Table of Contents

Volume 1 Driver Information and Entertainment. . .. . . . 8-1

0-1
Preface ..........................................
Dangers, Warnings, and Cautions ............. 0-3
General Information........................... 1-1
General Information ............................ 1-3
Air/Wind Noise ................................ 1—33
Maintenance and Lubrication ................ 1-35
Squeaks and Rattles ......................... 1-37
Vibration Diagnosis and Correction .......... 1—38
Waterleaks .................................... 1-92
Body Hardware and Trim ...................... 2—1
Exterior Trim ................................... 2—3
Floor Coverings and Headlinings ............ 2-18
Instrument Panel and Console Trim .......... 2-29
Interior Trim and Paneling .................... 2-63
Body Repair .................................... 3-1
Bolted Exterior Body Panels and Closures . . 3-3 ..
Bumpers and Fascias ........................ 3-50
Collision Repair ............................... 3-68
Frame and Underbody ...................... 3-143
Paint and Coatings .......................... 3-159
Plastic Panel Information and Repair. . .. . .. 3-162
Body Systems .................................. 4-1
Fixed and Moveable Windows ................. 4—5
Horns ......................................... 4—71
Lighting ....................................... 4-81
Mirrors ....................................... 4-221
Vehicle Access .............................. 4—237
Wipers and Washers ........................ 4-324
Brakes .......................................... 5-1
Antilock Brake System ......................... 5-5
Disc Brakes ................................... 5-54
Drum Brakes .................................. 5-87
Hydraulic Brakes ............................ 5-108
Park Brake .................................. 5-182
Diagnostic Overview ........................... 6-1
Programming and Setup ....................... 6-3
Vehicle Diagnostic Information ............... 6-15
Driveline/Axle .................................. 7-1
Wheel Drive Shafts ............................ 7-3
Cellular, Entertainment, and Navigation ....... 8-3_
Displays and Gauges ......................... 8-77
Secondary and Configurable Customer
Controls .................................... 8-110
INDEX ................................. |NDEX—1
Volume 2
Preface .................................... 0-1
Dangers, Warnings, and Cautions .......... 0—3
Engine .......................................... 9-1
Cruise Control ................................ 9-11
Engine Controls/Fuel - 1.4L (LUV) ........... 9-26
Engine Controls/Fuel - 1.8L (LUW, LWE). .. 9-312
Engine Cooling .............................. 9-597
Engine Electrical ............................ 9-682
Engine Exhaust ............................. 9-734
Engine Mechanical - 1.4L (LUV) ............ 9-755
Engine Mechanical-1.8L(LUW,LWE).... . 9-932
HVAC .......................................... 10-1
Heating, Ventilation, and Air Conditioning . .. 10-3
HVAC —Manual .............................. 10—63
INDEX ................................. |NDEX-1
Volume 3
Preface .................................... 0-1
Dangers, Warnings, and Cautions .......... 0—3
Power and Signal Distribution ............... 11—1
Data Communications ........................ 11-3
Power Outlets ............................... 11—72
Wiring Systems and Power
Management ............................... 11-79
Roof ............................................ 12-1
Sunroof ....................................... 12-3
Safety and Security ........................... 13-1
Immobilizer .................................... 13—3
Remote Functions ........................... 13-33
Seat Belts ................................... 13—47
Supplemental Inflatable Restraints . . .. . . . .. 13-68
Theft Deterrent ............................. 13-148

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Seats ........................................... 14-1 Transmission ................................. 17—1
Seat Hardware, Trim, and Upholstery ........ 14-3 Automatic Transmission - 6T30/6T40/6T45/
Seat Heating and Cooling ................... 14-34 6T50 (MH8, MH9) ........................... 17—7
Clutch ...................................... 17—400
Steering ....................................... 15-1
15-3 Manual Transmission - F13-5/F15-5/
Power Steering ............................... 17—426
15-25 F17—5(M26) ...............................
Steering Wheel and Column ................
Manual Transmission - M20/M32
Suspension ................................... 16-1 (MR5, M24) ............................... 17-539
Front Suspension ............................. 16-3 Shift Lock Control .......................... 17-594
Rear Suspension ............................ 16-24 INDEX-1
INDEX .................................
Suspension General Diagnosis ............. 16-35
Tire Pressure Monitoring .................... 16—45
Tires and Wheels ............................ 16—55
Wheel Alignment ............................ 16-69

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 Table of Contents 021

Section 0

Dangers, Warnings, and Cautions

Dangers, Warnings, and Cautions ............ 0-3
Definition of Danger, Warning, Caution,
and Note ........................................ 0—3
Approved Equipment for Collision Repair
Warning ......................................... 0-3
Batteries Produce Explosive Gases Warning 0-3
Battery Disconnect Warning ..................... 0-4
Brake Dust Warning .............................. 0-4
Brake Fluid IrritantWarning ...................... 0—4
Brake Fluid Warning ............................. 0—4
Checking Hot Transmission Fluid through Drain
Plug Hole Warning .............................. 0-4
Collision Sectioning Warning ..................... 0-4
Cracked Window Warning ....................... 0-4
Defroster Outlet Warning ......................... 0-4
Electric Coolant Fan Warning .................... 0-4
Exhaust Service Warning ........................ 0-4
Eye Protection Warning .......................... 0-4
Fuel and Evaporative Emission Pipe Warning 0-4
Fuel Vapors in Evaporative Emission
Components Warning ........................... 0-5
Gasoline/Gasoline Vapors Warning .............. 0—5
Glass and Sheet Metal Handling Warning . . . 0—5
Halogen Bulb Warning ........................... 0-5
Hood Hold—OpenDevice Warning ................ 0-5
Parking Brake and Drive Wheels Warning ... . . . 0—5
Protective Gogglesand Glove Warning .......... 0-5
Radiator Cap Removal Warning ................. 0—5
Relieving Fuel Pressure Warning ................ 0—5
Repair Material Curing Warning .................. 0-5
Safety Glasses and CompressedAir Warning ... 0-5
Safety Glasses Warning ......................... 0-5
Safety Goggles and Fuel Warning ............... 0-6
Sensing and DiagnosticModule Handling
Warning ......................................... 0-6
Sensing and Diagnostic Module Voltage after
Ignition is Turned Off Warning .................. 0—6
Servicing the SIR System Warning ............... 0—6
SIR Deployed Inflator Modules Are Hot
Warning ......................................... 0-6
SIR Inflatable Module Deployment Outside
Vehicle Warning ................................ 0—6
SIR InflatorModule Disposal Warning ........... 0—6
SIR InflatorModule Handling and Storage
Warning ......................................... 0-6
SIR Seatbelt Pretensioner Handling Warning .... 0-6
SIR Warning ..................................... 0-7
Torque-to-Yield Fastener Warning ............... 0—7
Work Stall Test Warning .......................... 0—7
Air in the Power Steering System Caution . . . 0—7
Avoid Damage to GridLines Caution ............ 0-7
Belt Dressing Caution ............................ 0-7
Brake Caliper Caution ............................ 0-7
Brake Fluid Damage to Electrical Connections
Caution ......................................... 0—7
Brake Fluid Effects on Paint and Electrical
Components Caution ........................... 0—7
Catalytic Converter Movement Caution .......... 0-7
Clean, Dry, Low Pressure Gas Source
Caution ......................................... 0-8
Clearcoat/Ultraviolet Screeners Caution ......... 0-8
Clutch Hydraulic System Lubricant Caution ...... 0-8
Component Fastener Tightening Caution ........ 0-8
Compressed Air Should Not Exceed 98 kPa (14
psi) Caution ..................................... 0—8
Drive Axle Caution ............................... 0-8
Engine Coolant Thermostat Housing Caution 0-8
Engine Lifting Caution ............................ 0—8
Engine Mounting Caution ........................ 0—8
Exterior Trim Emblem Removal Caution . . . . . 0-8
Fastener Caution................................. 0-8
Filling the Master Cylinder Caution ............... 0-8
Flex Decoupler Caution .......................... 0-8
Fuel and Evaporative Emission Hose/Pipe
Connection Cleaning Caution ................... 0-8
Fuel Pressure Caution ........................... 0-9
Fuel Tank Strap Fastener Caution ............... 0-9
Heated Oxygen and Oxygen Sensor Caution 0-9
Heated Oxygen Sensor Resistance Learn Reset
Caution ......................................... 0-9
Ignition OFF When Disconnecting Battery
Caution ......................................... 0—9
Installing Hoses without Twists or Bends
Caution ......................................... 0—9
Liftgate AssistRod Caution ...................... 0—9
Oxygen Sensor Caution .......................... 0-9

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022 Table of Contents
Power Steering Hose Disconnected Caution .... 0—9 Tape Corners of Panel Caution ................. 0—10
Steering Column in Look Position Caution .... . . . 0—9 Test Probe Caution ............................. 0-10
Steering Wheel in the Full Turn Position Torque-to—YieldFastener Caution ............... 0—10
Caution ........................................ 0-10 Using Proper Power Steering Fluid Caution .... 0-10
Steering Wheel Straight and Column Locked Vehicle Lifting and Jacking Caution ............. 0—10
Caution ........................................ 0-10 Windshield Installation Caution ................. 0-10

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Dangers, Warnings, and Cautions
Definition of Danger, Warning,
Caution, and Note
The diagnosis and repair procedures in a GM Service
Manual contain both general and specific Dangers,
Warnings, Cautions, Notes or lmportants. GM is
dedicated to the presentation of service informationthat
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 Importantsare 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
- Improperrepair 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. Ifa 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. Ifa 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. lfa CAUTION is not heeded,
the following consequences may occur:
~ Damage to the vehicle
- Unnecessary vehicle repairs
. Unnecessary component replacement
~ Improperoperation or performance of the system
or component under repair
\‘
A
M
‘Mfi.
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2013 (US/Canada)
Sonic (5377994)
Manual
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Dangers, Warning and Cautions O=3
- Damage to any systems or components which are
dependent upon the proper operation of the
system or component under repair
- Improperoperation 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 informationfor 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
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.
Batteries Produoe Explosive Gases
Warning
Warning: Batteries produce explosive gases.
Batteries contain corrosive acid. Batteries supply
levels of electrical current high enough to cause
burns. Therefore, in order to reduce the risk of
personal injury while working near a battery,
observe the following guidelines:
- Always shield your eyes.
- Avoid leaning over the battery whenever
possible.
- Do not expose the battery to open flames or
sparks.
- Do not allow battery acid to contact the eyes or
the skin.
— Flush any contacted areas with water
immediately and thoroughly.
— Get medical help.
0:4 Dangers, Warnings, and Cautions

Battery Disconnect Warning not use fluid from an open container that may be
contamina ted with water. Improper or contaminated
Warning: Unless directed otherwise, the ignition fluid could result in damage to components, or loss
and start switch must be in the OFF or LOCK of braking, with possible injury.
position, and all electrical loads must be OFF
before servicing any electrical component.
Checking Hot Transmission Fluid
Disconnect the negative battery cable to prevent an
electrical spark should a tool or equipment come in through Drain Plug Hole Warning
contact with an exposed electrical terminal. Failure
Warning: The engine must be running when the
to follow these precautions may result in personal
transmission fluid fill plug is removed, or excessive
injury and/or damage to the vehicle or its
fluid loss will occur. Transmission fluid may be hot.
components.
Since the actual fluid level is unknown, stand clear
For Vehicles equipped with OnStar® (UE1) with when removing the fill plug. Have a container ready
Back Up Battery: to capture any lost fluid. Do not turn the engine off
with the fill plug removed, as you can be injured by
The Back Up Battery is a redundant power supply hot transmission fluid being expelled out of the oil
to allow limited OnSta functionality in the event of fill opening.
a main vehicle battery power disruption to the VCIM
(OnStar®moduIe). Do not disconnect the main Collision Sectioning Warning
vehicle battery or remove the OnSta fuse with the
ignition key in any position other than OFF. Warning: Sectioning should be performed only in
Retained accessory power (RAP) should be allowed the recommended areas. Failure to do so may
to time out or be disabled (simply opening the compromise the structural integrity of the vehicle
driver door should disable RA P) before and cause personal injury if the vehicle is in a
disconnecting power. Disconnecting power to the collision.
OnStar® module in any way while the ignition is On
or with RAP activated may cause activation of the Cracked Window Warning
OnStar® Back-Up Battery (BUB) system and will
discharge and permanently damage the back-up Warning: If a window is cracked but still intact,
battery. Once the Back-Up Battery is activated it will crisscross the window with masking tape in order
stay on until it has completely discharged. The BUB to reduce the risk of damage or personal injury.
is not rechargeable and once activated the BUB
must be replaced. Defroster Outlet Warning
Warning: If broken glass falls into the defroster
Brake Dust Warning outlets, it can be blown into the passenger
Warning: Avoid taking the following actions when compartment and cause personal injury.
you service wheel brake parts:
- Do not grind brake linings. Electric Coolant Fan Warning
~ Do not sand brake linings. Warning: An electric fan under the hood can start
- Do not clean wheel brake parts with a dry brush up even when the engine is not running and can
or with compressed air. injure you. Keep hands, clothing and tools away
from any underhood electric fan.
Some models or aftermarket brake parts may
contain asbestos fibers which can become airborne Service Warning
Exhaust
in dust. Breathing dust with asbestos fibers may
cause serious bodily harm. Use a water-dampened Warning: In order to avoid being burned, do not
cloth in order to remove any dust on brake parts. service the exhaust system while it is still hot.
Equipment is available commercially in order to Service the system when it is cool.
perform this washing function. These wet methods
prevent fibers from becoming airborne. Eye Protection Warning

Irritant Warning Warning: Approved safety glasses and gloves

Brake Fluid
should be worn when performing this procedure to
Warning: Brake fluid may irritate eyes and skin. In reduce the chance of personal injury.
case of contact, take the following actions:
0 Eye contact—rinse thoroughly with water. Fuel and Evaporative Emission Pipe
- Skin contact—wash with soap and water. Warning
- If ingested—consult a physician immediately. Warning: In order to reduce the risk of fire and
personal injury observe the following items:
Brake Fluid Warning
- Replace all nylon fuel pipes that are nicked,
Warning: Use only Delco Supreme 11, GM P/ scratched or damaged during installation, do
N 12377967 (Canadian P/N 992667), or equivalent not attempt to repair the sections of the nylon
DOT3 brake fluid from a clean, sealed container. Do fuel pipes

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 ,2-
Dangers, Warnings, and Cautions 0=o

- Do not hammer directly on the fuel harness Hood Hold-Open Device Warning
body clips when installing new fuel pipes. Warning: When a hood hold open device is being
Damage to the nylon pipes may result in a removed or installed, provide alternate support to
fuel leak. avoid the possibility of damage to the vehicle or
0 Always cover nylon vapor pipes with a wet personal injunl.
towel before using a torch near them. Also,
never expose the vehicle to temperatures Brake and Drive Wheels
higher than 115°C (239°F) for more than Parking
one hour, or more than 90°C (194°F) for any Warning
extended period.
Warning: Apply the parking brake and block the
- Apply a few drops of clean engine oil to the drive wheels before performing this procedure in
male pipe ends before connecting fuel pipe order to prevent bodily injury.
fittings. This will ensure proper reconnection
and prevent a possible fuel leak. (During and Glove
normal operation, the O-rings located in the Protective Goggles
female connector will swell and may prevent Warning
proper reconnection if not lubricated.)
Warning: Always wear protective goggles and
in Evaporative Emission gloves when removing exhaust parts as falling rust
Fuel Vapors and sharp edges from worn exhaust components
Components Warning could result in serious personal injury.
Warning: Do not breathe the air through the EVAP
component tubes or hoses. The fuel vapors inside Radiator Cap Removal Warning
the EVAP components may cause personal injury. Warning: To avoid being burned, do not remove the
radiator cap or surge tank cap while the engine is
GasolinelGasoline Vapors Warning hot. The cooling system will release scalding fluid
and steam under pressure if radiator cap or surge
Warning: Gasoline or gasoline vapors are highly
tank cap is removed while the engine and radiator
flammable. A fire could occur if an ignition source
are still hot.
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 Relieving Fuel Pressure Warning
extinguisher nearby. Warning: Remove the fuel tank cap and relieve the
fuel system pressure before servicing the fuel
Glass and Sheet Metal Handling system in order to reduce the risk of personal
Warning injury. After you relieve the fuel system pressure, a
small amount of fuel may be released when
Warning: When working with any type of glass or servicing the fuel lines, the fuel injection pump,
sheet metal with exposed or rough edges, wear or the connections. In order to reduce the risk of
approved safety glasses and gloves in order to personal injury, cover the fuel system components
reduce the chance of personal injury. with a shop towel before disconnection. This will
catch any fuel that may leak out. Place the towel in
Halogen Bulb Warning an'approved container when the disconnection is
complete. ‘
Warning: Halogen bulbs contain gas under
pressure. Handling a bulb improperly could cause it Material Curing Warning
Repair
to shatter into flying glass fragments. To help avoid
personal injury: Warning: At least 24 hours are required for
complete curing of repair material. The repair area
o Turn off the lamp switch and allow the bulb to should not be physically disturbed until after that
cool before changing the bulb.
time. Insufficient curing of urethane adhesive may
- Leave the lamp switch OFF until the bulb allow unrestrained occupants to be ejected from
change is complete. the vehicle resulting in personal injury.
- Always wear eye protection when changing a
halogen bulb. Safety Glasses and Compressed Air
- Handle the bulb only by its base. Avoid
touching the glass. Warning
- Keep dirt and moisture off the bulb. Warning: Wear safety glasses when using
compressed air in order to prevent eye injury.
- Properly dispose of the used bulb.
- Keep halogen bulbs out of the reach of Warning
children. Safety Glasses
Warning: Wear safety glasses in order to avoid eye
damage.

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0=6 Dangers, Warnings, and Cautions

Safety Goggles and Fuel Warning SIR Inflatable Module Deployment

Warning: Always wear safety goggles when Outside Vehicle Warning
working with fuel in order to protect the eyes from Warning: When you are deploying an inflator
fuel splash. module for disposal, perform the deployment
procedures in the order listed. Failure to follow the
Sensing and Diagnostic Module procedures in the order listed may result in
Handling Warning personal injury.

Warning: Be careful when you handle a sensing

and diagnostic module (SDM). Do not strike or jolt
the SDM. Before applying power to the SDM:
- Remove any dirt, grease, etc. from the
mounting surface
- Position the SDM horizontally on the mounting
surface
- Point the arrow on the SDM toward the front of
the vehicle
- Tighten all of the SDM fasteners and SDM
bracket fasteners to the specified torque value
Failure to follow the correct procedure could cause
air bag deployment, personal injury,
or unnecessary SIR system repairs.
Sensing and Diagnostic Module
Voltage after Ignition is Turned
Warning
Warning: The sensing and the diagnosis module
(SDM) can maintain sufficient voltage to deploy the
airbags and pretensioners for up to 1 minute after
the ignition has been turned OFF and the fuse has
been removed. If the airbags and pretensioners are
not disconnected, do not begin service until
one minute has been passed after disconnecting
power to the SDM. Failure to do so may cause
personal injury.
Servicing the SIR System Warning
Warning: When performing service on or around
the SIR components or the SIR wiring, follow the
procedures listed below in order to temporarily
disable the SIR system. Failure to follow the
procedures could result in the following:
- Air bag deployment
- Personal injury
0 Otherwise unneeded SIR system repairs
SIR Deployed lnflator Modules
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 lnflator 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 lnflator Module Handling and
Storage Warning
Off 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 infla tor module:
- Make sure the air bag opening points away
from the surface on which the inflator module
rests.
0 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
Are 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.
0 Make sure the opening, from which the seat
belt webbing extends, faces downward and the
seat belt webbing hangs freely.
/

2013
—Sonic
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m_FM
tA
 Dangers, Warnings, and Cautions 0A7

Failure to observe these guidelines may result in
personal injury.
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 Disabling the SIR System.
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.
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 112km/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
brea thing dangerous gases.
Air in the Power Steering System
Caufion
Caution: Ifthe 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 Damage to Grid Lines Caution
Caution: Ifyou use a razor blade or other sharp tool in
order to remove the adhesives or foreign objects from
the inside of the rear window, use the blade carefully.
Damage to the grid lines 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 Damage to Electrical
Connections Caution
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—sealand
wipe off brake fluid containers to prevent spills.
and
Fluid Effects on Paint
Brake
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. lf any brake fluid
comes in contact with painted surfaces, immediately
flush the area with water. Ifany brake fluid comes in
contact with electrical connections, wiring, or cables,
use a clean shop cloth to wipe away the fluid.
Catalytic Converter Movement
Caufion
Caution: To prevent internal damage to the flexible
coupling of the catalytic converter assembly, the
converter must be supported. The vertical movement at
the rear of the catalytic converter assembly must not
exceed 6 degrees up or down.

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Manual
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0n8 Dangers, Warnings, and Cautions

Dry, Low Pressure Gas Engine Lifting Caution

Clean,
Source Caution
Caution: Use the Evaporative Emission (EVAP)
System Tester (EEST) GE 41413—Ain order to provide
a clean, dry, low pressure nitrogen gas source. Do not
substitute any other pressurized source, gas or
othenlvise. Damage may result to the EVAP system,
test equipment or cause a safety risk.
Clearcoat/Ultraviolet Screeners
Cauflon
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 Hydraulic System Lubricant
Caufion
Caution: Do not use mineral or paraffin-base oil in the
clutch hydraulic system. These fluids may damage the
rubber parts in the cylinders.
Caution: When raising or supporting the engine for
any reason, do not use a jack under the oil pan, any
sheet metal, or the crankshaft pulley. Lifting the engine
in an unapproved manner may cause component
damage.
Engine Mounting Caution
Caution: Broken engine mountings can cause
misalignment of certain drive-train components.
Misalignment of drive-train components causes
eventual destruction of the drive-train components.
Ifone engine mount breaks, the rest of the engine
mounts will have increased stress put on them. This
could cause the rest of the engine mounts to break.
Exterior Trim Emblem Removal
Cauflon
Caution: Use a plastic, flat—bladedtool to prevent paint
damage when removing an emblemlname plate.
Fastener Caution

Component Fastener Tightening
Caufion
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.
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 fastenerjoint 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.

Not Exceed Filling the Master Cylinder Caution

Compressed Air Should
98 kPa (14 psi) Caution Caution: When filling the master cylinder, use only
Delco Supreme 11, GM P/N 12377967 (Canadian P/
Caution: When using compressed airto remove N 992667), or equivalent DOT 3 brake fluid. Do not use
components, air pressure should not exceed 98 kPa a container which has been used for petroleum based
(14 psi). fluids, or a container which is wet with water. Petroleum
based fluids will cause swelling and distortion of rubber
Drive Axle Caution parts in the hydraulic brake system, and water will mix
Caution: Support the lower control arms in the normal with brake fluid, lowering the boiling point. Keep all fluid
containers capped to prevent contamination.
horizontal position in order to avoid damage to the drive
axles. Do not operate the vehicle in gear with the
Flex Decoupler Caution
wheels hanging down at full travel.
Caution: Do not over-flex or damage the flexjoint
Engine Coolant Thermostat Housing when moving the flex joint from the normal mounting
Caufion position.

Caution: Use care when performing this procedure. Fuel and Evaporative Emission
Use of excessive force may damage the coolant Cleaning
thermostat. HoselPipe Connection
Cauflon
Caution: Clean all of the following areas before
performing any disconnections in order to avoid
possible contamination in the system:
. The fuel pipe connections #
_M.rcm
t

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Manual
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 and Cautions 0-9
Dangers, Warnings,
soldered since
circumstances should repairs be
reference being
. The hose connections this could result in the air
connections
- The areas surrounding the obstructed.

Oxygen Sensor Resistance

Fuel Pressure Caution Heated
pressure to exceed the Caution '
Caution: Do not allow the fuel Learn Reset
to the fuel pressure perform the
specified value because damage may result. Caution: When replacing the H028
regulator or the fuel pressure gauge
following:
tool, regardless of
Strap Fastener Caution - A code clear with a scan
Fuel Tank whether or not a DTC is set
by steps,
Caution: Tighten the strap fasteners the specified learn reset with a scan
fasteners, until - H028 heater resistance
alternating between the tool, where available
tighten the strap
torque is reached. A failure to Perform the above in order to
reset the H028
the bottom of the tank
fasteners as specified will cause fuel gauge resistance learned value and avoid possible H028
result in the
to flex upward. This will in the tank when failure.
indicating that there IS fuel remaining
the tank is empty. OFF When Disconnecting
Ignition
and Oxygen Sensor Caution
Heated Oxygen Battery
OFF when
Caufion Caution: Always turn the ignition cables, battery
from either the connecting or disconnecting battery
Caution: Do not remove the pigtail oxygen sensor to do so may
or the chargers, orjumper cables. Failing
heated oxygen sensor (H028) connectorwill affect damage the Powertrain Control
Module (PCM) or other
(028). Removing the pigtail or the electronic components.
sensor operation.
Do not drop the or
Handle the oxygen sensor carefully. connector and the Installing Hoses without Twists
H028. Keep the in—lineelectrical other contaminants.
louvered end free of grease, dirt, or Bends Caution
any type. must not be
Do not use cleaning solvents of Caution: The inlet and outlet hoses
or terminals. Do not bend or distort the
Do not repair the wiring, connectorpigtail wiring, twisted during installation. installation easier. Failure
Replace the oxygen sensor if the inlet or outlet hoses to make result in component
connector, or terminal is damaged. to follow these procedures could
is obtained by way of damage.
This external clean air reference wires. Any attempt
and heater
the oxygen sensor signal terminals could result Assist Rod Caution
or Liftgate
to repair the wires, connectors,
reference and degraded the end of the liftgate/
in the obstruction of the air Caution: Apply pressure only at or attaching. Do
are removing
sensor performance. hood assist rod that you of the rod because
The following guidelines should
be used when NOTapply pressure to the middle
servicing the heated oxygen sensor: damage or bending will result.
or other materials to
- Do not apply contact cleaner connectors. These Sensor Caution
the sensor or vehicle harness Oxygen
causing poor sensors carefully in order
materials may get into the sensor Caution: Handle the oxygen
component. Keep the
performance. to prevent damage to the exhaust inlet and free of
pigtail and harness electrical connector and the
- Do not damage the sensor wires inside are solvents on the
wires in such a way that the contaminants. Do not use cleaning sensor.
for foreign the
exposed. This could provide a path cause
sensor. Do not drop or mishandle
materials to enter the sensor and
Hose Disconnected
performance problems. Power Steering
lead wires are not
- Ensure the sensor or vehicle bends or kinks could Caufion
bent sharply or kinked. Sharp
the lead wire. with any power
block the reference air path through Caution: Do not start the vehicle disconnected. When
oxygen sensor ground steering gear inlet or outlet hoses
- Do not remove or defeat the that utilize the disconnected, plug or cap all openings
of components.
wire, where applicable. Vehicles contamination or loss of
may rely on this ground as the Failure to do so could result in
ground wired sensor damage to the system.
Removal of the power steering fluid and
only ground contact to the sensor. performance.
ground wire will cause poor engine Position
Column in Lock
seal remains intact on Steering
- Ensure that the peripheral in order to prevent
the vehicle harness connector Cauflon
damage due to water intrusion. The engine facing straight
Packard's Crimp Caution: With wheels of the vehicle
harness may be repaired using ahead, secure the steering wheel utilizing steering
Terminal Repair Kit. Under no column lock, or a
and Splice Seals column anti—rotation pin, steering
of the steering column
strap to prevent rotation. Locking

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0- l0 Dangers, Warnings, and Cautions
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. Ifyou think the SIR coil has
became un-centered, refer to your specific SIR coil’s
centering procedure to re-center SIR Coil.
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—rotationpin, 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 intermediate shaft(s)
- 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. Ifyou think the SIR coil has
became un-centered, refer to your specific SIR coil’s
centering procedure to re—centerSIR Coil.
Tape Corners of Panel Caution
Caution: When removing body panels, apply tape to
corners of panel and adjacent surfaces to help prevent
paint damage.
Probe Caution
Test
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
J-35616-F GM Approved Terminal Release Tool Kit in
order to front probe terminals. Do not use paper clips or
other substitutes to probe terminals.
When using the J—35616-FGM Approved Terminal
Release Tool 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 J-35616-F GM Approved Terminal Release Tool Kit
label on the inside ofthe J-35616—FGM Approved
Terminal Release Tool Kit for the correct adapter along
with the connector end view for terminal size.
Torque-to-Yield Fastener Caution
Caution: This vehicle is equipped with torque-to—yield
or single use fasteners. Install a NEW torque-to-yieldor
single use fastener when installing this component.
Failure to replace the torque—to-yieldor single use
fastener could cause damage to the vehicle or
component.
Using Proper Power Steering Fluid
Cauflon
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.
Vehicle Lifting and Jacking Caution
Caution: Perform the following steps before beginning
any vehicle lifting orjacking procedure:
0 Remove or secure all of the vehicle contents in
order to avoid any shifting or any movement that
may occur during the vehicle lifting orjacking
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 orjacking equipment manufacturer.
- Perform the vehicle liftingorjacking procedure on
a clean, hard, dry, level surface.
- Perform the vehicle lifting orjacking procedure
only at the identified lift points. DO NOT allow the
lifting equipment orjacking 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.
Windshield Installation Caution
Caution: Do not use spacers when installing a
windshield. The stress caused by the spacers may
damage the windshield.
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 Table of Contents la'l

Section 1

General Information

1—37
1-3 Squeaks and Rattles .........................
General Information ........................... . . .. . . .1-37
1—3 Diagnostic Information and Procedures
Introduction ....................................... 1—37
1-3 Squeaks and Rattles ............................
Arrows and Symbols ............................. ................... 1—37
1—4 Special Tools and Equipment
Acronyms and Units ..............................
1-38
Customer Concern Verification Sheets . . . . . 1-10 Vibration Diagnosis and Correction . . .. . . . .
1-38
Vehicle, Engine and Transmission ID and VIN Specifications ...................................
1-38
Location, Derivative and Usage ............... 1—11 Tire and Wheel Runout Specifications ..........
.1-38
Vehicle Certification, Tire Placard, Anti-Theft, Diagnostic Information and Procedures . . .. . .
Label .................... 1—13 Vibration Diagnosis, Starting Point, and
and Service Parts ID
.................................. 1—14 Correction ..................................... 1—38
RPO Code List
1-39
Fasteners ....................................... 1-19 Vibration Analysis - Road Testing ...............
1-22 Component Rotational Speed Calculation . 1—41
.
Thread Inserts ..................................
1-43
Registered and Non-Registered Trademarks 1—22 Vibration Analysis - Tire and Wheel .............
1-46
Door Lock and Ignition Lock Folding and Vibration Analysis - Hub and/or Axle Input ......
1-24 1-48
Non-Folding Key Cutting ...................... Vibration Analysis - Engine .....................
1-49
Door Lock and Ignition Lock Folding Key Blade Engine Order Classification .....................
Removal and Installation ...................... 1-24 Vibration Analysis - Engine/Accessory
Lock Cylinder Coding (Free Isolation ....................................... 1-52
Front Side Door
1-56
Wheeling) ..................................... 1-26 Vibration Analysis - Engine Balance ............
1-60
Front Side Door Lock Cylinder Coding (Non Vibration Diagnostic Aids .......................
1-27 Vibration Diagnostic Aids —Vibration Intermittent
Free Wheeling) ................................
1—28 1—60
Lock Cylinder Coding — Ignition ................. or Not Duplicated ..............................
Vibration Diagnostic Aids - Vibration Duplicated,
Rear Compartment Lid Lock Cylinder
......................................... 1-30 Component Not Identified ..................... 1-61
Coding
1-31 Vibration Diagnostic Aids —Vibration Duplicated,
Lifting and Jacking the Vehicle ..................
1—62
Special Tools and Equipment ................... 1-32 Difficult to lsolate/Balance Component ........
1—32 Duplicated,
Special Tools Ordering Information ............. Vibration Diagnostic Aids —Vibration
1—33 Appears to Be Potential Operating
AirNVind Noise ................................ 1-62
Characteristic ..................................
Diagnostic Information and Procedures . . .. . . .1—33
1—33 Symptoms - Vibration Diagnosis and
Air/Wind Noise .................................. 1-62
1—33 Correction .....................................
Tracing Powder or Chalk Test .................. Vehicle—to—Vehicle Diagnostic Comparison . 1—64
1—33
Air Pressure Test ............................... ...................... 1—64
1-34 Tire and Wheel Inspection
Soap Suds or Bubble Test ...................... Measurement
1-34 Tire and Wheel Assembly Runout
Repair Instructions .............................. 1-65
1-34 - On-Vehicle ...................................
Exterior Windnoise .............................. Measurement
1—34 Tire and Wheel Assembly Runout
InteriorWindnoise .............................. 1-66
1—34 —Off Vehicle ...................................
Special Tools and Equipment ................... .......... 1-69
Brake RotorlDrum Balance Inspection
............... 1-35 Runout
Maintenance and Lubrication Hub/Axle Flange and Wheel Stud
Specifications ................................... 1—35 inspection ..................................... 1-70
................... 1—35 Test ........ 1-71
Approximate Fluid Capacities Tire and Wheel Assembly Isolation
......... 1-35
Fluid and Lubricant Recommendations
Maintenance Items ............................. 1-35
Maintenance ..................................... 1-36
Maintenance Schedule ......................... 1-36

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“i=2 Table of Contents
Repair Instructions .............................. 1—72
Tire and Wheel Assembly Balancing - Off
Vehicle ........................................ 1-72
Tire and Wheel Assembly Balancing -
On—Vehicle.................................... 1-76
Tire-to-Wheei Match-Mounting (Vectoring) . 1-77
Tire and Wheel Assemny-to-Hub/Axle Flange
Match-Mounting ............................... 1-78
Description and Operation ...................... 1-78
Vibration Theory and Terminology .............. 1-78
Electronic Vibration Analyzer (EVA) Description
and Operation ................................. 1-88
Vibrate Software Description and Operation .... 1-90
Reed Tachometer Description .................. 1-90
Special Tools and Equipment ................... 1—91
Waterleaks .................................... 1—92
Diagnostic Information and Procedures . . .. . . .1-92
Waterleak Test Preparation ..................... 1-92
Recommended Materials (Waterleak Repair)” .1 —93
Dust Leaks ...................................... 1-93
Water Hose Test ................................ 1—94
Air Hose Test ................................... 1—94
Repair Instructions .............................. 1-94
Body Waterleak Repair ......................... 1-94
Stationary Window Waterleak Repair ........... 1—95
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 General lnformation 1=3

General Information

Introduction

Arrows and Symbols

This service manual uses various symbols in order to
describe different service operations.

2 2

EEX 2:]\ r b ‘
:>

4 5

6') 1i

7 a

a \o»

10 11

\.....

13

196216
Legend
(1) Front of Vehicle
(2) View Detail
View Detail
Ambient Air Mixed with Another Gas or
Indicate Temperature Change
Motion or Direction
View Angle
Dimension (1:2)
Ambienthlean 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

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134 General information

Acronyms and Units

Acronyms
Acronym Meaning Definition
Indicatesthata vehiclehas 2 drivenwheelsOR thata 4WDvehicle
2WD Tw0-WheelDrive usesonly2 wheelsforpropulsion.So itcan bethedescriptionofa
vehicleconfigurationOR theoperationalmodeofthedrivetrain.
Four—wheeled vehiclewitha drivetrainthatallowsall fourwheelsto
receivepowerfromtheenginesimultaneouslywhichprovidesbetter
controlonvarioussurfaces.Can be usedto describethe
4WD Drive
Four—Wheel configurationof thevehicleOR as theoperationalmodeofthe
drivetrain.4WDvehiclesusuallycanturn2 wheelsoffto bein a 2WD
mode.See also AWD.
A/C Air Conditioning Thecoolingand dehumidification ofindoorairfor thermalcomfort.
Usedin contextof convertingelectricalanalogsignalstodigital
A/D Analogto Digital signals.
Systemon motorvehicleswhichpreventsthewheelsfromlooking
ABS AntilockBrakingSystem whilebrakingwhichhelpsthedrivermaintaincontrolin heavy
brakingconditions.
AC AlternatingCurrent An electricalcurrentwhosemagnitudeanddirectionvarycyclically.
Methodof impressingdataontoan alternating-current (AC)carrier
AM AmplitudeModulation waveform.
APP AcceleratorPedal Position A pedalthatcontrolsthethrottlevalve.
AlI-wheel-drive systemsaredesignedtofunctionon all typesof
surfaces,bothon—andoff-road,andmostofthemcannotbe
AWD Drive
AlI—Wheel fourwheeldrive.See
switchedoff.This can also be calledfull—time
also4WD.
Americanwiregaugeis a standardizedwiregaugesystemused
since 1857predominantlyin theUnitedStatesforthediametersof
AWG AmericanWire Gauge round,solid,nonferrous,electricallyconductingwire.
E.g.a wireofAWG1Ohas a diameterof2.588mm,AWG20
correspondsto a diameterof0.812mm.
B+ BatteryPositiveVoltage Theelectricalpotentialon thepositiveterminalofthebattery.
BARO BarometricPressure Atmosphericpressureas measuredby a barometer.
BodyControlModule This modulesuppliesvehicleoccupantswithvisualand audible
BCM informationandcontrolsvariousvehiclefunctions,
BECM BatteryEnergyControlModule Controlmoduleused to regulatethebatteryvoltage.
BrakePedal Position Positionofthefootpedalthatmovesa pistonin themasterbrake
BPP cylinder.
CAN ControllerArea Network Serialdataconnectionbetweencontrolmodulesby Bosch
Chassis ControlModule The modulethatcontrolsvariousvehiclefunctionsontheChassis,
CCM likeEngine/TransMount,ActiveGrilleAir Shutter,Load
Leveling,etc...
CompactDisc A smallopticaldisk onwhichdatasuch as music,text,orgraphic
CD imagesis digitallyencoded.
CompressedNaturalGas This a substituteforgasolineor dieselfuel.Itis madeby
CNG compressingnaturalgas (whichis mainlycomposedby methane
(CH4),in a percentagerangeof70%to 98%)
CarbonMonoxide This is a productofthe incompletecombustionofcarbon-containing
CO compounds,at roomtemperaturethisis a gas. Itconsistsof one
carbonatomcovalentlybondedtooneoxygenatom.
CarbonDioxide Chemicalcompoundcomposedoftwooxygenatomscovalently
C02 bondedtoa singlecarbonatom.
ConnectorPositionAssurance Partof an electricalconnectorthatpreventsthe connectorfrom
CPA movingoutof its socket.Usuallyneedsto be pressedto unlockthe
connectorwhendisconnectingit.
ClutchPedal Position A leveroperatedwiththefootthatcontrolsthecouplingthat
CPP connectsor disconnectsdrivingand drivenpartsofa driving
mechanism.

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 General information 15

Acronyms (cont'd)
Definition
Acronym Meaning
Used in conjunctionwithCV joints,whichsame connecttwoshaftsat an
ConstantVelocity always have the rotationalspeed
anglewhilebothshafts
CV withoutvariations.
speeds oftwo
A transmissioninwhichtheratioofthe rotational vehicleorother
shafts,as theinputshaftand outputshaftof agiven range,providing
CVT ContinuouslyVariableTransmission machine,can be variedcontinuouslywithina improves fuel economy.
an infinitenumberof possible ratios which

Drive D on thetransmissiongearselectorlever.
D radio(carries
DigitalAudio Broadcast Technologyfor broadcastingofaudiousingdigital
DAB informationvia digitalsignal) transmission.

DirectCurrent Continuouscurrent,constantflowof electriccharge.

DC underneaththe
DataLink Connector This is an electronicconnectortypicallylocatedThe connectorhas
driver's side dashboard, j ust above the pedals.
DLC 16 pins.
severalfunctionsin
DigitalMultimeter Electronicmeasuringinstrumentthatcombines an ammeter,voltmeter,
one unit.The most basic instruments include
DMM and ohmmeter.
performanceengines,
Dual OverheadCamshaft Dual overheadcamshafts(DOHC)are higher higher speeds because
theyproducemorepower,andcan runat
they allowan engineto have four valves per cylinder.
DOHC camshafthandlesthe
Each camshaftoperatestwoof thevalves,one
intakevalves,andone handles the exhaustvalves
or sootfromthe
Diesel ParticulateFilter Devicedesignedto removediesel particulatematter
DPF exhaustgas ofa diesel engine.
thatautomatically
DaytimeRunningLamps Whitelightsmountedonthefrontof an automobile intended for daytimeuse,to
switchonwhenthekey is turned andare
DRL increasethevisibilityofthe automobile.
the distance
DistanceSensingCruise Control A typeof cruisecontrolthatautomaticallymaintains
DSCC betweenvehicles.
for digitalsignal
DigitalSignal Processor VAspecializedmicroprocessordesignedspecifically
DSP processing,generallyin real-time computing.
computer,indicatingthe
DiagnosticTroubleCode An electronicsignalstoredin an automotive
DTC presenceof a faultdetectedby that computer.
7A popularopticaldisc storagemedia formatthesize ofa CD. Used
DVD mainlyfor moviesbutalso fordata. DVD has no spelledoutversion
VersatileDisc,
DVD (officiallyitdoes notmeanDigitalVideo Disc or Digital
itjust meansDVD).
for antilock
ElectronicBrake ControlModule This modulecontainsa microprocessorand software
EBCM brakingsystem operation.
This electronicmoduleworkswitha vehicle's sensors and engine
EngineControlModule controldevicesto insure thatthe engine operates at maximum
performs three vital functions.
efficiencyand performance.it Analyzes thedata
Receives electronicsignalsfromenginesensors. (based on the pre-set
ECM and makesan engine performance decision
Sends an “output c ommand" to an
parameterswithintheunit).
actuatorthatadjustsengineperformance.
A measureofhowhotor coldthe fluidwhich flowsthroughthe
EngineCoolantTemperature enginein orderto preventits overheating,transferring
theheat
ECT device to other devices that utilizeor dissipate it.
producedby the
and otherdevicesto
ElectricallyErasableProgrammable A non-volatilestoragechip used in computers calibration tablesor device
storesmall amounts of volatile data, e.g.
EEPROM Read-OnlyMemory configuration.
reductiontechnique
ExhaustGas Recirculation ls an NOx (nitrogenoxide and nitrogendioxide) EGR worksby
used in mostgasolineand diesel engines.
the engine
recirculatinga portionof an engine'sexhaustgas backto
EGR cylinders.
Electromagneticinterference(alsocalledradio frequency
ElectromagneticInterference interference)is a disturbance that affects an electrical circuitdueto
EMI conduction or electromagnetic r adiation
eitherelectromagnetic
emitted froman external s ource.
«N
’
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1‘6 General information

Acronyms (cont'd)
Acronym Meaning Definition
ESD ElectrostaticDischarge The suddenand momentary electriccurrentthatflowsbetweentwo
objectsat differentelectricalpotentials.
EV ElectricVehicle A categoryofvehicles thatonlyhavean electricdrivesystem.
EVAP EvaporativeEmission A systemthatcontrolsthefuelfumesin thefueltank.
FM FrequencyModulation Intelecommunication thisis a waytoconveyinformationovera
carrierwaveby varyingitsfrequency.
FWD Front-WheelDrive A formof engine/transmission layoutusedin motorvehicles,where
theenginedrivesthe frontwheelsonly.
GeneralMotorsLocalArea Network A locaI-areanetworkis a computernetworkcoveringa small
GMLAN geographicarea,likea homeorvehicle.This specifictypeof LAN
connectsseveral controllersinsidethevehicleandwas developedby
GeneralMotors.
GPS GlobalPositioningSystem Satellite—based navigationsystemmadeupof a networkof24
satellitesplacedintoorbitbytheUS. Departmentof Defense.
GSM GlobalSystemfor Mobile Globallyacceptedstandardfordigitalcellularcommunication.
Communications
Gross VehicleWeight Maximumtotalweightofa roadvehicleor trailerthatis loaded,
GVW includingtheweightofthevehicleitselfplus fuel,passengers,cargo,
andtrailertongueweight.
HD HeavyDuty Robustdesignto accommodatelargeworkloads.
HighIntensityDischarge A typeof lightthatproducesa brightlightby usinggas filledbulbs.
HID (gasis usuallymercury,metalhalide,and high-pressuresodium)
Uses verylittlebatterypowerandis a very"cool"light. ‘
HeatedOxygenSensor Heatedoxygensensorshavean internalheatercircuitthatbringsthe
sensoruptooperatingtemperaturemorequicklythanan unheated
H028 sensor.An oxygensensormustbe hot(about600—650°F) beforeit
willgeneratea voltagesignal.The hotexhaustfromthe enginewill
provideenoughheatto bringan 02 sensoruptooperating
temperature.
HeatingVentilationAir Conditioning This systemis sometimesreferredtoas climatecontrol.Ventilation
HVAC airductsinstalledthroughouta vehiclethatsupplyconditionedair to
a roomthroughrectangularor roundoutletvents,
lZC Circuit
Inter-lntegrated SerialdataconnectionbetweenIntegratedCircuits(microchips)
insidea controlmoduleinventedby Phillips
lAT IntakeAir Temperature Temperatureoftheairenteringintakeairflowsystemof theengine.
lCE InternalCombustionEngine An enginein whichthecombustionoffuelandan oxidizer(typically
air)occursin a confinedspacecalled a combustionchamber.
lD Identification Numberor Code thatidentifiesa componentor controlmodule.Can
bewrittenon thepartor betransmittedon a busor via radio.
lSP InternetServiceProvider A companythatfurnishescorporationsand individualconsumers
withvariousservices,mainlyaccesstothe Internet.
ISS inputShaftSpeed Rotationalspeedoftheinputshaftofa transmission.
LAN LocalArea Network StandardnetworkconnectionPC’s.
LCD LiquidCrystal Display A thin,flatdisplaydevicemadeupof anynumberof coloror
monochromepixelsarrayedin frontofa lightsourceor reflector.
LightEmittingDiode Smalllightbulbs thatfiteasilyintoan electricalcircuittheydo not
LED havea filamentthatwill burnout,andtheydo notgetespeciallyhot.
Theyare illuminatedsolelybythe movementof electronsin a
semiconductormaterial.
LlN Local lnterconnectNetwork Computernetworkingbussystemusedwithinautomotivenetwork
architectures.SimilartoCAN, butcheaperand less powerful.
LPG LiquefiedPetroleumGas A mixtureof mainlypropaneand butane,producedcommerciallyand
storedunderpressureto keepit in a liquidstate.
MAF Mass Air Flow The amountof air drawnintotheengine
MAP ManifoldAbsolutePressure Pressurein theengineintakesystemafterthe throttlevalve
referencedtoa perfectvacuum.

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Manual
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 General Information 1:?

Acronyms (cont'd)
Meaning Definition
Acronym
with
MultipleDiagnosticsInterface A deviceused by GM dealersthatenablesa PC to communicate
MD] thecontrolmodulesin a vehicle.
MIL MalfunctionIndicatorLamp An indicatorofthe internalstatusof a car engine.
MOST MediaOrientedSystemsTransport Serial communicationbusto transmitaudioandvideo information.
N Neutral A stateof thetransmissionin whichit is notengaged.
alloy
NiMH Nickel MetalHydride A typeof rechargeablebatterythatuses a hydrogenabsorbing
forthe negativeelectrode.
NitrogenOxides Refersto anyofthefollowingoxygencompoundsof nitrogenor a
mixtureofthem.NitricOxide,Nitrogendioxide,Nitrous Oxide,
NOx Dinitrogen Dinitrogen
trioxide, tetroxide, D initrogen pentoxide.

02 Oxygen A colorless,odorless,tasteless,gaseouschemicalelementwiththe
chemicalsymbol0 andatomicnumber8.
in
028 OxygenSensor An electronicdevicethatmeasuresthe proportionofoxygen(02)
thegas or liquidbeing analyzed. ‘
A generictermreferringto a vehicle'sself—diagnostic and reporting
OBD Diagnostic
On—Board
capability.
OEM OriginalEquipmentManufacturer A producerthatprovidesa productto its customers,who proceedto
modifyor bundleit beforedistributingittotheircustomers.
OSS OutputShaftSpeed Rotationalspeedof theoutputshaftofa transmission.
vehicle.
P Park A statein whichthe transmissionis set so onecan leavethe
PCB PrintedCircuitBoard A thinplateonwhichchipsand otherelectroniccomponentsare
placed.
and
PCM PowertrainControlModule A controlmodulethatfeaturesthefunctionsofboth,theengine
the transmissioncontrolmodule.‘
An internationalstandardsbodyand tradeassociation withover
PersonalComputerMemoryCard
IndustryAssociation 100membercompaniesthatwas foundedin 1989to establish
standardsfor IntegratedCircuitcardsand topromote
PCMCIA interchangeability amongmobilecomputerswhereruggedness,low
power,and smallsize werecritical.
PIN Number
PersonalIdentification A secret numericpasswordsharedbetweena userand a systemthat
can beused to authenticatetheuser tothesystem.
to
PPE PersonalProtectiveEquipment Protectiveclothing,helmets,goggles,or othergarmentdesigned
protectthewearer'sbodyfrom injury.
Low Park, Reverse,Neutral,Drive,Low (automatictransmission
pRNDL Park. Reverse,Neutral,Drive, positions).
PTC PositiveTemperatureCoefficient Refersto materialsthatexperiencean increasein electrical
resistancewhentheirtemperatureis raised.
A splineddriveshaft,usuallyon a tractoror truckthatcan be usedto
PowerTake-Off attachment o r separate machine. This
providepowerto an
PTO mechanismallowsimplementstodrawenergyfromthetractor‘s
engine.
PVC PolyvinylChloride A thermoplasticcopolymer.
PWM Pulse WidthModulation Squareshapedtypeof signalthatcarriestheinformationin theratio
betweenonand offtimes.
R Reverse Rearward:directedor movingtowardthe rear;
integrated
RAM RandomAccess Memory A typeof computerdata storage.Ittodaytakestheformof
circuitsthatallowthe storeddata to be accessedin anyorder.
This is theheatintensityof theradiatorcoolantmeasured in degrees.
RadiatorCoolantTemperature systemthat removes theengine
The radiatoris a partof thecooling glycol)
RCT heat.Coolantis a mixtureof waterand antifreeze(ethylene system,
whichlowersthe freezing pointof thewater in thecoolant
theair.
thisfluid also picksup heatfromtheengineand transfersit to
small
RadioDataSystem A standardfromthe EuropeanBroadcastingUnionfor sending
amountsof digitalinformation using conventional F M radio
RDS broadcasts.

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128 General information
Acronyms (cont'd)
Definition
Acronym Meaning
A frequencyor rateof oscillationwithin the rangeofabout3 Hz and
Radio Frequency to frequency of alternatingcurrent
300GHz. This rangecorresponds detectradiowaves.
RF electrical signals usedto produce and
and otherelectronic
Read-OnlyMemory A class of storagemediausedin computers modified. '
devices. Data stored in ROM cannot be
ROM
assemblies,and systems
RegularProductionOption A threedigitllettercode givento parts, RPO codes designate
originally installed onthe vehicle. These
RPO optionsandare assignedby GeneralMotors.
An auxiliarysetof controlsthatoperate the mainaudiosystemfrom
Rear Seat Audio therearseat.Rear passengers can also operatea differentmedia
RSA sourcethanthefrontpassengers.
A commonengine/transmission layoutin whichtheengineis in the
Rear-WheelDrive rearmid-engineand
frontof thevehicle,butthefrontmid-engine,
RWD rearengine layouts arealso used.
levelin thevehicleas
The volumecontrolis setfor a desiredsound
Speed ControlledVolume thevehicle increases its speed, the sound levelis adjusted.
SCV
GeneralMotorsvehicles.
The namegivento airbag modulesusedin
SDM Sensingand DiagnosticModule Card.Thisis used
SubscriberIdentityModule Partof a removablesmartcard IntegratedCircuit as mobile computersand
for mobilecellulartelephonedevices such
SlM cards securely store the service-subscriberkey
mobile phones.
allowsusersto change
usedto identifya subscriber.The SIM card from one mobilephoneand
SIM phonesby simplyremovingtheSIM card
another mobile phone or broadband telephony
inserting itinto
device.
membrane,
SupplementalInflatableRestraint Technicaltermfor theair bag.Air bagis a stretchable to provide cushioningto
whichinflatesduring an automobile accident
prevent injuryto the passengers.
SIR the passenger'sheadand torsoto
This is an interfacethatenablesthe serial (onebit at a time)
Serial PeripheralInterface exchangeofdata betweentwo devices. An SPl operatesinfull
mode. This means that data can be transferredin both
duplex technologylike CAN
SPl directionsatthe same time.Itis a standardbus
or |2C.
softwarein control
Systemthatenablesrepairfacilitiesto updatethe
Service ProgrammingSystem modules.
SP8
towingcapacityofa pickup
A passengervehiclewhichcombinestheofa minivan.
SportUtilityVehicle truckwiththe passenger—carrying space
SUV
to a vehicle
Indicatorlampor symbolfora malfunctionrelated
ServiceVehicle Soon componentor system.
SVS
Message spokenonradioregardingtheroute. movementof vehiclesor
TrafficAnnouncement pedestriansthroughan areaor alonga The buttonson radios
often labeledTA.
TA thatenablethis announcementsarealso
A motorwhichmovestheenginethrottle plateor valve,controlledby
ThrottleActuatorControl limitsthe amountofair
the enginecontrolmodule.A throttleplate engine.
TAC enteringa internal c ombustion gasoline
component's
TransmissionAdaptivePressure The transmissioncontrolmodulelearnseach accordingly.
characteristicsand adjusts fluid pressure
TAP
engineto an automatic
Resides in a torqueconverterto connectan are correctto
TorqueConverterClutch transmission.The clutch is applied when conditions
crankshaft t o transmission inputshaft.
TCC achievea 1:1ratioof engine
transmissions.Ituses
TransmissionControlModule A modulethatcontrolselectronicautomatic provided bythe Engine
sensorsfromthevehicleas wellas data
Module to calculate how and whento changegearsin the
TCM Control and shiftquality.
vehiclefor optimumperformance,fuel economy
combustion
The pistonis in its highestpositionrelativetothe
Top Dead Center chamber.
TDC
softwarethatprovides
TechlineinformationSystem The PC-based globaldealershipdiagnostic most recentservice
the technicianthe abilityto reference the
TIS informationvia theservice department‘s c omputer.
electricconnectorthat
TerminalPositionAssurance An additionallockingmechanisminsidean
TPA holds thepins in place.
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2013 (5377994)
Manual
Service
 General information

Acronyms (cont'd)
Meaning Definition
Acronym
A telecommunication systemfor broadcastingand receivingmoving
TV Television soundover a distance.
picturesand
USB UniversalSerial Bus A typeof communicationbus connectionbetweena computeranda
peripheraldevice.
VehicleCommunicationsInterface A diagnostictoolthatcommunicatesto modulesof multiple
VCI communicationprotocolsin a vehicleby convertingvehicleserial
datainto PC serialdata communication.
VlN Number
Vehicle Identification Used by manufacturersto uniquelyidentifymotorvehicles using
17characters.
loss
VehicleStabilityControlModule This moduleuses informationfromseveralsensorsto detecta apply
ofvehicletraction,thenworks withthe antilockbrake systemto
VSCM individualbrakesto helpkeep thevehicleon its intendedpath.
Vehicle Speed Sensor Sends data regardinghowfast thecar is travelingat themomentof
VSS driving.Itis designedto be ableto recordthe rateat whichthe
vehicle’scrankshaftis spinning.
Whenthe throttlebladeor valveis at its maximumopen position,
WideOpenThrottle maximum airto enteran internalc ombustion gasoline
WOT allowing
engine. ‘
WLAN WirelessLocalArea Network Standardto transmitdigitaldatavia radiofrequency.
XM SatelliteRadio Holdings(XM)is oneof twosatelliteradio
servicesin theUnitedStatesand Canada.XM provides
. . pay-for-serviceradio,analogousto cable television.Itsservice
XM (SatelliteRadio) includes73 differentmusicchannels,39news,sports,talk,and
XM entertainment channels,21 regionaltrafficand weatherchannelsand
23 play-by-playsportschannels(2008).
A markuplanguagethatdefinesa setof rulesfor encoding
documentsin a formatthatis bothhuman-readable and
XML ExtensibleMarkupLanguage
machine-readable.

Units cont'd
. , (_ ) _,,
Units Unit Meaning Definition
U ‘t M _ D f‘ "ti
a m e n o km/L kilometer/Iiter Flow
"2' 8 Met " 9 A ' ' "
L/100km Litersper 100 Kilometers Flow
n; Aquare e er Elreat_ l
L/h Litersper Hour Flow
Ah AmpereH Electrical
lein Litersper Minute Flow
C Cmplerebour Elec rtcal
MPG Milesper Gallon Flow
ouom ectnca
Electrical ,, Flow
dBm DecibelMeter mg/s Milligramsper Second
Electrical ,, Flow
dBmV DecibelMillivolt mg/stroke Milligramsperstroke
mV/DIV MillivoltsperDivision Electrical ft feet Length
MillivoltsperSecond Electrical , Length
mV/s El ' | In Inch
Q Oh
m Meter Length
111 ectrlca
Electrical . ,
V Volt
m1 Mlle Length
V/DlV V It D' ' ' El t ' l bar Bar Mechanical
V/ Voltsper Ml'nl'smnd Elec flea]
bar/min Bars perMinute Mechanical
V2118 V)?t: per l Isecon Electrical
in.H20 Inchesof Water Mechanical
C ab' M'll' t Flectnca
u l I r OW in.HZO/s Inchesof Waterper Mechanical
mm3/stroke Strolfe Imeers pe
Flow second Mechanical
l/h Gallons er Hour Fl kPa/s KilopascalsperSecond
98/ p d
N Newton Mechanical
/S:Sk gramsper 88:00:: Flow
m N-m NewtonMeter Mechanical
g S ro e Krla 8per r: 060 Flow
0 re s e Pa Pascal Mechanical
kg/100km p r
K}.o?ne{2r ow
Pals Pascals perSecond Mechanical
kg/h KilogramsperHour Flow

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1:310 General Information

Units (cont'd) Units (cont'd)

Unit Meaning Definition Unit Meaning Definition
Metersper Second Movement
lb ft PoundFoot Mechanical m/s2 Squared
. '
PSI Pound-Forceper Mechanical
SquareInch MPH MilesperHour Movement
Counts Misc. mm/s MillimetersperSecond Movement
Counts
Cycles Misc. d Day Time
Cycles
Decibel Misc. h Hour Time
dB
Degree Misc. hh:mm:ss Hour:Minute:Second Time
°
°C DegreeCentigrade Misc. ms/DIV Millisecondsper Division Time
DegreeCrankshaft Misc. min Minute Time
a
CA Angle ' ‘ s Second Time
DegreeFahrenheit Mtsc. s/DIV Secondsper Division Time
F Time
Is DegreeperSecond MISC. -mm-dd Year-Month-Day
Hz Hertz Misc. W (2digits)
Kilobitpersecond Misc. Year-Month-Day Time
kbit/s . . preferred)
yyyy—mm-dd (4digits,
Ix Lux Misc.
3 .
PartsperMillion Misc. rn CUb'cMeter Volume
ppm
Percent Misc. gal Gallon Volume
%
Percentsper Minute Misc. L Liter. Volume
%lmin
Percentsper Second Misc. mL milliliters Volume
%lsec Volume
Pulses Pulses Misc. US gal US Gallon
Ratio Misc. US pt US Pint Volume
:1
RevolutionsperMinute Misc. US qt U_SQuart Volume
RPM Weight
Misc. kg KIIOgram
Steps Steps
Misc. . . .
W/m2 Watts er 8 uareMeter Customer Concern Verification
p 9
g g (Acceleration) Movement
. Sheets
km/h KilometersperHour Movement ._ .
The GM Customer Concern Verification Sheets have
m/s Metersper Second Movement been designed to improve communications between
m/sa Metersper Second Movement the service customer and the technician. The more
Cubed clearly the technician understands the concern and its
symptoms, the more likely the concern will be fixed
right the first time.

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2013 (US/Canada)
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 General information "in’l'l

Engine and Transmission ID

Vehicle,
and VIN Location, Derivative and

Usage

153729
is the
The vehicle identification number (VIN) plate
identifier of the vehicle. The VIN plate is located
legal
instrument panel (VP)
on the upper left corner of the
and can be seen through the windshield from the
outside of the vehicle:
ID and VIN Location, Derivative and Usage
Vehicle, Engine and Transmission
Character Description
Position Definition
1 UnitedStates
1 CountryofOrigin 3 Mexico
Manufacturer G GeneralMotors
2
Make 1 Chevrolet
3
A ChevroletSonicLS (Automatic)
B ChevroletSonic LS (Manual)
C ChevroletSonic LT (Automatic)
4—5 Vehicle Line/Series D ChevroletSonicLT (Manual)
E ChevroletSonic LTZ (Automatic)
F ChevroletSonic LTZ (Manual)
5 69 —Sedan,4—Door, 4 Window,Notchback
6 Body Style 6 48 —Sedan,4-Door,4 Window,Hatchback
A Active ManualBelts,AirbagDelete
-
Active ManualBelts,Airbag- Driver& Passenger
C Front(1strow)
-
Active ManualBelts,Airbag- Driver& Passenger
D Front(1strow), & FrontSeat Side (1strow)
-
RestraintSystem Active ManualBelts,Airbags—Driver& Passenger
Roof Side
7 Front(1strow),& Front Seat Side (1strow),
(all seatingrows)
Active ManualBelts,Airbags—Driver& Passenger Seat
Front(1strow),FrontSeat Side (1strow)& Rear
Side (2ndrow),RoofSide (allseatingrows),Driver&
Passengerknee(1strow)

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Manual
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'l-1'2 General Information

Vehicle, Engine and Transmission ID and VIN Location, Derivative and Usage (cont'd)
Position Definition Character Description
B RPO LUV Engine—Gas, 4 Cylinder,1.4L,MFl,DOHC,
Turbo,VVT,Alum,E85 Max
RPO LDE Engine—Gas, 4 Cylinder,1.6L,MFl, DOHC,
C VVT,VariableCamshaftPhasing,VariableIntake
Module(VIM)
8 EngineType RPO LFJ - Gas, 4 Cylinder,1.6LMFl, E100Max
G) RPO LWE Engine—Gas, 4 Cylinder,1.8L,MFI,DOHC,
VVT, 103KW
RPO LUW Engine—Gas/Ethanol,4 Cylinder,1.8L,
MFI,103KW,DOHC, E85
Check Digit Calculatedby POMS
10 ModelYear 2013
Orion
11 PlantLocation
(DAUXI RamosArizpe
12~17 PlantSequenceNumber PlantSequenceNumber

1.6L (LDEILFJ) Engine ID and VlN Derivative M20-6 (MZ7) Transmission ID and VIN Derivative
Locafion Location
Refer to Engine Identification on page 9953. Refer to Transmission IdentificationInformationon
page 17—593.
6T30/6T40/6T45/6T50(MH9) Transmission ID and
WM Derivative Location
Refer to Transmission Identification Informationon
page 17—31 7.

(US/Canada)
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2013 (5377994)
Manual
Service
 General information i=13

Anti-Theft, and Service Parts ID Label

Vehicle Certification, Tire Placard,

Certification Plate Location

.04.
x ‘0
11mm!)
,
1““l
a .,
£0

2505197

The vehicle identification number (VlN) plate is

attached to the top of the front end upper tie bar which
is located under the radiator opening upper cover.
Identification Plate Location

GM DAEWOOAuto& TeohologyCompany———@ )
fi
i
[ ]

KG
KG 0
Body
KG
Color
“3—;| @@@®
@® KG
[O]

2327669

Legend (5) Combination Weight (GVW +Braked Trailer

(1) Manufacturer Name Weight)
(2) Whole Vehicle Type Approval Number (6) Maximum Permissible Axle Weight —Front
(3) VlN (Vehicle Identification Number) (7) Maximum Permissible Axle Weight —Rear
(4) cvw (8) Body Color

(US/Canada)
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2013 (5377994)
Manual
Service
'l«l4 General Information

Tire Placard

fi \
fl TIRE AND LOADING INFORMATION
@370 RENSEIGNEMENTS SUR LES PNEUS ET DE CHARGEMENT
1(70 l l .
[ occUPANTs 1 TOTAL [:I IFRDNTIAVANTEl REARIARRIERECD
Thecombinedweightof occupantsandcargoshouldneverexceed kg or lbs.
ne doitjamalsdépasser1:
Lepoldstotaldesoccupantsetdu chargement kg ou lb.
,
TIRE SIZE COLD TIRE PRESS RE
PNEU DIMENSIONS PHESSION DES PNEUS FRDID
FRONT 1 I I 0
AVANT 1

“EA“ E
AHRIERE I | l

9522211533 I I I
Q /

2858476
The tire placard label is located on the driver side B- Rpo Description
pillar and displays the followmg assessments: _ .
. Tire size A69 Restraint- SeatBeltTensnoner, Front,VAR. 2
. Tire pressure A70 Restraint- Seat BeltTensioner,Front
__ LockControlRR CMPT - LID,REM CONT
Front A90 ELEC Release
—Rear . . .. L00k ControlRR CMPT - LlD, REM CONT
—Various loading conditions A94 ManualRelease
RPO Code List AAL Restraint- Knee,Bolster,LH /RH

The following table provides the description of the ABR Window‘ ManualOperated'FrontDoor
Regular Production Option (RPO) codes that are ADL RestraintSystem-Seat,Inflatable,Driver&
available on the vehicle. The vehicle's RPO list is Passenger,SingleStage
printed on the Service Parts Identification Label. AE2 Latch_RearCompartment,Safety,Manual

RPO Description AG5 eP

:Z'Ieats s t M I2w
01A TrimColorSeat- Jet BlackVAR 1 AH3 AdtusterFasstesngetr“:3 ‘ '82? D éy
01E TrimColorSeat - DK Titanium AH9 AdJ_USterFrontseat- Manual 2Way’Dr'Yer
01K TrimColorSeat—Brick R JutsértPron‘ lea _ Balrt‘uaAd'tay’Hn'vehrt
01s TrimColorSeat- MED Titanium AHU Fretfmra'”rov's'ons' e 5' “‘5 e“ 9'9 ’
02R TrimCOR)"Seat' MED Cashmere AJ3 RestraintSystem—Seat, inflatable,Driver,
02v TrimColorSeat- Jet Black & StitchingBrick Front
1A9 TrimColorDoorPanel - MED Cashmere AJC figjfigmgread) FrontSeat,UP/DOW”
T' D P l - DK T't '
1N: r1mColor oor ane . Ianium AJD Restraint- Head,FrontSeat,Up/Down,
1BF TrimColorDoorPanel - Brick Fore/Aft Adjustment,FoldingPassenger
4AA InteriorTrim- Jet Black AJG Driver&
RestraintSystem- Seat,in_flatabte,
4AQ InteriorTrim_ V DK Pewter Passenger,Front& SeatSide,SingleStage

5EA Equipment- Package,C02 - Reduction AKJ W'ndSh'eldStyle' Shade Band

9L3 TireSpare_None AKM WindowType- Clear

A33 Window—PowerOperated,Rear DRS AKN WindowType‘ Tinted

A55 Window—PowerOperated,Driver AKP WindowType' 80'5"Absorbing
- htRear Com art -
t—Lid, ALO Sensorlndicator-inflatable
. RestraintFront
’
L k C ntrolRI
KeyAcgtivated
Tgfigateo, p men Passengerl ChildPresenceDetector
A60
A66 Window- PowerOperated,Passenger AM7 Seat RearT Folding
AMA Seat Rear—SplitBack,Folding,Headrest

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2013 (US/Canada)
Sonic (5377994)
Manual
Service
«r’
.fl.’~
N
H
 General information ’llS

RPO Description
Description
RPO C99 Switch—lNFL RST l/P MDL MAN
AN1 Seat Rear - Bench Suppression
.
.
AQ2 Net—Convenience,Package iflw
AQP Restraint—Head, Rear Seat, Center CD4 wig System—Windshield,Pulse, Variable
AR1 RestraintSystem_ (None)
CF5 Roof- Sun, Glass, Sliding,ELEC
Seat‘ FrontBKT' Standard _ .
AR7
SystemRear —Seat, SHLDR, D05 ArImRest FrontISeat,Dr1ver
Restraint
RETR, 3 Point,3 SHLDR
AT7 W/
D31 Mirror,
AU3 Lock Control—Side Door,Electronic Mirrorl/S FrontVAN - Sunshade,wlo
/. D6J Passenger,w/ Mirror
and RH,
AWB 253:1? g¥§f2mpfififir—Seat, LH HandleO/S Door —Body Color,Chrome
Strip
Driver D7A
AXG Window_PowerOperated_Express HandleO/S Door- Black
D72
Up I Down HandleO/S Door- Body Color Black
Driver D75
AYO RestraintSystem—Seat, Inflatable, D87 Handle_O/S, L/Gate,R/CMPT,
Roof Side
and PassengerFront,Seat Side,
Driver& Handle' O/S' LlGate, R/CMPT’ COW
RestraintSystem- Seat, Inflatable, D91
AYC PassengerFront,Seat Side, Roof Side, D90 Sensor- FrontAirbag(EFS) - Single
Single Stage MirrorO/S_LH & RH, RemoteControl,
Driver& DCB
RestaintSystem—Seat, Inflatable, & Rear ManualFolding,Black
Passenger Front,Front Seat Side . Control,
AYF Knee MirrorO/S- LH & RH, Remote
Seat Side, Roof Side, DG2
————/ . ManualFolding,Color
B37 govermg—Floor Mat, Frontand Rear, / Control,
ux11a DG6 MirrorOlS - LH & RH, Remote
ry CONT, Electric,ManualFolding,Heated,Color
.
B9U LOCkControlRR CMPT - L/GateREM //.
l/S FrontVAN - Sunshade,Dr1ver&
ELEC Open/Close DHG Mll‘i‘OI‘
Passenger,wlo Mirror
ICDJompartment —Stowage,FrontSeat,
BA8
assen er DL6 MirrorO/S- LH & RH, RemoteControl,
. g _ Electric,ManualFolding,Color
Equ1pment j SeCUFItySystem, . Control,
BAH Immobilization,Step Two DL7 MirrorO/S- LH & RH, Remote Color
, Electric.Heated,PowerFolding,
BCM Covering- Load Compartment,Movable MirrorHS FrontVAN - Sunshade,w/Mirror,
DNJ
BCO Plant Code - Bogota,Colombia We Cover
Driver&
BGY Plant Code - DongYue, China MirrorIISFrontVAN - Sunshade,
-- _ DLV Passenger,w/Mirror& Cover
BPF EggfiaerEnggismnsFront,Lower
DUJ Ashtray- Smoker‘sPackage
BTT Alarm_RemotePanic
E17 BumperT 2'5 mph
BTV RemoteStart—Engine BumperT 5'0 mph I
E19
BUP Plant Code - Bupyeong1, Korea Handle' ”8' Door, Chrome
E21
BXQ Ornamentation - EXTR, PLR APLQ, Reveal, E22 Handle—Assist, Rear
Black Handle—Assist, Passenger
E27
C25 WiperSystem- Rear Window,intermittent Chrome
E3E Handle-0/s, LlGate, RlCMPT,
Heater- Heating/DefrosterSystem, f/. , .
C32 —2 kg
Fire Extingu13her
Reinforced,Electric E7Y
Heater—Duct,RR PASS E91 Pocket—FrontSeat Back, Passenger
f/I 035 . . ,
HVAC System- Heater, OutstdeAir,w1thFan EBL TrimSeat- Cloth,Flash
C41 . . ,
Defogger- RR Window, Electric EBM TrimSeat—Cloth,Breva
C49 . ._ _
C60 HVAC System- Air ConditionerFRT,
MAN ECE TrimSeat—Leather(TBD1—GSV)(GMDAT)
Controls Ratio- TransaxleFinal Drive4.11
HTR F77
C7B HVAC System_Air ConditionerFRT, FE1 SuspensionSystem_ Soft Ride
ControlOnly
Core Not Required,Fan Speed - System_ Spec1al ~ and
- Ride
3271311111130“
Switch- DirectionalSignal,Wiper,Reverse FE4
080 Mount,STRG WHL
FE9 Certification—Emission,Federal
C91 Lamp' INTR' ROOf’Courtesy Fuel System- Electronic,Returnless
Reading FHA
095 Lamp,'NTR' Roof,Courtesy8‘ Dual Ratio- TransaxleFinal Drive3.47
I7 FHB

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2013 (5377994)
Manual
Service
 ,1
la'lo General information

RPO Description RPO Description

FHF TrimDoor—HardTouchPaint GQJ PrimaryColor- Exterior,GrandCanyon
FHG TrimDoor—SoftTouchPaint BrownMET (894T) I
FHN VehicleFuel-GasolineE5 GQM mfigyggggor' EXter'or'Boracay3"”
FHP VehicleFuel‘ GasolineE20 GQV PrimaryColor—Exterior,FlameRed
FHS VehicleFuel‘ GasolineE85 GQW PrimaryColor- Exterior,UrbanGrey (658R)
FHT VehicleFuel' GasolineE100 J93 BrakeSystem- Power,FRT Disc,RR Drum,
FHY VehicleFuel- DieselB10 ABS, 15"
FP9 Ratio- TransaxleFinalDrive3.55 J94 Brake?gstem- Power,FRT Disc,RR
rum,
FV1 Ratio-TransaxleFinalDrive3.72 B k S t P FRTD' RR D
ra e s em- ower, ISC, rum,
FV2 Ratio- TransaxleFinalDrive4.18 J97 ABS, 14X
FV5 Ratio—TransaxleFinalDrive4.19 JBD Booster_Brake,SingleRate
FV7 Ratio- TransaxleFinalDrive429 JBE Booster_Brake,DualRate
FVE Ratio- TransaxleFinalDrive4.63 JDE Bumper_Front&Rear,Lightweight
FVG Ratio-TransaxleFinalDrive4.64 JPW BrakeSystem_powerIFRT Disc,RR
FX1 Ratio- TransaxleFinalDrive3.94 Drum,14
FX3 RideAnd Handling—AutomaticElectronic K12 Filter- Air:Pollutant
Controlled K33 CruiseControl- Automatic,Electronic,
FXB Ratio- TransaxleFinalDrive3.65 SpeedGovernor
FY2 Ratio_TransaxleFinalDrive3J4 K34 CruiseControl- Automatic,Electronic
G83 - _TganIsaxleEthal
IEatio ~ DrIISveII4I4IZI
- d SII K4E Battery—LN3,AGM, 12V,7OAH,
760ENCCA
GAN MngGrg6§6gfl X enor, WI0 a e Iver K09 Generator—120Amp
PrimaryColor—Exterior, CarbonFlash Met K60 Generator—100Amp
GAR ,
(G)5010 K97 Generator—80Amp
GAZ (Péigaéglfolor—Exterior,OlympicWhite KA1 Heater_Seat,Front
_ , KE3 Knob—TRANS CONT Lever,Chrome
GBA PrimaryColor—Exterior,Black(G)8555
, _ KG9 Generator—140Amp
GBE PrimaryColor- Exterior,CrystalClaret ,
Tintcoat(G)5050 Kl2 Knob-TRANS CONT Lever,Polyurethane
GBV PrimaryColor- Exterior,CyberGray MET KL7 Conversion—PropaneGas (LPGas)
(G)637R KL9 ENG Control- Stop/Startsvs
GCD PrimaryColor- Exterior,BrightWhite(686H) KNV Knob_TRANS CONT Lever,SatinSilver,
GCN PrimaryColor- Exterior,VictoryRed 9260 Chrome
GCO PrimaryColor- Exterior,SCO Yellow(9414) KPK Heater- Oil Pan
PrimaryColor- Exterior,InfernoOrange KPL Cap - FUGI Fill,Locking
GCR MET (502Q) KRK Knob-TRANS CONT Lever,Leather,Satin
PrimaryColor—Exterior,MistyLake Silver,Chrome
GCW ' Met(683R) KTD Key- PrimaryRigid,AdditionalRigid
GEL mangggmor ‘ EX‘e’W»Dynam'cOrange KTF Key- PrimaryFoldable,AdditionalFoldable
PrimaryColor ExteriorSuperRed KTH LockControl-Side DoorLock/Unlock
_ ' . .
GGE (G)717R KTI Klt,Tlre-lnflator
GlY PrimaryColor- Exterior,GalaxySilver KTJ LockControl- Side DoorLock/ Unlock,
MET (519F) TrunkRelease
GJP PrimaryColor- Exterior,Grenada KTK LockControl- Side DoorLock/ Unlock,
Black(446P) RemoteStart
GLF PrimaryColor- Exterior,Space Blue KTL LockControl- Side DoorLock/Unlock,
Metallic819T TrunkRelease,RemoteStart
GMN PrimaryColor—Exterior,Desert ‘ KTM Key- PrimaryFoldable,AdditionalRigid
Bloom(8768) . ..
I I KTN Equtpment- AdditionalKey (NoButtons)
cos 13G”)???
JCO'Or'EXter'Or’Chew Red MET L2| Engine- Gas, 4 Cyl, 1.4L,MFI,L4, DOHC,
FAM O, 74 KW,E85 MAX, GME

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 General information 'l=17

RPO Description
Description
RPO NA3 EmissionSystem—Japan
Engine- Gas, 4 Cyl, 1.4L,MFI,L4, DOHC, (Rear
L2N Lock —ElectricalChild Lock System
FAM O, 74 KW, E20 MAX, GME NCG
DoorLatch)
PDA,
LCU Engine- Gas, 4 Cyl, 1.4L,MFI,DOHC, Certification- Emission,Geographically
FAM AlB, GMDAT RestrictedRegistrationfor Vehicles
upto
DOHC, NE1
LDC Engine- Gas, 4 Cyl, 1.2L,MFI, 14,000 LBS GVW
PT—JV, VariableCamshaftPhasing EmissionSystem—EEC 09
NE9
LDD Engine—Gas, 4 Cyl, 1.4L,MFI,DOHC, EmissionSystem—Federal,NLEV
VariableCamshaftPhasing,FAM 0 NF7
DOHC, VVT, Steering—Power,Non-variableRatio,
Engine- Gas, 4 Cyl, 1.6L,MFl, Intake
NM
Electric
LDE VariableCamshaftPhasing,Variable
Module (VIM) NPH ExhaustSystem- HeavyDuty
DOHC,
LDV Engine- Diesel,4 Cyl, 1.3L,L4, Dl, NQU EmissionSystem—Korean,ULEV
Turbo,55KW, 190NM
DOHC, VVT, NT3 EmissionSystem—EEC 00
Engine- Gas, 4Cyl, 1.6L,MFI,E85
LED
Variableintake Module (VIM), MAX NT4 EmissionSystem—EEC 05
Engine—Gas, 4 Cyl, 1.6L, MFI, E100 MAX NT7 EmissionSystem—Federal,Tier2
LFJ
VehicleDrive—Left HandDrive NU6 EmissionSystem- California,PZEV
LHD Interface,
Engine- Diesel,4 Cyl, 1.3L,CRl,
DOHC, NZA Control- SteeringWheel,Wireless
Controls
LSF Radio & Phone, Handsfree
Turbo-VGT
DOHC,
Engine- Gas, 4 Cyl, 1.4L,MFI,MAX ORN Plant Code - Orion,MI,USA
LUV
Turbo,VVT. ALUM, GME, E85 PZY Plate - Skid Front& Rear
LUW Engine-Gas, 4 Cyl, 1.8L,MFI, 103KW, Q1G Tire All - 185/75R14SL 89H BW
HW1
DOHC, E85 MAX BW AL2
51KW Q1H TireAll —P195/65R15SL 89H
LWD Engine- Gas, 4Cyl, 1.2L,MFI,DOHC, BW HW2
VVT, Q1W Tire All - 195/65R158L91H
LWE Engine-Gas, 4 Cyl, 1.8L,MFI,DOHC, HW3
103KW, GME Q1X Tire All - 205/55R16SL 91H BW
AL3
Transmission- Manual5 Speed, Opel,
65
030 TireAll - P205/50R17SL 88V BW
2ND, 1.323 3RD, 0.946 4TH, BW HW3
M26 MM, 1.96 Q5| Tire All - 205/5OR17SL 89V
0.7565TH,F17 (WR) HW3
Q6K Tire All - 195/65R15SL 91H BW
M97 ShifterInterlock- Brake,TRANS HW4
06L TireAll - 205/55R16SL 91H BW
MDC MoldingB/S Upper- Bright
Brazil, Jack —Mechanical,withTools
MEM Transmission- ManualFWD 5 Speed,UR) Q8E
ALS
180MM,3.9091ST,0.6745TH (F17; QBO Tire All - P185/75R14SL 89H BW
MlCR AL3
MFH Transmission- Manual5 Speed, D16 QLG Tire All —P205l55R16SL 89H BW
X24F BW AL2 (Low
MH9 Transmission- Auto6 Speed, HMD, QZF TireIAll- P195/65R15SL 89H
SHD, Resnstance)
MX3 Transmission—Manual5 Speed,Y4M
1ST 3.667,5TH 0.761 RHD Vehicle Drive—RightHandDrive
HW2 (Low
Transmission—Manual5 Speed, GMDAT, RQ4 TireIAlI- 195/65R15SL 91H BW
D16 Intermediate Semi—wide, 72MM, ReSIstance)
MXP
3.7271ST,0.7635TH Wheel—14X5.5,J,Steel,Design1
Opel, 76.5 RRB
MZ4 Transmission- Manual6 Speed,WR) Wheel—15X6.0,J,Aluminum, Design 1
MM, 3.821ST.0.615 6TH, (M32 RRK
1
Transmission- Manual6 Speed, Opel,
76.5 RRL Wheel - 15x60, J, Steel, Design
MZ7 6TH (M20) 1
MM, 4.2731ST,0.614 RRV Wheel—16x6.0,J,AIuminum,Design
CONT
N08 Lock Control- Fuel Filler Door,REM R87 Wheel —17x65, J, Aluminum,Design1
N12 ExhaustSystem—Rear Exit T39 Lamp- TurnSignal,AUX
N30 SteeringWheel—Deluxe T3U Lamp—FrontFog
Reduced
N33 SteeringColumn—TiltType T3W Lamp ISystem—DaytimeRunning,
IntenSItyLow Beam
N34 SteeringWheel —Leather,3 Spokes Regular
SteeringColumn—Tilt,Telescoping T3X Lamp ISystem—DaytimeRunning,
N37 lntenSItyLow Beam
Steering—Power,Non—Variable Ratio
N40 T43 Spoiler—Rear
N45 SteeringWheel—3 Spokes Acoustical
Alarm—OverspeedWarning,
T44
N54 SteeringWheel—3 Spokes, Sport Headlamps- Halogen
T4A
N81 Tire Spare- Full Size

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
l-‘l8 General information

RPO Description RPO Description

T67 Battery—LN3,FLA, 12V,70AH,512ENCCA UQQ SpeakerSystem—(None)
T83 HeadlampsControl- AutomaticOn - Off UQJ RestraintProvisions- Child,lSOFIX 2
. PointOnly
TB1 Lamp—TaIIandStop,Korea
. RestraintProvisions—Child,ISOFIX 2 Point
TBU P'am COde' 6 OCtOberC'tynEgypt UQK Point/LATCH (INC2 TopTether
OnIIy,
TCU LicensePlate- Front& RearMounting,ECE POIntS)
TD1 Reflector—SafetyTriangle RestraintProvisions- Child,ISOFIX 2 Point
_ . UQL Only,Point/ LATCH (WC 3 TopTether
TL6 GrIlle~RadIator,Black . Points)
TM7 Battery—‘LN2,FLA, 12V,6OAH,438ENCCA U88 Radio_AM/FMStereo,Seek /Scan,CD,
TN9 Battery—LN1,FLA, 12v,50AH,375ENCCA AutoTone:ClockvETR, MP3. RDS
TR1 Lamp_Tail& Stop USR Receptacle- USB
HeadlampsControl_ LevelingSystem, UTJ TheftDeterrent—Electrical,Unauthorized
TRS Manual Entry
_ ' L I TheftDeterrent- Mechanical,Double
1:: :1“: 8:111:51?” .
U04 HPOIeréI eIar,Nt I ga e, por UW4 SpeakerSystem~4, Custom
80m; Inge (In: t K'l t UW6 SpeakerSystem—6, Custom‘
U18 Lpee (”Indef—I25”:8” ’ 'IomeIer UYO Battery—LNO,FLA, 12v,4OAH,300ENCCA
025 Cgfifie‘synter'or’ear °mparme” ' v22 Grille—Radiator,Chrome
U2K DigitalAudioSystem_S-Band V48 Coolant—EngineMaximumProtection
U58 RadioFaceplate—IntegratedCenterConsole V5M Calibration‘ TOM,NeutralldleControl
U68 Center
Display—DriverInformation V01 ProvisionOptions‘ Europe
U71 Antenna_ RoofIRadio VDB Provisions—FirstAid Kit
Antenna_Roof Radio GPS Phone, VEE BumperFront- BodyColor,Front& Rear
UBA ’ ’ ’ . . _
S-BandXM VGC PaIntEtchPreventIve
Protector- FIIm,
UC1 Speedometer—Instrument, Miles VHY Protector_ BodySheetMetal,High
U03 Control- SteeringWheel,Radio& Phone, CorrOSIon PreventIve
RedundantControls VK8 Holder~Eyeglasses
UD7 Sensor Indicator_ Rear ParkingASSiSt VKD LicensePlate- Front& Rear Mounting,SAE
UDB DisplayInstrument —DriverInfoEnhanced t Graph't
pane|Center _Instrumen, Ie
(Segmented) VMO SilverMET
DisplayInstrument —TripOdometer Bumper- FrontLowSpeed,Rear Light
UDG (Segmented) VMT Weight
UE1 CommunicationSystem-Vehicle,G.P.S.1 VYK panelCenter_instrument,Jet Black
UE3 CommunicationSystem-Vehicle.G.P.S.3 W1Y Control_SteeringWheel,Radio,Redundant
UG7 TheftDeterrentI-VehicleTrackingand Controls
RestartPrevent'on WU5 Switch—IlP LP Dimmer
UGM Sensor Equipment-OutsideAir Temperature ChaSSIS -
I, EngIne
- _ p rotect'IonK't
Sensor XL4 Compartment
UHO Indicator—Seat BeltWarning, LH XL7 FrequenciesRating_315MHZ,Long
UH1 Indicator—Seat BeltWarning, RH D'Stance '
UH5 Indicator— Seat BeltWarning,RearSeat XL8 FrequenciesRating' 433 MHZ
Radio_AM/FMStereo,Seek/Scan,CD, XX7 Radio—Provisions,installation,VAR3
UH7 ETR: Clock DSPIMP3 WMA USB. AUX/ YF5 Certification- Emission,California
IN,WirelessInterface . .
_ , , , YG3 Ornamentatlon —EXTR, Head&TaIlLamps,
UJ2 lndIcator- EngIneOIILIfe ChromeBezel
UJM TirePress Indicator- ManualLearn YG5 OrnamentationI- EXTR, Head&TailLamps,
UL5 Radio_(None) HIghGloss FInIsh
UM7 Radio—AM/FMStereo,Seek/Scan, ZAA TireSpare‘ Compact
Clock, ETR
UPF WirelessInterface- ShortRange,VoiceREC

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 General lntormation 1:19

Fasteners

Metric Fasteners
using the
This vehicle provides fastener dimensionsapproximate
metric system. Most metric fasteners are
fasteners. Make
in diameter to equivalent English
replacements using fasteners of the same nominal
diameter, thread pitch, and strength.
metric fasteners
A number marking identifies the OE number also
except cross-recess head screws. The
indicates the strength of the fastener material.
identifies a
A Posidrive® or Type 1A cross-recess use a
metric cross-recess screw. For best results,
or equivalent, in
Type 1A cross-recess screwdriver,
Posidrive® recess head screws.
American
GM Engineering Standards and North lSO-defined
Industries have adopted a portion of the
was to
standard metric fastener sizes. The purpose
fastener sizes used while
reduce the number of thread size.
retaining the best thread qualities in each nearly the
screw, with
For example, the metric M6.0 X 1 replaced the
same diameter and 25.4 threads per inch
thread pitch is
English 1/4—20and 1/4—28screws. The thread
coarse and fine
midway between the English
pitches.
Fastener Strength Identification

171891

Class)
Legend
Class) (3) English Bolt, Grade7 (Strength
(1) English Bolt, Grade 2 (Strength (4) English Bolt, Grade8 (Strength Class)
Grade 5 (Strength Class)
(2) English Bolt,

(US/Canada)
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2013 (5377994)
Manual
Service
'l -20 General lnformation
(5) Metric Nut, Strength Class 9 (6) Metric Bolts, Strength Class increases as
Numbers Increase

The most commonly used metric fastener strength order to determine if the fastener may be reused and
property classes are 9.8 and 10.9. The class the applicable thread—Iockingcompound to apply to the
identification is embossed on the head of each bolt. fastener.
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. ~~M
The correct fasteners are available through GM SPO. 12345
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
6 7 9
The metric fasteners on GM products are designed to
new, international standards. The following are the
common sizes and pitches, except for special
applications:
~ M6.0X1
° M8X1.25
Legend
- M1OX1.5
(1) Prevailing Torque Nut, Center Lock Type
- M12X1.75 (2) Prevailing Torque Nut, Top Lock Type
- M14X2.00 (3) Prevailing Torque Nut, Nylon Patch Type
- M16X2.00 (4) Prevailing Torque Nut, Nylon Washer
InsertType
Prevailing Torque Fasteners
(5) Prevailing Torque Nut, Nylon InsertType
Prevailing torque fasteners create a thread interface (6) Prevailing Torque Bolt, Dry Adhesive
between the fastener and the fastener counterpart in Coating Type
order to prevent the fastener from loosening. (7) Prevailing Torque Bolt, Thread Profile
All Metal Prevailing Torque Fasteners Deformed Type
(8) Prevailing Torque Bolt, Nylon Strip Type
These fasteners accomplish the thread interface by a
designed distortion or deformation in the fastener. (9) Prevailing Torque Bolt, Out-of—RoundThread
Area Type
Nylon Interface Prevailing Torque Fasteners
These fasteners accomplish the thread interface by the A prevailing torque fastener may be reused ONLY if:
presence of a nylon material on the fastener threads. 1 The fastener and the fastener counterpart are
clean and not damaged
Adhesive Coated Fasteners
0 There is no rust on the fastener
These fasteners accomplish the thread interface by the - The fastener develops the specified minimum
presence of a thread-Iocking compound on the fastener torque against its counterpart prior to the fastener
threads. Refer to the appropriate repair procedure in seafing

Metric Prevailing Torque Fastener Minimum Torque Development

Specification
Application Metric I English
All MetalPrevailingTorqueFasteners
6 mm 0.4NW 4 lbin
8 mm 0.8N-m 7 lbin
10mm 1.4N-m 12Ibin
12mm 2.1N-m 19|bin
14mm 3N°m 27lb in

(US/Canada)
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2013 (5377994)
Manual
Service
 General Information 1:21

Minimum Torque Develop ment (cont'd)

Prevailing Torque Fastener
Metric Specification
___’_______._._——’——-
Metric English
Application 37lb in
4.2N-m
16mm 7N-m 52 lb In
20 mm 10.5N-m 93lb In
24 mm
Fasteners
Nylon InterfacePrevailingTorque 0.3N-m 3 lb in
5 mm 0.5Nm 5 lb in
8 mm 1.1N-m 10lbin
10mm 1.5N-m 13lbin
12mm 2.3N'm 20lb in
14mm 3.4N-m 301bin
16mm 5.5N-m 49lb in
20 mm 8.5N-m 75lb in
24 mm

Minimum Torque Development

Prevailin 9 Torque Fastener
English Specification
EngHsh
Application

All MetalPrevailingTorqueFasteners 0.5N-m 4.5lb in

1/4in 0.8N'm 7.51bin
5/16in 1.3N'm 11.5lb in
3/8in 1.8N-m 16|bin
7/16in 2.3N'm 20lb in
1/2in 3.2N°m 28lb in
9/16in 4N1m 36lb in
5/8in 7 N-m 54lb in
3/4in
Fasteners
Nylon InterfacePrevailingTorque 0.3N-m 3 lb in
1/4in 0.6N-m 5|bin
5/16in 1N°m 9 lb in
3/8in 1.3N-m 12|bin
7/16in 1.8N-m 16lb in
1/2in 2.5N-m 22lb in
9/16in 3.4N-m 30lb in
5/8in 5N-m 45 lbin
3/4in

—
2013 (US/Canada)
Sonic (5377994)
Manual
Service
1122 General information

Thread Inserts
General Purpose Thread Repair Kits.
These kits are available commercially.
Repair Procedure

W0

:1 \

4963
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.
4962 5. Lubricate the insert with light engine oil, except
Warning: Refer to Safety Glasses Warning on when installing in aluminum and install the insert.
page 0-5.
6. lfthe tang of the insert does not break off when
Note: Refer to the thread repair kit manufacturer backing out the installer, break the tang off with a
instructions regarding the size of the drill and tap drift.
to use.
Avoid any buildup of chips. Back out the tap every few Registered and Non-Registered
turns and remove the chips. Trademarks
1. Determine the size, the pitch, and the depth of the Listed below are Registered Trademarks (®)or
damaged thread. Ifnecessary, adjust the stop Non—RegisteredTrademarks (TM)which may appear in
collars on the cutting tool and tap to the required this service manual.
depth.
2. Drill out the damaged threads. Clean out any Registered and Non-Registered
chips. Trademarks
3. Lubricate the tap with light engine oil. Tap the hole. A
Clean the threads.
Ac®
ACCUTURN®
ACDelco®
ActiveFuelManagementTM
Acuzinc®
Airbank®
Allison®
AMMCO®
AUTOFUSE®
AUTOTRAC®

Bendix®
Bluetooth®
BON—AMI®
Bosch®

2013
—
Sonic
(US/Canada)
Service
Manual
(5377994)
 General information 1423

and Non-Registered Registered and Non-Registered

Registered
(cont‘d) Trademarks (cont'd)
Trademarks
H
Bose®
C HomelinkTM
Caterpillar® HYDRA-MATIC®
I
CAT®
C-Quam® Illumination®
D INSTA-TRAc®
Delco® Intune®
L
DelcoBose®
Delco Electronics® LOCTITETM
Delco Freedom® LordFusorTM
. M
DelcoLoc II®
Delco Moraine® MAGNASTEER®
DelcoRemy® Maxifuse®
DelcoSound® Metripack®
Delco Supreme® Micropack®
DelcoTech® Minifuse®
DELCORE® Mr Goodwrench®
N
Delphi®
DEx-COOL® Northstar®
O
DEXOIL®
DEXRON® OnStar®
DEXSTEERTM Optikleen®
P
DNR®
Dolby® PASS-KEY®
DR® PASS-KEYII®
Duracell® PASSLOCKTM
Duraguard® PK3®
Durastop® Posidrive®
DuramaxTM Pro®
E Q

EatonCorporation® Quad4®
R
EMD®
ETR® RAINSENSETM
F RapidFire®
s
FLO—LITE®
G ScotchBriteTM
GeneralMotors® ScotchguardTM
GM® Signals®
GM GoodwrenchService® SikkensTM
GM Optikleen® Soft—Ray®
GM PartsTM Solar—Ray®
GM Pass® Stabilitrak®
GM Ultralite® Sunrayce®
GMAC® Superlube®
Goodwrench® Syclone®
GTP®
“Mmmw
—
2013 (US/Canada)
Sonic (5377994)
Manual
Sen/ice
'l 24 General information

Registered and Non-Registered

Trademarks (cont'd)
T

Tech2®
Techline®
Teflon®
Tefzel®
Theft—|®
Theftlock®
Tiltmaster®
TORX®
Transjel®
Transguide®
TwilightSentinel®

Ultralite® 2760548
Caution: Failure to properly support the Remote
Keyless Entry (RKE) transmitter assembly while
Velcro® replacing the key blade may cause internal damage to
the transmitter assembly.
WeatherpackTM 1. insert the RKE transmitter in the fixture as shown.

Door Lock and Ignition Lock Folding

and Non-Folding Key Cutting
High Security keys are available from the service parts
system.
Obtain the key code from the security card or from the
GM Dealer World, Parts, Key Code Look Up system.
Ifyou have the key code and access to a Triax—E.,BD
Laser or other code key cutting machine from the GM
Dealer Equipment Catalog, you may cut a new key.
Ifyou have the original key and access to a Matrix 8,
BD Laser or other key duplicating machine, you may
duplicate the key.
Ifyou do not have a high security key cutting machine,
order the side out key from the service parts system.
Include the key code in the NOTE field. Indicate the
timing and the method of the shipment.
inspect the new key operation in the lock cylinder.
Ensure the new key operates effectively.
2760553
Door Lock and Ignition Lock Folding Note: Itmay be necessary to dress the pin drift on a
Key Blade Removal and Installation grinder to maintain the diameter in order to drive the pin
through the housing.
Special Tools
2. Using the 80-51098 fixture, drive the retention pin
80-51098 Flip Key Blade Fixture from the transmitter assembly as shown.
For equivalent region tools, refer to Special Tools on
page 1—32.

(US/Canada)
~Sonic
2013 (5377994)
Manual
Service
 General lnior‘mation 1225

2760561
2760557
the roll pin flush
transmitter 6. Using the 30-51098 fixture, drive
3. Remove the key blade from the to the surface. .
assembly.
4. Install the coded blank into the transmitter blade
assembly, insure the indentation on the key
faces the retention pin.

2760560
chrome
Note: Use caution not to damage the surface,
plating, in the following steps.
pin half way
5. Using needle nose pliers, insert the
into the transmitter assembly.

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
1226 General information

Front Side Door Lock Cylinder 5. Turn the cylinder so the side with the 4 tumbler
spring wells faces up. This side uses right
Coding (Free Wheeling) tumblers.
Special Tools 6. Insert the tumbler springs into the 4 spring pockets.
80—49753Assembly Tool 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).

2196837
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. 2197418
Note: All lock cylinders for side milled keys have right 12. Load the cylinder into the BO—49753assembly tool
and left tumblers. The location of the tooth of the so that the clutch (1) indexes with the notch in the
tumbler determines whether it is right of left. opening of the tool (2).
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. Insertthe 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.

(US/Canada)
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2013 (5377994)
Manual
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 General information 1127
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. Insertthe key into the lock and function the lock to
check for proper assembly and smooth operation.

Front Side Door Lock Cylinder

Coding (Non Free Wheeling)

2197416
13. Load the assembly tool with the lock cylinder into a
vice and tightenthe vice ONLY enough to hold the
tool and lock the cylinder in place.

2225941
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.
2196837
1. Hold the door lock cylinder (1) so the side with the
14. insert the roll pin (7) into the driver (6) and install it 4 tumbler spring pockets faces up, pocket nearest
using a 1/16inch pin punch. to the cylinder head.
15. Insert the buffer(8) in the case (9),verify the buffer 2. insert the tumbler springs (2) into the 4 spring
is properly seated. pockets. This side uses left tumblers.

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128 General information
3. Install the tumbler (3) for key cut position one in the 12. With the lock cylinder assembly installed in the
slot nearest to the front of the lock cylinder. Install case (5), install the retainer (6) and stake the
the remaining tumblers, key cut positions 3, 5, and retainer in place using a small punch and hammer
7, following the key code and same process. Press to peen the case material onto the exposed ends of
the tumblers in place until they are secure. the installed retainer (6).
4. Check the correct loading of the tumblers by 13. Insert the key into the lock and function the lock to
inserting the key into the cylinder. All tumblers check for proper assembly and smooth operation.
should be flush with the lock cylinder body.
5. Turn the cylinder so the side with the 4 tumbler Lock Cylinder Coding - Ignition
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. Insertthe sleeve (4) onto the cylinder assembly.

2197408
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 seIf-retaining.Itfollows the key code with
the first tumbler being the first depth of the key code,
closest to the head of the key.
2225941
11. Insert the assembly into the case (5).

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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. Insertthe tumbler
spring into each of the spring pockets of the
cylinder assembly. This side of the cylinder used
right tumblers.
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General information 1 =29
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.
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.
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.
. Insert the cylinder into the sleeve (4) as shown in
the print. Make sure the actuator stays located
properly in the cylinder.
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. Insertand 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.
'l=30 General information

Rear Compartment Lid Lock Cylinder Coding

The rear compartment lid lock cylinder uses 7 of the
7 cut positions. The tumbler positions are staggered
from side to side, 4 on one side and 3 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 or left.
Illustrations in this procedure show the righttumblers
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. Tumbler spring (2) and tumbler (3) are to be
assembled into the cylinder(1). In this case start
with the tumbler nearest the cylinder head and
work through until the last tumbler at the base. Use
the key as a tool by pushing it in step by step to
hold the already assembled tumblers in place.
2510231
. Check the correct loading of the tumblers by
inserting the key into the cylinder. All tumblers
should be flush with the lock cylinder body.
Assemble the restoring spring (4) onto the rear of
the cylinder.
Tape the pad (5) onto the housing (6).
Grease the housing.
Insertthe lock cylinder (1) into the housing (6).
Remove the key from the cylinder.
Install the lever (7) onto the end of the cylinder(1).
. Attach the E-ring (8) to the cylinder, then crimp it to
retain the lever assembly.
Snap the rod retainer (9) into the hole in the
|ever(7).
10. Insertthe key into the lock and function the lock to
check for proper assembly and smooth operation.

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 General information 1:131

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 body and structure depending on lifting
equipment used. Refer to the manufacturer
recommendation for their applications of low profile lift
arms system for their lifting equipment.

tit

1S.

Danger: 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.
Danger: 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 orjacking 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 orjacking
procedure.
- The lifting equipment or thejacking 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 orjacking equipment manufacturer.
2496986
- Perform the vehicle lifting orjacking procedure on
a clean, hard, dry, level surface.
- Perform the vehicle lifting orjacking procedure
only at the identified lift points. DO NOT allow the
lifting equipment orjacking 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/orthe vehicle contents.
Lift
Vehicle Lifting— Frame Contact
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 liftingthe vehicle with a frame—contactlift, place
the rear lift pads on the rocker outer panel weld flange,
as shown.

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1-32 General information
Vehicle Jacking Special Tools Ordering Information
Caution: When you arejacking the vehicle at the front The special service tools shown in this service manual
locations, be certain that the jack or thejack lift pad that have product numbers beginning with J, BO, GE,
does not contact the front fascia, front fascia air dam, CH, DT, EN, EL, SA, OR KM are available for
or the front fenders. Ifsuch contact occurs, vehicle worldwide distribution from:
damage may result. When jacking at selected front SPX Service Solutions
locations additional clearance may be required for the Kent-Moore Tools
jacking points. 28635 Mound Road
Note: When you are lifting a vehicle with a service Warren, MI, USA, 48092-3499
jack, block the wheels at the opposite end from which
you are lifting. Usejack stands to provide additional Phone: 1-800-GM-TOOLS (US & Canada)
support. Monday through Friday
8:00 am—7:00pm Eastern Standard Time
When using a service jack under the front of the vehicle Fax: 1-800-578-7375 or 586-578-7321
use one of the following locations: www.gmspeciaIservicetools.spx.com (Us &
Canada only)
Front of Vehicle
The TECH 2, MDl diagnostic tools & accessories,
Place the service jack pad in the same location as dealer equipment
shown for the front lift pads.
Dealer Equipment and Services
Rear of Vehicle 5775 Enterprise Dr.
Note: Placejackstands ONLY under strong and stable Warren, MI, U.S.A, 48092-3463 ,
vehicle structures. Phone: 1-800-GM-TOOLS (US & Canada)
Place the service jack pad in the same location as Monday through Friday
shown for the rear lift pads. 8:00 am~6:00pm EST
Fax: 1—586—578-7205
Special Tools and Equipment www.GMDEsolutions.net (US only) or
www.des—canada.ca(Canada only)

Illustration Tool Numberl Description

21-1
_ 30-51098
Flip Key BladeFixture

2902359

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 Aieri‘nd Noise ‘1-33

AirNVind Noise
Information and
Diagnostic
Procedures
Aierind Noise
Special Tools
° CH-39570 Chassis Ear
- GE—41416Ultrasonic Leak Detector
Warning: An assistant should drive the vehicle
while the technician checks for the location of the
reported condition. Otherwise, personal injury
could result.
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 untilthe 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
chassis ear or GE-41416 leak detector.
1 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 vehicles
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 weather—strips
- 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.
Test
Air Pressure
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.

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1:34 Air/Wind Noise

Soap Suds or Bubble Test Interior Windnoise

1. Mask off the pressure relief valves. Warning: An assistant should drive the vehicle
2. Close all the windows and the doors. while the technician checks for the location of the
3. Turn the vehicles ventilation fan to the on position, reported condition. Otherwise, personal injury
with the selector on high speed and in the could result.
defrost mode. Interiorwindnoise is not heard when the window is
4. Unlock and close the doors. lowered. Interiorwindnoise is caused by the air leaving
5. Apply the soap solution to the potential leak areas. the inside of the vehicle through a seal or a seam.
6. Look for bubbles revealing escaping air. 1. Tape over the relief valves to cause added air
pressure within the vehicle.
Repair Instructions 2. Test drive the vehicle and listen for windnoise or a
whistle.
3. Pull the vehicle over and make the temporary
Exterior Windnoise repairs using masking tape. Ifyou cannot
determine the source of the windnoise, perform
Warning: An assistant should drive the vehicle one or more of the following diagnostic tests:
while the technician checks for the location of the
reported condition. Otherwise, personal injury ' Air Pressure Test on page 1-33
could result. - Soap Suds or Bubble Test on page 1—34
Exterior windnoise is louder when the vehicle is driven - Tracing Powder or Chalk Test on page 1-33
with one or more windows down. Exterior windnoise
occurs when air passes over the body panels, the Special Tools and Equipment
seams, or the openings. Use the following items during
the test drive in order to aid in the detection of leaks:
Illustration Tool Numberl Description
' Mechanic's stethoscope or heater hose
- Masking tape—51mm (2 in) width
- Strip caulk
° A water soluble marking pencil
1. While driving, determine the location of the exterior CH—39570
windnoise by lowering one window at a time. Ifthe J-3957O
location corresponds with the condition in step 2, Chassis Ear
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 643842
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. GE-41416
5. When all the reported leak conditions are located, J-41416
make permanent repairs using the proper UltrasonicLeakDetector
alignment techniques and the sealing materials.

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 Maintenance and Lubrication L35

Maintenance and Lubrication

Specifications

Approximate Fluid Capacities

The following approximate capacities are given in
English and metric conversions. All capacities are
approximate. When adding, be sure to fill to the
approximate level as recommended in this manual.
Recheck fluid level afterfilling.

Specification
Metric I English
Application
AutomaticTransaxleFluid(MH9)
7.5liters l 8.0quarts
6T30
ManualTransaxleFluid
1.9liters 2.0quarts
M20/M32(M27)
1.8liters 1.9quarts
D16(MFH)
1.6liters 1.7quarts
F17—5(M26/MEM)
0.6liters 0.63quarts
BrakeFluid
0.6liters 0.63quarts
PowerSteeringSystemFluid
EngineCoolant
4.7liters 5.0quarts
1.2L Engine
6.6liters 7.0quarts
1.3L Engine
6.0liters 6.3quarts
1.4L Engine
5.6liters 5.9quarts
1.6L Engine
6.0liters 6.3quarts
1.8L Engine
EngineOil withFilter
3.75liters 4.0quarts
1.2L (LDC/LWD)
3.5liters 3.7quarts
1.3L (LDV/LSF)
4.0liters 4.3quarts
1.4L (L2l/LDD)
4.5liters 4.8quarts
1.6L (LDE)
4.5liters 4.8quarts
1.8L (LUW/LWE)

Maintenance Items
Fluid and Lubricant
Recommendations The Normal Maintenance Replacement Parts
information will only be found in the Owner's Manual.
The Recommended Fluids and Lubricants information Refer to the Maintenance Schedule subsection of the
will be found in the Owner's Manual. Refer to the Owner's Manual.
Maintenance Schedule subsection of the Owner's You may be able to use the search information function
Manual. using the words Replacement Parts.
You may be able to use the Search information function
using the words Fluids or Lubricants.
Most transmission, transfer case, front and rear axle
lubricant recommendations will be found in those
service categories (subsections).

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l=36 Maintenance and Lubrication

Maintenance Refer to the Maintenance Schedule subsection of the

Owner's Manual, or you may be able to use the search
information function using the words Scheduled
Maintenance.
Maintenance Schedule
The Maintenance Schedule information will only be
found in the Owner's Manual.

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 Squeaks and Rattles 137

Squeaks and Rattles

Special Tools and Equipment

Diagnostic Information and
Procedures
Illustration Tool Numberl Description

Squeaks and Rattles

Note: Squeaks and rattles are caused by improperly
controlled relative motion between vehicle components.
CH-39570
There are 4 ways to prevent squeaks and rattles.
J—3957O
. Attach the component that squeaks or rattles Chassis Ear
securely.
- Separate the components that squeak or rattleto
prevent contact.
0 Insulate the components that squeak or rattle. 643842
- Insulate low uniformfriction surfaces to eliminate
stickslip motion.

GE-41416
J—41416
UltrasonicLeak Detector

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1:38 Vibration Diignosis and Correction

Vibration Diagnosis and Correction

Specifications

Tire and Wheel Runout Specifications

Specification
Application Metric English
TireandWheelAssembly—LateralandRadial
Off-Vehicle 1.27mm 0.050in
On-Vehicle 1.52mm 0.060in
Wheel,Aluminum
Lateral 0.762mm 0.030in
Radial 0.762mm 0.030in
Wheel,Steel
Lateral 1.143mm 0.045in
Radial 1.015mm 0.040in
WheelHub/AxleFlange—Guideline 0.132mm 0.0052in
WheelStud—Guideline 0.25mm 0.010in

- Vibrate Software Description and Operation on

Diagnostic Information and
Procedures
Vibration Diagnosis, Starting
and Correction
The information contained in this Vibration Diagnosis
and Correction section is designed to cover various
vehicle designs and configurations. Not all content will
apply to all vehicles.
Note: The following steps must be completed before
using the analysis tables or the symptom tables.
1. Perform the Vibration Analysis - Road Testing on
page 1—39table before using the other Vibration
Analysis tables or the Symptom tables in order to
effectively diagnose the customer's concern.
The use of Vibration Analysis —Road Testing will
first provide duplication of virtually any vibration
concern and then identify the correct procedure for
diagnosing the area of concern which has been
duplicated.
2. Review the following Vibration Diagnostic Process.
3. Review the general descriptions to familiarize
yourself with vibration theory and terminology, the
EL—38792—AElectronic Vibration Analyzer (EVA) 2,
and the EL-38792—VS Vibrate Software.
Reviewing this information will help you determine
whether the condition described by the customer is
a potential operating characteristic or not.
Refer to the following:
- Vibration Theory and Terminology on page 1—78
- Electronic Vibration Analyzer (EVA) Description
and Operation on page 1-88
page 1-90
0 Reed Tachometer Description on page 1-90
Vibration Diagnostic Process
Note: Using the following steps of the vibration
Point,
diagnostic process will help you to effectively
narrow-down and pin—pointthe search for the specific
source of a vibration concern and to arrive at an
accurate repair.
1. Gather specific informationon the customer's
vibration concern.
2. Perform the road testing steps in sequence as
identified in Vibration Analysis —Road Testing in
order to duplicate the customer's concern and
evaluate the symptoms of the concern under
changing conditions. Observe what the vibration
feels like and what it sounds tike. Observe when
the symptoms first appear, when they change, and
when they cease.
3. Determine if the customer's vibration concern is
truly an abnormal condition or something that is
potentially an operating characteristic of the
vehicle.
4. Systematically eliminate or “rule-out”possible
vehicle systems.
5. Focus diagnostic efforts on the remaining vehicle
system and systematically eliminate or “rule—out”
possible components of that system.
6. Make a repair on the remaining component,
or components, which have not been eliminated
systematically, and must therefore be the cause of
the vibration.

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 Vibration Diagnosis and Correction 1’39

7. Verify that the customer's concern has been Vibration Analysis - Road Testing
eliminated or at least brought to an acceptable
level. Test Description
8. Again perform the road testing steps in sequence The numbers below refer to the step numbers on the
as identified in Vibration Analysis - Road Testing in diagnostic table.
order to verify that the vehicle did not have more
5. Obtaining rotational speed for the components
than one vibration occurring. rotating at tire/wheel speed is critical to
Preliminary Visual/Physical Inspection systematically eliminating specific vehicle
component groups. These component rotational
0 inspect for aftermarket equipment and speeds can be generated by using the
modifications which could affect the operation of EL—38792-VSVibrate Software, or through
the vehicle rotating component systems. calculating them manually.
- Inspect the easily accessible or visible Note: Be certain to OBSERVE for disturbances that
' components of the vehicle rotating component match the customer description.FIRST, then look at the
systems for obvious damage or conditions which EL-38792-A Electronic Vibration Analyzer 2 (EVA 2)
could cause the symptom. frequency which corresponds with that disturbance.
- Inspect the tire inflation pressures forthe proper
pressure. 10. Proper location of the EL—38792-AElectronic
Vibration Analyzer 2(EVA 2), sensor onto the
Diagnostic Aids component which is most excited by the vibration
disturbance is critical to obtaining an accurate
Impropercomponent routing or isolation, frequency reading.
or components which are worn or faulty may be the
cause of intermittentconditions that are difficult to This test will duplicate virtually any disturbance
duplicate. Ifthe vibration concern could not be which occurs while the vehicle is in motion.
duplicated by following the steps of the Vibration 11. Accelerate to a speed high enough above the
Diagnostic Process, refer to Vibration Diagnostic Aids speed of the disturbance to allow for the time
on page 1-60. needed to shift into NEUTRAL and for the engine
to decrease in RPM to idle speed, before coasting
down through the disturbance range.
12. 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
1 DidyoureviewtheDiagnosticStartingPoint—VibrationDiagnosis? Go to Step2 -
DidthecustomerconcernindicatethatthevibrationoccursONLY
whilethevehicleis standingstill? Go to Step6 Go to Step3
Visuallyinspectthe tireandwheelassemblies,steering
componentsandsuspensioncomponentsforanypossiblefaults.
Are thetireandwheelassemblies,steeringcomponentsand
suspensioncomponentsin goodworkingcondition? Go to Step5 Go to Step4
Note: Do NOToperatethevehicleuntilthefaultsarecorrected.
Correctthefaultswiththetireandwheelassemblies,steering
components,and/orthesuspensioncomponentsbefore
proceeding.
Didyoucorrectthefaultswiththetireand wheelassemblies,
steeringcomponents,and/orthesuspensioncomponents? Go to Step5 Go to Step3
1. Obtainthedriveaxlefinaldriveratio.
2. IftheEL-38792-VSVibrateSoftware,is available,obtainthe
transmissiongearratios.
3. IftheEL-38792-VSVibrateSoftwareis NOTavailable,take
noteofthetiresize oneachaxle,thencalculatethetire
rotationalspeedforeachsize tireused.Referto Component
RotationalSpeed Calculationonpage 1-41.
DidyouobtainthepowertrainratiosforusewiththeEL-38792—VS
VibrateSoftware,or calculatethecomponentrotationalspeeds,
if EL-38792-VSVibrateSoftwareis NOTavailable? Go to Step6
1. Installa scantool.
2. Withthescan tool,bringupthePowertrainControlModule
datalistandselectEngineSpeed.
Isthescantooloperatingproperly? Go to Step7

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140 Vibration Diagnosis and Correction

Vibration Analysis - Road Testing (cont'd)

Step Action Yes No
UsingtheEL-38792-AElectronicVibrationAnalyzer2 (EVA2),is
thepreferredmethodforgatheringnecessaryvibration
frequencydata.
IftheEL-38792-AElectronicVibrationAnalyzer2 (EVA2) is not
available,the necessaryvibrationfrequencydatawillhave to be
obtainedbasedon symptomsobservedduringtesting.Review
Symptoms- VibrationDiagnosisand Correctiononpage 1—62 to
becomefamiliarwiththepossiblefrequencyranges.
is theEL-38792-AElectronicVibrationAnalyzer2 (EVA2) available
foruse? Go to Step8 Go to Step9
‘ InstalltheEL-38792-AElectronicVibrationAnalyzer2 (EVA2). Go to Electronic
ls theEL-38792-AElectronicVibrationAnalyzer2 (EVA2)operating VibrationAnalyzer
properly? (EVA)Descriptionand
Operationon
Go to Step9 page 1-88
DidthecustomerconcernindicatethatthevibrationoccursONLY Go to Vibration
whilethevehicleis standingstill? Analysis-Engineon
page 1-48 Go to Step 10
1. lnstalltheEL-38792-AElectronicVibrationAnalyzer2 (EVA2)
sensor,if available,tothecomponentidentifiedbythe
customeras mostrespondenttothevibration.Ifnocomponent
was identified,installthe EL-38792-AElectronicVibration
Analyzer2 (EVA2)sensor,if available,to thesteeringcolumn.
Youmayhaveto movethesensortootherlocationslater.
2. Selecta smooth,levelroadandslowlyacceleratethe vehicle
upto highwayspeed.
3. Observethevehiclefordisturbancesthatmatchthe customer
descriptionandnotethe followingconditions:
10 - Thevehiclespeed
- TheengineRPM
- Thetransmissiongearrangeand thespecificgear
- Thevibrationfrequencyreading,ifdetectedbythe
EL-38792-AElectronicVibrationAnalyzer2 (EVA2)
- Thefeel and/orsoundof thedisturbance
4. Ifthevibrationseemsto excitea particularcomponentofthe
vehiclemorethanthesteeringcolumn,thenmovethe
EL-38792-AElectronicVibrationAnalyzer2 (EVA2)sensor,
ifavailable,ontothatcomponentandrepeatsteps2 and3. Go to Vibration
DiagnosticAids on
Wereyouable toduplicatethecustomerconcern? Go to Step11 page 1-60
1. Acceleratethe vehicleto a speedhigherthanthespeedat
whichthedisturbanceoccurs.
Note: Ifthevehicle is equippedwithan automatictransmission,let
11 thevehiclecoastto a stopbeforeshiftingbackintogear.
2. Shiftthevehicle intoNEUTRAL andallowthe vehicleto coast
downthroughthedisturbancerange.
Doesthedisturbancestilloccurwhilecoasting-downin NEUTRAL? Go to Step13 Go to Step 12
1. Selecta smooth,levelroadandslowlyacceleratethe vehicle
uptothespeed atwhichthedisturbanceoccurs.
2. Decelerateandsafelydownshiftby onegearrange.
12 3. Operatethevehicleat thesameVEHICLE SPEED at which
thedisturbanceoccurs. Go to Vibration
Analysis- Huband/or Go to Vibration
Doesthesame disturbancestilloccurwhilegoingthesame vehicle Axle Inputon Analysis—Engineon
speedin a lowergear range? page 1—46 page 1-48
IftheEL-38792-AElectronicVibrationAnalyzer2(EVA 2) is not
available,referto Symptoms- VibrationDiagnosisand Correction
13 onpage 1-62. Go to Symptoms-
VibrationDiagnosis
DidtheEL-38792-AElectronicVibrationAnalyzer2 (EVA2)detecta andCorrectionon
dominantfrequency? Go to Step14 page 1-62

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)

Vibration Analysis - Road
Step Action
1. Ifthe EL-38792-VSVibrateSoftwareIS available,use the
‘ driveaxle finaldrive ratio,the specifictransmissiongearratio,
andthe engineRPM to makea comparisontothe dominant
frequencyreadingrecorded.
14 Ifthe EL-38792-VSVibrateSoftwareis NOTavailable,
comparethedominantfrequencyreadingrecordedto the
componentrotationaldatawhichyou calculatedpreviously.
Doesthefrequencydataclearlyfallwithinthetire/wheel
parametersONLY?
Component Rotational Speed
Calculation
Special Tools
EL—38792—A Electronic Vibration Analyzer (EVA) 2
For‘equivalent regional tools, refer to Special Tools and
Equipment on page 1-91.
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 kmlh
(5 mph). Use the Enter key to advance and the Exit key
to backup.
1. On the Main Menu screen, select Auto Mode.
2. On the Suspected Source screen, select Vehicle
Speed.
3. On the Tire Info Source screen, select Manual
Entry.
4. On the Tire Width screen, enter the specific width
of the tires.
For example: For a P245l45/R18 tire, enter 245.
5. On the Aspect Ratio screen, enter the specific
aspect ratio of the tires.
For example: Fora P245l45/R18 tire, enter 0.45.
6. On the Rim Diameter screen, enterthe specific rim
diameter size.
For example: For a P245l45/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 04518.0 —FrontWheel Drive.
Itthe tire size displayed is correct, press Enter.
9. On the Vehicle Speed Units screen, press Enter,
disregard mph or kmlh.
10. Press the Exit key several times slowly while
watching the backwards progression of the
screens. Stop at the Tire Info Source screen.
(US/Canada)
-Sonic
2013 (5377994)
Manual
Sen/ice
Vibration Diagnosis and Correction '1=41
Testing (cont'd)
Yes No
Go to Symptoms-
Go to Vibration VibrationDiagnosis
Analysis—Tireand and Correctionon
Wheelon page 1-43 page 1-62
11. On the Tire InfoSource screen, select RPS
at 5 mph.
12. The next screen will display the revolutions per
second (RPS) at 8 kmlh (5 mph) for that specific
tire size.
For example: The P245l45/R18 will display
1.08 RPS.
Calculating Tire Revolutions Per Second at 8 kmlh
(5 mph) — Without EVA
Ifthe EL-38792—AElectronic 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 P245l45/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 P245l45/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 P245l45/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 P245l45/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 P245l45/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 P245l45/R18 tire, 6.283185 X
approximate tire and wheel assembly radius
33.09 cm = approximate tire and wheel assembly
circumference 207.911 cm.
'l=42 Vibration Diagnosis and Correction
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 P245l45/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 kmlh (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 of8 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 kmlh (60 mph) has
121NCREMENTS of8 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: Ifthe 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 on
page 1-62.
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. Ifthe frequencies match, then a
first-order disturbance related to the rotation of the
tire/wheel assemblies is present.
lfthe 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-ordertire/wheel assembly rotation related
13 Hz X 3, for third order =39 Hz third-ordertire/
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.
Ifafter 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 11/2—8 km/h (1—5mph) of
speedometer error.
Ifthe possible tire/wheel assembly rotational speed
related frequencies still do not match the dominant
frequency of the disturbance, the disturbance is most
likely torque/Ioadsensitive.
Ifafter 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.
2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Vibration Diagnosis and Correction 1:43

Vehicle Information
mph Year: Model:
Complaint Speed:
Symptom: VIN:
Engine: Trans:
Frequency:
Tire Size: Axle Ratio: __
Engine Speed: rpm

Gear: TPC Spec:

Tire/Wheel Speed

= increments of 8 km/h
Vibration mph +8 (km/h)5 (mph)
/5 mph
Occurs at:
Tire/Wheel Speed,
RPS (Hz)
8/ 5km/h x kmlh*
at 8 RPS
tire = 1st order
mph
increments [5 mph
(fromtable)

x 2 = 2nd order
1st order

x 3 = 3rd order
1st order

per
'RPSrevolutions equates
second; per
locycles (Hz).
second

Vibration Analysis - Tire and Wheel
Test Description
The numbers below refer to the step numbers in the
diagnostic table:
4. A build—upof foreign material on a tire and wheel
assembly and/or a damaged, abnormally or
excessively worn tire and wheel assembly could
cause a vibration disturbance.
6. Tire and wheel assemblies that exhibit excessive
runout when measured while mounted on the
vehicle, may or may not be contributing to,
or causing a vibration disturbance. On—vehicle
runout, if present, could contribute to, or cause a
vibration disturbance, but the cause of the
on—vehiclerunout may not be the tire and wheel
assemblies.
7. Tire and wheel assemblies that exhibit excessive
runout when measured off of the vehicle could
cause a vibration disturbance.
95609
9. Tire and wheel assemblies that exhibit marginal
runout—within acceptable limits, but close to the
maximum—when measured off of the vehicle could
still be contributing to a vibration disturbance, if its
mating hub/axle flange also exhibits marginal
runout. When the tire and wheel assembly and the
hub axle flange are mounted to each other, the
combined stack-up of their marginal amounts of
runout could combine to produce an excessive
amount of runout, which could cause a vibration
disturbance.
14. Brake rotors and/or brake drums, if equipped, that
exhibit excessive imbalance could contribute to,
or possibly cause a vibration disturbance.
15. A hub/axle flange and/or wheel studs that exhibit
excessive runout could cause a vibration
disturbance.

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
1=44 Vibration Diagnosis and Correction
16. When the tire and wheel assembly and the hub
axle flange are mounted to each other, the
combined stack-up of their marginal amounts of
runout could combine to produce an excessive
amount 0f runout, Wh'ChC(?U'dcause a.V'brat'°U
disturbance. Match-mountlng or vectoring the tire
20. Vibration disturbances could be affected by,
or possibly caused by, components that are
susceptible to steering input and/or torque—load
input.
22. On-vehicle balancing, or finish-balancing can be
used to reduce small amounts Ofimbalance which

modify the amount of combined runout. stack-up of the tire and wheel assembly with other
18. Force variation may be present in a tire and wheel components which may exhibit marginal balance.
assembly that exhibited acceptable balance and
runout. Force variation, if present, could contribute
to, or cause a vibration disturbance.

Vibration Analysis - Tire and Wheel

Step Action Yes No
Has theVibrationAnalysis—RoadTestingtablebeencompleted? Go to Vibration
Analysis-Road
Go to Step2 Testingonpage 1-39
Basedon theVibrationAnalysis—RoadTestingtable,is the
concernfirst-ordertireandwheelassemblyrelated? Go to Step4 Go to Step3
Basedon theVibrationAnalysis—RoadTestingtable,is the Go to Vibration
concernsecond-order,or higher—order
tireandwheelassembly Analysis-Road
related? Go to Step 18 Testingonpage 1-39
Visuallyinspectthetireandwheelassembliesforthefollowing:
' Debrisbuild—up, suchas packedmud,undercoating,ice/snow
buildup,roadtar,etc.
0 Damage,abnormalor excessivewear
Referto Tireand WheelInspectiononpage 1—64.
Doanyofthetireandwheelassembliesexhibitanyofthe
conditionslisted? Go to Step5 Go to Step6
1. Removethedebrisfromthetireandwheelassemblies.
2. Replacethedamaged,abnormallyor excessivelywornwheels
or tiresas necessary.
Didyoucompletetherepairor replacement? Go to Step23
Measuretheon-vehiclerunoutofthetireandwheelassemblies.
Referto Tireand WheelAssemblyRunoutMeasurement-
On-Vehic/eonpage 1-65.
Doestherunoutmeasurementindicatea runoutconcern? Go to Step 7 Go to Step12
Measuretheoff-vehiclerunoutofthetireandwheelassemblies.
Referto Tireand WheelAssemblyRunoutMeasurement- Off
Vehicleonpage 1—66.
Doestherunoutmeasurementindicatea runoutconcern? Go to Step 19 Go to Step8
Isthevehicleequippedwithrun-flattires? Go to Step 12 Go to Step9
Are anyofthetireandwheelassemblyrunoutmeasurements
marginal;withinacceptablelimits,butclosetothemaximum? Go to Step 10 Go to Step15
Note: Ensurethateachtireandwheelassemblythatis
match-mounted is properlybalancedbeforereinstallingtothe
vehicle.
1. Match-mountthetire-to-wheel
foreachtireandwheel
assemblywithmarginalrunout.Referto Tire-to—Wheel
10 Match-Mounting(Vectoring)onpage 1—77.
2. Measuretherunoutof each match-mounted tireandwheel
assembly.Referto Tireand WheelAssemblyRunout
Measurement—OffVehicleonpage 1—66.
Wereyouabletosignificantlyreducetheamount0ftire andwheel
assemblyrunout? Go to Step 11 Go to Step19
Re-measuretheon-vehiclerunoutofthetireandwheelassemblies.
Referto Tireand WheelAssemb/yRunoutMeasurement-
11 On-Vehic/eonpage 1-65.
Doesthemeasurementindicatea runoutconcern? Go to Step 15 Go to Step23

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Diagnosis and Correction “L45
Vibration

Vibration Analysis - Tire and Wheel (cont'd)

Yes No
Step Action
Tire
inspectthe balanceof thetireandwheelassemblies.Referto 1~72.
and WheelAssembly Balancing— Off Vehicleonpage
12 Go to Step 13 Go to Step14
Are anyor thetireand wheelassembliesoutof balance?
Tire Go to Vibration
Balancethetireand wheelassembliesas necessary.Referto DiagnosticAids on
and Wheel Assembly Balancing - Off Vehicleonpage 1—72.
13 Go to Step23 page 1-60
Wereyou ableto achievebalance?
for
1. inspectthebrakerotorsand brakedrums,if equipped,
damage.
2. Inspectthe balanceofthe brakerotorsand brakedrums,
Brake Rotor/Drum Balance Inspectionon
if equipped.Referto
14 page 1—69.
thatare
3. Replace brakerotorsand/orbrakedrums,if equipped,
damaged and/orout of balance.
Go to Step23 Go to Step 17
Didyou findand correcta condition?
wheel
1. Measuretherunoutofthe hub/axleflangesandthe
studs,if equipped.
and
2. Inspectthewheel bolts,if equipped,for straightness
damage.
Inspection
3. Referto Hub/Ax/eFlange and WheelStud Runout
onpage 1-70.
replace
15 4. Ifthe inspectionprocedureindicatesa runoutconcern,
the appropriate components:
° Wheel studs,if equipped
« Wheel bolts,if equipped
. Wheel bearing/hubassembly Go to Step16
Go to Step23
Didyou findand correcta condition?
1. Match-mountthetireandwheelassemblies-to-hub/axle
flanges.Referto Tireand WheelAssembly-to-Hub/Axle
Flange Match-Mounting onpage 1-78.
2. Re-measure the on-vehicle runoutof tireand wheel
16 assemblies.Referto Tireand WheelAssembly Runout
Measurement- On-Vehicleonpage 1-65.
tire
Wereyou ableto significantlyreducethe amountof on—vehicle Go to Step23 Go to Step2
andwheel assembly runout?
Wheel
Inspectforradialand lateralforcevariation.Referto Tireand
Assembly Isolation Teston page 1—71.
17
Wereyou ableto isolateoneor moreof thetireandwheel Go to Step19 Go to Step20
assembliesas thecause ofthedisturbance?
Wheel
Inspectforradialand lateralforcevariation.Referto Tireand
AssemblyIsolationTeston page 1-71.
18
Wereyou ableto isolateoneor moreof thetire andwheel Go to Step19 Go to Step21
assembliesas thecause ofthe disturbance?
of
Replace anytires and/orwheelsthatwere isolatedas thecause
19 the disturbance, a s necessary.
Go to Step23
Didyou completethe replacement?
Referto
PerformtheVibrationAnalysis—Hub/AxleInputtable.
Vibration Analysis- Hub and/or Axle Inputonpage 1-46.
20 Go to Step23 Go to Step22
Didyou findand correcta condition?
Referto Go to Vibration
PerformtheVibrationAnalysis—Hub/AxleInputtable. DiagnosticAids on
Vibration Analysis- Hub and/orAx/e Inputonpage 1-46.
21 Go to Step23 page 1—60
Didyou findand correcta condition?
Finish-balancethetire andwheelassemblieson-vehicle.Referto 1-76.
22 Tireand WheelAssembly Balancing- On-Vehic/eonpage
finish balancing? Go to Step23
Didyou completethe on—vehicle

—
2013 (US/Canada)
Sonic (5377994)
Manual
Service
'‘"fl”
’N‘w
l=46 Vibration Diagnosis and Correction

Vibration Analysis - Tire and Wheel (cont'd)

‘ Step Action Yes No
1. Installor connectanycomponentsthatwereremovedor
disconnectedduringdiagnosis.
23 2. PerformtheVibrationAnalysis—RoadTestingtable.Referto
VibrationAnalysis- Road Testingonpage 1-39.
Isthevibrationstillpresent? Go to Step2 SystemOK

Vibration Analysis _ Hub and/or Axle 8. Damaged orworn wheel bearings may cause a
noise or vibration that may be transferred into the
InPUt passenger compartment.
- - 9. Damaged or worn suspension components may
TeSt Description cause a noise or vibration that may be transferred
The numbers below refer to the step numbers on the into the passenger compartment,
diagnostic table: . . . 10. Damaged or worn powertrain mounts andlor
2. ThIStest WI|l_determine the effect 0f turnlng Input exhaust mounts may cause a noise of vibration
0“ the Vibration. that may be transferred into the passenger
6. This test will determine the effect of an initial heavy compartment.
torque load 0” the Vibration. 11. Incorrect trim height may cause binding and/or
7. Damaged or worn wheel drive shafts may cause a interference between components that may
noise or vibration that may be transferred into the produce a Vibration.
passenger compartment.

Vibration Analysis - Hub andlor Axle Input

Step Action Yes No
Has theVibrationAnalysis—RoadTestingtablebeencompleted? Go to Vibration
Analysis-Road
Go to Step2 Testingonpage 1-39
1. Operatethevehicleatthespeed of thevibrationconcern.
2. Whilemaintainingtheconcernspeed,drivethevehicle
throughslow,sweepingturns—firstin onedirection,thenin the
otherdirection.
3. Observethevehicleforchangesin thevibrationdisturbance.
4. Selecta smooth,levelsurface,suchas an emptyparkinglotor
2 a remoteroad.
5. Whilemaintainingthevehicleattheconcernspeedif possible,
drivethevehiclethroughsharpturns;360degrees—firstin
one direction,thenin theotherdirection.
6. Observethevehicleforchangesin thevibrationdisturbance.
Didthecharacteristicsofthevibrationchangesignificantly-
becomeworseor goaway*duringthesesteps? Go to Step3 Go to Step6
3 Didyou heara clickingnoiseand/orfeel a shudderduringthese '
steps? Go to Step7 Go to Step4
Didyou heara growlingnoiseduringthesesteps? Go to Step8 Go to Step5
Didyou heara poppingnoiseduringthesesteps? Go to Step9 Go to Step12
1. Withthevehicleat a stand-still,applytheregularbrakeand
placethetransmissionin thelowestforwardgear.
Note: Do notacceleratetothepointofcausingthedrivewheelsto
6 squeal,slip or hop—thiswouldobscuretheresultsof thetest.
3. Releasetheregularbrakesand accelerateaggressivelyto
32km/h(20mph?‘ . . . , Go to Vibration
4. ObservethevehlcleforchangesIntheVlbratlondisturbance. DiagnosticAids on
Didyoufeel a shudderor shakingduringthesesteps? Go to Step7 page 1—60
1. inspectthewheeldriveshafts,if equipped,fordamage,
abnormaland/orexcessivewear.
7 2. if theinspectionindicatedthata wheeldriveshaftis damaged,
abnormallyandlorexcessivelyworn,replacetheshaft.
Didyoufindandcorrecta condition? G0 to Step12 Go to Step9

—
2013 (US/Canada)
Sonic (5377994)
Manual
Service
 Diagnosis and Correction 1:47
Vibration

Analysis - Hub andlor Axle Input (cont'd)

Vibration
Yes No
Step Action
damage.
1. inspectthewheelbearingsfor wear and/or Go to Vibration
bearings found to bewornandlor
8 2. Replace anyof thewheel DiagnosticAids on
damaged. Go to Step12 page 1-60
Didyou find and correcta condition?
forwear,
1. Inspectthefollowingsuspensioncomponents
contact with othervehicle
damage, looseness andlor possible
components:
- Struts/shockabsorbers
9 - Springs
' Bushings
- Insulators
foundto be worn,
2. Replace anyof the suspensioncomponents
other vehicle components.
damaged, loose andlor contacting Go to Step 10
Go to Step 12
Didyou find andcorrecta condition?
transmission,transfer
1. Inspectthe powertrainmounts—engine, equipped——and any
case, and direct-mount i
differential, f
powertrainbracesforthe followingconditions:
- Loose andlormissingfasteners
. Improperalignment
- Cracked,dry—rotted, and/oroil-soakedinsulators
insulators
- Twisted,broken,torn,and/orcollapsed
- Bent,twisted,andlordeformed brackets
2. Replace powertrainmountsas necessary.
forthefollowing:
3. inspectthe exhaustsystemcomponents
' Loose andlormissingfasteners
—HeatShields
straps
10 —Jointsandlorcoupling,nuts,bolts,studs,clamps,
—Bracketandlorinsulatormounting
components
° Inadequateclearanceto bodyandlorchassis
and HOT;in
Inspectwiththe exhaustsystembothCOLD
NEUTRAL, FORWARD and REVERSE gears
~Improperalignment
' Disconnectedandlormissinginsulators
- Cracked,dry-rotted,andloroil-soakedinsulators
collapsed
' Stretched,twisted,broken,torn,andlor
insulators
brackets
' Bent,twisted,cracked,andlordeformed
system componentsas
4. Repair,replace,andlorrealignexhaust
necessary. Go to Step12 Go to Step11
Didyou findand correcta condition? Go to Vibration
necessary.Referto
inspectthevehicletrimheightand adjustas DiagnosticAids 0,,
11 TrimHeightInspection onpage 16—42. page 1—60
Go to Step12
Didyou findandcorrecta condition?
were removedor
1. Installor connectany componentsthat
disconnectedduring diagnosis.
table.Referto
12 2. PerformtheVibrationAnalysis—Road Testing
VibrationAnalysis —Road Testingonpage 1-39. Go to Step2 SystemOK
Isthevibrationstill present?

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
1448 Vibration Diagnosis and Correction

Vibration Analysis - Engine

Special Tools
EL—38792-AElectronic Vibration Analyzer (EVA) 2
For equivalent regional tools, refer to Special Tools and
Equipment on page 1—91.
Test Description
The numbers below refer to the step numbers on the
diagnostic table.
2. 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 No
Warning: Refer to WorkStall Test Warningon page 0-7.
Has theVibrationAnalysis—RoadTestingtablebeencompleted? Go to Vibration
Analysis-Road
Go to Step2 Testingonpage 1-39
Usinga scantool,determineif anyDTCs are set. Go to Diagnostic
2 WereanyDTCs set? StartingPoint- Vehicle
onpage 6-66 Go to Step3
1. Blockthefrontwheels.
2. ApplyBOTH theservicebrakesandtheparkbrake.
3. WiththescantoolandtheEL-38792-AElectronicVibration
Analyzer(EVA)2, if available,stillinstalled,starttheengine.
4. Place thetransmissionin NEUTRAL or PARK.
5. SlowlyincreasetheengineRPM tothelevelatwhichthe
disturbanceis mostnoticeable.
6. RecordtheengineRPM obtainedonthescantoolandthe
mostdominantfrequencyreadingifobtainedon the
EL-38792-AElectronicVibrationAnalyzer(EVA)2, if available.
3 7. Place thetransmissionin DRIVE.
8. SlowlyincreasetheengineRPM tothelevelatwhichthe
disturbanceis mostnoticeable.
9. RecordtheengineRPM obtainedonthescantoolandthe
mostdominantfrequencyreadingifobtainedon the
_ EL-38792-AElectronicVibrationAnalyzer(EVA)2, if available.
10. Ifnofrequencydatawas obtained,or if theEL-38792-A
ElectronicVibrationAnalyzer(EVA)2, is notavailable,place
thetransmissionintoREVERSE, thenrepeatsteps8 and9.
Reverse-Ioading of thepowertrainmayincreaseor changethe Go to Vibration
characteristicsof thevibration. DiagnosticAids on
Wereyouabletoduplicatethecustomer'sconcern? Go to Step4 page 1-60
DidtheEL—38792-A ElectronicVibrationAnalyzer(EVA)2 detecta Go to Vibration
4 dominantfrequency,or was a significantvibrationpresent? Analysis - Engine/
Accessoty Isolationon
page 1-52 Go to Step5

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Manual
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 Diagnosis and Correction 1449
Vibration

Vibration Analysis - Engine (cont'd)

Yes No
Step Action
Comparethetestresultsof the customer'svehicle tothe resultsof
thesame testsrun, at thesame engine RPM, on an
equally-equipped, same modelyearand type,KNOWN GOOD
vehicle.Referto Vehicle-to-Vehicle DiagnosticComparisonon
page 1—64.
1. Installa scantool intothe knowngoodvehicle.
2. lnstallthe EL-38792-AElectronicVibration Analyzer(EVA)2,
known good vehicle; placethe sensorin
if available,intothe
exactlythesame locationas Itwas placedin thecustomer's
vehicle.
Blockthefrontwheels.
Apply BOTH the servicebrakesandthe park brake.
Startthe engine.
Place thetransmissionin NEUTRAL or PARK.
the
Slowlyincreasethe engineRPM to thelevel atwhich
NP’V‘PP’
disturbancewas mostnoticeablein the customer'svehicle.
RecordtheengineRPM obtainedon thescan tooland the
mostdominantfrequencyreadingif obtainedontheif available.
EL-38792-AElectronicVibrationAnalyzer(EVA)2,
Place the transmissionin DRIVE.
. SlowlyincreasetheengineRPM to thelevel atwhichthe
disturbancewas mostnoticeablein the customer'svehicle.
11. RecordtheengineRPM obtainedonthe scanonthe tooland the
most dominant f requency readingif obtained
available.
EL-38792-AElectronicVibrationAnalyzer(EVA)2, if
obtained, o r ifthe EL-38792-A
12. Ifno frequencydatawas place
ElectronicVibrationAnalyzer(EVA)2, is notavailable,and11. Go to Vibration
thetransmission into REVERSE, then repeatsteps10
the Analysis -Engine/
Reverse-loadingofthe powertrainmay increaseor change (30to Vibration
Accessory Isolationon
characteristicsof thevibration. DiagnosticAids on
page 1-60 page 1-52
Didbothofthevehiclesexhibitthesame characteristics?

Engine Firing Frequency Classification

Engine Order Classification
Engine firing frequency is a term used to describe the
number of firing pulses (one firing pulse =one cylinder
Engine First Order Classification of the
minute firing) that occur during ONE complete revolution
1. Convert the engine speed in revolutions per crankshaft, multiplied by the number of crankshaft
(RPM), recorded during duplication of the
revolutions per second, Hz.
disturbance into Hertz , revolutions per second
(RPS), by dividing the RPM by 60 seconds. Refer 1. Calculate the engine firing frequency.
4—stroke
to the following example: - To determine the firing frequency of a
engine during ONE complete revolution of the
1,200 RPM divided by 60 =20 HZ (or RPS)
crankshaft, multiply the engine speed,
Compare the dominant frequency in Hz, recorded converted into Hz, by HALF of the total number
during duplication of the disturbance with the of cylinders in the engine.
engine speed just converted into Hz, to determine into
if they are related. - For example: The engine speed, converted
Hz, was 20 Hz; if the vehicle was equipped with
Ifthe dominantfrequency in Hz, recorded during a V8 engine, 4 of the 8 cylinders would actually
duplication of the disturbance and the engine fire during ONE complete revolution of the
speed, converted into Hz, ARE related, then an crankshaft.
engine FIRST ORDER related disturbance is Hz)
present. Engine first order disturbances are usually —Multiply the converted engine speed (20
related to an imbalanced component. Refer to the by 4 cylinders firing.
Engine Order Related Disturbances table. 20 Hz X 4 =80 Hz
at
Ifthe dominant frequency in Hz, recorded during —The engine firing frequency for a V8 engine
of 1,200 RPM,
duplication of the disturbance and the engine the original engine speed
speed, converted into Hz, are NOT related, then recorded during duplication of the
determine if the disturbance is related to the disturbance, would be 80 Hz.
engine's firing frequency. Proceed to Engine Firing —In like manner, a 6—cylinderengine would
Frequency Classification. have a firing frequency of 60 Hz at the same
engine speed of 1,200 RPM.
20HZX3=60HZ

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Manual
Sen/ice
1:50 Vibration Diagnosis and Correction
2. Compare the dominantfrequency in Hz, recorded Engine Driven Accessories Related to
during duplication of the disturbance with the
Engine Order
engine firing frequency in Hz, just calculated, to
determine if they are related. Engine driven accessory systems can be related to
3. if the dominant frequency in Hz, recorded during specific engine orders depending upon the relationship
duplication of the disturbance and the engine firing of the accessory pulley diameter to the crankshaft
frequency in Hz, just calculated ARE related, then pulley diameter. For example:
an engine FIRING FREQUENCY related - if the crankshaft pulley measured 20 cm (8 in) in
disturbance is present. Engine firing frequency diameter and one of the engine driven accessory
disturbances are usually related to improper pulleys measured 10 cm (4 in) in diameter, than
isolation ofa component. Refer to the Engine that accessory pulley would rotate 2 times for
Order Related Disturbances table. every one rotation of the crankshaft pulley. Ifthat
4. Ifthe dominantfrequency in Hz, recorded during accessory system was not isolated properly,
duplication of the disturbance and the engine firing or was not operating properly, it would be
frequency in Hz, just calculated are NOT related, identifiable as a 2nd order engine related
then determine if the disturbance is related to disturbance.
another engine order classification. Proceed to - In like manner, if an engine driven accessory
Other Engine Order Classification. pulley measured 5 cm (2 in) in diameter, than that
accessory pulley would rotate 4 times for every
Other Engine Order Classification one rotation of the crankshaft pulley. lfthat
1. Multiply the engine speed, converted into Hz, accessory system was not isolated properly,
recorded during duplication of the disturbance by or was not operating properly, it would be
different possible order—numbers,other than 1 (first identifiable as a 4th order engine related
order) or the number used to determine the firing disturbance.
frequency of the engine. Engine driven accessories that contribute to, are
2. Compare the dominantfrequency in Hz, recorded excited by, or are the sole cause of a disturbance are
during duplication of the disturbance with the other usually doing so because of improper isolation that
possible engine orders just calculated, to causes a transfer path into the passenger compartment
determine if they are related. or to another major component of the vehicle body.
3. lfthe dominantfrequency in Hz, recorded during Using the EL-38792-VS Vibrate Software, accurately
duplication of the disturbance and one of the other measuring the diameters of the accessory pulleys and
engine order frequencies in Hz, just calculated the crankshaft pulley, and performing the appropriate
ARE related, then an engine related disturbance of diagnostic procedures completely will lead to the
that order is present. Ifan engine related ‘ specific accessory system which is either contributing
disturbance is present that is NOT related to first to, or causing the customer's concern.
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 Order Related Disturbances
Engine Arrangement
L4 L4 90 DegreeV6'
Engine W/O Balance With Balance With Balance
Order Shaft Shaft L5 60DegreeV6
L6 Shaft 90DegreeV8
Abnormal— Abnormal-
1/2Order Abnormal— Abnormal— Abnormal— Abnormal— LikelySingle LikelySingle Abnormal-
LikelySingle LikelySingle LikelySingle LikelySingle Cylinder Cylinder LikelySingle
Torque Cylinder Cylinder Cylinder Cylinder Misfireandlor Misfireandlor Cylinder
Sensmve Misfire Misfire Misfire Misfire EGR/Fuel EGR/Fuel Misfire
Variance Variance
Abnormal— Abnormal— Abnormal— Abnormal — Abnormal — Abnormal— Abnormal-
1stOrder Likely Likely Likely Likely Likely Likely Likely
Component Component Component Component Component Component Component
lmbalance Imbalance lmbalance lmbalance lmbalance lmbalance lmbalance
Abnormal— Abnormal-
LikelyBankto LikelyBankto
1%Order Possible Possible Possible Possible BankEGR/ BankEGR/ Possible
EngineDriven EngineDriven EngineDriven EngineDriven FUBlVariance FuelVariance EngineDriven
Torque Accessory Accessory Accessory Accessory Possible Possible Accessory
SenSItIve Related Related Related Related EngineDriven EngineDriven Related
Accessory Accessory
Related Related

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Manual
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 Vibration Diagnosis and Correction 151

Engine Order Related Disturbances (cont'd)

Engine Arrangement
L4 90 DegreeV6
L4
With Balance With Balance
Engine W/O Balance Shaft 90 DegreeV8
Shaft Shaft L5 L6 60 DegreeV6
Order
Characteristic Characteristic
Characteristic of Engine of Engine .
of Engine . . .
PPSS'b'? Arrangement Arrangement EnginePF’SS'blfe
2ndOrder Arrangement 9035'“? P959“? , . Driven
Non . EngineDriven EngineDriven EngineDriven T P089“? Accessory
Accessory Accessory Accessory T POSS'bl.e
Torque T PossublIe Powertra'“ Powertram Related
Sensitive Powertra'" Related Related Related Isolation Isolation
isolation Related Related
Related
Characteristic Characteristic
—ENG|NE —ENGlNE Abnormal_
FIRING FIRING LikelyBank to
FREQUENCY FREQUENCY
Possible Possible Possible Bank EGR/
2ndOrder - Possible - Possible Possible
Powertrain Powertrain EngineDriven EngineDriven EngineDriven EngineDriven FuelVariance
Isolation Accessory Accessory Accessory Accessory
TorunIe Isolation Related
Related Related Related Related
Sensutlve Related
Possible
Possible Possible Engine Driven
EngineDriven EngineDriven Accessory
Accessory Accessory Related
Related Related
Characteristic
—ENGINE
FIRING
FREQUENCY
Possible Possible Possible Possible
Order
2 1/2 Possible Possible - Possible Driven EngineDriven
Powertrain Engine Driven Engine Driven Engine
T EngineDriven EngineDriven Accessory Accessory Accessory
Accessory Accessory |SO|at|00 Accessory
8 orunIe Related Related Related Related
ensutlve Related Related Related
Possible
EngineDriven
Accessory
Related
Characteristic Characteristic Characteristic
—ENGlNE —ENGlNE —ENG|NE
FIRING FIRING FIRING
FREQUENCY FREQUENCY FREQUENCY
—Possible - Possible _ Possible Possible
3rdOrder Possible Possible Possible Engine Driven
Powertrain Powertrain Powertrain
EngineDriven Engine Driven EngineDriven lSOlathh ISOIatIOD Accessory
TorunIe Accessory Accessory Accessory Isolation Related
Related Related Related Related Related Related
Sensmve
Possible Possible Possible
EngineDriven EngineDriven EngineDriven
Accessory Accessory Accessory
Related Related Related
Cheracteristic
Characteristic Characteristic _ ENGINE
—Minimal —Minimal
Amount—of Amount—of FREgRLIJhéfiCY
Engine Engine . | P 'bl
.l . . l
Arrangement Arrangement Posstble Posstbe POSSlb e - OSS|I9
th0 d _ - _ . POSSIbe Powertrain
Engine Driven Engine Driven Engine Driven Engine Driven
4 r er p $38629 P PVSesfilblie A ccessory Accessory Isolation
R |t d
Torque ° F '"
Isolation ° Ta“
Isolation A ccessory Accessory
Sensitive Related Related Related ea e
Related Related Related
Possible
Possible Possible Engine Driven
EngineDriven Engine Driven Accessory
Accessory Accessory Related
Related Related

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Manual
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1:52 Vibration Diagnosis and Correction
Vibration Analysis - Engine]
A I I .
ccessory SO at'on
Test Description
The numbers below refer to the step numbers 0” the
dIagnostIctable. . have been altered, it is possible that these
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 andlor aligned powertrain
components andlor exhaust system components
may create a transfer path into the passenger
compartment.
When loosening powertrain mounts in order to
re—bedthe powertrain observe the following:
Do not loosen the mount bracket—to-enginebolts/
nuts, do not loosen the mount bracket-to-vehicle
frame bolts/nuts if mount brackets are used.
Loosen the mount—to-mountbracket 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—rotatingengine driven accessory components
can no longer produce a unique disturbance. Ifa
disturbance is still present, but the characteristics
component systems are acting as a transfer path
for engine firing frequency or a first order engine
disturbance.
lfa disturbance is still present, but the
characteristics have NOT been altered, it is NOT
likely that these component systems are acting as
a transferIpathfor engine firing frequency or a first
order engIne dIsturbance.
10. Ifthe 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 eXIstIngfrequency. SUChas
engIne fIrIngpulses, or creatIng a disturbance.
11. A toose, damaged, misalIgned, or defectIve engIne
drIven accessory system Insulatorandlor bracket
may create a transfer path '“to the passenger
compartment. , _
12. Removmg the engIne drIven accessory and
bracket, 0,"brackets from the ?“Q‘Pe allows a,,
thorough InspectIonto determine Ifany condItIons
are present that may create a transfer path into the
passenger compartment.

Vibration Analysis - EnginelAccessory Isolation

Step Action I Yes I No
Warning: Refer to WorkStall Test Warningon page 0-7.
Wereyou sentherefromtheVibrationAnalysis—Enginetable? Go to Vibration
1 Analysis-Engineon
Go to Step2 page 1-48
2 IstheEL-38792-AElectronicVibrationAnalyzer(EVA)2, available? Go to Step3 Go to Step5
1. UsingtheengineRPM andfrequencydatarecordedforthe
customer's vehicle,determinetheorderofenginerotationto
whichthedisturbanceIsrelated.
2. Determinethepossiblecausesofthedisturbanceas it relates
to a specificorderofenginerotation.
Referto EngineOrderClassificationonpage 1-49.
DoestheEngineOrderClassificationtableindicatethatthe
disturbanceis ofthesameorderas theenginefiringfrequency? Go to Step5 Go to Step4
4 DoestheEngineOrderClassificationtableindicatethatthe
disturbanceis likelyrelatedtoenginedrivenaccessories? G0 to Step8 Go to Step5
Inspectthepowertrainmounts—engine, transmission,transfer
case, anddirect—mount driveaxle,if equipped—andanypowertrain
bracesforthefollowingconditions:
' Loose andlormissingfasteners
' Improperalignment
5 - Cracked,dry-rotted,andloroil—soaked insulators
- Twisted,broken,torn,andlorcollapsedinsulators
~Bent,twisted,and/ordeformedbrackets
Realignor replacepowertrainmountsas indicatedbythe
inspection.
Didyoufindandcorrecta condition? G0 to Step 13 Go to Step6

(US/Canada)
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2013 (5377994)
Manual
Service
 Diagnosis and Correction 1:53
Vibration

Isolation (cont'd)
Vibration Analysis - EngineIAccessory
Yes No
Step Action
following:
Inspecttheexhaustsystemcomponentsforthe
' Loose andlormissingfasteners
—HeatShields
- Jointsandlorcouplings:
Nuts,bolts,studs,clamps,straps
—Bracketandlorinsulatormounting
components
Inadequateclearanceto bodyandlorchassis
system both COLD and HOT;in
Inspectwiththeexhaust
NEUTRAL, FORWARD and REVERSE gears
0 Improperalignment
- Disconnectedandlormissinginsulators
and/oroil—soaked insulators
- Cracked,dry—rotted,
collapsedinsulators
- Stretched,twisted,broken,torn,and/or
brackets
- Bent,twisted,cracked,andlordeformed
componentsas
Repair,replace,and/orrealignexhaustsystem
indicatedbythe inspection. Go to Step13 Go to Step 7
Didyou findand correcta condition?
if availableor
Performthe PowertrainMountBalance Procedure the powertrain:
performthefollowingprocedure to re-bed
mountsand exhaust
1. Loosen,butdo notremove,all powertrain
systemhangers.
if equipped,moves
2. Ensurethatthe exhaustflexiblecoupling,
freely.
3. Startthe engine.
transmissionfromDRlVE
4. Settlethe powertrainby shiftingthe
to REVERSE.
5. Place the transmissionintoNEUTRAL.
6. TurnOFFtheignition.
powertrainin a
7. Tightenallof the loosenedfastenerswiththe
relaxed position.
Go to Step13
Didyou completethe operation?
than60 secondswiththe
Caution: Do notrun the enginefor longeroverheating
o r andlor
accessorydrivebelt,or beltsremoved,
damage may result.
belts.
1. Removetheengineaccessorydrivebelt,or
Block thefrontwheels.
brake.
Apply BOTH the servicebrakesandthe park
engine.
Withthe scan toolstill installed,startthe
Place the transmissionin NEUTRAL or PARK.
during
Increasethe engineRPM t0 the level recorded
53°91‘99”!“
duplicationof the disturbance.
transmissionin DRIVE.
T‘ Allowthe engineto idle,thenplace the
to the level recorded during
8. Increasethe engineRPM
duplicationof the disturbance.
9. TurnOFF the ignition.
belts.
10. installthe engineaccessorydrivebelt,or Go to Step10 Go to Step9
eliminated?
Was the disturbancesignificantlyreducedor Go to Step 15
alteredbutstill present? Go to Step11
Werethe characteristicsofthe disturbance

(US/Canada)
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Manual
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1=54 Vibration Diagnosis and Correction

Vibration Analysis - EnginelAccessory isolation (cont'd)

Step Action Yes No
1. Markthefaceofthesuspectedaccessorypulleys,including
any relatedidlerpulleys,neartheouteredgewitha paintmark.
2. InstalltheEN—38792-25 inductivePickupTimingLight,tothe
EL—38792-A ElectronicVibrationAnalyzer(EVA)2.
For informationontheuse of theEVA features,referto
ElectronicVibrationAnalyzer(EVA)Descriptionand Operation
onpage 1-88.
3. Blockthefrontwheels.
4. ApplyBOTHtheservicebrakesandtheparkbrake.
5. WiththescantoolandtheEL-38792-AElectronicVibration
Analyzer(EVA)2, stillinstalled,starttheengine.
6. SelecttheSmartStrobefeatureontheEL-38792-AElectronic
VibrationAnalyzer(EVA)2.
7. Entertherecordedfrequencyofthedisturbanceas theinitial
frequencyforstrobeoperation.
8. Havean assistantplacethetransmissionin NEUTRAL
or PARK.
10 9. SlowlyincreasetheengineRPM t0thelevelrecordedduring
duplicationofthedisturbance,thenmaintainthatspeed.
10. UsingtheEL-38792-AinductivePickupTimingLight,check
each ofthesuspectedaccessorypulleystodetermineif anyof
themis relatedtothefrequencyofthedisturbance.
Checkeachoftheaccessorysystems,bothengagedand
undermaximumloadanddisengagedor underminimumload.
11. Allowtheengineto idle,thenplacethetransmissionin DRIVE.
12. SlowlyincreasetheengineRPM tothelevelrecordedduring
duplicationofthedisturbance,thenmaintainthatspeed
closely.
13. UsingtheEN-38792-25InductivePickupTimingLight,check
eachofthesuspectedaccessorypulleystodetermineif anyof
themis relatedtothefrequencyofthedisturbance.
Checkeachoftheaccessorysystems,bothengagedand
undermaximumloadanddisengagedor underminimumload.
14. TurnOFF theignition. Go to Vibration
Didyouidentifyanenginedrivenaccessorysystemas beingrelated DiagnosticAids on
tothefrequencyofthedisturbance? G0 to Step 11 page 1—60
inspectthecomponentsoftheenginedrivenaccessorysystemfor
thefollowing:
- Loose and/ormissingfasteners
—-HeatShields,if equipped
—Jointsandlorcouplings:
Nuts,bolts,studs,clamps,straps
—Bracketandlorinsulatormounting
' Inadequateclearancetobodyand/orchassis components
Inspectwiththeaccessorysystembothundera LOAD and NOT
loaded
11
- Improperalignment
' Bentor damagedpulleys
° Disconnectedandlormissinginsulators
- Cracked,dry-rotted,andloroil-soakedcomponentinsulators
- Stretched,twisted,broken,torn,and/orcollapsedcomponent
insulators
. Bent,twisted,crackedand/ordeformedcomponentbrackets
Repair,replace,andlorrealigntheenginedrivenaccessorysystem
componentsas indicatedbytheinspection.
Didyoufindandcorrecta condition? Go to Step 13 Go to Step12

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Vibration Diagnosis and Correction

- Engine/Accessory Isolation (cont'd)

Vibration Analysis
Yes No
Step Action
or brackets
1. Removetheenginedrivenaccessoryand bracket,
fromthe engine.
brackets,bolts/
2. Thoroughlyinspectthe accessorybracket,or the following:
nuts/studs, andthe accessory itselffor signsof
12 Bent,twisted,crackedandlordeformedconditions
these
3. Replaceanyof the componentsfoundto exhibitanyof
conditions.
4. Reinstallthecomponentsto theengine. Go to Step 17
Go to Step13
Didyoufindand correcta condition?
Checkthe vehicleto determineifthe disturbance is nowsignificantly
reducedor eliminated.Performthefollowingsteps:
1. lnstalla scantool intothecustomer'svehicle.
2. lnstallthe EL—38792-A ElectronicVibrationAnalyzer(EVA)2,
if available,intothe customer's vehicle;placethe sensorin
exactlythesame location as itwas originallyplacedin the
vehicle.
Blockthefrontwheels.
Apply BOTH the servicebrakesandthe parkbrake.
Startthe engine.
Place the transmissionin NEUTRAL or PARK.
Slowlyincreasethe engineRPM to thelevel atwhichthe
NP’P‘PS‘J
disturbancewas mostnoticeable.
andthe.
13 8. RecordtheengineRPM obtainedonthe scantool
mostdominantfrequencyreadingif obtainedontheif available.
EL-38792-AElectronicVibrationAnalyzer(EVA)2,
9. Place the transmissionin DRIVE.
10. Slowlyincreasethe engineRPM tothe levelat whichthe
disturbancewas mostnoticeable.
andthe
11. RecordtheengineRPM obtainedonthe scantool
mostdominantfrequencyreadingif obtainedontheif available.
EL-38792-AElectronicVibrationAnalyzer(EVA)2,
12. Ifthedisturbancehas beensignificantlyreduced or eliminated,
confirmthe‘results by placing the transmission into REVERSE,
thenrepeatsteps10 and11.Reverse-loadingofthe powertrain
may increaseor changethe characteristicsofthevibration. Go to Step14
Go to Step 18
Hasthe disturbancebeensignificantlyreducedor eliminated?
cause of
Haveyou investigatedpowertrainisolationas a possible Go to Step 15 Go to Step5
14 the disturbance?
possible Go to Vibration
Haveyou investigatedenginedrivenaccessoriesas a Analysis - Engine
15 causeof the disturbance? Balanceonpage 1—56 Go to Step 16
available? Go to Vibration
Isthe EL-38792-AElectronicVibrationAnalyzer(EVA)2 DiagnosticAids on
16 Go to Step8 page 1-60

Replacethe enginedrivenaccessorycomponentcausingthe
17 disturbance.
Go to Step 18
Didyou completethe replacement?
or
1. Installor connectany componentsthatwereremoved
disconnectedduringdiagnosis.
Referto
18 2. PerformtheVibrationAnalysis —Road Testingtable.
VibrationAnalysis - Road Testingonpage 1—39.
Go to Step2 SystemOK
Isthedisturbancestill present?

—
2013 (US/Canada)
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Manual
Service
1:56 Vibration Diagnosis and Correction

Vibration Analysis - Engine Balance
Test Description
The numbers below refer to the step numbers on the
diagnostic table.
4. Ifsufficient 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—indexingthe 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 FRONTand the REAR
edge allows for a determination to be made, which
will help to narrow down the cause of the
disturbance. ‘ 19. An engine crankshaft balancer that is damaged,
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—spotof
one to the light-spot of the other. Improperindexing
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 andlor
missing balance weights; andlor a clutch pressure
plate and clutch driven plate that has loose
springs, cracks, warpage, damage andlor 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 andlor
missing balance weights; andlor a clutch pressure
plate and clutch driven plate that has loose
springs, cracks, warpage, damage andlor 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, andlor imbalanced, can produce a
disturbance.
misaligned, andlor imbalanced, can produce a
disturbance.

Vibration Analysis - Engine Balance

Step Action Yes No
Wereyou sentherefromtheVibrationAnalysis—Engine/Accessory Go to Vibration
1 Isolationtable? Analysis-Engine/
AccessoryIsolationon
Go to Step2 page 1-52
is theEL-38792-AElectronicVibrationAnalyzer(EVA)2,available? Go to Vibration
2 DiagnosticAids on
Go to Step3 page 1-60
3 Isthevehicleequippedwitha manualtransmission? Go to Step11 Go to Step4
1. Raise andsupportthevehicle.Referto LiftingandJackingthe
Vehicleonpage 1-31.
2. Removetheflywheel/flexplate-to-torque converterbolts
access cover,if equipped.
3. Determineif sufficientclearanceexiststoseparatethe
4 transmissiontorqueconverterawayfromtheengineflywheel/
flexplateandsafelysecurethetorqueconverterfrom
accidentallyengagingwiththeflywheel/flexplate.
Istheresufficientclearancetoseparateandsafelysecurethe
transmissiontorqueconverterawayfromtheengineflywheel/
flexplate? G0 to Step5 G0 to Step11

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Manual
Service
 Vibration Diagnosis and Correction 1:57

Vibration Analysis - Engine Balance (cont'd)

Yes No
Step Action
. Withthe flywheel/flexplate—to-torque
_x converteraccess cover
position
stillremoved,andwiththevehiclestill raised,markthe the engine
ofthe transmission torque converter in relationto
flywheellflexplate.
the
2. Disconnectthetorqueconverterandmoveit awayfrom
flywheellflexplate.
the
9° Secure thetransmissiontorqueconverterawayfrom e ngagement with
engine flywheellflexplatet o avoid accidental
theflywheellflexplate.
idle.
Lowerthe vehicle,starttheengineandallowthe engineto
Referto Lifting and Jacking the
.01?Raise and supportthevehicle.
Vehicleon page 1-31.
6. Visuallyinspecttheflywheellflexplate for excessivelateral
runout.
7. Lowerthe vehicle.
8. TurnOFF the ignition. Go to Step6
exhibitexcessivelateralrunout? Go to Step8
Didtheflywheellflexplate
Jacking the
1. Raise and supportthevehicle.Referto Liftingand
Vehicleonpage 1-31.
2. Inspecttheflywheellflexplate forthefollowing:
- Loosenessat theenginecrankshaft
- Cracks andlordamage
- Missingbalanceweights Go to Step7
exhibitanyof the conditionslisted? Go to Step8
Didtheflywheellflexplate
awayfrom
1. Withthe transmissiontorqueconverterstill secured e ngagement
theengine flywheellflexplate t o avoid accidental
withthe flywheel/flexplate, lowerthevehicle.
Blockthefrontwheels.
. Apply BOTH the servicebrakesandthe parkbrake.
Vibration
. Withthe scantool andthe EL-38792-AElectronic
h@[fit
Analyzer(EVA)2 still installed,startthe engine.
Place the transmissionin NEUTRAL or PARK.
.035” Slowlyincreasethe engineRPM tothe levelat whichthe
disturbanceis mostnoticeable.
‘1. Recordthe engineRPM obtainedon thescanonthe tooland the
mostdominantfrequencyreadingif obtained
EL-38792—A ElectronicVibrationAnalyzer(EVA)2.
8. TurnOFF the ignition. Go to Step11
Go to Step9
Hasthedisturbancebeensignificantlyreducedor eliminated?
1. Iftheflywheellflexplate is looseat the enginecrankshaft,
tightenthe flywheellflexplate mountingboltsin sequenceand
to specification.
2. Iftheflywheellflexplate is cracked,damaged,andlorhas
missingbalanceweights,replacethe damagedflywheel/
flexplate.
Go to Step20
Didyou completethe tighteningor replacement?

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2013 (US/Canada)
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Manual
Service
158 Vibration Diagnosis and Correction

Vibration Analysis - Engine Balance (cont'd)

Step Action Yes No
. Raise andsupportthevehicle.Referto LiftingandJackingthe
Vehicleonpage 1~31.
. Re-indexthetransmissiontorqueconvertertotheengine
120degreesfromitsoriginalposition.
flywheel/flexplate,
Reconnectthetransmissiontorqueconverterto theengine
flywheellflexplate.
Lowerthevehicle.
Blockthefrontwheels.
ApplyBOTHtheservicebrakesandtheparkbrake.
WiththescantoolandtheEL-38792-AElectronicVibration
N935”?
Analyzer(EVA)2 stillinstalled,starttheengine.
9° Place thetransmissionin NEUTRAL or PARK.
SlowlyincreasetheengineRPM tothelevelatwhichthe
disturbanceis mostnoticeable.
10. RecordtheengineRPM obtainedonthescantoolandthe
mostdominantfrequencyreadingifobtainedon the
EL-38792-AElectronicVibrationAnalyzer(EVA)2.
11. if thedisturbanceis stillnoticeable,re—indexthetorque
converteragainto obtaintheleastamountof disturbance.
Has thedisturbancebeensignificantlyreducedor eliminated? Go to Step20 Go to Step 10
Replacetheout—of—balance transmissiontorqueconverter.
1O Go to Step20
Didyoucompletethereplacement?
1. Raise andsupportthevehicle.Referto LiftingandJackingthe
Vehicleonpage 1-31.
2. PositiontheEL—38792-A ElectronicVibrationAnalyzer(EVA)2
sensorontotheundersideof theengineoil pan,alongthe
FRONTedge.
Lowerthevehicle.
Blockthefrontwheels.
ApplyBOTHtheservicebrakesandtheparkbrake.
Withthescantoolandthe EL-38792-AElectronicVibration
93.01993
Analyzer(EVA)2, stillinstalled,starttheengine.
11 .“ Place thetransmissionin NEUTRAL or PARK.
SlowlyincreasetheengineRPM tothelevelatwhichthe
disturbanceis mostnoticeable.
RecordtheengineRPM obtainedonthescantooland the
mostdominantfrequencyreadingif obtainedon the
EL-38792-AElectronicVibrationAnalyzer(EVA)2 fromthe
undersideoftheengineoil pan.
10. Repeatsteps1 through9, placingtheEL-38792—A Electronic
VibrationAnalyzer(EVA)2 sensorontotheundersideofthe
engineoil pan,alongtheREAR edge.
IsthedisturbancegreateralongtheFRONTofthe engine? Go to Step19 Go to Step 12
12 ls thevehicleequippedwithan automatictransmission? Go to Step18 Go to Step 13
1. Raise andsupportthevehicle.Referto LiftingandJackingthe
Vehicleonpage 1-31.
2. Removetheflywheelinspectioncover.
13 3. Starttheengine.Allowthe enginetoidle.
4. Visuallyinspecttheengineflywheelclutchsurfacefor
excessivelateralrunout.
Doestheengineflywheelclutchsurfaceexhibitexcessivelateral
runout? Go to Step18 Go to Step 14

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Manual
Service
 Diagnosis and Correction 'l-59
Vibration

Analysis - Engine Balance (cont'd)

Vibration
Yes No
Step Action
mountingfor
Inspectthe clutchpressureplateto engineflywheel
14 properfactoryindexing. Go to Step16 Go to Step 15
tothe engineflywheel?
ls the clutchpressureplateproperlyindexed
drivenplatefrom
1. Removethe clutchpressureplateand clutch
the engineflywheel.
2. Inspectthe engineflywheelforthefollowing:
' Loosenessat the enginecrankshaft
- Cracks,warpageandlordamage
- Missingbalanceweights
drivenplatefor the
15 3. inspectthe clutchpressureplateand clutch
followmg:
dampersprings
- Loose and/ordamagedclutchdrivenplate
diaphragm
' Loose andlordamagedclutchpressureplate
spnngs
- Cracks,warpageandlordamage
' Missingbalanceweights Go to Step18 Go to Step17
Do anyof the aboveconditionsexist?
drivenplatefrom
1. Removethe clutchpressureplateand clutch
the engine flywheel.
2. Inspectthe'engineflywheelforthefollowing:
- Loosenessat the enginecrankshaft
- Cracks,warpageandlordamage
- Missingbalanceweights
drivenplatefor the
16 3. lnspeetthe clutchpressureplateand clutch
followmg:
dam'persprings
- Loose and/ordamagedclutchdrivenplate
clutchpressureplate diaphragm
. Loose andlordamaged
spnngs Go to Vibration
- Ctachs,warpageanId/or damage
DiagnosticAids on
' Missmg balanceweights page 1-60
Go to Step 18
Do anyof the aboveconditionsexist? _
17 Re-indexthe pressureplateto the engineflywheel. G0 to Step20
Didyou completethe re-indexing? _
18 Replacethe engineflywheellflexplate. G0 to Step20
Didyou completethe replacement? _
19 Replacethe enginecrankshaftbalancer. Go to Step20
Didyou completethe replacement?

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Manual
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1=60 Vibration Diagnosis and Correction

Vibration Analysis - Engine Balance (cont'd)

Step Action Yes No
Checkthevehicletodetermineif thedisturbanceis nowsignificantly
reducedor eliminated.Performthefollowingsteps:
1. Installor connectanycomponentsthatwereremovedor
disconnectedduringdiagnosis.
2. Installa scan toolintothecustomer'svehicle.
3. installtheEL-38792-AElectronicVibrationAnalyzer(EVA)2,
if available,intothecustomer'svehicle;placethesensorin
exactlythesamelocationas itwas originallyplacedin the
vehicle.
Blockthefrontwheels.
ApplyBOTHtheservicebrakesandtheparkbrake.
Starttheengine.
Place thetransmissionin NEUTRAL or PARK.
SlowlyincreasetheengineRPM tothelevelat whichthe
@NQ’SJ‘P
20 disturbancewas mostnoticeable.
RecordtheengineRPM obtainedon thescantoolandthe
mostdominantfrequencyreadingif obtainedon the
EL-38792-AElectronicVibrationAnalyzer(EVA)2, if available.
10. Place thetransmissionin DRlVE.
11. SlowlyincreasetheengineRPM tothelevelatwhichthe
disturbancewas mostnoticeable.
12. RecordtheengineRPM obtainedon thescan toolandthe
mostdominantfrequencyreadingifobtainedon the
EL-38792-AElectronicVibrationAnalyzer(EVA)2, if available.
13. Ifthedisturbancehas beensignificantlyreducedor eliminated,
confirmtheresultsby placingthetransmissionintoREVERSE,
thenrepeatsteps11and12.Reverse-loadingofthepowertrain Go to Vibration
mayincreaseor changethecharacteristicsofthevibration. DiagnosticAids on
Has thedisturbancebeensignificantlyreducedor eliminated? Go to Step21 page 1—60
PerformtheVibrationAnalysis—RoadTestingtable.Referto Go to Vibration
21 VibrationAnalysis-Road Testingonpage 1-39. DiagnosticAids on
Isthedisturbancestillpresent? page 1-60 SystemOK

Vibration Diagnostic Aids
Note: if you have not reviewed the Diagnostic Starting
Point —Vehicle and completed the Vibration Analysis
tables as indicated, refer to Diagnostic Starting Point -
Vehicle on page 6-66 BEFORE proceeding.
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 on page 1-60
- Vibration Diagnostic Aids - Vibration Dup/icated,
Component Not Identified on page 1-61
. Vibration Diagnostic Aids - Vibration Duplicated,
Difficult to lsolate/Ba/ance Component on
page 1-62
- Vibration Diagnostic Aids - Vibration Duplicated,
Appears to Be Potential Operating Characteristic
on page 1—62
Vibration Diagnostic Aids - Vibration
Intermittent or Not Duplicated
Note: Ifyou have not completed the Vibration Analysis
tables as indicated and reviewed Vibration Diagnostic
Aids, refer to Vibration Diagnostic Aids on page 1-60
BEFORE proceeding.
Ifyou 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 notfollowing
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

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 Vibration Diagnosis and Correction 161

cold ° Fluid Level in Accessory Systems

also occur; perhaps the vehicle has sat out in the
for a time and fails to reach full operating temperatures Accessories could exhibit a noise condition due to
during attempts to duplicate the concern. an abnormal amount of fluid contained in the
system of which the accessory is a part. For
Temperature, Ground-Out, example:
Accessory Load —An improper power steering fluid level could
produce noises in the power steering system.
Flat Spots on Tires —An improper air conditioning refrigerant level
or
Tires which have sat and been cool for a time can an excessive amount of refrigerant oil could
develop flat spots. produce noises or possibly vibrations in the air
conditioning system.
Irregular Wear on Tire Treads
- Incorrect Fluid Type in Accessory Systems
Tires which have sat and been cool for a time will be Accessories could exhibit a noise condition due to
stiffer and any irregular wear conditions will be more
noticeable than they will be once the tires have warmed the incorrect type of fluid contained in the system
of which the accessory is a part.
and softened.
Exhaust System Growth Vehicle Payload
vehicle
Exhaust systems may exhibit a ground-out condition The vibration concern may only occur when the
or towing a trailer; the
when cool which goes away once the system is hot. is carrying heavy payloads
The opposite may be true that the exhaust system
is vehicle may have been empty during duplication
fine when cool but a ground-out condition occurs once efforts.
the system reaches operating temperatures. Exhaust Heavy Payload
systems can grow by 21/2—5 cm (1—2in) when hot.
to
The vehicle may have been empty during attempts
Engine-Driven Accessory Noises duplicate the vibration concern, but the customer may
Note: When a stethoscope equipped with a probe is actually experience the vibration concern while the
used to assist in identifying possible vibrating vehicle is carrying a large payload.
components, the results must be compared to the
Trailer Towing
sound quality of the same accessory, in a
equally-equipped, same model year and type, KNOWN The customer may experience the vibration concern
GOOD vehicle, and under the same conditions. Refer only while towing a trailer.
to VehicIe-to-Vehic/e Diagnostic Comparison on Selection
page 1-64. Roadway
vibration
as The selection of roadways used to perform the vicinity
A stethoscope equipped with a probe can be used duplication procedures is likely to be in the near
means to assist in identifying accessories surface
an additional of the repair facility and may not provide a road
which may be causing or contributing to a vibration that is similar enough to the surface on which the
concern. customer usually drives the vehicle.
- Belt Whipping on a
The customer may only experience the vibration
An engine accessory drive belt, or belts could particular roadway. Perhaps the roadway is overly
exhibit a whipping condition if a belt is crowned or is very bumpy or rough.
deteriorating and deposits are building up on the
underside of the belt. Vibration Diagnostic Aids - Vibration
' Loose Mounting Brackets or Component Duplicated, Component Not
Ground—Out
Engine-driven accessories such as a generator, a ldenfified
power steering pump, or an air conditioning Analysis
Note: Ifyou have not completed the Vibration
compressor could exhibit noise conditions due to tables as indicated and reviewed Vibration Diagnostic
either loose mounting brackets or due to related Aids, refer to Vibration Diagnostic Aids on page
1-60
components of the system in a ground-out BEFORE proceeding.
condition during certain operation of that
accessory system. Aftermarket Add-On Accessories
the
- Cold or Hot Aftermarket accessories which have been added to
Accessories could exhibit noise conditions when vehicle can actually transmit and magnify lNHERENT
cool which go away once they are fully component rotational frequencies, if the accessories
warmed—up,or the opposite may be true. were not installed correctly.
that it is
- Load on an Accessory Component An accessory should be installed in such a way
isolated from becoming a possible transfer path into the
Accessories could exhibit a noise condition while if a set of running
vehicle. For example,
under a heavy load —perhaps when combined rest of the
with a cool orfully warmed—upcondition. boards has been installed improperly and they are
sensitive to a particular frequency of a rotating
- Bent or Misaligned Pulleys component, the running boards could begin to respond
Bent or mis—alignedpulleys in one or more
engine-driven accessory systems could contribute
to a noise or vibration condition.
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2013 (5377994)
Manual
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ln62 Vibration Diagnosis and Correction
to the frequency and actually create a disturbance once Check Service Bulletins
the amplitude of the frequency reaches a high enough If BOTH of the following statements are TRUE, then
point , probably at a higher vehicle speed. check service bulletins for the condition identified. it the
it the same set of running boards were installed condition has already been identified and investigated
properly——isolatedproperly—the transfer path would be prior to this vehicle, and has been determined to be
removed and the disturbance would no longer be something that is not truly an operating characteristic or
present. that perhaps is not design-intent, there will likely be
adjustments or corrections identified which will address
Vibration Diagnostic Aids - Vibration the condition.
Duplicated, Difficult to lsolatel - You CAREFULLY followed the steps indicated
through reviewing the Diagnostic Starting Point -
Balance Component Vibration Diagnosis and completing the Vibration
Note: Ifyou have not completed the Vibration Analysis Analysis tables identified and you have duplicated
tables as indicated and reviewed Vibration Diagnostic the vibration concern.
Aids, refer to Vibration Diagnostic Aids on page 1-60 . You have come to the conclusion through
BEFORE proceeding. comparison with a very equally-equipped, same
Ifyou have duplicated the vibration concern but have model year and type, KNOWN GOOD vehicle that
had difficulty in balancing a component or isolating a the customer's concern is a condition that appears
component, refer to the following information. to be a potential operating characteristic of the
vehicle.
Most vibration concerns are corrected or eliminated
through correcting excessive runout of a component, Diagnosis and
correcting balance of a component or isolating a Symptoms - Vibration
component which has come into abnormal contact with Correction
another object/component. Note: Perform the following steps in sequence
Components which can generate a lot of energy and BEFORE using these symptom tables.
are experiencing excessive runout, imbalance or
ground—outcan produce a vibration with a strong 1. Begin the diagnosis of a vibration concern by
enough amplitude that the vibration can transmit to reviewing Diagnostic Starting Point —Vehicle on
components which are closely related. This type of a page 6—66to become familiar with the diagnostic
condition is usually related to and sensitive to process used to properly diagnose vibration
torque-load. The most likely system that could exhibit concerns.
this type of a condition is the driveline. 2. Perform the Vibration Analysis - Road Testing on
page 1—39table before using these symptom
Vibration Diagnostic Aids - Vibration tables in order to duplicate and effectively
diagnose the customer's concern.
Duplicated, Appears to Be Potential
Operating Characteristic Symptom Tables
Note: Ifyou have not completed the Vibration Analysis Refer to a Vibration Analysis table as indicated in the
tables as indicated and reviewed Vibration Diagnostic following symptom tables, based on the most dominant
Aids, refer to Vibration Diagnostic Aids on page 1-60 characteristic of the customer's vibration concern, felt
BEFORE proceeding. or heard, that is evident during the appropriate
condition of the occurrence.

Vibration Symptoms that are Felt

Typical
Frequency
Category Description Range Condition of Occurrence Area of Focus
VehicleSpeed Sensitive Go to VibrationAnalysis-
IStilloccursduringcoastdown Wheel0'7
Tire8017'
Can sometimesbe seen orfeltin the 'n NEUTRAL page 143
steerIngwheel,seator console. 5—20Hz VehicleSpeedSensitive Go to VibrationAnalysis-
Shake . .
RelatedtermInology:shimmy. Affectedby torque/loadandlor HUDand/orAx/eInputon
wobble,waddle,shudder,hop steeringinput page 1-46
. .. Go to VibrationAnalysis-
EngineSpeedSenSItIve Engineonpage 1-48

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 Diagnosis and Correction 1163
Vibration

Vibration Symptoms that are Felt (cont'd)

Typical
Frequency Area of Focus
Description Range Condition of Occurrence
Category
VehicleSpeed Sensitive Go to VibrationAnaIySis-
Still occursduringcoast down Tire317dWheelon
'InNEUTRAL page 1-43
VehicleSpeed Sensitive Go to VibrationAnalysis -
Similarto thefeelingof holdinga 20—50Hz HUband/orAx/eInputon
..
Rou9hness JIgsaw. Affectedby torque/loadandlor
steeringinput page 7'46
. .. Go to VibrationAnalysis-
EngineSpeed SenSItIve Engine onpage 1-48

Vah‘C'eSpeed Sens'ttive Go to VibrationAnalysis -

Similarto thefeelingof holdingan
electricrazor.
Maybe feltin the handsthroughthe
BUZZ
steeringwheel,in thefeet through
thefloor,orin theseat ofthe pants.
May producea "pinsand needles"
sensationor mayputhandsor feet
Tingling "toSleep"-
Highestvibrationfrequencyrange
thatcan stillbe felt.
Affectedby torque/loadandlor
50—100HZ steerlng'“pUt
. ..
EngIneSpeed senSIthG
VehicleSpeed Sensitive
Affectedby torque/loadandlor
thge‘l?)t8:-iz steeringinput
,.
.
EngIneSpeed Sensmve
HUband/orAxle Input0"
page 1‘46
Go to VibrationAnal sis -
Engineonpage 1-4g
G0 ‘0 VibrationAnalysis ‘
HUDand/orAxIeInput0”
page 1-46
G t V'b t' n An I ,- _
5,3ng ghaplgge1223/8 s

Vibration Symptoms that are Heard

Typical
Frequency Area of Focus
Description Range Condition of Occurrence
Category Go to VibrationAnalysis -
heardas an interiornoise VehicleSpeed Sensitive
Usually Still occursduringcoast down Tireand Wheelon
SImIlartothe n0Iseof a bowlingball in NEUTRAL page 1-43
rollingdownan alley,deep thunder,
ora bass drum.
0 Related terminology—droning, 20—60Hz
Boom - - .
VehicleSpeed Sensitive Go to VibrationAnalysis -
?I‘Oan'ngv
QFOVgI'.“9' marmgv HUband/orAx/e“7P“t0”
Affectedby torque/loadandlor
rum Ing, ummIng _ steeringinput page 1—46
- May notbe accompanledby a
perceptiblevibrationor
roughness
Vehicle Speed Sensitive Go to VibrationAnalysis _
Similartothe soundof a bumblebee Affectedby torque/loadandlor Hub and/orAx/eInputon
or blowmgairacross thetop ofa P399 1'46
steeringinput
bottle.
Moanor - Relatedterminology—humming, 607120HZ b I
Drone buzzing,resonance . .. Go to Vi rationAna ysis -
. EngIneS eed SenSItIve »
. May be accompanIedby a p EngIneonpage 1'48
perceptiblevibrationsuch as
a buzz
VehicleSpeed Sensitive Go to VibrationAnalysis -
Affectedby torque/loadand/or HUband/orAx/eInput0'7
S' .| t th d h .d P399146
hmni‘bo e 30”“ 0” ew'“ Hz steeringinput
120—300
Howl .. Go to VibrationAnalysis-
. Engine onpage 1-48
EngIneSpeed SenSItIve
--
Vehicle8 peed Sensmve - -
to transmISSIon
mosquitoes, Go
.
Similarto
. . soundof
the
or vacuum 300 500Hz Affectedby torque/load
diagnosticinformation
WhIne tclI‘ratgiIrIigrtsanglnes,

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2013 (US/Canada)
Sonic (5377994)
Manual
Service
'l264 Vibration Diagnosis and Correction

Vehicle-to-Vehicle Diagnostic Tire and Wheel Inspection

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.
5? EO- 1072 "s
The comparison vehicle must match the customer's
vehicle in the following areas: ) 1‘” /?7@mg§
95$
' Model Year
- Make
- Model
- Body style
- Powertrain configuration
- Driveline configuration
- Final drive ratio
- Tire/wheel size and type
- Suspension package
- Trailering package 182126
- GVW rating The tires on all new production models have a tire
- Performance options performance criteria (TPC) rating number molded on
the sidewall. The TPC rating will appear as a 4—digit
- Luxury options number preceded by the letters TPC SPEC on the tire
wall near the tire size. A replacement tire should have
the same TPC rating.

(US/Canada)
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2013 (5377994)
Manual
Service
 Diagnosis and Correction l65
Vibration

Tire Wear

386773

Legend (4) Heavy Acceleration/Overinflation

(1) Hard Cornering/Underinflation (5) Wearlndicator
Rotation
(2) lncorrectAlignment/Lack of
Tire
(3) Incorrect Alignment/Non-uniform
the following
Inspect the tire and wheel assemblies for
conditions:
flat spots, and/or
- Unusual wear such as cupping,
heel-and-toe wear
tire howl,
These conditions can cause tire growl, the
slapping noises, andlor vibrations throughout
vehicle.
for the vehicle
' Proper inflation to specifications
I- Bulges in the sidewalls
abnormal
Do not confuse bulges, which are an are
condition, with normal ply splices which
indentations in the sidewall.
commonly seen as
- Bent rim flanges
Assembly Runout
Tire and Wheel
Measurement - On-Vehicle
1. Raise and support the vehicle.
and even bead
2. ClosIely inspect each tire for proper 176957
seatIng.
tire with tape (1) in
properly or evenly
3. Ifany of the tire beads were not proceed to 4. Wrap the circumference of each
seated, reseat the tire bead, then and the center tread area.
step 4. Refer to Tire and Wheel Removal for a smooth
Wrapping the tread with tape allows
Installation on page 16-60. reading of radial runout to be
and accurate
obtained.
taped portion of
5. Position the dial indicator on the is
the tire tread such that the dial indicator
perpendicular to the tire tread surface.
assembly one
6. Slowly rotate the tire and wheel the low spot.
complete revolution in order to find
at the low spot.
7. Set the dial indicator to zero

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2013 (5377994)
Manual
Service
 r‘/‘
’l=oo Vibration Diagnosis and Correction
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)
176958
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 anyjumps or dips due to sidewall splices.
11. Set the dial indicator to zero at the low spot.
12. Slowly rotate the tire and wheel assembly one
more complete revolution and measure the total
amount of lateral runout. Ignore anyjumps 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.
14. Lower the vehicle.
Tire and Wheel Assembly Runout
Measurement - Off Vehicle
1. Raise and support the 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.
. Ifany 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 on page 16-60.
. 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.
176957
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.
Position the dial indicator on the taped portion of
the tire tread such that the dial indicator is
perpendicular to the tire tread surface.
Slowly rotate the tire and wheel assembly one
complete revolution in order to find the low spot.
10. Set the dial indicator to zero at the low spot.
11. Slowly rotate the tire and wheel assembly one
more complete revolution and measure the total
amount of radial runout.
Specification
Maximum tire and wheel assembly radial runout -
measured off-vehicle: 1.27 mm (0.050 in)
2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Diagnosis and Correction 'l=67
Vibration

176958
of
12. Position the dial indicator on a smooth portion
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.
14. Set the dial indicator to zero at the low spot.
one
15. Slowly rotate the tire and wheel assembly
more complete revolution and measure the total
amount of lateral runout. Ignore anyjumps 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)
and
16. Repeat steps 6 through 15 until all of the tire
wheel assembly radial and lateral runout
measurements have been taken.
17. IfANY of the tire and wheel assembly runout
measurements were NOT within specifications,
proceed to step 19.
18. IfALL of the tire and wheel assembly runout
measurements WERE within specifications, then
is
the off—vehicletire and wheel assembly runout
considered acceptable.
176966
outer
19. Position the dial indicator on the horizontal still
surface of the wheel rim flange —with the tire
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.
20. Slowly rotate the tire and wheel assembly
one
spot.
complete revolution in order to find the low
the low spot.
21. Set the dial indicator to zero at
one
22. Slowly rotate the tire and wheel assembly total
more complete revolution and measure the
amount of wheel radial runout.
Specification
-
- Maximum aluminum wheel radial runout
measured off—vehicle,tire mounted: 0.762 mm
(0.030 in)
o Maximum steel wheel radial runout -
measured off-vehicle, tire mounted: 1.015 mm
(0.040 in)

I 2013 (US/Canada)
-Sonic (5377994)
Manual
Service
 ,« and Correction
1-0 8 Vibration Diagnosis
31. Using the matchmarks made prior to removal,
install the tire and wheel assemblies to the vehicle.
32. Lower the vehicle.
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.
o/c L\_r_l 7““ Dismount the tire from the wheel. Referto Tire
Dismounting and Mounting on page 16-63.
9’ Mount the wheel on a spin-type wheel balancer.
Locate the wheel on the balancer with a cone
through the back side of the center pilot hole.

176968
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.
24. Slowly rotate the tire and wheel assembly one
complete revolution in order to find the low spot.
25. Set the dial indicator to zero at the low spot.
26. Slowly rotate the tire and wheel assembly one
more complete revolution and measure the total
amount of wheel lateral runout.
Specification 176960
0 Maximum aluminum wheel lateral runout -
measured off-vehicle, tire mounted: 0.762 mm Position the dial indicator on the horizontal inner
(0.030 in) surface of the wheel rim flange —with the tire
dismounted —such that the dial indicator is
0 Maximum steel wheel lateral runout - perpendicular to the rim flange surface.
measured off—vehicle,tire mounted: 1.143 mm
(0.045 in) Wheel runout should be measured on both the
inboard and outboard rim flanges. Ignoreany
27. Repeat steps 19 through 26 until all of the wheel jumps or dips due to paint drips, chips, orwelds.
radial and lateral runout measurements have been
taken on each of the - tire and wheel —assemblies . Slowly rotate the wheel one complete revolution in
with assembly runout measurements which were order to find the low spot.
NOT within specifications. ." Set the dial indicator to zero at the low spot.
28. Ifany of the wheel runout measurements were Slowly rotate the wheel one more complete
NOT within specifications, proceed to Measuring revolution and measure the total amount of wheel
Wheel Runout —Tire Dismounted. radial runout.
29. For any of the wheel runout measurements which Specification
WERE within specifications, while the —tire and
- Maximum aluminum wheel radial runout-
wheel —assembly runout measurements were measured off—vehicle,tire dismounted:
NOT within specifications, replace the tire, then 0.762 mm (0.030 in)
balance the assembly. Refer to Tire and Wheel
Assembly Balancing - Off Vehicle on page 1—72. ' Maximum steel wheel radial runout-
measured off-vehicle, tire dismounted:
30. After replacement of any tires, always re—measure 1.015 mm (0.040 in)
the runout of the affected tire and wheel assembly,
or assemblies.

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
 Diagnosis and Correction 1269
Vibration
which
15. For any of the wheel runout measurements and
WERE within specifications, while the ~tire
wheel —assembly runout measurements were
then
NOT within specifications, replace the tire,
balance the assembly. Refer to Tire and Wheel
Assembly Balancing —Off Vehicle on page 1—72.
dismounting
16. Using the matchmarks made prior to
the tire, or tires, mount the tire, or tires to the
LU assembly,
wheel, or wheels, then balance the
Assembly
or assemblies. Refer to Tire and Wheel
Balancing - Off Vehicle on page 1—72.
and
Always measure the runout of any of the tire
wheel assemblies which have had the tires
dismounted and mounted.
removal,
17. Using the matchmarks made prior to
install the tire and wheel assemblies to the vehicle.
18. Lower the vehicle.

Brake RotorlDrum Balance

Inspection
176964 hoist.
1. Support the vehicle drive axle on a suitable
Refer to Lifting and Jacking the Vehicle on
9. Position the dial indicator on the vertical inner
surface of the wheel rim flange —with the tire page 1—31.
from the
dismounted —such that the dial indicator is 2. Remove the tire and wheel assemblies and
drive axle. Refer to Tire and Wheel Removal
perpendicular to the rim flange surface.
Installation on page 16-60.
Wheel runout should be measured on both the
inboard and outboard rim flanges. Ignore any Warning: Refer to Work Stall Test Warning on
jumps or dips due to paint drips, chips, or welds. page 0-7.
one complete revolution in the brake
10. Slowly rotate the wheel 3. Reinstall the wheel nuts in order to retain
order to find the low spot. rotors.
11. Set the dial indicator to zero at the low spot. 4. Run the vehicle at the concern speed
while
the wheel one more complete inspecting for the presence of the vibration.
12. Slowly rotate
revolution and measure the total amount of wheel Caution: Do not depress the brake pedal with with
the
lateral runout. andlor the brake drums removed, or
brake rotors
the brake
Specification the brake calipers repositioned away from
the brake system may result.
rotors, or damage to
- Maximum aluminum wheel lateral runout - remove the rotors
measured off-vehicle, tire dismounted: 5. Ifthe vibration is still present, to the
from the drive axle, then run the vehicle back
0.762 mm (0.030 in)
concern speed.
' Maximum steel wheel lateral runout - brake rotors
measured off—Vehicle,tire dismounted: 6. Ifthe vibration is eliminated when the
are removed from the drive axle, repeat the test
1.143 mm (0.045in) time. Replace the rotor
wheel with one rotor installed at a
13. Repeat steps 2 through 12 until all of the that is causing or contributing to the vibration
radial and lateral runout measurements —tire concern.
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.

(US/Canada)
4Sonic
2013 (5377994)
Manual
Service
1270 Vibration Diagnosis and Correction
182237
7. Ifa brake rotorwas 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, performthe following:
7.1. Mount the brake rotor/drumon a balancer in
the same manner as a tire and wheel
assembly.
Note: Check brake rotors/drumsfor static imbalance
only; ignore the dynamic imbalance readings.
7.2. lnspect the rotor/drumfor static imbalance.
There is not a set tolerance for brake rotor/drumstatic
imbalance. However, any brake rotor/drummeasured in
this same manner which is over 21 9 (V402) 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/drumthat is
replaced should be checked for imbalance in the same
manner.
Hub/Axle Flange and Wheel Stud
Runout Inspection
Special Tools
GE—8001Dial IndicatorSet, or equivalent
1. Raise and support the vehicle. Refer to Lifting and
Jacking the Vehicle on page 1-31.
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. Refer to Tire and Wheel Removal and
Installation on page 16-60.
4. Remove the brake rotors andlor 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.
((((((((((.
((((((((((.
205276
. Position the GE—8001Dial IndicatorSet,
or equivalent, on the machined surface of the
wheel hub/axle flange outside of the wheel studs.
. Rotate the hub one complete revolution in order to
find the low spot.
. Set the GE—8001Dial Indicator Set, or equivalent,
to zero at the low spot.
. 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)
lfthe 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/axleflange IS within
specification and the vehicle is equipped with
wheel bolts, proceed to step 19.
11. Ifthe runout of the wheelhub/axle flange is
marginal, the wheel hub may or may not be the
source of the disturbance.
12. Ifthe 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.
2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Wosis and Correction 1:71
Vibration

Tire and Wheel Assembly

Isolation Test

Force Variation
movement of
Force variation refers to a radial or lateral
which acts much like
the tire and wheel assembly
runout, however, force variation has to do with
variations in the construction of the tire. These
variations in tire construction may actually cause
wheel
vibration in a vehicle, even though the tire and
assembly runout and balance may be within
specifications.
Radial Force Variation

205279

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.
register on
14. Turn the hub one complete revolution to
each of the wheel studs.
equivalent,
15. Zero the GE-8001 Dial Indicator Set, or
on the lowest stud.
and
16. Rotate the hub one more complete revolution
measure the total amount of wheel stud —stud
circle - runout.
Specification —Guideline 176971
Wheel stud runout tolerance guideline: 0.254 mm the
(0.010 in) Radial force variation refers to the difference in
stiffness of a tire sidewall as the tire rotates and
—is
17. Ifthe runout of the wheel studs —stud circle contacts the road. Tire sidewalls have some
stiffness
marginal, the wheel studs may or may not be the tire, but these
due to splices in the different plies of
contributing to the disturbance. stiffness differences do not cause a problem unless the
—is
18. Ifthe runout of the wheel studs —stud circle force variation is excessive. Stiff spots (1) in a
tire
excessive, replace the wheel studs as necessary. sidewall can deflect a tire and wheel assembly upward
Measure the runout of the new wheel studs. as the assembly contacts the road.
portion on
19. lnspect the threads and the tapered seat
each of the wheel bolts for damage.
20. Wheel bolts exibiting damaged threads andlor
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.

i —
2013Sonic Service
(US/Canada) (5377994)
Manual
'l-72 Vibration Diagnosis and Correction
Lateral Force Runout
/ Q \\\\
W balance the assembly, or assemblies. Refer to Tire
M and Wheel Assembly Balancing - Off Vehicle on
175760
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—40km/h (5—25mph), 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 on
page 16-60.
2. Road test the vehicle to determine if the vibration is
still present. Refer to Vibration Analysis - Road
Testing on page 1-39.
3. Ifthe 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.
4. 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 on
page 16-60. Road test the vehicle to determine if
the vibration has returned. Refer to Vibration
Analysis —Road Testing on page 1-39.
5. 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.
6. Replace the tire, or tires on the vibration-causing
tire and wheel assembly, or assemblies, then
page 1-72.
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/orwhenever the balance readings
are questionable.
2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Diagnosis and Correction 1:73
Vibration
at the new
9. Cycle the balancer with the assembly
Balancer
Tire and Wheel Assembly locaflon.
Calibration Test 10. Inspect the balancer readings:
in this
Note: Ifthe balancer fails any of the steps Specification
test, the balancer should be calibrated
calibration
Ifthe Maximum variation: 7 g (1A02)
according to the manufacturer's instructions. the tire and wheel
balancer cannot be calibrated, contact the 11. Repeat steps 8 through 10 until at each of
assembly has been cycled and checked
manufacturer for assistance. on the balancer shaft.
the 4 locations
assembly
Inspect the calibration of the tire and wheel Balancing
balancer according to the manufacturer's Tire and Wheel Assembly
recommendations, or perform the following test. Guidelines
exhibit
Note: Tire and wheel assemblies which
vibrations even if the
excessive runout can produce
assemblies are balanced.
and wheel
Itis strongly recommended that the tire if
assembly runout be measured and corrected
BEFORE the assemblies are balanced.
necessary
assemblies has not
if the runout of the tire and wheel
and Wheel Assembly
yet been measured, refer to Tire
Off Vehicle on page 1-66 before
Runout Measurement -
proceeding.
There are 2 types of tire and wheel balance:
Static Balance

612344
any of the
1. Spin the balancer without a wheel or
adapters on the shaft.
2. Inspect the balancer readings.
Specification
Zero within 7 g (‘4 oz)
range,
3. Ifthe balancer is within the specification is within
balance a tire and wheel assembly —that
ZERO,
radial and lateral runout tolerances —to
using the same balancer.
been
4. After the tire and wheel assembly has to the
balanced, add an 85 g (3 oz) test weight
wheel at any location. 70074
Note the
5. Spin the tire and wheel assembly again. Static balance is the equal distribution
of weight around
wheel balance
readings.
balancer the wheel circumference. The in order to
- in the static and dynamic modes, the weights (2) are positioned on the wheel that have
Wheels
should call for 85 g (3 oz) of weight, offset the effects of a heavy spot (3). action called
180 degrees opposite the test weight. static imbalance can produce a bouncing
should be
o In the dynamic mode, the weight opposite
tramp.
called for on the flange of the wheel
the test weight.
g (3 oz), cycle
6. With the assembly imbalanced to 85
the balancer 5 times.
7. Inspect the balancer readings:
Specification
Maximum variation: 7 g (%oz)
the balancer
8. index the tire and wheel assembly on location.
shaft, 90 degrees from the previous

(US/Canada)
-Sonic
2013 (5377994)
Manual
Sen/ice
1:74 Vibration Diagnosis and Correction
Dynamic Balance
V I/I\I 7
\ /
\’I‘/
70079
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—vehiclebalancers 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—21g (1/2—% 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—planedynamic balancer set to the finest balance
mode available.
3018691
Note: Carefully follow the wheel balancer
manufacturers's instructions for proper mounting of the
center cone (1).
1. Raise and support the vehicle. Refer to Lifting and .
Jacking the Vehicle on page 1—31.
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 one at a
time and mount on a spin-type wheel balancer.
Refer to Tire and Wheel Removal and Installation
on page 16—60.
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 Tire and Wheel Removal and Installation
on page 16-60.
8. Lower the vehicle.
—
2013 (US/Canada)
Sonic (5377994)
Manual
Service
 Diagnosis and Correction ’l=75
Vibration

Wheel Weight Usage

balanced using
Tire and wheel assemblies can be
either the static or dynamic method.

Clip-on Weights

'I
S w

Ks

315790
when
Note: Use a nylon or plastic—tippedhammer to
weights
installing coated clip—onwheel balance polyester
minimize the possibility of damage to the
coating.
flange will
08 The contour and style of the wheel rimweight (1) should
determine which type of clip—onwheel
contour of the
be used. The weight should follow the grip the rim
rim flange. The weight clip should firmly
flange.
Weights
Wheel Weight Placement —CIip-on

448750
wheels with
Note: When balancing factory aluminum
use special
clip-on wheel balance weights, be sure to
polyester—coatedweights. These coated weights
damage to
reduce the potential for corrosion and
aluminum wheels.
for corrosion
These coated weights reduce the potential
and damage to aluminum wheels.
approved for
- MC (1) and AW (2) series weights are
use on aluminum wheels.
for use on steel
- P (3) series weights are approved
wheels only.
approved for use
- T (4) series coated weights are
on both steel and aluminum wheels.
448749
balance
When static balancing, locate the wheel g (1 02) or
if only 28
weights on the inboard flange (2)
oz) is called for,
less is called for. If more than 28 g (1 between the
split the weights as equally as possible
inboard (2) and outboard (1) flanges.
wheel balance
When dynamic balancing, locate the
and outboard (1) rim flanges
weights on the inboard (2)
specified by the wheel balancer.
at the positions

—
2013 (US/Canada)
Sonic (5377994)
Manual
Service
'l-76 Vibration Diagnosis and Correction
Adhesive Weights
Tire
- On-Vehicle
448752 balancer.
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 02) or
less is called for. If more than 28 g (1 02) is
called for, split the weights as equally as
possible between the wheel centerline and the
inboard edge of the innerwheel 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.
and Wheel Assembly Balancing
Special Tools
EL-38792—AElectronic Vibration Analyzer (EVA) 2
Ifafter following the tire and wheel vibration diagnostic
process, some amount of tire and wheel vibration is still
evident, an on-vehicle high—speedspin 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 mountingthe
tire and wheel assembly on the vehicle, as opposed to
the balance which was achieved on the off—vehicle
In order to perform an on—vehiclebalancing 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. Ifthe 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—vehiclebalance weights.
The purpose of on—vehiclebalance is to fine tune
the assembly balance already achieved
off—vehicle,not to start over.
- Leave all wheel trim installed whenever possible.
(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
 Diagnosis and Correction l-77
Vibration
a tire
than 56 g 3. Mount the tire and wheel assembly on
° Ifthe on—vehiclebalancer calls for more machine and break down the bead. Do not
(2 oz) of additional weight, split the weight the wheel at this time.
dismount the tire from
between the inboard and outboard flanges of the the
wheel, so as not to upset the dynamic balance
of Rotate the tire 180 degrees on the rim so that
balance. valve stem reference mark (8) is now at the
the assembly achieved in the off—vehicle
stem (6).
For wheel balance weight information, refer
to Tire 6 o‘clock position in relation to the valve
the bead in order to
and Wheel Assembly Balancing —Off Vehicle on You may need to lubricate
easily rotate the tire on the wheel.
page 1-72.
the fenders Reinflate the tire and seat the bead properly.
- If available, tape—offan area on top of
and the quarter panels, then place the vibration Mount the assembly on the tire balancer and
of the
sensor of the EL-38792—AElectronic Vibration remeasure the runout. Mark the new location
the tire.
Analyzer (EVA) 2 on the fender or quarter panel assembly runout high spot on
while it
above the specific tire and wheel assembly Ifthe assembly runout has been reduced
and is
is being on-vehicle balanced. within tolerance, no further steps are necessary.
The EL-38792-A Electronic Vibration Analyzer Balance the tire and wheel assembly, then install
following:
(EVA) 2 will provide a visual indication of the the assembly to the vehicle. Refer to the
amplitude of the vibration, and the effect that the . Tire and Wheel Assembly Balancing — Off
on-vehicle balance has on it. Vehicle on page 1-72
on
Match-Mounting - Tire and Wheel Removal and Installation
Tire-to-Wheel page 16-60
at or
(Vectoring) Ifthe clock location of the high spot remained (7)
original clock location of the high spot
near the
reduced,
and the assembly runout has NOT been
major contributor to the assembly
the wheel is the
runout concern.

“163

182218
Note: After remounting a tire to a wheel or after and
replacing a tire andlor a wheel, remeasure the tire
wheel assembly runout in order to verify that the to 182231
amount of runout has been reduced and brought
within tolerances. Ensure that the tire and wheel to the 9. Ifthe clock location of the high spot has
moved,
assembly is properly balanced before reinstalling however the assembly runout has NOT been
vehicle. reduced, perform the following steps:
the tire as is now
1. Mark the location of the high spot (3) on 9.1. Ifthe clock location of the high spot (7)
the off-vehicle tire and wheel 180 degrees from the
determined during at or near a position
tire
assembly runout measurement. original clock location of the high spot, the
the assembly runout
2. Place a reference mark (2) on the tire
sidewall at is the major contributor to
the location of the valve stem (5). concern.
now
- Always refer to the valve stem as the 12
o'clock 9.2. Ifthe clock location of the high spot is tire
in—between the 2 extremes, then both the
position.
its and the wheel are both contributing to the
- Refer to the location of the high spot (3) by assembly runout concern. Rotate the tire an
clock position on the wheel, relative to the additional 90 degrees in both the clockwise
valve stem.
and the counterclockwise directions to obtain
the lowest amount of assembly runout.

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’1-78 Vibration Diagnosis and Correction
Tire and Wheel Assemny-to-Hubl
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—vehicletire 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 on page 16-60.
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 on
page 16—60.
6. Remeasure the tire and wheel assembly
on-vehicle runout. Mark the new location of the
assembly on—vehiclerunout high spot on the tire.
Refer to Tire and Wheel Assembly Runout
Measurement - On—Vehic/eon page 1—65.
7. Ifthe assembly on-vehicle runout has been
reduced and is within tolerance, no further steps
are necessary.
8. Ifthe assembly runout has NOT been reduced,
perform the following steps:
8.1. Ifthe 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/drummounting flange is the major
contributor to the assembly on—vehiclerunout
concern.
8.2. Ifthe 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—vehiclerunout concern.
8.3. Ifthe 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—vehiclerunout.
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. Ifa 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
0 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 Ifa motor mount is collapsed.
A vibrating component operates at a consistent rate
(kmlh, 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
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 and Correction 1479
Vibration Diagnosis
and correcting the
path. Aligning the exhaust system eliminate the
grounded condition at the frame would
transfer path.
Basic Vibration Terminology
components of vibration
The following are the 2 primary
diagnosis:
objects
- The physical properties of
conducting mechanical
- The object's properties of
energy
The repetitive up and down or back and forth
customer
movement of a component cause most the common
complaints. The following are
vibration
components that vibrate:
- The steering wheel
- The seat cushion
- The frame
- The IP
following simple
Vibration diagnosis involves the
95585 outline:
and assign a value
unbalanced 1. Measure the repetitive motion second or cycles
is the to the measurement in cycles per
Inthe preceding picture, the source vibrations travels
tire. The transfer path is the route the per minute.
into the
through the vehicle's suspension system steering wheel, 2. Relate the frequency back on
terms of the
steering column. The responder is the
rotational speed of a component that is operating
as vibrating. Eliminating
which the customer reports usually correct the at the same rate or speed.
any one of these three elements will information, which 3. Inspect and test the components
for conditions that
condition. Decide, from the gathered
Adding a cause vibration.
element makes the most sense to repair. steps will help
the
brace to the steering column may keep is not a
steering For example, performing the following
wheel from vibrating, but adding a brace demonstrate the vibration theory:
The most direct and effective repair
practical solution.
would be to properly balance the tire.

95587

of a table, leaving
95586 1. Clamp a yardstick to the edge the edge of the
about 50 cm (20in) hanging over
example,
Vibration can also produce noise. As an table.
exhaust pipe grounded stick and release
consider a vehicle that has an is the engine 2. Pull down on the edge of the of the stick.
of the vibration the movement
to the frame. The source exhaust. The while observing
firing impulses traveling through the exhaust
transfer path is a grounded or bound—upfloor panel
is the frame. The
hanger. The responder produces
vibrates, acting as a large speaker, which the transfer
would be to eliminate
noise. The best repair

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1:80 Vibration Diagnosis and Correction
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. Inthis case, about 10 cycles in
one second. Ifwe 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 (10in) 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

95588
Legend
(1) 1stCycle (3) 3rd Cycle
(2) 2nd Cycle (4) Time

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 Vibration Diagnosis and Correction 1:81

Vibration Cycles in Powertrain

Components

95589
Legend
(1) Spindle
(2) 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.

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H32 Vibration Diagnosis and Correction

Frequency

117: /\.
1112/ .

AA A

..tYIVIVt/M

95590
Legend
(1) Amplitude (3) Time in Seconds
(2) Reference (4) 1 Second

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

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 Vibration Dijgflosis and Correction 1:83

Amplitude is the maximum value of a periodically

are
Amplitude varying quantity. Used in vibration diagnostics, we
referring it to the magnitude of the disturbance.
a
A severe disturbance would have a high amplitude;
minor disturbance would have a low amplitude.
Amplitude is measured by the amount of actual
movement, or the displacement. For example, consider
.- at
“...—L the vibration caused by an out-of—balancewheel
as opposed to 40 km/h (25 mph). As
80 km/h (50 mph)
the speed increases, the amplitude increases.
t
Free Vibration
1 absence
Free vibration is the continued vibration in the
of any outside force. Inthe 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.

95593
Legend
(1) Maximum
(2) Minimum
(3) Zero—to-PeakAmplitude
(4) Peak-to-Peak Amplitude

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"l-84 Vibration Diagnosis and Correction

Centrifugal Force Due to an Imbalance

90 180 270 360 90

95594
Legend
(1) Location of lmbalance (Degrees) (2) 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.

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 Vibration Diagnosis and Correction L85

ManualorResonantFTequency Resonance

,5 \

10

0 \32/20 64/40 97/60 \129/80 161/100

kmlh /mph
3

95595
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.
95596
Legend
(1) Frequency—cps
(2) Suspension Frequency
(3) Unbalanced Excitation
(4) PointofResonance
(5) 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.

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1:86 Vibration Diagnosis and Correction

Damping

95597
Legend
(1) Low Damping (2) 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.

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 Vibration Diagnosis and Correction 'l=87

Beating (Phasing)

1+2=3

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95599
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 ofa rotating component.

95600
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.

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1488 Vibration Diagnosis and Correction
95601
An oval—shapedtire with 2 high spots would create a
disturbance twice for every revolution. This is called
second—ordervibration. Three high spots would be
third-order,and so forth. Two first—ordervibrations 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)
For equivalent regional tools, refer to Special Tools and
Equipment on page 1-91.
The EL-38792—AElectronic Vibration Analyzer 2
(EVA 2), is a 12—voltpowered hand—helddevice, 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 (20ft)
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 Inputports 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 Analyzer2 (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-AElectronic Vibration Analyzer2
(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—AElectronic
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-and-down
direction. The EL-38792—AElectronic Vibration
Analyzer2 (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.
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EVA Software Cartridge
The EL-38792—AElectronic 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—60provides the EL-38792-A Electronic Vibration
Analyzer 2 (EVA 2) with an additional feature which can
be selected and utilized to assist Indiagnosing vibration
concerns.
Note: The Auto—Modefunction 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—featureis available through the
EL-38792—AElectronic Vibration Analyzer 2 (EVA 2)
Auto—Modefunction. 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—ordertire
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.
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Vibration Diagnosis and Correction 1189
EVA Strobe Balancing Function
The EL—38792-AElectronic 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-38792—AElectronic 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.
AveraginglNon-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 nluwill
(instantaneous) mode along with the Auto Mode,
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.
1:90 Vibration Diagnosis and Correction

EVA Display Analyzer (EVA) 2, and a scan tool, to help in

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95605
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—of—acceleration force.
Vibrate Software Description and
Operation
The EL—38792—VSVibrate 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
determining the source of a vibration concern. The
EL-38792-VS Vibrate Software is designed to provide
quick calculations and produce a chart ofthe rotational
speeds and frequency ranges for specific vehicle
systems and components, based upon vehicle data
parameters inputted by the user.
The EL-38792—VSVibrate 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
REED
HESONANT TACHOMETE}?
IllIIIIIIIIIIIIIIITIIIIIIIIIIII
1o 12 14 16 1B 20
W
20 30 4D 50 60 70 80
(ID @
386790
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—80Hz. 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.

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 Vibration Diagnosis and Correction 1‘91
Due to the limited diagnostic capability, limited Illustration Tool Number/Description
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—AElectronic Vibration Analyzer (EVA) 2. The EN 38792-25
EL—38792-AElectronic Vibration Analyzer (EVA) 2 has J 38792—25
been designed to overcome the shortcomings to the InductivePickupTiming
reed tachometer. Refer to Electronic Vibration Analyzer Light
(EVA) Description and Operation on page 1-88.

Special Tools and Equipment

Illustration Tool Number/Description

GE 8001
EL 38792—A J 8001
J 38792-A Dial IndicatorSet
ElectronicVibration
Analyzer(EVA)2

694161

EL 38792-VS
J 38792-VS
VibrationSoftware

694124

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
’I192 Waterleaks

Waterleaks

Diagnostic Information and

Watertest Stand Assembly
Procedures

Waterleak Test Preparation 20

- GM vehicles are designed to operate under
normal environmental conditions.
60"
- 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 carwashes.
- 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. Ill
- The first step in diagnosing a leak is determining
the conditions underwhich a leak occurs. Ifthe 17\
general leak area can be found, the exact entry 4
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. 15 16 67
14
- Ifleaks 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.

12 11 1°

154169
Legend
(1) Pipe (0.5 x 36in)
(2) Reducing Tee, Right Stand Only
(0.5x 0.5 X 0.25 in)
(3) Coupling, Left Stand Only, (0.5 in)
(4) Tee, Left Stand Only (0.5 in)
(5) Cross, Right Stand Only (0.51n)
(6) Pipe to Hose Nipple, Right Stand
Only (0.5 in)
(7) Female Hose Coupling (5/81n)
(8) InputHose, Right Stand Only (2.01t)
(5/8in diameter)
(9) Close Nipple (0.5 in)
(10) Cross (0.5 in) with WeId-On Cap (0.5in)
(11) Nipple (0.5x 12 in)
(12) Cap (0.5 in)
(13) Female Hose Coupling (5/81n)
(14) Cross Hose (12 ft) (5/8in diameter)
(15) Hose Quick Connect
(16) Pipe to Hose Nipple (0.5 in)
(17) Pipe (0.5 x 60in)
(18) Water Pressure Gauge, Right Stand Only

2013
-Sonic
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 Waterleaks 1:93

(19) Full Jet Spray Nozzle, No. 1/2GG—25or

Equivalent
(20) Coupling (0.5 in)
1. Assemble the water test stand as shown.

I III a

317526
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.
311845 6. In order to check the side windows for leaks,
2. Position the stands as shown. The water spray position the water stand towards the center of the
from the stands should overlap the vehicle as rear quarter, aiming the water spray 30 degrees
shown. down and 45 degrees toward the rear.
3. Have an assistant inside of the vehicle during the 7. In order to check the back window, aim the water
test in order to locate any leaks. spray 30 degrees down and 30 degrees toward the
front.
4. The water pressure at the nozzle should maintain a
155 kPa (22 psi), for at least 4 minutes.
Recommended Materials (Waterleak Repair)
Leak Areas Repair Materials
Bolts,Studs,andScrews Stripcaulk
LargeHoles 3MTMAutomotiveJointandSeam Sealer
Metaljoints Brushableseamsealer whichcan be painted
SmallCracks andPin Holes 3MTMDrip-CheckSealeror equivalent
VentilationDucts 3MTMAutoBeddingand GlazingCompoundor equivalent
Weatherstrips 3MTM08011WeatherstripAdhesiveor equivalent
Windshield,RearWindow Urethaneadhesive,caulkingkit,or equivalent

Dust Leaks 6. Examine the interior.

Dust in the shape of a small cone or slit will usually
Dust may leak into the vehicle where water will not. be found at the point of leakage.
This happens particularly in the lower portion of the
interior. 7. Mark the points of leakage.
Forward motion of the vehicle can create a slight Note: Ensure that the interior is darkened when
vacuum which pulls air and dust into the vehicle. performing this step.
In order to determine the location of dust leaks, perform 8. Shine bright lamps on the underside of the floor
the following steps: and the cowl.
Remove the mats from the floor.
Remove the mats from the kick panel.
Remove the insulation from the floor.
Remove the insulation from the kick panel.
Drive the vehicle on a dusty road.
@PPNT‘

(US/Canada)
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2013 (5377994)
Manual
Service
 1=94 WaterIeaks
9. Have an assistant mark any points inside of the Caution: The air hose test should only be used on fully
vehicle for any points where the light shines cured urethane adhesive. Otherwise, damage to the
through. urethane adhesive bead could result in additional
0 Inspect the weld joints. leaks.
- Inspect the body mounts. 1. Using a liquid detergent, diluted with water in a
10. Seal any leaks with an air-drying, body-sealing spray bottle, spray the window at the edges. Begin
compound. at the bottom and gradually move up and across
the top.
Water Hose Test 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

95572
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

639653
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. Ifthe floor carpet is wet, refer to Floor Carpet
Drying on page 2-18.

95574
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 Waterleaks "l=95

Stationary Window Waterleak Repair

639652
2. Cut out a portion of the adhesive caulking in the
leak area from inside or outside of the vehicle.
3. Clean and remove all loose particles of the
adhesive old caulking from the area.
4. Applyjoint body and seam sealer where the old
adhesive caulking was removed.
5. Allow the adhesive caulking to dry for several
hours.
6. Testforleaks.
7. Install the trim, if removed.
Warning: If any water enters the vehicle interior up
to the level of the carpet or higher and soaks the
carpet, the sensing and diagnostic module (SDM)
and the SDM harness connector may need to be
replaced. The SDM could be activated when
powered, which could cause deployment of the air
bag(s) and result in personal injury. Before
attempting these procedures, the SIR system must
be disabled. Refer to Disabling the SIR System.
With the ignition OFF, inspect the SDM mounting
area, including the carpet. If any significant soaking
or evidence of significant soaking is detected, you
must perform the following tasks:
1. Remove all water.
2. Repair the water damage.
3. Replace the SDM harness connector.
4. Replace the SDM.
Failure to follow these tasks could result in
possible air bag deployment, personal injury,
or otherwise unneeded SIR system repairs.
1. Ifthe floor carpet is wet refer to Floor Carpet Drying
on page 2-18.
2. Remove the trim moldings or the headliner in order
to repair the leak, if needed.
9° Determine the source of water entry.
4. Ifwater is leaking at the edge of the windshieid,
reseal the windshield using Urethane Adhesive
Caulking Kit GM P/N 12346392 or the equivalent.
5. Ifwater leaks into the vehicle at the sides of the
stationary windows, reseal the window using
Urethane Adhesive Caulking Kit GM P/N 12346392
or the equivalent.

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Manual
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1:96 Waterleaks

BLANK

2013
~Sonic
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(5377994) I
 Fable of Contents 21I

Section 2

Body Hardware and Trim

Exterior Trim ................................... 2-3 Rear Compartment Floor Panel Carpet

Specifications ..................................... 2—3
Fastener Tightening Specifications .............. 2—3
Repair Instructions ............................... 2-3
Emblem/Nameplate Replacement ............... 23
Body Panel Paint Protector
Replacement (VGC) ............................ 2-3
Body Side Upper Front Applique
Replacement ................................... 2-4
Liftgate Side Applique Replacement
(Hatchback) ..................................... 2-5
Rear Compartment Lid Applique
Replacement ................................... 2-6
Front License Plate Bracket Replacement . . . 2-7
Front Bumper Fascia Tow Eye Access Hole
Cover Replacement ............................ 2-8
Rear Bumper Fascia Tow Eye Access Hole Cover
Replacement ................................... 2-9
Radiator Grille Emblem/Nameplate
Replacement .................................. 2-10
Liftgate Emblem/Nameplate Replacement
(Hatchback) ................................... 2-11
Rear Compartment Lid Nameplate Replacement
(Sedan) ........................................ 2-12
Front Upper Grille Replacement ................ 2—13
Front Lower Grille Replacement ................ 2—14
Radiator Grille Opening Cover Replacement
(Upper Grille Cover) ........................... 2-15
Roof Panel Joint Finish Molding
Replacement .................................. 2—16
Rear End Spoiler Replacement
(Hatchback TTV) .............................. 2-17
Floor Coverings and Headlinings ........... 2-18
Specifications ................................... 2—18
Adhesives, Fluids, Lubricants, and Sealers ..... 2-18
Repair Instructions .............................. 2—18
Eliminating Unwanted Odors in Vehicles . . . 2-18
Floor Carpet Drying ............................. 2-18
Floor Panel Carpet Replacement ............... 2—19
Front Side Door Opening Floor Carpet Retainer
Replacement .................................. 2-20
Rear Side Door Opening Floor Carpet Retainer
Replacement .................................. 2-21
Rear Compartment Floor Panel Carpet
Replacement (Sedan) ......................... 2-22
Replacement (Hatchback) ..................... 2-23
Headlining Trim Panel Replacement (Hatchback
with Sunroof) .................................. 2—24
Headlining Trim Panel Replacement (Hatchback
without Sunroof) ............................... 2-25
Headlining Trim Panel Replacement (Sedan
with Sunroof) .................................. 2-26
Headlining Trim Panel Replacement (Sedan
without Sunroof) ............................... 2-27
Instrument Panel and Console Trim . . .. . . . . 2-29
Specifications ................................... 2-29
Fastener Tightening Specifications ............. 2-29
Repair Instructions .............................. 2-29
Instrument Panel Insulator Replacement . . . 2-29
Instrument Panel Knee Bolster Replacement ... 2-30
Instrument Panel Accessory Upper Trim Plate
Replacement .................................. 2-31
Instrument Panel Center Trim Panel
Replacement .................................. 2-32
Instrument Panel Center Upper Molding
Replacement .................................. 2—33
Instrument Panel Upper Trim Panel
Replacement —Right Side ..................... 2-34
Instrument Panel Upper Trim Panel
Replacement —Left Side ....................... 2-35
Instrument Panel Fuse Block Access Hole
Cover Replacement (WithoutAAL) ............ 2-36
Instrument Panel Fuse Block Access Hole
Cover Replacement (WithAAL) ............... 2-37
Instrument Panel Outer Trim Cover .
Replacement .................................. 2-38
InstrumentCluster Upper Bezel
Replacement .................................. 2-39
Instrument Panel Lower Trim Pad Cover
Replacement (WithoutAAL) ................... 2-40
Instrument Panel Lower Trim Pad Cover
Replacement (With AAL) ...................... 2—41
Instrument Panel Upper Compartment Door
Latch Replacement ............................ 2—42
Instrument Panel Compartment
Replacement .................................. 2-43
Instrument Panel Lower Compartment
Replacement .................................. 2-44

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22 Table of Contents
Instrument Panel Compartment Door Latch
Replacement .................................. 2-45
Instrument Panel Compartment Door Dampener
Replacement .................................. 2-46
InstrumentPanel Center Molding Replacement
(With U58) ..................................... 2-47
Instrument Panel Center Molding Replacement
(Without U58) .................................. 2-48
Instrument Panel Assemny Replacement .... . . 2-49
InstrumentPanel Lower Intermediate
Reinforcement Replacement .................. 2-50
InstrumentPanel Tie Bar Replacement ......... 2-51
Front Floor Console Cover Replacement
(Automatic Transmission) ..................... 2-55
Front Floor Console Cover Replacement
(Manual Transmission) ........................ 2-56
Front Floor Console Cup Holder
Replacement .................................. 2-57
Automatic Transmission Control Indicator
Opening Cover Replacement ................. 2-58
Front Floor Console Extension Replacement -
Right Side ..................................... 2—59
Front Floor Console Extension Replacement -
Left Side ....................................... 2-60
Front Floor Console Replacement .............. 2-61
Front Floor Console Bracket Replacement .... . 2-62
Interior Trim and Paneling ................... 2-63
Specifications ...................................
2-63
Fastener Tightening Specifications .............
2-63
Repair Instructions ..............................
263
Front Side Door Window Switch Bezel
Replacement (Left Side) .......................
2—63
Front Side Door Window Switch Bezel
‘
Replacement (Right Side) .....................
2—64
Rear Side Door Window Switch Bezel
Replacement ..................................
2-65
Front Side Door Upper Front Trim Panel
Replacement .................................. 2-66
Front Side Door Trim Replacement .............
2-67
Rear Side Door Upper Rear Trim Panel
Replacement (Hatchback) ..................... 2-68
Roof Rail Front Assist Handle Replacement .... 2-69
Roof Rail RearAssist Handle Replacement 2-70
Sunshade Replacement ........................ 2-71
Sunshade Support Replacement ............... 2-72
Windshield Side Garnish Molding
Replacement .................................. 2—73
»Body Rear Seat Back Trim Panel Replacement
(with AMA/AM7) ............................... 2—74
Center Pillar Upper Trim Panel Replacement 2-75
Center Pillar LowerTrim Panel Replacement 2-76
Body Lock Pillar Upper Trim Panel Replacement
(Hatchback) ................................... 2-77
Body Lock Pillar Upper Trim Panel Replacement
(Sedan) ........................................ 2—78
Quarter InnerTrim Finish Panel Replacement
(Hatchback) ................................... 2-79
Body Side Trim Panel Replacement (Sedan) 2—80
Rear Window Panel Trim Replacement ......... 281
Rear Compartment Stowage Shelf Replacement
(Hatchback) ................................... 2-82
Rear Side Door Trim Replacement
(Hatchback) ................................... 283
Rear Side Door Trim Replacement (Sedan) 2-84
Luggage Shade Replacement (Hatchback) ..... 2—85
Liftgate Trim Finish Panel Replacement
(Hatchback) ................................... 2-86
Rear Compartment Sill Trim Plate
Replacement .................................. 2—87
Rear Compartment Lid Inner Panel Trim
Replacement (Sedan) ......................... 288
Rear Compartment Side Trim Replacement -
Left Side (Sedan) .............................. 289
Rear Compartment Side Trim Replacement -
Right Side (Sedan) ............................ 2—90
Cargo Tie Down Loop Replacement ............ 2-91
Quarter Outer Panel Pressure Relief Valve
Replacement .................................. 2-92
2013
-Sonic
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Manual
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 Exterior Trim 223

Exterior Trim

Specifications

Fastener Tightening Specifications

Specification
Application Metric English
LiftgateAppliqueNut 5.0N-m 44 lbin
RadiatorGrilleBumperBolt 1.5N-m 13lbin
RearCompartmentLid AppliqueNut 5.0N'm 44 lb in
Rear End SpoilerNut 5.0N'm 44 lbIn
Rear End SpoilerBolt,forCross Bar Indicator 1.5N-m 13lb in
Rear End SpoilerScrew 1.5N-m 13lb in

13. Remove the masking tape and clean all tape

Repair Instructions
Emblem/Nameplate Replacement
Caution: Refer to Exterior TrimEmblem Removal
Caution on page 0-8.
1. The part and vehicle surface should be 21°C
(70°F) prior to installation. The vehicle should
remain inside in a temperature range 0121°C
(70°F) for 1 hour after assembly to allow the
adhesive to develop sufficient bond strength.
Using masking tape, mark two sides of the
placement where the old emblemlnameplate was
placed.
. Use a heat gun or equivalent, to heat the adhesive
backed emblemlnameplates.
. Aflat—bladedplastic tool can assist in the removal
process.
. Wipe the vehicle surface area with a 50/50 solution
by volume of isopropyl alcohol and clean drinkable
water.
Dry the area with a clean lint—freecotton cloth.
Close any doors, liftgates, endgates and rear
compartment lids where emblemlnameplates are
to be pIaced.
. When removing protective liners from adhesive
backed emblemlnameplates, be careful not to
touch the adhesive tape or allow the tape to come
in contact with dirt or any foreign matter prior to the
placement and adhesion.
. Remove the protective liner from the emblem/
nameplate.
10. Position, align and press the emblemlnameplate to
the previously marked location.
11. Using a clean towel and the palm of the hand,
press firmly for approximately 30 seconds, the
emblemlnameplate to the vehicle body panel
surface.
12. Ensure the emblemlnameplate is attached firmly to
the body panel surface.
residue from the vehicle body panel surface
around the emblemlnameplate attachment
location.
Body Panel Paint Protector
Replacement (VGC)
1. The paint protective film and vehicle surface
temperature should be 13—32°C(55-90°F) for best
results.
Automatic car washes should be avoided for at
least 24 hours after the paint protective film
application.
Wipe the vehicle surface with isopropyl alcohol or
flash naptha at the application area.
Dry the surface with a clean Iint-freecloth.
Create a mixture of 25 percent isopropyl alcohol
.01.“
and 75 percent water and two drops of baby
shampoo per 16 oz of fluid mixture.
. Remove the backing liner from the protective film
patch.
. Use the solution to liberally spray the adhesive
side of the protective patch, the mounting location
along with your hands.
Position the paint protective film patch to the
desired location on the vehicle.
Spray the surface of the film with the alcohol, water
and soap solution.
10. Using a dampened squeegee, start at the center of
the protective patch, working outward in order to
remove the air and solution from under the
protective patch.
11. Release any air bubbles with a pin.
12. Dry the surface with a clean, lint-free cotton cloth.

(US/Canada)
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2013 (5377994)
Manual
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24 Exterior Trim

Body Side Upper Front Applique Replacement

2498157
Body Side Upper Front Applique Replacement
Callout I ' ComponentName
Caution: Referto ExteriorTrimEmblemRemovalCautiononpage 0-8.
Preliminary Procedure
Openeithertheleftfrontor rightfrontdoorin ordertoaccess thebacksideof thebodyside upperfrontapplique.
1 I BodySide UpperFrontApplique

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Exterior I"rim 2:5

Liftgate Side Applique Replacement (Hatchback)

“k...
,fi.‘
.,,_
.

2507095

Liftgate Side Applique Replacement (Hatchback)

Callout Component Name
Preliminary Procedure
1. Openandsupporttherearliftgateassembly.
Removethe liftgatetrimfinishpanel.Referto LiftgateTrimFinishPanel Replacement(Hatchback)onpage 2-86.
Disconnecttheelectricalconnectors.
Removethefournutssecuringtheliftgateside appliqueto therearliftgateouterpanel.
Releasethe liftgateside appliquecenterretainerfromtheliftgatepanel.
91:593.“
LiftgateSide AppliqueNut(Qty:4)
Caution: Referto FastenerCautiononpage 0—8.
1
Tighten
5 N'm(44lb in)
2 LiftgateSide AppliqueRetainer
LiftgateRelease Switch
3 Procedure
Removethe liftgatereleaseswitch.Referto LiftgateRelease SwitchReplacementonpage 4-320
Rear LicensePlateLamp(Qty:2)
4 Procedure
Removetherearlicenseplatelamps.Referto Rear LicensePlate LampReplacement(Sedan)onpage 4-210or
Rear LicensePlate LampReplacement(Hatchback)onpage4-209. '
5 LiftgateSide Applique

(US/Canada)
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2013 (5377994)
Manual
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26 Exterior Trim

Rear Compartment Lid Applique Replacement

2507099
Rear Compartment Lid Applique Replacement
Callout Component Name
Preliminary Procedure
1. Openandsupporttherearcompartmentlid.
2. Removetherearcompartment lid innerpaneltrim.Referto Rear CompartmentLid InnerPanel TrimReplacement(Sedan)
onpage2-88.
3. Disconnecttheelectricalconnectors.
4. Removethefournutssecuringtherearcompartmentlidappliquetotherearcompartmentlid.
5. Releasethecenterretainerfromtherearcompartmentlid.
Rear CompartmentLid AppliqueNut(Qty:4)
Caution: RefertoFastenerCautiononpage0-8.
Tighten
5N-m(44lbin)
Rear CompartmentLid Retainer
LiftgateReleaseSwitch
Procedure
Removetheliftgatereleaseswitch.Referto LiftgateRelease SwitchReplacementonpage4—320
Rear LicensePlateLamp(Qty:2)
Procedure
Removetherearlicenseplatelamps.Referto Rear LicensePlateLampReplacement(Sedan)onpage4-210or
Rear LicensePlateLampReplacement(Hatchback)onpage4-209.
Rear CompartmentLid Applique

2013
-Sonic
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Service
Manual
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I

I Exterior Trim 2-7

I
I Front License Plate Bracket Replacement

2472856

Front License Plate Bracket Replacement

Callout Component Name
Preliminary Procedure
Removethefrontlicenseplateif equipped.
FrontLicensePlateBracketScrew(Qty:4)
Caution: Referto FastenerCautiononpage 0-8.
1
Tighten
1.5N'm(13lbin)
2 FrontLicensePlateBracket

(US/Canada)
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2013 (5377994)
Manual
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28 Exterior Trim

Front Bumper Fascia Tow Eye Access Hole Cover Replacement

2472862
Front Bumper Fascia Tow Eye Access Hole Cover Replacement
Callout Component Name
FrontBumperFascia FrontTowEyeAccess HoleCover
1 Procedure
1. Usinga smallflat-bladedtool,releasethecoverfromthefrontbumperfascia.
2. Usingneedlenose pIiers,releasethev-notchhookfromthesquarein thefrontfasciaandremove

2013
-Sonic
(US/Canada)
Sen/ice
Manual
(5377994)
Il
I .
I Exterior Trim 2-9
I
l Rear Bumper Fascia Tow Eye Access Hole Cover Replacement
I
I

o D K

0
O

2472868

Rear Bumper Fascia Tow Eye Access Hole Cover Replacement

Callout Component Name
Rear BumperFascia RearTowEye Access HoleCover
Procedure
1. Usinga smallflat-bladedtool,releasethecoverfromtherearbumperfascia.
2. Usingneedlenosepliers,releasethev-notchhookfromthesquarein therearfasciaand remove.

(US/Canada)
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2013 (5377994)
Manual
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21 0 Exterior Trim

Radiator Grille EmblemlNameplate Replacement

2472859

Radiator Grille EmblemlNameplate Replacement

Callout Component Name
Preliminary Procedure
1. Removethefrontbumperfascia.Referto FrontBumperFascia Replacementonpage3-55.
2. Removethefrontbumperenergyabsorber.Referto FrontBumperEnergyAbsorberReplacementonpage3-51.
1 RadiatorGrilleEmblem/Nameplate
2 RadiatorGrilleEmblem/ NameplateScrew(Qty:2)

(US/Canada)
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Manual
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 Exterior Trim 2u'l‘l

“O

2700042

Liftgate EmblemlNameplate Replacement (Hatchback)

Callout Component Name
LiftgateEmblemlNameplateAssembly
Caution: Referto ExteriorTrimEmblemRemovalCautiononpage 0—8.
Procedure
1. The partandsurfaceshouldbe21°C(70°F)priorto installation.The vehicleshouldremain21°C (70°F)for
one hourafterassemblyto allowadhesivetodevelopsufficientbondstrength.
2. Use a HeatGunor equivalentto removetheold nameplate.Clean all adhesivefromtheliftgatepaneland
wipethesurfacedrywitha clean Iint-freetowelpriorto installingthenewnameplate.
Whenremovingprotectivelinersfromtheadhesivetape,be carefulnottotouchtapewithhandsanddo not
allowtapetocomein contactwithdirtor anyforeignmatterpriorto adhesion.
Usingthepreviouswitnessmarksofthe oldemblemlnameplate or makingmeasurementsfromanother
alikevehicle,use maskingtapeto referencethealignmentofthenewemblemlnameplate to theliftgate
paneL
Close the rearliftgatepanelpriorto adhesion.
Usingthepalmof thehand,wetoutthe emblem/nameplate totherearliftgatepanelto ensurefulladhesion
oftheemblemis made.

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Manual
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2—12 Exterior Trim

Rear Compartment Lid Nameplate Replacement (Sedan)

2700043

Rear Compartment Lid Nameplate Replacement (Sedan)

Callout Component Name
RearCompartmentLid Nameplate
Caution: Referto ExteriorTrimEmblemRemovalCautiononpage 0—8.
Procedure
1. The partandsurfaceshouldbe 21°C (70°F)priorto installation.The vehicleshouldremain21°C (70°F)for
one hourafterassemblyto allowadhesivetodevelopsufficientbondstrength.
2. Use a HeatGunor equivalentto removetheoldnameplate.Clean all adhesivefromtherearcompartment
panelandwipethesurfacedrywitha cleanIint—free towelpriorto installingthenewnameplate.
Whenremovingprotectivelinersfromtheadhesivetape,be carefulnottotouchtapewithhandsanddo not
allowtapeto comein contactwithdirtor anyforeignmatterpriortoadhesion.
Close therearcompartmentlid priorto adhesion.
Usingthepalmofthehand,wetouttheemblemtotherearcompartmentlidtoensurefulladhesionofthe
emblemis made.

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Manual
Service
 Exterior Trim 2313

Front Upper Grille Replacement

.s‘m ll;
\:—\\‘1-\‘
0m
..mv

2472865

Front Upper Grille Replacement

Callout Component Name
Preliminary Procedure
Removethefrontbumperfascia.Referto FrontBumperFascia Replacementonpage3-55.
1 RadiatorUpperGrilleAssemblyScrew(Qty:6)
Caution: Referto FastenerCautiononpage 0-8.
RadiatorUpperGrille Assembly
2 Procedure
Releasetheouteruppergrillelockingtabsfromthefrontbumperfascia andpushthegrilleassemblyoutward
awayfromthefrontbumperfascia assembly.

—
2013 (US/Canada)
Sonic (5377994)
Manual
Service
2-‘l '11 Exterior Trim

Front Lower Grille Replacement

2495862

Front Lower Grille Replacement

Callout Component Name
Preliminary Procedures
1. Removethefrontbumperfascia assembly.Referto FrontBumperFascia Replacementonpage 3-55.
2. Removethefrontbumperfascia energyabsorber.Referto FrontBumperEnergyAbsorberReplacementonpage3-51.
RadiatorLowerFrontGrille
Procedure
1. Releasethefouruppertabsfromthefrontbumperfascia.
2. Releasethetwooutercentertabsfromthefrontbumperfascia.
1 3. Releasethefourlowertabsfromthefrontbumperfascia.
4. Push thelowergrilleassemblyoutward,fromthefrontbumperfasciain orderto remove.
5. Uponinstallation,indextherightcenteralignmentpinto thefrontbumperfasciafirst,followedbytheten
lockingtabson thelowergrilleassemblytothefrontbumperfascia.
6. Push thelockingtabsinwardat all tenlocations,in orderto securetheradiatorlowerfrontgrilletothefront
bumperfascia.
FrontLicensePlate BracketAssembly
2 Procedure
Removethefourscrewsandthefrontlicenseplatebracketto transfertothenewlowerfrontgrilleassembly,(if
equipped).

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Manual
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 Exterior Trim 2‘1 5

Radiator Grille Opening Cover Replacement (Upper Grille Cover)

2509444
Radiator Grille Opening Cover Replacement (Upper Grille Cover)
Callout | Component Name
PreliminaryProcedure
Removetheradiatoruppergrille.Referto FrontUpperGrilleReplacementonpage 2-13.
RadiatorGrilleOpeningCover(Upper)
1 Procedure
Releasethelockingtabssecuringtheradiatoropeninggrillecoverto theradiatoruppergrilleand remove.

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246 Exterior Trim

Roof Panel Joint Finish Molding Replacement

2472857
Roof Panel Joint Finish Molding Replacement
Callout Component Name
Caution: Referto ExteriorTrimEmblemRemovalCautiononpage 0-8.
Preliminary Procedures
1. Beginat therearedgeoftheroofpaneljointfinishmoldingandcarefullyprythemoldingfromtheroofditchclip.
2. Pull themoldingforwardoutoftheditch.
3. Carefullyliftthefrontedgefromthesecondroofditchclip.
4. Clean anyadhesiveresiduefromtheditchusinga 50/50 mixturebyvolumeof isoproyplalcoholandcleandrinkablewater.
5. Drytheditchwitha lintfreecottontowel.
RoofPanelJointFinishMolding
Procedure
1 1. Insertthefrontedgeofthefinishmoldingto theedgeof glass.
2. Usinga roller-typetool,rollthemoldingintotheditchfronttoreartoensurefulladhesionis made.
3. Tucktherearlipofthefinishmoldingtotheedgeofglass attherearoftheroofpanel.
4. Inspectthemoldingtoroofditchfit.

2013
-Sonic
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(5377994)
 Exterior Trim 2,17

Rear End Spoiler Replacement (Hatchback TTV)

....22.._..Lio~—.
2.2-»

2497986

Rear End Spoiler Replacement (Hatchback TTV)

Callout Component Name
Preliminary Procedure
Removetheliftgatetrimfinishpanel.Referto LiftgateTrimFinishPanel Replacement(Hatchback)onpage 2-86.
Rear End SpoilerNut(Qty:3)
Caution: Referto FastenerCautiononpage 0-8.
Tighten
5.0N-m(44lb in)
Rear End SpoilerScrew(Qty:4)
2 Tighten
1.5N-m(13lb in)
Clip Button
3 Tip: Uponassemblyoftherearspoilerto theliftgate,positionandsecuretheclip buttonto therearliftgate
spoilertoliftgateouterpanelfirst.
4 Rear End SpoilerAssembly

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2013 (5377994)
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2-18 Floor Coverings and Headlinings
Floor Coverings and Headlinings
Specifications
Adhesives, Fluids,
Application
GM VehicleCare OdorEliminator
Repair Instructions
Eliminating Unwanted Odors in
Vehicles
GM Vehicle Care Odor EIiminator,Refer to Adhesives,
Fluids, Lubricants, and Sealers on page 2—1 8 , may
control or eliminate odors in the interior and luggage
compartment areas of GM vehicles. This non—toxic,
biodegradable, odorless product has been shown to
greatly reduce or remove the following types of odor:
- Objectionable smells of mold and mildew resulting
from vehicle water leaks
- Customer created odors, such as smoke
You may safely use GM Vehicle Care Odor Eliminator
on fabrics, vinyl, leather, carpet, and sound deadening
materials. You may also induce this product into HVAC
modules and instrument panel ducts for the control of
non-bacterial related odors.
Note: This product leaves no residual scent and
should not be used as an air freshener.
This product may result in the permanent elimination of
an odor and may be preferable to customers whose
allergies make them sensitive to perfumes. This
product may effectively remove odors when directly
contacting the odor source. Incases such as water
leaks, use this product with diagnostic procedures to
first eliminate the primary cause of the odor. Then use
further applications on the residual odor to permanently
correct the vehicle condition.
How to Use this Product
- Spray GM Vehicle Care Odor Eliminator directly or
as an additive with carpet shampoo in steam
cleaners.
° Do not use on any interior surface that plain water
would deteriorate, because this product will have
the same effect. Also avoid letting this product
Lubricants, and Sealers
Type of Material GM Part Number
Fluids Referto ElectronicPartsCatalog.
come into contact with vinegar or any acidic
substance. Acid-based products will hamper the
effectiveness of GM Vehicle Care Odor Eliminator.
- Complete eight page treatment sheets are
enclosed within each case of GM Vehicle Care
Odor Eliminator. These treatment instructions
range from simple vehicle odor elimination to full
step by step procedures for odor removal from
water leaks.
- Instructions and cautions are printed on the bottle,
but additional help is available. Ifyou encounter a
persistent or recurring odor, you may call to obtain
additional information and usage suggestions.
Floor Carpet Drying
Ifthe carpet or the pad or insulator is wet, use the
following criteria for drying or for replacing the
components:
- For a 1—piececarpet assembly bonded to a cotton
or a fiber padding, replace the entire assembly.
- For a 2—piececarpet assembly with a cotton or a
fiber padding, replace the padding only. While the
carpet is out ofthe vehicle, dry the carpet using
the method described below.
- For a 1—piececarpet 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. Ifyou 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.
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II Floor Coverings and Headlinings 2:19

Floor Panel Carpet Replacement

4AM
~
”...—2‘

2495939

Floor Panel Carpet Replacement

Callout Component Name
Preliminary Procedures
1. Removefrontseats.Referto Driveror PassengerSeatRemovaland Installationonpage 14-4.
2. Removerearseatcushion.Referto Rear Seat CushionRemovalandInstallationonpage 14-24.
3. Removethefrontfloorconsole.Referto FrontFloor ConsoleReplacementonpage2-61.
4. Removethefrontsidedooropeningfloorcarpetretainer.Referto FrontSide DoorOpeningFloorCarpetRetainer
Replacementonpage2—20.
5. Removetherearsidedooropeningfloorcarpetretainer.Referto Rear Side DoorOpeningFloor CarpetRetainer
Replacementonpage2-21.
6. Removethecenterpillarlowertrimpanels.Referto CenterPillarLowerTrimPanel Replacementonpage2-76.
1 FrontFloorPanel CarpetAssembly

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2013 (5377994)
Manual
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2=20 Floor Coverings and Headlining

Front Side Door Opening Floor Carpet Retainer Replacement

2496582
Front Side Door Opening Floor Carpet Retainer Replacement
Callout Component Name
1 FrontSide DoorOpeningFloorCarpetRetainerRetainer
2 FrontSide DoorOpeningFloorCarpetRetainerClip
3 FrontSide DoorOpeningFloorCarpetRetainerClip (Qty:3)
4 FrontSide DoorOpeningFloorCarpetRetainerAssembly

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 Floor Coverings and Headlinings 221

I Rear Side Door Opening Floor Carpet Retainer Replacement

2496883

Rear Side Door Opening Floor Carpet Retainer Replacement

Callout I Component Name
Preliminary Procedure
Removetherearseatcushion.Referto Rear Seat CushionRemovalandInstallationonpage 14-24.
1 I RearSide DoorOpeningFloorCarpetRetainerAssembly

‘ -Sonic
2013 (US/Canada) (5377994)
Manual
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2=22 Floor Coverings and Headiini‘ngs

Rear Compartment Floor Panel Carpet Replacement (Sedan)

2497588

Rear Compartment Floor Panel Carpet Replacement (Sedan)

Callout Component Name
1 Rear CompartmentFloorPanelCarpetAssembly

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Manual
Sen/ice
I Floor Coverings ancl HeadIinms 2=23

Rear Compartment Floor Panel Carpet Replacement (Hatchback)

2512259

Rear Compartment Floor Panel Carpet Replacement (Hatchback)

Callout Component Name
1 RearCompartmentFloorPanelCarpetAssembly

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Manual
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2224 Floor Coverings and Headlinings

Headlining Trim Panel Replacement (Hatchback with Sunroof)

2675362
Headlining Trim Panel Replacement (Hatchback with Sunroof)
Callout I Component Name
Warning: Do not attemptto repair or alter thehead impact energy-absorbingmaterialglued to theheadliner or to the
garnish trims.If thematerial is damaged,replace theheadlinerand/or thegarnish trim.Failure to do so could result in
personal injury.
Caution: Ifa vehicleis equippedwitha headcurtaininflatormoduleensurethattheinflatormoduleandtetherare undamaged.
Iftetheror curtainairbagare damagedin anyway,theymustbe replaced.
Caution: Use carewhenworkingaroundtheheadcurtaininflatormodule.Sharptoolsmaypuncturethecurtainairbag.Ifthe
headcurtaininflatormoduleis damagedin anyway,it mustbe replaced.
Preliminary Procedures
1. DisabletheSIR system.Referto SIR DisablingandEnablingonpage 13-112.
Removethesunshade.Referto SunshadeReplacementonpage2-71.
Removethesunshadesupport.Referto SunshadeSupportReplacementonpage 2-72.
Removetheroofrailfrontassist handle.Referto RoofRail FrontAssist HandleReplacementonpage269.
Removetheroofrailrearassist handle.Referto RoofRail RearAssist HandleReplacementonpage2-70.
Removethedomelampbezel.Referto DomeLampBezel Replacementonpage4-190.
Removethewindshieldheadercourtesylamp.Referto WindshieldHeaderCourtesyLampReplacementonpage4—191.
Removethewindshieldside garnishmolding.Referto WindshieldSide GarnishMoldingReplacementonpage2—73.
5990.”.0‘91998!”
Removethebodylockpillaruppertrimpanel.Referto BodyLockPillar UpperTrimPanel Replacement(Hatchback)on
page2-77or BodyLock Pillar UpperTrimPanel Replacement(Sedan)onpage 2-78.
10. Removethecenterpillaruppertrimpanel.Referto CenterPillar UpperTrimPanel Replacementonpage2-75.
11. Movethefrontseatfullyforwardandrecline.
1 HeadlinerTrimPanel Retainer(Qty:3)
HeadlinerTrimPanelAssembly
2 Procedure
Disconnecttheelectricalconnectors.

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 Floor Coverings and Headlinings 2:25

Headlining Trim Panel Replacement (Hatchback with Sunroof) (cont'd)

Callout Component Name
Note: WheninstaIIinga newheadliner,tapeanyunusedconnectortotheheadlinerwitha highadhesivetape.

Headlining Trim Panel Replacement (Hatchback without Sunroof)

2510665

Headlining Trim Panel Replacement (Hatchback without Sunroof)

Callout I Component Name
Warning: Donot attemptto repair or alter theheadimpact energy-absorbingmaterialglued to theheadliner or to the
garnish trims.If thematerialis damaged,replace theheadliner and/orthegarnish trim.Failure to do so could result in
personal injury.
Caution: Ifa vehicleis equippedwitha headcurtaininflatormoduleensurethattheinflatormoduleandtetherare undamaged.
Iftetheror curtainairbagare damagedin anyway,theymustbe replaced.
Caution: Usecarewhenworkingaroundtheheadcurtaininflatormodule.Sharptoolsmaypuncturethecurtainairbag.Ifthe
headcurtainInflatormoduleis damagedin anyway,itmustbe replaced.
Preliminary Procedures
1. DisabletheSIR system.Referto SIR DisablingandEnablingonpage 13-112.
Removethesunshade.Referto SunshadeReplacementonpage 2-71.
Removethesunshadesupport.Referto SunshadeSupportReplacementonpage 2-72.
Removetheroofrailfrontassist handle.Referto RoofRail FrontAssist HandleReplacementonpage2—69.
Removetheroofrailrearassist handle.Referto RoofRaiIRearAssist HandleReplacementonpage2-70..
Removethedomelampbezel.Referto DomeLampBezel Replacementonpage 4-190.
Removethewindshieldheadercourtesylamp.Referto WindshieldHeaderCourtesyLampReplacementonpage 4-191.
Removethewindshieldside garnishmolding.Referto WindshieldSide GarnishMoldingReplacementonpage 2-73.
Removethebodylock pillaruppertrimpanel.Referto BodyLock Pillar UpperTrimPanel Replacement(Hatchback)on
5090499189310
page2-77or BodyLock Pillar UpperTrimPanel Replacement(Sedan)onpage 2-78.

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2:26 Floor Coverings and Headlinings

Headlining Trim Panel Replacement (Hatchback without Sunroof) (cont'd)

Callout I Component Name
10. Removethecenterpillaruppertrimpanel.Referto CenterPillar UpperTrimPanel Replacementonpage 2-75.
11. Movethefrontseatfullyforwardandrecline.
1 HeadlinerTrimPanel Retainer(Qty:5)
HeadlinerTrimPanelAssembly
2 Procedure
Disconnecttheelectricalconnectors.
Note: Wheninstallinga newheadliner,tapeanyunusedconnectortotheheadlinerwitha highadhesivetape.

Headlining Trim Panel Replacement (Sedan with Sunroof)

2677367

Headlining Trim Panel Replacement (Sedan with Sunroof)

Callout I Component Name
Warning: Do not attemptto repair or alter the head impact energy-absorbingmaterialglued to theheadliner or to the
garnish trims.If thematerialis damaged,replace the headliner and/orthegarnish trim.Failure to do so could result in
personal injury.
Caution: Ifa vehicleis equippedwitha headcurtaininflatormoduleensurethatthe inflatormoduleandtetherare undamaged.
Iftetheror curtainairbagare damagedin anyway,theymustbe replaced.
Caution: Use carewhenworkingaroundtheheadcurtaininflatormodule.Sharptoolsmaypuncturethecurtainairbag.Ifthe
headcurtaininflatormoduleis damagedin anyway,it mustbereplaced.
Preliminary Procedures
1. DisabletheSIR system.Referto SIR DisablingandEnablingonpage 13-112.
2. Removethesunshade.Referto SunshadeReplacementonpage 2-71.
3. Removethesunshadesupport.Referto SunshadeSupportReplacementonpage2-72.
4. Removetheroofrailfrontassisthandle.Referto RoofRai/FrontAssist HandleReplacementonpage 2-69.

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 Floor Coverings and Headlinings 2=27

Headlining Trim Panel Replacement (Sedan with Sunroof) (cont'd)

Callout I Component Name
Removetheroofrailrearassist handle.Referto RoofRail RearAssist HandleReplacementonpage2-70.
22-.."-..
MM_W Removethedomelampbezel. Referto DomeLampBezel Replacementonpage4-190.
Removethewindshieldheadercourtesylamp.Referto WindshieldHeaderCourtesyLampReplacementonpage 4~191.
Removethewindshieldside garnishmolding.Referto WindshieldSide GarnishMoldingReplacementonpage 273.
Removethebodylockpillaruppertrimpanel.Referto BodyLock Pillar UpperTrimPanelReplacement(Hatchback)on
$°P°.“F”.°"‘
page2-77or BodyLockPillar UpperTrimPanel Replacement(Sedan)onpage2—78. ,,
10. Removethecenterpillaruppertrimpanel.Referto CenterPillar UpperTrimPanel Replacementonpage 2-75.
11. Movethefrontseatfullyforwardandrecline.
1 HeadlinerTrimPanel Retainer(Qty:3)
HeadlinerTrimPanelAssembly
Procedure
Disconnecttheelectricalconnectors.
Note: Wheninstallinga newheadliner,tapeanyunusedconnectortotheheadlinerwitha highadhesivetape.

Headlining Trim Panel Replacement (Sedan without Sunroof)

2677368

Headlining Trim Panel Replacement (Sedan without Sunroof)

Callout I Component Name
Warning: Do not attemptto repair or alter thehead impact energy-absorbingmaterialglued to the headliner or to the
garnish trims.If thematerialis damaged,replace the headliner and/orthegarnish trim.Failure to do so could result in
personal injury.
Caution: Ifa vehicleis equippedwitha headcurtaininflatormoduleensurethattheinflatormoduleandtetherare undamaged.
Iftetheror curtainairbagare damagedin anyway,theymustbe replaced.
Caution: Use carewhenworkingaroundtheheadcurtaininflatormodule.Sharptools maypuncturethecurtainairbag.Ifthe
headcurtaininflatormoduleis damagedInanyway,itmustbe replaced.

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2013 (5377994)
Manual
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2-23 Floor Coverings and Headlinings

Headlining Trim Panel Replacement (Sedan without Sunroof) (cont'd)

Callout I Component Name
Preliminary Procedures
1. DisabletheSIR system.Referto SIR DisablingandEnablingonpage 13-112.
Removethesunshade.Referto SunshadeReplacementonpage 2-71.
Removethesunshadesupport.Referto SunshadeSuppon‘Replacementonpage 2-72.
Removetheroofrailfrontassisthandle.Referto RoofRai/FrontAssist HandleReplacementonpage 2-69.
Removetheroofrailrearassisthandle.Referto RoofRai/RearAssist HandleReplacementonpage 2-70.
Removethedomelampbezel.Referto DomeLampBezel Replacementonpage4-190.
Removethewindshieldheadercourtesylamp.Referto WindshieldHeaderCourtesyLampReplacementonpage4-191.
Removethewindshieldsidegarnishmolding.Referto WindshieldSide GarnishMoldingReplacementonpage2-73.
Removethebodylockpillaruppertrimpanel.Referto BodyLock Pillar UpperTrimPanel Replacement(Hatchback)on
@QNQP‘F‘WN
page2-77or BodyLock Pillar UpperTrimPanel Replacement(Sedan)onpage2-78.
10. Removethecenterpillaruppertrimpanel.Referto CenterPillar UpperTrimPanel Replacementonpage2—75.
11. Movethefrontseatfullyforwardandrecline.
1 HeadlinerTrimPanel Retainer(Qty:5)
HeadlinerTrimPanelAssembly
2 Procedure
Disconnecttheelectricalconnectors.
Note: Wheninstallinga newheadliner,tapeanyunusedconnectorto theheadlinerwitha highadhesivetape.

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Manual
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 Instrument Panel and Console Trim 2—29

Instrument Panel and Console Trim

Specifications

Fastener Tightening Specifications

Specification
Application Metric English
InstrumentPanelCompartmentDoorLatchStrikerBolt 9 N-m 80lb in
InstrumentPanel KneeBolsterFasteners 9 N-m 801bin
InstrumentPanelTie BarAssemblytoVehicleBodyBolts 22N-m 16lbft
InstrumentPanelTie BarAssemblyto HVAC ModuleFasteners 9 N-m 801bin
PanelTie Bar LowerSupportBracketto FrontFloorTunnel
gthtIrSument 22N-m 16lbft

InstrumentPanelTie Barto BrakePedal BracketBolts 9 N-m 80 lbin

InstrumentPanelTie Barto BrakePedal ReleaseBracketBolt 22N-m 16lbft
InstrumentPanelTie Barto CowlPanel Nut 22Nm 16lbft

Repair Instructions

Instrument Panel Insulator Replacement

2667878

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Manual
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2:30 Instrument PaneI and Console Trim

Instrument Panel Insulator Replacement

Callout I Component Name
Preliminary Procedures
1. DisabletheSIR system.Referto SIR DisablingandEnablingonpage 13-112.
2. Removethepassengerinflatablerestraintinstrumentpanellowermodule.Referto InstrumentPanel LowerAirbag
Replacement—PassengerSide onpage 13-123.
1 I Instrument
Panel Insulator

Instrument Panel Knee Bolster Replacement

2672322
Instrument Panel Knee Bolster Replacement
Callout Component Name
Preliminary Procedures
1. DisabletheSIR system.Referto SIR DisablingandEnablingon page 13-112.
2. Removethedriverinflatablerestraintinstrumentpanellowermodule.Referto InstrumentPanel LowerAirbagReplacement
-DriverSide onpage 13-122.
InstrumentPanel Knee BolsterFasteners(Qty:4)
Caution: RefertoFastenerCautiononpage0-8.
Tighten
9N-m(80lbin)
2 InstrumentPanelKnee Bolster

2013
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 Instrument Panel and Console Trim 2131

Instrument Panel Accessory Upper Trim Plate Replacement

L_s_ee~_a,v,,La.~./s_

2498784

Instrument Panel Accessory Upper Trim Plate Replacement

Callout I Component Name
Preliminary Procedure
Removetheinstrumentpanelcentermolding.Referto InstrumentPanel CenterMoldingReplacement(WithU58)on page 2—47
or InstrumentPanel CenterMoldingReplacement(WithoutU58)onpage2-48.
InstrumentPanelAccessoryUpperTrimPlateFastener(Qty:4)
1
Caution: RefertoFastenerCautiononpage 0-8.
InstrumentPanelAccessoryUpperTrimPlate(Qty:2)
Procedures
2 1. Use a flatbladedplastictrimtoolinordertodisengagetheretainerssecuringtheaccessoryuppertrim
platesto theinstrumentpanelassembly.
2. Whenreplacingtheaccessorytrimplates,transferall necessarycomponents.

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2:32 Instrument Panel and Console Trim

Instrument Panel Center Trim Panel Replacement

2498785
Instrument Panel Center Trim Panel Replacement
Callout Component Name
InstrumentPanelCenterTrimPanel (Qty:2)
Procedure
Use a flatbladedplastictrimtoolin ordertodisengagetheretainerssecuringthecentertrimplatesto the
instrumentpanelaccessoryuppertrimplates.

2013
-Sonic
(US/Canada)
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(5377994)
 Instrument Panei and Console I'rim 2:33

Instrument Panel Center Upper Molding Replacement

2498786

Instrument Panel Center Upper Molding Replacement

Callout Component Name
Preliminary Procedure
Removetheinstrumentpanelcentermolding.Referto InstrumentPanel CenterMoldingReplacement(WithU58)onpage 2-47
or InstrumentPanel CenterMoldingReplacement(WithoutU58)onpage2-48.
InstrumentPanel CenterUpperMolding
Procedures
1 1. Use a flatbladedplastictrimtoolin orderto disengagetheretainerssecuringthe centeruppertrimmolding
to theinstrumentpanelassembly.
2. Disconnectelectricalconnections.

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2=34 Instrument Panel and Console Trim

Instrument Panel Upper Trim Panel Replacement - Right Side

2498787

Instrument Panel Upper Trim Panel Replacement - Right Side

Callout I Component Name
Preliminary Procedure
, 1. DisabletheSIR system.Referto SIR DisablingandEnablingonpage 13-112.
2. Removetheinstrumentpanelcentermolding.Referto InstrumentPanel CenterMoldingReplacement(WithU58)on
page2—47 or InstrumentPanel CenterMoldingReplacement(WithoutU58)onpage 2-48. . ,
3. Removetheinstrument p anelcenteruppermolding. R eferto Panel
Instrument CenterUpperMoldingReplacement on
page2-33.
Removetheinstrumentpanellowercompartment. Referto InstrumentPanel LowerCompartmentReplacementon
page 2-44.
Removetherightinstrumentpanelaccessoryuppertrimplate.Referto InstrumentPanelAccessonl UpperTrimPlate
Replacementonpage2-31.
Removetherightinstrumentpaneloutertrimcover.Referto InstrumentPanel OuterTrimCoverReplacementon
page 2-38.
InstrumentPanel InflatableRestraintModuleFasteners(Qty:2)
Caution: Referto FastenerCautiononpage0-8.
1 Tighten
10N'm89lbin
2 InstrumentPanel UpperTrimPanel Fastener(Qty:3)
InstrumentPanel UpperTrimPanel
Procedures
3 1. Use a flatbladedplastictrimtoolin ordertodisengagetheretainerssecuringtheuppertrimpanelto the
instrumentpanelassembly.
2. Disconnecttheelectricalconnections.
3. Whenreplacingtheinstrumentpaneluppertrimpanel,transferall necessarycomponents.

2013
-Sonic
(US/Canada)
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Manual
(5377994)
 Instrument Panel and Console Trim 2235

Instrument Panel Upper Trim Panel Replacement - Left Side

2498788

Instrument Panel Upper Trim Panel Replacement - Left Side

Callout I Component Name
Preliminary Procedure
1. Removetheinstrumentclusterassembly.Referto InstrumentClusterReplacementonpage 8-104.
2. Removetheinstrumentpanelcentermolding.Referto InstrumentPanel CenterMoldingReplacement(WithU58)on
page2-47or InstrumentPanel CenterMoldingReplacement(WithoutU58)onpage2-48.
3. Removetheinstrumentpanelcenteruppermolding.Referto InstrumentPanel CenterUpperMoldingReplacementon
page2-33.
4. Removetheleftinstrumentpanelaccessoryuppertrimplate.Referto InstrumentPanelAccessoryUpperTrimPlate
Replacementonpage 2-31.
5. Removetheleftinstrumentpaneloutertrimcover.Referto InstrumentPanel OuterTrimCoverReplacementonpage 2-38.
InstrumentPanel UpperTrImPanel Fastener
1
Caution: Referto FastenerCautiononpage0-8.
InstrumentPanel UpperTrimPanel
Procedures
2 1. Use a flatbladedplastictrimtoolin ordertodisengagetheretainerssecuringtheuppertrimpaneltothe
instrumentpanelassembly.
2. Whenreplacingtheinstrumentpaneluppertrimpanel,transferall necessarycomponents.

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2013 (5377994)
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2:36 Instrument Panel and Console Trim

Instrument Panel Fuse Block Access Hole Cover Replacement (Without AAL)

2498790
Instrument Panel Fuse Block Access Hole Cover
Replacement (Without AAL)
Callout Component Name
InstrumentPanel Fuse BlockAccess HoleCover
Procedure
Grasptheloweredgeofthefuse blockcoverandpulloutwarddisengagingtheretainerssecuringthefuse block
covertotheinstrumentpanellowertrimpadcover.

2013
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I Instrument Panel and Console Trim 2-37

1’ Instrument Panel Fuse Block Access Hole Cover Replacement (With AAL)

2672031

Instrument Panel Fuse Block Access Hole Cover Replacement (With AAL)
Callout Component Name
InstrumentPanel Fuse BlockAccess HoleCover
1 Procedure
Grasptheloweredgeofthefuse blockcoverandpulloutwarddisengagingtheretainerssecuringthefuse block
covertotheinstrumentpanellowertrimpadcover.

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2013 (5377994)
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2138 Instrument Panel and Console Trim

Instrument Panel Outer Trim Cover Replacement

2498792

Instrument Panel Outer Trim Cover Replacement

Callout Component Name
InstrumentPanel OuterTrimCover(Qty:2)
Procedures
Use a flatbladedplastictrimtoolin ordertodisengagetheretainerssecuringtheInstrumentpaneloutertrim
coverstotheinstrumentpanelassembly.

(US/Canada)
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2013 (5377994)
Manual
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 Instrument Panel and Console Trim 2339

Instrument Cluster Upper Bezel Replacement

2498794

Instrument Cluster Upper Bezel Replacement

Callout Component Name
InstrumentPanel ClusterUpperBezel
Procedures
Use a flatbladedplastictrimtoolin ordertodisengagetheretainerssecuringthe instrumentpanelclusterupper
bezeltotheinstrumentclusterassembly.

(US/Canada)
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2013 (5377994)
Manual
Service
2240 Instrument Panel and Console Trim

Instrument Panel Lower Trim Pad Cover Replacement (Without AAL)

2498796
Instrument Panel Lower Trim Pad Cover Replacement (Without AAL)
Callout Component Name
1 InstrumentPanelLowerTrimPad Fastener(Qty:2)
Caution: RefertoFastenerCautiononpage0-8.
InstrumentPanelLowerTrimPad Cover
Procedures
2 1. Use a flatbladedplastictrimtoolin ordertodisengagetheretainerssecuringthelowertrimpadcovertothe
instrumentpanelassembly.
2. Disconnecttheelectricalconnectors.
3. Whenreplacingtheinstrumentpanellowertrimpadcover,transferall necessarycomponents.

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 Instrument Panel and Console Trim 2.4-1

Instrument Panel Lower Trim Pad Cover Replacement (With AAL)

2672030

Instrument Panel Lower Trim Pad Cover Replacement (With AAL)

Callout | Component Name
Preliminary Procedure
DisabletheSIR system.Referto SIR DisablingandEnablingonpage 13-112.
InstrumentPanel LowerTrimPad Fastener(Qty:4)
1 Caution: Referto FastenerCautiononpage 0-8.
InstrumentPanel LowerTrimPad Cover
Procedures
2 1. Use a flatbladedplastictrimtoolin orderto disengagetheretainerssecuringthelowertrimpadcoverto the
instrumentpanelassembly.
2. Disconnecttheelectricalconnectors.
3. Whenreplacingtheinstrumentpanellowertrimpad,transferall necessarycomponents.

I1 -Sonic
2013 Service
(US/Canada) (5377994)
Manual
2:42 Instrument Panel and Console Trim

Instrument Panel Upper Compartment Door Latch Replacement ‘

QM,
\\\\\

2498810
Instrument Panel Upper Compartment Door Latch Replacement
Callout Component Name
InstrumentPanel UpperCompartmentDoorLatch
Procedures
1. Opentheinstrumentpanelcompartmentdoor.
2. Unsnaptheinstrumentcompartmentdoorlatchfromthedoorassembly.

2013
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(5377994)
 Instrument Panel and Console Trim 2=43

Instrument Panel Compartment Replacement

2498797

Instrument Panel Compartment Replacement

Callout Component Name
Preliminary Procedure
Removetherightinstrumentpaneluppertrimpanel.Referto InstrumentPanel UpperTrimPanel Replacement—RightSide on
page 2-34.
1 InstrumentPanel CompartmentFastener(Qty:6)
Caution: Referto FastenerCautiononpage 0—8.
Instrument
Panel Compartment
2 Procedure
transferall necessarycomponentsif applicable.
Whenreplacingtheinstrumentpanelcompartment,

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(5377994)
2=44 Instrument Panel and Console i'rim

Instrument Panel Lower Compartment Replacement

2672033
Instrument Panel Lower Compartment Replacement
Callout Component Name
Preliminary Procedure
1. Opentheinstrumentpanellowercompartmentto thefullopenposition.
2. Disconnecttheinstrumentpanelcompartmentdampenerfromthecompartmentassembly.
InstrumentPanel LowerCompartmentAssembly
Procedures
1 1. Squeezethesides of thecompartmentassemblyandallowthecompartmentto movepastthecompartment
stops.
2. Unsnapthecompartmentassemblyfromtheinstrumentpanelassembly.
3. Whenreplacingtheinstrumentpanellowercompartment,transferall necessarycomponents.

2013
-Sonic
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Service
Manual
(5377994)
 I
l
I Instrument Panel and Console Trim 2-45
I
I Instrument Panel Compartment Door Latch Replacement
I
I
II
Il

2498816

Instrument Panel Compartment Door Latch Replacement

Callout Component Name
1 InstrumentPanel CompartmentDoorLatchFasteners(Qty:2)
Caution: RefertoFastenerCautiononpage0-8.
2 Panel CompartmentDoorLatchAssembly
Instrument

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2013 (5377994)
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2:46 Instrument Panel and Console l'rim

Instrument Panel Compartment Door Dampener Replacement

2672032
Instrument Panel Compartment Door Dampener Replacement
Callout I Component Name
Preliminary Procedure _
RemovetheinstrumentpanelIowercompartment. Referto InstrumentPanel LowerCompartmentReplacementonpage2-44.
InstrumentPanel CompartmentDoorDampener
1 Procedure
Unsnapthedampenerassemblyfromthe instrumentpanelassembly.

2013
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 Instrument Panel and Console Trim 2347

Instrument Panel Center Molding Replacement (With U58)

III HI

2498829

InStrument Panel Center Molding Replacement (With U58)

Callout Component Name
InstrumentPanel CenterMoldingAssembly
Procedure
1. Use a flatbladedplastictrimtoolin theshownlocations,thenrotatethetrimtool90°to releasethetopof
themoldingawayfromtheinstrumentpanelassembly.' ‘
2. Graspthe moldingwithbothhands,oneon eachside oftheair outlets,andpullstraightback,workingfrom
topto bottom.
3. Whenreplacingthecentermoldingassembly,transferall necessarycomponents.

2013
~Sonic
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(5377994)
2:48 Instrument Panel and Console Trim

Instrument Panel Center Molding Replacement (Without U58)

2498831
Instrument Panel Center Molding Replacement (Without U58)
Callout Component Name
InstrumentPanel CenterMoldingAssembly
Procedure
1. Use a flatbladedplastictrimtool in theshownlocations,thenrotatethetrimtool90°to releasethetopof
themoldingawayfromthe instrumentpanelassembly.
2. Graspthemoldingwithbothhands,oneon each side of theairoutlets,andpullstraightback,workingfrom
topto bottom.
3. Whenreplacingthecentermoldingassembly,transferall necessarycomponents.

2013
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(5377994)
 I
,,,,,, Instrument Panel and Console Trim 2421

I Instrument Panel Assembly Replacement

2673026

Instrument Panel Assembly Replacement

Callout Component Name
Preliminary Procedure
1. Removetherightandleftwindshieldsidegarnishmoldings.Referto WindshieldSide GarnishMoldingReplacementon
page2-73.
2. Removethefrontfloorconsoleassembly.Referto FrontFloorConsoleReplacementonpage2-61.
3. Removetherightandleftinstrumentpaneluppertrimpanels.Referto InstrumentPanel UpperTrimPanel Replacement-
RightSide onpage2-34andInstrumentPanel UpperTrimPanel Replacement- LeftSide onpage235.
t 4. Removetheradioassembly.Referto RadioReplacement(WithoutU88)onpage 8—59 or RadioReplacement(WithU88)
onpage8—58.
5. Removetheheaterandair conditioningcontrolassembly.Referto HeaterandAir ConditioningControlReplacementon
page 10—79.
6. Removetheinstrumentpanellowertrimpadcover.Referto InstrumentPanel LowerTrimPad CoverReplacement(Without
AAL) onpage2-40or InstrumentPanel LowerTrimPad CoverReplacement(WithAAL) onpage 2-41.
7. Removetheinstrumentpanelinsulator.Referto InstrumentPanel InsulatorReplacementonpage2-29
8. Removetheinstrumentpanellowerintermediatereinforcement.Referto InstrumentPanelLower/ntermediate
ReinforcementReplacementonpage 2-50.
9. Removetheinstrumentpanelkneebolster.Referto InstrumentPanel Knee BolsterReplacementonpage 2-30.
InstrumentPanel Fastener(Qty:11)
1
Caution: Referto FastenerCautiononpage 0-8.
InstrumentPanel CompartmentDoorLatchStrikerbolt
2 Tighten
9 N-m(80lb in)

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2013 (5377994)
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2:50 Instrument Panel and Console Trim

Instrument Panel Assembly Replacement (cont'd)

Callout Component Name
InstrumentPanelAssembly
Procedures
1. Notelocationandroutingoftheinstrumentpanelelectricalharnessassemblyin orderto ensureproper
installation.
3 2. Withtheaidofan assistantlifttheinstrumentpanelassemblyreanNardandupwardawayfromthetie bar
assembly.
3. Disconnecttheelectricalconnectors.
4. Removetheinstrumentpanelassemblyfromthevehicle.
5. Whenreplacingtheinstrumentpanelassembly,transferall necessarycomponents.

Instrument Panel Lower Intermediate Reinforcement Replacement

\v/

. 2672672
Instrument Panel Lower Intermediate Reinforcement Replacement
Callout I Component Name
Preliminary Procedures
1. DisabletheSIR system.Referto SIR Disablingand Enablingonpage 13-112.
2. Removethepassengerinflatablerestraintinstrumentpanellowermodule.Referto InstrumentPanel LowerAirbag
Replacement- PassengerSide onpage 13—123.
InstrumentPanel LowerReinforcementFasteners(Qty:4)
1
Caution: RefertoFastenerCautiononpage 0-8.
2 InstrumentPanel LowerIntermediate
Reinforcement

2013
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 Instrument Panel and Console Trim 2=5I
|nstrument Pane] Tie Bar 5. Remove the push—pinfastener(1) securing the left
I floor air outlet duct (2) to the instrument panel tie
Rep acement bar assembly.
Removal Procedure 6. Remove the Ieftfloorair outlet duct(2) from the
vehicle.
1. Remove the Instrument panel assembly. Refer to
InstrumentPanel Assembly Replacement on
page 2—49.
2. Remove the steering column and wheel from the
vehicle. Refer to Steering Column Replacement on
page 15-33.
3. Remove the air inlet grill panel. Referto Air/nlet
Grille Panel Replacement on page 4—374.

2498834
7. Remove the nut (1) securing the instrument panel
tie bar assembly to the cowl panel.

2672929
4. Unsnap the instrument panel fuse block (1) from
the instrument panel tie bar assembly and position
out of the way.

2498836
8. Remove the bolts (1) securing the instrument panel
tie bar assembly to the brake pedal bracket.

2672931

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 1’
2 :52 Instrument Panel and Console Trim

2539303 2500277
9. Remove the brake pedal release bracket bolts (1) 11. Remove the fasteners (1) securing the instrument
securing the instrument panel tie bar to the brake panel tie bar assembly to the HVAC module.
pedal mounting bracket.

2498843 Note: Support the HVAC Module in order to prevent
10. Remove the bolts (1) securing the right and left
instrument panel tie bar lower SUPPOITbrackets (2)
to the front floor tunnel panel.
2500291
damage.
12. Remove the bolts (1) securing the instrument panel
tie bar assembly to the vehicle body.
13. Note the location and routing of the instrument
panel wiring harness in orderto ensure proper
installation.
14. With the aid ofan assistant remove the instrument
panel tie bar assembly from the vehicle.
Installation Procedure
1. With the aid of an assistant position the instrument
panel tie bar assembly into the vehicle.
2. Install the instrument panel wiring harness
assembly to its in vehicle position as it was noted
in the removal procedure.

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I
Instrument Panel and Console Trim 2=53

2500291 2498843
3. Loosely install the bolts (1) securing the instrument 6. Loosely install the bolts (1) securing the right and
panel tie bar assembly to the vehicIe body. left instrument panel tie bar lower support
brackets (2) to the front floor tunnel panel.

‘2500277
4. Loosely install the fasteners (1) securing the
instrument panel tie bar assembly to the HVAC
module.
5. Remove the support from the HVAC module.
2539303
7. Loosely install the brake pedal release bracket
bolts (1) securing the instrument panel tie bar to
the brake pedal mounting bracket.

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2=54 Instrument Panel and Console Trim

\|._\\\!\II‘;I
w

2498836
8. Loosely install the bolts (1) securing the instrument
panel tie bar assembly to the brake pedal bracket.
2672931
16. Install the left floor air outlet duct (2) intothe
vehicle.
17. Install the push—pinfastener (1) securing the left
floor air outlet duct (2) to the instrument panel tie
bar assembly.

2498834
9. Loosely install the nut (1) securing the instrument
panel tie bar assembly to the cowl panel.
Caution: Refer to Fastener Caution on page 0-8.
10. Tighten the instrument panel tie bar to vehicle body
bolts to 22N-m(16 lb ft).
11. Tighten the instrument panel tie bar to HVAC
module fasteners to Wm (80 lb in).
12. Tighten the instrument panel tie bar lower support
bracket to front floor tunnel panel bolts to
22N'm(16 lb ft).
13. Tighten the instrument panel tie bar to the brake
pedal release bracket bolt to 22N-m(16 lb ft).
14. Tighten the instrument panel tie bar assembly to
the brake pedal bracket bolts to 9N-m(80 lb in).
15. Tighten the instrument panel tie bar assembly to
the cowl panel nut to 22N°m(16 lb ft).
2672929
18. Snap the instrument panel fuse block (1)onto the
instrument panel tie bar assembly.
19. Install the air inlet grill panel. Refer to AirIn/et Grille
Panel Replacement on page 4-374.
20. Install the steering column and wheel from the
vehicle. Refer to Steering Column Replacement on
page 15-33.
21. Install the Instrument panel assembly. Refer to
InstrumentPanel Assembly Replacement on
page 2—49.

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Manual
Service
 I
I
IIIII
II Instrument Panel and Console Trim 2523
I
I Front Floor Console Cover Replacement (Automatic Transmission)

I
I1
.1

2498292

Front Floor Console Cover Replacement (Automatic Transmission)

Callout Component Name
FrontFloorConsoleCoverAssembly
Procedures
1. Applytheparkingbrake.
1 2. Movetheshifterfrom"Park"to the“Neutral"position.
3. Usea flat-bladedplastictrimtoolInorderto releasetheretainerssecuringtheconsolecoverto theconsole
assembly.
4. Disconnecttheelectricalconnections.
5. Whenreplacingtheconsolecover,transferall necessarycomponents.

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2=56 Instrument Panel and Console Trim

Front Floor Console Cover

Replacement (Manual Transmission)
Removal Procedure

2498298
3. Feed the transmission control lever boot assembly
thru the opening in the console cover assembly (1).
4. Remove the console cover assembly (1)from the
vehicle.
2498295
Installation Procedure
1. Use a flat bladed plastic trim tool in order to
release the retainers securing the console
cover (1) to the console assembly.

2498296
2. Reach under the console cover assembly (1) and
release the retainer tabs securing the transmission
shift lever boot (2) to the console cover assembly.
2498298
1. Position the console cover assembly (1)to the
console assembly.
2. Feed the transmission control lever boot assembly
thru the opening in the consoIe cover assembly (1).

2013
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 Instrument Panel and Console Trim 2157
3. Snap the transmission control lever boot
assembly (2) to the console cover (1) ensuring the
retainer tabs lock the boot assembly to the cover.
4. Install the cover assembly to the console.

i\

2498296

Front Floor Console Cup Holder Replacement

2498300

Front Floor Console Cup Holder Replacement

Callout Component Name
Preliminary Procedure
.
Removethefrontfloorconsoleassembly.Referto FrontFloor ConsoleReplacementonpage 2—61

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2013 (5377994)
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2258 Instrument Panel and Console I‘rim

Front Floor Console Cup Holder Replacement (cont'd)

Callout Component Name
1 FrontFloorConsoleCup HolderFasteners(Qty:6)
Caution: Referto FastenerCautiononpage0-8.
2 FrontFloorConsoleCup HolderAssembly

Automatic Transmission Control Indicator Opening Cover Replacement

2498303

Automatic Transmission Control Indicator Opening Cover Replacement

Callout I Component Name
Preliminary Procedure
Removethefrontfloorconsolecover.Referto FrontFloorConsoleCover Replacement(ManualTransmission)onpage2-56or
FrontFloorConsoleCoverReplacement(AutomaticTransmission)onpage 2-55.
AutomaticTransmissionControlIndicatorOpeningCoverAssembly
Procedure
Releasetheretainerclips securingthetransmissioncontrolindicatortothefrontfloorconsolecover.

(US/Canada)
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2013 (5377994)
Manual
Service
 Instrument Panel and Console Trim

Front Floor Console Extension Replacement - Right Side

2498304

Front Floor Console Extension Replacement - Right Side

Callout Component Name
FrontFloorConsole Extension
Procedure
Use a flatbladedplastictrimtoolin orderto releasetheretainerssecuringtheextensiontotheconsole
assembly.

2013
-Sonic
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(5377994)
“2‘60 Instrument Panel and Console Trim

Front Floor Console Extension Replacement - Left Side

2675202
Front Floor Console Extension Replacement - Left Side
Callout Component Name
1 FrontFloorConsoleExtensionPush-InRetainer
FrontFloorConsoleExtension
2 Procedure
2:32:11?bladedplastictrimtoolinorderto releasetheretainerssecuringtheextensionto theconsole

2013
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 Instrument Panel and Console Trim 26'!

Front Floor Console Replacement

2673140

Front Floor Console Replacement

Callout Component Name
PreliminaryProcedures
1. Removetherightandleftfrontfloorconsoleextensions.Referto FrontFloorConsoleExtensionReplacement-RightSide
onpage 2—59 andFrontFloorConsoleExtensionReplacement- LeftSide onpage2—60.
2. Removethefrontfloorconsolecoverassembly.Referto FrontFloor ConsoleCoverReplacement(ManualTransmission)
onpage 2-56or FrontFloorConsoleCoverReplacement(AutomaticTransmission)onpage2—55.
FrontFloorConsoleFasteners(Qty:6)
Caution: RefertoFastenerCautiononpage 0-8.
Procedure
Movethefrontseatstothefullforwardpositionto access thefrontfloorconsolerearfasteners.
FrontFloorConsole
Procedures
1. Disconnecttheelectricalconnections.
2. Whenreplacingtheconsole,transferall necessarycomponents.

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2262 Instrument Panel and Console Trim

Front Floor Console Bracket Replacement

2675395

Front Floor Console Bracket Replacement

Callout Component Name
Preliminary Procedure
Removetheleftfrontfloorconsoleextensionpanel.Referto FrontFloorConsole ExtensionReplacement- LeftSide on
page2-60.
FrontFloorConsole ExtensionNuts(Qty:2)
1 Caution: Referto FastenerCautionon page0-8.
9 N-m(80lb in)
2 FrontFloorConsole Bracket

(US/Canada)
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2013 (5377994)
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 Interior Trim and Panelinfig 2-63
i I I I
*; Interior Trim and Paneling

,1 Specifications

Fastener Tightening Specifications

Specification
Application Metric English
CargoTie DownHookFastener 9 N-m 80lb in
RoofRail FrontAssist HandleFastener 6Wm 53lbin
RoofRail RearAssist HandleFastener 6N-m 53|bin

Repair Instructions

Front Side Door Window Switch Bezel Replacement (Left Side)

2502651

Front Side Door Window Switch Bezel Replacement (Left Side)

Callout Component Name
Preliminary Procedure
Removethefrontside doortrim.Referto FrontSide Door TrimReplacementonpage2-67.
FrontSide DoorWindowSwitchBezel Screw(Qty:8)
1 Caution: Referto FastenerCautiononpage 0-8.
2 FrontSide DoorWindowSwitchBezelAssembly

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2=64 Interior Trim and Paneling

Front Side Door Window Switch Bezel Replacement (Right Side)

2511553
Front Side Door Window Switch Bezel Replacement (Right Side)
Callout I Component Name
Preliminary Procedure
Removethefrontsidedoortrim.Referto FrontSide Door TrimReplacementonpage2-67.
1 FrontSide DoorWindowSwitchBezel Screw(Qty:8)
Caution: RefertoFastenerCautiononpage 0-8.
2 FrontSide DoorWindowSwitchBezel Assembly

2013
-Sonic
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 Interior Trim and Paneling ("l“
20:)

Rear Side Door Window Switch Bezel Replacement

ET 7 #
Wm J J

_/—— %
-’—;——.-::’—"’
i
1

2545441
Rear Side Door Window Switch Bezel Replacement
Callout l Component Name
Preliminary Procedure
Removetherearsidedoortrim.Referto Rear Side Door TrimReplacement(Sedan)onpage 2—84
or Rear Side DoorTrim
Replacement(Hatchback)onpage 2—83.
1 Rear Side DoorPull HandleFastener(Qty:2)
Caution: Referto FastenerCautiononpage 0-8.
Rear Side DoorWindowSwitchBezel Fastener(Qty:5)
Rear Side DoorWindowSwitchBezelAssembly

2013
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(5377994)
2.66 interior Trim and Paneling

Front Side Door Upper Front Trim Panel Replacement

2502894
Front Side Door Upper Front Trim Panel Replacement
Callout Component Name
FrontSide DoorUpperFrontTrimPanelAssembly
1 Procedure
Use theappropriateplastictrimtooltoaid in theremovalof thedoortrim.

2013
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 Interior Trim and Paneling 2=67

Front Side Door Trim Replacement

2502974

Front Side Door Trim Replacement

Callout Component Name
Preliminary Procedure
Removethefrontsidedoorupperfronttrimpanel.Referto FrontSide DoorUpperFrontTrimPanel Replacementonpage 2-66.
1 FrontSide DoorInsideHandleBolt FinishCap
FrontSide DoorInsideHandleFastener
2 Caution: Referto FastenerCautiononpage0—8.
FrontSide DoorTrimFastener
3 Procedure
toolto openthefrontside doortrimintegralcap toaccess thefastener.
Use a smallflat—bladed
FrontSide DoorTrimAssembly
Procedure
4 1. Use theappropriateplastictrimtoolto aid in theremovalofthedoortrim.
2. Pull upwardsonthedoorlockretainercabletodisengage.
3. Disconnecttheelectricalconnector.

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2=68 Interior Trim and Paneling

Rear Side Door Upper Rear Trim Panel Replacement (Hatchback)

2505586
Rear Side Door Upper Rear Trim Panel Replacement (Hatchback)
Callout ComponentName
RearSide DoorUpperRearTrimPanelAssembly
1 Procedure
Pullthedoorupperreartrimpanelawayfromtherearsidedoor.

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 interior I'rim and Paneling 2=89

Roof Rail Front Assist Handle Replacement

2508109
Roof Rail Front Assist Handle Replacement
Callout Component Name
RoofRail FrontAssist HandleFastener(Qty:2)
Caution: Referto FastenerCautiononpage 0-8.
Procedure
1 1. Foldtheassisthandledownwardandhold.
2. Use a smallflat-bladedtoolto opentheassisthandlecoversto access thescrews.
Tighten
6N~m(53 lbin)
2 RoofRail FrontAssist HandleAssembly

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2=70 Interior Trim and Paneling

Roof Rail Rear Assist Handle Replacement

2506115
Roof Rail Rear Assist Handle Replacement
Callout Component Name
RoofRail RearAssist HandleFastener(Qty:2)
Caution: Referto FastenerCautiononpage0-8.
Procedure
1. Foldtheassist handledownwardandhold.
2. Use a smallflat—bladed
tooltoopentheassist handlecoverstoaccess thescrews.
Tighten
6 N-m(53lb in)
RoofRail RearAssist HandleAssembly

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 Interior Trim and Paneling 2-71

Sunshade Replacement

2505648

Sunshade Replacement
Callout I Component Name
PreliminaryProcedure
Lowerthefrontoftheheadlinerto access thesunshadeelectricalconnector,if necessary.Referto HeadliningTrimPanel
Replacement(SedanwithSunroof)onpage 2—26 or HeadliningTrimPanel Replacement(HatchbackwithSunroof)onpage 2—24
or HeadliningTrimPanelReplacement(HatchbackwithoutSunroof)onpage 2-25or HeadliningTrimPanel Replacement
(SedanwithoutSunroof)onpage2-27.
SunshadeFastener(Qty:2)
1
Caution: RefertoFastenerCautiononpage 0—8.
SunshadeAssembly
Procedure
1. Squeezethetabsat thebase ofthesunshadeassemblyto removefromtheheadliner.
2. Disconnecttheelectricalconnector.

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2-72 Interior Trim and Paneling

Sunshade Support Replacement

2505642
Sunshade Support Replacement
Callout Component Name
SunshadeSupportFastener
1 Caution: Referto FastenerCautiononpage 0-8.
Note: Pull thecoverdownwardto access thefastener.
SunshadeSupportAssembly
2 Procedure
Unclipthesunshadefromthesupportandreposition.

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 Interior Trim and Paneling 2-73

2506385

Windshield Side Garnish Molding Replacement

Callout Component Name
PreliminaryProcedures
DisabletheSIR system,if equipped.Referto SIR DisablingandEnablingonpage 13—112.
WindshieldSide GarnishMoldingAssembly
Procedure
1. Tabsmustbe installedpriorto retainers.
2. Tabsto befullyseatedin theinstrumentpanel(l/P)trimpanelretainerandvalancepanel.
3. Disconnecttheelectricalconnectors.
4. Ensurethetetheris reattachedwheninstalled.

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2:74 Interior Trim and Paneling

Body Rear Seat Back Trim Panel Replacement (with AMAIAM7)

2677281
Body Rear Seat Back Trim Panel Replacement (with AMAIAM7)
Callout I Component Name
Preliminary Procedure
Removethebodysidetrimpanel.Referto BodySide TrimPanel Replacement(Sedan)onpage 2-80.
BodyRearSeat BackTrimPanel Retainer(Qty:3)
1 Procedure
Pull therearseatbackcushionlatchreleaselocatedon thetopof therearseat backcushion,andfoldtherear
seat backcushion)forward.
2 BodyRearSeat BackTrimPanelAssembly

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 Interior Trim and Paneling 2=75

\
a \(tox h:

I
I

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./

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2506705

Center Pillar Upper Trim Panel Replacement

Callout Component Name
Preliminary Procedure
1. Removethecenterpillarlowertrimpanel.Referto CenterPillarLowerTrimPanel Replacementonpage 2—76.
2. Removetheseatbeltfromthefrontseat.Referto Driveror PassengerSeat ShoulderBeltReplacement(withoutA69) on
page 13—131 or Driveror PassengerSeatShoulderBeltReplacement(WithA69)onpage 153-133.
CenterPillarUpperTrimPanelAssembly
1 Procedure
Whenreplacingthecenterpillaruppertrimpanel,feedtheseatbeltthroughthepanel.

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2-78 Interior Trim and Paneling

Center Pillar Lower Trim Panel Replacement

zz/
“1.1/(“fa
\ .

/E"'\

2506713
Center Pillar Lower Trim Panel Replacement
Callout Component Name
Preliminary Procedure
1. Removethefrontside dooropeningfloorcarpetretainer.Referto FrontSide DoorOpeningFloorCarpetRetainer
Replacementonpage 2—20.
2. Removetherearside dooropeningfloorcarpetretainer.Referto Rear Side DoorOpeningFloorCarpetRetainer
Replacementonpage 2—21 .
3. Moveseat tofullforwardposition.
CenterPillarLowerTrimPanelAssembly
1 Procedure
Ensuretheseatbeltwebbingdoes notbecometrappedduringinstallation.

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 interior Trim and Paneling 2777

2,21
2
.2 Body Lock Pillar Upper Trim Panel Replacement (Hatchback)

2511133

Body Lock Pillar Upper Trim Panel Replacement (Hatchback)

Callout l Component Name
Preliminary Procedure
DisabletheSIR system.Referto SIR DisablingandEnablingonpage 13—112.
1 InflatableRestraintAirbagCover
2 BodyLock PillarUpperTrimPanel Fastener
Caution: Referto FastenerCautiononpage 0-8.
BodyLock PillarUpperTrimPanelAssembly
3 Procedure
1. Graspthemoldingandpulloutwardto disengagetheintegralretainers.
2. Disconnecttheelectricalconnector,if equipped.

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Body Lock Pillar Upper Trim Panel Replacement (Sedan)

L’.‘ ’ ?’w" a
3.01 '\\\
w . .
2508470

Body Lock Pillar Upper Trim Panel Replacement (Sedan)

Callout 1 Component Name
Preliminary Procedure
1. DisabletheSIR system.Referto SIR DisablingandEnablingonpage 13-112.
2. Removethebodysidetrimpanel.Referto BodySide TrimPanel Replacement(Sedan)onpage 2-80.
BodyLock PillarUpperTrimPanelAssembly
1 Procedure
Pull outwardfromthetopfrontto disengageclips.

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 Interior Trim and Paneling 2279

Quarter Inner Trim Finish Panel Replacement (Hatchback)

“\\\\j

2511126

Quarter Inner Trim Finish Panel Replacement (Hatchback)

Callout l Component Name
Preliminary Procedures
1. Removetherearsidedooropeningfloorcarpetretainer.Referto Rear Side DoorOpeningFloor CarpetRetainer
Replacementonpage 2-21.
2. Removetherearseatcushion.Referto Rear Seat CushionRemovalandInstallationonpage 14-24.
3. Removerearseatback.Referto Rear Seat Back CushionRemovalandInstallation(40%)onpage 14-26or Rear‘Seat
Back CushionRemovaland Installation(60%)onpage 14-27.
4. Removethebodylockpillaruppertrimpanel.Referto BodyLock Pillar UpperTrimPanel Replacement(Hatchback)on
page 2—77or BodyLock Pillar UpperTrimPanel Replacement(Sedan)onpage2-78.
5. Removetherearcompartmentstowageshelf.Referto Rear CompartmentstowageShelfReplacement(Hatchback)on
page 2—82.
6. Removetherearcompartmentsill trimplate. Referto Rear Compan‘mentSill TrimPlate Replacementonpage 2—87.
7. Removetherearshoulderbelt.Referto ShoulderBeltReplacement- Rear (Sedan)onpage 13-63or ShoulderBelt
Replacement- Rear (Hatchback)onpage 13—64.
QuarterInnerTrimFinishPanelAssembly
Procedure
1 Use a trimtoolor equivalentto aid in removal.
Note: Afterinstallationofthequarterinnertrimpanel,ensuretherearseat beltis nottrappedunderthetrim
panel.Pull upon thebelttoverifyfull movementofthebelt.

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Body Side Trim Panel Replacement (Sedan)

2508766

Body Side Trim Panel Replacement (Sedan)

Callout ! Component Name
Preliminary Procedures
1. Removerearside dooropeningfloorcarpetretainer.Referto Rear Side DoorOpeningFloor CarpetRetainer
Replacementonpage2-21.
2. Removebodyrearseatbacktrimpanel.Referto BodyRear SeatBack TrimPanel Replacement(withAMA/AM?)on
page 2-74.
3. Removelowerrearshoulderbeltfastener.Referto ShoulderBelt Replacement-Rear (Sedan)onpage 13—63 or Shoulder
BeltReplacement- Rear o
(Hatchback) npage 13-64.
1 BodySideTrimPanel Push-lnRetainer
BodySide TrimPanelAssembly
2 Note: Ensureseat beltassemblyis routedoverand throughopeningin panelassembly.

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Rear Window Panel Trim Replacement

2677305

Rear Window Panel Trim Replacement

Callout Component Name
Preliminary Procedures
1. Removethebodylockpillaruppertrimpanel.Referto BodyLockPillar UpperTriniPanel Replacement(Hatchback)on
page 2-77or BodyLock Pillar UpperTrimPanel Replacement(Sedan)onpage 2-78.
2. Removethebodyrearseat backtrimpanel.Referto BodyRear Seat Back TrimPanel Replacement(withAMA/AM7)on
page 2-74.
RearWindow Panel TrimAssembly
1 Procedure
Whenreplacingtherearwindow paneltrimassembly,transferall necessarycomponents.

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Rear Compartment Stowage Shelf Replacement (Hatchback)

2510827
Rear Compartment Stowage Shelf Replacement (Hatchback)
Callout Component Name
1 Rear CompartmentStowageShelfAssembly

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 interior Trim and Paneling 2283

1i
2504859

Rear Side Door Trim Replacement (Hatchback)

Callout [ Component Name
Preliminary Procedure
Removetherearside doorupperreartrimpanel.Referto Rear Side DoorUpperRear TrimPanel Replacement(Hatchback)on
page 2-68.
1 Rear Side DoorInsideHandleBoltCap
Rear Side DoorInsideHandleFastener
2 Caution: Referto FastenerCautiononpage 0-8.
Procedure
Pull handlebackto removecap. Use suitabletoolto unsnap.
Rear Side DoorTrimFastener
3 Procedure
toolto opentherearside doortrimintegralcap to access thefastener.
Use a smallflat—biaded
Rear Side DoorTrimAssembly
Procedure
4 1. Use theappropriateplastictrimtooltoaid in theremovalofthedoortrim.
2. Pull upwards0nthedoorlockretainercabletodisengage.
3. Disconnecttheelectricalconnector.

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Rear Side Door Trim Replacement (Sedan)

2505429

Rear Side Door Trim Replacement (Sedan)

Callout Component Name
1 RearSide DoorinsideHandleBoltCap
Rear Side DoorinsideHandleFastener
2 Caution: Referto FastenerCautionon page 0-8.
Procedure
Pull handlebackto removecap. Use suitabletoolto unsnap.
Rear Side DoorTrim Fastener
3 Procedure
Use a smallflat-bladedtoolto opentherearside doortrimintegralcap toaccess thefastener.
RearSide DoorTrimAssembly
Procedure
4 1. Use theappropriateplastictrimtoolto aid in theremovalofthedoortrim.
2. Pull upwardsonthedoorlockretainercableto disengage.
3. Disconnecttheelectricalconnector.

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Luggage Shade Replacement (Hatchback)

2511125

Luggage Shade Replacement (Hatchback)

Callout Component Name
LuggageShadeAssembly
1 Procedure
Detachluggageshadefromuppersupport.

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Liftgate Trim Finish Panel Replacement (Hatchback)

2511130

Liftgate Trim Finish Panel Replacement (Hatchback)

Callout Component Name
1 LiftgateTrimFinishPanel Fastener
Caution: RefertoFastenerCautiononpage0-8.
2 LiftgateTrimFinishPanei Retainer(Qty:8)
LiftgateTrimFinishPanelAssembly
3 Procedure
Use a trimtoolor equivalentto aid in removal.

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Rear Compartment Sill Trim Plate Replacement

2508975
Rear Compartment Sill Trim Plate Replacement
Callout Component Name
Preliminary Procedure
Partiallyremovetherearcompartmentopeningweatherstrip.Referto Rear CompartmentLid WeatherstripReplacementon
page3—45.
1 Rear CompartmentSiliTrimPlateRetainer(Qty:4)
2 Rear CompartmentSiliTrimPlateAssembly

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Rear Compartment Lid Inner Panel Trim Replacement (Sedan)

2509122

Rear Compartment Lid Inner Panel Trim Replacement (Sedan)

Callout l Component Name
Preliminary Procedures
1. Removetherearcompartmentiid outerbumpers.
2. Removethelatchcover.
Rear CompartmentLid InnerPaneiTrimRetainer(Qty:13)
1 Procedure
Use a trimremovaltoolto aid in theremovaloftherearcompartmenttrimpanel.
2 Rear CompartmentLid InnerPanelTrim

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3 interior Trim and Paneiing 2289
Rear Compartment Side Trim Replacement - Left Side (Sedan)

2508931
Rear Compartment Side Trim Replacement - Left Side (Sedan)
Callout I Component Name
Preliminary Procedures
1. Removetherearcompartmentfloorpanelcarpet.Referto Rear CompartmentFloorPanel CarpetReplacement
(Hatchback)onpage2-23or Rear CompartmentFloorPanel CarpetReplacement(Sedan)onpage2-22.
2. Removetherearcompartmentsilltrimplate.Referto Rear CompartmentSill Trim
Plate Replacementonpage2-87.
1 RearCompartmentSide TrimRetainer(Qty:4)
2 RearCompartmentSide Trim

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Rear Compartment Side Trim Replacement - Right Side (Sedan)

2508924

Rear Compartment Side Trim Replacement - Right Side (Sedan)

Callout I Component Name
Preliminary Procedures
1. Removetherearcompartment floorpaneicarpet.Referto Rear CompartmentFloorPanel CarpetReplacement
(Hatchback)onpage 2-23or Rear CompartmentFloorPanel CarpetReplacement(Sedan)onpage 2—22.
2. Removetherearcompartmentsilltrimpiate.Referto Rear CompartmentSill TrimPlateReplacementonpage2—87.
1 Rear CompartmentSide TrimRetainer(Qty:4)
2 Rear CompartmentSide Trim

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Cargo Tie Down Loop Replacement

2547163
Cargo Tie Down Loop Replacement
Callout Component Name
CargoTie DownHookFastener
Caution: Referto FastenerCautiononpage0-8.
1 Tighten
9 N'm(80lb in)
2 CargoTie DownHookAssembly

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Quarter Outer Panel Pressure Relief Valve Replacement

/ 1::

Q a]

QW/

2498036

Quarter Outer Panel Pressure Relief Valve Replacement

Callout I Component Name
Preliminary Procedure
Removetherearbumperfascia.Referto Rear BumperFascia Replacement(Hatchback)onpage3-62
1 I QuarterOuterPanel PressureReliefValve Assembly

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 Table of Contents 311

Section 3

Body Repair

Bolted Exterior Body Panels and Hood Side Seai Replacement .................. 3-36
Closures ....................................... 3—3 Hood Rear Seai Replacement .................. 3—37
Specifications ..................................... 3—3 Hood Rear Weatherstrip Replacement . . .. . . . . . 3—38
Fastener Tightening Specifications .............. 3-3 Radiator Grilie Bumper Replacement ........... 3—39
Diagnostic Information and Procedures . . .. . . . .3-4 Front Opening Upper Cover Replacement ...... 3—40
DTC 83006 ...................................... 3-4 Liftgate Strut Replacement ..................... 3—41
Symptoms - Bolted Exterior Body Panels and Front Side Door Weatherstrip Replacement -
Closures ........................................ 3—5 Door Side ...................................... 3—42
Hood Ajar Indicator/Message Malfunction . . . 36 Front Side Door Weatherstrip Replacement -
Repair Instructions ............................... 3—8 Body Side ..................................... 3—43
Front End Upper Tie Bar Repiacement ........... 3—8 Liftgate Weatherstrip Replacement ............. 3-44
Hood Primary Latch Release Cable Rear Compartment Lid Weatherstrip
Replacement ................................... 3-9 Replacement .................................. 3—45
Front Side Door Adjustment .................... 3-10 Rear Side Door Upper Front Auxiliary
Front Side Door Replacement .................. 3—11 Weatherstrip Retainer Replacement .......... 3-46
Rear Side Door Adjustment (4 Door Notch Rear Side Door Weatherstrip Replacement -
Back 69) ....................................... 3-12 Door Side ...................................... 3-47
Rear Side Door Replacement ................... 3-13 Rear Side Door Weatherstrip Replacement -
Front Fender Replacement ..................... 3-14 Body Side ..................................... 3-48
Liftgate Adjustment ............................. 3—1 6 Description and Operation ...................... 3-49
Liftgate Replacement ........................... 3—17 Hood Ajar Indicator Description and
Hood Primary Latch Release Cable Handie Operation ...................................... 3-49
Repiacement .................................. 3-18 Special Tools and Equipment ................... 3—49
Front Side Door Upper Hinge and Lower Hinge Bumpers and Fascias ........................ 3—50
Replacement .................................. 3—19 Specifications ................................... 3-50
Hood Hinge Repiacement ...................... 3—20 Fastener Tightening Specifications ............. 3—50
Liftgate Hinge Replacement .................... 3—21 Repair Instructions .............................. 3—51
Rear Compartment Lid Rear Hinge Front Bumper Energy Absorber
Replacement .................................. 3-22 Replacement .................................. 3-51
Rear Side Door Upper Hinge and Lower Hinge Front Bumper Upper impact Bar
Replacement .................................. 3—23 Replacement .................................. 3-52
Hood Adjustment ............................... 3—24 Front Bumper Lower Impact Bar
Hood Replacement ............................. 3—25 Replacement .................................. 3—53
Hood InsulatorReplacement ................... 3—26 Front Bumper impact Bar Lower Bracket
Hood Primary and Secondary Latch Replacement .................................. 3—54
Replacement .................................. 3-27 Front Bumper Fascia Replacement ............. 3-55
Rear Compartment Lid Adjustment ............. 3-28 Front Bumper Fascia Guide Replacement ...... 3—56
Rear Compartment Lid Replacement ........... 3-29 Front Bumper Fascia Center Support Bracket
Front Side Door Check LinkRepiacement ...... 3-30 Repiacement .................................. 3-57
Rear Side Door Check LinkReplacement .... . . 3-31 Front Bumper Fascia Opening Lower Cover
Fuel Tank Filler Door Replacement ............. 3-32 Repiacement .................................. 3-58
Fuel Tank Filler Door Latch Housing Front Bumper Fascia Bracket Replacement .... 3-59
Replacement .................................. 3—33 Front Air Deflector Repiacement ................ 360
Hood Hold-Open Rod Replacement ............ 3—34 Front Bumper Fascia Air Deflector
Rear Compartment Lid Hinge Torque Rod Repiacement .................................. 3—61
Replacement .................................. 3-35
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Rear Bumper Fascia Replacement Description and Operation .................... 3-140
(Hatchback) ................................... 3-62 Dual Phase Steel .............................. 3-140
Rear Bumper Fascia Outer Guide Repiacement High Strength Low Alloy Steel ................. 3-141
(Sedan) ........................................ 3-63 MildSteel ...................................... 3—141
Rear Bumper Fascia Outer Guide Repiacement Ultra High Strength Dual Phase Steel ......... 3-141
(Hatchback) ................................... 3—64 Ultra High Strength Steel ...................... 3-142
Rear Bumper impact Bar Replacement Frame and Underbody ...................... 3-143
(Sedan) ........................................ 3—65 3-143
Specifications ..................................
Rear Bumper Impact Bar Replacement Fastener Tightening Specifications ............ 3—143
(Hatchback) ................................... 3-66 Repair Instructions ............................. 3—143
Special Tools and Equipment ................... 3-67 Drivetrain and Front Suspension Frame Skid
Collision Repair ............................... 3-68 Plate Replacement ........................... 3-143
Specifications ................................... 3-68 Drivetrain and Front Suspension Frame
Fastener Tightening Specifications ............. 3—68 Replacement ................................. 3—144
Dimensions - Body (5HB) ....................... 3-68 Front Wheelhouse Liner inner Front Extension
Dimensions —Body (4NB) ....................... 3-73 Repiacement (Left Side) ..................... 3-147
Visual identification . . . .'......................... 3-80 Front Wheelhouse Liner Inner Front Extension
Structure Identification (5HB) ................... 3—80 Repiacement (Right Side, LUV) .............. 3-148
Structure identification (4NB) ................... 3—83 Front Wheelhouse Liner Inner Front Extension
Repair Instructions .............................. 3—86 Replacement (Right Side, LWE, LUW) ....... 3-149
Front Bumper Impact Bar Replacement . . . . 3-86 Front Wheelhouse Liner Replacement
Front End Upper Tie Bar Replacement ......... 3—87 (Front) ........................................ 3-150
Front Wheelhouse Front Panel Front Wheelhouse Liner
Replacement .................................. 3-88 Repiacement (Rear) ......................... 3—151
Front Wheelhouse Panel Reinforcement Rear Wheelhouse Liner Replacement
Repiacement .................................. 3-90 (Hatchback —Right) .......................... 3-152
Front Compartment Upper Side Rail Rear Wheeihouse Liner Replacement (Sedan
Replacement .................................. 3-91 —Left) ......................................... 3—153
Front Compartment Side Rail Replacement 3-92 Rear Wheelhouse Liner Replacement
Front Hinge Pillar Body Sectioning ............. 3-94 (Hatchback - Left) ............................ 3-154
Body Hinge Pillar Lower Reinforcemeht Rear Wheeihouse Liner Repiacement (Sedan -
Replacement .................................. 3-96 Right) ........................................ 3—155
Roof Outer Panel Repiacement (5HB) .......... 3-97 Rear Wheeihouse Panel Liner Extension
Roof Outer Panel Repiacement (4NB) .......... 3-99 Replacement ................................. 3-156
Roof Front Header Panel Repiacement . . .. . . . 3-101 Front Compartment Front Insulator Cover
Roof Rear Header Panel Repiacement ................................. 3—157
Repiacement (5HB) .......................... 3-102 Special Tools and Equipment ................. 3—158
Rocker Inner Panel Repiacement ............. 3-104 Paint and Coatings .......................... 3—159
Rocker Outer Panel Sectioning ................ 3-105 Introduction .................................... 3—159
Body Side Frame Rocker Reinforcement Basecoat/Clearcoat Paint Systems ........... 3—159
Repiacement ................................. 3-108 Anti-Corrosion Treatment and
Front Side Door Outer Panel Replacement 3-109 . ............. 3—159
Repair (Base) ..................
Rear Side Door Outer Panel Replacement .... 3-110 Repair Instructions ............................. 3-160
Rear Compartment Floor Panel Clearcoat Repair without Repainting .......... 3-160
Replacement ................................. 3-112 3-160
Environmental Fallout (AcidRain) .............
Quarter Outer Panei Sectioning (5HB) .... . . . . 3-114 3-161
Paint Gauges ..................................
Quarter Outer Panel Sectioning (4NB) . . . . 3-117 Clearcoat Thickness ........................... 3—161
Quarter Inner Panel Replacement (4NB) . . 3—120 3—161
Rail Dust Damage Repair .....................
Quarter Inner Panel Sectioning (5H8) ......... 3-121
Plastic Panel Information and Repair ...... 3-162
Center Pillar Inner Panel Replacement ........ 3—125
Center Pillar Reinforcement Repiacement .... 3-126 Repair Instructions ............................. 3-162
Center Pillar Sectioning —Outer ............... 3-128 General Plastic Repair ......................... 3-162
Rear Raii Sectioning (5HB) .................... 3-131 Description and Operation .................... 3-162
Underbody Rear Side Raii Extension How to IdentifyPlastic Parts ................... 3-162
Replacement ................................. 3—134 Plastic identification and Refinishing
Rear End Panel Replacement ................. 3—136 Systems ...................................... 3—163
Tail Lamp Pocket Repiacement (5H8) ......... 3-137
Tail Lamp Pocket Repiacement (4NB) ......... 3—139

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 Bolted Exterior Body Panels and Closures 3’3

Bolted Exterior Body Panels and Closures

Specifications

Fastener Tightening Specifications

Specification
Application Metric English
FrontBumperimpactBar Bolt 100N-m 74lb in
FrontEnd UpperTie Bar Bolt 9 N-m 80 lb in
FrontEnd UpperTie Bar LowerBolt 22N-m 16lb in
FrontFenderBolts 9N°m 80lb in
FrontFenderNut 9N'm 80lb in
FrontSide DoorCheck LinkBoltto Body 22N-m 16lb in
FrontSide DoorCheck LinkNut 9 N-m 80lb in
FrontSide DoorLowerHingeto BodyBolt 32N-m 24 ibft
FrontSide DoorLowerHingeto DoorBolt 25Nm 18ibft
FrontSide DoorUpperHingeto BodyBolt 32N-m 24 lbft
FrontSide DoorUpperHingeto DoorBolt 25N-m 18lbft
'HoodHingeBolts 22N'm 16lbft
HoodHingeNuts 22Nm 16lbft
HoodPrimaryandSecondaryLatchBolts 22N'm . 16ibft
LiftgateHingeBolts 22Nm 16lbft
LiftgateHingeNuts 43N-m 32lbft
RadiatorOpeningUpperCover Bolts 4 Wm 36lb in
RearCompartmentLid Bolt '9 N'm .' 80lbft
RearCompartmentLid RearHingeBolt 9 NW 80lb in
RearSide DoorCheck LinkBoltto Body 22Nm 16lb in
RearSide DoorCheck LinkNut 9 N-m 80lb in
RearSide DoorLowerHingeto BodyBolts V 32N-m 24 lbft
RearSide DoorLowerHingeto DoorBolts 25NW 18lbft
RearSide DoorUpperHingeto BodyBolts 32NW 24 lbft
RearSide DoorUpperHingeto DoorBolts 25NW 18lbft

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3:4 Bolted Exterior Body Paneis and Closures

Diagnostic Information and Procedures

DTC B3006
Diagnostic Instructions
- Perform the Diagnostic System Check —Vehic/e
on page 6-66 prior to using this diagnostic
procedure.
- Review Strategy Based Diagnosis on page 6-58
for an overview of the diagnostic approach.
- Diagnostic Procedure Instructions on page 6-59
provides an overview of each diagnostic category.
DTC Descriptors
DTC B3006 01: Hood Ajar Circuit Short to Battery
DTC B3006 02: Hood Ajar Circuit Short to Ground
DTC B3006 04: Hood Ajar Circuit Open
Diagnostic Fault Information

Open/High Signal
Circuit Short to Ground Resistance Short to Voltage Performance
Signal B300602 B300604 B3006O1 -
,Ground — B3006O4 — -

CircuitlSystem Description Reference Information

The Body Control Module (BCM) applies B+ to the Schematic Reference
hood ajar signal circuit and monitors the voltage to
determine the position of the hood. When the hood is Immobilizer Schematics on page 13-4
closed, the switch is open and voitage remains high.
When the hood is open, the switch is closed and the Connector End View Reference
voitage is pulled low. Component Connector End Views on page 11—269
Conditions for Running the DTC Description and Operation
The BCM continuously monitors for this DTC Keyless Entry System Description and Operation on
page 13-44
Conditions for Setting the DTC
Electrical Information Reference
B3006 01
- Circuit Testing on page 11—526
The BCM detects that the hood ajar switch signal circuit
is shorted to battery. - Connector Repairs on page 11—548
- Testing for IntermittentConditions and Poor
B3006 02
Connections on page 11-531
The BCM detects that the hood ajar switch signal circuit - Wiring Repairs on page 11-537
is shorted to ground.
Scan Tool Reference
B3006 04
The BCM detects that the hood ajar switch signal Circuit Control Module References on page 6-3 for scan tool
is open. information

Action Taken When the DTC Sets Circuit/System Verification

~ The hood ajar switch input willbe ignored as a 1. Ignition ON.
content theft deterrent trigger. 2. Verify the scan tool Hood Ajar Switch parameter is
- Remote vehicie start will be disabled. Open when the hood is open and Closed when the
hood is closed.
Conditions for Clearing the DTC =>If the parameter does not change
- A current DTC wiii clear when the conditions for Refer to Circuit/System Testing.
setting the DTC are no longer present.
U If the parameter changes
- A history DTC will clear after 40 malfunction free
3. AIIOK.
ignition cycles.

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 Boited Exterior Body Panels and Closures 3-5

Circuit/System Testing 3. Test for 658—8060 between the signal terminai A

and the ground terminal C with the hood iatch in
1. ignition OFF and all vehicle systems OFF, the closed position.
disconnect the harness connector at the B55 Hood
Ajar Switch. it may take up to two minutes for all :> If not between 658—806(2
vehicle systems to power down. Replace the 855 Hood Ajar Switch.
2. Test for less than 10 0 between the ground Circuit U If between 658—806(2
terminal C and ground.
4. Test for 2080—25450 between the signai terminai
=>If 10 Q or greater B and the ground terminal C with the hood latch in
2.1. IgnitionOFF the closed position.
2.2. Test for less than 2 Q in the ground circuit end :> if not between 2080—2545(2
to end. Replace the 855 Hood Ajar Switch.
:> If2 Q or greater, repairthe open/high resistance U if between 2080—25450
in the circuit.
5. Test for 2738—33500 between the signal terminai
=9 Ifless than 2 Q, repair the open/high resistance A and the signal terminal 8 with the hood latch in
in the ground connection. the open position.
U If less than 10 Q :> if not between 2738—3350(2
(.0
. IgnitionON. Replace the 855 Hood Ajar Switch.
4. Test for greater than 11.5V between the signal
U if between 2738—3350(2
circuit terminal B and ground.
6. Test for 2080—25450 between the signal terminal
=>|f11.5Vor less A and the ground terminai C with the hood latch in
4.1. IgnitionOFF, disconnect the harness the open position.
connector at the K9 Body Control Module. :> if not between 2080—2545Q
4.2. Test for infinite resistance between the signal
circuit and ground. Replace the 855 Hood Ajar Switch.
:> Ifless than infinite resistance, repair the short to <: If between 2080-2545 (2
ground on the circuit. 7. Test for 658—806Q between the signal terminal 8
and the ground terminal C with the hood latch in
U Ifinfinite resistance.
the open position.
4.3. Test for less than 2 Q in the signal circuit end
to end. =>If not between 658—806(2
=>if2 Q or greater, repair the open/high resistance Replace the 855 Hood Ajar Switch.
in the circuit. U If between 658—8060
=>Ifless than 2 Q, replace the K9 Body Control 8. All OK.
Module.
Repair instructions
U if greater than 11.5 V
Perform the Diagnostic Repair Verification on
5. IgnitionOFF, disconnect the X4 and X7 harness page 6-92 after completing the repair.
connector at the K9 Body Control Module,
ignition ON. - Hood Primary and Secondary Latch Replacement
on page 3-27
6. Test for less than 1 V between the signal circuit
terminal B and ground. - Control Module References on page 6—3for Body
Control Module replacement, programming, and
=>If 1 Vor greater setup
Repair the short to voitage on the circuit.
U if less than 1 V Symptoms - Bolted Exterior Body
7. Test or replace the B55 Hood Ajar Switch. Panels and Closures

Component Testing Important: The following steps must be completed

before using the symptom tables.
1. IgnitionOFF, disconnect the harness connector at
1. Perform the Diagnostic System Check —Vehicle on
the 855 Hood Ajar Switch.
page 6-66 before using the symptom tables in
2. Test for 2738—3350Q between the signal terminal order to verify that all of the following are true:
A and the signal terminal B with the hood latch in
' There are no DTCs set.
the closed position.
- The control modules can communicate via the
=>if not between 2738—33509 serial data links.
Replace the 855 Hood Ajar Switch. 2. Review the system operation in order to familiarize
U If between 2738—3350(2 yourself with the system functions. Refer to Hood
Ajar Indicator Description and Operation on
page 3-49.

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«Sonic
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Service
Manual
(5377994)
”$6 Bolted Exterior Body Paneis and Ciosures

Visual/Physical inspection Intermittent

- inspect for aftermarket devices which could affect
the operation of the systems. Refer to Checking
Aftermarket Accessories on page 11—525.
' Inspect the easiiy accessible or visible system
components for obvious damage or conditions
which could cause the symptom.
Faulty electrical connections or wiring may be the
cause of intermittentconditions. Refer to Testingfor
IntermittentConditions and Poor Connections on
page 11—531. »
Symptom List
Refer to Hood Ajar lndicator/Message Malfunction on
page 3-6 in order to diagnose the symptom.

Hood Ajar lndicator/Message Malfunction

Diagnostic Instructions
- Perform the Diagnostic System Check —Vehicle
on page 6-66 prior to using this diagnostic
procedure.
- Review Strategy Based Diagnosis on page 6—58
for an overview of the diagnostic approach.
' Diagnostic Procedure Instructions on page 6-59
provides an overview of each diagnostic category.
DTC Descriptors
DTC B3006 01: Hood Ajar Circuit Short to Battery
DTC B3006 02: Hood Ajar Circuit Short to Ground
DTC B3006 04: Hood Ajar Circuit Open
Diagnostic Fault Information

Open/High Signal
Circuit Short to Ground Resistance Short to Voltage Performance
Signal 8300602 8300604 8300601 —-
Ground — 8300604 — -

Circuit/System Description Action Taken When the DTC Sets

The Body Control Module (BCM) applies 8+ to the 0 The hood ajar switch input willbe ignored as a
hood ajar signal circuit and monitors the voltage to content theft deterrent trigger.
determine the position of the hood. When the hood is 0 Remote vehicie start willbe disabled.
closed, the switch is open and voltage remains high.
When the hood is open, the switch is closed and the Conditions for Clearing the DTC
voltage is pulled low. - A current DTC willclear when the conditions for
Conditions for Running the DTC setting the DTC are no longer present.
- A history DTC will clear after 40 malfunction free
The BCM continuously monitors for this DTC
ignition cycles.
Conditions for Setting the DTC
Reference Information
B3006 01
Schematic Reference
The BCM detects that the hood ajar switch signal circuit
is shorted to battery. Immobilizer Schematics on page 13—4
B3006 02 Connector End View Reference
The BCM detects that the hood ajar switch signal circuit Component Connector End Views on page 11-269
is shorted to ground.
Description and Operation
B3006 04
Keyless Entry System Description and Operation on
The BCM detects that the hood ajar switch signal circuit page 1344
is open.
Electrical Information Reference
- Circuit Testing on page 11-526
- Connector Repairs on page 11—548

2013
-Sonic
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Service
Manual
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 Bolted Exterior Body Panels and Ciosures 3,7
Testing for IntermittentConditions and Poor 6. Test for less than 1 V between the signal circuit
Connections on page 11—531 terminai B and ground.
Wiring Repairs on page 11—537 2'} If 1 V or greater
Scan Tool Reference Repair the short to voltage on the Circuit.
Control Module References on page 6-3 for scan tool U If less than 1 V
information 7. Test or replace the 855 Hood Ajar Switch.
CircuitlSystem Verification Component Testing
1. ignition ON. 1. ignition OFF, disconnect the harness connector at
2. Verify the scan tool Hood Ajar Switch parameter is the 855 Hood Ajar Switch.
Open when the hood is open and Closed when the 2. Test for 2738—3350Q between the signal terminal
hood is closed. A and the signal terminal B with the hood latch in
2) If the parameter does not change the ciosed position.
Refer to CircuitlSystem Testing. If not between 2738-3350 Q
U If the parameter changes Replace the 855 Hood Ajar Switch.
3. Ail OK. If between 2738—3350Q
Test for 658-806 Q between the signal terminal A
CircuitlSystem Testing and the ground terminal C with the hood latch in
1. Ignition OFF and all vehicle systems OFF, the closed position.
disconnect the harness connector at the 855 Hood If not between 658-806 Q
Ajar Switch. it may take up to two minutes for all
Replace the 855 Hood Ajar Switch.
vehicle systems to power down.
. Test for less than 10 Q between the ground circuit If between 658—806Q
terminai C and ground. Test for 2080—2545Q between the signal terminal
8 and the ground terminal C with the hood latch in
If 10 Q or greater
the closed position.
2.1. IgnitionOFF
If not between 2080—2545Q
2.2. Test for less than 2 Q in the ground circuit end
to end. Replace the 855 Hood Ajar Switch.
=>If2 Q or greater, repair the open/high resistance c: if between 2080—2545Q
in the circuit. Test for 2738—3350Q between the signal terminal
=>Ifless than 2 Q, repair the open/high resistance A and the signal terminal 8 with the hood latch in
in the ground connection. the open position.
If less than 10 Q if not between 2738—3350Q
9° Ignition ON. Replace the 855 Hood Ajar Switch.
Test for greater than 11.5V between the signal if between 2738—3350Q
circuit terminal B and ground. Test for 2080—2545Q between the signal terminal
If 11.5 V or less A and the ground terminal C with the hood latch in
the open position.
4.1. IgnitionOFF, disconnect the harness
connector at the K9 Body Control Module. If not between 2080—2545Q
4.2. Test for infinite resistance between the signal Replace the B55 Hood Ajar Switch.
circuit and ground. If between 2080—2545Q
=>If less than infinite resistance, repair the short to Test for 658-806 Q between the signal terminal B
ground on the circuit. and the ground terminal C with the hood latch in
U If Infiniteresistance. the open position.
4.3. Test for less than 2 Q in the signal circuit end If not between 658—806Q
to end. Replace the 855 Hood Ajar Switch.
=>if2 Q or greater, repair the open/high resistance U If between 658—806Q
in the circuit.
8. Ali OK.
:> Ifless than 2 Q, replace the K9 Body Control
Module. Repair instructions
If greater than 11.5 V Perform the Diagnostic Repair Verification on
Ignition OFF, disconnect the X4 and X7 harness page 6-92 after completing the repair.
connector at the K9 Body Control Module, Hood Prima/y and Secondary Latch Replacement
ignition ON. on page 3-27
Control Module References on page 6-3 for Body
Control Module replacement, programming, and
setup

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
3-8 Bolted Exterior Body Paneis and Ciosures

Repair instructions

Front End Upper Tie Bar Replacement

2491633

Front End Upper Tie Bar Replacement

Callout Component Name
Preliminary Procedures
1. DisabletheSIR system.Referto SIR DisablingandEnablingonpage 13-112.
Removethefrontfascia.Referto FrontBumperFascia Replacementonpage3—55.
Removetheheadlamps.Referto HeadlampReplacementonpage4-193.
Removethefrontfenders.Referto FrontFenderReplacementonpage3-14.
RepositiontheradiatorwiththeA/C condenserfromtheuppertie bar.Referto RadiatorReplacement(LUV)onpage9-675
SNF‘P’N
or RadiatorReplacement(LDELUW)onpage9-678.
.03Removethehoodprimaryandsecondarylatch.Referto HoodPrimaryandSecondaryLatchReplacementonpage3-27.
Removethefrontendinflatablerestraintdiscriminatingsensor.Referto FrontEnd InflatableRestraintDiscriminating
SensorReplacementonpage 133-115.
FrontEnd UpperTieBar Bolt(Qty:2)
Caution: Referto FastenerCautiononpage 0—8.
Tighten
9 N-m(80lb in)
FrontEnd UpperTie Bar LowerBolt(Qty:4)
2 Tighten
22N-m(16lbft)
FrontBumperImpactBar Bolt(Qty:2)
3 Tighten
100N-m(74lbft)

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Manual
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 Boited Exterior Body Panels and Closures 339

Front End Upper Tie Bar Replacement (cont'd)

Callout Component Name
FrontEnd UpperTie Bar
Procedure
4 as needed.
1. Disconnecttheelectricalconnectors/harnesses
2. Disconnectthehoodiatchcablefromthetiebar.
3. Transferanypartsas needed.

Hood Primary Latch Release Cable Repiacement

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ggtg‘nri‘« ., 5%? . a ‘i‘ . ..

2472655

Hood Primary Latch Release Cable Repiacement

Callout Component Name
Preliminary Procedures
1. Removetheradiatoropeninguppercover.Referto FrontOpeningUpperCoverReplacementonpage3-40.
2. Removetheair inletgrille.RefertoAir InletGrillePanel Replacementonpage4-374.
HoodPrimaryLatchCable
Procedure
Disconnectthehoodprimarylatchreleasecablefromtheprimaryhoodlatch.
HoodPrimaryLatchReleaseCable Retainer
2 Procedure
Disconnectthehoodreleasecable retainersfromthehoodreleasecable.
3 HoodPrimaryLatchReleaseCable Grommet
HoodPrimaryLatchReleaseCable
4 Procedure
Disconnectthehoodprimarylatchreleasecablehandlefromthehoodlatchcable.Referto HoodPrimaryLatch
Release CableHandleReplacementonpage3-18.
2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
3=10 Bolted Exterior Body Panels and Ciosures

Front Side Door Adjustment

<—d

2563242
Front Side Door Adjustment
Callout I Component Name
Preliminary Procedure
RemovethefrontWheelhouseliner.Referto FrontWheelhouseLinerReplacement(Rear)onpage3-151or FrontWheelhouse
LinerReplacement(Front)onpage 3-150.
FrontSide Door
Caution: Referto FastenerCautiononpage0-8.
Procedure
1. Loosenthefrontside doorhingebolt(Qty:4)toadjustthefrontside door.
2. Adjustthefrontsidedoorin ordertoobtainan evengap betweenthefrontsidedoorandtheroof,therear
door,therockerpanelandthefrontfenderandso thatthefrontside doorisflushwiththeroof,thereardoor,
therockerpanelandthefrontfender.
Adjustment
- Frontsidedoorto roof
(a)4.5mmt 1.0mm(0.18in i 0.04in)
- Frontsidedoorto reardoor
(b)3.5mm: 0.75mm(0.14in i 0.03in)
- Frontsidedoorto rockerpanel
(c)5.0mm$1.0 mm(0.20in i 0.04in)
- Frontsidedoortofrontfender
(d)3.5mm10.75mm(0.14in i 0.03in)
Tighten
25N-m(19ibft)

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Bolted Exterior Body Panels and Closures 3AM

Front Side Door Replacement

20094
32

Front Side Door Replacement

Callout Component Name
Warning: Referto SIR Warningon page 0-7.
Preliminary Procedures
1. Markthelocationofthehingebeforeremovingtheboltswitha greasepencil.
2. Removethefrontdoortrimpanel.Referto FrontSide DoorTrimReplacementonpage 2-67.
FrontSide DoorCheck Link Boltto Body
Caution: Referto FastenerCautiononpage0-8.
Procedure
1. Removethewaterdeflector.
2. Disconnectthedoorelectricalconnector.
3. Supportthedoorbeforeremovingthehingebolts.
4. Withan assistant,removethedoor.
5. Afterthedoorhas beenremoved,ensurethatthedomelampisoff.ifthedomelampisonremovethe fuse.
Tighten
22N-m(16lbft)
FrontSide DoorUpperHingeBoitto Door(Qty:2)
2 Tighten
25Nm (18lbft)
FrontSide DoorLowerHingeBoltto Door(Qty:2)
3 Tighten
25N-m(18lbft)

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Manual
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3-12 Boited Exterior Body Panels and Ciosures

Front Side Door Replacement (cont'd)

Callout Component Name
FrontSide DoorAssembly
Procedure
1. Whenreplacingthedoorit isnecessarytotransferall of theinternalcomponents.
2. Ifthedoorstrikerneedsadjust.Referto FrontSide DoorLock StrikerAdjustmentonpage4-314.
3. Frontdooradjustment.Referto FrontSide DoorAdjustmentonpage3-10.

Rear Side Door Adjustment (4 Door Notch Back 69)

———><—d

i 1

ix:
2563229

Rear Side Door Adjustment (4 Door Notch Back 69)

Callout Component Name
RearSide Door
Caution: Referto FastenerCautiononpage 0-8.
Procedure
1. Loosenthereardoorhingebolt(Qty:4) toadjustthereardoor.
2. Adjustthereardoorin ordertoobtainan evengapbetweenthereardoorandtheroof,thequarterouter
panel,therockerpanelandthefrontsidedoorandso thatthereardoorisflushwiththeroof,thequarter
outerpanei,therockerpanelandthefrontside door.

2013
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Service
Manual
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 Bolted Exterior Body Panels and Ciosures 3443

Rear Side Door Adjustment (4 Door Notch Back 69) (cont'd)

Callout Component Name
Adjustment
- Rear side doorto roof
(a)4.5mmi 1.0mm(0.18in i 0.04in)
- Rearside doorto quarterouterpanel
(b)3.8mmi 0.75mm(0.15in i 0.03m)
- Rear side doorto rockerpanel
(c)5.0mm$1.0 mm(0.20in i 0.04in)
- Rearside doortofrontsidedoor
(d)3.5mmt 0.75mm(0.14in i 0.03in)
Tighten
25Nm (19lbft)

Rear Side Door Replacement

1571749

Rear Side Door Replacement

Callout Component Name
Warning: Refer to SIR Warningon page 0-7.
PreliminaryProcedures
1. Markthelocationofthehingebeforeremovingtheboltswitha greasepencil.
2. Removethereardoortrimpanel.Referto Rear Side DoorTrimReplacement(Sedan)on page2-84or Rear Side Door Trim
Replacement(Hatchback)onpage 2-83.

(US/Canada)
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2013 (5377994)
Manual
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3=i4 Bolted Exterior Body Panels and Ciosures

Rear Side Door Replacement (cont'd)

Callout Component Name
RearSide DoorCheck LinkBoltto Body
Caution: Referto FastenerCautiononpage0-8.
Procedure
1. Removethewaterdeflector.
2. Disconnectthedoorelectricalconnector.
3. Supportthedoorbeforeremovingthehingebolts.
4. Withan assistant,removethedoor.
5. Afterthedoorhas beenremoved,ensurethatthe domelampisoff.Ifthedomelampison removethefuse.
Tighten
22N'm(16lbft)
RearSide DoorHingeBolt to Door(Qty:2)
Tighten
32Nm (24lbft)
Rear Side DoorHingeBoltto Door(Qty:2)
Tighten
32N-m(24lbft)
RearSide DoorAssembly
Procedure
1. Whenreplacingthedoorit isnecessarytotransferall oftheinternalcomponents.
2. Ifthedoorstrikerneedsadjust.Referto Rear Side DoorLock StrikerAdjustmentonpage4-318.
3. Reardooradjustment.Referto Rear Side DoorAdjustment(4DoorNotchBack 69)onpage 3-12.

Front Fender Replacement

2472660
I.........

(US/Canada)
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2013 (5377994)
Manual
Service
 Boited Exterior Body Panels and Ciosures 3‘15

Front Fender Replacement

Callout Component Name
PreliminaryProcedures
1. Removethefrontbumperfascia. Referto FrontBumperFascia Replacementonpage 3-55.
2. Removetheheadlamp.Referto HeadlampReplacementonpage4-193.
3. RemovethefrontWheeihouselinerfrontandrear.Referto FrontWheelhouseLinerReplacement(Rear)onpage 3—151
or
FrontWheelhouseLinerReplacement(Front)onpage3-150.
4. Removethebodyside upperfrontapplique.Referto Body Side UpperFrontApp/iqueReplacementonpage 2-4.
5. Removethefrontbumperfascia guide.Referto FrontBumperFascia GuideReplacementonpage3-56.
FrontFenderBolt(Qty:3)
Caution: Referto FastenerCautiononpage 0-8.
Tighten
9 N‘m(801bin)
FrontFenderNut
Tighten
9 N-m(80lbin)
FrontFenderBolt(Qty:2)
Tighten
QN-m(80lbin)
FrontFenderBolt(Qty:2)
Tighten
9N-m(80lbin)
FrontFender
Procedure
1. Disconnecttheelectricalconnectors.
2. Transferpartsas needed.

2013
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Service
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3-16 Bolted Exterior Body Paneis and Closures

Liftgate Adjustment

2538537

Liftgate Adjustment
Callout Component Name
Liftgate
Caution: Referto FastenerCautiononpage 0-8.
Procedure
1. Loosenthe4 liftgatehingeboltstoadjustthe liftgate.
2. Adjusttheliftgateinordertoobtainan evengapbetweentheliftgateandtheroof,thequarterouterpanel,
thetaillampandrearbumperfascia andso thattheliftgateisflushwiththeroof,thequarterouterpanel,the
taillampandrearbumperfascia.
Adjustment:
- Liftgateto roof(a)5.5mm$1.0 mm(0.22ini 0.04in)
- Liftgateto quarterouterpanel(b)4.0mm11.0 mm(0.16ini 0.04in)
- Liftgateto taiilamp(0)3.5mm11.0 mm(0.14ini 0.04in)
' Liftgateto rearbumperfascia(d)5.0mm11.0 mm(0.20ini 0.04in)
Tighten
22N-m(16lbft)

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 Bolted Exterior Body Panels and Closures 3417

2479179

Liftgate Replacement
Callout Component Name.
Preliminary Procedures
1. Disconnecttheelectricalconnectors.
2. Disconnecttheliftgatestruts.Referto LiftgateStrutReplacementonpage3-41.
3. Removethebodylockpillaruppertrim.Referto BodyLockPillar UpperTrimPanel Replacement(Hatchback)onpage 2-77
or BodyLockPillar UpperTrimPanel Replacement(Sedan)onpage2-78.
LiftgateHingeBolt(Qty:4)
Caution: RefertoFastenerCautiononpage 0-8.
1 Tighten
22N-m(16lbft)
Liftgate
2 Procedure
1. Transferpartsas needed.
2. Adjusttheliftgateif needed.Referto LiftgateAdjustmentonpage3-16.

(US/Canada)
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2013 (5377994)
Manual
Service
348 Boited Exterior Body Panels and Closures

Hood Primary Latch Release Cable Handle Replacement

2407263
Hood Primary Latch Release Cable Handie Replacement
Callout I Component Name
Preliminary Procedure
Removethefrontsidedooropeningfloorcarpetretainer.Referto FrontSide DoorOpeningFloorCarpetRetainerReplacement
onpage 2-20.
HoodPrimaryLatchReleaseCable Handle
1 Procedure
Press thereleasecablehandleupwardto releasetheretainersfromtheinstrumentpanelbracket.
HoodPrimaryLatchReleaseCable
2 Procedure
Disconnectthehoodreleasecablefromthehoodreleasehandle.

2013
-Sonic
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i
i , . .
I Bolted Exterior Body Panels and Closures 3219

I Front Side Door Upper Hinge and Lower Hinge Replacement

1563330

Front Side Door Upper Hinge and Lower Hinge Replacement

Callout Component Name
FrontSide DoorUpperHingeto BodyBolt(Qty:2)
Caution: RefertoFastenerCautiononpage 0-8.
Procedures
1. Beforeremovingthedoor,applya doublelayerof maskingtapearoundtheperimeterof thepainted
surfaces.
1 2. Markthelocationofthehingebeingremoved.
3. RemovethefrontWheelhouseliner.Referto FrontWheelhouseLinerReplacement(Rear)onpage3-151or
FrontWheelhouseLinerReplacement(Front)onpage3-150.
4. Supportthedoorbeforeremovingthehingeboits.
Tighten
32Nm (24lbft)
FrontSide DoorUpperHingeto DoorBolt(Qty:2)
2 Tighten
25N-m(18lbft)
3 FrontSide DoorUpperHinge
FrontSide DoorLowerHingeto BodyBolt(Qty:2)
4 Tighten
32Nvm(24lbft)
FrontSide DoorLowerHingeto DoorBolt(Qty:2)
5 Tighten
25N-m(18lbft)

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
3=20 Bolted Exterior Body Panels and Ciosures

Front Side Door Upper Hinge and Lower Hinge Repiacement (cont'd)
Callout Component Name
FrontSide DoorLowerHinge
Procedure
ifthedoorstrikerneedsadjust.Referto FrontSide DoorLockStrikerAdjustmentonpage4-314.

Hood Hinge Replacement

2472657

Hood Hinge Replacement

Callout Component Name
Preliminary Procedures
1. Removethehood.Referto HoodReplacementonpage3-25.
2. Removethefrontfender.Referto FrontFenderReplacementonpage3-14.
HoodHingeBolt(Qty:2)
Caution: Referto FastenerCautiononpage 0-8.
Tighten
22Nm (16lbft)
HoodHinge
Procedure
Adjustthehoodandhingeifneeded.Referto HoodAdjustmentonpage 3-24.

(US/Canada)
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2013 (5377994)
Manual
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 Boited Exterior Body Panels and Ciosures 3:21

2479201

Liftgate Hinge Repiacement

Callout Component Name
Preliminary Procedures
1. Removetheliftgate.Referto LiftgateReplacementonpage3-17.
2. Lowertherearoftheheadlinertoaccess theinnerbolts.Referto HeadliningTrimPanel Replacement(SedanwithSunroof)
onpage 2-26or HeadliningTrimPanel Replacement(HatchbackwithSunrooflonpage 2-24or HeadliningTrimPanel
Replacement(HatchbackwithoutSunrooflonpage2—25 or HeadliningTrimPanelReplacement(SedanwithoutSunrooD
onpage 2-27.
3. Use a greasepencilto marktheliftgatehingepositiontothebodypriorto removal.
LiftgateHingeNut(Qty:2)
Caution: Referto FastenerCautiononpage0-8.
Tighten
43N-m(32lbft)
LiftgateHinge(Qty:2)
2 Procedure
Adjusttheliftgateifneeded.

2013
-Sonic
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Service
Manual
(5377994)
3:22 Bolted Exterior Body Paneis and Closures

Rear Compartment Lid Rear Hinge Replacement

2498271

Rear Compartment Lid Rear Hinge Replacement

Callout Component Name
Preliminary Procedures
1. Removetherearwindowtrimpanel.Referto Rear WindowPanel TrimReplacementonpage2-81.
2. Removetherearcompartmentlid.Referto Rear CompartmentLidReplacementonpage3-29.
3. Disconnecttherearcompartmentlid hingetorquerods.Referto Rear CompartmentLidHingeTorqueRod Replacementon
page 3-35. '
RearCompartmentLid Rear HingeBolt(Qty:2)
Caution: Referto FastenerCautionon page0-8.
Tighten
9N-m(80lb in)
RearCompartmentLid Rear Hinge
Procedures
1. Transferpartsas needed.
2. Adjusttherear compartmentiid if needed.Referto Rear CompartmentLid Adjustmentonpage3—28.

(US/Canada)
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2013 (5377994)
Manual
Service
 Bolted Exterior Body Paneis and Ciosures 3:23

Rear Side Door Upper Hinge and Lower Hinge Repiacement

13m 3

/6

/// (ms

4/// 811/

2908569
Rear Side Door Upper Hinge and Lower Hinge Replacement
Callout Component Name
RearSide DoorUpperHingeto BodyBoits(Qty:2)
Caution: Referto FastenerCautiononpage0-8.
Procedures
1. Beforeremovingthedoor,applya doublelayerof maskingtapearoundtheperimeterof thepainted
surfaces.
2. Markthelocationofthe hingebeingremoved.
3. Supportthedoorbeforeremovingthehingebolts.
Tighten
32Nm (24lbft)
RearSide DoorUpperHingeto DoorBolts(Qty:2)
Tighten
25N-m(18lbft)
Rear Side DoorUpperHinge
Rear Side DoorLowerHingeto BodyBolts(Qty:2)
Tighten
32Nm (24lbft)
Rear Side DoorLowerHingeto DoorBolts(Qty:2)
Tighten
25N-m(18lbft)
Rear Side DoorLowerHinge
Procedure
if thedoorstrikerneedsadjust.Referto Rear Side DoorLockStrikerAdjustmentonpage4—318.

2013
—Sonic
(US/Canada)
Service
Manual
(5377994)
3-24 Bolted Exterior Body Panels and Closures

Hood Adjustment

2537185

Hood Adjustment
Callout Component Name
Hood
Caution: Referto FastenerCautiononpage 0-8.
Procedure
1. Loosenthe4 hoodhingenuts.
2. Adjustthehoodin ordertoobtainan evengapon bothsides betweenthehoodand thefenders,the
headlampsandthe frontbumperfasciaandso thatthehoodis flushwithbothfendersonthefrontedge,the
frontbumperfascia andtheheadlamps.
Adjustment:
- Hoodtofrontfender(a)3.0mm1 0.75mm(0.12in 1 0.03in)
- Hoodto headlamp(b)3.0mm11.0 mm(0.12in1 0.04in)
- Hoodtofrontbumperfascia(c)3.0mm11.0 mm(0.12in1 0.04in)
Tighten
22Mom(16lbft)

..........
(US/Canada)
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2013 (5377994)
Manual
Service
 Bolted Exterior Body Panels and Ciosures 3=25

Hood Replacement

2469731

Hood Repiacement
Callout Component Name
Preliminary Procedure
Disconnectthewindshieldwashernozzlehose.
HoodHingeNut(Qty:4)
Caution: Referto FastenerCautiononpage0-8.
Procedure
Markthelocationofthehingetothe hoodwitha greasepenciltoaid in alignment.
Tighten
22Wm(16lbft)
Hood
Procedure
1. Transferpartsas needed.
2. Adjustthehoodifneeded.Referto HoodAdjustmentonpage 3-24.

(US/Canada)
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2013 (5377994)
Manual
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3‘26 Boited Exterior Body Panels and Closures

Hood insulator Replacement

2469732

Hood Insulator Replacement

Callout Component Name
1 HoodInsulatorPlasticRetainer(Qty:6)
HoodInsulator
2 Procedure
Ensurethe3 integraltabsaresecuredtothehood.

(US/Canada)
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2013 (5377994)
Manual
Service
 t
iI
,,,,,, Bolted Exterior Body Panels and Ciosures 3:27

i Hood Primary and Secondary Latch Repiacement

i
i . Q
I . \‘

IQ
« Ail

2472650
Hood Primary and Secondary Latch Repiacement
Callout Component Name
HoodPrimaryandSecondaryLatchBolt(Qty:2)
Caution: Referto FastenerCautiononpage 0-8.
Tighten
22Nm (16lbft)
HoodPrimaryandSecondaryLatch .
2 Procedure
Disconnectthereleasecablefromthehoodprimarylatch.

I 2013
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Service
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3=28 Bolted Exterior Body Panels and Ciosures

Rear Compartment Lid Adjustment

//

2538520

Rear Compartment Lid Adjustment

Callout Component Name
Rear CompartmentLid
Caution: Referto FastenerCautiononpage0-8
Procedure
1. Loosentherearcompartmentlidhingebolts(Qty:4)to adjusttherearcompartmentlid.
2. Adjusttherearcompartmentlid inordertoobtainan evengapbetweentherearcompartmentlidandthe
quarterouterpantherearfoglampandtherear bumperfasciaand so thattherearcompartmentlid is flush
withthequarterouterpanel,the rearfoglampandtherear bumperfascia.
Adjustment
- Rear compartmentlidto quarterouterpanel
(a)3.0mm1 0.75mm(0.12in 1 0.03in)
- Taillampto rearcompartmentlid
(b)3.0mm11.0 mm(0.12in 1 0.04in)
- Rearcompartmentlidto rearbumperfascia
(o)5.5mm11.5 mm(0.22in 1 0.06in)
Tighten
22N-m(16lbft)

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 Boited Exterior Body Paneis and Closures 3=29

Rear Compartment Lid Repiacement

2469724
Rear Compartment Lid Replacement
Callout Component Name
Preliminary Procedure
Removetherearcompartmentlidinnerpaneltrim.Referto Rear CompartmentLidInnerPanel TrimReplacement(Sedan)on
page2-88.
Rear CompartmentLid Bolt(Qty:4)
Caution: Referto FastenerCautiononpage 0-8.
Tighten
9 N-m(80lbft)
Rear CompartmentLid
Procedure
2 1. Disconnecttheelectricalconnector.
2. Adjusttherearcompartmentiidas needed.Referto Rear CompartmentLidAdjustmentonpage 3-28.
3. Transfercomponentsas necessary.

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(5377994)
3=30 Bolted Exterior Body Panels and Closures

Front Side Door Check Link Replacement

1958360

Front Side Door Check Link Repiacement

Callout Component Name
Preliminary Procedure
Removethefrontside doortrimpanel.Referto FrontSide DoorTrimReplacementonpage2-67.
FrontSide DoorCheckLink Boltto Body
Caution: Referto FastenerCautiononpage 0-8.
1 Note: Place thedoorwindowin thefullopenposition.
Tighten
22N-m(16lbft)
FrontSide DoorCheck LinkNut(Qty:2)
Procedure
2 Removethewaterdeflector.
Tighten
9 N-m(80lbin)
3 FrontSide DoorCheckLink

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 Bolted Exterior Body Panels and Ciosures 3-31

Rear Side Door Check Link Replacement

2218049

Rear Side Door Check Link Replacement

Callout I Component Name
Preliminary Procedures
1. Movethewindowtothefullupposition.
2. Removetherearsidedoortrimpanel.Referto Rear Side DoorTrimReplacement(Sedan)onpage 2-84or Rear Side Door
TrimReplacement(Hatchback)onpage283
RearSide DoorCheck LinkBoltto Body
Caution: Referto FastenerCautiononpage 0—8
Tighten
22Nm (16lbft)
RearSide DoorCheck LinkNut(Qty:2)
Procedure
2 Removethewaterdeflector.
Tighten
9 NW(80lb in)
3 RearSide DoorCheckLinkAssembly

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3:32 Bolted Exterior Body Panels and Closures

Fuel Tank Filler Door Repiacement

2469707

Fuel Tank Filler Door Replacement

Callout Component Name
FuelTankFillerDoor
Procedure
door,
Positionthefueltankfillerdoortothefull openposition.Usinglightoutwardslidingpressureonthefiller
releasethe retaineronthefuel tankfillerdoorfromthehinge.

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 Bolted Exterior Body Panels and Ciosures 3233

Fuel Tank Filler Door Latch Housing Repiacement

2469721

Fuel Tank Filler Door Latch Housing Replacement

Callout I Component Name
Preliminary Procedures
1. RemovetherearWheelhousepanelliner.Referto Rear WheelhouseLinerReplacement(Hatchback- Right)onpage3—152
or Rear WheelhouseLinerReplacement(Sedan- Left)onpage3-153or Rear WheelhouseLinerReplacement(Hatchback
- Left)onpage3—154 or Rear WheelhouseLinerReplacement(Sedan—Right)onpage3-155.
2. Removethefueltankfillerdoor.Referto Fuel TankFillerDoorReplacementonpage3—32.
FuelTankFillerDoorLatchHousingRetainer(Qty:4)
1 Procedure
Releasethe4 fillerdoorlatchhousingretainersonthebackofthehousing.
FuelTankFillerDoorLatchHousing
2 Procedure
Press thefueltankfillerhousingoutwardfromthefuelfillerpipeandthequarterpanel.

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3:34 Boited Exterior Body Panels and Ciosures

Hood Hold-Open Rod Replacement

2491162

Hood HoId-Open Rod Repiacement

Callout Component Name
HoodHoId-OpenRod
to
Warning: Whena hood hold open device is being removed or installed, provide alternatesupport
1 avoid thepossibility of damage to the vehicle or personal injury.
Procedure
Openthe retainerand removethe hoodhold-openrod.

(US/Canada)
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2013 (5377994)
Manual
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 Bolted Exterior Body Panels and Ciesures

Rear Compartment Lid Hinge Torque Rod Replacement

"“r-

2498276

Rear Compartment Lid Hinge Torque Rod Replacement

Callout I Component Name
Warning: Refer to HoodHoId-OpenDevice Warningon page 0-5.
Preliminary Procedure
Openandsupporttherearcompartmentlid.
Special Tools
BO-125TorqueRod Lifter
For equivalentregionaltools,referto Special Toolsonpage3-49.
Rear CompartmentLid HingeTorqueRod— RightSide
1
Note: Onlyusethespecialtoolto removeandinstalltherearcompartmentlid hingetorquerod.
Rear CompartmentLid HingeTorqueRod— LeftSide
Note: Onlyusethespecialtoolto removeandinstalltherearcompartmentlidhingetorquerod.

f 2013 (US/Canada)
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Manual
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 Exterior Body Panels and Closures
13=36 Bolted

Side Seai Replacement

Hood

M.

Hood Side Seal Replacement

om onen ame
t
e e US n eta e
.m r m
oo
) n. N
Hood Side Seai C
d h 6
S S P R
H

1.:
M
.nla

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2013 (5377994)
Manual
Service
 Bolted Exterior Body Panels and Closures 3=37

Hood Rear Seal Replacement

,‘W.__,_2-
2....
_
¢.

M229.

. \ \;‘-I\
5“ _ mmmmml/mmkws
\ \By’j; I VJ". ’

.r‘

2473413
Hood Rear Seal Replacement
Callout Component Name
HoodRearSeal
Procedure
1. Cleantheareawheretheseal willbe mounted.Use a suitablesolventwitha mixtureof 50percentisopropyl
1 alcoholand50percentwaterbyvolume,or high-flashnaphtha.
2. Warmtheair inletpanelusinga heatgun,to a minimum.priortothehoodrearouterseal installation.
3. Do NOTtouchtheadhesivesurfacewhentapeis removed.Peel thetapelineroffandinstalltheouterrear
hoodseal.
4. Positiontheendoftheseal intotheendof thehoodrearweatherstrip.

2013
-Sonic
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(5377994)
3—38 Bolted Exterior Body Paneis and Closures

Hood Rear Weatherstrip Replacement

_L

x0 \
I

§§II%‘%§I "II
“1.19, .V..1.1 , I I \ ..

\ E:\v’V—N: \\ ‘ A ‘ I

Hood Rear Weatherstrip Replacement

Callout Component Name
HoodRearWeatherstrip
1 Procedure
The hoodrearweatherstripis heldin placewith10 plasticretainersthatarepartof theair inletgrille.Carefully
pulltheweatherstripto theright/leftto releasefromthe retainerson theair inletgrille.

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1 Boited Exterior Body Panels and Closures 3=39

I Radiator Grille Bumper Replacement

2479283
Radiator Grille Bumper Replacement
Callout Component Name
PreliminaryProcedure
Removethefrontbumperfascia.Referto FrontBumperFascia Replacementonpage3-55.
RadiatorGrille BumperScrew(Qty:6)
1
Caution: Referto FastenerCautiononpage 0-8.
RadiatorGrilleBumper
2 Procedure
Pullgentlyon eachsideof theradiatorgrillebumpertodisengagefromthefrontbumperfascia.

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-Sonic
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1340 Bolted Exterior Body Panels and Closures

Front Opening Upper Cover Replacement

2507197

Front Opening Upper Cover Replacement

Callout Component Name
1 RadiatorOpeningUpperCover Screw(Qty:10)
Caution: RefertoFastenerCautiononpage 0-8.
RadiatorOpeningUpperCover Bolt(Qty:4)
2 Tighten
4 N-m(36lb in)
3 RadiatorOpeningUpperCover Push-lnRetainer(Qty:6)
4 RadiatorOpeningUpperCover

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 Boited Exterior Body Panels and Closures 3:41

Liftgate Strut Replacement

2479207

Liftgate Strut Replacement

Callout Component Name
LiftgateStrut
Warning: Whena lift gate hold open device is being removedor installed, provide alternatesupport to
avoid thepossibility of damageto the vehicle or personal injury.
Caution: Apply pressureonlyattheendofthe iiftgate/hood assist rodthatyouare removingor attaching.Do
NOTapplypressuretothemiddleoftherodbecausedamageor bendingwillresult.
Procedure
1. Releasethelockingtabsonthestrut.
2. Ensuretheclip is fullyseatedwhenthestrutis reinstalled.if theclipcannotbefullyseated.a newstrut
shouldbe installed.

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 Bolted Exterior Body Panels and Closures
342
Weatherstrip Replacement - Door Side
Front Side Door

2425031

Replacement - Door Side

Front Side Door Weatherstrip
Component Name
Callout
FrontSide DoorWeatherstripUpperRetainer
Procedure
position.
1. Openthefrontside doorto thefullyopen Check Link
2. Removethefrontsidedoor check linkboltfromthe bodyside only. Referto FrontSide Door
Replacementonpage 3-30.
fromthe upperrearcornerof thedoor.
3. Use a suitabletool,removethe push-inretainer
4. Pull theweatherstripoutof thedoorretainer.
FrontSide DoorWeatherstripRetainers(Qty:21)
FrontSide DoorWeatherstrip
Procedure
thedoorframeretainer.
1. Ensurethattheweatherstripis fullyseatedin
2. Verifyproperdooroperation.

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I Bolted Exterior Body Panels and Closures 3=43

I Front Side Door Weatherstrip Replacement - Body Side

2234097
Front Side Door Weatherstrip Replacement - Body Side
Callout I Component Name
Preliminary Procedure
1. Removetheuppercenterpillartrim.Referto CenterPillar UpperTrimPanel Replacementonpage 2-75.
2. Removethelowercenterpillartrim.Referto CenterPillarLowerTrimPanel Replacementonpage 2—76
3. Removethecarpetretainer.Referto FrontSide DoorOpeningFloor CarpetRetainerReplacementonpage2-20.
FrontSide DoorWeatherstripBodySide
Preliminary Procedure
1. Startingin thecenterbottomoftheweatherstrip,pulltheweatherstripupwardandawayfromthepinch-weld
flange.
1
2. Startin thecenterbottomofthepinch-weldflange.
3. Ensurethattheweatherstripand retainersarefullyseatedontheflangebeforeinstallingthefrontcarpet
retainer.
4. Inspectthedoorforproperoperation.

2013
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(5377994)
3=44 Bolted Exterior Body Panels and Closures

Liftgate Weatherstrip Replacement

2479213

Liftgate Weatherstrip Replacement

Callout Component Name
LiftgateWeatherstrip
Procedure
isopropyl
Clean theareawherethe sealwill be mounted.Use a suitablesolventwitha mixtureof50percent
alcoholand 50percentwaterby volume,or high-flashnaphtha.

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 Bolted Exterior Body Paneis and Closures 345

Rear Compartment Lid Weatherstrip Replacement

tfii

88118 .

2469723

Rear Compartment Lid Weatherstrip Replacement

Callout Component Name
RearCompartmentLidWeatherstrip
Procedure
1 1. Disconnectanyelectricalconnector.
2. Cleantheareawheretheseatwill be mounted.Use a suitablesolventwitha mixtureof 50percentisopropyl
alcoholand50percentwaterbyvolume,or high-fiashnaphtha.

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3-46 Bolted Exterior Body Panels and Ciosures

Rear Side Door Upper Front Auxiliary Weatherstrip Retainer Replacement

2425042

Rear Side Door Upper Front Auxiliary Weatherstrip Retainer Replacement

Callout Component Name

1 FrontSide DoorUpper FrontAuxiliaryWeatherstripRetainer(Qty:10)
Note: Iftheretainersare damagedwhenremovingtheymustbe replaced.
FrontSide DoorUpper FrontAuxiliaryWeatherstripRetainer
Procedure
1. Rearsidedoorweatherstripdoorside. Referto Rear Side DoorWeatherstripReplacement- DoorSide on
2 page 3-47.
Itis onlynecessaryto removetheuppersecondoftheweatherstripfromthedoorto replacethe
weatherstripretainer.
2. Startingin thecentertopoftheweatherstrip,pulltheweatherstripupwardandawayfromthedoorretainer.
3. inspectthedoorforproperoperationandsealing.

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Manual
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 Boited Exterior Body Panels and Closures 3-47

Rear Side Door Weatherstrip Replacement - Door Side

2476191
Rear Side Door Weatherstrip Replacement - Door Side
Callout Component Name
RearSide DoorWeatherstripUpperRetainers(Qty:3)
Procedure
1. Openthefrontsidedoorto thefullyopenposition.
2. Removethefrontside doorchecklinkboltfromthebodyside only. Referto FrontSide DoorCheckLink
Replacementonpage 3—30.
3. Use a suitabletool,removethepush-inretainersfromthecornersof thedoor.
4. Pulltheweatherstripoutofthedoorretainer.
RearSide DoorWeatherstripRetainers(Qty:21)
RearSide DoorWeatherstrip
Procedure
1. Ensurethattheweatherstripis fullyseatedin thedoorframeretainer.
2. Verifyproperdooroperation.

2013
-Sonic
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(5377994)
3=48 Bolted Exterior Body Panels and Ciosures

Weatherstrip Replacement - Body Side

Rear Side Door

'\

2244547

Replacement - Body Side

Rear Side Door Weatherstrip
I Component Name
Callout
Preliminary Procedures
UpperTrimPanel Replacementonpage 2-75.
1. Removetheuppercenterpillartrim.Referto CenterPillar
LowerTrimPanel Replacementonpage 2-76
2. Removethelowercenterpillartrim.Referto CenterPillar
OpeningFloorCarpetRetainerReplacementonpage 2-21.
3. Removethecarpetretainer.Referto Rear Side Door
RearSide DoorWeatherstripBodySide
Preliminary Procedure
weatherstripupwardandawayfromthe pinch-weld
1. Startingin thecenterbottomof theweatherstrip,pullthe
1 flange.
2. Startin thecenterbottomofthe pinch—weld flange.
3. Ensure thatthe and
weatherstrip retainersarefullyseatedon theflangebeforeinstallingthefrontcarpet
retainer.
4. inspectthe doorfor properoperation.

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 Boited Exterior Body Panels and Closures 349

Description and Operation Special Tools and Equipment

Hood Ajar Indicator Description and illustration Tool Numberl Description

Operation

Hood Ajar Switch

The body controi module (BCM) applies 8+ to the hood
BO-125
ajar signal circuit and monitors the voltage to determine
the position ofthe hood. When the hood is closed, the KM-125
switch is open and voltage remains high. When the TorqueRod Lifter
hood is open, the switch is closed and the voltage is
pulled low.
The BCM uses the hood ajar switch as a content theft
deterrent alarm trigger. 2027391

Hood Ajar IndicatorlMessage

When the hood is ajar, a message is displayed on the
BIG or the hood ajar indicator will be illuminated.

2013
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3-50 Bumpers and Fascias

Bumpers and Fascias

Specifications

Fastener Tightening Specifications

Specification
Application Metric English
FrontAir DeflectorBolts 8 N-m 71lbin
FrontBumperFascia Air DeflectorScrews 2.5N°m 22lbin
FrontBumperFascia BracketBolts 9 N'm 80lbin
FrontBumperFascia CenterSupportBolts 9N'm 80lbin
FrontBumperFascia LowerScrews 2.5N-m 22lbin
FrontBumperFascia OpeningLowerCoverBolts 22N-m 16lbft
FrontBumperFascia OpeningLowerCoverScrews 2.5N-m 22lbin
FrontBumperFascia Screws 2.5N'm 22lbin
FrontBumperimpactBar Bolts 100Mm 74lbin
FrontBumperimpactBar LowerBracketScrews 2.5N-m 22lbin
FrontBumperLowerimpactBracketBolts 22N-m 16ibft
HeadlampBolt 2.5N-m 22lbin
Rear BumperImpactBar Bolts 40N-m 30lbft
Rear BumperImpactBar Nuts 40N-m 30lbft
Rear Fascia Screws 2.5N-m 22lbin

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 Bumpers and Fascias 551

Repair Instructions

Front Bumper Energy Absorber Replacement

2474417
Front Bumper Energy Absorber Replacement
Callout Component Name
Preliminary Procedure
Removethefrontbumperfascia.Referto FrontBumperFascia Replacementonpage3-55.
1 FrontBumperEnergyUpperAbsorberPush—On Retainer(Qty:2)
FrontBumperEnergyUpperAbsorber
2 Procedure
Repositiontheelectricalharnessfromtheabsorber.

2013
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3:52 Bumpers and Fascias

Front Bumper Upper Impact Bar Replacement

,/
\Q

2472636

Front Bumper Upper Impact Bar Replacement

Callout Component Name
Preliminary Procedure
Removethefrontbumperfascia.Referto FrontBumperFascia Replacementonpage3-55.
FrontBumperImpactBar Bolt(Qty:8)
Caution: Referto FastenerCautionon page0-8.
Tighten
100Mm(74lbft)
FrontBumperImpactBar
Procedure
as needed.
1. Disconnecttheelectricalconnectors/harnesses
2. Transferanypartsas needed.

(US/Canada)
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i
i , _ . .-
I Bumpers and i-asmas 3-53
I
i Front Bumper Lower Impact Bar Replacement
i
1

I k /

2474415
Front Bumper Lower Impact Bar Replacement
Callout Component Name
Preliminary Procedure
Removethefrontbumperfascia. Referto FrontBumperFascia Replacementonpage 3-55.
FrontBumperLowerimpactBar BracketBolt(Qty:6)
Caution: RefertoFastenerCautiononpage 0-8.
Tighten
22Nm (16lb ft)
2 FrontBumperLowerimpactBar

2013
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3-54 Bumpers and Fascias

Front Bumper Impact Bar Lower Bracket Replacement

2475897

Front Bumper impact Bar Lower Bracket Replacement

Callout Component Name
Preliminary Procedure ,
Removethefrontbumperopeningcover.Referto FrontBumperFascia OpeningLowerCoverReplacementonpage3—58.
FrontBumperImpactBar LowerBracketScrew(Qty:3)
Caution: RefertoFastenerCautiononpage 0-8.
Tighten
8N-m(71lb in)
FrontBumperImpactBar LowerBracket
2 Procedure
Liftupthefrontofthelowerbracketenoughto releasethefrontguidetabfromthefrontfascia.

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 Bumpers and Fascias 3-55

Front Bumper Fascia Replacement

(|‘.—-_-—-;:..4 m”,l“.:-
_. o

2471802
Front Bumper Fascia Replacement
Callout Component Name
Preliminary Procedures
1. Removetheradiatoropeninguppercover.Referto FrontOpeningUpperCoverReplacementonpage3-40.
2. Removethefrontbumperopeninglowercover.Referto FrontBumperFascia OpeningLowerCoverReplacementon
page3-58.
3. RemovethefrontWheelhousefrontliner.Referto FrontWheelhouseLinerReplacement(Rear)onpage3-151or Front
WheelhouseLinerReplacement(Front)onpage3-150.
4. Disconnecttheambientairtemperaturesensorfromthelowergrille.
FrontBumperFascia Screw(Qty:2)
Caution: RefertoFastenerCautiononpage 0-8.
Tighten
6 NW(53lb in)
FrontBumperFascia LowerScrew(Qty:2)
2 Tighten
6N-m(53lb in)
FrontBumperFascia
Procedure
1. Carefullypusha smallnylonwedgebetweenthefasciaandthebrackettoseparatethejointslightly.
2. Spraya mixtureofsoapandcleandrinkablewaterintothejoint,toactas a lubricant.
3 3. inserta smallfiat-bladedtoolor plastictrimtoolintothefascia slotanddepressthetabsoneat a time.Pull
thefrontbumperfasciacarefullyforwardandoutwardin orderto releasetheretainingtabsfromthefront
bumperfasciaguides.
4. Disconnecttheelectricalconnectors.
5. On reassemblyofthefrontfasciatothevehicie,ensurethe4 supportretainersontheinsideoftheradiator
grillebumperare in positiontothefrontbumperfasciacentersupportbracket.

2013
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3-56 Bumpers and Fascias

Bumper Fascia Guide Replacement

Front

Izpjfilfl' 1
$543.! ..___._
.

(...-

ll

_' Ill!

2472638

Bumper Fascia Guide Replacement

Front
Component Name
Callout
page 0-4.
Warning: Refer to Eye Protection Warning on
Preliminary Procedure
BumperFascia Replacementonpage 3-55.
Removethe frontbumperfascia. Referto Front
HeadlampBolt
Caution: Referto FastenerCautiononpage 0-8.
Tighten
1ON-m(89lb in)
FrontBumperFascia Guide Rivet (Qty:2)
Special Tools
BO-594-AHand RivetTongs
Toolson page 3-67.
For equivalentregionaltools,referto Special
FrontBumperFascia Guide
3 Procedure
fromthe fender.
L Slide the guideforwardto releasethefrontretainer

(US/Canada)
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2013 (5377994)
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 Bumpers and Fascias 3=57
Front Bumper Fascia Center Support Bracket Replacement

{ 1 1
‘ , :; Q—Q Q ,
‘ 2 .a-.vr‘.“iWaF(~ UQAX k TE\T _ i’
" ’ 75%,: i ll!” ’/ ‘Q ! Q3575 .777 t '; '
. fig... A A A‘71J5‘122fi} ./ ~41
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11"! .9
%fii

2493252
Front Bumper Fascia
Center Support Bracket Replacement
Callout I Component Name
Preliminary Procedure
Removethefrontbumperfascia.Referto FrontBumperFascia Replacementonpage3—55.
FrontBumperFascia CenterSupportBolt(Qty:2)
Caution: Referto FastenerCautiononpage 0-8.
1 Tighten
9N°m(80lb in)
2 FrontBumperFascia CenterSupport

2013
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3-58 Bumpers and Fascias

Front Bumper Fascia Opening Lower Cover Replacement

z¢¢¢<2¢g¢2 "
/

g;

‘ %flfl

‘ - k (98‘

2475031

Front Bumper Fascia Opening Lower Cover Replacement

Callout ComponentName
1 FrontBumperFasciaOpeningLowerCover Push-InRetainer
FrontBumperFascia OpeningLowerCoverBolt (Qty:2)
Caution:Referto FastenerCautiononpage 0—8.
2 Tighten
22N-m(16lbft)
FrontBumperFascia OpeningLowerCoverScrew (Qty:3)
3 Tighten
2.5N-m(22lb in)
4 FrontBumperFascia OpeningLowerCover

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 Bumpers and Fascias 3:59
Front Bumper Fascia Bracket Replacement

2498259
Front Bumper Fascia Bracket Replacement
Callout Component Name
PreliminaryProcedure
1. Removethefrontbumperfascia. Referto FrontBumperFascia Replacementonpage 3—55.
2. Removethefrontbumperfasciacentersupportbracket.Referto FrontBumperFascia CenterSupportBracket
Replacementonpage 3—5 7.
FrontBumperFascia BracketBolt(Qty:4)
Caution:Referto FastenerCautiononpage0-8.
Tighten
9N-m(80lb in)
FrontBumperFasciaBracket
Note:Transferanypartsas needed.
3-80 Bumpers and Fascias

Front Air Deflector Replacement

2508989
Front Air Deflector Replacement
Callout Component Name
Preliminary
Procedure
1. Removefrontbumperfascia.Referto FrontBumperFascia Replacementonpage 3-55
2. Removetheheadlamp.Referto HeadlampReplacementonpage 4-193.
1 FrontAir DeflectorRetainers(Qty:2)
FrontAir DeflectorBolts(Qty:2)
Caution:Referto FastenerCautiononpage 0-8.
2
Tighten
8N-m(71|bin)
3 FrontAir Deflector

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 Bumpers and Fascias 3=61

2472666

Front Bumper Fascia Air Deflector Replacement

Callout Component Name
Preliminary Procedure
Removethefrontbumperfascia openinglowercover.Referto FrontBumperFascia OpeningLowerCoverReplacementon
page3-58.
FrontBumperFascia Air DeflectorScrew(Qty:4)
1 Caution:Referto FastenerCautiononpage 0-8.
Tighten
8 N'm(71|bin)
2 FrontBumperFascia Air Deflector

I 2013 (US/Canada)
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3=62 Bumpers and Fascias

Rear Bumper Fascia Replacement (Hatchback)

2489630

Rear Bumper Fascia Replacement (Hatchback)

Callout I Component Name
Preliminary Procedures
1. Removethe screwsfromtherearWheelhouselinerstothe rearfascia. Referto Rear WheelhouseLinerReplacement
or Rear
(Hatchback-Right)on page 3—152 or Rear WheelhouseLinerReplacement(Sedan- Left)onpage 3-153
LinerReplacement (Hatchback - Left)onpage or
3-154 Rear WheelhouseLinerReplacement(Sedan- Right)
Wheelhouse
onpage 3—155.
2. Disconnectthe rearelectricalconnectors.
1 Rear Fascia LowerPush-InRetainer(Qty:2)
Rear Fascia
Procedure
1. Carefullypush a smallnylonwedgebetweenthefascia andthe bracketto separatethejointslightly.
2 2. Spray8 mixtureofsoap andclean drinkablewaterintothejoint,to actas a lubricant.
3. Inserta smallflat-bladedtoolor plastictrimtool intothefascia slotand depressthetabs oneat a time.Pull
therear bumperfascia carefullyrearwardandoutwardin orderto releasethe retainingtabsfromthe rear
bumperfascia guides.
4. Transferpartsas needed.

(US/Canada)
-Sonic
2013 (5377994)
Manual
Sen/ice
l
g
t Bumpers and Fascias 3-63

I Rear Bumper Fascia Outer Guide Replacement (Sedan)

‘ V \%
4 fig“ ._\ -.\
~Mfig—‘fimfi ‘
. ~ .“ ke_'\ ,
\

2469730
Rear Bumper Fascia Outer Guide Replacement (Sedan)
Callout l Component Name
Warning: Refer to Eye Protection Warningon page 0-4.
Preliminary Procedure
Removetherearbumperfascia.Referto Rear BumperFascia Replacement(Hatchback)onpage3-62.
Rear BumperFascia OuterGuideRivet(Qty:7)
1 Special Tools
BO-594-AHandRivetTongs
Forequivalentregionaltools,referto Special Toolsonpage3-67.
2 Rear BumperFascia OuterGuide

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
3=64 Bumpers and Fascias

Rear Bumper Fascia Outer Guide Replacement (Hatchback)

2488858

Rear Bumper Fascia Outer Guide Replacement (Hatchback)

Callout l Component Name
Warning: Refer to Eye Protection Warningon page 0-4.
Preliminary Procedure
Removetherearbumperfascia.Referto Rear BumperFascia Replacement(Hatchback)onpage3-62.
Rear BumperFascia OuterGuideRivet(Qty:5)
1 Special Tools
BO-594—A HandRivetTongs
For equivalentregionaltools,referto Special Toolsonpage 3—67.
2 Rear BumperFascia OuterGuide

(US/Canada)
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2013 (5377994)
Manual
Service
 Bumpers and Fascias 3- 010‘1

Rear Bumper Impact Bar Replacement (Sedan)

2490228

Rear Bumper Impact Bar Replacement (Sedan)

Callout , Component Name
Preliminary Procedure
Removetherearbumperfascia.Referto Rear BumperFascia Replacement(Hatchback)onpage3-62.
Rear BumperImpactBar Bolt(Qty:4)
Caution: Referto FastenerCautiononpage 0-8.
Tighten
40NW (30lbft)
Rear BumperImpactBar Nut(Qty:2)
2 Tighten
4ON-m(30lbft)
Rear BumperImpactBar
3 Procedure
Transferany partsas needed.

(US/Canada)
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2013 (5377994)
Manual
Service
3=66 Bumpers and Fascias

Rear Bumper Impact Bar Replacement (Hatchback)

2490217

Rear Bumper Impact Bar Replacement (Hatchback)

Callout Component Name
Preliminary Procedure
Removetherearbumperfascia. RefertoRear BumperFascia Replacement(Hatchback)onpage 3—62.
Rear BumperImpactBarBolt(Qty:4)
Caution: Referto FastenerCautiononpage 0-8.
Tighten
40N-m(301bft)
Rear BumperImpactBarNut(Qty:2)
2 Tighten
40N-m(30lbft)
Rear BumperImpactBar
3 Procedure
Transferanypartsas needed.

(US/Canada)
-Sonic
2073 (5377994)
Manual
Service
 Bumpers and Fascias 3=67

Special Tools and Equipment

Illustration Tool Numberl Description

BO-594—A
HandRivetTongs

2019559

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
3268 Collision Repair

Collision Repair

Specifications

Fastener Tightening Specifications

I Specification
Application Metric English
FrontUpperTie Bar Bolts 9 N-m 80lbin
FrontUpperTie Bar SupportBolts 22N-m 161bft

Dimensions - Body (5HB)

Point—to-pointmeasurements 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.
Point-to-Point Measurements

Front End

W? >9 0
@\©

2505754
Legend
(1) 926mm (2) 926mm

(US/Canada)
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2013 (5377994)
Manual
Service
 Collision Repair 3=-59

Engine Compartment

2505756
Legend
(1) 1201mm (4) 1300mm
(2) 944mm (5) 1409mm
(3) 599mm

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
3=70 Collision Repair

Front End Lower

@0, O(6
2“r—mlfip fl
= ed; _‘3_(‘fl nl'-r-I-llF-Il$;7\h—\_IY&\_
I—I
7

J31

2505757
Legend
(1) 928mm (5) 910mm
(2) 1122 mm (6) 440mm
(3) 1110mm (7) 852mm
(4) 633mm (8) 584mm

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Collision Repair 3:71

Rear End Lower

flflvmuwgg“:
‘Mw
.1
A

2505758
Legend
(1) 1233mm (3) 627mm
(2) 1259mm (4) 966mm

—
2013 (US/Canada)
Sonic (5377994)
Manual
Service
3-72 Collision Repair

Rear End

\ v’ ‘~_a 77
%°/ \"x \ \
\\\\w}

F
J
@n n “W—g A:A_;é;;;;z;=E7/f
(‘1

©
Q? Rfle/Hgfli—gjj/

4:in » \.K—flt” . ‘
Q. gé n _/@
1r _T—(’—-—1_7
dfiwfifiéFfifiEE 5%:27w:
Qjoi Z05\ —% ML
‘El 7
\w u/w \_ 20,—159—17 ()ij ~| /:
o e 177‘?!" 1 w/.
I‘ ’ F (0) t @ ~
...:év/"ew la. :
Hana.
— .
‘5:iw/I $_i, i\%.72 2 5" Q“: LG):
wz ‘ . m -‘ g n

2505760
Legend
(1) 1425mm (2) 1132mm

,,,,,,,,,,

(US/Canada)
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2013 (5377994)
Manual
Service
 Collision Repair 3-73

Side

2505761
Legend
(1) 985mm (6) 946mm
(2) 1319mm (7) 1005mm
(3) 955mm (8) 1277mm
(4) 981mm (9) 772mm
(5) 611mm

Dimensions - Body (4NB)

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.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
3-74 Collision Repair

Point—to-Point Measurements

Front End

o: 1] o ; . Q o 9
1
k $7179 7 E 7‘
, ‘0
-./ - ,
.. 7
(a a — '4M V/ /O'/D
,7 s Q7
1O‘ 1
i . 6‘); “Mix: (:3 , °-{.' , .. :9 . j .
Hm“ . ' Am I" 1“ \ “ a ulnll 1

; u\ ("1’
\" ° ° tam ‘//1»E1\M\\\'
m Ha; 7 // “w ~, .
’e 5; no .. \ 2 9 .No .27 5",!
{ .WL/f 5) g 2 ,\\/ "-g 5) ‘7
‘~ {1) ® 2 ® (3% '

2505754
Legend
(1) 926mm (2) 926mm

—
2013 (US/Canada)
Sonic (5377994)
Manual
Service
 Collision Repair 3,75

Engine Compartment

2505756
Legend
(1) 1201mm (4) 1300mm
g; gggmm (5) 1409mm
mm

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
3:76 Cotlision Repair

Front End Lower

2505757
Legend
(1) 928mm , (5) 910mm
1122mm (6) 440mm
(2)
(3) 1110mm (7) 852mm
(4) 633mm 1 (8) 584mm

(US/Canada)
~Sonic
2013 (5377994)
Manual
Service
,,,,,, Collision Repair 3-77

1 Rear End Lower

X? 1% 1.
?_LIILJIUHDXiU 11;“ f
011
° 1

2505764
Legend
(1) 1233mm (6) 1504mm
(2) 1259mm (7) 1052 mm
(3) 627mm E8; 417mm
(4) 966mm 9 965mm
(5) 1035mm

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
3-78 Collision Repair

Rear End

f7

§_ -[ “—1 r 5
1‘
, 7 .%
o\<‘
93; 17.11.11 .11 'I
'7"
l’Ifl—‘\\\£gigi‘ 0<30 _________
gQ§\/
/

77‘2
:7 Jr/F’J’mo?‘ O /<aa ()..—W) (
0 ' 0. \777
1: ,9 g“
IHVfiIIm

2505766
Legend
(1) 1396mm (2) 1130mm

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Coltision Repair 3-79

Side

7 F

2505767

(1) 985mm (6) 946mm

(2) 1319mm (7) 886mm
(3) 955mm (8) 1155mm
(4) 981mm (9) 776mm
(5) 611mm

2013
-Sonic
(US/Canada)
Sen/ice
Manual
(5377994)
3-80 Collision Repair

Visual Identification

Structure Identification (5HB)

Front View

2552199

Number Description
1 FrontCompartmentSide
Rail (Front)
FrontWheelhousePanel
2 Reinforcement
FrontWheelhouseFront
3 Panel
4 FrontCompartmentSide
Rail (Rear)
5 RoofFrontHeaderPanel
6 RoofOuterPanel
7 RoofRear InnerPanel
View Front
Material Procedure
- innerSide Rail—HighStrength
LowA/on Steelonpage 3-141 Side Rail Replacement
FrontCompan‘ment
- OuterSide Rail—HighStrength 0” P3993‘92
LowA/loySteelon page3-141
. FrontWheelhousePanel Reinforcement
Ml’d Steelonpage 3441 Replacementonpage3-90
0 FrentWheelhouseFrontPanel-
MildSteelonpage 3441 , FrontWheelhouseFrontPanel Replacement
- FrontSuspensnonStrutHousung— 0,,page3-88
HighStrengthLowAlloy Steelon
page3-141
HighStrengthLowAlloy Steelon FrontCompafimentSide Rail Replacement
page3—141 onpage3-92
UltraHighStrengthSteelon RoofFrontHeaderPanelReplacementon
page3442 page 3401
Roof OuterPanel Replacement(5HB)on
Mild Steelonpage 3-141 page 3-97or Roof OuterPanel Replacement
(4NB)onpage 3-99
. Steelonpage3_141 RoofRear HeaderPanel Replacement(5H8)
onpage3402
MI/d

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2013 (5377994)
Manual
Service
 Collision Repair 3=81

View Front (cont'd)

Number Description Material Procedure
8 CenterPillarInnerPanel DualPhase Steelonpage3-140 CenterPillar InnerPaneIReplacementon
page3-125
9 BodyLock Pillarinner MildSteelonpage 3441 QuarterlnnerPanel Sectioning(5HB)on
Reinforcement page3-121
10 RearWheelhouseOuter MildSteelonpage 3-141 QuarterInnerPanelSectioning(5HB)on
Panel page3-121
0 CenterPillarReinforcement— High
StrengthLowAl/oySteelon
page 3-141
- CenterPillarUpperStiffener— - .
11 CenterPillarReinforcement UltraHighStrengthSteelon CenterPillar ReinforcementReplacementon
page3-126
page 3-142
° CenterPillarLowerStiffener-
HighStrengthLowAlloy Steelon
page 3-141
12 QuarterOuterPanel MildSteelonpage3-141 QuarterOuterPanelSectioning
13 CenterPillar—Outer Mild Steelonpage3—141 CenterPillar Sectioning- Outeron
page3-128
14 RockerOuterPanel Mild Steelonpage3-141 RockerOuterPanelSectioningon
page3-105
15 FrontHingePillar Body MildSteelonpage3-141 FrontHingePillarBodySectioningon
page3-94
16 BodyHingePillar Lower HighStrengthLowA/loy Steelon BodyHingePillarLowerReinforcement
Reinforcement page3-141 Replacementonpage3-96
17 RockerInnerPanel UltraHighStrengthDualPhase Steel RockerInnerPanelReplacementon
onpage 3-141 page3-104
18 BodySide FrameRocker UltraHighStrengthDualPhase Steel BodySide FrameRockerReinforcement
Reinforcement onpage 3-141 Replacementonpage3-108
19 FrontCompartmentUpper HighStrengthLowAlloy Steelon FrontCompartmentUpperSide Rail
Side Rail page3-141 Replacementonpage3-91
20 FrontEnd UpperTie Bar Mild Steelonpage3-141 FrontEnd UpperTieBar Replacementon
page3-87

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
3=82 Collision Repair

Rear View

2552208

Number Description
1 Rear End Panel
2 TailLampPocket
3 Rear Side DoorOuterPanel
4 FrontSide DoorOuterPanel
. Rail.
5 UnderbodyRearSide
View Rear
Material Procedure
Mild Steelonpage3—141 Rear End Panel Replacement
TailLampPocketReplacement(5HB)on
Mild Steelonpage 3-141 page 3-137or TailLampPocket
Replacement(4NB)onpage3-139
Mild Steelonpage 3—141 RearSide DoorOuterPanel Replacement
Mild Steelonpage 3-141 FrontSide DoorOuterPanel Repiacement
H‘ h St thL I St I . . .
pge 396219 OWAloy ee on Rear RailSectioning

Rear CompartmentFloor 4 _ Rear CompartmentFloorPanel

6 Panel M’IdSteel0" page3 141 Replacementonpage3-112

7
Rear End LowerPanel
Reinforcement page 3441 LowAlloy Steelon
HighStrength Rear End Panel Replacement

8 Rear End LowarPanel UltraHighStrengthDualPhase Steel Rear End Panel Replacement

ReinforcementExtension onpage3—141

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2013 (5377994)
Manual
Service
 Collision Repair 383

Structure Identification (4NB)

Front View

14

2552196
View Front
Number Description Material Procedure
- innerSide Rail—HighStrength
1 FrontCompaltmentSide LOWA/IOY 3169/0” page3441 FrontCompartmentSide Rail Replacement
Rall(Front) - OuterSide Rail—HighStrength onpage 3-92
LowAlloy Steelonpage3-141
2 FrontWheelhouseFront
Panel .
MildSteelonpage3-141 FrontWheelhouse
onpage 3-88 FrontPanel Replacement

3 FrontWheelhousePanel
4 FrontCompartmentSide
Rail(Rear)
5 RoofFrontHeaderPanel
- FrontWheeihouseFrontPanel-
MildSteelonpage 3-141
- FrontSuspensionStrutHousing— Egogégghfi/gouseFrontPanel Replacement
HighStrengthLowAlloy Steelon
page3-141
HighStrengthLowAlloy Steelon FrontCompan‘mentSide Rail Replacement
page 3-141 onpage 3-92
UltraHighStrengthSteelon
page3442 RoofFrontHeaderPanel
page 3401 Replacementon

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
3434 Collision Repair

View Front (cont'd)

Number Description Material Procedure
Roof OuterPanel Replacement(5HB)on
6 RoofOuterPanel MildSteelonpage3-141 page 3-97or Roof OuterPanel Replacement
(4NB)onpage3-99

7 CenterPillar innerPanel DualPhase Steelonpage3—140 CenterPillarlnnerPane/Rep/acement on

page 3-125
RearWheeihouseOuter . _141 QuarterInnerPanel Sectioning(5HB)on
page3421
8 Panel Ml/dSteelonpage3

- CenterPillarReinforcement— High
StrengthLowAlloy Steelon
page3-141
- CenterPillar UpperStiffener— . ,
9 CenterPillar Reinforcement UltraHighStrengthSteelon r ReinforcementReplacementon
C: "$951413
page3-142 p g
. CenterPillarLowerStiffener-
HighStrengthLowAlloy Steelon
page3-141
10 QuarterOuterPanel MildSteelonpage3-141 QuarterOuterPanelSectioning
. . Steelonpage3-141 CenterPillarSectioning- Outeron
page3-128
11 CenterPillar— Outer MI/d
. Steelonpage3-141 RockerOuterPanel Sectioningon
page3405
12 RockerOuterPanel Mild
CenterPillar—OuterFront .
MildSteelonpage3—141 FrontHingePillarBodySectioningon
page3_94
13 HingePillarBody
14 BodyHingePillarLOwer HighStrengthLowAlloy Steelon BodyHingePillarLowerReinforcement
Reinforcement page3—141 Replacementonpage3—96
UltraHighStrengthDualPhase Steel RockerInnerPanel
page 3_104 Replacementon
15 RockerinnerPanei onpage3-141
16 BodySide FrameRocker UltraHighStrengthDualPhase Steel Body Side FrameRockerReinforcement
Reinforcement onpage3-141 Replacementonpage3—108
17 FrontCompartmentUpper HighStrengthLowAlloy Steelon FrontCompartmentUpperSide Rail
Side Rail page3-141 Replacementonpage3-91
Replacementon
18 FrontEnd UpperTie Bar MildSteelonpage3—141 page 3-87UpperTieBar
FrontEnd

r
"‘”'7
(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
 Collision Repair 385
1 Rear View

Number Description
1 RearEnd Panel
2 TailLampPocket
RearSide DoorOuterPanel MildSteelonpage 3—141
FrontSide DoorOuterPanel MildSteelonpage3-141
5 . Rail-
UnderbodyRear Side
RearCompartmentFloor
6 Panel
7 UnderbodyRear Side
RearRail
8 Rear End LowerPanei
Reinforcement
RearEnd LowerPanel
9 ReinforcementExtension
2505771
View Rear
Material Procedure
MildSteelonpage 3—141 Rear End Panel Replacement
TailLampPocketReplacement(5HB)on
MildSteelonpage3-141 page3-137or TailLampPocket
Replacement(4NB)onpage 3-139
RearSide DoorOuterPanel Replacement
FrontSide DoorOuterPanel Replacement
HighStrengthLowAlloy Steelon
page3441 . . .
Rear Rail Sectionlng
. Rear CompartmentFloorPanel
MlldSteelonpage3441 Replacementonpage3-112
HighStrengthLowA/loySteelon UnderbodyRear Side Rail Extension
page3—141 Replacementonpage3—134
HighStrengthLowAlloy Steelon
page3441 Rear End Panel Replacement
UltraHighStrengthSteel on
page3-142 Rear End Panel Replacement

{ 2013
—
Sonic
(US/Canada)
Service
Manual
(5377994)
3~86 Collision Repair

Repair Instructions

Front Bumper Impact Bar

Replacement

Removal Procedure
Warning: Refer to Approved Equipment for
Collision Repair Warning on page 0-3.
1. Disable the SIR system. Refer to SIR Disabling
and Enabling on page 13-112.
2. Disconnect the negative battery cable. Refer to
Battery Negative Cable Disconnection and
Connection on page 9-713.
9’ Remove all related panels and components.
Repair as much of the damage as possible to
factory specifications. Refer to Dimensions —Body
(5HB) on page 3—68or Dimensions - Body (4NB)
on page 3-73. 2745550
Remove the sealers and anti-corrosion materials 8. Remove the damaged impact bar (1).
from the repair area. Refer to Anti-Corrosion
Treatment and Repair (Base) on page 3-159. Installation Procedure
. Locate and mark all factory welds.

2745552
2745549
. Drill 8 mm (5/16 in) holes for plug welding along the
7. Drill all factory welds (1). Note the number and edges of the service panel (1) as noted from the
location of welds for installation of the service original panel.
assembly. . Clean and prepare the attaching surfaces for
welding.

—
2013 (US/Canada)
Sonic (5377994)
Manual
Service
 Collision Repair 3437

Front End Upper Tie Bar

Replacement

Removal Procedure
Warning: Refer to Approved Equipment for
Collision Repair Warning on page 0-3.
Warning: Refer to Glass and Sheet Metal Handling
Warning on page 0-5.
1. Disable the SlR System. Refer to SIR Disabling
and Enabling on page 13-112.
2. Disconnect the negative battery cable. Refer to
Battely Negative Cable Disconnection and
Connection on page 9—713.
00. Remove all related panels and components.
. Visually inspect the damage. Repair as much of
the damage as possible.
. Remove the sealers and anti—corrosionmaterials
from the repair area, as necessary. Refer to
2745550 Anti-Corrosion Treatmentand Repair (Base) on
page 3-159.
3. Position the impact bar (1) on the vehicle.
4. Verify the fit of the bar.
5. Clamp the impact bar into position.

2505772
Locate and mark all the necessary factory welds of
the front upper tie bar assembly.
2745554
Drill all factory welds. Note the number and
Plug weid accordingly (1). iocation of welds for installation of the service
Apply the sealers and anti—corrosionmaterials to assembly.
the repair area, as necessary. Refer to Remove the front end upper tie bar support bolts
Anti-Corrosion Treatmentand Repair (Base) on (1) and front and upper tie bar bolts (2).
page 3—159. Remove the front end upper tie bar assembly (3).
Paint the repaired area. Refer to Basecoat/
Clearcoat Paint Systems on page 3-159.
Install all related panels and components.
. Connect the negative battery cable. Refer to
Battery Negative Cable Disconnection and
Connection on page 9—713.
11. Enable the SIR system. Refer to SIR Disabling and
Enabling on page 13—112.

2013
- Sonic
(US/Canada)
Service
Manual
(5377994)
3=88 Collision Repair

installation Procedure

2505773
1. Drill 8 mm (5/16in) plug weld holes as necessary
on service parts, in the locations noted from the
original assembly (1).
2. Clean and prepare the mating surface forwelding,
as necessary.
2505775
7. When the service assembly is correctly positioned,
plug weld accordingly (1).
8. Measure frequently to ensure proper fit and
alignment.
9. Clean and prepare all welded surfaces.
10. Apply the seaiers and anti—corrosionmaterials to
the repair area, as necessary. Refer to
Anti-Corrosion Treatmentand Repair (Base) on
page 3-159.
11. Paint the repaired area. Referto Basecoat/
Clearcoat Paint Systems on page 3—159.
12. Install all related panels and components.
13. Connect the negative battery cable. Refer to
Battery Negative Cable Disconnection and
Connection on page 9-713.
14. Enable the SIR system. Refer to SIR Disabling and
Enabling on page 13-112.

Front Wheelhouse Front Panel

Replacement

2505774 Note: Sectioning of the front Wheelhouse assembly is
3. Position the front upper tie bar support (1) and front
upper tie bar (2)on the vehicle
4. Verify the fit of the front end upper tie bar.
Caution: Refer to Fastener Caution on page 0-8.
5. Install the front upper tie bar support bolts (3) and
tighten to 22 N-m(16 lb ft).
6. Install the front upper tie bar bolts (4) and tighten to
9 N-m(80 lb in).
Removal Procedure
1. Disable the SIR system. Refer to SIR Disabling
and Enabling on page 13-112.
2. Disconnect the negative battery cable. Refer to
Battery Negative Cable Disconnection and
Connection on page 9-713.
not recommended. The front Wheelhouse service panel
is serviced as a complete assembly, which includes the
upper front strut mounting surface. The upper strut
mounting surface is a dimensionally critical area.
3. Remove the sealers and anti—corrosionmaterials
from the repair area, as necessary. Refer to
Anti-Corrosion Treatmentand Repair (Base) on
page 3—159.
Note: Inspect the front of the cowl for damage. if the
metal surface is damaged, the cowl panel must be !
repaired to restore the structural integrityof the vehicle.

(US/Canada)
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2013 (5377994)
Manual
Service
 Collision Repair 3:89

Repair as much of the damage as possible. 3. Apply GM-approved weld—thrucoating or

equivalent to all mating surfaces. Refer to
Anti—CorrosionTreatment and Repair (Base) on
page 3—159.

2505781
Locate, mark, and drill out all factory welds (1).
Note the number and location of welds for 2505783
installation of the service assembly.
6. Remove the frontWheelhouse from the vehicle. . Position the service front Wheelhouse front panel
to the vehicle (1). Clamp the front Wheelhouse in
Installation Procedure place.

2505782
Note: if the location of the original plug weld holes
cannot be determined, or if structural weId—thru
adhesive is present, space the plug weid holes every
40 mm (1 in).
1. Drill 8 mm (5I16 in) plug weld holes as necessary
on service part, in the locations noted from the
original assembly (1).
Clean and prepare the mating surfaces for welding,
as necessary.
2505785
. When the service assembly is correctly positioned,
plug weld accordingly (1).
. Measure frequently to ensure proper fit and
alignment.
. Clean and prepare all welded surfaces.
. Apply the sealers and anti-corrosion materials to
the repair area, as necessary. Refer to
Anti—CorrosionTreatment and Repair (Base) on
page 3-159.
. Paint the repaired area. Refer to Basecoat/
Clearcoat Paint Systems on page 3—159.

—
2013 (US/Canada)
Sonic (5377994)
Manual
Service
3=90 Collision Repair
Installation Procedure
10. Install all related panels and components.
11. Connect the negative battery cable. Refer to
Battery Negative Cable Disconnection and
Connection on page 9—713.
12. Enable the SIR system. Refer to SIR Disabling and
Enabling on page 13-112.

Front Wheelhouse Panel

Reinforcement Replacement

Removal Procedure
Warning: Refer to Approved Equipment for
Collision Repair Warning on page 0-3.
Warning: Refer to Glass and Sheet Metal Handling
Warning on page 0-5.
1. Disable the SIR System. Refer to SIR Disabling
and Enabling on page 13-112.
2. Disconnect the negative battery cable. Refer to
Battery Negative Cable Disconnection and
Connection on page 9-713.
3. Remove all related panels and components. 2505777
4. Visually inspect the damage. Repair as much of . Drill 8 mm (5I16 in) holes for plug welding along
the damage as possible. the edges of the front Wheelhouse panel
5. Remove the sealers and anti-corrosion materials reinforcement as noted from the original panel (1).
from the repair area, as necessary. Refer to . Clean and prepare the attaching surfaces for
Anti—CorrosionTreatment and Repair (Base) on welding.
page 3-159.

2505778
2505776
of . Position the front Wheelhouse panel reinforcement
6. Locate and mark all the necessary factory welds on the vehicle (1).
the front Wheelhouse panel reinforcement.
. Verify the fit of the front Wheelhouse panel
7. Drill all factory welds (1). Note the number and reinforcement.
location of welds for installation of the service
assembly. . Clamp the front Wheelhouse panel reinforcement
into position.
8. Remove the front Wheelhouse panel
reinforcement.

,,,,,,
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 Collision Repair 3=91

- 2505780 2551807
6. Plug weld accordingly (1). 7. Drill all factory weldsi(1). Note the number and
7. Apply the sealers and anti—corrosionmaterials to location Ofwelds for Installation0f the SBN'CG
the repair area, as necessary. Refer to assembly.
Anti-Corrosion Treatmentand Repair (Base) on
page 3-159.
8. Paint the repaired area. Refer to Basecoat/
Clearcoat Paint Systems on page 3-159.
9. Install all related panels and components.
10. Connect the negative battery cable. Refer to
Battely Negative Cable Disconnection and
Connection on page 9-713.
11. Enable the SIR system. Refer to SIR Disabling and.
Enabling on page 13-112.

Front Compartment Upper Side Rail

Replacement

Removal Procedure
Warning: Refer to Approved Equipment for
Collision Repair Warning on page 0-3.
1. Disable the SIR system. Refer to SIR Disabling
and Enabling on page 13—112.
2. Disconnect the negative battery cable. Refer to 2551809
Battery Negative Cable Disconnection and _
Connection on page 9—713. 8. Grind factory weld seams (1).
3. Remove all related panels and components.
4. Repair as much of the damage as possible to
factory specifications. Refer to Dimensions —Body
(5HB) on page 3-68 or Dimensions - Body (4NB)
on page 3-73.
5. Remove the sealers and anti—corrosionmaterials
from the repair area. Refer to Anti—Corrosion ’
Treatmentand Repair (Base) on page 3-159.
Note: Do not damage any inner panels or
reinforcements.
6. Locate and mark all the necessary factory welds
and weid seams of the front compartment upper
side rail.

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339.2 Collision Repair

2551810 2552931
9. Remove the front compartment upper side rail (1). Note: Plug weld factory slots in the front hinge pillar
body area (1) as noted from the original panel.
Installation Procedure 6. Plug weld accordingly (1).
7. Clean and prepare all welded surfaces.
8. Apply the sealers and anti-corrosion materials to
the repair area, as necessary. Refer to
Anti—CorrosionTreatmentand Repair (Base) on
page 3—159.
9. Paint the repaired area. Refer to Basecoat/
Clearcoat Paint Systems on page 3-159.
10. Install all related panels and components.
11. Connect the negative battery cable. Refer to
Battery Negative Cable Disconnection and
Connection on page 9—713.
12. Enable the SlR‘system. Refer to SIR Disabling and
Enabling on page 13-112.

Front Compartment Side Rail

Replacement

2552930
Note: Ifthe location of the original plug weld hoies
cannot be determined, or if structural weId-thru
adhesive is present, space the plug weld holes every
40 mm (1 in) apart.
1. Drill 8 mm (5/16in) holes for plug weld as
necessary on service part, in the locations noted
from the original assembly (1).
2. Clean and prepare the mating surfaces for welding,
as necessary.
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.
Removal Procedure
Warning: Refer to Approved Equipment for
Collision Repair Warning on page 0-3.
Warning: Refer to Glass and Sheet Metal Handling
Warning on page 0-5.
1. Disable the SIR System. Refer to SIR Disabling
and Enabling on page 13-112.
2. Disconnect the negative battery cable. Refer to
Battery Negative Cable Disconnection and
Connection on page 9—713.
3. Remove all related panels and components.
4. Visually inspect the damage. Repair as much of
the damage as possible.
5. Remove the sealers and anti—corrosionmaterials
from the repair area, as necessary. Refer to
Anti-Corrosion Treatmentand Repair (Base) on
page 3-159.

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 Collision Repair 3-93

2505795 2505798

6. Locate and mark all the necessary factory welds of . Position the front compartment side rail on the
the front compartment side rail. vehicle (1).
7. Drill all factory welds (1). Note the number and . Verify the fit of the front compartment side rail.
location of welds for installation of the service . Clamp the front compartment side rail into position.
assembly.
8. Remove the front compartment side rail.
Installation Procedure

2505800
. Plug weld accordingly (1).
. Apply the sealers and anti—corrosionmaterials to
2505796 the repair area, as necessary. Refer to
Anti-Corrosion Treatmentand Repair (Base) on
1. Drill 8 mm (5I16 in) holes for plug welding along page 3-159.
the edges of the front compartment side rail as
. Paint the repaired area. Refer to Basecoat/
noted from the original panel (1). Clearcoat Paint Systems on page 3-159.
2. Clean and prepare the attaching surfaces for
. Install all related panels and components.
welding.
. Connect the negative battery cable. Refer to
Battery Negative Cable Disconnection and
Connection on page 9-713.
. Enable the SIR system. Refer to SIR Disabling and
Enabling on page 13-112.

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2013 (5377994)
Manual
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3-84 Collision Repair

Front Hinge Pillar Body Sectioning

Removal Procedure
Warning: Refer to Approved Equipment for
Collision Repair Warning on page 0-3.
Warning: Refer to Collision Sectioning Warning on
page 0-4.
Warning: Refer to Glass and Sheet Metal Handling
Warning on page 0-5.
1. Disable the SIR system. Refer to SIR Disabling
and Enabling on page 13-112.
2. Disconnect the negative battery cable. Refer to
Battery Negative Cable Disconnection and
Connection on page 9-713.
3. Remove all the related panels and components.
4. Visually inspect the damage. Repair as much of
the damage as possible.
5. Remove the sealers and anti-corrosion materials
2505818
from the repair area, as necessary. Refer to
Anti—CorrosionTreatmentand Repair (Base) on Note: Do not damage any inner panels or
page 3-159. reinforcements.
7. Cut the panel where sectioning is to be
performed (1).
8. Locate and mark all the necessary factory welds of
the front hinge pillar body.

2505817
Note: Sectioning can be done anywhere in the straight
area along the rocker panel. c:
6. Create cut lines (1) on the front hinge pillar body.
2505819
9. Drill all the factory welds (1). Note the number and
location of welds for installation of the service
assembly.

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 Collision Repair 395

G3 Q!

2505820 2505823
10. Remove the damaged front hinge pillar body (1). 3. Drill 8 mm (5I16 in) holes for plug welding along
the edges of the front hinge pillar body as noted
Installation Procedure from the original panel (1).
4. Clean and prepare the attaching surfaces for
welding.

2505821
1. Cut the front hinge pillar body in corresponding
locations to fit the remaining original panel. The
sectioning joint should be trimmed to overlap the
remaining original panel by 25 mm (1 in) at each
joint location (1).
2. Prepare aii mating surfaces as necessary.
G3
2505820
.07Position the front hinge pillar body on the
vehicle (1).
Verify the fit of the front hinge pillar body.
5‘93Clamp the front hinge pillar body into position.

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3296 Collision Repair

2505824 2505825
Plug weld accordingly (1). 7. Drill all factory welds (1). Note the number and
To create a solid weld at the sectioning joint, with location of welds for installation of the service
minimum heat distortion, make 25 mm (1 in) stitch assembly.
welds along the seam with 25 mm (1 in) gaps
between them. Then go back and complete the
stitch weld.
10. Apply the sealers and anti-corrosion materials to
the repair area, as necessary. Refer to
Anti-Corrosion Treatment and Repair.
11. Paint the repaired area. Refer to Basecoav
Clearcoat Paint Systems on page 3—159.
12. Install all related panels and components.
13. Connect the negative battery cable. Refer to
Battely Negative Cable Disconnection and
Connection on page 9-713.
14. Enable the SIR system. Refer to SIR Disabling and
Enabling on page 13-112.

Body Hinge Pillar Lower

Reinforcement Replacement

Removal Procedure
Warning: Refer to Approved Equipment for
Collision Repair Warning on page 0-3. 2505826
1. Disabie the SIR system. Refer to SIR Disabling 8. Remove the damaged front hinge pillar body
and Enabling on page 13-112. reinforcement (1).
2. Disconnect the negative battery cable. Refer to Installation Procedure
Battery Negative Cable Disconnection and
Connection on page 9-713. 1. Prepare all mating surfaces as necessary.
Remove all related panels and components. 2. Align the front hinge pillar body reinforcement.
Repair as much of the damage as possible. Refer
to Dimensions - Body (5HB) on page 3-68 or
Dimensions - Body (4NB) on page 3-73.
Remove the sealers and anti—corrosionmaterials
from the repair area. Refer to Anti—Corrosion
Treatment and Repair (Base) on page 3-159.
. Locate and mark all the necessary factory welds of
the front hinge pillar body.
,,,,,,,,,,

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 Collision Repair 3=97

2505827 2505829
3. Drill 8 mm (5I16 in) holes for plug welding along Plug weid accordingly (1).
the edges of the front hinge pillar body as noted Apply the sealers and anti-corrosion materials to
from the original panel (1). the repair area, as necessary. Refer to
4. Clean and prepare the attaching surfaces for Anti—CorrosionTreatmentand Repair (Base) on
welding. page 3—159.
10. Paint the repaired area. Refer to Basecoat/
Clearcoat Paint Systems on page 3-159.
11. Install all related panels and components.
12. Connect the negative battery cable. Refer to
Battery Negative Cable Disconnection and
Connection on page 9-713.
13. Enable the SIR system. Refer to SIR Disabling and
Enabling on page 13-112.

Roof Outer Panel Replacement (5HB)

Removal Procedure
Warning: Refer to Approved Equipment for
Collision Repair Warning on page 0-3.
1. Disable the SIR system. Refer to SIR Disabling
and Enabling on page 13—112.
2. Disconnect the negative battery cable. Refer to
Battery Negative Cable Disconnection and
Connection on page 9—713.
Remove all related panels and components.
2505826
Visually inspect the damage. Repair as much of
5. Position the front hinge pillar body reinforcement the damage as possible.
on the vehicle (1). Remove the sealers and anti-corrosion materials
6. Verify the fit of the front hinge pillar body from the repair area, as necessary. Refer to
reinforcement. Anti—CorrosionTreatmentand Repair (Base) on
7. Clamp the front hinge pillar body reinforcement into page 3-159.
position. Locate and mark all factory welds.

2013
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3=98 Collision Repair
Installation Procedure

2505830 &

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.
2505832
1. Drill 8 mm (5I16in) holes for plug welding along
the edges of the service panel as noted from the
original panel (1).
2. Clean and prepare the attaching surfaces for
welding.

2505831

9. Remove the damaged roof panel (1).

2505833

3. Apply one—partwindshield urethane adhesive as

noted from the original panel (1).

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 Collision Repair 3:99

Roof Outer Panel Replacement (4NB)

Removal Procedure
Warning: Refer to Approved Equipment for
Collision Repair Warning on page 0-3.
1. Disable the SIR system. Refer to SIR Disabling
and Enabling on page 13-112.
2. Disconnect the negative battery cable. Refer to
Battely Negative Cable Disconnection and
Connection on page 9713.
9° Remove all related panels and components.
Visually inspect the damage. Repair as much of
the damage as possible.
Remove the sealers and anti—corrosionmaterials
from the repair area, as necessary. Refer to
Anti—CorrosionTreatment and Repair (Base) on
page 3-159.
Locate and mark all factory welds.
2505831
4. Position the roof panel (1) on the vehicle.
5. Verify the fit of the panel.
6. Clamp the panel into position.

2505835
Drill all factory welds (1). Note the number and
location of welds for installation of the service
assembly.
. Cut the adhesive with an appropriate tool.
2505834
Plug weld accordingly (1).
Apply the sealers and anti-corrosion materials to
the repair area, as necessary. Refer to
Anti—CorrosionTreatmentand Repair (Base) on
page 3-159.
Paint the repaired area. Refer to Basecoat/
Clearcoat Paint Systems on page 3-159.
10. lnstall all related panels and components.
11. Connect the negative battery cable. Refer to
Battery Negative Cable Disconnection and
Connection on page 9-713.
12. Enable the SIR system. Refer to SIR Disabling and
Enabling on page 13—112.

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3=100 Collision Repair

2505837 2505840

9. Remove the damaged roof panel (1). 3. Apply one—partwindshield urethane adhesive (1)
_ as noted from the original panel.
Installation Procedure

2505837
2505838
4. Position the roof panel (1) on the vehicle.
1. Drill 8 mm (5I16 in) holes for plug welding along 5 Verify the fit of the panel
the edges of the service panel as noted from the ' . '. .
original panel (1). 6. Clamp the panel Into posmon.
2. Clean and prepare the attaching surfaces for
welding.

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 Collision Repair 3-10'l

2505841 2505843
7. Plug weld accordingly (1). 7. Drill all factory welds (1). Note the number and
8. Apply the sealers and anti-corrosion materials to location of welds for installation of the service
the repair area, as necessary. Refer to assembly.
Anti—CorrosionTreatmentand Repair (Base) on
page 3-159.
9. Paint the repaired area. Refer to Basecoat/
Clearcoat Paint Systems on page 3-159.
10. Install all related panels and components.
11. Connect the negative battery cable. Refer to
Battery Negative Cable Disconnection and
Connection on page 9-713.
12. Enable the SIR system. Refer to SIR Disabling and
Enabling on page 13-112.

Roof Front Header Panel

Replacement

Removal Procedure
Warning: Refer to Approved Equipment for
Collision Repair Warning on page 0-3.
Note: The rooffront header panel is made of Ultra
High Strength Steel and should be replaced only at
factoryjoints. Repairing or sectioning of this part is not
recommended. Refer to Ultra High Strength Steel on 2505844
page 3-142. 8. Remove the damaged roof front header panel (1).
1. Disable the SIR system. Refer to SIR Disabling
and Enabling on page 13-112.
2. Disconnect the negative battery cable. Refer to
Battery Negative Cable Disconnection and
Connection on page 9-713.
9" Remove all related panels and components.
4. Repair as much of the damage as possible to
factory specifications. Refer to Dimensions —Body
(5HB) on page 3—68or Dimensions - Body (4NB)
on page 3-73.
5. Remove the sealers and anti-corrosion materials
from the repair area. Refer to Anti—Corrosion
Treatmentand Repair (Base) on page 3—159.
6. Locate and mark all factory welds.

2013
-Sonic
(US/Canada)
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(5377994)
3:102 Collision Repair

Installation Procedure

2505846
6. Plug weld accordingly (1).
2505845 ‘1. Apply the sealers and anti-corrosion materials to
1. Drill 8 mm (5I16 in) holes for plug welding along the repair area, as necessary. Refer to
the edges of the service panel as noted from the Anti—CorrosionTreatmentand Repair (Base) on
original panel (1). page 3—159.
2. Clean and prepare the attaching surfaces for 8. Paint the repaired area. Refer to Basecoat/
welding. Clearcoat Paint Systems on page 3—159.
9. install all related panels and components.
10. Connect the negative battery cable. Refer to
Battery Negative Cable Disconnection and
Connection on page 9-713.
11. Enable the SIR system. Refer to SIR Disabling and
Enabling on page 13-112.

Roof Rear Header Panel

Replacement (5HB)

Removal Procedure
Warning: Refer to Approved Equipment for
Collision Repair Warning on page 0-3.
1. Disable the SIR system. Refer to SIR Disabling
and Enabling on page 13-112.
2. Disconnect the negative battery cable. Refer to
Battery Negative Cable Disconnection and
Connection on page 9-713.
9° Remove all related panels and components.
2505844 4. Repair as much of the damage as possible to
factory specifications. Refer to Dimensions - Body
3. Position the roof front header (1) panel on the (5HB) on page 3-68 or Dimensions —Body (4NB)
vehicle. on page 3-73.
4. Verify the fit of the panel. 5. Remove the sealers and anti—corrosionmaterials
from the repair area. Refer to Anti—Corrosion
5. Clamp the roof front header panel into position. Treatmentand Repair (Base) on page 3159.
6. Locate and mark all factory welds.

(US/Canada)
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2013 (5377994)
Manual
Service
 Collision Repair 34103

Installation Procedure

2505847
7. Drill all factory welds (1). Note the number and
location of welds for installation of the service 2505849
assembly.
1. Drill 8 mm (5I16 in) holes for plug welding along
the edges of the service panel (1) as noted from
the original panel.
2. Clean and prepare the attaching surfaces for
welding.

2505848
8. Remove the damaged rear header panel (1).

2505848
3. Position the roof rear header(1) panel on the
vehicle.
4. Verify the fit of the panel.
5. Clamp the roof rear header panel into position.

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(US/Canada)
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(5377994)
3:104 Collision Repair

2505850 2505851

. Plug weld accordingly (1). 6. Locate and mark all the necessary factory welds of
the rocker inner panel.
Apply the sealers and anti—corrosionmaterials to
the repair area, as necessary. Refer to 7. Drill all factory weids (1). Note the number and
Anti—CorrosionTreatmentand Repair (Base) on location of welds for installation of the service
page 3-159. assembly.
Paint the repaired area. Refer to Basecoat/
Clearcoat Paint Systems on page 3-159.
. lnstall all related panels and components.
. Connect the negative battery cable. Refer to
Battery Negative Cable Disconnection and
Connection on page 9-713.
11. Enable the SIR system. Refer to SIR Disabling and
Enabling on page 13—112.

Rocker Inner Panel Replacement

Removal Procedure
Warning: Refer to Approved Equipment for
Collision Repair Warning on page 0-3.
Note: The rocker inner panel is made of Ultra High
Strength Dual Phase Steel and should be replaced only
at factoryjoints. Repairing or sectioning of this part is
not recommended. Refer to Ultra High Strength Dual
Phase Steel on page 3-141.
1. Disable the SIR system. Refer to SIR Disabling 2505852
and Enabling on page 13-112.
2. Disconnect the negative battery cable. Refer to 8. Remove the damaged rocker inner panel (1).
Batte/y Negative Cable Disconnection and
Connection on page 9—713.
Remove all related panels and components.
Repair as much of the damage as possible to
factory specifications. Refer to Dimensions - Body
(5HB) on page 3—68or Dimensions - Body (4NB)
on page 3-73.
Remove the sealers and anti—Corrosionmaterials
from the repair area. Refer to Anti-Corrosion
Treatmentand Repair (Base) on page 3-159.

(US/Canada)
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2013 (5377994)
Manual
Service
 Collision Repair 34105

Installation Procedure

2505854
6. Plug the weld accordingly (1).
2505853 7. Apply the sealers and anti—corrosionmaterials to
1. Drill 8 mm (5I16 in) holes for plug welding along the repair area, as necessary. Refer to
the edges of the quarter outer panel (1) as noted Anti-Corrosion Treatmentand Repair (Base) on
from the original panel. page 3-159.
2. Clean and prepare the attaching surfaces for 8. Paint the repaired area. Refer to Basecoat/
welding. Clearcoat Paint Systems on page 3-159.
9. install all related panels and components.
10. Connect the negative battery cable. Refer to
Battery Negative Cable Disconnection and
Connection on page 9-713.
11. Enable the SIR system. Refer to SIR Disabling and
Enabling on page 13-112.

Rocker Outer Panel Sectioning

Removal Procedure
Warning: Refer to Approved Equipment for
Collision Repair Warning on page 0-3.
Warning: Refer to Collision Sectioning Warning on
page 0-4.
Warning: Refer to Glass and Sheet Metal Handling
Warning on page 0-5.
1. Disable the SIR system. Refer to SIR Disabling
and Enabling on page 13—112.
2. Disconnect the negative battery cable. Refer to
2505852 Battery Negative Cable Disconnection and
Connection on page 9-713.
3. Position the rocker inner panel on the vehicle (1). 9° Remove all related panels and components.
4. Verify the fit of the panel. 4. Visually inspect the damage. Repair as much of
5. Clamp the rocker inner panel into position. the damage as possible.
5. Remove the sealers and anti—corrosionmaterials
from the repair area, as necessary. Refer to
Anti—CorrosionTreatmentand Repair (Base) on
page 3—159.

2013
—
Sonic
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Manual
(5377994)
32106 Coilislon Repair

1.. ..
.44”?

|‘~——————_—’——_——-
‘n3

7\ 1

2505872 2505874
6. Create cut lines on the rocker outer panel (1). 8. Locate and mark all the necessary factory welds of
the rocker outer panel.
9. Drill all factory welds. Note the number and
location of welds for installation of the service
assembly. ‘

2505873
Note: Do not damage any inner panels or
reinforcements.
7. Cut the panel where sectioning is to be 2505875
performed (1).
10. Remove the damaged rocker outer panel (1).

—
2013 (US/Canada)
Sonic (5377994)
Manual
Service
 Collision Repair 3-107

Installation Procedure

2505875
5. Position the rocker outer panel on the vehicle (1).
2505877 6. Verify the fit of the rocker outer panel.
1. Cut the rocker outer panel in corresponding 7. Clamp the rocker outer panel into position.
locations to fit the remaining original panel. The
sectioning joint should be trimmed to overlap the
remaining original panel by 25 mm (1 inch) at each
joint location (1).
2. Prepare alt mating surfaces as necessary.

2505880
(9 8. Plug weld accordingly (1).
9. To create a solid weld with minimum heat
distortion, make 25 mm (1 in) stitch welds along
2505878 the seam with 25 mm (1 in) gaps between them.
Then go back and complete the stitch weid.
3' Drill a 8 mm 15’1“") hoies for plug welding along 10. Apply the sealers and anti—corrosionmaterials to
the edges of the rocker outer panel as noted from the repair area as necessary. Refer to
the original panel (1)' Anti—CorrosionTreatmentand Repair (Base) on
4. Cleah and prepare the attaching surfaces for page 3-159.
welding. 11. Paint the repaired area. Refer to Basecoat/
Clearcoat Paint Systems on page 3-159.
12. Install all related panels and components.
13. Connect the negative battery cable. Refer to
Battery Negative Cable Disconnection and
Connection on page 9-713.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
3n'l08 Coitision Repair
14. Enable the SIR system. Refer to SIR Disabling and
Enabling on page 13-112.

Body Side Frame Rocker

Reinforcement Replacement

Removal Procedure
Warning: Refer to Approved Equipment for
Collision Repair Warning on page 0-3.
Warning: Refer to Glass and Sheet Metal Handling
Warning on page 0-5.
Note: The body side frame rocker reinforcement is
made of Ultra High Strength Dual Phase Steel and
should be replaced only at factoryjoints. Repairing or
sectioning of this part is not recommended. Refer to
Ultra High Strength Dual Phase Steel on page 3—141.
1. Disable the SIR system. Refer to SIR Disabling
and Enabling on page 13-112.
2. Disconnect the negative battery cable. Refer to 2505903
Battery Negative Cable Disconnection and
Connection on page 9-713. 8. Remove the damaged body side frame rocker
3. Remove all related panels and components. reinforcement (1).
4. Repair as much of the damage as possible to Installation Procedure
factory specifications. Refer to Dimensions —Body
(5HB) on page 3—68or Dimensions —Body (4NB) 1. Align the body side frame rocker reinforcement.
on page 3-73.
5. Remove the sealers and anti—corrosionmaterials
from the repair area, as necessary. Refer to
Anti—CorrosionTreatmentand Repair (Base) on
page 3—159.
6. Locate and mark all the necessary factory welds of
the body side frame rocker reinforcement.

. .I
7FA‘., .nf‘
z.. w:

‘a-«‘29
:_—:."“
V
,A A
/.

2505904
2. Drill a 8 mm (5/16in) holes for plug welding along
the edges of the quarter outer panel (1) as noted
from the original panel.
3. Clean and prepare the attaching surfaces for
welding.

2505900
7. Drill all factory welds (1). Note the number and
location of welds for installation of the service
assembly.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Collision Repair (M 09
12. Enable the SlR system. Refer to SIR Disabling and
Enabling on page 13-112.

Front Side Door Outer Panel

Replacement

Removal Procedure
Note: According to different corrosion warranties, only
the regional mandatoryjoining methods are allowed.
1. Disable the SIR System. Refer to SIR Disabling
and Enabling on page 13—112.
2. Disconnect the negative battery cable. Refer to
Battery Negative Cable Disconnection and
Connection on page 9—713.
Remove the front side door. Refer to Front Side
Door Replacement on page 3—11.
Remove the front side door outside handle. Refer
to Front Side Door Outside Handle Replacement
on page 4-291.
2505903 Remove the outside rearview mirror. Refer to
P Position the body side frame rocker reinforcement Outside Rearview Mirror Replacement (Power) on
on the vehicle (1). page 4-229 or Outside Rearview Mirror
Replacement (Manual) on page 4-228.
.0" Verify the fit of the body side frame rocker
reinforcement. Remove the seaiers and anti-corrosion materials
from the repair area, as necessary. Refer to
Clamp the body side frame rocker reinforcement Anti-Corrosion Treatmentand Repair (Base) on
into position. page 3-159.

2505905 2505989
Plug the weld accordingly (1). 7. Grind the edges of the front side door outer
9°."Apply the sealers and anti—corrosionmaterials to panel (1) to separate the outer door panel from the
the repair area, as necessary. Refer to doorshew
Anti—CorrosionTreatmentand Repair (Base) on
page 3-159.
Paint the repaired area. Refer to Basecoat/
Clearcoat Paint Systems on page 3-159.
10. lnstall all related panels and components.
11. Connect the negative battery cable. Refer to
Battely Negative Cable Disconnection and
Connection on page 9-713.

2013
- Sonic
(US/Canada)
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Manual
(5377994)
3=110 Collision Repair

2505990 2505991
Warning: Inspection of the door guard beam for 4. Continue to hammer in stages along the hem
damage must be performed before replacement of flanges (1).
the door outer panel. If damage to the door guard 5. Apply the sealers and anti-corrosion materials to
beam is found the door must be replaced. Failure to the repair area, as necessary. Refer to
do so may compromise the structural integrity of Anti—CorrosionTreatment and Repair (Base) on
the vehicle and may cause personal injury if the page 3—159.
vehicle is involved in a collision.
6. Install the outside rearview mirror.Refer to Outside
8. Remove the front side door outer door panel (1). Rearview Mirror Replacement (Power) on
9. Remove the sealers and anti-corrosion materials page 4—229or Outside Rearview Mirror
from the repair area, as necessary. Refer to Replacement (Manual) on page 4—228.
Anti—CorrosionTreatmentand Repair (Base) on 7. Install the front side door outside handle. Refer to
page 3-159 Front Side Door Outside Handle Replacement on
10. Straighten the edges of the door shell. page 4-291.
8. Install the front side door. Refer to Front Side Door
Installation Procedure Replacement on page 3-11.
1. Align the front side door outer panel. 9. Paint the repaired area. Refer to Basecoat/
2. Verify the fit of the front side door outer panel. Clearcoat Paint Systems on page 3-159.
10. Install all related panels and components.
11. Connect the negative battery cable. Refer to
Battery Negative Cable Disconnection and
Connection on page 9—713.
12. Enable the SIR system. Refer to SIR Disabling and
Enabling on page 13-112.

Rear Side Door Outer Panel

Replacement

Removal Procedure
Warning: Refer to Glass and Sheet Metal Handling
Warning on page 0-5.
Note: According to different corrosion warranties, only
the regional mandatory joining methods are allowed.
1. Disable the SIR System. Refer to SIR Disabling
and Enabling on page 13-112.
2. Disconnect the negative battery cable. Refer to
Battery Negative Cable Disconnection and
2505990 Connection on page 9-713.
3. Remove the rear side door. Refer to Rear Side
3. Clamp the front side door outer panel (1) into Door Replacement on page 3—13.
position.
(US/Canada)
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Manual
Service

4. Remove the rear side door outside handle. Refer to
Rear Side Door Outside Handle Replacement
(Hatchback) on page 4—298or Rear Side Door
Outside Handle Replacement (Sedan) on
. page 4-297.
’ 5. Remove the sealers and anti—corrosionmaterials
from the repair area, as necessary. Refer to
Anti-Corrosion Treatmentand Repair (Base) on Installation
page 3—159.
2505992
6. Grind the edges of the rear side door outer panel
(1) to separate the outer door panel from the door
shell.
2505993
Warning: Inspection of the door guard beam for
damage must be performed before replacement of
the door outer panel. If damage to the door guard
1 beam is found the door must be replaced. Failure to
1 do so may compromise the structural integrity of
the vehicle and may cause personal injury if the
1 vehicle is involved in a collision.
1 2013
—
Sonic
(US/Canada)
Service
Manual
(5377994)
Collision Repair 3;! 1'1
7. Remove the rear side door outer door panel (1).
8. Remove the sealers and anti—corrosionmaterials
from the repair area, as necessary. Refer to
Anti—CorrosionTreatmentand Repair (Base) on
page 3-159.
9. Straighten the edges of the door shell.
Procedure
1. Align the rear side door outer panel.
2. Verify the fit of the rear side door outer panel.
%
2505993
3. Clamp the rear side door outer panel (1)1nto
position.
2505996
4. Continue to hammer in stages along the hem
flanges (1).
5. Apply the sealers and anti—corrosionmaterials to
the repair area, as necessary. Refer to
Anti-Corrosion Treatmentand Repair (Base) on
page 3-159.
3=112 Collision Repair
6. install the rear side door outside handle. Refer to
Rear Side Door Outside Handle Replacement
(Hatchback) on page 4-298 or Rear Side Door
Outside Handle Replacement (Sedan) on
page 4-297. 2 11‘”
7. install the rear side door. Refer to Rear Side Door
Replacement on page 3—13.
8. Paint the repaired area. Refer to Basecoat/
Clearcoat Paint Systems on page 3-159.
9. Install all related panels and components.
10. Connect the negative battery cable. Refer to
Battery Negative Cable Disconnection and \1=.
Connection on page 9-713. k .‘ET-Jfiuil’z go
5__ ~:
11. Enable the SIR system. Refer to SIR Disabling and
Enabling on page 153-112.

Rear Compartment Floor Panel

Replacement

Removal Procedure 2505906

Warning: Refer to Approved Equipment for 8. Drill all factory welds (1). Note the number and
Collision Repair Warning on page 0-3. location of welds for installation of the service
Warning: Refer to Glass and Sheet Metal Handling assembly.
Warning on page 0-5.
1. Disable the SIR system. Refer to SIR Disabling
and Enabling on page 13—112.
2. Disconnect the negative battery cable. Refer to
Battery Negative Cable Disconnection and
Connection on page 9-713.
9° Remove all related panels and components.
4. Visually inspect the damage. Repair as much of
the damage as possible.
5. Remove the sealers and anti—corrosionmaterials
from the repair area, as necessary. Refer to
Anti—CorrosionTreatmentand Repair (Base) on
page 3—159.
6. Locate and mark all the necessary factory welds of
the rear compartment floor panel.
7. Note the number and location of weld studs for
installation of the service assembly.

2505908
9. Remove the damaged rear compartment floor
panel (1).
Installation Procedure
1. Align the rear compartment floor panel.

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Manual
Service
 Collision Repair 34113

2505913
2. Drill a 8 mm (5I16in) holes for plug Welding along
the edges of the rear compartment floor panel as
noted from the original panel (1).
3. Clean and prepare the attaching surfaces for
welding.
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.
2505915
8. Dr11|8mm (5I16 in) for plug welding along the
edges of the floor panel rear reinforcement, the
spare wheel carrier bracket, the shipping device
and the floor panel reinforcement as noted from the
original panel (1).
9- Cieah 3'79 prepare the 3118011109 surfaces for
welding.
10. Position the floor panel rear reinforcement, the
spare wheel carrier bracket, the shipping device
and the floor panel reinforcement on the vehicle.
11. Verify the fit of the floor panel rear reinforcement,
the spare wheel carrier bracket, the shipping
device and the floor panel reinforcement.

2505914
7. Plug the weld accordingly (1).
2505916
12. Plug weld accordingly (1).
13. Weld accordingly the weld studs as noted.
14. Apply the sealers and anti-corrosion materials to
the repair area, as necessary. Refer to
Anti-Corrosion Treatmentand Repair (Base) on
page 3-159.
2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
3-1'14 Collision Repair
15. Paint the repaired area. Refer to Basecoat/
Clearcoat Paint Systems on page 3—159.
16. Install all related panels and components.
17. Connect the negative battery cable. Refer to
Battery Negative Cable Disconnection and
Connection on page 9—713.
18. Enable the SIR system. Refer to SIR Disabling and
Enabling on page 13—112.

Quarter Outer Panel

Sectioning (5HB)

Removal Procedure
Warning: Refer to Approved Equipment for
Collision Repair Warning on page 0-3.
Warning: Refer to Collision Sectioning Warning on
page 0-4.
CF:
Warning: Refer to Glass and Sheet Metal Handling
Warning on page 0-5. 2505920
Note: According to different corrosion warranties, only Note: Do not damage any inner panels or
the regional mandatory joining methods are allowed. reinforcements.
1. Disabie the SIR System. Referto SIR Disabling 7. Cut the panel where sectioning is to be
and Enabling on page 13-112. performed (1).
2. Disconnect the negative battery cable. Refer to
Battery Negative Cable Disconnection and
Connection on page 9—713.
9° Remove all related panels and components.
4. Visually inspect the damage. Repair as much of
the damage as possible.
5. Remove the sealers and anti—corrosionmaterials
from the repair area, as necessary. Refer to
Anti—CorrosionTreatmentand Repair (Base) on
page 3-159.

1111/
Ni

2505921
8. Open the Wheelhouse flanging (1).
9. Locate and mark all the necessary factory welds of
the quarter outer panel.

2505918
6. Create cut lines on the quarter outer panel (1).

(US/Canada)
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 Collision Repair 3-‘115

Installation Procedure

. .‘ \\

llL/L
Ni

2505922
10. Drill all factory welds (1). Note the number and
location of welds for installation of the service 2505925
assembly. 1. Cut the quarter outer panel in corresponding
locations to fit the remaining original panel. The
sectioning joint should be trimmed to overlap the
remaining original panel by 25 mm (1 inch) at each
joint location (1).
2. Prepare all mating surfaces as necessary.

2505924
11. Remove the damaged quarter outer panel (1).

2505926
3. Drill 8 mm (5/16in) holes for plug welding along the
edges of the quarter outer panel as noted from the
original panel (1).
4. Clean and prepare the attaching surfaces for
welding.

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2013 (5377994)
Manual
Service
3x116 Co1iision Repair

§§

7 7

2505928 2505929

5. Apply one—partwindshield urethane adhesive (1) . Plug weld accordingly (1).

as noted from the original panel. . To create a solid weid 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.

2505924
6. Position the quarter outer panel on the vehicle (1).
7. Verify the fit of the quarter outer panel. 2505931
8. Clamp the quarter outer panel into position.
11. Pre-fiange wheel housing. Using a flat faced body
hammer, bend over the flanged edge 45, at the
same time holding a hard rubber block against it.
Use structural adhesive in the area. Continue to
hammer in stages along the hem flanges.
12. Bend the wheel arch.
13. Apply the seaiers and anti—corrosionmaterials to
the repair area, as necessary. Refer to
Anti—CorrosionTreatment and Repair (Base) on
page 3-159.
14. Paint the repaired area. Refer to Basecoat/
Clearcoat Paint Systems on page 3-159.
15. lnstall all related panels and components.

(US/Canada)
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2013 (5377994)
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Service
 Collision Repair 3=117
16. Connect the negative battery cable. Refer to
Battery Negative Cable Disconnection and
Connection on page 9-713.
17. Enable the SIR system. Refer to SIR Disabling and
Enabling on page 13—112.

Quarter Outer Panel

Sectioning (4NB)

Removal Procedure
Warning: Refer to Approved Equipment for
Collision Repair Warning on page 0-3.
Warning: Refer to Collision Sectioning Warning on
page 0-4.
Warning: Refer to Glass and Sheet Metal Handling
Warning on page 0-5.
Note: According to different corrosion warranties, oniy
the regional mandatoryjoining methods are allowed.
1. Disable the SIR system. Refer to SIR Disabling 2505933
and Enabling on page 13-112. Note: Do not damage any inner panels or
2. Disconnect the negative battery cable. Refer to reinforcements.
Battery Negative Cable Disconnection and 7. Cut the panel where sectioning is to be
Connection on page 9—713. performed (1).
C0
. Remove all related panels and components.
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
Anti-Corrosion Treatmentand Repair (Base) on
page 3-159.

2505935
8. Open the Wheelhouse flanging (1).
9. Locate and mark all the necessary factory welds of
the quarter outer panel.

2505932
6. Create cut lines on the quarter outer panel (1).

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
3-1'18 Collision Repair
Installation Procedure

2505936
10. Drill all factory welds‘(1). Note the number and
location of welds for installation of the service 2505939
assembly. 1. Cut the quarter outer panel in cerresponding
locations to fit the remaining original panel. The
sectioning joint should be trimmed to overlap the
remaining original panel by 25 mm (1 inch) at each
joint location (1).
2. Prepare all mating surfaces as necessary.

2505938
11. Remove the damaged quarter outer panel (1).

2505940
3. Drill a 8 mm(5/161n)h01esfor plug welding along
the edges of the quarter outer panel as noted from
the original panel (1).
4. Clean and prepare the attaching surfaces for
welding.

(US/Canada)
»Sonic
2013 (5377994)
Manual
Service
 Collision Repair 3:119

if/t'.

f.
154
.
'1
11:};
.;1151.11

2505941
5. Apply one-part windshield urethane adhesive (1)
as noted from the original panel.
2505942
Plug weld accordingly (1).
. 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.

2505938
6. Position the quarter outer panel on the vehicle (1).
7. Verify the fit of the quarter outer panel. 2505931
8. Clamp the quarter outer panel into position.
11. Pre—flangewheel housing. Using a flat faced body
hammer, bend over the flanged edge 45, at the
same time holding a hard rubber block against it.
Use structural adhesive in the area. Continue to
hammer in stages along the hem flanges.
12. Bend the wheel arch.
13. Apply the sealers and anti-corrosion materials to
the repair area, as necessary. Refer to
Anti—CorrosionTreatmentand Repair (Base) on
page 3-159.
14. Paint the repaired area. Refer to Basecoat/
Clearcoat Paint Systems on page 3-159.
15. Install all related panels and components.
1
2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
3420 Collision Repair
16. Connect the negative battery cable. Refer to
Battery Negative Cable Disconnection and
Connection on page 9-713.
17. Enable the SIR system. Refer to SIR Disabling and
Enabling on page 13-112.

Quarter Inner Panel

Replacement (4NB)

Removal Procedure
Warning: Refer to Approved Equipment for
Collision Repair Warning on page 0-3.
Warning: Refer to Glass and Sheet Metal Handling
Warning on page 0-5.
1. Disable the SIR System. Refer to SIR Disabling
and Enabling on page 13—112.
2. Disconnect the negative battery cable. Refer to
Battery Negative Cable Disconnection and
Connection on page 9-713. 2505958
9° Remove all related panels and components.
4. Visually inspect the damage. Repair as much of 8. Remove the damaged rear Wheelhouse outer
the damage as possible. panel (1).
5. Remove the 'sealers and anti-corrosion materials Installation Procedure
from the repair area, as necessary. Refer to
1. Prepare all mating surfaces as necessary.
Anti-Corrosion Treatmentand Repair (Base) on
page 3—159. 2. Align the rear Wheelhouse outer panel.
6. Locate and mark all the necessary factory welds of
the rear Wheelhouse outer panel.

2505959
3. Drill 8 mm (5/161n)hoiesforp1ug welding aiong
2505957 the edges of the rear Wheelhouse outer panel as
noted from the original panel (1).
7. Drill all factory welds (1). Note the number and
location of welds for installation of the service 4. Clean and prepare the attaching surfaces for
assembly. welding.

(US/Canada)
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2013 (5377994)
Manual
Service
 Collision Repair 3-‘121

Quarter Inner Panel Sectioning (5HB) ,

Removal Procedure
Warning: Refer to Approved Equipment for
Collision Repair Warning on page 0-3.
Warning: Refer to Collision Sectioning Warning on
page 0-4.
Warning: Refer to Glass and Sheet Metal Handling
Warning on page 0-5.
1. Disable the SIR System. Refer to SIR Disabling
and Enabling on page 13-112.
2. Disconnect the negative battery cable. Refer to
Battery Negative Cable Disconnection and
Connection on page 9-713.
9° Remove all related panels and components.
4. Visually inspect the damage. Repair as much of
the damage as possible.
5. Remove the sealers and anti-corrosion materials
2505958 from the repair area, as necessary. Refer to
Anti—CorrosionTreatmentand Repair (Base) on
. Position the rear Wheelhouse outer panel on the page 3-159.
vehicle (1).
Verify the fit of the rear Wheelhouse outer panel.
Clamp the rear Wheelhouse outer panel into
position.

2505943
6. Create cut lines on the body lock pillar inner
reinforcement (1).
2505961
Plug weld accordingly (1).
. Apply the sealers and anti-corrosion materiais to
the repair area, as necessary. Refer to
Anti-Corrosion Treatmentand Repair (Base) on
page 3-159.
10. Paint the repaired area. Refer to Basecoat/
Clearcoat Paint Systems on page 3—159.
1
11. Install all related panels and components.
12. Connect the negative battery cable. Refer to
Battery Negative Cable Disconnection and
Connection on page 9-713.
1 13. Enable the SIR system. Refer to SIR Disabling and
Enabling on page 13—112.

1 2013
- Sonic
(US/Canada)
Service
Manual
(5377994)
3-122 Coilision Repair

2505944 2505948

Note: DO ”Qt damage any inner panels or 10. Remove the damaged body lock pillar inner
remforcements. reinforcement (1).
7. Cut the panel where sectioning is to be
performed (1).
8. Locate and mark all the necessary factory welds of
the body lock pillar inner reinforcement.

2505949
11. Locate and mark all the necessary factory welds of
the rear Wheelhouse outer panel.
12. Drill ail factory welds (1). Note the number and
2505947 location of welds for installation of the service
9. Drill all factory welds (1). Note the number and assembly.
location of welds for installation of the service
assembly.

(US/Canada)
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2013 (5377994)
Manual
Service
 Collision Repair 32123

2505950 2505950
13. Remove the damaged rear Wheelhouse outer 3. Position the rear Wheelhouse outer panel (1).
panel (11- 4. Verify the fit of the panel. '
|nsta||ation Procedure 5. Clamp the rear Wheelhouse outer panel into
position.

2505952
2505953
1. Drill 8 mm (5/16 in) holes for plug welding along
the edges of the rear Wheelhouse outer panel as 6. Plug weld accordingly (1).
noted from the original panel (1).
2. Clean and prepare the attaching surfaces for
welding. ,

2013
-Sonic
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Manual
(5377994)
342—4 Collision Repair
14. Clean and prepare the attaching surfaces for
welding.

\8. ”’

2505954
7. Cut the body lock pillar inner reinforcement in
corresponding locations to fit the remaining original 2505948
panel (1). The sectioning joint should be trimmed
to allow a gap of one-and-one-haif—timesthe metal 15. Position the body lock pillar inner
thickness at the sectioning joint. reinforcement (1).
8. Create a 50 mm (2 in) backing plate from the 16. Verify the fit of the panel.
unused portion of the service part. 17. Clamp the body lock pillar inner reinforcement into
9. Drill 8 mm (5I16 in) along the sectioning cut on the position.
remaining original part. Locate these holes 13 mm
(1/2 in) from the edge of part and spaced 40 mm
(1 1I2 in) apart.
1
10. Prepare ail mating surfaces as necessary.
11. Fit the backing plates halfway into the sectioning
joints, clamp in place and plug weld to the vehicle.
12. Align the body lock pillar inner reinforcement.

2505956
18. Plug weld accordingly (1).
19. Apply the sealers and anti—corrosionmaterials to
the repair area, as necessary. Refer to
Anti-Corrosion Treatmentand Repair (Base) on
page 3-159.
20. Paint the repaired area. Referto Basecoat/
2505955 Clearcoat Paint Systems on page 3—159.
13. Dr11|8mm (5/16 in) holes for plug welding along . lnstall all related panels and components.
the edges of the body lock pillar inner
reinforcement as noted from the original panel (1).

(US/Canada)
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2013 (5377994)
MaHUaI
Service
 Collision Repair 3425
22. Connect the negative battery cable. Refer to
Battery Negative Cable Disconnection and
Connection on page 9-713.
23. Enable the SIR system. Refer to SIR Disabling and
Enabling on page 13-112.

Center Pillar Inner Panel

Replacement

Removal Procedure
Warning: Refer to Approved Equipment for
Collision Repair Warning on page 0-3.
Warning: Refer to Glass and Sheet Metal Handling
Warning on page 0-5.
1. Disable the SIR System. Referto SIR Disabling
and Enabling on page 13-112.
2. Disconnect the negative battery cable. Refer to
Battery Negative Cable Disconnection and
Connection on page 9-713.
2505869
w. Remove all related panels and components.
4. Visually inspect the damage. Repair as much of 8. Remove the damaged center pillar inner panel (1).
the damage as possible.
Installation Procedure
5. Remove the sealers and anti—corrosionmaterials
from the repair area, as necessary. Refer to 1. Prepare all mating surfaces as necessary.
Anti-Corrosion Treatmentand Repair (Base) on 2. Align the center pillar inner panel.
page 3-159.
6. Locate and mark all factory welds.

<9

2505870
3. Drill 8 mm (5I16 in) holes for plug welding along
2505867 the edges of the center pillar inner panel (1) as
7. Dr11|ail factory welds (1). Note the number and noted from the original panel.
location of welds for installation of the service 4. Clean and prepare the attaching surfaces for
assembly. welding.

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
3=126 Coilision Repair
13. Connect the negative battery cable. Refer to
Battely Negative Cable Disconnection and
Connection on page 9-713.
14. Enable the SIR system. Refer to SIR Disabling and
Enabling on page 13-112.

Center Pillar Reinforcement

Replacement

Removal Procedure
Warning: Refer to Approved Equipment for
Collision Repair Warning on page 0-3.
Warning: Refer to Glass and Sheet Metal Handling
Warning on page 0-5.
Note: The center pillar upper stiffener is made of Dual
Phase Steel and should be replaced only at factory
joints. Repairing or sectioning of this part is not
recommended. Refer to Dual Phase Steel on
page 3-140.
2505869
1. Disable the SIR system. Refer to SIR Disabling
5. Position the center piilar inner panel on the and Enabling on page 13-112.
vehicle (1). 2. Disconnect the negative battery cable. Refer to
6. Verify the fit of the center piilar inner panel. Battery Negative Cable Disconnection and
Connection on page 9-713.
7. Clamp the center pillar inner panel into position.
3. Remove all related panels and components.
4. Visually inspect the damage. Repair as much of
the damage as possible.
5. Remove the sealers and anti—corrosionmateria1s
from the repair area, as necessary. Refer to
Anti—CorrosionTreatment and Repair (Base) on
page 3—159.
6. Locate and mark all the necessary factory welds of
the center pillar reinforcement.

2505866
8. Plug weld accordingly (1).
9. 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.
10. Apply the sealers and anti—oorrosionmaterials to
the repair area, as necessary. Referto
Anti—CorrosionTreatmentand Repair (Base) on 2505863
page 3-159.
11. Paint the repaired area. Refer to Basecoat/ 7. Drill all factory welds (1). Note the number and
Clearcoat Paint Systems on page 3—159. location of welds for installation of the service
related panels and components. assembly.
12. |nsta11a1|

—
2013 (US/Canada)
Sonic (5377994)
Manila!
Service
 Collision Repair 3427

2505864 2505864
8. Remove the damaged center pillar 5. Position the center pillar reinforcement on the
reinforcement (1). vehicie (1).
Installation Procedure 6. Verify the fit of the oentehpillar re1nforeement._.
. 7. Clamp the center p1|1ar reinforcement Intoposmon.
1. Prepare all mating surfaces as necessary.
2. Align the center pillar reinforcement.

: 2505866
2505865
3. Drill a 8 mm (5I16 in) holes for plug welding along
the edges Ofthe oe'nterplliar relnforcement as
noted from the orlglnal panel (1).
4' 9'93.“ and prepare the attaching surfaces for
welding.
8. Plug weld accordingly (1).
9' $24.13;:giggergsaggcgggggrgggpgatena's t0
Anti-Corrosion Treatmentand Repair (Base on
page 3459'
10. Paint the repaired area. Refer to Basecoat/
Clearcoat Paint Systems on page 3—159.
11. install all related panels and components.
12. Connect the negative battery cable. Refer to
Battery Negative Cable Disconnection and
Connection on page 9-713.
13. Enable the SlR system. Refer to SIR Disabling and
Enabling on page 13-112.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
34128 Collision Repair

Center Pillar Sectioning - Outer

Removal Procedure
Warning: Refer to Approved Equipment for
Collision Repair Warning on page 0-3.
Warning: Refer to Collision Sectioning Warning on
page 0-4. 1
11111.11
Warning: Refer to Glass and Sheet Metal Handling
Warning on page 0-5.
Note: This procedure was developed to allow full
access for the replacement of the center pillar
reinforcement replacement since sectioning is not
endorsed or recommended to the reinforcement due to
the Ultra High Strength Steel on page 3—142.
1. Disable the SIR system. Refer to SIR Disabling
and Enabling on page 133-112.
2. Disconnect the negative battery cable. Refer to
Batteiy Negative Cable Disconnection and
Connection on page 9-713. 2551445
3. Remove all related panels and components. 7. Measure 13 mm (1/2in) from the forward and
4. Visually inspect the damage. Repair as much of rearward edges of the center pillar reinforcement
the damage as possible ' and mark a vertical line (1).
5. Remove the seaiers and anti—corrosionmaterials
from the repair area, as necessary. Refer to
Anti—CorrosionTreatment and Repair (Base) on
page 3—159.
5432‘

11111111

2551447
8. Measure up 1 inch from the door opening feature
line (1) and mark a horizontal line.
2505855
6. Remove the weather—strip,observe the flange in
the center pillar area. There will be a 3—metal
staCk-up. The center layer is the center pillar
reinforcement (1).

—
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 Collision Repair 3-129

_L

‘1
1
1
111111.11

2551448 2505858
9. Cut access window (1) in the center pillar outer. 12. Remove the damaged center pillar outer panel
10. Perform additional sectioning procedures as 390110“(1)-
needed depending on damage to vehicle. Refer to Installation Procedure
Rocker Outer Panel Sectioning on page 3-105 or
Front Hinge Pillar Body Sectioning on page 3—94.

4;:
2505859
2505857 1. From the service part, out the panel in
11. Locate and drill out all factory welds (1). Note the Corresponding 100311003 t0 pverlap thelremaining
number and location of welds for installation of the 01‘9'93' Pane' by 25 mm (1 m) at 930“ 10”“
service part, Iocatlon (1).

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3430 Coiiision Repair

2505861 2551449
2. Dr11|8mm (5/16 in) holes for plug welding in the
service part (1), as necessary, in the corresponding
locations noted on the original panel and along
sectioned joint.
3. Clean and prepare the attaching surfaces for
welding.

2551450
6. To create a solid weld with minimum heat
distortion, make a 25 mm (1 in) stitch weld along
the seam with gaps of 25 mm (1 in) gaps between
them. Go back and complete the stitch weld (1).
2505858
." Clean and prepare all of the welded surfaces
4. Position the center pillar outer panel (1) to the 8. Apply the sealers and anti-corrosion materials to
vehicle. Clamp the pillar in place. the repair area, as necessaryRefer to
Anti—CorrosionTreatmentand Repair (Base) on
page 3-159.
9. Paint the repaired area. Refer to Basecoat/
Clearcoat Paint Systems on page 3—159.
10. Install all related panels and components.
11. Connect the negative battery cable. Refer to
Battery Negative Cable Disconnection and
Connection on page 9-713.
12. Enable the SIR system. Refer to SIR Disabling and
Enabling on page 13—112.

2013
-Sonic
(US/Canada)
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(5377994)
 Collision Repair 3-13'1

Rear Rail Sectioning (5HB)

Removal Procedure
Warning: Refer to Approved Equipment for
Collision Repair Warning on page 0-3.
Warning: Refer to Collision Sectioning Warning on
page 0-4.
Warning: Refer to Glass and Sheet Metal Handling
Warning on page 0-5.
1. Disable the SIR System. Refer to SIR Disabling
and Enabling on page 13-112. £7946
2. Disconnect the negative battery cable. Refer to
Battery Negative Cable Disconnection and
Connection on page 9—713.
3. Remove all related panels and components.
4. Visually inspect the damage. Repair as much of
the damage as possible.
5. Remove the sealers and anti—corrosionmaterials
from the repair area, as necessary. Refer to 2726040
Anti-Corrosion Treatmentand Repair (Base) on
page 3-159. 8. Remove the damaged the rear side rail gusset (1).
6. Locate and mark all the necessary factory welds of
the rear side rail gusset.

2505962
9. Create cut lines on the rear side rail (1).
2726039
7. Drill all factory welds (1). Note the number and
location of welds for installation of the service
assembly.

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3-132 Collision Repair

2505963 2505965
Note: Do not damage any other panels or
reinforcements.
10. Cut the panel where sectioning is to be
performed (1).
11. Locate and mark all the necessary factory welds of
the rear side rail.

2551452
14. Drill two 8 mm (5/16in) plug weld holes on each of
the 3 sides of the rear rail (1). Position the center of
the holes 10 mm (3/8 in) from the cut edge.
2505964
12. Drill all factory welds (1). Note the number and
location of welds for installation of the service
assembly.

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 Collision Repair 3433

Installation Procedure

2551453
9. Cut the upper outer flanges of the rear portion of
2726043 the rear rail service part. Cut the flanges back to
1. Remove the rear side rail gusset (1) from the first scribe line and remove the tabs _
service part, 10. Cut the lower radius corners of the serVIce part
2. rear
Locate
rail.the original cutting line on the service part back to the first scribe line and remove the smatl
corners. . . ,
3. Align a sliding square or similar tool to the original 11‘ Bend the bottom S'de 0f theslightly
serVIce
- - ~ - - sectioning location inward bypart at thea
aligning
cutting line and scribe a line acress the rall: vice grip flanging tool or similar tool at the first
4. Use the same tool to transfer this scribed lIne onto scribed line.
the S'des and the weld flanges ofthe rail. 12. Clean and prepare the attaching surfaces for
5. Place a mark forward, 25 mm (1 In)from the welding.
scribed tineon all 3 sides of the service rail.
6. Use the tool to scribe a line on all 3 sides and weld
flanges of the rail.

2505985
13. Position the rear side rail (1)on the vehicle.
2505966
7. Cut at the scribe line (1).
8. Remove the rear portion of the rail.

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3=134 Collision Repair

’/ ”11’4“ °
. ./

. -». b %‘I 1
- Q ,

179$ '

2551455 2726048

14. Tack weld the part into position (1).
15. lnspect the service rear rail for proper dimensions,
using 3—dimensionalmeasuring equipment.
16. Plug weld at each 8 mm (5/16in) plug weld hole
location.
17. Stitch weld along the entire sectioning joint. Make
welds along the seam with 25 mm (1 in) gaps
between. Weld the gaps.
21. Plug the weld accordingly (1).
22. Clean and prepare the welded surfaces.
23. Apply the sealers and anti-corrosion materials to
the repair area, as necessary. Refer to
Anti-Corrosion Treatmentand Repair (Base) on
page 3—159
24. Paint the repaired area. Refer to Basecoat/
Clearcoat Paint Systems on page 3-159 Basecoat/
Clearcoat Paint Systems.
25. Install all related panels and components.
26. Connect the negative battery cable. Refer to
Battery Negative Cable Disconnection and
Connection on page 9-713.
27. Enable the SIR system. Refer to SIR Disabling and
Enabling on page 13-112.

Underbody Rear Side Rail Extension

Replacement

Removal Procedure
Warning: Refer to Approved Equipment for
Collision Repair Warning on page 0-3.
Warning: Refer to Glass and Sheet Metal Handling
Warning on page 0-5.
1. Disable the SIR System. Refer to SIR Disabling
and Enabling on page 13-112.
2. Disconnect the negative battery cable. Refer to
2726040 Battery Negative Cable Disconnection and
Connection on page 9—713.
18. Position the rear side rail gusset on the vehicle (1). 9° Remove all related panels and components.
19. Verify the fit of the rear side rail gusset. 4. Visually inspect the damage. Repair as much of
20. Clamp the rear side rail gusset into position. the damage as possible.
5. Remove the sealers and anti—corrosionmaterials
from the repair area, as necessary. Referto
Anti—CorrosionTreatmentand Repair (Base) on
page 3—159.
6. Locate and mark all factory welds.

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 Collision Repair 3-135
Installation Procedure

2505970
7. Drill all factory welds (1). Note the number and
location of welds for installation of the service 2505972
assembly.
1. Drill 8 mm (5I161n)holes for plug welding along
the edges of the rear side rail extension (1) as
noted from the original panel.
2. Clean and prepare the attaching surfaces for
welding.

2505971
8. Remove the damaged rear side rail extension (1).

2505971
3. Position the rear side rail extension on the
vehicle (1).
4. Verify the fit of the rear side rail extension.
5. Clamp the rear side rail extension into position.

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3436 Collision Repair
Note: Note the number and location of welds for
installation of the service assembly.
6. Locate and mark all the necessary factory welds of
the body rear end panel.

2505973
6. Plug weld accordingly (1).
7. Apply the sealers and anti-corrosion materials to
the repair area, as necessary. Refer to
Anti—CorrosionTreatment and Repair (Base) on
page 3-159. , 2505974
8. Paint the repaired area. Refer to Basecoat/ 7. Drill all factory welds (1).
Clearcoat Paint Systems on page 3—159.
9. lnstall all related panels and components.
10. Connect the negative battery cable. Refer to
Battery Negative Cable Disconnection and
. Connection on page 9—713.
11. Enable the SIR system. Refer to SIR Disabling and
Enabling on page 13—112.

Rear End Panel Replacement

Removal Procedure
Warning: Refer to Approved Equipment for
Collision Repair Warning on page 0-3.
Warning: Refer to Glass and Sheet Metal Handling
Warning on page 0-5.
Note: The rear end lower panel reinforcement
extension is made of Ultra High Strength Dual Phase
Steel and should be replaced only at factoryjoints.
Repairing or sectioning of this part is not
recommended. Refer to Ultra High Strength Dual
Phase Steel on page 3-141. 2505975
1. Disable the SIR System. Referto SIR Disabling 8. Remove the body rear end panel (1).
and Enabling on page 153—112.
2. Disconnect the negative battery cable. Refer to
Battery Negative Cable Disconnection and
Connection on page 9-713.
9° Remove all related panels and components.
4. Visually inspect the damage. Repair as much of
the damage as possible.
5. Remove the sealers and anti—corrosionmaterials
from the repair area, as necessary. Refer to
Anti—CorrosionTreatment and Repair (Base) on
page 3—159.

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 Collision Repair 3-137
Installation Procedure

2505978
Plug weld accordingly.
2505977
.‘1 Apply the sealers and anti—corrosionmaterials to
Note: Ifthe location of the original plug weld holes can the repair area, as necessary. Refer to
not be determined, space the plug weld holes every Anti—CorrosionTreatmentand Repair (Base) on
40 mm (1 1/2in). page 3—159.
1. Drill 8 mm (5I16 in) holes for plug welding along . Paint the repaired area. Refer to Basecoat/
the edges of the body rear end panel (1) as noted Clearcoat Paint Systems on page 3-159.
from the original panel. lnstall all related panels and components.
2. Clean and prepare the attaching surfaces for . Connect the negative batterycable. Refer to
welding. Battery Negative Cable Disconnection and
Connection on page 9-713.
11. Enable the SIR system. Refer to SIR Disabling and
Enabling on page 13-112.

Tail Lamp Pocket Replacement (5HB)

Removal Procedure
Warning: Refer to Approved Equipment for
Collision Repair Warning on page 0-3.
Warning: Refer to Glass and Sheet Metal Handling
Warning on page 0-5.
1. Disable the SlR system. Refer to SIR Disabling
and Enabling on page 13—112.
2. Disconnect the negative battery cable. Refer to
Battely Negative Cable Disconnection and
Connection on page 9-713.
Remove all related panels and components.
Visually inspect the damage. Repair as much of
the damage as possible.
2505975 Remove the sealers and anti—corrosionmaterials
from the repair area, as necessary. Refer to
3. Position the body rear end panel on the vehicle (1). Anti-Corrosion Treatmentand Repair (Base) on
4. Verify the fit of the body rear end panel. page 3—159.
5. Clamp the body rear and panel into position. Locate and mark all the necessary factory welds of
the body rear end panel.

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3:138 Collision Repair
Installation Procedure

2505980

7. Drill all factory welds (1). Note the number and
location of welds for installation of the service
assembly.
2505982
1. Drill 8 mm (5I16in) holes for plug welding along
the edges of the tail lamp pocket (1) as noted from
the original panel.
. Clean and prepare the attaching surfaces for
welding.

2505981

8. Remove the tail lamp pocket (1).

2505981
3. Position the tail lamp pocket on the vehicle (1).
4. Verify the fit of the tail lamp pocket.
5. Clamp the tail lamp pocket into position.

,,,,,,,,,
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 Collision Repair 3-139

2505983 2505984
. Plug the weld accordingly (1). 7. Drill all factory welds (1). Note the number and
Apply the sealers and anti—corrosionmaterials to location of welds for installation of the service
the repair area, as necessary. Refer to assembly.
Anti—CorrosionTreatmentand Repair (Base) on
page 3-159.
Paint the repaired area. Refer to Basecoat/
Clearcoat Paint Systems on page 3-159.
lnstall all related panels and components.
. Connect the negative battery cable. Refer to
Battery Negative Cable Disconnection and
Connection on page 9-713.
11. Enable the SIR system. Refer to SIR Disabling and
Enabling on page 13-112.

Tai | Lamp Pocket Replacement (4NB)

Removal Procedure
Warning: Refer to Approved Equipment for
Collision Repair Warning on page 0-3.
Warning: Refer to Glass and Sheet Metal Handling
Warning ‘on page 0-5.
1. Disable the SIR system. Refer to SIR Disabling
and Enabling on page 13— 112.
2505985
2. Disconnect the negative battery cable. Refer to
Battery Negative Cable Disconnection and 8. Remove the tail lamp pocket (1).
Connection on page 9—713.
Remove all related panels and components.
. Visually inspect the damage. Repair as much of
the damage as possible.
. Remove the sealers and anti—corrosionmaterials
from the repair area, as necessary. Refer to
Anti-Corrosion Treatmentand Repair (Base) on
page 3-159.
Locate and mark all the necessary factory welds of
the body rear end panel.

2013
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(5377994)
3-140 Collision Repair

Installation Procedure

2505988
6. Plug the weld accordingly (1).
2505986 7. Apply the sealers and anti—oorrosionmaterials to
1. Drill 8 mm (5/16in) holes for plug welding along the repair area, as necessary. Refer to
the edges of the tail lamp pocket (1) as noted from Anti—CorrosionTreatmentand Repair (Base) on
the original panel. page 3-159.
2. Clean and prepare the attaching surfaces for 8. Paint the repaired area. Refer to Basecoat/
welding. Clearcoat Paint Systems on page 3-159.
9. Install all related panels and components.
10. Connect the negative battery cable. Refer to
Battery Negative Cable Disconnection and
Connection on page 9—713.
11. Enable the SIR system. Refer to SIR Disabling and
Enabling on page 13—112.

Description and Operation

Dual Phase Steel

This information provides repair recommendations and
general guidelines for steel classified as Dual Phase
Steel (dual phase steel with a tensile strength up to and
including 800 MPa), also known as DP.
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.
2505985 Recommended Repairs
3. Position the tail lamp pocket on the vehicle (1). - Cold repairs can be performed on this type of
steel, unless the damage includes kinks. lfthe
4. Verify the fit of the tail lamp pocket.
damage includes kinks, the part should be
5. Clamp the tail lamp pocket into position. 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.
(US/Canada)
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Manual
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- 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.
General Motors recommends the following when
repairing or replacing this type of steel during collision
repair. ' - This type of steel can be used as a sleeve,
Recommended Repairs
0 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.
- Controlled use of heat can be used to repair
damage, if the heat does not exceed 650° C
(1200° F). The heat should be applied a maximum
of 2 times, for up to 90 seconds.
- 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, during sectioning procedures.
° 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.
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
General Motors recommends the following when
repairing or replacing this type of steel during collision
repair.
2013
-Sonic
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Collision Repair 3-141
Recommended Repairs
- Cold repairs can be performed on this type of
steel, unless the damage includes kinks. if the
damage includes kinks, thepart should be
replaced.
- Controlled use of heat can be used to repair
damage, if the heat does not exceed 650° C
(1200° F). The heat should be applied a maximum
of 2 times, for up to 90 seconds.
' Sectioning or partial replacement of this type of
steel is recommended only at approved locations,
in a specific sectioning procedure.
or backer plate, when recommended in a specific
sectioning procedure.
° Squeeze resistance spotwelding 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.
- MlG brazing can be used on this type of steel.
Ultra High Strength Dual Phase Steel
This information provides repair recommendations and
general guidelines for steel classified as Ultra High
Strength Dual Phase Steel (dual phase steel with a
tensile strength greater than 800 MPa), also known
as DPX.
General Motors recommends the following when
repairing or replacing this type of steel during collision
repair.
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.
- This classification of steel cannot be used as a
backing reinforcement or a sleeve for a sectioning
joint, unless a specific procedure is available.
Recommended Repairs
- Squeeze resistance spotwelding can be used to
replace factory spot welds, where applicable.
- MIG plug welding can be used to replace factory
spot welds.
- MIG brazing can be used to replace factory spot
welds.
3-142 Collision Repair

Steel The use of heat to repair damage is not

Ultra High Strength
This information provides repair recommendations and
general guidelines for steel classified as Ultra High
Strength Steel, also know as UHSS. This type of steel
normally has a tensile strength greater than 700 MPa.
This includes the common steel names of:
~ Ultra High Strength Steel (UHSS)
- Martensitic Steel (MS)
- Press Hardened Steel (PHS)
- Boron Steel
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.
recommended for this type of steel.
Stitch welding is not recommended for this type of
steel.
This type of steel can not be used as a backing
reinforcement or a sleeve for a sectioning joint.
Recommended Repairs
0 Squeeze resistance spot welding can be used to
replace factory spot welds, where applicable.
MIG plug welding can be used to replace factory
spot welds._
MIG brazing can be used to replace factory spot
welds.

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 Frame and Underbody 3-143

Frame and Underbody

Specifications

Fastener Tightening Specifications

Specification
Application Metric English
DrivetrainandFrontSuspensionFrameBoltCenter 135N-m 100lbft
DrivetrainandFrontSuspensionFrameBolt Front 58N-m 43 lbft
DrivetrainandFrontSuspensionFrameBolt Rear 135Mm 100lbft
FrontCompartmentFrontInsulatorCover Bolts 22N-m 16lbft
FrontCompartmentFrontInsulatorCoverScrews—EuropeOnly 2.5N'm 22lb in
FrontWheelhouseLinerInnerFrontExtensionScrews 3 N-m 27 lb in
FrontWheelhouseLinerScrew—Front 3N-m 27 lb in
FrontWheelhouseRear LinerNut 3 N-m 27lb in
FrontWheelhouseRearLinerScrew 3 N-m 27lb in
PowerSteeringFluidCoolingPipe Bolt,if equipped 9 N-m 80lb in
PowerSteeringInletandOutletHose Bolt,if equipped 9 N-m 80lb in
RearWheelhousePanel LinerNut 2 Wm 18lbin
RearWheelhousePanel LinerScrew 3 N'm 27lb in
Skid Plate Fasteners 22N'm 161bft
TransmissionRearMountBracketBolts 100Nm 74lbft

2. Remove the mounting bolts (1)for the front

Repair Instructions suspension frame skid plate.
3. Remove the front suspension frame skid plate (2).
Drivetrain and Front Suspension Installation Procedure
Frame Skid Plate Replacement
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and
Jacking the Vehicle on page 1~31.

2508614
1. Position the front suspension frame skid plate (2)
on the frame.
Caution: Refer to Fastener Caution on page 0-8.
2508614
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35144 Frame and Underbody
2. install the front suspension frame skid plate
mounting bolts (2) and tighten to 22 N-m(16 lb ft).

Drivetrain and Front Suspension

Frame Replacement
Special Tools
EN—45059Angle Meter
For equivalent regional tools, refer to Special Tools on
page 3—158.
Removal Procedure
1. Support the radiator and condenser from above
using the upper brackets on each side.
2. Raise the vehicle on a hoist. Refer to Lifting and h. I \ a . 7
Jacking the Vehicle on page 1—31. \. 9%"
3. Remove the front tire and wheel assembly. Refer to .5“;
Tire and Wheel Removal and Installation on
page 16-60.
4. Remove the skid plate from the front frame, 2531740
if equipped. Refer to Drivetrain and Front
Suspension Frame Skid Plate Replacement on 10. Remove the steering rack retaining bolts (1) and
page 3-143. discard.
5. Remove the left and right front wheel house liner 11. Using mechanics wire, secure the power steering
inner front extensions. Refer to Front Wheelhouse gear to the vehicle.
Liner Inner Front Extension Replacement (Left 12. Disconnect the hydraulic power steering hoses
S/de) on page 3-147 or Front Wheelhouse Liner from the front frame, if equipped.
Inner Front Extension Replacement (Right Side, 13. Disconnect the exhaust isolators (2) from the front
LUV) on page 3-148 or Front Wheelhouse Liner suspension frame.
Inner Front Extension Replacement (Right Side,
LWE, LUW) on page 3—149. 14. Disconnect the power brake booster pump hose
and connector, if equipped.
6. Remove the front bumper impact bar lower
bracket. Refer to Front Bumperlmpact Bar Lower 15. Remove the reartransmission mount bracket to
Bracket Replacement on page 3—54. rear mount through bolt (1).
7. Disconnect the steering linkage tie rod end from 16. Remove both frame support braces.
the steering knuckle. Refer to Steering Linkage 17. Using a suitable support table or equivalent,
Outer Tie Rod Replacement on page 15-17. support the front suspension frame.
8. Disconnect the lower ball joints from the steering
knuckles. Refer to Lower Control Arm
Replacement on page 16—12.
9. Disconnect the stabilizer links from the strut
assemblies.

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“’‘~ .,, -. €59. é“ s

2492995
18. Remove the upper frame suspension retaining
bolts (1).

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 Frame and Underbody 3-145

2508892 2539413
19. Remove the frame front bolts (1). 3. Using two suitable drifts for adjusting pins, have an
20. Remove the frame rear bolts (2). assistant vertically insert and hold the drifts
through the front suspension frame and floor
21. Remove the frame (3) from the vehicle.
panel (1).
22. Remove the following components, if replacing the Caution: Refer to Fastener Caution on page 0-8.
frame:
4. Install the frame rear bolts (2) and tighten to
' The lower control arms—Refer to Lower Control 135 Nm (100 lbft).
Arm Replacement on page 16-12.
5. Install the frame front bolts (1) and tighten to 58 Nm
~ The stabilizer shaft—Refer to Stabilizer Shaft (43 lb ft).
Replacement on page 16-3.
- The front bumper lower impact bar—Refer to
Front Bumper Lower Impact Bar Replacement
on page 3-53.
- The power brake booster pump, if equipped-
Refer to Power Brake Booster Pump
Replacement on page 5-178.
installation Procedure
1. Install the following components on the drivetrain
and front suspension frame if removed:
- The power brake booster pump, if equipped-
Refer to Power Brake Booster Pump
Replacement on page 5—178.
- The front bumper lower impact bar—Refer to
Front Bumper Lower Impact Bar Replacement
on page 3-53. wag: _, /; ‘_' > ‘13:»
- The stabilizer shaft—Refer to Stabilizer Shaft .«
Replacement on page 16-3.
° The lower control arms—Refer to Lower Control
Arm Replacement on page 16-12.
2. Install the frame (3) into the vehicle. 2492995
6. Installthe upper frame suspension retaining
bolts (1) and tighten to 135 Nm (100 lb ft)
7. Installthe frame braces and tighten the fasteners
to 22 N-m(16 lb ft).
8. Remove the support for the power steering gear.

2013
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3-146 Frame and Underbody
13. Connect the power brake booster pump hose and
connector, if equipped.
\ '03 14. Connect the lower ball joints to the steering
knuckles. Refer to Lower Control Arm
Replacementon page 16—12.
15. Connect the stabilizer links to the strut assemblies.
Refer to Stabilizer Shaft Link Replacement on
page 16-8.
16. Connect the steering linkage tie rod end to the
steering knuckle. Referto Steering Linkage Outer
Tie Rod Replacement on page 15—17.
17. Install the front bumper impact bar lower bracket.
Refer to Front Bumper Impact Bar Lower Bracket
Replacement on page 3-54.
18. Install the left and right front wheel house liner
inner front extensions. Refer to Front Wheelhouse
Liner InnerFront Extension Replacement (Left
Side) on page 3—147or Front Wheelhouse Liner
Inner Front Extension Replacement (Right Side,
LUV) on page 3-148 or Front Wheelhouse Liner
2531740 Inner Front Extension Replacement (Right Side,
LWE, LUW) on page 3—149.
9. Install the steering gear retaining fasteners (1).
Refer to Steering Gear Replacement on 19. Install the skid plate to the front frame, if equipped.
page 15—20. Refer to Drivetrain and Front Suspension Frame
Skid Plate Replacement on page 3-143.
10. Connect the hydraulic power steering hoses to the
front frame, if equipped. 20. Install the front tire and wheel assembly. Refer to
Tire and Wheel Removal and Installation on
11. Connect the exhaust isolators (2)to the front page 16-60.
suspension frame.
21. Lower the vehicle.
22. Remove the support of the radiator and condenser.

V I

(‘0.

2531747
12. Install the rear transmission mount bracket to rear
mount through bolt (1). Refer to Transmission Rear
Mount Replacement on page 17—217.

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
 Frame and Underbody 3-147
Front Wheelhouse Liner Inner Front Extension Replacement (Left Side)

2472648
Front Wheelhouse Liner Inner Front Extension Replacement (Left Side)
Callout l Component Name
Preliminary Procedure
Removethetireandwheelassembly.Referto Tireand WheelRemovalandInstallationonpage 16-60.
FrontWheelhouseLinerinnerFrontExtensionScrew(Qty:2)
Caution: Referto FastenerCautiononpage0—8.
Tighten
3 N-m(27lbin)
FrontWheelhouseLinerInnerFrontExtensionPush-InRetainer(Qty:2)
FrontWheelhouseLinerInnerFrontExtension

2013
—Sonic
(US/Canada)
Service
Manual
(5377994)
3-148 Frame and Underbody

Wheelhouse Liner Inner Front Extension Replacement (Right Side, LUV)

Front

2965819

Front Wheelhouse Liner Inner Front Extension Replacement (Right Side, LUV)

Callout I Component Name

Preliminary Procedure
1. Removethetireandwheelassembly.Referto Tireand WheelRemovalandInstallationonpage 16-60.
2. Removethefrontfasciaopeninglowercover.Referto FrontBumperFascia OpeningLowerCoverReplacementon
page 3-58.
Front
3. RemovethefrontWheelhousefrontliner.Referto FrontWheelhouseLinerReplacement(Rear)onpage 3-151or
WheelhouseLinerReplacement(Front)onpage3-150
FrontWheelhouseLinerInnerFrontExtensionScrew(Qty:2)
Caution: Referto FastenerCautiononpage 0-8.
Tighten
3 N-m(27lbin)
FrontWheelhouseLinerInnerFrontExtensionPush-InRetainer(Qty:3)
3 FrontWheelhouseLinerInnerFrontExtension

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
 Frame and Underbody 3-149
Front Wheelhouse Liner Inner Front Extension Replacement (Right Side,
LWE, LUW)

,.
,,5»
I

2965819
Front Wheelhouse Liner Inner Front Extension Replacement (Right Side, LWE, LUW)
Callout I Component Name
PreliminaryProcedure
1. Removethetireandwheelassembly.Referto Tireand WheelRemovalandInstallationonpage 16-60.
2. Removethefrontfasciaopeninglowercover.Referto FrontBumperFascia OpeningLowerCoverReplacementon
page3-58.
3. RemovethefrontWheelhousefrontliner.Referto FrontWheelhouseLinerReplacement(Rear)onpage 3-151or Front
WheelhouseLinerReplacement(Front)onpage3-150
4. Removetheaircleanerintakeduct.RefertoAir CleanerInletDuctReplacementonpage9-579
FrontWheelhouseLinerInnerFrontExtensionScrew(Qty:2)
Caution: Referto FastenerCautiononpage0-8.
Tighten
3 N-m(27lb in)
FrontWheelhouseLinerInnerFrontExtensionPush—ln Retainer(Qty:3)
3 FrontWheelhouseLinerInnerFrontExtension

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
3-150 Frame and Underbody

Front Wheelhouse Liner Replacement (Front)

2472643

Front Wheelhouse Liner Replacement (Front)

Callout Component Name
Preliminary Procedure
Removethetire andwheelassembly.Referto Tireand WheelRemovalandInstallationonpage 16—60.
FrontWheelhouseLinerScrew—Front(Qty:5)
Caution: RefertoFastenerCautiononpage 0—8.
Tighten
2.5N-m(22lbin)
2 FrontWheelhouseLinerPush-ln Retainer—Front(Qty:2)
FrontWheelhouseLiner—Front
3 Procedure
Disengagetheupperinterlockingretainers.

,,,,,,,,,
(US/Canada)
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2013 (5377994)
Manual
Service
 Frame and Underbody 3-151
Front Wheelhouse Liner Replacement (Rear)

2472647
Front Wheelhouse Liner Replacement (Rear)
Callout Component Name
Preliminary Procedure
Removethetireandwheelassembly.Referto Tireand WheelRemovaland Installationonpage 16-60.
FrontWheelhouseRear LinerScrew(Qty:2)
Caution: Referto FastenerCautiononpage 0-8.
Tighten
3N-m(27lb in)
FrontWheelhouseRear LinerNut(Qty:3)
2 Tighten
3N-m(27lb in)
3 FrontWheelhouseRear LinerPush-lnRetainer(Qty:2)
FrontWheelhouseRear Liner
4 Procedure
Disengagetheupperinterlockingretainers.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
3-l52 Frame and Underbody

Rear Wheelhouse Liner Replacement (Hatchback - Right)

2486756

Rear Wheelhouse Liner Replacement (Hatchback - Right)

Callout I Component Name

Preliminary Procedure
16—60.
Removethe tireandwheelassembly.Referto Tireand WheelRemovalandInstallationonpage
Rear WheelhousePanel LinerScrew(Qty:5)
Caution: Referto FastenerCautionon page0-8.
Tighten
3N-m(27lb in)
Rear WheelhousePanel LinerNut(Qty:4)
2 Tighten
2N-m(18lb in)
3 Rear WheelhousePanel LinerPush-lnRetainer
RearWheeIhousePanel Liner

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
 Frame and Underbody 3=153

Rear Wheelhouse Liner Replacement (Sedan - Left)

2508337
Rear Wheelhouse Liner Replacement (Sedan - Left)
Callout Component Name
Preliminary Procedure
Removethetireandwheelassembly.Referto Tireand WheelRemovalandInstallationonpage 16—60.
RearWheelhousePanel LinerScrew(Qty:4)
Caution: Referto FastenerCautiononpage 0-8.
Tighten
3 NW (27lb in)
RearWheelhousePanelLinerPush-InRetainer
RearWheelhousePanelLiner

2013
-Sonic
(US/Canada)
Selvice
Manual
(5377994)
3—154 Frame and Underbody

Rear Wheelhouse Liner Replacement (Hatchback - Left)

2486630

Rear Wheelhouse Liner Replacement (Hatchback - Left)

Callout I Component Name
Preliminary Procedure
Removethetireandwheelassembly.Referto Tireand WheelRemovaland Installationonpage 16—60.
RearWheelhousePanel LinerNut
Caution: Referto FastenerCautionon page0-8.
Tighten
2N-m(18lbin)
RearWheelhousePanel LinerScrew(Qty:5)
2 Tighten
3 N-m(27lbin)
3 RearWheelhousePanel Liner

(US/Canada)
-Sonic
2013 (5377994)
Manual
Sen/ice
 . Frame and Underbody 3=155
Rear Wheelhouse Liner Replacement (Sedan - Right)

2483050
Rear Wheelhouse Liner Replacement (Sedan - Right)
Callout Component Name
Preliminary Procedure
Removethetireandwheelassembly.Referto Tireand WheelRemovaland Installationonpage 16-60.
RearWheelhousePanel LinerScrew(Qty:4)
Caution: RefertoFastenerCautiononpage 0—8.
Tighten
3 N-m(27lb in)
RearWheelhousePanel LinerNut(Qty:4)
2 Tighten
2 N'm(18lb in)
3 RearWheelhousePanel LinerPush-InRetainer
RearWheelhousePanel Liner

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
3456 Frame and Underbody

Rear Wheelhouse Panel Liner Extension Replacement

//
2472702

Rear Wheelhouse Panel Liner Extension Replacement

Callout Component Name
PreliminaryProcedure
Removethetireand wheelassembly.Referto Tireand WheelRemovaland Installationonpage 16-60.
1 RearWheelhousePanel LinerExtensionNut (Qty:2)
Caution: Referto FastenerCautiononpage 0-8.
2 RearWheelhousePanelLinerExtension

(US/Canada)
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2013 (5377994)
Manual
Service
 Frame and Underbody 3-157
Front Compartment Front Insulator Cover Replacement

2509978
Front Compartment Front Insulator Cover Replacement
Callout Component Name
FrontCompartmentFrontInsulatorCoverScrew(Qty:2)
Caution: RefertoFastenerCautiononpage0—8.
1 Tighten
2.5N-m(22lbin)
FrontCompartmentFrontinsulatorCover Bolt(Qty:4)
2 Tighten
22Nm(16lbft)
3 FrontCompartmentFrontInsulatorCover

h_w_._~_
W
_
”2MW

I
2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
3=158 Frame and Underbody

Special Tools and Equipment

Illustration Tool Numberl Description

EN-45059
J-45059
AngleMeter

1197696

.........
(US/Canada)
-Sonic
2013 (5377994)
Manua/
Service

Paint and Coatings
Introduction
Basecoathlearcoat 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 (Base)
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 doorlocks,
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—typeanti—corrosionmaterial is essential.
After repair andlor 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—corrosioncompounds are light-bodied materials
designed to penetrate between metal—to-metal
surfaces, such as pinch—weldjoints, hem flanges, and
integral panel attaching points where metal surfaces
are difficult to coat with conventional undercoating
2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
Paint and Coating CH 59
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):
PermatexPart
Number Description
310-JDl—UCA1 PermatexCanisterandWandAssembly
310-81881 PermatexAmberRust Proofing(24oz)
(Qtyof 12)
310-81882 PermatexAmberRust Proofing(1gal)
Exterior Protectants
The following product is available from *ECP, Inc.
Contact them at 1-800-323-3521 or www.ecpinc.net.
Part Number Description
178660 Nox RustX-121B (12cans percase)
The following products are available from your local
*3M®distributor,or call 1-800-521-8180, ext. 779—5165.
3M®Part
Number Description
08804 Water—Based Undercoat
08801 No Clean-UpApplicatorGun
05917 WeId-ThruCoating
08891 RustFighter-l
The following product is available from *Transtar
Autobody Technologies. Contact the company at
1—800-824-2843or www.tat—co.com
Part Number Description
4353 Weld-ThroughPrimer
*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.
 3:160 Paint and Coatings
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 reseallng. 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—ontype, 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
anti—corrosionmaterials 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—typeconstruction and when
configurations of the metal panels limit access to
interior surfaces.
Instructions
Repair
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) on page 3-160
or Rail Dust Damage Repair on page 3—161.
Important: Follow all of the instructions from the
manufacturer of the polishing material.
3. Use a paint gauge before,‘during, and after
sanding andlor polishing, to avoid removing too
much clearcoat. Refer to Paint Gauges on
page 3-161.
Environmental Fallout (Acid Rain)
Caution: Refer to Clearcoat/Ultravlolet Screeners
Caution on page 0-8.
Note: Always refer to the manufacturer's packaged
instructions for the detailed procedures of materials
used for compounding andlor 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 a GM approved
Liquid Wash and Wax kit.
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 on page 3-159.
Surface Level Contamination Repair
1. Thoroughly wash and dry the contaminated area,
with a GM approved Liquid Wash and Wax kit.
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—typepolish with a foam panel.
lf damage has been repaired, remove any swirl
marks with a dual action orbital polisher and
foam pad.
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 on
page 3—1 61.
3. Wet sand and finesse polish the contaminated test
area. Ifduring 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 on page 3-159.
,,,,,,,,
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Manual
Service

Paint Gauges
Paint thickness gauges measure the total thickness of
the vehicle finish. Itis 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-TOOLSfor information:
Paint Thickness Gauges
- 147-5437—ETGStandard model
0 147-5437-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—2mils [00015—00020 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.
2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
Paint and Coatings 3-161
Rail Dust Damage Repair
Warning: Refer to Eye Protection Warning on
page 0-4.
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. Itcan 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 thepaint.
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 a GM
approved Liquid Wash and Wax kit
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—AcidBased). If,upon inspection, some
particles are still present, the process may be
repeated. Ifthe damage has been repaired,
complete the repair to the entire panel.
6. Polish the entire panel after the removal process.
Ifsmall pits remain in the Clearcoat after all of the
damage has been repaired, refer to Clearcoat
Repair without Repainting on page 3-160.
3-162 Plastic Panel information and Repair

Plastic Panel Information and Repair

- Inspect the rear side of the work area before
Repair Instructions making repairs in order to avoid possible damage
to wires, motors, etc.

General Plastic Repair Description and Operation

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 How to Identify Plastic Parts
sheet molded compound or RIM rigid plastic,
observe the following guidelines:
- Workin a properly ventilated area
l+
- Apply protective cream to any exposed skin
- Remove any mixture that comes into contact SAE PVC 3mm
with skin
- Wash skin with cold water to remove glass and +l
resin dust SAE
- Use a sander with a vacuum attachment t
- Follow the repair material manufacturer's
SMC
instructions
Also, always wear the following:
- An approved respirator, or air supplied
respirator
- Eye protection TPO
- Rubber gloves
- Earplugs H 1:
- Pro tective clo thing
The following procedures should be followed when 95570
repairing all types of thermoset plastic: Plastic parts can be identified by the SAE code, which
- Follow the manufacturer's application and curing is usually found on the rear of the part, and/or by the
recommendations. characteristics of the plastic. Knowing the type of
- Do not intermix systems. Use the supplies and the plastic aids in selecting the proper repair materials and
repair materials from the same manufacturer. in selecting the proper repair procedure.
- Clean the inner and outer surfaces of the repair Look for the SAE code stamped into the part.
area with a soap impregnated scouring pad in
order to remove any dirt or mold release agent. Code Found
- Clean the area with a wax and grease remover, Match the code to those in the plastic identification
using only enough of the remover to dampen a chart to determine whether the plastic is thermoplastic
cloth. Allow the panel to dry thoroughly. or thermoset plastic, and whether the plastic is rigid or
flexible. Refer to Plastic Identification and Refinishing
- Remove the surface finish from the area to be
Systems on page 3-163.
repaired. Adhesives are designed to adhere to the
plastic substrate, not the finish. No Code Found
- Prime a metal surface before applying the repair Warning: Do NOT use a plastic burn test to
material. 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
non—polyolefin.

2013
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Sonic
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 Plastic Panel information and Repair 3-183

Float Test Thermoplastic and thermoset plastics can be either

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—polyolefinsinks.
rigid or flexible. Thermoplastic plastic parts are best
repaired with a hot iron plastic material—feedwelder, but
are usually replaced. Thermoset plastic can be repaired
with epoxy or other more rigid 2 package repair
material.
For general repair instructions, refer to General Plastic
Repair on page 3-162.

Abrasion Test
° Sand 3 spot nearthe damaged area with Grade 36
Roloc Disc.
- Thermoplastic polyolefin material melts or frays
when sanded.
- Thermoset non-polyolefin material sands cleanly.
Plastic Identification and Refinishing Systems
Identifying
Symbol—Old Chemical Composition or Plastic Typical Area(s)Where Examples of Common
Symbol in ( )5 Family Name Part is Used [Trade Names Type of Plastic
ArmreStSW90“ ' ABS I Absafil) Magnumy
ABS Acrylonitriie/Butadiene-Styrene Console,IPC' Steering Cycolac,Dyel, Thermoplastic
ColumnBracket/
Jacket,TrimMolding Kralastic‘ Lustran

ABS +PC Acrylonitriie/Butadiene-Styrene

Polycarbonate + InstrumentPanel,iPC Bayblend,Cycoloy,
KHA, Pulse ..
Rigid
Head RestCover,
ABS /PVC ABS/Vinyl(Soft) InstrumentPanel Pad, ABS Vinyl Flexible,Vinyl
TrimMolding/Panel
EPDM -
EthylenePropyleneDleneMonomer BodyImpact
Panel,Bumper
Strip EPDM, Nordel ..
Rigid

EVA (EVAC) Ethylene/VinylAcetate HeadRsegfttgrfifir,

MISC Elvax,Microthane Flexible

' Heggéatrgpgffisls, Nylon,Capron,Zytel, .'

PA Polyamlde Extensions,Exterior Rllsan,WSEn‘HVydyne, ngld
FinishTrimPanels
ExteriorFinishTrim .
PA, Pol amide Panel,Headlamp capéfigéwlvog’yeylon’ Rigid,
PAG, PAGG y Bezel,QuarterPanel WellamidyZytei Thermoset
Extension ’ y
PA +PPE Polymide+PolypheneyleneEther ExteriorTrim,Fender GTX Thslirgng’set
PBT +TEEE Polybutylene,Terephthalate+Ether, Fascia, RockerPanel --
(PBTP +EEBC) Ester BlockCompound Molding 89"” M R‘g'd
Interior
. Rigid/Hard .
Calibre,Lexan,Merlon, --
Rigid,
PC Polycarbonate TrimPanel,Valance Makrolon Thermoset
Panel
Polycarbonate+Polybutylene, . Macroblend,Valox, Flexible,
PC +PETP Terephthalate BumperFascua Xenoy Thermoset
Fuel TankShield’ Inner
. Alathon .
Dylan’ Forlflex ..
PE Polyethylene FenderPanel,Interior . ’
TrimPanel,Seat Belt Hl-fax,ngeggg. Marlex, ' ngld,
Thermoplastic
Cover,Spoiler,Valance
Amberol,Bakelite, Ri id
PF PhenolFormaldehyde Ashtray Durez,Genal,Phenolic, Thergno’set
Plyophen,Resinox

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
3-184 Plastic Panel information and Repair

Plastic Identification and Refinishing Systems (cont'd)

Identifying
Symbol—Old Chemical Composition or Plastic Typical Area(s)Where Examples of Common
Symbol in ( )s Family Name Part is Used /Trade Names Typeof Plastic
BumperFascia, Cowl
Panel' DeflectorPanel’ Azdel' Dapien’
DoorPanel' inner
. Escorene,Marlex, .
FleXIble,
PP Polypropylene Mofigiflgekilglfielggnel Novolen,Oleflo,Profax, Thermoplastic
Load Floor,Radiator Tenlte
Shroud,WheelCover
Bezels,Chromed Ri id
PPE (PPO) PolyphenyleneEther Plastic,Headlamp Noryl,Oleflo,Prevex Thergnoset
Door,Ornaments
Durathon.Dylan,
PS Polystyrene Dash Panel,DoorPanel Lustrex,Polystyrol, Flexible,Soft
Styron

PUR PolyurethaneThermoset
(Unsatu’rated) BumperFascia, Filler
Panel,Front/Rear Ba fiex Castethane
Body R)|/MéRlM SRiM ’ Thermoset
Panel,PickupBox ’ ’
. . . InteriorSoftTrim,l/P Geon,Pliovic,Unichem, . Vinyl.
PVC PolyvmylChloride(Vinyl) Skins,RoofCover Vinoflex,Vinyl,Vinylite FIeXIble,
CenterConsole,Glove
SAN (SA) StyreneAcrylonitrite Box Door,InteriorTrim Foracryl,Lustran,Tyril Rigid
Panel
TEO (EP, Air Dam,Bumper EPI, EPII,TPO, TPR Flexible,
EPM, TPO) Ethylene/ Propylene(Rubber) Fascia,ValancePanel (ThermoplasticRubber) Thermoplastic
TPO . .
ThermalPlasticOletln BumperCovers Flexible
TPO Thermoplastic

TPU (TPUR) Polyurethane,Polyolefin BumperFascia,Gravel

Deflector,SoftFiller Estane
R ’lPellethane
T . ’ ThFlexible
|' t'
Panel,WindowMolding 03’3“ OX'” arm” as '0
Air Scoop,Air Spoiler,
Fascia Extension' . ..
UP Polyester/Thermoset Hood, Instrument
Housing,Rear . Fiberglass
PremI—giass, ’
Seiectron, Rigid,
Thermoset
CompartmentLid,Roof, SMC, Vibrinmat
VentilationGrid
For symbolsnotlistedin thistable,contacttheSocietyofAutomotiveEngineers,400CommonwealthDrive,Warrendale,PA
15096-0001.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)

Section
Body Systems
Fixed and Moveable Windows ................ 4-5
Specifications ..................................... 4-5
Fastener Tightening Specifications .............. 4-5
Schematic and Routing Diagrams ............... 4-5
Moveable Window Schematics .................. 4-6
Defogger Schematics ............................ 4-8
Diagnostic Information and Procedures . . .. . . . .4—9
DTC BO283 ...................................... 4—9
DTC B3163 ..................................... 4-11
DTC B3205 ..................................... 4-14
Symptoms - Fixed and Moveable Windows ..... 4-15
Rear Window Defogger Malfunction ............ 4-16
Power Windows Malfunction .................... 4-18
Side DoorWindow Mechanical Diagnosis . . 4-25
Repair Instructions .............................. 4-26
Windshield Replacement ....................... 4-26
Windshield Upper Reveal Molding
Replacement .................................. 4-28
Front Side Door Window Replacement ......... 4-29
Rear Side Door Window Replacement
(Sedan)‘ ........................................ 4-30
Rear Side Door Window Replacement
(Hatchback) ................................... 4—32
Rear Side Door Stationary Window
Replacement .................................. 4-33
Rear Window Replacement ..................... 4—34
Rear Window Reveal Molding Replacement .... 4—36
Liftgate Window Replacement .................. 4-36
Front Side Door Window Switch Replacement
(Left Side) ..................................... 4—38
Front Side Door Window Switch Replacement
(Right Side) .................................... 4-39
Rear Side Door Window Switch
Replacement .................................. 4-40
Front Side Door Window Regulator
Replacement .................................. 4-41
Window Motor Programming —Express
Function ....................................... 4-42
Front Side Door Window Regulator Motor
Replacement .................................. 4—43
Rear Side Door Window Regulator
Replacement (Sedan) ......................... 4-44
Rear Side Door Window Regulator
Replacement (Hatchback) ..................... 4-45
Rear Side Door Window Regulator Motor
Replacement .................................. 4—46
2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
Table of Contents 441
4
Front Side Door Window Regulator Handle
Replacement .................................. 4-47
Rear Side Door Window Regulator Handle
Replacement .................................. 4-48
Front Side Door Window Rear Guide
Replacement .................................. 4-49
Rear Side Door Window Rear Guide
Replacement .................................. 4—50
Front Side Door Window Outer Sealing Strip
Replacement .................................. 4-51
Rear Side Door Window Outer Sealing Strip
Replacement (Sedan) ......................... 4-52
Rear Side Door Window Outer Sealing Strip
Replacement (Hatchback) ..................... 4-53
Front Side Door Window Weatherstrip
Replacement .................................. 4-54
Rear Side Door Window Weatherstrip
Replacement (Hatchback) ..................... 4-55
Rear Side Door Window Weatherstrip
Replacement (Sedan) ......................... 4-56
Adhesive Installation of Windshields . . . . . . . 4-57
Adhesive Installation of Rear Windows ......... 4-61
Adhesive Installation of Liftgate Windows . . 4—65
Description and Operation ...................... 4-68
Full—CutMethod Description .................... 4-68
Power Windows Description and Operation 4-69
Rear Window Defogger Description and
Operation ...................................... 4—69
Stationary Window Description ................. 4—70
Urethane Adhesive Description ................. 4-70
Special Tools and Equipment ................... 4—70
Horns .......................................... 4—71
Specifications ................................... 4—71
Fastener Tightening Specifications ............. 4—71
Schematic and Routing Diagrams .............. 4—71
Horn Schematics ............................... 4-72
Diagnostic Information and Procedures . . .. . . .4—73
DTC B2750 ..................................... 4—73
Symptoms - Horns .............................. 4-74
Horns Malfunction .............................. 4-75
Repair Instructions .............................. 4—78
Horn Replacement .............................. 4-78
Steering Wheel Horn Contact Replacement 4—79
Description and Operation ...................... 4—80
Horns System Description and Operation . . 4—80
4-2 Table of Contents
Lighting ........................................ 4-81
Specifications ................................... 4-81
Fastener Tightening Specifications ............. 4-81
Schematic and Routing Diagrams .............. 4—81
Headlights/Daytime Running Lights (DRL)
Schematics .................................... 4-82
Fog Lights Schematics ......................... 4-84
Exterior Lights Schematics ..................... 4-85
InteriorLights Schematics ...................... 4-89
InteriorLights Dimming Schematics ............ 4-91
Diagnostic Information and Procedures . . .. . . .4-93
DTC 81480 ..................................... 4-93
DTC 82530 ..................................... 4-95
DTC 82545 ..................................... 4-97
DTC 8256A ..................................... 4—99
DTC 82570 .................................... 4-101
DTC 82575 or 82699 .......................... 4-103
DTC 8257A .................................... 4—105
DTC 82578 .................................... 4—108
DTC 82580 .................................... 4-110
DTC 82585 or 83867 .......................... 4-112
DTC 82610 .................................... 4-115
DTC 82615 .................................... 4-117
DTC 82625 .................................... 4-119
DTC 82645 .................................... 4-121
DTC 82652 .................................... 4-123
DTC 83596 .................................... 4-125
DTC 83650 .................................... 4-127
DTC 83806 .................................... 4-129
DTC 83881 or 83882 .......................... 4-131
DTC 83883 .................................... 4—134
DTC 83884 .................................... 4-137
DTC 83948 or 83949 .......................... 4-139
DTC 83950 or 83951 .......................... 4-142
DTC C0277 or C0890 ......................... 4-145
DTC 00297 .................................... 4-148
Symptoms - Lighting ........................... 4-149
Backup Lamps Malfunction (Automatic
Transmission) ................................ 4—150
Backup Lamps Malfunction (Manual
Transmission) ................................ 4-151
Courtesy Lamps Malfunction .................. 4-154
Daytime Running Lamps Malfunction .... . . . . . 4-155
Dome Lamps Malfunction ..................... 4-157
Front Fog Lamps Malfunction ................. 4-159
Hazard Lamps Malfunction .................... 4-161
Headlamps Malfunction ....................... 4-163
InteriorBacklighting Malfunction .............. 4-169
Park, License, and/or Tail Lamps
Mirrors .......................................
Malfunction ................................... 4-174
Rear Compartment Lamp Malfunction ......... 4-177
Stop Lamps Malfunction .......................
4-178
Turn Signal Lamps and/or indicators
Malfunction ................................... 4-181
Repair Instructions .............................
4-185
Brake Pedal Position Sensor Calibration .... . . 4—185
Brake Pedal Position Sensor Replacement 4-186
Headlamp Switch Replacement ............... 4—187
Hazard Warning Switch Replacement ......... 4—188
Reading Lamp Replacement .................. 4-189
Dome Lamp Bezel Replacement .............. 4-190
Windshield Header Courtesy Lamp
Replacement ................................. 4-191
Dome Lamp Bulb Replacement ............... 4—192
Headlamp Replacement ....................... 4-193
Headlamp Bulb Replacement ................. 4-194
Headlamp Housing Bracket Replacement ..... 4-195
Headlamp Bracket Replacement .............. 4-196
Headlamp Aiming ............................. 4-196
Front Fog Lamp Replacement ................. 4-199
Front Fog Lamp Bulb Replacement ........... 4—200
Front Fog Lamp Cover Replacement
(Without T3U) ................................ 4-201
Fog Lamp Aiming .............................. 4-202
Parking and Turn Signal Lamp Bulb
Replacement ................................. 4—203
High Mount Stop Lamp Replacement
(Sedan) ...................................... 4-204
High Mount Stop Lamp Replacement
(Hatchback) .................................. 4-205
Cargo Center Courtesy Lamp Bulb
Replacement (Hatchback) ................... 4—206
Cargo Center Courtesy Lamp Bulb
Replacement (Sedan) ........................ 4-207
Backup Lamp Bulb Replacement (Sedan) 4208
Rear License Plate Lamp Replacement
(Hatchback) .................................. 4-209
Rear License Plate Lamp Replacement
(Sedan) ...................................... 4-210
Rear License Plate Lamp Bulb Replacement
(Sedan) ....................................... 4—211
Rear License Plate Lamp Bulb Replacement
(Hatchback) .................................. 4-212
Tail Lamp Replacement (Sedan) .............. 4-213
Tail Lamp Replacement (Hatchback) .......... 4-214
Stop and Turn Signal Lamp Bulb Replacement
(Sedan) ...................................... 4-215
Rear Compartment Courtesy Lamp
Replacement (Hatchback) ................... 4—21 6
Rear Compartment Courtesy Lamp
Replacement (Sedan) ........................ 4-217
Description and Operation .................... 4-217
Exterior Lighting Systems Description and
Operation .................................... 4-217
InteriorLighting Systems Description and
Operation .................................... 4-219
4-221
Specifications .................................. 4—221
Fastener Tightening Specifications ............ 4-221
Schematic and Routing Diagrams ............
4-221
Outside Rearview Mirror Schematics .......... 4—222
Diagnostic Information and Procedures ...... 4—223
Symptoms - Mirrors ............................
4—223
Heated Mirrors Malfunction .................... 4—223
Power Mirror Malfunction ...................... 4—225
2013
-Sonic
(US/Canada)
Service
Manual
(5377994)

Repair Instructions ............................. 4228
Outside Rearview Mirror Replacement
(Manual) ..................................... 4-228
Outside Rearview Mirror Replacement
(Power) ..................................... 4-229
Outside Rearview Mirror Housing Rear Cover
Replacement ................................. 4-230
Outside Rearview Mirror Remote Control
Switch Replacement ......................... 4—231
Outside Rearview Mirror Motor
Replacement ................................. 4—232
Outside Rearview Mirror Glass
Replacement ................................. 4—233
Outside Rearview Mirror Housing
Replacement .................................
Inside Rearview Mirror Replacement ..........
Description and Operation ....................
Outside Mirror Description and Operation . 4-236
Vehicle Access ..............................
Specifications ..................................
Fastener Tightening Specifications ............
Schematic and Routing Diagrams ............
Door Lock/lndicator Schematics ...............
Release Systems Schematics .................
Diagnostic Information and Procedures ...... 4—243
DTC 82494 ....................................
DTC 8252C ...................................
DTC 8252E ....................................
DTC 83125, 83130, or 83135 .................
DTC 83140 or 83150 ..........................
DTC 8324A or 83245 .........................
DTC 83265 ....................................
DTC 83618 ....................................
DTC 83930 ....................................
Symptoms - Vehicle Access ...................
Hatch Release Malfunction ....................
Door Ajar IndicatorMalfunction ................
Power Door Child Lock Malfunction ...........
Power Door Locks Malfunction ................
Trunk Release Malfunction ....................
Door Will Not Open/Close, Door Binding, or
Looks, Handles, or Cylinders Do Not
Function ......................................
Repair Instructions .............................
Front Side Door Inside Handle Cable
Replacement
......................... 4-287
Rear Side Door Inside Handle Cable
Replacement .................................
Front Side Door Lock Cylinder
Replacement .................................
Rear Door Lock Cylinder Replacement ........ 4—290
Front Side Door Outside Handle
Replacement .................................
Front and Rear Side Door Outside Handle Rod
Clip Replacement ............................
Front Side Door Outside Handle Bracket
Replacement .................................
2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
l
Table of Contents 423
Rear Side Door Outside Handle Bracket
Replacement ................................. 4—294
Liftgate Latch Replacement ................... 4—295
Rear Compartment Lid Inside Handle
Replacement ................................. 4—296
Rear Side Door Outside Handle Replacement
(Sedan) ...................................... 4297
Rear Side Door Outside Handle Replacement
(Hatchback) .................................. 4-298
Front Side Door Latch Replacement .......... 4-299
Rear Compartment Lid Latch Replacement 4-300
Rear Side Door Latch Replacement ........... 4-301
Front Side Door Lock Cylinder Opening Cover
Replacement ................................. 4-302
4-234 Rear Side Door Lock Cylinder Opening Cover
4-235 Replacement ................................. 4-303
4-236 Front Side Door Locking Rod Replacement 4-304
Front Side Door Lock Cylinder Rod
Replacement ................................. 4-305
4—237
Front Side Door Outside Handle Rod
4—237
Adjustment ................................... 4-306
4—237
Front Side Door Outside Handle Rod
4-237
Replacement ................................. 4-307
4-238
Rear Side Door Looking Rod Replacement
4-241
(Sedan) ...................................... 4—308
Rear Side Door Locking Rod Replacement
4-243
(Hatchback) .................................. 4-309
4-245
Rear Side Door Looking Rod Bellcrank
4-247
Replacement ................................. 4-310
4—249
Rear Side Door Outside Handle Rod
4-253
Adjustment ................................... 4-311
4-256
Rear Side Door Outside Handle Rod
4-258
Replacement (Hatchback) ................... 4-312
4-260
Rear Side Door Outside Handle Rod
4-262
Replacement (Sedan) ........................ 4-313
4-264
Front Side Door Lock Striker Adjustment ...... 4—314
4—264
Front Side Door Lock Striker Replacement .... 4—315
4-268
Liftgate Latch Striker Replacement ............ 4-316
4-271
Rear Compartment Lid Latch Striker
4-275
Replacement ................................. 4-317
4—280
Rear Side Door Lock Striker Adjustment .... . . 4-318
Rear Side Door Lock Striker Replacement . . .. 4—319
Liftgate Release Switch Replacement ......... 4—320
4283
Door Lock Switch Replacement ............... 4-321
4-287
Description and Operation .................... 4-322
Door Ajar Indicator Description and
Operation .................................... 4-322
Luggage Compartment Description and
4-288
Operation .................................... 4-322
Power Door Locks Description and
4—289
Operation .................................... 4—323
Wipers and Washers ........................ 4-324
4291 Specifications .................................. 4-324
Fastener Tightening Specifications ............ 4-324
4—292 Schematic and Routing Diagrams ............ 4-324
Wiper/Washer Schematics .................... 4-325
4-293
44 Table of Contents
Diagnostic Information and Procedures . . . . . .4-328
DTC 83708 .................................... 4—328
DTC 83715 or 83875 .......................... 4—332
DTC 83811 .................................... 4-338
DTC 83873 (withoutC25) ..................... 4-341
DTC 83873 (with C25) ........................ 4-344
Symptoms - Wiper/Washer Systems .......... 4-347
Windshield Wiper System Malfunction . . . . 4-347
Washer Malfunction (withoutC25) ............ 4-353
Washer Malfunction (with C25) ................ 4-356
Rear Wiper System Malfunction ............... 4-359
Rear Washer System Malfunction ............. 4-363
Wiper Blade Element Check .................. 4-365
Repair Instructions ............................. 4-366
Windshield Wiper and Washer Switch
Replacement ................................. 4-366
Windshield Washer Nozzle Hose
Replacement ................................. 4~367
Windshield Washer Nozzle Replacement .... . 4—368
Rear Window Washer Nozzle Replacement .. . 4-369
Windshield Washer Soivent Container Hose
Replacement ................................. 4—370
Windshield Washer Solvent Container Filler
Tube Replacement ........................... 4-371
Windshield Washer Solvent Container
Replacement ................................. 4—372
Windshield Washer Pump Replacement . . .. . .4-373
Air Inlet Grille Panel Replacement ............. 4—374
Windshield Wiper Arm Replacement .......... 4—375
Rear Window WiperArm Replacement . . . 4-376
Windshield Wiper Blade Replacement . . . . 4—377
Rear Window Wiper Blade Replacement . . .. . . 4—378
Windshield Wiper Motor Replacement . . . . 4—379
Rear Window Wiper Motor Replacement
(Hatchback) .................................. 4-380
Windshield Wiper System Module
Replacement ................................. 4-381
Rear Window Wiper Motor Grommet
Replacement ................................. 4-382
Windshield Outside Moisture Sensor Cover
Replacement ................................. 4-383
Windshield Glass Cleaning .................... 4—383
Wiper Blade Element Cleaning ................ 4—383
Wiper Chatter Repair .......................... 4—383
Description and Operation .................... 4—384
Rear Wiper/Washer System Description and
Operation .................................... 4-384
Wiper/Washer System Description and
Operation .................................... 4-384
Special Tools and Equipment ................. 4-386

2013
-Sonic
(US/Canada)
Sen/I'ce
Manual
(5377994)
 Fixed and Moveable Windows 4.5

Fixed and Moveable Windows

Specifications
M»-
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Fastener Tightening Specifications

Specification
Application Metric English
FrontSide DoorWindowGuide Nuts 11N-m 97lb in
FrontSide DoorWindowRear Guide Bolts 11N-m 97lb in
FrontSide DoorWindowRegulatorPower/ManualScrews 11N-m 97lb in
FrontSide DoorWindowRegulatorMotorBolts 5 N-m 44 lb in
RearSide DoorWindowGuide Nuts 11N-m 96lb in
FrontSide DoorWindowRegulatorPower/ManualScrews 11Nm 97lb in
RearSide DoorWindowRear Guide Bolts 11N-m 97lb in
RearSide DoorWindowRegulatorMotorBolts 5 N-m 44 lb in
RearSide DoorWindowWeatherstripLowerScrew 9 N-m 80lb in
RearSide DoorWindowWeatherstripUpperScrew 3 N'm 27lb in

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(US/Canada)
Service
Manual
(5377994)
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2013
-Sonic _ Manual
(US/Canada)
Service (5377994)
 Fixed and Moveable Windows 42-9

Diagnostic Information and Procedures

DTC B0283

Diagnostic Instructions
- Perform the Diagnostic System Check —Vehicle
on page 6-66 prior to using this diagnostic
procedure.
- Review Strategy Based Diagnosis on page 6—58
for an overview of the diagnostic approach.
- Diagnostic Procedure Instructions on page 6-59
provides an overview of each diagnostic category.
DTC Descriptors
DTC 80283 02: Rear Defrost Circuit Short To Ground
DTC 80283 05: Rear Defrost Circuit High Voltage/Open
Diagnostic Fault Information

Open/High Signal
Circuit Short to Ground Resistance Short to Voltage Performance
Controi 8028302 8028305 8028305 -
Ground —— 8028305 —— ~-

CircuitlSystem Description Reference Information

Battery positive voltage is supplied through a 30A fuse Schematic Reference
in the underhood fuse block, to the Rear Defogger
Relay switched input. When the rear window defogger Defogger Schematics on page 4-8
switch is pressed, The HVAC control module
Connector End View Reference
commands the rear window defogger system by
supplying voltage to the Rear Defogger Relay coil. The Component Connector End Views on page 11-269
Rear Defogger Relay is energized and the defogger
indicator is illuminated. With the relay energized, Description and Operation
battery positive voltage is allowed from the relay Rear Window Defogger Description and Operation on
switched input through the switch contacts and out the page 4-69
relay switched output to the rear window defogger grid.
Electrical Information Reference
Conditions for Running the DTC
- Circuit Testing on page 11-526
Battery voltage must be between 9—16V.
- Connector Repairs on page 11—548
Conditions for Setting the DTC ' Testing for IntermittentConditions and Poor
Connections on page 11—531
30283 02
° Wiring Repairs on page 11-537
The HVAC control module detects a short to ground in
the relay coil control circuit. Scan Tool Reference
B0283 05 Control Module References on page 6—3for scan tool
information
The HVAC control module detects a short to voltage or
an open/high resistance in the relay coil control Circuit. CircuitlSystem Verification
Action Taken When the DTC Sets 1. Engine Running.
The rear window defogger will malfunction. 2. Verify the E18 Rear Defogger Grid turns ON and
OFF when pressing the rear window defogger
Conditions for Clearing the DTC switch.
- The DTC will be current for as long as the fault is =>If the E18 Rear Defogger Grid does not turn ON
present. or OFF
. When the fault is no longer present, the DTC will Refer to CircuitlSystem Testing
be a history DTC. U If the E18 Rear Defogger Grid turns ON and OFF
- A history DTC will clear after 50 ignition cycles. 3. All OK.

2013
—Sonic
(US/Canada)
Service
Manual
(5377994)
4='l0 Fixed and Moveable Windows
CircuitlSystem Testing
1. Ignition OFF and all vehicle systems OFF,
disconnect the KR5 Rear Defogger Relay. Itmay
take up to 2 minutes for all vehicle systems to
power down.
2. Test for less than 10 Q between the ground circuit
terminal 85 and ground.
:> If 10 Q or greater
2.1. Ignition OFF.
2.2. Test for less than 2 Q in the ground circuit and
to end.
2 If2 Q or greater, repair the open/high resistance
in the circuit.
=>Ifless than 2 Q, repair the open/high resistance
in the ground connection.
it If less than 10 Q
3. Connect a test lamp between the control circuit
terminal 86 and the ground circuit terminal 85,
Engine Running.
4. Verify the test lamp turns ON and OFF when
pressing the rear window defogger switch.
:> if the test lamp is always OFF
4.1. Ignition OFF, disconnect the harness
connector at the K33 HVAC control module.
4.2. Test for infinite resistance between the control
Circuit and ground.
=>Ifless than infinite resistance, repair the short to
ground on the circuit.
ii Ifinfinite resistance
4.3. Test for less than 2 Q in the control circuit end
to end.
=>If2 Q or greater, repair the open/high resistance
in the circuit.
=>If less than 2 Q, replace the K33 HVAC control
module.
:> If the test lamp is always ON
4.1. Ignition OFF, disconnect the harness
connector at the K33 HVAC control module,
Engine Running.
4.2. Test for less than 1 V between the control
circuit and ground.
=>lf1 V or greater, repair the short to voltage on
the circuit.
=>if less than 1 V, replace the K33 HVAC control
module.
U If the test lamp turns ON and OFF
5. Test or replace the KR5 Rear Defogger Relay.
Component Testing
Relay Test
1. IgnitionOFF, disconnect the KR5 Rear Defogger
Relay.
2. Test for 60—180Q between terminals 85 and 86.
2 If less than 60 Q or greater than 180 Q
Replace the KR5 Rear Defogger Relay.
U If between 60-180 Q
3. Test for infinite resistance between the terminals
listed below:
- 30 and 86
0 30 and 87
- 30 and 85
- 85 and 87
=>If less than infinite resistance
Replace the KR5 Rear Defogger Relay.
<=lf infinite resistance
4. Install a 3 A fused jumper wire between relay
terminal 85 and 12 V. Install a jumper wire between
relay terminal 86 and ground.
5. Test for less than 2 Q between terminals 30 and 87.
=>If 2 Q or greater
Replace the KR5 Rear Defogger Relay.
U If less than 2 Q
6. All OK
Repair Instructions
Perform the Diagnostic Repair Verification on
page 6-92 after completing the repair.
- Re/ay Replacement (Within an Electrical Center)
on page 11-607or Relay Replacement (Attached
to Wire Harness) on page 11~607
- Control Module References on page 6-3 for the
HVAC control module replacement, programming
and setup

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Fixed and Moveable Windows 4211

DTC B3168

Diagnostic Instructions
- Perform the Diagnostic System Check - Vehicle
on page 6-66 prior to using this diagnostic
procedure.
- Review Strategy Based Diagnosis on page 6—58
for an overview of the diagnostic approach.
0 Diagnostic Procedure Instructions on page 6—59
provides an overview of each diagnostic category.
DTC Descriptor
DTC 83168 00: Driver Window Switch Malfunction
Diagnostic Fault Information

Open/High Signal
Circuit Short to Ground Resistance Short to Voltage Performance
DriverWindowMotorControl 8316800 1 1 -
1.DriverWindowMalfunction

CircuitlSystem Description Description and Operation

The driver window motor is supplied with 8+ voltage Power Windows Description and Operation on
which is used to power the motor and also used as a page 4-59
reference voltage within the logic circuit. When the . ,
driver window switch is pressed, a switch is closed Electrical Informatlon Reference
causing the reference voltage in the appropriate circuit . Circuit Testing on page 11-526
in the window motor to drop, the window motor
responds by moving the window in the direction '
Connector Repairs 0” page ""548
commanded. ' and Poor
Easting :or Intermittentfioggcrztions
. . , onnec tons on page -
CondItIons for RunnIng the DTC . Wiring Repairs on page 114537
Battery voltage must be between 9—16V. Scan Tool Reference

CondItIons for SettIng the DTC Control Module References on page 6-3 for scan tool
The driver window motor has detected the driver left information .
front window switch is active for greater than . . . . .
60 seconds. CIrCUItISystem VerIfIcatIon

Action Taken When the DTC Sets 1' Ign‘.t'°nON' .

. . , . 2. VerIfy the scan tool parameters lIsted below
The drIverpower WindowWIII malfunctIon. change when pressing and pulling the?driver
Conditions for Clearing the DTC wégiigwcontrol sw1tchon the drIver WIndowmaster
. The DTC will be current for as long as the fault is , Driver Window Main Control Down Switch _
present. Inactive and Active
- The DTC will change from current to history when , Driver Window Main Control Up Switch _
the fault is no longer present. inactive and Active
- A history DTC will clear after 100 consecutive , Driver Window Main Control Express Switch _
ignition cycles if the condition for the malfunction Inactive and Active
is no longer present.
=>If any parameter does not change
Reference Information Refer to CircuitlSystem Testing
Schematic Reference U If all the parameters change
Moveable Window Schematics on page 4-6 3- A” OK-
Connector End View Reference
Component Connector End Views on page 11—269

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4=12 Fixed and Moveable Windows
CircuitlSystem Testing
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.
2. Test for less than 10 Q between the ground circuit
terminal11 and ground.
2 If 10 Q or greater
2.1. IgnitionOFF.
2.2. Test for less than 2 Q in the ground circuit end
to end.
2 If2 Q or greater, repair the open/high resistance
in the circuit.
2 If less than 2 Q, repair the open/high resistance
in the ground connection.
U If less than 10 Q
9*”Ignition ON.
4. Verify the scan tool Driver Window Main Control
Down Switch parameter is Inactive.
2 If not Inactive
4.1. ignition OFF, disconnect the harness
connector at the M74D Window Motor-Driver.
4.2. Test for infinite resistance between the S79D
Window Switch-Driver signal circuit terminal 8
and ground.
2 If less than infinite resistance, repairthe shortto
ground on the circuit.
2 Ifinfinite resistance, replace the M74D Window
Motor-Driver. ,
U If Inactive
5. Install a 3 A fused jumper wire between the signal
circuit terminal 8 and the ground circuit terminal 11.
6. Verify the scan tool Driver Window Main Control
Down Switch parameter is Active
2 If not Active
6.1. ignition OFF, remove the 3 A fused jumper
wire, disconnect the harness connector at the
M74D Window Motor-Driver, ignition ON.
6.2. Test for less than 1 V between the S79D
Window Switch-Driver signal circuit terminal 8
and ground.
2 If 1 V or greater, repair the short to voltage on
the circuit.
U if less than 1 V
6.3. Test for less than 2 Q in the signal circuit and
to end.
2 If2 Q or greater, repair the open/high resistance
in the circuit.
2 if less than 2 Q, replace the M74D Window
Motor—Driver.
U If Active
7. Verify the scan tool Driver Window Main Control
Up Switch parameter is inactive.
2 If not Inactive
7.1. IgnitionOFF, disconnect the harness
connector at the M74D Window Motor-Driver.
7.2. Test for infinite resistance between the S79D
Window Switch-Driver signal circuit terminal 9
and ground.
2 If less than infinite resistance, repairthe short to
ground on the circuit.
2 If infinite resistance, replace the M74D Window
Motor—Driver.
U If Inactive
8. Install a 3 A fused jumperwire between the signal
circuit terminal 9 and the ground circuit terminal 11.
9. Verify the scan tool Driver Window Main Control
Up Switch parameter is Active
2 If not Active
9.1. IgnitionOFF, remove the 3 A fused jumper
wire, disconnect the harness connector at the
M74D Window Motor—Driver,ignition ON.
9.2. Test for less than 1 V between the S79D
Window Switch—Driversignal circuit 9 and
ground.
2 If 1 Vor greater, repair the short to voltage on
the circuit.
U If less than 1 V
9.3. Test for less than 2 Q in the signal circuit end
to end.
2 If2 Q or greater, repair the open/high resistance
in the circuit.
2 If less than 2 Q, replace the M74D Window
Motor—Driver.
U lf Active
10. Verify the scan tool Driver Window Main Control
Express Switch parameter is Inactive.
2 If not inactive
10.1. IgnitionOFF, disconnect the harness
connector at the M74D Window Motor-Driver.
10.2. Test for infinite resistance between the S79D
Window Switch-Driver signal circuit terminal
10 and ground.
2 Ifless than infinite resistance, repair the short to
ground on the circuit.
2 If infinite resistance, replace the M74D Window
Motor—Driver.
U If Inactive
11. Install a 3 A fused jumper wire between the signal
circuit terminal 10 and the ground circuit
terminal 11.
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 Fixed and Moveable Windows 4-13
3 12. Verify the scan tool Driver Window Main Control - Ground terminal 11 and control terminal 9
Express Switch parameter is Active - Ground terminal 11 and control terminal 10
2 If not Active 2 If less than infinite resistance
12.1. IgnitionOFF, remove the 3 A fused jumper Replace the S79D Window Switch—Driver.
wire, disconnect the harness connector at
the M74D Window Motor—Driver,ignition ON. U If infinite resistance
12.2. Test for less than 1 V between the S79D 3. Test for less than 3 Q between the ground terminal
Window Switch-Driver signal circuit 10 and 11and the control terminal 9 with the switch in the
ground. Up position.
2 If 1 V or greater, repair the short to voltage on 2 If 3 Q or greater
the circuit. Replace the S79D Window Switch—Driver.
U Ifless than 1 V U If less than 3 Q
12.3. Test for less than 2 Q in the signal circuit end 4. Test for less than 3 Q between the ground terminal
to end. 11and the control terminal 8 with the switch in the
2 If2 Q or greater, repair the open/high resistance Down position.
in the circuit. 2 If 3 Q or greater
2 Ifless than 2 Q, replace the M74D Window Replace the S79D Window Switch—Driver.
Motor-Driver.
U If less than 3 Q
U lf Active 5. All OK
13. Test or replace the S79D Window Switch-Driver.
Repair Instructions
Component Testing
Perform the Diagnostic Repair Verification on
Driver Window Switch page 6-92 after completing the repair.
1. Ignition OFF, disconnect the harness connector at - Front Side Door Window Regulator Motor
the S79D Window Switch—Driver. Replacement on page 4-43
2. Test for infinite resistance between the terminals - Front Side Door Window Switch Replacement
listed below with the switch in the open position: (Left Side) on page 4-38 or Front Side Door
' Groundterminal11 and control terminal 7 Window Switch Replacement (Right Side) on
page 4-39
- Groundterminal11 and control terminal 8

t 2013
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Sonic
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444 Fixed and Moveable Windows

DTC B3205

Diagnostic Instructions
' Perform the Diagnostic System Check - Vehicle
on page 6-66 prior to using this diagnostic
procedure.
- Review Strategy Based Diagnosis on page 6-58
for an overview of the diagnostic approach.
' Diagnostic Procedure Instructions on page 6-59
provides an overview of each diagnostic category.
DTC Descriptors
DTC 83205: Driver Window Motor
For symptom byte information refer to: Symptom Byte Action Taken When the DTC Sets
List on page 6—85
The driver power window will malfunction.
CircuitlSystem Description
Conditions for Clearing the DTC
The body control module (BCM) monitors, receives and
transmits serial data to each of the doors switches and B3205 00
window motors. When a window switch has been Installing a compatible window motor for that specific
activated on the driver window switch, a signal is sent make and model vehicle.
to the BCM which sends a signal to the appropriate
window motor and the window motor will move in the B3205 39
direction commanded. The driver window motor must be replaced before the
DTC can be cleared.
Conditions for Running the DTC
- The ignition switch is in the ON position. B3205 42
- Battery voltage must be between 9—16V. The driver window motor must be replaced before the
DTC can be cleared.
Conditions for Setting the DTC
33205 4B
B3205 00 The driver window motor must be normalized before
The BCM has detected that the compatibility code the DTC can be cleared.
stored in the driver window motor does not match the
compatibility code stored in the BCM. Reference Information
B3205 39 Schematic Reference
An internal malfunction has been detected by the BCM Moveable Window Schematics on page 4—6
in the driver window motor while commanding the
window UP or DOWN. Connector End View Reference

B3205 42 Component Connector End Views on page 11—269

The BCM wiil automatically attempt to download the Description and Operation
calibration program into the driver window motor (As Power Windows Description and Operation on
will occur when the window motor has been replaced), page 4-69
if the first calibration program fails to load, the BCM will
attempt to download the calibration program a second Electrical Information Reference
time. Ifthis download fails, the BCM will set
appropriate DTC. . Circuit Testing on page 11-526
° Connector Repairs on page 11-548
B3205 4B
. Testing for IntermittentConditions and Poor
The BCM has detected that the driver window is not Connections on page 11-531
“normalized” and can set for the following reasons: ' Wiring Repairs on page 11-537
~ When the battery has been disconnected
Scan Tool Reference
- When the battery has been replaced
o When the door wiring harness has been Control Module References on page 6-3 for scan tool
disconnected information
- When the window motor has been disconnected.

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 Fixed and Moveable Windows 4-15

CircuitlSystem Verification VisuaI/Physical Inspection

1. Ignition ON
2. Verify the driverwindow functions while
commanding the Driver Window Motor Up and
Down with a scan tool.
2 If the Up and Down does not work
Replace the M74D Window Motor — Driver.
U If the UP and DOWN works
3. Verify the driverwindow performs the Express Up
and Express Down functions with the driver
window switch. ' -
2 If the driver window does not Express Up and
Express Down
Normalize the driver window motor, refer to
Window Motor Programming —Express
Function on page 4-42.
U If the driver window performs the Express Up
and Express Down functions
4. All OK.
Repair Instructions
Perform the Diagnostic Repair Verification on
page 6-92 after completing the repair.
Front Side Door Window Regulator Motor Replacement
on page 4-43
Symptoms - Fixed and Moveable
Windows
Important Preliminary Checks Before Starting:
1. Perform the Diagnostic System Check - Vehicle on
page 6-66 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 power window system operation or rear
window defogger system operation in order to
familiarize yourself with the system functions.
Refer to the following:
- Rear Window Defogger Description and
Operation on page 4-69
- Power Windows Description and Operation on
page 4-69
~ Inspect for aftermarket devices which could affect
the operation of the rear window defogger. Refer
to Checking AftermarketAccessories on
page 11—525. ,
- Inspect the easily accessible or visible system
components for obvious damage or conditions
which could cause the symptom.
Intermittent
Note:
Inspect for proper installation of electrical
components if an intermittentcondition exists.
Inspect for aftermarket theft deterrent devices,
lights, and cellular phones. Ensure that no
aftermarket equipment is connected to the class 2
circuit. Ifyou can not locate an intermittent
condition, a cellular phone signal may cause the
condition. Faulty electrical connections or wiring
may be the cause of intermittentconditions. Refer
to Testing for IntermittentConditions and Poor
Connections on page 11-531.
- 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
intermittentconditions. The malfunction must be
present in order to locate the problem.
Poor electrical connections or wiring cause most
intermittentconditions. 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 intermittentcondition. 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
Refer to a symptom diagnostic procedure from the
following list in order to diagnose the symptom:
- Rear Window Defogger Malfunction on page 4—16
- Power Windows Malfunction on page 4-18

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4a'l6 Fixed and Moveable Windows

Rear Window Defogger Malfunction

Diagnostic Instructions
- Perform the Diagnostic System Check - Vehicle
on page 6-66 prior to using this diagnostic
procedure.
- Review Strategy Based Diagnosis on page 6-58
for an overview of the diagnostic approac h.
- Diagnostic Procedure Instructions on page 6-59
provides an overview of each diagnostic category.
Diagnostic Fault Information

Open/High Signal
Circuit Short to Ground Resistance Short to Voltage Performance
Relay 8+ 1 1 — -
RelayControl 8028302 8028305 8028305 -
RelayGround — 8028305 —— -
Rear DefoggerGridControl 1 1 2 -
Rear DefoggerGridGround —~ 1 — -
1. Rear DefoggerGridlnoperative
2. Rear DefoggerGridAlwaysON

CircuitlSystem Description CircuitlSystem Verification

Battery positive voltage is supplied through 3 30A fuse 1. Engine running.
in the underhood fuse block, to the rear defogger reIay 2. Verify the scan tool Rear Defogger Switch
switched input. When the rear window defogger switch parameter changes between Active and Inactive
is pressed, The HVAC control module commands the when pressing the rear window defogger switch.
rear window defogger system by supplying voltage to
the rear defogger relay coil. The rear defogger relay is 2 If the parameter does not change between
energized and the defogger indicator is illuminated. Active and Inactive
With the relay energized, battery positive voltage is Replace the K33 HVAC control module.
allowed from the relay switched input through the U If the parameter changes between Active and
switch contacts and out the relay switched output to the Inactive
rear window defogger grid.
3. Verify the E18 Rear Defogger Grid turns ON and
Reference Information OFF when pressing the rear window defogger
switch.
Schematic Reference
2 If the E18 Rear Defogger Grid does not turn ON
Defogger Schematics on page 4—8 and OFF
Connector End View Reference Refer to CircuitlSystem Testing
Component Connector End Views on page 11-269 (z If the E18 Rear Defogger Grid turns 0N and OFF
4. Verify the rear window defog indicator turns ON
Description and Operation and OFF when commanding the IlluminateAll
Rear Window Defogger Description and Operation on Indicators On and Off with a scan tool.
page 4-69 2 If the rear window defog indicator does not turn
ON and OFF
Electrical Information Reference
Replace the K33 HVAC control module.
- Circuit Testing on page 11-526
U If the rear window defog indicator turns ON
- Connector Repairs on page 11—548 and OFF
- Testing for IntermittentConditions and Poor 5. All OK.
Connections on page 11-531
~ Wiring Repairs on page 11—537
Scan Tool Reference
Control Module References on page 6-3 for scan tool
information

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 Fixed and Moveable Windows 41-17

CircuitlSystem Testing
1. ignition OFF and all vehicle systems OFF,
disconnect the KR5 Rear Defogger Relay. Itmay
take up to 2 minutes for all vehicle systems to
power down.
Test for less than 10 Q between the ground circuit
terminal 85 and ground.
If 10 Q or greater
2.1. IgnitionOFF.
2.2. Test for less than 2 Q in the ground circuit end
to end.
2 If2 Q or greater, repair the open/high resistance
in the circuit.
2 If less than 2 Q, repair the open/high resistance
in the ground connection.
If less than 10 Q
.0" Engine Running
Verify a test lamp illuminates between the 8+
circuit terminal 30 and ground.
If the test lamp does not illuminate
2 Replace the X50A Fuse Block—Underhood
If the test lamp illuminates
Connect a test lamp between the control circuit
terminal 86 and the ground circuit terminal 85.
Verify the test lamp turns ON and OFF pressing the
rear window defogger switch.
If the test lamp is always OFF
6.1. IgnitionOFF, remove the test lamp, disconnect
the harness connector at the K33 HVAC
Control Module.
6.2. Test for infinite resistance between the control
circuit and ground.
2 Ifless than infinite resistance, repair the short to
ground on the circuit.
U If infinite resistance
6.3. Test for less than 2 Q in the control circuit end
to end.
2 If2 Q or greater, repair the open/high resistance
in the circuit.
2 If less than 2 Q, replace the K33 HVAC Control
Module.
If the test lamp is always ON
6.1. IgnitionOFF, remove the test lamp, disconnect
the harness connector at the K33 HVAC
Control Module, ignition ON.
6.2. Test for less than 1 V between the control
circuit and ground.
2 If 1 V or greater, repair the short to voltage on
the circuit.
2 Ifless than 1 V, replace the K33 HVAC Control
Module.
If the test lamp turns ON and OFF
. Verify that a test lamp does not illuminate between
the control Circuit terminal 87 and ground.
If the test lamp illuminates
Repair the short to voltage on the control circuit
If the test lamp does not illuminate
IgnitionOFF and all vehicle systems OFF,
disconnect the X2 harness connector at the E18
Rear Defogger Grid. Itmay take up to 2 minutes for
all vehicle systems to power down.
. Test for less than 10 Q between the ground circuit
terminal 1 and ground.
If 10 Q or greater
9.1. IgnitionOFF.
9.2. Test for less than 2 Q in the ground circuit and
to end.
2 If2 Q or greater, repair the open/high resistance
in the circuit.
2 if less than 2 Q, repair the open/high resistance
in the ground connection.
If less than 10 Q
. Connect the X2 harness connector at the E18 Rear
Defogger Grid.
. IgnitionON, connect a 30 A fused jumper wire
between the 8+ circuit terminal 30 and the control
circuit terminal 87.
. Verify the E18 Rear Defogger Grid is activated.
If the E18 Rear Defogger Grid does not activate
12.1. Ignition OFF, remove thejumperwire,
disconnect the X1 harness connector at the
E18 Rear Defogger Grid.
12.2. Test for infinite resistance between the
control circuit and ground.
2 If less than infinite resistance, repair the short to
ground on the circuit.
U If infinite resistance
12.3. Test for less than 2 Q in the control circuit end
to end.
2 If2 Q o‘r'greater,repair the open/high resistance
in the circuit.
2 If less than 2 Q, replace the E18 Rear
Defogger Grid.
U If the E18 Rear Defogger Grid activates
13. 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 Q between terminals 85 and 86.
:> If less than 60 Q or greater than 180 Q
Replace the KR5 Rear Defogger Relay.
U If between 60-180 Q
3. Test for infinite resistance between the terminals
listed below:
- 30 and 86
- 30 and 87

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4=l8 Fixed and Moveable Windows
- 30 and 85
° 85 and 87
:> If less than infinite resistance
Replace the KR5 Rear Defogger Relay.
If infinite resistance
Install a 3 A fused jumper wire between relay
terminal 85 and 12V. Install a jumper wire between
relayterminai 86 and ground.
9‘ Test for less than 2 Q between terminals 30 and 87.
2 If 2 Q or greater
Replace the KR5 Rear Defogger Relay.
U If less than 2 Q
6. All OK
Rear Defogger Grid Test
Note: Lightly touch the grid lines when testing with the
test lamp. Ifthe 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
U If the test lamp remains dim at the middle of
each grid line.
3. All OK
Repair Instructions
Perform the Diagnostic Repair Verification on
page 6—92after completing the diagnostic procedure.
Relay Replacement (Within an Electrical Center)
on page 11-607or Relay Replacement (Attached
to Wire Harness) on page 11-607
Rear Window Replacement on page 4-34
Liftgate Window Replacement on page 4-36
Control Module References on page 6—3for HVAC
Control Module replacement, programming and
setup

Power Windows Malfunction

Diagnostic Instructions
Perform the Diagnostic System Check - Vehicle
on page 6—66prior to using this diagnostic
procedure.
Review Strategy Based Diagnosis on page 6-58
for an overview of the diagnostic approach.
Diagnostic Procedure Instructions on page 6-59
provides an overview of each diagnostic category.
Diagnostic Fault Information

Open/High Signal
Circuit Short to Ground Resistance Short to Voltage Performance
DriverWindowSwitchIgnition,Terminal6 7, 9 7, 9 — -
DriverWindowSwitchIgnition,Terminal13 2, 5 4 — —-
DriverWindowSwitchGround — 1 — —-
DriverWindowMotor8+ U153400 U153400 — -
DriverWindowMotorDownControl 83168 02 2 2 ~-
DriverWindowMotorExpressControl 83168 02 2 2 —-
DriverWindowMotorUpControl 83168 02 2 2 --
DriverWindowMotorGround — U153400 —— -
PassengerWindowSwitchIgnition 2, 5 3 — -
PassengerWindowSwitchSignal 2, 5 5 5 -

(US/Canada)
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2013 (5377994)
Manual
Service
 Fixed and Moveable Windows 4-19

OpenIHigh Signal
Circuit Short to Ground Resistance Short to Voltage Performance
PassengerWindowMotorControl 2, 5 5 5 —-
LeftRearWindowSwitchSignal 7, 9 7 7 -
LeftRearWindowSwitchLockoutControl 7, 9 6 10 -
LeftRearWindowMotorControi ; 7, 9 7 -
RightRearWindowSwitchSignal 7, 9 9 -
RightRearWindowSwitchLockoutControl 7, 9 8 1O —-
RightRearWindowMotorControl 7, 9 9 9 -
1.All PowerWindowslnoperative
2. DriverWindowlnoperative
3. PassengerWindowlnoperativefromPassengerSwitch
4. PassengerWindowlnoperativefromDriverSwitch
5. PassengerWindowlnoperativefromDriverandPassengerSwitches
6. LeftRearWindowlnoperativefromLeftRearSwitch
7. LeftRearWindowlnoperativefromDriverandLeftRearSwitches
8. RightRearWindowlnoperativefromRightRearSwitch
9. RightRearWindowlnoperativefromDriverandRightRearSwitches
10.RearWindowLockoutlnoperative

CircuitlSystem Description Diagnostic Aids

The driver side window consists of a driver window A window motor that has not been normalized will no
switch and a window motor capable of express up and longer perform the express up and express down
express down functions. When the driver window functions, this may occur during the following
switch is pressed or pulled, the voltage within the conditions:
appropriate signal circuit drops and the window motor ' When a window motor has been disconnected
will then performthe commanded function.
' When a door harness has been disconnected
The driver power window switch contains individual
window switches for each of power windows. All - When the battery has been disconnected or
windows may be controlled up and down from the driver replaced
power window switch. The individual passenger power To normalize the window motor refer to Window Motor
window switches will only control the up and down Programming - Express Function on page 4—42.
operation of their respective powerwindow.
Reference Information
Each power window contains a reversible power
window motor.The direction the window travels is Schematic Reference
dependent upon the polarity of the supply voltage. 8y
reversing polarity of the supply voltage the window Moveable Window Schematics on page 4-6
motor will move up or down. Each power window motor Connector End View Reference
is internally circuit breaker protected.
Battery voltage is supplied to the power window switch Component Connector End Views on page 11—269
through the accessory voltage supply circuit. The Description and Operation
power window switch also receives a constant ground
source. The power window motor control circuits are Power Windows Description and Operation on
connected to ground through the normally closed up page 4—69
and down contacts of the power window switch. When Electrical Information Reference
the power switch is placed in the down position, the
power window motor down control circuit is switched to - Circuit Testing on page 11-526
12 Vand is applied to the down side of the power - Connector Repairs on page 11-548
window motor.Since the other side of the power motor
° Testing for IntermittentConditions and Poor
is connected to ground through the normally closed
Connections on page 11—531
contacts of the up switch, the window travels down. By
placing the power window switch in the up position, the - Wiring Repairs on page 11-537
polarity of the power window motor is reversed and the Scan Tool Reference
window travels up.
Control Module References on page 6-3 for scan tool
information

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4.20 Fixed and Moveable Windows
CircuitlSystem Verification
1 ignition ON
2. Verify the M74D Window Motor—Driverfunctions
while commanding the Driver Window Motor Up
and Down with a scan tool.
2 If the M74D Window Motor-Driver does not
move UP and DOWN as commanded
Refer to CircuitlSystem Testing — Driver
Window Motor Malfunction.
U If the M74D Window Motor-Driver moves UP
and DOWN as commanded
3. Verify the M74D Window Motor-Driver moves while
commanding the window UP and DOWN with the
S79D Window Switch—Driver.
2 If the M74D Window Motor-Driver does not
move UP and DOWN as commanded
Refer to CircuitlSystem Testing — Driver
Window Switch Malfunction.
U If the M74D Window Motor-Driver moves UP
and DOWN as commanded
4. Verify the M74D Window Motor—Driverperforms the
express UP and express DOWN functions with the
S79D Window Switch-Driver.
2 If the driver window does not express UP or
express DOWN
Normalize the M74D Window Motor—Driver,
refer to Window Motor Programming - Express
Function on page 4-42.
4.1. Verify the M74D Window Motor—Driver
performs the express UP and express DOWN
functions with the S79D Window Switch—Driver
2 If the M74D Window Motor-Driver does not
express UP or express DOWN
Refer to CircuitlSystem Testing — Driver
Window Switch Malfunction.
U If the M74D Window Motor-Driver performs the
express UP and express DOWN functions
5. Verify the M74P Window Motor-Passenger
performs the UP and DOWN functions at both the
S798 Window Switch—Driverand S79P Window
Switoh-Passenger.
2 If the M74P Window Motor-Passenger is
inoperative from both the S79D Window
Switch-Driver and S79P Window
Switch-Passenger
Refer to CircuitlSystem Testing - Passenger
Window lnoperative From 80th Switches.
2 If the M74P Window Motor-Passenger is
inoperative from the S79P Window
Switch-Passenger only
Refer to CircuitlSystem Testing ~ Passenger
Window lnoperative From A Single Switch.
2 If the M74P Window Motor—Passenger is
inoperative from the S79D Window
Switch-Driver only
Refer to CircuitlSystem Testing —Passenger
Window lnoperative From A Single Switch.
If the M74P Window Motor-Passenger performs
the UP and DOWN functions at both
l.
S79D Window Switch-Driver and S79P Window
‘
Switch-Passenger
Verify the left rear and right rear M74 Window
Motor performs the UP and DOWN functions at
both the S79D Window Switch-Driver and each of
the rear 879 Window Switch.
If a M74 Window Motor is inoperative from both
the driver and rear window switch
Refer to CircuitlSystem Testing —Rear Window
lnoperative From 80th Switches
If a rear M74 Window Motor is inoperative from
the rear window switch only
Refer to CircuitlSystem Testing —Rear Window
Switch lnoperative
If a M74 Window Motor is inoperative from the
driver window switch only
Test or replace the S79D Window Switch—Driver.
If the M74 Window Motor performs the UP and
DOWN functions at both the S79D Window
Switch-Driver and the rear 879 Window Switch
. Look out the rear window switches by pressing the
lockout switch on the S79D Window Switoh-Driver.
. Verify the left rear and right rear M74 Window
Motor is inoperative at both of the rear 879 Window
Switch .
If both rear M74 Window Motor continue to
function from the rear 879 Window Switch
Refer to CircuitlSystem Testing —Rear Window
Lockout lnoperative
U If both rear M74 Window Motor is inoperative
from the rear S79 Window Switch
9. All OK.
CircuitlSystem Testing
Driver Window Motor Malfunction
1. IgnitionOFF and all vehicle systems OFF,
disconnect the harness connector at the
M74D Window Motor—Driver.Itmay take up to
2 minutes for all vehicle systems to power down.
Test for less than 10 Q between the ground circuit
terminal 1 and ground.
If 10 Q or greater
2.1. IgnitionOFF.
2.2. Test for less than 2 Q in the ground circuit and
to end.
2 If2 Q or greater, repair the open/high resistance
in the circuit.
2 If less than 2 Q, repair the open/high resistance
in the ground connection.
U If less than 10 Q
3. ignition ON.
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4. Verify a test lamp illuminates between the 8+
circuit terminal 2 and ground.
:> If the test lamp does not illuminate and the
circuit fuse is good
4.1. IgnitionOFF.
4.2. Test for less than 2 Q in the 8+ circuit and
to end.
2 If2 Q or greater, repair the open/high resistance
in the circuit.
2 Ifless than 2 Q, verify the fuse is not open and
there is voltage at the fuse.
If the test lamp does not illuminate and the
circuit fuse is open
4.1. IgnitionOFF.
4.2. Test for infinite resistance between the 8+
circuit and ground.
2 Ifless than infinite resistance, repair the short to
ground on the circuit
2 If infinite resistance, replace the M74D Window
Motor-Driver.
If the test lamp illuminates
Test for 5—10 V between the serial data circuit
terminal 4 and ground
If less than 5 V
5.1. IgnitionOFF, disconnect the harness
connector at the K9 Body Control Module.
5.2. Test for infinite resistance between the serial
data circuit and ground.
2 Ifless than infinite resistance, repair the short to
ground on the circuit.
U Ifinfinite resistance
5.3. Test for less than 2 Q in the serial data circuit
end to end.
2 If2 Q or greater, repair the open/high resistance
on the circuit.
2 Ifless than 2 Q, replace the K9 Body Control
Module.
If greater than 10 V
5.1. IgnitionOFF, disconnect the harness
connector at the K9 Body Control Module,
ignition ON.
5.2. Test for less than 1 V between the serial data
circuit and ground.
. 2 If 1 Vor greater, repair the short to voltage on
the circuit.
U Ifless than 1 V, replace the K9 Body Control
Module.
U If between 5—10V
6. Replace the M74D Window Motor—Driver.
Fixed and Moveable Windows 4-21
Driver Window Switch Malfunction
1. IgnitionOFF and all vehicle systems OFF,
disconnect the harness connector at the S79D
Window Switch-Driver. Itmay take up to 2 minutes
for all vehicle systems to power down.
Test for less than 10 Q between the ground circuit
terminal 11 and ground.
If 10 Q or greater
2.1. ignition OFF.
2.2. Test for less than 2 Q in the ground circuit end
to end.
2 It2 Q or greater, repair the open/high resistance
in the circuit.
2 Ifless than 2 Q, repairthe open/high resistance
in the ground connection.
if less than 10 Q
9’ IgnitionON.
Verify the scan tool Driver Window Main Control
Down Switch parameter is Inactive.
If not Inactive
4.1. Ignition OFF, disconnect the harness
connector at the M74D Window Motor—Driver.
4.2. Test for infinite resistance between the signal
circuit terminal 8 and ground.
2 Ifless than infinite resistance, repair the short to
ground on the circuit.
2 Ifinfinite resistance, replace the M74D Window
Motor-Driver.
If Inactive
install a 3 A fused jumper wire between the signal
circuit terminal 8 and the ground circuit terminal 11.
Verify the scan tool Driver Window Main Control
Down Switch parameter is Active
If not Active
6.1. IgnitionOFF, disconnect the harness
connector at the M74D Window Motor—Driver,
ignition ON.
6.2. Test for less than 1 V between the signal
circuit terminal 8 and ground.
2 If 1 V or greater, repair the short to voltage on
the circuit.
U -Ifless than 1 V
6.3. Test for less than 2 Q in the signal circuit end
to end.
2 If2 Q or greater, repair the open/high resistance
in the circuit.
2 Ifless than 2 Q, replace the M74D Window
Motor-Driver.
If Active

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4122 Fixed and Moveable Windows
7. Verify the scan tool Driver Window Main Control
Up Switch parameter is Inactive.
:> If not Inactive
7.1. Ignition OFF, disconnect the harness
connector at the M74D Window Motor-Driver.
7.2. Test for infinite resistance between the signal
circuit terminal 9 and ground.
2 Ifless than infinite resistance, repair the short to
ground on the circuit.
2 if infinite resistance, replace the M74D Window
Motor—Driver.
If Inactive
Install a 3 A fused jumper wire between the signal
circuittermina19 and the ground circuit terminal 11.
Verify the scan tool Driver Window Main Control
Up Switch parameter is Active
If not Active
9.1. Ignition OFF, disconnect the harness
connector at the M74D Window Motor-Driver,
ignition ON.
9.2. Test for less than 1 V between the signal
circuit terminal 9 and ground.
2 If 1 V or greater, repair the short to voltage on
the circuit.
U If less than 1 V
9.3. Test for less than 2 Q in the signal circuit end
to end.
2 If2 Q or greater, repair the open/high resistance
in the circuit.
2 If less than 2 Q, replace the M74D Window
Motor-Driver.
If Active
. Verify the scan tool Driver Window Main Control
Express Switch parameter is Inactive.
If not Inactive
10.1. Ignition OFF, disconnect the harness
connector at the M74D Window Motor—Driver.
10.2. Test for infinite resistance between the signal
circuit terminal 7 and ground.
2 If less than infinite resistance, repair the short to
ground on the circuit.
2 If infinite resistance, replace the M74D Window
Motor-Driver.
U If Inactive
. Install a 3 A fused jumper wire between the signal
circuit terminal 7 and the ground circuit terminal 11.
12. Verify the scan tool Driver Window Main Control
Express Switch parameter is Active
2 If not Active
12.1. IgnitionOFF, disconnect the harness
connector at the M74D Window Motor-Driver,
ignition ON.
12.2. Test for less than 1 V between the signal
circuit terminal 7 and ground.
2 |f1 V or greater, repair the short to voltage on
the circuit.
U Ifless than 1 V
12.3. Test for less than 2 Q in the signal circuit end
to end.
2 If2 Q or greater, repair the open/high resistance
in the circuit.
2 Ifless than 2 Q, replace the M74D Window
Motor-Driver.
U If Active
13. Test or replace the S79D Window Switoh-Driver.
Passenger Window lnoperative From Both Switches
1. ignition OFF and all vehicle systems OFF,
disconnect the harness connector at the
S79P Window Switch-Passenger. it may take up to
2 minutes for all vehicle systems to power down.
. Test for less than 10 Q between the control circuit
terminal 3 and ground.
If 10 Q or greater
2.1. IgnitionOFF, disconnect the harness
connector at the S79D Window Switch-Driver.
2.2. Test for less than 2 Q in the control circuit and
to end.
2 If2 Q or greater, repair the open/high resistance
in the circuit.
2 Ifless than 2 Q, replace the S79D Window
Switch—Driver.
If less than 10 Q
Test for less than 10 Q between the control circuit
terminal 6 and ground.
If 10 Q or greater
3.1. IgnitionOFF, disconnect the harness
connector at the S79D Window Switch-Driver.
3.2. Test for less than 2 Q in the control circuit end
to end.
2 If2 Q or greater, repair the open/high resistance
in the circuit.
2 Ifless than 2 Q, replace the S79D Window
Switch-Driver.
c If less than 10 Q
. Connect a test lamp between the control circuit
terminal 3 and control circuit terminal 6,
ignition ON.
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5. Verify the test lamp turns ON when commanding
the UP and DOWN functions with the
S79D Window Switch-Driver.
If the test lamp remains OFF during either of the
commands
5.1. IgnitionOFF, disconnect the harness
connector at the S79D Window Switch-Driver.
5.2. Test for infinite resistance between each
control circuit and ground.
2 Ifless than infinite resistance, repair the short to
ground on the circuit.
2 Ifinfinite resistance, replace the S79D Window
Switch-Driver.
If the test lamp turns 0N during each of the
commands
. Ignition OFF and all vehicle systems OFF, connect
the harness connector at the S79P Window
Switch-Passenger and disconnect the harness
connector at the M74P Window Motor—Passenger.
Itmay take up to 2 minutes for all vehicle systems
to power down.
. Test for less than 10 Q between the control circuit
terminal A and ground.
If 10 Q or greater
7.1. IgnitionOFF, disconnect the harness
connector at the S79P Window
Switch-Passenger.
7.2. Test for less than 2 Q in the control circuit end
to end.
2 If2 Q or greater, repair the open/high resistance
in the circuit.
2 Ifless than 2 Q, replace the S79P Window
Switch-Passenger.
If less than 10 Q
. Test for less than 10 Q between the control circuit
terminal 8 and ground.
If 10 Q or greater
8.1. ignition OFF, disconnect the harness
connector at the S79P Window
Switch-Passenger.
8.2. Test for less than 2 Q in the control circuit end
to end.
2 if 2 Q or greater, repair the open/high resistance
in the circuit.
2 If less than 2 Q, replace the S79P Window
Switch—Passenger.
If less than 10 Q
. Connect a test lamp between the control circuit
terminal A and control circuit terminal 8,
ignition ON.
Fixed and Moveable Windows 4-23
10. Verify the test lamp turns ON when commanding
the UP and DOWN functions with the
S79P Window Switch—Passenger.
If the test lamp remains OFF during either of the
commands
10.1. IgnitionOFF, disconnect the harness
connector at the S79P Window
Switch—Passenger.
10.2. Test for infinite resistance between each
control circuit and ground.
2 Ifless than infinite resistance, repair the short to
ground on the circuit.
2 Ifinfinite resistance, replace the S79P Window
Switch-Passenger.
U If the test lamp turns 0N during each of the
commands '
11. Test or replace the M74P Window
Motor—Passenger.
Passenger Window lnoperative From A Single
Switch
1. IgnitionOFF, disconnect the harness connector at
the appropriate S79P Window Switch-Passenger
or S79D Window Switch-Driver, ignition ON
Verify a test lamp illuminates between the ignition
circuit terminal listed below and ground.
0 S79P Window Switch-Passenger — ignition
circuit terminal 5
- S79D Window Switch-Driver — ignition circuit
terminal 13
If the test lamp does not illuminate
2.1. IgnitionOFF.
2.2. Test for less than 2 Q in the ignition circuit end
to end.
2 If2 Q or greater, repair the open/high resistance
in the circuit.
2 If less than 2 Q, verify the fuse is OK and there
is voltage at the fuse.
If the test lamp illuminates
Test or replace the S79P Window
Switch-Passenger or S79D Window Switch-Driver,.
Rear Window lnoperative From Both Switches
1. IgnitionOFF, disconnect the harness connector at
the S79D Window Switch-Driver. Ignition ON
2. Verify a test lamp illuminates between the ignition
circuit terminal 6 and ground.
:> If the test lamp does not illuminate and the
circuit fuse is good
2.1. IgnitionOFF.
2.2. Test for less than 2 Q in the ignition circuit and
to end.
2 if 2 Q or greater, repair the open/high resistance
in the circuit.
2 Ifless than 2 Q, refer to Retained Accessory
Power Malfunction on page 11—520.

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424 Fixed and Moveable Windows
2 If the test lamp does not illuminate and the 7. Verify the test lamp turns ON when commanding
circuit fuse is open the UP and DOWN states with the S79D Window
2.1. Ignition OFF. Switch-Driver.
2.2. Test for infinite resistance between the ignition 2 If the test lamp remains OFF during either of the
circuit and ground. commands
2 if less than infinite resistance, repair the short to 7.1. IgnitionOFF, disconnect the harness
ground on the circuit. connector at the S79D Window Switch-Driver.
7.2. Test for infinite resistance between each
U If infinite resistance
control circuit and ground.
2.3. Test for infinite resistance between the control
circuit terminals listed below and ground: 2 If less than infinite resistance, repairthe short to
ground on the circuit.
. Control circuit terminal 1
2 If infinite resistance, replace the S79D Window
0 Control circuit terminal 2 Switch-Driver.
' Control circuit terminal 3
U If the test lamp turns ON during each of the
- Control circuit terminal 4 commands
- Control circuit terminal 5 8. IgnitionOFF and all vehicle systems OFF, connect
2 Ifless than infinite resistance, repair the short to the harness connector at the rear 879 Window
ground on the circuit. Switch and disconnect the harness connector at
2 If infinite resistance, replace the S79D Window the rear M74 Window Motor. Itmay take up to
Switch-Driver. 2 minutes for all vehicle systems to power down.
9. Test for less than 10 Q between the control circuit
U If the test lamp illuminates terminal listed below and ground:
3. Ignition OFF and all vehicle systems OFF, connect ~ Control terminal A
the harness connector at the S79D Window
Switch—Driverand disconnect the harness ° Control terminal 8
connector at the appropriate rear S79 Window 2 If 10 Q or greater
Switch. Itmay take up to 2minutes for all vehicle 9.1. IgnitionOFF, disconnect the harness
systems to power down connector at the rear 879 Window Switch.
4. Test for less than 10 Q between the control circuit 9.2. Test for less than 2 Q in the control circuit end
terminal 3 and ground. to end.
2 If 10 Q or greater 2 If2 Q or greater, repair the open/high resistance
4.1. ignition OFF, disconnect the harness in the circuit.
connector at the S79D Window Switch—Driver. 2 If less than 2 Q, replace the rear 879 window
4.2. Test for less than 2 Q in the control circuit end switch.
to end.
U If less than 10 Q
2 if 2 Q or greater, repair the open/high resistance
10. Connect a test lamp between the control circuit
in the circuit. terminal A and the control circuit terminal 8,
2 If less than 2 Q, replace the S79D Window ignition ON.
Switch—Driver. 11. Verify the test lamp turns ON when commanding
U If less than 10 Q the UP and DOWN states with the rear
5. Test for less than 10 Q between the control circuit 879 Window Switch.
terminal 6 and ground. 2 If the test lamp remains OFF during either of the
2 If 10 Q or greater commands
5.1. Ignition OFF, disconnect the harness 11.1. IgnitionOFF, disconnect the harness
connector at the S790 Window Switch-Driver. connector at the rear 879 Window Switch.
5.2. Test for less than 2 Q in the control circuit end 11.2. Test for infinite resistance between each
to end. control circuit and ground.
2 If2 Q or greater, repair the open/high resistance 2 if less than infinite resistance, repairthe short to
in the circuit. ground on the circuit.
2 Ifless than 2 Q, replace the S79D Window 2 Ifinfinite resistance, replace the rear
Switch—Driver. 879 Window Switch.
U If less than 10 Q U If the test lamp turns ON during each of the
commands
6. Connect a test lamp between the control circuit
terminal 3 and control circuit terminal 6, 12. Test or replace the rear M74 Window Motor.
ignition ON.

(US/Canada)
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2013 (5377994)
Manual
Service

Rear Window Lockout lnoperative
1. ignition OFF, disconnect the harness connector at
the appropriate rear 879 Window Switch.
Ignition ON
. Connect a test lamp between the control circuit
terminal 5 and ground.
. Verify the test lamp turns ON and OFF when
commanding the rear window lockout ON and OFF
with the rear window lockout switch.
Ifthe test lamp is always OFF
3.1. IgnitionOFF, disconnect the harness
connector at the S79D Window Switch-Driver.
3.2. Test for infinite resistance between the control
circuit and ground.
2 if less than infinite resistance, repair the short to
ground on the circuit.
U Ifinfinite resistance
3.3. Test for less than 2 Q in the control circuit end
to end.
2 If2 Q or greater, repair the open/high resistance
in the circuit.
2 If less than 2 Q, replace the S79D Window
Switch-Driver.
If the test lamp is always ON
3.1. IgnitionOFF, disconnect the harness
connector at the S79D Window Switch-Driver,
ignition ON.
3.2. Test for less than 1 V between the control
circuit and ground.
2 If 1 V or greater, repair the short to voltage on
the circuit.
2 Ifless than 1 V, replace the S79D Window
Switch-Driver.
U If the test lamp turns 0N and OFF
4. Test or replace the rear 879 Window Switch.
Fixed and Moveable Windows 4-25
Component Testing
1. Ignition OFF, disconnect the harness connector at
the appropriate passenger or rear M74 Window
Motor.
. Install a 20 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 M74 Window Motor does not perform the
UP and DOWN functions
Replace the passenger or rear M74 Window
Motor.
U If the M74 Window Motor performs the UP and
DOWN functions
3. All OK
Repair Instructions
Perform the Diagnostic Repair Verification on
page 6-92 after compieting the repair.
Front Side Door Window Regulator Motor
Replacement on page 4-43
Rear Side Door Window Switch Replacement on
page 4-40
Rear Side Door Window Regulator Replacement
(Sedan) on page 4-44 or Rear Side Door Window
Regulator Replacement (Hatchback) on page 4-45
Front Side Door Window Switch Replacement
(Left Side) on page 4-38 or Front Side Door
Window Switch Replacement (Right Side) on
page 4-39

Side Door Window Mechanical Diagnosis

Cause I Correction
DEFINITION: A mechanicalconditionthatrequiresa correctionforproperoperationoftheside doorwindow.
Referto Symptoms- Fixedand MoveableWindowsonpage4-15priorto beginningthistable.
Check properglass alignment/attachment anddoorseal installation.
Check switchandswitchbezeltosee if sticking.
Intermittent
Operation Checkwireharnessforpinched/shorted wire.
THISSTEP APPLIESTO ALL TWO PIN MOTOR CONNECTORS ONLY.Perform
electricaldiagnostics,byfirstapplying12voltpowersupplytothe regulatormotorto
verifymotorfunction.
Check properglass alignment/attachment.
Checkfordefectiveseal and/orproperseal installation.
Glass Binds
Check fordebrisin glass runchannel.
Checkforglass runchannelposition.
Check forloosefastenersandretorqueif required.
Regulator/GiassRattles
Check thattheglass is inthechannelandreinstallif notpositionedcorrectly.
Checkforothercomponentsin theglass pathsuchas wireharness,impactfoam,lock
NoisyOperation rods,or cables.
Check forproperglass alignment/attachment anddoorseal installation.

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426 Fixed and Moveable Windows

Side Door Window Mechanical Diagnosis (cont'd)

Cause Correction
Windnoise Check seals,mirrorpatch,and glass alignment.
False glass reversal,theglassgoes Check seals,reinitializetheglass and/orrealigntheglass.
downunexpectedly. Checkfordebrisin theglass runchannel.

Repair Instructions

Windshield Replacement
Special Tools
' BO-24402-A Glass Sealant Remover (Cold Knife)
- BO—39032Stationary Glass Removal Tool
- Use an adhesive that is approved by GM
For equivalent regional tools, refer to Special Tools on
page 4—70.
Removal Procedure
1. Open the hood.
2. Remove the windshield wiper arms. Refer to
Windshield Wiper Arm Replacement on
page 4-375.
3. Remove the air inlet grille. Refer to Airlnlet Grille
Panel Replacement on page 4-374.
379905
4. Remove the inside rearview mirror. Refer to Inside
Rearview Mirror Replacement on page 4—235. Warning: Refer to Glass and Sheet Metal Handling
Warning on page 0-5.
5. Remove the interior windshield garnish moldings.
Refer to Windshield Side Garnish Molding Note: Before cutting out a stationary window,apply a
Replacement on page 2—73. double layer of masking tape around the perimeter of
the painted surfaces and the interior trim.
Warning: Ifbroken glass falls into the defroster
outlets, it can be blown into the passenger 7. Using the appropriate tool, carefully cut the
compartment and cause personal injury. windshield reveal molding (1) in order to access
the auto-adhesive bead. Refer to Windshield
6. Cover to protect the following parts from broken
Upper Reveal Molding Replacement on page 4-28.
glass:
- Upper dash pad
- Defroster outlets and NC outlets
- Seats and carpeting

71179

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 Fixed and Moveable Windows 4-27
Note: Keep the cutting edge of the appropriate tool
against the window.There are window locating pins,
one in each upper corner of the window. Use care Not
to remove or cut them off when removing the window.
if the window locator pins are cut, it will be necessary to
tape the window in place.
8. This will allow the auto—adhesiveto be separated
from the window.
- Leave a base of auto—adhesiveon the
pinchweld flange.
- The only suitable lubrication is clean water.
- Use BO-24402—AGlass Sealant Remover (Cold
Knife).
- BO-39032 Stationary Glass Removal Tool,
or equivalent in order to remove the window.

10. With an assistant, remove the window (2) from the
Installation
379883
9. Use the appropraite tool to remove the bottom of
the window from the auto—adhesive.Keep the
cutting edge of the tool against the window. Do this
from inside the vehicle.
2424998
vehicle. Check that the retainers (1) are still
attached to the window before installing.
Procedure
1. Install the windshield into the opening. Refer to
Adhesive Installation of Windshields on page 4-57.
2. install the rearview mirror.Refer to Inside Rearview
Mirror Replacement on page 4-235.
3. Install the interior windshield garnish moldings.
Refer to Windshield Side Garnish Molding
Replacement on page 2-73.
4. Install the air inlet grille. Refer to Air Inlet Grille
Panel Replacement on page 4-374.
5. Install the windshield wipers arms. Refer to
Windshield WiperArm Replacement on
page 4-375.
6. Remove the double layer of masking tape around
the perimeter of the painted surfaces and the
interior trim.
7. Close the hood.

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4428 Fixed and Moveable Windows

Windshield Upper Reveal Molding Replacement

2425010
Windshield Upper Reveal Molding Replacement
Callout Component Name
Preliminary Procedures
Removethewindshieldto replacetherevealmolding.Referto WindshieldReplacementonpage4-26.
WindshieldRevealMolding
Warning: Refer to Glass and Sheet MetalHandling Warningon page 0-5.
Procedure
1 1. Markthewindowat bothends beforeremovetherevealmoldingforinstalling.
2. Place thewindowon a cleananddrysurface.
3. Use a suitableplastictool,use carewhenreleasingtherevealmoldingnotto pryonthewindow.
4. Cleanaroundtheedgesandsurfaceofthe windowandmoldingwitha 50/50mixtureof isopropylalcohol
andwaterbyvolumeon a dampenedlintfreecloth.

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 Fixed and Moveable Windows 4-29

3 Front Side Door Window Replacement

2425014
Front Side Door Window Replacement
Callout Component Name
Warning: Refer to Glass and Sheet MetalHandling Warningon page 0-5.
Preliminary Procedures
1. Removethefrontsidedoortrimpanel.Referto FrontSide Door TrimReplacementonpage 2-67.
2. Removethefrontsidedoorrearguide.Referto FrontSide Door WindowRear GuideReplacementonpage 4-49
3. Removethefrontsidedoorwindowoutersealingstrip.Referto FrontSide DoorWindowOuterSealingStripReplacement
onpage4-51.
FrontSide DoorWindowRegulatorGuideNuts(Qty:2)
Caution: Referto FastenerCautiononpage 0-8.
Procedure
1. Use maskingtape,tapeofftheouterdoorframeandappliqueto preventscratching.
2. Removethefrontsidedoorwaterdeflector.
3. Loosennutsso thatthewindowcan be removedfromtheguides.
4. Inorderto removethewindowoutoftheframe,carefullygraspandtiltthewindowas youguidethewindow
upandforward.
Tighten
11N-m(97lbin)

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-Sonic
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Manual
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4=30 Fixed and Moveable Windows

Front Side Door Window Replacement (cont'd)

Callout Component Name
FrontSide DoorWindow
Procedure
1. Lowerthewindowtoaligntheguidenutswiththeaccess holesin theinnerdoorpanel.
2 2. Donotoperatetheregulatormotorwithoutsupportingthewindow.Ensurethatthewindowremainsin the
guidewhenoperatingtheregulatormotor.
3. Carefullymovetheregulatorupwardforshortslowintervals,whileensuringthatthewindowremainsin the
guide.
4. Inspectthewindowforproperoperationbeforeinstallingthetrimpanel.

Rear Side Door Window Replacement (Sedan)

2425008

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
 Fixed and Moveable Windows 4-31

Rear Side Door Window Replacement (Sedan)

Callout Component Name
Warning: Refer to Glass and Sheet Metal Handling Warningon page 0-5.
Preliminary Procedures
1. Removetherearsidedoortrimpanel.Referto Rear Side DoorTrimReplacement(Sedan)onpage2-84or Rear Side Door
TrimReplacement(Hatchback)onpage2-83.
2. Removetherearsidedoorrearguide.Referto Rear Side DoorWindowRear GuideReplacementonpage4-50.
3. Removetherearsidewindowoutersealingstrip.Referto Rear Side Door WindowOuterSealingStripReplacement
(Hatchback)onpage4-53or Rear Side DoorWindowOuterSealingStripReplacement(Sedan)onpage 4-52.
Rear Side DoorWindowGuide Nut(Qty:2)
Caution: Referto FastenerCautiononpage0-8.
Procedure
1. Use maskingtape,tapeofftheouterdoorframeandappliqueto preventscratching.
2. Removetherearside doorwaterdeflector.
3. Loosennutsontheguideso thatthewindowcan be removed.
4. Inorderto removethewindowoutoftheframe,carefullygraspandtiltthewindowas youguidethewindow
upandforward.
Tighten
11N-m(97lb in)
Rear Side DoorWindow
Procedure
1. Alignthewindowguidewiththeaccess holesin theinnerdoorpanel.
2. Installthewindowtotheguide.
2 3. Donotoperatetheregulatormotorwithoutsupportingthewindow.Ensurethatthewindowremainsin the
guidewhenoperatingtheregulatormotor.
Carefullymovetheregulatorupwardforshortslow intervals,whileensuringthatthewindowremainsin the
guide.Tightenthenutstothewindowguide.
Inspectthewindowforproperoperationbeforeinstallingthetrimpanel.

2013
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4.32 Fixed and Moveable Windows

Rear Side Door Window Replacement (Hatchback)

2476171

Rear Side Door Window Replacement (Hatchback)

Callout Component Name
Warning: Refer to Glass and Sheet MetalHandling Warningon page 0-5.
Preliminary Procedures
1. Removetherearside doortrimpanel.Referto Rear Side Door TrimReplacement(Sedan)onpage 2-84or Rear Side Door
TrimReplacement(Hatchback)onpage 2-83.
2. Removetherearside doorrearguide.Referto Rear Side Door WindowRear GuideReplacementonpage4—50.
3. Removetherearsidewindowoutersealingstrip.Referto Rear Side Door WindowOuterSealingStrip Replacement
(Hatchback)onpage4—53or Rear Side DoorWindowOuterSealingStrip Replacement(Sedan)onpage 4-52.
RearSide DoorWindowGuideNut(Qty:2)
Caution: RefertoFastenerCautiononpage 0—8.
Procedure
1. Use maskingtape,tape offtheouterdoorframeandappliqueto preventscratching.
1 2. Removetherearsidedoorwaterdeflector.
3. Loosennutsonthe guideso thatthewindowcan be removed.
4. in orderto removethewindowoutoftheframe,carefullygraspand tiltthewindowas youguidethewindow
up andforward.
Tighten
11N-m(97lbin)

(US/Canada)
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2013 (5377994)
Manual
Service
 Fixed and Moveable Windows 4-33

Rear Side Door Window Replacement (Hatchback) (cont'd)

Callout Component Name
Rear Side DoorWindow
Procedure
1. Alignthewindowguidewiththeaccess holesin theinnerdoorpanel.
2. Installthewindowtotheguide.
3. Donotoperatetheregulatormotorwithoutsupportingthewindow.Ensurethatthewindowremainsin the
guidewhenoperatingtheregulatormotor.
4. Carefullymovetheregulatorupwardforshortslowintervals,whileensuringthatthewindowremainsin the
guide.Tightenthe nutstothewindowguide.
5. Inspectthewindowforproperoperationbeforeinstallingthetrimpanel.

Rear Side Door Stationary Window Replacement

2425020

Rear Side Door Stationary Window Replacement

Callout I Component Name
Warning: Refer to Glass and Sheet Metal Handling Warningon page 0-5.
Preliminary Procedures
Removetherearside doorwindow.Referto Rear Side Door WindowReplacement(Hatchback)onpage4-32or Rear Side Door
WindowReplacement(Sedan)onpage4—30.
Rear Side DoorWindowWeatherstripLowerBolt
Caution: Referto FastenerCautiononpage 0-8.
1 Tighten
9 NW(80lb in)
Tip: Theweatherstripandwindowis servicedas oneassembly.

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434 Fixed and Moveable Windows

Rear Side Door Stationary Window Replacement (cont'd)

Callout Component Name

Rear Side DoorWindowWeatherstripUpperScrew
Procedures
1. Pull theweatherstripoutofthe upperretainerto exposethe screw.
2 2. Removetheweatherstripfromthefrontandrearlowerguides.
3. Grasp bothuppercorners,pullforwardreleasingassemblyfromthedoorframe.
Tighten
3 N-m(27lbin)
Rear Side DoorWindowWeatherstrip
Procedures
3 1. Inserttheweatherstripdownwardin theguideuntilfullyseated.
2. Carefullymovetheregulatorupwardforshortslowintervals,whileensuringthatthewindowremainsinthe
guides.
3. Inspectthedoorwindowforproperoperationbeforeinstallingthedoortrimpanel.

Rear Window Replacement 4. Disconnect the rearwindow radio antenna

connector.
Specnal Tools Warning: If broken glass falls into the defroster
- BO—24402-AGlass Sealant Remover (Cold Knife) outlets, it can be blown into the passenger
- BO-39032 Stationary Glass Removal Tool compartment and cause personal mJ'WY-
. Use an adhesive that is approved by GM 5. Cover to protect the following parts from broken
For equivalent regional tools, refer to Special Tools on glass:
page 4-70 - Upper dash pad
Removal Procedure - Defroster outlets and NC outlets
' 8 eats a nd ca rpetin9
Warning: Ifa windowis crackedbutstillintact,
crisscross the window with masking tape in order
to reduce the risk of damage or personal injury.
Note: Before cutting out a stationary window, apply a
double layer of masking tape around the perimeter of
the painted surfaces and innertrim.
1. Open the rear compartment lid.

\Q‘

....
7 R

71179
Note: Keep the cutting edge of the appropriate tool
against the window. There are window locating pins,
one in each upper corner of the window. Use care Not
to remove or cut them off when removing the window.
Ifthe window locator pins are cut, it will be necessary to
tape the window in place.
401856 6. This will allow the auto-adhesive to be separated

2. Disconnect the rear window defogger electrical from the wmdow.

connectors.
3. Disconnect the OnStar®antenna, if equipped.
(US/Canada)
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2013 (5377994)
Manual
Service
 Fixed and Moveable Windows 4:35
7. Remove the rearwindow reveal molding. Refer to
Rear Window Reveal Molding Replacement on
page 4-36.
- Leave a base of urethane on the pinchweld
flange.
. The only suitable lubrication is clear water.
- The only suitable lubrication is Clear water.
- BO—24402—A Glass Sealant Remover (Cold
Knife).
- BO-39032 Stationary Glass Removal Tool.

Installation
379883
8. Use the appropriate tool to remove the bottom of
the window from the auto-adhesive. Keep the
cutting edge of the tool against the window. Do this
from inside the vehicle.
2424997
9. With an assistant, remove the window (2) from the
vehicle. Check that the retainers (1) are still
attached to the window before installing.
Procedure
1. install the rear window into the opening. Refer to
Adhesive Installation of Rear Windows on
page 4-61.
2. Connect the rear window defogger electrical
connectors.
3. Install the rear window radio antenna connector.
® . .
4' Connect the QnStar antenn®a, 'f equnpped.l
Check‘the radio and OnStar system to verify
reception.
5. Close the rear compartment lid.
6. Remove the double layer of masking tape around
the perimeter of the painted surfaces and the
interior trim.

2013
-Sonic
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4—36 Fixed and Moveable Windows

Rear Window Reveal Molding Replacement

2425011

Rear Window Reveal Molding Replacement

Callout Component Name
Preliminary Procedures
Removetherearwindowto replacetherevealmolding.Referto Rear WindowReplacementonpage4-34.
RearWindowRevealMolding
Warning: Refer to Glass and Sheet MetalHandling Warningon page 0-5.
Procedure
1 1. Markthewindowat bothends beforeremovetherevealmoldingforinstalling.
2. Place thewindowon a cleananddrysurface.
3. Use a suitableplastictool,use carewhenreleasingtherevealmoldingnotto pryonthewindow.
4. Clean aroundtheedges andsurfaceof thewindowand moldingwitha 50/50mixtureof isopropylalcohol
andwaterby volumeon a dampenedlintfree cloth.

Liftgate Window Replacement Removal Procedure

Special Tools
o BO—24402—AGlass Sealant Remover (Cold Knife)
. 5039032 Stationary Glass Removal Tool
- Use an adhesive that is approved by GM
For equivalent regional tools, refer to Special Tools on
page 4-70
Warning: Refer to Cracked Window Warning on
page 0-4.
Note: Before cutting out a stationary window, apply a
double layer of masking tape around the perimeterof
the painted surfaces and the interior trim.
1. Open the liftgate.
2. Remove the liftgate trim. Refer to Liftgate Trim
Finish Panel Replacement (Hatchback) on
page 2—86.
3. Disconnect the electrical connectors from the
liftgatewindow defogger bus bar.

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 Fixed and Moveable Windows 4-37
4. Remove the rearwindow wiper arm. Refer to Rear
Window Wiper Arm Replacement on page 4-376.
5. Remove the rearspoiler. Refer to Rear End Spoiler
Replacement (Hatchback TTV) on page 2—17.
Warning: Refer to Defroster Outlet Warning on
page 0-4.
6. Cover the following parts to protect from broken
glass:
' Upper dash pad
- Defroster outlets and NC outlets
. Seats and carpeting

379883
Note: Keep the cutting edge of appropriate tool the
against the window. Do this from inside the vehicle.
8. Use the appropraite tool to remove the bottom of
the window from the auto—adhesive.Keep the
cutting edge of the tool against the window. Do this
from inside the vehicle.

71179
Note: Keep the cutting edge ofthe appropriate tool
against the window. There are window locating pins,
one in each upper corner of the window. Use care Not
to remove or cut them off when removing the window.
lfthe window locator pins are cut, it will be necessary to
tape the window in place.
7. This will allow the auto—adhesiveto be separated
from the window.
' Leave a base of auto-adhesive on the
pinchweld flange.
- The only suitable lubrication is clean water.
- Use BO-24402—AGlass Sealant Remover (Cold
Knife).
- BO—39032Stationary Glass Removal Tool, 2424999
or equivalent in order to remove the window.
9. With an assistant, remove the window (1)from the
vehicle.

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4-38 Fixed and Moveable Windows

Installation Procedure 4. Connectt thetlifttrgattewigdow defogger electrical

connec ms. 0 e _US ar. . , . ,
1. Install the liftgate window into the opening. Refer to 5. Install the liftgate trim. Refer to Liftgate Tr/mlesh
Adhesive Installation OfLiftgate Windows on
page 4—65. Panel Replacement (Hatchback) on page 2—86.
2. Install the rear spoiler. Refer to Rear End Spoiler 6- Remove the double layer 0f masking tape around
Replacement (Hatchback TTV) on page 247' the perimeter of the palnted surfaces and the
3. Install the rear window wiper arm. Refer to Rear Interiortnrn.
Window WiperArm Replacement on page 4-376. 7' Close the liftgate.

Front Side Door Window Switch Replacement (Left Side)

2502699

Front Side Door Window Switch Replacement (Left Side)

Callout I Component Name
Preliminary Procedure
Removethefrontsidedoorwindowswitchbezel. Referto FrontSide DoorWindowSwitchBezel Replacement(RightSide)on
page 2-64or FrontSide DoorWindowSwitchBezel Replacement(LeftSide)on page 2-63.
FrontSide DoorWindowSwitchAssembly
Procedure
1. Disconnecttheelectricalconnectors.
2. Referto ControlModuleReferenceson page6-3for programmingandset upprocedures.

(US/Canada)
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 Fixed and Moveable Windows 4=39

Front Side Door Window Switch Replacement (Right Side)

2502706
Front Side Door Window Switch Replacement (Right Side)
Callout I Component Name
Preliminary Procedure
Removethefrontside doorwidowswitchbezel.Referto FrontSide DoorWindowSwitchBezel Replacement(RightSide)on
page2-64or FrontSideDoor WindowSwitchBezel Replacement(LeftSide)onpage 2-63.
FrontSide DoorWindowSwitchAssembly
Procedure
1. Disconnecttheelectricalconnectors.
2. Referto ControlModuleReferencesonpage6-3for programmingandset up procedures.

2013
-Sonic
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4440 Fixed and Moveable Windows

Rear Side Door Window Switch Replacement

2545460

Rear Side Door Window Switch Replacement

Callout Component Name
Preliminary Procedure
Removetherearsidedoorwindowswitchbezel. Referto Rear Side DoorWindowSwitchBezel Replacementonpage2-65.
RearSide DoorWindowSwitchAssembly
Procedure
1. Disconnectthe electricalconnectors.
2. Referto ControlModuleReferencesonpage 6-3forprogrammingandset upprocedures.

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
 Fixed and Moveable Windows 4am
Front Side Door Window Regulator Replacement

2425013
Front Side Door Window Regulator Replacement
Callout Component Name
Warning: Refer to Glass and SheetMetal Handling Warningon page 0-5.
Preliminary Procedure
Removethefrontside doorwindowfromtheguide.Do Notremovethewindowfromthevehicle,raisethewindowtothefullyup ‘
position,tapein place.Referto FrontSide Door WindowReplacementonpage 4-29.
FrontSide DoorWindowRegulatorScrew(Qty:4)
Caution: RefertoFastenerCautiononpage 0-8.
Procedure
1. Removethefrontside doorwaterdeflector.
2. Loosenthewindowguidenuts,Do Notremovethenutsfromtheguide.
3. Disconnecttheelectricconnectorfromtheregulatormotor.
Tighten
11Nm (97lbin)
FrontSide DoorWindowRegulator
Procedure
2 1. Transferthefrontside doorwindowregulatormotor.Referto FrontSide DoorWindowRegulatorMotor
Replacementonpage 4-43.
2. Inspectthedoorwindowforproperoperationbeforeinstallingthedoortrimpanel.

2013
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442 Fixed and Moveable Windows
Window Motor Programming - Window
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
- When a door harness has been disconnected
' When the battery has been disconnected or
replaced
Note: When DTC B3205 4B is set, the following
warnings will be displayed on the driver information
center:
Open, then Close DriverWindow
These warnings will clear once the window has been
"Normalized" and the 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. Ifthis occurs, verify that the door is
completely closed then repeat the normalizing
procedure.
1. lgnition 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.
Motor Relearn Procedure
A relearn procedure may need to be performed for any
Local Interconnect Network (LIN) window motorfor the
following conditions:
° When the window glass is out of alignment
- When the window glass has been replaced
0 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.
To relearn the window motor,follow these steps:
1. lgnition 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.
(US/Canada)
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2013 (5377994)
Manual
Service
 Fixed and Moveable Windows 4-43

Front Side Door Window Regulator Motor Replacement

2425015
Front Side Door Window Regulator Motor Replacement
Callout l Component Name
Warning: Refer to Glass and Sheet MetalHandling Warningon page 0-5.
Preliminary Procedure
Removethefrontsidedoorwindowregulator.FrontSide Door WindowRegulatorReplacementonpage4-41.
FrontSide DoorWindowRegulatorMotorScrew(Qty:3)
Caution: Referto FastenerCautiononpage 0-8.
Procedure
1 1. Removethefrontsidedoorwaterdeflector.
2. Disconnecttheelectricconnectorfromtheregulatormotor.
Tighten
5 N'm(44lbin)
FrontSide DoorWindowRegulatorMotor
2 Procedure
Inspectthedoorwindowforproperoperationbeforeinstallingthedoortrim.

2013
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Sonic
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411-44 Fixed and Moveable Windows

Rear Side Door Window Regulator Replacement (Sedan)

2425018
Rear Side Door Window Regulator Replacement (Sedan)
Callout I _ ComponentName
Warning: Refer to Glass and Sheet MetalHandling Warningon page 0-5.
Preliminary Procedure
Removethefrontsidedoorwindowfromtheguide.Do Notremovethewindowfromthevehicle,raisethewindowtothefullyup
position,tapein place.Referto Rear Side DoorWindowReplacement(Hatchback)onpage4-32or Rear Side Door Window
Replacement(Sedan)onpage4-30.
Rear Side DoorWindowRegulatorScrew(Qty:3)
Caution: Referto FastenerCautiononpage0—8.
1. Removetherearsidedoorwaterdeflector.
2. Loosenthewindowguidenuts,Do Notremovethenutsfromtheguide.
3. Disconnectthedoorelectricalconnector.
4. Removetherearsidedoorwindowfromtheguide.Referto Rear Side DoorWindowRear Guide
Replacementonpage4-50.
Do Notremovethewindowfromthevehicle,raisethewindowtothefullyupposition,tapein place.
Tighten
11N-m(97lb in)
Rear Side DoorWindowRegulator
Procedure
2 1. Transfertherearsidedoorwindowregulatormotor.Referto Rear Side DoorWindowRegulatorMotor
Replacementonpage4-46.
2. Inspectthedoorwindowforproperoperationbeforeinstallingthedoortrimpanel.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Fixed and Moveable Windows 445

Rear Side Door Window Regulator Replacement (Hatchback)

fiv-fl‘w

2476168
Rear Side Door Window Regulator Replacement (Hatchback)
Callout I Component Name
Warning: Refer to Glass and Sheet Metal Handling Warningon page 0-5.
Preliminary Procedure
Removethefrontsidedoorwindowfromtheguide.Do notremovethewindowfromthevehicle,raisethewindowtothefullyup
position,tapein place.Referto Rear Side DoorWindowReplacement(Hatchback)onpage 4—32 or Rear Side Door Window
Replacement(Sedan)onpage4-30.
Rear Side DoorWindowRegulatorScrew(Qty:3)
Caution: Referto FastenerCautiononpage 0-8.
Procedure
1. Removetherearside doorwaterdeflector.
2. Loosenthewindowguidenuts.Do notremovethenutsfromtheguide.
1 3. Disconnectthedoorelectricalconnector.
4. Removetherearside doorwindowfromtheguide.Referto Rear Side Door WindowRear Guide
Replacementonpage 4—50.
Do notremovethewindowfromthevehicle,raisethewindowtothefullyupposition,tapein place.
Tighten
11N'm(97lb in)
Rear Side DoorWindowRegulator
Procedure
2 1. Transfertherearside doorwindowregulatormotor.Referto Rear Side DoorWindowRegulatorMotor
Replacementonpage 4-46.
2. Inspectthedoorwindowforproperoperationbeforeinstallingthedoortrimpanel.

2013
-Sonic
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Service
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(5377994)
4-46 Fixed and Moveable Windows

Rear Side Door Window Regulator Motor Replacement

2425019
Rear Side Door Window Regulator Motor Replacement
Callout I Component Name
Warning: Refer to Glass and Sheet MetalHandling Warningon page 0~5.
Preliminary Procedure
Removetherearside doorwindowregulator.Referto Rear Side Door WindowRegulatorReplacement(Sedan)onpage4-44or
Rear Side Door WindowRegulatorReplacement(Hatchback)onpage 4-45.
Rear Side DoorWindowRegulatorMotorScrew(Qty:3).
Caution: RefertoFastenerCautiononpage 0-8.
Procedure
1. Removetherearsidedoorwaterdeflector.
1 2. Removetherearsidedoorwindowfromtheguide.Do Notremovethewindowfromthevehicle,raisethe
windowtothefullyupposition,tapein place.
3. Disconnecttheelectricalconnectorfromthewindowregulatormotor.
Tighten
5N-m(44lb in)
Rear Side DoorWindowRegulatorMotor
2 Procedure
inspectthedoorwindowforproperoperationbeforeinstallingthedoortrimpanel.

2013
-Sonic
(US/Canada)
Sen/ice
Manual
(5377994) i
 Fixed and Moveable Windows 4447
Front Side Door Window Regulator Handle Replacement

2259113
Front Side Door Window Regulator Handle Replacement
Callout Component Name
FrontSide DoorWindowRegulatorHandleClip
1 Procedure
Use theappropriatetool,removetheclipfromhandle.
2 FrontSide DoorWindowRegulatorHandle

2013
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448 Fixed and Moveable Windows

Rear Side Door Window Regulator Handle Replacement

2255229
Rear Side Door Window Regulator Handle Replacement
Callout Component Name
Rear Side DoorWindowRegulatorHandleClip
1 Procedure
Use theappropriatetool,removetheclipfromhandle.
2 Rear Side DoorWindowRegulatorHandle

2013
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Service
Manual
(5377994)
 Fixed and Moveable Windows 4449

Front Side Door Window Rear Guide Replacement

2425017
Front Side Door Window Rear Guide Replacement
Callout Component Name
Preliminary Procedure
Removethefrontsidedoortrimpanel.Referto FrontSide Door TrimReplacementonpage2-67.
FrontSide DoorWindowRear GuideNut(Qty:2)
Caution: Referto FastenerCautiononpage 0-8.
Procedure
1. Removethefrontside doorwaterdeflector.
2. Do notremovethewindowfromthevehicle,raisethewindowto thefullyupposition.
3. Pulltheweatherstripoutfromtheinnerchanneloftheguide.
Tighten
11N-m(97lb in)
FrontSide DoorWindowRear Guide
Tip: Inspectthewindowforproperoperationbeforeinstallingthetrimpanel.

2013
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Manual
(5377994)
4-50 Fixed and Moveable Windows

Rear Side Door Window Rear Guide Replacement

2476170
Rear Side Door Window Rear Guide Replacement
Callout I Component Name
Preliminary Procedure
Removetherearsidedoortrimpanel.Referto Rear Side DoorTrimReplacement(Sedan)onpage 2—84 or Rear SideDoorTrim
Replacement(Hatchback)onpage2-83.
RearSide DoorWindowRear GuideNut(Qty:3)
Caution: Referto FastenerCautiononpage 0-8.
Procedure
1. Removetherearside doorwaterdeflector.
1 2. Do Notremovethewindowfromthevehicle,raisethewindowtothefullyup position.
3. Pull theweatherstripoutfromtheinnerchanneloftheguide.
Tighten
11N°m(97lbin)
2 RearSide DoorWindowRear Guide
Tip: Inspectthedoorwindowforproperoperationbeforeinstallingthedoortrimpanel.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Fixed and Moveable Windows 4-51

Front Side Door Window Outer Sealing Strip Replacement

#1

2259126
Front Side Door Window Outer Sealing Strip Replacement
Callout Component Name
FrontSide DoorWindowOuterSealingStrip
Procedure
1. Do Notremovetheoutsiderearviewmirror.
1 2. Use theappropriatetool,lifttherearcornerofthesealingstripandpullupwardandawayfromthedoor
flange.
3. Press firmlyto insertthefrontside doorwindowsealingstripbackon thedoorflange.
4. lnspectthedoorwindowforproperoperation.

2013
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Service
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(5377994)
4.52 Fixed and Moveable Windows

Rear Side Door Window Outer Sealing Strip Replacement (Sedan)

2257515
Rear Side Door Window Outer Sealing Strip Replacement (Sedan)
Callout Component Name
RearSide DoorWindowOuterSealingStrip
Procedure
Use theappropriatetool,liftone endupandpullawayfromthedoorflangeto remove.

2013
-Sonic
(US/Canada)
Service
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 Fixed and Moveable Windows 4=53

Rear Side Door Window Outer Sealing Strip Replacement (Hatchback)

2425049
Rear Side Door Window Outer Sealing Strip Replacement (Hatchback)
Callout Component Name
RearSide DoorWindowOuterSealingStripScrew
Caution: Referto FastenerCautiononpage0—8.
1 Tighten
2 N'm(18lbin)
Note: Openthereardoortothefullopenpositionto exposetherearsidedoorwindowoutersealingstripscrew
thatis locatedon thefrontinneredgeof thedoor.
Rear Side DoorWindowOuterSealingStrip
Procedure
2 1. Use theappropriatetool,liftthefrontcornerofthesealingstripand ‘pullupwardandawayfromthedoor
flange.
2. Pressfirmlyto inserttherearside doorwindowsealingstripbackon thedoorflange.
3. Inspectthedoorwindowforproperoperationbeforeinstallingthedoortrimpanel.

2013
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4=54 Fixed and Moveable Windows

Front Side Door Window Weatherstrip Replacement

2425016

Front Side Door Window Weatherstrip Replacement

Callout Component Name
Preliminary Procedures
1. Removefrontside doortrimpanel.Referto FrontSide DoorTrimReplacementonpage 2-67.
2. Removetheoutsiderearviewmirror.Referto OutsideRearviewMirrorReplacement(Power)onpage 4-229or Outside
RearviewMirrorReplacement(Manual)onpage4-228.
FrontSide DoorWindowWeatherstrip
Procedure
1. Place thewindowin thefullydownposition.
2. Removethewaterdeflector.
3. Grasp bothuppercornersofthe windowweatherstrip,pulldownwardreleasingthe assemblyfromthe door
frame.
Inserttheweatherstripdownwardin thefrontand rearchanneluntilfullyseated.
Positionthewindowweatherstripin theupperrearcorneroftheframe,worktheweatherstriparoundthe
doorframe.
Carefullymovetheregulatorupwardforshortslowintervals,whileensuringthatthewindowremainsin the
channels.
Inspectthedoorwindowforproperoperationbeforeinstallingthedoortrimpanel.

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2013 (US/Canada)
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Manual
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 Fixed and Moveable Windows 4-55

Rear Side Door Window Weatherstrip Replacement (Hatchback)

2476172
Rear Side Door Window Weatherstrip Replacement (Hatchback)
Callout I Component Name
Preliminary Procedure
Removetherearside doorwindow. Referto Rear Side Door WindowReplacement(Hatchback)onpage4-32or Rear Side Door
WindowReplacement(Sedan)onpage4-30.
Rear Side DoorWindowWeatherstrip
Procedure
1. Removetherearsidedoorwaterdeflector.
Removetheweatherstripfromthefrontandrearlowerwindowguides.
Graspbothuppercorners,pulldownwardreleasingtheweatherstripfromthedoorframe.
Inserttheweatherstripdownwardin thewindowguidesuntilfullyseated.
.0199!“
Carefullymovetheregulatorupwardforshortslow intervals,whileensuringthatthewindowremainsin the
guides.
Inspectthedoorwindowforproperoperationbeforeinstallingthedoortrimpanel.

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4-56 Fixed and Moveable Windows

Rear Side Door Window Weatherstrip Replacement (Sedan)

2425020

Rear Side Door Window Weatherstrip Replacement (Sedan)

Callout I Component Name
Preliminary Procedures
1. The reardoorsidewindowweatherstripandwindowis servicedas one assembly.Referto Rear Side DoorStationary
WindowReplacementonpage4-33.
2. Removetherearside doorwindow.Referto Rear Side DoorWindowReplacement(Hatchback)onpage4-32orRear Side
DoorWindowReplacement(Sedan)onpage 4-30.
RearSide DoorWindowWeatherstripLowerBolt
Caution: Referto FastenerCautiononpage 0-8.
1 Procedure
Removetherearsidedoorwaterdeflector.
Tighten
9N'm(80lb in)
RearSide DoorWindowWeatherstripUpperScrew
Procedure
1. Pull thedoorweatherstripoutoftheupperretainertoexposethescrew.
2 2. Removetheweatherstripfromthefrontandrearlowerguides.
3. Grasp bothuppercorners,pulldownwardreleasingtheweatherstripfromthedoorframe.
Tighten
3 N-m(27lbin)

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2013 (5377994)
Manual
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 Fixed and Moveable Windows 4-57

Rear Side Door Window Weatherstrip Replacement (Sedan) (cont'd)

Callout Component Name
Rear Side DoorWindowWeatherstrip
Procedure
3 1. Inserttheweatherstripdownwardin theguideuntilfullyseated.
2. Carefullymovetheregulatorupwardforshortslowintervals,whileensuringthatthewindowremainsin the
guides.
3. Inspectthedoorwindowforproperoperationbeforeinstallingthedoortrimpanel.

Adhesive Installation of Windshields

Warning: Refer to Glass and Sheet Metal Handling
Warning on page 0-5.
1. Use a urethane adhesive systems which meet GM
Specification GM 3651G.
2. Remove all mounds or loose pieces of urethane
adhesive from the pinchweld area.
3. Ifthe original window is being reused, remove all
but approximately 2 mm (3/64in) of the existing
bead of urethane adhesive from the pinchweld
flange 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 ofthe window:
. The flange of the window opening
- High weld
- Solder spots
. Hardened sealer
' Any other obstruction or irregularity in the 245283
pinchweld flange Warning: Failure to prep the area prior to the
Note: Ifcorrosion of the pinch—weldflange is present or application of primer may cause insufficient
if sheet metal repairs or replacements are required, the bonding of urethane adhesive. Insufficient bonding
pinch—weldflange must be refinished in order to restore of urethane adhesive may allow unrestrained
the bonding area strength. If paint repairs are required, occupants to be ejected from the vehicle resulting
mask the flange bonding area prior to applying the color in personal injury.
coat in order to provide a clean primer only surface. 7. Apply the primer to the surface of the pinch-weld
Materials such as BASF DE15®,DuPont 2610®, flange (1).
Sherwin—WilliamsPSE 4600 and NP70®and
Martin-Semour 5120 and 5130®PPG DP90LF SPlES/ 8. Allow the pinch—weldprimer to dry per
HECKER 3688/8590 —3688/5150 —4070/5090 auto—adhesiveinstructions by the manufacturer's.
STANDOX11158/13320 —14653/14980 products are 9. With an assistant, dry fit the window (1) to the
approved for this application. opening in order to determine the correct position.
5. After repairing the opening as indicated, perform
the following steps:
5.1. Remove all traces of broken glass from the
outer cowl panel, seats, floor and defroster
ducts.
5.2. 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.
6. Verify all primers and urethane adhesive are within
expiration dates.

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4-58 Fixed and Moveable Windows

745571 161424

10. Use masking tape in order to mark the locations (1) 13. Apply bonded-glass primer and let dry per
of the window (2) in the opening. auto-adhesive instructions by the manufacturer’s.
11. Cut the masking tape in the center and remove the
window from the opening.

379890
12. Apply glass prep clear to the area approximately
10—16mm (3/8—5/8in) around the entire perimeter
of the window inner surface.
Immediately wipe the glass primed area using a
clean, lint—freecloth.
245290
14. Apply the auto-adhesive primer—application(2)
around the perimeter of the window (1) per
auto-adhesive instructions by the manufacturer’s.
15. Apply the glass primer black to the same areas (2)
that glass prep clear was applied.
16. Allow the glass primer to dry per auto-adhesive
instructions by the manufacturer’s.

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 Fixed and Moveable Windows 4=59

2424992 245315
17. Install the window reveal molding (1). Refer to 19. Use the edge of the window as a guide for the
Windshield Upper Reveal Molding Replacement on nozzle in order to apply the urethane adhesive (1)
page 4-28. to the inner surface of the window (3).

161427 2424998
Note: if the locating pins were cut off it will be
18' gzfizgfitjr’tgggfihtxgfiscgggng gun m order to apply necessary to tape the window in plaee until the _
, , auto—adheswecures per auto-adheswe Instructions by
Cut the applicator nozzle to provxdeda V out to the manufacturer’s.
apply the auto-adhesive.
20. With an assistant, align the window locating
pins (1) to the slots located in each corner of the
pinch—weldflange. Lower the window (2) to touch
the auto—adhesive.

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-Sonic
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4=60 Fixed and Moveable Windows

706204 95572
Note: Do not direct a hard stream of high pressure
21. Gently depress the window on the auto—adhesive water to the freshly applied urethane adhesive. ‘
bead until the window reveal molding is seated.
22. Tape the window to the body in order to minimize 24. Use a soft spray of warm water in order to
movement and until the auto—adhesivecures per immediately water test the window.
auto-adhesive instructions by the manufacturer’s. 25. Inspect the window for leaks.
26. If any leaks are found, use a plastic paddle in order
to apply extra urethane adhesive at the leak point.
27. 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 21°C
(70°F) or greater and with at least 30 percent
relative humidity. Allow at least 24 hours for
the complete curing of the urethane adhesive.
0 For the chemicaI-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.
28. Maintain the following conditions in order to
properly cure the urethane adhesive:
~ Partially lower a door window in order to
prevent pressurebuildups when closing doors
706194 before the urethane adhesive cures.
' Do not drive the vehicle until the urethane
23. Ensure all excess urethane adhesive is cleaned adhesive is cured. Refer to the above curing
from the body before water test. times.
- Do not use compressed air in order to dry the
urethane adhesive.
29. Complete the window installation.

(US/Canada)
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Manual
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 Fixed and Moveable Windows 4:61

Adhesive Installation of Rear

Windows
Warning: Refer to Glass and Sheet Metal Handling
aw
N
v,_
MN.
..M Warning on page 0-5.
1. Use a urethane adhesive systems which meet GM
Specification GM 3651G.
2. Remove all mounds or loose pieces of urethane
adhesive from the pinchweld area.
3. if the original window is being reused, remove all
but approximately 2 mm (3/64in) of the existing
bead of urethane adhesive from the pinchweld
flange 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:
- The flange of the window opening
- High weld
- Solderspots
- Hardened sealer 245283
- Any other obstruction or irregularity in the Warning: Failure to prep the area prior to the
pinchweld flange application of primer may cause insufficient
bonding of urethane adhesive. Insufficient bonding
Note: Ifcorrosion of the pinch—weldflange is present or of urethane adhesive may allow unrestrained
if sheet metal repairs or replacements are required, the occupants to be ejected from the vehicle resulting
pinch—weldflange must be refinished in order to restore in personal injury.
the bonding area strength. If paint repairs are required,
mask the flange bonding area prior to applying the color 7. Apply the primer to the surface of the pinch-weld
coat in order to provide a clean primer only surface. flange (1).
Materials such as BASF DE15®,DuPont 2610®, 8. Allow the pinoh-weld primer to dry per
Sherwin-Williams PSE4600 and NP70®and auto-adhesive instructions by the manufacturer’s.
Martin-Semour 5120 and 5130®PPG DP90LF SPIES/
HECKER 3688/8590 —3688/5150 —4070/5090
STANDOX11158/13320 —14653/14980 products are
approved for this application.
5. After repairing the opening as indicated, perform
the following steps:
5.1. Remove all traces of broken glass from the
outer cowl panel, seats, floor and defroster
ducts.
5.2. 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.
6. Verify all primers and urethane adhesive are within
expiration dates.

745571
9. Use masking tape in order to mark the locations (1)
of the window (2) in the opening.
10. Cut the masking tape in the center and remove the
window from the opening.

2013
-Sonic
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462 Fixed and Moveable Windows

//

379890 245290

11. Apply glass prep clear to the area approximately
10—16mm (3/8—5/8in) around the entire perimeter
of the window inner surface.
immediately wipe the glass primed area using a
clean, lint-free cloth.
13. Apply the auto—adhesiveprimer—application(2)
around the perimeter of the window (1) per
auto-adhesive instructions by the manufacturer’s.
14. Apply the glass primer black to the same areas (2)
that glass prep clear was applied.
15. Allow the glass primer to dry per auto-adhesive
instructions by the manufacturer’s.

161424
12. Apply bonded-glass primer and let dry per
auto—adhesiveinstructions by the manufacturer’s. 2424993
16. Install the window reveal molding (1). Installthe
window reveal molding. Refer to Rear Window
Reveal Molding Replacement on page 4-36.

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 Fixed and Moveable Windows 4=63

161427 757629
17. Use a cartridge-type caulking gun in order to apply Note: Ifthe locating pins were cut off it will be
a smooth, continuous bead. necessary to tape the window in place until the
auto-adhesive cures per auto—adhesiveinstructions by
Cut the applicator nozzle to provided a V out to the manufacturer's.
apply the auto-adhesive.
19. With an assistant, align the window locating
. pins (1) to the slots located in each corner of the
pinch-weld flange. Lower the window (2) to touch
the auto-adhesive.

245315
18. 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). 745571
20. Ifthe locating pins were damaged, align the
masking tape (1) lines on the window (2) and
the body.

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-Sonic
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4-64 Fixed and Moveable Windows

706204 95572
Note: Do not direct a hard stream of high pressure
21. Gently depress the window on the auto—adhesive water to the freshly applied urethane adhesive.
bead until the window reveal molding is seated.
22. Tape the window to the body in order to minimize 24. Use a soft spray of warm water in order to
movement and until the auto—adhesivecures per immediately water test the window.
auto-adhesive instructions by the manufacturer’s. 25. Inspect the window for leaks.
26. If any leaks are found, use a plastic paddle in order
to apply extra urethane adhesive at the leak point.
27. 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 21°C
(70°F) 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 chemicaI-curing type of urethane
adhesive, allow a minimum of 1 hour.
Do NOTphysicaIIy disturb the repair area until after
these minimum times have elapsed.
28. 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
706194 before the urethane adhesive cures.
- Do not drive the vehicle until the urethane
23. Ensure all excess urethane adhesive is cleaned adhesive is cured. Refer to the above curing
from the body before water test. times.
° Do not use compressed air in order to dry the
urethane adhesive.
29. Complete the window installation.

—
2013 (US/Canada)
Sonic (5377994)
Manual
Service
 Fixed and Moveable Windows 1‘“
4205

Adhesive Installation of Liftgate

Windows
I Warning: Refer to Glass and Sheet Metal Handling
Warning on page 0-5.
1. Use a urethane adhesive systems which meet GM
Specification GM 3651G.
2. Remove all mounds or loose pieces of urethane
adhesive from the pinchweld area.
3. Ifthe original window is being reused, remove all
but approximately 2 mm (3/64in) of the existing
bead of urethane adhesive from the pinchweld
flange 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:
- The flange of the window opening
- High weld
- Solder spots
- Hardened sealer 245283
- Any other obstruction or irregularity in the Warning: Failure to prep the area prior to the
pinchweld flange applica tion of primer may cause insufficient
bonding of urethane adhesive. Insufficient bonding
Note: Ifcorrosion of the pinch—weldflange is present or of urethane adhesive may allow unrestrained
if sheet metal repairs or replacements are required, the occupants to be ejected from the vehicle resulting
pinch-weld flange must be refinished in order to restore in personal injury.
the bonding area strength. If paint repairs are required,
mask the flange bonding area prior to applying the color 7. Apply the primer to the surface of the pinch-weld
coat in order to provide a clean primer only surface. flange (1).
Materials such as BASF DE15®, DuPont 2610®, 8. Allow the pinch-weld primer to dry per
Sherwin-Williams PSE 4600 and NP70®and auto-adhesive instructions by the manufacturer’s.
Martin-Semour 5120 and 5130®PPG DP90LF SPlES/
9. With an assistant, dry fit the window (1) to the
HECKER 3688/8590 —3688/5150 —4070/5090
opening in order to determine the correct position.
STANDOX11158/13320 —14653/14980 products are
approved for this application.
5. After repairing the opening as indicated, perform
the following steps:
5.1. Remove all traces of broken glass from the
outer cowl panel, seats, floor and defroster
ducts.
5.2. 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.
6. Verify all primers and urethane adhesive are within
expiration dates.

745571
10. Use masking tape in order to mark the locations (1)
of the window (2) in the opening.
11. Cut the masking tape in the center and remove the
window from the opening.

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-Sonic
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4-66 Fixed and Moveable Windows

379890
12. Apply glass prep clear to the area approximately
10—16mm (3/8—5/8in) around the entire perimeter
of the window inner surface.
Immediately wipe the glass primed area using a
clean, lint-free cloth.
245290
14. Apply the auto—adhesiveprimer-application (2)
around the perimeter of the window (1) per
auto-adhesive instructions by the manufacturer’s.
15. Apply the glass primer black to the same areas (2)
that glass prep clear was applied.
16. Allow the glass primer to dry per auto-adhesive
instructions by the manufacturer’s.

161424
13. Apply bonded-glass primer and let dry per
auto-adhesive instructions by the manufacturer’s. 161427
17. Use a cartridge-type caulking gun in order to apply
a smooth, continuous bead.
Cut the applicator nozzle to provided a V out to
apply the auto-adhesive.
18. Install the window reveal molding, if equipped.

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-Sonic
(US/Canada)
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 Fixed and Moveable Windows 467

245315 745571
19. Use the edge of the window as a guide for the 21. Ifthe locating pins were damaged, align the
nozzle in order to apply the urethane adhesive (1) masking tape (1) lines on the window (2) and
to the inner surface of the window (3). the body.

2424999 - 706204
Note: Ifth‘talcticatirlgpins (wereCUtIOffit WIIIE): 22. Gently depress the window on the auto-adhesive
necessary .0 ape e wm OWm p ace u_n' e . bead until the window reveal molding is seated.
auto-adheswe cures per auto-adheswe Instructions by , , , , .
the manufacturer’s. 23. Tape the Windowto. the body In order
. to mInImIze
. . ‘ movement and until the auto—adheswecures per
20. With an 838181301. align the WIHdOW10C31mQ auto—adhesiveinstructions by the manufacturer’s.
pins (2) to the slots located in each corner of the
pinch—weldflange. Lower the window (1) to touch
the auto—adhesive.

2013
<Sonic
(US/Canada)
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4-68 Fixed and Moveable Windows
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 21°C
(70°F) 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 chemicaI-curing type of urethane
adhesive, allow a minimum of 1 hour.

\\\k Do' NOT physically disturb the repair area until after
these minimum times have elapsed.
29. 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
706194 times.
24. Ensure all excess urethane adhesive is cleaned ‘ Do not use compressed air in order to dry the
from the body before water test. urethane adhesive.
30. Complete the window installation.

Description and Operation

Full-Cut Method Description

\\\\\\\
\ or if sheet metal repairs or replacements are
\zv- \A\
\‘\\
Note: Do not direct a hard stream of high pressure
water to the freshly applied urethane adhesive.
25. Use a soft spray of.warm water in order to
immediately water test the window.
26. Inspect the window for leaks.
27. Ifany leaks are found, use a plastic paddle in order
to apply extra urethane adhesive at the leak point.
28. Retest the window for leaks.
\\ : Note:
Ifcorrosion of the pinch—weldflange is present,
required, refinish the pinch—weldflange in order to
present a clean, primer—onlysurface.
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.
Appropriate materials for these primer applications
are typically 2 component cataéyzed products. Use
materials such as BASF DE15 , DuPont 2610®,
Sherwin-Williams PSE 4600 and NP7O®and
Martin—Semour5120 ,5130®, PPG DP90LF
SPIES/HECKER 3688/8590 —3688/5150 —4070/
5090 STANDOX11158/13320 —14653/14980
95572
products are approved for this application. Follow
the manufacturer's directions for the mix, the
application, and the drying times.
- After repairing the opening as indicated, shake the
pinch-weld primer black #3well. Using a new
dauber, apply the primer to the primed surface of
the flange in the bonding area. Allow the primer to
dry for 10 minutes.
Use only the full cut method, also known in the field as
full strip method, when installing windows.
This method includes the following:
The replacement of a majority of the urethane
adhesive bead. Remove all but approximately
2 mm (3/64in) of the existing bead of urethane
adhesive from the pinch—weldflange.
Apply pinch—weldprimer to any exposed painted
areas on the pinch-weld flange.

—
2013 (US/Canada)
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Manual
Sen/ice I

No mounds or loose pieces of urethane adhesive
should remain on the pinch-weld flange. Do not remove
all traces of urethane adhesive.
Power Windows Description and
Operation
Power Window System Components
The power window system consists of the following
components:
- Driver window switch
' Front passenger window switch
- Left rear window switch
0 Right rear window switch
- Window regulator motors in each of the doors
- 30 amp fuse
- 25 amp fuse
Power Window System Controls
The power window system can be controlled by a
power window up or down switch activation.
Window Operation and the Driver
Window Switch
When the ignition switch is in the RUN orACCY
position, or Retained Accessory Power (RAP) is
enabled, battery positive voltage is supplied to the
driver window switch. Ground for the switch is provided
by a ground circuit connected to a ground stake. When
the driver window switch is pressed in the down
position, the voltage is applied to the driver window
motor down circuit and ground is applied to the driver
window motor up circuit causing the window to open.
When the driver window switch is pressed in the up
position, the polarity is reversed, voltage and ground
are applied to the opposite circuits and the window
closes. Inorder to control the passenger windows from
the driver door, the driver window switch assembly
contains a separate window switch for each passenger
door window. These window switches operate in the
same way as the driver window switch, except that the
applied voltage and ground must also pass through the
local passenger, left rear or right rear window switch in
order to command the respective window motor.
The driver window switch also provides power and
ground for the local rear window switches. Battery
positive voltage is supplied, through the power window
master switch lockout signal circuit, to each remote rear
window switch. The remote front passenger door
window switch has a separate battery positive voltage
circuit, however, this circuit is spliced into the driver
window switch voltage supply circuit within the IP Fuse
Block. Ground for all three of the passenger door
switches, is also supplied by the driver window switch.
Driver Express Up and Express Down
Power Window Motor (If Equipped)
The driver door may be equipped with a smart window
motor that will detect excessive resistance while
performing the express up function and automatically
reverse direction to prevent injuw to any occupants that
may become trapped between the closing window and
2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
Fixed and Moveable Windows 4-69
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.
Lockout Switch Feature
The driver window switch contains a rear window
lockout switch which disconnects the battery positive
voltage supply to the remote rear passenger door
window switches, disabling them. The remote front
passenger door window switch cannot be locked out.
Window Operation and the Passenger
Window Switches
When the ignition switch is in the RUN orACCY
position, or Retained Accessory Power (RAP) is
enabled, battery positive voltage is supplied to each of
the remote passenger door window switches. When a
remote window switch is pressed in the down position,
voltage is applied to the window motor down circuit and
ground is applied to the window motor up circuit,
causing the window to open. When the window switch
is pressed in the up position, the polarity is reversed,
voltage and ground are applied to the opposite circuits,
and the window closes.
Rear Window Defogger Description
and Operation
Rear Window Defogger System
Components
The rear window defogger system consist of the
following components:
° The HVAC control module
° The body control module (BCM)
- The rear defogger relay
- The rear window grid
Rear Window Defogger Operation
The BCM supplies 12 V to the rear window defogger
switch signal circuit to the HVAC control module. When
you depress the rear window defogger switch, the rear
window defogger switch pulls the signal circuit low. The
BCM interprets as a request for the rear window
defogger system. The BCM enables the rear window
defogger system by supplying voltage to the rear
defogger relay coil. The relay coil supply voltage is also
spliced off internally in the BCM to the supply voltage
circuit of the rear window defogger indicator. The rear
defogger relay is energized and the rear window
defogger indicator is illuminated. With the relay
energized, battery positive voltage is allowed from the
relay switched input through the switch contacts and
out the relay switched output to the rear window
defogger grid.
440 Fixed and Moveable Windows
When you start the engine and press the rear window Special Tools and Equipment
defogger switch for the first time, the defogger cycle
lasts for 15 minutes. Further operation results in
7.5 minute defogger cycles. The rear defogger feature Illustration Tool Number/Description
will not time out if vehicle speed is above 80 km/h
(50 mph). The defogger cycle resets to 15 minutes
when you cycle the ignition to the OFF position and
then to the ON position.
BO-24402-A
Stationary Window Description J—24402—A
Most stationary windows, specifically Windshields, are Glass SealantCold Knife
retained to the body with adhesive which adheres the Remover
window to the body, increasing structural integrity.The
reinstallation of the windows with adhesive requires
complete replacement of the adhesive bead, and is
known as the full cut method. All stationary windows 3898
must use a adhesive systems which meet GM
Specification GMW—15672.

Urethane Adhesive Description BO—39032

For replacement of any adhesive—installedwindow, use J-39032
the full cut method only. StationaryGlass
Use an adhesive that is approved by GM, Specification RemovalTool
GMW—15672.
Use these materials based on specific manufacturer.
Do NOT intermix primers or adhesives from one 3905
manufacturer to another.
Always follow the system manufacturers instructions for
application, handling, and curing.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994) i
 Horns

Horns

Specifications

Fastener Tightening Specifications

Specification
Application Metric English
HornNut 17N-m 13lbft
SteeringWheelHornContactBolts 5.5N-m 49 lbin

Schematic and Routing Diagrams

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-Sonic
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Service
Manual
(5377994)
 0

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Diagnostic Information and Procedures

DTC B2750

Diagnostic Instructions
' Perform the Diagnostic System Check —Vehicle
on page 6-66 prior to using this diagnostic
procedure.
- Review Strategy Based Diagnosis on page 6-58
for an overview of the diagnostic approach.
- Diagnostic Procedure Instructions on page 6—59
provides an overview of each diagnostic category.
DTC Descriptors
DTC 32750: Horn Relay Secondary Circuit
For symptom byte information refer to: Symptom Byte
List on page 6-85
Diagnostic Fault Information

Open/High Signal
Circuit Short to Ground Resistance Short to Voltage Performance
Control B275002 B275004 B275001 -

CircuitlSystem Description Conditions for Clearing the DTC

The Body Control Module provides a ground for the ' The DTC clears when the fault is no longer
Horn printed circuit board relay within the underhood detected.
fuse block. The underhood fuse block will then provide - The current DTC will become history when the
B+ voltage to the horn control circuit, sounding request for the output is removed.
the horn.
. The history DTC will clear after 50 consecutive
Conditions for Running the DTC fault-free ignition cycles have occurred.
When the horn output is actively being requested by the Reference Information
Body Control Module.
Schematic Reference
Conditions for Setting the DTC
Horn Schematics on page 4-72
32750 01
Connector End View Reference
The Body Control Module detects a short to voltage in
the horn relay control circuit. Component Connector End Views on page 11—269
32750 02 Description and Operation
The Body Control Module detects a short to ground in Horns System Description and Operation on page 4-80
the horn relay control circuit.
Electrical Information Reference
32750 04
- Circuit Testing on page 11—526
The Body Control Module detects an open/high
- Connector Repairs on page 11-548
resistance in the horn relay control circuit.
- Testing for IntermittentConditions and Poor
Action Taken When the DTC Sets Connections on page 11-531
B2750 01, 32750 04 - Wiring Repairs on page 11-537
The Body Control Module will command the horn when Scan Tool Reference
requested but the horn will be inoperative. Control Module References on page 6—3for scan tool
B2750 02 information
The horn will sound continuously until the horn is
disconnected or when the horn overheats and becomes
inoperative.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
' 4=74 Horns
CircuitlSystem Verification
1. lgnition 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
Refer to CircuitlSystem Testing.
l} If the P12 Horn turns 0N and OFF
3 All OK.
CircuitlSystem Testing
1. lgnition 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
2.1. lgnition OFF, disconnect the harness
connector at the P12 Horn, ignition ON.
2.2. Test for less than 1 V between the control
circuit terminal 2 and ground.
=>lf 1 V or greater, repair the short to voltage on
the circuit.
:> If less than 1 V, test or replace the P12 Horn.
If the P12 Horn is not activated
Connect a 15A fused jumper wire between the
control circuit terminal D4 and B+.
.6 Verify the P12 Horn activates.
If the P12 Horn does not activate
4.1. lgnition OFF, remove the jumper wire,
disconnect the harness connector at the P12
Horn, ignition ON.
4.2. Test for infinite resistance between the control
circuit and ground.
=>If less than Infinite resistance, repair the short to
ground on the circuit.
ii Ifinfinite resistance
4.3. Test for less than 2 Q in the control circuit end
to end.
=>lf 2 Q or greater, repair the open/high resistance
in the circuit.
=>Ifless than 2 0, test or replace the P12 Horn.
If the P12 Horn activates
lgnition 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.
O). Verify the P12 Horn is not activated.
If the P12 Horn is activated
6.1. lgnition OFF, disconnect the X2 harness
connector at the X50A Fuse
Block—Underhood.
6.2. Test for infinite resistance between the control
circuit terminal 19 X5 at the K9 Body Control
Module and ground.
2» If less than Infinite resistance, repair the short to
ground on the circuit.
:> If infinite resistance, test or replace the X50A
Fuse BIock-Underhood.
U If the P12 Horn is not activated
7. Connect a 3 A fused jumper wire between the
control circuit terminal 19 and ground.
8. Verify the P12 Horn activates.
=>If the P12 Horn does not activate
8.1. lgnition OFF, remove the jumper wire,
disconnect the X2 harness connector at the
X50A Fuse Block-Underhood, ignition ON.
8.2. Test for less than 1 V between the control
circuit terminal 19 X5 at the K9 Body Control
Module and ground.
:> If 1V or greater, repair the short to voltage on
the circuit.
U Ifless than 1 V
8.3. Test for less than 2 Q in the control circuit end
to end.
=>If2 Q or greater, repair the open/high resistance
in the circuit.
=>Ifless than 2 (2,test or replace the X50A Fuse
Block—Underhood.
U If the P12 Horn activates
9. Replace the K9 Body Control Module.
Instructions
Repair
Perform the Diagnostic Repair Verification on
page 6-92 after completing the repair.
Front Compartment Fuse Block Replacement on
page 11-609
Control Module References on page 6-3 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 on
page 6-66 , before using the symptom tables in
order to verify that all of the following are true:
0 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 on page 4-80.
(US/Canada)
-Sunic
2013 (5377994)
Manual
Service
 Horns 4.75
Visual/Physical Inspection Intermittent
- Inspect for aftermarket devices which could affect Faulty electrical connections or wiring may be the
the operation of the horn system. Refer to cause of intermittentconditions. Refer to Testing for
Checking Aftermarket Accessories on IntermittentConditions and Poor Connections on
page 11-525. page 11-531.
- Inspect the easily accessible or visible system
components for obvious damage or conditions Symptom List
which could cause the symptom. Refer to a symptom diagnostic procedure Horns
- Perform the following if a horn buzzes or has a Malfunction on page 4-75 in order to diagnose the
harsh tone. symptom.
—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).

Horns Malfunction
Diagnostic Instructions
- Perform the Diagnostic System Check —Vehicle
on page 6-66 prior to using this diagnostic
procedure.
- Review Strategy Based Diagnosis on page 6—58
for an overview of the diagnostic approach.
- Diagnostic Procedure Instructions on page 6-59
provides an overview of each diagnostic category.
Diagnostic Fault Information

‘ Open/High , Signal
Circuit Short to Ground Resistance Short to Voltage Performance
HornSwitchSignal 1 2 2 -
HornRelay Control B275002 8275004 B275001 —-
HornControl 2 2 1 -
HornGround —— 2 — -
1.HornAlwaysOn
2. Hornlnoperative

CircuitlSystem Description Ifdiagnosing a Horn—Poor Tone condition, inspect the

The Body Control Module monitors the horn switch following:
signal circuit, when the horn pad is pressed, the Body - Debris or water in the horn assembly
Control Module detects the drop in the horn switch - Proper horn mounting hardware torque—Refer to
signal circuit and provides a ground forthe Horn printed Fastener Tightening Specifications on page 4-71.
circuit board relay within the underhood fuse block. The - Debris in the joint where the horns attach to the
underhood fuse block will then provide B+ voltage to vehicle
the horn control circuit, sounding the horns
- Debris in direct contact with the horn
Diagnostic Aids ' Vehicle components vibrating while the horn is
A short to ground in the horn relay control circuit or a sounding
short to voltage in the horn control circuit will cause the
horns to sound continuously until the horns overheat Reference Information
and become inoperative. . Schematic Reference
Rotate the steering wheel while pressing the horn pad
Horn Schematics on page 4—72
to identify intermittentand poor connections within the
steering column. Connector End View Reference
Component Connector End Views on page 11-269

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
4=76 Horns
Description and Operation
Horns System Description and Operation on page 4—80
Electrical Information Reference
- Circuit Testing on page 11—526
- Connector Repairs on page 11-548
- Testing for IntermittentConditions and Poor
Connections on page 11—531
- Wiring Repairs on page 11—537
Scan Tool Reference
Control Module References on page 6-3 for scan tool
information
CircuitlSystem Verification
1. lgnition ON.
2. Verify the scan tool Horn Switch parameter
changes between Active and Inactive when
pressing and releasing the horn pad.
:> If the parameter does not change
Refer to CircuitlSystem Testing — Horn Switch
Malfunction.
U If the parameter changes
3. Verify the P12 Horn turns ON and OFF and emits 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 CircuitlSystem Testing ~Horns or Horn
Command Malfunction.
=>If the sound emitted is not clear and even
Refer to CircuitlSystem Testing —Horn -
Poor Tone.
ti If the P12 Horn turns 0N and OFF and emit a
even and clear tone
4. All OK.
CircuitlSystem Testing
Horn Switch Malfunction
Note: Refer to SIR Service Precautions on
page 13—113.
1. lgnition OFF, disconnect the X1 harness connector
at the X85 Steering Wheel Air Bag Coil.
lgnition ON
2. Verify the scan tool Horn Switch parameter is
Inactive.
=>If not Inactive
2.1. Ignition OFF, disconnect the harness
connector at the K9 Body Control Module.
2.2. Test for infinite resistance between the signal
circuitterminal 1 and ground.
:> Ifless than infinite resistance, repairthe short to
ground on the circuit.
=9 lf infinite resistance, replace the K9 Body
Control Module.
U lflnactive
3. Install a 3 A fused jumper wire between the signal
circuit terminal 1 and ground.
4. Verify the scan tool Horn Switch parameter is
Active.
:> If not Active
4.1. lgnition OFF, remove thejumperwire,
disconnect the harness connector at the K9
Body Control Module, ignition ON.
4.2. 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.
it if less than 1 V
4.3. Test for less than 2 Q in the signal circuit and
to end.
=>If2 Q or greater, repair the open/high resistance
in the circuit.
=>Ifless than 2 Q, replace the K9 Body Control
Module.
U If Active
5. Test or replace the 833 Horn Switch.
Horns or Horn Command Malfunction
1. lgnition OFF, and all vehicle systems OFF.
Disconnect the harness connector at the P12 Horn.
Itmay take up to 2 minutes for all vehicle systems
to power down.
Test for less than 10 0 between the ground circuit
terminal 1 and ground.
If 10 Q or greater
2.1. Ignition OFF.
2.2. Test for less than 2 Q in the ground circuit end
to end.
=>lf 2 Q or greater, repair the open/high resistance
in the circuit.
:> If less than 2 Q, repair the open/high resistance
in the ground connection.
If less than 10 (1
Connect a test lamp between the control circuit
terminal 2 and ground, ignition ON.
. Verify the test lamp does not turn ON and OFF
when commanding the Horn Relay On and Off with
a scan tool.
If the test lamp turns 0N and OFF
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.
=>If the P12 Horn is activated
6.1. lgnition OFF, disconnect the harness
connector at the P12 Horn, ignition ON.
6.2. Test for less than 1 V between the control
circuit terminal 2 and ground.
:> If 1V or greater, repair the short to voltage on
the circuit.
:> Ifless than 1 V, test or replace the P12 Horn.
If the P12 Horn is not activated
(US/Canada)
-Sonic
2013 (5377994)
Manual
Sen/ice

7. Connect a 15 A fused jumper wire between the
control circuit terminal D4 and B+.
8. Verify the P12 Horn activates.
:> If the P12 Horn does not activate
8.1. lgnition OFF, remove the jumperwire,
disconnect the harness connector at the
P12 Horn, ignition ON.
8.2. Test for infinite resistance between the control
circuit and ground.
=>Ifless than Infiniteresistance, repairthe short to
ground on the circuit.
U lf infinite resistance
8.3. Test for less than 2 Q in the control circuit end
to end.
=>If2 Q or greater, repair the open/high resistance
in the circuit.
=>Ifless than 2 Q, test or replace the P12 Horn.
U If the P12 Horn activates
9. lgnition 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.
10. Verify the P12 Horn is not activated.
=>If the P12 Horn is activated
10.1. lgnition OFF, disconnect the X2 harness
‘ connector at the X50A Fuse
Block-Underhood.
10.2. Test for infinite resistance between the
control circuit terminal 19 X5 at the K9 Body
Control Module and ground.
=>Ifless than Infiniteresistance, repair the short to
ground on the circuit.
=>Ifinfinite resistance, replace the X50A Fuse
Block—Underhood.
U If the P12 Horn is not activated
11. Connect a 3 A fused jumper wire between the
control circuit terminal 19 and ground.
12. Verify the P12 Horn activates.
=>If the P12 Horn does not activate
12.1. lgnition OFF, remove the jumper wire,
disconnect the X2 harness connector at the
X50A Fuse Block-Underhood, ignition ON.
12.2. Test for less than 1 V between the control
circuit terminal 19 X5 at the K9 Body Control
Module and ground.
:> lf1 V or greater, repair the short to voltage on
the circuit.
U Ifless than 1 V
12.3. Test for less than 2 Q in the control circuit end
to end.
=>If2 Q or greater, repair the open/high resistance
in the circuit.
2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
Horns 4-77
:> If less than 2 Q, replace the X50A Fuse
Block—Underhood.
U If the P12 Horn activates
13. Replace the K9 Body Control Module.
Horn - Poor Tone
1. lgnition OFF and all vehicle systems OFF,
disconnect the harness connector at the P12 Horn.
Itmay take up to 2 minutes for all vehicle systems
to power down.
2. Test for less than 10 Q between the ground circuit
terminal 1 and ground.
=>If 10 Q or greater
2.1. IgnitionOFF.
2.2. Test for less than 2 Q Inthe ground circuit and
to end.
=>If2 Q or greater, repair the high resistance in
the circuit.
=>if less than 2 Q, repair high resistance in the
ground connection.
U If less than 10 Q
3. lgnition OFF, disconnect the X1 harness connector
at the X50A Fuse Block-Underhood.
4. Test for less than 2 Q between the P12 Horn
control circuit terminal 2 and the X50A Fuse
Block-Underhood control circuit terminal D4 X1.
=>lf 2 Q or greater
Repair the high resistance in the control circuit.
U If less than 2 Q
5. Test or replace the P12 Horn.
Component Testing
Horn Test
1. IgnitionOFF, disconnect the harness connector at
the P12 Horn.
2. Install a 15A fused jumper wire between the
control terminal 2 and 12V. Install a jumper wire
between the ground terminal1 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.
U If the P12 Horn turns 0N and OFF
4. All OK
Repair Instructions
Perform the Diagnostic Repair Verification on
page 6—92after completing the repair.
- Steering Wheel Horn Contact Replacement on
page 4-79
- Horn Replacement on page 4—78
- Front Compartment Fuse Block Replacement on
page 11—609
- Control Module References on page 6-3 for Body
Control Module replacement, programming and
setup
4=78 Horns

Repair Instructions

Horn Replacement

2472670
Horn Replacement
Callout Component Name
Preliminary PrOcedure
Removethefrontwheelhouselinerfront.RefertoFront WheelhouseLinerReplacement(Rear)onpage3—151
or Front
WheelhouseLinerReplacement(Front)onpage3-150.
HornNut
Caution: Referto FastenerCautiononpage0-8.
Tighten
17N-m(13lbft)
Horn
2 Procedure
Disconnecttheelectricalconnector.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Horns 439

2496191
Steering Wheel Horn Contact Replacement
Callout Component Name
Preliminary Procedure
Removethesteeringwheelinflatablerestraintmodule.RefertoAirbagSteeringWheelModuleReplacementonpage 13-118.
SteeringWheel HornContactSpringRetainerBolt(Qty:3)
Caution: RefertoFastenerCautiononpage 0-8.
Tighten
5.5N-m(49lb in)
SteeringWheelHornContactAssembly
2 Procedure
Disconnecttheelectricalconnectors.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
480 Home

and Operation Circuit Operation

Description
The BCM controls the horn operation, when the horn
switch is pressed, it closes a switch pulling the horn
Horns System Description and signal circuit low. When the BCM detects the drop in
voltage in the horn switch signal circuit, it energizes the
Operation PCB Horn relay which provides B+ voltage to the horn
control circuit, sounding the horn.
System Description
When the vehicle is in the Off Power Mode the BCM will ‘
The horn system consists of the following components: attempt to detect a stuck or continuously activated horn
- 15A circuit fuse switch. When enabled, activation of the horn will be
- Underhood fuse block (contains a non-serviceable limited to 10 seconds to protect the horn from
PCB Horn relay) excessive use.
- Horn switch
- Horn
- Body control module (BCM)
System Operation
- The vehicle horn is activated whenever 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 on
page 13—153.
—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 on page 13—44.

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
i Lig nting 4:61

I Lighting

1 Specifications

Fastener Tightening Specifications

Specification
Application Metric English
FrontFog LampBolt 1.5N-m 13lbin
HeadlampBolt 2.5N-m 22 lbin
HighMountStopLampBolt 2.5N-m 22 lbin
RearLicensePlateLampBolt 1.0N-m 9 lbin
TailLampBolt 2.5N-m 22 lbin

Schematic and Routing Diagrams

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
4=82 Lighting

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Manual
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 Lighting 4-93

Diagnostic Information and Procedures

DTC B1480

Diagnostic Instructions
- Perform the Diagnostic System Check - Vehicle
on page 6-66 prior to using this diagnostic
procedure.
- Review Strategy Based Diagnosis on page 6-58
for an overview of the diagnostic approach.
- Diagnostic Procedure Instructions on page 6-59
provides an overview of each diagnostic category.
DTC Descriptor
DTC B1480 02: Battery Rundown Protection Circuit Short to Ground
Diagnostic Fault Information

Opeanigh Signal
Circuit Short to Ground Resistance Short to Voltage Performance
F11DA(BCM7)FuseB+ 1,2 1,2 — -
DomeLampsControl 8261502 2 2 ~-
ReadingLampsControl B148002 1 1 -
Dome/ReadingLamps- FrontGround — 1,2 — -
Dome/ReadingLamps-Rear Ground —- 1,2 — -
1.CourtesyLampsMalfunction
2. DomeLampsMalfunction

CircuitlSystem Description Reference Information

The body control module (BCM) supplies battery Schematic Reference
voltage to the reading lamps via the courtesy lamp
control circuit. The front reading lamps controlled by an - Interior Lights Schematics on page 4-89
individual switch that is activated by the operator when - Body Control System Schematics on page 11-8
additional cabin lighting is required. In the event that
the reading lamp were to remain illuminated for more Connector End View Reference
than 10 minutes with the ignition switch in the OFF Component Connector End Views on page 11-269
position and no doors opened, the BCM will deactivate
the reading lamp control circuit to prevent total battery Description and Operation
discharge.
InteriorLighting Systems Description and Operation on
Conditions for Running the DTC page 4—21 9
Battery voltage must be between 9—16V. Electrical Information Reference
Conditions for Setting the DTC - Circuit Testing on page 11—526
The BCM detects a short to ground in the reading lamp - Connector Repairs on page 11-548
control circuit. - Testing for IntermittentConditions and Poor
Connections on page 11-531
Actions Taken When the DTC Sets - Wiring Repairs on page 11—537
The BCM will disable the circuit and the reading lamp
will be inoperative. Scan Tool Reference
Control Module References on page 6—3for scan tool
Conditions for Clearing the DTC information
- The condition responsible for setting the DTC no
longer exists.
- A history DTC will clear once 100 consecutive
malfunction-free ignition cycles have occurred.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
4,94 LIgEIng
Testing
CircuitlSystem
1. lgnition OFF, exterior lamps OFF, disconnect the
harness connectors at the E37F dome/reading
lamps—frontand E378 dome/reading
Iamps—an row.
2. Connect a test lamp between the appropriate
control circuit terminal listed below and ground.
- E37F dome/reading lamps —front terminal 1
with 095
- E37F dome/reading lamps —front terminal 4
with 090/091
- E37B dome/reading lamps —2nd row terminal 4
with C90/C95
3. Verify the test lamp turns ON and OFF when
commanding the Inadvertent Load ON and OFF
with a scan tool.
=>If the test lamp is always OFF
3.1. lgnition OFF, disconnect the X7 harness
connector at the K9 body control module.
3.2. Test for infinite resistance between the control
circuit and ground.
=>If less than infinite resistance, repair the short to
ground on the circuit.
U lf infinite resistance
3.3. Test for less than 2 Q in the control circuit end
to end.
=>If2 Q or greater, repair the open/high resistance
in the circuit.
:> Ifless than 2 Q, replace the K9 body control
module.
:> If the test lamp is always ON
3.1. IgnitionOFF, disconnect the X7 harness
connector at the K9 body control module,
ignition ON.
3.2. Test for less than 1 V between the control
circuit terminal and ground.
=>If 1 V or greater, repair the short to voltage on
the circuit.
=>Ifless than 1 V, replace the K9 body control
module.
It If the test lamp turns ON and OFF
4. Test or replace the appropriate E37 dome/reading
lamps.
Repair Instructions
Perform the Diagnostic Repair Verification on-
page 6-92 after completing the repair.
- Dome Lamp Bulb Replacement on page 4—192
0 Reading Lamp Replacement on page 4—189
- Control Module References on page 6-3 for BCM
replacement, programming, and setup
(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
 Lighting 4&5

DTC 32530

Diagnostic Instructions
- Perform the Diagnostic System Check - Vehicle
on page 6-66 prior to using this diagnostic
procedure.
- Review Strategy Based Diagnosis on page 6-58
for an overview of the diagnostic approach.
' Diagnostic Procedure Instructions on page 6-59
provides an overview of each diagnostic category.
DTC Descriptors
DTC 32530 01: Front Fog Lamps Control Circuit Short to Battery
DTC 32530 02: Front Fog Lamps Control Circuit Short to Ground
DTC 32530 04: Front Fog Lamps Control Circuit Open
Diagnostic Fault Information

Open/High Signal
Circuit Short to Ground Resistance Short to Voltage Performance
FrontFog LampandInstrumentPanel Dimmer 32573 03, _ _
SwitchB+ 3140503 8257303
FrontFog LampandInstrumentPanel Dimmer
SwitchSignal 32573 03 3257303 1 __

FrontFog LampRelayControl 832255%%%i' 832255?)

(2)31 3253001 -
FrontFog LampControl 1 1 1 -
FrontFog LampGround—Left — 1 — -
FrontFog LampGround—Right — 1 — -
1.FrontFog LampsMalfunction

CircuitlSystem Description Conditions for Setting the DTC

The front fog lamp switch is an input to the body control DTC 32530 01
module (BCM) and is contained in the headlamp switch
assembly. The BCM supplies voltage to the front fog The BCM detects a short to voltage in the front fog lamp
lamp switch via the front fog lamp and instrument panel relay control circuit for 5 seconds or greater.
dimmer switch 3+ circuit. When the front fog lamp DTC 32530 02
switch is pressed, voltage from the B+ circuit is pulled
down through the frontfog lamp switch resistor. The The BCM detects a short to ground in the front fog lamp
front fog lamp resistor is part of the resistor ladder that relay control circuit.
also provides the dimming signals for the instrument DTC B2530 04
panel dimmer switches. The BCM receives the voltage
signal through the frontfog lamp and instrument panel The BCM detects an open in the front fog lamp relay
dimmer switch signal circuit. control circuit.
The front fog lamp relay is supplied with battery voltage Actions Taken When the DTC Sets
at all times. The front fog lamp switch signal circuit is
grounded momentarily by pressing the front fog lamp DTC B2530 01 and B2530 04
switch. The body control module (BCM) energizes the The front fog lamps will not operate when the park
front fog lamp relay by applying ground to the front fog lamps are ON and the front fog lamp switch is active.
lamp relay control circuit. When the front fog lamp relay
is energized, the relay switch contacts close and DTC 32530 02
batter voltage is applied through the front fog lamp The front fog lamps always ON.
fuse to the front fog lamp control circuit which
illuminates the front fog lamps. Conditions for Clearing the DTC
Conditions for Running the DTC - The condition responsible for setting the DTC no
longer exists.
- Battery voltage must be between 9—16V.
- A history DTC will clear once 100 consecutive
- Front fog lamps ON. malfunction—freeignition cycles have occurred.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
4-96 Lghtig
:> If less than 2 Q, replace the X50A Fuse Block -
Reference Information
Underhood.
Schematic Reference U If the test lamp illuminates
Fog Lights Schematics on page 4-84 3. Ignition OFF, connect a 3 A fused jumper between
the control circuit terminal 13 and ground.
Connector End View Reference
4. Remove the front fog lamp fuse at the X50A Fuse
Component Connector End Views on page 11-269 Block —Underhood, ignition ON.
Description and Operation 5. Verify a test lamp illuminates between the front fog
lamp fuse B+ switch control terminal and ground.
Exterior Lighting Systems Description and Operation =>If the test lamp does not illuminate
on page 4-217
5.1. IgnitionOFF, disconnect the X2 harness
Electrical Information Reference connector at the X50A Fuse Block -
Underhood, ignition ON.
- Circuit Testing on page 11-526
5.2. Test for less than 1 V between the control
- Connector Repairs on page 11-548 circuitterminal13 and ground.
. Testing for IntermittentConditions and Poor
Connections on page 11-531 :> If 1 V or greater, repair the short to voltage on
the circuit.
0 Wiring Repairs on page 11—537
=>Ifless than 1 V, replace the X50A Fuse Block -
Scan Tool Reference Underhood.
Control ModuleReferences on page 6—3for scan tool II If the test lamp illuminates
information 6. Test or replace the K9 Body Control Module.
CircuitlSystem Testing Repair Instructions
1. lgnition OFF, disconnect the X5 harness connector Perform the Diagnostic Repair Verification on
at the K9 Body Control Module, ignition ON. page 6—92after completing the repair.
2. Verify a test lamp illuminates between the control ° Front Compartment Fuse Block Replacement on
circuit terminal 13 and ground. page 11—609
=>If the test lamp does not illuminate ~ Control Module References on page 6-3 for BCM
2.1. Ignition OFF, disconnect the X2 harness replacement, programming, and setup
connector at the X50A Fuse Block -
Underhood.
2.2. Test for infinite resistance between the control
circuit terminal and ground.
=>Ifless than infinite resistance, repairthe short to
ground on the circuit.
It If infinite resistance
2.3. Test for less than 2 Q in the control circuit and
to end.
=>If2 Q or greater, repair the open/high resistance
in the circuit.

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
 Lighting 4497

DTC 32545

Diagnostic Instructions
- Perform the Diagnostic System Check —Vehicle
on page 6-66 prior to using this diagnostic
procedure.
- Review Strategy Based Diagnosis on page 6-58
for an overview of the diagnostic approach.
- Diagnostic Procedure Instructions on page 6—59
provides an overview of each diagnostic category.
DTC Descriptors
DTC 32545 01: Backup Lamps Circuit Short to Battery
DTC 32545 02: Backup Lamps Circuit Short to Ground
DTC 32545 04: Backup Lamps Circuit Open

Diagnostic Fault Information

Opeanigh Signal
Circuit Short to Ground Resistance Short to Voltage Performance
F1ODA(BCM 6)Fuse B+ 1 1 — -
BackupLampSwitchSignal(Manual P0812 P0812 1 ~-
Transmission)
BackupLampsControl 3254502 3254504 3254501 -
BackupLampSwitchGround(Manual —- P0812 — -
Transmission)
BackupLampGround—Left 1
BackupLampGround—Right 1
1.BackupLampsMalfunction

CircuitlSystem Description Conditions for Running the DTC

Automatic Transmission Battery voltage must be between 9—16V.
With the engine running and the transmission in the Engine RUNNING.
reverse position, the transmission control module Transmission placed in REVERSE gear.
(TCM) sends a serial data message to the body control
module (BCM). The message indicates that the gear Conditions for Setting the DTC
selector is in the reverse position. The BCM applies DTC 32545 01
battery voltage to the backup lamps control circuit
illuminating the backup lamps. Once the driver moves The BCM detects a short to voltage in the backup
the gear selector out of the reverse position, a message lamps control circuit.
is sent by the TCM via serial data requesting the BCM DTC 32545 02
to remove battery voltage from the backup lamps
control circuit. The engine must be running for the The BCM detects a short to ground in the backup lamps
backup lamps to operate. control circuit.
Manual Transmission DTC B2545 04
The engine control module (ECM) provides a signal The BCM detects an open/high resistance in the
circuit to the backup lamp switch which is permanently backup lamps control circuit.
grounded. With the engine running and the
transmission in the reverse position, the backup lamp Actions Taken When the DTC Sets
switch signal circuit is pulled low and the ECM DTC 32545 02 and B2545 04
responds by sending a serial data message to the body
control module (BCM). The message indicates that the The backup lamps will not operate.
gear selector is in the reverse position. The BCM DTC 32545 01
applies battery voltage to the backup lamps control
circuit illuminating the backup lamps. Once the driver The backup lamps are always ON.
moves the gear selector out of the reverse position, a
message is sent by the ECM via serial data requesting
the BCM to remove battery voltage from the backup
lamps control circuit. The engine must be running for
the backup lamps to operate.
2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
4—98 Lighting

Conditions for Clearing the DTC 4. lgnition OFF, exterior lamps OFF, trunk latch
latched, remove the appropriate E5 Backup Lamp
- The condition responsible for setting the DTC no bulb at the appropriate E42 Tail Lamp Assembly.
longer exists.
5. Test for less than 5 0 between the ground circuit at
- A history DTC will clear once 100 consecutive the socket terminal and ground.
malfunction-free ignition cycles have occurred.
=>If 5 Q or greater
Reference Information 5.1. lgnition OFF.
Schematic Reference 5.2. Test for less than 2 Q in the ground circuit end
to end. '
Exterior Lights Schematics on page 4-85 =>If2 Q or greater, repair the open/high resistance
Body Control System Schematics on page 11-8 in the circuit.
Connector End View Reference =>if less than 2 Q, repair the open/high resistance
in the ground connection.
Component Connector End Views on page 11-269
U If less than 5 Q
Description and Operation
6. Connect a test lamp between the control circuit at
Exterior Lighting Systems Description and Operation the socket terminal and ground, ignition ON.
on page 4-217 7. Verify the test lamp turns ON and OFF when
Information Reference commanding the Backup Lamps ON and OFF with
Electrical
a scan tool.
- Circuit Testing on page 11-526 =>If the test lamp is always OFF
- Connector Repairs on page 11-548 7.1. IgnitionOFF, disconnect the X7 harness
- Testing for IntermittentConditions and Poor connector at the K9 Body Control Module.
Connections on page 11-531 7.2. Test for infinite resistance between the control
- Wiring Repairs on page 11-537 circuit and ground.
Scan Tool Reference =>Ifless than infinite resistance, repair the short to
ground on the circuit.
Control Module References on page 6-3 for scan tool
information U Ifinfinite resistance
7.3. Test for less than 2 Q in the control circuit end
CircuitlSystem Testing to end.
1. lgnition OFF, disconnect the X5 harness connector :> If2 Q or greater, repair the open/high resistance
at the K9 Body Control Module, ignition ON. in the circuit.
2. Verify a test lamp illuminates between the B+ =>Ifless than 2 Q, replace the K9 Body Control
circuit terminal 4 and ground. Module.
=>If the test lamp does not illuminate and the =>If the test lamp is always ON
circuit fuse is good 7.1. lgnition OFF, disconnect the X7 harness
2.1. lgnition OFF. connector at the K9 Body Control Module,
2.2. Test for less than 2 Q in the B+ circuit end ignition ON.
to end. 7.2. Test for less than 1 V between the control
=>lf 2 Q or greater, repair the open/high resistance circuit terminal and ground.
in the circuit. =>If 1 V or greater, repair the short to voltage on
=>Ifless than 2 Q, verify the fuse is not open and the circuit.
‘ there is voltage at the fuse. =>Ifless than 1 V, replace the K9 Body Control
: If the test lamp does not illuminate and the Module.
circuit fuse is open U If the test lamp turns ON and OFF
2.1. lgnition OFF. 8. Test or replace the appropriate E5 Backup Lamp.
2.2. Test for infinite resistance between the B+
circuit and ground. Repair Instructions
=>Ifless than infinite resistance, repair the short to Perform the Diagnostic Repair Verification on
ground on the circuit. page 6-92 after completing the repair.
:> Ifinfinite resistance, replace the K9 Body - Backup Lamp Bulb Replacement (Sedan) on
Control Module. page 4-208
' Control Module References on page 6—3for BCM
U If the test lamp illuminates replacement, programming, and setup
3. lgnition OFF, connect the X5 harness connector at
the K9 Body Control Module.

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
 Lighting 4-99

DTC 3256A

Diagnostic Instructions
. Perform the Diagnostic System Check - Vehicle
M
.2...
2...-
..“«A on page 6-66 prior to using this diagnostic
procedure.
~ Review Strategy Based Diagnosis on page 6-58
for an overview of the diagnostic approach.
- Diagnostic Procedure Instructions on page 6-59
provides an overview of each diagnostic category.
DTC Descriptor
DTC 3256A 02: Liftgate Lamp Control Circuit Short to Ground

Diagnostic Fault Information

Opeanigh Signal
Circuit Short to Ground Resistance Short to Voltage Performance
F8DA (BCM 4)Fuse 3+ 1 1 _ _
Rear CompartmentCourtesyLampControl 3256A02 1 1 -
Rear CompartmentCourtesyLampGround - 1 _ __
1. Rear CompartmentLampMalfunction

CircuitlSystem Description Description and Operation

The body control module (BCM) applies battery voltage InteriorLighting Systems Description and Operation on
to the rear compartment courtesy lamp through the rear page 4-219
compartment lamp control circuit. When the BCM
receives a rear compartment lid open input from the Electrical Information Reference
rear compartment lid latch, the BCM applies battery 0 Circuit Testing on page 11-526
voltage to the rear compartment lamp control circuit
illuminating the rear compartment courtesy lamp. In the . Connector Repairs on page 11-548
event that the rear compartment lamp were to remain - Testing for IntermittentConditions and Poor
illuminated for more than 10 minutes with the ignition Connections on page 11-531
switch in the OFF position and no doors opened, the ' Wiring Repairs on page 11-537
BCM will deactivate the rear compartment lamp control
circuit to prevent total battery discharge. Scan Tool Reference

Conditions for Running the DTC Control Module References on page 6-3 for scan tool
information
- Battery voltage must be between 9—16V.
. Rear compartment OPEN. CircuitlSystem Testing
1. IgnitionOFF, exterior lamps OFF, trunk latch
Conditions for Setting the DTC latched, disconnect the harness connector at the
The BCM detects a short to ground on the rear E88 Rear Compartment Courtesy Lamp.
compartment courtesy lamp control circuit. 2. Test for less than 5 Q between the ground circuit
terminal2 and ground.
Actions Taken When the DTC Sets
:> If 5 Q or greater
The rear compartment lamp is inoperative.
2.1. IgnitionOFF.
Conditions for Clearing the DTC 2.2. Test for less than 2 .Qin the ground circuit end
' The condition responsible for setting the DTC no to end.
longer exists. =>lf 2 Q or greater, repair the open/high resistance
- A history DTC will clear once 100 consecutive in the circuit.
malfunction-freeignition cycles have occurred. =>Ifless than 2 Q, repairthe open/high resistance
in the ground connection.
Reference Information
U If less than 5 Q
Schematic Reference 3. Connect a test lamp between the control circuit
InteriorLights Schematics on page 4-89 terminal1 and ground, ignition ON.
Connector End View Reference
Component Connector End Views on page 11-269

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
41-100 Lighting
4. Verify the test lamp turns ON and OFF when :> If less than 1V, replace the K9 Body Control
commanding the Trunk Lamp ON and OFF with a Module.
scan tool. U If the test lamp turns ON and OFF
If the test lamp is always OFF 5. Test or replace the E88 Rear Compartment
4.1. IgnitionOFF, disconnect the X7 harness Courtesy Lamp.
connector at the K9 Body Control Module.
Repair Instructions
4.2. Test for infinite resistance between the control
circuit and ground. Perform the Diagnostic Repair Verification on
=>Ifless than infinite resistance, repair the short to page 6—92after completing the repair.
ground on the circuit. Rear Compartment Courtesy Lamp Replacement
(Hatchback) on page 4-216 or Rear Compartment
U lf infinite resistance Courtesy Lamp Replacement (Sedan) on
4.3. Test for less than 2 Q in the control circuit end page 4-21 7
to end. Control Module References on page 6-3 for BCM
=>If2 Q or greater, repair the open/high resistance replacement, programming, and setup
in the circuit.
=>Ifless than 2 Q, replace the K9 Body Control
Module. .
If the test lamp is always ON
4.1. lgnition OFF, disconnect the X7 harness
connector at the K9 Body Control Module,
ignition ON.
4.2. Test for less than 1 V between the control
circuit terminal and ground.
=>If 1 V or greater, repair the short to voltage on
the circuit.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Lighting 4-101

DTC 32570

Diagnostic Instructions
- Perform the Diagnostic System Check —Vehicle
on page 6-66 prior to using this diagnostic
procedure.
' Review Strategy Based Diagnosis on page 6-58
for an overview of the diagnostic approach.
0 Diagnostic Procedure Instructions on page 6-59
provides an overview of each diagnostic category.
DTC Descriptor
DTC 32570 02: Trunk Lamp Control Circuit Short to Ground
Diagnostic Fault Information

Opeanigh Signal
Circuit Short to Ground Resistance Short to Voltage Performance
F8DA (BCM 4) Fuse 3+ 1 1 — -
Rear CompartmentCourtesyLampControl 3257002 1 1 -
Rear CompartmentCourtesyLampGround - 1 _ _
1.Rear CompartmentLampMalfunction

CircuitlSystem Description Description and Operation

The body control module (BCM) applies battery voltage Interior Lighting Systems Description and Operation on
to the rear compartment courtesy lamp through the rear page 4-219
compartment lamp control circuit. When the BCM
receives a rear compartment lid open input from the Electrical Information Reference
rear compartment lid latch, the BCM applies battery Circuit Testing on page 11-526
voltage to the rear compartment lamp control circuit
illuminating the rear compartment courtesy lamp. In the Connector Repairs on page 11-548
event that the rear compartment lamp were to remain Testing for IntermittentConditions and Poor
illuminated for more than 10 minutes with the ignition Connections on page 11-531
switch in the OFF position and no doors opened, the Wiring Repairs on page 11~537
BCM will deactivate the rear compartment lamp control
circuit to prevent total battery discharge. Scan Tool Reference
Control Module References on page 6-3 for scan tool
Conditions for Running the DTC
information
- Battery voltage must be between 9-16 V.
- Rear compartment OPEN. CircuitlSystem Testing
1. lgnition OFF, exterior lamps OFF, trunk latch
Conditions for Setting the DTC latched, disconnect the harness connector at the
The BCM detects a short to ground on the rear E88 Rear Compartment Courtesy Lamp.
compartment courtesy lamp control circuit. Test for less than 5 Q between the ground circuit
terminal 2 and ground.
Actions Taken When the DTC Sets
If 5 Q or greater
The rear compartment lamp is inoperative.
2.1. IgnitionOFF.
Conditions for Clearing the DTC 2.2. Test for less than 2 Q in the ground circuit end
- The condition responsible for setting the DTC no to end.
longer exists. :> If2 Q or greater, repair the open/high resistance
- A history DTC will clear once 100 consecutive in the circuit.
malfunction—freeignition cycles have occurred. :> Ifless than 2 Q, repair the open/high resistance
in the ground connection.
Reference Information
If less than 5 Q
Schematic Reference Connect a test lamp between the control circuit
InteriorLights Schematics on page 4-89 terminal 1 and ground, ignition ON.
Connector End View Reference
Component Connector End Views on page 11-269

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4-102 Lighting
4. Verify the test lamp turns ON and OFF when =>If less than 1 V, replace the K9 Body Control
commanding the Trunk Lamp ON and OFF with a Module.
scan tool. U If the test lamp turns ON and OFF
If the test lamp is always OFF 5. Test or replace the E88 Rear Compartment
4.1. IgnitionOFF, disconnect the X7 harness Courtesy Lamp.
connector at the K9 Body Control Module.
Repair Instructions
4.2. Test for infinite resistance between the control
circuit and ground. Perform the Diagnostic Repair Verification on
page 6-92 after completing the repair.
:> Ifless than infinite resistance, repair the short to
ground on the circuit. Rear Compartment Courtesy Lamp Replacement
(Hatchback) on page 4-216 or Rear Compartment
U Ifinfinite resistance Courtesy Lamp Replacement (Sedan) on
4.3. Test for less than 2 Q in the control circuit end page 4-217
to end. Control Module References on page 6-3 for BCM
=>If2 Q or greater, repair the open/high resistance replacement, programming, and setup
in the circuit.
=>Ifless than 2 Q, replace the K9 Body Control
Module. ,
If the test lamp is always ON
4.1. lgnition OFF, disconnect the X7 harness
connector at the K9 Body Control Module,
ignition ON.
4.2. Test for less than 1 V between the control
circuit terminal and ground.
:> If 1 V or greater, repair the short to voltage on
the circuit.

(US/Canada)
-Sonic
2013 (5377994)
ManUal
Service
 Li‘gmting 4-103
DTC 32575 or B2699
Diagnostic Instructions
~ Perform the Diagnostic System Check - Vehicle
on page 6-66 prior to using this diagnostic
procedure.
- Review Strategy Based Diagnosis on page 6-58
for an overview of the diagnostic approach.
- Diagnostic Procedure Instructions on page 6-59
provides an overview of each diagnostic category.
DTC Descriptors
DTC 32575 01: Headlamps Control Circuit Short to Battery
DTC 32575 02: Headlamps Control Circuit Short to Ground
DTC 32575 04: Headlamps Control Circuit Open
DTC 32699 01: Right Headlamp Control Circuit Short to Battery
DTC 32699 02: Right Headlamp Control Circuit Short to Ground
DTC 32699 04: Right Headlamp Control Circuit Open
Diagnostic Fault Information

Open/High Signal
Circuit Short to Ground Resistance Short to Voltage Performance
F7DA (BCM 3)Fuse B+ 1 1 — -
F8DA (BCM 4)Fuse 3+ 1 1 — -
LowBeamHeadlampControl—Left 3257502 3257504 3322557753,)g} -

LowBeamHeadlampControl—Right 3269902 3269904 gégggg} -

HeadlampGround—Left — 3257504 — -
HeadlampGround—Right , — 3269904 — -
1. HeadlampsMalfunction

CircuitlSystem Description DTC 32699 02

With the headlamp switch in the ON position, the The BCM detects a short to ground in the right low
headlamp switch headlamp ON signal circuit is beam headlamp control circuit.
grounded through the headlamp switch. The body
control module (BCM) responds by applying battery Actions Taken When the DTC Sets
positive voltage to the left and right low beam headlamp ~ When DTC 32575 sets, the left low beam
control circuits illuminating the low beam headlamps. headlamp will be inoperative.
Conditions . When DTC 32699 sets, the right Iow beam
for Running the DTC headlamp will be inoperative.
- Battery voltage must be between 9—16V.
- Low beam headlamps ON. Conditions for Clearing the DTC
- The condition responsible for setting the DTC no
Conditions for Setting the DTC longer exists.
DTC B2575 01 and B2575 04 - A history DTC will clear once 100 consecutive
malfunction—freeignition cycles have occurred.
The BCM detects a short to voltage or an open/high
resistance in the left low beam headlamp control circuit. Reference Information
DTC B2575 02 Schematic Reference '
The BCM detects a short to ground in the left low beam
headlamp control circuit. Headlights/Daytime Running Lights (DRL) Schematics
on page 4-82
DTC B2699 01 and B2699 04
Connector End View Reference
The BCM detects a short to voltage or an open/high
resistance in the right low beam headlamp control Component Connector End Views on page 11—269
circuit.

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4~'I04 Lighting
Description and Operation :> Ifless than 1 V, replace the K9 body control
module.
Exterior Lighting Systems Description and Operation
on page 4-217 U If the test lamp turns ON and OFF
5. Test or replace the E13L headlamp bulb —left.
Electrical Information Reference
DTC B2699
Circuit Testing on page 11-526
1. Ignition OFF, exterior lamps OFF, disconnect the
Connector Repairs on page 11-548 harness connector at the E13R headlamp —right.
Testing for IntermittentConditions and Poor 2. Test for less than 5 Q between the ground circuit
Connections on page 11-531 terminal D and ground.
Wiring Repairs on page 11-537 If 5 Q or greater
Scan Tool Reference 2.1. lgnition OFF.
Control Module References on page 6-3 for scan tool 2.2. Test for less than 2 Q in the ground circuit end
information to end.
=>If2 Q or greater, repair the open/high resistance
CircuitlSystem Testing in the circuit.
DTC 32575 =>If less than 2 Q, repair the open/high resistance
1. lgnition OFF, exterior lamps OFF, disconnect the in the ground connection.
harness connector at the E13L headlamp - left. If less than 5 Q
2. Test for less than 5 Q between the ground circuit Connect a test lamp between the control Circuit
terminal D and ground. terminal A and ground, ignition ON.
If 5 Q or greater Verify the test lamp turns ON and OFF when
2.1. Ignition OFF. commanding the Right Low Beam/Daytime
Running Lamp ON and OFF with a scan tool.
2.2. Test for less than 2 Q in the ground circuit end
to end. If the test lamp is always OFF
=>lf 2 Q or greater, repair the open/high resistance 4.1. lgnition OFF, disconnect the X4 harness
in the circuit. connector at the K9 body control module.
:> Ifless than 2 Q, repair the open/high resistance 4.2. Test for infinite resistance between the control
in the ground connection. circuit and ground.
:> If less than infinite resistance, repair the short to
If less than 5 Q
ground on the circuit.
. Connect a test lamp between the control circuit
terminal A and ground, ignition ON. U Ifinfinite resistance
. Verify the test lamp turns ON and OFF when 4.3. Test for less than 2 Q in the control circuit end
commanding the Left Low Beam/Daytime Running to end.
Lamp ON and OFF with a scan tool. =>If2 Q or greater, repair the open/high resistance
If the test lamp is always OFF in the circuit.
4.1. lgnition OFF, disconnect the X4 harness =>If less than 2 Q, replace the K9 body control
connector at the K9 body control module. module.
4.2. Test for infinite resistance between the control If the test lamp is always CM
circuit and ground. 4.1. IgnitionOFF, disconnect the X4 harness
:> Ifless than infinite resistance, repair the short to connector at the K9 body control module,
ground on the circuit. ignition ON.
U lf infinite resistance 4.2. Test for less than 1 V between the control
circuit terminal and ground.
4.3. Test for less than 2 Q in the control circuit end
to end. =>If 1 V or greater, repair the short to voltage on
the circuit.
=>If2 Q or greater, repair the open/high resistance
in the circuit. =>If less than 1 V, replace the K9 body control
module.
=>Ifless than 2 Q, replace the K9 body control
module. U If the test lamp turns ON and OFF
If the test lamp is always ON 5. Test or replace the E13R headlamp bulb —right.
4.1. lgnition OFF, disconnect the X4 harness Repair Instructions
connector at the K9 bOdy control module,
ignition ON. Perform the Diagnostic Repair Verification on
page 6-92 after completing the repair.
4.2. Test for less than 1 V between the control
circuit terminal and ground. Headlamp Bulb Replacement on page 4-194
Control Module References on page 6-3 for BCM
=>If 1 V or greater, repair the short to voltage on
replacement, programming, and setup
the circuit.

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
 Lighting +105

DTC 3257A

Diagnostic Instructions
- Perform the Diagnostic System Check —Vehicle
on page 6-66 prior to using this diagnostic
procedure.
° Review Strategy Based Diagnosis on page 6—58
for an overview of the diagnostic approach.
- Diagnostic Procedure Instructions on page 6-59
provides an overview of each diagnostic category.
DTC Descriptor
DTC 3257A 00: Headlamp Switch InputSignals Correlation Malfunction
Diagnostic Fault Information

Open/High Signal
Circuit Short to Ground Resistance Short to Voltage Performance
HeadlampSwitchPark LampsON Signal 2 3257A00 2 -
HeadlampSwitchHeadlampsOFF Signal 3257A00 1 1 --
HeadlampSwitchHeadlampsON Signal 3257AOO 1 1 —-
HeadlampSwitchGround — 1 — -
1.HeadlampsMalfunction
2. Park,License,and/orTailLampsMalfunction

CircuitlSystem Description Actions Taken When the DTC Sets

For headlamp operation, the body control module
(BCM) monitors three signal circuits from the headlamp
switch. When the headlamp switch is in the AUTO
position, the three signal circuits are unaffected and the
BCM relies on the ambient light sensor input to turn the
headlamps and daytime running lamps (DRLs) ON and
OFF. When the headlamp switch is placed in the OFF
position, the headlamp switch headlamps OFF signal
circuit is grounded, indicating to the BCM that the
exterior lamps should be turned OFF. With the
headlamp switch in the PARK LAMPS position, the
headlamp switch park lamps ON signal circuit is
grounded, indicating that the park lamps have been
requested. When the headlamp switch is in the
HEADLAMP position, both the headlamp switch park
lamps ON signal circuit and the headlamp switch
headlamps ON signal circuit are grounded. The BCM
responds by commanding the park lamps and
headlamps ON.
Conditions for Running the DTC
Battery voltage must be between 9-16 V.
° When DTC 3257A 00 is present on the headlamp
switch headlamps OFF signal circuit, the low
beam headlamps are always ON in the AUTO
position. The headlamp switch operates in all
positions other than AUTO. The AUTO headlamp
defeat is inoperative.
- When DTC 3257A 00 is present on the headlamp
switch headlamps ON signal circuit, the low beam
headlamps are always ON. The BCM disregards
all headlamp switch inputs.
~ When DTC 3257A 00 is present on the headlamp
switch park lamps ON signal circuit, the park
lamps and low beam headlamps are inoperative in
the PARK and HEAD positions. Headlamps and
park lamps operate in AUTO position.
Conditions for Clearing the DTC
- The condition responsible for setting the DTC no
longer exists.
0 A histow DTC will clear once 100 consecutive
malfunction-free ignition cycles have occurred.

Conditions for Setting the DTC Reference Information

- The BCM detects an open/high resistance in the Schematic Reference
headlamp switch park lamps ON signal circuit.
- The BCM detects a short to ground in the Headlights/Daytime Running Lights (DRL) Schematics
on page 4-82
headlamp switch headlamps ON signal circuit.
- The BCM detects a short to ground in the Connector End View Reference
headlamp switch headlamps OFF signal circuit. Component Connector End Views on page 11-269
Description and Operation
Exterior Lighting Systems Description and Operation
on page 4-217

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4406 Lghting
Electrical Information Reference
Circuit Testing on page 11—526
Connector Repairs on page 11-548
Testing for IntermittentConditions and Poor
Connections on page 11-531
Wiring Repairs on page 11-537
Scan Tool Reference
Control Module References on page 6—3for scan tool
information
CircuitlSystem Testing
1. Ignition OFF, all doors closed, all accessories OFF,
disconnect the harness connector at the
S30 Headlamp Switch. Itmay take up to 2 minutes
for all vehicle systems to power down.
. Test for less than 15 Q between the ground circuit
terminal 6 and ground.
If 15 Q or greater
2.1. lgnition OFF.
2.2. Test for less than 2 Q in the ground circuit end
to end.
=>If2 Q or greater, repair the open/high resistance
in the circuit.
=>Ifless than 2 Q, repair the open/high resistance
in the ground connection.
If less than 15VQ
9° IgnitionON._
Verify the scan tool Automatic Headlamps Disable
Switch parameter is Inactive.
If not Inactive
4.1. Ignition OFF, disconnect the X1 harness
connector at the K9 Body Control Module.
4.2. Test for infinite resistance between the signal
circuit terminal 5 and ground.
=>Ifless than infinite resistance, repair the short to
ground on the circuit.
=>lf infinite resistance, replace the K9 Body
Control Module.
If Inactive
. Install a 3 A fused jumper wire between the signal
circuit terminal 5 and the ground circuit terminal 6.
Verify the scan tool Automatic Headlamps Disable
Switch parameter is Active.
If not Active
6.1. Ignition OFF, disconnect the X1 harness
connector at the K9 Body Control Module,
ignition ON.
6.2. Test for less than 1 V between the signal
circuit terminal 5 and ground.
:> If 1 V or greater, repair the short to voltage on
the circuit.
U Ifless than 1 V
6.3. Test for less than 2 Q in the signal circuit end
to end.
=>lf 2 Q or greater, repair the open/high resistance
in the circuit.
:> If less than 2 Q, replace the K9 Body Control
Module.
If Active
. Verify the scan tool Park Lamps Switch parameter
is Inactive.
If not Inactive
7.1. IgnitionOFF, disconnect the X1 harness
connector at the K9 Body Control Module.
7.2. Test for infinite resistance between the signal
circuit terminal 3 and ground.
2 If less than infinite resistance, repairthe short to
ground on the circuit.
=>Ifinfinite resistance, replace the K9 Body
Control Module.
If Inactive
. Install a 3 A fused jumperwire between the signal
circuit terminal 3 and the ground circuit terminal 6.
Verify the scan tool Park Lamps Switch parameter
is Active.
If not Active
9.1. lgnition OFF, disconnect the X1 harness
connector at the K9 Body Control Module,
ignition ON.
9.2. Test for less than 1 V between the signal
circuit terminal 3 and ground.
=>lf 1 V or greater, repair the short to voltage on
the circuit.
U If less than 1 V
9.3. Test for less than 2 Q in the signal circuit end
to end.
=>If2 Q or greater, repair the open/high resistance
in the circuit.
=>If less than 2 Q, replace the K9 Body Control
Module.
If Active
Verify the scan tool Headlamps On Switch
parameter is Inactive.
If not Inactive
10.1. lgnition OFF, disconnect the X1 harness
connector at the K9 Body Control Module.
10.2. Test for infinite resistance between the signal
circuit terminal 4 and ground.
=>if less than infinite resistance, repair the short to
ground on the circuit.
=>If infinite resistance, replace the K9 Body
Control Module.
U If Inactive
. Install a 3 A fused jumper wire between the signal
circuit terminal 4 and the ground circuit terminal 6.
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12. Verify the scan tool Headlamps On Switch
parameter is Active.
l a If not Active
12.1. IgnitionOFF, disconnect the X1 harness
connector at the K9 Body Control Module,
ignition ON.
122. Test for less than 1 V between the signal
circuit terminal 4 and ground.
=>lf1 V or greater, repair the short to voltage on
the circuit.
U Ifless than 1 V
12.3. Test for less than 2 Q in the signal circuit end
to end.
a If2 Q or greater, repair the open/high resistance
in the circuit.
Lighting 4-107
=>If less than 2 Q, replace the K9 Body Control
Module.
U lf Active
13. Test or replace the 830 Headlamp Switch.
Repair Instructions
Perform the Diagnostic Repair Verification on
page 6—92after completing the repair.
- Headlamp Switch Replacement on page 4-187
- Control Module References on page 6—3for BCM
replacement, programming, and setup

I, 2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
4-108 Lighting

DTC B257B

Diagnostic Instructions
. Perform the Diagnostic System Check - Vehicle
on page 6—66prior to using this diagnostic
procedure.
- Review Strategy Based Diagnosis on page 6-58
for an overview of the diagnostic approach.
‘ Diagnostic Procedure Instructions on page 6-59
provides an overview of each diagnostic category.
DTC Descriptors
DTC 32573 03: Lighting Control Switch Signal Low Voltage
DTC 32573 07: Lighting Control Switch Signal High Voltage
Diagnostic Fault Information

Short to Open/High Signal

Circuit Ground Resistance Short to Voltage Performance

InstrumentPanel DimmerSwitch3+Reference 3321512350)? 3257303 ~— -

InstrumentPanel DimmerSwitchSignal 3257303 3257303 32573 07 -

3261002 3261004 3261001 -
LED BacklightDimmingControlTerminal8 X2
3252E02 3252E02 1 -
LED BacklightDimmingControlTerminal5 X1
HazardWarningSwitchLED BacklightDimming 1 1 1
Control
LeverPosmonIndicator
Efcnksl’ghstséznntsrgllfi 3265202 1 1 _

1. InteriorBacklightingMalfunction

CircuitlSystem Description Conditions for Setting the DTC

The instrument panel dimmer switch is used to increase DTC B257B 03
and decrease the brightness of the interior backlighting - The BCM detects a short to ground or an open/
components. The instrument panel dimmer switch high resistance in the instrument panel dimmer
provides a voltage signal to the body control module switch 3+ circuit.
(BCM) that will increase as the brightness of the lights
are increased and decrease as the brightness of the . The BCM detects a short to ground or an open/
lights are decreased. The BCM provides a low high resistance in the instrument panel dimmer
reference signal and a 3+ voltage reference to the switch signal circuit.
instrument panel dimmer switch. When the instrument DTC B257B 07
panel dimmer switch is placed in the desired position,
The BCM detects a short to voltage in the instrument
the dimmed voltage setting is applied from the
instrument panel dimmer switch through the instrument panel dimmer switch signal circuit.
panel dimmer switch signal circuit to the BCM. The Actions Taken When the DTC Sets
BCM interprets the signal and applies a pulse width
modulated (PWM) voltage through the light emitting The BCM will not dim any interior backlighting. All
diode (LED)dimming control circuits illuminating the interior backlighting will default to the level selected
interior backlighting to the requested level of prior to the fault being present.
brightness. for Clearing the DTC
Conditions
Conditions for Running the DTC ' The condition responsible for setting the DTC no
- Battery voltage must be between 9—16V. longer exists.
. Park Lamps ON. - A history DTC will clear once 100 consecutive
malfunction-free ignition cycles have occurred.
Reference Information
Schematic Reference
InteriorLights Dimming Schematics on page 4-91

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2013 (5377994)
Manual
Service
 Lighting 4409
Connector End View Reference 3. Verify a test lamp does not illuminate between the
B+ circuit terminal 1 and the signal circuit
Component Connector End Views on page 11-269 terminal 12.
Description and Operation =>If the test lamp illuminates
Interior Lighting Systems Description and Operation on 3.1. lgnition OFF, disconnect the X1 harness
page 4—219 connector at the K9 Body Control Module.
Electrical Information Reference 3.2. Test for infinite resistance between the signal
circuit and ground.
- Circuit Testingon page 11-526 =>If less than infinite resistance, repair the short to
- Connector Repairs on page 11—548 ground on the circuit.
' Testing for IntermittentConditions and Poor =>lf infinite resistance, replace the K9 Body
Connections on page 11—531 Control Module.
- Wiring Repairs on page 11-537 U If the test lamp does not illuminate
Scan Tool Reference 4. Test for 8+ between the B+ circuit terminal 1 and
the signalcircuitterminal12.
Control Module References on page 6—3for scan tool
information :> If less than 3+
4.1. IgnitionOFF, disconnect the X1 harness
CircuitlSystem Testing connector at the K9 Body Control Module,
1. lgnition OFF and all vehicle systems OFF, ignition ON.
disconnect the harness connector at the 4.2. Test for less than 1 V between the signal
830 Headlamp Switch, ignition ON. circuit terminal 12 and ground.
2. Test for 8+ between the B+ circuit terminal 1 and =>If 1 Vor greater, repairthe short to voltage on
ground. the circuit.
=>If less than 3+ U lfiess than 1 V
2.1. lgnition OFF, disconnect the X3 harness 4.3. Test for less than 2 Q in the signal circuit end
connector at the K9 Body Control Module. to end.
2.2. Test for infinite resistance between the B+ =>If2 Q or greater, repair the open/high resistance
Circuitand ground. in the circuit.
=>If less than infinite resistance, repair the short to =>Ifless than 2 Q, replace the K9 Body Control
ground on the circuit. Module.
U If infinite resistance ti If B+
2.3. Test for less than 2 Q in the B+ circuit end 5. Test or replace the S30 Headlamp Switch.
to end.
=>If2 Q or greater, repair the open/high resistance Repair Instructions
in the circuit. Perform the Diagnostic Repair Verification on
=>Ifless than 2 Q, replace the K9 Body Control page 6 92 after completing the repair
Module. - Headlamp Switch Replacement on page 4-187
U |fB+ - Control Module References on page 6— 3 for BCM
replacement, programming, and setup

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
4-1 110 Lithtinig

DTC 32580

Diagnostic Instructions
- Perform the Diagnostic System Check - Vehicle
on page 6—66prior to using this diagnostic
procedure.
. Review Strategy Based Diagnosis on page 6-58
for an overview of the diagnostic approach.
‘ Diagnostic Procedure Instructions on page 6-59
provides an overview of each diagnostic category.
DTC Descriptors
DTC B2580 01: Headlamp High Beam Control Circuit Short to Battery
DTC 32580 02: Headlamp High Beam Control Circuit Short to Ground
DTC B2580 04: Headlamp High Beam Control Circuit Open
Diagnostic Fault Information

Open/High Signal
Short to Ground Resistance Short to Voltage Performance
Circuit
1 1 —- —-
F7DA (BCM 3) Fuse B+
1 1 —— —-
F8DA (BCM 4) Fuse B+
?32255%%%i' B32255E8%%i, 3258001 —'
HeadlampHighBeamRelay Control
1 1 1 —-
HighBeam HeadlampControl—Left
1 1 1 ~-
HighBeam HeadlampControl—Right
— 3257504 — -
HeadlampGround—Left
— B269904 — ‘ _
HeadlampGround—Right
1. HeadlampsMalfunction

Description DTC 32580 04

CircuitlSystem
The BCM detects an open in the headlamp high beam
The high beam and flash to pass functions are relay control circuit.
contained within the turn signaI/multifunctionswitch.
The BCM provides the turn signal/multifunction switch Actions Taken When the DTC Sets
with two signal circuits, the high beam signal circuit and
the flash to pass signal circuit. When the low beam The high beam headlamps and flash to pass will not
headlamps are ON and the turn signal/multifunction operate.
switch is placed in the high beam position, ground is Conditions for Clearing the DTC
applied to the BCM through the high beam signal
circuit. The BCM responds to the high beam request by - The condition responsible for setting the DTC no
applying ground to the high beam relay control circuit longer exists.
which energizes the high beam relay. With the high - A history DTC will clear once 100 consecutive
beam relay energized, the switch contacts close malfunction—freeignition cycles have occurred.
allowing battery voltage to flow through the high beam
fuses to the high beam control circuits illuminating the Reference Information
high beam headlamps. Reference
Schematic
Conditions for Running the DTC
Headlights/Daytime Running Lights (DRL) Schematics
- Battery voltage must be between 9—16 V. on page 4—82
- High beam headlamps ON. Connector End View Reference
Conditions for Setting the DTC Component Connector End Views on page 11—269
DTC 32580 01 Description and Operation
The BCM detects a short to voltage in the headlamp Exterior Lighting Systems Description and Operation
high beam relay control circuit. on page 4—21 7
DTC 32580 02
The BCM detects a short to ground in the headlamp
high beam relay control circuit.

(US/Canada)
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2013 (5377994)
Manual
Service

Electrical Information Reference
Circuit Testing on page 11—526
Connector Repairs on page 11-548
Testing for IntermittentConditions and Poor
Connections on page 11-531
Wiring Repairs on page 11-537
Scan Tool Reference
Control Module References on page 6—3for scan tool
information
CircuitlSystem Testing
1. lgnition OFF, remove the KR48 Headlamp High
Beam Relay.
2. Connect a test lamp between the control circuit
terminal 86 and B+, ignition ON.
3. Verify the test lamp turns ON and OFF when
commanding the High Beams ON and OFF with a
scan tool.
If the test lamp is always OFF
3.1. IgnitionOFF, disconnect the X5 harness
connector at the K9 Body Control Module,
ignition ON.
3.2. Test for less than 1 V between the control
circuit terminal and ground.
=>If 1 V or greater, repair the short to voltage on
the circuit.
U Ifless than 1 V
Lighting 4411
3.3. lgnition OFF.
3.4. Test for less than 2 Q in the control circuit end
to end.
:> lf 2 Q or greater, repair the open/high resistance
in the circuit.
=>If less than 2 Q, replace the K9 Body Control
Module.
If the test lamp is always CM
3.1. lgnition OFF, disconnect the X5 harness
connector at the K9 Body Control Module.
3.2. Test for infinite resistance between the control
circuit terminal and ground.
=>If less than infinite resistance, repair the short to
ground on the circuit.
=>lf infinite resistance, replace the K9 Body
Control Module.
U if the test lamp turns ON and OFF
4. Test or replace the KR48 Headlamp High Beam
Relay.
Repair Instructions
Perform the Diagnostic Repair Verification on
page 6—92after completing the repair.
Relay Replacement (Within an Electrical Center)
on page 11-607or Relay Replacement (Attached
to Wire Harness) on page 11-607
Control Module References on page 6-3 for BCM
replacement, programming, and setup

1' 2013
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Sonic
(US/Canada)
Service
Manual
(5377994)
4~1l2 Lighting

DTC 32585 or 33867

Diagnostic Instructions
- Perform the Diagnostic System Check —Vehicle
on page 6—66prior to using this diagnostic
procedure.
- Review Strategy Based Diagnosis on page 6—58
for an overview of the diagnostic approach.
- Diagnostic Procedure Instructions on page 6-59
provides an overview of each diagnostic category.
DTC Descriptors
DTC 32585 01: Left Park Lamps Control Circuit Short to Battery
DTC 32585 02: Left Park Lamps Control Circuit Short to Ground
DTC 32585 04: Left Park Lamps Control Circuit Open
DTC 33867 01: Right Park Lamps Control Circuit Short to Battery
DTC 33867 02: Right Park Lamps Control Circuit Short to Ground
DTC 33867 04: Right Park Lamps Control Circuit Open

Diagnostic Fault Information

Short to Opeanigh Short to Voltage Signal

Ground Resistance Performance
Circuit
2 3257A00 ‘ 2 —-
HeadlampSwitchPark LampsON Signal
_ 3388301,
3388304 3388301 --
LicensePlate LampControl 3388302
3258501,
FrontPark andRear Side MarkerLamps 3258504 3258504 -
Control- Left 3258502
3386701,
FrontPark andRear Side MarkerLamps B386704 3386704 ‘
Control- Right B386702
3388102 3388104 3388101 —-
RearTail/StopLampsControl- Left
3388202 3388204 3388201 -
RearTail/StopLampsControl- Right
—— 2 — —-
HeadlampSwitchGround
. 3388301,
3388304 —- —-
LicensePlate LampGround- Left ——

. . 3388301,
3388304 — —-
License PlateLamp Ground- Right —
— 1 — —-
Park LampGround- LeftFront
— 1 — —-
Park LampGround- RightFront
—— 1 —— ~-
RearTail/StopLampsGround-Left
— 1 — -
RearTail/StopLampsGround- Right
— 1 — -
Side MarkerLamp Ground- LeftRear
— 1 — -
Side MarkerLamp Ground- RightRear
1. Park,License,and/orTailLamps Malfunction
2. Park LampSwitchMalfunction

Description Conditions for Setting the DTC

CircuitlSystem
When the headlamp switch is placed in the HEAD or DTC 32585 01 and 32585 04
PARK position, ground is applied to the park lamp The BCM detects a short to voltage or an open/high
switch ON signal circuit to the body control module resistance in the left front park lamps control circuit.
(BCM). The BCM responds by applying voltage to the
park lamps, tail lamps, and license lamps control DTC 32585 02
circuits illuminating the park, tail, and license lamps. The BCM detects a short to ground in the leftfront park
for Running the DTC lamps control circuit.
Conditions
- Battery voltage must be between 9—16V.
- Park lamps ON.
(US/Canada)
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2013 (5377994)
Manual
Service
 Lighting 4-113
DTC 33867 01 and 33867 04 CircuitlSystem Testing
The BCM detects a short to voltage or an open/high
DTC 32585
resistance in the right front park lamps control circuit.
1. IgnitionOFF, exterior lamps OFF, trunk latch
DTC 33867 02 latched, disconnect the harness connector at the
The BCM detects a short to ground in the right front appropriate left front park lamp or left rear side
park lamps control circuit. marker lamp.
Test for less than 5 Q between the appropriate
Actions Taken When the DTC Sets ground circuit terminal listed below and ground.
DTC 32585 01 - E4N park/tum signal lamp —left terminal C
The left park lamps are always ON. - E2LR side marker lamp —left rear socket
terminal
DTC 32585 02 and 32585 04
If 5 Q or greater
The left park lamps are always OFF. 2.1. IgnitionOFF.
DTC 33867 01 2.2. Test for less than 2 Q in the ground circuit end
The right park lamps are always ON. to end.
=>If2 Q or greater, repair the open/high resistance
DTC 33867 02 and 33867 04
in the circuit.
The right park lamps are always OFF.
=>Ifless than 2 Q, repairthe open/high resistance
Conditions for Clearing the DTC in the ground connection.
- The condition responsible for setting the DTC no <2 If less than 5 0
longer exists. Connect a test lamp between the appropriate
- A history DTC will clear once 100 consecutive control Circuit terminal listed below and ground,
malfunction-free ignition cycles have occurred. ignition ON.
' E4N park/turnsignal lamp —— left terminal A
Reference Information
' E2LR side marker lamp —left rear socket
Schematic Reference terminal
. Verify the test lamp turns ON and OFF when
Exterior Lights Schematics on page 4-85 commanding the Left Park Lamps ON and OFF
Connector End View Reference with a scan tool.
Component Connector End Views on page 11-269 If the test lamp is always OFF
4.1. IgnitionOFF, disconnect the X4 harness
Description and Operation connector at the K9 body control module.
Exterior Lighting Systems Description and Operation 4.2. Test for infinite resistance between the control
on page 4-217 circuit and ground.
Electrical Information Reference =>Ifless than infinite resistance, repair the short to
ground on the circuit.
- Circuit Testingon page 11—526
0 Ifinfinite resistance
. Connector Repairs on page 11-548
4.3. Test for less than 2 Q in the control circuit end
- Testing for IntermittentConditions and Poor to end.
Connections on page 11-531
2 If2 Q or greater, repair the open/high resistance
- Wiring Repairs on page 11-537 in the circuit.
Scan Tool Reference =>Ifless than 2 Q, replace the K9 body control
Control Module References on page 6—3for scan tool module.
information If the test lamp is always ON
4.1. IgnitionOFF, disconnect the X4 harness
connector at the K9 body control module,
ignition ON.
4.2. Test for less than 1 V between the control
circuit terminal and ground.
=>If 1 V or greater, repair the short to voltage on
the circuit.
=>Ifless than 1 V, replace the K9 body control
module.
If the test lamp turns ON and OFF
. Test or replace the appropriate left park/
marker lamp.

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4-114 Lighting
DTC 33867 =>If less than 2 Q, replace the K9 body control
1. lgnition OFF, exterior lamps OFF, trunk latch module.
latched, disconnect the harness connector at the If the test lamp is always ON
appropriate right front park lamp or right rear side 4.1. Ignition OFF, disconnect the X4 harness
marker lamp.
connector at the K9 body control module,
. Test for less than 5 0 between the appropriate ignition ON.
ground circuit terminal listed below and ground.
4.2. Test for less than 1 V between the control
- E4P park/turnsignal lamp —right terminal C circuit terminal and ground.
' E2RR side marker lamp ~right rear socket =>If 1 V or greater, repair the short to voltage on
terminal the circuit.
If 5 Q or greater 2 Ifless than 1 V, replace the K9 body control
2.1. lgnition OFF. module.
2.2. Test for less than 2 Q in the ground circuit end If the test lamp turns ON and OFF
to end. Test or replace the appropriate right park/
=>If2 Q or greater, repair the open/high resistance marker lamp.
in the circuit.
Repair Instructions
:> Ifless than 2 Q, repair the open/high resistance
in the ground connection. Perform the Diagnostic Repair Verification on
page 6-92 after completing the repair.
If less than 5 Q
Tail Lamp Replacement (Hatchback) on
. Connect a test lamp between the appropriate
page 4-214 or Tail Lamp Replacement (Sedan) on
control circuit terminal listed below and ground,
page 4-213
ignition ON.
Parking and Turn Signal Lamp Bulb Replacement
0 E4P park/turnsignal lamp —right terminal A
on page 4—203
- E2RR side marker lamp —right rear socket
Control Module References on page 6-3 for BCM
terminal ‘ replacement, programming, and setup
Verify the test lamp turns ON and OFF when
commanding the Right Park Lamps ON and OFF
with a scan tool.
If the test lamp is always OFF
4.1. IgnitionOFF, disconnect the X4 harness
connector at the K9 body control module.
4.2. Test for infinite resistance between the control
circuit and ground.
=>Ifless than infinite resistance, repair the short to
ground on the circuit.
0 If infinite resistance
4.3. Test for less than 2 Q in the control circuit end
to end.
:> If2 Q or greater, repair the open/high resistance
in the circuit.

2013
.Sonic
(US/Canada)
Service
Manual
(5377994)
 Lighting 41-115

DTC 32610

Diagnostic Instructions
- Perform the Diagnostic System Check - Vehicle
on page 6—66prior to using this diagnostic
procedure.
- Review Strategy Based Diagnosis on page 6—58
for an overview of the diagnostic approach.
- Diagnostic Procedure Instructions on page 6-59
provides an overview of each diagnostic category.
DTC Descriptors
DTC 32610 01: Passenger Compartment Dimming 1 Circuit Short to Battery
DTC 32610 02: Passenger Compartment Dimming 1 Circuit Short to Ground
DTC 32610 04: Passenger Compartment Dimming 1 Circuit Open

Diagnostic Fault Information

Opeanigh Signal
Circuit Short to Ground Resistance Short to Voltage Performance
LED BacklightDimmingControlTermina18
X2 3261002 3261004, 1 3261001, 1 -
1.InteriorBacklightingMalfunction

CircuitlSystem Description Actions Taken When the DTC Sets

The instrument panel dimmer switch is used to increase The BCM will disable the LED backlight dimming
and decrease the brightness of the interior backlighting control circuits.
components. The instrument panel dimmer switch
provides a voltage signal to the body control module Conditions for Clearing the DTC
(BCM) that will increase as the brightness of the lights - The condition responsible for setting the DTC no
are increased and decrease as the brightness of the longer exists.
lights are decreased. The BCM provides a low
0 A history DTC will clear once 100 consecutive
reference. signal, and 3+ voltage reference circuits to malfunction—freeignition cycles have occurred.
the instrument panel dimmer switch. When the
instrument panel dimmer switch is placed in the desired Reference Information
position, the dimmed voltage setting is applied from the
instrument panel dimmer switch through the instrument Schematic Reference
panel dimmer switch signal circuit to the BCM. The
BCM interprets the signal andapplies a pulse width InteriorLights Dimming Schematics on page 4-91
modulated (PWM) voltage through the light emitting Connector End View Reference
diode (LED) dimming control circuits illuminating the
interior backlighting to the requested level of Component Connector End Views on page 11-269
brightness. Description and Operation
Conditions for Running the DTC InteriorLighting Systems Description and Operation on
- Battery voltage must be between 9—16V. page 4—21 9
- Park lamps ON. Electrical Information Reference
Conditions for Setting the DTC - Circuit Testing on page 11-526
- Connector Repairs on page 11~548
DTC 32610 01
' Testing for IntermittentConditions and Poor
The BCM detects a short to battery in the LED backlight Connections on page 11-531
dimming control circuit terminal 8 X2.
- Wiring Repairs on page 11-537
DTC 32610 02
Scan Tool Reference
The BCM detects a short to ground in the LED backlight
dimming control circuittermina18 X2. Control Module References on page 6-3 for scan tool
information
DTC 32610 04
The BCM detects an open/high resistance in the LED
backlight dimming control circuit terminal 8 X2.

2013
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Manual
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4-116 Lightiflg
CircuitlSystem Testing
Note: Each component with backlighting may need to
be disconnected to isolate a short to voltage or short to
ground. Use the schematics to identify the following:
- Backlighting components the vehicle is
equipped with
- Each component‘s control and ground circuit
terminals
- Component locations on the backlighting
control circuit
1. lgnition OFF, all doors closed, all accessories OFF,
disconnect the harness connector at the
component with inoperative backlighting. Itmay
take up to 2 minutes for all vehicle systems to
power down.
2. Test for less than 15 Q between the appropriate
ground circuit terminal listed below and ground.
- S13D door lock switch —driver —terminal1
~ 830 headlamp switch —terminal 6
- S48E multifunction switch —center console -
terminal 9
- S70R steering wheel controls switch —right -
terminal 5
- S70L steering wheel controls switch —left -
terminal 7
=>If 15 Q or greater
2.1. lgnition OFF.
2.2. Test for less than 2 Q in the ground circuit end
to end.
=>If2 Q or greater, repair the open/high resistance
in the circuit.
:> if less than 2 Q, repair the open/high resistance
in the ground connection.
0 If less than 15 Q
3. Connect a test lamp between the appropriate
control circuit terminal listed below and ground.
- K33 HVAC control module —terminal 8
- S133 door lock switch —driver —terminal 2
' 830 headlamp switch —terminal 7
- S48E multifunction switch —center console -
terminal 10
- S70R steering wheel controls switch —right -
terminal 4
- S70L steering wheel controls switch —left -
terminal 6
4. Verify the test lamp turns ON and OFF when
commanding the LED Backlight Dimming ON and
OFF with a scan tool. '
If the test lamp is always OFF
4.1. IgnitionOFF, disconnect the X2 harness
connector at the K9 body control module.
4.2. Test for infinite resistance between the control
circuit and ground.
=>Ifless than infinite resistance, repair the short to
ground on the circuit.
U Ifinfinite resistance
4.3. Test for less than 2 Q in the control circuit end
to end.
=>If2 Q or greater, repair the open/high resistance
in the circuit.
=>Ifless than 2 Q, replace the K9 body control
module.
If the test lamp is always ON
4.1. lgnition OFF, disconnect the X2 harness
connector at the K9 body control module,
ignition ON.
4.2. Test for less than 1 V between the control
circuit terminal and ground.
=>If 1 Vor greater, repair the short to voltage on
the circuit.
==> if less than 1 V, replace the K9 body control
module.
If the test lamp turns ON and OFF
Test or replace the component with inoperative
backlighting.
Repair Instructions
Perform the Diagnostic Repair Verification on
page 6-92 after completing the repair. .
o Headlamp Switch Replacement on page 4-187
Door Lock Switch Replacement on page 4—321
Radio and Telephone Control Switch
Replacement on page 8—63
Control'Modu/e References on page 6—3for BCM
or HVAC control module replacement,
programming, and setup
2013
—
Sonic
(US/Canada)
Service
Manual
(5377994)
 Lighting 4-117
DTC 32615

Diagnostic Instructions
- Perform the Diagnostic System Check - Vehicle
on page 6-66 prior to using this diagnostic
procedure.
~ Review Strategy Based Diagnosis on page 6—58
for an overview of the diagnostic approach.
- Diagnostic Procedure Instructions on page 6—59
provides an overview of each diagnostic category.
DTC Descriptor
DTC 32615 02: Passenger Compartment Dimming 2 Circuit Short to Ground

Diagnostic Fault Information

OpenIHigh Signal
Circuit Short to Ground Resistance Short to Voltage Performance
F11DA(3CM 7) Fuse B+ 1,2 1,2 — -
DomeLampsControl 3261502 2 2 -
ReadingLampsControl 3148002 -
Dome/ReadingLamps- FrontGround — 1,2 — -
Dome/ReadingLamps- Rear Ground —— 1,2 — -
1.CourtesyLampsMalfunction
2. DomeLampsMalfunction

CircuitlSystem Description Reference Information

The body control module (BCM) applies battery voltage Schematic Reference
to the dome/reading lamps through the dome/reading
lamp control circuit. When any door is opened, the jam InteriorLights Schematics on page 4-89
switch contacts close and the BCM receives a door—ajar
input. lfthe BCM receives a door lock or unlock input or Connector End View Reference
a rear hatch open input,the BCM will activate the Component Connector End Views on page 11—269
dome/reading lamp control circuit, providing battery
voltage to dome/reading lamps. In the event that any of Description and Operation
these courtesy lamps were to remain illuminated for InteriorLighting Systems Description and Operation on
more than 10 minutes with the ignition switch in the page 4-219
OFF position and no doors opened, the BCM will
deactivate the courtesy lamp control circuit to prevent Electrical Information Reference
total battery discharge.
- Circuit Testing on page 11—526
Conditions for Running the DTC - Connector Repairs on page 11-548
Battery voltage must be between 9-16 V. ' Testing for IntermittentConditions and Poor
Connections on page 11-531
Conditions for Setting the DTC - Wiring Repairs on page 11—537
The BCM detects a short to ground in the dome lamps
control circuit. Scan Tool Reference
Control Module References on page 6—3for scan tool
Actions Taken When the DTC Sets information
The BCM will disable the dome lamps control circuit.
Conditions for Clearing the DTC
- The condition responsible for setting the DTC no
longer exists.
- A history DTC will clear once 100 consecutive
malfunction—freeignition cycles have occurred.

2013
—Sonic
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Manual
(5377994)
4=118 Lighting
Testing
CircuitlSystem
1. lgnition OFF, all doors closed, all accessories OFF,
disconnect the harness connector at the
E37F dome/reading lamps —front and E37 3 dome/
reading lamps —2nd row. Itmay take up to
2 minutes for all vehicle systems to power down.
. Test for less than 10 Q between the appropriate
ground circuit terminal listed below and ground.
- E37F dome reading lamps —front terminal 2
with 090/091
o E37F dome reading lamps —fronttermina| 6
with 095
- E373 dome reading lamps - 2nd row terminal 2
with 090/095
If 10 Q or greater
2.1. lgnition OFF.
2.2. Test for less than 2 Q in the ground circuit end
to end.
=>lf 2 Q or greater, repair the open/high resistance
in the circuit.
:> Ifless than 2 Q, repair the open/high resistance
in the ground connection.
U If less than 10 Q
3. Connect a test lamp between the appropriate
control circuit terminal listed below and ground.
' E37F dome reading lamps —front terminal 3
with 090/091
- E37F dome reading lamps —fronttermina| 2
with 095
- E373 dome reading lamps —2nd row terminal 3
with 090/095
4. Verify the test lamp turns ON and OFF when
commanding the Courtesy Lamps ON and OFF
with a scan tool.
If the test lamp is always OFF
4.1. IgnitionOFF, disconnect the X7 harness
connector at the K9 body control module.
4.2. Test for infinite resistance between the control
circuit and ground.
=>Ifless than infinite resistance, repair the short to
ground on the circuit.
0 If infinite resistance
4.3. Test for less than 2 Q in the control circuit end
to end.
:> If2 Q or greater, repair the open/high resistance
in the circuit.
=>Ifless than 2 Q, replace the K9 body control
module.
If the test lamp is always ON
4.1. IgnitionOFF, disconnect the X7 harness
connector at the K9 body control module,
ignition ON.
4.2. Test for less than 1 V between the control
circuit terminal and ground.
=>If 1 V or greater, repair the short to voltage on
the circuit. ‘
:> If less than 1V, replace the K9 body control
module.
0 If the test lamp turns ON and OFF
5. Test or replace the inoperative E37 dome/
reading lamp.
Repair Instructions
Perform the Diagnostic Repair Verification on
page 6-92 after completing the repair.
Dome Lamp Bulb Replacement on page 4-192
Reading Lamp Replacement on page 4-189
0 Control Module References on page 6-3 for 30M
replacement, programming, and setup
(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
 Lighting 4-119

DTC 32625

Diagnostic Instructions
' Perform the Diagnostic System Check —Vehicle
on page 6—66prior to using this diagnostic
procedure.
° Review Strategy Based Diagnosis on page 6-58
for an overview of the diagnostic approach.
- Diagnostic Procedure Instructions on page 6—59
provides an overview of each diagnostic category.
DTC Descriptors
DTC 32625 01: Display Dimming Pulse Width Modulation Output Circuit Short to Battery
DTC 32625 02: Display Dimming Pulse Width Modulation Output Circuit Short to Ground
DTC 32625 04: Display Dimming Pulse Width Modulation Output Circuit Open
Diagnostic Fault Information

Open/High Signal
Circuit Short to Ground Resistance Short to Voltage Performance
LED BacklightDimmingControlTerminal5 X1 3262502 3262504 3262501 —-

CircuitlSystem Description Reference Information

The instrument panel dimmer switch is used to increase Schematic Reference
and decrease the brightness of the interior backlighting
components. The instrument panel dimmer switch InteriorLights Dimming Schematics on page 4-91
provides a voltage signal to the body control module
Connector End View Reference
(30M) that will increase as the brightness of the lights
are increased and decrease as the brightness of the Component Connector End Views on page 11-269
lights are decreased. The 30M provides a low
reference, signal, and 3+ voltage reference circuits to Description and Operation
the instrument panel dimmer switch. When the InteriorLighting Systems Description and Operation on
instrument panel dimmer switch is placed in the desired page 4-219
position, the dimmed voltage setting is applied from the
instrument panel dimmer switch through the instrument Electrical Information Reference
panel dimmer switch signal circuit to the ECM. The
- Circuit Testing on page 11-526
30M interprets the signal and applies a pulse width
modulated (PWM) voltage through the LED backlight - Connector Repairs on page 11—548
dimming control circuit illuminating the LED - Testing for IntermittentConditions and Poor
backlighting to the requested level of brightness. Connections on page 11—531
- Wiring Repairs on page 11-537
Conditions for Running the DTC
- Battery voltage must be between 9—16V. Scan Tool Reference
- Park lamps ON. Control Module References on page 6—3for scan tool
information
Conditions for Setting the DTC
The 30M detects a short to ground in the LED backlight CircuitlSystem Testing
dimming control circuit terminal 5 X1. 1. lgnition OFF, disconnect the X2 harness connector
at the K33 HVAC control module.
Actions Taken When the DTC Sets
2. Connect a test lamp between the control circuit
The LED backlight dimming control circuit driver is terminal 9 and ground.
shut down.
Conditions for Clearing the DTC
- The condition responsible for setting the DTC no
longer exists.
- A history DTC will clear once 100 consecutive
malfunction—freeignition cycles have occurred.

1 2013
«Sonic
(US/Canada)
SeIVI'ce
Manual
(5377994)
4-l20 Lighting
3. Verify the test lamp turns ON and OFF when
commanding the LED Backlight Dimming ON and
OFF with a scan tool.
If the test lamp is always OFF
3.1. lgnition OFF, disconnect the X1 harness
connector at the K9 body control module.
3.2. Test for infinite resistance between the control
circuit and ground.
=>If less than infinite resistance, repair the short to
ground on the circuit.
0 if infinite resistance
3.3. Test for less than 2 Q in the control circuit end
to end.
=>lf 2 Q or greater, repair the open/high resistance
in the circuit.
=>If less than 2 Q, replace the K9 body control
module.
=>If the test lamp is always CM
3.1. lgnition OFF, disconnect the X1 harness
connector at the K9 body control module,
ignition ON.
3.2. Test for less than 1 V between the control
circuit terminal and ground.
=>lf 1 V or greater, repair the short to voltage on
the circuit.
=>If less than 1 V, replace the K9 body control
module.
0 If the test lamp turns ON and OFF
4. Test or replace the K33 HVAC control module.
Repair Instructions
Perform the Diagnostic Repair Verification on
page 692 after completing the repair.
Control Module References on page 6—3for 30M or
HVAC control module replacement, programming, and
setup

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
 Lighting 4421

DTC 32645

Diagnostic Instructions
- Perform the Diagnostic System Check - Vehicle
on page 6-66 prior to using this diagnostic
procedure.
- Review Strategy Based Diagnosis on page 6-58
for an overview of the diagnostic approach.
‘ Diagnostic Procedure Instructions on page 6—59
provides an overview of each diagnostic category.
DTC Descriptors
DTC 32645 03: Ambient Light Sensor Circuit Low Voltage
DTC 32645 07: Ambient Light Sensor Circuit High Voltage

Diagnostic Fault Information

Open/High Signal
Circuit Short to Ground Resistance Short to Voltage Performance
AmbientLightSensorSignal 3264503 3264507 3264507 -
LowBeamHeadlampControl—Left 3257502 3257504 3257501, -
3257504
LowBeamHeadlampControl—Right 3269902 3269904 3269901, -
3269904
AmbientLightSensorGround — 3264507 —— -
HeadlampGround—Left — 1 — —-
HeadlampGround—Right — 1 — -
1. HeadlampsMalfunction

CircuitlSystem Description DTC 32645 07

The ambient light sensor is used to monitor outside - The 30M detects a short to voltage or an open/
lighting conditions. The body control module (BCM) high resistance in the ambient light sensor signal
provides a 5-volt reference signal to the ambient light circuit.
sensor. Depending on outside lighting conditions, the - The 30M detects an open/high resistance in the
ambient light sensor provides a voltage signal to the ambient light sensor ground circuit.
BCM that will vary between 0.2 and 4.9 volts. The 30M
monitors the ambient light sensor signal circuit to Actions Taken When the DTC Sets
determine if outside lighting conditions are correct for - Automatic headlamp system and daytime running
either daytime running lights (DRL) or automatic lamps are inoperative.
headlamp system control when the headlamp switch is - The 30M defaults to low light status and
in the AUTO position. Indaylight conditions, the 30M commands the low beam headlamps ON.
will command the low beam headlamps (DRLs) ON by
applying low voltage to the low beam headlamp control Conditions for Clearing the DTC
circuits illuminating the low beam headlamps at
reduced intensity.Any function or condition that turns - The condition responsible for setting the DTC no
on the headlamps will cancel DRL operation. longer exists.
- A history DTC will clear once 100 consecutive
Conditions for Running the DTC malfunction-free ignition cycles have occurred.
Battery voltage must be between 9-16 V.
Reference information
Conditions for Setting the DTC Schematic Reference
DTC 32645 03 Headlights/Daytime Running Lights (DRL) Schematics
The 30M detects a short to ground in the ambient light on page 4—82
sensor signal circuit.
Connector End View Reference
Component Connector End Views on page 11-269
Description and Operation
Exterior Lighting Systems Description and Operation
on page 4-217

2013
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Manual
(5377994)
4—122 Lighting
Information Reference :> If infinite resistance, replace the K9 Body
Electrical Control Module.
Circuit Testing on page 11-526 U If greater than 4.65 V
Connector Repairs on page 11-548 5. Install a 3 A fused jumper wire between the signal
Testing for IntermittentConditions and Poor circuit terminal 5 and the ground circuit terminal 6.
Connections on page 11-531 6. Verify the scan tool Ambient Light Sensor
Wiring Repairs on page 11537 parameter is less than 0.196 V.
Scan Tool Reference :> If 0.196 V or greater
6.1. lgnition OFF, disconnect the X2 harness
Control Module References on page 6-3 for scan tool connector at the K9 Body Control Module,
information ignition ON.
CircuitlSystem Testing 6.2. Test for less than 1 V between the signal
scan tool disconnected, all doors circuit terminal 5 and ground.
1. Ignition OFF,
closed, all accessories OFF, open and close =>If 1 V or greater, repair the short to voltage on
drivers door, disconnect the harness connector at the circuit.
the 310 Ambient Light Sensor. Itmay take up to 0 Ifless than 1 V
2 minutes for all vehicle systems to power down.
6.3. Test for less than 2 Q in the signal circuit end
Test for less than 15 Q between the ground circuit to end.
terminal 6 and ground.
=>If2 Q or greater, repair the open/high resistance
If 15 Q or greater in the circuit.
2.1. lgnition OFF. :> If less than 2 Q, replace the K9 Body Control
2.2. Test for less than 2 Q in the ground circuit end Module.
to end.
U If less than 0.196 V
=>If2 Q or greater, repair the open/high resistance 7. Test or replace the B10 Ambient Light Sensor.
in the circuit.
=>.If less than 2 Q, repair the open/high resistance Repair Instructions
in the ground connection. Perform the Diagnostic Repair Verification on
If less than 15 Q page 6—92after completing the repair.
9° Ignition ON. Sun Load Temperature Sensor Replacement on
page 10—83
Verify the scan tool Ambient Light Sensor
parameter is greater than 4.65 V. Control Module References on page 6—3for 30M
replacement, programming, and setup
If 4.65 V or less
4.1. lgnition OFF, disconnect the X2 harness
connector at the K9 Body Control Module.
4.2. Test for infinite resistance between the signal
circuit terminal 5 and ground.
:> if less than infinite resistance, repair the short to
ground on the circuit.

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
 Lighting 4-123

DTC 32652

Diagnostic Instructions
0 Perform the Diagnostic System Check —Vehicle
on page 6—66prior to using this diagnostic
procedure.
- Review Strategy Based Diagnosis on page 6-58
for an overview of the diagnostic approach.
- Diagnostic Procedure Instructions on page 6-59
provides an overview of each diagnostic category.
DTC Descriptor
DTC 32652 02: Passenger Compartment Dimming 3 Circuit Short to Ground
Diagnostic Fault Information

Open/High Signal
Circuit Short to Ground Resistance Short to Voltage Performance
TransmissionShiftLeverPositionIndicator
BacklightingControl 3265202 1 1
TransmissionShiftLeverPositionIndicator 1 _ _
Ground
1.InteriorBacklightingMalfunction

CircuitlSystem Description Conditions for Clearing the DTC

The instrument panel dimmer switch is used to increase ' The condition responsible for setting the DTC no
and decrease the brightness of the interior backlighting longer exists.
components. The instrument panel dimmer switch ' A history DTC will clear once 100 consecutive
provides a voltage signal to the body control module malfunction—freeignition cycles have occurred.
(30M) that will increase as the brightness of the lights
are increased and decrease as the brightness of the Reference Information
lights are decreased. The 30M provides a low
reference, signal, and 3+ voltage reference circuits to Schematic Reference
the instrument panel dimmer switch. When the Interior Lights Dimming Schematics on page 4-91
instrument panel dimmer switch is placed in the desired
position, the dimmed voltage setting is applied from the Connector End View Reference
instrument panel dimmer switch through the instrument
panel dimmerswitch signal circuit to the BCM. The Component Connector End Views on page 11-269
BCM interprets the signal and applies a pulse width Description and Operation
modulated (PWM) voltage through the LED dimming
control circuits illuminating the interior backlighting to Interior Lighting Systems Description and Operation on
the requested level of brightness. page 4-219

Conditions for Running the DTC Electrical Information Reference

- Battery voltage must be between 9—16V. ' Circuit Testing on page 11-526
- Park lamps ON. - Connector Repairs on page 11-548
° Testing for IntermittentConditions and Poor
Conditions for Setting the DTC Connections on page 11—531
The 30M detects a short to ground in the transmission - Wiring Repairs on page 11-537
shift lever position indicator backlighting control circuit.
Scan Tool Reference
Actions Taken When the DTC Sets
Control Module References on page 6-3 for scan tool
The 30M will disable the transmission shift lever information
position indicator backlighting control circuit.

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4-124 fightingr

CircuitlSystem Testing 2 Ifless than 2 Q, replace the K9 body control

1. ignition OFF, scan tool disconnected, all doors
Closed, all accessories OFF, disconnect the
harness connector at the P2 transmission shift
lever position indicator. Itmay take up to 2 minutes
for all vehicle systems to power down.
2. Test for less than 15 Q between the ground circuit
terminal 2 and ground.
2 If 15 Q or greater
2.1. lgnition OFF.
22. Test for less than 2 Q in the ground circuit end
to end.
2 If2 Q or greater, repair the open/high resistance
in the circuit.
2 Ifless than 2 Q, repair the open/high resistance
in the ground connection.
0 If less than 15 Q
3. Connect a test lamp between the control Circuit
terminal1 and ground.
4. Verify the test lamp turns ON and OFF while
turning the headlamp switch ON and OFF.
2 If the test lamp is always OFF
4.1. IgnitionOFF, disconnect the X6 harness
connector at the K9 body control module.
4.2. Test for infinite resistance between the control
circuit and ground.
2 Ifless than infinite resistance, repair the short to
ground on the circuit.
0 Ifinfinite resistance
4.3. Test for less than 2 Q in the control circuit end
to end. -
2 If2 Q or greater, repair the open/high resistance
in the Circuit.
module.
2 If the test lamp is always ON
4.1. Ignition OFF, disconnect the X6 harness
connector at the K9 body control module,
ignition ON.
4.2. Test for less than 1 V between the control
circuit terminal and ground.
2 If 1 V or greater, repair the short to voltage on
the circuit.
2 Ifless than 1 V, replace the K9 body control
module.
U If the test lamp turns 0N and OFF
5. Test or replace the P2 transmission shift lever
position indicator.
Repair Instructions
Perform the Diagnostic Repair Verification on
page 6-92 after completing the repair.
' Transmission Control Replacement on
page 17-193
0 Control Module References on page 6-3 for BCM
replacement, programming, and setup

2013
—
Sonic
(US/Canada)
Service
Manual
(5377994)
 Lighting 4:125

DTC B3596

Diagnostic Instructions
0 Perform the Diagnostic System Check - Vehicle
on page 6—66prior to using this diagnostic
procedure.
' Review Strategy Based Diagnosis on page 6-58
for an overview of the diagnostic approach.
- Diagnostic Procedure Instructions on page 6—59
provides an overview of each diagnostic category.
DTC Descriptor
DTC 33596 00: Hazard Lamps Request Circuit Malfunction

Diagnostic Fault Information

Short to Open/High Signal

Circuit Ground Resistance Short to Voltage Performance
HazardWarningSwitchSignal ‘ 1 1 1 3359600
HazardWarningSwitchLED Backlighting 2
Control 2 2 -
HazardWarningSwitchGround - 1 _ _
1. HazardLampsMalfunction
2. HazardWarningSwitchBacklightingMalfunction

CircuitlSystem Description Description and Operation

The hazard flashers may be activated in any power Exterior Lighting Systems Description and Operation
mode. The hazard warning switch signal circuit is on page 4-217
momentarily grounded when the hazard warning switch
is pressed. The body control module (BCM) responds Electrical Information Reference
to the hazard warning switch signal input by supplying - Circuit Testing on page 11-526
battery voltage to all fourtum signal lamps in an ON
and OFF duty cycle. When the hazard warning switch is - Connector Repairs on page 11-548
activated, the 30M sends a serial data message to the ' Testing for IntermittentConditions and Poor
instrument cluster requesting both turn signal indicators Connections on page 11—531
to be cycled ON and OFF. - Wiring Repairs on page 11-537
Conditions for Running the DTC Scan Tool Reference
- Battery voltage must be between 9—16V. Control Module References on page 6—3for scan tool
- Hazard lamps ON. information
Conditions for Setting the DTC CircuitlSystem Testing
The hazard warning switch input is Active for longer 1. IgnitionOFF, scan tool disconnected, all doors
than 60 seconds. closed, all accessories OFF, disconnect the
harness connector at the 826 Hazard Warning
Actions Taken When the DTC Sets Switch. it may take up to 2 minutes for all vehicle
The hazard lamps are inoperative. systems to power down.
2. Test for less than 5 Q between the ground circuit
Conditions for Clearing the DTC terminal 3 and ground.
- The condition responsible for setting the DTC no 2 If 5 Q or greater
longer exists.
2.1. lgnition OFF.
- A history DTC will clear once 100 consecutive
2.2. Test for less than 2 Q in the ground circuit end
maifunction-free ignition cycles have occurred.
to end.
Reference Information 2 If2 Q or greater, repair the open/high resistance
in the Circuit.
Schematic Reference
2 Ifless than 2 Q, repair the open/high resistance
Exterior Lights Schematics on page 4—85 in the ground connection.
Connector End View Reference 0 If less than 5 Q
Component Connector End Views on page 11-269 3. IgnitionON.

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4=126 Lighting
4. Verify the scan tool Hazard Lamps Switch
parameter is Inactive.
If not Inactive
4.1. lgnition OFF, disconnect the X2 harness
connector at the K9 Body Control Module.
4.2. Test for infinite resistance between the signal
circuit terminal1 and ground.
2 Ifless than infinite resistance, repairthe short to
ground on the circuit.
2 If infinite resistance, replace the K9 Body
Control Module.
If Inactive
. Install a 3 A fused jumperwire between the signal
circultterminal1 and ground.
. Verify the scan tool Hazard Lamps Switch
parameter is Active.
if not Active
6.1. IgnitionOFF, disconnect the X2 harness
connector at the K9 Body Control Module,
ignition ON.
6.2. Test for less than 1 V between the signal
circuit terminal1 and ground.
2 If 1 Vor greater, repair the short to voltage on
the circuit.
0 Ifless than 1 V
6.3. Test for less than 2 Q in the signal circuit end
to end.
2 If2 Q or greater, repair the open/high resistance
in the circuit.
2 if less than 2 Q, replace the K9 Body Control
Module.
11 If Active
7. Test or replace the 826 Hazard Warning Switch.
Repair Instructions
Perform the Diagnostic Repair Verification on
page 6-92 after completing the repair.
. Hazard Warning Switch Replacement on
page 4—188
. Control Module References on page 6-3 for 30M
replacement, programming, and setup

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Lighting 4427

DTC 33650

Diagnostic Instructions
- Peltorm the Diagnostic System Check - Vehicle
on page 6—66prior to using this diagnostic
procedure.
° Review Strategy Based Diagnosis on page 6-58
for an overview of the diagnostic approach.
- Diagnostic Procedure Instructions on page 659
provides an overview of each diagnostic category.
DTC Descriptor
DTC 33650 08: High Beam Request Signal Circuit Performance —Signal Invalid
Diagnostic Fault Information

Open/High Signal
Circuit Short to Ground Resistance Short to Voltage Performance
HeadlampSwitchHeadlampsOFF Signal 3257A00 1 1 -
HeadlampSwitchHeadlampsON Signal 3257A00 1 1 —-
HeadlampSwitchPark LampsON Signal 2 3257A00 2 -
TurnSignal/Multifunction
Signal SwitchFlashToPass 3380600 1 1 -
TurnSignal/Multifunction
Signal SwitchHighBeam 3365008 1 1 —-
HeadlampSwitchGround — 1 — -
TurnSignal/Multifunction
SwitchGround — 1 — -
1.HeadlampsMalfunction
2. Park,License,and/orTailLampsMalfunction

CircuitlSystem Description Reference Information

When the low beam headlamps are on and the turn Schematic Reference
signaI/multifunctionswitch is placed in the high beam
position, ground is applied to the body control module Headlights/Daytime Running Lights (DRL) Schematics
(30M) through the high beam signal circuit. The 30M on page 4-82
responds to the high beam request by applying ground
Connector End View Reference
to the high beam relay control circuit which energizes
the high beam relay. With the high beam relay Component Connector End Views on page 11—269
energized, the switch contacts close allowing battery
voltage to flow through the high beam fuses to the high Description and Operation
beam control circuits illuminating the high beam Exterior Lighting Systems Description and Operation
headlamps. on page 4—217
Conditions for Running the DTC Electrical Information Reference
Battery voltage must be between 9-16 V. - Circuit Testing on page 11-526
Conditions for Setting the DTC - Connector Repairs on page 11—548
The 30M detects a short to ground in the turn signal/ - Testing for IntermittentConditions and Poor
multifunctionswitch high beam signal circuit. Connections on page 11-531
~ Wiring Repairs on page 11—537
Actions Taken When the DTC Sets
Scan Tool Reference
The high beam headlamps will not operate.
Control Module References on page 6-3 for scan tool
Conditions for Clearing the DTC information
' The condition responsible for setting the DTC no
longer exists.
- A history DTC will clear once 100 consecutive
malfunction—freeignition cycles have occurred.

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Manual
(5377994)
4-128 Lighting

CircuitlSystem Testing 5. Install a 3 A fused jumper wire between the signal

1. lgnition OFF, scan tool disconnected, all doors
closed, all accessories OFF, disconnect the
harness connector at the 878 Turn Signal/
Multifunction Switch. Itmay take up to 2 minutes
for all vehicle systems to power down.
. Test for less than 15 Q between the ground circuit
terminal 3 and ground.
If 15 Q or greater
2.1. lgnition OFF.
2.2. Test for less than 2 Q in the ground circuit end
to end.
2 if 2 Q or greater, repair the open/high resistance
in the circuit.
2 Ifless than 2 Q, repair the open/high resistance
in the ground connection.
If less than 15 Q
9’ IgnitionON.
. Verify the scan tool High Beam Select Switch
parameter is Inactive.
If not Inactive
4.1. Ignition OFF, disconnect the X3 harness
connector at the K9 Body Control Module.
4.2. Test for infinite resistance between the signal
circuit terminal 2 and ground.
2 if less than infinite resistance, repair the short to
ground on the circuit.
2 Ifinfinite resistance, replace the K9 Body
Control Module.
If Inactive
circuit terminal 2 and the ground circuit terminal 3.
6. Verify the scan tool High Beam Select Switch
parameter is Active.
2 If not Active
6.1. Ignition OFF, disconnect the X3 harness
connector at the K9 Body Control Module,
ignition ON.
6.2. Test for less than 1 V between the signal
circuit terminal 2 and ground.
2 If 1 V or greater, repair the short to voltage on
the circuit.
U Ifless than 1 V
6.3. Test for less than 2 Q in the signal circuit end
to end.
2 if 2 Q or greater, repair the open/high resistance
in the circuit.
2 Ifless than 2 Q, replace the K9 Body Control
Module.
U If Active
7. Test or replace the 878 Turn Signal/Multifunction
Switch.
Repair Instructions
Perform the Diagnostic Repair Verification on
page 6—92after completing the repair.
- Turn Signal Multifunction Switch Replacement on
page 15-31
- Control Module References on page 6—3for 30M
replacement, programming, and setup

2013
-Sonic
(US/Canada)
Sen/ice
Manual
(5377994)
 Lighting 4:129

DTC 33806

Diagnostic Instructions
- Perform the Diagnostic System Check - Vehicle
on page 6—66prior to using this diagnostic
procedure.
- Review Strategy Based Diagnosis on page 6-58
for an overview of the diagnostic approach.
- Diagnostic Procedure Instructions on page 6-59
provides an overview of each diagnostic category.
DTC Descriptor
DTC 33806 00: High Beam and Headlamp Flash Select Circuit Malfunction
Diagnostic Fault Information

Open/High Signal
Circuit Short to Ground Resistance Short to Voltage Performance
HeadlampSwitchHeadlampsOFF Signal 3257A00 1 1 ~-
HeadlampSwitchHeadlampsON Signal 3257A00 1 1 -
HeadlampSwitchPark LampsON Signal 2 3257A00 2 -
SwitchFlashToPass
TurnSignaI/Multifunction 3380600 1 1 _
Signal
SwitchHighBeam
TurnSignal/Multifunction 3365008 1 1 _
Signal
HeadlampSwitchGround —- 1 — -
SwitchGround
TurnSignaI/Multifunction — 1 — -
1. HeadlampsMalfunction
2. Park,License,and/orTailLampsMalfunction

CircuitlSystem Description Conditions for Clearing the DTC

When the turn signal/multifunction switch is 0 The condition responsible for setting the DTC no
momentarily placed in the flash to pass position, longer exists.
ground is applied to the body control module (30M) - A history DTC will clear once 100 consecutive
through the flash to pass signal circuit. The 30M malfunction—freeignition cycles have occurred.
responds to the flash to pass request by applying
ground to the high beam relay control circuit which Reference Information
energizes the high beam relay. With the high beam
relay energized, the switch contacts close allowing Schematic Reference
battery voltage to flow through the high beam fuses to Headlights/Daytime Running Lights (DRL) Schematics
the high beam control circuits illuminating the high on page 4-82
beam headlamps. The high beam headlamps will only
illuminate for as long at the flash to pass switch is Connector End View Reference
activated.
Component Connector End Views on page 11-269
Conditions for Running the DTC Description and Operation
Battery voltage must be between 9—16V.
Exterior Lighting Systems Description and Operation
Conditions for Setting the DTC on page 4-217,
The 30M detects a short to ground in the turn signal/ Electrical Information Reference
multifunction switch flash to pass signal circuit.
- Circuit Testing on page 11—526
Actions Taken When the DTC Sets ' Connector Repairs on page 11-548
The high beam lamps and the high beam indicator on . Testing for IntermittentConditions and Poor
the instrument cluster are always ON. Connections on page 11—531
' Wiring Repairs on page 11-537
Scan Tool Reference
Control Module References on page 6—3for scan tool
information

(US/Canada)
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2013 (5377994)
Manual
Serice
4-130 LightingL

CircuitlSystem Testing 5. Install a 3 A fused jumper wire between the signal

1. lgnition OFF, scan tool disconnected, all doors
closed, all accessories OFF, disconnect the
harness connector at the S78 Turn Signal/
Multifunction Switch. it may take up to 2 minutes
for all vehicle systems to power down.
. Test for less than 15 Q between the ground circuit
terminal 3 and ground.
If 15 Q or greater
2.1. lgnition OFF.
2.2. Test for less than 2 Q in the ground circuit end
to end.
2 If2 Q or greater, repair the open/high resistance
in the circuit.
2 Ifless than 2 Q, repair the open/high resistance
in the ground connection.
If less than 15 Q
9° Ignition ON.
Verify the scan tool Headlamps Flash Switch
parameter is Inactive.
If not Inactive
4.1. lgnition OFF, disconnect the X3 harness
connector at the K9 Body Control Module.
4.2. Test for infinite resistance between the signal
circuit terminal 4 and ground.
2 Ifless than infinite resistance, repair the short to
ground on the circuit.
2 if infinite resistance, replace the K9 Body
Control Module.
lf Inactive
circuit terminal 4 and the ground circuit terminal 3.
6. Verify the scan tool Headlamps Flash Switch
parameter is Active.
2; If not Active
6.1. lgnition OFF, disconnect the X3 harness
connector at the K9 Body Control Module,
ignition ON.
6.2. Test for less than 1 V between the signal
circuit terminal 4 and ground.
2 If 1 V or greater, repair the short to voltage on
the circuit.
U Ifless than 1 V
6.3. Test for less than 2 Q in the signal circuit end
to end.
2 |12Q or greater, repair the open/high resistance
in the circuit.
2 lf less than 2 Q, replace the K9 Body Control
Module.
If Active
Test or replace the 878 Turn Signal/Multifunction
Switch.
Repair Instructions
Perform the Diagnostic Repair Verification on
page 692 after completing the repair.
Turn Signal Multifunction Switch Replacement on
page 15-31
Control Module References on page 6-3 for 30M
replacement, programming, and setup

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
 Lighting 4.131

DTC 33881 or 33882

Diagnostic Instructions
- Perform the Diagnostic System Check - Vehicle
on page 6—66prior to using this diagnostic
procedure.
~ Review Strategy Based Diagnosis on page 6-58
for an overview of the diagnostic approach.
. Diagnostic Procedure Instructions on page 6-59
provides an overview of each diagnostic category.
DTC Descriptors
DTC 33881 01: Tail Lamp Circuit Short to Battery
DTC 33881 02: Tail Lamp Circuit Short to Ground
DTC 33881 04: Tail Lamp Circuit Open
DTC 33882 01: Right Tail Lamp Circuit Short to Battery
DTC 33882 02: Right Tail Lamp Circuit Short to Ground
DTC 33882 04: Right Tail Lamp Circuit Open

Diagnostic Fault Information

Short to Open/High Short to Voltage Signal

Circuit Ground Resistance Performance
HeadlampSwitchPark LampsON Signal 2 3257A00 2 -
LicensePlateLampControl 3388302 8393(888%%4 3388301 -
ESQtrgérllfeaftqd
RearSide MarkerLamps 3258502 3258504 1322558855%11 _

Egorzittrgarlggrli‘cti
RearSide MarkerLamps 3386702 3386704 @33886377C31, _

RearTail/StopLampsControl- Left 3388102 3388104 3388101 -

RearTail/StopLampsControl- Right ' 3388202 3388204 3388201 -
HeadlampSwitchGround — 2 — -
LicensePlate LampGround- Left ~ 1 — -
LicensePlate LampGround- Right — 1 — -
Park LampGround- LeftFront — 1 — -
Park LampGround- RightFront — 1 - —-
RearTail/StopLampsGround- Left — 1 —— -
RearTail/StopLampsGround- Right — 1 — -
Side MarkerLampGround—LeftRear —- 1 — -
Side MarkerLampGround- RightRear — 1 — -
1.Park,License,and/orTailLampsMalfunction
2. Park LampSwitchMalfunction

CircuitlSystem Description Conditions for Setting the DTC

When the headlamp switch is placed in the HEAD or DTC 33881 01
PARK position, ground is applied to the park lamp
switch ON signal circuit to the body control module The 30M detects a short to voltage in the left rear tail
(30M). The 30M responds by applying voltage to the lamp control circuit.
park lamps, tail lamps, and license lamps control DTC 33881 02
circuits illuminating the park, tail, and license lamps.
The 30M detects a short to ground in the left rear taii
Conditions for Running the DTC lamp control circuit.
- Battery voltage must be between 9—16V. DTC 33881 04
- Park lamps ON. The 30M detects an open/high resistance in the left
rear tail lamp control circuit.

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4=132 Lighting
DTC 33882 01 2 Ifless than 2 Q, repair the open/high resistance
The BCM detects a short to voltage in the right rear tail in the ground connection.
lamp control circuit. U If less than 5 Q
DTC 33882 02 3. Connect a test lamp between the control circuit at
the socket terminal and ground, ignition ON.
The 30M detects a short to ground in the right rear tail
iamp control circuit. 4. Verify the test lamp turns ON and OFF when
commanding the Left Park Lamps ON and OFF
DTC 33882 04 with a scan tool.
The 30M detects an open/high resistance in the right 2 If the test lamp is always OFF
rear tail lamp control circuit. 4.1. lgnition OFF, disconnect the X4 harness
connector at the K9 body control module.
Actions Taken When the DTC Sets
4.2. Test for infinite resistance between the control
The appropriate tail lamp will not operate. circuit and ground.
Conditions for Clearing the DTC 2 Ifiess than infinite resistance, repair the short to
ground on the circuit.
- The condition responsible for setting the DTC no
longer exists. U if infinite resistance
- A history DTC will clear once 100 consecutive 4.3. Test for less than 2 Q in the control circuit end
malfunction—freeignition cycles have occurred. to end.
2 lf 2 Q or greater, repair the open/high resistance
Diagnostic Aids in the circuit.
Note: When testing at the rearturn signal iamp bulb 2 If less than 2 Q, replace the K9 body control
socket, make sure all measurements and test lamp
module.
connections are in the correct terminal location and do
not come in contact with each other during testing. 2 If the test lamp is always ON
4.1. IgnitionOFF, disconnect the X4 harness
Reference Information connector at the K9 body control module,
ignition ON.
Schematic Reference
4.2. Test for less than 1 V between the control
Exterior Lights Schematics on page 4-85 circuit terminal and ground.
Connector End View Reference 2 If 1 Vor greater, repair the short to voltage on '
the circuit.
Component Connector End Views on page 11-269
2 Ifless than 1 V, replace the K9 body control
Description and Operation module.
Exterior Lighting Systems Description and Operation U If the test lamp turns ON and OFF
on page 4—217 5. Test or replace the E5AAtaillstop lamp —left.
Electrical Information Reference DTC 33882
- Circuit Testing on page 11—526 1. lgnition OFF, exterior lamps OFF, trunk latch
latched, remove the E5AB tail/stop lamp bulb -
- Connector Repairs on page 11-548
right.
- Testing for IntermittentConditions and Poor
Connections on page 11—531 2. Test for less than 5 Q between the ground circuit at
the socket terminal and ground.
- Wiring Repairs on page 11-537
2 If 5 Q or greater
Scan Tool Reference 2.1. IgnitionOFF.
Control Module References on page 6-3 for scan tool 2.2. Test for less than 2 Q in the ground circuit end
information to end.
2 If2 Q or greater, repair the open/high resistance
CircuitlSystem Testing
in the circuit.
DTC 33881 2 lf less than 2 Q, repair the open/high resistance
1. lgnition OFF, exterior lamps OFF, trunk latch in the ground connection.
latched, remove the E5AAtail/stop lamp bulb —left. U If less than 5 Q
2. Test for less than 5 Q between the ground circuit at 3. Connect a test lamp between the control circuit at
the socket terminal and ground. the socket terminal and ground, ignition ON.
2 If 5 Q or greater
2.1. lgnition OFF.
2.2. Test for less than 2 Q in the ground circuit end
to end.
2 If2 Q or greater, repair the open/high resistance
in the circuit.
2013
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Service
Manual
(5377994)
 Ligi’tting 4-133
4. Verify the test lamp turns ON and OFF when 2 Ifless than 1 V, replace the K9 body control
commanding the Right Park Lamps ON and OFF module.
with a scan tool. U If the test lamp turns ON and OFF
2 if the test lamp is always OFF 5. Test or replace the E5AB tail/stop lamp —right.
4.1. lgnition OFF, disconnect the X5 harness
connector at the K9 body control module. Repair Instructions
4.2. Test for infinite resistance between the control Perform the Diagnostic Repair Verification on
circuit and ground. page 6-92 after completing the repair.
2 Ifless than infinite resistance, repair the short to ' Tail Lamp Replacement (Hatchback) on
ground on the circuit. page 4-214 or Tail Lamp Replacement (Sedan) on
page 4-213
U Ifinfinite resistance
- Stop and Turn Signal Lamp Bulb Replacement
4.3. Test for less than 2 Q in the control circuit end
(Sedan) on page 4-215
to end.
- Control Module References on page 6-3 for 30M
2 lf 2 Q or greater, repair the open/high resistance replacement, programming, and setup
in the circuit.
2 Ifless than 2 Q, replace the K9 body control
module.
2 If the test lamp is always ON
4.1. lgnition OFF, disconnect the X5 harness
connector at the K9 body control module,
ignition ON.
4.2. Test for less than 1 V between the control
circuit terminal and ground.
2 If 1 V or greater, repair the short to voltage on
the circuit.

201.?
«Sonic
(US/Canada)
Service
Manual
(5377994)
4-134 Lighting

DTC B3883

Diagnostic Instructions
- Perform the Diagnostic System Check - Vehicle
on page 6—66prior to using this diagnostic
procedure.
- Review Strategy Based Diagnosis on page 6—58
for an overview of the diagnostic approach.
- Diagnostic Procedure Instructions on page 6-59
provides an overview of each diagnostic category.
DTC Descriptors
DTC 33883 01: License Plate Lamp Circuit Short to Battery
DTC 33883 02: License Plate Lamp Circuit Short to Ground
DTC 33883 04: License Plate Lamp Circuit Open
Diagnostic Fault Information

. Open/High Signal
Circuit Short to Ground Resistance Short to Voltage Performance
3387301, 3387301,
3387304, 3387304,
F5DA (BCM 1)Fuse B+ 3388301, 3388301, — -
3388304, 3388304,
0029701 0029701
. 3388301,
License PlateLampControl 3388302 3388304 3388301 -
. . 3388301,
License PlateLampGround—Right —— 3388304 — -
. 3388301,
License PlateLampGround—Left — 3388304 — -

CircuitlSystem Description DTC 33883 02

When the headlamp switch is placed in the HEAD or The BCM detects a short to ground in the license lamps
PARK position, ground is applied to the park lamp control circuit.
switch ON signal circuit to the body control module DTC 33883 04
(BCM). The 30M responds by applying voltage to the
park lamps, tail lamps, and license lamps control o The 30M detects an open/high resistance in the
circuits illuminating the park, tail, and license lamps. license lamps control circuit.
- The 30M detects an open/high resistance in the
Conditions for Running the DTC license lamps ground circuit.
Battery voltage must be between 9—16V. - The 30M detects a short to ground or an open/
high resistance in the F5DA (BCM 1)fuse 3+
DTC 33883 01 circuit.
Headlamp switch in OFF position.
Actions Taken When the DTC Sets
DTC 33883 02 or 33883 04
Headlamp switch in PARK or ON positions. DTC 33883 01
License lamps always ON.
Conditions for Setting the DTC
DTC 33883 02 or 33883 04
DTC 33883 01 License lamps inoperative.
- The 30M detects a short to voltage in the license
lamps control circuit. Conditions for Clearing the DTC
- The 30M detects an open/high resistance in the - The condition responsible for setting the DTC no
license lamps ground circuit. longer exists.
- The BCM detects a short to ground or an open/ - A history DTC will clear once 100 consecutive
high resistance in the F5DA (30M 1) fuse 3+ malfunction-free ignition cycles have occurred.
circuit.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Lighting 4=135

Reference Information 5. Test for less than 5 Q between each ground circuit
terminal 2 and ground.
Schematic Reference 2 If 5 Q or greater
Exterior Lights Schematics on page 4-85 5.1. lgnition OFF.
Connector End View Reference 5.2. Test for less than 2 Q in the ground circuit end
to end.
Component Connector End Views on page 11-269
2 If2 Q or greater, repair the open/high resistance
Description and Operation in the circuit.
Exterior Lighting Systems Description and Operation 2 If less than 2 Q, repair the open/high resistance
on page 4-217 in the ground connection.
Electrical Information Reference U If less than 5 Q
6. Connect a test lamp between the E7L License
- Circuit Testing on page 11-526 Plate Lamp —Left control circuit terminal 1 and
- Connector Repairs on page 11-548 ground, ignition ON.
- Testing for IntermittentConditions and Poor 7. Verify the test lamp turns ON and OFF when
Connections on page 11-531 commanding the License Plate Lamps ON and
- Wiring Repairs on page 11—537 OFF with a scan tool.
2 If the test lamp is always OFF
Scan Tool Reference
7.1. IgnitionOFF, disconnect the X4 harness
Control Module References on page 6-3 for scan tool connector at the K9 Body Control Module.
information 7.2. Test for infinite resistance between the control
CircuitlSystem Testing circuit and ground.
1. IgnitionOFF, disconnect the X2 harness connector 2 If less than infinite resistance, repair the short to
at the K9 Body Control Module, ignition ON. ground on the circuit.
2. Verify a test lamp illuminates between the 3+ U lf infinite resistance
circuit terminal 1 and ground. 7.3. Test for less than 2 Q in the control circuit end
2 If the test lamp does not illuminate and the to end.
circuit fuse is good 2 If2 Q or greater, repair the open/high resistance
2.1. lgnition OFF. in the circuit.
2.2. Test for less than 2 Q in the 3+ circuit end 2 Ifless than 2 Q, replace the K9 Body Control
to end. Module.
2 |f2 Q or greater, repair the open/high resistance 2 If the test lamp is always ON
in the circuit. 7.1. lgnition OFF, disconnect the X4 harness
2 Ifless than 2 Q, verify the fuse is not open and connector at the K9 Body Control Module,
there is voltage at the fuse. ignition ON.
2 If the test lamp does not illuminate and the 7.2. Test for less than 1 V between the control
circuit fuse is open circuit terminal and ground.
2.1. IgnitionOFF. 2 If 1 V or greater, repair the short to voltage on
2.2. Test for infinite resistance between the 3+ the circuit.
circuit and ground. 2 Ifless than 1 V, replace the K9 Body Control
2 Ifless than infinite resistance, repair the short to Module.
ground on the circuit. U If the test lamp turns ON and OFF
2 Ifinfinite resistance, replace the K9 Body 8. Ignition OFF.
Control Module. 9. Connect a test lamp between the E7R License
U If the test lamp illuminates Plate Lamp —Right control circuit terminal 1 and
ground, ignition ON.
3. IgnitionOFF, connect the X2 harness connector at
the K9 Body Control Module.
4. lgnition OFF, exterior lamps OFF, rear hatch latch
latched, remove both E7 License Plate Lamp
bulbs.

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2013 (5377994)
Manual
Service
4436 Lighting
10. Verify the test lamp turns ON and OFF when Repair Instructions
commanding the License Plate Lamps ON and
OFF with a scan tool. Perform the Diagnostic Repair Verification on
page 692 after completing the repair.
If the test lamp is always OFF ' Rear License Plate Lamp Bulb Replacement
10.1. IgnitionOFF, disconnect the X4 harness (Sedan) on page 4-211 or Rear License Plate
connector at the K9 Body Control Module. Lamp Bulb Replacement (Hatchback) on
10.2. Test for infinite resistance between the page 4-212
control circuit and ground. - Control Module References on page 6-3 for 30M
2 Ifless than infinite resistance, repairthe short to replacement, programming, and setup
ground on the circuit.
U If infinite resistance
10.3. Test for less than 2 Q in the control circuit end
to end.
2 If2 Q or greater, repair the open/high resistance
in the circuit.
U If the test lamp turns ON and OFF
11. Test or replace the appropriate E7 License Plate
Lamp bulb.

2013
-Sonic
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Service
Manual
(5377994)
 Lighting 44137

DTC B3884

Diagnostic Instructions
- Perform the Diagnostic System Check - Vehicle
on page 6-66 prior to using this diagnostic
procedure.
- Review Strategy Based Diagnosis on page 6—58
for an overview of the diagnostic approach.
- Diagnostic Procedure Instructions on page 6-59
provides an overview of each diagnostic category.
DTC Descriptors
DTC 33884 01: Center High Mounted Brake Lamp Circuit Short to Battery
DTC 33884 02: Center High Mounted Brake Lamp Circuit Short to Ground
DTC 33884 04: Center High Mounted Brake Lamp Circuit Open
Diagnostic Fault Information

Open/High Short to Voltage Signal

Circuit Short to Ground Resistance Performance
CenterHighMountedStopLampControl 3388402 3388404 3388401
CenterHighMountedStopLampGround 1
1.StopLampsMalfunction

CircuitlSystem Description Conditions for Clearing the DTC

The brake pedal position sensor is used to sense the ~ The condition responsible for setting the DTC no
action of the driver application of the brake pedal. The longer exists.
brake pedal position sensor provides an analog voltage - A history DTO will clear once 100 malfunction-free
signal that will increase as the brake pedal is applied. ignition cycles have occurred.
The body control module (30M) provides a low
reference signal and a 5 V reference voltage to the Reference Information
brake pedal position sensor. When the variable signal
reaches a voltage threshold indicating the brakes have Schematic Reference
been applied, the 30M will apply battery voltage to the Exterior Lights Schematics on page 4-85
right and left stop lamp control circuits, engine control
module (ECM), and center high mounted stop lamp Connector End View Reference
control circuit.
Component Connector End Views on page 11-269
Conditions for Running the DTC Description and Operation
- Battery voltage must be between 9—16V.
Exterior Lighting Systems Description and Operation
- Brakes APPLIED. on page 4-217
Conditions for Setting the DTC Electrical Information Reference
DTC 33884 01 - Circuit Testing on page 11-526
The 30M detects a short to voltage in the center high - Connector Repairs on page 11-548
mounted stop lamp control circuit. o Testing for IntermittentConditions and Poor
DTC 33884 02 Connections on page 11—531
- Wiring Repairs on page 11-537
The 30M detects a short to ground in the center high
mounted stop lamp control circuit. Scan Tool Reference
DTC 33884 04 Control Module References on page 6-3 for scan tool
The 30M detects an open/high resistance in the center information
high mounted stop lamp control circuit.
Actions Taken When the DTC Sets
The BCM will not illuminate the center high mounted
stop lamp.

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4-138 lighting
2 Ifless than 2 Q, replace the K9 Body Control
CircuitlSystem Testing
Module.
1. IgnitionOFF, exterior lamps OFF, trunk latch If the test lamp is always ON
latched, disconnect the harness connector at the
E6 Center High Mounted Stop Lamp. 4.1. lgnition OFF, disconnect the X4 harness
connector at the K9 Body Control Module,
. Test for less than 5 Q between the ground circuit ignition ON.
terminal 3 and ground.
4.2. Test for less than 1V between the control
If 5 Q or greater circuit terminal and ground.
2.1. lgnition OFF.
2 If 1 V or greater, repair the short to voltage on
2.2. Test for less than 2 Q in the ground circuit end the circuit.
to end.
2 Ifless than 1 V, replace the K9 Body Control
2 If2 Q or greater, repair the open/high resistance Module.
in the circuit.
If the test lamp turns ON and OFF
2 if less than 2 Q, repair the open/high resistance
. Test or replace the E6 Center High Mounted
in the ground connection. Stop Lamp.
If less than 5 Q
Connect a test lamp between the control circuit Repair Instructions
terminal A and ground, ignition ON. Perform the Diagnostic Repair Verification on
Verify the test lamp turns ON and OFF when page 6-92 after completing the repair.
commanding the Center Brake Lamp ON and OFF ° High Mount Stop Lamp Replacement (Hatchback)
with a scan tool. on page 4205 or High Mount Stop Lamp
If the test lamp is always OFF Replacement (Sedan) on page 4—204
4.1. lgnition OFF, disconnect the X4 harness Control Module References on page 6-3 for 30M
connector at the K9 Body Control Module. replacement, programming, and setup
4.2. Test for infinite resistance between the control
circuit and ground.
2 Ifless than infinite resistance, repair the short to
ground on the circuit.
U lf infinite resistance
4.3. Test for less than 2 Q in the control circuit end
to end.
2 If2 Q or greater, repair the open/high resistance
in the circuit.

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2013 (5377994)
Manual
Service
 Lighting 4-139

DTC 33948 or 33949

Diagnostic Instructions
- Perform the Diagnostic System Check - Vehicle
on page 6-66 prior to using this diagnostic
procedure.
- Review Strategy Based Diagnosis on page 6-58
for an overview of the diagnostic approach.
- Diagnostic Procedure Instructions on page 6-59
provides an overview of each diagnostic category.
DTC Descriptors
DTC 33948 01: Left Front Turn Signal Circuit Short to Battery
DTC 33948 02: Left Front Turn Signal Circuit Short to Ground
DTC 33948 04: Left Front Turn Signal Circuit Open
DTC 33949 01: Right Front Turn Signal Circuit Short to Battery
DTC 33949 02: Right Front Turn Signal Circuit Short to Ground
DTC 33949 04: Right Front Turn Signal Circuit Open
Diagnostic Fault Information

Open/High
Circuit Short to Ground Resistance
F7DA (30M 3)Fuse 3+ 1 1
F8DA (30M 4) Fuse 3+ 1 1
F10DA(30M 6) Fuse 13+ 1 1
F11DA(30M 7) Fuse B+ 1 1
TurnSignalSwitchSignal—Left 1 1
TurnSignalSwitchSignal—Right 1 1
TurnSignalControl—LeftFront 3394802 3394804
Signal
Short to Voltage Performance
— ~-
— -
— -
— -
1 -
1 -
gégfig} -

TurnSignalControl—LeftRear 3395002 9395004 Egggg} -

TurnSignalControl—RightFront 133949
02 3394904 1313:3329); -

TurnSignalControl—RightRear 133951
02 133951
04 $333551
(511' -

TurnSignalLampGround—'LeftFront — Eggigglt’ —— -

TurnSignalLampGround—RightFront — g%%:%%1’— —-

TurnSignalLampGround—LeftRear — 33%55%%14 — -

TurnSignalLampGround—RightRear — 3133532111111 — -
TurnSignaI/Multifunction
SwitchGround — 1 — -
1.TurnSignalLampsand/orIndicatorsMalfunction

CircuitlSystem Description switch input bylapplying a pulsating voltage to the front

G d. I' d t 11t‘ t h . /
r09“ isapp '6’. a a Imes °.t e turn Signal
muitifunction sw1tch.The w"? 99%" lamps may only be
aCt'Yatedmm the ignition .SW'tChm the ON or START
posmons. When the turn Signal/multifunctionSWItchlS
placed in either the turn right or turn left position,
ground is applied to the body control module (30M)
through either the right turn or left turn signal switch
signal circuit. The 30M responds to the turn signal
and rear turn Signal lamps through there respective
control circuits. When a turn signal request is received
by the 30M a serial data message is sent to the
instrument cluster requesting the respective tum signal
indicator be pulsed ON and OFF
'
Conditions for Running the DTC
Battery voltage must be between 9‘16 V‘

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«L140 Lighting

Conditions for Setting the DTC CircuitlSystem Testing

DTC 33948 01 and 33948 04 DTC 33948
- The 30M detects an open/high resistance in the 1. IgnitionOFF, exterior lamps OFF, disconnect the
left front turn signal control circuit. harness connector at the E4N turn signal lamp -
- The 30M detects an open/high resistance in the left front.
left front turn signal ground circuit. 2. Test for less than 5 Q between the ground circuit
terminal 0 and ground.
DTC 33948 02
2 If 5 Q or greater
The 30M detects a short to ground in the left front turn
signal control circuit. 2.1. IgnitionOFF.
2.2. Test for less than 2 Q in the ground circuit end
DTC 33949 01 and 33949 04 to end.
. The 30M detects an open/high resistance in the 2 if 2 Q or greater, repair the open/high resistance
right front turn signal control circuit. in the circuit.
- The 30M detects an open/high resistance in the
2 Ifless than 2 Q, repair the open/high resistance
right front turn signal ground circuit.
in the ground connection.
DTC 33949 02 U If less than 5 Q
The 30M detects a short to ground in the rightfront turn 3. Connect a test lamp between the control circuit
signal control circuit. terminal 3 and ground, ignition ON.
Actions Taken When the DTC Sets 4. Verify the test lamp turns ON and OFF when
commanding the Left Front Turn Signal Lamp ON
DTC B3948 and OFF with a scan tool.
- The leftfront turn signal is inoperative. 2 If the test lamp is always OFF
- The left turn signal indicator on the instrument 4.1. IgnitionOFF, disconnect the X5 harness
cluster flashes rapidly. connector at the K9 body control module.
DTC B3949 4.2. Test for infinite resistance between the control
circuit and ground.
- The right front turn signal is inoperative.
. The right turn signal indicator on the instrument 2 Ifless than infinite resistance, repair the short to
cluster flashes rapidly. ground on the circuit.
U Ifinfinite resistance
Conditions for Clearing the DTC 4.3. Test for less than 2 Q in the control circuit end
- The condition responsible for setting the DTC no to end. ‘
longer exists. 2 If2 Q or greater, repair the open/high resistance
- A history DTC will clear once 100 consecutive in the circuit.
malfunction-free ignition cycles have occurred.
2 Ifless than 2 Q, replace the K9body control
Reference Information module. ‘ ‘ ‘
2 If the test lamp is always CM
Schematic Reference
4.1. IgnitionOFF, disconnect the X5 harneSs
Exterior Lights Schematics on page 4-85 connector at the K9 body control module,
Connector End View Reference ignition ON.
4.2. Test for less than 1 V between the control
Component Connector End Views on page 11-269 circuit terminal and ground.
Description and Operation 2 If 1 V or greater, repair the short to voltage on
the circuit.
Exterior Lighting Systems Description and Operation
on page 4-217 2 Ifless than 1 V, replace the K9 body control
module.
Electrical Information Reference
U If the test lamp turns ON and OFF
- Circuit Testing on page 11—526 5. Test or replace the E4N turn signal lamp bulb —left
- Connector Repairs on page 11-548 front.
- Testing for IntermittentConditions and Poor
Connections on page 11-531
- Wiring Repairs on page 11-537
Scan Tool Reference
Control Module References on page 6—3for scan tool
information

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DTC 33949
1. lgnition OFF, exterior lamps OFF, disconnect the
harness connector at the E4P turn signal lamp -
rightfront.
Test for less than 5 Q between the ground circuit
terminal 0 and ground.
If 5 Q or greater
2.1. lgnition OFF.
2.2. Test for less than 2 Q in the ground circuit end
to end.
2 If2 Q or greater, repair the open/high resistance
in the circuit.
2 Ifless than 2 Q, repair the open/high resistance
in the ground connection.
If less than 5 Q
Connect a test lamp between the control circuit
terminal 3 and ground, ignition ON.
. Verify the test lamp turns ON and OFF when
commanding the Right Front Turn Signal Lamp ON
and OFF with a scan tool.
if the test lamp is always OFF
4.1. IgnitionOFF, disconnect the X4 harness
connector at the K9 body control module.
4.2. Test for infinite resistance between the control
circuit and ground.
2 if less than infinite resistance, repair the short to
ground on the circuit.
U If infinite resistance
4.3. Test for less than 2 Q in the control circuit end
to end.
2 If2 Q or greater, repair the open/high resistance
in the circuit.
Lighting 4441
2 If less than 2 Q, replace the K9 body control
module.
2 If the test lamp is always CM
4.1. lgnition OFF, disconnect the X4 harness
connector at the K9 body control module,
ignition ON.
4.2. Test for less than 1 V between the control
circuit terminal and ground.
2 If 1 V or greater, repair the short to voltage on
the circuit.
2 Ifless than 1 V, replace the K9 body control
module.
if the test lamp turns 0N and OFF
. Test or replace the E4Pturn signal lamp bulb -
right front.
Repair Instructions
Perform the Diagnostic Repair Verification on
page 6-92 after completing the repair.
Parking and Turn Signal Lamp Bulb Replacement
on page 4-203
Control Module References on page 6-3 for BCM
replacement, programming, and setup

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Sonic
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Manual
(5377994)
4- 142 Lighting

DTC 33950 or 33951

Diagnostic Instructions
- Perform the Diagnostic System Check —Vehicle
on page 6—66prior to using this diagnostic
procedure.
- Review Strategy Based Diagnosis on page 6-58
for an overview of the diagnostic approach.
- Diagnostic Procedure Instructions on page 6-59
provides an overview of each diagnostic category.
DTC Descriptors
DTC 33950 01: Left Rear Turn Signal Circuit Short to Battery
DTC 33950 02: Left Rear Turn Signal Circuit Short to Ground
DTC 33950 04: Left Rear Turn Signal Circuit Open
DTC 33951 01: Right Rear Turn Signal Circuit Short to Battery
DTC 33951 02: Right Rear Turn Signal Circuit Short to Ground
DTC 33951 04: Right RearTurn Signal Circuit Open
Diagnostic Fault Information

Open/High Signal
Circuit Short to Ground Resistance Short to Voltage Performance
F7DA (30M 3) Fuse 3+ 1 1 — -
F8DA (30M 4) Fuse 3+ 1 1 — -
F1ODA(30M 6) Fuse 3+ 1 1 — —-
F11DA(30M 7) Fuse 3+ 1 1 — -
TurnSignalSwitchSignal—Left 1 1 1 —-
TurnSignalSwitchSignal—Right 1 1 1 -
. 3394801,
TurnSignalControl—LeftFront 3394802 3394804 3394804 ~-
_ 3395001,
TurnSignalControl—LeftRear 3395002 3395004 3395004 -
. . 3394901,
TurnSignal Control—RightFront 3394902 3394904 3394904 -
. . 3395101,
TurnSignal Control—RightRear 3395102 3395104 3395104 -
. 3394801,
TurnSignal LampGround—LeftFront — 3394804 — -
. . 3394901,
TurnSignal LampGround—RightFront — 133949
04 — -
.
TurnSignal LampGround—LeftRear 3395001,
— 3395004 — -

TurnSignal LampGround—RightRear — 533335511

(8111’ — -
TurnSignal/Multifunction
SwitchGround — 1 — -
1.TurnSignal Lampsand/orIndicatorsMalfunction

CircuitlSystem Description switch input by applying a pulsating voltage to the front

Ground is applied at all times to the turn signal/
multifunction switch. The turn signal lamps may only be
activated with the ignition switch in the ON or START
positions. When the turn signal/multifunction switch is
placed in either the turn right or turn left position,
ground is applied to the body control module (30M)
through either the right turn or left turn signal switch
signal circuit. The 30M responds to the turn signal
and rear turn signal lamps through there respective
control circuits. When a turn signal request is received
by the 30M, a serial data message is sent to the
instrument cluster requesting the respective turn signal
indicator be pulsed ON and OFF.
Conditions for Running the DTC
Battery voltage must be between 9-16 V.

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Manual
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 Lighting 44 43

Conditions for Setting the DTC Scan Tool Reference

DTC 33950 01 and 33950 04 Control Module References on page 6-3 for scan tool
information
- The 30M detects an open/high resistance in the
left rear turn signal control circuit. CircuitlSystem Testing
- The 30M detects an open/high resistance in the
left rear turn signal ground circuit. DTC 33950
1. IgnitionOFF, exterior lamps OFF, trunk latch
DTC 33950 02 latched, remove the E4LRturn signal lamp bulb -
The 30M detects a short to ground in the left rear turn left rear.
signal control circuit. 2. Test for less than 5 Q between the ground circuit at
DTC 33951 01 and 33951 04 the socket terminal and ground.
- The BCM detects an open/high resistance in the 2 If 5 Q or greater
right rear turn signal control circuit. 2.1. lgnition OFF.
- The BCM detects an open/high resistance in the 2.2. Test for less than 2 Q in the ground circuit end
right rear turn signal ground circuit. to end.
DTC 33951 02 2 |f2 Q or greater, repairthe open/high resistance
in the circuit.
The BCM detects a short to ground in the right rear turn
signal control circuit. 2 Ifless than 2 Q, repair the open/high resistance
in the ground connection.
Actions Taken When the DTC Sets U If less than 5 Q
DTC B3950 3. Connect a test lamp between the control circuit at
- The left rear turn signal is inoperative. the socket terminal and ground, ignition ON.
- The left turn signal indicator on the instrument 4. Verify the test lamp turns ON and OFF when
cluster flashes rapidly. commanding the Left Rear Turn Signal Lamp ON
and OFF with a scan tool.
DTC 33951
2 If the test lamp is always OFF
0 The right rearturn signal is inoperative.
4.1. IgnitionOFF, disconnect the X5 harness
- The right turn signal indicator on the instrument connector at the K9 body control module.
cluster flashes rapidly.
4.2. Test for infinite resistance between the control
Conditions for Clearing the DTC circuit and ground.
' The condition responsible for setting the DTC no 2 Ifless than infinite resistance, repair the short to
longer exists. ground on the circuit.
- A history DTC will clear once 100 consecutive U If infinite resistance
malfunction—freeignition cycles have occurred. 4.3. Test for less than 2 Q in the control circuit end
to end.
Diagnostic Aids
2 If2 Q or greater, repair the open/high resistance
Note: When testing at the rear turn signal lamp bulb in the circuit.
socket, make sure all measurements and test lamp
connections are in the correct terminal location and do 2 If less than 2 Q, replace the K9 body control
not come in contact with each other during testing. module.
2 if the test lamp is always ON
Reference Information 4.1. IgnitionOFF, disconnect the X5 harness
Schematic Reference connector at the K9 body control module,
ignition ON.
Exterior Lights Schematics on page 4-85 4.2. Test for less than 1 V between the control
Connector End View Reference circuit terminal and ground.
2 If 1 V or greater, repair the short to voltage on
Component Connector End Views on page 11—269
the circuit.
Description and Operation 2 Ifless than 1 V, replace the K9 body control
Exterior Lighting Systems Description and Operation module.
on page 4-217 U If the test lamp turns ON and OFF
Electrical Information Reference 5. Test or replace the E4LRturn signal lamp bulb -
left rear.
- Circuit Testingon page 11-526
- Connector Repairs on page 11—548
- Testing for IntermittentConditions and Poor
Connections on page 11-531
- Wiring Repairs on page 11-537

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Manual
(5377994)
4.144 Lighting
DTC 33951
1. lgnition OFF, exterior lamps OFF, trunk latch
latched, remove the E4RR turn signal lamp bulb -
right rear.
2. Test for less than 5 Q between the ground circuit at
the socket terminal and ground.
2 If 5 Q or greater
2.1. lgnition OFF.
2.2. Test for less than 2 Q in the ground circuit end
to end.
2 If2 Q or greater, repair the open/high resistance
in the circuit.
2 Ifless than 2 Q, repair the open/high resistance
in the ground connection.
U If less than 5 Q
3. Connect a test lamp between the control circuit at
the socket terminal and ground, ignition ON.
4. Verify the test lamp turns ON and OFF when
commanding the Right Rear Turn Signal Lamp ON
and OFF with a scan tool.
2 If the test lamp is always OFF
4.1. IgnitionOFF, disconnect the X4 harness
connector at the K9 body control module.
4.2. Test for infinite resistance between the control
circuit and ground.
2 Ifless than infinite resistance, repair the short to
ground on the circuit.
U Ifinfinite resistance
4.3. Test for less than 2 Q in the control circuit end
to end.
2 If2 Q or greater, repair the open/high resistance
in the circuit.
2 if less than 2 Q, replace the K9 body control
module.
2 If the test lamp is always ON
4.1. lgnition OFF, disconnect the X4 harness
connector at the K9 body control module,
ignition ON.
4.2. Test for less than 1 V between the control
circuit terminal and ground.
2 If 1 V or greater, repair the short to voltage on
the circuit.
2 Ifless than 1 V, replace the K9 body control
module.
U If the test lampturns 0N and OFF
5. Test or replace the E4RR turn signal lamp bulb -
right rear.
Repair Instructions
Perform the Diagnostic Repair Verification on
page 6-92 after completing the repair.
- Stop and Turn Signal Lamp Bulb Replacement
(Sedan) on page 4-215
- Control Module References on page 6-3 for 30M
replacement, programming, and setup

(US/Canada)
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2013 (5377994)
Manual
Service
 Lighting 4445

DTC 00277 or 00890

Diagnostic Instructions
- Perform the Diagnostic System Check - Vehicle
on page 6—66prior to using this diagnostic
procedure.
- Review Strategy Based Diagnosis on page 6—58
for an overview of the diagnostic approach.
- Diagnostic Procedure Instructions on page 659
provides an overview of each diagnostic category.
DTC Descriptors
DTC 00277 06: Brake Pedal Position Sensor Circuit Low Voltage/Open
DTC 00277 07: Brake Pedal Position Sensor Circuit High Voltage
DTC 00277 09: Brake Pedal Position Sensor Circuit Too Fast Transitions
DTC 00277 43: Brake Pedal Position Sensor Circuit Calibration Not Learned
DTC 00890 03: Control Module Voltage Reference Output 3 Circuit Low Voltage
DTC 00890 07: Control Module Voltage Reference Output 3 Circuit High Voltage
Diagnostic Fault Information

Opeanigh Signal
Circuit Short to Ground Resistance Short to Voltage Performance
0027706, 0027706, 0027707,
BrakePedal PositionSensor5V Reference 0089003, 0016171, 0089007, ~-
0016171 001615A 0016171
0027706 0027706, 0027707,
BrakePedal PositionSensorSignal UO14O71’ 0016171, 0089007, 00277 09
001615A‘ 0016171
CenterHighMountedStopLampControl 3388402 2 2 -
RearTail/StopLampControl—Left 3388102 3388104 3388101 -
RearTaii/StopLampControl—Right 3388202 3388204 3388201 —-
.. 0027707, UO15100,
BrakePedal PosttlonSensorLowReference — 0016171 U018400 -
CenterHighMountedStopLampGround — 2 — -
RearTail/StopLampGround—Left — 1 — —-
RearTail/StopLampGround—Right —— 1 — -
1.StopLampsMalfunction
2. CenterHighMountedStop LampMalfunction

CircuitlSystem Description Conditions for Setting the DTC

The brake pedal position (BPP) sensor is used to sense
the action of the driver application ofthe brake pedaL
The BPP sensor provides an analog voltage si gnal that
will increase as the brake pedal is applied. The body
control module (30M) provides a low reference signal
and a 5-voit reference voltage to the BPP sens or. When
the variable signal reaches a voltage threshold
indicating the brakes have been applied, the 30M will
apply battery voltage to the left and right stop lamp
control circuits as well as the center high mounted stop
lamp (CHMSL) control circuit illuminating the left and
right stop lamps and the CHMSL.
Conditions for Running the DTC
' Battery voltage must be between 9—16V.
- Brakes APPLIED.
DTC C0277 06
The 30M detects a short to ground or an open/
high resistance in the BPP sensor 5 V reference
circuit. '
' The 30M detects a short to ground or an open/
high resistance in the BPP sensor signal circuit.
DTC C0277 07
' The BCM detects a short to voltage in the BPP
sensor 5 V reference circuit.
The 30M detects a short to voltage in the BPP
sensor signal circuit.
The 30M detects an open/high resistance in the
BPP sensor low reference circuit.

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Manual
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4446 Lighting
DTC 00277 09 CircuitlSystem Testing
The 30M detects the BPP sensor signal is changing DTC C0277 06, 00277 07, 00890 03, and C0890 07
faster than possible under normal operating conditions.
1. lgnition OFF, disconnect the harness connector at
DTC 00277 43 the 322 brake pedal position sensor, ignition ON.
The DTC will set when the BPP sensor home position is 2. Verify a test lamp illuminates between the
not learned. appropriate low reference circuit terminal listed
below and 3+.
DTC 00890 03
- Terminal 2 —with MH8/MH9
The 30M detects a short to ground in the BPP sensor
5 V reference circuit. ' Terminal A —with M26/MZ4
2 If the test lamp does not illuminate
DTC 00890 07
2.1. IgnitionOFF, disconnect the X1 harness
o The 30M detects a short to voltage in the BPP connector at the K9 body control module.
sensor 5 V reference circuit.
2.2. Test for less than 2 Q in the low reference
- The 30M detects a short to voltage in the BPP circuit end to end.
sensor low reference circuit.
2 |f2 Q or greater, repair the open/high resistance
Actions Taken When the DTC Sets in the circuit.
- The Traction Control indicator is commanded ON. 2 Ifless than 2 Q, replace the K9 body control
- For DTC 00277 43, the stop lamps may not module.
activate at the expected brake pedal positions. U If the test lamp illuminates
Conditions for Clearing the DTC 3. lgnition ON.
4. Test for 4.8—5.2V between the appropriate 5 V
- The condition responsible for setting the DTC no reference circuit terminal listed below and ground.
longer exists.
- Terminal1 —with MH8/MH9
' For DTC 00277 07 the ignition must be cycled
before the code can be cleared. - Terminal 0 —with M26/MZ4
' For DTC 00277 43 a successful brake pedal 2 If less than 4.8 V
position sensor calibration has been performed. 4.1. IgnitionOFF, disconnect the X2 harness
~ A history DTC will clear once 50 malfunction-free connector at the K9 body control module.
ignition cycles have occurred. 4.2. Test for infinite resistance between the 5 V
- A DTC will not clear the current status until the reference circuit and ground.
next ignition cycle. 2 if less than infinite resistance, repairthe short to
ground on the circuit.
Reference Information
U Ifinfinite resistance
Schematic Reference 4.3. Test for less than 2 Q in the 5 V reference
Exterior Lights Schematics on page 4-85 circuit end to end.
Connector End View Reference 2 If2 Q or greater, repair the open/high resistanc
in the circuit. .
Component Connector End Views on page 11-269 2 If less than 2 Q, replace the K9 body control
Description and Operation module.
2 If greater than 5.2 V
Exterior Lighting Systems Description and Operation
on page 4-217 4.1. IgnitionOFF, disconnect the X2 harness
connector at the K9 body control module,
Electrical Information Reference ignition ON.
- Circuit Testing on page 11-526 4.2. Test for less than 1 V between the 5 V
0 Connector Repairs on page 11-548 reference circuit and ground.
- Testing for IntermittentConditions and Poor 2 If 1 V or greater, repair the short to voltage on
Connections on page 11-531 the circuit.
. Wiring Repairs on page 11-537 2 If less than 1 V, replace the K9 body control
module.
Scan Tool Reference
U If between 4.8—5.2V
Control Module References on page 6—3for scan tool
information

2013
-Sonic
(US/Canada)
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Manual
(5377994)
 Lighting 4447
5. Verify the scan tool Brake Pedal Applied parameter DTC 00277 43
is Inactive. 1. Verify DTC 00277 43 is not set.
2 If not Inactive 2 If DTC 00277 43 is set
5.1. lgnition OFF, disconnect the X2 harness 1.1. IgnitionON
connector at the K9 body control module,
ignition ON. 1.2. Perform the BPP sensor recalibration
procedure for the K9 body control module.
5.2. Test for less than 1 V between the appropriate Refer to Brake Pedal Position Sensor
signal circuit terminal listed below and ground. Calibration on page 4485.
- Terminal 3 —with MH8/MH9 1.3. Verify the DTC does not reset while operating
- Terminal 3—with M26/MZ4 the vehicle under the conditions for running
2 lf1 Vor greater, repair the short to voltage on the DTC.
the circuit. 2 Ifthe DTC resets, replace the 322 brake pedal
2 Ifless than 1 V, replace the K9 body control position sensor.
module. U Ifthe DTC does not reset
U If Active 1.4. All OK.
6. Install a 3 A fusedjumper wire between the U lf DTC C0277 4B is not set
appropriate 5-volt reference and signal circuit 2. All OK.
terminals listed below.
- 5 V reference terminal1 and signal termina13- DTC 00277 09
with MH8/MH9 1. Verify DTC 00277 09 is not set.
- 5 V reference terminal 0 and signal terminal 3 - 2 if DTC 00277 09 is set
with M26/MZ4 1.1. Replace the B22 brake pedal position sensor.
7. Verify the scan tool Brake Pedal Applied parameter 1.2. Perform the BPP sensor recalibration
is Active. procedure for the K9 body control module.
2 If not Active Refer to Brake Pedal Position Sensor
7.1. lgnition OFF, disconnect the X2 harness Calibration on page 4485.
connector at the K9 body control module. 1.3. Verify the DTC does not reset while operating
7.2. Test for infinite resistance between the signal the vehicle under the conditions for running
circuit and ground. the DTC.
2 Ifless than infinite resistance, repair the short to 2 Ifthe DTC resets, replace the K9 body control
ground on the circuit. module.
U lf infinite resistance U lf the DTC does not reset
7.3. Test for less than 2 Q in the signal circuit end 1.4. All OK.
to end. U If DTC 00277 09 is not set
2 If2 Q or greater, repair the open/high resistance 2. All OK.
in the circuit.
Repair Instructions
2 Ifless than 2 Q, replace the K9 body control
module. Perform the Diagnostic Repair Verification on
page 6-92 after completing the repair.
U If Active
° Brake Pedal Position Sensor Calibration on
8. Test or replace the B22 brake pedal position page 4485
senson
° Brake Pedal Position Sensor Replacement on
page 4-186
0 Control Module References on page 6-3 for 30M
replacement, programming, and setup

2013
—
Sonic
(US/Canada)
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Manual
(5377994)
4448 Lighting

DTC 00297

Diagnostic Instructions
' Perform the Diagnostic System Check - Vehicle
on page 6-66 prior to using this diagnostic
procedure.
- Review Strategy Based Diagnosis on page 6-58
for an overview of the diagnostic approach.
- Diagnostic Procedure Instructions on page 6-59
provides an overview of each diagnostic category.
DTC Descriptor
DTC 00297 02: Brake Applied Output Circuit Short to Ground
Diagnostic Fault Information

Open/High Signal
Circuit Short to Ground Resistance Short to Voltage Performance
BrakeAppliedSignal 0029702 0029702 1 -
1.CruiseControlMalfunction

CircuitlSystem Description Reference Information

The brake pedal position sensor is used to sense the Schematic Reference
action of the driver application of the brake pedal. The
brake pedal position sensor provides an analog voltage Exterior Lights Schematics on page 4-85
signal that will increase as the brake pedal is applied.
Connector End View Reference
The body control module (30M) provides a low
reference signal and a 5 V reference voltage to the Component Connector End Views on page 11—269
brake pedal position sensor. When the variable signal
reaches a voltage threshold indicating the brakes have Description and Operation
been applied, the 30M will apply battery voltage to the Exterior Lighting Systems Description and Operation
right and left stop lamp control circuits, engine control on page 4-217
module (ECM), and center high mounted stop lamp
control circuit. Electrical Information Reference

Conditions for Running the DTC - Circuit Testing on page 11-526

. Battery voltage must be between 9—16V. - Connector Repairs on page 11-548
- Brakes APPLIED. - Testing for IntermittentConditions and Poor
Connections on page 11—531
Conditions for Setting the DTC - Wiring Repairs on page 11-537
The 30M detects a short to ground or an open/high Scan Tool Reference
resistance on the brake applied signal circuit.
Control Module References on page 6—3for scan tool
Actions Taken When the DTC Sets information
The cruise control system is disabled. CircuitlSystem Testing
Conditions for Clearing the DTC 1. lgnition OFF, disconnect the X1 harness connector
- The condition responsible for setting the DTC no at the K20 engine control module.
longer exists. 2. Connect a test lamp between the appropriate
- A history DTC will clear once 50 consecutive signal circuit terminal listed below and ground,
malfunction—freeignition cycles have occurred. ignition ON.
- Terminal 25 —with LUW
Diagnostic Aids - Terminal 33 —with LUV
Verify that the brake pedal position sensor is properly
calibrated.

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3. Verify the test lamp turns ON and OFF while
pressing and releasing the brake pedal.
2 If the test lamp is always OFF
3.1. lgnition OFF, disconnect the X5 harness
connector at the K9 body control module.
3.2. Test for infinite resistance between the signai
circuit and ground.
2 if less than infinite resistance, repair the short to
ground on the circuit.
U lf infinite resistance
3.3. Test for less than 2 Q in the signal circuit end
to end.
2 If2 Q or greater, repair the open/high resistance
in the circuit.
2 If less than 2 Q, replace the K9 body control
module.
2 If the test lamp is always CM
3.1. lgnition OFF, disconnect the X5 harness
connector at the K9 body control module,
ignition ON.
3.2. Test for less than 1 V between the signal
circuit terminal and ground.
2 lf1 V or greater, repair the short to voltage on
the circuit.
2 if less than 1 V, replace the K9 body control
module.
U If the test lamp turns ON and OFF
4. Replace the K20 engine control module.
Repair Instructions
Perform the Diagnostic Repair Verification on
page 6-92 after completing the repair.
° Brake Pedal Position Sensor Calibration on
page 4485
- Control Module References on page 6-3 for 30M
or ECM replacement, programming, and setup
Symptoms - Lighting
Note: The following steps must be completed before
using a symptom table.
- Perform the Diagnostic System Check —Vehicle
on page 6—66before using a symptom table in
order to verify that all of the following conditions
are true:
- There are no DTCs set. 7
—The control modules can communicate via the
serial data link.
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(5377994)
Lighting 4.149
' Review the system description and operation in
order to familiarize yourself with the system
functions. Refer to the following:
—Exterior Lighting Systems Description and
Operation on page 4-217
—InteriorLighting Systems Description and ‘
Operation on page 4—219
Visual/Physical Inspection
- Inspect for aftermarket devices which could affect
the operation of the lighting system. Refer to
Checking Aftermarket Accessories on
page 11—525.
~ Inspect the easily accessible or visibie system
components for obvious damage or conditions
which could cause the symptom.
Intermittent
Thoroughly inspect the wiring and connectors. An
incomplete inspection of the wiring and connectors may
result in misdiagnosis causing part replacement with
the reappearance of the malfunction. Ifan intermittent
malfunction exists, refer to Testing for Intermittent
Conditions and Poor Connections on page 11-531.
Symptom List
Refer to a symptom diagnostic procedure from the
following list in order to diagnose the symptom:
- Backup Lamps Malfunction (Automatic
Transmission) on page 4450 or Backup Lamps
Malfunction (Manual Transmission) on page 4451
- Courtesy Lamps Malfunction on page 4454
- Daytime Running Lamps Malfunction on
page 4455
- Dome Lamps Malfunction on page 4457
- Front Fog Lamps Malfunction on page 4459
- Hazard Lamps Malfunction on page 4461
- Headlamps Malfunction on page 4463
- InteriorBacklighting Malfunction on page 4469
- Park, License, and/or Tail Lamps Malfunction on
page 4474
- Rear Compartment Lamp Malfunction on
page 4477
- Stop Lamps Malfunction on page 4478
0 TurnSignal Lamps and/orlndicators Malfunction
on page 4481
4450 Lighting

Backup Lamps Malfunction (Automatic Transmission)

Diagnostic Instructions
. Perform the Diagnostic System Check - Vehicle
on page 6-66 prior to using this diagnostic
procedure.
- Review Strategy Based Diagnosis on page 6—58
for an overview of the diagnostic approach.
- Diagnostic Procedure Instructions on page 6-59
provides an overview of each diagnostic category.

Diagnostic Fault Information

Open/High Signal
Circuit Short to Ground Resistance Short to Voltage Performance
F10DA (30M 6) Fuse 3+ 1 1 — —-
BackupLampsControl 3254502 3254504 3254501 -
BackupLampGround—Left - 1 _ _
BackupLampGround—Right - 1 — ———,
1.BackupLampsMalfunction

CircuitlSystem Description Scan Tool Reference

With the engine running and the transmission in the
reverse position, the transmission control module
(TCM) sends a serial data message to the body control
module (30M). The message indicates that the gear
selector is in the reverse position. The 30M applies
battery voltage to the backup lamps control circuit
illuminating the backup lamps. Once the driver moves
the gear selector out of the reverse position, a message
is sent by the TCM via serial data requesting the 30M
to remove battery voltage from the backup lamps
control circuit. The engine must be running for the
backup lamps to operate.
Diagnostic Aids
When testing at the backup lamp bulb socket, make
sure all measurements and test lamp connections are
in the correct terminal location and do not come in
contact with each other during testing.
Reference Information
Schematic Reference
Exterior Lights SChemat/cs on page 4—85
Body Control System Schematics on page 11-8
Connector End View Reference
Component Connector End Views on page 11—269
Description and Operation
Exterior Lighting Systems Description and Operation
on page 4—217
Electrical Information Reference
- Circuit Testing on page 11—526
- Connector Repairs on page 11~548
- Testing for IntermittentConditions and Poor
Connections on page 11-531
- Wiring Repairs on page 11-537
Control Module References on page 6-3 for scan tool
information
CircuitlSystem Testing
1. lgnition OFF, disconnect the X5 harness connector
at the K9 Body Control Module, ignition ON.
2. Verify a test lamp illuminates between the 3+
circuit terminal 4 and ground.
2 If the test lamp does not illuminate and the
circuit fuse is good
2.1. IgnitionOFF.
2.2. Test for less than 2 Q in the 3+ circuit end
to end.
2 If2 Q or greater, repair the open/high resistance
in the circuit.
2 Ifless than 2 Q, verify the fuse is not open and
there is voltage at the fuse.
2 If the test lamp does not illuminate and the
circuit fuse is open
2.1. lgnition OFF.
2.2. Test for infinite resistance between the 3+
circuit and ground.
2 Ifless than infinite resistance, repair the short to
ground on the circuit.
2 Ifinfinite resistance, replace the K9 Body
Control Module.
U If the test lamp illuminates
3. lgnition OFF, connect the X5 harness connector at
the K9 Body Control Module.
4. lgnition OFF, exterior lamps OFF, rear hatch latch
latched, remove the appropriate E5 Backup Lamp
bulb at the appropriate E42 Tail Lamp Assembly.

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Service

5. Test for less than 5 Q between the ground circuit at
the socket terminal and ground.
2 If 5 Q or greater
5.1. IgnitionOFF.
5.2. Test for less than 2 Q in the ground circuit end
to end.
2 If2 Q or greater, repair the open/high resistance
in the circuit.
2 if less than 2 Q, repair the open/high resistance
in the ground connection.
U if less than 5 Q
6. Connect a test lamp between the control circuit at
the socket terminal and ground, ignition ON.
7. Verify the test lamp turns ON and OFF when
commanding the Backup Lamps ON and OFF with
a scan tool.
2 If the test lamp is always OFF
7.1. lgnition OFF, disconnect the X7 harness
connector at the K9 Body Control Module.
7.2. Test for infinite resistance between the control
circuit and ground.
2 if less than infinite resistance, repair the short to
ground on the circuit.
U Ifinfinite resistance
7.3. Test for less than 2 Q in the control circuit and
to end.
2 If2 Q or greater, repair the open/high resistance
in the circuit.
Lighting 4451
2 if less than 2 Q, replace the K9 Body Control
Module.
2 If the test lamp is always ON
7.1. IgnitionOFF, disconnect the X7 harness
connector at the K9 Body Control Module,
ignition ON.
7.2. Test for less than 1 V between the control
circuit terminal and ground.
2 If 1 V or greater, repair the short to voltage on
the circuit.
2 Ifless than 1 V, replace the K9 Body Control
Module.
U If the test lamp turns 0N and OFF
8. Test or replace the appropriate E5 Backup Lamp.
Repair Instructions
Perform the Diagnostic Repair Verification on
page 6—92after completing the repair.
Backup Lamp Bulb Replacement (Sedan) on
page 4—208
Control Module References on page 6—3for 30M
replacement, programming, and setup

Backup Lamps Malfunction (Manual Transmission)

Diagnostic Instructions
Perform the Diagnostic System Check —Vehicle
on page 6-66 prior to using this diagnostic
procedure.
Review Strategy Based Diagnosis on page 6—58
for an overview of the diagnostic approach.
Diagnostic Procedure Instructions on page 6—59
provides an overview of each diagnostic category.
Diagnostic Fault Information

Open/High
Circuit Short to Ground Resistance
F10DA (BCM 6) FUSeB+ 1 1
BackupLampSwitchSignal P0812 P0812
BackupLampsControl 3254502 3254504
BackupLampSwitchGround — P0812
BackupLampGround—Left — 1
BackupLampGround—Right — 1
1.BackupLampsMalfunction
Signal
Short to Voltage Performance
— -
1 -
3254501 -
— -
— -
— —-

2013
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Manual
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4452 LightingL

CircuitlSystem Description
The engine control module (ECM) provides a signal
circuit to the backup lamp switch which is permanently
grounded. With the engine running and the
transmission in the reverse position, the backup lamp
switch signal circuit is pulled low and the ECM
responds by sending a serial data message to the body
control module (30M). The message indicates that the
gear selector is in the reverse position. The 30M
applies battery voltage to the backup lamps control
circuit illuminating the backup lamps. Once the driver
moves the gear selector out of the reverse position, a
message is sent by the ECM via serial data requesting
the ECM to remove battery voltage from the backup
lamps control circuit. The engine must be running for
the backup lamps to operate.
Diagnostic Aids
Note: When testing at the backup lamp bulb socket,
make sure all measurements and test lamp
connections are in the correct terminal location and do
not come in contact with each other during testing.
Reference Information
Schematic Reference
Exterior Lights Schematics on page 4—85
Body Control System Schematics on page 11-8
Connector End View Reference
Component Connector End Views on page 11-269
Description and Operation
Exterior Lighting Systems Description and Operation
on page 4—217
Electrical Information Reference
- Circuit Testing on page 11-526
- Connector Repairs on page 11-548
- Testing for IntermittentConditions and Poor
Connections on page 11-531
- Wiring Repairs on page 11-537
Scan Tool Reference
Control Module References on page 6-3 for scan tool
information
CircuitlSystem Verification
1. Engine ON.
2. Verify the scan tool Reverse Position Switch
parameter changes between ON and OFF while
shifting the vehicle between the neutral and
reverse gears.
2 If the parameter does not change
Refer to Backup Lamp Switch Malfunction.
U If the parameter changes
3. Verify the backup lamps turn ON and OFF when
commanding the Backup Lamps ON and OFF with
a scan tool.
2 If the backup lamps do not turn ON and OFF
Refer to Backup Lamps Malfunction.
U If the backup lamps turn ON and OFF
4. All OK.
CircuitlSystem Testing
Backup Lamp Switch Malfunction
1. lgnition OFF, exterior lamps OFF, all doors closed,
disconnect the harness connector at the
316 backup lamp switch. Itmay take up to
2 minutes for all vehicle systems to power down.
2. Test for less than 5 Q between the ground circuit
terminal 2 and ground.
2 If 5 Q or greater
2.1. IgnitionOFF.
2.2. Test for less than 2 Q in the ground circuit end
to end.
2 If2 Q or greater, repair the open/high resistance
in the circuit.
2 Ifless than 2 Q, repair the open/high resistance
in the ground connection.
U If less than 5 Q
(.0
. lgnition ON.
4. Verify the scan tool Reverse Position Switch
parameter is Off.
2 If not Off
4.1. lgnition OFF, disconnect the appropriate
harness connector listed below at the
K20 engine control module.
- X1 —with LDE/LUW
- X3 —with LUV
4.2. Test for infinite resistance between the signal
circuit terminal1 and ground.
2 Ifless than infinite resistance, repair the short to
ground on the circuit.
2 If infinite resistance, replace the K20 engine
control module.
U If Off
5. Install a 3 A fused jumper wire between the signal
circuit terminal 1 and the ground circuit terminal 2.
6. Verify the scan tool Reverse Position Switch
parameter is On.
2 If not On
6.1. lgnition OFF, disconnect the appropriate
harness connector listed below at the
K20 engine control module, ignition ON.
~X1 —WithLDE/LUW
- X3 —-withLUV

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6.2. Test for less than 1 V between the signal
circuit terminal 1 and ground.
2 If 1 V or greater, repair the short to voltage on
the circuit.
U Ifless than 1 V
6.3. Test for less than 2 Q in the signal circuit end
to end.
2 If2 Q or greater, repair the open/high resistance
in the circuit.
2 Ifless than 2 Q, replace the K20 engine control
module.
U If On
7. Test or replace the 316 backup lamp switch.
Backup Lamps Malfunction
1. lgnition OFF, disconnect the X5 harness connector
at the K9 body control module, ignition ON.
2. Verify a test lamp illuminates between the 3+
circuit terminal 4 and ground.
z) If the test lamp does not illuminate and the
circuit fuse is good
2.1. lgnition OFF.
2.2. Test for less than 2 Q in the 3+ circuit end
to end.
2 If2 Q or greater, repair the open/high resistance
in the circuit.
2 If less than 2 Q, verify the fuse is not open and
there is voltage at the fuse.
If the test lamp does not illuminate and the
circuit fuse is open
2.1. lgnition OFF.
2.2. Test for infinite resistance between the 3+
circuit and ground.
2 Ifless than infinite resistance, repair the short to
ground on the circuit.
2 If infinite resistance, replace the K9 body control
module.
If the test lamp illuminates
IgnitionOFF, connect the X5 harness connector at
the K9 body control module.
Ignition OFF, exterior lamps OFF, trunk latch
latched, remove the appropriate E5 backup lamp
bulb at the appropriate E42 tail lamp assembly.
. Test for less than 5 Q between the ground circuit at
the socket terminal and ground.
if 5 Q or greater
5.1. IgnitionOFF.
5.2. Test for less than 2 Q in the ground circuit end
to end.
2 If2 Q or greater, repair the open/high resistance
in the circuit.
2013
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Manual
(5377994)
Lighting 44 53
2 If less than 2 Q, repair the open/high resistance
in the ground connection.
U if less than 5 Q
6. Connect a test lamp between the control circuit at
the socket terminal and ground, ignition ON.
7. Verify the test lamp turns ON and OFF when
commanding the Backup Lamps ON and OFF with
a scan tool.
If the test lamp is always OFF
7.1. lgnition OFF, disconnect the X7 harness
connector at the K9 body control module.
7.2. Test for infinite resistance between the control
circuit and ground.
2 Ifless than infinite resistance, repair the short to
ground on the circuit.
U If infinite resistance
7.3. Test for less than 2 Q in the control circuit end
to end.
2 If2 Q or greater, repair the open/high resistance
in the circuit.
2 If less than 2 Q, replace the K9 body control
module.
If the test lamp is always CM
7.1. lgnition OFF, disconnect the X7 harness
connector at the K9 body control module,
ignition ON.
7.2. Test for less than 1 V between the control
circuit terminal and ground.
2 If 1 V or greater, repair the short to voltage on
the circuit.
2 If less than 1 V, replace the K9 body control
module.
U If the test lamp turns ON and OFF
8. Test or replace the appropriate E5 backup lamp.
Repair Instructions
Perform the Diagnostic Repair Verification on
page 692 after completing the repair.
Backup Lamp Bulb Replacement (Sedan) on
page 4-208
Backup Lamp Switch Replacement on
page 17—463
Backup Lamp Switch Replacement on
page 17—576
Control Module References on page 6—3for 30M
or ECM replacement, programming, and setup
4.154 Lighting

Courtesy Lamps Malfunction

Diagnostic Instructions
- Perform the Diagnostic System Check —Vehicle
on page 6—66prior to using this diagnostic
procedure.
' Review Strategy Based Diagnosis on page 6-58
for an overview of the diagnostic approach.
- Diagnostic Procedure Instructions on page 659
provides an overview of each diagnostic category.

Diagnostic Fault Information

Opeanigh Signal
Circuit Short to Ground Resistance Short to Voltage Performance
F11DA(30M 7) Fuse 3+ 1,2 1,2 — -
DomeLampsControl 3261502 2 2 -
ReadingLampsControl 3148002 1 1 -
Dome/ReadingLamps- FrontGround — 1,2 — ~-
Dome/ReadingLamps—Rear Ground — 1,2 — -
1.CourtesyLamps Malfunction
2. DomeLampsMalfunction

CircuitlSystem Description CircuitlSystem Testing

The body control module (30M) supplies battery 1. lgnition OFF, all doors closed, all accessories OFF,
voltage to the reading lamp via the courtesy lamp disconnect the harness connector at the
control circuit. The reading lamp is controlled by an E37F dome/reading lamps —front and E37 3 dome/
individual switch that is activated by the operator when reading lamps —2nd row. Itmay take up to
additional cabin lighting is required. In the event that 2 minutes for all vehicle systems to power down.
the courtesy reading lamp were to remain illuminated 2. Test for less than 10 Q between the appropriate
for more than 10 minutes with the ignition switch in the ground circuit terminal listed below and ground.
OFF position and no doors opened, the ECM will - E37F dome reading lamps —front terminal 2
deactivate the courtesy lamp control circuit to prevent with 090/091
total battery discharge.
. E37F dome reading lamps —front terminal 6
Reference Information with 095
- E373 dome reading lamps —2nd row terminal 2
Schematic Reference
with 090/095
Interior Lights Schematics on page 4-89 2 If 10 Q or greater
Connector End View Reference 2.1. IgnitionOFF.
Component Connector End Views on page 11-269 2.2. Test for less than 2 Q in the ground circuit end
to end.
Description and Operation 2 If2 Q or greater, repair the open/high resistance
Interior Lighting Systems Description and Operation on in the circuit.
page 4-219 2 if less than 2 Q, repair the open/high resistance
Electrical Information Reference in the ground connection.
U If less than 10 Q
~ Circuit Testing on page 11-526
3. Connect a test lamp between the appropriate
- Connector Repairs on page 11—548 control circuit terminal listed below and ground.
- Testing for IntermittentConditions and Poor . E37F dome reading lamps —front terminal 4
Connections on page 11-531 with 090/091
- Wiring Repairs on page 11—537 ~ E37F dome reading lamps —front terminal 1
Scan Tool Reference with 095
- E373 dome reading lamps —2nd row terminal 4
Control Module References on page 6—3for scan tool with 090/095
information

(US/Canada)
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2013 (5377994)
Manual
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 Lighting 4455
4. Verify the test lamp turns ON and OFF when 2 Ifless than 2 Q, replace the K9 body control
commanding the Inadvertent Load ON and OFF module.
with a scan tool. 2 If the test lamp is always ON
If the test lamp is always OFF 4.1. lgnition OFF, disconnect the X7 harness
4.1. IgnitionOFF, disconnect the X7 harness connector at the K9 body control module,
connector at the K9 body control module. ignition ON.
4.2. Test for infinite resistance between the control 4.2. Test for less than 1 V between the control
circuit and ground. circuit terminal and ground.
2 if less than infinite resistance, repair the short to 2 If 1 V or greater, repairthe short to voltage on
ground on the circuit. the circuit.
U lf infinite resistance 2 Ifless than 1 V, replace the K9 body control
4.3. Test for less than 2 Q in the control circuit end module.
to end. U If the test lamp turns ON and OFF
2 If2 Q or greater, repair the open/high resistance 5. Test or replace the inoperative E37 dome/
in the circuit. reading lamp.
Repair Instructions
Perform the Diagnostic Repair Verification on
page 692 after completing the repair.
- Dome Lamp Bu/b Replacement on page 4492
0 Reading Lamp Replacement on page 4489
- Control Module References on page 6-3 for 30M
replacement, programming, and setup

Daytime Running Lamps Malfunction

Diagnostic Instructions
Perform the Diagnostic System Check - Vehicle
on page 6-66 prior to using this diagnostic
procedure.
Review Strategy Based Diagnosis on page 6-58
for an overview of the diagnostic approach.
Diagnostic Procedure Instructions on page 6-59
provides an overview of each diagnostic category.
Diagnostic Fault Information

Open/High Signal
Circuit Short to Ground Resistance Short to Voltage Performance
F7DA (BCM 3)Fuse 3+ 1 1 — -
F8DA (30M 4)Fuse 3+ 1 1 — -
AmbientLightSensorSignal 3264503 3264507 3264507 —-
LowBeamHeadlampControl—Left 3257502 3257504 3257501, -
3257504
LowBeamHeadlampControl—Right 3269902 3269904 3269901, -
3269904
AmbientLightSensorGround — 3264507 — -
HeadlampGround—Left. — 1 — -
HeadlampGround—Right — 1 — -
1.HeadlampsMalfunction

2013
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(US/Canada)
Service
Manual
(5377994)
4456 Lighting
CircuitlSystem Description
The ambient light sensor is used to monitor outside
lighting conditions. The body control module (30M)
provides a low reference ground and 5-volt reference
signal to the ambient light sensor. Depending on
outside lighting conditions, the ambient light sensor
provides a voltage signal to the 30M that will vary
between 0.2 and 4.9 volts. The 30M monitors the
ambient light sensor signal circuit to determine if
outside lighting conditions are correct for either daytime
CircuitlSystem
running lights (DRL) or automatic headlamp system
control when the headlamp switch is in the AUTO
position. In daylight conditions, the 30M will command
the low beam headlamps (DRLs) ON by applying low
voltage to the low beam headlamp control circuits
illuminating the low beam headlamps at reduced
intensity. Any function or condition that turns on the
headlamps will cancel DRL operation.
Reference Information
Schematic Reference
Headlights/Daytime Running Lights (DRL) Schematics
on page 4-82
Connector End View Reference
Component Connector End ,Views on page 11-269
Description and Operation
Exterior Lighting Systems Description and Operation
on page 4—217
Electrical Information Reference
Circuit Testing on page 11-526
-
- Connector Repairs on page 11-548
- Testing for IntermittentConditions and Poor
Connections on page 11—531
- Wiring Repairs on page 11-537
Scan Tool Reference
Control Module References on page 6—3for scan tool
information
CircuitlSystem Verification
1. lgnition ON.
2. Verify the low beam headlamps turn on & off when
commanding the Low Beam Headlamps ON and
OFF with a scan tool.
2 If the low beam headlamps do not turn ON
and OFF
Refer to Headlamps Malfunction on
page 4463.
U If the low beam headlamps turn ON and OFF
3. Ignition ON, park brake released.
4. Verify the scan tool 30M Park Brake Status
parameter displays released.
2 If the park brake status parameter does not
display released
Refer to Brake Warning Indicator Malfunction
on page 5414.
U If the parameter displays released
5. Refer to Circuit/System Testing.
Testing
1. lgnition OFF, scan tool disconnected, all doors
closed, all accessories OFF, open and close
drivers door, disconnect the harness connector at
the 310 ambient light sensor. Itmay take up to
2 minutes for all vehicle systems to power down.
2. Test for less than 15 Q between the ground circuit
terminal 6 and ground.
2 If 15 Q or greater
2.1. IgnitionOFF.
2.2. Test for less than 2 Q in the ground circuit end
to end.
2 If2 Q or greater, repair the open/high resistance
in the circuit.
2 if less than 2 Q, repair the open/high resistance
in the ground connection.
U If less than 15 Q
9° lgnition ON.
4. Verify the scan tool Ambient Light Sensor
parameter is greater than 4.65 V.
2 If 4.65 V or less
4.1. lgnition OFF, disconnect the X2 harness
connector at the K9 body control module.
4.2. Test for infinite resistance between the signal
circuit terminal 5 and ground.
2 Ifless than infinite resistance, repair the short to
ground on the circuit.
2 Ifinfinite resistance, replace the K9 body control
module.
U If greater than 4.65 V
5. Install a 3 A fused jumper wire between the signal
circuit terminal 5 and the ground circuit terminal 6.
6. Verify the scan tool Ambient Light Sensor
parameter is less than 0.196 V.
2 If 0.196 V or greater
6.1. IgnitionOFF, disconnect the X2 harness
connector at the K9 body control module,
ignition ON.
6.2. Test for less than 1 V between the signal
circuit terminal 5 and ground.
2 If 1 V or greater, repair the short to voltage on
the circuit.
U Ifless than 1 V
6.3. Test for less than 2 Q in the signal circuit end
to end.
2 if 2 Q or greater, repair the open/high resistance
in the circuit.
(US/Canada)
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2013 (5377994)
Manual
Service
 Lighting 4457
2 If less than 2 Q, replace the K9 body control Repair Instructions
module.
Perform the Diagnostic Repair Verification on
U If less than 0.196V page 692 after completing the repair.
7. Test or replace the 310 ambient light sensor. - Sun Load Temperature Sensor Replacement on
page 10-83
' Control Module References on page 6-3 for 30M
replacement, programming, and setup

Dome Lamps Malfunction

Diagnostic Instructions
° Perform the Diagnostic System Check - Vehicle
on page 6-66 prior to using this diagnostic
procedure.
- Review Strategy Based Diagnosis on page 6—58
for an overview of the diagnostic approach.
- Diagnostic Procedure Instructions on page 659
provides an overview of each diagnostic category.
Diagnostic Fault Information

Opeanigh Short to Voltage Signal

Circuit Short to Ground Resistance Performance
F11DA(BCM 7)Fuse 3+ 1,2 1,2 —— -
DomeLampsControl 3261502 1 1 -
Dome/ReadingLampsGround—Front 1 1 1 -
Dome/ReadingLampsGround—Rear 1 1 1 -
1. DomeLampsMalfunction
2. TurnSignalLampsand/orIndicatorsMalfunction

CircuitlSystem Description Electrical Information Reference

When any door is opened, the door ajar switch contacts
close and the body control module (30M) receives a
door—openinput.The BCM illuminates the dome lamp
when any door is opened or a door Iock/unlock request
is activated with the key fob. After all doors have been
closed, the dome lamp will remain illuminated
approximately 3 seconds after the last door closes. In
the event that the dome lamp were to remain
illuminated for more than 10 minutes with the ignition
switch in the OFF position and no doors opened, the
30M will deactivate the dome lamp control circuit to
prevent total battery discharge.
Reference Information
Schematic Reference
InteriorLights Schematics on page 4—89
Connector End View Reference
Component Connector End Views on page 11—269
Description and Operation
InteriorLighting Systems Description and Operation on
page 4-219
- Circuit Testing on page 11-526
- Connector Repairs on page 11-548
- Testing for IntermittentConditions and Poor
Connections on page 11-531
- Wiring Repairs on page 11-537
Scan Tool Reference
Control Module References on page 6—3for scan tool
information
CircuitlSystem Verification
1. Ignition ON.
2. Verify the scan tool Door Ajar Sw. parameter
changes between Active and Inactive while
opening and closing each vehicle door.
2 If the parameter does not change
Refer to Door Ajar Indicator Malfunction on
page 4-268.
U If the parameter changes

(US/Canada)
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2013 (5377994)
Manual
Service
44 58 Lighting
3. Verify the dome lamps turn ON and OFF whiIe
commanding the Courtesy Lamps ON and OFF
with a scan tool.
2 If the dome lamps do not turn ON and OFF
Refer to CircuitlSystem Testing.
U If the dome lamps turn ON and OFF
4. All OK.
CircuitlSystem Testing
1. Ignition OFF, all doors closed, all accessories OFF,
disconnect the harness connector at the
E37F dome/reading lamps —front and E37 3 dome/
reading lamps —2nd row. Itmay take up to
2 minutes for all vehicle systems to power down.
. Test for less than 10 Q between the appropriate
ground circuit terminal listed below and ground.
- E37F dome reading lamps —front —terminal 2
with 090/091
- E37F dome reading lamps —front—terminai 6
with 095
- E373 dome reading Iamps —2nd row -
terminal 2 with 090/095
If 10 Q or greater
2.1. lgnition OFF.
2.2. Test for less than 2 Q in the ground circuit end
to end.
2 If2 Q or greater, repair the open/high resistance
in the circuit.
2 Ifless than 2 Q, repair the open/high resistance
in the ground connection.
If less than 10 Q
Connect a test lamp between the appropriate
control circuit terminal listed below and ground.
- E37F dome reading lamps —front—terminal3
with 090/091
- E37F dome reading lamps —front—termina|2
with 095
' E373 dome reading lamps —2nd row -
terminal 3 with 090/095
4. Verify the test lamp turns ON and OFF when
commanding the Courtesy Lamps ON and OFF
with a scan tool.
If the test lamp is always OFF
4.1. lgnition OFF, disconnect the X7 harness
connector at the K9 body control module.
4.2. Test for infinite resistance between the control
circuit and ground.
2 Ifless than infinite resistance, repair the short to
ground on the circuit.
U Ifinfinite resistance
4.3. Test for less than 2 Q in the control circuit and
to end.
2 If2 Q or greater, repair the open/high resistance
in the circuit.
2 Ifless than 2 Q, replace the K9 body control,
module.
If the test lamp is always ON
4.1. IgnitionOFF, disconnect the X7 harness
connector at the K9 body control module,
ignition ON. .
4.2. Test for less than 1 V between the control
circuit terminal and ground.
2 If 1 V or greater, repair the short to voltage on
the circuit.
2 Ifless than 1 V, replace the K9 body control
module.
U If the test lamp turns ON and OFF
5. Test or replace the Inoperative E37 dome/
reading lamp.
Repair lnstrUctions
Perform the Diagnostic Repair Verification on
page 6-92 after completing the repair.
Dome Lamp Bulb Replacement on page 4492
Control Module References on page 6-3 for 30M
replacement, programming, and setup
2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
il
l
1 Lighting 4459

1 Front Fog Lamps Malfunction

Diagnostic Instructions
- Perform the Diagnostic System Check - Vehicle
on page 6—66prior to using this diagnostic
j procedure.
0 Review Strategy Based Diagnosis on page 6—58
for an overview of the diagnostic approach.
. Diagnostic Procedure Instructions on page 6—59
provides an overview of each diagnostic category.
Diagnostic Fault Information

Open/High Signal
Circuit Short to Ground Resistance Short to Voltage Performance
F19UA (FRT FOG) Fuse 3+ 1 1 — -

FrontFog Lampand UPDimmerSwitch3+ (33’

[133212185 32573 03 —— -

FrontFog Lampand UPDimmerSwitchSignal 32573 03 32573 03 1 -

FrontFog LampRelayControl 322553%%24’ 1322%%%%i’ 3253001 -

FrontFog LampControl 1 1 1 -
FrontFogLampGround—Left — 1 ~— -
FrontFog LampGround—Right — 1 —— -
1.FrontFog LampsMalfunction

CircuitlSystem Description Electrical Information Reference

The front fog lamp switch is an input to the body control
module (30M) and is contained in the headlamp switch
assembly. The 30M supplies voltage to the front fog
lamp switch via the front fog lamp and UP dimmer
switch 3+ circuit. When the front fog lamp switch Is
pressed, voltage from the 3+ circuit is pulled down
through the frontfog lamp switch resistor. The front fog
lamp resistor is part of the resistor ladder that also
provides the dimming signals for the VP dimmer
switches. The 30M receives the voltage signal through
the front fog lamp and UP dimmer switch signal circuit.
The front fog lamp relay is supplied with battery voltage
at all times. The front fog lamp switch signal circuit is
grounded momentarily by pressing the front fog lamp
switch. The body control module (BCM) energizes the
front fog lamp relay by applying ground to the front fog
lamp reIaycontrol circuit. When the front fog lamp relay
is energized, the relay switch contacts close and
battery voltage is applied through the FRT FOG fuse to
the front fog lamp control circuit which illuminates the
front fog lamps.
Reference Information
Schematic Reference
Fog Lights Schematics on page 4—84
Connector End View Reference
Component Connector End Views on page 11-269
- Circuit Testing on page 11-526
. Connector Repairs on page 11-548
. Testing for IntermittentConditions and Poor
Connections on page 11-531
- Wiring Repairs on page 11—537
Scan Tool Reference
Control Module References on page 6—3for scan tool
information
CircuitlSystem Verification
1. IgnitionON, headlamps ON.
2. Verify the scan tool Front Fog Lamps Switch
parameter changes between Active and Inactive
while commanding the frontfog lamps ON and
OFF with the front fog lamp switch.
2 If the parameter does not change
Refer to Front Fog Lamp Switch Malfunction.
U If the parameter changes
3. Verify the front fog Iamps turn ON and OFF when
commanding the Front Fog Lamps ON and OFF
with a scan tool.
2 If the front fog lamps do not turn ON and OFF
Refer to Front Fog Lamps Malfunction.
U If the front fog lamps turn 0N and OFF

Description and Operation

Exterior Lighting Systems Description and Operation
on page 4-217

(US/Canada}
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2013 (5377994)
Manual
Service
4460 Lighting
4. Verify the front fog lamp indicator on the instrument
cluster turns ON and OFF while commanding the
front fog lamps ON and OFF with the front fog lamp
switch.
2) If the front fog lamp indicator does not turn ON
and OFF
Refer to Front Fog Lamp Indicator Malfunction.
U If the front fog lamp indicator turns 0N and OFF
5. AIIOK.
CircuitlSystem Testing
Front Fog Lamp Switch Malfunction
1. lgnition OFF and all vehicle systems OFF,
disconnect the harness connector at the
830 Headlamp Switch, ignition ON.
Test for 3+ between the 3+ circuit terminal 1 and
ground.
If less than 3+
2.1. IgnitionOFF, disconnect the X3 harness
connector at the K9 Body Control Module.
2.2. Test for infinite resistance between the 3+
circuit and ground.
2 Ifless than infinite resistance, repair the short to
ground on the circuit.
U If infinite resistance
2.3. Test for less than 2 Q in the 3+ circuit end
to end.
2 If2 Q or greater, repair the open/high resistance
in the circuit.
2 If less than 2 Q, replace the K9 Body Control
Module.
U If B+
3. Verify the scan tool LED Backlight Dimming
Command parameter is greater than 40%.
:> If 40% or less
3.1. IgnitionOFF, disconnect the X1 harness
connector at the K9 Body Control Module,
ignition ON.
3.2. Test for less than 1 V between the signal
circuitterminal12 and ground.
2 If 1 V or greater, repair the short to voltage on
the circuit.
2 Ifless than 1 V, replace the K9 Body Control
Module.
U If greater than 40%
4. Install a 3 A fused jumper wire between the signal
circuittermina|12 and the 3+ circuit terminal 1.
5. Verify the scan tool LED Backlight Dimming
Command parameter is less than 30%.
:> If 30% or greater
5.1. IgnitionOFF, disconnect the X1 harness
connector at the K9 Body Control Module.
5.2. Test for infinite resistance between the signal
circuit and ground.
2 Ifless than infinite resistance, repairthe short to
ground on the circuit.
U If infinite resistance
5.3. Test for less than 2 Q in the signal circuit end
to end.
2 If2 Q or greater, repair the open/high resistance
in the circuit.
2 If less than 2 Q, replace the K9 Body Control
Module.
U If less than 30%
6. Test or replace the 830 Headlamp Switch.
Front Fog Lamps Malfunction
1. lgnition OFF, disconnect the X5 harness connector
at the K9 Body Control Module, ignition ON.
2. Verify a test lamp illuminates between the control
circuitterminai13 and ground.
If the test lamp does not illuminate
2.1. Ignition OFF, disconnect the X2 harness
connector at the X50A Fuse Block 4
Underhood.
2.2. Test for infinite resistance between the control
circuit terminal and ground.
2 Ifless than infinite resistance, repairthe short to
ground on the circuit.
U Ifinfinite resistance
2.3. Test for less than 2 Q in the control circuit end
to end.
2 If2 Q or greater, repair the open/high resistance
in the circuit.
2 Ifless than 2 Q, replace the X50A Fuse Block ~
Underhood.
If the test lamp illuminates
. Ignition OFF, connect a 3Afused jumper between
the control circuit terminal 13 and ground.
Remove the F19UA fuse at the X50A Fuse Block -
Underhood, ignition ON.
Verify a test lamp illuminates between the F19UA
fuse 3+ switch control terminal and ground.
If the test lamp does not illuminate
5.1. Ignition OFF, disconnect the X2 harness
connector at the X5OA Fuse Block -
Underhood, ignition ON.
5.2. Test for less than 1 V between the control
circuittermina|13 and ground.
2 If 1 V or greater, repair the short to voltage on
the circuit.
2 Ifless than 1 V, replace the X50A Fuse Block -
Underhood.
If the test lamp illuminates
. IgnitionOFF, connect the X5 harness connector at
the K9 Body Control Module.
. Install the F19UA fuse at the X50A Fuse Block -
Underhood.
{US/Canada)
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2013 (5377994)
Manual
Service
 Lighting 446i
8. Disconnect the harness connector at the 2 If the test lamp is always ON
appropriate E29 Fog Lamp, ignition OFF, exterior 11.1. IgnitionOFF, disconnect the X1 harness
Iamps OFF. connector at the X50A Fuse Block —-
9. Test for less than 5 Q between the ground circuit Underhood, ignition ON.
terminal 1 and ground. 11.2. Test for less than 1 V between the control
2 If 5 Q or greater circuit terminal and ground.
9.1. IgnitionOFF. 2 If 1 V or greater, repair the short to voltage on
9.2. Test for less than 2 Q in the ground circuit end the circuit.
to end. 2 Ifless than 1 V, replace the X50A Fuse Block -
2 If2 Q or greater, repair the open/high resistance Underhood.
in the circuit. U If the test lamp turns ON and OFF
2 Ifless than 2 Q, repair the open/high resistance 12. Test or replace the appropriate E29 Fog Lamp.
in the ground connection.
Front Fog Lamp Indicator Malfunction
U If less than 5 Q
1. Ignition ON.
10. Connect a test lamp between the control circuit
terminal 2 and ground, ignition ON. 2. Verify the front fog lamp indicator turns ON and
OFF when commanding the Instrument Cluster All
11. Verify the test lamp turns ON and OFF when Indicators Test ON and OFF with a scan tool.
commanding the Front Fog Lamps ON and OFF
with a scan tool. 2 If the front fog lamp indicator is always OFF or
remains 0N
2 If the test lamp is always OFF
Replace the P16 InstrumentCluster.
11.1. lgnition OFF, disconnect the X1 harness
connector at the X50A Fuse Block - U If the front fog lamp indicator turns ON and OFF
Underhood. 3. Replace the K9 Body Control Module.
11.2. Test for infinite resistance between the
control circuit and ground. Repair Instructions
2 Ifless than infinite resistance, repair the short to Perform the Diagnostic Repair Verification on
ground on the circuit. page 6-92 after completing the repair.
- Headlamp Switch Replacement on page 4487
U Ifinfinite resistance
~ Front Fog Lamp Bulb Replacement on page 4-200
11.3. Test for less than 2 Q in the control circuit end
to end. . Front Compartment Fuse Block Replacement on
2 lf2Q t ' th /h' h ' t ”9911609
in the Eli‘rgfia er, repair e open lg rests ance - Control Module References on page 6-3 for 30M
‘ or InstrumentCluster replacement, programming,
2 Ifless than 2 Q, replace the X50A Fuse Biock — and setup
Underhood.

Hazard Lamps Malfunction

Diagnostic Instructions
' Perform the Diagnostic System Check —Vehicle
on page 6-66 prior to using this diagnostic
procedure.
- Review Strategy Based Diagnosis on page 6-58
for an overview of the diagnostic approach.
- Diagnostic Procedure Instructions on page 6-59
provides an overview of each diagnostic category.
Diagnostic Fault Information

Open/High Signal
Circuit Short to Ground Resistance Short to Voltage Performance
HazardWarningSwitchSignal 1 1 1 3359600
HazardWarningSwitchLED Backlighting 2 2 2 __
ControI
HazardWarningSwitchGround — 1 — -
1. HazardLampsMalfunction
2. HazardWarningSwitchBacklightingMalfunction
2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
4462 Lighting

CircuitlSystem Description 4. Verify the hazard warning switch backlighting turns

ON and OFF while commanding the Hazard
The hazard flashers may be activated in any power Lamps Switch Backlight ON and OFF with a
mode. The hazard warning switch signai circuit is scan tool.
momentarily grounded when the hazard warning switch
is pressed. The body control module (30M) responds 2 If the hazard warning switch backlighting does
to the hazard warning switch signal input by supplying not turn ON and OFF
battery voltage to all four turn signal lamps in an ON Referto Hazard Warning Switch Backlighting
and OFF duty cycle. When the hazard warning switch is Malfunction.
activated, the 30M sends a serial data message to the
U If the hazard warning switch backlighting turns
instrument cluster requesting both turn signal indicators
ON and OFF
to be cycIed ON and OFF.
5. All OK.
The instrument panel dimmer switch controls are
located on the headlamp switch assembly and are used CircuitlSystem Testing
to increase and decrease the brightness of the interior
backlighting components. When the instrument panel Hazard Warning Switch Malfunction
dimmer switch is placed in a desired brightness 1. IgnitionOFF, scan tool disconnected, all doors
position, the body control module (30M) receives a closed, all accessories OFF, disconnect the
signal from the instrument panel dimmer switch and harness connector at the S26 Hazard Warning
responds by applying a pulse width modulated (PWM) Switch. Itmay take up to 2 minutes for all vehicle
voltage to the hazard switch LED backlighting control systems to power down.
circuit illuminating the LED to the desired level of
brightness. 2. Test for less than 5 Q between the ground circuit
terminal 3 and ground.
Reference Information 2 If 5 Q or greater
Schematic Reference 2.1. Ignition OFF.
2.2. Test for less than 2 Q in the ground circuit end
Exterior Lights Schematics on page 4-85 to end.
Connector End View Reference 2 If2 Q or greater, repairthe open/high resistance
Component Connector End Views on page 11—269 in the circuit.
2 Ifless than 2 Q, repairthe open/high resistance
Description and Operation in the ground connection.
Exterior Lighting Systems Description and Operation U If less than 5 Q
on page 4—217 9’ IgnitionON.
Electrical Information Reference 4. Verify the scan tool Hazard Lamps Switch
parameter is Inactive.
- Circuit Testing on page 11-526
0 Connector Repairs on page 11—548 2 If not Inactive
- Testing for IntermittentConditions and Poor 4.1. Ignition OFF, disconnect the X2 harness
Connections on page 11—531 connector at the K9 Body Control Module.
- Wiring Repairs on page 11-537 4.2. Test for infinite resistance between the signal
circuit terminal 1 and ground.
Scan Tool Reference 2 Ifless than infinite resistance, repair the short to
Control Module References on page 6-3 for scan tool ground on the circuit.
information 2 Ifinfinite resistance, replace the K9 Body
Control Module.
CircuitlSystem Verification
U If Inactive
1. lgnition ON.
5. Install a 3 A fused jumper wire between the signal
2. Verify the scan tool Hazard Lamps Switch circuit terminal 1 and ground.
parameter changes between Active and Inactive
while commanding the hazard Iamps ON and OFF 6. Verify the scan tool Hazard Lamps Switch
with the hazard warning switch. parameter is Active.
2 If the parameter does not change 2 If not Active
Refer to Hazard Warning Switch Malfunction. 6.1. Ignition OFF, disconnect the X2 harness
connector at the K9 Body Controi Module,
U If the parameter changes ignition ON.
3. Verify all left and right turn signal Iamps turn ON 6.2. Test for less than 1 V between the signal
and OFF while commanding the hazard Iamps ON circuit terminal 1 and ground.
and OFF with the hazard warning switch.
2 If 1 Vor greater, repair the short to voltage on
2 If all turn signal lamps do not turn ON and OFF the circuit.
Refer to Turn Signal Lamps and/or Indicators U Ifless than 1V
Malfunction on page 4481
U If all turn signal Iamps turn ON and OFF
(US/Canada)
-Sonic
2013 (5377994)
Manual
Service

6.3. Test for less than 2 Q in the signal circuit end
to end.
2 If2 Q or greater, repair the open/high resistance
in the circuit.
2 If less than 2 Q, replace the K9 Body Control
Module.
U If Active
7. Test or replace the 826 Hazard Warning Switch.
Hazard Warning Switch Backlighting Malfunction
1. Ignition OFF, scan tool disconnected, all doors
closed, all accessories OFF, disconnect the
harness connector at the S26 Hazard Warning
Switch. Itmay take up to 2 minutes for all vehicle
systems to power down.
2. Test for less than 5 Q between the ground circuit
terminal 3 and ground.
2 If 5 Q or greater
2.1. lgnition OFF.
2.2. Test for Iess than 2 Q in the ground circuit end
to end.
2 If2 Q or greater, repair the open/high resistance
in the circuit.
2 Ifless than 2 Q, repair the open/high resistance
in the ground connection.
U If less than 5 Q
3. Connect a test lamp between the control Circuit
terminal 2 and ground, IgnitionON.
4. Verify the test lamp turns ON and OFF when
commanding the Hazard Lamps Switch Backlight
ON and OFF with a scan tool.
2 If the test lamp is always OFF
4.1. IgnitionOFF, disconnect the X1 harness
connector at the K9 Body Control Module.
Lighting 44 63
4.2. Test for infinite resistance between the control
circuit and ground.
2 Ifless than infinite resistance, repair the short to
ground on the circuit.
U Ifinfinite resistance
4.3. Test for Iess than 2 Q in the control circuit end
to end.
2 If2 Q or greater, repair the open/high resistance
'” the C'rcu't'
: $553131“ 2 0’ replace the K9 Body Control
2 If the test lamp is always CM
4.1. IgnitionOFF, disconnect the X1 harness
connector at the K9 Body Control ModuIe,
ignition ON.
4.2. Test for less than 1 V between the control
circuit terminal and ground.
2 If 1 V or greater, repair the short to voltage on
the circuit.
2 Ifless than 1 V, replace the K9 Body Control
Module.
U If the test lamp turns ON and OFF
5. Test or replace the S26 Hazard Warning Switch.
Repair Instructions
Perform the Diagnostic Repair Verification on
page 6-92 after completing the repair.
- Hazard Warning Switch Replacement on
page 4488
- Control Module References on page 6-3 for 30M
replacement, programming, and setup

Headlamps Malfunction
Diagnostic Instructions
. Perform the Diagnostic System Check - Vehicle
on page 6-66 prior to using this diagnostic
procedure.
' Review Strategy Based Diagnosis on page 6—58
for an overview of the diagnostic approach.
' Diagnostic Procedure Instructions on page 659
provides an overview of each diagnostic category.
Diagnostic Fault Information

Open/High Signal
Circuit Short to Ground Resistance Short to Voltage Performance
F7DA (30M 3) Fuse 3+ 1 1 — —-
F8DA (30M 4) Fuse 3+ 1 1 — -
LowBeamHeadlampControl—Left 3257502 3257504 3257501,
3257504 -

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
4464 Lighting

Open/High Signal
Circuit Short to Ground Resistance Short to Voltage Performance
. 3258002, 3258002,
3258004 3258001 —-
HeadlampHighBeamRelayControl 3258004

LowBeamHeadlampControl—Right 3269902 3269904 giggggk -

HighBeamHeadlampControl—Left 2 2 2 -
HighBeam HeadlampControl—Right 2 2 2 -
HeadlampSwitchHeadlampsOFF Signal 3257A00 3 3 —-
HeadlampSwitchHeadlampsON Signal B257A00 3 3 -
SwitchFlashTo Pass
TgrnSignal/Multifunction 3380600 4 4 _
Signal
SwitchHighBeam
TurnSignaI/Muitifunction 3365008 4 4 _
Signal
HeadlampGround—Left —— 3257504 — -
HeadlampGround—Right — 3269904 — —-
HeadlampSwitchGround — 3 — -
SwitchGround
TurnSignal/Multifunction — 4 — -
1. HeadlampsMalfunction—LowBeam
2. HeadlampsMalfunction—HighBeam
3. HeadlampSwitchMalfunction
SwitchMalfunction
4. TurnSignaI/Multifunction

CircuitlSystem Description
The body control module (30M) monitors three signal
circuits from the headlamp switch. When the headlamp
switch is in the AUTO position, all three signal circuits
are open. When placed in the AUTO position, the 30M
monitors inputs from the ambient light sensor to
determine if headlamps are required or if daytime
running Iamps will be activated based on outside
lighting conditions. When the headlamp switch is
placed in the OFF position, the headlamp switch
headlamps OFF signal circuit is grounded, indicating to
the ECM that the exterior Iamps should be turned OFF.
With the headlamp switch in the PARK position, the
headlamp switch park Iamps ON signal circuit is
grounded, indicating that the park Iamps have been
requested. When the headlamp switch is placed in the
HEADLAMP position, both the headlamp switch park
Iamps ON signal circuit and the headlamp switch
headlamps ON signal circuit are grounded. The 30M
responds to the inputs by illuminating the park lamps
and headlamps. When the low beam headlamps are
requested, the 30M applies 3+ to both low beam
headlamp control circuits illuminating the low beam
headlamps.
The high beam and flash to pass functions are
contained within the turn signaI/multifunctionswitch.
The 30M provides the turn signaI/muitifunctionswitch
with two signal circuits, the high beam signal circuit and
the flash to pass signal circuit. When the low beam
headlamps are ON and the turn signal/multifunction
switch is placed in the high beam position, ground is
applied to the ECM through the high beam signal
circuit. The 30M responds to the high beam request by
applying ground to the high beam reIay control circuit
which energizes the high beam relay. With the high
beam relay energized, the switch contacts close
allowing battery voltage to flow through the high beam
fuses to the high beam control circuits illuminating the
high beam headlamps.
When the turn signaI/multifunctionswitch is
momentarily placed in the flash to pass position,
ground is applied to the 30M through the flash to pass
signal circuit. The 30M responds by applying ground to
the high beam relay controIcircuit which energizes the
high beam relay illuminating the high beams for a brief
moment or until the flash to pass switch is released.
Reference Information
Schematic Reference
- Headlights/Daytime Running Lights (DRL)
Schematics on page 4-82
- Body Control System Schematics on page 11-8
Connector End View Reference
Component Connector End Views on page 11—269
Description and Operation
Exterior Lighting Systems Description and Operation
on page 4-217
Electrical Information Reference
~ Circuit Testing on page 11-526
- Connector Repairs on page 11—548
. Testing for IntermittentConditions and Poor
Connections on page 11-531
- Wiring Repairs on page 11—537
Scan Tool Reference
Control Module References on page 6—3for scan tool
information

2013
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(US/Canada)
Service
Manual
(5377994)

CircuitlSystem Verification
1. Ignition ON.
2. Verify the scan tool Headlamps On Switch
parameter changes between Active and Inactive
whiIe commanding the headlamp ON and OFF with
the headlamp switch.
If the parameter does not change
Refer to Headlamp Switch Malfunction.
If the parameter changes
. Verify the scan tool Automatic Headlamps DisabIe
Switch parameter changes between Active and
Inactive while commanding the automatic lamp
control ON and OFF with the headlamp switch.
If the parameter does not change
Referto Headlamp Switch Malfunction.
If the parameter changes
Verify the scan tool Headlamps Flash Switch
parameter changes between Active and Inactive
while commanding the flash to pass ON and OFF
with the turn signal/multifunction switch.
If the parameter does not change
Refer to Turn Signal/Multifunction Switch
Malfunction.
If the parameter changes
Verify the scan tool High Beam Select Switch
parameter changes between Active and Inactive
while commanding the high beams ON and OFF
with the turn signal/multifunction switch.
If the parameter does not change
Refer to Turn Signal/Multifunction Switch
Malfunction.
If the parameter changes
. Verify the left Iowbeam/daytime running Iamp turn
ON and OFF when commanding the Left Low
Beam/Daytime Running Lamp ON and OFF with a
scan tool.
If the left low beam/daytime running lamp does
not turn 0N and OFF
Refer to Headlamps Malfunction —Low Beam.
If the left low beam/daytime running lamp turns
ON and OFF
Verify the right low beam/daytime running lamp
turn ON and OFF when commanding the Right
Low Beam/Daytime Running Lamp ON and OFF
with a scan tool.
If the right low beam/daytime running lamp
does not turn 0N and OFF
Refer to Headlamps Malfunction —Low Beam.
If the right low beam/daytime running lamp
turnsON and OFF
Verify the high beams turn ON and OFF when
commanding the High Beams ON and OFF with a
scan tool.
If the high beams do not turn ON and OFF
Refer to Headlamps Malfunction ~ High Beam.
If the high beams turn ON and OFF
2013
-Sonic
(US/Canada)
SeIVice
Manual
(5377994)
Lighting 4-155
Verify the high beam indicator on the instrument
cluster turns ON and OFF whiIe commanding the
All Indicators Test ON and OFF with a scan tool.
If the high beam indicator does not turn ON
and OFF
Refer to High Beam Indicator Malfunction.
U If the high beam indicator turns ON and OFF
10. AIIOK.
CircuitlSystem Testing
Headlamp Switch Malfunction
1. Ignition OFF, scan tool disconnected, all doors
closed, all accessories OFF, disconnect the
harness connector at the 830 headiamp switch.
Itmay take up to 2 minutes for all vehicle systems
to power down.
. Test for less than 15 Q between the ground circuit
terminal 6 and ground.
If 15 Q or greater
2.1. Ignition OFF.
2.2. Test for less than 2 Q in the ground circuit end
to end.
2 If2 Q or greater, repairthe open/high resistance
in the circuit.
2 Ifless than 2 Q, repair the open/high resistance
in the ground connection.
If less than 15 Q
9° lgnition ON.
Verify the scan tool Automatic Headlamps Disable
Switch parameter is Inactive.
If not Inactive
4.1. IgnitionOFF, disconnect the X1 harness
connector at the K9 body control module.
4.2. Test for Infiniteresistance between the signal
circuit terminal 5 and ground.
2 If less than infinite resistance, repair the short to
ground on the circuit.
2 If infinite resistance, replace the K9 body control
module.
If Inactive
Install a 3 A fused jumper wire between the signal
circuit terminal 5 and the ground circuit terminal 6.
Verify the scan tool Automatic Headlamps Disable
Switch parameter is Active.
If not Active
6.1. IgnitionOFF, disconnect the X1 harness
connector at the K9 body control module,
ignition ON.
6.2. Test for less than 1 V between the signal
circuit terminal 5 and ground.
2 If 1 V or greater, repair the short to voltage on
the circuit.
U Ierss than 1 V
6.3. Test for less than 2 Q in the signal circuit end
to end.
2 If2 Q or greater, repair the open/high resistance
in the circuit.
4.155 Lighting
2 Ifless than 2 Q, replace the K9 body control
module. ‘ parameter is Active.
If Active
Verify the scan tool Park Lamps Switch parameter
isInacfive.
If not Inactive
7.1. Ignition OFF, disconnect the X1 harness
connector at the K9 body control module.
7.2. Test for infinite resistance between the signal
circuit terminal 3 and ground.
2 IfIess than infinite resistance, repair the short to
ground on the circuit.
2 If infinite resistance, replace the K9 body control
module.
If Inactive
Install a 3 A fused jumper wire between the signal
circuit terminal 3 and the ground circuit terminal 6.
Verify the scan tool Park Lamps Switch parameter
is Active.
If not Active
9.1. Ignition OFF, disconnect the X1 harness
connector at the K9 body control module,
ignition ON.
9.2. Test for less than 1 V between the signal
circuitterminai 3 and ground.
2 If 1 V or greater, repair the short to voltage on
the circuit.
U Ifless than 1 V
9.3. Test for less than 2 Q Inthe signal circuit end
to end.
2 If2 Q or greater, repair the open/high resistance
in the circuit.
2 Ifless than 2 Q, replace the K9 body control
module.
If Active
. Verify the scan tool Headlamps On Switch
parameter is InaCtive.
If not Inactive
10.1. Ignition OFF, disconnect the X1 harness
connector at the K9 body control module.
10.2. Test for infinite resistance between the signal
circuit terminal 4 and ground.
2 Ifless than infinite resistance, repair the short to
ground on the circuit.
2 Ifinfinite resistance, replace the K9 body control
module.
U If Inactive
. Install a 3 A fused jumper wire between the signal
circuit terminal 4 and the ground circuit terminal 6.
12. Verify the scan tool Headlamps On Switch
:> If not Active
12.1. IgnitionOFF, disconnect the X1 harness
connector at the K9 body control module,
ignition ON.
12.2. Test for less than 1 V between the signal
circuit terminal 4 and ground.
2 If 1 Vor greater, repair the short to voltage on
the circuit.
U Ifless than 1 V
12.3. Test for less than 2 Q in the signal circuit end
to end.
2 If2 Q or greater, repair the open/high resistance
in the circuit.
2 Ifless than 2 Q, replace the K9 body control
module.
U If Active
13. Test or replace the 830 headlamp switch.
Turn Signal/Multifunction Switch Malfunction
1. lgnition OFF, scan tool disconnected, all doors
closed, all accessories OFF, disconnect the
harness connector at the 878 turn signal/
multifunction switch. Itmay take up to 2 minutes for
all vehicle systems to power down.
Test for Iess than 15 Q between the ground circuit
terminal 3 and ground.
If 15 Q or greater
2.1. lgnition OFF.
2.2. Test for less than 2 Q in the ground circuit end
to end.
2 If2 Q or greater, repair the open/high resistance
in the circuit.
2 Ifless than 2 Q, repair the open/high resistance
in the ground connection.
If less than 15 Q
9° IgnitionON.
. Verify the scan tool High Beam Select Switch
parameter is Inactive.
If not Inactive
4.1. IgnitionOFF, disconnect the X3 harness
connector at the K9 body control module.
4.2. Test for infinite resistance between the signal
circuit terminal 2 and ground.
2 Ifless than infinite resistance, repairthe short to
ground on the circuit.
2 Ifinfinite resistance, replace the K9 body control
module.
If Inactive
Install a 3 A fused jumper wire between the signal
circuit terminal 2 and the ground circuit terminal 3.
2013
—Sonic
(US/Canada)
Service
Manual
(5377994)

6. Verify the scan tool High Beam Select Switch
parameter is Active.
2) If not Active
6.1. IgnitionOFF, disconnect the X3 harness
connector at the K9 body control module,
ignition ON.
6.2. Test for less than 1 V between the signal
circuit terminal 2 and ground.
2 If 1 V or greater, repair the short to voltage on
the circuit.
U Ifless than 1 V
6.3. Test for less than 2 Q Inthe signal circuit end
to end.
2 If2 Q or greater, repair the open/high resistance
in the circuit.
2 Ifless than 2 Q, repIace the K9 body control
module.
If Active
Verify the scan tool Headlamps Flash Switch
parameter Is Inactive.
If not Inactive
7.1. lgnition OFF, disconnect the X3 harness
connector at the K9 body control module.
7.2. Test for infinite resistance between the signal
circuit terminal 4 and ground.
2 Ifless than infinite resistance, repair the short to
ground on the circuit.
2 Ifinfinite resistance, replace the K9 body control
module.
If Inactive
Install a 3 A fused jumper wire between the signal
circuit terminal 4 and the ground circuit terminal 3.
Verify the scan tool Headlamps Flash Switch
parameter is Active.
If not Active
9.1. lgnition OFF, disconnect the X3 harness
connector at the K9 body control module,
ignition ON.
9.2. Test for less than 1 V between the signal
circuit terminal 4 and ground.
2 If 1 V or greater, repair the short to voltage on
the circuit.
U Ifless than 1 V
9.3. Test for less than 2 Q in the signal circuit end
to end.
2 If2 Q or greater, repair the open/high resistance
in the circuit.
2 IfIess than 2 Q, replace the K9 body controI
module.
If Active
. Test or replace the S78 turn signaI/multifunction
switch. ‘
Lighting 44 67
Headlamps Malfunction —Low Beam
1. Ignition OFF, disconnect the X1 harness connector
at the K9 body control module, ignition ON.
2. Verify a test lamp illuminates between the 3+
circuit terminal 2 and ground.
If the test lamp does not illuminate and the
circuit fuse is good
2.1. Test for less than 2 Q in the 3+ circuit end
to end.
2 If2 Q or greater, repair the open/high resistance
in the circuit.
2 Ifless than 2 Q, verify the fuse is not open and
there is voltage at the fuse.
If the test lamp does not illuminate and the
circuit fuse is open
2.1. Test for infinite resistance between the 3+
circuit and ground.
2 If less than infinite resistance, repair the short to
ground on the circuit.
2 If infinite resistance, replace the K9 body control
module.
If the test lamp illuminates
Verify a test lamp illuminates between the 3+
circuit terminal 3 and ground.
If the test lamp does not illuminate and the
circuit fuse is good
3.1. Test for less than 2 Q in the 3+ circuit end
to end.
2 If2 Q or greater, repair the open/high resistance
in the circuit.
2 Ifless than 2 Q, verify the fuse is not open and
there is voltage at the fuse.
If the test lamp does not illuminate and the
circuit fuse is open
3.1. Test for infinite resistance between the 3+
circuit and ground.
2 If less than infinite resistance, repair the short to
ground on the circuit.
2 If infinite resistance, replace the K9 body control
module.
If the test lamp illuminates
Ignition OFF, connect the X1 harness connector at
the K9 body control module.
Ignition OFF, exterior lamps OFF, disconnect the
harness connector at the appropriate
E13 headlamp.
Test for less than 5 Q between the ground circuit
terminal D and ground.
If 5 Q or greater
6.1. Ignition OFF.
6.2. Test for less than 2 Q in the ground circuit and
to end.
2 If2 Q or greater, repair the open/high resistance
in the circuit.
2 If less than 2 Q, repair the open/high resistance
in the ground connection.
If less than 5 Q

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
4468 LightingL
7. Connect a test lamp between the control circuit
terminal A and ground, ignition ON.
8. Verify the test lamp turns ON and OFF when
commanding the appropriate Low Beam/Daytime
Running Lamp ON and OFF with a scan tool.
If the test lamp is always OFF
8.1. IgnitionOFF, disconnect the X4 harness
connector at the K9 body control module.
8.2. Test for infinite resistance between the control
circuit and ground.
2 Ifless than infinite resistance, repair the short to
ground on the circuit.
U Ifinfinite resistance
8.3. Test for less than 2 Q in the control circuit end
to end.
2 |f2 Q or greater, repair the open/high resistance
in the circuit.
2 Ifless than 2 Q, replace the K9 body control
moduie.
If the test lamp is always ON
8.1. IgnitionOFF, disconnect the X4 harness
connector at the K9 body control module,
ignition ON.
8.2. Test for less than 1 V between the control
circuit terminal and ground.
2 If 1 V or greater, repair the short to voltage on
the circuit.
2 Ifless than 1 V, replace the K9 body control
moduie.,
U If the test lamp turns ON and OFF
9. Test or replace the appropriate E4 headlamp -
Iow beam.
Headlamps Malfunction —High Beam
1. Ignition OFF, remove the KR48 headlamp high
beam relay.
2. Connect a test lamp between the control circuit
terminal 86 and 3+, ignition ON.
3. Verify the test lamp turns ON and OFF when
commanding the High Beams ON and OFF with a
scan tool.
If the test lamp is always OFF
3.1. lgnition OFF, disconnect the X5 harness
connector at the K9 body control module,
ignition ON.
3.2. Test for less than 1 V between the control
circuit terminal and ground.
2 If 1 V or greater, repair the short to voltage on
the circuit.
U Ifless than 1 V
3.3. Ignition OFF.
3.4. Test for less than 2 Q in the control circuit end
to end.
2 If2 Q or greater, repair the open/high resistance
in the circuit.
2 Ifless than 2 Q, replace the K9 body control
module.
If the test lamp is always ON
3.1. IgnitionOFF, disconnect the X5 harness
connector at the K9 body control module.
3.2. Test for infinite resistance between the control
circuit terminal and ground.
2 Ifless than infinite resistance, repair the short to
ground on the circuit.
2 If infinite resistance, replace the K9 body control
module.
<=If the test lamp turns ON and OFF
IgnitionOFF, exterior Iamps OFF, connect the
KR48 headlamp high beam relay.
Disconnect the harness connector at the
appropriate E13 headlamp.
. Test for less than 5 Q between the ground circuit
terminal D and ground.
If 5 Q or greater
6.1. IgnitionOFF.
6.2. Test for less than 2 Q in the ground circuit end
to end.
2 If2 Q or greater, repair the open/high resistance
in the circuit.
2 Ifless than 2 Q, repair the open/high resistance
in the ground connection.
If less than 5 Q
Connect a test lamp between the control circuit
terminal 3 and ground, ignition ON.
Verify the test lamp turns ON and OFF when
commanding the High Beams ON and OFF with a
scan tool.
If the test lamp is always OFF
8.1. IgnitionOFF, disconnect the X1 harness
connector at the X50A fuse block -
underhood.
8.2. Test for infinite resistance between the control
circuit and ground.
2 Ifless than infinite resistance, repair the short to
ground on the circuit.
U Ifinfinite resistance
8.3. Test for Iess than 2 Q in the control circuit end
to end.
2 If2 Q or greater, repair the open/high resistance
in the circuit.
2 Ifless than 2 Q, replace the KR48 headlamp
high beam relay.
If the test lamp is always ON
8.1. IgnitionOFF, disconnect the X1 harness
connector at the X50A fuse block -
underhood, ignition ON.
8.2. Test for less than 1 V between the control
circuit terminal and ground.
2 If 1 V or greater, repair the short to voltage on
the circuit.
2013
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(US/Canada)
Service
Manual
(5377994)

2 If less than 1 V, replace the KR48 headlamp
high beam relay.
U If the test lamp turns ON and OFF
9. Test or replace the appropriate E4 headlamp -
high beam.
High Beam Indicator Malfunction
1. IgnitionON.
2. Verify the high beam indicator turns ON and OFF
when commanding the InstrumentCluster AII
Indicators Test ON and OFF with a scan tool.
2 If the high beam indicator is always OFF or
remains 0N
Replace the P16 instrument cluster.
U If the high beam indicator turns ON and OFF
3. Replace the K9 body control module.
Lighting 446 9
Repair Instructions
Perform the Diagnostic Repair Verification on
page 6-92 after completing the repair.
Headlamp Switch Replacement on page 4487
0 Headlamp Bulb Replacement on page 4494
Relay Replacement (Within an Electrical Center)
on page 11—607or Relay Replacement (Attached
to Wire Harness) on page 11-607
Turn Signal Multifunction Switch Replacement on
page 15—31
Control Module References on page6-3 for 30M
or InstrumentCluster replacement, programming,
and setup

Interior Backlighting Malfunction

Diagnostic Instructions
Perform the Diagnostic System Check —Vehicle
on page 6-66 prior to using this diagnostic
procedure.
Review Strategy Based Diagnosis on page 6-58
for an overview of the diagnostic approach.
Diagnostic Procedure Instructions on page 659
provides an overview of each diagnostic category.
Diagnostic Fault Information

. Short to Opeanigh Signal

Circuit Ground Resistance Short to Voltage Performance
F10DA (30M 6)Fuse 3+ 1 1 — -
InstrumentPanelDimmerSwitch3+Reference [1332131708511332573 03 — —-
InstrumentPanelDimmerSwitchSignal 3257303 32573 03 32573 07 -
PassengerAir Bag DisableIndicator 3 3 3 _
BackIIghtIng
Control
LED BacklightDimmingControlTerminal8 X2 3261002 3261004 3261001 -
HazardWarningSwitchLED BacklightDimming 1 1 1
Control
32210111351502)?
figllftLeverPosmonlndlcator 3265202 1 1 _

LED BacklightDimmingControlTerminal5 X1 B252E02 3252E 02 1 -

PassengerAir Bag DisableIndicatorGround — 3 — —-
MultifunctionSwitch—CenterConsoleGround — 1 — -
DoorLock Switch—DriverGround — 1 ~— -
HazardLampsSwitch—Ground — 1 —- -
HeadlampSwitchGround 2 2 — —-
SteeringWheelControlsSwitch—LeftGround — 1 — -

I 2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
4H /0 Lighting

Short to Open/High Signal

Circuit Ground Resistance Short to Voltage Performance
SteeringWheelControlsSwitch—RightGround —- 1 _ _
TransmissionShiftLeverPositionIndicator 1 ‘ _
Ground
1. interiorBacklightingMalfunction
2. DimmerSwitchMalfunction
3. PassengerAir Bag DisableIndicatorBacklightingMalfunction

CircuitlSystem Description If the parameter does not change

The instrument panel dimmer switch is used to increase
and decrease the brightness of the interior backlighting
components. The instrument panel dimmer switch
provides a voltage signal to the body control module
(BCM) that will increase as the brightness of the lights
are increased and decrease as the brightness of the
lights are decreased. The BCM provides a low
reference signal and a 8+ voltage reference to the
instrument panel dimmer switch. When the instrument
panel dimmer switch is placed in the desired position,
the dimmed voltage setting is applied from the
instrument panel dimmer switch through the instrument
panel dimmer switch signal circuit to the BCM. The
BCM interprets the signal and applies a pulse width
modulated (PWM) voltage through the LED dimming
control circuits illuminating the interior backlighting to
the requested level of brightness.
Reference Information
Schematic Reference
Interior Lights Dimming Schematics on page 4-91
Connector End View Reference
Component Connector End Views on page 11—269
Description and Operation
Interior Lighting Systems Description and Operation on
page 4-219
Electrical Information Reference
. Circuit Testing on page 11-526
- Connector Repairs on page 11-548
- Testing for IntermittentConditions and Poor
Connections on page 11-531
- Wiring Repairs on page 11-537
Scan Tool Reference
Control Module References on page 6-3 for scan tool
information
CircuitlSystem Verification
1. Ignition ON.
2. Verify the scan tool LED Backlight Dimming
Command parameter changes between a high
percentage to a low percentage while operating the
dimmer switch from high to low.
Refer to Dimmer Switch Malfunction.
If the parameter changes
. Verify the backlighting components turn ON and
OFF while commanding the LED Backlight
Dimming ON and OFF with a scan tool.
If the backlighting components do not turn ON
and OFF
Referto interior Backlighting Malfunction.
If the backlighting components turn ON
and OFF
. Verify the hazard Iamps switch backlighting turns
ON and OFF while commanding the Hazard
Lamps Switch Backlight ON and OFF with a
scan tool.
If the hazard Iamps switch backlighting does
not turn ON and OFF
Referto Hazard Lamps Switch Backlighting
Malfunction.
If the hazard lamps switch backlighting turns
ON and OFF
. Verify the transmission shift lever position indicator
backlighting turns ON and OFF while turning the
park Iamps ON and OFF with the headlamp switch.
If the transmission shift lever position indicator
backlighting does not turn ON and OFF
Refer to Transmission Shift Lever Position
Indicator Backlighting Malfunction.
If the transmission shift lever position indicator
backlighting turns ON and OFF
. Verify the phrase PASSENGER AIR BAG is
illuminated on the Passenger Air Bag Disable
Indicator.
If the phrase PASSENGER AIR BAG is not
illuminated
Refer to Passenger Air Bag Disable Indicator
Backlighting Malfunction.
If the phrase PASSENGER AIR BAG is
illuminated
. All OK.

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
 I
I Lighting
l
I CircuitlSystem Testing
I Dimmer Switch Malfunction
1. IgnitionOFF and all vehicle systems OFF,
I 5. Test or replace the 830 Headlamp Switch.
,l disconnect the harness connector at the
830 Headlamp Switch, ignition ON.
Test for 8+ between the B+ circuit terminal1 and
ground.
If less than 3+
2.1. IgnitionOFF, disconnect the X3 harness
connector at the K9 Body Control Module.
2.2. Test for infinite resistance between the B+
circuit and ground.
=>Ifless than infinite resistance, repair the short to
ground on the circuit.
U Ifinfinite resistance
2.3. Test for less than 2 Q in the B+ circuit end
to end.
=>If2 Q or greater, repair the open/high resistance
in the circuit.
=>Ifless than 2 Q, replace the K9 Body Control
Module.
if B+
Verify a test lamp does not illuminate between the
B+ circuit terminal1 and the signal circuit
terminal 12.
If the test lamp illuminates
3.1. lgnition OFF, disconnect the X1 harness
connector at the K9 Body Control Module.
32. Test for infinite resistance between the signal
circuit and ground.
=>Ifless than infinite resistance, repairthe short to
ground on the circuit.
=>if infinite resistance, replace the K9 Body
Control Module.
If the test lamp does not illuminate
. Test for 8+ between the B+ circuit terminal 1 and
the signal circuit terminal 12.
If less than 3+
4.1. lgnition OFF, disconnect the X1 harness
connector at the K9 Body Control Module,
ignition ON.
4.2. Test for less than 1 V between the signal
circuitterminal12 and ground.
=>If 1 V or greater, repair the short to voltage on
the circuit.
U lfless than 1 V
4.3. Test for less than 2 Q in the signal circuit end
to end.
2: If2 Q or greater, repair the open/high resistance
in the circuit.
4‘1 7’]
:> lf less than 2 Q, replace the K9 Body Control
Module.
U If B+
Interior Backlighting Malfunction
Note: Each component with backlighting may need to
be disconnected to isolate a short to voltage or short to
ground. Use the schematics to identify the following:
- Backlighting components the vehicle is
equipped with
- Each component‘s control and ground circuit
terminals
- Component locations on the backlighting
control circuit
IgnitionOFF, all doors closed, all accessories OFF,
disconnect the harness connector at the
component with inoperative backlighting. Itmay
take up to 2 minutes for all vehicle systems to
power down.
. Test for less than 15 0 between the appropriate
ground circuit terminal listed below and ground.
- S13D Door Lock Switch —Driver terminal 1
- 830 Headlamp Switch —terminal 6
- S48E Multifunction Switch —Center Console
terminal 9
- 870R Steering Wheel Controls Switch —right
terminal 5
- S7OL Steering Wheel Controls Switch - left
terminal 7
=>If 15 Q or greater
2.1. lgnition OFF.
2.2. Test for less than 2 Q in the ground circuit end
to end.
=>lf 2 Q or greater, repair the open/high resistance
in the circuit.
=>if less than 2 Q, repairthe open/high resistance
in the ground connection.
If less than 15 (2
Connect a test lamp between the appropriate
control circuit terminal listed below and ground.
- K33 HVAC Control Module —terminal 8
° S13D Door Lock Switch —Driver terminal 2
- 830 Headlamp Switch —terminal 7
' S48E Multifunction Switch ~Center Console
terminal 10
- S70R Steering Wheel Controls Switch —Right
terminal 4
- S70L Steering Wheel Controls Switch —Left
terminal 6

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-Sonic
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44 72 Lighting
4. Verify the test lamp turns ON and OFF when
commanding the LED Backlight Dimming ON and
OFF with a scan tool.
:> If the test lamp is always OFF
4.1. IgnitionOFF, disconnect the X2 harness
connector at the K9 Body Control Module.
4.2. Test for infinite resistance between the control
circuit and ground.
=>if less than infinite resistance, repair the short to
ground on the circuit.
U Ifinfinite resistance
4.3. Test for less than 2 Q in the control circuit end
to end.
2:»If2 Q or greater, repair the open/high resistance
in the circuit.
=>Ifless than 2 Q, replace the K9 Body Control
Module.
=>If the test lamp is always ON
4.1. lgnition OFF, disconnect the X2 harness
connector at the K9 Body Control Module,
ignition ON.
4.2. Test for less than 1 V between the control
circuit terminal and ground.
=>lf 1 V or greater, repair the short to voltage on
the circuit.
=>Ifless than 1 V, replace the K9 Body Control
Module.
U If the test lamp turns ON and OFF
5. Test or replace the component with inoperative
backlighting.
Hazard Lamps Switch Backlighting Malfunction
1. IgnitionOFF, scan tool disconnected, all doors
closed, all accessories OFF, disconnect the
harness connector at the 826 Hazard Warning
Switch. Itmay take up to 2 minutes for all vehicle
systems to power down.
2. Test for less than 5 Q between the ground circuit
terminal 3 and ground.
:> If 5 Q or greater
2.1. lgnition OFF.
2.2. Test for less than 2 Q in the ground circuit and
to end.
=>If2 Q or greater, repair the open/high resistance
in the circuit.
:> Ifless than 2 Q, repair the open/high resistance
in the ground connection.
U If less than 5 Q
3. Connect a test lamp between the control Circuit
terminal 2 and ground, ignition ON.
4. Verify the test lamp turns ON and OFF when
commanding the Hazard Lamps Switch Backlight
ON and OFF with a scan tool.
:> If the test lamp is always OFF
4.1. lgnition OFF, disconnect the X1 harness
connector at the K9 Body Control Module.
4.2. Test for infinite resistance between the control
circuit and ground.
=>Ifless than infinite resistance, repairthe short to
ground on the circuit.
U If infinite resistance
4.3. Test for less than 2 Q in the control circuit and
to end.
=>If2 Q or greater, repair the open/high resistance
in the circuit.
=>if less than 2 Q, replace the K9 Body Control
Module.
=>If the test lamp is always ON
4.1. Ignition OFF, disconnect the X1 harness
connector at the K9 Body Control Module,
ignition ON.
4.2. Test for less than 1 V between the control
circuit terminal and ground.
=>If 1 V or greater, repair the short to voltage on
the circuit.
=>If less than 1V, replace the K9 Body Control
Module.
U If the test lamp turns ON and OFF
5. Test or replace the 826 Hazard Warning Switch.
Transmission Shift Lever Position Indicator
Backlighting Malfunction
1. lgnition OFF, scan tool disconnected, all doors
closed, all accessories OFF, disconnect the
harness connector at the P2 Transmission Shift
Lever Position Indicator.Itmay take up to
2 minutes for all vehicle systems to power down.
2. Test for less than 15 Q between the ground circuit
termina12 and ground.
:> If 15 Q or greater
2.1. lgnition OFF.
2.2. Test for less than 2 Q in the ground circuit end
to end.
=>lf 2 Q or greater, repair the open/high resistance
in the circuit.
2 Ifless than 2 Q, repair the open/high resistance
in the ground connection.
U If less than 15 Q
3. Connect a test lamp between the control circuit
terminal1 and ground.
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4. Verify the test lamp turns ON and OFF while
turning the headlamp switch ON and OFF.
:> If the test lamp is always OFF
4.1. lgnition OFF, disconnect the X6 harness
connector at the K9 Body Control Module.
4.2. Test for infinite resistance between the control
circuit and ground.
:> Ifless than infinite resistance, repair the short to
ground on the circuit.
U Ifinfinite resistance
4.3. Test for less than 2 Q in the control circuit end
to end.
=>If2 Q or greater, repair the open/high resistance
in the circuit.
:> if less than 2 Q, replace the K9 Body Control
Module.
If the test lamp is always CM
4.1. lgnition OFF, disconnect the X6 harness
connector at the K9 Body Control Module,
ignition ON.
4.2. Test for less than 1 V between the control
circuit terminal and ground.
=>If 1 V or greater, repair the short to voltage on
the circuit.
=>Ifless than 1 V, replace the K9 Body Control
Module.
If the test lamp turns ON and OFF
Test or replace the P2 Transmission Shift Lever
Position Indicator.
Passenger Air Bag Disable Indicator Backlighting
Malfunction
1. lgnition OFF, scan tool disconnected, all doors
closed, all accessories OFF, disconnect the
harness connector at the P14 Passenger Air Bag
Disable Indicator.Itmay take up to 2 minutes for all
vehicle systems to power down.
. Test for less than 5 Q between the ground circuit
terminal 3 and ground.
If 5 Q or greater
2.1. lgnition OFF.
22. Test for less than 2 Q in the ground circuit end
to end.
=>lf 2 Q or greater, repair the open/high resistance
in the circuit.
:> Ifless than 2 Q, repairthe open/high resistance
in the ground connection.
If less than 5 Q
Connect a test lamp between the control Circuit
terminal1 and ground.
1 2013
-Sonic
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Service
Manual
(5377994)
Lighting 4-173
4. Verify the test lamp turns ON and OFF while
turning the ignition switch ON and OFF.
:;>If the test lamp is always OFF
4.1. IgnitionOFF.
42. Test for infinite resistance between the control
circuit and ground.
=>if less than infinite resistance, repair the short to
ground on the circuit.
U if infinite resistance
4.3. Test for less than 2 Q in the control circuit end
to end.
=>lf 2 Q or greater, repair the open/high resistance
in the circuit.
If the test lamp is always ON
4.1. IgnitionOFF, remove the F28DA at the
X51A Fuse Block —Instrument Panel,
ignition ON.
4.2. Test for less than 1 V between the control
circuit terminal and ground.
=>If 1 V or greater, repair the short to voltage on
the circuit.
=>Ifless than 1 V, replace the X51A Fuse Block -
InstrumentPanel.
If the test lamp turns ON and OFF
Test or replace the P14 Passenger Air Bag Disable
Indicator.
Repair Instructions
Perform the Diagnostic Repair Verification on
page 6-92 after completing the repair.
Door Lock Switch Replacement on page 4-321
Hazard Warning Switch Replacement on
page 4-188
Headlamp Switch Replacement on page 4-187
Transmission Control Replacement on
page 17—193
Radio and Telephone Control Switch
Replacement on page 8—63
Control Module References on page 6-3 for BCM
replacement, programming, and setup
4-1 74 Lighting

Park, License, and/or Tail Lamps Malfunction

Diagnostic Instructions
- Perform the Diagnostic System Check —Vehicle
on page 6—66prior to using this diagnostic
procedure.
- Review Strategy Based Diagnosis on page 6—58
for an overview of the diagnostic approach.
- Diagnostic Procedure Instructions on page 6-59
provides an overview of each diagnostic category.

Diagnostic Fault Information

Short to Opeanigh Short to Voltage Signal

Circuit Ground Resistance , Performance
8387301, 8387301,
8387304, 8387304,
F5DA (BCM 1)Fuse 8+ 8388301, 8388301, — -
8388304, 8388304,
0029701 00297 01
F7DA (BCM 3) Fuse 8+ 1,3 1,3 — —-
F8DA (BCM 4) Fuse 8+ 1,3 1,3 — -
HeadlampSwitchPark LampsON Signal 2 8257A00 2 -
LicensePlateLampControl 8388302 BB%%8833%11' 8388301 -
Egfltga—rltfeatnd
RearSide MarkerLamps 8258502 8258504 2225588553, _

Efrfltrgérlgiegrhctj
Rear Side MarkerLamps 8386702 8386704 831322385778)? __

RearTail/StopLampsControi—Left 8388102 8388104 8388101 —-

RearTail/StopLampsControl- Right 8388202 8388204 8388201 -
HeadlampSwitchGround —- 2 — —-
LicensePlateLampGround- Left — Beggfilt’ — -

LicensePlateLampGround- Right — giggigl — —-

Park LampGround- LeftFront — 1 — -
Park LampGround- RightFront — 1 —— -
RearTail/StopLampsGround- Left — 1 — -
RearTail/StopLampsGround- Right — 1 — —-
Side MarkerLampGround- LeftRear — 1 — -
Side MarkerLampGround- RightRear — 1 — —-
1. Park,License,and/orTailLampsMalfunction
2. Park LampSwitchMalfunction
3. TurnSignalLampsand/orIndicatorsMalfunction

CircuitlSystem Description Diagnostic Aids

When the headlamp switch is placed in the HEAD or When testing at the park lamp bulb socket, make sure
PARK position, ground is applied to the park lamp all measurements and test lamp connections are in the
switch ON signal circuit to the body control module correct terminal location and do not come in contact
(BCM). The BCM responds by applying voltage to the with each other during testing.
park Iamps, tail lamps, and license Iamps control
circuits illuminating the park, tail, and license Iamps. Reference Information
Schematic Reference
Exterior Lights Schematics on page 4-85

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Connector End View Reference
Component Connector End Views on page 11-269
Description and Operation
Exterior Lighting Systems Description and Operation
on page 4—217
Electrical Information Reference
Circuit Testing on page 11-526
Connector Repairs on page 11-548
Testing for IntermittentConditions and Poor
Connections on page 11—531
Wiring Repairs on page 11-537
Scan Tool Reference
Control Module References on page 6-3 for scan tool
information
CircuitlSystem Verification
1. Ignition ON.
2. Verify the scan tool Park Lamp Switch parameter
changes between Active and inactive while
commanding the park Iamps ON and OFF with the
headlamp switch.
If the parameter does not change
Refer to Park Lamp Switch Malfunction.
If the parameter changes
. Verify the left park lamps turn ON and OFF when
commanding the Left Park Lamps ON and OFF
with a scan tool.
If the left park lamps do not turn ON and OFF
Refer to Park Lamps Malfunction.
if the left park lamps turn ON and OFF
Verify the right park lamps turn ON and OFF when
commanding the Right Park Lamps ON and OFF
with a scan tool.
If the right park Iamps do not turn ON and OFF
Refer to Park Lamps Malfunction.
if the right park lamps turn ON and OFF
Verify the license plate lamps turn ON and OFF
when commanding the License Plate Lamps ON
and OFF with a scan tool.
If the license plate Iamps do not turn ON
and OFF
Refer to License Plate Lamps Malfunction.
U If the license plate lamps turn ON and OFF
6 All OK.
CircuitlSystem Testing
Park Lamp Switch Malfunction
1. lgnition OFF, all doors closed, all accessories OFF,
disconnect the harness connector at the
830 headlamp switch. Itmay take up to 2 minutes
for all vehicle systems to power down.
2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
Lighting 4=175
Test for less than 15 Q between the ground circuit
terminal 6 and ground.
If 15 Q or greater
2.1. ignition OFF.
2.2. Test for less than 2 Q in the ground Circuit end
to end.
=>lf 2 Q or greater, repair the open/high resistance
in the circuit.
=>Ifless than 2 Q, repair the open/high resistance
in the ground connection.
If less than 15 Q
LO
. IgnitionON.
Verify the scan tool Park Lamps Switch parameter
is Inactive.
If not Inactive
4.1. Ignition OFF, disconnect the X1 harness
connector at the K9 body control module.
4.2. Test for infinite resistance between the signal
circuit terminal 3 and ground.
=>If less than infinite resistance, repair the short to
ground on the circuit.
=>lf infinite resistance, replace the K9 body control
module.
If Inactive
Install a 3 A fused jumper wire between the signal
circuit terminal 3 and the ground circuit terminal 6.
Verify the scan tool Park Lamps Switch parameter
is Active.
If not Active
6.1. lgnition OFF, disconnect the X1 harness
connector at the K9 body control module,
ignition ON.
6.2. Test for less than 1 V between the signal
Circuit terminal 3 and ground.
=>lf1 V or greater, repair the short to voltage on
the circuit.
U Ifless than 1 V
6.3. Test for less than 2 Q in the signal circuit end
to end.
=>If2 Q or greater, repair the open/high resistance
in the Circuit.
=>if less than 2 Q, replace the K9 body control
module.
U If Active
7. Test or replace the S30 headlamp switch.
Park Lamps Malfunction
1. IgnitionOFF, exterior lamps OFF, trunk latch
latched, disconnect the harness connector at the
appropriate park lamp.
2. Test for less than 5 Q between the appropriate
ground circuit terminal listed below and ground.
- E4Npark/turn signal lamp —left terminal C
- E4P park/turnsignal lamp - right terminal C
o E5AAtail/stop lamp - left terminal 3
- E5AB taiI/stoplamp - right terminal 3
4=176 Lighting
- E2LR side marker lamp - left rear socket 2 if less than 1 V, replace the K9 body control
terminal module.
. E2RR side marker lamp - right rear socket U If the test lamp turns ON and OFF
terminal 5. Test or replace the appropriate park lamp.
2 if 5 Q or greater
License Plate Lamps Malfunction
2.1. lgnition OFF.
1. lgnition OFF, exterior Iamps OFF, trunk latch
2.2. Test for less than 2 Q in the ground circuit end latched, remove both E7 license plate lamp bulbs.
to end.
2. Test for less than 5 Q between each ground circuit
2 If2 Q or greater, repair the open/high resistance terminal1 and ground.
in the circuit.
2 If 5 Q or greater
2 if less than 2 Q, repair the open/high resistance
2.1. lgnition OFF.
in the ground connection.
2.2. Test for less than 2 Q in the ground circuit end
U if less than 5 Q to end.
3. Connect a test lamp between the appropriate
2 If2 Q or greater, repair the open/high resistance
control circuit terminal listed below and ground,
in the circuit. ,
ignition ON.
- E4N park/turnsignal lamp —left terminal A 2 if less than 2 Q, repair the open/high resistance
in the ground connection.
- E4P park/turnsignal lamp - right terminal A
U If less than 5 Q
o E5AA tail/stop lamp - left terminal 2
3. Connect a test lamp between the license plate
- E5AB tail/stop lamp - right terminal 2
lamp —left control circuit terminal 2 and ground,
- E2LR side marker lamp - left rear socket ignition ON.
terminal 4. Verify the test lamp turns ON and OFF when
- E2RR side marker lamp - right rear socket commanding the License Plate Lamps ON and
terminal OFF with a scan tool.
4. Verify the test lamp turns ON and OFF when 2 If the test lamp is always OFF
commanding the appropriate Park Lamps ON and
OFF with a scan tool. 4.1. IgnitionOFF, disconnect the X4 harness
connector at the K9 body contrOlmodule.
2 If the test lamp is always OFF
4.2. Test for infinite resistance between the control
41. Ignition OFF, disconnect the appropriate circuit and ground.
harness connector listed below at the K9 body
control module. 2 Ifless than infinite resistance, repair the short to
ground on the circuit.
'- x4
U if infinite resistance
- x5
4.3. Test for less than 2 Q in the control circuit end
42. Test for infinite resistance between the control to end.
circuit and ground.
2 If2 Q or greater, repair the open/high resistance
2 Ifless than infinite resistance, repair the short to in the circuit.
ground on the circuit.
2 if less than 2 Q, replace the K9 body control
U Ifinfinite resistance module.
4.3. Test for less than 2 Q in the control circuit end
2 If the test lamp is always ON
to end.
4.1. IgnitionOFF, disconnect the X4 harness
2 If2 Q or greater, repair the open/high resistance connector at the K9 body control module,
in the circuit. ignition ON.
2 Ifless than 2 Q, replace the K9 body control 4.2. Test for less than 1 V between the control
module. circuit terminal and ground.
2 If the test lamp is always ON 2 If 1 V or greater, repair the short to voltage on
4.1. Ignition OFF, disconnect the appropriate the circuit.
harness connector listed below at the K9 body 2 Ifless than 1 V, replace the K9 body control
control module, ignition ON. module.
- X4
U If the test lamp turns ON and OFF
~X5
5. Connect a test lamp between the license plate
4.2. Test for less than 1 V between the control lamp —right control circuit terminal 2 and ground,
circuit terminal and ground. ignition ON.
2 If 1 Vor greater, repair the short to voltage on
the circuit.

2013
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6. Verify the test lamp turns ON and OFF when
commanding the License Plate Lamps ON and
OFF with a scan tool.
2 If the test lamp is always OFF
6.1. lgnition OFF, disconnect the X4 harness
connector at the K9 body control module.
6.2. Test for infinite resistance between the control
circuit and ground.
2 Ifless than infinite resistance, repair the short to
ground on the circuit.
U Ifinfinite resistance
6.3. Test for less than 2 Q in the control circuit end
to end.
2 If2 Q or greater, repair the open/high resistance
in the circuit.
2 Ifless than 2 Q, replace the K9 body control
module.
U If the test lamp turns ON and OFF
7. Test or replace the appropriate E7 license plate
lamp bulb.
Lighting 4-177
Repair Instructions
Perform the Diagnostic Repair Verification on
page 6—92after completing the repair.
' Headlamp Switch Replacement on page 4-187
- Tail Lamp Replacement (Hatchback) on
page 4—214or Tail Lamp Replacement (Sedan) on
page 4—21 3
- Parking and Turn Signal Lamp Bulb Replacement
on page 4-203
- Rear License Plate Lamp Bulb Replacement
(Sedan) on page 4—2110r Rear License Plate
Lamp Bulb Replacement (Hatchback) on
page 4-212
- Control Module References on page 6-3 for BCM
replacement, programming, and setup

Rear Compartment Lamp Malfunction

Diagnostic Instructions ,
- Perform the Diagnostic System Check - Vehicle
on page 6-66 prior to using this diagnostic
procedure.
' Review Strategy Based Diagnosis on page 6-58
for an overview of the diagnostic approach.
' Diagnostic Procedure Instructions on page 6-59
provides an overview of each diagnostic category.
Diagnostic Fault Information

Open/High Signal
Circuit Short to Ground Resistance Short to Voltage Performance
F8DA (BCM 4) Fuse B+ 1 1 — -
Rear CompartmentCourtesyLampControl 8257002 1 1 -
Rear CompartmentCourtesyLampGround —— 1 — —-
1. Rear CompartmentLampMalfunction

CircuitlSystem Description Reference Information

The body control module (BCM) applies battery voltage Schematic Reference
to the rear compartment courtesy lamp through the rear
compartment lamp control circuit. When the BCM InteriorLights Schematics on page 4-89
receives a rear compartment lid open input from the
Connector End View Reference
rear compartment lid latch, the BCM applies battery
voltage to the rear compartment lamp control circuit Component Connector End Views on page 11—269
illuminating the rear compartment courtesy lamp. Inthe
event that the rear compartment lamp were to remain Description and Operation
illuminated for more than 10 minutes with the ignition InteriorLighting Systems Description and Operation on
switch in the OFF position and no doors opened, the page 4-219
BCM will deactivate the rear compartment lamp control
circuit to prevent total battery discharge.

2013
-Sonic
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Manual
(5377994)
4-178 Lighting
Electrical Information Reference
Circuit Testing on page 11-526
Connector Repairs on page 11—548
Testing for IntermittentConditions and Poor
Connections on page 11-531
Wiring Repairs on page 11-537
Scan Tool Reference
Control Module References on page 6-3 for scan tool
information
CircuitlSystem Testing
1. lgnition OFF, exterior lamps OFF, trunk latch
latched, disconnect the harness connector at the
E88 Rear Compartment Courtesy Lamp.
Test for less than 5 Q between the ground circuit
terminal 2 and ground.
If 5 Q or greater
2.1. IgnitionOFF.
2.2. Test for less than 2 Q in the ground circuit end
to end.
2 If2 Q or greater, repair the open/high resistance
in the circuit.
2 If less than 2 Q, repair the open/high resistance
in the ground connection.
If less than 5 Q
. Connect a test lamp between the control circuit
terminal 1 and ground, ignition ON.
. Verify the test lamp turns ON and OFF when
commanding the Trunk Lamp ON and OFF with a
scan tool.
If the test lamp is always OFF
4.1. lgnition OFF, disconnect the X7 harness
connector at the K9 Body Control Module.
4.2. Test for infinite resistance between the control
circuit and ground.
2 Ifless than infinite resistance, repair the short to
ground on the circuit.
U lf infinite resistance
4.3. Test for less than 2 Q in the control circuit end
to end.
2 If2 Q or greater, repair the open/high resistance
in the circuit.
2 Ifless than 2 Q, replace the K9 Body Control
Module.
If the test lamp is always ON
4.1. IgnitionOFF, disconnect the X7 harness
connector at the K9 Body Control Module,
ignition ON.
4.2. Test for less than 1 V between the control
circuit terminal and ground.
2 If 1 V or greater, repair the short to voltage on
the circuit.
2 Ifless than 1 V, replace the K9 Body Control
Module.
If the test lamp turns ON and OFF
Test or replace the E88 Rear Compartment
Courtesy Lamp.
Repair Instructions
Perform the Diagnostic Repair Verification on
page 6—92after completing the repair.
Rear Compartment Courtesy Lamp Replacement
(Hatchback) on page 4-216 or Rear Compartment
Courtesy Lamp Replacement (Sedan) on
page 4-217
Control Module References on page 6—3for BCM
replacement, programming, and setup

Stop Lamps Malfunction

Diagnostic Instructions
Perform the Diagnostic System Check —Vehicle
on page 6—66prior to using this diagnostic
procedure.
Review Strategy Based Diagnosis on page 6-58
for an overview of the diagnostic approach.
Diagnostic Procedure Instructions on page 6—59
provides an overview of each diagnostic category.

Diagnostic Fault Information

Opeanigh Signal
Circuit Short to Ground Resistance Short to Voltage Performance
8387301, 8387301,
8387304, 8387304, -
F5DA (BCM 1)Fuse 8+ 8388301, 8388301, — -
8388304, 8388304,
0029701 0029701
F7DA (BCM 3) Fuse 8+ 1,3 1,3 -— —-

—
2013 (US/Canada)
Sonic (5377994)
Manual
Service
 Lighting 4-179

Open/High Signal
Circuit Short to Ground Resistance Short to Voltage Performance
F8DA(BCM 4)Fuse 8+ 1,3 1,3 —- -
0027706, 0027706, CO27707,
BrakePedal PositionSensor5V Reference 0089003, 00161 71, 0089007, —-
0016171 CO1615A C016171
0027706 0027706, CO27707,
BrakePedal PositionSensorSignal UO14O71‘ C016171, C089007, 0027709
C01615A 0016171
CenterHighMountedStopLampControl 8388402 2 2 —-
RearTail/StopLampControl~Left 8388102 8388104 8388101 —-
RearTail/StopLampControl—Right 8388202 8388204 8388201 -
.. 0027707,
0016171 UO151
UO18400,
00 -
BrakePedal PosmonSensor LowReference ——
CenterHighMountedStopLampGround — 2 — -
RearTail/StopLampGround—Left — 1 — -
RearTail/StopLampGround—Right — 1 — —-
1.Stop LampsMalfunction
2. CenterHighMountedStop LampMalfunction
3.TurnSignalLampsand/orIndicatorsMalfunction

CircuitlSystem Description ' Testing for IntermittentConditions and Poor

The brake pedal position (BPP) sensor is used to sense
the action of the driver application of the brake pedal.
The BPP sensor provides an analog voltage signal that
will increase as the brake pedal is applied. The body
control module (BCM) provides a low reference signal
and a 5-volt reference voltage to the BPP sensor. When
the variable signal reaches a voltage threshold .
indicating the brakes have been applied, the BCM will
apply battery voltage to the left and right stop lamp
control circuits as well as the center high mounted stop
lamp (CHMSL) control circuit illuminating the left and
right stop lamps and the CHMSL.
Diagnostic Aids
When testing at the stop lamp bulb socket, make sure
all measurements and test lamp connections are in the
correct terminal location and do not come in contact
with each other during testing.
Reference Information
Schematic Reference
Exterior Lights Schematics on page 4-85
Connector End View Reference
Component Connector End Views on page 11-269
Description and Operation
Exterior Lighting Systems Description and Operation
on page 4-217
Electrical Information Reference
' Circuit Testing on page 11-526
- Connector Repairs on page 11-548
Connections on page 11-531.
- Wiring Repairs on page 11—537
Scan Tool Reference
Control Module References on page 6-3 for scan tool
information
CircuitlSystem Verification
1. lgnition ON.
2. Verify the scan tool Brake Lamps Command
parameter changes between Active and Inactive
while pressing and releasing the brake pedal.
2 if the parameter does not change
Referto Brake Pedal Position Sensor
Malfunction.
U If the parameter changes
3. Verify the left brake lamp turns ON and OFF when
commanding the Left Rear Brake/Park Lamp ON
and OFF with a scan tool.
2 If the left brake lamp does not turn ON and OFF
Refer to Stop Lamps Malfunction.
<2 If the left brake lamp turns 0N and OFF
4. Verify the right brake lamp turns ON and OFF
when commanding the Right Rear Brake/Park
Lamp ON and OFF with a scan tool.
2 If the right brake lamp does not turn ON
and OFF
Refer to Stop Lamps Malfunction.
U If the right brake lamp turns ON and OFF

—
2013 (US/Canada)
Sonic (5377994)
Manual
Service
4480 Lighting
5. Verify the center high mounted stop lamp turns ON
and OFF when commanding the Center Brake
Lamp ON and OFF with a scan tool.
2 If the center high mounted stop does not turn
ON and OFF
Refer to Center High Mount Stop Lamp
Malfunction.
U If the center high mounted stop turns ON
and OFF
6. All OK.
CircuitlSystem Testing
Brake Pedal Position Sensor Malfunction
1. Ignition OFF, disconnect the harness connector at
the B22 brake pedal position sensor, ignition ON.
2. Test for less than 1 V between the appropriate low
reference circuit terminal listed below and ground.
- Terminal 2 —with MH9
- Terminal A —without MH9
2 If 1 Vor greater
2.1. Ignition OFF, disconnect the X1 harness
connector at the K9 body control module,
ignition ON.
2.2. Test for less than 1 V between the low
reference circuit and ground.
2 lf1 V or greater, repair the short to voltage on
the circuit.
2 If less than 1 V, replace the K9 body control
module.
U If less than 1 V
3. Test or replace the 822 brake pedal position
senson
Stop Lamps Malfunction
1. ignition OFF, exterior lamps OFF, trunk latch
latched, remove the appropriate E5Atail/stop
Center High Mount Stop Lamp Malfunction
lamp bulb.
2. Test for less than 5 Q between the ground circuit at
the socket terminal and ground.
2 If 5 Q or greater
2.1. ignition OFF.
2.2. Test for less than 2 Q in the ground circuit end
to end.
2 If2 Q or greater, repair the open/high resistance
in the circuit.
2 if less than 2 Q, repair the open/high resistance
in the ground connection.
U If less than 5 Q
3. Connect a test lamp between the control circuit at
the socket terminal and ground, ignition ON.
4. Verify the test lamp turns ON and OFF when
commanding the appropriate Rear Brake/Park I
Lamp ON and OFF with a scan tool.
If the test lamp is always OFF l
4.1. IgnitionOFF, disconnect the appropriate l
harness connector listed below at the K9 body
control module.
- X4 left stop lamp
- X5 right stop lamp
4.2. Test for infinite resistance between the control
circuit and ground.
2 Ifless than infinite resistance, repair the short to
ground on the circuit.
U Ifinfinite resistance
4.3. Test for less than 2 Q in the control circuit end
to end.
2 If2 Q or greater, repair the open/high resistance
in the circuit.
2 Ifless than 2 Q, replace the K9 body control
module.
If the test lamp is always ON
4.1. IgnitionOFF, disconnect the appropriate
harness connector listed below at the K9 body
controi module, ignition ON.
- X4|eft stoplamp
- X5rightstoplamp
4.1. Test for less than 1 V between the control
Circuitterminal and ground.
2 If 1 V or greater, repair the short to voltage on
the circuit.
2 Ifless than 1 V, replace the K9 body control
module.
U If the test lamp turns ON and OFF
5. Test or replace the appropriate E5A tail/stop lamp.
1. lgnition OFF, exterior lamps OFF, trunk latch
latched, disconnect the harness connector at the
E6 center high mounted stop lamp.
. Test for less than 5 Q between the ground circuit
terminal 8 and ground.
If 5 Q or greater
2.1. IgnitionOFF.
2.2. Test for less than 2 Q in the ground circuit and
to end.
2 If2 Q or greater, repair the open/high resistance
in the circuit.
2 Ifless than 2 Q, repair the open/high resistance
in the ground connection.
If less than 5 Q
. Connect a test lamp between the control circuit .
terminal A and ground, ignition ON.

2013
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(5377994) 1

4. Verify the test lamp turns ON and OFF when
commanding the Center Brake Lamp ON and OFF
with a scan tool.
2 If the test lamp is always OFF
4.1. lgnition OFF, disconnect the X4 harness
connector at the K9 body control module.
4.2. Test for infinite resistance between the control
circuit and ground.
2 Ifless than infinite resistance, repairthe short to
ground on the circuit.
U lf infinite resistance
4.3. Test for less than 2 Q in the control circuit end
to end.
2 If2 Q or greater, repair the open/high resistance
in the circuit.
2 Ifless than 2 Q, replace the K9 body control
module.
2 If the test lamp is always ON
4.1. lgnition OFF, disconnect the X4 harness
connector at the K9 body control module,
ignition ON.
4.2. Test for less than 1 V between the control
circuit terminal and ground.
2 lf1 Vor greater, repair the short to voltage on
the circuit.
Lighting 44181
2 If less than 1 V, replace the K9 body control
module.
U If the test lamp turns ON and OFF
5. Test or replace the E6 center high mounted
stop lamp.
Repair Instructions
Perform the Diagnostic Repair Verification on
page 6-92 after completing the repair.
~ High Mount Stop Lamp Replacement (Hatchback)
on page 4-205 or High Mount Stop Lamp
Replacement (Sedan) on page 4-204
- Brake Pedal Position Sensor Calibration on
page 4-185
o Brake Pedal Position Sensor Replacement on
page 4-186
- Stop and Turn Signal Lamp Bulb Replacement
(Sedan) on page 4-215
- Control Module References on page 6-3 for BCM
replacement, programming, and setup

Turn Signal Lamps and/or Indicators Malfunction

Diagnostic Instructions
' Perform the Diagnostic System Check - Vehicle
on page 6-66 prior to using this diagnostic
procedure.
- Review Strategy Based Diagnosis on page 6—58
for an overview of the diagnostic approach.
- Diagnostic Procedure Instructions on page 6—59
provides an overview of each diagnostic category.
Diagnostic Fault Information

Opeanigh Signal
Circuit Short to Ground Resistance Short to Voltage Performance
F7DA (BCM 3)Fuse 8+ 1 1 — —-
F8DA (BCM 4)Fuse 8+ 1 1 —— -
F10DA (BCM6)Fuse 8+ 1 1 — —-
F11DA(BCM 7)Fuse 8+ 1 1 —— —-
TurnSignalSwitchSignal—Left 2 2 2 -
TurnSignalSwitchSignal—Right 2 2 2 ~-
. - 8394801,
TurnSignalControl—LeftFront 8394802 8394804 8394804 ~-
. 8395001,
TurnSIgnalControl—LeftRear 8395002 8395004 3395004 -
. . 8394901,
TurnSIgnalControl—RIghtFront 8394902 8394904 8394904 -
. . 8395101,
TurnSIgnalControi—RIghtRear 8395102 8395104 8395104 —-

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4-182 Lighting

Open/High Signal
Circuit Short to Ground Resistance Short to Voltage Performance
. 8394801,
8394804 — -
TurnSignalLampGround—LeftFront —
. . 8394901,
8394904 — —-
TurnSIgnalLampGround—RIghtFront —
. 8395001,
8395004 — --
TurnSIgnalLampGround—LeftRear —
. . 8395101,
8395104 — -
TurnSIgnaILampGround—RIghtRear —
SwitchGround
TurnSignal/Muitifunction — 2 — -
1.TurnSignalLampsand/orIndicatorsMalfunction
SwitchMalfunction
2. TurnSignal/Multifunction

CircuitlSystem Description CircuitlSystem Verification

Ground is applied at all times to the turn signal/
multifunction switch. The turn signal Iamps may only be
activated with the ignition switch in the ON or START
positions. When the turn signal/multifunction switch is
placed in either the turn right or turn left position,
ground is applied to the body control module (BCM)
through either the right turn or left turn signal switch
signal circuit. The BCM responds to the turn signal
switch input by applying a pulsating voltage to the front
and rear turn signal lamps through there respective
control circuits. When a turn signal request is received
by the BCM, a serial data message is sent to the
instrument cluster requesting the respective turn signal
indicator be pulsed ON and OFF.
Diagnostic Aids
When testing at the turn signal lamp bulb socket, make
sure all measurements and test lamp connections are
in the correct terminal location and do not come in
contact with each other during testing.
Reference Information
Schematic Reference
- Exterior Lights Schematics on page 4—85
- Body Control System Schematics on page 11-8
Connector End View Reference
Component Connector End Views on page 11-269
Description and Operation
Exterior Lighting Systems Description and Operation
on page 4-217
Electrical Information Reference
. Circuit Testing on page 11-526
- Connector Repairs on page 11—548
. Testing for IntermittentConditions and Poor
Connections on page 11-531
- Wiring Repairs on page 11—537
Scan Tool Reference
Control Module References on page 6—3for scan tool
information
1. lgnition ON.
2. Verify the scan tool Right Turn Signal Switch and
Left Turn Signal Switch parameters change
between Active and Inactive while cycling the turn
signal switch between the right and left positions.
2 If the parameters do not change
Refer to Turn Signal/Multifunction Switch
Malfunction.
U If the parameters change
3. Verify the left front turn signal lamps turn ON and
OFF while commanding the Left Front Turn Signal
Lamp ON and OFF with a scan tool.
2 If the left front turn signal lamps do not turn ON
and OFF
Refer to Turn Signal Lamps Malfunction.
U If the left front turn signal lamps turn 0N
and OFF
4. Verify the right front turn signal Iamps turn ON and
OFF while commanding the Right Front Turn
Signal Lamp ON and OFF with a scan tool.
2 If the right front turn signal lamps do not turn
ON and OFF
Refer to Turn Signal Lamps Malfunction.
U If the right front turn signal lamps turn 0N
and OFF
5. Verify the left rear turn signal Iamps turn ON and
OFF while commanding the Left Rear Turn Signal
Lamp ON and OFF with a scan tool.
2 If the left rear turn signal lamps do not turn 0N
and OFF
Refer to Turn Signal Lamps Malfunction.
U If the left rear turn signal lamps turn ON
and OFF
6. Verify the right rear turn signal lamps turn ‘ON and
OFF while commanding the Right RearTurn Signal
Lamp ON and OFF with a scan tool.
2 If the right rear turn signal lamps do not turn
ON and OFF
Refer to Turn Signal Lamps Malfunction.
U If the right rear turn signal lamps turn ON
and OFF

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7. Verify the left and right turn signal indicators turn
ON and OFF while commanding the All Indicators
Test ON and OFF with a scan tool.
2) If the left or right turn signal indictors do not
turn ON and OFF
Refer to Turn Signal indicators Malfunction.
U If the left and right turn signal indictors turn 0N
and OFF
8. Ail OK.
CircuitlSystem Testing
Turn Signal/Multifunction Switch Malfunction
1. IgnitionOFF, scan tool disconnected, ail doors
closed, all accessories OFF, disconnect the
harness connector at the 878 turn signal/
multifunctionswitch. It may take up to 2 minutes for
all vehicle systems to power down.
. Test for less than 15 Q between the ground circuit
terminal 3 and ground.
If 15 Q or greater
2.1. ignition OFF.
2.2. Test for less than 2 Q in the ground circuit end
to end.
2 If2 Q or greater, repair the open/high resistance
in the circuit.
2 Ifless than 2 Q, repair the open/high resistance
in the ground connection.
If less than 15 Q
9° IgnitionON.
Verify the scan tool Left Turn Signal Switch
parameter is Inactive.
If not Inactive
4.1. lgnition OFF, disconnect the X3 harness
connector at the K9 body control module.
4.2. Test for infinite resistance between the signal
circuit terminal 1 and ground.
2 if less than infinite resistance, repair the short to
ground on the circuit.
2 If infinite resistance, replace the K9 body control
module.
If Inactive
Install a 3 A fused jumper wire between the signal
circuit terminal 1 and the ground circuit terminal 3.
Verify the scan tool Left Turn Signal Switch
parameter is Active.
If not Active
6.1. ignition OFF, disconnect the X3 harness
connector at the K9 body control module,
ignition ON.
6.2. Test for less than 1V between the signal
circuit terminal 1 and ground.
2 If 1 V or greater, repair the short to voitage on
the Circuit.
U Ifless than 1 V
I -Sonic
2013 (US/Canada) (5377994)
Manual
Service
Lighting 4-183
6.3. Test for less than 2 Q in the signal circuit end
to end.
2 If2 Q or greater, repair the open/high resistance
in the circuit.
2 If less than 2 Q, replace the K9 body control
module.
If Active
. Verify the scan tool Right Turn Signal Switch
parameter is Inactive.
If not inactive
7.1. lgnition OFF, disconnect the X3 harness
connector at the K9 body control module.
7.2. Test for infinite resistance between the signal
circuit terminal 7 and ground.
2 If less than infinite resistance, repair the short to
ground on the circuit.
2 If infinite resistance, replace the K9 body control
module.
If Inactive
Install a 3 A fused jumper wire between the signal
circuit terminal 7 and the ground circuit terminal 3.
. Verify the scan tool Right Turn Signal Switch
parameter is Active.
If not Active
9.1. IgnitionOFF, disconnect the X3 harness
connector at the K9 body control module,
ignition ON.
9.2. Test for less than 1 V between the signal
circuit terminal 7 and ground.
2 If 1 V or greater, repair the short to voltage on
the circuit.
U Ifless than 1 V
9.3. Test for less than 2 Q in the signal circuit end
to end.
2 If2 Q or greater, repair the open/high resistance
in the circuit.
2 If less than 2 Q, replace the K9 body control
module.
U If Active
10. Test or replace the 878 turn signal/multifunction
switch.
Turn Signal Lamps Malfunction
1. IgnitionOFF, disconnect the X1 harness connector
at the K9 body control module, ignition ON.
2. Verify a test lamp illuminates between the 8+
circuit terminal 2 and ground.
2 If the test lamp does not illuminate and the
circuit fuse is good _
2.1. Test for less than 2 Q in the 8+ circuit end
to end.
2 If2 Q or greater, repair the open/high resistance
in the circuit.
4:184 Ligfihting
2 Ifless than 2 Q, verify the fuse is not open and
there is voltage at the fuse.
if the test lamp does not illuminate and the
circuit fuse is open
2.1. Test for infinite resistance between the 8+
circuit and ground.
2 Ifless than infinite resistance, repair the short to
ground on the circuit.
2 if infinite resistance, replace the K9 body control
module.
If the test lamp illuminates
Verify a test lamp illuminates between the 8+
circuit terminal 3 and ground.
If the test lamp does not illuminate and the
circuit fuse is good
3.1. Test for less than 2 Q in the 8+ circuit end
to end.
2 if 2 Q or greater, repair the open/high resistance
in the circuit.
2 If less than 2 Q, verify the fuse is not open and
there is voltage at the fuse.
if the test lamp does not illuminate and the
circuit fuse is open
3.1. Test for infinite resistance between the 8+
circuit and ground.
2 if less than infinite resistance, repairthe short to
ground on the circuit.
2 If infinite resistance, replace the K9 body control
module.
<2 If the test lamp illuminates
IgnitionOFF, connect the X1 harness connector at
the K9 body control module.
Disconnect the X5 harness connector at the
K9 body control module, ignition ON.
. Verify a test lamp illuminates between the 8+
circuit terminal 3 and ground.
If the test lamp does not illuminate and the
circuit fuse is good
6.1. Test for less than 2 Q in the 8+ circuit end
to end.
2 If2 Q or greater, repair the open/high resistance
in the circuit.
2 Ifless than 2 Q, verify the fuse is not open and
there is voltage at the fuse.
If the test lamp does not illuminate and the
circuit fuse is open
6.1. Test for infinite resistance between the 8+
circuit and ground.
2 Ifless than infinite resistance, repair the short to
ground on the circuit.
2 If infinite resistance, replace the K9 body control
module.
If the test lamp illuminates
. Verify a test lamp illuminates between the 8+
circuit terminal 4 and ground.
If the test lamp does not illuminate and the
circuit fuse is good
7.1. Test for less than 2 Q in the 8+ circuit end
to end.
2 If2 Q or greater, repair the open/high resistance
in the circuit.
2 Ifless than 2 Q, verify the fuse is not open and
there is voltage at the fuse.
If the test lamp does not illuminate and the
circuit fuse is open
7.1. Test for infinite resistance between the 8+
circuit and ground.
2 Ifless than infinite resistance, repair the short to
ground on the circuit.
2 If infinite resistance, replace the K9 body control
module.
c if the test lamp illuminates
Ignition OFF, connect the X5 harness connector at
the K9 body control module.
lgnition OFF, exterior lamps OFF, trunk latch
latched, disconnect the harness connector at the
appropriate E4 turn signal lamp.
10. Test for less than 5 Q between the appropriate
ground circuit terminal listed below and ground.
- E4N park/turnsignal lamp —left terminal C
- E4P park/turnsignal lamp —right terminal C
- E4LR turn signal lamp —left rear socket terminal
- E4RR turn signal lamp —right rear socket
terminal
If 5 Q or greater
10.1. IgnitionOFF.
10.2. Test for less than 2 Q in the ground circuit
end to end.
2 If2 Q or greater, repair the open/high resistance
in the circuit. ‘
2 if less than 2 Q, repair the open/high resistance
in the ground connection.
U If less than 5 Q
. Connect a test lamp between the appropriate
control circuit terminal listed below and ground.
° E4N park/turnsignal lamp —left terminal 8
o E4P park/turnsignal lamp —right terminal 8
. E4LR turn signal lamp —left rear socket terminal
° E4RR turn signal lamp —right rear socket
terminal
12. Verify the test lamp turns ON and OFF when
commanding the appropriate Turn Signal Lamp ON
and OFF with a scan tool.
If the test lamp is always OFF
12.1. lgnition OFF, disconnect the appropriate
harness connector listed below at the
K9 body control module.
- X5Ieftturn signals
- X4 right turn signals
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,Leflv.
{#M‘
. Lighting 4—185
12.2. Test for infinite resistance between the Repair Instructions
control circuit and ground.
2 Ifless than infinite resistance, repairthe short to
ground on the circuit. Brake Pedal Position Sensor
U Ifinfinite resistance Calibration
12.3. Test for less than 2 Q in the control circuit end
to end. Calibration Criteria
2 if 2 Q or greater, repair the open/high resistance Note: Do not apply the brake pedal during the brake
in the circuit. pedal position sensor calibration procedure. Any
2 Ifless than 2 Q, replace the K9 body control movement of the brake pedal during this procedure will
module. cause the calibration procedure to fail. Ifthis occurs,
the brake pedal position sensor calibration must be
2 If the test lamp is always ON repeated.
12.1. lgnition OFF, disconnect the appropriate
Brake pedal position sensor calibration must be
harness connector listed below at the
performed after the brake pedal position sensor or body
K9 body control module, ignition ON.
control module (BCM) have been serviced. The
- X5leftturn signals calibration procedure will set the brake pedal position
- X4 right turn signals sensor home value. This value is used by the BCM to
12.2. Test for less than 1 V between the control determine the action of the driver applying the brake
circuit terminal and ground. System and to provide this information to the vehicle
subsystems via serial data.
2 if 1 V or greater, repair the short to voltage on
the circuit. Calibration Procedure
2 Ifless than 1 V, replace the K9 body control 1. Appiy the parking brake.
module. ' 2. Place the transmission in the PARK position for
U If the test lamp turns ON and OFF automatic transmission or NEUTRAL position for
13. Test or replace the appropriate E4 turn signal lamp. manual transmission.
Install a scan tool.
Turn Signal indicators Malfunction
PS”Clear all BCM DTCs before proceeding.
1. lgnition ON.
5. Navigate to the Configuration/Reset Functions
2. Verify the left and right turn signal indicators turn menu of the BCM.
ON and OFF while commanding the All Indicators
Test ON and OFF with a scan tool. 6. Select the Brake Pedal Position Sensor Learn
procedure and follow the directions displayed on
2 if the left or right turn signal indictors are the screen.
always OFF or remain ON
Replace the P16 instrument cluster.
U If the left and right turn signal indictors turn ON
and OFF
3. Replace the K9 body control module.
Repair Instructions
Perform the Diagnostic Repair Verification on
page 6-92 after completing the repair.
- Parking and TurnSignal Lamp Bulb Replacement
on page 4-203
- Turn Signal Multifunction Switch Replacement on
page 15-31
- Stop and Turn Signal Lamp Bulb Replacement
(Sedan) on page 4—215
- Control Module References on page 6—3for BCM
or InstrumentCluster replacement, programming,
and setup

i 2013
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(5377994)
4-186 Lighting

Brake Pedal Position Sensor installation Procedure

Replacement

Removal Procedure
1. Remove the instrument panel lower trim pad cover.
Refer to Instrument Panel Lower TrimPad Cover
Replacement (WithoutAAL) on page 2-40 or
InstrumentPanel Lower TrimPad Cover
Replacement (WithAAL) on page 2-41.

2511817
Note: Ensure the fork of the brake pedal position
sensor is positioned over the brake pedal post.
1. Install the brake pedal position sensor to the brake
pedal bracket.
Caution: Refer to Fastener Caution on page 0—8.
2. Install the brake pedal position sensor bolt (1)and
2511817 tighten to 3 Wm (27 lb in).
3. Connect the brake pedal position sensor electrical
2. Disconnect the brake pedal position sensor connector.
electrical connector.
4. Calibrate the brake pedal position sensor. Refer to
.03Remove the brake pedal position sensor bolt (1). Brake Pedal Position Sensor Calibration on
4. Remove the brake pedal position sensor. page 4-185.
. Install the instrument panel Iowertrim pad cover.
Refer to InstrumentPanel Lower TrimPad Cover
Replacement (WithoutAAL) on page 2—40or
Instrument Panel Lower TrimPad Cover
Replacement (WithAAL) on page 2-41.

2013
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 Lighting 4-187

Headlamp Switch Replacement

71 111'

2496206
Headlamp Switch Replacement
Callout I Component Name
Preliminary Procedure
Removetheinstrumentpanellowertrimpadcover.Referto InstrumentPanel LowerTrimPad CoverReplacement(Without
AAL) onpage 2-40or InstrumentPanel LowerTrimPad CoverReplacement(WithAAL) onpage 2—41
HeadlampSwitch
1 Procedure
1. Gentlydepresstabsto removetheswitchassemblyfromtheinstrumentpanellowercover.
2. Disconnecttheelectricalconnector.

2013
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4-188 Lighting

Hazard Warning Switch Replacement

2496185

Hazard Warning Switch Replacement

Callout Corriponent Name
Preliminary Procedure
Removetheheaterandairconditioningcontrol.Referto HeaterandAir ConditioningControlReplacementonpage 10—79.
1 HazardWarningSwitchBolts(Qty:2)
Caution: Referto FastenerCautiononpage 0-8.
HazardWarningSwitch
2 Procedure
Disconnecttheelectricalconnector.

—
2013 (US/Canada)
Sonic (5377994)
Manual
Service
 Lighting 4489

Reading Lamp Replacement

2674480
Reading Lamp Replacement
Callout Component Name
Preliminary Procedure
Removethedomelampbezel.Referto DomeLampBezel Replacementonpage4-190.
Readinglamp
Procedures
1. Releasetheclips retainingthereadinglampassemblyto thebezel.
2. Disconnecttheelectricalconnections.

l 2013
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44190 Lighting

Dome Lamp Bezel Replacement

2674478

Dome Lamp Bezel Replacement

Callout Component Name
DomeLampBezelCover
1 Procedures
1. Graspthebezelcoverand pulldownwardto removefromthelampassembly.
2. Disconnecttheelectricalconnections,as necessary.
2 DomeLampBezel Fasteners(Qty:2)
Caution: Referto FastenerCautiononpage 0—8.
DomeLampBezel
3 Procedures
1. Pull assemblydownwardto remove.
2. Disconnecttheelectricalconnections.

—
2013 (US/Canada)
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Manual
Service
 Lighting 4-191

Windshield Header Courtesy Lamp Replacement

2674482
Windshield Header Courtesy Lamp Replacement
Callout Component Name
WindshieldHeaderCourtesyLamp
Procedures
1 1. Graspthecourtesylampassemblyandpulldownwardto releasetheretainerclipssecuringthecourtesy
lampassemblytotheheadliner.
2. Disconnecttheelectricalconnections.

2013
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Service
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(5377994)
4-192 Lightiflg

Dome Lamp Bulb Replacement

2496806

Dome Lamp Bulb Replacement

Callout I Component Name
Preliminary Procedure
Removethewindshieldheadercourtesyiamp.Referto WindshieldHeaderCourtesyLampReplacementonpage4-191
1 I DomeLampBulb

(US/Canada)
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2013 (5377994)
Manual
Service
 Lighting 42193

Headlamp Replacement

ti” 71 05.252/
I / 2‘ |
/I
‘\\ TELQII=§_——I A4,:
. '14.?
\‘7:

2472837
Headlamp Replacement
Callout Component Name
Preliminary Procedure
Removethefrontbumperfascia.Referto FrontBumperFascia Replacementonpage3—55.
HeadlampAssemblyScrew(Qty:4)
Caution: Referto FastenerCautiononpage 0-8.
Tighten
2.5Nvm(22lb in)
HeadlampAssembly
Procedure
1. Disconnecttheelectricalconnectorbulbharnessandremovethe headlampassembly.
2. Aimthe headlampsafterreplacement.Referto HeadlampAimingonpage4-196.

2013
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4-194 Lyme;
Headlamp Bulb Replacement

2472839

Headlamp Bulb Replacement

Callout Component Name
Preliminary Procedure
Openand supportthe hoodassembly.
1 AccessoryBulb Cover(Qty:2)
Warning: Refer to Halogen Bulb Warningon page 0-5.
HeadlampBulb(LowBeam)
Procedure
1. Disconnecttheelectricalconnectorfromthebulbsocket.
2. Rotatethebulbsocketand removefromtheheadlamphousing.
HeadlampBulb(HighBeam)
Procedure
1. Disconnecttheelectricalconnectorfromthebulbsocket.
2. Rotatethebulbsocketa quarterturnand removefromtheheadlamphousing.

(US/Canada)
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2013 (5377994)
Manual
Service
 Lighting 4495

Headlamp Housing Bracket Replacement

2495856

Headlamp Housing Bracket Replacement

Callout Component Name
Preliminary Procedure
Removethefrontbumperfascia.Referto FrontBumperFascia Replacementonpage3—55.
HeadlampHousingBracketScrew(Qty:2)
Caution: Referto FastenerCautiononpage0-8.
Tighten
2.5N-m(22lb in)
HeadlampHousingBracket
2 Procedure
Releasethetabsonthehousingbracketfromthefrontbumperfasciaandremove.

2013
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4496 LighthS

Headlamp Bracket Replacement

2563259

Headlamp Bracket Replacement

Callout Component Name
Preliminary Procedure
Removethefrontbumperfascia.Referto FrontBumperFascia Replacementonpage3-55.
HeadlampBracketScrew(Qty:4)
Caution: Referto FastenerCautiononpage 0-8.
Tighten
2.5N-m(22lb in)
2 HeadlampBracket

HeadIamp Aiming The screen will be 1.52 m (5 ft) high x 3.66 m

Visual Aiming Preparation Procedure
Note: Some state and local laws specify requirements
for headlamp aim. Comply with all of these laws when
performing any headlamp aiming operations.
Headlamp aim should be Checked:
- When a new headlamp capsule is installed.
- Ifservice or repairs to the front end area have,
or may have, disturbed the headlamps or their
mounting.
The aiming screen should meet the following criteria:
- The area will consist of a level surface large
enough to allow for a vehicle and an additional
7.62 m (25ft) measured from face of lamps to the
front of the aiming screen.
(12 ft)wide with a matte white surface well
shaded from extraneous light, and properly
adjusted to the floor on which the vehicle stands.
Provisions should be made to align the aiming
screen parallel with the vehicle.
The screen shall be provided with a fixed vertical
centerline, two laterally adjustable vertical tapes,
and one vertically adjustable horizontal tape.
Ifa regular commercial aiming screen is not
available, the screen may consist of a vertical wall
having a clear uninterruptedarea approximately
1.83 m (6 ft) high and 3.66 m (121t)wide. The
surface should be finished with a washable
non—glosswhite paint.

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Manual
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280087
- After the aiming screen has been set up in a
permanent location, paint a reference line on the
floor directly under the lens of the lamps to
indicate the proper location of the headlamps
when they are being aimed:
—Distance between headlamps (1)
—Center line of screen (2)
—Adjustable vertical pointer (3)
—Adjustable horizontal tape (4)
—Diagram of light screen (5)
—Vertical center line ahead of right headlamp
pointer position (6)
—7.62 m (25 ft)(7)
—Car axis (8)
—-Adjustable vertical pointer
—Horizontal center line of lamps
—Vertical center line ahead of left headlamp
Prior to aiming the headlamps, the following steps must
be taken:
1. Remove any snow, ice or mud from the vehicle.
2. The vehicle must have a full tank of gas.
3. Stop all other work on the vehicle.
I 2013
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Lighting 4-197
. Ifany service has been performed on the vehicle,
make sure that all of the components are back in
their original place.
The vehicle must be on a level surface.
2505631
The vehicle left tires must be aligned with the
reference line extending from the screen with the
headlamps aligned with the reference line.
Do not load any cargo in the vehicle.
The vehicle must contain approximately 75 kg
(165 lb) on the driver seat.
Inflatethe tires to the proper pressure.
Simulate the vehicle loads if the intended use of
the vehicle is for hauling heavy loads or towing a
trailer.
11. Rock the vehicle in order to stabilize the
suspension.
12. Turn on the headlamps to low beam and observe
the left and the top edges of the high intensity zone
on the screen. The edges of the high intensity zone
should fall within the specifications.
4498 Lighting

Headlamp Aiming Procedure

1. Open the hood.

I6 ©

|<—7.6m(25fi)——>

476831
Note: DO NOT cover the headlamp. This may cause
excessive heat build up.
413400 8. Turn ON the low beam headlamps. Block the light
from projecting onto the screen from the passenger
2. Measure from the floorto the center of the side headlamp.
headlamp bulb. Some headlamps have an aim dot
marked on the headlamp lens. -
3. At the screen, measure from the floor and place
the horizontai tape at the measured distance.
4. Measure from the reference line on the floor to the
left headlamp bulb centerline.
5. At the screen, measure from the reference line and
place the vertical tape at the measured distance.
6. Measure from the reference line on the floor to the
right headlamp bulb centerline.
7. At the screen, measure from the reference line and
place the vertical tape at the measured distance.

2506058
9. Adjust the vertical aim screw ( as shown by the
arrow ) of the headlamps to the specifications
required by the state and the local authorities, or as
shown in step number 8.
10. Repeat the aiming procedure for the passenger
side headlamp while blocking the light from
projecting onto the screen from the driver side
headlamp.
11. Turn the headlamps OFF.
12. Close the hood.

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-Sonic
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Manual
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 Lighting 4499

Front Fog Lamp Replacement

\ ’d 1"-
I
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a,4
‘lIl'dll'
.
./ "l;

'I / .1
I E7
N

2 1

2497952
Front Fog Lamp Replacement
Callout Component Name
Preliminary Procedure
1. Removeeithertherightfrontor leftfrontwheelhouseliner.Referto FrontWheelhouseLinerReplacement(Rear)on
page3—151 or FrontWheelhouseLinerReplacement(Front)onpage3-150.
2. Disconnecttheelectricalconnectorfromthefoglampbulbsocket.
FrontFogLampScrew(Qty:3)
1 Caution: RefertoFastenerCautiononpage 0-8.
Removethethreefog lampmountingscrewsfromthefrontbumperfascia.
FrontFogLamp
2 Procedure
Aimthefrontfoglampsafterreplacement.Referto Fog LampAimingonpage4-202.

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4:200 Lgfling

Front Fog Lamp Bulb Replacement

2497963

Front Fog Lamp Bulb Replacement

Callout Component Name
Preliminary Procedure
1. Removeeitherthe leftfrontor rightfrontwheelhouseliner.Referto FrontWheelhouseLinerReplacement(Rear)on
page3-151or FrontWheelhouseLinerReplacement(Front)onpage3-150.
2. Disconnectthe electricalconnectorto thefoglampbulb.
FrontFog LampBulb
Warning: Refer to HalogenBulb Warningon page 0-5.
Procedure
and removefromthefoglamphousing.
Turnthefog lampbulbsocketcounter-clockwise

(US/Canada)
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2013 (5377994)
Manual
Service
 Lighting 44.201

Front Fog Lamp Cover Replacement (Without T3U)

”@QQQQ

2472866

Front Fog Lamp Cover Replacement (Without T3U)

Callout I Component Name
Preliminary Procedure
Removethefrontwheelhouseliner.Referto FrontWheelhouseLinerReplacement(Rear)onpage3-151or FrontWheelhouse
LinerReplacement(Front)onpage3-150.
FrontFog LampFrontCover
1 Procedure
Releasethetabssecuringthefrontfoglampfrontcovertothefrontbumperfasciaandremove.

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4:202 Lighting

Fog Lamp Aiming . Measure from the center of the fog lamp to the
ground line. Using this measurement, mark the
Preparation Procedure horizontal centerline (2) of the fog lamp on the
target screen directly in front of the vehicle.
Note: Horizontal aim is not adjustable on this vehicle.
Vertical aim is done by an adjusting nut located on the . Turn ON the fog lamps. The top of the fog lamp
rear of the fog lamp. Prior to aiming the fog lamps, beam image (4) on the target screen should be
perform the following steps: 102 mm (4 in) below the center of the fog lamp lens
height.
1. Completely assemble all of the components on the
vehicle.
2. Place the vehicle on a level surface.
3. Stop all unnecessary operations or work that could
affect the ride height of the vehicle.
Close the doors and verify that the luggage
compartment is empty.
. Stabilize the suspension by rocking the vehicle
sideways.
Ensure that the fuel level is full.
. Ensure that the tires are inflated to the proper
pressure.
. Ensure that the driver or a similar weight,
approximately 75 kg (165 lb), is in the vehicle
driver seat.
Aiming Procedure

2502532
4. Adjust the fog lamp as required using the adjusting
screw above the projector lens on the outside of
the front bumper fascia.
5. Turn OFF the fog lamps.

276650
1. Park the vehicle 7.6 m (25ft) awayfrom the target
screen.

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Manual
Service
 Lightifi) 4-203

Parking and Turn Signal Lamp Bulb Replacement

2472842
Parking and Turn Signal Lamp Bulb Replacement
Callout Component Name
Preliminary Procedures
1. Openandsupportthehoodassembly.
2. Repositiontheair cleanerinletducton thepassengersideoftheenginecompartment.
3. Removethelowbeamaccessorybulbcoverin ordertoaccess thefrontparkingandturnsignallampbulbsocket.
ParkingandTurnSignalLampBulbSocket
1 Procedure
Rotatethebulbsocketcounter-clockwise andremovefromtheheadlamphousing.
ParkingandTurnSignalLampBulb
2 Procedure
Push inwardandrotatetheparkingandturnsignalbulbcounter-clockwisein orderto remove.

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4.204 Lighting

High Mount Stop Lamp Replacement (Sedan)

/-:'.'L
I/---h
r'm--=---

2472847

High Mount Stop Lamp Replacement (Sedan)

Callout Component Name
Preliminary Procedure
1. Removetherearwindowpaneltrim.Referto Rear WindowPanel TrimReplacementonpage 2—81.
2. Place therearwindowpaneltrimface downon a clean protectedsurfaceto access andremovethehighmountstop lamp
screws.
HighMountStopLampScrew (Qty:2)
1
Caution: RefertoFastenerCautiononpage 0-8.
HighMountStopLamp
Tip: The highmountstoplampis (LED)LightEmittingDiodeandis servicedas an assembly.

(US/Canada)
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2013 (5377994)
Manual
Service
 Lighting 4205

High Mount Stop Lamp Replacement (Hatchback)

2498830
High Mount Stop Lamp Replacement (Hatchback)
Callout Component Name
Preliminary Procedure
Openandsupporttheliftgateassembly.
HighMountStop LampBolt(Qty:2)
Caution: Referto FastenerCautiononpage 0-8.
Tighten
2.5Wm(22lb in)
HighMountStop LampCover
2 Procedure
Removethecoverandthefourscrewsfromthehighmountstoplamp.
HighMountStop LampAssembly
3 Procedure
Releasetheelectricalconnectorand(LED)LightEmittedDiodelampfromthecover.

2013
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(5377994)
4=206 Lighting

Cargo Center Courtesy Lamp Bulb Replacement (Hatchback)

2496812
Cargo Center Courtesy Lamp Bulb Replacement (Hatchback)
Callout Component Name
Rear CompartmentCourtesyLamp
1 RefertoRear CompartmentCourtesyLampReplacement(Hatchback)onpage4-216or Rear Compartment
CourtesyLampReplacement(Sedan)onpage4-217
2 CargoLampBulb

2013
-Sonic
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(5377994)
 Lighting 4207

Cargo Center Courtesy Lamp Bulb Replacement (Sedan)

2507472
Cargo Center Courtesy Lamp Bulb Replacement (Sedan)
Callout Component Name
Rear CompartmentCourtesyLamp
1 Referto Rear CompartmentCourtesyLampReplacement(Hatchback)onpage4-216or Rear Compartment
CourtesyLampReplacement(Sedan)onpage 4-217
2 Cargo LampBulb

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4=208 Lighting

Backup Lamp Bulb Replacement (Sedan)

2472854

Backup Lamp Bulb Replacement (Sedan)

Callout Component Name
Preliminary Procedure
Removethetaillampassembly.Referto TailLampReplacement(Hatchback)onpage 4-214or TailLampReplacement(Sedan)
onpage 4-213.
Back Up LampBulbSocket
1 Procedure
andremovefromthetaillamphousing.
Rotatethebackuplampbulbsocketcounter—clockwise
Back Up LampBulb
2 Procedure
on thebulbandremovefromthelampsocket.
Push inwardwhilerotatingcounter-clockwise

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Sonic (5377994)
Manual
Service
 Lighting 4-209

2489521
Rear License Plate Lamp Replacement (Hatchback)
Callout Component Name
Preliminary Procedure
1. Openandsupporttheliftgateassembly.
2. At theleftside ofthelamp,inserta smallflat—blade
intothelamphousingedgeandpushslightlysidewaysto disengagethe
lamphousingfromtherearapplique.
3. Pull androtatethehousingdownwardfarenoughto removeandaccess thelampsocketandelectricalharness.
Rear LicensePlateLampSocket
1 Procedure
Rotatethelampsocketcounter-clockwiseandremovefromthelamphousing.
2 Rear LicensePlateLamp

2013
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(5377994)
41-210 Lighting

Rear License Plate Lamp Replacement (Sedan)

2472846

Rear License Plate Lamp Replacement (Sedan)

Callout Component Name
Preliminary Procedure
atthearrowlocationatthelamphousingedge.
1. Inserta smallflat~blade
2. Push inwardslightlyandrotatedownward.
3. Pull thehousingdownfar enoughto access thelampsocketand electricalharness.
Rear LicensePlate LampSocket
1 Procedure
Rotatethelampsocketa quarterturnandremove.
2 Rear LicensePlate Lamp

(US/Canada)
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2013 (5377994)
Manual
Service
 Lighting 44211

Rear License Plate Lamp Bulb Replacement (Sedan)

2472844
Rear License Plate Lamp Bulb Replacement (Sedan)
Callout Component Name
Preliminary Procedure
Removetherearlicenseplatelamphousing.Referto Rear LicensePlateLampReplacement(Sedan)onpage4-210or Rear
License PlateLampReplacement(Hatchback)onpage4-209.
1 LicensePlate LampSocket
LicensePlate LampBulb
2
Tip: Pullthebulbstraightoutofthelampsocket.

2013
<Sonlc
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(5377994)
41-212 Lfiig‘nting

Rear License Plate Lamp Bulb Replacement (Hatchback)

2495867
Rear License Plate Lamp Bulb Replacement (Hatchback)
Callout I Component Name
Preliminary Procedure
Removetherearlicenseplatelamphousing.Referto Rear LicensePlateLampReplacement(Sedan)onpage4—210 or Rear
LicensePlate LampReplacement(Hatchback)onpage 4-209.
LicensePlateLampSocket
1 Procedure
andremovefromthelamphousing.
Rotatetheelectricallampsocketa quarterturncounter—clockwise
LicensePlateLampBulb
2 Procedure
Pull thebulbstraightoutoftheelectricallampsocket.

2013
-Sonic
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Manual
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 Lighting 4-213

Tail Lamp Replacement (Sedan)

2486673
Tail Lamp Replacement (Sedan)
Callout Component Name
Preliminary Procedure
Openandsecuretherearcompartmentlid.
TailLampBolt/Screw(Qty:2)
Caution: Referto FastenerCautiononpage 0-8.
Tighten
2.5N'm(22lb in)
TailLampElectricalHarness
2 Procedure
Removeall threetaiilampbulbsocketswithbulbs.
3 TailLamp

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4-214 Lighting

Tail Lamp Replacement (Hatchback)

2489525
Tail Lamp Replacement (Hatchback)
Callout Component Name
Preliminary Procedure
Openandsupporttheliftgateassembly.
TailLampBolt/Screw(Qty:2)
1 Caution: RefertoFastenerCautiononpage0-8.
Tighten
2.5N-m(221b in)
TailLampAssembly
Procedure
1. Holdbothsides ofthetaillampassemblyandgivea quickpullrearwardin ordertodisengagethetwo
2 locatorpinsfromthebodysideouterpanel.
2. Rotateall threebulbsocketsandremovefromthetaillamphousing,beingcarefulnotto damagethe
exposedbulbs.
3. Disengagethetaillampbulbelectricalharnessfromtheretainerclipson thetaillamphousing.

2013
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 Lighting 4215
Stop and Turn Signal Lamp Bulb Replacement (Sedan)

2538914
Stop and Turn Signal Lamp Bulb Replacement (Sedan)
Callout I - Component Name
Preliminary Procedure
Removethetaillampassembly.Referto TailLampReplacement(Hatchback)onpage 4-214or TailLampReplacement(Sedan)
onpage 4-213.
TailLampSocket
1 Procedure
Rotatethelampsocketcounter—clockwiseandremovethesocketfromthelamphousing.
ParkandStop LampBulb
2 Procedure
Push thebulbinwardwhilerotatingcounter-clockwiseto remove.
3 TurnSignal Bulb
4 Back Up Bulb

2013
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4-216 Lightinfig

Rear Compartment Courtesy Lamp Replacement (Hatchback)

2496808

Rear Compartment Courtesy Lamp Replacement (Hatchback)

Callout Component Name
RearCompartmentCourtesyLampAssembly
Procedure
1. Use theappropriatetrimtoolin orderto releasethelampassemblyfromtherearquartertrimpanel.
2. Disconnecttheelectricalconnection.

(US/Canada)
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2013 (5377994)
Manual
Service
 Lighting 4-217
Rear Compartment Courtesy Lamp Replacement (Sedan)

2507468
Rear Compartment Courtesy Lamp Replacement (Sedan)
Callout Component Name
Rear CompartmentCourtesyLampAssembly
Procedure
1. Usetheappropriatetrimtooiin orderto releasethelampassemblyfromtherearquartertrimpanel.
2. Disconnecttheelectricalconnection.

Low Beam Headlamps

Description and Operation
The body control module (BCM) monitors three signal
circuits from the headlamp switch. When the headlamp
Exterior switch is in the AUTO position, all three signal circuits
Lighting Systems are open. When placed in the AUTO position, the BCM
Description and Operation monitors inputs from the ambient light sensor to
determine if headlamps are required or if daytime
Exterior Lamps running lamps will be activated based on outside
The exterior lighting system consist of the following lighting conditions. When the headlamp switch is
lamps if equipped: placed in the OFF position, the headlamp switch
headlamps OFF signal circuit is grounded, indicating t0
' Backup Iamps
the BCM that the exterior iamps should be turned OFF.
' Front fog lamps With the headlamp switch in the PARK position, the
- Hazard warning lamps headlamp switch park Iamps ON signal circuit is
~ Headlamps grounded, indicating that the park lamps have been
requested. When the headlamp switch is placed in the
' Park, tail and license lamps HEADLAMP position, both the headlamp switch park
- Stop lamps Iamps ON signal circuit and the headlamp switch
- Turn signal lamps headlamps ON signal Circuit are grounded. The BCM
responds to the inputs by illuminating the park lamps
and headlamps. When the low beam headlamps are

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4=218 Lighting
requested, the BCM applies 8+ to both low beam
headlamp control circuits illuminating the low beam
headlamps.
The BCM will also command the low beam headlamps
ON during daylight conditions when the following
conditions are met:
. Headlamp switch in the AUTO position
- Windshield wipers ON
. Vehicle in any gear but PARK —automatic
transmission
- Vehicle in motion —manual transmission
When the BCM commands the low beam headlamps
ON, the operator will notice the interior backlighting for
the instrument cluster and the various other switches
dim to the level of brightness selected by the instrument
panel dimmer switch.
High Beam Headlamps
When the low beam headlamps are ON and the turn
signal/multifunction switch is placed in the high beam
position, ground is applied to the BCM through the high
beam signal circuit. The BCM responds to the high
beam request by applying ground to the high beam
relay control circuit which energizes the high beam
relay. With the high beam reiay energized, the switch
contacts close allowing battery voltage to flow through
the left and right high beam fuses to the high beam
controi circuits illuminating the left and right high beam
headlamps.
Daytime Running Lamps (DRL)
The daytime running lamps (DRL) will illuminate the
right and left low beam headlamps continuously. The
DRLs will operate when the following conditions
are met:
' The ignition is in the RUN or CRANK position
- The shift lever is out of the PARK position for
vehicles equipped with automatic transmissions or
the parking brake is released for vehicles with
manual transmissions
' The low and high beam headlamps are OFF
The ambient light sensor is used to monitor outside
lighting conditions. The ambient light sensor provides a
voltage signal that will vary between 0.2 and 4.9 volts
depending on outside lighting conditions. The body
control module (BCM) provides a 5-volt reference
signal to the ambient light sensor which is permanently
grounded. The BCM monitors the ambient light sensor
signal circuit to determine if outside lighting conditions
are correct for either daytime running lights (DRL) or
automatic headlamp system control when the
headlamp switch is in the AUTO position. In daylight
conditions the BCM will command the low beam
headlamps ON. The iow beam headlamps are the
designated DRL’s. During low light conditions the BCM
will command the low beam headlamps ON. Any
function or condition that turns on the headlamps will
cancel DRL operation.
Flash to Pass (FTP)
When the turn signal/multifunction switch is
momentarily placed in the flash to pass (FTP) position,
ground is applied to the turn signal/multifunction switch.)
The turn signal/multifunction switch applies ground to
the body control module (BCM) through the FTP switch
signal circuit. The BCM then applies ground to the high
beam relay control circuit. This energizes the high
beam relay, closing the switch side contacts of the high
beam relay, applying battery voltage to the left and right
high beam fuses. Battery voltage is applied from the
high beam fuses through the high beam control circuit
to the high beam headlamp assemblies. This causes
the high beam headlamps to illuminate at full brightness
momentarily.
Front Fog Lamps
The front fog lamp switch is an input to the body control
module (BCM) and is contained in the headlamp switch
assembly. The BCM supplies voltage to the front fog
lamp switch via the front fog lamp and instrument panel
dimmer switch 8+ circuit. When the front fog lamp
switch is pressed, voltage from the 8+ circuit is pulled
down through the front fog lamp switch resistor. The
front fog lamp resistor is part of the resistor ladder that
also provides the dimming signals for the instrument
panel dimmer switches. The BCM receives the voltage
signal through the front fog lamp and instrument panel
dimmer switch signal circuit.
The front fog lamp relay is supplied with batteryvoltage
at all times. The front fog lamp switch signal circuit is
grounded momentarily by pressing the frontfog lamp
switch. The body control module (BCM) energizes the
front fog lamp relay by applying ground to the front fog
lamp relay control circuit. When the front fog lamp relay
is energized, the relay switch contacts close and
battery voltage is applied through the frontfog lamp
fuse to the front fog lamp control circuit which
illuminates the front fog lamps.
Hazard Lamps
The hazard flashers may be activated in any power
mode. The hazard warning switch signal circuit is
momentarily grounded when the hazard warning switch
is pressed. The body control module (BCM) responds
to the hazard warning switch signal input by supplying
battery voltage to all four turn signal lamps in an ON
and OFF duty cycle. When the hazard warning switch is
activated, the BCM sends a serial data message to the
instrument cluster requesting both turn signal indicators
to be cycled ON and OFF.
The instrument panel dimmer switch controls are
located on the headlamp switch assembly and are used
to increase and decrease the brightness of the interior
backlighting components. When the instrument panel
dimmer switch is placed in a desired brightness
position, the body control module (BCM) receives a
signal from the instrument panel dimmer switch and
responds by applying a pulse width modulated (PWM)
voltage to the hazard switch LED backlighting control
circuit illuminating the LED to the desired level of
brightness.
Park, Tail, and License Lamps
When the headlamp switch is placed in the HEAD or
PARK position, ground is applied to the park lamp
switch ON signal circuit to the body control module
(BCM). The BCM responds by applying voltage to the
park lamps, tail lamps, and license lamps control
circuits illuminating the park, tail, and license Iamps.
2013
-Sonic
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Service
Manual
(5377994)

Stop Lamps
The brake pedal position (BPP) sensor is used to sense
the action of the driver application of the brake pedal.
The BPP sensor provides an analog voitage signal that
will increase as the brake pedal is applied. The body
control module (BCM) provides a low reference signal
and a 5-volt reference voltage to the BPP sensor. When
the variable signal reaches a voltage threshold
indicating the brakes have been applied, the BCM will
apply batteryvoltage to the left and right stop lamp
control circuits as well as the center high mounted stop
lamp (CHMSL) control circuit illuminating the left and
right stop lamps and the CHMSL.
Turn Signal Lamps
Ground is applied at all times to the turn signa‘l/
multifunctionswitch. The turn signal Iamps may only be
activated with the ignition switch in the ON or START
positions. When the turn signal/multifunction switch is
placed in either the turn right or turn left position,
ground is applied to the body control module (BCM)
through either the right turn or left turn signal switch
signai circuit. The BCM responds to the turn signal
switch input by applying a pulsating voltage to the front
and rear turn signal lamps through there respective
control circuits. When a turn signal request is received
by the BCM, a serial data message is sent to the
instrument cluster requesting the respective turn signal
indicator be pulsed ON and OFF.
Backup Lamps
Automatic Transmission
With the engine ON and the transmission in the reverse
position, the transmission control module (TCM) sends
a serial data message to the body control module
(BCM). The message indicates that the gear selector is
in the reverse position. The BCM applies battery
voltage to the backup iamps control circuit illuminating
the backup lamps. Once the driver moves the gear
selector out of the reverse position, a message is sent
by the TCM via serial data requesting the BCM to
remove battery voltage from the backup Iamps control
circuit. The engine must be running for the backup
iamps to operate.
Manual Transmission
The engine control module (ECM) provides a signal
circuit to the backup lamp switch which is permanently
grounded. With the engine ON and the transmission in
the reverse position, the backup lamp switch signal
circuit is pulled low and the ECM responds by sending
a serial data message to the body control module
(BCM). The message indicates that the gear selector is
in the reverse position. The BCM applies battery
voltage to the backup lamps control circuit illuminating
the backup Iamps. Once the driver moves the gear
selector out of the reverse position, a message is sent
by the ECM via serial data requesting the BCM to
remove batteryvoltage from the backup lamps control
circuit. The engine must be running for the backup
lamps to operate.
2013
—Sonic
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Service
Manual
(5377994)
Lighting 4219
Battery Run Down Protection]
Inadvertent Power
To provide battery run down protection, the exterior
Iamps will be deactivated automatically under certain
conditions. The BCM monitors the state of the
headlamp switch. Ifthe park or headlamp switch is ON
when the ignition switch is placed in either the CRANK
or RUN position and then placed in the OFF position,
the BCM initiates a 10 min timer.At the end of the
10 min, the BCM will turn off the control power output to
the park lamp controls as well as the headlamp relay
coils, deactivating the exterior lamps. This feature will
be cancelled if any power mode other than OFF
becomes active. The BCM will disable battery run down
protection if any of the following conditions exist. The
park or headlamp switch is placed in the ON to OFF
position, and back to the ON position during battery run
down protection. The BCM determined that the park or
headlamp switch was not active when the ignition was
turned OFF.
Interior Lighting Systems
Description and Operation
Interior Lamps
The interior lighting consist of two groups. This first
group includes lamps that may not be dimmed.
° Dome/readinglamps , ,
° Rear compartment courtesy lamp
Dome Lamps
When any door is opened, the associated doorjamb
switch closes providing a door open input to the body
control module (BCM). The BCM responds by applying
battery positive voltage to the dome lamp control circuit
illuminating the dome lamp. The dome lamp will turn
OFF immediately if the ignition switch is turned to the
ON position or approximately 20 seconds after all doors
are closed. The dome lamp will normally turn OFF
using the theater dimming feature when controlled by
the BCM. lfthe operator inadvertently leaves any
interior lamp ON, the BCM will turn all interior lamps
OFF after 10 minutes has passed since any switch
activation has been detected by the BCM.
Keyless Entry interior Illumination
When the operator uses the keyless entry transmitter in
order to unlock the doors, the BCM receives a
door—unlocksignal. The BCM must receive inputs from
various systems that indicate that the ignition switch is
OFF, the courtesy lamp switch is OFF, and all doors are
closed before the BCM will activate the interior lamps.
The courtesy iamps will remain ON for 20 seconds after
the door is closed. The BCM will turn off the courtesy
lamps OFF through the theater dimming feature. Ifthe
door locks are activated to the LOCK position, or if the
ignition switch is turned to either the RUN or CRANK
position, the courtesy lamps will turn OFF immediately.
4:220 Lighting
Rear Compartment Courtesy Lamp
The BCM provides battery positive voltage to the rear
compartment courtesy lamp. When the rear
compartment is opened, the rear compartment latch
opens providing a rear compartment open input to the
BCM. The BCM responds by applying battery positive
voltage to the rear compartment lamp control circuit
illuminating the rear compartment lamp.
Reading Lamps
The inadvertent power supply voltage circuit from the
BCM prOvides battery positive voltage the reading
lamp. When the reading lamp switch is activated, the
switch contacts close providing a path to ground and
the reading lamp illuminates. lfthe operator
inadvertently leaves a reading lamp ON, the BCM will
turn all interior lamps OFF after 10 minutes has passed
since any switch activation has been detected by
meBCM.
Interior Lamps Dimming
The second group includes iamps which may be
dimmed.
- Door lock switch ~driver
- Hazard warning switch
- Headlamp switch
- HVAC control head assembly
- Instrumentcluster
- Multifunction switch —center console
- Radio
0 Steering wheel control switch —left
- Steering wheel control switch —right
- Transmission shift lever position indicator
When the headlamp switch is placed in the PARK or
HEAD position, the park lamp switch signal circuit
provides an input to the body control module (BCM).
The BCM responds by applying voltage to the park
lamps as well as the dimming control circuits
illuminating all components with interior backlighting.
All LED and incandescent backlighting turns ON at the
dimming level indicated by the instrument panel
dimmer switch. The instrument panel dimmer switch is
a momentary type switch and utilizes a resistor ladder
to accomplish dimming controls. The instrument panel
dimmer switch contains a battery positive voltage
reference circuit and a signal circuit from the BCM.
When the instrument panel dimmer switch is held in the
decrease brightness position, the BCM receives a low
voltage signal via the instrument panel dimmer switch
signal circuit. The BCM responds by decreasing the
brightness of all interior backlighting by decreasing the
voltage supplied to the backlighting components via the
dimming control circuits. When the instrument panel
dimmer switch is held in the increase brightness
position, the BCM receives a high voltage signal via the
instrument panel dimmer switch signal circuit. The BCM
responds by increasing the brightness of all interior
backlighting by increasing the voltage supplied to the
backlighting components via the dimming control
circuits.
Battery Rundown Protection/
Inadvertent Power
The BCM inadvertent power supply voltage circuit
provides battery positive voltage to all of the interior
iamps. Inthe event that any of these Iamps were to
remain illuminated for a period of more than 10 minutes
with the ignition switch in the OFF position, the BCM
will deactivate the inadvertent power supply voltage
circuit to prevent total battery discharge.
2013
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Sonic
(US/Canada)
Service
Manual
(5377994)
 Mirrors 4-221

Mirrors

Specifications

Fastener Tightening Specifications

Specification
Application Metric English
InsideRearviewMirrorFastener 2 N-m 18lb in
OutsideRearviewMirrorInnerActuatorFastener 5 N-m 44 lb in
OutsideRearviewMirrorFastener 10N-m 89lb in

Schematic and Routing Diagrams

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 "I
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4-222 Mirrors

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IIIIIII

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Mirrors 4.223

Diagnostic Information and Visual/Physical Inspection

Procedures
Symptoms - Mirrors
Note: The following steps must be completed before
using the symptom tables.
1. Perform the Diagnostic System Check - Vehicle on
page 6—66before 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
Outside Mirror Description and Operation on
page 4—236.
- Inspect for aftermarket devices which could affect
the operation of the system. Refer to Checking
Aftermarket Accessories on page 11-525.
- inspect the 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 intermittentconditions. Refer to Testing for
IntermittentConditions and Poor Connections on
page 11-531.
Symptom List
Refer to a symptom diagnostic procedure from the
following list in order to diagnose the symptom:
- Heated Mirrors Malfunction on page 4-223
' Power Mirror Malfunction on page 4-225

Heated Mirrors Malfunction

Diagnostic Instructions
- Perform the Diagnostic System Check - Vehicle
on page 6—66prior to using this diagnostic
procedure.
' Review Strategy Based Diagnosis on page 6-58
for an overview of the diagnostic approach.
' Diagnostic Procedure Instructions on page 6-59
provides an overview of each diagnostic category.
Diagnostic Fault Information

Open/High Signal
Circuit Short to Ground Resistance Short to Voltage Performance
LeftHeatedMirrorElementControl 2 1 3 —-
DriverOutsideRearviewMirrorGround — 1 —— -
RightHeatedMirrorElementControl 2 1 3 —-
PassengerOutsideRearviewMirrorGround —— 1 — ~-
1.SingleHeatedMirrorlnoperative
2. BothHeatedMirrorslnoperative
3. HeatedMirrorsAlwaysOn

CircuitlSystem Description Description and Operation

The rear defogger relay supplies voltage to the outside Outside Mirror Description and Operation on
rearview mirror heater elements based on the current page 4—236
state of the rear window defogger. The relay supplies 8
+through the driver/passenger mirror heating element Electrical Information Reference
control circuit when a request is seen. 0 Circuit Testing on page 11—526
Reference Information ' Connector Repairs on page 11—548
- Testing for IntermittentConditions and Poor
Schematic Reference Connections on page 11-531
Outside Rearview Mirror Schematics on page 4-222 - Wiring Repairs on page 11—537
Connector End View Reference Scan Tool Reference
Component Connector End Views on page 11—269 Control Module References on page 6—3for scan tool
information.

2013
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Sonic
(US/Canada)
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Manual
(5377994)
4=224 Mirrors
CircuitlSystem Verification
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 on
page 4-16.
if the E18 Rear Defogger Grid turns ON and OFF
Verify the mirror glass of the A9A Outside
Rearview Mirror-Driver and the A98 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 A98 Outside Rearview
Mirror-Passenger do not become warm
Refer to CircuitlSystem Testing.
If the mirror glass of the A9A Outside Rearview
Mirror-Driver and the A98 Outside Rearview
Mirror—Passenger become warm
4. All OK.
CircuitlSystem Testing
1. IgnitionOFF and all vehicle systems OFF,
disconnect the harness connector at the
appropriate A9 Outside Rearview Mirror. Itmay
take up to 2 minutes for all vehicle systems to
power down.
. Test for less than 10 Q between the ground circuit
terminal G and ground.
If 10 Q or greater
2.1. Ignition OFF.
2.2. Test for less than 2 Q in the ground circuit and
to end.
2 If2 Q or greater, repair the open/high resistance
in the circuit.
2 Ifless than 2 Q, repair the open/high resistance
in the ground connection.
If less than 10 Q
. Engine Running, connect a test lamp between the
control circuit terminal F and the ground circuit
terminal G.
4. Verify the test lamp turns ON and OFF when
commanding the Rear Defogger On and Off with a
scan tool.
2 If the test lamp is always OFF
4.1. IgnitionOFF, remove the test lamp, disconnect
the harness connector at the X50A Fuse
Block—Underhood.
4.2. Test for infinite resistance between the control
circuit and ground.
2 Ifless than infinite resistance, repair the short to
ground on the circuit.
U Ifinfinite resistance
4.3. Test for less than 2 Q in the control circuit end
to end.
2 if 2 Q or greater, repair the open/high resistance
in the circuit.
2 Ifless than 2 Q, replace the A9 Outside
Rearview Mirror.
U If the test lamp is always ON
4.1. ignition OFF, remove the test lamp, disconnect
the harness connector at the X50A Fuse
Block-Underhood, ignition ON.
4.2. Test for less than 1 V between the control
circuit and ground.
2 If 1 V or greater, repair the short to voltage on
the circuit.
2 Ifless than 1V, replace the X50A Fuse
Block—Underhood
U If the test lamp turns 0N and OFF
5. Test or replace the A9 Outside Rearview Mirror.
Repair Instructions
Perform the Diagnostic Repair Verification on
page 6—92after completing the repair.
Outside Rearview Mirror Glass Replacement on
page 4—233
Front Compartment Fuse Block Replacement on
page 11-609
(US/Canada)
~Sonic
2013 (5377994)
Manual
Service
 Mirrors 4-225

Power Mirror Malfunction

Diagnostic Instructions
- Perform the Diagnostic System Check - Vehicle
on page 6—66prior to using this diagnostic
procedure.
~ Review Strategy Based Diagnosis on page 6-58
for an overview of the diagnostic approach.
- Diagnostic Procedure Instructions on page 6—59
provides an overview of each diagnostic category.
Diagnostic Fault Information

Open/High Signal
Circuit Short to Ground Resistance Short to Voltage Performance
OutsideRearviewMirrorSwitch8+ 1 __ _
DriverMirrorMotorHorizontalControl
DriverMirrorMotorVerticalControl
PassengerMirrorMotorHorizontalControl
PassengerMirrorMotorVerticalControl 4.2.—34A (:0ka)
OutsideRearviewMirrorSwitchGround - ALOOJMM
1. BothOutsidePowerMirrorsInoperative
2. DriverOutsidePowerMirrorMalfunction
3. PassengerOutsidePowerMirrorMalfunction

CircuitlSystem Description CircuitlSystem Verification

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. 8+ is applied to the
switch from the power mirror fuse and when a
movement position switch is selected, voltage is sent to
the commanded mirrorvia a mirror control circuit. The
opposite mirrorcontrol circuit acts as a ground circuit
for the bi—directionalmirror motor. Ground is the appiied
through the switch.
Reference Information
Schematic Reference
Outside Rearview Mirror Schematics on page 4-222
Connector End View Reference
Component Connector End Views on page 11-269
Description and Operation
Outside Mirror Description and Operation on
page 4—236
Electrical Information Reference
- Circuit Testingon page 11-526
0 Connector Repairs on page 11-548
- Testing for IntermittentConditions and Poor
Connections on page 11—531
- Wiring Repairs on page 11-537
1. Verify the mirror glass of the A9A Outside
Rearview Mirror-Driver and the A98 Outside
Rearview Mirror-Passenger move UP, DOWN,
LEFT and RIGHT with the S52 Outside Rearview
Mirror Switch.
2 If both outside mirror glasses do not move
Refer to CircuitlSystem Testing — 80th Outside
Rearview Mirrors lnoperative.
2 If the driver outside mirror glass does not move
UP, DOWN, LEFT or RIGHT
Refer to CircuitlSystem Testing — Driver
Outside Mirror Movement Malfunction.
2 If the passenger outside mirror glass does not
move UP, DOWN, LEFT or RIGHT
Refer to CircuitlSystem Testing -—Passenger
Outside Mirror Movement Malfunction.
U If the mirror glass of the A9A Outside Rearview
Mirror-Driver and the A98 Outside Rearview
Mirror-Passenger move UP, DOWN, LEFT and
RIGHT
2. Ail OK.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
4:226 Mirrors

CircuitlSystem Testing Driver Outside Mirror Movement Malfunction

1. IgnitionOFF, disconnect the X501 inline harness
Both Outside Rearview Mirrors Inoperative connector at the A9A Outside Rearview
1. lgnition OFF and all vehicle systems OFF, Mirror—Driver.Ignition ON
disconnect the harness connector at the 852 2. Connect a test lamp between the control circuit
Outside Rearview Mirror Switch. Itmay take up to terminal A and control circuit terminal 8.
2 minutes for all vehicle systems to power down.
3. Verify the test lamp turns ON when commanding
. Test for less than 10 Q between the ground Circuit the UP and DOWN states with the 852 Outside
terminal 5 and ground. Rearview Mirror Switch.
If 10 Q or greater 2 If the test lamp remains OFF during either of the
2.1. lgnition OFF. commands
2.2. Test for less than 2 Q in the ground circuit and 3.1. lgnition OFF, remove the test lamp, disconnect
to end. the harness connector at the S52 Outside
2 If2 Q or greater, repair the open/high resistance Rearview Mirror Switch.
in the circuit. 3.2. Test for infinite resistance between each
2 if less than 2 Q, repair the open/high resistance control circuit and ground.
in the ground connection. 2 Ifless than infinite resistance, repair the short to
if less than 10 Q ground on the circuit.
Verify a test lamp illuminates between the 8+ U Ifinfinite resistance
circuit terminal 4 and ground. 3.3. Test for less than 2 Q in each control circuit
If the test lamp does not illuminate and the end to end.
circuit fuse is good 2 If2 Q or greater, repair the open/high resistance
3.1. IgnitionOFF. in the circuit.
3.2. Test for less than 2 Q in the 8+ circuit end 2 Ifless than 2 Q, test or replace the 852 Outside
to end. Rearview Mirror Switch.
2 If2 Q or greater, repair the open/high resistance 2 If the test lamp is always ON
'1. .in the circuit. 3.1. lgnition OFF, remove the test lamp, disconnect
:2 Ifless than 2 Q, verify the fuse is not open and the harness connector at the 852 Outside
there is voltage at the fuse. Rearview Mirror Switch, ignition ON.
If the test lamp does not illuminate and the 3.2. Test for less than 1 V between each control
circuit fuse is open circuit and ground.
3.1. Ignition OFF. 2 H1 V or greater, repair the short to voltage on
the circuit.
3.2. Test for infinite resistance between the 8+
circuit and ground. 2 Ifless than 1 V, test or replace the S52 Outside
2 Ifless than infinite resistance, repair the short to Rearview Mirror Switch
ground on the circuit. U If the test lamp turns ON during each of the
commands
U |finfinite resistance
4. Connect a test lamp between the controi circuit
3.3. Test for infinite resistance between each of the
terminal A and control circuit terminal C.
control circuit terminals listed below and
ground: 5. Verify the test lamp turns ON when commanding
the LEFT and RIGHTstates with the 852 Outside
- Control circuit terminal 1
Rearview Mirror Switch.
- Control circuit terminal 2
2 If the test lamp remains OFF during either of the
- Control circuit terminal 3 commands
1 Control circuit terminal 7 5.1. IgnitionOFF, remove the test lamp, disconnect
- Control circuit terminal 8 the harness connector at the 852 Outside
- Control circuit terminal 9 Rearview Mirror Switch.
2 Ifless than infinite resistance, repair the short to 5.2. Test for infinite resistance between each
ground on the circuit. control circuit and ground.
2 if infinite resistance, replace the M77 Outside 2 Ifless than infinite resistance, repair the short to
Rearview Mirror Motor. ground on the circuit.
c if the test lamp illuminates U Ifinfinite resistance
Test or replace the 852 Outside Rearview Mirror 5.3. Test for less than 2 Q in each control circuit
Switch. end to end.
2 112Q or greater, repair the open/high resistance
in the circuit.

201.?
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(5377994)

2 if less than 2 Q, test or replace the S52 Outside
Rearview Mirror Switch.
2 If the test lamp is always ON
5.1. lgnition OFF, remove the test lamp, disconnect
the harness connector at the 852 Outside
Rearview Mirror Switch, ignition ON.
5.2. Test for less than 1 V between each control
circuit and ground.
2 If 1 V or greater, repair the short to voltage on
the circuit.
2 Ifless than 1 V, test or replace the S52 Outside
Rearview Mirror Switch
U Hthe test lamp turns ON during each of the
commands
6. Test or replace the M77D Outside Rearview Mirror
Motor-Driver.
Passenger Outside Mirror Movement Malfunction
1. lgnition OFF, disconnect the X601 inline harness
connector at the A98 Outside Rearview
Mirror-Passenger. lgnition ON
2. Connect a test lamp between the control circuit
terminal A and control circuit terminal 8.
3. Verify the test lamp turns ON when commanding
the UP and DOWN states with the 852 Outside
Rearview Mirror Switch.
2 if the test lamp remains OFF during either of the
commands
3.1. lgnition OFF, remove the test lamp, disconnect
the harness connector at the 852 Outside
Rearview Mirror Switch.
3.2. Test for infinite resistance between each
control circuit and ground.
2 Ifless than infinite resistance, repair the short to
ground on the circuit.
U Ifinfinite resistance
3.3. Test for less than 2 Q in each control circuit
end to end.
2 If2 Q or greater, repair the open/high resistance
in the circuit.
2 if less than 2 Q, test or replace the 852 Outside
Rearview Mirror Switch.
2 if the test lamp is always 0N
3.1. IgnitionOFF, remove the test lamp, disconnect
the harness connector at the 852 Outside
Rearview Mirror Switch, ignition ON.
3.2. Test for less than 1 V between each control
circuit and ground.
2 If1 V or greater, repairthe short to voltage on
the circuit.
(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
Mirrors 4227
2 If less than 1 V, test or replace the 852 Outside
Rearview Mirror Switch
U If the test lamp turns ON during each of the
commands
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
Rearview Mirror Switch.
2 If the test lamp remains OFF during either of the
commands
5.1. ignition OFF, remove the test lamp, disconnect
the harness connector at the 352 Outside
Rearview Mirror Switch.
5.2. Test for infinite resistance between each
control circuit and ground.
2 Ifless than infinite resistance, repair the short to
ground on the circuit.
U If infinite resistance
5.3. Test for less than 2 Q in each control circuit
end to end.
2 If2 Q or greater, repair the open/high resistance
in the circuit.
2 If less than 2 Q, test or replace the 852 Outside
Rearview Mirror Switch.
2 If the test lamp is always ON
5.1. lgnition OFF, remove the test lamp, disconnect
the harness connector at the 852 Outside
Rearview Mirror Switch, ignition ON.
5.2. Test for less than 1 V between each control
circuit and ground.
2 if 1 V or greater, repair the short to voltage on
the circuit.
2 if less than 1 V, test or replace the 852 Outside
‘ Rearview Mirror Switch
U If the test lamp turns ON during each of the
commands
6. Test or replace the M77P Outside Rearview Mirror
Motor—Passenger.
Repair instructions
Perform the Diagnostic Repair Verification on
page 6-92 after completing the repair.
- Outside Rearview Mirror Remote Control Switch
Replacement on page 4—231
- Outside Rearview Mirror Motor Replacement on
page 4-232
4228 Mirrors

Repair Instructions

Outside Rearview Mirror Replacement (Manual) .

2425021

Outside Rearview Mirror Replacement (Manual)

Callout Component Name
Preliminary Procedures
1. Removethefrontsidedoorupperfronttrimpanel.Referto FrontSide DoorUpperFrontTrimPanel Replacementon
page 2—66.
2. Removetheoutsiderearviewmirrorboltaccess holeonthefrontside doortrimpanel.
OutsideRearviewMirrorFastener(Qty:3)
Caution: RefertoFastenerCautiononpage0-8.
Tighten
1ON'm(891bin)
OutsideRearviewMirror
Procedure
1. Transfertheoutsiderearviewmirrorknob.
2. inspecttheoutsidemirrorforproperoperationbeforeinstallingthedoortrimpanel.

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
 Mirrors 4-229

//

2425022
Outside Rearview Mirror Replacement (Power)
Callout Component Name
Preliminary Procedures
1. Removethefrontsidedoorupperfronttrimpanel.Referto FrontSide DoorUpperFrontTrimPanel Replacementon
page2-66.
2. Removetheoutsiderearviewmirrorboltaccess holeon thefrontsidedoortrim.
OutsideRearviewMirrorFastener(Qty:3)
Caution: RefertoFastenerCautiononpage 0-8.
1 Procedure
Disconnecttheelectricalconnector.
Tighten
10N‘m(89lb in)
OutsideRearviewMirror
2 Procedure
inspecttheoutsidemirrorforproperoperationbeforeinstallingthedoortrimpanel.

2013
—Sonic
(US/Canada)
Service
Manual
(5377994)
4-230 Mirrors

Outside Rearview Mirror Housing Rear Cover Replacement

ii
I
l

2425023

Outside Rearview Mirror Housing Rear Cover Replacement

Caliout I Component Name
Preliminary Procedures
Removetheoutsiderearviewmirrorglass.Referto OutsideRearviewMirrorGlass Replacementonpage4233.
OutsideRearviewMirrorHousingCover
Note:
1. Afterthemirrorglass has beenremovedtheretainerscan beaccessedto release.
2. Alignthehousingcoverwiththeslots inthemirrorhousing,pushdownwardlockingretainersin place.
3. Inspecttheoutsidemirrorforproperoperation.

(US/Canada)
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2013 (5377994)
Manual
Service
 Mirrors 4-231

I Outside Rearview Mirror Remote Control Switch Replacement

2502876

Outside Rearview Mirror Remote Control Switch Replacement

Callout I Component Name
Preliminary Procedure
Removethefrontsidedoorwidowswitchbezel. Referto FrontSide DoorWindowSwitchBezel Replacement(RightSide)on
page2—64 or FrontSide Door WindowSwitchBezel Replacement(LeftSide)onpage 2—63.
OutsideRemoteControlRearviewMirrorSwitchAssembly
Procedure
1. Disconnecttheelectricalconnector.
2. Referto ControlModuleReferencesonpage 6-3forprogrammingandset upprocedures.

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
4-232 Mirrors

Outside Rearview Mirror Motor Replacement

2259515

Outside Rearview Mirror Motor Replacement

Callout Component Name
OutsideRearviewMirrorGlass
1 Procedure
Removetheoutsiderearviewmirrorglass. Referto OutsideRearviewMirrorGlass Replacementonpage4-233.
OutsideRearviewMirrorInnerActuatorFastener(Qty:3)
Caution: Referto FastenerCautiononpage0—8.
2 Procedure
Disconnecttheoutsidemirrorinneractuatorelectricalconnector.
Tighten
5N-m(44lbin)
3 OutsideRearviewMirrorInnerActuator
Note: Inspecttheoutsidemirrorforproperoperation.

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
 Mirrors 4233

Outside Rearview Mirror Glass Installation Procedure

Replacement

Removal Procedure
Warning: Approved safety glasses and gloves
should be worn when performing this procedure to
reduce the chance of personal injury.
1. Place masking tape over the mirror glass.

/4

#,
625761
C21: 1. Place the mirror glass on the lower motor ring
retainers.
2. Place one hand on the back of the mirror housing,
N using the flat palm of the other hand press inward
locking the mirror glass to the motor ring.
3. Remove the masking tape from the mirror glass.
167809 4. inspect the outside mirrorfor proper operation.
2. Carefully push the outside rearview mirror glass
upward and into the right corner of the mirror
housing, allowing access to the bottom edge.
3. Grasp the bottomedge of the mirror glass firmly, lift
it up and pull rearward until the mirror glass
releases the motor ring.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
4—234 Mirrors

Outside Rearview Mirror Housing Replacement

2425027

Outside Rearview Mirror Housing Replacement

Callout Component Name
Preliminary Procedures
on
1. Removethe outsiderearviewhousingcover.Referto OutsideRearviewMirrorHousingRear CoverReplacement
page4-230.
2. Removethe outsiderearviewmirrormotor.Referto OutsideRearviewMirrorMotorReplacementonpage4-232.
OutsideRearviewMirrorHousingFastener(Qty:4)
Caution: Referto FastenerCautiononpage0-8.
Tighten
5 N°m(44lbin)
OutsideRearviewMirrorHousing
2 Procedure
inspectthe outsidemirrorforproperoperationbeforeinstallingthedoortrimpanel.

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
 Mirrors 4-235

Inside Rearview Mirror Replacement

2425033
Inside Rearview Mirror Replacement
Callout Component Name
InsideRearviewMirrorCover
1 Procedure
1. Removethewireharnesscover,slidingthecoverupwardreleasingthecoverfromthesupport.
2. Disconnectedtheconnectorfromthemirrorbase.
insideRearviewMirrorScrew
Caution: Referto FastenerCautiononpage 0-8.
Procedure
2 1. Adjustthe mirrortothefullupwardposition,loosenthescrewat thebase in orderto removethemirrorfrom
thebutton.
2. Slidethemirrorin an upwardmotionin orderto remove.
Tighten
2N'm(18lb in)
3 insideRearviewMirror

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
4=236 Mirrors

Operation The four positions of the direction switch have dual

Description and
switch contacts. Each of the contacts are connected to
opposing sides of the appropriate power mirrormotors
through the selector switch. The selector switch
Outside Mirror Description and completes these circuits depending on the position of
Operation the selector switch, L or R.
Ifthe selector switch is placed in the L position and the
Power Mirror System Components up switch is pressed, battery voltage will be supplied to
The power mirror system consists of the following the left outside rearview mirror vertical motorthrough
components: the left mirror motor vertical control circuit and ground
through the left mirror motor common control circuit.
- Outside rearview mirror switch
if the down switch is pressed, battery voltage will be
- Mirror selector switch supplied to the left outside rearview mirror vertical
- Driver outside rearview mirror motor through the left mirror motor common control
- Passenger outside rearview mirror circuit and ground through the left mirror motorvertical
control circuit.
Each of the outside rearview mirror contains two
motors. The vertical motor operates the mirror in the up The remainder of the mirrorfunctions operate in the
and down directions, and the horizontal motor operates same manner as described above. Placing the power
the mirror in the left and right directions. mirror switch in opposing positions, left/rightor up/
down, will reverse the polarity to the mirror motor,
Power Mirror System Controls reversing the direction of movement.
The outside rearview mirror switch is a four position Heated Mirrors (If Equipped)
directional switch: Up, Down, Left and Right.
The heated mirrors are controlled through the rear
The mirror select switch is a three position switch: ieft, defog relay. Whenever the rear window defogger is
neutrai/foid, and right. turned on battery voltage is supplied to the mirror
Power Mirror System Operation heater elements through the left and right mirrorheater
element control circuits.
The outside rearview mirror switch receives battery
voltage from the underhood fuse block The power
mirror switch also receives a constant ground.

—
2013 (US/Canada)
Sonic (5377994)
Manual
Service
 Vehicle Access 4237

Vehicle Access

Specifications
2-242.-.
22..“
.2
..

Fastener Tightening Specifications

Specification
Application Metric English
FrontSide DoorLock CylinderClampScrew 5 N-m 44 lb in
FrontSide DoorLock Screws 1ON-m 89lb in
FrontSide DoorOutsideHandleBracketScrew 5 N-m 44 lb in
FrontSide DoorStrikerScrews 22N-m 16lbft
LiftgateLatchScrews 9 N-m 80 lbin
LiftgateLatchStrikerBolts 22N-m 16lbft
Rear CompartmentLid LatchScrew 9 N-m 80 lbin
Rear CompartmentLid LatchStrikerBolts 22N-m 16lbft
Rear Side DoorLock CylinderClampScrew 5 N'm 44 lbin
Rear Side DoorLock Screws 10N-m 89 lbin
Rear Side DoorOutsideHandleBracketScrew 5 N-m 44 lbin
Rear Side DoorStrikerScrews 22Wm 16lbft

Schematic and Routing Diagrams

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
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Sonic
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(5377994)
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2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Vehicle Access 4-243

Diagnostic Information and PrOcedures

DTC B2494

Diagnostic Instructions
Perform the Diagnostic System Check —Vehicle
on page 6-66 prior to using this diagnostic
procedure.
Review Strategy Based Diagnosis on page 6-58
for an overview of the diagnostic approach.
Diagnostic Procedure Instructions on page 6-59
provides an overview of each diagnostic category.
DTC Descriptor
DTC 32494 00: Liftgate Handle Switch Circuit Malfunction
Diagnostic Fault Information

Open/High Signal
Circuit Short to Ground Resistance Short to Voltage Performance
Signal 8249400 1 1 -
Ground —- 1 _ _
1.ExteriorRearCompartmentLid ReleaseSwitchMalfunction

CircuitlSystem Description Description and Operation

When the ignition is ON, the body control module Luggage Compartment Description and Operation on
(BCM) supplies a signal to the liftgate unlatch switch page 4-322
through the liftgate release switch signal circuit. When
the liftgate unlatch switch is pressed, the voltage within Electrical Information Reference
the signal circuit is pulled low and in response, the . Circuit Testing on page 11-526
BCM will energize the liftgate unlatch relay.
0 Connector Repairs on page 11-548
Conditions for Running the DTC ' Testing for IntermittentConditions and Poor
The system voltage is 9—16 V. Connections on page 11-531
- Wiring Repairs on page 11-537
Conditions for Setting the DTC
Scan Tool Reference
The BCM detects a short to ground in the liftgate
release switch signal circuit for greater than 60 seconds Control Module References on page 6-3 for scan tool
information
Action Taken When the DTC Sets
The BCM ignores the inputfrom the liftgate unlatch CircuitlSystem Verification
switch. 1. lgnition ON.
2. Verify the scan tool Trunk Lid/Liftgate Window
Conditions for Clearing the DTC Exterior Unlatch Switch parameter changes
This DTC will be current for as long as the fault is between Active and inactive when pressing and
present. releasing the liftgate unlatch switch.
When the fault is no longer present, the DTC will =>If the parameter does not change
be a history DTC.
Refer to CircuitlSystem Testing.
A history DTC will clear after 50 ignition cycles.
U If the parameter changes
Reference Information 3. All OK.
Schematic Reference
Release Systems Schematics on page 4-241
Connector End View Reference
Component Connector End Views on page 11-269

2013
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Manual
(5377994)
4244 Vehicle Access

CircuitlSystem Testing 6. Verify the scan tool Trunk Lid/Liftgate Window

1. IgnitionOFF and all vehicle systems OFF,
disconnect the harness connector at the S468
liftgate unlatch switch. it may take up to 2 minutes
for all vehicle systems to power down.
2. Test for less than 10 0 between the ground circuit
terminal 2 and ground.
=>If 10 Q or greater
2.1. IgnitionOFF.
2.2. Test for less than 2 Q in the ground circuit end
to end.
2» if 2 Q or greater, repair the open/high resistance
in the circuit.
:> lf less than 2 Q, repair the open/high resistance
in the ground connection.
U If less than 10 Q
9° lgnition ON.
4. Verify the scan tool Trunk Lid/Liftgate Window
Exterior Unlatch Switch parameter is Inactive.
=>If not Inactive
4.1. lgnition OFF, disconnect the harness
connector at the K9 body control module.
4.2. Test for infinite resistance between the signal
circuit terminal 1 and ground.
:> Ifless than infinite resistance, repair the short to
ground on the Circuit.
=>Ifinfinite resistance, replace the K9 body control
module.
U If Inactive
5. Install a 3 A fused jumper wire between the signal
circuit terminal 1 and the ground circuit terminal 2.
Exterior Unlatch Switch parameter is Active.
=>If not Active
6.1. IgnitionOFF, disconnect the harness
connector at the K9 body control module,
ignition ON.
6.2. 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.
U Ifless than 1 V
6.3. Test for less than 2 Q in the signal circuit end
to end.
:> If2 Q or greater, repair the open/high resistance
in the circuit.
:> Ifless than 2 Q, replace the K9 body control
module.
U If Active
7. Test or replace the S468 liftgate unlatch switch.
Component Testing
1. lgnition OFF, disconnect the harness connector at
the S468 liftgate unlatch switch.
2. Test for infinite resistance between the signal
terminal 1 and the ground terminal 2 with the switch
in the open position.
=>If less than infinite resistance
Replace the S468 liftgate unlatch switch.
U If infinite resistance
3. Test for less than 3 Q between the signal terminal 1
and the ground terminal 2 with the switch in the
closed position.
2 If 3Q or greater
Replace the S468 liftgate unlatch switch.
U If less than 3 Q
4. All OK
Repair Instructions
Perform the Diagnostic Repair Verification on
page 6-92 after completing the diagnostic procedure.
0 Liftgate Release Switch Replacement on
page 4-320
- Control Module References on page 6-3 for BCM
replacement, programming and setup

2013
-Sonic
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Service
Manual
(5377994)
 Vehicle Access 4-245
DTC B252C

Diagnostic Instructions
- Perform the Diagnostic System Check —Vehicle
on page 6-66 prior to using this diagnostic
procedure.
- Review Strategy Based Diagnosis on page 6-58
for an overview of the diagnostic approach.
- Diagnostic Procedure Instructions on page 6—59
provides an overview of each diagnostic category.
DTC Descriptor
DTC 3252C 00: Child Security Lock Switch Circuit

Diagnostic Fault Information

Opeanigh Signal
Circuit Short to Ground Resistance Short to Voltage Performance
Signal 8252C00 1 1
Ground - 1 _
1.Child SecurityLockoutMalfunction

CircuitlSystem Description Connector End View Reference

The body control module (BCM) monitors the voltage Component Connector End Views on page 11-269
level in the child security door lockout switch signal
circuit, when the switch is in the open position the Description and Operation
voltage in the signal circuit will be equal to the B+ Power‘ Door LocksDescription and Operation on
voltage level. When the child security door lockout page 4-323
switch is pressed, voltage within the signal circuit drops
and the BCM will detect the voltage drop and will Electrical Information Reference
energize the Door Lock relay to disable the interior rear
door handles. 0 Circuit Testing on page 11-526
. Connector Repairs on page 11-548
Conditions for Running the DTC ~ Testing for IntermittentConditions and Poor
The system voltage is 9—16V. Connections on page 11-531
' Wiring Repairs on page 11-537
Conditions for Setting the DTC
The BCM has detected a short to ground on the child Scan Tool Reference
security lockout switch signal circuit for greater than Control Module References on page 6-3 for scan tool
60 seconds. information
Action Taken When the DTC Sets CircuitlSystem Verification
- The interior rear door handles will always be 1. lgnition ON.
disabled or will not lockout depending upon the
2. Verify the scan tool Left Rear Child Security Lock
latch states when the fault occurred
Switch and Right Rear Child Security Lock Switch
- The BCM will ignore the input from the lookout parameters change between Inactive and Active
switch. when pressing and depressing the child security
lockout switch.
Conditions for Clearing the DTC
:> If the parameters do not change
- The DTC will be current for as long as the fault is
present. Refer to CircuitlSystem Testing.
- When the fault is no longer present, the DTC will U If the parameters change
be a history DTC. 3. All OK.
- A history DTC will clear after 50 ignition cycles.
Reference Information
Schematic Reference
Door Lock/Indicator Schematics on page 4-238

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4‘246 Vehicle Access

CircuitlSystem Testing :> if less than 2 Q, replace the K9 body control

module.
1. lgnition OFF and all vehicle systems OFF,
disconnect the harness connector at the U If the parameter changes
S48E multifunction switch—centerconsole. it may 5. Test or replace the S48E multifunction
take up to 2 minutes for all vehicle systems to switch-center console.
power down.
Component Testing
. Test for less than 10 Q between the ground circuit
terminal 9 and ground. 1. lgnition OFF, disconnect the harness connector at
the S48E multifunction switch-center console.
if 10 Q or greater
2. Test for infinite resistance between the signal
2.1. Ignition OFF. terminal 7 and the ground terminal 9 with the
2.2. Test for less than 2 Q in the ground circuit end switch in the open position.
to end.
=>If less than infinite resistance
=>If2 Q or greater, repair the open/high resistance
in the circuit. Replace the S48E multifunction switch-center
console.
=>Ifless than 2 Q, repair the open/high resistance
in the ground connection. U If infinite resistance
3. Test for less than 3 Q between the signal terminal 7
If less than 10 Q
and the ground terminal 9 with the switch in the
lnstall a 3 A fused jumper wire between the signal closed position.
circuit terminal 7 and the ground circuit terminal 9
:> If 3 Q or greater
Verify the scan tool Left Rear Child Security Lock
Switch and Right Rear Child Security Lock Switch Replace the S48E multifunction switch—center
parameters changes to Active from inactive. console.
If the parameter does not change U If less than 3 Q
4.1. lgnition OFF, disconnect the harness 4. All OK
connector at the K9 body control module,
Repair Instructions
ignition ON.
4.2. Test for less than 1 V between the signal Perform the Diagnostic Repair Verification on
circuit and ground. page 6-92 after completing the repair.
:> If 1 V or greater, repair the short to voltage on - Front Floor Console Multifunction Switch
Replacement on page 8—105
the circuit.
- Control Module References on page 6-3 for the
U Ifless than 1 V BCM replacement, programming and setup
4.3. Test for less than 2 Q in the signal circuit end
to end.
=>If2 Q or greater, repair the open/high resistance
in the circuit.

—
2013 (US/Canada)
Sonic (5377994)
Manual
Service
 Vehicle Access $247

DTC 8252E

Diagnostic Instructions
. Perform the Diagnostic System Check —Vehicle
on page 6-66 prior to using this diagnostic
procedure.
- Review Strategy Based Diagnosis on page 6—58
for an overview of the diagnostic approach.
- Diagnostic Procedure Instructions on page 6-59
provides an overview of each diagnostic category.
DTC Descriptor
DTC B252E 02: Child Security Lock Switch Indicator Circuit Short To Ground
Diagnostic Fault Information

Open/High Signal
Circuit Short to Ground Resistance Short to Voltage Performance
Control 8252E02 1 1 —~
1.ChildSecurityIndicatorlnoperative

CircuitlSystem Description Electrical Information Reference

The body control module (BCM) will provide a ground ' Circuit Testing on page 11-526
for the child door lock indicator control circuit when the - Connector Repairs on page 11-548
BCM receives a child door lockout command. The
indicator will illuminateto indicate that the interior rear - Testing for IntermittentConditions and Poor
door handles have been disabled. Connections on page 11-531
- Wiring Repairs on page 11-537
Conditions for Running the DTC
Scan Tool Reference
The system voltage is 9—16V.
Control Module References on page 6-3 for scan tool
Conditions for Setting the DTC information
The BCM has detected a short to ground on the child
CircuitlSystem Verification
security lockout indicator control circuit for greater than
60 seconds. 1. lgnition ON.
2. Verify the function of the child lockout indicator
Action Taken When the DTC Sets when commanding the Child Lockout Indicator ON
The child lockout system will function normally when and OFF with a scan tool.
commanded by the BCM, but the Child security lockout =>If the child lockout indicator is always ON or
indicator will be continuously illuminated. always OFF
Conditions for Clearing the DTC Refer to CircuitlSystem Testing —Lockout
- The DTC will be current for as long as the fault is indicator Malfunction.
present. U If the child lockout indicator turns ON and
- When the fault is no longer present, the DTC will turns OFF
be a history DTC. 3. AMOK.
- A history DTC will clear after 50 ignition cycles Testing
CircuitlSystem
Reference Information 1. Ignition OFF, disconnect the X1 harness connector
at the S48E Multifunction SwitCh—CenterConsole.
Schematic Reference lgnition ON
Door Lock/lndicator Schematics on page 4-238 2. Connect a test lamp between the control circuit
terminal 6 and B+.
Connector End View Reference
Component Connector End Views on page 11-269
Description and Operation
Power Door Locks Description and Operation on
page 4-323

(US/Canada)
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2013 (5377994)
Manual
Service
42248 Vehicle Access
3. Verify the test lamp turns ON and OFF when =>Ifless than 2 Q, replace the K9 Body Control
commanding the Child Lockout IndicatorON and Module.
OFF with a scan tool. =>If the test lamp is always ON
:> If the test lamp is always OFF 3.1. IgnitionOFF, disconnect the harness
3.1. lgnition OFF, disconnect the harness connector at the K9 Body Control Module.
connector at the K9 Body Control Module, 32. Test for infinite resistance between the control
ignition ON. circuit and ground.
3.2. Test for less than 1 V between the control =>Ifless than infinite resistance, repairthe short to
circuit and ground. ground on the circuit.
=>If 1 V or greater, repair the short to voltage on =>Ifinfinite resistance, replace the K9 Body
the circuit. Control Module.
U Ifless than 1 V U If the test lamp turns 0N and OFF
3.3. lgnition OFF. 4. Test or replace the S48E Multifunction
3.4. Test for less than 2 Q in the control circuit end Switch—CenterConsole.
to end.
Repair Instructions
=>If2 Q or greater, repair the open/high resistance
in the circuit. Perform the Diagnostic Repair Verification on
page 6-92 after completing the repair procedure.
° Front Floor Console Multifunction Switch
Replacement on page 8-105
- Control Module References on page 6-3 for BCM
replacement, programming and setup

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
 Vehicle Access 4.249

DTC B3125, B3130, or B3135

Diagnostic Instructions
~ Perform the Diagnostic System Check - Vehicle
on page 6—66prior to using this diagnostic
procedure.
- Review Strategy Based Diagnosis on page 6-58
for an overview of the diagnostic approach.
- Diagnostic Procedure Instructions on page 6-59
provides an overview of each diagnostic category.
DTC Descriptors
DTC B3125: Driver Door Only Unlock Circuit
DTC B3130: All Doors Unlock Circuit
DTC B3135: All Doors Lock Circuit
For symptom byte information refer to: Symptom Byte
List on page 6-85
Diagnostic Fault Information

Open/High Signal
Circuit Short to Ground Resistance Short to Voltage Performance
8312502, B3125O2,
BCM B+ B313002, B313002, — -
B313502 B313502
BCM Ground — 1,2, 3,4 _ _
B312502,
DoorLock/UnlockControl 8313002, 2, 3,4 1,2, 3,4 -
B313502
B312502,
DoorLock Control B313002, 1 1,2, 3,4 -
B313502
B312502,
DriverDoorLatchUnlockControl 8313002, 1 1,2, 3,4 -
B313502
8312502,
LeftRear DoorLatchLockControl 8313002, 3 1,2, 3,4 -
8313502
B312502,
LeftRear DoorLatchUnlockControl B313002, 3 1,2, 3,4 -
B313502
B312502,
PassengerDoorLatchLockControl B313002, 2 1,2, 3,4 -
B313502 '
B312502,
PassengerDoorLatchUnlockControl 8313002, 2 1,2, 3,4 -
B313502
. B312502,
RightRear DoorLatchLockControl 8313002, 4 1,2, 3,4 ~-
8313502
B312502,
RightRear DoorLatchUnlockControi B313002, 4 1,2, 3,4 -
8313502
1. DriverDoorLock Malfunction
2. PassengerDoorLock Malfunction
3. LeftRear DoorLock Malfunction
4. RightRearDoorLock Malfunction

2013
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(US/Canada)
Service
Manual
(5377994)
4-250 Vehicle Access

CircuitlSystem Description CircuitlSystem Verification

The Body Control Module (BCM) controls the driver and
passenger door latches. When the BCM receives a
driver door unlock, passenger door unlock or all door
lock command, it will provide voltage to the appropriate
door lock circuits and ground to the opposite door lock
circuits causing the actuator to perform the lock or
unlock function.
Conditions for Running the DTC
When the output is actively being requested by
the BCM.
Conditions for Setting the DTC
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.
Action Taken When the DTC Sets
The power door locks will be inoperative.
1. lgnition ON.
2. 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 CircuitlSystem Testing —Driver Door
Lock Malfunction.
:> If one or more, but not all, passenger door
LOCK or UNLOCK functions do not work
Refer to CircuitlSystem Testing —Passenger
Door Lock Malfunction.
=>If all door LOCK and UNLOCK functions do
not work
Refer to CircuitlSystem Testing —Aii Door Lock
lnoperative.
U If the LOCK and UNLOCK function for all doors
works
3. All OK.

Conditions for Clearing the DTC CircuitlSystem Testing

- The DTC will be current for as long as the fault is Driver Door Lock Malfunction
present. 1. lgnition OFF, disconnect the harness connector at
- When the fault is no longer present, the DTC will the A23D Door Latch Assemny—Driver.
be a history DTC. lgnition ON.
- A history DTC will clear after 50 ignition cycles. Note: Leaving the DMM connected between a control
circuit and ground for greater than 20 seconds will
Reference Information cause the K9 Body Control Module to interpretthe test
Schematic Reference as a system fault and will cause the voltage on the
control circuit to drop to OV. Ifthe voltage drops to 0 V,
Door Lock/lndicator Schematics on page 4—238 operate the door locks using the door lock switch to
Body Control System Schematics on page 11-8 restore the voltage for testing.
Connector End View Reference 2. Test for greater than 7 V between the control circuit
terminal 3 and ground.
Component Connector End Views on page 11—269 =>If 7 V or less
Description and Operation 2.1. lgnition OFF, disconnect the X6 harness
connector at the K9 Body Control Module.
Power Door Locks Description and Operation on
page 4-323 2.2. Test for infinite resistance between the control
circuit and ground.
Electrical Information Reference
=>Ifless than infinite resistance, repairthe short to
- Circuit Testing on page 11-526 ground on the circuit.
- Connector Repairs on page 11-548 U Ifinfinite resistance
0 Testing for IntermittentConditions and Poor 2.3. Test for less than 2 Q in the control circuit end
Connections on page 11-531 to end.
- Wiring Repairs on page 11-537 =>If2 Q or greater, repair the open/high resistance
Scan Tool Reference on the circuit.
:> Ifless than 2 Q, replace the K9 Body Control
Control Module References on page 6-3 for scan tool Module.
information
U If greater than 7 V
Note: Leaving the DMM connected between a control
circuit and ground for greater than 20 seconds will
cause the K9 Body Control Module to interpretthe test
as a system fault and will cause the voltage on the
control circuit to drop to OV. Ifthe voltage drops to 0 V,
operate the door locks using the door lock switch to
restore the voltage for testing.

—
2013 (US/Canada)
Sonic (5377994)
Manual
Service

3. Test for greater than 7 V between the control Circuit
terminal 2 and ground.
=>If 7 V or less
3.1. lgnition OFF, disconnect the X6 harness
connector at the K9 Body Control Module.
All Door Locks Inoperative
3.2. Test for infinite resistance between the control
circuit and ground.
:> if less than infinite resistance, repairthe short to
ground on the circuit.
U if infinite resistance
3.3. Test for less than 2 Q in the control circuit end
to end.
=>If2 Q or greater, repair the open/high resistance
on the Circuit.
=>Ifless than 2 Q, replace the K9 Body Control
Module.
U If greater than 7 V
4. Test or replace the A23D Door Latch Assembly-
Driver.
Passenger Door Lock Malfunction
1. lgnition OFF, disconnect the harness connector at
the appropriate passenger or rear A23 Door Latch
Assembly. lgnition 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. Ifthe voltage drops to 0 V,
operate the door locks using the door lock switch to
restore the voltage fortesting.
2. Test for greater than 7 V between the control circuit
terminal listed below and ground:
' A23P Door Latch Assembiy-Passenger -
control terminal 7
- A23P Door Latch Assembly-Passenger -
control terminal 8
- A23RR Door Latch Assemny-Right Rear —-
control terminal 7
' A23RR Door Latch Assemny-Right Rear -
control terminal 8
o A23LR Door Latch Assembly-Left Rear -
control terminal 2
- A23LR Door Latch Assembly-Left Rear ——-
control terminal 3
:> If 7 V or less
2.1. lgnition OFF, disconnect the X6 harness
connector at the K9 Body Control Module.
2.2. Test for infinite resistance between the control
circuit and ground.
=>Ifless than infinite resistance, repair the short to
ground on the circuit.
U lf infinite resistance
2.3. Test for less than 2 Q in the control Circuit and
to end.
=>if 2 Q or greater, repair the open/high resistance
on the circuit.
2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
Vehicle Access 4-251
=>if less than 2 Q, replace the K9 Body Control
Module.
U if greater than 7 V
3. Test or replace the A23 Door Latch Assembly.
1. IgnitionOFF and all vehicle systems OFF,
disconnect the X6 harness connector at the
K9 Body Control Module. Itmay take up to
2 minutes for all vehicle systems to power down.
. Test for less than 10 Q between the ground circuit
terminal 3 and ground.
If 10 Q or greater
2.1. IgnitionOFF.
2.2. Test for less than 2 Q in the ground circuit end
to end.
=>If2 Q or greater, repair the open/high resistance
in the circuit.
=>If less than 2 Q, repair the open/high resistance
in the ground connection.
If less than 10 Q
lgnition OFF, disconnect the X2 harness connector
at the K9 Body Control Module, ignition ON.
Verify a test lamp illuminates between the B+
circuit terminal 4 and ground.
If the test lamp does not illuminate and the
circuit fuse is good
4.1. lgnition OFF.
4.2. Test for less than 2 Q in the B+ circuit end
to end.
=>If2 Q or greater, repair the open/high resistance
in the circuit.
=>If less than 2 Q, verify the fuse is not open and
there is voltage at the fuse.
If the test lamp does not illuminate and the
circuit fuse is open
4.1. IgnitionOFF.
4.2. Test for infinite resistance between the B+
circuit and ground.
=>If less than infinite resistance, repairthe short to
ground on the circuit.
U If infinite resistance
4.3. Disconnect the harness connector at each of
the A23 Door Latch Assemblies.
4.4. Test for infinite resistance between each
control circuit and ground.
=>Ifless than infinite resistance, repair the short to
ground on the circuit.
=>Ifinfinite resistance, replace the appropriate
A23 Door Latch Assembly.
If the test lamp illuminates
lgnition OFF, connect the X2 and X6 harness
connectors at the K9 Body Control Module.
Disconnect the harness connector at the
A23D Door Latch Assembly—Driver,ignition ON.
4=252 Vehicle Access
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 door lock switch to
restore the voltage for testing.
6. Test for greater than 7V between the control circuit
terminal 2 and ground.
=>If 7 V or less
6.1. lgnition OFF, disconnect the X6 harness
connector at the K9 Body Control Module.
6.2. Test for infinite resistance between the control
circuit terminal listed below and ground:
. Control circuitterminal 1 X6
- Control circuit terminal 2 X6
- Control circuit terminal 4 X6
:> ifless than infinite resistance, repairthe short to
ground on the circuit.
=>Ifinfinite resistance, replace the K9 Body
Control Module.
U If greater than 7 V
7. Replace the K9 Body Control Module.
Component Testing
1. lgnition OFF, disconnect the harness connector at
the appropriate A23 Door Latch Assembly.
2. Install a 25A 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 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.
U If the actuator performs the LOCK and UNLOCK
function
3. All OK
Repair Instructions
Perform the Diagnostic Repair Verification on
page 6—92after completing the repair.
- Front Side Door Latch Replacement on
page 4-299
. Rear Side Door Latch Replacement on
page 4-301
~ Control Module References on page 6-3 for BCM
replacement, programming and setup
(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
 Vehicle Access 4253

DTC 33140 or B3150

Diagnostic Instructions
1 - Perform the Diagnostic System Check - Vehicle
1 on page 6-66 prior to using this diagnostic
‘ procedure.
- Review Strategy Based Diagnosis on page 6-58
for an overview of the diagnostic approach.
- Diagnostic Procedure Instructions on page 6-59
provides an overview of each diagnostic category.
DTC Descriptors
DTC B3140 00: Driver Door Unlock Switch Circuit
DTC B3150 00: Left Front Door Lock Switch Circuit

Diagnostic Fault Information

Opeanigh Signal
Circuit Short to Ground Resistance Short to Voltage Performance
LockSignal B315000 1 1 -
UnlockSignal B314000 2 2 —-
Ground — 3 — -
1.DoorLockSwitchLock FunctionInoperative
2. DoorLockSwitchUnlockFunctionInoperative
3. DoorLockSwitchLockand UnlockFunctionslnoperative

CircuitlSystem Description Conditions for Clearing the DTC

The BCM monitors the voltage level of the door lock ° The DTC will be current for as long as the fault is
and door unlock signal circuits. When the driver door present.
lock switch is in the open position, the voltage level in - When the fault is no longer present, the DTC will
the signal circuit will be near 0 V. When the driver door be a history DTC.
lock switch is pressed to the lock or unlock position, a
signal will be sent to the BCM requesting a lock or - A history DTC will clear after 50 ignition cycles.
unlock command. Reference Information
Conditions for Running the DTC Schematic Reference
The system voltage is 9—16 V.
Door Lock/lndicator Schematics on page 4—238
Conditions for Setting the DTC Connector End View Reference
B3140 00 Component Connector End Views on page 11—269
The BCM detects short to ground in the unlock signal Description and Operation
circuit for greater than 60 seconds.
Power Door Locks Description and Operation on
B3150 00 page 4-323
The BCM detects a short to ground in the lock signal
circuit for greater than 60 seconds. Electrical Information Reference
° Circuit Testing on page 11—526
Action Taken When the DTC Sets
- Connector Repairs on page 11-548
B3140 00 - Testing for IntermittentConditions and Poor
The BCM will ignore the unlock signal and the doors Connections on page 11-531
will not unlock when using the driver door lock switch. - Wiring Repairs on page 11—537
B3150 00 Scan Tool Reference
The BCM will ignore the lock signal and the doors will Control Module References on page 6-3 for scan tool
not look when using the driver door lock switch. information

2013
-Sonic
(US/Canada)
Service
Manda!
(5377994)
4=254 Vehicle Access
Circuit/System Verification
1 ignition ON
2. Verify the scan tool BCM Central Door Lock Switch
on Console parameter changes from Inactive to
Look and Unlock when pushing the appropriate
switch on the driver door lock switch.
=>If the parameter does not change
Refer to CircuitlSystem Testing.
U If the parameter changes
3 AMOK.
CircuitlSystem Testing
1. Ignition OFF and all vehicle systems OFF,
disconnect the harness connector at the
S13D door lock switch-driver. it may take up to
2 minutes for all vehicle systems to power down.
2. Test for less than 10 Q between the ground circuit
terminal1 and ground.
:> If 10 Q or greater
2.1. IgnitionOFF.
2.2. Test for less than 2 Q in the ground circuit end
to end.
:> If2 Q or greater, repair the open/high resistance
in the circuit.
=>Ifless than 2 Q, repair the open/high resistance
in the ground connection.
U If less than 10 Q
9° IgnitionON.
4. Verify the scan tool Central Door Lock Switch on
Console parameter is Inactive.
=>if not Inactive
4.1. lgnition OFF, disconnect the X2 harness
connector at the K9 body control module.
4.2. Test for infinite resistance between the signal
circuitterminal15 and ground.
=>Ifless than infinite resistance, repair the short to
ground on the circuit.
4.3. Test for infinite resistance between the signal
circuitterminal19 and ground.
=>Ifless than infinite resistance, repair the short to
ground on the circuit.
=>Ifinfinite resistance, replace the K9 body control
module.
U lf Inactive
5. Install a 3 A fused jumper wire between the signal
circuit terminal 3 and the ground circuit terminal 1.
6. Verify the scan tool Central Door Lock Switch on
Console parameter is Unlock.
=>If not Unlock
6.1. lgnition OFF, disconnect the X2 harness
connector at the K9 body control module,
ignition ON.
6.2. Test for less than 1 V between the signal
circuit terminal 15 and ground.
=>if 1 V or greater, repair the short to voltage on
the circuit.
U Ifless than 1 V
6.3. Test for less than 2 Q in the signal circuit end
to end.
=>If2 Q or greater, repair the open/high resistance
in the circuit.
=>Ifless than 2 Q, replace the K9 body control
module.
U If Unlock
7. Install a 3 A fused jumper wire between the signal
circuit terminal 4 and the ground circuitterminai1.
8. Verify the scan tool Central Door Lock Switch on
Console parameter is Lock.
=>If not Lock
8.1. IgnitionOFF, disconnect the X2 harness
connector at the K9 body control module,
ignition ON.
8.2. Test for less than 1 V between the signal
Circuit terminal 19 and ground.
=>If 1 V or greater, repair the short to voltage on
the circuit.
U Ifless than 1 V
8.3. Test for less than 2 Q in the signal circuit end
to end.
=>If2 Q or greater, repair the open/high resistance
in the circuit.
=>if less than 2 Q, replace the K9 body control
module.
U If Lock
9. Test or replace the S13D door lock switch—driver.
Component Testing
1. lgnition OFF, disconnect the harness connector at
the S13D door lock switch-driver.
2. Test for infinite resistance between the signal
terminal 4 and the ground terminal 1 with the switch
in the open position.
2 If less than infinite resistance
Replace the S13D door lock switch—driver.
U If infinite resistance
3. Test for infinite resistance between the signal
terminal 3 and the ground terminal 1 with the switch
in the open position.
2:»If less than infinite resistance
Replace the S13D door lock switch-driver.
U If infinite resistance
(US/Canada)
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2013 (5377994)
Manual
Service
 Vehicle Access 4-255
. Test for less than 2 Q between the signal terminal 4 Repair instructions
and the ground terminal 1 with the switch in the
Lock position. Perform the Diagnostic Repair Verification on
page 6—92after completing the diagnostic procedure.
If 2 Q or greater
- Door Lock Switch Replacement on page 4-321
Replace theS13D door lock switch-driver. - Control Module References on page 6-3 for BCM
If less than 2 Q replacement, programming and setup
. Test for less than 2 Q between the signal terminal 3
and the ground terminal 1 with the switch in the
Unlock position.
If 2 Q or greater
Replace the S13D door lock switch-driver.
If less than 2 Q
. All OK

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
44256 Vehicle Access

DTC B324A or B3245

Diagnostic Instructions
- Perform the Diagnostic System Check —Vehicle
on page 6-66 prior to using this diagnostic
procedure.
- Review Strategy Based Diagnosis on page 6-58
for an overview of the diagnostic approach.
- Diagnostic Procedure Instructions on page 6-59
provides an overview of each diagnostic category.
DTC Descriptors
DTC B324A 01: Rear Cargo Door Unlock Motor Circuit Short to Battery
DTC B3245 02: Rear Cargo Door Lock Motor Circuit Short to Ground

Diagnostic Fault Information

Open/High Signal
Circuit Short to Ground Resistance Short to Voltage Performance
Control B324502 1 B324A01 -
1.LiftgateRelease Malfunction

CircuitlSystem Description Description and Operation

When the body control module (BCM) receives a Luggage Compartment Description and Operation on
liftgate release command, it will provide voltage to one page 4-322
side of the relay and ground to the other side of the
relay. This will energize the relay causing the switch Electrical Information Reference
side of the relay to close and will then provide B+ - Circuit Testing on page 11—526
voltage to the liftgate or rear closure latch. Connector Repairs on page 11—548
-
Conditions for Running the DTC - Testing for IntermittentConditions and Poor
- The system voltage is 9—16V. Connections on page 11-531
- When the relay is actively commanded by . Wiring Repairs on page 11—537
the BCM. Scan Tool Reference
Conditions for Setting the DTC Control Module References on page 6—3for scan tool
information
B324A 01
The BCM detects a short to voltage in the liftgate CircuitlSystem Verification
release relay control circuit. 1. lgnition ON.
B3245 02 2. Verify the operation of the liftgate latch by pressing
the liftgate unlatch switch.
The BCM detects a short to ground in the liftgate
release relay control circuit. :> If the liftgate latch does not UNLATCH
Refer to CircuitlSystem Testing.
Action Taken When the DTC Sets
U If the liftgate latch does UNLATCH
The liftgate latch will be inoperative.
3. AlIOK.
Conditions for Clearing the DTC
CircuitlSystem Testing
- The DTC will be current for as long as the fault is
present. 1. lgnition OFF, disconnect the KR95A liftgate unlatch
relay. IgnitionON.
- When the fault is no longer present, the DTC will
be a history DTC. 2. Connect a test lamp between the control circuit
terminal1 and ground.
- A history DTC will clear after 50 ignition cycles.
Reference Information
Schematic Reference
Release Systems Schematics on page 4-241
Connector End View Reference
Component Connector End Views on page 11-269
—
2013 (US/Canada)
Sonic (5377994)
Manual
Service

3. Verify the test lamp briefly illuminates when
commanding the Trunk Lid Unlatch On and Off with
a scan tool.
If the test lamp is always OFF
3.1. IgnitionOFF, disconnect the harness
connector at the K9 body control module.
3.2. Test for infinite resistance between the control
circuit and ground.
=>if less than infinite resistance, repair the short to
ground on the circuit.
U If infinite resistance
3.3. Test for less than 2 Q in the control circuit end
to end.
=>If2 Q or greater, repair the open/high resistance
in the circuit.
=>If less than 2 Q, replace the K9 body control
module.
If the test lamp is always ON
3.1. lgnition OFF, disconnect the harness
connector at the K9 body control module,
ignition ON.
3.2. Test for less than 1 V between the control
circuit and ground.
=>If 1 V or greater, repair the short to voltage on
the circuit.
=>If less than 1 V, replace the K9 body control
module.
4: If the test lamp turns 0N and OFF
Connect a test lamp between the control circuit
terminal 2 and B+.
Verify the test lamp briefly illuminates when
commanding the Trunk Lid Unlatch On and Off with
a scan tool.
If the test lamp is always OFF
5.1. lgnition OFF, disconnect the harness
connector at the K9 body control module,
ignition ON.
5.2. Test for less than 1 V between the control
circuit and ground.
=>If 1 V or greater, repair the short to voltage on
the circuit.
U If less than 1 V
5.3. lgnition OFF.
5.4. Test for less than 2 Q in the control circuit end
to end.
=>If2 Q or greater, repair the open/high resistance
in the circuit.
2013
-Sonic
(US/Canada)
Service
Manual
{5377994)
Vehicle Access 4257
:> If less than 2 Q, replace the K9 body control
module.
:> If the test lamp is always ON
5.1. lgnition OFF, disconnect the harness
connector at the K9 body control module.
5.2. Test for infinite resistance between the control
circuit and ground.
=>If less than infinite resistance, repair the short to
ground on the circuit.
=>If infinite resistance, replace the K9 body control
module.
U If the test lamp turns ON and OFF
6. Test or replace the KR95A|iftgate unlatch relay.
Component Testing
Relay Test
1. IgnitionOFF, disconnect the KR95A liftgate unlatch
relay.
2. Test for 60—200Q between terminals 1 and 3.
=>If less than 60 Q or greater than 200 Q
Replace the KR95A liftgate unlatch relay.
If between 60—200Q
Test for infinite resistance between the terminals
listed below:
° 4 and 3
- 4 and 5
~ 4 and 1
' 5 and 1
If less than infinite resistance
Replace the KR95A liftgate unlatch relay.
4: If infinite resistance
Install a 3 A fused jumper wire between relay
terminal 3 and 12 V. Install a jumper wire between
relay terminal 1 and ground.
Test for less than 2 Q between terminals 4 and 5.
=>lf 2 Q or greater
Replace the KR95A liftgate unlatch relay.
U If less than 2 Q
6. All OK
Repair Instructions
Perform the Diagnostic Repair Verification on
page 6-92 after completing the diagnostic procedure.
Relay Replacement (Within an Electrical Center)
on page 11—607or Re/ay Replacement (Attached
to Wire Harness) on page 11—607
Control Module References on page 6-3 for BCM
replacement, programming and setup
4-258 Vehicle Access

DTC B3265

Diagnostic Instructions
- Perform the Diagnostic System Check —Vehicle
on page 6-66 prior to using this diagnostic
procedure.
. Review Strategy Based Diagnosis on page 6-58
for an overview of the diagnostic approach.
- Diagnostic Procedure Instructions on page 6-59
provides an overview of each diagnostic category.
DTC Descriptors
DTC B3265: Trunk Lid Unlatch Output Circuit
For symptom byte information refer to: Symptom Byte
List on page 6-85
Diagnostic Fault Information

OpmVHMh Sbnm
Circuit Short to Ground Resistance Short to Voltage Performance
Control 8326502 8326504 B326501 -
Ground — 8326504 — -

CircuitlSystem Description Reference Information

When the Body Control Module (BCM) receives a Schematic Reference
liftgate release command, it will provide voltage to the
relay. This will energize the relay causing the switch Release Systems Schematics on page 4—241
side of the relay to close and will then provide B+ Connector End View Reference
voltage to the rear compartment lid latch.
Component Connector End Views on page 11-269
Conditions for Running the DTC
Description and Operation
. The system voltage is 9—16V.
- When the relay is actively commanded by Luggage Compartment Description and Operation on
the BCM. page 4-322
Electrical Information Reference
Conditions for Setting the DTC
. Circuit Testing on page 11-526
B3265 01
- Connector Repairs on page 11—548
The BCM detects a short to voltage in the Rear
Compartment Lid Unlatch Relay control circuit. - Testing for IntermittentConditions and Poor
Connections on page 11-531
B3265 02 - Wiring Repairs on page 11-537
The BCM detects a short to ground in the Rear Scan Tool Reference
Compartment Lid Unlatch Relay control circuit.
Control Module References on page 6—3for scan tool
B3265 04
information
The BCM detects an open/high resistance in the Rear
Compartment Lid Unlatch Relay control circuit or an CircuitlSystem Verification
open/high resistance in the relay ground circuit. 1. IgnitionON.
Action Taken When the DTC Sets 2. Verify the operation of the M40 Rear Compartment
Lid Latch when commanding the Trunk Lid Unlatch
The rear compartment lid latch will be inoperative. with a scan tool.
Conditions for Clearing the DTC :> If the M40 Rear Compartment Lid Latch does
- The DTC will be current for as long as the fault is not UNLATCH
present. Refer to CircuitlSystem Testing.
- When the fault is no longer present, the DTC will U If the M40 Rear Compartment Lid Latch does
be a history DTC. UNLATCH
- A history DTC will clear after 50 ignition cycles. 3. All OK.

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
 Vehicle Access 4-259

CircuitlSystem Testing =>Ifless than 1 V, replace the K9 Body Control

.MWJL,
WM
, Module.
1. lgnition OFF and all vehicle systems OFF,
disconnect the KRQSB Rear Compartment Lid
Unlatch Relay. Itmay take up to 2 minutes for all
vehicle systems to power down.
2. Test for less than 10 Q between the ground circuit
terminal 2 and ground.
=>If 10 Q or greater
2.1. lgnition OFF.
2.2. Test for less than 2 Q in the ground circuit end
to end.
=>If2 Q or greater, repair the open/high resistance
in the circuit.
=>Ifless than 2 Q, repair the open/high resistance
in the ground connection.
U If less than 10 Q
3. Connect a test lamp between the control circuit
terminal 1 and the ground circuit terminal 2.
4. Verify the test lamp briefly turns ON and OFF when
commanding the Trunk Lid Unlatch with a scan tool
with a scan tool.
=>If the test lamp is always OFF
4.1. lgnition OFF, disconnect the harness
connector at the K9 Body Control Module.
4.2. Test for infinite resistance between the control
circuit and ground.
=>Ifless than infinite resistance, repair the shortto
ground on the circuit.
U If infinite resistance
4.3. Test for less than 2 Q in the control circuit end
to end. ' =>If 2 Q or greater
=>If2 Q or greater, repair the open/high resistance
in the circuit.
=>Ifless than 2 Q, replace the K9 Body Control
Module.
:> If the test lamp is always CM
4.1. lgnition OFF, disconnect the harness
connector at the K9 Body Control Module,
ignition ON.
4.2. Test for less than 1 V between the control
circuit and ground.
=>If 1 V or greater, repair the short to voltage on
the circuit.
U If the test lamp turns ON and OFF
5. Test or replace the KRQSB Rear Compartment Lid
Unlatch Relay. ‘
Component Testing
Relay Test
1. lgnition OFF, disconnect the KRQSB Rear
Compartment Lid Unlatch Relay.
2. Test for 60—200Q between terminals 1 and 3.
=>If less than 60 Q or greater than 200 Q
Replace the KR95B Rear Compartment Lid
Unlatch Relay.
U lf between 60—200Q
3. Test for infinite resistance between the terminals
listed below:
- 4 and 3
- 4 and 5
- 4 and 1
- 5 and 1
=>If less than infinite resistance
Replace the KRQSB Rear Compartment Lid
Unlatch Relay.
U If infinite resistance
4. Install a 3 A fused jumper wire between relay
terminal 3 and 12 V. Install ajumper wire between
relay terminal 1 and ground.
.01Test for less than 2 Q between terminals 4 and 5.
Replace the KR95B Rear Compartment Lid
Unlatch Relay.
U If less than 2 Q
6. All OK
Repair Instructions
Perform the Diagnostic Repair Verification on
page 6—92after completing the repair.
- Relay Replacement (Within an Electrical Center)
on page 11-607 or Relay Replacement (Attached
to Wire Harness) on page 11-607
' Control Module References on page 6—3for BCM
replacement, programming and setup

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
4260 Vehicle Access

DTC B3618

Diagnostic Instructions
- Perform the Diagnostic System Check —Vehicle
on page 6-66 prior to using this diagnostic
procedure.
' Review Strategy Based Diagnosis on page 6-58
for an overview of the diagnostic approach.
- Diagnostic Procedure Instructions on page 6-59
provides an overview of each diagnostic category.
DTC Descriptor
DTC B3618 00: Exterior Liftgate Unlatch Switch Circuit Malfunction
Diagnostic Fault Information

Open/High Signal
Circuit Short to Ground Resistance Short to Voltage Performance
Signal B361800 1 1 —-
Ground . — 1 _ _
1.ExteriorRear CompartmentLid ReleaseSwitchMalfunction

CircuitlSystem Description Connector End View Reference

When the ignition is ON, the body control module Component Connector End Views on page 11-269
(BCM) supplies a signal to the rear compartment lid
unlatch switch through the trunk release switch signal Description and Operation
circuit. When the exterior rear compartment lid release Luggage Compartment Description and Operation on
switch is pressed, the voltage within the signal circuit is page 4—322
pulled low and in response, the BCM will energize the
trunk release relay. Electrical Information Reference

Conditions for Running the DTC - Circuit Testing on page 11-526

- Connector Repairs on page 11-548
The system voltage is 9—16V.
- Testing for IntermittentConditions and Poor
Conditions for Setting the DTC Connections on page 11—531
The BCM detects a short to ground in the rear - Wiring Repairs on page 11—537
compartment lid release switch signal circuit for greater Scan Tool Reference
than 60 seconds
Control Module References on page 6—3for scan tool
Action Taken When the DTC Sets information
The BCM ignores the input from the rear compartment
lid unlatch switch. CircuitlSystem Verification
1. IgnitionON.
Conditions for Clearing the DTC
2. Verify the scan tool Trunk Lid/Liftgate Window
- This DTC will be current for as long as the fault is Exterior Unlatch Switch parameter changes
present. between Active and Inactive when pressing and
' When the fault is no longer present, the DTC will releasing the rear compartment lid unlatch
_be a history DTC. switch-exterior.
- A history DTC will clear after 50 ignition cycles. :> If the parameter does not change
Reference Information Refer to CircuitlSystem Testing.
U If the parameter changes
Schematic Reference
3. All OK.
Release Systems Schematics on page 4-241

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
 Vehicle Access 4-261

CircuitlSystem Testing :5 If less than 2 Q, replace the K9 body control

module.
1. lgnition OFF and all vehicle systems OFF,
disconnect the harness connector at the S58A rear U If Active
compartment lid unlatch switch—exterior.Itmay 7. Test or replace the 858A rear compartment lid
take up to 2 minutes for all vehicle systems to unlatch switch-exterior.
power down.
Component Testing
2. Test for less than 10 Q between the ground Circuit
terminal 2 and ground. 1. lgnition OFF, disconnect the harness connector at
:> If 10 Q or greater the 858A rear compartment lid unlatch
switch—exterior.
2.1. lgnition OFF.
2. Test for infinite resistance between the signal
2.2. Test for less than 2 Q in the ground circuit and terminal 1 and the ground terminal 2 with the switch
to end. in the open position.
:> If2 Q or greater, repair the open/high resistance =>If less than infinite resistance
in the circuit.
Replace the 858A rear compartment lid unlatch
:> if less than 2 Q, repair the open/high resistance switch-exterior.
in the ground connection.
U If infinite resistance
U If less than 10Q
3. Test for less than 3 Q between the signal terminal 1
. lgnition ON.
(.0 and the ground terminal 2 with the switch in the
4. Verify the scan tool Trunk Lid/Liftgate Window closed position.
Exterior Unlatch Switch parameter is inactive. ‘ =>If 3 Q or greater
=>If not Inactive Replace the 858A rear compartment lid unlatch
4.1. lgnition OFF, disconnect the harness switch—exterior.
connector at the K9 body control module.
U If less than 3 Q
4.2. Test for infinite resistance between the signal
4. All OK
circuit terminal1 and ground.
=>if less than infinite resistance, repair the short to Repair Instructions
ground on the circuit. Perform the Diagnostic Repair Verification on
=>If infinite resistance, replace the K9 body control page 6-92 after completing the diagnostic procedure.
module. - Liftgate Release Switch Replacement on
U If Inactive page 4-320
5. Install a 3 A fused jumper wire between the signal ' Control Module References on page 6-3 for BCM
circuit terminal1 and the ground circuit terminal 2. replacement, programming and setup
6. Verify the scan tool Trunk Lid/Liftgate Window
Exterior Unlatch Switch parameter is Active.
=>If not Active
6.1. lgnition OFF, disconnect the harness
connector at the K9 body control module,
ignition ON.
6.2. Test for less than 1 V between the signal
circuit and ground.
=>lf 1 V or greater, repair the short to voltage on
the circuit.
U if less than 1 V
6.3. Test for less than 2 Q in the signal circuit end
to end.
:> if 2 Q or greater, repair the open/high resistance
in the circuit.

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
4-262 Vehicle Access

DTC B3930
Diagnostic Instructions
- Perform the Diagnostic System Check - Vehicle
on page 6—66prior to using this diagnostic
procedure.
- Review Strategy Based Diagnosis on page 6-58
for an overview of the diagnostic approach.
- Diagnostic Procedure Instructions on page 6—59
provides an overview of each diagnostic category.
DTC Descriptors
DTC B3930 01: Child Security Lock Motors Circuit Short to Battery
DTC B3930 02: Child Security Lock Motors Circuit Short to Ground
DTC B3930 04: Child Security Lock Motors Circuit Open
Diagnostic Fault Information

Openflfigh Sbnal
Circuit Short to Ground Resistance Short to Voltage Performance

am 8.22232 882,212.12 — -

DoorLock SecurityRelayControl B393002 BB:3%I3%%141 Egggg(2)11 __

UnderhoodFuse BlockGround — agggggf _ _

CircuitlSystem Description The body control module detects a short to ground or

an open/high resistance in the body control module B+
The body control module controls the child security lock circuit.
relay when it receives a command to lockout the rear
doors. The relay will apply voltage to both child security Action Taken When the DTC Sets
circuits at the rear door latches to disable the interior - The interior rear door handles will always be
rear door handles. disabled or will not lockout depending upon the
Conditions for Running the DTC latch states when the fault occurred
being actively commanded - The body control module will command the
When the Door Lock relay is
lockout indicator to flash ON and OFF for
by the body control module. 30 seconds when the lookout switch is pressed to
Conditions for Setting the DTC indicate a fault in the system.

B3930 01 Conditions for Clearing the DTC

The body control module detects a short to voltage or - The DTC will be current for as long as the fault is
an open/high resistance in the door lock security relay present. ‘
control circuit. . When the fault is no longer present, the DTC will
The body control module detects a an open/high be a history DTC.
resistance in the underhood fuse block ground circuit. . A history DTC will clear after 50 ignition cycles.
The body control module detects a short to ground or Reference Information
an open/high resistance in the body control module B+
circuit. Schematic Reference
B3930 02 Door Lock/lndicator Schematics on page 4-238
The BCM detects a short to ground in the door lock Connector End View Reference
security relay control circuit.
Component Connector End Views on page 11-269
B3930 04
Description and Operation
The body control module detects a short to voltage or
an open/high resistance in the door lock security relay Power Door Locks Description and Operation on
control circuit. page 4—323
The body control module detects a an open/high
resistance in the underhood fuse block ground circuit.

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Electrical Information Reference
° Testing for IntermittentConditions and Poor
Connections on page 11-531
- Circuit Testing on page 11—526
. Wiring Repairs on page 11-537
- Connector Repairs on page 11-548
Scan Tool Reference
Control Module References on page 6—3for scan tool
information
CircuitlSystem Verification
1. lgnition 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
Refer to CircuitlSystem Testing.
U 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.
=>If both interior door handles do not open the
rear doors
Refer to CircuitlSystem Testing.
U If both interior door handles open the rear
doors
4 All OK.
CircuitlSystem Testing
1. lgnition OFF and all vehicle systems OFF,
disconnect the X2 harness connector at the
X50A Fuse Block-Underhood. Itmay take up to
2 minutes for all vehicle systems to power down.
2. Test for less than 10 Q between the ground circuit
terminal C5 and ground.
=>If 10 Q or greater
2.1. IgnitionOFF.
2.2. Test for less than 2 Q in the ground circuit end
to end.
=>If2 Q or greater, repair the open/high resistance
in the circuit.
=>if less than 2 Q, repair the open/high resistance
in the ground connection.
U if less than 10 Q
3. IgnitionOFF, connect the X2 harness connector at
the X50A Fuse Block-Underhood. Disconnect the
X4 harness connector at the K9 Body Control
Module, ignition ON.
Vehicle Access 4=263
4. Verify that a test lamp does not illuminate between
the control circuit terminal 8 and ground.
:> If the test lamp illuminates
4.1. lgnition OFF, remove the test lamp, disconnect
the X2 harness connector at the X50A Fuse
Block—Underhood.
4.2. Test for less than 1 V betweenthe K9 Body
Control Module control circuit terminal 8 X4
and ground.
=>If 1 V or greater, repair the short to voltage on
the circuit.
=>Ifless than 1 V, replace the X50A Fuse
Block-Underhood.
if the test lamp is not illuminated
Connect a 3A fused jumper wire between the
control circuit terminal 8 and B+.
. Listen for an audible click from the X50A Fuse
Biock-Underhood as the KR113 Child Security
Lock Disable Relay activates.
If the KR113 Child Security Lock Disable Relay
does not activate
6.1. lgnition OFF, remove thejumperwire,
disconnect the X2 harness connector at the
X50A Fuse BIock-Underhood.
6.2. Test for infinite resistance between the K9
Body Control Module control circuit terminal 8
X4 and ground.
2» If less than infinite resistance, repair the short to
ground on the circuit.
U If infinite resistance
6.3. Test for less than 2 Q in the control circuit end
to end.
=>lf 2 Q or greater, repair the open/high resistance
in the circuit.
=>If less than 2 Q, replace the X50A Fuse
BIock—Underhood.
U If the KR113 Child Security Lock Disable Relay
activates
7. Replace the K9 Body Control Module.
Repair Instructions
Perform the Diagnostic Repair Verification on
page 6-92 after completing the repair.
Front Compartment Fuse Block Replacement on
page 11-609
Control Module References on page 6—3body
control module replacement, programming and
setup

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4:264 Vehicle Access

Symptoms - Vehicle Access Intermittent

Note: The following steps must be completed before Faulty electrical connections or wiring may be the
using the symptom tables. cause of intermittentconditions. Refer to Testing for
IntermittentConditions and Poor Connections on
1. Perform the Diagnostic System Check - Vehicle on page 11-531.
page 6—66.
- There are no DTCs set Symptom List
. The control modules can communicate via the Refer to a symptom diagnostic procedure from the
serial data link following list in order to diagnose the symptom:
2. Review the system operation in order to familiarize - Hatch Release Malfunction on page 4—264
yourself with the system functions. Refer to the - Power Door Child Lock Malfunction on page 4-271
following systems description: . Door Ajar Indicator Malfunction on page 4-268
- Door Ajar Indicator Description and Operation - Power Door Locks Malfunction on page 4-275
on page 4-322
. Trunk Release Malfunction on page 4-280
' Luggage Compartment Description and
Operation on page 4—322 - Door Will Not Open/C/ose, Door Binding, or Locks,
Handles, or Cylinders Do Not Function on
- Power Door Locks Description and Operation
on page 4323 page 4'28‘3
VisualIPhysical Inspection
' Inspect for aftermarket devices which may affect
the operation of the system. Refer to Checking
Aftermarket Accessories on page 11-525.
- inspect the easily accessible or visible system
components for obvious damage or conditions
which may cause the symptom.

Hatch Release Malfunction

Diagnostic Instructions
- Perform the Diagnostic System Check —Vehicle
on page 6—66prior to using this diagnostic
procedure.
- Review Strategy Based Diagnosis on page 6-58
for an overview of the diagnostic approach.
- Diagnostic Procedure Instructions on page 6—59
provides an overview of each diagnostic category.
Diagnostic Fault Information

Open/High Signal
Circuit Short to Ground Resistance Short to Voltage Performance
LiftgateRelaySwitchB+ 2 2 — . -
LiftgateUnlatchSwitchSignal B249400 1 1 -
LiftgateRelayControlLow — 2 — -
LiftgateRelayControlHigh B324502 2 B324A01 -
LiftgateLatchGround — 2 — -
LiftgateUnlatchSwitchGround — 1 — -
1. LiftgateReleaseSwitchMalfunction
2. LiftgateReleaseMalfunction

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CircuitlSystem Description
The liftgate unlatch switch is an input to the body
control module (BCM). The BCM supplies a 12 V signal
to the liftgate unlatch switch and when the switch is
pressed, signal circuit voltage goes low. When the BCM
receives a liftgate release signal it will monitorthe
status to the door latches. if the vehicle doors are
locked, the BCM will ignore the request, if the doors are
unlocked, the BCM will supply voltage and ground to
the liftgate release relay coil, energizing the relay.
When the relay is energized, battery voltage flows
through the closed contacts of the relay to the liftgate
latch assembly which activates allowing for the liftgate
to be raised to the open position.
Diagnostic Aids
An intermittentshort to ground in the liftgate unlatch
switch Signal circuit may cause the BCM to command
the liftgate to open if the vehicle is in park and the doors
are unlocked. Ifthe vehicle has a history of the liftgate
opening unexpectedly, inspect the point where the
wires enter the liftgate unlatch switch for corrosion or
eVidence of water intrusion.
Note: Verify all doors have been commanded
UNLOCK with a scan tool prior to commanding the
liftgate to unlatch
Reference Information
Schematic Reference
Release Systems Schematics on page 4-241
Connector End View Reference
Component Connector End Views on page 11-269
Description and Operation
Luggage Compartment Description and Operation on
page 4-322
Electrical Information Reference
- Circuit Testing on page 11—526
- Connector Repairs on page 11—548
- Testing for IntermittentConditions and Poor
Connections on page 11-531
° Wiring Repairs on page 11-537
Scan Tool Reference
Control Module References on page 6-3 for scan tool
information
CircuitlSystem Verification
1. IgnitionON.
2. Verify the scan tool Trunk Lid/Liftgate Window
Exterior Unlatch Switch parameter changes
between Active and Inactive when pressing and
releasing the S46B Liftgate Unlatch Switch.
2 If the parameter does not change
Refer to CircuitlSystem Testing — Liftgate
Release Switch lnoperative
U If the parameter changes
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Vehicle Access 4-285
3. Verify the operation of the liftgate when
commanding the M30 Liftgate Latch to UNLATCH
by pressing the S46B Liftgate Unlatch Switch.
2 If the M30 Liftgate Latch does not UNLATCH
Refer to CircuitlSystem Testing ——Liftgate
Release Actuator lnoperative
U If the M30 Liftgate Latch does UNLATCH
4. All OK.
CircuitlSystem Testing
Liftgate Release Switch lnoperative
1. IgnitionOFF 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.
2. Test for less than 10 Q between the ground circuit
terminal 2 and ground.
2 If 10 Q or greater
2.1. lgnition OFF.
2.2. Test for less than 2 Q in the ground circuit end
to end.
2 If2 Q or greater, repair the open/high resistance
in the circuit.
2 Ifless than 2 Q, repair the open/high resistance
in the ground connection.
U if less than 10 Q
9’ lgnition ON.
4. Verify the scan tool Trunk Lid/Lifigate Window
Exterior Unlatch Switch parameter is Inactive.
2 if not Inactive
4.1. lgnition OFF, disconnect the harness
connector at the K9 Body Control Module.
4.2. Test for infinite resistance between the signal
circuit terminal 1 and ground.
2 Ifless than infinite resistance, repair the short to
ground on the circuit. _
2 If infinite resistance, replace the K9 Body
Control Module.
U lf Inactive ,
5. install a 3 A fused jumper wire between the signal
circuit terminal 1 and the ground circuit terminal 2.
6. Verify the scan tool Trunk Lid/Liftgate Window
Exterior Unlatch Switch parameter is Active.
2 If not Active '
6.1. lgnition OFF, remove the 3 A fused jumper
wire, disconnect the harness connector at the
K9 Body Control Module, ignition ON.
6.2. Test for less than 1 V between the signal
circuit and ground.
2 If 1 V or greater, repair the short to voltage on
the circuit.
U Ifless than 1 V
6.3. Test for less than 2 Q in the signal circuit end
to end.
2 if 2 Q or greater, repair the open/high resistance
in the circuit.
4-266 Vehicle Access
2 if less than 2 Q, replace the K9 Body Control
Module.
U If Active
7. Test or replace the S46B Liftgate Unlatch Switch.
Release Actuator lnoperative
1. IgnitionOFF, disconnect the KR95A Liftgate
Unlatch Relay. lgnition ON
2. Verify a test lamp illuminates between the B+
circuit terminal 3 and ground.
2 If the test lamp does not illuminate and the
circuit fuse is good
2.1. lgnition OFF.
2.2. Test for less than 2 Q in the B+ circuit end
to end.
2 if 2 Q or greater, repair the open/high resistance
in the circuit.
2 Ifless than 2 Q, verify the fuse is not open and
there is voltage at the fuse.
2 If the test lamp does not illuminate and the
circuit fuse is open
2.1. lgnition OFF.
2.2. Test for infinite resistance between the B+
circuit and ground.
2 Ifless than infinite resistance, repair the short to
ground on the circuit.
U Ifinfinite resistance,
2.3. Disconnect the harness connector at the
M30 Liftgate Latch.
2.4. Test for infinite resistance between the control
circuit terminal 5 and ground.
2 If less than infinite resistance, repairthe short to
ground on the circuit.
2 Ifinfinite resistance, replace the KR95A Liftgate
Unlatch Relay
U If the test lamp illuminates
3. Connect a test lamp between the control circuit
terminal1 and ground.
4. lgnition ON, verify the test lamp turns ON and OFF
when pressing and releasing the S46B Liftgate
Unlatch Switch.
2 If the test lamp is always OFF
4.1. Ignition OFF, remove the test lamp, disconnect
the harness connector at the K9 Body Control
Module.
4.2. Test for infinite resistance between the control
circuit and ground.
2 Ifless than infinite resistance, repairthe short to
ground on the circuit.
U if infinite resistance
4.3. Test for less than 2 Q in the control circuit end
to end.
2 If2 Q or greater, repair the open/high resistance
in the circuit.
2 if less than 2 Q, replace the K9 Body Control 1
Module. 1
If the test lamp is always ON I
4.1. IgnitionOFF, remove the test lamp, disconnect 1
the harness connector at the K9 Body Controi ‘
Module, ignition ON.
4.2. Test for less than 1 V between the control
circuit and ground.
2 if 1 V or greater, repair the short to voltage on
the circuit.
2 Ifless than 1 V, replace the K9 Body Control
Module.
If the test lamp turns ON and OFF
. Connect a test lamp between the control circuit
terminal 2 and B+.
. Verify the test lamp turns ON and OFF when
pressing and releasing S46B Liftgate Unlatch
Switch.
If the test lamp is always OFF
6.1. ignition OFF, remove the test lamp, disconnect
the harness connector at the K9_BodyControl
Module, ignition ON.
6.2. Test for less than 1 V between the control
circuit and ground.
2 If 1 V or greater, repair the short to voltage on
the circuit.
U Ifless than 1 V
6.3. lgnition OFF.
6.4. Test for less than 2 Q in the control circuit end
to end.
2 If2 Q or greater, repairthe open/high resistance
in the circuit.
2 Ifless than 2 Q, replace the K9 Body Control
Module.
If the test lamp is always ON
6.1. lgnition OFF, remove the test lamp, disconnect
the harness connector at the K9 Body Control
Module.
6.2. Test for infinite resistance between the control
circuit and ground.
2 Ifless than infinite resistance, repair the short to
ground on the circuit.
2 Ifinfinite resistance, replace the K9 Body
Control Module.
If the test lamp turns 0N and OFF
. Verify that a test lamp does not illuminate between
the control circuit terminal 5 and ground.
If the test lamp illuminates
Repair the short to voltage on the control circuit
If the test lamp does not illuminate
. lgnition OFF and all vehicle systems OFF,
disconnect the harness connector at the
M30 Liftgate Latch. Itmay take up to 2 minutes for
all vehicle systems to power down.
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 Vehicle Access 4-267
9. Test for less than 10 Q between the ground circuit 3. Test for less than 3 Q between the signal terminal 1
terminal 1 and ground. and the ground terminal 2 with the switch in the
:> If 10 Q or greater closed position.
9.1. lgnition OFF. 2 If 3 Q or greater
92. Test for less than 2 Q in the ground circuit end Replace the S46B Liftgate Unlatch Switch.
to end. U If less than 3 Q
2 If2 Q or greater, repair the open/high resistance 4. All OK
in the circuit.
Relay Test
2 Ifless than 2 Q, repair the open/high resistance
in the ground connection. 1. lgnition OFF, disconnect the KR95A Liftgate
Unlatch Relay.
If less than 10 Q
2. Test for 60—200Q between terminals 1 and 3.
. Connect the harness connector at the M30 Liftgate
Latch 2 If less than 60 Q or greater than 200 Q
11. IgnitionON, connect a 10 A fused jumper wire Replace the KR95A Liftgate Unlatch Relay.
between the B+ circuit terminal 3 and the control If between 60-200 Q
circuit terminal 5. Test for infinite resistance between the terminals
12. Verify the M30 Liftgate Latch is activated. listed below:
If the M30 Liftgate Latch does not activate ° 4 and 3
12.1. lgnition OFF, disconnect the harness - 4 and 5
connector at the M30 Liftgate Latch. - 4 and 1
12.2. Test for less than 2 Q in the control circuit end - 5 and 1
to end.
If less than infinite resistance
2 If2 Q or greater, repair the open/high resistance
in the circuit. Replace the KR95A Liftgate Unlatch Relay.
2 Ifless than 2 Q, replace the M30 Liftgate Latch. If infinite resistance
Install a 3 A fused jumperwire between relay
U If the M30 Liftgate Latch activates
terminal 3 and 12 V. lnstall ajumper wire between
13. Test or replace the KR95A Liftgate Unlatch Relay. relayterminal 1 and ground.
Component Testing Test for less than 2 Q between terminals 4 and 5.
2 If 2 Q or greater
Liftgate Latch
Replace the KR95A Liftgate Unlatch Relay.
1. IgnitionOFF, disconnect the harness connector at
the M30 Liftgate Latch. U If less than 2 Q
2. Install a 10 A fused jumper wire between the 6. All OK
control terminal 3 and 12 V. Install a jumper wire
between the ground terminal 1 and ground. Repair Instructions
Verify the M30 Liftgate Latch activates Perform the Diagnostic Repair Verification on
page 6—92after completing the repair procedure.
2 If the M30 Liftgate Latch does not activate.
Relay Replacement (Within an Electrical Center)
Replace the M30 Liftgate Latch. on page 11-607or Relay Replacement (Attached
U If the M30 Liftgate Latch does activate. to Wire Harness) on page 11-607
4. AIIOK Liftgate Release Switch Replacement on
page 4-320 .
Liftgate Release Switch
Liftgate Latch Replacement on page 4-295
1. lgnition OFF, disconnect the harness connector at
the S46B Liftgate Unlatch Switch. Control Module References on page 6-3 for BCM
replacement, programming and setup
2. Test for infinite resistance between the signal
terminal 1 and the ground terminal 2 with the
switch in the open position.
If less than infinite resistance
Replace the S463 Liftgate Unlatch Switch.
lf infinite resistance

2013
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Manual
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4268 Vehicle Access

Door Ajar Indicator Malfunction

Diagnostic Instructions
- Perform the Diagnostic System Check - Vehicle
on page 6—66prior to using this diagnostic
procedure.
- Review Strategy Based Diagnosis on page 6-58
for an overview of the diagnostic approach.
- Diagnostic Procedure Instructions on page 6-59
provides an overview of each diagnostic category

Diagnostic Fault Information

Open/High Signal
Circuit Short to Ground Resistance Short to Voltage Performance
DriverDoorAjarSwitchSignal 1 2 1 -
DriverDoorLatchGround — 2 — -
LeftRear DoorAjarSwitchSignal 1 2 1 -
LeftRear DoorLatchGround —— 2 — -
LiftgateAjarSwitchSignal 1 2 2 -
RearCompartmentLid LatchGround — 2 — -
PassengerDoorAjarSwitchSignal 1 2 1 —-
PassengerDoorLatchGround — 2 — -
RightRearDoorAjarSwitchSignal 1 2 1 -
RightRearDoorLatchGround — 2 — —-
1.Ajar IndicatorAlways Illuminated
2. Ajar IndicatorlnoperativeWhenDoor,Liftgate,TrunkIsOpen

CircuitlSystem Description Description and Operation

Depending upon if the vehicle is equipped with driver Door Ajar Indicator Description and Operation on
express up/down powerwindows or standard power page 4-322
windows, affects how the driver door ajar signal circuits
are configured and monitored. Electrical Information Reference
Ifthe vehicle is equipped with driver express up/down - Circuit Testing on page 11-526
power windows, the driver window motor provides a . Connector Repairs on page 11-548
12V signal to the driver door ajar switch signal circuit.
The body control module (BCM) provides a 12V signal - Testing for IntermittentConditions and Poor
to each of the driver, passenger, rear door ajar switch Connections on page 11-531
signal circuits and the trunk/liftgateajar signal circuit. - Wiring Repairs on page 11~537
The door ajar switches are integral to each door latch Scan Tool Reference
assembly and the trunk/liftgateajar switch is integral to
the liftgate latch and the rear compartment lid latch. Control Module References on page 6—3for scan tool
When a door, trunk or liftgate is opened, the normally information
open ajar switch closes. With the ajar switch closed,
ground is provided to the ajar switch signal circuit. The CircuitlSystem Verification
driver window motor and/or BCM the voltage drop and 1. lgnition ON.
sends a serial data message to the instrument panel to 2. Verify the scan tool Driver Door Ajar Switch
display the door ajar indicator. parameter changes between Inactive and Active
Reference Information when opening and closing the driver door.
2 If the parameter does not change
Schematic Reference
Refer to CircuitlSystem Testing —Door Ajar
Door Lock/lndicator Schematics on page 4238 Switch
Connector End View Reference U If the parameter changes
Component Connector End Views on page 11—269

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3. Verify the scan tool Passenger Door Ajar Switch
parameter changes between Inactive and Active
when opening and closing the passenger door.
2 If the parameter does not change
Refer to CircuitlSystem Testing —Door Ajar
Switch
U If the parameter changes
4. Verify the scan tool Left Rear Door Ajar Switch
parameter changes between inactive and Active
when opening and closing the left rear door.
2 If the parameter does not change
Refer to CircuitlSystem Testing —Door Ajar
Switch
U If the parameter changes
5. Verify the scan tool Right Rear Door Ajar Switch
parameter changes between inactive and Active
when opening and closing the right rear door.
2 If the parameter does not change
Refer to CircuitlSystem Testing —Door Ajar
Switch
U If the parameter changes
6. Verify the scan tool Rear Closure Ajar Switch
parameter changes between Inactive and Active
when opening and closing the trunk or the rear
hatch.
2 If the parameter does not change
Refer to CircuitlSystem Testing —Trunk/Hatch
Ajar Switch
U If the parameter changes
7. All OK.
CircuitlSystem Testing
Door Ajar Switch
1. Ignition OFF and all vehicle systems OFF,
disconnect the harness connector at the
appropriate A23 door latch assembly. Itmay take
up to 2 minutes for all vehicle systems to
power down.
. Test for less than 10 Q 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 assemny—leftrear —ground
circuit terminal 8
' A23RR door latch assemny-right rear —ground
circuit terminal 3
lf10 Q or greater
2.1. IgnitionOFF.
2.2. Test for less than 2 Q in the ground circuit end
to end.
2 if 2 Q or greater, repair the open/high resistance
in the circuit.
2 Ifless than 2 Q, repair the open/high resistance
in the ground connection.
U If less than 10 Q
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2013 (US/Canada)
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Vehicle Access 4-269
9’ lgnition ON.
Verify the appropriate scan tool Door Ajar Switch
parameter is Inactive.
If not inactive
4.1. IgnitionOFF, disconnect the harness
connector at the appropriate component listed
below:
- M74D window motor —driver (AXG)
- K9 body control module (withoutAXG)
4.2. Test for infinite resistance between the signal
circuit terminal listed below and ground.
- A23D door latch assembiy—driver—signal
circuit terminal 6
- A23P door latch assembly-passenger -
signal circuit terminal 1
- A23LR door latch assembly—Ieftrear -
signal circuit terminal 6
- A23RR door latch assemny-right rear -
signal circuit terminal 1
2 If less than infinite resistance, repair the short to
ground on the circuit.
2 If infinite resistance, replace the appropriate
component.
If Inactive
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-ieft rear —signal
circuit terminal 6
- A23RR door latch assembly-right rear —signal
circuit terminal 1
. Verify the scan tool Door Ajar Switch parameter is
Active.
If not Active
6.1. lgnition OFF, disconnect the harness
connector at the appropriate component listed
below, ignition ON.
- M74D window motor —driver (AXG)
- K9 body control module (withoutAXG)
6.2. Test for less than 1 V between the signal
circuit and ground.
2 If 1 V or greater, repair the short to voltage on
the circuit.
U Ifless than 1 V
6.3. Test for less than 2 Q in the signal circuit end
to end.
2 If2 Q or greater, repair the open/high resistance
in the circuit.
2 Ifless than 2 Q, replace the appropriate
component.
If Active
Test or replace the A23 door latch assembly.
427 D Vehicle Access
Trunk/Hatch Ajar Switch
1. IgnitionOFF and all vehicle systems OFF,
disconnect the harness connector at the M40 rear
compartment lid latch or the M30 liftgate latch.
Itmay take up to 2 minutes for all vehicle systems
to power down.
2. Test for less than 10 Q between the ground circuit
terminal listed below and ground.
- M30 liftgate latch —ground circuit terminal 1
' M40 rear compartment lid latch —ground circuit
terminal 2
2 If 10 Q or greater
2.1. Ignition OFF.
2.2. Test for less than 2 Q in the ground circuit and
to end.
2 if 2 Q or greater, repair the open/high resistance
in the circuit.
2 Ifless than 2 Q, repair the open/high resistance
in the ground connection.
U If less than 10 Q
9" Ignition ON.
4. Verify the scan tool Rear Closure Ajar Switch
parameter is Inactive.
2 If not Inactive
4.1. Ignition OFF, disconnect the harness
connector at the K9 body control module.
4.2. Test for infinite resistance between the signal
circuit terminal 5 and ground.
2 Ifless than infinite resistance, repair the short to
ground on the circuit.
2 Ifinfinite resistance, replace the K9 body
control module.
U If Inactive
5. Install a 3 A fused jumper wire between the signal
circuit terminal and the ground circuit terminal
listed below:
- M30 liftgate latch —signal circuit terminal 2 and
ground circuit terminal 1
- M40 rear compartment lid latch —signal circuit
terminal 4 and ground circuit terminal 2
6. Verify the scan tool Rear Closure Ajar Switch
parameter is Active.
2 If not Active
6.1. lgnition OFF, disconnect the harness
connector at the K9 body control module,
ignition ON.
6.2. Test for less than 1 V between the signal
circuit and ground.
2 If 1 V or greater, repair the short to voltage on
the circuit.
U Ifless than 1 V
6.3. Test for less than 2 Q in the signal circuit and
to end.
2 If2 Q or greater, repair the open/high resistance
in the circuit.
2 if less than 2 Q, replace the K9 body control
module.
U If Active
7. Test or replace the M40 rear compartment lid latch
or the M30 liftgate latch.
Component Testing
1. lgnition OFF, disconnect the harness connector at
the appropriate A23 door latch assembly.
2. Test for infinite resistance between the signal
terminal and the ground terminals listed below with
the switch in the open position.
- A23D door latch assembly—driver—signal
terminal 6 and ground terminal 8
- A23P door latch assemny—passenger —signal
terminal1 and ground terminal 3
- A23LR door latch assemny—Ieftrear—signal
terminal 6 and ground terminal 8
' A23RR door latch assemny—rightrear —signal
terminal1 and ground terminal 3
2 If less than infinite resistance
Replace the A23 door latch assembly.
U If infinite resistance
3. Test for less than 3 Q between the signal and the
ground terminal listed below with the switch in the
closed position.
~ A23D door latch assembly—driver4 signal
terminal 6 and ground termina18
- A23P door latch assemny—passenger —signal
terminal1 and ground terminal 3
' A23LR door latch assemny—leftrear —signal
terminal 6 and ground terminal 8
- A23RR door latch assemny-right rear —— signal
terminal1 and ground terminal 3
2 If 3 Q or greater
Replace the A23 door latch assembly.
U If less than 3 Q
4. All OK
Repair Instructions
Perform the Diagnostic Repair Verification on
page 6-92 after completing the diagnostic procedure.
- Front Side Door Latch Replacement on
page 4-299
0 Rear Side Door Latch Replacement on
page 4-301 _
0 Front Side Door Window Regulator Motor
Replacement on page 4—43
- Liftgate Latch Replacement on page 4295
' Rear Compartment Lid Latch Replacement on
page 4—300
° Control Module References on page 6—3for BCM
replacement, programming and setup
2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Vehicle Access 4-271

Power Door Child Lock Malfunction

Diagnostic Instructions
- Perform the Diagnostic System Check - Vehicle
on page 6-66 prior to using this diagnostic
procedure.
- Review Strategy Based Diagnosis on page 6—58
for an overview of the diagnostic approach.
- Diagnostic Procedure Instructions on page 6-59
provides an oven/iew of each diagnostic category.
Diagnostic Fault Information

Open/High Signal
Circuit Short to Ground Resistance Short to Voltage Performance
8393001, 8393001,
BCM 3+ 3393004 3393004 " _
ChildSecurityDoorLockoutSignal 82520 00 1 1 -
LeftRear DoorLockStatusSignal 2 2 2 —-
RightRear DoorLockStatusSignal 2 2 2 ~-
DoorLock RelayControl 8393002 8393001,
8393004 8393001,
8393004 -
Child SecurityDoorLockoutIndicatorControl 8252E02 3 3 -
8312502,
LeftRear DoorLatchLockoutControi 8313002, 1 1 -
8313502
8312502,
LeftRear DoorLatchUnlockControl 8313002, 1 1 —-
8313502
8312502,
RightRear DoorLatchLockoutControl 8313002, 2 2 —-
8313502
8312502,
RightRear DoorLatchUnlockControl 8313002, 2 2 —-
8313502
DoorLock RelayGround — 8393001,
8393004 —~ -
LeftRear DoorLatchGround — 2 — -
RightRear DoorLatchGround — 2 — ~-
1.Child DoorLockoutSwitchMalfunction
2. Child DoorLockoutMalfunction
3. Child SecurityDoorLockoutIndicatorMalfunction

CircuitlSystem Description activated. Ifthe BCM detects a fault in the child door
lockout system, it will command the lockout indicator to
The child door lockout switch on the front floor console flash ON and OFF for 30 seconds.
controls the child locks on the rear doors. The lockout
switch is an inputto the Body Control Module (BCM) Reference Information
and the BCM controls the Door Lock relay. When the
BCM detects a voltage drop on the child door lockout Schematic Reference
signal circuit, itwill apply voltage to the Door Lock relay - Door Lock/lndicator Schematics on page 4-238
coil, this will energize the relay and the contact within
the relay will then direct the voltage to lock the left rear - InteriorLights Dimming Schematics on page 4-91
and right rear child locks and then isolate them from the Connector End View Reference
normal door lock system to prevent the rear doors from
being opened by using the interior rear door handles. Component Connector End Views on page 11-269
The BCM will then provide a ground for the lockout Description and Operation
indicator causing the indicator to illuminate to notify the
driver that the child door lockout system has been Power Door Locks Description and Operation on
page 4-323

—
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Sonic (5377994)
Manual
Service
42.272 Vehicle Access
does not
If a single interior rear door handle
Electrical Information Reference open the rear door
Door
Testing for IntermittentConditions and
Poor Refer to CircuitlSystem Testing —Single
Connections on page 11—531 Security Lockout Malfunction.
the rear
Circuit Testing on page 11-526 U If both interior door handles open
Wiring Repairs on page 11—537 doors
Connector Repairs on page 11-548 6 All OK.
Scan Tool Reference CircuitlSystem Testing
6-3 for scan tool
Control Module References on page Lockout Switch Inoperative
OFF,
information 1. lgnition OFF and all vehicle systems the
Verification disconnect the harness connector at
CircuitlSystem Console. it may
S48E Multifunction Switch-Center
1. lgnition ON. take up to 2 minutes for all vehicle systems to
Lock Motors
2. Verify the scan tool Child Security On and
power down.
Command parameter changes between ground circuit
switch. Test for less than 10 Q between the
Off when pressing the child lockout
terminal 9 and ground.
If the parameter does not change If 10 Q or greater
Lockout
Refer to CircuitlSystem Testing — 2.1. lgnition OFF.
lnoperative. circuit and
Switch 2.2. Test for less than 2 Q in the ground
If the parameter changes to end.
indicator resistance
Verify the function of the child lockout indicator ON 2 If2 Q or greater, repair the open/high
when commanding the Child Lockout in the circuit.
and OFF with a scan tool. 2 if less than 2 Q, repair the open/high
resistance
always ON or
If the child lockout indicator is in the ground connection.
always OFF If less than 10 Q
Lockout
Refer to CircuitlSystem Testing — 9° lgnition ON.
Indicator Malfunction. signal circuit
0N and Test for greater than 10 V between the
If the child lockout indicator turns terminal 7 and ground.
turns OFF
door If 10 V or less
Verify the operation of both interior rear harness
handles do not open the rear doors when 4.1. lgnition OFF, disconnect the Module.
ON connector at the K9 Body Control
commanding the Child Security Lock Motors the signal
with a scan tool. 4.2. Test for infinite resistance between
open the rear circuit and ground.
If both interior rear door handles the short to
doors 2 if less than infinite resistance, repair
Security ground on the circuit.
Refer to CircuitlSystem Testing — circuit end
Lockout lnoperative. 4.3. Test for less than 2 Q in the signal
opens the to end.
If a single interior rear door handle resistance
rear door 2 if 2 Q or greater, repair the open/high
Door in the circuit.
Refer to CircuitlSystem Testing —Single Control
Security Lockout Malfunction. 2 If less than 2 Q, replace the K9 Body
not open the Module.
If both interior door handles do
rear doors U If greater than 10 V
Verify the operation of both interior
rear door 5. Test or replace the S48E Multifunction
handles will open the rear doors when Switch-Center Console.
OFF
commanding the Child Security Lock Motors Lockout Indicator Malfunction
with a scan tool. OFF,
do not open 1. lgnition OFF, and all vehicle systems the
If both interior rear door handles disconnect the harness connector at
Console.
the rear doors S48E Multifunction Switch-Center
Security control circuit
Refer to CircuitlSystem Testing — 2. Connect a test lamp between the
Lockout lnoperative. terminal 8 and ground.

—
2013 (US/Canada)
Sonic (5377994)
Manual
Service
l
3. IgnitionON, verify the test lamp turns ON and OFF
‘ when commanding the LED Backlight Dimming ON
1 and OFF W'tha scan tool.
1 Z) If the teSt lamp is always OFF
1 3.1. lgnition OFF, disconnect the harness
connector at the K9 Body Control Module.
Security Lockout lnoperative
3.2. Test for infinite resistance between the control
circuit and ground.
2 If less than infinite resistance, repair the short to
ground on the circuit.
U If infiniteresistance
3.3. Test for less than 2 Q in the control circuit end
to end.
2 If2 Q or greater, repair the open/high resistance
in the circuit.
2 Ifless than 2 Q, replace the K9 Body Control
Module.
If the test lamp is always ON
3.1. lgnition OFF, disconnect the harness
connector at the K9 Body Control Module,
ignition ON. ‘ P’UConnect a test lamp between the control circuit
3.2. Test for less than 1 V between the control
circuit and ground.
2 If 1 V or greater, repair the short to voltage on
the circuit.
2 Ifless than 1 V, replace the K9 Body Control
Module.
If the test lamp turns ON and OFF
. Connect a test lamp between the control circuit
terminal 6 and 8+. lgnition ON
. Verify the test lamp turns ON and OFF when
commanding the Child Lockout Indicator ON and
OFF with a scan tool.
If the test lamp is always OFF
5.1. lgnition OFF, disconnect the harness
connector at the K9 Body Control Module,
ignition ON.
5.2. Test for less than 1 V between the control
circuit and ground.
2 If 1V or greater, repair the short to voltage on
the circuit.
U Ifless than 1 V
5.3. lgnition OFF.
5.4. Test for less than 2 Q in the control circuit and
to end.
2 If2 Q or greater, repair the open/high resistance
in the circuit.
2 Ifless than 2 Q, replace the K9 Body Control
Module.
If the test lamp is always CM
5.1. IgnitionOFF, disconnect the harness
connector at the K9 Body Control Module.
5.2. Test for infinite resistance between the control
circuit and ground.
2 If less than infinite resistance, repair the short to
ground on the circuit.
(US/Canada)
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2013 (5377994)
Manual
Service
Vehicle Access 4273
2 if infinite resistance, replace the K9 Body
Control Module. _
U If the test lamp turns ON and OFF
6. Test or replace the S48E Multifunction
Switch—CenterConsole.
1. IgnitionOFF, disconnect the X2 harness connector
at the X50A Fuse Block—Underhood.
2 Test for less than 10 Q between the ground circuit
.
terminal C5 and ground.
If 10 Q or greater
2.1. IgnitionOFF.
2.2. Test for less than 2 Q in the ground circuit end
to end.
2 if 2 Q or greater, repair the open/high resistance
in the circuit.
2 If less than 2 Q, repairthe open/high resistance
in the ground connection.
If less than 10 Q
terminal D5 and ground, ignition ON.
. Verify the test lamp turns ON and OFF when
commanding the Child Security Lock Motors ON
and OFF with a scan tool.
If the test lamp is always OFF
4.1. lgnition OFF, disconnect the harness
connector at the K9 Body Control Module.
4.2. Test for infinite resistance between the control
circuit and ground.
2 If less than infinite resistance, repair the short to
ground on the circuit.
U If infinite resistance
4.3. Test for less than 2 Q in the control circuit end
to end.
2 if 2 Q or greater, repair the open/high resistance
in the circuit.
2 If less than 2 Q, replace the K9 Body Control
Module.
If the test lamp is always ON
4.1. lgnition OFF, disconnect the harness
connector at the K9 Body Control Module,
ignition ON.
4.2. Test for less than 1 V between the control
circuit and ground.
2 if 1 V or greater, repair the short to voltage on
the circuit.
2 if less than 1 V, replace the K9 Body Control
Module.
If the test lamp turns ON and OFF
. Replace the X50A Fuse Block—Underhood.
4:2 74 Vehicle Access
Single Door Security Lockout Malfunction
1. lgnition OFF and all vehicle systems OFF,
disconnect the harness connector at the
appropriate rearA23 Door Latch Assembly. Itmay
take up to 2 minutes for all vehicle systems to
power down.
2. Test for less than 10 Q between the ground circuit
terminal listed below and ground:
- A23RR Door Latch Assembly—RightRear -
ground terminal 3
- A23LR Door Latch Assembly-Left Rear -
ground terminal 8
2 If 10 Q or greater
2.1. Ignition OFF.
2.2. Test for less than 2 Q in the ground circuit and
to end.
2 If2 Q or greater, repair the open/high resistance
in the circuit.
2 Ifless than 2 Q, repair the open/high resistance
in the ground connection.
U If less than 10 Q
9’ ignition ON.
4. Verify the scan tool Rear Child Security Lock
Switch parameter is Inactive.
2 If not Inactive
4.1. Ignition OFF, disconnect the harness
connector at the K9 Body Control Module.
4.2. Test for infinite resistance between the signal
circuit terminal listed below and ground.
- A23LR Door Latch Assembly—LeftRear -
signal circuit terminal 9 y ground on the circuit.
- A23RR Door Latch Assembly—RightRear -
signal circuit terminal 4
2 Ifless than infinite resistance, repair the short to
ground on the circuit.
2 If infinite resistance, replace the K9 Body
Control Module.
U If Inactive
5. Install a 3 A fused jumper wire between the signal
circuit terminals listed below and ground:
- A23LR Door Latch Assembly-Left Rear -
signal circuit terminal 9
° A23RR Door Latch Assembly-Right Rear —-
signal circuit terminal 4
6. Verify the scan tool Rear Child Security Lock
Switch parameter is Active.
2 If not Active
6.1. lgnition OFF, disconnect the harness
connector at the K9 Body Control Module,
ignition ON.
6.2. Test for less than 1 V between the signal
circuit and ground.
2 If 1 V or greater, repair the short to voltage on
the circuit.
U Ifless than 1 V
6.3. Test for less than 2 Q in the signal circuit end
to end.
2 If2 Q or greater, repair the open/high resistance
in the circuit.
2 Ifless than 2 Q, replace the K9 Body Control
Module.
U If Active
7. Connect a test lamp between control circuit
terminals listed below, ignition ON.
- A23LR Door Latch Assembly-Left Rear -
control circuit terminal 4 and control circuit
terminal 7
. A23RR Door Latch Assemny—Right Rear --
control circuit terminal 2 and control circuit
terminal 9
8. Verify the test lamp turns ON and OFF when
commanding the Child Security Lock Motors with a
scan tool.
2 If the test lamp remains OFF during either of the
commands
8.1. IgnitionOFF, disconnect the harness
connector at the K9 Body Control Module.
8.2. Test for infinite resistance between each
control circuit and ground.
2 Ifless than infinite resistance, repairthe short to
2 If infinite resistance, replace the K9 Body
Control Module.
U If the test lamp turns ON during each of the
commands
9. Test or replace the rear A23 Door Latch Assembly.
Component Testing
Child Security Lockout Switch Test
1. lgnition OFF, disconnect the harness connector at
the S48E Multifunction Switch-Center Console.
2. Test for infinite resistance between the signal
terminal 7 and the ground terminal 9 with the
switch in the open position.
2 If less than infinite resistance
Replace the S48E Multifunction Switch-Center
Console.
U If infinite resistance
3. Test for less than 3Q between the signal terminal 7
and the ground terminal 9 with the switch in the
closed position.
2 If 3 Q or greater
Replace the S48E Multifunction Switch-Center
Console.
U If less than 3 Q
4. All OK

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
 Vehicle Access 4275
Door Latch Test Repair Instructions
1. ignition OFF, disconnect the harness connector at Perform the Diagnostic Repair Verification on
the appropriate rear A23 Door Latch Assembly. page 6-92 after completing the repair.
2. Install a 30 A fused jumperwire between one of the ' Rear Side Door Latch Replacement on
control terminals and 12 V. Momentarily install a page 4-301
jumper wire between the other control terminal and
ground. Reverse the jumper wires at least two - Front Floor Console Multifunction Switch
times, the rear A23 Door Latch Assembly should Replacement on page 8-105
perform the LOCK and UNLOCK functions. - Front Compartment Fuse Block Replacement on
page 11—609
2 If the function does not perform the LOCK and
UNLOCK function 0 Control Module References on page 6-3 BCM
replacement, programming and setup
Replace the rear A23 Door Latch Assembly.
U If the function performs the LOCK and UNLOCK
function
3. All OK

Power Door Locks Malfunction

Diagnostic Instructions
- Perform the Diagnostic System Check —Vehicle
on page 6-66 prior to using this diagnostic
procedure.
- Review Strategy Based Diagnosis on page 6-58
for an overview of the diagnostic approach.
- Diagnostic Procedure Instructions on page 6-59
provides an overview of each diagnostic category.
Diagnostic Fault Information

Open/High Signal
Circuit Short to Ground Resistance Short to Voltage Performance
BCM 8+ 8312502, 8312502, — -
8313002, 8313002,
8313502 8313502
DoorLockSwitchSignal 8315000 1 1 -
DoorUnlockSwitchSignal 8314000 1 1 -
8312502,
DriverDoorUnlockControl 8313002, 2 2 ~
8313502
8312502,
DoorsLockControl 8313002, 2, 3,4 2,3,4 -
8313502
8312502,
PassengerDoorsUnlockControi‘ 8313002, 3,4 3,4 -
8313502
DriverDoorLockSwitchGround —— 1 — -
1.DriverDoorLockSwitchMalfunction
2. DriverDoorUnlockMalfunction
3. DoorUnlockMalfunction
4. DoorLock Malfunction

CircuitlSystem Description together. When the door latch assemblies are not
active, all actuator lock and unlock control circuits are
The Body Control Module (BCM) powers the reversible supplied a floating voltage door driver by the BCM.
door latch assemblies by providing battery positive Transitioning of the lock actuators to the lock or
voltage and ground to the appropriate lock and unlock unlocked position depends upon which control circuits
control circuits of the door latch assemblies. The lock receive voltage and which control circuits receive
and unlock control circuits of the rear doors and ground.
passenger door latch assemblies are all connected
2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
4276 Vehicle Access
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
Diagnostic Aids
Verify the smooth and consistent mechanical operation
of each part of the door latch system prior to performing
extensive electrical diagnostics
Any door that does not function smoothly or
consistently, refer to Door Will Not Open/C/ose, Door
Binding, or Locks, Handles, or Cylinders Do Not
Function on page 4-283.
Reference Information
Schematic Reference
- Door Lock/lndicator Schematics on page 4-238
- Body Control System Schematics on page 11—8
Connector End View Reference
Component Connector End Views on page 11269
Description and Operation ‘ in the circuit.
Power Door Locks Description and Operation on
page 4—323
Electrical Information Reference
- Circuit Testing on page 11-526
- Connector Repairs on page 11-548
o Testing for IntermittentConditions and Poor
Connections on page 11-531
- Wiring Repairs on page 11-537
Scan Tool Reference
Control Module References on page 6-3 for scan tool
information
CircuitlSystem Verification
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.
2 If the parameter does not change
Refer to CircuitlSystem Testing —Door Lock
Switch Malfunction.
U If the parameter changes
3. Verify all vehicle doors Lock and Unlock when
commanding the All Doors Lock/Unlock with a
scan tool.
2 If only the driver door LOCK or UNLOCK
functions do not work
Refer to CircuitlSystem Testing —Driver Door
Lock Malfunction.
2 If one or more, but not all, passenger door
LOCK or UNLOCK functions do not work
Refer to CircuitlSystem Testing —Passenger
Door Lock Malfunction.
2 If all door LOCK and UNLOCK functions do
not work
Refer to CircuitlSystem Testing —AIIDoor Lock
Inoperative.
U If the LOCK and UNLOCK function for all doors
works
4. All OK.
CircuitlSystem Testing
Door Lock Switch Malfunction
1. lgnition OFF and all vehicle systems OFF,
disconnect the harness connector at the
S13D Door Lock Switch-Driver. it may take up to
2 minutes for all vehicle systems to power down.
2. Test for less than 10 Q between the ground circuit
terminal1 and ground.
2 If 10 Q or greater
2.1. lgnition OFF.
2.2. Test for less than 2 Q in the ground circuit end
to end.
2 If2 Q or greater, repair the open/high resistance
2 If less than 2 Q, repair the open/high resistance
in the ground connection.
U If less than 10 Q
9° Ignition ON.
4. Test for greater than 10 V between the signal circuit
termina13 and ground.
2 lf10Vorless
4.1. IgnitionOFF, disconnect the harness
connector at the K9 Body Control Module.
4.2. Test for infinite resistance between the signal
circuit and ground.
2 if less than infinite resistance, repairthe short to
ground on the circuit.
4.3. Test for less than 2 Q in the signal circuit end
to end.
2 If2 Q or greater, repair the open/high resistance
in the circuit.
2 Ifless than 2 Q, replace the K9 Body Control
Module.
U If greater than 10 V

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)

5. Test for greater than 10 V between the signal circuit
terminal 4 and ground.
2 lf10Vorless
5.1. lgnition OFF, disconnect the harness
connector at the K9 Body Control Module.
5.2. Test for infinite resistance between the signal
circuit and ground.
2 Ifless than infinite resistance, repair the short to
ground on the circuit.
5.3. Test for less than 2 Q in the signal circuit end
to end.
2 If2 Q or greater, repair the open/high resistance
in the circuit.
2 if less than 2 Q, replace the K9 Body Control
Module.
U If greater than 10 V
6. Test or replace the S13D Door Lock Switch—Driver.
Driver Door Lock Malfunction
1. lgnition OFF, verify the harness connector is firmly
seated and secure for the A23D Door Latch
Assembly-Driver.
2 if the harness connector not seated or secure
Firmly seat and secure the harness connector
at the A23D Door Latch Assemny—Driver.
U If the harness connector is firmly seated and
secure
2. Disconnect the harness connector at the
A238 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. Ifthe voltage drops to OV,
operate the door locks using the door lock switch to
restore the voltage for testing.
3. Test for greater than 7 V between the control circuit
terminal 3 and ground.
2 If 7 V or less
3.1. lgnition OFF, disconnect the X6 harness
connector at the K9 Body Control Module.
3.2. Test for infinite resistance between the control
circuit and ground.
2 Ifless than infinite resistance, repair the short to
ground on the circuit.
U Ifinfinite resistance
3.3. Test for less than 2 Q in the control circuit and
to end.
2 If2 Q or greater, repair the open/high resistance
on the circuit.
2 Ifless than 2 Q, replace the K9 Body Control
Module.
U If greater than 7 V
(US/Canada)
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2013 (5377994)
Manual
Service
Vehicle Access 4.277
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 fauit and will cause the voltage on the
control circuit to drop to 0 V. lfthe voltage drops to 0 V,
operate the door locks using the door lock switch to
restore the voltage for testing.
4. Test for greater than 7 V between the control circuit
terminal 2 and ground.
2 |f7Vor less
4.1. lgnition OFF, disconnect the X6 harness
connector at the K9 Body Control Module.
4.2. Test for infinite resistance between the control
circuit and ground.
2 Ifless than infinite resistance, repair the short to
ground on the circuit.
U If infinite resistance
4.3. Test for less than 2 Q in the control circuit end
to end.
2 If2 Q or greater, repair the open/high resistance
on the circuit.
2 If less than 2 Q, replace the K9 Body Control
Module.
U If greater than 7 V
5. Test or replace the A23D Door Latch Assembly-
‘ Driver.
Passenger Door Lock Malfunction
1. lgnition OFF, verify the harness connector is firmly
seated and secure for the appropriate passenger
or rear A23 Door Latch Assembly.
2 If the harness connector not seated or secure
Firmly seat and secure the harness connector
at the passenger or rear A23 Door Latch
Assembly.
U if the harness connector is firmly seated and
secure
2. Disconnect the harness connector at the
appropriate passenger or rear A23 Door Latch
Assembly. IgnitionON.
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. Ifthe voltage drops to 0 V,
operate the door locks using the door lock switch to
restore the voltage for testing.
4-278 Vehicle Access
3. Test for greater than 7 V between the control circuit
terminal listed below and ground:
- A238 Door Latch Assembly-Passenger -
control circuit terminal 7
- A23RR Door Latch Assemny—Right Rear -
control circuit terminal 7
' A23LR Door Latch Assembly-Left Rear -
control circuit terminal 2
2 If 7 V or less
3.1. lgnition OFF, disconnect the X6 harness
connector at the K9 Body Control Module.
3.2. Test for infinite resistance between the control
circuit and ground.
2 If less than infinite resistance, repair the short to
ground on the circuit.
U lf infinite resistance
3.3. Test for less than 2 Q in the control circuit end
to end.
2 112Q or greater, repair the open/high resistance
on the circuit.
2 Ifless than 2 Q, replace the K9 Body Control
Module.
U If greater than 7 V
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. lfthe voltage drops to 0 V,
operate the door locks using the door lock switch to
restore the voltage for testing.
4. Test for greater than 7 V between the control circuit
terminal listed below and ground:
- A23P Door Latch Assembly—Passenger -
control circuit terminal 8
- A23RR Door Latch Assembiy-Right Rear -
control circuit terminal 8
- A23LR Door Latch Assemny-Left Rear -
control circuit terminal 3
2 If 7 V or less
4.1. IgnitionOFF, disconnect the X2 harness
connector at the X50A Fuse Block-Underhood.
4.2. Disconnect the X6 harness connector at the
K9 Body Control Module.
4.3. Test for less than 2 Q between the control
circuit terminals listed below:
' X50A Fuse Block-Underhood control circuit
terminal 87 X2 and A23P Door Latch
Assemny-Passenger control circuit
terminal 8
' X50A Fuse Block—Underhoodcontrol circuit
terminal 84 X2 and K9 Body Control
Module control circuit terminal 2 X6
2 if greater than 2 Q, repair the open/high
resistance on the circuit.
4.1. Connect the X2 harness connector at the
X50A Fuse Biock—Underhood
4.2. Test for less than 2 Q between the A23P Door
Latch Assembly—Passenger control circuit
terminal 8 and the K9 Body Control Module
control circuit terminal 2 X6
2 Ifgreater than 2 Q, replace the X50A Fuse
Biock—Underhood.
4.1. Connect the X6 harness connector at the K9
Body Control Module
4.2. IgnitionON, 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
U If greater than 7 V
5. Test or replace the A23 Door Latch Assembly.
All Door Locks lnoperative
1. lgnition OFF, disconnect the X2 harness connector
at the K9 Body Control Module, ignition ON.
2. Verify a test lamp illuminates between the 8+
circuit terminal 4 and ground.
:9 If the test lamp does not illuminate and the
circuit fuse is good
2.1. lgnition OFF.
2.2. Test for less than 2 Q in the 8+ circuit end
' to end.
2 lf2 Q or greater, repair the open/high resistance
in the circuit.
2 If less than 2 Q, verify the fuse is not open and
there is voltage at the fuse.
If the test lamp does not illuminate and the
circuit fuse is open
2.1. ignition OFF.
2.2. Test for infinite resistance between the 8+
circuit and ground.
2 if less than infinite resistance, repair the short to
ground on the circuit.
U If infinite resistance
2.3. Disconnect the harness connector at each of
the A23 Door Latch Assemblies.
2.4. Test for infinite resistance between each
control circuit and ground.
2 If less than infinite resistance, repair the short to
ground on the circuit.
2 If infinite resistance, replace the appropriate
A23 Door Latch Assembly.
If the test lamp illuminates
lgnition OFF, connect the X2 harness connector at
the K9 Body Control Module. Disconnect the
harness connector at the A23D Door Latch
Assemny—Driver, ignition ON.
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-Sonic
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Note: Leaving the DMM connected between a control
circuit and ground for greater than 20 seconds will
.1 cause the K9 Body Control Module to interpretthe test
1 as a system fault and will cause the voltage on the
1 control circuit to drop to 0 V. Ifthe voltage drops to 0 V,
operate the door locks using the door lock switch to
restore the voltage for testing.
4. Test for greater than 7 V between the control circuit
terminal 2 and ground.
2 If 7 V or less
4.1. lgnition OFF, disconnect the X6 harness
connector at the K9 Body Control Module.
4.2. Test for infinite resistance between the control
circuit terminal listed below and ground:
- Control circuitterminal 1 X6
- Control circuit terminal 2 X6
' Control circuit terminal 4 X6
2 If less than infinite resistance, repair the short to
ground on the circuit.
2 If infinite resistance, replace the K9 Body
Control Module.
U If greater than 7 V
5. Replace the K9 Body Control Module.
Component Testing
Central Door Lock Switch
1. lgnition OFF, disconnect the harness connector at
the S13D Door Lock Switch-Driver.
2. Test for infinite resistance between the signal
terminal 3 and the ground terminal1 with the switch
in the open position.
2 If less than infinite resistance
Replace the S13D Door Lock Switch—Driver.
U If infinite resistance
3. Test for infinite resistance between the signal
terminal 4 and the ground terminal 1 with the switch
in the open position.
2 If less than infinite resistance
Replace the S13D Door Lock Switch-Driver
U If infinite resistance
(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
Vehicle Access 4279
4. Test for less than 2 Q between the signal terminal 4
and the ground terminal 1 with the switch in the
Lock position.
2 If 2 Q or greater
Replace the S13D Door Lock Switch-Driver.
U If less than 2 Q
5. Test for less than 2 Q between the signal terminal 3
and the ground terminal 1 with the switch in the
Unlock position.
2 If 2 Q or greater
Replace the S13D Door Lock Switch-Driver.
U If less than 2 Q
6. AlIOK
Door Latch Assembly
1. IgnitionOFF, disconnect the harness connector at
the appropriate A23 Door Latch Assembly.
2. Install a 25 A fused jumper wire between one of the
control terminals and 12V. Momentarily install a
jumper wire between the other control terminal and
ground. Reverse the jumper wires at least two
times, the A23 Door Latch Assembly should
perform the LOCK and UNLOCK function.
2 If the actuator does not perform the LOCK and
UNLOCK function
Replace the A23 Door Latch Assembly.
U If the actuator performs the LOCK and UNLOCK
function
3. All OK
Repair Instructions
Perform the Diagnostic Repair Verification on
page 6-92 after completing the repair.
- Door Lock Switch Replacement on page 4—321
' Front Side Door Latch Replacement on
page 4—299
- Rear Side Door Latch Replacement on
page 4—301
- Front Compartment Fuse Block Replacement on
page 11—609
- Control Module References on page 6-3 for,BCM
replacement, programming and setup
4=280 Vehicle Access

Trunk Release Malfunction

Diagnostic Instructions
- Perform the Diagnostic System Check - Vehicle
on page 6-66 prior to using this diagnostic
procedure.
' Review Strategy Based Diagnosis on page 6—58
for an overview of the diagnostic approach.
~ Diagnostic Procedure Instructions on page 6-59
provides an overview of each diagnostic category.

Diagnostic Fault Information

Open/High Signal
Circuit Short to Ground Resistance Short to Voltage Performance
Rear CompartmentRelaySwitch8+ 2 2 —— -
Rear CompartmentUnlatchSwitchSignal 8361800 1 1 -
Rear CompartmentRelayControl 8326502 8326504 8326501 —-
Rear CompartmentRelayGround — 8326504 — -
Rear CompartmentLid LatchControl 2 2 2 -
Rear CompartmentLid LatchGround — 2 — -
Rear CompartmentUnlatchSwitchGround — 1 — -
1. RearCompartmentLid ReleaseSwitchMalfunction
2. Rear CompartmentLid LatchMalfunction

CircuitlSystem Description Electrical Information Reference

The rear compartment lid unlatch switch is an input to
the Body Control Module (BCM). The BCM supplies a
12 V signal to the rear compartment lid unlatch switch
and when the switch is pressed, signal circuit voltage
goes low. When the BCM receives a trunk release
signal it will monitor the status to the door latches. lfthe
vehicle doors are locked, the BCM will ignore the
request, if the doors are unlocked, the BCM will supply
voltage and ground to the rear compartment lid release
relay coil, energizing the relay. When the relay is
energized, battery voltage flows through the closed
contacts of the relay to the rear compartment lid latch
which activates allowing for the trunk lid to be raised to
the open position.
Diagnostic Aids
An intermittentshort to ground in the rear compartment
lid unlatch switch circuit may cause the BCM to
command the trunk to open if the vehicle is in park and
the doors are unlocked. Ifthe vehicle has a history of
the trunk opening unexpectedly, inspect the point
where the wires enter the rear compartment lid unlatch
switch for corrosion or evidence of water intrusion.
Reference Information
Schematic Reference
Release Systems Schematics on page 4-241
Connector End View Reference
Component Connector End Views on page 11—269
Description and Operation
Luggage Compartment Description and Operation on
page 4—322
- Circuit Testing on page 11—526
- Connector Repairs on page 11-548
- Testing for IntermittentConditions and Poor
Connections on page 11-531
0 Wiring Repairs on page 11-537
Scan Tool Reference
Control Module References on page 6—3for scan tool
information
CircuitlSystem Verification
1. lgnition ON.
2. Verify the scan tool Trunk Lid/Liftgate Window
Exterior Unlatch Switch parameter changes
between Active and inactive when pressing and
releasing the S58A Rear Compartment Lid Unlatch
Switch-Exterior.
2 If the parameter does not change
Refer to Circuit/System Testing — Trunk
Release Switch Inoperative
U If the parameter changes
3. Verify the operation of the M40 Rear Compartment
Lid Latch when commanding the Trunk Lid Unlatch
with a scan tool.
2 If the M40 Rear Compartment Lid Latch does
not UNLATCH
Refer to CircuitlSystem Testing — Release
Actuator lnoperative
U If the M40 Rear Compartment Lid Latch does
UNLATCH
4. All OK.

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 Vehicle Access 4281

CircuitlSystem Testing Release Actuator lnoperative

Trunk Release Switch Inoperative
. lgnition OFF and all vehicle systems OFF,
disconnect the harness connector at the
S58A Rear Compartment Lid Unlatch
Switch-Exterior. Itmay take up to 2 minutes for all
vehicle systems to power down.
Test for less than 10 Q between the ground circuit
terminal 2 and ground.
If 10 Q or greater
2.1. lgnition OFF.
2.2. Test for less than 2 Q in the ground circuit end
to end.
2 If2 Q or greater, repair the open/high resistance
in the circuit.
2 If less than 2 Q, repair the open/high resistance
in the ground connection.
If less than 10 Q
9° lgnition ON.
Verify the scan tool Trunk Lid/Liftgate Window
Exterior Unlatch Switch parameter is Inactive.
If not Inactive
4.1. IgnitionOFF, disconnect the harness
connector at the K9 Body Control Module.
4.2. Test for infinite resistance between the signal
circuit terminal 1 and ground.
2 If less than infinite resistance, repairthe short to
ground on the circuit.
2 If infinite resistance, replace the K9 Body .
Control Module. ,
If Inactive
Install a 3 A fused jumper wire between the signal
circuitterminal 1 and the ground circuit terminal 2.
Verify the scan tool Trunk Lid/Liftgate Window
Exterior Unlatch Switch parameter is Active.
If not Active
6.1. lgnition OFF, disconnect the harness
connector at the K9 Body Control Module,
ignition ON.
6.2. Test for less than 1 V between the signal
circuit and ground.
2 If 1 V or greater, repair the short to voltage on
the circuit.
U lfless than 1 V
6.3. Test for less than 2 Q in the signal circuit end
to end.
2 If2 Q or greater, repair the open/high resistance
in the circuit.
2 If less than 2 Q, replace the K9 Body Control
Module.
lf Active
Test or replace the 858A Rear Compartment Lid
Unlatch Switch—Exterior.
1. Ignition OFF and all vehicle systems OFF,
disconnect the KR958 Rear Compartment Lid
Unlatch Relay. Itmay take up to 2 minutes for all
vehicle systems to power down.
Test for less than 10 Q between the ground circuit
terminal 2 and ground.
If 10 Q or greater
2.1. IgnitionOFF.
2.2. Test for less than 2 Q in the ground circuit end
to end.
2 If2 Q or greater, repair the open/high resistance
in the circuit.
2 Ifless than 2 Q, repair the open/high resistance
in the ground connection.
If less than 10 Q
9° IgnitionON.
Verify a test lamp illuminates between the 8+
circuit terminal 3 and ground.
If the test lamp does not illuminate and the
circuit fuse is good
4.1. lgnition OFF.
4.2. Test for less than 2 Q in the 8+ circuit end
to end.
2 If2 Q or greater, repair the open/high resistance
in the circuit.
2 Ifless than 2 Q, verify the fuse is not open and
there is voltage at the fuse.
If the test lamp does not illuminate and the
circuit fuse is open
4.1. lgnition OFF.
4.2. Test for infinite resistance between the 8+
circuit and ground.
2 If less than infinite resistance, repair the short to
ground on the circuit.
U lf infinite resistance,
4.3. Disconnect the harness connector at the
M40 Rear Compartment Lid Latch.
4.4. Test for infinite resistance between the control
circuit terminal 5 and ground.
2 Ifless than infinite resistance, repair the short to
ground on the circuit.
2 Ifinfinite resistance, replace the KR958 Rear
Compartment Lid Unlatch Relay
If the test lamp illuminates
Connect a test lamp between the control circuit
terminal 1 and the ground circuit terminal 2.
Verify the test lamp briefly turns ON when
commanding the Trunk Lid Unlatch with a
scan tool.
If the test lamp is always OFF
6.1. lgnition OFF, disconnect the harness
connector at the K9 Body Control Module.
6.2. Test for infinite resistance between the control
circuit and ground.

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4:282 Vehicle Access
2 if less than infinite resistance, repair the short to
ground on the circuit.
U lf infinite resistance
6.3. Test for less than 2 Q in the control circuit end
to end. 13. Test or replace the KR958 Rear Compartment Lid
2 if2 Q or greater, repair the open/high resistance
in the circuit.
Component
2 Ifless than 2 Q, replace the K9 Body Control
Module. Rear Compartment Lid Latch
If the test lamp is always ON
6.1. IgnitionOFF, disconnect the harness
connector at the K9 Body Control Module,
ignition ON.
6.2. Test for less than 1 V between the control
circuit and ground.
2 if 1 V or greater, repair the short to voltage on
the circuit.
2 Ifless than 1 V, replace the K9 Body Control
Module.
If the test lamp turns ON and OFF
. Verify that a test lamp does not illuminate between
the control circuit terminal 5 and ground.
If the test lamp illuminates Trunk Release Switch
Repair the short to voltage on the control circuit
If the test lamp does not illuminate
IgnitionOFF and all vehicle systems OFF,
disconnect the harness connector at the M40 Rear
Compartment Lid Latch. Itmay take up to
2 minutes for all vehicle systems to power down.
. Test for less than 10 Q between the ground circuit
terminal 2 and ground.
If 10 Q or greater
9.1. IgnitionOFF.
9.2. Test for less than 2 Q in the ground circuit and
to end.
2 if 2 Q or greater, repair the open/high resistance
in the circuit.
2 Ifless than 2 Q, repair the open/high resistance
in the ground connection.
if less than 10 Q
. Connect the harness connector at the M40 Rear
Compartment Lid Latch Relay Test
11. ignition ON, connect a 10 A fused jumper wire
between the 8+ circuit terminal 3 and the control
circuit terminal 5.
12. Verify the M40 Rear Compartment Lid Latch is
activated.
If the M40 Rear Compartment Lid Latch does
not activate
12.1. ignition OFF, disconnect the harness
connector at the M40 Rear Compartment Lid
Latch.
12.2. Test for less than 2 Q in the control circuit and
to end.
2 if 2 Q or greater, repair the open/high resistance
in the circuit.
2 Ifless than 2 Q, replace the M40 Rear
Compartment Lid Latch.
U If the M40 Rear Compartment Lid Latch
activates
Unlatch Relay.
Testing
1. lgnition OFF, disconnect the harness connector at
the M40 Rear Compartment Lid Latch.
2. Install a 10A fusedjumperwire between the
control terminal1 and 12V. Install ajumperwire
between the ground terminal 2 and ground.
3. Verify the M40 Rear Compartment Lid Latch
activates
2 If the M40 Rear Compartment Lid Latch does
not activate.
Replace the M40 Rear Compartment Lid Latch.
U If the M40 Rear Compartment Lid Latch does
activate.
4. All OK
1. lgnition OFF, disconnect the harness connector at
the 858A Rear Compartment Lid Unlatch
Switch—Exterior.
2. Test for infinite resistance between the signal
terminal 1 and the ground terminal 2 with the
switch in the open position.
2 If less than infinite resistance
Replace the S58A Rear Compartment Lid
Unlatch Switch-Exterior.
U If infinite resistance
3. Test for less than 3 Q between the signal terminal 1
and the ground terminal 2 with the switch in the
closed position.
2 If 3 Q or greater
Replace the S58A Rear Compartment Lid
Unlatch Switch-Exterior.
U If less than 3 Q
4. All OK
1. lgnition OFF, disconnect the KR958 Rear
Compartment Lid Unlatch Relay.
2. Test for 60—200Q between terminals 1 and 3.
2 If less than 60 Q or greater than 200 Q
Replace the KR958 Rear Compartment Lid
Unlatch Relay.
U If between 60-200 Q
3. Test for infinite resistance between the terminals
listed below:
- 4and3
v 4and5
- 4and1
- 5and1

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 Vehicle Access 4283
2 If less than infinite resistance Repair Instructions
Replace the KR958 Rear Compartment Lid Perform the Diagnostic Repair Verification on
Unlatch Relay. page 6-92 after completing the repair.
U lf infinite resistance - Relay Replacement (Within an Electrical Center)
4. install a 3 A fused jumper wire between relay on page 11—607or Relay Replacement (Attached
terminal 3 and 12 V. Install a jumper wire between to Wire Harness) on page 11-607
relay terminal 1 and ground. . Rear Compartment Lid Latch Replacement on
5. Test for less than 2 Q between terminals 4 and 5. Page 4300
2 If 2 Q or greater - Liftgate Release Switch Replacement on
page 4-320
Replace the KR95B Rear Compartment Lid
Unlatch Relay. - Control Module References on page 6—3for BCM
replacement, programming and setup
U If less than 2 Q
6. All OK
Door Will Not OpenlClose, Door Binding, or Locks, Handles, or Cylinders Do Not Function
Step 1 Action Yes I No
DEFINITION:Thisdiagnostictableis designedto addressthemechanicaldiagnosisofthedoorlatchingsystem,whichcould
inciudetheinsideandoutsidehandles,latchrods/cables,latches,or latchcylinders.
DidyouperformtheDiagnosticSystemCheck—Vehicle? Go to Diagnostic
1 SystemCheck -
Go to Step2 Vehicleonpage 6-66
Wereyousentherefroma VehicleAccess SymptomTable? Go to Symptoms-
2 VehicleAccess on
Go to Step3 page 4-264
3 Doesthedooropenwiththeoutsidehandle? Go to Step4 Go to Step 10
4 Doesthedooropenwiththeinsidehandle? Go to Step5 Go to Step 11
5 Doesthemanuallatchknoblatchandunlatchthelatchsmoothly
withoutbinding? Go to Step6 Go to Step 12
6 Doesthedoorlatchswitchand/orthekeylessentrytransmitterlatch
andunlatchthedoorlatchor doorlatches? Go to Step7 Go to Step 14
7 Istheoutsidekeycylinderlooseor doesitrattleorfallout?(if
equipped) .‘ Go to Step15 Go to Step8
8 Doestheoutsidekey cylinderlatchandunlatchthelatchand
functionsmoothlywithoutbinding?(ifequipped) Go to Step9 Go to Step 16
9 Doesthedoorbind,does ittakeexcessiveefforttoopen,or is it
misaligned? Go to Step17 Go to Step 18

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4=284 Vehicle Access

Door Will Not OpenlClose, Door Binding, or Locks, Handles, or Cylinders Do Not Function
(cont'd) '
Step Action Yes No
if thedoorwillnotopenwiththeoutsidehandle,or thehandleis
obstructedor loose,checkthefollowing:
- For coldweatherfreezing,thawas necessary.
- Check thehandleforforeignmaterial.Removematerialas
necessary.
- Check thehandlegrabbarforloosenessor damage.Repairas
necessary.
- Check thehandleforfulltravel.
Iftheissue is notresolved,removethetrimpanelas necessaryto
gainaccess to doorhardwareandcheckthefollowing:
- Check thehandlechassisforloosefasteners,brokenchassis
inserts,looseor missingspring,or a loose,missingor bentrod
10 lever.
' Check forbentrodto theoutsidehandle.
- Check thatthehandlegrabbarengagestherodleverproperly.
' Check forinterferenceof rodandhandletoothercomponentsin
thedoor.
- Check thathandlerodis securelyattachedat bothlatchand
handle.
- Check if rodis positionedproperlyin theclipon thelatch.At rest
position,thehandleshouldbefullyagainstthedownstopand
thelatchlevershouldbe atthebottomof itstravel.Correctby
openingclip,repositioningrodin clip andclosingcliptillit snaps,
as necessary.
Didyoufindandcorrectthecondition? Go to Step18 Go to Step11
Doorwill notopenwiththeinsidehandle:
- Check theinsidehandleforforeignmaterial.Removematerialas
necessary.
° Check thatthehandleis secure.Correctas necessary.
11 - Ifreardoor,verifychildsecurityis notengaged.
- Removethetrimpanelas necessaryto andchecktheinside
handlerod/cableattachmentsat boththelatchand handle.Ifthe
cable is kinkedor pinched,correctas necessary.
Didyoufindandcorrectthecondition? Go to Step18 Go to Step12
The doorwillnotor is difficultto unlatchwiththeinsidemanual
latchknob: ‘
- For coldweatherfreezing,thawas necessary
- Check thelatchknobfora loosecondition.Repairor replaceas
necessary.
Check thelatchknobforbindingor draggingusingthefollowing
procedure:
1. Removethelatchknob.
2. if conditiongoesaway,checkfordrag/interference ofthelatch
knobagainsttheinnerbeltseal,or thetrimpanel.Correctas
12 required.
Iffurtheractionis required,removethetrimpanelandcheckthe
latchrodandlatchknobforinterferencewiththefollowing:
- Waterdeflector/paper
- Side impactfoam
' Rod grommetin sheetmetal
' Glass runchannel
- Otherrodsor cables
- Trimpanel
Didyoufindandcorrectthecondition? Go to Step18 Go to Step13

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 Vehicle Access 41-285

Door Will Not OpenlClose, Door Binding, or Locks, Handles, or Cylinders Do Not Function
(cont'd)
Step Action Yes No
Witha manuallock,if thelatchwillnotfunctionproperlydo the
following:
1. FunctiontheIock/unlatchleveronthelatchto unlatchthe
latch.Checkforhighinternalresistance.
2. Withthedooropen,manuallyclosethelatchwitha
screwdriver.
13 3. Checkthelatchforinternalbindingby actuatingthelatchwith
theinsidedoorhandlelever.
4. Manuallyclose thelatchwitha screwdriveragain.
5. Checkthelatchforinternalbindingby actuatingthelatchwith
theoutsidedoorhandlelever.
Didyoufindandcorrectthecondition? Go to Step 18 Go to Step 14
Ifpowerlocksare includedin vehicleoptionsanddo notfunction
witheitherthekeylessentrytransmitteror switch:
1. Forcoldweatherfreezing,thawas necessary.
2. Removetrimpadas requiredandcheckthefollowing:
- Verifydoorharnesshas appropriatepowerconnectorsfor
switchesand latch.
- Checkharnessconnectorpinsforcorrosion.
~Assurewireharnessconnectorsareseatedandlocked
properlyat latchandswitch.Removeandre-seatif
required.
‘ Checkdoorharnessforcuts/chafing/corrosion. Correct]
replaceas required.
- Checkfor 12Vat latchanddoorswitch.Correct/proceed
14 accordingly.
' CheckBCM fortroublecodes.Correct/proceed
accordingly. ‘
3. Ifpowerlocksstilldo notfunctiondo thefollowing:
3.1. Removelatchfromdoorcavity.
3.2. Connectlatchto electricalconnectoroutsidethedoor.
3.3. Functionpowerlock/unlatchswitchin bothlatchand
unlatchdirections.WatchforIock/unlatch leveron latch
to movecompletelyfromone positionto theother.
3.4. if leverdoes notmove,removeconnectorfromold latch
andattachto newlatchoutsideofdoorcavity.
3.5. Verifynewlatchis functional,if so,attachrodsand install
newlatchin door.
Didyoufindandcorrectthecondition? Go to Step 18 Go to Step 15
Ifthekeycylinderis loosedo thefollowing:
- Removethetrimif necessary.
15 - Checkthattheretainingclip is properlyseated.(ifequipped)
- Checkthatthefasteneris properlytorqued.(ifequipped)
Didyoufindandcorrectthecondition? Go to Step 18 Go to Step 16

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41—286 Vehicle Access

Door Will Not OpenlClose, Door Binding, or Locks, Handles, or Cylinders Do Not Function
(cont'd)
Step Action Yes No
Theoutsidekeycylinderwill notlatchandunlatchthe latchand
functionsmoothlywithoutbinding:
1. For coldweatherfreezing,thawas necessary
2. Removetrimif required.
3. Check thatthekey cylinderrodis securelyattachedbothtothe
key cylinderpawlandthelatch.
4. Check thatkeycylinderlever.rod andlatchleverarefreeof
16 interferences.Removeinterferencesas required.
5. Check thatlatchcylinderrodis routedproperly.Re-routeas
required.
6. Removerodfromlatchcylinderandactuatecylinder.Check for
internalresistance.Lubricatelatchcylinderas required
7. VerifyCylinderrotateswithvehiclekey.Ifnot,codeand
replacecylinderto matchvehiclekey.See latchcylinder
codingandreplacing.
Didyoufindandcorrectthe condition? (30to Step18 Go to Step 17
The dooris difficulttoopen:
~Checkforinterferencewiththefender,adjacentdoor.body
openingor doorstrikerandadjustas necessary.
- Checkforbindingdoorhinges.Lubricateor align/adjustas G0 toFrontSide Door
17 necessary_ Adjustmenton
, Check thedoorcheckllnkforbinding.
- - - Lubricateas
- necessary. page3-10or Rear
Side DoorAdjustment
- Adjustthedooras necessary. (4DoorNotchBack
Didyoufindandcorrectthe condition? Go to Step18 69)onpage3-12
Verifyproperoperationofthedoorclosingsystem.
- Outsidehandle
- insidehandle
' Manuallock/unlatch
—Outsidekeycylinder
18 —Insideiatchknob
—Doublepullhandle
- Powerlock/unlatch
—Key fob
—Doorswitches
~Dooropening/closing effort
is theconditionstillpresent? Go to Step1 SystemOK

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 5
Vehicle A CCe S 4:287

Repair Instructions

Front Side Door Inside Handle Cable Replacement

2260494

Front Side Door Inside Handle Cable Replacement

Callout Component Name
PreliminaryProcedure
Removethefrontside doorlatch.Referto FrontSide DoorLatchReplacementonpage4-299.
1 FrontSide DoorInsideHandleCable Cover
Tip: Opentheinsidehandlecablecoverto access therelease.
2 FrontSide DoorInsideHandleCable

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4=288 Vehicle Access

Rear Side Door Inside Handle Cable Replacement

2260494
Rear Side Door Inside Handle Cable Replacement
Cailout Component Name
Preliminary Procedure
Removetherearsidedoorlatch.Referto Rear Side DoorLatchReplacementonpage 4-301.
RearSide DoorInsideHandleCable Cover
1
Tip: Opentheinsidehandlecablecoverto access therelease.
2 RearSide DoorinsideHandleCable

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 Vehicle Access 44289

Front Side Door Lock Cylinder Replacement

y.._l
”i.
...

1568783

Front Side Door Lock Cylinder Replacement

Callout Component Name
1 FrontSide DoorLockCylinderScrewAccess Plug
Tip: Use theappropriatetool,removetheplug.
FrontSide DoorLock CylinderClampScrew
Caution: Referto FastenerCautiononpage 0-8.
Procedure
Do Notremovethecylinderclampscrewcompletelyfromthehousing,unscrewthescrewto a hardstop,
2 releasingthecylinderfromthehousing.
Tip: Itis notnecessarytoremovetheoutsidedoorhandleor housingto replacethelockcylinder.
Tighten
5N'm(44lb in)
FrontSide DoorLock CylinderCover
3 Procedure
Removethelockcylindercover.Referto FrontSide DoorLock CylinderOpeningCoverReplacementon
page4-302.
FrontSide DoorLock Cylinder
4 Procedure
1. Ensurethatthelockcylindergasketis in placewheninstallingthelockcylindertothehandle.
2. Inspectthelockcylinderforproperoperation.

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4-290 Vehicle Access

Door Lock Cylinder Replacement

Rear

2478192

Cylinder Replacement
Rear Door Lock
Component Name
Callout
Screw Access Plug
1 Rear Side Door Lock CylinderOpeningCover
cover.
Tip: Use a flat-bladedtoolto removethe
Rear Side Door Lock CylinderClamp Screw
0-8.
Caution: Referto FastenerCautionon page
Procedure hardstop,removethe
fromthe housing.unscrewthe screwto a
2 Do Not removethe cylinderscrewcompletely
cylinder.
Tighten
5N-m(44lb in)
Rear Side DoorLock Cylinder
Procedure Replacementon
3 Side Door Lock CylinderOpeningCover
Removethe lock cylindercover.Referto Rear
page 4—303.

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Manual
Service
 Vehicle Access 4n29'l

2177979
Front Side Door Outside Handle Replacement
Caliout Component Name
FrontSide DoorOutsideHandle
Procedure
1. Removethefrontsidedoorwaterdeflector.
2. Disconnecttheelectricalconnector.
3. Removetheaccess holepluglocatedon theinsideopeningofthedoorthatconcealsthescrewforthelatch
cylinderclamp.
Puiland holdthedoorhandlein theopenposition.
Whileholdingthedoorhandle,unscrewthelatchcylinderclampscrewuntilitcomesto a hardstop.
Releasethehandle,by nowthehandleshouldstayin theopenposition.
Removethelockcylinder,gentlypullitstraightout.
@NQWP
Removetheoutsidedoorhandlebyslidingrearwardsandthenoutin a swingingmotion.
9. Inspectthedoorlockingsystemforproperoperationbeforeinstallingthetrimpanel.
Tip: Whilescrewingin thescrewforthelockcylinderholdthehandlein theopenposition,thiswillavoidthedoor
handlefromsnappingoncethespringpressureis relievedandthedoorhandlereturnsto theclose position.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
4-292 Vehicle Access

Front and Rear Side Door Outside Note: Use the appropriate tool to push in on the
retaining tabs (1) located on each side of the old clip to
Handle Rod Clip Replacement remove.
Removal Procedure 2. Remove the old outside door handle rod Clip (1)
from the door latch.
Installation Procedure

2829645
Note: Itmaybe 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.
2790592
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-Ioad,
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.

2790591
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.

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
 Vehicle Access 4:293

Front Side Door Outside Handle Bracket Replacement

2019711
Front Side Door Outside Handle Bracket Replacement
Callout Component Name
Preliminary Procedures
1. Removethefrontsidedoortrimpanel.Referto FrontSide DoorTrimReplacementonpage 2—67.
2. Removethefrontsidedooroutsidehandle.Referto FrontSide DoorOutsideHandleReplacementonpage4-291.
FrontSide DoorOutsideHandleBracketScrew
Caution: Referto FastenerCautiononpage0—8.
1 Procedure
Removethefrontsidedoorwaterdeflector.
Tighten
5 NW(44lb in)
FrontSide DoorOutsideHandleBracket
Procedure
1. Releasefrontside dooroutsidehandlerodmechanismat shiftlinkagelever—clip.
2. Releasethefrontside doorlatchcylinderrodfromthedoorlatch.
3. Transfercomponentsas necessary.
4. Inspectthedoorlatchsystemforproperoperationbeforeinstailingthedoortrimpanel.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
4—‘294 Vehicle Access

Rear Side Door Outside Handle Bracket Replacement

2019653
Rear Side Door Outside Handle Bracket Replacement
Callout I Component Name
Preliminary Procedures
1. Removetherearsidedoortrimpanel.Referto Rear Side Door TrimReplacement(Sedan)onpage2-84or RearSide Door
TrimReplacement(Hatchback)onpage2—83.
2. Removetherearside dooroutsidehandle.Referto Rear Side DoorOutsideHandleReplacement(Hatchback)on
page 4-298or Rear Side DoorOutsideHandleReplacement(Sedan)onpage4-297.
RearSide DoorOutsideHandleBracketScrew
Caution: Referto FastenerCautiononpage 0-8.
1 Procedure
Removetherearside doorwaterdeflector.
Tighten
5 N'm(44lbin)
RearSide DoorOutsideHandleBracket
Procedure
2 1. Releaserearsidedooroutsidehandlerodmechanismatshiftlinkagelever—clip.
2. Releasetherearside doorlatchcylinderrodfromthedoorlatch.
3. Transfercomponentsas necessary.
4. Inspectthedoorlatchsystemforproperoperationbeforeinstallingthedoortrimpanei.

2013
—
Sonic
(US/Canada)
Service
Manual
(5377994)
 Vehicle Access 4:295

Liftgate Latch Replacement

2479214

Liftgate Latch Replacement

Callout Component Name
Preliminary Procedures
1. Removetheliftgatetrimfinishpanel.Referto LiftgateTrimFinishPanel Replacement(Hatchback)onpage 2-86,
2. Removetheliftgatelatchcover.
LiftgateLatchScrew(Qty:2)
Caution: RefertoFastenerCautiononpage0-8.
Tighten
9 NW(80lbin)
LiftgateLatchAssembly
Procedure
1. Disconnecttheelectricalconnector.
2. Adjusttheliftgateifneeded.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
4:296 Vehicle Access

Rear Compartment Lid inside Handle Replacement

2577198
Rear Compartment Lid Inside Handle Replacement
Callout Component Name
Preliminary Procedure
Removetherearcompartmentiidinnerpaneltrim.Referto Rear CompartmentLid InnerPanel TrimReplacement(Sedan)on
page2-88.
Rear CompartmentLid insideLatchHandleAccess Cover
1 Procedure
Depresstheretainersandslidetheaccess covertoaccess thecable.
Rear CompartmentLid InsideLatchHandleCable
2 Procedure
Disconnecttherearcompartmentlid insidelatchhandlecablefromthelatch.
Rear CompartmentLid InsideLatchHandleCable Retainer
3 Procedure
Uncliptherearcompartmentlid insidelatchhandlecableclipfromtherearcompartmentlid.
4 Rear CompartmentLid InsideLatchHandle

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Vehicle Access 4=297

l Rear Side Door Outside Handle Replacement (Sedan)

2177979

Rear Side Door Outside Handle Replacement (Sedan)

Callout Component Name
Preliminary Procedures .
Removetherearside doorlockcylinderopeningcover.Referto Rear Side DoorLock CylinderOpeningCoverReplacementon
page4-303.
Rear Side DoorOutsideHandle
Procedures
1. Removetherearside doorwaterdeflector.
2. Removetheaccess holepiuglocatedontheinsideopeningof thedoorthatconcealsthescrewforthelock
cylinderclamp. .
Puil and holdthedoorhandlein theopenposition.
Whileholdingthedoorhandle,unscrewthelockcylinderclampscrewuntilit comesto a hardstop.
Releasethehandle.by nowthehandleshouldstayin theopenposition.
Removethelockcylinder,gentlypullitstraightout.
Removetheoutsidedoorhandleby slidingrearwardsandthenoutin a swingingmotion.
71.039155.“
8. Inspectthedoorlockingsystemforproperoperationbeforeinstallingthetrimpanel.
Tip: Whilescrewingin thescrewforthelockcylinderholdthehandlein theopenposition,thiswillavoidthedoor
handlefromsnappingoncethespringpressureis relievedandthedoorhandlereturnstotheclose position.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
$298 Vehicle Access

Rear Side Door Outside Handle Replacement (Hatchback)

2425047

Rear Side Door Outside Handle Replacement (Hatchback)

Callout I Component Name
Preliminary Procedures
Removetherearsidedoortrim.Referto Rear Side Door TrimReplacement(Sedan)onpage 2-84or Rear Side DoorTrim
Replacement(Hatchback)onpage 2-83.
RearSide DoorOutsideHandleRod Clip
Procedure
1. Place thewindowinthefullupposition.
2. Removethewaterdeflector.
3. Removetheoutsidedoorhandlerod fromtheclip,Do notremovetherodfromthedoorlock.
RearSide DoorOutsideHandleScrews(Qty:2)
Caution: Referto FastenerCautiononpage 0-8.
Tighten
9N'm(80lbin)
RearSide DoorOutsideHandlePush-ln Retainers(Qty:2)
Tip: Iftheretainersare brokenwhenremovingtheyMustbe replaced.
RearSide DoorOutsideHandle
Procedure
Inorderto preventoutsidehandleleverpre—ioad, look,outsidehandleshall befullysecuredto thedoorpriorto
securingintegrallockcliptooutsidehandlerod. Integrallockclipshall be in thefullup positionwhilesecuringto
outsidehandlerod.Referto Rear Side DoorOutsideHandleRodAdjustmentonpage4-311.
Note: inspectthedoorlocksystemfor properoperationbeforeinstallingthedoortrim.

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
 Vehicle Access 4-299

2425036

Front Side Door Latch Replacement

Callout Component Name
Preliminary Procedure
Removethefrontsidedoortrimpanel.Referto FrontSide Door TrimReplacementonpage2-67.
FrontSide DoorLock Screw(Qty:3)
Caution: Referto FastenerCautiononpage 0—8.
Procedures
1. Removethewaterdeflector.
1 2. Releasethefrontinsidedoorhandlecable retainersfromthedoor.
3. Removethefrontside doorwindowrearguide.Referto FrontSide DoorWindowRear GuideReplacement
onpage4-49.
Tighten
10N-m(89lb in)
FrontSide DoorLockAssembly
Procedure
2 1. Disconnectthefrontside doorlockelectricalconnector.
2. Transferthefrontside doorlockrods.
3. Frontoutsidedoorhandlerodadjustment.Referto FrontSide DoorOutsideHandleRod Adjustmenton
page4—306.

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
4-300 Vehicle Access

Rear Compartment Lid Latch Replacement

41%
@1111 11111:?“

“KKK

°aao‘ J//
/o \\ I-\ >83»

m m
\__/

2479218
Rear Compartment Lid Latch Replacement
Callout Component Name
Preliminary Procedure
Removetherearcompartmentlidinnerpaneltrim.Referto Rear CompartmentLid InnerPanel TrimReplacement(Sedan)on
page 2—88.
Rear CompartmentLid LatchScrew (Qty:2)
Caution: Referto FastenerCautiononpage0-8.
Tighten
9N-m(80lb in)
Rear CompartmentLatch
Procedure
1. Disconnecttheelectricalconnection.
2. Slidethelatchtotherightand upto removefromthecompartmentlid.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Vehicle Access 4-301

Rear Side Door Latch Replacement

2425041

Rear Side Door Latch Replacement

Callout l Component Name
Preliminary Procedure
Removetherearside doortrimpanel.Referto Rear Side DoorTrimReplacement(Sedan)onpage 2-84or Rear Side DoorTrim
Replacement(Hatchback)onpage283.
Rear Side DoorLockScrew (Qty:3)
Caution: Referto FastenerCautionon page 0-8.
Procedures
1. Removethewaterdeflector.
1 2. Releasetherearinsidedoorhandlecabieretainersfromthedoor.
3. Removetherearside doorwindowrearguide.Referto Rear Side DoorWindowRear GuideReplacement
onpage4-50.
Tighten
10N-m(89lb in)
Rear Side DoorLockAssembly
Procedure
2 1. Disconnecttherearsidedoor lockelectricalconnector.
2. Transfertherearside doorlockrods.
3. Rearoutsidedoorhandlerodadjustment.Referto Rear Side DoorOutsideHandleRod Adjustmenton
page4-311.

(US/Canada)
«Sonic
2013 (5377994)
Manual
Sen/ice
4-302 Vehicle Access

Front Side Door Lock Cylinder Opening Cover Replacement

2019753

Front Side Door Lock Cylinder Opening Cover Replacement

Callout Component Name
FrontSide DoorLock CylinderOpeningCover
Procedure
1. Removethefrontsidedoorlockcylinder,Do Notremovetheoutsidedoorhandle.Referto FrontSide Door
Lock CylinderReplacementonpage4-289.
2. Do Notremovethelockcylinderscrewcompletelyfromthehousing.Unscrewthescrewtoa hardstop,
removethecylinder.
Tip: Use a smallflat-bladedtoolto releasethelockcylinderbezelretainerslocationon bothsides.

—
2013 (US/Canada)
Sonic (5377994)
Manual
Service
 1‘
Vehicle Access 41-303
hhhhh
l
1 Rear Side Door Lock Cylinder Opening Cover Replacement

2476194

Rear Side Door Lock Cylinder Opening Cover Replacement

Callout Component Name
RearSide DoorLockCylinderOpeningCover
Procedure
1. Removetherearsidedoorlockcylinder,Do Notremovetheoutsidedoorhandle.Referto Rear DoorLock
1 CylinderReplacementonpage 4-290.
2. DoNotremovethe lockcylinderscrewcompletelyfromthehousing.Unscrewthescrewtoa hardstop,
removethecylinder.
toolto releasethelockcylinderbezelretainerslocationon bothsides.
Tip: Usea smallflat—bladed

—
2013 (US/Canada)
Sonic (5377994)
Manual
Service
 1
+304 Vehicle Access 1
Front Side Door Locking Rod Replacement 1

2019703
Front Side Door Locking Rod Replacement
Callout Component Name
Preliminary Procedure
1. Removethefrontside doorwindowrearguide.Referto FrontSide Door WindowRear GuideReplacementonpage4-49.
2. Removethefrontside doorlock . Referto FrontSide DoorLatchReplacementonpage4-299.Do Notremovethelock
completelyfromthedoor,lowerthelocktodisconnecttherod.
FrontSide DoorLock Rod
Procedure
1. Place thewindowinthefullup position.
2. Removethewaterdeflector.
1 3. Transfercomponentsas necessary.
4. Inorderto preventoutsidehandleleverpre-load,look,outsidehandle,handlebracketandcover/capshall
befullysecuredtothedoorpriortosecuringintegrallockcliptooutsidehandlerod.Integrallockclipshall
be in thefullup positionwhilesecuringtooutsidehandlerod.Referto FrontSide DoorOutsideHandleRod
Adjustmentonpage4-306.
Tip: Inspectthedoorlocksystemforproperoperationbeforeinstallingthedoortrimpanel.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Vehicle Access 4605

Front Side Door Lock Cylinder Rod Replacement

..Wer2.
‘2“,
..n

2019751
Front Side Door Lock Cylinder Rod Replacement
Callout Component Name
Preliminary Procedure
1. Removetherearsidedoorwindowrearguide.Referto Rear Side Door WindowRear GuideReplacementonpage4-50.
2. Removetherearsidedoorlock.Referto Rear Side DoorLatchReplacementonpage4-301.
Rear Side DoorLock CylinderRod
Procedure
1. Place thewindowinthefullup position.
2. Removethewaterdeflector.
1 3. Inorderto preventoutsidehandleleverpre-load,look,outsidehandle,handlebracketandcover/capshall
befullysecuredto thedoorpriorto securingintegrallockclip tooutsidehandlerod.Integrallockclipshall
be inthefullup positionwhilesecuringtooutsidehandlerod.Referto FrontSide DoorOutsideHandleRod
Adjustmentonpage4—306.
Tip: Inspectthedoorlocksystemforproperoperationbeforeinstallingthedoortrimpanel.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
4=306 Vehicle Access

Front Side Door Outside Handle Rod Adjustment

2244557

Front Side Door Outside Handle Rod Adjustment

Callout Component Name
Preliminary Procedures
Removethefrontside doortrimpanel.Referto FrontSide Door TrimReplacementonpage2-67
FrontSide DoorOutsideHandleRod Retainer
1 Procedure
Removethefrontsidedoorwaterdeflector.
FrontSide DoorOutsideHandleRod
Procedure
1. Positionthefrontside dooroutsidehandlerodin theretainerin orderto eliminateanyfreeplayin the
outsidedoorhandle.
2. Adjustthetravelof thehandleby removingthethreadedrodfromtheretainer.
3. installtheretainercoverclosedover thethreadedfrontside dooroutsidehandlerod.
4. Inspectthedoorlocksystemforproperoperationbeforeinstallingthetrimpanel.
Tip: Use a fiat—headtoolto opentheretainerfromthethreadedrod connectingthelocktothe outsidehandle.

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
 1 Access 41-307
Vehicle
"""1 Front Side Door Outside Handle Rod Replacement

1
l

2177981
Front Side Door Outside Handle Rod Replacement
Callout Component Name
Preliminary Procedure
Removethefrontside dooroutsidehandlebracket.Referto FrontSide DoorOutsideHandleBracketRep/acementon
page4—293.
FrontSide DoorOutsideHandleRod
Procedure
1. Place thewindowin thefullupposition.
2. Removethewaterdeflector.
1 3. Openthehandlerodby releasingtheclipattheendof thehandlerod.
4. Inorderto preventoutsidehandleleverpre-load,look,outsidehandle,handlebracketandcover/capshall
befuIlysecuredtothedoorpriorto securingintegrallock cliptooutsidehandlerod.Integraliockclip shall
be in thefullup positionwhilesecuringto outsidehandlerod.Referto FrontSide DoorOutsideHandleRod
Adjustmentonpage4—306.
Tip: Inspectthedoorlocksystemforproperoperationbeforeinstallingthedoortrimpanel.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
4308 Vehicle Access

Rear Side Door Locking Rod Replacement (Sedan)

2019703
Rear Side Door Locking Rod Replacement (Sedan)
Callout Component Name
Preliminary Procedure
Removetherearside doorlock.Referto Rear Side DoorLatchReplacementonpage4-301.Do Notremovethelockcompletely
fromthedoor,lowerthelocktodisconnecttherod.
Rear Side DoorLock Rod
Procedure
1. Place thewindowin thefullup position.
2. Removethewaterdeflector.
1 3. Transfercomponentsas necessary.
4. Inorderto preventoutsidehandieleverpre-load,lock,outsidehandle,handlebracketandcover/capshall
befullysecuredtothedoorpriortosecuringintegrallockcliptooutsidehandlerod.Integrallockclipshall
be in thefullup positionwhilesecuringto outsidehandlerod.Referto Rear Side DoorOutsideHandleRod
Adjustmentonpage4-311.
Tip: Inspectthedoorlocksystemforproperoperationbeforeinstallingthedoortrimpanel.

2013
-Som‘c
(US/Canada)
Service
Manual
(5377994)
l
l
1
1 Vehicle Access 44309
1
i1
l Rear Side Door Locking Rod Replacement (Hatchback)

2425044
Rear Side Door Locking Rod Replacement (Hatchback)
Callout l Component Name
Removetherearside doortrim.Referto Rear Side DoorTrimReplacement(Sedan)onpage 2—84
or Rear Side DoorTrim
Replacement(Hatchback)onpage 2-83
Rear Side DoorLock Rod
Procedure
1. Removethewaterdeflector.
2. Transferthelockrodbutton.
Note: Inspectthedoorlocksystemforproperoperationbeforeinstallingthedoortrimpanel.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
4-310 Vehicle Access

Rear Side Door Locking Rod Bellcrank Replacement

2425048
Rear Side Door Locking Rod Bellcrank Replacement
Callout 1 Component Name
Preliminary Procedures
Removetherearside doortrimpanel.Referto Rear Side DoorTrimReplacement(Sedan)onpage 2—84
or Rear SideDoorTrim
Replacement(Hatchback)onpage2-83.
Rear Side DoorLockRod BellcrankCenterRetainer
Procedure
1 1. Place thewindowinthefullupposition.
2. Removethewaterdeflector.
Note: Use a smallflat-bladedtoolto releasetheretainerfromthecenterofthebellcrank.
2 RearSide DoorLockRod BellcrankCenter
3 Rear Side DoorLock Rod BellcrankRetainerto Door
Note: inspectthedoorlocksystemforproperoperationbeforeinstallingthedoortrimpanel.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Vehicle Access 4-311

Rear Side Door Outside Handle Rod Adjustment

2244557

Rear Side Door Outside Handle Rod Adjustment

Callout 1 Component Name
Preliminary Procedures
Removetherearside doortrimpanel.Referto Rear Side Door TrimReplacement(Sedan)onpage2—84 or Rear Side DoorTrim
Replacement(Hatchback)onpage2-83.
Rear Side DoorOutsideHandleRod Retainer
1 Procedure
Removetherearside doorwaterdeflector.
Rear Side DoorOutsideHandleRod
Procedure
1. Positiontherearside dooroutsidehandlerodin theretainerin orderto eliminateanyfreeplayin the
outsidedoorhandle.
2. Adjustthetravelof thehandleby removingthethreadedrodfromtheretainer.
3. Installtheretainercoverclosedoverthethreadedfrontsidedooroutsidehandlerod.
4. Inspectthedoorlockingsystemforproperoperationbeforeinstallingthetrimpanel.
Tip: Use a flat—headtooitoopenthe retainerfromthethreadedrodconnectingthelockto theoutsidehandle.

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
4-312 Vehicle Access

Rear Side Door Outside Handle Rod Replacement (Hatchback)

1’ /
:
e ‘5‘%‘
“\V / _o /:
‘ ’/ \(‘1m
1 \\\\ ‘ {\

2425045
Rear Side Door Outside Handle Rod Replacement (Hatchback)
Callout 1 Component Name
Preliminary Procedures
Removetherearsidedoortrim.Referto Rear Side DoorTrimReplacement(Sedan)onpage 2-84or Rear Side DoorTrim
Replacement(Hatchback)onpage2-83.
RearSide DoorOutsideHandleRod UpperRetainer
1 Procedure
Removethewaterdeflector
RearSide DoorOutsideHandleRod
Procedure
1. Use a flat—headtoolto openthelowerretainerfromthethreadedrodconnectingthelocktotheoutside
handle.
2. Positiontherearside dooroutsidehandlerodin theretainerin orderto eliminateanyfreeplayinthe
2 outsidedoorhandle.
3. Adjustthetravelofthehandleby removingthethreadedrodfromtheretainer.
4. Inorderto preventoutsidehandleleverpre-Ioad,locktheoutsidehandleshall befullysecuredtothedoor
priorto securingintegrailockCliptooutsidehandlerod.Integrallockclipshall be in thefulluppositionwhile
securingto outsidehandlerod.Referto Rear Side DoorOutsideHandleRod Adjustmentonpage4-311.
5. Inspectthedoorlocksystemforproperoperationbeforeinstallingthetrimpanel.

2013
—
Sonic
(US/Canada)
Service
Manual
(5377994)
 Vehicle Access 4-313

Rear Side Door Outside Handle Rod Replacement (Sedan)

2177981

Rear Side Door Outside Handle Rod Replacement (Sedan)

Callout 1 Component Name

Preliminary Procedures
Removetherearside doortrimpanel.Referto Rear Side DoorTrimReplacement(Sedan)onpage 2—84 or Rear Side DoorTrim
Replacement(Hatchback) o npage2-83.
Rear Side DoorOutsideHandleRod
Procedures
1 1. Removetherearside doorwaterdeflector.
2. Openthehandlerodclip.
3. Inspectthedoor lockingsystemforproperoperationbeforeinstallingthetrimpanel.Referto Rear Side
DoorOutsideHandleRod Adjustmentonpage4-311.

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
4-314 Vehicle Access

Front Side Door Lock Striker 2. Close the door onto the striker and note if the door
drags on the striker causing the door to move
Adjustment upward or downward upon contact with the striker.
To determine if striker adjustment is required, proceed Also note the closing effortto fully engage the lock.
as follows: . Using a grease pencil, mark around the strikerfor
reference of the original position. Loosen the
striker.
. Move the striker to eliminate drag on the striker
and door lock and to achieve the proper door
position within the door opening. Start with the up/
down position, then position the striker to achieve
proper alignment to the door opening. Set the in/
out adjustment for the proper door seal
engagement making sure the door closing efforts
are correct.
Caution: Refer to Fastener Caution on page 0-8.
5. Tighten the striker bolts. Tighten the front side door
striker screws to 22 NW (16 lb ft).

928781
1. Ensure the door is properly aligned within the door
opening before proceeding with the striker
adjustment.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Vehicle Access 4-315
.1,"
...-

Front Side Door Lock Striker Replacement

2374034

Front Side Door Lock Striker Replacement

Callout Component Name
FrontDoorLock StrikerScrews (Qty:2)
Caution: Referto FastenerCautionon page 0-8.
1 Tighten
22N-m(161bft)
FrontDoorLock Striker
2 Procedure
4-314.
Ensurethealignmentofthestriker.Referto FrontSide DoorLock StrikerAdjustmentonpage

(US/Canada)
-Sonic
2013 (5377994)
Manual
Sen/ice
41-316 Vehicle Access

Liftgate Latch Striker Replacement

2479285
Liftgate Latch Striker Replacement
Callout Component Name
Preliminary Procedure
Removetherearcompartmentsill trimplate.Referto Rear CompartmentSill TrimPlateReplacementonpage2-87.
LiftgateLatchStrikerBolt(Qty:2)
Caution: Referto FastenerCautiononpage 0-8.
Tighten
22N-m(16lbft)
2 LiftgateLatchStriker

2013
—Sonic
(US/Canada)
Service
Manual
(5377994)
 Vehicle Access 4-317

2479285

Rear Compartment Lid Latch Striker Replacement

Callout Component Name
Preliminary Procedure
Removethe rearcompartmentsill trimplate.Referto Rear CompartmentSill TrimPlateReplacementonpage2—87.
LatchStrikerBolt(Qty:2)
Caution: Referto FastenerCautiononpage 0-8.
Tighten
22N-m(16lbft)
2 RearCompartmentLid LatchStriker

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
41-318 Vehicle Access

Rear Side Door Lock Striker 2. Close the door onto the striker and note ifthe door
drags on the striker causing the door to move
Adjustment upward or downward upon contact with the striker.
To determine if striker adjustment is required, proceed Also note the closing effort to fully engage the lock.
as follows: . Using a grease pencil, mark around the strikerfor
reference of the original position. Loosen the
striker.
. Move the striker to eliminate drag on the striker
and door lock and to achieve the proper door
position within the door opening. Start with the up/
down position, then position the striker to achieve
proper alignment to the door opening. Set the in/
out adjustment for the proper door seal
engagement making sure the door closing efforts
are correct.
Caution: Refer to Fastener Caution on page 0—8.
5. Tighten the striker bolts. Tighten the rear side door
striker bolts to 22 N'm(161b ft).

928781
1. Ensure the door is properly aligned within the door
opening before proceeding with the striker
adjustment.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Vehicle Access 4=319

Rear Side Door Lock Striker Replacement

2250927

Rear Side Door Lock Striker Replacement

Callout Component Name
Rear Side DoorLockStrikerScrew(Qty:2)
Caution: Referto FastenerCautiononpage0-8.
Tighten
22N°m(16lbft)
Rear Side DoorLockStriker
Procedures
1. Ensurethespaceris in place.
2. Ensureproperalignmentafterinstallation.Referto Rear Side DoorLock StrikerAdjustmentonpage 4-318.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
4-320 Vehicle Access

Liftgate Release Switch Replacement

2479292
Liftgate Release Switch Replacement
Callout Component Name
Preliminary Procedure
Removetheliftgateside applique.Referto LiftgateSideAppliqueReplacement(Hatchback)onpage2—5.
LiftgateReleaseSwitch
1 Procedure
Depresstheretainersonthebacksideoftheswitchandpushtheswitchoutfromtheapplique.

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
 Vehicle Access 4421

Door Lock Switch Replacement

2496166

Door Lock Switch Replacement

Callout Component Name
Preliminary Procedure
Removetheheaterand air conditioningcontrol.Referto HeaterandAir ConditioningControlReplacementonpage 10-79.
DoorLockSwitchBo|ts(Qty:2)
1 Caution: Referto FastenerCautiononpage 0-8.
DoorLock Switch
Procedure
Disconnecttheelectricalconnector.

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
4~322 Vehicle Access

Operation open ajar switch closes. With the ajar switch closed,
Description and
ground is provided to the ajar switch signal circuit. The
BCM detects the voltage drop and sends a serial data
message to the instrument panel to display the door
Door Ajar Indicator Description and ajar indicator
Operation
Luggage Compartment Description
Door Ajar Indicator System
and Operation
Components
The door ajar indicator system consists of the following Luggage Compartment Release System
components: Components
. Body control module (BCM) ° Body control module (BCM)
- instrument panel cluster . Exterior rear compartment lid release switch
- Driver door latch (Sedan)
' Passenger door latch ' Liftgate unlatch switch (Hatchback)
- Left rear door latch ' Rear compartment lid latch (Sedan)
- Right rear door latch - Liftgate latch (Hatchback)
° Liftgate latch ° Rear compartment lid release relay (Sedan)
° Rear compartment lid latch ' Liftgate release relay (Hatchback)
- Driver window motor Luggage Compartment Release
Driver Door Ajar (AXG) Operation
The driver window motor supplies a 12 V signal to the Trunk/Liftgate Release Switch
door ajar switch within the door latch, when the driver
door is open the door ajar switch closes pulling the 12 V The BCM monitors supplies a 12 V signal to the release
signal low. When the driver window motor detects the switch so that when the switch is pressed, the voltage
drop in the 12 V signal circuit, it will then communicate within the signal circuit is pulled low and in response,
this status to the BCM via local interconnect network the BCM will detect the voltage drop and check the
(LIN) bus. The BCM communicates with the instrument status of the door lock system. if the doors are locked,
cluster via serial data message. The instrument panel the BCM will ignore the request, if the All Doors
cluster, upon receipt of this serial data message, will Unlocked has been commanded, the BCM will
illuminate the driver door ajar indicator and also send a recognize the request and will provide voltage to the
serial data message to the radio to activate the door release relay.
ajar audible warning when the vehicle speed is greater Rear Compartment Lid Latch
then 8 km/h (5 mph).
When BCM receives a rear compartment release
DriverlPassenger/Rear Door Ajar command from the release switch, the BCM applies
brief pulse of voltage to the release relay control circuit,
(Without AXG)
which energizes the coil side of the relay. The switch
The body control module (BCM) supplies a 12 V signal side of the release relay then momentarily closes,
to each of the door latches, these latches contain an supplying a brief pulse of battery positive voltage to the
ajar switch which is normally open when the door is rear compartment latch. The rear compartment latch is
closed. When a door is ajar or open, the contacts of the continuously grounded and when it receives the voltage
ajar switch will close causing the voltage in the signal pulse, it will become energized and the latch will
circuit to drop to zero volts. The BCM will detect the activate releasing the trunk lid or liftgate so that the
voltage drop and will send a message to the instrument trunk lid or liftgate may be manually raised to an open
panel cluster. The instrument panel cluster, upon position.
receipt of this message, will illuminate the appropriate
door ajar message in the driver information center and Keyless Entry Transmitter
also send a message to the radio to activate the door The BCM may also get a rear compartment release
ajar audible warning when the vehicle speed is greater command from the remote keyless entry module. When
then 8 km/h (5 mph). the trunk button is pressed on the keyless entry
transmitter,a rear compartment release request is sent
Trunk/Liftgate Ajar to the remote keyless entry module, the remote keyless
The body control module (BCM) provides a 12 V signal entry module will then send a serial data message to
to the trunk ajar signal circuit. The liftgate latch and the the BCM to command the release of the trunk/liftgate.
rear compartment lid latch contain an ajar switch which
is normally open when the trunk or liftgate is closed.
When the liftgate or trunk or is opened, the normally

(US/Canada)
-Sonic
2013 (5377994)
Manual
Sen/ice
 Vehicle Access 4323

Power Door Locks Description and The following three Circuits are used to operate
the lock:
Operation ' Driver door unlock
Door Lock System Components ' Passenger door unlock
The power door lock system consists of the following ~ All door lock
components: Child Door Lockout Operation
- Central door lock switch
The operator has the option to disable the interior rear
- Child door lockout switch door handles to prevent the unauthorized opening of
° Door lock actuators in each of the doors the rear door doors while still retaining normal rear
- Body control module (BCM) exterior door handle functions. When the child door
lockout switch is pressed, the BCM will energize the
- Underhood fuse block door lock security relay, send a 12V pulse to the rear
Door Lock System Controls door latches activating the lookout feature and will
command the child lockout indicator to illuminate. The
The power door lock system can be controlled by any of rear door plungers will still function normally by
the following: pressing the central door lock switch but the child
- A door lock switch LOCK or UNLOCK activation lockout latches will disable the interior rear door
- A mechanical key cylinder Iock/unlock handles. Pressing the child lockout switch again will
signal a command to the BCM which will de-energize
- A keyless entry transmitter activation the door lock security relay, send a 12V pulse to the
- An automatic door lock activation rear door latches to de-active the lockout feature and
- An automatic door unlock activation restore normal interior rear door handle functions and
the turn off the child lockout indicator.
Door Lock Operation The rear door latches contain switches that are open
When a door lock switch is activated in the lock or when the rear doors are not locked out and closed
unlock position the body control module (BCM) will when the rear doors are locked out which is monitored
receive a ground signal on either the door lock switch by the BCM to determine the lockout status of rear door
lock or unlock signal circuits. latches
The BCM, upon receipt ofa lock switch lock or unlock Ifthe child lockout indicator flashes while trying to
signal, will supply voltage to the door lock actuator lock lockout the rear door handles indicates that there is a
or unlock control circuits. Since the opposite side of the fault detected in the child lockout system and one or
lock actuator is connected to ground through the other both interior rear door handles may not be disabled.
lock actuator control circuit, the doors will then look or
unlock as commanded.

(US/Canada)
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2013 (5377994)
Manual
Service
4:324 Wipers and Washers

Wipers and Washers

Specifications

Fastener Tightening Specifications

Specification
Application Metric English
Air InletGrillePanel Screw 2.5N-m 22lbin
RearWindowWiperArmNut 1ON-m 89|bin
RearWindowWiperMotorBolt 9N'm 80|bin
WindshieldWasherSolventContainerNut 5 N'm 44lbin
WindshieldWiperArm Nut 25Nm 18lb ft
WindshieldWiperMotorBracketScrew 8.5N'm 75lbin
WindshieldWiperSystemModuleBolt 18N-m 13lbft

Schematic and Routing Diagrams

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
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2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
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2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 and Washers 44327
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(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
 4-328 Wipers and Washers

Diagnostic Information and Procedures

DTC B370B
Diagnostic Instructions
- Perform the DiagnosticSystem Check - Vehicle
on page 6-66 priorto usingthis diagnostic
procedure.
- Review Strategy Based Diagnosison page 6-58
for an overview of the diagnosticapproach.
' DiagnosticProcedure Instructions on page 6-59
providesan overview of each diagnosticcategory.
DTC Descriptor
DTC B3708: Rear Wiper Function Control Circuit
For symptom byte information,
refer to Symptom Byte
Liston page 6-85.
Diagnostic Fault Information

Open/High Signal
Circuit Short to Ground Resistance Short to Voltage Performance
RearWiperMotorB+ 1
RearWiperSwitchSignal 1
1 1
RearWiperMotorControl 1 1 2
RearWiperRelay Control 83708 02 83708 04 83708 01
RearWiperRelay Ground 1
RearWindow WiperGround - 1 __ _
1.RearWiper lnoperative
2. RearWiperAlwaysON

CircuitlSystem Description wipermotor control circuit.The rear wipermotorwill

The body control module (BCM) controlsthe rear wiper continue to operate usingthe constant B+ circuituntilit
motor based on an input from the rear wiperswitch, is inthe park position.
which is part of the windshieldwiper/washer switch. Conditions for Running the DTC
The BCM monitorsthe windshieldwiper/washer switch
through two separate signalcircuitsand a low - IgnitionON
reference circuit.The rear wiperswitchusesa resistor - The system voltage is between 9—16V.
ladder to determine low speed, intermittent,and rear
washer operation. The BCM monitorsapplies and Conditions for Setting the DTC
monitorsvoltage on the rear wiperswitchsignalcircuit.
When the rear wiperswitchis placed inthe low speed, B3703 01
intermittent,or rear washer position,the voltage is A short to voltage is detected inthe rear wiperrelay
pulled downthrough a different resistorinthe resistor control circuit.
ladder, reducing the voltage seen at the BCM. The
B3703 02
BCM willrespond by commandingthe specificrear
wiperfunction. A short to ground is detected inthe rear wiperrelay
The rear wipermotor is controlled by the BCM through control circuit.
the rear wiperrelay. A constant 8+ and ground are 33703 04
suppliedto the rearwiper motor.When rear wiper
operation is requested, the BCM willapply voltage to An open or high resistance is detected inthe rear wiper
the rear wiperrelay control circuit.This willcause the relay control circuit.
contacts inthe rearwiper relay to closeand apply 8+ to Action Taken When the DTC
the rear wipermotor through the rear wipercontrol Sets
circuit,enabling rear wiperoperation. When the rear Rear wiperoperation is disabled.
wiperrequest is no longer present, the contacts inthe
rear wiperrelay willopen, removing B+ from the rear Conditions for Clearing the DTC
The DTC willclear when the conditionsfor setting the
DTC are no longer present.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 4-329
Wipers and Washers

CircuitlSystem Testing
Reference Information Switch Malfunction
Rear WiperNVasher
vehicle systems OFF,
Schematic Reference 1. ignition OFF and all connector at the 882
page 4—325 disconnect the harness
Wiper/Washer Schematics on Switch. It may take up to
Windshield Wiper/Washer
Reference systems to power down.
Connector End View 11 min for all vehicle
between the low reference
Viewson page 11-269 Test for less than 10 (2
Component Connector End circuit terminal 2 and ground.
Description and Operation If 10 Q or greater
and Operation on
Wiper/Washer System Description 2.1. Ignition OFF.
Q in the low reference
page 4—384 2.2. Test for less than 2
Reference circuit end to end.
Electrical Information the open/high resistance
page 11-526 =>If 2 Q or greater, repair
- Circuit Testing on in the circuit.
on page 11-548 replace the K9 Body Control
- Connector Repairs =>if less than 2 Q,
Conditions and Poor
' Testing for Intermittent11-531 Module.
Connections on page
page 11—537 If less than 10 Q
- Wiring Repairs on
9’ ignition ON.
Scan Tool Reference between the signal circuit
Test for greater than 8 V
on page 6—3for scan tool terminal 4 and ground.
Control Module References
information If less than 8 V
the harness
CircuitlSystem Verification 4.1. Ignition OFF, disconnect Body Control Module.
connector at the K9
1. ignition ON. resistance between the signal
Rear Wiper Switch parameter 4.2. Test for infinite
2. Verifythe scan tool and Off when cycling the rear circuit and ground to
changes between On resistance, repair the short
wiper switch ON and OFF. 2 If less than infinite
not change ground on the circuit.
=>If the parameter does
Testing —Rear Wiper/ ii If infinite resistance
Refer to CircuitlSystem Q in the signal circuit end
Washer Switch Malfunction. 4.3. Test for less than 2
to end.
it If the parameter
changes the open/high resistance
Wiper Motor cycleswhen =>lf 2 Q or greater, repair
3. Verifythe M45 Rear wiper ON with the rear wiper in the circuit.
commanding the rear the K9 Body Control
switch. =>If less than 2 Q, replace
Motor does not cycle Module.
:> If the M45 RearWiper
Testing —Rear Wiper lf 8 V or greater connector
Refer to CircuitlSystem disconnect the X2 harness
Motor Malfunction ShitIgnition OFF, Module, ignition ON.
Motor cycles at the K9 Body Control Windshield
ii If the M45 Rear Wiper V between the 882
Wiper Motor returns to the . Test for less than 1 signal circuit terminal 4 and
4. Verifythe M45 Rear rear wipersare turned
OFF Wiper/Washer Switch
park position when the to ground.
Motor does not return
=>If the M45 Rear Wiper If 1 V or greater
the park position on the circuit.
Testing —Rear Wiper Repair the short to voltage
Refer to CircuitlSystem
Motor Malfunction If less than 1 V
882 Windshield Wiper/Washer
Motor returns to the park 7. Test or replace the
U If the M45 Rear Wiper Switch.
position
5. All OK.

Service
(US/Canada)
Sonic (5377994)
Manual
—
2013
4-330 Wipers and Washers
Rear Wiper Motor Malfunction
1. Ignition OFF, and all vehicle systems OFF.
Disconnect the harness connector at the M45 Rear
Wiper Motor. it may take up to 2 min for all vehicle
systems to power down.
2. Test for lessthan 10 Q between the ground circuit
terminal 3 and ground.
:> If 10 Q or greater
2.1. Test for lessthan 2 Q in the ground circuit end
to end.
=>lf 2 Q or greater, repair the open/high resistance
in the circuit.
2» Iflessthan 2 Q, repair the open/high resistance
in the ground connection.
U if less than 10 Q
9° Ignition ON.
4. Verify a test lamp illuminates between the B+
circuit terminal 2 and ground.
=>If the test lamp does not illuminate
4.1. IgnitionOFF, remove the test lamp.
Disconnect the X2 harness connector at the
X50A Fuse Block—Underhood.
4.2. Test for lessthan 2 Q in the control circuit end
to end.
=>lf 2 Q or greater, repair the open/high resistance
in the circuit.
: Iflessthan 2 Q, test or replace the X50A Fuse
Block—Underhood.
U If the test lamp illuminates
5. Connect a test lamp between the control circuit
terminal 1 and ground.
6. Verify the test lamp does NOT turn ON and OFF
when commanding the rear wiper ON and OFF
with the rear wiper switch.
=>If the test lamp turns ON and OFF
Test or replace the M45 Rear Wiper Motor.
U If the test lamp does not turn ON and OFF
7. Ignition OFF, connect the harness connector at the
M45 Rear Wiper Motor. Disconnect the X2 harness
connector at the X50A Fuse Block—Underhood, it
may take up to 2 min for all vehicle systems to
power down.
8. Test for lessthan 10 Q between each ground
circuit terminal listed below and ground:
- Terminal 05
- Terminal H5
=>If 10 Q or greater
8.1. Test for lessthan 2 Q in the ground circuit end
to end.
=>lf2 Q or greater, repair the open/high resistance
in the circuit.
=>if less than 2 Q, repair the open/high resistance
in the ground connection.
U If less than 10 Q
9. Ignition ON.
10. Verify the M45 Rear Wiper Motor is not activated.
2 If the M45 Rear Wiper Motor is activated
10.1. IgnitionOFF, disconnect the harness
connector at the M45 Rear Wiper Motor,
ignition ON.
10.2. Test for lessthan 1 V between the control
circuit terminal 1 and ground.
=>If 1 V or greater, repairthe short to voltage on
the circuit.
=>Iflessthan 1 V, replace the M45 Rear Wiper
Motor.
U If the M45 Rear Wiper Motor is not activated
11. Connect a 20 A fusedjumper wire between both of
the circuits listed below and B+.
' B+ Circuit Terminal H4
° Control Circuit Terminal H3
12. Verify the M45 Rear Wiper Motor activates.
=>If the M45 Rear Wiper Motor does not activate
12.1. IgnitionOFF, remove the jumperwire,
disconnect the harness connector at the M45
Rear Wiper Motor, ignition ON.
12.2. Test for infinite resistance between the
control circuit and ground.
=>Iflessthan infinite resistance, repair-theshort to
ground on the circuit.
U lf infinite resistance
12.3. Test for lessthan 2 Q in the control circuit
end to end.
=>If2 Q or greater, repair the open/high resistance
in the circuit.
=>Iflessthan 2 Q, replace the M45 Rear Wiper
Motor.
U If the M45 Rear Wiper Motor activates
13. ignition OFF, connect the X2 harness connector at
the X50A Fuse Block—Underhood. Disconnect the
X4 harness connector at the K9 Body Control
Module, ignition ON.
14. Verify the M45 Rear Wiper Motor is not activated.
=>If the M45 Rear Wiper Motor is activated
14.1. IgnitionOFF, disconnect the X2 harness
connector at the X50A Fuse Block-
Underhood, ignition ON.
14.2. Test for lessthan 1 V between the control
circuit terminal 10 and ground.
=>If 1 V or greater, repair the short to voltage on
the circuit.
=>Iflessthan 1 V, replace the X50A FuseBlock-
Underhood.
U If the M45 Rear Wiper Motor is not activated
15. Connect a 10 A fusedjumperwire between the
control circuit terminal 10 and B+.
2013
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Service
Manual
(5377994)
 Wipers and Washers 4-331

the range specified

Motor activates. 3. Verify the resistance is within terminal 4 and the
16. Verify the M45 Rear Wiper below between the signal circuit
cycling the
=>If the M45 Rear Wiper Motor
does not activate low reference circuit terminal 2 by and Rear
switch between Rear Wiper position
jumper wire,
16.1. Ignition OFF, remove the connector at the Washers position.
disconnect the X2 harness
X50A Fuse Block—Underhood. - Rear Wiper : 624—644Q
kQ
16.2. Test for infinite resistance
between the o RearWiper Sweep : 1.8—2.2
control circuit and ground. - Rear Washer : 5.9—6.4kQ
repair the short to
:> if less than infinite resistance, =>If not within the specific range
ground on the circuit. Replace the 882 Windshield Wiper/Washer
U Ifless than infinite resistance Switch.
control circuit
16.3. Test for less than 2 Q in the U If within the specific range
end to end.
open/high resistance 4. All OK
=>lf 2 Q or greater, repair the
in the circuit. Repair Instructions
the X5OA Fuse Verification on
=>If less than 2 Q, test or replace Perform the Diagnostic Repair
Block— Underhood. page 6—92after completing the repair.
Replacement
U If the M45 Rear Wiper Motor
activates 0 Rear Window Wiper Motor
(Hatchback) on page 4-380
Control Module.
17. Test or replace the K9 Body Replacement on
0 Front Compartment Fuse Block
Component Testing page 11-609
Switch
Windshield WiperNVasher Switch - Windshield Wiper and Washer
Replacement on page 4-366
harness connector at
1. Ignition OFF, disconnect the Switch. on page 6-3 for body
- Control Module References programming, and
the S82 Windshield Wiper/Washer
control module replacement,
between the signal
2. Test for infinite resistance terminal 2 with the setup.
terminal 4 and the low reference
rear wiper switch in the OFF position.
=>If less than infinite resistance
Replace the 882 Windshield Wiper/Washer
Switch.
U lf infinite resistance

—
2013 (US/Canada)
Sonic (5377994)
Manual
Sen/ice
4-332 Wipers and Washers

DTC B3715 or B3875

Diagnostic Instructions
~ Perform the Diagnostic System Check —Vehicle
on page 6-66 priorto usingthis diagnostic
procedure.
- Review Strategy Based Diagnosison page 6-58
for an overview of the diagnostic approach.
- Diagnostic Procedure Instructions on page 6-59
providesan overview of each diagnostic category.
DTC Descriptors
DTC B3715 01: WindshieldWiper Relay Circuit Short to Battery
DTC B3715 02: WindshieldWiper Relay Circuit Short to Ground
DTC B3715 04: WindshieldWiper Relay Circuit Open
DTC B3875 01: WindshieldWiper High Speed Relay Circuit Short to Battery
DTC B3875 02: WindshieldWiper High Speed Relay Circuit Short to Ground
DTC B3875 04: WindshieldWiper High Speed Relay Circuit Open
Diagnostic Fault Information

Opeanigh Signal
Circuit Short to Ground Resistance Short to Voltage Performance
Windshield WiperSwitchLowSignalterminal3 1 1 1
Windshield WiperSwitchHighSignalterminal1 4 2 2
Windshield WiperMotorParkSwitchSignal
terminal2 3 3
FrontWiperRelayControlterminal85 8371502 B371504 B371501
Windshield WiperHighSpeed RelayControl 8387502
terminal86 B387504 B387501
FrontWiperMotorControlterminal4 1 1 4
FrontWiperMotorSpeedControlterminal5 1 1 4
Windshield WiperSwitchLowReference
terminal2 1,2 1,2 -
Windshield WiperMotorGroundterminal1 - 1,2,3 —— -
Windshield WiperRelayGroundterminal86 -
1.Delayor LowSpeedWiperslnoperative
2. HighSpeedWiperslnoperative
3. WipersDo NotPark
4. WipersAlwaysON

CircuitlSystem Description Conditions for Running the DTC

The body control module (BCM) controls the wiper
motor based on input from the windshieldwiper/washer
switch. The BCM monitors the wiper/washer switch
through two separate signal circuits and a low
reference circuit. The windshieldwiper switch high
signal circuit is usedto determine high speed wiper
operation, the windshield wiper switch low signal is
usedto determine low speed, intermittent,and mist
operation through the useof a resistor ladder, and the
windshieldwasher switch signal circuit is usedto
determine washer operation.
The BCM controls the windshieldwiper motor through
two output controls, controlling two relays which
determine the desiredwiper speed, high or low.
° The DTC runsonly when a wiper output is actively
being requested by the BCM.
- The system voltage is between 9—16V.
Conditions for Setting the DTC
- A short to ground is detected inthe 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.
Action Taken When the DTC Sets
The BCM willnot activate the wiper output.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Wipers and Washers 4-333
Motor changes
5. Verifythe M75 WindshieldWiper cycling the 882
Conditions for Clearing the DTC between Off, Low, and High when
Off,
condition for WindshieldWiper/Washer Switch between
- A current DTC willclear when the
setting the fault is no longer present. Low,and High.
does not cycle
0 A history DTC willclear after 50
consecutive 2 If the Windshield Wiper Motor
ignition cycleswithout a fault present. between Off, Low, and High
Windshield
Refer to CircuitlSystem Testing —
Reference Information Wiper Motor Malfunction
Schematic Reference U If the Windshield Wiper Motor cycles between
Off, Low, and High
Wiper/Washer Schematics on page 4-325
6. ignition OFF.
Connector End View Reference 7. Verifythe scan tool Windshield
Wiper Park Switch
11-269
Component Connector End Viewson page parameter is Active.
Description and Operation =>If the parameter does not change
Windshield
Operation on Refer to CircuitlSystem Testing —
Wiper/Washer System Description and Wiper Motor Malfunction.
page 4-384
U If the parameter changes
Electrical Information Reference
8 All OK.
0 Circuit Testing on page 11-526 Testing
CircuitlSystem
- Connector Repairs on page 11—548
Malfunction
- Testing for IntermittentConditions
and Poor WindshieldWiperNVasher Switch
OFF,
Connections on page 11—531 1. Ignition OFF and all vehicle systems the 882
disconnect the harness connector at
- Wiring Repairs on page 11-537 take up to
WindshieldWiper/Washer Switch. Itmay
Scan Tool Reference to power down.
11min for all vehicle systems
for scan tool the low reference
Control Module References on page 6-3 2. Test for less than 10 Q between
information circuit terminal 2 and ground.
CircuitlSystem Verification =>If 10 Q or greater
2.1. Ignition OFF, disconnect the harness
1. Ignition ON. connector at the K9 Body Control Module.
High Speed
2. Verifythe scan tool WindshieldWiperActive and 2.2. Test for less than 2 Q in the low
reference
Switch parameter changes between
windshield circuit and to end.
Inactive when activating the high speed resistance
wipers. :> If2 Q or greater, repair the open/high
inthe circuit.
=>If the parameter does not change Control
=>If less than 2 Q, replace the K9 Body
Refer to CircuitlSystem Testing —Windshield Module.
Wiper/Washer Switch Malfunction.
U If less than 10 Q
U If the parameter changes
Switch 9° Ignition ON.
3. Verifythe scan tool WindshieldWiper Low when Wiper High Speed
parameter Changes between Off and 4. Verifythe scan tool Windshield
Switch parameter is Inactive.
activating the low speed windshieldwipers.
=>If the parameter does not change =>If not Inactive
Refer to CircuitlSystem Testing —Windshield 4.1. Ignition OFF, disconnect the harness
connector at the K9 Body Control Module.
Wiper/Washer Switch Malfunction. the signal
4.2. Test for infinite resistance between
U If the parameter changes circuitterminal 1 and ground.
Switch
4. Verifythe scan tool WindshieldWiper and Delay 5 =>If less than infinite resistance, repair
the short to
parameter changes between Delay 1 the circuit.
windshield ground on
when cycling the intermittent speed K9 Body
wipers. =>lf infinite resistance, replace the
Control Module.
:> If the parameter does not change
Test or replace the 882 WindsheildWiper/ U lf Inactive
between the signal
Washer Switch. 5. Install a 3 A fusedjumper wire circuit
circuit terminal 1 and the low reference
U If the parameter changes terminal 2.

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4-334 Wipers and Washers
6. Verifythe scan tool WindshieldWiperHigh Speed WindshieldWiper Motor Malfunction
Switch parameter is Active. 1. IgnitionOFF and all vehicle systems OFF,
2} If not Active disconnect the harness connector at the M75
6.1. IgnitionOFF, remove thejumper wire, WindshieldWiperMotor. it may take up to 2 min for
disconnect the harness connector at the K9 all vehicle systems to power down.
Body Control Module, ignition ON. Test for lessthan 10 Q between the ground circuit
6.2. Test for lessthan 1 V between the signal terminal 1 and ground.
Circuitand ground. If 10 Q or greater
=>lf1 V or greater, repair the short to voltage on 2.1. ignition OFF.
the circuit. 2.2. Test for less than 2 Q in the ground circuit end
U Iflessthan 1 V to end.
6.3. Test for lessthan 2 Q in the signal circuit end =>If2 Q or greater, repair the open/high resistance
to end. in the circuit.
=>If2 Q or greater, repair the open/high resistance =>Iflessthan 2 Q, repair the open/high resistance
in the circuit. in the ground connection.
=>if lessthan 2 Q, replace the K9 Body Control If less than 10 Q
Module. .93 ignition ON.
lf Active Verifythe scan tool WindshieldWiperPark Switch
Test for greater than 8 V between the signal circuit parameter is Inactive.
terminal 3 and ground. If not Inactive
If less than 8 V 4.1. Ignition OFF, disconnect the harness
7.1. IgnitionOFF, disconnect the harness connector at the K9 Body Control Module.
connector at the K9 Body Control Module. 4.2. Test for infinite resistance between the signal
7.2. Test for infinite resistance between the signal circuit terminal 2 and ground.
circuit and ground a Iflessthan infinite resistance, repair the short to
:> Iflessthan infinite resistance, repairthe short to ground on the circuit.
ground on the circuit. =>Ifinfinite resistance, replace the K9 Body
U lf infinite resistance Control Module.
7.3. Test for lessthan 2 Q in the signal circuit end If Inactive
to end. . Install a 3 A fusedjumper wirebetween the signal
=>If2 Q or greater, repair the open/high resistance circuit terminal 2 and the ground circuit terminal 1.
in the circuit. . Verifythe scan tool WindshieldWiperPark Switch
=>if lessthan 2 Q, replace the K9 Body Control parameter is Active.
Module. If not Active
lf 8 V or greater 6.1. IgnitionOFF, remove thejumper wire,
Ignition OFF, disconnect the X3 harness connector disconnect the harness connector at the K9
at the K9 Body Control Module, ignition ON. Body Control Module, ignition ON.
Test for lessthan 1 V between the 882 Windshield 6.2. Test for less than 1 V between the signal
Wiper/Washer Switch signal circuit terminal 3 and circuit and ground.
ground. =>If 1 V or greater, repair the short to voltage on
If 1 V or greater the circuit.
Repair the short to voltage on the circuit. U Iflessthan 1 V
If less than 1 V 6.3. Test for less than 2 Q in the signal circuit and
to end.
. Test or replace the S82 WindshieldWiper/Washer
Switch. =>If2 Q or greater, repair the open/high resistance
in the circuit.
=>Iflessthan 2 Q, replace the K9 Body Control
Module.
If Active
Ignition OFF and all vehicle systems OFF,
disconnect the KR12B WindshieldWiperRelay.
Itmay take up to 2 minfor all vehicle systems to
power down.

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 4-335
Wipers and Washers
Control
:> if lessthan 2 Q, replace the K9 Body
between each ground circuit
8. Test for less than 10 Q groUnd: Module.
terminal listed below and ON
:> If the test lamp is always
- Terminal 86 test lamp,
12.1. Ignition OFF, remove theconnector at the K9
- Terminal 87A disconnect the harness
ON.
If 10 Q or greater Body Control Module, ignition
betWeen the control
8.1. ignition OFF. 12.2. Test for less than 1 V
ground circuit end circuit and ground.
8.2. Test for less than 2 Q in the short to voltage on
to end. =>lf 1 V or greater, repair the
open/high resistance the circuit.
=>lf 2 Q or greater, repair the K9 Body Control
in the circuit. =>if less than 1 V, replace the
open/high resistance Module.
=>If less than 2 Q, repair the OFF
in the ground connection. If the test lamp turns 0N and
the KR12B WindshieldWiper
If less than 10 Q ignition OFF, connect Windshield
Relay and disconnect the KR12C ON.
ignition ON. Wiper Speed Control Relay,
ignition
between the B+
. Verifya test lamp illuminates circuit 14. Test for less than 10 Q
between the control circuit
circuit terminal 87 and the ground
terminal 30 and ground.
terminal 87A.
illuminate and the If 10 Q or greater
If the test lamp does not WindshieldWiper
circuit fuse is good Test or replace the KR12B
Underhood. Relay.
Replace the X50A Fuse Block—
illuminate and the U If less than 10 Q
If the test lamp does not between the control circuit
circuit fuse is open 15. Connect a test lamp
test lamp. terminal 30 and ground.
10.1. Ignition OFF, remove the Wiper ON and OFF when
Disconnect the KR12C Windshield 16. Verifythe test lamp turns Motor Relay
Speed Control Relay. commanding the WindshieldWiper
between each Low and Off with a scan tool.
10.2. Test for infinite resistance ON and OFF
control circuit listed below and ground: If the test lamp does not turn
WindshieldWiper
. Terminal 87A Test or replace the KR12B
. Terminal 87 Relay.
OFF
=>If less than infinite resistance,
repair the short to If the test lamp turns ON and
between the B+
ground on the circuit. . Verifya test lamp illuminates
the M75 circuit terminal 85 and ground.
=>lf infinite resistance, replace illuminate
WindshieldWiper Motor If the test lamp does not
—Underhood.
U If the test lamp illuminates Replace the X50A Fuse Block
the control circuit
. Connect a test lamp between terminal 86. If the test lamp illuminates
the ground circuit B+ circuit
terminal 85 and Connect a test lamp between the terminal 86.
ON and OFF when circuit
12. Verifythe test lamp turns Wiper Motor Relay
terminal 85 and the control
commanding the Windshield and OFF when
Verifythe test lamp turns ON
Low and Off with a scan tool. commanding the Windshield Wiper High Speed
a scan tool.
If the test lamp is always OFF Relay High and Off with
test lamp,
12.1. ignition OFF, remove the at the K9 it the test lamp is always
OFF
disconnect the harness connector test lamp,
19.1. Ignition OFF, remove theconnector at the K9
Body Control Module. disconnect the harness
between the ON.
12.2. Test for infinite resistance Body Control Module, ignition
control circuit and ground. V between the control
19.2. Test for less than 1
repair the short to
:> If less than infinite resistance, circuit and ground.
ground on the circuit. short to voltage on
=>If 1 V or greater, repair the
U lf infinite resistance the circuit.
the control circuit end
12.3. Test for less than 2 Q in U if less than 1 V
to end. 19.3. Ignition OFF.
open/high resistance the control circuit end
=>lf 2 Q or greater, repair the 19.4. Test for less than 2 Q in
in the circuit. to end.
open/high resistance
=>lf 2 Q or greater, repair the
in the circuit.

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4-336 Wipers and Washers
:> Iflessthan 2 Q, replace the K9 Body Control
Module.
If the test lamp"Is always ON
19.1. ignition OFF, remove the test lamp,
disconnect the harness connector at the K9
Body Control Module.
19.2. Test for infinite resistance between the
control circuit and ground.
=>Iflessthan infinite resistance, repair the short to
ground on the circuit.
=>If infinite resistance, replace the K9 Body
Control Module.
U If the test lamp turns ON and OFF
20. IgnitionOFF, connect the KR1ZC Windshield
Wiper Speed Control Relay.
21. Connect a test lamp between the M75 Windshield
Wiper Motor control circuit terminal 4 and ground
circuit terminal 1, ignition ON.
22. Verifythe test lamp turns ON and OFF when
commanding the WindshieldWiper Motor Relay
Low and Off with a scan tool.
if the test lamp is always OFF
22.1. ignition OFF, remove the test lamp,
disconnect the KR1ZC WindshieldWiper
Speed Control Relay.
22.2. Test for infinite resistance between the
control circuit and ground.
=>Iflessthan infinite resistance, repair the short to
ground on the circuit.
U Ifinfinite resistance
22.3. Test for lessthan 2 Q in the control circuit end
to end.
=>If2 Q or greater, repair the open/high resistance
in the circuit.
=>Iflessthan 2 Q, test or replace the KR12C
WindshieldWiper Speed Control Relay.
if the test lamp is always ON
22.1. IgnitionOFF, remove the test lamp,
disconnect the KR12C WindshieldWiper
Speed Control Relay, ignition ON.
22.2. Test for lessthan 1 V between the control
circuit and ground.
=>lf1 V or greater, repair the short to voltage on
the circuit.
=>if lessthan 1 V, test or replace the KR12C
WindshieldWiper Speed Control Relay.
If the test lamp turns ON and OFF
23. Connect a test lamp between the M75 Windshield
Wiper Motor control circuit terminal 5 and ground
circuitterminal 1, ignition ON.
24. Verifythe test lamp turns ON and OFF when
commanding the WindshieldWiper High Speed
Relay High and Off with a scan tool.
If the test lamp is always OFF
24.1. IgnitionOFF, remove the test lamp,
disconnect the KR12C WindshieldWiper
Speed Control Relay.
24.2. Test for infinite resistance between the
control circuit and ground.
=>Iflessthan infinite resistance, repair the short to
ground on the circuit.
U Ifinfinite resistance
24.3. Test for less than 2 Q in the control circuit end
to end.
:> If2 Q or greater, repair the open/high resistance
in the circuit.
=>if lessthan 2 Q test or replace the KR12C
WindshieldWiper Speed Control Relay.
If the test lamp is always 0N
24.1. IgnitionOFF, remove the test lamp,
disconnect the KR12C WindshieldWiper
Speed Control Relay, ignition ON.
24.2. Test for lessthan 1 V between the control
circuit and ground.
=>If 1 V or greater, repair the short to voltage on
the circuit.
=>if lessthan 1 V, test or replace the KR1ZC
WindshieldWiper Speed Control Relay.
U If the test lamp turns ON and OFF
25. Test or replace the M75 WindshieldWiper Motor.
Component Testing
WindshieldWiperNVasher Switch
1. IgnitionOFF, disconnect the harness connector at
the 882 WindshieldWiperNVasher Switch.
2. Test for infinite resistance between the signal
terminal 1 and the low reference terminal 2 with the
high speedswitch in the open position.
If less than infinite resistance
Replace the 882 WindshieldWiper/Washer
Switch.
If infinite resistance
. Test for iessthan 2 Q between the signal circuit
terminal 1 and the low reference circuit terminal 2
with the high speedswitch in the closedposition.
If 2 Q or greater
Replace the 882 WindshieldWiper/Washer
Switch.
c If less than 2 Q
. Test for infinite resistance between the signal
terminal 3 and the low reference terminal 2 with the
low speedswitch in the open position.
If less than infinite resistance
Replace the 882 WindshieldWiper/Washer
Switch.
If infinite resistance
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 Wipers and Washers 4-337
5. Verifythe resistance readings are within the Test for lessthan 5 Q between terminals 30
specifiedrange listed below between the signal and 87A.
circuit terminal 3 and the low reference circuit If 5 Q or greater
terminal 1 by pushingthe switch in the listed
positions below: Replace the relay.
- Delayi :3.75-3.8_5kQ If less than 5 Q
- Delay 2 : 2.75-2.85kQ . Install a 10A fusedjumper wirebetween relay
' Delay 3 : 1.95-2.05kQ terminal 85 and 12 V. Install a jumper wirebetween
relay terminal 86 and ground.
- Delay4 : 1.25-1.35kQ
03. Test for lessthan 5 Q between terminals 30 and 87.
' Delay5 : 765-775Q
=>If 5 Q or greater
=>If not within the specified range
Replace the relay.
Replace the 382 WindshieldWiper/Washer
Switch. U If less than 5 Q
U If within the specified range 7. AMOK
6. All OK Repair Instructions
Relay Test Perform the Diagnostic Repair Verification on
1. Ignition OFF, disconnect the appropriate relay. page 6-92 after completing the repair.
2. Test for 60—200Q between terminals 85 and 86. WindshieldWiper Motor Replacement on
page 4—379
=>if less than 60 or greater than 200
Front Compartment Fuse Block Replacement on
Replace the relay. page 11—609
U If between 60—200Q Relay Replacement (Within an Electrical Center)
3. Test for infinite resistance between the terminals on page 11-607or Relay Replacement (Attached '
listed below: to WireHarness)on page 11-607
- 30 and 86 WindshieldWiper and Washer Switch
' 30 and 87 Replacement on page 4-366
~ 30 and 85 Control Module References on page 6-3 for BCM
replacement, programming and setup
- 85 and 87
=>If less than infinite resistance
Replace the relay.
U lf infinite resistance

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4=338 Wipers and Washers

DTC B3811

Diagnostic Instructions
- Peitorm the Diagnostic System Check - Vehicle
on page 6—66priorto usingthis diagnostic
procedure.
- ReviewStrategy Based Diagnosison page 6—58
for an overviewof the diagnostic approach.
- Diagnostic Procedure Instructions on page 6-59
providesan overviewof each diagnostic category.
DTC Descriptor
DTC B3811: Rear Washer Relay Circuit
For symptom byte information, refer to Symptom Byte
List on page 6-85.
Diagnostic Fault Information

Open/High Signal
Circuit Short to Ground Resistance Short to Voltage Performance
RearWasherSwitchSignal 1 1 1 -
RearWindowWasherPumpRelay Control 1 B381104 B3811O1 -
WasherPumpControl
RearWindshield 1 1 2 -
WasherPumpGround
RearWindshield ~— 1 — -
1.RearWasherlnoperative
2. RearWasherAlwaysON

CircuitlSystem Description Conditions for Setting the DTC

The body control module (BCM) controls the rear B3811 01
washer based on an input from the rear wiper switch, A short to voltage has been detected on the rear
which is part of the windshieldwiper/washer switch.
windowwasher pump relay control circuit
The BCM monitors the windshieldwiper/washer switch
through two separate signal circuits and a low B3811 04
reference circuit. The rear wiper switch uses a resistor A open/high resistance has been detected on the rear
ladder to determine low speed,intermittent,and rear window washer pump relay control circuit
washer operation. The BCM monitors applies and
monitors voltage on the rear wiper switch signal circuit. Action Taken When the DTC Sets
When the rear wiper switch is placed in the low speed,
intermittent,or rear washer position, the voltage is Rear washer operation is disabled.
pulled down through a different resistor in the resistor Conditions for Clearing the DTC
ladder, reducing the voltage seen at the BCM. The
BCM willrespondby commanding the specificrear - A current DTC clears when the diagnostic runs
wiper function. and passes.
The windshieldwasher usesa singlewindshield ‘ A histow DTC willclear after 50 consecutive
washer pump to provide fluidfor both the front and rear ignition cycleswithout a fault present.
washers.Changing the polarity of the motor willcause
Reference Information
it to spinin opposite directions, feeding fluidto the front
or rear. When rear washersare requested, the BCM Schematic Reference
applies voltage to the rear windowwasher pump relay
control circuit. This causesthe contacts in the rear Wiper/Washer Schematics on page 4—325
washer pump relay to closeand suppliesvoltage to the Connector End View Reference
windshieldwasher pump. Ground for the windshield
washer pump is provided through the windshield Component Connector End Viewson page 11-269
washer pump relay, which is switched to ground in it’s
at—reststate. Description and Operation
Wiper/Washer System Description and Operation on
Conditions for Running the DTC
page 4-384
° ignition ON
- The system voltage is between 9—16V

(US/Canada)
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2013 (5377994)
Manual
Service

Electrical Information Reference
Circuit Testing on page 11-526
Connector Repairs on page 11-548
Testing for IntermittentConditions and Poor
Connections on page 11-531
Wiring Repairs on page 11-537
Scan Tool Reference
Control Module References on page 6—3for scan tool
information
CircuitlSystem Verification
1. IgnitionON.
2. Verifythe scan tool Rear Wiper Switch parameter
changes between On and Off when cycling the rear
wiper switch ON and OFF.
If the parameter does not change
Refer to Rear Wiper System Malfunction on ,
page 4-359
If the parameter changes
Verifythe G24 WindshieldWasher Pump turns on
and off when commanding the rear washersOFF
and ON with the rear washer switch
If the Rear WindowWashersdo not turn ON
Refer to CircuitlSystem Testing
U If the Rear WindowWashersturn 0N
4 All OK.
CircuitlSystem Testing
1. IgnitionOFF, and all vehicle systems OFF.
Disconnect the X2 harness connector at the X50A
Fuse Block —Underhood. it may take up to 2 min
for all vehicle systems to power down.
Test for lessthan 10 Q between the ground circuit
terminal C5 and ground:
If 10 Q or greater
2.1. Test for lessthan 2 Q in the ground circuit end
to end.
=>lf2 Q or greater, repair the open/high resistance
in the circuit.
=>Iflessthan 2 Q, repair the open/high resistance
in the ground connection.
If less than 10 Q
Connect the X2 harness connector and disconnect
the X1 harness connector at the X50A Fuse Block
—Underhood.
Test for infinite resistance between each of the
control circuit terminals listed below and ground.
4.1. Terminal G3
4.2. Terminal H3
If less than Infinite resistance
Repair the short to ground on the circuit.
If infinite resistance
Connect the X1 harness connector at the X50A
Fuse Block —Underhood. Disconnect the harness
connector at the G24 WindshieldWasher Pump,
ignition ON.
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Wipers and Washers 4-339
6. Test for lessthan 1 V between the control circuit
terminals listed below and ground:
- Terminalt
- Terminal2
lf1 V or greater
6.1. IgnitionOFF, disconnect the X1 harness
connector at the X50A Fuse Block -
Underhood.
6.2. Test for less than 1 V between the control
circuit and ground.
=>If 1 V or greater, repair the short to voltage on
‘ ' the circuit.
=>Iflessthan 1 V, test or replace the X50A Fuse
Block —Underhood.
{z If less than 1 V
ignition OFF, and all vehicle systems OFF. Itmay
take up to 2 min for all vehicle systems to
power down.
Test for lessthan 10 Q between the control circuit
terminal 1 and ground.
If 10 Q or greater
8.1. IgnitionOFF, disconnect the X1 harness
connectors at the X50A Fuse Block -
Underhood.
8.2. Test for less than 2 Q in the control circuit end
to end:
=>If2 Q or greater, repair the open/high resistance
in the circuit.
=>Ifless than 2 Q, replace the X50A Fuse Block -
Underhood.
If less than 10 Q
Test for lessthan 10 Q between the control circuit
terminal 2 and ground.
If 10 Q or greater
9.1. Ignition OFF, disconnect the X1 harness
connectors at the X50A Fuse Block -
Underhood.
9.2. Test for less than 2 Q in the control circuit end
to end:
:> lf2 Q or greater, repair the open/high resistance
in the circuit.
=>Ifless than 2 Q, replace the X50A Fuse Block -
Underhood.
If less than 10 Q
. Connect a test lamp between the control circuit
terminal 1 and the control circuit terminal 2,
ignition ON.
. Verifythe test lamp doesNOT turn ON and OFF
when commanding the rear washer ON and OFF
with the rear washer switch.
If the test lamp turns 0N and OFF
Test or replace the G24 Windshield
Washer Pump.
If the test lamp does not turn ON and OFF
ignition OFF, connect the harness connector at the
G24 WindshieldWasher Pump. Disconnect the X2
harness connector at the X50A Fuse Block -
Underhood, ignition ON.
4=340 Wipers and Washers
13. Connect a test lamp between the control circuit
terminal GZ and ground.
14. Verifythe test lamp turns ON and OFF when
commanding the rear washer ON and OFF with the
rear washer switch.
:> If the test lamp is always OFF
14.1. Ignition OFF, remove the test lamp.
Disconnect the X1 harness connector at the
K9 Body Control Module.
14.2. Test for infinite resistance between the
control circuit and ground.
=>If lessthan infinite resistance, repair the short to
ground on the circuit.
U If infinite resistance.
14.3. Test for less than 2 Q in the control circuit
and to end.
=>If2 Q or greater, repair the short to ground on
the circuit.
:> Ifless than 2 Q, replace the K9 Body Control
Module
:> If the test lamp is always ON
14.1. Ignition OFF, remove the test lamp.
Disconnect the X1 harness connector at the
K9 Body Control Module, ignition ON.
14.2. Test for lessthan 1 V between the control
circuit and ground.
=>lf Q or greater, repair the short to voltage on
2
the circuit.
=>Ifless than 2 Q, replace the K9 Body Control
Module
U If the test lamp turns ON and OFF.
15. Test or replace the X50A Fuse Block —Underhood.
Repair Instructions
Perform the Diagnostic Repair Verification on
page 6-92 after completing the repair.
. WindshieldWasher Pump Replacement on
page 4-373
- Front Compartment Fuse Block Replacement on
page 11-609 .
. Windshield Wiper and Washer Switch
Replacement on page 4-366
- Control Module References on page 643for body
control module replacement, programming, and
setup.

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Manual
Service
 Wipers and Washers 4-341

DTC B3873 (without C25)

Diagnostic Instructions
Perform the Diagnostic System Check —Vehicle
on page 6—66priorto usingthis diagnostic
procedure.
ReviewStrategy Based Diagnosis on page 6-58
for an overviewof the diagnostic approach.
Diagnostic Procedure Instructions on page 6—59
providesan overviewof each diagnostic category.
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
Diagnostic Fault Information

Short to Ground Open/High Signal

Circuit Resistance Short to Voltage Performance
WindshieldWasherSwitchSignal 2 1 1 —-
WindshieldWasherPumpControl 1 1 2 -
WindshieldWasherRelayControl B387302 B3873O4 B387301 -
WindshieldWasherPumpGround —— 1 — -
1.Washerlnoperative
2. WasherAlwaysON

CircuitlSystem Description Connector End View Reference

The body control module (BCM) controls the windshield Component Connector End Viewson page 11-269
washer pump based on an input from the windshield
wiper/washer switch. The BCM monitors the washer Description and Operation
switch through the windshield washer switch signal Wiper/Washer System Description and Operation on
circuit. When the washer switch is closed,low page 4—384
reference is suppliedto the windshieldwasher switch
signal circuit. When this is the case, the BCM will Electrical Information Reference
command the windshield washer pump and the low
speedwiperson. - Circuit Testing on page 11-526
- Connector Repairs on page 11—548
Conditions for Running the DTC - Testing for IntermittentConditions and Poor
- IgnitionON. Connections on page 11-531
- The system voltage is between 9—16 V. - Wiring Repairs on page 11537
Conditions for Setting the DTC Scan Tool Reference
- A short to ground or an open/high resistance is Control Module References on page 6-3 for scan tool
detected in the windshieldwasher relay control information
circuit.
CircuitlSystem Verification
- A short to voltage is detected in the windshield
washer relay control circuit. 1. Ignition ON.
2. Verifythe scan tool WindshieldWasher Switch
Action Taken When the DTC Sets parameter changes between Active and Inactive
Washer operation is suspended. when pressingand releasing the windshield
washer switch.
Conditions for Clearing the DTC =>If the parameter does not change
A current DTC clears when the diagnostic runsand
Refer to CircuitlSystem Testing —Windshield
passes.
Wiper/Washer Switch Malfunction.
Reference Information U If the parameter changes
Schematic Reference
Wiper/Washer Schematics on page 4—325

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4-342 Wipers and Washers
3. Verifythe windshieldwashers turn ON when
commanding the WindshieldWasher Relay Active
with a scan tool.
:> If the Windshield Washers do not turn ON
Refer to CircuitlSystem Testing —Windshield
Washer Pump Malfunction
U If the WindshieldWashers turn ON
4. All OK.
CircuitlSystem Testing
WindshieldWiperNVasher Switch Malfunction
1. ignition OFF and all vehicle systems OFF,
disconnect the harness connector at the S82
WindshieldWiper/Washer Switch. Itmay take up to
11 min for all vehicle systems to power down.
Test for less than 10 Q between the low reference
circuit terminal 2 and ground.
if 10 Q or greater
2.1. Ignition OFF.
2.2. Test for lessthan 2 Q in the low reference
circuit end to end.
=>If2 Q or greater, repair the open/high resistance
in the circuit.
=>if less than 2 Q, replace the K9 Body Control
Module.
If less than 10 Q
.03 Ignition ON.
Verifythe scan tool WindshieldWasher Switch
parameter is Inactive.
If not Inactive
4.1. Ignition OFF, disconnect the harness
connector at the K9 Body Control Module.
4.2. Test for infinite resistance between the signal
circuit terminal 5 and ground.
:> if less than infinite resistance, repair the short to
ground on the circuit.
=>If infinite resistance, replace the K9 Body
Control Module.
If inactive
Install a 3 A fusedjumper wirebetween the signal
circuit terminal 5 and the low reference circuit
terminal 2.
. Verifythe scan tool WindshieldWasher Switch
parameter is Active.
If not Active
6.1. Ignition OFF, remove the jumperwire,
disconnect the harness connector at the K9
Body Control Module, ignition ON.
6.2. Test for lessthan 1 V between the signal
circuit and ground.
=>If 1 V or greater, repair the short to voltage on
the circuit.
U if less than 1 V
6.3. Test for lessthan 2 Q in the signal circuit end
to end.
=>If2 Q or greater, repair the open/high resistance
in the circuit.
:> if lessthan 2 Q, replace the K9 Body Control
Module.
U If Active
7. Test or replace the 882 WindshieldWiper/Washer
Switch.
WindshieldWasher Pump Malfunction
1. Ignition OFF, and all vehicle systems OFF.
Disconnect the harness connector at the G24
WindshieldWasher Pump. Itmay take up to 2 min
for all vehicle systems to power down.
Test for lessthan 10 Q between the ground circuit
terminal 2 and ground.
If 10 Q or greater
2.1. Test for lessthan 2 Q in the ground circuit end
to end.
=>lf 2 Q or greater, repair the open/high resistance
in the circuit.
=>Ifless than 2 Q, repair the open/high resistance
in the ground connection.
If less than 10 Q
Connect a test lamp between the control circuit
terminal 1 and the ground circuit terminal 2,
ignition ON.
Verifythe test lamp does NOT turn ON and OFF
when commanding the WindshieldWasher Relay
Active and Inactive with a scan tool.
If the test lamp turns ON and OFF
Test or replace the 624 Windshield
Washer Pump.
If the test lamp does not turn 0N and OFF
ignition OFF, connect the harness connector at the
G24 WindshieldWasher Pump. Disconnect the X2
harness connector at the X50A FuseBlock -
Underhood, Itmay take up to 2 min for all vehicle
systems to power down.
Test for lessthan 10 Q between the ground circuit
terminal C5 and ground.
If 10 Q or greater
6.1. Test for lessthan 2 Q in the ground circuit end
to end.
=>If2 Q or greater, repair the open/high resistance
in the circuit.
:> Ifless than 2 Q, repair the open/high resistance
in the ground connection.
If less than 10 Q
." ignition ON.
Verifythe G24 WindshieldWasher Pump is not
activated.
If the GZ4 WindshieldWasher Pump is
activated
8.1. IgnitionOFF, disconnect the harness
connector at the G24 WindshieldWasher
Pump, ignition ON.
8.2. Test for lessthan 1 V between the control
circuitterminal 1 and ground.
=>If 1V or greater, repair the short to voltage on
the circuit.
(US/Canada)
-Sonic
2013 (5377994)
Manual
Service

2 Iflessthan 1V, replace the (324 Windshield
Washer Pump.
U If the 624 WindshieldWasher Pump is not
activated
9. Disconnect the X1 harness connector at the X50A
Fuse Block —Underhood.
10. Connect a 20 A fusedjumper wirebetween the
control circuit terminal 63 and B+.
11. Verifythe 624 WindshieldWasher Pump activates.
2 If the 624 WindshieldWasher Pump does not
activate
11.1. ignition OFF, remove thejumperwire,
disconnect the harness connector at the 624
WindshieldWasher Pump.
11.2. Test for infinite resistance between the
control circuit and ground.
2 If lessthan Infiniteresistance, repairthe short to
ground on the circuit.
U If infinite resistance
11.3. Test for lessthan 2 Q in the control circuit end
to end.
2 If2 Q or greater, repair the open/high resistance
in the circuit.
2 Iflessthan 2 Q, replace the G24 Windshield
Washer Pump.
U If the 624 WindshieldWasher Pump activates
12. IgnitionOFF, connect the X1 harness connector at
the X50A Fuse Block —Underhood. Disconnect the
X4 harness connector at the K9 Body Control
Module, ignition ON.
13. Verifythe 624 WindshieldWasher Pump is not
activated.
2 If the 624 WindshieldWasher Pump is
activated
13.1. ignition OFF, disconnect the X2 harness
connector at the X50A Fuse Block -
Underhood, ignition ON.
13.2. Test for lessthan 1 V between the control
circuit terminal 69 and ground.
2 lf1 Vor greater, repair the short to voltage on
the circuit.
2 Iflessthan 1 V, replace the X50A Fuse Block -
Underhood.
U If the 624 WindshieldWasher Pump is not
activated
14. Connect a 10 A fusedjumper wirebetween the
control circuit terminal 14 and B+.
Wipers and Washers 4-343
15. Verifythe G24 WindshieldWasher Pump activates.
2 If the 624 WindshieldWasher Pump does not
activate
15.1. IgnitionOFF, remove thejumper wire,
disconnect the X2 harness connector at the
X50A Fuse Block —Underhood.
15.2. Test for infinite resistance between the
control circuit and ground.
2 Iflessthan infinite resistance, repair the short to
ground on the circuit.
U Iflessthan infinite resistance
15.3. Test for lessthan 2 Q in the control circuit end
to end.
2 If2 Q or greater, repair the open/high resistance
in the circuit.
2 Iflessthan 2 Q, test or replace the X50A Fuse
Block - Underhood.
U If the 624 WindshieldWasher Pump activates
16. Replace the K9 Body Control Module.
Component Testing
WindshieldWiperNVasher Switch
1. IgnitionOFF, disconnect the harness connector at
the 882 WindshieldWiper/Washer Switch.
2. Test for infinite resistance between the signal
terminal 5 and the low reference terminal 2 with the
switch in the open position.
2 If less than infinite resistance
Replace the S82 WindshieldWiperNVasher
Switch.
U lf infinite resistance
3. Test for lessthan 2 Q between the signal circuit
terminal 5 and the low reference circuit terminal 2
with the switch in the closedposition.
2 If 2 Q or greater
Replace the 882 WindshieldWiper/Washer
Switch.
U If less than 2 Q
4. All OK
Repair Instructions
Perform the Diagnostic Repair Verification on
page 6-92 after completing the repair.
- Front Compartment Fuse Block Replacement on
page 11-609
' WindshieldWasher Pump Replacement on
page 4-373
- WindshieldWiper and Washer Switch
Replacement on page 4—366
- Control Module References on page 6-3 for BCM
replacement, programming and setup

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
4-344 Wipers and Washers

DTC B3873 (with C25)

Diagnostic Instructions
- Perform the Diagnostic System Check - Vehicle
on page 6-66 priorto usingthis diagnostic
procedure.
' Review Strategy Based Diagnosison page 6—58
for an overview of the diagnostic approach.
- Diagnostic Procedure Instructions on page 6-59
providesan overview of each diagnostic category.
DTC Descriptors
DTC B3873: Front Washer Relay Circuit
For symptom byte information, refer to Symptom Byte
List on page 6-85.
Diagnostic Fault Information

Short to Ground Open/High Signal

Resistance Short to Voltage Performance
Circuit
2 1 1 -
WasherSwitchSignal
Windshield
1 1 2 —-
WasherPumpControl
Windshield
8387302 B3873O4 B3873O1 -
WasherRelay Control
Windshield
— 1 — —-
WasherPumpGround
Windshield
1.Washer lnoperative
2. WasherAlways ON

Description B3873 02
CircuitlSystem
A short to ground has been detected on the windshield
The body control module (BCM) controls the windshield washer pump relay control circuit
washer based on an input from the windshield washer
switch, which is part of the windshield wiper/washer B3873 04
switch. The BCM monitors the windshield washer
An open/high resistance has been detected on the
switch through a discrete signal circuit. When the windshieldwasher pump relay control circuit
washer switch is pressed,the signal circuit is pulled to
ground. The BCM willrespondby commanding the Action Taken When the DTC Sets
washer function.
Washer operation is suspended.
The windshieldwasher uses a singlewindshield
washer pump to provide fluidfor both the front and rear Conditions for Clearing the DTC
washers. Changing the polarity of the motor willcause
A current DTC clears when the diagnostic runsand
it to spinin opposite directions, feeding fluidto the front passes.
or rear. When front washers are requested, the BCM
applies voltage to the windshieldwasher pump relay Reference Information
control circuit. Thiscauses the contacts in the
windshieldwasher pump relay to closeand supplies Schematic Reference
voltage to the windshield washer pump. Ground for the
windshieldwasher pump is provided through the rear Wiper/Washer Schematics on page 4-325
windowwasher pump relay, which is switched to Connector End View Reference
ground in it’s at—reststate.
Component Connector End Viewson page 11—269
Conditions for Running the DTC
Description and Operation
' Ignition ON.
Wiper/Washer System Description and Operation on
- The system voltage is between 9—16V. page 4-384
Conditions for Setting the DTC Electrical Information Reference
B3873 01 - Circuit Testing on page 11~526
A short to voltage has been detected on the windshield ° Connector Repairs on page 11—548
washer pump relay control circuit - Testing for IntermittentConditions and Poor
Connections on page 11—531
- Wiring Repairs on page 11-537
—
2013 (US/Canada)
Sonic (5377994)
Manual
Sen/ice
 Wipers and Washers 4:345

6. Verifythe scan tool WindshieldWasher Switch

Scan Tool Reference
Control Module References on page 6—3for scan tool
information
CircuitlSystem Verification
1. Ignition ON.
2. Verifythe scan tool WindshieldWasher Switch
parameter changes between Active and inactive
when pressingand releasing the washer switch.
If the parameter does not change
Refer to CircuitlSystem Testing —Washer
Switch Malfunction.
If the parameter changes
Verifythe 624 WindshieldWasher Pump activates
when commanding the WindshieldWasher Relay
Active with a scan tool.
If the WindshieldWashers do not turn ON
Refer to CircuitlSystem Testing —Windshield
Washer Pump Malfunction
U If the WindshieldWashers turn 0N
4 All OK.
CircuitlSystem Testing
Washer Switch Malfunction
1. Ignition OFF and all vehicle systems OFF,
disconnect the harness connector at the 882
Windshield WiperNVasher Switch. Itmay take up to
11 min for all vehicle systems to power down.
Test for lessthan 10 Q between the low reference
circuit terminal 2 and ground.
If 10 Q or greater
2.1. Ignition OFF.
2.2. Test for lessthan 2 Q in the low reference
circuit end to end.
2 If2 Q or greater, repair the open/high resistance
in the circuit.
2 Ifless than 2 Q, replace the K9 Body Control
Module.
If less than 10 Q
.03ignition ON.
Verifythe scan tool WindshieldWasher Switch
parameter is Inactive.
If not Inactive
4.1. Ignition OFF, disconnect the harness
connector at the K9 Body Control Module.
4.2. Test for infinite resistance between the signal
circuit terminal 5 and ground.
2 Ifless than infinite resistance, repairthe short to
ground on the circuit.
2 Ifinfinite resistance, replace the K9 Body
Control Module.
If Inactive
Install a 3 A fusedjumper wirebetween the signal
circuit terminal 5 and the low reference circuit
terminal 2.
parameter is Active.
:> If not Active
6.1. Ignition OFF, remove the jumper wire,
disconnect the harness connector at the K9
Body Control Module, ignition ON.
6.2. Test for lessthan 1 V between the signal
circuit and ground.
2 If 1 V or greater, repair the short to voltage on
the circuit.
U Iflessthan 1 V
6.3. Test for less than 2 Q in the signal circuit end
to end.
2 if 2 Q or greater, repair the open/high resistance
in the circuit.
2 if lessthan 2 Q, replace the K9 Body Control
Module.
U lf Active
7. Test or replace the 882 WindshieldWiper/Washer
Switch.
WindshieldWasher Pump Malfunction
1. Ignition OFF, and all vehicle systems OFF.
Disconnect the X2 harness connector at the X50A
Fuse Block —Underhood. Itmay take up to 2 min
for all vehicle systems to power down.
Test for lessthan 10 Q between the ground circuit
terminal C5 and ground:
If 10 Q or greater
2.1. Test for less than 2 Q in the ground circuit end
to end.
2 if 2 Q or greater, repair the open/high resistance
in the circuit.
2 if lessthan 2 Q, repair the open/high resistance
in the ground connection.
If less than 10 Q
Connect the X2 harness connector and disconnect
the X1 harness connector at the X50A Fuse Block
—Underhood.
Test for infinite resistance between each of the
control circuit terminals listed below and ground.
4.1. Terminal 63
4.2. Terminal H3
If less than Infinite resistance
Repair the short to ground on the circuit.
lf infinite resistance
Connect the X1 harness connector at the X50A
Fuse Block —— Underhood. Disconnect the harness
connector at the G24 WindshieldWasher Pump,
ignition ON.

(US/Canada)
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2013 (5377994)
Manual
Service
44346 Wipers and Washers
6. Test for lessthan 1 V between the control circuit
terminals listed below and ground:
- Termina|1
- Terminal 2
2 lf1 V or greater
6.1. ignition OFF, disconnect the X1 harness
connector at the X50A Fuse Block -
Underhood.
6.2. Test for lessthan 1 V between the control
circuit and ground.
2 If 1 V or greater, repair the short to voltage on
the circuit.
2 Ifless than 1 V, test or replace the X50A Fuse
Block —Underhood.
If less than 1 V
. Ignition OFF, and all vehicle systems OFF. Itmay
take up to 2 min for all vehicle systems to
power down.
Test for lessthan 10 Q between the control circuit
terminal 1 and ground.
If 10 Q or greater
8.1. IgnitionOFF, disconnect the X1 harness
connectors at the X50A Fuse Block -
Underhood.
8.2. Test for lessthan 2 Q in the control circuit end
to end: ‘ circuit and ground.
2 lf2 Q or greater, repair the open/high resistance
in the circuit.
2 if lessthan 2 Q, replace the X5OA Fuse Block -
Underhood.
If less than 10 Q
Test for lessthan 10 Q between the control circuit
terminal 2 and ground.
If 10 Q or greater
9.1. IgnitionOFF, disconnect the X1 harness
connectors at the X5OA Fuse Block -
Underhood.
9.2. Test for lessthan 2 Q in the control circuit end
to end:
2 If2 Q or greater, repair the open/high resistance
in the circuit.
2 Ifless than 2 Q, replace the X50A Fuse Block -
Underhood.
If less than 10 Q
Connect a test lamp between the control circuit
terminal 1 and the control circuit terminal 2,
ignition ON.
. Verifythe test lamp does NOT turn ON and OFF
when commanding the rear washer ON and OFF
with the rear washer switch.
if the test lamp turns ON and OFF
Test or replace the 624 Windshield
Washer Pump.
If the test lamp does not turn ON and OFF
ignition OFF, connect the harness connector at the
624 WindshieldWasher Pump. Disconnect the X2
harness connector at the X50A Fuse Block -
Underhood, ignition ON.
13. Connect a test lamp between the control circuit
termina169 and ground.
14. Verifythe test lamp turns ON and OFF when
commanding the WindshieldWasher Relay Active
with a scan tool.
If the test lamp is always OFF
14.1. IgnitionOFF, remove the test lamp.
Disconnect the X4 harness connector at the
K9 Body Control Module.)
14.2. Test for infinite resistance between the
control circuit and ground.
2 if lessthan infinite resistance, repair the short to
ground on the circuit.
U Ifinfinite resistance.
14.3. Test for lessthan 2 Q in the control circuit
and to end.
2 if 2 Q or greater, repair the short to ground on
the circuit.
2 Ifless than 2 Q, replace the K9 Body Control
Module
If the test lamp is always ON
14.1. ignition OFF, remove the test lamp.
Disconnect the X4 harness connector at the
K9 Body Control Module, ignition ON.
14.2. Test for lessthan 1 V between the control
2 If2 Q or greater, repair the short to voltage on
the circuit.
2 Iflessthan 2 Q, replace the K9 Body Control
Module
U If the test lamp turns 0N and OFF.
15. Test or replace the X50A Fuse Block —Underhood.
Component Testing
Washer Switch
1. Ignition OFF, disconnect the harness connector at
the 882 WindshieldWiperNVasher Switch.
2. Test for infinite resistance between the signal
terminal 5 and the low reference terminal 2 with the
switch in the open position.
If less than infinite resistance
Replace the S82 WindshieldWiper/Washer
Switch.
If infinite resistance
Test for lessthan 2 Q between the signal circuit
terminal 5 and the low reference circuit terminal 2
with the switch in the closedposition.
If 2 Q or greater
Replace the 882 WindshieldWiperNVasher
Switch.
<=If less than 2 Q
All OK
(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
 Wipers and Washers 4-347

Repair Instructions Visual/Physical Inspection

Perform the Diagnostic Repair Verification on
page 6—92after completing the repair.
- Front Compartment Fuse Block Replacement on
page 11-609
- WindshieldWasher Pump Replacement on
page 4-373
- WindshieldWiper and Washer Switch
Replacement on page 4—366
0 Control Module References on page 6-3 for body
control module replacement, programming, and
setup.
Symptoms - WiperNVasher Systems
Note: The following steps must be completed before
usingthe symptom tables:
1. Perform Diagnostic System Check - Vehicle on
page 6—66, in order to verify that all of the following
conditions are true:
- No DTCs are set.
- The control modulescan communicate via the
serial data link.
2. Refer to Wiper/Washer System Description and
Operation on page 4-384 in order to familiarize
yourselfwith the system functions.
- Inspect for aftermarket deviceswhich may affect
the operation of the windshieldwiper/washer
system. Refer to Checking Aftermarket
Accessorieson page 11-525.
- Inspect the easily accessible or visiblesystem
components for obviousdamage or conditions
which may cause the symptom.
- inspect the washerfluid reservoirforthe proper
fluidlevel.
Intermittent
Faulty electrical connections or wiring may be the
cause of intermittentconditions. Refer to Testing for
IntermittentConditions and Poor Connections on
page 11—531.
Symptom List
Refer to a symptom diagnostic procedure from the
following list in order to diagnose the symptom:
- WindshieldWiper System Malfunction on
page 4-347
- Washer Malfunction (without C25) on page 4—353
or Washer Malfunction (with 025) on page 4-356
- Rear Washer System Malfunction on page 4—363
- Rear Wiper System Malfunction on page 4-359

Windshield Wiper System Malfunction

Diagnostic Instructions
' Perform the Diagnostic System Check - Vehicle
on page 6-66 priorto usingthis diagnostic
procedure.
' Review Strategy Based Diagnosison page 6-58
for an overview of the diagnostic approach.
' Diagnostic Procedure Instructions on page 6-59
providesan overview of each diagnostic category.
DTC Descriptors
DTC B3715 01: WindshieldWiper Relay Circuit Short to Battery
DTC B3715 02: WindshieldWiper Relay Circuit Short to Ground
DTC 33715 04: WindshieldWiper Relay Circuit Open
DTC B3875 01: WindshieldWiper High Speed Relay Circuit Short to Battery
DTC B3875 02: WindshieldWiper High Speed Relay Circuit Short to Ground
DTC B3875 04: WindshieldWiper High Speed Relay Circuit Open

Diagnostic Fault Information

Open/High Signal
Circuit Short to Ground Resistance Short to Voltage Performance
WiperSwitchLowSignalterminal3 1 1 1 -
Windshield
WiperSwitchHighSignalterminal1 4 2 2 —-
Windshield
WiperMotorPark SwitchSignal 3 3 _ _
Windshield
terminal2
8371502 B3715O4 B371501 --
FrontWiper RelayControlterminal85
WiperHighSpeed RelayControl __
Windshield
terminal86 B387502 B387504 8387501

(US/Canada)
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2013 (5377994)
Manual
Service
4-348 Wipers and Washers

Open/High Signal
Circuit Short to Ground Resistance Short to Voltage Performance
FrontWiperMotorControlterminal4 1 1 4 -
FrontWiperMotorSpeedControlterminal5 1 1 4 ~-
Windshield WiperSwitchLowReference _ 12 12 _
terminal2 ’ ’
Windshield WiperMotorGroundterminal1 — 1,2, 3 — -
Windshield WiperRelayGroundterminal86 — 1 — —-
1. Delayor LowSpeedWiperslnoperative
2. HighSpeedWiperslnoperative
3. WipersDo NotPark
4. Wipers AlwaysON

CircuitlSystem Description Description and Operation

The body control module (BCM) controls the wiper
motor based on input from the windshieldwiper/washer
switch. The BCM monitors the wiper/washer switch
through two separate signal circuits and a low
reference circuit. The windshieldwiper switch high
signal circuit is usedto determine high speedwiper
operation, the windshieldwiper switch low signal is
usedto determine low speed,intermittent,and mist
operation through the use of a resistor ladder, and the
windshieldwasher switch signal circuit is usedto
determine washer operation.
The BCM controls the windshieldwiper motor through
two output controls, controlling two relays which
determine the desiredwiper speed,high or low.
Conditions for Running the DTC
- The DTC runsonly when a wiper output is actively
being requested by the BCM.
- The system voltage is between 9—16V.
Conditions for Setting the DTC
- 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.
Action Taken When the DTC Sets
The BCM willnot activate the wiper output.
Conditions for Clearing the DTC
- A current DTC willclear when the condition for
setting the fault is no longer present.
- A history DTC willclear after 50 consecutive
ignition cycleswithout a fault present.
Reference Information
Schematic Reference
Wiper/Washer Schematics on page 4-325
Connector End View Reference
Component Connector End Viewson page 11-269
Wiper/Washer System Description and Operation on
page 4-384
Electrical Information Reference
' Circuit Testing on page 11-526
' Connector Repairs on page 11-548
- Testing for IntermittentConditions and Poor
Connections on page 11-531
- Wiring Repairs on page 11—537
Scan Tool Reference
Control Module References on page 6-3 for scan tool
information
CircuitlSystem Verification
1. IgnitionON.
2. Verifythe scan tool WindshieldWiper High Speed
Switch parameter changes between Active and
Inactive when activating the high speedwindshield
wipers. ‘
2 If the parameter does not change
Refer to CircuitlSystem Testing —Windshield
Wiper/Washer Switch Malfunction.
U If the parameter changes
3. Verifythe scan tool WindshieldWiper Switch
parameter changes between Off and Low when
activating the low speedwindshield wipers.
2 If the parameter does not change
Refer to Circuit/System Testing - Windshield
Wiper/Washer Switch Malfunction.
(z If the parameter changes
4. Verifythe scan tool WindshieldWiper Switch
parameter changes between Delay 1 and Delay 5
when cycling the intermittentspeedwindshield
wipers.
2 If the parameter does not change
Test or replace the 882 WindsheildWiper/
Washer Switch.
U If the parameter changes

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Wipers and Washers 4-349

Wiper High Speed

Motor changes 6. Verifythe scan tool Windshield
5. Verifythe M75 WindshieldWiper cycling the 882 Switch parameter is Active.
between Off, Low, and High when
Off, 2) If not Active
WindshieldWiperNVasher Switch between wire,
Low, and High. 6.1. ignition OFF, remove thejumper at the K9
does not cycle disconnect the harness connector
2 If the WindshieldWiper Motor Body Control Module, ignition ON.
between Off, Low, and High
the signal
Windshield 6.2. Test for less than 1 V between
Refer to CircuitlSystem Testing — circuit and ground.
Wiper Motor Malfunction
to voltage on
cycles between 2 if 1 V or greater, repair the short
U If the WindshieldWiper Motor the circuit.
Off, Low, and High
U Iflessthan 1 V
6. ignition OFF. circuit end
Wiper Park Switch 6.3. Test for less than 2 Q in the signal
7. Verifythe scan tool Windshield to end.
parameter is Active. open/high resistance
2 if 2 Q or greater, repair the
2 If the parameter does not change in the circuit.
Windshield
Refer to CircuitlSystem Testing — Body Control
2 if less than 2 Q, replace the K9
Wiper Motor Malfunction. Module.
U If the parameter changes lf Active
8. All OK. the signal circuit
Test for greater than 8 V between
Testing terminal 3 and ground.
CircuitlSystem
Malfunction If less than 8 V
WindshieldWipeerasher Switch harness
systems OFF, 7.1. Ignition OFF, disconnect the
1. Ignition OFF and all vehicle connector‘at the K9 Body Control Module.
disconnect the harness connector at the 882
between the signal
Windshield Wiper/Washer Switch. Itmay take up to 7.2. Test for infinite resistance
power down. circuit and ground
11 min for all vehicle systems to repair the short to
Test for less than 10 Q between the
low reference 2 Ifless than infinite resistance,
circuit terminal 2 and ground. ground on the circuit.
If 10 Q or greater U lf infinite resistance
circuit end
2.1. Ignition OFF, disconnect the
harness 7.3. Test for less than 2 Q in the signal
connector at the K9 Body Control Module. to end.
resistance
2.2. Test for less than 2 Q in the low reference 2 If2 Q or greater, repair the open/high
circuit end to end. in the circuit.
Body Control
2 if 2 Q or greater, repair the open/high
resistance 2 if less than 2 Q, replace the K9
in the circuit. Module.
Control
2 Ifless than 2 Q, replace the K9 Body lf 8 V or greater
harness connector
Module. 9°UIgnition OFF, disconnect the X3 ignition ON.
at the K9 Body Control Module,
If less than 10 Q 882 Windshield
.03ignition ON. Test for less than 1 V between the terminal 3 and
High Speed Wiper/Washer Switch signal circuit
Verifythe scan tool WindshieldWiper ground.
Switch parameter is Inactive.
If 1 V or greater
If not Inactive circuit.
harness Repair the short to voltage on the
4.1. ignition OFF, disconnect the Module.
connector at the K9 Body Control If less than 1 V
the signal Wiper/Washer
4.2. Test for infinite resistance between 0. Test or replace the S82 Windshield
circuitterminal 1 and ground. Switch.
the short to
2 if less than infinite resistance, repair
ground on the circuit.
K9 Body
2 if infinite resistance, replace the
Control Module.
lf Inactive
between the signal
. Install a 3 A fusedjumper wire circuit
circuit terminal 1 and the low reference
terminal 2.

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
4-350 Wipers and Washers
WindshieldWiper Motor Malfunction
1. IgnitionOFF and all vehicle systems OFF,
disconnect the harness connector at the M75
WindshieldWiper Motor. Itmay take up to 2 min for
all vehicle systems to power down.
. Test for lessthan 10 Q between the ground circuit
terminal 1 and ground. .
If 10 Q or greater
2.1. IgnitionOFF.
2.2. Test for lessthan 2 Q in the ground circuit end
to end.
2 If2 Q or greater, repair the open/high resistance
in the circuit.
2 if lessthan 2 Q, repair the open/high resistance
in the ground connection.
if less than 10 Q
9’ IgnitionON.
Verifythe scan tool WindshieldWiper Park Switch
parameter is Inactive.
If not Inactive
4.1. ignition OFF, disconnect the harness
connector at the K9 Body Control Module.
4.2. Test for infinite resistance between the signal
circuit terminal 2 and ground.
2 Iflessthan infinite resistance, repair the short to
ground on the circuit.
2 if infinite resistance, replace the K9 Body
Control Module.
If Inactive
Install a 3 A fusedjumper wirebetween the signal
circuit terminal 2 and the ground circuit terminal 1.
Verifythe scan tool WindshieldWiper Park Switch
parameter is Active.
If not Active
6.1. IgnitionOFF, remove thejumperwire,
disconnect the harness connector at the K9
Body Control Module, ignition ON.
6.2. Test for lessthan 1 V between the signal
circuit and ground.
2 lf1 V or greater, repair the short to voltage on
the circuit.
U Iflessthan 1 V
6.3. Test for lessthan 2 Q in the signal circuit end
to end.
2 if 2 Q or greater, repair the open/high resistance
in the circuit.
2 If lessthan 2 Q, replace the K9 Body Control
Module.
lf Active
. IgnitionOFF and all vehicle systems OFF,
disconnect the KR12B WindshieldWiper Relay.
Itmay take up to 2 min for all vehicle systems to
power down.
8. Test for less than 10 Q betWeen each ground circuit
terminal listed below and ground:
. Terminal 86
- Terminal 87A
If 10 Q or greater
8.1. IgnitionOFF.
8.2. Test for lessthan 2 Q in the ground circuit end
to end.
2 If2 Q or greater, repair the open/high resistance
in the circuit.
2 if lessthan 2 Q, repair the open/high resistance
in the ground connection.
If less than 10 Q
. Ignition ON.
. Verifya test lamp illuminates between the B+
circuit terminal 87 and the ground circuit
terminal 87A.
If the test lamp does not illuminate and the
circuit fuse is good
Replace the X50A Fuse Block —Underhood.
If the test lamp does not illuminate and the
circuit fuse is open
10.1. IgnitionOFF, remove the test lamp.
Disconnect the KR12C WindshieldWiper
Speed Control Relay.
10.2. Test for infinite resistance between each
control circuit listed below and ground:
. Terminal 87A
. Terminal 87
2 Iflessthan infinite resistance, repair the short to
ground on the circuit.
2 Ifinfinite resistance, replace the M75
WindshieldWiper Motor
U If the test lamp illuminates
. Connect a test lamp between the control circuit
terminal 85 and the ground circuit terminal 86.
12. Verifythe test lamp turns ON and OFF when
commanding the WindshieldWiper Motor Relay
Low and Off with a scan tool.
If the test lamp is always OFF
12.1. IgnitionOFF, remove the test lamp,
disconnect the harness connector at the K9
Body Control Module.
12.2. Test for infinite resistance between the
control circuit and ground.
2 Iflessthan infinite resistance, repair the short to
ground on the circuit.
U Ifinfinite resistance
12.3. Test for lessthan 2 Q in the control circuit end
to end.
2 If2 Q or greater, repair the open/high resistance
in the circuit.

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service

2 If lessthan 2 Q, replace the K9 Body Control
Module.
If the test lamp is always ON
12.1. ignition OFF, remove the test lamp,
disconnect the harness connector at the K9
Body Control Module, ignition ON.
12.2. Test for lessthan 1 V between the control
circuit and ground.
2 If 1 V or greater, repair the short to voltage on
the circuit.
2 if lessthan 1 V, replace the K9 Body Control
Module.
If the test lamp turns ON and OFF
. Ignition OFF, connect the KR12B WindshieldWiper
Relay and disconnect the KR12C Windshield
Wiper Speed Control Relay, ignition ON.
. Test for lessthan 10 Q between the control circuit
terminal 30 and ground.
If 10 Q or greater
Test or replace the KR12B WindshieldWiper
Relay.
if less than 10 Q
Connect a test lamp between the control circuit
terminal 30 and ground.
. Verifythe test lamp turns ON and OFF when
commanding the WindshieldWiper Motor Relay
Low and Off with a scan tool.
If the test lamp does not turn ON and OFF
Test or replace the KR12B WindshieldWiper
Relay.
If the test lamp turns ON and OFF
. Verifya test lamp illuminates between the B+
circuit terminal 85 and ground.
If the test lamp does not illuminate
Replace the X50A Fuse Block —Underhood.
If the test lamp illuminates
. Connect a test lamp between the B+ circuit
terminal 85 and the control circuit terminal 86.
. Verifythe test lamp turns ON and OFF when
commanding the WindshieldWiper High Speed
Relay High and Off with a scan tool.
If the test lamp is always OFF
19.1. IgnitionOFF, remove the test lamp,
disconnect the harness connector at the K9
Body Control Module, ignition ON.
19.2. Test for lessthan 1 V between the control
circuit and ground.
2 if 1 V or greater, repair the short to voltage on
the circuit.
U if lessthan1V
19.3. IgnitionOFF.
19.4. Test for lessthan 2 Q in the control circuit end
to end.
2 If2 Q or greater, repair the open/high resistance
in the circuit.
(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
Wipers and Washers 4-351
2 if lessthan 2 Q, replace the K9 Body Control
Module.
If the test lamp is always ON
19.1. IgnitionOFF, remove the test lamp,
disconnect the harness connector at the K9
Body Control Module.
19.2. Test for infinite resistance between the
control circuit and ground.
2 if lessthan infinite resistance, repair the short to
ground on the circuit.
2 If infinite resistance, replace the K9 Body
Control Module.
If the test lamp turns ON and OFF
20. IgnitionOFF, connect the KR12C Windshield
Wiper Speed Control Relay.
21. Connect a test lamp between the M75 Windshield
Wiper Motor control circuit terminal 4 and ground
circuit terminal 1, ignition ON.
22. Verifythe test lamp turns ON and OFF when
commanding the WindshieldWiper Motor Relay
Low and Off with a scan tool.
If the test lamp is always OFF
22.1. IgnitionOFF, remove the test lamp,
disconnect the KR12C WindshieldWiper
Speed Control Relay.
22.2. Test for infinite resistance between the
control circuit and ground.
2 If lessthan infinite resistance, repair the short to
ground on the circuit.
U If infinite resistance
22.3. Test for lessthan 2 Q in the control circuit end
to end. .
2 If2 Q or greater, repair the open/high resistance
in the circuit.
2 If lessthan 2 Q, test or replace the KR12C
WindshieldWiper Speed Control Relay.
if the test lamp is always ON
22.1. ignition OFF, remove the test lamp,
disconnect the KR1ZC WindshieldWiper
Speed Control Relay, ignition ON.
22.2. Test for lessthan 1 V between the control
circuit and ground.
2 If 1 V or greater, repair the short to voltage on
the circuit.
2 If lessthan 1 V, test or replace the KR12C
WindshieldWiper Speed Control Relay.
if the test lamp turns ON and OFF
23. Connect a test lamp between the M75 Windshield
Wiper Motor control circuit terminal 5 and ground
circuitterminal 1, ignition ON.
4—352 Wipers and Washers
24. Verifythe test lamp turns ON and OFF when . Test for infinite resistance between the signal
commanding the WindshieldWiper High Speed terminal 3 and the low reference terminal 2 with the
Relay High and Off with a scan tool. low speedswitch in the open position.
If the test lamp is always OFF If less than infinite resistance
24.1. Ignition OFF, remove the test lamp, Replace the 882 WindshieldWiper/Washer
disconnect the KR12C WindshieldWiper Switch.
Speed Control Relay.
If infinite resistance
24.2. Test for infinite resistance between the
Verifythe resistance readings are withinthe
control circuit and ground.
specifiedrange listed below between the signal
2 if lessthan infinite resistance, repair the short to circuit terminal 3 and the low reference circuit
ground on the circuit. terminal 1 by pushing the switch in the listed
U lf infinite resistance positions below:
24.3. Test for lessthan 2 Q in the control circuit end 0 Delay 1 :3.75-3.85kQ
to end. ° Delay 2 :2.75-2.85kQ
2 If2 Q or greater, repair the open/high resistance ’ Delay 3 : 1.95—2.05kQ
in the circuit. - Delay 4: 1.25-1.35kQ
2 If lessthan 2 Q, test or replace the KR126 - Delay 5 : 765—775Q
WindshieldWiper Speed Control Relay. If not within the specified range
If the test lamp is always ON Replace the 882 WindshieldWiper/Washer
24.1. Ignition OFF, remove the test lamp, Switch.
disconnect the KR12C WindshieldWiper
U If within the specified range
Speed Control Relay, ignition ON.
24.2. Test for lessthan 1 V between the control 6. All OK
circuit and ground. Relay Test
2 lf1 V or greater, repair the short to voltage on 1. Ignition OFF, disconnect the appropriate relay.
the circuit. 2. Test for 60—200Q between terminals 85 and 86.
2 If lessthan 1 V, test or replace the KR12C z) If less than 60 or greater than 200
WindshieldWiper Speed Control Relay.
Replace the relay.
U If the test lamp turns ON and OFF
lf between 60-200 Q
25. Test or replace the M75 WindshieldWiper Motor.
Test for infinite resistance between the terminals
Component Testing listed below:
- 30 and 86
WindshieldWipeerasher Switch
- 30 and 87
1. IgnitionOFF, disconnect the harness connector at
the 882 WindshieldWiper/Washer Switch. - 30 and 85
2. Test for infinite resistance between the signal - 85 and 87
terminal 1 and the low reference terminal 2 with the If less than infinite resistance
high speedswitch in the open position.
Replace the relay.
If less than infinite resistance
If infinite resistance
Replace the 882 WindshieldWiper/Washer . Test for lessthan 5 Q between terminals 30
Switch. and 87A.
lf infinite resistance lf 5 Q or greater
Test for less than 2 Q between the signal circuit
Replace the relay.
terminal 1 and the low reference circuit terminal 2
with the high speedswitch in the closedposition. If less than 5 Q
If 2 Q or greater . Install a 10 A fusedjumper wirebetween relay
terminal 85 and 12 V. install a jumper wirebetween
Replace the 882 WindshieldWiper/Washer relay terminal 86 and ground.
Switch.
Test for lessthan 5 Q between terminals 30 and 87.
if less than 2 Q
2 If 5 Q or greater
Replace the relay.
If less than 5 Q
All OK

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Wipers and Washers 4:353

. Relay Replacement (Within an Electrical Center)

Repair Instructions
on page 11-607or Relay Replacement (Attached
Perform the Diagnostic Repair Verification on to Wire Harness) on page 11—607
page 6-92 after completing the repair. - WindshieldWiper and Washer Switch
- WindshieldWiper Motor Replacement on Replacement on page 4—366
page 4-379 - Control Module References on page 6—3for BCM
~ Front Compartment Fuse Block Replacement on replacement, programming and setup
page 11—609

Washer Malfunction (without 625)

Diagnostic Instructions ,
- Perform the Diagnostic System Check - Vehicle
on page 6-66 prior to usingthis diagnostic
procedure.
- Review Strategy Based Diagnosis on page 6-58
for an overview of the diagnostic approach.
' Diagnostic Procedure Instructions on page 6-59
providesan overview of each diagnostic category.
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
Diagnostic Fault Information

Short to Ground Open/High Signal

Circuit Resistance Short to Voltage Performance
Signal 2 1 1 -
WasherSwitch
Windshield
1 1 2 -
WasherPumpControl
Windshield
B3873O2 B3873O4 B387301 -
WasherRelay Control
Windshield
WasherPumpGround — 1 —— -
Windshield
1.Washerlnoperative
2.WasherAlwaysON

Description Action Taken When the DTC Sets

CircuitlSystem
The body control module (BCM) controls the windshield Washer operation is suspended.
washer pump based on an input from the windshield Conditions for Clearing the DTC
wiper/washer switch. The BCM monitors the washer
switch through the windshieldwasher switch signal A current DTC clears when the diagnostic runsand
circuit. When the washer switch is closed,low passes.
reference is suppliedto the windshieldwasher switch
signal circuit. When this is the case, the BCM will Reference Information
command the windshieldwasher pump and the low Schematic Reference
speedwiperson.
Wiper/Washer Schematics on page 4—325
Conditions for Running the DTC
Connector End View Reference
- IgnitionON.
- The system voltage is between 9—16V. Component Connector End Viewson page 11—269
Description and Operation
Conditions for Setting the DTC
o A short to ground or an open/high resistance is Wiper/Washer System Description and Operation on
detected in the windshieldwasher relay control page 4-384
circuit.
- A short to veltage is detectedin the windshield
washer relay control circuit.

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
4—354 Wipers and Washers
Electrical Information Reference
Circuit Testing on page 11-526
Connector Repairs on page 11-548
Testing for IntermittentConditions and Poor
Connections on page 11-531
Wiring Repairs on page 11—537
Scan Tool Reference
Control Module References on page 6-3 for scan tool
information
CircuitlSystem Verification
1. Ignition ON.
2. Verifythe scan tool WindshieldWasher Switch
parameter changes between Active and Inactive
when pressingand releasing the windshield
washer switch.
If the parameter does not change
Refer to CircuitlSystem Testing —Windshield
Wiper/Washer Switch Malfunction.
if the parameter changes
Verifythe windshieldwashersturn ON when
commanding the WindshieldWasher Relay Active
with a scan tool.
If the WindshieldWashers do not turn ON
Refer to CircuitlSystem Testing —Windshield
Washer Pump Malfunction
U If the WindshieldWashers turn ON
4. All OK.
CircuitlSystem Testing
WindshieldWipeerasher Switch Malfunction
1. ignition OFF and all vehicle systems OFF,
disconnect the harnessconnector at the S82
WindshieldWiperNVasher Switch. Itmay take up to
11 min for all vehicle systems to power down.
Test for lessthan 10 Q between the low reference
circuit terminal 2 and ground.
If 10 Q or greater
2.1. Ignition OFF.
2.2. Test for lessthan 2 Q in the low reference
circuit and to end.
2 If2 Q or greater, repair the open/high resistance
in the circuit.
2 Ifless than 2 Q, replace the K9 Body Control
Module.
If less than 10 Q
9° Ignition ON.
Verifythe scan tool WindshieldWasher Switch
parameter is inactive.
If not Inactive
4.1. Ignition OFF, disconnect the harness
connector at the K9 Body Control Module.
4.2. Test for infinite resistance between the signal
circuit terminal 5 and ground.
2 If less than infinite resistance, repair the short to
ground on the circuit.
2 if infinite resistance, replace the K9 Body
Control Module.
If Inactive
. Install a 3 A fusedjumper wirebetween the signal
circuit terminal 5 and the low reference circuit
terminal 2.
Verifythe scan tool WindshieldWasher Switch
parameter is Active.
If not Active
6.1. IgnitionOFF, remove the jumperwire,
disconnect the harnessconnector at the K9
Body Control Module, ignition ON.
6.2. Test for lessthan 1 V between the signal
circuit and ground.
2 if 1 V or greater, repair the short to voltage on
the circuit.
U Iflessthan 1 V
6.3. Test for lessthan 2 Q in the signal circuit end
to end.
2 If2 Q or greater, repair the open/high resistance
in the circuit.
2 if lessthan 2 Q, replace the K9 Body Control
Module.
U If Active
7. Test or replace the 882 WindshieldWiper/Washer
Switch.
WindshieldWasher Pump Malfunction
1. IgnitionOFF, and all vehicle systems OFF.
Disconnect the harnessconnector at the 624
WindshieldWasher Pump. it may take up to 2 min
for all vehicle systems to power down.
Test for lessthan 10 Q between the ground circuit
terminal 2 and ground.
If 10 Q or greater
2.1. Test for lessthan 2 Q in the ground circuit end
to end.
2 If2 Q or greater, repair the open/high resistance
in the circuit.
2 Iflessthan 2 Q, repair the open/high resistance
in the ground connection.
If less than 10 Q
Connect a test lamp between the control circuit
terminal 1 and the ground circuit terminal 2,
ignition ON. ,
Verifythe test lamp does NOT turn ON and OFF
when commanding the WindshieldWasher Relay
Active and Inactive with a scan tool.
If the test lamp turns ON and OFF
Test or replace the 624 Windshield
Washer Pump.
If the test lamp doesnot turn ON and OFF
IgnitionOFF, connect the harness connector at the
624 WindshieldWasher Pump. Disconnect the X2
harness connector at the X50A Fuse Block -
Underhood, Itmay take up to 2 min for all vehicle
systems to power down.
(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
 Wipers and Washers 41-355

6. Test for lessthan 10 Q between the ground circuit
terminal C5 and ground.
If 10 Q or greater
6.1. Test for lessthan 2 Q in the ground circuit end
to end.
2 If2 Q or greater, repair the open/high resistance
in the circuit.
2 if lessthan 2 Q, repair the open/high resistance
in the ground connection.
If less than 10 Q
T‘ IgnitionON.
Verifythe 624 WindshieldWasher Pump is not
activated.
If the 624 Windshield Washer Pump is
activated
8.1. IgnitionOFF, disconnect the harness
connector at the 624 WindshieldWasher
Pump, ignition ON.
8.2. Test for less than 1V between the control
circuitterminal 1 and ground.
2 If 1 V or greater, repair the short to voltage on
the circuit.
2 if lessthan 1 V, replace the 624 Windshield
Washer Pump.
If the 624 WindshieldWasher Pump is not
activated
Disconnect the X1 harnessconnector at the X50A
Fuse Block —Underhood.
. Connect a 20 A fusedjumper wirebetween the
control circuit terminal 63 and B+.
. Verifythe 624 WindshieldWasher Pump activates.
If the 624 WindshieldWasher Pump does not
activate
11.1. IgnitionOFF, remove thejumper wire,
disconnect the harness connector at the 624
WindshieldWasher Pump.
11.2. Test for infinite resistance between the
control circuit and ground.
2 Iflessthan Infinite resistance, repairthe short to
ground on the circuit.
U lf infinite resistance
11.3. Test for lessthan 2 Q in the control circuit end
to end.
2 If2 Q or greater, repair the open/high resistance
in the circuit.
2 Ifless than 2 Q, replace the 624 Windshield
Washer Pump.
If the 624 WindshieldWasher Pump activates
. IgnitionOFF, connect the X1 harness connector at
the X50A Fuse Block —Underhood. Disconnect the
X4 harness connector at the K9 Body Control
Module, ignition ON.
13. Verifythe 624 WindshieldWasher Pump is not
activated.
:> If the 624 WindshieldWasher Pump is
activated
13.1. Ignition OFF, disconnect the X2 harness
connector at the X50A Fuse Block -
Underhood, ignition ON.
13.2. Test for lessthan 1 V between the control
circuit terminal 69 and ground.
2 if 1 V or greater, repair the short to voltage on
the circuit.
2 Ifless than 1V, replace the X50A Fuse Block -
Underhood.
If the 624 WindshieldWasher Pump is not
activated
14. Connect a 10 A fusedjumper wirebetween the
control circuit terminal 14 and B+.
. Verifythe 624 WindshieldWasher Pump activates.
2 If the 624 WindshieldWasher Pump does not
activate
15.1. ignition OFF, remove the jumperwire,
disconnect the X2 harness connector at the
X5OA Fuse Block —Underhood.
15.2. Test for infinite resistance between the
control circuit and ground.
2 Ifless than infinite resistance, repair the short to
ground on the circuit.
U if lessthan infinite resistance
15.3. Test for lessthan 2 Q in the control circuit end
to end.
2 If2 Q or greater, repair the open/high resistance
in the circuit.
2 if lessthan 2 Q, test or replace the X50A Fuse
Block —Underhood.
U If the 624 WindshieldWasher Pump activates
16. Replace the K9 Body Control Module.
Component Testing
WindshieldWiperNVasher Switch
1. Ignition OFF, disconnect the harness connector at
the 882 WindshieldWiperNVasher Switch.
2. Test for infinite resistance between the signal
terminal 5 and the low reference terminal 2 with the
switch in the open position.
If less than infinite resistance
Replace the S82 WindshieldWiper/Washer
Switch.
If infinite resistance
. Test for less than 2 Q between the signal circuit
terminal 5 and the low reference circuit terminal 2
with the switch in the closedposition.
If 2 Q or greater
Replace the S82 WindshieldWiper/Washer
Switch.
<2If less than 2 Q
All OK

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
4-356 Wipers and Washers

Instructions - WindshieldWiper and Washer Switch

Repair
Replacement on page 4—366
Perform the Diagnostic Repair Verification on - Control Module References on page 6-3 for BCM
page 6-92 after completing the repair. replacement, programming and setup
- Front Compartment Fuse Block Replacement on
page 11—609
- WindshieldWasher Pump Replacement on
page 4-373

Washer Malfunction (with C25)

Diagnostic Instructions
- Perform the Diagnostic System Check —Vehicle
on page 6-66 prior to usingthis diagnostic
procedure.
- Review Strategy Based Diagnosis on page 6-58
for an overview of the diagnostic approach.
- Diagnostic Procedure Instructions on page 6-59
providesan overview of each diagnostic category.
DTC Descriptors
DTC B3873: Front Washer Relay Circuit
For symptom byte information, refer to Symptom Byte
List on page 6-85.
Diagnostic Fault Information

Short to Ground Opeanigh Signal

Circuit Resistance Short to Voltage ‘ Performance
WasherSwitchSignal
Windshield 2 1 1 -
WasherPumpControl
Windshield 1 1 2 -
WasherRelay Control
Windshield 8387302 8387304 8387301 —-
WasherPumpGround
Windshield — 1 — -
1.Washer lnoperative
2. WasherAlways ON

CircuitlSystem Description Conditions for Running the DTC

The body control module (BCM) controls the windshield - Ignition ON.
washer based on an input from the windshieldwasher 0 The system voltage is between 9—16V.
switch, which is part of the windshieldwiper/washer
switch. The BCM monitors the windshield washer Conditions for Setting the DTC
switch through a discrete signal circuit. When the
B3873 01
washer switch is pressed,the signal circuit is pulled to
ground. The BCM willrespondby commanding the A short to voltage has been detected on the windshield
washer function. washer pump relay control circuit
The windshieldwasher uses a singlewindshield B3873 02
washer pump to provide fluidfor both the front and rear
washers.Changing the polarity of the motor willcause A short to ground has been detected on the windshield
it to spinin opposite directions, feeding fluidto the front washer pump relay control circuit
or rear. When front washersare requested, the BCM B3873 04
applies voltage to the windshieldwasher pump relay
control circuit. This causesthe contacts in the An open/high resistance has been detected on the
windshieldwasher pump relay to closeand supplies windshieldwasher pump relay control circuit
voltage to the windshieldwasher pump. Ground for the Action Taken When the DTC Sets
windshieldwasher pump is provided through the rear
window washer pump relay, which is switched to Washer operation is suspended.
ground in it’s at—reststate.

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
 Wipers and Washers 4=357

the DTC 2 Iflessthan 2 Q, replace the K9 Body Control

Conditions for Clearing
A current DTC clears when the diagnostic runsand
passes.
Reference Information
Schematic Reference
Wiper/Washer Schematics on page 4-325
Connector End View Reference
Component Connector End Viewson page 11—269
Description and Operation
Wiper/Washer System Description and Operation on
page 4—384
Electrical Information Reference
- Circuit Testing on page 11-526
' Connector Repairs on page 11-548
' Testing for IntermittentConditions and Poor
Connections on page 11-531
- Wiring Repairs on page 11-537
Scan Tool Reference
Control Module References on page 6-3 for scan tool
information
CircuitlSystem Verification
1. IgnitionON.
2. Verifythe scan tool WindshieldWasher Switch
parameter changes between Active and Inactive
when pressingand releasing the washer switch.
2 If the parameter does not change
Refer to CircuitlSystem Testing - Washer
Switch Malfunction.
U If the parameter changes
3. Verifythe 624 WindshieldWasher Pump activates
when commanding the WindshieldWasher Relay
Active with a scan tool.
2 If the WindshieldWashers do not turn 0N
Refer to CircuitlSystem Testing —Windshield
Washer Pump Malfunction
U If the WindshieldWashers turn ON
4 All OK.
CircuitlSystem Testing
Washer Switch Malfunction
1. IgnitionOFF and all vehicle systems OFF,
disconnect the harness connector at the S82
WindshieldWiper/Washer Switch. Itmay take up to
11 min for all vehicle systems to power down.
2. Test for lessthan 10 Q between the low reference
circuit terminal 2 and ground.
2 If 10 Q or greater
2.1. ignition OFF.
2.2. Test for lessthan 2 Q in the low reference
circuit end to end.
2 If2 Q or greater, repair the open/high resistance
in the circuit.
Module.
U If less than 10 Q
3. IgnitionON.
4. Verifythe scan tool WindshieldWasher Switch
parameter is Inactive.
2 If not Inactive
4.1. ignition OFF, disconnect the harness
connector at the K9 Body Control Module.
4.2. Test for infinite resistance between the signal
circuit terminal 5 and ground.
2 Iflessthan infinite resistance, repair the short to
ground on the circuit.
2 Ifinfinite resistance, replace the K9 Body
Control Module.
U lflnactive
5. install a 3 A fusedjumper wirebetween the signal
circuit terminal 5 and the low reference circuit
terminal 2.
6. Verifythe scan tool WindshieldWasher Switch
parameter is Active.
2 If not Active
6.1. IgnitionOFF, remove the jumper wire,
disconnect the harness connector at the K9
Body Control Module, ignition ON.
6.2. Test for lessthan 1 V between the signal
circuit and ground.
2 If 1 V or greater, repair the short to voltage on
the circuit.
U Ifless than 1 V
6.3. Test for lessthan 2 Q in the signal circuit end
to end.
2 if 2 Q or greater, repair the open/high resistance
in the circuit.
2 Iflessthan 2 Q, replace the K9 Body Control
Module.
U If Active
7. Test or replace the 882 WindshieldWiper/Washer
Switch.
WindshieldWasher Pump Malfunction
1. IgnitionOFF, and all vehicle systems OFF.
Disconnect the X2 harness connector at the X5OA
Fuse Block —Underhood. Itmay take up to 2 min
for all vehicle systems to power down.
2. Test for lessthan 10 Q between the ground circuit
terminal C5 and ground:
2 If 10 Q or greater
2.1. Test for lessthan 2 Q in the ground circuit end
to end.
2 If2 Q or greater, repair the open/high resistance
in the circuit.
2 if lessthan 2 Q, repair the open/high resistance
in the ground connection.
U If less than 10 Q
3. Connect the X2 harness connector and disconnect
the X1 harness connector at the X50A Fuse Block
—Underhood.

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
42.353 Wipers and Washers
4. Test for infinite resistance between each of the 10. Connect a test lamp between the control circuit
control circuit terminals listed below and ground. terminal 1 and the control circuitterminal 2,
ignition ON.
4.1. Terminal 63
11. Verifythe test lamp does NOT turn ON and OFF
4.2. Terminal H3
when commanding the rear washer ON and OFF
If less than Infinite resistance with the rear washer switch.
Repair the short to ground on the circuit. If the test lamp turns 0N and OFF
If infinite resistance Test or replace the 624 Windshield
. Connect the X1 harness connector at the X50A Washer Pump.
Fuse Block —Underhood. Disconnect the harness If the test lamp does not turn ON and OFF
connector at the 624 WindshieldWasher Pump,
. IgnitionOFF, connect the harness connector at the
ignition ON. 624 WindshieldWasher Pump. Disconnect the X2
Test for lessthan 1 V between the control circuit harness connector at the X50A Fuse Block -
terminals listed below and ground: Underhood, ignition ON.
- Terminal 1 13. Connect a test lamp between the control circuit
- Terminal 2 terminal 69 and ground.
lf1 V or greater 14. Verifythe test lamp turns ON and OFF when
6.1. IgnitionOFF, disconnect the X1 harness commanding the WindshieldWasher Relay Active
connector at the X50A Fuse Block - with a scan tool.
Underhood. If the test lamp is always OFF
6.2. Test for lessthan 1 V between the control 14.1. Ignition OFF, remove the test lamp.
circuit and ground. Disconnect the X4 harness connector at the
2 lf1 V or greater, repair the short to voltage on K9 Body Control Module.
the circuit. 14.2. Test for infinite resistance between the
control circuit and ground.
2 Iflessthan 1 V, test or replace the X50A Fuse
Block —Underhood. 2 Iflessthan infinite resistance, repair the short to
ground on the circuit.
If less than 1 V
ignition OFF, and all vehicle systems OFF. it may U lf infinite resistance.
take up to 2 min for all vehicle systems to 14.3. Test for less than 2 Q in the control circuit
power down. end to end.
Test for less than 10 Q between the control circuit 2 If2 Q orgreater, repair the short to ground on
terminal 1 and ground. the circuit.
if 10 Q or greater 2 Iflessthan 2 Q, replace the K9 Body Control
8.1. IgnitionOFF, disconnect the X1 harness Module
connectors at the X50A Fuse Block - If the test lamp is always 0N
Underhood. 14.1. IgnitionOFF, remove the test lamp.
8.2. Test for lessthan 2 Q in the control circuit end Disconnect the X4 harness connector at the
to end: K9 Body Control Module, ignition ON.
2 If2 Q or greater, repair the open/high resistance 14.2. Test forless than 1 V between the control
in the circuit. circuit and ground.
2 Iflessthan 2 Q, replace the X50A Fuse Block - 2 If2 Q or greater, repair the short to voltage on
Underhood. the circuit. .
If less than 10 Q 2 Iflessthan 2 Q, replace the K9 Body Control
. Test for less than 10 Q between the control circuit Module
terminal 2 and ground. U If the test lamp turns 0N and OFF.
If 10 Q or greater 15. Test or replace the X50A Fuse Block —Underhood.
9.1. Ignition OFF, disconnect the X1 harness Testing
Component
connectors at the X50A Fuse Block -
Underhood. Washer Switch
9.2. Test for lessthan 2 Q in the control circuit end 1. Ignition OFF, disconnect the harness connector at
to end: the 882 WindshieldWiperNVasher Switch.
2 If2 Q or greater, repair the open/high resistance 2. Test for infinite resistance between the signal
in the circuit. terminal 5 and the low reference terminal 2 with the
2 Iflessthan 2 Q, replace the X50A Fuse Block - switch in the open position.
Underhood. 2 If less than infinite resistance
If less than 10 Q Replace the 882 WindshieldWiper/Washer
Switch.
U If infinite resistance
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 Wipers and Washers . 4-359

3. Test for less than 2 Q between the signal circuit Repair Instructions
terminal 5 and the low reference circuit terminal 2 Perform the Diagnostic Repair Verification on
with the switch in the closed position. page 6-92 after completing the repair.
2 If 2 Q or greater - Front Compartment Fuse Block Replacement on
Replace the 882 WindshieldWiper/Washer page 11-609
Switch. - WindshieldWasher Pump Replacement on
page 4—373
U If less than 2 Q
0 WindshieldWiper and Washer Switch
4. All OK Replacement on page 4—366
- Control Module References on page 6-3 for body
control module replacement, programming, and
setup.

Rear Wiper System Malfunction

Diagnostic Instructions
- Perform the Diagnostic System Check - Vehicle
on page 6—66prior to usingthis diagnostic
procedure.
- Review Strategy Based Diagnosis on page 6—58
for an overview of the diagnostic approach.
- Diagnostic Procedure Instructions on page 6—59
providesan overview of each diagnostic category.
DTC Descriptor
DTC B3708: RearWiper Function Control Circuit
For symptom byte information, refer to Symptom Byte
List on page 6-85.
Diagnostic Fault Information

OpenIHigh Signal
Short to Ground Resistance Short to Voltage Performance
Circuit
— 1 — -
RearWiperMotor8+
1 1 1 —-
RearWiperSwitchSignal
1 1 2 --
RearWiperMotorControl
83708 02 83708 04 83708 01 —-
RearWiperRelay Control
— 1 —- -
RearWiperRelay Ground
—- 1 —— —-
RearWindowWiperGround
1.Rear Wiper lnoperative
2. RearWiperAlwaysON
ladder, reducing the voltage seen at the BCM. The
CircuitlSystem Description BCM willrespond by commanding the specificrear
The body control module (BCM) controls the rear wiper wiper function.
motor based on an input from the rear wiper switch, The rear wiper motor is controlled by the BCM through
which is part of the windshieldwiper/washer switch. the rear wiper relay. A constant 8+ and ground are
The BCM monitors the windshieldwiper/washer switch supplied to the rear wiper motor. When rear wiper
through two separate signal circuits and a low operation is requested, the BCM willapply voltage to
reference circuit. The rear wiper switch uses a resistor the rear wiper relay control circuit. Thiswillcause the
ladder to determine low speed, intermittent, and rear contacts in the rear wiper relay to closeand apply 8+ to
washer operation. The BCM monitors applies and the rear wiper motor through the rear wiper control
monitors voltage on the rear wiper switch signal circuit. circuit, enabling rear wiper operation. When the rear
When the rear wiper switch is placed in the low speed, wiper request is no longer present, the contacts in the
intermittent,or rear washer position, the voltage is rear wiper relay willopen, removing 8+ from the rear
pulled down through a different resistor in the resistor

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4=360 Wipers and Washers
wiper motor control circuit. The rear wiper motor will 3. Verifythe M45 Rear Wiper Motor cycleswhen
continue to operate usingthe constant 8+ circuit until it commanding the rear wiper ON with the rear wiper
is in the park position. switch.
2 If the M45 Rear Wiper Motor does not cycle
Conditions for Running the DTC
Refer to CircuitlSystem Testing —Rear Wiper
' Ignition ON Motor Malfunction
- The system voltage is between 9—16V. 4: If the M45 Rear Wiper Motor cycles
Conditions for Setting the DTC 4. Verifythe M45 Rear Wiper Motor returns to the
park position when the rear wipersare turned OFF
B370B 01 2 If the M45 Rear Wiper Motor does not return to
A short to voltage is detected in the rear wiper relay the park position
control circuit. Refer to Circuit/System Testing - Rear Wiper
B3703 02 Motor Malfunction
A short to ground is detected in the rear wiper relay U If the M45 Rear Wiper Motor returns to the park
control circuit. position
B370B 04 5 All OK.
An open or high resistance is detected in the rear wiper CircuitlSystem Testing
relay control circuit.
Rear Wiper/Washer Switch Malfunction
Action Taken When the DTC Sets 1. Ignition OFF and all vehicle systems OFF,
Rear wiper operation is disabled. disconnect the harness connector at the 882
WindshieldWiperNVasher Switch. Itmay take up to
Conditions for Clearing the DTC 11 min for all vehicle systems to power down.
The DTC willclear when the conditions for setting the 2. Test for lessthan 10 Q between the low reference
DTC are no longer present. circuit terminal 2 and ground.
2 If 10 Q or greater
Reference Information
2.1. ignition OFF.
Schematic Reference 2.2. Test for lessthan 2 Q in the low reference
Wiper/Washer Schematics on page 4325 circuit end to end.
2 If2 Q or greater, repair the open/high resistance
Connector End View Reference in the circuit.
Component Connector End Viewson page 11—269 2 Iflessthan 2 Q, replace the K9 Body Control
Description and Operation Module.
U If less than 10 Q
Wiper/Washer System Description and Operation on
page 4—384 3. Ignition ON.
4. Test for greater than 8 V between the signal circuit
Electrical Information Reference terminal 4 and ground.
- Circuit Testing on page 11-526 2 If less than 8 V
- Connector Repairs on page 11-548 4.1. ignition OFF, disconnect the harness
- Testing for IntermittentConditions and Poor connector at the K9 Body Control Module.
Connections on page 11-531 4.2. Test for infinite resistance between the signal
- Wiring Repairs on page 11-537 circuit and ground
Scan Tool Reference 2 Iflessthan infinite resistance, repair the short to
ground on the circuit.
Control Module References on page 6-3 for scan tool
information U If infinite resistance
4.3. Test for lessthan 2 Q in the signal circuit and
CircuitlSystem Verification to end.
1. ignition ON. 2 If2 Q or greater, repair the open/high resistance
2. Verifythe scan tool Rear Wiper Switch parameter in the circuit.
changes between On and Off when cycling the rear 2 if lessthan 2 Q, replace the K9 Body Control
wiper switch ON and OFF. Module.
2 If the parameter does not change 2 If 8 V or greater
Refer to CircuitlSystem Testing —Rear Wiper/ 5. Ignition OFF, disconnect the X2 harness connector
Washer Switch Malfunction. at the K9 Body Control Module, ignition ON.
U If the parameter changes

(US/Canada)
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Manual
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Test for lessthan 1 V between the 882 Windshield
Wiper/Washer Switch signal circuit terminal 4 and
ground.
lf1 V or greater
Repair the short to voltage on the circuit.
If less than 1 V
Test or replace the 882 WindshieldWiper/Washer
Switch.
Rear Wiper Motor Malfunction
1. IgnitionOFF, and all vehicle systems OFF.
Disconnect the harness connector at the M45 Rear
Wiper Motor. Itmay take up to 2 min for all vehicle
systems to power down.
. Test for lessthan 10 Q between the ground circuit
terminal 3 and ground.
If 10 Q or greater
2.1. Test for lessthan 2 Q in the ground circuit end
to end.
2 if 2 Q or greater, repair the open/high resistance
in the circuit.
2 Iflessthan 2 Q, repair the openlhigh resistance
in the ground connection.
If less than 10 Q
9° Ignition ON.
. Verifya test lamp illuminates between the B+
circuit terminal 2 and ground.
If the test lamp does not illuminate
4.1. IgnitionOFF, remove the test lamp.
Disconnect the X2 harness connector at the
X50A Fuse Block —Underhood.
4.2. Test for lessthan 2 Q in the control circuit end
to end.
2 If2 Q or greater, repair the openlhigh resistance
in the circuit.
2 If lessthan 2 Q, test or replace the X50A Fuse
Block - Underhood.
If the test lamp illuminates
Connect a test lamp between the control circuit
terminal 1 and ground.
Verifythe test lamp does NOT turn ON and OFF
when commanding the rear wiper ON and OFF
with the rear wiper switch.
If the test lamp turns 0N and OFF
Test or replace the M45 Rear Wiper Motor.
if the test lamp does not turn 0N and OFF
Ignition OFF, connect the harness connector at the
M45 Rear Wiper Motor. Disconnect the X2 harness
connector at the X50A Fuse Block —Underhood, it
may take up to 2 min for all vehicle systems to
power down.
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Wipers and Washers 4-361
8. Test for less than 10 Q between each ground
circuit terminal listed below and ground:
- Terminal C5
. Terminal H5
2 If 10 Q or greater
8.1. Test for lessthan 2 Q in the ground circuit and
to end.
2 if 2 Q or greater, repair the openlhigh resistance
in the circuit.
2 if lessthan 2 Q, repair the openlhigh resistance
in the ground connection.
U If less than 10 Q
5° ignition ON.
10. Verifythe M45 Rear Wiper Motor is not activated.
2 If the M45 Rear Wiper Motor is activated
10.1. IgnitionOFF, disconnect the harness
connector at the M45 Rear Wiper Motor,
ignition ON.
10.2. Test for less than 1 V between the control
circuitterminal 1 and ground.
2 If 1 V or greater, repair the short to voltage on
the circuit. 4
2 Ifless than 1 V, replace the M45 RearWiper
Motor.
U if the M45 Rear Wiper Motor is not activated
11. Connect a 20 A fusedjumperwire between both of
the circuits listed below and 8+.
- 8+ Circuit Terminal H4
' Control Circuit Terminal H3
12. Verifythe M45 Rear Wiper Motor activates.
2 if the M45 Rear Wiper Motor does not activate
12.1. IgnitionOFF, remove thejumperwire,
disconnect the harness connector at the M45
Rear Wiper Motor, ignition ON.
12.2. Test for infinite resistance between the
control circuit and ground.
2 If lessthan infinite resistance, repair the short to
ground on the circuit.
U Ifinfinite resistance
12.3. Test for less than 2 Q in the control circuit
end to end.
2 If2 Q or greater, repair the openlhigh resistance
in the circuit.
2 If lessthan 2 Q, replace the M45 Rear Wiper
Motor.
U If the M45 Rear Wiper Motor activates
13. Ignition OFF, connect the X2 harness connector at
the X50A Fuse Block —Underhood. Disconnect the
X4 harness connector at the K9 Body Control
Module, ignition ON.
4-352 Wipers and Washers
14. Verifythe M45 Rear Wiper Motor is not activated.
2 If the M45 Rear Wiper Motor is activated
14.1. Ignition OFF, disconnect the X2 harness
connector at the X50A Fuse Block -
Underhood, ignition ON.
14.2. Test for lessthan 1 V between the control
circuit terminal 10 and ground.
2 lf1 V or greater, repair the short to voltage on
the circuit.
2 lfless than 1 V, replace the X50A Fuse Block -
Underhood.
U If the M45 Rear Wiper Motor is not activated
15. Connect a 10 A fusedjumper wire between the
control circuitterminal 10 and 8+.
16. Verifythe M45 Rear Wiper Motor activates.
2 If the M45 Rear Wiper Motor does not activate
16.1. Ignition OFF, remove thejumperwire,
disconnect the X2 harness connector at the
X50A Fuse Block —Underhood.
16.2. Test for infinite resistance between the
control circuit and ground.
2 Iflessthan infinite resistance, repair the short to
ground on the circuit.
U Iflessthan infinite resistance
16.3. Test for lessthan 2 Q in the control circuit
end to end.
2 If2 Q or greater, repair the openlhigh resistance
in the circuit.
2 Iflessthan 2 Q, test or replace the X50A Fuse
Block —Underhood.
U If the M45 Rear Wiper Motor activates
17. Test or replace the K9 Body Control Module.
Component Testing
WindshieldWiperNVasher Switch
1. IgnitionOFF, disconnect the harness connector at
the S82 WindshieldWiper/Washer Switch.
2. Test for infinite resistance between the signal
terminal 4 and the low reference terminal 2 with the
rear wiper switch in the OFF position.
2 If less than infinite resistance
Replace the 882 WindshieldWiper/Washer
Switch.
U If infinite resistance
3. Verifythe resistance is within the range specified
below between the signal circuit terminal 4 and the
low reference circuit terminal 2 by cycling the
switch between Rear Wiper position and Rear
Washers position.
~ Rear Wiper :624—644Q
' RearWiper Sweep : 1.8—2.2kQ
- RearWasher: 5.9—6.4kQ
2 If not within the specific range
Replace the 882 WindshieldWiper/Washer
Switch.
U If within the specific range
4. All OK
Repair Instructions
Perform the Diagnostic Repair Verification on
page 6—92after completing the repair.
' Rear Window Wiper Motor Replacement
(Hatchback) on page 4—380
. Front Compartment Fuse Block Replacement on
page 11-609
- WindshieldWiper and Washer Switch
Replacement on page 4-366
- Control Module References on page 6-3 for body
control module replacement, programming, and
setup.
(US/Canada)
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2013 (5377994)
Manual
Service
 Wipers and Washers i"
4=30

Rear Washer System Malfunction

Diagnostic Instructions
~ Perform the Diagnostic System Check - Vehicle
on page 6-66 prior to using this diagnostic
procedure.
- Review Strategy Based Diagnosis on page 6-58
for an overview of the diagnostic approach.
- Diagnostic Procedure Instructions on page 6-59
providesan overview of each diagnostic category.
DTC Descriptor
DTC B3811: Rear Washer Relay Circuit
For symptom byte information, refer to Symptom Byte
List on page 6—85.
Diagnostic Fault Information

Open/High Signal
Circuit Short to Ground Resistance Short to Voltage Performance
RearWasherSwitchSignal 1 1 1 —-
RearWindowWasherPumpRelayControl 1 8381104 8381101 -
Rear WindshieldWasherPumpControl 1 1 2 -
Rear WindshieldWasherPumpGround — 1 — -
1. Rear Washerlnoperative
2. RearWasherAlwaysON

CircuitlSystem Description Conditions for Setting the DTC

The body control module (BCM) controls the rear B3811 01
washer based on an input from the rear wiper switch,
which is part of the windshieldwiper/washer switch. A short to voltage has been detected on the rear
The BCM monitors the windshieldwiper/washer switch window washer pump relay control circuit
through two separate signal circuits and a low B3811 04
reference circuit. The rear wiper switch uses a resistor
ladder to determine low speed, intermittent,and rear A open/high resistance has been detected on the rear
washer operation. The BCM monitors applies and window washer pump relay control circuit
monitors voltage on the rear wiper switch signal circuit.
Action Taken When the DTC Sets
When the rear wiper switch is placed in the low speed,
intermittent,or rear washer position, the voltage is Rear washer operation is disabled.
pulled down through a different resistor in the resistor
ladder, reducing the voltage seen at the BCM. The Conditions for Clearing the DTC
BCM willrespond by commanding the specificrear - A current DTC clears when the diagnostic rims
wiper function. and passes.
The windshieldwasher uses a single windshield - A history DTC willclear after 50 consecutive
washer pump to provide fluidfor both the front and rear ignition cycles without a fault present.
washers. Changing the polarity of the motor willcause
it to spinin opposite directions, feeding fluidto the front Reference Information
or rear. When rear washers are requested, the BCM
Schematic Reference
applies voltage to the rear window washer pump relay
control circuit. Thiscauses the contacts in the rear Wiper/Washer Schematics on page 4—325
washer pump relay to closeand suppliesvoltage to the
windshieldwasher pump. Ground for the windshield Connector End View Reference
washer pump is provided through the windshield Component Connector End Viewson page 11—269
washer pump relay, which is switched to ground in it’s
at-rest state. Description and Operation

Conditions for Running the DTC Wiper/Washer System Description and Operation on
page 4-384
. Ignition ON
- The system voltage is between 9—16V

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4:364 Wipers and Washers
Electrical Information Reference 6. Test for lessthan 1 V between the control circuit
terminals listed below and ground:
Circuit Testing on page 11-526 - Terminal1
0 Connector Repairs on page 11—548
- Terminal2
Testing for IntermittentConditions and Poor
Connections on page 11—531 If 1 V or greater
Wiring Repairs on page 11-537 6.1. IgnitionOFF, disconnect the X1 harness
connector at the X50A Fuse Block -
Scan Tool Reference Underhood.
Control Module References on page 6-3 for scan tool 6.2. Test for lessthan 1 V between the control
information circuit and ground.
2 If 1 V or greater, repair the short to voltage on
CircuitlSystem Verification the circuit.
1. Ignition ON. 2 Iflessthan 1 V, test or replace the X50A Fuse
2. Verifythe scan tool Rear Wiper Switch parameter Block —Underhood.
changes between On and Off when cycling the rear If less than 1 V
wiper switch ON and OFF.
ignition OFF, and all vehicle systems OFF. it may
If the parameter does not change take up to 2 min for all vehicle systems to
Refer to Rear Wiper System Malfunction on power down.
page 4-359 Test for lessthan 10 Q between the control circuit
if the parameter changes terminal 1 and ground.
Verifythe 624 Windshield Washer Pump turns on If 10 Q or greater
and off when commanding the rearwashers OFF 8.1. IgnitionOFF, disconnect the X1 harness
and ON with the rear washer switch connectors at the X50A Fuse Block -
if the Rear Window Washers do not turn ON Underhood.
Refer to CircuitlSystem Testing 8.2. Test for lessthan 2 Q in the control circuit end
to end:
U If the Rear Window Washers turn ON
2 If2 Q or greater, repair the openlhigh resistance
4 All OK.
in the circuit.
CircuitlSystem Testing 2 Iflessthan 2 o, replace the xsoA FuseBlock -
Underhood.
1. Ignition OFF, and all vehicle systems OFF.
Disconnect the X2 harness connector at the X50A c if less than 10 Q
Fuse Block —Underhood. Itmay take up to 2 min . Test for lessthan 10 Q between the control circuit
for all vehicle systems to power down. terminal 2 and ground.
Test for less than 10 Q between the ground circuit If 10 Q or greater
terminal C5 and ground:
9.1. IgnitionOFF, disconnect the X1 harness
If 10 Q or greater connectors at the X50A Fuse Block -
2.1. Test for lessthan 2 Q in the ground circuit and Underhood.
to end. 9.2. Test for lessthan 2 Q in the control circuit end
2 If2 Q or greater, repair the open/high resistance to end:
in the circuit. 2 If2 Q or greater, repair the openlhigh resistance
2 if lessthan 2 Q, repair the openlhigh resistance in the circuit.
in the ground connection. 2 Iflessthan 2 Q, replace the X50A FuseBlock -
If less than 10 Q Underhood.
Connect the X2 harness connector and disconnect If less than 10 Q
the X1 harness connector at the X50A Fuse Block . Connect a test lamp between the control circuit
—Underhood. terminal 1 and the control circuit terminal 2,
Test for infinite resistance between each of the ignition ON.
control circuit terminals listed below and ground. . Verifythe test lamp does NOT turn ON and OFF
4.1. Terminal 63 when commanding the rearwasher ON and OFF
4.2. Terminal H3 with the rear washerswitch.
If less than Infinite resistance If the test lamp turns ON and OFF
Repair the short to ground on the circuit. Test or replace the 624 Windshield
Washer Pump.
lf infinite resistance
It the test lamp does not turn ON and OFF
Connect the X1 harness connector at the X5OA
Fuse Block —Underhood. Disconnect the harness . IgnitionOFF, connect the harness connector at the
connector at the 624 Windshield Washer Pump, 624 Windshield Washer Pump. Disconnect the X2
ignition ON. harness connector at the X50A Fuse Block -
Underhood, ignition ON.
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 Wipers and Washers 4-365
13. Connect a test lamp between the control circuit Wiper Blade Element Check
terminal 62 and ground.
14. Verify the test lamp turns ON and OFF when
commanding the rear washer ON and OFF with the
rear washer switch.
If the test lamp is always OFF
14.1. ignition OFF, remove the test lamp.
Disconnect the X1 harness connector at the
K9 Body Control Module.
14.2. Test for infinite resistance between the
control circuit and ground.
2 lfless than infinite resistance, repair the short to
ground on the circuit.
U lf infinite resistance.
14.3. Test for lessthan 2 Q in the control circuit
end to end.
2 lf2 Q or greater, repair the short to ground on
the circuit.
2 if lessthan 2 Q, replace the K9 Body Control
Module
if the test lamp is always ON
334256
14.1. IgnitionOFF, remove the test lamp. 1. Remove the blade from the wiper arm. Refer to
Disconnect the X1 harness connector at the Windshield Wiper Blade Replacement'on '
K9 Body Control Module, ignition ON. page 4-377.
14.2. Test for lessthan 1 V between the control . Look down the length of the wiper blade core
circuit and ground. element.
2 If2 Q or greater, repair the short to voltage on . Ifthe blade core element contacting the glass is
the circuit. not :15 degree within the wiper central line, then
2 Iflessthan 2 Q, replace the K9 Body Control replace the blade core element. install the wiper
Module blades on the wiper arms.
U If the test lamp turns ON and OFF.
15. Test or replace the X50A Fuse Block —Underhood.
Repair Instructions
Perform the Diagnostic Repair Verification on
page 6-92 after completing the repair.
Windshield Washer Pump Replacement on
page 4-373
Front Compartment Fuse Block Replacement on
page 11-609
Windshield Wiper and Washer Switch
Replacement on page 4—366
Control Module References on page 6-3 for body
control module replacement, programming, and
setup.

2013
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(5377994)
4=366 Wipers and Washers

Repair Instructions

Windshield Wiper and Washer Switch Replacement

2508970

Windshield Wiper and Washer Switch Replacement

Callout Component Name
Preliminary Procedure
Removetheuppertrimcoverandthe lowertrimcoverfromthesteeringcolumn.Referto SteeringColumnLowerTrimCover
Replacementonpage 15-29.
WindshieldWiperandWasherSwitch
Procedure
1 1. Disconnectanyelectricalconnectorsas necessary.
2. Releasetheplasticretainingtabsandremovethewindshieldwiperandwasherswitchfromtheturnsignal
switchbracket.

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 Wipers and Washers 4-367

Windshield Washer Nozzle Hose Replacement

2497593

Windshield Washer Nozzle Hose Replacement

Callout Component Name
Preliminary Procedure
Removethehoodinsulator.Referto HoodInsulatorReplacementonpage 3-26.
WindshieldWasherNozzle Hose
Procedure
1. Disconnectthewindshieldwasherhoseatthefrontfenderupperlefthandbracketfromthewindshield
washersolventcontainerpumphose.
Disconnectthewindshieldwasherhoseretainerat thehoodhinge.
Disconnectall threewasherhoseretainersfromtheundersideof thehoodassembly.
Disconnectthewindshieldwasherhoseat bothwindshieldwashernozzlespouts.
Removethewindshieldwasherhosefromthevehicle.
.U‘FWPJ

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2013 (5377994)
Manual
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4-388 Wipers and Washers

Windshield Washer Nozzle Replacement

2495872
Windshield Washer Nozzle Replacement
Callout Component Name
Preliminary Procedure
Removethehoodinsulator.Referto HoodInsulatorReplacementonpage3—26.
WindshieldWasherNozzle
Procedure
1 1. Disconnectthewindshieldwasherhoseat thewashernozzlebeingserviced.
2. Usingtwofingers,squeezethelockingtabson theundersideofthehoodon thewashernozzle.
3. Pushthewashernozzleoutwardfromthehoodwhilerotatingthewashernozzleto theright.
4. Removethewindshieldwashernozzlefromthehoodassembly.

2013
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(US/Canada)
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 Wipers and Washers 4 ~369

Rear Window Washer Nozzle Replacement

2502578

Rear Window Washer Nozzle Replacement

Callout Component Name
PreliminaryProcedure
Removetheinsidehighmountstoplamp.Referto HighMountStopLamp Replacement(Hatchback)onpage 4-205or High
MountStopLampReplacement(Sedan)on page4-204.
RearWindowWasherNozzle
Procedure
1. Accesstherearwindowwashernozzlethroughtheholein behindthehighmountedstoplamp.
2. Disconnectthewasherhosefromthespout.
3. Pinchthetwotabsonthe rearwindowwashernozzleand pushthenozzleupthroughtheliftgatehole.
4. Removetherearwindowwashernozzlefromthevehicle.

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4-370 Wipers and Washers

Windshield Washer Solvent Container Hose Replacement

2497852

Windshield Washer Solvent Container Hose Replacement

Callout I Component Name
Preliminary Procedure
Removetheleftfrontwheelhouseliner.Referto FrontWheelhouseLinerReplacement(Rear)onpage 3-151or Front
WheelhouseLiner Replacement(Front)onpage3—150.
WindshieldWasherPump Hose
Procedure
1. Place a cleansuitabledrainpanunderthewasherpumparea.
2. Pullthehosefromthe windshieldwasherpumpspoutfirst.
1 3. Recoverthe windshieldwashersolventfrominsidethe hose.
4. Disconnectthewindshieldwasherpumphosefromthe windshieldwashernozzle hosenearthefrontfender
frontbracket.
5. Disengagethe windshieldwasherpumphosefromthetwo retentionclipsonthewindshieldwasher
container.
6. Removethewindshieldwasherpumphosefromthevehicle.

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 Wipers and Washers 4=371
Windshield Washer Solvent Container Filler-Tube Replacement

2\\l‘
. ar
a 2:23.‘_
I—‘fliflwh
N .. —‘i v
'L
‘W

2497092
Windshield Washer Solvent Container Filler Tube Replacement
Callout | Component Name
Preliminary Procedure
1. Openandsupportthehoodassembly.
2. Graspthetopportionof thewindshieldwashercontainerfillertubeandrotatethetube1/8turncounterclockwiseto unlock
fromthewindshieldwashersolventcontainerlocktabs.
3. Pullthetubestraightfromthewindshieldwashersolventcontainer.
4. Inspectand/orreplacetheseal on thewindshieldwashercontainerfillertubeif damaged.
WindshieldWasherSolventContainerFillerTube
Procedure
1. Inspecttheseal on thefillertube,replaceas needed.
1 2. Removeandtransferthewindshieldwashersolventcontainercap.
3. Uponinstallationof thewindshieldwashersolventcontainerfillertubeback intothewindshieldwasher
solventcontainer,ensureto twistthefillertube1/8turnclockwiseandlock thefillertubeintothecontainer
locktabs.

2013
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4=372 Wipers and Washers

Windshield Washer Solvent Container Replacement

2497222

Windshield Washer Solvent Container Replacement

Callout Component Name
Preliminary Procedures
Filler Tube
1. Removethe windshieldwashersolventcontainerfillertube.Referto WindshieldWasherSolventContainer
Replacementonpage 4-371.
(Rear)on
2. Removetheleftsidefrontportionofthefrontwheelhouseliner.Referto FrontWheelhouseLinerReplacement
page 3-151or FrontWheelhouseLinerReplacement onpage
(Front) 3—150.
hose.
3. Disconnectthe windshieldwasherhosefromthe windshieldwashersolventcontainerwasherpump
Disconnectthewindshieldwasherpumpelectricalconnectorfromthewasherpump.
WindshieldWasherSolventContainerWasherPumpHose
1 Procedure
Disengagethewasherpumphosefromthewasherpumpspoutandthe windshieldwashercontainer
retentiontabs.
WindshieldWasherSolventContainerNut(Qty:3)
Caution: Referto FastenerCautiononpage0-8.
Tighten
5.0N-m(44lb in)
WindshieldWasherSolventContainer
Procedure
frontouter
1. Removethewindshieldwashersolventcontainerfromthethreestudson thefrontcompartment
siderailand batterytraysupport.
2. Removethewindshieldwasherpumpfromthewindshieldwashersolventcontainer.
3. Emptythewindshieldwashersolventintoa suitableapprovedcleancontainer.
Transferpartsas needed.

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 Wipers and Washers 4.373
Windshield Washer Pump Replacement

2497851
Windshield Washer Pump Replacement
Callout Component Name
Preliminary Procedure
Removethefrontleftfrontwheelhouseliner.Referto FrontWheelhouseLinerReplacement(Rear)onpage 3-151or Front
WheelhouseLinerReplacement(Front)onpage 3-150.
WindshieldWasherPump Hose
1 Procedure
Place a cleansuitabledrainpanunderthewindshieldwasherpumpareato recoverthewindshieldwasher
solventwhenthewindshieldwasherpumphoseis disconnected.
WindshieldWasherPump
Procedure
1. Disconnecttheelectricalconnectortothewindshieldwasherpump.
2. Usingtwoflat—bladed tools,placethebladesoneach sideof thewasherpump,underthewindshield
washerpumpgrommet.
3. Twistthetwoflat—blades in oppositedirectionsto liftthewasherpumpfromthewindshieldwashersolvent
container.
Disengagethewasherpumpfromthewindshieldwashercontainer.
Removethewindshieldwasherpumpanddiscardthewindshieldwasherpumpgrommet.

2013
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(US/Canada)
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(5377994)
4-374 ‘JVi'pers and Washers

Air Inlet Grille Panel Replacement

2503304
Air Inlet Grille Panel Replacement
Callout Component Name
Preliminary Procedure
1. Removebothwiperarmassemblies.Referto WindshieldWiperArmReplacementonpage4-375.
2. Removebothouterhoodrearseals. Referto HoodRear Seal Replacementonpage 3-37.
Air InletGrillePanel Retainer(Qty:4)
1 Procedure
Releaseandremovetheretainersfromtheair inletgrillepanel.
Air InletPanel Screw
Caution: Referto FastenerCautiononpage0-8.
Procedure
2 1. Removethescrewcoverfromtheairinletgrillepanel.
2. Removetheair inletgrillepanelscrew.
Tighten
2.5N-m(22lbin)
Air InletGrillePanel
Procedure
3 1. Liftthefrontedgeofthegrillepaneloffthefrontedgeofthe dash upperextensionpanelopeningcover.
2. Slide thegrillepanelforwardfrombothhoodhinges.
3. Removethegrillepanelfromthe vehicle.
4. Removethehoodrearweather-strip. Referto HoodRear WeatherstripReplacementonpage3—38.

2013
-Sonic
(US/Canada)
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 Wipers and Washers 43 75
Windshield Wiper Arm Replacement

1'

2502681
Windshield Wiper Arm Replacement
Callout Component Name
Preliminary Procedure
Openandsupportthehoodassembly.
WindshieldWiperArmNutCap
1
Tip: Usea smallflat-bladedtoolin orderto releasethefinishcapfromthewiperarmassembly.
WindshieldWiperArmNut
Caution: RefertoFastenerCautionon page 0-8.
2 Tighten
25N-m(18lbft)
WindshieldWiperArm
Procedure
1. Urseftthe
80—49385pullerin ordertoassist in theremovalofthewiperarmfromthewipermodulepivot
s a .
3 2. Removethewiperarmfromthepivotshaft.
3. Cleanthepivotshaftknurls witha softwirebrushbeforeinstallinga newwiperarm.
Special Tools
80—49385WiperArmPuller
Forequivalentregionaltools,referto Special Toolsonpage4-386.

2013
-Sonic
(US/Canada)
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(5377994)
4=376 Wipers and Washers

Rear Window Wiper Arm Replacement

2489513

Rear Window Wiper Arm Replacement

Callout Component Name
Preliminary Procedure
Usinga smallflat—bladedtool,releasethelockingtabsandlifttheendof thewiperarmnutcoverin orderto access andremove
therearwiperarm nut.
Rear WindowWiperArmNut
Caution: Referto FastenerCautiononpage 0—8.
Tighten
1ON-m(89lb in)
RearWindowWiperArm
while
2 Tip: Alignandholdtherearwindowwiperarmbladeto theedgeof theblackoutontherearliftgatewindow
tightening.

—
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Manual
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 Wipers and Washers 44377
l Windshield Wiper Blade Replacement

2500338
Windshield Wiper Blade Replacement
Callout Component Name
Preliminary Procedure
1. ServiceUpandholdthewiperarmoffthewindshieldwhenperformingthewiperbladereplacement.
Pinchthetwotabson topofthewiperblade.
Rotatethebottomedgeof thewiperblade,downward,awayfromthewiperarm.
Detachthewiperbladefromthehookendofthewindshieldwiperarm.
Carefullyreturnthewindshieldwiperarmbacktotheglass untilthenewwiperbladeis installed.
@PPN
1 WindshieldWiperBladeAssembly

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4:3 78 Wipers and Washers

Rear Window Wiper Blade Replacement

2512221

Rear Window Wiper Blade Replacement

Callout l Component Name
Preliminary Procedure
Lifttherearwindowwiperarmofftherearwindowandreleasethe rearwindowwiperbladefromtherearwindowwiperarm.
1 l RearWindowWiperBlade

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Manual
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 Wipers and Washers 4-379

Windshield Wiper Motor Replacement

2497155
Windshield Wiper Motor Replacement
Callout Component Name
Preliminary Procedure
Removethewipersystemmodule.Referto WindshieldWiperSystemModuleReplacementonpage4-381
WindshieldWiperMotorBracketScrew(Qty:2)
1 Caution: Referto FastenerCautiononpage 0-8.
Tighten
8.5N-m(75lb in)
WindshieldWiperMotor
Procedure
1. Usea wiperlinkageseparatoror similartool,separatethetransmissiondrivelinkfromthewipermotor
2 crankarmballstud.
2. Use a wiperlinkageinstalleror similartool,installthetransmissiondrivelinkontothewipermotorcrankarm
ballstud.
Tip: Applya smallamountofgreasetotheinnercupon thetransmissionlinktoaid in installation.

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(US/Canada)
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4:380 Wipers and Washers

Rear Window Wiper Motor Replacement (Hatchback)

2495878

Rear Window Wiper Motor Replacement (Hatchback)

Callout Component Name
Preliminary Procedure
1. Openandsupportthe liftgateassembly.
2. Removetherearwindowwiperarmassembly.Referto Rear WindowWiperIArmReplacementonpage4-376.
3. Removetherearliftgatetrimfinishpanel.Referto LiftgateTrimFinishPanel Replacement(Hatchback)onpage2-86.
4. Disconnecttherearwindowwipermotorelectricalconnector.
RearWindowWiperMotorBolt(Qty:3)
1 Caution: Referto FastenerCautiononpage0—8.
Tighten
9 NW(80lb in)
RearWindowWiperMotor
Procedure
2 1. Pulltherearwindowwipermotorinwardfromthe rearliftgate.
2. Releasethewipermotorpivotshaftfromtherearwindowwipermotorwindowgrommet.
3. Carefullyremovetherearwindowwipermotorfromtheliftgateinnerpanelassembly.

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 Wipers and Washers 4=381
Windshield Wiper System Module Replacement

’mfié’é’?’ \
lib—D‘AL‘ESE ,, K

2497153
Windshield Wiper System Module Replacement
Callout Component Name
Preliminary Procedures
1. Openandsupportthehoodassembly.
2. Removetheair inletgrillepanel.Referto Airlnlet GrillePanel Replacementonpage 4-374.
WindshieldWiperSystemModuleBolt(Qty:2)
Caution: Referto FastenerCautiononpage 0-8.
1 Tighten
18N-m(13lbft)
WindshieldWiperSystemModule
Procedure
2 1. Liftthewipersystemmodulefromtheplenumbrackets.
2. Disconnecttheelectricalconnectorfromthewindshieldwipermotor.
3. Removethewindshieldwipersystemmodulefromtheplenum.

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4-382 Wipers and Washers

Rear Window Wiper Motor Grommet Replacement

2510804
Rear Window Wiper Motor Grommet Replacement
Callout 1 Component Name
Preliminary Procedure
Removetherearwindowwipermotor.Referto Rear WindowWiperMotorReplacement(Hatchback)onpage4—380.
RearWindowWiperMotorGrommet
1 Tip: Applysomelubricanttotheoutsideofthegrommetuponinstallationto aid in installationthroughtheliftgate
glassopening.

2013
-Sonic
(US/Canada)
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Manual
(5377994)
 Wipers and Washers 4-«383

Moisture Sensor Cover Replacement

Windshield Outside

//—,¢:-
4’?

2?

©15th7-

2742469

Outside Moisture Sensor Cover Replacement

Windshield
Component Name
Callout
WindshieldOutsideMoistureSensor Cover
1 Procedure
Graspthe coverin thecenterandgentlyslidetothe right.

Wiper Chatter Repair

Windshield Glass Cleaning
Clean the windshield with windshield cleaner. Refer to
the electronic parts catalog or use equivalent cleaner.
The cleaner shouldnot harm the paint finishor scratch
the glass. The glass is clean when the water no longer
beads, but sheets across the entire glass surface.
Blade Element Cleaning
Wiper
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.
Some vehicles may exhibit a condition where the
windshield wipers chatter and/or wipe unevenly.
Several items may contribute to this condition. To
completely repair this condition, ALL of the items listed
shouldbe tested and repaired as necessary.
- Clean the windshield glass. Refer to Windshield
Glass Cleaning on page 4—383.
- Clean the wiper blade elements. Refer to Wiper
Blade Element Cleaning on page 4-383.
o Inspect the wiper blade element set.

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4384 Wipers and Washers
Description and Operation
Rear WiperNVasher System
Description and Operation
The rear window wiper motor is located inside the
hatchback door and is directly connected to the rear
window wiper. Ignitionvoltage is supplied to the rear
wiper motor through the wiper switch. The hatchback
rear window washer systems equipped with a separate
washer fluidpump, hose,and nozzle. Ignitionvoltage is
supplied to the washer pump through the wiper switch.
Attached to the reservoir is a washer pump, which
pumps fluidthrough a hoseto the nozzle mounted on
the hatch.
Description
WiperNVasher System
and Operation
WiperNVasher System Components
The wiper/washer system consists of the following
electrical components:
- Windshield Wiper Relay
0 Windshield Wiper Speed Control Relay
- Windshield Washer Pump Relay
. Windshield Outside Moisture Sensor
_° Windshield Washer FluidPump
- Windshield Wiper Motor
- Window Wiper/Washer Switch
- Windshield Wiper Motor Fuse
- Windshield Washer FluidPump Fuse
' Body Control Module (BCM)
- Rear Window Wiper Motor
' Rear Window Wiper Motor Fuse
- Rear Window Wiper Relay
- Rear Window Washer Pump Relay
- Rear Window Washer Pump Fuse
Windshield Wiper System
The body control module (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 of6
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, Intermittent1 thru 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. Itshouldbe 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
pullsthe 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 pullsthe
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 sidedrive, one low
sidedrive) are usedto control two external wiper motor
relays: front wiper motor on/offrelay: which provides
the wiper motor with battery power when it is activated
by the high sidedrive 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 motors on/off relay to the
motors high speed input. When left deactivated, the
normally closed contacts connect the power supplied
by the wiper motors on/offrelay to the motors low
speed input. The input usedby 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 closesto ground pulling the park signal
circuit low.
To initiate low speed operation, the BCM only energizes
the front wiper motor on/off relay. Thisallows battery
voltage from the wiper fuseto be applied through the
switched contacts of the wiper motor on/of‘frelay,
through the normally closed contacts of the wiper high/
low speed relay, to the low speed control circuit of the
windshield wiper motor.
Redundant high speed switch pass through. The BCM
provides redundant circuitry which places battery
power on its wiper motor on/offrelay outputwith
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/offrelay and the wiper
high/low speed relay. This allows battery voltage from
the wiper fuseto be applied through the switched
contacts of the wiper motor on/offrelay, through the
switched contacts of the wiper high/lowspeed relay, to
the high speed control circuit of the windshield wiper
motor.
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Parking the 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 occurswhile in a low speed
wiper mode. Thisrequiresthat 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 attemptingto park. in order to park the
wipers, the BCM monitors the park circuit until the park
switch pullsthe park circuit to ground. At this time, the
BCM willimmediately deactivate the wiper motor on/off
relay. The relay contacts willswitch back to their
normally closedposition and willapply ground to the
wiper motor power inputs through the normally closed
contacts of the wiper high/Iowrelay. Thisdeactivates
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 willcontinue to operate the motor until
the wipers reach the park position. lfthe 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. Ifthe ignition is turned OFF while the wipers are in
mid-cycle, the wipers willstop immediately, regardless
of position. The BCM willpark the wipers next time the
ignition is turned ON. . spray fluidon the rear window. The BCM Controls the
The windshield wiper system MIST operation is
identical to LOW speed operation, except that the MIST
switch is a pressand release type switch. When the
wiper switch is moved to the MIST position and
released, low speed wiper motor operation is started
and willcontinue until 1 cycle is complete. Ifthe wiper
switch is moved to the MIST position and held, the
wiper motor willoperate in the LOW speed mode until
the switch is released.
Windshield wiper intermittentoperation 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 switches
intermittent 1 thru intermittent5 settings. The wiper
operation is as follows
1. The BCM willinitiate 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
intermittentdelay switch setting.
4. When the delay time expires repeat Steps 1 and 3
until the system is turned off or taken out of
intermittentmode. Ifthe 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.
Intermittentwiper operation may be vehicle speed
sensitive. When enabled, the speed compensated
intermittentfeature causesthe intermittentwiper delay
intervals to become shorter as a function of increased
speed. As vehicle speed is reduced the intervals will
become closerto the predetermined
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Manual
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Wipers and Washers 44385
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 suppliesbattery power to
the coil of the washer pump relay. Thisenergizes the
relay, which switches battery power to the pump motor.
The BCM willalso activate continuous low speed
windshield wipesas described above. Upon
deactivation of the windshield wash control switch, the
wiper control module (BCM) shall deactivate the wash
motor and willalso park the wiper motor asdescribed
above unlessthe drip wipe feature is enabled. On some
vehicles the drip wipe feature willbe 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 seconds.
On vehicles with the Rear Wash feature a single
reversing wash motor may be utilized for both the front
and rear wash operation. in this system the wash motor
is operated in one direction to spray fluidon the front
windshield and then operated in the reverse direction to
reversing wash motor through two High Side Drive
outputs. One controls the Front Wiper Motor Relay and
one controls the Rear Wiper Relay.
Rain Sense Mode and Rain Sense
Indicator
When this feature is activated on rain senseequipped
vehicles, the wiper subsystem performs front
windshield wipesaccording to the amount of moisture
detected on the windshield. The BCM will control the
wiper motor speed, as indicated above, based on wipe
requests that it receives from a moisture sensor(rain
sensemodule) which is mechanically attached to the
windshield through a windshield mounted optic coupler.
The system uses a master/slave configuration utilizing
a local interconnect network (LIN) based serial data
communication system. The BCM is designated as the
master, while the rain sense module is designated the
slave. As the system master, the BCM usesthe LIN
serial communication bus to enable or disable rain
sensemodule operation, communicate wiper control
switch settings, and wiper motor position information to
the rain sense module. The rain sense module requests
wiper motor function, and provides the BCM with
system status and diagnostic information for diagnostic
reporting.When this feature is present, the BCM uses
the front wiper control switches intermittent1 thru
intermittent5 settings to activate the system and to act
as the automatic wiper sensitivity control. Thisallows
the driver to adjust the moisture level at which the rain
Sensor requests the BCM to automatically wipe the
windshield. The intermittent 1 setting corresponds to
the lowest sensitivity and intermittent5 the highest
sensitivity.
4:386 Wipers and Washers
Some vehicles (if calibrated) shall display an AUTO
front wiper indicator when the feature is active. This
indicator shall notify the driver of the vehicle that the
rain sensoris ready to perform automatic wiping of the
windshieldupon detection of moisture.
This indicator shall be requested when all of the
following are true:
1. Power mode is RUN.
2. If single steering column switch equipped: The
front wiper switch is SENSITIVITY1 through
SENSITIVITY5.
3. Ifdual steering column stalk equipped: The front
wiper switch stalk angle is SENSITIVITY.
The above indicator shall be turned OFF when any of
the following become true:
1. Power mode becomes OFF, CRANK or
ACCESSORY.
2. Front wiper switch is changed to OFF, MIST, LOW
or HlGH.
Rear Wiper System
On vehicles equipped with a Rear Wiper, the BCM
determines of the Rear Wipe/Wash System Mode of
Operation by monitoring the multiplexed output of the
Rear Wipe/Wash Switch. The Rear Wipe Wash Switch
uses a reference ground signal from the BCM. The
BCM provides a switched Battery pull-up for the Rear
WiperNVasher Switch output signal it receives. All the
BCM inputs are recognized as active when the Rear
Wiper Switch provides a path to the referenced ground
signal. The Rear Wiper/Washer signal received by the
BCM is the result of 3 resistors in the Rear Wiper
Switch configured as a resistor ladder network. This
signal is connected to a BCM Analog to Digital Input
which also provides a switched Battery pull-up for the
circuit. Depending on the function selected (Low,
Intermittent,Off, Wash), the Rear 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 Rear Wiper Motor Relay
and the RearWasher Relay.
The BCM Controls the single speed Rear Wiper Motor
by its Active High output to the external Rear Wiper
Motor Relay. When the BCM activates its output and
applies Battery to the coil of the relay, the relay
energizes, allowing Battery voltage from the fuseto be
applied through the switched contacts of the Rear
Wiper Motor Relay to the Rear Wiper Motors control
input. The motor then operates continuously at low
speed. The BCM doesnot control the parking of the
Rear Wiper Motor, it is selfparking. When the BCM
deactivates its output, the contacts of the Rear Wiper
Motor Relay switch back to ground which will be used
by the wiper for Dynamic Braking. The Rear Wipers
internal park switch and circuitry willsustain motor
operation until the wiper arm has returned to its Park
position.
Rear Wash
When the Body Control Module detects that the Rear
wiper/wash switch has activated the momentary Wash
switch, it activates a High Side Drive output which
suppliesBattery to the coil of the Rear Washer Pump
Relay. Thisenergizes the Relay, which switches
Battery Power to the Washer Pump Motor. The BCM
willalso activate continuous Low Speed Windshield
Wipersas described above. The BCM software will
attempt to detect a stuck Rear Wash Switch. A stuck
Rear Wash Switch condition is detected if the Rear
Wash Motor Relay Output has been continuously active
for 10 secondsor more. Upon detecting this the BCM
willfail soft the state of the Rear Wash Control to
inactive. Thisshall cause the System to perform as if
the momentary Wash control had been released.
Special Tools and Equipment
Illustration Tool Number/Description
80-49385
80-6626
KM-6626
80201912
WiperArmPuller
70147
2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Table of Contents I\
U‘II

Section 5

Brakes

Antilock Brake System ........................ 55 Disc Brakes ................................... 5-54

Specifications ..................................... 5-5
Fastener Tightening Specifications .............. 5—5
Schematic and Routing Diagrams ............... 5—5
Antilock Brake System Schematics .............. 56
Diagnostic Information and Procedures . . .. . . . .5—9
DTC 82745 ...................................... 5-9
DTC 60035, 60040, 60045, or 60050 .......... 5-11
DTC 60110 ..................................... 5-14
DTC 60131 ..................................... 5-16
DTC 60161 ..................................... 5—18
DTC 60186, 60196, or 60287 .................. 5-19
DTC 60201 ..................................... 5—21
DTC 60242 or P0856 ........................... 5-23
DTC 60277 ..................................... 5-24
DTC 6027C ..................................... 5-26
DTC 60292 ..................................... 5-27
DTC 60561 ..................................... 5—29
DTC 60568 ..................................... 5-31
DTC 6056E ..................................... 5-32
DTC 60710 ..................................... 5—33
DTC 61251 ..................................... 5-35
Symptoms —Antilock Brake System ............ 5—36
ABS Indicator Malfunction ...................... 5-36
Traction Control/Stability Control indicator
Malfunction .................................... 5-37
Repair Instructions .............................. 5-38
Antilock Brake System Automated Bleed ....... 5-38
Steering Angle Sensor Centering ............... 5-39
Electronic Brake Control Module
Replacement .................................. 539
Brake PressureModulator Valve
Replacement .................................. 5-40
Brake PressureModulator Valve Bracket
Replacement .................................. 5-44
Front Wheel Speed Sensor Replacement . . 5-44
Rear Wheel Speed SensorReplacement ....... 5-47
Vehicle Yaw Sensor Learn ...................... 5-49
Vehicle Yaw Sensor Replacement .............. 5-50
Description and Operation ...................... 5-51
ABS Description and Operation ................ 5-51
Special Tools and Equipment ................... 5-53
Specifications ................................... 5-54
Fastener Tightening Specifications ............. 554
DiscBrake Component Specifications .......... 5-54
Diagnostic Information and Procedures . . .. . . .555
Brake Rotor ThicknessMeasurement .......... 555
Brake Rotor ThicknessVariation
Measurement .................................. 5-55
Brake Rotor Surface and Wear Inspection ...... 5-56
Brake Rotor AssembledLateral Runout
Measurement .................................. 556
Brake Pad Inspection ........................... 5—58
Brake Caliper Inspection ........................ 5-58
Front Disc Brake Mounting and Hardware
Inspection ..................................... 5-59
Rear Disc Brake Mounting and Hardware
inspection ..................................... 5-60
Repair Instructions .............................. 5-61
Front Disc Brake Pads Replacement ........... 5-61
Rear Disc Brake Pads Replacement ............ 5-63
Brake Pad and Rotor Burnishing ............... 5—65
Front Brake Caliper Replacement .............. 5-65
Rear Brake Caliper Replacement ............... 5-66
Front Brake Caliper Overhaul ................... 5-69
Front Brake Caliper Bracket Replacement ...... 5—70
Rear Brake Caliper Bracket Replacement . . 5—74
Front Brake Rotor Replacement ................ 5—77
Rear Brake Rotor Replacement ................ 5-79
Front Brake Shield Replacement ............... 5-81
Rear Brake Shield Replacement ................ 5-82
Brake Rotor AssembledLateral Runout
Correction ..................................... 5—83
Brake Rotor AssembledLateral Runout
Correction —Indexing .......................... 5-83
Brake Rotor AssembledLateral Runout .
Correction - On Vehicle Lathe ................. 5-84
Brake Rotor Refinishing ........................ 5-85
Description and Operation ...................... 5-86
Disc Brake System Description and
Operation ...................................... 5-86
Special Tools and Equipment ................... 5-86

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52 Table of Contents
Drum Brakes .................................. 5—87
Specifications ................................... 5-87
Fastener Tightening Specifications ............. 5—87
Drum Brake Component Specifications ......... 5-87
Diagnostic Information and Procedures . . .. . . .5-87
Brake Drum Diameter Measurement ........... 5-87
Brake Drum Surface and Wear Inspection ...... 5-88
Drum Brake Hardware Inspection .............. 5—89
Drum Brake Adjusting Hardware Inspection 5—89
Repair Instructions .............................. 5-90
Brake Drum Replacement (J93, J94) ........... 5-90
Brake Drum Refinishing ........................ 591
Brake Shoe Replacement (J93, J94) ........... 5-92
Rear Brake Backing Plate Replacement ........ 5—95
Drum Brake Hardware Replacement
(J93, J94) ...................................... 5-97
Drum Brake Adjusting Hardware Replacement
(J93, J94) .................................... 5-100
Rear Brake Cylinder Replacement ............ 5-102
Rear Brake Cylinder Overhaul ................. 5—104
Drum Brake Adjustment ....................... 5—105
Description and Operation .................... 5—106
Drum Brake System Description and
Operation .................................... 5—106
Special Tools and Equipment ................. 5—107
Hydraulic Brakes ............................ 5—108
Specifications .................................. 5—108
Fastener Tightening Specifications ............ 5—108
Brake Component Specifications .............. 5-108
Brake System Specifications .................. 5-108
Schematic and Routing Diagrams ............ 5—108
Hydraulic Brake Schematics .................. 5-109
Diagnostic Information and Procedures . . .. . .5-110
DTC 60267 .................................... 5-110
Symptoms - Hydraulic Brakes ................. 5—111
Brake Booster Pump Motor Malfunction ....... 5—112
Brake Warning Indicator Malfunction .......... 5-114
Brake Pulsation ................................ 5-116
Brake System Noise ........................... 5—117
Braking Action Uneven - Pullsto One Side .... 5-118
Braking Action Uneven - Front to Rear . ... . . . . 5-120
Brake Pedal ExcessiveTravel ................. 5-121
Brake Pedal ExcessiveEffort .................. 5-123
Brakes Drag ................................... 5-125
Brake System Slow Release .................. 5-126
Brake FluidLoss .............................. 5-127
Disc Brake System Diagnosis ................. 5—128
Drum Brake System Diagnosis ................ 5-131
Hydraulic Brake System Diagnosis ............ 5-134
Brake Assist System Diagnosis ............... 5-138
Brake System Vehicle Road Test .............. 5-141
Brake Pedal Travel Measurement and
Inspection .................................... 5-141
Brake System Vacuum Source Test ........... 5-142
Brake System External Leak inspection ....... 5-143
Brake System InternalLeak Test .............. 5-143
Hydraulic Brake Component Operation Visual
Inspection .................................... 5-144
Brake Pipe and Hoseinspection .............. 5—145
Brake Pedal PushrodInspection .............. 5-145
Repair Instructions ............................. 5-145
Master Cylinder Reservoir Filling .............. 5-145
Master Cylinder Reservoir Replacement .... . . 5-146
Master Cylinder Replacement ................. 5-147
Master Cylinder Bench Bleeding .............. 5—150
Brake FluidLevel IndicatorSwitch
Replacement ................................. 5-150
Brake Pedal AssemblyReplacement .......... 5-151
Brake PressureModulator Valve Pipe
Replacement ......................... . ....... 5-156
Brake Pipe Replacement ...................... 5-158
Front Brake Hose Replacement ............... 5162
Rear Brake Hose Replacement (Body to Axle -
Drum Brake) ................................. 5-164
Rear Brake Hose Replacement (Body to Axle -
Disc Brake) ................................... 5—165
Rear Brake Hose Replacement (Axle to
Caliper) ...................................... 5—167
Hydraulic Brake System Bleeding
(Pressure).................................... 5—169
Hydraulic Brake System Bleeding (Manual) ... 5—170
Hydraulic Brake System Flushing............. 5-172
PowerVacuum Brake Booster
Replacement ................................. 5-173
Power Brake Booster Vacuum Check Valve
and Hose Replacement ...................... 5—175
Power Brake Booster Vacuum Sensor
Replacement ................................. 5-176
Power Brake Booster Pump Replacement 5178
Description and Operation .................... 5-180
Brake Assist System Description and
Operation .................................... 5—180
Brake Booster Vacuum AssistDescription and
Operation .................................... 5—180
Brake Warning System Description and
Operation .................................... 5-181
Hydraulic Brake System Description and
Operation .................................... 5-181
Special Tools and Equipment ................. 5-181
Park Brake ................................... 5-182
Specifications .................................. 5—182
Fastener Tightening Specifications ............ 5—182
Diagnostic Information and Procedures . . .. . .5—182
Symptoms —Park Brake ....................... 5182
Park Brake Will Not Hold or Release .......... 5182
Park Brake System Diagnosis (Drum
Brake) ........................................ 5183
Park Brake System Diagnosis (DiscBrake) 5—185
Park Brake Hardware inspection .............. 5—186
2013
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Manual
(5377994)
 Table of Contents 53

Repair Instructions ............................. 5—186 Parking Brake Cable Replacement (Disc

5—186 Brake) ........................................ 5—192
Parking Brake Lever Replacement ............
Parking Brake indicator Switch Parking Brake Adjustment (Drum Brake) . . 5-197
Replacement ................................. 5—188 Parking Brake Adjustment (DiscBrake) . . . 5-198
Description and Operation .................... 5-199
Parking Brake Cable Replacement (Drum
Brake) ........................................ 5-189 Park Brake System Description and
Operation .................................... 5-199

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Manual
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52 Table of Contents

BLANK

(US/Canada)
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2013 (5377994)
Manual
Service
 Antilock Brake System 5=5

Antilock Brake System

Specifications

Fastener Tightening Specifications

Specification
Application Metric English
BrakePipe Fitting 18N-m 13lbft
BrakePressure ModulatorValveBolt 11N-m 97lb in
BrakePressure ModulatorValveBracketNut 17N-m 12lbft
ElectronicBrakeControlModuleBolt 3 N-m 26 lb in
RearWheelSpeedSensor ConnectorCoverNut 2 N-m 18lb in
WheelSpeedSensorBolt— Frontand Rear 8 N-m 71lb in
Yaw SensorNut 9 N'm 80 lbin

Schematic and Routing Diagrams

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
 _ _ _

5=6 Antilock Brake System _

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Sonic (5377994)
Manual
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2013
—
Sonic
(US/Canada)
Service
Manual
(5377994)
5=8 Antilock Brake
o System

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2013 Service
(US/Canada) (5377994)
Manual
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 Antilock Brake System 52)

Diagnostic Information and Procedures

DTC 82745

Diagnostic Instructions
- Perform the Diagnostic System Check - Vehicle
on page 6-66 prior to usingthis diagnostic
procedure.
- Review Strategy Based Diagnosis on page 6—58
for an overview of the diagnostic approach.
- Diagnostic Procedure Instructions on page 6-59
provides an overview of each diagnostic category.
DTC Descriptors
DTC 82745 02: Traction Control Switch Circuit Short to Ground
DTC 82745 71: Traction Control Switch Circuit invalid Data
Diagnostic Fault Information

Open/High Signal
Circuit Short to Ground Resistance Short to Voltage Performance
. 8274502,
3274571 1 1 8274571
Sgnal
Ground _ 1 _ _
1.TractionControlSwitchinoperative

CircuitlSystem Description Conditions for Clearing the DTC

The Body Control Module monitors the signal circuit - The conditions for setting the DTC are no longer
from the Traction Control Switch. When the Traction present.
Control Switch is pressedonce, the Body Control - The Electronic Brake Control Module clears the
Module willrequest the Electronic Brake Control history DTC when a current DTC is not detected in
Module via serial data to disable the traction control. 40 consecutive drive cycles.
When the Traction Control Switch is pressedand held
for five seconds,the Body Control Module willrequest Reference Information
the Electronic Brake Control Module to disable the
electronic stability control. The Electronic Brake Control Schematic Reference
Module willrequest the InstrumentCluster via serial Antilock Brake System Schematics on page 5-6
data to turn the Traction Control Off and the Stability
Control Off indicator ON to notify the driver of the Connector End View Reference
deactivation. Component Connector End Viewson page 11—269'
Conditions for Running the DTC Description and Operation
- Ignition ON. ABS Description and Operation on page 551
- Ignitionvoltage is greater than 8 V.
Electrical Information Reference
Conditions for Setting the DTC
- Circuit Testing on page 11—526
32745 02 - Connector Repairs on page 11—548
The Body Control Module detects a short to ground on - Testing for IntermittentConditions and Poor
the signal circuit. Connections on page 11-531
B2745 71 - Wiring Repairs on page 11—537
The Body Control Module detects an erratic signal or Scan Tool Reference
invalid serial data from the Traction Control Switch.
Control Module References on page 6-3 for scan tool
Action Taken When the DTC Sets information
- The Electronic Brake Control Module stores
the DTC.
- The Electronic Brake Control Module disables the
traction and the stability control for the duration of
the ignition cycle.

(US/Canada)
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2013 (5377994)
Manual
Service
5,10 Antilock Brake System

CircuitlSystem Verification 6. Verify the scan tool Traction Control Switch

parameter is Active.
1. lgnition ON :> If not Active
2. Verify the InstrumentCluster Traction Control
indicator turns ON and OFF when commanding the 6.1. lgnition OFF, disconnect the X2 harness
instrument Cluster All indicators ON and OFF with connector at the K9 Body Control Module,
a scan tool. ignition ON.
6.2. Test for lessthan 1 V between the signal
If the indicator does not turn 0N and OFF circuit and ground.
Replace the P16 InstrumentCluster :> If 1 V or greater, repair the short to voltage on
If the indicator turns ON and OFF the circuit.
Verify the scan tool Traction Control Switch U if lessthan 1 V
parameter changes between Active and Inactive 6.3. Test for lessthan 2 Q in the signal circuit and
while pressing and releasing the traction control to end.
switch.
:> If2 Q or greater, repair the openlhigh resistance
If the parameter does not change in the circuit.
Refer to CircuitlSystem Testing. :> Iflessthan 2 Q, replace the K9 Body Control
1i If the parameter changes Module.
4. Ali OK. U If Active
CircuitlSystem Testing 7. Test or replace the S48E Multifunction
Switch-Center Console.
1. lgnition OFF, scan tool disconnected, and all
vehicle systems OFF, disconnect the harness Component Testing
connector at the S48E Multifunction Switch—Center 1. lgnition OFF, disconnect the harness connector at
Console. Itmay take up to 2 minutes for all vehicle the S48E Multifunction Switch—CenterConsole.
systems to power down.
2. Test for infinite resistance between the signal
Test for lessthan 10 0 between the ground circuit terminal 5 and the ground terminal 9 with the switch
terminal 9 and ground. in the open position.
If 10 Q or greater If less than infinite resistance
2.1. lgnition OFF
Repiace the S48E Multifunction Switch—Center
2.2. Test for lessthan 2 Q in the ground circuit end Console.
to end.
If infinite resistance
=>If2 Q or greater, repair the openlhigh resistance
in the circuit. Test for lessthan 2 0 between the signal terminal 5
and the ground terminal 9 with the switch in the
:> Iflessthan 2 Q, repair the openlhigh resistance closed position.
in the ground connection.
If 2 Q or greater
If less than 10 Q
Replace the S48E Multifunction Switch—Center
9’ lgnition ON. Console.
Verify the scan tool Body Control Module Traction u If less than 2 (2
Control Switch parameter is Inactive.
4. All OK.
If not Inactive
4.1. lgnition OFF, disconnect the X2 harness Repair Instructions
connector at the K9 Body Control Module. Perform the Diagnostic Repair Verification on
4.2. Test for infinite resistance between the signal page 6-92 after completing the repair.
circuit terminal 5 and ground. Front Floor Console Multifunction Switch
=>Ifless than infinite resistance, repair the short to Replacement on page 8-105.
ground on the circuit. Control Module References on page 6—3for Body
:> If infinite resistance, replace the K9 Body Control Module, Electronic Brake Control Module
Control Module. or InstrumentCluster replacement, programming
and setup
If Inactive
Install a 3 A fused jumperwire between the signal
circuit terminal 5 and the ground circuit terminal 9.

(US/Canada)
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2013 (5377994)
Manual
Service
 Antilock Brake System a=i'l

DTC 00035, 00040, 00045, or 00050

Diagnostic Instructions
Vehicle
- Perform the Diagnostic System Check -
on page 6-66 priorto using this diagnostic
procedure.
6—58
- Review Strategy Based Diagnosis on page
for an overview of the diagnostic approach.
6—59
- Diagnostic Procedure Instructions on page
provides an overview of each diagnostic category.

DTC Descriptors
Low Voltage/Open
DTC 00035 06: Left Front Wheel Speed Sensor
Circuit Signal Erratic
DTC 00035 0F: Left Front Wheel Speed Sensor
Circuit Signal Low Signal Amplitude
DTC 00035 18: Left Front Wheel Speed Sensor
Not Plausible
DTC 00035 5A: Left Front Wheel Speed Sensor
Low Voltage/Open
DTC 00040 06: Right Front Wheel Speed Sensor
Circuit Signal Erratic
DTC 00040 0F: Right Front Wheel Speed Sensor
Circuit Signal Low Signal Amplitude
DTC 00040 18: Right Front Wheel Speed Sensor
Not Plausible
DTC 00040 5A: Right Front Wheel Speed Sensor
Speed Sensor Low Voltage/Open
DTC 00045 06: Left Rear Wheel
Circuit Signal Erratic
DTC 00045 0F: Left Rear Wheel Speed Sensor
Circuit Signal Low Signal Amplitude
DTC 00045 18: Left Rear Wheel Speed Sensor
Not Plausible
DTC 00045 5A: Left Rear Wheel Speed Sensor
Sensor Low Voltage/Open
DTC 00050 06: Right Rear Wheel Speed
Circuit Signal Erratic
DTC 00050 0F: Right Rear Wheel Speed Sensor
Circuit Signal Low Signal Amplitude
DTC 00050 18: Right Rear Wheel Speed Sensor
Plausible
DTC 00050 5A: Right Rear Wheel Speed Sensor Not
Diagnostic Fault Information

OpenIHigh Signal
Short to Ground Short to Voltage Performance
Resistance
Circuit
00035 GP,
0003506 00035 18,
0003506 00035 5A
Left FrontSensor Ignition
000350F,
0003506 0003506 00035 18,
00035 06 00035 5A
LeftFrontSensor Signal
00040 0F,
0004006 00040 18,
00040 06 00040 5A
RightFrontSensor Ignition
00040 0F,
0004006 00040 06 00040 18,
0004006 00040 5A
RightFrontSensor Signal
00045 OF,
0004506 00045 18,
0004506 00045 5A
LeftRear Sensor lgnition
00045 OF,
‘ 0004506 00045 06 00045 18,
0004506 00045 5A
LeftRear Sensor Signal
00050 0F,
0005006 00050 18,
0005006 00050 5A
RightRear Sensor lgnition
00050 OF,
0005006 00050 06 00050 18,
0005006 00050 5A
Right Rear SensorSignal

(US/Canada)
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2013 (5377994)
Manual
Service
b=l2 Antilock Brake System
Component
. Physicaldamage
- Debrison thewheelspeedsensoror theencoderring
. Looseor wornwheelbearing
WheelSpeed Sensor ' Looseor improperlymountedsensor
. Air gapbetweenthewheelspeedsensorandthe
encoderringtoolarge
- Waterintrusionin thewiringharness
CircuitlSystem Description
The wheel speeds are detected by active wheel speed
sensorsand encoder rings. The encoder ring consists
of permanent magnets. Each wheel speed sensor
receives ignition voltage from the electronic brake
control module and provides an alternating current
square wave signal to the electronic brake control
module. As the wheel spins,the electronic brake
control module usesthe frequency of the square wave
signal to calculate the wheel speed.
Conditions for Running the DTC
C0035 06, C0040 06, C0045 06, or C0050 06
- lgnition ON.
- lgnition voltage is greater than 8 V.
C0035 0F, C0040 0F, 00045 0F, or C0050 0F
- IgnitionON.
- lgnition voltage is greater than 8 V.
- Vehicle speed is greater than 20 km/h (12 MPH).
C003518, C004018, C004518, or C005018
- Ignition ON.
- lgnition voltage is greater than 8 V.
- No other wheel speed circuit DTCs are set.
° At least two other wheel speed circuits are not
0 km/h (0 MPH).
C0035 5A, C0040 SA, 00045 5A, or C0050 5A
- lgnition ON.
- lgnition voltage is greater than 8 V.
. The vehicle speed is greater than 20 km/h
(12 MPH).
Conditions for Setting the DTC
00035 06, 00040 06, 00045 06, or 00050 06
- A short to voltage is detected on a wheel speed
signal.
- A short to ground or an openlhigh resistance is
detected on a wheel speed signal.
- A short to ground or an openlhigh resistance is
detected on a wheel speed ignition circuit.
C003518, C004018, C004518, or C005018
- One wheel speed is less than 2 km/h (1.2 MPH).
. The remaining wheel speeds are greater than
10 km/h (62 MPH) for 0.154 seconds.
‘ The difference between the remaining wheel
speeds are lessthan 4 km/h (2.5 MPH) from each
other for more than 2 minutes.
DTC Symptom
Condition Bytes i
J
‘
0F,18,or 5A
00035 0F, 00040 0F, 00045 0F, or 00050 OF
The electronic brake control module detected a rapid
variation in the wheel speed. The wheel speed changes
20 km/h (12 MPH) or more in 0.7 seconds. The change
must occur 56 times with no more than 0.7 seconds
between occurrences.
C0035 5A, C0040 5A, C0045 5A, or C0050 5A
The difference between fastest and slowest wheel
speed is greater than 60% for more than 2 minutes.
Action Taken When the DTC Sets
' The ABS indicator turns ON.
- The traction/stabllity control indicator turns ON,
ifequipped with electronic stability control.
. The electronic brake distribution does not function
optimally with multiple wheel speed sensor
DTCs set.
- The electronic brake control module disables the
ABS, the traction control and the stability control
for the duration of the ignition cycle.
Conditions for Clearing the DTC
- The condition for setting the DTC is no longer
present.
- The history DTC willclear after 40 consecutive
fault-free ignition 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.
- Inspect the wheel speed sensor for contamination,
physical damage, and correct installation.
- Iftwo or more wheel speed sensorsare
inoperative, diagnose each wheel speed sensor
individually.
- If any of the symptom codes 0F, 18 or 5A are set,
refer to the Diagnostic Fault Informationtable for
possiblemechanical 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 signsof water intrusion.
Reference Information
Schematic Reference
Antilock Brake System Schematics on page 5-6
Connector End View Reference
Component Connector End Viewson page 11-269
(US/Canada)
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2013 (5377994)
Manual
Service

Description and Operation
ABS Description and Operation on page 5-51
Electrical Information Reference
- Circuit Testing on page 11—526
~ Connector Repairs on page 11—548
° Testing for IntermittentConditions and Poor
Connections on page 11-531
- Wiring Repairs on page 11—537
Scan Tool Reference
Control Module References on page 6-3 for scan tool
information
CircuitlSystem Verification
1. Test drive the vehicle in a straight line at a speed
greater than 40 kmlh (25 MPH).
2. Verify all scan tool Wheel Speed Sensor
parameters are within 4 km/h (2.5 MPH) of each
other.
=>If any parameter is not within 4 kmlh (2.5 MPH)
of each other
Refer to CircuitlSystem Testing.
ii If each parameter is within 4 km/h (2.5 MPH) of
each other
3. All OK.
CircuitlSystem Testing
1. lgnition OFF and all vehicle systems OFF,
disconnect the harness connectors at the
appropriate 85 Wheel Speed Sensor and the
harness connector at the K17 Electronic Brake
Control Module, ignition ON.
2. Test for lessthan 1 V between the appropriate
K17 Electronic Brake Control Module harness
connector terminals listed below and ground:
- BSLF Left Front Wheel Speed Sensor -
terminal 34 and terminal 21
' B5RF Right Front Wheel Speed Sensor -
terminal 18 and terminal 31
' B5LR Left Rear Wheel Speed Sensor -
terminal 33 and terminal 20
- BSRR Right Rear Wheel Speed Sensor -
terminal 19 and terminal 32
=>If 1 V or greater
Repair the short to voltage on the circuit.
U If less than 1 V
9° lgnition OFF.
4. Test for infinite resistance between the
K17 Eiectronic Brake Control Module harness
connector terminals listed below and ground:
' B5LF Left Front Wheel Speed Sensor-
terminal 34 and terminal 21
- BSRF Right Front Wheel Speed Sensor —-
terminal 18 and termina131
(US/Canada)
-Sonic
2013 (5377994)
Manual
Sen/ice
Antilock Brake System 5u’l3
- B5LR Left Rear Wheel Speed Sensor -
terminal 33 and terminal 20
- BSRR Right Rear Wheel Speed Sensor -
terminal19 and terminal 32
=>If less than infinite resistance
Repair the short to ground on the circuit.
U If infinite resistance
5. Test for lessthan 2 0 between the B5 Wheel
Speed Sensor harness connector terminal 1 and
the K17 Electronic Brake Control Module harness
connector terminal listed below:
- B5LF Left Front Wheel Speed Sensor -
terminal 34
- B5RF Right Front Wheel Speed Sensor -
terminal 18
. BSLR Left Rear Wheel Speed Sensor ~
terminal 33
- B5RR Right Rear Wheel Speed Sensor -
terminal 19
=>lf 2 Q or greater
Repair the open/high resistance in the circuit.
it If less than 2 Q
6. Test for less than 2 0 between the B5 Wheel
Speed Sensor harness connector terminal 2 and
the K17 Electronic Brake Control Module harness
connector terminal listed below:
- B5LF Left Front Wheel Speed Sensor -
terminal 21
' BSRF Right Front Wheel Speed Sensor -
terminal 31
- B5LR Left Rear Wheel Speed Sensor -
terminal 20
. B5RR Right Rear Wheel Speed Sensor -
terminal 32
=>lf 2 Q or greater
Repair the openlhigh resistance inthe circuit.
ii If less than 2 Q
7. Replace the B5 Wheel Speed Sensor.
8. 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.
ii If the DTC does not set
9. All OK.
Repair Instructions
Perform the Diagnostic Repair Verification on
page 6—92after completing the repair.
- Front Wheel Speed Sensor Replacement on
page 5—44
0 Rear Wheel Speed Sensor Replacement on
page 5-47
- Control Module References on page 6—3for
Electronic Brake Control Module replacement,
programming and setup
5-14 Antilock Brake System

DTC 00110

Diagnostic Instructions
- Perform the Diagnostic System Check —Vehicle
on page 6—66prior to usingthis diagnostic
procedure.
- Review Strategy Based Diagnosison page 6-58
for an overview of the diagnostic approach.
- Diagnostic Procedure Instructions on page 6-59
provides an overview of each diagnostic category.
DTC Descriptors
DTC C0110 04: Pump Motor Circuit Open
DTC C0110 06: Pump Motor Circuit Low Voitage/Open
DTC C0110 61: Pump Motor Stuck
Diagnostic Fault Information

. . Open/High Signal
Performance
Circwt Short to Ground Resistance Short to Voltage

B+Terminal1 0020100 0020100 — -

. 0011004,
0011006 # -
GroundTermina|13 —

GroundTerminal38 — U0121 -— -

Component Condition DTCs

- Wear
PumpMotor 0 Damage 0011061
~Lock

CircuitlSystem Description Conditions for Setting the DTC

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 ABS operation is required the
electronic brake control module activates the pump
motor relay and battery voltage is provided to the pump
motor.
Conditions for Running the DTC
C0110 04 or C0110 06
lgnition ON.
00110 61
' The vehicle speed is greater than 20 km/h
(13 MPH), and brake is not applied.
- The test is initiated once per ignition cycle, when
the vehicle speed is greater than 15 km/h (9 MPH),
and a fault was set on the last ignition cycle.
00110 04 or 00110 06
- The ground circuit is open, and the feedback
voltage is greater than 5 V for 0.5 seconds,the
pump is not activated.
- The electronic brake control module detects a low
voltage in the pump motor supplycircuit when the
feedback voltage is lessthan 5 V for greater than
500 ms, and the pump motor is not activated.
00110 61
The pump motor continues to rotate briefly after
deactivation creating a feedback voltage. The
electronic brake control module sets the DTC if the
measured feedback voltage indicates a binding or
stalled pump motor.
Action Taken When the DTC Sets
' The ABS indicator turns ON.
- The traction/stabilitycontrol indicator turns ON,
if equipped with electronic stability control.
- The electronic brake control module disables the
ABS, the traction control and the electronic
stability control for the duration of the ignition
cycle.

—
2013 (US/Canada)
Sonlc (5377994)
Manual
Service
 Antilock Brake System 545

Conditions for Clearing the DTC 2 Iflessthan 2 Q, repair the openlhigh resistance
inthe ground connection.
- The condition for setting the DTC is no longer
present. U If less than 10 Q
- The history DTC willclear after 40 consecutive 9° ignition ON.
fault—freeignition cycles have occurred. 4. Verify a test lamp illuminates between the B+
circuit terminal 1 and ground.
Reference Information
=>If the test lamp does not illuminate and the
Schematic Reference circuit fuse is good
Antilock Brake System Schematics on page 5-6 4.1. IgnitionOFF.
4.2. Test for less than 2 Q in the B+ circuit end
Connector End View Reference to end.
Component Connector End Viewson page 11-269 =>If2 Q or greater, repairthe openlhigh resistance
Description and Operation in the circuit.
=>Iflessthan 2 Q, verify the fuseis not open and
ABS Description and Operation on page 5—51 there is voltage at the fuse.
Electrical Information Reference =>If the test lamp does not illuminate and the
- Circuit Testing on page 11-526 circuit fuse is open
4.1. IgnitionOFF.
- Connector Repairs on page 11—548
4.2. Test for infinite resistance between the B+
- Testing for IntermittentConditions and Poor
circuit and ground.
Connections on page 11-531
' Wiring Repairs on page 11-537 ::>Ifless than infinite resistance, repair the short to
ground on the circuit.
Scan Tool Reference =>If infinite resistance, replace the Q5 Brake
Control Module References on page 6-3 for scan tool Pressure Modulator.
information U If the test lamp illuminates
CircuitlSystem Verification 9" Replace the 05 Brake Pressure Modulator.
1. lgnition ON 6. Verify the DTC does not set while operating the
vehicle within the Conditions for Running the DTC.
2. Verify the ABS pump motor turns ON and OFF
when commanding the ABS Pump Motor ON and :> If the DTC sets
OFF with a scan tool. Replace the K17 Electronic Brake Control
=>If the pump motor does not turn ON and OFF Module.
Refer to CircuitlSystem Testing. U If the DTC does not set
U If the pump motor turns ON and OFF 7. All OK.
3. All OK. Repair Instructions
CircuitlSystem Testing Perform the Diagnostic Repair Verification on
page 6-92 after completing the repair.
1. IgnitionOFF and all vehicle systems OFF,
disconnect the harness connector at the - Brake Pressure Modulator Valve Replacement on
K17 Electronic Brake Control Module. Itmay take page 5-40
up to 2 min for all vehicle systems to power down. - Control Module References on page 6—3for
2. Test for lessthan 10 0 between the ground circuit Electronic Brake Control Module replacement,
terminals listed below and ground: programming and setup
- Terminal 13
-_ Terminal 38
=>If 10 Q or greater
2.1. lgnition OFF
2.2. Test for less than 2 Q in the ground circuit end
to end.
=>If2 Q or greater, repair the open/high resistance
in the circuit.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
5:16 Antilock Brake System

DTC 00131

Diagnostic Instructions
- Perform the Diagnostic System Check - Vehicle
on page 6—66prior to usingthis diagnostic
procedure.
. Review Strategy Based Diagnosison page 6-58
for an overview of the diagnostic approach.
. Diagnostic Procedure Instructions on page 6-59
provides an overview of each diagnostic category.
DTC Descriptors
DTC C0131 00: Traction Control System Pressure Circuit Malfunction
DTC C0131 5A: Traction Control System Pressure Circuit Not Plausible

CircuitlSystem Description Reference Information

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 sendsa 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 informationfor vehicle stability
control.
Conditions for Running the DTC
IgnitionON.
Conditions for Setting the DTC
00131 00
The electronic brake control module detects the brake
pressure is out of specifiedrange.
C0131 5A
The electronic brake control module does not detect
that the master cylinder pressure changed after driving
the vehicle at a speed greater than 40 kmlh (25 MPH)
and performing three brake stops.
Action Taken When the DTC Sets
- The traction/stability control indicator turns ON.
0 The electronic brake control module disablesthe
traction/stabiiity or the duration of the ignition
cycle, and the ABS remains functional.
Conditions for Clearing the DTC
. The condition for setting the DTC is no longer
present.
. The history DTC willclear after 40 consecutive
fauIt-freeignition cycles have occurred.
Diagnostic Aids
Diagnose all other stop lamp DTCs or Symptoms prior
to performing this diagnostic procedure.
Schematic Reference
' Antilock Brake System Schematics on page 5-6
- Exterior Lights Schematics on page 4-85
Connector End View Reference
Component Connector End Viewson page 11-269
Description and Operation
ABS Description and Operation on page 5-51
Electrical Information Reference
- Circuit Testing on page 11—526
~ Connector Repairs on page 11-548
- Testing for IntermittentConditions and Poor
Connections on page 11—531
- WiringRepairs on page 11—537
Scan Tool Reference
Control Module References on page 6—3for scan tool
information
CircuitlSystem Verification
1. IgnitionON.
2. Verify the stop lamps turn ON and OFF while
applying and releasing the brake pedal.
:> If the stop lamps do not turn ON and OFF
Refer to Symptoms - Lighting on page 4-149.
U If the stop lamps turn ON and OFF
3. Verify the Brake Pedal Position Sensor or the
brake pedal are not bindingcausing residual brake
pressure to be detected, while the brake lights
operate properly.
=>If a condition is found
Repair or replace the appropriate component.
U If a condition is not found

—
2013 (US/Canada)
Sonic (5377994)
Manual
Service
 Antilock Brake System 5-17

4. Verify the scan tool Brake Pressure Sensor Repair Instructions

parameter Changes from OV to 1V when the brake Perform the Diagnostic Repair Verification on
pedal is applied. page 6-92 after completing the repair.
=>If the Brake Pressure Sensor parameter does ' Brake Pressure Modulator Valve Replacement on
notchange page 5—40
4.1. Replace the Q5 Brake Pressure Modulator. ~ Control Module References on page 6—3for
4.2. Verify the DTC does not setwhile operating Electronic Brake Control Module replacement,
the vehicle within the Conditions for Running programming and setup
the DTC.
=>if the DTC sets, replace the K17 Electronic
Brake Control Module.
U Ifthe DTC does not set.
4.3. All OK.
U If the Brake Pressure Sensor parameter
changes
5. All OK.

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
5=‘l8 Antilock Brake System

DTC 00161

Diagnostic Instructions
- Perform the Diagnostic System Check - Vehicle
on page 6—66prior to usingthis diagnostic
procedure.
- Review Strategy Based Diagnosison page 6-58
for an overview of the diagnostic approach.
- Diagnostic Procedure Instructions on page 6-59
provides an overview of each diagnostic category.
DTC Descriptors
DTC 00161 5A: Antilock Brake System Brake Switch Not Plausible
DTC 00161 71: Antilock Brake System Brake Switch Invalid Data

CircuitlSystem Description Reference Information

When the brake pedal is applied, the body control Schematic Reference
module sendsa serial data message to the electronic
brake control module in reference to the brake pedal Antilock Brake System Schematics on page 5-6
positions.The electronic brake control module
compares the correlation between the brake pedal Connector End View Reference
position and the amount of brake pressure it senses Component Connector End Viewson page 11-269
from the brake pressure sensor,which is internal to the
brake pressure modulator. Itusesthis information to Description and Operation
control the vehicle during an stability control event. ABS Description and Operation on page 551
Conditions for Running the DTC Electrical Information Reference
- ignition ON. - Circuit Testing on page 11-526
- Ignitionvoltage is greater than 8 V. - Connector Repairs on page 11-548
Conditions for Setting the DTC - Testing for IntermittentConditions and Poor
Connections on page 11—531
- The electronic brake control module detects the
brake pedal is not applied when the brake ' WiringRepairs on page 11-537
pressure is greater 15 bar (218 PSI) for 3 seconds. Scan Tool Reference
' The electronic brake control module does not
detect that the stop lamp switch signal changed Control Module References on page 6—3for scan tool
after drivingthe vehicle at a speed greater than information
40 km/h (25 MPH) and performing three brake CircuitlSystem Verification
stops.
1. lgnition ON.
Action Taken When the DTC Sets 2. Verify the stop lamps turn ON and OFF while
- The traction/stabilitycontrol indicator offturns ON, applying and releasing the brake pedal.
if equipped with electronic stability control. =>If the stop lamps do not turn ON and OFF
- The electronic brake control module disablesthe Refer to Symptoms —Lighting on page 4-149.
traction/stabilityfor the duration of the ignition
cycle, and the ABS remains functional. U If the stop lamps turn ON and OFF
3. Verify the Brake Pedal Position Sensoror the
Conditions for Clearing the DTC brake pedal are not bindingcausing residual brake
- The condition for setting the DTC is no longer pressure to be detected, while the brake lights
present. operate properly.
- The history DTC willclear after 40 consecutive =>lfa condition is found
fault—freeignition cycles have occurred. Repair or replace the appropriate component.
Diagnostic Aids U If a condition is not found
- DTC 00161 may set if the brake pedal is applied 4. All OK.
while accelerating.
Repair Instructions
- Diagnose all other stop lamp DTCs or Symptoms
prior to performing this diagnostic procedure. Perform the Diagnostic Repair Verification on
page 6-92 after completing the repair.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Antilock Brake System 5:1 9

DTC 00186, 00196, or 00287

Diagnostic Instructions
' Perform the Diagnostic System Check —Vehicle
on page 6—66prior to usingthis diagnostic
procedure.
- Review Strategy Based Diagnosison page 6—58
for an overview of the diagnostic approach.
0 Diagnostic Procedure Instructions on page 6—59
provides an overview of each diagnostic category.
DTC Descriptors
DTC 00186 5A: Lateral Acceleration Sensor Signal Not Plausible
DTC 00186 71: Lateral Acceleration Sensor Signal Invalid Data
DTC 00196 5A: Yaw Rate Circuit Not Plausible
DTC 00196 71: Yaw Rate Circuit Invalid Data
DTC 00287 5A: Longitudinal Acceleration Sensor Circuit Not Plausible
DTC 00287 71: Longitudinal Acceleration Sensor Circuit Invalid Data

Diagnostic Fault Information

Opeanigh Signal
Circuit Short to Ground Resistance Short to Voltage Performance
12V Reference U0125 U0125 —- -
Ground — U0125 — -

CircuitlSystem Description Action Taken When the DTC Sets

The Lateral Accelerometer and the Yaw Rate Sensors - The Traction/stability Control indicator turns ON.
are combined into one sensorcalled the Muiti—axis - The Electronic Brake Control Module disablesthe
Acceleration Sensor. The Eiectronic Brake Control electronic stability control system for the duration
Module supplies12 V reference to the Multi-axis of the ignition cycle.
Acceleration Sensor. The Multi-axis Acceleration
Sensor communicates with the Electronic Brake Conditions for Clearing the DTC
Control Module via serial data. The module activates ' The condition for setting the DTC is no longer
the stability control function depending on Multi-axis present.
Acceleration Sensor input.
- The history DTC willclear after 40 consecutive
Conditions for Running the DTC fauIt—freeignition cycles have occurred.
IgnitionON. Reference Information
Conditions for Setting the DTC Schematic Reference
00186 5A, 00186 71, 00196 5A, or 00196 71 Antilock Brake System Schematics on page 5-6
' The Multi—axisAcceleration Sensor reports an Connector End View Reference
internal failure.
- The Multi-axis Acceleration Sensor learned the Component Connector End Viewson page 11—269
wrong offset value. Description and Operation
- incorrectly mounted Multi-axis Acceleration
Sensor. ABS Description and Operation on page 551
Electrical Information Reference
00287 5A
The Longitudinal Acceleration Signal may not be - Circuit Testing on page 11-526
plausible with the vehicle speed. - Connector Repairs on page 11-548
00287 71 - Testing for IntermittentConditions and Poor
Connections on page 11-531
The Electronic Brake Control Module received an
invalid Longitudinal Acceleration Signal. 0 WiringRepairs on page 11-537
Scan Tool Reference
Control Module References on page 6-3 for scan tool
information

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
5:20 Antilocx Brake System

CircuitlSystem Testing 6.2. Test for infinite resistance between the 12 V

1. IgnitionON.
2. Verify that no communication DTCs are set.
z) If any communication DTCs are set
Refer to Diagnostic Trouble Code (DTC) List -
Vehicle on page 6-69.
If no communication DTCs are set
IgnitionOFF, scan tool disconnected, and all
vehicle systems OFF, disconnect the harness
connector at the B119 Multi-axis Acceleration
Sensor. Itmay take up to 2 minutes for all vehicle
systems to power down.
. Test for less than 10 0 between the ground circuit
terminal 6 and ground.
If 10 Q or greater
4.1. IgnitionOFF
4.2. Test for lessthan 2 Q in the ground circuit end
to end.
=>If2 Q or greater, repair the openlhigh resistance
in the circuit.
=>if lessthan 2 Q, repair the openlhigh resistance
in the ground connection.
If less than 10 Q
.01 lgnition ON.
Verify that a test lamp illuminates between the 12 V
reference circuit terminal 5 and ground.
If the test lamp does not illuminate
6.1. IgnitionOFF, disconnect the harness
connector at the K17 Electronic Brake Control
Module.
reference circuit and ground.
=>Iflessthan infinite resistance, repair the short to
ground on the circuit.
U If infinite resistance
6.3. Test for lessthan 2 Q in the 12 V reference
circuit end to end.
=>If2 Q or greater, repair the openlhigh resistance
in the circuit.
:> Ifless than 2 Q, replace the K17 Electronic
Brake Control Module.
U If the test lamp illuminates
." Replace the B119 Multi-axis Acceleration Sensor.
8. Verify the DTC does not set while operating the
vehicle within the Conditions for Running the DTC.
2:»If the DTC sets
Replace the K17 Electronic Brake Control
Module.
U If the DTC does not set
9. All OK.
Repair Instructions
Perform the Diagnostic Repair Verification on
page 6—92after completing the repair.
- Vehicle Yaw Sensor Replacement on page 5-50
. Control Module References on page 6-3 for
Electronic Brake Control Module replacement,
programming and setup

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Antilock Brake System 5221

DTC 00201

Diagnostic Instructions
- Perform the Diagnostic System Check - Vehicle
on page 6—66prior to usingthis diagnostic
procedure.
- Review Strategy Based Diagnosison page 6—58
for an overview of the diagnostic approach.
0 Diagnostic Procedure Instructions on page 6-59
provides an overview of each diagnostic category.
DTC Descriptor
DTC 00201 00: Antilock Braking System Enable Relay Primary Circuit

. . Open/High Signal
Performance
CII‘CUIt Short to Ground Resistance Short to Voltage

B+Terminal1 0020100 0020100 — —--

. 0011004,
0011006 — -
GroundTermina|13 ——

GroundTerminal38 — U0121 —— -

CircuitlSystem Description Connector End View Reference

Battery positive voltage is supplied to the electronic Component Connector End Viewson page 11-269
brake control module at all times through a 40 A fuse
Description and Operation
located in the underhood fuse block. The electronic
brake control module usesthis voltage to power the ABS Description and Operation on page 5-51
pump motor.The pump motor is an integral part of the
brake pressure modulator,while the pump motor relay Electrical Information Reference
is integral to the electronic brake control module. The Circuit Testing on page 11-526
pump motor relay is not engaged during normal system
operation. When the ABS, traction/stabiiityoperation is Connector Repairs on page 11-548
required the electronic brake control module activates Testing for IntermittentConditions and Poor
the pump motor relay and turns the pump motor ON. Connections on page 11-531
WiringRepairs on page 11-537
Conditions for Running the DTC
- IgnitionON. Scan Tool Reference
- Ignitionvoltage is greater than 8 V. Control Module References on page 6—3for scan tool
information
Conditions for Setting the DTC
is lessthan 4 V. CircuitlSystem Testing
The pump motor supplyvoltage
1. lgnition OFF all vehicle systems OFF, disconnect
Action Taken When the DTC Sets the harness connector at the K17 Electronic Brake
- The ABS indicatorturns ON. Control Module. Itmay take up to 2 minutes for all
vehicle systems to power down.
- The traction/stabilitycontrol indicator turns ON,
if equipped with electronic stability control. Test for lessthan 10 Q between each ground circuit
terminal listed below and ground:
' The electronic brake control moduie disablesthe
ABS, the traction control and the stability control - Terminal 13
for the duration of the ignition cycle. ° Terminal 38
Conditions for Clearing the DTC if 10 Q or greater
the DTC is no longer 2.1. lgnition OFF
- The condition for setting
present. 2.2. Test for less than 2 Q in the ground circuit end
to end.
- The history DTC willclear after 40 consecutive
fault—freeignition cycles have occurred. =>If2 Q or greater, repair the openlhigh resistance
in the circuit.
Reference Information =>Iflessthan 2 Q, repair the openlhigh resistance
Schematic Reference in the ground connection.
If less than 10 Q
Antilock Brake System Schematics on page 5-6
IgnitionON.

(US/Canada}
-Sonic
2013 (5377994)
Manual
Service
5—22 Antilock Brake System
B+ :> If infinite resistance, replace the Q5 Brake
4. Verify a test lamp illuminates between the Pressure Modulator.
circuit terminal 1 and ground.
U If the test lamp illuminates
2) If the test lamp does not illuminate and the
circuit fuse is good .0“ Repiace the Q5 Brake Pressure Modulator.
the
4.1. lgnition OFF. 6. Verify the DTC does not set while operating
vehicle within the Conditions for Running the DTC.
4.2. Test for less than 2 Q in the B+ circuit end
to end. :> If the DTC sets
=>lf 2 Q or greater, repair the openlhigh resistance Replace the K17 Electronic Brake Control
in the circuit. Module.
2 Ifless than 2 Q, verify the fuseis not open and U If the DTC does not set
there is voltage at the fuse. 7. All OK.
If the test lamp does not illuminate and the Repair Instructions
circuit fuse is open
4.1. lgnition OFF. Perform the Diagnostic Repair Verification on
page 6—92after completing the repair.
4.2. Test for infinite resistance between the B+ on
circuit and ground. ~ Brake Pressure Modulator Valve Replacement
to page 5—40
=>If less than infinite resistance, repair the short
ground on the circuit. ~ Control Module References on page 6—3for
Electronic Brake Control Module replacement,
programming and setup

—
2013 (US/Canada)
Sonic (5377994)
Manual
Service
 [a
Antilock Brake System 3223

DTC 00242 or P0856

Diagnostic Instructions
- Perform the Diagnostic System Check - Vehicle
on page 6—66prior to usingthis diagnostic
procedure.
- Review Strategy Based Diagnosison page 6—58
for an overview of the diagnostic approach.
- Diagnostic Procedure Instructions on page 6-59
providesan overview of each diagnostic category.
DTC Descriptors
DTC C0242 00: Powertrain Control Module Indicated Traction Control Malfunction
DTC P0856: Traction Control Torque Request Circuit Malfunction

CircuitlSystem Description Electrical Information Reference

When traction control is active, the Electronic Brake - Circuit Testing on page 11-526
Control Module sendsa serial data message to the - Connector Repairs on page 11-548
Engine Control Module requesting torque reduction.
- Testing for IntermittentConditions and Poor .
When certain Engine Control Module DTCs are set, the
Engine Control Module willnot be able to perform the Connections on page 11-531
torque reduction for traction control. A serial data - WiringRepairs on page 11-537
message is sent to the Electronic Brake Control Module Scan Tool Reference
indicating that traction control is not allowed.
Control Module References on page 6-3 for scan tool
Conditions for Running the DTC information
Engine running.
CircuitlSystem Verification
Conditions for Setting the DTC 1. Ignition ON.
The Engine Control Module detects a fault that 2. Verify that no other DTCs are set except for 00242
prevents it from performing a traction control function or P0856.
and sendsa serial data message to the Electronic
=>If any other DTCs are set
Brake Control Module indicating that torque reduction is
not allowed. Refer to the Diagnostic Trouble Code (DTC) List
- Vehicle on page 6-69.
Action Taken When the DTC Sets
U If no other DTCs are set
- The Traction/stability Control Indicator Off turns 9° Replace the K20 Engine Control Module.
ON, if equipped with electronic stability control.
4. Verify that DTC 00242 or P0856 does not set while
- The Electronic Brake Control Module disablesthe operating the vehicle within the Conditions for
Traction/stability Control for the duration of the Running the DTC.
ignition cycle.
=>If DTC C0242 or P0856 sets
Conditions for Clearing the DTC Replace the K17 Electronic Brake Control
- The condition for setting the DTC is no longer Module.
present. U If DTC 00242 or P0856 does not set
' The history DTC willclear after 40 consecutive 5. All OK.
fauIt-freeignition cycleshave occurred.
Repair Instructions
Reference Information
Perform the Diagnostic Repair Verification on
Schematic Reference page 6—92after completing the repair.
Antilock Brake System Schematics on page 5—6 Control Module References on page 6-3 for Electronic
Brake Control Module and Engine Control Module
Connector End View Reference ‘ replacement, programming and setup
Component Connector End Viewson page 11-269
Description and Operation
ABS Description and Operation on page 5-51

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
5.24 Antilock Brake System

DTC 00277

Diagnostic Instructions
- Perform the Diagnostic System Check - Vehicle
on page 6—66prior to usingthis diagnostic
procedure.
- Review Strategy Based Diagnosison page 6-58
for an overview of the diagnostic approach.
- Diagnostic Procedure Instructions on page 6-59
provides an overview of each diagnostic category.
DTC Descriptors
DTC C0277 43: Brake Pedal Position Sensor Circuit Calibration Not Learned

CircuitlSystem Description Reference Information

When the brake pedal is applied, the body control Schematic Reference
module sendsa serial data message to the electronic
brake control module in reference to the brake pedal - Antilock Brake System Schematics on page 5-6
positions. The electronic brake control module - Exterior Lights Schematics on page 4-85
compares the correlation between the brake pedal End View Reference
Connector
position and the amount of brake pressure it senses
from the brake pressure sensor,which is internal to the Component Connector End Viewson page 11-269
brake pressure modulator. Itusesthis information to
control the vehicle during an stability control event. Description and Operation

for Running the DTC - ABS Description and Operation on page 5-51
Conditions
- Exterior Lighting Systems Description and
- Brakes Applied. Operation on page 4—217
- Battery voltage must be between 9—16V.
Electrical Information Reference
Conditions for Setting the DTC
- Circuit Testing on page 11-526
The body control module sendsinvalid brake pedal
- Connector Repairs on page 11—548
position data to the electronic brake control module.
- Testing for IntermittentConditions and Poor
The DTC may set in the body control module and/or Connections on page 11—531
electronic brake control module, when the brake
pedal position sensorhome position is not learned. ‘ Wiring Repairs on page 11-537
Scan Tool Reference
Actions Taken When the DTC Sets
' The ABS indicator is commanded ON. Control Module References on page 6-3 for scan tool
information
- The red brake indicator is commanded ON.
- The stop lamps may not activate at the expected CircuitlSystem Verification
brake pedal positions. 1. Verify DTC 00277 is not set in the K9 Body Control
- The traction/stability control indicator turns ON, Module.
if equipped with electronic stability control. :> If DTC is set
Conditions for Clearing the DTC Refer to DTC 00277 or C0890 on page 4—145.
- The condition responsible for setting the DTC no U If DTC is not set
longer exists. 2. ignition ON
- A DTC willnot clear the current status until the 3. Verify the scan tool Body Control Module Brake
next ignition cycle. Pedal Position Sensor Learned Released Position
- A successfulbrake pedal position sensor is YES.
calibration has been performed. =>If the released position is not YES
o A history DTC will clear once 40 malfunction-free Perform the Brake Pedal Position Sensor
ignition cycles have occurred. Learn. Refer to Brake Pedal Position Sensor
Calibration on page 4-185.
U If the released position is YES

(US/Canada)
~Sonic
2013 (5377994)
Manual
Service
 Antilock Brake System 525
4. Verify the DTC does not set while operating the Repair instructions
vehicle within the Conditions for Running the DTC.
Perform the Diagnostic Repair Verification on
:> If the DTC sets page 692 after completing the repair.
Replace the K17 Electronic Brake Control Control Module References on page 6-3 for Electronic
Module. Brake Control Module replacement, programming and
U If the DTC does not set setup
5. All OK.

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
5-26 Antilock Brake System

DTC 00270

Diagnostic Instructions
. Perform the Diagnostic System Check —Vehicle
on page 6—66prior to usingthis diagnostic
procedure.
- Review Strategy Based Diagnosison page 6-58
for an overview of the diagnostic approach.
- Diagnostic Procedure Instructions on page 6-59
provides an overview of each diagnostic category.
DTC Descriptor
DTC C027C: Front Brake DiscsHigh Temperature
For symptom byte information refer to Symptom Byte Description and Operation
List on page 6—85.
ABS Description and Operation on page 5-51
CircuitlSystem Description
Electrical Information Reference
The electronic brake control module monitors how often
the traction control or the stability control system . Circuit Testing on page 11-526
activates in order to calculate an estimate of the front ' Connector Repairs on page 11—548
brake discstemperature. In most cases the high - Testing for IntermittentConditions and Poor
temperatures are caused by extended traction control Connections on page 11-531
activation. Ifthe electronic brake control module
calculates that the front brake components - Wiring Repairs on page 11-537
temperatures are too high, the electronic brake control Scan Tool Reference
module willtemporarily suspendthe traction control
system function until the front brake discscool down. Control Module References on page 6—3for scan tool
information
Conditions for Running the DTC
lgnition ON. CircuitlSystem Verification
Note: Since most occurrences of this DTC are caused
Conditions for Setting the DTC by excessive brake usage, review with the customer
The electronic brake control module detects the the conditions under which the DTC set.
calculated temperature of the brake components is 1. Allow the brakes to cool down before
higher than 500°C (932°F). performing test.
Action Taken When the DTC Sets 2. Verify that no other DTCs are set.
- The traction/stability control indicator turns ON. =>If any other DTCs are set
- The electronic brake control module disables the Refer to Diagnostic Trouble Code (DTC) List -
traction control and stability control for the Vehicle on page 6-69.
duration of the ignition cycle. U If no other DTCs are set
Conditions for Clearing the DTC 3. Verify DTC 0027C does not set while driving the
vehicle under normal braking conditions. Refer to
- The condition for setting the DTC is no longer Brake System Vehicle Road Test on page 5—141.
present.
- The history DTC willclear after 40 consecutive
fault—freeignition cycles have occurred. =>If the DTC sets
Replace the K17 Electronic Brake Control
Diagnostic Aids Module.
DTC 0027C does not indicate a malfunction has U If the DTC does not set
occurred. This DTC indicates there was excessive
traction control or stability control activation that caused 4. Ali OK.
the high temperatures. Repair Instructions
Reference Information Perform the Diagnostic Repair Verification on
page 6—92after completing the repair.
Schematic Reference
Control Module References on page 6—3for Electronic
Antilock Brake System Schematics on page 5-6 Brake Control Module replacement, programming and
setup
Connector End View Reference
Component Connector End Views on page 11~269

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Antilock Brake System 5427

DTC 00292

Diagnostic Instructions
0 Perform the Diagnostic System Check - Vehicle
on page 6—66prior to usingthis diagnostic
procedure.
- Review Strategy Based Diagnosison page 6-58
for an overview of the diagnostic approach.
- Diagnostic Procedure Instructions on page 6—59
provides an overview of each diagnostic category.
DTC Descriptor
DTC C02921A: Multi-Axis Acceleration Sensor Module Circuit Performance - Bias Level Out of Range
Diagnostic Fault Information

Opeanigh Signal
Circuit Short to Ground Resistance Short to Voltage Performance
12V Reference U0125,
C02921A U0125 — ~-
Ground — U0125 — -

CircuitlSystem Description Connector End View Reference

The Lateral Accelerometer and the Yaw Rate Sensors Component Connector End Views on page 11-269
are combined into one sensorcalled the Multi-axis
Acceleration Sensor. The Electronic Brake Control Description and Operation
Module suppliesa 12 V reference to the Multi-axis ABS Description and Operation on page 5-51
Acceleration Sensor. The Multi-axis Acceleration
Sensor communicates with the Electronic Brake Electrical Information Reference
Control Module via serial data. The module activates
the stability control function depending on Multi-axis - Circuit Testing on page 11-526
Acceleration Sensor input. - Connector Repairs on page 11-548
- Testing for IntermittentConditions and Poor
Conditions for Running the DTC Connections on page 11—531
- lgnition ON. - Wiring Repairs on page 11—537
- lgnition voltage is greater than 8 V.
Scan Tool Reference
Conditions for Setting the DTC Control Module References on page 6—3for scan tool
The Electronic Brake Control Module detects that the information
sensorsupplyvoltage feedback indicates that the
voltage level is lessor greater than 1 V for more than CircuitlSystem Testing
100 milliseconds. 1. Verify the B119 Multi-axis Acceleration Sensor is
installed correctly.
Action Taken When the DTC Sets
:> If loose or incorrect installation
- The Electronic Brake Control Module shuts down
the 12 V reference to the multi—axisacceleration Correct the installation of the component.
senson U If installed correctly
- The Electronic Brake Control Module disables the 2. IgnitionOFF, scan tool disconnected, and all
vehicle stability enhancement system for the vehicle systems OFF, disconnect the harness
duration of the ignition cycle. connector at the B119 Multi-axis Acceleration
Sensor. Itmay take up to 2 minutes for all vehicle
Conditions for Clearing the DTC systems to power down.
° The condition for setting the DTC is no longer 3. Test for lessthan 5 Q between the ground circuit
present. terminal 6 and ground.
- The history DTC will clear after 40 consecutive =>If 5 Q or greater
fault—freeignition cycles have occurred.
3.1. IgnitionOFF.
Reference Information 3.2. Test for lessthan 2 Q in the ground circuit end
to end.
Schematic Reference
:> If2 Q or greater, repair the openlhigh resistance
Antilock Brake System Schematics on page 5-6 in the circuit.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
5-28 Antilock Brake System
=>Ifless than 2 Q, repair the openlhigh resistance =>Iflessthan 2 Q, replace the K17 Electronic
in the ground connection. Brake Control Module.
U If less than 5 Q If the test lamp illuminates
4. IgnitionON. .03 Replace the B119 Multi-axis Acceleration Sensor.
5. Verify that a test lamp illuminates between the 12 V Verify the DTC does not set while operating the
reference circuit terminal 5 and ground. vehicle within the Conditions for Running the DTC.
:> If the test lamp does not illuminate If the DTC sets
5.1. lgnition OFF, disconnect the harness Replace the K17 Electronic Brake Control
connector at the K17 Electronic Brake Control Module.
Module. U If the DTC does not set
5.2. Test for infinite resistance between the 12 V 8. All OK.
reference circuit and ground.
=>Iflessthan infinite resistance, repair the short to Repair Instructions
ground on the circuit. Perform the Diagnostic Repair Verification on
U Ifinfinite resistance page 6—92after completing the repair.
5.3. Test for lessthan 2 Q in the 12 V reference Control Module References on page 6—3for Electronic
circuit end to end. Brake Control Module replacement, programming and
setup
=>If2 Q or greater, repair the open/high resistance
in the circuit.

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
 Antilock Brake System 5429

DTC 00561

Diagnostic Instructions
Vehicle
~ Perform the Diagnostic System Check —
on page 6—66prior to using this diagnostic
procedure.
page 6-58
° Review Strategy Based Diagnosison
for an overview of the diagnostic approach.
page 6-59
- Diagnostic Procedure Instructions on category.
provides an overview of each diagnostic

DTC Descriptor
Stored Engine Speed Out of Range
DTC C0561 77: System Disabled information Range
Stored Acceleration Pedal Position Out of
DTC C0561 78: System Disabled Information
Stored TransmissionGear Invalid Data
DTC 00561 79: System Disabled Information
Electrical Information Reference
CircuitlSystem Description
the - Circuit Testing on page 11—526
The electronic brake control module disableselectronic
traction and the stability control when other - Connector Repairs on page 11-548
that effect Poor
control modules set DTCs for components - Testing for IntermittentConditions and
the operation of the brake system. Connections on page 11-531

for Running the DTC o Wiring Repairs on page 11-537

Conditions
- Engine Running. Scan Tool Reference
scan tool
o lgnition voltage is greater than 8 V. Control Module References on page 6—3for
information
Conditions for Setting the DTC
an invalid Verification
The electronic brake control module receives than CircuitlSystem
more
serial data message from another module C0561 77 or C0561 78
ten times.
1. lgnition ON.
DTC Sets
Action Taken When the 2. Verify there are no other DTCs set.
- The ABS system remains functional. =>If any other DTCs are set
module disables the List
- The electronic brake control Refer to the Diagnostic Trouble Code (DTC)
stability control for the entire ignition cycle. —Vehicle on page 6—69.
Conditions for Clearing the DTC U If no other DTCs are set
- The condition for the DTC is no longer
present. 3. Replace the K20 Engine Control Module.
operating the
- The history DTC will clear after 40
consecutive 4. Verify the DTC does not set while the DTC.
within the conditions for Running
fault—freedrive cycles have occurred. vehicle
:> If the DTC sets
Diagnostic Aids
the brake Replace the K17 Electronic Brake Control
This DTC indicates there are no problems in Module.
control
system. The body control module, engine
module, and transmission control module should
be U If the DTC does not set
checked for a possiblefault first. 5. All OK.
Reference Information C0561 79
1. lgnition ON.
Schematic Reference
2. Verify there are no other DTCs set.
5—6
Antilock Brake System Schematics on page =>If any other DTCs are set
List
Connector End View Reference Refer to the Diagnostic Trouble Code (DTC)
- Vehicle on page 6—69.
Component Connector End Views on page 11-269
U If no other DTCs are set
Description and Operation Module.
3. Replace the K71 TransmissionControl
5-51
ABS Description and Operation on page

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2013 (5377994)
Manual
SeNice
F Brake System
0230 Antilock
4. Verify the DTC does not set while operating the Repair Instructions
vehicle within the conditions for Running the DTC. Perform the Diagnostic Repair Verification on
=>If the DTC sets page 6-92 after completing the repair.
Replace the K17 Electronic Brake Control Control Module References on page 6—3for Electronic
Module. Brake Control Module, Engine Control Module,
or TransmissionControl Module replacement,
U If the DTC does not set programming and setup
5. All OK.

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
 Antilock Brake System 531

DTC 0056D

Diagnostic Instructions
. Perform the Diagnostic System Check - Vehicle
on page 6—66prior to usingthis diagnostic
procedure.
° Review Strategy Based Diagnosis on page 6—58
for an overview of the diagnostic approach.
~ Diagnostic Procedure Instructions on page 6-59
provides an overview of each diagnostic category.
DTC Descriptor
DTC C056D 00: Electronic Control Unit Hardware Malfunction
Connector End View Reference
CircuitlSystem Description
The Electronic Brake Control Module detects an Component Connector End Views on page 11-269
internal malfunction. Description and Operation
Conditions for Running the DTC ABS Description and Operation on page 5—51
- lgnition ON. Electrical Information Reference
- lgnition voltage is greater than 8V.
. Circuit Testing on page 11-526
Conditions for Setting the DTC - Connector Repairs on page 11-548
The Electronic Brake Control Module detects an - Testing for IntermittentConditions and Poor
internal malfunction. Connections on page 11-531
- Wiring Repairs on page 11—537
Action Taken When the DTC Sets
- The ABS Indicator turns ON. Scan Tool Reference
0 The red Brake Warning Indicator turns ON. Control Module References on page 6-3 for scan tool
. The Traction/stabiiity Control Indicator turns ON, information
if equipped with electronic stability control. CircuitlSystem Verification
- The Electronic Brake Control Module disables the
ABS, and the Traction/stability for the duration of 1. Verify that DTC CO56D is not set.
the ignition cycle. =>If the DTC is set
for Clearing the DTC Replace the K17 Electronic Brake Control
Conditions
Module.
- The condition for setting the DTC is no longer
present. U If the DTC is not set
The history DTC will clear after 40 consecutive 2. All OK.
-
fault—freeignition cycles have occurred. Repair Instructions
Reference Information Perform the Diagnostic Repair Verification on
page 6-92 after completing the repair.
Schematic Reference
Control Module References on page 6-3 for Electronic
Antilock Brake System Schematics on page 5—6 Brake Control Module replacement, programming and
setup

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
5232 Antilock Brake System

DTC 0056E

Diagnostic Instructions
0 Perform the Diagnostic System Check —Vehicle
on page 6-66 prior to usingthis diagnostic
procedure.
. Review Strategy Based Diagnosis on page 6—58
for an overview of the diagnostic approach.
. Diagnostic Procedure Instructions on page 6-59
provides an overview of each diagnostic category.
DTC Descriptors
DTC C056E 42: Electronic Control Unit Software Calibration Not Programmed
DTC C056E 47: Electronic Control Unit Software VIN Not Programmed

Conditions for Running the DTC Description and Operation

- lgnition ON. ABS Description and Operation on page 551
- lgnition voltage is greater than 8 V. Electrical Information Reference
Conditions for Setting the DTC - Circuit Testing on page 11—526
A new service replacement Electronic Brake Control ' Connector Repairs on page 11-548
Module contains a unique manufacturing calibration. - Testing for IntermittentConditions and Poor
This DTC will be current whenever a new Electronic Connections on,page 11-531
Brake Control Module is installed on a vehicle prior to
the Service Programming System (SPS) event..The - Wiring Repairs on page 11-537
DTC will remain current until the Electronic Brake Scan Tool Reference
Control Module has undergone a successfulprogram.
Once the program event is completed, the DTC goes Control Module References on page 6—3for scan tool
into history and can be cleared. After the DTC is information
cleared it can not return.
CircuitlSystem Verification
Action Taken When the DTC Sets 1. Verify that DTC CO56E is not set.
- The ABS Indicatorturns ON. =>If the DTC is set
- The red Brake Warning indicator turns ON. 1.1. lgnition ON
- The Traction/stability Control Indicatorturns ON, 1.2. Program the K17 Electronic Brake Control
if equipped with electronic stability control. Module.
‘ The Electronic Brake Control Module disables the 1.3. Verify the DTC does not set after driving the
ABS,and the Traction/stabilityfor the duration of vehicle above 40 km/h (25 MPH).
the ignition cycle.
=>Ifthe DTC sets, replace the K17 Electronic
Conditions for Clearing the DTC Brake Control Module.
- The condition for setting the DTC is no longer U Ifthe DTC does not set.
present. 1.4. All OK.
- The history DTC will clear after 40 consecutive U If the DTC is not set
fault—freeignition cycles have occurred. 2. All OK.
Reference Information Repair Instructions
Schematic Reference Perform the Diagnostic Repair Verification on
page 6-92 after completing the repair.
Antilock Brake System Schematics on page 5-6
Control Module References on page 6-3 for Electronic
Connector End View Reference Brake Control Module replacement, programming and
Component Connector End Views on page 11-269 setup

(US/Canada)
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2019 (5377994)
Manual
Service
 Antilock Brake System 533

DTC 00710

Diagnostic Instructions
- Perform the Diagnostic System Check - Vehicle
on page 6—66prior to usingthis diagnostic
procedure.
~ Review Strategy Based Diagnosison page 6-58
for an overview of the diagnostic approach.
- Diagnostic Procedure Instructions on page 6—59
provides an overview of each diagnostic category.
DTC Descriptors
DTC C0710 4B: Steering Position Signal Calibration Not Learned
DTC C0710 5A: Steering Position Signal Not Plausible
DTC 00710 71: Steering Position Signal Invalid Data
Diagnostic Fault Information

Open/High Signal
Circuit Short to Ground Resistance Short to Voltage Performance
12VReference U0126,0071071 U0126,0071071 — CO7105A
Ground — U0126,C071071 — -

CircuitlSystem Description Action Taken When the DTC Sets

The Steering Wheel Angle Sensor receives a 12 V - The ABS remains functional.
reference from the Electronic Brake Control Module. - The Electronic Brake Control Module disables the
The Electronic Brake Control Module receives serial stability control for the duration of the ignition
data message inputs from the Steering Wheel Angle cycle.
Sensor identifying the position and direction of the
steering wheel rotation.The module utilizes this signal Conditions for Clearing the DTC
to calculate the driver intended driving direction. - The condition for setting the DTC is no longer
Conditions for Running the DTC present.
- The history DTC will clear after 40 consecutive
The condition for running the DTC willnot occur until fault—freeignition cycles have occurred.
the initialization phase has been completed. The
initialization of the Electronic Brake Control Module Diagnostic Aids
occurs when the following conditions have been met:
- Improperly mounted or loose Steering Wheel
- lgnition voltage is greater than 8 V. Angie Sensor.
- The initialization happens once each ignition cycle - Inspect the vehicle for proper alignment. The car
when the vehicle speed is greater than 20 km/h should not pull in either direction while driving
(12 MPH) and the vehicle is driven in a straight straight on a level surface.
line without the brake pedal being applied.
- Confirm that all tires are of the proper size and that
Conditions for Setting the DTC all are matching brands. Check and adjust all tires
to the stated cold air pressure as identified on the
C0710 4B tire placard. Ifa mis—sized or non-matching brand
The Steering Wheel Angle Sensor is not calibrated after tire is present, inform the customer that in order for
installation. the vehicle stability enhanced system to function
normally, tires need to be a uniform size and
C0710 5A rolling diameter.
- The Steering Wheel Angle Sensor is out of the
specified range. Reference Information
- The Steering Wheel Angle Sensor offset is out of Schematic Reference
the specified range.
Antilock Brake System Schematics on page 5—6
00710 71
Connector End View Reference
The Steering Wheel Angie Sensor Signal is not
plausible with the Yaw Rate Signal and Lateral Component Connector End Views on page 11-269
Acceleration Signal. Description and Operation
ABS Description and Operation on page 5—51

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Manual
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5434 Antilock Brake System
Electrical Information Reference 3. lgnition ON.
- Circuit Testing on page 11-526 4. Verify that a test lamp illuminates between the
12 reference circuit terminal 5 and ground.
- Connector Repairs on page 11-548
:> If the test lamp does not illuminate
- Testing for IntermittentConditions and Poor
Connections on page 11—531 4.1. lgnition OFF, disconnect the harness
connector at the K17 Electronic Brake Control
- Wiring Repairs on page 11~53? Module
Scan Tool Reference 4.2. Test for infinite resistance between the
Control Module References on page 6-3 for scan tool 12 reference circuit and ground.
information =>If lessthan infinite resistance, repairthe short to
ground on the circuit.
CircuitlSystem Verification
U If infinite resistance
1. IgnitionON. 4.3. Test for lessthan 2 Q in the 12 reference
2. Verify the scan tool Steering Wheel Position circuit end to end.
parameter corresponds to the actual steering
=>If2 Q or greater, repair the openlhigh resistance
wheel position as the steering wheel is turned
in the circuit.
through its entire range of motion.
=>If the parameter does not correspond with the =>If lessthan 2 Q, replace the K17 Electronic
Brake Control Module.
steering wheel position or the reading is erratic
U If the test lamp illuminates
Refer to CircuitlSystem Testing.
S“ Replace the B99 Steering Wheel Angle Sensor.
U If the parameter reading corresponds with the
steering wheel position 6. Verify the DTC does not set while operating the
vehicle within the Conditions for Running the DTC.
3. All OK.
:> If the DTC sets
CircuitlSystem Testing Replace the K17 Electronic Brake Control
1. lgnition OFF all vehicle systems OFF, disconnect Module.
the harness connector at the B99 Steering Wheel U If the DTC does not set
Angle Sensor. it may take up to 2 minutes for all
vehicle systems to power down. 7. All OK.
2. Test for lessthan 10 Q between the ground circuit Repair Instructions
terminal 6 and ground.
Perform the Diagnostic Repair Verification on
=>If 10 Q or greater page 6-92 after completing the repair.
2.1. IgnitionOFF - Steering Angle Sensor Replacement on
2.2. Test for lessthan 2 Q in the ground circuit end page 15—36
to end. - Control Module References on page 6-3 for
=>If2 Q or greater, repair the openlhigh resistance Electronic Brake Control Module replacement,
in the circuit. programming and setup
=>Iflessthan 2 Q, repair the openlhigh resistance
in the ground connection.
U If less than 10 Q

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 F
Antilock Brake System 0-35

DTC 01251

Diagnostic Instructions
- Perform the Diagnostic System Check —Vehicle
on page 6—66prior to usingthis diagnostic
procedure.
- Review Strategy Based Diagnosison page 6-58
for an overview of the diagnostic approach.
- Diagnostic Procedure Instructions on page 6—59
provides an overview of each diagnostic category.
DTC Descriptors
DTC C1251: Lateral Acceleration Sensor Performance
For symptom byte information refer to Symptom Byte Description and Operation
List on page 6-85.
ABS Description and Operation on page 5-51
CircuitlSystem Description
Electrical Information Reference
The yaw rate, lateral acceleration and longitudinal
acceleration sensorsare combined into one multi—axis - Circuit Testing on page 11—526
acceleration sensor, external to the electronic brake - Connector Repairs on page 11-548
control module. The electronic brake control module - Testing for IntermittentConditions and Poor
suppliesignition voltage to the multi-axis acceleration Connections on page 11-531
sensor. The multi-axis acceleration sensor
communicates with the electronic brake control module - Wiring Repairs on page 11—537
via serial data. The electronic brake control module Scan Tool Reference
activates the stability control function depending on the
multi-axis acceleration sensor input. The transmission Control Module References on page 6-3 for scan tool
control module sets this DTC. information

Conditions for Running the DTC CircuitlSystem Verification

Engine running 1. lgnition ON.
2. Verify that no other DTCs are set except for C1251
Conditions for Setting the DTC is set
The transmission control module detects a fault that =>If any other DTCs are set
prevents it from performing a hill hold start assist
function. Refer to Diagnostic Trouble Code (DTC) List -
Vehicle on page 6-69.
Action Taken When the DTC Sets U If no other DTCs are set
- The traction/stabilitycontrol indicator turns ON. 9° Replace the K71 TransmissionControl Module.
- The electronic brake control module disables the 4. Verify that DTC C1251 does not set while operating
traction control and the stability control for the the vehicle within the Conditions for Running
duration of the ignition cycle. the DTC.
Conditions for Clearing the DTC :> If the DTC sets
- The DTC clears when the diagnostic runsand Replace the K17 Electronic Brake Control
passes. Module.
- The history DTC willclear after 40 consecutive U If the DTC does not set
fault-free ignition cycles have occurred. 5. All OK.
Reference Information Repair Instructions
Schematic Reference Perform the Diagnostic Repair Verification on
page 6—92after completing the repair.
Antilock Brake System Schematics on page 5-6 Control Module References on page 6-3 for Electronic
Connector End View Reference Brake Control Module or TransmissionControl Module
replacement, programming and setup
Component Connector End Views on page 11-269

2013
—
Sonic
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Service
Manual
(5377994)
5136 Antilock Brake System

Symptoms - Antilock Brake System Reference Information

Note: The following Steps must be completed before
usingthe symptom tables.
1. Perform the Diagnostic System Check - Vehicle on
page 6-66 before usingthe 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 ABS
Description and Operation on page 5-51.
Visual/Physical Inspection
' Inspect for aftermarket devices which may affect
the operation of the antilock brake system. Refer
to Checking AftermarketAccessories on
page 11-525.
' Inspect the easily accessible or visiblesystem
components, for obviousdamage or conditions,
which could cause the symptom.
- Inspect the master cylinder reservoir for the
correct brake fluidlevel.
Intermittent
Faulty electrical connections or wiring may be the
cause of intermittentconditions. Refer to Testing for
IntermittentConditions and Poor Connections on
page 11-531.
Symptom List
Refer to a symptom diagnostic procedure from the
following list in order to diagnose the symptom:
- ABS Indicator Malfunction on page 5-36
~ Traction Control/Stabi/ity Control Indicator
Malfunction on page 5-37
ABS Indicator Malfunction '
Diagnostic Instructions
- Perform the Diagnostic System Check - Vehicle
on page 6-66 prior to usingthis diagnostic
procedure.
- Review Strategy Based Diagnosison page 6-58
for an overview of the diagnostic approach.
- Diagnostic Procedure Instructions on page 6-59
provides an overview of each diagnostic category.
CircuitlSystem Description
The InstrumentCluster turns the ABS indicator ON for
five seconds after the ignition is turned ON, or when the
Electronic Brake Control Module detects a fault and
sendsa serial data message to the InstrumentCluster
commanding the indicator ON.
Schematic Reference
Antilock Brake System Schematics on page 5—6
Connector End View Reference
Component Connector End Viewson page 11—269
Description and Operation
ABS Description and Operation on page 5—51
Electrical Information Reference
- Circuit Testing on page 11-526
. Connector Repairs on page 11-548
- Testing for IntermittentConditions and Poor
Connections on page 11-531
- Wiring Repairs on page 11—537
Scan Tool Reference
Control Module References on page 6—3for scan tool
information.
CircuitlSystem Verification
1. lgnition ON.
2. Verify that no DTCs are set.
:> If any DTCs are set
Refer to Diagnostic Trouble Code (DTC) List -
Vehicle on page 6-69.
U If no DTCs are set
3. Verify the InstrumentCluster ABS indicator turns
ON and OFF when commanding the All Indicators
ON and OFF with a scan tool.
=>If the ABS indicator does not turn ON and OFF
Replace the P16 instrument Cluster.
c If the ABS indicator turns ON and OFF
4. Verify the ABS indicator turns off five seconds after
the ignition is turned ON.
=>If the ABS indicator does not turn OFF
Replace the K17 Electronic Brake Control
Module.
U If the ABS indicator turns OFF
5. All OK.
Repair Instructions
Perform the Diagnostic Repair Verification on
page 6-92 after completing the repair.
Control Module References on page 6-3 for Electronic
Brake Control Module or instrument Cluster
replacement, programming and setup

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Antilock Brake System 5-‘37

Traction ControllStabiIity Control Indicator Malfunction

Diagnostic Instructions
° Perform the Diagnostic System Check - Vehicle
on page 6-66 prior to usingthis diagnostic
procedure.
° Review Strategy Based Diagnosison page 6—58
for an overview of the diagnostic approach.
- Diagnostic Procedure Instructions on page 6-59
provides an overview of each diagnostic category.

Diagnostic Fault Information

Open/High Signal
Short to Ground Resistance Short to Voltage Performance
Circuit
. B274502,
B274571 1 1 B274571
Signal
— 1 — -
Ground
1.TractionControlinoperative

CircuitlSystem Description Scan Tool Reference

The Instrument Cluster illuminates the Traction/stability
Control indicator, Traction Control Off indicator and
Stability Control Off indicator for five seconds after the
ignition is turned ON. When the Electronic Brake
Control Module detects a fault it sendsa serial data
message to the instrument Cluster commanding the
Traction/stability Control indicator ON.
The Body Control Module monitors the signal circuit
from the Traction Control Switch. When the Traction
Control Switch is pressed once, the Body Control
Module sendsa serial data message to the Electronic
Brake Control Module to disable the traction control
system. 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 willrequest the Instrument Cluster to
turn the Traction Control Off and the Stability Control
Off indicator ON to notify the driver of the deactivation.
Reference Information
Schematic Reference
Antilock Brake System Schematics on page 5-6
Connector End View Reference
Component Connector End Views on page 11-269
Description and Operation
ABS Description and Operation on page 5—51
Electrical Information Reference
- Circuit Testing on page 11-526
- Connector Repairs on page 11-548
- Testing for IntermittentConditions and Poor
Connections on page 11—531
- Wiring Repairs on page 11—537
Control Module References on page 6-3 for scan tool
information.
Verification
CircuitlSystem
1. lgnition ON
2. Verify the instrument Cluster Traction Control
indicator turns ON and OFF when commanding the
Instrument Cluster All Indicators ON and OFF with
a scan tool.
=>If the indicator does not turn ON and OFF
Replace the P16 Instrument Cluster.
U If the indicator turns ON and OFF
3. Verify the scan tool electronic brake control module
Traction Control Switch parameter changes
between Active and Inactive while pressing and
releasing the traction control switch.
=>If the parameter does not change
Refer to CircuitlSystem Testing.
U If the parameter changes
4. All OK.
CircuitlSystem Testing
1. lgnition OFF, scan tool disconnected, and all
vehicle systems OFF, disconnect the harness
connector at the S48E Multifunction Switch—Center
Console. Itmay take up to 2 minutes for all vehicle
systems to power down.
2. Test for lessthan 5 Q between the ground circuit
terminal 9 and ground.
:> If 5 Q or greater
2.1. IgnitionOFF
2.2. Test for less than 2 Q in the ground circuit end
to end.
:> If2 Q or greater, repair the openlhigh resistance
in the circuit.

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
5-38 Antilock Brake System
=>Iflessthan 2 Q, repair the openlhigh resistance Repair Instructions
in the ground connection.
Perform the Diagnostic Repair Verification on
U If less than 5 Q page 6-92 after completing the repair.
.03 lgnition ON. ° Front Floor Console Multifunction Switch
4. Verify the scan tool Traction Control Switch Replacement on page 8-105
parameter is Inactive. - Refer to Control Module References on page 6-3
=>If not Inactive for Body Control Module, Electronic Brake Control
4.1. IgnitionOFF, disconnect the X2 harness Moduie or instrument Cluster replacement,
connector at the K9 Body Control Module. programming and setup
4.2. Test for infinite resistance between the signal Repair Instructions
circuit terminal 5 and ground.
=>lfless than infinite resistance, repair the short to
ground on the circuit. Antilock Brake System Automated
=>Ifinfinite resistance, replace the K9 Body Bleed
Control Module.
Warning: Refer to Brake Fluid Irritant Warning on
U lflnactive page 0-4.
5. Install a 3 A fused jumper wire between the signal
Caution: Refer to Brake FluidEffects on Paint and
circuit terminal 5 and the ground circuit terminal 9. Electrical Components Caution on page 0—7.
6. Verify the scan tool Traction Control Switch
Note: Before performing the Antilock Brake System
parameter is Active. (ABS) Automated Bleed Procedure, first perform a
=>If not Active pressure bleed of the base brake system. Refer to
6.1. lgnition OFF, disconnect the X2 harness Hydraulic Brake System Bleeding (Pressure) on
connector at the K9 Body Control Module, page 5-169 or Hydraulic Brake System Bleeding
ignition ON. (Manual) on page 5—170.The automated bleed
6.2. Test for lessthan 1 V between the signal procedure is recommended when one of the following
circuit and ground. conditions exists:
=>If 1 V or greater, repair the short to voltage on - Base brake system bleeding does not achieve the
the circuit. desired pedal height or feel.
U Iflessthan 1 V - Extreme lossof brake fluidhas occurred.
6.3. Test for less than 2 Q in the signal circuit end - Air ingestion is suspected in the secondary circuits
to end. of the hydraulic brake modulator assembly.
=>lf 2 Q or greater, repair the openlhigh resistance The ABS Automated Bleed Procedure usesa scan tool
to cycle the system solenoid valves and run the pump
in the circuit.
in order to purge any air from the secondary circuits.
:> Iflessthan 2 Q, replace the K9 Body Controi These circuits are normally closed off and are only
Module. opened during system initialization at vehicle start up
U If Active and during ABS operation. The automated bleed
procedure opens these secondary circuits and allows
7. Test or replace the S48E MultifunCtion
any air trapped in these circuits to flow out toward the
Switch-Center Console.
brake calipers.
Component Testing Caution: The Auto Bleed Procedure may be
1. lgnition OFF, disconnect the harness connector at terminated at any time during the process by pressing
the S48E Multifunction Switch-Center Console. the EXIT button. No further Scan Tool prompts
pertaining to the Auto Bleed procedure will be given.
2. Test for infinite resistance between the signal After exiting the bleed procedure, relieve bleed
terminal 5 and the ground terminal 9 with the switch pressure and disconnect bleed equipment per
in the open position. manufacturers instructions. Failure to properly relieve
=>If less than infinite resistance pressure may result in spilled brake fluidcausing
Replace the S48E Multifunction Switch—Center damage to components and painted surfaces.
Console. 1. Raise and support the vehicle. Refer to Lifting and
Jacking the Vehicle on page 1—31.
U If infinite resistance
3. Test for less than 2 Q between the signal circuit 2. Remove all four tire and wheel assemblies. Refer
terminal 5 and the ground terminal 9 with the switch to Tire and Wheel Removal and Installation on
in the closed position. page 16-60.
3. Inspect the brake system for leaks and visual
:> If 2 Q or greater
damage. Refer to Symptoms - Hydraulic Brakes on
Replace the S48E Multifunction Switch-Center page 5—111, repair or replace components as
Console. needed.
U If less than 2 Q 4. Lower the vehicle.
4. All OK.

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 Antilock Brake System 539

5. inspect the battery state of charge. Refer to Battery 5. Select Steering Wheel Angle Sensor Reset in the
Inspection/Test on page 9-702. Steering Wheel Angle Sensor Moduie Control
Functions list or in the EBCM Module Setup iist.
6. Install a scan tool.
6. Follow the scan tool directions to complete the
7. Turn the ignition ON, with the engine OFF. learn procedure.
8. With the scan tool, establish communications with 7. Select Steering Wheel Angle Sensor Learn in the
the ABS system. Select Control Functions. Select Steering Wheel Angle Sensor Module Functions
Automated Bleed from the Control list or in the EBCM Module Setup list.
Functions menu.
8. Follow the scan tool directions to complete the
9. Raise and support the vehicle. Refer to Lifting and learn procedure.
Jacking the Vehicle on page 1-31.
9. Clear any DTCs that may be set.
10. Following the directions given on the scan tool,
pressure bleed the base brake system. Refer to Brake Control Module
Hydraulic Brake System Bleeding (Pressure) on Electronic
page 5169 or Hydraulic Brake System Bleeding Replacement
(Manual) on page 5-170.
11. Follow the scan tool directions until the desired Removal Procedure
brake pedal height is achieved. Warning: Refer to Brake Fluid Irritant Warning on
12. Ifthe bleed procedure is aborted, a malfunction page 0-4.
exists. Perform the following steps before Caution: Refer to Brake FluidEffects on Paint and
resuming the bleed procedure: Electrical Components Caution on page 0-7.
- Ifa DTC is detected, refer to Diagnostic Trouble 1. Remove the battery tray. Refer to Battery Tray
Code (DTC) List - Vehicle on page 6-69 , and Replacement on page 9-721.
diagnose the appropriate DTC.
2. Disconnect the electronic brake control module
- Ifthe brake pedal feels spongy, perform the (EBCM) electrical connector.
conventional brake bleed procedure again.
Refer to Hydraulic Brake System Bleeding
(Pressure) on page 5169 or Hydraulic Brake
System Bleeding (Manual) on page 5-170.
13. When the desired pedal height is achieved, press
the brake pedal to inspect for firmness.
14. Lower the vehicle.
15. Remove the scan tool.
16. Installthe tire and wheel assemblies. Refer to Tire
and Wheel Removal and Installation on
page 16-60.
17. Inspect the brake fluidlevel. Refer to Master
Cylinder Reservoir Filling on page 5-145.
18. Road test the vehicle while inspecting that the
pedal remains high and firm.

Steering Angle Sensor Centering

The steering angle sensor does not require centering
often. Centering of the steering angle sensor might be
required after certain service procedures are
performed. Some of these procedures are as follows: 2535377
- Electronic brake control module (EBCM)
replacement 3. Remove the EBCM bolts (1),
- Steering angle sensor replacement
- Steering gear replacement
- Steering column replacement
- Collisionor other physical damage
The steering angle sensor centering procedure can be
completed with a scan tool usingthe following steps:
1. Usingthe steering wheel, align the front wheels
forward.
2. Apply the parking brake, or set the transmission in
the park (P) position.
3. Installthe scan tool to the data link connector.
4. Turn the ignition ON, and the engine OFF.

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5-40 Antilock Brake System

2535378
Note: Do not pry the components apart.
4. Carefully separate the EBCM (1)from the BPMV.
5. Clean the sealing surfaces of the EBCM and the '
BPMV with denatured alcohol and allow to dry.
Installation Procedure
2535377
Caution: Refer to Fastener Caution on page 0-8.
2. Install the EBCM bolts (1)and tighten to 3 N°m
(26 lb in). ,
3. Connect the EBCM electrical connector.
4. Install the battery tray. Refer to Battery Tray
Replacement on page 9—721.
5. Program the EBCM. Refer to Control Module
References on page 6—3.

Brake Pressure Modulator Valve

Replacement

2535378 Note:
1. Install the EBCM (1)to the BPMV.
Removal Procedure
Warning: Refer to Brake Fluid Irritant Warning on
page 0-4. _
Caution: Refer to Brake FluidEffects on Paint and
Electrical Components Caution on page 0-7.
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. Place the ignition switch in the OFF position.
2. Remove the battery tray. Refer to Battery Tray
Replacement on page 9-721.
The area around the electronic brake control
module (EBCM) and brake pressure modulatorvalve
(BPMV) assembly must be free from loose dirt to
prevent contamination of disassembled ABS
components.
3. Clean the area surrounding the EBCM/BPMV of
any accumulated dirt and debris.
4. Disconnect the EBCM electrical connector.

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 Antilock Brake System 5=41

LWQEU‘ . ,

2495345 2495352

5. Disconnect the master cylinder secondary brake
pipe fitting(1) from the BPMV.
6. Cap the brake pipe fitting and plug the BPMV inlet
port to prevent brake fluidloss and contamination.
9. Reference mark the BPMV outlet brake pipe
fittings (1) and disconnect the fittings.
10. Cap the brake pipe fittings and plug the BPMV
outlet ports to prevent brake fluidloss and
contamination.

Alglglll
L!i’ 9\9
ll o_e/A_
~~
Iq"; \.,;,/ 41.,f‘
§lag§

2495349
2833466
7. Disconnect the master cylinder primary brake pipe
fitting(1) from the BPMV. 11. Remove the protective caps (1) from the BPMV
8. Cap the brake pipe fitting and plug the BPMV inlet bracket nutS-
port to prevent brake fluidloss and contamination.

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5-42 Antilock Brake System

2535376 2535379
12. Remove the EBCM/BPMV and bracket assembly Cami“: Refer to Fastener Caution 0" Page 0-8-
nuts (1). 3. InstaIIItheBPMV bolts (1) and tighten to 11N-m
13. Remove the EBCM/BPMV and bracket assembly (97 ”3 "1)-
from the vehicle.

1 1

2535376
2535379 4. Install the EBCM/BPMV and bracket assembly to
14. Remove the BPMV bolts (1). the vehicle.
15' Remove the BPMV bracket. 5. install the EBCM/BPMV and bracket assembly
16. if installing a new BPMV, remove the EBCM. Refer "”ts(1)and t'ghte” t017N'm(12"° ft)-
to Electronic Brake Control Module Replacement
on page 5-39.
Installation Procedure
1. If installing a new BPMV, install the EBCM. Refer
to Electronic Brake Control Module Replacement
on page 5—39.
2. Install the BPMV bracket to the BPMV.

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 rm
Antilock Brake System 3.43

8. IW‘§“ /I, -—'/////—:é'.l;1/

5.9 ‘
=1.
2:A fi’
\(Vfi‘g‘

2833466 2495349

6. Install the protective caps (1)to the BPMV 9. Connect the master cylinder primary brake pipe
bracket nuts. fitting(1) to the BPMV and tighten to 18 N-m
(13 lb ft).

ym/g/j r‘l’i‘l‘kiifj .f\ o \'\/\\

2495352
2495345
Note: Install the brake pipes in the same locations
referenced during removal. 10. Connect the master cylinder secondary brake pipe
7. Install the BPMV outlet brake pipe fittings (1) to the fitting(1) to the BPMV and tighten to 18 N-m
BPMV outlet ports. (13 lb ft).
8. Connect the brake pipe fittings and tighten to 11. Connect the EBCM electrical connector.
18N~m(13 lbft). 12. Installthe battery tray. Refer to Battery Tray
Replacement on page 9—721.
13. Bleed the hydraulic brake system. Refer to
Hydraulic Brake System Bleeding (Pressure) on
page 5-169 or Hydraulic Brake System Bleeding
(Manual) on page 5—170.
14. Perform the Diagnostic System Check - Vehicle on
page 6—66.

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5=44 Antilock Brake System

15. Observe the brake pedal feel after performing the Installation Procedure
diagnostic system check. Ifthe pedal now feels 1. Install the BPMV bracket to the BPMV.
spongy, air may have been in the secondary
hydraulic circuit of the brake modulator which may
have been introduced into the primary circuit. Ifthe
pedal feels spongy, bleed the antilock brake
system. Refer to Antilock Brake System
Automated Bleed on page 5-38.

Brake Pressure Modulator Valve

Bracket Replacement

Removal Procedure
1. Remove the brake pressure modulator valve
(BPMV) and bracket assembly. Refer to Brake
Pressure Modulator Valve Replacement on
page 5-40.

2535379
Caution: Refer to Fastener Caution on page 0-8.
2. Install the BPMV bolts (1) and tighten to 11N-m
(97 lb in).
3. Install the BPMV and bracket assembly. Refer to
Brake Pressure Modulator Valve Replacement on
page 5-40.

Front Wheel Speed Sensor

Replacement

Removal Procedure
Warning: Refer to Brake Dust Warning on page 0-4.
and
2535379 1. Raise and support the vehicle. Refer to Lifting
Jacking the Vehicle on page 1-31.
2. Remove the BPMV bolts (1). 2. Remove the tire and wheel assembly. Refer to Tire
3. Remove the BPMV bracket. and Wheel Removal and Installation on
page 16—60.
3. Clean the wheel speed sensor mounting area on
the steering knuckle of any accumulated dirt and
debris.

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 2495364 2495371

4. Disconnect the wheel speed sensor electrical 6. Remove the wheel speed sensor bolt (1).
connector (1) and release the connector from the
vehicle body.

3"
'16?
)- i

2495375

2495367 7. Carefully remove the wheel speed sensor (1) from

the steering knuckle by pulling the sensor straight
5. Release the wheel speed sensor harness upward usinga slight twisting motion.
grommets (1) from the brake hose brackets.

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5=46 Antilock Brake System

Installation Procedure

2495367
3. Install the wheel speed sensor harness
2495375 grommets (1) to the brake hose brackets.
1. install the wheel speed sensor (1) to the steering
knuckle.

_ 2495371
Caution: Refer to Fastener Caution on page 0-8.
2. Install the wheel speed sensor bolt (1) and tighten
to 8 N-m(71 lb in).
2495364
4. Connect the wheel speed sensor electrical
connector (1) and install the connector to the
vehicle body.
5. Install the tire and wheel assembly. Refer to Tire
and Wheel Removal and Installation on
page 16—60.
6. Perform the Diagnostic System Check - Vehicle on
page 6—66.

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 r"
Antilock Brake System o=47

Rear Wheel Speed Sensor

Replacement

Removal Procedure
Warning: Refer to Brake Dust Warning on page 0-4.
1. Raise and support the vehicle. Refer to Lifting and
Jacking the Vehicle on page 1—31.
2. Remove the tire and wheel assembly. Referto Tire
and Wheel Removal and Installation on
page 16—60.

2495379
6. Disconnect the wheel speed sensor electrical
connector (1) and release the connector from the
wheelhouse bracket.
7. Release the wheel speed sensor harness
retainer (2) from the wheel cylinder brake pipe.
8. Release the wheel speed sensor harness
grommets (3) from the bracket.

2535380
3. Remove the rear wheel speed sensor harness
connector cover nuts (1).

2495386
9. Remove the wheel speed sensor bolt (1).

2535381
4. Remove the rear wheel speed sensor harness
connector cover (1).
5. Clean the rear drum brake area around the wheel
speed sensor of any accumulated dirt and debris.

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5=48 Antilock Brake System

2495387 2495386
10. Remove the wheel speed sensor (1)from the rear Caution: Referto Fastener Caution 0” page 0'9-
drum brake spacer by pulling the sensor straight 2. Install the wheel speed sensor bolt (1) and tighten
upward usinga slight twisting motion. 108 N'm (71 lb In).
Installation Procedure

2495379
2495337 3. Connect the wheel speed sensor electrical
connector (1) and install the connector to the
1. Install the wheel speed sensor (1)to the rear drum wheelhouse bracket.
brake spacer. 4. Install the wheel speed sensor harness retainer (2)
to the wheel cylinder brake pipe.
Note: Ifthe wheel speed sensor grommets are
equipped with a molded rib, position the grommets with
the rib at the open end of the wheel speed sensor
harness brackets. Do not twist the wheel speed sensor
harness.
5. Installthe wheel speed sensor harness
grommets (3) to the bracket.

2013
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 Antilock Brake System 5249

8. install the tire and wheel assembly. Refer to Tire

and Wheel Removal and Installation on
page 16-60.
9. Perform the Diagnostic System Check —Vehicle on
page 6-66.

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:
- Electronic brake control module (EBCM)
replacement
- Multi—axisacceleration sensor replacement
The yaw rate sensor calibration procedure can be
completed with a scan tool usingthe following steps:
1. Place vehicle on a level surface.
2. Apply the parking brake, or set the transmission in
the park position.
2535381 3. Install the scan tool to the data link connector.
4. Turn the ignition ON, and the engine OFF.
6. install the rear wheel speed sensor harness
connector cover (1). 5. Select Yaw Rate Sensor Reset in the Multi-axis
Acceleration Sensor Module Control Functions list.
6. Follow the scan tool directions to complete the
calibration procedure.
7. Select Yaw Rate Sensor Learn in the Multi-axis
Acceleration Sensor Module Control Functions list.
8. Follow the scan tool directions to complete the
calibration procedure.
9. Clear any DTCs that may be set.

2535380

7. Install the rear wheel speed sensor harness

connector cover nuts (1) and tighten to 2 N-m
(18 lb in).

—
2013 (US/Canada)
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Manual
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5~50 Antilock Brake System

Vehicle Yaw Sensor Replacement

2505572

Vehicle Yaw Sensor Replacement

Callout Component Name
Preliminary Procedures
1. TurntheignitionOFF.
2. Removethefrontfloorconsole.Referto FrontFloorConsoleReplacementonpage 2-61.
YawSensor Nut
1 Caution: RefertoFastenerCautiononpage0-8.
Tighten
9N-m(80lb in)
VehicleYaw SensorwithVehicleLateralandLongitudinalAccelerometer
Procedure
1. Aftertheinstallationis complete,configuretheyawsensor.Referto Multi-AxisAccelerationSensorModule
ProgrammingandSetuponpage6-11.
2. Aftertheinstallationis complete,performthe VehicleYawSensorLearnonpage5-49.

2013
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Sonic
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Description and Operation
ABS Description and Operation
This vehicle is equipped with the MGH 60 Mando
electronic stability control antilock brake system. The
electronic brake control module and the brake pressure
modulator are serviced separately. The brake pressure
modulator usesa four circuit configuration to control
hydraulic pressure to each wheel independently.
The following vehicle performance enhancement
systems are provided.
~ ABS
- Electronic brake distribution
. Hill Start Hold
- Traction Control System
- Vehicle Stability Enhancement System
The following components are involved in the operation
of the above systems.
- Electronic Brake Control Module—The electronic
brake control module controls the system
functions and detects failures.
- Brake pressure modulator—The brake pressure
modulator contains the hydraulic valves and pump
motor that are controlled electrically by the
electronic brake control module. The brake
pressure modulator uses a four circuit
configuration with a diagonal split. The brake
pressure modulator directs fluidfrom the reservoir
of the master cylinder to the left front and right rear
wheels and fluidfrom the other reservoir to the
right front and left rear wheels. The diagonal
circuits are hydraulically isolated so that a leak or
malfunction in one circuit will allow continued
braking ability on the other.
The brake pressure modulator contains the
following components:
—Pump motor
—inlet valves (one per wheel)
—Outlet valves (one per wheel)
—Two traction control/stability control supply
valves
—Two traction control/stability control isolation
valves
—Brake pressure sensor
- Wheel speed sensors—The wheel speed sensors
are Active sensorsthat receive a 12—voltpower
supplyvoltage from the electronic brake control
module and provides an output signal to the
module. As the wheel spins,the wheel speed
sensor sendsthe electronic brake control module
a DC square wave signal. The electronic brake
control module usesthe frequency of the square
wave signal to calculate the wheel speed.‘
. Traction Control Switch —The vehicle stability
enhancement system and the engine torque
reduction function of the traction control system
are manually disabled or enabled by pressing the
taction traction control switch.
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Antilock Brake System 551
- Steering Wheel Angle Sensor —The electronic
brake control module receives serial data
message inputs from the steering wheel angle
sensor. The steering wheel angle signal is used to
calculate the driver intended driving direction.
- Multi—axisAcceleration Sensor —The yaw rate and
lateral acceleration sensorsare combined into one
multi—axisacceleration sensor, external to the
electronic brake control module. The electronic
brake control module receives serial data
message inputs from the yaw rate and lateral
acceleration sensor and activates stability control
depending on multi—axisacceleration sensor input.
Initialization Sequence
The electronic brake control module performs
one initialization test each ignition cycle. The
initialization of the electronic brake control module
occurs when both the following conditions occur:
- The vehicle speed is greater than 20 km/h
(12 MPH).
. The stop lamp switch is not applied.
The initialization sequence cycles each solenoid valve
and the pump motor,as well as the necessary relays,
for approximately 1.5 seconds 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 electronic brake control module defines a drive
cycle as the completion of the initialization sequence.
Antilock Brake System
When wheel slipis detected during a brake application,
the ABS enters antilock mode. During antilock 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
brake. The ABS cannot, however, increase hydraulic
pressure above the amount which is transmitted by the
master cylinder during braking.
During antilock 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 electronic brake control module responds
to wheel speed sensor inputs and attempts to prevent
wheel slip.These pedal pulsations are present only
during antilock 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 antilock braking
on dry pavement, intermittentchirping noises may be
heard as the tires approach slipping.These noisesand
pedal pulsations are considered normal during antilock
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—ABSsystems. Maintaining a constant
force on the brake pedal provides the shortest stopping
distance while maintaining vehicle stability.
5-52 Antilock Brake System
Pressure Hold
The electronic brake control module closes the inlet
valve and keeps the outlet valve closed in order to
isolate the system when wheel slipoccurs. This holds
the pressure steady on the brake so that the hydraulic
pressure does not increase or decrease.
Pressure Decrease
The electronic brake control module decreases the
pressure to individual wheels during a deceleration
when wheel slipoccurs. The inlet valve is closed and
the outlet valve is opened. The excess fluidis stored in
the accumulator until the return pump can return the
fluidto the master cylinder.
Pressure Increase
The electronic brake control module increases the
pressure to individual wheels during a deceleration in
order to reduce the speed of the wheel. The inlet valve
is opened and the outlet valve is closed. The increased
pressure is delivered from the master cylinder.
Electronic Brake Distribution
The electronic brake distribution is a control system
that replaces the hydraulic proportioning function of the
mechanical proportioning valve in the base brake
system. The electronic brake distribution control
system is part of the operation software in the
electronic brake control module. The electronic brake
distribution uses active control with existing ABS in
order to regulate the vehicle's rear brake pressure.
The red brake warning indicator is illuminated when the
electronic brake distribution function is disabled.
Hill Start Hold
Note: The HillStart Hold feature will not operate if the
Stability control is disabled.
Some vehicles are equipped with the HillHold Start
technology feature. When stopped on a hill, the Hill
Start Hold feature prevents the vehicle from rolling
before driving off, whether facing uphill or downhill by
holding the brake pressure during the transition
between when the driver releases the brake pedal and
starts to accelerate. The Electronic Brake Control
Module calculates the brake pressure, which is needed
to hold the vehicle on an incline or grade greater than
5% and locksthat pressure for up to two seconds by
commanding the appropriate solenoid valves ON and
OFF when the brake pedal is released. The stop lamps
willstay illuminated during the Hill-Hold operation even
though the brake pedal is released, this is considered
normal operation.
The HillStart Hold feature is determined by the
electronic brake control module usingthe following
inputs:
- Accelerator pedal position sensor
- Brake pedal position sensor
- Multi-axis acceleration sensor
Traction Control System
When drive wheel slipis noted while the brake is not
applied, the electronic brake control module will enter
traction control mode.
First, the electronic brake control module requests the
engine control module to reduce the amount of torque
to the drive wheels via the serial data. The engine
control module reduces torque to the drive wheels by
retarding spark timing and turning offfuel injectors. The
engine control module reports the amount of torque
delivered to the drive wheels via the serial data circuit.
- Pressure hold
. Pressure increase
o Pressure decrease
Vehicle Stability Enhancement System
The vehicle stabiiity enhancement system adds an
additional level of vehicle control to the electronic brake
control module.
Yaw rate is the rate of rotation about the vehicles
vertical axis. The vehicle stability enhancement system
is activated when the electronic brake control module
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 from the following
parameters:
- The position ofthe steering wheel
- The speed of the vehicle
° The lateral acceleration of the vehicle
The difference between the desired yaw rate and the
actual yaw rate is the yaw rate error, which is a
measurement of over steer or under steer. if the yaw
error becomes too large, the electronic brake control
module attempts to correct the vehicles yaw rate
motion by applying differential braking to the
appropriate wheel. The amount of differential braking
applied to the left or right front wheel is based on both
the yaw rate error and side sliprate error.
The vehicle stability enhancement system activations
generally occur during aggressive driving, in turns or on
bumpy roads without much use of the accelerator
pedal. When braking during vehicle stability
enhancement system activation, the pedal pulsations
feel different than the ABS pedal pulsations. The brake
pedal pulsates at a higher frequency during vehicle
stability enhancement system activation.
Information Indicator
Driver
Brake Warning Indicator
The instrument cluster turns five brake warning
indicator ON when the following occurs:
' The instrument cluster performs the bulb check.
- The electronic brake control module detects some
faults, such as more than two wheel speed
sensorsare defective or the failure relating to the
basic brake system occurs and sendsa serial data
message to the instrument cluster requesting
illumination.
- The park brake is engaged or the brake fluidlevel
is low.
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Manual
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 Antilock Brake System 553

ABS Warning Indicator Stability Control System OFF Indicator

The instrument cluster turns the ABS warning indicator The instrument cluster turns the Stability Control Off
ON when the following occurs: indicator ON when the following occurs:
- The instrument cluster performs the bulb check. - The instrument cluster performs the bulb check.
- The electronic brake control module detects a ° The driver manually disables the stability control
malfunction which disables the ABS and sendsa by pressing an holding the traction control switch
serial data message to the instrument cluster down for five seconds. The electronic brake
requesting illumination. control module sendsa serial data message to the
instrument cluster requesting illumination.
Traction Control SystemlStability Control
- The electronic brake control module detects a
System Warning Indicator malfunction which disables the stability control
system it sendsa serial data message to the
The instrument cluster turns the traction control system/ instrument cluster requesting illumination of the
stability control system warning indicator ON when the Stability Control Off indicator.
following occurs:
- The instrument cluster performs the bulb check. Special Tools and Equipment
- The electronic brake control module detects a
malfunction which disables the traction control or
stability control and sendsa serial data message Illustration Tool Number] Description
to the instrument cluster requesting illumination.
Traction Control System OFF Indicator
The instrument cluster turns the Traction Control Off
indicator ON when the following occurs: EL 35616-F
- The instrument cluster performs the bulb check. J 35616
- The driver manually disables the traction control TerminalTestKit
by pressing the traction control switch one time
and releasing it. The body control module and
electronic brake control module sendsa serial
data message to the instrument cluster requesting 8917
illumination.
° The electronic brake control module detects a
malfunction which disables the traction control and
sendsa serial data message to the instrument
cluster requesting illumination of the Traction
Control Off indicator.

—
2013 (US/Canada)
Sonic (5377994)
Manual
Service
52-54 Disc Brakes

Disc Brakes

Specifications

Fastener Tightening Specifications

Specification
Application Metric , English
BrakeCaliperBleederValve 17N-m 13lbft
BrakeCaliperBracketBolt 100N-m 74lbft
BrakeCaliperGuide Pin Bolt 28N-m 21lbft
BrakeHose FittingBolt 4ON-m 30lbft
BrakePipe Fitting 18N°m 13lbft
BrakeRotorBolt 9 N-m 80lbin
BrakeShield Bolt 9 Wm 80lbin

Disc Brake Component Specifications

Specification
Application Metric English
FrontRotor
RotorDiameter 276.0mm . 10.866in
RotorDiscardThickness* 23.0mm 0.905in
RotorMaximumAllowableAssembledLateralRunout 0.06mm 0.002in
RotorMaximumAllowableScoring 1.50mm 0.059in
RotorMaximumAllowableThicknessVariation 0.02mm 0.0008in
RotorMinimumAllowableThicknessAfterRefinish 24.0mm 0.945in
RotorThicknessNew 26.0mm 1.024in
Rear Rotor
RotorDiameter 268.0mm 10.551in
RotorDiscardThickness* 10.0mm 0.393in
RotorMaximumAllowableAssembledLateralRunout 0.05mm 0.002 in
RotorMaximumAllowableScoring 1.50mm 0.059in
RotorMaximumAllowableThicknessVariation 0.02mm 0.0008in
RotorMinimumAllowableThicknessAfterRefinish 10.2mm 0.402in
RotorThicknessNew 12.0mm 0.472in
*All brakerotorshavea minimumthicknessdimensioncast intothem.Replaceanyrotorthatis wornor machinedbelowthis
specification.

(US/Canada)
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2013 (5377994)
Manual
Service

and
Diagnostic Information
Procedures
Brake Rotor Thickness Measurement
Warning: Refer to Brake Dust Warning on page 0-4.
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 on page 5-61.
2308612
N. Clean the friction surfaces of the brake rotorwith
denatured alcohol, or an equivalent approved
brake cleaner.
3. Usinga micrometer(1) calibrated in
thousandths-of—a—millimeter, ,
or ten—thousandths—of-an—inch, measure and record
the thickness of the brake rotor at four or more
points, evenly spaced around the brake rotor.
Make sure 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 brake rotor,about 13 mm (1/2in),for
each measurement.
. Compare the lowest thickness measurement
4:.
recorded to the specifications. Refer to Disc Brake
Component Specifications on page 5—54..
U1. Ifthe lowest thickness measurement of the brake
rotor is above the minimum allowable thickness
after refinishing specification, the brake rotor may
be able to be refinished, depending upon surface
and wear conditions which may be present.
0). Ifthe lowest thickness measurement of the brake
rotor is at or below the discard thickness
specification, the brake rotor requires replacement.
(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
Disc Brakes '
5 05UK
Brake Rotor Thickness Variation
Measurement
Warning: Refer to Brake Dust Warning on page 0-4.
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.
1. Ifthe 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 on page 5—61.
2. Clean the friction surfaces of the brake rotor with
denatured alcohol, or an equivalent approved
brake cleaner.
2308612
3. Usinga 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 brake rotor.
Make sure 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 brake rotor,about 13 mm (1/2in),for
each measurement.
4. Calculate the difference between the highest and
lowest thickness measurements recorded to obtain
the amount of thickness variation.
Note: Whenever a brake rotor is refinished or
replaced, the assembled lateral runout (LRO) of the
brake rotor must be measured to make sure optimum
performance of the discbrakes.
5. Compare the thickness variation measurement to
the following specification:
5=56 Disc Brakes
Specification
0 J93, J94: 0.02 mm (0.0008 in)
- JPW, .197:0.02 mm (0.0008 in)
6. Ifthe brake rotor thickness variation measurement
exceeds the specification, the brake rotor requires
refinishing or replacement.
Brake Rotor Surface and Wear
Inspection
Warning: Refer to Brake Dust Warning on page 0-4.
1. Ifthe inboard friction surface of the brake rotor is
not accessible, reposition and support the caliper
with the brake pads. Refer to Front DiscBrake
Pads Replacement on page 5-61.
2. Clean the friction surfaces of the brake rotor with
denatured alcohol, or an equivalent approved
brake 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 brake rotor.
- Cracks and/or heat spots
- Too much blueing discoloration
4. Ifthe friction surfaces of the brake rotor exhibit one
or more of the braking surface conditions, the
brake rotor requires refinishing or replacement.
2308612
5. Usinga micrometer(1) calibrated in
thousandths—of—a—milIimeter,
or ten—thousandths-of—an-inch, measure and record
the scoring depth of any grooves present on the
brake rotor friction surfaces.
6. Compare the groove scoring depth recorded to the
following specification:
Specification
Brake rotor maximum allowable scoring: 1.50 mm
(0.059 in) .
7. Ifthe brake disc rotor scoring depth exceeds the
specification, or if an excessive amount of scoring
is present, the brake rotor requires refinishing or
replacement.
Brake Rotor Assembled Lateral
Runout Measurement
Special Tools
- CH—41013Rotor Surfacing Kit
- CH—42450-AWheel Hub Resurfacing Kit
- CH-45101 Hub and Wheel Runout Gauge
- CH—45101—100 Conical Brake Rotor Washers
For equivalent regional tools, refer to Special Tools on
page 5—86. ‘
Warning: Refer to Brake Dust Warning on page 0-4.
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—11,300km (3,000—7,000mi).
- Brake rotor thickness variation MUST be
inspected BEFORE inspecting for assembled
lateral runout (LRO). Thickness variation
exceeding the maximum acceptable level can
cause brake pulsation. Refer to Brake Rotor
Thickness Variation Measurement on
page 5—55.
1. Matchmark the position of the brake rotorto 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 ofthe hub/axle flange
and the brake rotor to make sure that there are no
foreign particles, corrosion, rust, or debris
remaining. lfthe wheel hub/axle flange and/or
brake rotor mating surfaces exhibit these
conditions, perform the following steps:
2.1. Remove the brake rotorfrom the vehicle.
Refer to Front Brake Rotor Replacement on
page 5-77. “
2.2. Usingthe CH—42450-Awheel hub resurfacing
kit, thoroughly clean any rust or corrosion from
the mating surface of the hub/axle flange.
2.3. Usingthe CH—41013rotor resurfacing kit,
thoroughly clean any rust or corrosion from the
mating surface ofthe brake rotor.
2.4. Clean the friction surfaces of the brake rotor
with denatured alcohol, or an equivalent
approved brake cleaner.
(US/Canada)
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2013 (5377994)
Manual
Service
 Disc Brakes (J?
(“lit ‘1‘.

3. Install the rotor to the hub/axle flange usingthe 9. Ifthe brake rotor meets the following criteria,
matchmark made prior to removal. proceed to step 10.
- The rotor is within specifications and is being
REUSED.
1 2 - The rotor has NOT been refinished.
/— - The rotor does not exhibit thickness variation
/ \ exceeding the maximum allowable level.
fa
/ \

9 m

2308615
4. Hold the brake rotorfirmly in place against the hub/
axle flange and install one of the CH—45101-100
conical brake rotorwashers (1), and one lug
nut (2) onto the upper—mostwheel stud.
5. Continue to hold the brake rotor secure and tighten
the '“9 ””t firm” by hand'
2308617
6. Install the remaining CH-45101-100 conical brake
rotor washers (1)and lug nuts onto the wheel studs
and tighten the nuts firmly by hand in the tightening
sequence. . .
7- Tighten the lug nuts Insequence, in order to
properly secure the rotor. Refer to Tire and Wheel
Removal and Installation on page 16-60.
8. Ifthe brake rotor has been REFINlSHEDor
REPLACED with a new rotor,proceed to step14.
2303513
10. Mount a dial indicator, CH-45101 hub and wheel
runout gauge (1), 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:
11.1. Rotate the rotor until the lowest reading is
displayed on the indicator dial, then set the
dial to zero.
11.2. Rotate the rotor until the highest reading is
displayed on the dial.
11.3. Mark the location of the high spot relative to
the nearest wheel stud, or studs.
11.4. Measure and record the amount of
assembled 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)
13_ [fthe brake rotor assembled LRO is within
specifications, proceed to step 18.
hethe brake rotor assembled LRO exceeds the
specification, refinish the rotor to ensure true
parallelism. Refer to Brake Rotor Refinishing on
page 5-85. After refinishing the rotor,proceed to
step 14.

(US/Canada)
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2013 (5377994)
Manual
Service
558 Disc Brakes
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.
15.1. Rotate the rotor until the lowest reading is
displayed on the indicator dial, then set the
dial to zero.
15.2. Rotate the rotor until the highest reading is
displayed on the dial.
15.3. Mark the location of the high spot relative to
the nearest wheel stud, or studs.
15.4. Measure and record the amount of
assembled 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) .
17. Ifthe brake rotor assembled LRO measurement
exceeds the specification, bring the LRO to within
specifications. Refer to Brake RotorAssemb/ed
Lateral Runout Correction on page 5—83.
18. Itthe brake rotor assembled LRO measurement is
within specification, install the brake caliper and
depress the brake pedal several times to secure
the brake rotor in place before removing the
CH—45101—100 conical brake rotor washers and
the lug nuts.
Brake Pad Inspection
31717171717171 71717171717171
2327888
Warning: Refer to Brake Dust Warning on page 0-4.
1. inspect the discbrake pads at regular intervals,
orwhenever the tire and wheel assemblies are
removed from the vehicle.
. lf replacement is necessary, always replace disc
brake pads in axle sets.
. Inspect both edges of the discbrake pad friction
surfaces (3).The highest rate of wear normally
occurs at the trailing edge of the discbrake pads.
. Inspect the thickness of the disc brake pads (3) in
order to ensure that they have not worn
prematurely. The disc brake pad wear should be
approximately even per axle set.
. Front brake pads have integral, audible wear
sensors(1). When the discbrake pad wear
reaches the minimum allowable thickness, the
wear sensor contacts the disc brake rotor(2). The
wear indicator will then produce an audible,
high-pitched warning noise during wheel rotation.
. Replace the discbrake pads when the friction
surface (3) is worn to within 2.00 mm (0.079 in) of
the mounting plates.
. Verify that any discbrake pad shimsthat may be
required are in place and not damaged or
excessively corroded. Replace any missingor
damaged shimsin order to preserve proper disc
brake performance.
. Replace the discbrake pads if any have separated
from the mounting plates.
. Inspect the discbrake pads friction surfaces for
cracks, fractures, or damage which may cause
noise or otherwise impair discbrake performance.
Brake Caliper Inspection
2308620
Warning: Refer to Brake Dust Warning on page 0-4.
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.
2013
-Sonic
(US/Canada)
Service
Manual
(5377994)

2. Inspect the caliper piston dust boot seal (2) 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. lnspect for brake fluidleakage around the caliper
piston dust boot seal (6) and on the discbrake
pads. Ifthere is any evidence of brake fluid
leakage, the brake caliper requires overhaul or
replacement.
2308622
4. 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. Ifthe
caliper piston is frozen or difficult to bottom, the
caliper requires overhaul or replacement.
- Inserta discarded inner brake pad (2) or block
of wood in front of the piston. Usinga large
C-clamp (1) installed over the body of the
caliper (3) and against the brake pad or block of
wood, slowlybottomthe piston in the bore.
(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
Disc Brakes 51-59
Front Disc Brake Mounting and
Inspection
Hardware
Warning: Refer to Brake Dust Warning on page 0-4.
2027304
1. Inspect the fluidlevel in the brake master cylinder
reservoir.
2. Ifthe brake fluidlevel is midway between the
maximum-full point and the minimum allowable
level then no brake fluidneeds to be removed from
the reservoir before proceeding.
3. Ifthe brake fluid level is higher than midway
between the maximum-full point and the minimum
allowable level then remove brake fluidto the
midway point before proceeding.
4. Raise and support the vehicle. Refer to Lifting and
Jacking the Vehicle on page 1-31.
5. Remove the tire and wheel assembly. Refer to Tire
and Wheel Removal and Installation on
page 16-60.
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.
7. Compress the front caliper pistons.
7.1. Install a large C—clampover the top of the
caliper housing and against the back of the
outboard pad (1).
7.2. Slowly tighten the C-clamp until the pistons
are pushed completely into the caliper bores.
7.3. Remove the C—clampfrom the caliper.
5460 Disc Brakes
8. 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. Ifthe 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 bushingsfor wear or damage.
Ifwear or damage conditions are found,
replacement of the brake caliper mounting bolts
and/or the brake caliper mounting bracket
bushings is necessary.
9. Remove the brake caliper mounting bolts from the
brake caliper mounting bracket and support the
brake caliper usingheavy mechanics wire. Do Not
remove the hydraulic brake hose from the caliper.
Refer to Front Brake Caliper Replacement on
page 5—65.
10. Remove the disc brake pads (1,2) from the brake
caliper mounting bracket (3).
11. Inspect the disc brake pad mounting hardware for
the following:
- Missingmounting 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.
12. Ifany of the conditions listed are found, the disc
brake pad mounting hardware requires
replacement.
13. 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.
- Looseness in the brake caliper mounting
bracket (3).
- Bent or damaged brake caliper mounting
bolts (1).
- Cracked or torn boots (4).
- Missingboots.
~ 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 discbrake pads to the brake caliper
mounting bracket.
17. Install the discbrake caliper to the brake caliper
mounting bracket. Refer to Front Brake Caliper
Replacement on page 565.
Rear Disc Brake Mounting and
Hardware Inspection
Warning: Refer to Brake Dust Warning on page 0-4.
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.
1. Without disconnecting the hydraulic brake hose
fitting, remove rear brake caliper and support with
heavy mechanics wire. Refer to Rear DiscBrake
Pads Replacement on page 5-63.

\\

2028131
2. Remove the discbrake pads (1)from the brake
344219 caliper mounting bracket (2).
3. Inspect the discbrake pad mounting
14. Inspect the caliper bolts (1) for the following:
hardware (3)for the following:
' Binding
' Missingmounting hardware.
- Seizing
- Excessive corrosion.

2013
—
Sonic
(US/Canada)
Service
Manual
(5377994)
 Disc Brakes 5=61
. Bent pad retainer spring.
- Looseness at the brake caliper bracket.
' Looseness at the disc brake pads.
° Excessive contaminants in the brake caliper
bracket surface and caliper bracket bolt
threaded holes.
4. if any of the conditions listed are found, the disc
brake pad mounting hardware requires
replacement.
5. Ensure the discbrake pads are held firmly in place
on the caliper bracket, yet slide easily on the
mounting hardware without binding.
6. Install the discbrake pads to the caliper bracket.
7. Install the rear brake caliper to the bracket. Refer
to Rear DiscBrake Pads Replacement on
page 5—63

Repair Instructions

2375915
Front Disc Brake Pads Replacement

Removal Procedure - DO NOT use any air tools to remove or install

Warning: Refer to Brake Dust Warning on page 0-4.
Note: Always replace disc brake pads in axle sets.
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, no brake fluidneeds to be removed before
proceeding.
3. Ifthe brake fluid level is higher than midway
between the maximum-full point and the minimum
allowable level, remove brake fluid to the midway
point before proceeding.
4. Raise and support the vehicle. Refer to Lifting and
Jacking the Vehicle on page 1-31.
5. Remove the tire and wheel assembly. Refer to Tire
and Wheel Removal and Installation on
page 16-60.
6. Place a large C-clamp over the brake caliper body
and against the outer brake pad.
7. Usingthe C—clamp,compress the brake caliper
piston fully into the brake caliper bore.
the guide pin bolts. Use hand tools ONLY.
- Install an open end wrench to hold the caliper
guide pin in line with the brake caliper while
removing or installing the caliper guide pin bolt.
DO NOTallow the open end wrench to come in
contact with the brake caliper. Allowing the
open end wrench to come in contact with the
brake caliper will cause a pulsation when the
brakes are applied.
8. Usinga backup wrench to hold the brake caliper
guide pin stationary, remove the lower brake
caliper guide pin bolt (1).
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.
9. Rotate the brake caliper upward and support with
heavy mechanics wire or equivalent.

2013
~Sonic
(US/Canada)
Service
Manual
(5377994)
562 Disc Brakes

Installation Procedure
1. Thoroughly clean the contact surfaces of the brake
caliper bracket of any corrosion or debris.

2375916
Note: Note the location of the brake pad wear sensor 1
for correct installation.
10. Remove the inner brake pad (1).
11. Remove the outer brake pad (2). 2375917
Note: If installing new brake pads, install new brake
pad springs.
2. Install the upper and lower brake pad springs(1).

' \
7 I”’\-.\\V\\
.1.
~y:.~., \ [(271 :0 .
I’S7UK@’};V

.. 4:» \L// /‘.‘ 3‘4?» ‘ .

. "471:/.1131"

2375917
12. Remove the upper and lower brake pad
springs(1).
13. If installing new brake pads, discard the brake pad . 2375916
springs. Note: Note the location of the brake pad wear sensor
for correct installation.
3. Install the inner brake pad (1).
4. Install the outer brake pad (2).
5. Position the brake caliper over the brake pads and
to the caliper bracket.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)

2375915
Caution: Refer to Fastener Caution on page 0-8.
6. Usinga backup wrench to hold the brake caliper
guide pin stationary, install the lower brake caliper
guide pin bolt (1)and tighten to 28 N-m(21 lb ft).
7. Install the tire and wheel assembly. Referto Tire
and Wheel Removal and Installation on
page 16-60.
8. With the engine OFF, gradually apply the brake
pedal to approximately 2/3 of its travel distance.
9. Slowly release the brake pedal.
10. Wait 15 seconds, then repeat steps 8-9 until a firm
brake pedal is obtained. This will properly seat the
brake caliper piston and brake pads.
11. Fill the master cylinder reservoir. Refer to Master
Cylinder Reservoir Filling on page 5-145.
12. Burnish the brake pads and rotors. Refer to Brake
Pad and Rotor Burnishing on page 5—65.
Rear Disc Brake Pads Replacement
Removal Procedure
Warning: Refer to Brake Dust Warning on
page 0-4.
Note: Always replace disc brake pads in axle sets.
1. Inspect the fluid level in the brake master cylinder
reservoir. ,
2. Ifthe brake fluid level is midway between the
maximum-full point and the minimum allowable
level, no brake fluid needs to be removed before
proceeding.
3. Ifthe brake fluid level is higher than midway
between the maximum—fullpoint and the minimum
allowable level, remove brake fluid to the midway
point before proceeding.
(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
Disc Brakes 5:63
4. Raise and support the vehicle. Refer to Lifting and
Jacking the Vehicle on page 1-31.
5. Remove the tire and wheel assembly. Referto Tire
and Wheel Removal and Installation on
page 16-60.
2843743
Note:
- DO NOT use any air tools to remove or install
the guide pin bolts. Use hand tools ONLY.
~ Install an open end wrench to hold the caliper
guide pin in line with the brake caliper while
removing or installing the caliper guide pin bolt.
DO NOT allow the open end wrench to come in
contact with the brake caliper. Allowing the
open end wrench to come in contact with the
brake caliper will cause a pulsation when the
brakes are applied.
6. Usinga backup wrench to hold the brake caliper
guide pinsstationary, remove the brake caliper
guide pin bolts (1).
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.
7. Remove the brake caliper and support with heavy
mechanics wire.
564 Disc Brakes

2843745 2843746
8. Remove the outer disc brake pad (1). Note: if installing new brake pads, install new brake

9. Remove the inner discbrake pad (2). pad springs.

3. Install the discbrake pad springs(1).

2843746
Note: If replacing the disc brake pads, discard the 2843745
springs. 4. Install the outer discbrake pad (1).
10. Remove the disc brake pad springs (1). 5. Install the inner discbrake pad (2).
- Note: Ensure the notches in the caliper piston are
InStallatlon Procedure properly aligned with the pinson the discbrake pad
1. Usinga brake caliper piston spanner tool, rotate backing plate,
while applying
the caliper piston clockwisecaliper .. . .
pressure to the face of the piston to 6. PosrtIonthe brake caliper over the disc brake pads
compress the piston into the caliper bore. and t0 the caliper bracket.
2. Thoroughly clean the contact surfaces of the brake
caliper bracket of any corrosion or debris.

—
2013 (US/Canada)
Sonic (5377994)
Manual
Service
 Disc Brakes 5155
Note: Use care to avoid overheating the brakes while
performing this step as it may adversely affect the
heating characteristics of the NEW brake pad material.
3. Usingmoderate 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: Refer to Brake Dust Warning on page 0-4.
Warning: Refer to Brake Fluid Irritant Warning on
page 0-4.
1. Raise and support the vehicle. Refer to Lifting and
Jacking the Vehicle on page 1—31.
2843743
2. Remove the tire and wheel assembly. Refer to Tire
Caution: Refer to Fastener Caution on page 0—8. and Wheel Removal and Installation on
7. Usinga backup wrench to hold the brake caliper page 16—60.
guide pinsstationary, install the brake caliper guide
pin bolts (1) and tighten to 28 N-m(21 lb ft).
8. Installthe tire and wheel assembly. Refer to Tire
and Wheel Removal and Installation on
page 16-60. ’i/ (9
9. With the engine OFF, gradually apply the brake
l) gafl/B‘\\x
pedal to approximately 2/3 of its travel distance.
10. Slowly release the brake pedal. i i “/- 2E
11. Wait 15 seconds, then repeat steps 9-10 until a firm /
brake pedal is obtained. This will properly seat the i
. \s
M /: It»)
brake caliper piston and brake pads.
12. Fill the master cylinder reservoir. Refer to Master
Cylinder Reservoir Filling on page 5-145.
13. Burnish the brake pads and rotors. Refer to Brake
Pad and Rotor Burnishing on page 565.

Brake Pad and Rotor Burnishing

Warning: Road test a vehicle under safe conditions
and while obeying all traffic laws. Do not attempt
any maneuvers that couldjeopardize vehicle
control. Failure to adhere to these precautions 2375918
could lead to serious personal injury and vehicle
damage. 3. Remove the brake hose fitting bolt (1).
Note: Do not reuse the brake hose fitting gaskets.
Burnishing the brake pads and brake rotors is
necessary in order to ensure that the braking surface 4. Remove and discard the brake hose fitting
are properly prepared after service has been performed gaskets (2)from the brake hose fitting (3).
on the discbrake system. 5. Cap the brake hose fittingto prevent brake fluid
This procedure should be performed whenever the disc lossand contamination.
brake rotors have been refinished or replaced, and/or
whenever the 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).

(US/Canada)
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Manual
Service
 Caution: Refer to Fastener Caution on page 0-8.
2. Using a backup wrench to hold the brake caliper
guide pin stationary, install the brake caliper guide
pin bolts (1)and tighten to 28 Nm (21 lbft).

1 2 3 2

-’'I’I
'.
(IL

§a‘
\‘e ‘,/-‘
’7'"
I'll:
Pl/
l"‘V -‘—:’E+’\“~"
'ray
» 7"»?‘\
A-
«x
2375919 IE, - v.4 (. ‘
.A"‘«f
-' \\ #5
\ ./:_
- DO NOT use any air tools to remove or install
the guide pin bolts. Use hand tools ONLY.
- install an open end wrench to hold the caliper 2375918
guide pin in line with the brake caliper while Note: Install new brake hose fitting gaskets.
removing or installing the caliper guide pin bolt.
DO NOT allow the open end wrench to come in 3. Assemble the brake hose fitting bolt (1)and
contact with the brake caliper. Allowing the the 2 new brake hose fitting gaskets (2)to the
open end wrench to come in contact with the brake hose fitting (3).
brake caliper will cause a pulsation when the 4. Install the brake hose assembly and tighten the
brakes are applied. brake hose fitting bolt to 40 Nm (30 lb ft).
Using a backup wrench to hold the brake caliper 5. Bleed the hydraulic brake system. Refer to
guide pin stationary, remove the brake caliper Hydraulic Brake System Bleeding (Pressure) on
guide pin bolts (1). page 5-169 or Hydraulic Brake System Bleeding
7. Remove the brake caliper. (Manual) on page 5—170.
6. Install the tire and wheel assembly. Referto Tire
Installation Procedure and Wheel Removal and Installation on
page 16-60.

1 Rear Brake Caliper Replacement

9
_ ‘ Removal Procedure
@ 714‘
\%E}I”,"" W Warning: Refer to Brake Dust Warning on
Q.) ...vg ,hfiisg." \. \ page 0-4.
\ .)'a.!U‘\‘\‘_\
/ 9:: till Warning: Refer to Brake Fluid Irritant Warning on
7
\\4.:~;. page 0-4.
W“ ”55?”
1. Raise and support the vehicle. Refer to Lifting and
Jacking the Vehicle on page 1-31.
‘msie 3f“! 2. Remove the tire and wheel assembly. Refer to Tire
and Wheel Removal and Installation on
page 16-60.

2375919
1. Position the brake caliper over the brake pads and
to the caliper bracket.

(US/Canada)
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2013 (5377994)
Manual
Service
 Disc Brakes 5=o7

2843784
3. Remove the parking brake cable retaining
clip (1)from the parking brake cable bracket.
2843788
5. Remove the brake hose fitting bolt (1).
Note: Do not reuse the brake hose fitting gaskets.
6. Remove and discard the brake hose fitting
gaskets (2)from the brake hose fitting (3).
7. Cap the brake hose fitting to prevent brake fluid
loss and contamination.

‘>/ .i’ Hflg

4‘ ‘ 3.,- ‘ .fl-7'
-\r1
:Lfl 49/

r=iw
2 - t_-

2843786

4. Disconnect the parking brake cable (1)from the

actuator lever, remove the cable from the bracket
and position aside.
2843789
Note:
- DO NOT use any air tools to remove or install
the guide pin bolts. Use hand tools ONLY.
- Install an open end wrench to hold the caliper
guide pin in line with the brake caliper while
removing or installing the caliper guide pin bolt.
DO NOT allow the open end wrench to come in
contact with the brake caliper. Allowing the
open end wrench to come in contact with the
brake caliper will cause a pulsation when the
brakes are applied.

—
2013 (US/Canada)
Sonic (5377994)
Manual
Sen/ice
5=68 Disc Brakes
8. Using a backup wrench to hold the brake caliper
guide pins stationary, remove the brake caliper
guide pin bolts (1).
9. Remove the brake caliper.
Installation Procedure
Note: The brake caliper piston must be fully retracted
into the caliper bore before installation.
1. Using a brake caliper piston spanner tool, rotate
the brake caliper piston clockwise while applying
pressure to the face of the caliper piston to
compress the piston into the caliper bore.

2843788
Note: Install new brake hose fitting gaskets.
4. Assemble the brake hose fitting bolt (1)and the
new brake hose fitting gaskets (2)to the brake
hose fitting (3).
5. Install the brake hose assembly and tighten the
brake hose fitting bolt to 40 N-m(30 lb ft).

2843789
Note: Ensure the notches in the caliper piston are
properly aligned with the pins on the disc brake pad
backing plate.
2. Position the brake caliper over the brake pads and
to the caliper bracket.
Caution: Refer to Fastener Caution on page 0-8.
3. Using a backup wrench to hold the brake caliper
guide pins stationary, install the brake caliper guide
pin bolts (1) and tighten to 28 N-m(21 lb ft).

2843786
6. Install the parking brake cable (1)to the parking
brake cable bracket and the actuator lever.

—
2013 (US/Canada)
Sonic (5377994)
Manual
Service
 Disc Brakes o=69

QI‘xJ-E“ . :3.
.‘f'\\:.'-‘
¢ti "‘11:;
'- v '/.,,.I >
>\A\|l/.1>\
"fill“.

2843784 2027571

7. install the parking brake cable retaining 2. Remove the brake caliper piston from the caliper
clip (1)from the parking brake cable bracket. bore by directing low pressure compressed air into
the caliper (1) through the fluid inlet hole.
8. Bleed the hydraulic brake system. Refer to
Hydraulic Brake System Bleeding (Pressure) on
page 5—169or Hydraulic Brake System Bleeding
(Manual) on page 5—170.
9. Installthe tire and wheel assembly. Refer to Tire
and Wheel Removal and Installation on
page 16-60.

Front Brake Caliper Overhaul

Disassembly Procedure
Warning: Refer to Brake Dust Warning on page 0-4.
Warning: Refer to Brake Fluid Irritant Warning on
page 0-4.
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. Ifthe pistons are 2027576
blown out, even with the padding provided, it may be 3. Remove the piston dust boot seal (1)from the seal
damaged. counterbore in the caliper (4). Discard the
1. Remove the brake caliper from the vehicle. Refer boot seal.
to Front Brake Caliper Replacement on page 5—65. 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. Ifcracks, scoring, pitting, excessive rust, and/or
excessive corrosion are present in the caliper bore,
replace the caliper assembly.

(US/Canada)
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Manual
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5-70 Disc Brakes
8. Iflight 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

2027577
4. install the new piston dust boot seal (1) over the
caliper piston (2).
5. Install the bottom half of the caliper piston into the
caliper bore.
6. Compress the caliper piston to the bottom of the
caliper bore.
7. Fully seat the piston dust boot seal into caliper
counterbore.
Caution: Refer to Fastener Caution on page 0-8.
8. install the bleeder valve to the caliper.
' J93, J94: Tighten the valve to 17 Nm (13 lb ft)
- JPW, J97: Tighten the valve to 9N-m (80 lb in)
9. Install the bleeder valve cap.
10. install the brake caliper to the vehicle. Refer to
Front Brake Caliper Replacement on page 5-65.

Front Brake Caliper Bracket

2027576
1. Lubricate the new piston seal (3) with brake fluid
from a Clean, sealed brake fluid container.
2. Install the lubricated, new piston seal into the
caliper bore.
3. Apply a thin coat of brake fluid from a clean, sealed
brake fluid container.
Replacement
Removal Procedure
Warning: Refer to Brake Dust Warning on page 0-4.
1. Raise and support the vehicle. Refer to Lifting and
Jacking the Vehicle on page 1-31.
2. Remove the tire and wheel assembly. Referto Tire
and Wheel Removal and Installation on
page 16-60.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Disc Brakes 5471

2375920 2375921
Note: Note the location of the wear sensor for correct
Note:
installation.
- DO NOT use any air tools to remove or install
the guide pin bolts. Use hand tools ONLY. 5. Remove the inner brake pad (1).
- Install an open end wrench to hold the caliper 6. Remove the outer brake pad (2).
guide pin in line with the brake caliper while
removing or installing the caliper guide pin bolt.
DO NOT allow the open end wrench to come in
contact with the brake caliper. Allowing the
open end wrench to come in contact with the
brake caliper will cause a pulsation when the
brakes are applied.
3. Hold the brake caliper guide pin stationary and
remove the brake caliper guide pin bolts (1).
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.
4. Remove the brake caliper and support with heavy
mechanics wire or equivalent.

1873947

7. Remove the brake pad springs (1).

—
2013 (US/Canada)
Sonic (5377994)
Manual
Service
5=72 Disc Brakes

_ 1t

2375922 1873956
Note: The upper brake caliper guide pin is equipped
12. Remove the brake caliper bracket (1).
with a bushing and must be installed in the same
location. Installation Procedure
8. Remove the upper brake caliper guide pin (1).
9. Remove the lower brake caliper guide pin (2).
10. Remove the 2 brake caliper guide pin seals. 1") G!" ‘.

1873956
1. Installthe brake caliper bracket (1).

1873953
Note: Do not reuse the brake caliper bracket bolts.
11. Remove and discard the brake caliper bracket
bolts (1).

2013
—Sonic
(US/Canada)
Service
Manual
(5377994)
 Disc Brakes 5-73

1873953 2375922
Caution: Refer to Fastener Caution on page 0-8. 4. Install the 2 brake caliper guide pin seals.
- pm
5 . Ensure the brake cali per guide - seals are fully
2. Install
. . caliper bracket bolts (1) and
2 new brake
tighten to 100 N "1174") ft)‘ seated in the groove of the brake caliper bracket.
Note: The upper brake caliper guide pin is equipped
with a bushing and must be installed in the same
locafion.
6. Install the upper brake caliper guide pin (1).
7. Install the lower brake caliper guide pin (2).
8. Ensure the brake caliper guide pin seals are fully
seated in the groove of the brake caliper
guide pins.

1873947
3. Install the brake pad springs (1).

2375921
Note: Note the location of the wear sensor for correct
installation.
9. Install the inner brake pad (1).
10. Install the outer brake pad (2).
11. Position the brake caliper over the brake pads and
to the caliper bracket.

—
2013 (US/Canada)
Sonic (5377994)
Manual
Service
5—74 Disc Brakes

Note:
- DO NOT use any air tools to remove or install
the guide pin bolts. Use hand tools ONLY.
- Install an open end wrench to hold the caliper
guide pin in line with the brake caliperwhile
removing or installing the caliper guide pin bolt.
DO NOTallow the open end wrench to come in
contact with the brake caliper. Allowing the
open end wrench to come in contact with the
brake caliper will cause a pulsation when the
brakes are applied.
3. Using a backup wrench to hold the brake caliper
guide pins stationary, remove the brake caliper
guide pin bolts (1).
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
2375920 brake hose and in turn may cause
a brake fluid leak.
12. Using a backup wrench to hold the brake caliper 4. Remove the brake caliper and support with heavy
guide pin stationary, install the brake caliper guide mechanics wire.
pin bolts (1)and tighten to 28 N-m(21 lbft).
13. Install the tire and wheel assembly. Referto Tire
and Wheel Removal and Installation on
page 16-60.

Rear Brake Caliper Bracket

Replacement

Removal Procedure
Warning: Refer to Brake Dust Warning on
page 0-4.
1. Raise and support the vehicle. Refer to Lifting and
Jacking the Vehicle on page 1—31.
2. Remove the tire and wheel assembly. Refer to Tire
and Wheel Removal and Installation on
page 16-60.

2843745
5. Remove the outer disc brake pad (1).
6. Remove the inner disc brake pad (2).

2843743

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Disc Brakes 5=75

2843746 2844044

7. Remove the disc brake pad springs (1). 10. Remove the brake caliper guide pin seals (1).

° 17;; .'
fiflm".

2844041
8. Remove the upper brake caliper guide pin (1).
Note: The lower brake caliper guide pin is equipped
with a bushing and must be installed in the same
location.
9. Remove the lower brake caliper guide pin (2).
2844047
Note: Do not reuse the brake caliper bracket bolts.
11. Remove and discard the brake caliper bracket
b01113“)-
12. Remove the rear brake caliper bracket.

(US/Canada)
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2013 (5377994)
Manual
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5J6 Disc Brakes

Installation Procedure
1. Install the rear brake caliper bracket.

2844041
4. Installthe upper brake caliper guide pin (1).
Note: The lower brake caliper guide pin is equipped
2844047 with a bushing and must be installed in the same
Caution: Refer to Fastener Caution on page 0-8. location.
2. Install new brake caliper bracket bolts (1) and 5. Installthe lower brake caliper guide pin (2).
tighten to 100 N-m(74 lb ft).

\\

2843746
2844044
Note: Ensure the brake caliper guide pin seals are fully 6. Installthe disc brake pad springs (1).
seated in the groove of the brake caliper bracket.
3. install the brake caliper guide pin seals (1).

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Disc Brakes 57?

Brake Rotor Replacement

Front
Special Tools
Kit
- CH—41013Rotor Resurfacing
Resurfacing Kit
' CH—42450-AWheel Hub
to Special Tools on
For equivalent regional tools, refer
page 5-86.
Removal Procedure
0-4.
Warning: Refer to Brake Dust Warning on page
Refer to Lifting and
1. Raise and support the vehicle.
Jacking the Vehicle on page 1-31.
assembly. Refer to Tire
2. Remove the tire and wheel on
and Wheel Removal and Installation
page 16-60.

2843745
(1).
7. install the outer disc brake pad
brake pad (2).
8. install the inner disc
over the disc brake pads
9. Position the brake caliper
and to the brake caliper bracket.

2/

2506040
caliper bracket bolts.
Note: Do not reuse the brake
brake caliper bracket
3. Remove and discard the
bolts (1).
with heavy
Caution: Support the brake caliper it is separated
mechanic wire, or equivalent, whenever
flexible brake hose is
from its mount and the hydraulic the caliper in this
still connected. Failure to support
hose to bear the
manner will cause the flexible brake damage to the
cause
weight of the caliper, which may
2843743 brake hose and in turn may cause a brake fluid leak.
bracket as an
wrench to hold the brake caliper 4. Remove the brake caliper and mechanics wire
10. Using a backup assembly and support with heavy
stationary, install the brake caliper guide
guide pins or equivalent.
(21 lb ft).
pin bolts (1) and tighten to 28 N-m
assembly. Refer to Tire
11. install the tire and wheel
and Wheel Removal and Installation on
page 16-60.

(US/Canada)
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2013 (5377994)
Manual
Service
 2332712 2332713

5. Remove the brake rotor bolt (1). 4. Install the brake rotor (1).

2332713 2332712
Caution: Refer to Fastener Caution on page 0—8.
6. Remove the brake rotor(1)
_ 5. Install the brake rotor bolt (1)and tighten to 9N-m
Installation Procedure (80lbin)
1. If installing a new brake rotor,clean the friction 6. Position the brake caliper and bracket assembly
surfaces of the brake rotor with denatured alcohol over the brake rotor and to the steering knuckle.
or equivalent.
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—41013Rotor Resurfacing Kit,
thoroughly clean any rust or corrosion from the
mating surface of the rotor to the hub/axle flange.

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
 Disc Brakes 5:79

2844313
2506040
Note: Do not reuse the brake caliper bracket bolts.
Note: Do not reuse the brake caliper bracket bolts.
3. Remove and discard the brake caliper bracket
7. install 2 new brake caliper bracket bolts (1) and bolts (1).
tighten to 100 N-m(74 lb ft).
8. Install the tire and wheel assembly. Refer to Tire Caution: Support the brake caliper with heavy
and Wheel Removal and Installation on mechanic wire, or equivalent, whenever it is separated
page 16-60. from its mount and the hydraulic flexible brake hose is
still connected. Failure to support the caliper in this
9. Burnish the brake pads and rotors. Refer to Brake mannerwill cause the flexible brake hose to bear the
Pad and Rotor Burnishing on page 5-65. weight of the caliper, which may cause damage to the
brake hose and in turn may cause a brake fluid leak.
Rear Brake Rotor Replacement
4. Remove the brake caliper and bracket as an
Special Tools assembly and support with heavy mechanics wire.
- CH-41013 Rotor Resurfacing Kit
° CH-42450-A Wheel Hub Resurfacing Kit
For equivalent regional tools, refer to Special Tools on
page 5-86.
Removal Procedure
Warning: Refer to Brake Dust Warning on
page 0-4.
1. Raise and support the vehicle. Refer to Lifting and
Jacking the Vehicle on page 1—31.
2. Remove the tire and wheel assembly. Refer to Tire
and Wheel Removal and Installation on
page 16-60.

2844319

5. Remove the brake rotor bolt (1).

(US/Canada)
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2013 (5377994)
Manual
Service
5280 Disc Brakes

2844324 2844319
Caution: Refer to Fastener Caution on page 0-8.
6. Remove the brake rotor(1).
5. Install the brake rotor bolt (1)and tighten to 9 N-m
Installation Procedure (80 lb in).
1. If installing a new brake rotor,clean the friction 6. Position the brake caliper and bracket assembly
surfaces of the brake rotor with denatured alcohol. over the brake rotor and to the suspension
knuckle.
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 rotor to the hub/axle flange.

2844313
7. Install new brake caliper bracket bolts (1)and
tighten to 100 N~m(74 lb ft).
8. Install the tire and wheel assembly. Refer to Tire
and Wheel Removal and Installation on
2844324 page 16-60.
4. Install the brake rotor (1). 9. Burnish the brake pads and rotors. Refer to Brake
Pad and Rotor Burnishing on page 5—65.

(US/Canada)
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2013 (5377994)
Manual
Service
 F‘
Disc Brakes {)«81

Front Brake Shield Replacement Installation Procedure

Removal Procedure
Warning: Refer to Brake Dust Warning on page 0-4.
1. Raise and support the vehicle. Refer to Lifting and
Jacking the Vehicle on page 1-31.
2. Remove the front tire and wheel assembly. Refer to
Tire and Wheel Removal and Installation on
page 16-60.
3. Remove the front brake rotor. Refer to Front Brake
Rotor Replacement on page 5-77.

CASHIER”
2512955
1. Install the front brake shield (1).

2512954
4. Remove the front brake shield bolts (1).

2512954
Caution: Refer to Fastener Caution on page 0—8.
2. Install the front brake shield bolts (1) and tighten to
9 N-m(80 lb in).
3. install the front brake rotor. Refer to Front Brake
Rotor Replacement on page 5-77.
4. Install the tire and wheel assembly. Refer to Tire
and Wheel Removal and Installation on
page 16-60.

2512955
5. Remove the front brake shield (1).

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
5:82 Disc Brakes
Rear Brake Shield Rep|acement 5. Remove the rear brake shield(1).

Removal Procedure Installation Procedure

Warning: Refer to Brake Dust Warning on

page 0-4.
1. Raise and support the vehicle. Refer to Lifting and
Jacking the Vehicle on page 1-31.
2. Remove the rear tire and wheel assembly. Refer to
Tire and Wheel Removal and Installation on
page 16-60.
3. Remove the rear brake rotor. Refer to Rear Brake
Rotor Replacement on page 5-79.

2844410
1. install the rear brake shield (1).

2844406
4. Remove the rear wheel bearing and hub
assembly (1). Refer to Rear Wheel Bearing and
Hub Replacement (Drum Brake) on page 16—24or
Rear Wheel Bearing and Hub Replacement (Disc
Brake) on page 16-25.

2844406
2. Install the rear wheel bearing and hub
assembly (1). Refer to Rear Wheel Bearing and
Hub Replacement (Drum Brake) on page 16-24 or
Rear Wheel Bearing and Hub Replacement (Disc
Brake) on page 16—25.
3. Install the rear brake rotor. Refer to Rear Brake
Rotor Replacement on page 5—79.
4. install the rear tire and wheel assembly. Refer to
Tire and Wheel Removal and Installation on
page 16—60.

2844410

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
 Disc Brakes 5:83

Brake Rotor Assembled Lateral

Runout Correction
Note:
' 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 on page 5—55.
- 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—7,000mi). Refer to Brake Rotor
Assembled Lateral Runout Measurement on
page 556.
Review the following acceptable methods for bringing
the brake disc assembled LRO to within specifications.
Determine which method to use for the 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—O.127mm (0001—0005 in). Indexing is
used to achieve the best possible match of high
spots to low spots between related components.
Refer to Brake RotorAssemb/ed Lateral Runout
Correction - Indexing on page 5-83.
~ 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 RotorAssemb/ed Lateral
Runout Correction - On Vehicle Lathe on
page 5-84.
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
CH-45101-100 Conical Brake Rotor Washers
For equivalent regional tools, refer to Special Tools on
page 586.
Warning: Refer to Brake Dust Warning on page 0-4.
5
9m
2308615
Note:
- 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 on
page 5-55.
- Brake rotor assembled LRO exceeding the
maximum allowable specification can cause
thickness variation to develop in the brake rotor
over time, usually between 4,800-11,3OO km
(3,000—7,000mi). Refer to Brake Rotor
Assembled Lateral Runout Measurement on
page 5-56.
1. Remove the CH—45101—100 conical brake rotor
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 particles or debris remaining.
3. index the brake rotor in a different orientation to the
hub/axle flange.
4. Hold the rotorfirmly in place against the hub/axle
flange and install one of the CH—45101-100conical
brake rotor washers (1) and one lug nut (2) onto
the upper—mostwheel stud.
5. Continue to hold the rotor secure and tighten the
lug nut firmly by hand.

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51-84 Disc Brakes
Note:
‘ Brake rotorthickness 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 on page 5-55.
- 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—11,300km
(3,000—7,000mi). Refer to Brake Rotor
Assembled Lateral Runout Measurement on
page 5-56.
. Ensure that the brake caliper and brake caliper
bracket that are already being supported, are clear
from contacting any rotating components, such as
the brake rotor.
Remove the CH-45101-100 conical brake rotor
washers and the lug nuts that were installed during
2308617 the assembled LRO measurement procedure and/
or the indexing correction procedure.
install the remaining CH-45101-100 conical brake
rotorwashers and lug nuts onto the wheel studs (1) . inspect the mounting surface of the hub/axle flange
and tighten the nuts firmly by hand in the tightening and the brake rotor to ensure that there are no
sequence. foreign particles or debris remaining.
Tighten the lug nuts in sequence, in order to Set up the lathe, following the manufacturer
properly secure the rotor. Refer to Tire and Wheel instructions.
Removal and Installation on page 16-60. Refinish the brake rotor,following the brake lathe
Measure the assembled LRO of the brake rotor. manufacturers instructions.
Refer to Brake RotorAssemb/ed Lateral Runout . After each successive cut, inspect the brake rotor
Measurement on page 5-56. thickness. Refer to Brake Rotor Thickness
. Compare the amount of change between this Measurement on page 5-55.
measurement and the original measurement. Ifat any time the brake rotor exceeds the minimum
10. Ifthis measurement is within specifications, allowable thickness after refinish specification, the
proceed to step 14. brake rotor must be replaced. After replacing the
brake rotor, proceed to step 10.
11. lfthis measurement still exceeds specifications,
repeat steps 1—9until the best assembled LRO After refinishing the brake rotor,use the following
measurement is obtained. procedure in order to obtain the desired
non—directionalfinish:
12. Matchmark the final location of the rotor to the
wheel studs if the orientation is different than it was 8.1. Follow the brake lathe manufacturer
originally. recommended speed setting for applying a
non-directional finish.
13. Ifthe brake rotor assembled LRO measurement
still exceeds the maximum allowable specification, 8.2. Using moderate pressure, apply the
refer to Brake RotorAssemb/ed Lateral Runout non-directional finish:
Correction on page 5-83. - Ifthe lathe is equipped with a
14. Ifthe brake rotor assembled LRO is within non-directional finishing tool, apply the
specification, install the brake caliper and depress finish with 120-gritaluminum oxide
the brake pedal several times to secure the rotor in sandpapen
place before removing the CH-45101-100 conical o Ifthe lathe is not equipped with a
brake rotor washers and the lug nuts. non-directional finishing tool, apply the
finish with a sanding block and 150-grit
Brake Rotor Assembled Lateral aluminum oxide sandpaper.
Runout Correction - On Vehicle 8.3. After applying a non—directionalfinish, clean
each friction surface of the brake rotor with
Lathe denatured alcohol, or an equivalent approved
brake cleaner.
Special Tools
Remove the lathe from the vehicle.
CH—45101—100 Conical Brake Rotor Washers
. Measure the assembled LRO of the brake rotor.
For equivalent regional tools, refer to Special Tools on Refer to Brake RotorAssemb/ed Lateral Runout
page 5-86. Measurement on page 5-56.
Warning: Refer to Brake Dust Warning on page 0-4.

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11. if the brake rotor assembled LRO measurement
still exceeds the maximum allowable specification,
refer to Brake RotorAssemb/ed Lateral Runout
Correction on page 5-83.
12. if the brake rotor assembled LRO is within
specification, install the brake caliper and depress
the brake pedal several times to secure the brake
rotor in place before removing the CH—45101—100
conical brake rotorwashers and the lug nuts.
Brake Rotor Refinishing
Special Tools
- CH-41013 Rotor Resurfacing Kit
- CH—42450-AWheel Hub Resurfacing Kit
For equivalent regional tools, refer to Special Tools on
page 5-86.
Warning: Refer to Brake Dust Warning on page 0-4.
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 rotorfriction surface
—Scoring of the disc brake rotorfriction surface
less than the maximum allowable specification
4 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 on page 5—55.
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: Ifthe 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.
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Disc Brakes 5185
Note: Whenever the brake rotor has been separated
from the hub/axle flange, clean any rust or
contaminants from the hub/axle flange and the brake
rotor mating surfaces. Failure to do this may result in
increased assembled lateral runout (LRO) of the brake
rotor,which could lead to 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.
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. 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 on page 5-55.
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
non—directionalfinish:
12.1. Follow the brake lathe manufacturer's
recommended speed setting for applying a
non-directional finish.
12.2. Using moderate pressure, apply the
non—directionalfinish:
. Ifthe lathe is equipped with a
non-directional finishing tool, apply the
finish with 120-gritaluminum oxide
sandpapen
' Ifthe lathe is not equipped with a
non—directionalfinishing tool, apply the
finish with a sanding block and 150-grit
aluminum oxide sandpaper.
5486 Disc Brakes
Note: Thoroughly cleaning the brake rotorwill prevent pads apply the outputforce to the friction surfaces on
the possible transfer of finite metal dust left as a both sides of the brake rotors, which slows the rotation
by—productof machining to the brake pad material of the tire and wheel assemblies. The correct function
during the burnishing process, thereby reducing the of both the brake pad and brake caliper hardware is
possibility for brake squeal or other brake noises to essential for even distribution of braking force.
occun
Special Tools and Equipment
12.3. After applying a non—directionalfinish, clean
each friction surface of the brake rotor with a
solution of mild dish washing detergent and Illustration Tool Number/Description
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.
CH-41013
13. Remove the brake rotor from the brake lathe. J 41013
(8"
14. Measure the assembled LRO of the brake rotor to RotorResurfacingKit
ensure optimum performance of the disc brakes.
Refer to Brake RotorAssemb/ed Lateral Runout
Measurement on page 5-56.
15. Ifthe brake rotor assembled LRO measurement 2028167
exceeds the specification, bring the LRO to within
specifications. Refer to Brake RotorAssemb/ed
Lateral Runout Correction on page 5-83.

Description and Operation

‘ CH-42450—A
J 42450-A
Disc Brake System Description and WheelHub ResurfacingKit
Operation

System Component Description 2028165

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. CH-45101
J45101
Disc Brake Rotors: Uses mechanical output force
applied to friction surfaces from the disc brake pads to HubandWheelRunout
Gauge
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 2028168
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 CH-45101-100
motion of the brake caliper to the brake pads when
mechanical output force is applied. J 45101-100
ConicalBrakeRotor
System Operation Washers
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 2028164
housings draw the outer brake pads inward. This allows
the output force to be equally distributed. The brake

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 Drum Brakes

Drum Brakes

Specifications

Fastener Tightening Specifications

Specification
Application Metric English
BleederValveBolt 9N-m 80 lb in
BrakeDrumBolt 9N'm 801bin
BrakePipe Fitting 18N-m ' 13lbft
Rear BrakeCylinderBolt 10N-m 89 lb in

Drum Brake Component Specifications

Specification
Application Metric English
BrakeDrumDiameter - Discard 231.0mm 9.094in
BrakeDrumDiameter- New 230.0mm 9.055in
BrakeDrumMaximumAllowableRadialRunout 0.04mm 0.002in
BrakeDrumMaximumAllowableScoring 0.50mm 0.02in
BrakeDrumMaximumDiameterAfterRefinish 230.75mm 9.085in
BrakeShoe LiningMinimumThickness 1.40mm 0.055in
BrakeShoe LiningThickness- New 5.00mm 0.197in
BrakeShoe Lining-to-Drum Clearance 040-090 mm 0.016-0035in

Warning: Refer to Brake Dust Warning on page 0-4.

Diagnostic Information and 1. Remove brake drum. Refer to Brake Drum
Procedures Replacement (J93, J94) on page 5-90
2. Clean the brake shoe lining contact surface of the
brake drum (2) with denatured alcohol or an
Brake Drum Diameter Measurement equivalent approved brake cleaner.
Using a brake drum micrometer (1) calibrated in
thousandthseof—an—inch, measure and record the
largest diameter of the brake drum at four or more
1 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.
Compare the largest diameter measurement
recorded to the brake drum component
specifications. Refer to Drum Brake Component
Specifications on page 587.
Ifthe 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.
2027507

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5‘88 Drum Brakes
7. If the largest diameter measurement of the brake Compare the groove, or scoring depth recorded to
drum is equal to or greater than the discard the following specification: '
diameter specification; the drum requires Specification
replacement.
Brake drum maximum allowable scoring: 0.50 mm
8. install brake drum. Refer to Brake Drum (0.020 in)
Replacement (J93, J94) on page 5-90.
lfthe brake drum scoring depth exceeds the
specification, or if an excessive amount of scoring
Brake Drum Surface and Wear
is present, the drum requires refinishing or
Inspection replacement.
Special Tools . Mount the brake drum on a brake lathe.
CH-8001 Dial indicator Set
For equivalent regional tools, refer to Special Tools on
page 5107.
Warning: Refer to Brake Dust Warning on page 0-4.
1. With the brake drum removed, clean the brake
shoe lining contact surface of the brake drum with
denatured alcohol or an equivalent approved brake
cleaner.
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.
- Cracks and/or heat spots
- Excessive blueing discoloration
- Missing balance weights
3. Ifthe braking surface of the brake drum exhibits
one or more of the braking surface conditions 2308633
listed, the drum requires refinishing or
replacement. . Mount a dial indicator, CH—8001indicator (1),
or equivalent, and position the indicator buttonso 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.
. Measure and record the radial runout of the
brake drum.
9.1. Rotate the drum until the lowest reading is
displayed on the indicator dial, then zero
the dial.
9.2. Rotate the drum until the highest reading is
displayed on the dial.
10. Compare the radial runout of the brake drum to the
following specification:
Specification
Brake drum maximum allowable radial runout:
0.03 mm (0.001 in)
11. Ifthe brake drum radial runout exceeds the
specification, the drum requires refinishing or
replacement.

2308630
4. Using a brake drum micrometer 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.

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 r"
Drum Brakes 0-89

Drum Brake Adjusting Hardware

Inspection

7%?“
49% 7485mm“
'g,mmmmww —"
0

2327857
Warning: Refer to Brake Dust Warning on page 0-4. 2327855
1. Visually inspect the drum brake upper return Warning: Refer to Brake Dust Warning on page 0-4.
spring (1)for the following conditions: 1. Visually inspect the adjuster actuator spring (1) for
4 Excessive corrosion the following conditions:
4 Excessive stretching 4 Excessive stretching
4 Broken 4 Excessive bending
4 Missing 4 Excessive corrosion
2. Ifany of the conditions listed were found, the drum 4 Broken
brake upper return spring requires replacement. 4 Missing
3. Visually inspect the park brake apply lever (2)for 2. Ifany of the conditions listed were found, the
the following conditions: adjuster actuator spring requires replacement.
- Bent 3. Visually inspect the adjuster actuator lever (2) for
4 Broken the following conditions:
4 Missing 4 Bent
4. Ifany of the conditions listed were found, the park 4 Broken
brake shoes require replacement. 4 The lever engagement surface
5. Visually inspect the drum brake shoe hold down excessively worn
springs and cups (3) and pins for the following 4 Excessively bent or broken spring
conditions: attachment tab
4 Excessive corrosion 4 Missing
4 Broken 4. Ifany of the conditions listed were found, the
4 Missing adjuster actuator lever requires replacement.
4 Bent pins 5. Visually inspect the adjuster assembly (3) for the
6. Ifany of the conditions listed were found, the hold following conditions:
down springs, cups, and pins require replacement. 4 Bent
7. Visually inspect the drum brake lower return 4 Broken
spring (4)for the following conditions: 4 Seized adjuster wheel threads
4 Excessive corrosion 4 Excessively worn, damaged, or missing teeth
4 Excessive stretching 6. Ifany of the conditions listed were found, the
4 Broken adjuster assembly requires replacement.
4 Missing
8. Ifany of the conditions listed were found, the drum
brake lower spring requires replacement.

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5=90 Drum Brakes

Repair Instructions

Brake Drum Replacement (J93, J94)

Special Tools
4 CH—41013Rotor Resurfacing Kit
4 CH—42450-AWheel Hub Resurfacing Kit
For equivalent regional tools, refer to Special Tools on
page 5-107.
Removal Procedure
Warning: Refer to Brake Dust Warning on page 0-4.
1. Release the park brake.
2. Raise and support the vehicle. Refer to Lifting and
Jacking the Vehicle on page 1—31.
3. Remove the tire and wheel assembly. Refer to Tire
and Wheel Removal and Installation on
page 16-60.
2511176
5. Remove the brake drum (1).
6. If reinstalling the brake drum, use the CH-41013
Rotor Resurfacing Kit to clean the wheel hub
flange mating surface of the brake drum of any
corrosion.
Installation Procedure
1. Using the CH—42450-AWheel Hub Resurfacing Kit
to clean the wheel hub flange of any corrosion.
2. Adjust the drum brakes. Refer to Drum Brake
Adjustment on page 5-105.

2511170
4. Remove the brake drum bolt (1).

2511176
3. Install the brake drum (1).
Caution: Refer to Fastener Caution on page 0-8.

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2511170
4. install the brake drum screw (1)and tighten to
9 N4m(801bin).
5. Install the tire and wheel assembly. Refer to Tire
and Wheel Removal and Installation on
page 16-60.
6. Apply the brakes 2 or 3 times to seat and center the
brake shoes on the brake drum.
Brake Drum Refinishing
Special Tools
CH-41013 Rotor Resurfacing Kit
CH-42450-A Wheel Hub Resurfacing Kit
For equivalent regional tools, refer to Special Tools on
page 5-107.
Warning: Refer to Brake Dust Warning on page 0-4.
1. The brake drums do not require refinishing as part
of routine brake system service. Do not refinish
brake drums in an attempt to correct the following
conditions:
4 Brake system noise (squeal, growl, groan)
4 Uneven andlor premature brake lining wear
4 Superficial or cosmetic corrosion/rust of the
brake drum surface
4 Scoring of the brake drum surface (less than
the maximum allowable specification)
2. Brake drums should only be refinished if the
following conditions exist:
4 Excessive corrosion/rust andlor pitting
4 Cracks andlor heat spots
4 Excessive blueing discoloration
4 Scoring of the brake drum surface (in excess of
the maximum allowable specification)
4 Radial runout in excess of the maximum
allowable specification
2013
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Drum Brakes 5491
. Inspect each of the brake drums and determine if
the brake drums can be refinished and remain
within the maximum allowable diameter after
refinish specification:
3.1. With the tire and wheel assemblies removed,
measure the diameter of each of the brake
drums. Refer to Brake Drum Diameter
Measurement on page 5-87.
3.2. lnspect each of the brake drums for excessive
surface wear andlor radial runout. Refer to
Brake Drum Surface and Wear Inspection on
page 5—88.
. Ifthe brake drums can be refinished, proceed with
the rotor refinishing procedure.
. If necessary, use the CH—41013rotor resurfacing
kit in order to thoroughly clean any corrosion/rust
from the brake drum flange.
. Mount the brake drum to the brake lathe according
to the lathe manufacturer instructions.
Ensure that any vibration dampening attachments
are securely in place.
With the brake lathe running, slowly bring in the
cutting tool until itjust contacts the brake drum
friction surface.
Observe the witness mark on the brake drum. Ifthe
witness mark extends approximately
three—quartersor more of the way around the brake
drum surface, the brake drum is properly mounted
to the lathe.
10. Ifthe witness mark does not extend three-quarters
or more of the way around the brake drum,
re-mount the brake drum to the lathe.
11. Following the brake lathe manufacturer
instructions, refinish the brake drum.
12. After each successive cut, inspect the brake drum
diameter. Refer to Brake Drum Diameter
Measurement on page 5-87.
13. Ifat any time the brake drum exceeds the
maximum allowable diameter after refinish
specification, the brake drum must be replaced.
14. After refinishing the brake drum, use the following
procedure in order to obtain the desired
non—directionalfinish:
14.1. Follow the brake lathe manufacturer's
recommended speed setting for applying
non-directional finish.
14.2. Using the moderate pressure, apply the
non—directionalfinish:
4 Ifthe lathe is equipped with a
non-directional finishing tool, apply the
finish with 120—gritaluminum oxide
sandpapen
4 if the lathe is not equipped with a
non—directionalfinishing tool, apply the
finish with a sanding block and 150—grit
aluminum oxide sandpaper.
5-92 Drum Brakes
14.3. After applying a non-directional finish, clean
the friction surface of the brake drum with
denatured alcohol or an equivalent brake
cleaner and wipe the friction surface using a
clean shop towel to remove metal particles
remaining from machining. Repeat the
cleaning process if necessary to remove all
metal particles.
15. Remove the brake drum from the brake lathe.
16. If necessary, use the CH-42450-A wheel hub
resurfacing kit in order to thoroughly clean any
corrosion from the wheel bearing flange.

Brake Shoe Replacement (J93, J94)

Removal Procedure
Warning: Refer to Brake Dust Warning on page 0-4.
Note: Always replace brake shoes in axle sets.
1. Raise and support the vehicle. Refer to Lifting and
Jacking the Vehicle on page 1—31. 2511181
2. Remove the tire and wheel assembly. Refer to Tire 5. Remove brake shoe adjuster (1).
and Wheel Removal and Installation on
page 16-60.
3. Remove the brake drum. Refer to Brake Drum
Replacement (J93, J94) on page 5-90.

2511185
6. Remove the brake shoe adjuster actuator |ever(1).

2511177
4. Remove the upper brake shoe return spring (1).

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 Drum Brakes 5:93

2511188
7. Remove the brake shoe hold down spring and cup
assemblies (1) by compressing the spring and
rotating the assembly1/4turn.
2511190
Spread the top of the brake shoe assembly (1) and
liftthe assembly over the wheel hub.
Release the park brake actuator lever from the
park brake cable eyelet.

2511192
8. Remove the hold down spring and cup assembly 2511191
pins (1). 11. Remove the lower brake shoe return spring (1).
12. Inspect the drum brake hardware and replace any
components, as necessary. Refer to Drum Brake
Hardware Inspection on page 5-89.
installation Procedure
1. Clean the drum brake backing plate of any dirt and
debris.
2. Apply a light coat of high temperature brake
lubricant to the brake drum backing plate shoe
contact surfaces.

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5494 Drum Brakes

2511191 2511192

3. install the lower brake shoe return spring (1). 7. Install the hold down spring and cup assembly
pins (1).

2511190
2511188
4. Install the park brake actuator lever to the park
brake cable eyelet. 8. Install the brake shoe hold down spring and cup
5. Spread the top of the brake shoe assembly (1)and assemblies (1) by compressmg the 313009and
lift the assembly over the wheel hub. r0149""09 the assembly1/4turn.
6. Position the brake shoe assembly to the drum
brake backing plate.

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 2511185
9. Install the brake shoe adjuster actuator lever (1).
2511177
11. Install the upper brake shoe return spring (1).
12. Adjust the drum brakes. Refer to Drum Brake
Adjustment on page 5-105.
13. Install the brake drum. Refer to Brake Drum
Replacement (J93, J94) on page 5-90.
14. install the tire and wheel assembly. Refer to Tire
and Wheel Removal and Installation on
page 16-60.

Rear Brake Backing Plate

Replacement

Removal Procedure
Warning: Refer to Brake Dust Warning on page 0-4.
1. Raise and support the vehicle. Refer to Lifting and
Jacking the Vehicle on page 1-31.
2. Remove the tire and wheel assembly. Refer to Tire
and Wheel Removal and Installation on 4
page 16—60.
. Remove the rear wheel speed sensor, if equipped.
Refer to Rear Wheel Speed Sensor Replacement
2511181 on page 547.
10. Install brake shoe adjuster (1). Remove the rear brake cylinder. Refer to Rear
Brake Cylinder Replacement on page 5-102.
Remove the brake shoes. Refer to Brake Shoe
Replacement (J93, J94) on page 5-92.

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5=95 Drum Brakes
2507695
6. Remove the rear wheel bearing and hub
assembly (1). Refer to Rear Wheel Bearing and
Hub Replacement (Drum Brake) on page 16-24 or
Rear Wheel Bearing and Hub Replacement (Disc
Brake) on page 16-25.
2507697
Note: The park brake cable connector is part of the
cable attached to the rear brake backing plate.
7. Disconnect the front park brake cable from the
. park brake cable connector (1).
8. Remove the rear brake backing plate (2).
9. if necessary, remove the park brake cable from the
rear brake backing plate by compressing the park
brake cable locking tab.
Installation Procedure
1. If removed, install the park brake cable to the rear
brake backing plate.
2. Ensure the park brake cable locking tab is fully
engaged in the rear brake backing plate.
2507697
. Insert the front park brake cable into the park brake
cable connector (1).
. install the rear brake backing plate (2).
2507695
. Install the rear wheel bearing and hub
assembly (1). Refer to Rear Wheel Bearing and
Hub Replacement (Drum Brake) on page 16-24 or
Rear Wheel Bearing and Hub Replacement (Disc
Brake) on page 16—25.
. Install the rear wheel speed sensor, if equipped.
Refer to Rear Wheel Speed Sensor Replacement
on page 5-47.
. Install the rear brake cylinder. Refer to Rear Brake
Cylinder Replacement on page 5—102.
. Install the brake shoes. Refer to Brake Shoe
Replacement (J93, J94) on page 5-92.
. Install the tire and wheel assembly. Refer to Tire
and Wheel Removal and Installation on
page 16—60.
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2013 (5377994)
Manual
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 Drum Brakes 5497

Drum Brake Hardware Replacement

(J93, J94)

Removal Procedure
Warning: Refer to Brake Dust Warning on page 0-4.
1. Raise and support the vehicle. Refer to Lifting and
Jacking the Vehicle on page 1-31.
2. Remove the tire and wheel assembly. Referto Tire
and Wheel Removal and Installation on
page 16—60.
3. Remove the brake drum. Refer to Brake Drum
Replacement (J93, J94) on page 5—90.

2511185
6. Remove the brake shoe adjuster actuator lever (1).

2511177
4. Remove the upper brake shoe return spring (1).

2511188
7. Remove the brake shoe hold down spring and cup
assemblies (1) by compressing the spring and
rotating the assembly 1/4turn.

2511181
5. Remove brake shoe adjuster(1).

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5498 Drum Brakes

)K‘JV

3
9“ ““1; I ,.

2511192 2511191
8. Remove the hold down spring and cup assembly 11. Remove the lower brake shoe return spring (1).
pins (1). 12. Inspect the drum brake hardware and replace any
components, as necessary. Refer to Drum Brake
Hardware Inspection on page 5-89.
Installation Procedure
1. Clean the drum brake backing plate of any dirt and
debris.
2. Apply a light coat of high temperature brake
lubricant to the brake drum backing plate shoe
contact surfaces.

2511190
9. Spread the top of the brake shoe assembly (1) and
lift the assembly over the wheel hub.
10. Release the park brake actuator lever from the
park brake cable eyelet.

2511191
3. Install the lower brake shoe return spring (1).

2013
-Sonic
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 Drum Brakes 5=99

2511190 2511188

4. install the park brake actuator lever to the park 8. Install the brake shoe hold down spring and cup
brake cable eyelet. assemblies (1) by compressing the spring and
5. Spread the top of the brake shoe assembly (1)and rotating the assembly1/4turn.
lift the assembly over the wheel hub.
6. Position the brake shoe assembly to the drum
brake backing plate.

1 2511185
1
9. install the brake shoe adjuster actuator lever (1).

2511192
7. Install the hold down spring and cup assembly
pins (1).

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54100 Drum Brakes
2. Remove the tire and wheel assembly. Refer to Tire
and Wheel Removal and Installation on
page 16-60.
3. Remove the brake drum. Refer to Brake Drum
Replacement (J93, J94) on page 5-90.

2511181
10. Install brake shoe adjuster(1).

2511177
4. Remove the upper brake shoe return spring (1).

2511177
11. Install the upper brake shoe return spring (1).
12. Adjust the drum brakes. Refer to Drum Brake
Adjustment on page 5105.
13. Install the brake drum. Refer to Brake Drum
Replacement (J93, J94) on page 5-90. 2511181
14. install the tire and wheel assembly. Refer to Tire 5. Remove brake shoe adjuster (1).
and Wheel Removal and Installation on
page 16-60.

Drum Brake Adjusting Hardware

Replacement (J93, J94)

Removal Procedure
Warning: Refer to Brake Dust Warning on page 0-4.
1. Raise and support the vehicle. Refer to Lifting and
Jacking the Vehicle on page 1-31.

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2013 {5377994)
Manual
Service
 Drum Brakes 54101
4. Install the brake shoe adjuster actuator lever (1).

2511185
6. Remove the brake shoe adjuster actuator lever(1).
2511181
7. Inspect the drum brake adjusting hardware and
replace any damaged components as necessary. 5. Install brake shoe adjuster(1).
Refer to Drum Brake Adjusting Hardware
Inspection on page 5—89.
8. Disassemble the brake shoe adjuster and
thoroughly clean the adjuster screw threads of any
corrosion.
9. Apply a light coat of high temperature brake
lubricant to the brake shoe adjuster screw threads.
installation Procedure
1. Assemble the brake shoe adjuster, setting the
adjuster to the fully retracted position.
2. Clean the drum brake backing plate of any dirt and
debris.
3. Apply a light coat of high temperature brake
lubricant to the brake drum backing plate shoe
contact surfaces.

2511177
Install the upper brake shoe return spring (1).
Adjust the drum brakes. Refer to Drum Brake
Adjustment on page 5105.
Install the brake drum. Refer to Brake Drum
Replacement (J93, J94) on page 5—90.
Install the tire and wheel assembly. Refer to Tire
and Wheel Removal and Installation on
page 16-60.

2511185

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
5402 Drum Brakes

Rear Brake Cylinder Replacement

Removal Procedure
Warning: Refer to Brake Dust Warning on page 0-4.
Warning: Refer to Brake Fluid Irritant Warning on
page 0-4.
1. Raise and support the vehicle. Refer to Lifting and
Jacking the Vehicle on page 1-31.
2. Remove the tire and wheel assembly. Referto Tire
and Wheel Removal and Installation on
page 16-60.
3. Remove the brake drum. Refer to Brake Drum
Replacement (J93, J94) on page 5-90.
4. Remove the drum brake adjusting hardware. Refer
to Drum Brake Adjusting Hardware Replacement
(J93, J94) on page 5-100.
5. Clean the area surrounding the wheel cylinder of
dirt and debris.
2507684
7. Disconnect the brake pipe fitting(1).
Cap the brake pipe fitting to prevent brake fluid
loss and contamination.

2507681
6. Remove the rear brake cylinder bleeder valve
bolt (1) and cap (2).

2507686
8. Remove the rear brake cylinder bolts (1).

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Manual
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 Drum Brakes 5-103

/ .4945

l/\}

2507686
2507688
Caution: Refer to Fastener _ Caution on page 0—8.
_
9. Spread the top of the brake shoes slightly and 2. Install the rear brake cylinder bolts (1) and tighten
remove the rear brake cylinder (1). to 10 N-m(89 lb in).
Installation Procedure

2507684

2507688 3. Connect the brake pipe fitting(1) and tighten to

18 N4m(131bft).
1. Spread the top of the brake shoes slightly and
install the rear brake cylinder (1).

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5 l04 Drum Brakes

2507681 2507691
Install the rear brake cylinder bleeder valve bolt (1) 3. Remove and discard the brake cylinder dust
and tighten to 9 N4m(80 lb in). seals (1).
Install the rear brake cylinder bleeder valve
bolt cap (2).
Install the drum brake adjusting hardware. Refer to
Drum Brake Adjusting Hardware Replacement
(J93, J94) on page 5100.
. Adjust the drum brakes. Refer to Drum Brake
Adjustment on page 5105.
Install the brake drum. Refer to Brake Drum
Replacement (J93, J94) on page 5—90.
install the tire and wheel assembly. Refer to Tire
and Wheel Removal and Installation on
page 16—60. ‘
10. Bleed the hydraulic brake system. Refer to
Hydraulic Brake System Bleeding (Pressure) on
page 5—169or Hydraulic Brake System Bleeding
(Manual) on page 5170.

Rear Brake Cylinder Overhaul

Disassembly Procedure
Warning: Refer to Brake Dust Warning on page 0-4.
Warning: Refer to Brake Fluid Irritant Warning on
page 0-4.
1. Raise and support the vehicle. Refer to Lifting and
Jacking the Vehicle on page 1-31.
2. Remove the rear brake cylinder. Refer to Rear
Brake Cylinder Replacement on page 5102.
2507692
4. Remove the brake cylinder pistons (1)and
spring (2).
5. Remove and discard the brake cylinder piston
seals.
6. Inspect the brake cylinder bore for excessive
corrosion, scoring, nicks, and pitting.
7. lfthe brake cylinder bore exhibits the above
conditions, the brake cylinder assembly requires
replacement.
8. Remove light corrosion in the cylinder bore with a
fine crocus cloth.
9. Thoroughly clean the brake cylinder and pistons
with denatured alcohol and dry with filtered,
non-Iubricated compressed air.

2013
—
Sonic
(US/Canada)
Service
Manual
(5377994)
 Drum Brakes 5105

Procedure Drum Brake Adjustment

Assembly
1. Lightly lubricate the new piston seals and brake
cylinder bore with GM approved brake fluid from a
clean, sealed, brake fluid container.
2. Assemble the new piston seals with the lip of the
seals facing inward to the brake cylinder pistons.
Special Tools
CH-21177-A Drum to Brake Shoe Clearance Gauge
For equivalent regional tools, refer to Special Tools on
page 5-107.
Warning: Refer to Brake Dust Warning on page 0-4.
1. Ensure the park brake lever is in the fully released
position.
2. Remove the front floor console cupholder insert.

2507692

3. Install the brake cylinder pistons (1)and

spring (2)into the brake cylinder bore.
2513001
Note: Use ONLY HAND TOOLS when loosening or
tightening the adjusting nut.
3. Using ONLY HAND TOOLS, loosen the adjusting
nut (1) completely to the end of the front cable
threaded rod.
4. Raise and support the vehicle. Refer to Lifting and
Jacking the Vehicle on page 1—31.
5. Remove the rear tire and wheel assemblies. Refer
to Tire and Wheel Removal and Installation on
page 16—60.
6. Remove the brake drums. Refer to Brake Drum
Replacement (J93, J94) on page 5-90.

2507691
Note: Do not lubricate the brake cylinder dust seals.
4. install the new brake cylinder dust seals (1).
5. Install the rear brake cylinder. Refer to Rear Brake
Cylinder Replacement on page 5—102.
6. Bleed the hydraulic brake system. Refer to
Hydraulic Brake System Bleeding (Pressure) on
page 5169 or Hydraulic Brake System Bleeding
(Manual) on page 5-170.

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2013 (5377994)
Manual
Service
5-106 Drum Brakes
891757
7. Position the CH-21177—ADrum to Brake Shoe
Clearance Gauge to the widest point of the brake
drum inside diameter.
8. Firmly hand tighten the set screw on the
CH-21177-A Drum to Brake Shoe Clearance
Gauge.
891758 brake shoes. The output force is then distributed
9. Remove the CH—21177—A Drum to Brake Shoe
Clearance Gauge from the brake drum and
position it over the corresponding brake shoe
assembly at its widest point.
10. While holding the CH-21177—ADrum to Brake
Shoe Clearance Gauge in position, insert a proper
feeler gauge between one side of the CH-21177—A
Drum to Brake Shoe Clearance Gauge, and the
corresponding brake shoe lining.
11. Rotate the brake shoe adjuster screw until the
brake shoe linings contact the CH-21177—ADrum
to Brake Shoe Clearance Gauge and the feeler
gauge. Refer to Drum Brake Component
Specifications on page 5-87.
12. Repeat the above steps for the opposite brake
drum and brake shoe assembly.
13. Install the brake drums. Refer to Brake Drum
Replacement (J93, J94) on page 5—90.
14. Adjust the park brake. Refer to Parking Brake
Adjustment (Drum Brake) on page 5-197 or
Parking Brake Adjustment (Disc Brake) on
page 5-198.
15. Install the rear tire and wheel assemblies. Refer to
Tire and Wheel Removal and Installation on
page 16-60.
16. Lower the vehicle.
17. Install the front floor console cupholder insert.
Description and Operation
Drum Brake System Description and
Operation
System Component Description
The drum brake system consists of the following:
Drum Brake Shoes: Applies mechanical output force,
from hydraulic brake wheel cylinders, to friction
surfaces of brake drums.
Brake Drums: Uses mechanical outputforce applied
to friction surface from drum brake shoes to slow speed
of tire and wheel assembly rotation.
Brake Drum 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 outputforce is
relieved.
Brake Drum Adjusting Hardware: Provides
automatic adjustments 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
between the primary and secondary brake shoes as the
shoes expand toward the friction surface of the brake
drums. The brake shoes apply the outputforce to the
friction surface of the brake drums, which slows the
rotation of the tire and wheel assemblies. The proper
friction of both the drum brake hardware and adjusting
hardware is essential to the proper distribution of
braking force.
2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Drum Brakes 5-107

Illustration Tool Number/Description

Special Tools and Equipment

illustration Tool Number/Description

CH 42450-A
J 42450-A
WheelHub ResurfacingKit
CH 21177
9
J 21177-A
Drumto BrakeShoe
ClearanceGauge 2028165

9123

CH 8001
J 8001
Dial IndicatorSet
CH 41013
5" J41013
RotorResurfacingKit

2028167

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
5108 Hydraulic Brakes

Hydraulic Brakes

Specifications

Fastener Tightening Specifications

Specification
Application Metric English
BrakeandClutchPedal ReleaseBracketto Pedal MountingBracketBolt 22N4m 16lbft
Bracketto SteeringColumn
glefirljfeofggmcgfittglrgcekfilBFijtlease 22Nm 16lbft

BrakeHose FittingBolt 40N4m 30lbft

BrakePedal BracketBolt 9 N4m 80lb in
BrakePedal BracketNut 19Nm 14lbft
BrakePipe Fitting 18N-m 13lbft
MasterCylinderNut 50Nm 37lbft
PowerBrakeBoosterPumpBracketBolt 22N4m 16lbft
PowerBrakeBoosterPumpBracketBoltandNut 22Nm 16lbft
PowerVacuumBrakeBoosterBolt 19Nm 14lbft

Brake Component Specifications

Specification
Application Metric English
BrakeCaliperBleederValve 17N4m 13lbft
RearBrakeCylinderBleederValve 9N4m 8OIbin

Brake System Specifications

Specification
Application Metric English
BrakePedalTravel
Maximumspecificationwith450N (101lbs)offorceappliedtothepedal 48-58 mm in
1-9—2-3
withtheignitionOFF andtheboosterpowerreservedepleted.

Schematic and Routing Diagrams

2013
—Sonic
(US/Canada)
Service
Manual
(5377994)
 Hydraulic Brakes 54109

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(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
5H 0 Hydraulic Brakes

Diagnostic Information and Procedures

DTC C0267

Diagnostic Instructions
4 Perform the Diagnostic System Check - Vehicle
on page 6—66prior to using this diagnostic
procedure.
4 Review Strategy Based Diagnosis on page 6-58
for an overview of the diagnostic approach.
4 Diagnostic Procedure Instructions on page 6-59
provides an overview of each diagnostic category.
DTC Descriptor
DTC C0267: Low Brake Fluid indicated
For symptom byte information refer to Symptom Byte
List on page 6—85.
Diagnostic Fault Information

Open/High Signal
Circuit Short to Ground Resistance Short to Voltage Performance
Signal C026700 C026700 — —-
Ground — C026700 —— -

CircuitlSystem Description Electrical information Reference

The brake fluid level switch monitors the level of the 4 Circuit Testing on page 11-526
brake fluid in the brake fluid reservoir. When the 4 Connector Repairs on page 11—548
electronic brake control module sees low brake fluid
4 Testing for IntermittentConditions and Poor
level, the DTC is set. Connections on page 11-531
Conditions for Running the DTC 4 Wiring Repairs on page 11-537
IgnitionON. Scan Tool Reference
Conditions for Setting the DTC Control Module References on page 6-3 for scan tool
Low brake fluid level is detected for 8 3. information

Action Taken When the DTC Sets CircuitlSystem Verification

4 The electronic brake control module disables the 1. Verify that the brake is above minimum level.
traction control and stability control for the :> If low
duration of the ignition cycle. Refer to Brake Fluid Loss on page 5—127.
4 The traction control/stability controI-active 11 If above minimum level
indicator turns ON.
N lgnition ON.
4 The brake warning indicator turns ON.
3. Verify the scan tool Brake Fluid Level Sensor
Conditions for Clearing the DTC parameter is OK.
The condition for setting the DTC is no longer present. :> If the parameter is Low
Information Refer to CircuitlSystem Testing.
Reference
U If the parameter is OK
Schematic Reference
4. All OK.
Hydraulic Brake Schematics on page 5—109
CircuitlSystem Testing
Connector End View Reference
1. lgnition OFF and all vehicle systems OFF,
Component Connector End Views on page 11-269 disconnect the harness connector at the B20 Brake
Fluid Level Switch. it may take up to 2 min for all
Description and Operation vehicle systems to power down.
Hydraulic Brake System Description and Operation on
page 5-181

—
2013 (US/Canada)
Sonic (5377994)
Manual
Service
 Hydraulic Brakes 54111
. Test for less than 10 Q between the ground circuit Symptoms - Hydraulic Brakes
terminal 2 and ground.
Note: The following steps must be completed before
If 10 Q or greater using the symptom tables.
2.1. lgnition OFF.
1. Perform the Brake System Vehicle Road Test on
2.2. Test for less than 2 Q in the ground circuit end page 5-141 before using the hydraulic brake .
to end. symptom tables in order to duplicate the customers
=>lf 2 Q or greater, repair the openlhigh resistance concern.
in the circuit. Review the system operation in order to familiarize
=>if less than 2 Q, repair the openlhigh resistance yourself with the system functions. Refer to the
in the ground connection. following:
if less than 10 Q 4 Brake Warning System Description and
Operation on page 5181
IgnitionON.
4 Hydraulic Brake System Description and
83.030
Verify the scan tool Brake Fluid Level Sensor
Operation on page 5181
parameter is Low.
4 Brake Booster Vacuum Assist Description and
If the parameter is not Low Operation on page 5180
4.1. lgnition OFF, disconnect the harness 4 Brake Assist System Description and Operation
connector at the K17 Electronic Brake Control on page 5-180
Module.
4 ABS Description and Operation on page 5—51
4.2. Test for infinite resistance between the signal
circuit terminal 1 and ground. VisuallPhysical Inspection
=>If less than infinite resistance, repair the short to Inspect for aftermarket devices which could affect
ground on the circuit. the operation of the hydraulic brake system. Refer
=>If infiniteresistance, replace the K17 Electronic to Checking AftermarketAccessories on
Brake Control Module. page 11-525.
If the parameter is Low Inspect the easily accessible or visible system
components, for obvious damage or conditions,
. Install a 3 A fused jumper wire between the signal which could cause the symptom.
circuit terminal 1 and ground.
. Verify the scan tool Brake Fluid Level Sensor intermittent
parameter is OK. Faulty electrical connections or wiring may be the
If the parameter is not OK cause of intermittentconditions. Refer to Testing for
6.1. lgnition OFF, disconnect the harness IntermittentConditions and Poor Connections on
connector at the K17 Electronic Brake Control page 11-531.
Module, ignition ON. Symptom List
6.2. Test for less than 1 V between the signal
circuit and ground. Refer to a symptom diagnostic procedure from the
following list in order to diagnose the symptom:
=>lf 1 Vor greater, repair the short to voltage on
4 Brake Booster Pump Motor Malfunction on
the circuit.
page 5112
0 If less than 1V. 4 Brake Warning Indicator Malfunction on
6.3. Test for less than 2 Q in the signal circuit end page 5114
to end. 4 Brake Pulsation on page 5-116
=>If2 Q or greater, repair the openlhigh resistance 4 Brake System Noise on page 5—117
in the circuit.
4 Braking Action Uneven - Pulls to One Side on
=>Ifless than 2 Q, replace the K17 Electronic page 5—118
Brake Control Module. 4 Braking Action Uneven - Front to Rear on
U If the parameter is OK page 5—120
7. Test or replace the B20 Brake Fluid Level Switch. 4 Brake Pedal Excessive Travel on page 5121
4 Brake Pedal Excessive Effort on page 5-123
Repair Instructions
4 Brakes Drag on page 5125
Perform the Diagnostic Repair Verification on
page 6-92 after completing the repair. 4 Brake System Slow Release on page 5-126
0 Brake Fluid Level Indicator Switch Replacement 4 Brake Fluid Loss on page 5127
on page 5—150
Control Module References on page 6—3for
electronic brake control module replacement,
programming and setup.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
54112 Hydraulic Brakes

Brake Booster Pump Motor Malfunction

Diagnostic Instructions
4 Perform the Diagnostic System Check —Vehicle
on page 6-66 prior to using this diagnostic
procedure.
4 Review Strategy Based Diagnosis on page 6-58
for an overview of the diagnostic approach.
4 Diagnostic Procedure Instructions on page 6-59
provides an overview of each diagnostic category.

Diagnostic Fault Information

Open/High Signal
Circuit Short to Ground Resistance Short to Voltage Performance
BrakeBoosterPumpMotorB+ 1
BrakeBoosterVacuumSwitchlgnition -
BrakeBoosterPump MotorControl 1
BrakeBoosterPump MotorGround - A—A—A—l ANA
1.BrakeBoosterPump MotorAlwaysOff
2. BrakeBoosterPumpMotorAlways On

CircuitlSystem Description CircuitlSystem Verification

The brake booster vacuum switch monitors the amount 1. Verify that the brake booster vacuum system has
of vacuum available to the power brake booster. When no damage, leakage or incorrect installation.
the vacuum within the system drops, the switch within =>If damage, leakage or incorrect installation is
the brake booster vacuum switch closes allowing found
voltage to be supplied to the brake booster pump
motor. Refer to Brake Assist System Diagnosis on
page 5138.
Reference Information U If the inspection is OK
Schematic Reference 2. Refer to CircuitlSystem Testing.
Hydraulic Brake Schematics on page 5109 CircuitlSystem Testing
Connector End View Reference 1. lgnition OFF and all vehicle systems OFF,
disconnect the harness connector at the M9 Brake
Component Connector End Views on page 11-269 Booster Pump Motor. Itmay take up to 2 min for all
Description and Operation vehicle systems to power down.
2. Test for less than 10 0 between the ground circuit
Brake Booster Vacuum Assist Description and terminal1 and ground.
Operation on page 5-180
=>If 10 Q or greater
Electrical Information Reference 2.1. Test for less than 2 Q in the ground circuit end
4 Circuit Testing on page 11-526 to end.
4 Connector Repairs on page 11-548 =>If2 Q or greater, repair the openlhigh resistance
4 Testing for IntermittentConditions and Poor in the circuit.
Connections on page 11-531 2 Ifless than 2 Q, repair the openlhigh resistance
4 Wiring Repairs on page 11—537 in the ground connection.
U if less than 10 Q
Scan Tool Reference
3. IgnitionON.
Control Module References on page 6—3for scan tool
information

(US/Canada)
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2013 (5377994)
Manual
Service

. Verify that a test lamp illuminates between the B+
circuit terminal 5 and ground.
if the test lamp does not illuminate and the
circuit fuse is good
4.1. IgnitionOFF.
4.2. Test for less than 2 Q in the B+ circuit end
to end.
2 If2 Q or greater, repairthe openlhigh resistance
in the circuit.
=>Ifless than 2 Q, verify the fuse is not open and
there is voltage at the fuse.
If the test lamp does not illuminate and the
circuit fuse is open
4.1. IgnitionOFF.
4.2. Test for infinite resistance between the B+
circuit and ground.
2 if less than infinite resistance, repair the short to
ground on the circuit.
=>Ifinfinite resistance, replace the M9 Brake
Booster Pump Motor.
If the test lamp illuminates
. lgnition OFF, connect the harness connector at the
M9 Brake Booster Pump Motor and disconnect the
harness connector at the B190 Brake Booster
Vacuum Switch, ignition ON.
. Verify that a test lamp illuminates between the
ignition circuit terminal 1 and ground.
If the test lamp does not illuminate and the
circuit fuse is good
6.1. lgnition OFF.
6.2. Test for less than 2 Q in the ignition circuit end
to end.
=>lf 2 Q or greater, repair the open/high resistance
in the circuit.
=>Ifless than 2 Q, verify the fuse is not open and
there is voltage at the fuse.
If the test lamp does not illuminate and the
circuit fuse is open . 2. Verify the M9 Brake Booster Pump Motor activates.
6.1. IgnitionOFF.
6.2. Test for infinite resistance between the ignition
circuit and ground.
=>Ifless than infinite resistance, repairthe short to
ground on the circuit.
U Ifinfinite resistance
6.3. Disconnect the harness connector at the
M9 Brake Booster Pump Motor.
Hydraulic Brakes 5-113
6.4. Test for infinite resistance between the control
circuit and ground.
:> if less than infinite resistance, repairthe short to
ground on the circuit.
:> Ifinfinite resistance, replace the M9 Brake
Booster Pump Motor.
U If the test lamp illuminates
7. Verify that a test lamp does not illuminate between
the control circuit terminal 2 and ground.
=>If the test lamp illuminates
Repair the short to voltage on the control circuit.
U If the test lamp does not illuminate
8. Connect a 10 A fused jumper wire between the
ignition circuit terminal 1 and the control circuit
terminal 2.
9. Verify the M9 Brake Booster Pump Motor activates.
=>If the brake booster pump motor does not
activate
9.1. lgnition OFF
9.2. Test for less than 2 Q in the control circuit end
to end.
=>If2 Q or greater, repairthe openlhigh resistance
in the circuit.
=>Ifless than 2 Q, replace the M9 Brake Booster
Pump Motor.
U If the brake booster pump motor activates
10. Test or replace the B19C Brake Booster Vacuum
Switch.
Component Testing
1. lgnition OFF, disconnect the harness connector at
the M9 Brake Booster Pump Motor. Install a 30 A
fused jumper wire between the B+ circuit terminal 5
and B+. Install a 7.5 A fused jumper wire between
the ignition circuit termina|2 and B+. Install a
jumper wire between the ground circuit terminal 1
and ground.
=>if the brake booster pump motor does not
activate
Replace the M9 Brake Booster Pump Motor.
U If the brake booster pump motor activates
3. All OK.
Repair Instructions
Perform the Diagnostic Repair Verification on
page 6-92 after completing the repair.
Power Brake Booster Pump Replacement on
page 5-178

2013
-Sonic
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(5377994)
521-14 Hydraulic Brakes

Brake Warning indicator Malfunction

Diagnostic Instructions
4 Perform the Diagnostic System Check - Vehicle
on page 6-66 prior to using this diagnostic
procedure.
4 Review Strategy Based Diagnosis on page 6-58
for an overview of the diagnostic approach.
4 Diagnostic Procedure Instructions on page 6-59
provides an overview of each diagnostic category.
Diagnostic Fault Information

Open/High Signal
Circuit Short to Ground Resistance Short to Voltage Performance
BrakeFluidLevelSignal C026700 C026700 1 —-
Park BrakeSignal 1 1 1 -
Ground — C026700 — —-
1. BrakeWarningIndicatorMalfunction

CircuitlSystem Description 3. Verify the scan tool Electronic Brake Control

Module Brake Fluid Level Sensor is Ok.
The instrument cluster turns ON the brake warning
indicator for 5 s after ignition ON. The body control :> If the parameter is Low
module monitors the parking brake switch and will Refer to CircuitlSystem Testing - Brake Fluid
request the instrument cluster via serial data to turn the Level Switch Malfunction.
brake warning indicator ON when the parking brake is
applied. When the electronic brake control module <=If the parameter is Ok
detects a fault, it sends a serial data message to the 4. Verify the scan tool Body Control Module Park
instrument‘cluster commanding the indicator ON. Brake Switch parameter changes between Applied
and Released while applying and releasing the
Reference Information parking brake.
Schematic Reference =>if the parameter does not change
Hydraulic Brake Schematics on page 5-109 Refer to CircuitlSystem Testing - Park Brake
Switch Malfunction.
Connector End View Reference U If the parameter changes
Component Connector End Views on page 11—269 5. Verify the brake warning indicator turns ON and
OFF, when commanding the instrument cluster All
Description and Operation Indicators On and Off with a scan tool.
Hydraulic Brake System Description and Operation on =>If the brake warning indicator does not turn ON
page 5-181 and OFF
Electrical Information Reference Replace the P16 InstrumentCluster.
4 Circuit Testing on page 11-526 U If the brake warning indicator turns ON
and OFF
4 Connector Repairs on page 11-548
6. All OK.
4 Testing for IntermittentConditions and Poor
Connections on page 11-531 CircuitlSystem Testing
4 Wiring Repairs on page 11-537 Note: Circuit/System Verification must be performed
Scan Tool Reference before CircuitlSystem Testing.
Control Module References on page 6—3for scan tool Brake Fluid Level Switch Malfunction
information 1. lgnition OFF and all vehicle systems OFF,
CircuitlSystem Verification disconnect the harness connector at the 820 Brake
Fluid Level Switch. Itmay take up to 2 minutes for
1. Verify that the brake fluid is above minimum level. all vehicle systems to power down.
=>lf low 2. Test for less than 10 0 between the ground circuit
Refer to Brake Fluid Loss on page 5127. terminal 2 and ground.
U If above minimum level =>If 10 Q or greater
2. Ignition ON. 2.1. lgnition OFF.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)

2.2. Test for less than 2 Q in the ground circuit end
to end.
:> If2 Q or greater, repair the open/high resistance
in the circuit.
=>If less than 2 Q, repair the openlhigh resistance
in the ground connection.
If less than 10 Q
lgnition ON.
. Verify the scan tool Electronic Brake Control
Module, Brake Fluid Level Sensor parameter
is Low.
If the parameter is not Low
4.1. IgnitionOFF, disconnect the harness
connector at the K17 Electronic Brake Control
Module. ‘ circuit terminal 1 and ground.
4.2. Test for infinite resistance between the signal
circuit termina|1 and ground.
=>lfless than infinite resistance, repairthe short to
ground on the circuit.
=>If infinite resistance, replace the K17 Electronic
Brake Control Module.
if the parameter is Low
Install a 3 A fused jumper wire between the signal
circuit termina|1 and ground.
Verify the scan tool Electronic Brake Control
Module, Brake Fluid Level Sensor parameter is Ok.
If the parameter is Low
6.1. lgnition OFF, disconnect the harness
connector at the K17 Electronic Brake Control
Module, ignition ON.
6.2. Test for less than 1 V between the signal
circuit and ground.
=>lf1 V or greater, repair the short to voltage on
the circuit.
U If less than 1V.
6.3. Test for less than 2 Q in the signal circuit end
to end.
=>If2 Q or greater, repair the openlhigh resistance
in the circuit.
=>if less than 2 Q, replace the K17 Electronic
Brake Control Module.
U If the parameter is 0k
7. Test or replace the B20 Brake Fluid Level Switch.
Park Brake Switch Malfunction
1. lgnition 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.
lf physical damage or incorrect installation is
found
Test or replace the B80 Park Brake Switch.
if the inspection is OK
2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
Hydraulic Brakes 5—115
3. lgnition ON.
4. Verify the scan tool Park Brake Switch parameter
is Released.
If the parameter is Applied
4.1. lgnition OFF, disconnect the harness
connector at the K9 Body Control Module.
4.2. Test for infinite resistance between the signal
circuit terminal 1 and ground.
2 if less than infinite resistance, repair the short to
ground on the circuit.
=>Ifinfinite resistance, replace the K9 Body
Control Module.
If the parameter is Released
Install a 3 A fused jumper wire between the signal
Verify the scan tool Park Brake Switch parameter
is Applied.
If the parameter is Released
6.1. IgnitionOFF, disconnect the harness
connector at the K9 Body Control Module,
ignition ON.
6.2. Test for less than 1 V between the signal
circuit and ground.
=>lf1 V or greater, repair the short to voltage on
the circuit.
U Ifless than 1 V.
6.3. Test for less than 2 Q in the signal circuit end
to end.
=>If2 Q or greater, repair the open/high resistance
in the circuit.
=>if less than 2 Q, replace the K9 Body Control
Module.
U if the parameter is Applied
7. Test or replace the B80 Park Brake Switch.
Repair Instructions
Perform the Diagnostic Repair Verification on
page 6-92 after completing the repair.
Brake Fluid Level Indicator Switch Replacement
on page 5-150
Parking Brake Indicator Switch Replacement on
page 5-188
Control Module References on page 6-3 for body
control module replacement, programming and
setup.
., ,\
5:110 Hydraulic Brakes

Brake Pulsation
Step Action I Yes No
DEFINITION:Fluctuationorpulsationis feltthroughthebrakepedal,steeringwheel,seat,floor,andlorinthe vehicleONLYwhen
braking.
Wereyou sentherefromthe HydraulicBrakeSymptomtable? Go to Symptoms-
1 HydraulicBrakeson
Go to Step2 page 5-111
1. Inspectthedisc brakesystemfor thefollowingconditions:
4 Excessivethicknessvariationof rotorfrictionsurfaces
4 Excessiveassembledlateralrunout(LRO)ofrotorfriction
surfaces
4 Hardspots,heatchecks.blueingdiscolorationof rotor
frictionsurfaces;possiblydueto brakedrag
4 Excessivecorrosionof rotorfrictionsurfaces;includingred,
2 grayor blackoxidation
4 Loose,damagedor missingcaliperor lininghardware
4 Bentofdamagedcaliperor mountingcomponent
4 ExcessiveLRO ofwheelhub/axieflange;dueto damage
andlorlooseor excessivelywornbearings
2. Adjust,repairor replacecomponentsas necessary.Referto
Disc BrakeSystemDiagnosisonpage 5-128.
Didyoufindand correcta condition? , Go to Step4 Go to Step3
1. inspectthedrumbrakesystemfor thefollowingconditions:
4 Outof roundor damageddrum
4 Excessiveradialrunoutofdrumfrictionsurface
4 Hardspots,heatchecks,blueingdiscolorationofdrum
frictionsurface;possiblydueto brakedrag
3 4 Bentofdamageddrum
4 Excessiveradialrunoutofwheelhub/axleflange;duet6
damageandlorloose or excessivelywornbearings
2. Adjust,repairor replacecomponentsas necessary.Referto G S -
DrumBrakeSystemDiagnosisonpage 5—131. 0 to ymptoms
HydraulicBrakeson
Didyoufindand correcta condition? Go to Step4 page 5-111
1. Installor connectcomponentsthatwereremovedor
disconnectedduringdiagnosis.
4 2. Roadtestthevehicle in orderto confirmproperoperation.
Referto BrakeSystem VehicleRoad Testonpage 5-141.
Istheconditionstillpresent? Go to Step2 SystemOK

(US/Canada)
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2013 (5377994)
Manual
Service
 Hydraulic Brakes 54117

Brake System Noise

Step Action Yes No
DEFINITION:Vehicleexhibitsabnormalnoisewhenbraking;vehiclemayexhibitabnormalnoiseduringmotionjustafterbrake
pedalrelease.
WereyousentherefromtheHydraulicBrakeSymptomtable? Go to Symptoms-
1 HydraulicBrakes
Go to Step2 onpage5—111
1. Inspectthedisc brakesystemforthefollowingconditions:
4 Liningwearindicatorcontactwithrotor
4 Debristrappedbetweenrotorand splashshieldor backingplate;
andlordebristrappedbetweenrotorand linings
4 Contaminatedlinings
4 Aftermarketlinings
4 Glazedlinings
4 Distorted,crackedordamagedlinings
4 Excessivelywornlinings
4 Damagedor excessivelyworncaliperhardwareandlorlining
hardware
2 4 Incorrectlyinstalled,looseor missingcaliperhardwareandlor
lininghardware
4 Lack oflubricationor excessivecorrosionon metaltometal
contactsurfaces
4 Bentordamagedsplash shieldor backingplate
4 Hardspots,heatchecks,blueingdiscolorationof rotorfriction
surfaces
4 Glazedrotorfrictionsurfaces
4 Bentordamagedcaliperor mountingcomponent
2. Adjust,repairor replacecomponentsas necessary.Referto Disc
BrakeSystemDiagnosisonpage 5-128.
Didyoufindand correcta condition? Go to Step10 Go to Step3
1. Inspectthedrumbrakesystemforthefollowingconditions:
4 Glazedlinings
4 Contaminatedlinings
4 Aftermarketlinings
4 Distorted,damagedor excessivelywornlinings
4 Improperadjustment
4 Weakor damagedreturnspringor springs
4 Weakor damagedholddownspringor springs
4 Cracked,scored,excessivelywornor damageddrum
3 4 Outofroundor damageddrum
4 Hardspots,heatchecks,blueingdiscolorationof drumfriction
surface
4 Threaded0r spiralgroovesin drumfrictionsurface
4 Distortedor damagedbackingplate
4 Lack oflubricationon backingplate
4 Excessivedustor foreignmatterin drum _
2. Adjust,repairor replacecomponentsas necessary.Referto Drum
BrakeSystemDiagnosisonpage 5-131.
Didyoufindand correcta condition? Go to Step10 Go to Step4

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2013 (US/Canada)
Sonic (5377994)
Manual
Service
54118 Hydraulic Brakes

Brake System Noise (cont'd)

Step Action Yes No
1. Inspectthebrakeassist systemforthefollowingconditions:
4 Lackoflubricationor excessivelywornpushrodor pedalpivotsor
pivotbushings
4 Bentordamagedpedalpushrod,pedal,or pedalbracket
4 Damagedor improperlyoperatingvacuumboosterandlorcheck
valve,ifequipped
4 Lowpowersteeringfluidlevel.if equippedwithhydraulicboost
4 Improperlytensioned,excessivelywornor damagedpower
steeringbelt,if equippedwithhydraulicboost
4 Restrictedreturnhosefromhydraulicbooster,if equipped
4 Improperlyoperatinghydraulicbooster,ifequipped
4 Improperlyfunctioningpowersteeringsystem,if equippedwitha
hydraulicboosterassembly
4 Contaminatedpowersteeringfluid,if equippedwithhydraulic
boost
2. Adjust,repairor replacecomponentsas necessary.Referto Brake
Assist SystemDiagnosisonpage 5-138.
Didyoufindandcorrecta condition? Go to Step10 Go to Step5
1. inspectthehydraulicbrakesystemforthefollowingconditions.
4 improperoperationofwheelcylinderpistons,ifequipped
4 Improperoperationof caliperpistons
4 Contaminatedbrakefluid
2. Adjust,repairor replacecomponentsas necessary.Referto Hydraulic
BrakeSystemDiagnosisonpage 5134.
Didyoufindandcorrecta condition? Go to Step10 Go to Step6
Isthevehicieequippedwitha drum-in-rotor typeof parkbrakesystem? Go to Step7 Go to Step9
Ensuretheparkbrakeshoesare notadjustedtootightly,possiblycausinga
noiseundercertainconditions.
Are theparkbrakeshoes adjustedtootightly? Go to Step8 Go to Step9
1. Clean andinspecttheparkbrakeshoes forexcessivewearand/or
damage.
2. Inspectthedrumportionoftherotorsfor excessivewear,blueing
discoloration,heatspots,andexcessiveradialrunout.
3. Ifanyoftheseconditionsare present,replacetheaffected
components.
4. Adjusttheparkbrakesystem.
Didyoufindandcorrecta condition? Go to Step10 Go to Step9
Inspecttheparkbrakesystemforproperoperation.Referto Park Brake
SystemDiagnosis(DrumBrake)on page5-183or Park BrakeSystem Go to Symptoms-
Diagnosis(DiscBrake)onpage 5-185. HydraulicBrakes
Didyoufindandcorrecta condition? Go to Step10 onpage5-111
1. Installor connectcomponentsthatwereremovedor disconnected
duringdiagnosis.
1O 2. Roadtestthevehiclein orderto confirmproperoperation.Referto
BrakeSystemVehicleRoad Testonpage 5-141.
is theconditionstillpresent? Go to Step2 SystemOK

BmHngAdannmmn-PMBto 6. Steering components that are not operating

correctly may cause a disturbance to the vehicle
One Side during application of the brake system.
Test Description
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 application of the brake system.

(US/Canada)
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2013 (5377994)
Manual
Service
 Hydraulic Brakes 5=119

Braking Action Uneven - Pulls to One Side

Action I Yes | No
Step
DEFINITION:Vehiclepullsto one sideonlywhenbraking.
Go to Symptoms-
Wereyou sentherefromthe HydraulicBrake Symptomtable? HydraulicBrakeson
1 Go to Step2 page 5-111

1. Inspectthehydraulicbrakesystemforthe followingconditions:
4 Kinked,pinchedor damagedbrakepipeor flexible
brakehose
4 Stickingor improperlyoperatingcaliperpiston
2 4 Stickingor improperlyoperatingwheelcylinderpistons
4 Brakefluidleak
2. Adjust,repairor replacecomponentsas necessary.Referto
HydraulicBrakeSystemDiagnosison page 5—134.
Go to Step7 Go to Step3
Didyou findand correcta condition?
1. Inspectthedisc brakesystemforthe followingconditions:
4 Contaminatedlinings
4 Glazedlinings
4 Distorted,crackedor damagedliningson one side
4 Loose,damagedor missingcaliperhardwareandlorlining
hardware
3 4 Incorrectliningsonone side
4 Hardspots,heatchecks, blueingdiscolorationofrotor
frictionsurfaces;possiblydue to brakedrag
4 Glazedrotorfrictionsurfaces
4 Bentor damagedcaliperor mountingcomponent
2. Adjust,repairor replacecomponentsas necessary.Referto
Disc BrakeSystemDiagnosison page 5-128.
Go to Step7 Go to Step4
Didyoufindandcorrecta condition?
1. Inspectthedrumbrakesystemforthe followingconditions:
4 improperadjustmentor improperadjusteroperation
4 Weakor damagedreturnspringor springs
4 Glazedlinings
4 Contaminatedlinings
4 4 Distortedor damagedlinings
4 incorrectliningson one side
4 Excessivelywornor damageddrumon one side
2. Adjust,repairor replacecomponentsas necessary.Referto
DrumBrake SystemDiagnosison page 5-131.
Go to Step7 Go to Step5
Didyoufindandcorrecta condition?
1. inspectthesuspensionsystemfor thefollowingconditions:
4 incorrecttirepressure
4 Loose suspensioncomponentconnections
4 Excessivelywornor damagedsuspensioncomponents
2. Adjust,repairor replacecomponentsas necessary.
Referto Symptoms- SuspensionGeneralDiagnosison
page 16-35.
Go to Step 7 Go to Step6
Didyoufindandcorrecta condition?

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2013 (US/Canada)
Sonic (5377994)
Manual
Service
54120 Hydraulic Brakes

Braking Action Uneven - Pulls to One Side (cont'd)

Step Action Yes No
1. Inspectthesteeringsystemfor thefollowingconditions:
4 Loosesteeringcomponentconnections
6 4 Excessivelywornor damagedsteeringcomponents
2. Adjust,repairor replacecomponentsas necessary.Referto G t S m tm _
Symptoms- PowerSteeringSystemonpage 15-11. Hfidfauficgrgke: on
Didyoufindandcorrecta condition? Go to Step7 page 5-111
1. Installor connectcomponentsthatwereremovedor
disconnectedduringdiagnosis.
7 2. Roadtestthevehiclein orderto confirmproperoperation.
Referto BrakeSystemVehicleRoad Testonpage5-141.
Istheconditionstillpresent? Go to Step2 SystemOK

Braking Action Uneven - Front to Rear

Test Description
The number below refers to the step number on the
diagnostic table:
5. Suspension components that are not operating
properly may cause a disturbance to the vehicle
during application of the brake system.

Braking Action Uneven - Front to Rear

Step Action I Yes No
DEFINITION:Brakingactionor stoppingforcesensitiveor grabbingandlormorepronounced atthefrontor at therearaxle.
Sensitiveor grabbingbrakes:Excessivebrakejump-inforcerelativeto brakepedalinput.
WereyousentherefromtheHydraulicBrakeSymptomtable? Go to Symptoms-
1 , HydraulicBrakeson
Go to Step2 page 5-111
1. Inspectthehydraulicbrakesystemforthefollowingconditions:
4 Improperoperationofwheelcylinderpistons,if equipped
4 Improperoperationofcaliperpistons
4 Kinked,pinchedor damagedbrakepipeor flexible
brakehose
2 4 Brakefluidleak
valve,if equipped
4 Improperlyfunctioningproportioning
4 Improperoperationofdynamicrearproportioning (DRP)
system,if equipped
2. Adjust,repairor replacecomponentsas necessary.Referto
HydraulicBrakeSystemDiagnosisonpage5-134.
Didyoufindandcorrecta condition? Go to Step7 Go to Step3
1. Inspectthedisc brakesystemforthefollowingconditions:
4 Contaminatedlinings
4 Glazedlinings
4 Distorted,crackedordamagedlinings
4 Excessivelywornlinings
4 Aftermarketlinings
3 4 Damagedor excessivelyworncaliperhardwareandlor
lininghardware
4 Hardspots,heatChecks,blueingdiscolorationof rotor
frictionsurfaces
4 Glazedrotorfrictionsurfaces
2. Adjust,repairor replacecomponentsas necessary.Referto
Disc BrakeSystemDiagnosisonpage5-128.
Didyoufindandcorrecta condition? Go to Step7 Go to Step4

(US/Canada)
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2013 (5377994)
Manual
Service
 Hydraulic Brakes 5- i2’i

Braking Action Uneven - Front to Rear (cont'd)

Step Action Yes No
1. Inspectthedrumbrakesystemforthefollowingconditions.
4 Contaminatedlinings
4 Improperadjustment
4 Excessivelywornor damagedlinings
4 Weakor damagedreturnspringor springs
4 4 Excessivelywornor damageddrums
4 Hardspots,heatchecks,blueingdiscolorationof drum
frictionsurface
4 Distortedor damagedbackingplate
2. Adjust,repairor replacecomponentsas necessary.Referto
DrumBrakeSystemDiagnosisonpage5-131.
Didyoufindandcorrecta condition? Go to Step7 Go to Step5
1. Inspectthesuspensionsystemforthefollowingconditions:
4 Loosesuspensioncomponentconnections
4 Excessivelywornor damagedsuspensioncomponents
5 2. Adjust,repairor replacecomponentsas necessary.
Referto Symptoms- SuspensionGeneralDiagnosison
page 16-35.
Didyoufindandcorrecta condition? Go to Step7 Go to Step6
1. inspectthebrakeassistsystemforthefollowingconditions:
4 Binding,bentor damagedpedalpushrod,pedal,or pedal
bracket
4 Damagedor improperlyoperatingvacuumbooster,
if equipped
4 Damagedor improperlyoperatinghydraulicbooster,
ifequipped
2. Adjust,repairor replacecomponentsas necessary.Referto Go to Symptoms-
BrakeAssist SystemDiagnosisonpage 5-138. HydraulicBrakeson
Didyoufindandcorrecta condition? Go to Step7 page5-111
1. Installor connectcomponentsthatwereremovedor
disconnectedduringdiagnosis.
7 2. Roadtestthevehiclein orderto confirmproperoperation.
Referto BrakeSystemVehicleRoad Testonpage5-141.
is theconditionstill present? Go to Step2 SystemOK

Brake Pedal Excessive Travel

Step Action | Yes No
DEFINITION:Brakepedaltravelsfurtherthanexpectedtoobtainfirmpedalandlorfirmpedalcannotbeobtained,pedalfades
away,or pedalis spongy.
WereyousentherefromtheHydraulicBrakeSymptomtable? Go to Symptoms-
1 HydraulicBrakeson
Go to Step2 page5-111
inspectthetravelandfeelof brakepedalapplies.Performthefollowing:
1. Applythebrakepedalseveraltimestofullydepletethepower
reserve.
2. Withpowerreservedepleted,applythebrakepedalwithtight,
steadypressureandholdfor15seconds.Observepedaltravel
andfeel. __
3. Applythebrakepedalwithlight,steadypressure,thenwithout
pumpingthepedal,reducepressureandreapplypressureseveral
times.Observepedaltravelandfeelforeachapply.
4. Applythebrakepedalslowly,thenreleaseandapplythepedal
quickly.Observepedaltravelandfeelforeachapply.
Didyoucompletethe brakepedaltravelandfeei inspections? Go to Step3

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
53122 Hydraulic Brakes

Brake Pedal Excessive Travel (cont'd)

Step Action Yes No
1. inspectthehydraulicbrakesystemforthe conditionslisted,based
on thefollowingsymptomsobservedduringthepedaltraveland
feelinspections.
4 Pedalfeelwas spongy.
—Air in hydraulicsystem
—Externalbrakefluidleaks
—Soft,weakor damagedhydraulichoses;expandingunder
pressure
4 Pedalfellawayand/ortraveledto or almosttofloor.
—Externalbrakefluidleaks
—Poor brakefluidquality;lowboilingpoint
—Internalbrakefluidleaks;improperlyfunctioningmaster
cylinder
4 Pedalwas somewhatfirmthendroppedslightly,or pedalrose
withsuccessiveapplies,or pedaltravelwas differentbetween
3 slowandquickapplies.
—internalbrakefluidleaks;improperlyfunctioningmaster
cylinder
—Poor brakefluidquality;lowboilingpoint
—Bindingwheelcylinderpistons,if equipped
4 Pedal returnedto restslowlyafteranyoftheapplies.
—Internallydamagedflexiblebrakehoses;hinderingfluid
return
—Bindingcaliperpistons
—Bindingwheelcylinderpistons,if equipped
—Internalbrakefluidleaks;improperlyfunctioningmaster
cylinder
2. Repairor replacecomponentsas necessary.Referto Hydraulic
BrakeSystemDiagnosisonpage5-134.
3. Re-inspectbrakepedalapplytravelandfeel. .
Didyoufindandcorrecta condition? Go to Step9 Go to Step4
1. Inspectthedrumbrakesystem,if equipped,forthefollowing
conditions:
4 Improperadjustmentor improperadjusteroperation
4 Glazed or excessivelywornlinings
4 Cracked,distortedor damagedlinings
4 Cracked,excessivelyworn,distortedor damageddrums
4 4 Beii-mouthor barrel-shapeddrumfrictionsurface
4 Hardspots,heatchecks,blueingdiscolorationofdrumfriction
surface
2. Adjust,repairor replacecomponentsas necessary.Referto Drum
BrakeSystemDiagnosisonpage5-131.
3. Re—inspectbrakepedalapplytravelandfeel.
Didyoufindandcorrecta condition? Go to Step9 Go to Step5
1. inspectthedisc brakesystemforthefollowingconditions:
4 Cracked,excessivelywornor damagedlinings
4 Cracked,excessivelywornor damagedrotors
4 Improperlyoperating,bindingor damagedcaliperhardware
and/orlininghardware
4 Looseor missingcaliperhardwareand/orlininghardware
5 4 Excessiveassembledlateralrunout(LRO)ofrotorfriction
surfaces
4 Bentor damagedcaliperor mountingcomponent
2. Adjust,repairor replacecomponentsas necessary.Referto Disc
BrakeSystemDiagnosisonpage5—128.
3. Re—inspect brakepedalapplytravelandfeel.
Didyoufindandcorrecta condition? Go to Step9 Go to Step6

2013
~Sonic
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Manual
(5377994)
 Hydraulic Brakes 5-123

Brake Pedal Excessive Travel (cont'd)

Yes No
Step . Action
Inspectforproperbrakepedaltravel.Referto BrakePedal Travel
6 Measurementand Inspectiononpage 5-141. Go to Step7
Go to Step8
Isthe brakepedaltraveldistancewithinthe acceptablelimits?
1. Inspectforworn,missing,misaligned,bentor damagedbrake
pedalsystemcomponents.
4 Forthe brakepedal pushrodcomponentinspection,referto
BrakePedal PushrodInspectiononpage 5—145.
4 Inspectthebrake pedalbushingsfor binding,excessivewear
7 and/ordamageand inspectthe brakepedalfora misaligned,
bent,andlordamagedcondition.
2. Replacethe brakepedalsystemcomponentsthatareworn,
missing,misaligned,bentor damaged.
Didyoufindand replaceany worn,missing,misaligned,bentor Go to Step9 Go to Step8
damagedbrakepedal systemcomponents?
1. Inspectthebrakeassist systemforthefollowingconditions:
4 Vacuumleaks andlorimproperlyoperatingcheckvalve,
if equippedwithvacuumassist
4 Powersteeringfluidleaks,if equippedwithhydraulicpower
8 assist
.
4 Damagedor improperlyoperatingbrakeboosterassembly
Go to Symptoms_
2. Adjust,repairor replacecomponentsas necessary.Referto Brake HydraulicBrakes on
Assist SystemDiagnosison page 5-138.
Go to Step9 page 5-111
Didyoufindand correcta condition?
1. Installor connectcomponentsthatwere removedor disconnected
duringdiagnosis.
9 2. Roadtestthevehicle in orderto confirmproperoperation.Referto
Brake SystemVehicleRoad Teston page5-141. SystemOK
Go to Step2
Istheconditionstill present?

Brake Pedal Excessive Effort

I Yes No
Step Action
toobtaingoodbrakingactionandlorstopping
DEFINITION:Brakepedalrequiresan increasedamountof inputfromthedriver
distanceis increased.
Go to Symptoms-
Wereyou senthere fromtheHydraulicBrake Symptomtable? HydraulicBrakeson
Go to Step2 page 5-111

1. Inspectthebrakeassist systemfor thefollowingconditions:

4 Vacuumleaks,if equippedwithvacuumpowerassist
4 Powersteeringfluidleaks,if equippedwithhydraulicpower
assist
4 Lackof lubrication,bindingor excessivelywornpushrodor
2 pedalpivotsor pivotbushings
4 Bentor damagedpedal pushrod,pedal,or pedalbracket
4 Damagedor improperlyoperatingbrakeboosterassembly
2. Adjust,repairor replacecomponentsas necessary.Referto
BrakeAssist SystemDiagnosison page 5-138.
Go to Step6 Go to Step3
Didyou findand correcta condition?

(US/Canada)
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2013 (5377994)
Manual
Service
5-124 Hydraulic Brakes

Brake Pedal Excessive Effort (cont'd)

Step ' Action Yes No
1. Inspectthehydraulicbrakesystemforthefollowingconditions:
4 Bindingcaliperpistons
4 Bindingwheelcylinderpistons,if equipped
4 Internallydamagedflexiblebrakehoses;hindering
fluidflow
4 Externalbrakefluidleaks
3 4 Kinkedor damagedflexiblebrakehoses and/orpipes
4 Internalbrakefluidleaks;improperlyoperatingmaster
cylinder
4 Poor brakefluidquality;lowboilingpoint
2. Adjust,repairor replacecomponentsas necessary.Referto
HydraulicBrakeSystemDiagnosisonpage5-134.
Didyoufindandcorrecta condition? Go to Step6 Go to Step4
1. Inspectthedisc brakesystemforthefollowingconditions:
4 Excessivelywornlinings
4 Glazed linings
4 Cracked,distortedor damagedlinings
4 Contaminatedlinings
4 Binding,damagedor excessivelyworncaliperhardware
andlorlininghardware
4 4 Lack of lubricationor excessivecorrosionon metalto metal
contactsurfaces
4 Excessivelywornor corrodedrotorfrictionsurfaces
4 Glazed rotorfrictionsurfaces
4 Hardspots,heatchecks,blueingdiscolorationof rotor
frictionsurfaces
2. Adjust,repairor replacecomponentsas necessary.Referto
Disc BrakeSystemDiagnosisonpage 5-128.
Didyoufindandcorrecta condition? Go to Step6 Go to Step5
1. Inspectthedrumbrakesystem,if equipped,forthefollowing
conditions:
4 Excessivelywornlinings
4 Improperadjustmentor improperadjusteroperation
4 Glazed linings
4 Cracked,distortedor damagedlinings
4 Contaminatedlinings
5 4 Outof roundor damageddrum
4 Beii—mouth or barrei-shapeddrumfrictionsurface
4 Hardspots,heatchecks,blueingdiscolorationof drum
frictionsurface
4 Lack oflubricationon backingplate
4 Excessivedustorforeignmatterin drum
2. Adjust,repairor replacecomponentsas necessary.Referto G t S _
DrumBrakeSystemDiagnosisonpage 5-131. on
Hgdgufiéngrtgze:
Didyoufindandcorrecta condition? Go to Step6 page 5-111
1. Installor connectcomponentsthatwereremovedor
disconnectedduringdiagnosis.
6 2. Roadtestthevehiclein orderto confirmproperoperation.
Referto BrakeSystemVehicleRoad Testonpage5—141.
Istheconditionstillpresent? Go to Step2 SystemOK

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 Hydraulic Brakes 54125

Brakes Drag
Yes No
Step Action I
by brake system
delayedrelease;vehicie motionmaybe hindered
DEFINITION:Brakesystemdoes notfullyreleaseor has
withoutappiyingbrakes. Go to Symptoms-
table?
Wereyousent herefromthe HydraulicBrakeSymptom HydraulicBrakes on
1 Go to Step2 page 5-111
switchandloran
2 is thevehicleequippedwithan adjustablestoplamp Go to Step3 Go to Step4
adjustablecruise control release switch?
to ensurethat
1. Inspectthestoplampswitchfor properadjustment
thebrakepedalis fully releasing.
equipped,for proper
3 2. inspectthe cruise controlreleaseswitch,if fully releasing.
adjustmentto ensurethatthe brakepedalis Go to Step 15 Go to Step4
Didyoufindandcorrecta condition? Go to Step7
typeof park brake system? Go to Step5
4 Isthevehicleequippedwitha drum-in—rotor
possibly
Ensuretheparkbrakeshoes arenotadjustedtootightly,
5 causing drag under certainconditions. Go to Step8
Go to Step6
L Are theparkbrakeshoes adjustedtoo tightly?
excessivewear andlor
1. Clean and inspecttheparkbrakeshoesfor
damage.
wear,biueing
2. Inspectthedrumportionof the rotorsfor excessive
6 discoloration and heat spots.
the affected
3. Ifany oftheseconditionsare present,replace
components.
4. Adjustthepark brakesystem. Go to Step15 Go to Step8
Didyou findand correcta condition?
thefollowing
1. Inspectthedrumbrakesystem,if equipped,gfor
conditions:
4 Improperadjustment
4 Weakor damagedreturnspringor springs
4 Distortedor damagedlinings
7 4 Outof roundor damageddrum
4 Weakor damagedholddownspringor springs
4 Lack of lubricationon backingplate
4 Distortedor damagedbackingplate
Referto Drum
2. Adjust,repairor replacecomponentsas necessary.
Brake SystemDiagnosis onpage 5-131.
Go to Step 15 Go to Step8
Didyou findand correcta condition?
Referto Park Brake
inspecttheparkbrakesystemfor properoperation. Park Brake System
SystemDiagnosis(Drum Brake) onpage 5-183or
8 Diagnosis (Disc Brake) onpage 5-185. Go to Step9
Go to Step 15
Didyou findand correcta condition?
conditions:
1. Inspectthedisc brakesystemforthefollowing
missing caliper hardwareand/
4 Binding,incorrectlyinstalledor o f liningsandof
or lining hardware—Ensure free movement
caliper,if equipped with slidingtype caliper.
metalto metal
4 Lack of lubricationor excessivecorrosionon
contactsurfaces
9 4 Distortedor damagedlinings
and/orlining
4 Damagedor excessivelyworncaliperhardware
hardware
4 Bentor damagedcaliperor mountingcomponent
Referto Disc
2. Adjust,repairor replacecomponentsas necessary.
Brake SystemDiagnosisonpage 5-128.
Go to Step 15 Go to Step 10
Didyoufindand correcta condition?
brakepedal.
1. Separatethe brakeboosterpushrodfromthe
determine if the brake dragcondition
10 2. Inspectthe brakecornersto
is stiIlpresent. Go to Step 11
condition? Go to Step12
Dothe brakecornersstill exhibitthebrakedrag

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 Hydraulic Brakes

Brakes Drag (cont'd)

Step Action Yes No
1. Inspectthepushrodforimproperpositionandlordamage.
Correctlypositionor replacethepushrodif necessary.
11 2. Inspectthebrakepedalassemblyfordamageandreplaceif
necessary.
Didyoucompletetherepairor replacement? Go to Step15
1. Forvacuumboostsystems,disconnectthevacuumcheckvalve
fromtheboosterto relievevacuumreserve.
2. Separatethemastercylinderfromthebrakebooster.Do not
12 disconnectanybrakepipes.
3. Inspectthebrakecornerstodetermineifthebrakedragcondition
is stillpresent.
Dothebrakecornersstillexhibitthebrakedragcondition? Go to Step14 Go to Step13
Replacethebrakeboosterassembly.
13 Go to Step15
Didyoucompletethe replacement?
1. inspectthehydraulicbrakesystemforthe followingconditions:
4 Improperoperationofwheelcylinderpistons,if equipped
4 Improperoperationofcaliperpistons
4 Contaminatedbrakefluid
14 4 internallydamagedflexiblebrakehoses;hinderingbrake
release
4 Damagedor improperlyoperatingmastercylinder
2. Adjust,repairor replacecomponentsas necessary.Referto Go to Symptoms-
HydraulicBrake SystemDiagnosisonpage5-134. HydraulicBrakeson
Didyoufindand correcta condition? Go to Step 15 page5-111
1. installor connectcomponentsthatwereremovedor disconnected
duringdiagnosis.
15 2. Roadtestthevehiclein ordertoconfirmproperoperation.Referto
BrakeSystemVehicleRoad Testonpage 5-141.
is theconditionstill present? Go to Step2 SystemOK

Brake System Slow Release

Step Action Yes No
DEFINITION:Brakesystemreleasesandreturnsto restslowly;vehiclemotionis hinderedby brakesystembrieflyafterrelease
of brakepedal.
Wereyou sentherefromthe HydraulicBrakeSymptomtable? Go to Symptoms-
1 HydraulicBrakeson
Go to Step2 page5-111
1. inspectthehydraulicbrakesystemforthe followingconditions:
4 improperoperationofwheelcylinderpistons,if equipped
4 Improperoperationofcaliperpistons
4 Internallydamagedflexiblebrakehoses;hinderingbrake
release
4 Contaminatedbrakefluid
4 Damagedor improperlyoperatingmastercylinder
2. Adjust,repairor replacecomponentsas necessary.Referto
HydraulicBrake SystemDiagnosisonpage5—134.
Didyoufindand correcta condition? Go to Step6 G0 to Step3

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 Hydraulic Brakes 5-127

Brake System Siow Release (cont'd)

Step Action Yes No
1. Inspectthebrakeassist systemforthefollowingconditions:
4 Binding,bentor damagedpedalpushrod,pedal,or pedal
bracket
4 Damagedor improperlyoperatingvacuumbooster,if equipped
3 4 Restrictedreturnhosefromhydraulicbooster,if equipped
4 Damagedor improperlyoperatinghydraulicbooster,
if equipped
2. Adjust,repairor replacecomponentsas necessary.Referto Brake
Assist SystemDiagnosisonpage 5-138.
Didyoufindandcorrecta condition? Go to Step6 Go to Step4
1. Inspectthedrumbrakesystem,if equipped,forthefollowing
conditions:
4 Weakordamagedreturnspringorsprings
4 Distortedor damagedlinings
4 4 Outofroundor damageddrum
4 Lack oflubricationon backingplate
4 Distortedor damagedbackingplate
2. Adjust,repairor replacecomponentsas necessary.Referto Drum
BrakeSystemDiagnosisonpage 5-131.
Didyoufindandcorrecta condition? Go to Step6 Go to Step5
1. Inspectthedisc brakesystemforthefollowingconditions:
4 Damagedor excessivelyworncaliperhardwareandlorlining
hardware
4 Distortedor damagedlinings
5 4 Lack oflubricationor excessivecorrosionon metalto metal
contactsurfaces
4 Bentor damagedcaliperor mountingcomponent
2. Adjust,repairor replacecomponentsas necessary.Referto Disc Go to Symptoms_
BrakeSystemDiagnosisonpage 5-128. HydraulicBrakeson
Didyoufindandcorrecta condition? Go to Step6 page 5-111 ’
1. installor connectcomponentsthatwereremovedor disconnected
duringdiagnosis.
6 2. Roadtestthevehiclein orderto confirmproperoperation.Referto
BrakeSystemVehicleRoad Testonpage5141.
Istheconditionstillpresent? Go to Step2 SystemOK

Brake Fluid Loss

Step Action Yes No
DEFINITION:Brakefluidlevelis lownotrelatedto liningwear.
WereyousentherefromtheHydraulicBrakeSymptomtable? Go to Symptoms-
1 HydraulicBrakeson
Go to Step2 page 5—111
1. Inspectthefollowinghydraulicbrakesystemcomponentsfor
brakefluidleaks:
4 Flexiblebrakehoseconnections;threadedandbolted
4 Flexiblebrakehosecrimpingjoints
4 Brakepipefittings '
4 Caliperpistonseals
2 4 Wheelcylinderpistonseals, if equipped
4 Mastercylinderreservoir
4 Mastercylinderreservoirlowpressurehose,if equipped
4 Brakepressuremodulatorvalve(BPMV)assembly,ifequipped
2. Repairor replacecomponentsas necessary.Referto Hydraulic
BrakeSystemDiagnosisonpage 5-134.
Didyoufindandcorrecta condition? Go to Step5 Go to Step8

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5-128 Hydraulic Brakes

Brake Fluid Loss (cont'd)

Step Action Yes No
1. Disconnectthevacuumcheckvalvefromtheboosterto relieve
vacuumreserve.
2. Separatethemasteroylinderfromthevacuumbrakebooster.Do
3 notdisconnectanybrakepipes.
3. inspecttherearof themastercylinderfora brakefluidleak.
. . ‘ Go to Symptoms-
4. Inspectforbrakeflutdin thevacuumbrakebooster. HydraulicBrakeson
Didyoufindthebrakefluidleak? Go to Step4 page 5-111
4 Replacethebrakemastercylinderandthevacuumbrakebooster. __
Didyoucompletethereplacement? Go to Step5
1. Installor connectcomponentsthatwereremovedordisconnected
duringdiagnosis.
5 2. Roadtestthevehicleto confirmproperoperation.Referto Brake
SystemVehicleRoad Testonpage 5—141.
Istheconditionstillpresent? Go to Step2 SystemOK

Disc Brake System Diagnosis
Test Description
The numbers below refer to the step numbers on the
diagnostic table:
9. Lubricant leaks from non-brake system
components may come in contact with and
contaminate brake system components.
10. Lubricant leaks from non—brakesystem
components may come in contact with and
contaminate brake system components
' lead to thickness variation.
12. Disc brake rotor shields/backing plates that come
in contact with disc brake rotors may cause brake
system noise.
. Disc brake rotor thickness variation that exceeds
the maximum acceptable level can cause brake
pulsation.
19. Disc brake rotbr thickness variation thatexceeds
the maximum acceptable level can cause brake
pulsation.
.
22. DISCbrake rotor assembled lateral runout(LRO)
that exceeds the maxnmumacceptable level can

Disc Brake System Diagnosis

1Step Action I Yes No
DEFINITION:This diagnostictableis designedto diagnoseONLYthecomponentsoftheDISCbrakesystemin orderto
determineif theDISCbrakesystemis operatingcorrectly.Youwillbedirectedby theappropriateSymptomtabletogotoother
brakesystemdiagnostictablesas appropriate.
Wereyou sentherefroma BrakeSymptomtable? Go to Symptoms-
1 HydraulicBrakeson
Go to Step2 page 5111
Visuallyinspectthedisc brakepadsforthefollowingconditions:
Referto BrakePad Inspectiononpage 5-58.
4 Liningthicknessbelowspecifications
2 4 Unevenandlorabnormalwear—edge-to-edgeandlorside-to-side
4 Loosenessordamage~includingbrakepadhardware
4 Evidenceofcontamination froman externalsubstance
Didyoufindanyconditionsto indicatea concernwithanyofthefront
and/orreardisc brakepads? Go to Step3 Go to Step12
3 Are anyofthefrontdisc brakepadscontaminated? Go to Step8 Go to Step4
4 Are anyofthefrontdisc brakepadswornunevenly? Go to Step7 Go to Step5
5 Are anyofthefrontdisc brakepadsandlorbrakepadhardwarelooseor
damaged? Go to Step7 Go to Step6
1. Removeandinspecttheworndisc brakepadsforglazing,
looseness,heatspotsor damage.
6 2. Replacetheworndisc brakepadsas a completeaxleset.Referto -
FrontDisc BrakePads Replacementonpage5—6 1.
Didyoucompletetheinspectionand replacement? Go to Step 12

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 Hydraulic Brakes 5-129

Disc Brake System Diagnosis (cont'd)

Yes No
Step Action
Caution: Supportthe brakecaliperwithheavymechanicwire,
or equivalent,wheneverit is separatedfromits mountand thehydraulic
flexiblebrakehoseis still connected.Failureto supportthe caliperin
thismannerwillcause theflexiblebrakehose to bearthe weightof the
caliper,whichmaycause damageto thebrakehose andin turnmay
causea brakefluidleak.
Note: Do NOT disconnectthehydraulicbrakeflex hosesfromthe
calipers.
1. Removethefrontbrakecaliper,as appropriate,fromthe mounting
bracketand supportthe brakecaliper.Referto FrontBrake
CaliperReplacementonpage 5-65.
2. Inspectthedisc brakecalipermountingbracketand themounting/
slidinghardwareforthefollowingconditions:
4 Bindingor seized hardware
4 Worn,damagedor missinghardwarecomponents
4 Loose,bent,cracked,or damagedbrakecaliper mounting
bracket
3. Replacecomponentsas required.Referto FrontBrake Caliper
BracketReplacementonpage 5-70
4. Replacethe unevenly-worn, looseor damageddisc brakepads as
a completeaxle set.Referto FrontDisc BrakePads Replacement
onpage 5-61.
Go to Step 12
Didyou completethe inspectionand replacement?
1. Inspectthedisc brakecalipers,brakehoses andbrake pipesfor
evidenceof an externalbrakefluidleak.
2. Replaceanycomponentsfoundtobe leakingbrakefluid.Referto
thefollowingproceduresas required:
4 FrontBrake CaliperOverhaulonpage 5-69
4 FrontBrake CaliperReplacementonpage 5-65
4 FrontBrakeHose Replacementonpage 5-162
4 BrakePipe Replacementonpage 5-158
Didyou findand correctthe sourceof theleak causingcontamination of
Go to Step 11 Go to Step9
thebrakepads?
1. inspectthewheeldriveshaftouterseals fordamageandevidence
ofa greaseleak.
2. Replaceanywheeldriveshaftseal thatis foundto be leaking
greasewhichmaybe thesourceofthe contaminationto thebrake
pads.Referto FrontWheelDriveShaft OuterJoint andBoot
Replacementonpage 7-11.
Didyoufindand correctthesourceofthe leak causingcontamination of
Go to Step 11 Go to Step 10
thebrakepads?
1. Inspecttheautomatictransmissioncoolingsystem lines,
ifequipped,fordamageandevidenceof an externalfluidleak
whichmay be thesource ofthe contaminationtothe pads.
10 2. Replaceany componentsfoundto beleakingwhichmay bethe
sourceof the contaminationto thepads.
Didyou findandcorrectthesourceofthe leakcausing contamination of
Go to Step 11
the pads?

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5-‘l30 Hydraulic Brakes

Disc Brake System Diagnosis (cont'd)

Step Action Yes No
1. Clean theremainingdisc brakesystemcomponentsto remove
anytracesof thecontaminant.
Caution: Supportthebrakecaliperwithheavymechanicwire,
or equivalent,wheneverit is separatedfromitsmountandthehydraulic
flexiblebrakehoseis stillconnected.Failuretosupportthecaliperin
thismannerwillcause theflexiblebrakehoseto beartheweightof the
caliper,whichmaycausedamagetothebrakehoseandin turnmay
causea brakefluidleak.
Note: Do NOTdisconnectthehydraulicbrakeflex hosesfromthe
calipers.
2. Removethefrontdisc brakecaliperfromthebrakecaliper
mountingbracketandsupportthebrakecaliper.Referto Front
11 BrakeCaliperReplacementonpage5-65.
3. Inspectthedisc brakecalipermounting/slidinghardwareforthe
followingconditions:
Referto FrontDisc BrakeMountingandHardwareInspectionon
page 5-59.
4 Bindingor seized hardware
4 Distorted,worn,damagedor missinghardwarecomponents
4. Replacethebrakemounting/sliding hardwarecomponentsas
required.Referto FrontDisc BrakeMountingandHardware
Inspectiononpage 5-59.
5. Replacethecontaminatedbrakepadsas a completeaxleset.
Referto FrontDisc BrakePads Replacementonpage5—61.
Didyou completethecleaning,inspectionandreplacement? Go to Step 12
1. Checkthethicknessof eachofthedisc brakerotors.
Note: Makethefollowingdetermination andanswerthequestion
individuallyforEACH rotor.
12 2. Makea determinationforeachbrakerotorif thebrakerotorcan be
REFINlSHED and REMAINABOVE theminimumrequirements.
Referto BrakeRotorThicknessMeasurementonpage5-55.
Doesthebrakerotormeettheminimumrequirementsfor
REFINlSHiNG? Go to Step 13 Go to Step 16
Note: Makethefollowingdetermination andanswerthequestion
individuallyforEACH rotor.
lnspecteachofthebrakerotorsfor thicknessvariationthatexceedsthe
13 maximumacceptablelevel.Referto BrakeRotorThicknessVariation
Measurementonpage 5—55.
Doesthebrakerotorexhibitthicknessvariationthatexceedsthe
maximumacceptablelevel? Go to Step15 Go to Step 14
1. lnspecteachofthe brakerotorsforthefollowingsurfaceandwear
conditions:
Referto BrakeRotorSurfaceand WearInspectiononpage5-56.
4 Heavyrustandlorpitting
4 Cracksand/orheatspots
4 Excessiveblueingdiscoloration
14 4 Deepor excessivescoringbeyondmaximumacceptablelevel
Note: Makethefollowingdetermination andanswerthequestion
individuallyforEACH rotor.
2. Makea determinationforeach brakerotorif thebrakerotor
requiresrefinishingbasedupontheresultsof theinspection.
3. Ifthebrakerotorexhibitsanyof theconditionslistedpreviously,it
requiresrefinishing.
DoesthebrakerotorrequireREFINlSHiNG? Go to Step 15 Go to Step20

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 Hydraulic Brakes 54-131

Disc Brake System Diagnosis (cont'd)

Step Action Yes No

1. Refinishthebrakerotor.Referto BrakeRotorRefinishingon
page 5-85.
15 2. Inspectthebrakerotorthickness.Referto BrakeRotorThickness
Measurementonpage5—55.
Wereyouable toREFINISHthebrakerotorwithinthe minimum
requirements? Go to Step20 Go to Step 19
16 is thebrakedisc at or belowtheDISCARD requirements? Go to Step 19 Go to Step 17
Note: Makethefollowingdeterminationandanswerthe question
individuallyforEACH rotor.
lnspecteachof thebrakerotorsforthicknessvariationthatexceedsthe
17 maximumacceptablelevel.Referto BrakeRotor ThicknessVariation
Measurementonpage 5-55.
Doesthebrakerotorexhibitthicknessvariationthatexceedsthe
maximumacceptablelevel? Go to Step 19 Go to Step 18
1. Inspecteachofthebrakerotorsforthefollowingsurfaceandwear
conditions:
Referto BrakeRotorSurfaceand WearInspectiononpage5—56.
4 Heavyrust andlorpitting
4 Cracksandlorheatspots
4 Excessiveblueingdiscoloration
18 4 Deeporexcessivescoringbeyondmaximumacceptablelevel
Note: Makethefollowingdeterminationandanswerthequestion
individuallyforEACH rotor. ‘
2. Makea determination foreach brakerotorif therotorrequires
replacementbaseduponthe resultsofthe inspection.
Ifthebrakerotorexhibitsanyofthe conditionslistedpreviously,it
requiresreplacement.
DoesthebrakerotorrequireREPLACEMENT? Go to Step 19 Go to Step20
Note: Whenevera brakerotoris replaced,the assembledlateralrunout
(LRO)ofthebrakerotormustbe measuredtoensureoptimum
performanceofthedisc brakes.
19
Replacethebrakerotor.Referto FrontBrakeRotorReplacementon
page 5-77.
Didyoucompletethe replacement? Go to Step22
Note: Makethefollowingdeterminationandanswerthe question
individuallyforEACH rotor.
lnspecteachofthe brakerotorsfor assembledlateralrunout(LRO)that
20 exceedsthemaximumacceptablelevel. Referto BrakeRotor
AssembledLateralRunoutMeasurementonpage556.
DoesthebrakerotorexhibitassembledLRO thatexceedsthe
maximumacceptablelevel? Go to Step21 Go to Step22
CorrecttheLRO foreach brakerotorthatwas determinedto haveLRO
exceedingthemaximumacceptablelevel. Referto BrakeRotor
21 AssembledLateralRunoutCorrectiononpage5—83.
Didyoucompletetheoperation? Go to Step22
Installor connectcomponentsthatwereremovedor disconnected Disc Brake
duringdiagnosis. SystemOK
22 ReturntoSymptom
Didyoucompletetheoperation?
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.

—
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5- l 32 Hydraulic Brakes

Drum Brake System Diagnosis

Step 1 Action I Yes No
DEFINITION:This diagnostictableis designedto diagnoseONLY thecomponentsoftheDRUM brakesysteminorderto
determineiftheDRUM brakesystemis operatingproperly.Youwillbe directedby theappropriateSymptomtabletogoto other
brakesystemdiagnostictablesas appropriate.
Wereyou sentherefroma BrakeSymptomtable? Go to Symptoms-
1 HydraulicBrakeson
Go to Step2 page5-111
1. Removethebrakedrums.Referto BrakeDrumReplacement
(J93,J94)onpage 5-90.
2. Inspectthedrumbrakeshoes forthefollowingconditions:
4 Liningthicknessbelowspecifications
2 4 UnevenandlorabnormalWear—edge-to-edgeandlor
side-to-side
4 Looseness,damage,glazing,or incorrectliningmaterial
Didyoufindany conditionsto indicatea concernwithanyof thedrum
brakeshoes? Go to Step3 Go to Step 7
3 Are anyofthebrakeshoes contaminated? Go to Step4 Go to Step5
1. inspectthewheelcylindersforevidenceofanexternalbrake
fluidleak.
4 2. Replaceanywheel cylinderthatis foundtobe leakingbrakefluid. —-
Referto Rear Brake CylinderReplacementonpage 5-102.
Didyoucompletethe inspectionandreplacement? Go to Step6
1. Inspectthedrumbrake hardwareforanycomponentswhichare
worn,damaged,discoloreddueto stress,brokenor missing.Refer
toDrumBrake HardwareInspectiononpage5-89.
5 2. Replacecomponentsas required.Referto DrumBrakeHardware
Replacement(J93,J94)onpage 5-97. -
3. Replacethedrumbrakeshoes.Referto BrakeShoeReplacement
(J93,J94)onpage 5-92.
Didyoucompletethe inspectionandreplacement? Go to Step8
1. Cleantheremainingdrumbrakesystemcomponentsto remove
anytracesofthe contaminants.
2. Inspectthedrumbrake hardwareforanycomponentswhichare
worn,damaged,discoloreddueto stress,brokenor missing.Refer
to DrumBrake HardwareInspectiononpage5-89.
3. Replacethedrumbrakehardwarecomponentsas required.Refer
to DrumBrakeHardwareReplacement(J93,J94)onpage 5-97.
4. Replacethecontaminatedbrakeshoes.Referto BrakeShoe
Replacement(J93,J94)onpage 5-92.
Didyoucompletethe cleaning,inspectionandreplacement? Go to Step8
1. Inspectthedrumbrakehardwareforanycomponentswhichare
worn,damaged,discoloreddueto stress,brokenor missing.Refer
to DrumBrakeHardwareInspectiononpage5-89.
2. Replacecomponentsas required.Referto DrumBrakeHardware
Replacement(J93,J94)onpage 5-97.
Didyoucompletetheinspectionand,if necessary,thereplacement? Go to Step8
1. Checkthediameterofeachofthe brakedrums.
Note: Makethefollowingdeterminationandanswerthe question
individuallyforEACH brakedrum.
8 2. Makea determinationforeach brakedrumif thedrumcan be
REFINlSHED and REMAINABOVE theminimumrequirements.
Referto BrakeDrumDiameterMeasurementonpage5-87.
Doesthebrakedrummeettheminimumrequirementsfor
REFINlSHiNG? Go to Step9 Go to Step 11

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 Hydraulic Brakes 54133

Drum Brake System Diagnosis (cont'd)

Step Action Yes No
1. Inspecteachof the brakedrumsforthefollowingsurfaceandwear
conditions:
RefertoBrakeDrumSurfaceand WearInspectiononpage5-88.
4 Brakingsurfaceconditions
—Heavyrustandlorpitting
—Cracksand/orheatspots
—Excessiveblueingdiscoloration
—Missingbalanceweights
4 Brakingsurfacewearconditions
—Deepor excessivescoringbeyondmaximumacceptable
level
9 —Radialrunoutbeyondmaximumacceptablelevel
Note: Makethefollowingdeterminationandanswerthequestion
individuallyforEACH brakedrum.
2. Makea determinationforeach brakedrumif thedrumrequires
refinishingbasedupontheresultsof theinspection.
Ifthebrakedrumexhibitsanyofthefollowingconditions,it
requiresrefinishing:
4 Drumexhibitsone or moreofthebrakingsurfaceconditions
listedpreviously.
4 Drumis beyondtheacceptablelevelin one or moreofthe
brakingsurfacewearconditionslistedpreviously
DoesthebrakedrumrequireREFINlSHiNG? Go to Step 10 Go to Step 14
1. Refinishthebrakedrum.Referto BrakeDrumRefinishingon
page5-91.
10 2. Inspectthebrakedrumdiameter.Referto BrakeDrumDiameter
Measurementonpage 5-87.
Wereyouableto REFINISHthebrakedrumwithintheminimum
requirements? Go to Step 14 Go to Step 13
11 is thebrakedrumat or belowtheDISCARD requirements? Go to Step 13 Go to Step 12
1. Inspecteachof thebrakedrumsforthefollowingsurfaceandwear
conditions:
Referto BrakeDrumSurfaceand WearInspectiononpage5—88.
4 Brakingsurfaceconditions
—Heavyrustandlorpitting
—Cracksandlorheatspots
—Excessivebiueingdiscoloration
—Missingbalanceweights
4 Brakingsurfacewearconditions
—Missingbalanceweights
12 —Radialrunoutbeyondmaximumacceptablelevel
Note: Makethefollowingdeterminationandanswerthequestion
individuallyforEACH brakedrum.
2. Makea determinationforeach brakedrumif thedrumrequires
replacementbasedupontheresultsoftheinspection.
Ifa brakedrumexhibitsanyofthefollowingconditions,it requires
replacement:
4 Drumexhibitsone or moreofthebrakingsurfaceconditions
listedpreviously
4 Drumis beyondtheacceptablelevelin oneor moreofthe
brakingsurfacewearconditionslistedpreviously
DoesthebrakedrumrequireREPLACEMENT? Go to Step 13 Go to Step 14
Replacethebrakedrum.Referto BrakeDrumReplacement(J93,J94) ‘
13 onpage5-90. _
Didyoucompletethereplacement? Go to Step 14

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Manual
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5-134 Hydraulic Brakes

Drum Brake System Diagnosis (cont'd)

Step Action Yes No
Inspectthebrakeshoes forproperadjustment.Referto DrumBrake
14 Adjustmentonpage5-105.
Are thebrakeshoesadjustedproperly? Go to Step18 Go to Step 15
Inspectthecomponentsofthebrakedrumadjustmenthardwaresystem
forfreemovementandcorrectoperation.Referto DrumBrake
15 AdjustingHardwareInspectiononpage 5-89.
Dothedrumbrakeadjustinghardwarecomponentsoperatefreelyand
correctly? Go to Step17 Go to Step 16
Replacethedrumbrakeadjustinghardwarecomponentsas necessary.
Referto DrumBrakeAdjustingHardwareReplacement(J93,J94) on
16 page 5-100. -
Isthereplacementcomplete? Go to Step17
Adjustthedrumbrakeshoes.Referto DrumBrakeAdjustmenton
17 page5'105- ‘ Returnto Symptom
Wereyouableto completetheadjustment? G0 to Step20 Table
Inspectthedrumbrakebackingplateforthefollowing:
18 4 Excessivewearor rust
4 Damageandlorevidenceofcontactwiththebrakedrum
Doesthedrumbrakebackingplateexhibitany of theseconditions? Go to Step19 Go to Step20
Repairor replacethedrumbrakebackingplateas necessary.Referto
19 Rear BrakeBackingPlate Replacementonpage 5—95. _
Didyoucompletethe repairor replacement? Go to Step20
Installor connectcomponentsthatwereremovedor disconnects DrumBrake
20 duringdiagnosis. ' SystemOK _
Didyoucompletethe operation? Returnto Symptom
Table

Hydraulic Brake System Diagnosis

Step Action Yes No
DEFINITION:This diagnostictableis designedtodiagnoseONLY thecomponentsoftheHYDRAULIC brakesystemin orderto
determineif theHYDRAULICbrakesystemis operatingproperly.Youwill be directedby theappropriateSymptomtabletogoto
otherbrakesystemdiagnostictablesas appropriate.
Wereyousent herefroma BrakeSymptomtable? Go to Symptoms-
1 HydraulicBrakeson
Go to Step2 page 5-111
inspectandadjustthe brakefluidlevelin thebrakemastercylinder.
Referto MasterCylinderReservoirFillingonpage5-145.
Was thebrakefluidlevellow? Go to Step3 Go to Step4
1. Inspectthebrakefluidforthefollowingconditions,indicatingbrake
fluidcontamination:
4 Fluidseparation,indicatingtwotypesoffluidare present
—Swirledappearance—oil-basedsubstance
—Layeredappearance—silicone-basedsubstance
4 Fluiddiscoloration
—Cloudyappearance—moisture
—Darkappearance/suspended particlesinfluid—dirt,rust,
corrosion,brakedust
2. inspectthemastercylinderreservoircap diaphragmandthe
reservoir-to-mastercylindergrommetsforswelling,indicatingfluid
contamination.
Do anyoftheaboveconditionsexist? Go to Step5 Go to Step6

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 Hydraulic Brakes 5-135

Hydraulic Brake System Diagnosis (cont'd)

Yes No
Step Action
indicatingbrake
1. Inspectthebrakefluidfor thefollowingconditions,
fluidcontamination:
4 Fluidseparation,indicatingtwotypesoffluidare present
—Swirledappearance—oil—based substance
—Layeredappearance_ silicone-based substance
4 Fluid discoloration
—Cloudyappearance—moisture
—Darkappearance/suspended particlesin fluid—dirt,rust,
corrosion,brakedust
2. inspectthe mastercylinderreservoircap diaphragm andthe
reservoir—to-master cylindergrommetsfor swelling,indicatingfluid
contamination. Go to Step 12
Go to Step5
Doanyofthe above conditionsexist?
Brake
1. Flushthe hydraulicbrakesystem.Referto Hydraulic
System Flushing onpage 5-172.
2. if thebrakefluidWAS contaminatedwithan oil—based or a
silicone—based fluid,indicated byfluid separation and/ora swollen
mastercylinderreservoircap diaphragmandlorswollen
reservoir-to-master cylindergrommets,performthefollowing
steps.Referto the proceduresindicated.
2.1. RemoveALL ofthefollowingcomponentslisted.Each
componentcontainsinternalrubberseals/liningswhichhave
beencontaminated.
alcohol,
2.2. Cleanoutthe hydraulicbrakepipes usingdenatured
or equivalent.
2.3. Drythe brake pipesusing non-lubricated, filteredair.
following components listed.
2.4. Repairor replaceALL ofthe
Each componentcontainsinternalrubberseals/liningswhich
havebeen contaminated.
4 Replacethebrakemastercylinderreservoircap
diaphragm.
4 MasterCylinderReplacementonpage 5-147
4 Brake mastercylinderreservoir:Cleanthe brake master
cylinderreservoirusingdenaturedalcohol,or equivalent,
thendry the reservoirusing non—lubricated, filteredair,
or if necessary,replacethebrakemastercylinder
reservoir.
4 FrontBrake Hose Replacementonpage 5-162
4 Rear Brake Hose Replacement(BodytoAxle - Drum
Brake)on page 5-164or Rear Brake Hose Replacement
(BodytoAxle -Disc Brake)on page 5-165or Rear Brake
Hose Replacement(Axleto Caliper)on page 5—167
4 FrontBrake CaliperOverhaulonpage 5—69
4 FrontBrake CaliperReplacementonpage 5-65
4 Rear Brake CylinderReplacementonpage 5102
4 Brake Pressure ModulatorValveReplacementon
page 5-40
3. Ifthe brakefluidwas NOTcontaminatedwithan oil-basedfluid,
butWAS contaminatedwithwateror dirt,rust,corrosion, andlor
brakedust, replace thebrake master cylinder reservoir cap
diaphragmwhichmay have allowedmoistureor dirtto enterthe
system.
4. Refilland bleedthe hydraulicbrakesystem.Referto Hydraulic
Brake SystemBleeding(Pressure)onpage 5-169or Hydraulic
Brake SystemBleeding(Manual)onpage 5-170.
Didyou completethe operationandany requiredrepairsandlor Go to Step9
replacements?

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54 35 Hydraulic Brakes

Hydraulic Brake System Diagnosis (cont'd)

Step Action Yes No
1. inspectthefollowinghydraulicbrakesystemcomponentsfor
externalfluidleaks.Repairor replaceanyofthecomponents
foundto be leakingbrakefluid.Refertothe appropriate
procedures:
4 Brakemastercylinderreservoircap diaphragm
4 MasterCylinderReplacementonpage5147
4 FrontBrakeHose Replacementonpage5-162
4 Rear BrakeHose Replacement(BodytoAxle -DrumBrake)
onpage 5-164or Rear BrakeHoseReplacement(Bodyto
Axle -Disc Brake)onpage 5-165or Rear BrakeHose
Replacement(AxletoCaliper)onpage 5-167
4 BrakePipe Replacementonpage 5-158
4 FrontBrakeCaliperOverhaulonpage5—69
4 FrontBrakeCaliperReplacementonpage5-65
4 Rear BrakeCylinderOverhaulonpage 5-104
4 Rear BrakeCylinderReplacementonpage5-102
4 BrakePressureModulatorValveReplacementonpage 5-40
2. Ifyou repairedor replacedanyofthebrakesystemcomponents
listed,bleedthehydraulicbrakesystem.Referto HydraulicBrake
SystemBleeding(Pressure)onpage 5-169or HydraulicBrake
SystemBleeding(Manual)onpage5-170.Whilebleedingthe
hydraulicbrakesystem,observeforthefollowingconditions:
4 Thepresenceofair inthesystemat a bleedervalvelocation
otherthanat therepairlocation,exceptifthe brakemaster
cylinder,andlortheproportioningvalveassembly,was
replaced
4 An unrestrictedandevenflowof brakefluidperaxleduringthe
bleedingprocedure
Didyoufindandcorrecta condition? Go to Step7 Go to Step 12
Was thereair in thesystemat a bleedervalvelocationotherthanat the
repairlocation,exceptifthebrakemastercylinder,andlorthe
proportioning valveassembly,was replaced? Go to Step 19 Go to Step8
Was theflowof brakefluidunrestrictedandevenperaxleduringthe
bleedingprocedure? Go to Step9 Go to Step 10
Inspectthehydraulicfunctionofthebrakecalipersandlorwheel
cylinders,if equippedforproperoperation.Referto HydraulicBrake
ComponentOperationVisualInspectiononpage5-144.
Was thehydraulicfunctionofthebrakecalipers/wheelcylinders
operatingproperly? Go to Step21 Go to Step 14
10 Was theflowofbrakefluidrestrictedor uneventhroughfrontaxle
hydrauliccomponentsduringthebleedingprocedure? Go to Step 13 Go to Step 11
11 Was theflowof brakefluidrestrictedor uneventhroughrearaxle
hydrauliccomponentsduringthebleedingprocedure? Go to Step 17
Inspectthehydraulicfunctionof thebrakecalipers/wheelcylindersfor
properoperation.Referto HydraulicBrakeComponentOperation
12 VisualInspectiononpage5-144.
Was thehydraulicfunctionofthebrakecalipers/wheelcylinders
operatingproperly? Go to Step 15 Go to Step 13

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 Hydraulic Brakes 5-137

Hydraulic Brake System Diagnosis (cont'd)

Step Action Yes No
Determineif thebrakecaliperis restrictingtheflowofbrakefluidand/or
notoperatingproperly:
1. Raise andsupportthevehicle.Referto LiftingandJackingthe
Vehicleonpage 1-31.
2. Removethetireandwheelassemblies.Referto Tireand Wheel
RemovalandInstallationonpage 16—60.
13 3. Openthesuspectedbrakecaliperbleedervalve.
4. Usinga largeC—clamp, compressthebrakecaliperpistonand
observeforan unrestrictedflowof brakefluidandforfree
movementof thebrakecaliperpiston.
5. Close thecaliperbleedervalve.
Wastheflowof brakefluidunrestrictedanddidthecaliperpistonmove
freely? Go to Step 17 Go to Step 14
Repairor replaceany brakecaliper/wheelcylinderthatwas not
operatingproperly.Refertotheappropriateprocedure.
4 FrontBrakeCaliperOverhaulonpage5-69
14 4 FrontBrakeCaliperReplacementonpage 5-65
4 RearBrake CylinderReplacementonpage5102
Didyoucompletetherepairandlorreplacement? Go to Step21
Bleedthehydraulicbrakesystemto observeforthepresenceofair in
thesystemandto observeforan unrestrictedandevenflowof brake
fluidperaxleduringthebleedingprocedure.Referto HydraulicBrake
15 SystemBleeding(Pressure)onpage5-169or HydraulicBrakeSystem
Bleeding(Manual)onpage5-170.
Wasthereair in thesystem? Go to Step 19 Go to Step 16
16 Wastheflowof brakefluidunrestrictedandevenperaxleduringthe
bleedingprocedure? Go to Step21 Go to Step 17
1. Inspectthehydraulicbrakepipesandflexiblebrakehosesfor
signsof a fluidrestriction;such as beingbent,kinked,pinchedor
damaged.Referto BrakePipe andHose Inspectionon
page5-145.
2. Replaceanyof thehydraulicbrakepipesand/orflexiblebrake
hosesfoundto be bent,kinked,pinched,or damaged.Refertothe
followingproceduresas necessary:
4 FrontBrakeHose Replacementonpage5-162
17
4 Rear BrakeHose Replacement(BodytoAxle —DrumBrake)
onpage5-164or Rear BrakeHose Replacement(Bodyto
Axle - Disc Brake)onpage 5—165 or Rear BrakeHose
Replacement(Axleto Caliper)onpage5-167
3. Ifnoneofthehydraulicbrakepipesorflexiblebrakehoseswere
visiblybent,kinked,pinched,or damaged,replacethehydraulic
brakeflexhose at therestrictedlocation.
Didyoufindandcorrecta condition? Go to Step21 Go to Step 18
Replacethebrakemodulatorassembly,in orderto correctthehydraulic
brakedynamicrearproportioning mechanicaloperation.Referto Brake
18 PressureModulatorValveReplacementonpage5-40.
Didyoucompletethereplacement? Go to Step21
1. Inspectthehydraulicbrakesystemcomponentsforbrakefluid
seepageat a seal andlorfittinglocation,whichmayhavedrawnair
intothesystem.
2. Inspectthehydraulicbrakesystemcomponentsforevidenceofa
19 recentrepair,whichmayhaveintroducedairintothesystem.
3. Repairor replaceanyofthecomponentsfoundto be installed
incorrectlyor seepingbrakefluid.
Didyoufindandcorrecta condition? Go to Step21 Go to Step20

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54138 Hydraulic Brakes

Hydraulic Brake System Diagnosis (cont'd)

Step Action Yes No
1. Inspectthebrakemastercylinderforinternalfluidleaks.Referto
BrakeSystemInternalLeak Testonpage 5-143.
20 2. Repairor replacethebrakemastercylinderif it is foundto be
leakingbrakefluidinternally.Referto MasterCylinder
Replacementonpage5-147. ReturntoSymptom
Didyoufindandcorrecta condition? Go to Step21 Table
installor connectcomponentsthatwereremovedor disconnected HydraulicBrake
21 duringdiagnosis. SystemOK
Didyoucompletetheoperation? Returnto Symptom
Table

Brake Assist System Diagnosis

Step Action Yes No
DEFINlTlON:This diagnostictableis designedtodiagnoseONLY thecomponentsofthebrakeASSIST systemin orderto
determineifthebrakeASSISTsystemis operatingproperly.YouwillbedirectedbytheappropriateSymptomtabletogo toother
brakesystemdiagnostictablesas appropriate.
1 Wereyou sentherefroma BrakeSymptomtable? Go to Step3 Go to Step2
Wereyou sentheredirectlyfroman electricaldiagnosticto Go toDiagnostic
2 investigatevacuumas a possibleconcern? ' StartingPoint- Vehicle
Go to Step5 onpage 6-66
lnspectforproperbrakepedaltravel.Referto BrakePedal Travel
3 MeasurementandInspectiononpage 5-141.
is thebrakepedaltraveldistancewithintheacceptablelimits? G0 to Step5 Go to Step4
1. lnspectforworn,missing,misaligned,bentor damagedbrake
pedalsystemcomponents.
4 Inspectthebrakepedalfora misaligned,bentandlor
damagedcondition. .
4 Inspectthebrakepedalbushingsforexcessivewearand/ Go to”WW” Brake
4 or damage SystemDiagnOSIs on
' page 5-134to check
2. Replacethebrakepedalsystemcomponentsthatareworn, forinternaland
missing,misaligned,bentor damaged. externalfluidleaksand
Didyoufindandreplaceanyworn,missing,misaligned,bentor air in thehydraulic
damagedbrakepedalsystemcomponents? Go to Step5 brakesystem
Check theenginevacuumsourcethatsuppliesvacuumto the Go to EngineControls
vacuumbrakebooster.Referto Brake SystemVacuumSourceTest Diagnostics
onpage 5—142. information to check
5 is thevacuumreadingwithintheacceptablelimits? forvacuumissues,
includingvacuum
pumpoperation,
Go to Step6 if equipped
6 Doestheconditionoccurduringcoldstart-upconditions? Go to Step 7 Go to Step8
Check enginevacuum,andvacuumpumpoperation,if equipped,
underthesamecoldstart-upconditions.Referto EngineControls
7 Diagnostics.
Didyoufindandcorrecta condition? Go to Step22 Go to Step9
8 Duringthevacuumsourcetest,didthevacuumboostercheckvalve
operateproperly? Go to Step 10 Go to Step9
9 Replacethevacuumboostercheckvalve,if equipped.
Didyoucompletethereplacement? Go to Step 10
Ifequippedwitha boostermountedseparatevacuumsensor,
inspectthevacuumsensorgrommetforcracks,cuts,dry—rot,
10 or damage.
Doesthevacuumsensorgrommetexhibitanyoftheconditions
listed? Go to Step 11 Go to Step12

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 Hydraulic Brakes 54139

Brake Assist System Diagnosis (cont'd)

Step Action Yes No
Replacethevacuumsensorgrommet.
11
Didyoucompletethe replacement? Go to Step 12
1. Ifthevehicleis equippedwitha vacuumsensor,installa
scan tool.
12 2. UsingtheDataDisplayfunction,determineif brakebooster
vacuumsensordatais availablewithineitherthechassis
brakecontrolsareaorthepowertrainenginecontrolsarea.
is vacuumsensordataavailablethroughthescan tool? Go to Step 13 Go to Step16
Performthevacuumboosterleak-downtestusinga scan tool:
1. Releasethebrakepedal.
2. Acceleratetheengineto approximately3000RPM, then
releasethethrottle.Wait2—3secondsandrepeatonce.
3. TurntheignitionOFF.
4. TurntheignitionON. Do notstarttheengine.
5. Observeandrecordthevacuumsensorreadingonthescan
13 toolovera periodof60seconds. ,
Note: Vacuumreadingswilldecreaseby approximately2.7kPa
(0.8Hg)forevery305m (1000ft)ofelevationabovesea level.
6. Determinetherateofvacuumleak.
Specification
Maximumallowablevacuumleakrate:10kPa (3in Hg)
in60seconds
Was therateofvacuumleakwithinthe specifiedallowablerange? Go to Step 18 Go to Step14
1. Depletethevacuumreserveby pressingthebrakepedal
severaltimes,or by removingthevacuumboostercheck
valve.
2. Separatethemastercylinderfromthevacuumbrakebooster.
Do notdisconnectanybrakepipes.Referto MasterCylinder
Replacementonpage5-147.
14 3. Ifequippedwitha vacuumseal on therearofthemaster
cylinder,inspecttheseal fordamageandcorrectpositioning
onthemastercylinder.Replacethevacuumseal as
necessary.
4. Carefullyreinstallthemastercylindertothebrakebooster.
Referto MasterCylinderReplacementonpage 5-147.
Didyoucompletetheoperation? Go to Step 15
Performthevacuumboosterleak-downtestusinga scan tool:
1. Releasethebrakepedal.
2. Acceleratetheenginetoapproximately3000RPM, then
releasethethrottle.Wait2—3secondsand repeatonce.
3. TurntheignitionOFF.
4. TurntheignitionON.Do notstarttheengine.
5. Observeandrecordthevacuumsensorreadingon thescan
15 toolovera periodof60seconds.
Note: Vacuumreadingswilldecrease byapproximately2.7kPa
(0.8Hg)forevery305m(1000ft)ofelevationabovesea level.
6. Determinetherateofvacuumleak.
Specification
Maximumallowablevacuumleakrate:10kPa (3in Hg)
in 60seconds
Was therateofvacuumleakwithinthespecifiedallowablerange? Go to Step22 Go to Step21

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5-140 Hydraulic Brakes

Brake Assist System Diagnosis (cont'd)

Step Action Yes No
1. Separatethemastercylinderfromthevacuumbrakebooster.
Do notdisconnectanybrakepipes.Beforeremovingthe
mastercylinder,firstdepletethevacuumby removingthe
checkvalveor applyingthebrakepedalseveraltimes.Referto
MasterCylinderReplacementonpage 5-147.
16 2. Ifequippedwitha vacuumseal ontherearofthemaster
cylinder,inspecttheseal fordamageandcorrectpositioning
onthemastercylinder.
3. Ifequippedwitha vacuumseal thatis partof thebooster,
inspectthesealfordamage.
Doesthevacuumseal exhibitanyoftheconditionslisted? Go to Step17 Go to Step18
1. if equippedwitha vacuumsealon therearofthemaster
cylinder,replacethevacuumseal as necessary.Ensurethe
seal is positionedcorrectlyduringinstallation.
2. Ifequippedwitha vacuumsealthatrequiresreplacementand
17 whichis partofthebooster,theboosterassemblymustbe _
replaced.
3. Carefullyreinstallthemastercylindertothebrakebooster.
Referto MasterCylinderReplacementonpage 5-147.
Didyoucompletethereplacement? Go to Step18
Performthevacuumboostfunctionaltest:
1. Ifstillseparated,reinstallthemastercylindertothebooster.
Referto MasterCylinderReplacementonpage 5-147.
2. if theenginewas startedafterreinstallingthemastercylinder
tothebooster,performthefollowing:
WiththeengineOFF, depressthebrakepedalseveraltimesto
18 depletethevacuumreserve.
3. Depressandmaintainmoderatefootpressureon thebrake
pedaL
4. Starttheengineandobservepedaloperation.
5. Observeforaudiblevacuumleaks.
The brakepedalshouldfallslightly,thenhold.
Istherean audiblevacuumleakcomingfromthebrakepedalarea? Go to Step21 Go to Step19
19 Didthebrakepedalfallslightlyaftertheenginewas started,
thenhold? Go to Step20 Go to Step21
Performthevacuumboosterleak-downtest:
1. Releasethebrakepedal.
2. Acceleratetheengineto approximately3000RPM, then
releasethethrottle.Wait243 secondsand repeatonce.
3. TurntheignitionOFF.
20 P Wait60seconds.
5. Depressthebrakepedal2 timesto checkforvacuumbooster
availablevacuumreserve.Observepedaleffort.
4 Bothpedalappliesshouldbe assisted
4 The amountof assistcoulddiminishslightlywiththe
secondapply
Werebothpedalappliespowerassisted? Go to Step22 Go to Step21
Replacethevacuumbrakebooster.Referto PowerVacuumBrake
21 BoosterReplacementonpage5—173. _
Didyoucompletethereplacement? Go to Step22
installor connectanycomponentsthatwereremovedor BrakeAssist
22 disconnectedduringdiagnosis. SystemOK _
Didyoucompletetheoperation? Returnto Symptom
Table

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Road Test
Brake System Vehicle
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.
. inspect the brake master cylinder reservoir fluid
level and adjust only if necessary for brake system
road testing. Refer to Master Cylinder Reservoir
Filling on page 5-145.
. 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.
Procedure
Road Testing
Warning: Road test a vehicle under safe conditions
and while obeying all traffic laws. Do not attempt
any maneuvers that couldjeopardize vehicle
control. Failure to adhere to these precautions
could lead to serious personal injury and vehicle
damage.
1. Start the engine and allow it to idle.
2. Visually inspect if the brake warning indicator lamp
remains illuminated.
3. Ifthe 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 on page 5-111.
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.
With the transmission in PARK or Neutral, lightly
apply the brake pedal. Observe both the pedal feel
and the pedal travel.
4 Ifthe brake pedal apply felt spongy, or the pedal
travel was excessive, DO NOT drive the vehicle
until it is repaired.
4 Ifthe brake pedal apply did not feel spongy and
the pedal travel was excessive, proceed to
step 6.
Release and apply the brakes.
While continuing to apply the brakes, shift the
transmission into DRIVE or 1st, 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.
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
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Hydraulic Brakes 5-141
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.
4 Ifthe brake pedal apply effortwas excessive,
or the pedal travel was excessive, DO NOT
continue to test drive the vehicle until it is
repaired.
4 if the brake pedal apply effortwas not
excessive and the pedal travel was not
excessive, proceed to step 9.
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 the assistant.
10. 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.
11. Select a smooth, dry, clean and level road that is
as free of heavy traffic as possible for brake
system moderate speed road testing.
12. Drive the vehicle at a moderate speed. Observe for
a pull andlor incorrect tracking of the vehicle
without the brakes applied.
13. 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 andlor
brake drag.
4 Ifthe brake pedal apply effortwas excessive,
or the pedal travel was excessive, DO NOT
continue to test drive the vehicle until it is
repaired.
4 if the brake pedal apply effortwas not
excessive and the pedal travel was not
excessive, proceed to step 14.
14. 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 andlor
uneven braking action —either side to side, or front
to rear.
A small amount of vehicle front and dip is expected
during a moderate apply of the brakes.
15. Ifthe brake pedal apply effortwas excessive,
or the pedal travel was excessive, DO NOT
continue to test drive the vehicle until it is repaired.
Brake Pedal Travel Measurement and
Inspection
Special Tools
CH-28662 Brake Pedal Effort Gauge
For equivalent regional tools, refer to Special Tools on
page 5-181.
1. With the ignition OFF and the brakes cool, apply
the brakes 3—5times, or until the brake pedal
becomes firm, in order to deplete the brake booster
power reserve.
5-142 Hydraulic Brakes
2327966
2. Install the CH-28662 gauge (1), orequivalent, to
the brake pedal (3).
3. Measure and record the distance (a) from the
brake pedal (3)to the rim of the steering wheel (2).
Note the points of measurement.
2327964
4. Apply and maintain a force of 445 N (100 lb) to the
brake pedal, as indicated on the CH—28662
gauge (1), or equivalent.
5. While maintaining 445 N (100 lb) offorce to the
brake pedal (3), measure and record the
distance (b)from the same point on the brake
pedal (3) to the same point on the rim of the
steering wheel (2).
6. Release the brake pedal (3) and repeat steps 4
and 5 to obtain a second measurement. After
obtaining a second measurement, proceed to
step 7.
7. Average the first and second measurements
recorded for the 2 applies of the brakes.
8. Subtract the initial unapplied distance (a),from the
average applied distance (b) to obtain the brake
pedal travel measurement (0).
Specification
Maximum brake pedal travel —measured with the
ignition OFF, brake booster power assist depleted,
and the brakes cool.
Brake System Vacuum Source Test
Note:
4 Engine temperature, accessory load, and
elevation level will affect engine vacuum.
4 Vacuum readings will decrease by approximately
2.7 kPa (0.8 in Hg) for every 305 m (1000ft) of
elevation above sea level.
1. Disconnect the engine vacuum hose from the
vacuum brake booster check valve.
2. Install a vacuum gauge to the engine
vacuum hose.
9’ Install a scan tool to the vehicle.
4. Start the engine and allow the engine to idle until
normal operating temperatures are reached.
Note: To obtain the gauge pressure from the manifold
absolute pressure (MAP) sensor, subtract the absolute
pressure of the MAP sensor from atmospheric
pressure.
5. With the vehicle in PARK or NEUTRAL with the
park brake on, the engine idling, and the air
conditioning (A/C) system OFF, check to see if the
engine vacuum reading is the gauge pressure
calculated from the pressure of the MAP sensor
indicated on the scan tool.
6. Turn the ignition OFF.
7. Ifthe engine vacuum reading is within the specified
normal range, proceed to step11.
8. Ifthe engine vacuum reading is NOT within the
specified normal range, inspect the engine vacuum
hose for the following conditions.
4 Loose connection to the engine
4 Collapse, deformation or contamination
4 Cracks, cuts, or brittleness
9. Ifany of these conditions were found with the
engine vacuum hose, replace the hose, then
repeat steps 2—5.
10. 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.
11. Remove the vacuum brake booster check valve
from the booster.
12. Install the check valve to the engine vacuum hose.
13. Install the vacuum gauge to the check valve.
14. Start the engine and allow the engine to idle in park
or neutral with the park brake on and with the A/C
system OFF, until normal operating temperatures
are reached.
15. Turn the ignition OFF.
(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
 Hydraulic Brakes 5=143
Note: To obtain the gauge pressure from the manifold components exhibit signs of brake fluid leakage,
absolute pressure (MAP) sensor, subtract the absolute repair or replace those components. After the
pressure of the MAP sensor from atmospheric repair or replacement, reinspect the hydraulic
pressure. brake system to assure proper function.
16. Visually inspect the engine vacuum reading is
Brake System, Internal Leak Test
maintained at the same gauge pressure as the
pressure obtained form the MAP sensor as Warning: Refer to Brake Fluid Irritant Warning on
indicated on the scan tool. page 0-4.
17. Ifthe engine vacuum reading is maintained within Caution: Refer to Brake Fluid Effects on Paint and
the specified normal range, proceed to step 19. Electrical Components Caution on page 0-7.
18. if the engine vacuum reading is NOT maintained 1. Start the engine and allow it to idle.
within the specified normal range, replace the 2. Apply light, steady pressure to the brake pedal.
vacuum brake booster check valve, then repeat Observe both the brake pedal feel and travel.
steps 12—16.
3. Release the brakes and turn the ignition OFF.
19. Inspect the vacuum brake booster check valve
grommet for the following conditions: 4. Ifthe brake pedal apply felt spongy, but the brake
pedal travel was not excessive, perform the
4 Loose connection to the vacuum brake booster following steps:
4 Deformation or contamination 4.1. inspect the brake system for external leaks.
4 Cracks, cuts or brittleness Refer to Brake System External Leak
20. Ifany of these conditions were found with the Inspection on page 5-143.
check valve grommet, replace the grommet. 4.2. Pressure bleed the brake system in order to
purge any air that may be trapped in the
Brake System External Leak system. Refer to Hydraulic Brake System
Inspection « Bleeding (Pressure) on page 5-169 or
Hydraulic Brake System Bleeding (Manual) on
Warning: Refer to Brake Fluid Irritant Warning on page 5-170.
page 0-4.
Caution: Refer to Brake Fluid Effects on Paint and
Electrical Components Caution on page 0-7.
1. In order to inspect for external brake fluid leaks,
first inspect 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.
2. lfthe fluid level is abnormally low, adjust the brake
fluid level. Refer to Master Cylinder Reservoir
Filling on page 5-145.
3. Start the engine and allow it to idle.
4. Apply constant, moderate foot pressure to the
brake pedal.
Ifthe brake pedal gradually falls away while under
foot pressure, there may be a brake fluid leak.
5. Turn the ignition OFF.
6. Visually inspect the following brake system
components for brake fluid leaks, excessive
corrosion, and damage. Give particular attention to 2327963
all brake pipe and flexible hose connections to 5. Ifthe brake pedal apply did not feel spongy, but the
ensure that there are not any slight brake fluid brake pedal travel was excessive, perform the
leaks —even though the brake pedal may feel firm following steps:
and hold steady:
5.1. Loosen the master cylinder—to-vacuumbrake
4 Master cylinder brake pipe fittings booster retaining nuts.
4 All brake pipe connections 5.2. Carefully pull the master cylinder away from
4 Brake pipes the vacuum brake boosterjustenough to
4 Brake hoses and connections inspect the mounting surface of the master
4 Brake calipers andlor wheel cylinders cylinder.
7. While slight dampness around the master cylinder 5.3. lnspect the master cylinder mounting surface
reservoir can be considered acceptable, brake fluid at the primary piston (2)for brake fluid leaks.
leaking from any of the brake system components
requires immediate attention. lf any of these

2013
-Sonic
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Manual
(5377994)
54144 Hydraulic Brakes
6. lfthe 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.
. if the master cylinder primary piston (2) does not
exhibit any leakage, pressure bleed the brake
system. Refer to Hydraulic Brake System Bleeding
(Pressure) on page 5169 or Hydraulic Brake
System Bleeding (Manual) on page 5-170.
. Ifthe 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).
. Ifthe 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
Disc Brake
3%413
1%
2327961
1. With the tire and wheel assemblies removed and
the brake rotors retained by wheel lug nuts,
visually inspect the brake caliper pistondust
boot (2) sealing area to ensure that there are no
brake fluid leaks.
. if any evidence of a brake fluid leak is present, the
brake caliper requires overhaul or replacement.
. While the brake system is at rest (4),observe the
position of the brake caliper piston (1) in relation to
the brake caliper housing.
. Have an assistant apply and release the brake
pedal several times while you observe the
operation of the hydraulic brake caliper.
4.1. Observe the brake caliper piston (1) for
unrestricted and even movement during each
apply of the brake system (5).
4.2. Observe the brake caliper piston (1)for an
unrestricted and even return motion during
each release of the brake system (6).
. Ifthe brake 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 brake
caliper may require overhaul or replacement.
Drum Brakes
2327960
. With the rear tire and wheel assemblies and the
brake drums removed, visually inspect the wheel
cylinder pistons boot sealing areas to ensure that
there are no brake fluid leaks.
. If any evidence of a brake fluid leak is present, the
brake wheel cylinder requires replacement.
. Using firm hand pressure, simultaneously and
evenly apply force on both brake shoes in order to
compress the wheel cylinder pistons into
their bore.
. Evenly release the force from both brake shoes to
allow the wheel cylinder pistons to return.
. Ifone or both of the wheel cylinder pistons did not
exhibit unrestricted and even movement during
apply andlor release of force, the wheel cylinder
may require replacement.
(US/Canada)
—Sonic
2013 (5377994)
Manual
Service
 Hydraulic Brakes 5-145

Brake Pipe and Hose Inspection Brake Pedal Pushrod Inspection

Warning: Refer to Brake Fluid Irritant Warning on
page 0-4.
Caution: Refer to Brake Fluid Effects on Paint and
Electrical Components Caution on page 0-7.
1. Visually inspect all of the brake pipes for the
following conditions:
4 Kinks, incorrect routing, missing ordamaged
retainers
4 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 correctly
supported at ride height in order to maintain the
proper relationship of the flexible brake hoses to
the chassis.

2027696
1. Disconnect the brake pedal pushrod (2) from the
brake pedal.
2. Reposition the pedal pushrod boot (1) toward the
front of the vehicle to expose as much of the pedal
pushrod (2) as possible.
3. Inspect the brake pedal pushrod (2) for
straightness.
4. Ifthe brake pedal pushrod (2) is not straight, then
the pushrod requires replacement.
5. Return the pedal pushrod boot (1) to its original
position on the pedal pushrod (2).
6. Connect the brake pedal pushrod (2) to the brake
pedaL

2327958
4. Visually inspect all of the flexible brake hoses for
the following conditions:
4 Kinks (1),improper routing, twists, chafing,
missing or damaged retainers
4 Leaking connections, perished, cracked,
blistered, brittleor bulging hoses
5. Ifany 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 inspect for soft spots (2), indicating an
internal restriction. Inspect the entire length of
each flexible brake hose.
7. Ifany of the flexible brake hoses were found to
have soft spots (2),then the identified flexible
brake hose, or hoses require replacement.
Repair Instructions
Master Cylinder Reservoir Filling
Warning: Refer to Brake Fluid Irritant Warning on
page 0-4.
Caution: Refer to Brake Fluid Effects on Paint and
Electrical Components Caution on page 0—7.
1. Visually inspect the brake fluid level through the
brake master cylinder reservoir.
2. Ifthe brake fluid level is at or below the haIf—full
point during routine fluid checks, the brake system
should be inspected for wear and possible brake
fluid leaks.
3. lfthe 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—offup to
the maximum-fill level.
4. If brake system service was just completed, the
brake fluid may be topped—offup to the
maximum-fill level.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
5-146 Hydraulic Brakes
5. Ifthe brake fluid level is above the half—fullpoint,
adding brake fluid is not recommended under
normal conditions.
6. if brake fluid is to be added to the master cylinder
reservoir, clean the outside of the reservoir on and
around the reservoir cap prior to removing the cap
and diaphragm. Use only GM approved brake fluid
from a clean, sealed brake fluid container.

Master Cylinder Reservoir

Replacement

Removal Procedure
Warning: Refer to Brake Fluid Irritant Warning on
page 0-4.
Caution: Refer to Brake Fluid Effects on Paint and
Electrical Components Caution on page 0—7.
1. Remove the brake master cylinder. Refer to Master
Cylinder Replacement on page 5-147.
2511339
3. Remove the master cylinder reservoir(1)by
carefully pulling straight upward.
4. Remove the brake fluid level indicator switch,
if necessary. Refer to Brake Fluid Level Indicator
Switch Replacement on page 5150.

2511338
2. Remove and discard the brake master cylinder
reservoir roll pin (1).

2511341
5. Remove the brake master cylinder reservoir
seals (1).
6. If replacing the master cylinder reservoir, discard
the reservoir seals.

2013
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Sonic
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 Hydraulic Brakes 5-147

Installation Procedure

2511341
1. Lightly lubricate the brake master cylinder reservoir
seals (1)with GM approved brake fluid from a
clean, sealed, brake fluid container.
2. Install the lubricated brake master cylinder
reservoirseals to the brake master cylinder.
2511338
5. Install a new brake master cylinder reservoir
roll pin (1).
6- Install the brake master cylinder. Refer to Master
Cylinder Replacement on page 5—147.
Master Cylinder Replacement
Removal Procedure
Warning: Refer to Brake Fluid Irritant Warning on
page 0-4.
Caution: Refer to Brake Fluid Effects on Paint and
Electrical Components Caution on page 0-7.
1. Place the ignition switch in the OFF position.
2. Remove the battery.Refer to Batte/y Replacement
on page 9-719.
3. Disconnect the brake fluid level indicator switch
electrical connector.
4. Using a suitable suction device, remove and
properly discard the brake fluid from the brake
master cylinder reservoir.
5. On manual transmission equipped vehicles,
disconnect the clutch master cylinder reservoir
hose. Refer to Clutch Master Cylinder Reservoir
Hose Replacement on page 17-407

2511339
3. Install the master cylinder reservoir (1) by firmly
pressing straight downward.
4. Install the brake fluid level indicator switch,
if removed. Refer to Brake Fluid Level Indicator
Switch Replacement on page 5-150.

(US/Canada)
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2013 (5377994)
Manual
Selvice
5-‘l48 Hydraulic Brakes

1 s; "
’9 . .‘.fixes. :4 /
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2511297 2511323
6. Disconnect the master cylinder secondary brake 10. Remove the master cylinder nuts (1).
pipe fitting (1)- 11. Remove the brake master cylinder.
7. Cap the brake pipe fitting and plug the master
cylinder outlet port to prevent brake fluid loss and
contamination.

2511342
12. Remove the master cylinder seal (1).
2511300 13. inspect the master cylinder seal for damage or
deterioration and replace, if necessary.
8. Disconnect the master cylinder primary brake pipe
fittin (1) 14. Remove the brake fluid level indicator switch,
9 ' . . . if necessary. Refer to Brake Fluid Level Indicator
9. Cap the brake pipe fitting and plug the master Switch Replacement on page 5-150_
cylinder outlet port to prevent brake fluid loss and
contamination. 15. Remove the master cylinder reserVOIr,
if necessary. Refer to Master Cylinder Reservoir
Replacement on page 5-146.
Installation Procedure
1. Install the master cylinder resen/oir, if removed.
Refer to Master Cylinder Reservoir Replacement
on page 5146.
2. Bench bleed the master cylinder. Refer to Master
Cylinder Bench Bleeding on page 5-150.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Hydraulic Brakes 5-149
3. Installthe brake fluid level indicator switch,
if removed. Refer to Brake Fluid Level Indicator
Switch Replacement on page 5-150.

1I
WII"

Ilia

2511300
7. Connect the master cylinder primary brake pipe
fitting (1) and tighten to 18N4m(13 lb ft).
2511342
4. Installthe master cylinder seal (1).
5. Installthe master cylinder to the power vacuum
brake booster.

_ , 2511323
Caution: Refer to Fastener Caution on page 0-8. .
6. Installthe master cylinder nuts (1) and tighten to
50 N4m(37 ”J ft)-
2511297
8. Connect the master cylinder secondary brake pipe
fitting (1) and tighten to 18N4m(13 lb ft).
9. On manual transmission equipped vehicles,
connect the clutch master cylinder reservoir hose.
Refer to Clutch Master Cylinder Reservoir Hose
Replacement on page 17.407
10. Connect the brake fluid level indicator switch
electrical connector.
11. install the battery. Refer to Battery Replacement on
page 9—719.
12. Bleed the hydraulic brake system. Refer to
Hydraulic Brake System Bleeding (Pressure) on
page 5169 or Hydraulic Brake System Bleeding
(Manual) on page 5—170.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
5-150 Hydraulic Brakes

Master Cylinder Bench Bleeding 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.
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
cylinderwith a clean shop cloth to prevent brake
fluid spills.
12. Remove the master cylinder from the vice.

Brake Fluid Level Indicator Switch

Replacement

Removal Procedure
1. Disconnect the brake fluid level indicator switch
electrical connector.

2327941 \ o k ' ///

Warning: Refer to Brake Fluid Irritant Warning on 7
4' (9.631
U) '~\\\!
page 0-4. '
c §‘1\{\{‘\‘\‘»4 /
Caution: Refer to Brake Fluid Effects on Paint and 5" \ v%
Electrical Components Caution on page 0-7. 4.43
1. Secure the mounting flange of the brake master
cylinder in a bench vice 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.
5. Fill the master cylinder reservoir to the maximum
fill level with brake fluid from a clean, sealed brake 2910018
fluid container. Refer to Master Cylinder Reservoir
Filling on page 5-145. 2. Using a small, flat—bladedtool, lift the locking tab
6. Ensure that the ends of the transparent hoses on the underside of the brake fluid level indicator
running into the master cylinder reservoir are fully switch (1) and remove the switch.
submerged in the brake fluid. 3. Inspect the master cylinder reservoirfor damage
7. Using a smooth, round-ended tool, depress and and replace, if necessary. Refer to Master Cylinder
release the primary piston as far as it will travel, a Reservoir Replacement on page 5-146.
depth of about 25 mm (1 in), several times.
Observe the flow of fluid coming from the ports. Installation Procedure
As air is bled from the primary and secondary 1. Install the master cylinder reservoir, if removed.
pistons, the effort required to depress the primary Refer to Master Cylinder Reservoir Replacement
piston will increase and the amount of travel will on page 5-146.
decrease.

2013
—
Sonic
(US/Canada)
Service
Manual
(5377994)
 Hydraulic Brakes 0-151

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2910018 2539300
2. install the brake fluid level indicator switch (1) by 3. Remove the brake pedal assembly upper nuts (1)
pressing the switch firmly into the brake master
cylinder reservoir.
3. Connect the brake fluid level indicator switch
electrical connector. //\¥,

Brake Pedal Assembly Replacement ‘1'.

/V:- ‘ "lttlull'é‘
Removal Procedure
1. Remove the battery tray. Refer to Battery Tray
Replacement on page 9-721.

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V\‘ 1. 2539301
- \Ftfirfl'fi! .-.
?&‘w‘ e I 4. Remove the brake pedal assembly lower nuts (1)
~ x“ 16‘ /,, ‘ ‘
5. Remove the steering column. Refer to Steering
Column Replacement on page 15-33.

2539299
2. Remove the power vacuum brake booster bolts (1).

—
2013 (US/Canada)
Sonic {5377994)
Manual
Service
5-152 Hydraulic Brakes

2539302 2539304
6. Remove the brake pedal release bracket bolt (1). 8. Remove the brake pedal release bracket (1).
9. Disconnect the brake pedal position sensor
electrical connector.
10. On manual transmission equipped vehicles,
disconnect the clutch pedal position sensor
electrical connector.

2539303
7. Remove the brake pedal release bracket bolts (1).

2530987
11. On manual transmission equipped vehicles,
disconnect the clutch master cylinder pushrod
retainer (1). Refer to Clutch Master Cylinder
Replacement on page 17—408

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
 Hydraulic Brakes 51-153

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7

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2511814
2492203

12. On manual transmission equipped vehicles, 15. Remove the right upper brake pedal assembly
remove the clutch master cylinder bolts (1) and bolt (1).
position aside the clutch master cylinder (2)without
disconnecting the clutch fluid pipe. Clutch Master
Cylinder Replacement on page 17-408
13. Position aside any wiring harnesses attached to
the brake pedal assembly bracket, as necessary.

2512966
\Y/
16. Using a suitable tool, carefully cut off the 2 upper
brake pedal assembly locating pins (1).
17. Remove the brake pedal assembly from the
2511810 vehicle.
18. Remove any necessary components from the
14. Remove the left upper brake pedal assembly brake pedal assembly.
bolt (1).
Installation Procedure
1. Using a suitable tool, carefully cut off the 2 upper
brake pedal assembly locating pins.
2. Install any removed components from the brake
pedal assembly.
3. Install the brake pedal assembly to the vehicle.

(US/Canada)
-Sonic
2013 (5377994)
Manual
SeNice
5-154 Hydraulic Brakes

/17/1. ‘1‘“ “‘-

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2539301 2511814
Caution: Refer to Fastener Caution on page 0-8. 6. Install the right upper brake pedal assembly
4. Install the brake pedal assembly lower nuts (1)and bolt (1) and tighten to 9N°m(80 lb in).
tighten to 19 Nm (14 lb ft).

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2511810
2539300
7. Install the teftupper brake pedal assembly
Caution: Refer to Fastener Caution on page 0-8. bolt (1)and tighten to 9 NW(80 lb in).
5. Install the brake pedal assembly upper nuts (1)and
8. Reposition any wiring harnesses attached to the
tighten to 19 N-m(14 lb ft). brake pedal assembly bracket, as necessary.

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
 Hydraulic Brakes 54 55

2492203 2539304
9. On manual transmission equipped vehicles, install 12. Install the brake pedal release bracket (1).
the clutch master cylinder bolts (1) and the clutch
master cylinder(2). Refer to Clutch Master
Cylinder Replacement on page 17—408.

2539303
13. Install the brake pedal release bracket bolts (1)and
2530987 tighten to 22 N-m(16 lb ft).

10. On manual transmission equipped vehicles,

connect the clutch master cylinder pushrod
retainer (1). Refer to Clutch Master Cylinder
Replacement on page 17—408.
11. On manual transmission equipped vehicles,
connect the clutch pedal position sensor electrical
connector.

—
2013 (US/Canada)
Sonic (5377994)
Manual
Service
5-156 Hydraulic Brakes
Brake Pressure Modulator Valve Pipe
Replacement

Removal Procedure
Warning: Refer to Brake Fluid Irritant Warning on
page 0-4.
Caution: Refer to Brake Fluid Effects on Paint and
Electrical Components Caution on page 0-7.
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. Remove the battery.Refer to Battery Replacement
on page 9-719.
2. Clean the area surrounding the brake pressure
modulator valve (BPMV) of any accumulated dirt
H and debris.
2539302
14. Install the brake pedal release bracket bolt (1) and
tighten to 22 N-m(16 lb ft).
15. Connect the brake pedal position sensor electrical
connector.
16. Install the steering column. Refer to Steering
Column Replacement on page 15-33.

15 (“:13

2511297
3. Disconnect the master cylinder secondary brake
pipe fitting (1)from the master cylinder.
4. Plug the master cylinder outlet port to prevent
brake fluid loss and contamination.

2539299
17. Install the power vacuum brake booster
bolts (1) and tighten to 19 N-m(14 lb ft).
18. Install the battery tray. Refer to Battery Tray
Replacement on page 9-721.

—
2013 (US/Canada)
Sonic (5377994)
Manual
Service
 Hydraulic Brakes 5-157

2495345 2495349
5. Disconnect the master cylinder secondary brake 10. Disconnect the master cylinder primary brake pipe
pipe fitting(1)from the BPMV. fitting (1)from the BPMV.
6. Plug the BPMV inlet port to prevent brake fluid loss 11. Plug the BPMV inlet port to prevent brake fluid loss
and contamination. and contamination.
7. Remove the master cylinder secondary brake pipe 12. Remove the master cylinder primary brake pipe
assembly. assembly.
Installation Procedure
1. Install the master cylinder primary brake pipe
assembly.

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2511300
8. Disconnect the master cylinder primary brake pipe
fitting(1)from the master cylinder.
9. Plug the master cylinder outlet port to prevent 2495349
brake fluid loss and contamination.
Caution: Refer to Fastener Caution on page 0-8.
2. Connect the master cylinder primary brake pipe
fitting (1) to the BPMV and tighten to 18 Nm
(13 lb ft).

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
5458 Hydraulic Brakes

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2511300 2511297

3. Connect the master cylinder primary brake pipe
fitting (1)to the master cylinder and tighten to
18N-m (13 lb ft).
4. Install the master cylinder secondary brake pipe
assembly.
6. Connect the master cylinder secondary brake pipe
fitting (1)to the master cylinder and tighten to
18 N-m(13 lbft).
7. Install the battery.Refer to Battery Replacement on
page 9—719.
8. Bleed the hydraulic brake system. Refer to
Hydraulic Brake System Bleeding (Pressure) on
page 5-169 or Hydraulic Brake System Bleeding
(Manual) on page 5—170.

Brake Pipe Replacement

Special Tools
CH-45405 Brake Pipe Flaring Kit
For equivalent regional tools, refer to Special Tools on
page 5—181.

2495345
5. Connect the master cylinder secondary brake pipe
fitting (1) to the BPMV and tighten to 18 Nm
(13 lb ft).

900937
Warning: Refer to Brake Fluid Irritant Warning on
page 0-4.

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service

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.
Caution: Refer to Brake Fluid Effects on Paint and
Electrical Components Caution on page 0—7.
Note: When servicing the brake pipes, note the
following:
- Ifsectioning the brake pipe, use replacement
pipe ofthe same type and outside diameter.
- Use fittings ofthe appropriate size and type.
- Only create flares of the same type or design as
originally equipped on the vehicle.
1. Inspect the area of brake pipe to be repaired or
replaced.
2. Release the brake pipe to be replaced from the
retainers, as required.
3. Select an appropriate location to section the brake
pipe, if necessary.
- Allow adequate clearance in order to maneuver
the CH-45405 Brake Pipe Flaring Kit.
' Avoid sectioning the brake pipe at bands 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 (3/16in)
diameter pipe
' 9.50 mm (0.374 in) for 6.35 mm (1/4in)
diameter pipe
' 12.67 mm (0.499 in) for 7.94 mm (5/16in)
diameter pipe
Note: Ensure that the brake pipe end to be flared is cut
at a square, 90 degree angle to the pipe length.
6. Using the pipe cutter included in the CH—45405
Brake Pipe Flaring Kit, 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.
Hydraulic Brakes 5-159
900939
9. Strip the nylon coating from the brake pipe and to
be flared, if necessary.
9.1. Select the appropriate blade on the coating
stripping tool included in the CH-45405 Brake
Pipe Flaring Kit, by unthreading the blade
block from the stripping tool and installing the
block with the desired blade facing the tool
rollers.
Specification
0 6.35 mm (0.250 in) blade for 4.76 mm
(3/16in) diameter pipe
- 9.50 mm (0.374 in) blade for 6.35 mm
(1/4in) and 7.94 mm (5/16in)
diameter pipe
9.2. Insertthe brake pipe end to be flared into the
stripping tool to the depth of the ledge on the
tool rollers.
9.3. 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: Do not gouge the metal surface of the
brake pipe.
9.4. Rotate the stripping tool in a clockwise
direction, ensuring that the brake pipe end
remains against the tool roller ledges.
9.5. After each successive revolution of the
stripping toot, 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.
9.6. Loosen the thumbwheel of the tool and
remove the brake pipe.
Note: Ensure that all loose remnants of the nylon
coating have been removed from the brake pipe.
9.7. Inspect the stripped and of the brake pipe to
ensure that the proper amount of coating has
been removed.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
5460 Hydraulic Brakes
Specification 14. Select the corresponding die set and install the die
, 6.35 mm (0250 in) for 4.76 mm (3/161“) halves into'the die cage Wlththe full, flat face Of
diameter pipe one duefacmg the clamping screw, and the
. 9 50 mm (0 374 in)for6 35mm (“4 in) counterbores of both dies facmg the forming ram.
and 7.94 mm (5/16in) diameter pipe

900943
900947 15. P_lacethe flat face of an unused die (1) against the
10. Chamfer the inside and outside diameter of the glgeatitraslyerfelgéfligabrgféggfggg 9%: firmly
((933111:
pipe with the de-burring tool included in the . '
OH _45405 Brake Pipe - Kit.
- Flaring - 16. Insertthe prepared end of. the pipe . flared
. to be .
. . . through the back of the dies until the pipe ISseated
11. Install the tube nuts on the brake pipe, noting their against the flat surface of the unused die (1)
orientation. '
17. Remove the unused die (1).
12. Clean the brake pipe and the CH-45405 Brake Ensure that the rear of both dies are seated firmly
18.
Pipe Flaring Kit of lubricant, contaminants, and
against the enclosed end of the die cage.
debris.
19. Firmly hand tighten the clamping screw (2) against
the dies.

900942
13. Loosen the die clamping screw of the CH-45405 900944
Brake Pipe Flaring Kit.
20. Select the appropriate forming mandrel and place
into the forming ram.

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service

21. Rotate the hydraulic fluid control valve clockwise to
the closed position.
. Rotate the body of the CH—45405Brake Pipe
Flaring Kit until it bottoms against the die cage.
900946
23. While guiding the forming mandrel into the
exposed end of pipe to be flared, operate the lever
of the CH-45405 Brake Pipe Flaring Kit 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.
900948
25. Insertthe finishing cone into the forming ram.
26. Rotate the hydraulic fluid control valve clockwise to
the closed position.
27. Rotate the body of the CH-45405 Brake Pipe
Flaring Kit until it bottoms against the die cage.
2013
- Sonic
(US/Canada)
Service
Manual
(5377994)
Hydraulic Brakes 54 61
28. While guiding the finishing cone into the exposed
and of pipe to be flared, operate the lever of the
CH-45405 Brake Pipe Flaring Kit 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.
1201234
32. Inspect the brake pipe flare for correct shape and
diameter (a).
Specification
. 6.74—7.10mm(0.265—0.279in)f1are diameter
for 4.76 mm (3/16in) diameter pipe
' 8.57—9.27mm (0344—0358 in) flare diameter
for 6.35 mm (1/4in) diameter pipe
- 10.42—10.79mm (0410—0425 in) flare
diameter for 7.94 mm (5/16 in) diameter pipe
33. lf 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 (3/4in) 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.
36. Bleed the hydraulic brake system. Refer to
Hydraulic Brake System Bleeding (Pressure) on
page 5-169 or Hydraulic Brake System Bleeding
(Manual) on page 5—170.
37. With the aid of an assistant, inspect the brake pipe
flares for leaks by starting the engine and applying
the brakes.
5-162 Hydraulic Brakes

Front Brake Hose Replacement

1
Removal Procedure
Warning: Refer to Brake Dust Warning on page 0-4.
k“.
Warning: Refer to Brake Fluid Irritant Warning on (GI)
page 0-4.
Danger: Do not use a service jack to lift this
vehicle. Lifting the vehicle with a jack could cause
the vehicle to slip off the jack and roll; this could
cause injury or death.
1. Raise and support the vehicle. Refer to Lifting and
Jacking the Vehicle on page 1-31.
2. Remove the tire and wheel assembly. Refer to Tire
and Wheel Removal and Installation on
page 16-60.
«lll/I

2396312
fix 9 F“ \ /
5. Remove the brake hose retainer(1).
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2512985
3. Remove the brake pipe fitting (1)from the front
brake hose.
4. Cap the brake pipe fitting to prevent brake fluid
loss and contamination.
2396315
6. Release the brake hose grommet (1)from the strut
bracket.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Hydraulic Brakes 51 63

11’! ,_3.

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2387041 2396315
7. Remove the brake hose fitting bolt (1). 3. Installthe brake hose grommet (1)to the strut
8. Remove and discard the brake hose fitting bracket.
gaskets (2)from the brake hose fitting(3).
9. Remove the brake hose.
1
Installation Procedure
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2398312
4. Installthe brake hose to the wheelhouse bracket
and install the retainer(1).
2387041
1. Assemble the brake hose fitting bolt (1)and the
new brake hose fitting gaskets (2)to the brake
hose fitting(3).
Caution: Refer to Fastener Caution on page 0—8.
2. Install the brake hose assembly to the brake
caliper and tighten the fitting bolt to 40 Nm
(30 lb ft).

2013
—Sonic
(US/Canada)
Service
Manual
(5377994)
5:1 64 Hydraulic Brakes

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2512985 2456822
5. Installthe brake pipe fitting(1) to the front brake 3. Disconnect the brake pipe fittings (1)from the
hose and tighten the fittingto 18 N-m(13 lb ft). brake hose.
6. Bleed the hydraulic brake system. Refer to 4. Cap the brake pipe fittings to prevent brake fluid
Hydraulic Brake System Bleeding (Pressure) on loss and contamination.
page 5-169 or Hydraulic Brake System Bleeding
(Manual) on page 5-170.
Install the tire and wheel assembly. Refer to Tire
and Wheel Removal and Installation on
page 16-60.

Rear Brake Hose Replacement (Body

to Axle - Drum Brake)

Removal Procedure
Warning: Refer to Brake Dust Warning on page 0-4.
Warning: Refer to Brake Fluid Irritant Warning on
page 0-4.
1. Raise and support the vehicle. Refer to Lifting and
Jacking the Vehicle on page 1—31.
2. Remove the tire and wheel assembly. Refer to Tire
and Wheel Removal and Installation on
page 16-60.

2456824
5. Remove the brake hose locking clips (1).
6. Remove the brake hose.

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
 Hydraulic Brakes 5—165
Installation Procedure Rear Brake Hose Replacement (Body
1. Install the brake hose to the brackets on the rear to Axle - Disc Brake)
and axle and floor panel.
Removal Procedure
Warning: Refer to Brake Dust Warning on
page 0-4.
Warning: Refer to Brake Fluid Irritant Warning on
page 0-4.
1. Raise and support the vehicle. Refer to Lifting and
Jacking the Vehicle on page 1—31.
2. Remove the tire and wheel assembly. Refer to Tire
and Wheel Removal and Installation on
page 16-60.

2456824
2. Installthe brake hose locking clips (1).

2844641
3. Remove the brake pipe fitting (1)from the rear
brake hose.
4. Cap the brake pipe fitting to prevent brake fluid
loss and contamination.

‘ \ '- ((

2456822
Caution: Refer to Fastener Caution on page 0-8.
3. Connect the brake pipe fittings (1)to the brake
hose and tighten to 18 N-m(13 lb ft).
4. Bleed the hydraulic brake system. Refer to
Hydraulic Brake System Bleeding (Pressure) on
page 5—169or Hydraulic Brake System Bleeding
(Manual) on page 5—170.
5. Install the tire and wheel assembly. Refer to Tire
and Wheel Removal and Installation on
page 16—60.

2844644

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
52166 Hydraulic Brakes
5. Remove the brake hose retainer (1). Installation Procedure
1. Install the brake hose.

@444

2844649
6. Remove the brake pipe fitting (1)from the rear 2844653
brake hose. 2. Install the brake hose retainer(1).
7. Cap the brake pipe fitting to prevent brake fluid
loss and contamination.

2844649
Caution: Refer to Fastener Caution on page 0-8.
2844653
3. Install the brake pipe fitting (1)to the rear brake
8. Remove the brake hose retainer (1). hose and tighten the fitting to 18 NW(13 lb ft).
9. Remove the brake hose.

—
2013 (US/Canada)
Sonic (5377994)
Manual
Service
 Hydraulic Brakes 51 67

Rear Brake Hose Replacement (Axle

to Caliper)

Removal Procedure
Warning: Refer to Brake Dust Warning on
page 0-4.
Warning: Refer to Brake Fluid Irritant Warning on
page 0-4.
1. Raise and support the vehicle. Refer to Lifting and
Jacking the Vehicle on page 1-31.
2. Remove the tire and wheel assembly. Refer to Tire
and Wheel Removal and Installation on
page 16-60.

2844644
4. Install the brake hose retainer (1).

2844497
,3. Remove the brake pipe fitting (1)from the rear
brake hose.
4. Cap the brake pipe fitting to prevent brake fluid
loss and contamination.

2844641
5. Install the brake pipe fitting(1)to the rear brake
hose and tighten the fitting to 18 N-m(13 lb ft).
6. Bleed the hydraulic brake system. Refer to
Hydraulic Brake System Bleeding (Pressure) on
page 5169 or Hydraulic Brake System Bleeding
(Manual) on page 5-170.
7. Install the tire and wheel assembly. Refer to Tire
and Wheel Removal and Installation on
page 16-60.

2844501

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
51 68 Hydraulic Brakes
5. Remove the brake hose retainer(1).

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11’1‘9’4355 5““;
9'96 (

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2844501
3. Install the brake hose to the wheelhouse bracket
2843788 and install the retainer(1).
6. Remove the brake hose fitting bolt (1).
Note: Do not reuse the brake hose fitting gaskets.
7. Remove and discard the brake hose fitting
gaskets (2)from the brake hose fitting (3).
8. Remove the brake hose.
Installation Procedure

2843788
1. Assemble the brake hose fitting bolt (1)and the
new brake hose fitting gaskets (2)to the brake
hose fitting (3).
Caution: Refer to Fastener Caution on page 078.
2. Install the brake hose assembly to the brake
caliper and tighten the fitting bolt to 40 N-m
(30 lb ft).
2844497
4. Install the brake pipe fitting(1)to the rear brake
hose and tighten the fitting to 18 Nm (13 lb ft).
5. Bleed the hydraulic brake system. Refer to
Hydraulic Brake System Bleeding (Pressure) on
page 5-169 or Hydraulic Brake System Bleeding
(Manual) on page 5-170.
6. Install the tire and wheel assembly. Refer to Tire
and Wheel Removal and Installation on
page 16-60.

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
 Hydraulic Brakes 5=~169

Hydraulic Brake System Bleeding the component and repeat steps 3.3—3.8until
each of the ports on the component has
(Pressure) been bled.
Special Tools 3.10. After completing the final component port
bleeding procedure, ensure that each of the
- CH—29532Diaphragm Type Brake Pressure brake pipe fittings is properly tightened.
Bleeder
Fill the brake master cylinder reservoir to the
- CH-35589-A Brake Pressure Bleeder Adapter maximum—filllevel with the approved brake fluid
Warning: Refer to Brake Fluid Irritant Warning on from a clean, sealed brake fluid container. Ensure
page 0-4. the master cylinder reservoir remains at least
Caution: Refer to Brake Fluid Effects on Paint and half—fullduring this bleeding procedure. Add fluid
Electrical Components Caution on page 0—7. as needed to remain the proper level.
1. Place a clean shop cloth beneath the brake master Clean the outside of the reservoir on and around
cylinder reservoir to catch brake fluid spills. the reservoir cap prior to removing the cap and
diaphragm.
2. With the ignition OFF and the brakes cool, apply
the brakes 3—5times, or until the brake pedal effort Set up the brake pressure bleeder following the
manufacturer's instructions. _
increases significantly, to deplete the brake
booster power reservoir. Open the brake pressure bleeder fluid valve to
3. Ifyou have performed a master cylinder bench allow pressurized brake fluid to enter the brake
bleeding on this vehicle, or if you have system.
disconnected the brake pipes from the Wait approximately 30 seconds, and then inspect
proportioning valve assembly or the brake the entire hydraulic brake system in order to
modulator assembly, you must perform the ensure that there are no existing external brake
following steps to bleed air at the ports of the fluid leaks. ‘
hydraulic components. Any brake fluid leaks identified require repair prior
3.1. Fill the master cylinder reservoir to the to completing this procedure.
maximum-fulllevel with the approved brake
fluid from a clean, sealed brake fluid container.
lf removal of the reservoir cap and diaphragm
is necessary, clean the outside of the reservoir
on and around the cap prior to removal.
3.2. With the brake pipes installed securely to the
master cylinder, proportioning valve assembly,
or the brake pressure modulator valve
assembly, loosen and separate one of the
brake pipes from the port of the component.
Note: For the proportioning valve assembly or the
brake pressure modulator valve assembly, perform
these steps in the sequence of system flow; begin with
the fluid feed pipes on the master cylinder.
3.3. Allow a small amount of brake fluid to gravity
bleed from the open port of the component.
3.4. Connect the brake pipe fitting to the
component and tighten securely.
3.5. Have an assistant slowly depress the brake
pedal fully and maintain steady pressure on
the pedal. 2327910
3.6. Loosen the same brake pipe fittingto burge air
from the open port of the component. Install a proper box-end wrench onto the RIGHT
REAR wheel hydraulic circuit bleeder valve (1).
3.7. Tighten the brake pipe fitting, then have the
assistant slowly release the brake pedal. . Install a transparent hose over the end of the wheel
hydraulic Circuit bleeder valve (1).
3.8. Wait 15 seconds, then repeat steps 3.3—3.7
until all air is purged from the same port of 10. Submerge the open end of the transparent hose
each component. into a transparent container (2) partially filled with
the approved brake fluid from a clean, sealed
3.9. With the brake pipe fitting installed securely to brake fluid container.
the master cylinder, proportioning valve
assembly, or brake pressure modulator 11. Loosen the bleeder valve to purge air from the
assembly after all air has been purged from wheel hydraulic circuit. Allow fluid to flow until air
the first port of the component that was bled, bubbles stop flowing from the bleeder, then tighten
loosen and separate the next brake pipe from the bleeder valve.
12. Tighten the wheel circuit bleeder valve securely.

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
5:170 Hydraulic Brakes
13. install a proper box—endwrench onto the LEFT
FRONT wheel hydraulic circuit bleeder valve.
14. install a transparent hose over the end of the wheel
hydraulic circuit bleeder valve, then repeat steps
10—12.
15. Install a proper box—endwrench onto the LEFT
REAR wheel hydraulic circuit bleeder valve.
16. Install a transparent hose over the end of the wheel
hydraulic circuit bleeder valve, then repeat steps
10~12.
17. install a proper box—endwrench onto the RIGHT
FRONTwheeI hydraulic circuit bleeder valve.
18. Install a transparent hose over the end of the wheel
hydraulic circuit bleeder valve, then repeat steps
10—12.
19. After completing the final wheel hydraulic circuit
bleeding procedure, ensure that each of the 4
wheel hydraulic circuit bleeder valves is properly
tightened.
20. Close the brake pressure bleeder fluid valve.
21. Remove the brake pressure bleeder from the brake
master cylinder reservoir.
22. Fill the brake master cylinder reservoir to the
maximum-full level with the approved brake fluid
from a clean, sealed brake fluid container.
23. Slowly depress and release the brake pedal.
Observe the feel of the brake pedal.
24. Ifthe brake pedal feels spongy, repeat the bleeding
procedure again. Ifthe brake pedal still feels
spongy after repeating the bleeding procedure,
perform the following step:
24.1. Inspect the brake system for external leaks.
Refer to Brake System External Leak
Inspection on page 5—143.
24.2. Ifequipped with antilock brakes, using a scan
toll, perform the antilock brake system
automated bleeding procedure to remove
any air that may have been trapped in the
brake pressure modulator valve (BPMV).
Refer to Antilock Brake System Automated
Bleed on page 5—38
25. Turn the ignition ON, with the engine OFF. Check
to see if the brake system warning lamp is
illuminated.
Note: DO NOTallow the vehicle to be driven until it is
diagnosed and repaired.
26. Ifthe brake system warning lamp remains
illuminated, refer to Symptoms - Hydraulic Brakes
on page 5-111.
Hydraulic Brake System Bleeding
(Manual)
Warning: Refer to Brake Fluid Irritant Warning on
page 0-4.
Caution: Refer to Brake Fluid Effects on Paint and
Electrical Components Caution on page 0-7.
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.
Ifhydraulic 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—5times, 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. 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 on page 1—35.
5. Install a proper box-end wrench onto the wheel
hydraulic circuit bleeder valve which has been
serviced.
6. install a transparent hose over the end of the
bleeder valve.
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.
8. Have an assistant slowly press the brake pedal
fully and maintain steady pressure on the pedal.
9. Loosen the bleeder valve to purge airfrom the
wheel hydraulic circuit.
10. Tighten the bleeder valve, then have the assistant
slowly release the brake pedal.
11. Wait 15 seconds, then repeat steps 8—10until 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 clean, sealed brake fluid container.
14. Slowly press and release the brake pedal. Observe
the brake pedal feel.
15. lfthe 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 NOTallow the vehicle to be driven until it is
diagnosed and repaired.
2013
-Sonic
(US/Canada)
Service
Manual
(5377994)

17. Ifthe brake system warning lamp remains
illuminated, refer to Diagnostic Starting Point -
Vehicle on page 6—66.
Bleeding the Complete Brake Hydraulic System
1. With the ignition OFF and the brakes cool, apply
the brakes 3—5times, or until the brake pedal effort
increases significantly, in order to deplete the
brake booster power reserve.
. Place a clean shop cloth beneath the brake master
cylinder to catch brake fluid spills.
Clean the outside of the reservoir on and around
the reservoir cap prior to removing the cap and
diaphragm.
. Ifthe brake pipes have been removed from the
Fill the brake master cylinder reservoir to the
maximum—fulllevel with GM approved brake fluid
from a 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 on page 1-35.
if the master cylinder was replaced, the master
cylinder must be bench bled. Refer to Master
Cylinder Bench Bleeding on page 5—150.
Ifthe brake pipes have been removed from the
master cylinder, the following steps must be
performed.
6.1. 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.
6.2. 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.
6.3. install the front brake pipe fitting to the front
port of the brake master cylinder and tighten
the fitting.Refer to Fastener Tightening
Specifications on page 5-108.
6.4. Have an assistant slowly press the brake
pedal fully and maintain steady pressure on
the pedal.
6.5. Loosen the front brake pipe fitting from the
front port of the brake master cylinder to purge
air from the master cylinder port.
6.6. Tighten the front brake pipe fitting,then have
the assistant slowly release the brake pedal.
6.7. Wait 15 seconds, then repeat
steps 6.4—6.6until all air is purged from the
front brake pipe fitting of the front port of the
master cylinder.
6.8. 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 on page 5-108.
6.9. With the front brake pipe fitting installed
securely to the front port of the brake master
cylinder, loosen and separate the rear brake
pipe fittingfrom the rear port of the brake
master cylinder.
(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
Hydraulic Brakes 5-1'71
6.10. Repeat steps 6.2—6.7for the rear port of the
brake master cylinder.
6.11. After all air is purged from the rear port of the
brake master cylinder, tighten the rear
master cylinder brake pipe fitting. Refer to
Fastener Tightening Specifications on
page 5-108.
6.12. Slowly press and release the brake pedal.
Observe the brake pedal feel.
6.13. Ifthe brake pedal feels spongy, proceed to
step 7.
6.14. if the brake pedal feels firm, proceed to
step 24.
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.
7.1. Loosen and separate one of the master
cylinder brake pipe fittings from the inlet port of
the assembly to be bled.
7.2. 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.
7.3. install the brake pipe fitting and to the inlet port
of the assembly and tighten securely.
7.4. Have an assistant slowly press the brake
pedal fully and maintain steady pressure on
the pedal.
7.5. Loosen the same brake pipe fitting to purge air
from the open port of the assembly.
7.6. Tighten the brake pipe fitting,then have the
assistant slowly release the brake pedal.
7.7. Wait 15 seconds, then repeat
steps 7.4-7.6 until all air is purged from the
brake pipe fitting of the assembly.
7.8. Repeat steps 7.1—7.7for all of the remaining
ports of the assembly.
7.9. After bleeding each port of the assembly,
tighten all of the brake pipe fittings on the
assembly. Refer to Fastener Tightening
Specifications on page 5108.
7.10. Fill the master cylinder reservoir to the
maximum-full level with GM approved brake
fluid from a clean, sealed brake fluid
container.
7.11. Slowly press and release the brake pedal.
Observe the brake pedal feel.
7.12. if the brake pedal feels spongy, proceed to
step 8.
7.13. Ifthe brake pedal feels firm, proceed to
step 24.
. Install a proper box—endwrench onto the RIGHT
REAR wheel hydraulic circuit bleeder valve.
. Install a transparent hose over the end of the
bleeder valve.
51 72 Hydraulic Brakes
10. Submerge the open end of the transparent hose
into a transparent container partially filled with GM
approved brake fluid from a clean, sealed brake
fluid container.
11. Have an assistant slowly press the brake pedal
fully and maintain steady pressure on the brake
pedaL
12. Loosen the bleeder valve to purge airfrom the
wheel hydraulic circuit.
13. Tighten the bleeder valve, then have the assistant
slowly release the brake pedal.
14. Wait 15 seconds,then repeatsteps11-13 until all
air is purged from the wheel hydraulic circuit.
15. Tighten the RIGHT REAR hydraulic wheel circuit
bleeder valve securely.
16. Install a proper box—endwrench onto the LEFT
REAR wheel hydraulic circuit bleeder valve, then
repeat steps 9—14..
17. Install a proper box—endwrench onto the RIGHT
FRONT wheel hydraulic circuit bleeder valve, then
repeat steps 9—14..
18. Install a proper box-end wrench onto the LEFT
FRONT wheel hydraulic circuit bleeder valve, then
repeat steps 9-14..
19. 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.
20. Fill the master cylinder reservoir to the
maximum-full level with GM approved brake fluid
from a clean, sealed brake fluid container.
21. Slowly press and release the brake pedal. Observe
the brake pedal feel.
22. Ifthe brake pedal feels spongy, perform the
following procedure.
22.1. Ifequipped with antilock brakes, install a
scan tool and perform the Antilock Brake
System Automated Bleed on page 5-38 to
remove air which may be trapped in
the BPMV.
22.2. Inspect the hydraulic brake system for
external leaks. Refer to Brake System
External Leak Inspection on page 5-143.
22.3. Repeat the Bleeding the Complete Brake
Hydraulic System procedure.
23. Ifthe brake pedal still feels spongy, pressure bleed
the hydraulic brake system. Refer to Hydraulic
Brake System Bleeding (Pressure) on page 5-169
or Hydraulic Brake System Bleeding (Manual) on
page 5—170
24. Turn the ignition switch ON with the engine OFF.
Check to see if the brake system warning lamp
remains illuminated.
Note: DO NOTallow the vehicle to be driven until the
brake system is diagnosed and repaired.
25. if the brake system warning lamp remains
illuminated, refer to Diagnostic Starting Point -
Vehicle on page 6-66.
Hydraulic Brake System Flushing
Warning: Refer to Brake Fluid Irritant Warning on
page 0-4.
Caution: Refer to Brake Fluid Effects on Paint and
Electrical Components Caution on page 0-7.
1. lnspect the brake fluid for the following conditions,
indicating brake fluid contamination:
- Fluid separation, indicating 2types offluid 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 andlor 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—basedor a silicone-based substance, indicated
by fluid separation and/or a swollen master
cylinder reservoir cap diaphragm andlor swollen
reservoir—to-mastercylinder grommets, perform the
following:
3.1. 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:
. Master Cylinder Replacement on
page 5-147
. Front Brake Hose Replacement on
page 5-162
- Rear Brake Hose Replacement (Body to
Axle - Drum Brake) on page 5—164or Rear
Brake Hose Replacement (Body to Axle -
Disc Brake) on page 5—165or Rear Brake
Hose Replacement (Axle to Caliper) on
page 5-167
~Front Brake Caliper Replacement on
page 5-65
- Rear Brake Cylinder Replacement on
page 5—102
. Brake Pressure Modulator Valve
Replacement on page 5—40
3.2. Clean out all the hydraulic brake pipes using
denatured alcohol, or equivalent.
3.3. Dry the brake pipes using non-lubricated,
filtered air.
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 Hydraulic Brakes 5-173
3.4. Repair or replace ALL of the following
components listed and install them to the
vehicle. Each component contains internal
rubber sealsllinings which have been
contaminated by the contaminated brake fluid
in the brake hydraulic system.
Refer to the procedures indicated:
- Master Cylinder Replacement on
page 5147; 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
andlor damage and replace if necessary.
Refer to Master Cylinder Reservoir
Replacement on page 5-146.
- Front Brake Hose Replacement on
page 5-162
- Rear Brake Hose Replacement (Body to
Axle - Drum Brake) on page 5-164 or Rear
Brake Hose Replacement (Body to AX/e - 2512974
Disc Brake) on page 5-165 or Rear Brake
Hose Replacement (Axle to Caliper) on . Remove the power brake booster vacuum check
page 5-167 valve (1)from the power vacuum brake booster.
Front Brake Caliper Replacement on . Remove the instrument panel lower trim pad cover.
page 5-65 Refer to InstrumentPanel Lower TrimPad Cover
Replacement (WithoutAAL) on page 2-40 or
Rear Brake Cylinder Replacement on InstrumentPanel Lower TrimPad Cover
page 5—102 Replacement (With AAL) on page 2-41.
° Brake Pressure Modulator Valve
Replacement on page 5-40
4. Ifthe brake fluid WAS NOT contaminated with an
oil-based or a silicone-based substance, but WAS
contaminated with water or dirt, rust, corrosion,
andlor brake dust, replace the brake master
cylinder reservoir cap diaphragm which may have
allowed the moisture or particles to enter the
hydraulic system.
5. Fill the brake master cylinder reservoir to the
maximum-fili level with the approved brake fluid
from a clean, sealed brake fluid container.
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 (Pressure) on page 5-169 or
Hydraulic Brake System Bleeding (Manual) on
page 5—170.

Power Vacuum Brake Booster

Replacement 2539396

Removal Procedure
1. With the engine OFF, apply and release the brake
pedal several times until the pedal becomes firm to
deplete the power vacuum brake booster vacuum
reserve.
2. Remove the battery tray. Refer to Battery Tray
Replacement on page 9-721.
3. Disconnect the power vacuum brake booster
vacuum sensor electrical connector, if equipped.
. Compress the tabs on the top and bottom of the
brake booster pushrod retainer (1)and lift the
brake pedal (2) rearward to disconnect the brake
pedal from the power brake booster pushrod.
. Inspect the brake booster pushrod retainer for
damage and replace, if necessary.
. Remove the master cylinder. Refer to Master
Cylinder Replacement on page 5-147.

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5-174 Hydraulic Brakes
Installation Procedure
1. Install the power vacuum brake booster gasket,
if removed.

2495352
9 . Ifequipped with antilock brakes, disconnect the
front and rear brake pipe fittings (1)from the brake
pressure modulator valve (BPMV). Refer to Brake
Pressure Modulator Valve Replacement on 2511360
page 5-40.
2. Installthe power vacuum brake booster and bolts.
Caution: Refer to Fastener Caution on page 0-8.
Note: Do not over tighten the power vacuum brake
booster bolts. if the power vacuum brake booster bolts
are over tightened, the brake pedal may remain applied
after a high pressure brake pedal application.
3. Installthe power vacuum brake booster
bolts (1)and tighten to 19 N-m(14 lb ft).

2511360
10. Completely loosen the power vacuum brake
booster bolts (1).
11. Remove the power vacuum brake booster.
12. Inspect the power vacuum brake booster gasket
for damage and replace, if necessary.

2495352
4. if equipped with antilock brakes, connect the front
and rear brake pipe fittings (1)to the brake
pressure modulator valve (BPMV). Refer to Brake
Pressure Modulator Valve Replacement on
page 5-40.

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 Hydraulic Brakes 54175
5. Install the master cylinder. Refer to Master Cylinder 10. Install the instrument panel lower trim pad cover.
Replacement on page 5-147. Refer to Instrument Panel Lower TrimPad Cover
Replacement (WithoutAAL) on page 2-40 or
InstrumentPanel Lower TrimPad Cover
Replacement (WithAAL) on page 2—41.
11. Install the battery tray. Refer to Battery Tray
Replacement on page 9—721 .
_/'
Power Brake Booster Vacuum Check
Valve and Hose Replacement
a ‘2 " \"’
...,
, //\\\ Removal Procedure
1. With the engine OFF, apply and release the brake
pedal several times to deplete the power vacuum
brake booster vacuum reserve.

2512974
6. Installthe power brake booster vacuum check
valve (1)to the power vacuum brake booster.
7. Connect the power vacuum brake booster vacuum
sensor electrical connector, if equipped.

2512974
‘
2. Disconnect the power brake booster check
valve (1)from the power vacuum brake booster
grommet.

2539396
8. Installthe power brake booster pushrod
retainer (1)to the power brake booster pushrod,
if removed.
Note: Ensure the power vacuum brake booster
pushrod retainer is fully seated in the brake pedal arm.
9. Position the brake pedal (2)to the power brake
booster pushrod retainer and firmly seat the brake
pedal to the retainer.

2511350

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5:176 Hydraulic Brakes
3. Disconnect the power brake booster vacuum pipe Power Brake Booster Vacuum
quick connect (1)from the intake manifold
vacuum port. Sensor Replacement
4. Remove the power brake booster vacuum pipe. Removal Procedure
Installation Procedure 1. With the engine OFF, apply and release the brake
pedal several times to deplete the power vacuum
1. Install the power brake booster vacuum pipe to the brake booster vacuum reserve.
vehicle.
2. Disconnect the power brake booster vacuum
sensor electrical connector.

2511350
2. Connect the power brake booster vacuum pipe 2511345
quick connect (1)to the intake manifold
vacuum port. 3. Disconnect the power brake booster vacuum
sensor (1)from the power vacuum brake booster
grommet.

2512974
Note: A small amount of denatured alcohol may be 2511347
used to lubricate the power vacuum brake booster
grommet. . Disconnect the power brake booster vacuum 'pipe
3. Install the power brake booster check valve (1)to quick connect (1)from the power brake
the power vacuum brake booster grommet. booster pump.

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 Hydraulic Brakes 5a'l 77

2511350 2511347
5. Disconnect the power brake booster vacuum pipe 3. Connect the power brake booster vacuum pipe
quick connect (1)from the intake manifold fitting. quick connect (1)to the power brake
6. Remove the power brake booster vacuum pipe and booster pump.
vacuum sensor assembly.
Installation Procedure
1. install the power brake booster vacuum pipe and
vacuum sensor assembly.

2511345
Note: A small amount of denatured alcohol may be
used as a lubricant for assembly.
4. Connect the power brake booster vacuum
sensor (1) to the power vacuum brake booster
2511350 grommet.
2. Connect the power brake booster vacuum pipe 5. Connect the power brake booster vacuum sensor
quick connect (1)to the intake manifold fitting. electrical connector.

2013
-Sonic
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5178 Hydraulic Brakes

Power Brake Booster Pump

Replacement

Removal Procedure
1. With the engine OFF, apply the brake pedal
several times until the brake pedal becomes firm to
deplete the vacuum brake booster vacuum
reserve.
2. Remove the battery tray. Refer to Battery Tray
Replacement on page 9-721.
3. Disconnect the power brake booster pump
electrical connector.

2511353
7. Remove the power brake booster pump front
bracket bolt (1).

2511347
4. Disconnect the power brake booster vacuum pipe
quick connect (1)from the power brake
booster pump.
5. Raise and support the vehicle. Refer to Lifting and
Jacking the Vehicle on page 1-31.
6. Remove the left front tire and wheel assembly.
Refer to Tire and Wheel Removal and Installation
on page 16-60.
2511355
8. Disconnect the power brake booster pump vent
hose grommet (1).
9. Release the vent hose from the vehicle body.

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 Hydraulic Brakes 5-179

2511351 2511355
10. Remove the power brake booster pump bracket . Install the vent hose to the vehicle body.
bolt (1)and nut(2). ‘ . Connect the power brake booster pump vent hose
11. Lower the vehicle. grommet (1).
12. Remove the power brake booster pump.
Installation Procedure
1. Install the power brake booster pump.
2. Raise and support the vehicle. Refer to Lifting and
Jacking the Vehicle on page 1-31.

2511351
Caution: Refer to Fastener Caution on page 0-8.
3. Install the power brake booster pump bracket
bolt (1) and nut (2)and tighten to 22 N-m(16 lb ft).
2511353
6. install the power brake booster pump front bracket
bolt (1) and tighten to 22 Nm (16 lb ft).
7. Install the left front tire and wheel assembly. Refer
to Tire and Wheel Removal and Installation on
page 16-60.
8. Lower the vehicle.

2013
«Sonic
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5=180 Hydraulic Brakes
2511347
9. Connect the power brake booster'vacuum pipe
quick connect (1) to the power brake
booster pump.
10. Connect the power brake booster pump electrical
connector.
11. Install the battery tray. Refer to Battery Tray
Replacement on page 9-721.
Description and Operation
Brake Assist System Description and
Operation
System Component Description
The brake assist system consists of the following:
Brake Pedal: Receives, multiplies and transfers brake
system input force from driver.
Brake Pedal Pushrod: Transfers multiplied input force
received from the brake pedal to the vacuum 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 booster.
Return springs maintain the booster in a rest position.
When brake system input force is applied, vacuum to
the rear of the diaphragm 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
source vacuum for a spark ignition engine is normally
derived from the intake manifold.
Vacuum Source Delivery System: Enables delivery
and retention of source vacuum for vacuum brake
booster.
System Operation
Under normal driving conditions, without the brakes
applied, vacuum is allowed to act on both sides of the
diaphragm within the vacuum brake booster. When the
brake pedal is applied, the effort by the driver is
multiplied due to the relative length of the brake pedal
in relationship to its pivot point and the point at which
the push rod to the vacuum brake booster is attached.
Movement of the push rod causes a valve within the
vacuum brake booster to close between the two sides
of the diaphragm, thus isolating each side. Italso
allows a valve to open that allows atmospheric
pressure to act on the pedal side of the vacuum brake
booster while maintaining vacuum on the vacuum
source side of the diaphragm. The movement of the
brake pedal pushrod is transferred to the hydraulic
brake master cylinder via the vacuum brake booster.
The pressure differential within the vacuum brake
booster reduces the effort required by the driver in
applying the brakes.
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.
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 Hydraulic Brakes 5481

Brake Warning System Description System Operation

and Operation Mechanical force is converted into hydraulic pressure
by the master cylinder, regulated to meet braking
Brake Warning Indicator system demands by the pressure balance control
system, and delivered to the hydraulic brake wheel
The instrument cluster turns the brake warning
circuits by the pipes and flexible hoses. The wheel
indicator ON when the following occurs:
apply components then convert the hydraulic pressure
- The instrument cluster performs the bulb check. back into mechanical force which presses brake linings
The brake warning indicator illuminates for 5 s. against rotating brake system components.
- When the Electronic Brake Control Module
(EBCM) detects low brake fluid level it sends a Special Tools and Equipment
serial data message to the instrument cluster,
which will illuminate the red brake indicator.
- The Body Control Module (BCM) detects that the Illustration Tool Number]Description
parking brake is engaged. The instrument cluster
receives a serial data message from the BCM
requesting illumination.
Driver Information Center Messages CH 28662
When the Electronic Brake Control Module (EBCM) J 28662
detects low brake fluid level it sets DTC C0267 and BrakePedal EffortGauge
sends a serial data message to the Driver Information
Center , which will display Brake Fluid Low message.

Hydraulic Brake System Description 1006

and Operation

System Component Description

The hydraulic brake system consists of the following: CH 29532
Hydraulic Brake Master Cylinder Reservoir: J 29532
Contains a supply of brake fluid for the hydraulic brake DiaphragmPressure
system. Bleeder
Hydraulic Brake Master Cylinder: Converts
mechanical inputforce into hydraulic output pressure.
Hydraulic output pressure is distributed from the master 153125
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 CH 35589-A
distribution of braking force. Pressure balance control J 35589—A
on non-ABS equipped vehicles, is achieved through a BrakePressureBleeder
proportioning valve assembly. Pressure balance control Adapter
on ABS equipped vehicles, is achieved through
electronic brake distribution (EBD), which is a function
of the ABS modulator.
2352475
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 CH 45405
output force.
J 45405
BrakePipe FlaringKit

900934

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54182 Park Brake

Park Brake

Specifications

Fastener Tightening Specifications

Specification
Application Metric English
ParkingBrakeCable BracketBolt 22N-m 16lbft
ParkingBrakeIndicatorSwitchBolt 2N-m 18lbin
ParkingBrakeLeverNut 22Nm ' 16lbft

Visual/Physical Inspection
Diagnostic information and
° lnspect for aftermarket devices which could affect
Procedures the operation of the park brake system.
' Inspect the easily accessible or visible system
components for obvious damage or conditions
Symptoms - Park Brake which could cause the symptom.
Note: Review the system operation in order to Symptom List
familiarize yourself with the system functions. Refer to
Park Brake System Description and Operation on Refer to a symptom diagnostic procedure from the
page 5—199 following list in order to diagnose the symptom:
- Park Brake Will Not Ho/d or Release on
page 5—182
- Park Brake System Diagnosis (Drum Brake) on
page 5-183 or Park Brake System Diagnosis (Disc
Brake) on page 5—185
Park Brake Will Not Hold or Release
Step Action Yes No
Wereyousentherefroma Park BrakeSymptomtable? Go toSymptoms
1 - Park Brakeon
Go to Step2 page5-182
inspecttheparkbrakesystemforproperoperation.Referto Park Brake
SystemDiagnosis(DrumBrake)onpage 5-183or Park BrakeSystem
2 Diagnosis(DiscBrake)onpage5-185.
Didyoufindandcorrecta condition? Go to Step6 Go to Step3
Inspectthedrumbrakesystemforproperoperation.Referto DrumBrake
3 SystemDiagnosisonpage 5-131.
Didyoufindandcorrecta condition? Go to Step6 Go to Step4
Inspectthedisc brakesystemforproperoperation.Referto Disc BrakeSystem
4 Diagnosisonpage5—128.
Didyoufindandcorrecta condition? Go to Step6 Go to Step5
Inspectthehydraulicbrakesystemforproperoperation.Referto Hydraulic Go toSymptoms
5 BrakeSystemDiagnosisonpage 5-134. _ParkBrakeon
Didyoufindandcorrecta condition? Go to Step6 page5-182
Roadtestthevehiclein ordertoconfirmcorrectoperation.Referto Brake
6 SystemVehicleRoad Testonpage5-141.
is theconditionstillpresent? Go to Step2 SystemOK

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 Park Brake 51 83

Park Brake System Diagnosis (Drum Brake)

Step Action I Yes No
DEFINlTION:This diagnostictableis designedtodiagnoseONLY thecomponentsofthePARK brakesystemin orderto
determineifthePARK brakesystemis operatingproperly.YouwillbedirectedbytheappropriateSymptomtableto go to other
brakesystemdiagnostictablesas appropriate.
1 Wereyousentherefroma HydraulicBrakeSymptomtable? Go to Step4 Go to Step2
2 Wereyousentherefroma Park BrakeSymptomtable? Go to Step4 Go to Step3
Isthesymptomrelatedtotheabilityoftheparkbrakesystemto holdandlor Go to Symptoms
release? Go to Symptoms -Hydraulic
—Park Brakeon Brakes on
page5-182 page 5-111
1. Raise andsupportthevehiclewiththerearaxlesupportedbyjack stands.
Referto LiftingandJackingtheVehicleonpage 1-31.
2. ShiftthetransmissionintoNEUTRAL.
3. WiththeparkbrakeRELEASED, attemptto rotatetherearwheelsto
checktherearbrakesfora significantamountofdrag.
Dotherearbrakeshavea substantialamountofdrag? Go to Step11 Go to Step5
1. Withthetransmissionstillin NEUTRAL, applytheparkbrake.
2. Attemptto rotatetherearwheelstochecktherearbrakesfora significant
amountofdrag.
Dotherearbrakeshavea significantamountofdrag? Go to Step6 Go to Step7
1. Releasetheparkbrake.
2. Rotatetherearwheelstocheck.therearbrakesfora significantreduction
in theamountof drag.
Didtherearbrakesexhibita significantreductionin theamountof drag? Go to Step20 Go to Step11
1. Removethebrakedrums.Referto BrakeDrumReplacement(J93,J94)
onpage 5-90.
2. Visuallychecktheparkbrakecableconnectionsandthecablesthatare
accessibleon theUNDERSIDEofthevehiclefordisconnectionsandlor
damage.
Wereanyor theparkbrakecablesdisconnectedandlordamaged? Go to Step8 Go to Step9
Reconnector replacetheparkbrakecablesas necessary.Referto Parking
BrakeCableReplacement(DrumBrake)onpage 5-189or ParkingBrake
CableReplacement(DiscBrake)onpage 5-192.
Didyoucompletetherepairandlorreplacement? Go to Step9
Checktheadjustmentoftheparkbrake.Referto ParkingBrakeAdjustment
(DrumBrake)onpage 5-197or ParkingBrakeAdjustment(DiscBrake)on
page5-198.
Wastheparkbrakeadjustedproperly? Go to Step11 Go to Step10
Adjusttheparkbrake.Referto ParkingBrakeAdjustment(DrumBrake)on
1O page5-197or ParkingBrakeAdjustment(DiscBrake)onpage 5-198.
Wereyouableto attainadjustmentoftheparkbrake? Go to Step16 Go to Step11
Caution: Do notdepressthebrakepedalwiththebrakerotorsand/orthe
brakedrumsremoved,or withthebrakecalipersrepositionedawayfromthe '
brakerotors,ordamagetothebrakesystemmayresult.
1. Removethebrakedrums.Referto BrakeDrumReplacement(J93,J94)
onpage 5-90.
11 2. Inspecttheparkbrakehardwareforloose,damaged,brokenor missing
components.Referto Park BrakeHardwareInspectiononpage 5-186.
3. Check thedrumbrakeadjustersfora seizedcondition.
Dotheparkbrakehardwareand/orthedrumbrakeadjustersrequire
replacement? Go to Step12 Go to Step 13
1. Replaceparkbrakehardwarecomponentsas necessary.Referto Brake
Shoe Replacement(J93,J94)onpage5-92.
12 2. Replacethedrumbrakeadjustinghardwareas necessary.Referto Drum
BrakeAdjustingHardwareReplacement(J93,J94)onpage 5-100.
Didyoucompletethereplacement? Go to Step13
Havean assistantapplyandreleasetheparkbrake,whileyouobservethe
13 parkbrakecablesforfreemovement.
Dotheparkbrakecables movefreely? Go to Step14 Go to Step 17

2013
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5-‘184 Park Brake

Park Brake System Diagnosis (Drum Brake) (cont'd)

Step Action Yes No
Checktheadjustmentoftheparkbrake.Referto ParkingBrakeAdjustment
14 (DrumBrake)onpage 5-197or ParkingBrakeAdjustment(DiscBrake)on
page 5-198.
Was theparkbrakeadjustedproperly? Go to Step16 Go to Step 15
Adjusttheparkbrake.RefertoParkingBrakeAdjustment(DrumBrake)on
15 page 5-197or ParkingBrakeAdjustment(DiscBrake)onpage 5—198. Go to Step25
Wereyouabletoattainadjustmentoftheparkbrake? Go to Step 16
1. Withthetransmissionstillin NEUTRAL, applytheparkbrake.
2. Attemptto rotatetherearwheelsto checktherearbrakesfora significant
amountofdrag.
16 3. Release theparkbrake. .
4. Rotatetherearwheelstocheckthe rearbrakesfora significantreduction
of drag. Returnto
Doestheparkbrakeapplyandreleaseproperly? Go to Step27 SymptomTable
1. Removethebrakedrums.Referto BrakeDrumReplacement(J93,J94)
onpage 5-90.
2. Disconnecttheparkbrakecable connectionsthatare accessibleonthe
17 UNDERSIDE of thevehicleone at a timeandcheckeachcableforfree
movement.
Didanyof theparkbrakecablesaccessible ontheundersideof thevehicle
requirereplacement? Go to Step18 Go to Step 19
Replaceanyoftheparkbrakecables thatdo nothavefreemovement—not
releasingproperly.Referto ParkingBrake CableReplacement(DrumBrake)
18 onpage 5-189or ParkingBrakeCableReplacement(DiscBrake)on
page 5—192.
Didyou completethereplacement? G0 to Step23
Replacetheparkbrakeleverassembly—notreleasingproperly.Referto
19 ParkingBrakeLeverReplacementonpage 5—186.
Didyou completethereplacement? Go to Step24
Check theadjustmentoftheparkbrake.Referto ParkingBrakeAdjustment
(DrumBrake)onpage 5—197 orParkingBrakeAdjustment(DiscBrake)on
20 page 5-198.
Was the parkbrakeadjustedproperly? Go to Step27 Go to Step21
Adjusttheparkbrake.RefertoParkingBrakeAdjustment(DrumBrake)on
21 page 5-197or ParkingBrakeAdjustment(DiscBrake)onpage5-198.
Wereyouableto attainadjustmentoftheparkbrakesystem? Go to Step26 Go to Step22
1. Removethebrakedrums.Referto BrakeDrumReplacement(J93,J94)
onpage 5-90.
2. Check thedrumbrakeadjusterfora seizedcondition.
22
3. Replacethedrumbrakeadjustinghardwareas necessary.Referto Drum
BrakeAdjustingHardwareReplacement(J93,J94)onpage 5—100.
Didyoufindandcorrecta condition? Go to Step23 Go to Step25
Adjusttheparkbrake.RefertoParkingBrakeAdjustment(DrumBrake)on
23 page 5-197or ParkingBrakeAdjustment(DiscBrake)onpage5-198.
Wereyou abletoattainadjustmentof theparkbrakesystem? Go to Step26 Go to Step25
Adjusttheparkbrake.RefertoParkingBrakeAdjustment(DrumBrake)on
24 page 5—197 or ParkingBrakeAdjustment(DiscBrake)onpage5-198. Returnto
Wereyou abletoattainadjustmentoftheparkbrakesystem? Go to Step26 SymptomTable
1. Replacethecomponentthatis usedtoadjusttheparkbrakesystem.
Referto ParkingBrakeLeverReplacementonpage5-186.
25 2. Adjusttheparkbrake.Referto ParkingBrakeAdjustment(DrumBrake)
onpage 5-197or ParkingBrakeAdjustment(DiscBrake)onpage 5-198. Returnto
Didyoucompletethe replacementandadjustment? Go to Step26 SymptomTable

—
2013 (US/Canada)
Sonic (5377994)
Manual
Service
 Park Brake 5485

Park Brake System Diagnosis (Drum Brake) (cont'd)

Step Action Yes No
1. Withthetransmissionin NEUTRAL,applythe parkbrake.
2. Attempttorotatetherearwheelstocheckthe rearbrakesfora significant
amountofdrag.
26 3. Releasetheparkbrake.
4. Rotatetherearwheelsto checktherearbrakesfora significantreduction
0fdrag. Returnto
Didtheparkbrakeapplyandreleaseproperly? Go to Step27 SymptomTable
Installor connectanycomponentsthatwereremovedor disconnectedduring Park Brake
27 diagnosis. SystemOK _
Didyoucompletethe operation? Returnto
SymptomTable

Park Brake System Diagnosis (Disc Brake)

Step Action I Yes I 1 No
DEFINITION:Thisdiagnostictableis designedtodiagnoseONLY themechanicalcomponentsofthePARK brakesystemin
ordertodetermineif thePARK brakesystemis operatingproperly.Youwillbedirectedby theappropriateSymptomtableto go to
otherbrakesystemdiagnostictablesas appropriate.
1 Wereyousentherefroma HydraulicBrakeSymptomtable? Go to Step4 Go to Step2
2 Wereyousentherefroma Park BrakeSymptomtable? Go to Step4 Go to Step3
Isthesymptomrelatedtotheabilityoftheparkbrakesystemto hold Go to Symptoms— Go to Symptoms-
3 and/orrelease? Park Brakeon HydraulicBrakeson
page5-182 page 5-111
1. Raise andsupportthevehiclewiththerearaxlesupportedby
jack stands.Referto LiftingandJackingthe Vehicleon
page 1-31.
4 2. Withtheparkbrake RELEASED, attemptto rotatetherear
wheelstocheckthe rearbrakesfora significantamount
ofdrag.
Dotherearbrakeshavea significantamountofdrag? Go to Step8 Go to Step5
1. Applytheparkbrake.
5 2. Attempttorotatetherearwheelsto checktherearbrakesfora
significantamountofdrag.
Dotherearbrakeshavea significantamountofdrag? Go to Step 13 Go to Step6
Visuallyinspectthe parkbrakecable connectionsandthecables
thatareaccessibleontheUNDERSIDE ofthevehiclefor
6 disconnectionsand/ordamage.
Wereanyofthepark brakecablesdisconnectedandlordamaged? Go to Step7 Go to Step8
Reconnector replacetheparkbrakecablesas necessary.Referto
ParkingBrakeCable Replacement(DrumBrake)onpage 5—189 or
7 ParkingBrakeCable Replacement(DiscBrake)onpage 5—192. _
Didyoucompletethe repairandlorreplacement? Go to Step 13
1. Disconnecttherearparkbrakecablesfromtheequalizerand
fromthebrakecaliperpistonapplylevers.Referto Parking
BrakeCableReplacement(DrumBrake)onpage 5—189 or
ParkingBrakeCable Replacement(DiscBrake)on
page5-192.
2. Havean assistantapplyand maintainthecaliperpistonapply
levertoapplythe caliperpiston.
8 3. Attempttorotatetherearwheelstocheckthe rearbrakesfora
significantamountofdrag.
4. Releasethecaliperpistonapplylever.
5. Repeatsteps2, 3, and4 fortheotherside ofthevehicle.
6. Rotatetherearwheelstocheckthebrakefora significant
reductionofdrag.
Didthebrakecalipersapplyandreleaseproperly? Go to Step 10 Go to Step9

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
3486 Park Brake

Park Brake System Diagnosis (Disc Brake) (cont'd)

Step Action Yes No
Replacetheappropriaterearbrakecaliper.Referto Rear Brake
CaliperRep/acementonpage5-66.
Didyou completethereplacement? Go to Step 13
Withtheaidof anassistant,applyandreleasetheparkingbrake
10 whileobservingthecablesforfree movement.
Didtheparkbrakecablesmovefreely? Go to Step 12 Go to Step11
Replaceanyoftheparkbrakecables inspectedthatdo nothave
freemovement.Referto ParkingBrakeCableReplacement(Drum
11 Brake)onpage5-189or ParkingBrakeCableReplacement(Disc
Brake)onpage5-192.
Didyoucompletethereplacement? Go to Step 13
Inspecttheparkbrakeleverassemblyforproperoperationand
replaceit necessary.RefertoParkingBrakeLeverReplacementon
12 page 5-186.
Didyoucompletethereplacement? Go to Step 13
Installor connectanycomponentsthatwereremovedor Park Brake
disconnectedduringdiagnosis. SystemOK
13 ‘ Didyoucompletetheoperation? Go to Symptoms- -
Park Brakeon
page5-182

Park Brake Hardware Inspection Note: The brake shoe and park brake lever are not
serviced separately. If either component requires
replacement, they must be replaced as an assembly.
2. if any of the conditions listed were found, the park
brake lever and brake shoe assembly requires
2 replacement.
4" ..« Repair Instructions
/..)
-)§~
/":/,3“?'1)1»)m)»))))»»»»»g»)»»
Parking Brake Lever Replacement
@619, -' \l Removal Procedure
\lr ’3 1. Remove the front floor console. Refer to Front
(G Floor Console Replacement on page 2—61 .
@k// o 2. Ensure that the park brake lever is in the fully
released position.
W. .0882; 3. Disconnect the electrical connector from the park
brake warning lamp switch.
343'

2308635
Warning: Refer to Brake Dust Warning on page 0-4.
1. Visually inspect the park brake lever(1) and the
lever pivot pin (2) for the following conditions:
- The lever being bent or broken at any point -
particularly at the cable attachment
- A seized or binding condition at lever pivot pin
. A broken lever pivot pin

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
 Park Brake 5:187

Wm

2513001
4. Using ONLY HAND TOOLS, loosen the adjusting
nut (1) completely to the end of the front cable
threaded rod.
2513002
Caution: Refer to Fastener Caution on page 0—8.
2. install the park brake lever mounting nuts (1)and
tighten to 22 Nm (16 lb ft).
3. Connect the electrical connector to the park brake
warning lamp switch.

\( l,» “

7N

2513002
5. Remove the park brake lever mounting nuts (1).
6. While removing the front cabie threaded rod from
the park brake lever assembiy, remove the park
brake lever assembly from the vehicle.
Installation Procedure
1. While intstaliing the front cable threaded rod to the
park brake lever assembly, install the park brake
iever assembly to the vehicle.
2513001
4. Loosely install the adjusting nut (1)to front cable
threaded rod.
5. Adjust the park brake cable tension. Refer to
Parking Brake Adjustment (Drum Brake) on
page 5-197 or Parking Brake Adjustment (Disc
Brake) on page 5—198.
6. Installthe front floor console. Refer to Front Floor
Console Replacement on page 2-61.

2013
~Sonic
(US/Canada)
Selvice
Manual
(5377994)
5! 88 Park Brake

Parking Brake Indicator Switch Installation Procedure

Replacement

Removal Procedure
1. Remove the front floor console. Refer to Front
Floor Console Replacement on page 2-61.
2. Ensure that the park brake lever is in the fully
released position.
3. Disconnect the electrical connector from the park
brake warning indicator switch.

2512999
1. Install the parking brake indicator switch (1).

2512998
4. Remove the parking brake indicator switch bolt (1).

2512998
Caution: Refer to Fastener Caution on page 0-8.
2. Install the parking brake indicatorswitch
bolt (1) and tighten to 2 N'm (18 lb in).
3. Connect the electrical connector to the park brake
warning lamp switch.
4. Install the front floor console. Refer to Front Floor
Console Replacement on page 2-61.

2512999
5. Remove the parking brake indicator switch (1).

(US/Canada)
-Sonic
2013 {5377994)
Manual
Service
 Park Brake 5-189

Parking Brake Cable Replacement Release the parking brake cable routing clips (2).
(Drum Brake) . Release the parking brake cabie collars (3)from
the floor tunnel bracket.
Removal Procedure . Disconnect the park brake lever cable from the
1. Remove the front floor console. Refer to Front equalizer (4).
Floor Console Replacement on page 2-61. . Raise and support the vehicle. Refer to Lifting and
2. Ensure that the parking brake lever is in the fully Jacking the Vehicle on page 1-31.
released position.

2513004
2513001 11. Remove the left parking brake cable bracket
3. Using ONLY HAND TOOLS, remove the adjusting bolt (1).
nut (1)from the end of the front park brake cable
threaded rod.
4. Remove the rear seat cushion. Refer to Rear Seat
Cushion Removal and Installation on page 14-24.
5. Position the rearfloor carpet fowvardto access the
parking brake cable pass through grommets.

2513005
12. Disconnect the left parking brake cable
connector (1)from the left parking brake
cable end (2)
13. Release the left parking brake cable
retainer (3)from the rear axle bracket.
2513008
6. Release the parking brake cable pass through
grommets (1).

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
5490 Park Brake
Installation Procedure

’i ilTwr’w: '7‘1M § “ii”:k_/"' ° “

{£7 "

2513006
14. Remove the right parking brake cable bracket
bolt (1). 2513008
1. Installthe parking brake cable pass through
grommets (1). -
2. Installthe parking brake cable routing clips (2).
3. Install the parking brake cable collars (3)to the
fioortunnel bracket.
4. Connect the park brake lever cable to the park
brake cable equalizer (4).
5. Reposition the rear floor carpet.
6. Install the rear seat cushion. Refer to Rear Seat
Cushion Removal and Installation on page 14-24.
7. Raise and support the vehicle. Refer to Lifting and
Jacking the Vehicle on page 1—31.

2513007
15. Disconnect the right parking brake cable
connector (1)from the right parking brake
cable end (2)
16. Release the Ieftparking brake cabie
retainer (3)from the rear axle bracket.
17. Feed the parking brake cabie through the
vehicle body.
18. Lower the vehicle and remove the parking brake '7'
1.6
cable and equalizer assembly from inside the M553}
vehicle.

2513007
8. Connect the right parking brake cable
connect0r(1) to the right parking brake
cable end (2)

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
 Park Brake 5-191

9. Install the right parking brake cabie retainer (3)to

the rear axle bracket.

2513004
13. Install the left parking brake cable bracket
bolt (1) and tighten to 22 N'm (16 lb ft).
2513006
14. Lower the vehicle.
Caution: Refer to Fastener Caution on page 0-8.
10. Install the right parking brake cable bracket
bolt (1) and tighten to 22 N-m(16 lb ft).

2513005
11. Connect the left parking brake cable
connector (1) to the left parking brake cable end (2)
12. Install the left parking brake cable retainer(3)to the
rear axle bracket.
2513001
15. Using ONLY HAND TOOLS, loosely install the
adjusting nut (1)to the front park brake cable
threaded rod.
16. Adjust the parking brake. Refer to Parking Brake
Adjustment (Drum Brake) on page 5197 or
Parking Brake Adjustment (Disc Brake) on
page 5-198.
17. Install the front floor console. Refer to Front Floor
Console Replacement on page 2-61.

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
5-192 Park Brake

Parking Brake Cable Replacement Release the parking brake cable routing Clips (2).
(Disc Brake) Release the parking brake cabie collars (3)from
the floor tunnel bracket.
Removal Procedure Disconnect the park brake lever cable from the
1. Remove the frontfioor console. Refer to Front equalizer (4).
Floor Console Replacement on page 2-61. 10. Raise and support the vehicle. Refer to Lifting and
2. Ensure that the parking brake lever is in the fully Jacking the Vehicle on page 1-31.
released position.

2844776
2513001 11. Remove the left front parking brake cable bracket
3. Using ONLY HAND TOOLS, remove the adjusting bolt (1).
nut (1)from the end of the front park brake cable
threaded rod.
4. Remove the rear seat cushion. Referto Rear Seat
Cushion Removal and Installation on page 14-24.
5. Position the rear floor carpet fowvardto access the
parking brake cable pass through grommets.

2844779
12. Remove the left rear parking brake cable bracket
bolt (1).

2513008
6. Release the parking brake cable pass through
grommets (1).

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Park Brake 5-193

\\ ' R
a ‘1"
E.»

2843784 2846911
13. Remove the left parking brake cable retaining 15. Remove the fuel tank aero shield nuts (1) and the
ciip (1)from the parking brake cabie bracket. shield.

2843786 2846888
14. Disconnect the left parking brake cabie (1)from the 16. Remove the right front parking brake cable bracket
actuator lever and remove the left parking brake bolt (1).
cable from the cable bracket.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
5194 Park Brake

§.\' {J 1
[.1.
i"
I: .°

I ®_ ..
‘3‘ W511,

2846891 2846895
17. Remove the right rear parking brake cable bracket 19. Disconnect the right parking brake cabie (1)from
bolt (1). the actuator lever and remove the right parking
brake cable from the cable bracket.
20. Feed the parking brake cabie through the
vehicle body.
21. Lower the vehicle and remove the parking brake
cable and equalizer assembly from inside the
vehicle.
Installation Procedure

2846894
18. Remove the right parking brake cable retaining
clip (1)from the parking brake cable bracket.

2513008
. Installthe parking brake cable pass through
grommets (1).
. Install the parking brake cable routing clips (2).
. Install the parking brake cable collars (3)to the
floor tunnel bracket.
Connect the park brake lever cable to the park I‘
brake cable equalizer (4).
Reposition the rear floor carpet.

2013
.Sonic
(US/Canada)
Service
Manual
(5377994)
 Park Brake 5=i 95

6. Install the rear seat cushion. Refer to Rear Seat

Cushion Removal and Installation on page 14—24.
7. Raise and support the vehicle. Refer to Lifting and
Jacking the Vehicle on page 1-31.

111% r9, -
. El ,
ii ., o
it . L,” 2 2, 2 -
\ db = ’
=' _ ’w'.
l‘ ’ ~7:; ’4‘,

2846891
Caution: Refer to Fastener Caution on page 0—8.
10. install the right rear parking brake cabie bracket
bolt (1) and tighten to 22 N~m(16 lb ft).

2846895
L/ / . ... ‘
8. install the right parking brake cable to the cable
bracket and connect the right parking brake / ..a‘wv
l/I'Qgfiggbéj'l
cable (1)to the actuator lever. ,/ ‘Céli . i.¥#\ 3 //— LI
tl/én
fif</ “" Il

0
‘11—"
I..3-

2512-"
$1

2846886
11. Install the right front parking brake cable bracket
bolt (1) and tighten to 22 N-m(16 lb ft).

2846894
9. install the right parking brake cable retaining
clip (1)to the parking brake cable bracket.

(US/Canada)
«Sonic
2013 (5377994)
Manual
Service
5-196 Park Brake

: " 7n: .
-=;;~2,.”-94.
—§[E v‘,- ‘_ ..w x-, ‘_

3‘14““ ../ .—___,‘ gr’\

\/// I; \_\_ :“\— ‘
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V‘ ‘ . / ‘ . 4..-"5!.“ ‘2,'5'-
’._Ih\“\\“'
L a

2846911 2843784
12. Install the fuel tank aero shield and the nuts (1). 14. Install the left parking brake cable retaining
clip (1)to the parking brake cable bracket.

2843786
13. Install the left parking brake cable to the cabie
bracket and connect the left parking brake
cabie (1)to the actuator iever.
2844779
15. Install the left rear parking brake cable bracket
bolt (1) and tighten to 22 N-m(16 lb ft).

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Park Brake 5st 97

Parking Brake Adjustment (Drum

Brake)
Note: The park brake cable adjusting nut is a nylon
lock type. Use ONLY HAND TOOLS whenever
tightening or loosening the adjusting nut.
. Apply and fully release the park brake several
times. Verify that the park brake lever releases
completely.
Turn ON the ignition. Verify the red BRAKE
warning lamp is not illuminated.
Ifthe 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.
Ifthe red BRAKE warning lamp remained
illuminated and there were no other visible causes,
refer to Symptoms - Hydraulic Brakes on
2844776 page 5111.
16. install the left front parking brake cable bracket .01Turn OFF the ignition.
bolt (1) and tighten to 22 N-m(16 lb ft). 6. Remove the front floor console. Refer to Front
17. Lower the vehicle. Floor Console Replacement on page 2-61.

2513001 2513001

18. Using ONLY HAND TOOLS, loosely install the
adjusting nut (1)to the front park brake cable
threaded rod.
19. Adjust the parking brake. Refer to Parking Brake
Adjustment (Drum Brake) on page 5-197 or
Parking Brake Adjustment (Disc Brake) on
page 5-198.
20. Install the frontfioor consoie. Refer to Front Floor
Console Replacement on page 2-61.
10. Adjust the rear drum brakes. Refer to Drum Brake
With the park brake lever in the released position,
loosen the adjusting nut (1) enough to completely
relieve tension on the front cable.
Raise and support the vehicle. Raise the vehicle
just enough to allow rear tire and wheel assembly
removal and rear drum adjustment. Refer to Lifting
and Jacking the Vehicle on page 1—31.
. Remove the rear tire and wheel assemblies. Refer
to Tire and Wheel Removal and Installation on
page 16-60.
Adjustment on page 5-105.

2013
—
Sonic
(US/Canada)
Service
Manual
(5377994)
5-196 Park Brake
11. Ensure there is no brake shoe drag after . Ifthe red BRAKE warning lamp remained
adjustment by rotating the brake drums. Ifdrag illuminated and there were no other visible causes, 1
exists, re-center the brake shoes and perform the refer to Symptoms - Hydraulic Brakes on 1
brake shoe adjustment again. page 5-111. .
12. install 2 wheel nuts to the wheel studs and firmly . Turn OFFthe ignition.
hand tighten in order to retain the brake drums. . Remove the front floor console. Refer to Front
13. Fully release the park brake lever. Floor Console Replacement on page 2-61.
14. Tighten the park brake cable adjusting nut (1) until
the threaded portion of the front park brake cable
extends beyond the adjusting nut
approximately 27 mm (1.06 in).
15. Apply the park brake lever.
16. Attempt to rotate the rear brake drums. There
should be no rotation forward or rearward.
17. Fully release the park brake lever.
18. Verify the park brake is released by rotating the
rear brake drums. The drums should rotate freely
and exhibit no brake shoe drag.
19. Ifthe drums do not rotate freely, repeat the park
brake cable adjustment procedure.
20. Raise the park brake lever 3 detent positions and
attempt to rotate the rear brake drums:
. One of the brake drums should not rotate
forward or rearward.
. The other brake drum should not rotate forward
or rearward, or should require substantial effort
to rotate.
2513001
21. Raise the park brake lever one additional detent
position and attempt to rotate the rear brake With the park brake lever in the released position,
drums. loosen the adjusting nut(1) enough to completely
22. Verify that the left and right brake drums cannot be relieve tension on the front cable.
rotated. . Raise and support the vehicie. Raise the vehicle
23. Remove the wheel nuts retaining the brake drums. just enough to allow the rear tire and wheel
24. Install the rear tire and wheel assemblies. Refer to assemblies to be rotated. Refer to Lifting and
Tire and Wheel Removal and Installation on Jacking the Vehicle on page 1—31.
page 16—60. . Ensure there is no brake drag by rotatingthe tire
25. Lower the vehicle. and wheei assemblies. Ifdrag exists, verify the
park brake apply levers are fully against the stops
26. Install the front floor console. Refer to Front Floor on the rear brake calipers.
Console Replacement on page 2-61.
10. Tighten the park brake cable adjusting nut (1)until
27. Release the park brake lever. the threaded portion of the front park brake cabie
extends beyond the adjusting nut
Parking Brake Adjustment (Disc approximately 27 mm (1.06 in).
Brake) 11. Apply the park brake lever.
Note: The park brake cabie adjusting nut is a nylon 12. Attempt to rotate the rear tire and wheel
lock type. Use ONLY HAND TOOLS whenever assemblies. There should be no rotationforward or
tightening or loosening the adjusting nut. rean/vard.
1. Apply and fully release the park brake several 13. Fully release the park brake lever.
times. Verify that the park brake lever releases 14. Verify the park brake is released by rotatingthe
completely. rear tire and wheel assemblies. The tire and wheel
2. Turn ON the ignition. Verify the red BRAKE assemblies should rotate freely and exhibit
warning lamp is not illuminated. no drag.
3. Ifthe red BRAKE warning lamp is illuminated, 15. Ifthe tire and wheel assemblies do not rotate
verify the following: freely, repeat the park brake cable adjustment
procedure.
' The park brake lever is in the fully released
position and against the stop.
0 There is no slack in the park brake cables.

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
 Park Brake 52-199

16. Raise the park brake lever 3 detent positions and
attemptto rotate the rear tire and wheel
assemblies:
o One of the tire and wheel assemblies should
not rotate forward or rearward.
- The other tire and wheel assembly should not
rotatetoward or rearward, or should require
substantial effortto rotate.
17. Raise the park brake lever one additional detent
position and attempt to rotate the rear tire and
wheei assemblies.
18. Verify that the left and right tire and wheel
assemblies cannot be rotated.
19. Lower the vehicle.
20. install the front floor console. Refer to Front Floor
Console Replacement on page 2-61.
21. Release the park brake lever.
Description and Operation
Park Brake System Description and
Operation
System Component Description
The park brake system consists of the following:
Park Brake Lever Assembly: Receives, multiplies,
and transfers park brake system apply input force from
driver to park brake cable system.
Releases applied park brake system when lever
release buttonis depressed and lever is returned to the
at rest position.
Park Brake Cables: Transfers input force received
from park brake iever, through park brake cabie
equalizer, to park brake apply lever.
Park Brake Cable Equalizer: Evenly distributes input
force to both the left and right park brake units.
Threaded front park brake cabie adjuster is also used
to remove slack in park brake cables.
Park Brake Apply Lever: Multiplies and transfers
input force to park brake actuatorladjuster.
Park Brake ActuatorlAdjuster: Uses multiplied input
force from apply lever to expand drum brake shoes
toward the friction surface of the brake drum.
Threaded park brake actuators/adjusters are also used
to control clearance between the drum brake shoes and
the friction surface of the brake drum.
System Operation
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 cabie equalizer, to the left and right park brake
apply levers. The park brake apply levers multiply and
transfer the apply input force to the park 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 wheei
assemblies. The park brake lever assembly releases
an applied park brake system when it is released and
returned to the at rest position.

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
5-200 Park Brake

BLANK

2013
—Sonic
(US/Canada)
Service
Manual
(5377994)
 Table of Contents 6:1

Section 6

Diagnostic Overview

Programming and Setup ...................... 6—3 Vehicle Diagnostic Information ............. 6-15
Diagnostic Information and Procedures . . .. . . . .6-3 Specifications ................................... 6-15
Control Module References ...................... 6—3 Body Control Module Scan Tool Information .... 6—1 5
Repair Instructions ............................... 6—4 Communication Interface Module Scan Tool
Body Control Module Programming and information .................................... 6-27
Setup ........................................... 6-4 Driver Seat and Passenger Seat Heater Control
Communication interface Module Programming Module Scan Tool Information ................. 6—28
and Setup ....................................... 6—6 Electronic Brake Control Module Scan Tool
Control Solenoid Valve and Transmission Control Information(Without FX3) ..................... 629
Module Assembly Programming and Setup Electronic Brake Control Module Scan Tool
(6T30/6T40/6T45/6T50) ........................ 6—6 Information(With FX3) ........................ 6—30
Electronic Brake Control Module Programming Engine Control Moduie Scan Tool
and Setup ....................................... 6—7 information .................................... 633
Engine Control Module Programming and Fuel Pump Flow Control Module Scan Tool
Setup ........................................... 6-7 Information .................................... 6-40
Fuel Pump Control Module Programming and Heating, Ventilation and Air Conditioning Control
Setup ........................................... 6-9 Module Scan Tool Information ................. 6-42
Heated Seat Control Module Programming and Inflatable Restraint Passenger Presence
Setup ........................................... 6-9 System Scan Tool Information ................. 6-43
HVAC System Control Module Programming Inflatable Restraint Sensing and Diagnostic
and Setup ..................................... 6—10 Module Scan Tool Information ................. 6-44
Inflatable Restraint Sensing and Diagnostic InstrumentCluster Scan Tool information . .647
Module Programming and Setup .............. 6—10 Power Steering Control Module Scan Tool
InstrumentCluster Programming and Setup .... 6-11 Information .................................... 6—48
Multi-Axis Acceleration Sensor Module Radio Scan Tool information .................... 6-48
Programming and Setup ....................... 6-11 Transmission Control Module Scan Tool
Passenger Presence System Programming and Information(6T30/6T40/6T45/6T50) .......... 6—49
Setup .......................................... 6-12 Diagnostic Information and Procedures . . .. . . .6—58
Power Steering Control Module Programming Strategy Based Diagnosis ...................... 6-58
and Setup ..................................... 6-12 Diagnostic Procedure Instructions .............. 6-59
Radio Programming and Setup ................. 6-12 Diagnostic System Check Instructions .......... 6-62
Remote Control Door Lock Receiver Diagnostic Starting Point —Vehicle .............. 6—66
Programming and Setup ...................... 6-13 Diagnostic System Check - Vehicle ............. 6-66
Service Programming System (SP8) ........... 6—13 Powertrain Diagnostic Trouble Code (DTC) Type
Sunroof Control Module Programming and Definitions ..................................... 6—68
Setup .......................................... 6—14 Diagnostic Trouble Code (DTC) List -
Theft Deterrent Moduie Programming and Vehicle ........................................ 669
Setup .......................................... 6-14 Symptom Byte List .............................. 6-85
Special Tools and Equipment ................... 6-14 Symptoms —Vehicle ............................. 6-90
Engine Does Not Crank ......................... 6-91
Engine Cranks But Does Not Run .............. 6—91
Inspection/Maintenance System Check .... . . . . 6-91
Diagnostic Repair Verification .................. 6—92

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
6=2 Table of Contents

BLANK

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Programming and Setup 623

Programming and Setup

Diagnostic Information and Procedures

Control Module References

Code Control Module/Scan Schematic Repair Instruction Programming and
Tool Information Setup
. DataLink Referencesonpage 11-66
' DiagnosticSystemCheck- Vehicleonpage 6-66
- DiagnosticTroubleCode (DTC)List —Vehicleonpage 6-69
- Symptoms- Vehicleonpage 6—90
RadioReplacement
RadioScan (WithoutU88)on
A11 . oTool
Informatlon
Radio/Navigation
. System page
npage 6-48 Schematicsonpage84 8-59or Radio
R6placement (WithU88)
RadioProgrammingand
Setuponpage 6-12
onpage 8-58
BodyControlModule Body ControlModule Body ControlModule
K9 Scan ToolInformationon 33%n?ggégoégy 393113 Replacementon ProgrammingandSetup
page6-15 p 9 page 11-67 onpage6-4
ElectronicBrakeControl
ModuleScan Tool
Information(Without . .
FX3)on ..
ElectronicBrakeControl Schematicsonpage5-6 M 5 3 p M dS g 697
ModuleScan Tool page ' 9 an etuponpage '
Information(WithFX3)
onpage 6-30
- EngineControls . EngineControl
Schematicson ModuleReplacement
page 9-314forthe onpage 9-531forthe
1.6L(LDE LED 1.6L(LDE LED
LFJ LGE LLU LXV) or LFJ LGE LLU LXV)or
EngineControlModule 1.8L(ZHO‘LFHLUW 1.8L(2HO'LFHLUW EngineControlModule
K20 Scan ToolInformation
on LWE)engIne LWE)engine ProgrammingandSetup
P8996'33 - EngineControls - EngineControl 0" page6'7
Schematicson ModuleReplacement
page9-28forthe 1.2L onpage 9-242forthe
(L2QLDC LWD)or 1.2L(LZQLDC LWD)
1.4L(L21L2N LDD or 1.4L (L2lL2N LDD
LUH LUJ LUV)engine LUH LUJ LUV)engine
_ . - Fuel TankFuel Pump
EngineControls ModuleReplacement
Schematicson (SteelTank)on
page 9-314forthe age 9_559forthe
1.6L(LDE LED 86L (LDE LED
LFJ LGE LLU LXV) or Li=JLGE LLU LXV)or
FueIPumpFlow Control 1.8L(ZHO'LFHLUW 1 8L (2H0LFH LUW Fue/PumpControl
K27 ModuleScan Tool LWE)engine LWE)engine ModuleProgramming
Information
onpage 6-40 . EngineControls . F l T k F [P and Setuponpage 6-9
Schematicson ue an ue ump
ModuleReplacement
page 9-28forthe1.2L on a 9 9-261forthe
(L20 LDC LWD)or p 9
1.2L(L2QLDC LWD)
1.4L(L2lL2N
LUH LDD
LUJ LUV)engine or 1.4L (L2lL2N LDD
LUH LUJ LUV)engine
DriverSeat and
PassengerSeatHeater Heated/Coo/edSeat Egfltrjfiggjzter HeatedSeat Control
K29 ControlModuleScan Schematicson Re /aoementon ModuleProgramming
ToolInformation on page 14-35 p 14-46
page and Setuponpage 6-9
page6—28 '
Heating,Ventilationand HeaterandAir
K33 Air ConditioningControl HVAC Schematicson ConditioningControl flfifiesgfiéeggzg/ZOI
ModuleScan Tool page 10-64 Replacementon andSetu 0% a 6 65110
Information onpage 6-42 page 10-79 p p g

2013
—
Sonic
(US/Canada)
Service
Manual
(5377994)
6344 Programming and Setup

Control Module References (cont'd)

Code Control Module/Scan Schematic Repair Instruction Programmingand
Tool information Setup
InflatableRestraint AirbagSensingand InflatableRestraint
SensingandDiagnostic SIR Schematicson DiagnosticModule SensingandDiagnostic
K36 ModuleScan Tool page 13-69 Replacementon ModuleProgramming
Information onpage 6—44 page 13-117 andSetuponpage 6-10
PowerSteeringControl . SteeringColumn PowerSteeringControl
K43 ModuleScan Tool [8323:2322er a e 15_4 Replacementon ModuleProgramming
Information onpage 6-48 p 9 page 15-33 and Setuponpage 6-12
. SunroofActuatorMotor SunroofControlModule
K61 SunroofControlModule jgggogichemat/cs 0" Replacementon Programmingand Setup
page 12-12 onpage 6-14
ControlSolenoidValve ,
andTransmissionControl ControlSolenoidValve Control30’9”?” Valve
MOdUIB Assembly AutomaticTransmission and TransmissionControl and TransmISSIon
ModuleAssembly Control
K71 TransmissionControl ControlsSchematicson ModuleAssembly .
RePIacementon Programming and Setup
M0dU9/ 3, Ga" T00/ page 17—30 (6T30/6T40/6T45/6T50)
Informatlon (6T30/6T40/ page 17-209 0,,page6_6
6T45/6T50)onpage 6-49
CommunicationInterface . CommunicationInterface Communication Interface
K73 ModuleScan Tool OnstarSchematicson ModuleReplacement on ModuleProgramming
page8-6 page 8-54 and Setuponpage 6—6
Information onpage 6-27
. RemoteControlDoor RemoteControlDoor
K77 RemoteControlDoor Eggggggggzon Lock Receiver Lock Receiver
LockReceiver a e 13_34 Replacementon Programmingand Setup
p 9 page 13-43 onpage 6-13
InflatableRestraint AirbagFrontPassenger
PassengerPresence SIR Schematicson PresenceSensor PassengerPresenoe
SystemProgramming
K85 ?ystemfcan Tool 6 43 page 13-69 Replaggrgigzton and Setuponpage 6-12
n ormaIononpage - page -
.. Control .
. . Schematics TheftDeterrentModule TheftDeterrent
Programming Module
and Setup
K89 immobIlIzer lmmobl/Izer Replacementon
Moduie onpage 13'4 page 13—28 onpage 6-14
InstrumentClusterScan
. on t (:70tsClu
Ig(39/721: InstrumentCluster
t r 8-78 Replacement on .Cluster
Instrument
Programmmg and Setup
P16 ToolInformation o"Sp:ge
page6-47 page 8—104 onpage 6—11

Stable battery voltage is critical during

Repair Instructions
Body Control Module Programming
and Setup
Special Tools
- EL—49642SPS Programming Support Tool
° EL-46079 Tire Pressure Monitor Diagnostic Tool
For equivalent regional tools, refer to Special Tools on
page 6-14.
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. Ifthere is an interruption
during programming, programming failure or
control module damage may occur.
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; interiorlights,
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 (l/M) system status indicators to NO.
Module
Replace and Program Control
To program a replacement Body Control Module
(BCM), perform the following procedure:
1. install EL—49642SPS programming support tool.

(US/Canada)
—Sonic
2013 (5377994)
Manual
Service

Note: Make sure the vehicle ignition switch state is in
appropriate position for the following step.
- For Key lgnition 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 (SP8)
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:
0 Key IgnitionSystem: 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—12min. and progress will appear to have
stopped during this process. This is a normal security
timer response and a restart should not be performed.
Ifthe DTC 3389A 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 0r Remote Key and
follow the on—screeninstructions. 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 monitordiagnostic tool must be used to
activate each tire pressure sensor for vehicles
with UJM.
' For Key IgnitionSystem, begin with the ignition
in the RUN position.
- 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
on—screeninstructions.
2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
Programming and Setup 6=5
8. Check the driver information center display for
additional messages regarding further calibration
instructions. Ifthere 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. IfABS, Traction Control andlor Stabilitrak
indicators are ON and DTC C0161 is set in the
electronic brake control module after performing
BCM programming and setup, do the following:
10.1. Disconnect the scan tool from the data link
connector.
10.2. IgnitionOFF, all access doors closed, all
vehicle systems OFF, and all keys at least
3 meters away from the vehicle. Itmay take
up to 2 minutes to power down.
10.3. IgnitionON, verify DTC C0161 is in history.
If not, repeat the above step to make sure the
vehicle is in sleep mode.
10.4. Use the scan tool to clear the DTCs.
Reprogram Control Module
To program an existing BCM, perform the following
procedure:
1. Install EL-49642 SP8 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 ON power mode.
2. Access the Service Programming System (SP8)
and follow the on-screen instructions.
3. On the SPS Supported Controllers screen, select
BCM Body Control Module - Programming and
follow the on—screeninstructions.
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
on-screen instructions.
5. Check the driver information center display for
additional messages regarding further calibration
instructions. Ifthere 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.
6-6 Programmiflg and Setup
7. IfABS, Traction Control andlor Stabilitrak
indicators are ON and DTC C0161 is set in the
electronic brake control module after performing
BCM programming and setup, do the following:
7.1. Disconnect the scan tool from the data link
connector.
7.2. IgnitionOFF, 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.
7.3. lgnition ON, verify DTC C0161 is in history.
If not, repeat the above step to make sure the
vehicle is in sleep mode.
7.4. 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. lgnition ON. Ensure the control module, DLC and
programming tool connections are secure and the
SP8 software is up to date.
2. Verify the control module can be reprogrammed.
=>If the control module cannot be reprogrammed
2.1. IgnitionOFF for one minute, ignition ON.
2.2. Verify the control module can be
reprogrammed.
2;»Ifthe control module cannot be reprogrammed,
replace the control module.
ii Ifthe control module can be reprogrammed.
2.3. All OK.
it If the control module can be reprogrammed
3. All OK.
Repair Instructions
Perform the Diagnostic Repair Verification on
page 6—92after completing the repair.
Control Module References on page 6-3 for Control
Module replacement, programming and setup
Communication Interface Module
Programming and Setup
Special Tools
EL—49642SPS Programming Support Tool
For equivalent regional tools, refer to Special Tools on
page 6-14.
Each ofthe following service procedures require
programming or setup procedures to be performed on
the communication interface module.
Communication Interface Module
Replacement
Note:
- Itis 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®allvehicles with and without an
active OnStar®subscription to insure the unit has
been setup properly for the vehicle it has be®en
installed into and also to update the OnStar®with '
the correct unit information
. To initialize the Turn-by—Turnfeature, 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 (OTlM), and toggle the
TTY mode after completing the Communication
Interface Module installation and setup
procedures.
Install EL-49642 SP8 programming support tool.
NA. Access the Service Programming System (SP8)
and follow the on— screen instructions.
3. On the SPS Supported Controllers screen, select
ONSU Onstar®Module Setup and Service,
Activation and follow the on— screen instructions.
4. At the end of programming, choose the "Clear All
DTCs” function on the SPS screen.
5. The default language for the new Communication
Interface Module is English. To change to an
alternate language, access the scan tool.
6. Informthe 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
(6T30l6T40/6T45I6T50)
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 sewiced separately.
Transmission Control Module (TCM)
Replacement
Ifthe TCM is replaced, the following procedures must
be performed:
1. TCM Reprogramming
2. The Transmission Adaptive Values Learn. Refer to
Transmission Adaptive Values Learn on
page 17—163.
(US/Canada)
-Sonic
2013 (5377994)
Manual
Service

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.
- Insome 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. Ifthe TCM needs to be reprogrammed. Refer to
Service Programming System (SP8) on page 6-13.
2. Perform the Transmission Adaptive Values Learn.
Refer to Transmission Adaptive Values Learn on
page 17-163. _ the on-soreen instructions.
Note: After programming, perform the following to
avoid future misdiagnosis:
1. Turn the ignition OFF for 30 seconds.
2. Turn the ignition ON with the engine OFF.
3. Use the scan tool in order to retrieve history DTCs
from all modules.
4. Clear all history DTCs.
Setup for Component Replacement
The replacement of some components will require a
setup procedure for complete repair.
Ifany of the following components are replaced, the
Transmission Adaptive Values Learn on page 17-163
procedure must be performed:
- Transmission replacement
. Any internal transmission repair
- Any speed sensor
Refer to Transmission Adaptive Values Learn on
page 17—163.
Electronic Brake Control Module
Programming and Setup
Note:
- DO NOT program a control module unless
directed to by a service procedure or a service
bulletin. Ifthe ECU is not properly configured with
the correct calibration software, the ECU 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. Ifthere is an interruption
during programming, programming failure or ECU
damage may occur.
- 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.
2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
Progflmming and Setup 6-7
. Clear DTCs after programming is complete.
Clearing powertrain DTCs will set the Inspection/
Maintenance (I/iVl)system status indicators to NO.
Replace and Program Electronic Brake
Control Module or Reprogram
Electronic Brake Control Module
To program a replacement or an existing Electronic
Brake Control Module, perform the following procedure:
1. Access the Service Programming System (SP8)
and follow the on-screen instructions.
2. On the SPS Supported Controllers screen, select
Electronic Brake Control ModuIe-Programming
and follow the on-screen instructions.
3. On the SPS Supported Controllers screen, select
Electronic Brake Control ModuIe—Setupand follow
4. On the SPS Supported Controllers screen, select
Electronic Brake Control ModuIe—Configurationand
follow the on—screeninstructions.
5. At the end of programming, choose the “Clear All
DTCs" function on the SPS screen.
6. With a scan tool, access the Electronic Brake
Control Module, Configuration/Reset Functions,
Steering Wheel Angle Sensor Learn. Refer to
Steering Angle Sensor Centering on page 5-39.
7. With a scan tool, access the Electronic Brake
Control Module, Configuration/Reset Functions,
Yaw Rate Sensor Learn. Refer to Vehicle Yaw
Sensor Learn on page 5-49.
Unsuccessful Programming Recovery
Inthe event of an interrupted or unsuccessful
programming event, perform the following steps:
1. DO NOT turn the lgnition 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. Ifthe ECU can still not be programmed, turn the
IgnitionOFF for at least one minute.
4. Turn the IgnitionON, and attempt to reprogram the
ECU. The ECU should program.
=>lfthe ECU still cannot be programmed, replace
the ECU.
Engine Control Module Programming
and Setup
Note:
- DO NOT program a control module unless
directed to by a service procedure or a service
bulletin. Ifthe control'module is not properly
configured with the correct calibration software,
the control module will not control all of the vehicle
features properly. ‘
68 Programming and Setup
- Ensure the programming tool is equipped with the
latest software and is securely connected to the
data link connector. Ifthere 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.
- Tum 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 (IIM)system status indicators to NO.
- Prior to programming, record the engine oil life
percentage remaining.
Reference Information
Special Tools
EL-49642 SPS Programming Support Tool
For equivalent regional tools, refer to Special Tools on
page 6-14.
Replace and Program Control Module
To program a replacement engine control
module (ECM), perform the following procedure:
1. Install EL—49642SPS Programming Support Tool.
2. Access the Service Programming System (SP8)
and follow the on—screeninstructions.
3. On the SPS Supported Controllers screen, select
Engine Control Module - Programming and follow
the on-screen instructions.
4. On the SPS Supported Controllers screen, select
Engine Control Module —Setup and follow the
on-screen instructions.
5. On the SPS Supported Controllers screen, select
Engine Control Module - Configuration and follow
the on-screen instructions.
6. On the SPS Supported ControIlers screen, select
Engine Function —Learn/Setup and follow the
on—screeninstructions.
7. At the end of programming, choose the “ClearAlI
DTCs” function on the SPS screen.
8. With a scan tool, perform the Theft Deterrent
Programming. Refer to Immobilizer System
Component Programming on page 13-29.
Warning: Replacement or reprogramming of the
ECM, or replacement of the clutch pedal position
sensor (CPPS) or clutch pedal requires that a CPPS
learn procedure be performed. Failure to perform
the CPPS learn procedure may result in personal
injury or damage to the vehicle or its components if
the vehicle is in gear and the starter motor is
accidentally engaged.
9. With a scan tool, perform the Clutch Pedal Position
Sensor Learn, if applicable. Refer to Clutch Pedal
Position Sensor Learn on page 17-562.
10. With a scan tool, perform the CKP System
Variation Learn. Refer to the following:
0 Crankshaft Position System Variation Learn on
page 9-243 for the 1.4L engine
- Crankshaft Position System Variation Learn on
page 9—532for the 1.6L or 1.8L engine
11. With a scan tool, perform the ThrottIe/IdleLearn
procedure. Refer to the following:
' Thrott/e/ldleLearn on page 9-278 for the 1.4L
engine
~ Throttle/IdleLearn on page 9-533 for the 1.6L
or 1.8L engine
12. With a scan tool, reset the Engine Oil Life
Remaining back to the original percentage
recorded before the control module was replaced,
if available.
Reprogram Control Module
To reprogram an existing ECM, perform the following
procedure:
1. Access the Service Programming System (SP8),
and follow the on-screen instructions.
2. On the SPS Supported Controllers screen, select
Engine Control Module - Programming and follow
the on-screen instructions.
3. On the SPS Supported Controllers screen, select
Engine Control Module - Setup and follow the
on—screeninstructions.
4. On the SPS Supported Controllers screen, select
Engine Control Module - Configuration and follow
the on-screen instructions.
5. On the SPS Supported Controllers screen, select
Engine Function - Learn/Setup and follow the
on—screeninstructions. ‘
6; At the end of programming, choose the "Clear All
DTCs” function on the SPS screen.
7. With a scan tool, reset the Engine Oil Life
Remaining back to the original percentage
recorded before the control module was replaced,
if available.
Unsuccessful Programming Recovery
Inthe 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 software is up to date.
2013
-Sonic
(US/Canada)
Service
Manual
(5377994)

2. Verify the control module can be reprogrammed.
=>If the control module cannot be reprogrammed
2.1. IgnitionOFF for one minute, ignition ON.
2.2. Verify the control module can be
reprogrammed.
: lfthe control module cannot be reprogrammed,
replace the control module.
ii Ifthe control module can be reprogrammed.
2.3. All OK.
U If the control module can be reprogrammed
3. All OK.
Repair Instructions
Perform the Diagnostic Repair Verification on
page 6—92after completing the repair.
Refer to Control Module References on page 6-3 for
control module 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. The battery is fully charged.
2. The MDI data link connectors are secure.
3. The scan tool is loaded with the most current ~
software version.
4. All disconnected modules and devices are
reconnected securely.
5. 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 (SP8)
and follow the on—screeninstructions.
2. On the SPS Supported Controllers screen, select
FPCM Fuel Pump Flow Control Module —~
Programming and follow the on—screen
instructions.
lfthe fuel pump control module fails to accept the
program, verify all scan tool and fuel pump control
module connections are secure.
2013
-Sonlc
(US/Canada)
Service
Manual
(5377994)
Programming and Setup 6=9
Note: After programming is completed, perform the
following to avoid future misdiagnosis:
1. Turn the Vehicle OFF for 10 seconds.
Open and close the door.
Connect the scan tool to the data link connector.
Vehicle in Service Mode, engine OFF.
SHPWN
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. The battery is fully charged.
2. The MDI data link connectors are secure.
3. The scan tool is loaded with the most current
software version.
4. All disconnected modules and devices are
reconnected securely.
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 (SP8) on page 6-13.
2. On the SPS Supported Controllers screen, select
HVSMF Front Seat Heating Control Module -
Programming and follow the on-screen
instructions.
lfthe 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. Turn the ignition OFF for 10 seconds.
Open and close the door.
Connect the scan tool to the data link connector.
IgnitionON, engine OFF.
.0125?!“
Clear all DTCs from all modules.
6-‘l0 Programming and Setup
HVAC System Control Module
Programming and Setup
Note:
- DO NOT program a control module unless
directed to by a service procedure or a service
bulletin. Ifthe ECU is not properly configured with
the correct calibration software, the ECU 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. Ifthere is an interruption
during programming, programming failure or ECU
damage may occur.
- 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 (IIM)system status indicators to NO.
Diagnostic Aids
During HVAC programming you may be required to
select multiple calibrations dependant upon vehicie
equipment. Have the vehicle build/RPO information
available during the following procedure to ensure the
correct calibrations are selected.
Replace and Program ECU or
Reprogram ECU
To program a replacement or an existing ECU, perform
the following procedure:
1. Access the Service Programming System (SPS)
and follow the on-screen instructions.
2. On the SPS Supported Controllers screen, select
Remote Heater and Air Conditioning -
Programming and follow the on-screen
instructions.
3. At the end of programming, choose the “Clear All
DTCs" function on the SPS screen.
Unsuccessful Programming Recovery
Inthe event of an interrupted or unsuccessful
programming event, perform the following steps:
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. Ifthe ECU can still not be programmed, turn the
ignition OFF for at least one minute.
4. Turn the ignition ON and attemptto reprogram the
ECU. The ECU should program.
=>Ifthe ECU still cannot be programmed, replace
the ECU.
Inflatable Restraint Sensing and
Diagnostic Module Programming and
Setup
Special Tools
EL—49642 SPS Programming Support Tool
For equivalent regional tools, refer to Special Tools on
page 6-14.
Note:
- DO NOT program a control module unless
directed to by a service procedure or a service
bulletin. Ifthe ECU is not properly configured with
the correct calibration software, the ECU 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. Ifthere is an interruption
during programming, programming failure or ECU
damage may occur.
0 Stable battery voltage is critical during
programming. Any fluctuation, 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.
- 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 power mode.
- Clear DTCs after programming is complete.
Clearing powertrain DTCs will set the Inspection/
Maintenance (IIM)system status indicators to NO.
Diagnostic Aids
The air bag indicator light may remain ON afterthe
body control module (BCM), or SDM is replaced, and
during the programming procedure for the BCM until
afterthe procedure is completed. When installing a new
SDM, there may be several DTCs set prior to
programming. Once programmed, these DTCs should
be history and can be cleared.
Replace and Program ECU or
Reprogram ECU
To program a replacement or an existing Inflatable
Restraint Sensing and Diagnostic Moduie, performthe
following procedure:
1. Install EL-49642 SPS Programming Support Tool.
2. Access the Service Programming System (SP8)
and follow the on-screen instructions.
3. On the SPS Supported ControIlers screen, select
Inflatable Restraint Sensing and Diagnostic
Module - Programming and follow the on-screen
instructions.
(US/Canada)
-Sonic
2013 (5377994)
Manual
Service

4. On the SPS Supported Controllers screen, select
Inflatable Restraint Sensing and Diagnostic
Module —Setup and follow the on—screen
instructions.
5. At the end of programming, choose the “Clear All
DTCs" function on the SPS screen.
Unsuccessful Programming Recovery
In the event of an interruptedor unsuccessful
programming event, perform the following steps:
1. DO NOT turn the vehicle 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. Ifthe ECU can still not be programmed, turn the
vehicle OFF for at least one minute.
4. Vehicle in Service Mode, attempt to reprogram the
ECU. The ECU should program.
=>Ifthe ECU still cannot be programmed, replace
the ECU.
Instrument Cluster Programming and
Setup
Special Tools
EL-49642 SPS Programming Support Tool
For equivalent regional tools, refer to Special Tools on
page 6-14.
Note:
0 DO NOT program a control module unless
directed to by a service procedure or a service
bulletin. Ifthe ECU is not properly configured with
the correct calibration software, the ECU 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. Ifthere is an interruption
during programming, programming failure or ECU
damage may occur.
' Stable battery voltage is critical during
programming. Any fluctuation, 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.
- 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.
2013
-Sonic
(US/Canada)
Service
Manual
{5377994)
Programming and Setup 6n'l'l
Replace and Program ECU or
Reprogram ECU
To program a replacement or an existing ECU, perform
the following procedure:
1. Install EL-49642 SPS programming support tool.
2. Access the Service Programming System (SP8)
and follow the on—screeninstructions.
3. On the SPS Supported Controllers screen, select
InstrumentCluster —Programming and follow the
on-screen instructions.
4. On the SPS Supported Controllers screen, select
InstrumentCluster —Setup and follow the
on—screeninstructions.
5. On the SPS Supported Controllers screen, select
InstrumentCluster —Configuration and follow the
on—screeninstructions.
6. At the end of programming, choose the “Clear All
DTCs" function on the SPS screen.
Unsuccessful Programming Recovery
In the event of an interrupted or unsuccessful
programming event, perform the following steps:
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. Ifthe 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.
=>Ifthe ECU still cannot be programmed, replace
the ECU.
Multi-Axis Acceleration Sensor
Module Programming and Setup
Note:
- DO NOT program a control module unless
directed to by a service procedure or a service
bulletin. Ifthe Multi-axis Acceleration Sensor or
InertiaSensor Module (IMU) is not properly
configured with the correct calibration software,
the Electronic Brake Control Module will not
control all of the vehicle features properly.
- Stable battery voltage is critical during
configuration. Any fluctuation, spiking, over
voltage or loss of voltage will interrupt
configuration. 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.
6-12 Programming and Setup
- During the configuration procedure, follow the
SPS prompts for the correct ignition switch
position.
' Clear DTCs after configuration is complete.
Multi-Axis Acceleration Sensor Module
Configuration
Note: The Multi—axisAcceleration Sensor is also
known as the InertiaSensor Module (IMU) in SP8. The
sensor must be configured using SPS before the
vehicle Yaw Sensor Learn is performed.
A replacement Multi-axis Acceleration Sensor Module,
requires the following procedure:
1. Install EL-49642 SPS Programming Support Tool..
2. Access the Service Programming System (SP8)
and follow the on—screeninstructions.
3. On the SPS Supported Controllers screen, select
IMU InertiaSensor Module —Configuration and
follow the on-screen instructions.
4. At the end of programming, choose the “Clear All
DTCs” function on the SPS screen.
5. With a scan tool, perform the Yaw Sensor Learn.
Refer to Vehicle Yaw Sensor Learn on page 5-49.
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 on page 13-109 for the
rezeroing procedure.
Power Steering Control Module
Programming and Setup
The following service procedures require either a
programming or a setup event performed for a
complete repair.
Power Steering Control Module
Replacement
Ifthe steering column power steering control module
needs to be is replaced, the power steering control
module needs to be programmed with the following
procedures:
1. Connect a scan tool to the vehicle and access
SPS. Refer to Service Programming System (SP8)
on page 6-13.
2. Perform the SPS function Power Steering Control
Module —Programming and follow the on—soreen
instructions.
3. Clear DTCs after completing the programming
procedure.
Power Steering Control Module
Reprogramming
Do not reprogram the power steering 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 (SP8)
on page 6-13.
2. Perform the SPS function Power Steering Control
Module —Programming and follow the on-screen
instructions.
3. Clear DTCs after completing the programming
procedure.
Radio Programming and Setup
Special Tools
EL—49642 SPS Programming Support Tool
Note:
' DO NOT program a control module unless
directed to by a service procedure or a service
bulletin. lfthe ECU is not properly configured with
the correct calibration software, the ECU 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. Ifthere is an interruption
during programming, programming failure or ECU
damage may occur.
- Stable battery voltage is critical during
programming. Any fluctuation, spiking, over
voltage or loss of voltage will interrupt
programming. Install the EL-49642 SPS
Programming Support Tool to maintain system
voltage. Ifnot 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.
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.
2013
-Sonic
{US/Canada)
Service
Manual
(5377994)
 Pwmmijg and Setup 6=13

- The XM satellite radio (if equipped) is integrated Review the information below to ensure proper
into the radio. IfXM was activated in the previous programming protocol.
radio, the replacement radio will require no Note:
additional activation steps. Customer subscription
information is transferred to the replacement radio - DO NOT program a control module unless you are
directed by a service procedure or you are
when a replacement radio is ordered. directed by a General Motors service bulletin.
Replace and Program ECU or Programming a control module at any other time
will not permanently correct a customers concern.
Reprogram ECU
- Itis essential that the TIS terminal, MDI, andlor
To program a replacement or an existing ECU, perform Scan Tool, is equipped with the latest software
the following procedure: before performing service programming.
1. Install EL-49642 SPS Programming Support Tool. - Due to the time requirements of programming a
2. Access the Service Programming System (SP8) controller, install EL—49642SPS Programming
and follow the on-screen instructions. Support Tool to maintain system voltage. Stable
3. On the SPS Supported Controllers screen, select battery voltage is critical during programming. Any
Radio —Programming and follow the on-screen fluctuation, spiking, over voltage or loss of voltage
instructions. will interrupt programming. Ifthe above tool is not
available, DO NOT connect a battery charger,
4. At the end of programming, choose the “Clear All connect-a fully charged 12V jumper or booster
DTCs" function on the SPS screen. pack disconnected from the AC voltage supply.
Unsuccessful Programming Recovery - Some modules will require additional
programming/setup events to be performed before
Inthe event of an interrupted or unsuccessful or after programming.
programming event, perform the following steps:
- Some vehicles may require the use of a CANDi or
1. DO NOT turn the ignition OFF. Ensure that all MDI module for programming.
ECU, DLC and programming tool connections are
secure and the TIS terminal operating software is - Review the appropriate service information for
up to date. these procedures.
2. Attempt to reprogram the ECU. - DTCs may set during programming. Clear DTCs
after programming is complete.
3. lfthe ECU can still not be programmed, turn the
ignition OFF for at least one minute. 0 Clearing powertrain DTCs will set the Inspection/
Maintenance (IIM)system status indicators to NO.
4. Turn the ignition ON and attempt to reprogram the
ECU. The ECU should program. Ensure the following conditions are met before
programming a control module:
=>Ifthe ECU still cannot be programmed, replace
the ECU. - Vehicle system voltage:
—There is not a charging system concern. AII
Remote Control Door Lock Receiver charging system concerns must be repaired
before programming a control module.
Programming and Setup
—Battery voltage is greater than 12 volts but less
Diagnostic Aids than 16 volts. The battery must be fully charged
before programming the control module.
The remote control door lock receiver only functions as
an antenna, receiving the signals sent by the keyless —Turn OFF or disable any system that may put a
load on the vehicles battery,such as the
entry transmitter and forwarding them to the body
following components:
control module (BCM). The keyless entry software is
contained wholly within the BCM. - Interior lights
- Exterior lights including daytime running lights
Replace and Program ECU or (DRL)——Appiyingthe parking brake, on most
Reprogram ECU vehicles, disables the DRL system
This ECU does not require SPS programming or any - Heating, ventilation, and air conditioning
setup procedures. (HVAC) systems
- Engine cooling fans
Service Programming System (SPS) - Radio, etc.
Special Tools - The ignition switch must be in the proper position.
SPS prompts you to turn ON the ignition, with the
EL-49642 SPS Programming Support Tool engine OFF. DO NOT change the position of the
For equivalent regional tools, refer to Special Tools on ignition switch during the programming procedure,
page 6—14. unless instructed to do so.
For step-by—stepcontrol module programming
instructions, please refer to the techline information
system (TIS) terminal.

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
6-14 Programmingflnd Setup
' Make certain aIItool connections are secure, Sunroof Control Module
including the following components and circuits:
Programming and Setup
—Scan Tool
When replacing the sunroof motor/controlmodule, the
- The RS-232 communication cable port sunroof motor/actuator initialization/teaoh procedure
- The connection at the data link must be followed. Refer to Sunroof Motor/Actuator
connector (DLC) Initialization/Teach Process on page 12—12before
- The voltage supply circuits starting the repair procedure.
—MDI
Theft Deterrent Module Programming
- The USB, Ethernet or Wireless
communication port and Setup
- The connection at the data link
connector (DLC) Replace and Program ECU or
- DO NOT disturb the tool harnesses while Reprogram ECU
programming. Ifan interruption occurs during the This ECU does not require SPS programming or any
programming procedure, programming failure or setup procedures.
control module damage may occur.
In the event of an interruptedor unsuccessful Special Tools and Equipment
programming event, performthe following steps:
1. DO NOT turn the ignition OFF. Ensure that all Illustration Tool Number/Description
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. lfthe control module can still not be programmed, EL 46079
turn the ignition OFF for at least one minute. J 46079
4. Turn the ignition ON and attempt to reprogram the TirePressureMonitor
control module. The control module should DiagnosticTool
program.
=>Ifthe 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 on EL 49642
page 6-3 for the appropriate control module EL 50113
Programming and Setup document for any required
procedures. Europe—Use recommended
equivalentworkshop
equipment
SPS Programming
SupportTool

2223727

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
 r\
Vehicle Diagnostic Information 0215

Vehicle Diagnostic Information

Specifications

Body Control Module Scan Tool Information

Body Control Module Scan Tool Data Parameters

Parameter ] System State I Expected Value I Definition
Operating Conditions: lgnitionON,Vehiclein Park,All DoorsClosed
.. . Accessory/ The scan tooldisplaysOff,Accessory,Run,or Crank.
5 V IgnitionSW'tCh — Key Out This parameterdisplaystheignitionswitchmode.
. . . This parameterdisplays
commandas theinteriorlightingambient1
a percentage.
Accent Lighting1 Command — Varies
Accessory —— Active The scan tooldisplaysActiveor Inactive.
AccessoryPowerMode __ Varies This parameterdisplaysignitionswitchaccessoryLED
IndicatorCommand PWM commandas a percentage.
Accessory RelayCommand ~— Active The scan tooldisplaysActiveor Inactive.
Acoessory/Retained The scantooldisplaysActiveor Inactive.This
Accessory PowerRelay — Active parameterdisplaystheretainedaccessorypowerrelay
Command status.
. The scan tooldisplaysActiveor Inactive.This
A” DoorLOCKCommand _ InactIve parameterdisplaysthedoorlockstatus.
. . . The scan tooldisplaysvolts.This parameterdisplays
Ambient“9'“ Sensor _ VarIes theambientlightsensorsignalvoltage.
. . . The scan tooldisplaysUnknown,Night,or Day.This
AmbientL'ghtStatus _ N'ght parameterdisplaystheambientlightlevelstatus.
AutomaticHeadlamps _ Inactive The scan tooldisplaysActiveor lnactive.This
DisableSwitch parameterdisplaystheheadlampdisableswitchstatus.
. .
. TransmISSIon The scan tooldisplaysOffor On.This parameter
Automatlc — Off . . . tapuptapdownsw1tch
dIsplaysthetransmISSIon -
ManualShiftSwitch
status.
BackupLampsRelay _ Inactive The scan tooldisplaysActiveor Inactive.This
Command parameterdisplaysthebackuplampsrelaystatus.
The scan tooldisplaysActiveor Inactive.This
BatteryLowatStart — Inactive parameterdisplaysActivewhenthebatterylevelis low
whenthevehiclestarts.
The scan tooldisplaysNo orYes whena battery
BatteryReconnectDetected _ No disconnect/reconnecteventhas beendetected.
BatteryVoltage — Varies The scan tooldisplaysthecurrentbatteryvoltage.
egméiontrolledCharging — Active The scan tooldisplaysActiveor Inactive.
_ - The scan tooldisplaysActiveor Inactive.This
Zegggjée%rfilharglng
3511:: — Inactive parameterdisplaysActivewhentheBCM has detected
9 a lowbatteryvoltagecondition.
BootSoftwarePartNumber — Varies The scan tooldisplaysthebootsoftwarepartnumber.
__ . The scan tooldisplaysActiveor Inactive.This
BrakeLampCommand Inactive parameterdisplaysthebrakelampcommandstatus.
BrakePedal InitialTraveI No .
The scan tooldisplaysNo or Yes.
PositionAchieved —

BrakePedal PositionSensor — No The scan tooldisplaysNo or Yes.

HighVoltageDuringLearn

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
,\ (x Information
o-lo Vehicle Diafignostic

Body Control Module Scan Tool Data Parameters (cont'd)

Parameter System State Expected Value Definition
The scantooldisplaysNo or Yes.This parameter
BrakePedal
Learn PositionSensor — No displaysYeswhenthe brakepedalpositionsensorhas
learned.
.. The scantooldisplaysNo or Yes.This parameter
Egtfieaefi:Irnzogg'gigfnensor — Yes displaysYes whenthebrakepedalpositionsensorhas
learnedthehomeposition.
BrakePedal PositionSensor .
LowVoltageDuringLearn — No The scantooldIsplaysNo orYes.

BrakePedal PositionSensor __ No The scan tooldisplaysNo orYes.This parameter

MoveDuringLearn displaysthebrakepedalsensorlearnstatus.
BrakePedal PositionSensor
PulledUpfromHome — No The scan tooldisplaysNo orYes.
Position
.. The scantooldisplaysthebrakepedalpositionas
a:léfezggal PosmonSensor — Varies voltagevalue.This parameterdisplaysthecurrent
brakepedalpositionsensorreference.
BrakePedal PulledUpfrom .
’The scantooldIsplaysNo or Yes.
HomePosition — No

Tr
. . .
I Sh ftor .
The scan tooldisplaysActiveor
. . This
Inactive. .
In't:kH:ckaSncflgrlISosi
B dORctuat —- Inactive dIsplaystheremotestart
fiiasrtirrnyeter diagnosticstatus

BrakeTransmissionShift The scantooldisplaysActiveor Inactive.This

InterlockSolenoidActuator — Inactive parameterdisplaysthelastremotestartdiagnostic
Command statushistory.
_ . The scantooldisplaysthe softwaremodulecalibration
. .
CallbratlonPartNumber 1_20 Varies partnumber.

CenterBrakeLamp _ Inactive The scantooldisplaysActiveor Inactive.This

Command parameterdisplaysthecenterbrakelampstatus.
CentralDoorLock Switchon __ Inactive The scantooldisplaysActiveor Inactive.This
CenterConsole parameterdisplaysthedriverdoorlockswitchstatus.
. . . The scantooldisplaysActiveor Inactive.This
LOCKIndicator
gglrirgisaencdunty — Inactive parameterdisplaysthechildsecuritylockindicator
commandstatus.
ContentTheftDeterrent __ Disarmed The scan tooldisplaysOff,Armed,or Disarmed.This
AlarmStatus parameterdisplaysthecontenttheftalarmstatus.

gggfiggygfifgfifigt _ No The scan tooldisplaysNo or Yes.This parameter

Closed displaysthecontenttheftdeterrentsystemstatus.
The scantooldisplaysActiveor Inactive.This
82?;figfiqrmegge — Inactive parameterdisplaystheremotestartdiagnosticstatus
historyorthelastremotestartdiagnosticstatushistory.
The scantooldisplaysNone,Driverdoor,Passenger
door,Leftreardoor,Rightreardoor,Rearclosure,
Midgate,TonneauCover,Hood,IgnitionVoltage,
ContentTheftDeterrent _ None Telematicsenhancedservice
Intrusion,Inclination,
TriggerHistory1-3 alarm,Batteryreconnectdetected,UnauthorizedPWM
change,SecurityIndicatesTamper,or Glass Breakage.
This parameterdisplaysthecontenttheftdeterrent
triggerhistorystatus.
CourtesyLampsDutyCycle _ Varies This parameterdisplaystheinteriorlightsdimming
Command commandas a percentage.
This parameterdisplaystheremotestartdiagnostic
CrankAbort —— Inactive statushistoryorthe lastremotestartdiagnosticstatus
history.
CruiseChargingSet Level — Varies This parameterdisplayscruisechargingsetlevel.
The scantooldisplaysCANCEL, OFF, ON,RESUME,
Cruise ControlSwitchStatus — OFF SET or ERROR. This parameterdisplaysthecruise
controlswitchstatus.

(US/Canada)
~Sonic
2013 (5377994)
Manual
Service
 Vehicle Diagnostic Information 647

Body Control Module Scan Tool Data Parameters (cont'd)

Parameter System State Expected Value Definition
The scan tooldisplaysNone,Driverdoor,Passenger
door,Leftreardoor,Rightreardoor,Rear closure,
Midgate,TonneauCover,Hood,IgnitionVoltage,
CurrentContentTheft _ None Intrusion,Inclination,Telematicsenhancedservice
DeterrentTrigger alarm,Batteryreconnectdetected,UnauthorizedPWM
change,SecurityIndicatesTamper,Glass Breakage.
This parameterdisplaysthecontenttheftdeterrent
currentalarmtrigger.
CurrentDriver — 1-8 This parameterdisplaysthecurrentdriverinvehicle.
DisableBattery
Command Saver Relay — . . . .
Inactive The scan tooldisplaysActIveor Inactive.
. _ . The scan tooldisplaysActiveor Inactive.This
DomeLampSWItCh Inactive parameterdisplaysthedomelampswitchstatus.
. . . . The scan tooldisplaysActiveor Inactive.This
DrIverDoorAjarsw'tCh — Inactive parameterdisplaysthedriverdoorAjarswitchstatus.
. The scan tooldisplaysActiveor Inactive.This
DriverDoorUnlock
Command — Inactive parameterdisplaysthedriverdoorunlockcommand
status
DriverWindowLearned — Yes The scan tooldisplaysNo orYes.
. . . The scan tooldisplaysActiveor Inactive.This
820731113? MamControl — Inactive parameterdisplaysthedriverwindowmaincontrol
downswitchinputstatus.
. . . The scan tooldisplaysActiveor Inactive.This
Egggsévggvfi‘g’h'wam
Control — Inactive parameterdisplaysthedriverwindowswitchexpress
inputstatus.
. . I The scan tooldisplaysActiveor Inactive.This
DriverWlndowMainControl — Inactive parameterdisplaysthedriverwindowswitchUP input
Up SWItch status
‘ The scan tooldisplaysDown,ExpressDown,Express,
. . LocalSwitch Up, Error,Inhibit,or LocalSwitchOverridden.This
DriverWindowMotorMode _ Overridden parameterdisplaysthedriverwindowmotormode
status.
Egarfilrteaagttery
Saver Relay — Inactive The scan tooldisplaysActiveor Inactive.
End ModelPartNumber —- Varies This parameterdisplaystheendmodelpartnumber.
This parameterdisplaystheremotestartdiagnostic
EngineStalled —— Inactive statushistoryorthelastremotestartdiagnosticstatus
history.
EnvironmentIdentification — Unknown Lgifiggggfiizifg :31; gztyjihicleenvironment
. .. . . The scantooldisplaysActiveor Inactive.This
EnVIronmentIdentification _ Inactive parameterdisplaysthefrontfoglampsstatus.
FrontFog LampsRelay _ Inactive The scan tooldisplaysActiveor Inactive.This
Command parameterdisplaysthefrontfoglamprelaystatus.
. . The scan tooldisplaysActiveor Inactive.This
FrontFog LampsSW'tCh _ Inathe parameterdisplaysthefrontfoglampswitchstatus.
.
FrontPassengerWIndow . The scan tooldisplaysActiveor
. Inactive.T
. his
MainControlDownSwitch — Inactive gagacngestgrtgésplays
thefrontpassengerWindowdown

. The scan tooldisplaysActiveor Inactive.This

Iggi'htEggingigye/Isgdgwitch
.
FrontPassengerWindow
MainControlUpSwitch
— Inactive parameterdispIaysthepassengerwindowswitch
expressinputstatus.
. The scan tooldisplaysActiveor
. Inactive.
. This.
— Inactive i[3125;'szitngeatleur8ftIsplays
thepassengerwmdowSWItchUP

. The scan tooldispIayskPa or PSI.This parameter

FrontTirePressureon
Placard — Varies displaysthespecifiedtirepressureplacardinformation
programmedin theBCM fortirepressuremonitoring.

2013
—
Sonic
(US/Canada)
Service
Manual
(5377994)
648 Vehicle Diagnostic Information

Body Control Module Scan Tool Data Parameters (cont'd)

Parameter System State Expected Value Definition
Fuel EconomyMode The scan tooldisplaysActiveor Inactive.This
$3122)?' LOWChargIng — Inactive parameterdisplaysthefueleconomymodestatus.

GeneratorRegulator .
VarIes t
I percenage.
The scan t00|d'Ispays
Setpoint —
. . The scan tooldisplaysActiveor Inactive.This
HazardLampssw'tCh _ InactIve parameterdisplaysthehazardlampsswitchstatus.
. . . scan tooldisplayspercentage.
The . . This parameter
HazardLampsSWItch
. — VarIes displayshazardSWItchbacklightlevelPWMcommand
BackhghtCommand status.
. _ . The scan tooldisplaysActiveor Inactive.This
HeadlampsOn SW'tCh Inactive parameterdisplaystheheadlamponswitchstatus.
~ The scan tooldisplaysActiveor Inactive.This
HeadlampsFlash Switch — Inactive parameterdisplaystheheadlampsflashtopass switch
status,
. . _ . The scan tooldisplaysActiveor Inactive.This
H'ghBeamSelect SWltCh Inactlve parameterdisplaysthehighbeamswitchstatus.
. _ . The scan tooldisplaysActiveor Inactive.This
H'ghBeamCommand Inactlve parameterdisplaysthehighbeamcommandstatus.
This parameterdisplaytheremotestartdiagnostic
HoodAjarSwitch — Inactive statushistoryorthelastremotestartdiagnosticstatus
history.
This parameterdisplaytheremotestartdiagnostic
HoodAjarSwitchSignal 1 — Inactive statushistoryorthelastremotestartdiagnosticstatus
history.
.. The scan tooldisplaysCLOSED, AJAR, orOPENED.
HOOdPosmon _ CLOSED This parameterdisplaysthehoodposition.
HornRelayCommand — Inactive The scan tooldisplaysActiveor Inactive.
HornSwitch —— Inactive The scan tooldisplaysActiveor Inactive.
.
Varies This parameterdisplaysthestateoftheidleboostIeveI
as counts.
IdleBoostLevel2—3Counter —

IdleChargingSet Level —— Varies This parameterdisplaysidlechargingset level.

gifitgigyggfiflsngmh — Varies The scan tooldisplaysas a percentage.

. Reference
. . SWItch _ . This parameterdisplaystheignitionswitchvoltage
reference.
IgnItIon Varies

IgnitionSwitchSignal _ Varies This parameterdispIaystheignitionswitchsignal

Voltage voltage.
IgnitionSwitchStatus — Inactive This parameterdisplaystheignitionswitchstatus.
.. . The scan tooldisplaysUnknown,Incorrect,Not
EngineT0
IsmarlntobllizerAllows — Unknown Allowed,orValid.This parameterdisplaysthe
immobilizerstatus.
ImmobilizerAutomaticLearn — .
InactIve The scan tooldisplaysActiveor Inactive.This
Timer parameterdisplaystheautomaticlearntimerstatus.
.. . The scan tooldisplaysIncorrect,Correct,Not
EnVIronment
{3233:214er — Unknown Received,NotProgrammedor Unknown.This
parameterdisplaystheimmobilizersourcestatus.
.. __ . The scan tooldisplaysActiveor Inactive.This
ImmobilizerPasswordLearn Inactive parameterdisplaysthepasswordlearnstatus.
Learn
grgroggicffiggzs/sword —— Varies This parameterdisplaystheautolearntimerstatus.

mmgptiliéerSecurityCode — No The scan tooldisplaysNo or Yes.

ImmobilizerSecurityCode —— No The scan tooldisplaysNo or Yes.

Lookout

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Body
Parameter
ImmobilizerSecurityCode
Programmed
. The scantooldisplaysOn orOff.This parameter
InPark SW'tChStatus
InadvertentLoadCommand
IndicatorDimmingDuty
Cycle Command
Interior/Courtesy
Lighting
MasterSwitch
InteriorTrunkLid/Liftgate
WindowUnlatchSwitch
Key CaptureSolenoid
Actuator
Key Fob 1-4BatteryStatus
_ ActuateFoldingTop,StartEngine,Stop Engine,
_ .
Key Fob 1 4 Function
Key Fob inVehicle
Key InCylinderSwitch
1:36,
msg#32313
SW'tCh/Key
Key IInlgnItIon
II
Status
Key Part Number
Key Type
Last DoorLockFunction
LED BacklightDimming
Command
LeftBrakeLampCommand
I .
LeftDedicatedDaytime
RunningLampCommand
LeftFrontTirePressure
LeftFrontTirePressure
Identification
LeftFrontTirePressure
Sensor LocationLearned
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-Sonic
(US/Canada)
Service
Manual
(5377994)
Vehicle Diagnostic Information 649
Control Module Scan Tool Data Parameters (cont'd)
System State Expected Value Definition
— Yes The scantooldisplaysNo orYes.
— On displaystheparkswitchstatus.
— Active The scantooldisplaysActiveor Inactive.
__ Varies The scantooldisplayspercentage.This parameter
displaysindicatorlightingPWM commandstatus.
__ Door The scantooldisplaysDooror otherlightingswitch
status.
— . . . .
Inactive The scantooldisplaysActIveor InactIve.
_ Active The scantooldisplayActiveor Inactive.This parameter
displayscolumnlookinputstatus.
The scantooldisplaysOK orotherkeyfobbattery
—— OK status.This parameterdisplaysthekeyfobbattery
status.
The scantooldisplaysInactive,Lock,UnlockDriver
Door,All DoorUnlock,ReleaseRearClosure,Actuate
LeftSlidingDoor,ActuateRightSlidingdoor,Panic
Alarm,Release Fueldoor,ActuatePowerWindows,
_ . Programmed,LocatorAlarm,Close Liftgate,Open
Undefined Liftgate,StopLiftgateWhileClosing,Stop Liftgate
Whileopening,DeadlockAll Doors,Stop Liftgate
Motion,StartLiftgateMotion,Stop LeftSlidingDoor
Motion,StopRightSlidingDoorMotion,Comfortopen,
or Comfortclose.This parameterdisplaysthekeyfob
functionstatus.
_ Inactive This parameterdisplaysthecurrentkeyfobInthe
vehicle.
— Active The scantooldisplaysActiveor Inactive.
— Yes The scantooldisplaysNo orYes.
_ I
Inacthe
The scantooldisplaysKey Outor Key In.This
parameterdisplaysthe keyin ignitionstatus.
— Varies This parameterdisplaysthekeypartnumber.
The scantooldisplaysUnknown,MasterKey,Valet
— MasterKey Key,FleetKey,or Unconfigured.This parameter
displaysthekeytype.
The scantooldisplaysNO Action,PC UNDB Lock,PC
Unlock,Unlock,UnlockDriver,UnlockPassenger,
AIIDoorsLook UnlockLeftRear,UnlockRightRear,UniockCargo
Liftgate,UnlockDriverSide,UnlockPassengerSide,
UnlockNonDriver,UnlockAll, LockAll, DBL Lock,
or UNDBL Lock.
The scantooldisplaysas a percentage.This parameter
— Varies displaysLED backlightdimmingPWM command
status.
I The scantooldisplayspercentage.This parameter
— Varies displaysIeftbrakelampcommandstatus.
. The
. scantooldisplayspercentage.
. . T. his parameter
— Varies gézfigysIeftdedicateddaytimerunnInglampcommand
—— Varies This parameterdisplaysleftfronttirepressurein PSI.
__ Varies This parameterdisplaysleftfronttirepressure
sensorID.
_ Yes The scantooldisplaysNo orYes. This parameter
displaytirepressuremonitorsystemlearnedstatUs.
6320 Vehicle Diagnostic
Body Control
Parameter
LeftFrontTire Pressure
Sensor Mode
LeftFrontTirePressure
Status
16:?15223;? SignalBulb
LeftFrontTurnSignal/
HazardLampCommand
LeftLowBeam/Daytime
RunningLampCommand
LeftPark LampsCommand
I I
LeftRear DoorAjarSW'tCh
LeftRearTire Pressure
LeftRearTire Pressure
Identification
LeftRearTire Pressure
SensorLocationLearned
. The scantooldisplaysLearnMode,Undefined,
5:2;33085: Pressure
LeftRearTire Pressure
Status
LeftRearTurnSignalBulb
OutFeedback
LeftRearTurnSignal/Hazard
LampCommand
LeftRearWindowMain
ControlDownSwitch
LeftRearWindowMain
ControlExpressSwitch
LeftRearWindowMain
ControlUp Switch
LeftRearWindow
MotorMode
LeftRearWindowSWitCh
at Door
. .
LeftTurnSignalSW'tCh
LicensePlate Lamps
Command
Load ReductionLevel2-3
Counter
, The scantooldisplaysActiveor Inactive.This
LowBeamRelayCommand
ManufacturersEnable
Counter
MasterKeys Learned
ModuleDiagnosticAddress
Numberof Key Fobs In
Vehicle
Information
Module Scan Tool Data Parameters
System State Expected Value
LearnMode-
PressureTriggered EnterOffMode,ExitOffMode,or LearnModePressure
_ Normal
—— Inactive
— .
Inactive
_ Varies
_ I
VarIes
_ I
Inactive
— Varies
_ Varies
_ Yes
— Stationary
__ Normal
_ Inactive
. .
— InactIve
__ Inactive
_ Inactive
_ Inactive
_ Local Switch
Overridden
— Inactive
_ .
InactIve
. .
— Inactive
. .
— VarIes
— Inactive
— Varies
_ I
Varies
— Varies
_ 1
(cont'd)
Definition
The scantoolparameterdisplaysLearnMode,
Undefined,RemeasureDataMode,RollingMode,
Triggered.
The scantooldisplaysUnknown,Normal,VeryLow
Pressure,Low,WeakSignal,or High.
The scantooldisplaysActiveor Inactive.
. .
The scantooldispIaysActiveor .
InactIve.
The scantooldisplayspercentage.This parameter
displaysIeftlowbeam/daytimerunninglampstatus.
The scantooldisplayspercentage.This parameter
displaysrearexteriorlightingstatus.
This parameterdisplaysActiveor Inactive.This
parameterdisplaystheleftreardoorajarswitchstatus.
This parameterdisplaysleftreartirepressurein PSI.
This parameterdisplaysleftreartirepressure
sensorID.
The scantooldisplaysNo or Yes.This parameter
displaystirepressuremonitorsystemlearnedstatus.
RemeasureDataMode,RollingMode,EnterOffMode,
ExitOffMode,or LearnModePressureTriggered.
The scantooldispIaysUnknown,Normal,VeryLow
Pressure,Low,WeakSignal,or High.
The scantooldispIaysActiveor Inactive.The
-parameterdisplaysturnlampoutagestatus.
. .
The scantooldisplaysActIveor InactIve.
The scantooldisplayActiveor Inactive.This parameter
displaysdriverwindowswitchinputs.
The scantooldisplayActiveor Inactive.Thisparameter
displaysdriverwindowswitchinputs.
The scantooldisplaysActiveor Inactive.This
parameterdisplaysdriverwindowswitchinputs.
The scantooldisplaysDown,Express,Up,Inhibit,
or LocalSwitchOverridden.
The scantooldisplaysActiveor Inactive.
The scantooldisplaysActiveor Inactive.This
parameterdisplaystheleftturnsignalswitchstatus.
. .
ThescantooldisplaysActiveor Inactive.
Thescantooldisplayas counts.
parameterdisplaystheheadlamplowbeamrelay
status.
This parametertooldisplaysvariouscountervalues.
This parameter
keysIe amed. displaysthetotalnumberofmaster
This parameterdisplaysmoduiediagnosticaddress.
This parameterdisplaysthenumberoffobslocatedin
thevehicle.
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-Sonic
(US/Canada)
Service
Manual
(5377994)
 Vehicle Diagnostic Information 621

Body Control Module Scan Tool Data Parameters (cont'd)

Parameter
Odometer
OutsideRearView Mirror
CourtesyLampCommand
I I
Park Brakesw'tCh
Park LampsSwitch
PassengerDoorAjarSwitch
PassengerDoorLock Switch
gavefignger
DoorUnlock
PassengerDoor(s)Unlock
Command
. The scantooldisplaysNoor Yes.This parameter
PassengerWindowLearned
PassengerWindow
MotorMode
I .
Efissagriger
WindowSW'tCh
I Key Type
PreVIous
PrimaryKey Status
Push ButtonIgnitionSwitch
Push ButtonIgnitionSwitch
Voltage
Rear ClosureAjarSwitch
gaigfilosure CylinderLOCK
System State Expected Value
— Varies
_ Inactive
— Active
— Inactive
— Inactive
— Inactive
— Inactive
_ Inactive
“— Yes
_ LocalSwitch
Overridden
— Inactive
_ Unknown
— Yes
— Inactive
_ Varies
— Active
— Inactive
Definition
This parameterdisplaysthevehiclemileage.
The scantooldisplaysActiveor Inactive.This
parameterdisplaysfrontexteriorlightingstatus.
Thescan tooldisplaysActiveor Inactive.This
parameterdisplaysfrontexteriorlightingstatus.
The scantooldisplaysActiveor Inactive.This
parameterdisplaysActivewhentheparklampswitchis
activated.
The scantooldisplaysActiveor Inactive.This
parameterdisplaysthepassengerdoorajarswitch
status.
The scan tooldisplaysActiveor Inactive.This
parameterdisplaysthepassengerdoorlockswitch
status.
The scantooldisplaysActiveor Inactive.This
parameterdisplaysthepassengerdoorunlockswitch
status.
The scantooldisplaysActiveor Inactive.This
parameterdisplaysthepassengerdoorunlockstatus.
displaysthepassengerwindowlearnedstatus.
Thescan tooldisplaysDown,Express,Up, Inhibit,
or LocalSwitchOverridden.
Thescan tooldisplaysActiveor Inactive.This
parameterdisplaysthepassengerwindowswitch
status.
This parameterdisplayspreviousdriveridentification
devicetype.
The scantooldisplaysNo or Yes.
The scantooldisplaysActiveor Inactive.
This parameterdisplaysthepushbuttonignitionswitch
voltage.
Thescan tooldisplaysActiveor Inactive.
The scan tooldisplaysActiveor Inactive.

Sfigrcilgaiifghcwinder — Inactive The scantooldisplaysActiveor Inactive.

This parameterdisplaysthereartirepressurein kPa or
RearTirePressureon _ Varies PSI.This parameterdisplaysthespecifiedtirepressure
Placard placardinformationprogrammedin theBCM fortire
pressuremonitoring.
EggtirgaltE/Idotj/gltage — Voltage Thescan tooldisplaysvoltage.
I This parameterdisplaystheremotestartdiagnostic
RemoteVehicleStart
AttemptsExhausted —— Varies statushistoryor thelastremotestartdiagnosticstatus
historyor remainingstartattempts.
I This parameterdisplaystheremotestartdiagnostic
Remote'VehIcle
CrankTIme Start — Inactive statushistoryor thelastremotestartdiagnosticstatus
history.
I This parameterdisplaystheremotestartdiagnostic
RemoteVehicleStart
Disabledby Driver —— Inactive statushistoryor thelastremotestartdiagnosticstatus
history.
RemoteVehicleStartSource IgnitionSwitchStart The scan tooldisplaysBodyControlmoduleor Power
Take-offStart.
RemoteVehicleStarts This parameterdisplaystheremotestartdiagnostic
Exhausted Varies statushistoryor thelastremotestartdiagnosticstatus
historyor remainingremotestarts.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
6«22 Vehicle Diagnostic
Body Control
Parameter
. _
R'ghtBrakeLampCommand
RightDedicatedDaytime
RunningLampCommand
RightFrontTirePressure
EighttfrotntTirePressure
en ImaIon ' sensor .
RightFrontTirePressure
SensorLocationLearned
. .
Pressure
ggnhstoirlsAgtd-gre
RightFrontTirePressure
Status
RightFrontTurnSignalBulb
OutFeedback
RightFrontTurnSignal/
HazardLampCommand
Right LowBeam/Daytime
RunningLampCommand
. _
R'ghtPark LampsCommand
RightRear DoorAjar Switch
RightRearTirePressure
Sightseer TirePressure
en ImaIon
RightRearTirePressure
SensorLocationLearned
RightRearTirePressure
Sensor Mode
‘ parameterdisplaysthepressuresensormodestatus.
I I
TIrePressure
gathJSRear
RightRearTurnSignal Bulb
OutFeedback
RightRearTurnSignal/
HazardLampCommand
RightRearWindowMain
Control DownSwitch
RightRearWindowMain
ControlExpressSwitch
RightRearWindowMain
ControIUp Switch
RightRearWindow
MotorMode
RightRearWindowSWitCh
at Door
. . . _
R'ghtTurnSignalSW'tCh
RunAbort
Run Relay Command
Run/Crank
Information
Module Scan Tool Data Parameters (cont'd)
System State Expected Value Definition
. The scan tooldisplaypercentage.This parameter
Varies displaysrightbrakelampPWM commandstatus.
_ Varies The scan tooldisplaypercentage.This parameter
displaysrightdedicatedDRL PWM commandstatus.
—— Varies This parameterdisplaysrightfronttirepressurein PSI.
_ Varies displaysrightfronttirepressure
This palrgmeter
.
— Yes The scantooldisplaysNo or Yes.
The scan tooldisplaysLearnMode,Undefined,
— Stationary RemeasureDataMode,RollingMode,EnterOffMode,
ExitOffModeor LearnModePressureTriggered.
_ Normal The scan tooldisplaysUnknown,Normal,VeryLow
Pressure,Low,WeakSignal,or High.
_ . . . .
Inactlve The scan tooIdIsplaysActiveor Inactive.
_ I . . .
Inactive.
InactIve The scan tooldIsplaysActiveor
_ Varies The scantooldisplayspercentage.This parameter
displaysrightlowbeam/daytime runninglampstatus.
. The scantooldisplayspercentage.This parameter
Varies displaysrearexteriorlightingstatus.
— Inactive The scan tooldisplaysActiveor Inactive.
—— Varies This parameterdisplaysrightreartirepressurein PSI.
__ Varies displaysrightreartirepressure
This pail'gmeter
sensor .
.
— Yes The scan tooldIsplaysNo orYes.
The scan tooldisplaysLearnMode,Undefined,
__ LearnMode— RemeasureDataMode,RollingMode,EnterOffMode,
PressureTriggered ExitOffMode,or LearnModePressureTriggered.This
The scan tooldisplaysUnknown,Normal,VeryLow
— Normal Pressure,Low,WeakSignalor High.Thisparameter
displaystherightreartirepressurestatus.
. . . .
— Inactive The scan tooldisplaysActiveor Inactive.
_ . . . .
Inactive.
Inactive The scan tooldisplaysActiveor
. . . .
—— Inactive The scan tooldisplaysActiveor InactIve.
. . . .
— Inactive The scan tooldIsplaysActiveor Inactive.
. . . .
— Inactive The scan tooldisplaysActiveor inactive.
_ LocalSwitch The scantooldisplaysDown,Express,Up,Inhibit,
Overridden or LocalSwitchOverridden.
— Inactive The scan tooldisplaysActiveor Inactive.
. The scantooldisplaysActiveor Inactive.This
Inactive parameterdisplaystherightturnsignalswitchstatus.
This parameterdisplaystheremotestartdiagnostic
— Inactive statushistoryorthelastremotestartdiagnosticstatus
history.
— Active The scan tooldisplaysActiveor Inactive.
— Inactive The scan tooldisplaysActiveor Inactive.
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 Vehicle Diagnostic Information 6-23

Body Control Module Scan Tool Data Parameters (cont'd)

Parameter System State Expected Value Definition
Run/CrankRelayCommand — Active The scan tooldisplaysActiveor Inactive.
The scan tooldisplayspercentage.This parameter
E%?é§:§:tc!3c)$¥1vr:;$tflciode —- Varies displaysignitionswitchrunLED PWM command
status.
SecondaryKey Status —— ‘No The scantooldisplaysNo orYes.
SecurityIndicatorCommand _ Varies The scantooldisplayspercentage.This parameter
displayssecurityLED PWM commandstatus.
The scan tooldisplaysNo TireType,MetricStandard
StandardLoad Load,MetricExtraLoad,LoadRangeC, LoadRange
SelectedFrontTireType D,or LoadRangeE. This parameterdisplaysthefront
tiretype. '
The scan tooldisplaysNoTireType,MetricStandard
StandardLoad Load,MetricExtraLoad,LoadRangeC, LoadRange
SelectedRearTireType D, or LoadRangeE. This parameterdisplaystherear
tiretype.
Thescan tooldisplayspercentage.This parameter
Start-UpStateof Charge _ Varies displaysstartupstateofchargestatus.
_ I The scan tooldisplayspercentage.This parameter
StateOfCharge Varies displaysstateof chargestatus.
SunroofEnabled — Active The scantooldisplaysActiveor Inactive.
re
gagfgmrgrtgtru — Inactive The scan tooldisplaysActiveor Inactive.
SunroofNotLearned — Inactive The scantooldisplaysActiveor Inactive.
The scan tooldisplaysClosed,Open,Venting,Comfort
SunroofPosition — Closed Open,Closing.Opening.This parameterdisplaysthe
currentsunroofposition.
The scan tooldisplaysSunroofSecureClose,Venting,
SunroofRemoteCommand — Inactive Close, or Open.This parameterdisplaysthelast
sunroofremotecommand.
The scantooldisplaysInactive,ExpressOpen,Open,
I I I ExpressClose, Close, Shortto Ground,Shortto
SunroofShdeSWltCh — InactIve Battery,or Stuck.This parameterdisplaysthesunroof
slideswitchstatus.
Thescan tooldisplaysInactive,Open,Close,Shortto
Ground,Shortto Batteryor Stuck.This parameter
SunroofSlideSwitch —— Inactive displaysthesunrooftiltswitchstatus.Whentheswitch
experiencesa malfunctionShortto Ground,Shortto
Batteryor Stuckwill bedisplayed.
e Motor
53211355311333: _ Inactive Thescan tooldisplaysActiveor Inactive.
The scantooldisplaysInactive,ExpressOpen,Open,
. . ExpressClose, Close. Shortto Ground,Shortto
SW'tCh
Sunroof/Sunshade _ Inactive Battery,or Stuck.This parameterdisplaysthesunroof
or sunshadeswitchstatus.
SunshadeEnabled — Active Thescan tooldisplaysActiveor Inactive.
SunshadeNotLearned — Inactive The scan tooldisplaysActiveor Inactive.
The scan tooldisplaysAjar,Closed,Opened,Closing,
SunshadePosition — Closed or Opening.This parameterdisplaysthesunshade
positionstatus.
SunshadeRemote __ Inactive The scantooldisplaysClose or Open.This parameter
Command displaysthelastsunshaderemotecommand.
TamperStatus — No The scantooldisplaysNo orYes.
TelematicsEnhanced __ No The scan tooldisplaysNo orYes.This parameter
ServiceOverrideActive displaysvehicletheftdeterrentsystemstatus.
TotalKeys Learned ~— Varies This parameterdisplaysthenumberof keyslearned.

—
2013 (US/Canada)
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Manual
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6I=24 Vehicle Diagiostic
Body Control
Parameter
TractionControlSwitch
TransponderAuthentication
TransponderKey Status
TrunkLampCommand
Window
TrunkLid/Liftgate
ExteriorUnlatchSwitch
Window
TrunkLid/Liftgate
UnlatchCommand
ValetKeys Learned
ValetModeStatus
I .
ValetSW'tCh
Vehicle Identification
Number(VIN)
WindowLockoutSwitch
marggggrl‘ggrfi‘omugfigimh
WindshieldWasherRelay
Command
WindshieldWasherSwitch
gmgihieldWiperPark
WindshieldWiper High
Speed RelayCommand
WindshieldWiperHigh
Speed Switch
WindshieldWiperMotor
Relay Command
DuringSweep Stalled
WindshieldWiper
WindshieldWiperStalledin
Park Position
WindshieldWiperSwitch
Information
Module Scan Tool Data Parameters (cont'd)
System State Expected Value Definition
The scantooldisplaysActiveor Inactive.This
— Inactive parameterdisplaysActivewhenthetractioncontrol
switchis active.
The scantooldisplays Inactive,Initializing,ID
Received,PasswordReceived,Data Reception
—— Initializing Complete,or DataTransmissionComplete.This
parameterdisplaysthetransponderkeycommunication
status.
The scantooldisplaysOK, LINBus Initialization
Malfunction,AntennaInitializationMalfunction,
PasswordError,No ValidKey Detected,LINBus
_ OK CommunicationMalfunction,orAntennaMalfunction.
This parameterdisplaysthetransponderkey
communicationerrorstatus.
— Varies Thescan tooldisplaysas percentage.
. . . .
— Inactive The scantooldisplaysActiveor InaotIve.
I I I
I or InaotIve.
— Inactlve Thescan tooldIsplaysActive
_ Varies This parameterdisplaysthenumberofvaletkeys
learned.
This parameterdisplaystheremotestartdiagnostic
— Inactive statushistoryorthe lastremotestartdiagnosticstatus
history.
The scantooldisplaysActiveor Inactive.This
* Inactive parameterdisplaysActivewhenthevaletswitchis on.
_ Varies This parameterdisplaysthevehicleidentification
number.
—- Inactive The scantooldisplaysActiveor Inactive.
—— Inactive ThescantooIdisplaysActiveor Inactive.
_ Inactive The scantooldisplaysActiveor Inactive.This
parameterdisplaysthewindshieldwasherrelaystatus.
Thescan tooldisplaysActiveor Inactive.This
—— Inactive parameterdisplaysthewindshieldwasherswitch
status.
—- Active Thescan tooldisplaysActiveor Inactive.
. . . .
—— InactIve The scantooldisplaysActiveor Inactive.
_ . I I I
Inactive.
InactIve Thescantool displaysActiveor
_ Inactive Thescantool displaysActiveor Inactive.This
parameterdisplaysthewindshieldwiperrelaystatus.
_ . . . .
Inactive Thescan tooldisplaysActiveor InactIve.
_ Inactive The scantooldisplaysActiveor Inactive.This
parameterdisplaysthewindshieldwiperstalledstatus.
The scantooldisplaysOff,Delay1,Delay2,Delay3,
—- Off Delay4, Delay5, or Low.This parameterdisplaysthe
windshieldwiperswitchstatus.
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 Vehicle Diagnostic Information 625

Body Control Module Scan Tool Output Controls

Scan Tool Output
Control Description
Accent Lighting1 The BCM activatestheaccentlightingwhenyouselectOn.Thevalueshouldbe 100%.All accent
Command lightingshouldilluminateuntilcommandedOff.
AccessoryPowerMode The BCM activatestheaccessoryindicatorwhenyouselectOn.The valueshouldbe 100%.The
IndicatorCommand yellowLED accessoryindicatoronstartbuttonshouldilluminateuntilcommandedOff.
Acoessory/Retained The BCM actuatestheretainedaccessorypowerrelaywhenyouselectOn.The retainedaccessory
Accessory PowerRelay powerrelayshouldturnon allowingspecificvehiclefunctionstooperate.
Command
A|IDoorsLock The BCM activatesall doorslookwhenyouselectLock.All doorsshouldlook.
Command
BackupLamps The BCM actuatesthebackuplampsrelaywhenyou selectOn.The backuplampsshouldilluminate
Command untilcommandedOff.Enginemustberunning.
The BCM activatesthebatterysaverrelaywhenyou selectEnable.This commandsets thelow
BatterySaver Relay powermoderelayinthestateinwhichitdoes notsupplypowerto thenon-essentialpartsofthe
vehicle.This is usedto preventthebatteryfrombeingdepletedwhenthevehicleis notusedfora
longperiodoftime.
BrakePedal Position The BCM activatesthebrakepedalpositionsensorlearnwhenyouselectLearn.The brakepedal
Sensor Learn positionsensorlearnprocedureshouldstart.
CenterBrakeLamp The BCM activatesthecenterbrakelampwhenyou selectOn.The centerbrakelampshould
Command illuminateuntilcommandedOff.
ChildSecurityLock The BCM actuatesthechildsecuritydoormotorwhenyou selectLook.Thechildsecuritydoors
Motors Command shouldlook.
Clear DriverWindow
LearnedValues WhenyouselectClear thecleardriverwindowlearnprocedureshouldstart.
Clear Passenger WhenyouselectClear theclearleftrearwindowlearnprocedureshouldstart.
WindowLearnedValues
CourtesyLamps The BCM activatesthecourtesylampswhenyouselectOn.Thevalueshouldbe 100%.Thecourtesy
Command lampsshouldilluminateuntilcommandedOff.
DriverDoorUnlatch The BCM activatestheoutputcircuittounlatchthedriverdoorwitha passiveentrypassivestart
Command whenyouselectUnlatch.Thereis NO doorhandleonthistypeofvehicletoopenthedoor.Instead,
thereis a padthatyou pressto unlatchthedoor.
DriverDoorUnlock
Command The BCM pulsesthedriverdoorunlockmotorwhenyouselectUnlock.Thedriverdoorshouldunlock.
DriverWindow The BCM activatesthedriverwindowmotorwhenyouselectUp/Down/Stop/Express Up/Express
MotorMode Down.The driverwindowshouldfollowtheappropriatecommand.
FrontFog Lamps The BCM actuatesthefrontfoglampsrelaywhenyouselectOn.Thefrontfoglampsrelayshould
Command turnon.
HazardLampsSwitch The BCM activatesthehazardlampsswitchwhenyouselectOn.The valueshouldbe 100%.The
BacklightCommand hazardlampsswitchbacklightshouldilluminateuntilcommandedOff.
HighBeams The BCM activatesthehighbeamcommandwhenyou selectOn.The highbeamlightsshould
illuminate.The headlampshaveto beon.
HornRelay The BCM activatesthehornwhenyouselectOn.The hornshouldsound.
The BCM activatestheinadvertentloadcommandwhenyou selectOn.(Itis an electronicrequestto
InadvertentLoad shutdownan electricalor electronicdevicethatis drawingpowerfromthebatteryat a timewhen
Command thereshouldbe noactivity,usuallyafterthekeyhas beenremovedfromtheignitionfora period
of time.)
LED BacklightDimming The BCM activatestheLED backlightdimmingwhenyou selectOn.The valuesshouldbe 100%.The
Command LED backlightdimmingforcontrolswitchesshouldilluminateuntilcommandedOff.
LeftBrakeLamp The BCM activatestheleftbrakelampwhenyouselectOn.Thevaluesshouldbe 100%.The left
Command brakelampshouldilluminateuntilcommandedOff.
LeftDedicatedDaytime
RunningLamp The BCM activatestheleftdedicateddaytimerunninglampwhenyouselectON. Thevaluechanges
Command to 100%.The leftdaytimerunninglampshouIdilluminate.
LeftFrontTurnSignal The BCM activatestheleftfrontturnsignallampwhenyou selectOn.The leftfrontturnsignallamp
LampCommand shouldilluminateuntilcommandedOff.
LeftPark Lamps The BCM activatestheleftparklampswhenyouselectON witha valueof 100%.The leftparklamps
Command shouldilluminate.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
e2 0‘; Vehicle Diagnostic Information

Body Control Module Scan Tool Output Controls (cont'd)

Scan Tool Output
Control Description
LeftRearTurnSignal The BCM activatestheleftrearturnsignallampwhenyou selectOn.The leftrearturnsignallamp
LampCommand shouldilluminateuntilcommandedOff.
The BCM activatestheleftrearwindowmotorwhenyou selectUp/Down/Stop/Express Down.The
LeftRearWindowMotor leftrearwindowshouldfollowtheappropriatecommand.
LicensePlate Lamps The BCM activatesthelicenseplatelampswhenyouselect On.The licenseplatelightsshouldturn
Command onuntilcommandedOff.
TheBCM actuatestherearcompartmentlid releaseactuatorwhenyouselectUnlatch.Thetrunkor
LiftgateUnlatch liftgateshouldopen.
LINBus Device WhenyouselectUpdatetheLINBus Devicepartnumberandcalibrationpartnumbershouldbe
Data
Identification updated.
LowBeamRelay The BCM activatesthelowbeamswhenyou selectOn.The lowbeamlightsshouldturnon.
Command
OutsideRearView TheBCM activatestheoutsiderearviewmirrorcourtesylampwhenyouselectOn.The outsiderear
MirrorCourtesyLamp viewmirrorcourtesylamp(atthe bottom)shouldilluminate.
Command
PassengerDoor(s) The BCM activatestheoutputcircuitto unlatchthepassengerdoorwitha passiveentrypassivestart
whenyou selectUnlatch.Thereis NO doorhandleon thistypeofvehicletoopenthedoor.Instead,
UnlatchCommand thereis a padthatyoupressto unlatchthedoor.
PassengerDoor(s) The BCM pulsesthepassengerdoorunlockmotorwhenyouselectUnlock.The passengerdoor
UnlockCommand shouldunlock.
PassengerWindow TheBCM activatesthepassengerwindowmotorwhenyou selectUp/Down/Stop/Express Up/
Motor ExpressDown.The passengerwindowshouldfollowtheappropriatecommand.
RightBrakeLamp The BCM activatestherightbrakelampwhenyou selectOn.The valueshouldbe 100%.Theright
Command brakelampshouldilluminateuntilcommandedOff.
RightDedicated The BCM activatestherightdedicateddaytimerunninglampwhenyouselectOn.Thevalueshould
DaytimeRunningLamp be 100%.The rightdaytimerunninglampshouldilluminate.
Command
RightFrontTurnSignal TheBCM activatestherightfrontturnsignallampwhenyouselectOn.The rightfrontturnsignal/
LampCommand hazardlampshouldilluminate.
RightPark Lamps The BCM activatestherightparklampswhenyouselect ONwitha valueof 100%.The rightpark
Command lampsshouldilluminate. ,
RightRearTurnSignal The BCM activatestherightrearturnsignal/hazardlampwhenyouselectOn.The rightrearturn
LampCommand signallampshouldilluminateuntilcommandedOff.
RightRearWindow The BCM activatestherightrearwindowmotorwhenyou seiectUp/Down/Stop/Express Down.The
Motor rightrearwindowshouldfollowtheappropriatecommand.
Run RelayCommand The BCM actuatestherunrelaywhenyouselect On.The runrelayshouldturnon.
$311433? Relay TheBCM actuatestherun/crankrelaywhenyou selectOn.The run/crankrelayshouldturnon.
Run/StartPowerMode The BCM activatestherun/startlampwhenyouselectOn.Thevalueshouldbe 100%.Thegreen
IndicatorCommand LED on enginestart/stopbuttonshouldilluminateuntilcommandedOff.
SecurityIndicator The BCM activatesthesecurityindicatorcommandwhenyou selectOn.Thesecurityindicatorat
Command centerof dash (orat DRL sensor)shouldilluminateuntilcommandedOff.
TirePressureSensors The BCM activatesthetirepressuresensorlearnprocedurewhenyou selectLearn.
Learn
TireType/Pressure Whenyou selectOK, youcan changetiretypeandloadrange.
Selection
TransmissionRange The BCM activatesthetransmissionrangeindicatorwhenyouselectOn.Thetransmissionrange
Indicator indicatorat theshiftershouldilluminateuntilcommandedOff.
The BCM activatesthetrunklampwhenyouselectOn. The valueshouldbe 100%.Thetrunklamp
TrunkLampCommand shouldilluminateuntilcommandedOff.
WindshieldWasher The BCM actuatesthewindshieldwasherrelaywhenyouselectOn.Thewindshieldwasherrelay
RelayCommand shouldturnon.

(US/Canada)
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2013 (5377994)
Manual
Service
 Vehicle Diagnostic Information 6=27

Body Control Module Scan Tool Output Controls (cont'd)

Scan Tool Output
Control Description
WindshieldWiperHigh The BCM actuatesthewindshieldwiperhighspeedrelaywhenyouselectOn.Thewindshieldwiper
Speed RelayCommand highspeedrelayshouldturnon.
WindshieldWiperMotor The BCM actuatesthewindshieldwipermotorrelaywhenyou selectOn.Thewindshieldwipermotor
RelayCommand relayshouldturnon.

Communication Interface Module Scan Tool Information

Telematics Communication Interface Control Module Scan Tool Data Parameters

Parameter | System State I ExpectedValue l Description
OperatingConditions: IgnitionON
GPS Data
DeadReckoningCalibration Calibratedor
Status —— CalibratedNot Indicates
I I calibration
thedeadreckonIng . . status.

Indicatesthemethodusedtodeterminecurrent
.. I . Method
PosmonCalibration __ . location.(0)GPS, (1)WheelSpeedDeadReckoning
VarIes only,(2)CombinedWheelSpeedandGPS, (3)Gyro
only,(4)CombinedGyroandGPS, (5)No Fix
Month — MM This displaysthecurrentmonth.
Day — DD This displaysthecurrentdayofthemonth.
Year — YY This displaysthecurrentyear.
Hour _ HH This displaystheGPS currenthour(24hourformat
—GMT).
Minute — MM This displaystheGPS currentminute.
Second — SS This displaystheGPS currentsecond.
. ‘ The scan tooldisplaysYes or No.Yes is displayedif
GPS Signal — Varies thereis a GPS signalreceivedby thetelematics
communicationinterfacecontrolmodule.
Signal StrengthData
CurrentTransceiver _ Varies The scan tooldisplaysa 2—5digitvalue.This is the
Identifier . transceiveridentificationnumber.
. ’ The scan tooldisplays0—127.This is thetelematics
GSM SignalStrength — Varies communicationinterfacecontrolmodulesignal
strength.
I II This is thesignaltypereceivedby thetelematics
SIgnaIType _ D'g'tal communicationinterfacecontrolmodule.
Bluetooth Data
Bluetooth — Enabled Indicatesif theBluetoothsystemis enabledor
disabled.
. Indicatesthecurrentlinkstatus.(0)Unconnected,(1)
BluetoothLinkStatus — Varies Connected/Idle,(2)Call active,(3)3-waycalling
acfive
BluetoothLinkQuality _ Varies The scan tooldisplaysa decimalvaluebetween0
and255.
BluetoothPhoneto . .
TelematicsCommunication A t' I t' Displays'thet'bluetfeth
phontattolteleénatlcs
th t' t'
InterfaceControlModule — c weor nac Ive c?mmumcaIonIne ace con r0 mo u e au en IcaIon
AuthenticationStatus Sa ”3‘
BluetoothPhoneto
TelematicsCommunication . . Displaysthebluetoothphonetotelematics
InterfaceControlModule ‘7 Activeor InactIve communicationinterfacecontrolmodulestatus.
CommunicationStatus
BluetoothPhoneVoice . . Displaysthebluetoothphonetovoicerecognition
RecognitionStatus “— Acme or Inactive status.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
6-28 Vehicle Diafignostic Information

Telematics Communication Interface Control Module Scan Tool Output Controls

OutputControl Description
This showsthedatarecordedwhenDTC B1000was set inthetelematicscommunication
B1000Information interfacecontrolmodule.
The telematicscommunicationinterfacecontrolmoduleilluminatesthegreenLED whenON
GreenIndicator is selected.
WhenON is selected,telematicscommunicationinterfacecontrolmoduiecommands
PhoneCall Test OnStarto connecttotheOnStarCenter.
The telematicscommunicationinterfacecontrolmoduleilluminatestheredLED whenON is
Red Indicator selected.
The telematicscommunicationinterfacecontrolmoduleperformsa preferredroaminglist
PreferredRoamingList Update (PRL) updatewhenthisis selected.
RemoteVehicleSpeed Limiting This functionresetsthespeedlimitingfeature.
Reset

Driver Seat and Passenger Seat Heater Control Module Scan Tool Information

Front Seat Heating Control Module Scan Tool Data Parameters

Parameter Expected Value I Description
OperatingConditions: EngineRunning
Thescan tooldisplaysInactiveorActive.This parameter
DriverSeatCushionHeating
Command Inactive displaysthecommandedoutputfromtheseat heatingcontrol
moduletotheseat heaterelements.
Thescan tooldisplays0 —5V. Thevoltagedisplayedis an input
. . _ totheseatheatingcontrolmodulefromtheseatcushion
ggxggrSeatCushionTemperature Varies temperaturesensor.Highervoltagereadingsindicatecoolerseat
temperatureswhilelowervoltagereadingsindicatewarmerseat
temperatures.
The scantooIdisplaysOff,HighMedium,or Low.Whenthe
DriverSeat HeatingNenting/ Off heatedseat is active,thisparameterdisplaystheselected
CoolingLevel temperaturesetting.
DriverSeat Heating/Venting/ Off ThescantooldisplaysOffor Back& CushionHeat.This
CoolingMode parameterindicatestheheatedseatmodeofoperation.
Thescan tooldisplaysInactiveorActive.This parameter
PassengerSeat CushionHeating
Command Inactive displaysthecommandedoutputfromtheseat heatingcontrol
moduletotheseatheaterelements.
Thescan tooldisplays0 —5V. Thevoltagedisplayedis an input
. totheseatheatingcontrolmodulefromtheseatcushion
?:?:?gfurrggaénggihlon Varies temperaturesensor.Highervoltagereadingsindicatecoolerseat
p temperatureswhilelowervoltagereadingsindicatewarmerseat
temperatures.
. . The scantooldisplaysOff,HighMedium,or Low.Whenthe
Egfifingfgvifat HeatIngNentIng/ Off heatedseat is active,thisparameterdisplaystheselected
9 temperaturesetting.
PassengerSeat Heating/Venting/ .Off ThescantooldisplaysOffor Back& CushionHeat.This
CoolingMode parameterindicatestheheatedseatmodeof operation.

Front Seat Heating Control Module Scan Tool Output Controls

ControIFunctions Description
OperatingConditions: EngineRunning
DriverSeat CushionHeating This outputcontrolis usedto commandthedriverseatheaterelementsOn.
PassengerSeat CushionHeating This outputcontrolis usedto commandthepassengerseatheaterelementsOn.

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
 Vehicle DLagEIstic Information 629

Electronic Brake Control Module

Scan Tool Information (Without FX3)
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 Parameter

Expected
System State Value Description
Parameter
OperatingConditions:lgnitionON
-— 0V The scan tooldisplaysthepumpmotorvoltage.
ABS PumpMotorVoltage
I I __ The scan tooldisplaysOK or Malfunction.
OK Malfunctionis displayedwhenthe ABS is defective.
Ant'IOCkBrakingSystem
Panic Brake The scan tooldisplaysOK whenthe brakefluid is at
I _ thebrake fluidis low.
Assist Status correctlevel and Lowwhen
BrakeF'U'dLevelSensor
I. Brakepedal released Inactive The scan tooldisplaysInactiveor Active depending
Active on thestateofthe brakepedal.
BrakePedal PosmonSensor Brakepedalappiied
Brakepedal released 0‘1 V The scan tooldisplays0—5V dependingon the
Brakepedalapplied 1_5V appliedhydraulicbrakepressure.
Brake PressureSensor
. . . The scan tooldisplaysOK or Malfunction.
—— OK Malfunctionis dISpIayedwhenthe dynamicrear
gaggle Rear Proportioning proportioningsystemis defective.
. The scantool displaysInactiveorActive.Activeis
33:2: Olem'd — Inactive displayedwhenthe leftfrontinletsolenoidvalveis
0211/2132; commandedON.
The scan tooldisplaysInactiveor Active.Activeis
Solenoid — Inactive displayedwhenthe leftfrontoutletsolenoidvalveis
bgflzrlggegbuatfkt commandedON.
_ ‘0km/h The scantooldisplayskm/hdependingon the
LeftFrontWheelSpeed currentspeedof theleftfrontwheelspeed sensor.
Sensor
. The scan tooldisplaysInactiveorActive.Activeis
\L/Ztit/Egaéreléiéztciolenmd —— Inactive displayedwhenthe leftrearinletsolenoidvalve is
commandedON.
I The scan tooldisplaysInactiveor Active.Activeis
SolenOId —— Inactive displayedwhenthe leftrearoutletsolenoidvalveis
02135122228135; commandedON.
__ 0 km/h The scan tooldisplayskmlhdependingonthe
LeftRear WheelSpeed currentspeed oftheleftrearwheel speedsensor.
Sensor
The scan tooldisplaysOK or Malfunction.
—— OK Malfunctionis displayedwhenthe panicbrakeassist
Panic BrakeAssist Status systemis defective.
I The scan tooldisplays Inactiveor Active.Activeis
PumpMotorRelay Feedback — InactIve displayedwhenthe pumpmotoris commandedON.

I I The scantooldisplaysInactiveor Active.Activeis

. Inactive displayedwhenthe isolationsolenoidvalveis
ngggelgglbaafknSolenOId #
. commandedON.
I I The scantooldisplaysInactiveor Active.Activeis
I Inactive displayedwhenthe primesolenoidvalveis
sgwgrgezgggcfimeno'd —
commandedON.
I The scan tooldisplaysInactiveor Active.Activeis
I Inactive displayedwhenthe rightfrontinletsolenoidvalve is
SoIenoud
$33; Eggégglgl: —
commandedON.
I The scantooldisplaysInactiveorActive.Activeis
I Inactive displayedwhenthe rightfrontoutletsolenoidvalveis
5:13;iggétgtét‘tetSOIenO'd —
commandedON.
__ 0 km/h The scan tooldisplayskm/hdependingon the
RightFrontWheelSpeed currentspeedof therightfrontwheelspeed sensor.
Sensor

—
2013 (US/Canada)
Sonic (5377994)
Manual
Service
6=30 Vehicle Diagnostic Information

Electronic Brake Control Module Scan Tool Data Parameter (cont'd)

Expected
Parameter System State Value Description
. . The scantooldisplaysInactiveor Active.Activeis
R'ghtRear InletSolenOId —— Inactive displayedwhentherightrearinIetsolenoidvalveis
VaIveFeedback commandedON
. . ThescantooldisplaysInactiveor Active.Activeis
R'ghtRearOutletSoIenOId — Inactive displayedwhentherightrearoutletsolenoidvalveis
ValveFeedback commandedON
RightRearWheelSpeed _ 0 km/h ThescantooldispIayskmlhdependingon the
Sensor currentspeedoftherightrearwheelspeedsensor.
. ThescantooldisplaysInactiveor Active.Activeis
secondary'So'at‘c’” — Inactive displayedwhentheisolationsolenoidvalveis
SolenOIdValve Feedback commandedON
. . ThescantooldisplaysInactiveor Active.Activeis
SecondaryPrimeSolenOId — Inactive displayedwhentheprimesolenoidvalveis
ValveFeedback commandedON
. . Thescantooldis Ia °.This is thecurrent osition
SteeringWheelAngle — Varies ofthesteeringangleyssensor. p
SystemVoltage _ 1144 V Tgliteasgian
tooldIsplaysV. ThIsIsthecurrentbattery

TractionControlSystem
VehicleStability
EnhancementSystemRelay
Feedback
. ..
\éfipigrliigrfgnltltéystem
Switch
VehicleStabilitySystem
ThescantooldisplaysOK or Malfunction.
— OK Malfunctionis displayedwhenthetractioncontrol
systemis defective.
_ . I I or Activedependmg
The scantooldIsplaysInactIve - -
Inactive onthestateofthestabilitycontrol.
Tractioncontrolswitch Active
released The scantooldisplaysActiveor Inactivedepending
Tractioncontrolswitch Inactive . onthestatusoftheTCS/ESC SWItch.
pressed
The scantooldisplaysOK or Malfunction.
— OK Malfunctionis displayedwhenthevehiclestability
enhancementsystemis defective.

Electronic Brake Control Module Scan Tool Output Controls

OutputControl
ABS PumpMotor
FrontTractionControlIsolationValve
FrontTractionControlPrimeValve
LeftFrontABS SolenoidValves
' LeftRearABS SolenoidValves
RearTractionControlIsolationValve
RearTractionControlPrimeValve
RightFrontABS SolenoidValves
RightRearABS SolenoidValves
Description
CommandstheABS pumpmotorIncreaseor Decrease.
CommandsthesolenoidvalveON or OFF.
CommandsthesolenoidvalveON or OFF.
CommandsthesolenoidvalvesON or OFF.
CommandsthesolenoidvalvesON or OFF.
CommandsthesolenoidvalveON or OFF.
CommandsthesolenoidvalveON or OFF.
CommandsthesolenoidvalvesON or OFF.
CommandsthesolenoidvalvesON or OFF.

Electronic Brake Control Module

Scan Tool Information (With FX3)
The Electronic Brake Control Module 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.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Vehicle Diagnostic Information 6=3l

Electronic Brake Control Module Scan Tool Data Parameter

Parameter
OperatingConditions:IgnitionON
AccelerationPedal Position
Signal ReceivedfromECM
ABS PumpMotorVoltage
AntilockBrakingSystem
. ThescantooldisplaysOK whenthebrakefluidis at
BrakeF|u1dLevelSensor
I.
BrakePedal PosmonSensor
Expected
System State Value Description
_
_ Invalid The scantooldisplaysInvalidorValiddependingon
theacceleratorpedalsignalreceivedfromthe ECM.
—— OV Thescantooldisplaysthepumpmotorvoltage.
ThescantooldisplaysOK or Malfunction.
— OK Malfunctionis displayedwhentheABS detectsa
fault.
_ OK correctleveland Lowwhenthebrakefluidis low.
Brakepedalreleased Inactive ThescantooldisplaysInactiveorActivedepending
Brakepedalapplied Active onthestateofthebrakepedal.

. Brakepedalreleased 0‘1 V Thescantooldisplays0—5V dependingon the

Brake PressureSensor
Brake Switch,Traction
ControlSwitchSignal
ReceivedFromBodyControl
Module
_ I . .
géflfig‘lc RearProportIonIng
LateralAcceleration
. ThescantooldisplaysInactiveorActive.Activeis
bgfigrggéclirgggfolenmd
. ThescantooldisplaysInactiveorActive.Activeis
LeftFrontOutletSolenotd
VaIVeFeedback
LeftFrontWheelSpeed
Sensor
LeftRear InletSolenoid
ValveFeedback
Brakepedalapplied 1_5V appliedhydraulicbrakepressure.
_ Invalid Thescan tooldisplaysInvalidor Validdependingon
thesignalreceivedfromtheBCM.
ThescantooldisplaysOK or Malfunction.
— OK Malfunctionis displayedwhenthedynamicrear
proportioningsystemis defective.
Thescantooldisplaysm/sz.This is thecurrentrate
— Varies ofthevehicleaccelerationor decelerationas
reportedby thelateralaccelerometersensor.
— Inactive displayedwhentheleftfrontinletsolenoidvalveis
commandedON.
— Inactive displayedwhentheleftfrontoutletsolenoidvalveis
commandedON.
Thescantooldisplayskm/hr(MPH)dependingon
0 km/h(MPH) thecurrentspeedoftheleftfrontwheelspeed
senson
ThescantooldisplaysInactiveorActive.Activeis
— Inactive displayedwhentheleftrearinletsolenoidvalveis
commandedON.

I ThescantooldisplaysInactiveorActive.Activeis
LeftRearOutletSolenOId - Inactive displayedwhentheleftrearoutletsolenoidvalveis
ValveFeedback commandedON.
Thescantooldisplayskm/h(MPH)dependingon
LeftRearWheelSpeed 0 km/h(MPH) thecurrentspeedof theleftrearwheelspeed
Sensor senson
Thescantooldisplaysm/sz.This is thecurrentrate
LongitudinalAcceleration — Varies ofthevehicleaccelerationor decelerationas
reportedbythelongitudinalaccelerometersensor.
ThescantooldisplaysOK or Malfunction.
Panic BrakeAssist Status —— OK Malfunctionis displayedwhenthepanicbrakeassist
systemis defective.
I Thescan tooldisplaysInactiveorActive.Activeis
PumpMotorRelayFeedback — InactIve displayedwhenthepumpmotoris commandedON.
. . . ThescantooldisplaysInactiveorActive.Activeis
SolenOId
521?:gelgghaagkn — Inactive displayedwhentheisolationsolenoidvalveis
commandedON.
I I I ThescantooldisplaysInactiveorActive.Activeis
Primaryane SolenOId — Inactive displayedwhentheprimesolenoidvalveis
ValveFeedback commandedON.

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
 Vehicle Diagnostic Information

Electronic Brake Control Module Scan Tool Data Parameter (cont'd)

Parameter
. .
R'ghtFrontInletSolenOId
ValveFeedback
. .
R'ghtFrontOutletSOIenO'd
ValveFeedback
. The scan tooldisplayskm/hr(MPH)dependingon
E'ght FrontWheelSpeed
ensor
. .
R'ghtRear InletSolenOId
ValveFeedback
. I
R'ghtRear OutletSOIenO'd
ValveFeedback
. The scantooldisplayskmlh(MPH)dependingon
E'ght RearWheelSpeed
ensor
SecondaryIsolation
SolenoidValveFeedback
Expected
System State Value Description
The scan tooldisplaysInactiveorActive.Activeis
— Inactive displayedwhentherightfrontinletsolenoidvalveis
commandedON
The scantooldisplaysInactiveor Active.Activeis
— Inactive displayedwhentherightfrontoutletsolenoidvalveis
commandedON
— 0 km/h(MPH) thecurrentspeedoftherightfrontwheelspeed
sensor.
The scan tooldisplaysInactiveorActive.Activeis
— Inactive displayedwhentherightrearinletsolenoidvalveis
commandedON
The scan tooldisplaysInactiveorActive.Activeis
— Inactive displayedwhentherightrearoutletsolenoidvalveis
commandedON.
—- 0 kmlh(MPH) thecurrentspeedoftherightrearwheelspeed,
sensor.
' The scan tooldisplaysInactiveorActive.Activeis
— Inactive gifmfiégjhghthe IsolationsolenOIdvalveIs

. . The scan tooldisplaysInactiveorActive.Activeis

SecondaryPrimeSOIenO'd — Inactive displayedwhentheprimesolenoidvalveis
ValveFeedback commandedON
. . The scan tooldisplays°.This is thecurrentposition
SteeringWheelAngle 7' VarIes ofthesteeringanglesensor.
. ~ The scantooldisplaysOK or Malfunction.
Angle
gteeringCWhteel — OK Malfunctionis displayedwhenthesteeringangle
ensor en erIng sensorcenterpositionis notlearned.
SystemVoltage _ 1144V tooldisplaysV. ThIsISthecurrentbattery
Igleasggan

, The scantooldisplaysOK or Malfunction.

TractionControlSystem — OK Malfunctionis displayedwhenthetractioncontrol
systemdetectsa fault.
. . . The scantooldisplaysInactiveorActivedepending
TractionControlSWItCh _ Inactive onthestateofthetractioncontrolswitch. _
TorqueSignalReceived _ Invalid The scan tooldisplaysInvalidor Validdependingon
FromECM thetorquesignalreceivedfromtheECM.
TorqueSignal Received _ Invalid The scan tooldisplaysInvalidorValiddependingon
FromTCM thetorquesignalreceivedfromtheTCM.
VehicleStability . I
The scantooldIsplaysInactIve I I
I orActivedepending
EnhancementSystemRelay _ InactIve on thestateofthestabilitycontrol.
Feedback
Tractioncontrolswitch .
InactIve
- '' released
Stab'lt'tgstem
\E/elplicle . . The scan tooldisplaysActiveor Inactivedepending
n .anc men y TractionCOHtFOISWltCh , onthestatusofthevehiclestabilitycontrolswitch.
SW'tCh pressedand heldfor Active
fiveseconds.
The scan tooldisplaysOK or Malfunction.
VehicleStabilitySystem — OK Malfunctionis displayedWhenthevehiclestability
enhancementsystemis defective.
Yaw RateSignal __ Varies ThIsdIsplays /sec.The scantooldisplaystheSignal
receivedfromtheyawratesensor.

(US/Canada)
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2013 (5377994)
Manual
Service
 Vehicle Diagnostic Information 633

Electronic Brake Control Module Scan Tool Output Controls

Output Control Description

ABS PumpMotor
AutomatedBrakeBleed
TractionControlLeftFrontSolenoidValves
TractionControlLeftRear SolenoidValves
TractionControlRightFrontSolenoidValves
TractionControlRightRear SolenoidValves
ABS LeftFrontSolenoidValves
ABS LeftRear SolenoidValves
ABS RightFrontSolenoidValves
ABS RightRear SolenoidValves
CommandstheABS pumpmotorIncreaseor Decrease.
This is usedin orderto bleedtheABS hydraulics.
Commandsthe solenoidvalve ON orOFF.
Commandsthe solenoidvalve ON or OFF.
Commandsthe solenoidvalves ON or OFF.
Commandsthe solenoidvalves ON or OFF.
Commandsthe solenoidvalve ON or OFF.
Commandsthe solenoidvalve ON or OFF.
Commandsthe solenoidvalves ON or OFF.
Commandsthe solenoidvalves ON or OFF.

Tool The scan tool values from a properly running engine

Engine Control Module Scan
may be used for comparison with the engine you are
Information diagnosing. The Engine Scan Tool Data List represents
values that may be seen on a normally running engine.
The Engine Control Module Scan Tool Data List
contains all engine related parameters that are Note: A scan tool that displays faulty data should not
available on the scan tool. The list is arranged in be used. The scan tool concern should be reported to
alphabetical order. A given parameter may appear in the manufacturer. Use of a faulty scan tool can result in
any one of the data lists, and in some cases may misdiagnosis and unnecessary parts replacement.
appear more than once, or in more than one data list in Only the parameters listed below are referenced in this
order to group certain related parameters together. service manual for use in diagnosis. Ifall values are
Use the Engine Scan Tool Data List only after the within the typical range described below, refer to
following is determined: Symptoms - Engine Controls on page 9-511 for engine
. The Diagnostic System Check - Vehicle on diagnosis.
page 6-66 is completed.
- No diagnostic trouble codes (DTCs) are set.
- On-board diagnostics are functioning properly.
Engine Control Module Scan Tool Data Parameters
Parameter I System State I Expected Value I Description
or NeutraI/Closed
Hose Hot/ClosedThrottIe/Park L oop/AccessoriesOff/Brake
Operating Conditions: EngineIdling/Radiator
Pedal Released
This parameterdisplaysthe voltagesensed
on the5V referencecircuitsat thecontrol
5Volt
2, or 3
Reference1, lgnitionON 5V module.The scantoolwill displaya higher
valueat highervoltage.The scan toolwill
displaya lowervalue at lowervoltage.
This parameterdisplaysOK if thereis no5 V
5Volt Reference1, 2, referencecircuitcondition.Ifthecircuitis
or 3 CircuitStatus IgnitionON OK shortedto groundor shortedto 8+,Faultis
displayed.
A/C OFF V*
0.75—1.5 This parameterdisplaysthe voltagefromthe
A/C highside pressuresensorsignalcircuitto
A/C HighSide Pressure thecontrol module.
Sensor NO ON 1.3—2.5V*
*Varieswithtemperatureandrelativehumidity.
450—650kPa*(65- This parameterdisplaysthe pressurefromthe
. . A/C OFF 95(PSI)* A/C highside pressuresensor signalcircuitto
A/C HighSide Pressure thecontrolmodule.
1117—2350kPa*(162— . _
Sensor EngineSpeed at
2 000RPM 341PSI)* *Varieswithtemperatureandrelativehumidity.
This parameterdisplayswhetherthecontrol
A/C OffforWOT A/C ON No moduleis commandingtheA/C compressor
ClutchrelayOFF forwide openthrottle(WOT).
I This parameterdisplayswhethertheNC
NC DisableNC NO ON No pressureis outofrangefornormaloperation
PressureOutof Range as determinedby thecontrolmodule.

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6=34 Vehicle Diagnostic Information

Engine Control Module Scan Tool Data Parameters (cont'd)

Parameter System State Expected Value Description
This parameterdisplaysthestateoftheair
é“? C?DrgflquSSé
CIUtCh NO ON On conditioning(A/C)ciutchrelaycontrolcircuit
e ay as commandedby thecontrolmodule.
This parameterdisplaysthestateoftheA/C
. requestinputtothecontrolmodulefromthe
A/C RequestSignal NO ON Yes heating,ventilation,andair conditioning
(HVAC)controls.
Acceleratorpedal”0t 0% This parameterdisplaystheangleofthe
AcceleratorPedal actuated acceleratorpedalposition(APP) as calculated
Position Accelerator edalfull bythecontrolmoduleusingthesignalsfrom
actuated p y 100% theAPP sensors.
This parameterdisplaystheratioofairtofuel
as calculatedby thecontrolmodulebasedon
varioussensorinputs.Thescantoolwill
. . displaya lowerairfuelratiowhena richerair
éIr/tfuglEquwacljence — Varies tofuelmixtureis commanded.Thescan tool
a '0 omman willdisplaya higherairfuelratiowhena
leanerairtofuelmixtureis commanded.In
closedloopoperationtheairfueIratioshould
normallybe approximately14.7:1.
Acceleratorpedal“0t 0.88—1.08
V This parameterdisplaystheactualvoltageon
APP Sensor1 actuated theacceleratorpedalposition(APP)Sensor1
Acceleratorpedalfully 4 17—437V signalcircuitas measuredbythecontrol
actuated ' ’ module. .
Acceleratorpedal“0t 0.39—0.59V This parameterdisplaystheactualvoltageon
APP Sensor2 actuated theacceleratorpedalposition(APP)Sensor2
Acceleratorpedalfully 2 02—222V signalcircuitas measuredbythecontrol
actuated ' ' moduie.
This parameterdisplaysthebarometric
BARO _ 65—104kPa (8—16PSI) pressure(BARO).The controlmoduleuses
Varieswithaltitude thebarometricpressuresensorinputforfuel
controltocompensateforaltitudedifferences.
ControlModuleVoltage This parameterdisplaysthestateofthe
B+ ignitionsystemvoltageavailableatthecontrol
Signal module.
This parameterdisplaysthecommandedstate
ofthecoolingfan relay1 controlcircuit.The
CoolingFan Relay 1 coolingfan relay1 shouldbeON whenthe
Varies scantoolindicatesthefancontrolrelay1
Command commandis ON. The coolingfan relay1
shouldbe OFF whenthescan toolindicates
thefancontrolRelay1 Commandis OFF.
This parameterdisplaysthecommandedstate
ofthecoolingfan relay2 controlcircuit.The
coolingfan relay2 shouldbe ON whenthe
CoolingFan Relay2 Varies scan toolindicatesthefancontrolRelay2
Command commandis ON.The coolingfan relay2
shouldbeOFF whenthescantoolindicates
thefan controlRelay2 commandis OFF.
This parameterdisplaysthecommandedstate
ofthecoolingfan relay3 controlcircuit.The
CoolingFan Relay3 coolingfan relay3 shouldbeON whenthe
Command Varies scan toolindicatesthefancontrolRelay3
commandis ON. The coolingfanrelay3
shouldbeOFF whenthescantoolindicates
thefancontrolRelay3 commandis OFF.
This parameterdisplaysthepositionlearned
CPP LearnedApply fortheclutchpedalposition(CPP)sensor
Position whentheclutchpedalis fullyappliedduring
theassociatedlearnprocedure.
This parameterdisplaysthepositionlearned
CPP LearnedRelease fortheclutchpedalpositionsensorwhenthe
Position clutchpedalis released.

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Engine Control Module Scan Tool Data Parameters (cont'd)

Parameter System State Expected Value Description
This parameterdisplaysthedisplacementof
theclutchpedal(correctedand normalized
baseduponits learnedreleasedandfully
CPP Sensor Varies appliedpositions),where0%correspondsto
theclutchpedalbeingreleasedand 100%
correspondstotheclutchpedalbeingfully
applied.
This parameterdisplaystheclutchpedal
CPP Sensor Varies positionsensoranaloginputas a percentage
of its referencevoltage.
Transmissionin Parkor DisplaysUnknown,1,2, 3,4, 5, or 6.This
CurrentGear Neutral 1—6 parameterindicatesthecurrentcommanded
gearposition.
DesiredECT Varies This parameterdisplaysthedesiredengine
coolanttemperature(ECT)in degrees.
This parameterdisplaysthedesiredengine
DesiredIdleSpeed 600—950RPM idlespeed as commandedby thecontrol
module.
This parameterdisplaysthedesiredthrottle
DesiredThrottlePosition 2—6% positionanglecommandedby thecontrol
module.
This parameterdisplaysthedistance
DistanceSince DTC accumulatedsincean emissiondiagnostic
Cleared Varies troublecodewas cleared.The scantoolwill
displayincreasingdistanceas thevehicleis
driven.
DistanceSince Last This parameterdisplaysthedistance
Malfunction Varies accumulatedwhentheemissiondiagnostic
troublecode lastfailed.
This parameterdisplaysthedistance
DistanceThis Driving accumulatedsincean emissiondiagnostic
Cycle Varies troublecodewas cleared.The scan toolwill
displayincreasingdistanceas thevehicleis
driven.
-39 to +140°C(-38 to This parameterdisplaysthetemperatureof
_ +284°F theenginecoolantbasedon inputtothe
ECT Sensor1 . ) controlmodulefromtheenginecoolant
Varies temperature(ECT)sensor1.
-39 to +140°C(—38to This parameterdisplaysthetemperatureof
ECT Sensor2 _ +284°F) theradiatorcoolantbasedon inputtothe
controlmodulefromtheradiatorcoolant
Varies temperature(ECT)sensor2.
. .. This parameterdisplaysthevoltageavailable
EngineControlslgnItIon — B+ at theenginecontrolignitionrelaypinofthe
RelayFeedbackSignal
controlmodule.
-39 to +140°c(—38to This parameterdisplaysthetemperatureof
EngineCoolant +284°F) theenginecoolantbasedon inputtothe
Temperature controlmodulefromtheenginecoolant
Varies temperature(ECT)sensor1.
?RSIrmeogtg?lfigtater _ 0—1000/ This parameterdisplaysthecommandedduty
Command ° cyclefortheenginecoolantthermostat.
. . 11—20%
EngineIdlIng Varies This parameterdisplaysthecalculatedengine
EngineLoad E d loadin percentbasedon inputstothecontrol
nginespee at modulefromvariousenginesensors.
2500RPM 254%
This parameterdisplaysif thelevelofthe
EngineOil LevelSwitch _ OK engineoil is withinrangeas determinedbythe
controlmodulefrominformationreceivedfrom
theengineoil levelswitch.

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Engine Control Module Scan Tool Data Parameters (cont'd)

Parameter System State Expected Value Description
This parameterdisplaysthestateofthe
engineoil pressureas determinedby the
controlmodule.The controlmodulemonitors
EngineOil Pressure OK theengineoil pressureswitchtodetermineif
Switch theengineoil pressureis sufficient.Thescan
tooldisplaysLowwhenthe engineoil
pressureis belowa predetermined value.
This parameterdisplaysthetimeelapsed
since theenginewas started.Thescan tool
EngineRunTime EngineOperating Varies willdisplaythetimein hours,minutesand
seconds.The engineruntimewillresetto
zerowhentheenginestopsrunning.
EngineCranking Greaterthan60 RPM This parameterdisplaysthespeedofthe
EngineSpeed Approximately650- enginecrankshaftrotationfrominformation
EngineIdling 950RPM receivedfromthecrankshaftpositionsensor.
This parameterdisplaystheon—time orduty
cycleof theevaporativeemission(EVAP)
EVAP PurgeSolenoid canisterpurgesolenoidcommandedbythe
10—20% controlmodule.Zeropercentindicatesno
ValveCommand
purge.One hundredpercentindicatesfull
purge.
ExhaustCamshaft EngineIdling 0—255 This parameterdisplaysan incrementing
PositionActiveCounter counterwhenthecontrolmodulereceivesa
signalfromtheexhaustcamshaft
position(CMP)sensor.
This parameterdisplaysthecommandedduty
ExhaustCamshaft 45—75% cyclefortheexhaustcamshaftas
PositionCommand commandedby thecontrolmodule.
This parameterdisplaystheapproximatefuel
levelin thefueltankas a voltage.The control
modulecalculatesthislevelusingthe signal
fromthesensorusedto monitorthefuelinthe
Fuel LevelSensor Varies tank.The scantoolwilldisplaya lowreading
whenthefuellevel inthetankis nearempty.
The scantoolwilldisplaya highreadingwhen
thefuellevelin thetankis highor nearfull.
IgnitionON, engineOFF Fuelpumponfor2 s This parameterdisplaysthecontrolmodules
Fuel PumpRelay commandedstateofthefuelpumprelay
Command Engineidling On controlcircuit.
This parameterdisplaysthepressure/vacuum
FuelTankPressure insidethefueltank.A negativevalueindicates
0.00inch a vacuum,whilea positivevalueindicatesa
Sensor
pressure.
This parameterdisplaysthevoltagesignal
FuelTankPressure 1.3—1.7V receivedby thecontrolmodulefromthefuel
Sensor tankpressuresensor.
This parameterindicatesthegeneratorfield
dutycycle as commandedbythevoltage
regulatoror controlmodule.Thescantoolwill
GeneratorF-Terminal 40—70% displaya highervaluefora higher
Signal commandedgeneratoroutput,anda lower
valuefora lowercommandedgenerator
output.
IgnitionON, EngineOFF 50—900mV This parameterindicatestheheatedoxygen
sensor(H028) sensor1 or 2, outputvoltage
as measuredbythecontrolmodule.Thescan
H0281 or H028 2 toolwilldisplaya highervalueduringa rich
EngineOperating Varies
condition,anda lowervalueduringa lean
condition.
This parameterdisplaystheamperageofthe
H028 HeaterSensor1 0.42—0.62
A H028 heatercommandedbythecontrol
or 2 module.

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 Vehicle Diagnostic Information 6437

Engine Control Module Scan Tool Data Parameters (cont'd)

Parameter System State Expected Value Description
This parameterdisplaysthecommandedstate
of theH028 1 or H028 2 heaterbythe
H028 1 or H028 2 controlmodule.The scan toolwilldisplaya
HeaterCommand 0—99% highervalueas theheatercommandis
increased,anda lowervalueif theheateris
notcommandedON.
This parameterdisplaysthetemperatureof
IATSensor —39to+140°C( -38 to theair enteringtheair inductionsystembased
+284°F) on inputtothecontrolmodulefromtheintake
air temperature(IAT)sensor.
This parameterdisplaysthevoltage
IATSensor 0—5V calculatedbythecontrolmodulefromthe
intakeairtemperaturesensor.
IgnitionAccessory This parameterdisplaysthestateofthe
Signal ON ignitionaccessorypositioninputtothecontrol
modulefromtheignitionswitch.
This parameterdisplaysactivewhenthe
IgnitionSwitchStatus Active ignitionswitchis supplyingbatteryvoltageto
thecontrolmoduleignitioncircuit.
IntakeCamshaft This parameterdisplaysthecommandedduty
PositionCommand 45—75% cyclefortheintakecamshaftas commanded
by thecontrolmodule.
IntakeManifoldTuning This parameterdisplaysthestateoftheintake
ControlValveControl Off manifoldtuningvalvesolenoidcontrolcircuit
CircuitCommand as commandedby thecontrolmodule.
This parameterdisplaysthecommandedLong
LongTermFuelTrim -5 to +5% TermFuelTrimcorrectionbythecontrol
module.
This parameterdisplaysthepressurefromthe
MAP Sensor 26—52kPa manifoldabsolutepressure(MAP)sensorto
thecontrolmodule.
MAP Sensor 0.98—1.42
V This parameterdisplaysthesignalvoltage
fromtheMAP sensortothecontrolmodule.
Park/NeutralPosition This parameterdisplaysthepositionofthe
Switch Park/Neutral transmissionselectionas Park/Neutralor
in gear.
This parameterdisplaysthestatusofthe
operatingmodeof thecontrolmoduleusedto
ReducedEnginePower Inactive reduceenginepowerto preventcatalystor
enginedamageor dueto anaffectedthrottle
actuatorcontrol(TAC)system.
This parameterdisplaystheamountoffuel
remainingin thefueltankas measuredin
percentage.Thecontrolmoduledetermines
0—100% theamountoffuelremainingin thetankby
RemainingFuel inTank
Varies usinginformationfromthefuellevelsensors.
The scan toolwilldisplaya highervaluewitha
fullfueltank,anda lowervaluewithan empty
fueltank.
ManualTransmissionReverseSwitchON
ReversePositionSwitch OFF indicatesthatthereverseswitchhardwire
inputtotheECM is active.
This parameterdisplaystheshortterm
correctionto thefueldeliverybythecontrol
modulein responseto oxygensensor.Ifthe
oxygensensorindicatesa leanair/fuel
ShortTermFuelTrim -5 to +5% mixture,thecontrolmodulewilladdfuel
increasingtheshorttermfueltrimabove0.
Iftheoxygensensorindicatesa richair/fuel
mixture,thecontrolmodulewillreducefuel
decreasingtheshorttermfueltrimbelow0.

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Engine Control Module Scan Tool Data Parameters (cont'd)

Parameter System State Expected Value Description
The scan tooldisplaysON or OFF.The scan
StarterRelayCommand OFF tooldisplaysOFF untiltheignitionis placed
intotheCRANK position.
This parameterindicatesthestatusofTAC
controlbythecontrolmodule.Thescan tool
TAC ForcedEngine willdisplayYES if theenginehasbeenshut
Shutdown NO
downdue toa throttlecontrolfault.Thescan
toolwilldisplayNO if theenginehasnotbeen
shutdownby a throttlecontrolfault.
This parameterindicatesthestatusoftheTAC
motordriverbytheECM. The scantoolwill
TAC Motor Enabled displayEnabledif TAC motoroperationis
allowed.The scantoolwilldisplaydisabledif
theTAC motoris disabled.
0—100% This parameterdisplaysthepercentageof the
TAC MotorCommand commandedstateoftheTAC motorbythe
Varies controlmodule.
This parameterdisplaystheactualthrottle
ThrottlePosition 2—6% positionangleindicatedbythe controlmodule
usinginformationfromthetwothrottleposition
sensors.
Acceleratorpedalnot This parameterdisplaysthevoltagesignal
actuated 4.14—4.34V
senttothecontrolmodulefromthrottle
ThrottlePosition positionsensor1 ofthethrottleassembly.The
Sensor 1 throttlepositionsensor1 is a rangeofvalues
Acceleratorpedalfully indicatinga highvoltagewhenthethrottleis
actuated 3.50—3.37V
closedto a lowvoltagewhenthethrottleplate
is fullyopen.
Acceleratorpedalnot This parameterdisplaysthevoItagesignal
actuated 0.68—0.88V
senttothecontrolmodulefromthrottle
ThrottlePosition positionsensor2 ofthethrottleassembly.The
Sensor2 throttlepositionsensor2 is a rangeofvalues
Acceleratorpedalfully indicatinga lowvoltagewhenthethrottleis
actuated 1.35—1.55
V
closedtoa highvoltagewhenthethrottleplate
is fullyopen.
This parameterdisplaysa calculatedvalve
basedon engineload,throttleposition,and
TorqueDeliveredSignal Varies otherengineinputs.This parameteris
calculatedtowithin20 N m(15lbft)of actual
measuredenginetorque.
This parameterindicateshowmuchignition
sparktimingis beingretardedduetoall
controlsystemsmonitoredbythecontrol
TotalKnockRetard 0 Degrees module.The scantoolwilldisplaya highvalve
duringextremeconditionssuchas high
temperaturesandantilockbraking.Thescan
toolwill displaya lowervalueduringlighter
drivingconditions.
This parameterdisplaysthetotalnumberof
TotalMisfire Counts cylinderfiringeventsthatthecontrolmodule
detectedas misfiresforthelast200
crankshaftrevolutionsampleperiod.
This parameterdisplaysthespeedofthe
vehicleas calculatedbythe transmission
VehicleSpeedSensor 0 km/h(0MPH) controlmodule(TCM)frominformation
receivedfromthevehiclespeed
sensor(VSS).
Warm—upsSince DTC This parameterdisplaysthenumberof
Cleared Varies
warm-upssincetheDTC was cleared.

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 Vehicle Diagnostic Information 6439

Engine Control Module (ECM) Scan Tool Output Controls

OutputControl Description
ThisfunctionactivatestheA/C compressorrelay.The normalcommandedstateoftheA/C
relayis None.TheNC compressorwillturnON or OFF whencommandedON or OFF. The
systemremainsin thecommandedstateuntilcancelledbythescantool.The scan tool
initiatesthetestwhenthefollowingconditionsare met:
A/C ClutchRelay - Inthecorrectpowermode
- A/C highside pressureis in range
- Enginespeedis in range
- Ignitionvoltageis in range.
- Thereare noA/C pressuresensorDTCs set.
This devicecontrolis usedto triggertheprocedureto learntheclutchpedalfuIIyapplied
ClutchPedal PositionLearn position.
Thisfunctioncontrolsthecoolingfan relay1.The normalcommandedstateofthefan relay
is None.The scan toolinitiatesthetestwhenthefollowingconditionsare met:
CoolingFan - Enginecoolanttemperatureis notoutof range
- Inthecorrectpowermode.
Thisfunctionis usedto resettheengineoil life.Theengineoil remaininglifeis determined
EngineOil LifeReset fromenginerevolutionsandthedistancedrivensince thelastoil change.
ThisfunctioncontrolstheEVAP purgesolenoidvalve.The normalcommandedstateis
None.The systemwill increaseordecreasetheamountof purgeby changingthedutycycle
ofthepurgevalvein 10%incrementswithina rangeof O—100%. Thescan toolinitiatesthe
testwhenthefollowingconditionsare met:
EVAP PurgeSolenoidValve - Thevacuumlevelin theEVAP purgesystemis withinrange.
- Thereare no EVAP DTCs set.
~The EVAP systemtestis notin progress.
- InthecorrectPowerMode.
EVAP Test Activatestheon-boardEVAP diagnostictest.
ThisfunctioncontrolstheEVAP ventsolenoid.The normalcommandedstateis none.When
commandedON, theventvalveswitchesto notventing.WhencommandedOFF, thevent
valveswitchestoventing.Thescantoolindicatesthetestwhenthefollowingconditions
are met:
EVAP VentSolenoidValve - The vacuumlevelin theEVAP purgesystemis withinrange.
- Thereare no EVAP DTCs set.
° The EVAP systemtestin notin process.
- Inthecorrectpowermode.
Thisfunctioncontrolstheselectedcamshaftactuatorsolenoid.The normalcommanded
stateis None.Thesystemwillincreaseor decreasetheangleoftheselectedcamshaftin 5
degreeincrements.The scantoolinitiatesthetestwhenthefollowingconditionsare met:
- The engineis operating.
ExhaustCamshaftPosition - The commandedcamshaftpositionis notoutof range.
Actuator - Thereare nocrankshaftpositionor camshaftpositionsensorDTCs set.
- Engineoil temperatureis notoutof range.
- Inthecorrectpowermode.
Iftheactuatoris disabledafter30s, theactuatorcontrolis notallowedagainon thesame
actuatorfor60s.
Thisfunctioncontrolsthefuelpumprelay.The normalcommandedstateis None.When
commandedON or OFF,theECM turnsthefuelpumpON or OFF.The scan toolinitiatesthe
testwhenthefollowingconditionsare met:
Fuel PumpRelay - The enginespeedIs0 RPM. ‘
- Inthecorrectpowermode.
- Theoutputcontroltimerhas notexpired.
- The ignitionvoltageis withinrange.
FuelTrimReset Thisfunctionis usedto resetthelearnedfueltrimvaluestotheirinitialvalues.

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5340 Vehicle Diagnostic Information

Engine Control Module (ECM) Scan Tool Output Controls (cont'd)

Output Control
GeneratorL~Terminal
H028 HeaterSensor 1or 2
IntakeCamshaftPosition
Actuator
IntakeManifoldRunnerControl
Valve
MalfunctionIndicatorLamp(MIL) None.WhencommandedON or OFF,the ECM turnsthemalfunctionindicatorlamp(MIL)
ThrottlePosition
Description
Thisfunctionis usedtooverridethestateof thegeneratorL terminaloutput.The
commandedstatesareON andOFF. SelectingOFF commandstheECM to turnOFF the
generatorandstopgeneratingan outputvoltage.Thescantool initiatesthetestwhenthe
followingconditionsare met:
- The engineis operatingtoturnOFF thecomponent.
- Thevehiclespeedis 0 km/h(0MPH).
- Inthecorrectpowermode.
- Theoutputcontroltimerhas notexpired.
Thisfunctioncontrolsthe selectedH028 heater.The'normalcommandedstateis None,on,
andoff.CommandingtheH028 heaterON turnsontheheaterdriver.The scantoolinitiates
thetestwhenthefollowingconditionsare met:
- Theengineis operating.
~Theexhausttemperatureis withinrange.
' Inthecorrectpowermode.
- The H028 heatersare notovertemperature.
- The ignitionvoltageis notoutof rangewhilecommandingtheheatersON.
This functioncontrolstheselectedcamshaftactuatorsolenoid.The normalcommanded
stateis None.The systemwillincreaseor decreasetheangleoftheselectedcamshaftin 5
degreeincrements.Thescan toolinitiatesthetestwhenthefollowingconditionsare met:
- Theengineis operating.
' Thecommandedcamshaftpositionis notoutof range.
- Thereare nocrankshaftpositionor camshaftpositionsensorDTCs set.
- Engineoiltemperatureis notoutof range.
- Inthecorrectpowermode.
Iftheactuatoris disabledafter30s, theactuatorcontrolis notallowedagainonthesame
actuatorfor60s.
This devicecontrolis usedto overridethestateofthe intakemanifoldtuningvalveoutput.
A outputtestis usedtoselectwhethercommandingtheintakemanifoldtuningvalveoutput
on or offresultsin thevalvebeingcommandedclosedor open.
Thisfunctioncontrolsthe malfunctionindicatorlamp(MIL).The normalcommandedstateis
ON or OFF.Thisoutputcan also be monitoredon thescantooldataparameterMIL
Command.Thesystemremainsin thecommandedstateuntilcancelledbythe scantool.
Thisfunctioncontrolsthethrottlevalvein 10%increments.Thescan toolinitiatesthetest
whenthefollowingconditionsare met:
- Theenginespeedis 0 RPM.
- Thevehiclespeedis 0 km/h(0MPH).
The systemremainsinthe commandedstateuntilcancelledby thescan tool.

Fuel Pump Flow Control Module Scan Tool Information

Fuel Pump Flow Control Module Scan Tool Data Parameters

Parameter | System State I Expected Value I Description
OperatingConditions: IgnitionON/EngineIdlingat NormalOperatingTemperature/Vehicleis in Parkor Neutral
DesiredFuel Pressure _ , ThisdisplayskPa (psi).This
306'8kPa (44.5p30 is thedesiredfuelpressure.
Thescan tooldisplaysOn or
Fuel PumpCommand — On Off.This is thecurrentstateof
thefuelpumpcommand.
Thisdisplays%.Thisis the
Fuel PumpSignalCommand — ' Varies commandedfuelpumpsignal
measuredin percentage.
ThisdisplayskPa (psi).This
Fuel PressureSensor —— 2964—3103kPa (43—45
psi) is thecurrentpressureat the
fuelpressuresensor.

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 Vehicle Diagnostic Information fiaél‘l

Fuel Pump Flow Control Module Scan Tool Data Parameters (cont'd)
Parameter System State Expected Value Description
Fuel PressureSensor — 4.90—5.01Volts ThisdisplaysVolts.This is the
fuelpressuresensorvoltage
.. . . This displaysVolts.This is the
Ignition1 Signal ‘— Varies currentignition1 signal.
This displaysa numericvalue.
LT Fuel PumpTrim — Varies This is thelongterm(LT)fuel
pumptrim.
Thisdisplaysa numericvalue.
ST Fuel PumpTrim —— Varies This is theshortterm(ST)fuel
4 pumptrim.

Fuel Pump Flow Control Module Scan Tool Output Controls

Output Control Description
Fuel PressureControl This outputcontrolis usedtocontrolthefuelpressure.
Fuel Pump This outputcontrolis usedtocommandthefuelpumpON andOFF.
Fuel PumpTrimReset This outputcontrolis usedto resetthefuelpumptrim.

Active Grille Air Shutter Scan Tool Data Parameters (If Equipped)
Parameter I System State I Expected Value I Description
OperatingConditions: lgnitionON/EngineIdlingat NormalOperatingTemperature/Vehicleis in Parkor Neutral
ActiveGrilleAirShutter - Thisdisplays%.This is the
I. — Varies - - ~
commandedactivegrilleair
PosmonCommand shutterposition.
. . . This displays%.This is the
égts'I/t‘ieognue
A'r Shutter — Varies actualactivegrilleairshutter
position.
Thescan tooldisplaysOn or
Cold TemperatureMode — On/Off Off.This is thecurrentstateof
theCold TemperatureMode.
Thescan tooldisplays°C (°
AmbientAir Temperature — Varies F).This is thecurrentambient
airtemperature.

Active Grille Air Shutter Scan Tool Output Controls (If Equipped)
Output Control Description
This outputcontrolis usedto performtheActiveGrilleAir ShutterActuatortest.Itis usedto cycle the
ActiveGrilleA'r Shutter
Actuator activegrilleair shutteropenandclosed.The testresultwilldisplaypass orfailbasedontheabilityof
the louversto cycleopenandclosed.

Exhaust Flow Control Valve Scan Tool Data Parameters (If Equipped)
Parameter I System State I Expected Value I Description
OperatingConditions: IgnitionON/EngineIdlingat NormalOperatingTemperature/ Vehicleis in Parkor Neutral
ExhaustFlowControlValve ExhaustFlowValve
Command _ Open/Closed CommandedState
Eérnfirltisatnfjlow
ControlValve __ % ExhaustFlowValve
Commanded Duty
Cycle (O%-100%)
ExhaustFlowControlValve . . ExhaustFlowValveControl
PerformanceMode — Active/lnactive Status

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Exhaust Flow Control Valve Scan Tool Data Parameters (If Equipped) (cont'd)
Parameter System State Expected Value Description
ExhaustFlowControlValve Active/Inactive ExhaustFlowValveControl
RumbleMode Status
ExhaustFlowControlValve — Active/lnactive EQELSJSt
FlowValveControl

Exhaust Flow Control Valve Scan Tool Output Controls (If Equipped)
Output Control Description
ExhaustFlowControl
ValveCommand This outputcontrolis usedto cycletheexhaustflowcontrolvalveopenandclosed.

Heating, Ventilation and Air Conditioning Control Module Scan Tool

Information

Heating Ventilation and Air Conditioning Control Module Scan Tool Data Parameters
Expected
Parameter System State Value Description
OperatingConditions: lgnitionON
Engine Disengaged
running,A/
C Off The scan tooldisplaysEngagedor Disengaged
A/C CompressorClutchStatus Engine dependingonthestateoftheA/C compressor.
running,A/ Engaged
C On
A/C EvaporatorTemperature _ —zt((:‘t1%:gg°c
The scan tooldisplays°C (°F).This is thecurrent
Sensor 176°F) temperatureattheA/C evaporatortemperaturesensor.
. t . The scantooldisplayskPa. This is thecurrentpressure
A/C HighSide PressureSensor — Varies of theA/C refrigerant.

. A/C Off Off The scan tooldisplaysOn or Offdependingon the

A/C Indicator NC On On stateoftheA/C mode.
. A/C Off Inactive The scan tooldisplaysActiveor Inactivedependingon
NO RequestSignal NC On Active thestateoftheA/C mode.
A/C Switch .
Inactive
A/C Switch released The scan tooldisplaysActiveor Inactivedependingon
NO Switch . thestateoftheA/C switch.
pressed Active
Air recirculation
modeis Off
. . . deactivated The scan tooldisplaysOn or Offdependingon the
A" ReCIrcuIation
LED Air recirculation stateof theRecirculationmode.
modeis On
activated
Air.recirculation .
Inactive -
. . . . SW'tChreleased The scan tooldisplaysActiveor Inactivedependingon
A" ReCIrculatlon
ModeSW'tCh Air recirculation . thestateoftheairrecirculationmodeswitch.
switchpressed Active
AmbientAir Temperature _ 483%";397C The scan tooldisplays°C (°F).This is thecurrent
(Filtered) 176°F) temperatureattheambientairtemperaturesensor.

BatteryVoltage — 11—14
V The scan tooldisplaysV.‘Thisis thecurrentbattery
voltage.

EngineCoolantTemperature -40 to +215°C The scantooldisplays°C (°F).This is thecurrent

(—40to +419°F) enginecoolanttemperature.

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 VehkfleEfiagnosficlnFOHnaHon 643
Heating Ventilation and Air Conditioning Control Module Scan Tool Data Parameters
(cont'd)
Expected
Parameter System State Value Description
IgnitionVoltage 1144 V IgleazzantooldisplaysV. This is thecurrentignition

Rear defogger Off

. i3deactivated Thescan tooldisplaysOn orOffdependingonthe
Rear DefoggerIndicator Reardefogger on stateofthereardefogger.
is activated
Rear defogger Inactive
Rear Defo erSwitch SW'tChreleased The scan tooldisplaysActiveor Inactivedependingon
99 Rear defogger .
Active thestateofthereardefoggerswitch.
switchpressed

Heating Ventilation and Air Conditioning Control Module Scan Tool Output Controls
OutputControl Description
A/C Switch This controlfunctionsimulatesthestateoftheA/C switch.
WhenOn is selected,theHVAC controlmodulecommandstheair recirculationdoorfrom
Air RecirculationModeSwitch outsideairto recirculation.WhenOffis selected,theHVAC controlmodulecommandsthe
air recirculationdoorfromrecirculationtooutsideair.
IlluminateAll Indicators This controlfunctionwillilluminateall indicatorson theHVAC controlmodule.

Inflatable Restraint Passenger Presence System Scan Tool Information

Passenger Presence Module Scan Tool Data Parameters

Parameter I Expected Value I Definition
OperatingConditions: lgnitionON
Varies,8 Digit The scan tooldisplaysthepartnumberof thePPS module
Base ModelPartNumber Number whichis storedin nonvolatilememory.
BatteryVoltage Volts The scantoolwilldisplay batteryvoltage.
. . Varies,8 Digit The scantooldisplaysthepartnumberofthecalibration
ca'mrat'c’"PartNumber Number file in thePPS module.
Varies,8 Digit The scantooldisplaysthe partnumberofthe PPS module
End ModelPartNumber Number in production.
Manufacturer's
TraceabilityNumber Varifiagfelrmgit ?Ateslggnnt‘gglucllésplays
the 16dIgIttraceabilitynumberin

The scan tooldisplays Unknown,CalibrationMode,Empty

PassengerClassification
PassengerPresence ModulePrimaryKey
PassengerPresenceSystem
ReportingDTC(s)
PassengerSeat OccupancyStatus
Off/Accessory]
PowerMode
Seat,SmallOccupantType1,Small OccupantType2,
SmallOccupantType3, SmallOccupantType4, Large
OccupantType1, LargeOccupantType2, LargeOccupant
EmptySeat Type3, LargeOccupantType4, ModuleSetup,Not
Available,ChildSeat FacingRearward,ChildSeat Facing
Forward,ChildSeat FacingUnknownDirection.This is the
stateofwhatoccupiesthe passengerseat,as monitored
by thepassengerpresencesystem.
HexValue The scan toolindicatesthe primarykey Hexvalue.
Yes/No The PPS modulewillreportif thereare DTCs set in the
passengerpresencemodule.
The scan tooldisplaysUndefined,EmptySeat, Occupied,
or Invalid.This is thestateofthepassengerseat if it is
EmptySeat occupiedor emptyandmonitoredby thepassenger
presencesystem.
Run/Crank The scan toolwilldisplaythe powermodeof thevehicle.
Request

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6=44 Vehicle Diagnostic
Passenger
Parameter
SoftwarePart Number
Inflatable Restraint
Sensing
Parameter
OperatingConditions: Vehiclein ServiceMode
2ndRow LeftSeat BeltReminder
SensorPad EnableStatus
2ndRowLeftSeat BeltReminder
Sensor Pad LearnStatus
2ndRow LeftSeat BeltStatus
2ndRowMiddleSeat
ReminderSensor PadBelt
Enable
Status
2ndRow MiddleSeat Belt
ReminderSensor Pad Learn
Status
2ndRowMiddleSeat BeltStatus
2Rgminczl‘grhgens‘eor
dR 'ddl S 32d
t BEnable
It
Status
2ndRow MiddleSeat Belt
ReminderSensor Pad Learn
Status
2ndRow RightSeat BeltStatus
Air Bag MalfunctionIndicator
Base ModelPart Number
CalibrationPartNumber
DeploymentLoop 1-18Enable
Status
DeploymentLoop 1-18Learn
Status
DeploymentLoop 1-18
Resistance
DeploymentLoop 1-18Type
Information
Presence Module Scan Tool Data Parameters (cont'd)
Expected Value Definition
Varrileusrhggigitl‘tgfifin tooldisplaysthesoftwarepartnumberin thePPS
Sensing and Diagnostic Module Scan Tool Information
and Diagnostic Module Scan Tool Data Parameters
I Expected Value I Definition
The scan tooldisplaysif theleftrearseat beltremindersensor
Disabled/Enabled
padis enabledtotheSDM.
Thescan tooldisplaysLearnedor NotLearned.Learnedis
Learned/NotLearned displayedif theleftrearseat beltremindersensorpadhas been
learnedbytheSDM.
The scan tooldisplaysBuckledor Unbuckled.This is thestateof
Buckled/Unbuckled theleftrearseatbeltswitchwhentheseat beltis buckledor
unbuckled.
. . . .
Disabled/Enabled The scan tooldisplaysIftherearmiddleseat beltreminder
sensorpadis enabledto theSDM.
The scan tooldisplaysLearnedor NotLearned.Learnedis
Learned/NotLearned displayedif therearmiddleseatbeltremindersensorpadhas
beenlearnedbytheSDM.
Thescan tooldisplaysBuckledor Unbuckled.This is thestateof
Buckled/Unbuckled themiddlerearseatbeltswitchwhentheseat beltis buckledor
unbuckled.
. . . .
Disabled/Enabled The scan tooldisplaysIftherearrightseat beltreminder
sensor
padis enabledtotheSDM.
Thescan tooldisplaysLearnedor NotLearned.Learnedis
Learned/NotLearned displayedif therearrightseat beltremindersensorpadhas
beenlearnedbytheSDM.
The scan tooldisplaysBuckledor Unbuckled.This is thestateof
Buckled/Unbuckled therightrearseatbeltswitchwhentheseat beltis buckledor
unbuckled.
The scan toolwilldisplayOn or Flashesif thereis a problemwith
On/Off/Flashes theSIR system.Any problemsWithintheSIR systemWill
illuminatetheair bagindicator.The indicatorwilleitherflashor
stayon.
Varies,8 DigitNumber Thescan tooldisplaysthepartnumberof theSDM whichis
storedin nonvolatilememory.
Varies,8 DigitNumber The scan tooldisplaysthepartnumberofthe calibrationfile in
theSDM.
The scan tooldisplaysEnabledor Disabled.This is thestatusof
Enabled/Disabled theair bagor pretensioner.
The scan tooldisplaysLearnedor Notlearned.Learnedis
Learned/NotLearned displayedif theSDM has definedthenumberloopprogrammed
froman air bagor pretensioner.
The scan tooldisplaystheresistanceofthe learnedloopofthe
1.44—4.25
Ohms airbagor pretensionerwhenconnectedtotheSDM.
Varies Thescan tooldisplaysthenameoftheair bagor pretensioner
associatedwiththelooptype1—18.
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Sensing and Diagnostic
Parameter
DriverSeat BeltReminder
Indicator
DriverSeat BeltSensorEnable
Status
DriverSeat BeltSensorLearn
Status
DriverSeat BeltStatus
. ..
DriverSeat PosmonSensor
DriverSeat PositionSensor
EnableStatus
DriverSeat PositionSensor
LearnStatus
End ModelPartNumber
ImpactSensor 1-8EnableStatus
lmpactSensor1-8LearnStatus
ImpactSensor 1-8Type
inflatableRestraintSensingand
DiagnosticModulePrimaryKey
Manufacturer'sTraceability
Number
ModuleSetup
PassengerAir Bag Disabled
Switch
PassengerAir Bag OffIndicator
PassengerAir Bag On Indicator
PassengerAir Bag Status
PassengerAir Bag Disable
IndicatorEnableStatus
PassengerAir Bag Disable
IndicatorLearnStatus
PassengerAir Bag Disable
SwitchEnableStatus
PassengerAir Bag Disable
SwitchLearnStatus '
PassengerAir Bag Enable
IndicatorEnableStatus
PassengerAir Bag Enable
IndicatorLearnStatus
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Vehicle Diagnostic Information 645
Module Scan Tool Data Parameters (cont'd)
Expected Value Definition
The scantooldisplaysOh if thisindicatoris on.lfthe indicatoris
On/Off on it meanstheseatbelthas notbeenbuckled.
The scantooldisplaysittheseatbeltsensorintheseatbelt
Enabled/Disabled buckleis enabledtotheSDM.
The scan tooldisplaysLearnedor NotLearned.LearnedIs
Learned/Notlearned displayedif thedriverseat beltsensorhas beenlearnedby
theSDM.
The scantooldisplaysBuckledor Unbuckled.This is thestateof
Buckled/Unbuckled thedriverseatbeltswitchwhentheseatbeltis buckledor
unbuckled.
The scantoolwilldisplayif
Rearward/Forward ofthesensorset position. thedriverseatis forwardor rearward
Enabled/Disabled The scan tooldisplaysif theseatpositionsensoris enabledto
theSDM.
The scan tooldisplaysLearnedor NotLearned.Learnedis
Learned/NotLearned displayedif thedriverseat positionsensorhas beenlearnedby
theSDM.
Varies,8 DigitNumber The scan tooldisplaysthepartnumberoftheSDM in
production.
Enabled/Disabled The scantooldisplaysEnabledor DisabledThis is thestatusof
theimpactsensor.
The scan tooldisplaysLearnedor Notlearned.Learnedis
Learned/NotLearned displayediftheSDM has learnedandhas assigneda numberto
thatimpactsensor.
The scan tooldisplaysthenameoftheimpactsensorassociated
Equipped/NotEquipped withthetype1—8.
HexValue The scan toolindicatestheprimarykey Hexvalue.
Varies,16DigitNumber The scantooldisplaysthe16digittraceabilitynumberin
theSDM.
Incomplete/Complete The scan toolindicatesiftheSDM is set up.
On/Off The scan tooldisplaysOffwhenthecustomermanuallyturnsthe
passengerairbagoffwiththisswitch,
The scantooldisplaysOffwhenthepassengerindicatoris not
On/Off illuminated.This indicatoris offwhenthedisableswitchis in the
offpositionor nooneis sittingin thepassengerseat.
The scan tooldisplaysOn whenthepassengerindicatoris
On/Off illuminated.Thisindicatoris onwhenthedisableswitchis in the
on positionandsomeoneis sittingin thepassengerseat.
Enabled/Disabled 312685831tooldisplaysif thepassengerair bagis enabledto
Enabled/Disabled The scan tooldisplaysif thepassengerair bagdisableindicator
is enabledtotheSDM.
The scan tooldisplaysLearnedor NotLearned.Learnedis
Learned/NotLearned displayedif theSDM has learnedthestatusofthepassengerair
bagdisableindicator.
Enabled/Disabled The scantooldisplaysif thepassengerair bagdisableswitchis
enabledtotheSDM.
The scan tooldisplaysLearnedor NotLearned.Learnedis
Learned/NotLearned displayediftheSDM has learnedthestatusofthepassengerair
bagdisableswitch.
The scantooldisplaysif thepassengerair bagenableindicator
Enabled/Disabled is enabledtotheSDM.
The scan tooldisplaysLearnedor NotLearned.Learnedis
Learned/NotLearned displayediftheSDM has learnedthestatusofthepassengerair
bagenableindicator.
8-48 Vehicle Diagnostic
Sensing and Diagnostic
Parameter
PassengerClassification
PassengerPresenceDetection
SystemEnableStatus
PassengerPresenceDetection
SystemLearnStatus
PassengerPresenceDetection
SystemReportingDTC(s)
PassengerSeat BeltReminder
Indicator
PassengerSeat Belt Reminder
IndicatorEnableStatus
PassengerSeat Belt Reminder
IndicatorLearnStatus '
PassengerSeat Belt Reminder
Sensor Pad EnableStatus
PassengerSeat BeltReminder
SensorPad LearnStatus
PassengerSeat BeltSensor
EnableStatus
PassengerSeat BeltSensor
LearnStatus
PassengerSeat BeltStatus
PassengerSeat Occupancy
Status
..
PassengerSeat PosmonSensor
PassengerSeat PositionSensor
EnableStatus
PassengerSeat PositionSensor
LearnStatus
PowerMode
. .
PrimaryKey Status
2921133]
Key StatusLast lgnition
' . . Thescan tooldisplaysa HexvalueindicatingtheSDM received
ReceivedPrimaryKey
RolloverSensor EnableStatus
RolloverSensor LearnStatus
SecurityCode Accepted
SecurityCode Lockout
SecurityCode LockoutActive
Timer
Information
Module Scan Tool Data Parameters (cont'd)
Expected Value Definition
00—07 Thescan toolwilldisplaywhattypeof individualis sittingin the
passengerseat.
Enabled/Disabled Thescan tooldisplaysif thepassengerpresencesystemis
enabledtotheSDM.
Thescan tooldisplaysLearnedor NotLearned.Learnedis
Learned/NotLearned displayediftheSDM has learnedthepassengerpresence
system.
The SDM will reportifthereare DTCs set inthepassenger
Yes/No presencemodule.
On/Off Thescan tooldisplaysOn if thisindicatoris on.Iftheindicatoris
on itmeanstheseatbelthas notbeenbuckled.
Disabled/Enabled Thescan tooldisplaysif thepassengerseatbeltreminder
indicatoris enabledtotheSDM.
Thescan tooldisplaysLearnedor NotLearned.Learnedis
Learned/NotLearned displayedifthepassengerseat beltreminderindicatorhas been
learnedbytheSDM.
Disabled/Enabled Thescan tooldisplaysifthepassengerseatbeltreminder
sensorpadis enabledto theSDM.
Thescan tooldisplaysLearnedor NotLearned.Learnedis
Learned/NotLearned displayedifthepassengerseat beltremindersensorpadhas
beenlearnedbytheSDM.
Enabled/Disabled The scan tooldisplaysiftheseat positionsensoris enabledto
theSDM.
The scan tooldisplaysLearnedor NotLearned.Learnedis
Learned/Notlearned displayedifthepassengerseat beltsensorhas beenlearnedby
theSDM.
The scantooldisplaysBuckledor Unbuckled.This is thestateof
Buckled/Unbuckled thepassengerseatbeltswitchwhentheseatbeltis buckledor
unbuckled.
. The scantooldisplaysOccupiedifsomeoneis sittingin the
EmptySeat/Occupled passengerseat.
The scantoolwilldisplayifthepassengerseat is forwardor
Rearward/Forward rearward0fthesensorset position.
Disabled/Enabled The scantooldisplaysifthe passengerseatpositionsensorpad
is enabledto theSDM.
The scantooldisplaysLearnedor NotLearned.Learnedis
Learned/NotLearned displayedifthepassengerseat positionsensorhas been
learnedby theSDM.
R
Ofg’ggfasggflgswl . . .
The scantoolWilldisplaythepowermodeofthevehicle.
. Thescan tooldisplaysValidif theprimarykeymatcheswhatis
VaIId/lnvalld storedto memoryintheSDM.
InvalidNalid The SDM checkstosee if theprimarykeydatareceivedis valid.
HexValue primarykeydata.
Disabled/Enabled The scantooldisplaysiftherolloversensoris enabledto
theSDM.
Learn/Unlearn The scantooldisplaysLearnedor NotLearned.Learnedis
displayedifthe rolloversensorhas beenlearnedbytheSDM.
The SDM eitheracceptsthesecuritycodeor itdoesnot.The
Yes/No scantooldisplaysYes ifthesecuritycodehas beenacceptedby
theSDM.
Yes/No Thescan tooldisplaysYes IftheSDM has beenlockedout
becauseof thesecuritycode notbeingaccepted.
RandomValue The SDM uses a timerbeforethesecuritycodeis lockedin
theSDM.
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 Vehicle Diagnostic Information 6=47

and Diagnostic Module Tool Data Parameters

Scan (cont'd)
Sensing
Parameter Expected Value Definition
The scantool displaysYes if theSDM has been programmed
SecurityCode Programmed Yes/No withthe securitycode.
SecurityCode Programming The SDM uses a counterfor thevalueofthe securitycode
RandomValue programming.
Counter
SecurityCode Reset Counter RandomValue The SDM uses a counterto resetthevalueofthe securitycode.
SoftwarePart Number Varies,8 DigitNumber The scantool displaysthe softwarepartnumberin theSDM.
Number
Vehicle Identification Varies,17 DigitNumber TheVIN numberof thevehicle programmedintothe SDM.
The scantool displaysYes iftheVIN has been programmedinto
VIN Programmed Yes/No theSDM.
VIN ProgrammingCounter RandomValue The SDM uses thiscounterwhileprogrammingtheVIN.

Instrument Cluster Scan Tool Information

Instrument Cluster Scan Tool Data Parameters

Parameter I Expected Value I Description

Operating Conditions: ON
Ignition
The scantool displaysVolts.This is thecurrentbatteryvoltage
BatteryVoltage 12—14V signal. - - - ~
The scantool displaysActive or Inactive.This is thestateofthe
Key InIgnitionStatus Active/lnactive keyin ignitionswitch.
The scantool displaysVolts.This is thecurrentdriver
CenterSwitch
DriverInformation Varies informationcenterswitchinputvoltage.
The scantool displayseitherInactive,Up, Down,or Menu.This
CenterSwitch
DriverInformation Inactive Isthestateof thedriverinformationcenterswitch.
The scantool displaysActive or Inactive.This is thestateofthe
Reset Switch Active/lnactive resetswitch.
AmbientAir Temperature 15°C The scantool displaysoutsidetemperaturein°C.
WasherFluid LevelSwitch Open The scantool displayseitherOpen,Closed, or NotAvailable.
The scantool displaysActive or Inactivedependingon thestate
OdometerLockStatus Active/lnactive oftheodometer.

EngineSpeed 0 RPM The scantool displaysthefilteredvalueof enginespeed.

VehicleSpeed 0 kmlh The scantool displaysthefilteredvehiclespeedvalue.
Fuel LevelSensor The scantool displaysthe filteredvalueof thefuel level.
The scantool displaysthefilteredvalueof theenginecoolant
EngineCoolantTemperature temperature.
The scantool displaysthe filteredvalueof theengineoil
EngineOil Pressure pressure.

Instrument Cluster Tool Output Controls

Scan
Output Control Description
fromminimumto maximum.
InstrumentClusterGaugeSweep This functionis usedto commandthegaugestosweep
Increase
DriverInformationCenter This functionis usedto commandthedimmingofthe driverinformationdisplayto
Dimming or Decreaseby 10%;
instrumentclusterto Increaseor
InstrumentPanel DimmerSwitch This functionis usedto commandthedimmingofthe
Decreaseby 10%.
DriverInformationCenter This functionis usedto commandthedriverinformationcentersegmentsON andOFF.
Segments
All Indicators This functionis usedto commandall theindicatorsON or OFF.
usingthe scantool.
DriverInformationCenterOptions This functionis usedto commandthedriverinformationcenterbuttons

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648 Vehicle Diagnostic Information

Instrument Cluster Scan Tool Output Controls (cont'd)

OutputControl Description
OdometerProgramming Thisfunctionis usedtocommandtheodometerto reset.
CAN Bus ConfigurationLearn Thisfunctionis usedto ResetthesourceIDforlowspeedCAN Bus communications.

Power Steering Control Module Scan Tool Information

The power steering control module scan tool data

parameters list contains all power steering 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.

Power Steering Control Module Scan Tool Data Parameters

Expected
Parameter System State Value Description
Operating Conditions: IgnitionON
BatteryVoltage — Varies This displaysbatteryvoltage.
CalculatedSystemTemperature _ Varies :Iwéseirsnthe
calculatedtemperatureof thepowersteering

PowerSteeringControlModule __ Varies The scan tooldisplaysitthecenterprocedurehas been

CenterProcedure completedor not.
PowerSteeringControlModule _ Varies The scan tooldisplaysifthecalibrationstatushas been
SPS CalibrationStatus completedor not.
This displaysN-m.This is thecalculatedforceofthe
SteeringInputTorque —— Varies steeringshaft,as monitoredbythepowersteering
controlmodule.
SteeringWheelAngle — Varies This displaysthesteeringwheelanglein degrees.

Radio Scan Tool Information

Radio Scan Tool Data Parameters

Parameter I ExpectedValue I Definition
Operating Conditions: IgnitionON
Thescan tooldisplaysEnabledor Disabled.This indicatesif the
AntennaModule Enabled systemuses an antennamoduleandtheoutputstatusbetweenthe
radioandtheantennamodule.
AuxiliaryAudioInput The scan tooldisplaysPresentor NotPresent.This parameter
NotPresent displayspresentwhenan auxiliaryinputis connected.
BatteryVoltage Varies The scan tooldisplaysvolts.This is thevoltageattheinputto the
radio.
. . . . The scan tooldisplaysPresentor NotPresent.This is thestateofthe
DigitalRadioReceiver Present DigitalAudioBroadcast.
Thescan tooldisplaysOff,Accessory,Runor CrankRequest.This is
PowerMOde Run thecurrentpowermodeoftheradio.
. . . This displaysthesignalstrengthin dB. This is thesignalstrengthof
Rale SignalStrength Varies thecurrentlytunedradiostation.
TheftLookArmed LearnedVIN The scan tooldisplaysLearnedVINor
VIN programming in theradio. No VIN.This is thestateofthe,

The scan tooldisplaysActiveor Inactive.This is thestateofthetheft

RadioTheftLockStatus Inactive locksystem.Activeindicatestheradiois locked.Inactiveindicatesthe
theftlocksystemis armedandtheradiois unlocked.
TestBenchMode Thescan tooldisplaysActiveor Inactive.This parameterindicatesif
'“aCt'Ve theradiois in benchor usermode.

End ModelPartNumber End ModelPartNumberis the partnumberforthehardwareofthe

Varies controlmodulewithsoftwareandcalibrations.

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 Vehicle Diagnostic Information 849

Radio Scan Tool Data Parameters (cont'd)

Parameter Expected Value Definition
Base ModelPartNumber Varies Effivixggh‘dpfarltiEggqobnesr.
is thepartnumberforthehardwarewithout

BootSoftwarePartNumber Varies The scantooldisplaysthebootsoftwareIDnumber.

CalibrationPartNumber1
CalibrationPartNumber2
CalibrationPartNumber3
CalibrationPartNumber4
CalibrationPartNumber5
CalibrationPartNumber6
CalibrationPartNumber7
CalibrationPartNumber8
CalibrationPartNumber9
CalibrationPartNumber10
DigitalRadioReceiverID
Vin Digits2-17 A Varies
SubscriberID
ModuleDiagnosticAddress
DateProgrammed
Varies The scantooldisplaysthesoftwaremoduleID1.
Varies The scantooldisplaysthesoftwaremoduleID2.
Varies The scantooldisplaysthesoftwaremoduleID3.
Varies The scantooldisplaysthesoftwaremoduleID4.
Varies The scantooldisplaysthesoftwaremoduleID5.
Varies The scantooldisplaysthesoftwaremoduleID6.
Varies The scantooldisplaysthesoftwaremoduleID7.
Varies The scantooldisplaysthesoftwaremoduleID8.
Varies The scantooldisplaysthesoftwaremoduleID9.
Varies The scantooldisplaysthesoftwaremoduleID10.
Varies The scantooldisplaystheDigitalAudioBroadcastreceiverID.
The scantooldisplaysthelearnedVIN digits2-17.
Identifiesthealphanumericdealercodeor thetester's(Tech2,MDI
Varies etc.)serialnumber.This stringis programmedintotheECU memory
duringthelastprogrammingevent.
80 Displaysthe2 digitdiagnosticaddressofthecontrolmodule.
Varies DisplaysthedatewhentheECU was lastprogrammed.

Radio Scan Tool Output Controls

ScanControl
Tool Output - .
Description
LeftFront8 eaker This outputcontrolis usedto commandthespeakerON andOFF.CommandingthespeakerON will
p generatea testtoneto be generatedthroughtheselectedloudspeaker.
LeftRear 8 eaker This outputcontrolis usedto commandthespeakerON and OFF.CommandingthespeakerON will
p generatea testtoneto be generatedthroughtheselectedloudspeaker.
- This outputcontrolis usedto commandthespeakerON andOFF. CommandingthespeakerON will
nght FrontSpeaker generatea testtoneto be generatedthroughtheselectedloudspeaker.
. This outputcontrolis usedto commandthespeakerON andOFF.CommandingthespeakerON will
RightRear Speaker generatea testtoneto be generatedthroughtheselectedloudspeaker.
Eject This outputis a commandtoejectthedisc.

Transmission Control Module Scan
Tool Information (6T30I6T40/
6T45/6T50)
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 morethan 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. lfa scan tool displays
other parameters, those values are not recommended
by General Motors for use in diagnosis.
Ifall values are within the expected range described
below, refer to Symptoms —Automatic Transmission on
page 17-157 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.

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Ta
«50 Vehicle Diagwostic Information

Scan Tool Data Parameters

Parameter I System State I Expected Value Description
OperatingConditions: Engineat idle,upperradiatorhosehot,closedthrottle,transmissionin Park,closedloopoperation,
accessoriesOFF, brakepedalnotapplied.
This parameterdisplaystheactualtimeofthe
lastadaptable1—2 shift.Theshifttimeis based
1—2ShiftTime Varies Seconds onthegearratiochangeafterthecommanded
1-2shift.
This parameterdisplaystheactualtimeofthe
Seconds lastadaptable2-3shift.Theshifttimeis based
2—3ShiftTime Varies onthegearratiochangeafterthecommanded
2-3shift.
This parameterdisplaystheactualtimeofthe
Seconds lastadaptable3-4shift.Theshifttimeis based
3—4ShiftTime Varies on thegearratiochangeafterthecommanded
3-4shift.
This parameterdisplaystheactualtimeofthe
lastadaptable4-5shift.Theactualshifttimeis
4—5ShiftTime Varies Seconds obtainedby measuringthetimerequiredfor
theinputshafttodeceleratefromthe.previous
ratioto thecurrentratio.
This parameterdisplaystheactualtimeofthe
Seconds last5—6 shift.The shifttimeis baseonthe
5—6ShiftTime Varies gearratiochangeafterthe commanded
5-6shift.
This parameterdisplaysthestatusofthe
brakeswitchcircuitinput.Appliedindicatesa
zerovoltageinput,brake pedalapplied.
BrakePedal Switch Released Applied/Released Releasedindicatesa voltageinput,brake
pedalreleased.The scantooldisplays
Appliedor Released.
This parameterdisplaysa calculatedvalue,
whichis determinedby theacceleratorpedal
positionandtheactualthrottleposition,used
to optimizetransmissioncontrols.
CalculatedThrottle Varies % Itrepresentsthedriver’sintendedrequestfor
Position torqueoracceleration.The rangeis O-100%,
where0%representsan idleor coastrequest
and 100%representsa requestforwideopen
throttle(WOT).
ControlModuleVoltage This parameterdisplaysthesystemvoltage
9-19 Volts measuredat themodulewakeupsignalfeed.
Signal
This parameterdisplaysActiveor Inactive.
The scantooldisplaysActivewhenthegear
selectoris in themanualmode(M)positionor
DriverShift Inactive Active/Inactive leftoftheD position,whichenablesTAP shift.
ControlMode The scantooldisplaysInactivewhenthegear
selectoris notintheM or leftof Dposition,
TAP shiftdisabled.
This parameterdisplaysthecurrentrequest
fromtheTAP ShiftSystem.This parameter
willdisplayupshift,downshiftor invalid
Upshift/Downshift/ dependingon theamountofvoltage
DriverShiftRequest None None/Invalid measuredat theremoteshiftselectorinput
andalsowilldisplaynonewhenthereis no
request.
This parameterdisplaystheinputsignalfrom
theenginecoolanttemperature(ECT)sensor.
ECT is highat 151°C(304°F)whenthesignal
voltageis low(0V). ECT is lowat -40°C .
EngineCoolant Varies °C (°F) (—40°F) whenthesignalvoltageis high(5V).
Temperature This parametervalueis determinedbythe
enginecontrolmoduleandcommunicatedto
theTCM throughtheHighSpeedGMLAN
Serial Datalink.

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