, can withstand normal current draws that are associated with vehicle operations. However,
care must be used in order to avoid overloading any of these circuits. When testing for opens or shorts, do not
ground or apply voltage to any of the ECM circuits unless the diagnostic procedure instructs you to do so. These
circuits should only be tested with a DMM unless the diagnostic procedure instructs otherwise.
Emissions Diagnosis For State I/M Programs
This OBD II equipped vehicle is designed to diagnose any conditions that could lead to excessive levels of the
following emissions:
Hydrocarbons (HC)
Carbon monoxide (CO)
Oxides of nitrogen (NOx)
Evaporative emission (EVAP) system losses
Should this vehicle's on-board diagnostic system (ECM) detect a condition that could result in excessive
emissions, the ECM turns ON the MIL and stores a DTC that is associated with the condition.
Aftermarket (Add-On) Electrical And Vacuum Equipment
CAUTION: Do not attach add-on vacuum operated equipment to this vehicle. The use
of add-on vacuum equipment may result in damage to vehicle components
or systems.
CAUTION: Connect any add-on electrically operated equipment to the vehicle's
electrical system at the 12 V battery (power and ground) in order to
prevent damage to the vehicle.
Aftermarket, add-on, electrical and vacuum equipment is defined as any equipment installed on a vehicle after
leaving the factory that connects to the vehicle's electrical or vacuum systems. No allowances have been made
in the vehicle design for this type of equipment.
Add-on electrical equipment, even when installed to these strict guidelines, may still cause the powertrain
system to malfunction. This may also include equipment not connected to the vehicle electrical system, such as
portable telephones and radios. Therefore, the first step in diagnosing any powertrain condition is to eliminate
all of the aftermarket electrical equipment from the vehicle. After this is done, if the problem still exists, the
problem may be diagnosed in the normal manner.

Electrostatic Discharge (ESD) Damage
NOTE:
In order to prevent possible electrostatic discharge damage to the ECM, DO

NOT touch the connector pins on the ECM.
The electronic components that are used in the control systems are often designed to carry very low voltage.
These electronic components are susceptible to damage caused by electrostatic discharge. Less than 100 V of
static electricity can cause damage to some electronic components. By comparison, it takes as much as 4, 000 V
for a person to even feel a static discharge.
There are several ways for a person to become statically charged. The most common methods of charging are
by friction and by induction. An example of charging by friction is a person sliding across a car seat.
Charging by induction occurs when a person with well insulated shoes stands near a highly charged object and
momentarily touches ground. Charges of the same polarity are drained off leaving the person highly charged
with the opposite polarity. Static charges can cause damage, therefore, it is important to use care when handling
and testing electronic components.
Emissions Control Information Label
The underhood Vehicle Emissions Control Information Label contains important emission specifications. This
identifies the year, the displacement of the engine in liters, and the class of the vehicle.
This label is located in the engine compartment of every General Motors vehicle. If the label has been removed,
it can be ordered from GM service parts operations (GMSPO).
EVAPORATIVE EMISSION CONTROL SYSTEM DESCRIPTION
Typical Evaporative Emission (EVAP) System Hose Routing Diagram

Fig. 2: View Of Evaporative Emission (EVAP) System Hose Routing Diagram

Callout
1
2
3
4
5
6
7
8
9
10
11
12
13
Component Name
Evaporative Emissions (EVAP) Purge Solenoid Valve
EVAP Canister
EVAP Vapor Tube
Vapor Recirculation Tube
Fuel Tank Pressure Sensor
Fuel Filler Cap (Some Vehicles May Have A Capless Design)
Fuel Fill Pipe Inlet Check Valve
Fuel Tank
EVAP Canister Vent Solenoid Valve
Vent hose
EVAP Purge Tube
Purge Tube Check Valve, Turbo-Charged Applications Only
EVAP Canister Purge Tube Connector

EVAP System Operation
The evaporative emission (EVAP) control system limits fuel vapors from escaping into the atmosphere. Fuel
tank vapors are allowed to move from the fuel tank, due to pressure in the tank, through the EVAP vapor tube,
into the EVAP canister. Carbon in the canister absorbs and stores the fuel vapors. Excess pressure is vented
through the vent hose and EVAP vent solenoid valve to the atmosphere. The EVAP canister stores the fuel
vapors until the engine is able to use them. At an appropriate time, the engine control module (ECM) will
command the EVAP purge solenoid valve ON, allowing engine vacuum to be applied to the EVAP canister.
With the normally open EVAP vent solenoid valve OFF, fresh air is drawn through the vent solenoid valve and
the vent hose to the EVAP canister. Fresh air is drawn through the canister, pulling fuel vapors from the carbon.
The air/fuel vapor mixture continues through the EVAP purge tube and EVAP purge solenoid valve into the
intake manifold to be consumed during normal combustion. The ECM uses several tests to determine if the
EVAP system is leaking or restricted.
Purge Solenoid Valve Leak Test
If the EVAP purge solenoid valve does not seal properly fuel vapors could enter the engine at an undesired
time, causing driveability concerns. The ECM tests for this by commanding the EVAP purge solenoid valve
OFF and the vent solenoid valve ON which seals the system. With the engine running, the ECM then monitors
the fuel tank pressure (FTP) sensor for an increase in vacuum. The ECM will log a fault if a vacuum develops in
the tank under these test conditions.
Large Leak Test
This diagnostic creates a vacuum condition in the EVAP system. When the enabling criteria has been met, the
ECM commands the normally open EVAP vent solenoid valve closed and the EVAP purge solenoid valve
open, creating a vacuum in the EVAP system. The ECM then monitors the FTP sensor voltage to verify that the
system is able to reach a predetermined level of vacuum within a set amount of time. Failure to achieve the
expected level of vacuum indicates the presence of a large leak in the EVAP system or a restriction in the purge
path. The ECM will log a fault if it detects a weaker than expected vacuum level under these test conditions.
Canister Vent Restriction Test
If the EVAP vent system is restricted, fuel vapors will not be properly purged from the EVAP canister. The
ECM tests this by commanding the EVAP purge solenoid valve ON while commanding the EVAP vent
solenoid valve OFF, and then monitoring the FTP sensor for an increase in vacuum. If the vacuum increases
more than the expected amount, in a set amount of time, a fault will be logged by the ECM.
Small Leak Test
The engine off natural vacuum diagnostic is the small-leak detection diagnostic for the EVAP system. The
engine off natural vacuum diagnostic monitors the EVAP system pressure with the ignition OFF. Because of
this, it may be normal for the ECM to remain active for up to 40 min after the ignition is turned OFF. This is
important to remember when performing a parasitic draw test on vehicles equipped with engine off natural
vacuum.
When the vehicle is driven, the temperature rises in the tank due to heat transfer from the exhaust system. After
the vehicle is parked, the temperature in the tank continues to rise for a period of time, then starts to drop. The

engine off natural vacuum diagnostic relies on this temperature change, and the corresponding pressure change
in a sealed system, to determine if an EVAP system leak is present.
The engine off natural vacuum diagnostic is designed to detect leaks as small as 0.51 mm (0.020 in).
EVAP System Components
The EVAP system consists of the following components:

EVAP Purge Solenoid Valve
The EVAP purge solenoid valve controls the flow of vapors from the EVAP system to the intake manifold. The
purge solenoid valve opens when commanded ON by the ECM. This normally closed valve is pulse width
modulated (PWM) by the ECM to precisely control the flow of fuel vapor to the engine. The valve will also be
opened during some portions of the EVAP testing when the engine is running, allowing engine vacuum to enter
the EVAP system.
Purge Tube Check Valve
Turbocharged vehicles have a check valve in the purge tube between the EVAP purge solenoid valve and the
EVAP canister to prevent pressurization of the EVAP system under boost conditions. Note that the presence of
this one-way check valve prevents pressure testing the EVAP system for leaks at the EVAP canister purge tube
connector.
EVAP Canister
The canister is filled with carbon pellets used to absorb and store fuel vapors. Fuel vapor is stored in the canister
until the ECM determines that the vapor can be consumed in the normal combustion process.
Vapor Recirculation Tube
A vapor path between the fuel fill pipe and the vapor tube to the carbon canister is necessary for Vehicle
Onboard Diagnostics to fully diagnose the EVAP system. It also accommodates service diagnostic procedures
by allowing the entire EVAP system to be diagnosed from either end of the system.
Fuel Tank Pressure Sensor
The FTP sensor measures the difference between the pressure or vacuum in the fuel tank and outside air
pressure. The ECM provides a 5 V reference and a ground to the FTP sensor. Depending on the vehicle, the
sensor can be located in the vapor space on top of the fuel tank, in the vapor tube between the canister and the
tank, or on the EVAP canister. The FTP sensor provides a signal voltage back to the ECM that can vary
between 0.1-4.9 V. A high FTP sensor voltage indicates a low fuel tank pressure or vacuum. A low FTP sensor
voltage indicates a high fuel tank pressure.
Fuel Fill Pipe Check Valve
The check valve on the fuel fill pipe is there to prevent spit-back during refueling.

EVAP Vent Solenoid Valve

The EVAP vent solenoid valve controls fresh airflow into the EVAP canister. The valve is normally open. The
canister vent solenoid valve is closed only during EVAP system tests performed by the ECM.
Fuel Fill Cap
The fuel fill cap is equipped with a seal and a vacuum relief valve.
Capless Fuel Fill
Some vehicles may have a capless fuel fill design behind a locking fuel door. There is no fuel fill cap to
remove. One just fully inserts the fuel nozzle into the fill neck, making sure it latches before refueling. Flapper
valves close to seal this interface once the fill nozzle is removed.
FUEL SYSTEM DESCRIPTION
Fuel System Overview
The fuel system is an electronic returnless on-demand design. A returnless fuel system reduces the internal
temperature of the fuel tank by not returning hot fuel from the engine to the fuel tank. Reducing the internal
temperature of the fuel tank results in lower evaporative emissions.
The fuel tank stores the fuel supply. An electric turbine style fuel pump attaches to the fuel tank fuel pump
module inside the fuel tank. The fuel pump supplies fuel through the fuel feed pipe to the fuel injection system.
The fuel tank fuel pump module contains a reverse flow check valve. The check valve maintains fuel pressure
in the fuel feed pipe and the fuel rail in order to prevent long cranking times.
Electronic Returnless Fuel System
The electronic returnless fuel system is a microprocessor controlled fuel delivery system which transports fuel
from the tank to the fuel rail. It functions as an electronic replacement for a traditional, mechanical fuel pressure
regulator. A pressure relief regulator valve within the fuel tank provides an added measure of over pressure
protection. Desired fuel pressure is commanded by the engine control module (ECM), and transmitted to the
fuel pump flow control module via a GMLAN serial data message. A liquid fuel pressure sensor provides the
feedback the fuel pump flow control module requires for Closed Loop fuel pressure control.
Fuel Pump Flow Control Module
The fuel pump flow control module is a serviceable GMLAN module. The fuel pump flow control module
receives the desired fuel pressure message from the engine control module (ECM) and controls the fuel pump
located within the fuel tank to achieve the desired fuel pressure. The fuel pump flow control module sends a 25
kHz PWM signal to the fuel pump, and pump speed is changed by varying the duty cycle of this signal.
Maximum current supplied to the fuel pump is 15 A. A liquid fuel pressure sensor provides fuel pressure
feedback to the fuel pump flow control module.

The fuel pressure sensor is a serviceable 5 V, 3-pin device. It is located on the fuel feed line forward of the fuel
tank, and receives power and ground from the fuel pump flow control module through a vehicle wiring harness.
The sensor provides a fuel pressure signal to the fuel pump flow control module, which is used to provide
Closed Loop fuel pressure control.
Fuel Tank
The fuel tank stores the fuel supply. The fuel tank is located in the rear of the vehicle. The fuel tank is held in
place by 2 metal straps that are attached to the underbody. The fuel tank is molded from high-density
polyethylene.
Fuel Filler Cap
The fuel fill pipe has a tethered fuel filler cap. A torque-limiting device prevents the cap from being
overtightened. To install the cap, turn the cap clockwise until the cap clicks audibly. This indicates that the cap
is correctly torqued and fully seated.
Fuel Tank Fuel Pump Module
The fuel tank fuel pump module consists of the following components:
The fuel level sensor

The fuel pump
The fuel strainer
The pressure relief regulator valve
The jet pump
Fuel Level Sensor
The fuel level sensor consists of a float, a wire float arm, and a ceramic resistor card. The position of the float
arm indicates the fuel level. The fuel level sensor contains a variable resistor which changes resistance in
correspondence with the position of the float arm. The ECM sends the fuel level signal via a High Speed CANBus signal to the body control module (BCM). The BCM then sends the information via a Low Speed CANBus signal to the instrument cluster to display the fuel level. When the fuel level falls below 11% the instrument
cluster illuminates the low fuel level indicator. The ECM also monitors the fuel level input for various
diagnostics.
Fuel Pump
The fuel pump is mounted in the fuel tank fuel pump module reservoir. The fuel pump is an electric pump. Fuel
is pumped to the fuel injection system at a pressure that is based on feedback from the fuel pressure sensor. The
fuel pump delivers a constant flow of fuel even during low fuel conditions and aggressive vehicle maneuvers.
The fuel pump flex pipe acts to dampen the fuel pulses and noise generated by the fuel pump.
Fuel Strainer
The fuel strainer is attached to the lower end of the fuel tank fuel pump module. The fuel strainer is made of

woven plastic. The functions of the fuel strainer are to filter contaminants and to wick away fuel. Normally, the
fuel strainer does not require maintenance. Fuel stoppage at this point indicates that the fuel tank contains an
abnormal amount of sediment or contamination.
Jet Pump
The jet pump is located in the fuel tank fuel pump module. Fuel pump flow loss, caused by vapor expulsion in
the pump inlet chamber, is diverted to the jet pump through a restrictive orifice located on the pump cover. The
jet pump fills the reservoir of the fuel tank fuel pump module.
Pressure Relief Regulator Valve
The pressure relief regulator valve replaces the typical fuel pressure regulator used on a mechanical returnless
fuel system. The pressure relief regulator valve is closed during normal vehicle operation. The pressure relief
regulator valve is used to vent pressure during hot soaks and also functions as a fuel pressure regulator in the
event of the fuel pump flow control module defaulting to 100% pulse width modulation (PWM) of the fuel
pump. Due to variation in the fuel system pressures, the opening pressure for the pressure relief regulator valve
is set higher than the pressure that is used on a mechanical returnless fuel system pressure regulator.
Nylon Fuel Pipes
WARNING: Refer to Fuel and Evaporative Emission Pipe Warning .
Nylon pipes are constructed to withstand maximum fuel system pressure, exposure to fuel additives, and
changes in temperature.
Heat resistant rubber hose or corrugated plastic conduit protect the sections of the pipes that are exposed to
chafing, high temperature, or vibration.
Nylon fuel pipes are somewhat flexible and can be shaped around gradual turns under the vehicle. However, if
nylon fuel pipes are forced into sharp bends, the pipes may kink and restrict the flow of fuel. Also, once
exposed to fuel, nylon pipes may become stiffer and are more likely to kink if bent too far. Exercise special care
when working on a vehicle with nylon fuel pipes.
Quick-Connect Fittings
Nylon fuel pipes are somewhat flexible and can be shaped around gradual turns under the vehicle. However, if
nylon fuel pipes are forced into sharp bends, the pipes may kink and restrict the flow of fuel. Also, once
exposed to fuel, nylon pipes may become stiffer and are more likely to kink if bent too far. Exercise special care
when working on a vehicle with nylon fuel pipes.
Fuel Rail Assembly
The fuel rail assembly is attached to the engine intake manifold. The fuel rail assembly performs the following
functions:

Positions the injectors in the intake manifold

Distributes fuel evenly to the injectors
Fuel Injectors
The fuel injector assembly is a solenoid device controlled by the ECM that meters pressurized fuel to a single
engine cylinder. The ECM energizes the high-impedance, 12 ohms, injector solenoid to open a ball valve,
normally closed. This allows fuel to flow into the top of the injector, past the ball valve, and through a director
plate at the injector outlet. The director plate has machined holes that control the flow of fuel, generating a
spray of finely atomized fuel at the injector tip. Fuel from the injector tip is directed at the intake valve, causing
the fuel to become further atomized and vaporized before entering the combustion chamber. This fine
atomization improves fuel economy and emissions.
Fuel Metering Modes of Operation
The ECM monitors voltages from several sensors in order to determine how much fuel to feed to the engine.
The ECM controls the amount of fuel delivered to the engine by changing the fuel injector pulse width. The fuel
is delivered under one of several modes.
Starting Mode
The ECM supplies voltage to the fuel pump control module when the ECM detects that the ignition is ON. The
voltage from the ECM to the fuel pump control module remains active for 2 s, unless the engine is in Crank or
Run. While this voltage is being received, the fuel pump control module closes the ground switch of the fuel
tank fuel pump module and also supplies a varying voltage to the fuel tank fuel pump module in order to
maintain the desired fuel line pressure. The ECM calculates the air/fuel ratio based on inputs from the engine
coolant temperature (ECT), manifold absolute pressure (MAP), mass air flow (MAF), and throttle position
sensors. The system stays in starting mode until the engine speed reaches a predetermined RPM.
Clear Flood Mode
If the engine is flooded with fuel during starting and will not start, the clear flood mode can be manually
enabled. To enable Clear Flood Mode, press the accelerator to wide open throttle (WOT). The ECM will
completely turn OFF the fuel injectors and will maintain this mode as long as the ECM detects a WOT
condition with engine speed below a predetermined value.
Run Mode
The run mode has 2 conditions called Open Loop and Closed Loop. When the engine is first started and the
engine speed is above a predetermined RPM, the system begins Open Loop operation. The ECM ignores the
signal from the heated oxygen sensor (HO2S). The ECM calculates the air/fuel ratio based on inputs from the
engine coolant temperature (ECT), manifold absolute pressure (MAP), mass air flow (MAF), and throttle
position sensors. The system stays in Open Loop until meeting the following conditions:
The HO2S has varying voltage output, showing that the HO2S is hot enough to operate properly.
The ECT sensor is above a specified temperature.
A specific amount of time has elapsed after starting the engine.

Specific values for the above conditions exist for each different engine, and are stored in the electrically
erasable programmable read-only memory (EEPROM). The system begins Closed Loop operation after
reaching these values. In Closed Loop, the ECM calculates the air/fuel ratio, injector ON time, based upon the
signal from various sensors, but mainly from the HO2S. This allows the air/fuel ratio to stay very close to
14.7:1.
Acceleration Mode
When the driver pushes on the accelerator pedal, air flow into the cylinders increases rapidly. To prevent
possible hesitation, the ECM increases the pulse width to the injectors to provide extra fuel during acceleration.
This is also known as power enrichment. The ECM determines the amount of fuel required based upon throttle
position, engine coolant temperature (ECT), manifold absolute pressure (MAP), mass air flow (MAF), and
engine speed.
Deceleration Mode
When the driver releases the accelerator pedal, air flow into the engine is reduced. The ECM monitors the
corresponding changes in throttle position, mass air flow (MAF), and manifold absolute pressure (MAP). The
ECM shuts OFF fuel completely if the deceleration is very rapid, or for long periods, such as long, closedthrottle coast-down. The fuel shuts OFF in order to prevent damage to the catalytic converters.
Battery Voltage Correction Mode
When the battery voltage is low, the ECM compensates for the weak spark delivered by the ignition system in
the following ways:
Increasing the amount of fuel delivered

Increasing the idle RPM
Increasing the ignition dwell time
Fuel Cutoff Mode
The ECM cuts OFF fuel from the fuel injectors when the following conditions are met in order to protect the
powertrain from damage and improve driveability:
The ignition is OFF. This prevents engine run-on.

The ignition is ON but there is no ignition reference signal. This prevents flooding or backfiring.
The engine speed is too high, above red line.
The vehicle speed is too high, above rated tire speed.
During an extended, high speed, closed throttle coast down-This reduces emissions and increases engine
braking.
During extended deceleration, in order to prevent damage to the catalytic converters
Fuel Trim
The ECM controls the air/fuel metering system in order to provide the best possible combination of driveability,

fuel economy, and emission control. The ECM monitors the heated oxygen sensor (HO2S) signal voltage while
in Closed Loop and regulates the fuel delivery by adjusting the pulse width of the injectors based on this signal.
The ideal fuel trim values are around 0 percent for both short and long term fuel trim. A positive fuel trim value
indicates the ECM is adding fuel in order to compensate for a lean condition by increasing the pulse width. A
negative fuel trim value indicates that the ECM is reducing the amount of fuel in order to compensate for a rich
condition by decreasing the pulse width. A change made to the fuel delivery changes the long and short term
fuel trim values. The short term fuel trim values change rapidly in response to the HO2S signal voltage. These
changes fine tune the engine fueling. The long term fuel trim makes coarse adjustments to fueling in order to recenter and restore control to short term fuel trim. A scan tool can be used to monitor the short and long term
fuel trim values. The long term fuel trim diagnostic is based on an average of several of the long term speed
load learn cells. The ECM selects the cells based on the engine speed and engine load. If the ECM detects an
excessively lean or rich condition, the ECM will set a fuel trim diagnostic trouble code (DTC).
KNOCK SENSOR SYSTEM DESCRIPTION
The knock sensor system enables the engine control module (ECM) to control the ignition timing for the best
possible performance while protecting the engine from potentially damaging levels of detonation. The ECM
uses the knock sensor system to test for abnormal engine noise that may indicate detonation, also known as
spark knock.
Sensor Description
This knock sensor system uses one or two flat response dual-wire sensors. The sensor uses piezo-electric crystal
technology that produces an alternating current (AC) voltage signal of varying amplitude and frequency based
on the engine vibration or noise level. The amplitude and frequency are dependant upon the level of knock that
the knock sensor detects. The ECM receives the knock sensor signal through 2 isolated signal circuits.
If the ECM has determined that knock is present, it will retard the ignition timing to attempt to reduce the
knock. The ECM is capable of controlling spark retard on an individual cylinder basis. The ECM will always
try to work back to a zero compensation level, or no spark retard. knock sensor diagnostics are calibrated to
detect faults with the knock sensor circuitry inside the ECM, the knock sensor wiring, or the knock sensor
voltage output. Some diagnostics are also calibrated to detect constant noise from an outside influence such as a
loose/damaged component or excessive mechanical engine noise.
THROTTLE ACTUATOR CONTROL (TAC) SYSTEM DESCRIPTION

Fig. 3: Throttle Actuator Control (TAC) System

The engine control module (ECM) is the control center for the throttle actuator control (TAC) system. The
ECM determines the driver's intent based on input from the accelerator pedal position sensors, then calculates
the appropriate throttle response based on the throttle position sensors. The ECM achieves throttle positioning
by providing a pulse width modulated voltage to the throttle actuator motor. The throttle blade is spring loaded
in both directions, and the default position is slightly open.
Modes Of Operation
Normal Mode
During the operation of the TAC system, several modes, or functions, are considered normal. The following
modes may be entered during normal operations:
Minimum pedal value-At key-up, the ECM updates the learned minimum pedal value.
Minimum throttle position values-At key-up, the ECM updates the learned minimum throttle position
value. In order to learn the minimum throttle position value, the throttle blade is moved to the Closed
position.
Ice break mode-If the throttle blade is not able to reach a predetermined minimum throttle position, the
ice break mode is entered. During the ice break mode, the ECM commands the maximum pulse width
several times to the throttle actuator motor in the closing direction.
Minimum pedal value-At key-up, the ECM updates the learned minimum pedal value.
Battery saver mode-After a predetermined time without engine RPM, the ECM commands the Battery

Saver mode. During the Battery Saver mode, the TAC module removes the voltage from the motor
control circuits, which removes the current draw used to maintain the idle position and allows the throttle
to return to the spring loaded default position.
Reduced Engine Power Mode
When the ECM detects a condition with the TAC system, the ECM may enter a reduced engine power mode.
Reduced engine power may cause one or more of the following conditions:
Acceleration limiting-The ECM will continue to use the accelerator pedal for throttle control, however,
the vehicle acceleration is limited.
Limited throttle mode-The ECM will continue to use the accelerator pedal for throttle control, however,
the maximum throttle opening is limited.
Throttle default mode-The ECM will turn OFF the throttle actuator motor, and the throttle will return to
the spring loaded default position.
Forced idle mode-The ECM will perform the following actions:
Limit engine speed to idle positioning the throttle position, or by controlling the fuel and spark if
the throttle is turned OFF.
Ignore the accelerator pedal input.
Engine shutdown mode-The ECM will disable fuel and de-energize the throttle actuator.
TURBOCHARGER SYSTEM DESCRIPTION
Fig. 4: Turbocharger System Description Diagram


Callout
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Component Name
Turbocharger Bypass Solenoid Valve
Multifunction Intake Air Sensor
Turbocharger Wastegate Regulator Solenoid Valve
Turbocharger
Turbocharger Bypass Valve
Turbocharger Wastegate Actuator
Engine Exhaust Manifold
Manifold Absolute Pressure (MAP) Sensor
Vacuum Tank (Integral to Intake Manifold)
Intake Manifold
Throttle Body
Intake Air (Boost) Pressure and Temperature Sensor
Charge Air Cooler
Turbocharger Description and Operation
A turbocharger is a forced induction device used for increasing power output of an internal combustion engine.
By using the exhaust gas forces to compress intake air, a turbocharged engine is more powerful and efficient
than a naturally aspirated engine with the same displacement. The dual-scroll turbocharger is mounted on the
exhaust manifold and the lightweight turbine is driven by the waste energy generated by the flow of the exhaust
gases. The turbine is connected by a shaft to the compressor which is mounted in the induction system of the
engine. The compressor vanes compress the intake air above atmospheric pressure, thereby greatly increasing
the density of the air entering the engine.
The turbocharger incorporates a wastegate that is controlled by the ECM, by means of a pulse width modulated
(PWM) solenoid, to regulate the pressure ratio of the compressor. An integral turbocharger bypass valve,
controlled by the ECM through a remotely mounted solenoid, is used to prevent compressor surging and
damage by opening during abrupt closed throttle conditions. The bypass valve opens during closed throttle
deceleration conditions, which allows the air to recirculate in the turbocharger and maintain compressor speed.
During a wide open throttle command, the bypass valve closes to optimize turbo response.
The turbocharger is connected to the engine oiling system by a supply and drain tube and synthetic oil is
installed at the factory. Synthetic oil is required for its friction-reducing capabilities and high-temperature
performance. There is a cooling system circuit in the turbocharger that utilizes the engine coolant to further
reduce operating temperatures.
Turbocharger Wastegate Solenoid Valve
The wastegate valve opens and closes a bypass passage beside the turbine wheel. A spiral spring works in the
closing direction while the pressure in the diaphragm works in the opening direction. The ECM supplies a
PWM signal to the solenoid valve, which then allows pressure from the turbo to come through. When the
pressure overcomes the spring force the actuator rod begins to move, opening the wastegate valve to a
corresponding degree. The ECM changes wastegate valve opening by varying the PWM signal, which regulates

the turbine speed.

At low loads, the wastegate valve is closed. All the exhaust gas then passes through the turbine. At high loads,
the volume of exhaust gas is greater, which makes the turbine wheel rotate faster. This delivers a greater air
displacement to the engine.
When the air displacement becomes so large that the current air mass per combustion cannot be controlled with
the throttle alone, the turbo must be regulated. This is done by opening the wastegate valve so that some of the
exhaust gas passes through the wastegate. Consequently, this gas does not contribute to driving the turbine and
the turbine speed will be regulated so that the turbo air displacement will be correct.
When certain DTCs are set the ECM will limit the amount of available boost pressure. Limiting boost pressure
is accomplished by the ECM controlling the wastegate actuator solenoid valve and maintaining the duty cycle at
0 %. This means that the ECM will not actively close the wastegate during greater engine loads. The system at
this point is limited to mechanical boost. Mechanical boost means that the wastegate will still move, but the
amount of motion is limited by the mechanical properties of the return spring within the diaphragm valve, the
pneumatic properties of the actuator, and the physics of the exhaust gas flow in the exhaust system.
The turbocharger wastegate diaphragm valve assembly has a threaded rod and nut that connects the diaphragm
of the valve to the wastegate. This rod is adjusted to factory specifications and is not adjustable.
The following diagrams illustrate the turbocharger wastegate closed and open conditions:
Turbocharger Wastegate Closed

Fig. 5: TC Wastegate Closed

Callout
1
2
3
4
5
6
Turbocharger Wastegate Open
Component Name
Turbocharger Wastegate Actuator Solenoid Valve with Duty Cycle
at 100 percent
Compressor
Turbine
Exhaust Gas Pressure
Spring Force
Turbocharger Wastegate Diaphragm Valve

Fig. 6: TC Wastegate Open

Callout
1
2
3
4
5
6
7
Component Name
Turbocharger Wastegate Actuator Solenoid Valve with Duty Cycle
at 0 percent
Compressor
Turbine
Regulating Pressure
Exhaust Gas Pressure
Spring Force
Turbocharger Wastegate Diaphragm Valve
The wastegate is completely closed at idle. All of the exhaust energy is passing through the turbine.
During normal operation, when wide open throttle is requested at lower engine speeds, the ECM commands the
wastegate solenoid with a duty cycle of 100 % to minimize any turbo lag. During engine loads in the middle
and upper RPM ranges, the ECM commands the solenoid with a duty cycle of about 65 %.

Turbocharger Bypass Solenoid Valve
The turbocharger bypass valve prevents the turbo from exceeding the pump limit at low flow and high pressure.
This occurs when the engine is running with a load and the throttle suddenly closes. In this case, flow is almost
null and pressure is very high. This not only is damaging to the turbocharger, but also generates noise and
decelerates turbine speed. The ECM supplies a voltage signal to the solenoid valve output driver, which
regulates the open or closed valve position.
Accelerator Pedal Depressed
The bypass valve is closed. The force in the return spring integrated in the valve presses the valve cone against
its seat in the turbo housing. The valve is turned OFF.
Accelerator Pedal Released
In order to avoid pressure spikes in the intake manifold and unloading or overrunning the turbo, the ECM sends
a voltage signal to the bypass valve, which will then open. The compressed air on the pressure side of the turbo
is led to the intake via the open valve. When the pressure drops, the turbine speed can be kept relatively high
and the turbocharger is prevented from exceeding the pump limit.
Charge Air Cooler
The turbocharger is supported by an air-to-air charge air cooler system, which uses fresh air drawn through a
heat exchanger to reduce the temperature of the warmer compressed air forced through the intake system. Inlet
air temperature can be reduced by up to 100C (180F), which enhances performance. This is due to the higher
density of oxygen in the cooled air, which promotes optimal combustion. The charge air cooler is connected to
the turbocharger and to the throttle body by flexible ductwork that requires the use of special high torque
fastening clamps. In order to prevent any type of air leak when servicing the ductwork, the tightening
specifications and proper positioning of the clamps is critical, and must be strictly adhered to.

2013 ENGINE PERFORMANCE Engine Controls and Fuel - 1.4L LUV - Diagnostic Information and Procedures - Cruze
2013 ENGINE PERFORMANCE

Engine Controls and Fuel - 1.4L LUV - Diagnostic Information and Procedures - Cruze

DTC P0010, P0013, OR P2088-P2091
DTC Descriptors
DTC P0010
Intake Camshaft Position Actuator Solenoid Valve Control Circuit
DTC P0013
Exhaust Camshaft Position Actuator Solenoid Valve Control Circuit
DTC P2088
Intake Camshaft Position Actuator Solenoid Control Circuit Low Voltage
DTC P2089
Intake Camshaft Position Actuator Solenoid Control Circuit High Voltage
DTC P2090
Exhaust Camshaft Position Actuator Solenoid Control Circuit Low Voltage
DTC P2091
Exhaust Camshaft Position Actuator Solenoid Control Circuit High Voltage
Circuit
Short to
Ground
Camshaft Position
P0010,
P0013,
High Resistance
Open
Short to
Voltage
P0010,
P0010,
P0013,
P0010, P0013
Signal Performance
P0011, P0014

High Control
P2088,
P2090
Camshaft Position
Low Reference
P0013
P0010, P0013
P0010,
P0013
P2089,
P2091
-
The camshaft position actuator system enables the Engine Control Module (ECM) to change the timing of the
camshafts while the engine is operating. The Camshaft Position Actuator Solenoid Valve signal from the ECM
is pulse width modulated (PWM). The ECM controls the Camshaft Position Actuator Solenoid Valve duty cycle
by controlling the amount of solenoid valve ON time. The Camshaft Position Actuator Solenoid Valve controls
the advance or the retard of each camshaft. The Camshaft Position Actuator Solenoid Valve controls the oil
flow that applies the pressure to advance or retard the camshafts.
The ECM controls the Camshaft Position Actuator Solenoid Valve by suppling a 12 V pulse width modulated
(PWM) signal. The ECM supplies a ground to the low reference circuit.
The ignition voltage is greater than 11 V

The ignition switch is in the crank or run position.
The ECM has commanded the Camshaft Position Actuator Solenoid Valve ON.
The DTCs run continuously once the above conditions are met.
for greater than 5 seconds.
DTCs P0010, P0013, P2088, P2089, P2090 and P2091 are type B DTCs.
DTCs P0010, P0013, P2088, P2089, P2090 and P2091 are type B DTCs.
Diagnostic Aids
If the condition is intermittent, move the related harnesses and connectors, with the engine operating, while
monitoring the scan tool Circuit Test Status parameters for the component. The Circuit Test Status parameters
change from OK or Not Run to Malfunction if there is a condition with the circuit or a connection.
Schematic Reference


Camshaft Actuator System Description
Circuit Testing
Connector Repairs
Wiring Repairs
DTC Type Reference

Scan Tool Reference
NOTE:
If a crankshaft or camshaft position sensor DTC is set, the Camshaft

Position Actuator output control will not function.
1. Ignition ON.
2. Verify DTC P0335, P0336, P0340, and P0341 is not set.
3. Verify the scan tool parameters listed below do not display Malfunction:
Camshaft Position Actuator Solenoid Valve Control Circuit Open test status
Camshaft Position Actuator Solenoid Valve Control Circuit High Voltage test status
Camshaft Position Actuator Solenoid Valve Control Circuit Low Voltage test status


4. Engine idling at normal operating temperature.
5. Verify the scan tool parameters listed below do not display Malfunction when commanding the
appropriate scan tool Camshaft Position Actuator from 0-10 and back to 0 with a scan tool:
Camshaft Position Actuator Solenoid Valve Control Circuit Open test status
Camshaft Position Actuator Solenoid Valve Control Circuit High Voltage test status
Camshaft Position Actuator Solenoid Valve Control Circuit Low Voltage test status

If the DTC sets

8. All OK.
1. Ignition OFF and all vehicle systems OFF, disconnect the harness connector at the appropriate Q6
Camshaft Position Actuator Solenoid Valve. It may take up to 2 minutes for all vehicle systems to power
down.
2. Test for less than 5 ohms between the low reference circuit terminal 1and ground.
If less than 5 ohms
3. Ignition ON.
NOTE:
A test lamp must be used for this test. The control circuit is pulled-up to a
low current voltage. The current is too low to illuminate a test lamp. A
voltage on the control circuit is normal.
4. Verify that a test lamp does not illuminate between the control circuit terminal 2and ground.

5. Remove the test lamp.
6. Verify the scan tool parameters listed below do not display Malfunction when commanding the Camshaft
Position Actuator Solenoid Valve ON with a scan tool:
Intake Camshaft Position Actuator Solenoid Valve Control Circuit Low Voltage Test Status
Exhaust Camshaft Position Actuator Solenoid Valve Control Circuit Low Voltage Test Status
Intake Camshaft Position Actuator Solenoid Valve Control Circuit High Voltage Test Status
Exhaust Camshaft Position Actuator Solenoid Valve Control Circuit High Voltage Test Status
If 2 ohms or greater, repair the open/high resistance or short to ground in the circuit.
7. Test or replace the Q6 Camshaft Position Actuator Solenoid Valve.
Component Testing
1. Ignition OFF, disconnect the harness connector at the Q6 Camshaft Position Actuator Solenoid Valve.
Replace the Q6 Camshaft Position Actuator Solenoid Valve.
3. Test for infinite resistance between each terminal and the Q6 Camshaft Position Actuator Solenoid Valve
housing.
If not infinite resistance

4. All OK.
Repair Instructions


Control Module References for Engine Control Module replacement, programming and setup.
DTC P0011 OR P0014

DTC Descriptors
DTC P0011
Intake Camshaft Position System Performance
DTC P0014
Exhaust Camshaft Position System Performance
Circuit
Camshaft Position
High Control
Short to
Ground
P0010,
P0013,
P2088,
P2090
Camshaft Position
Low Reference
High Resistance
Open
P0010, P0013
P0010,
P0013
P0010, P0013
P0010,
P0013
Short to
Voltage
P0010,
P0013,
P2089,
P2091
Signal Performance
P0011, P0014
The camshaft position (CMP) actuator system enables the engine control module (ECM) to change the timing of
the camshafts while the engine is operating. The camshaft position actuator solenoid valves are operated
hydraulically in order to change the angle of the camshaft relative to crankshaft position. The camshaft position
actuator solenoid valves are controlled by the engine control module (ECM). The ECM sends a pulse width
modulated signal to the camshaft position actuator solenoid valves. The camshaft position actuator solenoid
valves control the amount of engine oil flow that applies the pressure to advance or retard the camshafts.
DTC P0010, P0013, P0016, P0017, P0335, P0340, P0341, P0365, or P0366 is not set.

The ignition voltage is between 11-32 V.

The camshaft position actuator is enabled.
The rate of change in the camshaft position is less than 3 for 4 s.
DTCs P0011 and P0014 runs continuously once the above conditions are met for greater than 0.1 s.
The ECM detects a difference between the camshaft position angle and the desired camshaft position angle is
greater than 6 to 10 based on engine coolant temperature and engine speed.
DTCs P0011 and P0014 are Type B DTCs.


Diagnostic Aids
The engine oil condition has a major impact on the camshaft actuator system.
A low oil level condition may set this DTC. The engine may require an oil change. Inquire with the
customer when the last oil change was performed. You may also monitor the scan tool Engine Oil Life
Remaining parameter. Advise the customer an oil change may be required.
Inspect the engine for any recent engine mechanical repairs. An incorrectly installed camshaft, camshaft
actuator, or timing belt can cause this DTC to set.
A resistance greater than 8 ohms on the camshaft position actuator solenoid valve control circuit may set
this DTC. If you suspect high resistance, ground the control circuit while the engine is idling. The scan
tool Intake or Exhaust Camshaft Position Actuator Solenoid Valve Control Circuit Low Voltage Test
Status should display Malfunction. If the parameter displays OK, test the control circuit for high
resistance.
Schematic Reference

Circuit Testing
Connector Repairs
Wiring Repairs
DTC Type Reference

Scan Tool Reference
NOTE:
The engine oil level and the oil pressure are critical to the correct
operation of the camshaft position actuator system. Verify that the
engine has the correct oil level and the correct oil pressure before
continuing with this diagnostic.
The engine oil condition has a major impact on the camshaft actuator
system. Debris in the oil can interfere with the camshaft position
actuator solenoid and the mechanical camshaft actuator operation.
Inspect for dirty or degraded crankcase oil. The engine may require
an oil change. Inquire with the customer when the last oil change was
performed. You may also monitor the scan tool Engine Oil Life
Remaining parameter. Advise the customer an oil change may be
required.
1. Ignition ON.
2. Verify the correct engine oil pressure. Refer to Oil Pressure Diagnosis and Testing
If the oil level and the oil pressure are not correct
Repair as necessary
If the oil level and the oil pressure are correct
NOTE:
If a crankshaft or camshaft position sensor DTC is set, the scan tool

Camshaft Position Actuator output control will not function.
3. Verify DTC P0010, P0013, P0016, P0017, P0335, P0336, P0340, P0341, P0365, P0366, P2088, P2089,
P2090 or P2091 is not set.

4. Engine idling.
5. Verify the scan tool parameters are less than 2 in each of the commanded states when commanding the
Camshaft Position Actuator from 0-20 and back to 0 with the scan tool.
Intake Camshaft Position Variance
Exhaust Camshaft Position Variance
If 2 or greater

If less than 2
6. Verify that DTC P0011 or P0014 is not set.

If none of the DTCs set
If the DTC sets

9. All OK.
1. Ignition OFF, disconnect the harness connector at the appropriate Q6 Camshaft Position Actuator
Solenoid Valve. It may take up to 2 minutes for all vehicle systems to power down.
If less than 5 ohms
3. Ignition ON.

NOTE:
A test lamp must be used for this test. The control circuit is pulled-up to a
low current voltage, 1.5-4.5 V on the control circuit is normal.
6. Verify the scan tool parameters listed below do not display Malfunction when commanding the
appropriate Camshaft Position Actuator Solenoid Valve ON with a scan tool.
Intake Camshaft Position Actuator Solenoid Valve Control Circuit Low Voltage Test Status
Exhaust Camshaft Position Actuator Solenoid Valve Control Circuit Low Voltage Test Status
Intake Camshaft Position Actuator Solenoid Valve Control Circuit High Voltage Test Status
Exhaust Camshaft Position Actuator Solenoid Valve Control Circuit High Voltage Test Status
If 2 ohms or greater, repair the open/high resistance or short to ground in the circuit.
7. Ignition OFF, remove the Q6 Camshaft Position Actuator Solenoid Valve.
8. Verify the conditions listed below do not exist with the Q6 Camshaft Position Actuator Solenoid Valve:
1. Torn, restricted, mis-positioned, or missing screens.
2. Engine oil leak between the oil sealing lands of the solenoid. Inspect the lands of the solenoid for
nicks.
3. Oil seepage at the solenoid connector.
If a condition is not found
NOTE:
After swapping toe solenoids, install jumper wires to the appropriate

terminals of the harness connectors and the solenoids.
9. Ignition OFF, swap the Q6 Camshaft Position Actuator Solenoid Valve with the Q6 Camshaft Position
Actuator Solenoid Valve that is operating correctly.

10. Engine idling.

11. Verify the scan tool Camshaft Position Variance parameter is less than 2 in each of the commanded
states when commanding the Camshaft Position Actuator from 0-20 and back to 0 with a scan tool.
If 2 or greater
Replace the mechanical camshaft position actuator.
If less than 2
12. Test or replace the Q6 Camshaft Position Actuator Solenoid Valve.
Component Testing
1. Ignition OFF, disconnect the harness connector at the Q6 Camshaft Position Actuator Solenoid Valve.
2. Test for 7-12 ohms between the control terminal 2 and the low reference circuit terminal 1.
3. Test for infinite resistance between each terminal and the Q6 Camshaft Position Actuator Solenoid Valve
housing.
If not infinite resistance

4. All OK
Repair Instructions

DTC P0016 OR P0017

DTC Descriptors

DTC P0016
Crankshaft Position - Intake Camshaft Position Not Plausible
DTC P0017
Crankshaft Position - Exhaust Camshaft Position Not Plausible
The engine control module (ECM) uses the crankshaft position sensor, intake camshaft position sensor, and the
exhaust camshaft position sensor information to monitor the correlation between the crankshaft, intake
camshaft, and exhaust camshaft position.
DTCs P0335, P0336, P0340, P0341, P0365, P0366, P0641, or P0651 is not set
The camshaft position actuator solenoid valves are in the parked position.
The DTCs run continuously once the above conditions are met.
The ECM detects a camshaft to crankshaft misalignment. The DTC sets if the crankshaft position sensor signal
is 10 degrees before or after the normal position in relation to the crankshaft angle while the engine is running.


Diagnostic Aids
The following conditions can also set the DTCs:
A short to ground in a camshaft position actuator solenoid valve control circuit.

Crankshaft end play out of specification.
A crankshaft reluctor wheel that has moved in relationship to top dead center (TDC).


DTC Type Reference
Scan Tool Reference
1. Ignition ON.
2. Verify DTC P0335, P0336, P0340, P0341, P0365, P0366, P0641 or P0651 is not set.
3. Engine Running at normal operating temperature.
If the DTC is set
Inspect for the following and repair as necessary:

A Q6 Camshaft Position Actuator Solenoid Valve that is stuck in the full advance or retard
position.
The correct installation of the Q6 Camshaft Position Actuator Solenoid Valves.
The correct installation of the B23 Camshaft Position Sensors.
The correct installation of the B26 Crankshaft Position Sensor.
A timing chain tensioner condition.
An incorrectly installed timing chain.
Excessive play in the timing chain.
A crankshaft reluctor wheel that has moved in relationship to top dead center (TDC) on the
crankshaft.
If the DTC sets
A mechanical condition listed above still exists.


7. All OK.
Repair Instructions

Camshaft Position Sensor Replacement
Crankshaft Position Sensor Replacement
Timing Chain Tensioner Replacement
DTC P0030-P0032, P0036-P0038, P0053, P0054, P0135, OR P0141

DTC Descriptors
DTC P0030
HO2S Heater Control Circuit Sensor 1
DTC P0031
HO2S Heater Control Circuit Low Voltage Sensor 1
DTC P0032
HO2S Heater Control Circuit High Voltage Sensor 1
DTC P0036
HO2S Heater Control Circuit Sensor 2
DTC P0037
HO2S Heater Control Circuit Low Voltage Sensor 2
DTC P0038
HO2S Heater Control Circuit High Voltage Sensor 2

DTC P0053
HO2S Heater Resistance Sensor 1
DTC P0054
HO2S Heater Resistance Sensor 2
DTC P0135
HO2S Heater Performance Sensor 1
DTC P0141
HO2S Heater Performance Sensor 2
Circuit
HO2S Heater Voltage

Supply
HO2S Heater Control
Short to
Ground
P0030,
P0036,
P0102,
P0132,
P0134,
P0135,
P0138,
P0141,
P0443, *
P0030,
P0031,
P0036,
P0037,
P0053,
P0054,
P0135,
P0141
High Resistance
P0030, P0036,
P0132, P0134,
P0135, P0138,
P0140, P0141,
P0154, P0155,
P0158, P0160,
P0161
P0030, P0036,
P0053, P0132,
P0135, P0138,
P0140, P0141
Open
Short to
Voltage
Signal Performance
P0030,
P0036,
P0132,
P0134,
P0135,
P0138,
P0140,
P0141
P0690
P0135, P0141
P0030,
P0036,
P0132,
P0134,
P0135,
P0138,
P0140,
P0141
P0030,
P0032,
P0036,
P0038,
P0132,
P0134,
P0135,
P0138,
P0140,
P0141,
P0690
P0135, P0141
*Opens Fuse
HO2S Sensor 1 Current/HO2S Sensor 2 Current

Circuit
Short to Ground
Parameter Normal Range: 0.2-1.5 A
Open
Short to Voltage

HO2S Heater Low Control

HO2S Heater Voltage Supply
0A
0A
0A
0A
0A
0.2-2 A
Heated oxygen sensors (HO2S) are used for fuel control and post-catalyst monitoring. Each HO2S compares the
oxygen content of the surrounding air with the oxygen content in the exhaust stream. Each HO2S must reach
operating temperature to provide an accurate voltage signal. A heating element inside each of the HO2S
minimizes the time required for the sensor to reach operating temperature. Voltage is provided to the heater by
an ignition voltage circuit through a fuse. With the engine running, ground is provided to the heater by the
HO2S heater low control circuit, through a low side driver within the engine control module (ECM). The ECM
uses pulse-width modulation (PWM) to control the HO2S heater operation to maintain a specific HO2S
operating temperature range.
P0030, P0031, P0032, P0036, P0037 and P0038

The engine speed is greater than 400 RPM.
The DTCs run continuously when the above conditions are met for greater than 5 s.
P0053 and P0054
DTCs P0111, P0112, P0113, P0114, P0116, P0117, P0118, P0119 or P2610 are not set.
The system voltage is less than 32 V.
The ignition is OFF for greater than 8 h.
The ECT is between -30 to +45C (-22 to +113F).
The engine coolant temperature (ECT) and the intake air temperature (IAT) are within 8C (14F).
The DTCs run once per valid cold start-up when the above conditions are met.
P0135 and P0141
DTCs P0116, P0117, P0118, P0119 or P0128 are not set.

The HO2S heaters are at operating temperature.
The scan tool HO2S Heater device control is not active.
The commanded HO2S heater duty cycle is greater than 0%.
The DTCs run twice per drive cycle when the above conditions are met for greater than 30 s.
P0030, P0031, P0032, P0036, P0037 and P0038

for greater than 5 s.
P0053 and P0054
The ECM detects the HO2S heater is not within 7.5-13 ohms at engine start-up.
P0135 and P0141
The ECM detects the HO2S heater current is less than 0.30 A or greater than 2.5 A for greater than 8 s.
DTC P0030, P0031, P0032, P0036, P0037, P0038, P0053, P0054, P0135, and P0141 are Type B DTCs.
DTC P0030, P0031, P0032, P0036, P0037, P0038, P0053, P0054, P0135, and P0141 are Type B DTCs.
Diagnostic Aids
If the condition is intermittent, move the related harnesses and connectors, with the engine operating,
while monitoring the scan tool circuit status parameters for the component. The circuit status parameters
will change from OK or Not Run to Malfunction if there is a condition with the circuit or a connection.
An open fuse in the HO2S heater circuit may be caused by the heater element in one of the sensors. The
condition may not be present until the sensor operates for a period of time. If no fault is present in the
heater circuit, monitor the amperage of each heater with a scan tool to determine if one of the heater
elements is the cause of the open fuse. Inspect the sensor pigtail or the harness for contacting the exhaust
system.
Schematic Reference
Circuit Testing
Connector Repairs
Wiring Repairs

DTC Type Reference

Scan Tool Reference
1. Engine idling.
2. Verify the parameters listed below do not display Malfunction.
HO2S 1 or 2 Heater Control Circuit Low Voltage Test Status
HO2S 1 or 2 Heater Control Circuit Open Test Status
HO2S 1 or 2 Heater Control Circuit High Voltage Test Status
If the DTC sets

5. All OK.
1. Ignition OFF, disconnect the harness connector at the appropriate B52 Heated Oxygen Sensor. Ignition
ON.
2. Verify that a test lamp illuminates between the ignition voltage circuit terminal 1 and ground.
1. Ignition OFF.

If infinite resistance, test all components connected to the fuse and replace as necessary.
3. Verify that a test lamp does not illuminate between the ignition voltage circuit terminal 1 and the control
circuit terminal 2.
1. Ignition OFF, remove the test lamp, disconnect the harness connector at the K20 Engine Control
Module.
5. Verify the scan tool HO2S 1 or 2 Heater Control Circuit High Voltage Test Status parameter is OK when
commanding the HO2S Heater Sensor 1 or 2 ON with a scan tool.
If OK is displayed
NOTE:
Less than 10 ohms of additional resistance on the ignition voltage

circuit, or control circuit may set a DTC. If there is a resistance on a
circuit, the driver will remain ON and the scan tool HO2S High
Voltage Test Status parameter will display OK.
Performing this test may set additional DTCs.
6. Install a 10 A fused jumper wire between the control circuit terminal 2 and the ignition voltage circuit
terminal 1.
NOTE:
This test may only be performed once per key cycle. If test is repeated,
ignition OFF, allow the engine control module to shut down completely,
then ignition ON.
7. Verify the scan tool HO2S 1 or 2 Heater Control Circuit High Voltage Test Status parameter is
Malfunction when commanding the HO2S Heater Sensor 1 or 2 ON with a scan tool.
Module.


8. Test or replace the B52 Heated Oxygen Sensor.
Component Testing
1. Ignition OFF, disconnect the harness connector at the appropriate B52 Heated Oxygen Sensor.
2. Test for 8-20 ohms between the ignition voltage circuit terminal 1 and the control circuit terminal 2.
If not within the specified range, replace the B52 Heated Oxygen Sensor.
3. All OK.
Repair Instructions
Heated Oxygen Sensor Replacement - Sensor 1

Perform the scan tool Heated Oxygen Sensor Resistance Learn Reset after replacing a HO2S.
Control Module References for ECM replacement, programming and setup.
DTC P0033-P0035
DTC Descriptors
DTC P0033
Turbocharger Bypass Solenoid Valve Control Circuit
DTC P0034
Turbocharger Bypass Solenoid Valve Control Circuit Low Voltage
DTC P0035
Turbocharger Bypass Solenoid Valve Control Circuit High Voltage

Short to
Ground
Circuit
Ignition Voltage Circuit
P0030, P0034,
P0036, P0134,
P0135, P0245,
P0443, P0598*
Control Circuit
Open/High
Resistance
P0030, P0033,
P0034, P0036,
P0134, P0135,
P0140, P0141,
P0243, P0245,
P0443, P0597
P0034
P0033
Short to
Voltage
Signal Performance
P0010, P0013,
P0035, P0443,
P0690
* Ignition fuse opens.

The turbocharger incorporates a wastegate that is controlled by a pressure differential, that is determined by the
engine control module (ECM) by means of a PWM solenoid valve, in order to regulate the pressure ratio of the
turbocharger. A turbocharger bypass valve also controlled by the ECM by utilizing a remotely mounted
solenoid valve is integrated into the bypass valve to prevent turbocharger surging and damage from vibrations
by opening during abrupt closed throttle conditions. When the valve is open during closed throttle deceleration
conditions, the bypass valve allows the air to recirculate in the turbocharger and maintain turbocharger speed.
Within a calibrated range during the closed throttle event, or upon a wide open throttle command the valve will
then close to optimize turbo response. The bypass solenoid valve has the following circuits:
Ignition voltage
Turbocharger bypass solenoid valve control
As engine load and engine speed increases, the turbocharger bypass solenoid valve remains commanded ON by
the ECM. As soon as the throttle closes the turbocharger bypass solenoid valve is commanded OFF by the
ECM, in order to allow the turbocharger bypass valve to open and allow the turbocharger air to recirculate,
there by preventing turbocharger surging.
The engine is not cranking.

The powertrain relay voltage is greater than 11 V.
The run/crank voltage is greater than 6 V.
The DTC run continuously when the above conditions are met.
The ECM detects an open, a short to ground, or a short to voltage on the turbocharger bypass solenoid valve
control circuit for greater than 1 s.

DTC P0033, P0034, P0035 are Type B DTCs.

DTC P0033, P0034, P0035 are Type B DTCs.

Schematic Reference
Turbocharger System Description
Circuit Testing
Connector Repairs
Wiring Repairs
DTC Type Reference

Scan Tool Reference
1. Ignition ON, Verify the parameters listed below do not display Malfunction when commanding the
Turbocharger Bypass Solenoid Valve ON and OFF with a scan tool:
Turbocharger Bypass Solenoid Valve Control Circuit Low Voltage Test Status
Turbocharger Bypass Solenoid Valve Control Circuit Open Test Status
Turbocharger Bypass Solenoid Valve Control Circuit High Voltage Test Status


3. Verify a DTC does not set.
If a DTC sets

If a DTC does not set
4. All OK
1. Ignition OFF, disconnect the harness connector at the Q40 Turbocharger Bypass Solenoid Valve. Ignition
ON.
NOTE:
An internal short in any component supplied by the fuse may cause

the fuse to open and set a DTC when the component is activated.
If infinite resistance, test all components connected to the ignition voltage circuit for a short
and replace as necessary.
3. Verify that a test lamp does not illuminate between the control circuit terminal 1 and the ignition circuit
terminal 2.
1. Ignition OFF, disconnect the harness connector at the K20 Engine Control Module. Remove the
test lamp.


Remove the test lamp.
Verify the scan tool Turbocharger Bypass Solenoid Valve Control Circuit High Voltage Test Status
parameter is OK when commanding the Turbocharger Bypass Solenoid Valve Active with a scan tool.
If OK is displayed
Install a 3 A fused jumper wire between the control circuit terminal 1 and the ignition circuit terminal 2.
Verify the scan tool Turbocharger Bypass Solenoid Valve Control Circuit High Voltage Test Status
parameter is Malfunction when commanding the Turbocharger Bypass Solenoid Valve Active with a scan
tool.
Test or replace the Q40 Turbocharger Bypass Solenoid Valve.
4.
5.
6.
7.
8.
Repair Instructions
Charge Air Bypass Regulator Solenoid Valve Replacement

DTC P0068 OR P1101

DTC Descriptor
DTC P0068
Throttle Body Air Flow Performance

DTC P1101
Intake Air Flow System Performance
The engine control module (ECM) compares actual airflow based on throttle position (TP) to a calculated
airflow based on manifold absolute pressure (MAP) sensor, and mass air flow (MAF).
DTC P0068
The engine speed is at least 800 RPM.

The ignition voltage is at least 6.4 V.
DTC P1101
DTC P0102, P0103, P0107, P0111, P0112, P0113, P0116, P0117, P0118, P0335, or P0336 is not set
The engine speed is between 400-7, 000 RPM
The engine coolant temperature (ECT) is between -7 to +125C (+19 to +257F).
The intake air temperature (IAT) is between -20 to +125C (-4 to +257F).
Conditions for Setting the DTCs
The ECM detects that the actual airflow rate is greater than the calculated airflow.
Action Taken When the DTCs Set
DTC P0068 is a type A DTC.

DTC P0068 is a type B DTC; with RPO LDD.
DTC P1101 is a type B DTC.
Conditions for Clearing the DTCs
DTC P0068 is a type A DTC.

DTC P0068 is a type B DTC; with RPO LDD.
DTC P1101 is a type B DTC.
Schematic Reference


Circuit Testing
Connector Repairs
Wiring Repairs
DTC Type Reference

Scan Tool Reference
1. Ignition ON.
2. Verify that DTC DTC P0641, P0651, P0697, or P06A3 is not set.
Refer to DTC P0641, P0651, P0697, or P06A3 (ECM) for further diagnosis.
3. Ignition ON.
4. Verify the scan tool Throttle Body Idle Airflow Compensation parameter is less than 90 %.
If 90 % or greater
Refer to Throttle Body Inspection and Cleaning .

If less than 90 %
5. Verify the scan tool Throttle Position Sensors 1 and 2 Agree/Disagree parameter displays Agree while
performing the Throttle Sweep Test with a scan tool.
If Disagree
Refer to DTC P0121-P0123, P0222, P0223, or P2135 (LUV) for further diagnosis.
If Agree

6. Determine the current vehicle testing altitude.

7. Verify the scan tool MAP Sensor pressure parameter is within the range specified in the Altitude Versus
Barometric Pressure table.
If the MAP Sensor parameter is not in range
Refer to DTC P0106 for further diagnosis.
If the MAP Sensor parameter is within range
8. Verify the engine is equipped with a turbocharger.
If not equipped with a turbocharger
Refer to Step 11.

If equipped with a turbocharger
9. Verify the scan tool Boost Pressure Sensor parameter is within the range specified in the Altitude Versus
If the Boost Pressure Sensor parameter is not in range

If the Boost Pressure Sensor parameter is within range
10. Verify the scan tool Boost Pressure Sensor parameter decreases after starting the engine.
If the Boost Pressure Sensor parameter does not decrease

11. Engine idling, verify the scan tool MAP Sensor pressure parameter is between 26-52 kPa (3.8-7.5 PSI)
and changes with accelerator pedal input.
If not between 26-52 kPa (3.8-7.5 PSI) or does not change

If between 26-52 kPa (3.8-7.5 PSI) and changes
12. Verify the scan tool MAF Sensor g/s parameter changes smoothly and gradually as the engine speed is
increased and decreased while performing the actions listed below.
1. Engine idling
2. Perform the scan tool snapshot function.
3. Increase the engine speed slowly to 3, 000 RPM and then back to idle.
4. Exit from the scan tool snapshot and review the data.
5. Observe the MAF Sensor parameter frame by frame with a scan tool.
If the MAF Sensor parameter does not change smoothly and gradually


If the MAF Sensor parameter changes smoothly and gradually
If the DTC does set
Refer to Circuit/System Testing below for further diagnosis.

15. All OK
NOTE:

1. Verify the integrity of the entire air induction system by verifying that none of the following conditions
exist:
Any damaged components
Improper operation of turbocharger wastegate actuator or bypass valve; where equipped
Improperly installed components
Collapsed, restricted, or damaged components
Loose clamps, cracks, or other damage
An air flow restriction
Restricted air filter
Splits, kinks, leaks, or improper connections at the vacuum hoses
Vacuum leaks at the intake manifold, MAP sensor, and throttle body
Water intrusion
Any snow or ice buildup, in cold climates
Contamination of the MAF sensor element
Missing, restricted, or leaking exhaust components-Refer to Symptoms - Engine Exhaust for
further diagnosis.
Repair or replace component as appropriate.
If no condition is found
2. Test the engine for a mechanical condition. Refer to Symptoms - Engine Mechanical for diagnosis.


3. All OK
Repair Instructions

DTC P0096 OR P0111
DTC Descriptors
DTC P0096
Intake Air Temperature (IAT) Sensor 2 Performance
DTC P0111
Intake Air Temperature (IAT) Sensor 1 Performance
IAT Sensor 1
Circuit
Sensor
Short to
Ground
Open/High
Resistance
P0112, P0114,
P2199**
P0113, P0114,
P2199**
Short to
Voltage
P0113*,
P0114,
P2199**
P0097, P0113,
Low Reference
P11C2, P2227,
*
P2229
*Internal ECM or sensor damage may occur if the circuit is shorted to B+.
**Where used.
Signal Performance
P0111, P0114
IAT Sensor 2
Circuit
Short to
Ground
Open/High
Resistance
Short to
Voltage
Signal Performance

5 V Reference
P0097, P0651,
P11C2,
P2199**,
P2227, P2228
P0097, P11C3,
P2199**
P0096, P0097,
P11C2, P2199**,
P2227, P2228
P0097, P0651,
P11C2,
P2199**,
P2227, P2228
P0097*, P11C2,
P2199**
P0097, P11C2,
P2199**
P0097, P0113,
P11C2, P2227,
Low Reference
*
P2229
**Where used.
Sensor
IAT Sensor 1
Circuit
Short to Ground Open or High Resistance Short to Voltage
Sensor
150C (302F)
-40C (-40F)
-40C (-40F)*
Low Reference
-40C (-40F)
-40C (-40F)*
*Internal ECM or sensor damage may occur if the circuit is shorted to B+
IAT Sensor 2
Circuit
-40C (-40F)
-40C (-40F)
5 V Reference
10 Hz
10 Hz
-40C (-40F)*
Signal
-40C (-40F)
-40C (-40F)
10 Hz*
-40C (-40F)
Ground
10 Hz
The sensors listed below are integrated within the multifunction intake air sensor:
IAT sensor 1
IAT sensor 2
Humidity sensor
MAF sensor
BARO pressure sensor

The intake air temperature (IAT) sensor 1 is a variable resistor that changes the voltage on the engine control
module (ECM) supplied 5 V signal circuit. The signal varies with inlet air temperature in the sensor bore and is
displayed by the scan tool as C (F). The IAT sensor 2 and the humidity sensor share the same circuit. The IAT
sensor 2 signal is displayed by the scan tool as Hz (Hertz) and C (F).
The IAT sensor 1 produces an analog signal on pin-8 of the sensor. The IAT sensor 2 produces a frequency
modulated signal on pin-1 of the sensor.
The sensors listed below share an ECM supplied 5 V reference circuit:
IAT sensor 2
Humidity sensor
Barometric pressure (BARO) sensor
The sensors listed below share an ECM supplied low reference circuit:
IAT sensor 1
IAT sensor 2
Humidity sensor
IAT Sensor 1 - Temperature, Resistance, Voltage Table

IAT Sensor 1
IAT Sensor 1 Resistance
Cold
High
Warm
Low
IAT Sensor 1 Signal Voltage

High
Low
IAT Sensor 2 - Temperature, Frequency Table

IAT Sensor 2
IAT Sensor 2 Frequency
Cold
45 Hz
Warm
302 Hz
IAT Sensor 2 Temperature

-40C (-40F)
104C (219F)
P0096 and P0111
DTCs P0097, P0098, P0111, P0112, P0113, P0117, P0118, P00EA, P00EB, or P1682 are not set.
The ignition has been OFF at least 8 hours.
Ignition voltage is at least 11 V.
These DTCs run once per ignition cycle when the enabling conditions are met.
P0096

The ECM determines the absolute difference between IAT sensor 1 start-up temperature and the IAT
sensor 2 start-up temperature is greater than 25C (45F).
AND
AND
sensor 3 start-up temperature is less than or equal to 25C (45F).
This DTC runs once per ignition cycle when the enabling conditions are met.
NOTE:
P0111 Can fail under any of the following 3 sets of conditions.
P0111 - Condition 1
AND
AND
sensor 3 start-up temperature is less than or equal to 25C (45F).
P0111 - Condition 2
The ECM determines the IAT sensor 2 start-up temperature is between the IAT sensor 1 and IAT sensor 3
start-up temperatures.
AND
AND
The ECM determines the absolute difference between IAT sensor 2 and the IAT sensor 1 start-up
temperatures is greater than absolute difference between IAT sensor 2 and the IAT sensor 3 start-up
temperatures.

P0111 - Condition 3
The ECM determines the IAT sensor 3 start-up temperature is between the IAT sensor 1 and IAT sensor 2
start-up temperatures.
AND
AND
temperatures is greater than absolute difference between IAT sensor 3 and the IAT sensor 2 start-up
temperatures.
DTC P0111 runs once an ignition cycle when the any one, of the above 3 enabling sets of conditions is met.


Diagnostic Aids
With the ignition ON, when the engine is OFF and is cold; properly functioning IAT sensors 1 and 2 will
gradually increase the scan tool IAT Sensor 1 and 2 parameters. This is due to the heat that is generated
by the multifunction intake air sensor internal heating elements.
The Humidity sensor and the IAT sensor 2 signals are sent to the ECM on the same circuit. If the IAT
Sensor 2 parameter displays the values: 10 Hz; -40C (-40F), and there are also Humidity Sensor DTCs,
check for a circuit problem.
Schematic Reference

Circuit Testing
Connector Repairs
Wiring Repairs
DTC Type Reference

Scan Tool Reference
Special Tools
EL-38522-A Variable Signal Generator
1. Ignition ON.
NOTE:
To minimize the effects of residual engine heat and sensor internal heating
elements, perform Steps 3 and 4 of this verification procedure only if the
ignition has been OFF for 8 hours or more.
3. Ignition ON.
4. Verify the following scan tool parameters are within 25C (45F) of each other.
Start-Up IAT Sensor 1
IAT Sensor 2
IAT Sensor 3; where equipped
If not within 25C (45F)
If within 25C (45F)
5. Engine idling, verify the following scan tool parameters are between: -38 and +149C (-36 and +300F).

IAT Sensor 1
IAT Sensor 2
If not between: -38 and +149C (-36 and +300F)
Refer to Circuit System Testing below.
If between: -38 and +149C (-36 and +300F)

If the DTC does set

8. All OK
NOTE:

1. Check the integrity of the entire air induction system and verify that none of the following conditions
exist:
A loose or disconnected charge air cooler hose or pipe; where equipped
A blocked or obstructed charge air cooler, including: after-market grill covers; where equipped
Any snow or ice build-up at the charge air cooler in cold climates; where equipped
Any mud or dirt build-up at the charge air cooler; where equipped
A restricted or collapsed air intake duct
An intake manifold leak
A MAP sensor seal that is leaking, missing, or damaged
A misaligned or damaged air intake duct
Any water intrusion in the induction system
An Intake Manifold Resonator with a leaking seal, or a cracked or broken housing
If a condition exists
If no condition exists
2. Ignition OFF, and all vehicle systems OFF, it may take up to 2 min. for all vehicle systems to power
down. Disconnect the harness connector at the B75C Multifunction Intake Air sensor.

If 2 ohms or greater, repair the open or high resistance in the circuit.
If less than 2 ohms
4. Ignition ON, test for 4.8-5.2 V between the 5 V reference circuit terminal 2 and ground.
If less than 4.8 V
NOTE:
If the 5 V reference circuit is shorted to a voltage the engine control

module or the sensor may be damaged.
2. Ignition ON, test for less than 1 V between the 5 V reference circuit and ground.
5. Ignition ON, test for 4.8-5.2 V between the signal circuit terminal 8 and ground.
If less than 4.8 V
NOTE:
If the signal circuit is shorted to a voltage the engine control module

or the sensor may be damaged.

6.
7.
8.
9.
2. Ignition ON, test for less than 1 V between the signal circuit and ground.
Ignition ON, verify the scan tool IAT Sensor 1 parameter is colder than -39C (-38F).
If warmer than -39C (-38F).
If colder than -39C (-38F).
Ignition OFF, install a 3 A fused jumper wire between the signal circuit terminal 8 and the low reference
circuit terminal 7.
Verify the scan tool IAT Sensor 3 parameter is warmer than 150C (302F).
If colder than 150C (302F).
If less than 1 V
3. Ignition OFF.
If warmer than 150C (302F).
Ignition ON, test for 4.8-5.2 V between the signal terminal 1 and ground.
If less than 4.8 V


NOTE:

10. Determine if EL-38522-A Variable Signal Generator or equivalent is available.
EL-38522-A, Variable Signal Generator; or equivalent is not available
2. Operate the vehicle within the Conditions for Running the DTC. You may also operate the vehicle
within the conditions that you observed from the freeze frame/failure records data.
If the DTC sets
Refer to step 17.
If no DTCs set
4. All OK.
EL-38522-A, Variable Signal Generator; or equivalent is available
11. Ignition OFF, connect the leads of the EL-38522-A Variable Signal Generator as follows:
Red lead to the signal circuit terminal 1 at the harness connector
Black leads to ground
Battery voltage supply lead to B+
12. Set the EL-38522-A Variable Signal Generator to the following specifications.
Signal switch to 5 V
Duty Cycle switch to 50 % (Normal)
Frequency switch to 30 Hz
13. Ignition ON, verify the scan tool IAT Sensor 2 parameter is between 28-32 Hz.
If not between 28-32 Hz

If between 28-32 Hz
14. Ignition OFF and all vehicle systems OFF, disconnect the B111B Turbocharger Boost/Intake Air
Temperature sensor. It may take up to 2 min for all vehicle systems to power down.

If less than 2 ohms
If less than 4.8 V
NOTE:

17. Ignition ON, verify the scan tool IAT Sensor 3 parameter is colder than -39C (-38F).
18. Ignition OFF, install a 3 A fused jumper wire between the signal circuit terminal 1 and the low reference
circuit terminal 2.
19. Verify the scan tool IAT Sensor 3 parameter is warmer than 150C (302F).


If less than 1 V
3. Ignition OFF.
20. Test or replace the appropriate temperature sensor.
Component Testing

1. Ignition OFF, disconnect the harness connector at the B75C Multifunction Intake Air sensor.
NOTE:
A thermometer can be used to test the sensor off the vehicle.
2. Test the IAT sensor 1 by varying the sensor temperature while monitoring the sensor resistance. Compare
the readings with the Temperature Versus Resistance - Intake Air Temperature Sensor (Bosch
Sensor) , Temperature Versus Resistance - Intake Air Temperature Sensor (Delco Sensor) table for
Bosch Sensors. The resistance values should be in range of the table values.
If not within the specified range.
Replace the B75C Multifunction Intake Air sensor.
If within the specified range.
3. All OK

1. Test the IAT Sensor 2 by varying the sensor temperature while monitoring the air temperature with a
thermometer. Compare the readings with the scan tool IAT Sensor 2 parameter. The values should be
within 5%.
If not within 5%.
If within 5%.
2. All OK

Turbocharger Boost/Intake Air Temperature sensor

1. Ignition OFF, disconnect the harness connector at the B111B Turbocharger Boost/Intake Air Temperature
sensor.
NOTE:
the appropriate sensor. The resistance values should be in range of the table values.
Replace the B111B Turbocharger Boost/Intake Air Temperature sensor.
3. All OK
Repair Instructions
Intake Air Pressure and Temperature Sensor Replacement for turbocharger boost/intake air
temperature sensor replacement
Mass Airflow Sensor Replacement for multifunction intake air sensor replacement
Control Module References for Engine Control Module replacement, programming, and setup.
DTC P0097 OR P0098

DTC Descriptors
DTC P0097
Intake Air Temperature (IAT) Sensor 2 Circuit Low Voltage
DTC P0098
Intake Air Temperature (IAT) Sensor 2 Circuit High Voltage

IAT Sensor 2
Short to
Open/High
Short to
Ground
Resistance
Voltage
P0097, P0651,
P0097, P0651,
P0096**, P0097,
P11C2**,
P11C2**,
5 V Reference
P11C2**, P2199**,
P2199**,
P2199**,
P2227, P2228
P2227, P2228
P2227, P2228
P0097,
P0097*,
P0097, P11C2**,
Sensor
P11C3**,
P11C2**,
P2199**
P2199**
P2199**
P0097, P0113,
Low Reference
*
P11C2**, P2227,
P2229
**Where used.
Circuit
Signal Performance
-
IAT Sensor 2
Circuit
-40C (-40F)
-40C (-40F)
5 V Reference
10 Hz
10 Hz
-40C (-40F)*
Signal
-40C (-40F)
-40C (-40F)
10 Hz*
-40C (-40F)
Ground
10 Hz
Intake Air Temperature (IAT) sensor 1

IAT sensor 2
Humidity sensor
Mass Air Flow (MAF) sensor
Barometric (BARO) pressure sensor
The IAT sensor 2 and the humidity sensor share the same circuit. The IAT sensor 2 signal is displayed by the
scan tool as Hertz (Hz) and C (F).

IAT sensor 2
Humidity sensor
IAT sensor 1
IAT sensor 2
Humidity sensor
IAT Sensor 2 - Temperature, Frequency Table

IAT Sensor 2
IAT Sensor 2 Frequency
Cold
45 Hz
Warm
302 Hz
IAT Sensor 2 Temperature

-40C (-40F)
104C (219F)
P0097 and P0098

The Ignition voltage is at least 11 V.
The DTCs run continuously within the enabling conditions.
P0097
NOTE:
The scan tool display range is between -40 and +150C (-40 and +302F).
The ECM detects that the IAT sensor 2 signal is less than 10 Hz, colder than -60C (-76F), for greater than 5 s.
P0098
The ECM detects that the IAT sensor 2 signal is greater than 390 Hz, warmer than 150C (302F), for greater
than 5 s.

DTCs P0097 and P0098 are Type C DTCs; with RPO LDD.
The ECM commands the cooling fans ON.
Conditions for Clearing the MIL/DTCs


DTCs P0097 and P0098 are Type C DTCs; with RPO LDD.
Diagnostic Aids
With the ignition ON, when the engine is cold and not running, properly functioning IAT sensor 2 will
gradually increase the scan tool IAT Sensor 2 parameters. This is due to the heat that is generated by the
multifunction intake air sensor heating elements.
The humidity sensor and the IAT sensor 2 signals are sent to the ECM on the same circuit. If the IAT
Sensor 2 parameter displays the values: 10 Hz; -40C (-40F), and there are also Humidity Sensor DTCs,
check for a circuit problem.
Schematic Reference
Circuit Testing
Connector Repairs
Wiring Repairs
DTC Type Reference

Scan Tool Reference
Control Module References Control Module References for scan tool information
Special Tools
1. Ignition ON.

NOTE:
3. Ignition ON.
IAT Sensor 2
If within 25C (45F)
IAT Sensor 1
IAT Sensor 2

If the DTC does set

8. All OK
NOTE:

If less than 2 ohms
If less than 4.8 V
NOTE:

If less than 4.8 V


NOTE:

If the DTC sets
Refer to step 9.
If no DTCs set
4. All OK.

If between 28-32 Hz
9. Test or replace the B75C Multifunction Intake Air sensor.
Component Testing


Test the IAT Sensor 2 by varying the sensor temperature while monitoring the air temperature with a
thermometer. Compare the readings with the scan tool IAT Sensor 2 parameter. The values should be within
5%.
If not within 5%.

If within 5%.
All OK
Repair Instructions
Mass Airflow Sensor Replacement for multifunction intake air sensor replacement.
DTC P00C7
DTC Descriptor
DTC P00C7
Intake Air Pressure Measurement System - Multiple Sensors Not Plausible
The Intake Air Pressure Measurement System consists of 3 sensors:
The barometric pressure (BARO) sensor

The manifold absolute pressure (MAP) sensor
The turbo boost sensor
DTCs P0106, P0107, P0108, P2122, P2123, P2127, P2128, P2138 or P2610 are not set.


Time between current ignition cycle and the last time the engine was running is greater than 10 s.
Manifold pressure between 50-115 kPa (7.25-16.68 PSI).
BARO pressure between 50-115 kPa (7.25-16.68 PSI).
Turbocharger boost pressure between 50-115 kPa (7.25-16.68 PSI).
This DTC runs continuously within the enabling conditions.
The ECM detects an inconsistency between pressure sensors in the induction system in which a particular
sensor cannot be identified as the failed sensor. The difference is greater than 10 kPa (1.5 PSI).
DTC P00C7 is a Type B DTC.

DTC P00C7 is a Type B DTC.

Schematic Reference
Circuit Testing
Connector Repairs
Wiring Repairs
DTC Type Reference

Scan Tool Reference

1. Ignition ON, observe the DTC information with a scan tool. Verify that DTCs P0106, P0107, P0236,
P0237, P0238, P2227, P2228, P2229, or P2230, are not set.
If none of the DTCs is set
2. Ignition ON, verify the following scan tool parameters are within range of the Altitude vs. Barometric
Pressure table. Refer to: Altitude Versus Barometric Pressure table.
Barometric Pressure
Manifold Absolute Pressure
Boost Pressure
If a sensor parameter is not within range
Refer to the appropriate diagnostic below for further diagnosis.

Barometric Pressure (BARO) Sensor. Refer to: DTC P2227-P2230
Manifold Absolute Pressure (MAP) Sensor. Refer to: DTC P0106
Turbocharger Boost Pressure Sensor. Refer to: DTC P0236
If all sensor parameters are within range
3. All OK
Repair Instructions

Control Module References for Engine Control Module replacement, programming and setup.
DTC P00EA OR P00EB
DTC Descriptors
DTC P00EA
Intake Air Temperature (IAT) Sensor 3 Circuit Low Voltage
DTC P00EB

Intake Air Temperature (IAT) Sensor 3 Circuit High Voltage

IAT Sensor 3
Short to
Open/High
Short to
Ground
Resistance
Voltage
P00EA,
Sensor
P00E9, P00EB
P00EB*
P00EB
Low Reference
P00E9, P00EB
P00EB*
Circuit
Signal Performance
P00E9
-
IAT Sensor 3
Circuit
Parameter Normal Range: Varies with ambient temperature; and engine bay conditions
Sensor
130C (266F)
-40C (-40F)
-40C (-40F)*
Low Reference
-40C (-40F)
-40C (-40F)*
The intake air temperature (IAT) sensor 3 is a variable resistor that changes an engine control module (ECM)
supplied 5 V signal. The signal varies with inlet air temperature and is displayed by the scan tool as C (F).
The IAT sensor 3 is integrated with the throttle inlet absolute pressure sensor in the sensor bore, which is
located before the throttle body. The ECM provides a ground for the IAT sensor 3 low reference circuit.
P00EA and P00EB

The DTCs run continuously when the above conditions are met.
P00EA
The ECM detects that the IAT sensor 3 signal is warmer than 149C (300F) for at least 5 s.
P00EB
NOTE:

The ECM detects that the IAT sensor 3 signal is colder than -60C (-76F) for at least 5 s.
DTCs P00EA and P00EB are Type B DTCs.

DTCs P00EA and P00EB are Type B DTCs.

Schematic Reference
Circuit Testing
Connector Repairs
Wiring Repairs
DTC Type Reference

Scan Tool Reference
1. Ignition ON.

NOTE:
3. Ignition ON.
IAT Sensor 2
IAT Sensor 3
If within 25C (45F)
5. Engine idling, verify the IAT Sensor 3 scan tool parameter is between: -38 and +128C (-36 and +262F).

If the DTC does set

8. All OK
NOTE:



If less than 2 ohms
If less than 4.8 V
NOTE:

circuit terminal 1.

If less than 1 V
3. Ignition OFF.
7. Test or replace the B111B Turbocharger Boost/Intake Air Temperature sensor.
Component Testing

sensor.
NOTE:
3. All OK
Repair Instructions
temperature replacement
DTC P00E9

DTC Descriptor
DTC P00E9
Intake Air Temperature (IAT) Sensor 3 Circuit Performance
IAT Sensor 3
Short to
Open/High
Short to
Circuit
Ground
Resistance
Voltage
P00EA,
Sensor
P00E9, P00EB
P00EB*
P00EB
Low Reference
P00E9, P00EB
P00EB*
Signal Performance
P00E9
-
IAT Sensor 3
Circuit
Parameter Normal Range: Varies with ambient temperature; and engine bay conditions
Sensor
130C (266F)
-40C (-40F)
-40C (-40F)*
Low Reference
-40C (-40F)
-40C (-40F)*
The intake air temperature (IAT) sensor 3 is a variable resistor that changes an engine control module (ECM)
supplied 5 V signal. The signal varies with inlet air temperature and is displayed by the scan tool as C (F).
The IAT sensor 3 is integrated with the B111B Turbocharger Boost/Intake Air Temperature Sensor in the
sensor bore, which is located before the throttle body. The ECM supplies a ground for the IAT sensor 3 low
reference circuit.
The IAT sensor 1 and IAT sensor 2 are part of the B75C Multifunction Intake Air Sensor. The IAT sensor 1
produces an analog signal on pin-8 of the sensor. The IAT sensor 2 produces a frequency modulated signal on
pin-1 of the sensor.
IAT Sensor 3
Cold
High
Warm
Low
P00E9

High
Low

DTCs P0097, P0098, P00EA, P00EB, P0111, P0112, P0113, P0117, P0118, or P1682 are not set.
The vehicle has been OFF at least 8 hours.
Ignition voltage is at least 11 V.
This DTC runs once per ignition cycle when the enabling conditions are met.
NOTE:
P00E9 Can fail under any of the following 3 sets of conditions.
P00E9-Condition 1
sensor 2 start-up temperature is less or equal to 25C (45F).
AND
AND
P00E9-Condition 2
The ECM determines the IAT sensor 1 start-up temperature is between the IAT sensor 3 and the IAT
sensor 2 start-up temperatures
AND
AND
temperatures is greater than the absolute difference between IAT sensor 2 and the IAT sensor 1 start-up
temperatures.
P00E9-Condition 3
The ECM determines the IAT sensor 2 start-up temperature is between the IAT sensor 3 and the IAT
sensor 1 start-up temperatures
AND

temperatures is greater than 25C (45F).
AND
The absolute difference between IAT sensor 3 and the IAT sensor 2 start-up temperatures is greater than
the absolute difference between IAT sensor 2 and the IAT sensor 1 start-up temperatures.
DTC P00E9 runs once an ignition cycle when one of the above 3 enabling sets of conditions are met.
DTC P00E9 is a Type B DTC.

DTC P00E9 is a Type B DTC.

Schematic Reference
Circuit Testing
Connector Repairs
Wiring Repairs
DTC Type Reference

Scan Tool Reference
Special Tools


1. Ignition ON.
NOTE:
3. Ignition ON.
IAT Sensor 2
IAT Sensor 3
If within 25C (45F)
5. Engine idling, verify the IAT Sensor 3 scan tool parameter is between: -38 and +128C (-36 and +262F).

If the DTC does set

8. All OK

exist:
A loose or disconnected charge air cooler hose or pipe
A blocked or obstructed charge air cooler, including: after-market grill covers
Any snow or ice build-up at the charge air cooler in cold climates
Any mud or dirt build-up at the charge air cooler
A restricted or collapsed air intake duct
An intake manifold leak
A MAP sensor seal that is leaking, missing, or damaged
A misaligned or damaged air intake duct
Any water intrusion in the induction system
An Intake Manifold Resonator with a leaking seal, or a cracked or broken housing
If no condition exists
2. Ignition OFF and all vehicle systems OFF, disconnect the B75C Multifunction Intake Air sensor. It may
take up to 2 min for all vehicle systems to power down.
If less than 2 ohms
If less than 4.8 V
NOTE:


5. Ignition ON, test for 4.8-5.2 V between the signal terminal 8 and ground.
If less than 4.8 V
NOTE:

circuit terminal 7.

If less than 1 V
3. Ignition OFF.
If less than 2 ohms
If less than 4.8 V
NOTE:



circuit terminal 1.
If less than 1 V
3. Ignition OFF.
If less than 4.8 V
NOTE:



If the DTC sets
Refer to step 20.

If no DTCs set
4. All OK.

If between 28-32 Hz
20. Test or replace the appropriate temperature sensor.
Component Testing

NOTE:

3. All OK

1. Test the IAT Sensor 2 by varying the sensor temperature while monitoring the air temperature with a
thermometer. Compare the readings with the scan tool IAT Sensor 2 parameter. The values should be
within 5%.
If not within 5%.
If within 5%.
2. All OK

sensor.
NOTE:
3. All OK
Repair Instructions

DTC P0101
DTC Descriptor
DTC P0101
Mass Air Flow (MAF) Sensor Performance
MAF Sensor
Short to
Open/High
Short to
Circuit
Ground
Resistance
Voltage
Ignition Voltage
P0102
P0102, P01101
P0690
Sensor
P0102, P1101
P0102, P1101
P0102*
Ground
P0102
Signal Performance
P0101
P0101, P1101
-
MAF Sensor
Circuit
Short to Ground
Open
Operating Conditions: Engine running at various operating conditions
Parameter Normal Range: 2, 000-10, 000 Hz
Ignition Voltage
0 Hz
0 Hz
Sensor
0 Hz
0 Hz
Ground
0 Hz
Circuit Description

IAT sensor 2
Short to Voltage
0 Hz*
-

Humidity sensor
The MAF sensor is an air flow meter that measures the amount of air flowing in the sensor bore. The engine
control module (ECM) uses the MAF sensor signal to provide the correct fuel delivery for all engine speeds and
loads. A small quantity of air entering the engine indicates a deceleration or idle condition. A large quantity of
air entering the engine indicates an acceleration or high load condition.
The ECM applies 5 V to the MAF sensor signal circuit. The sensor produces a variable frequency signal based
on the inlet air flow through the sensor bore. The signal varies with engine load and is displayed by the scan
tool as Hertz (Hz) and grams per second (g/s). Vehicle ignition voltage and ground circuits are also supplied to
the MAF sensor.
The intake flow rationality diagnostic provides the within-range rationality check for the mass air flow (MAF),
manifold absolute pressure (MAP), and the throttle position sensors. This is an explicit model-based diagnostic
containing 4 separate models for the intake system.
The estimates of MAF and MAP obtained from this system of models and calculations are then compared to the
actual measured values from the MAF, MAP, and the throttle position sensors and to each other to determine
the appropriate DTC to fail.
IAT sensor 2
Humidity sensor
IAT sensor 1
IAT sensor 2
Humidity sensor
DTCs P0096, P0097, P0098, P0102, P0103, P0107, P0111, P0112, P0113, P0116, P0117, P0118, P0119,
P0237, P0238, P0335, P0336, P2227, P2228, P2229, or P2230 are not set.
The engine speed is between 400-6, 000 RPM.
The engine coolant temperature (ECT) is between -7 and +125C (+19 and +257F).
The intake air temperature (IAT) is between -20 and +100C (-4 and +212F).

The engine control module (ECM) detects that the actual measured airflow from the MAF, MAP, and throttle
position sensors is not within range of the calculated airflow that is derived from the system of models for
greater than 2 s.
DTC P0101 is a Type B DTC.


Diagnostic Aids
Certain aftermarket air filters may cause this DTC to set.

Certain aftermarket air induction systems may cause this DTC to set.
Modifications to the air induction system may cause this DTC to set.
Schematic Reference
Circuit Testing
Connector Repairs
Wiring Repairs
DTC Type Reference

Scan Tool Reference
Special Tools


1. Ignition ON.
3. If you were sent here from DTC P0068, P0106, P0121, P0236, or P1101; refer to Circuit/System Testing
below.
4. Ignition ON.
If 90 % or greater

If less than 90 %
If Disagree
If Agree

If the MAP Sensor parameter is within range
Refer to Step 12.




If the Boost Pressure Sensor parameter does decrease
12. Engine idling, verify the scan tool MAP Sensor pressure parameter is between 26-52 kPa (3.8-7.5 PSI)
If not between 26-52 kPa (3.8-7.5 PSI) or does not change

If between 26-52 kPa (3.8-7.5 PSI) and changes
1. Engine idling

If the DTC does set
Refer to Circuit/System Testing for further diagnosis.

16. All OK
NOTE:


1. Check the integrity of the entire air induction system by verifying that none of the following conditions
exist:
Improper operation of turbocharger wastegate actuator or bypass valve; where equipped
Improperly installed components
Collapsed, restricted, or damaged components
Loose clamps, cracks, or other damage
Splits, kinks, leaks, or improper connections at the vacuum hoses
Vacuum leaks at the intake manifold, MAP sensor, and throttle body
Water intrusion
Any snow or ice buildup, in cold climates
Contamination of the Multifunction Intake Air sensor element
Ignition OFF, disconnect the harness connector at the B75C Multifunction Intake Air sensor.
1. Ignition OFF.
If less than 2 ohms
Ignition ON.
Verify that a test lamp illuminates between the ignition circuit terminal 5 and ground.
1. Ignition OFF, remove the test lamp and remove the fuse for the ignition circuit.
2.
3.
4.
5.

3. Test for greater than 2 ohms between the ignition circuit terminal 5 and ground.
If less than 2 ohms, repair the short to ground on the circuit.
If greater than 2 ohms, test all the components connected to the circuit and repair or replace
as necessary.
If a test lamp illuminates
If less than 4.8 V
If the DTC sets
Refer to step 11.
If no DTCs set
4. All OK.

Frequency switch to 5 kHz

10. Engine idling, verify the scan tool MAF Sensor parameter is between 4, 950-5, 050 Hz.
If not between 4, 950-5, 050 Hz.

If between 4, 950-5, 050 Hz.
Repair Instructions
DTC P0102 OR P0103

DTC Descriptors
DTC P0102
Mass Air Flow (MAF) Sensor Circuit Low Frequency
DTC P0103
Mass Air Flow (MAF) Sensor Circuit High Frequency
MAF Sensor
Short to
Open/High
Short to
Ground
Resistance
Voltage
Circuit
Ignition Voltage
P0102
P0102, P01101
P0690
Sensor
P0102, P1101
P0102, P1101
P0102*
Ground
P0102
Signal Performance
P0101
P0101, P1101
-

MAF Sensor
Circuit
Short to Ground
Open
Parameter Normal Range: 2, 000-10, 000 Hz
Ignition Voltage
0 Hz
0 Hz
Sensor
0 Hz
0 Hz
Ground
0 Hz
Short to Voltage
0 Hz*
-
Circuit Description

IAT sensor 2
Humidity sensor
The MAF sensor is an air flow meter that measures the amount of air flowing in the sensor bore. The engine
control module (ECM) uses the MAF sensor signal to provide the correct fuel delivery for all engine speeds and
loads. A small quantity of air entering the engine indicates a deceleration or idle condition. A large quantity of
air entering the engine indicates an acceleration or high load condition.
The ECM applies 5 V to the MAF sensor signal circuit. The sensor produces a variable frequency signal based
on the inlet air flow through the sensor bore. The signal varies with engine load and is displayed by the scan
tool as Hertz (Hz) and grams per second (g/s). Vehicle ignition voltage and ground circuits are also supplied to
the MAF sensor.
IAT sensor 2
Humidity sensor
IAT sensor 1
IAT sensor 2
Humidity sensor

The engine is running for at least 1 s.

The engine speed is at least 300 RPM.
The ignition signal is at least 10 V.
The above conditions are met for at least 1 s.
P0102
The ECM detects that the MAF Sensor signal parameter is less than 1, 837 Hz (about 0.39 g/s) for at least 250
cylinder firing events.
P0103
The ECM detects that the MAF Sensor signal parameter is at least 13, 200 Hz (about 810 g/s) for at least 250
cylinder firing events.

Conditions for Clearing the MIL/DTCs

Diagnostic Aids
Verify that any electrical aftermarket devices are properly connected and grounded. Refer to Checking
Schematic Reference
Circuit Testing
Connector Repairs


Wiring Repairs
DTC Type Reference

Scan Tool Reference
Special Tools
1. Engine idling, verify the scan tool MAF Sensor parameter is between 1.75-5.5 g/s.
If not between 1.75-5.5 g/s
If between 1.75-5.5 g/s
1. Engine idling

If the DTC does set
Refer to Circuit/System Testing for further diagnosis.


5. All OK
NOTE:

1. Ignition OFF. Disconnect the sensor chassis ground.
If less than 2 ohms, repair the open/high resistance in the chassis ground connection.
If less than 2 ohms
3. Ignition ON.
4. Verify that a test lamp illuminates between the ignition circuit terminal 5 and ground.
3. Test for greater than 2 ohms between the ignition circuit terminal 5 and ground.
If less than 2 ohms, repair the short to ground on the circuit.
If greater than 2 ohms, test all the components connected to the circuit and repair or replace
as necessary.
If a test lamp illuminates
If less than 4.8 V

If the DTC sets
Refer to step 10.
If no DTCs set
4. All OK.
Frequency switch to 5 kHz
9. Engine idling, verify the scan tool MAF Sensor parameter is between 4, 950-5, 050 Hz.
If not between 4, 950-5, 050 Hz.

If between 4, 950-5, 050 Hz.
Repair Instructions

DTC P0106
DTC Descriptor
DTC P0106
Manifold Absolute Pressure (MAP) Sensor Performance
Circuit
5 V Reference
Signal
Low Reference
Short to
Ground
P0107, P0697
P0107
-
Open/High
Resistance
P0106, P0107
P0106, P0107
P0106, P0108
Short to
Voltage
P0108, P0697
P0108
-
Signal Performance
P0106
P0106
P0106
MAP Sensor
Circuit
Short to Ground
Open
Parameter Normal Range: 12-103 kPa (1.7-14.9 psi)
5 V Reference
0 kPa (0 psi)
0 kPa (0 psi)
Signal
0 kPa (0 psi)
0 kPa (0 psi)
80-103 kPa
Low Reference
(11.6-14.9 psi)
MAP Sensor, when equipped with Turbocharger
Circuit
Short to Ground
Open
5 V Reference
0 kPa (0 psi)
0 kPa (0 psi)
Short to Voltage
104 kPa (15.1 psi)

104 kPa (15.1 psi)*
-
Short to Voltage
255 kPa (36.9 psi)

Signal
0 kPa (0 psi)
0 kPa (0 psi)
255 kPa (36.9
Low Reference
psi)
255 kPa (36.9 psi)*

-
Circuit Description
The manifold absolute pressure (MAP) sensor measures the pressure inside the intake manifold. Pressure in the
intake manifold is affected by engine speed, throttle opening, air temperature, barometric pressure (BARO); and
where equipped turbocharger output. A diaphragm within the MAP sensor is displaced by the pressure changes
that occur from the varying load and operating conditions of the engine. The sensor translates this action into
electrical resistance.
The MAP sensor wiring includes 3 circuits. The engine control module (ECM) supplies a regulated 5 volts to
the sensor on a 5 V reference circuit. The ECM supplies a ground on a low reference circuit. The MAP sensor
provides a signal voltage to the ECM, relative to the pressure changes, on the MAP sensor signal circuit. The
ECM converts the signal voltage input to a pressure value.
Under normal operation the greatest pressure that can exist in the intake manifold is at ignition ON, engine
OFF, which is equal to the BARO. Where equipped, a turbocharger can increase the pressure above BARO,
when the vehicle is operated at wide-open throttle (WOT). The lowest manifold pressure occurs when the
vehicle is idling or decelerating. The ECM monitors the MAP sensor signal for pressure outside of the normal
range.
DTCs P0107, P0108, P0111, P0112, P0113, P0114, P0116, P0117, P0118, P0119, P0128, P0335, P0336
are not set.
The engine speed is between 400-6 500 RPM.
The engine coolant temperature (ECT) sensor is between -7 to +125C (19.4-257F).
The intake air temperature (IAT) sensor is between -20 to +125C (-4 to +257F).
This DTC runs continuously when the above conditions are met.
The ECM detects that the MAP sensor pressure is not within range of the calculated pressure that is derived
from the system of models for more than 0.5 s.



Schematic Reference
Circuit Testing
Connector Repairs
Wiring Repairs
DTC Type Reference

Scan Tool Reference
Special Tools
EN-23738-A Vacuum Pump
1. Ignition ON.
2. Verify that DTC P0641, P0651, P0697, or P06A3 is not set.
If none of the DTC are set
3. If you were sent here from DTC P0068, P0101, P0121, P0236, or P1101; refer to Circuit/System Testing
below.
4. Ignition ON.

If 90% or greater
If less than 90%
If Disagree
If Agree

If the MAP Sensor parameter is in range
Refer to Step 12.


If the Boost Pressure Sensor parameter is in range

12. Engine idling, verify the scan tool MAP Sensor pressure parameter is between 26-52 kPa (3.8-7.5 psi)
If not between 26-52 kPa (3.8-7.5 psi) or does not change


If between 26-52 kPa (3.8-7.5 psi) and changes
1. Engine idling
Refer to DTC P0101.

If the MAF Sensor parameter does change smoothly and gradually
If the DTC sets

16. All OK.
exist:
Improper operation of turbocharger wastegate actuator or bypass valve, where equipped
Loose or improper installation of the turbocharger and the charge air cooler, including the flexible
ductwork, where equipped
Any vacuum leak
Improperly routed vacuum hoses
In cold climates, inspect for any snow or ice buildup at the BARO port on the ECM, where
equipped
A restriction in the MAP sensor port or the BARO port
Proper operation of the Positive Crankcase Ventilation (PCV) system
Missing, restricted or leaking exhaust components. Refer to Symptoms - Engine Exhaust .
Engine mechanical condition; for example: low compression or incorrect timing chain installation.

Refer to Symptoms - Engine Mechanical .

Repair or replace the component as appropriate.
Ignition OFF and all vehicle systems OFF, disconnect the B74 Manifold Absolute Pressure sensor. It may
Test for less than 2 ohms between the low reference circuit terminal 2 and ground.
1. Ignition OFF, disconnect the K20 Engine Control Module, listed below:
X2 harness connector, ECM with 2 face mounted connectors
If less than 2 ohms
Ignition ON.
Test for 4.8-5.2 V between the 5 V reference circuit terminal 1 and ground.
If less than 4.8 V
2.
3.
4.
5.
NOTE:




Ignition ON, verify the scan tool MAP Sensor parameter is less than 0.5 V.
If 0.5 V or greater
2. Ignition ON, test for less than 1 V between the signal circuit terminal 3 and ground.
If less than 0.5 V
Ignition OFF, install a 3 A fused jumper wire between the signal circuit terminal 3 and the 5 V reference
circuit terminal 1.
Ignition ON, verify the scan tool MAP voltage parameter is greater than 4.5 V.
If 4.5 V or less
2. Remove the jumper wire, test for infinite resistance between the signal circuit terminal 3 and
ground.
Test or replace the B74 Manifold Absolute Pressure sensor.
6.
7.
8.
9.
Component Testing
NOTE:
You must perform the Circuit/System Testing in order to Check the integrity of
the MAP sensor circuits before proceeding with the Component Testing.
Skewed Sensor Test

1. Ignition OFF, remove the B74 Manifold Absolute Pressure sensor from the engine. Connect the harness
to the sensor, if disconnected.
2. Ignition ON, apply -17 kPa (5.0 inHg) of vacuum to the B74 Manifold Absolute Pressure sensor, with the
EN-23738-A Vacuum Pump. Verify the scan tool MAP pressure parameter decreases between 13-21 kPa
(1.8-3.0 psi).

If the parameter does not decrease between 13-21 kPa (1.8-3.0 psi).
Replace the B74 Manifold Absolute Pressure sensor.
If the parameter does decrease between 13-21 kPa (1.8-3.0 psi).

3. Apply -34 kPa (10.0 inHg) of vacuum to the B74 Manifold Absolute Pressure sensor, with the EN-23738A Vacuum Pump. Verify the scan tool MAP pressure parameter decreases between 30-38 kPa (4.4-5.5
psi).

4. All OK.
Erratic Signal Test

1. Ignition OFF, remove the B74 Manifold Absolute Pressure sensor and disconnect the harness.
2. Install a 3 A fused jumper wire between the 5 V reference circuit terminal 1 of the sensor and the sensor
harness.
3. Install a jumper wire between the low reference circuit terminal 2 of the sensor and ground.
4. Install a jumper wire to the signal circuit terminal 3 of the sensor.
5. Connect a DMM between the jumper wire and ground.
6. Ignition ON, observe the DC voltage on the DMM. Slowly apply between 0-15kPa of vacuum to the
sensor with the EN-23738-A Vacuum Pump. Verify the voltage changes, without any spikes or dropouts,
between 4.9-0.2 V.
If not between 4.9-0.2 V or has spikes or dropouts
If between 4.9-0.2 V and there are no spikes or dropouts
7. All OK.
Repair Instructions
Manifold Absolute Pressure Sensor Replacement

Control Module References for Engine Control Module replacement, programming and setup
DTC P0107 OR P0108


DTC Descriptors
DTC P0107
Manifold Absolute Pressure (MAP) Sensor Circuit Low Voltage
DTC P0108
Manifold Absolute Pressure (MAP) Sensor Circuit High Voltage
Circuit
5 V Reference
Signal
Low Reference
Short to
Ground
P0107, P0697
P0107
-
Open/High
Resistance
P0106, P0107
P0106, P0107
P0106, P0108
Short to
Voltage
P0108, P0697
P0108
-
Signal Performance
P0106
P0106
P0106
MAP Sensor
Circuit
Short to Ground
Open
5 V Reference
0 kPa (0 psi)
0 kPa (0 psi)
Signal
0 kPa (0 psi)
0 kPa (0 psi)
80-103 kPa
Low Reference
(11.6-14.9 psi)
MAP Sensor, when equipped with Turbocharger
Circuit
Short to Ground
Open
5 V Reference
0 kPa (0 psi)
0 kPa (0 psi)
Signal
0 kPa (0 psi)
0 kPa (0 psi)
255 kPa (36.9
Low Reference
psi)
Short to Voltage
104 kPa (15.1 psi)

104 kPa (15.1 psi)*
-
Short to Voltage
255 kPa (36.9 psi)

255 kPa (36.9 psi)*
-

Circuit Description
The manifold absolute pressure (MAP) sensor measures the pressure inside the intake manifold. Pressure in the
intake manifold is affected by engine speed, throttle opening, air temperature, barometric pressure (BARO); and
where equipped turbocharger output. A diaphragm within the MAP sensor is displaced by the pressure changes
that occur from the varying load and operating conditions of the engine. The sensor translates this action into
electrical resistance.
The MAP sensor wiring includes 3 circuits. The engine control module (ECM) supplies a regulated 5 volts to
the sensor on a 5 V reference circuit. The ECM supplies a ground on a low reference circuit. The MAP sensor
provides a signal voltage to the ECM, relative to the pressure changes, on the MAP sensor signal circuit. The
ECM converts the signal voltage input to a pressure value.
Under normal operation the greatest pressure that can exist in the intake manifold is at ignition ON, engine
OFF, which is equal to the BARO. Where equipped, a turbocharger can increase the pressure above BARO,
when the vehicle is operated at wide-open throttle (WOT). The lowest manifold pressure occurs when the
vehicle is idling or decelerating. The ECM monitors the MAP sensor signal for pressure outside of the normal
range.
P0107
DTCs P0120, P0121, P0122, P0123, P0220, P0221, P0222, P0223 or P0641 are not set
The throttle position is greater than or equal to 0% when the engine speed is less than or equal to 1 000
RPM
or
The throttle position is greater than or equal to 12.5% when the engine speed is greater than 1 000 RPM.
P0108
The engine has been running for a length of time that is determined by the start up coolant temperature.
The length of time ranges from 5.5 minutes at colder than -30C (-22F) to 10 s at greater than 30C
(+86F).
DTCs P0120, P0121, P0122, P0123, P0220, P0221, P0222, P0223 or P0641 are not set
The throttle position is less than or equal to 1% when the engine speed is less than or equal to 1 200
RPM.
or
The throttle position is less than or equal to 20% when the engine speed is greater than 1 200 RPM.

P0107
The ECM detects that the MAP sensor voltage is less than 0.05 V for greater than 5 s.
P0108
The ECM detects that the MAP sensor voltage is more than 4.9 V for greater than 5 s.


Schematic Reference
Circuit Testing
Connector Repairs
Wiring Repairs
DTC Type Reference

Scan Tool Reference
Special Tools
EN-23738-A Vacuum Pump


1. Ignition ON.
3. Engine idling, verify the scan tool MAP voltage parameter is between 0.3-4.8 V and changes with
accelerator pedal input.
If not between 0.3-4.8 V or does not change

If between 0.3-4.8 V and changes
the conditions that you observed in the Freeze Frame/Failure Records data.
If the DTC sets

6. All OK.
1. Ignition OFF and all vehicle systems OFF, disconnect the B74 Manifold Absolute Pressure sensor. It may
If less than 2 ohms
3. Ignition ON.

If less than 4.8 V

NOTE:


5. Ignition ON, verify the scan tool MAP Sensor parameter is less than 0.5 V.
If 0.5 V or greater
If less than 0.5 V
6. Ignition OFF, install a 3 A fused jumper wire between the signal circuit terminal 3 and the 5 V reference
circuit terminal 1.
7. Ignition ON, verify the scan tool MAP voltage parameter is greater than 4.5 V.
If 4.5 V or less

2. Remove the jumper wire, test for infinite resistance between the signal circuit terminal 3 and
ground.
8. Test or replace the B74 Manifold Absolute Pressure sensor.
Component Testing
NOTE:
You must perform the Circuit/System Testing in order to Check the integrity of
the MAP sensor circuits before proceeding with the Component Testing.
Skewed Sensor Test

1. Ignition OFF, remove the B74 Manifold Absolute Pressure sensor from the engine. Connect the harness
to the sensor, if disconnected.
2. Ignition ON, apply -17 kPa (5.0 inHg) of vacuum to the B74 Manifold Absolute Pressure sensor, with the
EN-23738-A Vacuum Pump. Verify the scan tool MAP pressure parameter decreases between 13-21 kPa
(1.8-3.0 psi).
3. Apply -34 kPa (10.0 inHg) of vacuum to the B74 Manifold Absolute Pressure sensor, with the EN-23738A Vacuum Pump. Verify the scan tool MAP pressure parameter decreases between 30-38 kPa (4.4-5.5
psi).

4. All OK.
Erratic Signal Test

1. Ignition OFF, remove the B74 Manifold Absolute Pressure sensor and disconnect the harness.
2. Install a 3 A fused jumper wire between the 5 V reference circuit terminal 1 of the sensor and the sensor
harness.
3. Install a jumper wire between the low reference circuit terminal 2 of the sensor and ground.

4. Install a jumper wire to the signal circuit terminal 3 of the sensor.

5. Connect a DMM between the jumper wire and ground.
6. Ignition ON, observe the DC voltage on the DMM. Slowly apply between 0-15kPa of vacuum to the
sensor with the EN-23738-A Vacuum Pump. Verify the voltage changes, without any spikes or dropouts,
between 4.9-0.2 V.
If not between 4.9-0.2 V or has spikes or dropouts
If between 4.9-0.2 V and there are no spikes or dropouts
7. All OK.
Repair Instructions
Manifold Absolute Pressure Sensor Replacement

Control Module References for Engine Control Module replacement, programming and setup
DTC P0112, P0113, OR P0114

DTC Descriptors
DTC P0112
Intake Air Temperature (IAT) Sensor Circuit Low Voltage
DTC P0113
Intake Air Temperature (IAT) Sensor Circuit High Voltage
DTC P0114
Intake Air Temperature (IAT) Sensor Circuit Intermittent
IAT Sensor 1
Short to
Open/High
Short to

Circuit
Sensor
Ground
Resistance
P0112, P0114,
P2199**
P0113, P0114,
P2199**
Voltage
P0113*,
P0114,
P2199**
P0097, P0113,
P11C2**, P2227,
*
P2229
**Where used.
Low Reference
Signal Performance
P0111**, P0114
IAT Sensor 1
Circuit
Sensor
150C (302F)
-40C (-40F)
-40C (-40F)*
Low Reference
-40C (-40F)
-40C (-40F)*
IAT sensor 1
IAT sensor 2
Humidity sensor
MAF sensor
The intake air temperature (IAT) sensor 1 is a variable resistor that changes the voltage on the engine control
module (ECM) supplied 5 V signal circuit. The signal varies with inlet air temperature in the sensor bore and is
displayed by the scan tool as C (F).
The IAT sensor 1 produces an analog signal on pin-8 of the sensor. The IAT sensor 2 produces a frequency
modulated signal on pin-1 of the sensor.
IAT sensor 2
Humidity sensor

IAT sensor 1
IAT sensor 2
Humidity sensor

IAT Sensor 1
Cold
High
Warm
Low

High
Low
P0112, P0113, and P0114

The DTCs run continuously when the above conditions are met.
P0112
The ECM detects that the IAT sensor signal is warmer than 149C (300F) for at least 5 s.
P0113
NOTE:
The ECM detects that the IAT sensor signal is colder than -60C (-76F) for at least 5 s.
P0114
The ECM detects that the IAT sensor signal is intermittent or has abruptly changed for at least 5 s.


Diagnostic Aids
With the ignition ON, when the engine is cold and not running, a properly functioning IAT sensor 1 will

gradually increase the scan tool IAT Sensor 1 parameter. This is due to the heat that is generated by the
multifunction intake air sensor internal heating elements.
Schematic Reference
Circuit Testing
Connector Repairs
Wiring Repairs
DTC Type Reference

Scan Tool Reference
1. Ignition ON.
NOTE:
3. Ignition ON.

IAT Sensor 2
If within 25C (45F)

IAT Sensor 1
IAT Sensor 2

If the DTC does set

8. All OK
NOTE:

If less than 2 ohms
3. Ignition ON, test for 4.8-5.2 V between signal circuit terminal 8 and ground.
If less than 4.8 V

NOTE:

circuit terminal 7.
If less than 1 V
3. Ignition OFF.


Component Testing

NOTE:
3. All OK
Repair Instructions
DTC P0116
DTC Descriptor
DTC P0116
Engine Coolant Temperature (ECT) Sensor Performance

Short to
Open/High
Circuit
Ground
Resistance
Signal Circuit
P0117
P0118
Low Reference
P0118
*ECM or sensor damage may occur if the circuit is shorted to B+
Short to
Voltage
P0118*
P0118*
Signal Performance
P0116, P0119, P0128
P0116, P0128
ECT Sensor
Circuit
Short to Ground
Operating Conditions: Engine operating in closed loop
Parameter Normal Range: Varies with coolant temperature
Signal
140C (284F)
Low Reference
-
Open
Short to Voltage
-40C (-40F)
-40C (-40F)
-40C (-40F)
-40C (-40F)
The engine coolant temperature (ECT) sensor is a variable resistor that measures the temperature of the engine
coolant. The engine control module (ECM) supplies 5 V to the ECT sensor signal circuit and a ground for the
low reference circuit.
The purpose of this diagnostic is to determine if the input from the ECT sensor is skewed warmer than normal.
The internal clock of the ECM will record the amount of time the engine is OFF. If the required engine OFF
time is met at start-up, the ECM will compare the temperature difference between the actual measured ECT and
a calibrated ECT model. The information for this model is derived from the previous drive cycle and includes
the accumulated mass air flow (MAF), the engine run time, the ambient air temperature and the ECT at the end
of the drive cycle.
If the ECM detects that the temperature difference between the measured and modeled ECT is not within an
acceptable operating range of each other, then the ECM will continue to run this diagnostic to determine if a
block heater was active during the engine OFF time.

DTCs P0111, P0112, P0113, P0117, P0118, P0722, P0723 or P2610 are not set.
The ignition has been off for greater than 8 h before the engine is started.
P0116 Engine Running, Sensor Signal Stuck Test
The ECM detects that the ECT sensor signal has abruptly changed a minimum of 20C (68F) warmer
than intake air temperature (IAT) at engine start.

The measured ECT is greater than measured IAT at engine start, is not within range of the calibrated
model.
P0116 Engine Running, Sensor Within Range Test
The ECT at engine start is not within range of the calibrated model.
The ECT is greater than measured IAT at engine start, is not within range of the calibrated model.

The cooling fans will be commanded ON.
The A/C compressor will be commanded OFF.

Diagnostic Aids
Inspect the ECT sensor terminals for corrosion and for engine coolant leaking through the sensor. Engine
coolant that is leaking through the sensor will create a high resistance short to ground. This condition
results in less voltage on the ECT sensor signal circuit, which is interpreted by the ECM as a warmer
ECT.
An intake air temperature (IAT) sensor that is biased colder at various ambient temperatures due to
greater resistance than is normal will increase the range between these 2 sensors. Measure and record the
resistance of the IAT sensor at various ambient temperatures, then compare those measurements to the
Temperature vs. Resistance table. Refer to Temperature Versus Resistance (ECT) .
Test the ECT sensor at various temperature levels in order to evaluate the possibility of a biased sensor. A
sensor that is biased warmer can result in a driveability condition. Refer to Temperature Versus
Resistance (ECT) .
A slight to moderate resistance in the IAT sensor signal circuit or low reference circuit will increase the
range between these two sensors. This condition results in a greater voltage on the IAT sensor signal
circuit, which is interpreted by the ECM as a colder IAT.
If the condition is intermittent, allow the vehicle to sit for greater than 8 h with the ignition OFF, may
help isolate the condition. Compare the scan tool and ECT Sensor temperature sensor values at ignition
on. The Radiator Coolant Temperature Sensor and the ECT Sensor values should display within 3C (5
F).
Schematic Reference


Circuit Testing
Connector Repairs
Wiring Repairs
DTC Type Reference

Scan Tool Reference
1. Ignition ON, observe the DTC information with a scan tool. Verify that DTC P0112, P0113, P0117, or
P0118 are not set.
If any of the DTCs are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle .
2. Ignition off, inspect the cooling system surge tank for the proper coolant level. Refer to Loss of Coolant ,
and Cooling System Draining and Filling (Static Fill) , Cooling System Draining and Filling (GE47716 Fill) .
3. If the ignition has been OFF for 8 h or greater, observe the scan tool parameters list below. The
temperatures should be within 20C (68F).
ECT Sensor
IAT Sensor
4. Engine running, observe the ECT Sensor parameter. The reading should be between -39 to +120C (-38
to +148F) depending on the current ambient temperature and the vehicle operating conditions.
data.
1. Ignition OFF, disconnect the harness connector at the B34 Engine Coolant Temperature Sensor.
2. Inspect the B34 Engine Coolant Temperature Sensor terminals for corrosion and for engine coolant
leaking through the sensor.
3. Ignition OFF for 1 min, test for less than 5 ohms between the low reference circuit terminal 2 and ground.
If greater than the specified range, test the low reference circuit for an open/high resistance. If the
circuit tests normal, replace the K20 Engine Control Module.
4. Ignition ON, verify the scan tool ECT Sensor parameter is colder than -39C (-38F).

If greater than the specified range, test the signal circuit terminal 1 for a short to ground. If the
circuit tests normal, replace the K20 Engine Control Module.
terminal 2. Verify the scan tool ECT Sensor parameter is greater than 130C (266F).
If less than the specified range, test the signal circuit for a short to voltage or an open/high
resistance. If the circuit tests normal, replace the K20 Engine Control Module.
6. If all circuits test normal, test or replace the B34 Engine Coolant Temperature Sensor.
Component Testing
Static Test
1. Ignition off, disconnect the harness connector at the B34 Engine Coolant Temperature Sensor.
NOTE:
A thermometer can be used to test the sensor off vehicle.
2. Test the B34 Engine Coolant Temperature Sensor by varying the sensor temperature while monitoring the
sensor resistance. Compare the readings with the Temperature Versus Resistance (ECT) table and
verify that the resistance is within 5% of the specification.
If not within the specified range, replace the B34 Engine Coolant Temperature Sensor.
Repair Instructions

DTC P0117, P0118, OR P0119

DTC Descriptors
DTC P0117
Engine Coolant Temperature (ECT) Sensor Circuit Low Voltage
DTC P0118

Engine Coolant Temperature (ECT) Sensor Circuit High Voltage

DTC P0119
Engine Coolant Temperature (ECT) Sensor Circuit Intermittent
Circuit
Signal
Short to
Ground
Open/High
Resistance
P0117
P0118, P0119
Low Reference
P0118, P0119
*ECM or sensor damage may occur if the circuit is shorted to B+.
Short to
Voltage
P0118*,
P0119
-
Signal Performance
P0116, P0128
P0128
ECT Sensor
Circuit
Short to Ground
Open
Parameter Normal Range: Varies with engine coolant temperature
Signal
140C (284F)
-40C (-40F)
Low Reference
-40C (-40F)
Short to Voltage
-40C (-40F)
-
The engine coolant temperature (ECT) sensor is a variable resistor that measures the temperature of the engine
coolant. The engine control module (ECM) supplies 5 V to the ECT sensor signal circuit and a ground for the
low reference circuit. This diagnostic checks for an open, short to ground or an intermittent circuit condition
between the ECM and ECT sensor.
P0117
The ignition is ON.

OR
The engine is running for greater than 10 s.

OR
The engine run time is less than 10 s when the intake air temperature (IAT) is colder than 50C (122F).

P0118
The ignition is ON.

OR

OR
The engine run time is less than 10 s when the IAT is warmer than 0C (32F).
P0119
P0117
The ECM detects that the ECT is warmer than 149C (300F) for greater than 5 s.
P0118
The ECM detects that the ECT is colder than -39C (-38F) for greater than 5 s.
P0119
The ECM detects that the ECT is intermittent or has abruptly changed for greater than 4 seconds.
DTC P0117, P0118 or P0119 are a Type B DTC.

The cooling fans will be commanded ON.
The Engine Coolant Temperature Gauge is inoperative.
The AC compressor will be commanded OFF.
DTC P0117, P0118 or P0119 are a Type B DTC.

Schematic Reference


Circuit Testing
Connector Repairs
Wiring Repairs
DTC Type Reference

Scan Tool Reference
1. Ignition ON.
2. Verify the scan tool ECT Sensor parameter is between -39 to + 120C (-38 to +248F) and changes with
engine run time.
If not between -39 to + 120C (-38 to +248F) or does not change
If between -39 to + 120C (-38 to +248F) and changes
If the DTC sets

5. All OK.
1. Ignition OFF and all vehicle systems OFF, disconnect the harness connector at the B34 Engine Coolant
Temperature Sensor. It may take up to 2 minutes for all vehicle systems to power down.

3.
4.
5.
6.
7.
If less than 5 ohms
Ignition ON.
Verify the scan tool ECT Sensor parameter is colder than -39C (-38F).
If warmer than -39C (-38F)
If colder than -39C (-38F)
terminal 2.
Verify the scan tool ECT sensor parameter is warmer than 137C (280F).
If colder than 137C (280F)
If less than 1 V
3. Ignition OFF.
If warmer than 137C (280F)
Test or replace the B34 Engine Coolant Temperature Sensor.
Component Testing
1. Ignition OFF, disconnect the harness connector at the B34 Engine Coolant Temperature Sensor.
2. Test the ECT sensor by varying the sensor temperature while monitoring the sensor resistance. Compare
the readings with the Temperature Versus Resistance (ECT) table. The resistance values should be in
range of the table values.
Replace the B34 Engine Coolant Temperature Sensor.


4. All OK.
Repair Instructions

Engine Control Module Replacement engine control module replacement, programming, and setup
DTC P0121-P0123, P0222, P0223, OR P2135 (LUV)

DTC Descriptors
DTC P0121
Throttle Position Sensor 1 Performance
DTC P0122
Throttle Position Sensor 1 Circuit Low Voltage
DTC P0123
Throttle Position Sensor 1 Circuit High Voltage
DTC P0222
Throttle Position Sensor 2 Circuit Low Voltage
DTC P0223
Throttle Position Sensor 2 Circuit High Voltage
DTC P2135

Throttle Position Sensors 1-2 Not Plausible

Circuit
5 V Reference
Throttle Position Sensor
1 Signal
Throttle Position Sensor
2 Signal
Short to
Ground
High Resistance
Open
P0122,
P0222
Short to
Voltage
P06A3,
P2135
P06A3
P2135
P0122
P2135
P0122
P0123
P0068, P0121
P0222
P2135
P0223
P0223
P0068, P0121
P2135
P0123,
P0223
P0068, P0121
Low Reference
Signal Performance
P0068, P0121
Throttle Position Sensor 1

Circuit
Short to Ground
Open
Normal Range: 4.75-0.35 V
5 V Reference
0V
0V
Throttle Position Sensor 1 Signal
0V
0V
Low Reference
4-5 V
Throttle Position Sensor 2
Circuit
Short to Ground
Open
Parameter Normal Range: 0.35-4.65 V
5 V Reference
0V
0V
Throttle Position Sensor 2 Signal
0V
5V
Low Reference
5V
Short to Voltage
5V
5V
-
Short to Voltage
5V
5V
-
The throttle body assembly contains 2 throttle position sensors. The throttle position sensors are mounted to the
throttle body assembly and are not serviceable. The throttle position sensors provide a signal voltage that
changes relative to throttle blade angle. The engine control module (ECM) supplies the throttle position sensors
with a common 5 V reference circuit, a common low reference circuit, and two independent signal circuits.
The throttle position sensors have opposite functionality. throttle position sensor 1 signal voltage decreases and
throttle position sensor 2 signal voltage increases as the accelerator pedal increases to wide open throttle
(WOT).

P0122, P0123, P0222, and P0223
DTC P06A3 is not set.

The run/crank or powertrain relay voltage is greater than 6 V and reduced power is not active.
The ignition is ON or the engine is operating.
DTC P0122, P0123, P0222, P0223 run continuously when the above conditions are met.
P0121
No Active or Pending DTCs.

The engine coolant temperature (ECT) is between -7 to +125C (19-257F).
The intake air temperature (IAT) is between -20 to +125C (-4 to +257F).
DTC P0121 runs continuously when the above conditions are met.
P2135
DTC P0122, P0123, P0222, P0223, or P06A3 is not set.

The run/crank or powertrain relay voltage is greater than 6 V and reduced power is not active.
The ignition is ON or the engine is operating.
DTC P2135 runs continuously when the above conditions are met.
P0121
The ECM detects the throttle position sensor is stuck within range for greater than 1 s.
P0122
The ECM detects the throttle position sensor 1 voltage is less than 0.325 V for greater than 1 s.
P0123
The ECM detects the throttle position sensor 1 voltage is greater than 4.75 V for greater than 1 s.
P0222
The ECM detects that the throttle position sensor 2 voltage is less than 0.25 V for greater than 1 s.
P0223
The ECM detects the throttle position sensor 2 voltage is greater than 4.59 V for greater than 1 s.
P2135

The ECM detects the difference between the throttle position sensor 1 and throttle position sensor 2 exceeds a
predetermined value for greater than 1 s.
DTC P0122, P0123, P0222, P0223, and P2135 are Type A DTCs.
The ECM commands the TAC system to operate in the Reduced Engine Power mode.
A message center or an indicator displays Reduced Engine Power.
Under certain conditions the control module commands the engine OFF.
DTCs P0122, P0123, P0222, P0223, and P2135 are Type A DTCs.
Diagnostic Aids
A high resistance condition on the throttle position and throttle actuator control circuits could cause a
DTC to set.
If the accelerator pedal is pressed to the wide open throttle position, the throttle blade angle or Throttle
Position angle is limited to less than 40 percent.
Schematic Reference
Throttle Actuator Control (TAC) System Description
Circuit Testing
Connector Repairs
Wiring Repairs
DTC Type Reference


Scan Tool Reference
1. Ignition ON.
2. If you were sent here from DTC P0068, P0101, P0106, or P1101 refer to Circuit/System Testing below.
90 % or greater

If less than 90 %
5. Verify the scan tool Throttle Position Sensor 1 and Throttle Position Sensor 2 voltage parameters are
between 1.0-4.0 V and change with accelerator pedal input.
If not between 1.0-4.0 V or does not change

If between 1.0-4.0 V and changes
6. Verify the scan tool Throttle Position Sensor 1 and 2 Agree/Disagree parameter displays Agree while
If Disagree

If Agree
8. Verify the scan tool MAP Sensor pressure parameter is within range specified in the Altitude Versus
The MAP Sensor pressure is not in range
Refer to DTC P0106.
The MAP Sensor pressure is within range

9. Engine idling.
10. Verify the scan tool MAP Sensor pressure parameter is between 26-52 kPa (3.8-7.5 psi) and changes with
Refer to DTC P0106.
1. Engine idling
The MAF Sensor parameter does not change smoothly and gradually
Refer to DTC P0101.

The MAF Sensor parameter changes smoothly and gradually
12. Verify the scan tool Boost Pressure Sensor pressure and BARO parameters are within 3 kPa (0.4 psi).
The parameters are not within 3 kPa (0.4 psi)
Refer to DTC P0236.

The parameters are within 3 kPa (0.4 psi)
13. Verify the scan tool MAP Sensor parameter and the Boost Pressure Sensor parameter are within 20 kPa
(2.9 psi) during a WOT acceleration at the time of the 1-2 shift.
Refer to DTC P0236.

If the DTC sets

16. All OK

NOTE:
Disconnecting the throttle body harness connector causes additional

DTCs to set.
1. Ignition OFF, and all vehicle systems OFF, disconnect the harness connector at Q38 Throttle Body. It
2. Test for less than 5 ohms between the low reference circuit terminal C and ground.
If less than 5 ohms
3. Ignition ON.
4. Test for 4.8-5.2 V between the 5 V reference circuit terminal E and ground.
If less than 4.8 V
5. Ignition ON.
6. Test for less than 1 V between the throttle position sensor 1 signal circuit terminal D and ground.
If 1.0 V or greater
If 1.0 V or less
7. Install a 3 A fused jumper wire between throttle position sensor 1 signal circuit terminal D and the 5 V

reference circuit terminal E.

8. Verify the scan tool throttle position sensor 1 voltage parameter is greater than 4.8 V.
If 4.8 V or less
If 4.8 or greater
9. Test for 4.8-5.2 V between the throttle position sensor 2 signal circuit terminal F and ground.
If less than 4.8 V
10. Test or replace the Q38 Throttle Body.
Repair Instructions
Throttle Body Assembly Replacement

Repair Verification
1. Install any components that have been removed or replaced during diagnosis.
2. Perform any adjustments, programming or setup procedures that are required when a component is
removed or replaced.
3. Clear the DTCs with a scan tool.

down.
5. Ignition ON.
6. Verify the Throttle Position Sensors 1 and 2 Agree/Disagree parameter displays Agree while performing
the Throttle Sweep Test with a scan tool.
If Disagree
Test or replace the Q38 Throttle Body assembly.
If Agree
7. If the repair was related to a DTC, duplicate the Conditions for Running the DTC and use the Freeze
Frame/Failure Records, if applicable, in order to verify the DTC does not set.
If DTC sets
If DTC does not set
8. All OK
DTC P0128
DTC Descriptor
DTC P0128
Engine Coolant Temperature (ECT) Below Thermostat Regulating Temperature
The engine control module (ECM) monitors the temperature of the engine coolant for engine control and
enabling criteria for some diagnostics. The amount of air flow into an engine is proportional to the amount of
heat an engine generates. The ECM monitors the amount of air flow into the engine to calculate engine coolant
temperature (ECT). The ECM uses the calculated temperature to determine if the engine has warmed up to the
thermostat regulating temperature. If the ECT does not increase normally or does not reach the thermostat
regulating temperature, diagnostics that use the ECT as enabling criteria, may not run when expected. If the
ECT fails to reach the thermostat regulating temperature, before a predetermined amount of air flow enters the
engine, the DTC sets.
DTCs P00B3, P00B6, P0101, P0102, P0103, P0111, P0112, P0113, P0116, P0117 or P0118 are not set.

Average Airflow is greater than 11 g/s.

Thermostat Heater duty commanded cycle 10%.
Engine not run time 30 min
Engine run time between 22 s and 30 min
The DTC runs once per ignition key cycle.
The ECM detects that the actual engine coolant temperature is 26C (78.8F) colder than the commanded
engine coolant temperature while the IAT is between 10-65C (50-149F)
or
The ECM detects that the actual engine coolant temperature is 46C (114.8F) colder than the commanded
engine coolant temperature while the IAT is between -7C to +10C (-19.4 to+50F)


Schematic Reference
Circuit Testing
Connector Repairs
Wiring Repairs
DTC Type Reference

Scan Tool Reference


1. Verify the cooling system is filled to the correct coolant level. Refer to Loss of Coolant , and Cooling
System Draining and Filling (Static Fill) , Cooling System Draining and Filling (GE-47716 Fill) .
If the coolant level is not correct
Repair as necessary
If the coolant level is correct
2. Verify the DTC P00B7, P0116, P0117, P0118, P0597, P0598, or P0599 is not set.
If a DTC is set

If a DTC is not set
3. Engine running for 15 min with the A/C OFF, increase the engine speed to 3, 000 RPM.
4. Verify the scan tool ECT Sensor parameter is greater than 79C (174F) when commanding the Engine
Coolant Thermostat Heater to 0%.
If less than 79C (174F)
Replace the E41 Engine Coolant Thermostat Heater.

If greater than 79C (174F)
If the DTC sets
Refer to Step 1.
7. All OK.
Component Testing
1. Ignition OFF, disconnect the B34 Engine Coolant Temperature Sensor harness connector at the sensor.
2. Test for refer to Temperature Versus Resistance (ECT) Temperature Versus Resistance between the
signal circuit terminal 1 and the low reference terminal 2.
If the temperature versus resistance are not within the specified ranges

If the temperature versus resistance are within the specified ranges


4. All OK.
Repair Instructions

Engine Coolant Thermostat Housing Removal
Control Module References for engine control module replacement, programming and setup.
DTC P0131, P0132, P0134, P0137, P0138, OR P0140

DTC Descriptors
DTC P0131
HO2S Circuit Low Voltage Sensor 1
DTC P0132
HO2S Circuit High Voltage Sensor 1
DTC P0134
HO2S Circuit Insufficient Activity Sensor 1
DTC P0137
HO2S Circuit Low Voltage Sensor 2
DTC P0138

HO2S Circuit High Voltage Sensor 2

DTC P0140
HO2S Circuit Insufficient Activity Sensor 2
HO2S 1 or 2
Short to
Ground
Circuit
HO2S High Signal
P0131, P0137
HO2S Low Signal
P0131, P0137,
P0171
Open/High
Resistance
P0132, P0134,
P0138, P0140
P0132, P0134,
P0138, P0140
Short to
Signal Performance
Voltage
P0132, P0134,
P0133, P1133
P0138, P0140
P0132, P0134,
P0133, P1133
P0138, P0140
HO2S 1 or 2
Circuit
Short to Ground
Operating Conditions: Engine operating in Closed Loop
Parameter Normal Range: 200-800 mV
High Signal
0 mV
Low Signal
-
Open
Short to Voltage
1, 700-2, 100 mV
1, 700-2, 100 mV
1, 700-2, 100 mV
1, 700-2, 100 mV
The heated oxygen sensors (HO2S) are used for fuel control and catalyst monitoring. Each HO2S compares the
oxygen content of the surrounding air with the oxygen content of the exhaust stream. When the engine is
started, the control module operates in an open loop mode, ignoring the HO2S signal voltage while calculating
the air to fuel ratio. While the engine runs, the HO2S heats up and begins to generate a voltage within a range of
0-1 275 mV. Once sufficient HO2S voltage fluctuation is observed by the control module, closed loop is
entered. The control module uses the HO2S voltage to determine the air to fuel ratio. An HO2S voltage that
increases toward 1 000 mV indicates a rich fuel mixture. An HO2S voltage that decreases toward 0 mV
indicates a lean fuel mixture.
The heating elements inside each HO2S heat the sensor to bring the sensor up to operating conditions faster.
This allows the system to enter closed loop earlier and the control module to calculate the air to fuel ratio
sooner.
DTC P0131 or P0137
P0451, P0452, P0453, P0454, P0455, P0496, P1101, P1516, P2101, P2119, P2135 and P2176 are not set.


The fuel level is greater than 10%.
The mass air flow (MAF) is between 2-60 g/s.
The fuel composition is less than 87% ethanol.
The fuel system is in Closed Loop.
The vehicle is not decelerating.
The DTC P0131 runs continuously when the above conditions are met for greater than 3 s.
The DTC P0137 runs continuously when the above conditions are met for greater than 5 s.
DTC P0132 or P0138
P0443, P0446, P0449, P0451, P0452, P0453, P0454, P0455, P0496, P1101, P1516, P2101, P2119, P2135
and P2176 are not set.
Engine run time is greater than 5 s.
The DTC P0132 and P0138 run continuously when the above conditions are met for greater than 3 s.
DTC P0134 or P0140
DTCs P0068, P0101, P0102, P0103, P0121, P0122, P0123, P0222, P0223, P1516, P2101, P2119, P2135
HO2S heater warm up is finished.
Engine run time is greater than 5 s.
The engine has been operating for greater than 50 s.
P0131
The engine control module (ECM) detects that the heated oxygen sensor (HO2S) voltage is less than 20 mV for
greater than 38 s.
P0137
The engine control module (ECM) detects that the heated oxygen sensor (HO2S) is shorted to ground for

greater than 38 s.
P0132 or P0138
The ECM detects that the heated oxygen sensor (HO2S) voltage is greater than 1 050 mV for greater than 10 s.
P0134 or P0140
The ECM detects that the heated oxygen sensor (HO2S) voltage is greater than 1 700 mV for greater than 10 s.
DTCs P0131, P0132, P0134, P0137, P0138 and P0140 are Type B DTCs.
DTCs P0131, P0132, P0134, P0137, P0138 and P0140 are Type B DTCs.
Schematic Reference
Circuit Testing
Connector Repairs
Wiring Repairs
DTC Type Reference

Scan Tool Reference
1. Ignition ON
2. Verify no HO2S heater DTCs are set.

If a DTC is set
If a DTC is not set

3. Engine running.
4. Verify the scan tool HO2S 1 or 2 parameters are between 50-1, 050 mV.
If not between 50-1, 050 mV

If between 50-1, 050 mV
If the DTC sets

7. All OK.
1. Ignition OFF and all vehicle systems OFF, disconnect the appropriate B52 Heated Oxygen Sensor
harness connector. It may take up to 2 minutes for all vehicle systems to power down. Ignition ON.
2. Test for 1.7-3.0 V between the high signal circuit terminal 4 and ground.
If less than 1.7 V
2. Test for infinite resistance between the high signal circuit terminal 4 and ground.
3. Test for less than 2 ohms in the high signal circuit end to end.
If greater than 3 V
1. Ignition OFF, disconnect the harness connector at the K20 Engine Control Module. Ignition ON.
2. Test for less than 1 V between the high signal circuit terminal 4 and ground.

3. Verify the scan tool HO2S 1 or 2 parameter is between 1.73.0 V.

If less than 1.7 V
2. Test for infinite resistance between the low signal circuit terminal 3 and ground.
4. Connect a 3 A fused jumper wire between the high signal circuit terminal 4 and the low signal circuit
terminal 3.
NOTE:
The low signal circuit is tied to a pull-up circuit within the engine control
module. A voltage of 0.0-1.1 V on the low signal circuit is normal.
5. Verify the scan tool HO2S 1 or 2 parameter displays 0.0 V.

2. Test for less than 2 ohms in the low signal circuit end to end.
If less than 2 ohms
3. Test for less than 1 V between the low signal circuit terminal 3 and ground.
If 0.0 V
6. Verify none of the conditions listed below exist:
Water intrusion in the B52 HO2S harness connector
Low or high fuel system pressure-Refer to Fuel System Diagnosis .
Fuel that is contaminated-Refer to Alcohol/Contaminants-in-Fuel Diagnosis .
Fuel saturation of the evaporative emission (EVAP) canister
Exhaust leaks
Engine vacuum leaks
If any of the conditions exist
If none of the conditions exist
7. Test or replace the B52 Heated Oxygen Sensor.
Repair Instructions


Perform the scan tool Heated Oxygen Sensor Resistance Learn Reset after replacing an HO2S.
DTC P0133, P013A, P013B, P013E, P013F, P015A, P015B, P2270, OR P2271
DTC Descriptors
DTC P0133
HO2S Slow Response Sensor 1
DTC P013A
HO2S Slow Response Rich to Lean Sensor 2
DTC P013B
HO2S Slow Response Lean to Rich Sensor 2
DTC P013E
HO2S Delayed Response Rich to Lean Sensor 2
DTC P013F
HO2S Delayed Response Lean to Rich Sensor 2
DTC P015A
HO2S Delayed Response Rich to Lean Sensor 1
DTC P015B
HO2S Delayed Response Lean to Rich Sensor 1
DTC P2270
HO2S Signal Stuck Lean Sensor 2

DTC P2271
HO2S Signal Stuck Rich Sensor 2
Short to
Ground
Circuit
HO2S High Signal
P0131, P0137
HO2S Low Signal
P0137
Open/High
Resistance
P0132, P0134,
P0138, P0140
P0132, P0134,
P0138, P0140
Short to
Voltage
Signal Performance
P0132, P0134,
P0133
P0138, P0140
P0132, P0134,
P0133
P0138, P0140
HO2S 1 or 2
Circuit
Short to Ground
Operating Conditions: Engine operating in Closed Loop
Parameter Normal Range: 200-800 mV
HO2S 1 or 2 Signal
0 mV
HO2S 1 or 2 Low Signal
-
Open
Short to Voltage
1 700-2 100 mV
1 700-2 100 mV
1 700-2 100 mV
1 700-2 100 mV
The heated oxygen sensors (HO2S) are used for fuel control and catalyst monitoring. Each HO2S compares the
oxygen content of the surrounding air with the oxygen content of the exhaust stream. When the engine is
started, the control module operates in an open loop mode, ignoring the HO2S signal voltage while calculating
the air to fuel ratio. While the engine runs, the HO2S heats up and begins to generate a voltage within a range of
0-1 275 mV. Once sufficient HO2S voltage fluctuation is observed by the control module, closed loop is
entered. The control module uses the HO2S voltage to determine the air to fuel ratio. An HO2S voltage that
increases toward 1 000 mV indicates a rich fuel mixture. An HO2S voltage that decreases toward 0 mV
indicates a lean fuel mixture.
The heating elements inside each HO2S heat the sensor to bring the sensor up to operating conditions faster.
This allows the system to enter closed loop earlier and the control module to calculate the air to fuel ratio
sooner.
DTC P0133
DTCs P0068, P0096, P0097, P0098, P00B3, P00B4, P00B6, P00C7, P0101, P0102, P0103, P0106,
P0107, P0108, P0111, P0112, P0113, P0114, P0116, P0117, P0118, P0119, P0121, P0122, P0123,
P0128, P0131, P0132, P0134, P0201, P0202, P0203, P0204, P0222, P0223, P0300, P0442, P0443,
P0446, P0449, P0451, P0452, P0453, P0454, P0455, P0496, P1101, P1516, P2101, P2119, P2135, P2176


The engine speed parameter is between 1 300-3 500 RPM.
The engine coolant temperature (ECT) is hotter than 65C (149F).
The intake air temperature (IAT) is hotter than -40C (-40F).
P013A
DTCs P0068, P0096, P0097, P0098, P00B6, P0101, P0102, P0103, P0106, P0107, P0108, P0111, P0112,
P0113, P0114, P0116, P0117, P0118, P0119, P0121, P0122, P0123, P0171, P0172, P0201, P0202,
P0203, P0204, P0222, P0223, P0300, P1101, P1516, P2096, P2097, P2101, P2119, P2135, P2176 are not
set.
DTC P013B, P013E, P013F, P2270 and P2271 have run.
DTC P013E and P2270 have passed.
DTC P013A runs once per trip.
P013B
P0113, P0114, P0116, P0117, P0118, P0119, P0121, P0122, P0123, P0171, P0172, P0201, P0202,
set.
DTC P013A, P013E, P013F, P2270 and P2271 have run.
DTC P013F and P2271 have passed.
DTC P013B runs once per trip.
P013E
P0113, P0114, P0116, P0117, P0118, P0119, P0121, P0122, P0123, P0171, P0172, P0201, P0202,
set.

DTC P013A, P013B, P013F, P2270 and P2271 have run.

DTC P2270 have passed.
DTC P013E runs once per trip.
P013F
P0113, P0114, P0116, P0117, P0118, P0119, P0121, P0122, P0123, P0171, P0172, P0201, P0202,
set.
DTC P013A, P013B, P013E, P2270 and P2271 have run.
DTC P2270 and P2271 have passed.
DTC P013F runs once per trip.
P015A and P015B
P0118, P0119, P0121, P0122, P0123, P0128, P0131, P0132, P0134, P0171, P0172, P0201, P0202,
P0203, P0204, P0222, P0223, P0300, P0442, P0443, P0446, P0449, P0452, P0453, P0455, P0496,
P16F3, P2101 or P2135 are not set.
The device controls are not active.
The HO2S heater is commanded ON for greater than 40 s.
The engine coolant temperature (ECT) is hotter than 60C (140F).
The intake air temperature (IAT) is hotter than -40C (-40F).
The engine speed is between 1 550-3 500 RPM to initially enable the test.
The vehicle speed is between 70-125 km/h (44-78 mph) to initially enable the test.
The engine speed is between 1 350-3 650 RPM to keep the test enabled.
The vehicle speed is between 65-130 km/h (41-81 mph) to keep the test enabled.
The evaporative emission (EVAP) diagnostics are not in control of purge.
The predicted catalytic converter temperature is between 550-900C (1 022-1 652F).
DTC P015A runs once per trip, during the deceleration fuel cut-off (DFCO) mode, when the above
conditions are met.
DTC P015B runs once per trip, during the fuel enrich mode, when the above conditions are met.

P2270
P0113, P0114, P0116, P0117, P0118, P0119, P0121, P0122, P0123, P0171, P0172, P0201, P0202,
set.
DTC P013A, P013B, P013E, P013F, P2270 and P2271 have run.
DTC P2270 and P2271 have passed.
DTC P2270 runs once per drive cycle when the above conditions are met for 5 s.
P2271
P0113, P0114, P0116, P0117, P0118, P0119, P0121, P0122, P0123, P0171, P0172, P0201, P0202,
set.
DTC P013A, P013B, P013E, P013F and P2270 have run.
DTC P013A, P013E and P2270 have passed.
DTC P2270 runs once per drive cycle when the above conditions are met for 5 s.
P0133
The ECM detects that the HO2S 1 average response time is more than a calculated value.
DTC P0133 sets within 60 s when the above condition is met.
P013A
The ECM detects that the accumulated mass air flow monitored during rich to lean transitions between 150-450
mV is more than 6 g.

P013B
The ECM detects that the accumulated mass air flow monitored during rich to lean transitions between 335-650
mV is more than 25 g.
P013E
The ECM detects that the Post O2 sensor voltage is greater than 450 mV and the accumulated mass air flow
monitored during the delayed Response Test is greater than 20 g.
P013F
The ECM detects that the Post O2 sensor voltage is less than 350 mV and the accumulated mass air flow
monitored during the delayed Response Test is greater than 70 g.
P0140
The ECM detects that the heated oxygen sensor (HO2S) 2 parameter is greater than 1 700 mV.
P2270
The ECM detects that the heated oxygen sensor (HO2S) 2 sensor cannot achieve voltage equal to or less
than 775 mV.
and
The ECM detects that the accumulated mass air flow monitored during the Stuck Lean Voltage Test is
more than 38 g.
P2271
The ECM detects that the heated oxygen sensor (HO2S) 2 sensor cannot achieve voltage equal to or less
than 100 mV.
and
The ECM detects that the accumulated mass air flow monitored during the stuck rich voltage test is more
than 25 g.
DTCs P0133, P0134, P013E, P013F, P0140, P2270 are P2271 Type B DTCs.
DTCs P013A and P013B are Type A DTCs.
DTCs P0133, P0134, P013E, P013F, P0140, P2270 are P2271 Type B DTCs.

DTCs P013A and P013B are Type A DTCs.
Schematic Reference
Circuit Testing
Connector Repairs
Wiring Repairs
DTC Type Reference

Scan Tool Reference
1. Ignition ON.
2. Verify no HO2S heater DTCs are set
If a HO2S heater DTC is set
If no HO2S heater DTC is set
3. Allow the engine to reach operating temperature, engine running.
4. Verify the scan tool HO2S Sensor 1 or 2 voltage parameters are between 50-1 050 mV.
If not between 50-1 050 mV

If between 50-1 050 mV
5. Verify none of the following conditions exist:
Lean or rich fuel injectors

Water intrusion in the HO2S harness connector

Low or high fuel system pressure-Refer to Fuel System Diagnosis .
Fuel that is contaminated-Refer to Alcohol/Contaminants-in-Fuel Diagnosis .
Fuel saturation of the evaporative emission (EVAP) canister
Exhaust leaks
Engine vacuum leaks
Engine oil consumptions-Refer to Symptoms - Engine Cooling .
Engine coolant consumption-Refer to Symptoms - Engine Cooling .
If any of the above conditions exist
If none of the above conditions exist

If the DTC sets
Replace the B52 Heated Oxygen Sensor.

8. All OK.
Repair Instructions

Perform the scan tool Heated Oxygen Sensor Resistance Learn Reset after replacing a HO2S.
DTC P0171 OR P0172

DTC Descriptors
DTC P0171

Fuel Trim System Lean

DTC P0172
Fuel Trim System Rich
The engine control module (ECM) controls a Closed Loop air/fuel metering system in order to provide the best
possible combination of driveability, fuel economy, and emission control. The ECM monitors the heated
oxygen sensor (HO2S) signal voltage, and adjusts the fuel delivery based on the signal voltage while in Closed
Loop. A change made to the fuel delivery changes the long and short term fuel trim values. The short term fuel
trim values change rapidly in response to the HO2S signal voltages. These changes fine tune the engine fueling.
The long term fuel trim values change in response to trends in the short term fuel trim The long term fuel trim
makes coarse adjustments to fueling in order to re-center and restore control to short term fuel trim. The ideal
fuel trim values are around 0 %. A positive fuel trim value indicates that the ECM is adding fuel in order to
compensate for a lean condition. A negative fuel trim value indicates that the ECM is reducing the amount of
fuel in order to compensate for a rich condition.
DTCs P0030, P0053, P0101, P0102, P0103, P0106, P0107, P0108, P0131-P0135, P0201-P0204, P0300P0304, P0411, P0442, P0455, P0458, P0496, P0506, P0507, P1248, P1249, P124A, P124B, P2147,
P2148, P2150, P2151, P2153, P2154, P2156, P2157, P2227, P2228, P2229, P2230, P2440, or P2444 are
not set.
The engine is in Closed Loop status.
The catalyst monitor diagnostic intrusive test, post 02 diagnostic intrusive test, and EVAP diagnostic test
are not active.
The engine coolant temperature (ECT) is between -20C and +150C (-4F and +302F).
The intake air temperature (IAT) is between -20C and +150C (-4F and +302F).
The manifold absolute pressure (MAP) is between 10-255 kPa (1.5-37 psi).
The barometric pressure (BARO) is greater than 70 kPa (10.2 psi).
The fuel level is greater than 10 % and no fuel sensor fault is present.
This diagnostic runs continuously when the above conditions have been met.
The average long term fuel trim weighted average value is greater or less than a calibrated value.
The above condition is present for approximately 3 min after the Conditions for Running the DTC have
been met.



Diagnostic Aids
Allow the engine to reach operating temperature. With the engine running, observe the HO2S parameter
with a scan tool. The HO2S value should vary from approximately 40 mV to approximately 900 mV, and
respond to fueling changes.
The normal Short Term Fuel Trim and Long Term Fuel Trim parameters should be between +10 and -10
% with 0 % the optimum, with the engine running at operating temperature.
It is very unlikely that an HO2S will cause this DTC to set without the occurrence of the circuit related
HO2S DTCs. Do not replace an HO2S to address this DTC without first performing all the steps in
Circuit/System Verification.
Any un-metered air into the engine causes this DTC to set. Thoroughly inspect all areas of the engine for
vacuum leaks.
A MAF sensor condition can cause this DTC without setting a MAF DTC. If there is a MAF sensor
condition, the MAF sensor parameters will appear to be within range.
Inspect the air filter for being the correct one for this application. Make sure that the engine oil fill cap is
in place and that it is tight. Verify that the engine oil dip stick is fully seated.
Certain aftermarket air filters may cause a DTC to set.
Certain aftermarket air induction systems or modifications to the air induction system may cause a DTC
to set.
Certain aftermarket exhaust system components may cause a DTC to set.
Circuit Testing
Connector Repairs
Wiring Repairs
DTC Type Reference

Scan Tool Reference

1. Ignition ON.
2. Verify no other DTCs are set.
If a DTC is set

If no DTC is set
the conditions that you observed in the Freeze Frame/Failure Records data.
If any of the DTCs set

6. All OK.
1. Ignition ON.
2. Verify the manifold absolute pressure sensor is within the range specified for your altitude. Refer to
Altitude Versus Barometric Pressure
Refer to DTC P0106
3. Engine running, allow the engine to reach operating temperature.
4. Verify the Long Term Fuel Trim parameter is between -30 % and +30 %.
If not within the specified range, verify that none of the conditions listed below exist:
P0171
Mass air flow (MAF) sensor signal skewed. If the Short Term Fuel Trim parameter changes greater
than 20 % when the MAF sensor is disconnected, refer to DTC P0101.
Fuel contamination. Refer to Alcohol/Contaminants-in-Fuel Diagnosis .
Missing, restricted, or leaking exhaust components. Refer to Symptoms - Engine Exhaust .

Malfunctioning fuel injectors. Refer to Fuel Injector Diagnosis .

Split, kinked, or improperly connected vacuum hoses
Insufficient fuel in the tank
Low fuel pressure. Refer to Fuel System Diagnosis .
Vacuum leaks at the intake manifold, the throttle body, and the injector O-rings.
Leaks in the air induction system and the air intake ducts
Missing air filter element
Cracked EVAP canister
Evaporative pipes obstructed or leaking
Leaks in the crankcase ventilation system
P0172
Mass air flow (MAF) sensor signal skewed. If the Short Term Fuel Trim parameters for both banks
changes greater than 20 % when the MAF sensor is disconnected, refer to DTC P0101.
Fuel contamination. Refer to Alcohol/Contaminants-in-Fuel Diagnosis .
Missing, restricted, or leaking exhaust components. Refer to Symptoms - Engine Exhaust .
Malfunctioning fuel injectors. Refer to Fuel Injector Diagnosis
Collapsed or restricted air intake duct
Excessive fuel pressure. Refer to Fuel System Diagnosis
Dirty or restricted air filter
Objects blocking the throttle body
Improper operation of the evaporative emissions control system
Excessive fuel in the crankcase. Change the engine oil as necessary.
5. Test the engine for a mechanical condition. Refer to Symptoms - Engine Mechanical .
Repair Instructions
DTC P018B-P018D

DTC Descriptors
DTC P018B
Fuel Pressure Sensor Performance
DTC P018C
Fuel Pressure Sensor Circuit Low Voltage
DTC P018D
Fuel Pressure Sensor Circuit High Voltage
Circuit
5 V Reference
Signal
Low Reference
Short to
Ground
P018C, P0641,
P06A6
P018C
-
Open/High
Resistance
Short to
Voltage
Signal Performance
P018C
P018D
P06A6
P018C
P018D
P018D
-
P018B
P06A6
The fuel pressure sensor is located on the fuel line. The fuel pressure sensor monitors the fuel pressure in the
fuel line. The fuel pump control module monitors the voltage signal from the fuel pressure sensor.

DTCs P018C, P018D, P0231, P0232, P023F, P064A, P1255 or P06A6 are not active.
DTC P0641 has not failed this ignition cycle.
Fuel pump control is enabled and the fuel pump control state is normal.
The engine has been running for at least 5 seconds.
The fuel pump control module does not detect a change in the fuel pressure of at least 30 kPa (4.4 psi) when the
fuel pump is operating. The fuel pressure sensor performance diagnostic provides a means to detect fuel
pressure sensor output that is stuck within the normal operating range of the sensor.
DTCs P018B, P018C and P018D are Type A DTCs.

DTCs P018B, P018C and P018D are Type A DTCs.

Diagnostic Aids
Using the Failure Records data may help locate an intermittent condition. If you cannot duplicate the DTC, the
information in the Failure Records can help determine how many miles since the DTC set. The Fail Counter and
Pass Counter can help determine how many ignition cycles that the diagnostic test reported a pass and/or a fail.
Schematic Reference
Fuel System Description
Circuit Testing
Connector Repairs
Wiring Repairs
DTC Type Reference

Scan Tool Reference
1. Engine running.
2. Verify the scan tool Fuel Pressure Sensor Voltage parameter is between 0.2-4.8 V.

3. All OK.
NOTE:
Verify that the fuel tank is not empty. Only perform this diagnostic if there
is at least 2 gallons of fuel in the fuel tank. Clear the DTC, and start and
run the engine. Verify that the DTC resets before proceeding with the
circuit system testing. If the DTC does not reset, refer to diagnostic aids.
1. Ignition OFF and all vehicle systems OFF, disconnect the harness connector at the B47 Fuel Pressure
Sensor. It may take up to 2 minutes for all vehicle systems to power down.
1. Ignition OFF, disconnect the harness connector at the K27 Fuel Pump Control Module.
If less than 2 ohms, replace the K27 Fuel Pump Control Module.
3. Ignition ON.
If less than 4.8 V
1. Ignition OFF, disconnect the harness connector at the K27 Fuel Pump Control Module, ignition
ON.
If less than 1 V, replace the K27 Fuel Pump Control Module.
5. Verify the scan tool Fuel Pressure Sensor Voltage parameter is less than 1 V.
If 1 V or greater
1. Ignition OFF, disconnect the harness connector at the K27 Fuel Pump Control Module, ignition
ON.

If less than 1 V, replace the K27 Fuel Pump Control Module.
If less than 1 V
6. Install a 3 A fused jumper wire between the signal circuit terminal 1 and the 5 V reference circuit terminal
3, wait 15 seconds.
7. Verify the scan tool Fuel Pressure Sensor Voltage parameter is greater than 4.8 V.
If 4.8 V or less
8. Test or replace the B47 Fuel Pressure Sensor.
Repair Instructions

DTC P0201, P0202, P0203, P0204, P0261, P0262, P0264, P0265, P0267, P0268, P0270, OR P0271
DTC Descriptors
DTC P0201
Cylinder 1 Injector Control Circuit
DTC P0202
DTC P0203


DTC P0204
DTC P0261
Cylinder 1 Injector Control Circuit Low Voltage
DTC P0262
Cylinder 1 Injector Control Circuit High Voltage
DTC P0264
DTC P0265
DTC P0267
DTC P0268
DTC P0270
DTC P0271
Circuit
Ignition Voltage
Short to
Ground
Open/High
Resistance
Short to
Voltage
Signal Performance
P0201*,
P0202*,
P0203*,
P0204*,
P0261*,
P0201**, P0202**,
P0203**, P0204**,
P0261**, P0264**,

P0264*,
P0267**, P0270**
P0267*,
P0270*
P0201, P0261
P0201, P0300
P0202, P0264
P0202, P0300
P0203, P0267
P0203, P0300
P0204, P0270
P0204, P0300
Injector 1 Control
P0262, P0300
Injector 2 Control
P0265, P0300
Injector 3 Control
P0268, P0300
Injector 4 Control
P0271, P0300
* Open fuse, cranks no start.
** Cranks no start if the condition is between the fuse and the splice.
The engine control module (ECM) enables the appropriate fuel injector pulse for each cylinder. Ignition voltage
is supplied to the fuel injectors. The ECM controls each fuel injector by grounding the control circuit via a solid
state device called a driver. The ECM monitors the status of each driver. If the ECM detects an incorrect
voltage for the commanded state of the driver, a fuel injector control circuit DTC sets.

The control module detects an incorrect voltage on the fuel injector control circuit for greater than 5 s.
DTCs P0201, P0202, P0203, P0204, P0261, P0262, P0264, P0265, P0267, P0268, P0270, and P0271 are Type
B DTCs.
DTCs P0201, P0202, P0203, P0204, P0261, P0262, P0264, P0265, P0267, P0268, P0270, and P0271 are Type
B DTCs.
Diagnostic Aids
Performing the Fuel Injector Diagnosis may help isolate an intermittent condition. Refer to Fuel Injector
Diagnosis .
Schematic Reference


Circuit Testing
Connector Repairs
Wiring Repairs
DTC Type Reference

Scan Tool Reference
Special Tool
CH 34730-2C Noid Light, if available
1. Engine cranking or running.

2. Verify the scan tool parameters listed below do not display Malfunction.
Cylinder 1-4 Injector Control Circuit Low Voltage Test Status
Cylinder 1-4 Injector Control Circuit Open Test Status
Cylinder 1-4 Injector Control Circuit High Voltage Test Status
If the DTC sets

5. All OK.

1. Ignition OFF, disconnect the harness connector at the appropriate Q17 Fuel Injector, ignition ON.
1. Ignition OFF, remove the test lamp, and disconnect all components on the circuit.
3. Replace the fuse, ignition ON.
4. Verify the fuse is good after connecting each of the components one at a time.
If the fuse opens, replace the component that opens the fuse when connected.
If the fuse is good, all OK.
3. Ignition OFF, connect the test lamp to the affected fuel injector connector.
4. Engine cranking.
5. Verify the test lamp turns ON and OFF.
1. Ignition OFF, remove the test lamp, disconnect the X2 harness connector at the K20 Engine
If less than 1 V
3. Ignition OFF.
1. Ignition OFF, remove the test lamp, disconnect the X2 harness connector at the K20 Engine
Control Module.

6. Test or replace the appropriate Q17 Fuel Injector.

Component Testing
Fuel Injector Diagnosis

Repair Instructions
Fuel Injector Replacement

DTC P0231, P0232, OR P023F

DTC Descriptors
DTC P0231
Fuel Pump Control Circuit Low Voltage
DTC P0232
Fuel Pump Control Circuit High Voltage
DTC P023F
Fuel Pump Control Circuit
Circuit
Control
Low Reference
Short to
Ground
P0231
-
Open/High
Resistance
P023F
P023F
Short to
Voltage
P0232
-
Signal
Performance
P023F, P2635
P023F, P2635
The engine control module (ECM) supplies voltage to the fuel pump control module when the ECM detects that
the ignition is on. The voltage from the ECM to the fuel pump control module remains active for 2 seconds,

unless the engine is in crank or run. While this voltage is being received, the fuel pump control module supplies
a varying voltage to the fuel tank pump module in order to maintain the desired fuel line pressure.
P0231, P023F
P0232
The control enable voltage signal supplied for the ECM to fuel pump control module is inactive for 4 seconds
after engine has been shut off.
The fuel pump control module detects a fault on the fuel pump voltage circuit that is less than 11 V or greater
than 18 V.
DTCs P0231, P0232, and P023F are Type A DTCs.

DTCs P0231, P0232, and P023F are Type A DTCs.

Diagnostic Aids
Using the Failure Records data may help locate an intermittent condition. If you cannot duplicate the DTC, the
information in the Failure Records can help determine how many miles since the DTC set. The Fail Counter and
Pass Counter can help determine how many ignition cycles that the diagnostic test reported a pass and/or a fail.
On vehicles equipped with a high pressure mechanical pump on Direct Fuel Injection engines, the vehicle may
continue to run even though the pump in the fuel tank is not operating.
Schematic Reference


Circuit Testing
Connector Repairs
Wiring Repairs
DTC Type Reference

Scan Tool Reference
1. Ignition OFF and all vehicle systems OFF, disconnect the harness connector at the A7 Fuel Pump and
Level Sensor Assembly. It may take up to 2 minutes for all vehicle systems to power down.
3. Connect a test lamp between the control circuit terminal 1 and the low reference circuit terminal 2.
4. Ignition ON.
5. Verify the test lamp turns ON and OFF when commanding the fuel pump ON and OFF using the scan
tool ECM fuel pump enable control function.

If less than 1 V, replace the K27 fuel pump control module.
6. Replace the A7 Fuel Pump and Level Sensor Assembly.
Repair Instructions
Fuel Tank Fuel Pump Module Replacement

DTC P0234 OR P0299

DTC Descriptors
DTC P0234
Engine Overboost
DTC P0299
Engine Underboost
Circuit Description
The boost pressure sensor is integrated with the turbocharger boost/intake air temperature sensor. The boost
pressure sensor measures the range of pressures between the turbocharger and the throttle body. The sensor
used on this engine is a three atmosphere sensor. Pressure in this portion of the induction system is affected by
engine speed, throttle opening, turbocharger boost pressure, Intake air temperature (IAT), barometric pressure
(BARO), and the efficiency of the charge air cooler.
The sensor provides a signal voltage to the engine control module (ECM), relative to the pressure changes.
Under normal operation the greatest pressure that can exist in this portion of the induction system at ignition
ON, engine OFF is equal to the BARO. When the engine is operated at wide-open throttle (WOT) the
turbocharger can increase the pressure to near 240 kPa (34.8 psi). The pressure is equal to the BARO when the
engine is idling or decelerating.

P0108, P0111, P0112, P0113, P0114, P0116, P0117, P0118, P0119, P0121, P0122, P0123, P0128,
P0222, P0223, P0234, P0236, P0237, P0238, P0243, P0245, P0246, P0299, P16F3, P2101, P2227,
P2228, P2229 or P2230 are not set.
Engine speed between 2, 450-6, 000 RPM.
Desired boost pressure between 135-220 kPa (19.58-31.90 PSI).
Ambient pressure between 60-120 kPa (8.70-17.40 PSI).
Coolant temperature between -40 to +120C (-40 to +248F)
Intake air temperature between -40 to +80C (-40 to +176F)
P0234
The ECM detects that the actual boost pressure is greater than the desired boost pressure for greater than 2 s.
P0299
The ECM detects that the actual boost pressure is less than the desired boost pressure for greater than 2.5 s.

The ECM will disable boost control and limit the system to mechanical boost only, resulting in a substantial
decrease in engine power.

Diagnostic Aids
The charged air cooler is connected to the turbocharger and to the throttle body by flexible duct work that
requires the use of special high torque fastening clamps. These clamps cannot be substituted. In order to
prevent any type of air leak when servicing the duct work, the tightening specifications and proper
positioning of the clamps is critical, and must be strictly adhered to.
An excessively worn wastegate pivot pin may allow the wastegate to open slightly when commanded
closed, which may result in P0299 being set.
Schematic Reference


Circuit Testing
Connector Repairs
Wiring Repairs
DTC Type Reference

Scan Tool Reference
Special Tools
GE-23738-A Vacuum Pump
1. Ignition ON.
2. Verify DTC P0033, P0034, P0035, P0236, P0237, P0238, P0243, P0245, or P0246 is not set.
3. Verify the scan tool BARO Sensor parameter is within the range specified in the Altitude Versus
Barometric Pressure table for the current testing altitude.
If the parameter is not within the range specified in the table.
Refer to DTC P2227-P2230 .

If the parameter is within the range specified in the table.

4. Verify the scan tool MAP Sensor and BARO Sensor parameters are within 3 kPa (0.4 psi).
If the parameters are not within 3 kPa (0.4 psi).
Refer to DTC P0106.

If the parameters are within 3 kPa (0.4 psi).
5. Verify the scan tool Boost Pressure Sensor and BARO Sensor parameters are within 3 kPa (0.4 psi).
If the parameters are not within 3 kPa (0.4 psi).
Refer to DTC P0236.

If the parameters are within 3 kPa (0.4 psi).
6. Verify a click is heard or felt from the Q40 turbocharger bypass valve solenoid when commanding the
Turbocharger Bypass Solenoid Valve between Active and Inactive with a scan tool.
If a click is not heard or felt

If a click is heard or felt
7. Verify a series of clicks, which increase in frequency, are heard or felt from the Q42 turbocharger
wastegate solenoid valve when commanding the Turbocharger Wastegate Solenoid Valve between 15100 % with a scan tool.
If a series of clicks in increasing frequency are not heard or felt

If a series of clicks in increasing frequency is heard or felt
If the parameters are not within 20 kPa (2.9 psi)

If the parameter are within 20 kPa (2.9 psi)
If a DTC sets

11. All OK
1. Verify the conditions listed below do not exist:

Loose clamps, cracks or other damage in the air intake duct system
Collapsed or restricted intake duct system
Any air flow restriction
Any air leak between the turbocharger and the throttle body, including the charge air cooler
assembly
Splits, kinks or improper connections at the vacuum hoses
Any vacuum leak
Restricted, leaking or incorrect routing of hoses going to the components listed below:
Turbocharger wastegate solenoid valve
Turbocharger bypass solenoid valve
Intake manifold and turbocharger vacuum reservoir on the bottom of intake manifold
Turbocharger
Turbocharger wastegate actuator
Turbocharger bypass valve
Missing, restricted or leaking exhaust components. Refer to Restricted Exhaust
Exhaust leak between the turbocharger and the exhaust manifold
Restricted turbocharger oil supply line
Loose or incorrect installation of any components
Repair or replace the affected component as necessary.
NOTE:

The hose is located between the air cleaner outlet hose and the
turbocharger compressor.
2. Ignition OFF, disconnect the turbocharger wastegate solenoid valve hose at the turbocharger and apply 51
kPa (15 inches Hg) of vacuum to the hose with the GE 23738-A . Ignition ON.
3. Verify the pressure decreases to 0 kPa (0 inches Hg) when commanding the Turbocharger Wastegate
Solenoid Valve to 15 % with a scan tool.
If the pressure does not decrease to 0 kPa (0 inches Hg)
Replace the Q42 turbocharger wastegate solenoid valve

If the pressure decreases to 0 kPa (0 inches Hg)

Connect the turbocharger wastegate solenoid valve hose to the turbocharger.
Disconnect the wastegate solenoid valve hose from the turbocharger wastegate actuator and connect the
exhaust/pressure port of the GE 23738-A , or a suitable hand pressure pump, to the actuator.
Verify the wastegate actuator rod moves when applying pressure to the actuator.
If the actuator does not move
1. Disconnect the wastegate actuator arm from the wastegate.
2. Verify the wastegate actuator rod moves when applying pressure to the actuator.
If the actuator does not move, replace the turbocharger wastegate actuator
If the actuator moves, replace the turbocharger
If the actuator moves
Disconnect the Q40 Turbocharger Bypass Solenoid Valve vacuum supply hose at the intake manifold.
Connect the GE 23738-A to the manifold.
4.
5.
6.
7.
8.
NOTE:
Allow engine idle to stabilize before continuing.
9. Engine Idling, verify the vacuum gauge displays between 45-67 kPa (13-20 inches Hg) of vacuum.
Repair the vacuum source.
NOTE:
The vacuum reservoir (tank) is integral to intake manifold and is located at

the bottom of the manifold.
10. Ignition OFF, disconnect the vacuum hose at the turbocharger vacuum reservoir.
11. Connect the GE 23738-A to the vacuum reservoir and apply 34 kPa (10 inches Hg) of vacuum.
12. Verify the reservoir holds vacuum for at least 10 s.
If the vacuum is not held for at least 10 s
Replace the intake manifold
If the vacuum is held for at least 10 s
13. Connect the vacuum hose to the reservoir.
NOTE:
Disconnect the Q40 Turbocharger Bypass Solenoid Valve vacuum supply

hose at the intake manifold if not still disconnected from step 7.
14. Disconnect the vacuum hose at the turbocharger bypass valve and connect the GE 23738-A to the hose.
15. Engine idling, command the Turbocharger Bypass Solenoid Valve ON and OFF with a scan tool.

16. Verify the vacuum toggles between 0 kPa (0 inches Hg) to greater than 45 kPa (13 inches Hg).
Replace the Q40 turbocharger bypass solenoid valve
17. Connect any hoses that were disconnected during previous steps.
18. Verify the conditions listed below do not exist with the turbocharger assembly. Refer to Turbocharger
Cleaning and Inspection
Worn or damaged wastegate pivot pin
Cracked, damaged or worn turbine blades
Restricted wastegate, turbine, ports or passages
Foreign material
Damaged or restricted bypass valve assembly.
Repair or replace the turbocharger as necessary

19. Replace the turbocharger.
Repair Instructions
Charge Air Bypass Regulator Solenoid Valve Replacement

Intake Manifold Replacement
Turbocharger Replacement
Turbocharger Wastegate Regulator Solenoid Valve Replacement
DTC P0236
DTC Descriptor
DTC P0236

Turbocharger Boost Sensor Performance

Circuit Description
engine speed, throttle opening, turbocharger boost pressure, Intake air temperature (IAT), barometric pressure
DTC P0096, P0097, P0098, P0102, P0103, P0107, P0108, P0111, P0112, P0113, P0116, P0117, P0118,
P0119, P0128, P0237, P0238, P0335, P0336, P2227, P2228, P2229, or P2230 is not active.
Engine speed is between 400-7, 000 RPM.
Engine Coolant Temperature (ECT) is between -7 to +125C (19.4-257F).
Intake Air Temperature (IAT) is between -20 to +125C (-4 to +257F).
The DTC runs continuously when the above conditions have been met.
OR
DTC P0106, P0107, P0108, P0237, P0238, P2227, P2228, P2229, P2230, or P2610 s not active.
DTC P0107, P0108, P0237, P0238, P2228, or P2229 is not pending.
Ignition is ON.
Engine is OFF
The time between current ignition cycle and the last time the engine was running is greater than 6 s.
The DTC runs continuously when the above conditions have been met.
The ECM detects that various combinations of Turbocharger Intake Flow Rationality Diagnostic Failure
models, derived from engine speed, the BARO sensor, the MAF sensor, the MAP sensor, the throttle
position sensor and the turbocharger boost pressure sensor have failed when the engine is running.
OR
The ECM detects that the boost pressure sensor signal is less than 50 kPa (7.3 psi) or greater than 115 kPa
(16.7 psi) when the ignition is ON and the engine is NOT rotating.


The ECM will disable boost control and limit the system to mechanical boost only, resulting in a
substantial decrease in engine power.

Diagnostic Aids
The charge air cooler is connected to the turbocharger and to the throttle body by flexible duct work that
requires the use of special high torque fastening clamps. These clamps cannot be substituted. In order to
prevent any type of air leak when servicing the duct work, the tightening specifications and proper
positioning of the clamps is critical, and must be strictly adhered to.
Use a smoke generating device or a solution of dish soap and water in a spray bottle to pinpoint any
suspected air leaks in the induction system and in the charge air cooler assembly.
Schematic Reference
Circuit Testing
Connector Repairs
Wiring Repairs
DTC Type Reference

Scan Tool Reference

1. Verify that DTC P0641 is not set.

If the DTC is set
Refer to DTC P0641, P0651, P0697, or P06A3 (ECM) .
2. If you were sent here from DTC P0068, P0101, P0106, P0121, or P1101, refer to Circuit/System Testing
below.
3. Ignition ON.
4. Verify the scan tool Throttle Body Idle Airflow Compensation parameter is less than 90%.
90% or greater

If less than 90%
If Disagree
Refer to DTC P0121-P0123, P0222, P0223, or P2135 (LUV).

If Agree
6. Verify the scan tool BARO parameter is within the range specified in the Altitude Versus Barometric
Pressure table, for the current vehicle testing altitude.
BARO is not in range

BARO is within range
7. Verify the scan tool MAP Sensor pressure and BARO parameters are within 3 kPa (0.4 psi).
The parameters are not within 3 kPa (0.4 psi).
Refer to DTC P0106.

The parameters are within 3 kPa (0.4 psi).
8. Engine idling.
9. Verify the scan tool MAP Sensor pressure parameter is between 26-52 kPa (3.8-7.5 psi) and changes with
Refer to DTC P0106.


1. Engine idling
The MAF Sensor parameter does not change smoothly and gradually
Refer to DTC P0101.

The MAF Sensor parameter changes smoothly and gradually


If a DTC sets

15. All OK.
1. Verify that DTC P0237 or P0238 is not set.

If a DTC is set
Refer to DTC P0237 or P0238.


2. Verify the conditions listed below do not exist:
Loose clamps, cracks, or other damage in the air intake duct system
Collapsed or restricted air intake duct system
Splits, kinks or improper connections at the vacuum hoses
Missing, restricted or leaking exhaust components - Refer to Symptoms - Engine Exhaust .
Vacuum leaks at the intake manifold and throttle body
3. Replace the B111B turbocharger boost/intake air temperature sensor.
Repair Instructions
temperature sensor replacement.
DTC P0237 OR P0238

DTC Descriptors
DTC P0237
Turbocharger Boost Sensor Circuit Low Voltage
DTC P0238
Turbocharger Boost Sensor Circuit High Voltage
Short to
Open/High
Short to

Circuit
Ground
P0236, P0237,
P0340, P0365,
5 V Reference
P0452, P0532,
P0641, P2227
P0236, P0237,
Intake Air Pressure Signal
P2227
Low Reference
Resistance
Voltage
Signal Performance
P0236, P0237,
P2227
P0236, P0238,
P0453, P0641,
P2227
P0236
P0236, P0238,
P2227
P0236
P0236, P0237,
P2227
P0098, P0236,
P0238, P2227
Boost Pressure Sensor

Circuit
Short to Ground
Parameter Normal Range: BARO to 240 kPa (34.8 psi)
Operating Conditions: Engine running
5 V Reference
0 kPa (0 psi)
Boost Pressure Signal
0 kPa (0 psi)
Low Reference
-
Open
Short to Voltage
0 kPa (0 psi)
0 kPa (0 psi)
267 kPa (38.7 psi)
269 kPa (39 psi)

269 kPa (39 psi)
-
Circuit Description
engine speed, throttle opening, turbocharger boost pressure, intake air temperature (IAT), barometric pressure
Ignition is ON or the engine is running.

The DTCs run continuously when the above conditions have been met.
P0237
The ECM detects that the boost pressure sensor voltage is less than 1.0 V for greater than 5 s.
P0238

The ECM detects that the boost pressure sensor voltage is greater than 4.7 V for greater than 5 s.

The ECM will disable boost control and limit the system to mechanical boost only, resulting in a
substantial decrease in engine power.

Schematic Reference
Circuit Testing
Connector Repairs
Wiring Repairs
DTC Type Reference

Scan Tool Reference
1. Verify that DTC P0641 is not set.

If the DTC is set

Refer to DTC P0641, P0651, P0697, or P06A3 (ECM) .

2. Verify the scan tool BARO parameter is within the range specified in the Altitude Versus Barometric
Pressure table, for the current vehicle testing altitude.
BARO is not in range.

BARO is within range.


If the DTC sets

7. All OK.
1. Ignition OFF, and all vehicle systems OFF, disconnect the harness connector at the B111B turbocharger
boost/intake air temperature sensor. It may take up to 2 minutes for all vehicle systems to power down.
1. Ignition OFF, disconnect the X1 harness connector at the K20 engine control module.

If less than 5 ohms

3. Ignition ON.
If less than 4.8 V
1. Ignition OFF, disconnect the X1 harness connector at the K20 engine control module.
NOTE:


1. Ignition OFF, disconnect the X1 harness connector at the K20 engine control module, ignition ON.
If less than 1 V, replace the K20 engine control module.
5. Verify the scan tool Boost Pressure Sensor voltage parameter is less than 0.2 V.
If 0.2 V or greater
1. Ignition OFF, disconnect the X1 harness connector at the K20 engine control module, ignition ON.
If less than 0.2 V
6. Install a 3 A fused jumper wire between the signal circuit terminal 4 and the 5 V reference circuit terminal
3.
7. Verify the scan tool Boost Pressure Sensor voltage parameter is greater than 4.5 V.
If 4.5 V or less
1. Ignition OFF, remove the jumper wire, disconnect the X1 harness connector at the K20 engine
control module.


8. Test or replace the B111B turbocharger boost/intake air temperature sensor.
Repair Instructions
Control Module References for ECM replacement, programming, and setup
DTC P0243, P0245, OR P0246

DTC Descriptors
DTC P0243
Turbocharger Wastegate Solenoid Valve Control Circuit
DTC P0245
Turbocharger Wastegate Solenoid Valve Control Circuit Low Voltage
DTC P0246
Turbocharger Wastegate Solenoid Valve Control Circuit High Voltage
Circuit
Ignition Voltage Circuit
Short to
Ground
P0030, P0034,
P0036, P0134,
P0135, P0245,
P0443, P0598*
Open/High
Resistance
P0030, P0033,
P0034, P0036,
P0134, P0135,
P0140, P0141,
P0243, P0245,
P0443, P0597
Short to
Voltage
Signal Performance

Control Circuit
P0245
P0243
P0010, P0013,
P0246, P0443,
P0690
P0243
* Ignition fuse opens.

The BorgWarner dual scroll turbocharger incorporates a wastegate that is controlled by a pressure
differential, that is determined by the engine control module (ECM) by means of a pulse width modulation
(PWM) solenoid, in order to regulate the pressure ratio of the compressor. A charge air bypass valve also
controlled by the ECM by utilizing a remotely mounted solenoid is integrated into the bypass valve to prevent
compressor surging and damage from vibrations by opening during abrupt closed throttle conditions. When the
bypass valve is open during closed throttle deceleration conditions, the bypass valve allows the air to recirculate
in the turbocharger and maintain compressor speed. Within a calibrated range during the closed throttle event,
or upon a wide open throttle command the bypass valve will then close to optimize turbo response. The
turbocharger wastegate actuator has the following circuits:
Ignition voltage
Turbocharger wastegate solenoid control
At idle the turbocharger wastegate solenoid parameter is commanded to 0% by the ECM. When the engine load
and RPM first increases under a wide open throttle, the turbocharger wastegate solenoid parameter should
briefly be commanded as great as 90-100%. When the proper level of boost pressure is attained, the ECM will
decrease the PWM of the solenoid to a range of 65-85%. As soon as the throttle closes the ECM will command
the turbocharger wastegate solenoid parameter back to 0%, in order to allow the turbocharger waste gate to
open from the air pressure ratio differential, there by reducing the speed of the turbine.
Ignition ON or engine running.

The battery voltage is between 11-32 V.
The ECM detects an open, a short to ground, or a short to voltage on the turbocharger wastegate solenoid
control circuit for greater than 0.5 s.
DTCs P0243, P0245 and P0246 are Type B DTCs.

DTCs P0243, P0245 and P0246 are Type B DTCs.


Schematic Reference
Circuit Testing
Connector Repairs
Wiring Repairs
DTC Type Reference

Scan Tool Reference
1. Ignition ON
2. Verify a series of clicks, which increase in frequency, are heard or felt from the Q42 Turbocharger
Wastegate Solenoid Valve when commanding the Turbocharger Wastegate Solenoid Valve between 15100 % with a scan tool.
If a series of clicks in increasing frequency are not heard or felt
If a series of clicks in increasing frequency is heard or felt
3. Verify the parameters listed below do not display Malfunction when commanding the Turbocharger
Wastegate Solenoid Valve between 15-100 % with a scan tool.
Turbocharger Wastegate Solenoid Valve Control Circuit High Voltage Test Status
Turbocharger Wastegate Solenoid Valve Control Circuit Open Test Status
Turbocharger Wastegate Solenoid Valve Control Circuit Low Voltage Test Status


If a DTC sets

6. All OK
1. Ignition OFF, disconnect the harness connector at the Q42 Turbocharger Wastegate Solenoid Valve.
Ignition ON.
NOTE:
An internal short in any component supplied by the fuse may cause

the fuse to open and set a DTC when the component is activated.
If infinite resistance, test all components connected to the ignition voltage circuit for a short
and replace as necessary.
4. Verify the scan tool Turbocharger Wastegate Solenoid Valve Control Circuit Low Voltage Test Status
parameter is OK.


If OK is displayed
Verify the scan tool Turbocharger Wastegate Solenoid Valve Control Circuit High Voltage Test Status
parameter is OK.
If OK is displayed
Install a 3 A fused jumper wire between the control circuit terminal 1 and the ignition circuit terminal 2.
Verify the scan tool Turbocharger Wastegate Solenoid Valve Control Circuit High Voltage Test Status
parameter is Malfunction.
Module.
Test or replace the Q42 Turbocharger Wastegate Solenoid Valve.
5.
6.
7.
8.
Repair Instructions
Turbocharger Wastegate Regulator Solenoid Valve Replacement

DTC P025A
DTC Descriptor
DTC P025A
Fuel Pump Control Module Enable Circuit

Circuit
Control
Short to
Ground
P025A
Open/High
Resistance
P025A
Short to
Voltage
-
Signal
Performance
P025A
The engine control module (ECM) supplies voltage to the fuel pump control module when the ECM detects that
the ignition is on. The voltage from the ECM to the fuel pump control module remains active for 2 seconds,
unless the engine is in crank or run. While this voltage is being received, the fuel pump control module supplies
a varying voltage to the fuel tank pump module in order to maintain the desired fuel line pressure.
The ignition is ON.

The serial data message from the ECM to the fuel pump control module does not agree with the state of the
control enable voltage signal supplied from the ECM to the fuel pump control module for more than 2 seconds.
DTC P025A is a Type A DTC.

DTC P025A is a Type A DTC.

Schematic Reference
Circuit Testing

Connector Repairs
Wiring Repairs
DTC Type Reference

Scan Tool Reference
NOTE:
Verify that the fuel tank is not empty. Only perform this diagnostic if there is at
least 2 gallons of fuel in the fuel tank. Clear the DTC, and start and run the
engine. Verify that the DTC resets before proceeding with the circuit system
testing. If the DTC does not reset, refer to diagnostic aids.
1. Ignition OFF and all vehicle systems OFF, disconnect the harness connector at the K27 fuel pump control
module, ignition ON.
3. Verify the test lamp turns ON and OFF when commanding the fuel pump ON and OFF using the scan
tool ECM fuel pump enable control function.
1. Ignition OFF, disconnect the harness connector at the K20 engine control module, ignition ON.
4. Test or replace the K27 fuel pump control module.
Repair Instructions


Control Module References for ECM or fuel pump control module replacement, programming and setup
DTC P0300-P0304
DTC Descriptors
DTC P0300
Engine Misfire Detected
DTC P0301
Cylinder 1 Misfire Detected
DTC P0302
DTC P0303
DTC P0304
The engine control module (ECM) uses information from the crankshaft position sensor and the camshaft
position sensors in order to determine when an engine misfire is occurring. By monitoring variations in the
crankshaft rotation speed for each cylinder, the ECM is able to detect individual misfire events. A misfire rate
that is high enough can cause 3-way catalytic converter damage. The malfunction indicator lamp (MIL) will
flash ON and OFF when the conditions for catalytic converter damage are present. DTCs P0301 through P0304
correspond to cylinders 1 through 4. If the ECM is able to determine that a specific cylinder is misfiring, the
DTC for that cylinder will set, and the corresponding fuel injector is disabled and/or add fuel. The ECM will reenable the fuel injector after 3 crankshaft revolutions (6 for manual transmission vehicles) to determine if a
misfire is still present and either disable for 3 crankshaft revolutions (6 for manual transmission vehicles) again
or stay enabled, depending on whether the misfire is still present.

DTC 0010, P0011, P0013, P0014, P0016, P0017, P0018, P0019, P0020, P0021, P0023, P0024, P0068,
P00C8, P00C9, P0101, P0102, P0103, P0106, P0107, P0108, P0111, P0112, P0113, P0114, P0117,
P0118, P0119, P0122, P0123, P0191, P0192, P0193, P0222, P0223, P0335, P0336, P0340, P0341,
P0345, P0346, P0365, P0366, P0390, P0391, P0601, P0604, P0606, P0651, P16A0, P16A1, P16A2,
P16F3, P2101, P2135, P2227, P2228, P2229, or P2230 is not set.
The engine coolant temperature (ECT) sensor is between -7 to +125C (+19 to +257F).
The A/C compressor clutch is not changing states.
The fuel tank level is greater than 15%.
The ECM is not in fuel cut-off or deceleration fuel cut-off mode.
The ECM is not receiving a rough road signal.
The throttle angle is steady within 5%.
The throttle angle is greater than 3% when the vehicle speed is greater than 5 km/h (3 MPH).
The transmission is not changing gears.
The antilock brake system (ABS) and the traction control system, if equipped, is not active.
DTCs P0300, P0301, P0302, P0303, and P0304 run continuously when the above conditions are met.
The ECM is detecting a crankshaft rotation speed variation indicating a misfire sufficient to cause emission or
catalyst damaging levels to exceed mandated standards.
DTCs P0300-P0304 are Type B DTCs.

The ECM may disable up to two fuel injector's of the misfiring cylinder's when a catalyst damaging level
of misfire is present. And will flash the malfunction indicator lamp (MIL).
DTCs P0300-P0304 are Type B DTCs.

Diagnostic Aids
A misfire may only occur when the engine is under a load or when the engine is cold.
A misfire DTC may be caused by an excessive vibration from sources other than the engine. Inspect for
the following possible sources:
A tire or wheel that is out of round or out of balance
Variable thickness brake rotors
Certain rough road conditions

A damaged accessory drive component or belt

A damaged reluctor wheel
High resistance in the circuits of the injectors may set a misfire DTC without setting an injector DTC.
Test the injector circuits of the affected cylinder(s) for a high resistance if you suspect a condition.
The MIL indicator flashes when there is an engine misfire.
Schematic Reference
Circuit Testing
Connector Repairs
Wiring Repairs
DTC Type Reference

Scan Tool Reference
Special Tools
EL 26792 HEI Spark Tester

EN 36012-A Ignition System Diagnostic Harness

NOTE:
Before starting vehicle, review freeze frame data to determine if misfire sets
during cold start or warmed up operation. If the vehicle has a cold start problem
and the vehicle is started, the vehicle will require to be not started for many
hours before next attempt to operate the vehicle within the fail conditions.

1. Engine idling at the normal operating temperature, verify there is no abnormal engine noise.
2. Verify there is no abnormal engine noise.
If abnormal engine noises are present
Refer to Symptoms - Engine Mechanical .
If there are no abnormal engine noises
3. Verify no DTCs other than P0300-P0304 are set.
If any DTCs other than P0300-P0304 are set
If only DTCs P0300-P0304 are set

If no DTCs are set

4. Verify the scan tool Cylinder 1-4 Current Misfire Counter Misfire parameters do not increment.
If Misfire Current Counters are incrementing

If Misfire Current Counters are not incrementing
5. Engine idling.
6. Verify the engine speed changes when performing the Cylinder Power Balance Test with a scan tool.
If engine speed does not change

If engine speed does change
8. Verify the DTCs are not set.
If any of the DTCs set

9. All OK.
1. Perform the Crankshaft Position System Variation Learn procedure. Verify the scan tool displays
Learned Successful.

If the scan tool did not display Learned Successful

Inspect for the following conditions and repair as necessary:
Worn crankshaft main bearings

A damaged or misaligned reluctor wheel
Excessive crankshaft runout
Interference in the signal circuit of the crankshaft position sensor
The ignition switch is in the ON position until there is insufficient system voltage.
An ECM power disconnect with the ignition ON that may have erased the crankshaft position
system variation values and set DTC P0315
Debris between the crankshaft position sensor and the reluctor wheel
If the engine control module is still unable to complete the learn procedure, replace the K20 Engine
Control Module..
If the scan tool displays Learned Successful
2. Verify that the following conditions do not exist:
Vacuum hose splits, kinks, and incorrect connections
Engine vacuum leaks
Crankcase ventilation system for vacuum leaks
Fuel pressure that is too low or too high-Refer to Fuel System Diagnosis .
Contaminated fuel-Refer to Alcohol/Contaminants-in-Fuel Diagnosis .
Exhaust system restrictions
If a condition exist
Repair or replace as necessary.

If no conditions exist
3. Ignition OFF, remove the K35 Ignition Coil Module and connect the (EL 26792) HEI Spark Tester to the
coil of the misfiring cylinder.
4. Verify none of the conditions listed below exist with the boot of the K35 Ignition Coil Module:
Holes
Tears
Carbon tracking
Oil contamination
Water intrusion
If a condition exist
Repair or replace as necessary.
If no conditions exist

NOTE:
An erratic or weak spark is considered a no spark condition.
5. Verify the (EL 26792) HEI Spark Tester sparks while cranking or starting the engine.
If there is no spark
Refer to Electronic Ignition System Diagnosis for diagnosis of the ignition coil.
If there is spark
Ignition OFF, remove the spark plug from the misfiring cylinder.
Exchange the suspected spark plug with another cylinder that is operating correctly.
Engine idling.
Verify the scan tool Cylinder 1-4 Current Misfire Counter parameter does not increment on the spark plug
coil it was removed from.
If the misfire does follow the spark plug exchange
6.
7.
8.
9.
Replace the spark plug.

If the misfire does not follow the spark plug exchange
10. Test or inspect for the following:
A lean or rich Q17 Fuel Injector-Refer to Fuel System Diagnosis .
An engine mechanical condition-Refer to Symptoms - Engine Mechanical .
Repair Instructions
Ignition Coil Replacement

Spark Plug Replacement
Repair Verification
1. If the customer concern was a flashing MIL, operate the vehicle within the conditions for running DTC
P0420. Refer to DTC P0420 .
2. Clear the DTCs with a scan tool.
3. Turn OFF the ignition for 60 s.
the conditions that you observed from the freeze frame/failure records.
6. If the DTC fails this ignition, a misfire still exists.
DTC P0315


DTC Descriptor
DTC P0315
Crankshaft Position System Variation Not Learned
The crankshaft position sensor system variation learn feature is used to calculate reference period errors caused
by slight tolerance variations in the crankshaft, and the crankshaft position sensor. The calculated error allows
the engine control module (ECM) to accurately compensate for reference period variations. This enhances the
ability of the ECM to detect misfire events over a wider range of engine speed and load.
The crankshaft position sensor system variation compensating values are stored in ECM memory after a learn
procedure has been performed. If the actual crankshaft position sensor variation is not within the crankshaft
position sensor system variation compensating values stored in the ECM, DTC P0300 may set.
If the crankshaft position sensor system variation values are not stored in the ECM memory, DTC P0315 sets.

The DTC runs continuously.
The crankshaft position sensor system variation values are not stored in the ECM memory.
DTC P0315 is a Type A code.

DTC P0315 is a Type A code.

Diagnostic Aids
This test procedure requires that the vehicle battery has passed a load test and is completely charged. Refer to
Battery Inspection/Test .
Schematic Reference


Circuit Testing
Connector Repairs
Wiring Repairs
DTC Type Reference

Scan Tool Reference
NOTE:
The crankshaft position sensor system variation learn procedure may have to
be repeated up to 5 times before the procedure is learned.
1. Perform the crankshaft position variation learn procedure. Refer to Crankshaft Position System
Variation Learn .
2. If the crankshaft position variation learn procedure cannot be performed successfully, inspect for the
Any worn crankshaft main bearings
A damaged or misaligned reluctor wheel
Excessive crankshaft runout
Interference in the signal circuit of the B26 Crankshaft Position Sensor
The ignition switch is left in the ON position, until the battery is discharged
An ECM power disconnect, with the ignition ON, that may have erased the crankshaft position
sensor system variation values and set DTC P0315.
Any debris between the crankshaft position sensor and the reluctor wheel
If the ECM is still unable to complete the learn procedure, replace the K20 Engine Control Module.
Repair Instructions
Perform the Diagnostic Rep

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2013 Chevrolet Cruze

2013 GENERAL INFORMATION Dangers, Warnings, and Cautions - Cruze

2013 GENERAL INFORMATION

Serious bodily injury or death to the technician

Serious bodily injury or death to the technician

Serious bodily injury to the technician

2013 Chevrolet Cruze

the following consequences may occur:

Damage to the vehicle

NOTE or IMPORTANT Defined

ABS COMPONENT HANDLING WARNING

2013 Chevrolet Cruze

Avoid sparks and any source of ignition.

APPROVED EQUIPMENT FOR COLLISION REPAIR WARNING

2013 Chevrolet Cruze

Do not grind brake linings.

Some models or aftermarket brake parts may contain asbestos fibers

Eye contact-rinse thoroughly with water.

BRAKE FLUID WARNING

2013 Chevrolet Cruze

CLUTCH ACTUATOR CYLINDER WARNING

2013 Chevrolet Cruze

FUEL GAUGE LEAK WARNING

2013 Chevrolet Cruze

HOOD HOLD-OPEN DEVICE WARNING

2013 Chevrolet Cruze

SAFETY GOGGLES AND FUEL WARNING

2013 Chevrolet Cruze

SIR INFLATABLE MODULE DEPLOYMENT OUTSIDE VEHICLE WARNING

Do not carry the inflator module by the wires or connector.

2013 Chevrolet Cruze

Failure to observe these guidelines may result in personal injury.

Air bag deployment

In order to avoid the above conditions, observe the following guidelines:

Refer to SIR Component Views in order to determine if you are

STEERING ANGLE SENSOR INITIALIZATION WARNING

2013 Chevrolet Cruze

2013 Chevrolet Cruze

AIR IN THE POWER STEERING SYSTEM CAUTION

2013 Chevrolet Cruze

2013 Chevrolet Cruze

2013 Chevrolet Cruze

The fuel pipe connections

HEATED OXYGEN AND OXYGEN SENSOR CAUTION

Do not apply contact cleaner or other materials to the sensor or

2013 Chevrolet Cruze

Seals Terminal Repair Kit. Under no circumstances should repairs be

A code clear with a scan tool, regardless of whether or not a DTC is

2013 Chevrolet Cruze

STEERING COLUMN IN LOCK POSITION CAUTION

The steering column

After disconnecting these components, do not rotate the steering wheel or

The steering column

After disconnecting these components, do not rotate the steering wheel or

2013 Chevrolet Cruze

2013 Chevrolet Cruze

2013 Chevrolet Cruze

2013 GENERAL INFORMATION

2013 Chevrolet Cruze

Fig. 1: Identifying Different Service Operations Symbols

2013 Chevrolet Cruze

Antilock Braking System

2013 Chevrolet Cruze

Accelerator Pedal Position