Hummer H2 Service Repair Manual PDF 2

Factory Workshop Manual
Make
Hummer
Model
H2
Engine and year
V8-6.2L (2008)
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This manual was submitted by

Anonymous
Date
1st January 2018
Hummer H2 Workshop Manual (V8-6.2L (2008))
Hummer Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm
Module, (Vehicle Antitheft) > Component Information > Locations
Alarm Module: Locations
Instrument Panel/Center Console Component Views
Steering Column Components
1 - Inflatable Restraint Steering Wheel Module Coil 2 - Steering Angle Sensor 3 - Ignition Lock
Cylinder Solenoid 4 - Ignition Key Cylinder Case 5 - Theft Deterrent Module 6 - Ignition Key
Hummer Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm
Module, (Vehicle Antitheft) > Component Information > Locations > Page 7
Alarm Module: Service and Repair
Theft Deterrent Module Replacement

Hummer Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Central
Control Module > Component Information > Locations
Central Control Module: Locations
Instrument Panel Harness Components
1 - Digital Radio Receiver (U2K) 2 - Junction Block - I/P 3 - Speaker - Center 4 - Vehicle
Communication Interface Module (VCIM) (UE9) 5 - Remote Control Door Lock Receiver (RCDLR)
6 - Transfer Case Shift Control Module 7 - Fuse Block - I/P 8 - Body Control Module (BCM) 9 -
Junction Block - Body
Control Module > Component Information > Diagrams > Vehicle Communication Interface Module (VCIM) X1 (UE1)
Central Control Module: Diagrams Vehicle Communication Interface Module (VCIM) X1 (UE1)
Component Connector End Views
Vehicle Communication Interface Module (VCIM) X1 (UE1)

Control Module > Component Information > Diagrams > Vehicle Communication Interface Module (VCIM) X1 (UE1) > Page
13
Central Control Module: Diagrams Vehicle Communication Interface Module (VCIM) X2 (UE1)
Vehicle Communication Interface Module (VCIM) X2 (UE1)

Hummer Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Communications Control Module > Component Information > Service and Repair
Communications Control Module: Service and Repair
Communication Interface Module Replacement

Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 07-08-46-002D
> Jul > 09 > Audio System - Noise From Speakers When Using OnStar(R)
Emergency Contact Module: Customer Interest Audio System - Noise From Speakers When Using
OnStar(R)
TECHNICAL
Bulletin No.: 07-08-46-002D
Date: July 29, 2009
Subject: Audio Whine Noise from Radio Speakers When Using OnStar(R) (Install Noise
Suppression Filter)
Models:
2007-2010 GM Passenger Cars and Trucks (Including Saturn) 2007-2010 HUMMER H2, H3
2007-2009 Saab 9-7X Equipped with OnStar(R) (RPO UE1)
Supercede: This bulletin is being revised to update the Warranty Information. Please discard
Corporate Bulletin Number 07-08-46-002C (Section 08 - Body and Accessories).
Condition
Some customers may comment on an audio whine coming from the radio speakers when using the
OnStar(R) system. The amplitude and frequency of the whine will change with an increase or
decrease in engine speed.
Cause
This condition may be caused by electrical noise on the OnStar(R) Vehicle Communication
Interface Module (VCIM) battery feed wire being passed to the microphone output pins at the radio.
Correction
Technicians are to install a noise suppression filter, P/N 1224205, into the OnStar(R) battery
voltage circuit, a few centimeters (inches) from the VCIM. The filter package has three attached
wires - a single yellow wire at one end with a yellow wire and a black wire at the other. Install the
single yellow wire side into the battery voltage circuit towards the VCIM. Install the remaining single
yellow wire into the battery voltage circuit toward the fuse and the black wire to ground.
Important The noise suppression filter is polarity sensitive. The filter is designed to be most
effective when the end with the capacitor ground is connected towards the source of the electrical
noise. Install the filter in this polarity first. If the noise level is still not satisfactory, try disconnecting
the capacitor ground. In some cases, if the first installation does not correct the noise, try reversing
the filter polarity (removing the filter, turning it end for end and then reinstalling it) and grounding
the capacitor lead.
Parts Information
Warranty Information (excluding Saab U.S. Models)
For vehicles repaired under warranty, use the table above.

Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 07-08-46-002D
> Jul > 09 > Audio System - Noise From Speakers When Using OnStar(R) > Page 25
Warranty Information (Saab U.S. Models)
Disclaimer
Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-006C
> Jan > 08 > OnStar(R) - Incorrect Locations Reported During Calls
Emergency Contact Module: Customer Interest OnStar(R) - Incorrect Locations Reported During
Calls
Bulletin No.: 02-08-46-006C
Date: January 08, 2008
INFORMATION
Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During
OnStar(R) Call
Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008
HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X
with OnStar(R)
Supercede:
This bulletin is being revised to add model years. Please discard Corporate Bulletin Number
02-08-46-006B (Section 08 - Body and Accessories).
A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle
reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified
via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able
to identify this inaccurate location condition. Customers will then be notified through the mail by
OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R)
will instruct the customer to return to the dealership to have this condition corrected.
It is not necessary to reconfigure the vehicle after the following procedure.
In order to correct this condition you must cycle power to the OnStar(R) system. This can be done
by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R)
module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery.
The power needs to be removed from the system for approximately 15 minutes.
After completing this procedure the vehicle should be taken to an area with an unobstructed view of
the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to
reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue
OnStar(R) button and ask the advisor to verify the GPS position.
If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and
Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the
concern. If the normal diagnostics lead to module replacement you will need to contact Technical
Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the
diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out
within 24 hours and a pre-paid return package label will be included for returning the faulty part. By
returning the faulty part you will avoid a significant non-return core charge.
Warranty Information (excluding Saab US Models)
For vehicles repaired under warranty, use the table.
Warranty Information (Saab US Models)

> Jan > 08 > OnStar(R) - Incorrect Locations Reported During Calls > Page 30
For vehicles repaired under warranty use, the table.
Disclaimer
Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 05-08-46-004B
> Jan > 08 > OnStar(R) - Incorrect Number Assigned to Vehicle
Emergency Contact Module: Customer Interest OnStar(R) - Incorrect Number Assigned to Vehicle
Bulletin No.: 05-08-46-004B
INFORMATION
Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another

Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System
Models: 2000-2008 GM Passenger Cars and Trucks 2003-2008 HUMMER H2 2006-2008

HUMMER H3 2003-2008 Saturn Vehicles 2005-2008 Saab 9-7X
with OnStar(R) (RPO-UE1)
Supercede:
This bulletin is being revised to add the 2008 model year. Please discard Corporate Bulletin
Number 05-08-46-004A (Section 08 - Body and Accessories).
During diagnosis of an OnStar(R) concern the technician may be told that the OnStar(R) phone
number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these
concerns the Tech 2(R) with software version 22.005 (or higher) has the capability to change the
OnStar(R) phone number.
Service Procedure
With the Tech 2(R) build the vehicle to specifications within the Diagnostics area of the Tech 2(R).
For vehicles with physical-based diagnostics - under Body go to the OnStar(R) section. Then select
the Special Functions menu. For vehicles with functional-based diagnostics - under Body and
Accessories go to the Cellular Communication section. Select Module Setup and then Vehicle
Communication Interface Module.
Locate the Program Phone Number prompt and select it. The original phone number will be
displayed on the Tech 2(R) screen.
Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone
number.
Highlight the digits of the phone number one at a time and enter the new phone number using the
number keys on the Tech 2(R).
Press the Soft key at the base of the screen for Done once these numbers have been changed on
the screen.
Press the Soft key for Done again. The area code or new phone number has now been
programmed into the phone.
Cycle the ignition to Off and open the drivers door.
Press the blue OnStar(R) button to make sure that a normal connection can be made to the
OnStar(R) call center. If applicable make sure the Hands-Free Calling (HFC) works properly by
making a phone call.
If the system is working properly fax or voicemail a case closing into the OnStar(R) team at TAC
with the results. Dealers in Canada should submit case closing information through the GM
infoNET.
Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited
is resolved WITHOUT completing every step the remaining steps do not need to be performed. If
the procedure above does not resolve the condition you must contact TAC for further assistance.
This diagnostic approach was developed specifically for this condition and should not automatically
be used for other vehicles with similar symptoms.

Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 05-08-46-004B
> Jan > 08 > OnStar(R) - Incorrect Number Assigned to Vehicle > Page 35
Disclaimer
> Nov > 07 > OnStar(R) - Various Hands Free Issues
Emergency Contact Module: Customer Interest OnStar(R) - Various Hands Free Issues
Date: November 19, 2007
INFORMATION
Subject: Information on OnStar(R) System - Possible Loss of GPS Signal, Hands-Free Calling
Minutes Expire Prematurely and/or Inability to Add Hands-Free Calling Minutes
Models: 2001-2008 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2003-2008
with OnStar(R) System (RPO UE1)
Supercede:
This bulletin is being revised to add the 2008 model year, warranty information and to provide GPS
signal recovery steps (under Dealer Action heading) to do PRIOR to determining if the VIU/VCIM
needs replacement. Please discard Corporate Bulletin Number 02-08-46-007B (Section 08 - Body
& Accessories).
If the vehicle currently has analog-upgradable OnStar(R) hardware, then the customer should be
made aware of the digital upgrade program per the latest version of Service Bulletin #
05-08-46-006. Any analog OnStar system that is not upgraded prior to the end of 2007 will be
deactivated due to the upcoming phase-out of the analog cellular network in the U.S. and Canada.
If the vehicle has recently been upgraded or has had a service replacement unit installed, this
bulletin may not be applicable.
Certain 2001-2008 model year vehicles equipped with OnStar(R) may exhibit a condition with the
Global Positioning System (GPS) that causes inaccuracies in the GPS clock. The GPS system is
internal to the OnStar(R) Vehicle Interface Unit (VIU) or the Vehicle Communication Interface
Module (VCIM). This inaccuracy can result in a symptom where the OnStar(R) Call Center is
unable to obtain an accurate GPS signal, hands-Free Calling minutes expire prematurely and/or
the inability to add Hands-Free calling minutes.
Customer Notification
OnStar(R) will notify the customer by mail with instructions to contact their dealership service
department.
Dealer Action
Not all vehicles will require VIU/VCIM replacement.
The GPS signal in some vehicles may be recoverable. To determine if the signal is recoverable,
simply connect the Tech2(R) and using the GPS information data display option, observe the GPS
date and time. If the date/time stamps are equal to a date approximately 19 years in the future, the
GPS clock has exceeded its capacity and the VIU/VCIM will need to be replaced. If the date/time
stamp is in the past or near future, the GPS clock has simply generated an inaccurate value and
may be recoverable by performing the following power-up reset.
To initiate a power-up reset, battery voltage (batt. +) must be removed from the VIU/VCIM. The
preferred methods, in order, of initiating the reset are outlined below.
Remove the fuse that supplies Battery positive (Batt. +) voltage to the module (refer to the
applicable Service Information schematics for the appropriate fuse).
The next preferred method is to remove the connector to the OnStar(R) unit that Batt + is
contained.
The least preferable method is to remove the negative terminal of the vehicle battery. This will not
only initiate the power-up reset, but it may also result in the loss of radio presets and other stored
personalization information/settings in other modules as well.
After initiating the power-up reset, the GPS data will be set to the defaulted date and time and will
require an acquisition of the GPS signal in order to gain the proper date and time.
Acquiring the GPS signal requires running the vehicle in an open/unobstructed view of the sky.
First, contact OnStar(R) Technical Support by pressing the blue button. Allow the OnStar(R)
Technical Advisor to activate the GPS recovery process. This should take approximately 10
minutes. Continue to
> Nov > 07 > OnStar(R) - Various Hands Free Issues > Page 40
monitor the Tech2(R) for the current time and date. REMINDER - Keep in mind that the time
displayed on the Tech2(R) is in Greenwich Mean Time (GMT) and the offset is based on the time
zones relationship to GMT.
If replacement of the VIU/VCIM is necessary, you MUST reconfigure the OnStar® system. Failure
to reconfigure the system will result in an additional customer visit for repair. OnStar® VIU,
Generations 2 and 3, will require the technician to press the blue OnStar® button to reconfigure the
vehicle with an OnStar® advisor.
OnStar(R) VCIM, Generations 4-7 will require the technician to reconfigure the vehicle with the use
of the TIS2WEB and SPS applications (pass thru only), along with the Tech2(R).
The configuration and set-up procedure is a two-step process that must be completed step-by-step
without interruption or delay in between each step. This procedure enables an automated activation
without a button press by the technician to the OnStar(R) Call Center. Following this procedure, it
may take up to 24 hours for all OnStar(R) services to be fully activated.
How to Order Parts
If the OnStar(R) GPS date/time stamp is non-recoverable and the unit needs to be replaced,
dealers in the U.S. should contact Autocraft Electronics select the catalog item that contains this
bulletin number. Canadian dealers should contact MASS Electronics.
Dealers DO NOT need to call the GM Technical Assistance Center (TAC) for replacement
approval. Autocraft Electronics and MASS Electronics will be responsible for verifying that the
subject vehicle is a candidate for a replacement VIU/VCIM.

> Nov > 07 > OnStar(R) - Various Hands Free Issues > Page 41
Disclaimer
Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: >
07-08-46-002D > Jul > 09 > Audio System - Noise From Speakers When Using OnStar(R)
Emergency Contact Module: All Technical Service Bulletins Audio System - Noise From Speakers
When Using OnStar(R)
TECHNICAL
Date: July 29, 2009
Subject: Audio Whine Noise from Radio Speakers When Using OnStar(R) (Install Noise
Suppression Filter)
Models:
2007-2009 Saab 9-7X Equipped with OnStar(R) (RPO UE1)
Supercede: This bulletin is being revised to update the Warranty Information. Please discard
Corporate Bulletin Number 07-08-46-002C (Section 08 - Body and Accessories).
Condition
Some customers may comment on an audio whine coming from the radio speakers when using the
OnStar(R) system. The amplitude and frequency of the whine will change with an increase or
decrease in engine speed.
Cause
This condition may be caused by electrical noise on the OnStar(R) Vehicle Communication
Interface Module (VCIM) battery feed wire being passed to the microphone output pins at the radio.
Correction
Technicians are to install a noise suppression filter, P/N 1224205, into the OnStar(R) battery
voltage circuit, a few centimeters (inches) from the VCIM. The filter package has three attached
wires - a single yellow wire at one end with a yellow wire and a black wire at the other. Install the
single yellow wire side into the battery voltage circuit towards the VCIM. Install the remaining single
yellow wire into the battery voltage circuit toward the fuse and the black wire to ground.
Important The noise suppression filter is polarity sensitive. The filter is designed to be most
effective when the end with the capacitor ground is connected towards the source of the electrical
noise. Install the filter in this polarity first. If the noise level is still not satisfactory, try disconnecting
the capacitor ground. In some cases, if the first installation does not correct the noise, try reversing
the filter polarity (removing the filter, turning it end for end and then reinstalling it) and grounding
the capacitor lead.
Parts Information

07-08-46-002D > Jul > 09 > Audio System - Noise From Speakers When Using OnStar(R) > Page 47
Disclaimer
02-08-44-007D > May > 09 > OnStar(R) - Negative Impact of Cloth/Vinyl Roofs
Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Negative Impact of
Cloth/Vinyl Roofs
INFORMATION
Date: May 12, 2009
Subject: Negative Impact of Dealer-Installed Cloth/Vinyl Roofs on XM Radio and/or OnStar(R)

Systems
Models:
2002-2009 Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2009
HUMMER H3 2005-2009 Saab 9-7X with XM Radio (RPO U2K) and/or OnStar(R) (RPO UE1)
..............................................................................................................................................................
.................................................................................. Supercede: This bulletin is being revised to
include the 2009 model year. Please discard Corporate Bulletin Number 02-08-44-007C (Section
08 - Body and Accessories).
..............................................................................................................................................................
..................................................................................
Dealers should not install a cloth or vinyl roof on vehicles that have been ordered with the XM radio
option (RPO U2K) and/or OnStar(R) (RPO UE1). The performance of these systems may be
negatively impacted by the installation of the cloth/vinyl roof. Additionally, water leaks may result
from installing a cloth or vinyl roof on vehicles with roof-mounted antenna systems. Relocating the
antenna to another spot on the vehicle exterior, in order to install a cloth or vinyl roof, is not advised
either. The performance of the OnStar(R) and XM Radio antennas has been optimized for their
current locations. Relocating the antennas may result in a performance degradation.
Disclaimer
08-08-46-004 > Aug > 08 > OnStar(R) - Aftermarket Device Interference
Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Aftermarket Device
Interference
INFORMATION
Bulletin No.: 08-08-46-004
Date: August 14, 2008
Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services
Models: 2009 and Prior GM Passenger Car and Truck (including Saturn) 2009 and Prior HUMMER
H2, H3 Models 2009 and Prior Saab 9-7X
with OnStar(R) (RPO UE1)
This bulletin is being issued to provide dealer service personnel with information regarding
aftermarket devices connected to the Diagnostic Link Connector (DLC) and the impact to
OnStar(R) diagnostic probes and Vehicle Diagnostic e-mails.
Certain aftermarket devices, when connected to the Diagnostic Link Connector, such as, but not
limited to, Scan Tools, Trip Computers, Fuel Economy Analyzers and Insurance Tracking Devices,
interfere with OnStar's ability to perform a diagnostic probe when requested (via a blue button call)
by a subscriber. These devices also prohibit the ability to gather diagnostic and tire pressure data
for a subscriber's scheduled OnStar(R) Vehicle Diagnostic (OVD) e-mail.
These aftermarket devices utilize the Vehicles serial data bus to perform data requests and/or
information gathering. When these devices are requesting data, OnStar(R) is designed not to
interfere with any data request being made by these devices as required by OBD II regulations.
The OnStar(R) advisor is unable to definitively detect the presence of these devices and will only
be able to inform the caller or requester of the unsuccessful or incomplete probe and may in some
cases refer the subscriber/requester to take the vehicle to a dealer for diagnosis of the concern.
When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic

probe, or for concerns regarding completeness of the OnStar(R) Vehicle Diagnostic (OVD) e-mail,
verify that an aftermarket device was not present at the time of the requested probe. Regarding the
OVD e-mail, if an aftermarket device is interfering (including a Scan Tool of any type), the e-mail
will consistently display a "yellow" indication in diagnostics section for all vehicle systems except
the OnStar(R) System and Tire Pressure data (not available on all vehicles) will not be displayed
(i.e. section is collapsed). Successful diagnostic probes and complete OVD e-mails will resume
following the removal or disconnecting of the off-board device.
Disclaimer
06-08-46-005A > Jan > 08 > OnStar(R) - System Availability for The Hearing Impaired
Emergency Contact Module: All Technical Service Bulletins OnStar(R) - System Availability for The
Hearing Impaired
Bulletin No.: 06-08-46-005A
INFORMATION
Subject: Availability of OnStar(R) for Hearing Impaired
Models: 2007-2008 GM Passenger Cars and Light Duty Trucks (Including Saturn and Saab)
Except 2007 Cadillac CTS Except 2007-2008 HUMMER H2, H2 SUT Except 2007 Pontiac
Montana SV6 Except 2007-2008 Pontiac Vibe Except 2008 Pontiac G8 Except 2007 Saturn ION
VUE Except 2008 Saturn ASTRA
Supercede:
This bulletin is being revised to add models and model years. Please discard Corporate Bulletin
Number 06-08-46-005 (Section 08 - Body and Accessories).
This service bulletin is not applicable to GM of Canada dealers and retailers.
OnStar with Text Telephone Capability (TTY)
General Motors is pleased to announce that the safety and security of OnStar is now available to
our deaf hard of hearing and speech impaired customers. The current vehicles listed above as well
as forthcoming vehicles equipped with OnStar hardware version 7.0 or higher have the ability to
utilize texting telephones. Vehicle specific TTY capability can be determined by utilizing the VIN
lookup Tool. Additional information may be found by referring to www.onstar.com/tty
TTY equipment allows people who are deaf hard of hearing or speech impaired in-vehicle access
to 911 and basic OnStar(R) services by pressing the OnStar(R) blue button or red emergency
button. The keypad provides a means to communicate by allowing customers to type messages
back and forth with an OnStar(R) advisor or other party when using the OnStar(R) Hands-Free
Calling feature. A TTY is required at both ends of the conversation in order to communicate.
OnStar(R) Turn by Turn Navigation and Virtual Advisor are not available with the addition of TTY.
The Reimbursement Program
This equipment will be made available to eligible customers through GM Mobility and OnStar(R).
Under this program the customer must complete a GM Mobility application form. To take
advantage of the program vehicles must be adapted at the time of delivery for purchase / lease and
a dealer claim ($1,000 Maximum per GM Mobility guidelines) with the application form submitted to
GM Mobility. Saab dealers must fax documents. GM Dealers will receive electronic reimbursement
directly from GM Mobility. Saab dealers will receive a check directly from OnStar(R). Additional
questions or concerns should be directed to the OnStar Dealer Center at 1-(888) 667-8271 prompt
# 2.
How to Order
To order the dealer installed kit contact Auto Craft Electronics at 1-(800) 336-3998 or via the web at
www.autocraft.com. The kit consists of an OnStar Interface Module a Dial Pad (for making calls)
OTIM wiring harness the TTY device installation / Tech 2(R) programming instructions and owners
guide.
Warranty Information
The Ultra-Tec Compact C TTY device is manufactured by an independent manufacturer and is

covered by the manufacturers warranty. It is not covered under the GM New Vehicle Limited
Warranty. All other parts (OTIM dial pad and OTIM wiring harness) are covered by the standard
GM new vehicle parts and labor warranty. Replacement parts are available through AutoCraft
Electronics. Contact AutoCraft Electronics at 1-800-336-3998 or via the web at www.autocraft.com.
Warranty claims for the OTIM dial pad and OTIM wiring harness should be submitted through
normal warranty procedures using a sublet warranty claim with GM Labor Operation R5140.
06-08-46-005A > Jan > 08 > OnStar(R) - System Availability for The Hearing Impaired > Page 60
Disclaimer
02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect Locations Reported During Calls
Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Incorrect Locations
Reported During Calls
INFORMATION
Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During
OnStar(R) Call
with OnStar(R)
Supercede:
02-08-46-006B (Section 08 - Body and Accessories).
A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle
reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified
via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able
to identify this inaccurate location condition. Customers will then be notified through the mail by
OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R)
will instruct the customer to return to the dealership to have this condition corrected.
It is not necessary to reconfigure the vehicle after the following procedure.
In order to correct this condition you must cycle power to the OnStar(R) system. This can be done
by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R)
module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery.
The power needs to be removed from the system for approximately 15 minutes.
After completing this procedure the vehicle should be taken to an area with an unobstructed view of
the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to
reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue
OnStar(R) button and ask the advisor to verify the GPS position.
If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and
Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the
concern. If the normal diagnostics lead to module replacement you will need to contact Technical
Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the
diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out
within 24 hours and a pre-paid return package label will be included for returning the faulty part. By
returning the faulty part you will avoid a significant non-return core charge.
Warranty Information (excluding Saab US Models)
Warranty Information (Saab US Models)

02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect Locations Reported During Calls > Page 65
Disclaimer
05-08-46-004B > Jan > 08 > OnStar(R) - Incorrect Number Assigned to Vehicle
Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Incorrect Number
Assigned to Vehicle
INFORMATION
Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another

Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System
Models: 2000-2008 GM Passenger Cars and Trucks 2003-2008 HUMMER H2 2006-2008

HUMMER H3 2003-2008 Saturn Vehicles 2005-2008 Saab 9-7X
with OnStar(R) (RPO-UE1)
Supercede:
Number 05-08-46-004A (Section 08 - Body and Accessories).
During diagnosis of an OnStar(R) concern the technician may be told that the OnStar(R) phone
number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these
concerns the Tech 2(R) with software version 22.005 (or higher) has the capability to change the
OnStar(R) phone number.
Service Procedure
With the Tech 2(R) build the vehicle to specifications within the Diagnostics area of the Tech 2(R).
For vehicles with physical-based diagnostics - under Body go to the OnStar(R) section. Then select
the Special Functions menu. For vehicles with functional-based diagnostics - under Body and
Accessories go to the Cellular Communication section. Select Module Setup and then Vehicle
Communication Interface Module.
Locate the Program Phone Number prompt and select it. The original phone number will be
displayed on the Tech 2(R) screen.
Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone
number.
Highlight the digits of the phone number one at a time and enter the new phone number using the
number keys on the Tech 2(R).
Press the Soft key at the base of the screen for Done once these numbers have been changed on
the screen.
Press the Soft key for Done again. The area code or new phone number has now been
programmed into the phone.
Cycle the ignition to Off and open the drivers door.
Press the blue OnStar(R) button to make sure that a normal connection can be made to the
OnStar(R) call center. If applicable make sure the Hands-Free Calling (HFC) works properly by
making a phone call.
If the system is working properly fax or voicemail a case closing into the OnStar(R) team at TAC
with the results. Dealers in Canada should submit case closing information through the GM
infoNET.
Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited
is resolved WITHOUT completing every step the remaining steps do not need to be performed. If
the procedure above does not resolve the condition you must contact TAC for further assistance.
This diagnostic approach was developed specifically for this condition and should not automatically
be used for other vehicles with similar symptoms.

05-08-46-004B > Jan > 08 > OnStar(R) - Incorrect Number Assigned to Vehicle > Page 70
Disclaimer
02-08-46-007C > Nov > 07 > OnStar(R) - Various Hands Free Issues
Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Various Hands Free
Issues
INFORMATION
Subject: Information on OnStar(R) System - Possible Loss of GPS Signal, Hands-Free Calling
Minutes Expire Prematurely and/or Inability to Add Hands-Free Calling Minutes
with OnStar(R) System (RPO UE1)
Supercede:
This bulletin is being revised to add the 2008 model year, warranty information and to provide GPS
signal recovery steps (under Dealer Action heading) to do PRIOR to determining if the VIU/VCIM
needs replacement. Please discard Corporate Bulletin Number 02-08-46-007B (Section 08 - Body
& Accessories).
If the vehicle currently has analog-upgradable OnStar(R) hardware, then the customer should be
made aware of the digital upgrade program per the latest version of Service Bulletin #
05-08-46-006. Any analog OnStar system that is not upgraded prior to the end of 2007 will be
deactivated due to the upcoming phase-out of the analog cellular network in the U.S. and Canada.
If the vehicle has recently been upgraded or has had a service replacement unit installed, this
bulletin may not be applicable.
Certain 2001-2008 model year vehicles equipped with OnStar(R) may exhibit a condition with the
Global Positioning System (GPS) that causes inaccuracies in the GPS clock. The GPS system is
internal to the OnStar(R) Vehicle Interface Unit (VIU) or the Vehicle Communication Interface
Module (VCIM). This inaccuracy can result in a symptom where the OnStar(R) Call Center is
unable to obtain an accurate GPS signal, hands-Free Calling minutes expire prematurely and/or
the inability to add Hands-Free calling minutes.
OnStar(R) will notify the customer by mail with instructions to contact their dealership service
department.
Dealer Action
Not all vehicles will require VIU/VCIM replacement.
The GPS signal in some vehicles may be recoverable. To determine if the signal is recoverable,
simply connect the Tech2(R) and using the GPS information data display option, observe the GPS
date and time. If the date/time stamps are equal to a date approximately 19 years in the future, the
GPS clock has exceeded its capacity and the VIU/VCIM will need to be replaced. If the date/time
stamp is in the past or near future, the GPS clock has simply generated an inaccurate value and
may be recoverable by performing the following power-up reset.
To initiate a power-up reset, battery voltage (batt. +) must be removed from the VIU/VCIM. The
preferred methods, in order, of initiating the reset are outlined below.
Remove the fuse that supplies Battery positive (Batt. +) voltage to the module (refer to the
applicable Service Information schematics for the appropriate fuse).
The next preferred method is to remove the connector to the OnStar(R) unit that Batt + is
contained.
The least preferable method is to remove the negative terminal of the vehicle battery. This will not
only initiate the power-up reset, but it may also result in the loss of radio presets and other stored
personalization information/settings in other modules as well.
After initiating the power-up reset, the GPS data will be set to the defaulted date and time and will
require an acquisition of the GPS signal in order to gain the proper date and time.
Acquiring the GPS signal requires running the vehicle in an open/unobstructed view of the sky.
First, contact OnStar(R) Technical Support by pressing the blue button. Allow the OnStar(R)
Technical Advisor to activate the GPS recovery process. This should take approximately 10
minutes. Continue to
02-08-46-007C > Nov > 07 > OnStar(R) - Various Hands Free Issues > Page 75
monitor the Tech2(R) for the current time and date. REMINDER - Keep in mind that the time
displayed on the Tech2(R) is in Greenwich Mean Time (GMT) and the offset is based on the time
zones relationship to GMT.
If replacement of the VIU/VCIM is necessary, you MUST reconfigure the OnStar® system. Failure
to reconfigure the system will result in an additional customer visit for repair. OnStar® VIU,
Generations 2 and 3, will require the technician to press the blue OnStar® button to reconfigure the
vehicle with an OnStar® advisor.
OnStar(R) VCIM, Generations 4-7 will require the technician to reconfigure the vehicle with the use
of the TIS2WEB and SPS applications (pass thru only), along with the Tech2(R).
The configuration and set-up procedure is a two-step process that must be completed step-by-step
without interruption or delay in between each step. This procedure enables an automated activation
without a button press by the technician to the OnStar(R) Call Center. Following this procedure, it
may take up to 24 hours for all OnStar(R) services to be fully activated.
How to Order Parts
If the OnStar(R) GPS date/time stamp is non-recoverable and the unit needs to be replaced,
dealers in the U.S. should contact Autocraft Electronics select the catalog item that contains this
bulletin number. Canadian dealers should contact MASS Electronics.
Dealers DO NOT need to call the GM Technical Assistance Center (TAC) for replacement
approval. Autocraft Electronics and MASS Electronics will be responsible for verifying that the
subject vehicle is a candidate for a replacement VIU/VCIM.

02-08-46-007C > Nov > 07 > OnStar(R) - Various Hands Free Issues > Page 76
Disclaimer
05-08-46-009B > Jun > 07 > OnStar(R) - Language Change Information
Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Language Change
Information
Date: June 29, 2007

INFORMATION
Subject: Language Change for OnStar(R) System (U.S. and Canada Only)
HUMMER H2, H3 2006-2008 Saab 9-7X
with OnStar(R) (RPO UE1)
Built After and Including VIN Breakpoints Listed Below (2006 MY Only)
Attention:
This bulletin only applies to vehicles equipped with OnStar(R) Generation 6.1 or later with a Station
Identification (STID) Number in the following range: 16,000,000-17,000,000 or
20,000,000-21,999,999 or 23,500,001-26,000,000
Supercede:
This bulletin is being revised to update the service procedure and add a Canadian procedure.
Please discard Corporate Bulletin Numbers 05-08-46-009A and 05-08-46-008A (Section 08 - Body
and Accessories).
05-08-46-009B > Jun > 07 > OnStar(R) - Language Change Information > Page 81
Built After and Including the VIN Breakpoints shown.
The Generation (Gen) 6.1 OnStar(R) system found in these vehicles has the capability to change
the default English voice recognition to French or Spanish.
Changing the language of the OnStar(R) system will change the following features to the language
you select:
Voice recognition command prompts will be played in the language selected.
The voice recognition system will only recognize commands given in the selected language.
Once completed, this process completely changes all voice recognition and voice commands of the
OnStar(R) system. The process will need to be repeated in its entirety to change to a different
language, including English.
Method 1
Method 2
Method 3
The Gen 6.1 version of OnStar(R) does not require the use of the Service Programming System
(SPS) to change the voice recognition system. However, there are three ways to change the
language.
Disclaimer
Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for
Emergency Contact Module: > 07-08-44-016A > Aug > 07 > Entertainment System - Headrest DVD Monitor Inoperative
Television / Monitor: All Technical Service Bulletins Entertainment System - Headrest DVD Monitor
Inoperative
TECHNICAL
Subject: GM Accessories Headrest DVD System Display Monitor Inoperative (Install Cable
Connector Clamps)
Models
Supercede:
This bulletin is being revised to update the models affected list. Please discard Corporate Bulletin
Number 07-08-44-016 (Section 08 - Body & Accessories).
Condition
Some customers may comment on an inoperative display monitor or monitors in the GM

Accessories Headrest DVD System.
Cause
This condition may be caused by a loose connection at the display monitor cable connectors.
These connectors are located at the lower rear part of both front seats. Two cables are routed to
the display monitor in each seat.
Correction
A number of headrest monitors have been replaced under warranty and in many cases, no trouble
was found by the supplier when these units were
Emergency Contact Module: > 07-08-44-016A > Aug > 07 > Entertainment System - Headrest DVD Monitor Inoperative >
Page 90
analyzed. Therefore, technicians should be checking for loose connections and installing cable
connector clamps to ensure a positive and robust connection.
Technicians are to install a video cable connector clamp on each cable connector located under
each front seat. A total of four cable connector clamps, P/N 19159659, are required for each
vehicle.
The illustration above shows a pair of display monitor cable connectors without the cable clamps
installed.
The illustration above shows the display monitor cable connectors with the cable connector clamps.
The lower cable connector clamp is installed but not locked together. The upper cable connector
clamp is closed and locked.
The cable connector clamps have now been added as a permanent component to all GM
Accessories Headrest DVD Systems installation kits.
Parts Information

Page 91
Disclaimer
Page 97
analyzed. Therefore, technicians should be checking for loose connections and installing cable
connector clamps to ensure a positive and robust connection.
Technicians are to install a video cable connector clamp on each cable connector located under
each front seat. A total of four cable connector clamps, P/N 19159659, are required for each
vehicle.
The illustration above shows a pair of display monitor cable connectors without the cable clamps
installed.
The illustration above shows the display monitor cable connectors with the cable connector clamps.
The lower cable connector clamp is installed but not locked together. The upper cable connector
clamp is closed and locked.
The cable connector clamps have now been added as a permanent component to all GM
Accessories Headrest DVD Systems installation kits.
Parts Information

Page 98
Disclaimer
Keyless Entry Module > Component Information > Diagrams
Keyless Entry Module: Diagrams
Remote Control Door Lock Receiver (RCDLR)

Keyless Entry Module > Component Information > Service and Repair > Remote Control Door Lock Receiver Replacement
Keyless Entry Module: Service and Repair Remote Control Door Lock Receiver Replacement
Remote Control Door Lock Receiver Replacement

Keyless Entry Module > Component Information > Service and Repair > Remote Control Door Lock Receiver Replacement
> Page 104
Keyless Entry Module: Service and Repair Remote Control Door Lock Receiver Antenna
Replacement
Remote Control Door Lock Receiver Antenna Replacement

Hummer Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Parking
Assist Control Module > Component Information > Locations
Parking Assist Control Module: Locations
Passenger Compartment/Roof Component Views
Right Front Passenger Compartment
1 - Rear Object Sensor Control Module 2 - Inflatable Restraint Roof Rail Module - Right Front 3 -
Seat Belt Pretensioner - Right
Hummer Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component
Information > Technical Service Bulletins > Customer Interest: > 08-03-16-004A > Jan > 09 > Tire Monitor System -
Warning Lamp ON/Tire Pressure OK
Door Module: Customer Interest Tire Monitor System - Warning Lamp ON/Tire Pressure OK
TECHNICAL
Subject: Tire Pressure Light Stays On (Reprogram RCDLR)
Models: 2008-2009 Buick Lucerne 2008-2009 Cadillac CTS, DTS, Escalade, Escalade ESV,
Escalade EXT 2008-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2009 GMC
Sierra, Sierra Denali, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2009 HUMMER H2
2009 Saturn VUE
with Vehicle Build Dates Between January 1, 2008 and August 15, 2008
Supercede:
This bulletin is being revised to add the Avalanche and 2009 Saturn VUE to the models. Please
discard Corporate Bulletin Number 08-03-16-004 (Section 03 - Suspension).
Condition
Some customers may comment that the tire pressure light stays on even though tire pressure
values are correct. It should also be noted that no DIC messages have been displayed and a scan
tool will reveal no DTCs within the RCDLR.
Correction
Important:
From the controller list, select RCDLR Remote Control Door Lock Receiver (Pass-Thru Only).
If all the above conditions have been met, then reprogram the RCDLR. A revised service
calibration has been released to address this issue. Reprogram the RCDLR using the TIS2WEB
Service Programming System (SPS) application. As always, make sure your Tech 2(R) is updated
with the latest software version.
Important:
The Copy and Paste TPM Information function in Tech 2(R) must be used when reprogramming
the RCDLR. This function can be used to copy all the information that is related to the tire pressure
monitoring system (including tire sensor ID's) and paste the information into a freshly SPS
reprogrammed RCDLR. Refer to Remote Control Door Lock Receiver Programming and Setup in
SI for additional information.
Disclaimer
Information > Technical Service Bulletins > Customer Interest: > 07-08-64-022B > Jan > 09 > Mirrors - Curb Park Assist
Mirror Issues
Door Module: Customer Interest Mirrors - Curb Park Assist Mirror Issues
INFORMATION
Subject: Information On Curb Park Assist And Memory Related Issues On Outside Rearview
Mirrors
Models: 2008 and Prior GM Passenger Cars and Trucks (Including Saturn) (Excludes Cadillac
SRX) 2008 and Prior HUMMER H2, H3 2007 and Prior Saab 9-7X
with Memory Mirrors
Supercede:
This bulletin is being revised to indicate that technicians should reprogram the driver's side door
module for a memory or curb park assist issue. Please discard Corporate Bulletin Number
07-08-64-022A (Section 08 - Body and Accessories).
A large number of mirrors are being returned through the Warranty Parts Center (WPC) with
customer comments of curb park assist and memory setting issues. Returned part analysis
indicates that the mirrors are found to be fully functional. If you have a memory or curb park assist
issue, check the wiring, the respective door module and reprogram the driver's door module with
the latest software in TIS.
Disclaimer
Information > Technical Service Bulletins > All Technical Service Bulletins for Door Module: > 08-03-16-004A > Jan > 09 >
Tire Monitor System - Warning Lamp ON/Tire Pressure OK
Door Module: All Technical Service Bulletins Tire Monitor System - Warning Lamp ON/Tire
Pressure OK
TECHNICAL
Subject: Tire Pressure Light Stays On (Reprogram RCDLR)
Models: 2008-2009 Buick Lucerne 2008-2009 Cadillac CTS, DTS, Escalade, Escalade ESV,
Escalade EXT 2008-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2009 GMC
Sierra, Sierra Denali, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2009 HUMMER H2
2009 Saturn VUE
with Vehicle Build Dates Between January 1, 2008 and August 15, 2008
Supercede:
This bulletin is being revised to add the Avalanche and 2009 Saturn VUE to the models. Please
discard Corporate Bulletin Number 08-03-16-004 (Section 03 - Suspension).
Condition
Some customers may comment that the tire pressure light stays on even though tire pressure
values are correct. It should also be noted that no DIC messages have been displayed and a scan
tool will reveal no DTCs within the RCDLR.
Correction
Important:
From the controller list, select RCDLR Remote Control Door Lock Receiver (Pass-Thru Only).
If all the above conditions have been met, then reprogram the RCDLR. A revised service
calibration has been released to address this issue. Reprogram the RCDLR using the TIS2WEB
Service Programming System (SPS) application. As always, make sure your Tech 2(R) is updated
with the latest software version.
Important:
The Copy and Paste TPM Information function in Tech 2(R) must be used when reprogramming
the RCDLR. This function can be used to copy all the information that is related to the tire pressure
monitoring system (including tire sensor ID's) and paste the information into a freshly SPS
reprogrammed RCDLR. Refer to Remote Control Door Lock Receiver Programming and Setup in
SI for additional information.
Disclaimer
Information > Technical Service Bulletins > All Technical Service Bulletins for Door Module: > 07-08-64-022B > Jan > 09 >
Mirrors - Curb Park Assist Mirror Issues
Door Module: All Technical Service Bulletins Mirrors - Curb Park Assist Mirror Issues
INFORMATION
Subject: Information On Curb Park Assist And Memory Related Issues On Outside Rearview
Mirrors
Models: 2008 and Prior GM Passenger Cars and Trucks (Including Saturn) (Excludes Cadillac
SRX) 2008 and Prior HUMMER H2, H3 2007 and Prior Saab 9-7X
with Memory Mirrors
Supercede:
This bulletin is being revised to indicate that technicians should reprogram the driver's side door
module for a memory or curb park assist issue. Please discard Corporate Bulletin Number
07-08-64-022A (Section 08 - Body and Accessories).
A large number of mirrors are being returned through the Warranty Parts Center (WPC) with
customer comments of curb park assist and memory setting issues. Returned part analysis
indicates that the mirrors are found to be fully functional. If you have a memory or curb park assist
issue, check the wiring, the respective door module and reprogram the driver's door module with
the latest software in TIS.
Disclaimer
Information > Technical Service Bulletins > All Technical Service Bulletins for Door Module: > 08-08-64-013 > Aug > 08 >
Body - Door Module/Switch Programming Information
Door Module: All Technical Service Bulletins Body - Door Module/Switch Programming Information
INFORMATION
Bulletin No.: 08-08-64-013
Subject: Information on Reprogramming Replacement Door Modules/Switches
Models: 2006-2009 Buick Lucerne 2008-2009 Buick Enclave 2006-2009 Cadillac DTS 2007-2009
Cadillac Escalade, Escalade ESV, Escalade EXT, SRX 2008-2009 Cadillac CTS 2007-2009
Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Acadia, Sierra, Yukon, Yukon
Denali, Yukon XL, Yukon Denali XL 2008-2009 HUMMER H2 2007-2009 Saturn OUTLOOK
A large number of door modules are being returned through the Warranty Parts Center (WPC). The
returned part analyses indicate that the door modules/switches are missing their respective
software calibrations.
Important:
For step-by-step programming instructions, please refer to the Techline Information System (TIS)
terminal. Select the appropriate controller - Driver Door Module (DDM) or Passenger Door Module
(PDM).
Any time a new door module is replaced, the module will require the updated software and/or
calibration files using the TIS Service Programming System (SPS) application. Refer to Door
Control Module Programming and Setup in SI.
The information in this bulletin is being provided to help reduce the amount of door modules being
returned. Check the wiring at the respective door module, the door "doc-n-loc" electrical
connectors, software calibrations, and the specific hardware or wiring associated with the customer
complaint (e.g., window regulator, outside mirror, door handle, etc.) prior to replacing any door
module.
Disclaimer
Information > Technical Service Bulletins > All Other Service Bulletins for Door Module: > 08-08-64-013 > Aug > 08 > Body -
Door Module/Switch Programming Information
Door Module: All Technical Service Bulletins Body - Door Module/Switch Programming Information
INFORMATION
Bulletin No.: 08-08-64-013
Subject: Information on Reprogramming Replacement Door Modules/Switches
Models: 2006-2009 Buick Lucerne 2008-2009 Buick Enclave 2006-2009 Cadillac DTS 2007-2009
Cadillac Escalade, Escalade ESV, Escalade EXT, SRX 2008-2009 Cadillac CTS 2007-2009
Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Acadia, Sierra, Yukon, Yukon
Denali, Yukon XL, Yukon Denali XL 2008-2009 HUMMER H2 2007-2009 Saturn OUTLOOK
A large number of door modules are being returned through the Warranty Parts Center (WPC). The
returned part analyses indicate that the door modules/switches are missing their respective
software calibrations.
Important:
For step-by-step programming instructions, please refer to the Techline Information System (TIS)
terminal. Select the appropriate controller - Driver Door Module (DDM) or Passenger Door Module
(PDM).
Any time a new door module is replaced, the module will require the updated software and/or
calibration files using the TIS Service Programming System (SPS) application. Refer to Door
Control Module Programming and Setup in SI.
The information in this bulletin is being provided to help reduce the amount of door modules being
returned. Check the wiring at the respective door module, the door "doc-n-loc" electrical
connectors, software calibrations, and the specific hardware or wiring associated with the customer
complaint (e.g., window regulator, outside mirror, door handle, etc.) prior to replacing any door
module.
Disclaimer
Information > Locations > Driver Door Module (DDM)
Door Module: Locations Driver Door Module (DDM)
Door Component Views
Front Doors
1 - Courtesy Lamp-Driver Door 2 - Outside Rearview Mirror-Driver 3 - Memory/Heated Seat

Switch-Driver 4 - Driver Door Module (DDM) 5 - Speaker-LF Door 6 - Speaker-RF Door 7 -
Passenger Door Module (PDM) 8 - Heated Seat Switch-Passenger 9 - Outside Rearview
Mirror-Passenger 10 - Courtesy Lamp-Front Passenger Door 11 - Door Latch Assembly-Front
Passenger 12 - Inflatable Restraint Side Impact Sensor (SIS) - Right Front 13 - Window
Motor-Front Passenger Door 14 - Window Motor-Driver Door 15 - Inflatable Restraint Side Impact
Sensor (SIS) - Left Front
Information > Locations > Driver Door Module (DDM) > Page 141
16 - Door Latch Assembly-Driver Door
Door Module: Locations Passenger Door Module (PDM)
Front Doors

Information > Diagrams > Driver Door Module (DDM) X1
Door Module: Diagrams Driver Door Module (DDM) X1
Driver Door Module (DDM) X1

Information > Diagrams > Driver Door Module (DDM) X1 > Page 146


Door Module: Diagrams Passenger Door Module (PDM) X1
Passenger Door Module (PDM) X1

Door Module: Diagrams Passenger Door Module (PDM) X2
Passenger Door Module (PDM) X2

Hummer Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module >
Component Information > Diagrams
Keyless Entry Module: Diagrams
Remote Control Door Lock Receiver (RCDLR)

Component Information > Service and Repair > Remote Control Door Lock Receiver Replacement
Keyless Entry Module: Service and Repair Remote Control Door Lock Receiver Replacement
Remote Control Door Lock Receiver Replacement

Component Information > Service and Repair > Remote Control Door Lock Receiver Replacement > Page 155
Keyless Entry Module: Service and Repair Remote Control Door Lock Receiver Antenna
Replacement
Remote Control Door Lock Receiver Antenna Replacement

Hummer Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Memory Positioning Module
> Component Information > Locations
Memory Positioning Module: Locations
Driver Seat Sub-System Components
1 - X327 2 - Seat Adjuster Switch-Driver 3 - Memory Seat Module-C4 4 - Memory Seat Module-C3
5 - Seat Bolster/Lumbar Switch-Driver 6 - Seat Recline Motor-Driver 7 - X325 8 - X329 9 - X330 10
- C328 11 - Seat Rear Vertical Motor-Driver 12 - Seat Front Vertical Motor-Driver 13 - Memory Seat
Module-C2 14 - Memory Seat Module-C1 15 - Seat Horizontal Motor-Driver 16 - X326
Hummer Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay >
Component Information > Locations
Hummer Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module
Power Seat Control Module: Locations
Hummer Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Trunk / Liftgate
Control Module > Component Information > Locations
Power Trunk / Liftgate Control Module: Locations
Midgate Components (SUT)
1 - Midgate Latch-Right 2 - Midgate Latch Release Switch-Right 3 - Midgate Latch Release

Switch-Left 4 - Midgate Latch-Left 5 - Midgate Control Module
Midgate Components (SUT)

Hummer Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Trunk / Liftgate
Control Module > Component Information > Locations > Page 168
1 - Midgate Latch-Right 2 - Midgate Latch Release Switch-Right 3 - Midgate Latch Release

Switch-Left 4 - Midgate Latch-Left 5 - Midgate Control Module
Hummer Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module
Seat Heater Control Module: Locations
2nd Row Heated Seat Components (KA7)
1 - Heated Seat Control Module-RR 2 - 2nd Row Seat-LR 3 - Heated Seat Control Module-LR 4 -
Heated Seat Element Connector-LR 5 - X320 6 - Heated Seat Element Connector-RR 7 - X380 8 -
2nd Row Seat-RR
> Component Information > Locations > Page 172
Seat Heater Control Module: Diagrams
Rear Heated Seat Module

Seat Heater Control Module: Service and Repair
Rear Seat Heater Control Module Replacement

Hummer Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Module
Sunroof / Moonroof Module: Locations
Headliner (SUT)
1 - Courtesy/Reading Lamp - 2nd Row (-U42) 2 - Infrared Receiver (U42) 3 - Infrared Module (U42)
4 - Video Display (U42) 5 - Vanity Mirror Lamp - Right 6 - Overhead Console Reading Lamp-Driver
7 - Sunroof Switch (CF5) 8 - Onstar Button Assembly 9 - Overhead Console Reading
Lamp-Passenger 10 - Inflatable Restraint I/P Module Indicator 11 - Sunroof Module (CF5) 12 -
Remote Compass Module 13 - Ambient Air Temperature Sensor-Inside 14 - Cellular Microphone
15 - Vanity Mirror Lamp-Left
Headliner (SUV)
1 - Courtesy/Reading Lamp - 3rd Row (SUV) 2 - Courtesy/Reading Lamp - 2nd Row 3 - Vanity
Mirror Lamp-Left 4 - Overhead Console Reading Lamp-Driver 5 - Sunroof Switch (CF5) 6 - Onstar
Button Assembly 7 - Overhead Console Reading Lamp-Front Passenger 8 - Inflatable Restraint I/P
Module Indicator 9 - Vanity Mirror Lamp-Right 10 - Sunroof Module (CF5) 11 - Remote Compass
Module 12 - Cellular Microphone 13 - Ambient Air Temperature Sensor-Inside
Sunroof / Moonroof Module: Diagrams
Sunroof Module (CF5)

Hummer Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Trunk / Liftgate Relay >
Hummer Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake
Control Module > Component Information > Technical Service Bulletins > Recalls: > 07221 > Sep > 07 > Recall - Wheel
Speed Sensor Wiring/EBCM programming
Technical Service Bulletin # 07221 Date: 070919
Recall - Wheel Speed Sensor Wiring/EBCM programming
Subject: Product Safety - ABS Operation # 07221 - (09/19/2007)
Models: 2008 HUMMER H2
Condition
General Motors has decided that a defect, which relates to motor vehicle safety, exists in certain
2008 HUMMER H2 vehicles. Certain wires in the ABS wheel speed sensor wiring harness may be
reversed.
This condition could result in increased stopping distance under certain circumstances. If vehicle
stopping distance is increased, a crash could occur.
Correction
Depending on the VIN, dealers are to correct the ABS wheel speed sensor wiring if required,
reprogram the brake control module, or both.
Vehicles Involved
Speed Sensor Wiring/EBCM programming > Page 191
Involved vehicles, and their required repairs, are shown.
Important:
Dealers are to confirm vehicle eligibility prior to beginning repairs by using the GM Vehicle Inquiry
System (GMVIS).
For dealer with involved vehicles, a listing with involved vehicles containing the complete vehicle
identification number, customer name, and address information has been prepared and will be
provided through the applicable system listed below. Dealers will not have a report available if they
have no involved vehicles currently assigned.
-- US dealers - GM DealerWorld Recall Information
-- Canadian dealers - GMinfoNet Recall Reports
The listing may contain customer names and addresses obtained from Motor Vehicle Registration
Records. The use of such motor vehicle registration data for any purpose other than follow-up
necessary to complete this recall is a violation of law in several states/provinces/countries.
Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this
recall.
Parts Information
No parts are required for this recall.
Calibration Information
Do not attempt to order the calibration number from GMSPO. The calibration numbers required for
this service procedure are programmed into control modules via a Techline Tech 2(R) scan tool
and TIS 2 Web with the calibration update. Use TIS 2 Web version 9.0 2007 (available on
09/03/07). If you cannot access the calibration, call the Techline Customer Support Center and it
will be provided.
NOTICE:
before reprogramming, please check the battery condition to prevent a reprogramming error of any
of the modules due to battery discharge. Battery voltage must be between 12 and 16 volts during
reprogramming. If the vehicle battery is not fully charged, use jumper cables from an additional
battery. Be sure to turn off or disable any system that may put a load on the battery, such as
automatic headlamps, daytime running lights, interior lights, heating, ventilation, and air
conditioning (HVAC)system, radio, engine cooling fans, etc. A programming failure or control
module damage may occur if battery voltage guidelines are not observed.
The ignition switch must be in the proper position. The Service Programming System (SPS)
application prompts you to turn ON the ignition, with the engine OFF. DO NOT change the position
of the ignition switch during the programming procedure, unless instructed to do so.
Make certain all tool connections are secure, including the following components and circuits:
^ The RS-232 communication cable port
^ The connection at the data link connector (DLC)
^ The voltage supply circuits
DO NOT disturb the tool harnesses while programming. If an interruption occurs during the
programming procedure, programming failure or control module damage may occur.
DO NOT turn OFF the ignition if the programming procedure is interrupted or unsuccessful. Ensure
that all control module and DLC connections are secure and the TIS terminal operating software is
up to date.
1. Verify that there is a battery charge of 12 to 16 volts. The battery must be able to maintain a
charge during programming. Use an additional jump battery if necessary. Only use approved
Midtronics charger or Jumper Packs, etc. to maintain proper battery voltage during programming.
2. Reprogram the electronic brake control module (EBCM). Refer to SI and Service Programming
System (SPS) documentation for EBCM programming instructions, if required.
Courtesy Transportation
The General Motors Courtesy Transportation Program is intended to minimize customer

inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited
Warranty. The availability of courtesy transportation to customers whose vehicles are within the
warranty coverage period and involved in a product recall is very important in maintaining customer
satisfaction. Dealers are to ensure that these customers understand that shuttle service or some
other form of courtesy transportation is available and will be provided at no charge. Dealers should
refer to the General Motors Service Policies and Procedures Manual for courtesy transportation
guidelines.
Claim Information
Submit a Product Recall Claim with the information shown.

General Motors will notify customers of this recall on their vehicle (see copy of customer letter
shown in this bulletin).
Dealer Recall Responsibility - Foe US (US States, Territories and Possessions)
The US National Traffic and Motor Vehicle Safety Act provides that each vehicle that is subject to a
recall of this type must be adequately repaired within a reasonable time after the customer has
tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie
evidence of failure to repair within a reasonable time. If the condition is not adequately repaired
within a reasonable time, the customer may be entitled to an identical or reasonably equivalent
vehicle at no charge or to a refund of the purchase price less a reasonable allowance for
depreciation. To avoid having to provide these burdensome remedies, every effort must be made
to promptly schedule an appointment with each customer and to repair their vehicle as soon as
possible. In the recall notification letters, customers are told how to contact the US National
Highway Traffic Safety Administration if the recall is not completed within a reasonable time.
Dealer Recall Responsibility - All
All unsold new vehicles in dealers' possession and subject to this recall must be held and
inspected/repaired per the service procedure of this recall
bulletin before customers take possession of these vehicles.
Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of
mileage, age of vehicle, or ownership, from this time forward.
Customers who have recently purchased vehicles sold from your vehicle inventory, and for which
there is no customer information indicated on the dealer listing, are to be contacted by the dealer.
Arrangements are to be made to make the required correction according to the instructions
contained in this bulletin. A copy of the customer letter is shown in this bulletin for your use in
contacting customers. Recall follow-up cards should not be used for this purpose, since the
customer may not as yet have received the notification letter.
In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your
dealership for service in the future, you must take the steps necessary to be sure the recall
correction has been made before selling or releasing the vehicle.
Disclaimer
Service Procedure
Important:
See the Vehicles Involved section of this bulletin to determine the service required for each
individual vehicle.
Wire Repair (use only if applicable - refer to the Vehicles Involved section of this bulletin)
1. Hook up the Tech 2 to the vehicle.
1.1. Capture the DTCs, if required.
1.2. Clear the DTCs, if required.
1.3. Ensure that there are no DTCs present before proceeding to Step 2.
2. Lift and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI.
3. Disconnect the left front and left rear wheel speed sensor wires. The front wheel speed sensor
wire can be disconnected at the connection near the upper control arm pivot point on the frame (1).
The left rear wheel speed sensor wire can be disconnected at the wheel speed sensor on the end
of the axle housing near the wheel (2).
4. Using the Tech 2(R) determine if the DTC set corresponds to the wheel speed sensor that was
disconnected.
^ If the DTC set corresponds to the sensor disconnected, proceed to Step 11.
^ If the DTC set does NOT correspond to the sensor disconnected, then the left and right wheel
speed sensor wires are cross-wired. Lower the vehicle. Refer to the EBCM Wiring Schematic and
Step 5.
5. Locate the electronic brake control module connector (EBCM).
6. Press the release tab and remove the under hood fuse block cover.
7. Press and hold the release tab while lifting to remove the connector from the EBCM, and fully
open the connector to access the wires.
8. Remove the white dress cover from the connector.
9. Refer to the EBCM Wiring Schematic to locate the correct connector cavities and terminal wire
colors for the cross-wired wheel speed sensors. Note:
Wires into cavities 6 and 37 may be switched (front wheels) or wires into cavities 4 and 35 may be
switched (rear wheels).
10. Remove one of the cross-wired terminal wires from its connector cavity and install this terminal
wire in the correct location of the connector. Do likewise with the other cross-wired terminal wire.
The two wires should now be located in each other's original pin locations in the connector.
11. Connect the wheel speed sensors and clear the DTCs. Ensure that there are no DTCs set.
12. Lower the vehicle.
Reprogram Procedure - (use only if applicable - see the Vehicles Involved section of this bulletin)
Tech 2 Legacy or J2534 Pass - Thru Programming Method for the EBCM
Important:
If Tech 2 Legacy or J2534 Pass-Thru programming fails, call Techline Customer Support.
Control Module > Component Information > Technical Service Bulletins > Recalls: > NHTSA07V373000 > Aug > 07 > Recall
07V373000: ABS Wheel Speed Sensor Wiring
Electronic Brake Control Module: Recalls Recall 07V373000: ABS Wheel Speed Sensor Wiring
MAKE/MODELS: MODEL/BUILD YEARS: Hummer/H2 SUT 2008 Hummer/H2 Utility 2008
MANUFACTURER: General Motors Corp. NHTSA CAMPAIGN ID NUMBER: 07V373000 MFR'S
REPORT DATE: August 21, 2007
COMPONENT: Service Brakes, Air: Antilock: Wheel Speed Sensor
POTENTIAL NUMBER OF UNITS AFFECTED: 363
SUMMARY: On certain trucks, the wires in the abs wheel speed sensor front or rear harness may
be reversed.
CONSEQUENCE: This condition could result in increased stopping distance increasing the risk of
a crash.
REMEDY: Dealers will correct the ABS wheel speed sensor wiring and, if necessary, reprogram
the brake control module free of charge. The manufacturer has not yet provided an owner
notification schedule. Owners may contact Hummer AT 800-732-5493.
NOTES: GM recall No. 070221. Customers may also contact The National Highway Traffic Safety
Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to
http://www.safercar.gov.
Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 08-08-49-010B > Jul > 08 >
Computers/Controls - Mutiple Malfunctions/DTC's Set
Electronic Brake Control Module: Customer Interest Computers/Controls - Mutiple

Malfunctions/DTC's Set
TECHNICAL
Date: July 22, 2008
Subject: Loss Of High Speed GMLAN Communications, IPC Warning Lights On, DIC Messages,
No Crank, IPC Gauge Drop or Fluctuation, Door Lock Cycling, Hard Transmission Shift, DTCs
U0073, U0100, U0101, U0102, U0109, U0121, U0132, U0140, U2100 Set (Inspect Identified
Electrical Connections and Wiring for Faults)
Supercede:
This bulletin is being revised to update terminal part number information and location in Correction
Step 1 (Update with asterisks). Please discard Corporate Bulletin Number 08-08-49-010A (Section
Condition
Some customers may comment on one or more of the following symptoms:
^ Instrument panel gages drop or fluctuate.
^ Multiple service messages displayed on the DIC (Drivers Information Center).
^ Various instrument panel warning lights on.
^ Door locks cycle while driving.
^ No crank.
^ Vehicle shifts hard or defaults to 2nd or 3rd gear.
Upon investigation, the technician may find one or multiple communication codes, such as DTC
U0073, U2100, U0100, U0101 U0102, U0109, U0121, U0132, U0140 set as current or in history.
Correction
If you experience one or more of the symptoms above, please review the following areas for a
possible concern.
1. Inspect the EBCM connector for loose terminals or low pin retention at pins 8, 9, 23, and 24.
These pins are for circuits 2500 and 2501 for high speed GMLAN communications with the EBCM,
TCM, and ECM. Please use the proper test tool when checking pin tension. The proper test tool for
this EBCM is J-35616-64B, which should be supplied in your terminal test kit. If the pins are loose
or damaged, replaced all 4 pins with new terminals (*part number # SAITS - A03T - M064 located
in tray 14, position 24 of the GM terminal repair kit*).
2. Inspect the transmission pass-through connector for loose or low pin retention at pins 10, 11, 13,
and 14. Also make sure these pins are fully seated into the connector. See photos above for
location and photo that shows a terminal that was not fully seated into the transmission connector.
Repair
Computers/Controls - Mutiple Malfunctions/DTC's Set > Page 217
as needed.
3. Check for a pinched/cut wiring harness where the transmission harness is attached to the
transmission. The metal attachment clip may be cutting into the harness and shorting the high
speed GMLAN circuit to ground. (Location and style of clip is shown in photos above) Repair as
needed.
4. Check for chaffed or shorted wiring by the park brake bracket assembly to the left IP junction
block.
5. Inspect underneath the underhood bussed electrical center (UBEC) for pinch or chaffed wires on
the UBEC support bracket.
6. Check connector X1 (1) on the back of the left IP fuseblock for a loose connection. Reports from
the field have found the connector not fully seated and causing intermittent concerns. See photo
above for location.
For repairs performed under warranty, use the applicable published labor code and information.
Disclaimer
Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic
Brake Control Module: > 08-08-49-010B > Jul > 08 > Computers/Controls - Mutiple Malfunctions/DTC's Set
Electronic Brake Control Module: All Technical Service Bulletins Computers/Controls - Mutiple
TECHNICAL
Date: July 22, 2008
Supercede:
Condition
^ No crank.
Correction
possible concern.
Repair
Brake Control Module: > 08-08-49-010B > Jul > 08 > Computers/Controls - Mutiple Malfunctions/DTC's Set > Page 223
as needed.
needed.
block.
above for location.
Disclaimer
Brake Control Module: > 07221 > Sep > 07 > Recall - Wheel Speed Sensor Wiring/EBCM programming
Condition
reversed.
Correction
Vehicles Involved
Brake Control Module: > 07221 > Sep > 07 > Recall - Wheel Speed Sensor Wiring/EBCM programming > Page 228
Important:
System (GMVIS).
recall.
Parts Information
will be provided.
NOTICE:
up to date.

guidelines.
Claim Information

Disclaimer
Service Procedure
Important:
individual vehicle.
disconnected.
Step 5.
Important:
Brake Control Module: > NHTSA07V373000 > Aug > 07 > Recall 07V373000: ABS Wheel Speed Sensor Wiring
Electronic Brake Control Module: All Technical Service Bulletins Recall 07V373000: ABS Wheel
Speed Sensor Wiring
be reversed.
a crash.
Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic Brake
Control Module: > 08-08-49-010B > Jul > 08 > Computers/Controls - Mutiple Malfunctions/DTC's Set
TECHNICAL
Date: July 22, 2008
Supercede:
Condition
^ No crank.
Correction
possible concern.
Repair
Control Module: > 08-08-49-010B > Jul > 08 > Computers/Controls - Mutiple Malfunctions/DTC's Set > Page 254
as needed.
needed.
block.
above for location.
Disclaimer
Control Module: > 07221 > Sep > 07 > Recall - Wheel Speed Sensor Wiring/EBCM programming
Condition
reversed.
Correction
Vehicles Involved
Control Module: > 07221 > Sep > 07 > Recall - Wheel Speed Sensor Wiring/EBCM programming > Page 260
Important:
System (GMVIS).
recall.
Parts Information
will be provided.
NOTICE:
up to date.

guidelines.
Claim Information

Disclaimer
Service Procedure
Important:
individual vehicle.
disconnected.
Step 5.
Important:
Control Module: > NHTSA07V373000 > Aug > 07 > Recall 07V373000: ABS Wheel Speed Sensor Wiring
Speed Sensor Wiring
be reversed.
a crash.
Control Module > Component Information > Technical Service Bulletins > Page 281
Electronic Brake Control Module: Locations
Front of Vehicle/Engine Compartment Component Views
Engine Compartment
1 - Brake Fluid Level Switch 2 - Electronic Brake Control Module (EBCM) 3 - Throttle Actuator
Control (TAC) Module 4 - Fuse Block-Underhood 5 - Battery 6 - Engine Control Module (ECM) 7 -
Intake Air Temperature (IAT)/Mass Air Flow (MAF) Sensor 8 - A/C Low Pressure Switch 9 -
Accumulator
Powertrain Component Views
Engine Compartment
Accumulator
Control Module > Component Information > Diagrams > Electronic Brake Control Module (EBCM) X1
Electronic Brake Control Module: Diagrams Electronic Brake Control Module (EBCM) X1
Electronic Brake Control Module (EBCM) X1

Control Module > Component Information > Diagrams > Electronic Brake Control Module (EBCM) X1 > Page 285

Control Module > Component Information > Diagrams > Page 287
Electronic Brake Control Module: Service and Repair
Brake Master Cylinder with Power Brake Booster and Chassis Control Module Replacement
Removal Procedure Caution: Refer to Brake Fluid Irritant Caution (See: Brakes and Traction
Control/Service Precautions/Technician Safety Information/Brake Fluid Irritant Caution) .
Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice (See: Brakes and
Traction Control/Service Precautions/Vehicle Damage Warnings/Brake Fluid Effects on Paint and
Electrical Components Notice) .
1. Apply and release the brake pedal 20 times to deplete the hydraulic brake booster accumulator
reserve.
Important: Reference mark the brake pipe location for correct installation.
2. Remove the 2 rear brake pipes (1) from the brake master cylinder.
Cap the brake pipe fittings and plug the master cylinder outlet ports to prevent brake fluid loss and
contamination.
3. Remove the 2 front brake pipes (1) from the brake master cylinder.
contamination.
4. Disconnect the electrical connectors at the brake pressure modulator valve (BPMV). 5.
Disconnect the brake fluid level sensor electrical connector. 6. Remove the knee bolster. Refer to
Driver Knee Bolster Replacement (See: Body and Frame/Interior Moulding / Trim/Dashboard /
Instrument
Panel/Service and Repair/Driver Knee Bolster Replacement) .
7. Remove the brake master cylinder pushrod retainer bolt (1).

8. Remove the brake master cylinder pushrod retainer (1).
9. Simultaneously remove the brake master cylinder pushrod and the stoplamp switch (1) from the
brake pedal clevis pin.
Important: It may be necessary to reposition or remove some of the wiring harnesses from their
retainers to provide clearance to remove the brake master cylinder nuts.
10. Remove the brake master cylinder nuts (1).
11. Remove the brake master cylinder and power brake booster assembly (1).
Installation Procedure
1. Install the brake master cylinder and power brake booster assembly (1).
Notice: Refer to Fastener Notice (See: Service Precautions/Vehicle Damage Warnings/Fastener

Notice) .
2. Install the brake master cylinder nuts (1).
Tighten the nuts to 36 N.m (27 lb ft).
3. Position the wiring harnesses to the retainers, if removed.

4. Simultaneously install the brake master cylinder pushrod and the stoplamp switch (1) to the
5. Install the brake master cylinder pushrod retainer (1).

6. Install the brake master cylinder pushrod retainer bolt (1).
Tighten the bolt to 10 N.m (89 lb in).
7. Install the knee bolster. Refer to Driver Knee Bolster Replacement (See: Body and
Frame/Interior Moulding / Trim/Dashboard / Instrument
8. Install the 2 front brake pipes (1) to the brake master cylinder.
Tighten the fittings to 25 N.m (18 lb ft).
9. Connect the electrical connectors at the brake pressure modulator valve (BPMV).
10. Connect the brake fluid level sensor electrical connector.

11. Install the 2 rear brake pipes (1) to the brake master cylinder.
12. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding (Manual) (See:
Brakes and Traction Control/Brake
Bleeding/Service and Repair/Hydraulic Brake System Bleeding (Manual))Hydraulic Brake System

Bleeding (Pressure) (See: Brakes and Traction Control/Brake Bleeding/Service and
Repair/Hydraulic Brake System Bleeding (Pressure)) .
Hummer Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Traction Control
Module > Component Information > Technical Service Bulletins > Customer Interest: > 08-08-49-010B > Jul > 08 >
Traction Control Module: Customer Interest Computers/Controls - Mutiple Malfunctions/DTC's Set
TECHNICAL
Date: July 22, 2008
Supercede:
Condition
^ No crank.
Correction
possible concern.
Repair
Module > Component Information > Technical Service Bulletins > Customer Interest: > 08-08-49-010B > Jul > 08 >
as needed.
needed.
block.
above for location.
Disclaimer
Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-08-49-010B > Jul >
08 > Computers/Controls - Mutiple Malfunctions/DTC's Set
Traction Control Module: All Technical Service Bulletins Computers/Controls - Mutiple

TECHNICAL
Date: July 22, 2008
Supercede:
Condition
^ No crank.
Correction
possible concern.
Repair
Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-08-49-010B > Jul >
08 > Computers/Controls - Mutiple Malfunctions/DTC's Set > Page 309
as needed.
needed.
block.
above for location.
Disclaimer
Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Traction Control Module: >
04-06-04-054B > Nov > 10 > Aftermarket Parts - Non GM Parts And Accessories Info
Engine Control Module: All Technical Service Bulletins Aftermarket Parts - Non GM Parts And
Accessories Info
INFORMATION
Subject: Info - Non-GM Parts and Accessories (Aftermarket)
Models:
2011 and Prior GM Passenger Cars and Trucks
Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed
Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate
Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System).
The recent rise and expansion of companies selling non-GM parts and accessories has made it
necessary to issue this reminder to dealers regarding GM's policy on the use and installation of
these aftermarket components.
When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to
use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs,
special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the
same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty
repairs, special policy repairs or any repairs paid for by GM.
During a warranty repair, if a GM original equipment part is not available through GM Customer
Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources,
the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order
the circumstances surrounding why non-GM parts were used. The dealer must give customers
written notice, prior to the sale or service, that such parts or accessories are not marketed or
warranted by General Motors.
It should also be noted that dealers modifying new vehicles and installing equipment, parts and
accessories obtained from sources not authorized by GM are responsible for complying with the
National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed
by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design
characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully
understand that non-GM approved parts may not have been validated, tested or certified for use.
This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part
failure occurs as the result of the installation or use of a non-GM approved part, the warranty will
not be honored.
A good example of non-authorized modification of vehicles is the result of an ever increasing

supply of aftermarket devices available to the customer, which claim to increase the horsepower
and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to
one or more of the following modifications:
- Propane injection
- Nitrous oxide injection
- Additional modules (black boxes) that connect to the vehicle wiring systems
- Revised engine calibrations downloaded for the engine control module
- Calibration modules which connect to the vehicle diagnostic connector
- Modification to the engine turbocharger waste gate

Although the installation of these devices, or modification of vehicle components, can increase
engine horsepower and torque, they may also negatively affect the engine emissions, reliability
and/or durability. In addition, other powertrain components, such as transmissions, universal joints,
drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the
installation of these devices.
General Motors does not support or endorse the use of devices or modifications that, when
installed, increase the engine horsepower and torque. It is because of these unknown stresses,
and the potential to alter reliability, durability and emissions performance, that GM has adopted a
policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining
warranty coverage, to the powertrain and driveline components whenever the presence of a
non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is
subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or
06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for
calibration verification.
These same policies apply as they relate to the use of non-GM accessories. Damage or failure
from the use or installation of a non-GM accessory will not be covered under warranty. Failure
resulting from the alteration or modification of the vehicle, including the cutting, welding or
disconnecting of the vehicle's original equipment parts and components will void the warranty.
Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal
inquiry at either the local, state or federal level that
04-06-04-054B > Nov > 10 > Aftermarket Parts - Non GM Parts And Accessories Info > Page 315
results from the alteration or modification of a vehicle using non-GM approved parts or accessories.
Dealers should be especially cautious of accessory companies that claim the installation of their
product will not void the factory warranty. Many times these companies have even given direction
on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from
finding out that is has been installed.
Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada
by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair
is to be made on the vehicle, even with the installation of such non-GM approved components, the
customer is to be made aware of General Motors position on this issue and is to sign the
appropriate goodwill documentation required by General Motors.
It is imperative for dealers to understand that by installing such devices, they are jeopardizing not
only the warranty coverage, but also the performance and reliability of the customer's vehicle.
Disclaimer
09-08-68-001 > Nov > 09 > Engine Controls - Cruise Control Shuts Off During Use
Engine Control Module: All Technical Service Bulletins Engine Controls - Cruise Control Shuts Off
During Use
TECHNICAL
Bulletin No.: 09-08-68-001
Subject: Cruise Control Turns Off During Operation (Reprogram ECM)
Models:
2008-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Silverado
2008-2009 Chevrolet Avalanche, Suburban, Tahoe 2007-2009 GMC Sierra 2008-2009 GMC
Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2009 HUMMER H2
Condition
On rare occasions, some customers may comment that the cruise control turned off. This typically
occurs during operation and while pulling up and releasing both driver door window switches or
activating the heated windshield washer fluid system in cold weather conditions with a battery
charge below 80%.
Cause
Cruise control command cancellation is caused by a voltage spike that occurs when the driver door
window switches are released or when the heated washer fluid system is activated.
Correction
A revised calibration has been developed to address this condition. Technicians are to reprogram
the ECM with the latest calibrations available. This new service calibration is available on
TIS2WEB using the Service Programming System (SPS). Refer to the SPS procedures in SI. SPS
may require the technician to select the calibration from the ECM calibration screen.
Note
This calibration update should only be used when this loss of cruise control condition is
experienced.
When using a Tech 2(R) or a multiple diagnostic interface (MDI) for reprogramming, ensure that it
is updated with the latest software version.
During programming, the battery voltage must be maintained within the proper range of 12-15
volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming
Support Tool EL-49642) or equivalent during programming.
Disclaimer
Disclaimer
Hummer Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Trailer Brake
Control Module > Component Information > Technical Service Bulletins > Brakes - Aftermarket Trailer Brake Controller
Trailer Brake Control Module: Technical Service Bulletins Brakes - Aftermarket Trailer Brake
Controller
INFORMATION
Bulletin No.: 07-08-45-001F
Subject: Procedure for Installation of an Aftermarket Trailer Brake Controller
Models:
2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche,
Silverado, Suburban, Tahoe 2007-2011 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon
Denali XL 2008-2010 HUMMER H2 with Integrated Trailer Brake Controller
Supercede: This bulletin is being revised to combine information from bulletins 06-08-45-008D and
07-08-45-001E. Please discard Corporate Bulletin Numbers 07-08-45-001E and 06-08-45-008D
(Section 08 - Body and Accessories).
Important Installation of an electric brake controller and the wiring connections outlined in this
bulletin are the responsibility of the dealership or customer. These repairs should never be charged
to warranty. If you have any questions, please consult with your District Service Manager.
Some customers may request to have an aftermarket trailer brake controller added to their vehicle,
OR in lieu of the factory integrated trailer brake controller (ITBC) (RPO JL1).
Installation Instructions
Starting with the new 2007 full-size utilities and pickups and 2008 HUMMER H2, there is no longer
an electric trailer brake controller pigtail harness.
To install an aftermarket trailer brake controller, use the four blunt cut wires located near the data
link connector.
The following steps should be used to complete the installation.
Important Ensure that the ringlets are not interfering with the UBEC cover.
1. Place the terminal on the larger of the two studs at the front of the electrical center and secure
with an M8 nut. This is circuit #242 to stud #2, to
power the aftermarket trailer brake controller.
Important The fuse is already present in the vehicle to power the electrical trailer brake controller
system.
2. ONLY For Vehicles Equipped with JL1 - Locate connector X126 or X115 (varies with vehicle
build; refer to SI) near the underhood fuse block.
Refer to SI Document ID# 1849049 - I/P Harness-Engine Compartment. Circuit 47 from the blunt
cut wires near the data link connector will end
Control Module > Component Information > Technical Service Bulletins > Brakes - Aftermarket Trailer Brake Controller >
Page 334
at connector X126 terminal "G" or X115 terminal "B5." Obtain enough Dark Blue 12 gauge wire to
run from X126/X115 to the 7-way trailer connector at the bumper. On one end of the Dark Blue wire
attach terminal part number 15304732, located in Delphi Tray 8 and insert into X126 "G" or
terminal part number 15304720 located in Delphi Tray 19 and insert into X115 "B5." Run the Dark
Blue wire in its own conduit along the frame to the 7-way trailer connector at the bumper. Remove
circuit 47 from the 7-way trailer connector terminal "C" and tape the bare terminal and attach to the
harness. Attach terminal part number 12110853, located in Delphi Tray 4, to the other end of the
Dark Blue wire and insert it into the 7-way trailer connector terminal "C."
3. ONLY For Vehicles Equipped with JL1 - The Red/Black wire, circuit 242, must be connected to
stud #2 of the 30 Amp fuse of the underhood
fuse block. This wire is located between the left fender and the underhood fuse block.
Important This procedure will not result in any trailer brake related display messages to be set.
However, ITBC diagnostics will continue to function. If an ITBC fault is detected, a "Service Trailer
Brake System" message will be displayed on the driver information center (DIC) and an appropriate
DTC will be stored in the ITBC module. The operator will still be able to adjust gain and access the
"Trailer Gain / Output" display page in the DIC. However, the factory installed ITBC system will not
sense a trailer connection and will not provide output to the trailer.
4. Locate the trailer brake control circuits that are looped and taped to the main harness under the
instrument panel.
5. Pull the trailering wire harness down.
6. Match the vehicle harness label circuit functions to the trailer brake controller jumper harness
functions.
Important The color or wires to be joined together may not match.
- Dark Blue Wire: switched power from controller to trailer brakes
- Red with Black Stripe: fused vehicle power to electrical brake controller
Page 335
- Light Blue with White Stripe: Brake switch input to power electric brake controller
- White: ground
- Orange: CHMSL (Center High Mounted Stop Lamp) - not required with most systems
7. After completing the under dash connections to the electric brake controller, open the hood and
locate the red wire that is taped to the harness
between the underhood electrical center and the driver side front fender.
8. Break the tape on the red/black wire and pull it toward the front of vehicle. 9. Remove the lid
from the electrical center.
Auxiliary Power (Applies to All LD and 2007-2009 HD's Only) Without JL1
Circuit #742 for Auxiliary Power at the 7-way trailer connector is no longer connected by the GM
Assembly Plant. If the customer desires auxiliary power at the trailer connector location (i.e.
refrigeration, battery charger or interior light in the trailer), complete the following steps to connect
circuit #742:
1. Locate the red/black wire, looped and taped to the chassis harness, below the brake master
cylinder. 2. Break the tape and route the wire to the front of the underhood electrical center.
3. Place the terminal on the smaller of the two studs on the electrical center and secure with an M6
fastener. This is circuit #742 to stud #1 for
auxiliary power to the 7-way trailer connector.
4. ONLY for vehicles without RPO TP2 - Auxiliary Battery, install a 40 amp fuse to power the
circuit.
Important For vehicles equipped with RPO TP2 - Devices powered by this fuse will drain the
vehicle battery if left connected with the vehicle not running.
Page 336
This installation procedure is to be performed at the customer's request and at their expense. It is
not a warranty repair and a claim should not be submitted for reimbursement.
Disclaimer
Hummer Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor
Relay > Component Information > Locations > FAN CNTRL PCB Relay
Relay > Component Information > Locations > FAN CNTRL PCB Relay > Page 342
Radiator Cooling Fan Motor Relay: Locations

Hummer Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay >
Hummer Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay >
Component Information > Locations > Page 355
Compressor Clutch Relay: Service and Repair
Compressor Relay Replacement
Removal Procedure
1. Remove the cover from the underhood convenience center (1). 2. Remove the A/C compressor
relay (1) from the convenience center (2).
1. Install the A/C compressor relay (1) to the convenience center (2). 2. Install the cover to the
underhood convenience center (1).
Hummer Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component
Information > Technical Service Bulletins > Customer Interest: > 08-01-39-009B > Sep > 10 > A/C - Auto Climate Control
Defaults to Full Cold/Hot
Control Module HVAC: Customer Interest A/C - Auto Climate Control Defaults to Full Cold/Hot
TECHNICAL
Date: September 24, 2010
Subject: HVAC Automatic Climate Control Defaults to Full Cold or Full Hot Despite Controls Being
Set to Other Parameters, DTCs B0228, B0413, B0423, B0433, B3779 or B3782 Set (Reprogram
HVAC Control Module)
Models:
2008-2009 Buick Enclave 2007-2008 Cadillac Escalade Models 2007-2008 Chevrolet Avalanche,
Silverado, Suburban, Tahoe 2007-2009 GMC Acadia, Sierra, Yukon Models 2008 HUMMER H2
Models 2007-2009 Saturn OUTLOOK with Automatic Climate Control System (RPO CJ2)
Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin
Number 08-01-39-009A (Section 01 - HVAC).
Condition
Some customers may comment that the Heating, Ventilation and Air Conditioning (HVAC)
automatic climate control system defaults to full hot and/or full cold, despite the HVAC controls
being set to other parameters. This condition may not exist during the next ignition cycle and the
system may operate normally.
Technicians may find DTCs B0228, B0413, B0423, B0433, B3779 or B3782 set as Current or in
History.
Cause
This condition may be caused by a software anomaly.
Correction
Important If the vehicle is a 2007-2009 GMC Acadia or Saturn OUTLOOK with an additional
customer concern of an inaccurate ambient temperature display, then it may be necessary to
reprogram the HVAC control module AND relocate the ambient air temperature (AAT) sensor.
Refer to Corporate Bulletin Number 08-01-39-008A - HVAC Ambient Temperature Sensor Display
In Instrument Panel Cluster (IPC) Inaccurate Or Too High for more information.
Note The first step applies to the following vehicles: Avalanche, Escalade, Suburban, Tahoe,
Yukon.
1. Inspect for an open HVAC-IGN Fuse in the underhood fuse block.
‹› If the fuse is open, repair the short to ground.

2. A revised calibration has been released to address this condition. Reprogram the HVAC control
module using the Service Programming System
(SPS) with the latest calibration available on TIS2WEB. Refer to the HVAC Control Module
Programming and Setup procedure in SI.
3. When using a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated
with the latest software version. 4. When using a Tech 2(R) for reprogramming, ensure that it is
updated with the latest software version. 5. During programming, the battery voltage must be
maintained within the proper range of 12-15 Volts. Only use the approved Midtronics(R) PSC
550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during
programming.
6. After reprogramming clear all DTCs. Operate the vehicle within the Conditions for Running the
DTC and verify that DTCs B0228, B0413,
B0423, B0433, B3779 or B3782 do not reset as Current.
‹› If DTCs B0228, B0413, B0423, B0433, B3779, or B3782 are set as Current, refer to the DTC
diagnostic procedures in SI.
Information > Technical Service Bulletins > Customer Interest: > 08-01-39-009B > Sep > 10 > A/C - Auto Climate Control
Defaults to Full Cold/Hot > Page 364
Disclaimer
Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-01-39-009B > Sep > 10 > A/C - Auto
Climate Control Defaults to Full Cold/Hot
Control Module HVAC: All Technical Service Bulletins A/C - Auto Climate Control Defaults to Full
Cold/Hot
TECHNICAL
Subject: HVAC Automatic Climate Control Defaults to Full Cold or Full Hot Despite Controls Being
Set to Other Parameters, DTCs B0228, B0413, B0423, B0433, B3779 or B3782 Set (Reprogram
HVAC Control Module)
Models:
2008-2009 Buick Enclave 2007-2008 Cadillac Escalade Models 2007-2008 Chevrolet Avalanche,
Silverado, Suburban, Tahoe 2007-2009 GMC Acadia, Sierra, Yukon Models 2008 HUMMER H2
Models 2007-2009 Saturn OUTLOOK with Automatic Climate Control System (RPO CJ2)
Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin
Condition
Some customers may comment that the Heating, Ventilation and Air Conditioning (HVAC)
automatic climate control system defaults to full hot and/or full cold, despite the HVAC controls
being set to other parameters. This condition may not exist during the next ignition cycle and the
system may operate normally.
Technicians may find DTCs B0228, B0413, B0423, B0433, B3779 or B3782 set as Current or in
History.
Cause
This condition may be caused by a software anomaly.
Correction
Important If the vehicle is a 2007-2009 GMC Acadia or Saturn OUTLOOK with an additional
customer concern of an inaccurate ambient temperature display, then it may be necessary to
reprogram the HVAC control module AND relocate the ambient air temperature (AAT) sensor.
Refer to Corporate Bulletin Number 08-01-39-008A - HVAC Ambient Temperature Sensor Display
In Instrument Panel Cluster (IPC) Inaccurate Or Too High for more information.
Note The first step applies to the following vehicles: Avalanche, Escalade, Suburban, Tahoe,
Yukon.
1. Inspect for an open HVAC-IGN Fuse in the underhood fuse block.
‹› If the fuse is open, repair the short to ground.

2. A revised calibration has been released to address this condition. Reprogram the HVAC control
module using the Service Programming System
(SPS) with the latest calibration available on TIS2WEB. Refer to the HVAC Control Module
Programming and Setup procedure in SI.
3. When using a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated
with the latest software version. 4. When using a Tech 2(R) for reprogramming, ensure that it is
updated with the latest software version. 5. During programming, the battery voltage must be
maintained within the proper range of 12-15 Volts. Only use the approved Midtronics(R) PSC
550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during
programming.
6. After reprogramming clear all DTCs. Operate the vehicle within the Conditions for Running the
DTC and verify that DTCs B0228, B0413,
B0423, B0433, B3779 or B3782 do not reset as Current.
‹› If DTCs B0228, B0413, B0423, B0433, B3779, or B3782 are set as Current, refer to the DTC
diagnostic procedures in SI.
Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-01-39-009B > Sep > 10 > A/C - Auto
Climate Control Defaults to Full Cold/Hot > Page 370
Disclaimer
Information > Technical Service Bulletins > All Technical Service Bulletins: > 02-01-39-007B > Nov > 07 > A/C - Dual Zone
HVAC Battery Draw
Control Module HVAC: All Technical Service Bulletins A/C - Dual Zone HVAC Battery Draw
INFORMATION
Subject: Automatic Dual Zone HVAC Battery Draw
Models: 2004-2007 Buick Rainier 2003-2008 Cadillac Escalade Models 2002-2008 Chevrolet
TrailBlazer 2003-2008 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2002-2008 GMC Envoy
Models 2003-2008 GMC Sierra, Yukon Models 2002-2004 Oldsmobile Bravada 2003-2008
HUMMER H2, H3 2005-2008 Saab 9-7X
Supercede:
This bulletin is being revised to add models and model years. Please discard Corporate Bulletin
When diagnosing battery draws on trucks equipped with the automatic dual zone HVAC controls
(RPO CJ2), technicians should keep in mind that the control head does not completely "go to
sleep" until after 150-250 minutes, or up to 4-1/4 hours, from when the ignition key is turned OFF.
This is a normal condition. In these cases, DO NOT replace the control head.
Disclaimer
Information > Technical Service Bulletins > All Other Service Bulletins for Control Module HVAC: > 09-03-16-002A > Apr >
10 > Wheels/Tires - Tire Pressure Monitor Light ON
Low Tire Pressure Indicator: All Technical Service Bulletins Wheels/Tires - Tire Pressure Monitor
Light ON
# 09-03-16-002A: Dealership Service Consultant Procedure as Vehicle Comes into Service Drive
for Tire Pressure Monitor (TPM) System Message, Light and Customer Information - (Apr 27, 2010)
Subject: Dealership Service Consultant Procedure as Vehicle Comes into Service Drive for Tire
Pressure Monitor (TPM) System Message, Light and Customer Information
Models: 2006-2011 Cars and Light Duty Trucks (Including Saturn and Saab)
2006-2010 HUMMER H2, H3
ATTENTION
The information found in this bulletin is to be used as a dealership service consultant procedures
for customers coming into the service lane with an illuminated "low tire light" or comments on a
check tire pressure/low tire pressure/add air to tire or service tire monitor system message.
Maintaining proper tire pressures is an Owner's Maintenance item and is not covered under
warranty.
This bulletin is being revised to add model years and update additional bulletin reference
information. Please discard Corporate Bulletin Number 09-03-16-002 (Section 03 -- Suspension).
Customer Concerns and Confusion with the Tire Pressure Monitoring (TPM) System
The following procedure should be used by dealership service consultants when a customer comes
into the service drive with a "low tire light" on or comments on a check tire pressure/low tire
pressure/add air to tire or service tire monitor system message. The service consultant should
perform the following steps:
Procedure
Turn the key to ON, without starting the engine.
^ If the low tire light comes on and stays on solid with a check tire pressure/low tire pressure/add
air to tire message (on vehicles equipped with DIC),
advise the customer:
- The system is working properly.
- Properly adjusting all tire air pressures to the recommended levels and driving the vehicle will turn
the light off (refer to the Tire and Loading Information label on the driver side door).
- More detailed information can be found in the Owner Manual.
- Service is not covered under warranty - this maintenance is the responsibility of the owner.
- Give the customer a copy of the "GM Customer TPMS Information".
^ If the Tire Pressure Monitor (TPM) light blinks for one minute then stays on solid with a service
tire monitor system message (on vehicles equipped
with DIC):
- A TPM system problem exists. The vehicle should be written up accordingly and sent to your
service department for further DTC diagnosis and service.
- If dashes (--) are displayed in only one or two of the tire pressure readouts, it is likely caused by a
previous TPM system relearn that was performed incorrectly due to interference from another
vehicle's TPM system during the relearn process (refer to the Important statement later in this
bulletin regarding TPM relearn with a Tech 2(R)).
- If dashes (--) are displayed in all four of the tire pressure readouts, there is a system problem.
Follow the appropriate SI service procedures.
^ If a customer indicates the low tire light comes on for a few minutes when the vehicle is started,
then goes off after driving a while, advise the
customer:
- Most likely, air pressure in one or more of the tires is low enough to turn the light on when tires
are cold. After driving for a while, tires will heat
10 > Wheels/Tires - Tire Pressure Monitor Light ON > Page 380
up, allowing tire air pressure to increase above the threshold causing the light to go off. Properly
adjusting all tire air pressures to the recommended levels will correct this (Refer to the Tire and
Loading Information Label on the driver side door).
For more detailed information, refer to Corporate Bulletin Number 07-03-16-004C and TPMS
Training Course 13044.12T2.
Tire Pressure Light
At key on, without starting the vehicle:
Steady Solid Glowing TPM Indicator
If the TPM indicator appears as a steady glowing yellow lamp (as above), the system is functioning
properly and you should add air to the tires to correct this condition.
Blinking TPM Indicator
If the TPM indicator appears as a BLINKING yellow lamp for one minute and then stays on solid,
diagnostic service is needed.
The Effect of Outside Temperature on Tire Pressures
Important:
As a rule of thumb, tire pressure will change about 7kPa (1 psi) for every 6°C (10°F) decrease in
temperature - Tire pressure will drop when it gets colder outside, and rise when it gets warmer.
Under certain situations such as extreme outside temperature changes, the system may bring on a
solid light with a check tire pressure message. This should be considered normal and the system is
working properly. The light will turn off upon adding the proper amount of air to the tires (refer to the
Tire & Loading Information label in the driver's door opening). When properly adjusting tire air
pressure, the following steps are important to help optimize the system and prolong bringing a tire
pressure light on:
^ Use an accurate, high quality tire pressure gauge.
^ Never set the tire pressure below the specified placard value regardless of tire temperature or
ambient temperature.
^ Tire pressure should be set to the specified placard pressure at the lowest seasonal temperature
the vehicle will encounter during operation.
^ When adding proper tire air pressure, it is important to remember fluctuations in outside air
temperatures and tire temperatures effect tire air pressures.
^ After you have added the proper tire pressure, if the vehicle has a DIC (after the system has
updated), check to see if DIC displays are the same
readings as the tire pressure gauge used (adjust as necessary).
^ Only perform a TPM sensor re-learn after a tire rotation or system part replacements and use the
Tech 2(R) to initiate the relearn whenever possible to
avoid invalid sensor I.D. learns.
Important:
Always take outside temperature and tire temperature into consideration to properly set tire
pressures. Foe example, on colder days (20°F/-7°C), if setting tire pressure when the vehicle has
been indoors (60°F/16°C) or the tires are warm from being driven, it will be necessary to
compensate for the low outside temperature by adding 21-27 kPa (3-4 psi) more then the
placecard pressure. At some later time, when the vehicle has been parked outside for a while, the
tires will cool off and the pressures will drop back into the placecard range.
Important:
Recently, nitrogen gas (for use in inflating tires) has become available to the general customer
through some retailers. The use of nitrogen gas to inflate tires is a technology used in automobile
racing. Tires inflated with nitrogen gas may exhibit less of a pressure change in response to
outside temperature changes. Nitrogen gas inflation is compatible with GM TPM sensors. For
additional information, refer to Corporate Service Bulletin 05-03-10-020C.
Important:
All Models (Except the Pontiac Vibe): Do not perform a TPM relearn at PDI, the system has already
been set at the Assembly Plant. Do not perform a TPM relearn after adding air to the tires. The low
tire light is similar to the low fuel indicator and adding something (fuel, air) to the vehicle makes that
light turn back off again. Note that because of system behavior, some vehicles must be driven a
short distance before the sensors recognize the increase in pressure and turns the light off again.
Pontiac Vibe Only: Do not use the TPMS reset button to turn off the light. The system will update
and light will turn off when all tire pressures have been adjusted followed by short distance drive.
Important:
All models (except the Pontiac Vibe): Each tire monitor sensor is learned to a specific vehicle
corner. When performing a TPM relearn (only after a tire rotation or replacement of a TPM sensor
or Module), always use the Tech2(R) to initiate the J 46079 relearned process. Tech 2(R) - initiated
relearns lock out other vehicle TPM signals that may be broadcasting in the area. Only signals
initiated by the J 46079 tool will be accepted. This method avoids storing false TPM I.D.s and will
prevent customers from returning with dashes (--) displayed in tire pressure readouts and/or a
flashing tire pressure monitor (TPM) light. Checking the four TPM I.D.s with the Tech 2(R) prior to
and following relearn to verify they are the same can prevent invalid I.D. learns.
Pontiac Vibe Only: Tire Monitor Sensors are not learned to a specific vehicle corner. Do not
perform a TPM Reset after tire rotation. The TPMS Reset button must only be used during
pre-delivery inspection by the dealer to initialize the system (after all tire pressures have been
adjusted properly) or when a Tire Pressure Monitor System component is replaced. The J 46079
tool does not work on Vibe TPM sensors. A TPMS relearn on Vibe must be preformed with a Tech
2(R) to set the TPMS Module in learn mode. The TPMS sensor IDs are entered through the Tech
2(R). Refer to SI for further Vibe TPMS information.
Labor Operation and Repair Order/Warranty System Claim Required Documentation

Important:
The ONLY time labor operation E0726 or E0722 should be used is to diagnose for a system issue.
That should ONLY occur if, at key ON, without starting the engine, the Tire Pressure Monitor (TPM)
blinks for one minute and then stays on solid with a Service Tire Monitor System message (on
vehicles equipped with a DIC) If that occurs, a TPM system problem exists and the system will
have set a DTC. If one of these operastions is used, the following Repair Order and Warranty
System documentation are required:
^ Document the customer complaint on the Repair Order.
^ Document the TPMS DTC that has set on the Repair Order.
^ Enter the TPMS DTC in the Warranty System (WINS) in the Failure Code/DTC field on the claim
submission (refer to the Claims Processing Manual,
Section IV, Warranty claim Data, Page 6, Item G).
If the above information is not documented on the Repair Order and Warranty System, the claim
may be rejected. If the Warranty Parts Center (WPC) generates a request, this repair order
documentation must be sent back.
Customer TPMS Information

Frequently Asked Questions
Disclaimer
Tire Pressure Light
Important:
pressure light on:
Important:
Important:
Important:
Important:

Important:

Disclaimer
Information > Diagrams > HVAC Control Module X1
Control Module HVAC: Diagrams HVAC Control Module X1
HVAC Control Module X1

Information > Diagrams > HVAC Control Module X1 > Page 397


Control Module HVAC: Diagrams HVAC Control Module X4 (C69)
HVAC Control Module X4 (C69)

Information > Service and Repair > Auxiliary Blower Control Module Replacement
Control Module HVAC: Service and Repair Auxiliary Blower Control Module Replacement
Auxiliary Blower Control Module Replacement

Information > Service and Repair > Auxiliary Blower Control Module Replacement > Page 402
Control Module HVAC: Service and Repair Auxiliary HVAC Module Replacement
Auxiliary HVAC Module Replacement

Control Module HVAC: Service and Repair Blower Motor Control Module Replacement
Blower Motor Control Module Replacement

Control Module HVAC: Service and Repair HVAC - Automatic
Auxiliary Heater and Air Conditioning Control Module Replacement
Auxiliary Heater and Air Conditioning Control Module Replacement

HVAC Control Module Replacement
HVAC Control Module Replacement
Removal Procedure
1. Remove the center instrument panel (I/P) air outlet bezel. Refer to Instrument Panel Center Air
Outlet Bezel Replacement (See: Body and
Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel
Center Air Outlet Bezel Replacement) .
2. Remove the screws from the HVAC control module (2). 3. Depress the HVAC control module
tabs (3) and remove the HVAC control module (2) from the I/P (4). 4. Reposition the HVAC control
module (2) from the I/P panel (1). 5. Disconnect the electrical connectors from the HVAC control
module (2).
Important: The key should be in the off position when connecting the electrical connectors to
ensure proper calibration.
1. Connect the electrical connectors to the HVAC control module (2).
Important: Ensure that the HVAC control module tabs lock into place.
2. Install the HVAC control module (2) to the I/P (1).

Notice) .
3. Install the screws to the HVAC control module (2).
Tighten the screws to 1.9 N.m (17 lb in).
4. Install the center I/P air outlet bezel. Refer to Instrument Panel Center Air Outlet Bezel
Replacement (See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Center Air Outlet Bezel
Replacement) .
Important: Do not adjust any controls on the HVAC control module while the HVAC control module
is calibrating.
If interrupted improper HVAC performance will result.
5. Start the vehicle and let run for one minute .

Hummer Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Instrument Panel Control
Module > Component Information > Technical Service Bulletins > Customer Interest: > 07-08-49-026 > Dec > 07 >
Instruments - Gauge Needles Sweep When Using OnStar(R)
Instrument Panel Control Module: Customer Interest Instruments - Gauge Needles Sweep When
Using OnStar(R)
Bulletin No.: 07-08-49-026
Date: December 04, 2007
TECHNICAL
Subject: Instrument Panel Cluster (IPC) Performs A Running Reset/WOW During OnStar Usage
(Reprogram IPC)
Attention:
This service bulletin applies to IPC part numbers 25862694 and 25862695 only.
Condition
Some customers may comment that the Instrument Panel Cluster performs a running reset or
WOW display during OnStar(R) usage. The customer may notice that the IPC will momentarily
sweep the gauge pointers to zero (home position) and illuminate all the telltales as if they had
started their vehicle. The IPC does return to normal operation after the WOW.
Correction
the IPC using SPS with the latest software available on TIS2WEB. Refer to the Service
Programming System procedures in SI. As always, make sure your Tech 2(R) is updated with the
latest software version.
Disclaimer
Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Instrument Panel
Control Module: > 07-08-49-020D > Dec > 10 > Instruments - Odometer Programming Guide
Instrument Panel Control Module: All Technical Service Bulletins Instruments - Odometer
Programming Guide
INFORMATION
Subject: IPC Odometer Programming Method Quick Reference Guide
Models:
2005-2009 Saab 9-7X
Attention:
This bulletin applies to vehicles sold in the U.S. and Canada Only.
Supercede: This bulletin is being revised to add information for the 2011 model year and add new
2011 vehicles. Please discard Corporate Bulletin Number 07-08-49-020C (Section 08 - Body and
Accessories).
The purpose of this bulletin is to provide a reference guide to help identify which season odometer
programming method to use after replacing the instrument panel cluster (IPC). The three season
odometer programming methods in use today are listed below. In addition, this reference guide lists
the component where the season odometer value is stored. The season odometer value may be
stored in the IPC, the driver information center (DIC) or the integrated body control module (IBCM),
also commonly called a body control module (BCM).
Season Odometer Programming Methods in Use Today
1. IPC reprogramming and setup using the service programming system (SPS). 2. Odometer setup
at the electronic service center (ESC) when using an exchange IPC/DIC. 3. Tech 2(R) - The Tech 2
is used to set up a replacement BCM, which includes loading the odometer value that is displayed
and stored in the IPC. A
replacement IPC will display the previously stored vehicle odometer value, communicated from the
BCM, after cycling the ignition or driving the vehicle. *The odometer programming is integrated as
part of the BCM programming procedure. It is not a stand-alone event.
Control Module: > 07-08-49-020D > Dec > 10 > Instruments - Odometer Programming Guide > Page 421
Disclaimer
Control Module: > 07-08-49-026 > Dec > 07 > Instruments - Gauge Needles Sweep When Using OnStar(R)
Instrument Panel Control Module: All Technical Service Bulletins Instruments - Gauge Needles
Sweep When Using OnStar(R)
Bulletin No.: 07-08-49-026
TECHNICAL
Subject: Instrument Panel Cluster (IPC) Performs A Running Reset/WOW During OnStar Usage
(Reprogram IPC)
Attention:
This service bulletin applies to IPC part numbers 25862694 and 25862695 only.
Condition
Some customers may comment that the Instrument Panel Cluster performs a running reset or
WOW display during OnStar(R) usage. The customer may notice that the IPC will momentarily
sweep the gauge pointers to zero (home position) and illuminate all the telltales as if they had
started their vehicle. The IPC does return to normal operation after the WOW.
Correction
the IPC using SPS with the latest software available on TIS2WEB. Refer to the Service
Programming System procedures in SI. As always, make sure your Tech 2(R) is updated with the
Disclaimer
Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Instrument Panel Control
Module: > 07-08-49-020D > Dec > 10 > Instruments - Odometer Programming Guide
Instrument Panel Control Module: All Technical Service Bulletins Instruments - Odometer
Programming Guide
INFORMATION
Subject: IPC Odometer Programming Method Quick Reference Guide
Models:
2005-2009 Saab 9-7X
Attention:
This bulletin applies to vehicles sold in the U.S. and Canada Only.
Supercede: This bulletin is being revised to add information for the 2011 model year and add new
2011 vehicles. Please discard Corporate Bulletin Number 07-08-49-020C (Section 08 - Body and
Accessories).
The purpose of this bulletin is to provide a reference guide to help identify which season odometer
programming method to use after replacing the instrument panel cluster (IPC). The three season
odometer programming methods in use today are listed below. In addition, this reference guide lists
the component where the season odometer value is stored. The season odometer value may be
stored in the IPC, the driver information center (DIC) or the integrated body control module (IBCM),
also commonly called a body control module (BCM).
Season Odometer Programming Methods in Use Today
1. IPC reprogramming and setup using the service programming system (SPS). 2. Odometer setup
at the electronic service center (ESC) when using an exchange IPC/DIC. 3. Tech 2(R) - The Tech 2
is used to set up a replacement BCM, which includes loading the odometer value that is displayed
and stored in the IPC. A
replacement IPC will display the previously stored vehicle odometer value, communicated from the
BCM, after cycling the ignition or driving the vehicle. *The odometer programming is integrated as
part of the BCM programming procedure. It is not a stand-alone event.
Module: > 07-08-49-020D > Dec > 10 > Instruments - Odometer Programming Guide > Page 433
Disclaimer
Hummer Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Backup Lamp Relay >
Hummer Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp
Relay > Component Information > Locations
Hummer Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay >
Hummer Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > High Beam Relay >
Hummer Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component
Information > Locations
Hummer Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay >
Hummer Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay >
Component Information > Locations > TRLR STOP LT PCB Relay
Hummer Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay >
Component Information > Locations > TRLR STOP LT PCB Relay > Page 459
Hummer Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power
Distribution Relay > Component Information > Service and Repair > Relay Replacement (Attached to Wire Harness)
Power Distribution Relay: Service and Repair Relay Replacement (Attached to Wire Harness)
Relay Replacement (Attached to Wire Harness)
Removal Procedure
1. Locate the relay. Refer to the Master Electrical Component List (See: Locations/Component
Locations) to locate the relay in the vehicle. 2. Remove any fasteners which hold the relay in place.
3. Remove any connector position assurance (CPA) devices or secondary locks.
Important: Use care when removing a relay in a wiring harness when the relay is secured by
fasteners or tape.
4. Separate the relay (1) from the wire harness connector (2).
1. Connect the relay (1) to the wire harness connector (2). 2. Install any connector position
assurance (CPA) devices or secondary locks. 3. Install the relay using any fasteners or tape that
originally held the relay in place.
Distribution Relay > Component Information > Service and Repair > Relay Replacement (Attached to Wire Harness) > Page
465
Power Distribution Relay: Service and Repair Relay Replacement (Within an Electrical Center)
Relay Replacement (Within an Electrical Center)
Tools Required
J 43244 Relay Puller Pliers
Removal Procedure
1. Remove the electrical center cover. 2. Locate the relay. Refer to Electrical Center Identification
Views (See: Maintenance/Fuses and Circuit Breakers/Fuse/Application and ID) to locate
the electrical center where the relay exists.
Important: *
Always note the orientation of the relay.
* Ensure that the electrical center is secure, as not to put added stress on the wires or terminals.
3. Using the J 43244 (1) position the tool on opposing corners of the relay (2).
Notice: Use J43244 to pull the relay straight out from the electrical center terminals. The use of
pliers or a flat bladed tool could damage the electrical center.
4. Remove the relay (2) from the electrical center.

Distribution Relay > Component Information > Service and Repair > Relay Replacement (Attached to Wire Harness) > Page
466
1. Install the relay (2) in the same position as removed. 2. Install the electrical center cover.
Hummer Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins
> Body Controls - Body Control Module (BCM) Grounds
Body Control Module: Technical Service Bulletins Body Controls - Body Control Module (BCM)
Grounds
INFORMATION
Subject: Information on Body Control Module (BCM) Grounds
Models:
2006-2010 Buick Lucerne 2007-2010 Buick Enclave 2006-2010 Cadillac DTS 2007-2009 Cadillac
SRX 2008-2010 Cadillac CTS 2006-2008 Chevrolet Monte Carlo 2006-2010 Chevrolet Impala
2007-2009 Chevrolet Equinox 2008-2010 Chevrolet Express, Traverse 2007-2010 GMC Acadia
2008-2010 GMC Savana 2007-2009 Pontiac Torrent 2007-2010 Saturn OUTLOOK 2008-2010
Saturn VUE 2008-2010 HUMMER H2
Supercede: This bulletin is being revised to update the models, model years and information.
Please discard Corporate Bulletin Number 07-08-47-004B (Section 08 - Body & Accessories).
The purpose of this bulletin is to inform dealers of an issue that could cause internal module
damage to the Body Control Module (BCM).
The BCM may be damaged when the module is supplied with battery power and the ground path is
removed. You must remove the negative battery cable first before removing a BCM ground.
Issue 1
Below is a list of vehicles and the components that the BCM ground path passes through. The
negative battery cable must be removed when removing the components noted below.
- 2008-2010 HUMMER H2 (Instrument panel electrical center)
- 2008-2010 Saturn VUE (I/P splice pack)
Issue 2
It is important to note when removing a ring terminal ground, splice pack connector, or inline
harness connector for all the vehicles listed in the model section above, that it doesn't include a
BCM ground path. You must remove the negative battery cable if you determine that it is a BCM
ground path.
As an example: If the BCM grounds become disconnected, internal damage to the BCM will occur.
Other systems controlled by the BCM will also be affected, such as an inoperative or intermittent
condition in one or more of the following systems:
- Interior lighting will remain on or will not work
- Exterior lighting will remain on or will not work
- Remote keyless entry
- Door locks
- Power windows and mirrors
- Remote vehicle start
- Remote trunk release

> Body Controls - Body Control Module (BCM) Grounds > Page 473
Disclaimer
> Page 474
Body Control Module: Locations
Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Body Control
Module (BCM) X2
Body Control Module: Diagrams Body Control Module (BCM) X2
Body Control Module (BCM) X2

Module (BCM) X2 > Page 477



Body Control Module: Diagrams






Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Page 491
Body Control Module: Service and Repair
Body Control Module Replacement

Modules - Computers and Control Systems > Electronic Throttle Control Module > Component Information > Locations
Electronic Throttle Control Module: Locations
Engine Compartment
Accumulator
Engine Compartment
Modules - Computers and Control Systems > Electronic Throttle Control Module > Component Information > Locations >
Page 495
Accumulator
Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service
Bulletins > Customer Interest: > 09-08-68-001 > Nov > 09 > Engine Controls - Cruise Control Shuts Off During Use
Engine Control Module: Customer Interest Engine Controls - Cruise Control Shuts Off During Use
TECHNICAL
Bulletin No.: 09-08-68-001
Models:
Condition
charge below 80%.
Cause
Correction
Note
experienced.
Disclaimer
Bulletins > Customer Interest: > 08-08-49-010B > Jul > 08 > Computers/Controls - Mutiple Malfunctions/DTC's Set
Engine Control Module: Customer Interest Computers/Controls - Mutiple Malfunctions/DTC's Set
TECHNICAL
Date: July 22, 2008
Supercede:
Condition
^ No crank.
Correction
possible concern.
Repair
Bulletins > Customer Interest: > 08-08-49-010B > Jul > 08 > Computers/Controls - Mutiple Malfunctions/DTC's Set > Page
508
as needed.
needed.
block.
above for location.
Disclaimer
Bulletins > All Technical Service Bulletins for Engine Control Module: > 04-06-04-054B > Nov > 10 > Aftermarket Parts -
Non GM Parts And Accessories Info
Accessories Info
INFORMATION
Models:
not be honored.

- Propane injection

Non GM Parts And Accessories Info > Page 514
Disclaimer
Bulletins > All Technical Service Bulletins for Engine Control Module: > 09-08-68-001 > Nov > 09 > Engine Controls - Cruise
Control Shuts Off During Use
During Use
TECHNICAL
Bulletin No.: 09-08-68-001
Models:
Condition
charge below 80%.
Cause
Correction
Note
experienced.
Disclaimer
Bulletins > All Technical Service Bulletins for Engine Control Module: > 08-08-49-010B > Jul > 08 > Computers/Controls -
Mutiple Malfunctions/DTC's Set
Engine Control Module: All Technical Service Bulletins Computers/Controls - Mutiple

TECHNICAL
Date: July 22, 2008
Supercede:
Condition

^ No crank.
Correction
possible concern.
Repair
Mutiple Malfunctions/DTC's Set > Page 523
as needed.
needed.
block.
above for location.
Disclaimer
Bulletins > All Other Service Bulletins for Engine Control Module: > 04-06-04-054B > Nov > 10 > Aftermarket Parts - Non
GM Parts And Accessories Info
Accessories Info
INFORMATION
Models:
not be honored.

- Propane injection

GM Parts And Accessories Info > Page 529
Disclaimer
Bulletins > Page 530
Engine Control Module: Locations
Engine Compartment
Accumulator
Engine Compartment
Accumulator
Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Engine
Control Module (ECM) X1
Engine Control Module: Diagrams Engine Control Module (ECM) X1
Engine Control Module (ECM) X1

Control Module (ECM) X1 > Page 534


Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Page 537
Engine Control Module: Service Precautions
Powertrain Control Module and Electrostatic Discharge Notice
Notice: Do not touch the connector pins or soldered components on the circuit board in order to
prevent possible electrostatic discharge (ESD) damage to the PCM.
Engine Control Module: Description and Operation
Engine Control Module Description
The powertrain has electronic controls to reduce exhaust emissions while maintaining excellent
driveability and fuel economy. The engine control module (ECM) is the control center of this
system. The ECM monitors numerous engine and vehicle functions. The ECM constantly monitors
the information from various sensors and other inputs, and controls the systems that affect vehicle
performance and emissions. The ECM also performs the diagnostic tests on various parts of the
system. The ECM can recognize operational problems and alert the driver via the malfunction
indicator lamp (MIL). When the ECM detects a malfunction, the ECM stores a diagnostic trouble
code (DTC). The problem area is identified by the particular DTC that is set. The control module
supplies a buffered voltage to various sensors and switches. Review the components and wiring
diagrams in order to determine which systems are controlled by the ECM.
Malfunction Indicator Lamp (MIL) Operation
The malfunction indicator lamp (MIL) is located in the instrument panel cluster. The MIL will display
as either SERVICE ENGINE SOON or one of the following symbols when commanded ON:
The MIL indicates that an emissions related fault has occurred and vehicle service is required.
The following is a list of the modes of operation for the MIL:
* The MIL illuminates when the ignition is turned ON, with the engine OFF. This is a bulb test to
ensure the MIL is able to illuminate.
* The MIL turns OFF after the engine is started if a diagnostic fault is not present.
* The MIL remains illuminated after the engine is started if the control module detects a fault. A
diagnostic trouble code (DTC) is stored any time the control module illuminates the MIL due to an
emissions related fault. The MIL turns OFF after three consecutive ignition cycles in which a Test
Passed has been reported for the diagnostic test that originally caused the MIL to illuminate.
* The MIL flashes if the control module detects a misfire condition which could damage the catalytic
converter.
* When the MIL is illuminated and the engine stalls, the MIL will remain illuminated as long as the
ignition is ON.
* When the MIL is not illuminated and the engine stalls, the MIL will not illuminate until the ignition
is cycled OFF and then ON.
Engine Control Module: Service and Repair
Engine Control Module Replacement
Service of the engine control module (ECM) should normally consist of either replacement of the
ECM or electrically erasable programmable read only memory (EEPROM) programming. If the
diagnostic procedures call for the ECM to be replaced, the ECM should be inspected first to see if
the correct part is being used. If the correct part is being used, remove the faulty ECM and install
the new service ECM.
Notice:
* Turn the ignition OFF when installing or removing the control module connectors and
disconnecting or reconnecting the power to the control module (battery cable, powertrain control
module (PCM)/engine control module (ECM)/transaxle control module (TCM) pigtail, control
module fuse, jumper cables, etc.) in order to prevent internal control module damage.
* Control module damage may result when the metal case contacts battery voltage. DO NOT
contact the control module metal case with battery voltage when servicing a control module, using
battery booster cables, or when charging the vehicle battery.
* In order to prevent any possible electrostatic discharge damage to the control module, do no
touch the connector pins or the soldered components on the circuit board.
* Remove any debris from around the control module connector surfaces before servicing the
control module. Inspect the control module connector gaskets when diagnosing or replacing the
control module. Ensure that the gaskets are installed correctly. The gaskets prevent contaminant
intrusion into the control module.
* The replacement control module must be programmed.
Important: It is necessary to record the remaining engine oil life. If the replacement module is not
programed with the remaining engine oil life, the engine oil life will default to 100 percent. If the
replacement module is not programmed with the remaining engine oil life, the engine oil will need
to be changed at 5 000 km (3,000 mi) from the last engine oil change.
Removal Procedure
1. Using a scan tool, retrieve the percentage of remaining engine oil. Record the remaining engine
oil life.
2. Release the ECM cover mounting holes away from the mounting tabs on the ECM mounting
bracket. 3. Release the ECM cover from the mounting bracket. 4. Remove the ECM cover.
Notice: Refer to PCM and ESD Notice .
Notice: In order to prevent internal damage to the PCM, the ignition must be OFF when
disconnecting or reconnecting the PCM connector.
5. Loosen both ECM connector retaining bolts. 6. Disconnect the ECM harness connectors. 7.
Release the spring latch from the ECM. 8. Release the ECM mounting tabs from the ECM.
9. Remove the ECM from the engine compartment.
1. Install the ECM to the ECM mounting bracket ensuring that the mounting tabs are engaged. 2.
Secure the spring latch to the ECM.

Notice) .
3. Connect the ECM connectors to the ECM.
Tighten the fasteners to 8 N.m (71 lb in).
4. Install the ECM cover to the ECM mounting bracket, ensuring the mounting tabs on the ECM
mounting bracket are engaged into the mounting
holes in the ECM cover.
5. If a new ECM is being installed, program the ECM. Refer to Programming and Relearning (See:
Testing and Inspection/Programming and
Relearning) .
Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations
Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations >
Page 544
Main Relay (Computer/Fuel System): Testing and Inspection
Powertrain Relay Diagnosis
Diagnostic Instructions
* Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection
and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic
procedure.
* Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic
Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach.
* Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic
Overview/Diagnostic Procedure Instructions) provides an overview of each diagnostic category.
Typical Scan Tool Data
Circuit/System Description
The powertrain relay is a normally open relay. The relay armature is held in the open position by
spring tension. Battery positive voltage is supplied directly to the relay coil and the armature
contact at all times. The engine control module (ECM) supplies the ground path to the relay coil
control circuit via an internal integrated circuit called an output driver module (ODM). The ODM
output control is configured to operate as a low side driver for the powertrain relay. The ODM for
the powertrain relay also incorporates a fault detection circuit, which is continuously monitored by
the ECM. When the ECM commands the powertrain relay ON, ignition 1 voltage is supplied to the
ECM, and to several additional circuits.
Diagnostic Aids
This test procedure requires that the vehicle battery has passed a load test and is completely
charged. Refer to Battery Inspection/Test (See: Starting and Charging/Testing and
Inspection/Component Tests and General Diagnostics/Battery Inspection/Test) .
Reference Information Schematic Reference
Engine Controls Schematics (See: Diagrams/Electrical Diagrams/Powertrain Management/System

Diagram) Connector End View Reference
Component Connector End Views (See: Diagrams/Connector Views/Component Connector End

Views) Electrical Information Reference
* Circuit Testing (See: Accessories and Optional Equipment/Antitheft and Alarm

Systems/Diagrams/Diagnostic Aids/General Electrical Diagnostic Procedures/Circuit Testing/Circuit
Testing)
* Connector Repairs (See: Accessories and Optional Equipment/Antitheft and Alarm
Systems/Diagrams/Diagnostic Aids/General Electrical Diagnostic Procedures/Connector
Repairs/Connector Repairs)
* Testing for Intermittent Conditions and Poor Connections (See: Accessories and Optional
Equipment/Antitheft and Alarm Systems/Diagrams/Diagnostic Aids/General Electrical Diagnostic
Procedures/Circuit Testing/Testing For Intermittent and Poor Connections)
* Wiring Repairs (See: Accessories and Optional Equipment/Antitheft and Alarm

Systems/Diagrams/Diagnostic Aids/General Electrical Diagnostic Procedures/Wiring
Repairs/Wiring Repairs)
Scan Tool Reference
Programming and Relearning (See: Testing and Inspection/Programming and Relearning) for scan
tool information Special Tools
* J 35616 GM-Approved Terminal Test Kit
* J 43244 Relay Puller Pliers
Circuit/System Verification
1. Engine running, command the powertrain relay ON and OFF, with a scan tool, while observing
the following powertrain relay coil control circuit
Page 545
status parameters.
* Powertrain relay coil control Ckt. Short Gnd Test Status
* Powertrain relay coil control Ckt. Open Test Status
* Powertrain relay coil control Ckt. Short Volts Test Status Each parameter should toggle between
OK and Not Run or Not Run and OK
2. Ignition ON, engine OFF, with a test lamp, probe both test points of all the fuses that are
powered by the powertrain relay. The test lamp should
illuminate ON for at least one test point of each fuse.
3. Operate the vehicle within the Conditions for Running the DTC. You may also operate the
vehicle within the conditions that you observed from
the Freeze Frame/Failure Records data.
Circuit/System Testing
Important: You must perform the Circuit/System Verification first.
1. Ignition OFF, disconnect the powertrain relay. 2. Ignition ON, verify that a test lamp illuminates
between the powertrain relay coil B+, and ground.
‹› If the test lamp does not illuminate, test the B+ circuit for a short to ground or an open/high
resistance. If the circuit tests normal, test or
replace the battery positive cable to the underhood fuse block.
3. Ignition OFF, verify that a test lamp does not illuminate between the powertrain relay coil B+
circuit and the control circuit.
‹› If the test lamp illuminates, test the control circuit for a short to ground. If the circuit tests normal,
replace the ECM.
4. Remove the test lamp. 5. Command the powertrain relay ON, with a scan tool. Verify with a scan
tool that the powertrain relay Ckt. Short Volts Test Status parameter is
OK.
‹› If not the specified value, test the control circuit for a short to voltage. If the circuit tests normal,
replace the ECM.
6. Test the coil side of the powertrain relay for 65-110 ohms.
‹› If not within the specified value, replace the relay.
7. Ignition OFF, disconnect the ECM C1 connector. 8. Test the powertrain relay control circuit for
an open/high resistance.
‹› If the circuit tests normal, replace the ECM.
9. Verify that a test lamp does not illuminate between the relay ignition 1 voltage circuit and ground.
‹› If the test lamp illuminates, test the relay ignition 1 voltage circuit for a short to voltage. If the
circuit tests normal, replace the ECM.
10. Verify that a test lamp illuminates between the relay switch B+ and ground.
‹› If the test lamp does not illuminate, test the relay switch B+ circuit for a short to ground, or an
open/high resistance. If the circuits test normal,
and the fuse for the ignition 1 voltage circuit is open, test the ignition 1 voltage circuit to the ECM
for a short to ground. If the circuit tests normal, replace the ECM.
11. Connect a 20 A fused jumper wire between the relay switch B+ and the relay ignition 1 voltage
circuit. 12. Ignition ON, engine OFF, monitor the EC Ignition Relay Feedback parameter with a
scan tool. The parameter should display B+.
‹› If the parameter does not display B+, test the ignition 1 voltage circuit for an open/high
resistance. If the circuit tests normal, replace the ECM.
13. If all circuits test normal, replace the relay.
Repair Instructions
* Engine Control Module Programming and Setup (See: Testing and Inspection/Programming and
Relearning/Engine Control Module Programming and Setup)
* Engine Control Module Replacement (See: Engine Control Module/Service and Repair)
* Relay Replacement (Attached to Wire Harness) (See: Relays and Modules - Power and Ground
Distribution/Power Distribution Relay/Service and Repair/Relay Replacement (Attached to Wire
Harness))Relay Replacement (Within an Electrical Center) (See: Relays and Modules - Power and
Ground Distribution/Power Distribution Relay/Service and Repair/Relay Replacement (Within an
Electrical Center))
Page 546
Repair Verification
1. Install any components that have been removed or replaced during diagnosis. 2. Perform any
adjustment, programming, or setup procedures that are required when a component or module is
removed or replaced. 3. Clear the DTCs. 4. Turn OFF the ignition for 60 seconds. 5. Ignition ON,
command the powertrain relay ON and OFF with a scan tool, while observing the powertrain relay
circuit status parameters, The
circuit status parameters should change from OK to Not Run or Not Run to OK.
‹› If another DTC is present, refer to Diagnostic Trouble Code (DTC) List - Vehicle (See: Powertrain
Management/Computers and Control
Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions/Diagnostic Trouble Code

(DTC) List - Vehicle) and perform the appropriate diagnostic procedure.
Modules - Fuel Delivery and Air Induction > Fuel Pump Control Unit > Component Information > Locations
Fuel Pump Control Unit: Locations
Wheels/Vehicle Underbody Component Views
Fuel System Components
1 - Fuel Pump Control Module 2 - Fuel Tank 3 - Evaporative Emission (EVAP) Canister Vent
Solenoid Valve 4 - Fuel Pump and Sender Assembly 5 - Fuel Tank Pressure (FTP) Sensor 6 -
Evaporative Emission (EVAP) Canister
Modules - Fuel Delivery and Air Induction > Fuel Pump Control Unit > Component Information > Locations > Page 551
Fuel Pump Control Unit: Diagrams
Fuel System Control Module (FSCM)

Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations
Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations >
Page 556
procedure.
Diagnostic Aids
Engine Controls Schematics (See: Diagrams/Electrical Diagrams/Powertrain Management/System

Diagram) Connector End View Reference


Testing)

Scan Tool Reference
Page 557
status parameters.
replace the ECM.
OK.
replace the ECM.
Repair Instructions
* Engine Control Module Replacement (See: Relays and Modules - Computers and Control
Systems/Engine Control Module/Service and Repair)
* Relay Replacement (Attached to Wire Harness) (See: Relays and Modules - Power and Ground
Electrical Center))
Page 558
Repair Verification
‹› If another DTC is present, refer to Diagnostic Trouble Code (DTC) List - Vehicle (See: Powertrain
Management/Computers and Control

(DTC) List - Vehicle) and perform the appropriate diagnostic procedure.
Hummer Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Technical Service Bulletins > Customer Interest for Air Bag Control Module: > 08-09-41-002F >
Jun > 10 > Restraints - Air Bag Light ON/Multiple DTC's Set
Air Bag Control Module: Customer Interest Restraints - Air Bag Light ON/Multiple DTC's Set
TECHNICAL
Date: June 10, 2010
Subject: Diagnostic Information for Supplemental Inflatable Restraint (SIR) System, Intermittent
AIR BAG Indicator/Lamp Illuminated with DTC(s) B0012, B0013, B0015, B0016, B0019, B0020,
B0022, B0023, B0026, B0033, B0040, B0042 or B0044 Set (Inspect and Replace Connector
Position Assurance (CPA) Retainer)
Models:
2005-2007 Buick Rainier 2006-2009 Buick Allure (Canada only), LaCrosse, Lucerne 2008-2010
Buick Enclave 2006-2010 Cadillac DTS 2007-2010 Cadillac Escalade Models 2008-2009 Cadillac
SRX, XLR 2008-2010 Cadillac CTS, STS 2005-2006 Chevrolet SSR 2005-2009 Chevrolet
TrailBlazer, TrailBlazer EXT 2005-2010 Chevrolet Cobalt 2006-2007 Chevrolet Monte Carlo
2006-2010 Chevrolet Corvette, HHR, Impala, Malibu Models (includes Malibu Classic) 2007-2009
Chevrolet Equinox 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2010
Chevrolet Express 2009-2010 Chevrolet Traverse 2005-2009 GMC Envoy Models 2007-2010 GMC
Acadia, Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2010 GMC Savana
2005-2006 Pontiac Pursuit 2005-2009 Pontiac G6 2006-2009 Pontiac Solstice 2007-2009 Pontiac
G5, Torrent 2008-2009 Pontiac G8 2005-2009 Saab 9-7X 2007-2009 Saturn AURA, OUTLOOK,
SKY 2008-2009 Saturn VUE 2008-2009 HUMMER H2 2007-2008 Daewoo G2X 2007-2009 Opel
GT
Supercede: This bulletin is being revised to update the Warranty Information and add Saab
Warranty Information. Please discard Corporate Bulletin Number 08-09-41-002E (Section 09 -
Restraints).
Condition
- Some customers may comment on an intermittent or current AIR BAG indicator or lamp being
illuminated on the instrument panel cluster (IPC). Important This bulletin only applies to the
following DTCs:
- Technicians may observe DTC(s) B0012 04, 0D, 0E; B0013 04, 0D, 0E; B0015 04, 0D, 0E;
B0016 04, 0D, 0E; B0019 04, 0D, 0E; B0020 04, 0D, 0E; B0022, B0023 04, 0D, 0E; B0033 04, 0D,
0E; B0040 04, 0D, 0E; B0042 or B0044 set as Current or in History in the sensing and diagnostic
module (SDM).
Cause
This condition may be caused by a loose, missing, or damaged connector position assurance
(CPA) retainer at a supplemental inflatable restraint (SIR) module electrical connector, or a
deployment loop wiring harness electrical connector.
Correction
Jun > 10 > Restraints - Air Bag Light ON/Multiple DTC's Set > Page 568
Caution
When performing service on or near the SIR components or the SIR wiring, the SIR system must
be disabled. Failure to observe the correct procedure could cause deployment of the SIR
components. Serious injury can occur. Failure to observe the correct procedure could also result in
unnecessary SIR system repairs.
1. Perform the Diagnostic System Check-Vehicle. 2. Identify the DTC that is set AND review the
DTC Descriptor in the corresponding diagnostic procedure. Refer to Diagnostic Trouble Code
(DTC)
List-Vehicle in SI.
3. Using the information from the DTC Descriptor, determine the location of the affected electrical
connector. Refer to SIR Identification Views and
the Master Electrical Component List in SI.
4. Turn OFF the ignition and disable the supplemental inflatable restraint (SIR) system. Refer to
SIR Disabling and Enabling in SI. 5. BEFORE removing, INSPECT the CPA retainer at the
electrical connector.
Note The connector and connector position assurance (CPA) may seat independent of each other.
Both the connector and CPA should seat with an audible and/or tactile click. The CPA isolates the
shorting-bars within the connector allowing the deployment circuit to operate properly.
‹› If the CPA retainer is loose, damaged, or will not seat in the connector, replace it with a new one.
Reinstall the CPA correctly by first pushing
the connector body in completely, and then pushing the CPA retainer in completely.
‹› If the CPA retainer is not loose or damaged and is properly seated, proceed to Step 6.
6. Remove the CPA retainer and disconnect the electrical connector. Inspect the terminals for the
following conditions:
- Corrosion
- Contamination
- Terminal tension
- Damage
Important The terminals in the SIR/SRS system are made with a special plating. This plating
provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125
SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. DO NOT substitute
any other terminals for those in the repair kit.
‹› If the terminals are damaged, corrosion is observed, or have poor tension, repair or replace as
necessary. Apply dielectric grease, GM P/N
12345579 (in Canada, use P/N 10953481) on the connector pins and terminals when
reassembling. Refer to SIR/SRS Wiring Repairs in SI.
7. Connect the electrical connector, and install the CPA retainer. 8. Enable the supplemental
inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling in SI. 9. Clear the DTC with a
scan tool.
10. Verify that the DTC does not reset by performing the Diagnostic Repair Verification in SI.
‹› If any DTC resets, then refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI.
Parts Information
Note
If the CPA retainer P/N 54590003 (Orange CPA) cannot be located in the J-38125 SIR/SRS
terminal repair kit, contact Kent Moore Tools and order P/N 54590003-PKG to obtain a package of
5.
Jun > 10 > Restraints - Air Bag Light ON/Multiple DTC's Set > Page 569
Important Select the appropriate Labor Operation for the repair that is performed.
For vehicles repaired under warranty, use:
Disclaimer
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: >
08-09-41-002F > Jun > 10 > Restraints - Air Bag Light ON/Multiple DTC's Set
Air Bag Control Module: All Technical Service Bulletins Restraints - Air Bag Light ON/Multiple
DTC's Set
TECHNICAL
Date: June 10, 2010
Subject: Diagnostic Information for Supplemental Inflatable Restraint (SIR) System, Intermittent
AIR BAG Indicator/Lamp Illuminated with DTC(s) B0012, B0013, B0015, B0016, B0019, B0020,
B0022, B0023, B0026, B0033, B0040, B0042 or B0044 Set (Inspect and Replace Connector
Position Assurance (CPA) Retainer)
Models:
2005-2007 Buick Rainier 2006-2009 Buick Allure (Canada only), LaCrosse, Lucerne 2008-2010
Buick Enclave 2006-2010 Cadillac DTS 2007-2010 Cadillac Escalade Models 2008-2009 Cadillac
SRX, XLR 2008-2010 Cadillac CTS, STS 2005-2006 Chevrolet SSR 2005-2009 Chevrolet
TrailBlazer, TrailBlazer EXT 2005-2010 Chevrolet Cobalt 2006-2007 Chevrolet Monte Carlo
2006-2010 Chevrolet Corvette, HHR, Impala, Malibu Models (includes Malibu Classic) 2007-2009
Chevrolet Equinox 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2010
Chevrolet Express 2009-2010 Chevrolet Traverse 2005-2009 GMC Envoy Models 2007-2010 GMC
Acadia, Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2010 GMC Savana
2005-2006 Pontiac Pursuit 2005-2009 Pontiac G6 2006-2009 Pontiac Solstice 2007-2009 Pontiac
G5, Torrent 2008-2009 Pontiac G8 2005-2009 Saab 9-7X 2007-2009 Saturn AURA, OUTLOOK,
SKY 2008-2009 Saturn VUE 2008-2009 HUMMER H2 2007-2008 Daewoo G2X 2007-2009 Opel
GT
Supercede: This bulletin is being revised to update the Warranty Information and add Saab
Warranty Information. Please discard Corporate Bulletin Number 08-09-41-002E (Section 09 -
Restraints).
Condition
- Some customers may comment on an intermittent or current AIR BAG indicator or lamp being
illuminated on the instrument panel cluster (IPC). Important This bulletin only applies to the
following DTCs:
- Technicians may observe DTC(s) B0012 04, 0D, 0E; B0013 04, 0D, 0E; B0015 04, 0D, 0E;
B0016 04, 0D, 0E; B0019 04, 0D, 0E; B0020 04, 0D, 0E; B0022, B0023 04, 0D, 0E; B0033 04, 0D,
0E; B0040 04, 0D, 0E; B0042 or B0044 set as Current or in History in the sensing and diagnostic
module (SDM).
Cause
This condition may be caused by a loose, missing, or damaged connector position assurance
(CPA) retainer at a supplemental inflatable restraint (SIR) module electrical connector, or a
deployment loop wiring harness electrical connector.
Correction
08-09-41-002F > Jun > 10 > Restraints - Air Bag Light ON/Multiple DTC's Set > Page 575
Caution
When performing service on or near the SIR components or the SIR wiring, the SIR system must
be disabled. Failure to observe the correct procedure could cause deployment of the SIR
components. Serious injury can occur. Failure to observe the correct procedure could also result in
unnecessary SIR system repairs.
1. Perform the Diagnostic System Check-Vehicle. 2. Identify the DTC that is set AND review the
DTC Descriptor in the corresponding diagnostic procedure. Refer to Diagnostic Trouble Code
(DTC)
List-Vehicle in SI.
3. Using the information from the DTC Descriptor, determine the location of the affected electrical
connector. Refer to SIR Identification Views and
the Master Electrical Component List in SI.
4. Turn OFF the ignition and disable the supplemental inflatable restraint (SIR) system. Refer to
SIR Disabling and Enabling in SI. 5. BEFORE removing, INSPECT the CPA retainer at the
‹› If the CPA retainer is loose, damaged, or will not seat in the connector, replace it with a new one.
Reinstall the CPA correctly by first pushing
the connector body in completely, and then pushing the CPA retainer in completely.
‹› If the CPA retainer is not loose or damaged and is properly seated, proceed to Step 6.
6. Remove the CPA retainer and disconnect the electrical connector. Inspect the terminals for the
- Corrosion
- Contamination
- Terminal tension
- Damage
Important The terminals in the SIR/SRS system are made with a special plating. This plating
provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125
SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. DO NOT substitute
any other terminals for those in the repair kit.
‹› If the terminals are damaged, corrosion is observed, or have poor tension, repair or replace as
necessary. Apply dielectric grease, GM P/N
12345579 (in Canada, use P/N 10953481) on the connector pins and terminals when
reassembling. Refer to SIR/SRS Wiring Repairs in SI.
7. Connect the electrical connector, and install the CPA retainer. 8. Enable the supplemental
inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling in SI. 9. Clear the DTC with a
scan tool.
10. Verify that the DTC does not reset by performing the Diagnostic Repair Verification in SI.
‹› If any DTC resets, then refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI.
Parts Information
Note
If the CPA retainer P/N 54590003 (Orange CPA) cannot be located in the J-38125 SIR/SRS
terminal repair kit, contact Kent Moore Tools and order P/N 54590003-PKG to obtain a package of
5.
08-09-41-002F > Jun > 10 > Restraints - Air Bag Light ON/Multiple DTC's Set > Page 576
Important Select the appropriate Labor Operation for the repair that is performed.
Disclaimer
Component Information > Technical Service Bulletins > Page 577
Air Bag Control Module: Locations
Front Left Side of Passenger Compartment
1 - Seat Belt Pretensioner - Left 2 - Inflatable Restraint Roof Rail Module Connector - Left Front 3 -
Inflatable Restraint Roof Rail Module - Left Front 4 - Rollover Sensor 5 - Yaw Rate and Lateral
Acceleration Sensor 6 - Audio Amplifier 7 - Inflatable Restraint Sensing and Diagnostic Module
(SDM)
Air Bag Control Module: Diagrams

Inflatable Restraint Sensing and Diagnostic Module (SDM)

Air Bag Control Module: Service and Repair
Inflatable Restraint Sensing and Diagnostic Module Replacement

Hummer Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Occupant
Classification Module - Air Bag > Component Information > Technical Service Bulletins > Restraints - Passenger Presence
Sensing System Info.
Seat Occupant Classification Module - Air Bag: Technical Service Bulletins Restraints - Passenger
Presence Sensing System Info.
INFORMATION
Bulletin No.: 06-08-50-009E
Date: February 24, 2010
Subject: Information on Passenger Presence Sensing System (PPS or PSS) Concerns With
Custom Upholstery, Accessory Seat Heaters or Other Comfort Enhancing Devices
Models:
2010 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2,
H3 2009 and Prior Saab 9-7X Equipped With Passenger Presence Sensing System
Supercede: This bulletin is being revised to update the model years and to add an Important
statement. Please discard Corporate Bulletin Number 06-08-50-009D (Section 08 - Body and
Accessories).
Concerns About Safety and Alterations to the Front Passenger Seat
Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE THE

SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT AS RELEASED BY GM FOR THAT
VEHICLE. DO NOT ALTER THE SEAT COVERS OR SEAT-RELATED EQUIPMENT. ANY
ALTERATIONS TO SEAT COVERS OR GM ACCESSORIES DEFEATS THE INTENDED DESIGN
OF THE SYSTEM. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF
SUCH IMPROPER SEAT ALTERATIONS, INCLUDING ANY WARRANTY REPAIRS INCURRED.
The front passenger seat in many GM vehicles is equipped with a passenger sensing system that
will turn off the right front passenger's frontal airbag under certain conditions, such as when an
infant or child seat is present. In some vehicles, the passenger sensing system will also turn off the
right front passenger's seat mounted side impact airbag. For the system to function properly,
sensors are used in the seat to detect the presence of a properly-seated occupant. The passenger
sensing system may not operate properly if the original seat trim is replaced (1) by non-GM covers,
upholstery or trim, or (2) by GM covers, upholstery or trim designed for a different vehicle or (3) by
GM covers, upholstery or trim that has been altered by a trim shop, or (4) if any object, such as an
aftermarket seat heater or a comfort enhancing pad or device is installed under the seat fabric or
between the occupant and the seat fabric.
Aftermarket Seat Heaters, Custom Upholstery, and Comfort Enhancing Pads or Devices
Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE ONLY

SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT RELEASED AS GM
ACCESSORIES FOR THAT VEHICLE. DO NOT USE ANY OTHER TYPE OF SEAT COVERS OR
SEAT-RELATED EQUIPMENT, OR GM ACCESSORIES RELEASED FOR OTHER VEHICLE
APPLICATIONS. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH
IMPROPER SEAT ACCESSORIES, INCLUDING ANY WARRANTY REPAIRS MADE
NECESSARY BY SUCH USE.
Many types of aftermarket accessories are available to customers, upfitting shops, and dealers.
Some of these devices sit on top of, or are Velcro(R) strapped to the seat while others such as seat
heaters are installed under the seat fabric. Additionally, seat covers made of leather or other
materials may have different padding thickness installed that could prevent the Passenger Sensing
System from functioning properly. Never alter the vehicle seats. Never add pads or other devices to
the seat cushion, as this may interfere with the operation of the Passenger Sensing System and
either prevent proper deployment of the passenger airbag or prevent proper suppression of the
passenger air bag.
Disclaimer
Hummer Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay >
Hummer Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay >
Starter Relay: Service and Repair
Starter Motor Relay Replacement
Removal Procedure
1. Remove the underhood bussed electrical center (UBEC) cover. 2. Remove the starter motor
relay. Refer to Relay Replacement (Attached to Wire Harness) (See: Relays and Modules - Power
and Ground

Electrical Center)) .
1. Install the starter motor relay. Refer to Relay Replacement (Attached to Wire Harness) (See:
Relays and Modules - Power and Ground

Electrical Center)) .
2. Install the UBEC cover.

Hummer Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and
Modules - Suspension > Suspension Control Module > Component Information > Locations
Suspension Control Module: Locations
Air Suspension Unit (ZM6)
Rear Underbody
1 - X451 2 - Air Suspension Compressor 1 Connector 3 - Air Suspension Compressor 2 Connector

4 - Air Suspension Pressure Sensor 5 - Air Suspension Inlet Valve-LR 6 - Air Suspension Inlet
Valve-RR 7 - Air Suspension Exhaust Valve Connector 8 - Air Suspension Air Dryer 9 - Air
Suspension Compressor 1 10 - Air Suspension Compressor 2 11 - Air Suspension Module 12 -
X450
Modules - Suspension > Suspension Control Module > Component Information > Locations > Page 595
Suspension Control Module: Service and Repair

Module Assembly Electronic Suspension Control Replacement (Dual Compressors)
Removal Procedure
Caution: Do NOT remove an air supply pipe in an attempt to depressurize the air suspension.
Always follow the Air Suspension Depressurization Procedure in Air Suspension. Failure to follow
this procedure may cause personal injury or damage to the vehicle.
1. Remove the compressor assembly from the vehicle and place on a bench. Refer to Compressor
Assembly Automatic Level Control Air
Replacement (Dual Compressors) (See: Steering and Suspension/Suspension/Suspension Control

( Automatic - Electronic )/Compressor/Pump/Service and Repair/Compressor Assembly Automatic
Level Control Air Replacement (Dual Compressors)) .
2. Disconnect the electrical connection (1). 3. Remove the control module (2) from the bracket.
Modules - Suspension > Suspension Control Module > Component Information > Locations > Page 596
1. Install the control module (2) to the bracket. 2. Connect the electrical connection (1). 3. Install the
compressor assembly to the vehicle. Refer to Compressor Assembly Automatic Level Control Air
Replacement (Dual Compressors) (
See: Steering and Suspension/Suspension/Suspension Control ( Automatic - Electronic

)/Compressor/Pump/Service and Repair/Compressor Assembly Automatic Level Control Air
Replacement (Dual Compressors)) .
4. Perform the suspension position calibration procedure. Refer to Programming and Relearning
(See: Testing and Inspection/Programming and
Relearning) for programming and setup information.

Modules - Suspension > Suspension Main Relay > Component Information > Locations
Suspension Main Relay: Locations
Front Suspension
1 - Electronically Controlled Air Suspension Relay 2 - Wheel Speed Sensor (WSS) - RF 3 - Wheel
Speed Sensor (WSS) - LF
Modules - Suspension > Suspension Main Relay > Component Information > Locations > Page 600
Suspension Main Relay: Diagrams
Electronically Controlled Air Suspension Relay (ZM6)

Modules - Wheels and Tires > Tire Pressure Module > Component Information > Technical Service Bulletins > Tires/Wheels
- Tire Pressure Sensors Service/Re-Learning
Tire Pressure Module: Technical Service Bulletins Tires/Wheels - Tire Pressure Sensors
Service/Re-Learning
INFORMATION
Bulletin No.: 10-03-16-001
Date: July 19, 2010
Subject: TPMS System Service and Re-Learning Sensor IDs
Models:
2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and
Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted
Tire Pressure Sensors
In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM)
sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25
mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash
for approximately one minute and then remain on steady each time the ignition is turned ON,
indicating a diagnostic trouble code (DTC) has been set.
The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type
message. When the road tire is repaired and reinstalled in the original location, the TPM indicator
icon illumination and DIC message may remain displayed until the DTC is cleared.
To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to
clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn
procedure using a TPM diagnostic tool will provide the same results.
It is advised to perform the relearn procedure away from other vehicles to prevent picking up a
stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been
replaced, then the relearn procedure must be performed.
Disclaimer
Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Technical Service
Bulletins > Tires/Wheels - Tire Pressure Sensors Service/Re-Learning
Tire Pressure Monitor Receiver / Transponder: Technical Service Bulletins Tires/Wheels - Tire
Pressure Sensors Service/Re-Learning
INFORMATION
Bulletin No.: 10-03-16-001
Date: July 19, 2010
Models:
Disclaimer
Hummer Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Recalls: > 08080 > Mar > 08
> Campaign - Reprogram the TCM
Control Module: Recalls Campaign - Reprogram the TCM
# 08080: Service Update for Inventory Vehicles Only-Transmission Control Module Reprogram
(Low Speed Engine Braking Sensation Upon Automatic Downshift to First Gear) - Expires March
31, 2009 - (Mar 4, 2008)
Subject: 08080 -- Service Update for Inventory Vehicles Only - Transmission Control Module
Reprogram (Low Speed Engine Braking Sensation Upon Automatic Downshift to First Gear) --
Expires March 31, 2009
Models: 2008 HUMMER H2, H2 SUT
Equipped with 6 Speed Automatic Transmission (RPO MYC)
THIS SERVICE UPDATE INVOLVES VEHICLES IN DEALER INVENTORY ONLY AND WILL
EXPIRE MARCH 31, 2009.
Purpose
This bulletin provides a service procedure to reprogram the transmission control module (TCM) on
certain 2008 Hummer H2 and H2 SUT vehicles equipped with a 6 Speed automatic transmission
(RPO MYC). The new calibrations eliminate a low speed engine braking sensation upon automatic
downshift to first gear that may be unpleasant to some customers.
This service procedure should be completed on involved vehicles currently in dealership inventory
as soon as possible, but no later than March 31, 2009, at which time this bulletin will expire.
Vehicles Involved
A list of involved vehicles currently in dealer inventory is available on the "Service Update Bulletin
Information" link under the "Service" tab in DealerWorld (US), or attached to the Dealer
Communication (Canada), used to release this bulletin.
Important:
Dealers are to confirm vehicle eligibility prior to beginning repairs by using the system(s) below. Not
all vehicles within the above breakpoints may be involved.
-- GM dealers should use GMVIS.
and TIS 2 Web with the calibration update. Use TIS 2 Web version 3.0 for 2008 (available on
3/03/08); and on TIS DVD version 3.0/2008 or later, which will be mailed to dealers beginning
3/12/08. If you cannot access the calibration, call the Techline Customer Support Center.
Service Procedure
The "Required Field Actions" section of the GM Vehicle Inquiry System (GMVIS) must be checked
to determine if a specific vehicle requires this action. If GMVIS indicates that Service Update
Bulletin 08080 remains 'open' and TCM reprogramming has not taken place, reprogram the TCM
using a Tech 2®(R) scan tool with the calibration update from Techline Information System (TIS).
Notice:
Before reprogramming, please check the battery condition to prevent a reprogramming error of any
reprogramming. If the vehicle battery is not fully charged, use an additional jump battery if
necessary. Only use approved Midtronics charger or Jumper Packs, etc. to maintain proper battery
voltage during reprogramming. Be sure to turn off or disable any system that may put a load on the
battery, such as automatic headlamps, daytime running lights, interior lights, heating, ventilation,
and air conditioning (HVAC) system, radio, engine cooling fan, etc. A programming failure3 or
control module damage may occur if battery voltage guidelines are not observed.
The ignition switch must be in the proper position. The Tech 2(R) prompts you to turn ON the
ignition, with the engine OFF. DO NOT change the position of the ignition switch during the
programming procedure, unless instructed to do so.

> Campaign - Reprogram the TCM > Page 620
up to date.
Tech 2 Pass-Thru Method
1. Verify the battery charge of 12 to 16 volts. The battery must be able to maintain a charge during
programming. Use an additional jump battery if necessary. Only use approved Midtronics charger
or Jumper Packs, etc. to maintain proper battery voltage during programming.
2. Connect the Tech 2(R) to the vehicle and the TIS terminal.
3. Turn the ignition to ON with the engine off.
4. After all warning chimes inside the vehicle have stopped, turn on the Tech 2.
5. On the TIS terminal go into SPS Programming.
6. In the top box Select Diagnostic Tool select Tech 2 Legacy Pass-Thru.
7. In the lower box Select Programming Process select Reprogram ECU.
8. Follow instructions on the TIS terminal. When you get to the Supported Controllers screen:
8.1. In the top box select TCM, Transmission Control Module.
8.2. In the lower box select Normal.
8.3. Select NEXT.
9. Select NEXT when the calibrations screen displays.
10. Follow on screen prompts until programming is completed.
11. When programming is complete:
11.1. Turn off Tech 2.
11.2. Turn off ignition switch.
12. Wait 30 seconds.
13. Turn ignition switch to ON with engine off.
14. Turn on the Tech 2.

15. Go into diagnostics and check for DTC codes.
16. Clear all codes.
Claim Information
For vehicles repaired under this service update, use the table.
Disclaimer
Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: >
08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON
Control Module: Customer Interest A/T Controls - DTC P1825/P182E or P1915/MIL ON
INFORMATION
Date: March 03, 2010
Subject: Diagnostic Information for MIL Illuminated with DTC P1825, P182E or P1915 Found
Current or as History Code in TCM, No PRNDL Display, Potential No Engine Crank
Models:
2006-2009 Cadillac XLR-V 2006-2010 Cadillac STS-V 2007-2009 Cadillac SRX, XLR 2007-2010
Cadillac Escalade, Escalade ESV, Escalade EXT, STS 2008-2010 Cadillac CTS 2009-2010
Cadillac CTS-V 2006-2010 Chevrolet Corvette 2007-2010 Chevrolet Silverado 2008-2010
Chevrolet Suburban 2009-2010 Chevrolet Avalanche, Tahoe 2010 Chevrolet Camaro, Express
2007-2010 GMC Sierra, Yukon Denali, Yukon XL Denali 2008-2010 GMC Yukon XL 2009-2010
GMC Yukon 2010 GMC Savana 2008-2009 Pontiac G8 2008-2009 HUMMER H2 with 6L50 RPO
MYB, 6L80 RPO MYC or 6L90 RPO MYD Automatic Transmission
Supercede: This bulletin is being revised to remove the contact information in Step 4 under
HISTORY DTC heading and update the models and model years. Please discard Corporate
Bulletin Number 08-07-30-020D (Section 07 - Transmission).
The following diagnostic information will aid the technician if the MIL is illuminated with DTC P1825,
P182E or P1915. The DTC may be found current or as a history code in the TCM along with a no
PRNDL display and the potential for no engine crank.
1. Use the Tech 2(R) to capture and record Freeze Frame/Failure Data for all DTCs set. Review
the data to determine:
- Vehicle speed, commanded gear, transmission temperature, throttle position, transmission ratio,
transmission input and output speed sensor RPM when DTC set (use to attempt to duplicate
failure)
- IMS A/B/C/P and IMS state
2. Using the Tech 2(R), navigate to transmission data and scroll down to IMS. With the ignition ON
and the engine OFF, observe the IMS A/B/C/P
switch states and IMS states for each shift lever detent position. The chart following this list shows
the correct states.
3. If all IMS readings are normal, monitor the PNP status in the engine data list during DTC setting
to isolate a possible open or short to ground on
the dedicated PNP signal between the TEHCM and the ECM.
4. If the vehicle is a 2009 CTS, STS or SRX, proceed to Step 5 in the History DTC section below
before continuing with any additional evaluations. 5. If all IMS and PNP readings are normal, the
condition is intermittent in nature and determination of the defective component will be made based
on freeze frame data and previous repair history or warranty data. Proceed to History DTC below. If
the readings are not as specified above, the fault is still active. Proceed to the Active DTC section
below to determine which component(s) is defective.
08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 627
HISTORY DTC
If all readings are normal per Step 2 above, capture and record Freeze Frame/Failure Data, clear
DTCs and attempt to duplicate the fail conditions.
1. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of
"HLLL" and the IMS state of "Neutral/Drive 6",
complete the following:
Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM or low value,
Engine Torque >30 Nm.
Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission
or 2008 model year vehicles. These calibrations were updated before production began.
- Update the TCM calibration file to the latest released on TIS2WEB.
- Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted
rubber boot at the transmission end of the cable.
- Check and ensure proper cable adjustment.
- Determine if the shift lever can be hung-up between Neutral and Drive 6. If so, there may be
excessive drag in the system.
- Move the shift lever through each detent position, ensuring positive detent feel. If any concern is
noted, remove the transmission oil pan and repeat the shift lever movement. Ensure that the detent
spring roller moves to the bottom of the valley on the detent plate for each shift lever position.
Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms
should not be rubbing on either the IMS arm or detent plate.
- After completing the above steps, test drive the vehicle, moving the shifter through all detent
positions. If no issues are found, ensure all DTC codes are cleared from history and return the
vehicle to the customer. If the vehicle has been returned to the dealer with this Freeze Frame bit
codes after repairs, contact the person(s) below in Step 4.
2. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHLH"
and IMS state of "Blank", complete the
following:
Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS >0 RPM, Vehicle
Speed >0 MPH
- Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not,
continue with this bulletin.
vehicle to the customer.
3. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHHL"
and IMS state of "Invalid", complete the
following:
Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM, Vehicle
Speed >0 MPH
4. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of LLLH,
LLHL, LHLL or PNP Switch is P/N in all gears,
failure is a short to ground condition and is most likely in the Control Solenoid (with body and TCM)
Valve Assembly (TEHCM), complete the following:
- Obtain the following data and contact the PQC as the Control Solenoid (with body and TCM)
Valve Assembly (TEHCM) is currently on restriction. The PQC will engage engineering for
additional diagnostic support.
- Capture or record freeze frame or fail records if a DTC is set.
- Document the diagnostics completed leading to the decision to replace the control solenoid valve
and transmission control module.
LLLH and the vehicle is a 2009 CTS, STS or SRX,
the condition is most likely caused by an incorrectly adjusted shift linkage.
Important Typical Freeze Frame operating conditions: ISS and OSS both =0 RPM or ISS and OSS
both >0 RPM and/or vehicle is in some drive gear (transmission gear ratio matches one of the
forward gear ratios).
- Using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code
remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted
properly.
- Perform the Shift Control Linkage Adjustment as detailed in SI.
- After adjustment, using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS
A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not
adjusted properly. Repeat the adjustment.
- If no shifter adjustment issues are found, return to Step 4.

ACTIVE DTC/FAULT ACTIVE
If the fault is still active per Step 2 above, or after a test drive, continue with component tests
defined below:
1. Ensure proper system performance:
- Remove the transmission oil pan and repeat the shift lever movement, ensuring that the detent
2. Disconnect the IMS connector at the Control Solenoid (w/body and TCM) Valve Assembly
(TEHCM). With the Tech 2(R) connected and the
ignition ON and engine OFF, the Tech 2(R) should report all IMS states A/B/C/P as high (H) and
the PNP Switch should display "In Gear".
- If any of the A/B/C/P circuits displays low (L), the TEHCM is faulty and should be replaced. If the
Vehicle Build Date is prior to March 31, 2007, also replace the IMS.
- If the PNP Switch Circuit (Tech 2(R) Engine data) displays "Park/Neutral", a short exists in the
TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through
connector. Check for continuity between the pass-through P/N Signal pin 3 (refer to
Automatic Transmission Inline 16-Way Connector End View in SI) and the valve body assembly. If
continuity exists, a short to ground is present in the TEHCM and it should be replaced. If the
Vehicle Build Date is prior to March 31, 2007, also replace the IMS. If there is no continuity, the
problem is outside the transmission.
Important The bad bit should be consistent with the bad bit identified in Step 2.
3. Connect a 3-amp fused jumper wire between the common pin (Pin A) and pins B, C, D & F in the
TEHCM IMS connector (refer to Automatic
Transmission Internal Connector End Views in SI). As each circuit (B, C, D & F) is grounded with
ignition ON, engine OFF, the Tech 2(R) should display low (L) for the IMS bit.
- If any of the A/B/C/P circuits displays high (H) when grounded, the TEHCM is faulty and should
be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS.
- If Pin F in the PNP Switch Circuit (Tech 2(R) Engine data) displays "In Gear" when grounded, an
open exist in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission
pass-through connector. Check for continuity between the pass-through P/N Signal Pin 3 (refer to
Automatic Transmission Inline 16-Way Connector End View in SI) and TEHCM IMS connection Pin
F (refer to Automatic Transmission Internal Connector End Views in SI). If there is continuity, the
problem is outside the transmission. If there is no continuity, replace the TEHCM. If the Vehicle
Build Date is prior to March 31, 2007, also replace the IMS.
4. If the two tests above indicate correct TEHCM operation and the condition still exists, the IMS is
faulty and should be replaced.
5. Update the TCM calibration file to the latest released on TIS2WEB.
Disclaimer
08-07-30-012 > Mar > 08 > A/T - Clunk Noise First Gear/Engine Braking Sensation
Control Module: Customer Interest A/T - Clunk Noise First Gear/Engine Braking Sensation
TECHNICAL
Bulletin No.: 08-07-30-012
Subject: 6L80 Automatic Transmission - Tip In Low Speed Clunk in First Gear When Throttle is
Applied and Released, Engine Braking Sensation at Low Speeds (Reprogram TCM)
with 6L80 6-Speed Automatic Transmission (RPO MYC)
Condition
Some customers may comment that the vehicle has a "Tip In" low speed clunk in first gear when
the throttle is applied and released in normal "D" drive. Other customers may comment on an
engine braking sensation at low speeds in normal "D" drive.
Correction
A revised transmission calibration has been developed to address these issues. Reprogram the
transmission control module (TCM) with updated calibration files using the TIS2WEB Service
Programming System (SPS) application. As always make sure your Tech 2(R) is updated with the
Disclaimer
Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Control Module: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON
Control Module: All Technical Service Bulletins A/T Controls - DTC P1825/P182E or P1915/MIL
ON
INFORMATION
Models:
failure)
the correct states.
Bulletins for Control Module: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page
639
HISTORY DTC
following:
Speed >0 MPH
640
following:
Speed >0 MPH
properly.

defined below:
641
Disclaimer
Bulletins for Control Module: > 08-07-30-012 > Mar > 08 > A/T - Clunk Noise First Gear/Engine Braking Sensation
Control Module: All Technical Service Bulletins A/T - Clunk Noise First Gear/Engine Braking
Sensation
TECHNICAL
Bulletin No.: 08-07-30-012
Condition
Correction
Disclaimer
Bulletins for Control Module: > 08080 > Mar > 08 > Campaign - Reprogram the TCM
Control Module: All Technical Service Bulletins Campaign - Reprogram the TCM
31, 2009 - (Mar 4, 2008)
Purpose
Vehicles Involved
Important:
Service Procedure
Notice:

Bulletins for Control Module: > 08080 > Mar > 08 > Campaign - Reprogram the TCM > Page 650
up to date.
8.3. Select NEXT.

Claim Information
Disclaimer
Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins
for Control Module: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON
ON
INFORMATION
Models:
failure)
the correct states.
for Control Module: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 657
HISTORY DTC
following:
Speed >0 MPH
following:
Speed >0 MPH
properly.

defined below:
Disclaimer
for Control Module: > 08-07-30-012 > Mar > 08 > A/T - Clunk Noise First Gear/Engine Braking Sensation
Sensation
TECHNICAL
Bulletin No.: 08-07-30-012
Condition
Correction
Disclaimer
for Control Module: > 08080 > Mar > 08 > Campaign - Reprogram the TCM
31, 2009 - (Mar 4, 2008)
Purpose
Vehicles Involved
Important:
Service Procedure
Notice:

for Control Module: > 08080 > Mar > 08 > Campaign - Reprogram the TCM > Page 669
up to date.
8.3. Select NEXT.

Claim Information
for Control Module: > 08080 > Mar > 08 > Campaign - Reprogram the TCM > Page 670
Disclaimer
Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 671
Control Module: Service and Repair
Control Solenoid Valve and Transmission Control Module Assembly Replacement

Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 672
Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations
Control Module: Locations
Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Transfer Case Shift
Control Module X1
Control Module: Diagrams Transfer Case Shift Control Module X1
Transfer Case Shift Control Module X1

Control Module X1 > Page 679


Modules - Transfer Case > Control Module, Transfer Case > Component Information > Service and Repair > Procedures
Control Module: Procedures
Transfer Case Control Module Reprogramming
Set-up for Module Programming/Reprogramming
Important: Ensure that the vehicle battery is fully charged and that a battery charger is no longer
connected. If performing this procedure for module replacement, install new module before
proceeding.
* Turn OFF all accessories.
* Turn ON the ignition, with the engine OFF.
Remote Programming Feature
1. Connect the scan tool to the vehicle. 2. Power-up the scan tool and select the Service
Programming feature. 3. Select the appropriate vehicle. 4. Press the Request Info button on the
scan tool. 5. Disconnect the scan tool from the vehicle and connect the scan tool to the computer
station. 6. Follow the menu select items for reprogramming and provide information as to what type
of device you are programming and whether you are
reprogramming or replacing the electronic control unit (ECU).
7. Select "vehicle" from the selection menu. 8. Select the module you wish to Program. 9. Select
"Normal" for Programming Type.
10. Select the applicable software calibrations. 11. Transfer data file to the scan tool. 12.
Reconnect the scan tool to the vehicle. 13. Turn ON the ignition, with the engine OFF. 14. Select
the Service Programming feature on the scan tool. 15. Press the Program button on the scan tool.
Programming Using Scan Tool Pass-Through Connection
1. Connect the scan tool to vehicle and power it up. 2. Connect the computer station to the scan
tool. 3. Select "PC Using Scan Tool Connection" from the programming menu on the computer
5. Select "vehicle" from the selection menu. 6. Select the module you wish to program. 7. Select
"Normal" for Programming Type. 8. Select the applicable software calibrations. 9. Transfer data file
to the scan tool.
Modules - Transfer Case > Control Module, Transfer Case > Component Information > Service and Repair > Procedures >
Page 683
Control Module: Removal and Replacement
Transfer Case Shift Control Module Replacement
Removal Procedure
1. Remove the knee bolster. Refer to Driver Knee Bolster Replacement (See: Body and
2. Remove the electrical connectors (1) from the transfer case control module (2).
3. Release the transfer case control module from the bracket (1). 4. Remove the transfer case
control module (2).
Modules - Transfer Case > Control Module, Transfer Case > Component Information > Service and Repair > Procedures >
Page 684
1. Install the transfer case control module (2) to the bracket. 2. Ensure the transfer case control
module bracket clips (1) are securely retaining the module.
3. Install the electrical connectors (1) to the transfer case control module (2). 4. Install the knee
bolster. Refer to Driver Knee Bolster Replacement (See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument
5. Program the module. Refer to Transfer Case Control Module Reprogramming (See: Procedures)
. 6. Start the engine and test the automatic transfer case system for proper shift operation.
Hummer Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element
Relay > Component Information > Locations
Hummer Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield
Washer Relay > Component Information > Locations
Hummer Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control
Module > Component Information > Diagrams
Wiper Control Module: Diagrams
Rear Window Wiper/Washer Module (SUV)

Hummer Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control
Module > Component Information > Diagrams > Page 696
Wiper Control Module: Service and Repair
Rear Window Wiper Control Module Replacement

Hummer Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay >
Component Information > Locations > WIPER 1 PCB Relay
Hummer Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay >
Component Information > Locations > WIPER 1 PCB Relay > Page 701
Hummer Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment >
Steering Mounted Controls Assembly > Component Information > Service and Repair
Steering Mounted Controls Assembly: Service and Repair
Steering Wheel Control Switch Assembly Replacement

Hummer Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Console Lamp Switch >
Console Lamp Switch: Locations
Floor Console Components
1 - Console Bin Lamp Switch 2 - Auxiliary Power Outlet-Console 3 - PRNDL Lamps 4 - X356 5 -
Console Bin Lamp 6 - Automatic Transmission Shift Lock Control Solenoid
Hummer Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Console Lamp Switch >
Console Lamp Switch: Diagrams
Console Bin Lamp Switch

Hummer Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Hood Switch / Sensor >
Hood Ajar Switch > Component Information > Diagrams
Hood Ajar Switch: Diagrams
Hood Switch
Hummer Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock
Switch > Component Information > Service and Repair > Door Lock and Side Window Switch Replacement - Driver Side
Power Door Lock Switch: Service and Repair Door Lock and Side Window Switch Replacement -
Driver Side
Door Lock and Side Window Switch Replacement - Driver Side

Hummer Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock
Switch > Component Information > Service and Repair > Door Lock and Side Window Switch Replacement - Driver Side >
Page 720
Power Door Lock Switch: Service and Repair Door Lock and Side Window Switch Replacement -
Passenger Side
Door Lock and Side Window Switch Replacement - Passenger Side

Hummer Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Locations > Seat Adjuster Switch
Power Seat Switch: Locations Seat Adjuster Switch
Passenger Seat Sub-System Components

Component Information > Locations > Seat Adjuster Switch > Page 725
1 - Seat Horizontal Motor-Front Passenger 2 - Seat Front Vertical Motor-Front Passenger 3 - Seat
Rear Vertical Motor-Front Passenger 4 - X376 5 - X377 6 - X375 7 - Seat Recline Motor-Front
Passenger 8 - Seat Bolster/Lumbar Switch-Front Passenger 9 - Seat Adjuster Switch-Front
Passenger
Power Seat Switch: Locations Seat Bolster Switch

Passenger
Power Seat Switch: Locations Seat Lumbar Switch

Passenger
Component Information > Service and Repair > Front Seat Adjuster Switch Knob Replacement
Power Seat Switch: Service and Repair Front Seat Adjuster Switch Knob Replacement
Front Seat Adjuster Switch Knob Replacement

Component Information > Service and Repair > Front Seat Adjuster Switch Knob Replacement > Page 732
Power Seat Switch: Service and Repair Driver Seat and Passenger Seat Adjuster and Recliner
Switch Replacement
Driver Seat and Passenger Seat Adjuster and Recliner Switch Replacement
Component Information > Service and Repair > Front Seat Adjuster Switch Knob Replacement > Page 733
Power Seat Switch: Service and Repair Lumbar Switch Replacement
Lumbar Switch Replacement

Hummer Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch >
Seat Heater Switch: Locations
Hummer Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch >
Seat Heater Switch: Service and Repair
Front Seat Heater Switch Replacement

Hummer Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Memory Switch >
Seat Memory Switch: Locations
Front Doors

Sensor (SIS) - Left Front 16 - Door Latch Assembly-Driver Door
Component Information > Service and Repair > Procedures
Seat Memory Switch: Procedures
Memory Seat Calibration
The memory seat module uses position sensor inputs to establish soft stop locations for the
adjuster motors several millimeters ahead of the physical limits of the adjuster assembly. After
replacing a memory seat module or adjuster components, it may be necessary to reset the adjuster
motor soft stop locations. When the repair procedure has been completed, operate the seat
adjuster switch in every direction until the seat adjuster reaches its mechanical hard stop by
repeatedly pressing and releasing the switch as necessary.
Component Information > Service and Repair > Procedures > Page 743
Seat Memory Switch: Removal and Replacement
Driver Seat Adjuster Memory Switch Replacement

Hummer Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof
Switch > Component Information > Locations
Sunroof / Moonroof Switch: Locations
Headliner (SUT)
Switch > Component Information > Locations > Page 747
Headliner (SUV)
Sunroof / Moonroof Switch: Service and Repair
Sunroof Switch Replacement

Hummer Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Trunk / Liftgate Ajar
Trunk / Liftgate Ajar Switch: Locations
Liftgate (Except SUT)
1 - Center High Mounted Stop Lamp (CHMSL) Connector 2 - Rear Window Defogger Grid
Connector 3 - Rear Window Defogger Grid Connector 4 - Splice S900 5 - Rear Window Wiper
Module - w/Motor 6 - Door Lock Actuator - Liftgate 7 - Liftgate Ajar Switch - Left 8 - Liftgate Ajar
Switch - Right 9 - Splice S902 10 - Splice S901
Switch > Component Information > Diagrams > Liftgate Ajar Switch - Left (SUV)
Trunk / Liftgate Ajar Switch: Diagrams Liftgate Ajar Switch - Left (SUV)
Liftgate Ajar Switch - Left (SUV)

Switch > Component Information > Diagrams > Liftgate Ajar Switch - Left (SUV) > Page 754
Trunk / Liftgate Ajar Switch: Diagrams Liftgate Ajar Switch - Right (SUV)
Liftgate Ajar Switch - Right (SUV)

Hummer Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control >
Acceleration/Deceleration Sensor > Component Information > Service and Repair > Longitudinal Accelerometer
Replacement
Acceleration/Deceleration Sensor: Service and Repair Longitudinal Accelerometer Replacement
Longitudinal Accelerometer Replacement

Hummer Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control >
Replacement > Page 760
Acceleration/Deceleration Sensor: Service and Repair Vehicle Yaw Sensor with Vehicle Lateral
Accelerometer Replacement
Vehicle Yaw Sensor with Vehicle Lateral Accelerometer Replacement

Hummer Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid
Level Sensor/Switch > Component Information > Locations
Brake Fluid Level Sensor/Switch: Locations
Engine Compartment
Accumulator
Engine Compartment
Level Sensor/Switch > Component Information > Locations > Page 764
Accumulator
Level Sensor/Switch > Component Information > Locations > Page 765
Brake Fluid Level Sensor/Switch: Diagrams
Brake Fluid Level Switch

Hummer Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Lateral
Accelerometer > Component Information > Locations
Lateral Accelerometer: Locations
(SDM)
Hummer Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Lateral
Accelerometer > Component Information > Locations > Page 769
Lateral Accelerometer: Diagrams
Yaw Rate and Lateral Acceleration Sensor

Hummer Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking
Brake Warning Switch > Component Information > Diagrams
Parking Brake Warning Switch: Diagrams
Park Brake Switch

Brake Warning Switch > Component Information > Diagrams > Page 773
Parking Brake Warning Switch: Service and Repair
Parking Brake Indicator Switch Replacement
Removal Procedure
Caution: Refer to Battery Disconnect Caution .
1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and
Connection (See: Starting and
Charging/Battery/Battery Cable/Service and Repair/Battery Negative Cable Disconnection and

Connection) .
2. Remove the MID-Bussed Electrical Center from the bracket.
3. Disconnect the park brake warning lamp switch connector.
4. Remove the park brake warning lamp switch mounting bolt. 5. Remove the park brake warning
lamp switch.
Brake Warning Switch > Component Information > Diagrams > Page 774
1. Install the park brake warning lamp switch.
Notice: Refer to Fastener Notice .
2. Install the park brake warning lamp switch mounting bolt.
3. Connect the park brake warning lamp switch connector. 4. Install the MID-Bussed Electrical
Center bracket. 5. Connect the negative battery cable. Refer to Battery Negative Cable
Disconnection and Connection (See: Starting and Charging/Battery/Battery
Cable/Service and Repair/Battery Negative Cable Disconnection and Connection) .

Hummer Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Technical Service Bulletins > Recalls for Wheel Speed Sensor: > 07221 > Sep >
07 > Recall - Wheel Speed Sensor Wiring/EBCM programming
Condition
reversed.
Correction
Vehicles Involved
07 > Recall - Wheel Speed Sensor Wiring/EBCM programming > Page 783
Important:
System (GMVIS).
recall.
Parts Information
will be provided.
NOTICE:
up to date.

guidelines.
Claim Information

Disclaimer
Service Procedure
Important:
individual vehicle.
disconnected.
Step 5.
Important:
Speed Sensor > Component Information > Technical Service Bulletins > Recalls for Wheel Speed Sensor: >
NHTSA07V373000 > Aug > 07 > Recall 07V373000: ABS Wheel Speed Sensor Wiring
Wheel Speed Sensor: Recalls Recall 07V373000: ABS Wheel Speed Sensor Wiring
be reversed.
a crash.
Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed
Sensor: > 07221 > Sep > 07 > Recall - Wheel Speed Sensor Wiring/EBCM programming
Condition
reversed.
Correction
Vehicles Involved
Sensor: > 07221 > Sep > 07 > Recall - Wheel Speed Sensor Wiring/EBCM programming > Page 809
Important:
System (GMVIS).
recall.
Parts Information
will be provided.
NOTICE:
up to date.

guidelines.
Claim Information

Disclaimer
Service Procedure
Important:
individual vehicle.
disconnected.
Step 5.
Important:
Sensor: > NHTSA07V373000 > Aug > 07 > Recall 07V373000: ABS Wheel Speed Sensor Wiring
Wheel Speed Sensor: All Technical Service Bulletins Recall 07V373000: ABS Wheel Speed
Sensor Wiring
be reversed.
a crash.
Speed Sensor > Component Information > Technical Service Bulletins > Page 830
Wheel Speed Sensor: Locations
Front Suspension
Rear Suspension
1 - Rear Differential Lock Actuator 2 - Wheel Speed Sensor (WSS) - RR 3 - Ride Height Sensor -
Right 4 - Air Suspension Unit (ZM6) 5 - Wheel Speed Sensor (WSS) - LR 6 - Ride Height Sensor -
Left
Speed Sensor > Component Information > Diagrams > Wheel Speed Sensor (WSS) - Left Front
Wheel Speed Sensor: Diagrams Wheel Speed Sensor (WSS) - Left Front
Wheel Speed Sensor (WSS) - Left Front

Speed Sensor > Component Information > Diagrams > Wheel Speed Sensor (WSS) - Left Front > Page 834
Wheel Speed Sensor: Diagrams Wheel Speed Sensor (WSS) - Left Rear
Wheel Speed Sensor (WSS) - Left Rear

Wheel Speed Sensor: Diagrams Wheel Speed Sensor (WSS) - Right Front
Wheel Speed Sensor (WSS) - Right Front

Wheel Speed Sensor: Diagrams Wheel Speed Sensor (WSS) - Right Rear
Wheel Speed Sensor (WSS) - Right Rear

Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement
Wheel Speed Sensor: Service and Repair Front Wheel Speed Sensor Replacement
Front Wheel Speed Sensor Replacement Caution: Refer to Brake Dust Caution (See: Brakes and
Traction Control/Service Precautions/Technician Safety Information/Brake Dust Caution) .
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance) . 2.
Remove the tire and wheel. Refer to Tire and Wheel Removal and Installation (See:
Maintenance/Wheels and Tires/Service and Repair) . 3. Remove the brake rotor. Refer to Front
Brake Rotor Replacement (See: Brakes and Traction Control/Disc Brake System/Brake
Rotor/Disc/Service and Repair/Removal and Replacement/Front Brake Rotor Replacement) .
4. Remove the WSS cable mounting clip from the knuckle. 5. Remove the WSS cable mounting
clip from the upper control arm. 6. Remove the WSS cable mounting clip from the frame
attachment point. 7. Disconnect the WSS cable electrical connector.
8. Remove the wheel speed sensor (WSS) mounting bolt.
NOTICE: Carefully remove the sensor by pulling it straight out of the bore. DO NOT use a
screwdriver, or other device to pry the sensor out of the bore. Prying will cause the sensor body to
break off in the bore.
9. Remove the wheel speed sensor (5) from the hub/bearing assembly (4).
Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page 839
1. Install the WSS (5) into the hub/bearing assembly (4).
2. Install the WSS mounting bolt.
Tighten the WSS mounting bolt to 18 N.m (13 lb ft).
3. Install the WSS cable mounting clip to the knuckle. 4. Install the WSS cable mounting clip to the
upper control arm. 5. Install the WSS cable mounting clip to the frame attachment point. 6. Connect
the WSS cable electrical connector. 7. Install the brake rotor. Refer to Front Brake Rotor
Replacement (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service
and Repair/Removal and Replacement/Front Brake Rotor Replacement) .
8. Install the tire and wheel. Refer to Tire and Wheel Removal and Installation (See:
Maintenance/Wheels and Tires/Service and Repair) . 9. Return to Diagnostic Starting Point -
Antilock Brake System (See: Brakes and Traction Control/Antilock Brakes / Traction Control
Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Starting

Point - Antilock Brake System) .
Wheel Speed Sensor: Service and Repair Rear Wheel Speed Sensor Replacement
Rear Wheel Speed Sensor Replacement Caution: Refer to Brake Dust Caution (See: Brakes and
Traction Control/Service Precautions/Technician Safety Information/Brake Dust Caution) .
Removal Procedure
1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance) . 2. Disconnect
the electrical connector. 3. Remove the wheel speed sensor retaining bolt.
Important: If a shim was removed when the wheel speed sensor was removed, it must be
reinstalled to ensure proper operation.
4. Remove the wheel speed sensor and shim if present.
1. Install the shim, if removed with the sensor, and the wheel speed sensor.

Notice) .
2. Install the wheel speed sensor retaining bolt.

3. Connect the electrical connector. 4. Lower the vehicle. 5. Perform a low speed test to ensure the
wheel speed sensor is functioning properly:
1. Start the engine and allow it to idle. 2. Check to see if the ABS indicator or the traction assist
indicator remains illuminated. 3. If the ABS indicator or the traction assist indicator remains
illuminated, DO NOT proceed to drive the vehicle until it is diagnosed and
repaired. Check the wheel speed sensor electrical connector to ensure it is not damaged and is
installed properly. If the lamp remains illuminated, refer to Symptoms - Antilock Brake System
(See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Testing and
Inspection/Symptom Related Diagnostic Procedures/Symptoms - Antilock Brake System) .
4. Select a smooth, dry, clean, and level road or large lot that is as free of traffic and obstacles as
possible. 5. Drive the vehicle and maintain a speed of at least 16 km/h (10 mph) for at least 5
seconds. 6. Stop the vehicle and check to see if the ABS indicator or the traction assist indicator is
illuminated. 7. If an indicator is illuminated, refer to Diagnostic Starting Point - Antilock Brake
System (See: Brakes and Traction Control/Antilock Brakes /
Traction Control Systems/Testing and Inspection/Initial Inspection and Diagnostic

Overview/Diagnostic Starting Point - Antilock Brake System) .
Hummer Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Yaw Rate
Sensor > Component Information > Locations
Yaw Rate Sensor: Locations
(SDM)
Sensor > Component Information > Locations > Page 845
Yaw Rate Sensor: Diagrams

Yaw Rate Sensor: Service and Repair

Hummer Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant
Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations
Coolant Temperature Sensor/Switch (For Computer): Locations
Engine - Right Rear (L92)
1 - Ignition Coil 1 2 - Evaporative Emission (EVAP) Canister Purge Solenoid Valve 3 - Ignition Coil
5 4 - Fuel Injector 3 5 - Fuel Injector 5 6 - Ignition Coil 7 7 - Fuel Injector 7 8 - Engine Oil Pressure
(EOP) Sensor 9 - Knock Sensor (KS) 1 10 - Engine Coolant Temperature (ECT) Sensor 11 -
Engine Block Heater Connector 12 - Ignition Coil 3 13 - Fuel Injector 1
Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations >
Page 852
Coolant Temperature Sensor/Switch (For Computer): Diagrams
Engine Coolant Temperature (ECT) Sensor

Page 853
Coolant Temperature Sensor/Switch (For Computer): Service and Repair
Engine Coolant Temperature Sensor Replacement
Removal Procedure
Notice: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the
operation of the fuel control system.
1. Turn OFF the ignition.
2. Drain the cooling system below the level of the ECT sensor. Refer to Cooling System Draining
and Filling (Static Fill) (See: Engine, Cooling and
Exhaust/Cooling System/Service and Repair/Draining and Filling Cooling System)Cooling System

Draining and Filling (Vac-N-Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and
Repair/Draining and Filling Cooling System) .
3. Disconnect the electrical connector from the engine coolant temperature (ECT) sensor.
4. Remove the ECT sensor.
Notice: 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.
1. Coat the ECT sensor threads with sealer GM P/N 12346004 (Canadian P/N 10953480) or the
equivalent.

Notice) .
2. Install the ECT sensor.

Page 854
Tighten the ECT sensor to 20 N.m (15 lb ft).
3. Connect the ECT sensor electrical connector. 4. Refill the engine coolant. Refer to Cooling
System Draining and Filling (Static Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service
and Repair/Draining and Filling Cooling System)Cooling System Draining and Filling (Vac-N-Fill)
(See: Engine, Cooling and Exhaust/Cooling System/Service and Repair/Draining and Filling
Cooling System) .
Hummer Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component
Information > Diagrams > Diagram Information and Instructions
Oil Level Sensor: Diagram Information and Instructions

Master Electrical Schematic Icons
Electrical Symbols
Electrical Symbols
Voltage Indicators
General Icons
Information > Diagrams > Diagram Information and Instructions > Page 860
Switch Position Icons

Module Circuit Function Icons

Harness Components
Component Parts
Switches and Relays

Devices and Sensors

Oil Level Sensor: Diagnostic Aids
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to SIR Caution (See: Restraint Systems/Service Precautions/Technician Safety

Information/SIR Caution) .
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice .
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters (See: General Electrical Diagnostic Procedures/Circuit

Testing/Using Connector Test Adapters)
* Probing Electrical Connectors (See: General Electrical Diagnostic Procedures/Circuit

Testing/Probing Electrical Connectors)
* Troubleshooting with a Digital Multimeter (See: General Electrical Diagnostic Procedures/Circuit

Testing/Troubleshooting With A Digital Multimeter)
* Troubleshooting with a Test Lamp (See: General Electrical Diagnostic Procedures/Circuit

Testing/Troubleshooting With A Test Lamp)
* Using Fused Jumper Wires (See: General Electrical Diagnostic Procedures/Circuit Testing/Using
Fused Jumper Wires)
* Measuring Voltage (See: General Electrical Diagnostic Procedures/Circuit Testing/Measuring

Voltage)
* Measuring Voltage Drop (See: General Electrical Diagnostic Procedures/Circuit

Testing/Measuring Voltage Drop)
* Measuring Frequency (See: General Electrical Diagnostic Procedures/Circuit Testing/Measuring
Frequency)
* Testing for Continuity (See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For
Continuity)
* Testing for Short to Ground (See: General Electrical Diagnostic Procedures/Circuit

Testing/Testing For Short to Ground)
* Testing for a Short to Voltage (See: General Electrical Diagnostic Procedures/Circuit

Testing/Testing For A Short to Voltage)
* Testing for Intermittent Conditions and Poor Connections (See: General Electrical Diagnostic
* Inducing Intermittent Fault Conditions (See: General Electrical Diagnostic Procedures/Circuit

Testing/Inducing Intermittent Fault Conditions)
* Testing for Electrical Intermittents (See: General Electrical Diagnostic Procedures/Circuit

Testing/Testing For Electrical Intermittents)
* Scan Tool Snapshot Procedure (See: General Electrical Diagnostic Procedures/Circuit

Testing/Scan Tool Snapshot Procedure)
* Circuit Protection - Fuses (See: General Electrical Diagnostic Procedures/Wiring Repairs/Circuit

Protection - Fuses)
* Circuit Protection - Circuit Breakers (See: General Electrical Diagnostic Procedures/Wiring

Repairs/Circuit Protection - Circuit Breakers)
* Circuit Protection - Fusible Links (See: General Electrical Diagnostic Procedures/Wiring

Repairs/Circuit Protection - Fusible Links)
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough
pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the
wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can
consist of a wide variety of actions, including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure (See: General Electrical
Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure) . Another option is, with the
component commanded ON and OFF by the scan tool, move related connectors and wiring and
observe the component operation. With the engine running, move related connectors and wiring
while monitoring engine operation. If harness or connector movement affects the data displayed,
component/system operation, or engine operation, inspect and repair the harness/connections as
necessary.
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents (See: General Electrical Diagnostic
Procedures/Circuit Testing/Testing For Electrical Intermittents) .
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070 .
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis.
This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice .
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Measuring Voltage Drop
The following procedure determines the difference in voltage potential between 2 points.
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test 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 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
Backprobe
Important:
Backprobe connector terminals only when specifically required in diagnostic procedures.

* Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure

Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle
condition is current. This allows you to concentrate on making the condition occur, rather than
trying to view all the data in anticipation of the fault. The snapshot contains information around a
trigger point that you have determined. Only a single data list may be recorded in each snapshot.
The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows
comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a
first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be
lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing For A Short to Voltage
Testing for a Short to Voltage
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Testing For Continuity
Testing for Continuity
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load.
3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other
lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6.
If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing For Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.

Continuity)

If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. Refer to
Troubleshooting with a Digital Multimeter (See: General Electrical Diagnostic Procedures/Circuit

Testing/Troubleshooting With A Digital Multimeter) for information on connecting the J 39200 to the
circuit.
2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of
the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J
39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions (See: General
Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) .
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing For Intermittent and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
* Refer to Inducing Intermittent Fault Conditions (See: General Electrical Diagnostic

Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) in order to duplicate the
conditions required, in order to verify the customer concern.
* Refer to Testing for Electrical Intermittents (See: General Electrical Diagnostic Procedures/Circuit
Testing/Testing For Electrical Intermittents) for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions.
* Refer to Scan Tool Snapshot Procedure (See: General Electrical Diagnostic Procedures/Circuit
Testing/Scan Tool Snapshot Procedure) for advanced intermittent diagnosis and Vehicle Data
Recorder operation.
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.

Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing (See: General Electrical Diagnostic Procedures/Circuit
Testing/Circuit Testing) and Power Distribution Schematics (See: Diagrams/Electrical
Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Power
Distribution Schematics) .
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect
the connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing (See: General
Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) and Ground Distribution
Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground
Distribution/System Diagram/Ground Distribution Schematics) .
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating

temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the

condition. Refer to Inducing Intermittent Fault Conditions (See: General Electrical Diagnostic
conditions required.
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other

types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven

solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way

radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories (See: General Electrical Diagnostic
Procedures/Checking Aftermarket Accessories) .
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important:: DO NOT re-program the control module with the SAME software/calibration files that
are already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration. Refer to
Programming and Relearning (See: Testing and Inspection/Programming and Relearning) for
replacement, setup, and programming.
Testing For Short to Ground
Testing for Short to Ground
The following procedures test for a short to ground in a circuit.

With a DMM
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting With A Digital Multimeter
Troubleshooting with a Digital Multimeter
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors (See: General Electrical
Diagnostic Procedures/Circuit Testing/Probing Electrical Connectors) .
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp

Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminate
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
To properly operate this tool use the following procedures.
When testing for voltage:
1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
terminals.
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used. Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high
current is still present, it will open again. The circuit breaker will continue to cycle open and closed
until the condition causing the high current is removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or
electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible
link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same
gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips (See: General Electrical Diagnostic
Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Clips) .
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation ( See: Powertrain Management/Computers and Control Systems/Information
Bus/Description and Operation) .
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
(See: General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) for the
appropriate connector repair procedure.
GMLAN Wire Repair

Important: Refer to Wiring Repairs (See: General Electrical Diagnostic Procedures/Wiring
Repairs/Wiring Repairs) in order to determine the correct wire size for the circuit you are repairing.
You must obtain this information in order to ensure circuit integrity.
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Tools Required
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125 .
High Temperature Wiring Repairs
Tools Required
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* The correct crimp tool to attach the terminals to the wires

* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair

If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
crimper handles slightly in order to firmly
hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
achieved.
13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing:
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the
faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips (See: General
Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Clips) and
follow the instruction to repair the wire.
SIR/SRS Wiring Repairs
Tools Required
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)

requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors and terminals.
Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors

* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair

If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
10. Gradually move the heat barrel to the open end of the tubing:
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)

The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves (See:
General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice
Sleeves) .
Tools Required
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.

8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves

Tools Required
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
2. Cut the wire.

* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest.
8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice
sleeve has a stop in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate service manual wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with mylar tape.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Flat Wire Repairs (See: General Electrical Diagnostic Procedures/Wiring Repairs/Flat Wire
Repairs)
* GMLAN Wiring Repairs (See: General Electrical Diagnostic Procedures/Wiring Repairs/GMLAN

Wiring Repairs)
* High Temperature Wiring Repairs (See: General Electrical Diagnostic Procedures/Wiring

Repairs/High Temperature Wiring Repairs)
* Heated Oxygen Sensor Wiring Repairs (See: General Electrical Diagnostic Procedures/Wiring
Repairs/Heated Oxygen Sensor Wiring Repairs)
* Splicing Copper Wire Using Splice Clips (See: General Electrical Diagnostic Procedures/Wiring
Repairs/Splicing Copper Wire Using Splice Clips)
* Splicing Copper Wire Using Splice Sleeves (See: General Electrical Diagnostic
Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves)
* Splicing Twisted or Shielded Cable (See: General Electrical Diagnostic Procedures/Wiring

Repairs/Splicing Twisted or Shielded Cable)
* Splicing Inline Harness Diodes (See: General Electrical Diagnostic Procedures/Wiring

Repairs/Splicing Inline Harness Diodes)
* SIR/SRS Wiring Repairs (See: General Electrical Diagnostic Procedures/Wiring Repairs/SIR/SRS

Wiring Repairs)
AFL/EPC Connectors
AFL/EPC Connectors
Tools Required
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.

View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.

7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 .
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Tools Required

Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Bosch Connectors (ECM)
Tools Required
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.

6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
connector end view.
Bosch Connectors (0.64)

Tools Required
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
Terminal Replacement Procedure

1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Tools Required
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.

Connector Position Assurance Locks
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks (See: General Electrical Diagnostic Procedures/Connector

Repairs/Connector Position Assurance Locks)
* Terminal Position Assurance Locks (See: General Electrical Diagnostic Procedures/Connector

Repairs/Terminal Position Assurance Locks)
* Bosch Connectors (BSK) (See: General Electrical Diagnostic Procedures/Connector

Repairs/Bosch Connectors (BSK))Bosch Connectors (0.64) (See: General Electrical Diagnostic
Procedures/Connector Repairs/Bosch Connectors (0.64))Bosch Connectors (2.8 JPT) (See:
General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (2.8 JPT))Bosch
Connectors (ECM) (See: General Electrical Diagnostic Procedures/Connector Repairs/Bosch
Connectors (ECM))
* Delphi Connectors (Weather Pack) (See: General Electrical Diagnostic Procedures/Connector

Repairs/Delphi Connectors (Weather Pack))Delphi Connectors (Push To Seat) (See: General
Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Push To Seat))Delphi
Connectors (Pull To Seat) (See: General Electrical Diagnostic Procedures/Connector
Repairs/Delphi Connectors (Pull To Seat))Delphi Connectors (Micro-Pack 100W) (See: General
Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro-Pack 100W) )Delphi
Connectors (Micro .64) (See: General Electrical Diagnostic Procedures/Connector Repairs/Delphi
Connectors (Micro .64))Delphi Connectors (12-Way) (See: General Electrical Diagnostic
Procedures/Connector Repairs/Delphi Connectors (12-Way))
* Tyco/AMP Connectors (CM 42-Way) (See: General Electrical Diagnostic Procedures/Connector

Repairs/Tyco/AMP Connectors (CM 42-Way) )Tyco/AMP Connectors (Sensor) (See: General
Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Sensor))Tyco/AMP
Connectors (0.25 Cap) (See: General Electrical Diagnostic Procedures/Connector
Repairs/Tyco/AMP Connectors (0.25 Cap))Tyco/AMP Connectors (43-Way) (See: General
Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (43-Way))Tyco/AMP
Connectors (Door Module) (See: General Electrical Diagnostic Procedures/Connector
Repairs/Tyco/AMP Connectors (Door Module))
* Yazaki Connectors (2-Way) (See: General Electrical Diagnostic Procedures/Connector

Repairs/Yazaki Connectors (2-Way))Yazaki Connectors (16-Way) (See: General Electrical
Diagnostic Procedures/Connector Repairs/Yazaki Connectors (16-Way))
* Repairing Connector Terminals (See: General Electrical Diagnostic Procedures/Connector

Repairs/Repairing Connector Terminals)
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Tools Required
Removal Procedure
Follow the steps below in order to remove terminals from Micro .64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
View of the connector when released from the component.
View of another type of Micro 64 connector.

Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
used.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Tools Required
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.

2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.

7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.

After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Tools Required
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves (See: General
Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves) .

3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector. 4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Tools Required
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs (See: General Electrical
Diagnostic Procedures/Wiring Repairs/Wiring
Repairs) .
2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the
back until it catches. 4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Weather Pack)
Tools Required
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing
Connector Terminals (See: General Electrical Diagnostic
Procedures/Connector Repairs/Repairing Connector Terminals) .
7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join
connector halves. 9. Verify that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12-Way)
Tools Required
Removal Procedure
1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
4. Release the lower wiredress cover locking tab.
5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA . Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
used.
Repair Procedure
connector end view.
FCI Connectors
FCI Connectors
Tools Required
Removal Procedure
The release tab is located on the top of the wiredress cover.
dress
cover.
4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
Repair Procedure
connector end view.
JST Connectors
JST Connectors
Tools Required

Removal Procedure
1. While depressing the lock, remove the connector from the component.
2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
used.
Repair Procedure
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required

Removal Procedure
View of typical connector.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.

5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
Repair Procedure
connector end view.
Molex Connectors
Molex Connectors
Tools Required
forward.
3. The lever should be in the full forward position.

5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
terminals. Insure that the terminal is
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Tools Required
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
For sealed terminals, hand crimp the insulation wings around the seal and the cable.
8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required

3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
7. The illustration above identifies the entry canal where the terminal release tool will be inserted,
and the terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
Kit.
terminal.
Terminal Position Assurance Locks
Tyco/AMP Connectors (CM 42-Way)
Tools Required
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.

7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tools Required
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
2. While depressing the lock, pull the lever over and past the lock.

4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
Repair Procedure
connector end view.
Tyco/AMP Connectors (Sensor)

Tools Required

2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Tyco/AMP Connectors (0.25 Cap)
Tools Required
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA. Important: The TPA on this connector cannot be removed unless the
terminals are removed first. The TPA will come out of the connector body, but only slightly. When
the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA
with the terminals still in the connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tools Required
Removal Procedure
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the release tool being used for the larger terminals.
View of the release tool being used for the smaller terminals.
Repair Procedure
connector end view.
Yazaki Connectors (2-Way)
Tools Required

2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the
terminal that is being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Tools Required
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector. Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.

View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the

Repair Procedure
connector end view.
US English/Metric Conversion
Decimal and Metric Equivalents

Arrows and Symbols
Arrows and Symbols
This service manual uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 -
Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 -
Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Oil Level Sensor: Connector Views
Engine Oil Level Switch

Oil Level Sensor: Electrical Diagrams
Engine Mechanical Schematics

Information > Diagrams > Page 972
Oil Level Sensor: Service and Repair
Engine Oil Level Sensor and/or Switch Replacement
Removal Procedure
1. Drain the engine oil. Refer to Engine Oil and Oil Filter Replacement (See: Engine, Cooling and
Exhaust/Engine/Engine Lubrication/Engine
Oil/Service and Repair) .
2. Disconnect the oil level sensor electrical connector (6).
3. Remove the oil level sensor from the oil pan.

Notice) .
1. Install the oil level sensor to the oil pan.
Tighten the oil level sensor to 13 N.m (115 lb in).

2. Connect the oil level sensor electrical connector (6). 3. Fill the engine oil. Refer to Engine Oil and
Oil Filter Replacement (See: Engine, Cooling and Exhaust/Engine/Engine Lubrication/Engine
Oil/Service and Repair) .

Hummer Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor >
Oil Pressure Sensor: Locations
Oil Pressure Sensor: Diagrams
Engine Oil Pressure (EOP) Sensor

Oil Pressure Sensor: Service and Repair
Engine Oil Pressure Sensor and/or Switch Replacement

Special Tools
J 41712 Oil Pressure Sensor Socket
Removal Procedure
1. If necessary, remove the engine sight shield. Refer to Upper Intake Manifold Sight Shield
Replacement (6.0L (LQ4)) (See: Engine, Cooling and
Exhaust/Engine/Intake Manifold/Service and Repair/Upper Intake Manifold Sight Shield

Replacement) .
2. Disconnect the oil pressure sensor electrical connector (1).
3. Using J 41712 or equivalent, remove the oil pressure sensor.
1. Apply sealant to the threads of the oil pressure sensor. Refer to Sealers, Adhesives, and
Lubricants (See: Engine, Cooling and
Exhaust/Engine/Specifications/Sealers, Adhesives, and Lubricants) for the correct part number.

Notice) .
2. Using J 41712 or equivalent, install the oil pressure sensor.
Tighten the oil pressure sensor to 35 N.m (26 lb ft).
3. Connect the oil pressure sensor electrical connector (1). 4. If necessary, install the engine sight
shield. Refer to Upper Intake Manifold Sight Shield Replacement (6.0L (LQ4)) (See: Engine,
Cooling and

Replacement) .
Hummer Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor /
Switch HVAC > Component Information > Locations
Ambient Temperature Sensor / Switch HVAC: Locations
Engine Compartment
1 - Washer Fluid Level Sensor 2 - Window Washer Fluid Pump 3 - Windshield Wiper Motor and
Module 4 - Horn-Left 5 - Cooling Fan-Left 6 - Inflatable Restraint Front Sensor - Left 7 - Inflatable
Restraint Front Sensor - Right 8 - Cooling Fan-Right 9 - Ambient Air Temperature Sensor - HVAC
10 - Ambient Air Temperature Sensor - Mirror 11 - Horn-Right
Stationary Window Components

Switch HVAC > Component Information > Locations > Page 984
1 - Forward Lamp Harness 2 - Radiator Support 3 - Ambient Air Temperature Sensor - HVAC 4 -
Ambient Air Temperature Sensor - Mirror 5 - Inside Rearview Mirror Connector 6 - Vanity Mirror
Lamp Connector - Left 7 - Vanity Mirror Lamp Connector - Right 8 - Center High Mounted Stop
Lamp (CHMSL) Connector 9 - Rear Window Defogger Grid Connector 10 - Rear Window Defogger
Grid Connector
Ambient Temperature Sensor / Switch HVAC: Diagrams
Ambient Air Temperature Sensor - HVAC

Ambient Temperature Sensor / Switch HVAC: Service and Repair
Ambient Air Temperature Sensor Replacement

Hummer Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Cabin Temperature Sensor /
Switch > Component Information > Locations > Air Temperature Sensor
Cabin Temperature Sensor / Switch: Locations Air Temperature Sensor
HVAC Module
1 - Recirculation Actuator 2 - Air Temperature Sensor - Upper Right 3 - Air Temperature Sensor -
Upper Left 4 - Air Temperature Sensor - Lower Left 5 - Mode Actuator 6 - Blower Motor 7 - Blower
Motor Control Processor 8 - Air Temperature Actuator - Left 9 - Air Temperature Sensor - Lower
Right 10 - Air Temperature Actuator - Right
Switch > Component Information > Locations > Air Temperature Sensor > Page 991
Cabin Temperature Sensor / Switch: Locations Inside Ambient Air Temperature Sensor
Headliner (SUT)
Switch > Component Information > Locations > Air Temperature Sensor > Page 992
Headliner (SUV)
Switch > Component Information > Diagrams > Air Temperature Sensor - Upper Left
Cabin Temperature Sensor / Switch: Diagrams Air Temperature Sensor - Upper Left
Air Temperature Sensor - Upper Left

Switch > Component Information > Diagrams > Air Temperature Sensor - Upper Left > Page 995
Cabin Temperature Sensor / Switch: Diagrams Air Temperature Sensor - Upper Right
Air Temperature Sensor - Upper Right

Switch > Component Information > Diagrams > Air Temperature Sensor - Upper Left > Page 996
Cabin Temperature Sensor / Switch: Diagrams Inside Air Temperature Sensor - Front
Inside Air Temperature Sensor - Front

Switch > Component Information > Diagrams > Page 997
Cabin Temperature Sensor / Switch: Service and Repair
Inside Air Temperature Sensor Replacement
Removal Procedure
1. Remove the left windshield garnish molding. Refer to Windshield Side Garnish Molding
Trim/Trim Panel/Service and Repair/Windshield Side Garnish Molding Replacement) .
2. Remove the left sunshade. Refer to Sunshade Replacement (See: Body and Frame/Interior
Moulding / Trim/Sun Visor/Service and
Repair/Sunshade Replacement) .
3. Gently pull down the headliner. 4. Remove the inside air temperature sensor from the headliner.
5. Disconnect the electrical connector from the inside air temperature sensor.
6. Remove the inside air temperature sensor from the headliner.
1. Install the inside air temperature sensor to the headliner.
2. Connect the electrical connector to the inside air temperature sensor. 3. Install the left sunshade.
Refer to Sunshade Replacement (See: Body and Frame/Interior Moulding / Trim/Sun Visor/Service
and Repair/Sunshade
Replacement) .
4. Install the left windshield garnish molding. Refer to Windshield Side Garnish Molding
Trim/Trim Panel/Service and Repair/Windshield Side Garnish Molding Replacement) .

Hummer Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Discharge Air Temperature
Sensor / Switch, HVAC > Component Information > Service and Repair > Air Temperature Sensor Replacement - Lower
Left Side
Discharge Air Temperature Sensor / Switch: Service and Repair Air Temperature Sensor
Replacement - Lower Left Side
Air Temperature Sensor Replacement - Lower Left Side

Left Side > Page 1002
Replacement - Lower Right Side
Air Temperature Sensor Replacement - Lower Right Side

Replacement - Upper Left Side
Air Temperature Sensor Replacement - Upper Left Side

Replacement - Upper Right Side
Air Temperature Sensor Replacement - Upper Right Side

Hummer Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor /
Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > Air
Conditioning - A/C Low Pressure Switch Diagnostics
Low Pressure Sensor / Switch: Technical Service Bulletins Air Conditioning - A/C Low Pressure
Switch Diagnostics
INFORMATION
Subject: Diagnostic Information to Accurately Diagnose A/C Low Pressure Switch Using Kent
Moore Special Tool GE-47742
Models:
2002-2006 Cadillac Escalade, Escalade EXT 2003-2006 Cadillac Escalade ESV 1999-2007
Chevrolet Silverado 2000-2006 Chevrolet Suburban, Tahoe 2002-2007 Chevrolet Avalanche
1999-2007 GMC Sierra 2000-2006 GMC Yukon, Yukon XL 2001-2006 GMC Yukon Denali XL
2001-2007 GMC Sierra Denali, Yukon Denali XL 2003-2008 HUMMER H2 with Air Conditioning
Supercede: This bulletin is being revised to update the model years. Please discard Corporate
Bulletin Number 04-01-38-010 (Section 01 - HVAC).
Currently, technicians cannot accurately determine the air conditioning (A/C) low pressure switch
open/close pressure point by measuring pressure at the low side service port. This is because the
evaporator is between the low side service port and the A/C low pressure switch. Correlating
pressures measured at the low side service port to actual pressures at the A/C low pressure switch
port is difficult because of the multiple variables that impact pressure drop across the evaporator.
Providing a pressure range that would take into account all these variables would result in a
pressure range that would be too broad to be useful for diagnostic purposes. Kent Moore special
tool GE-47742 will allow technicians to monitor the actual pressures at which the A/C low pressure
switch opens and closes under actual operating conditions.
Technicians are to use the following steps to install and use Kent Moore special tool GE-47742 to
measure A/C low pressure switch opening and closing pressures:
1. Disconnect the wire harness from the A/C low pressure switch. 2. Remove the A/C low pressure
switch from the accumulator. 3. Install the A/C low pressure switch, using the threaded port with an
O-ring, onto special tool GE-47742. 4. Install special tool GE-47742, with the A/C low pressure
switch attached, onto the accumulator.
Important Removing the seal from the A/C low pressure switch wire harness connector is required.
Failure to remove the seal before plugging it into the switch will lead to misdiagnosis. The "plunger
effect" of plugging the connector with a seal into the A/C low pressure switch induces a pressure
on the back side of the switch. This pressure will skew the opening/closing characteristics of the
switch 34-69 kPa (5-10 psi) until the pressure bleeds off. The time required for the connection
induced pressure to bleed off can be 20 minutes or longer.
5. Remove the seal from the A/C low pressure switch wire harness connector. 6. Connect the wire
harness, without the seal, to the A/C low pressure switch. 7. Connect the low side service hose
from the ACR2000(R) or GE-48800 to the service port on special tool GE-47742. 8. Connect a
Tech2(R) to the vehicle. 9. Start the vehicle and maintain an engine speed of 1500 RPM. Set the
HVAC controls as follows:
- Set the A/C control switch to ON.
- Set the mode control switch to A/C and engage recirculation mode.
- Set the blower motor speed to LOW.
- Set the temperature control to full cold.
- Set the auxiliary blower motor speed to LOW. If equipped.

- Set the auxiliary temperature control to full cold. If equipped.
- The vehicle must be operating with no sun load (in the shade).
10. Use the Tech2(R) to determine the A/C low pressure switch status and the ACR2000(R) or
GE-48800 to determine the A/C low side pressure.
Simultaneously monitor the switch status and the pressure at which the A/C low pressure switch
opens and closes. The Tech2(R) will display switch status as "Normal" for Closed and "Low
Pressure" for Open. A properly operating switch should open between 138-172 kPa (20-25 psi)
Hummer Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor /
Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > Air
Conditioning - A/C Low Pressure Switch Diagnostics > Page 1010
and close between 275-317 kPa (40-46 psi).
11. Remove special tool GE-47742 after diagnosis is complete. 12. Install a new O-ring on the A/C
low pressure switch port on the accumulator. Lightly coat the new O-ring seal with mineral base
525 viscosity
refrigerant oil.
13. Install the A/C low pressure switch onto the accumulator.
Tighten Tighten the A/C low pressure switch to 6 Nm (44 lb in).
Important Remember to install the seal back onto the A/C low pressure switch wire harness
connector. Failure to replace the seal could result in terminal corrosion.
14. Reconnect the wire harness to the A/C low pressure switch.
Disclaimer
Hummer Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Solar Sensor, HVAC >
Component Information > Service and Repair
Solar Sensor: Service and Repair
Sun Load Sensor Replacement
Removal Procedure
1. Remove the I/P upper trim panel with windshield defroster nozzle grille. Refer to Instrument
Panel Upper Trim Panel with Windshield Defroster
Nozzle Grille Replacement (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Instrument Panel Upper Trim Panel with Windshield Defroster Nozzle
Grille Replacement) .
2. Remove the sun load sensor (2) from the I/P upper trim panel by turning 1/4 turn. 3. Disconnect
the electrical connector from the sun load sensor (3).
1. Connect the electrical connector to the sun load sensor (3). 2. Install the sun load sensor (2) to
the I/P upper trim panel by turning 1/4 turn clockwise. 3. Install the I/P upper trim panel with
windshield defroster nozzle grille. Refer to Instrument Panel Upper Trim Panel with Windshield
Defroster
Nozzle Grille Replacement (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Instrument Panel Upper Trim Panel with Windshield Defroster Nozzle
Grille Replacement) .
Hummer Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch >
Dimmer Switch: Locations
Instrument Panel and Console Overview
1 - Rear Wiper/Washer Switch (SUV) or Midgate Window Switch (SUT) 2 - Instrument Panel
Cluster (IPC) 3 - Turn Signal/Multifunction Switch 4 - Inflatable Restraint Steering Wheel Module 5 -
Steering Wheel Control Switch Assembly - Upper Right 6 - Ambient Light/Sunload Sensor
Assembly 7 - Transfer Case Shift Control Switch 8 - Analog Clock 9 - Radio/Navigation Unit 10 -
Inflatable Restraint I/P Module 11 - Inflatable Restraint I/P Module Disable Switch 12 - Cigar Lighter
13 - Rear Seat Audio (RSA) Controller 14 - Auxiliary Power Outlet - Console 1 15 - Audio/Video
Adapter (U42) 16 - Auxiliary Power Outlet - Console 2
17 - Accessory Switch Assembly (Tow Haul/Traction Control/Ride Height ) 18 - Steering Wheel
Control Switch Assembly - Lower Right 19 - Noise Compensation Microphone 20 - Steering Wheel
Control Switch Assembly - Lower Left 21 - Steering Wheel Control Switch Assembly - Upper Left
22 - Headlamp and Panel Dimmer Switch 23 - Data Link Connector (DLC) 24 - Universal Up/Down
Switch
Dimmer Switch: Diagrams
Headlamp and Panel Dimmer Switch

Hummer Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender >
Fuel Gauge Sender: Locations
Fuel Gauge Sender: Diagrams
Fuel Pump and Sender Assembly

Fuel Gauge Sender: Service and Repair
Fuel Sender Assembly Replacement
Tools Required
J 45722 Fuel Sender Lock Ring Wrench
Removal Procedure
1. Remove the fuel tank. Refer to Fuel Tank Replacement (See: Powertrain Management/Fuel
Delivery and Air Induction/Fuel Tank/Service and
Repair/Removal and Replacement) .
2. Remove fuel lines from sender assembly. Refer to Fuel Hose/Pipes Assembly Replacement
(See: Powertrain Management/Fuel Delivery and Air
Induction/Fuel Supply Line/Service and Repair/Fuel Hose/Pipes Assembly Replacement) .
Notice: Avoid damaging the lock ring. Use only J-45722 to prevent damage to the lock ring.
Notice: Do Not handle the fuel sender assembly by the fuel pipes. The amount of leverage
generated by handling the fuel pipes could damage the joints.
Important: Do NOT use impact tools. Significant force will be required to release the lock ring. The
use of a hammer and screwdriver is not recommended. Secure the fuel tank in order to prevent fuel
tank rotation.
3. Use the J 45722 and a long breaker-bar in order to unlock the fuel sender lock ring.
4. Remove the fuel sender assembly and the seal. Discard the seal.
Caution: Drain the fuel from the fuel sender assembly into an approved container in order to reduce
the risk of fire and personal injury. Never store the fuel in an open container.
5. Clean the fuel sender sealing surfaces.

Important: Some lock rings were manufactured with "DO NOT REUSE" stamped into them. These
lock rings may be reused if they are not damaged or warped.
Important: Inspect the lock ring for damage due to improper removal or installation procedures. If
damage is found, install a NEW lock ring.
Important: Check the lock ring for flatness.
6. Place the lock ring on a flat surface. Measure the clearance between the lock ring and the flat
surface using a feeler gage at 7 points. 7. If warpage is less than 0.41 mm (0.016 in), the lock ring
does not require replacement. 8. If warpage is greater than 0.41 mm (0.016 in), the lock ring must
be replaced.
1. Install the new seal on the fuel tank.
Important: The fuel pump strainer must be in a horizontal position when the fuel sender is installed
in the tank. When installing the fuel sender assembly, assure that the fuel pump strainer does not
block full travel of the float arm.
2. Install the fuel sender assembly into the fuel tank.

Important: Always replace the fuel sender seal when installing the fuel sender assembly. Replace
the lock ring if necessary. DO NOT apply any type of lubrication in the seal groove.
Ensure the lock ring is installed with the correct side facing upward. A correctly installed lock ring
will only turn in a clockwise direction.
3. Use the J 45722 in order to install the fuel sender lock ring. Turn the fuel sender lock ring in a
clockwise direction. 4. Install fuel lines to the sender assembly. Refer to Fuel Hose/Pipes Assembly
Replacement (See: Powertrain Management/Fuel Delivery and Air
5. Install the fuel tank. Refer to Fuel Tank Replacement (See: Powertrain Management/Fuel

Hummer Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Hood Ajar Switch >
Hood Ajar Switch: Diagrams
Hood Switch
Hummer Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Outside Temperature
Display Sensor > Component Information > Locations
Outside Temperature Display Sensor: Locations
Engine Compartment
Stationary Window Components

Display Sensor > Component Information > Locations > Page 1033
1 - Forward Lamp Harness 2 - Radiator Support 3 - Ambient Air Temperature Sensor - HVAC 4 -
Ambient Air Temperature Sensor - Mirror 5 - Inside Rearview Mirror Connector 6 - Vanity Mirror
Lamp Connector - Left 7 - Vanity Mirror Lamp Connector - Right 8 - Center High Mounted Stop
Lamp (CHMSL) Connector 9 - Rear Window Defogger Grid Connector 10 - Rear Window Defogger
Grid Connector
Display Sensor > Component Information > Locations > Page 1034
Outside Temperature Display Sensor: Diagrams
Ambient Air Temperature Sensor - Mirror

Hummer Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning
Switch > Component Information > Diagrams
Park Brake Switch

Removal Procedure

Connection) .
lamp switch.

Hummer Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor
> Component Information > Locations > Ambient Light Sensor Assembly
Ambient Light Sensor: Locations Ambient Light Sensor Assembly
Adapter (U42)
> Component Information > Locations > Ambient Light Sensor Assembly > Page 1045
16 - Auxiliary Power Outlet - Console 2 17 - Accessory Switch Assembly (Tow Haul/Traction
Control/Ride Height ) 18 - Steering Wheel Control Switch Assembly - Lower Right 19 - Noise
Compensation Microphone 20 - Steering Wheel Control Switch Assembly - Lower Left 21 -
Steering Wheel Control Switch Assembly - Upper Left 22 - Headlamp and Panel Dimmer Switch 23
- Data Link Connector (DLC) 24 - Universal Up/Down Switch
Ambient Light Sensor: Locations Ambient Sunload Sensor Assembly
Adapter (U42)
Ambient Light Sensor: Diagrams
Air Temperature Sensor - Upper Left

Ambient Light Sensor: Service and Repair
Ambient Light Sensor Replacement

Hummer Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Brake Light Switch: Locations
Stop Lamp Switch
1 - Vacuum Booster 2 - Brake Pedal 3 - Stop Lamp Switch 4 - Accelerator Pedal 5 - Stop Lamp
Switch Retainer 6 - Dash Panel
Brake Light Switch: Diagrams
Stop Lamp Switch

Brake Light Switch: Service and Repair
Stop Lamp Switch Replacement

Hummer Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch >
Combination Switch: Locations
Hummer Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch >
Switch
Hummer Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Console Lamp Switch
Console Lamp Switch: Locations
Hummer Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Console Lamp Switch
Console Lamp Switch: Diagrams
Console Bin Lamp Switch

Hummer Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp
Fog/Driving Lamp Switch: Locations
ISRVM and Off-Road Lamps Switch
1 - Inside Rearview Mirror (ISRVM) 2 - Off-Road Lamps Switch (USB, USC, USD, UNR) 3 -
Outside Temperature/Compass Display 4 - Rear Vision Camera Display (UVC)
Hummer Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Headlamp Switch: Locations
Switch
Headlamp Switch: Diagrams
Headlamp and Panel Dimmer Switch

Headlamp Switch: Service and Repair
Headlamp Switch Replacement

Hummer Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch >
Horn Switch: Service and Repair
Horn Switch Replacement

Hummer Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch >
Turn Signal Switch: Locations
Switch
Turn Signal Switch: Service and Repair
Turn Signal Multifunction Switch Replacement

Hummer Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Service and
Repair
Accelerator Pedal Position Sensor: Service and Repair
Accelerator Pedal Position Sensor Replacement
Removal Procedure
Notice: Handle the electronic throttle control components carefully. Use cleanliness in order to
prevent damage. Do not drop the electronic throttle control components. Do not roughly handle the
electronic throttle control components. Do not immerse the electronic throttle control components in
cleaning solvents of any type.
1. Remove the left instrument panel (I/P) lower closeout insulator panel. 2. Disconnect the
accelerator pedal position (APP) sensor harness connector.
Remove the accelerator pedal mounting bolts.
3. Remove the APP assembly.

1. Install the APP assembly to the steering column support bracket.
Notice: Refer to the Fastener Notice (See: Service Precautions/Vehicle Damage

Warnings/Fastener Notice) .
Important: Always use a torque wrench in order to obtain the proper torque.
2. Install the accelerator pedal mounting bolts.
Tighten the accelerator pedal mounting bolts to 20 N.m (15 lb ft).
3. Connect the APP sensor harness connector. 4. Verify that the vehicle meets the following
conditions:
* The vehicle is not in a Reduced Engine Power mode.
* The ignition is ON.
* The engine is OFF.
5. Connect a scan tool in order to test for a proper throttle-opening and throttle-closing range. 6.
Operate the accelerator pedal and monitor the throttle angles. The accelerator pedal should
operate freely, without binding, between a closed
throttle, and a wide open throttle (WOT).
7. Inspect the carpet fit under the accelerator pedal. 8. Install the left I/P lower closeout insulator
panel.
Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations
Air Flow Meter/Sensor: Locations
Engine Compartment
Accumulator
Engine Compartment
Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 1088
Accumulator
Air Flow Meter/Sensor: Diagrams
Intake Air Temperature (IAT)/Mass Air Flow (MAF) Sensor

Air Flow Meter/Sensor: Service and Repair
Mass Airflow Sensor/Intake Air Temperature Sensor Replacement
Removal Procedure
Important: Take care when handling the mass air flow/intake air temperature (MAF/IAT) sensor. Do
not dent, puncture, or otherwise damage the honeycell located at the air inlet end of the MAF/IAT.
Do not touch the sensing elements or allow anything including cleaning solvents and lubricants to
come in contact with them. Use a small amount of a non-silicone based lubricant, on the air duct
only, to aid in installation. Do not drop or roughly handle the MAF/IAT sensor.
1. Remove air intake resonator. Refer to Air Cleaner Resonator Outlet Duct Replacement (See:
Engine, Cooling and Exhaust/Engine/Tune-up and
Engine Performance Checks/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and
Repair) .
2. Disconnect the MAF/IAT sensor electrical connector. 3. Loosen the clamp securing the MAF/IAT
sensor to the air cleaner housing. 4. Remove the MAF/IAT sensor from the air cleaner assembly.
Important:: The embossed arrow on the MAF/IAT sensor indicates the proper air flow direction. The
arrow must point toward the engine.
1. Locate the air flow direction arrow (2) on the MAF/IAT sensor.
2. Install the MAF/IAT sensor on to the air cleaner housing. 3. Tighten the clamp securing the
MAF/IAT sensor to the air cleaner housing. 4. Connect the MAF/IAT electrical connector. 5. Install
air intake resonator. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Engine,
Cooling and Exhaust/Engine/Tune-up and
Repair) .
Switches - Computers and Control Systems > Battery Current Sensor > Component Information > Diagrams
Battery Current Sensor: Diagrams
Battery Current Sensor

Switches - Computers and Control Systems > Battery Current Sensor > Component Information > Diagrams > Page 1094
Battery Current Sensor: Service and Repair
Battery Current Sensor Replacement
Removal Procedure
1. Remove the negative battery cable. Refer to Battery Negative Cable Replacement (See: Starting
and Charging/Battery/Battery
Cable/Negative/Service and Repair/Battery Negative Cable Replacement) .
2. Mark the location of the battery current sensor on the battery cable with tape for reference during
installation. 3. Remove the tape securing the battery current sensor to the negative battery cable.
4. Mark the location of the negative battery cable clips (1) and remove the clips from the cable. 5.
Squeeze the negative battery cable branches together.
Important: Note the orientation of the battery current sensor prior to removal.
6. Slide the battery current sensor (2) off of the negative battery cable.
1. Squeeze the negative battery cable branches together.
Important: Ensure the battery current sensor is installed in the correct direction and location on the
negative battery cable.
2. Slide the NEW battery current sensor (2) up onto the negative battery cable to the location
previously marked during removal. 3. Wrap electrical tape around the battery current sensor leg in
order to secure the sensor to the negative battery cable. 4. Install the negative battery cable clips
(1) to the cable to the locations previously marked during removal. 5. Install the negative battery
cable. Refer to Battery Negative Cable Replacement (See: Starting and Charging/Battery/Battery

Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations
Camshaft Position Sensor: Locations
Engine - Left Rear (L92)
1 - Valve Lifter Oil Manifold Assembly (VLOM) 2 - Ignition Coil 8 3 - Fuel Injector 8 4 - Ignition Coil
6 5 - Fuel Injector 6 6 - Manifold Absolute Pressure (MAP) Sensor 7 - Throttle Body Assembly 8 -
Magnetic Sensor 9 - Camshaft Position (CMP) Sensor 10 - Fuel Injector 2 11 - Ignition 2 12 - A/C
Compressor 13 - Fuel Injector 4 14 - Ignition Coil 4 15 - Knock Sensor (KS) 2 16 - Starter
Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page
1099
17 - Crankshaft Position (CKP) Sensor
1100
Camshaft Position Sensor: Service Precautions
Camshaft Position Actuator Removal and Installation Caution
Caution: Do not push or pull on the reluctor wheel of the camshaft position (CMP) actuator during
removal or installation. The reluctor wheel is retained to the front of the CMP actuator by 3 roll pins.
Pushing or pulling on the wheel may dislodge the wheel from the front of the actuator. The actuator
return spring is under tension and may rotate the dislodged reluctor wheel, causing personal injury.
1101
Camshaft Position Sensor: Service and Repair
Camshaft Position Sensor Replacement

Removal Procedure
Important: Clean the area around the camshaft position (CMP) sensor before removal in order to
prevent debris from entering the engine.
1. Remove the engine sight shield. Refer to Upper Intake Manifold Sight Shield Replacement (6.0L
(LQ4)) (See: Engine, Cooling and

Replacement) .
2. Disconnect the CMP sensor electrical connector. 3. Remove the CMP sensor bolt. 4. Remove
the CMP sensor.
1. Install the CMP sensor.

Notice) .
2. Install the CMP sensor bolt.
Tighten the bolt to 25 N.m (18 lb ft).
3. Connect the CMP sensor electrical connector. 4. Install the engine sight shield. Refer to Upper
Intake Manifold Sight Shield Replacement (6.0L (LQ4)) (See: Engine, Cooling and

Replacement) .
Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Locations > Page 1105

Removal Procedure

equivalent.

Notice) .

Cooling System) .
Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations
Crankshaft Position Sensor: Locations
Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page
1111
1112
Crankshaft Position Sensor: Diagrams
Crankshaft Position (CKP) Sensor

Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair >
Procedures
Crankshaft Position Sensor: Procedures
Crankshaft Position System Variation Learn
1. Install a scan tool. 2. Monitor the engine control module (ECM) for DTCs with a scan tool. If other
DTCs are set, except DTC P0315, refer to Diagnostic Trouble Code
(DTC) List - Vehicle (See: Powertrain Management/Computers and Control Systems/Testing and
Inspection/Diagnostic Trouble Code Descriptions/Diagnostic Trouble Code (DTC) List - Vehicle) for
the applicable DTC that set.
3. Select the crankshaft position (CKP) variation learn procedure with a scan tool. 4. The scan tool
instructs you to perform the following:
1. Accelerate to wide open throttle (WOT). 2. Release throttle when fuel cut-off occurs. 3. Observe
fuel cut-off for applicable engine. 4. Engine should not accelerate beyond calibrated RPM value. 5.
Release throttle immediately if value is exceeded. 6. Block drive wheels. 7. Set parking brake. 8.
DO NOT apply brake pedal. 9. Cycle ignition from OFF to ON.
10. Apply and hold brake pedal. 11. Start and idle engine. 12. Turn A/C OFF. 13. Vehicle must
remain in Park or Neutral. 14. The scan tool monitors certain component signals to determine if all
the conditions are met to continue with the procedure. The scan tool only
displays the condition that inhibits the procedure. The scan tool monitors the following components:
* CKP sensors activity-If there is a CKP sensor condition, refer to the applicable DTC that set.
* Camshaft position (CMP) sensor activity-If there is a CMP sensor condition, refer to the
applicable DTC that set.
* Engine coolant temperature (ECT)-If the ECT is not warm enough, idle the engine until the engine
coolant temperature reaches the correct temperature.
5. Enable the CKP System Variation Learn Procedure with a scan tool.
Important: While the learn procedure is in progress, release the throttle immediately when the
engine starts to decelerate. The engine control is returned to the operator and the engine responds
to throttle position after the learn procedure is complete.
6. Accelerate to WOT. 7. Release when the fuel cut-off occurs. 8. Test in progress. 9. The scan tool
displays Learn Status: Learned this ignition. If the scan tool indicates that DTC P0315 ran and
passed, the CKP Variation Learn
Procedure is complete. If the scan tool indicates DTC P0315 failed or did not run, refer to DTC
P0315 (See: Powertrain Management/Computers and Control Systems/Testing and
Inspection/Diagnostic Trouble Code Tests and Associated Procedures/P Code Charts/P0315) . If
any other DTCs set, refer to Diagnostic Trouble Code (DTC) List - Vehicle (See: Powertrain
Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code
Descriptions/Diagnostic Trouble Code (DTC) List - Vehicle) for the applicable DTC that set.
10. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully. 11.
The CKP Variation Learn Procedure is also required when the following service procedures have
been performed, regardless of whether DTC
P0315 is set:
* A CKP sensor replacement
* An engine replacement
* A ECM replacement
* A harmonic balancer replacement
* A crankshaft replacement
* Any engine repairs which disturb the CKP sensor relationship

Procedures > Page 1115
Crankshaft Position Sensor: Removal and Replacement
Crankshaft Position Sensor Replacement
Removal Procedure
Important: Perform the Crankshaft Position System Variation Learn (See: Procedures) when the
crankshaft position sensor is removed or replaced.
Caution: Refer to Battery Disconnect Caution (See: Starting and Charging/Battery/Service

Precautions/Technician Safety Information/Battery Disconnect Caution) .
1. Disconnect the negative battery cable. 2. Raise the vehicle. Refer to Lifting and Jacking the
Vehicle (See: Maintenance) . 3. Remove the starter. Refer to Starter Motor Replacement (See:
Starting and Charging/Starting System/Starter Motor/Service and Repair) .
4. Disconnect the crankshaft position (CKP) sensor electrical connector.
5. Clean the area around the CKP sensor before removal in order to avoid debris from entering the
engine. 6. Remove the CKP sensor retaining bolt. 7. Remove the CKP sensor.
1. Install the CKP sensor.
Notice) .
2. Install the CKP sensor retaining fastener.
3. Connect the CKP sensor electrical connector.
4. Install the starter. Refer to Starter Motor Replacement (See: Starting and Charging/Starting
System/Starter Motor/Service and Repair) . 5. Lower the vehicle. 6. Connect the negative battery
cable. 7. Perform the CKP system variation learn procedure. Refer to Crankshaft Position System
Variation Learn (See: Procedures) .
Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations
Fuel Level Sensor: Locations
Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 1120
Fuel Level Sensor: Diagrams

Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel
Level Sensor Replacement
Fuel Level Sensor: Service and Repair Fuel Level Sensor Replacement
Fuel Level Sensor Replacement
Removal Procedure
1. Remove the fuel sender. Refer to Fuel Sender Assembly Replacement (See: Sensors and
Switches - Instrument Panel/Fuel Gauge Sender/Service
and Repair) .
2. Place the fuel sender on a clean work surface. 3. Disconnect the fuel level sensor electrical
connector (1) from the module connector.
4. Remove the fuel level sensor retaining clip. 5. Squeeze the retaining tabs together in order to
slide the fuel lever sensor off of the reservoir.
1. Slide the fuel lever sensor (3) onto the reservoir until the retaining tabs snap into place.
2. Connect the fuel level sensor electrical connector (1) to the module connector. 3. Install the fuel
sender. Refer to Fuel Sender Assembly Replacement (See: Sensors and Switches - Instrument
Panel/Fuel Gauge Sender/Service
and Repair) .
Level Sensor Replacement > Page 1123
Fuel Level Sensor: Service and Repair Fuel Sender Assembly Replacement
Tools Required
Removal Procedure
(See: Powertrain Management/Fuel Delivery and Air
tank rotation.

be replaced.

Replacement (See: Powertrain Management/Fuel Delivery and Air
5. Install the fuel tank. Refer to Fuel Tank Replacement (See: Powertrain Management/Fuel

Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations
Fuel Tank Pressure Sensor: Locations
Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page
1129
Fuel Tank Pressure Sensor: Diagrams
Fuel Tank Pressure (FTP) Sensor

1130
Fuel Tank Pressure Sensor: Service and Repair
Fuel Tank Pressure Sensor Replacement
Removal Procedure
2. Remove the fuel pressure sensor.
1. Install the fuel pressure sensor. 2. Install the fuel tank. Refer to Fuel Tank Replacement (See:
Powertrain Management/Fuel Delivery and Air Induction/Fuel Tank/Service and

Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations
Intake Air Temperature Sensor: Locations
Engine Compartment
Accumulator
Engine Compartment
Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page
1134
Accumulator
1135
Intake Air Temperature Sensor: Diagrams

1136
Intake Air Temperature Sensor: Service and Repair
Removal Procedure
Repair) .
Repair) .
Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations
Knock Sensor: Locations
Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 1140
Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Knock Sensor (KS) 1
Knock Sensor: Diagrams Knock Sensor (KS) 1
Knock Sensor (KS) 1

> Page 1143
Knock Sensor (KS) 2

Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Page 1144
Knock Sensor: Service and Repair
Knock Sensor Replacement
Removal Procedure
1. Remove the knock sensor wiring harness assembly.
2. Remove the knock sensor (KS).
1. Install the knock sensor.
Torque the sensor to 20 N.m (15 lb ft).
2. Install the knock sensor wiring harness assembly.

Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations
Manifold Pressure/Vacuum Sensor: Locations
Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations >
Page 1148
Page 1149
Manifold Pressure/Vacuum Sensor: Diagrams
Manifold Absolute Pressure (MAP) Sensor

Page 1150
Manifold Pressure/Vacuum Sensor: Service and Repair
Manifold Absolute Pressure Sensor Replacement
Removal Procedure

Replacement) .
2. Remove the engine sight shield bracket bolts. Position the bracket to the side 3. Disconnect the
manifold absolute pressure (MAP) sensor electrical connector.
4. Remove the MAP sensor (1) from the intake manifold.
Important: Lightly coat the MAP sensor seal with clean engine oil before installing the sensor.
Page 1151
1. Install the MAP sensor (1). Push the MAP sensor down in order to engage the sensor into the
retainer.
2. Connect the MAP sensor electrical connector. 3. Position the engine harness and sight shield
bracket to the intake manifold.

Notice) .
4. Install the engine sight shield bracket bolts.
Tighten the bracket bolts to 10 N.m (89 lb in).
5. Install the engine sight shield. Refer to Upper Intake Manifold Sight Shield Replacement (6.0L

Replacement) .
Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Locations
Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Locations > Page 1155


Special Tools
Removal Procedure

Replacement) .

Notice) .
Cooling and

Replacement) .
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Heated Oxygen
Sensor (HO2S) Bank 1 Sensor 1
Oxygen Sensor: Diagrams Heated Oxygen Sensor (HO2S) Bank 1 Sensor 1
Heated Oxygen Sensor (HO2S) Bank 1 Sensor 1

Sensor (HO2S) Bank 1 Sensor 1 > Page 1162



Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service Precautions > Excessive
Force and Oxygen Sensor Notice
Oxygen Sensor: Service Precautions Excessive Force and Oxygen Sensor Notice
Excessive Force and Oxygen Sensor Notice
Notice: The oxygen sensor may be difficult to remove when the engine temperature is below 48°C
(120°F). Excessive force may damage threads in the exhaust manifold or the exhaust pipe.
Force and Oxygen Sensor Notice > Page 1167
Oxygen Sensor: Service Precautions Heated Oxygen and Oxygen Sensor Notice
Heated Oxygen and Oxygen Sensor Notice
Notice: Do not remove the pigtail from either the heated oxygen sensor (HO2S) or the oxygen
sensor (O2S). Removing the pigtail or the connector will affect sensor operation.
Handle the oxygen sensor carefully. Do not drop the HO2S. Keep the in-line electrical connector
and the louvered end free of grease, dirt, or other contaminants. Do not use cleaning solvents of
any type.
Do not repair the wiring, connector or terminals. Replace the oxygen sensor if the pigtail wiring,
connector, or terminal is damaged.
This external clean air reference is obtained by way of the oxygen sensor signal and heater wires.
Any attempt to repair the wires, connectors, or terminals could result in the obstruction of the air
reference and degraded sensor performance.
These materials may get into the sensor causing poor performance.
* Do not damage the sensor pigtail and harness wires in such a way that the wires inside are
exposed. This could provide a path for foreign materials to enter the sensor and cause
performance problems.
* Ensure the sensor or vehicle lead wires are not bent sharply or kinked. Sharp bends or kinks
could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire, where applicable. Vehicles that utilize
the ground wired sensor may rely on this ground as the only ground contact to the sensor.
Removal of the ground wire will cause poor engine performance.
* Ensure that the peripheral seal remains intact on the vehicle harness connector in order to
prevent damage due to water intrusion. The engine harness may be repaired using Packard's
Crimp and Splice Seals Terminal Repair Kit. Under no circumstances should repairs be soldered
since this could result in the air reference being obstructed.
Oxygen Sensor: Service Precautions Heated Oxygen Sensor Resistance Learn Reset Notice
Heated Oxygen Sensor Resistance Learn Reset Notice
Notice: When replacing the HO2S perform the following:
* A code clear with a scan tool, regardless of whether or not a DTC is set
* HO2S heater resistance learn reset with a scan tool, where available
Perform the above in order to reset the HO2S resistance learned value and avoid possible HO2S
failure.
Oxygen Sensor: Service Precautions Silicon Contamination of Heated Oxygen Sensors Notice
Silicon Contamination of Heated Oxygen Sensors Notice
Notice: Contamination of the oxygen sensor can result from the use of an inappropriate RTV
sealant (not oxygen sensor safe) or excessive engine coolant or oil consumption. Remove the
HO2S and visually inspect the portion of the sensor exposed to the exhaust stream in order to
check for contamination. If contaminated, the portion of the sensor exposed to the exhaust stream
will have a white powdery coating. Silicon contamination causes a high but false HO2S signal
voltage (rich exhaust indication). The control module will then reduce the amount of fuel delivered
to the engine, causing a severe driveability problem. Eliminate the source of contamination before
replacing the oxygen sensor.
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated
Oxygen Sensor Replacement - Bank 1 Sensor 1
Oxygen Sensor: Service and Repair Heated Oxygen Sensor Replacement - Bank 1 Sensor 1
Heated Oxygen Sensor Replacement - Bank 1 Sensor 1
Tools Required
J 39194-B Oxygen Sensor Wrench
Removal Procedure
Caution: Refer to Vehicle Lifting Caution (See: Maintenance) .
1. Raise the vehicle.
Notice: Refer to Heated Oxygen and Oxygen Sensor Notice .
2. Disconnect the connector (1) for the HO2S.
Notice: Refer to Excessive Force and Oxygen Sensor Notice .
3. Remove the HO2S (2) using a J 39194-B .
Important: A special anti-seize compound is used on the heated oxygen sensor (HO2S) threads.
The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but
the glass beads remain, making the sensor easier to remove. New, or service replacement sensors
already have the compound applied to the threads. If the sensor is removed from an engine and if
for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied
before the reinstallation.
1. Coat the threads of the oxygen sensor with anti-seize compound GM P/N 5613695, if necessary.
Notice: Refer to Component Fastener Tightening Notice .
2. Install the HO2S (2) using a J 39194-B .
Tighten the sensor to 42 N.m (31 lb ft).
3. Connect the HO2S harness connector (1). 4. Lower the vehicle.

Oxygen Sensor Replacement - Bank 1 Sensor 1 > Page 1172
Tools Required
Removal Procedure

Tools Required
Removal Procedure

Tools Required
Removal Procedure

Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams
Throttle Position Sensor: Diagrams
Accelerator Pedal Position (APP) Sensor

Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Locations > Automatic Transmission Electronic Component Views
Transmission Position Switch/Sensor: Locations Automatic Transmission Electronic Component

Views
Automatic Transmission Electronic Component Views
Electronic Components
1 - Control Solenoid (with Body and TCM) Valve Assembly 2 - A/Trans Input and Output Speed
Sensor Assembly 3 - A/Trans Manual Shift Shaft Position Switch Assembly
Locations > Automatic Transmission Electronic Component Views > Page 1182
Transmission Position Switch/Sensor: Locations Park/Neutral Position (PNP) Switch
Park Neutral Position (PNP) Switch
1 - Automatic Transmission 4L60-E/4L65-E/4L70-E 2 - Park/Neutral Position (PNP) Switch

Locations > Page 1183
Transmission Position Switch/Sensor: Service and Repair
Manual Shift Shaft Position Switch Replacement

Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service
Bulletins > Customer Interest for Vehicle Speed Sensor: > 09-09-41-006 > Oct > 09 > Restraints - Service Airbag Message
Displayed
Vehicle Speed Sensor: Customer Interest Restraints - Service Airbag Message Displayed
TECHNICAL
Bulletin No.: 09-09-41-006
Date: October 22, 2009
Subject: Supplemental Inflatable Restraint (SIR) Lamp Illuminated, Service Airbag Message
Displayed, Intermittent DTCs B1011 and B0090 0F Only Set (Replace Inflatable Restraint Vehicle
Rollover Sensor (ROS))
Models:
2008-2009 HUMMER H2 SUV, H2 SUT
Condition
Some customers may comment that the supplemental inflatable restraint (SIR) lamp is
intermittently illuminated and/or the service airbag message is displayed.
The technician may find a repeat history DTC B1011 in the vehicle rollover sensor (ROS) and
B0090 0F in the sensing and diagnostic module (SDM) ONLY set in history.
Cause
This condition may be caused by an inflatable restraint vehicle rollover sensor (ROS) that
monitored an invalid vehicle speed signal (VSS) on the GMLAN serial data circuit. The invalid
vehicle speed signal can be the result of extended engine crank time or a delay in serial data
communications.
Correction
Important DO NOT replace the SDM for this condition.

Technicians are to remove and replace the inflatable restraint vehicle rollover sensor. Refer to
Inflatable Restraint Vehicle Rollover Sensor Replacement in SI.
Parts Information
Disclaimer
Bulletins > All Technical Service Bulletins for Vehicle Speed Sensor: > 09-09-41-006 > Oct > 09 > Restraints - Service
Airbag Message Displayed
Vehicle Speed Sensor: All Technical Service Bulletins Restraints - Service Airbag Message
Displayed
TECHNICAL
Bulletin No.: 09-09-41-006
Models:
Condition
Cause
communications.
Correction

Parts Information
Disclaimer
Vehicle Speed Sensor: Locations
Transfer Case Components
1 - Transfer Case 2 - Transfer Case Encoder/Motor Connector 3 - Vehicle Speed Sensor (VSS)
36 - Vehicle Speed Sensor (VSS) - Model Dependent 66 - Torque Converter Clutch (TCC)
Solenoid Valve 69 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch
367a - 1-2 Shift Solenoid (SS) Valve 367b - 2-3 Shift Solenoid (SS) Valve 377 - Pressure Control
(PC) Solenoid Valve 394 - 3-2 Shift Solenoid (SS) Valve Assembly 396 - Torque Converter Clutch
Pulse Width Modulation (TCC PWM) Solenoid Valve
Vehicle Speed Sensor: Diagrams
Vehicle Speed Sensor (VSS)

Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Service and
Repair
Removal Procedure


conditions:
panel.
Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations
Engine Compartment
Accumulator
Engine Compartment
Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 1207
Accumulator

Removal Procedure
Repair) .
Repair) .
Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Diagrams
Fuel Pressure Sensor/Switch: Diagrams
Fuel Line Pressure Sensor

Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Diagrams > Page
1213
Fuel Pressure Sensor/Switch: Service and Repair
Fuel Pressure Sensor Replacement
Removal Procedure
1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See:
Maintenance) . 2. Disconnect the chassis wiring harness electrical connector (1) from the fuel
pressure sensor.
3. Wrap a shop towel around the fuel pressure sensor fitting in order to absorb any fuel that may
leak out. 4. Remove the fuel pressure sensor from the fuel line. 5. Remove and discard the fuel
pressure sensor O-ring seal.
1214
1. Lubricate a NEW fuel pressure sensor O-ring seal with clean engine oil. 2. Install the NEW fuel
pressure sensor O-ring seal onto the fuel line fitting. 3. Wrap a shop towel around the fuel pressure
sensor fitting in order to absorb any fuel that may leak out.

Notice) .
4. Install the fuel pressure sensor to the fuel line.
5. Connect the chassis wiring harness electrical connector (1) to the fuel pressure sensor. 6. Lower
the vehicle. 7. Use the following procedure in order to inspect for leaks:
1. Turn the ignition ON, with the engine OFF, for 2 seconds. 2. Turn the ignition OFF for 10
seconds. 3. Turn the ignition ON, with the engine OFF.
1215
4. Inspect for fuel leaks.
Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams

Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations
Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 1223

Removal Procedure

Replacement) .
the CMP sensor.

Notice) .

Replacement) .
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 1229

Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Procedures
(DTC) List - Vehicle (See: Powertrain Management/Computers and Control Systems/Testing and
P0315 (See: Powertrain Management/Computers and Control Systems/Testing and
Inspection/Diagnostic Trouble Code Tests and Associated Procedures/P Code Charts/P0315) . If
any other DTCs set, refer to Diagnostic Trouble Code (DTC) List - Vehicle (See: Powertrain
Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code
Descriptions/Diagnostic Trouble Code (DTC) List - Vehicle) for the applicable DTC that set.
P0315 is set:
* A ECM replacement

Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Procedures >
Page 1233
Removal Procedure

Page 1234
Notice) .
Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair
> Procedures
Ignition Switch Lock Cylinder: Procedures
Key and Lock Cylinder Coding
Use Instruction Sheet Supplied
For the lock cylinder coding procedure, refer to the instruction sheet supplied in the lock cylinder
kit.
For key cutting information, refer to the instructions provided from the manufacturer of the key
cutting equipment used.
> Procedures > Page 1240
Ignition Switch Lock Cylinder: Removal and Replacement
Ignition Lock Cylinder Replacement
Removal Procedure

1. Disable the SIR system. Refer to SIR Disabling and Enabling (See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument Panel/Air
Bag(s) Arming and Disarming/Service and Repair) .
2. Remove the driver knee bolster. Refer to Driver Knee Bolster Replacement (See: Body and
Frame/Interior Moulding / Trim/Dashboard /
Instrument Panel/Service and Repair/Driver Knee Bolster Replacement) .
3. Remove the steering column shroud. Refer to Steering Column Shroud Replacement (See:
Steering and Suspension/Steering/Steering
Column/Service and Repair/Steering Column Shroud Replacement) .
4. With the key installed hold it in the START position.
5. Install an allen wrench into the hole on top of the ignition lock cylinder case.
Push down on the allen wrench to release the tab on the ignition lock cylinder inside the ignition
lock cylinder case.
6. Slide the ignition lock cylinder out of the ignition lock cylinder case.
Important: The gears between the ignition/start switch and the ignition lock cylinder case must be in
the correct position. Failure to do so will cause a misalignment of the gears in the ignition/start
switch and the ignition lock cylinder case, which may result in a NO START or BATTERY DRAIN.
1. Use a screwdriver to rotate the ignition lock cylinder case gear clockwise to the start position -
allowing it to spring return into the RUN position.
2. Install the key into the ignition lock cylinder. 3. Align the ignition lock cylinder and install it into the
ignition lock cylinder case. 4. Install the steering column shroud. Refer to Steering Column Shroud
Replacement (See: Steering and Suspension/Steering/Steering
5. Install the driver knee bolster. Refer to Driver Knee Bolster Replacement (See: Body and
6. Enable the SIR system. Refer to SIR Disabling and Enabling (See: Body and Frame/Interior
Ignition Lock Cylinder Case Replacement

Ignition Lock Cylinder Case Bracket Replacement

Switches - Ignition System > Knock Sensor > Component Information > Locations
Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 1246
Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Knock Sensor (KS) 1
Knock Sensor (KS) 1

Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Knock Sensor (KS) 1 > Page 1249
Knock Sensor (KS) 2

Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Page 1250
Removal Procedure

Hummer Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation
Air Bag Deactivation Switch: Locations
Switch
Air Bag Deactivation Switch: Diagrams
Inflatable Restraint I/P Module Disable Switch

Air Bag Deactivation Switch: Service and Repair
Inflatable Restraint Instrument Panel Module Disable Switch Replacement

Hummer Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Locations > Inflatable Restraint Sensor
Impact Sensor: Locations Inflatable Restraint Sensor
Front Doors

Component Information > Locations > Inflatable Restraint Sensor > Page 1262
Rear Passenger Doors
1 - Courtesy Lamp-LR Door 2 - Window Switch-LR 3 - Speaker-LR Door 4 - Speaker-RR Door 5 -

Widow Switch-RR Door 6 - Courtesy Lamp-RR Door 7 - Door Latch Assembly-RR Door 8 -
Inflatable Restraint Side Impact Sensor (SIS) - Right Rear 9 - Window Motor-RR Door 10 - Window
Motor-LR Door 11 - Inflatable Restraint Side Impact Sensor (SIS) - Left Rear 12 - Door Latch
Assembly-LR Door
Engine Compartment
Impact Sensor: Locations Rollover Sensor
(SDM)
Component Information > Diagrams > Inflatable Restraint Front Sensor - Left
Impact Sensor: Diagrams Inflatable Restraint Front Sensor - Left
Inflatable Restraint Front Sensor - Left

Component Information > Diagrams > Inflatable Restraint Front Sensor - Left > Page 1267
Impact Sensor: Diagrams Inflatable Restraint Front Sensor - Right
Inflatable Restraint Front Sensor - Right

Impact Sensor: Diagrams Inflatable Restraint Side Impact Sensor (SIS) - Left Front
Inflatable Restraint Side Impact Sensor (SIS) - Left Front

Impact Sensor: Diagrams Inflatable Restraint Side Impact Sensor (SIS) - Left Rear
Inflatable Restraint Side Impact Sensor (SIS) - Left Rear

Impact Sensor: Diagrams



Inflatable Restraint Side Impact Sensor (SIS) - Right Front
Inflatable Restraint Side Impact Sensor (SIS) - Right Front

Inflatable Restraint Side Impact Sensor (SIS) - Right Rear
Inflatable Restraint Side Impact Sensor (SIS) - Right Rear

Inflatable Restraint Vehicle Rollover Sensor
Inflatable Restraint Vehicle Rollover Sensor

Component Information > Service and Repair > Inflatable Restraint Front End Sensor Replacement
Impact Sensor: Service and Repair Inflatable Restraint Front End Sensor Replacement
Inflatable Restraint Front End Sensor Replacement

Component Information > Service and Repair > Inflatable Restraint Front End Sensor Replacement > Page 1279
Impact Sensor: Service and Repair Inflatable Restraint Vehicle Rollover Sensor Replacement
Inflatable Restraint Vehicle Rollover Sensor Replacement

Impact Sensor: Service and Repair Inflatable Restraint Side Impact Sensor Replacement - Front
Inflatable Restraint Side Impact Sensor Replacement - Front
Impact Sensor: Service and Repair Inflatable Restraint Side Impact Sensor Replacement - Rear
Inflatable Restraint Side Impact Sensor Replacement - Rear

Hummer Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant
Sensor > Component Information > Service and Repair
Seat Occupant Sensor: Service and Repair
Inflatable Restraint Passenger Presence System Replacement - Front

Hummer Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant
Sensor > Component Information > Service and Repair > Page 1286
Hummer Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Current
Sensor > Component Information > Diagrams

Sensor > Component Information > Diagrams > Page 1291
Removal Procedure

Hummer Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch >
Ignition Switch Lock Cylinder > Component Information > Service and Repair > Procedures
kit.
Ignition Switch Lock Cylinder > Component Information > Service and Repair > Procedures > Page 1298
Removal Procedure

lock cylinder case.


Hummer Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Steering > Steering Angle Sensor > Component Information > Locations
Steering Angle Sensor: Locations
Switches - Steering > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position
Sensor Replacement
Steering Angle Sensor: Service and Repair Steering Wheel Position Sensor Replacement
Steering Wheel Position Sensor Replacement
Sensor Replacement > Page 1308
Steering Angle Sensor: Service and Repair Steering Wheel Position Sensor Centering
Steering Wheel Position Sensor Centering

Removal Procedure
Important: Identify the type of steering wheel position sensor from the illustrations shown BEFORE
removing the sensor from the steering column. Once you have identified the steering wheel
position sensor, follow the instructions listed in the removal procedure.
1. Verify the type of steering wheel position sensor.
2. From the technicians point of view, the FRONT of the sensor (1) connector will be on the right.
Important: If reusing the existing sensor, you do not have to align the sensor before removal.
Centering is not required when it is time to reinstall.
3. Remove the connector from the sensor. 4. Remove the sensor (1) from the adapter and bearing
assembly. 5. To install the sensor, proceed to step 1 in the installation section.
6. From the technicians point of view, the FRONT of the sensor will have:
* A foam ring (2)
* A pin hole (1) for centering the pin-Note the location of the pin hole.
* A flush rotor flange cuff (4)
Important: If reusing the existing sensor, you must make an alignment mark on the rotor flange cuff
(3) before removing the sensor. Failure to do so will cause misalignment when installing the
sensor. A new sensor will be required if misaligned.
7. Make an alignment mark on the flush rotor flange cuff (3). 8. Remove the connector from the
sensor. 9. Remove the sensor from the adapter and bearing assembly.
10. To install the sensor, proceed to step 5 in the installation procedure.

* A raised rotor flange cuff (3)
* An alignment mark (2) on the rotor flange cuff (3) for installation
* A pin hole (1) for the centering pin-Note the location of the pin hole.
12. Remove the connector from the sensor. 13. Remove the sensor from the adapter and bearing
assembly. 14. To install the sensor, proceed to step 9 in the installation procedure.
* A pin hole (1) for the centering pin-Note location of the pin hole.
* A sensor clip in FRONT of the sensor
16. Remove the connector from the sensor. 17. Remove the sensor clip from the sensor. 18.
Remove the sensor from the adapter and bearing assembly. 19. To install the sensor, proceed to
step 13 in the installation procedure.
* An alignment mark (2) on the flush rotor flange cuff (3) for installation
* A foam ring (1)
Important: If reusing the existing sensor, no centering of the sensor is required.
1. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin
until the sensor is seated. 2. From the technicians point of view, the FRONT of the sensor (1)
connector will be on your right.
From the technicians point of view, the BACK of the sensor (2) connector will be on your left.
3. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the
adapter and bearing assembly. 4. Install the connector to the sensor.
* A foam ring (4)
* A flushed rotor flange cuff (6)
* An alignment mark (5) for installation
6. From the technicians point of view, the BACK of the sensor will have:
* Double D flats (1)
* A foam ring (3)
* An alignment tab (2) for installing into the adapter and bearing assembly
* A view of the inside of the connector
Important: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff
before installation. The alignment mark must stay aligned until the sensor is seated into the adapter
and bearing assembly.
If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until
the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new
sensor.

Important: If reusing the existing sensor, you must align the marks on the raised rotor flange cuff
sensor.
14. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for
installation. This sensor does not have double D
flats.
sensor.
flats.
sensor.
* A foam ring (6)
sensor.
Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Locations
Ride Height Sensor: Locations
Rear Suspension
Left
Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Locations > Page 1318
Ride Height Sensor: Diagrams
I/P Multifunction Switch Assembly X1

Switches - Suspension > Steering Angle Sensor > Component Information > Locations
Steering Angle Sensor: Locations
Switches - Suspension > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position
Sensor Replacement
Steering Angle Sensor: Service and Repair Steering Wheel Position Sensor Replacement
Steering Wheel Position Sensor Replacement
Steering Angle Sensor: Service and Repair Steering Wheel Position Sensor Centering
Steering Wheel Position Sensor Centering

Removal Procedure
Important: Identify the type of steering wheel position sensor from the illustrations shown BEFORE
removing the sensor from the steering column. Once you have identified the steering wheel
position sensor, follow the instructions listed in the removal procedure.
1. Verify the type of steering wheel position sensor.
2. From the technicians point of view, the FRONT of the sensor (1) connector will be on the right.
Important: If reusing the existing sensor, you do not have to align the sensor before removal.
Centering is not required when it is time to reinstall.
3. Remove the connector from the sensor. 4. Remove the sensor (1) from the adapter and bearing
assembly. 5. To install the sensor, proceed to step 1 in the installation section.
* A foam ring (2)
* A pin hole (1) for centering the pin-Note the location of the pin hole.
Important: If reusing the existing sensor, you must make an alignment mark on the rotor flange cuff
(3) before removing the sensor. Failure to do so will cause misalignment when installing the
sensor. A new sensor will be required if misaligned.
7. Make an alignment mark on the flush rotor flange cuff (3). 8. Remove the connector from the
sensor. 9. Remove the sensor from the adapter and bearing assembly.
10. To install the sensor, proceed to step 5 in the installation procedure.

* A sensor clip in FRONT of the sensor
16. Remove the connector from the sensor. 17. Remove the sensor clip from the sensor. 18.
Remove the sensor from the adapter and bearing assembly. 19. To install the sensor, proceed to
step 13 in the installation procedure.
* A foam ring (1)
Important: If reusing the existing sensor, no centering of the sensor is required.
1. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin
until the sensor is seated. 2. From the technicians point of view, the FRONT of the sensor (1)
connector will be on your right.
From the technicians point of view, the BACK of the sensor (2) connector will be on your left.
* A foam ring (4)
* A flushed rotor flange cuff (6)
* A foam ring (3)
* A view of the inside of the connector
sensor.

sensor.
flats.
sensor.
flats.
sensor.
* A foam ring (6)
sensor.
Switches - Suspension > Suspension Control Pressure Sensor/Switch > Component Information > Locations
Suspension Control Pressure Sensor/Switch: Locations
Air Suspension Unit (ZM6)
Rear Underbody
1 - X451 2 - Air Suspension Compressor 1 Connector 3 - Air Suspension Compressor 2 Connector

4 - Air Suspension Pressure Sensor 5 - Air Suspension Inlet Valve-LR 6 - Air Suspension Inlet
Valve-RR 7 - Air Suspension Exhaust Valve Connector 8 - Air Suspension Air Dryer 9 - Air
Suspension Compressor 1 10 - Air Suspension Compressor 2 11 - Air Suspension Module 12 -
X450
Switches - Suspension > Suspension Control Pressure Sensor/Switch > Component Information > Diagrams > Air
Suspension Sensor - Left Rear (ZM6)
Suspension Control Pressure Sensor/Switch: Diagrams Air Suspension Sensor - Left Rear (ZM6)
Air Suspension Sensor - Left Rear (ZM6)

Switches - Suspension > Suspension Control Pressure Sensor/Switch > Component Information > Diagrams > Air
Suspension Sensor - Left Rear (ZM6) > Page 1335
Suspension Control Pressure Sensor/Switch: Diagrams Air Suspension Sensor - Right Rear (ZM6)
Air Suspension Sensor - Right Rear (ZM6)

Switches - Suspension > Suspension Mode Switch > Component Information > Locations
Suspension Mode Switch: Locations
Luggage Compartment/Rear of Vehicle Component Views
Rear Compartment Components
1 - Mode Actuator-Auxiliary 2 - Air Temperature Actuator-Auxiliary 3 - HVAC Blower Control

Processor-Auxiliary 4 - Blower Motor-Auxiliary 5 - Inflatable Restraint Roof Rail Module - Right
Rear (AS3) 6 - Speaker - Right D-Pillar 7 - Auxiliary Power Outlet - Cargo 8 - Air Suspension
Inflator Switch (ZM6) 9 - Inflatable Restraint Roof Rail Module - Left Rear (AS3) 10 - Speaker - Left
D-Pillar
Switches - Suspension > Suspension Mode Switch > Component Information > Locations > Page 1339
Suspension Mode Switch: Diagrams
Air Suspension Inflator Switch (ZM6)

Switches - Suspension > Vehicle Speed Sensor Signal > Component Information > Locations
Vehicle Speed Sensor Signal: Locations
Front Suspension
Rear Suspension
Switches - Suspension > Vehicle Speed Sensor Signal > Component Information > Locations > Page 1343
Left
Switches - Suspension > Vehicle Speed Sensor Signal > Component Information > Diagrams > Wheel Speed Sensor
(WSS) - Left Front
Vehicle Speed Sensor Signal: Diagrams Wheel Speed Sensor (WSS) - Left Front

(WSS) - Left Front > Page 1346
Vehicle Speed Sensor Signal: Diagrams Wheel Speed Sensor (WSS) - Left Rear

Vehicle Speed Sensor Signal: Diagrams Wheel Speed Sensor (WSS) - Right Front

Vehicle Speed Sensor Signal: Diagrams Wheel Speed Sensor (WSS) - Right Rear

Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > Tires/Wheels
- Tire Pressure Sensors Service/Re-Learning
Tire Pressure Sensor: Technical Service Bulletins Tires/Wheels - Tire Pressure Sensors
Service/Re-Learning
INFORMATION
Bulletin No.: 10-03-16-001
Date: July 19, 2010
Models:
Disclaimer
- Tire Pressure Sensors Service/Re-Learning > Page 1354
Tire Pressure Sensor: Technical Service Bulletins Tires - Minimizing Damage to TPM Sensors
INFORMATION
Bulletin No.: 08-03-10-007
Date: May 16, 2008
Subject: Minimizing Damage to Tire Pressure Monitor (TPM) Sensors During Tire
Mounting/Dismounting
Models: 2009 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2009 and
Prior HUMMER H2, H3 2009 and Prior Saab 9-7X
with Wheel Mounted Tire Pressure Sensors
Minimizing Damage To TPM Sensors
All GM vehicles now in production and sold in the U.S., as well as many vehicles sold in Canada,
feature Tire Pressure Monitoring Systems that have valve stem mounted Tire Pressure Sensors.
When dismounting and mounting tires, care must be taken when breaking the bead loose from the
wheel. If the tire machines bead breaking fixture is positioned too close to the tire pressure sensor,
as the tire bead breaks away from the wheel it may be forced into, or catch on the edge of the tire
pressure sensor. This can damage the sensor and require the sensor to be replaced.
Care must also be taken when transferring the tire bead to the other side of the wheel rim. As the
tire machine rotates and the tire bead is stretched around the wheel rim, the bead can come in
contact with the sensor if it is not correctly positioned in relation to the mounting/dismounting head
prior to tire mounting/dismounting. This can also cause sensor damage requiring replacement.
Procedure
Notice:
Use a tire changing machine in order to dismount tires. Do not use hand tools or tire irons alone in
order to remove the tire from the wheel. Damage to the tire beads or the wheel rim could result.
Notice:
Do not scratch or damage the clear coating on aluminum wheels with the tire changing equipment.
Scratching the clear coating could cause the aluminum wheel to corrode and the clear coating to
peel from the wheel.
1. Remove the valve core from the valve stem.
2. Deflate the tire completely.
Important:
Rim-clamp European-type tire changers are recommended.
3. Use the tire changer in order to remove the tire from the wheel. Follow steps 4-7 to remove the
tire from the wheel.
4. When separating the tire bead from the wheel position the bead breaking fixture 90, 180 and 270
degrees from the valve stem.
5. Position the wheel and tire so the valve stem is situated at the 2 o'clock position relative to the
head. The tire iron or pry bar can be inserted when prying the outer tire bead up and over the
mounting/dismounting head.
6. Position the wheel and tire so that the valve stem is situated again at the 2 o'clock position
relative to the head. The tire iron or pry bar can be inserted when prying the inner tire bead up and
over the mounting/dismounting head.
7. Remove all residual liquid sealant from the inside of the tire and wheel surfaces. If any tire
sealant is noted upon tire dismounting on vehicles equipped with TPM replace the tire pressure
sensor.
8. Use a wire brush or coarse steel wool in order to remove any rubber, light rust or corrosion from
the wheel bead seats.
Important:
If bead seat corrosion has been identified as an air loss concern on the wheel being worked on,
refer to GM Service Bulletin # 08-03-10-006 for additional information on correcting the leak.
9. Apply GM P/N 12345884 (in Canada, P/N 5728223) or equivalent to the tire bead and the wheel
rim.
10. Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead
to the inside of the wheel rim.
11. Position the rim so that the valve stem (1) is situated at the 3 o'clock position relative to the
head (2). This will protect the sensor when the bottom bead seats.
12. After the bottom bead is on the wheel, reposition the wheel and tire so that the valve stem is
situated at the 9 o'clock position relative to the head. This will protect the sensor while mounting
the tire bead to the outside of the wheel.
13. Use the tire changer in order to install the tire to the wheel.
Caution:
To avoid serious personal injury, do not stand over tire when inflating. The bead may break when
the bead snaps over the safety hump. Do not exceed 275 kPa (40 psi) pressure when inflating any
tire if beads are not seated. If 275 kPa (40 psi) pressure will not seat the beads, deflate, lubricate
the beads and reinflate. Overinflating may cause the bead to break and cause serious personal
injury.
Important:
Allowable bead seating pressure is 345 kPa (50 psi) on Extended Mobility Tires.
14. Inflate the tire until it passes the bead humps. Be sure that the valve core is not installed at this
time.
15. Install the valve core to the valve core stem.
16. Inflate the tire to the proper air pressure.
17. Ensure that the locating rings are visible on both sides of the tire in order to verify that the tire
bead is fully seated on the wheel.
Parts Information
The product shown above is available from GM SPO.
Disclaimer
Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > Page 1358
Tire Pressure Sensor: Service and Repair

Tire Pressure Indicator Sensor Replacement (Clamp In Style)
Removal Procedure
1. Raise the vehicle on a suitable support. Refer to Lifting and Jacking the Vehicle (See:
Maintenance) . 2. Remove the tire/wheel assembly from the vehicle. Refer to Tire and Wheel
Removal and Installation (See: Maintenance/Wheels and Tires/Service
and Repair) .
Important: Before the tire is removed from the wheel, note the following items to avoid tire pressure
sensor damage upon tire dismounting:
* Place the sensors cap and valve on a dry clean surface after removal. The cap is aluminum and
the valve is nickel plated to prevent corrosion and are not to be substituted with a cap or valve
made of any other material.
When separating the tire bead from the wheel, position the bead breaking fixture 90 degrees from
the valve stem.
* Position the mounting/dismounting head so the tire iron, or pry bar can be inserted slightly
clockwise of the sensor body when prying the tire bead up and over the mounting/dismounting
head.
* Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead
to the out side of the wheel rim.
* Repeat items for inner bead.
3. Remove the tire from the wheel. Refer to Tire Mounting and Dismounting (See:
Maintenance/Wheels and Tires/Tires/Service and
Important: If any tire sealant is noted upon tire dismounting, remove all residual liquid sealant from
the inside of the tire and wheel surfaces.
4. Remove the tire pressure sensor nut. 5. Remove the tire pressure sensor.
1. Clean any dirt or debris from the grommet sealing area.
2. Insert the sensor in the wheel hole with the air passage facing away from the wheel.
Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > Page 1359
Notice) .
3. Install the sensor nut and position the sensor body parallel to the inside wheel surface while
torquing.
Tighten the sensor nut to 7 N.m (62 lb in).
Important: Before reinstalling the tire on the wheel, note the following items to avoid tire pressure
sensor damage upon tire mounting:
* Position the mounting/dismounting head 180 degrees from the valve stem.
* Position the bead transition area 45 degrees counterclockwise of the valve stem.
* Repeat items for outer bead.
4. Install the tire on the wheel. Refer to Tire Mounting and Dismounting (See: Maintenance/Wheels
and Tires/Tires/Service and Repair/Removal
and Replacement) .
Important: A service replacement tire pressure sensor is shipped in OFF mode. In this mode the
sensor unique identification code cannot be learned into the remote control door lock receiver
(RCDLR) memory. The sensor must be taken out of OFF mode by spinning the tire/wheel
assembly above 32 km/h (20 mph) in order to close the sensors internal roll switch for at least 10
seconds.
5. Install the tire/wheel assembly on the vehicle. Refer to Tire and Wheel Removal and Installation
(See: Maintenance/Wheels and Tires/Service and
Repair) .
6. Lower the vehicle. 7. Learn the tire pressure sensors. Refer to Tire Pressure Sensor Learn (See:
Instrument Panel, Gauges and Warning Indicators/Tire Monitoring
System/Service and Repair) .

Hummer Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations
Fluid Pressure Sensor/Switch: Locations
Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Automatic
Transmission Electronic Component Views

Views
Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Automatic
Transmission Electronic Component Views > Page 1369

Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 1370

Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations
Transmission Speed Sensor: Locations
Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Page 1374
Transmission Speed Sensor: Service and Repair
Input and Output Speed Sensor Replacement

Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations
Four Wheel Drive Selector Switch: Locations
Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 1379
Switch
Four Wheel Drive Selector Switch: Diagrams
Transfer Case Shift Control Switch

Four Wheel Drive Selector Switch: Service and Repair
Transfer Case Shift Control Switch Replacement

Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Locations
Speed Sensor: Locations
Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Locations > Page 1385
Speed Sensor: Diagrams

Speed Sensor: Service and Repair
Transfer Case Speed Sensor Replacement
Removal Procedure
1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance) . 2. Remove the
electrical connector from the speed sensor.
3. Remove the speed sensor and the O-ring from the transfer case.

Notice) .
1. Install the new rear speed sensor into the transfer case with a new O-ring seal.
Tighten the speed sensor to 17 N.m (13 lb ft).
2. Install the electrical connector to the speed sensor. 3. Lower the vehicle. Refer to Lifting and
Jacking the Vehicle (See: Maintenance) .
Hummer Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window
Switch > Component Information > Locations > Midgate Window Switch
Power Window Switch: Locations Midgate Window Switch
Adapter (U42)
Switch > Component Information > Locations > Midgate Window Switch > Page 1394
Switch > Component Information > Locations > Midgate Window Switch > Page 1395
Power Window Switch: Locations Window Switch
Rear Passenger Doors
1 - Courtesy Lamp-LR Door 2 - Window Switch-LR 3 - Speaker-LR Door 4 - Speaker-RR Door 5 -

Widow Switch-RR Door 6 - Courtesy Lamp-RR Door 7 - Door Latch Assembly-RR Door 8 -
Inflatable Restraint Side Impact Sensor (SIS) - Right Rear 9 - Window Motor-RR Door 10 - Window
Motor-LR Door 11 - Inflatable Restraint Side Impact Sensor (SIS) - Left Rear 12 - Door Latch
Assembly-LR Door
Switch > Component Information > Diagrams > Global Window Switch
Power Window Switch: Diagrams Global Window Switch
Global Window Switch

Switch > Component Information > Diagrams > Global Window Switch > Page 1398
Power Window Switch: Diagrams Midgate Window Switch (SUT)
Midgate Window Switch (SUT)

Power Window Switch: Diagrams Window Switch - Left Rear
Window Switch - Left Rear

Power Window Switch: Diagrams Window Switch - Right Rear
Window Switch - Right Rear

Switch > Component Information > Service and Repair > Door Lock and Side Window Switch Replacement - Driver Side
Power Window Switch: Service and Repair Door Lock and Side Window Switch Replacement -
Driver Side
Door Lock and Side Window Switch Replacement - Driver Side

Page 1403
Power Window Switch: Service and Repair Door Lock and Side Window Switch Replacement -
Passenger Side
Door Lock and Side Window Switch Replacement - Passenger Side

Page 1404
Power Window Switch: Service and Repair Rear Side Door Window Switch Replacement
Rear Side Door Window Switch Replacement

Hummer Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer
Fluid Level Switch > Component Information > Locations
Washer Fluid Level Switch: Locations
Engine Compartment
Fluid Level Switch > Component Information > Locations > Page 1409
Washer Fluid Level Switch: Diagrams
Windshield Washer Fluid Level Switch

Washer Fluid Level Switch: Service and Repair
Washer Solvent Container Level Sensor Replacement
Removal Procedure
1. Open the hood. 2. Remove the washer solvent from the washer solvent container. 3. Disconnect
the washer solvent level sensor (6) electrical connector. 4. Remove the A/C low pressure switch.
Refer to Air Conditioning (A/C) Low Pressure Switch Replacement (See: Sensors and Switches -
HVAC/Refrigerant Pressure Sensor / Switch/Service and Repair/Air Conditioning (A/C) Low

Pressure Switch Replacement) .
5. Mark the location of the sensor prior to removal.
Important: The level sensor arm hinges at the point called out (1). Before servicing the level sensor,
it is necessary to get the level sensor arm in a horizontal position. Failure to do so will result in
breakage of the level sensor.
6. Get the level sensor in a horizontal position by inserting a long, narrow tool through the washer
solvent fill hole, and gently raising the sensor arm.
7. Remove the level sensor from the washer solvent container.
1. Get the level sensor in a horizontal position as shown (1).
2. Install the level sensor (6) in the washer solvent container (5). Ensure to reference the locating
mark made during removal. 3. Connect the washer solvent electrical connector. 4. Install the A/C
low pressure switch. Refer to Air Conditioning (A/C) Low Pressure Switch Replacement (See:
Sensors and Switches -
HVAC/Refrigerant Pressure Sensor / Switch/Service and Repair/Air Conditioning (A/C) Low

Pressure Switch Replacement) .
5. Refill the washer solvent container. 6. Inspect for leaks. 7. Close the hood.
Hummer Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield
Washer Switch > Component Information > Locations
Windshield Washer Switch: Locations
Washer Switch > Component Information > Locations > Page 1415
Switch
Washer Switch > Component Information > Locations > Page 1416
Windshield Washer Switch: Diagrams
Rear Wiper/Washer Switch (SUV)

Hummer Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper
Wiper Switch: Locations
Switch
Wiper Switch: Diagrams
Rear Wiper/Washer Switch (SUV)

Hummer Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Alignment -
Specification/Requirement/Recommendation
Alignment: Technical Service Bulletins Alignment - Specification/Requirement/Recommendation
INFORMATION
Date: June 27, 2008
Subject: Wheel Alignment Specifications, Requirements and Recommendations for GM Vehicles
Models: 2009 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2009 and
Prior HUMMER H2 H3 2009 and Prior Saab 9-7X
Supercede:
This bulletin is being revised to add 2008 & 2009 model years. Please discard Corporate Bulletin
Number 05-03-07-009A (Section 03 - Suspension).
The purpose of this bulletin is to provide retail and wholesale personnel with General Motors
specifications requirements and recommendations for wheel alignment equipment and alignment
procedures.
Wheel Alignment Specifications
Technicians must refer to SI for the correct wheel alignment specifications for each vehicle. SI is
the only source of GM wheel alignment specifications that is up-to-date throughout the year.
The wheel alignment specifications loaded in any wheel alignment machine by the equipment
manufacturer may be incorrect and/or outdated, even if the dealership subscribes to the
manufacturers update service. GM used to send certain manufacturers an annual update of the
wheel alignment specifications for the new model year in early summer. Certain equipment
manufacturers now subscribe to GM's SI service to obtain updates for GM alignment specifications,
however, because changes to the wheel alignment specifications may occur during the model year,
dealership alignment machines may or may not be up to date with the current specifications.
Therefore, it is required that the technicians refer directly to SI for the latest updates and any
changes to the wheel alignment specifications.
Using incorrect and/or outdated specifications may result in unnecessary adjustments, irregular
and/or premature tire wear and repeat customer concerns.
Conditions Possibly Requiring a Wheel Alignment
^ Lead/pull defined as "at a constant highway speed on a typical straight road, the amount of effort
required at the steering wheel to maintain the vehicle's straight path".
^ Steering wheel off-center (clockwise or counterclockwise)
^ Unusual tire wear (slight to very slight "feathering" or "edge" wear on the shoulders of tires is
NOT considered unusual and should even up with a tire rotation at or before the next scheduled
maintenance interval)
^ Other repairs that affect wheel alignment
Alignment Equipment
Alignments must be performed with a quality alignment machine that will give accurate results
when performing alignment checks. "External Reference" (image-based camera technology) is
preferred.
Requirements
^ Computerized four wheel alignment system
^ Computer capable of printing before and after alignment reports
^ Computer capable of time and date stamp printout
^ Racking system must have jacking capability
^ Racking system must be capable of level to 1.6 mm (1/16 in)

Specification/Requirement/Recommendation > Page 1427
^ Appropriate wheel stops and safety certification
^ Built-in turn plates and slip plates
^ Wheel clamps capable of attaching to 20" or larger wheels
^ Racking capable of accepting any GM passenger car or light duty truck
^ Operator properly trained and ASE-certified (U.S. only) in wheel alignment
Recommendations
Racking should have front and rear jacking capability.
Equipment Maintenance and Calibration
Alignment machines must be regularly calibrated in order to give correct information. Most
manufacturers recommend the following:
^ Alignment machines with "internal reference" sensors should be checked (and calibrated if
necessary) every six months.
^ Alignment machines with "external reference" (image-based camera technology) should be

checked (and calibrated if necessary) once a year.
^ Racks must be kept level to within 1.6 mm (1/16 in).
^ If any instrument that is part of the alignment machine is dropped or damaged in some way check
the calibration immediately.
Check with the manufacturer of your specific equipment for their recommended service/calibration
schedule.
Warranty Claim Documentation
Important:
Failure to have proper documentation of the repair order may result in denial or chargeback of the
warranty claim.
In order to properly document a warranty claim for alignment, the following must be completed:
^ Details of the customers concern or complaint are to be noted at the time of repair order write-up
by recording the description of the customers problem.
^ The technicians description of the cause of the concern and the repairs performed must be
written on all copies of the repair order.
^ "Before" and "After" alignment settings are to be recorded on the repair order. An alignment
machine printout of "Before" AND "After" settings with date/time stamp is to be attached to the
repair order by dealers who have printout capable equipment.
^ Documentation of alignment machine calibration within the last 12 months must be available for
AVM (in Canada, DSM, for Saturn, DSSM) review upon request.
^ Prior wholesale approval required for vehicles under 800km (500 mi) or over 12,000 km (7,000
mi) (will now apply to Saturn retailers also). Refer to the GM Service Policies and Procedures
Manual for complete warranty policy information.
Alignment Process
When performing wheel alignment measurement and/or adjustment the following steps should be
taken:
Preliminary Steps
1. Verify that the vehicle has a full tank of fuel (compensate as necessary).
2. Inspect the wheels and the tires for damage.
3. Inspect the tires for the proper inflation and irregular tire wear.
4. Inspect the wheel bearings for excessive play.
5. Inspect all suspension and steering parts for looseness, wear, or damage.
Specification/Requirement/Recommendation > Page 1428
6. Inspect the steering wheel for excessive drag or poor return due to stiff or rusted linkage or
suspension components.
7. Inspect the vehicle trim height.
8. Compensate for frame angle on targeted vehicles (refer to Wheel Alignment Specifications in
SI).
Satisfactory vehicle operation may occur over a wide range of alignment angles. However, if the
wheel alignment angles are not within the range of specifications, adjust the wheel alignment to the
specifications. Refer to Wheel Alignment Specifications in SI. Give consideration to excess loads,
such as tool boxes, sample cases, etc. Follow the alignment equipment manufacturers instructions.
Measure/Adjust
Notice:
Prior to making any adjustments to wheel alignment on a vehicle technicians must verify that the
wheel alignment specifications loaded into the wheel alignment machine are up-to-date by
comparing these to the wheel alignment specifications for the appropriate model and model year in
SI. Using incorrect and/or outdated specifications may result in unnecessary adjustments irregular
and/or premature tire wear and repeat customer concerns.
Important:
When performing adjustments to vehicles requiring a 4-wheel alignment, set the rear wheel
alignment angles first in order to obtain proper front wheel alignment angles.
Perform the following steps in order to measure the front and rear alignment angles:
1. Install the alignment equipment according to the manufacturers instructions.
2. Jounce the front and the rear bumpers 3 times prior to checking the wheel alignment.
3. Measure the alignment angles and record the readings.
Adjust alignment angles to vehicle specification if necessary. Refer to Wheel Alignment

Specifications in SI Test drive the vehicle to ensure proper repair.
Disclaimer
Hummer Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Trim Height
Specifications
Alignment: Specifications Trim Height Specifications
Trim Height Specifications

Specifications > Page 1431
Alignment: Specifications Wheel Alignment Specifications
Wheel Alignment Specifications

Alignment: Specifications Fastener Tightening Specifications
Fastener Tightening Specifications

Hummer Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Caster
Description
Alignment: Description and Operation Caster Description
Caster Description
Caster Description
Caster is the tilting of the uppermost point of the steering axis either forward or backward, when
viewed from the side of the vehicle. A backward tilt is positive (+) and a forward tilt is negative (-).
Caster influences directional control of the steering but does not affect the tire wear . Caster is
affected by the vehicle height, therefore it is important to keep the body at its designed height.
Overloading the vehicle or a weak or sagging rear spring will affect caster. When the rear of the
vehicle is lower than its designated trim height, the front suspension moves to a more positive
caster. If the rear of the vehicle is higher than its designated trim height, the front suspension
moves to a less positive caster.
With too little positive caster, steering may be touchy at high speed and wheel returnability may be
diminished when coming out of a turn. If one wheel has more positive caster than the other, that
wheel will pull toward the center of the vehicle. This condition will cause the vehicle to pull or lead
to the side with the least amount of positive caster.
Description > Page 1435
Alignment: Description and Operation Camber Description
Camber Description
Camber Description
Camber is the tilting of the wheels from the vertical when viewed from the front of the vehicle.
When the wheels tilt outward at the top, the camber is positive (+). When the wheel tilts inward at
the top, the camber is negative (-). The amount of tilt is measured in degrees from the vertical.
Camber settings influence the directional control and the tire wear.
Too much positive camber will result in premature wear on the outside of the tire and cause
excessive wear on the suspension parts.
Too much negative camber will result in premature wear on the inside of the tire and cause
Unequal side-to-side camber of 1 degree or more will cause the vehicle to pull or lead to the side
with the most positive camber.
Alignment: Description and Operation Toe Description
Toe Description
Toe Description
Toe is a measurement of how much the front and/or rear wheels are turned in or out from a
straight-ahead position. When the wheels are turned in, toe is positive (+). When the wheels are
turned out, toe is negative (-). The actual amount of toe is normally only a fraction of a degree. The
purpose of toe is to ensure that the wheels roll parallel.
Toe also offsets the small deflections of the wheel support system that occur when the vehicle is
rolling forward. In other words, with the vehicle standing still and the wheels set with toe-in, the
wheels tend to roll parallel on the road when the vehicle is moving.
Improper toe adjustment will cause premature tire wear and cause steering instability.
Alignment: Description and Operation Setback Description
Setback Description
Setback applies to both the front and the rear wheels. Setback is the amount that one wheel may
be aligned behind the other wheel. Setback may be the result of a road hazard or a collision. The
first clue is a caster difference from side-to-side of more than 1 degree.
Alignment: Description and Operation
Caster Description
Caster Description
Caster Description
Caster is the tilting of the uppermost point of the steering axis either forward or backward, when
viewed from the side of the vehicle. A backward tilt is positive (+) and a forward tilt is negative (-).
Caster influences directional control of the steering but does not affect the tire wear . Caster is
affected by the vehicle height, therefore it is important to keep the body at its designed height.
Overloading the vehicle or a weak or sagging rear spring will affect caster. When the rear of the
vehicle is lower than its designated trim height, the front suspension moves to a more positive
caster. If the rear of the vehicle is higher than its designated trim height, the front suspension
moves to a less positive caster.
With too little positive caster, steering may be touchy at high speed and wheel returnability may be
diminished when coming out of a turn. If one wheel has more positive caster than the other, that
wheel will pull toward the center of the vehicle. This condition will cause the vehicle to pull or lead
to the side with the least amount of positive caster.
Camber Description
Camber Description
Camber Description
Camber is the tilting of the wheels from the vertical when viewed from the front of the vehicle.
When the wheels tilt outward at the top, the camber is positive (+). When the wheel tilts inward at
the top, the camber is negative (-). The amount of tilt is measured in degrees from the vertical.
Camber settings influence the directional control and the tire wear.
Too much positive camber will result in premature wear on the outside of the tire and cause
Too much negative camber will result in premature wear on the inside of the tire and cause
Unequal side-to-side camber of 1 degree or more will cause the vehicle to pull or lead to the side
with the most positive camber.
Toe Description
Toe Description
Toe Description
Toe is a measurement of how much the front and/or rear wheels are turned in or out from a
straight-ahead position. When the wheels are turned in, toe is positive (+). When the wheels are
turned out, toe is negative (-). The actual amount of toe is normally only a fraction of a degree. The
purpose of toe is to ensure that the wheels roll parallel.
Toe also offsets the small deflections of the wheel support system that occur when the vehicle is
rolling forward. In other words, with the vehicle standing still and the wheels set with toe-in, the
wheels tend to roll parallel on the road when the vehicle is moving.
Improper toe adjustment will cause premature tire wear and cause steering instability.
Setback Description
Setback Description
Setback applies to both the front and the rear wheels. Setback is the amount that one wheel may
be aligned behind the other wheel. Setback may be the result of a road hazard or a collision. The
first clue is a caster difference from side-to-side of more than 1 degree.
Thrust Angles Description
The front wheels aim or steer the vehicle. The rear wheels control tracking. This tracking action
relates to the thrust angle (3). The thrust angle is the path that the rear wheels take. Ideally, the
thrust angle is geometrically aligned with the body centerline (2).
In the illustration, toe-in is shown on the left rear wheel, moving the thrust line (1) off center. The
resulting deviation from the centerline is the thrust angle.
Lead/Pull Description
Lead/Pull Description
At a constant highway speed on a typical straight road, lead/pull is the amount of effort required at
the steering wheel to maintain the vehicle's straight path.
Important: Vehicles will tend to lead/pull in the direction of the road slope as part of normal
operation.
Lead/pull is usually caused by the following factors:
* Road slope
* Variability in tire construction
* Wheel alignment (front cross caster and camber)
* Unbalanced steering gear
* Electronic Power Steering (EPS) steering position and torque sensors not calibrated correctly, if
equipped.
Memory Steer Description
Memory Steer Description
Memory steer is when the vehicle wants to lead or pull in the direction the driver previously turned
the vehicle. Additionally, after turning in the opposite direction, the vehicle will want to lead or pull in
that direction.
Wander Description
Wander Description
Wander is the undesired drifting or deviation of a vehicle to either side from a straight path with
hand pressure on the steering wheel. Wander is a symptom of the vehicle's sensitivity to external
disturbances, such as road crown and crosswind, and accentuated by poor on-center steering feel.
Scrub Radius Description
Scrub Radius Description
Ideally, the scrub radius is as small as possible. Normally, the SAI angle and the centerline of the
tire and the wheel intersect below the road surface, causing a positive scrub radius. With struts, the
SAI angle is much larger than the long arm/short arm type of suspension. This allows the SAI angle
to intersect the camber angle above the road surface, forming a negative scrub radius. The smaller
the scrub radius, the better the directional stability. Installing aftermarket wheels that have
additional offset will dramatically increase the scrub radius. The newly installed wheels may cause
the centerline of the tires to move further away from the spindle. This will increase the scrub radius.
A large amount of scrub radius can cause severe shimmy after hitting a bump. Four-wheel drive
vehicles with large tires use a steering damper to compensate for an increased scrub radius. Scrub
radius is not directly measurable by the conventional methods. Scrub radius is projected
geometrically by engineers during the design phase of the suspension.
Hummer Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Page 1441
Alignment: Testing and Inspection
Trim Height Inspection
Trim Height Measurements
Trim height is a predetermined measurement relating to vehicle ride height. Incorrect trim heights
can cause bottoming out over bumps, damage to the suspension components, and symptoms
similar to wheel alignment problems. Check the trim heights when diagnosing suspension concerns
and before checking the wheel alignment.
Perform the following before measuring the trim heights:
1. Set the tire pressures to the pressure shown on the certification label. Refer to Vehicle
Certification, Tire Placard, Anti-Theft, and Service Parts ID
Label (See: Application and ID/Vehicle Certification, Tire Placard, Anti-Theft, and Service Parts ID
Label) .
2. Check the fuel level. Add additional weight if necessary to simulate a full tank. 3. Verify that the
rear compartment is empty except for the spare tire. 4. Verify that the vehicle is on a level surface,
such as an alignment rack.
Z Height Measurement
1. Lift the front bumper of the vehicle up about 38 mm (1.5 in). 2. Suddenly remove your hands. 3.
Allow the vehicle to settle into position. 4. Repeat this jouncing operation 2 more times.
5. Measure from the pivot bolt center line (3) down to the lower corner (5) of the lower ball joint (1)
in order to obtain the Z height measurement (4).
6. Push the front bumper of the vehicle down about 38 mm (1.5 in). 7. Suddenly remove your
hands. 8. Allow the vehicle to rise. 9. Repeat the operation for a total of 3 times.
10. Measure the Z dimension. 11. The true Z height dimension number is the average of the high
and the low measurements. Refer to Trim Height Specifications (See:
Specifications/Mechanical Specifications/Suspension/System Specifications/Trim Height

Specifications) .
Z Height Adjustment
Hummer Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Page 1442
1. For vehicles equipped with a torsion bar suspension, turn the bolt (1) that contacts the torsion
arm clockwise to raise, and counterclockwise to
lower, the height adjustment. One revolution of the bolt into the nut increases the Z height by
approximately 6 mm (0.2 in).
2. For vehicles without torsion bars, replace damaged or worn components as necessary.
D Height Measurement
The D height dimension measurement determines the proper rear end ride height. No adjustment
procedure is available. Repair may require replacement of suspension components.
1. With the vehicle on a flat surface, lift upward on the rear bumper 38 mm (1.5 in). 2. Suddenly
remove your hands. 3. Allow the vehicle to settle into position. 4. Repeat the jouncing operation 2
more times.
5. The D height is obtained by measuring the distance between the edge of the jounce cup along
the jounce bumper center line and the jounce pad on
the rear axle.
6. The true D height dimension number is the average of the high and the low measurements.
Refer to Trim Height Specifications (See:
Specifications/Mechanical Specifications/Suspension/System Specifications/Trim Height

Specifications) .
7. If these measurements are out of specifications, inspect for the following conditions:
* Sagging front suspension-Refer to Torsion Bar Replacement (See: Steering and

Suspension/Suspension/Torsion Bar/Service and Repair) .
* Sagging rear coil springs-Refer to Coil Spring Replacement (See: Steering and
Suspension/Suspension/Suspension Spring ( Coil / Leaf )/Service and Repair) .
* Proper air suspension operation
* Worn rear suspension components
* Improper tire inflation-Refer to Vehicle Certification, Tire Placard, Anti-Theft, and Service Parts ID
Label (See: Application and ID/Vehicle Certification, Tire Placard, Anti-Theft, and Service Parts ID
Label) .
* Improper weight distribution
* Collision damage
Hummer Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Wheel Alignment
Measurement
Alignment: Service and Repair Wheel Alignment Measurement
Wheel Alignment Measurement
Steering and vibration complaints are not always the result of improper alignment. One possible
cause is wheel and tire imbalance. Another possibility is tire lead due to worn or improperly
manufactured tires. Lead/pull is defined as follows: At a constant highway speed on a typical
straight road, lead/pull is the amount of effort required at the steering wheel to maintain the
vehicle's straight path. Lead is the vehicle deviation from a straight path on a level road without
pressure on the steering wheel. Refer to Radial Tire Lead/Pull Correction (See: Wheels and
Tires/Testing and Inspection/Symptom Related Diagnostic Procedures/Radial Tire Lead/Pull
Correction) in order to determine if the vehicle has a tire lead problem.
Before performing any adjustment affecting wheel alignment, perform the following inspections and
adjustments in order to ensure correct alignment readings:
* Inspect the tires for the proper inflation and irregular tire wear. Refer to Vehicle Certification, Tire
Placard, Anti-Theft, and Service Parts ID Label (See: Application and ID/Vehicle Certification, Tire
Placard, Anti-Theft, and Service Parts ID Label) and Tire Diagnosis - Irregular or Premature Wear
(See: Wheels and Tires/Testing and Inspection/Symptom Related Diagnostic Procedures/Tire
Diagnosis - Irregular or Premature Wear) .
* Inspect the runout of the wheels and the tires. Refer to Tire and Wheel Runout Specifications
(See: Body and Frame/Testing and Inspection/Vibration Diagnosis and
Correction/Specifications/Tire and Wheel Runout Specifications) .
* Inspect the wheel bearings for backlash and excessive play. Refer to Wheel Bearings Diagnosis
(See: Steering and Suspension/Suspension/Testing and Inspection/Component Tests and General
Diagnostics/Wheel Bearings Diagnosis) .
* Inspect the ball joints and tie rod ends for looseness or wear.
* Inspect the control arms and stabilizer shaft for looseness or wear.
* Inspect the steering gear for looseness at the frame. Refer to Fastener Tightening Specifications
(See: Steering and Suspension/Steering/Specifications/Power Steering) .
* Inspect the struts/shock absorbers for wear, leaks, and any noticeable noises. Refer to
Suspension Strut and Shock Absorber Testing - On Vehicle (See: Steering and
Suspension/Suspension/Testing and Inspection/Component Tests and General
Diagnostics/Suspension Strut and Shock Absorber Testing - On Vehicle) .
* Inspect the vehicle trim height. Refer to Trim Height Inspection (See: Steering and
Suspension/Suspension/Testing and Inspection/Component Tests and General Diagnostics/Trim
Height Inspection) .
* Inspect the steering wheel for excessive drag or poor return due to stiff or rusted linkage or
suspension components.
* Inspect the fuel level. The fuel tank should be full or the vehicle should have a compensating load
added.
Give consideration to excess loads, such as tool boxes, sample cases, etc. If normally carried in
the vehicle, these items should remain in the vehicle during alignment adjustments. Give
consideration also to the condition of the equipment being used for the alignment. Follow the
equipment manufacturer's instructions.
Satisfactory vehicle operation may occur over a wide range of alignment settings. However, if the
setting exceeds the service allowable specifications, correct the alignment to the service preferred
specifications. Refer to Wheel Alignment Specifications (See: Specifications/Wheel Alignment
Specifications) .
Perform the following steps in order to measure the front and rear alignment angles:
1. Install the alignment equipment according to the manufacturer's instructions. 2. Jounce the front
and the rear bumpers 3 times prior to checking the wheel alignment. 3. Measure the alignment
angles and record the readings.
Important: When performing adjustments to vehicles requiring a 4-wheel alignment, set the rear
wheel alignment angles first in order to obtain proper front alignment angles.
4. Adjust alignment angles to vehicle specification, if necessary. Refer to Wheel Alignment

Specifications (See: Specifications/Wheel Alignment
Specifications) .
Measurement > Page 1445
Alignment: Service and Repair Front Caster and Camber Adjustment
Front Caster and Camber Adjustment
Important: Caster measurements are now relative to ground.
1. The caster and camber adjustments are made by rotating the offset cam bolt and the cam in the
slotted frame bracket in order to reposition the
control arm.
Important: Before adjusting the caster and camber angles, jounce the front bumper 3 times to allow
the vehicle to return to normal height. Measure and adjust the caster and the camber with the
vehicle at curb height. The front suspension Z dimension is indicated in Trim Heights. Refer to Trim
Height Inspection (See: Steering and Suspension/Suspension/Testing and Inspection/Component
Tests and General Diagnostics/Trim Height Inspection) .
2. For an accurate reading, do not push or pull on the tires during the alignment process.
3. Determine the caster angle (2).
4. Determine the positive camber (2) or negative camber (3) angle. 5. Remove the pinned adjusting
cam insert. Do not reinstall the cam insert. 6. Loosen the upper control arm cam adjustment bolts.

Notice) .
7. Adjust the caster and the camber angle by turning the cam bolts until the specifications have
been met. When the adjustments are complete, hold
the cam bolt head in order to ensure the cam bolt position does not change while tightening the
nut.
Tighten the cam nuts to 190 N.m (140 lb ft).
8. Verify that the caster and the camber are still within specifications. Refer to Wheel Alignment
Specifications (See: Specifications/Wheel
Alignment Specifications) . When the caster and camber are within specifications, adjust the toe.
Refer to Front Toe Adjustment (See: Front Toe Adjustment) .
Alignment: Service and Repair Front Toe Adjustment
Front Toe Adjustment
1. Loosen the jam nut on the tie rod (1). 2. Rotate the inner tie rod (2) to the required toe
specification setting. Refer to Wheel Alignment Specifications (See: Specifications/Wheel
Alignment Specifications) .
3. Tighten the jam nut on the tie rod.
Tighten the tie rod jam to 68 N.m (50 lb ft).
4. Check the toe setting after tightening. 5. Re-adjust the toe setting if necessary.
Hummer Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System
Information > Specifications
Fuel Pressure: Specifications
Fuel Pressure (Key ON, Engine OFF)

............................................................................................................................................. 345-414
kPa (50-60 psi)
Information > Service Precautions > Technician Safety Information
Fuel Pressure: Technician Safety Information
Relieving Fuel Pressure Caution
Caution: Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel
system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a
small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the
connections. In order to reduce the risk of personal injury, cover the fuel system components with a
shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an
approved container when the disconnection is complete.
Information > Service Precautions > Technician Safety Information > Page 1454
Fuel Pressure: Vehicle Damage Warnings
Fuel Pressure Notice
Notice: Do not allow the fuel pressure to exceed the specified value because damage to the fuel
pressure regulator or the fuel pressure gage may result.
Information > System Diagnosis > Fuel Pressure Gage Installation and Removal
Fuel Pressure: Testing and Inspection Fuel Pressure Gage Installation and Removal
Fuel Pressure Gage Installation and Removal
Tools Required
CH-48027 Digital Pressure Gage
Installation Procedure Caution: Refer to Gasoline/Gasoline Vapors Caution (See: Powertrain

Management/Fuel Delivery and Air Induction/Fuel/Service Precautions) .
1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (With CH 48027) (See: Fuel
Filter/Fuel Pressure Release/Service and Repair/Fuel
Pressure Relief (With CH 48027))Fuel Pressure Relief (Without CH 48027) (See: Fuel Filter/Fuel
Pressure Release/Service and Repair/Fuel Pressure Relief (Without CH 48027)) .
2. Connect the CH-48027-1 (1) to the CH-48027-2 (2). 3. Remove the shop towel from around the
fuel rail service port, and place in an approved gasoline container. 4. Perform any tests and/or
diagnostics as needed. For the proper usage of the CH-48027 , refer to the manufacture's
directions.
Removal Procedure
Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 1457
1. Relieve the fuel system pressure, if required. Perform the following steps:
Caution: Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire
and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the
fuel pressure gage. Place the towel in an approved container when the connection of the fuel
pressure gage is complete.
1. Wrap a shop towel around the fuel rail service port. 2. Place the hose on the CH-48027-2 (2) into
an approved gasoline container. 3. Open the valve on the CH-48027-2 (2) in order to bleed any fuel
from the fuel rail. 4. Close the valve on the CH-48027-2 (2). 5. Remove the hose on the
CH-48027-2 (2) from the approved gasoline container. 6. Remove the shop towel from around the
fuel rail service port, and place in an approved gasoline container.
Notice: Clean all of the following areas before performing any disconnections in order to avoid
possible contamination in the system:
* The fuel pipe connections
* The hose connections

* The areas surrounding the connections
2. Disconnect the CH-48027-1 (1) from the CH-48027-2 (2). 3. Disconnect the CH-48027-2 (2) from
the CH-48027-3 (4). 4. Disconnect the CH-48027-3 (4) from the fuel rail service port. 5. Install the
fuel rail service port cap. 6. Install the engine cover, if required. 7. Tighten the fuel fill cap.
Fuel Pressure: Testing and Inspection Fuel System Diagnosis
Fuel System Diagnosis
procedure.
The engine control module (ECM) supplies a high voltage signal to the fuel pump control module
(FPCM) when the ECM detects that the ignition is ON. The high voltage signal from the ECM to the
FPCM remains active for 2 seconds, unless the engine is in Crank or Run. While this signal is
being received, the FPCM closes the ground switch of the fuel pump and also supplies a varying
voltage to the fuel tank pump module in order to maintain the desired fuel rail pressure.
The fuel system is a returnless on-demand design. The fuel pressure regulator is a part of the fuel
pump module, eliminating the need for a return pipe from the engine. A returnless fuel system
reduces the internal temperature of the fuel tank by not returning hot fuel from the engine to the
fuel tank. Reducing the internal temperature of the fuel tank results in lower evaporative emissions.
The fuel tank stores the fuel supply. An electric turbine style fuel pump attaches to the fuel pump
module inside the fuel tank. The fuel pump supplies high pressure fuel through the fuel filter and
the fuel feed pipe to the fuel injection system. The fuel pump provides fuel at a higher rate of flow
than is needed by the fuel injection system. The fuel pump also supplies fuel to a venturi pump
located on the bottom of the fuel pump module. The function of the venturi pump is to fill the fuel
pump module reservoir. The fuel pressure regulator, a part of the fuel pump module, maintains the
correct fuel pressure to the fuel injection system. The fuel pump module contains a reverse flow
check valve. The check valve and the fuel pressure regulator maintain fuel pressure in the fuel feed
pipe and the fuel rail in order to prevent long cranking times.
Reference Information Description and Operation
Fuel System Description (See: Powertrain Management/Computers and Control

Systems/Description and Operation/Fuel System Description) Electrical Information Reference

Testing)


Scan Tool Reference
* CH-48027 Digital Pressure Gage
* J 37287 Fuel Line Shut-off Adapter
Important:
* Repair all fuel system related DTCs before performing this diagnostic
* Inspect the fuel system for damage or external leaks before proceeding.
* Verify that adequate fuel is in the fuel tank before proceeding.
* The fuel pump relay may need to be commanded ON a few times in order to obtain the highest
possible fuel pressure.
* Before proceeding with this test review the User Manual CH 48027-5 for Safety Information and
Instructions.
1. Ignition OFF, all accessories OFF, install a CH-48027 . Refer to Fuel Pressure Gage Installation
and Removal (See: Fuel Pressure Gage
Installation and Removal) .
2. Ignition ON, engine OFF, command the fuel pump relay ON with a scan tool. Verify the fuel
pressure is between 345-414 kPa (50-60 psi) and
does not decrease more than 34 kPa (5 psi) in 1 minute.
Important: *
The fuel pump relay may need to be commanded ON a few times in order to obtain the highest
* DO NOT start the engine.
1. Ignition ON, engine OFF, command the fuel pump relay ON with a scan tool and observe the
fuel pressure gage while the fuel pump is operating.
Verify the fuel pressure is between 345-414 kPa (50-60 psi).
‹› If the fuel pressure is greater than the specified range, replace the fuel pump module. ‹› If the
fuel pressure is less than the specified range, test, inspect, and repair the items listed below. If all
items test normal, replace the fuel
pump module.
* Restricted fuel feed pipe
* Inspect the harness connectors and the ground circuits of the fuel pump for poor connections.
2. Verify that the fuel pressure does not decrease more than 34 kPa (5 psi) in 1 minute.
‹› If the fuel pressure decreases more than the specified value, perform the following procedure:
1. Ignition OFF, relieve the fuel pressure. Refer to Fuel Pressure Relief (With CH 48027) (See: Fuel
Filter/Fuel Pressure Release/Service and
Repair/Fuel Pressure Relief (With CH 48027))Fuel Pressure Relief (Without CH 48027) (See: Fuel
Filter/Fuel Pressure Release/Service and Repair/Fuel Pressure Relief (Without CH 48027)) .
2. Install the J 37287 between the fuel feed pipe and the fuel rail. 3. Open the valve on the J 37287
. 4. Ignition ON, command the fuel pump relay ON with a scan tool and bleed the air from the
CH-48027 . 5. Command the fuel pump relay ON and then OFF with a scan tool. 6. Close the valve
on the J 37287 . 7. Monitor the fuel pressure for 1 minute.
‹› If the fuel pressure decreases more than 34 kPa (5 psi) within the specified time, locate and
replace the leaking fuel injector(s). ‹› If the fuel pressure does not decrease more than 34 kPa (5
psi) within the specified time, replace the fuel pump module.
3. Relieve the fuel pressure to 69 kPa (10 psi). Verify that the fuel pressure does not decrease
more than 14 kPa (2 psi) in 5 minutes.
‹› If the fuel pressure decreases more than the specified value, replace the fuel pump module.
4. Operate the vehicle within the conditions of the customer's concern while monitoring the fuel
pressure with the CH-48027 . The fuel pressure
should not drop off during acceleration, cruise or hard cornering.
‹› If the fuel pressure drops off, test, inspect, and repair the items listed below. If all items test
normal, replace the fuel pump module.
* Inspect the harness connectors and the ground circuits of the fuel pump for poor connections
5. If the fuel system tests normal, refer to Symptoms - Engine Controls (See: Powertrain
Management/Computers and Control Systems/Testing and
Inspection/Symptom Related Diagnostic Procedures/Symptoms - Engine Controls) .
Repair Instructions
Perform the Diagnostic Repair Verification (See: Powertrain Management/Computers and Control
Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated
Procedures/Verification Tests and Procedures) after completing the diagnostic procedure.
* Fuel Hose/Pipes Assembly Replacement (See: Powertrain Management/Fuel Delivery and Air
Induction/Fuel Supply Line/Service and Repair/Fuel Hose/Pipes Assembly Replacement)
* Fuel Injector Replacement (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel
Injector/Service and Repair/Removal and Replacement)
* Fuel Sender Assembly Replacement (See: Instrument Panel, Gauges and Warning
Indicators/Fuel Gauge Sender/Service and Repair)
Hummer Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System
Idle Speed: Specifications
Information not supplied by the manufacturer

Hummer Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air
Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair
Air Cleaner Fresh Air Duct/Hose: Service and Repair
Air Cleaner Resonator Outlet Duct Replacement
Removal Procedure
1. Loosen the clamp and separate the air cleaner resonator outlet duct from the mass air
flow/intake air temperature (MAF/IAT) sensor assembly. 2. Loosen the clamp and separate the air
cleaner resonator outlet duct from the throttle body assembly. 3. Remove the air cleaner resonator
outlet duct.
1. Install the air cleaner resonator outlet duct to the throttle body assembly and the MAF/IAT sensor
assembly. 2. Tighten the clamps at the throttle body assembly and the MAF/IAT sensor assembly.
Hummer Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter
Element > Component Information > Service and Repair
Air Filter Element: Service and Repair
Air Cleaner Element Replacement
Removal Procedure
1. Loosen the 2 fasteners securing the air cleaner housing top cover. 2. Lift and rotate the top
cover of the air cleaner housing to gain access to the air filter element. 3. Lift out the air filter
element. 4. Inspect the air filter element for dust, dirt, or water. Clean or replace the air filter
element if required.
1. Install the air filter element into the air cleaner housing. 2. Rotate and install the top cover to the
air cleaner housing. 3. Insert the fasteners to secure the top cover.
Hummer Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure
Release > System Information > Service and Repair > Fuel Pressure Relief (With CH 48027)
Fuel Pressure Release: Service and Repair Fuel Pressure Relief (With CH 48027)
Fuel Pressure Relief (With CH 48027)
Special Tools
Caution: Refer to Gasoline/Gasoline Vapors Caution (See: Powertrain Management/Fuel Delivery

and Air Induction/Fuel/Service Precautions) .
1. If the fuel system requires repair, prevent fuel spillage by removing the fuel pump fuse. Refer to
Electrical Center Identification Views (See:
Fuses and Circuit Breakers/Fuse/Application and ID) .
2. Remove the engine cover, if required. 3. Loosen the fuel fill cap in order to relieve the fuel tank
vapor pressure. 4. Remove the fuel rail service port cap.
5. Wrap a shop towel around the fuel rail service port. 6. Connect the CH-48027-3 (4) to the fuel
rail service port. 7. Connect the CH-48027-2 (2) to the CH-48027-3 (4). 8. Place the hose on the
CH-48027-2 (2) into an approved gasoline container. 9. Open the valve on the CH-48027-2 (2) in
order to bleed any fuel from the fuel rail.
10. Close the valve on the CH-48027-2 (2). 11. Remove the hose on the CH-48027-2 (2) from the
approved gasoline container.

Release > System Information > Service and Repair > Fuel Pressure Relief (With CH 48027) > Page 1476
Important: If relieving the fuel pressure for the fuel pressure gage installation and removal, it is
NOT necessary to proceed with the following steps.
12. Disconnect the CH-48027-2 (2) from the CH-48027-3 (4). 13. Disconnect the CH-48027-3 (4)
from the fuel rail service port. 14. Remove the shop towel from around the fuel rail service port, and
place in an approved gasoline container. 15. Install the fuel rail service port cap. 16. Install the
engine cover, if required. 17. Tighten the fuel fill cap.
Fuel Pressure Release: Service and Repair Fuel Pressure Relief (Without CH 48027)
Fuel Pressure Relief (Without CH 48027) Caution: Refer to Gasoline/Gasoline Vapors Caution
(See: Powertrain Management/Fuel Delivery and Air Induction/Fuel/Service Precautions) .
2. Loosen the fuel fill cap in order to relieve the fuel tank vapor pressure. 3. Remove the engine
cover, if required. 4. Remove the fuel rail service port cap. 5. Wrap a shop towel around the fuel rail
service port and using a small flat-bladed tool, depress (open) the fuel rail test port valve. 6.
Remove the shop towel from around the fuel rail service port, and place in an approved gasoline
container. 7. Install the fuel rail service port cap. 8. Install the engine cover, if required. 9. Tighten
the fuel fill cap.
Fuel Pressure Release: Service and Repair Fuel Pressure Gage Installation and Removal
Tools Required

Pressure Relief (With CH 48027))Fuel Pressure
Relief (Without CH 48027) (See: Fuel Pressure Relief (Without CH 48027)) .
directions.
Removal Procedure

Hummer Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Firing Order > Component
Firing Order: Specifications
Ignition System Specifications

Hummer Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component
Information > Testing and Inspection
Ignition Cable: Testing and Inspection
Spark Plug Wire Inspection
Spark plug wire integrity is vital for proper engine operation. A thorough inspection will be
necessary to accurately identify conditions that may affect engine operation. Inspect for the
* Correct routing of the spark plug wires-Incorrect routing may cause cross-firing.
* Any signs of cracks or splits in the wires.
* Inspect each boot for the following conditions:
- Tearing
- Piercing
- Arcing
- Carbon tracking
- Corroded terminal
If corrosion, carbon tracking or arcing are indicated on a spark plug wire boot or on a terminal,
replace the wire and the component connected to the wire.
Information > Testing and Inspection > Page 1486
Ignition Cable: Service and Repair
Spark Plug Wire Replacement
Removal Procedure
1. Disconnect the spark plug wire at each spark plug.
* Twist each spark plug 1/2 turn.
* Pull only on the boot in order to remove the wire from each spark plug.
2. Disconnect the spark plug wire from the ignition coil.
* Twist each spark plug boot 1/2 turn.
* Pull only on the boot in order to remove the wires from the ignition coil.
Spark Plug Wire Length V8
* The Melco(R), square design, uses a spark plug wire (1) that is 145 mm (5.70 in) length cable
seal to cable seal.
* The Delphi(R), round design uses a spark plug wire (2) that is 110 mm (4.30 in) length cable seal
to cable seal.
* There are 2 different manufacturers for the ignition coils. the Melco(R) (1) square design, and the
Delphi(R) (2) round design. These 2 coils use 2 different spark plug wire, and mounting brackets.
* Melco(R), square design, coil mounting bracket (1).
* Delphi(R), round design, coil mounting bracket (2).
1. Install the spark plug wires at the ignition coil. 2. Install the spark plug wire to each spark plug. 3.
Inspect the wires for proper installation:
* Push sideways on each boot in order to inspect the seating.
* Reinstall any loose boot.

Hummer Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Spark Plug: Specifications

Information > Specifications > Page 1491
Spark Plug: Application and ID

Spark Plug: Testing and Inspection
Spark Plug Inspection
Spark Plug Usage
* Verify that the correct spark plug is installed. An incorrect spark plug causes driveability
conditions. Refer to Ignition System Specifications (See: Powertrain Management/Ignition
System/Specifications) for the correct spark plug.
* Ensure that the spark plug has the correct heat range. An incorrect heat range causes the
- Spark plug fouling - Colder plug
- Pre-ignition causing spark plug and/or engine damage - Hotter plug
* Inspect the terminal post (1) for damage:
- Inspect for a bent or broken terminal post (1).
- Test for a loose terminal post (1) by twisting and pulling the post. The terminal post (1) should
NOT move.
* Inspect the insulator (2) for flashover or carbon tracking, soot. This is caused by the electrical
charge traveling across the insulator (2) between the terminal post (1) and ground. Inspect for the
- Inspect the spark plug boot for damage.
- Inspect the spark plug recess area of the cylinder head for moisture, such as oil, coolant, or
water. A spark plug boot that is saturated causes arcing to ground.
* Inspect the insulator (2) for cracks. All or part of the electrical charge may arc through the crack
instead of the electrodes (3, 4).
* Inspect for evidence of improper arcing:
- Measure the gap between the center electrode (4) and the side electrode (3) terminals. Refer to
Ignition System Specifications (See: Powertrain Management/Ignition System/Specifications) . An
excessively wide electrode gap can prevent correct spark plug operation.
- Inspect for the correct spark plug torque. Refer to Ignition System Specifications (See: Powertrain
Management/Ignition System/Specifications) . Insufficient torque can prevent correct spark plug
operation. An over torqued spark plug, causes the insulator (2) to crack.
- Inspect for signs of tracking that occurred near the insulator tip instead of the center electrode (4).
- Inspect for a broken or worn side electrode (3).
- Inspect for a broken, worn, or loose center electrode (4) by shaking the spark plug.
* A rattling sound indicates internal damage.
* A loose center electrode (4) reduces the spark intensity.
- Inspect for bridged electrodes (3, 4). Deposits on the electrodes (3, 4) reduce or eliminates the
gap.
- Inspect for worn or missing platinum pads on the electrodes (3, 4), if equipped.
- Inspect for excessive fouling.
* Inspect the spark plug recess area of the cylinder head for debris. Dirty or damaged threads can
cause the spark plug not to seat correctly during installation.
Spark Plug Visual Inspection
* Normal operation - Brown to grayish-tan with small amounts of white powdery deposits are
normal combustion by-products from fuels with additives.
* Carbon fouled - Dry, fluffy black carbon, or soot caused by the following conditions:
- Rich fuel mixtures
* Leaking fuel injectors

* Excessive fuel pressure
* Restricted air filter element
* Incorrect combustion
- Reduced ignition system voltage output
* Weak coils
* Worn ignition wires
* Incorrect spark plug gap
- Excessive idling or slow speeds under light loads can keep spark plug temperatures so low that
normal combustion deposits may not burn off.
* Deposit fouling-Oil, coolant, or additives that include substances such as silicone, very white
coating, reduces the spark intensity. Most powdery deposits will not effect spark intensity unless
they form into a glazing over the electrode.
Spark Plug: Service and Repair
Spark Plug Replacement
Removal Procedure
1. Remove the spark plug wires. Refer to Spark Plug Wire Replacement (See: Ignition
Cable/Service and Repair) .
2. Loosen each spark plug 1 or 2 turns. 3. Brush or air blast away any dirt from around the spark
plugs. 4. Remove the spark plugs 1 at a time. Place each plug in a tray marked with the
corresponding cylinder numbers.
1. Properly position each spark plug washer. 2. Inspect each spark plug gap. Adjust each plug as
needed.
Spark plug gap: 1.524 mm (0.060 in)

Notice) .
3. Hand start the spark plugs in the corresponding cylinders. 4. Tighten the spark plugs.
* For used heads tighten the spark plugs to 15 N.m (11 lb ft).
* For new aluminum heads tighten the spark plugs to 20 N.m (15 lb ft).
* For new iron heads, tighten the spark plugs to 30 N.m (22 lb ft).
5. Install the spark plug wires. Refer to Spark Plug Wire Replacement (See: Ignition Cable/Service
and Repair) .
Hummer Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System
Compression Check: Specifications
COMPRESSION CHECK
- The minimum compression in any 1 cylinder should not be less than 70 percent of the highest
cylinder.
- No cylinder should read less than 690 kPa (100 psi).
- For example, if the highest pressure in any 1 cylinder is 1 035 kPa (150 psi), the lowest allowable
pressure for any other cylinder would be 725 kPa (105 psi). (1 035 x 70% = 725) (150 x 70% =
105).
Hummer Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System
Compression Check: Testing and Inspection
Engine Compression Test
1. Charge the battery if the battery is not fully charged. 2. Disable the ignition system. 3. Disable
the fuel injection system. 4. Remove all spark plugs. 5. Turn the ignition to the ON position. 6.
Depress the accelerator pedal to position the throttle plate wide open. 7. Start with the compression
gage at zero and crank the engine through 4 compression strokes, 4 puffs. 8. Measure the
compression for each cylinder. Record the readings. 9. If a cylinder has low compression, inject
approximately 15 ml (1 tablespoon) of engine oil into the combustion chamber through the spark
plug
hole. Measure the compression again and record the reading.
10. The minimum compression in any 1 cylinder should not be less than 70 percent of the highest
cylinder. No cylinder should read less than 690 kPa
(100 psi). For example, if the highest pressure in any 1 cylinder is 1 035 kPa (150 psi), the lowest
allowable pressure for any other cylinder would be 725 kPa (105 psi). (1 035 x 70% = 725) (150 x
70% = 105).
* Normal - Compression builds up quickly and evenly to the specified compression for each
cylinder.
* Piston Rings Leaking - Compression is low on the first stroke. Compression builds up with the
following strokes, but does not reach normal. Compression improves considerably when you add
oil.
* Valves Leaking - Compression is low on the first stroke. Compression usually does not build up
on the following strokes. Compression does not improve much when you add oil.
* If 2 adjacent cylinders have lower than normal compression, and injecting oil into the cylinders
does not increase the compression, the cause may be a head gasket leaking between the
cylinders.
Hummer Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System
Valve Clearance: Specifications
VALVE SYSTEM
Valve Lash ...........................................................................................................................................

..................................... Net Lash - No Adjustment
Hummer Workshop Manuals > Maintenance > Timing Component Alignment Marks > Component Information > Locations
Timing Component Alignment Marks: Locations

Hummer Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins >
Customer Interest for Drive Belt: > 08-06-01-008A > Jul > 09 > Engine - Various Drive Belt Symptoms
Drive Belt: Customer Interest Engine - Various Drive Belt Symptoms
INFORMATION
Date: July 27, 2009
Subject: Diagnosing Accessory Drive Belt / Serpentine Belt Noise and Availability and Use of
Kent-Moore EN-49228 Laser Alignment Tool - Drive Belt
Models:
2010 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2,
H3 Vehicles 2009 and Prior Saab 9-7X
Supercede: This bulletin is being revised to add a model year and update the Tool Information.
Please discard Corporate Bulletin Number 08-06-01-008 (Section 06 - Engine).
Background
Several aftermarket companies offer laser alignment tools for accessory drive systems that can be
very helpful in eliminating drive belt noise as a result of misaligned pulleys. Typically pricing ranges
from $160 - $200.
EN-49228 Laser Alignment Tool - Drive Belt
The GM Tool program has now made available a competitive, simple to use and time-saving laser
tool to assist in achieving precise alignment of the drive belt pulleys. This optional tool removes the
guesswork from proper pulley alignment and may serve to reduce comebacks from:
- Drive Belt Noise
- Accelerated Drive Belt Wear
- Drive Belt Slippage
Instructions
The instructions below are specific only to the truck Gen IV V-8 family of engines. These
instructions are only for illustrative purposes to show how the tool may be used. Universal
instructions are included in the box with the Laser Alignment Tool - Drive Belt.
Caution
- Do not look directly into the beam projected from the laser.
- Use caution when shining the laser on highly polished or reflective surfaces. Laser safety glasses
help reduce laser beam glare in many circumstances.
- Always use laser safety glasses when using the laser. Laser safety glasses are not designed to
protect eyes from direct laser exposure.
1. Observe and mark the serpentine belt orientation.

Customer Interest for Drive Belt: > 08-06-01-008A > Jul > 09 > Engine - Various Drive Belt Symptoms > Page 1514
2. Remove the serpentine belt from the accessory drive system.
3. Install the tool onto the power steering pulley. Position the legs of the tool into the outer grooves
of the pulley, farthest from the front of the
engine.
4. Install the retaining cord around the pulley and to the legs of the tool.
5. Put on the laser safety glasses provided with the tool. 6. Depress the switch on the rear of the
tool to activate the light beam. 7. Rotate the power steering pulley as required to project the light
beam onto the crankshaft balancer pulley grooves. 8. Inspect for proper power steering pulley
alignment.
- If the laser beam projects onto the second rib or raised area (1), the pulleys are aligned properly.
- If the laser beam projects more than one-quarter rib 0.9 mm (0.035 in) mis-alignment, adjust the
position of the power steering pulley as required.
- Refer to SI for Power Steering Pulley Removal and Installation procedures.
9. Install the serpentine belt to the accessory drive system in the original orientation.
10. Operate the vehicle and verify that the belt noise concern is no longer present.
Tool Information
Please visit the GM service tool website for pricing information or to place your order for this tool.
Customer Interest for Drive Belt: > 08-06-01-008A > Jul > 09 > Engine - Various Drive Belt Symptoms > Page 1515
Disclaimer
Customer Interest for Drive Belt: > 08-06-01-015 > Jul > 08 > Engine - Drive Belt Chirping Noise
Drive Belt: Customer Interest Engine - Drive Belt Chirping Noise
TECHNICAL
Bulletin No.: 08-06-01-015
Date: July 14, 2008
Subject: Accessory Drive Belt/Serpentine Belt Noise, Chirp Squeal or Squeak (Check Pulley
Alignment and Replace Belt, If Necessary)
Models: 2008-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2008-2009 Chevrolet
Avalanche, Silverado, Silverado HD, Suburban, Tahoe TrailBlazer, TrailBlazer SS 2009 Chevrolet
Colorado, Express 2008-2009 GMC Envoy, Envoy Denali, Sierra, Sierra HD, Sierra Denali, Yukon,
Yukon XL, Yukon Denali XL 2009 GMC Canyon, Savana 2008-2009 HUMMER H2, H3 2008-2009
Saab 9-7X V8
with Vortec(R) GEN IV V8 4.8L, 5.3L, 6.0L, 6.2L or Engine (VINs 3, 4, M, L, 0, C, J, H, U, Y, K, 8, 2

- RPOs LY2, LC9, LMF, LH6, LH8, LMG , LY5, LS2, L76, LY6, L92, L9H)
with or without Active Fuel Management System
Condition
Some customers may comment on an accessory drive belt/serpentine belt chirp squeal or squeak
noise from the engine compartment at idle or while driving.
Cause
This condition may be caused by a misaligned pulley and/or the accessory drive belt creating the
noise.
Correction
Notice:
Do not use belt dressing or silicone on the drive belt. Belt dressing may cause the composition of
the drive belt to break down. Failure to follow this recommendation will damage the drive belt.
Tip
very helpful in eliminating drive belt noise as a result of misaligned pulleys. Refer to Service
Bulletin 08-06-01-008. Additional information on EN-49228 Laser Belt Alignment Tool can also be
found in GM TECH LINK Publication, June 2008 Volume 10, No 6.
Check and/or adjust pulley alignment, then replace the accessory drive belt, if necessary. Refer to
Drive Belt Replacement-Accessory in SI.
Parts Information

Customer Interest for Drive Belt: > 08-06-01-015 > Jul > 08 > Engine - Drive Belt Chirping Noise > Page 1520
Disclaimer
Hummer Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Drive Belt: > 08-06-01-008A > Jul > 09 > Engine - Various Drive Belt Symptoms
Drive Belt: All Technical Service Bulletins Engine - Various Drive Belt Symptoms
INFORMATION
Date: July 27, 2009
Models:
Background
from $160 - $200.
- Drive Belt Noise
Instructions
Caution

Technical Service Bulletins for Drive Belt: > 08-06-01-008A > Jul > 09 > Engine - Various Drive Belt Symptoms > Page 1526
engine.
alignment.
Tool Information
Technical Service Bulletins for Drive Belt: > 08-06-01-008A > Jul > 09 > Engine - Various Drive Belt Symptoms > Page 1527
Disclaimer
Technical Service Bulletins for Drive Belt: > 08-06-01-015 > Jul > 08 > Engine - Drive Belt Chirping Noise
Drive Belt: All Technical Service Bulletins Engine - Drive Belt Chirping Noise
TECHNICAL
Bulletin No.: 08-06-01-015
Date: July 14, 2008
Saab 9-7X V8

Condition
Cause
noise.
Correction
Notice:
Tip
Parts Information

Technical Service Bulletins for Drive Belt: > 08-06-01-015 > Jul > 08 > Engine - Drive Belt Chirping Noise > Page 1532
Disclaimer
Hummer Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Page
1533
Drive Belt: Service Precautions
Belt Dressing Notice
Notice: 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.
Hummer Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Page
1534
Drive Belt: Description and Operation
Drive Belt System Description
The drive belt system consists of the following components:
* The drive belt
* The drive belt tensioner
* The drive belt idler pulley
* The crankshaft balancer pulley
* The accessory drive component mounting brackets
* The accessory drive components
- The power steering pump, if belt driven
- The generator
- The A/C compressor, if equipped
- The engine cooling fan, if belt driven
- The water pump, if belt driven
- The vacuum pump, if equipped
- The air compressor, if equipped
The drive belt system may use 1 belt or 2 belts. The drive belt is thin so that it can bend backwards
and has several ribs to match the grooves in the pulleys. The drive belts are made of different
types of rubbers, chloroprene or EPDM, and have different layers or plys containing either fiber
cloth or cords for reinforcement.
Both sides of the drive belt may be used to drive the different accessory drive components. When
the back side of the drive belt is used to drive a pulley, the pulley is smooth.
The drive belt is pulled by the crankshaft balancer pulley across the accessory drive component
pulleys. The spring loaded drive belt tensioner keeps constant tension on the drive belt to prevent
the drive belt from slipping. The drive belt tensioner arm will move when loads are applied to the
drive belt by the accessory drive components and the crankshaft.
The drive belt system may have an idler pulley, which is used to add wrap to the adjacent pulleys.
Some systems use an idler pulley in place of an accessory drive component when the vehicle is
not equipped with the accessory.
Hummer Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt
Chirping, Squeal, and Whine Diagnosis
Drive Belt: Testing and Inspection Drive Belt Chirping, Squeal, and Whine Diagnosis
Drive Belt Chirping, Squeal, and Whine Diagnosis
Diagnostic Aids
* A chirping or squeal noise may be intermittent due to moisture on the drive belts or the pulleys. It
may be necessary to spray a small amount of water on the drive belts in order to duplicate the
customers concern. If spraying water on the drive belt duplicates the symptom, cleaning the belt
pulleys may be the probable solution.
* If the noise is intermittent, verify the accessory drive components by varying their loads making
sure they are operated to their maximum capacity. An overcharged A/C system, power steering
system with a pinched hose or wrong fluid, or a generator failing are suggested items to inspect.
* A chirping, squeal or whine noise may be caused by a loose or improper installation of a body or
suspension component. Other items of the vehicle may also cause the noise.
* The drive belts will not cause a whine noise.
Test Description
The numbers below refer to the step numbers on the diagnostic table. 2. The noise may not be
engine related. This step is to verify that the engine is making the noise. If the engine is not making
the noise do not proceed further with this table. 3. The noise may be an internal engine noise.
Removing the drive belts one at a time and operating the engine for a brief period will verify the
noise is related to the drive belt. When removing the drive belt the water pump may not be
operating and the engine may overheat. Also DTCs may set when the engine is operating with the
drive belts removed. 4. Inspect all drive belt pulleys for pilling. Pilling is the small balls or pills or it
can be strings in the drive belt grooves from the accumulation of rubber dust. 6. Misalignment of
the pulleys may be caused from improper mounting of the accessory drive component, incorrect
installation of the accessory drive component pulley, or the pulley bent inward or outward from a
previous repair. Test for a misaligned pulley using a straight edge in the pulley grooves across 2 or
3 pulleys. If a misaligned pulley is found refer to that accessory drive component for the proper
installation procedure for that pulley. 10. Inspecting of the fasteners can eliminate the possibility
that a wrong bolt, nut, spacer, or washer was installed. 12. Inspecting the pulleys for being bent
should include inspecting for a dent or other damage to the pulleys that would prevent the drive belt
from not seating properly in all of the pulley grooves or on the smooth surface of a pulley when the
back side of the belt is used to drive the pulley. 14. This test is to verify that the drive belt tensioner
operates properly. If the drive belt tensioner is not operating properly, proper belt tension may not
be achieved to keep the drive belt from slipping which could cause a squeal noise. 15. This test is
to verify that the drive belt is not too long, which would prevent the drive belt tensioner from
working properly. Also if an incorrect length drive belt was installed, it may not be routed properly
and may be turning an accessory drive component in the wrong direction. 16. Misalignment of the
pulleys may be caused from improper mounting of the accessory drive component, incorrect
installation procedure for that pulley. 17. This test is to verify that the pulleys are the correct
diameter or width. Using a known good vehicle compare the pulley sizes. 19. Replacing the drive
belt when it is not damaged or there is not excessive pilling will only be a temporary repair.
Chirping, Squeal, and Whine Diagnosis > Page 1537
Drive Belt: Testing and Inspection Drive Belt Falls Off and Excessive Wear Diagnosis
Drive Belt Falls Off and Excessive Wear Diagnosis
Diagnostic Aids
If the drive belt repeatedly falls off the drive belt pulleys, this is because of pulley misalignment.
An extra load that is quickly applied on released by an accessory drive component may cause the
drive belt to fall off the pulleys. Verify the accessory drive components operate properly.
If the drive belt is the incorrect length, the drive belt tensioner may not keep the proper tension on
the drive belt.
Excessive wear on a drive belt is usually caused by an incorrect installation or the wrong drive belt
for the application.
Minor misalignment of the drive belt pulleys will not cause excessive wear, but will probably cause
the drive belt to make a noise or to fall off.
Excessive misalignment of the drive belt pulleys will cause excessive wear but may also make the
drive belt fall off.
Test Description
The numbers below refer to the step numbers on the diagnostic table. 2. This inspection is to verify
the condition of the drive belt. Damage may of occurred to the drive belt when the drive belt fell off.
The drive belt may of been damaged, which caused the drive belt to fall off. Inspect the belt for
cuts, tears, sections of ribs missing, or damaged belt plys. 4. Misalignment of the pulleys may be
caused from improper mounting of the accessory drive component, incorrect installation of the
accessory drive component pulley, or the pulley bent inward or outward from a previous repair.
Test for a misaligned pulley using a straight edge in the pulley grooves across two or three pulleys.
If a misaligned pulley is found refer to that accessory drive component for the proper installation
procedure of that pulley. 5. Inspecting the pulleys for being bent should include inspecting for a
dent or other damage to the pulleys that would prevent the drive belt from not seating properly in all
of the pulley grooves or on the smooth surface of a pulley when the back side of the belt is used to
drive the pulley. 6. Accessory drive component brackets that are bent or cracked will let the drive
belt fall off. 7. Inspection of the fasteners can eliminate the possibility that a wrong bolt, nut ,
spacer, or washer was installed. Missing, loose, or the wrong fasteners may cause pulley
misalignment from the bracket moving under load. Over tightening of the fasteners may cause
misalignment of the accessory component bracket. 13. The inspection is to verify the drive belt is
correctly installed on all of the drive belt pulleys. Wear on the drive belt may be caused by
mis-positioning the drive belt by one groove on a pulley. 14. The installation of a drive belt that is
too wide or too narrow will cause wear on the drive belt. The drive belt ribs should match all of the
grooves on all of the pulleys. 15. This inspection is to verify the drive belt is not contacting any
parts of the engine or body while the engine is operating. There should be sufficient clearance
when the drive belt accessory drive components load varies. The drive belt should not come in
contact with an engine or a body component when snapping the throttle.
Drive Belt: Testing and Inspection Drive Belt Rumbling and Vibration Diagnosis
Drive Belt Rumbling and Vibration Diagnosis
Diagnostic Aids
The accessory drive components can have an affect on engine vibration. Vibration from the engine
operating may cause a body component or another part of the vehicle to make rumbling noise.
Vibration can be caused by, but not limited to the air conditioning (A/C) system over charged, the
power steering system restricted or the incorrect fluid, or an extra load on the generator. To help
identify an intermittent or an improper condition, vary the loads on the accessory drive components.
The drive belt may have a rumbling condition that can not be seen or felt. Sometimes replacing the
drive belt may be the only repair for the symptom.
If replacing the drive belt, completing the diagnostic table, and the noise is only heard when the
drive belts are installed, there might be an accessory drive component with a failure. Varying the
load on the different accessory drive components may aid in identifying which component is
causing the rumbling noise.
Test Description
The numbers below refer to the step numbers on the diagnostic table. 2. This test is to verify that
the symptom is present during diagnosing. Other vehicle components may cause a similar
symptom. 3. This test is to verify that one of the drive belts is causing the rumbling noise or
vibration. Rumbling noise may be confused with an internal engine noise due to the similarity in the
description. Remove only one drive belt at a time if the vehicle has multiple drive belts. When
removing the drive belts the water pump may not be operating and the engine may overheat. Also
DTCs may set when the engine is operating with the drive belts removed. 4. Inspecting the drive
belts is to ensure that they are not causing the noise. Small cracks across the ribs of the drive belt
will not cause the noise. Belt separation is identified by the plys of the belt separating and may be
seen at the edge of the belt our felt as a lump in the belt. 5. Small amounts of pilling is normal
condition and acceptable. When the pilling is severe the drive belt does not have a smooth surface
for proper operation. 9. Inspecting of the fasteners can eliminate the possibility that the wrong bolt,
nut, spacer, or washer was installed. 11. This step should only be performed if the water pump is
driven by the drive belt. Inspect the water pump shaft for being bent. Also inspect the water pump
bearings for smooth operation and excessive play. Compare the water pump with a known good
water pump. 12. Accessory drive component brackets that are bent, cracked, or loose may put
extra strain on that accessory component causing it to vibrate.
Hummer Workshop Manuals > Maintenance > Drive Belt > Component Information > Service and Repair > Drive Belt
Replacement - Accessory
Drive Belt: Service and Repair Drive Belt Replacement - Accessory
Drive Belt Replacement - Accessory
Removal Procedure
1. Loosen the air cleaner outlet duct clamps at the following locations:
* Throttle body
* Mass airflow/intake air temperature (MAF/IAT) sensor
2. Remove the air cleaner outlet duct.
3. Install a breaker bar with hex-head socket to the drive belt tensioner bolt. 4. Rotate the drive belt
tensioner clockwise in order to relieve tension on the belt. 5. Remove the belt from the pulleys and
the drive belt tensioner. 6. Slowly release the tension on the drive belt tensioner. 7. Remove the
breaker bar and socket and from the drive belt tensioner bolt. 8. Clean and inspect the belt
surfaces of all the pulleys.
1. Route the drive belt around all the pulleys except the idler pulley. 2. Install the breaker bar with
hex-head socket to the belt tensioner bolt. 3. Rotate the belt tensioner clockwise in order to relieve
the tension on the tensioner. 4. Install the drive belt under the idler pulley.
Replacement - Accessory > Page 1545
5. Slowly release the tension on the belt tensioner. 6. Remove the breaker bar and socket from the
belt tensioner bolt. 7. Inspect the drive belt for proper installation and alignment.
Important: Align the arrow at the throttle body end of the duct with the throttle body attaching stud.
8. Install the air cleaner outlet duct.

Notice) .
9. Tighten the air cleaner outlet duct clamps at the following locations:
* Throttle body
* MAF/IAT sensor
Tighten the air cleaner outlet duct clamp screws to 7 N.m (62 lb in).
Drive Belt: Service and Repair Air Conditioning Compressor Belt Replacement
Air Conditioning Compressor Belt Replacement

Removal Procedure
1. Remove the accessory drive belt. Refer to Drive Belt Replacement - Accessory (See: Drive Belt
Replacement - Accessory) . 2. Raise and suitably support the vehicle. Refer to Lifting and Jacking
the Vehicle (See: ) . 3. Remove the engine protection shield. Refer to Engine Protection Shield
Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair
).
4. Install a ratchet into the air conditioning (A/C) belt tensioner adapter opening. 5. Rotate the A/C
belt tensioner clockwise in order to relieve tension on the belt. 6. Remove the A/C belt from the
pulleys. 7. Slowly release the tension on the A/C belt tensioner. 8. Remove the ratchet from the
A/C belt tensioner. 9. Clean and inspect the belt surfaces of all the pulleys.
1. Install the A/C belt around the crankshaft balancer. 2. Install a ratchet into the A/C drive belt
tensioner adapter opening. 3. Rotate the A/C belt tensioner clockwise in order to relieve tension on
the tensioner. 4. Install the A/C belt over the idler pulley. 5. Install the A/C belt around the A/C
compressor pulley. 6. Slowly release the tension on the A/C belt tensioner. 7. Remove the ratchet
from the A/C belt tensioner. 8. Inspect the A/C belt for proper installation and alignment. 9. Install
the engine protection shield. Refer to Engine Protection Shield Replacement (See: Body and
Frame/Frame/Skid Plate/Service and Repair) .

Notice) .
10. Install the engine shield bolts.
Tighten the engine shield bolts to 20 N.m (15 lb ft).
11. Lower the vehicle. 12. Install the accessory drive belt. Refer to Drive Belt Replacement -
Accessory (See: Drive Belt Replacement - Accessory) .
Hummer Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose >
Removal Procedure
outlet duct.
Hummer Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information >
Service and Repair
Removal Procedure
Hummer Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair
Fluid Filter - A/T: Service and Repair
Automatic Transmission Fluid, Fluid Pan and/or Filter Replacement

Hummer Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair >
Page 1559
Hummer Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service
and Repair > Fuel Pressure Relief (With CH 48027)
Special Tools


and Repair > Fuel Pressure Relief (With CH 48027) > Page 1565
the fuel fill cap.
Tools Required

directions.
Removal Procedure

Hummer Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Technical Service
Bulletins > Engine - Noise/Damage After Oil Filter Replacement
Oil Filter: Technical Service Bulletins Engine - Noise/Damage After Oil Filter Replacement
INFORMATION
Date: July 27, 2009
Subject: Information on Internal Engine Noise or Damage After Oil Filter Replacement
Models:
2010 and Prior Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3
2009 and Prior Saab 9-7X
Supercede: This bulletin is being updated to add model years. Please discard Corporate Bulletin
Number 07-06-01-016A (Section 06 - Engine/Propulsion System).
Important Engine damage that is the result of an incorrect or improperly installed engine oil filter is
not a warrantable claim. The best way to avoid oil filter quality concerns is to purchase ACDelco(R)
oil filters directly from GMSPO.
Oil filter misapplication may cause abnormal engine noise or internal damage. Always utilize the
most recent parts information to ensure the correct part number filter is installed when replacing oil
filters. Do not rely on physical dimensions alone. Counterfeit copies of name brand parts have been
discovered in some aftermarket parts systems. Always ensure the parts you install are from a
trusted source. Improper oil filter installation may result in catastrophic engine damage.
Refer to the appropriate Service Information (SI) installation instructions when replacing any oil
filter and pay particular attention to procedures for proper cartridge filter element alignment. If the
diagnostics in SI (Engine Mechanical) lead to the oil filter as the cause of the internal engine noise
or damage, dealers should submit a field product report. Refer to Corporate Bulletin Number
02-00-89-002I (Information for Dealers on How to Submit a Field Product Report).
Disclaimer
Oil Filter: Service and Repair
Engine Oil and Oil Filter Replacement
Removal Procedure
Important: In order to completely drain the oil from the oil pan internal baffling, the bottom of the oil
pan must be level during the oil drain procedure.
1. Open the hood. 2. Remove the oil fill cap. 3. Raise and suitably support the vehicle. Refer to
Lifting and Jacking the Vehicle (See: ) . 4. Place a oil drain pan under the oil pan drain plug. 5.
Remove the oil pan drain plug. 6. Drain the engine oil. 7. Wipe the excess oil from the drain plug
hole and plug.
8. Remove the oil filter from the engine block.
Important: Check the old oil filter to ensure that the filter seal is not left on the engine block.
9. Wipe the excess oil from the oil filter mounting.
1. Lubricate the oil filter seal with clean engine oil.

2. Install the oil filter to the engine block.
Tighten the oil filter to 30 N.m (22 lb ft).
3. Install the oil drain plug to the engine block.
Tighten the oil pan drain plug to 25 N.m (18 lb ft).
4. Lower the vehicle. 5. Fill the crankcase with the proper quantity and grade of engine oil. Refer to
Approximate Fluid Capacities (See: ) and Fluid and Lubricant
Recommendations (See: ) .
6. Remove the oil level indicator. 7. Wipe the indicator with a clean cloth. 8. Install the oil level
indicator. 9. Remove the oil level indicator in order to check the level.
10. Add oil if necessary. 11. Close the hood.

Hummer Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair >
Procedures
Heater Hose: Procedures
Auxiliary Heater and Air Conditioning Pipe Repair
Tools Required
J 41425 A/C Line Repair Kit
The rear A/C or heater lines can be repaired in sections.
Replacement lines through GMSPO contains all 4 lines in two sections.
Use the J 41425 when any of the following actions damage the rear A/C or heater lines:
* Rub-through
* Collision damage
* Leakage in the system
Minimum Tube Length Required Table
Important: When you section the rear A/C or heater lines, ensure that the correct minimum length
remains in the straight part of the line on both sides of the splice.
Follow the Straight Line Repair procedure in order to repair line damage in a straight section of line.
Follow the Line Sectioning Repair procedure in order to repair any damage in a bend area. Do not
repair the rear A/C or heater lines in a bend area, replace the lines. Maintaining the original line
shape will prevent vibrations and rub-through.
Straight Line Repair
1. Recover the refrigerant, if repairing the A/C lines. Refer to Refrigerant Recovery and Recharging
(See: Heating and Air Conditioning/Service and
Repair/Refrigerant Recovery and Recharging) .
2. Drain the coolant, if repairing the heater lines. Refer to Cooling System Draining and Filling
(Static Fill) (See: Engine, Cooling and

3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: ) . 4. Locate the
area that requires repair. 5. Obtain a length of replacement line to make the repair. 6. Use a tubing
cutter in order to cut and remove the section of damaged line.
Important: The length of the replacement line must be the same as the section being replaced.
7. Use a tubing cutter in order to cut the replacement line to length. 8. Use the cleaning pad from
the J 41425 in order to clean any burrs or grease from the line ends. Be sure to clean at least 19
mm (0.75 in) from the
line ends.
9. Use the LOK prep sealant in order to prep the line ends.
10. Apply one drop of the J 41425-3 sealing compound to the outside of each end of the line. 11.
Insert the line ends into the LOK fitting. 12. Rotate the LOK fitting one complete turn in order to
evenly distribute the sealing compound around the lines. 13. Install the correct LOK fitting jaws into
the J 41425-1 tool. 14. Install the J 41425-1 tool over the LOK connectors.
Verify that the LOK connector ends are positioned in the counter bores of the jaws.
Important: Hold the J 41425-1 tool body with a 3/8" breaker bar.
15. Tighten the forcing screw of the J 41425-1 tool.

When fully seated, the LOK connector collars will bottom out on the center shoulder of the LOK
fitting.
16. Loosen the forcing screw and remove the J 41425-1 tool from the repaired line. 17. Repeat
Step 8 through Step 16 to repair the other end of the line. 18. Verify that the LOK fittings are
correctly installed. 19. Lower the vehicle. 20. Refill the coolant, if drained. Refer to Cooling System
Draining and Filling (Static Fill) (See: Engine, Cooling and Exhaust/Cooling
System/Service and Repair/Draining and Filling Cooling System)Cooling System Draining and
Filling (Vac-N-Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair/Draining
and Filling Cooling System) .
21. Evacuate and recharge the refrigerant, if repairing the A/C lines. Refer to Refrigerant Recovery
and Recharging (See: Heating and Air
Conditioning/Service and Repair/Refrigerant Recovery and Recharging) .
Line Sectioning Repair

3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: ) . 4. Obtain a new
A/C or heater line for sectioning.
Important: Stagger the splices if repairing more than one line.
5. Scribe a mark on the line that will be sectioned. 6. Use a tubing cutter in order to cut the line or
lines being replaced. 7. Remove the section of line being replaced from the vehicle.
Important: The length of the replacement line must be the same as the line being replaced.
8. Install the replacement line to the vehicle. 9. Use a tubing cutter in order to cut the replacement
line to length.
10. Use the cleaning pad from the J 41425 in order to clean any burrs or grease. Be sure to clean
at least 19 mm (0.75 in) from the A/C line. 11. Use the LOK prep sealant in order to prep the A/C or
heater line. 12. Apply one drop of the J 41425-3 sealing compound to the outside of each line end.
13. Insert the line ends into the LOK fitting. 14. Rotate the LOK fitting one complete turn in order to
17. Hold the tool body with a 3/8" breaker bar. Turn the forcing screw until both of the connector
collars bottom on the center shoulder of the LOK
fitting.
18. Loosen the forcing screw. Remove the tool from the repaired line. 19. Verify that the LOK fitting
is correctly installed. 20. Lower the vehicle. 21. Refill the coolant, if drained. Refer to Cooling
System Draining and Filling (Static Fill) (See: Engine, Cooling and Exhaust/Cooling

Heater Hose: Removal and Replacement
Heater Inlet Hose Replacement
Tools Required
J 43181 Quick Connect Connector Removal Tool
Removal Procedure
1. Drain the cooling system. Refer to Cooling System Draining and Filling (Static Fill) (See: Engine,
Cooling and Exhaust/Cooling System/Service
Cooling System) .
2. Using the J 43181 disconnect the inlet heater hose from the heater core.
1. Install the J 43181 to the inlet heater core pipe. 2. Close the tool around the inlet heater core
pipe. 3. Firmly pull the tool into the quick connect end of the heater hose. 4. Firmly grasp the heater
hose. Pull the heater hose forward in order to disengage the hose from the heater core.
3. Remove the heater inlet hose (1) from the mounting clip (2).
4. Reposition the heater inlet hose clamp from the engine. 5. Remove the heater inlet hose (1) from
the engine. 6. Remove the heater inlet hose (1) from the vehicle.
1. Install the heater inlet hose (1) to the vehicle. 2. Install the heater inlet hose (1) to the engine. 3.
Install the heater inlet hose clamp to the engine.
4. Install the heater inlet hose (1) to the mounting clip (2).
5. Connect the heater inlet hose to the heater core.
Important: Firmly push the quick connect onto the heater core pipe until you hear an audible click.
6. Pull the heater inlet hose to ensure the connection. 7. Fill the cooling system. Refer to Cooling
and
Repair/Draining and Filling Cooling System)Cooling System Draining and Filling (Vac-N-Fill) (See:
Engine, Cooling and Exhaust/Cooling System/Service and Repair/Draining and Filling Cooling
System) .
Heater Outlet Hose Replacement

Tools Required
Removal Procedure
Cooling System) .
1. Install the J 43181 to the heater core inlet pipe. 2. Close the tool around the heater core inlet
pipe. 3. Firmly pull the tool into the quick connect end of the heater inlet hose. 4. Firmly grasp the
heater hose. Pull the heater hose forward in order to disengage the hose from the heater core.
3. Using the J 43181 disconnect the surge tank outlet hose from the heater core outlet.
1. Install the J 43181 to the heater core outlet pipe. 2. Close the tool around the heater core outlet
pipe. 3. Firmly pull the tool into the quick connect end of the heater outlet hose. 4. Firmly grasp the
4. Remove the surge tank outlet hose (3) from the mounting clip (2).
5. Reposition the surge tank outlet hose clamp (3) from the engine (2). 6. Remove the surge tank
outlet hose (6) from the engine (2).
7. Reposition the surge tank outlet hose clamp (5) from the surge tank (2). 8. Remove the surge
tank outlet hose (3) from the surge tank (2). 9. Remove the surge tank outlet hose (3) from the
vehicle.
1. Install the surge tank outlet hose (3) to the vehicle. 2. Install the surge tank outlet hose (3) to the
surge tank (2). 3. Install the surge tank outlet hose clamp (5) to the surge tank (2).
4. Install the surge tank outlet hose (6) to the engine (2). 5. Install the surge tank outlet hose clamp
(3) to the engine (2).
6. Install the surge tank outlet hose to the mounting clip.
7. Install the surge tank outlet hose (3) to the mounting clip (2).
8. Install the surge tank outlet hose to the heater core outlet pipe.
9. Pull the surge tank outlet hose to ensure the connection.
10. Install the heater inlet hose to the heater core.
11. Pull the inlet heater inlet hose to ensure the connection. 12. Fill the cooling system. Refer to
Cooling System Draining and Filling (Static Fill) (See: Engine, Cooling and Exhaust/Cooling
System/Service and
System) .
Auxiliary Heater Pipe Replacement - Front
Removal Procedure
1. Drain the engine coolant. Refer to Cooling System Draining and Filling (Static Fill) (See: Engine,
Cooling System) .
2. Remove the air cleaner resonator outlet duct replacement Air Cleaner Resonator Outlet Duct
Replacement (See: Filters/Air Cleaner Housing/Air
Cleaner Fresh Air Duct/Hose/Service and Repair) .
3. Squeeze the plastic retainer release tabs.
4. Pull the hose connection apart.

5. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: ) . 6. Remove the right assist
step if necessary. Refer to Assist Step Replacement (w/WS2, BVX) (See: Body and
Frame/Auxiliary Step / Running
Board/Service and Repair/Assist Step Replacement (w/WS2, BVX))Assist Step Replacement

(Tubular BVE) (See: Body and Frame/Auxiliary Step / Running Board/Service and Repair/Assist
Step Replacement (Tubular BVE)) .
7. Remove the front wheelhouse liner if necessary. Refer to Wheelhouse Panel Replacement (See:
Body and Frame/Fender/Front Fender/Front
Fender Liner/Service and Repair) .
8. Remove the auxiliary heater tubes connector nuts (2) from the intermediate connection point.
9. Remove the auxiliary heater tubes clip push pins (1) from vehicle frame locations.
10. Remove the auxiliary heater tubes (2) from vehicle.
11. Remove auxiliary heater tubes clip retaining push pin/bolt (1) if necessary. 12. Use a flat blade
release tool to open retaining clips (2). 13. Remove auxiliary heater tubes (3) from retaining clips.
Important: The replacement A/C and heater pipes are shipped in front and rear sections.
1. Install the auxiliary heater tubes (3) to the retaining clips (2). 2. Install the auxiliary heater tubes
(3) to the vehicle.
3. Install the auxiliary heater tubes clip push pins (1) to vehicle frame locations.
Notice) .
Important: Use a adjustable wrench or equivalent holding tool at tube connections to prevent
twisting.
Important: Mandatory torque sequence required for proper connections.
4. Install the auxiliary heater tube connection nuts (2) to the intermediate connection point.
Important: Firmly push the quick connect onto the main heater hose connection until you here an
audible click.
5. Install the auxiliary heater tubes (1) to the main heater hose connections. 6. Install the front
wheelhouse liner if necessary. Refer to Wheelhouse Panel Replacement (See: Body and
Frame/Fender/Front Fender/Front Fender
Liner/Service and Repair) .
7. Install the right assist step if necessary. Refer to Assist Step Replacement (w/WS2, BVX) (See:
Body and Frame/Auxiliary Step / Running

8. Lower the vehicle. 9. Fill the engine coolant. Refer to Cooling System Draining and Filling (Static
Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and
System) .
Auxiliary Heater Pipe Replacement - Rear
Removal Procedure
1. Drain the engine coolant. Refer to Cooling System Draining and Filling (Static Fill) (See: Engine,
Cooling System) .

4. Remove the rear wheelhouse liner. Refer to Wheelhouse Panel Replacement (See: Body and
6. Pinch the tabs together at auxiliary HVAC module fittings to remove the auxiliary heater tubes
(1).
7. Remove the heater tubes retaining push pins (1) at the frame locations. 8. Remove the heater
tubes retaining bolt (2) at the frame location. 9. Remove the auxiliary heater tubes (3) from the
frame.
10. Remove the auxiliary heater tubes from the vehicle.
11. Remove auxiliary heater tubes clip retaining push pin/bolt (1) if necessary. 12. Use a flat-bladed
release tool to open retaining clips (2). 13. Remove auxiliary heater tubes from vehicle.
(3) to the vehicle.

Notice) .
3. Install the auxiliary heater tube nut (2).
Tighten the nut to 7 N.m (62 lb in).
4. Install the auxiliary heater tube push pins (1).

5. Install the auxiliary heater tubes (1) to the auxiliary HVAC module.
twisting.
7. Install the rear wheelhouse liner. Refer to Wheelhouse Panel Replacement (See: Body and
Frame/Fender/Front Fender/Front Fender Liner/Service
and Repair) .

10. Fill the engine coolant. Refer to Cooling System Draining and Filling (Static Fill) (See: Engine,
Cooling and Exhaust/Cooling System/Service and
System) .
Hummer Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service
Bulletins > Customer Interest for Hose/Line HVAC: > 08-01-39-002 > Jan > 08 > Interior - Rattle From Right Side of
Instrument Panel
Hose/Line HVAC: Customer Interest Interior - Rattle From Right Side of Instrument Panel
Bulletin No.: 08-01-39-002
TECHNICAL
Subject: Rattle From Right Side Of Instrument Panel Typically Over Bumps (Reposition A/C
Compressor Discharge Line)
Models: 2007-2008 HUMMER H2
Condition
Some customers may comment on a rattle from the right side of the Instrument Panel (IP). The
noise typically occurs when going over bumps.
Cause
This condition may be caused by the discharge line from the Air Conditioning (A/C) compressor to
the condenser touching or close to the front lower inboard corner of the right wheel house panel
near the radiator. When going over bumps the A/C line may touch the wheelhouse panel and
cause a rattle.
Correction
Technicians are to reposition the A/C compressor discharge line as necessary to provide clearance
at the right wheelhouse panel. Create a 13 mm (0.50 in) gap between the line and the wheelhouse
panel. Do not move the line too far or it may touch the radiator vent hose and possibly restrict fluid
flow.

Disclaimer
Hummer Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Hose/Line HVAC: > 08-01-39-002 > Jan > 08 > Interior - Rattle From Right
Side of Instrument Panel
Hose/Line HVAC: All Technical Service Bulletins Interior - Rattle From Right Side of Instrument
Panel
Bulletin No.: 08-01-39-002
TECHNICAL
Subject: Rattle From Right Side Of Instrument Panel Typically Over Bumps (Reposition A/C
Compressor Discharge Line)
Condition
Some customers may comment on a rattle from the right side of the Instrument Panel (IP). The
noise typically occurs when going over bumps.
Cause
This condition may be caused by the discharge line from the Air Conditioning (A/C) compressor to
the condenser touching or close to the front lower inboard corner of the right wheel house panel
near the radiator. When going over bumps the A/C line may touch the wheelhouse panel and
cause a rattle.
Correction
Technicians are to reposition the A/C compressor discharge line as necessary to provide clearance
at the right wheelhouse panel. Create a 13 mm (0.50 in) gap between the line and the wheelhouse
panel. Do not move the line too far or it may touch the radiator vent hose and possibly restrict fluid
flow.
Disclaimer
Hummer Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair >
Procedures
Hose/Line HVAC: Procedures
Tools Required
* Rub-through
* Collision damage

3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: ) . 4. Locate the
area that requires repair. 5. Obtain a length of replacement line to make the repair. 6. Use a tubing
cutter in order to cut and remove the section of damaged line.
line ends.

fitting.
Draining and Filling (Static Fill) (See: Engine, Cooling and Exhaust/Cooling

3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: ) . 4. Obtain a new
A/C or heater line for sectioning.
line to length.
fitting.
System Draining and Filling (Static Fill) (See: Engine, Cooling and Exhaust/Cooling

Hose/Line HVAC: Removal and Replacement
Discharge Hose Replacement
Discharge Hose Replacement
Tools Required
J 39400-A Halogen Leak Detector
Removal Procedure
1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging (See: Heating and Air
Conditioning/Service and Repair/Refrigerant
Recovery and Recharging) .
2. Disconnect the electrical connector from the A/C recirculation switch. 3. Remove the A/C
recirculation switch from the A/C discharge hose.
4. Remove the discharge hose bolt (6) from the A/C compressor (4). 5. Remove the discharge
hose (5) from the A/C compressor (4).
6. Remove the discharge hose nut (1) from the condenser (2). 7. Remove the discharge hose (3)
from the condenser (2). 8. Remove the discharge hose (3) from the vehicle. 9. Discard all of the
used sealing washers.
10. Cap all of the A/C system openings.
1. Install the new sealing washers. Refer to Sealing Washer Replacement (See: Heating and Air
Conditioning/Coupler HVAC/A/C Coupler
O-ring/Service and Repair/Sealing Washer Replacement)
2. Install the discharge hose (3) to the vehicle. 3. Install the discharge hose (3) to the condenser
(2).
4. Install the nut (1) to the condenser (2).
Tighten the nut to 16 N.m (12 lb ft).
5. Install the discharge hose (5) to the A/C compressor (4). 6. Install the discharge hose bolt (6) to
the A/C compressor (4).
7. Install the A/C recirculation switch to the discharge hose (5) . 8. Connect the electrical connector
to the A/C recirculation switch. 9. Evacuate and recharge the A/C system. Refer to Refrigerant
Recovery and Recharging (See: Heating and Air Conditioning/Service and
10. Leak test the fittings of the component using the J 39400-A .
Suction Hose Replacement
Suction Hose Replacement

Tools Required
Removal Procedure
1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging (See: Heating and Air
Conditioning/Service and Repair/Refrigerant
Recovery and Recharging) .
2. Remove the suction hose mounting bolt (2) from the A/C compressor (4). 3. Remove the suction
hose (1) from the A/C compressor (4).
4. Remove the suction hose nut (1) from the accumulator (3). 5. Remove the suction hose (2) from
the accumulator (3). 6. Remove the suction hose (2) from the vehicle. 7. Discard all of the used
sealing washers. 8. Cap all of the A/C system openings.
1. Install the suction hose assembly to the vehicle. 2. Install the new sealing washers. Refer to
Sealing Washer Replacement (See: Heating and Air Conditioning/Coupler HVAC/A/C Coupler
O-ring/Service and Repair/Sealing Washer Replacement) .
3. Install the suction hose (2) to the accumulator (3).

4. Install the suction hose nut (1) to the accumulator (3).
5. Install the suction hose (1) to the compressor (4). 6. Install the suction hose mounting bolt (2) to
the A/C Compressor (4).
7. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging (See:
Heating and Air Conditioning/Service and
Auxiliary Air Conditioning Evaporator Tube Replacement
Auxiliary Air Conditioning Evaporator Tube Replacement

Auxiliary Air Conditioning Evaporator Front Tube Replacement
Auxiliary Air Conditioning Evaporator Front Tube Replacement
Special Tools
Removal Procedure
1. Recover the refrigerant from the system. Refer to Refrigerant Recovery and Recharging (See:
2. Remove the air cleaner resonator outlet duct. Refer to Air Cleaner Resonator Outlet Duct

3. Remove the auxiliary evaporator hose nuts (1) from the main evaporative hose connections. 4.
Separate auxiliary evaporator hoses (3) and O-rings (2).

8. Remove the auxiliary A/C tubes connector nuts (1) from the intermediate connection point.
9. Remove the auxiliary A/C tubes clip push pins (1) from vehicle frame locations.
10. Remove the auxiliary A/C tubes (2) from vehicle.
11. Remove auxiliary A/C tubes clip retaining push pin/bolt (1) if necessary. 12. Use a flat-bladed
release tool to open retaining clips (2). 13. Remove auxiliary A/C tubes from vehicle.
1. Install the auxiliary A/C evaporator tubes (3) to the retaining clips (2). 2. Install the auxiliary A/C
evaporator tubes (3) to the vehicle.
3. Install the auxiliary A/C tubes clip push pins (1) to vehicle frame locations.
4. Install new O-rings with replacement auxiliary A/C tubes. Refer to O-Ring Replacement (See:
Heating and Air Conditioning/Coupler HVAC/A/C
Coupler O-ring/Service and Repair/O-Ring Replacement) .

Notice) .
twisting.
5. Install the auxiliary A/C tube connection nuts (1) to the intermediate connection point.

9. Install the auxiliary evaporator hose nuts (1) to the main evaporative hose connections.
10. Install the air cleaner resonator outlet duct. Refer to Air Cleaner Resonator Outlet Duct
11. Recharge the refrigerant to the system. Refer to Refrigerant Recovery and Recharging (See:
Auxiliary Air Conditioning Evaporator Rear Tube Replacement
Auxiliary Air Conditioning Evaporator Rear Tube Replacement
Special Tools
Removal Procedure
1. Recover the refrigerant from the system. Refer to Refrigerant Recovery and Recharging (See:
2. Drain the engine coolant if necessary. Refer to Cooling System Draining and Filling (Static Fill)
(See: Engine, Cooling and Exhaust/Cooling

6. Remove the auxiliary A/C evaporator tubes connector nuts (1) from the intermediate connection
point. 7. Remove the auxiliary heater tubes connector nuts (2) if necessary.
8. Remove the retaining nut (1) and the auxiliary A/C evaporator tubes (3) from the auxiliary HVAC
module.
9. Remove the heater - A/C tubes retaining push pins (1) at the frame locations.
10. Remove the heater - A/C tubes retaining bolt (2) at the frame location. 11. Remove the auxiliary
A/C evaporator tubes (3) from the frame. 12. Remove the auxiliary A/C evaporator tubes from the
vehicle.
13. Remove auxiliary heater - A/C tubes clip retaining push pin/bolt (1) if necessary. 14. Use a
flat-bladed release tool to open retaining clips (2). 15. Remove auxiliary A/C tubes from vehicle.
1. Install the auxiliary A/C evaporator tubes (3) to the retaining clips (2). 2. Install the auxiliary A/C
evaporator tubes (3) to the vehicle.
Notice) .
3. Install the auxiliary heater - A/C tube nut (2).
4. Install the auxiliary heater - A/C tube push pins (1).
5. Install the auxiliary heater - A/C tubes (3) and the retaining nuts (1) to the auxiliary HVAC
module.

twisting.
8. Install the auxiliary heater - A/C tube connection nuts (1) to the intermediate connection point.
9. Install the auxiliary heater tubes connector nuts (2) if necessary.
and Repair) .

12. Lower the vehicle. 13. Fill the engine coolant. Refer to Cooling System Draining and Filling
(Static Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and
System) .
14. Recharge the refrigerant to the system. Refer to Refrigerant Recovery and Recharging (See:
Hummer Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service
Precautions
Power Steering Line/Hose: Service Precautions
Power Steering Hose Disconnected Notice
Notice: Do not start the vehicle with any power steering gear inlet or outlet hoses disconnected.
When disconnected, plug or cap all openings of components. Failure to do so could result in
contamination or loss of power steering fluid and damage to the system.
Precautions > Page 1629
Power Steering Line/Hose: Service and Repair
Power Steering Gear Inlet Pipe/Hose Replacement
Removal Procedure
1. Remove as much power steering fluid from the power steering reservoir as possible. 2. Remove
Frame/Frame/Skid Plate/Service and Repair
).
3. Place drain pans under the vehicle as needed.
4. Disconnect the power steering gear inlet hose (2) from the power steering pump (1) and discard
the O-ring seal.
5. Disconnect the power steering gear inlet hose from the steering gear and discard the O-ring
seal. 6. Remove the power steering gear inlet hose from the vehicle.
1. Position the power steering gear inlet hose to the vehicle.
Important: Start all power steering gear inlet hose fittings by hand before finalizing any torques.

Notice) .
2. Install a new O-ring seal and connect the power steering gear inlet hose to the steering gear.
Tighten the fitting to 28 N.m (21 lb ft).
3. Install a new O-ring seal and connect the power steering gear inlet hose (2) to the steering pump
(1).
Tighten the fitting to 28 N.m (21 lb ft).

4. Clean any excess power steering fluid from the vehicle and remove any drain pans. 5. Install the
engine protection shield. Refer to Engine Protection Shield Replacement (See: Body and
Frame/Frame/Skid Plate/Service and Repair) . 6. Fill and bleed the power steering system. Refer to
Power Steering System Bleeding (See: Steering and Suspension/Steering/Power Steering/Power
Steering Bleeding/Service and Repair) .

Hummer Workshop Manuals > Maintenance > Hoses > Radiator Hose > Component Information > Service and Repair >
Radiator Inlet Hose Replacement
Radiator Hose: Service and Repair Radiator Inlet Hose Replacement
Removal Procedure
Cooling System) .
3. Reposition the radiator inlet hose clamp (3) from the engine (1). 4. Remove the radiator inlet
hose (2) from the engine (1). 5. Remove the radiator inlet hose (4) from the mounting clip (3).
6. Reposition the radiator inlet hose clamp (5) from the radiator (6). 7. Remove the radiator inlet
hose (4) from the radiator (6). 8. Remove the inlet hose from the vehicle.
1. Install the radiator inlet hose (4) to the radiator (6). 2. Position the radiator inlet hose clamp (5) to
the radiator (6). 3. Install the radiator inlet hose (4) to the mounting clip (3). 4. Install the radiator
inlet hose (2) to the engine (1).
Radiator Inlet Hose Replacement > Page 1636
Position the radiator inlet hose clamp (3) to the engine (1).
6. Fill the cooling system. Refer to Cooling System Draining and Filling (Static Fill) (See: Engine,
System) .
Radiator Hose: Service and Repair Radiator Outlet Hose Replacement
Radiator Outlet Hose Replacement
Removal Procedure
Cooling System) .
3. Reposition the radiator outlet hose clamp (2) from the engine (1). 4. Remove the radiator outlet
hose (3) from the engine (1).
5. Reposition the radiator outlet hose clamp (2) from the radiator (1). 6. Remove the radiator outlet
hose (3) from the radiator (1). 7. Remove the outlet hose from the vehicle.
1. Install the radiator outlet hose (3) to the radiator (1). 2. Position the radiator outlet hose clamp (2)
to the radiator (1).
3. Install the radiator outlet hose (3) to the engine (1). 4. Position the radiator outlet hose clamp (2)
to the engine (1). 5. Install the air cleaner resonator outlet duct. Refer to Air Cleaner Resonator
Outlet Duct Replacement (See: Filters/Air Cleaner Housing/Air
6. Fill the cooling system. Refer to Cooling System Draining and Filling (Static Fill) (See: Engine,
System) .
Hummer Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications
Brake Fluid: Specifications
HYDRAULIC BRAKE SYSTEM

...........................................................................................................................................................
DOT-3 brake fluid.
Hummer Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins >
Cooling System - Updated Leak Detection Dye
Coolant: Technical Service Bulletins Cooling System - Updated Leak Detection Dye
INFORMATION
Subject: DEX-COOL(R) Coolant - New Leak Detection Dye J 46366 - Replaces J 29545-6
Models: 1996-2008 GM Passenger Cars and Light/Medium Duty Trucks* (including Saturn)
1997-2008 Isuzu T-Series Medium Duty Tilt Cab Models Built in Janesville and Flint 1999-2008
Isuzu N-Series Medium Duty Commercial Models with 5.7L or 6.0L Gas Engine
2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X
*EXCLUDING 2006 and Prior Chevrolet Aveo, Epica, Optra, Vivant and Pontiac Matiz, Wave
Supercede:
This bulletin is being revised to include additional model years. Please discard Corporate Bulletin
Leak detection dye P/N 12378563 (J 29545-6) (in Canada P/N 88900915) may cause
DEX-COOL(R) coolant to appear green in a black vessel making it appear to be conventional
(green) coolant. This may cause a technician to add conventional coolant to a low DEX-COOL(R)
system thus contaminating it. The green DEX-COOL(R) appearance is caused by the color of the
leak detection dye which alters the color of the DEX-COOL(R) coolant.
A new leak detection dye P/N 89022219 (J 46366) (in Canada P/N 89022220) has been released
that does not alter the appearance of the DEX-COOL(R) coolant. When adding the new leak
detection dye the color of the DEX-COOL(R) coolant will not change. For detecting leaks on any
system that uses DEX-COOL(R) leak detection dye P/N 89022219 (in Canada P/N 89022220)
should be used. The new leak detection dye can be used with both conventional and
DEX-COOL(R) coolant.
Disclaimer
Hummer Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity
Specifications
Coolant: Capacity Specifications
Cooling System
SUV Model ..........................................................................................................................................

......................................... 16.7 quarts (15.8 liters) SUT Model ...........................................................
........................................................................................................................ 15.4 quarts (14.6 liters)
NOTE: All capacities are approximate. When adding, be sure to fill to the approximate level.
Recheck fluid level after filling.
Hummer Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity
Coolant: Fluid Type Specifications
ENGINE COOLANT The cooling system in your vehicle is filled with DEX-COOL engine coolant.
This coolant is designed to remain in your vehicle for 5 years or 150,000 miles (240 000 km),
whichever occurs first, if you add only DEX-COOL extended life coolant.
A 50/50 mixture of clean, drinkable water and DEX-COOL coolant will: - Give freezing protection
down to -34°F (-37°C). - Give boiling protection up to 265°F (129°C). - Protect against rust and
corrosion. - Help keep the proper engine temperature. - Let the warning lights and gages work as
they should.
NOTICE: Using coolant other than DEX-COOL may cause premature engine, heater core or
radiator corrosion. In addition, the engine coolant may require changing sooner, at 30,000 miles
(50 000 km) or 24 months, whichever occurs first. Any repairs would not be covered by your
warranty. Always use DEX-COOL (silicate-free) coolant in your vehicle.
WHAT TO USE Use a mixture of one-half clean, drinkable water and one-half DEX-COOL coolant
which won't damage aluminum parts. If you use this coolant mixture, you don't need to add
anything else.
CAUTION: Adding only plain water to your cooling system can be dangerous. Plain water, or some
other liquid such as alcohol, can boil before the proper coolant mixture will. Your vehicle's coolant
warning system is set for the proper coolant mixture. With plain water or the wrong mixture, your
engine could get too hot but you would not get the overheat warning. Your engine could catch fire
and you or others could be burned. Use a 50/50 mixture of clean, drinkable water and DEX-COOL
coolant.
NOTICE: If you use an improper coolant mixture, your engine could overheat and be badly
damaged. The repair cost would not be covered by your warranty. Too much water in the mixture
can freeze and crack the engine, radiator, heater core and other parts.
If you have to add coolant more than four times a year, check your cooling system.
NOTICE: If you use the proper coolant, you do not have to add extra inhibitors or additives which
claim to improve the system. These can be harmful.
Hummer Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins >
A/T - Release of DEXRON(R)-VI A/T Fluid
Fluid - A/T: Technical Service Bulletins A/T - Release of DEXRON(R)-VI A/T Fluid
INFORMATION
Date: April 07, 2011
Subject: Release of DEXRON(R)-VI Automatic Transmission Fluid (ATF)
Models:
2008 and Prior GM Passenger Cars and Light Duty Trucks 2003-2008 HUMMER H2 2006-2008
HUMMER H3 2005-2007 Saturn Relay 2005 and Prior Saturn L-Series 2005-2007 Saturn ION
2005-2008 Saturn VUE with 4T45-E 2005-2008 Saab 9-7X Except 2008 and Prior Chevrolet Aveo,
Equinox Except 2006 and Prior Chevrolet Epica Except 2007 and Prior Chevrolet Optra Except
2008 and Prior Pontiac Torrent, Vibe, Wave Except 2003-2005 Saturn ION with CVT or AF23 Only
Except 1991-2002 Saturn S-Series Except 2008 and Prior Saturn VUE with CVT, AF33 or 5AT
(MJ7/MJ8) Transmission Only Except 2008 Saturn Astra
Attention:
DEXRON(R)-VI Automatic Transmission Fluid (ATF) is the only approved fluid for warranty repairs
for General Motors transmissions/transaxles requiring DEXRON(R)-III and/or prior DEXRON(R)
transmission fluids.
Supercede: This bulletin is being revised to update information. Please discard Corporate Bulletin
Number 04-07-30-037D (Section 07 - Transmission/Transaxle).
MANUAL TRANSMISSIONS / TRANSFER CASES and POWER STEERING
The content of this bulletin does not apply to manual transmissions or transfer cases. Any vehicle
that previously required DEXRON(R)-III for a manual transmission or transfer case should now use
P/N 88861800. This fluid is labeled Manual Transmission and Transfer Case Fluid. Some manual
transmissions and transfer cases require a different fluid. Appropriate references should be
checked when servicing any of these components.
Power Steering Systems should now use P/N 9985010 labeled Power Steering Fluid.
Consult the Parts Catalog, Owner's Manual, or Service Information (SI) for fluid recommendations.
Some of our customers and/or General Motors dealerships/Saturn Retailers may have some
concerns with DEXRON(R)-VI and DEXRON(R)-III Automatic Transmission Fluid (ATF) and
transmission warranty claims. DEXRON(R)-VI is the only approved fluid for warranty repairs for
General Motors transmissions/transaxles requiring DEXRON(R)-III and/or prior DEXRON(R)
transmission fluids (except as noted above). Please remember that the clean oil reservoirs of the
J-45096 - Flushing and Flow Tester machine should be purged of DEXRON(R)-III and filled with
DEXRON(R)-VI for testing, flushing or filling General Motors transmissions/transaxles (except as
noted above).
DEXRON(R)-VI can be used in any proportion in past model vehicles equipped with an automatic
transmission/transaxle in place of DEXRON(R)-III (i.e. topping off the fluid in the event of a repair
or fluid change). DEXRON(R)-VI is also compatible with any former version of DEXRON(R) for use
in automatic transmissions/transaxles.
DEXRON(R)-VI ATF
General Motors Powertrain has upgraded to DEXRON(R)-VI ATF with the start of 2006 vehicle
production.
Current and prior automatic transmission models that had used DEXRON(R)-III must now only use
DEXRON(R)-VI.
A/T - Release of DEXRON(R)-VI A/T Fluid > Page 1654
All 2006 and future model transmissions that use DEXRON(R)-VI are to be serviced ONLY with
DEXRON(R)-VI fluid.
DEXRON(R)-VI is an improvement over DEXRON(R)-III in the following areas:
* These ATF change intervals remain the same as DEXRON(R)-III for the time being.
2006-2008 Transmission Fill and Cooler Flushing
Some new applications of the 6L80 six speed transmission will require the use of the J 45096 -
Flushing and Flow Tester to accomplish transmission fluid fill. The clean oil reservoir of the
machine should be purged of DEXRON(R)-III and filled with DEXRON(R)-VI.
Parts Information
Disclaimer
Fluid - A/T: Technical Service Bulletins A/T - Oil Cooler Flush and Flow Essential Tool
INFORMATION
Bulletin No.: 02-07-30-052G
Subject: Automatic Transmission Oil Cooler Flush and Flow Test Essential Tool J 45096
TransFlow(R)
Models:
2011 and Prior Passenger Cars and Light Duty Trucks 2003-2010 HUMMER H2 2006-2010
HUMMER H3 with Automatic Transmission/Transaxle including Allison(R) Transmissions
Bulletin Number 02-07-30-052F (Section 07 - Transmission/Transaxle).
Important All labor operations that include removal of the transmission from the vehicle include
labor time to flush the transmission oil cooler system.
The J 45096 transmission oil cooling system flush and flow test tool replaces current tool J
35944-A. J 45096 is a self-contained unit utilizing a 12-volt flow meter, shop air supply and
DEXRON(R) VI automatic transmission fluid (ATF). In the flush mode, transmission fluid is cycled
through the transmission oil cooling system. High-pressure air is automatically injected into the fluid
stream adding agitation to the ATF oil to enhance the removal of contaminated ATF oil and debris.
In the flow mode, an electronic flow meter is used to measure the flow capability of the ATF oil
cooling system. A digital display indicates the ATF oil flow rate in gallons per minute (GPM) along
with the amount of ATF oil in the supply vessel, supply vessel ATF oil temperature, machine cycles
and the operating mode. The supply oil vessel has 30 L (32 qt) capacity and the waste oil vessel
has 32 L (34 qt) capacity. The waste oil vessel is constructed of a translucent composite material
that allows the user to easily identify the oil level. The waste oil vessel can accommodate vacuum
evacuation and gravity draining. In the code mode, a random, encrypted code is generated that can
be used for verification of flow test results.
Current essential cooler line adapters are used to connect the J 45096 to the automatic
transmission oil cooler lines that allows J 45096 to adapt to General Motors passenger cars and
light duty trucks, current and past models (except the Pontiac Vibe, Wave and Chevrolet Aveo).
The tool may be adapted for use on the Pontiac Vibe, Wave and Chevrolet Aveo by dealership
personnel with a barbed hose connector and rubber hose obtained locally. The
Vibe's/Wave's/Aveo's transmission has a transmission oil requirement which is slightly different
than DEXRON(R) VI ATF. However, flushing the cooler with DEXRON(R) VI automatic
transmission fluid is an acceptable service procedure. Very little fluid remains in the cooler after the
flush procedure and the residual DEXRON(R) VI ATF in the cooler is compatible with the
Vibe's/Wave's/Aveo's transmission fluid.
Notice
Insufficient oil flow through the ATF oil cooling system will cause premature transmission failure.
The required minimum ATF oil flow rate reading is directly related to the supply oil temperature.
Refer to the flow rate reference chart for the oil flow rate specification based on the temperature of
the ATF in the supply vessel.
Helpful Hints for Maintaining the Temperature at or above 18°C (65°F)
Important
- The temperature of the supply vessel oil must be 18°C (65°F) or greater for J 45096 to operate. It
is recommended to store the J 45096 in an area of the dealership where the room temperature
remains at or above 18°C (65°F) when not in use.
- Do not attempt to increase the fluid temperature in the Transflow(R) machine with an engine oil
dipstick, or any other immersion type heater. The Transflow(R) machine has a check valve in the
supply reservoir. Inserting a heater will damage the check valve and the subsequent repair
expense would be the dealer's responsibility.
- A heater blanket, P/N J-45096-10, is available for the Transflow(R) transmission cooling system
flushing tool. This heater fastens around the Transflow(R) internal supply vessel and runs on 110
volts AC. The heater will warm the ATF in the supply vessel to at least 18°C (65° F) and has a
thermostat to hold a constant temperature.
Store the Transmission Cooling System Service Tool, J 45096, Transflow(R) machine in a room
where the temperature is maintained at or above 18°C (65°F).
Keep the ATF level in the reservoir low when the Transmission Cooling System Service Tool, J
45096, Transflow(R), is not in use. Store several gallons of oil in an area where the temperature is
maintained at or above 18°C (65°F). Fill the reservoir of the J 45096 as needed before using the
machine on
each repair.
With the ATF in a tightly sealed container, place the container in a tub of hot water for a period of
time. Then pour the ATF into the reservoir. This method works best with a low fluid level in the
reservoir.
Place the Transflow(R) machine in the direct sunlight with the cabinet door open to expose the
reservoir to the rays of the warm sun.
Flush / Flow Test Procedure
Important All labor operations that include removal of the transmission from the vehicle and require
the transmission oil pan or transmission side cover to be removed include labor time to flush the
transmission oil cooler system.
Refer to SI for Automatic Transmission Oil Cooler Flushing and Flow Test J 45096 for the
appropriate procedure.
Important The J 45096 can be used to flush the transmission oil cooler system on an Allison
equipped vehicle, but the flow meter should not be utilized. Refer to SI for Automatic Transmission
Oil Cooler Flushing and Flow Test J 45096 for the appropriate flow check procedure.
Machine Displays
After completion of the flush and flow test, the following information is to be recorded on the repair
order. This information is displayed on the Transmission Cooling System Service Tool, J 45096,
Transflow(R) machine when the dial is in the code position.
- Tested flow rate (displayed in Gallons Per Minute (GPM)
- Temperature (displayed is degrees Fahrenheit)
- Cycle number (a number)
- Seven digit Alpha/Numeric flow code (i.e. A10DFB2)
Performing a transmission oil cooling system flush and flow test will use between 4.7-7.5 L (5-8 qts)
of DEXRON(R)VI transmission fluid. The amount
of transmission fluid (ATF), (DEXRON(R)VI) (fluid) that is to be charged for the flush portion of the
repair should not exceed the allowable charge for 7.5 L (2 gal) of fluid. This expense should be
shown in the Parts Section of the warranty claim document.
The Seven digit Alpha/Numeric flow code, i.e. A10DFB2, "MUST" be written on the job card and
placed in the comments section of the warranty claim. Any repair that requires the technician to
contact the Product Quality Center (PQC) must also include the seven digit flow code. The agent
will request the seven digit flow code and add the information to the PQC case prior to providing
authorization for the warranty claim.
The Seven digit Alpha/Numeric flow code, i.e. A10DFB2, "MUST" be written on the job card,
entered in the warranty claim labor operation Flush Code additional field (when available) and
Disclaimer
Fluid - A/T: Technical Service Bulletins A/T - Water/Coolant Contamination Information
INFORMATION
Bulletin No.: 08-07-30-035
Subject: Information on Water or Ethylene Glycol in Transmission Oil
with Automatic Transmission
Water or ethylene glycol in automatic transmission fluid (ATF) is harmful to internal transmission
components and will have a negative effect on reliability and durability of these parts. Water or
ethylene glycol in ATF will also change the friction of the clutches frequently resulting in shudder
during engagement or gear changes, especially during torque converter clutch engagement.
Indications of water in the ATF may include:
^ ATF blowing out of the transmission vent tube
^ ATF may appear cloudy or in cases of extreme contamination have the appearance of a
strawberry milkshake
^ Visible water in the oil pan
^ A milky white substance inside the pan area
^ Spacer plate gaskets that appear to be glued to the valve body face or case
^ Spacer plate gaskets that appear to be swollen or wrinkled in areas where they are not
compressed
^ Rust on internal transmission iron/steel components
If water in the ATF has been found and the source of the water entry has not been identified or if a
leaking in-radiator transmission oil cooler is suspected (with no evidence of cross-contamination in
the coolant recovery reservoir), a simple and quick test kit is available that detects the presence of
ethylene glycol in ATF. This kit should obtained and the ATF tested to make an accurate decision
on the need for radiator replacement. This can help to prevent customer comebacks if the
in-radiator transmission oil cooler is leaking and reduce repair expenses by avoiding radiator
replacement if the cooler is not leaking. These test kits can be obtained from:
Nelco Company 1047 McKnight Rd South Saint Paul MN 55119
Orders are shipped standard delivery time but can be shipped on a next day delivery basis for an
extra charge. One test kit will complete 10 individual fluid sample tests. For vehicles repaired under
warranty the cost of the complete test kit plus shipping charges should be divided by 10 and
submitted on the warranty claim as a Net item.
Important:
If water or coolant is found in the transmission, the following components MUST be replaced.
^ Replace all of the rubber type seals.
^ Replace all of the composition-faced clutch plates and/or bands.

^ Replace all of the nylon parts.
^ Replace the torque converter.

^ Thoroughly clean and rebuild the transmission, using new gaskets and oil filter.
^ Flush and flow check the transmission oil cooler using J45096. Refer to Corporate Bulletin
Number 02-07-30-052D or newer - Automatic Transmission Oil Cooler Flush and Flow Test
Essential Tool J45096 TransFlow.
^ Thoroughly inspect the engine cooling system and hoses and clean / repair as necessary.
Disclaimer
Hummer Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity
Specifications
Fluid - A/T: Capacity Specifications
AUTOMATIC TRANSMISSION Pan Removal ....................................................................................

..................................................................................................... 5.7 liters (6.0 quarts) Overhaul ......
..............................................................................................................................................................
......................... 9.9 liters (10.5 quarts) Complete Trans System ........................................................
........................................................................................................... 11.7 liters (12.4 quarts)
NOTE: ALL capacity specifications are approximate. When replacing or adding fluids, fill to the
recommended level and recheck fluid level.
Hummer Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity
Fluid - A/T: Fluid Type Specifications
AUTOMATIC TRANSMISSION FLUID TYPE

............................................................................................................................................ DEXRON
VI
Hummer Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1663
Fluid - A/T: Testing and Inspection
Transmission Fluid Check
This procedure checks the transmission fluid level, as well as the condition of the fluid itself.
Notice: Always use the proper automatic transmission fluid listed. Using incorrect automatic
transmission fluid may damage the vehicle.
Before checking the fluid level, perform the following:
1. Start the engine and park the vehicle on a level surface. Keep the engine running. 2. Apply the
parking brake and place the shift lever in PARK (P). 3. Depress the brake pedal and move the shift
lever through each gear range, pausing for about 3 seconds in each range. Then, move the shift
lever
back to PARK (P).
4. Allow the engine to idle 500-800 rpm for at least 1 minute. Slowly release the brake pedal. 5.
Keep the engine running and observe the transmission fluid temperature (TFT) using the Driver
Information Center (DIC) or a scan tool. 6. Using the TFT reading, determine and perform the
appropriate check procedure. If the TFT reading is not within the required temperature ranges,
allow the vehicle to cool, or operate the vehicle until the appropriate TFT is reached.
Cold Check Procedure
Important: Use this procedure only as a reference to determine if the transmission has enough fluid
to be operated safely until a hot check procedure can be made. The hot check procedure is the
most accurate method to check the fluid level. Perform the hot check procedure at the first
opportunity. Use this cold check procedure to check fluid level when the TFT is between 80°F and
90°F (27°C and 32°C).
1. Locate the transmission dipstick at the rear of the engine compartment, on the passenger's side
of the vehicle. 2. Flip the handle up, and then pull out the dipstick and wipe it with a clean rag or
paper towel. 3. Install the dipstick by pushing it back in all the way, wait three seconds and then
pull it back out again.
Important: Always check the fluid level at least twice. Consistent readings are important to
maintaining proper fluid level. If inconsistent readings are noted, inspect the transmission vent
assembly to ensure it is clean and unclogged.
4. Check both sides of the dipstick, and read the lower level. Repeat the check procedure to verify
the reading. 5. Inspect the color of the fluid on the dipstick. Refer to Fluid Condition Inspection in
this procedure. 6. If the fluid level is below the COLD check band, add only enough fluid as
necessary to bring the level into the COLD band. It does not take much
fluid, generally less than one pint (0.5L). Do not overfill.
7. If the fluid level is in the acceptable range, push the dipstick back in all the way, then flip the
handle down to lock the dipstick in place. 8. Perform a hot check at the first opportunity after the
transmission reaches a normal operating temperature between 160°F to 200°F (71°C to 93°C).
Hot Check Procedure
Important: Us this procedure to check the transmission fluid level when the TFT is between 160°F
and 200°F (71°C and 93°C). The hot check procedure is the most accurate method to check the
fluid level. The hot check should be performed at the first opportunity in order to verify the cold
check. The fluid level rises as fluid temperature increases, so it is important to ensure the
transmission temperature is within range.
the reading. 5. Inspect the color of the fluid on the dipstick. Refer to Fluid Condition Inspection. 6. A
safe operating fluid level is within the HOT crosshatch band on the dipstick. If the fluid level is not
within the HOT band, and the TFT is
between 160°F and 200°F (71°C and 93°C), add or drain fluid as necessary to bring the level into
the HOT band. If the fluid level is low, add only enough fluid to bring the level into the HOT band. It
does not take much fluid, generally less than one pint (0.5L). Do not overfill. Also, if the fluid level is
low, inspect the transmission for leaks. Refer to Fluid Leak Diagnosis (See: Transmission and
Drivetrain/Automatic Transmission/Transaxle/Testing and Inspection/Component Tests and
General Diagnostics/Fluid Leak Diagnosis) .
handle down to lock the dipstick in place. 8. If applicable and if the vehicle is equipped, reset the
transmission oil life monitor only if the fluid was changed.
Fluid Condition Inspection

Inspect the fluid color. The fluid should be red or dark brown.
* If the fluid color is very dark or black and has a burnt odor, inspect the fluid and inside of the
bottom pan for excessive metal particles or other debris. A small amount of "friction" material in the
bottom pan is a "normal" condition. If large pieces and/or metal particles are noted in the fluid or
bottom pan, flush the oil cooler and cooler lines and overhaul the transmission. If there are no signs
of transmission internal damage noted, replace the fluid filter assembly, repair the oil cooler, and
flush the cooler lines.
* Fluid that is cloudy or milky or appears to be contaminated with water indicates engine coolant or
water contamination. Refer to Engine Coolant/Water in Transmission (See: Transmission and
Drivetrain/Automatic Transmission/Transaxle/Testing and Inspection/Symptom Related Diagnostic
Procedures/Engine Coolant/Water in Transmission) .
Fluid - A/T: Service and Repair

Hummer Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications >
Capacity Specifications
Fluid - Differential: Capacity Specifications
DIFFERENTIAL FLUID CAPACITY Front Axle ...................................................................................

.................................................................................................... 1.73 Liters (1.83 Quarts) Rear Axle
..............................................................................................................................................................
.......................... 2.60 Liters (2.75 Quarts)
Hummer Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications >
Capacity Specifications > Page 1671
Fluid - Differential: Fluid Type Specifications
DIFFERENTIAL FLUID TYPE Front / Rear

..............................................................................................................................................................
SAE 75W-90 Synthetic Axle Lubricant
Hummer Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Service and Repair >
Procedures
Fluid - Differential: Procedures
Front Drive Axle
Front Axle Lubricant Level Inspection
1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: ) . 2. Make sure the vehicle is
level. 3. Inspect the front axle for leaks. Repair as necessary. 4. Remove the engine protection
shield (if equipped). Refer to Engine Protection Shield Replacement (See: Body and
Frame/Frame/Skid
Plate/Service and Repair) .
5. Clean the area around the front axle fill plug (1).
6. Remove the front axle fill plug (1). 7. Inspect the oil level.
The oil level should be between 0-10 mm (0-0.375 in) below the fill plug opening.
8. If the level is low, add oil until the level is even with the bottom edge of the fill plug opening. Use
the proper fluid. Refer to Fluid and Lubricant
9. Install the fill plug.
Tighten the plug to 33 N.m (24 lb ft).
10. Install the engine protection shield. Refer to Engine Protection Shield Replacement (See: Body
and Frame/Frame/Skid Plate/Service and Repair) . 11. Lower the vehicle.
Rear Drive Axle
Rear Axle Lubricant Level Inspection

1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: ) . 2. Make sure the vehicle is
level. 3. Inspect the rear axle for leaks. Repair as necessary. 4. Clean the area around the rear
axle fill plug.
5. Remove the rear axle fill plug. 6. Inspect the lubricant level.
The lubricant level should be between 0-10 mm (0-0.4 in) below the fill plug opening.
7. If the level is low, add lubricant until the level is even with the bottom edge of the fill plug
opening. Use the proper fluid. Refer to Fluid and
Lubricant Recommendations (See: ) .
8. Install the rear axle fill plug.
Tighten the rear axle fill plug to 33 N.m (24 lb ft).

Fluid - Differential: Removal and Replacement

Front Drive Axle
Front Axle Lubricant Replacement
Removal Procedure
1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: ) .
2. Remove the front differential carrier shield, if equipped. Refer to Engine Protection Shield
Replacement (See: Body and Frame/Frame/Skid
3. Clean the area around the front axle fill plug and the drain plug. 4. Remove the fill plug (1). 5.
Remove the drain plug (2). 6. Drain the fluid from the front axle differential.
1. Install the drain plug (2).
Tighten the drain plug to 33 N.m (24 lb ft).
2. Fill the front differential with lubricant. Use the proper fluid. Refer to Approximate Fluid
Capacities (See: ) and Fluid and Lubricant
3. Install the fill plug (1).
Tighten the fill plug to 33 N.m (24 lb ft).
4. Install the front differential carrier shield, if equipped. Refer to Engine Protection Shield
Rear Drive Axle
Rear Axle Lubricant Replacement

Removal Procedure
1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: ) .
2. Remove the rear axle fill plug.
3. Remove the rear axle drain plug. 4. Drain the lubricant into a suitable container. 5. Inspect the
drain plug for excessive metal particle accumulation. This accumulation is symptomatic of extreme
wear. 6. Clean the drain plug.

1. Install the rear axle drain plug.
Tighten the rear axle drain plug to 33 N.m (24 lb ft).
2. Fill the rear axle. Use the proper fluid. Refer to Approximate Fluid Capacities (See: ) and Fluid
and Lubricant Recommendations (See: ) .

Hummer Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Specifications >
Capacity Specifications
Fluid - Transfer Case: Capacity Specifications
Transfer Case Fluid .............................................................................................................................

........................................................ 1.5 qt (1.4 liters)
Capacity Specifications > Page 1682
Fluid - Transfer Case: Fluid Type Specifications
TRANSFER CASE FLUID TYPE .........................................................................................................

.......................................................... DEXRON-VI
Page 1683
Fluid - Transfer Case: Service and Repair
Transfer Case Fluid Replacement

Removal Procedure
Important: When performing the following service procedures, use only hand tools to remove and
install the fill or drain plugs.
1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: ) . 2. Remove the fill plug from
the transfer case.
Important: When draining the transfer case, make sure that an approved drain pan is used.
3. Remove the drain plug from the transfer case.

Notice) .
Important: If the drain or fill plug have to be replaced, used only aluminum replacement drain plugs.
1. Apply pipe sealant GM P/N 12346004 (Canadian P/N 10953480) to the threads on the drain
plug. 2. Install the drain plug in the transfer case.
3. Fill the transfer case to the bottom of the fill hole with the proper fluid. 4. Apply pipe sealant GM
P/N 12346004 (Canadian P/N 10953480) to the threads on the drain plug. 5. Install the fill plug.
6. Lower the vehicle. Refer to Lifting and Jacking the Vehicle (See: ) .
Hummer Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins >
Engine - Oil Consumption Verification
Engine Oil: Technical Service Bulletins Engine - Oil Consumption Verification
INFORMATION
Subject: Higher Than Expected Oil Consumption at 8600 GVW and Above
Models: 2000-2009 Chevrolet Express, Silverado, Suburban 2002-2009 Chevrolet Avalanche

2003-2009 Chevrolet Kodiak C4500-C5500 Series Models 2000-2009 GMC Savana, Sierra, Yukon
XL 2003-2009 GMC TopKick C4500-C5500 Series Models 2003-2009 HUMMER H2
with Gasoline Engine and Rated at 8600 GVW and above
Supercede:
This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number
03-06-01-023 (Section 06 - Engine/Propulsion System).
Information on Engine Oil Consumption Guidelines
All engines require oil to lubricate and protect the load bearing and internal moving parts from wear
including cylinder walls, pistons and piston rings. When a piston moves down its cylinder, a thin film
of oil is left on the cylinder wall. During the combustion process, part of this oil layer is consumed.
As a result, varying rates of oil consumption are accepted as normal in all engines.
Oil Consumption
Oil usage has a direct relationship with the amount of fuel used. The harder an engine works, the
more fuel and oil it will use. Therefore, oil usage as a factor of fuel usage is a more accurate
indicator of acceptable oil consumption levels than vehicle mileage for vehicles at or above 8600
GVW.
The accepted rate of oil consumption for gasoline engines in vehicles at or above 8600 GVW is
0.946 liter (1 qt) within 379 liters (100 gallons) of fuel used. This rate only applies to vehicles under
warranty, maintained in accordance with the appropriate maintenance schedule, driven at legal
speeds and within design intent of the vehicle.
Many factors can affect an owner's concern with oil consumption. Driving habits and vehicle
maintenance vary from owner to owner. Thoroughly evaluate each case before deciding whether
the vehicle in question has abnormal engine oil consumption.
Gasket and External Leaks
Inspect the oil pans, engine covers, and the engine oil cooler for leakage. Inspect for oil leakage
into the engine coolant.
Improper Reading of the Oil Level Indicator (Dipstick)
The vehicle must be parked on a level surface to obtain accurate oil level readings. Verify that the
dipstick tube is fully seated in the block. When checking the oil level, make sure the dipstick is
wiped clean before taking an oil level reading and fully depress the dipstick until the shoulder
bottoms out on the dipstick tube. The dipstick should be the proper part number for the
engine/vehicle that is being checked.
Not Waiting Long Enough After Running Engine to Check Oil Level
The vehicle should be allowed to sit for at least 15 minutes, after the engine has been shut off,
before taking an oil level reading to assure the oil has had enough time to drain back into the
crankcase. In order to ensure accurate results, the temperature of the oil should be close to the
same temperature as the last time the oil level was checked.
Improper Oil Fill After an Oil Change
Following an oil change, verify that the proper amount and type of oil was put in the engine and that
the oil level on the dipstick is not above the full mark or below the add marks. Refer to the Owner's
Manual or Service Manual for information on recommended oil quantity, viscosity, and quality.
Engine - Oil Consumption Verification > Page 1688
High Speed or High RPM Driving
Continuous driving at high speeds/high RPMs may increase oil consumption. Because this may not
always be an everyday occurrence, it is hard to determine exactly how much the oil economy will
be affected.
Towing or Heavy Usage
Towing a trailer or hauling additional weight will increase oil consumption. Large frontal area trailers
will further increase the work required from the engine, especially at highway speeds, and thus
increases the rate of oil consumption.
PTO Operation
Operation of a PTO will increase fuel and oil usage, as the PTO driven accessory uses engine
power to operate.
Crankcase Ventilation System
Verify that the positive crankcase ventilation (PCV) system is operating properly. Blockages,
restrictions or damage to the PCV system can result in increased oil use.
Oil Dilution from Condensation
On vehicles that are usually driven short distances, less than 8 km (5 mi), especially in colder
weather, condensation generated from cold engine operation may not get hot enough to evaporate
out of the oil. When this occurs, the dipstick may indicate that the oil level is over-full. Subsequent
driving on a trip of sufficient length to enable normal engine operating temperature for 30 minutes
or more, in order to vaporize excess moisture, may give the customer the impression of excessive
oil consumption.
Engine Temperature
If an engine is run at overheated temperatures (see Owner's Manual or Service Manual) for more
than brief periods, oil will oxidize at a faster than normal rate. In addition, gaskets may distort,
piston rings may stick, and excessive wear may result. Verify that all cooling system components
are in proper working order.
Engine Wear
Piston scuffing, excessive piston-to-wall clearance, tapered or out of round cylinders, worn,
damaged or improperly installed valve guides, seals and piston rings will all cause an increase in
oil consumption.
Measurement of Oil Consumption
Engines require a period of time to BREAK IN so that moving parts are properly seated. Therefore,
oil economy should not be tested until the vehicle has accumulated at least 8000 km (5000 mi) and
the oil has been changed for the first time. During initial engine break-in periods before the first oil
change, oil consumption may exceed 1.9 liters (2 quarts) or more per 379 liters (100 gallons) of fuel
used.
1. Verify that the engine has no external leaks. Repair as necessary.
2. Begin oil consumption test after next regularly scheduled oil and filter change. Oil changes
should not be performed during the test.
3. Verify that the engine is at normal operating temperature (see Owner's Manual or Service
Manual).
4. Park the vehicle on a level surface.
5. Wait at least 15 minutes, after the engine is shut off, before checking the oil level to make sure
that most of the oil has had time to drain back into the crankcase.
6. Verify that the oil level is at, but not above, the full mark on the dipstick and that the proper
viscosity and quality oil are being used as recommended in the Owner's Manual.
7. Dealer should record the vehicle mileage, date and engine hours at the start of the test on the
form shown above.
8. Ask the customer to verify and record the date, odometer, oil level, fuel added, and engine
hours, each time the vehicle is fueled, following steps
3-5 and return the vehicle to the dealership if the oil level is found at or below the add mark, 0.946
liter (1 qt) low, if possible. The dealer will add oil to return the oil level to full. If the oil level remains
above the add mark, the customer should continue to operate the vehicle and verify the engine oil
level until either the oil level drops to or below the add mark or at least 4800 km (3000 mi) has
accumulated since the test began before returning to the dealership for a final evaluation.
9. If the final evaluation shows that the engine uses more than 0.946 liter (1 qt) in 379 liters (100
gallons) of fuel used, follow the published symptom diagnostics as described in the appropriate
Service Manual. If the oil consumption test shows that the engine uses less than 0.946 liter (1 qt) in
379 liters (100 gallons) of fuel used, explain to the customer that their engine meets the guidelines
for oil consumption.
Disclaimer
Engine Oil: Technical Service Bulletins Engine - Oil Consumption Guideline Information
INFORMATION
Subject: Information on Engine Oil Consumption Guidelines
Models: 1998-2009 GM Passenger Cars and Gasoline Powered Light Duty Trucks Under 8500 LB
GVW (Including Saturn)
Supercede:
This bulletin is being revised to update model years. Please discard Corporate Bulletin Number
01-06-01-011D (Section 06 - Engine/Propulsion System).
of oil is left on the cylinder wall. During the power stroke, part of this oil layer is consumed in the
combustion process. As a result, varying rates of oil consumption are accepted as normal in all
engines.
Oil Consumption
The accepted rate of oil consumption for engines used in the vehicles referenced is 0.946 liter (1
qt) in 3200 km (2000 mi).
Important:
Certain models have a new GM Extended Warranty. Please refer to the appropriate Owner's
Manual for warranty information.
This rate only applies to personal use vehicles, under warranty, that are driven in a non-aggressive
manner and maintained in accordance with the appropriate maintenance schedule, with less than
58,000 km (36,000 mi), or 80,450 km (50,000 mi) for Cadillac, driven at legal speeds in an
unloaded (for trucks) condition.
Important:
This rate does not apply to vehicles that are driven in an aggressive manner, at high RPM, high
speeds, or in a loaded condition (for trucks). Oil consumption for vehicles driven under these
conditions will be more.
Many factors can affect a customer's concern with oil consumption. Driving habits and vehicle
Inspect the oil pan and engine covers for leakage due to over-tightened, damaged, or out of place
gaskets. Inspect oil lines and fittings for signs of leakage.
Verify that the dipstick tube is fully seated in the block. When checking the oil level, make sure the
dipstick is wiped clean before taking an oil level reading and fully depress the dipstick until the
shoulder bottoms out on the dipstick tube. The dipstick should be the proper part number for the
Notice:
Operating your vehicle with an oil level that is below the minimum level indicated on the engine oil
dipstick can result in severe engine damage. Repairs resulting from operating an engine with
insufficient oil are not covered under the terms of the New Vehicle Warranty.
Important:
Refer to Owner Manual in SI for checking and adding engine oil.
Some engines require more time than others for the oil to drain back into the crankcase. To assure
a sufficient amount of oil has drained back to the crankcase, and an accurate reading can be
obtained, the vehicle should be allowed to sit for at least 15 minutes, after the engine has been
shut off, before taking an oil level reading. In order to ensure accurate results, the temperature of
the oil should be close to the same temperature as the last time the oil level was checked.
Important:
This does not apply to some Corvette ZO6 equipped with the 7.0L LS7 engine (dry sump). Follow
the instructions in the Owner's Manual for checking the oil in this application.
Aggressive Driving, High Speed or High RPM Driving
Aggressive driving and/or continuous driving at high speeds/high RPMs will increase oil
consumption. Because this may not always be an everyday occurrence, it is hard to determine
exactly how much the oil economy will be affected.
A higher rate of oil consumption is normal for vehicles equipped with manual transmissions that are
driven aggressively. By "aggressive," we mean operation at high RPM (3,000 RPM to redline), with
frequent use of engine braking (using the engine to slow the vehicle). Vehicles that are driven
aggressively may consume engine oil at a rate of up to 0.946 L (1 quart) every 805 km (500 mi).
This is normal for a vehicle that is driven aggressively. No repair is necessary. This characteristic
does, however, require the owner to check the engine oil level at sufficiently frequent intervals,
especially when driving aggressively, to assure the oil level remains within the recommended
operating range. As the Owner's Manual recommends, you should check the oil level every time
you get fuel.
Towing a trailer will increase oil consumption and may cause oil consumption to fall below the
normal accepted rate referenced in this bulletin for an unloaded vehicle in a personal use
application. Large frontal area trailers will further increase the work required from the engine,
especially at highway speeds, and thus increases the rate of oil consumption.
restrictions, or damage to the PCV system can result in increased oil use.
Oil Dilution (Fuel and Water)
weather, unburned fuel and condensation generated from cold engine operation may not get hot
enough to evaporate out of the oil. When this occurs, the dipstick may indicate that the oil level is
over-full. Subsequent driving on a trip of sufficient length to enable normal engine operating
temperature for 30 minutes or more, in order to vaporize excess moisture and fuel, may give the
customer the impression of excessive oil consumption.
Engine Temperature
Engine Wear
oil consumption.
oil economy should not be tested until the vehicle has accumulated at least 6400 km (4000 mi). An
exception would be allowed only if an engine is reported to be using more than 0.946 liter (1 qt) in
1600 km (1000 mi).
Manual).
that the oil has had time to drain back into the crankcase.
5. Verify that the oil level is at, but not above, the full mark on the dipstick, and that the proper
6. Record the vehicle mileage, date, and exact oil level on the form shown above.
7. Ask the customer to verify the oil level, each time the vehicle is fueled, following steps 16 and
return the vehicle to the dealership if the oil level is found at or below the add mark, 0.946 liter (1
qt) low. If the oil level remains above the add mark, the customer should continue to operate the
vehicle and verify the engine oil level until 3200 km (2000 mi) has accumulated before returning to
the dealership for a final evaluation.
8. If the final evaluation shows that the engine uses more than 0.946 liter (1 qt) in 3200 km (2000
mi), follow the published symptom diagnostics as described in the appropriate Service Manual. If
the oil consumption test shows that the engine uses less than 0.946 liter (1 qt) in 3200 km (2000
mi), explain to the customer that their engine meets the guidelines for oil consumption.
Disclaimer
Engine Oil: Technical Service Bulletins Engine/Fuel System - Additive Information
INFORMATION
Date: June 17, 2008
Subject: Fuel and Oil Additives - Facts and Myths/Maximizing Fuel Economy
Models: 2009 and Prior GM Passenger Cars and Trucks (including Saturn) 2009 and Prior
HUMMER H2, H3 2009 and Prior Saab 9-7X
Attention:
Please direct this bulletin to the Service Manager, the Service Consultants and the Sales Staff. A
copy of this bulletin is encouraged to be given to your customer as it is written with the consumer in
mind. You may also post this bulletin in your customer lounge or waiting area.
Supercede:
Number 05-00-89-072A (Section 00 - General information).
A Statement About Fuel Economy
As gasoline prices have increased, the consumer has shifted priorities to become increasingly
concerned with fuel consumption. GM is presently proud to offer over 30 cars in the U.S. with EPA
highway estimates of at least 30 mpg. In Canada, vehicles are rated for fuel consumption in liters
per 100 kilometers. GM offers over 20 vehicles in Canada that consume less than 7.0 L/100 km on
the highway. The information below contains reasonable and prudent advice for your dealership
and the consumer to get the most from every gallon or liter of gas.
The information below is presented in two easy to understand sections:
^ What Not To Do: Engine and Fuel Additives, Alternate Fuels, and "Miracle" Products
^ What to Do: Maximizing Fuel Economy/Minimizing Costs
WHAT NOT TO DO: Engine and Fuel Additives, Alternate Fuels, and "Miracle" Products
Various unproven products with claims to improve vehicle fuel economy have been reported
ranging from magnets that align molecules to chemical combustion improvers.
Most products claiming to provide benefits are based on unsubstantiated claims. Those that do
present "scientific" results generally either have too little supporting data to be conclusive, have not
conducted experiments in a controlled fashion, or cannot be substantiated by anyone else but the
product's manufacturer.
The U.S. Federal Trade Commission summarizes results for products tested by the federal
government at www.ftc.gov/bcp/edu/pubs/consumer/autos/aut10.shtm. A review of the list shows
that the majority did not work, and for those that showed some effect, the benefit was too small to
be cost effective.
Harmful Ideas That May Damage Your Vehicle and Increase Emissions
One more recent poor idea to improve fuel economy that should not be attempted is to blend either
kerosene or diesel fuel into gasoline. Why? Both kerosene and diesel fuel are distillate fuels meant
for use in compression ignition engines, not spark ignition engines. They have very low octane and
since they are heavier (higher density) than gasoline, they will cause heavy engine deposits and
degradation of engine oil.
Notice:
Never put Kerosene or Diesel Fuel in your Gasoline Engine vehicle. This may result in inconsistent
performance and permanent damage to your vehicle that is not covered by your New Vehicle
Warranty.
Chemicals that are normally used as solvents also should not be used. These include acetone,
ketones, and methanol. These solvents can be incompatible with your vehicles rubber or sealing
components, and may dissolve the vehicle's paint finish. In the case of methanol, corrosion of
metal parts in the fuel system also may occur.
Notice:
Never use acetone, ketones, or methanol additives in your vehicle. Some of these solvents may
damage or corrode your fuel system. They are also very damaging to the painted surfaces of the
vehicle if spilled. Damage to vehicle components that result from non-approved or aftermarket
additives and devices are not covered under the terms of the New Vehicle Warranty. The only fuel
additive currently approved by GM is GM Fuel System Treatment Plus, P/N 88861011 (in Canada,
# 88861012).
WHAT TO DO: Maximizing Fuel Economy/Minimizing Costs
The best fuel economy possible is the direct result of proper maintenance and good driving habits.
Listed below are GM's recommendations to achieve the best mileage possible. The first group are
things to consider for your vehicle, while the second are tips relating to your driving habits.
Vehicle Considerations:
^ Tire Pressure - One of the major contributors to poor fuel economy are under inflated tires. Tires
low on pressure create drag that the vehicle's powertrain must overcome, wasting dollars in fuel.
Always keep your tires inflated to the proper pressure as shown on the vehicle placard. This not
only serves to increase gas mileage but cuts down on tire wear, further decreasing your costs per
mile.
^ Air Filter - A vehicle that has a dirty air filter can't efficiently draw air into the engine. This
restriction forces the engine to expend energy to "breathe" wasting fuel in the process. Change
recommendations are found in your vehicle Owner's Manual.
^ Proper Viscosity "Starburst" Rated Oil - Always use the proper viscosity oil in your engine. Oil that
has a higher than required viscosity will create more drag on the internal components of the
engine, causing more work for it, especially when cold. Each Owner's Manual contains information
on the proper type of oil for your vehicle. Look for the "starburst" symbol on the front of the bottle,
and the SM rating on the API circle on the back label. If you are in doubt, stop by your dealer for an
oil change, and any other services required. Most current GM vehicles are equipped with oil life
monitors to further assist on the "when" to change your oil. (Aveo/Wave/Optra/Epica currently do
not have oil life monitors).
Notice:
GM Vehicles DO NOT require additional engine oil additives. Some additives may cause harmful
effects to the internal seals and additionally void the terms of your vehicles New Car Warranty.
^ Top Tier Fuels - Some fuel manufacturers provide gasoline advertised as TOP TIER
DETERGENT GASOLINE (Chevron, Conoco, Phillips 66, Shell, Texaco, Entec Stations, MFA Oil
Company, 76, Somerset Oil, Aloha Petroleum, Tri-Par Oil Company, QuikTrip, and Kwik Trip) in the
U.S. and (Petro-Canada, Chevron, Shell, and Sunoco) in Canada. These fuels are preferable when
and where available. They help to keep your fuel injectors and intake valves free of deposits. Clean
engines provide optimal fuel economy, performance and reduced emissions. When Top Tier fuels
are not available, consider a bottle of GM Fuel System a bottle of GM Fuel System treatment
PLUS, P/N# 88861011 (in Canada, # 88861012), at oil change time which will remove intake
system and injector deposits. GM does not recommend any other fuel system cleaner.
Important:
DO NOT confuse Top Tier Fuels with Higher Octane (Plus/Premium Grade Fuel) commonly sold at
most all gas stations. Plus and Premium fuels are required in some high performance GM vehicles.
However, they do not necessarily represent higher detergency present in TOP TIER Detergent
Gasoline.
Important:
For additional information regarding Top Tier fuels and availability, please refer to Corporate
Bulletin Number 04-06-04-047G for U.S. or 05-06-04-022D for Canada.
Notice:
E85 FUELS: Only vehicles designated for use with E85 should use E85 blended fuel. E85
compatibility is designated for vehicles that are certified to run on up to 85% ethanol and 15%
gasoline. All other gasoline engines are designed to run on fuel that contains no more than 10%
ethanol. Use of fuel containing greater than 10% ethanol in non-E85 designated vehicles can
cause driveability issues, service engine soon indicators as well as increased fuel system
corrosion. See Corporate Bulletin Number 05-06-04-035C for additional information.
^ Use the Recommended Grade (Octane) Fuel
Purchasing higher than required octane fuel is a waste of money. Using higher octane fuels in a
vehicle that only required regular unleaded fuel will neither increase performance nor improve gas
mileage. In all cases refer to your owners manual and ONLY use the octane rated fuel
recommended for your vehicle.
Important:
In high performance GM vehicles that DO require Premium (91 octane or higher) fuel, you MUST
use fuels of at least this octane. Use of lower octane fuel may result in reduced performance,
knocking, and/or permanent engine damage not covered under the terms of the New Vehicle
Warranty.
^ Check Engine/Service Engine Soon Light - Is the Check Engine/SES light on? When this light is
on, the vehicles On-Board diagnostics computer has noticed that something is wrong. GM vehicles
have many sensors that the computer uses to both control and sense actual fuel usage. When the
computer lights the Check Engine/SES light it has lost some ability to run efficiently. This may
result in increased fuel consumption, increased emissions, and/or driveability concerns.
^ Spark Plugs - Even though most current GM vehicles have 160,000 km (100,000 mi) service
intervals for spark plugs, if your vehicle is at that point in its life, have the spark plugs changed to
assure proper running and continued efficient, trouble free operation. Refer to the applicable
Maintenance Schedule for spark plugs service intervals on Chevrolet Aveo, Optra, Epica, Pontiac
Vibe, Wave and Saturn Astra.
Changes In Driving Habits:
^ Slow Down, Drive Smoothly - Avoid quick/full throttle acceleration from a standstill in town and
high cruising speeds on the interstates. While the optimum MPG for highway cruising speed varies
from vehicle to vehicle, faster is almost always worse. If your vehicle is equipped with a Driver
Information Center that displays Instant Fuel Economy, select that read out and vary your cruising
speed while on the highway. The display will change continuously with uphill and downhill sections
but you should quickly be able to identify on level ground the speed range that your vehicle does
the best in.
^ Empty Your Trunk - Avoid leaving unnecessary items in your trunk. It takes power to move
increased weight and that means more gasoline consumption and reduced performance. While the
change may be slight, multiplied by thousands of miles, it all adds up.
^ Avoid Extended Idling - There is no need to idle your engine till it reaches operating temperature.
Idling wastes fuel.
^ Combine Trips - Your vehicle uses much more fuel when the engine is cold. This is especially
true in the winter months when the engine will take the longest to warm up. Combine errands or
trips so that the vehicle only needs to warm up once to encompass many different stops.
Disclaimer
Hummer Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity
Specifications
Engine Oil: Capacity Specifications
LUBRICATION SYSTEM
Oil Capacity
with Filter .............................................................................................................................................

..................................... 5.68 liters (6.0 quarts)
Oil Capacity
without Filter ........................................................................................................................................

..................................... 5.20 liters (5.5 quarts)
Hummer Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity
Engine Oil: Fluid Type Specifications
ENGINE OIL TYPE ..............................................................................................................................

..................................................................... 5W-30
LOOK FOR TWO THINGS: 1. Your vehicle's engine requires oil meeting GM Standard GM6094M.
2. SAE 5W-30 is best for your vehicle. These numbers on an oil container show its viscosity, or
thickness. Do not use other viscosity oils such as SAE 20W-50. Oils meeting these requirements
should also have the starburst symbol on the container. This symbol indicates that the oil has been
certified by the American Petroleum Institute (API). You should look for this information on the oil
container, and use only those oils that are identified as meeting GM Standard GM6094M and have
the starburst symbol on the front of the oil container.
NOTICE: Use only engine oil identified as meeting GM Standard GM6094M and showing the
American Petroleum Institute Certified For Gasoline Engines starburst symbol. Failure to use the
recommended oil can result in engine damage not covered by your warranty.
GM Goodwrench oil meets all the requirements for your vehicle.
If you are in an area of extreme cold, where the temperature falls below -20°F (-29°C), it is
recommended that you use either an SAE 5W-30 synthetic oil or an SAE 0W-30 oil. Both will
provide easier cold starting and better protection for your engine at extremely low temperatures.
ENGINE OIL ADDITIVES Do not add anything to your oil. The recommended oils with the starburst
symbol that meet GM Standard GM6094M are all you will need for good performance and engine
protection.
Hummer Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Page 1700
Engine Oil: Service and Repair
Removal Procedure
Lifting and Jacking the Vehicle (See: ) . 4. Place a oil drain pan under the oil pan drain plug. 5.
Remove the oil pan drain plug. 6. Drain the engine oil. 7. Wipe the excess oil from the drain plug
hole and plug.

Hummer Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Page 1701
Approximate Fluid Capacities (See: ) and Fluid and Lubricant

Hummer Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Specifications
Power Steering Fluid: Specifications
POWER STEERING SYSTEM GM Power Steering Fluid

....................................................................................................................................................... P/N
89021184 or equivalent. Canadian ......................................................................................................
............................................................................. P/N 89021186 or equivalent.
Hummer Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins
> A/C - Refrigerant Recovery/Recharge Equipment Info
Refrigerant: Technical Service Bulletins A/C - Refrigerant Recovery/Recharge Equipment Info
Bulletin No.: 08-01-38-001
INFORMATION
Subject: Information On New GE-48800 CoolTech Refrigerant Recovery/Recharge Equipment
Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2008 and
Prior HUMMER H2, H3 2005-2008 Saab 9-7X
Attention:
This bulletin is being issued to announce the release of GM approved Air Conditioning (A/C)
Refrigerant Recovery and Recharging Equipment that meets the new Society of Automotive
Engineers (SAE) J2788 Refrigerant Recovery Standards. The ACR2000 (J-43600) cannot be
manufactured in its current state after December 2007 and will be superseded by GE-48800.
The new J2788 standard does not require that GM Dealers replace their ACR2000 units.
ACR2000's currently in use are very capable of servicing today's refrigerant systems when used
correctly and can continue to be used. Details regarding the new SAE J2788 standard are outlined
in GM Bulletin 07-01-38-004.
Effective February 1 2008, new A/C Refrigerant Recovery/Recharging equipment (P/N GE-48800)
will be released as a required replacement for the previously essential ACR2000 (J-43600). This
equipment is SAE J2788 compliant and meets GM requirements for A/C Refrigerant System
Repairs on all General Motors vehicles, including Hybrid systems with Polyolester (POE)
refrigerant oil. This equipment will not be shipped as an essential tool to GM Dealerships.
In addition, this equipment is Hybrid compliant and designed to prevent oil cross contamination
when servicing Hybrid vehicles with Electric A/C Compressors that use POE refrigerant oil.
The ACR2000 (J-43600) will need to be retrofitted with a J-43600-50 (Hose - ACR2000 Oil Flush
Loop) to be able to perform Hybrid A/C service work. All Hybrid dealers will receive the J-43600-50,
with installation instructions, as a component of the Hybrid essential tool package. Dealerships that
do not sell Hybrids, but may need to service Hybrids, can obtain J-43600-50 from SPX Kent Moore.
Refer to GM Bulletin 08-01-39-001 for the ACR2000 Hose Flush procedure.
The High Voltage (HV) electric A/C compressor used on Two Mode Hybrid vehicles uses a
Polyolester (POE) refrigerant oil instead of a Polyalkylene Glycol (PAG) synthetic refrigerant oil.
This is due to the better electrical resistance of the POE oil and its ability to provide HV isolation.
Failure to flush the hoses before adding refrigerant to a Hybrid vehicle with an electric A/C
compressor may result in an unacceptable amount of PAG oil entering the refrigerant system. It
may cause a Battery Energy Control Module Hybrid Battery Voltage System Isolation Lost
Diagnostic Trouble Code (DTC P1AE7) to be set. Additionally, the A/C system warranty will be
voided.
Warranty Submission Requirements
The Electronically Generated Repair Data (snapshot summary) and printer functions have been
eliminated from the GE-48800. The VGA display and temperature probes were eliminated to
reduce equipment costs. As a result, effective immediately the 18 digit "Snapshot/Charge
Summary" code is no longer required for Air Conditioning (A/C) refrigerant system repairs that are
submitted for warranty reimbursement. The charge summary data from before and after system
repairs will continue to required, but documented on the repair order only. Both high and low
pressures and the recovery and charge amounts should be noted during the repair and entered on
the repair order. If using ACR2000 (J-43600), the "Snapshot/Charge Summary" printouts should
continue to be attached to the shops copy of the repair order.
The labor codes that are affected by this requirement are D3000 through D4500.
Disclaimer
Hummer Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity
Specifications
Refrigerant: Capacity Specifications
Refrigerant System Capacities

Hummer Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity
Refrigerant: Fluid Type Specifications

Hummer Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity
Specifications
Refrigerant Oil: Capacity Specifications

Hummer Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity
Refrigerant Oil: Fluid Type Specifications

Hummer Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Antilock Brake
System Automated Bleed Procedure
Brake Bleeding: Service and Repair Antilock Brake System Automated Bleed Procedure
Antilock Brake System Automated Bleed Procedure Caution: Refer to Brake Fluid Irritant Caution
(See: Brakes and Traction Control/Service Precautions/Technician Safety Information/Brake Fluid
Irritant Caution) .
Caution: Do not remove the reservoir cap while depressing and releasing the brake pedal. If the
cap is removed while depressing and releasing the brake pedal, pressurized brake fluid being
returned to the reservoir may leave the reservoir. Personal injury or vehicle damage could result.
Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11(R),
GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed
brake fluid container. The use of any type of fluid other than the recommended type of brake fluid,
may cause contamination which could result in damage to the internal rubber seals and/or rubber
linings of hydraulic brake system components.
Notice: Do Not allow the HBCi pump and motor to run more than 1 minute continuously. Allow 2
minutes cool down time between pump run times. Extended pump and motor run time could create
excessive heat, and damage the pump and motor assembly.
Important: Perform steps 1-4 below to bleed the HBCi accumulator circuit prior to performing a
base brake bleed.
1. Turn the ignition ON. Allow the pump and motor to run as required. The pump and motor will
stop automatically, and may run up to 10 seconds. 2. Depress the brake pedal 4 times. 3. Confirm
that brake fluid returns to the reservoir. 4. Repeat steps 1-3 until all air is purged from the
accumulator circuit (return fluid is clear and free from air).
Important: The base hydraulic brake system must be bled before proceeding. If you have not yet
performed the base hydraulic brake system bleeding procedure, refer to Hydraulic Brake System
Bleeding (Manual) (See: Hydraulic Brake System Bleeding (Manual)) Hydraulic Brake System
Bleeding (Pressure) (See: Hydraulic Brake System Bleeding (Pressure)) for hydraulic brakes
before proceeding.
5. Turn the ignition OFF, wait 15 seconds then depress and release the brake pedal 20 times to
deplete accumulator pressure. If the brake fluid clouds
and has air mixed with the fluid, wait until the fluid clears to proceed.
6. Turn the ignition ON and depress the pedal 20 times quickly. The pump and motor will be
activated. 7. Turn the ignition OFF, wait 15 seconds and repeat step 5 again. If the brake fluid
clouds and has air mixed with the fluid, wait until the fluid clears
to proceed.
8. Turn the ignition ON to activate the pump and motor. Allow the pump and motor to stop
automatically. The pump and motor will run about 10
seconds.
9. Install a scan tool to the vehicle.
10. Start the engine and allow the engine to idle. 11. Depress the brake pedal firmly and maintain
steady pressure on the pedal. 12. Using the scan tool, begin the automated bleed procedure. 13.
Follow the instructions on the scan tool to complete the automated bleed procedure. Release the
brake pedal between each test sequence. 14. Turn the ignition OFF. 15. Remove the scan tool
from the vehicle. 16. Fill the brake master cylinder reservoir to the maximum-fill level with Delco
Supreme11(R) GM P/N 12377967 (Canadian P/N 992667) or
equivalent DOT-3 brake fluid from a clean, sealed brake fluid container.
Hydraulic Brake System Bleeding (Manual)
)Hydraulic Brake System Bleeding (Pressure) (See: Hydraulic Brake System Bleeding (Pressure))
for hydraulic brakes.
18. With the ignition OFF, wait 15 seconds apply the brakes 20 times, or until the brake pedal
becomes firm, in order to deplete the brake booster
power reserve.
19. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 20. If the
pedal feels spongy, repeat the automated bleeding procedure. If the brake pedal still feels spongy
after repeating the automated bleeding
procedure inspect the brake system for external leaks. Refer to Brake System External Leak
Inspection (See: Brakes and Traction Control/Hydraulic System/Testing and Inspection/Component
Tests and General Diagnostics/Brake System External Leak Inspection) .
21. Turn the ignition key ON, with the engine OFF; check to see if the brake system warning lamp
remains illuminated. 22. If the brake system warning lamp remains illuminated, DO NOT allow the
vehicle to be driven until it is diagnosed and repaired. Refer to
Symptoms - Hydraulic Brakes (See: Brakes and Traction Control/Hydraulic System/Testing and
Inspection/Symptom Related Diagnostic Procedures/Symptoms - Hydraulic Brakes) .
23. Drive the vehicle to exceed 13 kph (8 mph) to allow ABS initialization to occur. Observe brake
peal feel. 24. If the brake pedal feels spongy, repeat the automated bleeding procedure until a firm
brake pedal is obtained.
System Automated Bleed Procedure > Page 1721
Brake Bleeding: Service and Repair Hydraulic Brake System Bleeding (Manual)
Hydraulic Brake System Bleeding (Manual) Caution: Refer to Brake Fluid Irritant Caution (See:
Brakes and Traction Control/Service Precautions/Technician Safety Information/Brake Fluid Irritant
Caution) .
1. Place a clean shop cloth beneath the brake master cylinder to prevent brake fluid spills. 2. If you
disconnected the brake pipes from the master cylinder, you must perform the following steps:
1. Ensure that the brake master cylinder reservoir is full to the maximum-fill level. If necessary add
Delco Supreme 11(R), GM P/N 12377967
(Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container.
If removal of the reservoir cap and diaphragm is necessary, clean the outside of the reservoir on
and around the cap prior to removal.
2. With all brake pipes installed securely to the master cylinder, loosen and separate the left front
brake pipe (4) from the brake master cylinder. 3. Allow a small amount of brake fluid to gravity
bleed from the open port of the master cylinder. 4. Connect the brake pipe to the master cylinder
port and tighten securely. 5. Have an assistant slowly depress the brake pedal fully and maintain
steady pressure on the pedal. 6. Loosen the same brake pipe to purge air from the open port of the
master cylinder. 7. Tighten the brake pipe, then have the assistant slowly release the brake pedal.
8. Wait 15 seconds, then repeat steps 2.5-2.7 until all air is purged from the same port of the
master cylinder. 9. With the left front brake pipe (4) installed securely to the master cylinder, after
all air has been purged from the front port of the master
cylinder, loosen and separate the right front brake pipe (3) from the master cylinder, then repeat
steps 2.5-2.8.
10. Turn the ignition key to the ON position. 11. With the right front brake pipe (3) installed securely
to the master cylinder, after all air has been purged from the right front port of the master
cylinder, loosen and separate the left rear brake pipe (1) from the master cylinder, then repeat
steps 2.5-2.8.
12. With the left rear brake pipe (1) installed securely to the master cylinder, after all air has been
purged from the left rear port of the master
cylinder, loosen and separate the right rear brake pipe (2) from the master cylinder, then repeat
steps 2.5-2.8.
13. After completing the final master cylinder port bleeding procedure, ensure all of the brake pipe
fittings are properly tightened. 14. Turn the ignition key to the OFF position, wait 15 seconds then
depress and release the brake pedal 20 times.
3. Fill the brake master cylinder reservoir with Delco Supreme 11(R), GM P/N 12377967 (Canadian
P/N 992667), or equivalent DOT-3 brake fluid
from a clean, sealed brake fluid container. Ensure that the brake master cylinder reservoir remains
at least half-full during this bleeding procedure. Add fluid as needed to maintain the proper level.
Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and
diaphragm.
4. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve. 5.
Install a transparent hose over the end of the bleeder valve. 6. Submerge the open end of the
transparent hose into a transparent container partially filled with Delco Supreme 11(R), GM P/N
12377967
7. Have an assistant turn the ignition ON, then partially apply and hold the brake pedal. DO NOT
pump the brake pedal. Fluid will flow when the
bleed valves are opened.
8. Loosen the bleeder valve to purge air from the wheel hydraulic circuit. 9. Tighten the bleeder
valve, then have the assistant slowly release the brake pedal.
10. Wait 15 seconds, then repeat steps 7-9 until all air is purged from the same wheel hydraulic
circuit. 11. With the right rear wheel hydraulic circuit bleeder valve tightened securely, after all air
has been purged from the right rear hydraulic circuit,
install a proper box-end wrench onto the LEFT REAR wheel hydraulic circuit bleeder valve.
12. Install a transparent hose over the end of the bleeder valve, then repeat steps 6-10. 13. Turn
the ignition OFF and wait 15 seconds. The assistant will now have to pump the brake pedal for fluid
to flow from open bleed valves. 14. With the left rear wheel hydraulic circuit bleeder valve tightened
securely, after all air has been purged from the left rear hydraulic circuit, install a
proper box-end wrench onto the RIGHT FRONT wheel hydraulic circuit bleeder valve.
15. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 16. With
the right front wheel hydraulic circuit bleeder valve tightened securely, after all air has been purged
from the right front hydraulic circuit,
install a proper box-end wrench onto the LEFT FRONT wheel hydraulic circuit bleeder valve.
17. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 18. After
completing the final wheel hydraulic circuit bleeding procedure, ensure that each of the 4 wheel
hydraulic circuit bleeder valves are properly
tightened.
19. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme 11(R), GM
P/N 12377967 (Canadian P/N 992667), or
equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. Refer to Master Cylinder
Reservoir Filling (See: Brakes and Traction Control/Hydraulic System/Brake Master
Cylinder/Service and Repair/Procedures) .
brake pedal feels spongy, repeat the bleeding procedure again. If the brake pedal still feels spongy
after repeating the bleeding procedure,
1. Inspect the brake system for external leaks. Refer to Brake System External Leak Inspection
(See: Brakes and Traction Control/Hydraulic
System/Testing and Inspection/Component Tests and General Diagnostics/Brake System External

Leak Inspection) .
2. Pressure bleed the hydraulic brake system in order to purge any air that may still be trapped in
the system.
22. Turn the ignition key ON, with the engine OFF. Check to see if the brake system warning lamp
remains illuminated.
Important: If the brake system warning lamp remains illuminated, DO NOT allow the vehicle to be
driven until it is diagnosed and repaired.
23. If the brake system warning lamp remains illuminated, refer to Symptoms - Hydraulic Brakes
System/Testing and Inspection/Symptom Related Diagnostic Procedures/Symptoms - Hydraulic

Brakes) .
Brake Bleeding: Service and Repair Hydraulic Brake System Bleeding (Pressure)
Hydraulic Brake System Bleeding (Pressure)
Tools Required
* J 29532 Diaphragm Pressure Bleeder, or equivalent
* J 35589-A Master Cylinder Bleeder Adapter
* J 44894-A Brake Bleeder Adapter
Caution: Refer to Brake Fluid Irritant Caution (See: Brakes and Traction Control/Service
Precautions/Technician Safety Information/Brake Fluid Irritant Caution) .
master cylinder.
9. With the left front brake pipe (4) installed securely to the master cylinder, after all air has been
purged from the front port of the master
steps 2.5-2.8.
steps 2.5-2.8.
steps 2.5-2.8.
P/N 12377967 (Canadian P/N 992667), or
equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. Clean the outside of the
reservoir on and around the reservoir cap prior to removing the cap and diaphragm.
4. Install the J 44894-A to the brake master cylinder reservoir. 5. Check the brake fluid level in the J
29532 , or equivalent. Add Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or
equivalent
DOT-3 brake fluid from a clean, sealed brake fluid container as necessary to bring the level to
approximately the half-full point.
6. Connect the J 29532 , or equivalent, to the J 44894-A . 7. Charge the J 29532 , or equivalent, air
tank to 175-205 kPa (25-30 psi). 8. Open the J 29532 , or equivalent, fluid tank valve to allow
pressurized brake fluid to enter the brake system. 9. Wait approximately 30 seconds, then inspect
the entire hydraulic brake system in order to ensure that there are no existing external brake fluid
leaks. Any brake fluid leaks identified require repair prior to completing this procedure.
10. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve.
11. Install a transparent hose over the end of the bleeder valve. 12. Submerge the open end of the
12377967
13. Loosen the bleeder valve to purge air from the wheel hydraulic circuit. Allow fluid to flow until air
bubbles stop flowing from the bleeder, then
tighten the bleeder valve.
14. With the right rear wheel hydraulic circuit bleeder valve tightened securely, after all air has been
purged from the right rear hydraulic circuit,
the left rear wheel hydraulic circuit bleeder valve tightened securely, after all air has been purged
from the left rear hydraulic circuit, install a
tightened.
21. Close the J 29532 , or equivalent, fluid tank valve, then disconnect the J 29532 , or equivalent,
from the J 44894-A . 22. Remove the J 44894-A from the brake master cylinder reservoir. 23. Fill
the brake master cylinder reservoir. Refer to Master Cylinder Reservoir Filling (See: Brakes and
Traction Control/Hydraulic System/Brake
Master Cylinder/Service and Repair/Procedures) .
brake pedal feels spongy perform the following steps:
System/Testing and Inspection/Component Tests and General Diagnostics/Brake System External

Leak Inspection) .
2. Using a scan tool, perform the antilock brake system automated bleeding procedure to remove
any air that may have been trapped in the HBCi.
Refer to Antilock Brake System Automated Bleed Procedure (See: Antilock Brake System
Automated Bleed Procedure) .
System/Testing and Inspection/Symptom Related Diagnostic Procedures/Symptoms - Hydraulic

Brakes) .
Brake Bleeding: Service and Repair Hydraulic Brake System Flushing
Hydraulic Brake System Flushing Caution: Refer to Brake Fluid Irritant Caution (See: Brakes and
Traction Control/Service Precautions/Technician Safety Information/Brake Fluid Irritant Caution) .
1. Inspect the brake fluid for the following conditions, indicating brake fluid contamination:
* Fluid separation, indicating 2 types of fluid are present-A substance other than the recommended
brake fluid has been introduced into the brake hydraulic system.
- Swirled appearance-Oil-based substance
- Layered appearance-Silicone-based substance
* Fluid discoloration, indicating the presence of moisture or particles that have been introduced into
the brake hydraulic system
- Cloudy appearance-Moisture
- Dark appearance/suspended particles in fluid-Dirt, rust, corrosion, brake dust
2. Inspect the master cylinder reservoir cap diaphragm and the reservoir-to-master cylinder
grommets for swelling, indicating brake fluid
contamination.
3. If the brake fluid WAS contaminated with an oil-based or a silicone-based substance, indicated
by fluid separation and/or a swollen master
cylinder reservoir cap diaphragm and/or swollen reservoir-to-master cylinder grommets, perform
the following:
1. Remove ALL of the following components listed from the vehicle. Each component contains
internal rubber seals/linings which have been
contaminated by the contaminated brake fluid in the brake hydraulic system. Refer to the
procedures indicated:
* Brake Master Cylinder with Power Brake Booster and Chassis Control Module Replacement
(See: Brakes and Traction Control/Hydraulic System/Brake Master Cylinder/Service and
Repair/Removal and Replacement/Brake Master Cylinder with Power Brake Booster and Chassis
Control Module Replacement)
* Front Brake Hose Replacement (See: Brakes and Traction Control/Hydraulic System/Brake
Hose/Line/Service and Repair/Front Brake Hose Replacement)
* Rear Brake Hose Replacement (Caliper) (See: Brakes and Traction Control/Hydraulic
System/Brake Hose/Line/Service and Repair/Rear Brake Hose Replacement (Caliper))Rear Brake
Hose Replacement (Jounce) (See: Brakes and Traction Control/Hydraulic System/Brake
Hose/Line/Service and Repair/Rear Brake Hose Replacement (Jounce))
* Front Brake Caliper Replacement (See: Brakes and Traction Control/Disc Brake System/Brake
Caliper/Service and Repair/Removal and Replacement/Front Brake Caliper Replacement)
* Rear Brake Caliper Replacement (See: Brakes and Traction Control/Disc Brake System/Brake
Caliper/Service and Repair/Removal and Replacement/Rear Brake Caliper Replacement)
2. Clean out all the hydraulic brake pipes using denatured alcohol, or equivalent. 3. Dry the brake
pipes using non-lubricated, filtered air. 4. Repair or replace ALL of the following components listed
and install them to the vehicle. Each component contains internal rubber
seals/linings which have been contaminated by the contaminated brake fluid in the brake hydraulic
system. Refer to the procedures indicated:
* Clean the brake master cylinder reservoir using denatured alcohol, or equivalent, then dry the
reservoir using non-lubricated, filtered air. Inspect the reservoir for cracks and/or damage and
replace if necessary. Refer to Master Cylinder Reservoir Replacement (See: Brakes and Traction
Control/Hydraulic System/Brake Master Cylinder/Service and Repair/Removal and
Replacement/Master Cylinder Reservoir Replacement) . Replace the brake master cylinder
reservoir cap.
* Front Brake Hose Replacement (See: Brakes and Traction Control/Hydraulic System/Brake
Hose/Line/Service and Repair/Front Brake Hose Replacement)
* Rear Brake Hose Replacement (Caliper) (See: Brakes and Traction Control/Hydraulic
System/Brake Hose/Line/Service and Repair/Rear Brake Hose Replacement (Caliper))Rear Brake
Hose Replacement (Jounce) (See: Brakes and Traction Control/Hydraulic System/Brake
* Front Brake Caliper Overhaul (See: Brakes and Traction Control/Disc Brake System/Brake
Caliper/Service and Repair/Overhaul/Front Brake Caliper Overhaul) or Front Brake Caliper
Replacement (See: Brakes and Traction Control/Disc Brake System/Brake Caliper/Service and
Repair/Removal and Replacement/Front Brake Caliper Replacement)
* Rear Brake Caliper Overhaul (See: Brakes and Traction Control/Disc Brake System/Brake
Caliper/Service and Repair/Overhaul/Rear
Brake Caliper Overhaul) or Rear Brake Caliper Replacement (See: Brakes and Traction
Control/Disc Brake System/Brake Caliper/Service and Repair/Removal and Replacement/Rear
Brake Caliper Replacement)
* HBCi components
4. If the brake fluid was NOT contaminated with an oil-based or a silicone-based substance, but
WAS contaminated with water or dirt, rust,
corrosion, and/or brake dust, replace the brake master cylinder reservoir cap which may have
allowed the moisture or particles to enter the hydraulic system.
5. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme 11(R) (GM
P/N 12377967) or equivalent DOT-3 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 (Manual) (See: Hydraulic Brake
System Bleeding (Manual))Hydraulic Brake System Bleeding (Pressure) (See: Hydraulic Brake
System Bleeding (Pressure)) .
Hummer Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair
Air Bag(s) Arming and Disarming: Service and Repair
SIR Disabling and Enabling
SIR component location affects how a vehicle should be serviced. There are parts of the SIR
system installed in various locations around a vehicle. To find the location of the SIR components
refer to SIR Identification Views (See: Restraint Systems/Air Bag Systems/Locations) .
There are several reasons for disabling the SIR system, such as repairs to the SIR system or
servicing a component near or attached to an SIR component. There are several ways to disable
the SIR system depending on what type of service is being performed. The following information
covers the proper procedures for disabling/enabling the SIR system.
SIR Service Precautions
Caution: When performing service on or near the SIR components or the SIR wiring, the SIR
system must be disabled. Failure to observe the correct procedure could cause deployment of the
SIR components. Serious injury can occur. Failure to observe the correct procedure could also
result in unnecessary SIR system repairs.
The inflatable restraint sensing and diagnostic module (SDM) maintains a reserved energy supply.
The reserved energy supply provides deployment power for the air bags if the SDM loses battery
power during a collision. Deployment power is available for as much as 1 minute after
disconnecting the vehicle power. Waiting 1 minute before working on the system after disabling the
SIR system prevents deployment of the air bags from the reserved energy supply.
General Service Instructions
The following are general service instructions which must be followed in order to properly repair the
vehicle and return it to its original integrity:
* Do not expose inflator modules to temperatures above 65°C (150°F).
* Verify the correct replacement part number. Do not substitute a component from a different
vehicle.
* Use only original GM replacement parts available from your authorized GM dealer. Do not use
salvaged parts for repairs to the SIR system.
Discard any of the following components if it has been dropped from a height of 91 cm (3 feet) or
greater:
* Inflatable restraint sensing and diagnostic module (SDM)

* Any Inflatable restraint air bag module
* Inflatable restraint steering wheel module coil
* Any Inflatable restraint sensor
* Inflatable restraint seat belt pretensioners
* Inflatable restraint Passenger Presence System (PPS) module or sensor
Disabling Procedure - Air Bag Fuse
1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the
ignition in the OFF position.
Important: The SDM may have more than one fused power input. To ensure there is no unwanted
SIR deployment, personal injury, or unnecessary SIR system repairs, remove all fuses supplying
power to the SDM. With all SDM fuses removed and the ignition switch in the ON position, the AIR
BAG warning indicator illuminates. This is normal operation, and does not indicate a SIR system
malfunction.
3. Locate and remove the fuse(s) supplying power to the SDM. Refer to SIR Schematics (See:
Diagrams/Electrical Diagrams/Air Bag Systems) or
Electrical Center Identification Views (See: Fuses and Circuit Breakers/Fuse/Application and ID) .
4. Wait 1 minute before working on the system.
Enabling Procedure - Air Bag Fuse
1. Place the ignition in the OFF position.

Hummer Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair
> Page 1730
2. Install the fuse(s) supplying power to the SDM. Refer to SIR Schematics (See:
Diagrams/Electrical Diagrams/Air Bag Systems) or Electrical
Center Identification Views (See: Fuses and Circuit Breakers/Fuse/Application and ID) .
3. Turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4.
Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate
as described. Refer to Diagnostic System
Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic
System Check - Vehicle) .
Disabling Procedure - Negative Battery Cable
1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the
ignition in the OFF position. 3. Disconnect the negative battery cable from the battery. Refer to
Battery Negative Cable Disconnection and Connection (See: Starting and

Connection) .
4. Wait 1 minute before working on system.
Enabling Procedure - Negative Battery Cable
1. Place the ignition in the OFF position. 2. Connect the negative battery cable to the battery. Refer
to Battery Negative Cable Disconnection and Connection (See: Starting and

Connection) .
3. Turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4.
Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate
as described. Refer to Diagnostic System
Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic
System Check - Vehicle) .
Hummer Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Technical
Service Bulletins > Electrical - Aftermarket Fuse Warning
Fuse: Technical Service Bulletins Electrical - Aftermarket Fuse Warning
Bulletin No.: 07-08-45-002
ADVANCED SERVICE INFORMATION
Subject: Service Alert: Concerns With Aftermarket Fuses in GM Vehicles
Concerns with Harbor Freight Tools "Storehouse" Branded Blade Type Fuses
General Motors has become aware of a fuse recall by Harbor Freight Tools/Storehouse for a
variety of aftermarket fuses. In two cases, these fuses have not provided protection for the wiring
system of the vehicles they were customer installed in.
Upon testing the 15 amp version, it was found that the fuse still would not "open" when shorted
directly across the battery terminals.
How to Identify These Fuses

Packed in a 120 piece set, the fuse has a translucent, hard plastic, blue body with the amperage
stamped into the top. There are no white painted numbers on the fuse to indicate amperage. There
are no identifying marks on the fuse to tell who is making it. The fuses are known to be distributed
by Harbor Freight Tools but there may be other marketers, and packaging of this style of fuse. It
would be prudent to replace these fuses if found in a customers vehicle. Likewise, if wiring
overheating is found you should check the fuse panel for the presence of this style of fuse.
All GM dealers should use genuine GM fuses on the vehicles they service. You should also
encourage the use of GM fuses to your customers to assure they are getting the required electrical
system protection. GM has no knowledge of any concerns with other aftermarket fuses. If
additional information becomes available, this bulletin will be updated.
Disclaimer
Hummer Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations >
Fuse Block - I/P
Fuse: Locations Fuse Block - I/P
Electrical Center Identification Views
Fuse Block - I/P, Label

Fuse Block - I/P > Page 1738
Fuse Block - I/P, Top View

Fuse Block - I/P, Bottom View

Fuse Block - I/P X1

Fuse Block - I/P X2

Fuse Block - I/P X3

Fuse Block - I/P X4
Fuse: Locations Fuse Block - Underhood
Fuse Block - Underhood, Label

Fuse Block - Underhood, Top View

Fuse Block - Underhood, Bottom View
Fuse Block - Underhood X1

Fuse Block - Underhood - X2




Fuse: Locations Junction Block - I/P
Junction Block - Left I/P, Label
Junction Block - Left I/P, Top View

Junction Block - Left I/P, Bottom View

Junction Block - Left I/P X1







Junction Block - I/P X11


Junction Block - Right I/P, Top View

Junction Block - Right I/P X1 (Wire Entry)
Junction Block - Right I/P X2


Fuse: Locations Instrument Panel Fuse Block
Fuse: Locations
Fuse Block - I/P



Fuse Block - I/P X1

Fuse Block - I/P X2

Fuse Block - I/P X3

Fuse Block - I/P X4
Fuse Block - Underhood







Junction Block - I/P















Instrument Panel Fuse Block

Center Instrument Panel Fuse Block

Underhood Fuse Block

Hummer Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application
and ID > Fuse Block - Underhood
Fuse: Application and ID Fuse Block - Underhood

and ID > Fuse Block - Underhood > Page 1834






Fuse: Application and ID Fuse Block - I/P



Fuse Block - I/P X1

Fuse Block - I/P X2

Fuse Block - I/P X3

Fuse Block - I/P X4
Fuse: Application and ID Junction Block - I/P














Hummer Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Service
and Repair > Underhood Electrical Center or Junction Block Replacement
Fuse Block: Service and Repair Underhood Electrical Center or Junction Block Replacement
Underhood Electrical Center or Junction Block Replacement
Removal Procedure

Connection) .
2. Remove the left fender upper brace.
3. Remove the electrical center brace cover assemble by lifting the cover (3) outwards to clear the
tabs. 4. Remove all fuses and relays.
5. Push on the tab (3) so that the electrical center can be rotated on the studs located at (2). 6.
Remove all connectors by removing the bolt (1) for each connector. 7. Disconnect all connectors
from the electrical center block.
8. Push on the tabs (2) in order to lift the electrical center (1) out of the housing.
and Repair > Underhood Electrical Center or Junction Block Replacement > Page 1880
9. To replace the engine electrical center bracket remove the 4 retaining bolts (1).
10. Remove the engine electrical center bracket assembly from the fender.
1. Install the engine electrical center bracket assembly to the front fender.
2. Install the 4 retaining bolts (1).
Tighten the 4 retaining bolts (1) to 9 N.m (80 lb in).
3. Align the electrical center block (1) stubs in the slots so that the tabs (2) retains it in place.
4. Connect the wire connectors to the lower portion of the electrical center block. 5. Connect the
wire connectors with the bolts to the electrical center block.
Tighten all connector bolts (1) to 9 N.m (80 lb in).
6. Ensure all wire connectors are securely connected. 7. Set the electrical center block in its resting
position till the tabs (3) locks in place.
8. Install the lower part of the cover (1). 9. With the cover (2) off, use the fuse location information
to install all fuses and relays.
10. Install the cover.
11. Install the fender upper brace. 12. Install the 4 fender upper brace bolts.
Tighten the 4 retaining bolts to 25 N.m (18 lb ft).
13. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and
Connection (See: Starting and Charging/Battery/Battery
14. Start vehicle and ensure all components function properly.

Fuse Block: Service and Repair Instrument Panel Electrical Center or Junction Block Replacement
- Left Side
Instrument Panel Electrical Center or Junction Block Replacement - Left Side
Removal Procedure
1. Remove the left side end panel. 2. Remove the knee bolster. Refer to Driver Knee Bolster
Replacement (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument
3. Disconnect all the wiring connectors from the fuse block. 4. Remove all the fuses. 5. Remove the
turn signal relay from the back of the fuse block. 6. From behind the fuse block, remove the
retaining bolt. 7. Insert a screw driver between the fuse block and the wire harness block to
separate. 8. Push on the retainers in order to remove the fuse block. 9. Remove the fuse block
from the vehicle.
1. Install the fuse block onto the IP assembly till it clicks in place. 2. Install the wire harness block to
the back of the fuse block.

Notice) .
3. Install the bolt.
4. Install the turn signal relay to the back of the fuse block. 5. Using the wiring diagram on the cover
of the fuse panel, install the fuses. 6. Install the electrical connectors. 7. Install the knee bolster.
Refer to Driver Knee Bolster Replacement (See: Body and Frame/Interior Moulding /
8. Install the left side end panel.

Fuse Block: Service and Repair Instrument Panel Electrical Center or Junction Block Replacement
- Right Side
Instrument Panel Electrical Center or Junction Block Replacement - Right Side
Removal Procedure
1. Remove the right side end panel. 2. Push in the tabs in order to remove the fuse block.
3. Pull out the fuse block out of the I/P in order to remove the retaining bolt. 4. Loosen the bolt. 5.
Insert a screw driver between the wire harness block and fuse block in order to separate. 6.
Separate the fuse block from the I/P harness block. 7. Remove the IP wiring harness block from
the vehicle.
1. Install the fuse block to the I/P wire harness block.

Notice) .
2. Install the retaining bolt.
Tighten the bolt to 6 N.m (53 lb in)
3. Install the fuse block to the I/P till it clicks in place.
4. Connect the wiring connectors to the fuse block.
Refer to Electrical Center Identification Views (See: Fuse/Application and ID) to ensure the right
connections are made.
5. Install the right side end panel.

Hummer Workshop Manuals > Maintenance > Service Reminder Indicators > Low Tire Pressure Indicator > Component
Information > Technical Service Bulletins > Customer Interest for Low Tire Pressure Indicator: > 09-03-16-002A > Apr > 10
> Wheels/Tires - Tire Pressure Monitor Light ON
Low Tire Pressure Indicator: Customer Interest Wheels/Tires - Tire Pressure Monitor Light ON
2006-2010 HUMMER H2, H3
ATTENTION
warranty.
Procedure
with DIC):
customer:
> Wheels/Tires - Tire Pressure Monitor Light ON > Page 1893
Tire Pressure Light
Important:
pressure light on:
Important:
Important:
Important:
Important:

Important:

Disclaimer
Information > Technical Service Bulletins > All Technical Service Bulletins for Low Tire Pressure Indicator: > 09-03-16-002A
> Apr > 10 > Wheels/Tires - Tire Pressure Monitor Light ON
Light ON
2006-2010 HUMMER H2, H3
ATTENTION
warranty.
Procedure
with DIC):
customer:
> Apr > 10 > Wheels/Tires - Tire Pressure Monitor Light ON > Page 1903
Tire Pressure Light
Important:
pressure light on:
Important:
Important:
Important:
Important:

Important:

Disclaimer
Information > Technical Service Bulletins > Page 1908
Low Tire Pressure Indicator: Service and Repair
Tire Pressure Sensor Learn
Special Tools
J-46079 Tire Pressure Monitor Diagnostic Tool
Learn Mode Description
The Tire Pressure Monitor (TPM) System uses the instrument panel cluster (IPC), body control
module (BCM), remote control door lock receiver (RCDLR), keyless entry transmitter, 4 radio
frequency transmitting pressure sensors, and the serial data circuit to perform the TPM learn mode
functions. The sensor learn procedure must be performed after every tire rotation, RCDLR
replacement, or sensor replacement. Once the learn mode has been enabled, each of the sensors
unique identification codes can be learned into the RCDLR memory. When a sensor ID has been
learned, the RCDLR sends a serial data message to the BCM to sound a horn chirp. This verifies
the sensor has transmitted its ID and the RCDLR has received and learned it. The RCDLR must
learn the sensor IDs in the proper sequence to determine correct sensor location. The first learned
ID is assigned to the left front location, the second to right front, the third to right rear and the fourth
to left rear. The turn signals will individually illuminate indicating which location is to be learned in
the proper sequence.
Sensor Functions Using J-46079
Each sensor has an internal low frequency coil. When the J-46079 is used in activate mode, it
produces a low frequency transmission that activates the sensor. The sensor responds to an low
frequency activation by transmitting in learn mode. When the RCDLR receives a learn mode
transmission while in TPM learn mode, it will assign that sensor ID to the location on the vehicle
relative to the order in which it was learned.
Sensor Functions Using Pressure Increase/Decrease Method
Each sensor takes a pressure measurement sample once every 30 seconds while in stationary
mode. If the tire pressure increases, or decreases by more than 8.3 kPa (1.2 psi) from the last
pressure measurement, another measurement will occur immediately to verify the change in
pressure. If a pressure change has indeed occurred, the sensor transmits in Learn mode. When
the RCDLR receives a Learn mode transmission while in TPM learn mode, it will assign that sensor
ID to the location on the vehicle relative to the order in which it was learned.
Learn Mode Cancellation
The learn mode will cancel if the ignition is cycled to OFF or if more than 2 minutes has elapsed for
any sensor that has not been learned. If the learn mode is cancelled before the first sensor is
learned, the original sensor IDs will be maintained. If the learn mode is canceled after the first
sensor is learned, the following will occur:
* All stored sensor IDs will be invalidated in the RCDLR memory.
* If equipped, the DIC will display dashes instead of tire pressures.
* DTC C0775 will be set.
These conditions will now require the learn procedure to be repeated for the system to function
properly.
TPM Learn Procedure

Important: Before proceeding, ensure that no other learn procedure is being performed
simultaneously or that tire pressures are not being adjusted on another TPM equipped vehicle
within close proximity. Stray signals from other TPM equipped vehicles just driving by can be
inadvertently learned. If any random horn chirps are heard from the vehicle while performing the
learn procedure, most likely a stray sensor has been learned and the procedure will need to be
cancelled and repeated. Under these circumstances, performing the TPM Learn Procedure away
from other vehicles would be highly recommended. In the event a particular sensor pressure
increase/decrease activation does not cause the horn to chirp, it may be necessary to rotate the
wheel valve stem to a different position due to the sensor signal is being blocked by another
component.
1. Place the ignition switch in the proper position as follows:
* With standard ignition switch, place the switch in the RUN position.
* With electronic keyless ignition, place the switch in the ACCY position.
2. Initiate the TPM Learn Mode using one of the following procedures:
* Using a scan tool, initiate the TPM Learn Mode. A double horn chirp will sound indicating the
Learn Mode has been enabled. The left front turn signal will also be illuminated.
* On vehicles equipped with keyless entry, simultaneously press the keyless entry transmitters lock
and unlock buttons until a double horn chirp sounds indicating the Learn Mode has been enabled.
The left front turn signal will also be illuminated.
Information > Technical Service Bulletins > Page 1909
* On vehicles not equipped with keyless entry, press and release the driver information center
(DIC) INFO button until the RELEARN TIRE POSITIONS message appears on the DIC display.
Press and hold the SET/RESET button until a double horn chirp sounds and the DIC displays a
TIRE LEARNING ACTIVE message indicating the Learn Mode has been enabled. The left front
turn signal will also be illuminated.
3. Starting with the left front tire, learn the tire pressure using one of the following methods:
* Hold the antenna of the J-46079 aimed upward against the tire sidewall close to the wheel rim at
the valve stem location. Press and release the activate button and wait for a horn chirp. Once the
horn chirp has sounded, the turn signal in the next location to be learned will illuminate.
Caution: Over inflating tires may cause personal injury or damage to the tires and wheels. When
increasing tire pressure do not exceed the maximum inflation pressure as noted on the tire
sidewall.
* Increase/decrease the tire pressure for 8-10 seconds then wait for a horn chirp. The horn chirp
may occur before or up to 30 seconds after the 8-10 second pressure increase/decrease time
period has been reached. Once the horn chirp has sounded, the turn signal in the next location to
be learned will illuminate.
4. After the horn chirp has sounded and the right front turn signal is illuminated, repeat step 3 for
the remaining 3 sensors in the following order:
1. Right front 2. Right rear 3. Left rear
5. After the LR sensor has been learned, a double horn chirp will sound indicating all sensors have
been learned. 6. Turn OFF the ignition to exit the learn mode. 7. After the learn mode has been
exited, adjust all tires to the recommended pressures. Refer to Vehicle Certification, Tire Placard,
Anti-Theft, and
Service Parts ID Label (See: Application and ID/Vehicle Certification, Tire Placard, Anti-Theft, and
Service Parts ID Label) .
Hummer Workshop Manuals > Maintenance > Service Reminder Indicators > Maintenance Required Lamp/Indicator >
Maintenance Required Lamp/Indicator: Service and Repair
SERVICE VEHICLE SOON or SERVICE ENGINE SOON INDICATOR
Your vehicle is equipped with a "SERVICE VEHICLE SOON"or a "SERVICE ENGINE SOON"
indicator. This indicator is not a maintenance indicator and does not mean a maintenance service
is required.
For additional "SERVICE VEHICLE SOON"or a "SERVICE ENGINE SOON" indicator information
refer to Malfunction Indicator Lamp.
For Maintenance Required Lamp/Indicator, refer to Oil Change Reminder Lamp.

Hummer Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component
Information > Testing and Inspection
Malfunction Indicator Lamp: Testing and Inspection
Malfunction Indicator Lamp (MIL) Diagnosis
procedure.
Overview/Diagnostic Procedure Instructions )provides an overview of each diagnostic category.
Ignition voltage is supplied to the malfunction indicator lamp (MIL). The engine control module
(ECM) turns the MIL ON by grounding the MIL control circuit.
* Instrument Cluster Schematics (See: Diagrams/Electrical Diagrams/Instrument Panel, Gauges

and Warning Indicators/System Diagram/Instrument Cluster Schematics)
* Engine Controls Schematics (See: Diagrams/Electrical Diagrams/Powertrain

Management/System Diagram)
Connector End View Reference


Testing)


Scan Tool Reference
Programming and Relearning (See: Testing and Inspection/Programming and Relearning)for scan
tool information
Ignition ON, the MIL should turn ON and OFF when commanded with a scan tool.
1. Ignition OFF, disconnect the harness connector at the instrument panel cluster (IPC). 2. Ignition
ON, verify that a test lamp illuminates between the ignition circuit and ground.
‹› If the test lamp does not illuminate, test the ignition circuit for a short to ground or an open/high
resistance. If the circuit tests normal and the
ignition circuit fuse is open, replace the IPC.
3. Connect a test lamp between the control circuit and the ignition circuit. 4. Command the MIL ON
and OFF with a scan tool. The test lamp should turn ON and OFF when changing between the
commanded states.
‹› If the test lamp is always ON, test the control circuit for a short to ground. If the circuit tests
normal, replace the ECM. ‹› If the test lamp is always OFF, test the control circuit for a short to
voltage or an open/high resistance. If the circuit tests normal, replace the
ECM.
5. If all circuits test normal, replace the IPC.
Repair Instructions
Hummer Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component
* Instrument Cluster Replacement (See: Instrument Panel, Gauges and Warning

Indicators/Instrument Cluster / Carrier/Service and Repair)
* Programming and Relearning (See: Testing and Inspection/Programming and Relearning)for

ECM replacement, setup, and programming
Hummer Workshop Manuals > Maintenance > Service Reminder Indicators > Oil Change Reminder Lamp > Component
Information > Service and Repair
Oil Change Reminder Lamp: Service and Repair
GM Oil Life System Resetting
The vehicle has a computer system that has a change engine oil light, indicating when to change
the engine oil and filter. This is based on engine revolutions and engine temperature, and not on
mileage. Based on driving conditions, the mileage at which an oil change will be indicated can vary
considerably. For the oil life system to work properly, the system must be reset every time the oil is
changed.
When the system has calculated that oil life has been diminished, it will indicate that an oil change
is necessary. The change engine oil light will come on. The oil must be changed as soon as
possible. It is possible that, if the vehicle is driven under the best conditions, the oil life system may
not indicate that an oil change is necessary for over a year. However, the engine oil and filter must
be changed at least once a year and at this time the system must be reset. If the system is ever
reset accidentally, the oil must be changed at 3,000 miles (5 000 km) since the last oil change.
Remember to reset the oil life system whenever the oil and filter is changed.
Resetting Procedure
With the Driver Information Center (DIC)
1. Press the fuel information button until Engine Oil Life appears on the screen. 2. Press and hold
the select button for five seconds. 3. OIL LIFE RESET will appear on the screen for 10 seconds. 4.
The oil life system is reset.
Without the Driver Information Center (DIC)
1. Turn the ignition key to RUN with the engine off. 2. Fully press and release the accelerator pedal
slowly three times within five seconds. If the OIL LIFE RESET message flashes for 10 seconds, the
system is resetting.
3. Turn the key to LOCK.
If the CHANGE ENGINE OIL message comes back on when vehicle is turned on, the ENGINE OIL
LIFE system has not reset. Repeat the procedure.
Hummer Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Service
Precautions
Vehicle Lifting: Service Precautions
Vehicle Lifting Caution
Caution: 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.
Vehicle Lifting: Service and Repair
Lifting and Jacking the Vehicle
Caution: 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.
the hoist.
Notice: Perform the following steps before beginning any vehicle lifting or jacking procedure:
* Remove or secure all of the vehicle's contents in order to avoid any shifting or any movement that
may occur during the vehicle lifting or jacking procedure.
* The lifting equipment or the jacking equipment weight rating must meet or exceed the weight of
the vehicle and any vehicle contents.
* The lifting equipment or the jacking equipment must meet the operational standards of the lifting
equipment or jacking equipment's manufacturer.
* Perform the vehicle lifting or jacking procedure on a clean, hard, dry, level surface.
* Perform the vehicle lifting or jacking procedure only at the identified lift points. DO NOT allow the
lifting equipment or jacking equipment to contact any other vehicle components.
Failure to perform the previous steps could result in damage to the lifting equipment or the jacking
equipment, the vehicle, and/or the vehicle's contents.
For lifting the vehicle, various lift points are recommended. Before you begin any lifting procedure,
place the vehicle on a clean, hard, level surface. Verify that all the lifting equipment meets weight
standards and is in good working order. Verify that all of the vehicle loads are equally distributed
and secure. If you are only supporting the vehicle at the frame side rails, verify that the lifting
equipment does not put too much stress on, or weaken, the frame side rails.
During hoisting, do NOT damage the fuel tanks, the exhaust system, or the underbody.
1 - Lower Control Arm Contact Points 1 - Lower Control Arm Contact Points 2 - Front Frame
Contact Points 2 - Front Frame Contact Points
3 - Rear Frame Contact Points 3 - Rear Frame Contact Points 4 - Rear Axle Contact Points 4 -
Rear Axle Contact Points 5 - Differential Contact Points
Frame Contact Hoist
Front Hoist Pads
Important: The front hoist pads must not contact the rocker panels, the front fenders, or the floor
pan.
Position the front hoist pads under the front frame between the lower control arm and the frame
pad.
Rear Hoist Pads
Important: The rear hoist pads must not contact the body rocker panels or the floor pan.
Position the rear hoist pads under the rear spring, just behind the hanger
Suspension Contact Hoist
Front Lift
Position the front lift under the outer edge of the front suspension lower control arms.
Rear Lift
Position the rear lift under the axle housing tubes on each side of the differential.
Do not damage the stabilizer bar.
Jacking
When you are lifting a vehicle with a vehicle jack or a floor jack, block the wheels at the opposite
end from which you are lifting. Use jack stands to provide additional support.
Under the Frame Rails
Important: The floor jack pad must not contact rocker panel or the floor pan.
Position the floor jack pad under the frame rail pad.
Under the Rear Differential
Position the floor jack pad under the center of the rear axle differential.
Do not damage the establisher bar.
Under the Rear Spring Hanger
Position the jack under the rear spring hanger.

Jack Stands
When you support the vehicle with jack stands, place the jack stands under the frame, the front
suspension crossmember, or the rear axle.
Hummer Workshop Manuals > Maintenance > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure
Module > Component Information > Technical Service Bulletins > Tires/Wheels - Tire Pressure Sensors
Service/Re-Learning
Service/Re-Learning
INFORMATION
Bulletin No.: 10-03-16-001
Date: July 19, 2010
Models:
Disclaimer
Hummer Workshop Manuals > Maintenance > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure
Monitor Receiver / Transponder > Component Information > Technical Service Bulletins > Tires/Wheels - Tire Pressure
Sensors Service/Re-Learning
INFORMATION
Bulletin No.: 10-03-16-001
Date: July 19, 2010
Models:
Disclaimer
Hummer Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire
Pressure Sensor > Component Information > Technical Service Bulletins > Tires/Wheels - Tire Pressure Sensors
Service/Re-Learning
Service/Re-Learning
INFORMATION
Bulletin No.: 10-03-16-001
Date: July 19, 2010
Models:
Disclaimer
Service/Re-Learning > Page 1942
INFORMATION
Bulletin No.: 08-03-10-007
Date: May 16, 2008
Procedure
Notice:
Notice:
Important:
sensor.
Important:
rim.
Caution:
injury.
Important:
time.
Parts Information
Disclaimer
Pressure Sensor > Component Information > Technical Service Bulletins > Page 1946

Removal Procedure
1. Raise the vehicle on a suitable support. Refer to Lifting and Jacking the Vehicle (See: ) . 2.
Remove the tire/wheel assembly from the vehicle. Refer to Tire and Wheel Removal and
Installation (See: Service and Repair) .
* When separating the tire bead from the wheel, position the bead breaking fixture 90 degrees from
the valve stem.
head.
3. Remove the tire from the wheel. Refer to Tire Mounting and Dismounting (See: Tires/Service
and Repair/Removal and Replacement) .

Notice) .
Pressure Sensor > Component Information > Technical Service Bulletins > Page 1947
torquing.
4. Install the tire on the wheel. Refer to Tire Mounting and Dismounting (See: Tires/Service and
seconds.
(See: Service and Repair) . 6. Lower the vehicle. 7. Learn the tire pressure sensors. Refer to Tire
Pressure Sensor Learn (See: Tire Monitoring System/Service and Repair) .
Hummer Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator >
Component Information > Technical Service Bulletins > Customer Interest for Low Tire Pressure Indicator: > 09-03-16-002A
> Apr > 10 > Wheels/Tires - Tire Pressure Monitor Light ON
Low Tire Pressure Indicator: Customer Interest Wheels/Tires - Tire Pressure Monitor Light ON
2006-2010 HUMMER H2, H3
ATTENTION
warranty.
Procedure
with DIC):
customer:
Tire Pressure Light
Important:
pressure light on:
Important:
Important:
Important:
Important:

Important:

Disclaimer
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Low Tire Pressure Indicator: >
09-03-16-002A > Apr > 10 > Wheels/Tires - Tire Pressure Monitor Light ON
Light ON
2006-2010 HUMMER H2, H3
ATTENTION
warranty.
Procedure
with DIC):
customer:
09-03-16-002A > Apr > 10 > Wheels/Tires - Tire Pressure Monitor Light ON > Page 1967
Tire Pressure Light
Important:
pressure light on:
Important:
Important:
Important:
Important:

Important:

Disclaimer
Low Tire Pressure Indicator: Service and Repair
Tire Pressure Sensor Learn
Special Tools
J-46079 Tire Pressure Monitor Diagnostic Tool
Learn Mode Description
The Tire Pressure Monitor (TPM) System uses the instrument panel cluster (IPC), body control
module (BCM), remote control door lock receiver (RCDLR), keyless entry transmitter, 4 radio
frequency transmitting pressure sensors, and the serial data circuit to perform the TPM learn mode
functions. The sensor learn procedure must be performed after every tire rotation, RCDLR
replacement, or sensor replacement. Once the learn mode has been enabled, each of the sensors
unique identification codes can be learned into the RCDLR memory. When a sensor ID has been
learned, the RCDLR sends a serial data message to the BCM to sound a horn chirp. This verifies
the sensor has transmitted its ID and the RCDLR has received and learned it. The RCDLR must
learn the sensor IDs in the proper sequence to determine correct sensor location. The first learned
ID is assigned to the left front location, the second to right front, the third to right rear and the fourth
to left rear. The turn signals will individually illuminate indicating which location is to be learned in
the proper sequence.
Sensor Functions Using J-46079
Each sensor has an internal low frequency coil. When the J-46079 is used in activate mode, it
produces a low frequency transmission that activates the sensor. The sensor responds to an low
frequency activation by transmitting in learn mode. When the RCDLR receives a learn mode
transmission while in TPM learn mode, it will assign that sensor ID to the location on the vehicle
relative to the order in which it was learned.
Sensor Functions Using Pressure Increase/Decrease Method
Each sensor takes a pressure measurement sample once every 30 seconds while in stationary
mode. If the tire pressure increases, or decreases by more than 8.3 kPa (1.2 psi) from the last
pressure measurement, another measurement will occur immediately to verify the change in
pressure. If a pressure change has indeed occurred, the sensor transmits in Learn mode. When
the RCDLR receives a Learn mode transmission while in TPM learn mode, it will assign that sensor
ID to the location on the vehicle relative to the order in which it was learned.
Learn Mode Cancellation
The learn mode will cancel if the ignition is cycled to OFF or if more than 2 minutes has elapsed for
any sensor that has not been learned. If the learn mode is cancelled before the first sensor is
learned, the original sensor IDs will be maintained. If the learn mode is canceled after the first
sensor is learned, the following will occur:
* All stored sensor IDs will be invalidated in the RCDLR memory.
* If equipped, the DIC will display dashes instead of tire pressures.
* DTC C0775 will be set.
These conditions will now require the learn procedure to be repeated for the system to function
properly.
TPM Learn Procedure

Important: Before proceeding, ensure that no other learn procedure is being performed
simultaneously or that tire pressures are not being adjusted on another TPM equipped vehicle
within close proximity. Stray signals from other TPM equipped vehicles just driving by can be
inadvertently learned. If any random horn chirps are heard from the vehicle while performing the
learn procedure, most likely a stray sensor has been learned and the procedure will need to be
cancelled and repeated. Under these circumstances, performing the TPM Learn Procedure away
from other vehicles would be highly recommended. In the event a particular sensor pressure
increase/decrease activation does not cause the horn to chirp, it may be necessary to rotate the
wheel valve stem to a different position due to the sensor signal is being blocked by another
component.
1. Place the ignition switch in the proper position as follows:
* With standard ignition switch, place the switch in the RUN position.
* With electronic keyless ignition, place the switch in the ACCY position.
2. Initiate the TPM Learn Mode using one of the following procedures:
* Using a scan tool, initiate the TPM Learn Mode. A double horn chirp will sound indicating the
Learn Mode has been enabled. The left front turn signal will also be illuminated.
* On vehicles equipped with keyless entry, simultaneously press the keyless entry transmitters lock
and unlock buttons until a double horn chirp sounds indicating the Learn Mode has been enabled.
The left front turn signal will also be illuminated.
* On vehicles not equipped with keyless entry, press and release the driver information center
(DIC) INFO button until the RELEARN TIRE POSITIONS message appears on the DIC display.
Press and hold the SET/RESET button until a double horn chirp sounds and the DIC displays a
TIRE LEARNING ACTIVE message indicating the Learn Mode has been enabled. The left front
turn signal will also be illuminated.
3. Starting with the left front tire, learn the tire pressure using one of the following methods:
* Hold the antenna of the J-46079 aimed upward against the tire sidewall close to the wheel rim at
the valve stem location. Press and release the activate button and wait for a horn chirp. Once the
horn chirp has sounded, the turn signal in the next location to be learned will illuminate.
Caution: Over inflating tires may cause personal injury or damage to the tires and wheels. When
increasing tire pressure do not exceed the maximum inflation pressure as noted on the tire
sidewall.
* Increase/decrease the tire pressure for 8-10 seconds then wait for a horn chirp. The horn chirp
may occur before or up to 30 seconds after the 8-10 second pressure increase/decrease time
period has been reached. Once the horn chirp has sounded, the turn signal in the next location to
be learned will illuminate.
4. After the horn chirp has sounded and the right front turn signal is illuminated, repeat step 3 for
the remaining 3 sensors in the following order:
1. Right front 2. Right rear 3. Left rear
5. After the LR sensor has been learned, a double horn chirp will sound indicating all sensors have
been learned. 6. Turn OFF the ignition to exit the learn mode. 7. After the learn mode has been
exited, adjust all tires to the recommended pressures. Refer to Vehicle Certification, Tire Placard,
Anti-Theft, and
Service Parts ID Label (See: Application and ID/Vehicle Certification, Tire Placard, Anti-Theft, and
Service Parts ID Label) .
Hummer Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Module >
Component Information > Technical Service Bulletins > Tires/Wheels - Tire Pressure Sensors Service/Re-Learning
Service/Re-Learning
INFORMATION
Bulletin No.: 10-03-16-001
Date: July 19, 2010
Models:
Disclaimer
Hummer Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Monitor Receiver
/ Transponder > Component Information > Technical Service Bulletins > Tires/Wheels - Tire Pressure Sensors
Service/Re-Learning
INFORMATION
Bulletin No.: 10-03-16-001
Date: July 19, 2010
Models:
Disclaimer
Hummer Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor >
Component Information > Technical Service Bulletins > Tires/Wheels - Tire Pressure Sensors Service/Re-Learning
Service/Re-Learning
INFORMATION
Bulletin No.: 10-03-16-001
Date: July 19, 2010
Models:
Disclaimer
Component Information > Technical Service Bulletins > Tires/Wheels - Tire Pressure Sensors Service/Re-Learning > Page
1986
INFORMATION
Bulletin No.: 08-03-10-007
Date: May 16, 2008
Procedure
Notice:
Notice:
Important:
1987
sensor.
Important:
rim.
1988
1989
Caution:
injury.
Important:
time.
Parts Information
Disclaimer

Removal Procedure
1. Raise the vehicle on a suitable support. Refer to Lifting and Jacking the Vehicle (See: ) . 2.
Remove the tire/wheel assembly from the vehicle. Refer to Tire and Wheel Removal and
Installation (See: Service and Repair) .
* When separating the tire bead from the wheel, position the bead breaking fixture 90 degrees from
the valve stem.
head.
3. Remove the tire from the wheel. Refer to Tire Mounting and Dismounting (See: Tires/Service

Notice) .
torquing.
4. Install the tire on the wheel. Refer to Tire Mounting and Dismounting (See: Tires/Service and
seconds.
(See: Service and Repair) . 6. Lower the vehicle. 7. Learn the tire pressure sensors. Refer to Tire
Pressure Sensor Learn (See: Service and Repair) .
Hummer Workshop Manuals > Maintenance > Wheels and Tires > Tires > Spare Tire > Component Information > Service
and Repair
Spare Tire: Service and Repair
Spare Tire Carrier Replacement
Removal Procedure
1. Unlatch and open the spare tire carrier swing arm.
2. Remove the spare tire stowage cover nut (1). 3. Remove the spare tire cover (2).
and Repair > Page 1996
4. Remove the spare tire mounting nuts. 5. Remove the spare tire from the spare tire carrier.
6. Remove the spare tire carrier assembly, perform the following steps:
1. Disconnect the license plate lamp harness electrical connector. 2. Remove the spare tire carrier
bolts. 3. Remove the spare tire carrier assembly.
Disassembly Procedure
Important: The following components of the spare tire carrier can be replaced, license plate lamp
harness, carrier swing arm, hinge, striker/sleeve, and latch mechanism and housing. Refer to the
following information for the disassembly of the spare tire carrier. These components can either be
disassembled on the vehicle or on a work bench.
1. Remove the license plate lamp screws.
2. Remove the license plate lamp harness from the clips on the carrier. 3. Remove the harness.
4. Remove the spare tire carrier swing arm from the hinge.
5. Remove the striker bolt and sleeve.

6. Remove the latch mechanism bolts, nuts, and spacers. 7. Remove the latch mechanism. 8.
Remove the latch mechanism isolator bolts. 9. Remove the latch mechanism isolator.
Service/Maintenance Information
Important: The spare tire carrier requires items inspected and/or replaced at scheduled vehicle
service intervals.
Check the carrier swing arm articulation and latching performance as follows:
* The swing arm closing effort is not to be excessive. Adjust the latch assembly, as required.
* The swing arm is to kick back beyond the latch casting after the latch handle is operated. Adjust
the latch assembly, as required.
Important: Under normal conditions the hinge assembly will NOT require lubrication.
Hinge assembly-If the hinge assembly needs to be greased, due to removal, the plug needs to be
removed and lubricated as stated below using GM P/N 89022180 (Canadian P/N 89022181).
1. Remove the M6 set screw (4). 2. Remove the 1/4 inch plug above the set screw. 3. Install a
grease (zerk) fitting (3) where the 1/4 inch plug was, apply grease, rotate the swing arm to ensure a
uniform coating over the internal
bushing.

Notice) .
4. Once the grease is seen exiting the set screw hole: stop, reinstall the set screw (4).
Tighten the set screw to 9 N.m (80 lb in).
5. Again, grease via the zerk fitting (3), continue articulating the swing arm until grease is just
visible on the casting grease seal (2). DO NOT
ALLOW THE SWING ARM TO LIFT DURING LUBRICATION. If the swing arm lifts, remove the set
screw (4) and apply downward pressure while rotating the swing arm. Continue until the swing arm
makes contact with the casting.
6. The hinge is now primed with the correct amount of grease. 7. Remove the zerk fitting (3) and
reinstall the 1/4 inch plug. 8. Reinstall the set screw (4).
Tighten the set screw and plug to 9 N.m (80 lb in).
Hinge assembly-Visually check the grease seal (2) for damage, replace as required.
Hinge assembly-Check the hard stop pad (1), replace as required.

Latch assembly-Check the latch isolator (2) for damage, replace as required. Thoroughly clean the
latch casting surfaces and bond the NEW isolator in place using LOCTITE Black Max 380(R)
adhesive or equivalent.
Latch assembly-Check for operation and apply Teflon dry lube GM P/N 12371287 (Canadian P/N
10953437) to the latch mechanism (1) as required.
Carrier frame-Check the endgate bump stop (2) rubber for damage, replace if required. Thoroughly
clean the surfaces and bond the NEW bump stop in place using LOCTITE Black Max 380(R)
adhesive or equivalent.
Carrier frame-Check the striker sleeve (1) for wear, replace as required.
Carrier frame-Check the lamp (3) for operation.
Service Alignment Procedure
1. The carrier should be loose installed to the vehicle.

Notice) .
2. Align the latch casting square, and tighten the bolts to specifications using the sequence shown.
Tighten the bolts to 95 N.m (70 lb ft).

3. Swing the carrier into the latch pocket so the striker pin touches the latch mechanism. 4. Insert a
shim (1) between the striker bottom and the latch pocket. 5. Early carriers with a red striker sleeve
will require a 5 mm shim, all other carriers with a yellow sleeve will require a 3 mm shim. 6. Secure
the hinge bolts using the specification shown above. 7. Remove the shim (1), the carrier is now
aligned and ready for use.
Assembly Procedure
Important: Thoroughly clean the latch casting surfaces and bond the NEW isolator in place using
LOCTITE Black Max 380(R) adhesive or equivalent.
1. Install the latch mechanism isolator, if necessary. 2. Install the latch mechanism isolator screws.
Tighten the screws to 9 N.m (80 lb in).
3. Install the latch mechanism, if necessary.

4. Install the latch mechanism bolts, spacers, and nuts.
5. Install the sleeve and striker bolt, if necessary.
6. Install the spare tire carrier swing arm to the hinge, if necessary.
7. Install the license plate lamp harness, if necessary. 8. Install the license plate lamp harness to
the clips on the carrier.
9. Install the license plate lamp screws, if necessary.
Tighten the screws to 2.5 N.m (22 lb in).
1. Install the spare tire carrier to the vehicle. Perform the following steps:
1. Position the spare tire carrier to the rear bumper. 2. Loose install the carrier bolts. Refer to the
Service Alignment Procedure above for alignment. 3. Connect the license plate lamp harness
2. Install the spare tire to the spare tire carrier. 3. Install the spare tire mounting nuts.

4. Install the spare tire cover (2). 5. Install the spare tire stowage cover nut (1) until snug. 6. Close
and ensure that the spare tire carrier is latched.
Hummer Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > Customer Interest: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire Pressure/Leaking Wheels
Wheels: Customer Interest Tires/Wheels - Low Tire Pressure/Leaking Wheels
TECHNICAL
Subject: Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant)
Models:
2011 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2010 and Prior
HUMMER H2, H3 2009 and Prior Saab 9-7X with Cast Aluminum Wheels
Supercede: This bulletin is being revised to update the model years and the bulletin reference
information. Please discard Corporate Bulletin Number 05-03-10-003E (Section 03 - Suspension).
Condition
Some customers may comment on a low tire pressure condition.
Diagnosis of the low tire pressure condition indicates an air leak through the cast aluminum wheel.
Cause
Porosity in the cast aluminum wheel may be the cause.
Notice
This bulletin specifically addresses issues related to the wheel casting that may result in an air
leak. For issues related to corrosion of the wheel in service, please refer to Corporate Bulletin
Number 08-03-10-006C - Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light
Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat).
Correction
1. Remove the tire and wheel assembly from the vehicle. Refer to the appropriate service
procedure in SI. 2. Locate the leaking area by inflating the tire to 276 kPa (40 psi) and dipping the
tire/wheel assembly in a water bath, or use a spray bottle with soap
and water to locate the specific leak location.
Important
- If the porosity leak is located in the bead area of the aluminum rim (where the tire meets the rim),
the wheel should be replaced.
- If two or more leaks are located on one wheel, the wheel should be replaced.
3. If air bubbles are observed, mark the location.
- If the leak location is on the tire/rubber area, refer to Corporate Bulletin Number 04-03-10-001F -
Tire Puncture Repair Procedures for All Cars and Light Duty Trucks.
- If the leak is located on the aluminum wheel area, continue with the next step.
4. Inscribe a mark on the tire at the valve stem in order to indicate the orientation of the tire to the
wheel. 5. Dismount the tire from the wheel. Refer to Tire Mounting and Dismounting. 6. Remove
the tire pressure sensor. Refer to Tire Pressure Sensor removal procedure in SI. 7. Scuff the
INSIDE rim surface at the leak area with #80 grit paper and clean the area with general purpose
cleaner, such as 3M(R) General Purpose
Adhesive Cleaner, P/N 08984, or equivalent.
8. Apply a 3 mm (0.12 in) thick layer of Silicone - Adhesive/Sealant, P/N 12378478 (in Canada, use
88900041), or equivalent, to the leak area. 9. Allow for the adhesive/sealant to dry.
Notice Caution must be used when mounting the tire so as not to damage the sealer. Damaging
the repair area may result in an air leak.
Bulletins > Customer Interest: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire Pressure/Leaking Wheels > Page
2016
10. Align the inscribed mark on the tire with the valve stem on the wheel. 11. Reinstall the Tire
Pressure Sensor. Refer to Tire Pressure Sensor installation procedure in SI. 12. Mount the tire on
the wheel. Refer to Tire Mounting and Dismounting. 13. Pressurize the tire to 276 kPa (40 psi) and
inspect for leaks. 14. Adjust tire pressure to meet the placard specification. 15. Balance the
tire/wheel assembly. Refer to Tire and Wheel Assembly Balancing - Off-Vehicle. 16. Install the tire
and wheel assembly onto the vehicle. Refer to the appropriate service procedure in SI.
Parts Information
Important The Silicone - Adhesive/Sealant comes in a case quantity of six. ONLY charge warranty
one tube of adhesive/sealant per wheel repair.
One leak repair per wheel.
Disclaimer
Bulletins > Customer Interest: > 08-03-10-006C > Apr > 10 > Wheels/Tires - Tire Slowly Goes Flat/Warning Light On
Wheels: Customer Interest Wheels/Tires - Tire Slowly Goes Flat/Warning Light On
TECHNICAL
Subject: Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated,
Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat)
Models:
2000-2011 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2
2006-2010 HUMMER H3 2005-2009 Saab 9-7X
Bulletin Number 08-03-10-006B (Section 03 - Suspension).
Condition
Some customers may comment on a tire that slowly loses air pressure over a period of days or
weeks.
Cause
Abrasive elements in the environment may intrude between the tire and wheel at the bead seat.
There is always some relative motion between the tire and wheel (when the vehicle is driven) and
this motion may cause the abrasive particles to wear the wheel and tire materials. As the wear
continues, there may also be intrusion at the tire/wheel interface by corrosive media from the
environment. Eventually a path for air develops and a 'slow' leak may ensue. This corrosion may
appear on the inboard or outboard bead seating surface of the wheel. This corrosion will not be
visible until the tire is dismounted from the wheel.
Notice
This bulletin specifically addresses issues related to wheel bead seat corrosion that may result in
an air leak. For issues related to porosity of the wheel casting that may result in an air leak, please
refer to Corporate Bulletin Number 05-03-10-006F - Low Tire Pressure, Leaking Cast Aluminum
Wheels (Repair with Adhesive Sealant)
Correction
In most cases, this type of air loss can be corrected by following the procedure below.
Important DO NOT replace a wheel for slow air loss unless you have evaluated and/or tried to
repair the wheel with the procedure below.
Notice
The repair is no longer advised or applicable for chromed aluminum wheels.

1. Remove the wheel and tire assembly for diagnosis. Refer to Tire and Wheel Removal and
Installation in SI. 2. After a water dunk tank leak test, if you determine the source of the air leak to
be around the bead seat of the wheel, dismount the tire to examine
the bead seat. Shown below is a typical area of bead seat corrosion.Typical Location of Bead Seat
Corrosion
Bulletins > Customer Interest: > 08-03-10-006C > Apr > 10 > Wheels/Tires - Tire Slowly Goes Flat/Warning Light On > Page
2021
Important Other forms of slow air leaks are possible. If the body of the tire, valve stem and wheel
flange show no signs of air seepage, refer to Corporate Bulletin Number 05-03-10-003D for
additional information on possible wheel porosity issues.
3. Bead seat corrosion is identified by what appears like blistering of the wheel finish, causing a
rough or uneven surface that is difficult for the tire to
maintain a proper seal on. Below is a close-up photo of bead seat corrosion on an aluminum wheel
that was sufficient to cause slow air loss. Close-Up of Bead Seat Corrosion
4. If corrosion is found on the wheel bead seat, measure the affected area as shown below.
- For vehicles with 32,186 km (20,000 mi) or less, the total allowable combined linear area of
repairable corrosion is 100 mm (4 in) or less. If the total area(s) of corrosion exceed these
dimensions, the wheel should be replaced.
- For vehicles that have exceeded 32,186 km (20,000 mi), the total allowable combined linear area
of repairable corrosion is 200 mm (8 in) or less. If the total area(s) of corrosion exceed these
5. In order to correct the wheel leak, use a clean-up (fine cut) sanding disc or biscuit to remove the
corrosion and any flaking paint. You should
remove the corrosion back far enough until you reach material that is stable and firmly bonded to
the wheel. Try to taper the edge of any flaking paint as best you can in order to avoid sharp edges
that may increase the chance of a leak reoccurring. The photo below shows an acceptable repaired
surface.
Notice Corrosion that extends up the lip of the wheel, where after the clean-up process it would be
visible with the tire mounted, is only acceptable on the inboard flange. The inboard flange is not
visible with the wheel assembly in the mounted position. If any loose coatings or corrosion extend
to the visible surfaces on the FACE of the wheel, that wheel must be replaced.
Important Remove ONLY the material required to eliminate the corrosion from the bead seating
surface. DO NOT remove excessive amounts of material. ALWAYS keep the sealing surface as
smooth and level as possible.
2022
Acceptably Prepared (Cleaned-Up) Wheel Surface
6. Once the corrosion has been eliminated, you should coat the repaired area with a commercially
available tire sealant such as Patch Brand Bead
Sealant or equivalent. Commercially available bead sealants are black rubber-like coatings that will
permanently fill and seal the resurfaced bead seat. At 21°C (70°F) ambient temperature, this
sealant will set-up sufficiently for tire mounting in about 10 minutes.Coated and Sealed Bead Seat
7. Remount the tire and install the repaired wheel and tire assembly. Refer to Tire and Wheel
Removal and Installation in SI.
Parts Information
Patch Brand Bead Sealer is available from Myers Tires at 1-800-998-9897 or on the web at
www.myerstiresupply.com. The one-quart size can of sealer will repair about 20 wheels.

2023
Disclaimer
Bulletins > Customer Interest: > 00-03-10-002E > Mar > 10 > Wheels - Chrome Wheel Staining/Pitting/Corrosion
Wheels: Customer Interest Wheels - Chrome Wheel Staining/Pitting/Corrosion
INFORMATION
Subject: Chemical Staining, Pitting, Corrosion and/or Spotted Appearance of Chromed Aluminum
Wheels
Models:
2010 and Prior GM Cars and Trucks (Including Saturn and Saab) 2003-2009 HUMMER H2
2006-2010 HUMMER H3
Supercede: This bulletin is being revised to add models and model years. Please discard
Corporate Bulletin Number 00-03-10-002D (Section 03 - Suspension).
Important You may give a copy of this bulletin to the customer.
What is Chemical Staining of Chrome Wheels? Figure 1
Chemical staining in most cases results from acid based cleaners (refer to Figure 1 for an
example). These stains are frequently milky or greenish in appearance. They result from using
cleaning solutions that contain hydrofluoric, oxalic and most other acids on chrome wheels (or any
wheels). Soap and water is usually sufficient to clean chrome wheels, but if a cleaner must be used
on chrome wheels, GM Chrome and Wire Wheel Cleaner, P/N 1052929 (in Canada, use P/N
10953202), or equivalent, is recommended. Do not use cleaning solutions that contain hydrofluoric,
oxalic and most other acids on chrome wheels (or any wheels).
Notice
Many wheel cleaner instructions advise to take care to avoid contact with painted surfaces. Most
customers think of painted surfaces as the fenders, quarter panels and other exterior sheet metal.
Many vehicles have painted brake calipers. Acidic wheel cleaners may craze, crack, or discolor the
paint on the brake calipers. Damage from wheel cleaners is not covered under the vehicle new car
warranty. Soap and water applied with a soft brush is usually all that is required to clean the
calipers.
Important GM Chrome and Wire Wheel cleaner, P/N 1052929 (in Canada, P/N 10953202), has a
mild phosphoric acid, which will not stain the chrome. However, do not use this product on
clear-coated aluminum wheels.
Whenever any wheel cleaner is used, it must be THOROUGHLY rinsed off of the wheel with clean,
clear water. Special care must be taken to rinse under the hub cap, balance weights, wheel nuts,
lug nut caps, between the wheel cladding and off the back side of the wheel.
Notice
Do not use cleaning solutions that contain hydrofluoric, oxalic and most other acids on chrome
wheels (or any wheels).
If the customer is unsure of the chemical make-up of a particular wheel cleaner, it should be
avoided.
Bulletins > Customer Interest: > 00-03-10-002E > Mar > 10 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page
2028
For wheels showing signs of milky staining from acidic cleaners, refer to Customer Assistance and
Instructions below.
Warranty of Stained Chrome Wheels
Stained wheels are not warrantable. Most acid based cleaners will permanently stain chrome
wheels. Follow-up with dealers has confirmed that such cleaners were used on wheels that were
returned to the Warranty Parts Center (WPC). Any stained wheels received by the WPC will be
charged back to the dealership. To assist the customer, refer to Customer Assistance and
Instructions below.
Pitting or Spotted Appearance of Chrome Wheels Figure 2
A second type or staining or finish disturbance may result from road chemicals, such as calcium
chloride used for dust control of unpaved roads. The staining will look like small pitting (refer to
Figure 2). This staining will usually be on the leading edges of each wheel spoke, but may be
uniformly distributed. If a vehicle must be operated under such conditions, the chrome wheels
should be washed with mild soap and water and thoroughly rinsed as soon as conveniently
possible.
Important Road chemicals, such as calcium chloride used for dust control of unpaved roads, can
also stain chrome wheels. The staining will look like small pitting. This staining will usually be on
the leading edges of each wheel spoke. This is explained by the vehicle traveling in the forward
direction while being splashed by the road chemical. If a vehicle must be operated under such
conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed
as soon as conveniently possible.
Warranty of Pitted or Spotted Chrome Wheels
Wheels returned with pitting or spotting as a result of road chemicals may be replaced one time.
Damage resulting from contact with these applied road chemicals is corrosive to the wheels finish
and may cause damage if the wheels are not kept clean.
Important Notify the customer that this is a one time replacement. Please stress to the customer
the vital importance of keeping the wheels clean if they are operating the vehicle in an area that
applies calcium chloride or other dust controlling chemicals! "GM of Canada" dealers require prior
Warranty Manager approval.
Customer Assistance and Instructions
GM has looked for ways customers may improve the appearance of wheels damaged by acidic
cleaners. The following product and procedure has been found to dramatically improve the
appearance of stained wheels. For wheels that have milky stains caused by acidic cleaners try the
following:
Notice
THE 3M CHROME AND METAL POLISH REQUIRED FOR THIS PROCEDURE IS AN

EXTREMELY AGGRESSIVE POLISH/CLEANER. THE WHEELS MUST BE CLEANED BEFORE
APPLICATION TO AVOID SCRATCHING THE WHEEL SURFACE. THIS PRODUCT WILL
REDUCE THE THICKNESS OF THE CHROME PLATING ON THE WHEEL AND IF USED
INCORRECTLY OR EXCESSIVELY MAY REMOVE THE CHROME PLATING ALL TOGETHER,
EXPOSING A LESS BRIGHT AND BRASSY COLORED SUB-LAYER. FOLLOW INSTRUCTIONS
EXACTLY.
1. Wash the wheels with GM Chrome and Wire Wheel Cleaner, P/N 1052929 (in Canada, use P/N
10953202). Follow the instructions as indicated
on the bottle for stubborn stains. This step will clean and may reduce wheel staining. Flood all
areas of the wheel with water to rinse.
2. Dry the wheels completely.
Notice Begin with a small section of the wheel and with light pressure buff off polish and examine
results. ONLY apply and rub with sufficient force and
Bulletins > Customer Interest: > 00-03-10-002E > Mar > 10 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page
2029
time to remove enough staining that you are satisfied with the results. Some wheels may be
stained to the extent that you may only achieve a 50% improvement while others may be able to be
restored to the original lustre. IN ALL CASES, only apply until the results are satisfactory.
3. Apply 3M Chrome and Metal Polish #39527* with a clean terry cloth towel. As you apply the
polish, the staining will be diminished. 4. When dry, buff off the polish with a clean portion of the
towel. 5. Repeat application of the 3M Chrome and Metal Polish until satisfied with the results. If
continued applications fail to improve the appearance
further discontinue use.
This procedure will improve the appearance of the wheels and may, with repeated applications,
restore the finish dramatically. For wheels that exhibit spotting from road chemicals the above
procedure may marginally improve the condition but will not restore the finish or remove the pitting.
In this type of staining the wheel finish has actually been removed in spots and no manner of
cleaning will restore the finish.
*We believe this source and their products to be reliable. There may be additional manufacturers of
such products/materials. General Motors does not endorse, indicate any preference for or assume
any responsibility for the products or material from this firm or for any such items that may be
available from other sources.
Parts Information
*This product is currently available from 3M. To obtain information for your local retail location
please call 3M at 1-888-364-3577.
Disclaimer
Bulletins > Customer Interest: > 04-03-10-012B > Feb > 08 > Wheels - Pitting/Brake Dust On Chrome Wheel
Wheels: Customer Interest Wheels - Pitting/Brake Dust On Chrome Wheel
INFORMATION
Subject: Pitting and Brake Dust on Chrome wheels
HUMMER H2, H3 2005-2008 Saab 9-7X
Supercede:
04-03-10-012A (Section 03 - Suspension).
Analysis of Returned Wheels
Chrome wheels returned under the New Vehicle Limited Warranty for pitting concerns have
recently been evaluated. This condition is usually most severe in the vent (or window) area of the
front wheels. This "pitting" may actually be brake dust that has been allowed to accumulate on the
wheel. The longer this accumulation builds up, the more difficult it is to remove.
Cleaning the Wheels
In all cases, the returned wheels could be cleaned to their original condition using GM Vehicle Care
Cleaner Wax, P/N 12377966 (in Canada, P/N 10952905). When using this product, you should
confine your treatment to the areas of the wheel that show evidence of the brake dust build-up.
This product is only for use on chromed steel or chromed aluminum wheels.
Parts Information
Wheel replacement for this condition is NOT applicable under the terms of the New Vehicle Limited
Warranty.
Disclaimer
Bulletins > All Technical Service Bulletins for Wheels: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire
Pressure/Leaking Wheels
Wheels: All Technical Service Bulletins Tires/Wheels - Low Tire Pressure/Leaking Wheels
TECHNICAL
Subject: Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant)
Models:
2011 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2010 and Prior
HUMMER H2, H3 2009 and Prior Saab 9-7X with Cast Aluminum Wheels
Supercede: This bulletin is being revised to update the model years and the bulletin reference
information. Please discard Corporate Bulletin Number 05-03-10-003E (Section 03 - Suspension).
Condition
Some customers may comment on a low tire pressure condition.
Diagnosis of the low tire pressure condition indicates an air leak through the cast aluminum wheel.
Cause
Porosity in the cast aluminum wheel may be the cause.
Notice
This bulletin specifically addresses issues related to the wheel casting that may result in an air
leak. For issues related to corrosion of the wheel in service, please refer to Corporate Bulletin
Number 08-03-10-006C - Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light
Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat).
Correction
1. Remove the tire and wheel assembly from the vehicle. Refer to the appropriate service
procedure in SI. 2. Locate the leaking area by inflating the tire to 276 kPa (40 psi) and dipping the
tire/wheel assembly in a water bath, or use a spray bottle with soap
and water to locate the specific leak location.
Important
- If the porosity leak is located in the bead area of the aluminum rim (where the tire meets the rim),
the wheel should be replaced.
- If two or more leaks are located on one wheel, the wheel should be replaced.
3. If air bubbles are observed, mark the location.
- If the leak location is on the tire/rubber area, refer to Corporate Bulletin Number 04-03-10-001F -
Tire Puncture Repair Procedures for All Cars and Light Duty Trucks.
- If the leak is located on the aluminum wheel area, continue with the next step.
4. Inscribe a mark on the tire at the valve stem in order to indicate the orientation of the tire to the
wheel. 5. Dismount the tire from the wheel. Refer to Tire Mounting and Dismounting. 6. Remove
the tire pressure sensor. Refer to Tire Pressure Sensor removal procedure in SI. 7. Scuff the
INSIDE rim surface at the leak area with #80 grit paper and clean the area with general purpose
cleaner, such as 3M(R) General Purpose
Adhesive Cleaner, P/N 08984, or equivalent.
8. Apply a 3 mm (0.12 in) thick layer of Silicone - Adhesive/Sealant, P/N 12378478 (in Canada, use
88900041), or equivalent, to the leak area. 9. Allow for the adhesive/sealant to dry.
Notice Caution must be used when mounting the tire so as not to damage the sealer. Damaging
the repair area may result in an air leak.
Bulletins > All Technical Service Bulletins for Wheels: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire
Pressure/Leaking Wheels > Page 2039
10. Align the inscribed mark on the tire with the valve stem on the wheel. 11. Reinstall the Tire
Pressure Sensor. Refer to Tire Pressure Sensor installation procedure in SI. 12. Mount the tire on
the wheel. Refer to Tire Mounting and Dismounting. 13. Pressurize the tire to 276 kPa (40 psi) and
inspect for leaks. 14. Adjust tire pressure to meet the placard specification. 15. Balance the
tire/wheel assembly. Refer to Tire and Wheel Assembly Balancing - Off-Vehicle. 16. Install the tire
and wheel assembly onto the vehicle. Refer to the appropriate service procedure in SI.
Parts Information
Important The Silicone - Adhesive/Sealant comes in a case quantity of six. ONLY charge warranty
one tube of adhesive/sealant per wheel repair.
One leak repair per wheel.
Disclaimer
Bulletins > All Technical Service Bulletins for Wheels: > 08-03-10-006C > Apr > 10 > Wheels/Tires - Tire Slowly Goes
Flat/Warning Light On
Wheels: All Technical Service Bulletins Wheels/Tires - Tire Slowly Goes Flat/Warning Light On
TECHNICAL
Subject: Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated,
Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat)
Models:
2000-2011 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2
2006-2010 HUMMER H3 2005-2009 Saab 9-7X
Bulletin Number 08-03-10-006B (Section 03 - Suspension).
Condition
Some customers may comment on a tire that slowly loses air pressure over a period of days or
weeks.
Cause
Abrasive elements in the environment may intrude between the tire and wheel at the bead seat.
There is always some relative motion between the tire and wheel (when the vehicle is driven) and
this motion may cause the abrasive particles to wear the wheel and tire materials. As the wear
continues, there may also be intrusion at the tire/wheel interface by corrosive media from the
environment. Eventually a path for air develops and a 'slow' leak may ensue. This corrosion may
appear on the inboard or outboard bead seating surface of the wheel. This corrosion will not be
visible until the tire is dismounted from the wheel.
Notice
This bulletin specifically addresses issues related to wheel bead seat corrosion that may result in
an air leak. For issues related to porosity of the wheel casting that may result in an air leak, please
refer to Corporate Bulletin Number 05-03-10-006F - Low Tire Pressure, Leaking Cast Aluminum
Wheels (Repair with Adhesive Sealant)
Correction
In most cases, this type of air loss can be corrected by following the procedure below.
Important DO NOT replace a wheel for slow air loss unless you have evaluated and/or tried to
repair the wheel with the procedure below.
Notice
The repair is no longer advised or applicable for chromed aluminum wheels.

1. Remove the wheel and tire assembly for diagnosis. Refer to Tire and Wheel Removal and
Installation in SI. 2. After a water dunk tank leak test, if you determine the source of the air leak to
be around the bead seat of the wheel, dismount the tire to examine
the bead seat. Shown below is a typical area of bead seat corrosion.Typical Location of Bead Seat
Corrosion
Flat/Warning Light On > Page 2044
Important Other forms of slow air leaks are possible. If the body of the tire, valve stem and wheel
flange show no signs of air seepage, refer to Corporate Bulletin Number 05-03-10-003D for
additional information on possible wheel porosity issues.
3. Bead seat corrosion is identified by what appears like blistering of the wheel finish, causing a
rough or uneven surface that is difficult for the tire to
maintain a proper seal on. Below is a close-up photo of bead seat corrosion on an aluminum wheel
that was sufficient to cause slow air loss. Close-Up of Bead Seat Corrosion
4. If corrosion is found on the wheel bead seat, measure the affected area as shown below.
- For vehicles with 32,186 km (20,000 mi) or less, the total allowable combined linear area of
repairable corrosion is 100 mm (4 in) or less. If the total area(s) of corrosion exceed these
- For vehicles that have exceeded 32,186 km (20,000 mi), the total allowable combined linear area
of repairable corrosion is 200 mm (8 in) or less. If the total area(s) of corrosion exceed these
5. In order to correct the wheel leak, use a clean-up (fine cut) sanding disc or biscuit to remove the
corrosion and any flaking paint. You should
remove the corrosion back far enough until you reach material that is stable and firmly bonded to
the wheel. Try to taper the edge of any flaking paint as best you can in order to avoid sharp edges
that may increase the chance of a leak reoccurring. The photo below shows an acceptable repaired
surface.
Notice Corrosion that extends up the lip of the wheel, where after the clean-up process it would be
visible with the tire mounted, is only acceptable on the inboard flange. The inboard flange is not
visible with the wheel assembly in the mounted position. If any loose coatings or corrosion extend
to the visible surfaces on the FACE of the wheel, that wheel must be replaced.
Important Remove ONLY the material required to eliminate the corrosion from the bead seating
surface. DO NOT remove excessive amounts of material. ALWAYS keep the sealing surface as
smooth and level as possible.
Acceptably Prepared (Cleaned-Up) Wheel Surface
6. Once the corrosion has been eliminated, you should coat the repaired area with a commercially
available tire sealant such as Patch Brand Bead
Sealant or equivalent. Commercially available bead sealants are black rubber-like coatings that will
permanently fill and seal the resurfaced bead seat. At 21°C (70°F) ambient temperature, this
sealant will set-up sufficiently for tire mounting in about 10 minutes.Coated and Sealed Bead Seat
7. Remount the tire and install the repaired wheel and tire assembly. Refer to Tire and Wheel
Removal and Installation in SI.
Parts Information
Patch Brand Bead Sealer is available from Myers Tires at 1-800-998-9897 or on the web at
www.myerstiresupply.com. The one-quart size can of sealer will repair about 20 wheels.

Disclaimer
Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-002E > Mar > 10 > Wheels - Chrome Wheel
Staining/Pitting/Corrosion
Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Staining/Pitting/Corrosion
INFORMATION
Subject: Chemical Staining, Pitting, Corrosion and/or Spotted Appearance of Chromed Aluminum
Wheels
Models:
2010 and Prior GM Cars and Trucks (Including Saturn and Saab) 2003-2009 HUMMER H2
2006-2010 HUMMER H3
Supercede: This bulletin is being revised to add models and model years. Please discard
Corporate Bulletin Number 00-03-10-002D (Section 03 - Suspension).
Important You may give a copy of this bulletin to the customer.
What is Chemical Staining of Chrome Wheels? Figure 1
Chemical staining in most cases results from acid based cleaners (refer to Figure 1 for an
example). These stains are frequently milky or greenish in appearance. They result from using
cleaning solutions that contain hydrofluoric, oxalic and most other acids on chrome wheels (or any
wheels). Soap and water is usually sufficient to clean chrome wheels, but if a cleaner must be used
on chrome wheels, GM Chrome and Wire Wheel Cleaner, P/N 1052929 (in Canada, use P/N
10953202), or equivalent, is recommended. Do not use cleaning solutions that contain hydrofluoric,
oxalic and most other acids on chrome wheels (or any wheels).
Notice
Many wheel cleaner instructions advise to take care to avoid contact with painted surfaces. Most
customers think of painted surfaces as the fenders, quarter panels and other exterior sheet metal.
Many vehicles have painted brake calipers. Acidic wheel cleaners may craze, crack, or discolor the
paint on the brake calipers. Damage from wheel cleaners is not covered under the vehicle new car
warranty. Soap and water applied with a soft brush is usually all that is required to clean the
calipers.
Important GM Chrome and Wire Wheel cleaner, P/N 1052929 (in Canada, P/N 10953202), has a
mild phosphoric acid, which will not stain the chrome. However, do not use this product on
clear-coated aluminum wheels.
Whenever any wheel cleaner is used, it must be THOROUGHLY rinsed off of the wheel with clean,
clear water. Special care must be taken to rinse under the hub cap, balance weights, wheel nuts,
lug nut caps, between the wheel cladding and off the back side of the wheel.
Notice
Do not use cleaning solutions that contain hydrofluoric, oxalic and most other acids on chrome
wheels (or any wheels).
If the customer is unsure of the chemical make-up of a particular wheel cleaner, it should be
avoided.
Staining/Pitting/Corrosion > Page 2051
For wheels showing signs of milky staining from acidic cleaners, refer to Customer Assistance and
Instructions below.
Warranty of Stained Chrome Wheels
Stained wheels are not warrantable. Most acid based cleaners will permanently stain chrome
wheels. Follow-up with dealers has confirmed that such cleaners were used on wheels that were
returned to the Warranty Parts Center (WPC). Any stained wheels received by the WPC will be
charged back to the dealership. To assist the customer, refer to Customer Assistance and
Instructions below.
Pitting or Spotted Appearance of Chrome Wheels Figure 2
A second type or staining or finish disturbance may result from road chemicals, such as calcium
chloride used for dust control of unpaved roads. The staining will look like small pitting (refer to
Figure 2). This staining will usually be on the leading edges of each wheel spoke, but may be
uniformly distributed. If a vehicle must be operated under such conditions, the chrome wheels
should be washed with mild soap and water and thoroughly rinsed as soon as conveniently
possible.
Important Road chemicals, such as calcium chloride used for dust control of unpaved roads, can
also stain chrome wheels. The staining will look like small pitting. This staining will usually be on
the leading edges of each wheel spoke. This is explained by the vehicle traveling in the forward
direction while being splashed by the road chemical. If a vehicle must be operated under such
conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed
as soon as conveniently possible.
Warranty of Pitted or Spotted Chrome Wheels
Wheels returned with pitting or spotting as a result of road chemicals may be replaced one time.
Damage resulting from contact with these applied road chemicals is corrosive to the wheels finish
and may cause damage if the wheels are not kept clean.
Important Notify the customer that this is a one time replacement. Please stress to the customer
the vital importance of keeping the wheels clean if they are operating the vehicle in an area that
applies calcium chloride or other dust controlling chemicals! "GM of Canada" dealers require prior
Warranty Manager approval.
Customer Assistance and Instructions
GM has looked for ways customers may improve the appearance of wheels damaged by acidic
cleaners. The following product and procedure has been found to dramatically improve the
appearance of stained wheels. For wheels that have milky stains caused by acidic cleaners try the
following:
Notice
THE 3M CHROME AND METAL POLISH REQUIRED FOR THIS PROCEDURE IS AN

EXTREMELY AGGRESSIVE POLISH/CLEANER. THE WHEELS MUST BE CLEANED BEFORE
APPLICATION TO AVOID SCRATCHING THE WHEEL SURFACE. THIS PRODUCT WILL
REDUCE THE THICKNESS OF THE CHROME PLATING ON THE WHEEL AND IF USED
INCORRECTLY OR EXCESSIVELY MAY REMOVE THE CHROME PLATING ALL TOGETHER,
EXPOSING A LESS BRIGHT AND BRASSY COLORED SUB-LAYER. FOLLOW INSTRUCTIONS
EXACTLY.
1. Wash the wheels with GM Chrome and Wire Wheel Cleaner, P/N 1052929 (in Canada, use P/N
10953202). Follow the instructions as indicated
on the bottle for stubborn stains. This step will clean and may reduce wheel staining. Flood all
areas of the wheel with water to rinse.
2. Dry the wheels completely.
Notice Begin with a small section of the wheel and with light pressure buff off polish and examine
results. ONLY apply and rub with sufficient force and
Staining/Pitting/Corrosion > Page 2052
time to remove enough staining that you are satisfied with the results. Some wheels may be
stained to the extent that you may only achieve a 50% improvement while others may be able to be
restored to the original lustre. IN ALL CASES, only apply until the results are satisfactory.
3. Apply 3M Chrome and Metal Polish #39527* with a clean terry cloth towel. As you apply the
polish, the staining will be diminished. 4. When dry, buff off the polish with a clean portion of the
towel. 5. Repeat application of the 3M Chrome and Metal Polish until satisfied with the results. If
continued applications fail to improve the appearance
further discontinue use.
This procedure will improve the appearance of the wheels and may, with repeated applications,
restore the finish dramatically. For wheels that exhibit spotting from road chemicals the above
procedure may marginally improve the condition but will not restore the finish or remove the pitting.
In this type of staining the wheel finish has actually been removed in spots and no manner of
cleaning will restore the finish.
*We believe this source and their products to be reliable. There may be additional manufacturers of
such products/materials. General Motors does not endorse, indicate any preference for or assume
any responsibility for the products or material from this firm or for any such items that may be
available from other sources.
Parts Information
*This product is currently available from 3M. To obtain information for your local retail location
please call 3M at 1-888-364-3577.
Disclaimer
Bulletins > All Technical Service Bulletins for Wheels: > 99-08-51-007D > Jan > 10 > Tires/Wheels - Refinishing Aluminum
Wheels
Wheels: All Technical Service Bulletins Tires/Wheels - Refinishing Aluminum Wheels
INFORMATION
Subject: Refinishing Aluminum Wheels
Models:
2010 and Prior Passenger Cars and Trucks (Including Saturn) 2003-2010 HUMMER H2 2006-2010
HUMMER H3 2005-2009 Saab 9-7X
Supercede: This bulletin is being revised to add additional model years and remove one outside
company reference. Please discard Corporate Bulletin Number 99-08-51-007C (Section 08 - Body
and Accessories).
This bulletin updates General Motor's position on refinishing aluminum wheels. GM does not
endorse any repairs that involve welding, bending, straightening or re-machining. Only cosmetic
refinishing of the wheel's coatings, using recommended procedures, is allowed.
Evaluating Damage
In evaluating damage, it is the GM Dealer's responsibility to inspect the wheel for corrosion,
scrapes, gouges, etc. The Dealer must insure that such damage is not deeper than what can be
sanded or polished off. The wheel must be inspected for cracks. If cracks are found, discard the
wheel. Any wheels with bent rim flanges must not be repaired or refinished. Wheels that have been
refinished by an outside company must be returned to the same vehicle. The Dealer must record
the wheel ID stamp or the cast date on the wheel in order to assure this requirement. Refer to
Refinisher's Responsibility - Outside Company later in this bulletin.
Aluminum Wheel Refinishing Recommendations
- Chrome-plated aluminum wheels Re-plating these wheels is not recommended.
- Polished aluminum wheels These wheels have a polyester or acrylic clearcoat on them. If the
clearcoat is damaged, refinishing is possible. However, the required refinishing process cannot be
performed in the dealer environment. Refer to Refinisher's Responsibility - Outside Company later
in this bulletin.
- Painted aluminum wheels These wheels are painted using a primer, color coat, and clearcoat
procedure. If the paint is damaged, refinishing is possible. As with polished wheels, all original
coatings must be removed first. Media blasting is recommended. Refer to GM Aluminum
Refinishing Bulletin #53-17-03A for the re-painting of this type of wheel.
- Bright, machined aluminum wheels These wheels have a polyester or acrylic clearcoat on them.
In some cases, the recessed "pocket" areas of the wheel may be painted. Surface refinishing is
possible. The wheel must be totally stripped by media blasting or other suitable means. The wheel
should be resurfaced by using a sanding process rather than a machining process. This allows the
least amount of material to be removed.
Important Do not use any re-machining process that removes aluminum. This could affect the
dimensions and function of the wheel.
Painting is an option to re-clearcoating polished and bright machined aluminum wheels. Paint will
better mask any surface imperfections and is somewhat more durable than clearcoat alone. GM
recommends using Corsican SILVER WAEQ9283 for a fine "aluminum-like" look or Sparkle
SILVER WA9967 for a very bright look. As an option, the body color may also be used. When using
any of the painting options, it is recommended that all four wheels be refinished in order to maintain
color uniformity. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for specific procedures
and product recommendations.
Refinisher's Responsibility - Outside Company
Important Some outside companies are offering wheel refinishing services. Such refinished wheels
will be permanently marked by the refinisher and are warranted by the refinisher. Any process that
re-machines or otherwise re-manufactures the wheel should not be used.
A refinisher's responsibility includes inspecting for cracks using the Zyglo system or the equivalent.
Any cracked wheels must not be refinished. No welding, hammering or reforming of any kind is
allowed. The wheel ID must be recorded and follow the wheel throughout the process in order to
assure that the same wheel is returned. A plastic media blast may be used for clean up of the
wheel. Hand and/or lathe sanding of the machined surface and the
Bulletins > All Technical Service Bulletins for Wheels: > 99-08-51-007D > Jan > 10 > Tires/Wheels - Refinishing Aluminum
Wheels > Page 2057
wheel window is allowed. Material removal, though, must be kept to a minimum. Re-machining of
the wheel is not allowed. Paint and/or clear coat must not be present on the following surfaces: the
nut chamfers, the wheel mounting surfaces and the wheel pilot hole. The refinisher must
permanently ID stamp the wheel and warrant the painted/clearcoated surfaces for a minimum of
one year or the remainder of the new vehicle warranty, whichever is longer.
Important Whenever a wheel is refinished, the mounting surface and the wheel nut contact
surfaces must not be painted or clearcoated. Coating these surfaces could affect the wheel nut
torque.
When re-mounting a tire on an aluminum wheel, coated balance weights must be used in order to
reduce the chance of future cosmetic damage.
Disclaimer
Bulletins > All Technical Service Bulletins for Wheels: > 04-03-10-012B > Feb > 08 > Wheels - Pitting/Brake Dust On
Chrome Wheel
Wheels: All Technical Service Bulletins Wheels - Pitting/Brake Dust On Chrome Wheel
INFORMATION
Subject: Pitting and Brake Dust on Chrome wheels
HUMMER H2, H3 2005-2008 Saab 9-7X
Supercede:
04-03-10-012A (Section 03 - Suspension).
Analysis of Returned Wheels
Chrome wheels returned under the New Vehicle Limited Warranty for pitting concerns have
recently been evaluated. This condition is usually most severe in the vent (or window) area of the
front wheels. This "pitting" may actually be brake dust that has been allowed to accumulate on the
wheel. The longer this accumulation builds up, the more difficult it is to remove.
Cleaning the Wheels
In all cases, the returned wheels could be cleaned to their original condition using GM Vehicle Care
Cleaner Wax, P/N 12377966 (in Canada, P/N 10952905). When using this product, you should
confine your treatment to the areas of the wheel that show evidence of the brake dust build-up.
This product is only for use on chromed steel or chromed aluminum wheels.
Parts Information
Wheel replacement for this condition is NOT applicable under the terms of the New Vehicle Limited
Warranty.
Disclaimer
Bulletins > All Other Service Bulletins for Wheels: > 99-08-51-007D > Jan > 10 > Tires/Wheels - Refinishing Aluminum
Wheels
Wheels: All Technical Service Bulletins Tires/Wheels - Refinishing Aluminum Wheels
INFORMATION
Subject: Refinishing Aluminum Wheels
Models:
2010 and Prior Passenger Cars and Trucks (Including Saturn) 2003-2010 HUMMER H2 2006-2010
HUMMER H3 2005-2009 Saab 9-7X
Supercede: This bulletin is being revised to add additional model years and remove one outside
company reference. Please discard Corporate Bulletin Number 99-08-51-007C (Section 08 - Body
and Accessories).
This bulletin updates General Motor's position on refinishing aluminum wheels. GM does not
endorse any repairs that involve welding, bending, straightening or re-machining. Only cosmetic
refinishing of the wheel's coatings, using recommended procedures, is allowed.
Evaluating Damage
In evaluating damage, it is the GM Dealer's responsibility to inspect the wheel for corrosion,
scrapes, gouges, etc. The Dealer must insure that such damage is not deeper than what can be
sanded or polished off. The wheel must be inspected for cracks. If cracks are found, discard the
wheel. Any wheels with bent rim flanges must not be repaired or refinished. Wheels that have been
refinished by an outside company must be returned to the same vehicle. The Dealer must record
the wheel ID stamp or the cast date on the wheel in order to assure this requirement. Refer to
Refinisher's Responsibility - Outside Company later in this bulletin.
Aluminum Wheel Refinishing Recommendations
- Chrome-plated aluminum wheels Re-plating these wheels is not recommended.
- Polished aluminum wheels These wheels have a polyester or acrylic clearcoat on them. If the
clearcoat is damaged, refinishing is possible. However, the required refinishing process cannot be
performed in the dealer environment. Refer to Refinisher's Responsibility - Outside Company later
in this bulletin.
- Painted aluminum wheels These wheels are painted using a primer, color coat, and clearcoat
procedure. If the paint is damaged, refinishing is possible. As with polished wheels, all original
coatings must be removed first. Media blasting is recommended. Refer to GM Aluminum
Refinishing Bulletin #53-17-03A for the re-painting of this type of wheel.
- Bright, machined aluminum wheels These wheels have a polyester or acrylic clearcoat on them.
In some cases, the recessed "pocket" areas of the wheel may be painted. Surface refinishing is
possible. The wheel must be totally stripped by media blasting or other suitable means. The wheel
should be resurfaced by using a sanding process rather than a machining process. This allows the
least amount of material to be removed.
Important Do not use any re-machining process that removes aluminum. This could affect the
dimensions and function of the wheel.
Painting is an option to re-clearcoating polished and bright machined aluminum wheels. Paint will
better mask any surface imperfections and is somewhat more durable than clearcoat alone. GM
recommends using Corsican SILVER WAEQ9283 for a fine "aluminum-like" look or Sparkle
SILVER WA9967 for a very bright look. As an option, the body color may also be used. When using
any of the painting options, it is recommended that all four wheels be refinished in order to maintain
color uniformity. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for specific procedures
and product recommendations.
Refinisher's Responsibility - Outside Company
Important Some outside companies are offering wheel refinishing services. Such refinished wheels
will be permanently marked by the refinisher and are warranted by the refinisher. Any process that
re-machines or otherwise re-manufactures the wheel should not be used.
A refinisher's responsibility includes inspecting for cracks using the Zyglo system or the equivalent.
Any cracked wheels must not be refinished. No welding, hammering or reforming of any kind is
allowed. The wheel ID must be recorded and follow the wheel throughout the process in order to
assure that the same wheel is returned. A plastic media blast may be used for clean up of the
wheel. Hand and/or lathe sanding of the machined surface and the
Bulletins > All Other Service Bulletins for Wheels: > 99-08-51-007D > Jan > 10 > Tires/Wheels - Refinishing Aluminum
Wheels > Page 2067
wheel window is allowed. Material removal, though, must be kept to a minimum. Re-machining of
the wheel is not allowed. Paint and/or clear coat must not be present on the following surfaces: the
nut chamfers, the wheel mounting surfaces and the wheel pilot hole. The refinisher must
permanently ID stamp the wheel and warrant the painted/clearcoated surfaces for a minimum of
one year or the remainder of the new vehicle warranty, whichever is longer.
Important Whenever a wheel is refinished, the mounting surface and the wheel nut contact
surfaces must not be painted or clearcoated. Coating these surfaces could affect the wheel nut
torque.
When re-mounting a tire on an aluminum wheel, coated balance weights must be used in order to
reduce the chance of future cosmetic damage.
Disclaimer
Wheels: Description and Operation
Replacement Wheels Description
Replace the wheel if any of the following conditions exist:
* The wheel exhibits excessive runout.
* The wheel is bent.
* The wheel is cracked.
* The wheel is severely rusted.
* The wheel is severely corroded.
Important: Air leaks caused by porosity on aluminum wheels are repairable.
* The wheel leaks air. Caution: If you are replacing the wheel(s), the wheel stud(s), the wheel nut(s)
or the wheel bolt(s), install only new GM original equipment parts. Installation of used parts or
non-GM original equipment parts may cause the wheel to loosen, loss of tire air pressure, poor
vehicle handling and loss of vehicle control resulting in personal injury.
Notice: The use of non-GM original equipment wheels may cause:
* Damage to the wheel bearing, the wheel fasteners and the wheel
* Tire damage caused by the modified clearance to the adjacent vehicle components
* Adverse vehicle steering stability caused by the modified scrub radius
* Damage to the vehicle caused by the modified ground clearance
* Speedometer and odometer inaccuracy
Replace the wheel, the wheel studs and the wheel/nuts, or the wheel bolts if applicable, if any of
the following conditions exist:
* The wheel has elongated bolt holes.
* The wheel/nuts, or bolts if applicable, loosen repeatedly.
Steel wheel identification is stamped into the wheel near the valve stem.
Aluminum wheel identification is cast into the inboard side of the wheel.
Hummer Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Service and Repair
> Aluminum Wheel Porosity Repair
Wheels: Service and Repair Aluminum Wheel Porosity Repair
Aluminum Wheel Porosity Repair
1. Remove the tire and wheel. Refer to Tire and Wheel Removal and Installation (See: Service and
Repair) . 2. Inflate the tire to the manufactures specified pressure as stated on the tire. 3.
Submerge the tire/wheel into a water bath in order to locate the leak. 4. Inscribe a mark on the
wheel in order to indicate the leak areas. 5. Inscribe a mark on the tire at the valve stem in order to
indicate the orientation of the tire to the wheel. 6. Remove the tire from the wheel. Refer to Tire
Mounting and Dismounting (See: Tires/Service and Repair/Removal and Replacement) .
Important: Do not damage the exterior surface of the wheel.
7. Use number 80 grit sandpaper to scuff the inside of the rim surface at the leak area. 8. Use
general purpose cleaner such as 3M(R), P/N 08984 or equivalent, to clean the leak area. 9. Apply
3 mm (0.12 in) thick layer of adhesive/sealant, GM P/N 12378478 (Canadian P/N 88900041) or
equivalent, to the leak area.
10. Allow for the adhesive/sealant to dry. 11. Align the inscribed mark on the tire with the valve
stem on the wheel. 12. Install the tire to the wheel. Refer to Tire Mounting and Dismounting (See:
Tires/Service and Repair/Removal and Replacement) . 13. Pressurize the tire to 276 kPa (40 psi).
14. Submerge the tire/wheel into a water bath in order ensure the leak is sealed. 15. Inflate the tire
to the specified pressure as stated on the tire placard. 16. Balance the tire and wheel. Refer to Tire
and Wheel Assembly Balancing - Off Vehicle (See: Body and Frame/Testing and
Inspection/Vibration
Diagnosis and Correction/Repair Instructions/Tire and Wheel Assembly Balancing - Off Vehicle) .
17. Install the tire and wheel. Refer to Tire and Wheel Removal and Installation (See: Service and
Repair) .
> Aluminum Wheel Porosity Repair > Page 2071
Wheels: Service and Repair Aluminum Wheel Refinishing
Aluminum Wheel Refinishing
Aluminum Wheel Refinishing Guidelines
Caution: To avoid personal injury when exposed to plastic media blast, hand and/or lathe sanding
dust, primer, color coat, and clearcoat, you must work in a properly ventilated area, wearing an
approved respirator, eye protection, earplugs and protective gloves and clothing.
Evaluating Damage
Important:
* Inspect the wheel for corrosion, scrapes, gouges, etc. Damage MUST NOT be deeper than what
can be sanded or polished off.
* Inspect the wheel for cracks. If cracks are found, discard the wheel.
* ALL wheels with bent rim flanges must not be repaired or refinished.
The re-machining and the re-clear coating of aluminum wheels is not recommended in the dealer
environment due to concerns of repair durability.
* Do not use any re-machining process that removes aluminum. This could affect the dimensions
and function of the wheel.
Aluminum Wheel Refinishing General Recommendations/Options
* Painted aluminum wheels use a primer, color coat, and clearcoat procedure. If the paint is
damaged, refinishing is possible. As with polished wheels, all original coatings must be removed
first. Media blasting is recommended. (See option number 1).
* If the clearcoat is damaged, it is possible to refinish with clearcoat only, however, the required
refinishing process cannot be performed in the dealer environment. Refer to Refinishers
Responsibility (Repair option #2).
* Re-plating of chrome-plated aluminum wheels is not recommended.
Repair Option Number 1
Material Required/Information Resources
* The Paint Manufactures Color Book
* Refer to the latest GM Approved Refinish Materials Booklet (GM 4901 MD-2005) for specific
products for aluminum refinishing.
Important: Chemical strippers are not recommended.
* Refer to specific Paint Manufactures for refinish procedures and process pertaining to "Aluminum
Refinishing". The procedure requires the wheel surface to be plastic media blasted to remove old
paint or clearcoat.
General Color Selection
* If the wheels being painted were previously clearcoated aluminum, and a painted aluminum look
is desired, using Corsican Silver WAEQ9283 for a fine "aluminum-like" look, or Sparkle Silver
WA9967 for a very bright look. Body color is another option to the customer that may also be used.
* Some specific colors may be recommended on certain models (currently SSR and GTO).
* If painting wheels that were previously clearcoated aluminum, it is recommended that all four
wheels and their center caps be refinished to maintain color uniformity.
General Refinishing Procedures-Removal
1. Remove the wheels from the vehicle. The tires may remain mounted on the wheels. 2. Remove
the balance weights and mark their locations on the tire. 3. Remove excess grease, etc. from the
wheels with wax and grease remover. 4. Have the wheels plastic media blasted to remove the
clearcoat.
Important: MASK OFF ALL MOUNTING SURFACES, whenever a wheel is refinished. The
mounting surface and the wheel nut contact surfaces must not be painted or clearcoated. Coating
these surfaces could affect the wheel nut torque.
5. Clean and mask and paint the wheels.
General Refinishing Procedures-Installation

> Aluminum Wheel Porosity Repair > Page 2072
1. Unmask the wheels. 2. Clean all wheel mounting surface of any corrosion, overspray, or dirt.
Important: When re-balancing a tire on an aluminum wheel, coated balance weights must be used
in order to reduce the chance of future cosmetic damage.
3. Install NEW coated balance weights at marked locations.
Important: Use a torque stick on an impact wrench, or a torque wrench to consistently and
uniformly fasten the wheel to the specified torque for the vehicle. The star pattern must be followed.
4. Install wheels on vehicle.
Repair Option Number 2. Outside Companies
* Some outside companies are offering wheel refinishing services. One such company, Transwheel
Corporation (800-892-3733), provides this service with GM guidelines. Other companies may also
exist.
* Any process that re-machines or otherwise remanufactures the wheel should not be used.
* The wheel ID must be recorded and follow the wheel throughout the process to assure that the
same wheel is returned. The refinisher must permanently ID stamp the wheel and warrant the
painted/clearcoated surfaces for a minimum of one year or the remainder of the new vehicle
warranty, whichever is longer.
* Paint and/or clearcoat must not be present on the following surfaces: the nut chamfers, the wheel
mounting surfaces and the wheel pilot hole.
* A refinishers responsibility includes inspecting for cracks using the Zyglo system or the
equivalent. Any cracked wheels must not be refinished. No welding, hammering or reforming of any
kind is allowed. A plastic media blast may be used for clean up of the wheel. Hand and/or lathe
sanding of the machined surface and the wheel window is allowed. Material removal, though, must
be kept to a minimum.
Hummer Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Testing and
Inspection
Wheel Bearing: Testing and Inspection
Wheel Bearings Diagnosis

Inspection > Page 2076
Wheel Bearing: Service and Repair
Front Wheel Hub, Bearing, and Seal Replacement
Removal Procedure
Notice: Never place vehicle on the ground with the halfshaft removed or the halfshaft nut torqued
improperly. Otherwise, bearing seals may become dislodged causing premature wear and/or
damage to the hub and bearing assembly.
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: ) . 2. Remove the
tire and wheel. Refer to Tire and Wheel Removal and Installation (See: Service and Repair) . 3.
Remove the rotor. Refer to Front Brake Rotor Replacement (See: Brakes and Traction Control/Disc
Brake System/Brake Rotor/Disc/Service and
Repair/Removal and Replacement/Front Brake Rotor Replacement) .
4. Remove the wheel speed sensor and brake hose mounting bracket bolt from the steering
knuckle. 5. Disconnect the electrical connection for the wheel speed sensor. 6. Remove the wheel
driveshaft nut retaining cover. 7. Remove the wheel driveshaft assembly retaining nut and washer
from the wheel driveshaft assembly.
Disengage the wheel driveshaft from the wheel hub and bearing.
8. Remove the wheel hub and bearing mounting bolts. 9. Remove the wheel hub and bearing and
splash shield from the vehicle.
10. Remove the O-ring seal from the steering knuckle bore. 11. Remove the wheel speed sensor
from the wheel hub and bearing. 12. Clean and inspect the O-ring seal. 13. Replace the seal if the
following conditions exist:
* Nicks
* Cuts
* Dry or brittle
* Compression set
1. Clean all corrosion or contaminates from the steering knuckle bore and the hub and bearing
assembly. 2. Lubricate the steering knuckle bore with wheel bearing grease or the equivalent.
3. Install the O-ring to the steering knuckle.

Notice) .
Inspection > Page 2077
4. Install the wheel speed sensor to the wheel hub and bearing.
Tighten the sensor mounting bolt to 18 N.m (13 lb ft).
5. Install the wheel hub and bearing and splash shield to the vehicle. 6. Install the wheel hub and
bearing mounting bolts.
Tighten the wheel hub to knuckle bolts to 180 N.m (133 lb ft).
7. Install the nut and washer retaining the wheel drive shaft assembly to the wheel hub and
bearing.
8. Connect the electrical connection for the wheel speed sensor. 9. Install the wheel speed sensor
and brake hose mounting bracket bolt to the steering knuckle.
10. Install the rotor. Refer to Front Brake Rotor Replacement (See: Brakes and Traction
Control/Disc Brake System/Brake Rotor/Disc/Service and
Repair) . 12. Lower the vehicle .
Hummer Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Axle Nut > Component Information >
Specifications
Axle Nut: Specifications
AXLE NUT TORQUE
Wheel Drive Shaft Hub And Bearing Nut

........................................................................................................................................... 235 N.m
(173 lb ft)
Hummer Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information >
Specifications
Wheel Fastener: Specifications
WHEEL LUG NUTS
Single Wheel Nuts ...............................................................................................................................

................................................ 190 N.m (140 lb ft)
Hummer Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information >
Wheel Fastener: Description and Operation
Metric Wheel Nuts and Bolts Description
Metric wheel/nuts and bolts are identified in the following way:
* The wheel/nut has the word Metric stamped on the face.
* The letter M is stamped on the end of the wheel bolt.
The thread sizes of metric wheel/nuts and the bolts are indicated by the following example: M12 x
1.5.
* M = Metric
* 12 = Diameter in millimeters
* 1.5 = Millimeters gap per thread

Hummer Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and
Repair > Front Suspension
Wheel Fastener: Service and Repair Front Suspension
Wheel Stud Replacement
Tools Required
J 43631 Ball Joint Remover
Removal Procedure
tire and wheel. Refer to Tire and Wheel Removal and Installation (See: Service and Repair) .
3. Remove the wheel stud from the hub flange using the J 43631 . 4. Remove the wheel stud from
the hub flange.
1. Install the new stud into the hub flange hole using firm hand pressure. 2. Install 4 washers to the
new wheel stud. 3. Thread a wheel nut onto the new stud with the flat side facing the front hub
flange . 4. Tighten the lug nut until the stud contacts the back of the hub flange. 5. Remove the
wheel nut. 6. Remove the washers. 7. Install the tire and wheel. Refer to Tire and Wheel Removal
and Installation (See: Service and Repair) . 8. Remove the safety stands. 9. Lower the vehicle.
Hummer Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and
Repair > Front Suspension > Page 2088
Wheel Fastener: Service and Repair Rear Suspension
Wheel Stud Replacement
Tools Required
J 43631 Ball Joint Remover

Removal Procedure
tire and wheel. Refer to Tire and Wheel Removal and Installation (See: Service and Repair) . 3.
Remove the rotor. Refer to Rear Brake Rotor Replacement (See: Brakes and Traction Control/Disc
Repair/Removal and Replacement/Rear Brake Rotor Replacement) .
4. Remove the axle shaft . Refer to Rear Axle Shaft Replacement (See: Transmission and
Drivetrain/Drive Axles, Bearings and Joints/Axle Shaft
Assembly/Axle Shaft/Service and Repair) .
5. Remove the wheel stud from the axle flange using the J 43631 .
1. Install the stud into the axle flange. 2. Install the 4 washers and the lug nut to the stud. 3. Tighten
the lug nut in order to draw the stud into the flange until the stud fully seats. 4. Remove the lug nut
and the washers. 5. Install the axle shaft . Refer to Rear Axle Shaft Replacement (See:
Transmission and Drivetrain/Drive Axles, Bearings and Joints/Axle Shaft
6. Install the rotor. Refer to Rear Brake Rotor Replacement (See: Brakes and Traction Control/Disc
Repair/Removal and Replacement/Rear Brake Rotor Replacement) .
Repair) . 8. Lower the vehicle.
Hummer Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Service Precautions
Vehicle Lifting: Service Precautions
Vehicle Lifting Caution
the hoist.
Hummer Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Service Precautions > Page 2092
Vehicle Lifting: Service and Repair
Lifting and Jacking the Vehicle
Caution: 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.
the hoist.
Notice: Perform the following steps before beginning any vehicle lifting or jacking procedure:
* Remove or secure all of the vehicle's contents in order to avoid any shifting or any movement that
may occur during the vehicle lifting or jacking procedure.
* The lifting equipment or the jacking equipment weight rating must meet or exceed the weight of
the vehicle and any vehicle contents.
* The lifting equipment or the jacking equipment must meet the operational standards of the lifting
equipment or jacking equipment's manufacturer.
* Perform the vehicle lifting or jacking procedure on a clean, hard, dry, level surface.
* Perform the vehicle lifting or jacking procedure only at the identified lift points. DO NOT allow the
lifting equipment or jacking equipment to contact any other vehicle components.
Failure to perform the previous steps could result in damage to the lifting equipment or the jacking
equipment, the vehicle, and/or the vehicle's contents.
For lifting the vehicle, various lift points are recommended. Before you begin any lifting procedure,
place the vehicle on a clean, hard, level surface. Verify that all the lifting equipment meets weight
standards and is in good working order. Verify that all of the vehicle loads are equally distributed
and secure. If you are only supporting the vehicle at the frame side rails, verify that the lifting
equipment does not put too much stress on, or weaken, the frame side rails.
During hoisting, do NOT damage the fuel tanks, the exhaust system, or the underbody.
1 - Lower Control Arm Contact Points 1 - Lower Control Arm Contact Points 2 - Front Frame
Contact Points 2 - Front Frame Contact Points
3 - Rear Frame Contact Points 3 - Rear Frame Contact Points 4 - Rear Axle Contact Points 4 -
Rear Axle Contact Points 5 - Differential Contact Points
Frame Contact Hoist
Front Hoist Pads
Important: The front hoist pads must not contact the rocker panels, the front fenders, or the floor
pan.
Position the front hoist pads under the front frame between the lower control arm and the frame
pad.
Rear Hoist Pads
Important: The rear hoist pads must not contact the body rocker panels or the floor pan.
Position the rear hoist pads under the rear spring, just behind the hanger
Suspension Contact Hoist
Front Lift
Position the front lift under the outer edge of the front suspension lower control arms.
Rear Lift
Position the rear lift under the axle housing tubes on each side of the differential.
Do not damage the stabilizer bar.
Jacking
When you are lifting a vehicle with a vehicle jack or a floor jack, block the wheels at the opposite
end from which you are lifting. Use jack stands to provide additional support.
Under the Frame Rails
Important: The floor jack pad must not contact rocker panel or the floor pan.
Position the floor jack pad under the frame rail pad.
Under the Rear Differential
Position the floor jack pad under the center of the rear axle differential.
Do not damage the establisher bar.
Under the Rear Spring Hanger
Position the jack under the rear spring hanger.

Jack Stands
When you support the vehicle with jack stands, place the jack stands under the frame, the front
suspension crossmember, or the rear axle.
Hummer Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information >
Specifications
COMPRESSION CHECK
cylinder.
105).
Hummer Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information >
plug
70% = 105).
cylinder.
oil.
cylinders.
Hummer Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft
Gear/Sprocket > Component Information > Specifications
Camshaft Gear/Sprocket: Specifications
CAMSHAFT SPROCKET BOLT
Tighten The Camshaft Sprocket Bolt

...................................................................................................................................................... 35
N.m (26 lb ft)
Hummer Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft,
Engine > Component Information > Description and Operation
Camshaft: Description and Operation
Camshaft Position Actuator and Solenoid Valve Description
Camshaft
The camshaft is designed to provide a lubrication path for pressurized engine oil to flow to the
camshaft position (CMP) actuator. Pressurized engine oil enters the camshaft at bearing journal
location number 2. Oil travels through the camshaft, out the front, and into the CMP actuator
solenoid valve.
Camshaft Position (CMP) Actuator Solenoid Valve

The CMP actuator solenoid valve consists of a housing, spool valve (1), spool return spring (2), oil
filter (3), inlet check ball return spring (4), and inlet check ball (5). Pressurized engine oil enters the
valve and travels through the filter to the spool. Spool position is controlled by the CMP magnet
and engine control module (ECM). When the spool is moved to the proper position, oil flow is
directed through the valve and into the CMP actuator assembly. The CMP solenoid valve is a
torque-to-yield design and should be replaced each time it is removed.
CMP Actuator Magnet

Engine > Component Information > Description and Operation > Page 2109
The CMP actuator magnet (752) is located in the engine front cover and is sealed by a gasket
(753). The CMP actuator magnet is controlled by a 12-volt pulse width modulated signal from the
ECM. When energized, the solenoid uses electromagnetic force on the magnet pintle to position
the spool valve of the CMP solenoid valve.
CMP Actuator
The CMP actuator is a vane type design that hydraulically changes angle or timing of the camshaft
relative to crankshaft position. The CMP actuator allows earlier or later intake and exhaust valve
opening during the 4-stroke engine cycle. The CMP actuator cannot vary the duration of valve
opening or valve lift. The CMP actuator is to be serviced as an assembly.
The CMP actuator consists of the CMP reluctor wheel (1), pins (2), return spring (3), front cover (4),
locking pin (5), locking pin spring (6), vanes and vane springs (7), rotor (8), stator (9), sealing
cover/thrust plate (10), and bolts (11).
Engine > Component Information > Service and Repair > Camshaft Position Actuator Magnet Replacement
Camshaft: Service and Repair Camshaft Position Actuator Magnet Replacement
Camshaft Position Actuator Magnet Replacement
Removal Procedure
1. Remove the water pump. Refer to Water Pump Replacement (See: Water Pump/Service and
Repair) . 2. Disconnect the engine harness electrical connector from the camshaft position (CMP)
actuator magnet. 3. Remove the CMP actuator magnet bolts (751) and magnet (752). 4. Remove
and discard the CMP actuator magnet gasket (753).
Important: The gasket surface should be free of oil or other foreign material during assembly.
Engine > Component Information > Service and Repair > Camshaft Position Actuator Magnet Replacement > Page 2112
1. Install a NEW CMP actuator magnet gasket (753) onto the CMP actuator magnet. 2. Install the
CMP actuator magnet (752) to the front cover.

Notice) .
3. Install the CMP actuator magnet bolts (751).
Tighten the bolts to 12 N.m (106 lb in).
4. Connect the engine harness electrical connector to the CMP actuator magnet. 5. Install the
water pump. Refer to Water Pump Replacement (See: Water Pump/Service and Repair) .
Camshaft: Service and Repair Camshaft Position Actuator Solenoid Valve Replacement
Camshaft Position Actuator Solenoid Valve Replacement
Tools Required
J 45059 Angle Meter
Removal Procedure
1. Remove the camshaft position (CMP) actuator magnet. Refer to Camshaft Position Actuator
Magnet Replacement (See: Camshaft Position
Actuator Magnet Replacement) .
2. Remove and discard the CMP actuator solenoid valve.
1. Install the a NEW CMP actuator solenoid valve until snug.
With the CMP actuator properly positioned onto the camshaft, the CMP actuator solenoid valve can
be threaded completely into the camshaft using light hand pressure. Tighten by hand until snug.

Notice) .
2. Tighten the CMP actuator solenoid valve.
1. Tighten the solenoid valve a first pass to 65 N.m (48 lb ft). 2. Tighten the solenoid valve a final
pass and additional 90 degrees using J 45059 .
3. Install the CMP actuator magnet. Refer to Camshaft Position Actuator Magnet Replacement
(See: Camshaft Position Actuator Magnet
Replacement) .
Camshaft: Service and Repair Camshaft Position Actuator Replacement
Camshaft Position Actuator Replacement
Tools Required
* EN 46330 Timing Belt Tensioner Retaining Pin
* J 45059 Angle Meter
Removal Procedure
1. Remove the oil pump. Refer to Oil Pump, Screen, and Crankshaft Oil Deflector Replacement
(See: Engine Lubrication/Oil Pump/Service and
Repair) .
2. Remove and discard the camshaft position (CMP) actuator solenoid valve (234).
3. Loosen and separate the CMP actuator and timing chain from the camshaft. Position your
fingers behind the actuator sprocket and pull the actuator
away from the front of the camshaft. Never pull on the reluctor wheel when attempting to remove
the actuator.
4. Remove the CMP actuator (235) and timing chain (208).
5. Insert and secure a tie strap (1) through the center of the actuator and over the reluctor wheel.
1. Compress the timing chain tensioner guide and install the EN 46330 .
Important: *
Properly locate the CMP actuator on the locating pin of the camshaft.
* The sprocket teeth and timing chain must mesh.
* The camshaft and the crankshaft sprocket alignment marks MUST be aligned properly.
* DO NOT use the CMP solenoid valve again. Install a NEW valve during assembly.
2. Identify the alignment hole (1) in the rear face of the CMP actuator and the locating pin (2) on the
front face of the camshaft.
3. Install the CMP actuator and timing chain. Align the hole in the rear face of the CMP actuator
with the locating pin on the front face of the
camshaft. If necessary, rotate the camshaft or crankshaft sprockets in order to align the timing
marks. Use care to install the actuator completely onto the front of the camshaft. Position your
fingers onto the face of the actuator sprocket and push the actuator onto the front of the camshaft.
Never push on the reluctor wheel when attempting to install the actuator.
4. Place a straight edge across the front face of the engine block and inspect for proper installation
of the CMP actuator and timing chain. With the
CMP actuator properly and completely installed onto the front of the camshaft, the timing chain will
not protrude beyond the front face of the engine block.
5. Install a NEW CMP actuator solenoid valve (234). With the CMP actuator properly positioned
onto the camshaft, the CMP actuator solenoid
valve can be threaded completely into the camshaft using light hand pressure. Tighten by hand
until snug.
6. Inspect the sprockets for proper alignment. The mark on the CMP actuator sprocket (1) should
be located in the 6 o'clock position and the mark on
the crankshaft sprocket (2) should be located in the 12 o'clock position.
7. Remove the EN 46330 .


Notice) .
8. Tighten the CMP actuator solenoid valve.
1. Tighten the valve a first pass to 65 N.m (48 lb ft). 2. Tighten the valve a final pass and additional
90 degrees using J 45059 .
9. Install the oil pump. Refer to Oil Pump, Screen, and Crankshaft Oil Deflector Replacement (See:
Engine Lubrication/Oil Pump/Service and
Repair) .
Camshaft: Service and Repair Camshaft Replacement
Camshaft Replacement
Removal Procedure
1. Remove the hood. Refer to Hood Replacement (See: Body and Frame/Doors, Hood and
Trunk/Hood/Service and Repair/Hood Replacement) . 2. Remove the radiator support. Refer to
Radiator Support Replacement () . 3. Remove the valve lifters from both cylinder heads. Refer to
Valve Lifter Replacement (See: Lifter / Lash Adjuster/Service and Repair) . 4. Remove the
camshaft sensor bolt and sensor. 5. Remove the engine front cover. Refer to Engine Front Cover
Removal (See: Service and Repair/Overhaul/Disassembly/Engine Front Cover
Removal) .
6. Rotate the engine until the timing marks are aligned.
Notice: Do not turn the crankshaft assembly after the timing chain has been removed in order to
prevent damage to the piston assemblies or the valves.
7. Remove the camshaft sprocket bolts. 8. Remove the camshaft sprocket and reposition the timing
chain.
9. Remove the camshaft retainer bolts and retainer.
Notice: All camshaft journals are the same diameter, so care must be used in removing or installing
the camshaft to avoid damage to the camshaft bearings.
10. Remove the camshaft.
1. Install three M8-1.25 x 100 mm (M8-1.25 x 4.0 in) bolts to the bolt holes in the front of the
camshaft. 2. Using the bolts as a handle, carefully rotate and pull the camshaft out of the engine
block. 3. Remove the three bolts from the camshaft.
11. Clean and inspect the camshaft and bearings. Refer to Camshaft and Bearings Cleaning and
Inspection (See: Service and
Repair/Overhaul/Component Service and Inspection/Camshaft and Bearings Cleaning and

Inspection) .
Important: If camshaft replacement is required, the valve lifters must also be replaced.
1. Lubricate the camshaft journals and the bearings with clean engine oil. 2. Install three M8-1.25 x
100 mm (M8-1.25 x 4.0 in) bolts to the bolt holes in the front of the camshaft.
Notice: All camshaft journals are the same diameter, so care must be used in removing or installing
the camshaft to avoid damage to the camshaft bearings.
3. Using the bolts as a handle, carefully install the camshaft into the engine block. 4. Remove the
three bolts from the front of the camshaft.
Important: Install the retainer plate with the sealing gasket facing the engine block.
The gasket surface on the engine block should be clean and free of dirt and/or debris.

Notice) .
5. Install the camshaft retainer and bolts.
Tighten the camshaft retainer bolts to 25 N.m (18 lb ft).
6. Inspect the camshaft sensor O-ring seal. If the O-ring seal is not cut or damaged, it may be
reused. 7. Lubricate the O-ring seal with clean engine oil. 8. Install the camshaft sensor and bolt.
Tighten the camshaft sensor bolt to 25 N.m (18 lb ft).
9. Install the camshaft sprocket and timing chain. Refer to Timing Chain and Sprocket
Replacement (See: Timing Components/Timing
Chain/Service and Repair) .
10. Install the engine front cover. Refer to Engine Front Cover Removal (See: Service and
Repair/Overhaul/Disassembly/Engine Front Cover
Removal) .
11. Install the valve lifters. Refer to Valve Lifter Replacement (See: Lifter / Lash Adjuster/Service
and Repair) . 12. Install the radiator support. Refer to Radiator Support Replacement () . 13. Install
the hood. Refer to Hood Replacement (See: Body and Frame/Doors, Hood and
Trunk/Hood/Service and Repair/Hood Replacement) . 14. Lower the hood to the normal position.
Hummer Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash
Adjuster, Valve > Component Information > Service and Repair
Lifter / Lash Adjuster: Service and Repair
Valve Lifter Replacement
Special Tools
J 3049-A Valve Lifter Remover
Removal Procedure
1. Remove the cylinder head and gasket. Refer to Cylinder Head Replacement - Left Side (See:
Cylinder Head Assembly/Service and
Repair/Cylinder Head Replacement - Left Side) or Cylinder Head Replacement - Right Side (See:
Cylinder Head Assembly/Service and Repair/Cylinder Head Replacement - Right Side) .
2. Remove the valve lifter guide bolts (1). 3. Remove the valve lifters and guide.
Important: Some valve lifters may be stuck in their bores because of gum or varnish deposits.
4. Use J 3049-A or equivalent in order to remove the valve lifters, if required.
5. Remove the valve lifters from the guide. 6. Organize or mark the components so that they can
be installed in the same location from which they were removed. 7. Clean and inspect the valve
lifters. Refer to Valve Lifters and Guides Cleaning and Inspection (See: Service and
Repair/Overhaul/Component
Service and Inspection/Valve Lifters and Guides Cleaning and Inspection) .
Hummer Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash
Adjuster, Valve > Component Information > Service and Repair > Page 2129
Important: When reusing valve lifters, install the lifters to their original locations.
1. Lubricate the valve lifters and engine block valve lifter bores with clean engine oil. 2. Insert the
valve lifters into the lifter guides.
Align the flat area on the top of the lifter with the flat area in the lifter guide bore. Push the lifter
completely into the guide bore.
3. Install the valve lifters and guide to the engine block.

Notice) .
4. Install the valve lifter guide bolt (1).
Tighten the valve lifter guide bolt (1) to 12 N.m (106 lb in).
5. Install the cylinder head and gasket. Refer to Cylinder Head Replacement - Left Side (See:
Cylinder Head Assembly/Service and Repair/Cylinder
Head Replacement - Left Side) or Cylinder Head Replacement - Right Side (See: Cylinder Head
Assembly/Service and Repair/Cylinder Head Replacement - Right Side) .
Hummer Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Push Rod >
Push Rod: Service and Repair
Valve Rocker Arm and Push Rod Replacement
Removal Procedure
1. Remove the valve rocker arm cover. Refer to Valve Rocker Arm Cover Replacement - Left Side
(See: Cylinder Head Assembly/Valve
Cover/Service and Repair/Valve Rocker Arm Cover Replacement - Left Side) or Valve Rocker Arm
Cover Replacement - Right Side (See: Cylinder Head Assembly/Valve Cover/Service and
Repair/Valve Rocker Arm Cover Replacement - Right Side) .
Important: Place the valve rocker arms, pushrods, and pivot support, in a rack so that the can be
installed in the same location from which they were removed.
2. Remove the valve rocker arm bolts. 3. Remove the valve rocker arms.
4. Remove the valve rocker arm pivot support.
5. Remove the pushrods. 6. Clean and inspect the valve rocker arms and pushrods. Refer to Valve
Rocker Arm and Push Rod Cleaning and Inspection (See: Service and
Repair/Overhaul/Component Service and Inspection/Valve Rocker Arm and Push Rod Cleaning
and Inspection) .
Important: When reusing the valve train components, always install the components to the original
location and position.
Component Information > Service and Repair > Page 2133
Valve lash is net build, no valve adjustment is required.
1. Lubricate the valve rocker arms and pushrods with clean engine oil. 2. Lubricate the flange of the
valve rocker arm bolts with clean engine oil.
Lubricate the flange or washer surface of the bolt that will contact the valve rocker arm.
3. Install the valve rocker arm pivot support.
Important: Make sure that the pushrods seat properly to the valve lifter sockets.
4. Install the pushrods.
Important: Make sure that the pushrods seat properly to the ends of the rocker arms. DO NOT
tighten the rocker arm bolts at this time.
5. Install the rocker arms and bolts.

6. Rotate the crankshaft until the number one piston is at top dead center (TDC) of the
compression stroke.
In this position, cylinder number one rocker arms will be off lobe lift, and the crankshaft sprocket
key will be at the 1:30 position. The engine firing order is 1,8,7,2,6,5,4,3. Cylinders 1,3,5 and 7 are
the left bank. Cylinder 2,4,6 and 8 are the right bank. Notice: Refer to Fastener Notice (See:
Service Precautions/Vehicle Damage Warnings/Fastener Notice) .
7. With the engine in the number one firing position, tighten the following valve rocker arm bolts:
* Tighten the cylinders 1,2,7 and 8 exhaust valve rocker arm bolts to 30 N.m (22 lb ft).
* Tighten the cylinders 1,3,4 and 5 intake valve rocker arm bolts to 30 N.m (22 lb ft).
8. Rotate the crankshaft 360 degrees. 9. Tighten the following valve rocker arm bolts:
* Tighten the cylinders 3, 4, 5 and 6 exhaust valve rocker arm bolts to 30 N.m (22 lb ft).
* Tighten the cylinders 2, 6, 7 and 8 intake valve rocker arm bolts to 30 N.m (22 lb ft).
10. Install the valve rocker arm cover. Refer to Valve Rocker Arm Cover Replacement - Left Side
Hummer Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm
Assembly > Component Information > Service and Repair
Rocker Arm Assembly: Service and Repair
Removal Procedure
and Inspection) .
Assembly > Component Information > Service and Repair > Page 2138

Assembly > Component Information > Service and Repair > Page 2139
compression stroke.
Hummer Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod
Bearing > Component Information > Specifications
Connecting Rod Bearing: Specifications
CONNECTING ROD
Connecting Rod Bearing Clearance
Production
...........................................................................................................................................................
0.023-0.065 mm (0.0009-0.0025 in)
Service .................................................................................................................................................
................. 0.023-0.076 mm (0.0009-0.003 in)
Connecting Rod Bore Diameter
Bearing End
........................................................................................................................................................
56.505-56.525 mm (2.224-2.225 in)
Connecting Rod Bore Out-of-Round
Bearing End - Production

................................................................................................................................. 0.004-0.008 mm
(0.00015-0.0003 in)
Bearing End - Service

....................................................................................................................................... 0.004-0.008
mm (0.00015-0.0003 in)
Connecting Rod Side Clearance

..................................................................................................................................... 0.11-0.51 mm
(0.00433-0.02 in)
CRANKSHAFT
Connecting Rod Journal Diameter
Production
.......................................................................................................................................................
53.318-53.338 mm (2.0991-2.0999 in)
Service .................................................................................................................................................
.................................... 53.308 mm (2.0987 in)
Connecting Rod Journal Out-of-Round
Production ...........................................................................................................................................
...................................... 0.005 mm (0.0002 in)
Service .................................................................................................................................................
........................................ 0.01 mm (0.0004 in)
Connecting Rod Journal Taper
Maximum for 1/2 of Journal Length - Production

..................................................................................................................... 0.005 mm (0.0002 in)
Maximum for 1/2 of Journal Length - Service

.......................................................................................................................... 0.02 mm (0.00078 in)
Crankshaft End Play

.......................................................................................................................................................
0.04-0.2 mm (0.0015-0.0078 in)
Crankshaft Main Bearing Clearance
Production
.............................................................................................................................................................
0.02-0.052 mm (0.0008-0.0021 in)
Service .................................................................................................................................................
................. 0.02-0.065 mm (0.0008-0.0025 in)
Crankshaft Main Journal Diameter
Production
...........................................................................................................................................................
64.992-65.008 mm (2.558-2.559 in)
Service .................................................................................................................................................
...................................... 64.992 mm (2.558 in)
Crankshaft Main Journal Out-of-Round
Production ...........................................................................................................................................
.................................. 0.003 mm (0.000118 in)
Service .................................................................................................................................................
...................................... 0.008 mm (0.0003 in)
Crankshaft Main Journal Taper
Production ...........................................................................................................................................
........................................ 0.01 mm (0.0004 in)
Service .................................................................................................................................................
...................................... 0.02 mm (0.00078 in)
Crankshaft Rear Flange Runout

...........................................................................................................................................................
0.05 mm (0.002 in)
Crankshaft Reluctor Ring Runout
Measured 1.0 mm (0.04 in) Below Tooth Diameter

........................................................................................................................ 0.7 mm (0.028 in)
Crankshaft Thrust Surface
Production
.............................................................................................................................................................
26.14-26.22 mm (1.029-1.0315 in)
Service .................................................................................................................................................
...................................... 26.22 mm (1.0315 in)
Crankshaft Thrust Surface Runout

.................................................................................................................................................... 0.025
mm (0.001 in)
PISTONS AND PINS
Pin - Piston Pin Clearance-to-Piston Pin Bore
Production
...........................................................................................................................................................
0.002-0.01 mm (0.00008-0.0004 in)
Hummer Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod
Bearing > Component Information > Specifications > Page 2144
Service
..............................................................................................................................................................
0.002-0.015 mm (0.00008-0.0006 in)
Pin - Piston Pin Diameter

..........................................................................................................................................
23.952-23.955 mm (0.943-0.943 in)
Pin - Piston Pin Fit in Connecting Rod Bore
Production
.........................................................................................................................................................
0.007-0.02 mm (0.00027-0.00078 in)
Service
............................................................................................................................................................
0.007-0.022 mm (0.00027-0.00086 in)
Piston - Piston Diameter
Measured Over Coating

........................................................................................................................................
96.002-96.036 mm (3.779-3.78 in)
Piston - Piston to Bore Clearance
Production
............................................................................................................................................ -0.036 to
+0.016 mm (-0.0014 to +0.0006 in)
Service Limit With Skirt Coating Worn Off

.............................................................................................................................. 0.071 mm (0.0028
in)
Hummer Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod,
Engine > Component Information > Technical Service Bulletins > Engine - Revised Connecting Rod Bolt Torque
Connecting Rod: Technical Service Bulletins Engine - Revised Connecting Rod Bolt Torque
Bulletin No.: 07-06-01-002
INFORMATION
Subject: Information on Revised Connecting Rod Bolt Torque for Small Block GEN III and GEN IV
Vortec(TM) V8 Engines
Models
A new connecting rod bolt torque specification was introduced to the GEN III and GEN IV
Vortec(TM) small block V8 engines. The connecting rod bolts should continue to be tightened using
two passes. The second pass value has been increased from 75 degrees to 85 degrees.
Install the connecting rod bolts and tighten. Refer to Piston, Connecting Rod, and Bearing
Installation in SI.
Tighten
Tighten the connecting rod bolts a first pass to 20 N.m (15 lb ft).
Tighten the connecting rod bolts a final pass to 85 degrees using the J 45059 Angle Meter.
Engine > Component Information > Technical Service Bulletins > Engine - Revised Connecting Rod Bolt Torque > Page
2149
Disclaimer
Engine > Component Information > Technical Service Bulletins > Page 2150
Connecting Rod: Specifications
ROD BEARING CAP TORQUE
Tighten The Bolts
- First Pass ..........................................................................................................................................

........................................... 20 N.m (15 lb ft)
- Final Pass ..........................................................................................................................................

....................... 85 degrees using the J 45059
CONNECTING ROD
Production
...........................................................................................................................................................
0.023-0.065 mm (0.0009-0.0025 in)
Service .................................................................................................................................................
................. 0.023-0.076 mm (0.0009-0.003 in)
Bearing End
........................................................................................................................................................
56.505-56.525 mm (2.224-2.225 in)

................................................................................................................................. 0.004-0.008 mm
(0.00015-0.0003 in)

....................................................................................................................................... 0.004-0.008
mm (0.00015-0.0003 in)

..................................................................................................................................... 0.11-0.51 mm
(0.00433-0.02 in)
CRANKSHAFT
Production
.......................................................................................................................................................
53.318-53.338 mm (2.0991-2.0999 in)
Service .................................................................................................................................................
.................................... 53.308 mm (2.0987 in)
Production ...........................................................................................................................................
...................................... 0.005 mm (0.0002 in)
Service .................................................................................................................................................
........................................ 0.01 mm (0.0004 in)

..................................................................................................................... 0.005 mm (0.0002 in)

.......................................................................................................................... 0.02 mm (0.00078 in)
Crankshaft End Play

.......................................................................................................................................................
0.04-0.2 mm (0.0015-0.0078 in)
Production
.............................................................................................................................................................
0.02-0.052 mm (0.0008-0.0021 in)
Service .................................................................................................................................................
................. 0.02-0.065 mm (0.0008-0.0025 in)
Production
...........................................................................................................................................................
64.992-65.008 mm (2.558-2.559 in)
Service .................................................................................................................................................
...................................... 64.992 mm (2.558 in)
Production ...........................................................................................................................................
.................................. 0.003 mm (0.000118 in)
Service .................................................................................................................................................
...................................... 0.008 mm (0.0003 in)
Production ...........................................................................................................................................
........................................ 0.01 mm (0.0004 in)
Service .................................................................................................................................................
...................................... 0.02 mm (0.00078 in)

...........................................................................................................................................................
0.05 mm (0.002 in)

........................................................................................................................ 0.7 mm (0.028 in)
Production
.............................................................................................................................................................
26.14-26.22 mm (1.029-1.0315 in)
Service .................................................................................................................................................
...................................... 26.22 mm (1.0315 in)
Engine > Component Information > Technical Service Bulletins > Page 2151
.................................................................................................................................................... 0.025
mm (0.001 in)
PISTONS AND PINS
Production
...........................................................................................................................................................
0.002-0.01 mm (0.00008-0.0004 in)
Service
..............................................................................................................................................................
0.002-0.015 mm (0.00008-0.0006 in)

..........................................................................................................................................
23.952-23.955 mm (0.943-0.943 in)
Production
.........................................................................................................................................................
0.007-0.02 mm (0.00027-0.00078 in)
Service
............................................................................................................................................................
0.007-0.022 mm (0.00027-0.00086 in)

........................................................................................................................................
96.002-96.036 mm (3.779-3.78 in)
Production
............................................................................................................................................ -0.036 to
+0.016 mm (-0.0014 to +0.0006 in)

.............................................................................................................................. 0.071 mm (0.0028
in)
Hummer Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft
Gear/Sprocket > Component Information > Specifications
Crankshaft Gear/Sprocket: Specifications
CRANKSHAFT PULLEY TORQUE
Tighten The Crankshaft Balancer Bolt

................................................................................................................................................ 330
N.m (240 lb ft)
Hummer Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main
Bearing > Component Information > Specifications
Crankshaft Main Bearing: Specifications
MAIN BEARING CAP
M10 Bolts (1-10) In Sequence
- First Pass ..........................................................................................................................................

........................................... 20 N.m (15 lb ft)
Important: To properly align the crankshaft thrust bearings, the final thrust of the crankshaft MUST
be in the forward direction.
Using a plastic-face hammer, tap the crankshaft rearward, then forward in order to align the thrust
bearings.
- Final Pass ..........................................................................................................................................

M10 studs (11-20) in sequence
- First Pass ..........................................................................................................................................

........................................... 20 N.m (15 lb ft)
- Final Pass ..........................................................................................................................................

Bearing Cap Side M8 Bolts. Tighten the bolt on 1 side of the bearing cap and then tighten the bolt
on the opposite side of the same bearing cap.
- Bearing Cap Side M8 Bolts
......................................................................................................................................................... 25
N.m (18 lb ft)
BLOCK
Camshaft Bearing Bore 1 and 5 Diameter

.................................................................................................................... 59.58-59.63 mm
(2.345-2.347 in) Camshaft Bearing Bore 2 and 4 Diameter
.................................................................................................................... 59.08-59.13 mm
(2.325-2.327 in) Camshaft Bearing Bore 3 Diameter
.............................................................................................................................. 58.58-58.63 mm
(2.306-2.308 in)
Crankshaft Main Bearing Bore Diameter

.................................................................................................................... 69.871-69.889 mm
(2.75-2.751 in) Crankshaft Main Bearing Bore Out-of-Round
................................................................................................................................. 0.006 mm
(0.0002 in)
Cylinder Bore Diameter

........................................................................................................................................
103.241-103.259 mm (4.065-4.065 in)
Cylinder Head Deck Height
Measuring from the Centerline of Crankshaft to the Deck Face

......................................................................... 234.57-234.82 mm (9.235-9.245 in)
Cylinder Head Deck Surface Flatness
Measured Within a 152.4 mm (6.0 in) Area

.................................................................................................................................. 0.11 mm (0.004
in)
Cylinder Head Deck Surface Flatness
Measuring the Overall Length of the Block Deck

......................................................................................................................... 0.22 mm (0.008 in)
Valve Lifter Bore Diameter

......................................................................................................................................
21.417-21.443 mm (0.843-0.844 in)
CONNECTING ROD
Production
...........................................................................................................................................................
0.023-0.065 mm (0.0009-0.0025 in)
Service .................................................................................................................................................
................. 0.023-0.076 mm (0.0009-0.003 in)

Bearing End
........................................................................................................................................................
56.505-56.525 mm (2.224-2.225 in)
Hummer Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main
Bearing > Component Information > Specifications > Page 2158

................................................................................................................................. 0.004-0.008 mm
(0.00015-0.0003 in)

....................................................................................................................................... 0.004-0.008
mm (0.00015-0.0003 in)

..................................................................................................................................... 0.11-0.51 mm
(0.00433-0.02 in)
CRANKSHAFT
Production
.......................................................................................................................................................
53.318-53.338 mm (2.0991-2.0999 in)
Service .................................................................................................................................................
.................................... 53.308 mm (2.0987 in)
Production ...........................................................................................................................................
...................................... 0.005 mm (0.0002 in)
Service .................................................................................................................................................
........................................ 0.01 mm (0.0004 in)

..................................................................................................................... 0.005 mm (0.0002 in)

.......................................................................................................................... 0.02 mm (0.00078 in)
Crankshaft End Play

.......................................................................................................................................................
0.04-0.2 mm (0.0015-0.0078 in)
Production
.............................................................................................................................................................
0.02-0.052 mm (0.0008-0.0021 in)

Service .................................................................................................................................................
................. 0.02-0.065 mm (0.0008-0.0025 in)
Production
...........................................................................................................................................................
64.992-65.008 mm (2.558-2.559 in)
Service .................................................................................................................................................
...................................... 64.992 mm (2.558 in)
Production ...........................................................................................................................................
.................................. 0.003 mm (0.000118 in)
Service .................................................................................................................................................
...................................... 0.008 mm (0.0003 in)
Production ...........................................................................................................................................
........................................ 0.01 mm (0.0004 in)
Service .................................................................................................................................................
...................................... 0.02 mm (0.00078 in)

...........................................................................................................................................................
0.05 mm (0.002 in)

........................................................................................................................ 0.7 mm (0.028 in)
Production
.............................................................................................................................................................
26.14-26.22 mm (1.029-1.0315 in)
Service .................................................................................................................................................
...................................... 26.22 mm (1.0315 in)

.................................................................................................................................................... 0.025
mm (0.001 in)
Hummer Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater >
Component Information > Service and Repair > Coolant Heater Replacement
Engine Block Heater: Service and Repair Coolant Heater Replacement
Coolant Heater Replacement
Dealer Installation Only
1. Drain the cooling system/engine block. Refer to Cooling System Draining and Filling (Static Fill)
(See: Cooling System/Service and
Cooling System/Service and Repair/Draining and Filling Cooling System) .
Maintenance) .
3. Remove the oil cooler hose bracket bolt (1). 4. Remove the oil cooler hose adapter bolts (2). 5.
Remove and discard the oil cooler hose adapter gasket. 6. Position the oil cooler hose adapter end
out of the way.

Notice) .
7. Install the coolant heater in place of the drain plug.
Tighten the coolant heater to 50 N.m (37 lb ft).
Important: The engine coolant heater cord must not touch the engine, hot pipes, manifold, or any
moving parts. Always keep the electrical cord neatly rolled up with the end of the cord tucked in the
center of the coil and secured in place.
8. Push the engine coolant heater cord electrical connector (2) firmly into the coolant heater (1).
Component Information > Service and Repair > Coolant Heater Replacement > Page 2163
9. Place the cord into position.
Notice: The heater cord must not touch the engine, hot pipes, manifold, or any moving parts. Route
the cord to the left front of the engine compartment securing with tie straps as necessary to prevent
damage.
10. Install the heater cord bolt and retainer.
Tighten the heater cord bolt to 8 N.m (71 lb in).
11. Position the oil cooler hose adapter. 12. Install a NEW oil cooler hose adapter gasket. 13.
Install the oil cooler hose adapter bolts (2).
Tighten the oil cooler hose adapter bolts to 12 N.m (106 lb in).
14. Install the oil cooler hose bracket bolt (1).
Tighten the oil cooler hose bracket bolt to 25 N.m (18 lb ft).
15. Lower the vehicle. 16. Fill the cooling system/engine block. Refer to Cooling System Draining
and Filling (Static Fill) (See: Cooling System/Service and
Cooling System/Service and Repair/Draining and Filling Cooling System) .
Engine Block Heater: Service and Repair Coolant Heater Cord Replacement
Coolant Heater Cord Replacement
Removal Procedure
Maintenance) . 2. Disconnect the coolant heater electrical connector (2).
3. Remove the coolant heater cord retainer and bolts. 4. Remove the coolant heater cord.
Notice: The heater cord must not touch the engine, hot pipes, manifold, or any moving parts. Route
the cord to the left front of the engine compartment securing with tie straps as necessary to prevent
damage.
1. Install the coolant heater cord.
2. Install the coolant heater cord bolts and retainer.
Tighten the coolant heater cord bolts to 8 N.m (71 lb in).

3. Connect the coolant heater electrical connector (2). 4. Lower the vehicle.
Hummer Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer -
Crankshaft Pulley > Component Information > Technical Service Bulletins > Customer Interest for Harmonic Balancer -
Crankshaft Pulley: > 08-06-01-015 > Jul > 08 > Engine - Drive Belt Chirping Noise
Harmonic Balancer - Crankshaft Pulley: Customer Interest Engine - Drive Belt Chirping Noise
TECHNICAL
Bulletin No.: 08-06-01-015
Date: July 14, 2008
Saab 9-7X V8

Condition
Cause
noise.
Correction
Notice:
Tip
Parts Information

Crankshaft Pulley > Component Information > Technical Service Bulletins > Customer Interest for Harmonic Balancer -
Crankshaft Pulley: > 08-06-01-015 > Jul > 08 > Engine - Drive Belt Chirping Noise > Page 2174
Disclaimer
Crankshaft Pulley > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Harmonic
Balancer - Crankshaft Pulley: > 08-06-01-015 > Jul > 08 > Engine - Drive Belt Chirping Noise
Harmonic Balancer - Crankshaft Pulley: All Technical Service Bulletins Engine - Drive Belt Chirping
Noise
TECHNICAL
Bulletin No.: 08-06-01-015
Date: July 14, 2008
Saab 9-7X V8

Condition
Cause
noise.
Correction
Notice:
Tip
Parts Information

Crankshaft Pulley > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Harmonic
Balancer - Crankshaft Pulley: > 08-06-01-015 > Jul > 08 > Engine - Drive Belt Chirping Noise > Page 2180
Disclaimer
Crankshaft Pulley > Component Information > Technical Service Bulletins > Page 2181
Harmonic Balancer - Crankshaft Pulley: Specifications

................................................................................................................................................ 330
N.m (240 lb ft)
Harmonic Balancer - Crankshaft Pulley: Service and Repair
Crankshaft Balancer Replacement
Special Tools
* J 41478 Crankshaft Front Oil Seal Installer
* J 41816 Crankshaft Balancer Remover
* J 41816-2 Crankshaft End Protector
* J 42386-A Flywheel Holding Tool
* J 41665 Crankshaft Balancer and Sprocket Installer
* J 45059 Angle Meter
Removal Procedure
1. Remove the fan shroud. Refer to Cooling Fan and Shroud Replacement (See: Cooling
System/Radiator Cooling Fan/Service and Repair/Cooling
Fan and Shroud Replacement) .
2. Remove the starter motor. Refer to Starter Motor Replacement (See: Starting and
Charging/Starting System/Starter Motor/Service and Repair) .
Important: *
Make sure that the teeth of the J 42386-A are fully engaged into the flywheel ring gear teeth.
* The crankshaft balancer is balanced as an individual component. It is not necessary to mark the
balancer prior to removal.

Notice) .
3. Install the J 42386-A .
Use one M10-1.5 x 120 mm and one M10-1.5 x 45 mm bolt for proper tool operation.
Tighten the J 42386-A to 50 N.m (37 lb ft).
4. Remove the crankshaft balancer bolt.
Do not discard the crankshaft balancer bolt. The balancer bolt will be used during the balancer
installation procedure.
5. Use the J 41816 and J 41816-2 in order to remove the crankshaft balancer. 6. Remove the J
41816 and the J 41816-2 from the crankshaft balancer. 7. Clean and inspect the crankshaft
balancer. Refer to Crankshaft Balancer Cleaning and Inspection (See: Service and
Repair/Overhaul/Component
Service and Inspection/Crankshaft Balancer Cleaning and Inspection) .
Important:
* Make sure that the teeth of J 42386-A are fully engaged into the flywheel ring gear teeth.
* The used crankshaft balancer bolt will be used only during the first pass of the balancer
installation procedure. Install a NEW bolt and tighten as described in the second, third and forth
passes of the balancer bolt tightening procedure.
* The crankshaft balancer installation and bolt tightening involves a four stage tightening process.
The first pass ensures that the balancer is installed completely onto the crankshaft. The second,
third, and forth passes tighten the new bolt to the proper torque.
* The balancer should be positioned onto the end of the crankshaft as straight as possible prior to
tool installation.
1. Install the crankshaft balancer onto the end of the crankshaft.

2. Use the J 41665 and J 41478 for the following steps:
1. Assemble the J 41478 threaded rod, nut, washer and J 41665 installer.
Insert the smaller end of the installer into the front of the balancer.
2. Use a wrench and hold the hex end of the threaded rod. 3. Use a second wrench and rotate the
installation tool nut clockwise until the balancer is started onto the crankshaft. 4. Remove the tool
and reverse the installation tool.
Position the larger end of the installer against the front of the balancer.
5. Use a wrench and hold the hex end of the threaded rod. 6. Use a second wrench and rotate the
installation tool nut clockwise until the balancer is installed onto the crankshaft. 7. Remove the
balancer installation tools.

Notice) .
3. Install the used crankshaft balancer bolt.
Tighten the USED crankshaft balancer bolt to 330 N.m (240 lb ft).
4. Remove the used crankshaft balancer bolt.
Important: The nose of the crankshaft should be recessed 2.4-4.48 mm (0.094-0.176 in) into the
balancer bore.
5. Measure for a correctly installed balancer.
If the balancer is not installed to the proper dimensions, install the J 41665 .
6. Install a NEW crankshaft balancer bolt.
1. Tighten the crankshaft balancer bolt a first pass to 50 N.m (37 lb ft). 2. Tighten the crankshaft
balancer bolt a second pass to 140 degrees using the J 45059 .
7. Remove the J 42386-A . 8. Install the starter motor. Refer to Starter Motor Replacement (See:
Starting and Charging/Starting System/Starter Motor/Service and Repair) . 9. Install the fan shroud
. Refer to Cooling Fan and Shroud Replacement (See: Cooling System/Radiator Cooling
Fan/Service and Repair/Cooling
Fan and Shroud Replacement) .

10. Install the accessory drive belt, if not equipped with A/C. Refer to Drive Belt Replacement -
Accessory (See: Drive Belts, Mounts, Brackets and
Accessories/Drive Belt/Service and Repair/Drive Belt Replacement - Accessory) .
11. Install the A/C drive belt, if equipped. Refer to Air Conditioning Compressor Belt Replacement
(See: Drive Belts, Mounts, Brackets and
Accessories/Drive Belt/Service and Repair/Air Conditioning Compressor Belt Replacement) .
12. Perform the crankshaft position (CKP) system variation learn procedure. Refer to Crankshaft
Position System Variation Learn (See: Powertrain
Management/Computers and Control Systems/Crankshaft Position Sensor/Service and

Repair/Procedures) .
Hummer Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine >
Component Information > Specifications
Piston: Specifications
CONNECTING ROD
Production
...........................................................................................................................................................
0.023-0.065 mm (0.0009-0.0025 in)
Service .................................................................................................................................................
................. 0.023-0.076 mm (0.0009-0.003 in)
Bearing End
........................................................................................................................................................
56.505-56.525 mm (2.224-2.225 in)

................................................................................................................................. 0.004-0.008 mm
(0.00015-0.0003 in)

....................................................................................................................................... 0.004-0.008
mm (0.00015-0.0003 in)

..................................................................................................................................... 0.11-0.51 mm
(0.00433-0.02 in)
CRANKSHAFT
Production
.......................................................................................................................................................
53.318-53.338 mm (2.0991-2.0999 in)
Service .................................................................................................................................................
.................................... 53.308 mm (2.0987 in)
Production ...........................................................................................................................................
...................................... 0.005 mm (0.0002 in)
Service .................................................................................................................................................
........................................ 0.01 mm (0.0004 in)

..................................................................................................................... 0.005 mm (0.0002 in)

.......................................................................................................................... 0.02 mm (0.00078 in)
Crankshaft End Play

.......................................................................................................................................................
0.04-0.2 mm (0.0015-0.0078 in)
Production
.............................................................................................................................................................
0.02-0.052 mm (0.0008-0.0021 in)
Service .................................................................................................................................................
................. 0.02-0.065 mm (0.0008-0.0025 in)
Production
...........................................................................................................................................................
64.992-65.008 mm (2.558-2.559 in)
Service .................................................................................................................................................
...................................... 64.992 mm (2.558 in)
Production ...........................................................................................................................................
.................................. 0.003 mm (0.000118 in)
Service .................................................................................................................................................
...................................... 0.008 mm (0.0003 in)
Production ...........................................................................................................................................
........................................ 0.01 mm (0.0004 in)
Service .................................................................................................................................................
...................................... 0.02 mm (0.00078 in)

...........................................................................................................................................................
0.05 mm (0.002 in)

........................................................................................................................ 0.7 mm (0.028 in)
Production
.............................................................................................................................................................
26.14-26.22 mm (1.029-1.0315 in)
Service .................................................................................................................................................
...................................... 26.22 mm (1.0315 in)

.................................................................................................................................................... 0.025
mm (0.001 in)
PISTON RINGS
Piston Ring End Gap - First Compression Ring
Measured in Cylinder Bore - Production

.................................................................................................................... 0.23-0.44 mm
(0.009-0.017 in)
Hummer Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine >
Component Information > Specifications > Page 2189
Measured in Cylinder Bore - Service

.......................................................................................................................... 0.23-0.5 mm
(0.009-0.0196 in)
Piston Ring End Gap - Second Compression Ring

...................................................................................................................... 0.44-0.7 mm
(0.017-0.027 in)

.......................................................................................................................... 0.44-0.76 mm
(0.0173-0.03 in)
Piston Ring End Gap - Oil Control Ring

.................................................................................................................... 0.18-0.75 mm
(0.007-0.029 in)

.......................................................................................................................... 0.18-0.81 mm
(0.007-0.032 in)
Piston Ring-to-Groove Clearance - First Compression Ring
Production
.........................................................................................................................................................
0.04-0.085 mm (0.00157-0.00335 in)
Service
..............................................................................................................................................................
0.04-0.085 mm (0.00157-0.00335 in)
Piston Ring-to-Groove Clearance - Second Compression Ring
Production
...........................................................................................................................................................
0.04-0.078 mm (0.00157-0.0031 in)
Service .................................................................................................................................................
............... 0.04-0.078 mm (0.00157-0.0031 in)
Piston Ring-to-Groove Clearance - Oil Control Ring
Production ...........................................................................................................................................
.................... 0.012-0.2 mm (0.0005-0.0078 in)

Service .................................................................................................................................................
................... 0.012-0.2 mm (0.0005-0.0078 in)
PISTONS AND PINS
Production
...........................................................................................................................................................
0.002-0.01 mm (0.00008-0.0004 in)
Service
..............................................................................................................................................................
0.002-0.015 mm (0.00008-0.0006 in)

..........................................................................................................................................
23.952-23.955 mm (0.943-0.943 in)
Production
.........................................................................................................................................................
0.007-0.02 mm (0.00027-0.00078 in)
Service
............................................................................................................................................................
0.007-0.022 mm (0.00027-0.00086 in)

........................................................................................................................................
96.002-96.036 mm (3.779-3.78 in)
Production
............................................................................................................................................ -0.036 to
+0.016 mm (-0.0014 to +0.0006 in)

.............................................................................................................................. 0.071 mm (0.0028
in)
Hummer Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine >
Piston Ring: Specifications
PISTON RINGS

.................................................................................................................... 0.23-0.44 mm
(0.009-0.017 in)

.......................................................................................................................... 0.23-0.5 mm
(0.009-0.0196 in)

...................................................................................................................... 0.44-0.7 mm
(0.017-0.027 in)

.......................................................................................................................... 0.44-0.76 mm
(0.0173-0.03 in)

.................................................................................................................... 0.18-0.75 mm
(0.007-0.029 in)

.......................................................................................................................... 0.18-0.81 mm
(0.007-0.032 in)
Production
.........................................................................................................................................................
0.04-0.085 mm (0.00157-0.00335 in)
Service
..............................................................................................................................................................
0.04-0.085 mm (0.00157-0.00335 in)
Production
...........................................................................................................................................................
0.04-0.078 mm (0.00157-0.0031 in)

Service .................................................................................................................................................
............... 0.04-0.078 mm (0.00157-0.0031 in)
Production ...........................................................................................................................................
.................... 0.012-0.2 mm (0.0005-0.0078 in)
Service .................................................................................................................................................
................... 0.012-0.2 mm (0.0005-0.0078 in)
PISTONS AND PINS
Production
...........................................................................................................................................................
0.002-0.01 mm (0.00008-0.0004 in)
Service
..............................................................................................................................................................
0.002-0.015 mm (0.00008-0.0006 in)

..........................................................................................................................................
23.952-23.955 mm (0.943-0.943 in)
Production
.........................................................................................................................................................
0.007-0.02 mm (0.00027-0.00078 in)
Service
............................................................................................................................................................
0.007-0.022 mm (0.00027-0.00086 in)

........................................................................................................................................
96.002-96.036 mm (3.779-3.78 in)
Production
............................................................................................................................................ -0.036 to
+0.016 mm (-0.0014 to +0.0006 in)

.............................................................................................................................. 0.071 mm (0.0028
in)
Hummer Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Rear Engine Plate >
Rear Engine Plate: Service and Repair
Engine Rear Cover Replacement
Tools Required
J 41476 Front and Rear Cover Alignment (at crankshaft seal area)
Removal Procedure
1. Remove the engine flywheel. Refer to Automatic Transmission Flex Plate Replacement (See:
Transmission and Drivetrain/Flex Plate/Service and
Repair) .
2. Remove the oil pan-to-rear cover bolts (1).
3. Remove the rear cover bolts. 4. Remove the rear cover and gasket. 5. Discard the rear cover
gasket. 6. Clean and inspect the rear cover. Refer to Crankshaft Rear Oil Seal Housing Cleaning
and Inspection (See: Service and
Repair/Overhaul/Component Service and Inspection/Crankshaft Rear Oil Seal Housing Cleaning

and Inspection) .
Important:
* Do not reuse the crankshaft oil seal or rear cover gasket.
* Do not apply any type of sealant to the rear cover gasket (unless specified).
* The special tool in this procedure is used to properly center the crankshaft rear oil seal.
* The crankshaft rear oil seal will be installed after the rear cover has been installed and aligned.
Install the rear cover without the crankshaft oil seal.
- All gasket surfaces should be free of oil or other foreign material during assembly.
- The crankshaft rear oil seal MUST be centered in relation to the crankshaft.
- An improperly aligned rear cover may cause premature rear oil seal wear and/or engine assembly
oil leaks.
1. Apply a 5 mm (0.20 in) bead of sealant 20 mm (0.80 in) long to the oil pan to engine block
junction. Refer to Sealers, Adhesives, and Lubricants (
See: Specifications/Sealers, Adhesives, and Lubricants) for the correct part number.
2. Install the rear cover gasket and cover. 3. Install the rear cover bolts until snug. Do not
overtighten.
4. Install the oil pan-to-rear cover bolts (1) until snug. Do not overtighten.
5. Rotate the crankshaft until two opposing flywheel bolt holes are parallel to the oil pan surface.
Important: The tapered legs of the alignment tool must enter the rear cover oil seal bore.
6. Install the J 41476 and bolts onto the rear of the crankshaft.
Notice) .
7. Tighten the J 41476 mounting bolts until snug. Do not overtighten.
1. Tighten the oil pan-to-rear cover bolts to 12 N.m (106 lb in). 2. Tighten the engine rear cover
bolts to 30 N.m (22 lb ft).
8. Remove the J 41476 . 9. Install a NEW crankshaft rear oil seal. Refer to Crankshaft Rear Oil
Seal Replacement (See: Seals and Gaskets/Crankshaft Main Bearing
Seal/Service and Repair) .
10. Install the engine flywheel. Refer to Automatic Transmission Flex Plate Replacement (See:
Repair) .
Hummer Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance >
System Information > Specifications
VALVE SYSTEM
Valve Lash ...........................................................................................................................................

Hummer Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release
> System Information > Service and Repair > Fuel Pressure Relief (With CH 48027)
Special Tools

Maintenance/Fuses and Circuit Breakers/Fuse/Application and ID) .

> System Information > Service and Repair > Fuel Pressure Relief (With CH 48027) > Page 2206
the fuel fill cap.
Tools Required

directions.
Removal Procedure

Hummer Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly
> Component Information > Service and Repair
Rocker Arm Assembly: Service and Repair
Removal Procedure
(See: Valve Cover/Service and Repair/Valve
Rocker Arm Cover Replacement - Left Side) or Valve Rocker Arm Cover Replacement - Right Side
(See: Valve Cover/Service and Repair/Valve Rocker Arm Cover Replacement - Right Side) .
and Inspection) .
> Component Information > Service and Repair > Page 2213

compression stroke.
(See: Valve Cover/Service and Repair/Valve
Rocker Arm Cover Replacement - Left Side) or Valve Rocker Arm Cover Replacement - Right Side
(See: Valve Cover/Service and Repair/Valve Rocker Arm Cover Replacement - Right Side) .
Hummer Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover >
Component Information > Service and Repair > Valve Rocker Arm Cover Replacement - Left Side
Valve Cover: Service and Repair Valve Rocker Arm Cover Replacement - Left Side
Valve Rocker Arm Cover Replacement - Left Side
Removal Procedure
(LQ4)) (See: Intake Manifold/Service and
Repair/Upper Intake Manifold Sight Shield Replacement) .
2. Remove the connector position assurance (CPA) lock. 3. Disconnect the main electrical
connector (2) feeding the ignition coils. 4. Remove the harness clips (1). 5. Reposition the engine
harness. 6. Remove the spark plug wires from the ignition coils.
* Twist each plug wire 1/2 turn.
* Pull only on the boot in order to remove the wire from the ignition coil.
7. Remove the ignition coil bracket studs from the rocker arm cover. 8. Remove the ignition coils
and bracket from the rocker arm cover. 9. Remove the valve rocker arm cover bolts.
10. Remove the valve rocker arm cover.

Component Information > Service and Repair > Valve Rocker Arm Cover Replacement - Left Side > Page 2219
11. Remove the gasket (1) from the rocker cover. 12. Discard the OLD gasket. 13. Clean and
inspect the rocker arm cover. Refer to Valve Rocker Arm Cover Cleaning and Inspection (See:
Service and
Repair/Overhaul/Component Service and Inspection/Valve Rocker Arm Cover Cleaning and

Inspection) .
Important:
* All gasket surfaces should be free of oil an/or other foreign material during assembly.
* DO NOT reuse the valve rocker arm cover gasket.
The valve rocker arm cover bolt grommets may be reused.
* If the PCV valve grommet has been removed from the rocker cover, install a NEW grommet
during assembly.
1. Install a NEW rocker cover gasket (1) into the valve rocker cover lip. 2. Install the valve rocker
arm cover onto the cylinder head. 3. Install new rocker arm cover grommets, if necessary.

Notice) .
4. Install the rocker arm cover bolts.

5. Apply threadlock to the threads of the bracket bolts. Refer to Sealers, Adhesives, and Lubricants
(See: Specifications/Sealers, Adhesives, and
Lubricants) for the correct part number.
6. Install the ignition coils and bracket to the rocker arm cover. 7. Install the ignition coil bracket
studs to the rocker arm cover.
Tighten the studs to 12 N.m (106 lb in).
8. Install the spark plug wires to the ignition coils. 9. Re-position the engine harness.
10. Install the harness clips (1). 11. Connect the main electrical connector (2) feeding the ignition
coils. 12. Install the CPA lock. 13. Install the engine sight shield. Refer to Upper Intake Manifold
Sight Shield Replacement (6.0L (LQ4)) (See: Intake Manifold/Service and

Valve Cover: Service and Repair Valve Rocker Arm Cover Replacement - Right Side
Valve Rocker Arm Cover Replacement - Right Side
Removal Procedure
(LQ4)) (See: Intake Manifold/Service and
2. Remove the connector position assurance (CPA) lock (5). 3. Disconnect the main electrical
connector (4) feeding the ignition coils. 4. Remove the harness clips (1). 5. Reposition the engine
harness. 6. Remove the spark plug wires from the ignition coils.
* Twist each plug wire 1/2 turn.
* Pull only on the boot in order to remove the wire from the ignition coil.
7. Reposition the surge tank/heater hoses from the heater hose bracket. 8. Remove the heater
hose bracket nut and bracket.
9. Remove the ignition coil bracket studs from the rocker arm cover.
10. Remove the ignition coils and bracket from the rocker cover. 11. Remove the positive
crankcase ventilation (PCV) fresh air hose.
12. Remove the valve rocker arm cover bolts. 13. Remove the valve rocker arm cover.
14. Remove the gasket (1) from the rocker cover. 15. Discard the OLD gasket.
16. Remove the oil fill cap from the oil fill tube. 17. Remove the oil fill tube from the rocker cover, if
required. 18. Discard the oil fill tube. 19. Clean and inspect the rocker arm cover. Refer to Valve
Rocker Arm Cover Cleaning and Inspection (See: Service and
Repair/Overhaul/Component Service and Inspection/Valve Rocker Arm Cover Cleaning and

Inspection) .
Important:
* All gasket surfaces should be free of oil or other foreign material during assembly.
* DO NOT reuse the valve rocker arm cover gasket.
* The valve rocker arm cover bolt grommets may be reused.

* If the oil fill tube has been removed from the rocker arm cover, install a NEW fill tube during
assembly.
1. Lubricate the O-ring seal of the NEW oil fill tube with clean engine oil. 2. Insert the NEW oil fill
tube into the rocker arm cover.
Rotate the tube clockwise until locked in the proper position.
3. Install the oil fill cap into the tube.
Rotate the cap clockwise until locked in the proper position.
4. Install a NEW rocker cover gasket (1) into the valve rocker cover lip.
5. Install the valve rocker arm cover onto the cylinder head. 6. Install new rocker arm cover
grommets, if necessary.

Notice) .
7. Install the rocker arm cover bolts and grommets.
8. Install the PCV fresh air hose.

9. Apply threadlock to the threads of the bracket bolts. Refer to Sealers, Adhesives, and Lubricants
(See: Specifications/Sealers, Adhesives, and
10. Install the ignition coils and bracket to the rocker arm cover. 11. Install the ignition coil bracket
studs to the rocker cover.
Tighten the studs to 12 N.m (106 lb in).
12. Install the heater hose bracket and nut.
13. Position the surge tank/heater hoses to the heater hose bracket.
14. Install the spark plug wires to the ignition coils. 15. Re-position the engine harness. 16. Install
the harness clips (1). 17. Connect the main electrical connector (4) feeding the ignition coils. 18.
Install the CPA lock (5). 19. Install the engine sight shield. Refer to Upper Intake Manifold Sight
Shield Replacement (6.0L (LQ4)) (See: Intake Manifold/Service and

Hummer Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring >
Component Information > Service Precautions
Valve Spring: Service Precautions
Valve Springs Can Be Tightly Compressed Caution
Caution: Valve springs can be tightly compressed. Use care when removing retainers and plugs.
Personal injury could result.
Component Information > Service Precautions > Page 2228
Valve Spring: Service and Repair
Valve Stem Oil Seal and Valve Spring Replacement
Special Tools
* J 22794 Spark Plug Port Adapter
* J 38606 Valve Spring Compressor
Removal Procedure
1. Remove the valve rocker arm. Refer to Valve Rocker Arm and Push Rod Replacement (See:
Rocker Arm Assembly/Service and Repair) . 2. Disconnect the spark plug wire at the spark plug.
* Twist each plug wire boot 1/2 turn.
* Pull only on the boot in order to remove the wire from the spark plug.
Important: Remove the spark plugs from the cylinder head with the engine at room temperature.
3. Loosen the spark plug 1 or 2 turns. 4. Brush or air blast away any dirt or debris from around the
spark plug. 5. Remove the spark plug.
6. Install J 22794 into the spark plug hole. 7. Attach an air hose to J 22794 . 8. Apply compressed
air to J 22794 in order to hold the valves in place.
9. Use J 38606 in order to compress the valve spring.

10. Remove the valve stem keys (225). 11. Carefully release the valve spring tension. 12. Remove
the J 38606 . 13. Remove the valve spring cap (224). 14. Remove the valve spring (223). 15.
Remove the valve stem oil seal and shim (222) assembly.
1. Clean the cylinder head valve spring seat and/or shim area. 2. Lubricate the valve guide and
valve stem oil seal with clean engine oil. 3. Install the valve stem oil seal and shim (222) assembly.
4. Install the valve spring (223). 5. Install the valve spring cap (224).
6. Compress the valve spring using the J 38606 . 7. Install the valve stem keys (225).
* Use grease in order to hold the valve keys in place.
* Make sure the keys seat properly in the groove of the valve stem.
* Carefully release the valve spring pressure, making sure the valve keys stay in place.
* Remove the J 38606 .
* Tap the end of the valve stem with a plastic faced hammer to seat the keys, if necessary.
8. Remove J 22794 from the spark plug port.

Notice) .
9. Hand start the spark plug.
Tighten the spark plug to 15 N.m (11 lb ft).
10. Install the spark plug wires at the ignition coil. 11. Install the spark plug wire to the spark plug.
12. Inspect the wires for proper installation:
* Push sideways on each boot in order to check for proper installation.
13. Install the valve rocker arm. Refer to Valve Rocker Arm and Push Rod Replacement (See:
Rocker Arm Assembly/Service and Repair) .
Hummer Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Drive Belt > Component Information > Technical Service Bulletins > Customer Interest for Drive Belt: > 08-06-01-008A > Jul
> 09 > Engine - Various Drive Belt Symptoms
Drive Belt: Customer Interest Engine - Various Drive Belt Symptoms
INFORMATION
Date: July 27, 2009
Models:
Background
from $160 - $200.
- Drive Belt Noise
Instructions
Caution

> 09 > Engine - Various Drive Belt Symptoms > Page 2242
engine.
alignment.
Tool Information
> 09 > Engine - Various Drive Belt Symptoms > Page 2243
Disclaimer
Drive Belt > Component Information > Technical Service Bulletins > Customer Interest for Drive Belt: > 08-06-01-015 > Jul >
08 > Engine - Drive Belt Chirping Noise
Drive Belt: Customer Interest Engine - Drive Belt Chirping Noise
TECHNICAL
Bulletin No.: 08-06-01-015
Date: July 14, 2008
Saab 9-7X V8

Condition
Cause
noise.
Correction
Notice:
Tip
Parts Information

Drive Belt > Component Information > Technical Service Bulletins > Customer Interest for Drive Belt: > 08-06-01-015 > Jul >
08 > Engine - Drive Belt Chirping Noise > Page 2248
Disclaimer
Drive Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Belt: >
08-06-01-008A > Jul > 09 > Engine - Various Drive Belt Symptoms
INFORMATION
Date: July 27, 2009
Models:
Background
from $160 - $200.
- Drive Belt Noise
Instructions
Caution

08-06-01-008A > Jul > 09 > Engine - Various Drive Belt Symptoms > Page 2254
engine.
alignment.
Tool Information
08-06-01-008A > Jul > 09 > Engine - Various Drive Belt Symptoms > Page 2255
Disclaimer
08-06-01-015 > Jul > 08 > Engine - Drive Belt Chirping Noise
TECHNICAL
Bulletin No.: 08-06-01-015
Date: July 14, 2008
Saab 9-7X V8

Condition
Cause
noise.
Correction
Notice:
Tip
Parts Information

08-06-01-015 > Jul > 08 > Engine - Drive Belt Chirping Noise > Page 2260
Disclaimer
Drive Belt > Component Information > Technical Service Bulletins > Page 2261
Drive Belt: Service Precautions
Belt Dressing Notice
Notice: 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.
Drive Belt > Component Information > Technical Service Bulletins > Page 2262
Drive Belt: Description and Operation
Drive Belt System Description
The drive belt system consists of the following components:
* The drive belt
* The drive belt tensioner
* The drive belt idler pulley
* The crankshaft balancer pulley
* The accessory drive component mounting brackets
* The accessory drive components
- The power steering pump, if belt driven
- The generator
- The A/C compressor, if equipped
- The engine cooling fan, if belt driven
- The water pump, if belt driven
- The vacuum pump, if equipped
- The air compressor, if equipped
The drive belt system may use 1 belt or 2 belts. The drive belt is thin so that it can bend backwards
and has several ribs to match the grooves in the pulleys. The drive belts are made of different
types of rubbers, chloroprene or EPDM, and have different layers or plys containing either fiber
cloth or cords for reinforcement.
Both sides of the drive belt may be used to drive the different accessory drive components. When
the back side of the drive belt is used to drive a pulley, the pulley is smooth.
The drive belt is pulled by the crankshaft balancer pulley across the accessory drive component
pulleys. The spring loaded drive belt tensioner keeps constant tension on the drive belt to prevent
the drive belt from slipping. The drive belt tensioner arm will move when loads are applied to the
drive belt by the accessory drive components and the crankshaft.
The drive belt system may have an idler pulley, which is used to add wrap to the adjacent pulleys.
Some systems use an idler pulley in place of an accessory drive component when the vehicle is
not equipped with the accessory.
Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping, Squeal, and Whine Diagnosis
Drive Belt: Testing and Inspection Drive Belt Chirping, Squeal, and Whine Diagnosis
Drive Belt Chirping, Squeal, and Whine Diagnosis
Diagnostic Aids
* A chirping or squeal noise may be intermittent due to moisture on the drive belts or the pulleys. It
may be necessary to spray a small amount of water on the drive belts in order to duplicate the
customers concern. If spraying water on the drive belt duplicates the symptom, cleaning the belt
pulleys may be the probable solution.
* If the noise is intermittent, verify the accessory drive components by varying their loads making
sure they are operated to their maximum capacity. An overcharged A/C system, power steering
system with a pinched hose or wrong fluid, or a generator failing are suggested items to inspect.
* A chirping, squeal or whine noise may be caused by a loose or improper installation of a body or
suspension component. Other items of the vehicle may also cause the noise.
* The drive belts will not cause a whine noise.
Test Description
The numbers below refer to the step numbers on the diagnostic table. 2. The noise may not be
engine related. This step is to verify that the engine is making the noise. If the engine is not making
the noise do not proceed further with this table. 3. The noise may be an internal engine noise.
Removing the drive belts one at a time and operating the engine for a brief period will verify the
noise is related to the drive belt. When removing the drive belt the water pump may not be
operating and the engine may overheat. Also DTCs may set when the engine is operating with the
drive belts removed. 4. Inspect all drive belt pulleys for pilling. Pilling is the small balls or pills or it
can be strings in the drive belt grooves from the accumulation of rubber dust. 6. Misalignment of
the pulleys may be caused from improper mounting of the accessory drive component, incorrect
installation procedure for that pulley. 10. Inspecting of the fasteners can eliminate the possibility
that a wrong bolt, nut, spacer, or washer was installed. 12. Inspecting the pulleys for being bent
should include inspecting for a dent or other damage to the pulleys that would prevent the drive belt
from not seating properly in all of the pulley grooves or on the smooth surface of a pulley when the
back side of the belt is used to drive the pulley. 14. This test is to verify that the drive belt tensioner
operates properly. If the drive belt tensioner is not operating properly, proper belt tension may not
be achieved to keep the drive belt from slipping which could cause a squeal noise. 15. This test is
to verify that the drive belt is not too long, which would prevent the drive belt tensioner from
working properly. Also if an incorrect length drive belt was installed, it may not be routed properly
and may be turning an accessory drive component in the wrong direction. 16. Misalignment of the
pulleys may be caused from improper mounting of the accessory drive component, incorrect
installation procedure for that pulley. 17. This test is to verify that the pulleys are the correct
diameter or width. Using a known good vehicle compare the pulley sizes. 19. Replacing the drive
belt when it is not damaged or there is not excessive pilling will only be a temporary repair.
Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping, Squeal, and Whine Diagnosis > Page
2265
2266
2267
Drive Belt: Testing and Inspection Drive Belt Falls Off and Excessive Wear Diagnosis
Drive Belt Falls Off and Excessive Wear Diagnosis
Diagnostic Aids
If the drive belt repeatedly falls off the drive belt pulleys, this is because of pulley misalignment.
An extra load that is quickly applied on released by an accessory drive component may cause the
drive belt to fall off the pulleys. Verify the accessory drive components operate properly.
If the drive belt is the incorrect length, the drive belt tensioner may not keep the proper tension on
the drive belt.
Excessive wear on a drive belt is usually caused by an incorrect installation or the wrong drive belt
for the application.
Minor misalignment of the drive belt pulleys will not cause excessive wear, but will probably cause
the drive belt to make a noise or to fall off.
Excessive misalignment of the drive belt pulleys will cause excessive wear but may also make the
drive belt fall off.
Test Description
The numbers below refer to the step numbers on the diagnostic table. 2. This inspection is to verify
the condition of the drive belt. Damage may of occurred to the drive belt when the drive belt fell off.
The drive belt may of been damaged, which caused the drive belt to fall off. Inspect the belt for
cuts, tears, sections of ribs missing, or damaged belt plys. 4. Misalignment of the pulleys may be
caused from improper mounting of the accessory drive component, incorrect installation of the
accessory drive component pulley, or the pulley bent inward or outward from a previous repair.
Test for a misaligned pulley using a straight edge in the pulley grooves across two or three pulleys.
If a misaligned pulley is found refer to that accessory drive component for the proper installation
procedure of that pulley. 5. Inspecting the pulleys for being bent should include inspecting for a
dent or other damage to the pulleys that would prevent the drive belt from not seating properly in all
of the pulley grooves or on the smooth surface of a pulley when the back side of the belt is used to
drive the pulley. 6. Accessory drive component brackets that are bent or cracked will let the drive
belt fall off. 7. Inspection of the fasteners can eliminate the possibility that a wrong bolt, nut ,
spacer, or washer was installed. Missing, loose, or the wrong fasteners may cause pulley
misalignment from the bracket moving under load. Over tightening of the fasteners may cause
misalignment of the accessory component bracket. 13. The inspection is to verify the drive belt is
correctly installed on all of the drive belt pulleys. Wear on the drive belt may be caused by
mis-positioning the drive belt by one groove on a pulley. 14. The installation of a drive belt that is
too wide or too narrow will cause wear on the drive belt. The drive belt ribs should match all of the
grooves on all of the pulleys. 15. This inspection is to verify the drive belt is not contacting any
parts of the engine or body while the engine is operating. There should be sufficient clearance
when the drive belt accessory drive components load varies. The drive belt should not come in
contact with an engine or a body component when snapping the throttle.
2268
2269
Drive Belt: Testing and Inspection Drive Belt Rumbling and Vibration Diagnosis
Drive Belt Rumbling and Vibration Diagnosis
Diagnostic Aids
The accessory drive components can have an affect on engine vibration. Vibration from the engine
operating may cause a body component or another part of the vehicle to make rumbling noise.
Vibration can be caused by, but not limited to the air conditioning (A/C) system over charged, the
power steering system restricted or the incorrect fluid, or an extra load on the generator. To help
identify an intermittent or an improper condition, vary the loads on the accessory drive components.
The drive belt may have a rumbling condition that can not be seen or felt. Sometimes replacing the
drive belt may be the only repair for the symptom.
If replacing the drive belt, completing the diagnostic table, and the noise is only heard when the
drive belts are installed, there might be an accessory drive component with a failure. Varying the
load on the different accessory drive components may aid in identifying which component is
causing the rumbling noise.
Test Description
The numbers below refer to the step numbers on the diagnostic table. 2. This test is to verify that
the symptom is present during diagnosing. Other vehicle components may cause a similar
symptom. 3. This test is to verify that one of the drive belts is causing the rumbling noise or
vibration. Rumbling noise may be confused with an internal engine noise due to the similarity in the
description. Remove only one drive belt at a time if the vehicle has multiple drive belts. When
removing the drive belts the water pump may not be operating and the engine may overheat. Also
DTCs may set when the engine is operating with the drive belts removed. 4. Inspecting the drive
belts is to ensure that they are not causing the noise. Small cracks across the ribs of the drive belt
will not cause the noise. Belt separation is identified by the plys of the belt separating and may be
seen at the edge of the belt our felt as a lump in the belt. 5. Small amounts of pilling is normal
condition and acceptable. When the pilling is severe the drive belt does not have a smooth surface
for proper operation. 9. Inspecting of the fasteners can eliminate the possibility that the wrong bolt,
nut, spacer, or washer was installed. 11. This step should only be performed if the water pump is
driven by the drive belt. Inspect the water pump shaft for being bent. Also inspect the water pump
bearings for smooth operation and excessive play. Compare the water pump with a known good
water pump. 12. Accessory drive component brackets that are bent, cracked, or loose may put
extra strain on that accessory component causing it to vibrate.
2270
Drive Belt > Component Information > Service and Repair > Drive Belt Replacement - Accessory
Drive Belt: Service and Repair Drive Belt Replacement - Accessory
Drive Belt Replacement - Accessory
Removal Procedure
1. Loosen the air cleaner outlet duct clamps at the following locations:
* Throttle body
* Mass airflow/intake air temperature (MAF/IAT) sensor
2. Remove the air cleaner outlet duct.
3. Install a breaker bar with hex-head socket to the drive belt tensioner bolt. 4. Rotate the drive belt
tensioner clockwise in order to relieve tension on the belt. 5. Remove the belt from the pulleys and
the drive belt tensioner. 6. Slowly release the tension on the drive belt tensioner. 7. Remove the
breaker bar and socket and from the drive belt tensioner bolt. 8. Clean and inspect the belt
surfaces of all the pulleys.
1. Route the drive belt around all the pulleys except the idler pulley. 2. Install the breaker bar with
hex-head socket to the belt tensioner bolt. 3. Rotate the belt tensioner clockwise in order to relieve
the tension on the tensioner. 4. Install the drive belt under the idler pulley.
Drive Belt > Component Information > Service and Repair > Drive Belt Replacement - Accessory > Page 2273
5. Slowly release the tension on the belt tensioner. 6. Remove the breaker bar and socket from the
belt tensioner bolt. 7. Inspect the drive belt for proper installation and alignment.
Important: Align the arrow at the throttle body end of the duct with the throttle body attaching stud.
8. Install the air cleaner outlet duct.

Notice) .
9. Tighten the air cleaner outlet duct clamps at the following locations:
* Throttle body
* MAF/IAT sensor
Drive Belt: Service and Repair Air Conditioning Compressor Belt Replacement
Air Conditioning Compressor Belt Replacement

Removal Procedure
1. Remove the accessory drive belt. Refer to Drive Belt Replacement - Accessory (See: Drive Belt
Replacement - Accessory) . 2. Raise and suitably support the vehicle. Refer to Lifting and Jacking
the Vehicle (See: Maintenance) . 3. Remove the engine protection shield. Refer to Engine
Protection Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair
).
4. Install a ratchet into the air conditioning (A/C) belt tensioner adapter opening. 5. Rotate the A/C
belt tensioner clockwise in order to relieve tension on the belt. 6. Remove the A/C belt from the
pulleys. 7. Slowly release the tension on the A/C belt tensioner. 8. Remove the ratchet from the
A/C belt tensioner. 9. Clean and inspect the belt surfaces of all the pulleys.
1. Install the A/C belt around the crankshaft balancer. 2. Install a ratchet into the A/C drive belt
tensioner adapter opening. 3. Rotate the A/C belt tensioner clockwise in order to relieve tension on
the tensioner. 4. Install the A/C belt over the idler pulley. 5. Install the A/C belt around the A/C
compressor pulley. 6. Slowly release the tension on the A/C belt tensioner. 7. Remove the ratchet
from the A/C belt tensioner. 8. Inspect the A/C belt for proper installation and alignment. 9. Install

Notice) .
10. Install the engine shield bolts.
11. Lower the vehicle. 12. Install the accessory drive belt. Refer to Drive Belt Replacement -
Accessory (See: Drive Belt Replacement - Accessory) .
Drive Belt Tensioner > Component Information > Testing and Inspection
Drive Belt Tensioner: Testing and Inspection
Drive Belt Tensioner Diagnosis
Inspection Procedure
Notice: Allowing the drive belt tensioner to snap into the free position may result in damage to the
tensioner.
Important: When the engine is operating the drive belt tensioner arm will move. Do not replace the
drive belt tensioner because of movement in the drive belt tensioner arm.
1. Remove the drive belt. Refer to Drive Belt Replacement - Accessory (See: Drive Belt/Service
and Repair/Drive Belt Replacement - Accessory) or
Air Conditioning Compressor Belt Replacement (See: Drive Belt/Service and Repair/Air
Conditioning Compressor Belt Replacement) .
2. Move the drive belt tensioner through its full travel.
* The movement should feel smooth.
* There should be no binding.
* The tensioner should return freely.
3. If any binding is observed, replace the drive belt tensioner. Refer to Drive Belt Tensioner
Replacement - Accessory (See: Service and
Repair/Drive Belt Tensioner Replacement - Accessory) or Drive Belt Tensioner Replacement - Air
Conditioning (See: Service and Repair/Drive Belt Tensioner Replacement - Air Conditioning) .
4. Install the drive belt. Refer to of Drive Belt Replacement - Accessory (See: Drive Belt/Service
and Repair/Drive Belt Replacement - Accessory)
or Air Conditioning Compressor Belt Replacement (See: Drive Belt/Service and Repair/Air
Drive Belt Tensioner > Component Information > Service and Repair > Drive Belt Tensioner Replacement - Accessory
Drive Belt Tensioner: Service and Repair Drive Belt Tensioner Replacement - Accessory
Drive Belt Tensioner Replacement - Accessory
Removal Procedure
1. Remove the accessory drive belt. Refer to Drive Belt Replacement - Accessory (See: Drive
Belt/Service and Repair/Drive Belt Replacement -
Accessory) .
2. Remove the drive belt tensioner bolts. 3. Remove the drive belt tensioner.
1. Install the drive belt tensioner. 2. Install the drive belt tensioner bolts.

Notice) .
3. Tighten the drive belt tensioner bolts.
Tighten the accessory drive belt tensioner bolts to 50 N.m (37 lb ft).
4. Install the accessory drive belt. Refer to Drive Belt Replacement - Accessory (See: Drive
Belt/Service and Repair/Drive Belt Replacement -
Accessory) .
Drive Belt Tensioner > Component Information > Service and Repair > Drive Belt Tensioner Replacement - Accessory >
Page 2281
Drive Belt Tensioner: Service and Repair Drive Belt Tensioner Replacement - Air Conditioning
Drive Belt Tensioner Replacement - Air Conditioning
Removal Procedure
1. Remove the air conditioning (A/C) drive belt. Refer to Air Conditioning Compressor Belt
Replacement (See: Drive Belt/Service and Repair/Air
2. Remove the A/C belt tensioner bolts. 3. Remove the A/C belt tensioner.
1. Install the A/C belt tensioner.

Notice) .
2. Install the A/C belt tensioner bolts.
Tighten the A/C belt tensioner bolts to 50 N.m (37 lb ft).
3. Install the A/C drive belt. Refer to Air Conditioning Compressor Belt Replacement (See: Drive
Belt/Service and Repair/Air Conditioning
Compressor Belt Replacement) .

Engine Mount > Component Information > Testing and Inspection
Engine Mount: Testing and Inspection
Engine Mount Inspection
Notice: Broken or deteriorated mounts can cause misalignment and destruction of certain drive
train components. When a single mount breaks, the remaining mounts are subjected to abnormally
high stresses.
Notice: 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. Due to the small clearance between the oil pan and the
oil pump screen, jacking against the oil pan may cause the pan to be bent against the pump
screen. This will result in a damaged oil pickup unit.
1. Measure the engine movement at the engine mount in order to check for damage to the rubber
portions of the mount.
1. Apply the park brake. 2. Start the engine. 3. Firmly apply and hold the primary brakes. 4. Have
an assistant stand to the side of the vehicle in order to observe for engine movement. 5. Slightly
load the engine shifting from drive to reverse a few times. 6. If the engine moves more than 24 mm
(0.945 in) from the at rest position, in either direction, check for loose engine mount bolts.
2. If the engine mount bolt torque is within specifications, check the condition of the engine mount.
3. Replace the engine mount if any of the following conditions exist:
* Heat check cracks cover the rubber cushion surface.
* The rubber cushion is separated from the metal plate of the mount.
* There is a split through the rubber cushion.

Engine Mount > Component Information > Service and Repair > Engine Mount Bracket Replacement - Left
Engine Mount: Service and Repair Engine Mount Bracket Replacement - Left
Engine Mount Bracket Replacement - Left Side
Removal Procedure
1. Remove the engine mount. Refer to Engine Mount Replacement - Left Side (See: Engine Mount
Replacement - Left) . 2. Remove the engine mount bracket bolts. 3. Remove the engine mount
bracket.
1. Install the engine mount bracket. 2. Perform the following procedure prior to installing the engine
mount bracket bolts:
* Remove all traces of the original adhesive patch.
* Clean the threads of the bolt with denatured alcohol or equivalent and allow to dry.
* Apply threadlocker GM P/N 12345382 (Canadian P/N 10953489) or equivalent to the bolts.

Notice) .
3. Install the engine mount bracket bolts.
Tighten the engine mount bracket bolts to 75 N.m (55 lb ft).
4. Install the engine mount. Refer to Engine Mount Replacement - Left Side (See: Engine Mount
Replacement - Left) .
Engine Mount > Component Information > Service and Repair > Engine Mount Bracket Replacement - Left > Page 2287
Engine Mount: Service and Repair Engine Mount Bracket Replacement - Right
Engine Mount Bracket Replacement - Right Side
Removal Procedure
1. Remove the engine mount. Refer to Engine Mount Replacement - Right Side (See: Engine
Mount Replacement - Right) . 2. Remove the engine mount bracket bolts. 3. Remove the engine
mount bracket.
1. Install the engine mount bracket. 2. Perform the following procedure prior to installing the engine
mount bracket bolts:
* Apply threadlocker GM P/N 12345382 (Canadian P/N 10953489) or equivalent to the bolts.

Notice) .
3. Install the engine mount bracket bolts.
Tighten the engine mount bracket bolts to 75 N.m (55 lb ft).
4. Install the engine mount. Refer to Engine Mount Replacement - Right Side (See: Engine Mount
Replacement - Right) .
Engine Mount: Service and Repair Engine Mount Replacement - Left
Engine Mount Replacement - Left Side
Removal Procedure
1. Remove the engine mount-to-frame bracket bolts. (Right side shown, left side similar). 2. Raise
and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance) .
3. Remove the engine shield bolts. 4. Remove the engine shield.
Important: DO NOT raise and/or support the engine by the crankshaft balancer, or oil pan.
5. Raise and suitably support the engine using adjustable (screw type) jack stands.
6. Remove the engine mount bolts. 7. Remove the engine mount.
1. Position the engine mount to the engine.

Notice) .
2. Install the engine mount bolts.
Tighten the engine mount bolts to 50 N.m (37 lb ft).
3. Lower the engine. 4. Remove the adjustable jack stands.
5. Position the engine shield to the vehicle. 6. Install the engine shield bolts.
8. Install the engine mount-to-frame bracket bolts (right side shown, left side similar).
Tighten the engine mount-to-frame bracket bolts to 65 N.m (48 lb ft).

Engine Mount: Service and Repair Engine Mount Replacement - Right
Engine Mount Replacement - Right Side
Removal Procedure
1. Remove the engine mount-to-frame bracket bolts. 2. Raise and suitably support the vehicle.
Refer to Lifting and Jacking the Vehicle (See: Maintenance) .
3. Remove the engine shield bolts. 4. Remove the engine shield. 5. Remove the air conditioning
(A/C) compressor. Refer to Compressor Replacement (See: Heating and Air
Conditioning/Compressor
HVAC/Service and Repair/Removal and Replacement/Compressor Replacement) .
Important: DO NOT raise and/or support the engine by the crankshaft balancer, or oil pan.
7. Raise and suitably support the engine using adjustable (screw type) jack stands.
8. Remove the engine mount bolts (left side shown, right side similar). 9. Remove the right engine
mount.
1. Position the right engine mount to the engine (left side shown, right side similar).

Notice) .
2. Install the engine mount bolts.
Tighten the engine mount bolts to 50 N.m (37 lb ft).
3. Lower the engine. 4. Remove the adjustable jack stands. 5. Install the starter motor. Refer to
Starter Motor Replacement (See: Starting and Charging/Starting System/Starter Motor/Service and
Repair) . 6. Install the A/C compressor. Refer to Compressor Replacement (See: Heating and Air
Conditioning/Compressor HVAC/Service and
Repair/Removal and Replacement/Compressor Replacement) .
7. Position the engine shield to the vehicle. 8. Install the engine shield bolts.
10. Install the engine mount-to-frame bracket bolts.
Tighten the engine mount-to-frame bracket bolts to 65 N.m (48 lb ft).

Idler Pulley > Component Information > Service and Repair
Idler Pulley: Service and Repair
Drive Belt Idler Pulley Replacement
Removal Procedure
1. Loosen the drive belt idler pulley bolt. 2. Remove the accessory drive belt. Refer to Drive Belt
Replacement - Accessory (See: Drive Belt/Service and Repair/Drive Belt Replacement -
Accessory) .
3. Remove the drive belt idler pulley and bolt.
1. Install the drive belt idler pulley and bolt to the generator bracket.
Snug the bolt finger tight.
2. Install the drive belt. Refer to Drive Belt Replacement - Accessory (See: Drive Belt/Service and
Repair/Drive Belt Replacement - Accessory) .
3. Tighten the drive belt idler pulley bolt.
Tighten the drive belt idler pulley bolt to 50 N.m (37 lb ft).
Hummer Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure >
Engine Oil Pressure: Specifications
LUBRICATION SYSTEM
Oil Pressure - Minimum - Hot
at 1,000 engine RPM ...........................................................................................................................

................................................ 41 kPa (6 psig) at 2,000 engine RPM .................................................
...................................................................................................................... 124 kPa (18 psig) at
4,000 engine RPM ...............................................................................................................................
........................................ 165 kPa (24 psig)
Engine Oil Pressure: Testing and Inspection
Oil Pressure Diagnosis and Testing
Tools Required
* EN-47971 Oil Pressure Gage Adapter
* J 21867 Pressure Gage
1. With the vehicle on a level surface, run the vehicle for a few minutes. Allow adequate drain down
time, 2-3 minutes, and measure the oil level. 2. If required, add the recommended grade engine oil
and fill the crankcase until the oil level measures full on the oil level indicator. 3. Run the engine
briefly, 10-15 seconds, and verify low or no oil pressure on the vehicle gage or light. 4. Listen for a
noisy valve train or a knocking noise. 5. Inspect for the following conditions:
* Oil diluted by water or glycol antifreeze Refer to Coolant in Engine Oil (See: Testing and
Inspection/Symptom Related Diagnostic Procedures/Coolant in Engine Oil) .
* Foamy oil, which may be caused by a cut or damaged oil pump screen O-ring seal
6. Remove the oil filter and install the EN-47971 (1). 7. Install the J 21867 (2), or equivalent to the
EN-47971 (1). 8. Run the engine and measure the engine oil pressure. 9. Compare the readings to
Engine Mechanical Specifications (See: Specifications/Engine Mechanical Specifications) .
10. If the engine oil pressure is below specifications, inspect the engine for 1 or more of the
* Oil pump worn or dirty Refer to Oil Pump Cleaning and Inspection (See: Service and
Repair/Overhaul/Component Service and Inspection/Oil Pump Cleaning and Inspection) .
* Oil pump-to-engine block bolts loose Refer to Oil Pump, Screen and Crankshaft Oil Deflector
Installation (See: Service and Repair/Overhaul/Assembly/Oil Pump, Screen and Crankshaft Oil
Deflector Installation) .
* Oil pump screen loose, plugged, or damaged
* Oil pump screen O-ring seal missing or damaged
* Malfunctioning oil pump pressure relief valve
* Excessive bearing clearance
* Cracked, porous, or restricted oil galleries
* Oil gallery plugs missing or incorrectly installed Refer to Engine Block Plug Installation (See:
Service and Repair/Overhaul/Assembly/Engine Block Plug Installation) .
* Improper operation of the active fuel management oil pressure relief valve Refer to Cylinder
Deactivation (Active Fuel Management) Oil Pressure Relief Valve Diagnosis and Testing (See:
Testing and Inspection/Component Tests and General Diagnostics/Cylinder Deactivation (Active
Fuel Management) Oil Pressure Relief Valve Diagnosis
and Testing) .
Hummer Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Dip Stick - Dip
Stick Tube > Component Information > Service and Repair
Engine Oil Dip Stick - Dip Stick Tube: Service and Repair
Oil Level Indicator and Tube Replacement
Removal Procedure
1. Remove the oil level indicator from the tube.
2. Remove the oil level indicator tube bolt. 3. Remove the oil level indicator tube from the engine
block.
Important: The O-ring seal may be reused if not cut or damaged.
4. Inspect the O-ring seal for cuts or damage. 5. Remove the O-ring seal from the tube (if required).
Hummer Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Dip Stick - Dip
Stick Tube > Component Information > Service and Repair > Page 2304
1. Lubricate the O-ring seal with clean engine oil. 2. Install the O-ring seal onto the oil level
indicator tube. 3. Install the oil level indicator tube behind the exhaust manifold. 4. Raise and
suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance) . 5. Install
the oil level indicator tube into the block. The tube must be installed with the collar flush to the
block. 6. Lower the vehicle.

Notice) .
7. Install the oil level indicator tube bolt
Tighten the oil level indicator tube bolt to 25 N.m (18 lb ft).
8. Install the oil level indicator to the tube.

Hummer Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component
Information > Technical Service Bulletins > Engine - Oil Consumption Verification
Engine Oil: Technical Service Bulletins Engine - Oil Consumption Verification
INFORMATION
Subject: Higher Than Expected Oil Consumption at 8600 GVW and Above
Models: 2000-2009 Chevrolet Express, Silverado, Suburban 2002-2009 Chevrolet Avalanche

2003-2009 Chevrolet Kodiak C4500-C5500 Series Models 2000-2009 GMC Savana, Sierra, Yukon
XL 2003-2009 GMC TopKick C4500-C5500 Series Models 2003-2009 HUMMER H2
with Gasoline Engine and Rated at 8600 GVW and above
Supercede:
Information on Engine Oil Consumption Guidelines
of oil is left on the cylinder wall. During the combustion process, part of this oil layer is consumed.
As a result, varying rates of oil consumption are accepted as normal in all engines.
Oil Consumption
Oil usage has a direct relationship with the amount of fuel used. The harder an engine works, the
more fuel and oil it will use. Therefore, oil usage as a factor of fuel usage is a more accurate
indicator of acceptable oil consumption levels than vehicle mileage for vehicles at or above 8600
GVW.
The accepted rate of oil consumption for gasoline engines in vehicles at or above 8600 GVW is
0.946 liter (1 qt) within 379 liters (100 gallons) of fuel used. This rate only applies to vehicles under
warranty, maintained in accordance with the appropriate maintenance schedule, driven at legal
speeds and within design intent of the vehicle.
Many factors can affect an owner's concern with oil consumption. Driving habits and vehicle
Inspect the oil pans, engine covers, and the engine oil cooler for leakage. Inspect for oil leakage
into the engine coolant.
The vehicle must be parked on a level surface to obtain accurate oil level readings. Verify that the
dipstick tube is fully seated in the block. When checking the oil level, make sure the dipstick is
wiped clean before taking an oil level reading and fully depress the dipstick until the shoulder
bottoms out on the dipstick tube. The dipstick should be the proper part number for the
The vehicle should be allowed to sit for at least 15 minutes, after the engine has been shut off,
before taking an oil level reading to assure the oil has had enough time to drain back into the
crankcase. In order to ensure accurate results, the temperature of the oil should be close to the
same temperature as the last time the oil level was checked.
Information > Technical Service Bulletins > Engine - Oil Consumption Verification > Page 2309
High Speed or High RPM Driving
Continuous driving at high speeds/high RPMs may increase oil consumption. Because this may not
always be an everyday occurrence, it is hard to determine exactly how much the oil economy will
be affected.
Towing a trailer or hauling additional weight will increase oil consumption. Large frontal area trailers
will further increase the work required from the engine, especially at highway speeds, and thus
increases the rate of oil consumption.
PTO Operation
Operation of a PTO will increase fuel and oil usage, as the PTO driven accessory uses engine
power to operate.
restrictions or damage to the PCV system can result in increased oil use.
Oil Dilution from Condensation
weather, condensation generated from cold engine operation may not get hot enough to evaporate
out of the oil. When this occurs, the dipstick may indicate that the oil level is over-full. Subsequent
driving on a trip of sufficient length to enable normal engine operating temperature for 30 minutes
or more, in order to vaporize excess moisture, may give the customer the impression of excessive
oil consumption.
Engine Temperature
Engine Wear
oil consumption.
oil economy should not be tested until the vehicle has accumulated at least 8000 km (5000 mi) and
the oil has been changed for the first time. During initial engine break-in periods before the first oil
change, oil consumption may exceed 1.9 liters (2 quarts) or more per 379 liters (100 gallons) of fuel
used.
2. Begin oil consumption test after next regularly scheduled oil and filter change. Oil changes
should not be performed during the test.
Manual).
that most of the oil has had time to drain back into the crankcase.
6. Verify that the oil level is at, but not above, the full mark on the dipstick and that the proper
7. Dealer should record the vehicle mileage, date and engine hours at the start of the test on the
form shown above.
8. Ask the customer to verify and record the date, odometer, oil level, fuel added, and engine
hours, each time the vehicle is fueled, following steps
3-5 and return the vehicle to the dealership if the oil level is found at or below the add mark, 0.946
liter (1 qt) low, if possible. The dealer will add oil to return the oil level to full. If the oil level remains
above the add mark, the customer should continue to operate the vehicle and verify the engine oil
level until either the oil level drops to or below the add mark or at least 4800 km (3000 mi) has
accumulated since the test began before returning to the dealership for a final evaluation.
9. If the final evaluation shows that the engine uses more than 0.946 liter (1 qt) in 379 liters (100
gallons) of fuel used, follow the published symptom diagnostics as described in the appropriate
Service Manual. If the oil consumption test shows that the engine uses less than 0.946 liter (1 qt) in
379 liters (100 gallons) of fuel used, explain to the customer that their engine meets the guidelines
for oil consumption.
Disclaimer
Engine Oil: Technical Service Bulletins Engine - Oil Consumption Guideline Information
INFORMATION
Subject: Information on Engine Oil Consumption Guidelines
Models: 1998-2009 GM Passenger Cars and Gasoline Powered Light Duty Trucks Under 8500 LB
GVW (Including Saturn)
Supercede:
This bulletin is being revised to update model years. Please discard Corporate Bulletin Number
01-06-01-011D (Section 06 - Engine/Propulsion System).
of oil is left on the cylinder wall. During the power stroke, part of this oil layer is consumed in the
combustion process. As a result, varying rates of oil consumption are accepted as normal in all
engines.
Oil Consumption
The accepted rate of oil consumption for engines used in the vehicles referenced is 0.946 liter (1
qt) in 3200 km (2000 mi).
Important:
Certain models have a new GM Extended Warranty. Please refer to the appropriate Owner's
Manual for warranty information.
This rate only applies to personal use vehicles, under warranty, that are driven in a non-aggressive
manner and maintained in accordance with the appropriate maintenance schedule, with less than
58,000 km (36,000 mi), or 80,450 km (50,000 mi) for Cadillac, driven at legal speeds in an
unloaded (for trucks) condition.
Important:
This rate does not apply to vehicles that are driven in an aggressive manner, at high RPM, high
speeds, or in a loaded condition (for trucks). Oil consumption for vehicles driven under these
conditions will be more.
Many factors can affect a customer's concern with oil consumption. Driving habits and vehicle
Inspect the oil pan and engine covers for leakage due to over-tightened, damaged, or out of place
gaskets. Inspect oil lines and fittings for signs of leakage.
Verify that the dipstick tube is fully seated in the block. When checking the oil level, make sure the
dipstick is wiped clean before taking an oil level reading and fully depress the dipstick until the
shoulder bottoms out on the dipstick tube. The dipstick should be the proper part number for the
Notice:
Operating your vehicle with an oil level that is below the minimum level indicated on the engine oil
dipstick can result in severe engine damage. Repairs resulting from operating an engine with
insufficient oil are not covered under the terms of the New Vehicle Warranty.
Important:
Refer to Owner Manual in SI for checking and adding engine oil.
Some engines require more time than others for the oil to drain back into the crankcase. To assure
a sufficient amount of oil has drained back to the crankcase, and an accurate reading can be
obtained, the vehicle should be allowed to sit for at least 15 minutes, after the engine has been
shut off, before taking an oil level reading. In order to ensure accurate results, the temperature of
the oil should be close to the same temperature as the last time the oil level was checked.
Important:
This does not apply to some Corvette ZO6 equipped with the 7.0L LS7 engine (dry sump). Follow
the instructions in the Owner's Manual for checking the oil in this application.
Aggressive Driving, High Speed or High RPM Driving
Aggressive driving and/or continuous driving at high speeds/high RPMs will increase oil
consumption. Because this may not always be an everyday occurrence, it is hard to determine
exactly how much the oil economy will be affected.
A higher rate of oil consumption is normal for vehicles equipped with manual transmissions that are
driven aggressively. By "aggressive," we mean operation at high RPM (3,000 RPM to redline), with
frequent use of engine braking (using the engine to slow the vehicle). Vehicles that are driven
aggressively may consume engine oil at a rate of up to 0.946 L (1 quart) every 805 km (500 mi).
This is normal for a vehicle that is driven aggressively. No repair is necessary. This characteristic
does, however, require the owner to check the engine oil level at sufficiently frequent intervals,
especially when driving aggressively, to assure the oil level remains within the recommended
operating range. As the Owner's Manual recommends, you should check the oil level every time
you get fuel.
Towing a trailer will increase oil consumption and may cause oil consumption to fall below the
normal accepted rate referenced in this bulletin for an unloaded vehicle in a personal use
application. Large frontal area trailers will further increase the work required from the engine,
especially at highway speeds, and thus increases the rate of oil consumption.
restrictions, or damage to the PCV system can result in increased oil use.
Oil Dilution (Fuel and Water)
weather, unburned fuel and condensation generated from cold engine operation may not get hot
enough to evaporate out of the oil. When this occurs, the dipstick may indicate that the oil level is
over-full. Subsequent driving on a trip of sufficient length to enable normal engine operating
temperature for 30 minutes or more, in order to vaporize excess moisture and fuel, may give the
customer the impression of excessive oil consumption.
Engine Temperature
Engine Wear
oil consumption.
oil economy should not be tested until the vehicle has accumulated at least 6400 km (4000 mi). An
exception would be allowed only if an engine is reported to be using more than 0.946 liter (1 qt) in
1600 km (1000 mi).
Manual).
that the oil has had time to drain back into the crankcase.
5. Verify that the oil level is at, but not above, the full mark on the dipstick, and that the proper
6. Record the vehicle mileage, date, and exact oil level on the form shown above.
7. Ask the customer to verify the oil level, each time the vehicle is fueled, following steps 16 and
return the vehicle to the dealership if the oil level is found at or below the add mark, 0.946 liter (1
qt) low. If the oil level remains above the add mark, the customer should continue to operate the
vehicle and verify the engine oil level until 3200 km (2000 mi) has accumulated before returning to
the dealership for a final evaluation.
8. If the final evaluation shows that the engine uses more than 0.946 liter (1 qt) in 3200 km (2000
mi), follow the published symptom diagnostics as described in the appropriate Service Manual. If
the oil consumption test shows that the engine uses less than 0.946 liter (1 qt) in 3200 km (2000
mi), explain to the customer that their engine meets the guidelines for oil consumption.
Disclaimer
Engine Oil: Technical Service Bulletins Engine/Fuel System - Additive Information
INFORMATION
Date: June 17, 2008
Attention:
Supercede:
be cost effective.
Notice:
Warranty.
Notice:
# 88861012).
mile.
Notice:
Important:
Gasoline.
Important:
Notice:
Important:
Warranty.
the best in.
Idling wastes fuel.
Disclaimer
Information > Specifications > Capacity Specifications
Engine Oil: Capacity Specifications
LUBRICATION SYSTEM
Oil Capacity
with Filter .............................................................................................................................................

..................................... 5.68 liters (6.0 quarts)
Oil Capacity
without Filter ........................................................................................................................................

..................................... 5.20 liters (5.5 quarts)
Information > Specifications > Capacity Specifications > Page 2320
Engine Oil: Fluid Type Specifications
ENGINE OIL TYPE ..............................................................................................................................

..................................................................... 5W-30
LOOK FOR TWO THINGS: 1. Your vehicle's engine requires oil meeting GM Standard GM6094M.
2. SAE 5W-30 is best for your vehicle. These numbers on an oil container show its viscosity, or
thickness. Do not use other viscosity oils such as SAE 20W-50. Oils meeting these requirements
should also have the starburst symbol on the container. This symbol indicates that the oil has been
certified by the American Petroleum Institute (API). You should look for this information on the oil
container, and use only those oils that are identified as meeting GM Standard GM6094M and have
the starburst symbol on the front of the oil container.
NOTICE: Use only engine oil identified as meeting GM Standard GM6094M and showing the
American Petroleum Institute Certified For Gasoline Engines starburst symbol. Failure to use the
recommended oil can result in engine damage not covered by your warranty.
GM Goodwrench oil meets all the requirements for your vehicle.
If you are in an area of extreme cold, where the temperature falls below -20°F (-29°C), it is
recommended that you use either an SAE 5W-30 synthetic oil or an SAE 0W-30 oil. Both will
provide easier cold starting and better protection for your engine at extremely low temperatures.
ENGINE OIL ADDITIVES Do not add anything to your oil. The recommended oils with the starburst
symbol that meet GM Standard GM6094M are all you will need for good performance and engine
protection.
Engine Oil: Service and Repair
Removal Procedure
Lifting and Jacking the Vehicle (See: Maintenance) . 4. Place a oil drain pan under the oil pan drain
plug. 5. Remove the oil pan drain plug. 6. Drain the engine oil. 7. Wipe the excess oil from the drain
plug hole and plug.

Approximate Fluid Capacities (See: Maintenance) and Fluid and
Lubricant Recommendations (See: Maintenance) .

Hummer Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine >
Component Information > Service and Repair > Engine Oil Cooler Pipe/Hose Quick Connect Fitting
Oil Cooler: Service and Repair Engine Oil Cooler Pipe/Hose Quick Connect Fitting
Engine Oil Cooler Pipe/Hose Quick Connect Fitting
Removal Procedure
1. Disengage the plastic caps from the quick connect fittings. Pull the caps back along the pipe. 2.
Using a bent-tip screwdriver or equivalent, pull on one of the open ends of the retaining ring in
order to rotate the retaining ring. 3. Rotate the retaining ring around the quick connector until the
retaining ring is out of position and can be completely removed.
Discard the retaining rings.
4. Remove the engine oil cooler line from the quick connector fitting at the radiator.
Pull the lines straight out from the connectors.
5. Clean all of the components in a suitable solvent, and dry them with compressed air. 6. Inspect
the fittings, the connectors, the cooler lines, and the cooler for damage, distortion, or restriction.
Replace parts as necessary.
Important: When performing the following procedure, do not reuse the old retaining rings. Replace
the old retaining rings with new ones.
Do not install the new retaining ring onto the fitting by pushing the retaining ring down over the
fitting.
1. Install a new retaining ring into each quick connector fitting.

Component Information > Service and Repair > Engine Oil Cooler Pipe/Hose Quick Connect Fitting > Page 2327
2. Hook one of the open ends of the retaining ring in one of the slots in the quick connector.
3. Rotate the retaining ring around the connector until the retaining ring is positioned with all 3 ears
through the 3 slots.
4. Ensure the 3 retaining ring ears can be seen from the inside of the connector and the retaining
ring can move freely in the slots.
5. Install the engine oil cooler line into the quick connector fitting until a click is heard or felt.
Pull back on the engine oil cooler lines to ensure a proper connection.
Important: Do not manually depress the retaining clip when installing the plastic cap.
6. Snap the plastic cap onto the quick connect fitting. 7. Ensure that the plastic cap is fully seated
against the fitting.
8. Ensure that no gap is present between the cap and the fitting. 9. Inspect and fill the engine oil to
the proper level.
Oil Cooler: Service and Repair Engine Oil Cooler Hose/Pipe Replacement
Engine Oil Cooler Hose/Pipe Replacement
Removal Procedure
1. Remove the engine oil cooler hoses from the radiator. Refer to Engine Oil Cooler Pipe/Hose
Quick Connect Fitting (See: Engine Oil Cooler
Pipe/Hose Quick Connect Fitting) .
2. Remove the engine oil cooler hoses from the fan shroud. 3. Raise and suitably support the
vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance) . 4. Remove the engine
protection shield bolts. 5. Remove the engine shield.
6. Remove the engine oil cooler hose bracket bolt (1). 7. Remove the engine oil cooler hose
adapter bolts (2). 8. Remove the engine oil cooler hose assembly and gasket.
Discard the gasket.
9. Inspect the fittings, connectors and cooler hoses for damage or distortion.
1. Install the engine oil cooler hose assembly and a new gasket.

Notice) .
2. Install the engine oil cooler hose adapter bolts (2).

3. Install the engine oil cooler hose bracket bolt (1).
4. Install the engine protection shield. 5. Install the engine shield bolts.
6. Install the engine oil cooler hoses to the fan shroud. 7. Install the engine oil cooler hoses to the
radiator. Refer to Engine Oil Cooler Pipe/Hose Quick Connect Fitting (See: Engine Oil Cooler
Pipe/Hose
Quick Connect Fitting) .

Hummer Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine >
Component Information > Technical Service Bulletins > Engine - Noise/Damage After Oil Filter Replacement
Oil Filter: Technical Service Bulletins Engine - Noise/Damage After Oil Filter Replacement
INFORMATION
Date: July 27, 2009
Subject: Information on Internal Engine Noise or Damage After Oil Filter Replacement
Models:
Supercede: This bulletin is being updated to add model years. Please discard Corporate Bulletin
Important Engine damage that is the result of an incorrect or improperly installed engine oil filter is
not a warrantable claim. The best way to avoid oil filter quality concerns is to purchase ACDelco(R)
oil filters directly from GMSPO.
Oil filter misapplication may cause abnormal engine noise or internal damage. Always utilize the
most recent parts information to ensure the correct part number filter is installed when replacing oil
filters. Do not rely on physical dimensions alone. Counterfeit copies of name brand parts have been
discovered in some aftermarket parts systems. Always ensure the parts you install are from a
trusted source. Improper oil filter installation may result in catastrophic engine damage.
Refer to the appropriate Service Information (SI) installation instructions when replacing any oil
filter and pay particular attention to procedures for proper cartridge filter element alignment. If the
diagnostics in SI (Engine Mechanical) lead to the oil filter as the cause of the internal engine noise
or damage, dealers should submit a field product report. Refer to Corporate Bulletin Number
02-00-89-002I (Information for Dealers on How to Submit a Field Product Report).
Disclaimer
Oil Filter: Service and Repair
Removal Procedure
Lifting and Jacking the Vehicle (See: Maintenance) . 4. Place a oil drain pan under the oil pan drain
plug. 5. Remove the oil pan drain plug. 6. Drain the engine oil. 7. Wipe the excess oil from the drain
plug hole and plug.

Approximate Fluid Capacities (See: Maintenance) and Fluid and

Hummer Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter >
Component Information > Service and Repair > Oil Filter Adapter Replacement
Oil Filter Adapter: Service and Repair Oil Filter Adapter Replacement
Oil Filter Adapter Replacement
Removal Procedure
1. Drain the engine oil. 2. Remove the oil filter.
3. Remove the oil filter adapter (1).
1. Install the oil filter adapter (1).
Tighten the oil filter adapter to 55 N.m (40 lb ft).

Component Information > Service and Repair > Oil Filter Adapter Replacement > Page 2341
2. Install the oil filter. 3. Refill the engine oil. Refer to Approximate Fluid Capacities (See:
Maintenance) and/or Fluid and Lubricant Recommendations (See:
Maintenance) .
Oil Filter Adapter: Service and Repair Oil Filter Bypass Valve Replacement
Oil Filter Bypass Valve Replacement
Removal Procedure
1. Drain the engine oil. 2. Remove the oil filter.
3. Remove the oil filter adapter (1). 4. Remove the oil filter bypass valve (2).
1. Install the oil filter bypass valve (2).
2. Install the oil filter adapter (1).
Tighten the oil filter adapter to 55 N.m (40 lb ft).

3. Install the oil filter.
4. Refill the engine oil. Refer to Approximate Fluid Capacities (See: Maintenance) and/or Fluid and
Lubricant Recommendations (See:
Maintenance) .
Hummer Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor >
Component Information > Diagrams > Diagram Information and Instructions

Electrical Symbols
Electrical Symbols
Voltage Indicators
General Icons
Component Information > Diagrams > Diagram Information and Instructions > Page 2348


Harness Components
Component Parts
Switches and Relays

Devices and Sensors


* Antenna location
Circuit Testing
Circuit Testing




Fused Jumper Wires)

Voltage)

Frequency)
Continuity)






Protection - Fuses)


Tools Required
J 25070 Heat Gun
necessary.
Salt Water Spray
condition.
cooling needs.
conditions.
when the DTC set.
Measuring Frequency
Measuring Frequency
measured.
Measuring Voltage
Measuring Voltage
points.
Frontprobe
terminals.
improper diagnosis.
connectors:
Backprobe
Important:

of a test probe.
connector.

lost.
With a DMM
With a Test Lamp
load.
Tools Required

Continuity)


circuit.
Tools Required
following items:

Recorder operation.

component side.






With a DMM
With a Test Lamp
shorted.
measurement.

Tools Required
pair of leads.
being tested.
terminals.
Tools Required
gage size.
Flat Wire Repairs
Flat Wire Repairs
Tools Required
energy circuits.
GMLAN Repairs
the repair.
GMLAN Wire Repair

splice.
(AWG) size.
achieved.
Tools Required
being obstructed.
sensor performance.
Tools Required
damaged wire.
Repair kit).
source.
exhaust pipes.

during the repair.

(AWG) size.
achieved.
achieved.
Tools Required

* A heat torch

SIR/SRS Wire Repair

together.
achieved.

Sleeves) .
Tools Required
2. Cut the wire.

closes.
existing wires.

Tools Required
2. Cut the wire.

achieved.
soldering tool.
new diode.
splice is made.
recommended.
Wiring Repairs
Wiring Repairs
Repairs)

Wiring Repairs)




Wiring Repairs)
AFL/EPC Connectors
AFL/EPC Connectors
Tools Required
Removal Procedure
forward.

dress
cover.

Repair Procedure
connector end view.
Tools Required

position.
Tools Required
Removal Procedure
cover.

Repair Procedure
connector end view.

Tools Required
body and pry up.
position.
used.

Tools Required
position.

Connector Repairs
Connector Repairs



Connectors (ECM))




Connector Anatomy
* Bosch
* Delphi
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
above it.
connection.
Tools Required
Removal Procedure

past the locks.
damaging it.
the tool may break.
used.
Repair Procedure
time.
Micro 64 terminals.
added wire.
from the wire.
visible.
Tools Required


remove the cover.
used.
added wire.

Tools Required
Terminal Removal
be replaced.
connector body.
Terminal Repair

Tools Required
Terminal Removal
Terminal Repair
Repairs) .
Tools Required
Tools Required
Removal Procedure
body.
cover off.
damaging it.
the connector.
used.
Repair Procedure
connector end view.
FCI Connectors
FCI Connectors
Tools Required
Removal Procedure
dress
cover.
Repair Procedure
connector end view.
JST Connectors
JST Connectors
Tools Required

Removal Procedure
connector body.
connector body.
used.
Repair Procedure
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required

Removal Procedure

Repair Procedure
connector end view.
Molex Connectors
Molex Connectors
Tools Required
forward.

Kit.
terminal.
Tools Required
Sumitomo Connectors
Sumitomo Connectors
Tools Required

* Terminal (1)
* Entry Canal (2)
connector.
terminal retainer.
Kit.
terminal.
Tools Required
Removal Procedure
component.

Tools Required
Removal Procedure

housing.
Repair Procedure
connector end view.

Tools Required

panel slides over.
Tools Required
assurance (CPA).
terminal.
Tools Required
Removal Procedure
damaging it.
Repair Procedure
connector end view.
Tools Required

Tools Required
Removal Procedure


Repair Procedure
connector end view.

Arrows and Symbols
Arrows and Symbols
Arrows and Symbols


Component Information > Diagrams > Page 2460
Removal Procedure
1. Drain the engine oil. Refer to Engine Oil and Oil Filter Replacement (See: Engine Oil/Service
and Repair) . 2. Disconnect the oil level sensor electrical connector (6).

Notice) .

Oil Filter Replacement (See: Engine Oil/Service and Repair) .
Hummer Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component
Oil Pan: Specifications
OIL PAN TORQUE
Oil Pan And Oil Pan-To-Oil Pan Front Cover Bolts

............................................................................................................................... 25 N.m (18 lb ft)
Oil Pan-To-Rear Cover Bolts ...............................................................................................................
................................................ 12 N.m (106 lb in)
Oil Pan: Service and Repair
Oil Pan Replacement
Removal Procedure
1. Remove the front differential. Refer to Differential Carrier Assembly Replacement (See:
Transmission and Drivetrain/Differential
Assembly/Differential Carrier/Service and Repair) .
3. Remove the crossbar bolts. 4. Remove the crossbar.
5. Remove the transmission cover bolt and cover. 6. Drain the engine oil and remove the engine oil
filter. 7. Re-install the drain plug and oil filter until snug.
8. Remove the transmission bolt and stud on the right side.

9. Remove the bottom bolt on the left side.
10. Disconnect the oil level sensor electrical connector (6).
11. Remove the battery cable channel bolt. 12. Slide the channel pin out of the oil pan tab.
13. Remove the following from the positive battery cable clip:
* Engine wiring harness clip
* Positive battery cable clip

14. Remove the engine oil cooler lines from the positive battery cable clip. 15. Remove the positive
battery cable clip bolt and clip.
16. Remove the oil pan bolts. 17. Remove the oil pan.
Important: DO NOT allow foreign material to enter the oil passages of the oil pan, cap or cover the
openings as required.
18. Drill (3) out the oil pan gasket retaining rivets (2), if required. 19. Remove the gasket (1) from
the pan. 20. Discard the gasket and rivets. 21. Clean and inspect the engine oil pan. Refer to Oil
Pan Cleaning and Inspection (See: Service and Repair/Overhaul/Component Service and
Inspection/Oil Pan Cleaning and Inspection) .
Important:
The alignment of the structural oil pan is critical. The rear bolt hole locations of the oil pan provide
mounting points for the transmission bellhousing. To ensure the rigidity of the powertrain and
correct transmission alignment, it is important that the rear of the block and the rear of the oil pan
must NEVER protrude beyond the engine block and transmission bellhousing plane.
* Do not reuse the oil pan gasket.
* It is not necessary to rivet the NEW gasket to the oil pan.

1. Apply a 5 mm (0.20 in) bead of sealant 20 mm (0.80 in) long to the engine block. Refer to
Sealers, Adhesives, and Lubricants (See:
Specifications/Sealers, Adhesives, and Lubricants) for the correct part number. Apply the sealant
directly onto the tabs of the front cover gasket that protrudes into the oil pan surface.
2. Apply a 5 mm (0.20 in) bead of sealant 20 mm (0.8 in) long to the engine block. Refer to Sealers,
Adhesives, and Lubricants (See:
Specifications/Sealers, Adhesives, and Lubricants) for the correct part number. Apply the sealant
directly onto the tabs of the rear cover gasket that protrudes into the oil pan surface.
Important: Be sure to align the oil gallery passages in the oil pan and engine block properly with the
oil pan gasket.
3. Pre-assemble the oil pan gasket to the pan.
* Install the gasket onto the pan.
* Install the oil pan bolts to the pan and through the gasket.
4. Install the oil pan, gasket and bolts to the engine block. 5. Tighten the oil pan bolts until snug. Do
not overtighten.
6. Install the transmission bolt and stud on the right side until snug.

Notice) .
7. Install the bottom bolt on the left side until snug.
1. Tighten the oil pan and oil pan-to-oil pan front cover bolts to 25 N.m (18 lb ft). 2. Tighten the oil
pan-to-rear cover bolts to 12 N.m (106 lb in). 3. Tighten the bellhousing, converter cover, and
transmission bolts/stud to 50 N.m (37 lb ft).
8. Install the positive battery cable clip and bolt to the oil pan.
Tighten the positive battery cable clip bolt to 9 N.m (80 lb in).
9. Install the engine oil cooler lines to the positive battery cable clip.
10. Install the following to the positive battery cable clip:
* Engine wiring harness clip
* Positive battery cable clip
11. Slide the channel pin in to the oil pan tab. 12. Install the battery cable channel bolt.
Tighten the battery cable channel bolt to 12 N.m (106 lb in).
13. Connect the oil level sensor electrical connector (6).
14. Install the transmission cover and bolt.

Tighten the transmission cover bolt to 12 N.m (106 lb in).
15. Install the crossbar. 16. Install the crossbar bolts.
Tighten the crossbar bolts to 100 N.m (74 lb ft).
17. Install the starter motor. Refer to Starter Motor Replacement (See: Starting and
Charging/Starting System/Starter Motor/Service and Repair) . 18. Install the front differential. Refer
to Differential Carrier Assembly Replacement (See: Transmission and Drivetrain/Differential
Assembly/Differential Carrier/Service and Repair) .
19. Install new engine oil and a new oil filter. Refer to Engine Oil and Oil Filter Replacement (See:
Engine Oil/Service and Repair) .
Hummer Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor >


Special Tools
Removal Procedure
Replacement (6.0L (LQ4)) (See: Intake
Manifold/Service and Repair/Upper Intake Manifold Sight Shield Replacement) .
Lubricants (See: Specifications/Sealers, Adhesives, and

Notice) .
shield. Refer to Upper Intake Manifold Sight Shield Replacement (6.0L (LQ4)) (See: Intake
Manifold/Service
and Repair/Upper Intake Manifold Sight Shield Replacement) .

Hummer Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine
Oil Pressure > Component Information > Specifications
Engine Oil Pressure: Specifications
LUBRICATION SYSTEM
Oil Pressure - Minimum - Hot
at 1,000 engine RPM ...........................................................................................................................

................................................ 41 kPa (6 psig) at 2,000 engine RPM .................................................
...................................................................................................................... 124 kPa (18 psig) at
4,000 engine RPM ...............................................................................................................................
........................................ 165 kPa (24 psig)
Oil Pressure > Component Information > Specifications > Page 2482
Engine Oil Pressure: Testing and Inspection
Oil Pressure Diagnosis and Testing
Tools Required
* EN-47971 Oil Pressure Gage Adapter
* J 21867 Pressure Gage
1. With the vehicle on a level surface, run the vehicle for a few minutes. Allow adequate drain down
time, 2-3 minutes, and measure the oil level. 2. If required, add the recommended grade engine oil
and fill the crankcase until the oil level measures full on the oil level indicator. 3. Run the engine
briefly, 10-15 seconds, and verify low or no oil pressure on the vehicle gage or light. 4. Listen for a
noisy valve train or a knocking noise. 5. Inspect for the following conditions:
* Oil diluted by water or glycol antifreeze Refer to Coolant in Engine Oil (See: Testing and
Inspection/Symptom Related Diagnostic Procedures/Coolant in Engine Oil) .
* Foamy oil, which may be caused by a cut or damaged oil pump screen O-ring seal
6. Remove the oil filter and install the EN-47971 (1). 7. Install the J 21867 (2), or equivalent to the
EN-47971 (1). 8. Run the engine and measure the engine oil pressure. 9. Compare the readings to
Engine Mechanical Specifications (See: Specifications/Engine Mechanical Specifications) .
10. If the engine oil pressure is below specifications, inspect the engine for 1 or more of the
* Oil pump worn or dirty Refer to Oil Pump Cleaning and Inspection (See: Service and
Repair/Overhaul/Component Service and Inspection/Oil Pump Cleaning and Inspection) .
* Oil pump-to-engine block bolts loose Refer to Oil Pump, Screen and Crankshaft Oil Deflector
Installation (See: Service and Repair/Overhaul/Assembly/Oil Pump, Screen and Crankshaft Oil
Deflector Installation) .
* Oil pump screen loose, plugged, or damaged
* Oil pump screen O-ring seal missing or damaged
* Malfunctioning oil pump pressure relief valve
* Excessive bearing clearance
* Cracked, porous, or restricted oil galleries
* Oil gallery plugs missing or incorrectly installed Refer to Engine Block Plug Installation (See:
Service and Repair/Overhaul/Assembly/Engine Block Plug Installation) .
* Improper operation of the active fuel management oil pressure relief valve Refer to Cylinder
Deactivation (Active Fuel Management) Oil Pressure Relief Valve Diagnosis and Testing (See:
Testing and Inspection/Component Tests and General Diagnostics/Cylinder Deactivation (Active
Fuel Management) Oil Pressure Relief Valve Diagnosis
Oil Pressure > Component Information > Specifications > Page 2483
and Testing) .
Hummer Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information >
Technical Service Bulletins > Engine - Intake Manifold Inspection/Replacement
Intake Manifold: Technical Service Bulletins Engine - Intake Manifold Inspection/Replacement
INFORMATION
Subject: Intake Manifold Inspection/Replacement After Severe Internal Engine Damage
Models:
Supercede: This bulletin is being revised to include additional model years. Please discard
Corporate Bulletin Number 00-06-01-026B (Section 06 - Engine).
When replacing an engine due to internal damage, extreme care should be taken when transferring
the intake manifold to the new Goodwrench service engine long block. Internal damage may result
in the potential discharge of internal engine component debris in the intake manifold via broken
pistons and/or bent, broken, or missing intake valves. After removing the intake manifold from the
engine, the technician should carefully inspect all of the cylinder head intake ports to see if the
valve heads are still present and not bent. Usually when the valve heads are missing or sufficiently
bent, internal engine component debris will be present to varying degrees in the intake port of the
cylinder head. If this debris is present in any of the cylinder head intake ports, the intake manifold
should be replaced. This replacement is required due to the complex inlet runner and plenum
configuration of most of the intake manifolds, making thorough and complete component cleaning
difficult and nearly impossible to verify complete removal of debris. Re-installation of an intake
manifold removed from an engine with deposits of internal engine component debris may result in
the ingestion of any remaining debris into the new Goodwrench service engine. This may cause
damage or potential failure of the new service engine.
Disclaimer
Technical Service Bulletins > Page 2488
Intake Manifold: Specifications
INTAKE MANIFOLD
Tighten The Intake Manifold Bolts In Sequence
1. First Pass .........................................................................................................................................

............................................. 5 N.m (44 lb in) 2. Final Pass ................................................................
.................................................................................................................... 10 N.m (89 lb in)
THROTTLE BODY
Throttle Body Bolts ..............................................................................................................................

.................................................. 10 N.m (89 lb in) Throttle Body Nuts ................................................
................................................................................................................................. 10 N.m (89 lb in)
Throttle Body Studs .............................................................................................................................
..................................................... 6 N.m (53 lb in)
Service and Repair > Intake Manifold Replacement
Intake Manifold: Service and Repair Intake Manifold Replacement
Intake Manifold Replacement
Removal Procedure
Important: The intake manifold, throttle body, fuel rail, and injectors may be removed as an
assembly. If not servicing the individual components, remove the manifold as a complete
assembly.
1. Remove the throttle body. Refer to Throttle Body Assembly Replacement (See: Powertrain
Management/Fuel Delivery and Air Induction/Throttle
Body/Service and Repair/Removal and Replacement) .
2. Remove the fuel injectors. Refer to Fuel Injector Replacement (See: Powertrain
Management/Fuel Delivery and Air Induction/Fuel
Injector/Service and Repair/Removal and Replacement) .
3. Disconnect the following electrical connectors:
* Manifold absolute pressure (MAP) sensor (1)
* Knock sensor (2)
4. Remove the knock sensor harness electrical connector from the intake manifold. 5. Set the
electrical harness aside.

Service and Repair > Intake Manifold Replacement > Page 2491
7. Remove the evaporative emission (EVAP) purge solenoid vent tube by performing the following:
1. Remove the EVAP tube end (2) from the solenoid (1). 2. Squeeze the EVAP pipe quick connect
fitting (3) retainer together. 3. Remove the EVAP tube end (3) from the vapor pipe.
8. Remove the EVAP purge solenoid bolt (2), solenoid (3), and isolator (1) from the intake manifold.
9. Remove the intake manifold bolts.
10. Remove the intake manifold.

11. Remove the intake manifold gaskets (1) from the intake manifold. 12. Discard the old intake
manifold gaskets. 13. Clean and inspect the intake manifold. Refer to Intake Manifold Cleaning and
Inspection (See: Service and Repair/Overhaul/Component Service
and Inspection/Intake Manifold Cleaning and Inspection) .
1. Install new intake manifold gaskets (1) to the intake manifold.
2. Install the intake manifold. 3. Apply a 5 mm (0.20 in) band of threadlock to the threads of the
intake manifold bolts. Refer to Sealers, Adhesives, and Lubricants (See:
Specifications/Sealers, Adhesives, and Lubricants) for the correct part number.

Notice) .
4. Install the intake manifold bolts.
1. Tighten the intake manifold bolts a first pass in sequence to 5 N.m (44 lb in). 2. Tighten the
intake manifold bolts a final pass in sequence to 10 N.m (89 lb in).
5. Install the EVAP purge solenoid vent tube to the solenoid (1) and vapor pipe.
Important: Lightly coat the MAP sensor seal with clean engine oil before installing.
6. Install the MAP sensor (1) to the intake manifold. 7. Route the electrical harness into position
over the engine.
8. Connect the knock sensor harness electrical connector to the intake manifold. 9. Connect the
following electrical connectors.
* MAP sensor (1)
* Knock sensor (2)
10. Install the fuel injectors. Refer to Fuel Injector Replacement (See: Powertrain
Management/Fuel Delivery and Air Induction/Fuel Injector/Service
11. Install the throttle body. Refer to Throttle Body Assembly Replacement (See: Powertrain
Management/Fuel Delivery and Air Induction/Throttle
Body/Service and Repair/Removal and Replacement) .

Intake Manifold: Service and Repair Upper Intake Manifold Sight Shield Replacement
Upper Intake Manifold Sight Shield Replacement (LQ4 - Gas, 8 CYL. 6.0L, MFI, Iron)
Removal Procedure
1. Loosen the intake manifold sight shield bolt. 2. Remove the sight shield from the sight shield
retainer. 3. Remove the sight shield retainer bolts and the retainer, if required.

Notice) .
1. Install the sight shield retainer and the bolts, if required.
Tighten the retainer bolts to 5 N.m (44 lb in).
Notice: Use care when installing the engine sight shield to avoid contacting the manifold absolute
pressure (MAP) sensor wire harness connector. Loss of engine performance or engine damage
may result.
2. Install the intake manifold sight shield to the retainer.

Intake Manifold: Service and Repair Engine Block Valley Cover Replacement
Engine Block Valley Cover Replacement
Removal Procedure
1. Remove the intake manifold. Refer to Intake Manifold Replacement (See: Intake Manifold
Replacement) . 2. Gently pry up the rubber covers. 3. Disconnect the knock sensor electrical
connectors.
4. Remove the knock sensors.
5. Remove the engine valley cover bolts. 6. Remove the engine valley cover and gasket. 7. Discard
the old gasket.
8. Remove the knock sensor oil seals (1) from the cover (2). 9. Clean and inspect the engine valley
cover. Refer to Engine Block Valley Cover Cleaning and Inspection (See: Service and
Repair/Overhaul/Component Service and Inspection/Engine Block Valley Cover Cleaning and

Inspection) .
Important: All gasket surfaces should be free of oil or other foreign material during assembly.
1. Lubricate the NEW knock sensor seals (1) with clean engine oil. 2. Install the knock sensor oil
seals (1) into the engine valley cover (2).
3. Install the engine valley cover and a NEW gasket onto the engine block.

Notice) .
4. Install the engine valley cover bolts.

5. Install the knock sensors.
Tighten the sensors to 20 N.m (15 lb ft).
6. Connect the knock sensor electrical connectors. 7. Push down on the rubber covers. 8. Install
the intake manifold. Refer to Intake Manifold Replacement (See: Intake Manifold Replacement) .
Hummer Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main
Bearing Seal > Component Information > Service and Repair
Crankshaft Main Bearing Seal: Service and Repair
Crankshaft Rear Oil Seal Replacement
Special Tools
J 41479 Crankshaft Rear Oil Seal Installer
Removal Procedure
1. Remove the engine flywheel. Refer to Automatic Transmission Flex Plate Replacement (See:
Repair) .
2. Remove the crankshaft rear oil seal (1) from the rear cover.
Important:
* The flywheel spacer (if applicable) must be removed prior to oil seal installation.
* Do not lubricate the oil seal inside diameter (ID) or the crankshaft surface.
* Do not reuse the crankshaft rear oil seal.
1. Lubricate the outside diameter (OD) of the oil seal (1) with clean engine oil.
DO NOT allow oil or other lubricants to contact the seal surface.
2. Lubricate the rear cover oil seal bore with clean engine oil.
DO NOT allow oil or other lubricants to contact the crankshaft surface.

Hummer Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main
Bearing Seal > Component Information > Service and Repair > Page 2503
3. Install the J 41479 tapered cone (2) and bolts onto the rear of the crankshaft. 4. Tighten the bolts
until snug. Do not overtighten. 5. Install the rear oil seal onto the tapered cone (2) and push the
seal to the rear cover bore. 6. Thread the J 41479 threaded rod into the tapered cone until the tool
(1) contacts the oil seal. 7. Align the oil seal into the tool (1). 8. Rotate the handle of the tool (1)
clockwise until the seal enters the rear cover and bottoms into the cover bore. 9. Remove the J
41479 .
10. Install the engine flywheel. Refer to Automatic Transmission Flex Plate Replacement (See:
Repair) .
Hummer Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft
Seal > Component Information > Service and Repair
Front Crankshaft Seal: Service and Repair
Crankshaft Front Oil Seal Replacement
Special Tools
J 41478 Crankshaft Front Oil Seal Installer
Removal Procedure
1. Remove the crankshaft balancer. Refer to Crankshaft Balancer Replacement (See: Cylinder
Block Assembly/Harmonic Balancer - Crankshaft
Pulley/Service and Repair) .
2. Remove the crankshaft oil seal (1) from the front cover.
Important:
* Do not lubricate the oil seal sealing surface.
* Do not reuse the crankshaft oil seal.
1. Lubricate the outer edge of the oil seal (1) with clean engine oil. 2. Lubricate the front cover oil
seal bore with clean engine oil.
3. Install the crankshaft front oil seal onto the J 41478 guide. 4. Install the J 41478 threaded rod
(with nut, washer, guide, and oil seal) into the end of the crankshaft.
Hummer Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft
Seal > Component Information > Service and Repair > Page 2507
5. Use the J 41478 in order to install the oil seal into the cover bore.
1. Use a wrench and hold the hex on the installer bolt. 2. Use a second wrench and rotate the
installer nut clockwise until the seal bottoms in the cover bore. 3. Remove the J 41478 . 4. Inspect
the oil seal for proper installation.
The oil seal should be installed evenly and completely into the front cover bore.
6. Install the crankshaft balancer. Refer to Crankshaft Balancer Replacement (See: Cylinder Block
Assembly/Harmonic Balancer - Crankshaft

Hummer Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal >
Valve Guide Seal: Service and Repair
Valve Stem Oil Seal and Valve Spring Replacement
Special Tools
* J 22794 Spark Plug Port Adapter
* J 38606 Valve Spring Compressor
Removal Procedure
1. Remove the valve rocker arm. Refer to Valve Rocker Arm and Push Rod Replacement (See:
Camshaft, Lifters and Push Rods/Rocker Arm
Assembly/Service and Repair) .
2. Disconnect the spark plug wire at the spark plug.
* Twist each plug wire boot 1/2 turn.
* Pull only on the boot in order to remove the wire from the spark plug.
Important: Remove the spark plugs from the cylinder head with the engine at room temperature.
3. Loosen the spark plug 1 or 2 turns. 4. Brush or air blast away any dirt or debris from around the
spark plug. 5. Remove the spark plug.
6. Install J 22794 into the spark plug hole. 7. Attach an air hose to J 22794 . 8. Apply compressed
air to J 22794 in order to hold the valves in place.
9. Use J 38606 in order to compress the valve spring.

10. Remove the valve stem keys (225). 11. Carefully release the valve spring tension. 12. Remove
the J 38606 . 13. Remove the valve spring cap (224). 14. Remove the valve spring (223). 15.
Remove the valve stem oil seal and shim (222) assembly.
1. Clean the cylinder head valve spring seat and/or shim area. 2. Lubricate the valve guide and
valve stem oil seal with clean engine oil. 3. Install the valve stem oil seal and shim (222) assembly.
4. Install the valve spring (223). 5. Install the valve spring cap (224).
6. Compress the valve spring using the J 38606 . 7. Install the valve stem keys (225).
* Use grease in order to hold the valve keys in place.
* Make sure the keys seat properly in the groove of the valve stem.
* Carefully release the valve spring pressure, making sure the valve keys stay in place.
* Remove the J 38606 .
* Tap the end of the valve stem with a plastic faced hammer to seat the keys, if necessary.
8. Remove J 22794 from the spark plug port.

Notice) .
9. Hand start the spark plug.
Tighten the spark plug to 15 N.m (11 lb ft).
10. Install the spark plug wires at the ignition coil. 11. Install the spark plug wire to the spark plug.
12. Inspect the wires for proper installation:
* Push sideways on each boot in order to check for proper installation.
13. Install the valve rocker arm. Refer to Valve Rocker Arm and Push Rod Replacement (See:
Camshaft, Lifters and Push Rods/Rocker Arm
Assembly/Service and Repair) .

Hummer Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor
> Component Information > Diagrams > Diagram Information and Instructions

Electrical Symbols
Electrical Symbols
Voltage Indicators
General Icons
> Component Information > Diagrams > Diagram Information and Instructions > Page 2520


Harness Components
Component Parts
Switches and Relays

Devices and Sensors


* Antenna location
Circuit Testing
Circuit Testing




Fused Jumper Wires)

Voltage)

Frequency)
Continuity)






Protection - Fuses)


Tools Required
J 25070 Heat Gun
necessary.
Salt Water Spray
condition.
cooling needs.
conditions.
when the DTC set.
Measuring Frequency
Measuring Frequency
measured.
Measuring Voltage
Measuring Voltage
points.
Frontprobe
terminals.
improper diagnosis.
connectors:
Backprobe
Important:

of a test probe.
connector.

lost.
With a DMM
With a Test Lamp
load.
Tools Required

Continuity)


circuit.
Tools Required
following items:

Recorder operation.

component side.






With a DMM
With a Test Lamp
shorted.
measurement.

Tools Required
pair of leads.
being tested.
terminals.
Tools Required
gage size.
Flat Wire Repairs
Flat Wire Repairs
Tools Required
energy circuits.
GMLAN Repairs
the repair.
GMLAN Wire Repair

splice.
(AWG) size.
achieved.
Tools Required
being obstructed.
sensor performance.
Tools Required
damaged wire.
Repair kit).
source.
exhaust pipes.

during the repair.

(AWG) size.
achieved.
achieved.
Tools Required

* A heat torch

SIR/SRS Wire Repair

together.
achieved.

Sleeves) .
Tools Required
2. Cut the wire.

closes.
existing wires.

Tools Required
2. Cut the wire.

achieved.
soldering tool.
new diode.
splice is made.
recommended.
Wiring Repairs
Wiring Repairs
Repairs)

Wiring Repairs)




Wiring Repairs)
AFL/EPC Connectors
AFL/EPC Connectors
Tools Required
Removal Procedure
forward.

dress
cover.

Repair Procedure
connector end view.
Tools Required

position.
Tools Required
Removal Procedure
cover.

Repair Procedure
connector end view.

Tools Required
body and pry up.
position.
used.

Tools Required
position.

Connector Repairs
Connector Repairs



Connectors (ECM))




Connector Anatomy
* Bosch
* Delphi
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
above it.
connection.
Tools Required
Removal Procedure

past the locks.
damaging it.
the tool may break.
used.
Repair Procedure
time.
Micro 64 terminals.
added wire.
from the wire.
visible.
Tools Required


remove the cover.
used.
added wire.

Tools Required
Terminal Removal
be replaced.
connector body.
Terminal Repair

Tools Required
Terminal Removal
Terminal Repair
Repairs) .
Tools Required
Tools Required
Removal Procedure
body.
cover off.
damaging it.
the connector.
used.
Repair Procedure
connector end view.
FCI Connectors
FCI Connectors
Tools Required
Removal Procedure
dress
cover.
Repair Procedure
connector end view.
JST Connectors
JST Connectors
Tools Required

Removal Procedure
connector body.
connector body.
used.
Repair Procedure
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required

Removal Procedure

Repair Procedure
connector end view.
Molex Connectors
Molex Connectors
Tools Required
forward.

Kit.
terminal.
Tools Required
Sumitomo Connectors
Sumitomo Connectors
Tools Required

* Terminal (1)
* Entry Canal (2)
connector.
terminal retainer.
Kit.
terminal.
Tools Required
Removal Procedure
component.

Tools Required
Removal Procedure

housing.
Repair Procedure
connector end view.

Tools Required

panel slides over.
Tools Required
assurance (CPA).
terminal.
Tools Required
Removal Procedure
damaging it.
Repair Procedure
connector end view.
Tools Required

Tools Required
Removal Procedure


Repair Procedure
connector end view.

Arrows and Symbols
Arrows and Symbols
Arrows and Symbols


> Component Information > Diagrams > Page 2632
Removal Procedure
1. Drain the engine oil. Refer to Engine Oil and Oil Filter Replacement (See: Engine
Lubrication/Engine Oil/Service and Repair) . 2. Disconnect the oil level sensor electrical connector
(6).

Notice) .

> Component Information > Diagrams > Page 2633
Oil Filter Replacement (See: Engine Lubrication/Engine Oil/Service and Repair) .
Hummer Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure


Special Tools
Removal Procedure
Replacement (6.0L (LQ4)) (See: Intake
Manifold/Service and Repair/Upper Intake Manifold Sight Shield Replacement) .
Lubricants (See: Specifications/Sealers, Adhesives, and

Notice) .
shield. Refer to Upper Intake Manifold Sight Shield Replacement (6.0L (LQ4)) (See: Intake
Manifold/Service
and Repair/Upper Intake Manifold Sight Shield Replacement) .

Hummer Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket >
Camshaft Gear/Sprocket: Specifications
CAMSHAFT SPROCKET BOLT
Tighten The Camshaft Sprocket Bolt

...................................................................................................................................................... 35
N.m (26 lb ft)
Hummer Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Crankshaft Gear/Sprocket >
Crankshaft Gear/Sprocket: Specifications

................................................................................................................................................ 330
N.m (240 lb ft)
Hummer Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component
Timing Chain: Service and Repair
Timing Chain and Sprocket Replacement
Special Tools
* J 8433 Two Jaw Puller
* J 41816-2 Crankshaft End Protector
* J 41558 Crankshaft Sprocket Remover
* J 41665 Crankshaft Balancer and Sprocket Installer
Removal Procedure
1. Remove the oil pump. Refer to Oil Pump, Screen, and Crankshaft Oil Deflector Replacement
(See: Engine Lubrication/Oil Pump/Service and
Repair) .
2. Rotate the crankshaft until the timing marks on the crankshaft and the camshaft sprockets are
aligned.
Notice: Do not turn the crankshaft assembly after the timing chain has been removed in order to
prevent damage to the piston assemblies or the valves.
3. Remove the camshaft sprocket bolts. 4. Remove the camshaft sprocket and timing chain.
5. Use the J 8433 , the J 41816-2 and the J 41558 in order to remove the crankshaft sprocket.
6. Remove the crankshaft sprocket.

Information > Service and Repair > Page 2650
7. Remove the crankshaft sprocket key, if required. 8. Clean and inspect the timing chain and
sprockets. Refer to Camshaft Position Actuator Cleaning and Inspection (See: Service and
Repair/Overhaul/Component Service and Inspection/Camshaft Position Actuator Cleaning and

Inspection) .
1. Install the key into the crankshaft keyway, if previously removed.
2. Tap the key (1) into the keyway until both ends of the key bottom onto the crankshaft.
3. Install the crankshaft sprocket onto the front of the crankshaft. Align the crankshaft key with the
crankshaft sprocket keyway.
4. Use the J 41665 in order to install the crankshaft sprocket.
Install the sprocket onto the crankshaft until fully seated against the crankshaft flange.
5. Rotate the crankshaft sprocket until the alignment mark is in the 12 o'clock position.
Important: *
Properly locate the camshaft sprocket locating pin with the camshaft sprocket alignment hole.
* The sprocket teeth and timing chain must mesh.
* The camshaft and the crankshaft sprocket alignment marks MUST be aligned properly.
Locate the camshaft sprocket alignment mark in the 6 o'clock position.
6. Install the camshaft sprocket and timing chain.
7. If necessary, rotate the camshaft or crankshaft sprockets in order to align the timing marks.

Notice) .
8. Install the camshaft sprocket bolts.
Tighten the camshaft sprocket bolts to 35 N.m (26 lb ft).
9. Install the oil pump. Refer to Oil Pump, Screen, and Crankshaft Oil Deflector Replacement (See:
Engine Lubrication/Oil Pump/Service and
Repair) .
Hummer Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Component
Alignment Marks > Component Information > Locations
Timing Component Alignment Marks: Locations

Hummer Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component
Timing Cover: Specifications
TIMING COVER TORQUE
Oil Pan To Front Cover Bolts ...............................................................................................................

.................................................. 25 N.m (18 lb ft) Engine Front Cover Bolts .......................................
................................................................................................................................. 25 N.m (18 lb ft)
Timing Cover: Service and Repair
Engine Front Cover Replacement
Special Tools
J 41476 Front and Rear Cover Alignment (at crankshaft seal area)
Removal Procedure
1. Remove the water pump. Refer to Water Pump Replacement (See: Water Pump/Service and
Repair) . 2. Remove the crankshaft balancer. Refer to Crankshaft Balancer Replacement (See:
Cylinder Block Assembly/Harmonic Balancer - Crankshaft
3. Remove the oil pan-to-front cover bolts.
4. Remove the front cover bolts. 5. Remove the front cover and gasket. 6. Discard the front cover
gasket. 7. Clean and inspect the engine front cover. Refer to Engine Front Cover Cleaning and
Inspection (See: Service and Repair/Overhaul/Component
Service and Inspection/Engine Front Cover Cleaning and Inspection) .
Important:
* Do not reuse the crankshaft oil seal or front cover gasket.
* Do not apply any type of sealant to the front cover gasket, unless specified.
* The special tool in this procedure is used to properly center the front crankshaft front oil seal.
- All gasket surfaces should be free of oil or other foreign material during assembly.
- The crankshaft front oil seal MUST be centered in relation to the crankshaft.
- An improperly aligned front cover may cause premature front oil seal wear and/or engine oil leaks.
1. Apply a 5 mm (0.20 in) bead of sealant 20 mm (0.80 in) long to the oil pan to engine block
junction. Refer to Sealers, Adhesives, and Lubricants (
See: Specifications/Sealers, Adhesives, and Lubricants) for the correct part number.
2. Install the front cover gasket and cover. 3. Install the front cover bolts until snug. Do not
overtighten.
4. Install the oil pan-to-front cover bolts until snug. Do not over tighten.
5. Install J 41476 to the front cover. 6. Align the tapered legs of the J 41476 with the machined
alignment surfaces on the front cover.

Notice) .
7. Install the crankshaft balancer bolt until snug. Do not overtighten.
1. Tighten the oil pan to front cover bolts to 25 N.m (18 lb ft). 2. Tighten the engine front cover bolts
to 25 N.m (18 lb ft).
8. Remove the J 41476 . 9. Install a NEW crankshaft front oil seal. Refer to Crankshaft Front Oil
Seal Replacement (See: Seals and Gaskets/Front Crankshaft Seal/Service
and Repair) .
10. Install the water pump. Refer to Water Pump Replacement (See: Water Pump/Service and
Repair) .
Hummer Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel
Pressure > System Information > Specifications

............................................................................................................................................. 345-414
kPa (50-60 psi)
Pressure > System Information > Service Precautions > Technician Safety Information
Pressure > System Information > Service Precautions > Technician Safety Information > Page 2666
Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal
Tools Required

directions.
Removal Procedure
Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 2669

procedure.
Fuel System Description (See: Powertrain Management/Computers and Control

Systems/Description and Operation/Fuel System Description) Electrical Information Reference
* Circuit Testing (See: Engine Lubrication/Oil Level Sensor/Diagrams/Diagnostic Aids/General

Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing)
* Connector Repairs (See: Engine Lubrication/Oil Level Sensor/Diagrams/Diagnostic Aids/General

Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs)
* Testing for Intermittent Conditions and Poor Connections (See: Engine Lubrication/Oil Level
Sensor/Diagrams/Diagnostic Aids/General Electrical Diagnostic Procedures/Circuit Testing/Testing
For Intermittent and Poor Connections)
* Wiring Repairs (See: Engine Lubrication/Oil Level Sensor/Diagrams/Diagnostic Aids/General

Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs)
Scan Tool Reference

Important:
Instructions.
Important: *
pump module.
5. If the fuel system tests normal, refer to Symptoms - Engine Controls (See: Powertrain
Management/Computers and Control Systems/Testing and
Inspection/Symptom Related Diagnostic Procedures/Symptoms - Engine Controls) .
Repair Instructions
* Fuel Hose/Pipes Assembly Replacement (See: Powertrain Management/Fuel Delivery and Air
Induction/Fuel Supply Line/Service and Repair/Fuel Hose/Pipes Assembly Replacement)
* Fuel Injector Replacement (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel
Injector/Service and Repair/Removal and Replacement)
* Fuel Sender Assembly Replacement (See: Instrument Panel, Gauges and Warning
Indicators/Fuel Gauge Sender/Service and Repair)
Hummer Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle
Speed > System Information > Specifications

Hummer Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air
Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair
Removal Procedure
outlet duct.
Hummer Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air
Cleaner Housing > Air Filter Element > Component Information > Service and Repair
Removal Procedure
Filter > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Relief (With CH 48027)
Special Tools


Filter > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Relief (With CH 48027) > Page
2688
2689
the fuel fill cap.
2690
Tools Required

directions.
Removal Procedure
2691

Hummer Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Firing
Order > Component Information > Specifications

Hummer Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks >
Ignition Cable > Component Information > Testing and Inspection
- Tearing
- Piercing
- Arcing
- Carbon tracking
- Corroded terminal
Ignition Cable > Component Information > Testing and Inspection > Page 2698
Removal Procedure
seal to cable seal.
to cable seal.
Ignition Cable > Component Information > Testing and Inspection > Page 2699

Hummer Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Specifications

Plug > Component Information > Specifications > Page 2703

Spark Plug Usage
conditions. Refer to Ignition System Specifications (See: Powertrain Management/Ignition
System/Specifications) for the correct spark plug.
NOT move.
Ignition System Specifications (See: Powertrain Management/Ignition System/Specifications) . An
excessively wide electrode gap can prevent correct spark plug operation.
- Inspect for the correct spark plug torque. Refer to Ignition System Specifications (See: Powertrain
Management/Ignition System/Specifications) . Insufficient torque can prevent correct spark plug
operation. An over torqued spark plug, causes the insulator (2) to crack.
gap.

* Weak coils
Removal Procedure
needed.

Notice) .
and Repair) .
Compression Check > System Information > Specifications
COMPRESSION CHECK
cylinder.
105).
Compression Check > System Information > Specifications > Page 2711
plug
70% = 105).
cylinder.
oil.
cylinders.
Hummer Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve
Clearance > System Information > Specifications
VALVE SYSTEM
Valve Lash ...........................................................................................................................................

Hummer Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Drive Pulley, Water Pump >
Component Information > Technical Service Bulletins > Customer Interest for Drive Pulley: > 08-06-01-015 > Jul > 08 >
Engine - Drive Belt Chirping Noise
Drive Pulley: Customer Interest Engine - Drive Belt Chirping Noise
TECHNICAL
Bulletin No.: 08-06-01-015
Date: July 14, 2008
Saab 9-7X V8

Condition
Cause
noise.
Correction
Notice:
Tip
Parts Information

Component Information > Technical Service Bulletins > Customer Interest for Drive Pulley: > 08-06-01-015 > Jul > 08 >
Engine - Drive Belt Chirping Noise > Page 2724
Disclaimer
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Pulley: > 08-06-01-015 >
Jul > 08 > Engine - Drive Belt Chirping Noise
Drive Pulley: All Technical Service Bulletins Engine - Drive Belt Chirping Noise
TECHNICAL
Bulletin No.: 08-06-01-015
Date: July 14, 2008
Saab 9-7X V8

Condition
Cause
noise.
Correction
Notice:
Tip
Parts Information

Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Pulley: > 08-06-01-015 >
Jul > 08 > Engine - Drive Belt Chirping Noise > Page 2730
Disclaimer
Hummer Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Cooling System Air Bleeder Pipe / Hose >
Component Information > Service and Repair > Coolant Air Bleed Pipe Assembly Replacement
Cooling System Air Bleeder Pipe / Hose: Service and Repair Coolant Air Bleed Pipe Assembly
Replacement
Coolant Air Bleed Pipe Assembly Replacement

Removal Procedure
1. Drain the cooling system. Refer to Cooling System Draining and Filling (Static Fill) (See: Service
and Repair/Draining and Filling Cooling
System)Cooling System Draining and Filling (Vac-N-Fill) (See: Service and Repair/Draining and
Filling Cooling System) .
2. Remove the generator. Refer to Generator Replacement (See: Starting and Charging/Charging
System/Alternator/Service and Repair/Generator
Replacement) .
3. Remove the coolant air bleed pipe bolts (1). 4. Remove the coolant air bleed pipe (2) with
gaskets (3).
5. Remove the gaskets from the coolant air bleed pipe and covers. 6. Discard the gaskets.
Component Information > Service and Repair > Coolant Air Bleed Pipe Assembly Replacement > Page 2736
7. Remove the coolant air bleed hose (1) from the pipe (2).
1. Install the coolant air bleed hose (1) onto the pipe (2).
Important: Install the gaskets properly onto the pipe and covers. Position the O-ring seal onto the
nipple portion of the pipe.
2. Install the gaskets onto the coolant air bleed pipe and covers.
3. Install the coolant air bleed pipe (2) and gaskets (3) onto the cylinder heads.

Notice) .
4. Install the coolant air bleed pipe bolts (1).
Tighten the coolant air bleed pipe bolts to 12 N.m (106 lb in).
5. Install the generator. Refer to Generator Replacement (See: Starting and Charging/Charging
System/Alternator/Service and Repair/Generator
Replacement) .
6. Fill the cooling system. Refer to Cooling System Draining and Filling (Static Fill) (See: Service
and Repair/Draining and Filling Cooling System
)Cooling System Draining and Filling (Vac-N-Fill) (See: Service and Repair/Draining and Filling
Cooling System) .
Cooling System Air Bleeder Pipe / Hose: Service and Repair Coolant Air Bleed Hose Replacement
Coolant Air Bleed Hose Replacement
Removal Procedure
2. Remove the engine sight shield. Refer to Positive Crankcase Ventilation Hose/Pipe/Tube
Replacement (See: Powertrain Management/Emission
Control Systems/Positive Crankcase Ventilation/PCV Valve Hose/Service and Repair) .
Replacement (See: Engine/Tune-up and Engine
Performance Checks/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair) .
4. Reposition the coolant air bleed hose clamp at the throttle body. 5. Remove the coolant air bleed
hose from the throttle body.
6. Reposition the hose clamp at the pipe. 7. Remove the coolant air bleed hose (1) from the pipe
(2). 8. Remove the coolant air bleed hose from the vehicle.
1. Install the coolant air bleed hose (1) to the pipe (2). 2. Position the hose clamp at the pipe.
3. Install the coolant air bleed hose to the throttle body. 4. Position the coolant air bleed hose clamp
at the throttle body. 5. Install the air cleaner resonator outlet duct. Refer to Air Cleaner Resonator
Outlet Duct Replacement (See: Engine/Tune-up and Engine
6. Install the engine sight shield. Refer to Positive Crankcase Ventilation Hose/Pipe/Tube
Replacement (See: Powertrain Management/Emission
Control Systems/Positive Crankcase Ventilation/PCV Valve Hose/Service and Repair) .
7. Add engine coolant, if necessary.

Hummer Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information >
Technical Service Bulletins > Cooling System - Updated Leak Detection Dye
Coolant: Technical Service Bulletins Cooling System - Updated Leak Detection Dye
INFORMATION
Subject: DEX-COOL(R) Coolant - New Leak Detection Dye J 46366 - Replaces J 29545-6
Models: 1996-2008 GM Passenger Cars and Light/Medium Duty Trucks* (including Saturn)
1997-2008 Isuzu T-Series Medium Duty Tilt Cab Models Built in Janesville and Flint 1999-2008
Isuzu N-Series Medium Duty Commercial Models with 5.7L or 6.0L Gas Engine
*EXCLUDING 2006 and Prior Chevrolet Aveo, Epica, Optra, Vivant and Pontiac Matiz, Wave
Supercede:
This bulletin is being revised to include additional model years. Please discard Corporate Bulletin
Leak detection dye P/N 12378563 (J 29545-6) (in Canada P/N 88900915) may cause
DEX-COOL(R) coolant to appear green in a black vessel making it appear to be conventional
(green) coolant. This may cause a technician to add conventional coolant to a low DEX-COOL(R)
system thus contaminating it. The green DEX-COOL(R) appearance is caused by the color of the
leak detection dye which alters the color of the DEX-COOL(R) coolant.
A new leak detection dye P/N 89022219 (J 46366) (in Canada P/N 89022220) has been released
that does not alter the appearance of the DEX-COOL(R) coolant. When adding the new leak
detection dye the color of the DEX-COOL(R) coolant will not change. For detecting leaks on any
system that uses DEX-COOL(R) leak detection dye P/N 89022219 (in Canada P/N 89022220)
should be used. The new leak detection dye can be used with both conventional and
DEX-COOL(R) coolant.
Disclaimer
Specifications > Capacity Specifications
Coolant: Capacity Specifications
Cooling System
SUV Model ..........................................................................................................................................

......................................... 16.7 quarts (15.8 liters) SUT Model ...........................................................
........................................................................................................................ 15.4 quarts (14.6 liters)
NOTE: All capacities are approximate. When adding, be sure to fill to the approximate level.
Recheck fluid level after filling.
Specifications > Capacity Specifications > Page 2746
Coolant: Fluid Type Specifications
ENGINE COOLANT The cooling system in your vehicle is filled with DEX-COOL engine coolant.
This coolant is designed to remain in your vehicle for 5 years or 150,000 miles (240 000 km),
whichever occurs first, if you add only DEX-COOL extended life coolant.
A 50/50 mixture of clean, drinkable water and DEX-COOL coolant will: - Give freezing protection
down to -34°F (-37°C). - Give boiling protection up to 265°F (129°C). - Protect against rust and
corrosion. - Help keep the proper engine temperature. - Let the warning lights and gages work as
they should.
NOTICE: Using coolant other than DEX-COOL may cause premature engine, heater core or
radiator corrosion. In addition, the engine coolant may require changing sooner, at 30,000 miles
(50 000 km) or 24 months, whichever occurs first. Any repairs would not be covered by your
warranty. Always use DEX-COOL (silicate-free) coolant in your vehicle.
WHAT TO USE Use a mixture of one-half clean, drinkable water and one-half DEX-COOL coolant
which won't damage aluminum parts. If you use this coolant mixture, you don't need to add
anything else.
CAUTION: Adding only plain water to your cooling system can be dangerous. Plain water, or some
other liquid such as alcohol, can boil before the proper coolant mixture will. Your vehicle's coolant
warning system is set for the proper coolant mixture. With plain water or the wrong mixture, your
engine could get too hot but you would not get the overheat warning. Your engine could catch fire
and you or others could be burned. Use a 50/50 mixture of clean, drinkable water and DEX-COOL
coolant.
NOTICE: If you use an improper coolant mixture, your engine could overheat and be badly
damaged. The repair cost would not be covered by your warranty. Too much water in the mixture
can freeze and crack the engine, radiator, heater core and other parts.
If you have to add coolant more than four times a year, check your cooling system.
NOTICE: If you use the proper coolant, you do not have to add extra inhibitors or additives which
claim to improve the system. These can be harmful.
Hummer Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component
Information > Service and Repair > Radiator Surge Tank Replacement
Coolant Reservoir: Service and Repair Radiator Surge Tank Replacement
Radiator Surge Tank Replacement
Removal Procedure
2. Reposition the surge tank inlet hose clamp (1) from the surge tank (2). 3. Remove the surge tank
inlet hose (6) from the surge tank (2). 4. Reposition the surge tank outlet hose clamp (5) from the
surge tank (2). 5. Remove the surge tank outlet hose (3) from the surge tank (2).
6. Remove the bolt (1) from the surge tank (4). 7. Remove the nut (3) from the surge tank (4). 8. If
equipped disconnect the electrical connector from the low coolant level switch. 9. Remove the
surge tank (4) from the vehicle (5).
1. Install the surge tank (4) to the vehicle (5). 2. If equipped connect the electrical connector to the
low coolant level switch.
3. Install the bolt (1) to the surge tank (4).

Information > Service and Repair > Radiator Surge Tank Replacement > Page 2751
4. Install the nut (3) to the surge tank (4).
5. Install the surge tank outlet hose (3) to the surge tank (2). 6. Position the surge tank outlet hose
clamp (5) to the surge tank (2). 7. Install the surge tank inlet hose (6) to the surge tank (2). 8.
Position the surge tank inlet hose clamp (1) to the surge tank (2). 9. Fill the cooling system. Refer
to Cooling System Draining and Filling (Static Fill) (See: Service and Repair/Draining and Filling
Cooling System
Cooling System) .
Coolant Reservoir: Service and Repair Radiator Surge Tank Inlet Hose/Pipe Replacement
Radiator Surge Tank Inlet Hose/Pipe Replacement
Removal Procedure
2. Reposition the surge tank inlet hose clamp from the radiator. 3. Remove the surge tank inlet
hose (1) from the radiator.
4. Reposition the surge tank inlet hose clamp (1) at the surge tank (2). 5. Remove the surge tank
inlet hose (6) from the surge tank (2).
1. Install the surge tank inlet hose (6) to the surge tank (2). 2. Position the surge tank inlet hose
clamp (1) to the surge tank (2).
3. Install the surge tank inlet hose (1) to the radiator. 4. Position the surge tank inlet hose clamp to
the radiator. 5. Fill the cooling system. Refer to Cooling System Draining and Filling (Static Fill)
(See: Service and Repair/Draining and Filling Cooling System
Cooling System) .
Coolant Reservoir: Service and Repair Radiator Surge Tank Outlet Hose/Pipe Replacement
Radiator Surge Tank Outlet Hose/Pipe Replacement
Tools Required
J 43181 Heater Line Quick Connect Release Tool
Removal Procedure
3. Disconnect the heater hose quick connect fitting.
1. Using the J 43181 disconnect the inlet heater hose from the heater core. 2. Install the J 43181 to
the heater core outlet pipe. 3. Close the tool around the heater core outlet pipe. 4. Firmly pull the
tool into the quick connect end of the heater hose. 5. Firmly grasp the heater hose. Pull the heater
hose forward in order to disengage the hose from the heater core.
4. Remove the heater hose (3) from the mounting clip (2).
vehicle.
surge tank (2). 3. Reposition the surge tank outlet hose clamp (5) to the surge tank (2).
4. Install the surge tank outlet hose (6) to the engine (2). 5. Reposition the surge tank outlet hose
clamp (3) to the engine (2). 6. Connect the heater inlet hose to the heater core.
7. Pull the heater inlet hose to ensure the connection.

8. Install the heater hose (3) to the mounting clip (2).
9. Connect the surge tank outlet hose to the heater core outlet pipe.
10. Pull the surge tank outlet hose to ensure the connection. 11. Install the air cleaner resonator
outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Engine/Tune-up and
Engine
Cooling System) .
Coolant Reservoir: Service and Repair Radiator Vent Inlet Hose Replacement
Radiator Vent Inlet Hose Replacement
Removal Procedure
3. Reposition the radiator vent inlet hose clamp from the radiator. 4. Remove the radiator vent inlet
hose (2) from the radiator. 5. Remove the radiator vent inlet hose (2) from the fan shroud retainer.
6. Reposition the radiator vent inlet hose clamp from the throttle body. 7. Remove the radiator vent
inlet hose (2) from the throttle body. 8. Remove the vent inlet hose from the vehicle.
1. Install the radiator vent inlet hose (2) to the throttle body. 2. Install the radiator vent inlet hose
clamp to the throttle body. 3. Install the radiator vent inlet hose (2) to the fan shroud retainer. 4.
Install the radiator vent inlet hose (2) to the radiator. 5. Install the radiator vent inlet hose clamp to
the radiator. 6. Install the air cleaner resonator outlet duct. Refer to Air Cleaner Resonator Outlet
Duct Replacement (See: Engine/Tune-up and Engine
Cooling System) .
Hummer Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor > Component Information > Diagrams > Cooling Fan - Left
Radiator Cooling Fan Motor: Diagrams Cooling Fan - Left
Cooling Fan - Left

Fan Motor > Component Information > Diagrams > Cooling Fan - Left > Page 2765
Radiator Cooling Fan Motor: Diagrams Cooling Fan - Right
Cooling Fan - Right

Fan Motor > Component Information > Diagrams > Page 2766
Radiator Cooling Fan Motor: Service and Repair
Engine Coolant Fan Motor Replacement
Removal Procedure
1. Remove the cooling blade(s). Refer to Engine Cooling Fan Replacement (See: Service and
Repair/Engine Cooling Fan Replacement) . 2. Remove the cooling fan motor bolts. 3. Remove the
cooling fan motor(s).
1. Install the cooling fan motor(s).

Notice) .
2. Install the cooling fan motor bolts.
3. Install the cooling fan blades. Refer to Engine Cooling Fan Replacement (See: Service and
Repair/Engine Cooling Fan Replacement) .
Fan Motor Relay > Component Information > Locations > FAN CNTRL PCB Relay
Fan Motor Relay > Component Information > Locations > FAN CNTRL PCB Relay > Page 2771

Hummer Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature
Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations
Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 2784

Removal Procedure
and Filling (Static Fill) (See: Service and
Service and Repair/Draining and Filling Cooling System) .
equivalent.

Notice) .

System Draining and Filling (Static Fill) (See: Service and Repair/Draining and Filling Cooling
Hummer Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information >
Service and Repair > Heater Core Replacement
Heater Core: Service and Repair Heater Core Replacement
Heater Core Replacement

Hummer Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information >
Service and Repair > Heater Core Replacement > Page 2791
Heater Core: Service and Repair Auxiliary Heater Core Replacement
Auxiliary Heater Core Replacement

Hummer Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information >
Service and Repair > Procedures
Heater Hose: Procedures
Tools Required
* Rub-through
* Collision damage
(Static Fill) (See: Service and Repair/Draining and
Filling Cooling System)Cooling System Draining and Filling (Vac-N-Fill) (See: Service and
Locate the area that requires repair. 5. Obtain a length of replacement line to make the repair. 6.
Use a tubing cutter in order to cut and remove the section of damaged line.
line ends.
fitting.
Service and Repair > Procedures > Page 2796
Draining and Filling (Static Fill) (See: Service and Repair/Draining and Filling Cooling
(Static Fill) (See: Service and Repair/Draining and
Filling Cooling System)Cooling System Draining and Filling (Vac-N-Fill) (See: Service and
Obtain a new A/C or heater line for sectioning.
line to length.
fitting.

Heater Hose: Removal and Replacement
Tools Required
Removal Procedure
1. Install the J 43181 to the inlet heater core pipe. 2. Close the tool around the inlet heater core
pipe. 3. Firmly pull the tool into the quick connect end of the heater hose. 4. Firmly grasp the heater
hose. Pull the heater hose forward in order to disengage the hose from the heater core.
3. Remove the heater inlet hose (1) from the mounting clip (2).
4. Reposition the heater inlet hose clamp from the engine. 5. Remove the heater inlet hose (1) from
the engine. 6. Remove the heater inlet hose (1) from the vehicle.
1. Install the heater inlet hose (1) to the vehicle. 2. Install the heater inlet hose (1) to the engine. 3.
Install the heater inlet hose clamp to the engine.
4. Install the heater inlet hose (1) to the mounting clip (2).
5. Connect the heater inlet hose to the heater core.
6. Pull the heater inlet hose to ensure the connection. 7. Fill the cooling system. Refer to Cooling
System
Cooling System) .
Tools Required
Removal Procedure
1. Install the J 43181 to the heater core inlet pipe. 2. Close the tool around the heater core inlet
pipe. 3. Firmly pull the tool into the quick connect end of the heater inlet hose. 4. Firmly grasp the
3. Using the J 43181 disconnect the surge tank outlet hose from the heater core outlet.
1. Install the J 43181 to the heater core outlet pipe. 2. Close the tool around the heater core outlet
pipe. 3. Firmly pull the tool into the quick connect end of the heater outlet hose. 4. Firmly grasp the
4. Remove the surge tank outlet hose (3) from the mounting clip (2).
vehicle.
surge tank (2). 3. Install the surge tank outlet hose clamp (5) to the surge tank (2).
4. Install the surge tank outlet hose (6) to the engine (2). 5. Install the surge tank outlet hose clamp
(3) to the engine (2).
6. Install the surge tank outlet hose to the mounting clip.
7. Install the surge tank outlet hose (3) to the mounting clip (2).
8. Install the surge tank outlet hose to the heater core outlet pipe.
9. Pull the surge tank outlet hose to ensure the connection.
10. Install the heater inlet hose to the heater core.
11. Pull the inlet heater inlet hose to ensure the connection. 12. Fill the cooling system. Refer to
Cooling System Draining and Filling (Static Fill) (See: Service and Repair/Draining and Filling
Cooling System
Cooling System) .
Removal Procedure
1. Drain the engine coolant. Refer to Cooling System Draining and Filling (Static Fill) (See: Service
2. Remove the air cleaner resonator outlet duct replacement Air Cleaner Resonator Outlet Duct
4. Pull the hose connection apart.
5. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance) .
6. Remove the right assist step if necessary. Refer to Assist Step Replacement (w/WS2, BVX)
(See: Body and Frame/Auxiliary Step / Running

9. Remove the auxiliary heater tubes clip push pins (1) from vehicle frame locations.
10. Remove the auxiliary heater tubes (2) from vehicle.
11. Remove auxiliary heater tubes clip retaining push pin/bolt (1) if necessary. 12. Use a flat blade
release tool to open retaining clips (2). 13. Remove auxiliary heater tubes (3) from retaining clips.
(3) to the vehicle.
3. Install the auxiliary heater tubes clip push pins (1) to vehicle frame locations.
Notice) .
twisting.
Important: Firmly push the quick connect onto the main heater hose connection until you here an
audible click.
5. Install the auxiliary heater tubes (1) to the main heater hose connections. 6. Install the front
wheelhouse liner if necessary. Refer to Wheelhouse Panel Replacement (See: Body and

8. Lower the vehicle. 9. Fill the engine coolant. Refer to Cooling System Draining and Filling (Static
Fill) (See: Service and Repair/Draining and Filling Cooling System
Cooling System) .
Removal Procedure
1. Drain the engine coolant. Refer to Cooling System Draining and Filling (Static Fill) (See: Service
right assist step if necessary. Refer to Assist Step Replacement (w/WS2, BVX) (See: Body and

6. Pinch the tabs together at auxiliary HVAC module fittings to remove the auxiliary heater tubes
(1).
7. Remove the heater tubes retaining push pins (1) at the frame locations. 8. Remove the heater
tubes retaining bolt (2) at the frame location. 9. Remove the auxiliary heater tubes (3) from the
frame.
10. Remove the auxiliary heater tubes from the vehicle.
11. Remove auxiliary heater tubes clip retaining push pin/bolt (1) if necessary. 12. Use a flat-bladed
release tool to open retaining clips (2). 13. Remove auxiliary heater tubes from vehicle.
(3) to the vehicle.

Notice) .
3. Install the auxiliary heater tube nut (2).
4. Install the auxiliary heater tube push pins (1).

5. Install the auxiliary heater tubes (1) to the auxiliary HVAC module.
twisting.
and Repair) .

10. Fill the engine coolant. Refer to Cooling System Draining and Filling (Static Fill) (See: Service
Cooling System) .
Hummer Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information >
Service and Repair > Radiator Replacement (Electric)
Radiator: Service and Repair Radiator Replacement (Electric)
Radiator Replacement (Electric)

Hummer Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information >
Service and Repair > Radiator Replacement (Electric) > Page 2816
Radiator: Service and Repair Radiator Air Baffle Assemblies and Deflectors
Radiator Air Baffle Assemblies and Deflectors
Removal Procedure
1. Remove the radiator air baffle retainers. 2. Remove the radiator air baffles (1) from the vehicle
(2).
1. Install the radiator air baffles (1) to the vehicle (2). 2. Install the radiator air baffle retainers.
Hummer Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information >
Testing and Inspection
Radiator Cap: Testing and Inspection
Pressure Cap Testing
Tools required
* J 24460-01 Cooling System Pressure Tester
* J 42401 Radiator Cap / Surge Tank Test Adapter
Pressure Cap Testing
Caution: To avoid being burned, do not remove the radiator cap or surge tank cap while the engine
is hot. The cooling system will release scalding fluid and steam under pressure if radiator cap or
surge tank cap is removed while the engine and radiator are still hot.
1. Remove the pressure cap. 2. Wash the pressure cap sealing surface with water.
3. Use the J 24460-01 (1) with J 42401 (2) in order to test the pressure cap. 4. Test the pressure
cap for the following conditions:
* Pressure release when the J 24460-01 exceeds the pressure rating of the pressure cap.
* Maintain the rated pressure for at least 10 seconds. Note the rate of pressure loss.
5. Replace the pressure cap under the following conditions:
* The pressure cap does not release pressure which exceeds the rated pressure of the cap.
* The pressure cap does not hold the rated pressure.

Hummer Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Hose > Component Information >
Service and Repair > Radiator Inlet Hose Replacement
Radiator Hose: Service and Repair Radiator Inlet Hose Replacement
Removal Procedure
3. Reposition the radiator inlet hose clamp (3) from the engine (1). 4. Remove the radiator inlet
hose (2) from the engine (1). 5. Remove the radiator inlet hose (4) from the mounting clip (3).
6. Reposition the radiator inlet hose clamp (5) from the radiator (6). 7. Remove the radiator inlet
hose (4) from the radiator (6). 8. Remove the inlet hose from the vehicle.
1. Install the radiator inlet hose (4) to the radiator (6). 2. Position the radiator inlet hose clamp (5) to
the radiator (6). 3. Install the radiator inlet hose (4) to the mounting clip (3). 4. Install the radiator
inlet hose (2) to the engine (1).
Service and Repair > Radiator Inlet Hose Replacement > Page 2824
Position the radiator inlet hose clamp (3) to the engine (1).
Cooling System) .
Radiator Hose: Service and Repair Radiator Outlet Hose Replacement
Radiator Outlet Hose Replacement
Removal Procedure
3. Reposition the radiator outlet hose clamp (2) from the engine (1). 4. Remove the radiator outlet
hose (3) from the engine (1).
5. Reposition the radiator outlet hose clamp (2) from the radiator (1). 6. Remove the radiator outlet
hose (3) from the radiator (1). 7. Remove the outlet hose from the vehicle.
1. Install the radiator outlet hose (3) to the radiator (1). 2. Position the radiator outlet hose clamp (2)
to the radiator (1).
3. Install the radiator outlet hose (3) to the engine (1). 4. Position the radiator outlet hose clamp (2)
to the engine (1). 5. Install the air cleaner resonator outlet duct. Refer to Air Cleaner Resonator
Outlet Duct Replacement (See: Engine/Tune-up and Engine
Cooling System) .
Hummer Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System >
Radiator Cooling Fan Motor Relay > Component Information > Locations > FAN CNTRL PCB Relay
Radiator Cooling Fan Motor Relay > Component Information > Locations > FAN CNTRL PCB Relay > Page 2832

Hummer Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System >
Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component

Removal Procedure
and Filling (Static Fill) (See: Service and
Service and Repair/Draining and Filling Cooling System) .
equivalent.

Notice) .

Hummer Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component
Thermostat: Specifications
The thermostat should begin to open ..................................................................................................

.............................................................. 87°C (188°F) The thermostat should be fully open ..............
.................................................................................................................................................. 97°C
(206°F). Replace the coolant thermostat if it does not operate properly between this temperature
range.
Hummer Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat Housing, Engine Cooling >
Thermostat Housing: Service and Repair
Engine Coolant Thermostat Housing Replacement
Removal Procedure
Important: The thermostat is not serviceable separately. The thermostat housing (water pump inlet)
and thermostat must be replaced as an assembly.
1. Drain the cooling system/engine block. Refer to Cooling System Draining and Filling (Static Fill)
(See: Service and Repair/Draining and Filling
Cooling System)Cooling System Draining and Filling (Vac-N-Fill) (See: Service and
2. Loosen the air cleaner outlet duct clamps at the throttle body and at the mass airflow (MAF)
sensor. 3. Remove the air cleaner outlet duct.
4. Remove the radiator outlet hose. 5. Remove the thermostat housing bolts. 6. Remove the
thermostat housing from the water pump.
1. Install the thermostat housing to the water pump.

Notice) .
2. Install the thermostat housing bolts.

Hummer Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat Housing, Engine Cooling >
3. Install the radiator outlet hose.
4. Install the air cleaner outlet duct. 5. Install the air cleaner outlet duct clamps at the throttle body
and at the mass airflow (MAF) sensor.
Cooling System) .
Hummer Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Drive Pulley, Water Pump
> Component Information > Technical Service Bulletins > Customer Interest for Drive Pulley: > 08-06-01-015 > Jul > 08 >
Engine - Drive Belt Chirping Noise
Drive Pulley: Customer Interest Engine - Drive Belt Chirping Noise
TECHNICAL
Bulletin No.: 08-06-01-015
Date: July 14, 2008
Saab 9-7X V8

Condition
Cause
noise.
Correction
Notice:
Tip
Parts Information

> Component Information > Technical Service Bulletins > Customer Interest for Drive Pulley: > 08-06-01-015 > Jul > 08 >
Engine - Drive Belt Chirping Noise > Page 2865
Disclaimer
> Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Pulley: > 08-06-01-015 >
Jul > 08 > Engine - Drive Belt Chirping Noise
Drive Pulley: All Technical Service Bulletins Engine - Drive Belt Chirping Noise
TECHNICAL
Bulletin No.: 08-06-01-015
Date: July 14, 2008
Saab 9-7X V8

Condition
Cause
noise.
Correction
Notice:
Tip
Parts Information

> Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Pulley: > 08-06-01-015 >
Jul > 08 > Engine - Drive Belt Chirping Noise > Page 2871
Disclaimer
Hummer Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Catalyst Shield >
Catalyst Shield: Service and Repair
Catalytic Converter Guard Replacement

Hummer Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component
Exhaust Manifold: Specifications
EXHAUST MANIFOLD BOLTS
Both Sides
Tighten the exhaust manifold bolts beginning with the center two bolts. Alternate from side-to-side,
and work toward the outside bolts.
- First Pass ..........................................................................................................................................

..................................... 15 N.m (11 lb ft)
- final pass ...........................................................................................................................................

.................................... 25 N.m (18 lb ft)
Information > Service and Repair > Exhaust Manifold Replacement - Left Side
Exhaust Manifold: Service and Repair Exhaust Manifold Replacement - Left Side
Exhaust Manifold Replacement - Left Side
Removal Procedure
Maintenance) . 2. Remove the exhaust manifold pipe nuts. 3. Lower the vehicle. 4. Remove the
spark plug wires. Refer to Spark Plug Wire Replacement (See: Engine/Tune-up and Engine
Performance Checks/Ignition
5. Remove the exhaust manifold bolts, manifold, and gasket. 6. Discard the gasket.
7. Remove the heat shield bolts (3), and shield (2) from the exhaust manifold (1), if necessary.
Information > Service and Repair > Exhaust Manifold Replacement - Left Side > Page 2882
Notice) .
1. Install the heat shield (2), and bolts (3) to the exhaust manifold (1), if necessary.
Important: *
Tighten the exhaust manifold bolts as specified in the service procedure. Improperly installed
and/or leaking exhaust manifold gaskets may affect vehicle emissions and/or On-Board
Diagnostics (OBD) II system performance.
* The cylinder head exhaust manifold bolt hole threads must be clean and free of debris or
threadlocking material.
* Do not apply sealant to the first three threads of the bolt.
2. Apply a 5 mm (0.2 in) wide band of threadlock GM P/N 12345493 (Canadian P/N 101953488) or
equivalent to the threads of the exhaust
manifold bolts.
3. Install the exhaust manifold, NEW gasket and bolts.
1. Tighten the exhaust manifold bolts a first pass to 15 N.m (11 lb ft). Tighten the exhaust manifold
bolts beginning with the center two bolts.
Alternate from side-to-side, and work toward the outside bolts.
2. Tighten the exhaust manifold bolts a final pass to 25 N.m (18 lb ft). Tighten the exhaust manifold
4. Install the spark plug wires. Refer to Spark Plug Wire Replacement (See: Engine/Tune-up and
Engine Performance Checks/Ignition Cable/Service
and Repair) .
5. Using a flat punch, bend over the exposed edge of the exhaust manifold gasket at the rear of the
left cylinder head. 6. Raise the vehicle.
7. Install the exhaust manifold pipe nuts.


Exhaust Manifold: Service and Repair Exhaust Manifold Replacement - Right Side
Exhaust Manifold Replacement - Right Side
Special Tools
J 43181 Heater Line Quick Connect Release Tool
Removal Procedure
Maintenance) . 2. Remove the exhaust manifold pipe nuts. 3. Lower the vehicle. 4. Remove the air
cleaner assembly. Refer to Air Cleaner Assembly Replacement (See: Engine/Tune-up and Engine
Performance Checks/Air
Cleaner Housing/Service and Repair) .
5. Drain the coolant. Refer to Cooling System Draining and Filling (Static Fill) (See: Cooling
System/Service and Repair/Draining and Filling
Cooling System)Cooling System Draining and Filling (Vac-N-Fill) (See: Cooling System/Service
and Repair/Draining and Filling Cooling System) .
6. Using the J 43181 , remove the heater core hoses from the heater core. Position aside. 7.
Remove the spark plug wires. Refer to Spark Plug Wire Replacement (See: Engine/Tune-up and
Engine Performance Checks/Ignition
8. Remove the oil level indicator tube. Refer to Oil Level Indicator and Tube Replacement (See:
Engine/Engine Lubrication/Engine Oil Dip Stick -
Dip Stick Tube/Service and Repair) .
9. Remove the exhaust manifold bolts, manifold, and manifold gasket.
10. Discard the gasket.
11. Remove the heat shield bolts (3), and shield (2) from the exhaust manifold (1).

Notice) .
1. Install the heat shield (2), and bolts (3) to the exhaust manifold (1), if necessary.
Important: *
Tighten the exhaust manifold bolts as specified in the service procedure. Improperly installed
and/or leaking exhaust manifold gaskets may affect vehicle emissions and/or On-Board
Diagnostics (OBD) II system performance.
* The cylinder head exhaust manifold bolt hole threads must be clean and free of debris or
threadlocking material.
* Do not apply sealant to the first three threads of the bolt.
2. Apply a 5 mm (0.2 in) wide band of threadlock GM P/N 12345493 (Canadian P/N 10953488) or
equivalent to the threads of the exhaust manifold
bolts.
3. Install the NEW manifold gasket, exhaust manifold, and bolts.
1. Tighten the exhaust manifold bolts a first pass to 15 N.m (11 lb ft). Tighten the exhaust manifold
2. Tighten the exhaust manifold bolts a final pass to 25 N.m (18 lb ft). Tighten the exhaust manifold
4. Using a flat punch, bend over the exposed edge of the exhaust manifold gasket at the front of
the right cylinder head. 5. Install the oil level indicator tube. Refer to Oil Level Indicator and Tube
Replacement (See: Engine/Engine Lubrication/Engine Oil Dip Stick -
Dip Stick Tube/Service and Repair) .
6. Install the spark plug wires. 7. Install the inlet heater hose. Refer to Heater Inlet Hose
Replacement (See: Cooling System/Heater Hose/Service and Repair/Removal and
Replacement/Heater Inlet Hose Replacement) .
8. Install the outlet heater hose. Refer to Heater Outlet Hose Replacement (See: Cooling
System/Heater Hose/Service and Repair/Removal and
Replacement/Heater Outlet Hose Replacement) .
9. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement (See:
Engine/Tune-up and Engine Performance Checks/Air Cleaner
Housing/Service and Repair) .

12. Lower the vehicle. 13. Fill the cooling system. Refer to Cooling System Draining and Filling
(Static Fill) (See: Cooling System/Service and Repair/Draining and Filling
Cooling System)Cooling System Draining and Filling (Vac-N-Fill) (See: Cooling System/Service
and Repair/Draining and Filling Cooling System) .
Hummer Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information >
Service and Repair
Exhaust Pipe: Service and Repair
Exhaust Manifold Pipe Replacement
Removal Procedure
Maintenance) . 2. Remove the engine protection shield. Refer to Engine Protection Shield
).
3. Remove the exhaust muffler. Refer to Muffler Replacement (See: Muffler/Service and Repair) .
4. Remove the clip around the engine harness and the oxygen sensor pigtail. 5. Disconnect the
connector position assurance (CPA) retainer. 6. Disconnect the oxygen sensor electrical connector.
7. If replacing the exhaust manifold pipe, remove the oxygen sensor.
8. Remove the exhaust manifold pipe nuts.
9. Remove the exhaust manifold pipe.
10. Slide the exhaust manifold pipe hanger out of the exhaust pipe hanger bracket. 11. Discard the
exhaust manifold pipe seal.
Service and Repair > Page 2890
1. Install a new exhaust manifold pipe seal to the exhaust manifold pipe. 2. Install the exhaust
manifold pipe. 3. Apply lubricant to the exhaust pipe hanger bracket, in order to aid in installation.
4. Slide the exhaust manifold pipe hanger into the exhaust pipe hanger bracket.

Notice) .
6. If the exhaust manifold pipe was replaced perform the following:
1. Apply anti-seize compound GM P/N 12377953 or equivalent to the threads of the old oxygen
sensor. 2. Install the old oxygen sensor.
Tighten the oxygen sensor to 42 N.m (31 lb ft).
7. If the exhaust manifold pipe was not replaced perform the following:
1. Connect the oxygen sensor electrical connector. 2. Connect the CPA retainer. 3. Install the clip
around the engine harness and the oxygen sensor pigtail.
8. Install the exhaust muffler. Refer to Muffler Replacement (See: Muffler/Service and Repair) . 9.
Install the engine protection shield. Refer to Engine Protection Shield Replacement (See: Body and

Hummer Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component
Information > Service and Repair > Floor Panel Heat Shield Replacement
Heat Shield: Service and Repair Floor Panel Heat Shield Replacement
Floor Panel Heat Shield Replacement
Removal Procedure
1. Remove the exhaust front heat shield nuts. 2. Remove the exhaust front heat shield from the
studs.
3. Remove the exhaust heat shield nuts. 4. Remove the exhaust heat shield(s) from the studs.
1. Install the exhaust heat shield to the studs.

Notice) .
2. Install the exhaust heat shield nuts.
Tighten the nuts to 9 N.m (80 lb in).

Information > Service and Repair > Floor Panel Heat Shield Replacement > Page 2896
3. Install the exhaust heat shield(s) to the studs. 4. Install the exhaust heat shield nuts.
5. Install the exhaust front heat shield to the studs. 6. Install the exhaust front heat shield nuts.

Information > Service and Repair > Floor Panel Heat Shield Replacement > Page 2897
Heat Shield: Service and Repair Exhaust Heat Shield Replacement - Dash Panel
Exhaust Heat Shield Replacement - Dash Panel
Removal Procedure
Maintenance) . 2. Remove the engine protection shield bolts and shield. Refer to Engine Protection
Shield Replacement (See: Body and Frame/Frame/Skid
3. Remove the exhaust heat shield nuts. 4. Remove the exhaust heat shield from the dash panel
studs (1, 3).
1. Install the exhaust heat shield to the dash panel studs (1, 3).

Notice) .
2. Install the exhaust heat shield nuts.
3. Install the engine protection shield and bolts. Refer to Engine Protection Shield Replacement
(See: Body and Frame/Frame/Skid Plate/Service and
Repair) .

Hummer Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information >
Service and Repair
Muffler: Service and Repair
Muffler Replacement
Special Tools
J 38185 Hose Clamp Pliers
Removal Procedure
1. Remove the spare tire wheel stowage lock cylinder.
2. Remove the spare tire from the hoist. 3. Remove the rear tires and wheels. Refer to Tire and
Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair) .
4. If vehicle is equipped with regular production option (RPO) Z55, disconnect the following right
side chassis harness electrical connectors:
* Electronic suspension rear position sensor (1)
* Rear shock (2)

5. If vehicle is equipped with RPO Z55, disconnect the following left side chassis harness electrical
connectors:
* Rear shock (2)
Important: Do not attempt to pry the rear suspension sensor link rod from the rear position sensor
ball stud.
6. Remove the left and right sensor link rods from the sensors, perform the following:
1. Support the sensor lever with your hand 2. Twist the link rod in order to remove it from the ball
stud
7. Install adjustable jack stands under the rear axle.
8. Remove the rear axle vent hose from the rear axle, if necessary. 9. Remove the vent hose
swivel clip from the rear brake crossover pipe.
10. Remove the rear shock absorbers lower bolts and nuts. 11. Lower the rear axle slightly, using
the adjustable jack stands, in order to remove the muffler.
12. Remove the exhaust muffler nuts.
13. Remove the muffler from the insulators.
1. Apply lubricant to the exhaust insulators in order to aid in installation. 2. Install the muffler to the
insulators.
3. Install the exhaust muffler nuts.

4. Raise the rear axle, using the adjustable jackstands. 5. Install the lower bolts and nuts to the rear
shock absorbers.
6. Remove the adjustable jack stands from under the rear axle.
7. Install the vent hose swivel clip to the rear brake crossover pipe. 8. Install the rear axle vent hose
to the rear axle, if necessary.
9. If vehicle is equipped with RPO Z55, install the left and right sensor link rods to the sensors.
10. Using J 38185 install the link rods to the ball studs on the sensor levers.
11. If vehicle is equipped with RPO Z55, connect the following left side chassis harness electrical
connectors:
* Rear shock (2)
12. If vehicle is equipped with RPO Z55, connect the following right side chassis harness electrical
connectors:
* Rear shock (2)
13. Install the rear tires and wheels. Refer to Tire and Wheel Removal and Installation (See:
Maintenance/Wheels and Tires/Service and Repair) .
14. Install the spare tire to the hoist.
15. Install the spare tire wheel stowage lock cylinder.

Hummer Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Seals and Gaskets, Exhaust > Exhaust
Pipe Gasket > Component Information > Service and Repair
Exhaust Pipe Gasket: Service and Repair
Exhaust Seal Replacement
Removal Procedure
Maintenance) . 2. Remove the engine protection shield. Refer to Engine Protection Shield
).
3. Disconnect the CPA retainer. 4. Disconnect the oxygen sensor electrical connector (1). 5.
Support the catalytic converter or exhaust manifold pipe with adjustable jackstands.
6. Remove the right exhaust manifold pipe nuts.
7. Remove the left exhaust manifold pipe nuts. 8. Remove the exhaust hanger mounting bracket
bolts. 9. Lower the catalytic converter or exhaust manifold pipe using the adjustable jackstands.
10. Remove the exhaust manifold pipe seal(s).
Hummer Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Seals and Gaskets, Exhaust > Exhaust
Pipe Gasket > Component Information > Service and Repair > Page 2909
1. Install the exhaust manifold pipe seal(s). 2. Raise the catalytic converter or exhaust manifold
pipe using the adjustable jackstands. 3. Install the exhaust hanger mounting bracket bolts.

Notice) .
4. Install the left exhaust manifold pipe nuts.
* Tighten the transmission bolts to 100 N.m (74 lb ft).
* Tighten the exhaust pipe hanger bracket bolts to 12 N.m (106 lb in).
* Tighten the exhaust manifold pipe nuts to 50 N.m (39 lb ft).
5. Install the right exhaust manifold pipe nuts.
6. Connect the oxygen sensor electrical connector (1). 7. Connect the CPA retainer. 8. Remove the
adjustable jackstands from catalytic converter or exhaust manifold pipe. 9. Install the engine
protection shields. Refer to Engine Protection Shield Replacement (See: Body and
Frame/Frame/Skid Plate/Service and Repair)

Hummer Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
> Body Controls - Body Control Module (BCM) Grounds
Grounds
INFORMATION
Models:
Issue 1
Issue 2
ground path.
- Door locks

> Body Controls - Body Control Module (BCM) Grounds > Page 2917
Disclaimer
> Page 2918
Module (BCM) X2










Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Page 2935

Modules - Computers and Control Systems > Electronic Throttle Control Module > Component Information > Locations
Engine Compartment
Accumulator
Engine Compartment
Modules - Computers and Control Systems > Electronic Throttle Control Module > Component Information > Locations >
Page 2939
Accumulator
Bulletins > Customer Interest: > 09-08-68-001 > Nov > 09 > Engine Controls - Cruise Control Shuts Off During Use
TECHNICAL
Bulletin No.: 09-08-68-001
Models:
Condition
charge below 80%.
Cause
Correction
Note
experienced.
Disclaimer
Bulletins > Customer Interest: > 08-08-49-010B > Jul > 08 > Computers/Controls - Mutiple Malfunctions/DTC's Set
TECHNICAL
Date: July 22, 2008
Supercede:
Condition
^ No crank.
Correction
possible concern.
Repair
Bulletins > Customer Interest: > 08-08-49-010B > Jul > 08 > Computers/Controls - Mutiple Malfunctions/DTC's Set > Page
2952
as needed.
needed.
block.
above for location.
Disclaimer
Accessories Info
INFORMATION
Models:
not be honored.

- Propane injection

Non GM Parts And Accessories Info > Page 2958
Disclaimer
Bulletins > All Technical Service Bulletins for Engine Control Module: > 09-08-68-001 > Nov > 09 > Engine Controls - Cruise
During Use
TECHNICAL
Bulletin No.: 09-08-68-001
Models:
Condition
charge below 80%.
Cause
Correction
Note
experienced.
Disclaimer
Mutiple Malfunctions/DTC's Set

TECHNICAL
Date: July 22, 2008
Supercede:
Condition

^ No crank.
Correction
possible concern.
Repair
Mutiple Malfunctions/DTC's Set > Page 2967
as needed.
needed.
block.
above for location.
Disclaimer
GM Parts And Accessories Info
Accessories Info
INFORMATION
Models:
not be honored.

- Propane injection

GM Parts And Accessories Info > Page 2973
Disclaimer
Engine Compartment
Accumulator
Engine Compartment
Accumulator
Control Module (ECM) X1



converter.
ignition is ON.
Notice:
Removal Procedure
oil life.

Notice) .
Relearning) .
Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations
Page 2988
procedure.
Diagnostic Aids
Engine Controls Schematics (See: Diagrams/Electrical Diagrams) Connector End View Reference

* Circuit Testing (See: Computers and Control Systems/Diagrams/Diagnostic Aids/General

* Connector Repairs (See: Computers and Control Systems/Diagrams/Diagnostic Aids/General
* Testing for Intermittent Conditions and Poor Connections (See: Computers and Control
Systems/Diagrams/Diagnostic Aids/General Electrical Diagnostic Procedures/Circuit
Testing/Testing For Intermittent and Poor Connections)
* Wiring Repairs (See: Computers and Control Systems/Diagrams/Diagnostic Aids/General

Scan Tool Reference
Page 2989
status parameters.
replace the ECM.
OK.
replace the ECM.
Repair Instructions
* Relay Replacement (Attached to Wire Harness) (See: Power and Ground Distribution/Power
Distribution Relay/Service and Repair/Relay Replacement (Attached to Wire Harness))Relay
Replacement (Within an Electrical Center) (See: Power and Ground Distribution/Power Distribution
Relay/Service and Repair/Relay Replacement (Within an Electrical Center))
Page 2990
Repair Verification
‹› If another DTC is present, refer to Diagnostic Trouble Code (DTC) List - Vehicle (See:
Computers and Control Systems/Testing and
Inspection/Diagnostic Trouble Code Descriptions/Diagnostic Trouble Code (DTC) List - Vehicle)

and perform the appropriate diagnostic procedure.
Modules - Fuel Delivery and Air Induction > Fuel Pump Control Unit > Component Information > Locations

Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations
Page 3000
procedure.
Diagnostic Aids



Scan Tool Reference
Page 3001
status parameters.
replace the ECM.
OK.
replace the ECM.
Repair Instructions
* Engine Control Module Replacement (See: Relays and Modules - Computers and Control
Systems/Engine Control Module/Service and Repair)
Page 3002
Repair Verification

Hummer Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Service and
Repair
Removal Procedure


conditions:
panel.
Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations
Engine Compartment
Accumulator
Engine Compartment
Accumulator

Removal Procedure
Fuel Delivery and Air Induction/Air Cleaner
Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair) .
air intake resonator. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Fuel Delivery
and Air Induction/Air Cleaner

Switches - Computers and Control Systems > Battery Current Sensor > Component Information > Diagrams

Removal Procedure

Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations
3022
3023
3024

Removal Procedure

Replacement) .
the CMP sensor.

Notice) .

Replacement) .

Removal Procedure

equivalent.

Notice) .

Cooling System) .
Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations
3034
3035

Procedures
(DTC) List - Vehicle (See: Computers and Control Systems/Testing and Inspection/Diagnostic
Trouble Code Descriptions/Diagnostic Trouble Code (DTC) List - Vehicle) for the applicable DTC
that set.
P0315 (See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code
Tests and Associated Procedures/P Code Charts/P0315) . If any other DTCs set, refer to
Diagnostic Trouble Code (DTC) List - Vehicle (See: Computers and Control Systems/Testing and
P0315 is set:
* A ECM replacement

Removal Procedure

Notice) .
Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations
Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 3043

Level Sensor Replacement
Removal Procedure
1. Remove the fuel sender. Refer to Fuel Sender Assembly Replacement (See: Fuel Delivery and
Air Induction/Fuel Tank/Fuel Gauge
Sender/Service and Repair) .
sender. Refer to Fuel Sender Assembly Replacement (See: Fuel Delivery and Air Induction/Fuel
Tank/Fuel Gauge Sender/Service
and Repair) .
Tools Required
Removal Procedure
1. Remove the fuel tank. Refer to Fuel Tank Replacement (See: Fuel Delivery and Air
Induction/Fuel Tank/Service and Repair/Removal and
Replacement) .
(See: Fuel Delivery and Air Induction/Fuel Supply
Line/Service and Repair/Fuel Hose/Pipes Assembly Replacement) .
tank rotation.

be replaced.

Replacement (See: Fuel Delivery and Air Induction/Fuel Supply
5. Install the fuel tank. Refer to Fuel Tank Replacement (See: Fuel Delivery and Air Induction/Fuel
Tank/Service and Repair/Removal and
Replacement) .
Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations
3052

3053
Removal Procedure
Replacement) .
Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and
Replacement) .
Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations
Engine Compartment
Accumulator
Engine Compartment
3057
Accumulator
3058

3059
Removal Procedure

Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations
Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 3063
Knock Sensor (KS) 1

> Page 3066
Knock Sensor (KS) 2

Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Page 3067
Removal Procedure

Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations
Page 3071
Page 3072

Page 3073
Removal Procedure

Replacement) .
Page 3074
retainer.

Notice) .

Replacement) .
Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Locations


Special Tools
Removal Procedure

Replacement) .

Notice) .
Cooling and

Replacement) .
Sensor (HO2S) Bank 1 Sensor 1




Force and Oxygen Sensor Notice
any type.
failure.
Oxygen Sensor Replacement - Bank 1 Sensor 1
Tools Required
Removal Procedure

Tools Required
Removal Procedure

Tools Required
Removal Procedure

Tools Required
Removal Procedure

Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams

Locations > Automatic Transmission Electronic Component Views

Views
Locations > Automatic Transmission Electronic Component Views > Page 3105


Bulletins > Customer Interest for Vehicle Speed Sensor: > 09-09-41-006 > Oct > 09 > Restraints - Service Airbag Message
Displayed
TECHNICAL
Bulletin No.: 09-09-41-006
Models:
Condition
Cause
communications.
Correction

Parts Information
Disclaimer
Bulletins > All Technical Service Bulletins for Vehicle Speed Sensor: > 09-09-41-006 > Oct > 09 > Restraints - Service
Airbag Message Displayed
Displayed
TECHNICAL
Bulletin No.: 09-09-41-006
Models:
Condition
Cause
communications.
Correction

Parts Information
Disclaimer

Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Service and
Repair
Removal Procedure


conditions:
panel.
Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations
Engine Compartment
Accumulator
Engine Compartment
Accumulator

Removal Procedure

Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Diagrams

3136
Removal Procedure
pressure sensor.
3137

Notice) .
3138
Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams

Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations

Removal Procedure

Replacement) .
the CMP sensor.

Notice) .

Replacement) .
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations

Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Procedures
that set.
P0315 is set:
* A ECM replacement

Page 3156
Removal Procedure

Page 3157
Notice) .
> Procedures
kit.
Removal Procedure

lock cylinder case.


Switches - Ignition System > Knock Sensor > Component Information > Locations
Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 3169
Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Knock Sensor (KS) 1
Knock Sensor (KS) 1

Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Knock Sensor (KS) 1 > Page 3172
Knock Sensor (KS) 2

Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Page 3173
Removal Procedure

Hummer Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure >

............................................................................................................................................. 345-414
kPa (50-60 psi)
System Information > Service Precautions > Technician Safety Information
System Information > Service Precautions > Technician Safety Information > Page 3180
System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal
Tools Required
Installation Procedure Caution: Refer to Gasoline/Gasoline Vapors Caution (See: Fuel Delivery and
Air Induction/Fuel/Service Precautions) .
directions.
Removal Procedure
System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 3183

procedure.
Fuel System Description (See: Computers and Control Systems/Description and Operation/Fuel
System Description) Electrical Information Reference



Scan Tool Reference

Important:
Instructions.
Important: *
pump module.
5. If the fuel system tests normal, refer to Symptoms - Engine Controls (See: Computers and
Control Systems/Testing and Inspection/Symptom
Related Diagnostic Procedures/Symptoms - Engine Controls) .
Repair Instructions
Perform the Diagnostic Repair Verification (See: Computers and Control Systems/Testing and
Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and
Procedures) after completing the diagnostic procedure.
* Fuel Hose/Pipes Assembly Replacement (See: Fuel Delivery and Air Induction/Fuel Supply
Line/Service and Repair/Fuel Hose/Pipes Assembly Replacement)
* Fuel Injector Replacement (See: Fuel Delivery and Air Induction/Fuel Injector/Service and
Repair/Removal and Replacement)
* Fuel Sender Assembly Replacement (See: Fuel Delivery and Air Induction/Fuel Tank/Fuel Gauge
Sender/Service and Repair)
Hummer Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed >

Hummer Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing
> Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair
Removal Procedure
outlet duct.
Hummer Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing
> Air Filter Element > Component Information > Service and Repair
Removal Procedure
Hummer Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel
Pressure Release > System Information > Service and Repair > Fuel Pressure Relief (With CH 48027)
Special Tools
Caution: Refer to Gasoline/Gasoline Vapors Caution (See: Fuel Delivery and Air
Induction/Fuel/Service Precautions) .

Pressure Release > System Information > Service and Repair > Fuel Pressure Relief (With CH 48027) > Page 3201
(See: Fuel Delivery and Air Induction/Fuel/Service Precautions) .
the fuel fill cap.
Tools Required
Installation Procedure Caution: Refer to Gasoline/Gasoline Vapors Caution (See: Fuel Delivery and
Air Induction/Fuel/Service Precautions) .
directions.
Removal Procedure

Hummer Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Firing Order >

Hummer Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable >
Component Information > Testing and Inspection
- Tearing
- Piercing
- Arcing
- Carbon tracking
- Corroded terminal
Component Information > Testing and Inspection > Page 3211
Removal Procedure
seal to cable seal.
to cable seal.

Hummer Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >


Spark Plug Usage
conditions. Refer to Ignition System Specifications (See: Ignition System/Specifications) for the
correct spark plug.
NOT move.
Ignition System Specifications (See: Ignition System/Specifications) . An excessively wide
electrode gap can prevent correct spark plug operation.
- Inspect for the correct spark plug torque. Refer to Ignition System Specifications (See: Ignition
System/Specifications) . Insufficient torque can prevent correct spark plug operation. An over
torqued spark plug, causes the insulator (2) to crack.
gap.

* Weak coils
Removal Procedure
needed.

Notice) .
and Repair) .
Hummer Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check
> System Information > Specifications
COMPRESSION CHECK
cylinder.
105).
Hummer Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check
> System Information > Specifications > Page 3224
plug
70% = 105).
cylinder.
oil.
cylinders.
Hummer Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Valve Clearance >
VALVE SYSTEM
Valve Lash ...........................................................................................................................................

Hummer Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position
Removal Procedure

conditions:
panel.
Hummer Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor >
Engine Compartment
Accumulator
Engine Compartment
Accumulator

Removal Procedure

Hummer Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature
Engine Compartment
Accumulator
Engine Compartment
Accumulator

Removal Procedure

Hummer Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Current Sensor >

Removal Procedure

Hummer Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Technical Service Bulletins > Body Controls - Body Control Module (BCM) Grounds
Grounds
INFORMATION
Models:
Issue 1
Issue 2
ground path.
- Door locks

Component Information > Technical Service Bulletins > Body Controls - Body Control Module (BCM) Grounds > Page 3253
Disclaimer
Component Information > Diagrams > Body Control Module (BCM) X2

Component Information > Diagrams > Body Control Module (BCM) X2 > Page 3257










Hummer Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor >

Removal Procedure

Replacement) .
the CMP sensor.

Notice) .

Replacement) .
Hummer Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature
Sensor/Switch (For Computer) > Component Information > Locations
Sensor/Switch (For Computer) > Component Information > Locations > Page 3281

Removal Procedure

equivalent.

Notice) .

Cooling System) .
Hummer Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >

(DTC) List - Vehicle (See: Testing and Inspection/Diagnostic Trouble Code Descriptions/Diagnostic
Trouble Code (DTC) List - Vehicle) for the applicable DTC that set.
P0315 (See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/P
Code Charts/P0315) . If any other DTCs set, refer to Diagnostic Trouble Code (DTC) List - Vehicle
(See: Testing and Inspection/Diagnostic Trouble Code Descriptions/Diagnostic Trouble Code
(DTC) List - Vehicle) for the applicable DTC that set.
P0315 is set:
* A ECM replacement

Removal Procedure


Notice) .
Hummer Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector >
Component Information > Diagrams > Data Link Connector (DLC)
Data Link Connector: Diagrams Data Link Connector (DLC)
Data Link Connector (DLC)

Hummer Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector >
Component Information > Diagrams > Data Link Connector (DLC) > Page 3297
Data Link Connector: Diagrams Data Link Resistor
Data Link Resistor

Hummer Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Actuator >
Component Information > Description and Operation
Electronic Throttle Actuator: Description and Operation
Throttle Actuator Control (TAC) System Description
Purpose
The throttle actuator control (TAC) system delivers improved throttle response and greater
reliability and eliminates the need for mechanical cable. The TAC system performs the following
functions:
* Accelerator pedal position sensing
* Throttle positioning to meet driver and engine demands
* Throttle position sensing
* Internal diagnostics
* Cruise control functions
* Manage TAC electrical power consumption
The TAC system includes the following components:
* The accelerator pedal position (APP) sensors
* The throttle body assembly
* The engine control module (ECM)
The accelerator pedal contains 2 individual APP sensors within the assembly. The Accelerator
Pedal Position (APP) sensors 1 and 2 are potentiometer type sensors each with 3 circuits:
* A 5-volt reference circuit
* A low reference circuit
* A signal circuit
The APP sensors are used to determine the pedal angle. The engine control module (ECM)
provides each APP sensor a 5-volt reference circuit and a low reference circuit. The APP sensors
provide the ECM with signal voltage proportional to the pedal movement. The APP sensor 1 signal
voltage at rest position is less than 1 volt and increases to above 4 volts as the pedal is actuated.
The APP sensor 2 signal voltage at rest position is near 0.5 volt and increases to more than 2 volts
as the pedal is actuated.
Throttle Body Assembly
The throttle assembly contains the following components:
* The throttle blade
* The throttle actuator motor
* The throttle position (TP) sensor 1 and 2
The throttle body functions similar to a conventional throttle body with the following exceptions:
* An electric motor opens and closes the throttle valve.

* The throttle blade is spring loaded in both directions and the default position is slightly open.
* There are 2 individual TP sensors within the throttle body assembly.
The TP sensors are used to determine the throttle plate angle. The TP sensors provide the engine
control module (ECM) with a signal voltage proportional to throttle plate movement. The TP sensor
1 signal voltage at closed throttle is above 4 volts and decreases as the throttle plate is opened.
The TP sensor 2 signal voltage at closed throttle is below 1 volt and increases as the throttle plate
is opened.
Engine Control Module
The engine control module (ECM) is the control center for the throttle actuator control (TAC)
system. The ECM determines the drivers intent and then calculates the appropriate throttle
response. The ECM achieves throttle positioning by providing a pulse width modulated voltage to
the TAC motor.
Modes of Operation
Normal Mode
During the operation of the throttle actuator control (TAC) system, several modes or functions are
considered normal. The following modes may be entered during normal operation:
Hummer Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Actuator >
Component Information > Description and Operation > Page 3301
* Minimum pedal value-At key-up the engine control module (ECM) updates the learned minimum
pedal value.
* Minimum throttle position (TP) values-At key-up the ECM updates the learned minimum TP value.
In order to learn the minimum TP value, the throttle blade is moved to the closed position.
* Ice break mode-If the throttle is not able to reach a predetermined minimum throttle position, the
ice break mode is entered. During the ice break mode, the ECM commands the maximum pulse
width several times to the throttle actuator motor in the closing direction.
* Battery saver mode-After a predetermined time without engine RPM, the ECM commands the
battery saver mode. During the battery saver mode, the TAC module removes the voltage from the
motor control circuits, which removes the current draw used to maintain the idle position and allows
the throttle to return to the spring loaded default position.
Reduced Engine Power Mode
When the ECM detects a condition with the TAC system, the ECM may enter a reduced engine
power mode. Reduced engine power may cause one or more of the following conditions:
* Acceleration limiting-The ECM will continue to use the accelerator pedal for throttle control;
however, the vehicle acceleration is limited.
* Limited throttle mode-The ECM will continue to use the accelerator pedal for throttle control;
however, the maximum throttle opening is limited.
* Throttle default mode-The ECM will turn off the throttle actuator motor and the throttle will return
to the spring loaded default position.
* Forced idle mode-The ECM will perform the following actions:
- Limit engine speed to idle by positioning the throttle position, or by controlling the fuel and spark if
the throttle is turned off.
- Ignore the accelerator pedal input.
* Engine shutdown mode-The ECM will disable fuel and de-energize the throttle actuator.
Hummer Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Control
Module > Component Information > Locations
Engine Compartment
Accumulator
Engine Compartment
Hummer Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Control
Module > Component Information > Locations > Page 3305
Accumulator
Hummer Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Technical Service Bulletins > Customer Interest: > 09-08-68-001 > Nov > 09 > Engine Controls -
Cruise Control Shuts Off During Use
TECHNICAL
Bulletin No.: 09-08-68-001
Models:
Condition
charge below 80%.
Cause
Correction
Note
experienced.
Disclaimer
Component Information > Technical Service Bulletins > Customer Interest: > 08-08-49-010B > Jul > 08 >
TECHNICAL
Date: July 22, 2008
Supercede:
Condition
^ No crank.
Correction
possible concern.
Repair
Component Information > Technical Service Bulletins > Customer Interest: > 08-08-49-010B > Jul > 08 >
as needed.
needed.
block.
above for location.
Disclaimer
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: >
Accessories Info
INFORMATION
Models:
not be honored.

- Propane injection

Disclaimer
During Use
TECHNICAL
Bulletin No.: 09-08-68-001
Models:
Condition
charge below 80%.
Cause
Correction
Note
experienced.
Disclaimer
08-08-49-010B > Jul > 08 > Computers/Controls - Mutiple Malfunctions/DTC's Set

TECHNICAL
Date: July 22, 2008
Supercede:
Condition
^ No crank.
Correction
possible concern.
Repair
08-08-49-010B > Jul > 08 > Computers/Controls - Mutiple Malfunctions/DTC's Set > Page 3333
as needed.
needed.
block.
above for location.
Disclaimer
Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: >
Accessories Info
INFORMATION
Models:
not be honored.

- Propane injection

Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: >
Disclaimer
Engine Compartment
Accumulator
Engine Compartment
Accumulator
Component Information > Diagrams > Engine Control Module (ECM) X1


Component Information > Diagrams > Engine Control Module (ECM) X1 > Page 3344


converter.
ignition is ON.
Notice:
Removal Procedure
oil life.

Notice) .
Relearning) .
Hummer Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor >

Component Information > Service and Repair > Fuel Level Sensor Replacement
Removal Procedure
and Repair) .
Component Information > Service and Repair > Fuel Level Sensor Replacement > Page 3357
Tools Required
Removal Procedure
Replacement) .
tank rotation.

be replaced.

Replacement) .
Hummer Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor >

Removal Procedure
Replacement) .
Replacement) .
Hummer Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator -
Electronic > Component Information > Service Precautions
Idle Speed/Throttle Actuator - Electronic: Service Precautions
Handling Idle Air Control Valve Notice
Notice: If the IAC valve has been in service: DO NOT push or pull on the IAC valve pintle. The
force required to move the pintle may damage the threads on the worm drive. Also, DO NOT soak
the IAC valve in any liquid cleaner or solvent, as damage may result.
Hummer Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Diagrams > Diagram Information and Instructions
Information Bus: Diagram Information and Instructions

Electrical Symbols
Electrical Symbols
Voltage Indicators
General Icons


Harness Components
Component Parts
Switches and Relays

Devices and Sensors

Information Bus: Diagnostic Aids

* Antenna location
Circuit Testing
Circuit Testing




Fused Jumper Wires)

Voltage)

Frequency)
Continuity)






Protection - Fuses)


Tools Required
J 25070 Heat Gun
necessary.
Salt Water Spray
condition.
cooling needs.
conditions.
when the DTC set.
Measuring Frequency
Measuring Frequency
measured.
Measuring Voltage
Measuring Voltage
points.
Frontprobe
terminals.
improper diagnosis.
connectors:
Backprobe
Important:

of a test probe.
connector.

lost.
With a DMM
With a Test Lamp
load.
Tools Required

Continuity)


circuit.
Tools Required
following items:

Recorder operation.

component side.






With a DMM
With a Test Lamp
shorted.
measurement.

Tools Required
pair of leads.
being tested.
terminals.
Tools Required
gage size.
Flat Wire Repairs
Flat Wire Repairs
Tools Required
energy circuits.
GMLAN Repairs
Operation ( See: Description and Operation) .
the repair.
GMLAN Wire Repair

splice.
(AWG) size.
achieved.
Tools Required
being obstructed.
sensor performance.
Tools Required
damaged wire.
Repair kit).
source.
exhaust pipes.

during the repair.

(AWG) size.
achieved.
achieved.
Tools Required

* A heat torch

SIR/SRS Wire Repair

together.
achieved.

Sleeves) .
Tools Required
2. Cut the wire.

closes.
existing wires.

Tools Required
2. Cut the wire.

achieved.
soldering tool.
new diode.
splice is made.
recommended.
Wiring Repairs
Wiring Repairs
Repairs)

Wiring Repairs)




Wiring Repairs)
AFL/EPC Connectors
AFL/EPC Connectors
Tools Required
Removal Procedure
forward.

dress
cover.

Repair Procedure
connector end view.
Tools Required

position.
Tools Required
Removal Procedure
cover.

Repair Procedure
connector end view.

Tools Required
body and pry up.
position.
used.

Tools Required
position.

Connector Repairs
Connector Repairs



Connectors (ECM))




Connector Anatomy
* Bosch
* Delphi
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
above it.
connection.
Tools Required
Removal Procedure

past the locks.
damaging it.
the tool may break.
used.
Repair Procedure
time.
Micro 64 terminals.
added wire.
from the wire.
visible.
Tools Required


remove the cover.
used.
added wire.

Tools Required
Terminal Removal
be replaced.
connector body.
Terminal Repair

Tools Required
Terminal Removal
Terminal Repair
Repairs) .
Tools Required
Tools Required
Removal Procedure
body.
cover off.
damaging it.
the connector.
used.
Repair Procedure
connector end view.
FCI Connectors
FCI Connectors
Tools Required
Removal Procedure
dress
cover.
Repair Procedure
connector end view.
JST Connectors
JST Connectors
Tools Required

Removal Procedure
connector body.
connector body.
used.
Repair Procedure
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required

Removal Procedure

Repair Procedure
connector end view.
Molex Connectors
Molex Connectors
Tools Required
forward.

Kit.
terminal.
Tools Required
Sumitomo Connectors
Sumitomo Connectors
Tools Required

* Terminal (1)
* Entry Canal (2)
connector.
terminal retainer.
Kit.
terminal.
Tools Required
Removal Procedure
component.

Tools Required
Removal Procedure

housing.
Repair Procedure
connector end view.

Tools Required

panel slides over.
Tools Required
assurance (CPA).
terminal.
Tools Required
Removal Procedure
damaging it.
Repair Procedure
connector end view.
Tools Required

Tools Required
Removal Procedure


Repair Procedure
connector end view.

Arrows and Symbols
Arrows and Symbols
Arrows and Symbols
Information Bus: Electrical Diagrams
Data Communication Schematics
Low Speed Bus - 1 of 3

High Speed Bus - 1 of 2
High Speed Bus - 2 of 2
Information Bus: Description and Operation
Data Link Communications Description and Operation
Circuit Description
The communication among control modules is performed through the high speed GMLAN serial
data circuits and the low speed GMLAN serial data circuit. The modules that need real time
communication are attached to the High Speed GMLAN network. The body control module (BCM)
is the gateway between the high and low speed networks. Refer to Body Control System
Description and Operation (See: Body and Frame/Body Control Systems/Description and
Operation) for more information about the gateway.
Signal supervision is the process of determining whether an expected signal is being received or
not. Some messages are sent on a periodic basis and are interpreted as a heartbeat of a device. If
such a signal is lost, the signal supervision part of the software will set a no communication DTC
(U. code) against the missing device. This code is mapped on the Tech 2 screen as a code against
the physical device. A lost communication DTC typically is set in modules other than the module
with a communication failure.
GMLAN High Speed Circuit Description
The data link connector (DLC) allows a scan tool to communicate with the high speed GMLAN
serial data circuit. The serial data is transmitted on 2 twisted wires that allow speed up to 500 Kb/s.
The twisted pair is terminated with two 120-ohm resistors, one is internal to the engine control
module (ECM) and the other is after the electronic brake control module (EBCM), or if equipped,
the suspension control module. The high speed GMLAN is a differential bus. The high speed
GMLAN serial data bus (+) and high speed GMLAN serial data (-) are driven to opposite extremes
from a rest or idle level. The idle level, which is approximately 2.5 volts, is considered recessive
transmitted data and is interpreted as a logic 1. Driving the lines to their extremes, adds 1 volt to
the high speed GMLAN serial data bus (+) and subtracts 1 volt from the high speed GMLAN serial
data bus (-) wire. If a communication signal is lost, the application will set a no communication code
against the respective control module. This code is mapped on the Tech 2 screen as a code
against the physical device. Note: a loss of serial data DTC does not represent a failure of the
module that the code is set in.
The high speed GMLAN serial data allows communication between the body control module
(BCM), ECM, transmission control module (TCM), vehicle communication interface module (VCIM),
4WD control module, EBCM, and the suspension control module depending on RPO.
GMLAN Low Speed Circuit Description
The data link connector (DLC) allows a scan tool to communicate with the low speed GMLAN serial
data circuit. The serial data is transmitted over a single wire to the appropriate control modules.
Under normal vehicle operating conditions, the speed of the buss is 33.33 Kb/s. This protocol
produces a simple pulse train sent out over the GMLAN low speed serial data bus. When a module
pulls the buss high, 5 volts, this creates a logic state of 0 on the buss. When the buss is pulled low,
0 volts, it is translated as a logic state of 1. To wake the control modules connected to the GMLAN
low speed serial data buss, a wake up signal is sent out over the buss. Modules connected to the
GMLAN low speed buss can be part of a virtual network as described in GMLAN High Speed
Circuit Description above. The modules on the GMLAN low speed serial data buss are connected
to the buss using several splice or "star" connectors separating groups of modules. The following
lists state the splices and modules connected to the low speed serial data circuits:
I/P Splice
* Data link connector (DLC), connected only to the instrument panel (I/P) splice
* Amplifier (Amp)
* Rear seat audio (RSA)
* Vehicle communication interface module (VCIM)
* Digital radio receiver (DRR)
* Inside rearview mirror module (ISRVM), connected through the mid I/P fuse block
* Instrument panel cluster (IPC)
* Body control module (BCM)
* Theft deterrent module (TDM)
* Heater ventilation and air conditioning (HVAC)
* Radio
* Driver door switch (DDS), connected through the left I/P fuse block
* Passenger door switch (PDS), connected through the right I/P fuse block
Body Splice
* Articulating running board module (ARBM)
* Ultrasonic park assist (UPA)
* Memory seat module (MSM)
* Liftgate module (LGM)
* Passenger presence system (PPS)
* Inflatable restraint vehicle rollover sensor (ROS)
* Inflatable restraint sensing and diagnostic module (SDM)
Data Link Connector (DLC)

The data link connector (DLC) is a standardized 16-cavity connector. The DLC low speed serial
data circuit is connected directly to the instrument panel (I/P) splice then to all other splices or
modules. Connector design and location is dictated by an industry wide standard, and is required to
provide the following:
* Pin 1 GMLAN low speed communications terminal
* Pin 4 scan tool power ground terminal
* Pin 5 common signal ground terminal
* Pin 6 high speed GMLAN serial data bus (+) terminal
* Pin 14 high speed GMLAN serial data bus (-) terminal
* Pin 16 scan tool power, battery positive voltage terminal
Serial Data Reference
The scan tool communicates over the various busses on the vehicle. When a scan tool is installed
on a vehicle, the scan tool will try to communicate with every module that could be optioned into
the vehicle. If an option is not installed on the vehicle, the scan tool will display No COMM for that
options specific control module.
In order to avert misdiagnoses of No Communication with a specific module, refer to Data Link
References (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Data Link
References) for a list of modules, the busses they communicate with, and the RPO codes for a
specific module.
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview
Information Bus: Initial Inspection and Diagnostic Overview
Diagnostic Starting Point - Data Communications
Diagnostic Starting Point - Data Communications
Begin the system diagnosis with Diagnostic System Check - Vehicle (See: Testing and
Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) . The
Diagnostic System Check - Vehicle will provide the following information:
* The identification of the control modules which are not communicating
* The identification of any stored diagnostic trouble codes (DTCs) and their status
The use of the Diagnostic System Check - Vehicle will identify the correct procedures to begin
vehicle diagnosis. These must be performed before system DTC or symptom diagnosis.
Data Link References
Data Link References
This table identifies which serial data link that a particular module uses for in-vehicle data
transmission. Some modules may use more than one data link to communicate. Some modules
may have multiple communication circuits passing through them without actively communicating on
that data link. This table is used to assist in correcting a communication malfunction. For the
description and operation of these serial data communication circuits refer to Data Link
Communications Description and Operation (See: Description and Operation) .
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3491
Information Bus: Symptom Related Diagnostic Procedures
Symptoms - Data Communications
Symptoms - Data Communications
Important: The following steps must be completed before using the symptom tables.
1. Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection
and Diagnostic Overview/Diagnostic System
Check - Vehicle) before using the symptom tables in order to verify that all of the following are true:
* There are no DTCs set.
* The control modules can communicate via the serial data links.
2. Review the system operation in order to familiarize yourself with the system functions. Refer to
Data Link Communications Description and
Operation (See: Description and Operation) .
Visual/Physical Inspection
* Inspect for aftermarket devices which could affect the operation of the systems. Refer to
Checking Aftermarket Accessories (See: Diagrams/Diagnostic Aids/General Electrical Diagnostic
* 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 intermittent conditions. Refer to Testing
for Intermittent Conditions and Poor Connections ( See: Diagrams/Diagnostic Aids/General
Electrical Diagnostic Procedures/Circuit Testing/Testing For Intermittent and Poor Connections) .
Symptom List
Refer to a symptom diagnostic procedure from the following list in order to diagnose the symptom:
* Scan Tool Does Not Power Up (See: Scan Tool Does Not Power Up)
* Scan Tool Does Not Communicate with High Speed GMLAN Device (See: Scan Tool Does Not
Communicate with High Speed GMLAN Device )
* Scan Tool Does Not Communicate with Low Speed GMLAN Device (See: Scan Tool Does Not
Communicate with Low Speed GMLAN Device)
Scan Tool Does Not Power Up

Scan Tool Does Not Power Up
procedure.
Diagnostic Fault Information
The data link connector (DLC) is a standardized 16 cavity connector. Connector design and
location is dictated by an industry wide standard, and is required to provide the following:
* Scan tool B+ voltage at terminal 16

* Scan tool ground at terminal 4
* Common ground at terminal 5
Diagnostic Aids
* The scan tool will power up with the ignition OFF. Some modules however, will not communicate
unless the ignition is ON and the power mode master (PMM) module sends the appropriate power
mode message.
* If the B+ circuit, ground circuits, and connections of the DLC are functioning properly, the
malfunction must be due to the scan tool/CANdi module.
Data Communication Schematics (See: Diagrams/Electrical Diagrams) Connector End View

Reference

Views) Description and Operation
Data Link Communications Description and Operation (See: Description and Operation) Electrical
Information Reference
* Circuit Testing (See: Diagrams/Diagnostic Aids/General Electrical Diagnostic Procedures/Circuit

Testing/Circuit Testing)
* Connector Repairs (See: Diagrams/Diagnostic Aids/General Electrical Diagnostic

Procedures/Connector Repairs/Connector Repairs)
* Testing for Intermittent Conditions and Poor Connections (See: Diagrams/Diagnostic

Aids/General Electrical Diagnostic Procedures/Circuit Testing/Testing For Intermittent and Poor
Connections)
* Wiring Repairs (See: Diagrams/Diagnostic Aids/General Electrical Diagnostic Procedures/Wiring

Scan Tool Reference
tool information.
1. Test for less than 2.0 ohms between the ground circuits terminal 4 of the DLC and ground, and
terminal 5 of the DLC and ground.
‹› If greater than the specified range, test the ground circuit for an open/high resistance.
2. Ignition ON, verify a test lamp illuminates between the B+ circuit terminal 16 at the DLC and
ground.
‹› If the test lamp does not illuminate, test the voltage supply circuit for a short to ground or an
open/high resistance.
3. If all circuits test normal, refer to the scan tool/CANdi module user guide.
Repair Instructions
Perform the Diagnostic Repair Verification (See: Testing and Inspection/Diagnostic Trouble Code
Tests and Associated Procedures/Verification Tests and Procedures) after completing the repair.
Scan Tool Does Not Communicate with High Speed GMLAN Device
Scan Tool Does Not Communicate with High Speed GMLAN Device
procedure.

Modules connected to the high speed GMLAN serial data circuits monitor for serial data
communications during normal vehicle operation. Operating information and commands are
exchanged among the modules when the ignition switch is in any position other than OFF. The
high speed GMLAN serial data circuits must be operational for the vehicle to start due to body
control module (BCM) and engine control module (ECM) communications. The vehicle theft
deterrent (VTD) module and ECM exchange information using the BCM as the gateway module
allowing communication between the high and low speed serial data busses. The low speed
GMLAN serial data circuit must also be operational for vehicle starting. The high speed GMLAN
serial data bus uses two 120 ohm terminating resistors that are in parallel with the high speed
GMLAN (+) and (-) circuits.
Diagnostic Aids
* Communication may be available between the BCM and the scan tool with the high speed
GMLAN serial data system inoperative. This condition is due to the BCM using both the high and
low speed GMLAN systems.
* Use the Data Link References (See: Initial Inspection and Diagnostic Overview/Data Link
References) to identify the high speed GMLAN serial data modules.
* This test is used for a total high speed GMLAN communication failure. If only one module is not
communicating and sets no DTC, ensure that the vehicle is equipped with the module, then use
DTC U0100-U0299 for diagnostics.
* An open in the DLC ground circuit terminal 5 will allow the scan tool to operate to set up the
vehicle on the tool and then not communicate with the vehicle. When the scan tool is to the point of
communicating with the vehicle, a message on the scan tool will indicate "no CANdi module
detected" and will not communicate.
* The engine will not start when there is a total malfunction of the high speed GMLAN serial data
bus. The following conditions may cause a total loss of high speed GMLAN data communication:
- A short between high speed GMLAN (+) and high speed GMLAN (-) circuits
- Any of the high speed GMLAN serial data circuits shorted to ground or voltage
- A module internal malfunction that causes a short to voltage or ground on the high speed GMLAN
circuits

* Data Communication Schematics (See: Diagrams/Electrical Diagrams)
* Programming and Relearning (See: Testing and Inspection/Programming and Relearning)




Connections)

1. Test for less than 1.0 ohm between the DLC ground circuit terminal 5 and ground.
‹› If greater than the specified range, test the ground circuit for open/high resistance.
2. Remove the terminator resistor. 3. Test for 110-130 ohms between the terminals of the resistor.
‹› If not within the specified range, replace the resistor.
4. Connect the terminator resistor. 5. Ignition OFF, disconnect the harness connector X3 of the
BCM. 6. Test for less than 2 ohms of resistance in the GMLAN serial data circuit between the DLC
terminal 6 and BCM terminal 16.
‹› If greater than specified, test the GMLAN serial data circuit for open/high resistance.
7. Ignition OFF, disconnect the harness connector X4 of the BCM. 8. Verify a test lamp illuminates
between each ground circuit terminal of the BCM listed below and B+.
* X3 terminal 1
* X3 terminal 5
* X4 terminal 9
‹› If the test lamp does not illuminate, test the ground circuit for an open/high resistance.
9. Ignition ON, verify a test lamp illuminates between each B+ circuit terminal of the BCM listed
below and ground.
* X4 terminal 1
* X4 terminal 3
* X4 terminal 4
‹› If the test lamp does not illuminate, test the B+ circuit for an open/high resistance or short to
ground.
10. Ignition OFF, disconnect the harness connector of the vehicle communication interface module
(VCIM). 11. Test for infinite resistance between the high speed GMLAN serial data circuit of the
DLC terminal 6 and ground, and terminal 14 and ground.
‹› If less than the specified range, test the serial data circuit for a short to ground.
12. Ignition ON, test for less than 1 volt between the high speed GMLAN serial data circuit of the
DLC terminal 6 and ground, and terminal 14 and
ground.
‹› If greater than the specified range, test the serial data circuit for a short to voltage.
13. Test for infinite resistance between the high speed GMLAN serial data circuits of the DLC
terminal 6 and 14.
‹› If less than the specified range, test the serial data circuits for a short between them.
14. Connect the harness connectors of the BCM and the VCIM. 15. Disconnect the harness
connector of the air suspension control module (ASCM). 16. Attempt to communicate with the
BCM. Communication should not be available.
‹› If communication is established, Test the serial data circuits between the ASCM and the
terminator resistor for a short to ground, short to
voltage, and a short between them. If the circuits test normal, replace the ASCM.
17. Ignition OFF, disconnect the harness connector of the fuel pump flow control module (FPCM).
18. Attempt to communicate with the BCM. Communication should not be available.
‹› If communication is established, test the serial data circuits for a short between the circuits, short
to voltage, or a short to ground between the
FPCM and the ASCM. If the circuits test normal, replace the FPCM.
19. Ignition OFF, disconnect the harness connector X2 of the electronic brake control module
(EBCM). 20. Attempt to communicate with the BCM. Communication should not be available.
EBCM and the FPCM. If the circuits test normal, replace the EBCM.
21. Ignition OFF, disconnect the harness connector X1 of the transfer case control module
(TCCM). 22. Attempt to communicate with the BCM. Communication should not be available.
TCCM and the EBCM. If the circuits test normal, replace the TCCM.
23. Ignition OFF, disconnect the harness connector X1 of the VCIM. 24. Attempt to communicate
with the BCM. Communication should not be available.
VCIM and the TCCM. If the circuits test normal, replace the VCIM.
25. Ignition OFF, connect the harness connectors of disconnected modules. 26. Ignition OFF,
disconnect the harness connector X1 of the ECM. 27. Attempt to communicate with the BCM.
Communication should not be available.
‹› If communication is established, replace the ECM.
28. Ignition OFF, disconnect the harness connector of the transmission control module (TCM).
Attempt to communicate with the BCM.
Communication should not be available.
TCM and the ECM. If the circuits test normal, replace the TCM.
29. Ignition OFF, disconnect the harness connector X3 of the BCM. 30. Test for infinite resistance
between the serial data circuits of BCM terminal 8 and ground, and between BCM terminal 9 and
ground.
‹› If less than the specified range, test the circuit for a short to ground.
31. Ignition ON, test for less than 1 volt between the serial data circuits of BCM terminal 8 and
ground, and between BCM terminal 9 and ground.
‹› If greater than the specified range, test the circuit for a short to voltage.
32. Test for infinite resistance between the serial data circuits of BCM terminal 8 terminal 9.
‹› If less than the specified range, test the serial data circuits for a short between them.
33. If the circuits test normal, replace the BCM.
Repair Instructions
module replacement, setup, and programming
* GMLAN Wiring Repairs (See: Diagrams/Diagnostic Aids/General Electrical Diagnostic

Procedures/Wiring Repairs/GMLAN Wiring Repairs)
Scan Tool Does Not Communicate with Low Speed GMLAN Device
Scan Tool Does Not Communicate with Low Speed GMLAN Device
procedure.

Modules connected to the low speed GMLAN serial data circuit monitor for serial data
communications during normal vehicle operation. Operating information and commands are
exchanged among the modules when the ignition switch is in any position other than OFF. The low
speed GMLAN serial data circuit must be operational for the vehicle to start so the vehicle theft
deterrent (VTD) module and body control module (BCM) can communicate. The low speed GMLAN
serial data circuit uses JX 205 as the common connection between the modules and the data link
connector (DLC).
Diagnostic Aids
* Use the Data Link References (See: Initial Inspection and Diagnostic Overview/Data Link
References) to identify the low speed GMLAN serial data modules.
* This test is used for a total low speed GMLAN communication failure. If only 1 module is not
communicating and sets no DTC, ensure that the vehicle is equipped with the module, then use
DTC U0100-U0299 for diagnostics.
* An open in the low speed GMLAN serial data circuit between the splice pack and a module will
only effect the specific module. This type of failure will set a loss of communication DTC for each
module effected, and the other modules will still communicate.
* An open in the DLC ground circuit terminal 5 will allow the scan tool to operate to set up the
vehicle on the tool and then not communicate with the vehicle. When the scan tool is to the point of
communicating with the vehicle, a message on the scan tool will indicate "no CANdi module
detected" and will not communicate.
* An open between the DLC and JX 205 will only effect the communication with the scan tool. The
vehicle modules will still communicate, and the vehicle will start.
* The engine will not start when there is a total malfunction of the low speed GMLAN serial data
circuit. The following conditions may cause a total loss of low speed GMLAN data communication:
- The low speed GMLAN serial data circuit shorted to ground or voltage.
- A module internal malfunction that causes a short to voltage or ground on the low speed GMLAN
circuit.
* Body Control System Schematics (See: Body and Frame/Body Control

Systems/Diagrams/Electrical Diagrams)
* Data Communication Schematics (See: Diagrams/Electrical Diagrams)



Connections)

Scan Tool Reference
tool information
1. Test for less than 1 ohm between the DLC ground circuit terminal 5 and ground.
‹› If greater than The specified range, test the ground circuit for open/high resistance.
2. Ignition OFF, disconnect the JX 205 harness connector at the splice pack. 3. Ignition ON, with a
scan tool, attempt to communicate with the instrument panel cluster (IPC). Communication should
be available.
‹› If no communication, disconnect the modules still connected to the DLC one at a time, starting
with the furthest from the DLC and attempt to
communicate after each disconnect. When communication occurs, test the serial data circuit for a
short to ground and a short to voltage between the last module disconnected and the previous
module disconnected. If the circuit tests normal, replace the last module disconnected. If no
communication is possible, test the serial data circuit for a short to ground, a short to voltage or an
open/high resistance between the last module disconnected and the DLC. If the circuit tests
normal, replace the last module disconnected.
4. Install a 3-amp fused jumper wire to JX 205 terminal A, harness side.
Important: Allow communications for 5 seconds after connecting a module with the jumper to
determine if communication is interrupted or not.
5. With IPC communications established, use the other end of the jumper wire to connect all other
terminals, harness side, one at a time and verify
that low speed communication remains available to the IPC.
‹› If low speed communication is interrupted after connecting an individual module at JX 205, test
the serial data circuit between JX 205 and the
last module connected for a short to voltage and short to ground. If the circuit tests normal, replace
the module that caused no communication.
Repair Instructions

module replacement, setup, and programming
* GMLAN Wiring Repairs (See: Diagrams/Diagnostic Aids/General Electrical Diagnostic

Procedures/Wiring Repairs/GMLAN Wiring Repairs)
Hummer Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component
Information > Diagrams > Knock Sensor (KS) 1
Knock Sensor (KS) 1

Information > Diagrams > Knock Sensor (KS) 1 > Page 3505
Knock Sensor (KS) 2

Removal Procedure

Hummer Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel
System) > Component Information > Locations
System) > Component Information > Locations > Page 3510
procedure.
Diagnostic Aids



Connections)

Scan Tool Reference
status parameters.

replace the ECM.
OK.
replace the ECM.
Repair Instructions
Repair Verification
‹› If another DTC is present, refer to Diagnostic Trouble Code (DTC) List - Vehicle (See: Testing
and Inspection/Diagnostic Trouble Code
Descriptions/Diagnostic Trouble Code (DTC) List - Vehicle) and perform the appropriate diagnostic
procedure.
Hummer Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp >
Malfunction Indicator Lamp: Testing and Inspection
Malfunction Indicator Lamp (MIL) Diagnosis
procedure.
Ignition voltage is supplied to the malfunction indicator lamp (MIL). The engine control module
(ECM) turns the MIL ON by grounding the MIL control circuit.
* Instrument Cluster Schematics (See: Diagrams/Electrical Diagrams/Instrument Panel, Gauges

and Warning Indicators/System Diagram/Instrument Cluster Schematics)
* Engine Controls Schematics (See: Diagrams/Electrical Diagrams)




Connections)

Scan Tool Reference
tool information
Ignition ON, the MIL should turn ON and OFF when commanded with a scan tool.
1. Ignition OFF, disconnect the harness connector at the instrument panel cluster (IPC). 2. Ignition
ON, verify that a test lamp illuminates between the ignition circuit and ground.
‹› If the test lamp does not illuminate, test the ignition circuit for a short to ground or an open/high
resistance. If the circuit tests normal and the
ignition circuit fuse is open, replace the IPC.
3. Connect a test lamp between the control circuit and the ignition circuit. 4. Command the MIL ON
and OFF with a scan tool. The test lamp should turn ON and OFF when changing between the
commanded states.
‹› If the test lamp is always ON, test the control circuit for a short to ground. If the circuit tests
normal, replace the ECM. ‹› If the test lamp is always OFF, test the control circuit for a short to
voltage or an open/high resistance. If the circuit tests normal, replace the
ECM.
5. If all circuits test normal, replace the IPC.
Repair Instructions
Tests and Associated Procedures/Verification Tests and Procedures) after completing the
diagnostic procedure.
Hummer Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp >
* Instrument Cluster Replacement (See: Instrument Panel, Gauges and Warning
Indicators/Instrument Cluster / Carrier/Service and Repair)

ECM replacement, setup, and programming
Hummer Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum

Removal Procedure

Replacement) .
retainer.

Notice) .

Replacement) .
Hummer Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor >


Special Tools
Removal Procedure

Replacement) .

Notice) .
Cooling and

Replacement) .
Hummer Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Diagrams > Heated Oxygen Sensor (HO2S) Bank 1 Sensor 1

Information > Diagrams > Heated Oxygen Sensor (HO2S) Bank 1 Sensor 1 > Page 3534



Information > Service Precautions > Excessive Force and Oxygen Sensor Notice
Information > Service Precautions > Excessive Force and Oxygen Sensor Notice > Page 3539
any type.
failure.
Information > Service and Repair > Heated Oxygen Sensor Replacement - Bank 1 Sensor 1
Tools Required
Removal Procedure

Information > Service and Repair > Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 > Page 3544
Tools Required
Removal Procedure

Tools Required
Removal Procedure

Tools Required
Removal Procedure

Hummer Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules -
Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Body
Controls - Body Control Module (BCM) Grounds
Grounds
INFORMATION
Models:
Issue 1
Issue 2
ground path.
- Door locks

Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Body
Controls - Body Control Module (BCM) Grounds > Page 3552
Disclaimer
Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page
3553
Computers and Control Systems > Body Control Module > Component Information > Diagrams > Body Control Module
(BCM) X2

(BCM) X2 > Page 3556









Computers and Control Systems > Body Control Module > Component Information > Diagrams > Page 3570

Computers and Control Systems > Electronic Throttle Control Module > Component Information > Locations
Engine Compartment
Accumulator
Engine Compartment
Computers and Control Systems > Electronic Throttle Control Module > Component Information > Locations > Page 3574
Accumulator
Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins >
Customer Interest: > 09-08-68-001 > Nov > 09 > Engine Controls - Cruise Control Shuts Off During Use
TECHNICAL
Bulletin No.: 09-08-68-001
Models:
Condition
charge below 80%.
Cause
Correction
Note
experienced.
Disclaimer
Customer Interest: > 08-08-49-010B > Jul > 08 > Computers/Controls - Mutiple Malfunctions/DTC's Set
TECHNICAL
Date: July 22, 2008
Supercede:
Condition
^ No crank.
Correction
possible concern.
Repair
Customer Interest: > 08-08-49-010B > Jul > 08 > Computers/Controls - Mutiple Malfunctions/DTC's Set > Page 3587
as needed.
needed.
block.
above for location.
Disclaimer
Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Engine Control Module: > 04-06-04-054B > Nov > 10 > Aftermarket Parts - Non GM Parts
And Accessories Info
Accessories Info
INFORMATION
Models:
not be honored.

- Propane injection

Technical Service Bulletins for Engine Control Module: > 04-06-04-054B > Nov > 10 > Aftermarket Parts - Non GM Parts
And Accessories Info > Page 3593
Disclaimer
Technical Service Bulletins for Engine Control Module: > 09-08-68-001 > Nov > 09 > Engine Controls - Cruise Control Shuts
Off During Use
During Use
TECHNICAL
Bulletin No.: 09-08-68-001
Models:
Condition
charge below 80%.
Cause
Correction
Note
experienced.
Disclaimer
Technical Service Bulletins for Engine Control Module: > 08-08-49-010B > Jul > 08 > Computers/Controls - Mutiple

TECHNICAL
Date: July 22, 2008
Supercede:
Condition

^ No crank.
Correction
possible concern.
Repair
Technical Service Bulletins for Engine Control Module: > 08-08-49-010B > Jul > 08 > Computers/Controls - Mutiple
Malfunctions/DTC's Set > Page 3602
as needed.
needed.
block.
above for location.
Disclaimer
Other Service Bulletins for Engine Control Module: > 04-06-04-054B > Nov > 10 > Aftermarket Parts - Non GM Parts And
Accessories Info
Accessories Info
INFORMATION
Models:
not be honored.

- Propane injection

Other Service Bulletins for Engine Control Module: > 04-06-04-054B > Nov > 10 > Aftermarket Parts - Non GM Parts And
Accessories Info > Page 3608
Disclaimer
Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page
3609
Engine Compartment
Accumulator
Engine Compartment
Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page
3610
Accumulator
Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Engine Control Module
(ECM) X1

(ECM) X1 > Page 3613


Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Page 3616
converter.
ignition is ON.
Notice:
Removal Procedure
oil life.

Notice) .
Relearning) .
Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations
Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 3623
procedure.
Diagnostic Aids



Connections)

Scan Tool Reference
status parameters.

replace the ECM.
OK.
replace the ECM.
Repair Instructions
Repair Verification
‹› If another DTC is present, refer to Diagnostic Trouble Code (DTC) List - Vehicle (See: Testing
and Inspection/Diagnostic Trouble Code
Descriptions/Diagnostic Trouble Code (DTC) List - Vehicle) and perform the appropriate diagnostic
procedure.
Hummer Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches -
Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Service and Repair
Removal Procedure

conditions:
panel.
Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations
Engine Compartment
Accumulator
Engine Compartment
Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 3633
Accumulator

Removal Procedure

Computers and Control Systems > Battery Current Sensor > Component Information > Diagrams

Computers and Control Systems > Battery Current Sensor > Component Information > Diagrams > Page 3639
Removal Procedure
Computers and Control Systems > Battery Current Sensor > Component Information > Diagrams > Page 3640

Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations
Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 3644

Removal Procedure

Replacement) .
the CMP sensor.

Notice) .

Replacement) .
Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information >
Locations

Removal Procedure

equivalent.

Notice) .

Cooling System) .
Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations
Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3656
Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3657

Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair >
Procedures
(DTC) List - Vehicle (See: Testing and Inspection/Diagnostic Trouble Code Descriptions/Diagnostic
Trouble Code (DTC) List - Vehicle) for the applicable DTC that set.
P0315 (See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/P
Code Charts/P0315) . If any other DTCs set, refer to Diagnostic Trouble Code (DTC) List - Vehicle
(See: Testing and Inspection/Diagnostic Trouble Code Descriptions/Diagnostic Trouble Code
(DTC) List - Vehicle) for the applicable DTC that set.
P0315 is set:
* A ECM replacement


Removal Procedure

Notice) .
Computers and Control Systems > Fuel Level Sensor > Component Information > Locations
Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 3665

Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Level Sensor
Replacement
Removal Procedure
and Repair) .
Tools Required
Removal Procedure
Replacement) .
tank rotation.

be replaced.

Replacement) .
Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations
Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 3674

Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 3675
Removal Procedure
Replacement) .
Replacement) .
Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations
Engine Compartment
Accumulator
Engine Compartment
Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 3679
Accumulator

Removal Procedure

Computers and Control Systems > Knock Sensor > Component Information > Locations
Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 3685
Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Knock Sensor (KS) 1
Knock Sensor (KS) 1

Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Knock Sensor (KS) 1 > Page
3688
Knock Sensor (KS) 2

Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Page 3689
Removal Procedure

Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations
Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 3693

Removal Procedure

Replacement) .
retainer.

Notice) .

Replacement) .
Computers and Control Systems > Oil Pressure Sensor > Component Information > Locations
Computers and Control Systems > Oil Pressure Sensor > Component Information > Locations > Page 3700


Special Tools
Removal Procedure

Replacement) .

Notice) .
Cooling and

Replacement) .
Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Heated Oxygen Sensor (HO2S)
Bank 1 Sensor 1

Bank 1 Sensor 1 > Page 3707



Computers and Control Systems > Oxygen Sensor > Component Information > Service Precautions > Excessive Force and
Oxygen Sensor Notice
Oxygen Sensor Notice > Page 3712
any type.
failure.
Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen
Sensor Replacement - Bank 1 Sensor 1
Tools Required
Removal Procedure

Sensor Replacement - Bank 1 Sensor 1 > Page 3717
Tools Required
Removal Procedure

Tools Required
Removal Procedure

Tools Required
Removal Procedure

Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams

Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations >

Views
Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations >
Automatic Transmission Electronic Component Views > Page 3727

Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page
3728

Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins >
Customer Interest for Vehicle Speed Sensor: > 09-09-41-006 > Oct > 09 > Restraints - Service Airbag Message Displayed
TECHNICAL
Bulletin No.: 09-09-41-006
Models:
Condition
Cause
communications.
Correction

Parts Information
Disclaimer
Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Vehicle Speed Sensor: > 09-09-41-006 > Oct > 09 > Restraints - Service Airbag Message
Displayed
Displayed
TECHNICAL
Bulletin No.: 09-09-41-006
Models:
Condition
Cause
communications.
Correction

Parts Information
Disclaimer
Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Page
3742
3743
3744

Hummer Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor >

Hummer Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position
Switch/Sensor, A/T > Component Information > Locations > Automatic Transmission Electronic Component Views

Views
Switch/Sensor, A/T > Component Information > Locations > Automatic Transmission Electronic Component Views > Page
3752

Switch/Sensor, A/T > Component Information > Locations > Page 3753

Hummer Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor >
Component Information > Technical Service Bulletins > Customer Interest for Vehicle Speed Sensor: > 09-09-41-006 > Oct
> 09 > Restraints - Service Airbag Message Displayed
TECHNICAL
Bulletin No.: 09-09-41-006
Models:
Condition
Cause
communications.
Correction

Parts Information
Disclaimer
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Vehicle Speed Sensor: >
09-09-41-006 > Oct > 09 > Restraints - Service Airbag Message Displayed
Displayed
TECHNICAL
Bulletin No.: 09-09-41-006
Models:
Condition
Cause
communications.
Correction

Parts Information
Disclaimer

Hummer Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Pump
Pulley > Component Information > Technical Service Bulletins > Customer Interest for Air Injection Pump Pulley: >
08-06-01-015 > Jul > 08 > Engine - Drive Belt Chirping Noise
Air Injection Pump Pulley: Customer Interest Engine - Drive Belt Chirping Noise
TECHNICAL
Bulletin No.: 08-06-01-015
Date: July 14, 2008
Saab 9-7X V8

Condition
Cause
noise.
Correction
Notice:
Tip
Parts Information

Pulley > Component Information > Technical Service Bulletins > Customer Interest for Air Injection Pump Pulley: >
08-06-01-015 > Jul > 08 > Engine - Drive Belt Chirping Noise > Page 3780
Disclaimer
Pulley > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Injection Pump
Pulley: > 08-06-01-015 > Jul > 08 > Engine - Drive Belt Chirping Noise
Air Injection Pump Pulley: All Technical Service Bulletins Engine - Drive Belt Chirping Noise
TECHNICAL
Bulletin No.: 08-06-01-015
Date: July 14, 2008
Saab 9-7X V8

Condition
Cause
noise.
Correction
Notice:
Tip
Parts Information

Pulley > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Injection Pump
Pulley: > 08-06-01-015 > Jul > 08 > Engine - Drive Belt Chirping Noise > Page 3786
Disclaimer
Hummer Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Catalyst
Shield > Component Information > Service and Repair
Catalyst Shield: Service and Repair
Catalytic Converter Guard Replacement

Hummer Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Canister Purge Solenoid > Component Information > Locations
Canister Purge Solenoid: Locations
Canister Purge Solenoid > Component Information > Locations > Page 3795
Canister Purge Solenoid: Diagrams
Evaporative Emission (EVAP) Canister Purge Solenoid Valve

Canister Purge Solenoid: Service and Repair
Evaporative Emission Canister Purge Solenoid Valve Replacement
Removal Procedure

Replacement) .
2. Push the evaporative emission (EVAP) pipe quick connect fitting retainer inward.
3. Disconnect the EVAP pipe (2) from the EVAP purge solenoid (1).
4. Disconnect the EVAP purge solenoid electrical connector. 5. Remove the EVAP purge solenoid
mount bolt (2). 6. Remove the EVAP purge solenoid (3) and the insulator (1) from the engine.
1. Install the insulator (1) on the EVAP canister purge valve (3). 2. Install the EVAP canister purge
valve (3) to the engine.

Notice) .
3. Install the EVAP canister purge valve mount bolt (2).
Tighten the EVAP canister purge valve mount bolt to 10.5 N.m (93 lb in).
4. Connect the EVAP pipe (2) to the EVAP canister purge valve (1). 5. Connect the EVAP canister
purge valve electrical connector.

Replacement) .
Evaporative Emission Control Canister > Canister Vent Valve > Component Information > Locations
Canister Vent Valve: Locations
Evaporative Emission Control Canister > Canister Vent Valve > Component Information > Locations > Page 3802
Canister Vent Valve: Diagrams
Evaporative Emission (EVAP) Canister Vent Solenoid Valve

Evaporative Emission Control Canister > Canister Vent Valve > Component Information > Locations > Page 3803
Canister Vent Valve: Service and Repair
Evaporative Emission Canister Vent Solenoid Valve Replacement

Evaporative Emissions Hose > Component Information > Service and Repair > Evaporative Emission Canister Vent
Hose/Pipe Replacement
Evaporative Emissions Hose: Service and Repair Evaporative Emission Canister Vent Hose/Pipe
Replacement
Evaporative Emission Canister Vent Hose/Pipe Replacement
Removal Procedure
Important: When replacing the evaporative emission (EVAP) pipe, always replace the pipe with
original equipment or parts that meet the GM specifications for this part. The replacement pipe
must have the same type of fittings as the original pipe in order to ensure the integrity of the
connection.
1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance) . 2. Clean all the
EVAP pipe connections and the surrounding areas before disconnecting in order to avoid possible
contamination of the EVAP
system.
3. Disconnect the EVAP vent pipe at the EVAP canister. 4. Disconnect the EVAP vent pipe at the
EVAP vent valve. 5. Remove the EVAP vent pipe from the mounting clips (1,3,4, and 5). 6. Cap the
EVAP vent valve and the EVAP canister in order to prevent possible EVAP system contamination.
1. Remove the caps from the EVAP vent valve and the EVAP canister. 2. Connect the EVAP vent
pipe (2) to the EVAP vent valve. 3. Connect the EVAP vent pipe to the EVAP canister. 4. Install the
EVAP vent pipe into the mounting clips (1,3,4, and 5). 5. Lower the vehicle.
Hose/Pipe Replacement > Page 3808
Evaporative Emissions Hose: Service and Repair Evaporative Emission Hoses/Pipes Replacement
- Canister/Fuel Tank
Evaporative Emission Hoses/Pipes Replacement - Canister/Fuel Tank
Removal Procedure
connection.
Caution: Refer to the Battery Disconnect Caution (See: Starting and Charging/Battery/Service
1. Disconnect the negative battery cable. 2. Relieve the fuel system pressure. Refer to Fuel
Pressure Relief (With CH 48027) (See: Fuel Delivery and Air Induction/Fuel Filter/Fuel Pressure
Release/Service and Repair/Fuel Pressure Relief (With CH 48027))Fuel Pressure Relief (Without
CH 48027) (See: Fuel Delivery and Air Induction/Fuel Filter/Fuel Pressure Release/Service and
Repair/Fuel Pressure Relief (Without CH 48027)) .
3. Drain the fuel tank. Refer to Fuel Tank Draining (See: Fuel Delivery and Air Induction/Fuel
Tank/Service and Repair/Procedures) . 4. Raise the vehicle. Refer to Lifting and Jacking the
Vehicle (See: Maintenance) . 5. Clean all fuel and EVAP pipe and hose connections and the
surrounding areas before disconnection in order to avoid possible contamination of the
fuel system.
Replacement) .
7. Remove the rear EVAP pipe from the fuel sender, the fuel tank roll over valve and the fuel tank
clips. 8. Cap the fuel sender EVAP pipe and the fuel tank roll over valve.
1. Remove the caps from the fuel sender EVAP pipe and the fuel tank roll over valve. 2. Connect
the rear EVAP pipe to the fuel sender, the fuel tank roll over valve, and the fuel tank clips.
Replacement) .
4. Lower the vehicle. 5. Refill the fuel tank. 6. Connect the negative battery cable. 7. Tighten the
fuel filler cap. 8. Perform the following procedure in order to inspect for leaks:
1. Turn ON the ignition for 2 seconds. 2. Turn OFF the ignition for 10 seconds. 3. Turn ON the
ignition. 4. Inspect for fuel leaks.
Evaporative Emissions Hose: Service and Repair Evaporative Emission Hoses/Pipes Replacement
- Engine
Evaporative Emission Hoses/Pipes Replacement - Engine
Removal Procedure
connection.
1. Clean the pipe connections and the surrounding areas before disconnecting in order to avoid
possible contamination of the EVAP system. 2. Disconnect the engine compartment EVAP pipe (2)
at the EVAP canister purge solenoid (1). 3. Disconnect the engine compartment EVAP pipe (3) at
the chassis EVAP pipe. 4. Remove the EVAP pipe from the engine. 5. Cap the EVAP canister
purge solenoid and the chassis EVAP pipe in order to prevent possible EVAP system
contamination.
1. Remove the caps from the EVAP canister purge solenoid and the chassis EVAP pipe. 2. Install
the EVAP pipe on the engine. 3. Connect the engine compartment EVAP pipe (3) to the chassis
EVAP pipe. 4. Connect the engine compartment EVAP pipe (2) to the EVAP canister purge
solenoid (1).
Evaporative Emissions Hose: Service and Repair Evaporative Emission Hose/Pipe Replacement -
Chassis
Evaporative Emission Hose/Pipe Replacement - Chassis
Removal Procedure
connection.
1. Clean all the EVAP pipe connections and the surrounding areas before disconnecting the pipes
in order to avoid possible contamination of the
EVAP system.
2. Disconnect the engine compartment EVAP pipe (6) from the chassis EVAP pipe (3). 3. Cap the
engine compartment EVAP pipe. 4. Raise the vehicle. Refer to Lifting and Jacking the Vehicle
(See: Maintenance) . 5. Remove the left hand catalytic converter. Refer to Catalytic Converter
Replacement (See: Catalytic Converter/Service and Repair) . 6. Remove the EVAP pipe from the
bellhousing stud clip (4). 7. Remove the EVAP pipe from the transmission bracket clip.
8. Disconnect the rear EVAP purge pipe from the EVAP canister. 9. Cap the rear EVAP purge pipe.
10. Note the position of the EVAP pipe for aid in installation. 11. Remove the EVAP pipe from the
retaining clips. 12. Remove the EVAP pipe.
1. Install the EVAP pipe into the retaining clips.
2. Remove the cap from the rear EVAP pipe. 3. Connect the rear EVAP purge pipe to the EVAP
canister.
4. Install the EVAP pipe into the transmission bracket clip. 5. Install the EVAP pipe into the
bellhousing stud clip (4). 6. Install the left hand catalytic converter. Refer to Catalytic Converter
Replacement (See: Catalytic Converter/Service and Repair) . 7. Lower the vehicle. 8. Remove the
cap from the engine compartment EVAP pipe. 9. Connect the engine compartment EVAP pipe (6)
to the chassis EVAP pipe (3).
Hummer Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation >
PCV Valve Hose > Component Information > Service and Repair
PCV Valve Hose: Service and Repair
Positive Crankcase Ventilation Hose/Pipe/Tube Replacement
Removal Procedure

Replacement) .
2. Remove the positive crankcase ventilation (PCV) hose from the intake manifold and valve rocker
arm cover.
3. Remove the vent hose from the throttle body and the valve rocker arm cover. 4. Replace the
hose as necessary.
Hummer Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation >
PCV Valve Hose > Component Information > Service and Repair > Page 3816
1. Install the hose as necessary. 2. Install the vent hose to the throttle body and the valve rocker
arm cover.
3. Install the PCV hose to the intake manifold and valve rocker arm cover. 4. Install the engine sight
Cooling and

Replacement) .
Hummer Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System

............................................................................................................................................. 345-414
kPa (50-60 psi)
Information > System Diagnosis > Fuel Pressure Gage Installation and Removal
Tools Required
Installation Procedure Caution: Refer to Gasoline/Gasoline Vapors Caution (See: Fuel/Service

Precautions) .
directions.
Removal Procedure

procedure.



Connections)

Scan Tool Reference

Important:
Instructions.
Important: *
pump module.
Repair Instructions
* Fuel Hose/Pipes Assembly Replacement (See: Fuel Supply Line/Service and Repair/Fuel
Hose/Pipes Assembly Replacement)
* Fuel Injector Replacement (See: Fuel Injector/Service and Repair/Removal and Replacement)
* Fuel Sender Assembly Replacement (See: Fuel Tank/Fuel Gauge Sender/Service and Repair)
Hummer Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release >
System Information > Service and Repair > Fuel Pressure Relief (With CH 48027)
Special Tools
Caution: Refer to Gasoline/Gasoline Vapors Caution (See: Fuel/Service Precautions) .

System Information > Service and Repair > Fuel Pressure Relief (With CH 48027) > Page 3833
(See: Fuel/Service Precautions) .
the fuel fill cap.
Tools Required

Precautions) .
directions.
Removal Procedure

Hummer Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System

Hummer Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position
Removal Procedure

conditions:
panel.
Hummer Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air
Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair
Removal Procedure
outlet duct.
Hummer Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter
Element > Component Information > Service and Repair
Removal Procedure
Hummer Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor >
Engine Compartment
Accumulator
Engine Compartment
Accumulator

Removal Procedure
1. Remove air intake resonator. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Air
Cleaner Housing/Air Cleaner Fresh Air
Duct/Hose/Service and Repair) .
air intake resonator. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Air Cleaner
Housing/Air Cleaner Fresh Air

Hummer Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information
> Technical Service Bulletins > Fuel System - TOP TIER Detergent Gasoline
Fuel: Technical Service Bulletins Fuel System - TOP TIER Detergent Gasoline
INFORMATION
Subject: TOP TIER Detergent Gasoline (Deposits, Fuel Economy, No Start, Power, Performance,
Stall Concerns) - Canada ONLY
Models: 2009 and Prior GM Passenger Cars and Trucks (Canada Only) 2009 and Prior Saab
Vehicles (Canada Only) 2009 and Prior Saturn Vehicles (Canada Only) 2003-2009 HUMMER H2
(Canada Only) 2006-2009 HUMMER H3 (Canada Only)
Supercede:
05-06-04-022D (Section 06 - Engine/Propulsion System). In the U.S., refer to Corporate Bulletin
Number 04-06-04-047H.
A new class of fuel called TOP TIER Detergent Gasoline is appearing at retail stations of some fuel
marketers. This gasoline meets detergency standards developed by six automotive companies. All
vehicles will benefit from using TOP TIER Detergent Gasoline over gasoline containing the "Lowest
Additive Concentration" recommended by the Canadian General Standards Board (CGSB). Those
vehicles that have experienced deposit related concerns may especially benefit from use of TOP
TIER Detergent Gasoline.
Top Tier Fuel Availability
Chevron was the first to offer TOP TIER Detergent Gasoline in Canada. Shell became the first
national gasoline retailer to offer TOP TIER Detergent Gasoline across Canada. Petro-Canada
began offering TOP TIER Detergent Gasoline nationally as of October 1, 2006. Sunoco began
offering TOP TIER Detergent Gasoline in March of 2007.
Gasoline Brands That Currently Meet TOP TIER Detergent Gasoline Standards
The following gasoline brands meet the TOP TIER Detergent Gasoline Standards in all octane
grades:
^ Chevron Canada (markets in British Columbia and western Alberta)
^ Shell Canada (nationally)
^ Petro-Canada (nationally)
^ Sunoco-Canada (Ontario)
What is TOP TIER Detergent Gasoline?
TOP TIER Detergent Gasoline is a new class of gasoline with enhanced detergency and no
metallic additives. It meets new, voluntary deposit control standards developed by six automotive
companies that exceed the detergent recommendations of Canadian standards and does not
contain metallic additives, which can damage vehicle emission control components.
> Technical Service Bulletins > Fuel System - TOP TIER Detergent Gasoline > Page 3860
Where Can TOP TIER Detergent Gasoline Be Purchased? Detergent Gasoline Be Purchased?
The TOP TIER program began in the U.S. and Canada on May 3, 2004. Some fuel marketers have
already joined and introduced TOP TIER Detergent Gasoline. This is a voluntary program and not
all fuel marketers will offer this product. Once fuel marketers make public announcements, they will
appear on a list of brands that meet the TOP TIER standards.
Who developed TOP TIER Detergent Gasoline standards?
TOP TIER Detergent Gasoline standards were developed by six automotive companies: BMW,
General Motors, Honda, Toyota, Volkswagen and Audi.
Why was TOP TIER Detergent Gasoline developed?
TOP TIER Detergent Gasoline was developed to increase the level of detergent additive in
gasoline. In the U.S., government regulations require that all gasoline sold in the U.S. contain a
detergent additive. However, the requirement is minimal and in many cases, is not sufficient to
keep engines clean. In Canada, gasoline standards recommend adherence to U.S. detergency
requirements but do not require it. In fact, many brands of gasoline in Canada do not contain any
detergent additive. In order to meet TOP TIER Detergent Gasoline standards, a higher level of
detergent is needed than what is required or recommended, and no metallic additives are allowed.
Also, TOP TIER was developed to give fuel marketers the opportunity to differentiate their product.
Why did the six automotive companies join together to develop TOP TIER?
All six corporations recognized the benefits to both the vehicle and the consumer. Also, joining
together emphasized that low detergency and the intentional addition of metallic additives is an
issue of concern to several automotive companies.
What are the benefits of TOP TIER Detergent Gasoline?
TOP TIER Detergent Gasoline will help keep engines cleaner than gasoline containing the "Lowest
Additive Concentration" recommended by Canadian standards. Clean engines help provide optimal
fuel economy and engine performance, and also provide reduced emissions. Also, the use of TOP
TIER Detergent Gasoline will help reduce deposit related concerns.
Who should use TOP TIER Detergent Gasoline?
All vehicles will benefit from using TOP TIER Detergent Gasoline over gasoline containing the
"Lowest Additive Concentration" recommended by Canadian standards. Those vehicles that have
experienced deposit related concerns may especially benefit from use of TOP TIER Detergent
Gasoline. More information on TOP TIER Detergent Gasoline can be found at
http://www.toptiergas.com/.
Disclaimer
> Technical Service Bulletins > Technical Service Bulletins: > 05-06-04-022E > Aug > 08 > Fuel System - TOP TIER
Detergent Gasoline
Fuel: Technical Service Bulletins Fuel System - TOP TIER Detergent Gasoline
INFORMATION
Stall Concerns) - Canada ONLY
Models: 2009 and Prior GM Passenger Cars and Trucks (Canada Only) 2009 and Prior Saab
Vehicles (Canada Only) 2009 and Prior Saturn Vehicles (Canada Only) 2003-2009 HUMMER H2
(Canada Only) 2006-2009 HUMMER H3 (Canada Only)
Supercede:
05-06-04-022D (Section 06 - Engine/Propulsion System). In the U.S., refer to Corporate Bulletin
Number 04-06-04-047H.
Additive Concentration" recommended by the Canadian General Standards Board (CGSB). Those
vehicles that have experienced deposit related concerns may especially benefit from use of TOP
TIER Detergent Gasoline.
Top Tier Fuel Availability
Chevron was the first to offer TOP TIER Detergent Gasoline in Canada. Shell became the first
national gasoline retailer to offer TOP TIER Detergent Gasoline across Canada. Petro-Canada
began offering TOP TIER Detergent Gasoline nationally as of October 1, 2006. Sunoco began
offering TOP TIER Detergent Gasoline in March of 2007.
The following gasoline brands meet the TOP TIER Detergent Gasoline Standards in all octane
grades:
^ Chevron Canada (markets in British Columbia and western Alberta)
^ Shell Canada (nationally)
^ Petro-Canada (nationally)
^ Sunoco-Canada (Ontario)
TOP TIER Detergent Gasoline is a new class of gasoline with enhanced detergency and no
metallic additives. It meets new, voluntary deposit control standards developed by six automotive
companies that exceed the detergent recommendations of Canadian standards and does not
contain metallic additives, which can damage vehicle emission control components.
> Technical Service Bulletins > Technical Service Bulletins: > 05-06-04-022E > Aug > 08 > Fuel System - TOP TIER
Detergent Gasoline > Page 3866
Where Can TOP TIER Detergent Gasoline Be Purchased? Detergent Gasoline Be Purchased?
The TOP TIER program began in the U.S. and Canada on May 3, 2004. Some fuel marketers have
already joined and introduced TOP TIER Detergent Gasoline. This is a voluntary program and not
all fuel marketers will offer this product. Once fuel marketers make public announcements, they will
appear on a list of brands that meet the TOP TIER standards.
TOP TIER Detergent Gasoline standards were developed by six automotive companies: BMW,
General Motors, Honda, Toyota, Volkswagen and Audi.
gasoline. In the U.S., government regulations require that all gasoline sold in the U.S. contain a
detergent additive. However, the requirement is minimal and in many cases, is not sufficient to
keep engines clean. In Canada, gasoline standards recommend adherence to U.S. detergency
requirements but do not require it. In fact, many brands of gasoline in Canada do not contain any
detergent additive. In order to meet TOP TIER Detergent Gasoline standards, a higher level of
detergent is needed than what is required or recommended, and no metallic additives are allowed.
Also, TOP TIER was developed to give fuel marketers the opportunity to differentiate their product.
All six corporations recognized the benefits to both the vehicle and the consumer. Also, joining
together emphasized that low detergency and the intentional addition of metallic additives is an
issue of concern to several automotive companies.
Additive Concentration" recommended by Canadian standards. Clean engines help provide optimal
fuel economy and engine performance, and also provide reduced emissions. Also, the use of TOP
TIER Detergent Gasoline will help reduce deposit related concerns.
Who should use TOP TIER Detergent Gasoline?
All vehicles will benefit from using TOP TIER Detergent Gasoline over gasoline containing the
"Lowest Additive Concentration" recommended by Canadian standards. Those vehicles that have
experienced deposit related concerns may especially benefit from use of TOP TIER Detergent
Gasoline. More information on TOP TIER Detergent Gasoline can be found at
http://www.toptiergas.com/.
Disclaimer
> Technical Service Bulletins > Technical Service Bulletins: > 04-06-04-047H > Jun > 08 > Fuel System - TOP TIER
Detergent Gasoline Information
Fuel: Technical Service Bulletins Fuel System - TOP TIER Detergent Gasoline Information
INFORMATION
Bulletin No.: 04-06-04-047H
Date: June 24, 2008
Stall Concerns) - U.S. Only
Models: 2009 and Prior GM Passenger Cars and Trucks (including Saturn) (U.S. Only) 2003-2009
HUMMER H2 (U.S. Only) 2006-2009 HUMMER H3 (U.S. Only) 2005-2009 Saab 9-7X (U.S. Only)
Supercede:
This bulletin is being revised to add model years and additional sources to the Top Tier Fuel
Retailers list. Please discard Corporate Bulletin Number 04-06-04-047G (Section 06 -
Engine/Propulsion System). In Canada, refer to Corporate Bulletin Number 05-06-04-022D.
Additive Concentration" set by the EPA. Those vehicles that have experienced deposit related
concerns may especially benefit from the use of TOP TIER Detergent Gasoline.
Intake valve: 10,000 miles with TOP TIER Detergent Gasoline
Intake valve: 10,000 miles with Legal Minimum additive
As of November 15, 2006, all grades of the gasoline brands shown above meet the TOP TIER
Detergent Gasoline Standards.
> Technical Service Bulletins > Technical Service Bulletins: > 04-06-04-047H > Jun > 08 > Fuel System - TOP TIER
Detergent Gasoline Information > Page 3871
TOP TIER Detergent Gasoline is a new class of gasoline with enhanced detergency. It meets new
voluntary deposit control standards developed by six automotive companies that exceed the
detergent requirements imposed by the EPA.
Where Can TOP TIER Detergent Gasoline Be Purchased?
The TOP TIER program began on May 3, 2004, and many fuel marketers have joined the program
and have introduced TOP TIER Detergent Gasoline. This is a voluntary program and not all fuel
marketers will offer this product. Once fuel marketers make public announcements they will appear
on a list of brands that meet the TOP TIER standards.
Where Can I find the Latest Information on TOP TIER Fuel and Retailers?
On the web please visit www.toptiergas.com for additional information and updated retailer lists.
TOP TIER Detergent Gasoline standards were developed by six automotive companies: Audi,
BMW, General Motors, Honda, Toyota and Volkswagen.
gasoline. The EPA requires that all gasoline sold in the U.S. contain a detergent additive. However,
the requirement is minimal and in many cases, is not sufficient to keep engines clean. In order to
meet TOP TIER Detergent Gasoline standards, a higher level of detergent is needed than what is
required by the EPA. Also, TOP TIER was developed to give fuel marketers the opportunity to
differentiate their product.
All six corporations recognized the benefits to both the vehicle and the consumer. Also joining
together emphasized that low detergency is an issue of concern to several automotive companies.
Additive Concentration" set by the EPA. Clean engines help provide optimal fuel economy and
performance and reduced emissions. Also use of TOP TIER Detergent Gasoline will help reduce
deposit related concerns.
Disclaimer
> Technical Service Bulletins > Technical Service Bulletins: > 05-00-89-072B > Jun > 08 > Engine/Fuel System - Additive
Information
Fuel: Technical Service Bulletins Engine/Fuel System - Additive Information
INFORMATION
Date: June 17, 2008
Attention:
Supercede:
be cost effective.
Notice:
Warranty.
Notice:
Information > Page 3876
# 88861012).
mile.
Notice:
Important:
Gasoline.
Important:
Notice:
Important:
Warranty.
the best in.
Idling wastes fuel.
Disclaimer
> Technical Service Bulletins > Technical Service Bulletins: > 05-00-89-078B > Feb > 08 > Fuel System - GM Fuel Systems
Treatment Plus(R)
Fuel: Technical Service Bulletins Fuel System - GM Fuel Systems Treatment Plus(R)
INFORMATION
Subject: GM Fuel System Treatment PLUS Fuel Sending Unit Corrosion and Fuel System Deposits
HUMMER H2, H3 2005-2008 Saab 9-7X
Supercede:
05-00-89-078A (Section 00 - General Information).
The GM Fuel System Treatment PLUS is not recommended for use with diesel fuel. The GM Fuel
System Treatment PLUS is specially formulated for use in gasoline and/or E85 fuels.
GM Fuel System Treatment PLUS
GM Fuel System Treatment PLUS P/N 88861011 (for U.S. ACDelco(R) use 88861013) (in Canada
88861012) is now available for use in gasoline engines.
Added Benefits and Uses
The PLUS portion of GM Fuel System Treatment PLUS is the addition of a filmer additive that
when used regularly can protect fuel system sending units from the corrosive effects of certain
sulfur contaminants found in some of todays gasoline.
Sulfur contamination can disrupt electrical continuity of certain fuel sending units and lead to erratic
or false fuel gauge readings. With scheduled usage GM Fuel System Treatment PLUS protects
against the effects of harmful sulfurs in gasoline.
The Four Benefits
Just pour in one bottle of the GM Fuel System Treatment PLUS into the fuel tank when refueling
around each oil change interval:
Cleans - Sulfur corrosion from fuel gauge sending units.

Prevents - Harmful sulfur components from attacking sensitive fuel system electronics.
Protects - By coating metallic surfaces of the fuel system.
Removes - Engine deposits left from use of poor quality fuels.
Parts Information
> Technical Service Bulletins > Technical Service Bulletins: > 05-00-89-078B > Feb > 08 > Fuel System - GM Fuel Systems
Treatment Plus(R) > Page 3882
Disclaimer
> Technical Service Bulletins > Technical Service Bulletins: > 06-06-04-035A > Feb > 08 > Fuel System - E85 Fuel Usage
Information
Fuel: Technical Service Bulletins Fuel System - E85 Fuel Usage Information
INFORMATION
Subject: Use of E85 Fuels in Vehicles Not Certified by GM as being FlexFuel Compatible /
Aftermarket Conversion of Vehicles to Operate on E85 Fuels
Models: 2008 and Prior GM Passenger Cars and Trucks NOT FlexFuel (E85) Compatible
(including Saturn) 2008 and Prior HUMMER H2, H3 2005-2008 Saab 9-7X
Supercede:
Aftermarket Conversions of Vehicles to Use E85 Fuels
General Motors has become aware of several companies that claim to be able to convert vehicles
equipped with gasoline engines to be compatible with E85 Fuels.
Vehicles certified by GM as being FlexFuel (E85) compatible contain numerous calibration and
component differences that are not conducive to an aftermarket retrofit.
General Motors DOES NOT support or endorse conversions that may alter the emissions and
related emissions components of its vehicles.
Repairs that may result from changes to GM built components and repairs that result from the use
of improper fuel such as the use of gasoline containing more than 10% Ethanol in a non-FlexFuel
certified vehicle are not covered under the terms of the New Vehicle Warranty.
E85 Compatible Vehicles
The only E85 compatible vehicles produced by General Motors are shown above.
> Technical Service Bulletins > Technical Service Bulletins: > 06-06-04-035A > Feb > 08 > Fuel System - E85 Fuel Usage
Disclaimer
> Technical Service Bulletins > Technical Service Bulletins: > 05-06-04-035C > Jul > 07 > Fuel System - E85 Fuel Usage
Precaution
Fuel: Technical Service Bulletins Fuel System - E85 Fuel Usage Precaution
Date: July 30, 2007
INFORMATION
Subject: Usage of E85 Fuels in GM Vehicles
Models: 1997-2008 GM Passenger Cars and Trucks (including Saturn) 2003-2008 HUMMER H2
2006-2008 HUMMER H3 1997-2008 Isuzu NPR Commercial Medium Duty Trucks 2005-2008
Saab 9-7X
Supercede:
This bulletin is being revised to add the 2008 model year and additional engines with E85
capability. Please discard Corporate Bulletin Number 05-06-04-035B (Section 06 -
Engine/Propulsion System).
Customer Interest in E85 Fuel
As the retail price of gasoline increases, some locations in the country are seeing price differentials
between regular gasoline and E85 where E85 is selling for substantially less than regular grade
gasoline. One result of this is that some customers have inquired if they are able to use E85 fuel in
non-E85 compatible vehicles.
Only vehicles designated for use with E85 should use E85 blended fuel.
E85 compatibility is designated for vehicles that are certified to run on up to 85% ethanol and 15%
ethanol.
Use of fuel containing greater than 10% ethanol in non-E85 designated vehicles can cause
driveability issues, service engine soon indicators as well as increased fuel system corrosion.
Using E85 Fuels in Non-Compatible Vehicles
General Motors is aware of an increased number of cases where customers have fueled
non-FlexFuel designated vehicles with E85. Fueling non-FlexFuel designated vehicles with E85, or
with fuels where the concentration of ethanol exceeds the ASTM specification of 10%, will result in
one or more of the following conditions:
Lean Driveability concerns such as hesitations, sags and / or possible stalling.
SES lights due to OBD codes.
Fuel Trim codes P0171 and / or P0174.
Misfire codes (P0300).
Various 02 sensor codes.
Disabled traction control or Stability System disabled messages.
Harsh / Firm transmission shifts.
Fuel system and / or engine mechanical component degradation.
If the dealer suspects that a non-FlexFuel designated vehicle brought in for service has been
fueled with E85, the fuel in the vehicle's tank should be checked for alcohol content with tool J
44175. If the alcohol content exceeds 10% the fuel should be drained and the vehicle refilled with
gasoline - preferably one of the Top Tier brands.
> Technical Service Bulletins > Technical Service Bulletins: > 05-06-04-035C > Jul > 07 > Fuel System - E85 Fuel Usage
Precaution > Page 3892
Repairs to non-FlexFuel vehicles that have been fueled with E85 are not covered under the terms
of the New Vehicle Warranty.
A complete list of GM's FlexFuel vehicles is shown, or at www.livegreengoyellow.com.
The only E85 compatible vehicles produced by General Motors are:
Only vehicles that are listed in the E85 Compatible Vehicles section of this bulletin and/or
www.livegreengoyellow.com are E85 compatible.
All other gasoline and diesel engines are NOT E85 compatible.
Repairs to non-FlexFuel vehicles that have been fueled with E85 are not covered under the terms
of the New Vehicle Warranty.
Disclaimer
> Technical Service Bulletins > Technical Service Bulletins: > Page 3893
Fuel: Technical Service Bulletins Engine/Fuel System - Additive Information
INFORMATION
Date: June 17, 2008
Attention:
Supercede:
be cost effective.
Notice:
Warranty.
Notice:
# 88861012).
mile.
Notice:
Important:
Gasoline.
Important:
Notice:
Important:
Warranty.
the best in.
Idling wastes fuel.
Disclaimer
> Technical Service Bulletins > All Other Service Bulletins for Fuel: > 08-06-01-008A > Jul > 09 > Engine - Various Drive
Belt Symptoms
INFORMATION
Date: July 27, 2009
Models:
Background
from $160 - $200.
- Drive Belt Noise
Instructions
Caution

Belt Symptoms > Page 3901
engine.
alignment.
Tool Information
Belt Symptoms > Page 3902
Disclaimer
> Technical Service Bulletins > All Other Service Bulletins for Fuel: > 08-06-01-015 > Jul > 08 > Engine - Drive Belt Chirping
Noise
TECHNICAL
Bulletin No.: 08-06-01-015
Date: July 14, 2008
Saab 9-7X V8

Condition
Cause
noise.
Correction
Notice:
Tip
Parts Information

> Technical Service Bulletins > All Other Service Bulletins for Fuel: > 08-06-01-015 > Jul > 08 > Engine - Drive Belt Chirping
Noise > Page 3907
Disclaimer
> Technical Service Bulletins > All Other Service Bulletins for Fuel: > Page 3908
Fuel: Technical Service Bulletins Fuel System - TOP TIER Detergent Gasoline Information
INFORMATION
Bulletin No.: 04-06-04-047H
Date: June 24, 2008
Stall Concerns) - U.S. Only
Models: 2009 and Prior GM Passenger Cars and Trucks (including Saturn) (U.S. Only) 2003-2009
HUMMER H2 (U.S. Only) 2006-2009 HUMMER H3 (U.S. Only) 2005-2009 Saab 9-7X (U.S. Only)
Supercede:
This bulletin is being revised to add model years and additional sources to the Top Tier Fuel
Retailers list. Please discard Corporate Bulletin Number 04-06-04-047G (Section 06 -
Engine/Propulsion System). In Canada, refer to Corporate Bulletin Number 05-06-04-022D.
Additive Concentration" set by the EPA. Those vehicles that have experienced deposit related
concerns may especially benefit from the use of TOP TIER Detergent Gasoline.
Intake valve: 10,000 miles with TOP TIER Detergent Gasoline
Intake valve: 10,000 miles with Legal Minimum additive
As of November 15, 2006, all grades of the gasoline brands shown above meet the TOP TIER
Detergent Gasoline Standards.
TOP TIER Detergent Gasoline is a new class of gasoline with enhanced detergency. It meets new
voluntary deposit control standards developed by six automotive companies that exceed the
detergent requirements imposed by the EPA.
Where Can TOP TIER Detergent Gasoline Be Purchased?
The TOP TIER program began on May 3, 2004, and many fuel marketers have joined the program
and have introduced TOP TIER Detergent Gasoline. This is a voluntary program and not all fuel
marketers will offer this product. Once fuel marketers make public announcements they will appear
on a list of brands that meet the TOP TIER standards.
Where Can I find the Latest Information on TOP TIER Fuel and Retailers?
On the web please visit www.toptiergas.com for additional information and updated retailer lists.
TOP TIER Detergent Gasoline standards were developed by six automotive companies: Audi,
BMW, General Motors, Honda, Toyota and Volkswagen.
gasoline. The EPA requires that all gasoline sold in the U.S. contain a detergent additive. However,
the requirement is minimal and in many cases, is not sufficient to keep engines clean. In order to
meet TOP TIER Detergent Gasoline standards, a higher level of detergent is needed than what is
required by the EPA. Also, TOP TIER was developed to give fuel marketers the opportunity to
differentiate their product.
All six corporations recognized the benefits to both the vehicle and the consumer. Also joining
together emphasized that low detergency is an issue of concern to several automotive companies.
Additive Concentration" set by the EPA. Clean engines help provide optimal fuel economy and
performance and reduced emissions. Also use of TOP TIER Detergent Gasoline will help reduce
deposit related concerns.
Disclaimer
Fuel: Technical Service Bulletins Fuel System - E85 Fuel Usage Information
INFORMATION
Subject: Use of E85 Fuels in Vehicles Not Certified by GM as being FlexFuel Compatible /
Aftermarket Conversion of Vehicles to Operate on E85 Fuels
Models: 2008 and Prior GM Passenger Cars and Trucks NOT FlexFuel (E85) Compatible
(including Saturn) 2008 and Prior HUMMER H2, H3 2005-2008 Saab 9-7X
Supercede:
Aftermarket Conversions of Vehicles to Use E85 Fuels
General Motors has become aware of several companies that claim to be able to convert vehicles
equipped with gasoline engines to be compatible with E85 Fuels.
Vehicles certified by GM as being FlexFuel (E85) compatible contain numerous calibration and
component differences that are not conducive to an aftermarket retrofit.
General Motors DOES NOT support or endorse conversions that may alter the emissions and
related emissions components of its vehicles.
Repairs that may result from changes to GM built components and repairs that result from the use
of improper fuel such as the use of gasoline containing more than 10% Ethanol in a non-FlexFuel
certified vehicle are not covered under the terms of the New Vehicle Warranty.
E85 Compatible Vehicles
The only E85 compatible vehicles produced by General Motors are shown above.
Disclaimer
> Technical Service Bulletins > Page 3912
Fuel: Specifications
GASOLINE OCTANE Use regular unleaded gasoline with a posted octane rating of 87 or higher. If
the octane rating is less than 87, you may notice an audible knocking noise when you drive,
commonly referred to as spark knock. If this occurs, use a gasoline rated at 87 octane or higher as
soon as possible. If you are using gasoline rated at 87 octane or higher and you hear heavy
knocking, your engine needs service.
GASOLINE SPECIFICATIONS At a minimum, gasoline should meet ASTM specification D 4814 in

the United States or CAN/CGSB-3.5 in Canada. Some gasolines may contain an octane-enhancing
additive called methylcyclopentadienyl manganese tricarbonyl (MMT). General Motors
recommends against the use of gasolines containing MMT.
CALIFORNIA FUEL If your vehicle is certified to meet California Emission Standards, it is designed
to operate on fuels that meet California specifications. See the underhood emission control label. If
this fuel is not available in states adopting California emissions standards, your vehicle will operate
satisfactorily on fuels meeting federal specifications, but emission control system performance may
be affected. The malfunction indicator lamp may turn on and your vehicle may fail a smog-check
test. If it is determined that the condition is caused by the type of fuel used, repairs may not be
covered by your warranty.
ADDITIVES To provide cleaner air, all gasolines in the United States are now required to contain
additives that will help prevent engine and fuel system deposits from forming, allowing your
emission control system to work properly. In most cases, you should not have to add anything to
your fuel. However, some gasolines contain only the minimum amount of additive required to meet
U.S. Environmental Protection Agency regulations. To help keep fuel injectors and intake valves
clean, or if your vehicle experiences problems due to dirty injectors or valves, look for gasoline that
is advertised as TOP TIER Detergent Gasoline. Also, your dealer has additives that will help
correct and prevent most deposit-related problems.
Gasolines containing oxygenates, such as ethers and ethanol, and reformulated gasolines may be
available in your area. General Motors recommends that you use these gasolines if they comply
with the specifications described earlier. However, E85 (85% ethanol) and other fuels containing
more than 10% ethanol must not be used in vehicles that were not designed for those fuels.
NOTICE: Your vehicle was not designed for fuel that contains methanol. Do not use fuel containing
methanol. It can corrode metal parts in the fuel system and also damage plastic and rubber parts.
That damage would not be covered under your warranty.
Some gasolines that are not reformulated for low emissions may contain an octane-enhancing
additive called methylcyclopentadienyl manganese tricarbonyl (MMT); ask the attendant where you
buy gasoline whether the fuel contains MMT. General Motors recommends against the use of such
gasolines. Fuels containing MMT can reduce the life of spark plugs and the performance of the
emission control system may be affected. The malfunction indicator lamp may turn on. If this
occurs, return to your dealer for service.
NOTICE: Your vehicle was not designed for fuel that contains methanol. Do not use fuel containing
methanol. It can corrode metal parts in your fuel system and also damage the plastic and rubber
parts. That damage would not be covered under your warranty.
Some gasolines that are not reformulated for low emissions may contain an octane-enhancing
additive called methylcyclopentadienyl manganese tricarbonyl (MMT); ask the attendant where you
buy gasoline whether the fuel contains MMT. General Motors does not recommend the use of such
gasolines. Fuels containing MMT can reduce the life of spark plugs and the performance of the
emission control system may be affected. The malfunction indicator lamp may turn on.
FUELS IN FOREIGN COUNTRIES If you plan on driving in another country outside the United
States or Canada, the proper fuel may be hard to find. Never use leaded gasoline or any other fuel
not recommended in the previous text on fuel. Costly repairs caused by use of improper fuel would
not be covered by your warranty. To check the fuel availability, ask an auto club, or contact a major
oil company that does business in the country where you will be driving.
> Technical Service Bulletins > Page 3913
Fuel: Service Precautions
Gasoline/Gasoline Vapors Caution
Caution: Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition source
is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of
fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby.
> Testing and Inspection > Alcohol/Contaminants-in-Fuel Diagnosis (Without Special Tool)
Fuel: Testing and Inspection Alcohol/Contaminants-in-Fuel Diagnosis (Without Special Tool)
Alcohol/Contaminants-in-Fuel Diagnosis (without Special Tool)
Description
Water contamination in the fuel system may cause driveability conditions such as hesitation,
stalling, no start, or misfires in one or more cylinders. Water may collect near a single fuel injector
at the lowest point in the fuel injection system, and cause a misfire in that cylinder. If the fuel
system is contaminated with water, inspect the fuel system components for rust, or deterioration.
Alcohol concentrations of 10 percent or greater in fuel can be detrimental to fuel system

components. Alcohol contamination may cause fuel system corrosion, deterioration of rubber
components, and subsequent fuel filter restriction. Some types of alcohol are more detrimental to
fuel system components than others. Ethanol is commonly used in gasoline, but in concentrations
of no more than 10 percent. Some fuels, such as E85, contain a very high percentage of ethanol.
Fuel with more than 10 percent ethanol may cause driveability conditions such as hesitation, lack
of power, stalling, or no start.
Alcohol in Fuel Testing Procedure
The fuel sample should be drawn from the bottom of the tank so that any water present in the tank
will be detected. The sample should be bright and clear. If alcohol contamination is suspected then
use the following procedure to test the fuel quality.
1. Using a 100 ml (3.4 oz) specified cylinder with 1 ml (0.03 oz) graduation marks, fill the cylinder
with fuel to the 90 ml (3.04 oz) mark. 2. Add 10 ml (0.34 oz) of water in order to bring the total fluid
volume to 100 ml (3.4 oz) and install a stopper. 3. Shake the cylinder vigorously for 10-15 seconds.
4. Carefully loosen the stopper in order to release the pressure. 5. Re-install the stopper and shake
the cylinder vigorously again for 10-15 seconds. 6. Put the cylinder on a level surface for
approximately 5 minutes in order to allow adequate liquid separation.
If alcohol is present in the fuel, the volume of the lower layer, which would now contain both alcohol
and water, will be more than 10 ml (0.34 oz). For example, if the volume of the lower layer is
increased to 15 ml (0.51 oz), this indicates at least 5 percent alcohol in the fuel. The actual amount
of alcohol may be somewhat more because this procedure does not extract all of the alcohol from
the fuel.
Particulate Contaminants in Fuel Testing Procedure
The fuel sample should be drawn from the bottom of the tank so that any water present in the tank
will be detected. The sample should be bright and clear. If the sample appears cloudy, or
contaminated with water, as indicated by a water layer at the bottom of the sample, use the
following procedure to diagnose the fuel.
1. Using an approved fuel container, draw approximately 0.5 liter (0.13 gal) of fuel. 2. Place the
cylinder on a level surface for approximately 5 minutes in order to allow settling of the particulate
contamination.
Particulate contamination will show up in various shapes and colors. Sand will typically be identified
by a white or light brown crystals. Rubber will appear as black and irregular particles. If particles
are found clean the entire fuel system thoroughly.
> Testing and Inspection > Alcohol/Contaminants-in-Fuel Diagnosis (Without Special Tool) > Page 3916
Fuel: Testing and Inspection Alcohol/Contaminants-in-Fuel Diagnosis (With Special Tool)
Alcohol/Contaminants-in-Fuel Diagnosis (with Special Tool)
Description
Water contamination in the fuel system may cause driveability conditions such as hesitation,
stalling, no start, or misfires in one or more cylinders. Water may collect near a single fuel injector
at the lowest point in the fuel injection system, and cause a misfire in that cylinder. If the fuel
system is contaminated with water, inspect the fuel system components for rust or deterioration.
Ethanol concentrations of greater than 10 percent can cause driveability conditions and fuel system
deterioration. Fuel with more than 10 percent ethanol could result in driveability conditions such as
hesitation, lack of power, stalling , or no start. Excessive concentrations of ethanol used in vehicles
not designed for it may cause fuel system corrosion, deterioration of rubber components, and fuel
filter restriction.
Test Procedure
1. Test the fuel composition using J 44175 Fuel Composition Tester and J44175-3 Instruction
Manual. 2. Subtract 50 from the reading on the DMM in order to obtain the percentage of alcohol in
the fuel sample. Refer to the examples in the Fuel
Composition Test Examples table.
3. If the fuel sample contains more than 15 percent ethanol, add fresh, regular gasoline to the
vehicle's fuel tank . 4. Test the fuel composition. 5. If testing shows the ethanol percentage is still
more than 15 percent, replace the fuel in the vehicle.
Hummer Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure
Release > System Information > Service and Repair > Fuel Pressure Relief (With CH 48027)
Special Tools
Caution: Refer to Gasoline/Gasoline Vapors Caution (See: Fuel/Service Precautions) .

(See: Fuel/Service Precautions) .
the fuel fill cap.
Tools Required

Precautions) .
directions.
Removal Procedure

Hummer Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Technical Service Bulletins > Customer Interest for Fuel Injector: > 03-06-04-030G > Apr > 09 > Fuel System -
Driveability Issues/MIL ON/Multiple DTC's
Fuel Injector: Customer Interest Fuel System - Driveability Issues/MIL ON/Multiple DTC's
TECHNICAL
Subject:
Various Driveability Symptoms Due to Clogged Fuel Injectors, MIL/SES DTCs P0171, P0172,
P0174, P0300, P1174, P1175 (Clean Fuel Injectors and/or Perform Injector Test With AFIT
CH-47976)
Models:
2005-2009 GM Passenger Cars and Light Duty Trucks 2005-2009 HUMMER H2 2006-2009
HUMMER H3 2005-2009 Saab 9-7X Equipped with Engine RPOs listed in the Table Below and
MULTEC(R) 2 Fuel Injectors
Attention:
GM does not support cleaning injectors on any engines that are not listed in this bulletin. Engines
other than the ones listed in this bulletin that diagnosis indicates having restricted injectors should
have those injectors replaced.
Supercede: This bulletin is being revised to update the model year to 2009 and to provide
applicable engine RPO table. Please discard Corporate Bulletin Number 03-06-04-030F (Section
06 - Engine/Propulsion System).
Condition
Some customers may comment on any of the following various driveability symptoms:
- Extended Crank Time
- Hard to Start
- MIL/SES Illuminated with DTCs
- Hesitation
- Lack of Power
- Surge or Chuggle
- Rough Idle
- Light or Intermittent Misfire
Cause
Due to various factors, the fuel injectors may become restricted. Extensive testing has
demonstrated that fuel related issues are the cause of clogged injectors. At this point, no specific
fuel, fuel constituent, or engine condition has been identified as causing the restriction. The
restriction causes the engine to operate at a lean air fuel ratio. This may either trigger the MIL to
illuminate or the engine to develop various driveability symptoms.
Correction
Fuel injector restrictions, deposits can be cleaned on the vehicle using the following procedure.
Under NO circumstances should this procedure be modified, changed or shortened. As a long term
solution, and to prevent reoccurrence, customers should be encouraged to use Top Tier Detergent
Gasoline. For further information on Top Tier detergent gasoline and fuel retailers, please refer to
the following Corporate Bulletin Numbers:
- 04-06-04-047G (U.S. Only)

Driveability Issues/MIL ON/Multiple DTC's > Page 3934
- 05-06-04-022D (Canada ONLY)
Notice
GM UPPER ENGINE AND FUEL INJECTOR CLEANER is the only injector cleaning agent
approved for use with General Motors fuel system components. Other injector cleaners may cause
damage to plastics, plated metals or bearings. General Motors has completed extensive laboratory
testing of GM Upper Engine and Fuel Injector Cleaner, and can assure its compatibility with
General Motors fuel system components, as long as the cleaning procedure is followed correctly.
Injector Cleaning Procedure
The following tools, or their equivalent, are required:
- CH-47976 Active Fuel Injector Tester (AFIT)
- J 35800-A Fuel Injector Cleaner
- J 37287 Fuel Line Shut-off Adapter
- * One bottle of GM Upper Engine and Fuel Injector Cleaner, P/N 88861802 (in Canada, P/N
88861804)
- * One bottle of GM Fuel System Treatment Plus, P/N 88861011 (in Canada, P/N 88861012)
Active Fuel Injector Tester (AFIT- CH-47976)
Some dealers may not have an Active Fuel Injector Tester (AFIT- CH-47976). Dealers can contact
1-800-GM-TOOLS (1-800-468-6657) to order an AFIT- CH-47976. Dealers still can test the fuel
injectors without an AFIT. Refer to Fuel Injector Diagnosis (w/ J 39021 or Tech 2(R)) in SI.
Important As mentioned in the AFIT User Guide, vehicles that are not listed in the AFIT menu can
still be tested with the AFIT. Depending on the model, it may be possible to enter the previous
model year and proceed with testing using the DLC connection. If this is not possible on the model
that you are working on, it will be necessary to use the direct connection method outlined in the
AFIT User Guide (See Pages 17-31).
General Motors recommends that the Active Fuel Injector Tester (AFIT) be used in testing fuel
injectors. If the SI diagnostics do not isolate a cause for this concern, use the Active Fuel Injector
Tester (AFIT - CH-47976) to perform an "Injector Test" as outlined in the AFIT User Guide.
The AFIT "Injector Test" measures the flow characteristics of all fuel injectors, which is more
precise when compared with the standard Tech 2(R) fuel injector balance test. As a result, the
AFIT is more likely to isolate the cause of a P1174 DTC (for example: if it is being caused by a fuel
injector concern).
The CH-47976 (Active Fuel Injector Tester - AFIT) can also be used to measure fuel pressure and
fuel system leak down. Also, as mentioned in the P1174 SI diagnosis, if the misfire current
counters or misfire graph indicate any misfires, it may be an indicator of the cylinder that is causing
the concern. Refer to Fuel Injector Diagnosis (w/CH-47976) in SI for additional instructions.
Training (U.S.)
To access the training video on AFIT, take the following path at the GM Training Website:
1. After logging into the gmtraining.com website, choose the link on the left side of the page titled
"web video library." 2. Then choose "technical." 3. Next, within the search box, type in September
course number "10206.09D. 4. This will bring up a link with this course. Scroll through to choose
"feature topic." 5. At this point, the seminar can be chosen to view or the video related to the AFIT.
Additional training is available from the gmtraining.com website. Please see TECHassist
16044.18T2 Active Fuel Injector Tester and also see 16044.14D1 GM Powertrain Performance for
more information on GM Upper Engine and Fuel Injector Cleaner.
Also, dealers can now download software updates for the AFIT at GM Dealer Equipment (GMDE)
on the web at http://www.gmde.net/AFIT.cfm.
Training (Canada)
To access the training video on AFIT, take the following path at the GMPro LMS Training Website:
1. After logging into the website, choose the link on the left side of the page titled "Catalog." 2. Then
choose "Catalog Search." 3. Next, within the search box, Select Course Number - Contains - "T"
then select search. 4. This will bring up a list of TECHassist courses. Scroll through to choose
"Active Fuel Injector Tester" and select "View." 5. At this point, a new window will open and the
program can be Launched.
on the web at http://www.gmde.net/softwareupdates/.
Techlink
Additional information can be found on AFIT (June 2006 Edition) and GM Upper Engine and Fuel
Injector Cleaner (November 2006 Edition) in Techlink. To access the articles, take the following
path:
1. Go to GM DealerWorld (U.S.) or the GM GlobalConnect (Canada). 2. Click on the Service Tab in

DealerWorld (in Canada, click Technican Resources in the Service Library of GM GlobalConnect).
3. Click on the GM Techlink Hyperlink. 4. Click on the Archives Hyperlink at GM Techlink.
- Click on 06-2006 in the Archives Section and Click on the Active Fuel Injector Tester Link in the
June 2006 Techlink Article.
- Click on 11-2006 in the Archives Section and Click on the GM Top Engine Cleaner Replaced Link
in the November 2006 Techlink Article.
Notice
recommended. DO NOT USE OTHER CLEANING AGENTS AS THEY MAY CONTAIN
METHANOL, WHICH CAN DAMAGE FUEL SYSTEM COMPONENTS. Under NO circumstances
should the GM Upper Engine and Fuel Injector Cleaner be added to the vehicle fuel tank.
Do not exceed the recommended cleaning solution concentration. Testing has demonstrated that
exceeding the recommended cleaning solution concentration does not improve the effectiveness of
this procedure.
Important Vehicles with less than 160 km (100 mi) on the odometer should not have the injectors
cleaned. These vehicles should have any out of specification injectors replaced.
1. For 4, 5 and 6 cylinder engines, empty two of the 30 ml (1 oz) reservoirs of the GM Upper
Engine and Fuel Injector Cleaner container into the J
35800-A - Injector Cleaning Tank then add 420 ml (14 oz) of regular unleaded gasoline. If you are
using any other brand of cleaning tank, you will need a total of 60 ml (2 oz) mixed with 420 ml (14
oz) of regular unleaded gasoline.
2. For 8 cylinder engines, empty two of the 30 ml (1 oz) reservoirs of the GM Upper Engine and
Fuel Injector Cleaner container into the J 35800-A -
Injector Cleaning Tank then add 420 ml (14 oz) of regular unleaded gasoline. If you are using any
other brand of cleaning tank, you will need a total of 60 ml (2 oz) of Upper Engine and Fuel Injector
Cleaner mixed with 420 ml (14 oz) of regular unleaded gasoline. This procedure will need to be
repeated for a second time for an 8 cylinder engine (8 cylinder engines receive 960 ml total fluid -
120 ml (4 oz) of Upper Engine and Fuel Injector Cleaner and 840 ml (28 oz) of gasoline.
3. Be sure to follow all additional instructions provided with the tool.
4. Electrically disable the vehicle fuel pump by either removing the fuel pump fuse or the fuel pump
relay and disconnecting the oil pressure switch
connector, if equipped.
5. Turn the ignition to the OFF position.
6. Relieve fuel pressure and disconnect the fuel feed and return lines at the fuel rail. Plug the fuel
feed and return lines coming off the fuel rail with J
37287, J 42873 or J 42964 as appropriate for the fuel system.
7. Connect the J 35800-A to the vehicle fuel rail.
8. Pressurize the J 35800-A to 510 kPa (75 psi).
9. Start and idle the engine until it stalls, due to lack of fuel. This should take approximately 15-20
minutes.
11. Disconnect the J 35800-A from the fuel rail.
12. Reconnect the vehicle fuel pump relay and oil pressure switch connector, if equipped.
13. Remove the J 37287, J 42873 or J 42964 and reconnect the vehicle fuel feed and return lines.
14. Start and idle the vehicle for an additional two minutes to ensure residual injector cleaner is
flushed from the fuel rail and fuel lines.
15. Pour the entire contents of GM Fuel System Treatment Plus (P/N 88861011 [in Canada, P/N
88861012]) into the tank and advise the customer
to fill the tank.
16. Review the benefits of using Top Tier Detergent gasoline with the customer and recommend
that they add a bottle of GM Fuel System
Treatment Plus to the fuel tank at every oil change. Regular use of GM Fuel System Treatment
Plus should keep the customer from having to repeat the injector cleaning procedure.
17. Road test the vehicle to verify that the customer concern has been corrected.
Parts Information
* Only 1/8 of the cost may be claimed for 4 and 6 cylinder engines and 1/4 of the cost for 8 cylinder
engines.
Disclaimer
Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Injector: > 03-06-04-030G > Apr > 09 >
Fuel System - Driveability Issues/MIL ON/Multiple DTC's
Fuel Injector: All Technical Service Bulletins Fuel System - Driveability Issues/MIL ON/Multiple
DTC's
TECHNICAL
Subject:
Various Driveability Symptoms Due to Clogged Fuel Injectors, MIL/SES DTCs P0171, P0172,
P0174, P0300, P1174, P1175 (Clean Fuel Injectors and/or Perform Injector Test With AFIT
CH-47976)
Models:
2005-2009 GM Passenger Cars and Light Duty Trucks 2005-2009 HUMMER H2 2006-2009
HUMMER H3 2005-2009 Saab 9-7X Equipped with Engine RPOs listed in the Table Below and
MULTEC(R) 2 Fuel Injectors
Attention:
GM does not support cleaning injectors on any engines that are not listed in this bulletin. Engines
other than the ones listed in this bulletin that diagnosis indicates having restricted injectors should
have those injectors replaced.
Supercede: This bulletin is being revised to update the model year to 2009 and to provide
applicable engine RPO table. Please discard Corporate Bulletin Number 03-06-04-030F (Section
06 - Engine/Propulsion System).
Condition
Some customers may comment on any of the following various driveability symptoms:
- Extended Crank Time
- Hard to Start
- MIL/SES Illuminated with DTCs
- Hesitation
- Lack of Power
- Surge or Chuggle
- Rough Idle
- Light or Intermittent Misfire
Cause
Due to various factors, the fuel injectors may become restricted. Extensive testing has
demonstrated that fuel related issues are the cause of clogged injectors. At this point, no specific
fuel, fuel constituent, or engine condition has been identified as causing the restriction. The
restriction causes the engine to operate at a lean air fuel ratio. This may either trigger the MIL to
illuminate or the engine to develop various driveability symptoms.
Correction
Fuel injector restrictions, deposits can be cleaned on the vehicle using the following procedure.
Under NO circumstances should this procedure be modified, changed or shortened. As a long term
solution, and to prevent reoccurrence, customers should be encouraged to use Top Tier Detergent
Gasoline. For further information on Top Tier detergent gasoline and fuel retailers, please refer to
the following Corporate Bulletin Numbers:
- 04-06-04-047G (U.S. Only)

Fuel System - Driveability Issues/MIL ON/Multiple DTC's > Page 3942
- 05-06-04-022D (Canada ONLY)
Notice
approved for use with General Motors fuel system components. Other injector cleaners may cause
damage to plastics, plated metals or bearings. General Motors has completed extensive laboratory
testing of GM Upper Engine and Fuel Injector Cleaner, and can assure its compatibility with
General Motors fuel system components, as long as the cleaning procedure is followed correctly.
The following tools, or their equivalent, are required:
- CH-47976 Active Fuel Injector Tester (AFIT)
- J 35800-A Fuel Injector Cleaner
- * One bottle of GM Upper Engine and Fuel Injector Cleaner, P/N 88861802 (in Canada, P/N
88861804)
- * One bottle of GM Fuel System Treatment Plus, P/N 88861011 (in Canada, P/N 88861012)
Active Fuel Injector Tester (AFIT- CH-47976)
Some dealers may not have an Active Fuel Injector Tester (AFIT- CH-47976). Dealers can contact
1-800-GM-TOOLS (1-800-468-6657) to order an AFIT- CH-47976. Dealers still can test the fuel
injectors without an AFIT. Refer to Fuel Injector Diagnosis (w/ J 39021 or Tech 2(R)) in SI.
Important As mentioned in the AFIT User Guide, vehicles that are not listed in the AFIT menu can
still be tested with the AFIT. Depending on the model, it may be possible to enter the previous
model year and proceed with testing using the DLC connection. If this is not possible on the model
that you are working on, it will be necessary to use the direct connection method outlined in the
AFIT User Guide (See Pages 17-31).
General Motors recommends that the Active Fuel Injector Tester (AFIT) be used in testing fuel
injectors. If the SI diagnostics do not isolate a cause for this concern, use the Active Fuel Injector
Tester (AFIT - CH-47976) to perform an "Injector Test" as outlined in the AFIT User Guide.
The AFIT "Injector Test" measures the flow characteristics of all fuel injectors, which is more
precise when compared with the standard Tech 2(R) fuel injector balance test. As a result, the
AFIT is more likely to isolate the cause of a P1174 DTC (for example: if it is being caused by a fuel
injector concern).
The CH-47976 (Active Fuel Injector Tester - AFIT) can also be used to measure fuel pressure and
fuel system leak down. Also, as mentioned in the P1174 SI diagnosis, if the misfire current
counters or misfire graph indicate any misfires, it may be an indicator of the cylinder that is causing
the concern. Refer to Fuel Injector Diagnosis (w/CH-47976) in SI for additional instructions.
Training (U.S.)
To access the training video on AFIT, take the following path at the GM Training Website:
1. After logging into the gmtraining.com website, choose the link on the left side of the page titled
"web video library." 2. Then choose "technical." 3. Next, within the search box, type in September
course number "10206.09D. 4. This will bring up a link with this course. Scroll through to choose
"feature topic." 5. At this point, the seminar can be chosen to view or the video related to the AFIT.
Additional training is available from the gmtraining.com website. Please see TECHassist
16044.18T2 Active Fuel Injector Tester and also see 16044.14D1 GM Powertrain Performance for
more information on GM Upper Engine and Fuel Injector Cleaner.
on the web at http://www.gmde.net/AFIT.cfm.
Training (Canada)
To access the training video on AFIT, take the following path at the GMPro LMS Training Website:
1. After logging into the website, choose the link on the left side of the page titled "Catalog." 2. Then
choose "Catalog Search." 3. Next, within the search box, Select Course Number - Contains - "T"
then select search. 4. This will bring up a list of TECHassist courses. Scroll through to choose
"Active Fuel Injector Tester" and select "View." 5. At this point, a new window will open and the
program can be Launched.
on the web at http://www.gmde.net/softwareupdates/.
Techlink
Additional information can be found on AFIT (June 2006 Edition) and GM Upper Engine and Fuel
Injector Cleaner (November 2006 Edition) in Techlink. To access the articles, take the following
path:
1. Go to GM DealerWorld (U.S.) or the GM GlobalConnect (Canada). 2. Click on the Service Tab in

DealerWorld (in Canada, click Technican Resources in the Service Library of GM GlobalConnect).
3. Click on the GM Techlink Hyperlink. 4. Click on the Archives Hyperlink at GM Techlink.
- Click on 06-2006 in the Archives Section and Click on the Active Fuel Injector Tester Link in the
June 2006 Techlink Article.
- Click on 11-2006 in the Archives Section and Click on the GM Top Engine Cleaner Replaced Link
in the November 2006 Techlink Article.
Notice
recommended. DO NOT USE OTHER CLEANING AGENTS AS THEY MAY CONTAIN
METHANOL, WHICH CAN DAMAGE FUEL SYSTEM COMPONENTS. Under NO circumstances
should the GM Upper Engine and Fuel Injector Cleaner be added to the vehicle fuel tank.
Do not exceed the recommended cleaning solution concentration. Testing has demonstrated that
exceeding the recommended cleaning solution concentration does not improve the effectiveness of
this procedure.
Important Vehicles with less than 160 km (100 mi) on the odometer should not have the injectors
cleaned. These vehicles should have any out of specification injectors replaced.
1. For 4, 5 and 6 cylinder engines, empty two of the 30 ml (1 oz) reservoirs of the GM Upper
Engine and Fuel Injector Cleaner container into the J
35800-A - Injector Cleaning Tank then add 420 ml (14 oz) of regular unleaded gasoline. If you are
using any other brand of cleaning tank, you will need a total of 60 ml (2 oz) mixed with 420 ml (14
oz) of regular unleaded gasoline.
Fuel Injector Cleaner container into the J 35800-A -
Injector Cleaning Tank then add 420 ml (14 oz) of regular unleaded gasoline. If you are using any
other brand of cleaning tank, you will need a total of 60 ml (2 oz) of Upper Engine and Fuel Injector
Cleaner mixed with 420 ml (14 oz) of regular unleaded gasoline. This procedure will need to be
repeated for a second time for an 8 cylinder engine (8 cylinder engines receive 960 ml total fluid -
120 ml (4 oz) of Upper Engine and Fuel Injector Cleaner and 840 ml (28 oz) of gasoline.
3. Be sure to follow all additional instructions provided with the tool.
4. Electrically disable the vehicle fuel pump by either removing the fuel pump fuse or the fuel pump
relay and disconnecting the oil pressure switch
connector, if equipped.
6. Relieve fuel pressure and disconnect the fuel feed and return lines at the fuel rail. Plug the fuel
feed and return lines coming off the fuel rail with J
37287, J 42873 or J 42964 as appropriate for the fuel system.
7. Connect the J 35800-A to the vehicle fuel rail.
8. Pressurize the J 35800-A to 510 kPa (75 psi).
9. Start and idle the engine until it stalls, due to lack of fuel. This should take approximately 15-20
minutes.
11. Disconnect the J 35800-A from the fuel rail.
12. Reconnect the vehicle fuel pump relay and oil pressure switch connector, if equipped.
13. Remove the J 37287, J 42873 or J 42964 and reconnect the vehicle fuel feed and return lines.
14. Start and idle the vehicle for an additional two minutes to ensure residual injector cleaner is
flushed from the fuel rail and fuel lines.
15. Pour the entire contents of GM Fuel System Treatment Plus (P/N 88861011 [in Canada, P/N
88861012]) into the tank and advise the customer
to fill the tank.
16. Review the benefits of using Top Tier Detergent gasoline with the customer and recommend
that they add a bottle of GM Fuel System
Treatment Plus to the fuel tank at every oil change. Regular use of GM Fuel System Treatment
Plus should keep the customer from having to repeat the injector cleaning procedure.
Parts Information
* Only 1/8 of the cost may be claimed for 4 and 6 cylinder engines and 1/4 of the cost for 8 cylinder
engines.
Disclaimer
Information > Specifications > Electrical Specifications
Fuel Injector: Electrical Specifications
Fuel Injector Resistance.......................................................................................................................

..................................................................11-14 ohms
Information > Specifications > Electrical Specifications > Page 3947
Fuel Injector: Pressure, Vacuum and Temperature Specifications
Pressure drop.......................................................................................................................................
...............................................................20 kPa (3 psi)
Information > Diagrams > Fuel Injector 1
Fuel Injector: Diagrams Fuel Injector 1
Fuel Injector 1
Information > Diagrams > Fuel Injector 1 > Page 3950
Fuel Injector 2
Fuel Injector 3
Fuel Injector 4
Fuel Injector: Diagrams
Fuel Injector 1
Fuel Injector 1
Fuel Injector 2
Fuel Injector 2
Fuel Injector 3
Fuel Injector 3
Fuel Injector 4
Fuel Injector 4
Fuel Injector 5
Fuel Injector 5
Fuel Injector 6
Fuel Injector 6
Fuel Injector 7
Fuel Injector 7
Fuel Injector 8
Fuel Injector 8
Fuel Injector: Technician Safety Information
Lower O-Ring Removal Caution
Caution: Verify that the lower (small) O-ring of each injector does not remain in the lower manifold
in order to reduce the risk of fire and personal injury.
If the O-ring is not removed with the injector, the replacement injector with new O-rings will not seat
properly in the injector socket. Improper seating could cause a fuel leak.
Fuel Injector: Vehicle Damage Warnings
Fuel Injector Balance Test Notice
Notice: Do Not repeat any portion of this test before running the engine in order to prevent the
engine from flooding.
Information > Testing and Inspection > Fuel Injector Diagnosis (w/J 39021 or Tech 2)
Fuel Injector: Testing and Inspection Fuel Injector Diagnosis (w/J 39021 or Tech 2)
Fuel Injector Diagnosis (w/J 39021 or Tech 2)
procedure.
Overview/Diagnostic Procedure Instructions) provide an overview of each diagnostic category.
The engine control module (ECM) enables the appropriate fuel injector pulse for each cylinder. The
ignition voltage is supplied directly to the fuel injectors. The ECM controls each fuel injector by
grounding the control circuit via a solid state device called a driver. A fuel injector coil winding
resistance that is too high or too low will affect the engine driveability. A fuel injector control circuit
DTC may not set, but a misfire may be apparent. The fuel injector coil windings are affected by
temperature. The resistance of the fuel injector coil windings will increase as the temperature of the
fuel injector increases.
When performing the fuel injector balance test, the scan tool is first used to energize the fuel pump
relay. The fuel injector tester or the scan tool is then used to pulse each injector for a precise
amount of time, allowing a measured amount of the fuel to be injected. This causes a drop in the
system fuel pressure that can be recorded and used to compare each injector.
Diagnostic Aids
* Monitoring the misfire current counters, or misfire graph, may help to isolate the fuel injector that
is causing the condition.
* Operating the vehicle over a wide temperature range may help isolate the fuel injector that is
causing the condition.
* Perform the fuel injector coil test within the conditions of the customer's concern. A fuel injector
condition may only be apparent at a certain temperature, or under certain conditions.




Connections)
DTC Type Reference
Powertrain Diagnostic Trouble Code (DTC) Type Definitions (See: Computers and Control
(DTC) Type Definitions) Scan Tool Reference
* J 39021 Fuel Injector Coil and Balance Tester
* J 39021-210 Injector Tester Adapter Box
* J 44602 Injector Test Adapter
* J 39021-301 V-6 Fuel Injector Test Adapter
Component Testing
Information > Testing and Inspection > Fuel Injector Diagnosis (w/J 39021 or Tech 2) > Page 3966
Fuel Injector Coil Test
Verify the resistance of each fuel injector with one of the following methods:
* If the engine coolant temperature (ECT) sensor is between 10-32°C (50-90°F), the resistance of
each fuel injector should be 11-14 ohms.
‹› If the injectors measure OK, perform the Fuel Injector Balance Test - Fuel Pressure Test. ‹› If not
within the specified range, replace the fuel injector.
* If the ECT sensor is not between 10-32°C (50-90°F), measure and record the resistance of each
fuel injector with a DMM. Subtract the lowest resistance value from the highest resistance value.
The difference between the lowest value and the highest value should be equal to or less than 3
ohms.
‹› If the difference is equal to or less than 3 ohms, refer to Fuel Injector Balance Test - Fuel
Pressure Test for further diagnosis of the fuel
injectors.
‹› If the difference is more than 3 ohms, add all of the fuel injector resistance values to obtain a
total resistance value. Divide the total resistance
value by the number of fuel injectors to obtain an average resistance value. Subtract the lowest
individual fuel injector resistance value from the average resistance value. Compute the difference
between the highest individual fuel injector resistance value and the average resistance value.
Replace the fuel injector that displays the greatest difference above or below the average.
Important:
* DO NOT perform this test if the engine coolant temperature (ECT) is above 94°C (201°F).
Irregular fuel pressure readings may result due to hot soak fuel boiling.
* Verify that adequate fuel is in the fuel tank before proceeding with this diagnostic.
Instructions.
Fuel Injector Balance Test-Fuel Pressure Test
1. Install a CH-48027 . Refer to Fuel Pressure Gage Installation and Removal (See: Fuel
Pressure/Testing and Inspection/Fuel Pressure Gage
2. Turn ON the ignition, with the engine OFF.
Important: *
3. Command the fuel pump relay ON with a scan tool. 4. Observe the fuel pressure gage with the
fuel pump commanded ON. The fuel pressure should be 345-414 kPa (50-60 psi).
‹› If the fuel pressure is not 345-414 kPa (50-60 psi), refer to Fuel System Diagnosis (See:
Inspection/Component Tests and General Diagnostics/Fuel System Diagnosis) .
5. Monitor the CH-48027 for one minute. The fuel pressure should not decrease more than 34 kPa
(5 psi).
‹› If the fuel pressure decreases more than 34 kPa (5 psi), refer to Fuel System Diagnosis (See:
Inspection/Component Tests and General Diagnostics/Fuel System Diagnosis) .
6. Perform the Fuel Injector Balance Test with Special Tool or the Fuel Injector Balance Test with
Tech 2.
Fuel Injector Balance Test with Special Tool
1. Set the amperage supply selector switch on the fuel injector tester to the Balance Test 0.5-2.5
amp position. 2. Connect the J 39021 , J 39021-210 , and the J 39021-301 to the fuel meter body.
3. Command the fuel pump relay ON and then OFF three times with a scan tool. On the last
command, as the fuel pressure begins to slowly degrade
and stabilize, select a fuel pressure within 34 kPa (5 psi) of the maximum pump pressure. Record
this fuel pressure. This is the starting pressure at which you will pulse each injector.
4. Command the fuel pump relay ON one more time and energize the fuel injector by depressing
the Push to Start Test button on the J 39021 at the
previously selected pressure.
5. After the injector stops pulsing, select Min from the Display Mode and record the Min pressure.
Important: New test results will not be recorded if the Min/Max results are not cleared after each
injector is tested.
6. Clear the Min/Max results. 7. Select Normal from the Display Mode.
8. Repeat steps 2 and 4 through 7 for each fuel injector. 9. Perform the Pressure Drop Calculation.
Fuel Injector Balance Test with Tech 2
1. Command the fuel pump relay ON and then OFF three times with a scan tool. On the last
command, as the fuel pressure begins to slowly degrade
and stabilize, select a fuel pressure within 34 kPa (5 psi) of the maximum pump pressure. Record
this fuel pressure. This is the starting pressure at which you will pulse each injector.
2. With a scan tool, select the Fuel Injector Balance Test function within the Special Functions
menu. 3. Select an injector to be tested. 4. Press Enter to prime the fuel system. 5. Energize the
fuel injector by depressing the Pulse Injector button on the scan tool at the previously selected
pressure. 6. After the injector stops pulsing, select Min from the Display Mode on the CH-48027
and record the Min pressure.
Important: New test results will not be recorded if the Min/Max results are not cleared after each
injector is tested.
7. Clear the Min/Max results on the CH-48027 . 8. Select Normal from the Display Mode on the
CH-48027 . 9. Press Enter on the scan tool to bring you back to the Select Injector screen.
10. Repeat steps 3 through 9 for each fuel injector. 11. Perform the Pressure Drop Calculation.
Pressure Drop Calculation
1. Subtract the minimum pressure from the starting pressure for one fuel injector. The result is the
pressure drop value. 2. Obtain a pressure drop value for each fuel injector. 3. Add all of the
individual pressure drop values except for the injector suspected of being faulty. This is the total
pressure drop. 4. Divide the total pressure drop by the number of fuel injectors that were added
together. This is the average pressure drop. The difference between
any individual pressure drop and the average pressure drop should not be more than 20 kPa (3
psi).
‹› If the difference between any individual pressure drop and the average pressure drop is more
than 20 kPa (3 psi), replace the fuel injector,
E-85 only. All other engine, refer to Fuel Injector Cleaning (See: Service and Repair/Procedures) .
Repair Instructions
Fuel Injector Replacement (See: Service and Repair/Removal and Replacement)

Fuel Injector: Testing and Inspection Fuel Injector Diagnosis (w/CH 47976)
Fuel Injector Diagnosis (w/CH 47976)
procedure.
Overview/Diagnostic Procedure Instructions) provide an overview of each diagnostic category.
The engine control module (ECM) enables the appropriate fuel injector pulse for each cylinder. The
ignition voltage is supplied directly to the fuel injectors. The ECM controls each fuel injector by
grounding the control circuit via a solid state device called a driver. A fuel injector coil winding
resistance that is too high or too low will affect the engine driveability. A fuel injector control circuit
DTC may not set, but a misfire may be apparent. The fuel injector coil windings are affected by
temperature. The resistance of the fuel injector coil windings will increase as the temperature of the
fuel injector increases.
The CH-47976 , is used to test the fuel pump, fuel system leak down, and the fuel injectors.
Following the User Guide, CH 47976-11, and the on screen prompts or selections, will indicate the
steps required to perform each of the available tests. The tester will perform all of the tests
automatically and display results of the test. The results can also be down loaded for storage and
printing.




Connections)

Special Tools
CH-47976 Active Fuel Injector Tester
Component Testing
Fuel Injector Coil Test

Verify the resistance of each fuel injector with one of the following methods:
* If the engine coolant temperature (ECT) sensor is between 10-32°C (50-90°F), the resistance of
each fuel injector should be 11-14 ohms.
‹› If the injectors measure OK, perform the Active Fuel Injector Tester (AFIT) Test Procedure. ‹› If
not within the specified range, replace the fuel injector.
* If the ECT sensor is not between 10-32°C (50-90°F), measure and record the resistance of each
fuel injector with a DMM. Subtract the lowest resistance value from the highest resistance value.
The difference between the lowest value and the highest value should be equal to or less than 3
ohms.
‹› If the difference is equal to or less than 3 ohms, refer to AFIT Test Procedure. ‹› If the difference
is more than 3 ohms, add all of the fuel injector resistance values to obtain a total resistance value.
Divide the total resistance
value by the number of fuel injectors to obtain an average resistance value. Subtract the lowest
individual fuel injector resistance value from the average resistance value. Compute the difference
between the highest individual fuel injector resistance value and the average resistance value.
Replace the fuel injector that displays the greatest difference above or below the average.
Important:
* DO NOT perform this test if the engine coolant temperature (ECT) is above 94°C (201°F).
Irregular fuel pressure readings may result due to hot soak fuel boiling.
* Verify that adequate fuel is in the fuel tank before proceeding with this diagnostic.
AFIT Test Procedure
1. Turn OFF all accessories. 2. Turn OFF the ignition. 3. Install the AFIT. Refer to the AFIT User
Guide. 4. Turn ON the AFIT and select the vehicle. 5. Turn ON the ignition and perform the Injector
Test.
‹› If the AFIT aborts testing due to fuel pressure or fuel leak down, refer to Fuel System Diagnosis
(See: Computers and Control
Systems/Testing and Inspection/Component Tests and General Diagnostics/Fuel System

Diagnosis) .
6. View the test results.
‹› If any injector exceeds the recommended tolerance, replace the injector(s), E-85 only. All other
engine, refer to Fuel Injector Cleaning (See:
Service and Repair/Procedures) .
Repair Instructions
Fuel Injector Replacement (See: Service and Repair/Removal and Replacement)

Information > Service and Repair > Procedures
Fuel Injector: Procedures
Fuel Injector Cleaning
Tools Required
* J 37287 Fuel Line Shut-Off Adapters
* J 35800-A Fuel Injector Cleaner
* J 42873-1 3/8 Fuel Line Shut-Off Valve
* J 42873-2 5/16 Return Pipe Shut-Off Valve
* J 42964-1 3/8 Fuel Pipe Shut-Off Valve
* J 42964-2 5/16 Fuel Pipe Shut-Off Valve
Notice:
* GM Upper Engine and Fuel Injector Cleaner is the only injector cleaning agent recommended.
DO NOT USE OTHER CLEANING AGENTS AS THEY MAY CONTAIN METHANOL, WHICH CAN
DAMAGE FUEL SYSTEM COMPONENTS.
* Under NO circumstances should the GM Upper Engine and Fuel Injector Cleaner be added to the
vehicle fuel tank, as it may damage the fuel pump and other system components.
* Do not exceed the recommended cleaning solution concentration. Higher concentrations may
damage fuel system components. Testing has demonstrated that exceeding the recommended
cleaning solution concentration does not improve the effectiveness of this procedure.
Important: Vehicles with less than 160 km (100 mi) on the odometer should not have the injectors
cleaned. These vehicles should have the injectors replaced.
1. Obtain J 35800-A (2).
Important: Make sure the valve at the bottom of the canister (3) is closed.
2. For 4, 5, and 6 cylinder engines, empty two of the 30 ml (1 oz) reservoirs of the GM Upper
Engine and Fuel Injector Cleaner twin reservoir
container into the J 35800-A , injector cleaning tank, then add 420 ml (14 oz) of regular unleaded
gasoline. If you are using any other brand of cleaning tank, you will need a total of 60 ml (2 oz) of
GM Upper Engine and Fuel Injector Cleaner mixed with 420 ml (14 oz) of regular unleaded
gasoline.
Fuel Injector Cleaner twin reservoir container into
the J 35800-A , injector cleaning tank, then add 420 ml (14 oz) of regular unleaded gasoline. If you
are using any other brand of cleaning tank, you will need a total of 60 ml (2 oz) of GM Upper
Engine and Fuel Injector Cleaner mixed with 420 ml (14 oz) of regular unleaded gasoline. This
procedure will need to be repeated for an 8 cylinder engine. The 8 cylinder engines receive 960 ml
total fluid-120 ml (4 oz) of GM Upper Engine and Fuel Injector Cleaner and 840 ml (28 oz) of
gasoline.
4. Fill the injector cleaning tank with regular unleaded gasoline. Be sure to follow all additional
instructions provided with the tool. 5. Electrically disable the vehicle fuel pump by removing the fuel
pump relay and disconnecting the oil pressure switch connector, if equipped. 6. Disconnect the fuel
feed and return line, if equipped, at the fuel rail. Plug the fuel feed and return line, if equipped,
coming off the fuel rail with J
37287 , or J 42964-1 , and J 42964-2 or J 42873-1 , and J 42873-2 as appropriate for the fuel
system.
7. Connect the J 35800-A to the vehicle fuel rail. 8. Pressurize the J 35800-A to 510 kPa (75 psi).
9. Start and idle the engine until it stalls due to lack of fuel. This should take approximately 15-20
minutes.
10. Turn the ignition to the OFF position. 11. Injectors should be flow-tested at this point. If further
cleaning is needed, a repeat of the above procedure should be done.
When the injector restriction returns to zero, proceed to step 12.

Information > Service and Repair > Procedures > Page 3972
12. Disconnect the J 35800-A from the fuel rail. 13. Reconnect the vehicle fuel pump relay and oil
pressure switch connector, if equipped. 14. Remove the J 37287 , or J 42964-1 and J 42964-2 , or
J 42873-1 and J 42873-2 and reconnect the vehicle fuel feed and return lines. 15. Start and idle the
vehicle for an additional two minutes to ensure residual injector cleaner is flushed from the fuel rail
and fuel lines. 16. Pour the entire contents of GM Fuel System Treatment Plus, GM P/N 88861011
(Canadian P/N 88861012) into a nearly empty tank and advise the
customer to refuel with up to 76 L (20 gal) of fuel.
17. Advise the customer to use only a Top Tier Detergent gasoline and to add a bottle of GM Fuel
System Treatment Plus to the fuel tank at every oil
change. Regular use of GM Fuel System Treatment Plus should keep the customer from having to
repeat the injector cleaning procedure.
Fuel Injector: Removal and Replacement
Fuel Injector Replacement
Removal Procedure
Notice: Use care in removing the fuel injectors in order to prevent damage to the fuel injector
electrical connector pins or the fuel injector nozzles. Do not immerse the fuel injector in any type of
cleaner. The fuel injector is an electrical component and may be damaged by this cleaning method.
Important: The Denso fuel injectors that are installed on the 5.3L (L59) E85 application will not
have O-rings and retaining clips serviced separately. Therefore the fuel injectors will be replaced
whenever an O-ring or clip needs to be replaced.
Important: The engine oil may be contaminated with fuel if the fuel injectors are leaking.
1. Remove the fuel rail. Refer to Fuel Injection Fuel Rail Assembly Replacement (See: Fuel
Rail/Service and Repair) . 2. Remove the fuel injector retainer clip (19). 3. Remove the fuel injector
(17).
4. Discard the fuel injector retainer clip (1). 5. Remove and discard the fuel injector O-ring seals (2,
4) from the injector.
Important: When ordering new fuel injectors, you must order the correct injector for the application
being serviced.
1. The fuel injector (1) is stamped with a part number identification (2). A four-digit build date code
(3), which indicates the month (4), day (5), year
(6), and the shift (7) that built the fuel injector.
2. Lubricate the NEW fuel injector O-ring seals (2, 4) with clean engine oil. 3. Install the NEW fuel
injector O-ring seals onto the fuel injector. 4. Install a NEW retainer clip (1) onto the fuel injector.
5. Install the fuel injector (17) into the fuel rail injector socket with the electrical connector facing
outward. The retainer clip (19) locks on to a flange
on the fuel rail injector socket.
6. Install the fuel rail. Refer to Fuel Injection Fuel Rail Assembly Replacement (See: Fuel
Rail/Service and Repair) .
Hummer Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component
Information > Service and Repair > Metal Collar Quick Connect Fitting Service
Fuel Line Coupler: Service and Repair Metal Collar Quick Connect Fitting Service
Metal Collar Quick Connect Fitting Service
Tool Required
J 41769 Fuel Line Quick Disconnect Tool
Removal Procedure
1. Relieve the fuel system pressure before servicing any fuel system connection. Refer to the Fuel
Pressure Relief (With CH 48027) (See: Fuel
Filter/Fuel Pressure Release/Service and Repair/Fuel Pressure Relief (With CH 48027))Fuel

Pressure Relief (Without CH 48027) (See: Fuel Filter/Fuel Pressure Release/Service and
Repair/Fuel Pressure Relief (Without CH 48027)) .
2. Remove the retainer from the quick-connect fitting.
Caution: Wear safety glasses when using compressed air in order to prevent eye injury.
3. Blow dirt out of the fitting using compressed air.
4. Choose the correct tool from the J 41769 tool set for the size of the fitting. Insert the tool into the
female connector, then push inward in order to
release the locking tabs.
5. Pull the connection apart.
Notice: If necessary, remove rust or burrs from the fuel pipes with an emery cloth. Use a radial
motion with the fuel pipe end in order to prevent damage to the O-ring sealing surface. Use a clean
shop towel in order to wipe off the male tube ends. Inspect all the connections for dirt and burrs.
Clean or replace the components and assemblies as required.
6. Use a clean shop towel in order to wipe off the male pipe end. 7. Inspect both ends of the fitting
for dirt and burrs. Clean or replace the components as required.
Information > Service and Repair > Metal Collar Quick Connect Fitting Service > Page 3979
Caution: Always apply a few drops of clean engine oil to the male pipe ends before connecting the
fuel pipe fittings in order to reduce the risk of fire and personal injury. This will ensure proper
reconnection and prevent a possible fuel leak. During normal operation, the O-rings located in the
female connector will swell and may prevent proper reconnection if not lubricated.
1. Apply a few drops of clean engine oil to the male pipe end.
2. Push both sides of the fitting together in order to snap the retaining tabs into place.
3. Once installed, pull on both sides of the fitting in order to make sure the connection is secure. 4.
Install the retainer to the quick-connect fitting.
Fuel Line Coupler: Service and Repair Plastic Collar Quick Connect Fitting Service
Plastic Collar Quick Connect Fitting Service
Removal Procedure
1. Relieve the fuel system pressure before servicing any fuel system connection. Refer to Fuel
Pressure Relief (With CH 48027) (See: Fuel
Filter/Fuel Pressure Release/Service and Repair/Fuel Pressure Relief (With CH 48027))Fuel

Pressure Relief (Without CH 48027) (See: Fuel Filter/Fuel Pressure Release/Service and
Repair/Fuel Pressure Relief (Without CH 48027)) . Caution: Refer to Safety Glasses and
Compressed Air Caution (See: Service Precautions/Technician Safety Information/Safety Glasses
and Compressed Air Caution) .
2. Using compressed air, blow any dirt out of the quick-connect fitting.
4. Pull the connection apart.
Caution: Refer to Fuel Pipe Fitting Caution (See: Service Precautions/Technician Safety
Information/Fuel Pipe Fitting Caution) .
1. Apply a few drops of clean engine oil to the male fuel pipe end.
2. Push both sides of the quick-connect fitting together in order to cause the retaining tabs to snap
into place.
3. Once installed, pull on both sides of the quick-connect fitting in order to make sure the
connection is secure.
Hummer Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch >

Removal Procedure
pressure sensor.

Notice) .
Hummer Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure >

............................................................................................................................................. 345-414
kPa (50-60 psi)
System Information > Service Precautions > Technician Safety Information
System Information > Service Precautions > Technician Safety Information > Page 3994
System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal
Tools Required

Precautions) .
directions.
Removal Procedure

procedure.



Connections)

Scan Tool Reference

Important:
Instructions.
Important: *
pump module.
Repair Instructions
* Fuel Hose/Pipes Assembly Replacement (See: Fuel Supply Line/Service and Repair/Fuel
Hose/Pipes Assembly Replacement)
* Fuel Injector Replacement (See: Fuel Injector/Service and Repair/Removal and Replacement)
* Fuel Sender Assembly Replacement (See: Fuel Tank/Fuel Gauge Sender/Service and Repair)
Hummer Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Control
Unit > Component Information > Locations
Unit > Component Information > Locations > Page 4003

Unit > Component Information > Locations > Page 4004
Hummer Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component
Information > Service Precautions
Fuel Rail: Service Precautions
Fuel Rail Stop Bracket Installation Caution
Caution: The fuel rail stop bracket must be installed onto the engine assembly. The stop bracket
serves as a protective shield for the fuel rail in the event of a vehicle frontal crash. If the fuel rail
stop bracket is not installed and the vehicle is involved in a frontal crash, fuel could be sprayed
possibly causing a fire and personal injury from burns.
Information > Service Precautions > Page 4008
Fuel Rail: Service and Repair
Fuel Injection Fuel Rail Assembly Replacement
Removal Procedure
Important: An 8-digit identification number is located on the fuel rail. Refer to this identification
number when servicing or when part replacement is required.
2. Remove the wire harness bracket nut (2). 3. Disconnect the evaporative emission (EVAP) purge
solenoid electrical connector (1). 4. Disconnect the generator electrical connector (3).
5. Disconnect the following electrical connectors:
* Manifold absolute pressure (MAP) sensor (1)
* Knock sensor (2)
6. Remove the knock sensor harness connector from the intake manifold.
7. Disconnect the electronic throttle control (ETC) electrical connector (2). Perform the following:
1. Disengage the gray retainer. 2. Push down the black clip. 3. Disconnect the connector.
8. Remove the connector position assurance (CPA) retainer (5). 9. Disconnect the following
electrical connectors from the right side of the engine:
* Main coil (4)
* Fuel injectors (3)
10. Remove the harness clips from the fuel rail (1).
11. Remove the CPA retainer from the left side of the engine. 12. Disconnect the following
electrical connectors from the left side of the engine:
* Main coil (2)
* Fuel injectors
13. Remove the harness clips from the fuel rail (1). 14. Reposition the engine wire harness aside.
15. Perform the following steps in order to disconnect the fuel injector electrical connectors:
1. Mark the connectors to their corresponding injectors to ensure correct reassembly. 2. Pull the
CPA retainer (2) on the connector up one click. 3. Push the tab (1) on the connector in. 4.
Disconnect the fuel injector electrical connector. 5. Repeat the steps for each injector electrical
connector.
16. Remove the positive crankcase ventilation (PCV) hose.
17. Disconnect the fuel feed pipe (1) from the fuel rail. Refer to Metal Collar Quick Connect Fitting
Service (See: Fuel Line Coupler/Service and
Repair/Metal Collar Quick Connect Fitting Service) .

18. Remove the fuel rail bolts.
Notice: *
Remove the fuel rail assembly carefully in order to prevent damage to the injector electrical
connector terminals and the injector spray tips. Support the fuel rail after the fuel rail is removed in
order to avoid damaging the fuel rail components.
* Cap the fittings and plug the holes when servicing the fuel system in order to prevent dirt and
other contaminants from entering open pipes and passages.
Important: Before removal, clean the fuel rail with a spray type engine cleaner, such as GM X-30A
or equivalent, if necessary. Follow the package instructions. Do not soak the fuel rail in liquid
cleaning solvent.
19. Remove the fuel rail.
20. Remove the fuel injector lower O-ring seal (4) from each injector, if necessary. 21. Discard the
O-ring seal.
1. Lubricate NEW fuel injector lower O-ring seals (4) with clean engine oil. 2. Install the NEW
O-ring seals (4) onto each injector, if necessary.
3. Install the fuel rail. 4. Apply a 5 mm (0.2 in) band of threadlock GM P/N 12345382 (Canadian
P/N 10953489), or equivalent to the threads of the fuel rail bolts.

Notice) .
5. Install the fuel rail bolts.
6. Connect the fuel feed pipe (1) to the fuel rail. Refer to Metal Collar Quick Connect Fitting Service
(See: Fuel Line Coupler/Service and
Repair/Metal Collar Quick Connect Fitting Service) .

7. Install the PCV hose.
8. Perform the following steps in order to connect the fuel injector electrical connectors:
1. Install the connectors to their corresponding injectors to ensure correct reassembly. 2. Connect
the fuel injector electrical connector. 3. Push the CPA retainer (2) on the connector in one click. 4.
Repeat the steps for each injector electrical connector.
9. Position the engine wire harness.
10. Connect the following electrical connectors to the left side of the engine:
* Main coil (2)
* Fuel injectors
11. Install the harness clips to the fuel rail (1). 12. Install the CPA retainer.
13. Connect the following electrical connectors to the right side of the engine:
* Main coil (4)
* Fuel injectors (3)
14. Install the CPA retainer (5). 15. Install the harness clips to the fuel rail (1). 16. Connect the ETC
electrical connector (2). Perform the following:
1. Connect the connector. 2. Engage the gray retainer.
17. Connect the following electrical connectors:
* MAP sensor (1)
* Knock sensor (2)
18. Install the knock sensor harness connector to the intake manifold.
19. Connect the EVAP purge solenoid electrical connector (1). 20. Connect the generator electrical
connector (3). 21. Install the wire harness bracket nut (2).
22. Tighten the fuel fill cap. 23. Connect the negative battery cable. Refer to Battery Negative
Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery
24. Use the following procedure in order to inspect for leaks:
seconds. 3. Turn the ignition ON, with the engine OFF. 4. Inspect for fuel leaks.
Hummer Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component
Fuel Return Line: Service and Repair
Fuel Hose/Pipes Replacement - Chassis
Removal Procedure
1. Relieve the fuel system pressure. Refer to the Fuel Pressure Relief (With CH 48027) (See: Fuel
2. Clean all the fuel pipe connections and the surrounding areas before disconnecting the pipes in
order to avoid possible contamination of the fuel
system.
3. Disconnect the fuel feed and return pipes (1, 2) from the fuel rail. Refer to Metal Collar Quick
Connect Fitting Service (See: Fuel Line
Coupler/Service and Repair/Metal Collar Quick Connect Fitting Service) .
4. Cap the fuel rail pipes. 5. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See:
Maintenance) . 6. Remove the left hand catalytic converter. Refer to Catalytic Converter
Replacement (See: Emission Control Systems/Catalytic Converter/Service
and Repair) .
7. Remove the fuel pipes from the bellhousing stud clip (4). 8. Remove the fuel pipes from the
transmission bracket clip.
9. Disconnect the chassis fuel feed hose at the fuel filter. Refer to Plastic Collar Quick Connect
Fitting Service (See: Fuel Line Coupler/Service and
Repair/Plastic Collar Quick Connect Fitting Service) .
10. Cap the rear fuel pipes. 11. Note the position of the fuel pipes for aid in installation. 12. Remove
the fuel pipes from the retaining clips. 13. Remove the fuel pipes.
Important: *
When replacing the fuel pipes, always replace them with original equipment or parts that meet the
GM specifications for those parts. The replacement pipes must have the same type of fittings as
the original pipes in order to ensure the integrity of the connection.
* DO NOT use copper or aluminum tubing to replace steel tubing. Only tubing meeting the 124-M
specification or the equivalent is capable of meeting all pressure, corrosion and vibration
characteristics necessary to ensure the durability standard required.
1. Install the fuel pipes into the retaining clips.

Hummer Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component
2. Remove the caps from the rear fuel pipes. 3. Connect the chassis fuel feed hose at the fuel filter.
Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and
4. Install the fuel pipes into the transmission bracket clip. 5. Install the fuel pipes into the
bellhousing stud clip (4). 6. Lower the vehicle. 7. Install the left hand catalytic converter. Refer to
Catalytic Converter Replacement (See: Emission Control Systems/Catalytic Converter/Service
and Repair) .
8. Remove the caps from the fuel rail pipes. 9. Connect the fuel feed and return pipes (1, 2) to the
fuel rail.
10. Tighten the fuel filler cap. 11. Connect the negative battery cable. Refer to Battery Negative

1. Turn ON the ignition, with the engine OFF, for 2 seconds. 2. Turn OFF the ignition for 10
seconds. 3. Turn ON the ignition, with the engine OFF. 4. Inspect for fuel leaks.

Replacement) .
Hummer Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component
Information > Service and Repair > Fuel Hose/Pipes Replacement - Chassis
Fuel Supply Line: Service and Repair Fuel Hose/Pipes Replacement - Chassis
Fuel Hose/Pipes Replacement - Chassis
Removal Procedure
1. Relieve the fuel system pressure. Refer to the Fuel Pressure Relief (With CH 48027) (See: Fuel
2. Clean all the fuel pipe connections and the surrounding areas before disconnecting the pipes in
system.
3. Disconnect the fuel feed and return pipes (1, 2) from the fuel rail. Refer to Metal Collar Quick
Connect Fitting Service (See: Fuel Line
Coupler/Service and Repair/Metal Collar Quick Connect Fitting Service) .
4. Cap the fuel rail pipes. 5. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See:
Maintenance) . 6. Remove the left hand catalytic converter. Refer to Catalytic Converter
Replacement (See: Emission Control Systems/Catalytic Converter/Service
and Repair) .
7. Remove the fuel pipes from the bellhousing stud clip (4). 8. Remove the fuel pipes from the
transmission bracket clip.
9. Disconnect the chassis fuel feed hose at the fuel filter. Refer to Plastic Collar Quick Connect
Fitting Service (See: Fuel Line Coupler/Service and
10. Cap the rear fuel pipes. 11. Note the position of the fuel pipes for aid in installation. 12. Remove
the fuel pipes from the retaining clips. 13. Remove the fuel pipes.
Important: *
When replacing the fuel pipes, always replace them with original equipment or parts that meet the
GM specifications for those parts. The replacement pipes must have the same type of fittings as
the original pipes in order to ensure the integrity of the connection.
* DO NOT use copper or aluminum tubing to replace steel tubing. Only tubing meeting the 124-M
specification or the equivalent is capable of meeting all pressure, corrosion and vibration
characteristics necessary to ensure the durability standard required.
1. Install the fuel pipes into the retaining clips.

Information > Service and Repair > Fuel Hose/Pipes Replacement - Chassis > Page 4024
2. Remove the caps from the rear fuel pipes. 3. Connect the chassis fuel feed hose at the fuel filter.
Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and
4. Install the fuel pipes into the transmission bracket clip. 5. Install the fuel pipes into the
bellhousing stud clip (4). 6. Lower the vehicle. 7. Install the left hand catalytic converter. Refer to
Catalytic Converter Replacement (See: Emission Control Systems/Catalytic Converter/Service
and Repair) .
8. Remove the caps from the fuel rail pipes. 9. Connect the fuel feed and return pipes (1, 2) to the
fuel rail.
10. Tighten the fuel filler cap. 11. Connect the negative battery cable. Refer to Battery Negative

1. Turn ON the ignition, with the engine OFF, for 2 seconds. 2. Turn OFF the ignition for 10
seconds. 3. Turn ON the ignition, with the engine OFF. 4. Inspect for fuel leaks.

Replacement) .
Information > Service and Repair > Fuel Hose/Pipes Replacement - Chassis > Page 4025
Fuel Supply Line: Service and Repair Fuel Hose/Pipes Assembly Replacement
Fuel Hose/Pipes Assembly Replacement
Removal Procedure
1. Clean all the fuel pipe and hose connections and the surrounding areas before disconnecting in
system.
2. Remove the fuel tank. Refer to Fuel Tank Replacement (See: Fuel Tank/Service and
3. Remove the rear fuel feed pipe and the rear fuel return pipe from the fuel sender and the fuel
tank clips. 4. Cap the fuel pipes in order to prevent possible fuel system contamination.
1. Remove the caps from the fuel pipes. 2. Connect the rear fuel feed pipe and the rear fuel return
pipe to the fuel sender and the fuel tank clips. 3. Install the fuel tank. Refer to Fuel Tank
Replacement (See: Fuel Tank/Service and Repair/Removal and Replacement) .
Hummer Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose >
Component Information > Service and Repair > Fuel Tank Filler Hose Replacement
Fuel Filler Hose: Service and Repair Fuel Tank Filler Hose Replacement
Fuel Tank Filler Hose Replacement
Removal Procedure
1. Clean all the fuel pipe and hose connections and the surrounding areas before disconnecting in
system.
2. Drain the fuel below the level of the filler tube and hose assembly. Refer to Fuel Tank Draining
(See: Service and Repair/Procedures) . 3. Raise the vehicle. Refer to Lifting and Jacking the
Vehicle (See: Maintenance) .
4. Loosen the fuel fill hose clamp at the fuel tank. 5. Loosen the fuel fill hose clamp at the fuel fill
pipe. 6. Remove the fuel fill hose and the hose clamps. 7. Cap the fuel tank opening.
1. Uncap the fuel tank opening.

Notice) .
2. Install the fuel fill hose and the hose clamps to the fuel fill pipe.
Tighten the clamps to 2.5 N.m (22 lb in).
3. Lower the vehicle. 4. Refill the fuel system.

Component Information > Service and Repair > Fuel Tank Filler Hose Replacement > Page 4031
Fuel Filler Hose: Service and Repair Fuel Tank Filler Pipe Replacement
Fuel Tank Filler Pipe Replacement
Removal Procedure
1. Clean all the fuel pipe and hose connections and the surrounding areas before disconnection in
system.
2. Remove the fuel filler cap. 3. Drain the fuel below the level of the fuel filler hose. Refer to Fuel
Tank Draining (See: Service and Repair/Procedures) .
4. Remove the fuel fill pipe housing/bezel to fuel fill pipe bolts. 5. Remove housing/bezel by rotating
clockwise. 6. Remove the left rear wheelhouse panel. Refer to Wheelhouse Panel Replacement
(See: Body and Frame/Fender/Front Fender/Front Fender
7. Disconnect the rear axle vent and air spring compressor hoses from the retainer on the fuel fill
pipe, if applicable. 8. Loosen the fuel vent hose to fuel tank clamp. 9. Loosen the fuel fill hose to
fuel tank clamp.
10. Disconnect the fuel fill pipe bracket bolt. 11. Disconnect the fuel fill and vent hoses from the fuel
tank. 12. Remove the fuel fill and vent pipe and hose assembly. 13. Cap the open end of the fuel
tank.
1. Uncap the fuel tank.

Notice) .
2. Install the fuel fill and vent pipe hose assembly to the fuel tank.
Tighten the clamps to 2.5 N.m (22 lb in).
3. Install the fuel fill pipe bracket bolt.

Component Information > Service and Repair > Fuel Tank Filler Hose Replacement > Page 4032
4. Connect the rear axle vent and air spring compressor hoses to the retainer on the fuel fill pipe, if
applicable. 5. Install the left rear wheelhouse panel. Refer to Wheelhouse Panel Replacement
(See: Body and Frame/Fender/Front Fender/Front Fender
6. Lower the vehicle. 7. Install fill pipe/housing bezel by fitting into offset slots and rotating
clockwise. 8. Install the fuel fill pipe housing to the fuel fill pipe bolts.
Tighten the bolts to 2.3 N.m (20 lb in).
9. Refill the fuel system.
10. Install the fuel filler cap.

Hummer Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck >
Component Information > Service and Repair > Fuel Tank Filler Pipe Housing Replacement (BASE)
Fuel Filler Neck: Service and Repair Fuel Tank Filler Pipe Housing Replacement (BASE)
Fuel Tank Filler Pipe Housing Replacement (BASE)
Removal Procedure
1. Remove the fuel filler cap (2) and disengage the tether clip (3) from the pocket (1).
2. Remove the screws (1) securing the pocket to the filler neck (3).
Component Information > Service and Repair > Fuel Tank Filler Pipe Housing Replacement (BASE) > Page 4037
3. With the screws removed, rotate the pocket (1) 1/8 turn counterclockwise in order to release the
pocket from the body quarter panel. 4. Remove the filler pocket from the vehicle.
1. Position the filler pocket to the body quarter panel opening.
2. Rotate the pocket (1) 1/8 turn clockwise in order to secure to the body quarter panel.
Notice) .
3. Install the screws (1) into the pocket (2) in order to secure the pocket to the filler neck (3).
4. Attach the fuel cap tether (3) to the fuel fill pocket (4). 5. Secure the fuel fill cap (2) to the fuel fill
neck (1).
Fuel Filler Neck: Service and Repair Fuel Tank Filler Pipe Housing Replacement (ND1)
Fuel Tank Filler Pipe Housing Replacement (ND1)
Removal Procedure
1. Open the fuel filler door. 2. Remove the fuel filler cap (1) in order to access the pocket screws. 3.
Remove the fuel pocket to filler neck screws. 4. Remove the fuel filler pocket with door from the
body side quarter panel. 5. Remove the allen screws only if the gasket seal needs replacing.
1. Position the fuel pocket to the fuel fill neck.

Notice) .
2. Install the 3 screws.
3. Install the fuel filler cap (1). 4. Close the fuel filler door.
Hummer Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge
Sender > Component Information > Locations
Fuel Gauge Sender: Locations
Sender > Component Information > Locations > Page 4044
Fuel Gauge Sender: Diagrams

Fuel Gauge Sender: Service and Repair
Tools Required
Removal Procedure
1. Remove the fuel tank. Refer to Fuel Tank Replacement (See: Service and Repair/Removal and
Replacement) . 2. Remove fuel lines from sender assembly. Refer to Fuel Hose/Pipes Assembly
Replacement (See: Fuel Supply Line/Service and Repair/Fuel
Hose/Pipes Assembly Replacement) .
tank rotation.

be replaced.

5. Install the fuel tank. Refer to Fuel Tank Replacement (See: Service and Repair/Removal and
Replacement) .
Hummer Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Shield >
Fuel Tank Shield: Service and Repair
Fuel Tank Shield Replacement
Removal Procedure
Remove the outer tank shield mounting nuts. 3. Remove the inner fuel tank shield mounting nuts.
4. With help of an assistant, remove the fuel tank shield from the vehicle.
1. With the help for an assistant, position the fuel tank shield on the fuel tank. 2. Hand tighten inner
fuel tank shield mounting nut. 3. Hand tighten the outer fuel tank shield mounting nut.
Hummer Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Shield >
Notice) .
4. Tighten the fuel tank shield nuts.
* Tighten the 6 mm nuts to 9 N.m (80 lb in).
* Tighten the 8 mm nuts to 18 N.m (13 lb ft).
* Tighten the fuel tank shield bolt to 25 N.m (18 lb ft).

Hummer Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component
Fuel Tank Unit: Locations
Fuel Tank Unit: Diagrams

Fuel Tank Unit: Service and Repair
Tools Required
Removal Procedure
1. Remove the fuel tank. Refer to Fuel Tank Replacement (See: Fuel Tank/Service and
Repair/Removal and Replacement) . 2. Remove fuel lines from sender assembly. Refer to Fuel
Hose/Pipes Assembly Replacement (See: Fuel Supply Line/Service and Repair/Fuel
tank rotation.

be replaced.

5. Install the fuel tank. Refer to Fuel Tank Replacement (See: Fuel Tank/Service and
Hummer Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator -
Electronic > Component Information > Service Precautions
Idle Speed/Throttle Actuator - Electronic: Service Precautions
Handling Idle Air Control Valve Notice
Notice: If the IAC valve has been in service: DO NOT push or pull on the IAC valve pintle. The
force required to move the pintle may damage the threads on the worm drive. Also, DO NOT soak
the IAC valve in any liquid cleaner or solvent, as damage may result.
Hummer Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel
System) > Component Information > Locations
procedure.
Diagnostic Aids



Connections)

Scan Tool Reference
status parameters.

replace the ECM.
OK.
replace the ECM.
Repair Instructions
* Engine Control Module Replacement (See: Computers and Control Systems/Engine Control
Module/Service and Repair)
Repair Verification

Hummer Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel
Delivery and Air Induction > Fuel Pump Control Unit > Component Information > Locations
Delivery and Air Induction > Fuel Pump Control Unit > Component Information > Locations > Page 4072

Delivery and Air Induction > Fuel Pump Control Unit > Component Information > Locations > Page 4073
Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations
Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 4077
procedure.
Diagnostic Aids



Connections)

Scan Tool Reference
status parameters.

replace the ECM.
OK.
replace the ECM.
Repair Instructions
* Engine Control Module Replacement (See: Computers and Control Systems/Engine Control
Module/Service and Repair)
Repair Verification

Hummer Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Service and Repair
Removal Procedure

conditions:
panel.
Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations
Engine Compartment
Accumulator
Engine Compartment
Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 4087
Accumulator

Removal Procedure
1. Remove air intake resonator. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Air
air intake resonator. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Air Cleaner
Housing/Air Cleaner Fresh Air

Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Diagrams

Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Diagrams > Page 4093
Removal Procedure
pressure sensor.

Notice) .
Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams

Hummer Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component
Information > Diagrams
Throttle Body: Diagrams
Throttle Body
Throttle Body: Procedures
Throttle Learn
Throttle Learn
Description
The engine control module (ECM) learns the airflow through the throttle body to ensure the correct
idle. The learned airflow values are stored within the ECM. These values are learned to adjust for
production variation and will continuously learn during the life of the vehicle to compensate for
reduced airflow due to coking. Anytime the throttle body airflow rate changes, for example due to
cleaning or replacing, the values must be relearned.
A vehicle that had a heavily coked throttle body that has been cleaned or replaced may take
several drive cycles to learn out the coking. To accelerate the process, the scan tool has the ability
to reset all learned values back to zero. A new ECM will also have values set to zero.
The idle may be unstable or a DTC may set if the learned values do not match the actual airflow.
Conditions for Running the Throttle Learn Procedure
With Scan Tool - Reset Procedure
* DTCs P0068, P0101, P0102, P0103, P0106, P0107, P0108, P0116, P0117, P0118, P0120,
P0122, P0123, P0128, P0171, P0172, P0174, P0175, P0201, P0202, P0203, P0204, P0205,
P0206, P0220, P0222, P0223, P0300, P0351, P0352, P0353, P0496, P0601, P0604, P0606,
P060D, P0641, P0651, P1516, P2101, P2119, P2120, P2122, P2123, P2125, P2127, P2128,
P2135, P2138, or P2176 are not set.
* Ignition ON, engine OFF.
* The vehicle speed sensor (VSS) is 0 km/h (0 mph).
Without Scan Tool - Learn Procedure
* DTCs P0068, P0101, P0102, P0103, P0106, P0107, P0108, P0116, P0117, P0118, P0120,
P0122, P0123, P0128, P0171, P0172, P0174, P0175, P0201, P0202, P0203, P0204, P0205,
P0206, P0220, P0222, P0223, P0300, P0351, P0352, P0353, P0496, P0601, P0604, P0606,
P060D, P0641, P0651, P1516, P2101, P2119, P2120, P2122, P2123, P2125, P2127, P2128,
P2135, P2138, or P2176 are not set.
* The engine speed is between 450-4,000 RPM.
* The manifold absolute pressure (MAP) is greater than 5 kPa.
* The mass air flow (MAF) is greater than 2 g/s.
* The ignition 1 voltage is greater than 10 volts.
Throttle Learn
With Scan Tool - Reset Procedure
1. Ignition ON, engine OFF, with a scan tool, perform the Idle Learn Reset in Module Setup. 2.
Start the engine, monitor the TB Idle Airflow Compensation parameter. The TB Idle Airflow
Compensation value should equal 0 percent and the
engine should be idling at a normal idle speed.

3. Clear the DTCs and return to the diagnostic that referred you here.
Important: Do NOT perform this procedure if DTCs are set. Refer to Diagnostic Trouble Code
Trouble Code Descriptions/Diagnostic Trouble Code (DTC) List - Vehicle) .
Without Scan Tool - Learn Procedure
1. Start and idle the engine in PARK for 3 minutes. 2. With a scan tool, monitor desired and actual
RPM. 3. The ECM will start to learn the new idle cells and Desired RPM should start to decrease.
4. Ignition OFF for 60 seconds. 5. Start and idle the engine in PARK for 3 minutes. 6. After the 3
minute run time the engine should be idling normal.
Important: During the drive cycle the check engine light may come on with idle speed DTCs. If idle
speed codes are set, clear codes so the ECM can continue to learn.
‹› If the engine idle speed has not been learned the vehicle will need to be driven at speeds above
70 km/h (44 mph) with several decelerations
and extended idles.
7. After the drive cycle, the engine should be idling normally.
‹› If the engine idle speed has not been learned, turn OFF the ignition for 60 seconds and repeat
step 6.
8. Once the engine speed has returned to normal, clear DTCs and return to the diagnostic that
referred you here.
Throttle Body Cleaning
Throttle Body Cleaning
1. Remove the air cleaner outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement
(See: Air Cleaner Housing/Air Cleaner Fresh Air
Caution: Turn OFF the ignition before inserting fingers into the throttle bore. Unexpected movement
of the throttle blade could cause personal injury.
Notice: Do not insert any tools into the throttle body bore in order to avoid damage to the throttle
valve plate.
2. Inspect the throttle body bore and the throttle valve plate for deposits. You will need to open the
throttle valve in order to inspect all surfaces.
Notice: Do not use any solvent that contains Methyl Ethyl Ketone (MEK). This solvent may damage
fuel system components.
3. Clean the throttle body bore and the throttle valve plate using a clean shop towel with GM top
engine cleaner, GM P/N 1052626 (Canadian P/N
993026) or AC-Delco Carburetor Tune-Up Conditioner, P/N X66-P or an equivalent product.
4. Install the air cleaner outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement (See:
Air Cleaner Housing/Air Cleaner Fresh Air

Throttle Body: Removal and Replacement
Throttle Body Assembly Replacement
Removal Procedure
Important: An eight digit part identification number is stamped on the throttle body casting. Refer to
this number if servicing, or part replacement is required.
1. Partially drain the cooling system in order to allow the hoses at the throttle body to be removed.
Refer to Cooling System Draining and Filling
(Static Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair/Draining and
Filling Cooling System)Cooling System Draining and Filling (Vac-N-Fill) (See: Engine, Cooling and
Exhaust/Cooling System/Service and Repair/Draining and Filling Cooling System) .
Important: Cover or plug any openings when servicing the throttle body in order to prevent possible
contamination.
2. Remove the air intake duct. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Air
3. Disconnect the throttle actuator motor harness connector. 4. Disconnect the coolant hoses from
the throttle body. 5. Remove the throttle body attaching bolts. 6. Remove the throttle body and the
gasket.
Important: Do not reuse the throttle body gasket. Install a new gasket during assembly.
7. Discard the throttle body gasket. 8. Inspect the crankcase ventilation hose and the tube. Replace
any damaged components.
1. Install a new throttle body gasket. 2. Install the throttle body assembly.

Notice) .
3. Install the throttle body attaching bolts.
Tighten the throttle body bolts to 10 N.m (89 lb in).
4. Connect the coolant hoses to the throttle body.
Important: Verify that the TAC harness connector and the connector seal are properly installed and
not damaged.
5. Connect the TAC harness connector.
6. Install the air intake duct. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Air
7. Connect the intake air temperature sensor harness connector. 8. Refill the cooling system. Refer
to Cooling System Draining and Filling (Static Fill) (See: Engine, Cooling and Exhaust/Cooling
System/Service
Cooling System) .
9. Verify that the vehicle meets the following conditions:
12. Start the engine. 13. Inspect for coolant leaks.

Hummer Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor >

Hummer Workshop Manuals > Powertrain Management > Ignition System > Firing Order > Component Information >
Specifications

Hummer Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component

Removal Procedure

Replacement) .
the CMP sensor.

Notice) .

Replacement) .
Hummer Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component

that set.
P0315 is set:
* A ECM replacement

Removal Procedure


Notice) .
Hummer Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information >
Testing and Inspection
- Tearing
- Piercing
- Arcing
- Carbon tracking
- Corroded terminal
Testing and Inspection > Page 4132
Removal Procedure
seal to cable seal.
to cable seal.
Testing and Inspection > Page 4133

Hummer Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information >
Service and Repair
Ignition Coil: Service and Repair
Ignition Coil Replacement
Removal Procedure
1. Disconnect the spark plug wires at the ignition coils.
2. Disconnect the ignition coil harness connector.
3. Remove the ignition coil mounting bolts.
4. Remove the ignition coil.
Hummer Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information >
1. Install the ignition coil to the bracket.
2. Install the ignition coil mounting bolts.
Tighten the ignition coil mounting bolts to 8 N.m (71 lb in).
3. Connect the ignition coil harness connector.
4. Connect the spark plug wires at the ignition coils.

Hummer Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information >
Locations
Diagrams > Knock Sensor (KS) 1
Knock Sensor (KS) 1

Diagrams > Knock Sensor (KS) 1 > Page 4144
Knock Sensor (KS) 2

Diagrams > Page 4145
Removal Procedure

Hummer Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Camshaft Position Sensor > Component Information > Locations
Camshaft Position Sensor > Component Information > Locations > Page 4150

Removal Procedure

Replacement) .
the CMP sensor.

Notice) .

Replacement) .
Crankshaft Position Sensor > Component Information > Locations
Crankshaft Position Sensor > Component Information > Locations > Page 4156
Crankshaft Position Sensor > Component Information > Locations > Page 4157

Crankshaft Position Sensor > Component Information > Service and Repair > Procedures
that set.
P0315 is set:
* A ECM replacement

Crankshaft Position Sensor > Component Information > Service and Repair > Procedures > Page 4160
Removal Procedure

Crankshaft Position Sensor > Component Information > Service and Repair > Procedures > Page 4161

Notice) .
Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Procedures
kit.
Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Procedures > Page 4167
Removal Procedure

lock cylinder case.


Knock Sensor > Component Information > Locations
Knock Sensor > Component Information > Locations > Page 4173
Knock Sensor > Component Information > Diagrams > Knock Sensor (KS) 1
Knock Sensor (KS) 1

Knock Sensor > Component Information > Diagrams > Knock Sensor (KS) 1 > Page 4176
Knock Sensor (KS) 2

Knock Sensor > Component Information > Diagrams > Page 4177
Removal Procedure

Hummer Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information >
Specifications


Spark Plug Usage
conditions. Refer to Ignition System Specifications (See: Specifications) for the correct spark plug.
NOT move.
Ignition System Specifications (See: Specifications) . An excessively wide electrode gap can
prevent correct spark plug operation.
- Inspect for the correct spark plug torque. Refer to Ignition System Specifications (See:
Specifications) . Insufficient torque can prevent correct spark plug operation. An over torqued spark
plug, causes the insulator (2) to crack.
gap.

* Weak coils
Removal Procedure
needed.

Notice) .
and Repair) .
Hummer Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids -
Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component
Information > Locations > Automatic Transmission Electronic Component Views
Pressure Regulating Solenoid: Locations Automatic Transmission Electronic Component Views
Information > Locations > Automatic Transmission Electronic Component Views > Page 4193
Pressure Regulating Solenoid: Locations Pressure Control (PC) Solenoid Valve
Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information >
Locations
Shift Interlock Solenoid: Locations
Shift Interlock Solenoid: Diagrams
Automatic Transmission Shift Lock Control Solenoid

Shift Interlock Solenoid: Service and Repair
Automatic Transmission Shift Lock Actuator Replacement
Removal Procedure
Important: After assembling the shift lock actuator, turn the ignition forward but do not start
(auxiliary position) and attempt to pull the lever from PARK with and without the brake pedal
depressed to verify there is no gear access without the brake pedal depressed.
Important: Ensure the key cannot be removed from the ignition unless both the shifter is in PARK
and the shift knob button has been depressed.
1. Remove the console. Refer to Front Floor Console Replacement (See: Body and Frame/Interior
Moulding / Trim/Console/Service and
Repair/Front Floor Console Replacement) .
2. Disconnect the shift lock actuator electrical connector (3).

3. Shift assembly to LOW position. 4. Loosen and remove the screw at the rear of the shifter
assembly. 5. Shift the assembly to the NEUTRAL position. 6. Loosen and remove the top screw of
the shift lock actuator through the lever slot. 7. Pull lever to the DRIVE position and remove the
shift lock actuator.
1. In the DRIVE position, depress the shift lock actuator button and realign into the shifter lever. 2.
Push lever to NEUTRAL.
Notice : Refer to Fastener Notice (See: Service Precautions/Vehicle Damage Warnings/Fastener

Notice) .
3. Install the top screw through the lever slot.
Tighten the actuator screw to 1.65 N.m (15 lb in).

4. Shift lever to LOW. 5. Install the screw at the rear of the shifter assembly.
6. Connect the electrical connector (3). 7. Install the console. Refer to Front Floor Console
Replacement (See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair/Front
Floor Console Replacement) .

Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information >
Specifications
Shift Solenoid: Specifications
Shift Solenoid Valve State and Gear Ratio

Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations >
Shift Solenoid: Locations Automatic Transmission Electronic Component Views
Shift Solenoid: Locations Shift Solenoid
Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Diagram Information and Instructions
Shift Solenoid: Diagram Information and Instructions

Electrical Symbols
Electrical Symbols
Voltage Indicators
General Icons
Diagram Information and Instructions > Page 4209


Harness Components
Component Parts
Switches and Relays

Devices and Sensors

Shift Solenoid: Diagnostic Aids

* Antenna location
Circuit Testing
Circuit Testing




Fused Jumper Wires)

Voltage)


Frequency)
Continuity)






Protection - Fuses)


Tools Required
J 25070 Heat Gun
necessary.
Salt Water Spray
condition.
cooling needs.
conditions.
when the DTC set.
Measuring Frequency
Measuring Frequency
measured.
Measuring Voltage
Measuring Voltage
points.
Frontprobe
terminals.
improper diagnosis.
connectors:
Backprobe
Important:

of a test probe.
connector.

lost.
With a DMM
With a Test Lamp
load.
Tools Required

Continuity)


circuit.
Tools Required
following items:

Recorder operation.

component side.






With a DMM
With a Test Lamp
shorted.
measurement.

Tools Required
pair of leads.
being tested.
terminals.
Tools Required

gage size.
Flat Wire Repairs
Flat Wire Repairs
Tools Required
energy circuits.
GMLAN Repairs
Operation ( See: Computers and Control Systems/Information Bus/Description and Operation) .
the repair.
GMLAN Wire Repair

splice.
(AWG) size.
achieved.
Tools Required
being obstructed.
sensor performance.
Tools Required
damaged wire.
Repair kit).
source.
exhaust pipes.

during the repair.

(AWG) size.
achieved.
achieved.
Tools Required

* A heat torch

SIR/SRS Wire Repair

together.
achieved.

Sleeves) .
Tools Required
2. Cut the wire.

closes.
existing wires.

Tools Required
2. Cut the wire.
achieved.
soldering tool.
new diode.
splice is made.
recommended.
Wiring Repairs
Wiring Repairs
Repairs)

Wiring Repairs)




Wiring Repairs)
AFL/EPC Connectors
AFL/EPC Connectors
Tools Required
Removal Procedure
forward.
dress
cover.

Repair Procedure
connector end view.
Tools Required

position.
Tools Required
Removal Procedure
cover.
Repair Procedure
connector end view.

Tools Required
body and pry up.
position.
used.

Tools Required
position.

Connector Repairs
Connector Repairs



Connectors (ECM))




Connector Anatomy
* Bosch
* Delphi
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
above it.
connection.
Tools Required
Removal Procedure
past the locks.
damaging it.
the tool may break.
used.
Repair Procedure
time.
Micro 64 terminals.
added wire.
from the wire.
visible.
Tools Required


remove the cover.
used.
added wire.

Tools Required
Terminal Removal
be replaced.
connector body.
Terminal Repair

Tools Required
Terminal Removal
Terminal Repair
Repairs) .
Tools Required
Tools Required
Removal Procedure
body.
cover off.
damaging it.
the connector.
used.
Repair Procedure
connector end view.
FCI Connectors
FCI Connectors
Tools Required
Removal Procedure
dress
cover.
Repair Procedure
connector end view.
JST Connectors
JST Connectors
Tools Required

Removal Procedure
connector body.
connector body.
used.
Repair Procedure
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required

Removal Procedure
Repair Procedure
connector end view.
Molex Connectors
Molex Connectors
Tools Required
forward.
Kit.
terminal.
Tools Required
Sumitomo Connectors
Sumitomo Connectors
Tools Required

* Terminal (1)
* Entry Canal (2)
connector.
terminal retainer.
Kit.
terminal.
Tools Required
Removal Procedure
component.

Tools Required
Removal Procedure
housing.
Repair Procedure
connector end view.

Tools Required

panel slides over.
Tools Required
assurance (CPA).
terminal.
Tools Required
Removal Procedure
damaging it.
Repair Procedure
connector end view.
Tools Required

Tools Required
Removal Procedure


Repair Procedure
connector end view.

Arrows and Symbols
Arrows and Symbols
Arrows and Symbols
Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and
Repair > Automatic Transmission Electronic Component Views
Shift Solenoid: Service and Repair Automatic Transmission Electronic Component Views
Repair > Automatic Transmission Electronic Component Views > Page 4321
Shift Solenoid: Service and Repair Control Solenoid Valve and Transmission Control Module
Assembly Replacement

Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component
Torque Converter Clutch Solenoid: Locations
Transmission and Drivetrain > Actuators and Solenoids - Differential > Actuator, Differential Lock > Component Information
> Locations
Actuator: Locations
Rear Suspension
Left
> Locations > Page 4330
Actuator: Diagrams
Rear Differential Lock Actuator

Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information
> Diagrams
Transfer Case Actuator: Diagrams
Transfer Case Encoder Motor

> Diagrams > Page 4335
Transfer Case Actuator: Service and Repair
Transfer Case Motor/Encoder Replacement
Removal Procedure
1. Remove the transfer case shield. Refer to Transfer Case Shield Replacement (See:
Transmission and Drivetrain/Transfer Case/Service and
Repair/Removal and Replacement/Transfer Case Shield Replacement) .
2. Disconnect the encoder motor electrical connector. 3. Remove the encoder motor bolts. 4.
Remove the encoder motor. 5. Remove the actuator insulator.
Important:
*
If the encoder motor is being replaced, ensure that the transfer case is in the neutral position.
Manually shift the transfer case at the shift shaft, using a crescent wrench if necessary.
* When installing the encoder motor, ensure that the encoder motor is indexed correctly and the
motor is flat against the transfer case before tightening the bolts.
1. Apply a 3.175 mm (1/8 in) bead of RTV sealant GM P/N 12345739 (Canadian P/N 10953541) or
equivalent to the sealing surface of the encoder
motor.
2. Rotate to align the shift detent lever with the encoder motor assembly and install the encoder
motor.

Notice) .
3. Loosely install the encoder motor mounting bolts. 4. Loosely install the encoder motor bracket
bolt.
Tighten the Encoder motor mounting bolts and the bracket bolt to 10 N.m (89 lb in).
5. Connect the encoder motor electrical connector. 6. Install the transfer case shield. Refer to
Transfer Case Shield Replacement (See: Transmission and Drivetrain/Transfer Case/Service and
Repair/Removal and Replacement/Transfer Case Shield Replacement) .

Hummer Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules -
Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical
Service Bulletins > Recalls: > 08080 > Mar > 08 > Campaign - Reprogram the TCM
31, 2009 - (Mar 4, 2008)
Purpose
Vehicles Involved
Important:
Service Procedure
Notice:

Service Bulletins > Recalls: > 08080 > Mar > 08 > Campaign - Reprogram the TCM > Page 4347
up to date.
8.3. Select NEXT.

Claim Information
Disclaimer
Service Bulletins > Customer Interest: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON
INFORMATION
Models:
failure)
the correct states.
Service Bulletins > Customer Interest: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON >
Page 4354
HISTORY DTC
following:
Speed >0 MPH
Page 4355
following:
Speed >0 MPH
properly.

defined below:
Page 4356
Disclaimer
Service Bulletins > Customer Interest: > 08-07-30-012 > Mar > 08 > A/T - Clunk Noise First Gear/Engine Braking Sensation
TECHNICAL
Bulletin No.: 08-07-30-012
Condition
Correction
Disclaimer
Service Bulletins > All Technical Service Bulletins for Control Module: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC
P1825/P182E or P1915/MIL ON
ON
INFORMATION
Models:
failure)
the correct states.
P1825/P182E or P1915/MIL ON > Page 4366
HISTORY DTC
following:
Speed >0 MPH
following:
Speed >0 MPH
properly.

defined below:
Disclaimer
Service Bulletins > All Technical Service Bulletins for Control Module: > 08-07-30-012 > Mar > 08 > A/T - Clunk Noise First
Gear/Engine Braking Sensation
Sensation
TECHNICAL
Bulletin No.: 08-07-30-012
Condition
Correction
Disclaimer
Service Bulletins > All Technical Service Bulletins for Control Module: > 08080 > Mar > 08 > Campaign - Reprogram the
TCM
31, 2009 - (Mar 4, 2008)
Purpose
Vehicles Involved
Important:
Service Procedure
Notice:

TCM > Page 4377
up to date.
8.3. Select NEXT.

Claim Information
TCM > Page 4378
Disclaimer
Service Bulletins > All Other Service Bulletins for Control Module: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC
ON
INFORMATION
Models:
failure)
the correct states.
HISTORY DTC
following:
Speed >0 MPH
following:
Speed >0 MPH
properly.

defined below:
Disclaimer
Service Bulletins > All Other Service Bulletins for Control Module: > 08-07-30-012 > Mar > 08 > A/T - Clunk Noise First
Sensation
TECHNICAL
Bulletin No.: 08-07-30-012
Condition
Correction
Disclaimer
Service Bulletins > All Other Service Bulletins for Control Module: > 08080 > Mar > 08 > Campaign - Reprogram the TCM
31, 2009 - (Mar 4, 2008)
Purpose
Vehicles Involved
Important:
Service Procedure
Notice:

Service Bulletins > All Other Service Bulletins for Control Module: > 08080 > Mar > 08 > Campaign - Reprogram the TCM >
Page 4396
up to date.
8.3. Select NEXT.

Claim Information
Page 4397
Disclaimer
Service Bulletins > Page 4398

Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component
Information > Diagrams > Transfer Case Shift Control Module X1

Information > Diagrams > Transfer Case Shift Control Module X1 > Page 4406


proceeding.
to the scan tool.
Removal Procedure
control module (2).
Hummer Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches -
Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information >
Locations
Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component

Views


Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Locations

Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component
Switch


Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component

Removal Procedure

Notice) .
Hummer Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > Recalls: > 07338A > Jun > 08 > Campaign - ECM Update for OBD
Improvements
PROM - Programmable Read Only Memory: Recalls Campaign - ECM Update for OBD
Improvements
SERVICE UPDATE
Bulletin No.: 07338A
Date: June 19, 2008
Subject: 07338A - Service Update for Inventory Vehicles Only - Cold Start P1400 On-Board
Diagnostic (OBD) System Improvement - Reprogram ECM Expires January 31, 2009
Models: 2008 Cadillac Escalade 2008 GMC Sierra, Yukon, Yukon XL 2008 HUMMER H2
Equipped with 6.2L V8 (RPO L92 - VIN 8) Engine and Located in Canada and the following United
States:
Alaska, Colorado, Connecticut, Delaware, Idaho, Illinois, Indiana, Iowa, Kansas, Maine, Maryland,
Massachusetts, Michigan, Minnesota, Montana, Nebraska, New Hampshire, New Jersey, New
York, North Dakota, Ohio, Oklahoma, Oregon, Pennsylvania, Rhode Island, South Dakota, Utah,
Vermont, Virginia, Washington, Wisconsin, Wyoming
Supercede:
THIS SERVICE UPDATE BULLETIN IS BEING REVISED TO EXTEND THE EXPIRATION DATE
AND UPDATE THE SERVICE PROCEDURE.
EXPIRE JANUARY 31, 2009.
Purpose
This bulletin provides a service procedure to reprogram the Engine Control Module (ECM)
calibration on certain 2008 Cadillac Escalade; GMC Sierra, Yukon, Yukon XL; and HUMMER H2
vehicles, equipped with a 6.2L V8 (RPO L92 VIN - 8) engine. The revised calibration corrects a
Service Engine Soon (SES) light for DTC P1400 after a cold start. To verify if an updated
calibration is required, refer to the following procedure in this bulletin. This service procedure
should be completed on involved vehicles currently in dealership inventory as soon as possible, but
no later than January 31, 2009, at which time this bulletin will expire.
Vehicles Involved
and the Techline Information System (TIS) 2000 terminal with the calibration update. Use data
version 12.0 for 2007 or later, available on TIS 2 Web November 26, 2007, and on TIS DVD
version 12.0/ 2007 or later, mailed to dealers beginning December 5, 2007. If you cannot access
the calibration, call the Techline Customer Support Center and it will be provided.
Service Procedure
Improvements > Page 4449
GMVIS must be checked to determine if a specific vehicle requires this action. If the system
indicates that Service Update Bulletin 07338 remains "open" and ECM reprogramming has not
taken place, reprogram the ECM using a Tech 2(R) scan tool with the calibration update from TIS 2
Web.
Service Programming System (SPS)
For step-by-step programming instructions, please refer to SI and the Techline Information System
(TIS) terminal.
Review the information below to ensure proper programming protocol
Important:
^ DO NOT program a control module unless you are directed by a service procedure or you are
directed by a General Motors Corporate service bulletin. Programming a control module at any
other time will not permanently correct customer's concern.
^ It is essential that the Multiple Diagnostic Interface (MDI) or Tech 2(R) and the TIS terminal are
equipped with the latest software before performing (SPS).
^ Due to the time requirements of programming a controller, it is recommended that an external

power source be used to maintain system voltage. Stable battery voltage is critical during
programming. Any fluctuation, spiking, over voltage or loss of voltage will interrupt programming.
To ensure trouble-free programming, GM recommends using one of the following external power
sources:
^ A Midtronics PCS charger
^ A fully charged 12V jumper or booster pack disconnected from the AC voltage supply
^ Some modules will require additional programming/setup events performed before or after
programming.
^ Some vehicles may require the use of a CANDi module for programming.
^ Review the appropriate service information for these procedures.
^ DTCs may set during programming. Clear DTCs after programming is complete.
^ Clearing powertrain DTCs will set the Inspection/Maintenance (I/M) system status indicators to
NO.
Ensure the following conditions are met before programming a control module:
^ FlexFuel (E85) Vehicles
^ The fuel composition learn function is inactive. Programming with the fuel composition learn
active will result in fuel trim DTC.
^ If necessary, drive the vehicle until the scan tool indicates that the fuel composition learn is
inactive.
^ Vehicle System Voltage
^ There is not a charging system concern. All charging system concerns must be repaired before
programming a control module.
^ Battery voltage is greater than 12 volts, but less than 16 volts. The battery must be fully charged
before programming the control module.
^ Turn OFF or disable any system that may put a load on the vehicle battery, such as the following
components:
^ Twilight sentinel
^ Interior lights
^ Daytime running lights (DRL) - Applying the parking brake, on most vehicles, disables the DRL
system
^ Heating, ventilation, and air conditioning (HVAC) systems
^ Engine cooling fans, radio, etc.
^ The ignition switch must be in the proper position. SPS prompts you to turn ON the ignition, with
the engine OFF. DO NOT change the position of the ignition switch during the programming
procedure, unless instructed to do so.
^ Make certain all tool connections are secure, including the following components and circuits:
Improvements > Page 4450
^ DO NOT disturb the tool harnesses while programming. If an interruption occurs during the
^ DO NOT turn OFF the ignition if the programming procedure is interrupted or unsuccessful.
Ensure that all control module and DLC connections are secure and the Tech 2(R) operating
software is up to date.
charge during programming. Use an additional jump battery, if necessary. Only use approved
2. Reprogram the engine control module (ECM). Refer to SI and Service Programming System
(SPS) documentation for ECM programming instructions, if required.
1. Connect the MDI or Tech 2(R) to the vehicle.
Important:
Select J 2534 MDI or Tech 2(R) Legacy Pass-Thru and Reprogram ECU from the Select
Diagnostic Tool and Programming Process screen. The J 2534 MDI will reprogram the module in
less time than the Tech 2(R) scan tool.
2. Select ECM Engine Control Module from the Supported Controllers screen.
3. Follow the on-screen instructions.
3. Using the MDI or Tech 2(R), clear all DTCs if required.
Claim Information
Disclaimer
Information > Technical Service Bulletins > Recalls: > 08080 > Mar > 08 > Campaign - Reprogram the TCM
PROM - Programmable Read Only Memory: Recalls Campaign - Reprogram the TCM
31, 2009 - (Mar 4, 2008)
Purpose
Vehicles Involved
Important:
Service Procedure
Notice:

Information > Technical Service Bulletins > Recalls: > 08080 > Mar > 08 > Campaign - Reprogram the TCM > Page 4455
up to date.
8.3. Select NEXT.

Claim Information
Information > Technical Service Bulletins > Recalls: > 08080 > Mar > 08 > Campaign - Reprogram the TCM > Page 4456
Disclaimer
Information > Technical Service Bulletins > Customer Interest: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC
PROM - Programmable Read Only Memory: Customer Interest A/T Controls - DTC P1825/P182E
or P1915/MIL ON
INFORMATION
Models:
failure)
the correct states.
HISTORY DTC
following:
Speed >0 MPH
following:
Speed >0 MPH
properly.

defined below:
Disclaimer
Information > Technical Service Bulletins > Customer Interest: > 09-08-68-001 > Nov > 09 > Engine Controls - Cruise
PROM - Programmable Read Only Memory: Customer Interest Engine Controls - Cruise Control
Shuts Off During Use
TECHNICAL
Bulletin No.: 09-08-68-001
Models:
Condition
charge below 80%.
Cause
Correction
Note
experienced.
Disclaimer
Information > Technical Service Bulletins > Customer Interest: > 08-06-04-045A > Oct > 08 > Engine Controls - MIL
ON/DTC's P1133/P1153
PROM - Programmable Read Only Memory: Customer Interest Engine Controls - MIL ON/DTC's
P1133/P1153
TECHNICAL
Subject: Malfunction Indicator Lamp (MIL) / Service Engine Soon (SES) Light On, DTCs
P1133-HO2S Slow Response Bank 1 Sensor 1 and/or P1153-HO2S Insufficient Switching Bank 2
Sensor 1 (Reprogram ECM)
Models
Attention:
Please inform the customer that this condition does not cause any driveability, reliability or
durability concern with their vehicle.
Supercede:
This bulletin is being revised to add the 2008 HUMMER H2. Please discard Corporate Bulletin
Number 08-06-04-045 (Section 06 - Engine/Propulsion System).
Condition
Some customers may comment that the MIL/SES light is illuminated.
Upon further investigation, technicians may find the Diagnostic Trouble Code(s) (DTCs) stored as
shown above.
Cause
This condition may be caused by the use of gasoline that exceeds the 80 Parts Per Million (PPM)
maximum U.S. Federal guideline for sulfur content, but is within the 80 PPM - 450 PPM sulfur
content special exemption allowed for small U.S. refineries and/or the greater than 80 PPM sulfur
content fuels found in other parts of the world. In Canada, federal regulations limit the sulphur
content for gasoline sold in Canada to 80 Parts Per Million (PPM) maximum with no exemptions.
Correction
Important:
Verify that the 12-volt battery has a battery charge of 12 to 16 volts. The battery must be able to
maintain a charge during programming. Only use approved Midtronics PSC-550 charger/maintainer
or equivalent to maintain proper battery voltage during programming. The J2534 MDI will
reprogram the modules in less time than the Tech 2(R) scan tool.
A revised engine calibration has been developed to address this condition, which is titled "New
calibration with diagnostic enhancements for DTCs P1133 and P1153". Technicians are to
reprogram the Engine Control Module (ECM) using the Service Programming System (SPS) with
the latest software available on TIS2WEB. Refer to the Engine Control Module Programming and
Setup (Gasoline Engines) and Service Programming System (SPS) procedures in SI for more
information. As always make sure your Tech 2(R) is updated with the latest software version.
Information > Technical Service Bulletins > Customer Interest: > 08-06-04-045A > Oct > 08 > Engine Controls - MIL
ON/DTC's P1133/P1153 > Page 4473
Disclaimer
Information > Technical Service Bulletins > Customer Interest: > 08-07-30-012 > Mar > 08 > A/T - Clunk Noise First
PROM - Programmable Read Only Memory: Customer Interest A/T - Clunk Noise First
TECHNICAL
Bulletin No.: 08-07-30-012
Condition
Correction
Disclaimer
Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: >
PROM - Programmable Read Only Memory: All Technical Service Bulletins Aftermarket Parts -
INFORMATION
Models:
not be honored.

- Propane injection

Disclaimer
09-06-04-026C > Aug > 10 > Engine, A/T Controls - Non-GM Calibration ID
PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine, A/T Controls -
Non-GM Calibration ID
INFORMATION
Subject: Identifying Non-GM (Aftermarket) Engine and Transmission Calibrations for V8 Gas
Engines Using Tech 2(R) or Global Diagnostic System (GDS)
Models:
2006-2011 GM Passenger Cars and Light Duty Trucks (Excluding Saab 9-7X) 2006-2009
HUMMER H2 2006-2010 HUMMER H3 Equipped with V8 Gas Powered Engines Only
Attention:
This bulletin applies to V8 gas powered engines ONLY. For Duramax(TM) diesel powered engines,
refer to the latest version of Corporate Bulletin Number 08-06-04-006G.
Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate
General Motors is identifying an increasing number of engine, transmission and catalytic converter
part failures that are the result of non-GM (aftermarket) engine and transmission control
calibrations being used.
When alteration to the GM-released engine or transmission control calibrations occurs, it subjects
powertrain and driveline components (engine , transmission, transfer case, driveshaft and rear
axle) to stresses that were not tested by General Motors. It is because of these unknown stresses,
subsequently removed.
Warranty coverage is based on the equipment and calibrations that were released on the vehicle at
time of sale, or subsequently updated by GM. That's because GM testing and validation matches
the calibration to a host of criteria that is essential to assure reliability, durability and emissions
performance over the life of the warranty coverage and beyond. Stresses resulting from
calibrations different from those tested and released by GM can damage or weaken components,
leading to poor performance and or shortened life.
Additionally, non-GM (aftermarket) issued engine control modifications often do not meet the same
emissions performance standards as GM issued calibrations. Depending on state statutes,
individuals who install engine control module calibrations that put the vehicle outside the
parameters of emissions certification standards may be subject to fines and/or penalties.
This bulletin outlines a procedure to identify the presence of non-GM (aftermarket) calibrations. GM
recommends performing this check whenever a hard part failure is seen on internal engine or
transmission components, or before an engine assembly or transmission assembly is being
replaced under warranty. It is also recommended that the engine calibration verification procedure
be performed whenever diagnostics indicate that catalytic converter replacement is indicated.
The PQC has a process to confirm the ECM/PCM calibration is GM issued. The PQC will require a
picture of the engine calibration verification screen, as outlined in this bulletin, before authorizing
any V8 gas powered engine replacement.
If a non-GM calibration is found and verification has taken place through GM, the remaining
powertrain and driveline warranty will be blocked and notated in GMVIS and the dealership will be
notified. This block prevents any UNAUTHORIZED warranty claim submission.
1. Connect the Tech 2(R) to the vehicle. 2. Go to: Diagnostics and build the vehicle. 3. Select:
Powertrain. 4. Select: Engine. 5. *Select: Engine Control Module or PCM. 6. *Select: Module ID
Information or I/M Information System if the Module ID Information selection is not available. 7. *If
"I/M information System" was selected, it may be necessary to select "Vehicle Information" in order
to display the calibration information.
‹› If the CVN information is displayed as "N/A", it will be necessary to contact the TCSC to obtain
the CVN information.
09-06-04-026C > Aug > 10 > Engine, A/T Controls - Non-GM Calibration ID > Page 4488
8. Take a CLEAR digital picture of the Tech 2(R) Vehicle Information screen showing the engine
Calibration IDs and Verification Numbers as
shown above. Retain the printout information and the Tech 2(R) screen photograph with the repair
order.
Note All pictures must be sent as a.jpg file.
9. E-mail a copy of the picture to [email protected] In the subject line of the e-mail include the
phrase "V8 Cal" as well as the complete VIN
and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC.
Include a brief description of the customer concern and cause of the concern.
Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail
reply will advise the dealer if the calibrations are OEM.
10. Allow two hours for the PQC to verify the calibrations and set up the case details.
‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM
Technical Assistance to discuss warranty
concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be
directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada).
11. You may call the PQC two hours after submitting the e-mail for authorization to replace the
assembly. This will provide them time to receive,
review and set up a case on the request. Please be prepared to provide all the usual
documentation that is normally required when requesting an assembly authorization from the PQC.
Tech 2(R) Displaying All Zeroes for the Verification Numbers on the Calibration ID and Verification
Number Screen
If the Tech 2(R) that you are using displays all zeroes for the Verification Numbers as shown, then
1. Update the Tech 2(R) with the latest software from TIS2WEB. 2. Turn OFF the ignition for 90
seconds. 3. Connect the Tech 2(R) to the vehicle. 4. Turn ON the ignition, and build the vehicle.
Observe the Tech 2(R) Calibration ID and Verification Number screen for proper operation.
‹› If the Tech 2(R) screen still does not display properly, then turn OFF the ignition for 90 seconds
again. Turn ON the ignition and observe the
same screen for proper operation.
Retrieving Calibrations From a Global A Vehicle
This information applies to the 2010 Camaro and is typical of the procedure that will be used on
Global A vehicles.

2. Connect the MDI to the Data Link Connector (DLC) of the vehicle.
Note Use the USB port to make the following MDI connection:
3. Connect the MDI to a PC or laptop that has been downloaded with the GDS application from
TIS2WEB.
Note At least one Diagnostic Package must be installed on the PC to perform diagnostics. If GDS
was just installed, select: Add New Diagnostic Package and then select: a Diagnostic Package to
download.
4. Click: On the GDS icon on the PC. 5. The Login Page will appear. 6. Select: A User. 7. The ID
Screen will appear. 8. Select: The serial number of the MDI being used. 9. Select: Connect.
10. Verify that the system status is ready by observing for a flashing PC light icon on the MDI. 11.
Select: Make, Model and Model Year, in order to build the vehicle. 12. Click: Upload VIN, to allow
the VIN to be reported to the PC. 13. At: The Verification step, turn ON the ignition, with the engine
OFF. 14. Select: Next Action. 15. The Home Page will appear. 16. Select: Next. 17. The Diagnostic
Screen will appear.
Note Due to vehicle build, software and RPO variations, GDS may ask for additional information in
Step 18.
18. Select: Engine ID, if prompted. 19. Select: Module Diagnostics. 20. Select: ECM. 21. Select: ID
Information. 22. The Diagnostics page will appear.
Typical View of GDS Calibration History Screen
Note GDS is capable of displaying up to 10 Calibration History events.

23. Select: Calibration History from the drop down menu in order to display the following items on
the screen:
- Calibration History Buffer
- Number of Calibration History Events Stored
- Calibration Part Number History
- Calibration Verification Number History
24. Select: Screenshot. 25. Name and save the file in an appropriate folder. 26. Select : Print, and
retain a copy of the screenshot with the repair order.
27. E-mail a copy of the screenshot to [email protected] In the subject line of the e-mail include the
- The Dealership Service Management must be involved in any situation that would justify the use
of labor operation Z1111.
- Notify the Fixed Operations Manager (FOM) (Warranty Manager (WM) in Canada) of the
situation.
- All claims will have to be routed to the FOM (WM in Canada) for approval.
- Please refer to Corporate Bulletin Number 09-00-89-016, Labor Operation Z1111 - Suspected
Tampering or Vehicle Modifications for important information.
Disclaimer
PROM - Programmable Read Only Memory: All Technical Service Bulletins A/T Controls - DTC
INFORMATION
Models:
failure)
the correct states.
HISTORY DTC
following:
Speed >0 MPH
following:
Speed >0 MPH
properly.

defined below:
Disclaimer
PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls -
TECHNICAL
Bulletin No.: 09-08-68-001
Models:
Condition
charge below 80%.
Cause
Correction
Note
experienced.
Disclaimer
08-06-04-045A > Oct > 08 > Engine Controls - MIL ON/DTC's P1133/P1153
PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls - MIL
TECHNICAL
Models
Attention:
Supercede:
Condition
shown above.
Cause
Correction
Important:
08-06-04-045A > Oct > 08 > Engine Controls - MIL ON/DTC's P1133/P1153 > Page 4506
Disclaimer
07338A > Jun > 08 > Campaign - ECM Update for OBD Improvements
PROM - Programmable Read Only Memory: All Technical Service Bulletins Campaign - ECM
Update for OBD Improvements
SERVICE UPDATE
Date: June 19, 2008
States:
Supercede:
Purpose
Vehicles Involved
Service Procedure
07338A > Jun > 08 > Campaign - ECM Update for OBD Improvements > Page 4511
Web.
(TIS) terminal.
Important:

sources:
programming.
NO.
inactive.
components:
^ Twilight sentinel
^ Interior lights
system
Important:
Claim Information
Disclaimer
PROM - Programmable Read Only Memory: All Technical Service Bulletins A/T - Clunk Noise First
TECHNICAL
Bulletin No.: 08-07-30-012
Condition
Correction
Disclaimer
08080 > Mar > 08 > Campaign - Reprogram the TCM
PROM - Programmable Read Only Memory: All Technical Service Bulletins Campaign -
Reprogram the TCM
31, 2009 - (Mar 4, 2008)
Purpose
Vehicles Involved
Important:
Service Procedure
Notice:

08080 > Mar > 08 > Campaign - Reprogram the TCM > Page 4521
up to date.
8.3. Select NEXT.

Claim Information
Disclaimer
Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: >
PROM - Programmable Read Only Memory: All Technical Service Bulletins Aftermarket Parts -
INFORMATION
Models:
not be honored.

- Propane injection

Disclaimer
09-06-04-026C > Aug > 10 > Engine, A/T Controls - Non-GM Calibration ID
PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine, A/T Controls -
Non-GM Calibration ID
INFORMATION
Subject: Identifying Non-GM (Aftermarket) Engine and Transmission Calibrations for V8 Gas
Engines Using Tech 2(R) or Global Diagnostic System (GDS)
Models:
2006-2011 GM Passenger Cars and Light Duty Trucks (Excluding Saab 9-7X) 2006-2009
HUMMER H2 2006-2010 HUMMER H3 Equipped with V8 Gas Powered Engines Only
Attention:
This bulletin applies to V8 gas powered engines ONLY. For Duramax(TM) diesel powered engines,
refer to the latest version of Corporate Bulletin Number 08-06-04-006G.
Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate
General Motors is identifying an increasing number of engine, transmission and catalytic converter
part failures that are the result of non-GM (aftermarket) engine and transmission control
calibrations being used.
When alteration to the GM-released engine or transmission control calibrations occurs, it subjects
powertrain and driveline components (engine , transmission, transfer case, driveshaft and rear
axle) to stresses that were not tested by General Motors. It is because of these unknown stresses,
subsequently removed.
Warranty coverage is based on the equipment and calibrations that were released on the vehicle at
time of sale, or subsequently updated by GM. That's because GM testing and validation matches
the calibration to a host of criteria that is essential to assure reliability, durability and emissions
performance over the life of the warranty coverage and beyond. Stresses resulting from
calibrations different from those tested and released by GM can damage or weaken components,
leading to poor performance and or shortened life.
Additionally, non-GM (aftermarket) issued engine control modifications often do not meet the same
emissions performance standards as GM issued calibrations. Depending on state statutes,
individuals who install engine control module calibrations that put the vehicle outside the
parameters of emissions certification standards may be subject to fines and/or penalties.
This bulletin outlines a procedure to identify the presence of non-GM (aftermarket) calibrations. GM
recommends performing this check whenever a hard part failure is seen on internal engine or
transmission components, or before an engine assembly or transmission assembly is being
replaced under warranty. It is also recommended that the engine calibration verification procedure
be performed whenever diagnostics indicate that catalytic converter replacement is indicated.
The PQC has a process to confirm the ECM/PCM calibration is GM issued. The PQC will require a
picture of the engine calibration verification screen, as outlined in this bulletin, before authorizing
any V8 gas powered engine replacement.
If a non-GM calibration is found and verification has taken place through GM, the remaining
powertrain and driveline warranty will be blocked and notated in GMVIS and the dealership will be
notified. This block prevents any UNAUTHORIZED warranty claim submission.
1. Connect the Tech 2(R) to the vehicle. 2. Go to: Diagnostics and build the vehicle. 3. Select:
Powertrain. 4. Select: Engine. 5. *Select: Engine Control Module or PCM. 6. *Select: Module ID
Information or I/M Information System if the Module ID Information selection is not available. 7. *If
"I/M information System" was selected, it may be necessary to select "Vehicle Information" in order
to display the calibration information.
‹› If the CVN information is displayed as "N/A", it will be necessary to contact the TCSC to obtain
the CVN information.
order.
Number Screen
Global A vehicles.

TIS2WEB.
download.
Screen will appear.
Step 18.

the screen:
situation.
Disclaimer
PROM - Programmable Read Only Memory: All Technical Service Bulletins A/T Controls - DTC
INFORMATION
Models:
failure)
the correct states.
HISTORY DTC
following:
Speed >0 MPH
following:
Speed >0 MPH
properly.

defined below:
Disclaimer
PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls -
TECHNICAL
Bulletin No.: 09-08-68-001
Models:
Condition
charge below 80%.
Cause
Correction
Note
experienced.
Disclaimer
08-06-04-045A > Oct > 08 > Engine Controls - MIL ON/DTC's P1133/P1153
PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls - MIL
TECHNICAL
Models
Attention:
Supercede:
Condition
shown above.
Cause
Correction
Important:
08-06-04-045A > Oct > 08 > Engine Controls - MIL ON/DTC's P1133/P1153 > Page 4551
Disclaimer
PROM - Programmable Read Only Memory: All Technical Service Bulletins A/T - Clunk Noise First
TECHNICAL
Bulletin No.: 08-07-30-012
Condition
Correction
Disclaimer
Disclaimer
order.
Number Screen
Global A vehicles.

TIS2WEB.
download.
Screen will appear.
Step 18.

the screen:
situation.
Disclaimer
07338A > Jun > 08 > Campaign - ECM Update for OBD Improvements
PROM - Programmable Read Only Memory: All Technical Service Bulletins Campaign - ECM
Update for OBD Improvements
SERVICE UPDATE
Date: June 19, 2008
States:
Supercede:
Purpose
Vehicles Involved
Service Procedure
Web.
(TIS) terminal.
Important:

sources:
programming.
NO.
inactive.
components:
^ Twilight sentinel
^ Interior lights
system
Important:
Claim Information
Disclaimer
08080 > Mar > 08 > Campaign - Reprogram the TCM
PROM - Programmable Read Only Memory: All Technical Service Bulletins Campaign -
Reprogram the TCM
31, 2009 - (Mar 4, 2008)
Purpose
Vehicles Involved
Important:
Service Procedure
Notice:

up to date.
8.3. Select NEXT.

Claim Information
Disclaimer
Hummer Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Automatic
Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Automatic
Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations
Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations > Page 4592

Removal Procedure


Notice) .


Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications

Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Automatic Transmission
Electronic Component Views
Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Automatic Transmission
Electronic Component Views > Page 4601
Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and
Instructions

Electrical Symbols
Electrical Symbols
Voltage Indicators
General Icons
Instructions > Page 4604


Harness Components
Component Parts
Switches and Relays

Devices and Sensors


* Antenna location
Circuit Testing
Circuit Testing




Fused Jumper Wires)

Voltage)


Frequency)
Continuity)






Protection - Fuses)


Tools Required
J 25070 Heat Gun
necessary.
Salt Water Spray
condition.
cooling needs.
conditions.
when the DTC set.
Measuring Frequency
Measuring Frequency
measured.
Measuring Voltage
Measuring Voltage
points.
Frontprobe
terminals.
improper diagnosis.
connectors:
Backprobe
Important:

of a test probe.
connector.

lost.
With a DMM
With a Test Lamp
load.
Tools Required

Continuity)


circuit.
Tools Required
following items:

Recorder operation.

component side.






With a DMM
With a Test Lamp
shorted.
measurement.

Tools Required
pair of leads.
being tested.
terminals.
Tools Required

gage size.
Flat Wire Repairs
Flat Wire Repairs
Tools Required
energy circuits.
GMLAN Repairs
the repair.
GMLAN Wire Repair

splice.
(AWG) size.
achieved.
Tools Required
being obstructed.
sensor performance.
Tools Required
damaged wire.
Repair kit).
source.
exhaust pipes.

during the repair.

(AWG) size.
achieved.
achieved.
Tools Required

* A heat torch

SIR/SRS Wire Repair

together.
achieved.

Sleeves) .
Tools Required
2. Cut the wire.

closes.
existing wires.

Tools Required
2. Cut the wire.
achieved.
soldering tool.
new diode.
splice is made.
recommended.
Wiring Repairs
Wiring Repairs
Repairs)

Wiring Repairs)




Wiring Repairs)
AFL/EPC Connectors
AFL/EPC Connectors
Tools Required
Removal Procedure
forward.
dress
cover.

Repair Procedure
connector end view.
Tools Required

position.
Tools Required
Removal Procedure
cover.
Repair Procedure
connector end view.

Tools Required
body and pry up.
position.
used.

Tools Required
position.

Connector Repairs
Connector Repairs



Connectors (ECM))




Connector Anatomy
* Bosch
* Delphi
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
above it.
connection.
Tools Required
Removal Procedure
past the locks.
damaging it.
the tool may break.
used.
Repair Procedure
time.
Micro 64 terminals.
added wire.
from the wire.
visible.
Tools Required


remove the cover.
used.
added wire.

Tools Required
Terminal Removal
be replaced.
connector body.
Terminal Repair

Tools Required
Terminal Removal
Terminal Repair
Repairs) .
Tools Required
Tools Required
Removal Procedure
body.
cover off.
damaging it.
the connector.
used.
Repair Procedure
connector end view.
FCI Connectors
FCI Connectors
Tools Required
Removal Procedure
dress
cover.
Repair Procedure
connector end view.
JST Connectors
JST Connectors
Tools Required

Removal Procedure
connector body.
connector body.
used.
Repair Procedure
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required

Removal Procedure
Repair Procedure
connector end view.
Molex Connectors
Molex Connectors
Tools Required
forward.
Kit.
terminal.
Tools Required
Sumitomo Connectors
Sumitomo Connectors
Tools Required

* Terminal (1)
* Entry Canal (2)
connector.
terminal retainer.
Kit.
terminal.
Tools Required
Removal Procedure
component.

Tools Required
Removal Procedure
housing.
Repair Procedure
connector end view.

Tools Required

panel slides over.
Tools Required
assurance (CPA).
terminal.
Tools Required
Removal Procedure
damaging it.
Repair Procedure
connector end view.
Tools Required

Tools Required
Removal Procedure


Repair Procedure
connector end view.

Arrows and Symbols
Arrows and Symbols
Arrows and Symbols
Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > Automatic

Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations
Actuators and Solenoids - Differential > Actuator, Differential Lock > Component Information > Locations
Actuator: Locations
Rear Suspension
Left
Actuators and Solenoids - Differential > Actuator, Differential Lock > Component Information > Locations > Page 4725
Actuator: Diagrams

Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams

Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Page 4730
Removal Procedure
1. Remove the transfer case shield. Refer to Transfer Case Shield Replacement (See: Transfer
Case/Service and Repair/Removal and
Replacement/Transfer Case Shield Replacement) .
Important:
*
Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Page 4731
motor.
motor.

Notice) .
bolt.
Transfer Case Shield Replacement (See: Transfer Case/Service and Repair/Removal and

Hummer Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids
- A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Automatic Transmission Electronic
Component Views
- A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Automatic Transmission Electronic
Component Views > Page 4738
- A/T > Shift Interlock Solenoid > Component Information > Locations
- A/T > Shift Interlock Solenoid > Component Information > Locations > Page 4742

Removal Procedure


Notice) .


- A/T > Shift Solenoid, A/T > Component Information > Specifications

- A/T > Shift Solenoid, A/T > Component Information > Locations > Automatic Transmission Electronic Component Views
- A/T > Shift Solenoid, A/T > Component Information > Locations > Automatic Transmission Electronic Component Views >
Page 4751
- A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions

Electrical Symbols
Electrical Symbols
Voltage Indicators
General Icons
- A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4754


Harness Components
Component Parts
Switches and Relays

Devices and Sensors


* Antenna location
Circuit Testing
Circuit Testing




Fused Jumper Wires)

Voltage)

Frequency)
Continuity)






Protection - Fuses)


Tools Required
J 25070 Heat Gun
necessary.
Salt Water Spray
condition.
cooling needs.
conditions.
when the DTC set.
Measuring Frequency
Measuring Frequency
measured.
Measuring Voltage
Measuring Voltage
points.
Frontprobe
terminals.
improper diagnosis.
connectors:
Backprobe
Important:

of a test probe.
connector.

lost.
With a DMM
With a Test Lamp
load.
Tools Required

Continuity)


circuit.
Tools Required
following items:

Recorder operation.

component side.






With a DMM
With a Test Lamp
shorted.
measurement.

Tools Required
pair of leads.
being tested.
terminals.
Tools Required
gage size.
Flat Wire Repairs
Flat Wire Repairs
Tools Required
energy circuits.
GMLAN Repairs
the repair.
GMLAN Wire Repair

splice.
(AWG) size.
achieved.
Tools Required
being obstructed.
sensor performance.
Tools Required
damaged wire.
Repair kit).
source.
exhaust pipes.

during the repair.

(AWG) size.
achieved.
achieved.
Tools Required

* A heat torch

SIR/SRS Wire Repair

together.
achieved.

Sleeves) .
Tools Required
2. Cut the wire.

closes.
existing wires.

Tools Required
2. Cut the wire.

achieved.
soldering tool.
new diode.
splice is made.
recommended.
Wiring Repairs
Wiring Repairs
Repairs)

Wiring Repairs)




Wiring Repairs)
AFL/EPC Connectors
AFL/EPC Connectors
Tools Required
Removal Procedure
forward.

dress
cover.

Repair Procedure
connector end view.
Tools Required

position.
Tools Required
Removal Procedure
cover.

Repair Procedure
connector end view.

Tools Required
body and pry up.
position.
used.

Tools Required
position.

Connector Repairs
Connector Repairs



Connectors (ECM))




Connector Anatomy
* Bosch
* Delphi
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
above it.
connection.
Tools Required
Removal Procedure

past the locks.
damaging it.
the tool may break.
used.
Repair Procedure
time.
Micro 64 terminals.
added wire.
from the wire.
visible.
Tools Required


remove the cover.
used.
added wire.

Tools Required
Terminal Removal
be replaced.
connector body.
Terminal Repair

Tools Required
Terminal Removal
Terminal Repair
Repairs) .
Tools Required
Tools Required
Removal Procedure
body.
cover off.
damaging it.
the connector.
used.
Repair Procedure
connector end view.
FCI Connectors
FCI Connectors
Tools Required
Removal Procedure
dress
cover.
Repair Procedure
connector end view.
JST Connectors
JST Connectors
Tools Required

Removal Procedure
connector body.
connector body.
used.
Repair Procedure
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required

Removal Procedure

Repair Procedure
connector end view.
Molex Connectors
Molex Connectors
Tools Required
forward.

Kit.
terminal.
Tools Required
Sumitomo Connectors
Sumitomo Connectors
Tools Required

* Terminal (1)
* Entry Canal (2)
connector.
terminal retainer.
Kit.
terminal.
Tools Required
Removal Procedure
component.

Tools Required
Removal Procedure

housing.
Repair Procedure
connector end view.

Tools Required

panel slides over.
Tools Required
assurance (CPA).
terminal.
Tools Required
Removal Procedure
damaging it.
Repair Procedure
connector end view.
Tools Required

Tools Required
Removal Procedure


Repair Procedure
connector end view.

Arrows and Symbols
Arrows and Symbols
Arrows and Symbols
- A/T > Shift Solenoid, A/T > Component Information > Service and Repair > Automatic Transmission Electronic Component
Views
Views > Page 4866

Views > Page 4867
- A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations
Hummer Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Technical Service Bulletins > Recalls: > 08080 > Mar > 08 > Campaign - Reprogram the TCM
31, 2009 - (Mar 4, 2008)
Purpose
Vehicles Involved
Important:
Service Procedure
Notice:

Component Information > Technical Service Bulletins > Recalls: > 08080 > Mar > 08 > Campaign - Reprogram the TCM >
Page 4879
up to date.
8.3. Select NEXT.

Claim Information
Component Information > Technical Service Bulletins > Recalls: > 08080 > Mar > 08 > Campaign - Reprogram the TCM >
Page 4880
Disclaimer
Component Information > Technical Service Bulletins > Customer Interest: > 08-07-30-020E > Mar > 10 > A/T Controls -
DTC P1825/P182E or P1915/MIL ON
INFORMATION
Models:
failure)
the correct states.
DTC P1825/P182E or P1915/MIL ON > Page 4886
HISTORY DTC
following:
Speed >0 MPH
following:
Speed >0 MPH
properly.

defined below:
Disclaimer
Component Information > Technical Service Bulletins > Customer Interest: > 08-07-30-012 > Mar > 08 > A/T - Clunk Noise
First Gear/Engine Braking Sensation
TECHNICAL
Bulletin No.: 08-07-30-012
Condition
Correction
Disclaimer
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 08-07-30-020E
> Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON
ON
INFORMATION
Models:
failure)
the correct states.
> Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 4898
HISTORY DTC
following:
Speed >0 MPH
following:
Speed >0 MPH
properly.

defined below:
Disclaimer
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 08-07-30-012 >
Mar > 08 > A/T - Clunk Noise First Gear/Engine Braking Sensation
Sensation
TECHNICAL
Bulletin No.: 08-07-30-012
Condition
Correction
Disclaimer
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 08080 > Mar >
08 > Campaign - Reprogram the TCM
31, 2009 - (Mar 4, 2008)
Purpose
Vehicles Involved
Important:
Service Procedure
Notice:

08 > Campaign - Reprogram the TCM > Page 4909
up to date.
8.3. Select NEXT.

Claim Information
08 > Campaign - Reprogram the TCM > Page 4910
Disclaimer
Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Module: > 08-07-30-020E >
Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON
ON
INFORMATION
Models:
failure)
the correct states.
Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 4916
HISTORY DTC
following:
Speed >0 MPH
following:
Speed >0 MPH
properly.

defined below:
Disclaimer
Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Module: > 08-07-30-012 >
Sensation
TECHNICAL
Bulletin No.: 08-07-30-012
Condition
Correction
Disclaimer
Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Module: > 08080 > Mar > 08
> Campaign - Reprogram the TCM
31, 2009 - (Mar 4, 2008)
Purpose
Vehicles Involved
Important:
Service Procedure
Notice:

up to date.
8.3. Select NEXT.

Claim Information
Disclaimer

Hummer Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Automatic Transmission
Dipstick - Dipstick Tube > Component Information > Service and Repair
Automatic Transmission Dipstick - Dipstick Tube: Service and Repair
Transmission Fluid Filler Tube and Seal Replacement

Hummer Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Technical Service Bulletins > A/T - Release of DEXRON(R)-VI A/T Fluid
Fluid - A/T: Technical Service Bulletins A/T - Release of DEXRON(R)-VI A/T Fluid
INFORMATION
Subject: Release of DEXRON(R)-VI Automatic Transmission Fluid (ATF)
Models:
2008 and Prior GM Passenger Cars and Light Duty Trucks 2003-2008 HUMMER H2 2006-2008
HUMMER H3 2005-2007 Saturn Relay 2005 and Prior Saturn L-Series 2005-2007 Saturn ION
2005-2008 Saturn VUE with 4T45-E 2005-2008 Saab 9-7X Except 2008 and Prior Chevrolet Aveo,
Equinox Except 2006 and Prior Chevrolet Epica Except 2007 and Prior Chevrolet Optra Except
2008 and Prior Pontiac Torrent, Vibe, Wave Except 2003-2005 Saturn ION with CVT or AF23 Only
Except 1991-2002 Saturn S-Series Except 2008 and Prior Saturn VUE with CVT, AF33 or 5AT
(MJ7/MJ8) Transmission Only Except 2008 Saturn Astra
Attention:
DEXRON(R)-VI Automatic Transmission Fluid (ATF) is the only approved fluid for warranty repairs
for General Motors transmissions/transaxles requiring DEXRON(R)-III and/or prior DEXRON(R)
transmission fluids.
Supercede: This bulletin is being revised to update information. Please discard Corporate Bulletin
Number 04-07-30-037D (Section 07 - Transmission/Transaxle).
MANUAL TRANSMISSIONS / TRANSFER CASES and POWER STEERING
The content of this bulletin does not apply to manual transmissions or transfer cases. Any vehicle
that previously required DEXRON(R)-III for a manual transmission or transfer case should now use
P/N 88861800. This fluid is labeled Manual Transmission and Transfer Case Fluid. Some manual
transmissions and transfer cases require a different fluid. Appropriate references should be
checked when servicing any of these components.
Power Steering Systems should now use P/N 9985010 labeled Power Steering Fluid.
Consult the Parts Catalog, Owner's Manual, or Service Information (SI) for fluid recommendations.
Some of our customers and/or General Motors dealerships/Saturn Retailers may have some
concerns with DEXRON(R)-VI and DEXRON(R)-III Automatic Transmission Fluid (ATF) and
transmission warranty claims. DEXRON(R)-VI is the only approved fluid for warranty repairs for
General Motors transmissions/transaxles requiring DEXRON(R)-III and/or prior DEXRON(R)
transmission fluids (except as noted above). Please remember that the clean oil reservoirs of the
J-45096 - Flushing and Flow Tester machine should be purged of DEXRON(R)-III and filled with
DEXRON(R)-VI for testing, flushing or filling General Motors transmissions/transaxles (except as
noted above).
DEXRON(R)-VI can be used in any proportion in past model vehicles equipped with an automatic
transmission/transaxle in place of DEXRON(R)-III (i.e. topping off the fluid in the event of a repair
or fluid change). DEXRON(R)-VI is also compatible with any former version of DEXRON(R) for use
in automatic transmissions/transaxles.
DEXRON(R)-VI ATF
General Motors Powertrain has upgraded to DEXRON(R)-VI ATF with the start of 2006 vehicle
production.
Current and prior automatic transmission models that had used DEXRON(R)-III must now only use
DEXRON(R)-VI.
Information > Technical Service Bulletins > A/T - Release of DEXRON(R)-VI A/T Fluid > Page 4939
All 2006 and future model transmissions that use DEXRON(R)-VI are to be serviced ONLY with
DEXRON(R)-VI fluid.
DEXRON(R)-VI is an improvement over DEXRON(R)-III in the following areas:
* These ATF change intervals remain the same as DEXRON(R)-III for the time being.
2006-2008 Transmission Fill and Cooler Flushing
Some new applications of the 6L80 six speed transmission will require the use of the J 45096 -
Flushing and Flow Tester to accomplish transmission fluid fill. The clean oil reservoir of the
machine should be purged of DEXRON(R)-III and filled with DEXRON(R)-VI.
Parts Information
Disclaimer
Fluid - A/T: Technical Service Bulletins A/T - Oil Cooler Flush and Flow Essential Tool
INFORMATION
TransFlow(R)
Models:
Notice
Important
machine on
each repair.
reservoir.
Machine Displays
Disclaimer
Fluid - A/T: Technical Service Bulletins A/T - Water/Coolant Contamination Information
INFORMATION
Bulletin No.: 08-07-30-035
compressed
Important:


Disclaimer
Fluid - A/T: Capacity Specifications
AUTOMATIC TRANSMISSION Pan Removal ....................................................................................

..................................................................................................... 5.7 liters (6.0 quarts) Overhaul ......
..............................................................................................................................................................
......................... 9.9 liters (10.5 quarts) Complete Trans System ........................................................
........................................................................................................... 11.7 liters (12.4 quarts)
Fluid - A/T: Fluid Type Specifications
AUTOMATIC TRANSMISSION FLUID TYPE

............................................................................................................................................ DEXRON
VI
Fluid - A/T: Testing and Inspection
Transmission Fluid Check
This procedure checks the transmission fluid level, as well as the condition of the fluid itself.
Notice: Always use the proper automatic transmission fluid listed. Using incorrect automatic
transmission fluid may damage the vehicle.
Before checking the fluid level, perform the following:
1. Start the engine and park the vehicle on a level surface. Keep the engine running. 2. Apply the
parking brake and place the shift lever in PARK (P). 3. Depress the brake pedal and move the shift
lever through each gear range, pausing for about 3 seconds in each range. Then, move the shift
lever
back to PARK (P).
4. Allow the engine to idle 500-800 rpm for at least 1 minute. Slowly release the brake pedal. 5.
Keep the engine running and observe the transmission fluid temperature (TFT) using the Driver
Information Center (DIC) or a scan tool. 6. Using the TFT reading, determine and perform the
appropriate check procedure. If the TFT reading is not within the required temperature ranges,
allow the vehicle to cool, or operate the vehicle until the appropriate TFT is reached.
Cold Check Procedure
Important: Use this procedure only as a reference to determine if the transmission has enough fluid
to be operated safely until a hot check procedure can be made. The hot check procedure is the
most accurate method to check the fluid level. Perform the hot check procedure at the first
opportunity. Use this cold check procedure to check fluid level when the TFT is between 80°F and
90°F (27°C and 32°C).
the reading. 5. Inspect the color of the fluid on the dipstick. Refer to Fluid Condition Inspection in
this procedure. 6. If the fluid level is below the COLD check band, add only enough fluid as
necessary to bring the level into the COLD band. It does not take much
fluid, generally less than one pint (0.5L). Do not overfill.
handle down to lock the dipstick in place. 8. Perform a hot check at the first opportunity after the
transmission reaches a normal operating temperature between 160°F to 200°F (71°C to 93°C).
Hot Check Procedure
Important: Us this procedure to check the transmission fluid level when the TFT is between 160°F
and 200°F (71°C and 93°C). The hot check procedure is the most accurate method to check the
fluid level. The hot check should be performed at the first opportunity in order to verify the cold
check. The fluid level rises as fluid temperature increases, so it is important to ensure the
transmission temperature is within range.
the reading. 5. Inspect the color of the fluid on the dipstick. Refer to Fluid Condition Inspection. 6. A
safe operating fluid level is within the HOT crosshatch band on the dipstick. If the fluid level is not
within the HOT band, and the TFT is
between 160°F and 200°F (71°C and 93°C), add or drain fluid as necessary to bring the level into
the HOT band. If the fluid level is low, add only enough fluid to bring the level into the HOT band. It
does not take much fluid, generally less than one pint (0.5L). Do not overfill. Also, if the fluid level is
low, inspect the transmission for leaks. Refer to Fluid Leak Diagnosis (See: Testing and
Inspection/Component Tests and General Diagnostics/Fluid Leak Diagnosis) .
handle down to lock the dipstick in place. 8. If applicable and if the vehicle is equipped, reset the
transmission oil life monitor only if the fluid was changed.
Fluid Condition Inspection

Inspect the fluid color. The fluid should be red or dark brown.
* If the fluid color is very dark or black and has a burnt odor, inspect the fluid and inside of the
bottom pan for excessive metal particles or other debris. A small amount of "friction" material in the
bottom pan is a "normal" condition. If large pieces and/or metal particles are noted in the fluid or
bottom pan, flush the oil cooler and cooler lines and overhaul the transmission. If there are no signs
of transmission internal damage noted, replace the fluid filter assembly, repair the oil cooler, and
flush the cooler lines.
* Fluid that is cloudy or milky or appears to be contaminated with water indicates engine coolant or
water contamination. Refer to Engine Coolant/Water in Transmission (See: Testing and
Inspection/Symptom Related Diagnostic Procedures/Engine Coolant/Water in Transmission) .
Fluid - A/T: Service and Repair

Hummer Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T >
Fluid Filter - A/T: Service and Repair

Hummer Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T >
Hummer Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T >
Component Information > Service and Repair > Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection
and Connection
Fluid Line/Hose: Service and Repair Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting
Disconnection and Connection
Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection

Removal Procedure
Important: Perform the following procedure when removing the retaining rings and cooler lines from
the quick connect fittings located on the radiator and/or the transmission.
1. Pull the plastic cap back from the quick connect fitting and down along the cooler line about 5 cm
(2 in). 2. Using a bent-tip screwdriver, pull on one of the open ends of the retaining ring in order to
rotate the retaining ring around the quick connect fitting
until the retaining ring is out of position and can be completely removed.
3. Remove the retaining ring from the quick connect fitting. 4. Discard the retaining ring.
5. Pull the cooler line straight out from the quick connect fitting.
Important: *
Do not reuse any of the existing oil lines or oil line fittings if there is excessive corrosion.
* Do not reuse any of the existing retaining rings that were removed from the existing quick connect
fittings. Install new retaining rings.
* Ensure the following procedures are performed when installing the new retaining rings onto the
fittings.
1. Install a new retaining ring into the quick connect fitting using the following procedure:
and Connection > Page 4960
2. Hook one of the open ends of the retaining ring in one of the slots in the quick connect fitting.
3. Rotate the retaining ring around the fitting until the retaining ring is positioned with all three ears
through the three slots on the fitting.
4. Do not install the new retaining ring onto the fitting by pushing the retaining ring.
5. Ensure that the three retaining ring ears are seen from inside the fitting and that the retaining
ring moves freely in the fitting slots.
6. Install the cooler line into the quick connect fitting. 7. Insert the cooler line end into the quick
connect fitting until a click is either heard or felt.
8. Do not use the plastic cap on the cooler line in order to install the cooler line into the fitting. 9.
Pull back sharply on the cooler line in order to ensure that the cooler line is fastened into the quick
connect fitting.
Important: Do not manually depress the retaining clip when installing the plastic cap.
10. Position (snap) the plastic cap onto the fitting. Do not manually depress the retaining ring when
installing the plastic cap onto the quick connect
fitting.
11. Ensure that the plastic cap is fully seated against the fitting.
12. Ensure that no gap is present between the cap and the fitting.
13. Ensure that the yellow identification band on the tube is hidden within the quick connect fitting.
14. A hidden yellow identification band indicates proper joint seating. 15. Fill the transmission to the
proper level with DEXRON(R) VI transmission fluid. Refer to Transmission Fluid Check (See:
Testing and
Inspection/Component Tests and General Diagnostics/Transmission Fluid Check) .

Fluid Line/Hose: Service and Repair Transmission Fluid Cooler Hose/Pipe Replacement
Transmission Fluid Cooler Hose/Pipe Replacement
Removal Procedure
1. Remove the radiator grille. Refer to Grille Replacement (See: Body and Frame/Grille/Service
and Repair/Grille Replacement) . 2. Remove the radiator lower grille. Refer to Lower Grille
Replacement (See: Body and Frame/Grille/Service and Repair/Lower Grille Replacement
).
3. Remove the transmission fluid cooler hose from the auxiliary oil cooler. Refer to Transmission
Fluid Cooler Hose/Pipe Quick-Connect Fitting
Disconnection and Connection (See: Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting
Disconnection and Connection) .
4. Remove the transmission fluid cooler hose from the radiator. Refer to Transmission Fluid Cooler
Hose/Pipe Quick-Connect Fitting Disconnection
and Connection (See: Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection
and Connection) .
catalytic converter guard. Refer to Catalytic Converter Guard Replacement (See: Engine, Cooling
and Exhaust/Exhaust
System/Catalytic Converter/Catalyst Shield/Service and Repair) .
7. Remove the cooling lines from the transmission. Refer to Transmission Fluid Cooler Hose/Pipe
Quick-Connect Fitting Disconnection and
Connection (See: Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and
Connection) .
8. Remove the oil cooling lines from the vehicle.
1. Install the transmission oil cooler lines to the vehicle. 2. Install the cooling lines to the
transmission. Refer to Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection
and Connection (
See: Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection) .
3. Install the catalytic converter guard. Refer to Catalytic Converter Guard Replacement (See:
Engine, Cooling and Exhaust/Exhaust
System/Catalytic Converter/Catalyst Shield/Service and Repair) .
4. Lower the vehicle. 5. Install the transmission fluid cooler hose to the radiator. Refer to
Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and
Connection (See: Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and
Connection) .
6. Install the transmission fluid cooler hose to the auxiliary oil cooler. Refer to Transmission Fluid
Cooler Hose/Pipe Quick-Connect Fitting
Disconnection and Connection (See: Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting
Disconnection and Connection) .
7. Install the radiator lower grille. Refer to Lower Grille Replacement (See: Body and
Frame/Grille/Service and Repair/Lower Grille Replacement) 8. Install the radiator grille. Refer to
Grille Replacement (See: Body and Frame/Grille/Service and Repair/Grille Replacement) .
Hummer Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T >
Fluid Pan: Specifications
TRANSMISSION FLUID PAN
Tighten The Bolts In The Sequence Shown

............................................................................................................................................. 9 N.m (80
lb in)
Fluid Pan: Service and Repair

Hummer Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure
Sensor/Switch, A/T > Component Information > Locations
Hummer Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T >
Component Information > Technical Service Bulletins > Customer Interest for Fluid Pump: > 08-07-30-023 > May > 08 > A/T
- Fluid Leak From The Bell Housing Area
Fluid Pump: Customer Interest A/T - Fluid Leak From The Bell Housing Area
TECHNICAL
Bulletin No.: 08-07-30-023
Date: May 08, 2008
Subject: 4L60-E/4L65-E/4L70&hyphen;E Automatic Transmission Fluid Leak from Oil Pump or Bell
Housing Area (Replace Torque Converter Hub-to-Oil Pump Seal Assembly)
Models: 2007-2008 Chevrolet Avalanche, Express, Silverado, Suburban, Tahoe, TrailBlazer

2007-2008 GMC Envoy, Savana, Sierra, Yukon, Yukon XL 2007-2008 HUMMER H2 2007-2008
Saab 9-7X
with 4L60-E, 4L65-E or 4L70&hyphen;E Automatic Transmission (RPOs M30, M32 or M70) and
4.8L, 5.3L or 6.0L V8 Engine
Attention:
This bulletin applies to vehicles built prior to December 2007.
Condition
Some customers may comment on an automatic transmission fluid leak. Upon further investigation,
the technician may find fluid leaking from the oil pump or bell housing area.
Cause
Investigation of 2007 transmissions has shown wear of the torque converter hub-to-pump seal
(243, illustrated in the Oil Pump Disassembled View in SI).
Correction
Verify that the leak is coming from the oil pump or bell housing area by the use of oil dye in the
transmission. Refer to Fluid Leak Diagnosis in SI. Clean the transmission suspected area of all
residual oil and drive the vehicle to see if the dye begins to appear. If the leak is coming from the
bell housing replace the torque converter seal.
Parts Information

Component Information > Technical Service Bulletins > Customer Interest for Fluid Pump: > 08-07-30-023 > May > 08 > A/T
- Fluid Leak From The Bell Housing Area > Page 4981
Disclaimer
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Pump: > 08-07-30-023 >
May > 08 > A/T - Fluid Leak From The Bell Housing Area
Fluid Pump: All Technical Service Bulletins A/T - Fluid Leak From The Bell Housing Area
TECHNICAL
Bulletin No.: 08-07-30-023
Date: May 08, 2008

Saab 9-7X
Attention:
Condition
Cause
Correction
Parts Information

Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Pump: > 08-07-30-023 >
May > 08 > A/T - Fluid Leak From The Bell Housing Area > Page 4987
Disclaimer
Hummer Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Parking Pawl, A/T >
Parking Pawl: Service and Repair
Manual Shift Detent Lever and Park Pawl Actuator Replacement

Hummer Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Parking Pawl, A/T >
Hummer Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating
Solenoid, A/T > Component Information > Locations > Automatic Transmission Electronic Component Views
Hummer Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating
Solenoid, A/T > Component Information > Locations > Automatic Transmission Electronic Component Views > Page 4996
Hummer Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules -
A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Recalls: > 08080 > Mar > 08 >
Campaign - Reprogram the TCM
31, 2009 - (Mar 4, 2008)
Purpose
Vehicles Involved
Important:
Service Procedure
Notice:

Campaign - Reprogram the TCM > Page 5006
up to date.
8.3. Select NEXT.

Claim Information
Campaign - Reprogram the TCM > Page 5007
Disclaimer
A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 08-07-30-020E >
Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON
INFORMATION
Models:
failure)
the correct states.
HISTORY DTC
following:
Speed >0 MPH
following:
Speed >0 MPH
properly.

defined below:
Disclaimer
A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 08-07-30-012 >
TECHNICAL
Bulletin No.: 08-07-30-012
Condition
Correction
Disclaimer
A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Control Module: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON
ON
INFORMATION
Models:
failure)
the correct states.
Control Module: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 5025
HISTORY DTC
following:
Speed >0 MPH
following:
Speed >0 MPH
properly.

defined below:
Disclaimer
Control Module: > 08-07-30-012 > Mar > 08 > A/T - Clunk Noise First Gear/Engine Braking Sensation
Sensation
TECHNICAL
Bulletin No.: 08-07-30-012
Condition
Correction
Disclaimer
Control Module: > 08080 > Mar > 08 > Campaign - Reprogram the TCM
31, 2009 - (Mar 4, 2008)
Purpose
Vehicles Involved
Important:
Service Procedure
Notice:

Control Module: > 08080 > Mar > 08 > Campaign - Reprogram the TCM > Page 5036
up to date.
8.3. Select NEXT.

Claim Information
Control Module: > 08080 > Mar > 08 > Campaign - Reprogram the TCM > Page 5037
Disclaimer
A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control
Module: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON
ON
INFORMATION
Models:
failure)
the correct states.
Module: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 5043
HISTORY DTC
following:
Speed >0 MPH
following:
Speed >0 MPH
properly.

defined below:
Disclaimer
Module: > 08-07-30-012 > Mar > 08 > A/T - Clunk Noise First Gear/Engine Braking Sensation
Sensation
TECHNICAL
Bulletin No.: 08-07-30-012
Condition
Correction
Disclaimer
Module: > 08080 > Mar > 08 > Campaign - Reprogram the TCM
31, 2009 - (Mar 4, 2008)
Purpose
Vehicles Involved
Important:
Service Procedure
Notice:

Module: > 08080 > Mar > 08 > Campaign - Reprogram the TCM > Page 5055
up to date.
8.3. Select NEXT.

Claim Information
Module: > 08080 > Mar > 08 > Campaign - Reprogram the TCM > Page 5056
Disclaimer
A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 5057

A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 5058
Hummer Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T
> System Information > Technical Service Bulletins > Customer Interest for Seals and Gaskets: > 08-07-30-023 > May > 08
> A/T - Fluid Leak From The Bell Housing Area
Seals and Gaskets: Customer Interest A/T - Fluid Leak From The Bell Housing Area
TECHNICAL
Bulletin No.: 08-07-30-023
Date: May 08, 2008

Saab 9-7X
Attention:
Condition
Cause
Correction
Parts Information

> System Information > Technical Service Bulletins > Customer Interest for Seals and Gaskets: > 08-07-30-023 > May > 08
> A/T - Fluid Leak From The Bell Housing Area > Page 5067
Disclaimer
> System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 08-07-30-023
> May > 08 > A/T - Fluid Leak From The Bell Housing Area
Seals and Gaskets: All Technical Service Bulletins A/T - Fluid Leak From The Bell Housing Area
TECHNICAL
Bulletin No.: 08-07-30-023
Date: May 08, 2008

Saab 9-7X
Attention:
Condition
Cause
Correction
Parts Information

> System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 08-07-30-023
> May > 08 > A/T - Fluid Leak From The Bell Housing Area > Page 5073
Disclaimer
> System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page 5074
Seals and Gaskets: By Symptom
Technical Service Bulletin # 08-07-30-023 Date: 080508
A/T - Fluid Leak From The Bell Housing Area
TECHNICAL
Bulletin No.: 08-07-30-023
Date: May 08, 2008

Saab 9-7X
Attention:
Condition
Cause
Correction
Parts Information

Disclaimer
Technical Service Bulletin # 08-07-30-023 Date: 080508
A/T - Fluid Leak From The Bell Housing Area
TECHNICAL
Bulletin No.: 08-07-30-023
Date: May 08, 2008

Saab 9-7X
Attention:
Condition
Cause
Correction
Parts Information

Disclaimer
> System Information > Service and Repair > Automatic Transmission Electrical Connector Passage Sleeve Replacement
Seals and Gaskets: Service and Repair Automatic Transmission Electrical Connector Passage
Sleeve Replacement
Automatic Transmission Electrical Connector Passage Sleeve Replacement

> System Information > Service and Repair > Automatic Transmission Electrical Connector Passage Sleeve Replacement >
Page 5079
Page 5080
Seals and Gaskets: Service and Repair Transmission Output Shaft Seal Replacement
Transmission Output Shaft Seal Replacement

Page 5081
Seals and Gaskets: Service and Repair Manual Shift Shaft and Seal Replacement
Manual Shift Shaft and Seal Replacement

Hummer Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches -
A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations
A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Automatic Transmission Electronic
Component Views

Views
A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Automatic Transmission Electronic
Component Views > Page 5090

A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 5091

A/T > Transmission Speed Sensor, A/T > Component Information > Locations
A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Page 5095

Hummer Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T >
Shift Interlock Solenoid > Component Information > Locations
Shift Interlock Solenoid > Component Information > Locations > Page 5100

Removal Procedure


Notice) .


Hummer Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >

Component Information > Locations > Automatic Transmission Electronic Component Views
Component Information > Locations > Automatic Transmission Electronic Component Views > Page 5109
Component Information > Diagrams > Diagram Information and Instructions

Electrical Symbols
Electrical Symbols
Voltage Indicators
General Icons


Harness Components
Component Parts
Switches and Relays

Devices and Sensors


* Antenna location
Circuit Testing
Circuit Testing




Fused Jumper Wires)

Voltage)

Frequency)
Continuity)






Protection - Fuses)


Tools Required
J 25070 Heat Gun
necessary.
Salt Water Spray
condition.
cooling needs.
conditions.
when the DTC set.
Measuring Frequency
Measuring Frequency
measured.
Measuring Voltage
Measuring Voltage
points.
Frontprobe
terminals.
improper diagnosis.
connectors:
Backprobe
Important:

of a test probe.
connector.

lost.
With a DMM
With a Test Lamp
load.
Tools Required

Continuity)


circuit.
Tools Required
following items:

Recorder operation.

component side.






With a DMM
With a Test Lamp
shorted.
measurement.

Tools Required
pair of leads.
being tested.
terminals.
Tools Required
gage size.
Flat Wire Repairs
Flat Wire Repairs
Tools Required
energy circuits.
GMLAN Repairs
the repair.
GMLAN Wire Repair

splice.
(AWG) size.
achieved.
Tools Required
being obstructed.
sensor performance.
Tools Required
damaged wire.
Repair kit).
source.
exhaust pipes.

during the repair.

(AWG) size.
achieved.
achieved.
Tools Required

* A heat torch

SIR/SRS Wire Repair

together.
achieved.

Sleeves) .
Tools Required
2. Cut the wire.

closes.
existing wires.

Tools Required
2. Cut the wire.

achieved.
soldering tool.
new diode.
splice is made.
recommended.
Wiring Repairs
Wiring Repairs
Repairs)

Wiring Repairs)




Wiring Repairs)
AFL/EPC Connectors
AFL/EPC Connectors
Tools Required
Removal Procedure
forward.

dress
cover.

Repair Procedure
connector end view.
Tools Required

position.
Tools Required
Removal Procedure
cover.

Repair Procedure
connector end view.

Tools Required
body and pry up.
position.
used.

Tools Required
position.

Connector Repairs
Connector Repairs



Connectors (ECM))




Connector Anatomy
* Bosch
* Delphi
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
above it.
connection.
Tools Required
Removal Procedure

past the locks.
damaging it.
the tool may break.
used.
Repair Procedure
time.
Micro 64 terminals.
added wire.
from the wire.
visible.
Tools Required


remove the cover.
used.
added wire.

Tools Required
Terminal Removal
be replaced.
connector body.
Terminal Repair

Tools Required
Terminal Removal
Terminal Repair
Repairs) .
Tools Required
Tools Required
Removal Procedure
body.
cover off.
damaging it.
the connector.
used.
Repair Procedure
connector end view.
FCI Connectors
FCI Connectors
Tools Required
Removal Procedure
dress
cover.
Repair Procedure
connector end view.
JST Connectors
JST Connectors
Tools Required

Removal Procedure
connector body.
connector body.
used.
Repair Procedure
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required

Removal Procedure

Repair Procedure
connector end view.
Molex Connectors
Molex Connectors
Tools Required
forward.

Kit.
terminal.
Tools Required
Sumitomo Connectors
Sumitomo Connectors
Tools Required

* Terminal (1)
* Entry Canal (2)
connector.
terminal retainer.
Kit.
terminal.
Tools Required
Removal Procedure
component.

Tools Required
Removal Procedure

housing.
Repair Procedure
connector end view.

Tools Required

panel slides over.
Tools Required
assurance (CPA).
terminal.
Tools Required
Removal Procedure
damaging it.
Repair Procedure
connector end view.
Tools Required

Tools Required
Removal Procedure


Repair Procedure
connector end view.

Arrows and Symbols
Arrows and Symbols
Arrows and Symbols
Component Information > Service and Repair > Automatic Transmission Electronic Component Views
Component Information > Service and Repair > Automatic Transmission Electronic Component Views > Page 5224

Component Information > Service and Repair > Automatic Transmission Electronic Component Views > Page 5225
Hummer Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component
Information > Service and Repair > Transmission Control Lever Knob Replacement
Shifter A/T: Service and Repair Transmission Control Lever Knob Replacement
Transmission Control Lever Knob Replacement

Information > Service and Repair > Transmission Control Lever Knob Replacement > Page 5230
Shifter A/T: Service and Repair Transmission Control Replacement
Transmission Control Replacement

Shifter A/T: Service and Repair Transmission Control Bracket Replacement
Transmission Control Bracket Replacement

Shifter A/T: Service and Repair Automatic Transmission Range Selector Lever Replacement
Automatic Transmission Range Selector Lever Replacement

Hummer Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift
Cable, A/T > Component Information > Adjustments
Shift Cable: Adjustments
Range Selector Lever Cable Adjustment
Adjustment Procedure
1. Ensure that the range selector cable is not restricted. 2. Ensure that the floor shift control is in
the PARK position. 3. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See:
Maintenance) . 4. Disconnect the range selector cable (4) from the range selector lever ball stud
(6). 5. Ensure that the range selector lever is in the mechanical PARK position. (Rotate the range
selector lever fully clockwise.)
6. Release the locking tab (1).
7. Slide the secondary lock cover (1) to the side.

Cable, A/T > Component Information > Adjustments > Page 5237
8. Carefully squeeze the locking tabs (2) together to disengage the primary lock.
9. Pull the primary lock (1) up. Spring tension will push the end of the cable past the ball stud.
Important: If the cable end is pushed rearward past the ball stud during the adjustment procedure,
it must be released and allowed to come forward of the ball stud. The cable end must then be
pushed back just enough to be installed to the ball stud.
10. Push the end of the cable until it is aligned with the ball stud.
11. Install the cable (4) to the ball stud (6).
12. Seat the primary lock (1) by pressing into the locked position.
Cable, A/T > Component Information > Adjustments > Page 5238
13. Slide the secondary lock (1) over the primary lock.
14. Be sure that the secondary lock tab (1) is securely in place. 15. Lower the vehicle. 16. Check
the vehicle for proper operation.
Cable, A/T > Component Information > Service and Repair > Range Selector Lever Cable Replacement
Shift Cable: Service and Repair Range Selector Lever Cable Replacement
Range Selector Lever Cable Replacement
Removal Procedure
1. Position the transmission shift control lever to the park position. 2. Raise the vehicle. Refer to
Lifting and Jacking the Vehicle (See: Maintenance) . 3. Ensure the transmission range selector
lever is positioned to mechanical park.
4. Remove the range selector cable retaining clip (2). 5. Remove the range selector cable (3) from
the range selector cable bracket (1) at the transmission. 6. Remove the range selector cable (3)
from the transmission range selector lever ball stud (4). 7. Lower the vehicle and ensure that the
shift lever is still in the park position.
Cable, A/T > Component Information > Service and Repair > Range Selector Lever Cable Replacement > Page 5241
9. Remove the range selector cable end (2) from the transmission shift control lever ball stud.
10. Remove the range selector cable (1) from the transmission shift control lever housing.
11. Remove the range selector cable grommet (1) from the floor panel. 12. Remove the range
selector cable from the vehicle.
1. Route the range selector cable through the hole in the floor panel. 2. Ensure that the
transmission shift control lever is in the park position.
3. Install the range selector cable grommet (1) to the floor panel.
4. Install the range selector cable (1) to the transmission shift control lever housing. 5. Install the
range selector cable end (2) to the transmission shift control lever ball stud. 6. Install the console.
Refer to Front Floor Console Replacement (See: Body and Frame/Interior Moulding /
Trim/Console/Service and Repair/Front
7. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance) . 8. Ensure that
the transmission range selector lever is in the mechanical park position.
9. Install the range selector cable (3) into the range selector cable bracket (1) at the transmission.
10. Install the range selector cable retaining clip (2). 11. Install the range selector cable (3) to the
transmission range selector lever ball stud (4). 12. Lower the vehicle.
Shift Cable: Service and Repair Range Selector Lever Cable Bracket Replacement
Range Selector Lever Cable Bracket Replacement

Hummer Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sun Gear > Component
Information > Technical Service Bulletins > A/T - Production Update
Sun Gear: Technical Service Bulletins A/T - Production Update
Bulletin No.: 07-07-30-008
Date: May 01, 2007
INFORMATION
Subject: 4L60-E/4L65-E/4L70-E Automatic Transmission Product Update
Models: 2005-2008 Passenger Cars and Light Duty Trucks 2005-2008 HUMMER H2, H3
2005-2008 Saab 9-7X
with 4L60-E14L65-E14L70-E Automatic Transmission (RPOs M30, M32, M33 and M70)
The purpose of this bulletin is to update technicians to changes in the 4L60-E, 4L65-E and 4L70-E
automatic transmission.
Input Carrier, Reaction Carrier Shaft and Bearing Changes

The parts contained in this change may not be interchangeable with the parts contained in the
transmission being serviced. When servicing the transmission, use the correct parts. Do not mix
parts.
Failure to use the correct parts will cause improper function and possible transmission distress.
Hummer Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sun Gear > Component
Information > Technical Service Bulletins > A/T - Production Update > Page 5248
This change contains a new, thicker thrust bearing with increased capacity and angled lip added for
assembly error proofing. The reaction carrier shaft bearing pocket and the input carrier bearing
surface have been modified to accommodate the new bearing. Each part has specific features to
allow identification from the prior design.
All transmissions with a build date of 3-12-07 (Julian date 7071) and later will have the new parts.
Anytime that an old bearing is being replaced with the new design bearing, the new input carrier
assembly and reaction carrier shaft must be used. The old design bearings will remain available
from SPO.
If the old design reaction carrier shaft or input carrier assembly need to be replaced, the new
design parts will need to be used. All three parts will back fit past models.
Disclaimer
Hummer Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Thrust Washer/Bearing,
A/T > Component Information > Technical Service Bulletins > A/T - Production Update
Thrust Washer/Bearing: Technical Service Bulletins A/T - Production Update
Bulletin No.: 07-07-30-008
Date: May 01, 2007
INFORMATION
Subject: 4L60-E/4L65-E/4L70-E Automatic Transmission Product Update
Models: 2005-2008 Passenger Cars and Light Duty Trucks 2005-2008 HUMMER H2, H3
2005-2008 Saab 9-7X
with 4L60-E14L65-E14L70-E Automatic Transmission (RPOs M30, M32, M33 and M70)
The purpose of this bulletin is to update technicians to changes in the 4L60-E, 4L65-E and 4L70-E
automatic transmission.
Input Carrier, Reaction Carrier Shaft and Bearing Changes

The parts contained in this change may not be interchangeable with the parts contained in the
transmission being serviced. When servicing the transmission, use the correct parts. Do not mix
parts.
Failure to use the correct parts will cause improper function and possible transmission distress.
Hummer Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Thrust Washer/Bearing,
A/T > Component Information > Technical Service Bulletins > A/T - Production Update > Page 5253
This change contains a new, thicker thrust bearing with increased capacity and angled lip added for
assembly error proofing. The reaction carrier shaft bearing pocket and the input carrier bearing
surface have been modified to accommodate the new bearing. Each part has specific features to
allow identification from the prior design.
All transmissions with a build date of 3-12-07 (Julian date 7071) and later will have the new parts.
Anytime that an old bearing is being replaced with the new design bearing, the new input carrier
assembly and reaction carrier shaft must be used. The old design bearings will remain available
from SPO.
If the old design reaction carrier shaft or input carrier assembly need to be replaced, the new
design parts will need to be used. All three parts will back fit past models.
Disclaimer
Hummer Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter >
Component Information > Technical Service Bulletins > Customer Interest: > 08-07-30-023 > May > 08 > A/T - Fluid Leak
From The Bell Housing Area
Torque Converter: Customer Interest A/T - Fluid Leak From The Bell Housing Area
TECHNICAL
Bulletin No.: 08-07-30-023
Date: May 08, 2008

Saab 9-7X
Attention:
Condition
Cause
Correction
Parts Information

Component Information > Technical Service Bulletins > Customer Interest: > 08-07-30-023 > May > 08 > A/T - Fluid Leak
From The Bell Housing Area > Page 5262
Disclaimer
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Torque Converter: >
01-07-30-010C > May > 08 > A/T - Torque Converter Replacement Guideline
Torque Converter: All Technical Service Bulletins A/T - Torque Converter Replacement Guideline
INFORMATION
Date: May 12, 2008
Subject: Automatic Transmission/Transaxle Torque Converter Replacement
Models: 2009 and Prior GM Passenger Cars and Trucks 2009 and Prior HUMMER H2, H3 2009
and Prior Saturn Cars and Light Duty Trucks (Except VTi Equipped Vehicles (RPO M16 and M75)
with ALL Automatic Transmissions and Transaxles
Supercede:
This bulletin is being revised to add the 2007-2009 model years. Please discard Corporate Bulletin
Number 01-07-30-010B (Section 07 - Transmission/Transaxle).
The purpose of this bulletin is to help technicians determine when a torque converter should be
replaced. Below is a list of general guidelines to follow.
The converter should NOT be replaced if the following apply:
^ DTC P0742 - TCC stuck on is set. This code is almost always the result of a controls condition
(i.e. stuck TCC solenoid/valve). Experience has shown that this code rarely indicates a mechanical
concern within the torque converter.
^ The fluid has an odor or is discolored but no evidence of metal contamination.
^ Fine metal particles (traces of metal flakes/gray color to fluid ) are found in the converter. This is
not harmful to the torque converter.
^ The vehicle has been exposed to high mileage.
^ A small amount of wear appears on the hub where the oil pump drive gear mates to the converter
(RWD only). A certain amount of such wear is normal for both the hub and oil pump gear. Neither
the converter nor the front pump assembly should be replaced.
The torque converter should be replaced under any of the following conditions:
^ The vehicle has TCC shudder and/or no TCC apply. First complete all electrical and hydraulic
diagnosis and check for proper engine operation. The converter clutch may be damaged. Also the
converter bushing and/or internal 0-ring may be damaged.
^ Evidence of damage to the oil pump assembly pump shaft turbine shaft drive sprocket support
and bearing or metal chips/debris in the converter.
^ Metal chips/debris are found in the converter or when flushing the cooler and the cooler lines.
^ External leaks in the hub weld area lug weld or closure weld.
^ Converter pilot is broken damaged or fits poorly into the crankshaft.
^ The converter hub is scored or damaged.
^ The transmission oil is contaminated with engine coolant engine oil or water.
^ If excessive end play is found after measuring the converter for proper end play (refer to Service
Manual).
^ If metal chips/debris are found in the fluid filter or on the magnet and no internal parts in the unit
are worn or damaged. This indicates that the material came from the converter.
^ The converter has an unbalanced condition that results in a vibration that cannot be corrected by
following Converter Vibration Procedures.
^ Blue converter or dark circular ring between lugs. This condition will also require a complete
cleaning of the cooler and a check for adequate flow
01-07-30-010C > May > 08 > A/T - Torque Converter Replacement Guideline > Page 5268
through the cooler.
^ Converter bearing noise determined by noise from the bell housing area in Drive or Reverse at
idle. The noise is gone in Neutral and Park.
^ If silicon from the viscous clutch is found in the lower pan (4T80-E ONLY).
Disclaimer
08-07-30-023 > May > 08 > A/T - Fluid Leak From The Bell Housing Area
Torque Converter: All Technical Service Bulletins A/T - Fluid Leak From The Bell Housing Area
TECHNICAL
Bulletin No.: 08-07-30-023
Date: May 08, 2008

Saab 9-7X
Attention:
Condition
Cause
Correction
Parts Information

08-07-30-023 > May > 08 > A/T - Fluid Leak From The Bell Housing Area > Page 5273
Disclaimer
Component Information > Technical Service Bulletins > All Other Service Bulletins for Torque Converter: > 01-07-30-010C >
May > 08 > A/T - Torque Converter Replacement Guideline
Torque Converter: All Technical Service Bulletins A/T - Torque Converter Replacement Guideline
INFORMATION
Date: May 12, 2008
Subject: Automatic Transmission/Transaxle Torque Converter Replacement
Models: 2009 and Prior GM Passenger Cars and Trucks 2009 and Prior HUMMER H2, H3 2009
and Prior Saturn Cars and Light Duty Trucks (Except VTi Equipped Vehicles (RPO M16 and M75)
with ALL Automatic Transmissions and Transaxles
Supercede:
This bulletin is being revised to add the 2007-2009 model years. Please discard Corporate Bulletin
Number 01-07-30-010B (Section 07 - Transmission/Transaxle).
The purpose of this bulletin is to help technicians determine when a torque converter should be
replaced. Below is a list of general guidelines to follow.
The converter should NOT be replaced if the following apply:
^ DTC P0742 - TCC stuck on is set. This code is almost always the result of a controls condition
(i.e. stuck TCC solenoid/valve). Experience has shown that this code rarely indicates a mechanical
concern within the torque converter.
^ The fluid has an odor or is discolored but no evidence of metal contamination.
^ Fine metal particles (traces of metal flakes/gray color to fluid ) are found in the converter. This is
not harmful to the torque converter.
^ The vehicle has been exposed to high mileage.
^ A small amount of wear appears on the hub where the oil pump drive gear mates to the converter
(RWD only). A certain amount of such wear is normal for both the hub and oil pump gear. Neither
the converter nor the front pump assembly should be replaced.
The torque converter should be replaced under any of the following conditions:
^ The vehicle has TCC shudder and/or no TCC apply. First complete all electrical and hydraulic
diagnosis and check for proper engine operation. The converter clutch may be damaged. Also the
converter bushing and/or internal 0-ring may be damaged.
^ Evidence of damage to the oil pump assembly pump shaft turbine shaft drive sprocket support
and bearing or metal chips/debris in the converter.
^ Metal chips/debris are found in the converter or when flushing the cooler and the cooler lines.
^ External leaks in the hub weld area lug weld or closure weld.
^ Converter pilot is broken damaged or fits poorly into the crankshaft.
^ The converter hub is scored or damaged.
^ The transmission oil is contaminated with engine coolant engine oil or water.
^ If excessive end play is found after measuring the converter for proper end play (refer to Service
Manual).
^ If metal chips/debris are found in the fluid filter or on the magnet and no internal parts in the unit
are worn or damaged. This indicates that the material came from the converter.
^ The converter has an unbalanced condition that results in a vibration that cannot be corrected by
following Converter Vibration Procedures.
^ Blue converter or dark circular ring between lugs. This condition will also require a complete
cleaning of the cooler and a check for adequate flow
Component Information > Technical Service Bulletins > All Other Service Bulletins for Torque Converter: > 01-07-30-010C >
May > 08 > A/T - Torque Converter Replacement Guideline > Page 5279
through the cooler.
^ Converter bearing noise determined by noise from the bell housing area in Drive or Reverse at
idle. The noise is gone in Neutral and Park.
^ If silicon from the viscous clutch is found in the lower pan (4T80-E ONLY).
Disclaimer
Hummer Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch
Solenoid, A/T > Component Information > Locations
Hummer Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Cover
Torque Converter Cover: Service and Repair
Transmission Converter Cover Replacement

Hummer Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler,
A/T > Component Information > Technical Service Bulletins > A/T - Oil Cooler Flush and Flow Essential Tool
Transmission Cooler: Technical Service Bulletins A/T - Oil Cooler Flush and Flow Essential Tool
INFORMATION
TransFlow(R)
Models:
Notice
Important
machine on
A/T > Component Information > Technical Service Bulletins > A/T - Oil Cooler Flush and Flow Essential Tool > Page 5290
each repair.
reservoir.
Machine Displays
Disclaimer
Transmission Cooler: Technical Service Bulletins A/T - Water/Coolant Contamination Information
INFORMATION
Bulletin No.: 08-07-30-035
compressed
Important:


Disclaimer
A/T > Component Information > Technical Service Bulletins > Page 5294
Transmission Cooler: Service and Repair
Transmission Fluid Auxiliary Cooler Replacement
Removal Procedure
1. Remove the transmission fluid cooler hoses from the transmission fluid auxiliary cooler. Refer to
Transmission Fluid Cooler Hose/Pipe
Quick-Connect Fitting Disconnection and Connection (See: Fluid Line/Hose/Service and

Repair/Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection)
.
2. Remove the bolts from the auxiliary oil cooler. 3. Remove the auxiliary oil cooler from the
vehicle.
1. Install the auxiliary oil cooler to the vehicle.

Notice) .
2. Install the bolts to the transmission fluid auxiliary cooler.
3. Install the transmission fluid cooler hoses to the transmission fluid auxiliary cooler. Refer to
Transmission Fluid Cooler Hose/Pipe Quick-Connect
Fitting Disconnection and Connection (See: Fluid Line/Hose/Service and Repair/Transmission Fluid
Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection) .
Hummer Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount,
A/T > Component Information > Testing and Inspection
Transmission Mount: Testing and Inspection
Transmission Mount Inspection
Notice: In order to avoid oil pan damage and possible engine failure, insert a block of wood that
spans the width of the oil pan bottom between the oil pan and the jack support.
1. Raise the transmission/transaxle in order to remove the weight from the transmission/transaxle
mount and create slight tension in the rubber. 2. Observe the transmission/transaxle mount while
raising the transmission/transaxle. Replace the transmission/transaxle mount if the
transmission/transaxle mount exhibits any of the following conditions:
Important: Black paint on the rubber will crack with time, this does no constitute a failure.
* The hard rubber surface is covered with heat check cracks.
* The rubber is separated from the metal plate of the transmission/transaxle mount.
* The rubber is split through the center of the transmission/transaxle mount.
3. If there is movement between the metal plate of the transmission/transaxle mount and its
attaching points, lower the transmission/transaxle on the
transmission/transaxle mount. Tighten the bolts or nuts attaching the transmission/transaxle mount
to the frame or transmission/transaxle mount bracket.
Hummer Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount,
A/T > Component Information > Testing and Inspection > Page 5298
Transmission Mount: Service and Repair
Transmission Mount Replacement

Hummer Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Switch/Sensor, A/T > Component Information > Locations > Automatic Transmission Electronic Component Views

Views
Switch/Sensor, A/T > Component Information > Locations > Automatic Transmission Electronic Component Views > Page
5303

Switch/Sensor, A/T > Component Information > Locations > Page 5304

Hummer Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Pressure
Test Port, A/T > Component Information > Service and Repair
Transmission Pressure Test Port: Service and Repair
Automatic Transmission Fluid Pressure Test Hole Plug Replacement
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance) .
2. Clean the surrounding area of the oil pressure test plug. 3. Remove the oil pressure test plug.

Notice) .
1. Install the oil pressure test plug.

Hummer Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Pressure
Test Port, A/T > Component Information > Service and Repair > Page 5308
Tighten the oil pressure test plug to 11 N.m (97 lb in).
2. Check the transmission fluid level (fill if necessary). Refer to Transmission Fluid Check (See:
Testing and Inspection/Component Tests and
General Diagnostics/Transmission Fluid Check) .

Hummer Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Locations
Hummer Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Locations > Page 5312

Hummer Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > Customer Interest: > 07-07-30-031D > Feb > 09 > A/T - MIL
ON/DTC P0751 Set
Valve Body: Customer Interest A/T - MIL ON/DTC P0751 Set
TECHNICAL
Subject: Malfunction Indicator Lamp (MIL) On - Check Engine Light, DTC P0751 (Diagnose and
Repair as Necessary)
Models
Supercede:
This bulletin is being revised to provide additional information on the new spacer plate. Please
discard Corporate Bulletin Number 07-07-30-031C (Section 07 - Transmission/Transaxle).
Condition
Some customers may comment on a malfunction indicator lamp (MIL) being illuminated.
A scan tool may reveal DTC P0751 set in the TCM as current or in history.
Correction
Follow the service instructions below based on the group your vehicle is in.
2007 Silverado or Sierra with 6L90 Transmission (MYD)
1. Inspect and note the transmission fluid level and condition. If the level is high or low, it should be
corrected and the vehicle road tested to verify that the condition is still present.
2. Remove the transmission bottom pan to inspect for possible debris.
^ If debris is found, the transmission should be disassembled to determine the source. Repair or
replace the transmission in the most economical method following guidelines in Corporate Bulletin
# 02-07-30-029.
^ If no debris is noted in the oil pan, remove the control valve body assembly and proceed to the
next step.
3. Disassemble the valve body to:

ON/DTC P0751 Set > Page 5321
^ Inspect transmission filter for any cracks, holes or split seams that may allow air to be sucked into
the pump.
^ Inspect the check balls for roundness ensuring that there are no flat spots.
^ Measure all the valve body bore plugs (328) for diameter. The specification is 11.502 mm +/-
0.004 mm. Undersize bore plugs should be replaced.
^ Inspect clutch select valve 2 (352) (Closest to the manual valve) in the lower valve body (351) for
freedom of movement and travel.
^ Inspect CBR1/ C456 Reg Valve (327) in the upper valve body (321) for freedom of movement
and travel.
^ Perform Control Solenoid Valve and Transmission Control Module Assembly Solenoid
Performance Test (SI Document ID # 1618572) to determine if shift solenoid # 1 is functioning
properly.
Important:
The seals included in plate kit, P/N 24236934, should be replaced when the valve body is
assembled. Do not reuse the old seals.
^ Replace the spacer plate with P/N 24245720. This spacer plate makes use of a revised gasket to
help reduce the occurrence of DTC P0751.
Important:
2008 Silverado or Sierra equipped with 6L90 (MYD) are built with this TCM calibration revision.
4. Reprogram the transmission control module (TCM) with updated calibration files using the
TIS2WEB Service Programming System (SPS) application. This new service calibration was
released with TIS satellite data update version 7.5 or later, available July 22, 2007. As always,
make sure your Tech 2(R) is updated with the latest software version.
5. After reprogramming the TCM, Service Fast Learn Adapts must be performed using the
Tech2(R). Check and clear all DTCs that may have set as a result of the programming process.
2006-2008 Vehicles with a 6L50, 6L80 or 6L90 Transmission (MYB, MYC or MYD) (Except 2007
Silverado and Sierra w/6L90)
# 02-07-30-029.
next step.
the pump.
and travel.
properly.
Important:
The seals included in plate kit, P/N 24236934 or 24238925, should be replaced when the valve
body is assembled. Do not reuse the old seals.
^ Replace the spacer plate with the appropriate part number from the list below. This spacer plate
makes use of a revised gasket to help reduce the occurrence of DTC P0751. This spacer plate is
used in vehicles built November 17, 2007 or later. It will not resolve a DTC P0751 concern on a
vehicle built November 17, 2007 or later.
Parts Information
For repairs performed under warranty, use the applicable published labor code.
Disclaimer
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 07-07-30-006B >
Mar > 10 > A/T - Control Valve/Solenoid Cleaning Information
Valve Body: All Technical Service Bulletins A/T - Control Valve/Solenoid Cleaning Information
INFORMATION
Subject: Information on Control Solenoid Valve and Transmission Control Solenoid Module
Assembly Cleaning Procedure for Rear Wheel Drive Six-Speed HYDRA-MATIC(R) Automatic
Transmissions when MIL/DTCs Set
Models:
GMC Yukon 2010 GMC Savana 2008-2009 Pontiac G8 2008-2009 HUMMER H2 Equipped with
Six Speed HYDRA-MATIC(R) 6L50, 6L80 or 6L90 Automatic Transmission (RPOs MYB, MYC,
MYD)
Supercede: This bulletin is being updated to add models and model years and to advise
technicians that the control solenoid valve assembly cleaning procedure is no longer valid. Please
discard Corporate Bulletin Number 07-07-30-006A (Section 07 - Transmission/Transaxle).
The control solenoid (w/body and TCM) valve assembly cleaning procedure has been determined
to be ineffective. This procedure will be removed from the scan tool and will be no longer available
for use. Reference to this procedure will be removed from SI diagnostics and labor operation
K9450 will be removed from the Labor Time Guide.
Disclaimer
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 08-07-30-006A >
Oct > 09 > A/T - HYDRA-MATIC(R) Control Valve Body Assembly Recon.
Valve Body: All Technical Service Bulletins A/T - HYDRA-MATIC(R) Control Valve Body Assembly
Recon.
INFORMATION
Subject: HYDRA-MATIC(R) 6L45 (MYA), 6L50 (MYB), 6L80 (MYC) and 6L90 (MYD), Rear Wheel
Drive Automatic Transmission Control Valve Body Assembly Reconditioning
Models:
2006-2009 Cadillac XLR 2006-2010 Cadillac STS 2007-2009 Cadillac SRX 2007-2010 Cadillac
Escalade, Escalade ESV, Escalade EXT 2008-2010 Cadillac CTS 2006-2010 Chevrolet Corvette
2007-2010 Chevrolet Silverado 2008-2010 Chevrolet Suburban 2009-2010 Chevrolet Avalanche,
Tahoe 2007-2010 GMC Sierra, Sierra Denali, Yukon Denali, Yukon Denali XL 2008-2010 GMC
Yukon XL 2009-2010 GMC Yukon 2008-2009 Pontiac G8 2008-2009 HUMMER H2 with 6L45,
6L50, 6L80 or 6L90 HYDRA-MATIC(R) Rear Wheel Drive Automatic Transmission (RPOs MYA,
MYB, MYC, MYD)
Supercede: This bulletin is being revised to update model years and add 6L45 transmission (RPO
MYA). Please discard Corporate Bulletin Number 08-07-30-006 (Section 07 -
Transmission/Transaxle).
The information outlined in this bulletin is designed to provide easy to follow control valve body
reconditioning instructions using the new illustrations to simplify reassembly of the 6L45, 6L50,
6L80 and/or 6L90 automatic transmission control valve body assembly.
Caution
Valve springs can be tightly compressed. Use care when removing retainers and plugs. Personal
injury could result.
Notice
After cleaning the transmission components, allow to air dry. Do not use cloth or paper towels in
order to dry any transmission components. Lint from the towels can cause component failure.
Notice
Do not reuse cleaning solvents. Previously used solvents may deposit sediment, which may
damage the component.
Inspection Procedure for Shift Concerns
1. Using the exploded view, inspect each bore for freedom of valve(s) movement and evidence of
debris. Pay particular attention to those valves
related to the customer's concern. IF VALVE BODY CLEANING IS NOT REQUIRED, DO NOT
DISASSEMBLE THE BORES UNLESS IT IS NECESSARY TO VERIFY MOVEMENT.
2. Verify movement of the valves in their normal installed position. Valves may become restricted
during removal or installation. This is normal due
to small tolerances between the valves and bores.
3. If a valve is restricted and cannot be corrected by cleaning the valve and bore, replace the valve
body. Describe the restricted valve on the repair
order.
Disassembly/Reassembly for Cleaning Debris
1. If a valve is restricted by a metal burr from machining that bore, remove the valve and burr.
Inspect the movement in the valve's normal position. If
no other debris or restrictions are found, reassemble the valve body and install in the transmission.
2. If the valve body has been contaminated with debris from another transmission component
failure, disassemble all bores for complete cleaning of
all valve body components. Keeping individual bore parts separated will make reassembly easier.
Use the following illustrations for positive identification and location of individual parts.
3. Using GM Brake Clean, or equivalent, in a safe and clean environment (clean aluminum pan),
clean the valve body and dry it with compressed air.
Oct > 09 > A/T - HYDRA-MATIC(R) Control Valve Body Assembly Recon. > Page 5333
Use appropriate eye protection.
4. Clean individual valve body components with GM Brake Clean, or equivalent. Coat each valve
with clean ATF and reassemble in each bore.
Check each valve for free movement during assembly of each bore.
Important Position the valve body as shown in the following illustrations for positive identification
and location of individual parts.
Control Valve Body Spring, Bolt, Bore Plug and Retainer Identification Chart (Metric)
Control Valve Body Spring, Bolt, Bore Plug and Retainer Identification Chart (Inch)
Disclaimer
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 07-07-30-031D >
Feb > 09 > A/T - MIL ON/DTC P0751 Set
Valve Body: All Technical Service Bulletins A/T - MIL ON/DTC P0751 Set
TECHNICAL
Subject: Malfunction Indicator Lamp (MIL) On - Check Engine Light, DTC P0751 (Diagnose and
Repair as Necessary)
Models
Supercede:
This bulletin is being revised to provide additional information on the new spacer plate. Please
discard Corporate Bulletin Number 07-07-30-031C (Section 07 - Transmission/Transaxle).
Condition
Some customers may comment on a malfunction indicator lamp (MIL) being illuminated.
A scan tool may reveal DTC P0751 set in the TCM as current or in history.
Correction
Follow the service instructions below based on the group your vehicle is in.
2007 Silverado or Sierra with 6L90 Transmission (MYD)
# 02-07-30-029.
next step.

Feb > 09 > A/T - MIL ON/DTC P0751 Set > Page 5343
the pump.
and travel.
properly.
Important:
The seals included in plate kit, P/N 24236934, should be replaced when the valve body is
assembled. Do not reuse the old seals.
^ Replace the spacer plate with P/N 24245720. This spacer plate makes use of a revised gasket to
help reduce the occurrence of DTC P0751.
Important:
2008 Silverado or Sierra equipped with 6L90 (MYD) are built with this TCM calibration revision.
4. Reprogram the transmission control module (TCM) with updated calibration files using the
TIS2WEB Service Programming System (SPS) application. This new service calibration was
released with TIS satellite data update version 7.5 or later, available July 22, 2007. As always,
make sure your Tech 2(R) is updated with the latest software version.
5. After reprogramming the TCM, Service Fast Learn Adapts must be performed using the
Tech2(R). Check and clear all DTCs that may have set as a result of the programming process.
2006-2008 Vehicles with a 6L50, 6L80 or 6L90 Transmission (MYB, MYC or MYD) (Except 2007
Silverado and Sierra w/6L90)
# 02-07-30-029.
next step.
the pump.
and travel.
properly.
Important:
The seals included in plate kit, P/N 24236934 or 24238925, should be replaced when the valve
body is assembled. Do not reuse the old seals.
^ Replace the spacer plate with the appropriate part number from the list below. This spacer plate
makes use of a revised gasket to help reduce the occurrence of DTC P0751. This spacer plate is
used in vehicles built November 17, 2007 or later. It will not resolve a DTC P0751 concern on a
vehicle built November 17, 2007 or later.
Parts Information
For repairs performed under warranty, use the applicable published labor code.
Disclaimer
Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Body: > 07-07-30-006B > Mar >
10 > A/T - Control Valve/Solenoid Cleaning Information
Valve Body: All Technical Service Bulletins A/T - Control Valve/Solenoid Cleaning Information
INFORMATION
Subject: Information on Control Solenoid Valve and Transmission Control Solenoid Module
Assembly Cleaning Procedure for Rear Wheel Drive Six-Speed HYDRA-MATIC(R) Automatic
Transmissions when MIL/DTCs Set
Models:
GMC Yukon 2010 GMC Savana 2008-2009 Pontiac G8 2008-2009 HUMMER H2 Equipped with
Six Speed HYDRA-MATIC(R) 6L50, 6L80 or 6L90 Automatic Transmission (RPOs MYB, MYC,
MYD)
Supercede: This bulletin is being updated to add models and model years and to advise
technicians that the control solenoid valve assembly cleaning procedure is no longer valid. Please
discard Corporate Bulletin Number 07-07-30-006A (Section 07 - Transmission/Transaxle).
The control solenoid (w/body and TCM) valve assembly cleaning procedure has been determined
to be ineffective. This procedure will be removed from the scan tool and will be no longer available
for use. Reference to this procedure will be removed from SI diagnostics and labor operation
K9450 will be removed from the Labor Time Guide.
Disclaimer
Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Body: > 08-07-30-006A > Oct >
09 > A/T - HYDRA-MATIC(R) Control Valve Body Assembly Recon.
Valve Body: All Technical Service Bulletins A/T - HYDRA-MATIC(R) Control Valve Body Assembly
Recon.
INFORMATION
Subject: HYDRA-MATIC(R) 6L45 (MYA), 6L50 (MYB), 6L80 (MYC) and 6L90 (MYD), Rear Wheel
Drive Automatic Transmission Control Valve Body Assembly Reconditioning
Models:
2006-2009 Cadillac XLR 2006-2010 Cadillac STS 2007-2009 Cadillac SRX 2007-2010 Cadillac
Escalade, Escalade ESV, Escalade EXT 2008-2010 Cadillac CTS 2006-2010 Chevrolet Corvette
2007-2010 Chevrolet Silverado 2008-2010 Chevrolet Suburban 2009-2010 Chevrolet Avalanche,
Tahoe 2007-2010 GMC Sierra, Sierra Denali, Yukon Denali, Yukon Denali XL 2008-2010 GMC
Yukon XL 2009-2010 GMC Yukon 2008-2009 Pontiac G8 2008-2009 HUMMER H2 with 6L45,
6L50, 6L80 or 6L90 HYDRA-MATIC(R) Rear Wheel Drive Automatic Transmission (RPOs MYA,
MYB, MYC, MYD)
Supercede: This bulletin is being revised to update model years and add 6L45 transmission (RPO
MYA). Please discard Corporate Bulletin Number 08-07-30-006 (Section 07 -
Transmission/Transaxle).
The information outlined in this bulletin is designed to provide easy to follow control valve body
reconditioning instructions using the new illustrations to simplify reassembly of the 6L45, 6L50,
6L80 and/or 6L90 automatic transmission control valve body assembly.
Caution
Valve springs can be tightly compressed. Use care when removing retainers and plugs. Personal
injury could result.
Notice
After cleaning the transmission components, allow to air dry. Do not use cloth or paper towels in
order to dry any transmission components. Lint from the towels can cause component failure.
Notice
Do not reuse cleaning solvents. Previously used solvents may deposit sediment, which may
damage the component.
Inspection Procedure for Shift Concerns
1. Using the exploded view, inspect each bore for freedom of valve(s) movement and evidence of
debris. Pay particular attention to those valves
related to the customer's concern. IF VALVE BODY CLEANING IS NOT REQUIRED, DO NOT
DISASSEMBLE THE BORES UNLESS IT IS NECESSARY TO VERIFY MOVEMENT.
2. Verify movement of the valves in their normal installed position. Valves may become restricted
during removal or installation. This is normal due
to small tolerances between the valves and bores.
3. If a valve is restricted and cannot be corrected by cleaning the valve and bore, replace the valve
body. Describe the restricted valve on the repair
order.
Disassembly/Reassembly for Cleaning Debris
1. If a valve is restricted by a metal burr from machining that bore, remove the valve and burr.
Inspect the movement in the valve's normal position. If
no other debris or restrictions are found, reassemble the valve body and install in the transmission.
2. If the valve body has been contaminated with debris from another transmission component
failure, disassemble all bores for complete cleaning of
all valve body components. Keeping individual bore parts separated will make reassembly easier.
Use the following illustrations for positive identification and location of individual parts.
3. Using GM Brake Clean, or equivalent, in a safe and clean environment (clean aluminum pan),
clean the valve body and dry it with compressed air.
09 > A/T - HYDRA-MATIC(R) Control Valve Body Assembly Recon. > Page 5355
Use appropriate eye protection.
4. Clean individual valve body components with GM Brake Clean, or equivalent. Coat each valve
with clean ATF and reassemble in each bore.
Check each valve for free movement during assembly of each bore.
Important Position the valve body as shown in the following illustrations for positive identification
and location of individual parts.
Control Valve Body Spring, Bolt, Bore Plug and Retainer Identification Chart (Metric)
Control Valve Body Spring, Bolt, Bore Plug and Retainer Identification Chart (Inch)
Disclaimer
Valve Body: Locations
Valve Body: Service and Repair
Control Valve Lower Body and Upper Body Replacement

Hummer Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T >
Component Information > Technical Service Bulletins > Customer Interest for Wiring Harness: > 08-07-30-021E > Jun > 10
> Electrical - Electrical Malfunction/Multiple DTCs
Technical Service Bulletin # 08-07-30-021E Date: 100607
Electrical - Electrical Malfunction/Multiple DTCs
TECHNICAL
Date: June 07, 2010
Subject: Loss of High Speed GMLAN Communications, Intermittent No Crank, IP Gage Fluctuation,
Intermittent Door Lock Cycling, Intermittent Chime Operation, Various IP Warning Lamps
Illuminated, Transmission May Not Shift, Communication DTCs U0073, U0100, U0101, U0102,
U0109, U0121 or U0140 Set (Repair Backed Out Terminal in Transmission Harness Connector,
Repair Open or Shorted GM High Speed LAN Circuits, Open or Shorted Data Link Resistor,
Correct Corrosion or Poor Connections in Various Control Module Connectors)
Models:
2007-2010 Cadillac Escalade Models, XLR 2009-2010 Cadillac Escalade Hybrid 2007-2010
Chevrolet Avalanche, Corvette, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Silverado
Hybrid, Tahoe Hybrid 2007-2010 GMC Sierra, Yukon Models 2008-2010 GMC Sierra Hybrid,
Yukon Hybrid 2008-2009 HUMMER H2
Equipped With 6 Speed 6L80 (RPO MYC) or 6L90 (RPO MYD) or Hybrid Two Mode 2ML70
Automatic Transmission
Please Refer to GMVIS
Supercede: This bulletin is being revised to update the Parts and Warranty Information. Please
discard Corporate Bulletin Number 08-07-30-021D (Section 07 - Transmission/Transaxle).
Condition
Some customers may comment on any of the following conditions:
- Instrument panel cluster (IPC) warning lamps may illuminate.
- The transmission may not shift or defaults to 2nd gear.
- The door locks may cycle by themselves.
- The engine may not crank intermittently.
- A driver information center (DIC) message is displayed.
- The IPC gages may fluctuate.
- Applying the brakes may cause the IPC to become erratic and the chimes to operate
simultaneously.
Depending on the vehicle, technicians may find one or more of the following High Speed GMLAN
Communications DTCs set as Current or History:
- U0073: Control Module Communications Bus OFF
- U0100: Lost Communication With ECM/PCM
- U0101: Lost Communication With TCM
- U0102: Lost Communication With Transfer Case Control Module
- U0109: Lost Communication With Fuel Pump Control Module

- U0121: Lost Communication With ABS Control Module
- U0140: Lost Communication With Body Control Module (BCM)
Cause
These conditions may be caused by, but not limited to, any of the following:
- The terminal(s) for the High Speed GMLAN Serial Data Bus has backed out of the 16-way
electrical connector to the automatic transmission.
- The terminal position assurance (TPA) lock in the transmission 16-way electrical connector is not
fully seated.
- The High Speed GMLAN Serial Data Bus circuits are open or shorted to ground.
- Corrosion in various control module connectors.
- Intermittent or poor connections in the inline connectors containing the High Speed GMLAN Serial
Data Bus circuits.
- The data link resistor is open or shorted.
- Water intrusion in various control module connectors.

> Electrical - Electrical Malfunction/Multiple DTCs > Page 5372
Parts Information
For transmission electrical repairs please note in the technicians comments field on the repair order
which terminal number(s) were repaired or replaced. Also if a male terminal is bent (transmission
side of connector), then indicate the bent terminal number on the repair order.
Disclaimer
Procedures to Diagnose/Chafed Wiring Harness at Trans Case
Information for the Procedures to Diagnose and Repair the Above Conditions
1. Perform the Diagnostic System Check-Vehicle to begin your diagnosis of these conditions. 2.
Perform a thorough visual inspection of the vehicle. 3. Depending on the vehicle, some of the
procedures may not be applicable. 4. The following procedure is the only one applicable to the
Corvette and XLR.
Chafed Wiring Harness at Transmission Case Retaining Clip and Inspection of the 16-way
Electrical Connector for Backed Out Terminals
1. Turn OFF the ignition and all accessories. 2. Disconnect the negative battery cable. Refer to
Battery Negative Cable Disconnection and Connection in SI. 3. Raise and support the vehicle.
Refer to Lifting and Jacking the Vehicle in SI.
4. Locate the 16-way electrical connector on the right side of the automatic transmission as shown.
5. Inspect for a pinched/cut wiring harness where it is attached at the transmission by a metal
attachment clip as shown. Inspect any of these harness
clips that you may observe as needed. If the wiring is damaged, repair as needed. Refer to Wiring
Systems and Power Management > Diagnostic Information and Procedures in SI.
6. Protect the harness by covering the sharp edge with butyl tape or a suitable material. Secure the
harness as needed.
7. Before disconnecting the 16-way connector, inspect for any backed out terminals (2) as shown.
Fully seated terminals (1) are shown for
comparison.
1. If a backed out terminal (2) is found, identify the terminal(s) on the repair order. 2. Look at the
connector in order to identify the number of the cavity with the backed out terminal. Refer to Wiring
Systems and Power
Management > Component Locator > Master Electrical Component List in SI.
8. Use the following procedure to disconnect the 16-way electrical connector:
1. For 2ML70 Only: Disconnect the 24-way electrical connector. 2. Release and hold the slide lock
on the wiring harness connector. 3. Rotate the connector lever and remove the connector from the
component.
9. Repair or replace the terminal(s) as necessary using the following procedure:

1. Locate the terminal position assurance (TPA) as shown.
Note The TPA cannot be removed from the connector while there are terminals present in the
connector body.
2. Use a small flat blade tool to push the TPA until it bottoms out.
3. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the
correct release tool is used. Use the J-38125-28
tool to release the terminals by inserting the tool into the terminal cavity as shown.
Note If the female terminal(s) must be replaced, it is part number 22124472200. It is located in
Yazaki tray number 12 in the J-38125 Terminal Repair Kit.
5. Repair or replace the terminal(s) as needed. Refer to the instructions in the J-38125 manual.
10. If the wiring is damaged, repair as needed. Refer to Wiring Systems and Power Management >
Diagnostic Information and Procedures in SI. 11. Slide the new terminal(s) into the correct cavity at
the back of the connector until it locks in place. The new terminal(s) should be even with the
other terminal(s).
12. Ensure that each terminal is locked in place by gently pulling on the wire.
Note The male terminal(s) cannot be repaired as they are an integral part of the transmission
control module (TCM).
13. Inspect for bent or misaligned terminal(s) in the transmission half of the electrical connector.
‹› If they are bent, use a suitable tool and apply gentle pressure to straighten them. Indicate on the
repair order the terminal number of the male
terminal that was bent.
‹› If they are damaged, refer to Control Solenoid Valve and Transmission Control Module Assembly
Replacement in SI.
14. Prior to installing the transmission connector, perform the following steps to ensure that the
TPA lock is fully seated.
Locate the TPA lock in the reassembled transmission connector. Refer to the arrow in the
illustration above, which points to a TPA lock. This one is in an unseated position. Using a small flat
blade tool, push to seat the TPA until it bottoms out. Verify the TPA is fully seated.
- If the TPA is off-center in the check window as shown, then it is only partially seated. Note the
large gap at the arrow. Reseat the TPA lock and ensure that it is fully seated.
- If the TPA lock is centered in the window as shown, then it is fully seated. The gaps shown by the
arrows should be even on both sides.
15. Install the transmission 16-way electrical connector.

16. Lower the vehicle. 17. Connect the negative battery cable. Refer to Battery Negative Cable
Disconnection and Connection in SI. 18. Clear any DTCs that may be present with a scan tool and
verify the proper operation of the vehicle.
Inspection of Fuse Block
Inspection of Fuse Block - I/P (Left Side) for Loose Connector X1
Battery Disconnect Caution and Battery Negative Cable Disconnection and Connection in SI.
3. Remove the left side fuse block as shown.
4. Inspect connector X1 (1) on the back of the fuse block for a loose connection as shown. Secure
the connector as needed. 5. Install the left side fuse block. 6. Connect the negative battery cable.
Refer to Battery Negative Cable Disconnection and Connection in SI. 7. Clear any DTCs that may
be present with a scan tool and verify the proper operation of the vehicle.
Chafed IP Wiring Harness Near Park Brake Pedal Assembly
The above condition may cause one or more of the following fuses to open:
- 60A - MBEC1 (#72) (Underhood)

- 30A - AMP (#40) (Underhood)
- 15A - RDO (#41) (Underhood)
- 10A - IPC (#46) (Underhood)
- 15A - AIRBAG BATT (#51) (Underhood)
- 10A - DSM (Left side of IP)
Five Areas of Potential Contact Have Been Identified
Five areas of potential contact have been identified:

- The IP wiring branch to C202 may have been routed outboard of the junction block (left IP) and
the retaining clip (1) off the branch may not have been fully seated. Possible point of contact (2).
- The IP wiring branch to C202 may have been pushed up and forward into the park brake
assembly and the retaining clip off the branch may not have been fully seated. Possible points of
contact (1, 2).
- The IP wiring branch to C202 may have never been secured into place as the gray retaining clip
(1) off the branch was never seated.
- The IP harness may be in hard contact with the top rear edge (1) of the park brake assembly.
- When releasing the park brake pedal, the moving part (1) at the end of the park brake release
cable may be coming into hard contact with the IP harness.
If a condition is suspected/found with one of the circuits running to C1 or C2 of the junction block or
to the inline IP-to-body connector (C202) or at any of these areas of concern then remove the front
driver side door sill plate, driver side body hinge pillar trim panel, left IP outer trim cover and
Battery Negative Cable Disconnection and Connection in SI. 3. Visually inspect the IP harness for
damage at the park brake pedal assembly. Refer to potential damage points shown in the photos -
at the side and
rear of the park brake assembly. Note that damage may be hidden from view. The harness may be
turned away from you, or covered by electrical tape.
4. Operate the park brake release lever. Observe the moving part at the end of the park brake
release cable as it may contact and damage the IP
harness. Inspect the IP harness at this point. Note that the damage may be hidden from view by
electrical tape. If the wiring is damaged, repair as needed. Refer to Wiring Systems and Power
Management > Diagnostic Information and Procedures in SI.
5. If the harness is still in contact with a sharp edge or point of the park brake assembly, route it
away from the contact point and secure it with tie
straps.
6. Protect the harness by covering the sharp edge with butyl tape or a suitable material.
7. Inspect how the IP branch to C202 is routed. Reroute the harness as necessary to match the
correct routing in the photo as shown. In order to route
the IP harness branch correctly (behind the junction block-left I/P), remove the cover from the
junction block-left I/P, unseat the junction block from the bracket.
8. Disconnect C202. Route the harness such that it lies between the "goalposts" of the junction
block bracket. Seat the junction block to the bracket
(harness will now be under the junction block).
9. Secure the harness by seating the grey offset retaining clip to the dashmat (or brown "buddy
clip" if present - usually on SUV's only). Reconnect
C202.
Connection in SI. 11. Clear any DTCs that may be present with a scan tool and verify the proper
operation of the vehicle.
Chafed IP Wiring Harness at Left Side Junction Block Mounting Bracket
Battery Negative Cable Disconnection and Connection in SI. 3. Remove the left side junction block.
Refer to Instrument Panel Electrical Center or Junction Block Replacement - Left Side in SI. 4.
Inspect for chafed/shorted wiring at the mounting bracket.
If the wiring is damaged, repair as needed. Refer to Wiring Systems and Power Management >
Diagnostic Information and Procedures in SI.
harness as needed. 6. Replace the left side junction block. Refer to Instrument Panel Electrical
Center or Junction Block Replacement - Left Side in SI. 7. Connect the negative battery cable.
Chafed Wiring Harness at Adjustable Pedals Motor
Battery Negative Cable Disconnection and Connection in SI.
3. Inspect the wiring harness for chafed/shorted wiring at the adjustable pedals motor as shown. 4.
Diagnostic Information and Procedures in SI. 5. Protect the harness by covering the sharp edge
with butyl tape or a suitable material. Secure the harness as needed. 6. Connect the negative
battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 7. Clear any
DTCs that may be present with a scan tool and verify the proper operation of the vehicle.
Chafed Wiring Harness at Transmission
Battery Negative Cable Disconnection and Connection in SI. 3. Raise the vehicle. Refer to Lifting
and Jacking the Vehicle in SI. 4. Support the transmission with a transmission jack. 5. Remove the
transmission support crossmember. Refer to Transmission Support Crossmember Replacement in
SI.
6. Lower the transmission sufficiently to provide access to the engine wiring harness where it
routes from the engine intake manifold to the
transmission bell housing as shown.
7. Release the wiring harness conduit from the retainers that secure it to the transmission and/or
transfer case.
Note IT WILL be necessary to extract the wiring harness from the protective conduit if chafing IS
NOT observed on exposed wiring.
8. Examine the harness for wiring that may be exposed outside of the conduit. Inspect ALL areas
for chafing as shown. If chafing is not observed on
exposed wiring then extract the wiring from the protective conduit and inspect ALL areas for
chafing.
‹› If chafing or damage is found, repair the wiring. Refer to Wiring Systems and Power
Management > Diagnostic Information and Procedures >
Wiring Repairs in SI.
9. Protect the wiring harness by covering the sharp edge with butyl tape or a suitable material.
Secure the wiring harness conduit as needed.
10. Raise the transmission as needed to install the transmission support crossmember. Refer to
Transmission Support Crossmember Replacement in
SI.
Chafed Wiring Harness at Engine Intake Manifold
Battery Negative Cable Disconnection and Connection in SI. 3. Remove the upper intake manifold
sight shield. Refer to Upper Intake Manifold Sight Shield Replacement in SI.
4. Release the wiring harness conduit from the retainers that secure it to the rear of the engine and
at the top of the transmission bell housing.
Note The engine intake manifold is shown removed to provide clarity.
5. Pull the wiring harness up gently at the rear of the engine (1) and inspect the wiring harness for
chafed/shorted wiring (2). If chafing is not
observed on exposed wiring then extract the wiring from the protective conduit and inspect ALL
areas for chafing.
‹› If chafing (1) or damage is found, repair the wiring. Refer to Wiring Systems and Power
Management > Diagnostic Information and
Procedures > Wiring Repairs in SI.
Secure the wiring harness conduit as needed. 7. Install the upper intake manifold sight shield.
Refer to Upper Intake Manifold Sight Shield Replacement in SI. 8. Connect the negative battery
cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 9. Clear any DTCs that
may be present with a scan tool and verify the proper operation of the vehicle.
Chafed Wiring Harness at Chassis Body Mounts Left Side Frame Rail
4. Inspect the wiring harness along the left side frame rail at the body mounts for chafed/shorted
wiring as shown. 5. If the wiring is damaged, repair as needed. Refer to Wiring Systems and Power
Management > Diagnostic Information and Procedures > Wiring
Repairs in SI.
harness as needed. 7. Lower the vehicle. 8. Connect the negative battery cable. Refer to Battery
Negative Cable Disconnection and Connection in SI. 9. Clear any DTCs that may be present with a
scan tool and verify the proper operation of the vehicle.
Chafed Wiring Harness Near Data Link Resistor
Chafed Wiring Harness Near Data Link Resistor Causing Intermittent No/Crank and/or Scan Tool
Does Not Communicate with High Speed GMLAN Device
4. Typical location of a data link resistor (3) mounted on the chassis.

5. Inspect the wiring harness near the data link resistor, between the truck box and frame for
chafed/shorted wiring as shown. Refer to Wiring
Systems and Power Management > Component Locator > Master Electrical Component List >
Data Link Resistor in SI. If the wiring is damaged, repair as needed. Refer to Wiring Systems and
Power Management > Diagnostic Information and Procedures > Wiring Repairs in SI.
6. Disconnect the electrical connector from the data link resistor. 7. Test the resistor for
110-130ohm.
‹› If not within the specified range, replace the data link resistor. ‹› If within the specified range,
refer to Scan Tool Does Not Communicate with High Speed GMLAN Device in SI.
8. Connect the electrical connector to the data link resistor. Secure the resistor as needed. 9.
Protect the harness by covering the sharp edge with butyl tape or a suitable material. Secure the
harness as needed.
Inspection of Engine Harness
Inspection of Engine Harness Connector X109 for Backed Out or Bent Terminals and Poor
Connections
Battery Negative Cable Disconnection and Connection in SI. 3. Locate the X109 connector. Refer
to Wiring Systems and Power Management > Component Locator > Master Electrical Component
List > X109
in SI.
4. Before disconnecting, verify the connector is fully seated together even though the lever is
locked down as shown.
If the connector is not fully seated, repair as needed. Refer to Wiring Systems and Power
Management > Diagnostic Information and Procedures > Connector Repairs in SI.
5. Inspect the connector for the following conditions:
- Backed out terminals
- Bent pins
- Corrosion
- Poor terminal fit (use the correct test probe)
‹› If a condition is found, repair as needed. Refer to Wiring Systems and Power Management >
Diagnostic Information and Procedures in SI. AND ‹› If corrosion is found, proceed to the section of
the bulletin titled: Repairing Fretting Corrosion to complete the repair.
Connections
1. Turn OFF the ignition and all accessories.

Connection in SI. 3. Locate the X115 connector. Refer to Wiring Systems and Power Management
> Component Locator > Master Electrical Component List > X115
in SI.
- Bent pins
- Corrosion
Hybrid Models Chafed Wiring Harness Locations/Inspections
Hybrid Models (HP2) Chafed Wiring Harness Locations and Inspection of Engine Harness
Connector X150 for Backed Out Terminals and Poor Connections at Ground Locations G102 and
G300
List > X150
in SI.
- Bent pins
- Corrosion
the bulletin titled: Repairing Fretting Corrosion to complete the connector repair.
5. Inspect for a misrouted/chafed harness rubbing on the cooling fins of the Transmission Auxiliary
Fluid Pump Control Module as shown.
6. Inspect for a chafed harness caused by a mispositioned retaining clip as shown. The chafing
condition usually occurs when the tab of the clip is
aligned with a slot in the conduit. If the wiring is damaged, repair as needed. Refer to Wiring
7. Locate ground connections G102 and G300. Refer to Wiring Systems and Power Management >
Component Locator > Master Electrical
Component List > G102 and G300 in SI.
8. Inspect G102 and G300 for a clean and tight connection. Undercoating has been found between
the eyelet and the frame resulting in a poor
connection.
If a condition is found, clean the area and repair as needed. Refer to Wiring Systems and Power
Connection in SI.
10. Clear any DTCs that may be present with a scan tool and verify the proper operation of the
vehicle.
Lost Communication With DTC's Set
Lost Communication with Various Control Modules and DTCs Set
DTC Descriptors
Note Depending on the vehicle there may be other DTCs set by other modules.
- DTC U0073 Control Module Communication Bus A Off
- DTC U0100 Lost Communication with Engine/Powertrain Control Module (ECM/PCM)
- DTC U0101 Lost Communication with Transmission Control Module (TCM)
- DTC U0102 Lost Communication with Transfer Case Control Module
- DTC U0121 Lost Communication with Electronic Brake Control Module (EBCM)
- DTC U0140 Lost Communication with Body Control Module (BCM)
1. Connect a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record
any existing history or current DTCs from all of the
control modules (refer to SI). If any DTC(s) are set, refer to the list above or the Diagnostic Trouble
Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may
be causing the condition (refer to SI).
Battery Negative Cable Disconnection and Connection in SI. 4. Disconnect the connector(s) at the
affected module. 5. Inspect the connector(s) for the following conditions:
- Bent pins
- Corrosion
- Water intrusion
Diagnostic Information and Procedures in SI AND ‹› If corrosion or water intrusion is found,
proceed to the section of the bulletin titled: Repairing Fretting Corrosion to complete the repair.
6. Reconnect the connector(s) at the affected modules. 7. Clear any DTCs that may be present
with a scan tool and verify the proper operation of the vehicle.
Repairing Fretting Corrosion
Note Fretting corrosion looks like little dark smudges on the electrical terminals and appear where
the actual electrical contact is being made. In less severe cases it may be unable to be seen or
identified without the use of a magnifying glass.
1. If any water intrusion is present in the connector, use pressure regulated compressed air to dry it
out.
2. DO NOT apply an excessive amount of dielectric lubricant as shown, to the connectors as

hydrolock may result when attempting to mate the
connectors.
Important Use ONLY a clean nylon brush that is DEDICATED to the repair of this specific
condition.
With a one-inch nylon bristle brush, apply dielectric lubricant P/N 12377900 (in Canada, 10953529
to both the module/component side and the harness side of the affected connector(s).
3. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present.
vehicle.
Component Information > Technical Service Bulletins > Customer Interest for Wiring Harness: > 08-08-49-010B > Jul > 08 >
Wiring Harness: Customer Interest Computers/Controls - Mutiple Malfunctions/DTC's Set
TECHNICAL
Date: July 22, 2008
Supercede:
Condition
^ No crank.
Correction
possible concern.
Repair
Component Information > Technical Service Bulletins > Customer Interest for Wiring Harness: > 08-08-49-010B > Jul > 08 >
as needed.
needed.
block.
above for location.
Disclaimer
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 08-07-30-021E
> Jun > 10 > Electrical - Electrical Malfunction/Multiple DTCs
Technical Service Bulletin # 08-07-30-021E Date: 100607
Electrical - Electrical Malfunction/Multiple DTCs
TECHNICAL
Date: June 07, 2010
Subject: Loss of High Speed GMLAN Communications, Intermittent No Crank, IP Gage Fluctuation,
Intermittent Door Lock Cycling, Intermittent Chime Operation, Various IP Warning Lamps
Illuminated, Transmission May Not Shift, Communication DTCs U0073, U0100, U0101, U0102,
U0109, U0121 or U0140 Set (Repair Backed Out Terminal in Transmission Harness Connector,
Repair Open or Shorted GM High Speed LAN Circuits, Open or Shorted Data Link Resistor,
Correct Corrosion or Poor Connections in Various Control Module Connectors)
Models:
2007-2010 Cadillac Escalade Models, XLR 2009-2010 Cadillac Escalade Hybrid 2007-2010
Chevrolet Avalanche, Corvette, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Silverado
Hybrid, Tahoe Hybrid 2007-2010 GMC Sierra, Yukon Models 2008-2010 GMC Sierra Hybrid,
Yukon Hybrid 2008-2009 HUMMER H2
Equipped With 6 Speed 6L80 (RPO MYC) or 6L90 (RPO MYD) or Hybrid Two Mode 2ML70
Automatic Transmission
Please Refer to GMVIS
Supercede: This bulletin is being revised to update the Parts and Warranty Information. Please
discard Corporate Bulletin Number 08-07-30-021D (Section 07 - Transmission/Transaxle).
Condition
Some customers may comment on any of the following conditions:
- Instrument panel cluster (IPC) warning lamps may illuminate.
- The transmission may not shift or defaults to 2nd gear.
- The door locks may cycle by themselves.
- The engine may not crank intermittently.
- A driver information center (DIC) message is displayed.
- The IPC gages may fluctuate.
- Applying the brakes may cause the IPC to become erratic and the chimes to operate
simultaneously.
Depending on the vehicle, technicians may find one or more of the following High Speed GMLAN
Communications DTCs set as Current or History:
- U0073: Control Module Communications Bus OFF
- U0100: Lost Communication With ECM/PCM
- U0101: Lost Communication With TCM
- U0102: Lost Communication With Transfer Case Control Module
- U0109: Lost Communication With Fuel Pump Control Module

- U0121: Lost Communication With ABS Control Module
- U0140: Lost Communication With Body Control Module (BCM)
Cause
These conditions may be caused by, but not limited to, any of the following:
- The terminal(s) for the High Speed GMLAN Serial Data Bus has backed out of the 16-way
electrical connector to the automatic transmission.
- The terminal position assurance (TPA) lock in the transmission 16-way electrical connector is not
fully seated.
- The High Speed GMLAN Serial Data Bus circuits are open or shorted to ground.
- Corrosion in various control module connectors.
- Intermittent or poor connections in the inline connectors containing the High Speed GMLAN Serial
Data Bus circuits.
- The data link resistor is open or shorted.
- Water intrusion in various control module connectors.

> Jun > 10 > Electrical - Electrical Malfunction/Multiple DTCs > Page 5398
Parts Information
For transmission electrical repairs please note in the technicians comments field on the repair order
which terminal number(s) were repaired or replaced. Also if a male terminal is bent (transmission
side of connector), then indicate the bent terminal number on the repair order.
Disclaimer
Procedures to Diagnose/Chafed Wiring Harness at Trans Case
Information for the Procedures to Diagnose and Repair the Above Conditions
1. Perform the Diagnostic System Check-Vehicle to begin your diagnosis of these conditions. 2.
Perform a thorough visual inspection of the vehicle. 3. Depending on the vehicle, some of the
procedures may not be applicable. 4. The following procedure is the only one applicable to the
Corvette and XLR.
Chafed Wiring Harness at Transmission Case Retaining Clip and Inspection of the 16-way
Electrical Connector for Backed Out Terminals
4. Locate the 16-way electrical connector on the right side of the automatic transmission as shown.
5. Inspect for a pinched/cut wiring harness where it is attached at the transmission by a metal
attachment clip as shown. Inspect any of these harness
clips that you may observe as needed. If the wiring is damaged, repair as needed. Refer to Wiring
harness as needed.
7. Before disconnecting the 16-way connector, inspect for any backed out terminals (2) as shown.
Fully seated terminals (1) are shown for
comparison.
1. If a backed out terminal (2) is found, identify the terminal(s) on the repair order. 2. Look at the
connector in order to identify the number of the cavity with the backed out terminal. Refer to Wiring
Systems and Power
Management > Component Locator > Master Electrical Component List in SI.
8. Use the following procedure to disconnect the 16-way electrical connector:
1. For 2ML70 Only: Disconnect the 24-way electrical connector. 2. Release and hold the slide lock
on the wiring harness connector. 3. Rotate the connector lever and remove the connector from the
component.
9. Repair or replace the terminal(s) as necessary using the following procedure:

1. Locate the terminal position assurance (TPA) as shown.
Note The TPA cannot be removed from the connector while there are terminals present in the
connector body.
2. Use a small flat blade tool to push the TPA until it bottoms out.
3. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the
correct release tool is used. Use the J-38125-28
tool to release the terminals by inserting the tool into the terminal cavity as shown.
Note If the female terminal(s) must be replaced, it is part number 22124472200. It is located in
Yazaki tray number 12 in the J-38125 Terminal Repair Kit.
5. Repair or replace the terminal(s) as needed. Refer to the instructions in the J-38125 manual.
10. If the wiring is damaged, repair as needed. Refer to Wiring Systems and Power Management >
Diagnostic Information and Procedures in SI. 11. Slide the new terminal(s) into the correct cavity at
the back of the connector until it locks in place. The new terminal(s) should be even with the
other terminal(s).
12. Ensure that each terminal is locked in place by gently pulling on the wire.
Note The male terminal(s) cannot be repaired as they are an integral part of the transmission
control module (TCM).
13. Inspect for bent or misaligned terminal(s) in the transmission half of the electrical connector.
‹› If they are bent, use a suitable tool and apply gentle pressure to straighten them. Indicate on the
repair order the terminal number of the male
terminal that was bent.
‹› If they are damaged, refer to Control Solenoid Valve and Transmission Control Module Assembly
Replacement in SI.
14. Prior to installing the transmission connector, perform the following steps to ensure that the
TPA lock is fully seated.
Locate the TPA lock in the reassembled transmission connector. Refer to the arrow in the
illustration above, which points to a TPA lock. This one is in an unseated position. Using a small flat
blade tool, push to seat the TPA until it bottoms out. Verify the TPA is fully seated.
- If the TPA is off-center in the check window as shown, then it is only partially seated. Note the
large gap at the arrow. Reseat the TPA lock and ensure that it is fully seated.
- If the TPA lock is centered in the window as shown, then it is fully seated. The gaps shown by the
arrows should be even on both sides.
15. Install the transmission 16-way electrical connector.

Inspection of Fuse Block
Inspection of Fuse Block - I/P (Left Side) for Loose Connector X1
Battery Disconnect Caution and Battery Negative Cable Disconnection and Connection in SI.
3. Remove the left side fuse block as shown.
4. Inspect connector X1 (1) on the back of the fuse block for a loose connection as shown. Secure
the connector as needed. 5. Install the left side fuse block. 6. Connect the negative battery cable.
The above condition may cause one or more of the following fuses to open:
- 60A - MBEC1 (#72) (Underhood)

- 30A - AMP (#40) (Underhood)
- 15A - RDO (#41) (Underhood)
- 10A - IPC (#46) (Underhood)
- 15A - AIRBAG BATT (#51) (Underhood)
- 10A - DSM (Left side of IP)
Five Areas of Potential Contact Have Been Identified
Five areas of potential contact have been identified:

- The IP wiring branch to C202 may have been routed outboard of the junction block (left IP) and
the retaining clip (1) off the branch may not have been fully seated. Possible point of contact (2).
- The IP wiring branch to C202 may have been pushed up and forward into the park brake
assembly and the retaining clip off the branch may not have been fully seated. Possible points of
contact (1, 2).
- The IP wiring branch to C202 may have never been secured into place as the gray retaining clip
(1) off the branch was never seated.
- The IP harness may be in hard contact with the top rear edge (1) of the park brake assembly.
- When releasing the park brake pedal, the moving part (1) at the end of the park brake release
cable may be coming into hard contact with the IP harness.
If a condition is suspected/found with one of the circuits running to C1 or C2 of the junction block or
to the inline IP-to-body connector (C202) or at any of these areas of concern then remove the front
driver side door sill plate, driver side body hinge pillar trim panel, left IP outer trim cover and
Battery Negative Cable Disconnection and Connection in SI. 3. Visually inspect the IP harness for
damage at the park brake pedal assembly. Refer to potential damage points shown in the photos -
at the side and
rear of the park brake assembly. Note that damage may be hidden from view. The harness may be
turned away from you, or covered by electrical tape.
4. Operate the park brake release lever. Observe the moving part at the end of the park brake
release cable as it may contact and damage the IP
harness. Inspect the IP harness at this point. Note that the damage may be hidden from view by
electrical tape. If the wiring is damaged, repair as needed. Refer to Wiring Systems and Power
5. If the harness is still in contact with a sharp edge or point of the park brake assembly, route it
away from the contact point and secure it with tie
straps.
6. Protect the harness by covering the sharp edge with butyl tape or a suitable material.
7. Inspect how the IP branch to C202 is routed. Reroute the harness as necessary to match the
correct routing in the photo as shown. In order to route
the IP harness branch correctly (behind the junction block-left I/P), remove the cover from the
junction block-left I/P, unseat the junction block from the bracket.
8. Disconnect C202. Route the harness such that it lies between the "goalposts" of the junction
block bracket. Seat the junction block to the bracket
(harness will now be under the junction block).
9. Secure the harness by seating the grey offset retaining clip to the dashmat (or brown "buddy
clip" if present - usually on SUV's only). Reconnect
C202.
Chafed IP Wiring Harness at Left Side Junction Block Mounting Bracket
Battery Negative Cable Disconnection and Connection in SI. 3. Remove the left side junction block.
Refer to Instrument Panel Electrical Center or Junction Block Replacement - Left Side in SI. 4.
Inspect for chafed/shorted wiring at the mounting bracket.
harness as needed. 6. Replace the left side junction block. Refer to Instrument Panel Electrical
Center or Junction Block Replacement - Left Side in SI. 7. Connect the negative battery cable.
Chafed Wiring Harness at Adjustable Pedals Motor
Battery Negative Cable Disconnection and Connection in SI.
3. Inspect the wiring harness for chafed/shorted wiring at the adjustable pedals motor as shown. 4.
Diagnostic Information and Procedures in SI. 5. Protect the harness by covering the sharp edge
with butyl tape or a suitable material. Secure the harness as needed. 6. Connect the negative
battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 7. Clear any
DTCs that may be present with a scan tool and verify the proper operation of the vehicle.
Chafed Wiring Harness at Transmission
Battery Negative Cable Disconnection and Connection in SI. 3. Raise the vehicle. Refer to Lifting
and Jacking the Vehicle in SI. 4. Support the transmission with a transmission jack. 5. Remove the
transmission support crossmember. Refer to Transmission Support Crossmember Replacement in
SI.
6. Lower the transmission sufficiently to provide access to the engine wiring harness where it
routes from the engine intake manifold to the
transmission bell housing as shown.
7. Release the wiring harness conduit from the retainers that secure it to the transmission and/or
transfer case.
Note IT WILL be necessary to extract the wiring harness from the protective conduit if chafing IS
NOT observed on exposed wiring.
8. Examine the harness for wiring that may be exposed outside of the conduit. Inspect ALL areas
for chafing as shown. If chafing is not observed on
exposed wiring then extract the wiring from the protective conduit and inspect ALL areas for
chafing.
‹› If chafing or damage is found, repair the wiring. Refer to Wiring Systems and Power
Management > Diagnostic Information and Procedures >
Wiring Repairs in SI.
Secure the wiring harness conduit as needed.
10. Raise the transmission as needed to install the transmission support crossmember. Refer to
Transmission Support Crossmember Replacement in
SI.
Chafed Wiring Harness at Engine Intake Manifold
Battery Negative Cable Disconnection and Connection in SI. 3. Remove the upper intake manifold
sight shield. Refer to Upper Intake Manifold Sight Shield Replacement in SI.
4. Release the wiring harness conduit from the retainers that secure it to the rear of the engine and
at the top of the transmission bell housing.
Note The engine intake manifold is shown removed to provide clarity.
5. Pull the wiring harness up gently at the rear of the engine (1) and inspect the wiring harness for
chafed/shorted wiring (2). If chafing is not
observed on exposed wiring then extract the wiring from the protective conduit and inspect ALL
areas for chafing.
‹› If chafing (1) or damage is found, repair the wiring. Refer to Wiring Systems and Power
Management > Diagnostic Information and
Procedures > Wiring Repairs in SI.
Secure the wiring harness conduit as needed. 7. Install the upper intake manifold sight shield.
Refer to Upper Intake Manifold Sight Shield Replacement in SI. 8. Connect the negative battery
cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 9. Clear any DTCs that
may be present with a scan tool and verify the proper operation of the vehicle.
Chafed Wiring Harness at Chassis Body Mounts Left Side Frame Rail
4. Inspect the wiring harness along the left side frame rail at the body mounts for chafed/shorted
wiring as shown. 5. If the wiring is damaged, repair as needed. Refer to Wiring Systems and Power
Management > Diagnostic Information and Procedures > Wiring
Repairs in SI.
harness as needed. 7. Lower the vehicle. 8. Connect the negative battery cable. Refer to Battery
Negative Cable Disconnection and Connection in SI. 9. Clear any DTCs that may be present with a
scan tool and verify the proper operation of the vehicle.
Chafed Wiring Harness Near Data Link Resistor
Chafed Wiring Harness Near Data Link Resistor Causing Intermittent No/Crank and/or Scan Tool
Does Not Communicate with High Speed GMLAN Device
4. Typical location of a data link resistor (3) mounted on the chassis.

5. Inspect the wiring harness near the data link resistor, between the truck box and frame for
chafed/shorted wiring as shown. Refer to Wiring
Systems and Power Management > Component Locator > Master Electrical Component List >
Data Link Resistor in SI. If the wiring is damaged, repair as needed. Refer to Wiring Systems and
Power Management > Diagnostic Information and Procedures > Wiring Repairs in SI.
6. Disconnect the electrical connector from the data link resistor. 7. Test the resistor for
110-130ohm.
‹› If not within the specified range, replace the data link resistor. ‹› If within the specified range,
refer to Scan Tool Does Not Communicate with High Speed GMLAN Device in SI.
8. Connect the electrical connector to the data link resistor. Secure the resistor as needed. 9.
Protect the harness by covering the sharp edge with butyl tape or a suitable material. Secure the
harness as needed.
Inspection of Engine Harness
Connections
List > X109
in SI.
4. Before disconnecting, verify the connector is fully seated together even though the lever is
locked down as shown.
If the connector is not fully seated, repair as needed. Refer to Wiring Systems and Power
Management > Diagnostic Information and Procedures > Connector Repairs in SI.
- Bent pins
- Corrosion
Connections
1. Turn OFF the ignition and all accessories.

Connection in SI. 3. Locate the X115 connector. Refer to Wiring Systems and Power Management
> Component Locator > Master Electrical Component List > X115
in SI.
- Bent pins
- Corrosion
Hybrid Models Chafed Wiring Harness Locations/Inspections
Hybrid Models (HP2) Chafed Wiring Harness Locations and Inspection of Engine Harness
Connector X150 for Backed Out Terminals and Poor Connections at Ground Locations G102 and
G300
List > X150
in SI.
- Bent pins
- Corrosion
the bulletin titled: Repairing Fretting Corrosion to complete the connector repair.
5. Inspect for a misrouted/chafed harness rubbing on the cooling fins of the Transmission Auxiliary
Fluid Pump Control Module as shown.
6. Inspect for a chafed harness caused by a mispositioned retaining clip as shown. The chafing
condition usually occurs when the tab of the clip is
aligned with a slot in the conduit. If the wiring is damaged, repair as needed. Refer to Wiring
7. Locate ground connections G102 and G300. Refer to Wiring Systems and Power Management >
Component Locator > Master Electrical
Component List > G102 and G300 in SI.
8. Inspect G102 and G300 for a clean and tight connection. Undercoating has been found between
the eyelet and the frame resulting in a poor
connection.
If a condition is found, clean the area and repair as needed. Refer to Wiring Systems and Power
Connection in SI.
vehicle.
Lost Communication With DTC's Set
Lost Communication with Various Control Modules and DTCs Set
DTC Descriptors
Note Depending on the vehicle there may be other DTCs set by other modules.
- DTC U0073 Control Module Communication Bus A Off
- DTC U0100 Lost Communication with Engine/Powertrain Control Module (ECM/PCM)
- DTC U0101 Lost Communication with Transmission Control Module (TCM)
- DTC U0102 Lost Communication with Transfer Case Control Module
- DTC U0121 Lost Communication with Electronic Brake Control Module (EBCM)
- DTC U0140 Lost Communication with Body Control Module (BCM)
1. Connect a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record
any existing history or current DTCs from all of the
control modules (refer to SI). If any DTC(s) are set, refer to the list above or the Diagnostic Trouble
Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may
be causing the condition (refer to SI).
Battery Negative Cable Disconnection and Connection in SI. 4. Disconnect the connector(s) at the
affected module. 5. Inspect the connector(s) for the following conditions:
- Bent pins
- Corrosion
- Water intrusion
Diagnostic Information and Procedures in SI AND ‹› If corrosion or water intrusion is found,
proceed to the section of the bulletin titled: Repairing Fretting Corrosion to complete the repair.
6. Reconnect the connector(s) at the affected modules. 7. Clear any DTCs that may be present
with a scan tool and verify the proper operation of the vehicle.
Note Fretting corrosion looks like little dark smudges on the electrical terminals and appear where
the actual electrical contact is being made. In less severe cases it may be unable to be seen or
identified without the use of a magnifying glass.
1. If any water intrusion is present in the connector, use pressure regulated compressed air to dry it
out.
2. DO NOT apply an excessive amount of dielectric lubricant as shown, to the connectors as

hydrolock may result when attempting to mate the
connectors.
Important Use ONLY a clean nylon brush that is DEDICATED to the repair of this specific
condition.
With a one-inch nylon bristle brush, apply dielectric lubricant P/N 12377900 (in Canada, 10953529
to both the module/component side and the harness side of the affected connector(s).
3. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present.
vehicle.
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 08-08-49-010B
> Jul > 08 > Computers/Controls - Mutiple Malfunctions/DTC's Set
Wiring Harness: All Technical Service Bulletins Computers/Controls - Mutiple Malfunctions/DTC's

Set
TECHNICAL
Date: July 22, 2008
Supercede:
Condition
^ No crank.
Correction
possible concern.
Repair
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 08-08-49-010B
> Jul > 08 > Computers/Controls - Mutiple Malfunctions/DTC's Set > Page 5418
as needed.
needed.
block.
above for location.
Disclaimer
Hummer Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Actuators and Solenoids - Differential
> Actuator, Differential Lock > Component Information > Locations
Actuator: Locations
Rear Suspension
Left
Hummer Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Actuators and Solenoids - Differential
> Actuator, Differential Lock > Component Information > Locations > Page 5424
Actuator: Diagrams

Hummer Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Carrier > Carrier Bearings
Carrier Bearings: Service and Repair
Differential Side Bearings Replacement
Tools Required
* J 22912-B Split Plate Bearing Puller
* J 29710 Differential Side Bearing Installer
* J 36597 Side Bearing Puller Pilot - 9.25 inch Axle
* J 45766 Differential Side Bearing Remover
* J 8092 Universal Driver Handle - 3/4 in - 10
* J 8433 Two Jaw Puller
Removal Procedure
1. Remove the differential assembly. Refer to Differential Replacement (See: Service and
Repair/Removal and Replacement/Rear Drive
Axle/Differential Replacement) .
2. Remove the left side differential side bearing by performing the following steps:
1. Install the J 45766 (3), the J 36597 (2), and the J 8433 (1) as shown. 2. Mount the J 8433 into a
vise. 3. Remove the differential side bearing by turning the J 8433-3 clockwise.
3. Remove the right side differential side bearing by performing the following steps:
1. Install the J 45766 (3), the J 36597 (2), and the J 8433 (1) as shown. 2. Mount the J 8433 into a
vise. 3. Remove the differential side bearing by turning the J 8433-3 clockwise.
Hummer Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Carrier > Carrier Bearings
1. Install the differential side bearings by doing the following:
1. In order to protect the differential case, install the J 36597 in the case on the side opposite the
bearing installation. 2. Install the J 29710 (2) and the J 8092 (1) onto the differential case bearing
as shown. 3. Drive the bearing onto the case using the J 29710 and the J 8092 .
2. Install the differential assembly. Refer to Differential Replacement (See: Service and
Hummer Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Cover > Component
Differential Cover: Service and Repair
Rear Axle Housing Cover and Gasket Replacement
Removal Procedure
1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance) . 2. Drain the rear
axle. Refer to Rear Axle Lubricant Replacement (See: Fluid - Differential/Service and
Repair/Removal and Replacement/Rear
Drive Axle) .
3. Remove the nut and brake pipe/harness bracket from the stud.
4. Note the location of the jounce hose bracket bolt (1) and the brake pipe/harness bracket stud (2)
before removal. 5. Remove the rear axle housing cover bolts (4).
Discard the rear axle housing cover bolts.
6. Remove the rear axle housing cover and gasket (3) from the axle housing.
1. Catch the oil in a drain pan. 2. Remove any gasket material from the rear axle housing and/or
the rear axle housing cover.
1. Install the gasket (3) and the rear axle housing cover.
Important: Do not reuse the rear axle housing cover bolts.
2. Install the jounce hose bracket with a new bolt (1) and the new brake pipe/harness bracket stud
(2) in their proper locations. Do not tighten.
3. Install the remaining new rear axle housing cover bolts.
Tighten all the rear axle housing cover bolts in a crosswise pattern to 40 N.m (30 lb ft).
4. Install the brake pipe/harness bracket and nut to the stud.
5. Fill the rear axle. Refer to Rear Axle Lubricant Replacement (See: Fluid - Differential/Service and
Axle) .

Hummer Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Lock > Actuator,
Differential Lock > Component Information > Locations
Actuator: Locations
Rear Suspension
Left
Hummer Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Lock > Actuator,
Differential Lock > Component Information > Locations > Page 5439
Actuator: Diagrams

Hummer Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Mount > Component
Information > Service and Repair > Differential Carrier Assembly Bushing Replacement (Differential Carrier)
Differential Mount: Service and Repair Differential Carrier Assembly Bushing Replacement
(Differential Carrier)
Differential Carrier Assembly Bushing Replacement (Differential Carrier)
Tools Required
J 45755 Front Axle Bushing Remover/Installer
Removal Procedure
1. Remove the differential carrier assembly. It is not necessary to drain the differential carrier
assembly. Seal the vent tube opening with a piece of
tape to prevent the axle lubricant from leaking from the differential carrier assembly. Refer to
Differential Carrier Assembly Replacement (See: Differential Carrier/Service and Repair) .
2. Install the J 45755-3 (2), J 45755-4 (3), and the forcing screw, bearing and the washers (1) over
the differential carrier assembly bushing as shown. 3. Remove the differential carrier assembly
bushing using the J 45755 .
1. Install the differential carrier assembly bushing into the differential carrier assembly bushing
bore.
2. Install the J 45755-2 (2), J 45755-1 (3), and the forcing screw, bearing and washers (1) over the
differential carrier assembly bushing as shown. 3. Press the bushing into the differential carrier
assembly bushing bore using the J 45755 . 4. Install the differential carrier assembly. Once the
differential carrier assembly is installed, remove the piece of tape in order to connect the vent
hose. Refer to Differential Carrier Assembly Replacement (See: Differential Carrier/Service and
Repair) .
Hummer Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Mount > Component
Information > Service and Repair > Differential Carrier Assembly Bushing Replacement (Differential Carrier) > Page 5444
Differential Mount: Service and Repair Differential Carrier Assembly Bushing Replacement (Inner
Axle Shaft Housing)
Differential Carrier Assembly Bushing Replacement (Inner Axle Shaft Housing)

Tools Required
J 45755 Front Axle Bushing Remover/Installer
Removal Procedure
1. Remove the inner shaft housing. Refer to Front Drive Axle Inner Shaft and Inner Shaft Housing
Replacement (See: Service and Repair/Removal
and Replacement/Front Drive Axle/Front Drive Axle Inner Shaft and Inner Shaft Housing
Replacement) .
2. Install the inner shaft housing into a vise.
inner shaft housing bushing as shown. 4. Remove the inner shaft housing bushing using the J
45755 .
1. Install the inner shaft bushing into the inner shaft housing bushing bore.
Ensure that the inner shaft bushing is positioned so that the bushing is being driven in from the
front of the inner shaft housing towards the rear of the inner shaft housing.
inner shaft housing bushing as shown. 3. Press the bushing into the inner shaft housing bore using
the J 45755 . 4. Remove the inner shaft housing from the vise. 5. Install the inner shaft housing.
Refer to Front Drive Axle Inner Shaft and Inner Shaft Housing Replacement (See: Service and
Repair/Removal
and Replacement/Front Drive Axle/Front Drive Axle Inner Shaft and Inner Shaft Housing
Replacement) .
Hummer Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component
Fluid - Differential: Capacity Specifications
DIFFERENTIAL FLUID CAPACITY Front Axle ...................................................................................

.................................................................................................... 1.73 Liters (1.83 Quarts) Rear Axle
..............................................................................................................................................................
.......................... 2.60 Liters (2.75 Quarts)
Fluid - Differential: Fluid Type Specifications
DIFFERENTIAL FLUID TYPE Front / Rear

..............................................................................................................................................................
SAE 75W-90 Synthetic Axle Lubricant
Fluid - Differential: Procedures
Front Drive Axle
Front Axle Lubricant Level Inspection
1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance) . 2. Make sure the
vehicle is level. 3. Inspect the front axle for leaks. Repair as necessary. 4. Remove the engine
protection shield (if equipped). Refer to Engine Protection Shield Replacement (See: Body and
Frame/Frame/Skid
5. Clean the area around the front axle fill plug (1).
6. Remove the front axle fill plug (1). 7. Inspect the oil level.
The oil level should be between 0-10 mm (0-0.375 in) below the fill plug opening.
8. If the level is low, add oil until the level is even with the bottom edge of the fill plug opening. Use
the proper fluid. Refer to Fluid and Lubricant
Recommendations (See: Maintenance) .
9. Install the fill plug.
Tighten the plug to 33 N.m (24 lb ft).
and Frame/Frame/Skid Plate/Service and Repair) . 11. Lower the vehicle.
Rear Drive Axle
Rear Axle Lubricant Level Inspection

1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance) . 2. Make sure the
vehicle is level. 3. Inspect the rear axle for leaks. Repair as necessary. 4. Clean the area around
the rear axle fill plug.
5. Remove the rear axle fill plug. 6. Inspect the lubricant level.
The lubricant level should be between 0-10 mm (0-0.4 in) below the fill plug opening.
7. If the level is low, add lubricant until the level is even with the bottom edge of the fill plug
opening. Use the proper fluid. Refer to Fluid and

Fluid - Differential: Removal and Replacement

Front Drive Axle
Front Axle Lubricant Replacement
Removal Procedure
2. Remove the front differential carrier shield, if equipped. Refer to Engine Protection Shield
3. Clean the area around the front axle fill plug and the drain plug. 4. Remove the fill plug (1). 5.
Remove the drain plug (2). 6. Drain the fluid from the front axle differential.
1. Install the drain plug (2).
2. Fill the front differential with lubricant. Use the proper fluid. Refer to Approximate Fluid
Capacities (See: Maintenance) and Fluid and Lubricant
Recommendations (See: Maintenance) .
3. Install the fill plug (1).
4. Install the front differential carrier shield, if equipped. Refer to Engine Protection Shield
Rear Drive Axle
Rear Axle Lubricant Replacement

Removal Procedure
2. Remove the rear axle fill plug.
3. Remove the rear axle drain plug. 4. Drain the lubricant into a suitable container. 5. Inspect the
drain plug for excessive metal particle accumulation. This accumulation is symptomatic of extreme
wear. 6. Clean the drain plug.

1. Install the rear axle drain plug.
Tighten the rear axle drain plug to 33 N.m (24 lb ft).
2. Fill the rear axle. Use the proper fluid. Refer to Approximate Fluid Capacities (See: Maintenance)
and Fluid and Lubricant Recommendations (
See: Maintenance) .

Hummer Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Output Shaft, Differential > Differential
Output Shaft Bearing > Component Information > Service and Repair
Differential Output Shaft Bearing: Service and Repair
Front Drive Axle Inner Shaft Seal and Inner Shaft Bearing Replacement
Tools Required
* J 2619-01 Slide Hammer
* J 29369-2 Bushing and Bearing Remover (2-3 inch)
* J 36609 Axle Tube Bearing Installer
* J 45225 Axle Seal Installer
Removal Procedure
1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance) . 2. Drain the
differential carrier assembly. Refer to Front Axle Lubricant Replacement (See: Fluid -
Differential/Service and Repair/Removal and
Replacement/Front Drive Axle) .
3. If replacing the right side seal, perform the following steps:
1. Remove the inner axle shaft and housing assembly from the differential carrier case assembly.
Refer to Front Drive Axle Inner Shaft and Inner
Shaft Housing Replacement (See: Service and Repair/Removal and Replacement/Front Drive
Axle/Front Drive Axle Inner Shaft and Inner Shaft Housing Replacement) .
2. Install the inner axle shaft housing into a vise.
Clamp only on the mounting flange of the inner axle shaft housing.
3. Install the J 29369-2 behind the inner axle shaft seal. 4. Install the J 2619-01 (2) to the J 29369-2
(1). 5. Remove the inner axle shaft seal using the J 2619-01 .
Output Shaft Bearing > Component Information > Service and Repair > Page 5460
4. If replacing the right side bearing, perform the following steps:
(1). 5. Remove the inner axle shaft seal using the J 2619-01 . 6. Install the J 29369-2 behind the
inner axle shaft bearing. 7. Install the J 2619-01 (2) to the J 29369-2 (1). 8. Remove the inner axle
shaft bearing using the J 2619-01 .
5. If replacing the left side seal and/or bearing, perform the following steps:
1. Remove the differential carrier assembly. Refer to Differential Carrier Assembly Replacement
(See: Differential Carrier/Service and Repair) . 2. Place the differential carrier assembly into a vise.
Clamp only on the mounting flange of the differential carrier assembly case.
3. Remove the inner axle shaft using a hammer and a brass drift. 4. Install the J 29369-2 (2) behind
the inner axle shaft seal or the inner axle shaft bearing as necessary. 5. Install the J 2619-01 (1) to
the J 29369-2 (2). 6. Remove the inner axle shaft seal and/or the inner axle shaft bearing using the
J 2619-01 .
1. If installing the right side bearing, perform the following steps:
2. Install the bearing with the square shoulder in using the J 36609 (1) and the J 8092 (2).
2. If installing the right side inner axle shaft seal, perform the following steps:
2. Install the new axle shaft seal using the J 45225 (1) and the J 8092 (2).
3. Install the inner axle shaft into the inner axle shaft housing.
Carefully tap the inner axle shaft into place with a soft-faced mallet.
4. Install the inner axle shaft and housing assembly to the differential carrier case assembly. Refer
to Front Drive Axle Inner Shaft and Inner Shaft
Housing Replacement (See: Service and Repair/Removal and Replacement/Front Drive Axle/Front
Drive Axle Inner Shaft and Inner Shaft
Housing Replacement) .
5. If installing the left side bearing and/or seal, perform the following steps:
1. Install the bearing with the square shoulder in using the J 36609 (2) and the J 8092 (1). 2. Install
the new axle shaft seal using the J 45225 and the J 8092 . 3. Install the inner axle shaft into the
differential case side gear using a soft-faced mallet until the retaining ring on the inner axle shaft is
fully
seated within the groove in the differential case side gear.
4. Pull back on the inner axle shaft to ensure that the inner axle shaft is properly retained in the
differential case side gear. 5. Install the front differential carrier assembly. Refer to Differential
Carrier Assembly Replacement (See: Differential Carrier/Service and
Repair) .
6. Fill the differential carrier assembly. Use the proper fluid. Refer to Front Axle Lubricant
Replacement (See: Fluid - Differential/Service and
Repair/Removal and Replacement/Front Drive Axle) .

Hummer Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential >
Pinion Bearing: Service and Repair
Drive Pinion Bearings Replacement
Tools Required
* J 7818 Inner Bearing Race Installer

* J 8092 Driver Handle
* J 22306 Rear Pinion Cup Bearing Installer
* J 22388 Pinion Oil Seal Installer - Rear
* J 22912-B Split Plate Bearing Puller
* J 36614 Inner Pinion Bearing Installer
Removal Procedure
tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation (See:
Maintenance/Wheels and Tires/Service and
Repair) .
3. Remove the brake calipers. Refer to Rear Brake Caliper Replacement (See: Brakes and
Traction Control/Disc Brake System/Brake
Caliper/Service and Repair/Removal and Replacement/Rear Brake Caliper Replacement) .
4. Remove the brake rotors. Refer to Rear Brake Rotor Replacement (See: Brakes and Traction
Control/Disc Brake System/Brake
Rotor/Disc/Service and Repair/Removal and Replacement/Rear Brake Rotor Replacement) .
5. Remove the axle shafts. Refer to Rear Axle Shaft Replacement (See: Drive Axles, Bearings and
Joints/Axle Shaft Assembly/Axle Shaft/Service
and Repair) .
6. Remove the differential. Refer to Differential Replacement (See: Service and Repair/Removal
and Replacement/Rear Drive Axle/Differential
Replacement) .
7. Remove the drive pinion from the axle. Refer to Drive Pinion and Ring Gear Replacement (See:
Pinion Gear/Service and Repair) .
8. Press the bearing off of the pinion using the J 22912-B . 9. Remove the shim.
10. Remove the pinion bearing cups from the axle housing using a hammer and a brass drift in the
slots provided. Move the drift back and forth
between one side of the cup and the other in order to work the cups out of the housing evenly.
1. Install the outer pinion bearing cup using the J 7818 (2) and the J 8092 (1).
2. Install the inner pinion bearing cup using the J 22306 (2) and the J 8092 (1). 3. Determine the
selective shim thickness for the pinion. Refer to Pinion Depth Adjustment (See: Service and
Repair/Removal and
Replacement/Rear Drive Axle/Pinion Depth Adjustment) .
4. Install the selective shim between the inner pinion bearing and the shoulder on the gear. 5.
Install the inner pinion bearing using the J 36614 .
Press the bearing on until the cone seats on the pinion shim.
6. Install a new collapsible spacer. 7. Lubricate the pinion bearings with axle lubricant. Use the
proper fluid. Refer to Fluid and Lubricant Recommendations (See: Maintenance) . 8. Install the
drive pinion into the axle housing. 9. Install the outer pinion bearing onto the pinion.
10. Install a new pinion oil seal using the J 22388 . 11. Apply sealant, GM P/N 12346004
(Canadian P/N 10953480) or equivalent, to the splines of the pinion yoke. 12. Install the pinion
yoke.
Notice: Do not hammer the pinion flange/yoke onto the pinion shaft. Pinion components may be
damaged if the pinion flange/yoke is hammered onto the pinion shaft.
13. Seat the pinion yoke onto the pinion shaft by tapping it with a soft-faced hammer until a few
pinion shaft threads show through the yoke. 14. Install the washer and a new pinion nut. 15. Install
the J 8614-01 onto the pinion yoke.

Notice) .
Important: If the rotating torque is exceeded, the pinion will have to be removed and a new
collapsible spacer installed.
16. Tighten the pinion nut while holding the J 8614-01 .
Tighten the nut until the pinion end play is just taken up. Rotate the pinion while tightening the nut
to seat the bearings.
17. Measure the rotating torque of the drive pinion using an inch-pound torque wrench.
The rotating torque of the drive pinion should be 1.7-3.4 N.m (15-30 lb in).
18. If the rotating torque of the drive pinion is less than 1.7 N.m (15 lb in), continue to tighten the
pinion nut until the specified torque is obtained.
Rotate the pinion several times to ensure the bearings have seated. Recheck the rotating torque
and adjust if necessary.
19. If the rotating torque of the drive pinion is greater than 3.4 N.m (30 lb in), remove the drive
pinion and replace the collapsible spacer and re-install
the drive pinion following the steps above.
21. Install the brake rotors. Refer to Rear Brake Rotor Replacement (See: Brakes and Traction
Control/Disc Brake System/Brake Rotor/Disc/Service
and Repair/Removal and Replacement/Rear Brake Rotor Replacement) .
22. Install the brake calipers. Refer to Rear Brake Caliper Replacement (See: Brakes and Traction
Control/Disc Brake System/Brake Caliper/Service
and Repair/Removal and Replacement/Rear Brake Caliper Replacement) .
23. Install the tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation (See:
Maintenance/Wheels and Tires/Service and Repair)
.
24. Fill the axle with lubricant. Use the proper fluid. Refer to Rear Axle Lubricant Replacement
(See: Fluid - Differential/Service and
Repair/Removal and Replacement/Rear Drive Axle) .

Hummer Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential >
Component Information > Service and Repair > Front Drive Axle
Pinion Flange: Service and Repair Front Drive Axle
Front Differential Drive Pinion Flange/Yoke, Seal, and Dust Deflector Replacement
Tools Required
* J 8614-01 Flange and Pulley Holding Tool
* J 36366 Pinion Oil Seal Installer
Removal Procedure
drive axle. Refer to Front Axle Lubricant Replacement (See: Fluid - Differential/Service and
Repair/Removal and Replacement/Front
Drive Axle) .
3. Remove the tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation (See:
Repair) .
4. Remove the brake calipers. Refer to Front Brake Caliper Replacement (See: Brakes and
Caliper/Service and Repair/Removal and Replacement/Front Brake Caliper Replacement) .
5. Remove the engine protection shield. Refer to Engine Protection Shield Replacement (See:
Body and Frame/Frame/Skid Plate/Service and Repair
).
6. Reference mark the relationship of the propeller shaft to the front axle pinon yoke.
7. Remove the yoke retainer bolts (6) and the yoke retainers (7) from the front axle pinion yoke (1).
Notice: When removing the propeller shaft, do not attempt to remove the shaft by pounding on the
yoke ears or using a tool between the yoke and the universal joint. If the propeller shaft is removed
by using such means, the injection joints may fracture and lead to premature failure of the joint.
8. Disconnect the propeller shaft (2) from the front axle pinion yoke (1).
Wrap the bearing caps with tape in order to prevent the loss of bearing rollers.
9. Support the propeller shaft and move out of the way as necessary.
Component Information > Service and Repair > Front Drive Axle > Page 5472
10. Measure the torque required in order to rotate the pinion. Use an inch-pound torque wrench.
Record the torque value for reassembly. This will
give the combined preload for the following components:
* The pinion bearings
* The pinion seal
* The carrier bearings
* The axle bearings
* The axle seals
11. Scribe a line (1) on the pinion shaft and the pinion yoke (2).
12. Install the J 8614-01 onto the pinion as shown. 13. Remove the pinion nut while holding the J
8614-01 .
14. Install the J 8614-2 (2) and the J 8614-3 (3) into the J 8614-01 (1) as shown. 15. Remove the
pinon yoke by turning the J 8614-3 (3) clockwise while holding the J 8614-01 (1).
Important: Carefully pry the seal from the bore. Do not distort or scratch the aluminum case.
16. Remove the oil seal using a suitable seal removal tool.
Important: Drive the seal in straight, not at an angle.
1. Install the oil seal by doing the following:
1. Position the oil seal in the bore. 2. Install the J 36366 over the oil seal. 3. Strike the J 36366 with
a hammer until the seal flange seats on the axle housing surface.
2. Apply sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent to the splines of the
drive pinion yoke. 3. Install the pinion yoke.
Align the reference marks made during removal.
pinion shaft threads show through the yoke. 5. Install the washer and a new pinion nut.
6. Install the J 8614-01 onto the pinion yoke as shown.

Notice) .
Tighten the pinion nut until the pinion end play is just taken up. Rotate the pinion while tightening
the nut to seat the bearings.
8. Measure the rotating torque of the pinion using an inch-pound torque wrench.
Compare the measurement with the rotating torque recorded earlier.
Tighten the pinion nut, in small increments, as needed, until the torque required in order to rotate
the pinion is 0.40-0.57 N.m (3-5 lb in) greater than the torque recorded during removal.
9. Once the specified torque is obtained, rotate the pinion several times to ensure the bearings
have seated. Recheck the rotating torque and adjust if
necessary.
10. Install the propeller shaft (5) to the pinion yoke (1).
11. Install the yoke retainers (7) and the yoke retainer bolts (6) to the pinion yoke (1).
Tighten the yoke retainer bolts to 25 N.m (18 lb ft).
12. Fill the drive axle. Refer to Front Axle Lubricant Replacement (See: Fluid - Differential/Service
and Repair/Removal and Replacement/Front
Drive Axle) .
13. Inspect the axle lubricant level, and add, if necessary. Refer to Front Axle Lubricant Level
Inspection (See: Fluid - Differential/Service and
Repair/Procedures/Front Drive Axle) .
and Frame/Frame/Skid Plate/Service and Repair) . 15. Install the brake calipers. Refer to Front
Brake Caliper Replacement (See: Brakes and Traction Control/Disc Brake System/Brake
Caliper/Service
and Repair/Removal and Replacement/Front Brake Caliper Replacement) .

Pinion Flange: Service and Repair Rear Drive Axle
Drive Pinion Flange/Yoke and/or Oil Seal Replacement
Tools Required
* J 8614-01 Flange/Pulley Holding Tool

Removal Procedure
Important: Observe and mark the positions of all the driveline components, relative to the propeller
shaft and the axles, prior to disassembly. These components include the propeller shafts, drive
axles, pinion flanges, output shafts, etc. Reassemble all the components in the exact places in
which you removed the parts. Follow any specifications, torque values, and any measurements
made prior to disassembly.
drive axle. Refer to Rear Axle Lubricant Replacement (See: Fluid - Differential/Service and
Drive Axle) .
Repair) .
4. Remove the brake calipers and rotors. Refer to Rear Brake Rotor Replacement (See: Brakes
and Traction Control/Disc Brake System/Brake
5. Reference mark the rear propeller shaft (3) to the rear axle pinion yoke (4). 6. Disconnect the
propeller shaft from the axle.
Wrap the bearing caps with tape in order to prevent the loss of bearing rollers. Support the
propeller shaft as necessary.
7. Measure the amount of torque required to rotate the pinion. Use an inch-pound torque wrench.
Record this measurement for reassembly. This will
* The pinion oil seal
* The differential case bearings
* The axle bearings
* The axle seals

8. Place an alignment mark between the pinion and the pinion yoke.
9. Install the J 8614-01 as shown.
10. Remove the pinion nut while holding the J 8614-01 . 11. Remove the washer.
pinion yoke by turning the J 8614-3 (3) clockwise while holding the J 8614-01 (1).
Use a container in order to retrieve the lubricant.
14. Remove the pinion oil seal. Use a suitable seal removal tool. Do not damage the housing.
1. Install a new pinion oil seal using the J 22388 or the J 44414 . 2. Apply sealant, GM P/N
12346004 (Canadian P/N 10953480) or equivalent, to the splines of the pinion yoke.
3. Install the pinion yoke.
Align the marks made during removal.
8. Measure the rotating torque of the pinion. Compare this measurement with the rotating torque
recorded during removal.
Tighten the nut in small increments, as needed, until the rotating torque is 0.40-0.57 N.m (3- 5 lb in)
greater than the rotating torque recorded during removal.
necessary.
11. Install the propeller shaft yoke retaining clamps and the bolts.
Tighten the propeller shaft yoke retaining clamp bolts to 25 N.m (18 lb ft).
12. Install the brake rotors and calipers. Refer to Rear Brake Rotor Replacement (See: Brakes and
13. Install the tire and the wheel. Refer to Tire and Wheel Removal and Installation (See:
Maintenance/Wheels and Tires/Service and Repair) . 14. Fill the drive axle. Refer to Rear Axle
Lubricant Replacement (See: Fluid - Differential/Service and Repair/Removal and
Replacement/Rear Drive
Axle) .
15. Inspect and add axle lubricant to the axle housing, if necessary. Refer to Rear Axle Lubricant
Level Inspection (See: Fluid - Differential/Service
and Repair/Procedures/Rear Drive Axle) .

Hummer Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component
Pinion Gear: Service and Repair
Drive Pinion and Ring Gear Replacement
Tools Required
* J 22536 Pinion Driver

Removal Procedure
Repair) .
and Repair) .
Replacement) .
7. Remove the pinion yoke and the seal. Refer to Drive Pinion Flange/Yoke and/or Oil Seal
Replacement (See: Pinion Flange/Service and
Repair/Rear Drive Axle) .
8. Install the J 22536 as shown.
Ensure that the J 22536 is firmly seated on the pinion.
9. Drive the pinion out using the J 22536 and a hammer.
Strike the J 22536 slowly. Do not let the pinion fall out of the rear axle housing.
10. Remove the collapsible spacer from the pinion. Discard the spacer. 11. Remove the pinion
bearings and the cups. Refer to Drive Pinion Bearings Replacement (See: Pinion Bearing/Service
and Repair) .
Important: The ring gear bolts have left-hand threads.
12. Remove the ring gear bolts. Discard the bolts.
Notice: Do not pry the ring gear from the differential case. Prying the ring gear from the differential
case may cause damage to the ring gear and/or the differential case.
13. Remove the ring gear from the differential. Drive the gear off with a brass drift if necessary.
Important: The mating surface of the ring gear and the differential case must be clean and free of
burrs before installing the ring gear.
1. Install the ring gear to the differential case.

2. Install the new left-hand ring gear bolts.
Hand start each bolt in ensure the ring gear is properly installed to the differential case.

Notice) .
3. Tighten the ring gear bolts alternately and in stages, gradually pulling the ring gear onto the
differential case.
Tighten the ring gear bolts in sequence to 140 N.m (103 lb ft).
4. Install the pinion bearing cups. Refer to Drive Pinion Bearings Replacement (See: Pinion
Bearing/Service and Repair) . 5. Determine the selective shim thickness for the pinion gear. Refer
to Pinion Depth Adjustment (See: Service and Repair/Removal and
6. Install the selective shim onto the drive pinion. 7. Install the inner pinion bearing to the pinion.
Refer to Drive Pinion Bearings Replacement (See: Pinion Bearing/Service and Repair) .
proper fluid. Refer to Fluid and Lubricant Recommendations (See: Maintenance) .
10. Install the drive pinion into the axle housing. 11. Install the outer pinion bearing onto the drive
pinion.
yoke.
The rotating torque of the drive pinion should be 1.7-3.4 N.m (15-30 lb in) for new bearings or
1.1-2.3 N.m (10-20 lb in) for used bearings.
20. If the rotating torque of the drive pinion is less than 1.7 N.m (15 lb in) for new bearings or 1.1
N.m (10 lb in) for used bearings, continue to tighten
the pinion nut until the specified torque is obtained. Rotate the pinion several times to ensure the
bearings have seated. Recheck the rotating torque and adjust if necessary.
21. If the rotating torque of the drive pinion is greater than 3.4 N.m (30 lb in) new bearings or 2.3
N.m (20 lb in) for used bearings, remove the drive
pinion and replace the collapsible spacer and re-install the drive pinion following the steps above.
23. Perform a gear tooth contact pattern check on the drive pinion and the ring gear. Refer to Gear
Tooth Contact Pattern Inspection (See: Service and
Repair/Removal and Replacement/Rear Drive Axle/Gear Tooth Contact Pattern Inspection) .
24. Install the axle shafts. Refer to Rear Axle Shaft Replacement (See: Drive Axles, Bearings and
Joints/Axle Shaft Assembly/Axle Shaft/Service and
Repair) .


Hummer Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component
Ring Gear: Service and Repair
Drive Pinion and Ring Gear Replacement
Tools Required
* J 22536 Pinion Driver

Removal Procedure
Repair) .
and Repair) .
Replacement) .
7. Remove the pinion yoke and the seal. Refer to Drive Pinion Flange/Yoke and/or Oil Seal
Replacement (See: Pinion Flange/Service and
Repair/Rear Drive Axle) .
8. Install the J 22536 as shown.
Ensure that the J 22536 is firmly seated on the pinion.
9. Drive the pinion out using the J 22536 and a hammer.
Strike the J 22536 slowly. Do not let the pinion fall out of the rear axle housing.
10. Remove the collapsible spacer from the pinion. Discard the spacer. 11. Remove the pinion
bearings and the cups. Refer to Drive Pinion Bearings Replacement (See: Pinion Bearing/Service
and Repair) .
Important: The ring gear bolts have left-hand threads.
12. Remove the ring gear bolts. Discard the bolts.
Notice: Do not pry the ring gear from the differential case. Prying the ring gear from the differential
case may cause damage to the ring gear and/or the differential case.
13. Remove the ring gear from the differential. Drive the gear off with a brass drift if necessary.
Important: The mating surface of the ring gear and the differential case must be clean and free of
burrs before installing the ring gear.
1. Install the ring gear to the differential case.

2. Install the new left-hand ring gear bolts.
Hand start each bolt in ensure the ring gear is properly installed to the differential case.

Notice) .
3. Tighten the ring gear bolts alternately and in stages, gradually pulling the ring gear onto the
differential case.
Tighten the ring gear bolts in sequence to 140 N.m (103 lb ft).
4. Install the pinion bearing cups. Refer to Drive Pinion Bearings Replacement (See: Pinion
Bearing/Service and Repair) . 5. Determine the selective shim thickness for the pinion gear. Refer
to Pinion Depth Adjustment (See: Service and Repair/Removal and
6. Install the selective shim onto the drive pinion. 7. Install the inner pinion bearing to the pinion.
Refer to Drive Pinion Bearings Replacement (See: Pinion Bearing/Service and Repair) .
proper fluid. Refer to Fluid and Lubricant Recommendations (See: Maintenance) .
10. Install the drive pinion into the axle housing. 11. Install the outer pinion bearing onto the drive
pinion.
yoke.
The rotating torque of the drive pinion should be 1.7-3.4 N.m (15-30 lb in) for new bearings or
1.1-2.3 N.m (10-20 lb in) for used bearings.
20. If the rotating torque of the drive pinion is less than 1.7 N.m (15 lb in) for new bearings or 1.1
N.m (10 lb in) for used bearings, continue to tighten
the pinion nut until the specified torque is obtained. Rotate the pinion several times to ensure the
bearings have seated. Recheck the rotating torque and adjust if necessary.
21. If the rotating torque of the drive pinion is greater than 3.4 N.m (30 lb in) new bearings or 2.3
N.m (20 lb in) for used bearings, remove the drive
pinion and replace the collapsible spacer and re-install the drive pinion following the steps above.
23. Perform a gear tooth contact pattern check on the drive pinion and the ring gear. Refer to Gear
Tooth Contact Pattern Inspection (See: Service and
Repair/Removal and Replacement/Rear Drive Axle/Gear Tooth Contact Pattern Inspection) .
24. Install the axle shafts. Refer to Rear Axle Shaft Replacement (See: Drive Axles, Bearings and
Joints/Axle Shaft Assembly/Axle Shaft/Service and
Repair) .


Hummer Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential >
System Information > Service and Repair > Front Drive Axle
Seals and Gaskets: Service and Repair Front Drive Axle
Tools Required
* J 29369-2 Bushing and Bearing Remover (2-3 inch)
* J 36609 Axle Tube Bearing Installer
* J 45225 Axle Seal Installer
Removal Procedure
differential carrier assembly. Refer to Front Axle Lubricant Replacement (See: Fluid -
Differential/Service and Repair/Removal and
Replacement/Front Drive Axle) .
3. If replacing the right side seal, perform the following steps:
(1). 5. Remove the inner axle shaft seal using the J 2619-01 .
System Information > Service and Repair > Front Drive Axle > Page 5495
4. If replacing the right side bearing, perform the following steps:
(1). 5. Remove the inner axle shaft seal using the J 2619-01 . 6. Install the J 29369-2 behind the
inner axle shaft bearing. 7. Install the J 2619-01 (2) to the J 29369-2 (1). 8. Remove the inner axle
shaft bearing using the J 2619-01 .
5. If replacing the left side seal and/or bearing, perform the following steps:
1. Remove the differential carrier assembly. Refer to Differential Carrier Assembly Replacement
(See: Differential Carrier/Service and Repair) . 2. Place the differential carrier assembly into a vise.
Clamp only on the mounting flange of the differential carrier assembly case.
3. Remove the inner axle shaft using a hammer and a brass drift. 4. Install the J 29369-2 (2) behind
the inner axle shaft seal or the inner axle shaft bearing as necessary. 5. Install the J 2619-01 (1) to
the J 29369-2 (2). 6. Remove the inner axle shaft seal and/or the inner axle shaft bearing using the
J 2619-01 .
1. If installing the right side bearing, perform the following steps:
2. Install the bearing with the square shoulder in using the J 36609 (1) and the J 8092 (2).
2. If installing the right side inner axle shaft seal, perform the following steps:
2. Install the new axle shaft seal using the J 45225 (1) and the J 8092 (2).
3. Install the inner axle shaft into the inner axle shaft housing.
Carefully tap the inner axle shaft into place with a soft-faced mallet.
4. Install the inner axle shaft and housing assembly to the differential carrier case assembly. Refer
to Front Drive Axle Inner Shaft and Inner Shaft
Housing Replacement (See: Service and Repair/Removal and Replacement/Front Drive Axle/Front
Drive Axle Inner Shaft and Inner Shaft
Housing Replacement) .
5. If installing the left side bearing and/or seal, perform the following steps:
1. Install the bearing with the square shoulder in using the J 36609 (2) and the J 8092 (1). 2. Install
the new axle shaft seal using the J 45225 and the J 8092 . 3. Install the inner axle shaft into the
differential case side gear using a soft-faced mallet until the retaining ring on the inner axle shaft is
fully
seated within the groove in the differential case side gear.
4. Pull back on the inner axle shaft to ensure that the inner axle shaft is properly retained in the
differential case side gear. 5. Install the front differential carrier assembly. Refer to Differential
Carrier Assembly Replacement (See: Differential Carrier/Service and
Repair) .
6. Fill the differential carrier assembly. Use the proper fluid. Refer to Front Axle Lubricant
Replacement (See: Fluid - Differential/Service and
Repair/Removal and Replacement/Front Drive Axle) .
Tools Required
* J 36366 Pinion Oil Seal Installer
Removal Procedure
drive axle. Refer to Front Axle Lubricant Replacement (See: Fluid - Differential/Service and
Repair/Removal and Replacement/Front
Drive Axle) .
Repair) .
4. Remove the brake calipers. Refer to Front Brake Caliper Replacement (See: Brakes and
Caliper/Service and Repair/Removal and Replacement/Front Brake Caliper Replacement) .
5. Remove the engine protection shield. Refer to Engine Protection Shield Replacement (See:
Body and Frame/Frame/Skid Plate/Service and Repair
).
6. Reference mark the relationship of the propeller shaft to the front axle pinon yoke.
7. Remove the yoke retainer bolts (6) and the yoke retainers (7) from the front axle pinion yoke (1).
9. Support the propeller shaft and move out of the way as necessary.
10. Measure the torque required in order to rotate the pinion. Use an inch-pound torque wrench.
Record the torque value for reassembly. This will
* The pinion seal
* The carrier bearings
* The axle bearings
* The axle seals
11. Scribe a line (1) on the pinion shaft and the pinion yoke (2).
12. Install the J 8614-01 onto the pinion as shown. 13. Remove the pinion nut while holding the J
8614-01 .
pinon yoke by turning the J 8614-3 (3) clockwise while holding the J 8614-01 (1).
Important: Carefully pry the seal from the bore. Do not distort or scratch the aluminum case.
16. Remove the oil seal using a suitable seal removal tool.
Important: Drive the seal in straight, not at an angle.
1. Install the oil seal by doing the following:
1. Position the oil seal in the bore. 2. Install the J 36366 over the oil seal. 3. Strike the J 36366 with
a hammer until the seal flange seats on the axle housing surface.
2. Apply sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent to the splines of the
drive pinion yoke. 3. Install the pinion yoke.

Notice) .
Tighten the pinion nut until the pinion end play is just taken up. Rotate the pinion while tightening
the nut to seat the bearings.
8. Measure the rotating torque of the pinion using an inch-pound torque wrench.
Compare the measurement with the rotating torque recorded earlier.
Tighten the pinion nut, in small increments, as needed, until the torque required in order to rotate
the pinion is 0.40-0.57 N.m (3-5 lb in) greater than the torque recorded during removal.
necessary.
11. Install the yoke retainers (7) and the yoke retainer bolts (6) to the pinion yoke (1).
12. Fill the drive axle. Refer to Front Axle Lubricant Replacement (See: Fluid - Differential/Service
Drive Axle) .
13. Inspect the axle lubricant level, and add, if necessary. Refer to Front Axle Lubricant Level
Inspection (See: Fluid - Differential/Service and
Repair/Procedures/Front Drive Axle) .
and Frame/Frame/Skid Plate/Service and Repair) . 15. Install the brake calipers. Refer to Front
Brake Caliper Replacement (See: Brakes and Traction Control/Disc Brake System/Brake
Caliper/Service
and Repair/Removal and Replacement/Front Brake Caliper Replacement) .

Seals and Gaskets: Service and Repair Rear Drive Axle
Drive Pinion Flange/Yoke and/or Oil Seal Replacement
Tools Required
* J 8614-01 Flange/Pulley Holding Tool

Removal Procedure
Important: Observe and mark the positions of all the driveline components, relative to the propeller
shaft and the axles, prior to disassembly. These components include the propeller shafts, drive
axles, pinion flanges, output shafts, etc. Reassemble all the components in the exact places in
which you removed the parts. Follow any specifications, torque values, and any measurements
made prior to disassembly.
drive axle. Refer to Rear Axle Lubricant Replacement (See: Fluid - Differential/Service and
Drive Axle) .
Repair) .
4. Remove the brake calipers and rotors. Refer to Rear Brake Rotor Replacement (See: Brakes
and Traction Control/Disc Brake System/Brake
5. Reference mark the rear propeller shaft (3) to the rear axle pinion yoke (4). 6. Disconnect the
propeller shaft from the axle.
Wrap the bearing caps with tape in order to prevent the loss of bearing rollers. Support the
propeller shaft as necessary.
7. Measure the amount of torque required to rotate the pinion. Use an inch-pound torque wrench.
Record this measurement for reassembly. This will
* The pinion oil seal
* The differential case bearings
* The axle bearings
* The axle seals

8. Place an alignment mark between the pinion and the pinion yoke.
9. Install the J 8614-01 as shown.
10. Remove the pinion nut while holding the J 8614-01 . 11. Remove the washer.
pinion yoke by turning the J 8614-3 (3) clockwise while holding the J 8614-01 (1).
Use a container in order to retrieve the lubricant.
14. Remove the pinion oil seal. Use a suitable seal removal tool. Do not damage the housing.
1. Install a new pinion oil seal using the J 22388 or the J 44414 . 2. Apply sealant, GM P/N
12346004 (Canadian P/N 10953480) or equivalent, to the splines of the pinion yoke.
3. Install the pinion yoke.
Align the marks made during removal.
8. Measure the rotating torque of the pinion. Compare this measurement with the rotating torque
recorded during removal.
Tighten the nut in small increments, as needed, until the rotating torque is 0.40-0.57 N.m (3- 5 lb in)
greater than the rotating torque recorded during removal.
necessary.
11. Install the propeller shaft yoke retaining clamps and the bolts.
Tighten the propeller shaft yoke retaining clamp bolts to 25 N.m (18 lb ft).
12. Install the brake rotors and calipers. Refer to Rear Brake Rotor Replacement (See: Brakes and
13. Install the tire and the wheel. Refer to Tire and Wheel Removal and Installation (See:
Maintenance/Wheels and Tires/Service and Repair) . 14. Fill the drive axle. Refer to Rear Axle
Lubricant Replacement (See: Fluid - Differential/Service and Repair/Removal and
Replacement/Rear Drive
Axle) .
15. Inspect and add axle lubricant to the axle housing, if necessary. Refer to Rear Axle Lubricant
Level Inspection (See: Fluid - Differential/Service
and Repair/Procedures/Rear Drive Axle) .

Hummer Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component
Axle Bearing: Service and Repair
Rear Axle Shaft Seal and/or Bearing Replacement
Tools Required
* J 8092 Driver Handle
* J 29709 Wheel Bearing Installer (9.5 inch Axle)
* J 29713 Axle Seal Installer (9.5 inch Axle)
* J 44685 Rear Axle Seal and Bearing Remover
Removal Procedure
tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See:
3. Drain the rear axle lubricant. Refer to Rear Axle Lubricant Replacement (See: Differential
Assembly/Fluid - Differential/Service and
4. Remove the rear axle housing cover. Refer to Rear Axle Housing Cover and Gasket
Replacement (See: Differential Assembly/Differential
Cover/Service and Repair) .
5. Remove the axle shaft. Refer to Rear Axle Shaft Replacement (See: Axle Shaft Assembly/Axle
Shaft/Service and Repair) . 6. Remove the axle shaft seal and the bearing from the axle housing
using the J 2619-01 and the J 44685 .
Hummer Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component
1. Install the axle shaft bearing using the J 29709 and the J 8092 . 2. Drive the axle shaft bearing
into the axle housing until the tool bottoms against the tube.
3. Install the axle shaft seal using the J 29713 . 4. Drive the tool into the bore until the axle shaft
seal bottoms flush with the tube. 5. Install the axle shaft. Refer to Rear Axle Shaft Replacement
(See: Axle Shaft Assembly/Axle Shaft/Service and Repair) . 6. Install the rear axle housing cover.
Refer to Rear Axle Housing Cover and Gasket Replacement (See: Differential
Assembly/Differential
7. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See:
Maintenance/Wheels and Tires/Service and Repair) . 8. Fill the rear axle with lubricant. Refer to
Rear Axle Lubricant Replacement (See: Differential Assembly/Fluid - Differential/Service and

Hummer Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Axle Shaft > Component Information > Service and Repair
Axle Shaft: Service and Repair
Rear Axle Shaft Replacement
Removal Procedure
3. Remove the brake rotor. Refer to Rear Brake Rotor Replacement (See: Brakes and Traction
4. Remove the rear cover and the gasket. Refer to Rear Axle Housing Cover and Gasket
5. Remove the rear wheel speed sensor. Refer to Rear Wheel Speed Sensor Replacement (See:
Brakes and Traction Control/Antilock Brakes /
Traction Control Systems/Wheel Speed Sensor/Service and Repair/Rear Wheel Speed Sensor
Replacement) .
6. Remove the pinion shaft lock bolt.
7. Remove the pinion shaft.

Axle Shaft > Component Information > Service and Repair > Page 5514
8. Push the flange of the axle shaft (1) toward the differential. 9. Remove the C-lock (4) from the
button end of the axle shaft (1).
Important: When removing the axle shaft, do not rotate the shaft. Rotating the shaft will misalign
the gears. Misaligning the gears will make assembly difficult.
10. Remove the axle shaft from the housing.
Important: Carefully insert the axle shaft in order to not damage the seal.
1. Install the axle shaft into the rear axle housing. 2. Slide the axle shaft into place allowing the
splines to engage the differential side gear.
3. Place the lock (4) on the button end of the axle shaft (1). 4. Pull the shaft flange outward in order
to seat the lock in the differential gear.
5. Align the hole in the pinion shaft with the bolt hole in the differential case.
6. Install the new pinion shaft locking bolt.
Tighten the pinion shaft locking bolt to 53 N.m (39 lb ft).
7. Install the rear cover and the gasket. Refer to Rear Axle Housing Cover and Gasket
8. Install the rear wheel speed sensor. Refer to Rear Wheel Speed Sensor Replacement (See:
Brakes and Traction Control/Antilock Brakes /
Traction Control Systems/Wheel Speed Sensor/Service and Repair/Rear Wheel Speed Sensor
Replacement) .
9. Install the brake rotor. Refer to Rear Brake Rotor Replacement (See: Brakes and Traction
Maintenance/Wheels and Tires/Service and Repair) . 11. Fill the rear axle. Refer to Rear Axle
Lubricant Replacement (See: Differential Assembly/Fluid - Differential/Service and Repair/Removal
and
Replacement/Rear Drive Axle) .

Constant Velocity Joint > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Boot
Replacement
Constant Velocity Joint: Service and Repair Wheel Drive Shaft Inner Joint and Boot Replacement
Wheel Drive Shaft Inner Joint and Boot Replacement
Tools Required
* J 35910 Drive Axle Seal Clamp Pliers
* J 36652-1 Drive Axle Clamp Swage Tool
* J 36652-98 Axle Swage Tool

Removal Procedure
1. Remove the wheel drive shaft. Refer to Wheel Drive Shaft Replacement (See: Service and
Repair) .
Important: Use caution when using the hand grinder by the tripot housing (1).
2. Use a hand grinder in order to cut through the swage ring (2). 3. Remove the tripot housing (1)
from the halfshaft. 4. Wipe the grease off of the housing (1). 5. Thoroughly degrease the tripot
housing (1). 6. Allow the tripot housing (1) to dry prior to assembly.
7. Using side cutters, remove the small boot retaining clamp. 8. Remove the following items from
the halfshaft bar:
1. The spacer ring (1) 2. The tripot spider assembly (2) 3. The tripot boot (3)
9. Clean the halfshaft bar (4). Use a wire brush in order to remove any rust in the seal mounting
area (grooves).
10. Inspect the needle rollers, needle bearings, and trunnion. Inspect the tripot housing for unusual
wear, cracks, or other damage. Replace any
damaged parts with the appropriate service kit.
1. Place the new small seal clamp (2) onto the small end of the joint seal (1). Compress the joint
seal (1) and small seal clamp (2) onto the halfshaft
bar.
2. Position the small end of the joint seal (1) into the joint seal groove (3) on the halfshaft bar.

Notice) .
3. Secure the small seal clamp (1) with J 35910 , or equivalent, a breaker bar, and a torque
wrench.
Tighten the small seal clamp (1) to 136 N.m (100 lb ft).
4. Inspect the gap dimension on the clamp ear. Continue tightening until the gap dimension is
reached.
Important: Assemble the tripot joint with the convolute retainer in the correct position, as illustrated.
5. Install the convolute retainer tool over the inboard joint seal, being sure to capture the following
convolutions:
* 2-5 for the 1500 model.
* 2-4 for the 2500, 3500, and Hummer H2 models.

6. Install the tripot spider assembly (3) onto the halfshaft bar (2). 7. Install the spacer ring (1) in the
groove at the end of the halfshaft bar (2).
8. Pack the tripot seal (4) and the tripot housing (1) with the grease supplied in the kit. The amount
of grease supplied in this kit has been
pre-measured for this application.

9. Assemble the tripot housing and the tripot seal using the following procedure:
1. Pinch the swage ring (2) slightly by hand in order to distort it into an oval shape. 2. Slide the
distorted swage ring (2) over the large diameter of the seal. 3. Place the tripot housing over the
spider assembly. 4. Install the seal onto the tripot housing. 5. Align the tripot seal (1), with the
swage ring (2) in place, over the flat area on the tripot housing (3).
10. For the 1500 models, assemble the bolts and the support plate to the base of the J 36652-98
and secure the base in a vise. 11. For the 2500, 3500, and HUMMER H2 models, assemble the
bolts and the support plate to the base of the J 36652-1 and secure the base in a
vise.
12. Position the inboard end (tripot end) of the halfshaft assembly into the base of the J 36652-98
for the 1500 models or J 36652-1 for the 2500,
3500 and Hummer H2 models.
13. Install the top half of the J 36652-98 for the 1500 models or J 36652-1 for the 2500, 3500 and
HUMMER H2 models. 14. Align the swage ring (2) and the swage ring clamp. 15. Insert the bolts.
Hand tighten the bolts until the bolts are snug.

16. Align the following during this procedure:
* The tripot boot (3)
* The tripot housing (1)
* The swage ring (2)
Tighten each bolt 180 degrees at a time. Alternate between the bolts until both sides of the top half
of the tool touch the bottom half .
* Loosen the bolts and remove the halfshaft assembly from the tool.
17. Inspect the inboard stroke position.
* Use measurement A for the 1500 models.
* Use measurement B for the 2500, 3500, and Hummer H2 models.

18. Remove the convolute retainer tool from the boot. 19. Install the wheel drive shaft. Refer to
Wheel Drive Shaft Replacement (See: Service and Repair) .
Constant Velocity Joint: Service and Repair Wheel Drive Shaft Outer Joint and Boot Replacement
Wheel Drive Shaft Outer Joint and Boot Replacement
Special Tools
* J 8059 Snap Ring Pliers

Removal Procedure
Repair) .
Important: Use caution when using the hand grinder by the CV joint outer race (1).
2. Use a hand grinder to cut through the swage ring (2). 3. Use side cutters to cut off the small boot
clamp (4).
4. Slide the boot (5) down the halfshaft bar (4) and away from the CV joint outer race (1). 5. Wipe
all grease away from the face of the CV joint. 6. Find the halfshaft bar retaining snap ring (3), which
is located in the inner race (2). 7. Spread the snap ring ears apart using J 8059 (or equivalent). 8.
Pull the CV joint (1) and the CV joint boot (5) from the halfshaft bar (4). 9. Discard the old CV joint
boot (5).
10. Place a brass drift against the CV joint cage (1). 11. Tap gently on the brass drift with a
hammer in order to tilt the cage (1). 12. Remove the first chrome alloy ball (2) when the CV joint
cage (1) tilts. 13. Tilt the CV joint cage (1) in the opposite direction to remove the opposing chrome
alloy ball (2). 14. Repeat this process to remove all six of the balls.
15. Pivot the CV joint cage (4) and the inner race 90 degrees to the center line of the outer race (1).
At the same time, align the cage windows (3) with
the lands of the outer race (2).
16. Lift out the cage (4) and the inner race.
17. Remove the inner race (1) from the cage (2) by rotating the inner race (1) upward. 18. Clean
the following items thoroughly with cleaning solvent. Remove all traces of old grease and any
contaminates.
* The inner and outer race assemblies
* The CV joint cage
* The chrome alloy balls
19. Dry all the parts. 20. Check the CV joint assembly for unusual wear, cracks, or other damage.
21. Replace any damaged parts. 22. Clean the halfshaft bar. Use a wire brush to remove any rust
in the seal mounting area (grooves).
1. Inspect all of the parts for unusual wear, cracks, or other damage. Replace the CV joint
assembly if necessary. 2. Put a light coat of the recommended grease on the inner (6) and the
outer race (8) grooves.
3. Hold the inner race (1) at 90 degrees to the centerline of the cage (2). 4. Align the lands of the
inner race (1) with the windows of the cage (2). 5. Insert the inner race (1) into the cage (2), by
rotating the inner race (1) downward.
6. Insert the cage (4) and inner race into the outer race (1).
7. Place a brass drift against the CV joint cage (1). 8. Tap gently on the brass drift with a hammer
in order to tilt the cage (1). 9. Install the first chrome alloy ball (2) when the CV joint cage (1) tilts.
10. Tilt the CV joint cage (1) in the opposite direction to install the opposing chrome alloy ball (2).
11. Repeat this process in order to install all six of the balls.
12. Pack the CV joint boot (1) and the CV joint assembly with the grease supplied in the kit. The
amount of grease supplied in this kit has been
13. Place the new small boot clamp (2) onto the CV joint seal (1). 14. Slide the CV joint boot (1)
onto the halfshaft bar. 15. Position the small end of the CV joint boot (1) into the joint boot groove
(3) on the halfshaft bar.

Notice) .
16. Secure the small boot clamp (1) using J 35910 or equivalent, a breaker bar, and a torque
wrench.
Tighten the small clamp (1) to 136 N.m (100 lb ft).
17. Check the gap dimension on the clamp ear. Continue tightening until the gap dimension is
reached.
18. Pinch the new swage ring (2) slightly by hand to distort it into an oval shape. 19. Slide the
distorted swage ring (2) over the large diameter of the boot (1).
Important: Be sure that the retaining ring side of the CV joint inner race faces the halfshaft bar (3)
before installation.
20. Slide the CV joint (4) onto the halfshaft bar (3). The retaining snap ring inside of the inner race
engages in the halfshaft bar groove with a click
when the CV joint (4) is in the proper position.
21. Pull on the CV joint (4) to verify engagement. 22. Slide the large diameter of the CV joint boot
(1), with the large swage ring (2) in place, over the outside edge of the CV joint outer race (4).
23. Clamp the CV joint boot (2) tightly to the CV joint outer race (1) with the large swage ring (4),
using the following procedure: 24. For the 1500 models, assemble the bolts and the support plate
to the base of the J 36652-1 and secure the base in a vise. For the 2500, 3500, and
Hummer H2 models, use the J 36652-2 .
25. Position the CV joint end (outboard end) of the halfshaft assembly in the bottom half of J
36652-1 or J 36652-2 .
* The CV joint boot (3)
* The CV joint assembly (1)
27. Install the top half of J 36652-1 or J 36652-2 onto the lower half of the tool, over the CV joint
boot (3) and the CV joint assembly (1). 28. Align the swage ring (2) and the swage ring clamp. 29.
Insert the bolts into J 36652-1 or J 36652-2 . Hand tighten the bolts until the bolts are snug.
of the tool touch the bottom half of the tool.
30. Loosen the bolts and remove the halfshaft assembly from the tool. 31. Install the wheel drive
shaft. Refer to Wheel Drive Shaft Replacement (See: Service and Repair) .
Constant Velocity Joint Boot > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Boot
Replacement
Constant Velocity Joint Boot: Service and Repair Wheel Drive Shaft Inner Joint and Boot
Replacement
Wheel Drive Shaft Inner Joint and Boot Replacement
Tools Required

Removal Procedure
Repair) .
Important: Use caution when using the hand grinder by the tripot housing (1).
2. Use a hand grinder in order to cut through the swage ring (2). 3. Remove the tripot housing (1)
from the halfshaft. 4. Wipe the grease off of the housing (1). 5. Thoroughly degrease the tripot
housing (1). 6. Allow the tripot housing (1) to dry prior to assembly.
7. Using side cutters, remove the small boot retaining clamp. 8. Remove the following items from
the halfshaft bar:
1. The spacer ring (1) 2. The tripot spider assembly (2) 3. The tripot boot (3)
9. Clean the halfshaft bar (4). Use a wire brush in order to remove any rust in the seal mounting
area (grooves).
10. Inspect the needle rollers, needle bearings, and trunnion. Inspect the tripot housing for unusual
wear, cracks, or other damage. Replace any
damaged parts with the appropriate service kit.
1. Place the new small seal clamp (2) onto the small end of the joint seal (1). Compress the joint
seal (1) and small seal clamp (2) onto the halfshaft
bar.
2. Position the small end of the joint seal (1) into the joint seal groove (3) on the halfshaft bar.

Notice) .
3. Secure the small seal clamp (1) with J 35910 , or equivalent, a breaker bar, and a torque
wrench.
Tighten the small seal clamp (1) to 136 N.m (100 lb ft).
4. Inspect the gap dimension on the clamp ear. Continue tightening until the gap dimension is
reached.
Important: Assemble the tripot joint with the convolute retainer in the correct position, as illustrated.
5. Install the convolute retainer tool over the inboard joint seal, being sure to capture the following
convolutions:
* 2-5 for the 1500 model.
* 2-4 for the 2500, 3500, and Hummer H2 models.

6. Install the tripot spider assembly (3) onto the halfshaft bar (2). 7. Install the spacer ring (1) in the
groove at the end of the halfshaft bar (2).
8. Pack the tripot seal (4) and the tripot housing (1) with the grease supplied in the kit. The amount
of grease supplied in this kit has been

9. Assemble the tripot housing and the tripot seal using the following procedure:
1. Pinch the swage ring (2) slightly by hand in order to distort it into an oval shape. 2. Slide the
distorted swage ring (2) over the large diameter of the seal. 3. Place the tripot housing over the
spider assembly. 4. Install the seal onto the tripot housing. 5. Align the tripot seal (1), with the
swage ring (2) in place, over the flat area on the tripot housing (3).
10. For the 1500 models, assemble the bolts and the support plate to the base of the J 36652-98
and secure the base in a vise. 11. For the 2500, 3500, and HUMMER H2 models, assemble the
bolts and the support plate to the base of the J 36652-1 and secure the base in a
vise.
12. Position the inboard end (tripot end) of the halfshaft assembly into the base of the J 36652-98
for the 1500 models or J 36652-1 for the 2500,
3500 and Hummer H2 models.
13. Install the top half of the J 36652-98 for the 1500 models or J 36652-1 for the 2500, 3500 and
HUMMER H2 models. 14. Align the swage ring (2) and the swage ring clamp. 15. Insert the bolts.
Hand tighten the bolts until the bolts are snug.

* The tripot boot (3)
* The tripot housing (1)
of the tool touch the bottom half .
* Loosen the bolts and remove the halfshaft assembly from the tool.
17. Inspect the inboard stroke position.
* Use measurement A for the 1500 models.
* Use measurement B for the 2500, 3500, and Hummer H2 models.

18. Remove the convolute retainer tool from the boot. 19. Install the wheel drive shaft. Refer to
Wheel Drive Shaft Replacement (See: Service and Repair) .
Constant Velocity Joint Boot: Service and Repair Wheel Drive Shaft Outer Joint and Boot
Replacement
Wheel Drive Shaft Outer Joint and Boot Replacement
Special Tools
* J 8059 Snap Ring Pliers

Removal Procedure
Repair) .
Important: Use caution when using the hand grinder by the CV joint outer race (1).
2. Use a hand grinder to cut through the swage ring (2). 3. Use side cutters to cut off the small boot
clamp (4).
4. Slide the boot (5) down the halfshaft bar (4) and away from the CV joint outer race (1). 5. Wipe
all grease away from the face of the CV joint. 6. Find the halfshaft bar retaining snap ring (3), which
is located in the inner race (2). 7. Spread the snap ring ears apart using J 8059 (or equivalent). 8.
Pull the CV joint (1) and the CV joint boot (5) from the halfshaft bar (4). 9. Discard the old CV joint
boot (5).
10. Place a brass drift against the CV joint cage (1). 11. Tap gently on the brass drift with a
hammer in order to tilt the cage (1). 12. Remove the first chrome alloy ball (2) when the CV joint
cage (1) tilts. 13. Tilt the CV joint cage (1) in the opposite direction to remove the opposing chrome
alloy ball (2). 14. Repeat this process to remove all six of the balls.
15. Pivot the CV joint cage (4) and the inner race 90 degrees to the center line of the outer race (1).
At the same time, align the cage windows (3) with
the lands of the outer race (2).
16. Lift out the cage (4) and the inner race.
17. Remove the inner race (1) from the cage (2) by rotating the inner race (1) upward. 18. Clean
the following items thoroughly with cleaning solvent. Remove all traces of old grease and any
contaminates.
* The inner and outer race assemblies
* The CV joint cage
* The chrome alloy balls
19. Dry all the parts. 20. Check the CV joint assembly for unusual wear, cracks, or other damage.
21. Replace any damaged parts. 22. Clean the halfshaft bar. Use a wire brush to remove any rust
in the seal mounting area (grooves).
1. Inspect all of the parts for unusual wear, cracks, or other damage. Replace the CV joint
assembly if necessary. 2. Put a light coat of the recommended grease on the inner (6) and the
outer race (8) grooves.
3. Hold the inner race (1) at 90 degrees to the centerline of the cage (2). 4. Align the lands of the
inner race (1) with the windows of the cage (2). 5. Insert the inner race (1) into the cage (2), by
rotating the inner race (1) downward.
6. Insert the cage (4) and inner race into the outer race (1).
7. Place a brass drift against the CV joint cage (1). 8. Tap gently on the brass drift with a hammer
in order to tilt the cage (1). 9. Install the first chrome alloy ball (2) when the CV joint cage (1) tilts.
10. Tilt the CV joint cage (1) in the opposite direction to install the opposing chrome alloy ball (2).
11. Repeat this process in order to install all six of the balls.
12. Pack the CV joint boot (1) and the CV joint assembly with the grease supplied in the kit. The
amount of grease supplied in this kit has been
13. Place the new small boot clamp (2) onto the CV joint seal (1). 14. Slide the CV joint boot (1)
onto the halfshaft bar. 15. Position the small end of the CV joint boot (1) into the joint boot groove
(3) on the halfshaft bar.

Notice) .
16. Secure the small boot clamp (1) using J 35910 or equivalent, a breaker bar, and a torque
wrench.
Tighten the small clamp (1) to 136 N.m (100 lb ft).
17. Check the gap dimension on the clamp ear. Continue tightening until the gap dimension is
reached.
18. Pinch the new swage ring (2) slightly by hand to distort it into an oval shape. 19. Slide the
distorted swage ring (2) over the large diameter of the boot (1).
Important: Be sure that the retaining ring side of the CV joint inner race faces the halfshaft bar (3)
before installation.
20. Slide the CV joint (4) onto the halfshaft bar (3). The retaining snap ring inside of the inner race
engages in the halfshaft bar groove with a click
when the CV joint (4) is in the proper position.
21. Pull on the CV joint (4) to verify engagement. 22. Slide the large diameter of the CV joint boot
(1), with the large swage ring (2) in place, over the outside edge of the CV joint outer race (4).
23. Clamp the CV joint boot (2) tightly to the CV joint outer race (1) with the large swage ring (4),
using the following procedure: 24. For the 1500 models, assemble the bolts and the support plate
to the base of the J 36652-1 and secure the base in a vise. For the 2500, 3500, and
Hummer H2 models, use the J 36652-2 .
25. Position the CV joint end (outboard end) of the halfshaft assembly in the bottom half of J
36652-1 or J 36652-2 .
* The CV joint boot (3)
* The CV joint assembly (1)
27. Install the top half of J 36652-1 or J 36652-2 onto the lower half of the tool, over the CV joint
boot (3) and the CV joint assembly (1). 28. Align the swage ring (2) and the swage ring clamp. 29.
Insert the bolts into J 36652-1 or J 36652-2 . Hand tighten the bolts until the bolts are snug.
of the tool touch the bottom half of the tool.
30. Loosen the bolts and remove the halfshaft assembly from the tool. 31. Install the wheel drive
shaft. Refer to Wheel Drive Shaft Replacement (See: Service and Repair) .
Hummer Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing >
Wheel Bearing: Testing and Inspection
Wheel Bearings Diagnosis

Wheel Bearing: Service and Repair
Front Wheel Hub, Bearing, and Seal Replacement
Removal Procedure
Notice: Never place vehicle on the ground with the halfshaft removed or the halfshaft nut torqued
improperly. Otherwise, bearing seals may become dislodged causing premature wear and/or
damage to the hub and bearing assembly.
Maintenance/Wheels and Tires/Service and Repair) . 3. Remove the rotor. Refer to Front Brake
Rotor Replacement (See: Brakes and Traction Control/Disc Brake System/Brake
Rotor/Disc/Service and
4. Remove the wheel speed sensor and brake hose mounting bracket bolt from the steering
knuckle. 5. Disconnect the electrical connection for the wheel speed sensor. 6. Remove the wheel
driveshaft nut retaining cover. 7. Remove the wheel driveshaft assembly retaining nut and washer
from the wheel driveshaft assembly.
Disengage the wheel driveshaft from the wheel hub and bearing.
8. Remove the wheel hub and bearing mounting bolts. 9. Remove the wheel hub and bearing and
splash shield from the vehicle.
10. Remove the O-ring seal from the steering knuckle bore. 11. Remove the wheel speed sensor
from the wheel hub and bearing. 12. Clean and inspect the O-ring seal. 13. Replace the seal if the
following conditions exist:
* Nicks
* Cuts
* Dry or brittle
* Compression set
1. Clean all corrosion or contaminates from the steering knuckle bore and the hub and bearing
assembly. 2. Lubricate the steering knuckle bore with wheel bearing grease or the equivalent.
3. Install the O-ring to the steering knuckle.

Notice) .
4. Install the wheel speed sensor to the wheel hub and bearing.
Tighten the sensor mounting bolt to 18 N.m (13 lb ft).
5. Install the wheel hub and bearing and splash shield to the vehicle. 6. Install the wheel hub and
bearing mounting bolts.
Tighten the wheel hub to knuckle bolts to 180 N.m (133 lb ft).
7. Install the nut and washer retaining the wheel drive shaft assembly to the wheel hub and
bearing.
8. Connect the electrical connection for the wheel speed sensor. 9. Install the wheel speed sensor
and brake hose mounting bracket bolt to the steering knuckle.
10. Install the rotor. Refer to Front Brake Rotor Replacement (See: Brakes and Traction
Control/Disc Brake System/Brake Rotor/Disc/Service and
Maintenance/Wheels and Tires/Service and Repair) . 12. Lower the vehicle .
Hummer Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Axle Nut >
Axle Nut: Specifications
AXLE NUT TORQUE
Wheel Drive Shaft Hub And Bearing Nut

........................................................................................................................................... 235 N.m
(173 lb ft)
Hummer Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller
Shaft > Component Information > Specifications
Drive/Propeller Shaft: Specifications
Fastener Tightening Specifications

Shaft > Component Information > Specifications > Page 5576
Drive/Propeller Shaft: Diagrams
Driveline Disassembled Views
Front Propeller Shaft
Front Propeller Shaft
1 - Propeller Shaft Universal Joint 2 - Propeller Shaft Tube 3 - Propeller Shaft Universal Joint 4 -
Propeller Shaft Slip Yoke 5 - Propeller Shaft Rear Slip Yoke Boot Clamp - Front 6 - Propeller Shaft
Rear Slip Yoke Boot 7 - Propeller Shaft Rear Slip Yoke Boot Clamp - Rear
One-Piece Propeller Shaft
One-Piece Propeller Shaft
1 - Propeller Shaft Slip Yoke 2 - Propeller Shaft Universal Joint Spider Bearing Retainer Ring 3 -
Propeller Shaft Universal Joint 4 - Propeller Shaft Tube 5 - Propeller Shaft Universal Joint Spider
Bearing Retainer Ring 6 - Propeller Shaft Universal Joint 7 - Propeller Shaft Bearing Retainer
8 - Propeller Shaft Bearing Retainer Bolt
Drive/Propeller Shaft: Description and Operation
Propeller Shaft Description and Operation
The propeller shaft is a tube with universal joints at both ends that do not require periodic
maintenance. The universal joints transmit power from the transfer case, or from the transmission
output shaft, to the differential.
Front Propeller Shaft Description
The front propeller shaft transmits rotating force from the transfer case to the front differential when
the transfer case is engaged. The front propeller shaft connects to the transfer case using a splined
slip joint.
One-Piece Propeller Shaft Description
A one-piece propeller shaft uses a splined slip joint in order to connect the driveline to the
transmission, or to the transfer case.
Propeller Shaft Phasing Description
The propeller shaft is designed and built with the yoke lugs, or the ears, in-line with each other.
This produces the smoothest running shaft possible. A propeller shaft that is designed with built-in
yoke lugs in-line is known as in-phase. An out-of-phase propeller shaft often causes vibration. The
propeller shaft generates vibration from speeding up and from slowing down each time that the
universal joint spins around. The vibration is similar to a person snapping a rope and watching the
wave reaction flow to the end. An in-phase propeller shaft is similar to 2 persons snapping a rope
at the same time and watching the waves meet and cancel each other. Cancelling the vibration
produces a smooth flow of power in the drive line. All splined shaft slip yokes are keyed in order to
ensure proper phasing.
Universal Joint Description
The universal joint is connected to the propeller shaft. The universal joint consists of 4 caps with
needle bearings and with grease seals. The caps and the seals are mounted on the trunnions of a
cross or of a spider. The bearings and the caps are greased at the factory. No periodic
maintenance is required. Two universal joints are used in a one-piece propeller shaft. Three
universal joints are used in a two-piece propeller shaft. The bearings and the caps are pressed into
the yokes. The bearings and the caps are held in place with snap rings, except for 2 bearings on
some models. These bearings on some models are attached to the pinion flange of the differential.
Universal joints handle the effects of various loads and of rear axle windup conditions during
acceleration and braking. The universal joint operation is efficient and safe within the designed
angle variations. When the design angle is exceeded, the operational life of the joint decreases.
Center Bearing Description
Center bearings support the driveline when using 2 or more propeller shafts. The center bearing is
a ball bearing in a rubber cushion that attaches to a frame crossmember. The manufacturer
lubricates the bearing and seals the bearing. The cushion allows vertical motion at the driveline and
helps isolate the vehicle from vibration.
Shaft > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview
Drive/Propeller Shaft: Initial Inspection and Diagnostic Overview
Diagnostic Starting Point - Propeller Shaft
Begin the system diagnosis by reviewing the system Description and Operation. Reviewing the
Description and Operation information will help you determine the correct symptom diagnostic
procedure when a malfunction exists. Reviewing the Description and Operation information will
also help you determine if the condition described by the customer is normal operation. Refer to
Symptoms - Propeller Shaft (See: Symptom Related Diagnostic Procedures/Symptoms - Propeller
Shaft) in order to identify the correct procedure for diagnosing the system and where the procedure
is located.
Shaft > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 5581
Drive/Propeller Shaft: Symptom Related Diagnostic Procedures
Symptoms - Propeller Shaft
Symptoms - Propeller Shaft
Before beginning diagnosis, review the system description and operation in order to familiarize
yourself with the system function. Refer to Propeller Shaft Description and Operation (See:
Description and Operation) .
Classifying the Symptom
Propeller Shaft symptoms can usually be classified into the following categories:
* Leaks
* Noises
* Vibrations
Leak and noise related symptoms are diagnosed within the Propeller Shaft section. For vibration
related symptoms, refer to Diagnostic Starting Point - Vibration Diagnosis and Correction (See:
Body and Frame/Testing and Inspection/Vibration Diagnosis and Correction/Diagnostic Information
and Procedures/Diagnostic Starting Point - Vibration Diagnosis and Correction) .
Visual/Physical Inspection
* Inspect the system for aftermarket devices which could affect the operation of the propeller shaft.
* Inspect the easily accessible or visible system components for obvious damage or conditions
which could cause the symptom.
Symptom List
Refer to a symptom diagnostic procedure from the following list in order to diagnose the symptom:
* Universal Joint Noise (See: Universal Joint Noise)
* Ping, Snap, or Click Noise (See: Ping, Snap, or Click Noise)
* Knock or Clunk Noise (See: Knock or Clunk Noise)
* Scraping Noise (See: Scraping Noise)

* Squeak Noise (See: Squeak Noise)
Universal Joint Noise
Universal Joint Noise
Ping, Snap, or Click Noise
Ping, Snap, or Click Noise

Shaft > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 5582
Knock or Clunk Noise
Knock or Clunk Noise
Scraping Noise
Scraping Noise
Squeak Noise
Squeak Noise
Shaft > Component Information > Service and Repair > Front Propeller Shaft Replacement
Drive/Propeller Shaft: Service and Repair Front Propeller Shaft Replacement
Front Propeller Shaft Replacement
Removal Procedure
Important: Before disassembly, observe and accurately mark all of the driveline components
relative to the propeller shaft and to the axles. These items include the following components:
* The propeller shafts
* The wheel drive shafts
* The pinion flanges
* The output shafts
Assemble all of the components in the exact relationship to each other prior to removal. Observe all
published specifications and tightening values, and any measurements obtained prior to
disassembly.
transfer case shield. Refer to Transfer Case Shield Replacement (See: Transfer Case/Service and
Repair/Removal and
3. Mark the relationship of the propeller shaft and of the front axle pinion yoke.
4. Remove the bolts (6) and the yoke retainers (7) from the front axle pinion yoke (1).
Important: Do not drop the bearing cap assemblies of the yoke end.
Shaft > Component Information > Service and Repair > Front Propeller Shaft Replacement > Page 5585
6. Disconnect the boot from the groove on the transfer case output shaft. 7. Remove the propeller
shaft from the transfer case output shaft by sliding the propeller shaft forward.
1. Inspect the splines of the transfer case output shaft for a sufficient coating of lubricant. If the
output shaft does not have a sufficient coating of
lubricant, lubricate the shaft with lubricant GM P/N 12345879 (Canadian P/N 10953511) or with an
equivalent lubricant meeting GM specification 9985830.
2. Install the propeller shaft splines into the transfer case output shaft.
3. Install the propeller shaft (5) to the front axle pinion yoke (1).
Align the reference marks that were made during removal.

Notice) .
4. Install the yoke retainers (7) and the bolts (6).
5. Install the boot onto the transfer case output shaft until the boot snaps into the groove on the
output shaft. 6. Install the transfer case shield. Refer to Transfer Case Shield Replacement (See:
Transfer Case/Service and Repair/Removal and

Drive/Propeller Shaft: Service and Repair Rear Propeller Shaft Replacement
Rear Propeller Shaft Replacement
Removal Procedure
Important: Observe and accurately reference mark all driveline components relative to the propeller
shaft and axles before disassembly. These components include the propeller shafts, the drive
axles, the pinion flanges, the output shafts, etc. All components must be reassembled in the exact
relationship to each other as they were when removed. In addition, published specifications and
torque values, as well as any measurements made prior to disassembly must be followed.
2. Reference mark the propeller shaft to the rear axle pinion yoke. 3. Reference mark the propeller
shaft to the transfer case. 4. Remove the bolts (1) and the yoke retainers (2) from the rear axle
pinion yoke (3).
5. Slide the propeller shaft forward in order to disconnect the propeller shaft from the rear axle
pinion yoke.
6. Slide the propeller shaft rearward in order to disconnect the propeller shaft from the transfer
case.
7. Remove the propeller shaft from the vehicle.
1. Inspect the splines of the slip yoke for a sufficient coating of lubricant. If the splines of the slip
yoke does not have a sufficient coating of lubricant,
lubricate the shaft with lubricant GM P/N 12345879 (Canadian P/N 10953511) or with an equivalent
lubricant meeting GM specification 9985830 .
2. Install the propeller shaft into the transfer case.

3. Install the propeller shaft (3) to the rear axle pinion yoke (4).

Notice) .
4. Install the yoke retainers (2) and bolts (1).

Shaft > Component Information > Service and Repair > Page 5589
Drive/Propeller Shaft: Tools and Equipment
Special Tools
Hummer Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint,
Drive/Propeller Shaft > Component Information > Service and Repair > Universal Joint Replacement - Nylon Injected Ring
Universal Joint: Service and Repair Universal Joint Replacement - Nylon Injected Ring
Universal Joint Replacement - Nylon Injected Ring
Tools Required
* J 9522-3 U Joint Bearing Separator
* J 9522-5 U Joint Bearing Spacer Remover
Notice: Never clamp propeller shaft tubing in a vise. Clamping could dent or deform the tube
causing an imbalance or unsafe condition. Always clamp on one of the yokes and support the shaft
horizontally. Avoid damaging the slip yoke sealing surface. Nicks may damage the bushing or cut
the lip seal.
1. Support the propeller shaft in a line horizontal with the table of a press. 2. Mark the propeller
shaft as to which end is the transmission end and which end goes to the rear axle.
3. Place the universal joint so that the lower ear of the yoke is supported on a 30 mm (1 1/8 in)
socket.
4. In order to shear the plastic retaining ring on the bearing cup, place J 9522-3 on the open
horizontal bearing cups. Press the lower bearing cup out
of the yoke ear.
5. If you do not completely remove the bearing cup, lift the cross and insert J 9522-5 between the
seal and the bearing cup you are removing.
Continue to press the bearing cup out of the yoke.
6. Rotate the propeller shaft. Press the opposite bearing cup out of the yoke. 7. Mark the
orientation of the slip yoke to the tube for proper reassembly. 8. Remove the cross from the yoke.
9. Remove the remaining universal joint parts from the yoke. If you are replacing the front universal
joint, remove the bearing cups in the slip yoke in
the same manner.
10. Inspect the retaining ring grooves for plastic. 11. Inspect the bearing cup bores in the yoke ears
for burrs or imperfections. 12. Clean the remains of the sheared plastic bearing retainers from the
grooves in the yoke. 13. The sheared plastic may prevent the bearing cups from pressing into
place and thus prevent the bearing retainers from properly seating.
Assembly Procedure
1. Remove the bearing cups from the universal joint.

Drive/Propeller Shaft > Component Information > Service and Repair > Universal Joint Replacement - Nylon Injected Ring >
Page 5594
2. Assemble 1 bearing cup part way into 1 side of the yoke. 3. Turn the yoke ear toward the
bottom. 4. Assemble the cross into the yoke so the trunnion seats freely into the bearing cup. 5.
With the trunnion seated in the bearing cup, press the bearing cup into the yoke until the bearing
cup is flush with the yoke ear.
6. Assemble the opposite bearing cup part way into the yoke ear. 7. Ensure that the trunnions start
straight and true into both bearing cups. 8. Press the opposite bearing cup into the yoke ear while
working the cross all the time in order to inspect for a free unbinding movement of the
trunnions in the bearing cups.
Important: If there seems to be a hang-up or binding, stop pressing, and inspect the needle
bearings for misalignment in the bearing cup.
9. Press the bearing cup into the yoke until the bearing retainer groove clears the inside of the
yoke.
10. Assemble the bearing retainer in the retainer groove. 11. Continue pressing until you can snap
both retainers into place.
Page 5595
12. If seating the retainer is difficult, spring the yoke slightly with a firm blow from a dead blow
hammer. 13. It may be necessary to lubricate the snap ring with a slight amount of chassis grease
so the snap ring seats in the bearing cup groove.
Page 5596
Universal Joint: Service and Repair Universal Joint Replacement - External Snap Ring
Universal Joint Replacement - External Snap Ring
Tools Required
* J 9522-3 U-Joint Bearing Separator
* J 9522-5 U-Joint Bearing Spacer Remover
Notice: Never clamp propeller shaft tubing in a vise. Clamping could dent or deform the tube
causing an imbalance or unsafe condition. Always clamp on one of the yokes and support the shaft
horizontally. Avoid damaging the slip yoke sealing surface. Nicks may damage the bushing or cut
the lip seal.
1. Support the propeller shaft in a line horizontal with the table of a press. 2. Mark the propeller
shaft in order to show which end connects to the transmission and which end goes to the rear axle.
3. Disassemble the snap rings by pinching the ends together with a pair of pliers. 4. If the ring does
not readily snap out of the groove in the yoke, tap the end of the cup lightly in order to relieve the
pressure from the ring.
5. Place the universal joint so that the lower ear of the yoke is supported on a 30 mm (1-1/8 in) hex
head socket or a 27 mm (1-1/16 in) socket.
6. Place J 9522-3 on the open horizontal bearing cups. Press the lower bearing cup out of the yoke
ear. 7. If you do not completely remove the bearing cup, lift the cross and insert J 9522-5 between
the seal and the bearing cup you are removing.
Continue pressing the bearing cup out of the yoke.
8. Rotate the propeller shaft . Press the opposite bearing cup out of the yoke. 9. Mark the
orientation of the slip yoke to the tube for proper reassembly.
10. Remove the cross from the yoke. 11. Remove the remaining universal joint parts from the yoke.
12. If you are replacing the front universal joint, remove the bearing cups in the slip yoke in the
same manner. 13. Inspect the retaining ring grooves for dirt, corrosion, or pieces of the old ring. 14.
Inspect the bearing cup bores for burrs or imperfections. 15. Clean the retaining ring grooves.
Corrosion, dirt, rust, or pieces of the old retaining ring may prevent the bearing cups from pressing
into place or
prevent the bearing retainers from properly seating.
Assembly Procedure
1. Remove the bearing cups from the universal joint.

Page 5597
2. Assemble 1 bearing cup part way into 1 side of the yoke. Turn the yoke ear toward the bottom.
3. Assemble the cross into the yoke so that the trunnion seats freely into the bearing cup.
4. With the trunnion seated in the bearing cup, press the bearing cup into the yoke until the bearing
cup is flush with the yoke ear. 5. Install the opposite bearing cup part way into the yoke ear. 6.
Ensure that the trunnions start straight and true into both bearing cups. 7. Press the opposite
bearing cup into the yoke ear while working the cross all the time in order to inspect for free
unbinding movement of the
trunnions in the bearing cups.
Important: If there seems to be a hang up or binding, stop pressing. Inspect the needle bearings for
misalignment in the bearing cup.
8. Press the bearing cup into the yoke until the bearing cup retainer groove is visible over the top of
the bearing cup.
9. Assemble the bearing retainer in the retainer groove.
10. Continue pressing until both retainers can be snapped into place.
Page 5598
11. If the retainer is difficult to seat, the yoke can be sprung slightly with a firm blow from a dead
blow hammer. 12. It may be necessary to lubricate the snap ring with a slight amount of chassis
grease so that the snap ring seats in the bearing cup groove.
Hummer Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications
Flex Plate: Specifications
FLEX PLATE
Flex Plate Bolts (1-6) In Sequence
- First Pass ..........................................................................................................................................

........................................... 20 N.m (15 lb ft)
- Second Pass .....................................................................................................................................

............................................ 50 N.m (37 lb ft)
- Final Pass ..........................................................................................................................................

........................................ 100 N.m (74 lb ft)
Hummer Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications > Page
5602
Flex Plate: Service and Repair
Automatic Transmission Flex Plate Replacement
Removal Procedure
1. Remove the automatic transmission. Refer to Transmission Replacement (See: Automatic

Transmission/Transaxle/Service and Repair/Removal
and Replacement/Transmission Replacement) . Important: Note the position and direction of the
engine flywheel before removal.
2. Remove the engine flywheel bolts. 3. Remove the automatic transmission engine flywheel.
4. Install two M11x1.5 mm bolts (1) to the threaded holes of the spacer, if applicable. 5. Rotate the
bolts clockwise to remove the spacer.
5603
6. Remove the spacer from the rear of the crankshaft, if applicable.
Important:
* The flywheel does not use a locating pin for alignment and will not initially seat against the
crankshaft flange or spacer (if applicable), but will be pulled onto the crankshaft by the engine
flywheel bolts. This procedure requires a three stage tightening process.
* Certain applications (6.0L) require a spacer and longer bolts for proper flywheel position.
1. Install the spacer (if applicable) onto the rear of the crankshaft.
2. Install the automatic transmission engine flywheel to the crankshaft.
Important: Longer flywheel bolts must be used on applications using a flywheel spacer.
3. Apply threadlock to the threads of the flywheel bolts. Refer to Sealers, Adhesives, and
5604

Notice) .
4. Install the engine flywheel bolts.
1. Tighten the engine flywheel bolts a first pass in sequence to 20 N.m (15 lb ft). 2. Tighten the
engine flywheel bolts a second pass in sequence to 50 N.m (37 lb ft). 3. Tighten the engine
flywheel bolts a final pass in sequence to 100 N.m (74 lb ft).
5. Install the automatic transmission. Refer to Transmission Replacement (See: Automatic

Transmission/Transaxle/Service and Repair/Removal and
Replacement/Transmission Replacement) .
Hummer Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays
and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Recalls: > 08080 > Mar
> 08 > Campaign - Reprogram the TCM
31, 2009 - (Mar 4, 2008)
Purpose
Vehicles Involved
Important:
Service Procedure
Notice:

> 08 > Campaign - Reprogram the TCM > Page 5615
up to date.
8.3. Select NEXT.

Claim Information
> 08 > Campaign - Reprogram the TCM > Page 5616
Disclaimer
and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: >
INFORMATION
Models:
failure)
the correct states.
HISTORY DTC
following:
Speed >0 MPH
following:
Speed >0 MPH
properly.

defined below:
Disclaimer
TECHNICAL
Bulletin No.: 08-07-30-012
Condition
Correction
Disclaimer
and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service
ON
INFORMATION
Models:
failure)
the correct states.
5634
HISTORY DTC
following:
Speed >0 MPH
5635
following:
Speed >0 MPH
properly.

defined below:
5636
Disclaimer
Sensation
TECHNICAL
Bulletin No.: 08-07-30-012
Condition
Correction
Disclaimer
31, 2009 - (Mar 4, 2008)
Purpose
Vehicles Involved
Important:
Service Procedure
Notice:

up to date.
8.3. Select NEXT.

Claim Information
Disclaimer
and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Other Service
ON
INFORMATION
Models:
failure)
the correct states.
5652
HISTORY DTC
following:
Speed >0 MPH
5653
following:
Speed >0 MPH
properly.

defined below:
5654
Disclaimer
Sensation
TECHNICAL
Bulletin No.: 08-07-30-012
Condition
Correction
Disclaimer
31, 2009 - (Mar 4, 2008)
Purpose
Vehicles Involved
Important:
Service Procedure
Notice:

up to date.
8.3. Select NEXT.

Claim Information
Disclaimer
and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 5666

and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 5667
and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations
and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Transfer Case Shift
Control Module X1



and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Service and Repair >
Procedures
proceeding.
to the scan tool.
Removal Procedure
control module (2).
Hummer Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain >
Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations
Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Automatic

Views
Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Automatic

Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page
5690

Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations
Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Page 5694

Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations
Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page
5699
Switch
5700

5701

Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Locations
Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Locations > Page 5705

Removal Procedure

Notice) .
Hummer Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case >
Transfer Case Actuator > Component Information > Diagrams

Transfer Case Actuator > Component Information > Diagrams > Page 5714
Removal Procedure
1. Remove the transfer case shield. Refer to Transfer Case Shield Replacement (See: Service and
Repair/Removal and Replacement/Transfer Case
Shield Replacement) .
Important:
*
Transfer Case Actuator > Component Information > Diagrams > Page 5715
motor.
motor.

Notice) .
bolt.
Transfer Case Shield Replacement (See: Service and Repair/Removal and Replacement/Transfer
Case
Hummer Workshop Manuals > Transmission and Drivetrain > Transfer Case > Case Adapter, Transfer Case > Component
Case Adapter: Service and Repair
Transfer Case Adapter Replacement
Removal Procedure
1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance) . 2. Support the
transmission with a suitable jack stand.
3. Remove the rear crossmember from the frame. 4. Remove the transfer case from the vehicle.
Refer to Transfer Case Assembly Replacement (See: Service and Repair/Removal and
Replacement/Transfer Case Assembly Replacement) .
5. Remove the mounting bolts from the adapter to the transmission. 6. Remove the adapter from
the transmission (automatic shown). 7. Remove the seal between the transfer case and the
adapter. 8. Remove the gasket from the adapter.
Important: Always use a new gasket and seal for the adapter. Do not use any type of sealant or
adhesive in place of or with the gasket or the seal.
1. Install the new seal onto the transfer case.
Important: The transfer case adapter must be installed so that the adapter is evenly seated to the
transmission before installing the retaining nuts.
Hummer Workshop Manuals > Transmission and Drivetrain > Transfer Case > Case Adapter, Transfer Case > Component
2. Install the adapter to the transmission.

Notice) .
3. Install the adapter mounting bolts to the transmission.
Tighten the mounting bolts to 50 N.m (36 lb ft).
Important: When installing the gasket to the adapter, make sure that the yellow printing on the
gasket is facing toward the transfer case (away from the transmission). The locating tab on the
gasket should always be pointing up.
4. Install the new gasket to the adapter. 5. Install the transfer case to the adapter. Refer to Transfer
Case Assembly Replacement (See: Service and Repair/Removal and
6. Install the crossmember in the vehicle.
Tighten the mounting bolts to 95 N.m (70 lb ft).
7. Remove the transmission jack from the transmission. 8. Check the fluid level of the transfer
case. Refer to Transfer Case Fluid Replacement (See: Service and Repair/Removal and
Replacement/Transfer
Case Fluid Replacement) .
9. Lower the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance) .
Hummer Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component



proceeding.
to the scan tool.
Removal Procedure
control module (2).
Hummer Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component
Fluid - Transfer Case: Capacity Specifications
Transfer Case Fluid .............................................................................................................................

........................................................ 1.5 qt (1.4 liters)
Fluid - Transfer Case: Fluid Type Specifications
TRANSFER CASE FLUID TYPE .........................................................................................................

.......................................................... DEXRON-VI
Fluid - Transfer Case: Service and Repair
Transfer Case Fluid Replacement

Removal Procedure
Important: When performing the following service procedures, use only hand tools to remove and
install the fill or drain plugs.
fill plug from the transfer case.
Important: When draining the transfer case, make sure that an approved drain pan is used.
3. Remove the drain plug from the transfer case.

Notice) .
Important: If the drain or fill plug have to be replaced, used only aluminum replacement drain plugs.
1. Apply pipe sealant GM P/N 12346004 (Canadian P/N 10953480) to the threads on the drain
plug. 2. Install the drain plug in the transfer case.
3. Fill the transfer case to the bottom of the fill hole with the proper fluid. 4. Apply pipe sealant GM
P/N 12346004 (Canadian P/N 10953480) to the threads on the drain plug. 5. Install the fill plug.
Hummer Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch >
Switch


Hummer Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case >
Control Module, Transfer Case > Component Information > Locations
Control Module, Transfer Case > Component Information > Diagrams > Transfer Case Shift Control Module X1

Control Module, Transfer Case > Component Information > Diagrams > Transfer Case Shift Control Module X1 > Page
5749

Control Module, Transfer Case > Component Information > Diagrams > Transfer Case Shift Control Module X1 > Page
5750

Control Module, Transfer Case > Component Information > Service and Repair > Procedures
proceeding.
to the scan tool.
Control Module, Transfer Case > Component Information > Service and Repair > Procedures > Page 5753
Removal Procedure
control module (2).
Control Module, Transfer Case > Component Information > Service and Repair > Procedures > Page 5754
Hummer Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System
Information > Service and Repair > Front Output Shaft Seal Replacement
Seals and Gaskets: Service and Repair Front Output Shaft Seal Replacement
Front Output Shaft Seal Replacement
Tools Required
* J 8092 Universal Handle
* J 43484 Front Output Shaft Seal Installer
Removal Procedure
Notice: Refer to Transfer Case Seal Removal Notice (See: Service Precautions) .
front propeller shaft from the vehicle. Refer to Front Propeller Shaft Replacement (See:
Drive/Propeller Shafts, Bearings and
Joints/Drive/Propeller Shaft/Service and Repair/Front Propeller Shaft Replacement) .
3. Insert a flat-tipped screw driver in the inner race. 4. Pry the inner race forward.
5. Insert a small pry bar in the inner race. 6. Pry the inner part of the seal from the outer seal body.
7. Remove the inner part of the seal.
Information > Service and Repair > Front Output Shaft Seal Replacement > Page 5759
8. Insert a flat-tipped screw driver or small pry bar in the space between the outer race of the seal
and the transfer case. 9. Pry the outer race out of the transfer case.
10. Remove the outer part of the seal.
1. Using the J 43484 (2) and the J 8092 (1), install the transfer case output seal. 2. Install the front
propeller shaft. Refer to Front Propeller Shaft Replacement (See: Drive/Propeller Shafts, Bearings
and Joints/Drive/Propeller
Shaft/Service and Repair/Front Propeller Shaft Replacement) .
3. Check the transfer case fluid level. Refer to Transfer Case Fluid Replacement (See: Service and
Fluid Replacement) .
Seals and Gaskets: Service and Repair Rear Output Shaft Seal Replacement
Rear Output Shaft Seal Replacement
Tools Required
J 45756 Rear Output Shaft Seal Installer
Removal Procedure
Maintenance) . 2. Remove the rear propeller shaft. Refer to Rear Propeller Shaft Replacement
(See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller
Shaft/Service and Repair/Rear Propeller Shaft Replacement) .
3. Remove the rear output shaft seal by prying it out with a flat-tipped screwdriver.
1. Using J 45756 , install a NEW front output shaft seal. 2. Install the rear propeller shaft. Refer to
Rear Propeller Shaft Replacement (See: Drive/Propeller Shafts, Bearings and
Joints/Drive/Propeller
Shaft/Service and Repair/Rear Propeller Shaft Replacement) .
3. Check the fluid level. Add fluid, if necessary. 4. Lower the vehicle.
Seals and Gaskets: Service and Repair Input Shaft Seal Replacement
Input Shaft Seal Replacement
Tools Required
* J 42738 Seal Installer
* J 36825 Output Shaft Oil Seal Remover
Removal Procedure
transfer case from the adapter. Refer to Transfer Case Assembly Replacement (See: Service and
Repair/Removal and
3. Using the J 36825 remove the input shaft seal from the transfer case by threading the self
tapping screw (2) into the seal.
Important: When installing the input shaft seal, make sure that the part numbers on the seal are
facing outward (toward the technician). The input shaft seal should be even with the surface of the
transfer case after installation.
1. Position the seal on the input shaft.

2. Using the J 42738 , install the input shaft seal in the transfer case. 3. Install the transfer case to
the adapter. Refer to Transfer Case Assembly Replacement (See: Service and Repair/Removal
and
Hummer Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case >
Four Wheel Drive Selector Switch > Component Information > Locations
Four Wheel Drive Selector Switch > Component Information > Locations > Page 5767
Switch


Speed Sensor, Transfer Case > Component Information > Locations
Speed Sensor, Transfer Case > Component Information > Locations > Page 5773

Removal Procedure

Notice) .
Hummer Workshop Manuals > Transmission and Drivetrain > Transfer Case > Shift Fork, Transfer Case > Component
Information > Technical Service Bulletins > Customer Interest for Shift Fork: > 08-04-21-005A > Mar > 09 > Drivetrain -
Parking Lot Shudder/Binds Turning in 4 High
Shift Fork: Customer Interest Drivetrain - Parking Lot Shudder/Binds Turning in 4 High
TECHNICAL
Subject: Borg Warner(R) NR3, NR4 Transfer Case - Parking Lot Shudder, Binds On Turns in 4
High Open, Crow Hop (Replace Plastic Mode Fork)
Models: 2006-2008 HUMMER H2, H3
with Borg Warner(R) Transfer Case 4493/4494 (H3 - RPO NR3) or Borg Warner(R) Transfer Case
4484 (H2 - RPO NR4)
Supercede: This bulletin is being revised to change the labor operation from a published operation
to a bulletin only operation. Due to this change, the time has been reduced. Please discard
Corporate Bulletin Number 08-04-21-005 (Section 04 - Driveline/Axle).
Condition
Some customers may comment on transfer case parking lot shudder or bind on turns in 4 HI
"Open" position on vehicles equipped with Borg Warner(R) 4484, 4493 or 4494 transfer cases.
Cause
The plastic mode fork in the transfer case may have melted, which binds the transfer case in a
partially applied position.
Correction
Important
Do Not replace the entire transfer case for the above concern.
Replace the damaged mode fork. Refer to Transfer Case Disassemble and Assemble in Service
Information (SI).
- H2 - Replace with P/N 19180821.
Parts Information
For Vehicles repaired under warranty, use the table.

Information > Technical Service Bulletins > Customer Interest for Shift Fork: > 08-04-21-005A > Mar > 09 > Drivetrain -
Parking Lot Shudder/Binds Turning in 4 High > Page 5785
Disclaimer
Information > Technical Service Bulletins > All Technical Service Bulletins for Shift Fork: > 08-04-21-005A > Mar > 09 >
Drivetrain - Parking Lot Shudder/Binds Turning in 4 High
Shift Fork: All Technical Service Bulletins Drivetrain - Parking Lot Shudder/Binds Turning in 4 High
TECHNICAL
Subject: Borg Warner(R) NR3, NR4 Transfer Case - Parking Lot Shudder, Binds On Turns in 4
High Open, Crow Hop (Replace Plastic Mode Fork)
Models: 2006-2008 HUMMER H2, H3
with Borg Warner(R) Transfer Case 4493/4494 (H3 - RPO NR3) or Borg Warner(R) Transfer Case
4484 (H2 - RPO NR4)
Supercede: This bulletin is being revised to change the labor operation from a published operation
to a bulletin only operation. Due to this change, the time has been reduced. Please discard
Corporate Bulletin Number 08-04-21-005 (Section 04 - Driveline/Axle).
Condition
Some customers may comment on transfer case parking lot shudder or bind on turns in 4 HI
"Open" position on vehicles equipped with Borg Warner(R) 4484, 4493 or 4494 transfer cases.
Cause
The plastic mode fork in the transfer case may have melted, which binds the transfer case in a
partially applied position.
Correction
Important
Do Not replace the entire transfer case for the above concern.
Replace the damaged mode fork. Refer to Transfer Case Disassemble and Assemble in Service
Information (SI).
Parts Information
For Vehicles repaired under warranty, use the table.

Information > Technical Service Bulletins > All Technical Service Bulletins for Shift Fork: > 08-04-21-005A > Mar > 09 >
Drivetrain - Parking Lot Shudder/Binds Turning in 4 High > Page 5791
Disclaimer
Hummer Workshop Manuals > Transmission and Drivetrain > Transfer Case > Speed Sensor, Transfer Case > Component

Removal Procedure

Notice) .
Hummer Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component
Information > Diagrams

Removal Procedure
1. Remove the transfer case shield. Refer to Transfer Case Shield Replacement (See: Service and
Important:
*
motor.
motor.

Notice) .
bolt.
Transfer Case Shield Replacement (See: Service and Repair/Removal and Replacement/Transfer
Case
Hummer Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids -
Locations

Removal Procedure


Notice) .


Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information >
Specifications

Diagram Information and Instructions

Electrical Symbols
Electrical Symbols
Voltage Indicators
General Icons


Harness Components
Component Parts
Switches and Relays

Devices and Sensors


* Antenna location
Circuit Testing
Circuit Testing




Fused Jumper Wires)

Voltage)


Frequency)
Continuity)






Protection - Fuses)


Tools Required
J 25070 Heat Gun
necessary.
Salt Water Spray
condition.
cooling needs.
conditions.
when the DTC set.
Measuring Frequency
Measuring Frequency
measured.
Measuring Voltage
Measuring Voltage
points.
Frontprobe
terminals.
improper diagnosis.
connectors:
Backprobe
Important:

of a test probe.
connector.

lost.
With a DMM
With a Test Lamp
load.
Tools Required

Continuity)


circuit.
Tools Required
following items:

Recorder operation.

component side.






With a DMM
With a Test Lamp
shorted.
measurement.

Tools Required
pair of leads.
being tested.
terminals.
Tools Required

gage size.
Flat Wire Repairs
Flat Wire Repairs
Tools Required
energy circuits.
GMLAN Repairs
the repair.
GMLAN Wire Repair

splice.
(AWG) size.
achieved.
Tools Required
being obstructed.
sensor performance.
Tools Required
damaged wire.
Repair kit).
source.
exhaust pipes.

during the repair.

(AWG) size.
achieved.
achieved.
Tools Required

* A heat torch

SIR/SRS Wire Repair

together.
achieved.

Sleeves) .
Tools Required
2. Cut the wire.

closes.
existing wires.

Tools Required
2. Cut the wire.
achieved.
soldering tool.
new diode.
splice is made.
recommended.
Wiring Repairs
Wiring Repairs
Repairs)

Wiring Repairs)




Wiring Repairs)
AFL/EPC Connectors
AFL/EPC Connectors
Tools Required
Removal Procedure
forward.
dress
cover.

Repair Procedure
connector end view.
Tools Required

position.
Tools Required
Removal Procedure
cover.
Repair Procedure
connector end view.

Tools Required
body and pry up.
position.
used.

Tools Required
position.

Connector Repairs
Connector Repairs



Connectors (ECM))




Connector Anatomy
* Bosch
* Delphi
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
above it.
connection.
Tools Required
Removal Procedure
past the locks.
damaging it.
the tool may break.
used.
Repair Procedure
time.
Micro 64 terminals.
added wire.
from the wire.
visible.
Tools Required


remove the cover.
used.
added wire.

Tools Required
Terminal Removal
be replaced.
connector body.
Terminal Repair

Tools Required
Terminal Removal
Terminal Repair
Repairs) .
Tools Required
Tools Required
Removal Procedure
body.
cover off.
damaging it.
the connector.
used.
Repair Procedure
connector end view.
FCI Connectors
FCI Connectors
Tools Required
Removal Procedure
dress
cover.
Repair Procedure
connector end view.
JST Connectors
JST Connectors
Tools Required

Removal Procedure
connector body.
connector body.
used.
Repair Procedure
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required

Removal Procedure
Repair Procedure
connector end view.
Molex Connectors
Molex Connectors
Tools Required
forward.
Kit.
terminal.
Tools Required
Sumitomo Connectors
Sumitomo Connectors
Tools Required

* Terminal (1)
* Entry Canal (2)
connector.
terminal retainer.
Kit.
terminal.
Tools Required
Removal Procedure
component.

Tools Required
Removal Procedure
housing.
Repair Procedure
connector end view.

Tools Required

panel slides over.
Tools Required
assurance (CPA).
terminal.
Tools Required
Removal Procedure
damaging it.
Repair Procedure
connector end view.
Tools Required

Tools Required
Removal Procedure


Repair Procedure
connector end view.

Arrows and Symbols
Arrows and Symbols
Arrows and Symbols
Repair > Automatic Transmission Electronic Component Views

Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component
> Locations
Actuator: Locations
Rear Suspension
Left
> Locations > Page 5948
Actuator: Diagrams

> Diagrams

Removal Procedure
1. Remove the transfer case shield. Refer to Transfer Case Shield Replacement (See: Transfer
Case/Service and Repair/Removal and
Important:
*
motor.
motor.

Notice) .
bolt.
Transfer Case Shield Replacement (See: Transfer Case/Service and Repair/Removal and

Hummer Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules -
Service Bulletins > Recalls: > 08080 > Mar > 08 > Campaign - Reprogram the TCM
31, 2009 - (Mar 4, 2008)
Purpose
Vehicles Involved
Important:
Service Procedure
Notice:

up to date.
8.3. Select NEXT.

Claim Information
Disclaimer
Service Bulletins > Customer Interest: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON
INFORMATION
Models:
failure)
the correct states.
Page 5972
HISTORY DTC
following:
Speed >0 MPH
Page 5973
following:
Speed >0 MPH
properly.

defined below:
Page 5974
Disclaimer
Service Bulletins > Customer Interest: > 08-07-30-012 > Mar > 08 > A/T - Clunk Noise First Gear/Engine Braking Sensation
TECHNICAL
Bulletin No.: 08-07-30-012
Condition
Correction
Disclaimer
ON
INFORMATION
Models:
failure)
the correct states.
HISTORY DTC
following:
Speed >0 MPH
following:
Speed >0 MPH
properly.

defined below:
Disclaimer
Service Bulletins > All Technical Service Bulletins for Control Module: > 08-07-30-012 > Mar > 08 > A/T - Clunk Noise First
Sensation
TECHNICAL
Bulletin No.: 08-07-30-012
Condition
Correction
Disclaimer
TCM
31, 2009 - (Mar 4, 2008)
Purpose
Vehicles Involved
Important:
Service Procedure
Notice:

TCM > Page 5995
up to date.
8.3. Select NEXT.

Claim Information
TCM > Page 5996
Disclaimer
ON
INFORMATION
Models:
failure)
the correct states.
HISTORY DTC
following:
Speed >0 MPH
following:
Speed >0 MPH
properly.

defined below:
Disclaimer
Service Bulletins > All Other Service Bulletins for Control Module: > 08-07-30-012 > Mar > 08 > A/T - Clunk Noise First
Sensation
TECHNICAL
Bulletin No.: 08-07-30-012
Condition
Correction
Disclaimer
Service Bulletins > All Other Service Bulletins for Control Module: > 08080 > Mar > 08 > Campaign - Reprogram the TCM
31, 2009 - (Mar 4, 2008)
Purpose
Vehicles Involved
Important:
Service Procedure
Notice:

Page 6014
up to date.
8.3. Select NEXT.

Claim Information
Page 6015
Disclaimer




proceeding.
to the scan tool.
Removal Procedure
control module (2).
Hummer Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches -
Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information >
Locations

Views


Locations

Switch



Removal Procedure

Notice) .
Hummer Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems >
Replacement

Hummer Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems >

Hummer Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake
Speed Sensor Wiring/EBCM programming
Condition
reversed.
Correction
Vehicles Involved
Important:
System (GMVIS).
recall.
Parts Information
will be provided.
NOTICE:
up to date.

guidelines.
Claim Information

Disclaimer
Service Procedure
Important:
individual vehicle.
disconnected.
Step 5.
Important:
Control Module > Component Information > Technical Service Bulletins > Recalls: > NHTSA07V373000 > Aug > 07 > Recall
07V373000: ABS Wheel Speed Sensor Wiring
be reversed.
a crash.

TECHNICAL
Date: July 22, 2008
Supercede:
Condition
^ No crank.
Correction
possible concern.
Repair
as needed.
needed.
block.
above for location.
Disclaimer
Brake Control Module: > 08-08-49-010B > Jul > 08 > Computers/Controls - Mutiple Malfunctions/DTC's Set
TECHNICAL
Date: July 22, 2008
Supercede:
Condition
^ No crank.
Correction
possible concern.
Repair
Brake Control Module: > 08-08-49-010B > Jul > 08 > Computers/Controls - Mutiple Malfunctions/DTC's Set > Page 6106
as needed.
needed.
block.
above for location.
Disclaimer
Brake Control Module: > 07221 > Sep > 07 > Recall - Wheel Speed Sensor Wiring/EBCM programming
Condition
reversed.
Correction
Vehicles Involved
Important:
System (GMVIS).
recall.
Parts Information
will be provided.
NOTICE:
up to date.

guidelines.
Claim Information

Disclaimer
Service Procedure
Important:
individual vehicle.
disconnected.
Step 5.
Important:
Brake Control Module: > NHTSA07V373000 > Aug > 07 > Recall 07V373000: ABS Wheel Speed Sensor Wiring
Speed Sensor Wiring
be reversed.
a crash.
Control Module: > 08-08-49-010B > Jul > 08 > Computers/Controls - Mutiple Malfunctions/DTC's Set
TECHNICAL
Date: July 22, 2008
Supercede:
Condition
^ No crank.
Correction
possible concern.
Repair
Control Module: > 08-08-49-010B > Jul > 08 > Computers/Controls - Mutiple Malfunctions/DTC's Set > Page 6137
as needed.
needed.
block.
above for location.
Disclaimer
Control Module: > 07221 > Sep > 07 > Recall - Wheel Speed Sensor Wiring/EBCM programming
Condition
reversed.
Correction
Vehicles Involved
Important:
System (GMVIS).
recall.
Parts Information
will be provided.
NOTICE:
up to date.

guidelines.
Claim Information

Disclaimer
Service Procedure
Important:
individual vehicle.
disconnected.
Step 5.
Important:
Control Module: > NHTSA07V373000 > Aug > 07 > Recall 07V373000: ABS Wheel Speed Sensor Wiring
Speed Sensor Wiring
be reversed.
a crash.
Engine Compartment
Accumulator
Engine Compartment
Accumulator
Control Module > Component Information > Diagrams > Electronic Brake Control Module (EBCM) X1


Removal Procedure Caution: Refer to Brake Fluid Irritant Caution (See: Service
Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice (See: Service
Precautions/Vehicle Damage Warnings/Brake Fluid Effects on Paint and Electrical Components
Notice) .
reserve.
contamination.
contamination.
Instrument


Notice) .



Brake Bleeding/Service and Repair/Hydraulic Brake
System Bleeding (Manual))Hydraulic Brake System Bleeding (Pressure) (See: Brake

Bleeding/Service and Repair/Hydraulic Brake System Bleeding (Pressure)) .
Hummer Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic
Control Assembly - Antilock Brakes > Component Information > Service and Repair
Hydraulic Control Assembly - Antilock Brakes: Service and Repair
Brake Pressure Modulator Valve Replacement
Special Tools
CH-47830 Holding Fixture
1. Remove the brake master cylinder and power brake booster assembly. Refer to Brake Master
Cylinder with Power Brake Booster and Chassis
Control Module Replacement (See: Hydraulic System/Brake Master Cylinder/Service and

Control Module Replacement) .
2. Install the CH-47830 (1) to the master cylinder assembly. 3. Position the CH-47830 with the
master cylinder assembly in a vise.
Control Assembly - Antilock Brakes > Component Information > Service and Repair > Page 6181
4. Remove the master cylinder reservoir (1). Refer to Master Cylinder Reservoir Replacement
(See: Hydraulic System/Brake Master
Cylinder/Service and Repair/Removal and Replacement/Master Cylinder Reservoir Replacement) .
5. Remove the power brake booster (1). Refer to Power Brake Booster Replacement (See: Power
Brake Assist/Hydraulic Brake Booster/Service and
Repair/Power Brake Booster Replacement) .

6. Remove the brake pressure modulator valve (BPMV) (1) bolts.
7. Remove the BPMV gasket (1) and the BPMV module assembly (2).
Discard the BPMV gasket.

8. Remove the brake fluid level sensor bracket bolt (1) and bracket (2) from the BPMV module
assembly.

Notice) .
1. Install the brake fluid level sensor bracket bolt (1) and bracket (2) to the BPMV module
assembly.

2. Install a new BPMV gasket (1) and the BPMV module assembly (2).
Important: Hand install the BPMV module assembly bolts prior to tightening the bolts to properly
locate the BPMV module assembly.
3. Install the BPMV (1) bolts.

4. Install the power brake booster (1). Refer to Power Brake Booster Replacement (See: Power
5. Install the master cylinder reservoir (1). Refer to Master Cylinder Reservoir Replacement (See:
Hydraulic System/Brake Master Cylinder/Service
and Repair/Removal and Replacement/Master Cylinder Reservoir Replacement) .

6. Remove the CH-47830 (1) from the master cylinder assembly. 7. Install the brake master
cylinder and power brake booster assembly. Refer to Brake Master Cylinder with Power Brake
Booster and Chassis


9. Refer to Programming and Relearning (See: Testing and Inspection/Programming and

Hummer Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Lateral
(SDM)
Hummer Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Lateral

Hummer Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control
Module > Component Information > Technical Service Bulletins > Customer Interest for Traction Control Module: >
TECHNICAL
Date: July 22, 2008
Supercede:
Condition
^ No crank.
Correction
possible concern.
Repair
Module > Component Information > Technical Service Bulletins > Customer Interest for Traction Control Module: >
as needed.
needed.
block.
above for location.
Disclaimer
Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Traction Control
Module: > 08-08-49-010B > Jul > 08 > Computers/Controls - Mutiple Malfunctions/DTC's Set

TECHNICAL
Date: July 22, 2008
Supercede:
Condition
^ No crank.
Correction
possible concern.
Repair
Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Traction Control
Module: > 08-08-49-010B > Jul > 08 > Computers/Controls - Mutiple Malfunctions/DTC's Set > Page 6205
as needed.
needed.
block.
above for location.
Disclaimer
Hummer Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > Recalls for Wheel Speed Sensor: > 07221 > Sep > 07 >
Condition
reversed.
Correction
Vehicles Involved
Recall - Wheel Speed Sensor Wiring/EBCM programming > Page 6214
Important:
System (GMVIS).
recall.
Parts Information
will be provided.
NOTICE:
up to date.

guidelines.
Claim Information

Disclaimer
Service Procedure
Important:
individual vehicle.
disconnected.
Step 5.
Important:
Sensor > Component Information > Technical Service Bulletins > Recalls for Wheel Speed Sensor: > NHTSA07V373000 >
Aug > 07 > Recall 07V373000: ABS Wheel Speed Sensor Wiring
be reversed.
a crash.
Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: >
07221 > Sep > 07 > Recall - Wheel Speed Sensor Wiring/EBCM programming
Condition
reversed.
Correction
Vehicles Involved
07221 > Sep > 07 > Recall - Wheel Speed Sensor Wiring/EBCM programming > Page 6240
Important:
System (GMVIS).
recall.
Parts Information
will be provided.
NOTICE:
up to date.

guidelines.
Claim Information

Disclaimer
Service Procedure
Important:
individual vehicle.
disconnected.
Step 5.
Important:
Sensor Wiring
be reversed.
a crash.
Sensor > Component Information > Technical Service Bulletins > Page 6261
Front Suspension
Rear Suspension
Sensor > Component Information > Technical Service Bulletins > Page 6262
Left
Sensor > Component Information > Diagrams > Wheel Speed Sensor (WSS) - Left Front

Sensor > Component Information > Diagrams > Wheel Speed Sensor (WSS) - Left Front > Page 6265



Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement
Front Wheel Speed Sensor Replacement Caution: Refer to Brake Dust Caution (See: Service
Precautions/Technician Safety Information/Brake Dust Caution) .
Removal Procedure
Brake Rotor Replacement (See: Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal
and
Replacement/Front Brake Rotor Replacement) .
Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page 6270
Replacement (See: Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and
Antilock Brake System (See: Testing and Inspection/Initial Inspection and Diagnostic
Overview/Diagnostic
Starting Point - Antilock Brake System) .

Rear Wheel Speed Sensor Replacement Caution: Refer to Brake Dust Caution (See: Service
Removal Procedure

Notice) .

(See: Testing and Inspection/Symptom Related Diagnostic Procedures/Symptoms - Antilock Brake
System) .
System (See: Testing and Inspection/Initial Inspection and
Diagnostic Overview/Diagnostic Starting Point - Antilock Brake System) .

Hummer Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Yaw Rate
(SDM)


Hummer Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair >
Antilock Brake System Automated Bleed Procedure
(See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Caution) .
Notice) .
base brake bleed.
before proceeding.
to proceed.
seconds.
power reserve.
Inspection (See: Hydraulic System/Testing and Inspection/Component Tests and General
Diagnostics/Brake System External Leak Inspection) .
Symptoms - Hydraulic Brakes (See: Hydraulic System/Testing and Inspection/Symptom Related

Diagnostic Procedures/Symptoms - Hydraulic Brakes) .
Antilock Brake System Automated Bleed Procedure > Page 6282
Service Precautions/Technician Safety Information/Brake Fluid Irritant Caution) .
Notice) .
steps 2.5-2.8.
steps 2.5-2.8.
steps 2.5-2.8.
diaphragm.
12377967
tightened.
P/N 12377967 (Canadian P/N 992667), or
Reservoir Filling (See: Hydraulic System/Brake Master Cylinder/Service and Repair/Procedures) .
(See: Hydraulic System/Testing and
Inspection/Component Tests and General Diagnostics/Brake System External Leak Inspection) .
the system.

Tools Required
Caution: Refer to Brake Fluid Irritant Caution (See: Service Precautions/Technician Safety
Information/Brake Fluid Irritant Caution) .
Notice) .
steps 2.5-2.8.
steps 2.5-2.8.
steps 2.5-2.8.
P/N 12377967 (Canadian P/N 992667), or
equivalent
12377967
tightened.
the brake master cylinder reservoir. Refer to Master Cylinder Reservoir Filling (See: Hydraulic
System/Brake Master Cylinder/Service and
Repair/Procedures) .
brake pedal feels spongy perform the following steps:
Inspection/Component Tests and General Diagnostics/Brake System External Leak Inspection) .

Hydraulic Brake System Flushing Caution: Refer to Brake Fluid Irritant Caution (See: Service
Notice) .
contamination.
the following:
(See: Hydraulic System/Brake Master Cylinder/Service and Repair/Removal and
Replacement/Brake Master Cylinder with Power Brake Booster and Chassis Control Module
Replacement)
* Front Brake Hose Replacement (See: Hydraulic System/Brake Hose/Line/Service and

Repair/Front Brake Hose Replacement)
* Rear Brake Hose Replacement (Caliper) (See: Hydraulic System/Brake Hose/Line/Service and
Repair/Rear Brake Hose Replacement (Caliper))Rear Brake Hose Replacement (Jounce) (See:
Hydraulic System/Brake Hose/Line/Service and Repair/Rear Brake Hose Replacement (Jounce))
* Front Brake Caliper Replacement (See: Disc Brake System/Brake Caliper/Service and
* Rear Brake Caliper Replacement (See: Disc Brake System/Brake Caliper/Service and
Repair/Removal and Replacement/Rear Brake Caliper Replacement)
replace if necessary. Refer to Master Cylinder Reservoir Replacement (See: Hydraulic
System/Brake Master Cylinder/Service and Repair/Removal and Replacement/Master Cylinder
Reservoir Replacement) . Replace the brake master cylinder reservoir cap.
* Front Brake Hose Replacement (See: Hydraulic System/Brake Hose/Line/Service and

Repair/Front Brake Hose Replacement)
* Rear Brake Hose Replacement (Caliper) (See: Hydraulic System/Brake Hose/Line/Service and
Repair/Rear Brake Hose Replacement (Caliper))Rear Brake Hose Replacement (Jounce) (See:
Hydraulic System/Brake Hose/Line/Service and Repair/Rear Brake Hose Replacement (Jounce))
* Front Brake Caliper Overhaul (See: Disc Brake System/Brake Caliper/Service and
Repair/Overhaul/Front Brake Caliper Overhaul) or Front Brake Caliper Replacement (See: Disc
Brake System/Brake Caliper/Service and Repair/Removal and Replacement/Front Brake Caliper
Replacement)
* Rear Brake Caliper Overhaul (See: Disc Brake System/Brake Caliper/Service and
Repair/Overhaul/Rear Brake Caliper Overhaul) or Rear Brake Caliper Replacement (See: Disc
Brake System/Brake Caliper/Service and Repair/Removal and Replacement/Rear Brake Caliper
Replacement)
* HBCi components
System Bleeding (Manual))Hydraulic Brake System Bleeding (Pressure) (See: Hydraulic Brake
System Bleeding (Pressure)) .
Hummer Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Service and
Repair
Brake Pedal Assy: Service and Repair
Brake Pedal Assembly Replacement

Removal Procedure
1. Without disconnecting the electrical connector, remove the stop lamp switch. Refer to Stop Lamp
Switch Replacement (See: Lighting and
Horns/Brake Light Switch/Service and Repair) .
2. Remove the nut from the brake pedal bolt. 3. Remove the brake pedal bolt. 4. Remove the brake
pedal.
1. Install the brake pedal. 2. Install the brake pedal bolt.

Notice) .
3. Install the nut to the brake pedal bolt.
Hold the nut stationary and tighten the brake pedal bolt to 47 N.m (35 lb ft).
4. Install the stop lamp switch. Refer to Stop Lamp Switch Replacement (See: Lighting and
Horns/Brake Light Switch/Service and Repair) .
Hummer Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information
> Service Precautions > Brake Caliper Notice
Brake Caliper: Service Precautions Brake Caliper Notice
Brake Caliper Notice
Notice: Support the caliper with a piece of wire to prevent damage to the brake line.
> Service Precautions > Brake Caliper Notice > Page 6296
Brake Caliper: Service Precautions Brake Caliper Supporting to Prevent Hose Damage Notice
Brake Caliper Supporting to Prevent Hose Damage Notice
Notice: 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.
> Service Precautions > Page 6297
Brake Caliper: Testing and Inspection
Brake Caliper Inspection Caution: Refer to Brake Dust Caution (See: Service
1. Inspect the brake caliper housing for cracks, excess wear, and/or damage. If any of these
conditions are present, the brake caliper requires
replacement.
2. Inspect the caliper piston dust boot seals 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. Inspect for brake fluid leakage around the caliper piston dust boot seals and on the disc brake
pads. If there is any evidence of brake fluid leakage,
the brake caliper requires overhaul or replacement.
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. If the
caliper piston is frozen or difficult to bottom, the caliper requires overhaul or replacement. Insert a
discarded inner brake pad (2) or block of wood in front of the pistons. Using 2 large C-clamps (1)
installed over the body of the caliper (3) and against the brake pad or block of wood, slowly bottom
the pistons evenly into the bores.
> Service and Repair > Removal and Replacement
Brake Caliper: Removal and Replacement
Front Brake Caliper Replacement

Front Brake Caliper Replacement Caution: Refer to Brake Dust Caution (See: Service
Precautions/Technician Safety Information/Brake Dust Caution) . Caution: Refer to Brake Fluid
Irritant Caution (See: Service Precautions/Technician Safety Information/Brake Fluid Irritant
Caution) .
Removal Procedure
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 fluid needs to be
removed from the
reservoir before proceeding.
3. If the brake fluid level is higher than midway between the maximum-full point and the minimum
allowable level, remove brake fluid to the
midway point before proceeding.
Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See:
6. Compress the brake caliper pistons.
* Install a large C-clamp over the top of the caliper housing and against the back of the outboard
pad.
* Slowly tighten the C-clamp until the pistons are pushed completely into the caliper bores.
* Remove the C-clamp from the caliper.
7. Clean all dirt and foreign material from the brake hose end.
Important: Install a rubber cap or plug to the exposed brake pipe fitting end to prevent brake fluid
loss and contamination.
8. Remove the brake hose to caliper bolt from the brake caliper. 9. Remove and discard the 2
copper brake hose gaskets. These gaskets may be stuck to the brake caliper housing or the brake
hose end.
10. Remove the brake hose from the caliper.

> Service and Repair > Removal and Replacement > Page 6300
11. Remove the 2 brake caliper mounting bolts.
Caution: Do not depress the brake pedal with the brake rotors/calipers and/or the brake drums
removed. Damage to the brake system may result. If brake system damage occurs and is not
repaired, vehicle damage and/or personal injury or death may result.
12. Remove the brake caliper from the brake caliper mounting bracket.
1. Install the brake caliper to the brake caliper mounting bracket. 2. Perform the following
procedure before installing the caliper guide pin bolts.
1. Remove all traces of the original adhesive patch. 2. Clean the threads of the bolt with brake
parts cleaner or the equivalent and allow to dry. 3. Apply Threadlocker GM P/N 12345493
(Canadian P/N 10953488) to the threads of the bolt.
3. Install the brake caliper guide pin bolts.
Tighten the brake caliper guide pin bolts to 108 N.m (80 lb ft).
4. Remove the rubber cap or plug from the exposed brake hose fitting end.
Important: Install 2 new copper brake hose gaskets.
5. Assemble the 2 new copper brake hose gaskets and the brake hose to caliper bolt to the brake
hose.
6. Install the brake hose to caliper bolt to the brake caliper.
Tighten the brake hose to caliper bolt to 40 N.m (30 lb ft).

Maintenance/Wheels and Tires/Service and Repair) . 9. Lower the vehicle.
10. Fill the master cylinder reservoir to the proper level with clean brake fluid. Refer to Master
Cylinder Reservoir Filling (See: Hydraulic
System/Brake Master Cylinder/Service and Repair/Procedures) .
Rear Brake Caliper Replacement
Rear Brake Caliper Replacement Caution: Refer to Brake Dust Caution (See: Service
Caution) .
Removal Procedure
between the maximum-full point and the minimum allowable level then no brake fluid needs to be
removed from
the reservoir before proceeding.
allowable level then remove brake fluid to the
pad.

hose end.
10. Remove the caliper guide pin bolts. 11. Remove the brake caliper from the vehicle. 12. Inspect
the caliper assembly. Refer to Brake Caliper Inspection (See: Testing and Inspection) .
Important: Use denatured alcohol to clean the outside surface of caliper boots before installing new
brake pads.
1. If you are installing new brake pads use a C-clamp in order to compress the pistons to the
bottom of the caliper bores. Use the old brake pad, a
metal plate or a wooden block across the face of the pistons in order to protect the pistons and the
caliper boots.
Important: Use a small flat-bladed tool and lift the inner edge of the caliper boots next to both
pistons to release any trapped air.
2. Ensure that the caliper boots are below the level of the face of both pistons. 3. Install the brake
caliper to the brake caliper mounting bracket. 4. Perform the following procedure before installing
the caliper guide pin bolts.
5. Install the brake caliper mounting bolts.
6. Tighten the brake caliper guide pin bolts.
hose.
9. Connect the brake hose at the caliper by installing the brake hose to caliper bolt.

Maintenance/Wheels and Tires/Service and Repair) . 12. Lower the vehicle. 13. Fill the master
cylinder reservoir to the proper level with clean brake fluid. Refer to Master Cylinder Reservoir
Filling (See: Hydraulic
Front Brake Caliper Bracket Replacement
Front Brake Caliper Bracket Replacement Caution: Refer to Brake Dust Caution (See: Service
Removal Procedure
1. Remove the caliper from the mounting bracket and support the caliper with heavy mechanic's
wire or equivalent. DO NOT disconnect the
hydraulic brake flexible hose from the caliper. Refer to Front Brake Caliper Replacement (See:
Front Brake Caliper Replacement) .
2. Remove the brake pads. 3. Remove the anti-rattle clips from the brake caliper bracket.
4. Remove the brake caliper bracket mounting bolts (2). 5. Remove the brake caliper bracket (1). 6.
Remove any contaminants or foreign material from the inside ends of the brake caliper bracket. 7.
Clean the mounting surface and threads of the brake caliper bracket.
1. Install the brake caliper bracket (1). 2. Perform the following procedure before installing the
brake caliper bracket mounting bolts.
* Apply Threadlocker GM P/N 12345493 (Canadian P/N 10953488).
3. Install the caliper bracket mounting bolts (2).
Tighten the brake caliper bracket mounting bolts to 300 N.m (221 lb ft).
4. Install the anti-rattle clips to the brake caliper bracket. 5. Install the brake pads to the brake
caliper bracket. 6. Slide the brake pads in until they contact the rotor. 7. Install the brake caliper.
Refer to Front Brake Caliper Replacement (See: Front Brake Caliper Replacement) . 8. Install the
10. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of its travel
distance.
11. Slowly release the brake pedal. 12. Wait 15 seconds, then repeat steps 10-11 until a firm pedal
is obtained. This will properly seat the brake caliper pistons and brake pads.
Rear Brake Caliper Bracket Replacement
Rear Brake Caliper Bracket Replacement Caution: Refer to Brake Dust Caution (See: Service
Removal Procedure
Tighten the caliper bracket mounting bolts to 165 N.m (122 lb ft).
distance. 11. Slowly release the brake pedal. 12. Wait 15 seconds, then repeat steps 10-11 until a
firm pedal is obtained. This will properly seat the brake caliper pistons and brake pads.
Brake Caliper: Overhaul
Front Brake Caliper Overhaul
Tools Required
J 45515 Brake Caliper Piston Boot Seal Installer
Caution: Refer to Brake Dust Caution (See: Service Precautions/Technician Safety

Information/Brake Dust Caution) . Caution: Refer to Brake Fluid Irritant Caution (See: Service
Notice) .
1. Replace all the components included in the repair kits used to service this brake caliper. 2.
Lubricate the rubber parts with new Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N
992667) or equivalent DOT-3 brake fluid to make
assembly easier.
3. If any hydraulic component is removed or disconnected, it may be necessary to bleed all or part
of the brake system. 4. The torque values specified are for dry, non-lubricated fasteners. 5.
Perform the service operations on a clean bench, free from all mineral oil materials.
6. Remove the brake caliper from vehicle. Refer to Front Brake Caliper Replacement (See:
Removal and Replacement/Front Brake Caliper
Replacement) .
7. Drain the brake fluid from the brake caliper.
Caution: Do not place your fingers in front of the piston in order to catch or protect the piston while
applying compressed air. This could result in serious injury.
Notice: Use clean cloths to pad interior of caliper housing during piston removal. Use just enough
air to ease the pistons out of the bores. If the pistons are blown out, even with the padding
provided, it may be damaged.
8. Place a 25 mm (1 in) block of wood between the caliper and the piston. 9. Install a large C-clamp
over the body of the brake caliper with the C-clamp ends against the rear of the caliper body and
against the block of wood.
10. Carefully remove the brake caliper piston by directing low pressure compressed air into the
brake caliper inlet hole. 11. Remove the C-clamp form the caliper. 12. Remove the block of wood
from the caliper. 13. Install clean cloths to pad the interior of the caliper housing between the
remaining caliper piston and the caliper body. 14. To cover the open caliper bore place a 25 mm (1
in) block of wood between the caliper body and the brake caliper dust boot seal. 15. Install a large
C-clamp over the body of the brake caliper with the C-clamp ends against the rear of the caliper
body and against the block of wood. 16. Carefully remove the brake caliper piston by directing low
pressure compressed air into the brake caliper inlet hole. 17. Remove the C-clamp form the caliper.
18. Remove the block of wood from the caliper.
Important: Care must be used when removing the piston boot and seal from the caliper. Use a
small plastic or wood tool for removal. Do not use a metal tool because it may damage the caliper
bore or seal groove.
19. Remove the piston boots from the brake caliper. 20. Remove the piston seals from the brake
caliper. 21. Remove the brake caliper bleeder valve and cap from the brake caliper.
Important: Do not use abrasives to clean the brake caliper piston.
22. Clean the brake caliper piston bore and seal counterbore, and the caliper piston with denatured
alcohol, or equivalent. 23. Dry the caliper piston bores and counterbores, and the piston with
non-lubricated, filtered air. 24. Inspect all of the brake caliper parts as follows.
* Piston-Inspect for scoring, nicks, cracks, wear, or corrosion. Replace the pistons if any damage is
found.
* Caliper Bore-Inspect for scoring, nicks, cracks, wear, or corrosion. Use crocus cloth to polish out
light corrosion. Otherwise, replace the caliper. Do not hone the caliper bore.
* Seal groove in the caliper bore for nicks or burrs. If found, replace the caliper.
25. Install the brake caliper bleeder valve and bleeder valve cap into the brake caliper. 26.
Lubricate the new piston seal with Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N
10953488) or equivalent DOT-3 brake fluid from a
clean, sealed brake fluid container.
27. Install the lubricated, new piston seals into the caliper bores. 28. Install the caliper piston into
the caliper bore. 29. Install the new piston dust boot seal over the piston. 30. Using the J 45515 ,
fully seat the piston dust boot seal in the caliper. 31. Install the brake caliper to the vehicle. Refer to
Front Brake Caliper Replacement (See: Removal and Replacement/Front Brake Caliper
Replacement) .
Rear Brake Caliper Overhaul
Rear Brake Caliper Overhaul Caution: Refer to Brake Dust Caution (See: Service
Caution) .
1. Remove the brake caliper from the vehicle. Refer to Rear Brake Caliper Replacement (See:
Removal and Replacement/Rear Brake Caliper
Replacement) .
2. Place a thin piece of wood in front of the piston in order to prevent damage. Remove the piston
by directing compressed air into the brake hose
inlet fitting port of the brake caliper housing.
3. Remove the piston boot. 4. Remove the piston seal. 5. Remove the brake caliper bleed screw
cap. 6. Remove the brake caliper bleed screw. 7. Inspect the brake caliper bore and the piston seal
groove for scoring and corrosion. If you find excessive scoring or corrosion around the piston
seal area, replace the brake caliper housing.
8. Inspect the brake caliper mounting bracket guide surfaces for corrosion and wear. Remove and
replace the brake caliper mounting bracket if
needed.
9. Clean all the residue from the brake pad guiding surfaces on the brake caliper housing and the
brake caliper mounting bracket.
10. Clean all the parts not included in the repair kit with denatured alcohol. 11. Dry all the parts with
filtered unlubricated compressed air. 12. Blow out all passages in the brake caliper housing and the
brake caliper bleeder valve.
Assembly Procedure
1. Install the brake caliper bleed screw.
Tighten the brake caliper bleed screw to 12 N.m (106 lb in).
2. Install the brake caliper bleed screw cap. 3. Lubricate the new piston seal and the brake caliper
bore seal groove with brake fluid, GM P/N 12388967 (Canadian P/N 992667). 4. Install new the
seal into the brake caliper bore seal groove. 5. Ensure that the seal is not twisted. 6. Lubricate the
brake caliper bore and the piston with brake fluid, GM P/N 12388967 (Canadian P/N 992667). 7.
Install the boot and the piston.
1. Install the boot over the end of the piston so that the fold will face toward the brake caliper
housing piston bore opening. 2. Seat the boot into the brake caliper bore groove. Slide the piston
into the brake caliper bore. 3. Push down the piston to the bottom of the brake caliper bore. 4.
Ensure that the boot properly seats into the piston groove and into the groove in the brake caliper
bore. 5. Repeat steps 5 and 6 for the remaining piston.
8. Install the brake caliper to the vehicle. Refer to Rear Brake Caliper Replacement (See: Removal
and Replacement/Rear Brake Caliper
Replacement) .
Hummer Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Technical Service Bulletins > Customer Interest for Brake Pad: > 08-05-23-004 > May > 08 > Brakes - Front Brake Squeal
Upon Application
Brake Pad: Customer Interest Brakes - Front Brake Squeal Upon Application
TECHNICAL
Bulletin No.: 08-05-23-004
Date: May 05, 2008
Subject: Front Brake Squeal/Squeak Noise (Replace Front Brake Pads)
Condition
Some customers may comment on a squeal or squeak noise from the front brakes on brake apply.
Correction
New front brake pads have been released to correct this condition. Replace the front brake pads
with P/N 25924485. Refer to Front Disc Brake Pads Replacement procedure in SI.
Parts Information
Disclaimer
Technical Service Bulletins > All Technical Service Bulletins for Brake Pad: > 08-05-23-004 > May > 08 > Brakes - Front
Brake Squeal Upon Application
Brake Pad: All Technical Service Bulletins Brakes - Front Brake Squeal Upon Application
TECHNICAL
Bulletin No.: 08-05-23-004
Date: May 05, 2008
Subject: Front Brake Squeal/Squeak Noise (Replace Front Brake Pads)
Condition
Some customers may comment on a squeal or squeak noise from the front brakes on brake apply.
Correction
New front brake pads have been released to correct this condition. Replace the front brake pads
with P/N 25924485. Refer to Front Disc Brake Pads Replacement procedure in SI.
Parts Information
Disclaimer
Brake Pad: Specifications
BRAKE PAD
Minimum Thickness .............................................................................................................................

............................................... 0.76 mm (0.030 in) Maximum Taper With Pad Friction Surfaces
Together ....................................................................................................................... 0.13 mm
(0.005 in)
Brake Pad: Testing and Inspection
Brake Pad Inspection Caution: Refer to Brake Dust Caution (See: Service Precautions/Technician
Safety Information/Brake Dust Caution) .
* Inspect the disc brake pads at regular intervals, or whenever the tire and wheel assemblies are
removed from the vehicle.
* If replacement is necessary, always replace disc brake pads in axle sets.
* Inspect both edges of the disc brake pad friction surfaces (3). The highest rate of wear normally
occurs at the trailing edge of the disc brake 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.
* Both front and rear disc brake pads have integral, audible wear sensors (1). When the disc brake
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 disc brake pads when the friction surface (3) is worn to within 0.76 mm (0.030 in) of
the mounting plates.
* Remove the brake calipers and inspect the friction surfaces of the inner and outer disc brake
pads to ensure that they are level. Place the disc brake pad friction surfaces together and measure
the gap between the surfaces. If more than 0.13 mm (0.005 in) gap exists midway between the
length of the disc brake pads, replace the disc brake pads.
* Verify that any disc brake pad shims that may be required are in place and not damaged or
excessively corroded. Replace any missing or damaged shims in order to preserve proper disc
brake performance.
* Replace the disc brake pads if any have separated from the mounting plates.
* Inspect the disc brake pads friction surfaces for cracks, fractures, or damage which may cause
noise or otherwise impair disc brake performance.
Service and Repair > Front Disc Brake Pads Replacement
Brake Pad: Service and Repair Front Disc Brake Pads Replacement
Front Disc Brake Pads Replacement Caution: Refer to Brake Dust Caution (See: Service
Removal Procedure
removed from the
6. Inspect the caliper operation. Refer to Brake Caliper Inspection (See: Brake Caliper/Testing and
Inspection) .
7. Remove the caliper mounting bolts and remove the caliper from the mounting bracket. Support
the caliper with heavy mechanic's wire or
equivalent. DO NOT disconnect the hydraulic brake flexible hose from the caliper.
8. Remove the brake pads from the caliper mounting bracket.

Service and Repair > Front Disc Brake Pads Replacement > Page 6329
9. Remove and discard the anti-rattle clips from the brake caliper mounting bracket.
10. Inspect the caliper and mounting bracket. Refer to Brake Caliper Inspection (See: Brake
Caliper/Testing and Inspection) .
1. Install new anti-rattle clips to the inside ends of the caliper mounting bracket. 2. Install the brake
pads to the caliper mounting bracket.
3. Install the brake caliper to the brake caliper bracket. 4. Perform the following procedure before
installing the caliper guide pin bolts.
Maintenance/Wheels and Tires/Service and Repair) . 7. Remove the safety stands. 8. Lower the
vehicle. 9. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of its travel
distance.
is obtained. This will properly seat the brake caliper pistons and brake pads. 12. Fill the master
Filling (See: Hydraulic
13. Burnish the brake pads and rotors. Refer to Brake Pad and Rotor Burnishing (See: Brake Pad
and Rotor Burnishing) .
Brake Pad: Service and Repair Rear Disc Brake Pads Replacement
Rear Disc Brake Pads Replacement Caution: Refer to Brake Dust Caution (See: Service
Removal Procedure
removed from the
Maintenance) . 5. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and
Installation (See: Maintenance/Wheels and Tires/Service and Repair)
6. Inspect the caliper operation. Refer to Brake Caliper Inspection (See: Brake Caliper/Testing and
Inspection) . 7. Place a C-clamp as shown. Slowly bottom the pistons of the caliper. It may be
necessary to reposition the C-clamp to allow both of the pistons to
bottom into the caliper bores.
hydraulic brake flexible hose from the caliper.
9. Inspect the caliper assembly. Refer to Brake Caliper Inspection (See: Brake Caliper/Testing and
Inspection) .
10. Remove the brake pads from the brake caliper bracket. 11. Remove and discard the anti-rattle
clips from the brake caliper mounting bracket.
caliper bracket.
3. Install the brake caliper to the mounting bracket. 4. Perform the following procedure before
installing the caliper guide pin bolts.
Maintenance/Wheels and Tires/Service and Repair) . 7. Lower the vehicle. 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 pedal is obtained. This will properly seat the
brake caliper pistons and brake pads. 11. Fill the master cylinder reservoir to the proper level with
clean brake fluid. Refer to Master Cylinder Reservoir Filling (See: Hydraulic
12. Burnish the brakes pads and rotors as necessary. Refer to Brake Pad and Rotor Burnishing
(See: Brake Pad and Rotor Burnishing) .
Brake Pad: Service and Repair Brake Pad and Rotor Burnishing
Brake Pad and Rotor Burnishing
Caution: Road test a vehicle under safe conditions and while obeying all traffic laws. Do not
attempt any maneuvers that could jeopardize vehicle control. Failure to adhere to these
precautions could lead to serious personal injury and vehicle damage.

Information/Brake Dust Caution) .
Burnishing the brake pads and brake rotors is necessary in order to ensure that the braking
surfaces are properly prepared after service has been performed on the disc brake system.
This procedure should be performed whenever the disc brake rotors have been refinished or
replaced, and/or whenever the disc brake pads have been replaced.
1. Select a smooth road with little or no traffic. 2. Accelerate the vehicle to 48 km/h (30 mph).
Important: Use care to avoid overheating the brakes while performing this step.
3. Using moderate to firm pressure, apply the brakes to bring the vehicle to a stop. Do not allow the
brakes to lock. 4. Repeat steps 2 and 3 until approximately 20 stops have been completed. Allow
sufficient cooling periods between stops in order to properly
burnish the brake pads and rotors.

Hummer Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component
Brake Rotor/Disc: Specifications
Disc Brake Component Specifications

Information > Testing and Inspection > Brake Rotor Assembled Lateral Runout Correction
Brake Rotor/Disc: Testing and Inspection Brake Rotor Assembled Lateral Runout Correction
Brake Rotor Assembled Lateral Runout Correction
Important:
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 (See: Brake Rotor Thickness Variation
Measurement) .
* Brake rotor assembled lateral runout (LRO) exceeding the maximum allowable specification can
cause thickness variation to develop in the brake rotor over time, usually between 4 800-11 300 km
(3,000-7,000 mi). Refer to Brake Rotor Assembled Lateral Runout Measurement (See: Brake Rotor
Assembled Lateral Runout Measurement) .
Review the following acceptable methods for bringing the brake rotor assembled LRO to within
specifications. Determine which method to use for the specific vehicle being repaired.
* Brake Rotor Assembled Lateral Runout Correction - Indexing (See: Brake Rotor Assembled
Lateral Runout Correction - Indexing) The indexing method of correcting assembled LRO is most
effective when the LRO specification is only exceeded by a relatively small amount: 0.025-0.127
mm (0.001-0.005 in). Indexing is used to achieve the best possible match of high spots to low spots
between related components.
* Brake Rotor Assembled Lateral Runout Correction - On Vehicle Lathe (See: Brake Rotor
Assembled Lateral Runout Correction - On Vehicle Lathe) The on-vehicle brake lathe method is
used to bring the LRO to within specifications through compensating for LRO while refinishing the
brake rotor.
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.
Information > Testing and Inspection > Brake Rotor Assembled Lateral Runout Correction > Page 6339
Brake Rotor/Disc: Testing and Inspection Brake Rotor Assembled Lateral Runout Correction -
Indexing
Brake Rotor Assembled Lateral Runout Correction - Indexing
Tools Required
* J 39544-KIT Torque-Limiting Socket Set, or equivalent
* J 45101-100 Conical Brake Rotor Washers

Important:
* Brake rotor thickness variation MUST be checked BEFORE checking for assembled lateral runout
Measurement) .
Brake rotor assembled LRO exceeding the maximum allowable specification can cause thickness
variation to develop in the brake rotor over time, usually between 4 800-11 300 km (3,000-7,000
mi). Refer to Brake Rotor Assembled Lateral Runout Measurement (See: Brake Rotor Assembled
Lateral Runout Measurement) .
1. Remove the J 45101-100 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 rotor firmly in place against the hub/axle
flange and install one of the J 45101-100 (1) and one lug nut (2) onto the upper-most wheel
stud.
5. Continue to hold the rotor secure and tighten the lug nut firmly by hand.
6. Install the remaining J 45101-100 and lug nuts onto the wheel studs and tighten the nuts firmly
by hand in a star-pattern.
7. Using the J 39544-KIT , or equivalent, tighten the lug nuts in a star-pattern to specification, in
order to properly secure the rotor. Refer to Tire and
8. Measure the assembled LRO of the brake rotor. Refer to Brake Rotor Assembled Lateral Runout
Measurement (See: Brake Rotor Assembled
9. Compare the amount of change between this measurement and the original measurement.
10. If this measurement is within specifications, proceed to step 14. 11. If this measurement still
exceeds specifications, repeat steps 1-9 until the best assembled LRO measurement is obtained.
12. Matchmark the final location of the rotor to the wheel studs if the orientation is different than it
was originally. 13. If the brake rotor assembled LRO measurement still exceeds the maximum
allowable specification, refer to Brake Rotor Assembled Lateral
Runout Correction (See: Brake Rotor Assembled Lateral Runout Correction) .
14. If the brake rotor assembled LRO is within specification, install the brake caliper and depress
the brake pedal several times to secure the rotor in
place before removing the J 45101-100 and the lug nuts.

Brake Rotor/Disc: Testing and Inspection Brake Rotor Assembled Lateral Runout Correction - On
Vehicle Lathe
Brake Rotor Assembled Lateral Runout Correction - On Vehicle Lathe
Tools Required
J 45101-100 Conical Brake Rotor Washers Caution: Refer to Brake Dust Caution (See: Service
Important:
Measurement) .
* Brake rotor assembled LRO exceeding the maximum allowable specification can cause thickness
1. Ensure that the caliper and caliper bracket that are already being supported, are clear from
contacting any rotating components, such as the brake
rotor.
measurement procedure and/or the indexing correction
procedure.
3. Inspect the mounting surface of the hub/axle flange and the brake rotor to ensure that there are
no foreign particles or debris remaining. 4. Set up the lathe, following the manufacturer's
instructions. 5. Refinish the brake rotor, following the brake lathe manufacturer's instructions. 6.
After each successive cut, inspect the brake rotor thickness. Refer to Brake Rotor Thickness
Measurement (See: Brake Rotor Thickness
Measurement) .
7. If at any time the brake rotor exceeds the minimum allowable thickness after refinish
specification, the brake rotor must be replaced. After
replacing the rotor, proceed to step 10.
8. After refinishing the brake rotor, use the following procedure in order to obtain the desired
non-directional finish:
1. Follow the brake lathe manufacturer's recommended speed setting for applying a non-directional
finish. 2. Using moderate pressure, apply the non-directional finish:
* If the lathe is equipped with a non-directional finishing tool, apply the finish with 120-grit aluminum
oxide sandpaper.
* If the lathe is not equipped with a non-directional finishing tool, apply the finish with a sanding
block and 150-grit aluminum oxide sandpaper.
3. After applying a non-directional finish, clean each friction surface of the brake rotor with
denatured alcohol, or an equivalent approved brake
cleaner.
9. Remove the lathe from the vehicle.
10. Measure the assembled LRO of the brake rotor. Refer to Brake Rotor Assembled Lateral
Runout Measurement (See: Brake Rotor Assembled
11. If the brake rotor assembled LRO measurement still exceeds the maximum allowable
specification, refer to Brake Rotor Assembled Lateral

Brake Rotor/Disc: Testing and Inspection Brake Rotor Thickness Measurement
Brake Rotor Thickness Measurement Caution: Refer to Brake Dust Caution (See: Service
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 (See: Brake Pad/Service and Repair/Front Disc Brake Pads Replacement)
and/or Rear Disc Brake Pads Replacement (See: Brake Pad/Service and Repair/Rear Disc Brake
Pads Replacement) .
2. Clean the friction surfaces of the brake rotor with denatured alcohol, or an equivalent approved
brake cleaner.
3. Using a micrometer 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 rotor. Ensure that the measurements are only taken
within the friction surfaces and that the micrometer is positioned the same distance from the outer
edge of the rotor, about 13 mm (1/2 in), for each measurement.
4. Compare the lowest thickness measurement recorded to the following specifications:
- Brake rotor minimum allowable thickness after refinishing 28.0 mm (1.102 in)
- Brake rotor discard thickness 27.50 mm (1.083 in)
5. If the lowest thickness measurement of the brake rotor is above the minimum allowable
thickness after refinishing specification, the rotor may be
able to be refinished, depending upon surface and wear conditions which may be present.
6. If the lowest thickness measurement of the brake rotor is at or below the minimum allowable
thickness after refinishing specification, the rotor may
not be refinished.
7. If the lowest thickness measurement of the brake rotor is at or below the discard thickness
specification, the rotor requires replacement.
Brake Rotor/Disc: Testing and Inspection
Important:
Measurement) .
(3,000-7,000 mi). Refer to Brake Rotor Assembled Lateral Runout Measurement (See: Brake Rotor
Assembled Lateral Runout Measurement) .
Review the following acceptable methods for bringing the brake rotor assembled LRO to within
specifications. Determine which method to use for the specific vehicle being repaired.
* Brake Rotor Assembled Lateral Runout Correction - Indexing (See: Brake Rotor Assembled
Lateral Runout Correction - Indexing) The indexing method of correcting assembled LRO is most
effective when the LRO specification is only exceeded by a relatively small amount: 0.025-0.127
mm (0.001-0.005 in). Indexing is used to achieve the best possible match of high spots to low spots
between related components.
* Brake Rotor Assembled Lateral Runout Correction - On Vehicle Lathe (See: Brake Rotor
Assembled Lateral Runout Correction - On Vehicle Lathe) The on-vehicle brake lathe method is
used to bring the LRO to within specifications through compensating for LRO while refinishing the
brake rotor.
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.
Tools Required

Important:
Measurement) .
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 rotor firmly in place against the hub/axle
flange and install one of the J 45101-100 (1) and one lug nut (2) onto the upper-most wheel
stud.
by hand in a star-pattern. 7. Using the J 39544-KIT , or equivalent, tighten the lug nuts in a
star-pattern to specification, in order to properly secure the rotor. Refer to Tire and
8. Measure the assembled LRO of the brake rotor. Refer to Brake Rotor Assembled Lateral Runout
Measurement (See: Brake Rotor Assembled
9. Compare the amount of change between this measurement and the original measurement.
10. If this measurement is within specifications, proceed to step 14. 11. If this measurement still
exceeds specifications, repeat steps 1-9 until the best assembled LRO measurement is obtained.
12. Matchmark the final location of the rotor to the wheel studs if the orientation is different than it
was originally. 13. If the brake rotor assembled LRO measurement still exceeds the maximum
allowable specification, refer to Brake Rotor Assembled Lateral
Tools Required
J 45101-100 Conical Brake Rotor Washers


Important:
Measurement) .
1. Ensure that the caliper and caliper bracket that are already being supported, are clear from
contacting any rotating components, such as the brake
rotor.
measurement procedure and/or the indexing correction
procedure.
3. Inspect the mounting surface of the hub/axle flange and the brake rotor to ensure that there are
no foreign particles or debris remaining. 4. Set up the lathe, following the manufacturer's
instructions. 5. Refinish the brake rotor, following the brake lathe manufacturer's instructions. 6.
After each successive cut, inspect the brake rotor thickness. Refer to Brake Rotor Thickness
Measurement (See: Brake Rotor Thickness
Measurement) .
specification, the brake rotor must be replaced. After
replacing the rotor, proceed to step 10.

oxide sandpaper.
cleaner.
9. Remove the lathe from the vehicle.
10. Measure the assembled LRO of the brake rotor. Refer to Brake Rotor Assembled Lateral
Runout Measurement (See: Brake Rotor Assembled
11. If the brake rotor assembled LRO measurement still exceeds the maximum allowable
specification, refer to Brake Rotor Assembled Lateral
Brake Rotor Thickness Measurement
Brake Rotor Thickness Measurement Caution: Refer to Brake Dust Caution (See: Service
Pads Replacement) .
brake cleaner.

4. Compare the lowest thickness measurement recorded to the following specifications:
5. If the lowest thickness measurement of the brake rotor is above the minimum allowable
thickness after refinishing specification, the rotor may be
able to be refinished, depending upon surface and wear conditions which may be present.
6. If the lowest thickness measurement of the brake rotor is at or below the minimum allowable
thickness after refinishing specification, the rotor may
not be refinished.
7. If the lowest thickness measurement of the brake rotor is at or below the discard thickness
specification, the rotor requires replacement.
Brake Rotor Thickness Variation Measurement
Brake Rotor Thickness Variation Measurement Caution: Refer to Brake Dust Caution (See: Service
Important: 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.
Pads Replacement) .
brake cleaner.

4. Calculate the difference between the highest and lowest thickness measurements recorded to
obtain the amount of thickness variation. 5. Compare the thickness variation measurement to the
following specification:
Brake rotor maximum allowable thickness variation: 0.025 mm (0.001 in)
Important: Whenever a brake rotor is refinished or replaced, the assembled lateral runout (LRO) of
the rotor must be measured to ensure optimum performance of the disc brakes.
6. If the brake rotor thickness variation measurement exceeds the specification, the rotor requires
refinishing or replacement.
Brake Rotor Surface and Wear Inspection
Brake Rotor Surface and Wear Inspection Caution: Refer to Brake Dust Caution (See: Service
and/or Rear Disc Brake Pads Replacement (See:
Brake Pad/Service and Repair/Rear Disc Brake Pads Replacement) .
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 rotor.
* Cracks and/or heat spots
* Excessive blueing discoloration
4. If the friction surfaces of the brake rotor exhibit one or more of the Braking Surface Conditions,
the rotor requires refinishing or replacement.

measure and record the scoring depth of any grooves
present on the rotor friction surfaces.
6. Compare the groove scoring depth recorded to the following specification:
Brake rotor maximum allowable scoring: 1.50 mm (0.059 in)
7. If the brake rotor scoring depth exceeds the specification, or if an excessive amount of scoring is
present, the rotor requires refinishing or
replacement.
Brake Rotor Assembled Lateral Runout Measurement
Brake Rotor Assembled Lateral Runout Measurement
Tools Required

* J 41013 Rotor Resurfacing Kit
* J 42450-A Wheel Hub Resurfacing Kit
* J 45101 Hub and Wheel Runout Gage

Important:
(3,000-7,000 mi).
Measurement) .
1. Matchmark the position of the brake rotor to the wheel studs if this has not been done already.
Important: Whenever the brake rotor has been separated from the hub/axle flange, any rust or
contaminants should be cleaned from the hub/axle flange and the brake rotor mating surfaces.
Failure to do this may result in excessive assembled lateral runout (LRO) of the brake rotor, which
could lead to brake pulsation.
2. Inspect the mating surface of the hub/axle flange and the brake rotor to ensure that there are no
foreign particles, corrosion, rust, or debris
remaining. If the wheel hub/axle flange and/or if the brake rotor mating surfaces exhibit these
conditions, perform the following steps:
1. Remove the brake rotor from the vehicle. Refer to Front Brake Rotor Replacement (See: Service
Brake Rotor Replacement) and/or Rear Brake Rotor Replacement (See: Service and
Repair/Removal and Replacement/Rear Brake Rotor
Replacement) .
2. Using the J 42450-A , thoroughly clean any rust or corrosion from the mating surface of the
hub/axle flange. 3. Using the J 41013 , thoroughly clean any rust or corrosion from the mating
surface of the brake rotor. 4. Clean the friction surfaces of the brake rotor with denatured alcohol,
or an equivalent approved brake cleaner.
3. Install the rotor to the hub/axle flange using the matchmark made prior to removal.
4. Hold the rotor firmly in place against the hub/axle flange and install one of the J 45101-100 (1),
and one lug nut (2) onto the upper-most wheel
stud.
by hand in a star-pattern. 7. Using the J 39544-KIT , or equivalent, tighten the lug nuts in a
star-pattern to specification, in order to properly secure the rotor. Refer to Tire and
8. If the brake rotor has been REFINISHED or REPLACED with a new rotor, proceed to step 14. 9.
If the brake rotor meets the following criteria, proceed to step 10.
* The rotor is within specifications and is being REUSED
* The rotor has NOT been refinished
* The rotor does NOT exhibit thickness variation exceeding the maximum allowable level
10. Mount a dial indicator, J 45101 , or equivalent, to the steering knuckle and position the indicator
button so it contacts the brake rotor friction
surface at a 90 degree angle, approximately 13 mm (0.5 in) from the outer edge of the rotor.
11. Measure and record the assembled LRO of the brake rotor.
1. Rotate the rotor until the lowest reading is displayed on the indicator dial, then set the dial to
zero. 2. Rotate the rotor until the highest reading is displayed on the dial. 3. Mark the location of the
high spot relative to the nearest wheel stud, or studs. 4. Measure and record the amount of LRO.
12. Compare the brake rotor assembled LRO to the following specification:
* Front brake rotor maximum allowable assembled lateral runout: 0.13 mm (0.005 in)
* Rear brake rotor maximum allowable assembled lateral runout: 0.13 mm (0.005 in)
13. If the brake rotor assembled LRO is within specifications, proceed to step 18.
If the brake rotor assembled LRO exceeds the specification, refinish the rotor to ensure true
parallelism, refer to Brake Rotor Refinishing (See: Service and Repair/Procedures) . After
refinishing the rotor, proceed to step 14.
14. Mount a dial indicator, J 45101 , or equivalent, to the steering knuckle and position the indicator
button so it contacts the brake rotor friction
surface at a 90 degree angle, approximately 13 mm (0.5 in) from the outer edge of the rotor.
15. Measure and record the assembled LRO of the brake rotor.
1. Rotate the rotor until the lowest reading is displayed on the indicator dial, then set the dial to
zero. 2. Rotate the rotor until the highest reading is displayed on the dial. 3. Mark the location of the
high spot relative to the nearest wheel stud, or studs. 4. Measure and record the amount of LRO.
16. Compare the brake rotor assembled LRO to the following specification:
* Front brake rotor maximum allowable assembled lateral runout: 0.13 mm (0.005 in)
* Rear brake rotor maximum allowable assembled lateral runout: 0.13 mm (0.005 in)
17. If the brake rotor assembled LRO measurement exceeds the specification, bring the LRO to
within specifications. Refer to Brake Rotor Assembled
Lateral Runout Correction (See: Brake Rotor Assembled Lateral Runout Correction) .
18. If the brake rotor assembled LRO measurement is within specification, install the brake caliper
and depress the brake pedal several times to secure
the rotor in place before removing the J 45101-100 and the lug nuts.
Brake Rotor/Disc: Procedures
Brake Rotor Refinishing
Tools Required

Important:
* The disc brake rotors do not require refinishing as part of routine brake system service. New disc
brake rotors do not require refinishing.
Do not refinish disc brake rotors in an attempt to correct the following conditions:
- Brake system noise - squeal, growl, groan
- Uneven and/or premature disc brake pad wear
- Superficial or cosmetic corrosion/rust of the disc brake rotor friction surface
- Scoring of the disc brake rotor friction surface less than the maximum allowable specification
* Before refinishing a brake rotor, the rotor MUST first be checked for adequate thickness to allow
the rotor to be refinished and remain above the minimum allowable thickness after refinish
specification. Refer to Brake Rotor Thickness Measurement (See: Testing and Inspection/Brake
Rotor Thickness Measurement) .
Disc brake rotors should only be refinished if they have adequate thickness to be refinished and if
one or more of the following conditions exist:
- Thickness variation in excess of the maximum allowable specification
- Excessive corrosion/rust and/or pitting
- Cracks and/or heat spots
- Excessive blueing discoloration
- Scoring of the disc brake rotor surface in excess of the maximum allowable specification
* Disc brake rotors may need to be refinished as part of the process for correcting brake rotor
assembled lateral runout (LRO) that exceeds the maximum allowable specification.
Important: If the vehicle is equipped with cross-drilled rotors, use a lathe with positive rake tooling.
This setup requires less cutting pressure, which will result in less vibration, and a better surface
finish. Also, use a vibration dampener when cutting. Otherwise, refinish according to the following
instructions.
Important: 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 J 42450-A , thoroughly clean any rust or corrosion from the mating surface of the
hub/axle flange. 2. Using the J 41013 , 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 (See: Testing and Inspection/Brake
Rotor Thickness Measurement) .
specification, the brake rotor must be replaced.
oxide sandpaper.
cleaner.
13. Remove the brake rotor from the brake lathe. 14. Measure the assembled LRO of the brake
rotor to ensure optimum performance of the disc brakes. Refer to Brake Rotor Assembled Lateral
Runout Measurement (See: Testing and Inspection/Brake Rotor Assembled Lateral Runout
Measurement) .
Lateral Runout Correction (See: Testing and Inspection/Brake Rotor Assembled Lateral Runout
Correction) .
Brake Rotor/Disc: Removal and Replacement
Caution: Road test a vehicle under safe conditions and while obeying all traffic laws. Do not
attempt any maneuvers that could jeopardize vehicle control. Failure to adhere to these
precautions could lead to serious personal injury and vehicle damage.

Burnishing the brake pads and brake rotors is necessary in order to ensure that the braking
surfaces are properly prepared after service has been performed on the disc brake system.
This procedure should be performed whenever the disc brake rotors have been refinished or
replaced, and/or whenever the disc brake pads have been replaced.
1. Select a smooth road with little or no traffic. 2. Accelerate the vehicle to 48 km/h (30 mph).
Important: Use care to avoid overheating the brakes while performing this step.
3. Using moderate to firm pressure, apply the brakes to bring the vehicle to a stop. Do not allow the
brakes to lock. 4. Repeat steps 2 and 3 until approximately 20 stops have been completed. Allow
sufficient cooling periods between stops in order to properly
burnish the brake pads and rotors.
Front Brake Rotor Replacement
Front Brake Rotor Replacement Caution: Refer to Brake Dust Caution (See: Service
Tools Required
Removal Procedure
Notice: Any new rotor must have the protective coating removed from the friction surfaces before
being placed in service. Remove the protective coating using denatured alcohol or an equivalent
brake cleaner, and wipe the surface clean with clean cloths. Do not use gasoline, kerosene, or
other oil base solvents which may leave an oily residue. This residue is damaging to the brake
lining and is flammable.
Maintenance) . 2. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and
Installation (See: Maintenance/Wheels and Tires/Service and Repair)
3. Mark the relationship of the rotor to the hub. 4. Install a C-clamp over the body of the brake
caliper, with the C-clamp ends against the rear of the caliper body and the outboard disc brake
pad. 5. Slowly tighten the C-clamp until the pistons are pushed into the caliper bores enough to
remove the caliper from the pads. 6. Remove the C-clamp from the caliper.
7. Remove the 2 brake caliper bracket mounting bolts.
8. Remove the brake caliper and brake caliper mounting bracket as an assembly and support with
heavy mechanic's wire or equivalent. DO NOT
disconnect the hydraulic brake flexible hose from the caliper.
9. Remove the rotor retaining push nuts from the wheel studs, if applicable.
10. It may be necessary to strike the end of the hub or the rotor with a dead-blow hammer to
separate the rotor from the hub.
11. Remove the rotor. 12. If the rotor is difficult to remove due to corrosion in the hub area use the
following procedure to remove the rotor.
* Clean all the surface areas and the threaded holes of contamination.
* Generously apply penetrating oil or the equivalent to the hub/rotor area.
* Insert (2) M10 x 1.5 bolts into the threaded holes of the rotor.
* Tighten both bolts evenly to force the rotor from the hub.
1. Use the J 42450-A to clean all rust and contaminants from the mating surface of the hub flange.
2. Use the J 41013 to clean all rust and contaminants from the inside diameter of the hat section of
the brake rotor to prevent any foreign material
from getting between the brake rotor and the hub flange.
3. Inspect the mating surfaces of the hub/axle flange and the rotor to ensure that there are no
foreign particles or debris remaining.
Important: If the rotor was removed using the jack screw method you must ensure that the hub
flange is free of nicks or marks caused by this procedure. Remove all raised nicks or marks before
installing the rotor.
4. Align the rotor to its original position on the hub, if applicable, and install the rotor. 5. If the brake
rotor was removed and installed as part of a brake system repair, measure the assembled lateral
runout (LRO) of the brake rotor to
ensure optimum performance of the disc brakes. Refer to Brake Rotor Assembled Lateral Runout
Measurement (See: Testing and Inspection/Brake Rotor Assembled Lateral Runout Measurement)
.
Correction) .
7. Install the caliper and caliper mounting bracket assembly. 8. Perform the following procedure
before installing the brake caliper bracket mounting bolts.
* Clean the threads of the bolt with brake parts cleaner or the equivalent and allow to dry.
* Apply Threadlocker GM P/N 12345493 (Canadian P/N 10953488) to the threads of the bolt.
9. Install the 2 caliper bracket mounting bolts.
Maintenance/Wheels and Tires/Service and Repair) . 11. Lower the vehicle. 12. With the engine
OFF, gradually apply the brake pedal to approximately 2/3 of its travel distance. 13. Slowly release
the brake pedal.
14. Wait 15 seconds, then repeat steps 12-13 until a firm pedal is obtained. This will properly seat
the brake caliper pistons and brake pads. 15. Fill the master cylinder reservoir to the proper level
with clean brake fluid. Refer to Master Cylinder Reservoir Filling (See: Hydraulic
Rear Brake Rotor Replacement
Rear Brake Rotor Replacement Caution: Refer to Brake Dust Caution (See: Service
Removal Procedure
Tools Required
1. Release the park brake. 2. Raise and suitably support the vehicle. Refer to Lifting and Jacking
the Vehicle (See: Maintenance) . 3. Remove the tire and wheel assembly. Refer to Tire and Wheel
Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair)
4. Mark the relationship of the rotor to the axle flange. 5. Install a C-clamp over the body of the
brake caliper, with the C-clamp ends against the rear of the caliper body and the outboard disc
brake pad. 6. Slowly tighten the C-clamp until the pistons are pushed into the caliper bores enough
to remove the caliper from the pads. 7. Remove the C-clamp from the caliper.
8. Remove the brake caliper bracket mounting bolts.
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. Remove the brake caliper and brake caliper bracket as an assembly and support with heavy
mechanic's wire or equivalent. DO NOT disconnect the
hydraulic brake flexible hose from the caliper.
10. Remove the rotor retaining push nuts from the wheel studs, if applicable. 11. It may be
necessary to strike the end of the hub or the rotor with a dead-blow hammer to separate the rotor
from the hub.
12. Remove the rotor by slowly turning the rotor while pulling the rotor away from the axle.
1. Use the J 42450-A to clean all rust and contaminants from the mating surface of the hub flange.
2. Use the J 41013 to clean all rust and contaminants from the inside diameter of the hat section of
the brake rotor to prevent any foreign material
from getting between the brake rotor and the hub flange.
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. Align the rotor to its original position on the hub, if applicable, and install the rotor by slowly
turning the rotor while pushing the rotor towards the
axle.
5. If the brake rotor was removed and installed as part of a brake system repair, measure the
assembled lateral runout (LRO) of the brake rotor to
ensure optimum performance of the disc brakes. Refer to Brake Rotor Assembled Lateral Runout
Measurement (See: Testing and Inspection/Brake Rotor Assembled Lateral Runout Measurement)
.
Correction) .
7. Install the caliper and the bracket as an assembly to the vehicle. 8. Perform the following
procedure before installing the caliper bracket mounting bolts.
* Clean the threads of the bolt with brake parts cleaner or the equivalent and allow to dry.
* Apply Threadlocker GM P/N 12345493 (Canadian P/N 10953488) to the threads of the bolt.
9. Install the caliper bracket mounting bolts.
Maintenance/Wheels and Tires/Service and Repair) . 11. Lower the vehicle. 12. With the engine
OFF, gradually apply the brake pedal to approximately 2/3 of its travel distance. 13. Slowly release
the brake pedal. 14. Wait 15 seconds, then repeat steps 12-13 until a firm pedal is obtained. This
will properly seat the brake caliper pistons and brake pads. 15. Fill the master cylinder reservoir to
the proper level with clean brake fluid. Refer to Master Cylinder Reservoir Filling (See: Hydraulic

Hummer Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System
Information > Service and Repair > Antilock Brake System Automated Bleed Procedure
(See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Caution) .
Notice) .
base brake bleed.
before proceeding.
to proceed.
seconds.
power reserve.
Inspection (See: Testing and Inspection/Component Tests and General Diagnostics/Brake System
External Leak Inspection) .
Symptoms - Hydraulic Brakes (See: Testing and Inspection/Symptom Related Diagnostic

Procedures/Symptoms - Hydraulic Brakes) .
Information > Service and Repair > Antilock Brake System Automated Bleed Procedure > Page 6364
Notice) .
steps 2.5-2.8.
steps 2.5-2.8.
steps 2.5-2.8.
diaphragm.
12377967
tightened.
P/N 12377967 (Canadian P/N 992667), or
Reservoir Filling (See: Brake Master Cylinder/Service and Repair/Procedures) .
(See: Testing and Inspection/Component Tests
and General Diagnostics/Brake System External Leak Inspection) .
the system.
(See: Testing and Inspection/Symptom Related

Tools Required
Notice) .
steps 2.5-2.8.
steps 2.5-2.8.
steps 2.5-2.8.
P/N 12377967 (Canadian P/N 992667), or
equivalent
12377967
tightened.
the brake master cylinder reservoir. Refer to Master Cylinder Reservoir Filling (See: Brake Master
Cylinder/Service and Repair/Procedures) . 24. Slowly depress and release the brake pedal.
Observe the feel of the brake pedal. 25. If the brake pedal feels spongy perform the following
steps:
(See: Testing and Inspection/Component Tests
and General Diagnostics/Brake System External Leak Inspection) .
(See: Testing and Inspection/Symptom Related

Hydraulic Brake System Flushing Caution: Refer to Brake Fluid Irritant Caution (See: Service
Notice) .
contamination.
the following:
(See: Brake Master Cylinder/Service and Repair/Removal and Replacement/Brake Master Cylinder
with Power Brake Booster and Chassis Control Module Replacement)
* Front Brake Hose Replacement (See: Brake Hose/Line/Service and Repair/Front Brake Hose
Replacement)
* Rear Brake Hose Replacement (Caliper) (See: Brake Hose/Line/Service and Repair/Rear Brake
Hose Replacement (Caliper))Rear Brake Hose Replacement (Jounce) (See: Brake
* Front Brake Caliper Replacement (See: Brake Caliper/Service and Repair/Removal and
Replacement/Front Brake Caliper Replacement)
* Rear Brake Caliper Replacement (See: Brake Caliper/Service and Repair/Removal and
Replacement/Rear Brake Caliper Replacement)
replace if necessary. Refer to Master Cylinder Reservoir Replacement (See: Brake Master
Cylinder/Service and Repair/Removal and Replacement/Master Cylinder Reservoir Replacement) .
Replace the brake master cylinder reservoir cap.
* Front Brake Hose Replacement (See: Brake Hose/Line/Service and Repair/Front Brake Hose
Replacement)
* Rear Brake Hose Replacement (Caliper) (See: Brake Hose/Line/Service and Repair/Rear Brake
Hose Replacement (Caliper))Rear Brake Hose Replacement (Jounce) (See: Brake
* Front Brake Caliper Overhaul (See: Brake Caliper/Service and Repair/Overhaul/Front Brake
Caliper Overhaul) or Front Brake Caliper Replacement (See: Brake Caliper/Service and
* Rear Brake Caliper Overhaul (See: Brake Caliper/Service and Repair/Overhaul/Rear Brake
Caliper Overhaul) or Rear Brake Caliper Replacement (See: Brake Caliper/Service and
Repair/Removal and Replacement/Rear Brake Caliper Replacement)
* HBCi components
System Bleeding (Manual))Hydraulic Brake
System Bleeding (Pressure) (See: Hydraulic Brake System Bleeding (Pressure)) .
Hummer Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service Precautions > Brake Caliper Notice
Brake Caliper: Service Precautions Brake Caliper Notice
Brake Caliper Notice
Notice: Support the caliper with a piece of wire to prevent damage to the brake line.
Information > Service Precautions > Brake Caliper Notice > Page 6374
Brake Caliper: Service Precautions Brake Caliper Supporting to Prevent Hose Damage Notice
Brake Caliper Supporting to Prevent Hose Damage Notice
Brake Caliper: Testing and Inspection
Brake Caliper Inspection Caution: Refer to Brake Dust Caution (See: Service
1. Inspect the brake caliper housing for cracks, excess wear, and/or damage. If any of these
conditions are present, the brake caliper requires
replacement.
2. Inspect the caliper piston dust boot seals 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. Inspect for brake fluid leakage around the caliper piston dust boot seals and on the disc brake
pads. If there is any evidence of brake fluid leakage,
the brake caliper requires overhaul or replacement.
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. If the
caliper piston is frozen or difficult to bottom, the caliper requires overhaul or replacement. Insert a
discarded inner brake pad (2) or block of wood in front of the pistons. Using 2 large C-clamps (1)
installed over the body of the caliper (3) and against the brake pad or block of wood, slowly bottom
the pistons evenly into the bores.
Information > Service and Repair > Removal and Replacement
Brake Caliper: Removal and Replacement
Front Brake Caliper Replacement

Front Brake Caliper Replacement Caution: Refer to Brake Dust Caution (See: Service
Caution) .
Removal Procedure
removed from the
pad.
hose end.
10. Remove the brake hose from the caliper.

Information > Service and Repair > Removal and Replacement > Page 6378
11. Remove the 2 brake caliper mounting bolts.
Caution: Do not depress the brake pedal with the brake rotors/calipers and/or the brake drums
removed. Damage to the brake system may result. If brake system damage occurs and is not
repaired, vehicle damage and/or personal injury or death may result.
12. Remove the brake caliper from the brake caliper mounting bracket.
1. Install the brake caliper to the brake caliper mounting bracket. 2. Perform the following
procedure before installing the caliper guide pin bolts.
hose.
6. Install the brake hose to caliper bolt to the brake caliper.

10. Fill the master cylinder reservoir to the proper level with clean brake fluid. Refer to Master
Cylinder Reservoir Filling (See: Brake Master
Rear Brake Caliper Replacement
Rear Brake Caliper Replacement Caution: Refer to Brake Dust Caution (See: Service
Caution) .
Removal Procedure
between the maximum-full point and the minimum allowable level then no brake fluid needs to be
removed from
the reservoir before proceeding.
allowable level then remove brake fluid to the
pad.

hose end.
10. Remove the caliper guide pin bolts. 11. Remove the brake caliper from the vehicle. 12. Inspect
the caliper assembly. Refer to Brake Caliper Inspection (See: Testing and Inspection) .
Important: Use denatured alcohol to clean the outside surface of caliper boots before installing new
brake pads.
1. If you are installing new brake pads use a C-clamp in order to compress the pistons to the
bottom of the caliper bores. Use the old brake pad, a
metal plate or a wooden block across the face of the pistons in order to protect the pistons and the
caliper boots.
Important: Use a small flat-bladed tool and lift the inner edge of the caliper boots next to both
pistons to release any trapped air.
2. Ensure that the caliper boots are below the level of the face of both pistons. 3. Install the brake
caliper to the brake caliper mounting bracket. 4. Perform the following procedure before installing
the caliper guide pin bolts.
5. Install the brake caliper mounting bolts.
6. Tighten the brake caliper guide pin bolts.
hose.
9. Connect the brake hose at the caliper by installing the brake hose to caliper bolt.

Maintenance/Wheels and Tires/Service and Repair) . 12. Lower the vehicle. 13. Fill the master
Filling (See: Brake Master
Front Brake Caliper Bracket Replacement
Front Brake Caliper Bracket Replacement Caution: Refer to Brake Dust Caution (See: Service
Removal Procedure
distance.
is obtained. This will properly seat the brake caliper pistons and brake pads.
Rear Brake Caliper Bracket Replacement
Rear Brake Caliper Bracket Replacement Caution: Refer to Brake Dust Caution (See: Service
Removal Procedure
Tighten the caliper bracket mounting bolts to 165 N.m (122 lb ft).
distance. 11. Slowly release the brake pedal. 12. Wait 15 seconds, then repeat steps 10-11 until a
firm pedal is obtained. This will properly seat the brake caliper pistons and brake pads.
Brake Caliper: Overhaul
Tools Required
J 45515 Brake Caliper Piston Boot Seal Installer

Information/Brake Dust Caution) . Caution: Refer to Brake Fluid Irritant Caution (See: Service
Notice) .
1. Replace all the components included in the repair kits used to service this brake caliper. 2.
Lubricate the rubber parts with new Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N
992667) or equivalent DOT-3 brake fluid to make
assembly easier.
3. If any hydraulic component is removed or disconnected, it may be necessary to bleed all or part
of the brake system. 4. The torque values specified are for dry, non-lubricated fasteners. 5.
Perform the service operations on a clean bench, free from all mineral oil materials.
6. Remove the brake caliper from vehicle. Refer to Front Brake Caliper Replacement (See:
Removal and Replacement/Front Brake Caliper
Replacement) .
7. Drain the brake fluid from the brake caliper.
Notice: Use clean cloths to pad interior of caliper housing during piston removal. Use just enough
air to ease the pistons out of the bores. If the pistons are blown out, even with the padding
provided, it may be damaged.
8. Place a 25 mm (1 in) block of wood between the caliper and the piston. 9. Install a large C-clamp
over the body of the brake caliper with the C-clamp ends against the rear of the caliper body and
against the block of wood.
10. Carefully remove the brake caliper piston by directing low pressure compressed air into the
brake caliper inlet hole. 11. Remove the C-clamp form the caliper. 12. Remove the block of wood
from the caliper. 13. Install clean cloths to pad the interior of the caliper housing between the
remaining caliper piston and the caliper body. 14. To cover the open caliper bore place a 25 mm (1
in) block of wood between the caliper body and the brake caliper dust boot seal. 15. Install a large
C-clamp over the body of the brake caliper with the C-clamp ends against the rear of the caliper
body and against the block of wood. 16. Carefully remove the brake caliper piston by directing low
pressure compressed air into the brake caliper inlet hole. 17. Remove the C-clamp form the caliper.
18. Remove the block of wood from the caliper.
Important: Care must be used when removing the piston boot and seal from the caliper. Use a
small plastic or wood tool for removal. Do not use a metal tool because it may damage the caliper
bore or seal groove.
19. Remove the piston boots from the brake caliper. 20. Remove the piston seals from the brake
caliper. 21. Remove the brake caliper bleeder valve and cap from the brake caliper.
Important: Do not use abrasives to clean the brake caliper piston.
22. Clean the brake caliper piston bore and seal counterbore, and the caliper piston with denatured
alcohol, or equivalent. 23. Dry the caliper piston bores and counterbores, and the piston with
non-lubricated, filtered air. 24. Inspect all of the brake caliper parts as follows.
* Piston-Inspect for scoring, nicks, cracks, wear, or corrosion. Replace the pistons if any damage is
found.
* Caliper Bore-Inspect for scoring, nicks, cracks, wear, or corrosion. Use crocus cloth to polish out
light corrosion. Otherwise, replace the caliper. Do not hone the caliper bore.
* Seal groove in the caliper bore for nicks or burrs. If found, replace the caliper.
25. Install the brake caliper bleeder valve and bleeder valve cap into the brake caliper. 26.
Lubricate the new piston seal with Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N
10953488) or equivalent DOT-3 brake fluid from a
clean, sealed brake fluid container.
27. Install the lubricated, new piston seals into the caliper bores. 28. Install the caliper piston into
the caliper bore. 29. Install the new piston dust boot seal over the piston. 30. Using the J 45515 ,
fully seat the piston dust boot seal in the caliper. 31. Install the brake caliper to the vehicle. Refer to
Front Brake Caliper Replacement (See: Removal and Replacement/Front Brake Caliper
Replacement) .
Rear Brake Caliper Overhaul
Rear Brake Caliper Overhaul Caution: Refer to Brake Dust Caution (See: Service
Caution) .
1. Remove the brake caliper from the vehicle. Refer to Rear Brake Caliper Replacement (See:
Removal and Replacement/Rear Brake Caliper
Replacement) .
2. Place a thin piece of wood in front of the piston in order to prevent damage. Remove the piston
by directing compressed air into the brake hose
inlet fitting port of the brake caliper housing.
3. Remove the piston boot. 4. Remove the piston seal. 5. Remove the brake caliper bleed screw
cap. 6. Remove the brake caliper bleed screw. 7. Inspect the brake caliper bore and the piston seal
groove for scoring and corrosion. If you find excessive scoring or corrosion around the piston
seal area, replace the brake caliper housing.
8. Inspect the brake caliper mounting bracket guide surfaces for corrosion and wear. Remove and
replace the brake caliper mounting bracket if
needed.
9. Clean all the residue from the brake pad guiding surfaces on the brake caliper housing and the
brake caliper mounting bracket.
10. Clean all the parts not included in the repair kit with denatured alcohol. 11. Dry all the parts with
filtered unlubricated compressed air. 12. Blow out all passages in the brake caliper housing and the
brake caliper bleeder valve.
Assembly Procedure
1. Install the brake caliper bleed screw.
Tighten the brake caliper bleed screw to 12 N.m (106 lb in).
2. Install the brake caliper bleed screw cap. 3. Lubricate the new piston seal and the brake caliper
bore seal groove with brake fluid, GM P/N 12388967 (Canadian P/N 992667). 4. Install new the
seal into the brake caliper bore seal groove. 5. Ensure that the seal is not twisted. 6. Lubricate the
brake caliper bore and the piston with brake fluid, GM P/N 12388967 (Canadian P/N 992667). 7.
Install the boot and the piston.
1. Install the boot over the end of the piston so that the fold will face toward the brake caliper
housing piston bore opening. 2. Seat the boot into the brake caliper bore groove. Slide the piston
into the brake caliper bore. 3. Push down the piston to the bottom of the brake caliper bore. 4.
Ensure that the boot properly seats into the piston groove and into the groove in the brake caliper
bore. 5. Repeat steps 5 and 6 for the remaining piston.
8. Install the brake caliper to the vehicle. Refer to Rear Brake Caliper Replacement (See: Removal
and Replacement/Rear Brake Caliper
Replacement) .
Hummer Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component
Brake Fluid: Specifications
HYDRAULIC BRAKE SYSTEM

...........................................................................................................................................................
DOT-3 brake fluid.
Hummer Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch
Engine Compartment
Accumulator
Engine Compartment
Accumulator

Hummer Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component
Information > Service and Repair > Brake Pipe Replacement
Brake Hose/Line: Service and Repair Brake Pipe Replacement
Brake Pipe Replacement
Tools Required
J 45405 Pipe Flaring Tool Kit Caution: Refer to Brake Fluid Irritant Caution (See: Service
Caution: 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.
Notice) .
Important: When servicing the brake pipes, note the following:
* If sectioning the brake pipe, use replacement pipe of the same type and outside diameter.
* Use fittings of the appropriate size and type.
* Only create flares of the same type or design as originally equipped on the vehicle.
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 J 45405 .
* Avoid sectioning the brake pipe at bends or mounting points.
4. Using a string or wire, measure the length of the pipe to be replaced including all pipe bends. 5.
Add to the measurement taken the appropriate additional length required for each flare to be
created.
* 6.35 mm (0.250 in) for 4.76 mm (3/16 in) diameter pipe
Important: 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 J 45405 , 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.
Information > Service and Repair > Brake Pipe Replacement > Page 6402
9. Strip the nylon coating from the brake pipe end to be flared, if necessary.
* Select the appropriate blade on the coating stripping tool included in the J 45405 , by unthreading
the blade block from the stripping tool and installing the block with the desired blade facing the tool
rollers.
- 6.35 mm (0.250 in) blade for 4.76 mm (3/16 in) diameter pipe
- 9.50 mm (0.374 in) blade for 6.35 mm (1/4 in) and 7.94 mm (5/16 in) diameter pipe
* Insert the brake pipe end to be flared into the stripping tool to the depth of the ledge on the tool
rollers.
* While holding the brake pipe firmly against the stripping tool roller ledges, rotate the thumbwheel
of the tool until the blade contacts the brake pipe coated surface. Important: Do not gouge the
metal surface of the brake pipe.
* Rotate the stripping tool in a clockwise direction, ensuring that the brake pipe end remains
against the tool roller ledges.
* After each successive revolution of the stripping tool, carefully rotate the thumbwheel of the tool
clockwise, in order to continue stripping the coating from the brake pipe until the metal pipe surface
is exposed.
* Loosen the thumbwheel of the tool and remove the brake pipe. Important: Ensure that all loose
remnants of the nylon coating have been removed from the brake pipe.
* Inspect the stripped end of the brake pipe to ensure that the proper amount of coating has been
removed.
- 6.35 mm (0.250 in) for 4.76 mm (3/16 in) diameter pipe
- 9.50 mm (0.374 in) for 6.35 mm (1/4 in) and 7.94 mm (5/16 in) diameter pipe
10. Chamfer the inside and outside diameter of the pipe with the de-burring tool included in the J
45405 . 11. Install the tube nuts on the brake pipe, noting their orientation. 12. Clean the brake pipe
and the J 45405 of lubricant, contaminants, and debris.
13. Loosen the die clamping screw of the J 45405 . 14. Select the corresponding die set and install
the die halves into the die cage with the full, flat face of one die facing the clamping screw, and the
counterbores of both dies facing the forming ram.
15. Place the flat face of an unused die (1) against the die halves in the clamping cage and hold
firmly against the counterbored face of the dies. 16. Insert the prepared end of the pipe to be flared
through the back of the dies until the pipe is seated against the flat surface of the unused die (1).
17. Remove the unused die (1). 18. Ensure that the rear of both dies are seated firmly against the
enclosed end of the die cage. 19. Firmly hand tighten the clamping screw (2) against the dies.
20. Select the appropriate forming mandrel and place into the forming ram. 21. Rotate the hydraulic
fluid control valve clockwise to the closed position. 22. Rotate the body of the J 45405 until it
bottoms against the die cage.
23. While guiding the forming mandrel into the exposed end of pipe to be flared, operate the lever
of the J 45405 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.
25. Insert the finishing cone into the forming ram. 26. Rotate the hydraulic fluid control valve
clockwise to the closed position.
27. Rotate the body of the J 45405 until it bottoms against the die cage. 28. While guiding the
finishing cone into the exposed end of pipe to be flared, operate the lever of the J 45405 until the
finishing cone bottoms
against the dies.
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.
32. Inspect the brake pipe flare for correct shape and diameter (a).
* 6.74-7.10 mm (0.265-0.279 in) flare diameter for 4.76 mm (3/16 in) diameter pipe
33. If necessary, using the removed section of brake pipe as a template, shape the new pipe with a
suitable brake pipe bending tool.
Important: When installing the pipe, maintain a clearance of 19 mm (3/4 in) from all moving or
vibrating components.
34. Install the pipe to the vehicle with the appropriate brake pipe unions, as required. 35. If
previously released, secure the brake pipe to the retainers. 36. Bleed the hydraulic brake system.
Refer to Hydraulic Brake System Bleeding (Manual) (See: Brake Bleeding/Service and
Repair/Hydraulic Brake
37. With the aid of an assistant, inspect the brake pipe flares for leaks by starting the engine and
applying the brakes.
Brake Hose/Line: Service and Repair Front Brake Hose Replacement
Front Brake Hose Replacement Caution: Refer to Brake Fluid Irritant Caution (See: Service
Notice) .
Removal Procedure
3. Clean all dirt and foreign material from the brake hose end and brake pipe fitting.
Important: Install a rubber cap or plug to the exposed brake pipe fitting end in order to prevent
brake fluid loss and contamination.
4. Use a backup wrench on the brake hose fitting end (2), disconnect the brake pipe fitting end (1)
from the brake hose (2), then cap or plug the brake
pipe fitting end.
5. Remove the brake hose retaining clip (3) from the brake hose mounting bracket.
6. Remove the brake hose bracket bolt from the upper control arm. 7. Remove the brake hose
bracket bolt from the steering knuckle.
hose end.
1. Assemble the 2 new copper brake hose gaskets and the brake hose bolt to the brake hose.

Notice) .
2. Install the brake hose to caliper bolt and 2 new washers to the brake caliper.
Important: The brake hose must not be twisted. Make sure the brake hose is not in contact with any
suspension component.
3. Install the brake hose bracket bolt and the bracket to the steering knuckle.
4. Install the brake hose bracket bolt and the bracket to the upper control arm.
5. Install the brake hose into the brake hose bracket. 6. Install the brake hose retaining clip (3). 7.
Remove the rubber cap or plug from the brake pipe fitting end. 8. Connect the brake pipe fitting end
(1) to the brake hose (2):
* Use a backup wrench on the brake hose fitting end (2).
* Do not bend the mounting bracket or the brake pipe.
Tighten the brake pipe fitting end (1) to 25 N.m (18 lb ft).
9. Bleed the hydraulic brake system. Refer to in Hydraulic Brake System Bleeding (Manual) (See:
Brake Bleeding/Service and Repair/Hydraulic
Brake System Bleeding (Manual))Hydraulic Brake System Bleeding (Pressure) (See: Brake
Important: Ensure that the brake hose does not make contact with any part of the suspension or
the tire/wheel assembly. Check the brake hose in extreme right and left turn conditions. If the brake
hose makes contact remove the brake hose and correct the condition.

Brake Hose/Line: Service and Repair Rear Brake Hose Replacement (Caliper)
Rear Brake Hose Replacement (Caliper) Caution: Refer to Brake Fluid Irritant Caution (See:
Notice) .
Removal Procedure
from the brake hose (1) then cap or plug the brake
pipe fitting end.
5. Remove the brake hose retaining clip (3) from the brake hose mounting bracket. 6. Remove the
brake hose (1) from the mounting bracket.
hose end.
3. Install the brake hose (1) into the mounting bracket.
4. Install the brake hose retaining clip (3). 5. Remove the rubber cap or plug from the exposed
brake pipe fitting end. 6. Connect the brake pipe fitting end (2) to the brake hose (1):

the tire/wheel assembly. If the brake hose makes contact remove the brake hose and correct the
condition.

Brake Hose/Line: Service and Repair Rear Brake Hose Replacement (Jounce)
Rear Brake Hose Replacement (Jounce) Caution: Refer to Brake Fluid Irritant Caution (See:
Notice) .
Removal Procedure
Clean all dirt and foreign material from the brake hose and brake pipe fittings.
Important: Install a rubber cap or plug to the exposed brake pipe fitting ends in order to prevent
3. Use a backup wrench on the hose fitting, disconnect the brake pipe fitting from the brake hose,
then cap or plug the brake pipe fitting end. 4. Remove the brake hose upper bracket bolt.
5. Using a backup wrench on the hose fittings, disconnect the brake pipe fittings from the brake
hoses (1), then cap or plug the brake pipe fitting
ends.
6. Remove the brake hose lower bracket bolt (2). 7. Remove the jounce hoses.
1. Install the rear jounce brake hoses (1).
2. Install the brake hose lower bracket and bolt (2) to the axle.
3. Remove the caps or plugs from the rear brake pipes and connect the pipes to the jounce hoses.
Tighten the brake pipe fittings to 25 N.m (18 lb ft).
Important: The hoses must not be twisted. Make sure the hoses are not in contact with any
4. With the weight of the vehicle on the suspension, install the brake hose bracket bolt. 5. Remove
the rubber cap or plug from the exposed brake pipe fitting end. 6. Connect the brake pipe fittings to
the brake hoses:
* Use a backup wrench on the hose fitting.
* Do not bend the bracket or the pipe.
Tighten the brake pipe fitting to 25 N.m (18 lb ft).
7. Ensure that the hose does not make contact with any part of the suspension. If the hose makes
contact, remove the hose and correct the condition. 8. Bleed the hydraulic brake system. Refer to
Hydraulic Brake System Bleeding (Manual) (See: Brake Bleeding/Service and Repair/Hydraulic
Brake

Brake Hose/Line: Service and Repair
Tools Required
J 45405 Pipe Flaring Tool Kit Caution: Refer to Brake Fluid Irritant Caution (See: Service
Caution: 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.
Notice) .
Important: When servicing the brake pipes, note the following:
* If sectioning the brake pipe, use replacement pipe of the same type and outside diameter.
* Use fittings of the appropriate size and type.
* Only create flares of the same type or design as originally equipped on the vehicle.
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 J 45405 .
* Avoid sectioning the brake pipe at bends or mounting points.
4. Using a string or wire, measure the length of the pipe to be replaced including all pipe bends. 5.
Add to the measurement taken the appropriate additional length required for each flare to be
created.
Important: 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 J 45405 , 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.
9. Strip the nylon coating from the brake pipe end to be flared, if necessary.
* Select the appropriate blade on the coating stripping tool included in the J 45405 , by unthreading
the blade block from the stripping tool and installing the block with the desired blade facing the tool
rollers.
- 6.35 mm (0.250 in) blade for 4.76 mm (3/16 in) diameter pipe
- 9.50 mm (0.374 in) blade for 6.35 mm (1/4 in) and 7.94 mm (5/16 in) diameter pipe
* Insert the brake pipe end to be flared into the stripping tool to the depth of the ledge on the tool
rollers.
* While holding the brake pipe firmly against the stripping tool roller ledges, rotate the thumbwheel
of the tool until the blade contacts the brake pipe coated surface. Important: Do not gouge the
metal surface of the brake pipe.
* Rotate the stripping tool in a clockwise direction, ensuring that the brake pipe end remains
against the tool roller ledges.
* After each successive revolution of the stripping tool, carefully rotate the thumbwheel of the tool
clockwise, in order to continue stripping the coating from the brake pipe until the metal pipe surface
is exposed.
* Loosen the thumbwheel of the tool and remove the brake pipe. Important: Ensure that all loose
remnants of the nylon coating have been removed from the brake pipe.
* Inspect the stripped end of the brake pipe to ensure that the proper amount of coating has been
removed.
- 6.35 mm (0.250 in) for 4.76 mm (3/16 in) diameter pipe
- 9.50 mm (0.374 in) for 6.35 mm (1/4 in) and 7.94 mm (5/16 in) diameter pipe
10. Chamfer the inside and outside diameter of the pipe with the de-burring tool included in the J
45405 . 11. Install the tube nuts on the brake pipe, noting their orientation. 12. Clean the brake pipe
and the J 45405 of lubricant, contaminants, and debris.
13. Loosen the die clamping screw of the J 45405 . 14. Select the corresponding die set and install
the die halves into the die cage with the full, flat face of one die facing the clamping screw, and the
counterbores of both dies facing the forming ram.
15. Place the flat face of an unused die (1) against the die halves in the clamping cage and hold
firmly against the counterbored face of the dies. 16. Insert the prepared end of the pipe to be flared
through the back of the dies until the pipe is seated against the flat surface of the unused die (1).
17. Remove the unused die (1). 18. Ensure that the rear of both dies are seated firmly against the
enclosed end of the die cage. 19. Firmly hand tighten the clamping screw (2) against the dies.
20. Select the appropriate forming mandrel and place into the forming ram. 21. Rotate the hydraulic
fluid control valve clockwise to the closed position. 22. Rotate the body of the J 45405 until it
bottoms against the die cage.
23. While guiding the forming mandrel into the exposed end of pipe to be flared, operate the lever
of the J 45405 until the forming mandrel bottoms
against the clamping dies.
hydraulic forming ram to retract.
25. Insert the finishing cone into the forming ram. 26. Rotate the hydraulic fluid control valve
clockwise to the closed position.
27. Rotate the body of the J 45405 until it bottoms against the die cage. 28. While guiding the
finishing cone into the exposed end of pipe to be flared, operate the lever of the J 45405 until the
finishing cone bottoms
against the dies.
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.
32. Inspect the brake pipe flare for correct shape and diameter (a).
33. If necessary, using the removed section of brake pipe as a template, shape the new pipe with a
suitable brake pipe bending tool.
Important: When installing the pipe, maintain a clearance of 19 mm (3/4 in) from all moving or
vibrating components.
34. Install the pipe to the vehicle with the appropriate brake pipe unions, as required. 35. If
previously released, secure the brake pipe to the retainers. 36. Bleed the hydraulic brake system.
Refer to Hydraulic Brake System Bleeding (Manual) (See: Brake Bleeding/Service and
Repair/Hydraulic Brake
37. With the aid of an assistant, inspect the brake pipe flares for leaks by starting the engine and
applying the brakes.
Front Brake Hose Replacement
Front Brake Hose Replacement Caution: Refer to Brake Fluid Irritant Caution (See: Service
Notice) .
Removal Procedure
from the brake hose (2), then cap or plug the brake
pipe fitting end.
5. Remove the brake hose retaining clip (3) from the brake hose mounting bracket.
6. Remove the brake hose bracket bolt from the upper control arm. 7. Remove the brake hose
bracket bolt from the steering knuckle.
hose end.

Notice) .
3. Install the brake hose bracket bolt and the bracket to the steering knuckle.
4. Install the brake hose bracket bolt and the bracket to the upper control arm.
5. Install the brake hose into the brake hose bracket. 6. Install the brake hose retaining clip (3). 7.
Remove the rubber cap or plug from the brake pipe fitting end. 8. Connect the brake pipe fitting end
(1) to the brake hose (2):
9. Bleed the hydraulic brake system. Refer to in Hydraulic Brake System Bleeding (Manual) (See:
Brake Bleeding/Service and Repair/Hydraulic
Brake System Bleeding (Manual))Hydraulic Brake System Bleeding (Pressure) (See: Brake
the tire/wheel assembly. Check the brake hose in extreme right and left turn conditions. If the brake
hose makes contact remove the brake hose and correct the condition.
Rear Brake Hose Replacement (Caliper)

Rear Brake Hose Replacement (Caliper) Caution: Refer to Brake Fluid Irritant Caution (See:
Notice) .
Removal Procedure
from the brake hose (1) then cap or plug the brake
pipe fitting end.
5. Remove the brake hose retaining clip (3) from the brake hose mounting bracket. 6. Remove the
brake hose (1) from the mounting bracket.
hose end.

3. Install the brake hose (1) into the mounting bracket.
4. Install the brake hose retaining clip (3). 5. Remove the rubber cap or plug from the exposed
brake pipe fitting end. 6. Connect the brake pipe fitting end (2) to the brake hose (1):

the tire/wheel assembly. If the brake hose makes contact remove the brake hose and correct the
condition.

Rear Brake Hose Replacement (Jounce)
Rear Brake Hose Replacement (Jounce) Caution: Refer to Brake Fluid Irritant Caution (See:
Notice) .
Removal Procedure
Clean all dirt and foreign material from the brake hose and brake pipe fittings.
3. Use a backup wrench on the hose fitting, disconnect the brake pipe fitting from the brake hose,
then cap or plug the brake pipe fitting end. 4. Remove the brake hose upper bracket bolt.
5. Using a backup wrench on the hose fittings, disconnect the brake pipe fittings from the brake
hoses (1), then cap or plug the brake pipe fitting
ends.
6. Remove the brake hose lower bracket bolt (2). 7. Remove the jounce hoses.
1. Install the rear jounce brake hoses (1).
2. Install the brake hose lower bracket and bolt (2) to the axle.
3. Remove the caps or plugs from the rear brake pipes and connect the pipes to the jounce hoses.
Tighten the brake pipe fittings to 25 N.m (18 lb ft).
Important: The hoses must not be twisted. Make sure the hoses are not in contact with any
4. With the weight of the vehicle on the suspension, install the brake hose bracket bolt. 5. Remove
the rubber cap or plug from the exposed brake pipe fitting end. 6. Connect the brake pipe fittings to
the brake hoses:
* Use a backup wrench on the hose fitting.
* Do not bend the bracket or the pipe.
Tighten the brake pipe fitting to 25 N.m (18 lb ft).
7. Ensure that the hose does not make contact with any part of the suspension. If the hose makes
contact, remove the hose and correct the condition. 8. Bleed the hydraulic brake system. Refer to
Hydraulic Brake System Bleeding (Manual) (See: Brake Bleeding/Service and Repair/Hydraulic
Brake


Power Brake Booster Inlet Hose Replacement
Power Brake Booster Inlet Hose Replacement
Tools Required
Removal Procedure
1. Using a suitable tool, remove the brake fluid from the master cylinder reservoir.
Discard the brake fluid into an approved container.
Control Module Replacement (See: Brake Master Cylinder/Service and Repair/Removal and
Replacement) .
5. Remove the power brake booster inlet hose roll pin (1). 6. Release the hose clamp at the master
cylinder reservoir and remove the inlet hose (2) with the union from the power brake booster and
the master
cylinder reservoir.
7. Remove the inlet hose union O-ring seal (3).
1. Install the inlet hose union O-ring seal (3). 2. Release the hose clamp at the master cylinder
reservoir and install the inlet hose (2) with the union to the power brake booster and the master
cylinder reservoir.
3. Install the power brake booster inlet hose roll pin (1).
Booster and Chassis
Replacement) .
Power Brake Booster Outlet Front Pipe Replacement
Power Brake Booster Outlet Front Pipe Replacement
Tools Required
Removal Procedure
Replacement) .
4. Disconnect the brake pipe fittings and remove the power brake booster outlet front pipe (1).

Notice) .
1. Install the power brake booster outlet front pipe (1) and connect the brake pipe fittings.
2. Remove the CH-47830 (1) from the master cylinder assembly. 3. Remove the brake master
Booster and Chassis
Replacement) .
Hummer Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly -
Antilock Brakes > Component Information > Service and Repair
Hydraulic Control Assembly - Antilock Brakes: Service and Repair
Brake Pressure Modulator Valve Replacement
Special Tools
Replacement) .
Antilock Brakes > Component Information > Service and Repair > Page 6433
(See: Brake Master Cylinder/Service and
Repair/Removal and Replacement/Master Cylinder Reservoir Replacement) .

6. Remove the brake pressure modulator valve (BPMV) (1) bolts.
7. Remove the BPMV gasket (1) and the BPMV module assembly (2).
Discard the BPMV gasket.

8. Remove the brake fluid level sensor bracket bolt (1) and bracket (2) from the BPMV module
assembly.

Notice) .
1. Install the brake fluid level sensor bracket bolt (1) and bracket (2) to the BPMV module
assembly.

2. Install a new BPMV gasket (1) and the BPMV module assembly (2).
Important: Hand install the BPMV module assembly bolts prior to tightening the bolts to properly
locate the BPMV module assembly.
3. Install the BPMV (1) bolts.

Brake Master Cylinder/Service and
Repair/Removal and Replacement/Master Cylinder Reservoir Replacement) .

Booster and Chassis
Replacement) .

9. Refer to Programming and Relearning (See: Testing and Inspection/Programming and

Hummer Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder >
Brake Master Cylinder: Procedures
Master Cylinder Reservoir Filling Caution: Refer to Brake Fluid Irritant Caution (See: Service
Notice) .
Important: Before checking the HB-Ci Master Cylinder Reservoir brake fluid level, the accumulator
fluid reserve must be drained. With the ignition OFF, wait 15 seconds then depress and release the
brake pedal 20 times to deplete accumulator reserve. Failure to drain the accumulator prior to
checking the brake fluid level can lead to system over filling.
1. Visually inspect the brake fluid level through the brake master cylinder reservoir. 2. If the brake
fluid level is at or below the half-full point during routine fluid checks, the brake system should be
inspected for wear and possible
brake fluid leaks.
3. If the brake fluid level is at or below the half-full point during routine fluid checks, and an
inspection of the brake system did not reveal wear or
brake fluid leaks, the brake fluid may be filled to the maximum-fill level.
4. If brake system service was just completed, the brake fluid may be filled to the maximum-fill
level. 5. If the brake fluid level is above the half-full point, adding brake fluid is not recommended
under normal conditions. 6. If brake fluid is to be added to the master cylinder reservoir, clean the
outside of the reservoir on and around the reservoir cap prior to removing
the cap and diaphragm. Use only Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N
992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container.
Brake Master Cylinder: Removal and Replacement
Notice) .
reserve.
contamination.
contamination.
Instrument


Notice) .




Master Cylinder Reservoir Replacement
Master Cylinder Reservoir Replacement
Tools Required
Removal Procedure
1. Using a suitable tool, remove the brake fluid from the master cylinder reservoir.
Discard the brake fluid into an approved container.
Control Module Replacement (See: Brake Master Cylinder with Power Brake Booster and Chassis
5. Release the brake fluid level sensor electrical connector (1) from the sensor bracket.
6. Remove the master cylinder reservoir roll pin (1).
7. Remove the master cylinder reservoir bolt (1).

8. Release the power brake booster inlet hose clamp (1), disconnect the hose and remove the
master cylinder reservoir (2). 9. Remove the 2 master cylinder reservoir grommets from the master
cylinder, if necessary.
1. Install the 2 master cylinder reservoir grommets to the master cylinder, if removed.
Important: Apply a small amount of clean brake fluid from a sealed container to the master cylinder
reservoir grommets prior to installing the reservoir.
2. Release the power brake booster inlet hose clamp (1), connect the hose and install the master
cylinder reservoir (2).

Notice) .
3. Install the master cylinder reservoir bolt (1).
4. Install the master cylinder reservoir roll pin (1).

5. Install the brake fluid level sensor electrical connector (1) to the sensor bracket.
Booster and Chassis
Control Module Replacement (See: Brake Master Cylinder with Power Brake Booster and Chassis
8. Fill the brake master cylinder reservoir. Refer to Master Cylinder Reservoir Filling (See:
Procedures) .
Master Cylinder Replacement
Master Cylinder Replacement Caution: Refer to Brake Fluid Irritant Caution (See: Service
Removal Procedure
(See: Master Cylinder Reservoir Replacement) .
3. Remove the brake pressure modulator valve (BPMV) gasket (1) and the BPMV module (2) from
the master cylinder. Refer to Brake Pressure
Modulator Valve Replacement (See: Hydraulic Control Assembly - Antilock Brakes/Service and
Repair) .
1. Install the BPMV gasket (1) and the BPMV module (2) to the master cylinder. Refer to Brake
Pressure Modulator Valve Replacement (See:
Hydraulic Control Assembly - Antilock Brakes/Service and Repair) .

Master Cylinder Reservoir Replacement) .

Hummer Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Actuator >
Parking Brake Actuator: Service and Repair
Parking Brake Actuator Replacement Caution: Refer to Brake Dust Caution (See: Service
Removal Procedure
1. Disable the park brake cable automatic adjuster. Refer to Parking Brake Cable Adjuster
Disabling (See: Parking Brake Cable/Service and
Repair/Procedures/Parking Brake Cable Adjuster Disabling)
.
4. Remove the rotor. Refer to Rear Brake Rotor Replacement (See: Disc Brake System/Brake
Rotor/Disc/Service and Repair/Removal and
Replacement/Rear Brake Rotor Replacement) .
5. Remove the axle shaft. Refer to Rear Axle Shaft Replacement (See: Transmission and
Drivetrain/Drive Axles, Bearings and Joints/Axle Shaft
6. Remove the park brake shoe. Refer to Parking Brake Shoe Replacement (See: Parking Brake
Shoe/Service and Repair) .
7. Remove the actuator (2) and rubber boot (1).
Hummer Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Actuator >
1. Install the rubber boot (1) and the actuator (2). 2. Install the park brake shoe. Refer to Parking
Brake Shoe Replacement (See: Parking Brake Shoe/Service and Repair) . 3. Install the axle shaft.
Refer to Rear Axle Shaft Replacement (See: Transmission and Drivetrain/Drive Axles, Bearings
and Joints/Axle Shaft
4. Adjust the park brake shoe. Refer to Park Brake Adjustment (See: Adjustments) . 5. Install the
rotor. Refer to Rear Brake Rotor Replacement (See: Disc Brake System/Brake Rotor/Disc/Service
and Repair/Removal and
Maintenance/Wheels and Tires/Service and Repair) . 7. Remove the safety stands. 8. Lower
vehicle. 9. Enable the park brake cable automatic adjuster. Refer to Parking Brake Cable Adjuster
Enabling (See: Parking Brake Cable/Service and
Repair/Procedures/Parking Brake Cable Adjuster Enabling) .

Hummer Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component
Parking Brake Cable: Procedures
Parking Brake Cable Adjuster Disabling
Parking Brake Cable Adjuster Disabling
Before any components of the parking brake system are serviced, the following procedure must be
followed. Two technicians are required to perform this procedure: one inside the vehicle and one
outside the vehicle.
Hold the pedal in the FULL upward position. 3. Pull rearward on the front park brake cable until the
pedal drum (2) reaches its full reset position. 4. Insert a scribe or the shaft of a thin screwdriver (1)
on an upward angle through the hole in the front of the pedal assembly, past the retracted pedal
drum, and into the hole in the back of the pedal assembly (3).
5. Slowly release the cable. 6. Remove the component that requires service.
Parking Brake Cable Adjuster Enabling
Parking Brake Cable Adjuster Enabling
If the park brake automatic adjuster has been disabled, the following two person procedure must
be performed.
1. Hold the park brake pedal in the FULL upward position.
2. Pull rearward on the front park brake cable until the tension is released from the scribe or nail (1)
installed through the holes in the pedal assembly. 3. Remove the scribe or screwdriver (1).
4. Slowly release the park brake cable until it returns to its original position. 5. Release the park
brake pedal. 6. Lower the vehicle. 7. Apply and release the park brake pedal to ensure that there is
no binding or sticking.
Parking Brake Cable: Removal and Replacement
Parking Brake Front Cable Replacement
Parking Brake Front Cable Replacement
Removal Procedure
Disabling (See: Procedures/Parking Brake Cable Adjuster
Disabling) .
2. Remove the park brake pedal. Refer to Parking Brake Lever Pedal Assembly Replacement
(See: Parking Brake Lever/Service and Repair/Parking
Brake Lever Pedal Assembly Replacement) .
3. Roll the carpet back to access cable grommet. 4. Raise and support the vehicle. Refer to Lifting
and Jacking the Vehicle (See: Maintenance) .
5. Disengage the grommet and the cable from the floor pan. 6. Disconnect the front cable from the
rear cable. 7. Remove the cable from the body mount by depressing the retaining tabs. 8. Remove
the cable.
1. Install the cable. 2. Snap the retainer tabs into the body mount. 3. Connect the front cable to the
rear cable. 4. Route the cable in through the floor pan and engage the grommet. 5. Remove the
safety stands. 6. Lower the vehicle.
7. Roll the carpet into place. 8. Install the park brake pedal. Refer to Parking Brake Lever Pedal
Assembly Replacement (See: Parking Brake Lever/Service and Repair/Parking
Brake Lever Pedal Assembly Replacement) .
9. Enable the park brake cable automatic adjuster. Refer to Parking Brake Cable Adjuster Enabling
(See: Procedures/Parking Brake Cable Adjuster
Enabling) .
Park Brake Cable Guide Replacement
Park Brake Cable Guide Replacement
Removal Procedure
1. Release the parking brake. 2. Raise and support the vehicle. Refer to Lifting and Jacking the
Vehicle (See: Maintenance) .
3. Remove the park brake cable guide bolt. 4. Remove the park brake cable guide (2). 5. Remove
the park brake guide from the park brake cable.
1. Install the park brake cable guide to the park brake cable. 2. Install the park brake cable guide
(2).

3. Install the park brake cable guide bolt.
4. Remove the safety stands. 5. Lower the vehicle.
Parking Brake Rear Cable Replacement - Left Side
Parking Brake Rear Cable Replacement - Left Side
Removal Procedure
Disabling) .
3. Disconnect the left rear cable from the front cable.
4. Remove the left rear cable (4) from the equalizer (1) by depressing the locking tabs.
5. Remove the left rear cable (3) from the cable support (2).
6. Remove the cable (3) from the backing plate (1) by compressing the spring to access and
depress the locking tabs, pull the cable out of the backing
plate, and routing the cable through the slot in the backing plate.
7. Remove the cable (3) from the lever (2).
8. Remove the left rear cable (1) from the cable guide (2). 9. Remove the cable from the vehicle.
1. Install the left rear cable taking care to correctly route the cable (1) through the cable guide (2).
2. Install the cable (3) to the lever (2). 3. install the cable (3) to the backing plate (1) by
compressing the spring, routing the cable through the slot in the backing plate and pressing the
cable into the backing plate until the locking tabs snap into place.
4. Install the left rear cable (3) to the cable support (2).
5. Install the left rear cable (4) to the equalizer (1) until the locking tabs snap into place.
6. Connect the left rear cable to the front cable. 7. Remove the safety stands. 8. Lower the vehicle.
(See: Procedures/Parking Brake Cable Adjuster
Enabling) .
Parking Brake Rear Cable Replacement - Right Side
Parking Brake Rear Cable Replacement - Right Side
Removal Procedure
Disabling) .
3. Disconnect the right rear cable from the equalizer.
4. Remove the right rear cable (1) from the cable support (2).
5. Remove the track bar clips (1) from the track bar.
7. Remove the cable (3) from the lever (2).
8. Remove the right rear cable (3) from the cable guide (2). 9. Remove the cable from the vehicle.
1. Install the right rear cable taking care to correctly route the cable (3) through the cable guide (2).
4. Position the right rear cable (2) and the clips (1) on the track bar.
5. Install the track bar clips to the locating tabs on the track bar.
6. Install the right rear cable (1) to the cable support (2).
7. Install the right rear cable to the equalizer. 8. Remove the safety stands. 9. Lower the vehicle.
10. Enable the park brake cable automatic adjuster. Refer to Parking Brake Cable Adjuster
Enabling (See: Procedures/Parking Brake Cable Adjuster
Enabling) .
Hummer Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Lever > Component
Information > Service and Repair > Parking Brake Release Handle Assembly Replacement
Parking Brake Lever: Service and Repair Parking Brake Release Handle Assembly Replacement
Parking Brake Release Handle Assembly Replacement

Removal Procedure

Connection) .
2. Remove the park brake release lever mounting bolt. 3. Remove the park brake release lever
handle from the knee bolster. 4. Remove the MID-Bussed Electrical Center from the bracket. 5.
Remove the park brake release cable housing from the pedal assembly. 6. Remove the park brake
release cable from the pedal assembly. 7. Note the routing of the cable as you remove the park
brake release handle assembly from the vehicle.
1. Install the park brake release handle assembly to the vehicle. Install the cable using the same
routing as the original cable. 2. Install the park brake release cable to the pedal assembly. 3. Install
the park brake release cable housing to the pedal assembly. 4. Install the MID-Bussed Electrical
Center to the bracket. 5. Install the park brake release lever handle to the knee bolster.
6. Install the park brake release lever mounting bolt.

Information > Service and Repair > Parking Brake Release Handle Assembly Replacement > Page 6485
Parking Brake Lever: Service and Repair Parking Brake Lever Pedal Assembly Replacement
Parking Brake Lever Pedal Assembly Replacement
Removal Procedure

Connection) .
Repair/Procedures/Parking Brake Cable Adjuster Disabling) .
3. Remove the left side hinge pillar panel. Refer to Body Hinge Pillar Trim Panel Replacement -
Left Side (See: Body and Frame/Interior Moulding
/ Trim/Trim Panel/Service and Repair/Body Hinge Pillar Trim Panel Replacement - Left Side) .
5. Disconnect the park brake warning lamp connection.
6. Disconnect the park brake release cable from the park brake lever.
7. Remove the park brake lever mounting nuts.

8. Disconnect the front park brake cable from the park brake lever. 9. Remove the park brake lever.
1. Connect the front park brake cable to the park brake lever.
2. Install the park brake lever.
3. Install the park brake lever mounting nuts.

4. Connect the park brake release cable to the park brake lever.
5. Connect the park brake warning lamp connector. 6. Install the MID-Bussed Electrical Center
bracket. 7. Install the left side hinge pillar panel. Refer to Body Hinge Pillar Trim Panel
Replacement - Left Side (See: Body and Frame/Interior Moulding /
Trim/Trim Panel/Service and Repair/Body Hinge Pillar Trim Panel Replacement - Left Side) .

(See: Parking Brake Cable/Service and

Hummer Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component
Parking Brake Shoe: Service and Repair
Parking Brake Shoe Replacement Caution: Refer to Brake Dust Caution (See: Service
Removal Procedure
Repair/Procedures/Parking Brake Cable Adjuster Disabling) .
Remove the tire and the wheel. Refer to Tire and Wheel Removal and Installation (See:
Maintenance/Wheels and Tires/Service and Repair) . 4. Remove the caliper and mounting bracket
as an assembly. Refer to Rear Disc Brake Pads Replacement (See: Disc Brake System/Brake
Pad/Service and Repair/Rear Disc Brake Pads Replacement) .
5. Remove the rotor. Refer to Rear Brake Rotor Replacement (See: Disc Brake System/Brake
7. Remove the cable (3) from the lever (2). 8. Remove the axle shaft. Refer to Rear Axle Shaft
Replacement (See: Transmission and Drivetrain/Drive Axles, Bearings and Joints/Axle Shaft
9. Remove the park brake shoe return springs (4, 6).

10. Remove the park brake shoe anchor springs and pins. 11. Remove the park brake shoes.
1. Clean the debris and the dust from the park brake components using a clean towel. 2. Install the
park brake shoes. 3. Install the park brake shoe anchor springs and pins.
4. Install the park brake shoe return springs (4, 6). 5. Adjust the park brake shoe. Refer to Park
Brake Adjustment (See: Adjustments) . 6. Install the axle shaft. Refer to Rear Axle Shaft
Replacement (See: Transmission and Drivetrain/Drive Axles, Bearings and Joints/Axle Shaft
7. Install the rotor. Refer to Rear Brake Rotor Replacement (See: Disc Brake System/Brake

10. Install the caliper and mounting bracket as an assembly. Refer to Rear Disc Brake Pads
Replacement (See: Disc Brake System/Brake Pad/Service
and Repair/Rear Disc Brake Pads Replacement) .
Maintenance/Wheels and Tires/Service and Repair) . 12. Remove the safety stands. 13. Lower the
vehicle. 14. Enable the park brake cable automatic adjuster. Refer to Parking Brake Cable Adjuster
Enabling (See: Parking Brake Cable/Service and

Hummer Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch >
Park Brake Switch

Removal Procedure

Connection) .
lamp switch.

Hummer Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster > Component
Information > Service and Repair > Brake Master Cylinder with Power Brake Booster and Chassis Control Module
Replacement
Hydraulic Brake Booster: Service and Repair Brake Master Cylinder with Power Brake Booster and
Chassis Control Module Replacement
Notice) .
reserve.
contamination.
contamination.
Instrument

Notice) .



Hydraulic Brake Booster: Service and Repair Power Brake Booster Replacement
Power Brake Booster Replacement
Tools Required
Removal Procedure

master cylinder assembly in a vise. 4. Remove the hydraulic brake booster accumulator. Refer to
Hydraulic Brake Booster Accumulator Replacement (See: Hydraulic Fluid
Accumulator/Service and Repair/Removal and Replacement) .
5. Remove the power brake booster inlet hose. Refer to Power Brake Booster Inlet Hose
Replacement (See: Hydraulic System/Brake
Hose/Line/Service and Repair/Power Brake Booster Inlet Hose Replacement) .
6. Remove the power brake booster outlet front pipe. Refer to Power Brake Booster Outlet Front
Pipe Replacement (See: Hydraulic System/Brake
Hose/Line/Service and Repair/Power Brake Booster Outlet Front Pipe Replacement) .
Important: Note the location of the black negative wire and the red positive wire. The black negative
wire is toward the front of the vehicle. The red positive wire is toward the rear of the vehicle.
7. Remove the black negative wire terminal plug (1) and the screw. 8. Remove the red positive wire
terminal plug (2) and the screw. 9. Disconnect the pump motor wire harness from the brake
pressure modulator valve (BPMV) module.
10. Remove the power brake booster pump bracket bolts (1).
11. Remove the power brake booster pump (1).
12. Remove the power brake booster pump damper retaining ring (1) by breaking and discarding
the retaining ring. 13. Remove the power brake booster pump damper (2) and the bracket (3).
14. Remove the power brake booster pump motor dampers (1).
1. Install the power brake booster pump motor dampers (1).

2. Install the power brake booster pump damper (2) and the bracket (3) to the pump motor. 3.
Install a new power brake booster pump damper retaining ring (1).
4. Install the power brake booster pump (1).

Notice) .
5. Install the power brake booster pump bracket bolts (1).
Important: Note the location of the black negative wire and the red positive wire. The black negative
wire is toward the front of the vehicle. The red positive wire is toward the rear of the vehicle.
6. Connect the pump motor wire harness to the BPMV module. 7. Install the black negative wire
terminal screw and the plug (1).
Tighten the screw to 3 N.m (27 lb in).
8. Install the red positive wire terminal screw and the plug (2).
Tighten the screw to 3 N.m (27 lb in).

9. Install the power brake booster outlet front pipe. Refer to Power Brake Booster Outlet Front Pipe
Hose/Line/Service and Repair/Power Brake Booster Outlet Front Pipe Replacement) .
10. Install the power brake booster inlet hose. Refer to Power Brake Booster Inlet Hose
Hose/Line/Service and Repair/Power Brake Booster Inlet Hose Replacement) .
11. Install the hydraulic brake booster accumulator. Refer to Hydraulic Brake Booster Accumulator
Replacement (See: Hydraulic Fluid
Accumulator/Service and Repair/Removal and Replacement) .
Booster and Chassis
Hummer Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Fluid Accumulator >
Hydraulic Fluid Accumulator: Procedures
Power Brake Booster Pump Fluid Accumulator Disposal

Hummer Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Fluid Accumulator >
Hydraulic Fluid Accumulator: Removal and Replacement
Hydraulic Brake Booster Accumulator Replacement

Hummer Workshop Manuals > Brakes and Traction Control > Trailer Brakes > Trailer Brake Control Module > Component
Information > Technical Service Bulletins > Brakes - Aftermarket Trailer Brake Controller
Controller
INFORMATION
Models:
link connector.
system.
Information > Technical Service Bulletins > Brakes - Aftermarket Trailer Brake Controller > Page 6527
instrument panel.
functions.
- White: ground
circuit #742:
circuit.
Disclaimer
Hummer Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control >
Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls: > 07221 > Sep > 07 >
Condition
reversed.
Correction
Vehicles Involved
Important:
System (GMVIS).
recall.
Parts Information
will be provided.
NOTICE:
up to date.

guidelines.
Claim Information

Disclaimer
Service Procedure
Important:
individual vehicle.
disconnected.
Step 5.
Important:
Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls: > NHTSA07V373000 >
Aug > 07 > Recall 07V373000: ABS Wheel Speed Sensor Wiring
be reversed.
a crash.
Electronic Brake Control Module > Component Information > Technical Service Bulletins > Customer Interest: >

TECHNICAL
Date: July 22, 2008
Supercede:
Condition
^ No crank.
Correction
possible concern.
Repair
Electronic Brake Control Module > Component Information > Technical Service Bulletins > Customer Interest: >
as needed.
needed.
block.
above for location.
Disclaimer
Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins
for Electronic Brake Control Module: > 08-08-49-010B > Jul > 08 > Computers/Controls - Mutiple Malfunctions/DTC's Set
TECHNICAL
Date: July 22, 2008
Supercede:
Condition
^ No crank.
Correction
possible concern.
Repair
for Electronic Brake Control Module: > 08-08-49-010B > Jul > 08 > Computers/Controls - Mutiple Malfunctions/DTC's Set >
Page 6571
as needed.
needed.
block.
above for location.
Disclaimer
for Electronic Brake Control Module: > 07221 > Sep > 07 > Recall - Wheel Speed Sensor Wiring/EBCM programming
Condition
reversed.
Correction
Vehicles Involved
for Electronic Brake Control Module: > 07221 > Sep > 07 > Recall - Wheel Speed Sensor Wiring/EBCM programming >
Page 6576
Page 6577
Page 6578
Page 6579
Page 6580
Page 6581
Page 6582
Page 6583
Page 6584
Page 6585
Important:
System (GMVIS).
recall.
Parts Information
will be provided.
NOTICE:
Page 6586
up to date.

guidelines.
Claim Information

Page 6587
Disclaimer
Service Procedure
Important:
individual vehicle.
Page 6588
disconnected.
Step 5.
Page 6589
Page 6590
Page 6591
Important:
Page 6592
for Electronic Brake Control Module: > NHTSA07V373000 > Aug > 07 > Recall 07V373000: ABS Wheel Speed Sensor
Wiring
Speed Sensor Wiring
be reversed.
a crash.
Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for
Electronic Brake Control Module: > 08-08-49-010B > Jul > 08 > Computers/Controls - Mutiple Malfunctions/DTC's Set
TECHNICAL
Date: July 22, 2008
Supercede:
Condition
^ No crank.
Correction
possible concern.
Repair
Electronic Brake Control Module: > 08-08-49-010B > Jul > 08 > Computers/Controls - Mutiple Malfunctions/DTC's Set >
Page 6602
as needed.
needed.
block.
above for location.
Disclaimer
Electronic Brake Control Module: > 07221 > Sep > 07 > Recall - Wheel Speed Sensor Wiring/EBCM programming
Condition
reversed.
Correction
Vehicles Involved
Electronic Brake Control Module: > 07221 > Sep > 07 > Recall - Wheel Speed Sensor Wiring/EBCM programming > Page
6608
6609
6610
6611
6612
6613
6614
6615
6616
6617
Important:
System (GMVIS).
recall.
Parts Information
will be provided.
NOTICE:
6618
up to date.

guidelines.
Claim Information

6619
Disclaimer
Service Procedure
Important:
individual vehicle.
6620
disconnected.
Step 5.
6621
6622
6623
Important:
6624
Electronic Brake Control Module: > NHTSA07V373000 > Aug > 07 > Recall 07V373000: ABS Wheel Speed Sensor Wiring
Speed Sensor Wiring
be reversed.
a crash.
Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 6629
Engine Compartment
Accumulator
Engine Compartment
Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 6630
Accumulator
Electronic Brake Control Module > Component Information > Diagrams > Electronic Brake Control Module (EBCM) X1

Electronic Brake Control Module > Component Information > Diagrams > Electronic Brake Control Module (EBCM) X1 >
Page 6633
Electronic Brake Control Module > Component Information > Diagrams > Electronic Brake Control Module (EBCM) X1 >
Page 6634

Electronic Brake Control Module > Component Information > Diagrams > Page 6635
Notice) .
reserve.
contamination.
contamination.
Instrument


Notice) .




Hummer Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Traction
Control Module > Component Information > Technical Service Bulletins > Customer Interest for Traction Control Module: >
TECHNICAL
Date: July 22, 2008
Supercede:
Condition
^ No crank.
Correction
possible concern.
Repair
Control Module > Component Information > Technical Service Bulletins > Customer Interest for Traction Control Module: >
as needed.
needed.
block.
above for location.
Disclaimer
Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Traction Control
Module: > 08-08-49-010B > Jul > 08 > Computers/Controls - Mutiple Malfunctions/DTC's Set

TECHNICAL
Date: July 22, 2008
Supercede:
Condition
^ No crank.
Correction
possible concern.
Repair
Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Traction Control
Module: > 08-08-49-010B > Jul > 08 > Computers/Controls - Mutiple Malfunctions/DTC's Set > Page 6657
as needed.
needed.
block.
above for location.
Disclaimer
Hummer Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Trailer
Brake Control Module > Component Information > Technical Service Bulletins > Brakes - Aftermarket Trailer Brake
Controller
Controller
INFORMATION
Models:
link connector.

system.
Controller > Page 6662
instrument panel.
functions.
- White: ground
circuit #742:
circuit.
Disclaimer
Hummer Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control >
Replacement


Hummer Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake
Fluid Level Sensor/Switch > Component Information > Locations
Engine Compartment
Accumulator
Engine Compartment
Fluid Level Sensor/Switch > Component Information > Locations > Page 6674
Accumulator
Fluid Level Sensor/Switch > Component Information > Locations > Page 6675

Hummer Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Lateral
(SDM)
Hummer Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Lateral

Parking Brake Warning Switch > Component Information > Diagrams
Park Brake Switch

Parking Brake Warning Switch > Component Information > Diagrams > Page 6683
Removal Procedure

Connection) .
lamp switch.
Parking Brake Warning Switch > Component Information > Diagrams > Page 6684

Hummer Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
07 > Recall - Wheel Speed Sensor Wiring/EBCM programming
Condition
reversed.
Correction
Vehicles Involved
Important:
System (GMVIS).
recall.
Parts Information
will be provided.
NOTICE:
up to date.

guidelines.
Claim Information

Disclaimer
Service Procedure
Important:
individual vehicle.
disconnected.
Step 5.
Important:
Speed Sensor > Component Information > Technical Service Bulletins > Recalls for Wheel Speed Sensor: >
be reversed.
a crash.
Sensor: > 07221 > Sep > 07 > Recall - Wheel Speed Sensor Wiring/EBCM programming
Condition
reversed.
Correction
Vehicles Involved
Important:
System (GMVIS).
recall.
Parts Information
will be provided.
NOTICE:
up to date.

guidelines.
Claim Information

Disclaimer
Service Procedure
Important:
individual vehicle.
disconnected.
Step 5.
Important:
Sensor: > NHTSA07V373000 > Aug > 07 > Recall 07V373000: ABS Wheel Speed Sensor Wiring
Sensor Wiring
be reversed.
a crash.
Front Suspension
Rear Suspension
Left
Speed Sensor > Component Information > Diagrams > Wheel Speed Sensor (WSS) - Left Front




Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement
Front Wheel Speed Sensor Replacement Caution: Refer to Brake Dust Caution (See: Service
Removal Procedure
Brake Rotor Replacement (See: Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal
and
Replacement (See: Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and
Antilock Brake System (See: Antilock Brakes / Traction Control Systems/Testing and
Inspection/Initial
Inspection and Diagnostic Overview/Diagnostic Starting Point - Antilock Brake System) .

Rear Wheel Speed Sensor Replacement Caution: Refer to Brake Dust Caution (See: Service
Removal Procedure

Notice) .

(See: Antilock Brakes / Traction Control Systems/Testing and Inspection/Symptom Related
Diagnostic Procedures/Symptoms - Antilock Brake System) .
System (See: Antilock Brakes / Traction Control
Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Starting

Point - Antilock Brake System) .
Hummer Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Yaw
Rate Sensor > Component Information > Locations
(SDM)
Rate Sensor > Component Information > Locations > Page 6755

Rate Sensor > Component Information > Locations > Page 6756

Hummer Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Battery Current
Sensor > Component Information > Diagrams

Removal Procedure
1. Remove the negative battery cable. Refer to Battery Negative Cable Replacement (See:
Battery/Battery Cable/Negative/Service and
Repair/Battery Negative Cable Replacement) .
cable. Refer to Battery Negative Cable Replacement (See: Battery/Battery Cable/Negative/Service
and Repair/Battery
Negative Cable Replacement) .

Hummer Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch >
Ignition Switch Lock Cylinder > Component Information > Service and Repair > Procedures
kit.
Removal Procedure

lock cylinder case.


Hummer Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay >
Hummer Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay >
Starter Relay: Service and Repair
Starter Motor Relay Replacement
Removal Procedure
1. Remove the underhood bussed electrical center (UBEC) cover. 2. Remove the starter motor
relay. Refer to Relay Replacement (Attached to Wire Harness) (See: Power and Ground
Distribution/Power Distribution
Relay/Service and Repair/Relay Replacement (Attached to Wire Harness))Relay Replacement

(Within an Electrical Center) (See: Power and Ground Distribution/Power Distribution Relay/Service
and Repair/Relay Replacement (Within an Electrical Center)) .
1. Install the starter motor relay. Refer to Relay Replacement (Attached to Wire Harness) (See:
Power and Ground Distribution/Power Distribution
Relay/Service and Repair/Relay Replacement (Attached to Wire Harness))Relay Replacement

(Within an Electrical Center) (See: Power and Ground Distribution/Power Distribution Relay/Service
and Repair/Relay Replacement (Within an Electrical Center)) .
2. Install the UBEC cover.

Hummer Workshop Manuals > Starting and Charging > Battery > Battery Cable > Negative, Battery Cable > System
Information > Service and Repair > Battery Negative Cable Replacement
Negative: Service and Repair Battery Negative Cable Replacement
Battery Negative Cable Replacement
Removal Procedure
Connection (See: Service and Repair/Battery Negative
Cable Disconnection and Connection) .
2. Raise and suitably support the vehicle with safety stands. Refer to Lifting and Jacking the
Vehicle (See: Maintenance) . 3. Remove the engine protection shield. Refer to Engine Protection
Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair
).
4. Remove the forward lamp wiring harness ground/negative cable bolt. 5. Remove the engine
wiring harness ground/negative cable bolt. 6. Remove the negative battery cable.
1. Install the negative battery cable. 2. Position the negative cable and forward lamp wiring harness
ring terminals to the frame.
Insert the anti-rotation tab on the forward lamp wiring harness into the hole in the frame. Notice:
Refer to Fastener Notice (See: Service Precautions/Vehicle Damage Warnings/Fastener Notice) .
3. Install the forward lamp wiring harness ground/negative cable bolt.
Tighten the forward lamp wiring harness ground/negative cable bolt to 9 N.m (80 lb in).
4. Position the negative cable and engine wiring harness ring terminals to the engine block.
Position the anti-rotation tab on the negative cable in the
correct location.
5. Install the engine wiring harness ground/negative cable bolt.
Tighten the engine wiring harness ground/negative cable bolt to 25 N.m (18 lb ft).
Information > Service and Repair > Battery Negative Cable Replacement > Page 6783
and Frame/Frame/Skid Plate/Service and Repair) . 7. Lower the vehicle. 8. Install the negative
cable clip to the positive cable clip.
Connection (See: Service and Repair/Battery Negative
Cable Disconnection and Connection) .

Information > Service and Repair > Battery Negative Cable Replacement > Page 6784
Negative: Service and Repair Engine Ground Strap Replacement
Engine Ground Strap Replacement
Removal Procedure
1. Remove the left hand catalytic convert. Refer to Catalytic Converter Replacement (See: Engine,
Cooling and Exhaust/Exhaust System/Catalytic
Converter/Service and Repair) .
2. Remove the engine wiring harness ground bolt. 3. Lower the vehicle.
4. Remove the ground strap nut from the stud at the front of dash. 5. Remove the ground strap
from the stud.
1. Install the ground strap to the stud.

Notice) .
2. Install the ground strap nut to the stud at the front of dash.
Hummer Workshop Manuals > Starting and Charging > Battery > Battery Cable > Ne

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Alarm Module: Locations

Instrument Panel/Center Console Component Views

Steering Column Components

Alarm Module: Service and Repair

Theft Deterrent Module Replacement

Central Control Module: Locations

Instrument Panel/Center Console Component Views

Instrument Panel Harness Components

Component Connector End Views

Vehicle Communication Interface Module (VCIM) X1 (UE1)

Component Connector End Views

Vehicle Communication Interface Module (VCIM) X2 (UE1)

Communications Control Module: Service and Repair

Communication Interface Module Replacement

Bulletin No.: 07-08-46-002D

Date: July 29, 2009

Warranty Information (excluding Saab U.S. Models)

For vehicles repaired under warranty, use the table above.

Warranty Information (Saab U.S. Models)

Bulletin No.: 02-08-46-006C

Date: January 08, 2008

It is not necessary to reconfigure the vehicle after the following procedure.

Warranty Information (excluding Saab US Models)

For vehicles repaired under warranty, use the table.

Warranty Information (Saab US Models)

For vehicles repaired under warranty use, the table.

Date: January 08, 2008

Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another

Models: 2000-2008 GM Passenger Cars and Trucks 2003-2008 HUMMER H2 2006-2008

with OnStar(R) (RPO-UE1)

Cycle the ignition to Off and open the drivers door.

Warranty Information (excluding Saab U.S. Models)

For vehicles repaired under warranty use, the table.

Warranty Information (Saab U.S. Models)

For vehicles repaired under warranty use, the table.

Date: November 19, 2007

with OnStar(R) System (RPO UE1)

Not all vehicles will require VIU/VCIM replacement.

How to Order Parts

Warranty Information (excluding Saab U.S. Models)

For vehicles repaired under warranty, use the table.

Warranty Information (Saab U.S. Models)

For vehicles repaired under warranty, use the table.

Bulletin No.: 07-08-46-002D

Date: July 29, 2009

Warranty Information (excluding Saab U.S. Models)

For vehicles repaired under warranty, use the table above.

Warranty Information (Saab U.S. Models)

Bulletin No.: 02-08-44-007D

Date: May 12, 2009

Subject: Negative Impact of Dealer-Installed Cloth/Vinyl Roofs on XM Radio and/or OnStar(R)

Bulletin No.: 08-08-46-004

Date: August 14, 2008

Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services

with OnStar(R) (RPO UE1)

When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic

Date: January 09, 2008

Subject: Availability of OnStar(R) for Hearing Impaired

This service bulletin is not applicable to GM of Canada dealers and retailers.

OnStar with Text Telephone Capability (TTY)