Wiring Systems and Power Management 112523

Vehicle Will Not Change Power Mode

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

Open/High Signal
Circuit Short to Ground Resistance Short to Voltage Performance
8+ 8137004, 8137004, _ _
8138004 8138004
.. . 8137004, 8137004,
lgnItIonTermIna|1 8138004 8138004 8137001 -
WW,
2.
.2
M.
,,2,....__~\_,4,.
\WWWWM
,.
«.
.. . 8137004,
lgnItIonTermInal3 8138004 8138004 8138001 -
8137004, '
IgnitionTerminal4 8138004, 8144104 8144101 ~
8144104
5 V Reference , — 1 — ~-
1.PowerModeMismatch

CircuitlSystem Description I Electrical Information Reference

The vehicle power mode master is the body control Circuit Testing on page 11-526
module (BCM). The ignition switch is a low current
switch with multiple discrete circuits to the BCM. The Connector Repairs on page 11-548
BCM logic uses the ignition switch positions to identify Testing for IntermittentConditions and Poor
the operator's desired power mode and activate Connections on page 11-531
specific discrete signals, and serial data messages for Wiring Repairs on page 11—537
the operation of different subsystems as necessary.
Other modules which have switched voltage inputs may Scan Tool Reference
operate in a default mode if the power mode master Control Module References on page 6-3 for scan tool
serial data message does not match what the individual information
module can detect from its own connections.
The power mode master will activate relays and other CircuitlSystem Verification
direct outputs of the power mode master as needed 1. Verify DTC U1814 is not set.
according to the calculated power mode. Some relays
2 If DTC is set
controlled by the BCM are switched ignition voltage
outputs that are pass through circuits within the BCM Refer to Diagnostic Trouble Code (DTC) List -
directly from the ignition switch. it these circuits short to Vehicle on page 6—69.
ground, the 8+ circuit fuse to the ignition switch If DTC is not set
will open.
.N ignition ON.
Reference Information Verify the scan tool power mode parameters
change when cycling the S39 Ignition Switch
Schematic Reference between OFF, ACCESSORY, ON, and CRANK.
Power Distribution Schematics on page 11-128 if the power mode parameters do not change
Connector End View Reference Refer to CircuitlSystem Testing.
Component Connector End Views on page 11—269 If the power mode parameters change
. All OK.
Description and Operation
Power Mode Description and Operation on
page 11-614

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11:524 Wiring Systems and Power Management

CircuitlSystem Testing 2 Ifless than 1 V, replace the K9 Body Control

Module.
1. ignition ON, disconnect the harness connector at
the S39 IgnitionSwitch while the ignition is ON. If between 4.8—5.2V
2. Verify a test lamp illuminates between the 8+ . Connect the harness connector at the S39 Ignition
circuit terminal 2 and ground. Switch.
:> If the test lamp does not illuminate and the IgnitionOFF.
circuit fuse is good . Disconnect the X3 harness connector at the K9
2.1. IgnitionOFF, remove the test lamp. Body Control Module, ignition ON.
2.2. Test for less than 2 Q in the 8+ circuit and . Verify a test Iamp illuminates between each of the
to end. ignition circuits listed below and ground: -wfl
_WW
.../2
.
2 If2 Q or greater, repair the open/high resistance . Ignitioncircuitterminal5
in the circuit. ° Ignitioncircuit terminal 6
2 Ifless than 2 Q, verify the fuse is good and If the test Iamp does not illuminate and the
there is voltage at the fuse. circuit fuse is good
If the test lamp does not illuminate and the 8.1. ignition OFF remove the test lamp.
circuit fuse is open 8.2. Test for less than 2 Q in the ignition circuit end
2.1. ignition OFF remove the test lamp. to end.
2.2. Test for infinite resistance between the 8+ 2 If2 Q or greater, repair the open/high resistance
circuit and ground. in the circuit.
2 Ifless than infinite resistance, repair the short to 2 if less than 2 Q, verify the fuse is good and
ground on one of the following circuits listed there is voltage at the fuse.
below: If the test lamp does not illuminate and the
Note: To help isolate a short to ground, it may be circuit fuse is open
necessary to disconnect modules that are connected to 8.1. IgnitionOFF remove the test lamp.
the following circuits:
8.2. Test for infinite resistance between the ignition
- 8+ circuitterminal 2 circuits listed below and ground.
- Ignitioncircuit terminal 1 - Ignitioncircuit terminal 5
. Ignitioncircuit terminal 3 - Ignitioncircuit terminal 6
° Ignitioncircuit terminal 4 2 Ifless than infinite resistance, repair the short to
U If the test lamp illuminates ground on the circuit.
3. IgnitionON. U Ifinfinite resistance, replace the K9 Body
4. Test for 4.8—5.2V between the 5 V reference circuit Control Module.
terminal 6 and ground. If the test Iamp illuminates
z) If less than 4.8 V IgnitionOFF with the key in.
4.1. IgnitionOFF, disconnect the X3 harness . Verify a test lamp illuminates between ignition
connector at the K9 Body Control Module. circuit terminal 15 and ground.
4.2. Test for infinite resistance between the 5 V If the test lamp does not illuminate and the
reference circuit and ground. circuit fuse is good
2 if less than infinite resistance, repair the short to 10.1. IgnitionOFF with the key out, remove the
ground on the circuit. test lamp.
U Ifinfinite resistance 10.2. Test for less than 2 Q in the ignition circuit
end to end.
4.3. Test for less than 2 Q in the 5 V reference
circuit end to end. 2 lf2 Q or greater, repair the open/high resistance
in the circuit.
2 If2 Q or greater, repair the open/high resistance
in the circuit.
2 Ifless than 2 Q, replace the K9 Body Control
Module.
if greater than 5.2 V
4.1. IgnitionOFF, disconnect the X3 harness
connector at the K9 Body Control Module.
4.2. Test for less than 1 V between the 5 V
reference circuit and ground.
2 If 1 V or greater, repair the short to voltage on
the circuit.

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 Wiring Systems ,-
and Power Management 111525
2 If less than 2 Q, verify the fuse is good and 13. Test for less than 1 V between each of the ignition
there is voltage at the fuse. circuits listed below and ground.
2 If the test lamp does not illuminate and the 1 Ignitioncircuitterminal 1
circuit fuse is open 1 ignition circuit terminal 3
10.1. IgnitionOFF with the key out remove the 1 Ignitioncircuit terminal 4
test Iamp.
2 lf1Vor greater
10.2. Test for infinite resistance between the
ignition circuit terminal 15 and ground. Repair the short to voltage on the circuit.
2 If less than infinite resistance, repairthe short to U If less than 1 V
ground on the circuit. 14. Test or replace the 839 IgnitionSwitch.
U lf infinite resistance, replace the K9 Body
Control Module. Component Testing
1. ignition OFF, disconnect the harness connector at
U If the test lamp illuminates
the 839 ignition Switch.
11. Connect the X3 harness connector at the K9 Body
2. Using the Resistance Test below, verify the
Control Module, ignition ON.
resistance between the terminals listed below
12. Disconnect the harness connector at the 839 match for each 839 IgnitionSwitch position.
Ignition Switch.
2 If any reading is other than specified
Replace the S39 IgnitionSwitch.
U If the readings match
3. All OK.
Resistance Test
IgnitionSwitch
Position Terminals 1 and 2 Terminals2 and 3 Terminals2 and 4 Terminals2 and 6 Terminals 4 and 6
OFF Key Out Infinite Infinite infinite Infinite infinite
OFF Key in Infinite Infinite <5.0Q Infinite Infinite
Accessory infinite <5.0Q Infinite Infinite Infinite
Run <5.0Q <5.0Q Infinite Infinite <5.0Q ‘
Start <5.0Q Infinite Infinite Infinite 1275—1325 Q

Repair Instructions malfunction indicator lamp (MIL) to turn ON, or causes

Perform the Diagnostic Repair Verification on
page 6-92 after completing the repair.
1 Ignition and Start Switch Replacement on
page 11-612
1 Control Module References on page 6-3 for body
control module replacement, programming and
setup
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be
difficult to use the diagnostic procedures contained in
the service manual. You should understand the basic
theory of electricity, and know the meaning of voltage
(V), current (A), and resistance (Q). You should also be
able to read and understand a wiring diagram, as well
as understand what happens in a circuit with an open or
a shorted wire.
Checking
Aftermarket Accessories
Warning: Refer to SIR Warning on page 0-7.
Caution: The 08D ll symbol is used on the circuit
diagrams in order to alert the technician that the circuit
is essential for proper 08D ll emission control circuit
operation. Any circuit which fails and causes the
emissions-related component damage, is identified as
an 08D |l circuit.
Do not connect aftermarket accessories into the
following circuits:
1 SIR circuits, all such circuits are indicated on
circuit diagrams with the SIR symbol.
1 088 ll circuits, all such circuits are indicated on
circuit diagrams with the 080” symbol.
Always check for aftermarket accessories (non—OEM)
as the first step in diagnosing electrical problems. Ifthe
vehicle is so equipped, disconnect the system to verify
that these add—onaccessories are not the cause of the
problems.
Possible causes of vehicle problems related to
aftermarket accessories include:
1 Power feeds connected to points other than the
battery
1 Antenna location
1 Transceiver wiring located too close to vehicle
electronic modules or wiring
1 Poor shielding or poor connectors on antenna
feed line
1 Check for recent service bulletins detailing
installation guidelines for aftermarket accessories.

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111-526 Wiring Systems and Power Management

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.
1 Using Connector TestAdapters on page 11-526
1 Probing Electrical Connectors on page 11-526
1 Troubleshooting with a Digital Multimeter on
page 11—527
1 Troubleshooting with a Test Lamp on page 11-528
1 Using Fused Jumper Wires on page 11-529
1 Measuring Voltage on page 11-529
1 Measuring Voltage Drop on page 11-529
1 Measuring Frequency on page 11-529
1 Testing Ground and Low Reference Circuits on
page 11-530
1 Testing for Continuity on page 11—530
1 Testing for Short to Ground on page 11-530
1 Testing for a Short to Voltage on page 11—531
1 Testing for IntermittentConditions and Poor
Connections on page 11-531
1 Inducing IntermittentFault Conditions on
page 11-533
1 Testing for Electrical Intermittentson page 11-534
1 Scan Tool Snapshot Procedure (GDS) on
page 11-535
1 Circuit Protection - Fuses on page 11—536
1 Circuit Protection - Circuit Breakers on
page 11-536
1 Circuit Protection - Fusible Links on page 11-536
Using Connector Test Adapters
Special Tools
1 EL-35616 Terminal Test Probe Kit
1 EL-38125—550Terminal Release Tool Kit
For equivalent regional tools, refer to Special Tools on
page 11—616.
Caution: Do not insert test equipment probes (DMM
etc.) into any connector or fuse block terminal. The
diameter of the test probes will deform most terminals.
A deformed terminal will cause a poor connection,
which will result in a system failure. Always use the
EL-35616 GM Approved Terminal Test Probe Kit in
order to front probe terminals. Do not use paper clips or
other substitutes to probe terminals.
When using the EL-35616 GM Approved Terminal Test
Probe Kit, ensure the terminal test adapter choice is the
correct size for the connector terminal. Do not visually
choose the terminal test adapter because some
connector terminal cavities may appear larger than the
actual terminal in the cavity. Using a larger terminal test
adapter will damage the terminal. Refer to the
EL—35616 GM Approved Terminal Test Probe Kit label
on the inside of the EL-35616 GM Approved Terminal
Test Probe Kit for the correct adapter along with the
connector end view.
Probing Electrical Connectors
Special Tools
EL-35616 Terminal Test Probe Kit
For equivalent regional tools, refer to Special Tools on
page 11-616.
Note: Always be sure to reinstall the connector
position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or
replacing terminals.
Front probe
Disconnect the connector and probe the terminals from
the mating side (front)of the connector.
Caution: Refer to Test Probe Caution on page 0-10.
Note: When probing female 0.64terminals, 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-35616-648 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.
Note: The proper adapter for probing the terminals for
fuses, relays, or diodes in an electrical center is
J-35616-35. Using any other tool or adapter may
damage the terminal being tested.
Refer to the following table as a guide in selecting the
correct test adapter for front probing connectors:

Test Adapter Description

J-35616-2A 150MaleProbeAdapter(gray)
J-35616-3 150FemaleProbeAdapter(gray)
J-35616-4A 280Male ProbeAdapter(purple)
J-35616-5 280FemaleProbeAdapter(purple)
J—35616—6 100WMale(round)ProbeAdapter(brown)
J—35616-7 100WFemale(round)ProbeAdapter(brown)
J-35616-8 1 WeatherPack Male ProbeAdapter(orange)
J-35616-9 WeatherPack FemaleProbeAdapter(orange)
J—35616-10 100WMale(round)ProbeAdapter(green)
J—35616-11 100WFemale(round)ProbeAdapter(green)
J-35616-12 130MaleProbeAdapter(blue)

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Test Adapter Description
J-35616-13 130FemaleProbeAdapter(blue)
J-35616-14 150MaleProbeAdapter(green)
J—35616—16 100Male ProbeAdapter(Itgreen)
J—35616—17 100FemaleProbeAdapter(Itgreen)
J-35616-18 220 MaleProbeAdapter(black)
J—35616—19 220 FemaleProbeAdapter(black)
J—35616-21 950 FemaleProbeAdapter(red)
J—35616—22 950Male ProbeAdapter(red)
J—35616-31 500MaleProbeAdapter(orange)
J—35616-32 500 FemaleProbeAdapter(orange)
J-35616-33 160/180MaleProbeAdapter(yellow)
J-35616-34 160/180FemaleProbeAdapter(yellow)
J-35616—35 280 MaleProbeAdapter(violet)
J—35616-40 480 MaleProbeAdapter(dkblue)
J-35616-41 480 FemaleProbeAdapter(dkblue)
J-35616-42 630Male ProbeAdapter(red)
J-35616-43 630 FemaleProbeAdapter(red)
J-35616-44 800Male ProbeAdapter(yellow)
J—35616-45 800FemaleProbeAdapter(yellow)
J-35616-54 280 Male(round)ProbeAdapter(tan)
J-35616-55 280 Female(round)ProbeAdapter(tan)
J-35616-648 0.64MaleProbeAdapter(ltblue)
J-35616-658 0.64FemaleProbeAdapter(Itblue)
J-35616-66 150Male(round)ProbeAdapter(yellow)
J-35616-67 150Female(round)ProbeAdapter(yellow)

Backprobe Troubleshooting with a Digital

Note:
1 Backprobe connector terminals only when
specifically required in diagnostic procedures.
1 Do not backprobe a sealed (Weather Pack®)
connector, less than a 280 series Metri—Pack
connector, a Micro—Packconnector, or a flat wire
connector.
1 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.
1 After backprobing any connector, inspect for
terminal damage. lfterminal 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.
Multimeter
Special Tools
EL—39200 Digital Multimeter (DMM)
For equivalent regional tools, refer to Special Tools on
page 11-616.
Caution: Refer to Test Probe Caution on page 0—10.
Digital Multimeter (DMM) Basic
Requirements
Service information is validated using digital
multimeters that meet or exceed the following
requirements. Using a multimeter that does not meet
these basic requirements may give inaccurate readings
which could lead to an incorrect diagnosis.
Display and Settings
1. Fourdigits displayed
2. Voltage, current, resistance, frequency, diode test
settings, and min-max function
3. Display positive and negative values

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‘11-528 Wiring Systems and Power Management
Voltage
1. Have at least 10 MQ input impedance
2. Test a DC voltage range of 0.1—1000 V.
3. Test an AC voltage range of 0.1—1000‘V.
Current ‘ continuous monitoring while you perform other
1. Test a DC current range of 0.1 pA—10A.
2. Test an AC current range of 0.1 uA—10A.
Resistance
Test a resistance range of 0.1 Q—40MQ and displays
infinite for a value greater than 40 MQ (O.L.
(Over—load))
Frequency
Test for a frequency range of 0.5 Hz~199 k Hz
Diode Test
1. Apply at least 1 mA when performing the diode
bias test
2. Display the break over voltage drop (0—3V) of a
forward biased diode
when a diode is
3. Display infinite (O.L. (Over—Ioad))
reverse biased
Min-Max Readings
1. Can update at a 25 ms sample rate
2. Saves and displays minimum and maximum
values
Note: Circuits which include any solid state control
modules, such as the engine control module (ECM),
should only be tested with a 10 MQ or higher
impedance digital multimeter such as the EL—39200.
The DMM instruction manual is a good source of
information and should be read thoroughly upon receipt
of the DMM as well as kept on hand forfuture
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 otherwords, 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.
Note: 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:
1 Probe both ends of the connector and either hold
the leads in place while manipulating the
connector or tape the leads to the harness for
operations or test driving. Refer to Probing
Electrical Connectors on page 11—526.
.wm
.\,_
.2
1 Disconnect the harness at both ends of the
suspected circuit where it connects either to a
component or to other harnesses.
1 Ifthe 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
Special Tools “2”2..
..M
EL—35616-200Test Light —Probe Kit
For equivalent regional tools, refer to Special Tools on
page 11-616.
Caution: Refer to Test Probe Caution on page 0—10.
A test Iamp can simply and quickly test a low
impedance circuit for voltage. A Digital Multimeter
(DMM) should be used instead ofa 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 Iampwill not illuminate even though
voltage is present.
The EL-35616-200 kit is Mioro-Pack compatible and
comprised of a 12 V 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.
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 Wiring Systems and Power Management 111529
Using Fused Jumper Wires 5. Connect the negative lead of the DMM to a good
ground.
Special Tools 6. The DMM displays the voltage measured at that
EL 35616-20F Fused Jumper Wire point.
For equivalent regional tools, refer to Special Tools on
page 11-616. Measuring Voltage Drop
Note: A fused jumper may not protect solid state Special Tools
components from being damaged.
EL—39200 Digital Multimeter (DMM)
For equivalent regional tools, refer to Special Tools on
page 11—616.
Caution: Refer to Test Probe Caution on page 0—10.
The following procedure determines the difference in
voltage potential between 2 points.

HotAtAllTimes
Fuse ,
Block
< 20 3)
RED
1 Switch
DMM K
(+)
312/“Ht
/
t" IBLU
i Solenoid
2389094
The EL 35616-20F Fused Jumper Wire includes
banana jack connectors that provide adaptation to most
.MWN‘
.. 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. 61704
1. Set the Digital Multimeter (DMM) to the V (DC)
Measuring Voltage position.
2. Connect the positive lead of the DMM to one point
Special Tools of the circuit to be tested.
EL-39200 Digital Multimeter (DMM) 3. Connect the negative lead of the DMM to the other
For equivalent regional tools, refer to Special Tools on point of the circuit.
page 11—616. 4. Operate the circuit.
Caution: Refer to Test Probe Caution on page 0-10. 5. The DMM displays the difference in voltage
The following procedure measures the voitage at a between the 2 points.
selected point in a circuit.
1. Disconnect the electrical harness connector for the Measuring Frequency
circuit being tested, if necessary. Special Tools
2. Enable the circuit and/or system being tested. Use
the following methods: EL—39200 Digital Multimeter (DMM)
1 Turn ON the ignition, with the engine OFF. For equivalent regional tools, refer to Special Tools on
page 11-616.
1 Turn ON the engine.
Caution: Refer to Test Probe Caution on page 0—10.
*1 Turn ON the circuit and/or system with a scan
tool in Output Controls. The f<|3l|owingprocedure determines the frequency of a
SIgna.
1 Turn ON the switch for the circuit and/or system
being tested. Note: Connecting the Digital Multimeter (DMM) to the
circuit before pressing the Hz button will allow the DMM
3. Select the V (AC) orV (DC)position on the Digital to autorange to an appropriate range.
Multimeter (DMM).
4. Connect the positive lead of the DMM to the point 1. Apply power to the circuit.
of the circuit to be tested. 2. Set the DMM to the V (AC) position.

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11=530 Wiring Systems and Power Management
3. Connect the positive lead of the DMM to the circuit 1 Any accessory that can work when the ignition
to be tested. is OFF
4. Connect the negative lead of the DMM to a good 1 Wait up to 60 seconds (after all other listed
ground. conditions are met)
5. Set to Hz on the DMM. Activating the DOOR LOCK function with a key fob can
6. The DMM will display the frequency measured. greatly reduce the time to achieve a valid ground or low
reference continuity test result.
Testing Ground and Low Reference
Testing for Continuity
Circuits
Because a test lamp can light with up to 200 Q in a Special Tools Wx"
‘\.4
....M
ground or low reference circuit they are not EL-39200 Digital Multimeter (DMM)
recommended to be used for this type of test. A low For equivalent regional tools, refer to Special Tools on
impedance test lamp can light and indicate the circuit is page 11-616.
good when there is as much as 20—30Q present, while
a high impedance test lamp can light with up to 200 Q Caution: Refer to Test Probe Caution on page 0-10.
present in the circuit. This is why the Digital Multi-Meter The following procedures verify good continuity in a
(DMM) is used when validating a ground or low circuit.
reference circuit continuity.
With a Digital Multimeter (DMM)
When using the DMM there are many vehicle
conditions that can affect the ground and low reference 1. Set the DMM to the Q position.
continuity testing. Ifthese conditions are not met, a 2. Disconnect the power feed (i.e. fuse, control
ground or low reference circuit test can fail on a good module) from the suspect circuit.
circuit. This may cause longer diagnosis time and 3. Disconnect the load.
incorrect component replacement.
4. Select the MlN MAX function on the DMM.
Any current flow through a ground or low reference
circuit, while being tested, will skew the DMM continuity 5. Connect one lead of the DMM to one end of the
reading, or display a reading higher than when there is circuit to be tested.
no current flowing. Performing a ground or low 6. Connect the other lead of the DMM to the other
reference circuit continuity test, in reference to the end of the circuit.
vehicles battery negative terminal, will have the highest 7. Ifthe DMM displays low or no resistance, the
risk of failing a good ground or low reference circuit test circuit has good continuity.
than any other ground reference point. The best ground
test points would be a control module housing (if the With a Test Lamp
control modules housing is metal and grounded), door Note: Only use the test Iamp procedure on low
jamb striker (if attached to metal), under dash metal impedance power and ground circuits.
frame work, engine block, or body ground studs (other
than where the negative battery cable is attached). 1. Remove the power feed (i.e. fuse, control module)
A typical DMM ground or low reference circuit continuity from the suspect circuit.
reading can be as high as 100 Q with the ignition ON, 2. Disconnect the load.
and drop to 15—25Q after the ignition is turned OFF. 3. Connect one lead of the test lamp to one end of the
The reading will drop below 10 Q after 30—40seconds, circuit to be tested.
then below 5 Q after 60 seconds. Once the vehicle 4. Connect the other lead of the test lamp to battery
completely goes to sleep (generally 3-10 minutes) the positive voltage.
reading will drop below 0.3 Q.
5. Connect the other end of the circuit to ground.
The following list of conditions may need to be met to
ensure a valid continuity reading on a ground or low 6. if the test Iamp illuminates (full intensity),then the
reference circuit: circuit has good continuity.
1 Ignition OFF
Testing for Short to Ground
1 Key out of the ignition switch (when not equipped
with keyless entry and remote start) Caution: Refer to Test Probe Caution on page 0-10.
1 Retained Accessory Power (RAP) OFF (open and The following procedures test for a short to ground in a
close the driver door after ignition OFF) circuit.
1 Battery charger set at a 2 A or less charge rate With a Digital Multimeter (DMM)
1 Scan tool not communicating with any vehicle 1. Remove the power feed (i.e. fuse, control module)
control module (in some cases it may need to be from the suspect circuit.
disconnected from the DLC)
2. Disconnect the load.
1 All entry doors closed
3. Set the rotary dial of the DMM to the Q position.
1 Headlamps OFF (auto headlamps disabled)
4. Connect one lead of the DMM to one end of the
1 Any delay lighting OFF circuit to be tested.
1 HVAC after blow OFF

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5. Connect the otherlead of the DMM to a good Testing for Intermittent Conditions
ground.
6. lfthe DMM does NOT display infinite resistance and Poor Connections
(OL), there is a short to ground in the circuit. Special Tools
With a Test Lamp EL-35616 Terminal Test Probe Kit
1. Remove the powerfeed (i.e. fuse, control module) For equivalent regional tools, referto Special Tools on
from the suspect circuit. page 11—616.
2. Disconnect the load. When the condition is not currently present, but is
indicated in DTC history, the cause may be intermittent.
3. Connect one lead of the test lamp to battery
An intermittentmay also be the cause when there is a
positive voltage.
customer complaint, but the symptom cannot be
4. Connect the other lead of the test lamp to one end duplicated. Refer to the Symptom Table of the system
of the circuit to be tested. that is suspect of causing the condition before trying to
m
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5. lfthe test lamp illuminates, there is a short to locate an intermittentcondition.
ground in the circuit. Most intermittentconditions are caused by faulty
electrical connections or wiring. Inspect for the
Fuse Powering Several Loads following items:
1. Review the system schematic and locate the fuse 1 Wiring broken inside the insulation
that is open.
1 Poor connection between the male and female
2. Open the first connector or switch leading from the terminal at a connector
fuse to each load.
1 Poor terminal to wire connection —Some
3. Connect a DMM across the fuse terminals (be sure conditions which fall under this description are
that the fuse is powered). poor crimps, poor solderjoints, crimping over the
1 When the DMM displays voltage the short is in wire insulation rather than the wire itself, and
the wiring leading to the first connector or corrosion in the wire to terminal contact area, etc.
switch. 1 Pierced or damaged insulation can allow moisture
1 Ifthe DMM does not display voltage refer to the to enter the wiring causing corrosion. The
next step. conductor can corrode inside the insulation, with
4. Close each connector or switch until the DMM little visible evidence. Look for swollen and stiff
displays voltage in order to find which circuit is sections of wire in the suspect circuits.
shorted. 1 Wiring which has been pinched, cut, or its
insulation rubbed through may cause an
Testing for a Short to Voltage intermittentopen or short as the bare area
touches other wiring or parts of the vehicle.
Special Tools 1 Wiring that comes in contact with hot or exhaust
EL-39200 Digital Multimeter (DMM) components
For equivalent regional tools, refer to Special Tools on 1 Refer to Inducing IntermittentFault Conditions on
page 11—616. page 11—533in order to duplicate the conditions
Caution: Refer to Test Probe Caution on page 0-10. required, in order to verify the customer concern.
The following procedure tests for a short to voltage in a 1 Refer to Testing for Electrical Intermittentson
circuit. page 11—534 for test procedures to detect
1. Remove the powerfeed (i.e. fuse, control module) intermittentopen, high resistance, short to ground,
from the suspect circuit. and short to voltage conditions.
2. Disconnect the load. 1 Refer to Scan Tool SnapshotProcedure (GDS) on
page 11-535for advanced intermittentdiagnosis
3. Set the Digital Multimeter (DMM) to the V (DC) and Vehicle Data Recorder operation.
position.
4. Connect the positive lead of the DMM to one end of Testing for Terminal Fretting
the circuit to be tested. Some intermittentconditions can be caused by wire
5. Connect the negative lead of the DMM to a good terminal fretting corrosion. Fretting corrosion is a
ground. build-up of insulating, oxidized wear debris that can
6. Turn ON the ignition and operate all accessories. form when there is a small motion between electrical
contacts. The oxidized wear debris can pile up enough
7. Ifthe voltage measured is greater than 1 V, there is at the electrical contact spots that the electrical
a short to voltage in the circuit. resistance across the connection increases. Movement
between the contacting surfaces as small as 10 to 100
microns can cause fretting. To put this in perspective, a
sheet of paper is about 100 microns thick, so fretting
motion is small and hard to see. Vibration and thermal
expansion/contraction are the main sources that create
fretting motion. Since vehicles vibrate and can
experience large temperature swings, they are a good
source for fretting motion. Tin, copper, nickel, and iron
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111532 Wiring Systems and Power Management
surfaces are all susceptible to fretting corrosion.
Fretting corrosion can be difficult to see but it looks like
small, dark smudges on the terminals contact surface.
To correct a fretting condition disconnect the suspect
connector and add dielectric grease / lubricant (Nyogel
7606 or equivalent, meeting GM specification
9986087) to both sides of the connector terminals.
Then reconnect the connector and wipe away any
excess lubricant. This will correct the additional
terminal contact resistance due to the terminal fretting
corrosion.
Testing for Proper Terminal Contact
Itis 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 intermittentlyopen
circuit.
Deformation is caused by probing the mating side of a
connector terminal without the proper adapter. Always
use the EL-35616 kit 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 intermittentlyopen
circuit.
Testing for Proper Terminal Contact in Bussed
Electrical Centers
Itis very important to use the correct test adapter when
testing for proper terminal contact of fuses and relays in
a bussed electrical center. Use the EL-35616 kit to test
for proper terminal contact. Failure to use the EL—35616
kit can result in improper diagnosis of the bussed
electrical center.
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 buiId-upwithin the connector body or
between terminals. This causes high terminal
resistance, intermittentcontact, 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/terminatedlead,
verify that the retention force is significantly
different between a known good terminal and the
suspect terminal. Replace the female terminal in
question.
Flat Wire Connectors
There are no serviceable parts for flat wire connectors
on the harness side or the component side.
Follow the procedure below in order to test terminal
contact:
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.
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.
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 into 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.
1 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
moduIe/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.
Operate the component to test the ability of the
circuit to carry sufficient current. Refer to Circuit
Testing on page 11—526and Power Distribution
Schematics on page 11-128.
1 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. Operate the component to test
the ability of the circuit to carry sufficient current.
Refer to Circuit Testing on page 11-526and
Ground Distribution Schematics on page 11-152.
Temperature Sensitivity
1 An intermittentcondition may occurwhen a
component/Connection reaches normal operating
temperature. The condition may occur only when
the component/conneotion is cold, or only when
the component/connection is hot.
1 Freeze Frame, Failure Records, Snapshot,
or Vehicle Data Recorder data may help with this
type of intermittentcondition, where applicable.
1 Ifthe intermittentis related to heat, review the data
for a relationship with the following:
—High ambient temperatures
—Underhood/engine generated heat
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—Circuit generated heat due to a poor connection,
or high electrical load
—Higher than normal load conditions, towing, etc.
1 if the intermittentis 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.
1 Informationfrom the customer may help to
determine if the trouble follows a pattern that is
temperature related.
1 Iftemperature is suspected of causing an
intermittentfault condition, attempt to duplicate the
condition. Refer to Inducing IntermittentFault
Conditions on page 11-533 in order to duplicate
the conditions required.
Electromagnetic Interference and
Electrical Noise
Some electrical components/circuits are sensitive to
electromagnetic interference or other types of electrical
noise. Inspect for the following conditions:
1 A mis—routedharness 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.
1 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.
1 improper installation of non-factory or aftermarket
add on accessories such as lights, 2—wayradios,
amplifiers, electric motors, remote starters, alarm
systems, cell phones, etc. — These accessories
may create interference in other circuits while
operating and the interference would disappear
when the accessory is not operating. Refer to
Checking Aftermarket Accessories on
page 11-525.
1 Test for an open diode across the A/C compressor
clutch and for other open diodes. Some relays
may contain a clamping diode.
1 The generator may be allowing AC noise into the
electrical system.
Incorrect Control Module
1 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.
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Note: 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.
1 Verify that the control module contains the correct
software/calibration. Ifincorrect programming is
found, reprogram the control module with the most
current software/calibration. Refer to Control
Module References on page 6—3for replacement,
setup, and programming.
Inducing Intermittent Fault
Conditions
Special Tools
J-25070 Heat Gun
For equivalent regional tools, refer to Special Tools on
page 11-616.
Many intermittentopen 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:
1 Wiggling the harness
1 Disconnecting a connector and reconnecting
1 Stressing the mechanical connection ofa
connector
1 Pulling on the harness or wire in order to identify a
separation/break inside the insulation
1 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 (GDS) on page 11-535.Another option is,
with the component commanded ON and OFF by the
scan tool, to move related connectors and wiring and
observe the component operation. With the engine
running, move related connectors and wiring while
monitoring engine operation. Ifharness 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, floor
jacks, 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 the Min/Max mode and
connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical
Intermittentson page 11-534.
Certainly, using the senses of sight, smell, and hearing
while manipulating the circuit can provide good results
as well.
111534 Wiring Systems and Power Management
There may be instances where circuit manipulation
alone will not meet the required criteria for the fault
condition to appear. In such cases Itmay 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.
High Temperature Conditions
Ifthe complaint tends to be heat related, you can
simulate the condition using the J-25070 heat gun.
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. lfa 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.
lfthis 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. Inaddition, circuit
cooling spray can be used to cool down a component or
circuit.
Once the vehicle, component, or harness has been
sufficiently cooled, manipulate the harness or
components in an effortto duplicate the concern.
Duplicating Failure Conditions
1 Ifnone of the previous tests are successful,
attempt to duplicate and/or capture the failure
conditions.
1 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.
1 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.
Testing for Electrical Intermittents
Special Tools
EL-39200 Digital Multimeter
For equivalent regional tools, refer to Special Tools on
page 11-616.
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.
1 Testing for Short to Ground on page 11—530
1 Testing for Continuity on page 11-530
1 Testing for a Short to Voltage on page 11—531
Ifthe fault is not identified, perform the procedure below
using the MIN MAX feature on the EL-39200 digital
multimeter (DMM). This feature allows you to
manipulate the circuit without having to watch the
DMM. The DMM will generate an audible tone when a
change is detected.
Note: The DMM must be used in order to perform the
following procedure since the DMM can monitor
current, resistance or voltagewhile recording the
minimum (MIN),and maximum (MAX) values
measured.
1. Connect the DMM to both sides of a suspected
connector (still connected), orfrom one end of a
suspected circuit to the other. Refer to
Troubleshooting with a Digital Multimeter on
page 11-527for information on connecting the
DMM to the circuit.
2. Set the DMM to the V (AC) orV (DC)position.
3. Select the voltage range feature of the DMM in
order to select the desired voltage range.
Note: The 100 ms RECORD mode Isthe length of time
an input must stay at a new value in order to record the
full change.
4. Select the MIN MAX function ofthe DMM. The
DMM displays the 100 ms RECORD and emits an
audible tone (beep).
5. Simulate the condition that is potentially causing
the intermittentconnection, either by wiggling the
connections or the wiring, test driving,
or performing other operations. Refer to Inducing
IntermittentFault Conditions on page 11—533.
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 until the MAX value is
displayed and note the value.
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8. Press the MIN MAX button until the MIN value is
displayed and note the value.
9. Determine the difference between the MIN and
MAX values.
1 Ifthe variation between the recorded MIN and
MAX voltage values is 1 V or greater an
intermittentopen or high resistance condition
exists. Repairthe condition as necessary.
1 Ifthe variation between the recorded MIN and
MAX voltage values is less than 1 V, an
intermittentopen or high resistance condition
does not exist.
Scan Tool Snapshot
Procedure (GDS)
Using Snapshots in Global Diagnostic
System (GDS)
Overview
A snapshot is a recording of what a control module on
the vehicle was receiving for Informationwhile 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. In GDS 2, snapshots are
automatically recorded whenever the user views
Module Diagnostics, Vehicle Diagnostics and/or
Systems Diagnostics. Module Diagnostics includes
DTC Data, Identification Information,Data Display,
Control Functions and Configuration/Reset Functions.
Vehicle Diagnostics includes Vehicle Wide DTCs.
Systems Diagnostics includes Inspection/Maintenance
...
2 Status and Inspection/Maintenance Information.
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-..
Snapshot Replay
The Snapshot Replay function allows reviews of
previously recorded vehicle snapshot data. This
information can be used in analysis of vehicle problems
and detection of trigger error conditions. The graph
function can be used to compare parameters to see if a
component is functioning properly. Recorded
snapshots can be selected for viewing by the following
two methods:
1 From the Home Page, click on Review Stored
Data. Inthe Snapshot Select Page, highlight the
vehicle in the upper pane and highlight the desired
snapshot in the lower pane, then click the Select
Snapshot button.
1 The user can view a snapshot without ending a
current on-vehicle diagnostic session by clicking
the Module button (when active) or Back button
until the Session Manager is displayed in the
menu. This is used when a user is viewing live
data and wants the quickest way to review the
data. Click on the Session Manager button.
Highlight the desired snapshot in the lower pane
and click Select Snapshot
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Systems and Power Management 112535
View Selections
The following information can be selected in the tabs at
the top of the screen:
1 Line Graph —Displays information from the
snapshot file in graph view. The Currentvalue of
the parameters is displayed on the screen. Use
the buttons on the right side to modify the
graph data.
1 Diagnostic Data Display —Displays incoming
informationfrom the snapshot file. The current
value of the parameters is displayed on the
screen. Use the buttons on the right side to modify
the data.
1 DTC Display —This tab will be displayed when a
DTC is current or the status has changed. The tab
will not be displayed when there are no DTCs.
1 Bookmarks —If bookmarks are present, this
displays the Type, Description and Time of
automatic and manually generated bookmarks.
1 System Information—Displays the GDS 2
Software Version and MDI Serial Number used
when the snapshot was recorded.
1 Selected Vehicle Configuration —Displays vehicle
options information.
Snapshot Replay Functions
To review the snapshot there are buttons at the bottom
of the window to control the cursor. From left to right the
buttons are:
1 Return to Frame 0 —This button returns the cursor
to frame 0.
1 Stop —This button pauses or stops the cursor.
Click the Play button to resume.
1 Play —This button starts the replay of the data.
1 Play Speed —— This button changes the speed
between 1x, 2x, 4x and 8x.
1 Back 1 Frame ~This buttonmoves the cursor
back 1 frame.
1 Fonivard 1 Frame —This button moves the cursor
forward 1 frame.
1 Previous Bookmark —This button moves the
cursor to the previous bookmark.
1 Next Bookmark ~This button moves the cursor
forward 1 bookmark.
111536 Wiring Systems and Power Management

Circuit Protection - Fuses Fuse Types (cont'd)

Special Tools Current Rating Amperes Color
EL—39200 Digital Multimeter (DMM) 60 Blue
For equivalent regional tools, refer to Special Tools on 50 Red
page 11~616.
J-Case Fuses
20 Blue
30 Pink
40 Green
50 Red
60 Yellow
MidiFuses
80 Black
MegaFuses
100 Black ,fm/
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2.2
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150 Black
200 Black

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. lfthere is a short or other
8786 type of overload condition in the circuit, the excessive
current will open the circuit between the circuit breaker
The fuse is the most common method of an automotive terminals. Two types of circuit breakers are used.
wiring circuit protection. Whenever there is an Circuit Breaker: This type opens when excessive
excessive amount of current flowing through a circuit current passes through it for a period of time. Itcloses
the fusible element will melt and create an open or again after a few seconds, and if the cause of the high
incomplete circuit. Fuses are a one time protection current is still present, it will open again. The circuit
device and must be replaced each time the circuit is breaker will continue to cycle open and closed until the
overloaded. To determine if a fuse is open, remove the condition causing the high current is removed.
suspected fuse and examine if the element in the fuse
is broken (2). If not broken (1), also check for continuity Positive Temperature Coefficient (PTC) Circuit
using a Digital Multimeter (DMM) or a continuity tester. Breaker: This type greatly increases its resistance
Ifthe element is broken or continuity is suspect, replace when excessive current passes through it. The
the fuse with one of equal current rating. excessive current heats the PTC device, as the device
heats its resistance increases. Eventually the
Fuse Types resistance gets so high that the circuit is effectively
open. Unlike the ordinary circuit breaker the PTC unit
Current Rating Amperes l Color will not reset until the circuit is opened, by removing the
Auto Fuses,MiniFuses voltage from its terminals. Once the voltage is removed
the circuit breaker wiIIre—closewithin a second or 2.
2 Gray
Violet Circuit Protection - Fusible Links
5 Tan Special Tools
7.5 Brown EL—39200 Digital Multimeter (DMM)
10 Red For equivalent regional tools, refer to Special Tools on
15 Blue page 11—616.
20 Yellow Note: When repairing a fusible link, fusible links out
longer than 225 mm (approximately 9 in) will not
25 Whiteor Natural provide sufficient overload protection.
30 Green Fusible link is wire designed to melt and break
MaxiFuses continuity when excessive current is applied. Itis often
20 located between or near the battery and starter or
Yellow
electrical center. Use a continuity tester or a Digital
30 LightGreen Multimeter (DMM) at each end of the wire containing
40 OrangeorAmber

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 WiringrSystems and Power Management 11=537
the fusible link in order to determine if it is broken. Repairing Damaged Wire Insulation
Ifbroken, it must be replaced with fusibie link of the
same gauge size. Ifthe wire insulation has been chafed, or broken,
enough to show the conductive portion of the wire, and
Wiring Repairs the wire is not damaged, determine the length of
insulation that needs to be repaired. Ifthe repair is less
The Wiring Repairs section contains the following types than 280 mm (11in), cut the wire within the damaged
of wiring repair information. Using these elements area. Then slide the appropriate heat shrink tubing
together will make wiring repairfaster and easier: (listed below) over the wire, and repair the wire by
1 Testing for IntermittentConditions and Poor splicing the wires together. Refer to Splicing Copper
Connections on page 11-531 Wire Using Splice Sleeves on page 11—544.Once the
1 Flat Wire Repairs on page 11~541 wire is spliced together slide heat shrink tubing over the
damaged area and apply heat to seal the repaired wire.
1 GMLAN and Media Oriented Systems Transport
(MOST) Wiring Repairs on page 11—606 Ifthe wire is damaged, or the damaged area is larger
than 280 mm (11in), then replace the damaged wire by
1 High Temperature Wiring Repairs on page 11—543 splicing in a new section of wire. Refer to Splicing
1 Heated Oxygen Sensor Wiring Repairs on Copper Wire Using Splice Sleeves on page 11~544.
page 11-543
1 Splicing Copper Wire Using Splice Sleeves on
page 11-544
1 Splicing Twisted or Shielded Cable on
page 11—546
1 Splicing Inline Harness Diodes on page 11—547
1 S/R/SRS Wiring Repairs on page 11-548
.2..“
2
_...Waw.
-,...-
.22
Heat Shrink Tubing Selection
Diameter Len th
SM Pbart _ _ Description Color _ g _
um er MetrIc English Metrlc English
12355003 9.5mm 0.375In TUbing;
Shrink Black 305mm 12in

12355005 12.7mm 0.5In TUbing;Shrink Black 305mm 12In

12355011 19.1mm 0.75In TUbing;

Shrink Black 305mm 12In

12355008 25.4mm 1.0In snTrlIanIin1gbo Black 305mm 12In

Coaxial Cable Repairs

Wire Size Conversion
The GM global coaxial cable repair strategy uses
Metric Wire Sizes (mm2) AWG Sizes coaxial cables, connectors and jumpers to repair
0.13 26 coaxial cables. The intent is to install the new service
cable in vehicle, but removal of the old cable is not
0.21 24 necessary. There are several repair scenarios:
0.32 22 1 New cables, jumpers, and connector housing are
0.52 20 required.
0.83 18 1 Only new cables are requiredwhile it is possible to
reuse the existing connector housing in vehicle.
1.31 16 A jumper may or may not be needed.
2.09 14 1 Only new connector housing are required, while it
3.31 12 is possible to reuse the existing cable in the
vehicle.
5.27 10
1 A new cable would need to be installed from
8.37 source to destination and by-pass the inIine
13.3 connector in some cases when an inline
connector is unrepairable (Example: a cracked
21.2 male end of a 1-way connector).
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111538 Wiring Systems and Power Management
Coaxial Cable Kits
Four different kits will be available to repair coaxial
cables. Components of each kit cannot be ordered
separately from the kit.
Communication Interface Module Antenna
Cable Kit (Kit # 13581174) is used to repair
Cellular coaxial cables. This kit uses R658 low
loss coaxial cables that are available in four
lengths. The coaxial cables can be attached
together in various lengths to closely match the
length of the faulty/damaged coaxial cable.
Digital Radio and Vehicle Locator Antenna
Coaxial Cable Kit (Kit # 13581173) is used to
repair XM and GPS coaxial cables. For vehicles
that have a combined GPS and Cellular/OnStar
signal on one cable, use Kit # 13581174. This kit
uses RG316 low loss coaxial cables that are
available in three lengths. The coaxial cables can
be attached together in various lengths to closely
match the length of the faulty/damaged coaxial
cable.
Digital Radio, Mobile Telephone and Vehicle
Locator Antenna Coaxial Cable Kit (Kit #
19119056) is used with OnStar, XM, and GPS
cables. This kit consists ofjumpers and
connectors. The jumpers are used to adapt
different types of connectors together (to attach
2-way and 3-way connector onto the long 7, 5, and
3 foot cables). The connectors are used to replace
existing connectors. The 1—wayand 2—way
connectors in the kit are in water-blue color
(differentthan what the vehicle is built with) and
are non-keyed (universal fit). The 3-way
connectors in the kit are in the same color as in
the vehicle.
Communication Interface Module Antenna
Cable Kit (Kit #22803854) is used for the OnStar
module on some vehicles built before the 2011
model year.
ome
.

Coaxial Cable Repair Kits

Repair Kit Name Description
RG58 coaxialcablewithfemale/female
connectors—7ft/2.1
m
RG58 coaxialcablewithfemale/male
connectors—5ft/1.5m
CommunicationInterfaceModuleAntennaCable Kit(Kit#13581174)
RG58 coaxialcablewithfemaIe/male
connectors—3.5ft/1.1m
RG58 coaxialcablewithfemale/male
connectors—3.5ft/1.1m
RG316coaxialcablewithfemaIe/female
connectors—7ft/2.1m
DigitalRadioandVehicleLocatorAntennaCoaxialCable Kit(Kit#13581173) RG316coaxialcablewithfemale/male
connectors—5ft/1.5m
R6316 coaxialcablewithfemaIe/male
connectors—3.5ft/1.1m
1-wayto 3-wayGen 1jumperforfemale
connector—Part#13581154—4in/100m
1-wayto 3-wayGen 1jumperformale
connector—Part#19119052—4in/1OCm
3—way
Gen 1 sub-kit Whitefemaleconnector
Whitemaleconnector
Bluefemaleconnector
Blue maleconnector
DigitalRadio,MobileTelephoneand 1-wayto 3-wayGen 2 jumperforfemale
VehicleLocatorAntennaCoaxialCable connector—Part#13581155—4in/100m
Kit(Kit#19119056) 1-wayto 3-wayGen 2 jumperformale
connector—Part#19119058—4in/1OCm
3—way
Gen 2 sub—kit Tanfemaleconnector
Tanmaleconnector
Grayfemaleconnector
Gray maleconnector
1—way to 2-wayGen 1jumperforfemale
2—way
Gen 1 sub—kit connector—Part#13581156—4in/10cm
Water-bluefemaleconnector

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 Wiring Systems and Power Management 11 =53?)

Coaxial Cable Repair Kits (cont'd)

Repair Kit Name Description
1-wayto2—way Gen 2jumperforfemale
connector-—Part# 13581157—4in/10cm
2-wayGen 2 sub-kit 1-wayto 2—way Gen 2jumperformale
(wide) connector—Part#13581158—4in/100m
Water-bluefemaleconnector
Water—blue maleconnector
1—way to 2—wayGen 2 and3 jumperfor
femaleconnector—Part#13582468-
4in/10cm
2-wayGen 2 and3 sub-kit Use the 1-wayto2-wayGen 2 jumperfor
(narrow) femaleconnector19119058—4in/10cm
fromthe2-wayGen 2 sub-kit.
Water-bluefemaleconnector
Water—blue maleconnector
Right—angle jumperwithwater—blue
universal1-wayconnector—4in/1OCm
CommunicationInterfaceModuleAntennaCable Kit (Kit#22803854) I 1-wayto miniUHF jumper—4in/100m

Connector Housing Repair Procedure

The connector housings (available in Digital Radio,
Mobile Telephone and Vehicle Locator Antenna Coaxial
Cable Kit) are available for 1—wayhousings, 2-way
housings and 3-way housings. Determine the
connector housing required:
1-way housing
No change to the service coaxial cable is necessary in
order to install the new coaxial cable into the vehicle.
2-way housing
A 4-inch jumper is required.
1. Determine the appropriate generation (1, 2, or 3)
and/or size (12.7mm or 8mm) of the 2-way housing
that is in the vehicle.
2. Remove the faulty/damaged coaxial cable from the
2—wayconnector housing by removing the terminal
position assurance (TPA) from the connector
housing and then slide the cable out of the
connector. 2695718
3. Install the new service coaxial cable into the
vehicle. Use the 4—inohjumper for the appropriate
2-way connector housing to connect the new
service coaxial cable to the connector housing.
4. Ifthe issue is found to be the connector housing
and not cable, a new connector housing may be
installed while reusing all other components.
3-way housing
A 4—inchjumper is required.
1. Determine the appropriate generation_(1or 2) and
keyed 3-way connector housing based on the
connector housing color.
2. Note the locations of each of the cables in 3-way
housing, as it is important for new cables be placed
in the appropriate terminal location in the new
connector. The connector housing colors are not
interchangeable.

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111540 Wiring Systems and Power Management
3. Remove the faulty/damaged coaxial cable from the Coaxial Cable Repair Procedure
3-way connector housing by using a pair of side/
diagonal cutters to hip and break away the 1. Identifythe fauIty/damaged coaxial cable.
housing. 2. Disconnect the faulty/damaged coaxial cable and
leave it in the vehicle.
3. Identifythe type of coaxial cable to be replaced
and match up with the appropriate pieces to repair
the damaged coaxial cable. Match up the type of
coaxial cable, cable length and connector types. In
some cases there may be extra length of cable
left over.

2115511”

2695719
4. Use caution not to damage the conductive ends of
the coaxial cables inside the connector housing.
Do not bend or force the terminal out or it could be
damaged.

2695722
4. Install the new coaxial cable in the vehicle.
Note: Avoid routing the new coaxial cable near sharp
edges that can damage the new coaxial cable.
Use tie—strapsto attach the new service coaxial
cable to existing harnesses or brackets. Use felt
tape/foam to reduce rattles, as necessary.
Note: To avoid permanent damage, do not pinch the
cable or bend it tighter than a 2 inch (5 centimeter)
radius.
5. Remove the faulty/damaged connectors,
if applicable.
6. Install new connectors orjumpers, as needed.
Refer to Connector Housing Repair Procedure.
7. Verify the repair by operating the system with the
engine running.

2695720
5. Install the new service coaxial cable into the
vehicle. Use the 4-inch jumper for the appropriate
color 3-way connector housing to connect the new W2.
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Wafi
2.¢_
service coaxial cable to the new 3—wayconnector
housing.
6. Ifthe issue is found to be the connector housing
and not cable, a new connector housing may be
installed while reusing all other components.

m,
NM
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 Wiring Systems and Power Management 11 641
Flat Wire Repairs
The flat wire within the flex wiring harness is not
serviceable. Ifan open or short exists within the flex
wiring harness the complete harness must be replaced.

Folded-Over Wire Repair

Special Tools
EL-38125—10Splice Sleeve Crimping Tool
For equivalent regional tooIs, refer to Special Tools on
page 11-616.
The GM global wire repair strategy uses connector
assemblies (pigtails)and terminated leads to repair
wiring harnesses.
To reduce and manage GM Service Parts proliferation,
the service pigtails and terminated leads are designed
with the largest wire gauge size that can be held by
either the terminal or the connector housing.
The folded over wire repair technique, in which the
copper wire strands are folded over before being 2527250
installed into a splice sleeve, allows the service part to
be used when repairing a smaller gauge size wire in a The larger harness size wires (1)wil| be placed in one
vehicle. This technique has passed all GM testing side ofthe splice sleeve and match the splice sleeve
standards. closely in size. The wires are moved into the splice
sleeve until they hit the stop (4) in the splice sleeve.
The smaller harness size wires (2) will be placed in the
other side of the splice sleeve. The smaller harness
size wires will be folded over (3) to match up with the
splice sleeve size.
Use the folded over wire repairfor: ,
Note: Increasing the amount of copper strands in the
smaller gauge size will allow for a better crimp
1 Splicing wires of 0.35 mm or less (22, 24, 26
gauge sizes)
Note: Vehicle side needs to be of same or less gauge
size (not greater than the sen/ice part’s gauge size)
1 Splicing wires of different gauges
Use the Service Information(SI) connector end—views
to determine:
1 Gauge size of wiring harness
1 Recommended Repair: Terminated Lead or Pigtail
The following table lists the acceptable variance within
the gauge size
Folded-Over Wire Selection Table
Harness Wire Gauge Connector Assembly (Pigtail)or TerminatedLead Wire Gauge Size
_ SalmonColor Blue Color YellowColor
Splice Sleeve Splice Sleeve Splice Sleeve
Metric — 0.35mm 0.5—0.8mm 1.0—2.0 mm 3.0—5.0 mm
— Gau$151115) 22 20—18 16—14 12—10
0.13mm 26 FoldOverWire FoldOverWire Fold OverWire NotAcceptable
0.22mm 24 FoldOverWire FoldOverWire FoldOverWire NotAcceptable
0.35mm 22 Fold OverWire FoldOverWire Fold OverWire NotAcceptable
0.5mm 20 NotAcceptable WiretoWire FoldOverWire NotAcceptable
0.75mm — NotAcceptable WiretoWire FoldOverWire NotAcceptable
0.8mm 18 NotAcceptable WiretoWire Fold OverWire NotAcceptable

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Folded-Over Wire Selection Table (cont'd)

Harness Wire Gauge Connector Assembly (Pigtail) or TerminatedLead Wire Gauge Size
1.0mm 16 NotAcceptable WiretoWire FoldOverWire NotAcceptable
1.5mm —— NotAcceptable NotAcceptable WiretoWire FoldOverWire
2.0mm 14 NotAcceptable NotAcceptable WiretoWire FoldOverWire
2.5mm — NotAcceptable NotAcceptable WiretoWire FoldOverWire
3.0-5.0mm 12210 NotAcceptable NotAcceptable NotAcceptable WiretoWire

Example
For an IP Harness of 0.22 mm (24 gauge on left side of
table) wire size, the SI connector end-view
recommends a pigtail with leads ofO.8 mm (18 gauge
on the top of the table) with a salmon colored DuraSeaI
splice sleeve of 0.5—1.0 mm (20—16gauge).
Follow these steps to use the folded over wire (1)
technique on an IP Harness.

2537879
I11 Note: Use EL-38125-10 splice sieeve crimping tool.
1. For wiring repair, refer to Splicing Copper Wire
Using Splice Sleeves on page 11-544.

5%

2527267
Strip twice the amount of insulation on the smaller (1)
wire (IP Harness is the lower wire) than normally §
required. Normally, the terminated leads have 5 mm of
insulation stripped off the wire.

1:@\1

2527270
2. Twist the wires before you fold them over to
prevent the wire strands from opening up. Fold
over the copper wire strands of the smaller (1)
gauge wire so that it is the same length as the
non-folded wire.

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1 Terminated leads or pigtails
1 The correct tools to remove the terminals from the
connectors
Use high temperature bulk wire rated at 150°C (302°F)
continuous temperature of the same or larger gauge
size as the original wire when repair damage wire. Also
replace any reflective tape that you remove during the
repair.
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:
1 Use high temperature bulk wire rated at 150°C
(302°F) continuous temperature to replace any
damaged wire.
1 Replace any heat shielding that is removed.
2527272 1 Cover any DuraSeaI splice sleeves with SCT1
3. Insert the folded over wire (1) into the splice shrink tubing.
sleeve. 1 After making a wiring repair, ensure that the
location of the wiring is not moved closer to the
heat source.
Identifying High Temperature Wiring
Note: High temperature areas would be areas located
near exhaust manifolds, catalytic converters, exhaust
pipes, and turbocharged engines.
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 Ifan
area is exposed to excessive heat before making a
wiring repair.

Heated Oxygen Sensor Wiring

2527273
Repairs
4. Use the proper crimp tool to crimp the splice sleeve
to the smaller wire (harness side of repair). Caution: Do not solder repairs under any
Complete the crimp as usual (using the heat tool to circumstances as this could result in the air reference
shrink the tube). being obstructed.
Ifthe heated oxygen sensor pigtail wiring, connector,
High Temperature’Wiring Repairs or terminal is damaged the entire oxygen sensor
Note: All wiring repairs need to be 200 mm from the assembly must be replaced. Do not attempt to repair
heat zone. Areas of consideration would be any area the wiring, connector. or terminals. In order for the
located near the exhaust manifolds, catalytic converter, sensor to function properly it must have a clean air
exhaust pipes, and turbocharged engines. reference. This clean air reference is obtained by way
of the oxygen sensor signal and heater wires. Any
.,._2..__2W2-.2_~_~-...~.Mw.
2
W
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222
y.
_ 2m‘wwmw2Items Required attempt to repair the wires, connectors or terminals
could result in the obstruction of the air reference and
1 DuraSeaI splice sleeves to crimp and seal
degrade oxygen sensor performance.
connections
1 High temperature SCT1 shrink tubing to protect
the splice sleeves

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1’11544 Wiring Systems and Power Management
The following guidelines should be used when
servicing the heated oxygen sensor:
1 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.
1 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.
1 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.
1 To prevent damage due to water intrusion, be sure
that the peripheral seal remains intact on the
vehicle harness connector.
Splice Sleeve
Crimp Tool Nest Color
Splice Sleeve Color 3Crimp Nests
Salmon(Yellow-Pink)
19168446 Red (1)or Red/Green(1)
Blue
B'”9 (2)
19168447
Yellow
19168448 Ye”°W(3)
Note: 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:
1 Use a sewing seam ripper, available from
sewing supply stores, in order to cut open the
harness in order to avoid wire insulation
damage.
1 Use the DuraSeal splice sleeves on all types of
insulation except Tefzel and coaxial.
1 Do not use the crimp and 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.
Splicing Copper Wire Using Splice
Sleeves
Special Tools
1 EL-38125-10 Splice Sleeve Crimping Tool
1 J-38125-5A Ultra Torch Special Tool
1 J—38125-8Splice Sleeve Crimping Tool
For equivalent regional tools, refer to Special Tools on
page 11-616.
Note: The DuraSeal splice sleeves have the following
2 critical features:
",_W
1 A special heat shrink sleeve environmentally seals
the splice. The heat shrink sleeve contains a
sealing adhesive inside.
1 A cross hatched (knurled) core crimp provides the
necessary low resistance contact integrityfor
these sensitive, low energy circuits.
Use only 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 are
special requirements such as moisture sealing. Follow
the instructions below in order to splice copper wire
using DuraSeal splice sleeves.
Selection
4 Crimp Nests Wire Gauge mm2/(AWG)
Red (2) 0.5-0.8/(18—20)
6)
Blue(3) 1.0—2.0/(14—1
3.0—5.0/(10—12)
Yellow(4)
3. Strip the insulation:
1 When adding a length of wire to the existing
harness, use the same size wire as the
original wire.
1 Perform one of the following items in order to
find the correct wire size:
—Find the wire on the schematic and convert to
regional wiring gauge size.
—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.
1 Strip approximately 5.0 mm (0.20 in) of
insulation from each wire to be spliced.
1 Do not nick or cut any of the strands. Inspect
the stripped wire for nicks or cut strands.
1 Ifthe wire is damaged, repeat this procedure
after removing the damaged section.
4. For high temperature wiring, 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.
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 Wiring
5. 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 eoding of the DuraSeal splice sleeves and
the crimp tOO'nests.
Systems and Power Management 11 1545
14 and 16 gauge wires. The smallest crimp nest (1)
is used for crimping 18 to 20 gauge wires. The
crimp nests are referenced in the table (farther
above) under the crimp tool nest color.
8. Use the splice sleeve crimp tool in order to position
the DuraSeal splice sleeve in the proper color nest
of the splice sleeve crimp tool. For the four crimp
nest tool, use the three largest crimp nests to crimp
the splice sleeves. For the three crimp nest tool,
use all three crimp nests to crimp the splice
sleeves. Use the four and three crimp tool
diagrams (above) and the table (fartherabove) to
match the splice sleeve with the correct crimp nest.
The crimp tool diagram callout numbers match the
numbers in the table (under crimp tool nest color).

5.0 mm (0.20")
__>

2414855
6. The EL-38125-10 splice sleeve crimping tool has
four crimp nests. The largest crimp nest (4) is used
for crimping 10 and 12 gauge wires. The second 3
largest crimp nest(3) is used for crimping 14 and
16 gauge wires. The third largest crimp nest (2) is
used for crimping 18 and 20 gauge wires. The
smallest crimp nest (1) is used for crimping 22 to
26 gauge wires. The crimp nests are referenced in
the table (fartherabove) under the crimp tool nest
color. 68639
9. 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.

68642
7. The J—38125-8splice sleeve crimping tool has
three crimp nests. The largest crimp nest (3) is
used for crimping 10 and 12 gauge wires. The
second largest crimp nest (2) is used for crimping

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High Temperature Wiring Repairs

Use the following procedures to perform high
temperature wiring repairs:
1. Centerthe high temperature SCT1 shrink tube
over the DuraSeal splice sleeve.
2. Using the heat torch, apply heat to the high
temperature heat shrink tubing.
3. Gradually move the heat from the center to the
Ll open end of the tubing:
m_
1 The tubing will shrink completely as the heat is
moved along the insulation.
1 A small amount of sealant will come out of the
end of the tubing when sufficient shrinkage is
achieved.
4. Replace any reflective tape and clips that may
have been removed during the repair.

Splicing Twisted or Shielded Cable

9502
10. Insert the wire into the splice sleeve barrel until the
wire hits the barrel stop.
11. 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 DuraSeal
splice sleeve. Repeat steps 4 and 6 for the
opposite end of the splice.
Twisted/shielded cable is used in order to protect wiring
from electrical noise. Two—conductorcable of this
construction is used between the radio and the
Delco-Bose® 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.

w-w
.WM
MWM

8798
1. Remove the outerjacket (1). Use care not to cut
into the drain wire of the mylar tape.
9503 2. Unwrap the tape. Do not remove the tape. Use the
12. Using the heat torch, apply heat to the crimped tape in order to rewrap the twisted conductors after
area of the barrel. the splice is made.
13. Start in the middle and gradually move the heat
barrel to the open ends of the tubing:
1 The tubing will shrink completely as the heat is
moved along the insulation.
1 A small amount of sealant will come out of the
end of the tubing when sufficient shrinkage is
achieved.

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<QE%B '-7/Ifi-'

8799
3. Prepare the splice. Untwist the conductors and
follow the instructions for Splicing Copper Wire
Using Splice Sleeves on page 11-544. Staggering
the splices by 65 mm (2.5 in) is recommended.
8800
Note: 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.
Ifthe mylar tape is damaged, use 3M product
AL-36FR to replace the damaged 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 electrical tape to replace the outer
insulation.
8801
5. Tape over the entire cable. Use a winding motion
when you apply the tape.
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.
1. Open the harness.
- Ifthe harness is taped, remove the tape.
- To avoid wiring insulation damage, use a
sewing seam ripper (available from sewing
supply stores) in order to cut open the harness.
- Ifthe harness has a black plastic conduit, pull
out the diode. '
2. Ifthe 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.
Note: Ifthe 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/
4O 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.

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8. Reinstall terminal(s) into the connector body if
previously removed.
Note: 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.
SIR/SRS Wiring Repairs
Note: Refer to SIR Service Precautions on
page 13-113.
For European regions —Ifthe SlR/SRS wiring,
connector, or terminal is damaged, the affected wiring
harness must be replaced. Do not attemptto repair the
wiring, connector, or terminals. Any attempt to repair
the wires, connectors, or terminals could result in
performance problems of the SIR/SRS System.
Operations on restraint systems must only be
performed by trained and qualified personnel.
Special Tools
EL-38125-10 Splice Sleeve Crimping Tool
For equivalent regional tools, refer to Special Tools on
page 11-616.
The Supplemental Inflatable Restraint (SIR) System/
Supplemental Restraint System (SR8) 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.
SIRISRS Connector Repair (Plastic
Body and Terminal Metal Pin)
Note: Do not use the terminals in the kit in order to
replace damaged SIR/SRS system terminals. Use
either an SlR/SRS pigtail or a terminated lead from the
SIR Repair Kit Tray.
The terminals in the SlR/SRS system are made with a
special plating. This plating provides the necessary
contact integrityfor the sensitive, low energy circuits.
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. Terminated leads can be used to
replace damaged terminals when replacing the
connector body.
SiR/SRS Component Wire Pigtail Repair
Note: 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. Ifa 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.
SIRISRS Wire Repair
Caution: Do not install more than 2 DuraSeal splice
sleeves per SlR deployment loop. A deployment loop
consists of both wires from the K36 InflatableRestraint
Sensing and Diagnostic Module to the deployable
component. Ifmore than 2 DuraSeal splice sleeves are
required for any SIR deployment loop, the complete
circuit of the loop must be replaced. More than 2
DuraSeal splice sleeves per deployment loop may
increase the resistance in the circuit causing a DTC to
be set.
Note: Refer to Wiring Repairs in the sen/ice
information connector end views or the vehicle
schematics in order to determine the correct wire size
for the circuit you are repairing. You must obtain this
information in order to ensure circuit integrity.
Ifany wire except the pigtail is damaged, repair the wire
by splicing in a new section of wire of the same gauge
size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal
splice sleeves and EL-38125-10 splice sleeve crimping
tool. For wiring repair, refer to Splicing Copper Wire
Using Splice Sleeves on page 11-544.
For connector position assurance (CPA), refer to
Connector Position Assurance Locks on page 11-552.
For terminal position assurance (TPA), refer to Terminal
Position Assurance Locks on page 11—552.
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.
Ifthe 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 on
page 11—552
- Terminal Position Assurance Locks on
page 11-552
~ AFL/EPC Connectors on page 11-552
- Bosch Connectors (BSK) on page 11-554or
Bosch Connectors (0.64) on page 11-555 or
Bosch Connectors (2.8 JPT) on page 11-556 or
Bosch Connectors (ECM) on page 11-557
- Delphi Connectors (Weather Pack) on
page 11-559or Delphi Connectors (Pull To Seat)
on page 11-561or Delphi Connectors (Push To
Seat) on page 11—560or Delphi Connectors
(12-Way) on page 11-567 or Delphi Connectors
(Micro .64) on page 11-564 or Delphi Connectors
(Steering Gear) on page 11-569 or Delphi
Connectors (Micro-Pack 100W) on page 11—561
. FCI Connectors (Lever Look) on page 11-569or
FCI Connectors (SIR) on page 11-571
' FEP Connectors (Steering Gear) on page 11-572
. JST Connectors on page 11-573
- Kostal Connectors (Glow Plug Control Module) on
page 11—574or Kostal Connectors (Transmission)
on page 11-576
- Molex Connectors on page 11~578
- Sumitomo Connectors on page 11—580 1‘
..._
.s
w
- Tyco/AMP Connectors (Sensor) on page 11—584
or Tyco/AMP Connectors (SIR) on page 11-598or
Tyco/AMP Connectors (Door Module) on
page 11-588or Tyco/AMP Connectors (102-Way
Inline) on page 11—590or Tyco/AMP Connectors
(0.25 Cap) on page 11—585or Tyco/AMP
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Connectors (Seat) on page 11-586or Tyco/AMP - JST (Japan Solderless Terminals)
Connectors (CM 42-Way) on page 11-583or Tyco/ - Kostel
AMP Connectors (43-Way) on page 11~586
- Molex
- Yazaki Connectors (2-Way) on page 11—600or
Yazaki Connectors (16—Way)on page 11-600 - Sumitomo
- Repairing Connector Terminals (Terminated Lead - Tyco/AMP
Repair) on page 11-602 or Repairing Connector - Yazaki
Terminals (Terminal Repair) on page 11—602 identifying the manufacturer ofa connector is often
difficult.When trying to determine the manufacturer of a
Connector Anatomy 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.

1709341 c1
.s.~_..,v~\.
..m
.
(1) Connector Positive Assurance (CPA)
(2) Assist Lever
(3) Wiredress Cover 1466850
(4) Seal Strain/Relief ‘- Most of AFLs connectors have EPC on their
(5) Slide Left Hand connector body. Some of the smaller connectors
(6) Slide Right Hand will not have any markings on them.
) Terminal Positive Assurance (TPA)
(8) Terminal Positive Assurance (TPA)
) Connector Seal
) Connector Housing
(11) InnerConnector

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
0 FCl (Framatome Connectors International) 1460356
- JAE (Japan Aviation Electronics)

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- 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.

Q? %

FMW
._H
hm
..m
W,,
1468768 --.—
\N
1,.
v...
P.E. 0-
/ JAE connector have JAE in small letters on their
connectors.
317-47 Dflflfl

1460486
- 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.

1468706
A JST connectors have JST in small letters on their
connectors, similar to that above. The location of
FCI the logo will vary with the connector size and style.

1460611
. FCI connectors may have the FCI logo on their
connectors. The logo is the letters FCl with an “A”
above it.

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v\ .9»

____.J

w
./,__..M'
”\J
V~
”W‘wmm
.u_s._._.,

1709340 1467225
Kostel has an "LK" with a circle around it. These Sumitomo has a unique symbol on their connector
connector are usually used as a transmissions and possibly a part number. The symbol is similar
connection. 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.

www‘-
aN
. .»

10 11
\ \UB'I V 2

1467199
Most Molex connectors will have the Molex logo
on the dresscover of the connector. in some cases 'V
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. 1467254
Yazaki has a wedge or arrow shape, similar to that
shown.

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Connector Position Assurance Locks

The connector position assurance (CPA) is a small
plastic insert that fits through the locking tabs of the
connector. CPAs are used in various connectors
throughout the vehicle. CPAs are also used in all SlR
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.

Terminal Position Assurance Locks

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. Ifthe TPA is removed, be sure to
reinstall it before reconnecting the connector. “K.
MM
fl-w
,_.
2.

AFLIEPC Connectors
1709284
Special Tools 2. Locate the connector position assurance (CPA) on
- EL-38125-550 Terminal Release Tool Kit the top of the wire dress cover. Slide the CPA
- EL—38125—580 Terminal Release Tool Kit fonNard.
- J-38125-12A Terminal Release Tool
~ J—38125—216 Terminal Release Tool
For equivalent regional tools, refer to Special Tools on
page 11-616.
Terminal Removal Procedure
Follow the steps below in order to remove terminals
from the connector.

1709285
3. Slide the lever lock forward while pressing down on
the lever lock release tab.

1709283
1. For connectors with a bolt in the dress cover, turn
the bolt counterclockwise to remove the connector
from the component.

NMA
-2.»
.,

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NW”

: &

QLQQE

1709286 1709288
4. View showing depressing of the lever lock
release tab. 8. Release the rear lower half ofthe Wiredress cover.

1709287
5. View of connector in released position.
FD Disconnect the connector from the component.
7. Locate the dress cover locking tabs at the corners
of the dress cover. Use a small flat—bladetool to
release the locking tabs and remove the dress
covet
1709289
9. Release the tabs that are holding the Wiredress
cover to the connector body.
10. Remove the nose piece by inserting a small
flat—bladetool 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.

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Bosch Connectors (BSK)

Special Tools
- EL-38125—550Terminal Release Tool Kit
- EL—38125-580Terminal Release Tool Kit
- J-38125-561 Terminal Release Tool
For equivalent regional tools, refer to Special Tools on
page 11-616.
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.

1709282
11. Use the J—38125—12Atoolto release the terminals
by lifting the terminal retaining tabs on the inside of
the connector.

1709281
12. 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.
13. Repair the terminal by following the Repairing
Connector Terminals (Terminated Lead Repair) on
page 11-602or Repairing Connector Terminals
(Terminal Repair) on page 11-602 procedure.
14. Insert the repaired terminal back into the cavity.
Repeat the diagnostic procedure to verify the
repair and reconnect the connector bodies.
1446346
4. Insertthe J—38125-561tool 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.
5. Carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. Ifthe terminal is
difficult to remove, repeat the entire procedure.
6. Repair the terminal by following the Repairing
Connector Terminals (Terminated Lead Repair) on
page 11-602 or Repairing Connector Terminals
(Terminal Repair) on page 11-602 procedure.
7. Insertthe repaired terminal back into the cavity.
Repeat the diagnostic procedure to verify the
repair and reconnect the connector bodies. ”4‘.
__
,_A
5”,
MM
,2..

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,WW
2.
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N
 Wiring Systems and Power Management 11655
Bosch Connectors (0.64)
Special Tools
- EL—38125—550 Terminal Release Tool Kit
. EL—38125—580 Terminal Release Tool Kit
' J—38125-560Terminal Release Tool
For equivalent regional tools, refer to Special Tools on
page 11-616.
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover.
...fimwwww‘...
“‘W~
2 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.
1442709
6. Locate the 2 dress cover locking tabs located on
the opposite side of the connector. Insert a small
flat—bladedtool between the cover at the connector
end and pry up.
7. Remove the dress cover.
8. Cut the tie wrap on the wire bundle.

w.-m~v\m_~
WWA.
.....s
‘_, 1442703 -
5. Locate the 2 dress cover locking tabs that are on
the wire end of the connector. Insert a small
flat—biadedtool between the cover and connector
body and pry up.

1442715
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.

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Terminal Insertion Procedure

1442734
11. Insertthe J-38125—560into the 2 triangular cavities
on each side of the terminal at the front of the
connector.
12. Carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. Ifthe terminal is
difficult to remove, repeat the entire procedure.
13. Repair the terminal by following the Repairing
Connector Terminals (Terminated Lead Repair) on
page 11-602 or Repairing Connector Terminals
(Terminal Repair) on page 11—602procedure.
14. Insert the repaired terminal back into the cavity.
Repeat the diagnostic procedure to verify the
repair and reconnect the connector bodies.
1442741
. 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)

Special Tools
EL-38125-550 Terminal Release Tool Kit
EL-38125-580 Terminal Release Tool Kit
J—38125-557Terminal Release Tool
For equivalent regional tools, refer to Special Tools on
page 11-616.
Terminal Removal Procedure
. 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.
Push the wire side of the terminal that is being
removed toward the connector and hold it in
position.

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Terminal Removal Procedure

1445490
5. insert the J—38125—557 into the 2 cavities on each
side of the terminal at the front of the connector 1709276
and push until you feel the tool disengage the 1. Locate the assist lever on the top of the connector.
terminal retainers. Move the assist lever to the fon/vardposition.
6. Carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. Ifthe terminal is
difficult to remove, repeat the entire procedure.
7. Repair the terminal by following the Repairing
Connector Terminals (Terminated Lead Repair) on
page 11-602 or Repairing Connector Terminals
(TerminalRepair) on page 11-602 procedure.
8. insert the repaired terminal back into the cavity.
Repeat the diagnostic procedure to verify the
repair and reconnect the connector bodies.

Bosch Connectors (ECM)

Special Tools
- EL-38125-550 Terminal Release Tool Kit
- EL—38125-580Terminal Release Tool Kit
- J—38125—213 Terminal Release Tool
- J-38125-556 Terminal Release Tool
For equivalent regional tools, refer to Special Tools on
page 11-616.
1709277
2. Disconnect the connector from the component.

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\U
M,,.
....M

1709273 1709278
3. Locate the dress cover locking tabs at the corners 5. Use a small flat-blade tool to remove TPA from the
of the connector. Use a small flat-blade tool to connector.
release the locking tabs and remove the dress
COVG F.

1709275

1709274 6. Use the J-38125—213 or the J—38125-556tool to

4. The terminal positive assurance (TPA) is located in
the front 0f the connector.
release the terminals by inserting the tool into the
terminal release cavity.
7. 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.
8. Repairthe terminal by following the Repairing
Connector Terminals (Terminated Lead Repair) on
page 11-602 or Repairing Connector Terminals
(Terminal Repair) on page 11-602procedure.
9. Insert the repaired terminal back into the cavity.
Repeat the diagnostic procedure to verify the
repair and reconnect the connector bodies.

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Wiring Systems and Power Management 11059
Note: 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.
10. Reconnect the connector bodies.
\
Delphi Connectors (Weather Pack)

.-a.,._
_\ Special Tools
- EL—38125—550 Terminal Release Tool Kit
- EL—38125-580Terminal Release Tool Kit
- J—38125—1OA Terminal Release Tool
For equivalent regional tools, refer to Special Tools on
page 11-616.
Terminal Removal Procedure ”?T‘QE
The following is the proper procedure for the repair of
Weather Pack®Connectors.

8803
4. Insertthe Weather Pack®terminal removal tool
J—38125—10A 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).
JL Note: Never use force to remove a terminal from a
.== 773: connector.
6. Inspect the terminal and connector for damage.
\/ Repair as necessary. Refer to Repairing Connector
1 Terminals (Terminated Lead Repair) on
page 11-602or Repairing Connector Terminals
(Terminal Repair) on page 11-602.
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
8802 satisfactorily.
1. Separate the connector halves (1). 10. Perform system check.
2. Open the secondary look. A secondary lock aids in 11. Repair the terminal by following the Repairing
terminal retention and is usually molded to the Connector Terminals (Terminated Lead Repair) on
connector (1). page 11—602or Repairing Connector Terminals
3. Grasp the wire and push the terminal to the (Terminal Repair) on page 11-602 procedure.
forward most position. Hold the wire in this 12. Insertthe repaired terminal back into the cavity.
position. Repeat the diagnostic procedure to verify the
repair and reconnect the connector bodies.

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11-560 Wiringjwstems and Power Management
Delphi Connectors (Push TO Seat) 4. Gently pull the cable and the terminal (2)0ut ofthe
back of the connector.
Special Tools
- EL-38125—550Terminal Release Tool Kit
- EL-38125—580Terminal Release Tool Kit
For equivalent regional tools, refer to Special Tools on
page 11—616.
Terminal Removal Procedure
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.

8804
gm 5. Re-form the locking device if you are going to
reuse the terminal (1).
6. Repair the terminal by following the Repairing
Connector Terminals (Terminated Lead Repair) on
page 11—602or Repairing Connector Terminals
(Terminal Repair) on page 11-602 procedure.
7. insert the repaired terminal back into the cavity.
Repeat the diagnostic procedure to verify the
repair and reconnect the connector bodies.
Terminal Insertion Procedure
8802 1. In order to reuse a terminal or lead assembly, refer
2. Separate the connector halves (1). to Wiring Repairs on page 11-537.
2. Ensure that the cable seal is kept on the terminal
side of the splice.
3. Insert the lead from the back untii it catches.
E 4. Install the TPA, CPA, and/or the secondary locks.

?%E

8803
3. Use the proper pick or removal tool (1) in order to
release the terminal.

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 Wirifig Systems and Power Management 11—561
Delphi Connectors (Pull To Seat) Terminal Insertion Procedure
Special Tools 1. Align the terminal and pull the wire from the back of
the connector in order to seat the terminal.
- EL-38125-550 Terminal Release Tool Kit
2. Ifthe connector is outside of the passenger
- EL-38125-580 Terminal Release Tool Kit compartment, apply dielectric grease to the
For equivalent regional tools, refer to Special Tools on connector.
page 11-616. 3. lnstall the TPA, CPA, and/or the secondary locks.
Terminal Removal Procedure
Delphi Connectors
Ifthe terminal is visibly damaged or is suspected of
having a faulty connection, the terminal should be (Micro-Pack 100W)
replaced.
Special Tools
. EL-38125—550Terminal Release Tool Kit
- EL—38125-580Terminal Release Tool Kit
- J-38125-12A Terminal Release Tool
For equivalent regional tools, refer to Special Tools on
page 11-616.
Terminal Removal Procedure
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.

904718
Follow the steps below in order to repair puII-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—Iineconnectors.
3. Remove the terminal position assurance (TPA) (\\\\\\.\.\.\\.\\.\.}.\\\\\\
device. r-r-F"
4. Review the connector end view to determine the
proper test probe and release tool.
5. insert the release tool into the front of the 1364951
connector body.
The first connector design of the Micro—Pack100W (1)
6. Grasp the wire at the back of the connector body has a white connector interface that holds the
and gently push the terminal out the front of the terminals. The second design of the Micro-Pack
connector body. 100W (2) has a gray interface to hold the terminals.
7. Repair the terminal by following the Repairing Also, the first design has terminal cavities that are
Connector Terminals (Terminated Lead Repair) on further apart (3 mm centerline) and offset from the other
page 11-602or Repairing Connector Terminals row of terminal cavities in the connector. The second
(Terminal Repair) on page 11—602procedure. design has terminals cavities that are closer together
8. Insertthe repaired terminal back into the cavity. (2.54 mm centerline) and aligned vertically. One other
Repeat the diagnostic procedure to verify the way to identify the second design is the thin strip of
repair and reconnect the connector bodies. material that runs along-the outside of the cavities.

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1364942
Note: 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—Pack100W connectors. Some Micro-Pack
100W connector disassembly procedures will vary. Use
this procedure as a guide.
1. Disconnect the connector from the component.
881004
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.

881006
6. Use fingers to squeeze the 2 locking legs of the
880994 COVER
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.

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881008 881017
2..2_WM_.._._...._.
,~
“WM“
W
\
NM”
_.
m 7. Apply pressure and gently rock the cover until one Use J-38125-12A to gently lift the terminal
looking leg is unseated. 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.
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
“.22!
.2_._,.M.w
~22 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.
11. Repair the terminal by following the Repairing
Connector Terminals (Terminated Lead Repair) on
page 11-602or Repairing Connector Terminals
(Terminal Repair) on page 11-602 procedure.
12. insert the repaired terminal back into the cavity.
Repeat the diagnostic procedure to verify the
repair and reconnect the connector bodies.
Terminal insertion Procedure
After the terminal is crimped to the wire perform the
881011 following procedure in order to replace Micro—Pack100
terminals.
8. Continue to apply pressure and rock the cover until 1. Slide the new terminal into the correct cavity at the
the second locking leg is unseated. Repeat back of the connector.
procedure for the other side of the dress cover and
remove the cover. 2. Push the terminal into the connector until it looks
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.
To assemble the connector, reverse the Terminal
Removal Procedure.

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114364 Wiring Systems and Power Management

Delphi Connectors (Micro .64)

Special Tools
- EL—38125—550 Terminal Release Tool Kit
- EL—38125-580Terminal Release Tool Kit
- J-38125—21Terminal Release Tool
For equivalent regional tools, refer to Special Tools on
page 11-616.
Terminal Removal Procedure
Follow the steps below in order to remove terminals
from Micro .64 connectors.

1709338
Depress the lock and pull the lever over and past
the lock.

863406
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.

1709339
View of the connector when released from the
component.

1709337
View of a typical Micro 64 connector.

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 Wirirg; Systems and Power Management 11~565

1709290 1709292
View of another type of Micro 64 connector. View of the connector when released from the
component.
2. Disconnect the connector from the component.

1709291
Depress the locks that are located on both sides of
the wire dress cover and pull the lever over and 863404
past the locks. . 3. Locate the dress cover locking tabs at the front of
the connector. Using a small flat—bladetool 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 looks are unlocked, lift the front of
the dress cover and pull it forward.

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’i'l=566 Wiring Systems and Power Management

K .

a :88

863400
Note: 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—bladetool
into the small slot on the TPA and pushing down
until the TPA releases. Gently pry the TPA out of
the connector.
09¢:
\fi
‘53
863390
7. 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.
8. Repair the terminal by following the Repairing
Connector Terminals (Terminated Lead Repair) on
page 11-602or Repairing Connector Terminals
(Terminal Repair) on page 11-602 procedure.
9. Insert the repaired terminal back into the cavity.
Repeat the diagnostic procedure to verify the
repair and reconnect the connector bodies.

/...
6O
.42}
4.8%
/ 4f. M/

863397
Note: 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 tool into the round canal
between the terminals cavities at the front of the
connector.

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 Wiriflg Systems and Power Management 11-567
Delphi Connectors (12-Way) 3. Locate the dress cover locking tabs on the dress
cover of the connector. Using a small flat—bladetool
Special Tools release all of the locking tabs.
- EL-38125-550 Terminal Release Tool Kit
- EL—38125—580 Terminal Release Tool Kit
- J-38125-12A Terminal Release Tool
For equivalent regional tools, refer to Special Tools on
page 11-616.
Terminal Removal Procedure
Follow the steps below in order to remove terminals
from the connector.

1709311
4. Release the lower wire dress cover locking tab.

1709308
1. Locate the lever lock on the wire dress cover.
Remove the connector position assurance (CPA)
and slide the lever look away from the
connector body.
2. Disconnect the connector from the component.

1709312
5. Release the upper wire dress cover locking tab.
6. Once the locks are unlocked, lift the dress
cover off.

1709309

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11-568 Wiring Systems and Power Management

WM

1709313 1709315
Note: Always use care when removing a terminal 9. Insert the J—38125-12Atoolto release the
position assurance (TPA) in order to avoid damaging it. terminals by inserting the tool into the terminal
7. Remove the TPA by inserting a small flat—biadetool release cavity.
into the locking tabs on both sides of the TPA.
Gently pry the TPA out of the connector.

1709314
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.
1709316
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.
11. Repair the terminal by following the Repairing
Connector Terminals (TerminatedLead Repair) on
page 11-602or Repairing Connector Terminals
(Terminal Repair) on page 11—602procedure.
12. Insert the repaired terminal back into the cavity.
Repeat the diagnostic procedure to verify the
repair and reconnect the connector bodies.

M‘W
M2”
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M
 Wiring Systems and Power Management 11669
Delphi Connectors (Steering Gear) ' J-38125—556Terminal Release Tool
- J—38125—560 Terminal Release Tool
Removal Procedure For equivalent regional tools, refer to Special Tools on
page 11—616.
Terminal Removal Procedure
Follow the steps below in order to remove terminals
from the connector.

\\\\
\

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’0

2374629
1. Use a small flat—bladedtool to release the locking
tab on the connector.

1709268
1. Slide the lever look forward while pressing down on
the lever lock release tab.
2. The release tab is located on the top of the
wiredress cover.

2374631
2. Push down the locking tab to release the
connector. The small flat—bladedtool may need to
be pushed down and angled back slightly to
depress the locking tab. Pull on the connector body
while releasing the locking tab to disconnect the
connector.
1709269
FCI Connectors (Lever Lock)
3. View of connector in released position.
Special Tools 4. Disconnect the connector from the component.
- EL-38125-550 Terminal Release Tool Kit
- EL—38125-580Terminal Release Tool Kit

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112570 Wiring Systems and Power Management
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

1709272
8. 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.
1709270
. Use a small flat—bladetool to slide the terminal Repair the terminal by following the Repairing
position assurance (TPA) up one notch on both Connector Terminals (Terminated Lead Repair) on
ends of the connector. The TPA is located page 11—602or Repairing Connector Terminals
underneath the wire dress cover. (Terminal Repair) on page 11-602 procedure.
10. Insert the repaired terminal back into the cavity.
Repeat the diagnostic procedure to verify the
repair and reconnect the connector bodies.

1709271
7. For the larger terminals insert the J—38125-556tool
to release the terminals by inserting the tool into
the terminal release cavity. For the smaller
terminals insert the J—38125—560 tool to release the
terminals by inserting the tool into the terminal
release cavity.

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 Wiring Systems and Power Management 11-571
FCI Connectors (SIR) Installation Procedure
Removal Procedure
Note: The orange or yellow connector position
assurance (CPA) must be released first to disconnect
or to connect the connector.

2374626
1. The CPA should be approximately 4 mm above the
yellow cover before installing the connector. Ifnot,
use a small flat-bladed tool to help release the
CPA. The CPA may also be released manually
2374625 without any tools.
1. Lift the orange or yellow CPA vertically (avoid lifting
on an angle to the connector) approximately 4 mm
to release the connector. Use a small flat-bladed
tool to help release the CPA. The CPA may also be
released manually without any tools.

3258546
2. Line up the connector key tabs with the initiator key
slots. Grab the connector on both sides and push
down into the initiator connector sub assembly until
fully seated.
3258545
2. Grab the connector on both sides and liftvertically
to disconnect the connector.

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11-572 Wiring Systems and Power Management

_’-—\ \

O D

3258548 2728308
3. After the connector is fully seated, push the CPA 2. Option 1:Twist the flat—bladedtool to push the top
down with your thumb until the CPA is touching the of the locking tab inward while pulling the
yellow cover on the connector. connector body out.

FEP Connectors (Steering Gear)

Removal Procedure /
Jy/

{:7 ..
‘

i—-—\

2728310
3. Option 2: Pry using the flat-bladed tool to depress
the locking tab while pulling the connector
body out.
2374629
1. Use a flat—bladedtool to release the locking tab on
the connector.

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 WiringrSystems and Power Management 11 :573
JST Connectors
RM“
Special Tools
' EL—38125—550 Terminal Release Tool Kit ..-
- EL—38125-580Terminal Release Tool Kit
- J—38125—553 Terminal Release Tool ‘4
For equivalent regional tools, refer to Special Tools on
page 11-616.
Terminal Removal Procedure
The JST connector family consists of seven unique ___}:1 {—ij
connector housings differentiated by color and keying.
This connector family is designed to use both 0.64 and K
2.8 sized terminals. ,
JST BCM Connector
GM Service Part# Color
88988806 Gray #4
88988837 Brown
1774100
88988838 Lt Green . __
2. Unlock the terminal posntionassurance (TPA):
88988839 Natural ..
- Posmon connector as shown (above) and
88988840 Lt Blue locate TPA staging cavities.
88988841 Black
88988842 Pink

2506090
- Using connector terminal release tool
J-38125—553(1) lift the TPA into the staged
1774096 position. Perform this step on both sides of
the TPA.
1. While depressing the lock, remove the connector
from the component.

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111574 Wiring Systems and Power Management

2506084 2506092
- You will feel the TPA click into place when fully ' The cavity on the left (1) is a 2.8 mm2cavity and
extended into the staged position. The figure the cavity on the right (2) is a 0.64 mm2cavity.
above shows the TPA (1) in the staged position. ° Place the tip of the connector terminal release
tool onto the connector lance (3) and deflect the
lance to the right (5) to release the lock. Hold
this released position.
' Holding the lance in the released position,
slightly pull on the suspect terminal to remove it
from the connector housing. The side TPA (4) is
a secondary lock.
4. Repairthe terminal by following the Repairing
Connector Terminals (Terminated Lead Repair) on
page 11-602or Repairing Connector Terminals
(Terminal Repair) on page 11-602 procedure.
5. Insertthe repaired terminal back into the cavity.
Repeat the diagnostic procedure to verify the
repair and reconnect the connector bodies.

Kostal Connectors (Glow Plug

Control Module)
Special Tools
- EL-38125-550 Terminal Release Tool Kit
2506091 - EL—38125—580 Terminal Release Tool Kit
- J-38125-24 Terminal Release Tool
3. Release the terminal from the connector:
. J-38125-560 Terminal Release Tool
' Position the connector as shown (above) and
locate the terminal release entry canal (1) of the For equivalent regional tools, refer to Special Tools on
suspect terminal. page 11-616.
- Insert the connector terminal release tool
J—38125—553 into the entry canal with the
angled side of the tool facing the connector wall
containing cavity 4(2).

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 WiringrSystems and Power Maggement 'l1u575
Terminal Removal Procedure

1709302
3. Use a small flat-blade tool to remove the dress
1709300 cover_ -
View of typical connector.

,_MWM2
2,2
wnw.2./22
25.
2.2
22
1709303
1709301 4. Slide the dress cover forward and off of the
View of connector in released position. 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.

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,~W
.2W
W

1709304
5. The terminal positive assurance (TPA) is located in
the front and rear of the connector.
Note: The front TPA cannot be removed from the
connector. Only move it to the preset position.
6. Use a small flat—bladetool to move the front TPA to
the preset position, outboard approximately
0.125 in. (3 mm).
10. Repair the terminal by following the Repairing
1709306
8. Use the J-38125—24or the J-38125-560 tool to
release the terminals by inserting the tool into the
terminal release cavity.
9. 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.
Connector Terminals (Terminated Lead Repair) on
page 11—602or Repairing Connector Terminals
(Terminal Repair) on page 11-602 procedure.

Kostal Connectors (Transmission)

Special Tools
43143331
- EL—38125-550Terminal Release Tool Kit
CMEHSJ-
- EL—38125-580Terminal Release Tool Kit
«343363
‘12:: ‘ J-38125—28Terminal Release Tool
For equivalent regional tools, refer to Special Tools on
page 11—616.

1709305
7. Use a small flat—bladetool to completely remove
the rear TPA from the connector.

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 Wiring Systems and Power Management 11577
Terminal Removal Procedure

Ul
g.

1921873
Note: The TPA cannot be removed from the connector
1921876 while there are terminals present in the connector body.
1. While depressing the lock, twist and remove the 3. Use a small flat-blade tool to push the TPA until it
connector from the component. bottoms out.

1921872 1921843
2. Locate the terminal position assurance (TPA). 4. Use the J—38125-28tool to release the terminals by
inserting the tool into the terminal cavity as shown
in the graphic.
5. 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.
6. Repair the terminal by following the Repairing
Connector Terminals (Terminated Lead Repair) on
page 11-602or Repairing Connector Terminals
(Terminal Repair) on page 11-602 procedure.

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114-578 Wiring Systems and Power Management
Terminai Insertion Procedure
After the terminal is replaced, perform the following
procedure in order to insert the terminal.
1. Slide the new terminal into the correct cavity at the
back of the connector.
2. Push the terminal into the connector until it looks
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.

1921872
5. Ensure the TPA is fully seated. The TPA should be
centered and flush with the connector body when
viewed.

Molex Connectors
Special Tools
- EL-38125-550 Terminai Release Tool Kit
- EL-38125—580Terminal Release Tool Kit
1921848 - J—38125-213Terminal Release Tool
3. Locate the TPA. For equivalent regional tools, refer to Special Tools on
page 11-616.
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on
the top of the wire dress cover. Slide the CPA
forward.

1921849
4. Use a small flat-blade toOlto push the TPA until it
bottoms out.

1709320
2. Slide the lever look foward while pressing down on
the lever lock release tab.

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 Wiring Systems and Power Managfiment 11-579

W
“22W“...M.
2.22
22.
N
M2.42.2222
1709258 1572878
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.

8&9 \V—I ‘1

llflmo

1709322
4. Disconnect the connector from the component.

1572905
7. Use a small fiat-blade tool to pry one side of the
nose piece up to the pre—stageposition. 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.

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 \~\
11-580 Wiring Systems and Power Management

Terminated Lead Repair

1. Remove the terminal.
2. Find the appropriate terminated lead.
3. Use the appropriate splice sleeves depending on
the gauge size.
4. Refer to Splicing Copper Wire Using Splice
Sleeves on page 11-544.
Terminal Insertion Procedure
After the terminal is replaced, perform the following
procedure in order to insert the terminal.
1. Slide the new terminal into the correct cavity at the
back of the connector.
2. Push the terminal into the connector until it looks
into place. The new terminal should be even with
the other terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector
disassembly procedure.
1572908
8. Use a small flat-blade tool to pry the other side of Sumitomo Connectors .Wa
v_m
.222
2.22
22.
the piece to the pre—stageposition. Ifthe nose Special Tools
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets - EL-38125-550 Terminal Release Tool Kit
with resistance from the connector body, you . EL—38125—580 Terminal Release Tool Kit
should feel the nose piece click into position. - J—38125-12ATerminal Release Tool
- J-38125—552Terminal Release Tool
° J—38125-553Terminal Release Tool
For equivalent regional tools, refer to Special Tools on
page 11-616.
222W
. ,22
Terminal Removal Procedure

1572911
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. Repair the terminal by following the Repairing
Connector Terminals (Terminated Lead Repair) on
page 11-602 or Repairing Connector Terminals 1709317
(Terminal Repair) on page 11-602 procedure.
1. Slide the lever look forward while pressing down on
11. insert the repaired terminal back into the cavity. the lever lock release tab.
Repeat the diagnostic procedure to verify the
repair and reconnect the connector bodies.

Wm
rNW
ww2
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 Wiring Systems and Power Management 11581

m 1:]
D o
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IE3} :
WUECDMEE
\~(mm HQ
0

1709319 1574069
2. Disconnect the connector from the component.
4. Relieve the tension on the nose piece retainers by
inserting J-38125-12A 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.

[—1
‘3 o
Illlulbifii
Hmm: El
H-
0
S g

1574033
3. Remove the dress cover by using a flat-blade tool
to release the connector locking tabs and pulling
off the dress cover.

1574058
5. Once the nose piece retainers are relaxed, use the
J-38125—552to pull up the nose piece by hooking
the tool under the nose piece and pulling up. The
nose piece should raise slightly.

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11-582 Wiring Systems and Power Management

1574184 1574218
. On the opposite side of the nose piece, use the Insert the J-38125—553tool into the entry canal and
J—38125-552pull up the nose piece by booking the pry up on the terminal retainer. The terminal
tool under the nose piece and pulling up. The nose retainer is a small plastic piece on the top of the 222
.222
W
.2
22.
_
22“
..
-2,
222
piece should release completely. Ifthe nose piece terminal. The terminal retainer must be held up
does not come off, repeat the procedure on the while the terminal is pulled out of the connector.
opposite side.

I/I/Ir/IA I

Am 1:1
_y

@1
51:3:t—:-——;'I;':I //‘//
ii .3. 171.29%] .1-‘Al-
84141181418 ';Iilll'(,,£l!’:~';’
# *\\“\\.‘ 421,4}.
111/11111111!”
LU //- fl/IIII/I/MI/I/Illlllln
4:4

1574534
1574213
The illustration shows a cutaway view of the
7. The illustration above identifies the entry canal connector to aid the technician in releasing the
where the terminal release tool will be inserted, terminal retainer.
and the terminal cavity. 10. Repair the terminal by following the Repairing
. Terminal (1) Connector Terminals (TerminatedLead Repair) on
- Entry Canal (2) page 11-602or Repairing Connector Terminals
(Terminal Repair) on page 11-602procedure.
11. Insert the repaired terminal back into the cavity.
Repeat the diagnostic procedure to verify the
repair and reconnect the connector bodies.

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Service
 Wirinngystems and Power Management 11683
Terminal Insertion Procedure
After the terminal is replaced, perform the following
procedure in order to insert the terminal.
1. Slide the new terminal into the correct cavity at the
back of the connector.
2. Push the terminal into the connector until it looks
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 connector
disassembly procedure.

TycolAMP Connectors (CM 42-Way)

Special Tools
- EL-38125-550 Terminal Release Tool Kit
- EL—38125-58OTerminal Release Tool Kit
- J-38125-12A Terminal Release Tool
For equivalent regional tools, refer to Special Tools on
page 11-616. 1263511
Terminal Removal Procedure . Using a small flat-bladed tool, push on the side of
the nose piece retainer while pushing the nose
1. Locate the connector position assurance (CPA) on
piece forward with your thumb. This will release the
the connector body and pull the CPA out. The CPA
terminal position assurance (TPA).
is on the wire harness side of connector.
2. Disconnect the connector from the component.

1263568
wn222222222222w‘W2222.2
,_
2,2222%,
_‘
2_‘ 1263409 . insert the J—38125—12A tool into the corresponding
terminal release cavity. The release cavities are
3. Use a small flat—bladedtool to gently pry off the the 2 center rows of cavities on one half of the
dress cover by inserting the tool under the cover connector.
opposite the harness side and prying up.
4. Remove the cover.

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11=584 Wiring Systems and Power Management

Terminal Removal Procedure

1. Disconnect the connector from the component.

1263581
7. Pressing the J—38125-12Atool in the release cavity
of the terminal you are removing, gently pull the
wire out of the back of the connector. Always 1454796
remember never use force when puttinga terminal
out of a connector. 2. Insertthe J—38125—11Atoolinto the cavity on the
lower right hand face of the connector until the
8. Repair the terminal by following the Repairing terminal release tang access panel slides over.
Connector Terminals (TerminatedLead Repair) on
page 11-602 or Repairing Connector Terminals
(Terminal Repair) on page 11-602 procedure.
9. Insert the repaired terminal back into the cavity.
Repeat the diagnostic procedure to verify the
repair and reconnect the connector bodies.

TycolAMP Connectors (Sensor)

Special Tools
- EL—38125-550Terminal Release Tool Kit
- EL-38125—580Terminai Release Tool Kit
- J-38125-11A Terminal Release Tool
For equivalent regional tools, refer to Special Tools on
page 11—616.

Ffl

1454799
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.
..22
-vM
Mn
..2.2
..
__
_
_.
7~

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 Wiring Systems and Power Management '11-585
Terminal Removal Procedure
1. Disconnect the connector from the component by
pressing down on the connector position
assurance (CPA).

»M
.22
2.
.22.
.

EEBBBBEBBBBEEEEB
BBBBBBEEBBBBBBEE

1454801
5. Insert the J-38125-11A 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. Ifthe
terminal is difficult to remove, repeat the entire
procedure.
6. Repair the terminal by following the Repairing
Connector Terminals (Terminated Lead Repair) on
page 11-602or Repairing Connector Terminals
(Terminal Repair) on page 11-602 procedure.
7. Insert the repaired terminal back into the cavity.
Repeat the diagnostic procedure to verify the
repair and reconnect the connector bodies.
TycolAMP Connectors (0.25 Cap)
Special Tools
- EL-38125-550 Terminal Release Tool Kit
- EL-38125-580 Terminal Release Tool Kit
- J-38125-24 Terminal Release Tool
For equivalent regional tools, refer to Special Tools on
page 11-616.
1459859
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.
Note: 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.

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11-586 Wiring Systems and Power Managgnent

TycolAMP Connectors (43-Way)

Special Tools
- EL-38125-550 Terminal Release Tool Kit
- EL-38125—580Terminal Release Tool Kit
- J—38125-12ATerminal Release Tool
- J-38125-13A Terminal Release Tool
For equivalent regional tools, refer to Special Tools on
page 11-616.
Terminal Removal Procedure
Follow the steps below in order to remove terminals
from the connector.
1. Locate the lever lock on the wire dress cover. Slide
the lever look 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-bladed
tool release all of the locking tabs.
.
1459860 4. Once the locks are unlocked, lift the dress
4. Ensure that the TPA is in the proper position to cover off.
remove the terminals.

1709323
1459861 Note: Always use care when removing a terminal
position assurance (TPA) in order to avoid damaging it.
5. While pushing the terminal fon/vard,insert the
J-38125—24in the release cavity above the terminal 5. Release the TPA by inserting a small flat-bladed
you are removing, gently pull the wire out of the tool into the blue locking tabs on both ends of the
back of the connector. Always remember never connector. Gently slide the TPA up to the released
use force when pulling a terminal out of a position on both ends.
connector.
6. Repair the terminal by following the Repairing
Connector Terminals (Terminated Lead Repair) on
page 11—602or Repairing Connector Terminals
(Terminal Repair) on page 11-602 procedure.
7. Insert the repaired terminal back into the cavity.
Repeat the diagnostic procedure to verify the
repair and reconnect the connector bodies.

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 ,-
Wiring Systems and Power Nianjgement 11-387

m '—Jr:1
O: BBBBBBBBBBBd
I:lBBEIEIBBBEIBEIBEJEI D :1
=7 EBBBBBBBBBEIB (201:0
m '11:)
l—l a

1709325 1709327
6. For the larger terminals insert the J-38125-13A tool View of the release tool being used for the larger
to release the terminals by inserting the tool into terminals.
the terminal release cavity. For the smaller
terminals insert the J—38125—12A tool to release the
terminals by inserting the tool into the terminal
release cavity.

1709328
View of the release tool being used for the smaller
terminals.
1709326 . While holding the removal tool in place, gently pull
the wire out of the back of the connector. Always
View of the release tool being used for the larger remember never use force when pulling a terminal
terminals. out of a connector.
. Repair the terminal by following the Repairing
Connector Terminals (Terminated Lead Repair) on
page 11-602or Repairing Connector Terminals
(Terminal Repair) on page 11—602procedure.
. Insertthe repaired terminal back into the cavity.
Repeat the diagnostic procedure to verify the
repair and reconnect the connector bodies.

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TycolAMP Connectors (Door Module) View of top of connector.

1. Locate the assist lever and lock on the top of the
Special Tools connector.
- EL-38125-550 Terminal Release Tool Kit
- EL—38125-580Terminal Release Tool Kit
. J—38125-12ATerminal Release Tool
For equivalent regional tools, refer to Special Tools on
page 11-616.
Terminal Removal Procedure

1709295
2. While depressing the lock, pull the lever over and
past the lock.

1709293
Side view of connector.

, :9

2:4

1709296
3. Disconnect the connector from the component.

1709294

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 Wiring Systems and Power Management 11589

1709297
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.
1709299
. Use the J—38125—12Atoolto release the terminals
by pressing on the tang.
. 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 the terminal by following the Repairing
Connector Terminals (TerminatedLead Repair) on
page 11-602 or Repairing Connector Terminals
(Terminal Repair) on page 11-602procedure.
. insert the repaired terminal back into the cavity.
Repeat the diagnostic procedure to verify the
repair and reconnect the connector bodies.

1709298
5. Once the locking tabs are unlocked, slide the inner
connector out of the rear of the connector housing.

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TycolAMP Connectors (102-Way

Inline)
Special Tools
- EL—38125—550 Terminal Release Tool Kit
~ EL—38125-580Terminal Release Tool Kit
- J-38125—11ATerminal Release Tool
0 J—38125-212Terminal Release Tool
- J-38125—216Terminal Release Tool
- J-38125-221 Terminal Release Tool
' J-38125-560 Terminal Release Tool
0 J-38125-566 Terminal Release Tool
For equivalent regional tools, refer to Special Too/son
page 11-616.
Terminal Removal Procedure

2146432
1. Pull the locking lever to the 90 degree position from
the connector body.

2146431
View of a typical connector in the assembled position.

2146434
2. With the locking lever in the 90 degree position and
the male connector body separated, it can be slid
outward for removal.

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.222
 Wiring Systems and Power Management 11:391

. 1"Q f/

2146435 2146439
3. Slide the male connector body out away from the 5. Using terminal release tool J-38125-566, press the
guide plates. prongs into the holes on each side of the terminal
to be removed to release the lock tabs and pull the
terminal out of the connector body.

2146438
Note: During assembly the terminal position
assurance (TPA) will not fully seat if any terminal is not 2146440
fully seated.
6. Using terminal release tool J-38125—560,press the
4. Using terminal release tool J—38125—11A
or prongs into the holes on each side of the terminal
equivalent, remove the TPA from the to be removed to release the lock tabs and pull the
connector body. terminal out of the connector body.

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.I—

WW
....

2146442 2146444
7. Using terminal release tool J—38125—221, press the 9. Move the locking lever 180 degrees from the
prongs into the holes on each side of the terminal connected position.
to be removed to release the lock tabs and pull the
terminal out of the connector body. .

2146445

2146443 10. With the locking lever in the 180 degree position
the guide plates can be removed from the
8. The female connector body may have an additional connector body.
connector hooked to the edge of the body. Use
terminal release tool J-38125-11A or equivalent to
release the locking tab and slide the connector off
the female body.

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 Wiring Systems and Power Management 11-593

2146446 2146449
Note: During assembly the TPA will not fully seat if any
terminal is not fully seated. 13. Terminal plate will bind slightly on each corner.

11. Using terminal release tool J-38125-11A or

equivalent, remove the TPA from the
connector body.

2146451
14. Using terminal release tool J—38125—221, press the
prongs into the holes on each side of the terminal
2146447 to be removed to release the lock tabs and pull the
terminal out of the connector body.
12. Using terminal release tool J—38125-216,lift the
terminal plate past the terminals and out of the
connector body cavity.

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2146452
15. Using terminal release tool J-38125-212, press the
prongs into the holes on each side of the terminal
to be removed to release the lock tabs and pull the
terminal out of the connector body.
- 2146449
17. Press the terminal plate back into the female
connector to the preset position. The plate will bind
slightly on each corner.

2146454
2146453
18. With the locking lever in the 180 degree position,
16. Using terminal release tool J-38125-560, press the align the guide plates to mesh with the gears on
prongs into the holes on each side of the terminal the locking lever.
to be removed to release the lock tabs and pull the
terminal out of the connector body.

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2146435 2146431
19. Slide the male connector body back inward toward 21. Move the lever into the locked position or in the
the guide plates. assembled position. This will pull the male
connector down into the female connector.
22. Repair the terminal by following the Repairing
Connector Terminals (TerminatedLead Repair) on
page 11-602or Repairing Connector Terminals
(Terminal Repair) on page 11-602 procedure.
23. Insertthe repaired terminal back into the cavity.
Repeat the diagnostic procedure to verify the
repair and reconnect the connector bodies.

2146434
l 20. With the locking lever in the 90 degree position and
the male connector body connected, it can be slid
inward for assembly.

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TycolAMP Connectors (Seat)

Special Tools
~ EL—38125-550Terminal Release Tool Kit
- EL—38125—580 Terminal Release Tool Kit
' J-38125—11ATerminalRelease Tool
- J-38125—212Terminal Release Tool
- J-38125-556 Terminal Release Tool
° J—38125—560 Terminal Release Tool
For equivalent regional tools, refer to Special Tools on
page 11-616.
Terminal Removal Procedure

2146424
Note: Terminal position assurance (TPA) is keyed and
can only be inserted in one direction.
3. Using terminal release tool J—38125—11Aor
equivalent, push the TPA tabs into the
connector body.

\ \

2146421
1. Grasp the locking slide lever and pull outward from
the end of the connector.

2146425
4. Pull the TPA from the connector body.

2146422
2. As the slide lever is pulled out the mating
connector is lifted from the seated position.

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 Wiring Systems and Power Management 11-597
N/Afwh

2146426 2146428
5. Using terminal release tool J-38125-11A or 7. Using terminal release tool J—38125-212,press the
equivalent, release the connector wire dress cover prongs into the holes each side of the terminal to
locking tab. be removed to release the lock tabs and pull the
terminal out of the connector body.

, / / .I.-

2146427
6. With the lock tab released, liftthe connector wire
dress cover from the connector body.
2146429
. Using terminal release tool J—38125—560, press the
prongs into the holes on each side of the terminal
to be removed to release the lock tabs and pull the
terminal out of the connector body.

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Removal Procedure

2146430
9. Using terminal release tool J—38125—556, press the
prongs into the holes on each side of the terminal 2146413
to be removed to release the lock tabs and pull the 1. Using your thumbs press down and slide the red
terminal out of the connector body. CPA away from the connector lever.
10. Repair the terminal by following the Repairing
Connector Terminals (Terminated Lead Repair) on
page 11—602or Repairing Connector Terminals
(Terminal Repair) on page 11-602 procedure.
11. Insert the repaired terminal back into the cavity.
Repeat the diagnostic procedure to verify the
repair and reconnect the connector bodies.

TycolAMP Connectors (SIR)

Special Tools
- EL—38125—550Terminai Release Tool Kit
0 EL—38125—580Terminal Release Tool Kit
- J-38125——11A Terminal Release Tool
- J—38125-215ATerminal Release Tool
For equivalent regional tools, refer to Special Tools on
page 11-616.

2146414
2. Using your thumb press down on the locking tab
and move the lever to the released position.

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 Wiring Systems and Power Management 11699

22%
2222.22
22.222‘-w
.2
,2.

2146417 2146419
3. Using terminal tool J-38125-11A or equivalent, 5. Using terminal tool J-38125-11A or equivalent,
release the wire dress cover locking tabs. remove the TPA by lifting straight off the
connector body.

2146418
. . . . 2146420
4. Pivot connector w1redress cover while removmg
from the connector body. 6. Using terminal release tool J—38125-215A,place
‘ the tip of the tool on the outside edge next to the
terminal and depress the lock tab and remove the
rear of the connector body.
Terminal Repair Procedure
Use the appropriate terminal and crimper in order to
replace the terminal.

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Yazaki Connectors (2-Way) 5. Insert the J—38125—553 on a slight upward angle

into the cavity below the terminal to be removed.
Special Tools Ensure that the pointed on the end of the tool is I‘M
22.2
- EL—38125—550 Terminal Release Tool Kit facing the bottom of the terminal and it stays in
contact with the terminal until it stops on the plastic
- EL-38125-580 Terminal Release Tool Kit
terminal retainer.
- J—38125—553 Terminal Release Tool
For equivalent regional tools, refer to Special Tools on
page 11-616.
Terminal Removal Procedure
1. Disconnect the connector from the component.

1454553
6. Gently prythe plastic terminal retainer down and
carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. Ifthe terminal is
difficult to remove, repeat the entire procedure.
1454532
7. Repair the terminal by following the Repairing
2. Insert a small flat—bladetool in the slot below the Connector Terminals (Terminated Lead Repair) on
front loaded terminal position assurance (TPA) and page 11-602 or Repairing Connector Terminals
pry UP- (Terminal Repair) on page 11—602procedure.
3. Remove the TPA by pulling it out of the connector. 8. Insert the repaired terminal back into the cavity.
4. Push the wire side of the terminal that is being Repeat the diagnostic procedure to verify the
removed toward the connector and hold it in repair and reconnect the connector bodies.
position.
Yazaki Connectors (16-Way)
Special Tools
- EL-38125—550Terminal Release Tool Kit
- EL-38125—580Terminal Release Tool Kit
° J—38125—215 Terminal Release Tool
For equivalent regional tools, refer to Special Tools on
page 11-616.

1454546

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 Wiring Systems and Power Management '1’1-601
Terminal Removal Procedure

1709335
4. View of the female half of the connector with male
1709336 terminals.
1. While depressing the lock, pull the two connector 5- US? the 438125-215 tool to release the terminals
halves apart. by Insertan the tool into the terminal release cavrty.
Note: The terminal position assurance (TPA) is fragile
and may break if not done carefully.
2. Use a small flat-blade tool to very carefully push
the TPA towards the face of the connector on both
sides of the connector.

1709332
6. View of the female half of the connector with male
terminals.

1709329
3. View of the male half of the connector with female
terminals.
222.22.222.222222222222222.M22222222222222nv_222
w.22222222_22222_22..
222222.222.

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Repairing Connector Terminals

(Terminal Repair) MPN
Special Tools
~ J-38125-580 Terminal Repair Kit
- J—38125—6 Crimp Tool
- J-38125-7 Crimp Tool
- J—38125-8Crimp Tool
0 J-38125-64 Crimp Tool
- J-38125—101Crimp Tool
. J-38125-641 Crimp Tool
. J-38125-642 Crimp Tool
0 J-38125-643 Crimp Tool
For equivalent regional tools, refer to Special Tools on
page 11-616.
Use the following repair procedures to repair each type
of terminal:
. For push to seat terminals, refer to Delphi
1709331
Connectors (Weather Pack) on page 11-559or
7. View of the male half of the connector with female Delphi Connectors (Pull To Seat) on page 11-561
terminals. or Delphi Connectors (Push To Seat) on
page 11-560 or Delphi Connectors (12—Way)on
8. While holding the removal tool in place, gently pull
out of the back of the connector. Always page 11—567or Delphi Connectors (Micro .64) on
the wire
page 11-564 or Delphi Connectors (Steering Gear)
remember never use force when pulling a terminal
-on page 11—569or Delphi Connectors (Micro—Pack
out of a connector.
100W) on page 11-561.
9. Repair the terminal by following the Repairing
Connector Terminals (Terminated Lead Repair) on . For pull to seat terminals, refer to Delphi
page 11-602or Repairing Connector Terminals _.Connectors (Weather Pack) on page 11-559 or
(Terminal Repair) on page 11—602procedure. Delphi Connectors (Pull To Seat) on page 11—561
or Delphi Connectors (Push To Seat) on
10. Insertthe repaired terminal back into the cavity. page 11—560or Delphi Connectors (12-Way) on
Repeat the diagnostic procedure to verify the page 11-567or Delphi Connectors (Micro .64) on
repair and reconnect the connector bodies. page 11—564or Delphi Connectors (Steering Gear)
on page 11-569or Delphi Connectors (Micro-Pack
Repairing Connector Terminals 100W) on page 11-561.
(Terminated Lead Repair) ' Note: The first step for all terminal repairs is to find the
connector end view in SI.
Special Tools
EL-38125-10 Splice Sleeve Crimp Tool Cable Seal Terminals
For equivalent regional tools, refer to Special Tools on 1. Cut off the terminal between the core and the
page 11—616. insulation crimp to minimize any wire loss.
Note: All repairs nearthe engine manifold, turbo 2. Remove the old seal.
engine and all exhaust pipes should follow the High 3. Apply the correct cable seal, per the wire gauge
Temperature Wiring Repairs procedures. size, from the kit. Slide the seal back along the wire
to enable removal of the insulation.
For high temperature wiring repairs, refer to High
Temperature Wiring Repairs on page 11-543. 4. To minimize wire loss, remove only the insulation
required.
Terminated leads are terminals that are crimped onto
wires. The terminated lead can be used throughout the 5. Using the connector end view, determine the
vehicle since it is designed for temperatures up to 150° correct crimp tool and crimp jaw.
C. The length of the wire is 450 mm. Align the seal with the end of the cable insulation.
1. Use the connector end view to identify the correct Position the stripped wire and seal in the terminal.
terminated lead. Hand Crimp the core wings first. 222
2.
22M
2.22
22.2
222
2. The terminated lead package should include a Hand Crimp the insulation wings around the seal
50.05%“?
DuraSeal splice sleeve. Ifnot, use the chart to in and the cable.
Splicing Copper Wire Using Splice Sleeves to
10. Solder all of the hand crimp terminals except the
identify the correct DuraSeal splice sleeve, refer to
Micro-Pack 100 and 0.64 sizes.
Splicing Copper Wire Using Splice Sleeves on
page 11—544.

i
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—‘
 Wiring Systems and Power Management 11603
Unsealed Terminals
1. Cut off the terminal between the core and the
insulation crimp to minimize any wire loss.
N To minimize wire loss, remove only the insulation
required.
Position the stripped wire in the terminal.
Hand Crimp the core wings first.
Hand Crimp the insulation wings around the cable.
93.01.69)
Solder all of the hand crimp terminals except the
Micro—Pack100 and 0.64 sizes.
Micro-Pack 100W Size Terminal
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 (Wjaw) crimping tool was developed to
crimp Micro—Pack100W 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 862185
connector perform the following procedure in order to 4. Insert the terminal into the crimp tool until the core
repair Micro-Pack 100 terminals. wings are flush with the anvil on the crimp tool. Be
1. Cut the wire as close to the terminal as possible. sure that the wings are pointed toward the crimp
Note: After cutting the damaged terminal from the wire, tool former and release the spring locator. The
determine if the remaining wire is long enough to reach locator will hold the terminal in place. inspect the
the connector without putting a strain on the wire. Ifthe alignment of the terminal wings with the crimp tool
wire is not long enough, splice a small length of the former. if the terminal wings are wider than the
same gauge wire to the existing wire, then crimp the crimp tool former, remove the terminal and bend
new terminal on the added wire. the terminal wings in slightly.
5. Place stripped wire into terminal.
2. Strip 5 mm (3/16in) of insulation from the wire.
6. Crimp the new terminal to the wire. if a jam occurs,
press the emergency release to open applicator.
Micro 0.64 Size Terminal
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
(Mjaw) 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—38125-64crimping 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.
Note: 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. Ifthe
wire is not long enough, splice a small length of the
same gauge wire to the existing wire, then crimp the
862167 new terminal on the added wire.
3. Depress the spring loaded locator of the 1. Cut the wire as close to the damaged terminal as
J 38125-101 (W jaw) crimping tool until the terminal possible.
holder is completely visible. 2. Strip 5 mm (3/16in) of insulation from the wire.

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875015 damage to the terminal(s) that are probed.
3. Depress the spring loaded locator of the crimping
tool until the terminal holder is completely visible.
875016
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.
Terminal Removal
Special Tools
1 EL-38125—550Terminal Release Tool Kit
1 EL-38125—580Terminal Release Tool Kit
1 EL-35616 Terminal Test Probe Kit
For equivalent regional tools, refer to Special Tools on
page 11—616.
Note: All repairs near the engine manifold, turbo
engine and all exhaust pipes should follow the High
Temperature Wiring Repair procedures.
1. Find the appropriate connector and view within the
connector end view section. The connector end
view has the following information:
1 Diagnostic probe tool
1 Terminal release tool
1 TerminaI/terminatedlead part numbers
Note: Not using the proper test kit probe may cause
2. Determine ifa terminal is damaged.
1 Locate the diagnostic probe tool from the
connector end view. The connector end view
describes the color and part number to help the
technician find and use the correct tool.
1. Connect the probe tool to the Digital Multimeter.
1 Insert the probe tool into the cavity and follow
the procedures from the Troubleshooting with a
Digital Multimeter on page 11-527.
3. Disconnect the connector body to perform the
repair.
4. Use the following procedure to remove the terminal
from the connector body.
Note: Several procedures for specific connector
bodies are called out in the Wiring Repairs section.
1 The terminal position assurance (TPA) and
connector position assurance (CPA) should be
removed before releasing the terminal for the
connector body.
1 Look at the connector end view to locate the
cavity of the damaged terminal and find the
proper terminal release tool from the terminal
release tool kit.
Note: Using the incorrect terminal release tool can
damage the connector body.
Note: Some terminals have a lever that must be
disengaged before the terminal can be released.
1 Insert the terminal release tool into the cavity.

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1774105
5. Gently pull the wire out of the back of the
connector.
6. Repair the terminal by following the Repairing
Connector Terminals (Terminated Lead Repair) on
page 11-602or Repairing Connector Terminals
(TerminalRepair) on page 11-602 procedure.
7. Insertthe repaired terminal back into the cavity.
Repeat the diagnostic procedure to verify the
repair and reconnect the connector bodies.

ignition Key Cannot Be Inserted, Rotated, or Removed from the Ignition Lock Cylinder
Step Action Yes No
1. Ensurethetransmissionshiftleveris inthePARK positionand
thesteeringcolumnis NOTin thelockedposition.
2. Verifytheignitionkey cannotbe removedfromtheignitionlock
cylinder.
Can theignitionkey be removedfromtheignitionlock cylinder? Go to Step4 Go to Step2
Verifytheignitionkey cannotbeturnedtothe OFF position.
Can theignitionkey be turnedtotheOFF position? Go to Step3 Go to Step7‘
Verifytheignitionkey cannotbe removedfromtheignitionlock
cylinder.
Can theignitionkey be removedfromtheignitionlock cylinder? Go to Step7 Go to Step12
Verifytheignitionkeycannotbefully insertedandrotatedwithout
stickingin any position.
Can theignitionkey befullyinsertedintotheignitionlock cylinder
andberotatedwithoutstickingin anyposition? Go to Step 7 Go to Step5
Inspectforan incorrect,worn,ordamagedignitionkey.
Istheignitionkey incorrect,worn,or damaged?
2.22.22NW22222222M2
.2.22
22.22222222222WW2222_222
,222 Go to Step 10 G0 to Step6
inspecttheignitionkey.Cleantheentiremiddlegrooveareaof the
side milledignitionkey.
Can thecleanedkey befullyinsertedintotheignitionlock cylinder
andbe rotatedwithoutstickingin anyposition? Go to Step 13 Go to Step 12
Verifytheadjustmentof theshiftcontrolcable. Referto Range
SelectorLeverCable Adjustmentonpage 17-196.
Can theignitionkey be turnedtotheOFF positionand be removed? Go to Step13 Go to Step8
Attemptto overridetheignitionlocksolenoid0n theignitionand
startswitchhousing.
Can theignitionkey be turnedtotheOFF positionand be removed? Go to Step9 Go to Step12

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ignition Key Cannot Be Inserted, Rotated, or Removed from the Ignition Lock Cylinder
(cont'd)
Step Action Yes No
Inspecttheelectricalsystemforimproperoperation.Referto 22.2
.22.
TestingforIntermittentConditionsandPoor Connectionson
9 page 11-531.
Can theignitionkeybeturnedtotheOFF positionandbe removed? Go to Step13 Go to Step11
1. Replacetheignitionkeywitha newcutkey.Referto Door
LockandIgnitionLookFoldingandNon-Fo/dingKey Cutting
onpage 1-24.
10
2. Programthetransmitter. Referto Key withIntegrated
Transmitter
Programmingonpage 13-30.
Didyoucompletetherepair? Go to Step 13 -
Replacethefloorshifter.Referto TransmissionControl
11 Replacementonpage 17—193.
Didyoucompletetherepair? Go to Step 13 -
Replacetheignitionlockcylinder.Referto IgnitionLock Cylinder
12 Replacementonpage 11-611.
Didyoucompletetherepair? Go to Step 13 -
Operatethesysteminordertoverifytherepair.
13 Didyoucorrectthecondition? SystemOK —-

information on GMLAN, refer to Data Link

Repair Instructions Communications Description and Operation on
page 11—68.

GMLAN and Media Oriented Systems GMLAN Connector Terminai Repair

Transport (MOST) Wiring Repairs
Special Tools
1 EL-38125-10 Splice Sleeve Crimping Tool
1 DuraSeal splice sleeves
1 A wire stripping tool
For equivalent regional tools, refer to Special Tools on
page 11~616.
The DuraSeal splice sleeves have the following
2 critical features:
1 A special heat shrink sleeve environmentally seals
the splice. The heat shrink sleeve contains a
sealing adhesive inside.
1 A cross hatched (knurled) core crimp provides
necessary contact integrityfor the sensitive, low
energy circuits.
The GM Local Area Network (GMLAN) System requires
special wiring repair procedures due to the sensitive
nature of the circuitry. Follow the specific procedures
and instructions when working on GMLAN connectors
and terminals.
GMLAN Repairs
Note: When making a repair to any GMLAN network,
the original wire length after the repair must be the
same length as before the repair. lfthe 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
Note: A terminated lead can be used to replace
damaged connector terminals for both high speed and
low speed GMLAN systems. When making a connector
terminal repair on a GMLAN high speed system with
twisted pair wires, do not untwist the wires more than
necessary to make the repair.
Ifthe individual terminals are damaged on any GMLAN
connection, use the appropriate connector repair
procedure in order to repair the terminal. Refer to
Connector Repairs on page 11—548for the appropriate
connector repair procedure.
GMLAN Wire Repair
Note: Refer to Wiring Repairs in the service
information connector end views or the vehicle
schematics in order to determine the correct wire size
for the circuit you are repairing. You must obtain this
information in order to ensure circuit integrity.
Ifany wire except the pigtail is damaged, repair the wire
by splicing in a new section of wire of the same gauge
size (0.5 mmz,0.8 mmz, 1.0 mm2etc.). Use the
DuraSeal splice sleeves and EL-38125-10 tool. For
wiring repair, refer to Splicing Copper Wire Using Splice
Sleeves on page 11-544.

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 Wiring Systems and Power Management 1160’?
Relay Replacement (Attached to Wire Installation Procedure
Harness)

Removal Procedure

791846
1. Connect the relay (1) to the wire harness
connector (2).
791846 2. lnstall any connector position assurance (CPA)
1. Locate the relay. Refer to the Master Electrical devices or secondary locks.
Component List on page 11-162to locate the relay 3. Install the relay using any fasteners or tape that
in the vehicle. originally held the relay in place.
2. Remove any fasteners which hold the relay in
place. Relay Replacement (Within an
3. Remove any connector position assurance (CPA) Electrical Center)
devices or secondary locks.
Note: Use care when removing a relay in a wiring Special Tools
harness when the relay is secured by fasteners or tape. EL—43244Relay Puller Pliers
4. Separate the relay (1)from the wire harness Removal Procedure
connector(2).
1. Remove the electrical center cover.
Note:
1 Always note the orientation of the relay.
1 Ifequipped with a notch style relay; observe the
location of the notch on the old relay to verify
the new relay is installed with the notch in the
same location.
1 Ensure that the electrical center is secure, as ‘
not to put added stress on the wires or
terminals.
2. Locate the relay. Refer to Electrical Center
Identification Views on page 11—240to locate the
electrical center where the relay exists.

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11-608 Wiring Systems and Power Management

Installation Procedure

222
,

786629
3. Using the EL-43244 (1) position the tool on
opposing corners of the relay (2). 786629
Caution: Use EL—43244 to pull the relay straight out 1. Install the relay (2) in the same position as
from the electrical center terminals. The use of pliers or removed.
a flat bladed tool could damage the electrical center. 2._Install the electrical center cover.
4. Remove the relay (2)from the electrical center.

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 Wiring Systems and Power Management 112609
Front Compartment Fuse Block
Replacement

Removal Procedure
1. Disconnect the battery negative cable. Refer to
Battery Negative Cable Disconnection and
Connection on page 9713.

2504710
Remove the junction block nut (1).
Remove the junction block bolts (2).
. Disconnect the wiring harness from thejunction
block base.
. Remove thejunction block (3) from the base.

2508802
2. Remove thejunction block cover (1).

2504774
. Disconnect the wiring harness from the junction
block base.
2504689 10. Remove the junction block nut (1) from the
block base.
3. Remove the positive battery cable nut (1) from the 11. Remove the junction block base (2)from the inner
junction block. wheelhouse.
4. Remove the positive battery cable (2) from the
junction block.

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11-610 Wiring Systems and Power Management
Installation Procedure

2504689
6. Position the positive battery cable to the junction
2504774 block
1. Position the junction block base (2) to the inner 7- “1313”the positive battery cable nut (2)and tighten
wheelhouse stud. to 5 N1m(44 lb 1n).
Caution: Refer to Fastener Caution on page 0-8.
2. Install thejunction block base nut (1) and tighten to
9 N1m(79 lb in). '

—: -\11¢
.II—LI 1:.li
1:11
111-‘11.» .

2508802
8. Install thejunction block cover(1).
9. Connect the battery negative cable. Refer to
2504710 Battery Negative Cable Disconnection and
.03Install the junction block to the base. Connection on page 9-713.
4. Install the junction block bolts (2) and tighten to
9N1m(79 lb in).
5. install thejunction block nut (1) and tighten to 7N1m
(61 lb in).

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 Wiring Systems and Power Management 11=611
Ignition Lock Cylinder Replacement installation Procedure
1. Ifyou are installing a new ignition lock cylinder,
Removal Procedure code the lock cylinder. Refer to Look Cylinder
1. Disconnect the battery negative cable. Refer to Coding - Ignition on page 1—28.
Battery Negative Cable Disconnection and
Connection on page 9—713.
2. Remove the uppertrim cover and the lower trim
cover from the steering column. Refer to Steering
Column Lower TrimCover Replacement on
page 15—29.
3. Insert the key into the ignition lock cylinder and
turn the key to the RUN position.

2222983
4. Push a pick—typetool into the access hole (2) in the
ignition and start switch housing and press the
ignition lock cylinder lock tab down.
5. Remove the ignition lock cylinder (1) from the
ignition and start switch housing.
2222983
. Turn the key to the RUN position and insert ignition
lock cylinder (1) into the ignition and start switch
housing.
. Turn the key to the LOCK position and remove the
key from the ignition lock cylinder.
. install the upper trim cover and the lower trim cover
to the steering column. Refer to Steering Column
Lower TrimCover Replacement on page 15—29.
. Connect the battery negative cable. Refer to
Battery Negative Cable Disconnection and
Connection on page 9—713.

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11-612 Wiring Systems and Power Management

Ignition and Start Switch Replacement

2508978
Ignition and Start Switch Replacement
Callout Component Name
Preliminary Procedures
1. Disconnectthebatterynegativecable.Referto BatteryNegativeCableDisconnectionand Connectiononpage9-713.
2. Removethesteeringcolumn.Referto SteeringColumnReplacementonpage 15-33.
1 ignitionandStartSwitchBolt(Qty:2)
Caution: Referto FastenerCautiononpage0—8.
IgnitionandStartSwitch
2 Procedure
Disconnectanyelectricalconnectorsas necessary.

2mm
WW
22.2
222
.WM

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 Wiriry Systems and Power Management ‘11-6’13
Ignition and Start Switch Housing Replacement

2508981
Ignition and Start Switch Housing Replacement
Callout Component Name
Preliminary Procedure
Removetheturnsignalswitchbracket.Referto TurnSignalSwitchBracketReplacementonpage 15-30.
IgnitionandStartSwitchHousingBolt
Caution: Referto FastenerCautiononpage 0-8.
1 Procedure
1. Discardtheoldignitionandstartswitchhousingbolt.
2. InstalltheNEW ignitionandstartswitchhousingboltandtightenuntiltheboltheadbreaksoff.
IgnitionandStartSwitchHousingStrap
2 Procedure
Installtherightside of thestraptothehookontherightside ofthehousing.
IgnitionandStartSwitchHousing
Procedure
1. Disconnectanyelectricalconnectorsas necessary.
2. Transfercomponentsas necessary.

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11.614 Wiring Systems and Power Management

Description and Operation Power Mode Description and Wn\

Electronic Park Lock Description
Operation
if the vehicle is equipped with automatic transmission
and a floor mounted console gear shift, it has an
electronic park lock system (EPL). The EPL system
purpose is to prevent the ignition key from being turned
to the OFF position when the transmission is in any
position other than PARK and the vehicle may still be
moving. The EPL system consists of an ignition lock
cylinder solenoid, and a park position switch that is
located in the A/Tshift lock control switch. The ignition
lock cylinder solenoid contains a pin that is spring
loaded to mechanically prevent the ignition key cylinder
from being turned to the lock position when the vehicle
transmission is not in the PARK position. Ifvehicle
power is lost, and/or the transmission is not in the Park
position the operator will not be able to turn the ignition
key to the lock position and will not be able to remove
the ignition key from the column.
Power
Operation
and Serial Data Power Mode Master
Power to many of this vehicles circuits is controlled by
the module that is designated the power mode master.
This vehicles power mode master is the body control
module (BCM). The BCM has multiple B+ circuits that
feed into it. Each of those circuits are partitioned within
the controller to drive certain outputs of the vehicle’s
body functions. An open or short in any one of the B+
circuits may induce multiple codes/or a section of
non-functionality within the BCM with the rest of the
BCM functioning normally. Inthis case it is useful to
refer to the power distribution schematics to determine
if the non—functionalpartition of the controller shares a
common B+ circuit. The ignition switch is a low current
switch with multiple discrete ignition switch signals to
the power mode master for determination of the power
mode that will be sent over the serial data circuits to the
other modules that need this information.The power
mode master will also activate relays and other direct
outputs of the power mode master as needed. The
power mode master determines which power mode
(Off, Accessory, Run, Crank Request) is required, and
reports this informationto other modules via serial data.
Modules which have switched voltage inputs may
operate in a default mode if the power mode serial data
message does not match what the individual module
can see from its own connections.
The power mode master receives ignition switch
signals to identify the operators desired power mode.
The Power Mode Parameters table below illustrates the
correct state of these input parameters (circuits) in
correspondence to the ignition switch position:
Mode Parameters

IgnitionSwitch Power Mode lgn. Off/Run/Crank AchgsgiggIVRun IgnitionRunlCrank

Position Transmitted \(Iglftfggncciifuqr) (Accescsory'Voltage (Ignitlgsguxl)?ltage
Ircmt)
OffKey Cut Off Key Out/ACC Inactive inactive
OffKey IN Off Key In/Off inactive Inactive
Accessory Accessory Key Out/ACC Active Inactive
Run Run Run Active Active
Start CrankRequest Crank Inactive Active

Relay Controlled Power Mode Push Button Start (If Equipped)

The BCM uses the discrete ignition switch inputs Off/
Run/Crank Voltage, Accessory Voltage, and Ignition1
Voltage, to distinguish the correct power mode. The
BCM, after determining the desired power mode, will
activate the appropriate relays for that power mode.
The retained accessory power relay remains on for a
timed period after the Ignition key is removed. Refer to
Retained Accessory Power Description and Operation
on page 11-615for more information on the retained
accessory power function.
The ignition mode switch has 2 LEDs that indicate the
vehicle power mode. When the vehicle is in the off
mode, both LED’s will be off. Pressing the ignition
mode switch button once (withoutthe brake pedal
applied), the vehicle enters the accessory mode and
the amber LED (ACC) will illuminate. The accessory
mode has a 5 minute timeout to reduce battery drain.
Pressing the ignition mode switch buttona second time
(withoutthe brake pedal applied), the vehicle enters the
run/startmode (withoutthe engine running)and the
green LED (Run/Start)will illuminate. With the ignition
off (withoutthe brake pedal applied) and pressing and
holding the push button start switch for up to
10 seconds will place the vehicle in run/startmode

2013
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 Wiring
(withoutthe vehicle running) and the green LED (Run/
Start) will illuminate. With the ignition off (withthe brake
pedal applied), pressing the ignition mode switch button
once, the vehicle will enter run/start mode and the
green LED (run/start)wi||illuminate. This will start the
engine. Both LED’s have the voltage supplied from the
body control module (BCM). The ignition mode switch
sends the ignition mode switch status to the passive
entry passive start module (PEPS) and to the BCM.
The PEPS module sends a redundant signal to the
BCM with the ignition mode switch status.
Battery Saver Mode (Transport Mode) (If
Equipped)
The battery saver mode (transport mode) reduces the
parasitic load of some modules during overseas
shipment or during vehicle storage conditions. This
improves the drain time on the battery (up to 70 days
without the battery going dead). When the vehicle is in
transport/storage,some features may have reduced
functionality while in the battery saver mode (transport
mode), such as disabling the Remote Function Actuator
or content theftfeatures.
The battery saver mode (transport mode) incorporates
a latching relay that when enabled disconnects some
modules from their ignition power or memory power
sources. Battery saver mode (transport mode) is
initiated by turning on the hazard flashers and then
turning the ignition key into the crank position or
pushing the push button start switch (if equipped) for
greater than 15 seconds. The mode is disengaged by
repeating the previous process causing the relay to
latch in the other direction. After battery saver mode
(transport mode) has been enabled, the BCM may not
AMLMM_
W
....m.
4
“,0. send the command to unlatch the relay until after the
NWW_.~W‘W
ignition has been switched to the off position for up to
1 minute. In battery saver mode (transport mode) the
BCM will send a command to latch the relay for
operation of those modules while the ignition is in the
run position and then again unlatching the relay after
the ignition is turned off. The DlC (if equipped) will
display Transport Mode is On when the transport mode
is enabled and Transport Mode is Off when the
transport mode is disabled. For vehicles not equipped
with a DIC, the battery indicator light will constantly
flash on the InstrumentCluster when transport mode is
enabled. Once the vehicle is running and the hazard
flashers are on, turning the ignition key into the crank
position or pushing the push button start switch (if
equipped) for greater than 15 seconds will latch the
relay in the other direction. This feature can be used as
many times as necessary if the vehicle is to be stored
for an extended period of time.
BCM Awake/Sleep States
The BCM is able to control or perform all of the BCM
functions in the awake state. The BCM enters the sleep
state when active control or normal monitoring of
system functions has stopped and a time limit has
passed. The BCM must detect certain wake-up inputs
before entering the awake state. The BCM monitors for
these inputs during the sleep state.
2013
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Systems and Power Management 112615
The BCM will enter the awake state ifany of the
following wake-up inputs are detected:
- Activity on the serial data line
' Detection of a battery reconnect
- Any door open signal
- Headlamps ON
- Key-in-ignition
- IgnitionON
~ Park lamps ON
- Keyless entry or remote start message
The BCM will enter a sleep state when all of the
following conditions exist:
- The ignition switch is OFF, key out.
- No activity exists on the serial data line.
- No outputs are commanded.
o No delay timers are actively counting.
- No wake-up inputs are present.
Ifall these conditions are met, the BCM will enter a low
power or sleep condition.
Retained Accessory Power
Description and Operation
Retained Accessory Power
The body control module (BCM) monitors the ignition
switch position, battery condition, and each door ajar/
open switch status to determine whether the retained
accessory power should be initiated or terminated.
Retained accessory power is controlled by two different
methods; relay control and serial data. Some modules
receive a retained accessory power message from the
BCM over the serial data circuits. Serial data controlled
retained accessory power is deactivated as required by
their modules retained accessory power mode
operation. Other subsystems are activated directly by
the BCM through a relay. Components and systems
that are active in retained accessory power are also
activated anytime the ignition is any position other than
OFF regardless of the door switch signals.
Relay Controlled Retained Accessory
Power
The BCM keeps the relay energized during all power
modes, except Off-Awake and Crank. The relay is also
energized for approximately 10 minutes after shutting
the ignition OFF and removing the key, providing no
door is opened.
Relay controlled retained accessory power will end
when one of the following conditions is met:
- The BCM receives an inputfrom any door ajar or
open switch indicating the opening of any door
after the ignition key is out of the ignition.
Note: Ifthe BCM is receiving any door ajar or open
signal from those switches when the ignition key is
turned OFF, retained accessory power will not initiate.
' The BCM internal timerfor the retained accessory
power expires after approximately 10 minutes.
- The BCM detects a decrease in battery capacity
below a prescribed limit.
‘l 1=616 Wiring Systems and Power Management
Systems powered by the retained accessory power Tool Number/
relay during the retained accessory power mode are as Illustration Description
follows:
Note: The vehicle may not be equipped with all
components as listed below.
- Accessory Power Receptacle
- Cigarette Lighter Receptacle EL—35616
% KM-609
- Window Switches
W?” ‘H % TerminalTestProbeKit
- Sunroof Control Module
- Sunroof Switch / ll 9‘
0 Mobile Device Wireless Charger Module
- Mobile Telephone Control Module 5917
- Traffic Data Receiver
- Transmission Shift Lever Position Indicator (w/
floor mounted console gear shift)
- Seat Heating Control Module EL-35616—200
Serial Data Controlled Retained KM—J-34142—B
TestLight~ProbeKit
Accessory Power
Retained accessory power systems controlled by serial
data are as follows:
Radio 1338380

Radio retained accessory power activation /termination

is the same as relay operation with one exception; the
only door switch that will turn off the radio during
retained accessory power is the driver door open EL-35616—20F
switch.
KM-963
Vehicle Communication Interface Module FusedJumperWire
(VCIM) (Onstar®) (If Equipped)
VCIM RAP activation/termination is the same as radio
operation with 1 exception; ifthere is an active call
when the ignition key is turned off the VCIM will remain
in RAP mode, and keep the radio in RAP mode until the
call is terminated.
EL-38125—10(Non—North
Special Tools and Equipment America)
EL-38125—EU (Europe)
Tool Numberl J-38125—8(North
Illustration Description AmericaOnly)
Splice SleeveCrimpTool
U
C 1% 2498072
’3 EL-25070
‘ EL-38125-5A
EL-38125-5
J-38125-5A
' HeatGun500—700F EL-38125-55O(North
AmericaOnly)
TerminalReleaseToolKit
78337

2736016

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2013 (5377994)
Manual
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MM
K"
Mo
2..M
Ad-»
.
 Wiring; Systems and Power Management 11:61 7
Tool Number/ Tool Number/
illustration Description illustration Description

EL-38125-580(Non-North
America) EL-43244
TerminalReleaseToolKit Relay PullerPliers

696431

m
M
._____...

EL-39200(North
AmericaOnly) EL-47955
MKM 874(Non-North J-2534
America) MultiDiagnostic
DigitalMultimeter InterfaceMDI

2191416

EL-42759
EL-50040(HoldenOnly)
IgnitionSwitchConnector
ReleaseTool CrimpingToolKit
VW,W‘4..
ewwwgvmwhwm.
.-.
2...
??flfgs
606621 2736014

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1’1-618 Wiring Systems and Power Management

mwm

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 Table of Contents 'l2-‘l

Section 12

Roof

Sunroof ........................................ 12-3 Sunroof Module Assembly Replacement .... . . 12—11

Specifications ................................... 12—3
Fastener Tightening Specifications ............. 12-3
Schematic and Routing Diagrams .............. 12-3
Sunroof Schematics ............................ 12-4
Diagnostic Information and Procedures . . .. . . .12-5
Symptoms - Roof ............................... 12-5
Power Sunroof Malfunction ..................... 12-5
Repair Instructions .............................. 12—8
Sunroof Air Deflector Replacement ............. 12—8
Sunroof Housing Front Drain Hose
Replacement .................................. 12-9
Sunroof Housing Rear Drain Hose
Replacement ................................. 12-10
Sunroof Motor/Actuator Initialization/Teach
Process ...................................... 12-12
Sunroof Actuator Motor Replacement ......... 12-12
Sunroof Sunshade Replacement .............. 12-13
Sunroof Window Seal Replacement ........... 12—14
Sunroof Switch Replacement ................. 12—15
Sunroof Window Height and Opening Fit
Adjustment ................................... 12-16
Sunroof Window Replacement ................ 12—17
Description and Operation .................... 12-18
Sunroof Description and Operation (Tilt and
Slide) ......................................... 12-18

wwwv.
fl..

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'12-2 Table of Contents

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2013
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 Sunroof 1.2-3

Sunroof
-‘vs...
\‘4
_,
2
Specifications

Fastener Tightening Specifications

Specification
Application Metric English
SunroofModuleBolts 9N-m 80lbin
SunshadeMotor/Actuator
Screws 6N-m 53lbin
SunroofWindowScrews 5N-m 44 lbin

Schematic and Routing Diagrams

-~rvM—Aawww
..

2013
-Sonic
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Service
Manual
(5377994)
 «x
1214‘ Sunroofxoo_m

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2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Sunroof "l2u5
.Nv‘¢,flw.
, Diagnostic Information and VisuallPhysical Inspection
Procedures - Inspect for aftermarket devices which could affect
the operation of the sunroof. Refer to Checking
Aftermarket Accessories on page 11—525.
Symptoms - Roof - inspect the easily accessible or visible system
components for obvious damage or conditions
1. There is no scan tool support for the sunroof since which could cause the symptom.
it not connected to the serial data link.
- Inspect for mechanical binding.
2. Review the system operation in order to familiarize
yourself with the system functions. Refer to Intermittent
Sunroof Description and Operation (Tilt and Slide) Faulty electrical connections or wiring may be the
on page 12—18. cause of intermittentconditions. Refer to Testing for
IntermittentConditions and Poor Connections on
page 11-531.
Symptom List
Refer to Power Sunroof Malfunction on page 12-5 in
order to diagnose the symptom.

Power Sunroof Malfunction

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

Open/High Signal
Circuit Short to Ground Resistance Short to Voltage Performance
B+ 1 1 — -
ignition 1 1 2 —-
Ground — 1 — -
SunroofOpenSwitchSignal 1 1 1 -
SunroofClose SwitchSignal 1 1 1 -
SunroofSwitchIgnition 1 1 — -
1.PowerSunroofMalfunction
2. Sunroofworkswithignitionoff

CircuitlSystem Description Reference Information

Battery voltage is applied to the sunroof module via the Schematic Reference
SUNROOF fuse. Ignitionvoltage is applied to the
sunroof switch via the MlRROR/SUNROOF fuse. The Sunroof Schematics on page 12-4
sunroof switch provides a voltage signal to the sunroof
control module. The sunroof control module then Connector End View Reference
applies ground and voltage to the motor control circuits Component Connector End Views on page 11—269
according to the sunroof direction selected. When the
sunroof reaches the end of it's travel, a limit switch is Description and Operation
engaged and a signal is sent to the sunroof control Sunroof Description and Operation (Tiltand Slide) on
module to stop the motor. page 12—18

2013
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12:6 Sunroof
Electrical Information Reference
Circuit Testing on page 11-526
Connector Repairs on page 11—548
Testing for IntermittentConditions and Poor
Connections on page 11-531
Wiring Repairs on page 11-537
CircuitlSystem Testing
1. Ignition OFF, disconnect the harness connector at
the 872 Sunroof Switch, Ignition ON.
2. Verify a test lamp illuminates between the ignition
circuitterminal 1 and ground.
if the test lamp does not illuminate and the
circuit fuse is good
2.1. ignition OFF.
2.2. Test for less than 2 Q in the ignition circuit end
to end.
:2 If2 Q or greater, repair the open/high resistance
in the circuit.
=>if less than 2 Q, verify the fuse is OK and there
is voltage at the fuse.
If the test lamp does not illuminate and the
circuit fuse is open
2.1. IgnitionOFF, disconnect the K61 Sunroof
Control Module
2.2. Test for infinite resistance between the ignition
circuit and ground.
=>If less than infinite resistance, repair the short to
ground on the circuit.
:> If infinite resistance, replace the K61 Sunroof
Control Module.
if the test lamp illuminates
Ignition OFF and all vehicle systems OFF. it may
take up to 2 minutes for all vehicle systems to
power down.
. Connect the harness connector at the S72 Sunroof
Switch, disconnect the harness connector at the
K61 Sunroof Control Module.
Test for less than 10 Q between the ground circuit
terminal 1 and ground.
if 10 Q or greater
5.1. IgnitionOFF.
5.2. Test for less than 2 Q in the ground circuit end
to end.
2 If2 Q or greater, repair the open/high resistance
in the circuit.
=>Ifless than 2 Q, repair the open/high resistance
in the ground connection.
If less than 10 Q
Verify a test lamp illuminates between the B+
circuit terminal 6 and ground.
If the test lamp does not illuminate and the
circuit fuse is good
6.1. ignition OFF.
6.2. Test for less than 2 Q in the B+ circuit end
to end.
=>lf 2 Q or greater, repair the open/high resistance
in the circuit.
=>If less than 2 Q, verify the fuse is not open and
there is voltage at the fuse.
If the test Iamp does not illuminate and the
circuit fuse is open
6.1. Ignition OFF.
6.2. Test for infinite resistance between the B+
circuit and ground.
=>If less than infinite resistance, repairthe short to
ground on the circuit.
=>If infinite resistance, replace the K61 Sunroof
Control Module.
If the test lamp illuminates
.“ Ignition ON.
. Verify a test lamp illuminates between the ignition
circuit terminal 3 and ground.
If the test lamp does not illuminate and the
circuit fuse is good
8.1. Ignition OFF.
8.2. Test for less than 2 Q in the ignition circuit end
to end.
=>If2 Q or greater, repair the open/high resistance
in the circuit.
=>If less than 2 Q, verify the fuse is OK and there
is voltage at the fuse.
If the test lamp does not illuminate and the
circuit fuse is open
8.1. Ignition OFF.
8.2. Test for infinite resistance between the ignition
circuit and ground.
=>if less than infinite resistance, repairthe short to
ground on the circuit.
=>If infinite resistance, replace the K61 Sunroof
Control Module.
<: If the test lamp illuminates
Ignition ON, connect a test lamp between the
signal circuit terminal 5 and ground.

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 Sunroof 12-7
10. Verify the test lamp illuminates when pressing the Component Testing
sunroof open switch.
1. ignition OFF, disconnect the harness connector at
=>If the test lamp does not illuminate the S72 Sunroof Switch.
10.1. IgnitionOFF. 2. Test for infinite resistance between the following
10.2. Test for less than 2 Q in the signal circuit end signal circuit terminals and the ignition terminal 1
to end. with the switch in the open position.
=>If2 Q or greater, repair the open/high resistance ° Terminal 2
in the circuit. - Terminal 3
ii if less than 2 Q :> If less than infinite resistance
10.3. Test for infinite resistance between the signal Replace the S72 Sunroof Switch.
circuit and ground.
it If infinite resistance
=>if less than infinite resistance, repairthe short to
ground on the circuit. 3. Test for less than 5 Q between the signal terminal 2
and the ignition terminal 1 with the sunroof open
=>Ifinfinite resistance, test or replace the switch pressed.
S72 Sunroof Switch.
=>If 5 Q or greater
it if the test lamp illuminates
Replace the S72 Sunroof Switch.
11. IgnitionON, connect a test lamp between the
signal circuit terminal 10 and ground. 4. Test for less than 5 Q between the signal terminal 3
and the ignition terminal 1 with the sunroof close
12. Verify the test lamp illuminates when pressing the switch pressed.
sunroof close switch.
2 If 5 Q or greater
=>If the test lamp does not illuminate
Replace the S72 Sunroof Switch.
12.1. IgnitionOFF.
12.2. Test for less than 2 Q in the signal circuit end U If less than 5 Q
to end. 5. All OK
2» If2 Q or greater, repair the open/high resistance Repair Instructions
in the circuit.
Perform the Diagnostic Repair Verification on
U Ifless than 2 Q page 6-92 after completing the repair.
12.3. Test for infinite resistance between the signal - Control Module References on page 6-3 for
circuit and ground. sunroof control module replacement,
=>Ifless than infinite resistance, repair the short to programming and setup.
ground on the circuit. - Sunroof Switch Replacement on page 12-15
=>lf infinite resistance, test or replace the
S72 Sunroof Switch.
U If the test lamp illuminates
13. Replace the K61 Sunroof Control Module.

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12:8 Sunroof

Repair Instructions

Sunroof Air Deflector Replacement

2536074

Sunroof Air Deflector Replacement

Callout Component Name
Preliminary Procedure
Removethesunroofmodule.Referto SunroofModu/eAssemblyReplacementonpage 12-11.
SunroofAir Deflector
1
Tip: Cycle thesunroofwindowtothefull rearwardposition.

2013 (US/Canada)
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Manual
Service
 Sunroof 'l2=9
Sunroof Housing Front Drain Hose Replacement

1'
2476177
Sunroof Housing Front Drain Hose Replacement
Callout Component Name
Preliminary Procedure
it is onlynecessaryto lowertheheadliner.Onlydo thosestepsin theheadlinerreplacementprocedurethatwilllowerthe
headlinerenoughto gainaccess tothepart.Referto HeadliningTrimPanel Replacement(SedanwithSunroof)onpage 2—26 or
HeadliningTrimPanel Replacement(HatchbackwithSunroof)onpage 2-24or HeadliningTrimPanel Replacement(Hatchback
withoutSunrooflonpage2—25 or HeadliningTrimPanel Replacement(SedanwithoutSunrooflonpage2—27.
1 SunroofHousingFrontDrainHose Retainers(Qty:4)
SunroofHousingFrontDrainHose
2 Procedure
1. Removethesunroofhousingfrontdrainhoseand grommetfromplenum.
2. Watertestthevehicle beforeinstallingtheheadlinerto ensurenowaterleaks.

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'12:10 Sunroof

Sunroof Housing Rear Drain Hose Replacement

2476176
Sunroof Housing Rear Drain Hose Replacement
Callout Component Name
Preliminary Procedures
1. it is onlynecessaryto lowertheheadliner.Onlydo thosestepsin theheadlinerreplacementprocedurethatwilllowerthe
headlinerenoughto gainaccess tothepart.Referto HeadliningTrimPanel Replacement(SedanwithSunrooflon
page 2-26or HeadliningTrimPanel Replacement(HatchbackwithSunroof)onpage2-24or HeadliningTrimPanel
Replacement(HatchbackwithoutSunroof)onpage2-25or HeadliningTrimPanelReplacement(SedanwithoutSunroof)
onpage2-27.
Removethebodysidetrimpanel.Referto BodyLockPillar UpperTrimPanel Replacement(Hatchback)onpage2-77or
BodyLock Pillar UpperTrimPanel Replacement(Sedan)onpage 2—78.
9° Removetherearwindowpaneltrim.Referto Rear WindowPanel TrimReplacementonpage2—81.
Removetherearcompartmenttrimontheside beingrepaired.Referto Rear CompartmentSide TrimReplacement- Right
Side (Sedan)onpage 2-90.
1 SunroofHousingRear DrainHoseRetainers(Qty:4)
SunroofHousingRear DrainHose
2 Procedure
1. Removethesunroofhousingreardrainhoseandgrommetfromtherearcompartmentquarterpanel.
2. Watertestthevehiclebeforeinstallingtheheadlinerto ensurenowaterleaks.

2013
-Sonic
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 Sunroof 12:11
“NW Sunroof Module Assembly Replacement

2476187
Sunroof Module Assembly Replacement
Callout I Component Name
PreliminaryProcedures
1. Removethesunroofwindow.Referto SunroofWindowReplacementonpage 12—17.
2. Removetheheadliner.Referto HeadliningTrimPanel Replacement(SedanwithSunroof)on page2—26 or HeadliningTrim
Panel Replacement(HatchbackWithSunroof)onpage 2-24or HeadliningTrimPanel Replacement(Hatchbackwithout
Sunroof)onpage 2-25or HeadliningTrimPanel Replacement(SedanwithoutSunrooflonpage 2-27.
3. Disconnectthefrontandrearsunroofdrainhoses.Referto SunroofHous/ngFrontDrainHose Replacementonpage 12-9
andSunroofHousingRear DrainHose Replacementonpage 12-10.
SunroofModuleBolts(Qty:9)
Caution: Referto FastenerCautiononpage 0-8.
Procedure
1 1. Withan assistant,lowerandremovethesunroofmoduleassemblyfromthevehicle.
2. Place thesunroofassemblyon a Cleandrysurface.
3. Transferall necessarycomponentstothenewmoduleassembly.
Tighten
9N-m(80lbin)
SunroofModule
Procedure
1. Securetheharnesstothesunroofmodule.
2. Adjustthesunroofwindow.Referto SunroofWindowHeightand OpeningFitAdjustmentonpage 12-16.
3. Verifytheproperoperationofthesunroofbeforesecuringtheheadliner.
4 . Ensurethemotor/actuator initialization/teach
processhas beendone.Referto SunroofMotor/Actuator
lnitialization/Teach
Process onpage 12-12.

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12-12 Sunroof
Sunroof Motor/Actuator Initiafization/ 1. Press and hold the sunroof switch to the vent open
T h P position until the sunroof window stops in the vent
eac rocess open position.
Note: Ifthe sunroof motor iSnew, cycle the‘stinroof 2. Again press and hold the sunroof switch to the vent
seven (7) times to teach the motor/actuatorinitialization open position for at least 10 seconds, then the
process. window should move slightly.
Perform the initialization/teach procedure on a reinstall 3- Verify the SUNOOfoperation.
motor or a new motor. Ensure the electrical harness on Ifthe initialization/teach procedure is not carried out
the headliner is connected to the sunroof motor, battery completely, it has to be started again.
power is applied, and the ignition switch is ON.
Note: Ifthe sunroof window doesn‘t go to the vent
open position first time, release the switch and press
the switch again.

Sunroof Actuator Motor Replacement

2476178
Sunroof Actuator Motor Replacement
Callout Component Name
Preliminary Procedure
Removethedomelampbezel.RefertoDomeLampBezel Replacementonpage4-190.
SunroofActuatorMotorScrew(Qty:3)
Caution: Referto FastenerCautiononpage0-8.
Procedure
1 1. Thesunroofwindowmustbe in thefullyclosedpositionbeforedisconnectingtheharness,toensure
synchronizationofthesunroofmotortothesunroofmodule.
2. Disconnecttheelectricalconnectorfromthesunroofmotor.
Tighten
6N-m(53lbin)

2013
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 Sunroof "l2-13
Sunroof Actuator Motor Replacement (cont'd)
Callout Component Name
SunroofActuatorMotor
Procedure
2 1. Pulldownwardto disengagetheactuatormotorfromthesunroofmodule.
2. installthemotor,verifythesunroofoperation.
3. Ensuretheactuatormotorinitialization/teach
processhasbeendone.Referto SunroofMotor/Aotuator
Initialization/Teach
Processonpage 12—12.
4. Verifytheproperoperationofthesunroofbeforeinstallingthedomelampbezel.

Sunroof Sunshade Replacement

2536075
Sunroof Sunshade Replacement
Callout Component Name
Preliminary Procedures
Removethesunroofmodule.Referto SunroofModuleAssembly Replacementonpage 12-11.
1 SunroofSunshadeStops (Qty:2)
SunroofSunshade
Procedure
2 1. Removethestopslocatedattherearofthe sunroofmodule.
2. Removethesunshadeby slidingit rearwardouttheends ofthemodule.
3. Verifytheproperoperationofthesunroofsunshadebeforesecuringthe headliner.

2013
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12:14 Sunroof

Sunroof Window Seal Replacement Installation Procedure

1. Using a clean dampened cloth wipe the seal with a
Removal Procedure small amount of the same window cleaner in order
1. Remove the sunroof window panel. Refer to to ease installation.
Sunroof Window Replacement on page 12-17.

\\

\/

548064
2. Remove the seal from the window panel frame by
pulling the seal away at one point and continuing
around the perimeter of the frame.
3. Clean around the edge of the inside surface of the
window with a 50/50 mixture of isopropyl alcohol
and water by volume on a dampened lint free cloth,
allow to air dry.
548088
2. Position the sunroof window panel seal onto the
window frame, locating the starting end of the seal
at the relief notch in the center of the passenger
side of the frame.
Note: Ensure that the seal is properly seated around
the entire perimeter of the window frame.
3. Firmly press the window seal into the retainer edge
of the sunroof window, a 50/50 mixture of soap and
water by volume will help in the installation.
4. Installthe sunroof window panel. Refer to Sunroof
Window Replacement on page 12-17.
5. Adjust the window panel height. Refer to Sunroof
Window Height and Opening Fit Adjustment on
page 12-16.
6. Inspect sunroof for proper operation.

2013
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 Sunroof 1245
Sunroof Switch Replacement

2674486
Sunroof Switch Replacement
Callout Component Name
Preliminary Procedure
Removethedomelampbezel. Referto DomeLampBezel Replacementonpage4-190.
SunroofSwitch
Procedure
1. Disconnectelectricalconnector.
2. Depresstabsto releaseswitch.

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12x16 Sunroof

Sunroof Window Height and Opening 3. Adjust the corners of the front window panel using «..K
#2..
the following guidelines:
Fit Adjustment
- Adjust the front of the sunroof window
Note: Correct adjustment cannot be achieved if the to 0.0 mm —1.0 mm (0.0 in - 0.04 in ) below the
sunroof window is closed from vent position. top surface of the roof panel.
1. Cycle the sunroof window from full open to closed ' Adjust the rear center line of the sunroof
position. window to2 mm to 3 mm (0 .08 in to 0.12 in )
below the top surface of the roof panel.
Caution: Refer to Fastener Caution on page 0-8.
4. Tighten the sunroof window adjustment screws to
5 N-m(44 lb in).
5. Cycle sunroof window through all positions.
6. inspect the sunroof window adjustment.Adjust if
necessary.

977336
Note: Do Not remove or lower headliner to access
sunroof window screws.
2. Loosen the adjusting screws on the window.

2013
-Sonic
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'
 Sunroof 12:17
Sunroof Window Replacement

2476134
Sunroof Window Replacement
Callout Component Name
SunroofWindowBolt(Qty:4)
Caution: Referto FastenerCautiononpage 0-8.
Tighten
5 N-m(44lbin)
SunroofWindow
Procedure
1. Turntheignitionon.
2. Slidethesunshadeto thefullreanNardposition.
3. Movethesunroofwindowto theventposition.
4 . Verifytheproperoperationofthesunroof.Referto SunroofWindowHeightand OpeningF/tAdjustmenton
page 12-16.

2013
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12:18 Sunroof

Description and Operation between the appropriate Sunroof Motor/Controlier

Sunroof Description and Operation
(Tilt and Slide)
The Tilt/Slide sunroof consists of a moving glass panel
and a manual sunshade. Inthe Tiit/Slide sunroof
system the rear of the glass tilts up above the roof line
for venting, and slides between the headliner and the
roof panel to open fully.
The sunshade is operated by manually pushing or
pulling it. Ithas a mechanical connection to the glass
causing it to open with the glass and keeping it from
closing more than the glass. Ifthe glass is fully closed it
will move without restriction.
The sunroof glass is controlled by an integrated motor/
controller containing the interface to the sunroof switch,
internal Hall effect position sensors, a bi-directional
motor as well as the necessary control electronics. The
Sunroof Motor/Controller is not connected to a serial
data communication bus thus the Service scan tool is
not capable of communicating with it.
The sunroof switch is connected directly to the Sunroof
Motor/Controller and is a momentary rocker type switch
with center off. it has two contacts, one for open
movement and one for close movement. When
activated, each switch contact completes the circuit
input and battery voltage provided by the energized
Rap/Accessory Relay.
Sunroof System Thermal Protection
The sunroof controller has a thermal protection
algorithm to protect the Sunroof controller and motor
from damage due to overheating conditions resulting
from excessive switch actuations. The thermal
protection algorithm will cause any new sunroof
commands to be ignored until the motor is allowed
to cool.
Sunroof Operation
The sunroof will operate when the vehicle is in either
the Run or Accessory Mode
OpenIC|ose
To open the sunroof, press and hold the rear of the
switch. The sunroof may be expressed to the fully open
position by pressing the switch twice within 3 seconds.
To close the sunroof, press and hold the front of the
switch. There is no express close function.
Vent
From the fully closed position, press and hold the front
of the switch to vent the sunroof. To close from the tilt
position, press the back of the switch.

2013
-Sonic
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Manual
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MM
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.«ww
 Table of Contents 13-1

Section 13

Safety and Security

Immobilizer .................................... 13-3 DTC 8310D—8310F ............................ 13—40

Schematic and Routing Diagrams .............. 13—3
Immobilizer Schematics ........................ 13-4
Diagnostic information and Procedures . . .. . . .13—5
DTC 82955 ..................................... 13-5
DTC 8302A ..................................... 13-7
DTC 83031 ..................................... 13-9
DTC 83055 .................................... 13-10
DTC 83050 ................................... 13—12
DTC 83060 .................................... 13-13
DTC 8389A .................................... 13-14
DTC 83902 .................................... 13-16
DTC 83935 .................................... 13-17
DTC 83976 .................................... 13-18
DTC 83984 .................................... 13-19
DTC P0513 .................................... 13-20
DTC P0633 .................................... 13-21
DTC P1629 .................................... 13-22
DTC P1628 .................................... 13—23
DTC P1630 .................................... 13-24
DTC P1631 .................................... 13—25
DTC P1649 .................................... 13-26
Symptoms —immobilizer ....................... 13—26
OnStar Stolen Vehicle Slowdown Active . . 13-27
Repair Instructions ............................. 13-28
Theft Deterrent Module Replacement ......... 13-28
Immobilizer System Component
Programming ................................. 13-29
Key with integrated Transmitter
Programming ................................. 13-30
Description and Operation .................... 13-31
Immobilizer Description and Operation ........ 1331
Remote Vehicle Speed Limiting Description
and Operation ................................ 13-32
Remote Functions ........................... 13-33
Schematic and Routing Diagrams ............ 13—33
Remote Function Schematics ................. 13-34
Diagnostic Information and Procedures . . .. . .13-35
DTC B3101 .................................... 13—35
DTC 83105 .................................... 13-37
DTC 83106 .................................... 13-38
DTC 83109-83113 ............................ 13-39
Symptoms —Remote Functions ................ 13-40
Keyless Entry System Malfunction ............ 13-41
Remote Vehicle Start Malfunction ............. 13—42
Repair instructions ............................. 13-43
Remote Control Door Lock Receiver
Replacement ................................. 13-43
Description and Operation .................... 13-44
Keyless Entry System Description and
Operation .................................... 13—44
Special Tools and Equipment ................. 13-46
Seat Belts .................................... 13-47
Specifications................ .................. 13-47
Fastener Tightening Specifications ............ 13-47
Schematic and Routing Diagrams ............ 13-47
Seat Belt Schematics .......................... 13-48
Diagnostic Information and Procedures ...... 13-49
Seat Belt System Operational and Functional
Checks ....................................... 13-49
DTC 80072 or 80073 .......................... 13-51
Symptoms —Seat Belts ........................ 13—53
Seat Belt Does Not Retract .................... 13-53
Seat Belt Indicator Malfunction - Driver ........ 13—53
Seat Belt Indicator Malfunction - Passenger . .. 13-55
Seat Belt Service Precautions ................. 13—57
Repair Instructions ....... '...................... 13—57
Repairs and Inspections Required After a
Collision ...................................... 13-57
Seat Belt Latch Stop Installation ............... 13—58
Front Seat Belt Buckle Replacement .......... 13-59
Rear Seat Belt Buckle Replacement .......... 1360
Rear Seat Center Shoulder Belt Replacement
(Sedan) ...................................... 13-61
Rear Seat Center Shoulder Belt Replacement
(Hatchback) .................................. 13—62
Shoulder Belt Replacement - Rear (Sedan) ... 13—63
Shoulder Belt Replacement —Rear
(Hatchback) .................................. 13—64
Front Seat Belt Guide Adjuster Replacement
(with AHU) ................................... 13-65
Description and Operation .................... 13—66
Seat Belt System Description and
Operation .................................... 13-66

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132 Table of Contents
Supplemental Inflatable Restraints ........ 13—68
Specifications .................................. 13-68
Fastener Tightening Specifications ............ 13-68
Schematic and Routing Diagrams ............ 13-68
SIR Schematics ............................... 13-69
Component Locator ............................ 13-73
SIR identification Views ....................... 13—73
Diagnostic Information and Procedures . . . . . .13-74
DTC 80012 or 80013 .......................... 13-74
DTC 80014, 80021, 80031, or 80038 ......... 13-78
DTC 80015, 8001A, 80018, or 80022 . . . . 13-81
DTC 80016, 80018, 80023, or 80025 ......... 13-85
DTC 80017 or 80024 .......................... 13-88
DTC 80019 or 80020 .......................... 13-91
DTC 80052 .................................... 13—95
DTC 80074 .................................... 13—96
DTC 80081 (Inflatable Restraint Sensing and
Diagnostic Module) .......................... 13—98
DTC 80081 (Passenger Presence
Module) ..................................... 13—100
DTC 80083—80088 ........................... 13—102
DTC 81001 .................................. 13-106
DTC B1019 .................................. 13-107
Passenger Presence System Rezeroing ..... 13-109
Symptoms —SIR .............................. 13-109
Air Bag Indicator Circuit Malfunction
(Driver) .............. ‘........................ 13—109
Air Bag Indicator Circuit Malfunction
(Passenger) ................................. 13-110
SIR Disabling and Enabling .................. 13-112
Repair Instructions ........................... 13-113
SIR Service Precautions ..................... 13-113
Inflatable Restraint Remote impact Sensor
Replacement ................................ 13-114
Front End Inflatable Restraint Discriminating
Sensor Replacement ....................... 13—115
Airbag Side impact Sensor Replacement
(withAYF/AYO) ............................. 13-116
Airbag Sensing and Diagnostic Module
Replacement ................................ 13—117
Airbag Steering Wheel Moduie
Replacement ................................ 13-118
Steering Wheel Airbag Coil Replacement 13-119
Airbag Steering Wheel Module Coil
Centering ................................... 13-120
Airbag instrument Panel Module
Replacement ............................... 13—121
Instrument Panel Lower Airbag Replacement
- Driver Side ................................ 13—122
Instrument Panel Lower Airbag Replacement
- Passenger Side ........................... 13-123
Airbag Front Passenger Presence Sensor
Replacement ............................... 13-124
Front Seat Outboard Seat Back Airbag
Replacement ............................... 13-125
Rear Seat Outboard Seat Back Airbag
Replacement ............................... 13—127
Instrument Panel Airbag Arming Status
Display Replacement ....................... 13-128
Airbag Roof Side Rail Module Replacement
—Rear ....................................... 13—129
Front Seat Belt Anchor Plate Tensioner
Replacement ............................... 13—130
Driver or Passenger Seat Shoulder Belt
Replacement (withoutA69) ................. 13-131
Driver or Passenger Seat Shoulder Belt
Replacement (withA69) .................... 13-133
Repairs and inspections Required After a
Collision .................................... 13-134
Inflatable Restraint Module Handling and
Scrapping ................................... 13—135
Pretensioner Handling and Scrapping . . . 13-142
Description and Operation ................... 13-145
Supplemental inflatable Restraint System
Description and Operation .................. 13—145
Special Tools and Equipment ................ 13—147
Theft Deterrent ............................. 13-148
Schematic and Routing Diagrams ........... 13-148
Theft Deterrent System Schematics .. .. . . . . . 13—149
Diagnostic Information and Procedures . . .. 13-150
Symptoms —Theft Deterrent .................. 13—150
Content Theft Deterrent Malfunction ......... 13-150
Security Indicator Malfunction ................ 13-151
Description and Operation ................... 13—153
Theft Systems Description and Operation ... 13-153
‘-«..
”2‘
2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 immobilizer 13=3

Immobilizer

Schematic and Routing Diagrams

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 umx
13,4 immobilizer
mo
<

m
N

mmm
...:

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5?
woo:
5:5

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3.0mm:
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EmEEfic.

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iiitl'il
..
1.11
1..
 r‘
immobilizer 'l3-o

Diagnostic Information and Procedures

DTC 82955
Diagnostic Instructions
0 Perform the Diagnostic System Check - Vehicle
on page 6—66prior to using this diagnostic
procedure.
- Review Strategy Based Diagnosis on page 6-58
for an overview of the diagnostic approach.
. Diagnostic Procedure Instructions on page 659
provides an overview of each diagnostic category.
DTC Descriptor
DTC 82955: Security Sensor Data Circuit
For symptom byte information, referto Symptom Byte
List on page 6-85.
Diagnostic Fault Information

Open/High Signal
Circuit Short to Ground Resistance Short to Voltage Performance
8+ 8295500 8295500 — —-
SerialData 8295500 8295500 8295500 8295500
LowReference — 8295500 — -
CircuitlSystem Description Conditions for Clearing the DTC
When an ignition key is inserted into the ignition lock - A current DTC will be cleared when the condition
cylinder and the ignition is switched ON, the for setting the DTC are no longer present.
transponder embedded in the key is energized by the - A history DTC will be cleared after
exciter coil surrounding the ignition lock cylinder. The
100 malfunction-free ignition cycles.
transponder transmits a signal to the body control
module (BCM). The BCM then compares this value to a Reference Information
value stored in memory. lfthe value is correct, the BCM
will send the prerelease password via the serial data Schematic Reference
circuit to the engine control module (ECM). Ifthe
learned key code does not match or a transponder Immobilizer Schematics on page 13-4
value is not received, the BCM will send the start Connector End View Reference
disable password to the ECM.
Component Connector End Views on page 11—269
Conditions for Running the DTC Description and Operation
Ignitionis in the Accessory or Run position.
Immobilizer Description and Operation on page 13-31
Conditions for Setting the DTC Electrical information Reference
The BCM detects a circuit fault on the immobilizer
antenna circuits. - Circuit Testing on page 11-526
. Connector Repairs on page 11-548
Action Taken When the DTC Sets - Testing for IntermittentConditions and Poor
' Vehicle starting will be disabled. Connections on page 11-531
- The security indicator in the instrument cluster will - Wiring Repairs on page 11-537
be illuminated. A service message will be
displayed in the driver information center. Scan Tool Reference
Control Module References on page 6-3 for scan tool
information

2013
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13- 6 immobilizer
CircuitlSystem Testing
1. ignition OFF and all vehicle systems OFF,
disconnect the harness connector at the
K89 Immobilizer Control Module. Itmay take up to
2 min for all vehicle systems to power down.
2. Verify a test lamp illuminates between the low
reference circuit terminal 1 and 8+.
:> if the test lamp does not illuminate
2.1. Ignition OFF, disconnect the harness
connector at the K9 Body Control Module.
2.2. Test for less than 2 Q in the low reference
circuit end to end.
=>If2 Q or greater, repair the open/high resistance
in the circuit.
=>Ifless than 2 Q, replace the K9 Body Control
Module.
U If the test Iamp illuminates
3. ignition ON.
Note: In some instances, the K9 Body Control Module
may only apply voltage for 3 s immediately after the
ignition is turned ON. Itmay be necessary to monitor
the DMM while turning the ignition ON to observe the
voltage.
4. Test for greater than 9 V between the 8+ circuit
terminal 3 and ground.
:> if 9 V or less
4.1. ignition OFF, disconnect the harness
connector at the K9 Body Control Module.
4.2. Test for infinite resistance between the 8+
circuit and ground.
=>Ifless than infinite resistance, repair the short to
ground on the circuit.
U lf infinite resistance
4.3. Test for less than 2 Q in the 8+ circuit end
to end.
=>If2 Q or greater, repair the open/high resistance
in the circuit.
:> Ifless than 2 Q, replace the K9 Body Control
Module. -.
U If greater than 9 V
Test for greater than 4 V between the serial data
circuit terminal 2 and ground.
If 4 V or less
5.1. IgnitionOFF, disconnect the harness
connector at the K9 Body Control Module.
5.2. Test for infinite resistance between the serial
data circuit and ground.
=>If less than infinite resistance, repair the short to
ground on the circuit.
U lf infinite resistance
5.3. Test for less than 2 Q in the serial data circuit
end to end.
=>If2 Q or greater, repair the open/high resistance
in the circuit.
: If less than 2 Q, replace the K9 Body Control
Module.
If greater than 4 V
IgnitionOFF, disconnect the X3 harness connector
at the K9 Body Control Module, ignition ON.
. Test for less than 1 V between the K89 Immobilizer
Control Module serial data circuit terminal 2 and
ground.
If 1 Vor greater
Repair the short to voltage on the circuit.
if less than 1 V
Replace the K89 immobilizer Control Module.
Verify DTC 82955 does not set while operating the
vehicle under the conditions for running the DTC.
lf DTC 82955 is set
Replace the K9 Body Control Module.
U If DTC 82955 is not set
10. AMOK.
Repair instructions
Perform the Diagnostic Repair Verification on
page 6-92 after completing the repair.
Control Module References on page 6-3 for body
control module or immobilizer control module
replacement, programming, and setup.
2013
-Sonic
(US/Canada)
Service
Manual
(5377994)

DTC B302A
Diagnostic Instructions
- Perform the Diagnostic System Check - Vehicle
on page 6-66 prior to using this diagnostic
procedure.
- Review Strategy Based Diagnosis on page 6—58
for an overview of the diagnostic approach.
' Diagnostic Procedure Instructions on page 6—59
provides an overview of each diagnostic category.
DTC Descriptor
DTC B302A: Mobile Telephone Communications Interface Requested immobilization
For symptom byte information, refer to Symptom Byte
List on page 6-85.
CircuitlSystem Description
As part of the vehicle telematics enhanced services, a
request may be sent to the body control module (BCM)
to disable vehicle starting. Ifa valid message is
received by the BCM requesting that starting be
disabled, the start enable message will not be sent to
the engine control module (ECM).
Conditions for Running the DTC
The BCM continuously monitors for this DTC.
Conditions for Setting the DTC
A start disable message has been received from the
telematics module.
Action Taken When the DTC Sets
Vehicle starting will be suspended and the security
indicator will be illuminated. ' ' Connector Repairs on page 11-548
Conditions for Clearing the DTC
- A current DTC will clear when the telematics start
disable request is no longer received.
' A history DTC will clear after 100 ignition cycles in
which the telematic start disable request is
not seen.
Diagnostic Aids
. DTC 8302A is only an indicator that a start disable
request has been received from the vehicle
telematics system and does not indicate a fault in
the immobilizer or telematics system.
. To remove the start disable request, the vehicle"
account must be updated with the OnStar stolen
vehicle team. This will require that a law
enforcement agency or the customer contact
OnStar to indicate that the vehicle has been
successfully and safely recovered.
immobilizer 13-7
° if the OnStar system has been disabled or
damage during a theft attempt,the system will not
be able to communicate and the start disable
request will not be removed. OnStar must be
functioning properly for the start disable request to
be removed.
Reference Information
Schematic Reference
Immobilizer Schematics on page 13-4
Connector End View Reference
Component Connector End Views on page 11-269
Description and Operation
Immobilizer Description and Operation on page 13-31
Electrical Information Reference
° Circuit Testing on page 11-526
- Testing for IntermittentConditions and Poor
Connections on page 11-531
- Wiring Repairs on page 11—537
Scan Tool Reference
Control Module References on page 6—3for scan tool
information
CircuitlSystem Verification
1. Verify the OnStar system is not damaged and is
operating properly, with no DTCs set.
=>If the OnStar system is damaged, inoperative,
or any OnStar DTCs are set
These concerns must be corrected before the
start disable can be removed.
U If the OnStar system is not damaged and is
operating properly
2. Press the blue OnStar buttonand ask the advisor
to be transferred to the stolen vehicle team to verify
the vehicle account has been updated.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
13-8 immobilizer
3. Verify that OnStar is aware the vehicle has been <: If the account has been properly updated
recovered and that the vehicle account has been Once the vehicle account has been updated and
updated. the start disable request has been removed,
=>lf OnStar has not been notified that the vehicle DTC 8302A will transition to a history DTC. Clear
has been recovered the history DTC.
Contact the customer and advise them that for
security purposes, they must contact OnStar
and the law enforcement agency to update the
vehicle account.

(US/Canada)
«Sonic
2013 (5377994)
Manual
Service
 Immobilizer 'l3n9

DTC B3031

Diagnostic Instructions
. Perform the Diagnostic System Check - Vehicle
on page 6-66 prior to using this diagnostic
procedure.
. Review Strategy Based Diagnosis on page 6—58
for an overview of the diagnostic approach.
- Diagnostic Procedure Instructions on page 6—59
provides an overview of each diagnostic category.
DTC Descriptor
DTC B3031: Security Controller In Learn Mode
For symptom byte information, refer to Symptom Byte Electrical Information Reference
List on page 6-85. o Circuit Testing on page 11—526
CircuitlSystem Description - Connector Repairs on page 11—548
When learning a coded key, the body control module - Testing for IntermittentConditions and Poor
(BCM) is placed in learn mode. DTC B3031 will set Connections on page 11—531
automatically as an indicator that the system is in learn - Wiring Repairs on page 11-537
mode and not as a fault indicator. Once the coded key
is learned, learn mode will be exited and the DTC Scan Tool Reference
cleared. Ifthe BCM does not exit learn mode, Control Module References on page 6—3for scan tool
DTC 83031 will remain current and indicate a fault. The information
instrument cluster security indicator will illuminate and
the driver information center will display a message. CircuitlSystem Verification
Conditions for Running the DTC 1. Verify all available keys are correct for the vehicle.
This can be accomplished by comparing the part
The immobilizer system is the learn coded keys state. number that is laser etched on the key to the part
for Setting the DTC number listed in the parts catalog.
Conditions
=>If a key is not correct
The DTC will set any time the BCM enters the learn
coded keys state. Replace the key
U If all keys are correct
Action Taken When the DTC Sets
2. Perform the Replacing Keys procedure. Refer to
The security indicator will illuminate. The driver Key with Integrated Transmitter Programming on
information center will display a message. page 13—30.
Conditions for Clearing the DTC 3. Verify the K9 Body Control Module learns the
vehicle key and exits the learn coded key state.
- A current DTC 83031 will be cleared upon the The scan tool Master Keys Learned parameter
successful exit of learn mode. should increment to 1.
- A history DTC will be cleared after
100 malfunction-free ignition cycles. =>If the K9 Body Control Module does not exit the
learn coded key state after the programming
Reference Information attempt
Replace the K9 Body Control Module
Schematic Reference
U If the K9 Body Control Module exits the learn
Immobilizer Schematics on page 13-4 coded key state after the programming attempt
Connector End View Reference 4. All OK.
Component Connector End Views on page 11-269 Repair Instructions
Description and Operation Perform the Diagnostic Repair Verification on
page 6-92 after completing the repair.
.M,
W» Immobilizer Description and Operation on page 13-31
MMMXsWH~N~ Control Module References on page 6-3 for body
control module replacement, programming, and setup.

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WV
“J.
_
(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
13-10 immobilizer
DTC B3055
Diagnostic Instructions
. Perform the Diagnostic System Check - Vehicle
on page 6-66 prior to using this diagnostic
procedure.
- Review Strategy Based Diagnosis on page 6-58
for an overview of the diagnostic approach.
- Diagnostic Procedure Instructions on page 6-59
provides an overview of each diagnostic category.
DTC Descriptor
DTC B3055: No Transponder Modulation or No Transponder
For symptom byte information,refer to Symptom Byte
List on page 6—85.
CircuitlSystem Description
Without BTM and/or ATH/ATS
When an ignition key is inserted into the ignition lock
cylinder and the ignition is switched ON, the
transponder embedded in the key is energized by the
exciter coil surrounding the ignition lock cylinder. The
transponder transmits a signal to the body control
module (BCM). The BCM then compares this value to a
value stored in memory. lfthe value is correct, the BCM
will send the prerelease password via the serial data
circuit to the engine control module (ECM). if the
learned key code does not match or a transponder
value is not received, the BCM will send the start
disable password to the ECM.
With BTM and/or ATH/ATS
When a ignition key is inserted into the key pocket/siot
and the ignition mode switch is pressed, the
transponder embedded in the key is energized by the
immobilizer antenna exciter coil. The transponder
transmits a signal to the body control module (BCM).
The BCM then compares this value to a value stored in
memory. if the value is correct, the BCM will send the
prerelease password via the serial data circuit to the
engine control module (ECM). Ifthe learned key code
does not match or a transponder value is not received,
the BCM will send the start disable password to
the ECM.
Conditions for Running the DTC
ignition is in the Accessory or Run position.
Conditions for Setting the DTC
The BCM is unable to measure the ignition key
transponder value.
Action Taken When the DTC Sets
- Vehicle starting will be disabled.
- The security indicator will illuminate. A service
message will be displayed in the driver information
center.
Conditions for Clearing the DTC
. A current DTC will be cleared when the BCM
detects a valid transponder value from the
ignition key.
0 A history DTC will be cleared after
100 malfunction—freeignition cycles.
Diagnostic Aids
- Because DTC 83055 may be caused by a
malfunctioning vehicle key, it is necessary to have
all available vehicle keys at the time of diagnosis.
A possible scenario would be a customer leaving
the vehicle with a spare key during the service
visit, but the key which they use everyday, not the
spare key, is the cause of the DTC. Not having all
available keys in this instance would result in the
customer concern not being duplicate or a
misdiagnosis.
- Ensure that the immobilizer control module is
properly installed and fully seated. An audible
and/or tactile click will indicate that the immobilizer
control module is fully seated. To ensure proper
transponder communication, the key must be in a
specific location in relation to the immobilizer
control module. Ifthe immobilizer control module
is not fully seated, transponder communication
may not occur and DTC B3055 will set.
- For vehicle without BTM and/orATH/ATS, verify
the customer is not attemptingto turn the ignition
with the vehicle key partially folded. To ensure
proper transponder communication, the key must
be in a specific location in relation to the
immobilizer control module. Attempting to start the
vehicle with the key in the ignition and partially
folded will result in no transponder communication
and DTC B3055 will set.
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Reference Information
Schematic Reference
Immobilizer Schematics on page 13-4
Connector End View Reference
Component Connector End Views on page 11-269
Description and Operation ‘N‘W
mar
Immobilizer Description and Operation on page 13-31
2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 immobilizer 'i3:11

Information Reference With BTM andlor ATHIATS

Electrical
- Circuit Testing on page 11—526
- Connector Repairs on page 11—548
- Testing for IntermittentConditions and Poor
Connections on page 11-531
o Wiring Repairs on page 11—537
Scan Tool Reference
Control Module References on page 6—3for scan tool
information
Verification
CircuitlSystem
Without BTM andlor ATHIATS
1. ignition ON.
2. Verify that DTC B1370, B1380, or B1441is not set.
=>If any of the DTCs are set
Refer to Diagnostic Trouble Code (DTC) List -
Vehicle on page 6—69.
, :> If a key is not correct
ii If none of the DTCs are set
body control module Accessory
3. Verify the scan tool
parameter changes between Active and Inactive
when turning the ignition ON and OFF.
=>If the parameter does not change
Refer to Vehicle Will Not Change Power Mode
on page 11-523.
<=If the parameter changes
4. Verify all available keys are correct for the vehicle.
This can be accomplished by comparing the part
number that is laser etched on the key to the part
number listed in the parts catalog.
=>If a key is not correct
Replace the appropriate key.
ii If all keys are correct
5. Verify that DTC B3055 does not setwhile
attempting to start the vehicle which each
available key.
=>lf DTC B3055 sets when attempting to start the
vehicle with only one of the available keys
Replace the appropriate key.
=>If DTC B3055 sets when attempting to start the
vehicle with all of the available keys
Replace the K89 Immobilizer Control Module.
ii If DTC B3055 does not set
6. All OK.
1. Ignition ON.
2. Verify that DTC B1370, 81380, or B1441is not set.
=>If any of the DTCs are set
Refer to Diagnostic Trouble Code (DTC) List -
Vehicle on page 6—69.
ii If none of the DTCs are set
3. Verify the scan tool body control module Accessory
parameter changes between Active and Inactive
when turning the ignition ON and OFF.
=>If the parameter does not change
Refer to Power Mode Mismatch on
page 11—515.
<2 If the parameter changes
4. Verify all available keys are correct for the vehicle.
This can be accomplished by comparing the part
number that is laser etched on the key to the part
number listed in the parts catalog.
Replace the appropriate key.
ii If all keys are correct
5. Remove the battery from each of the available
vehicle keys.
6. Verify that DTC B3055 does not set while
attempting to start the vehicle which each available
key. To start the vehicle with the key battery
removed, the key must be placed in the key
pocket/slot.
=>lf DTC B3055 sets when attempting to start the
vehicle with only one of the available keys
Replace the appropriate key.
=>lf DTC B3055 sets when attempting to start the
vehicle with all of the available keys '
Replace the K89 Immobilizer Control Module.
U If DTC B3055 does not set
7. All OK.
Repair Instructions
Perform the Diagnostic Repair Verification on
page 6—92after completing the repair.
Control Module References on page 6-3 for immobilizer
control module replacement, programming, and setup.

—
2013 (US/Canada)
Sonic (5377994)
Manual
Service
13-12 immobilizer

DTC B305C

Diagnostic Instructions
- Perform the Diagnostic System Check - Vehicle
on page 6-66 prior to using this diagnostic
procedure.
- Review Strategy Based Diagnosis on page 6-58
for an overview of the diagnostic approach.
- Diagnostic Procedure Instructions on page 6—59
provides an overview of each diagnostic category.
DTC Descriptor
DTC B305C: Immobilizer Transponder of Wrong Type Programmed
For symptom byte information, refer to Symptom Byte Conditions for Clearing the DTC
List on page 6-85.
~ A current DTC will be cleared when the BCM
CircuitlSystem Description detects a programed transponder type that
matches the equipped system on the vehicle.
Without BTM andlor ATHIATS . A history DTC will be cleared after
When an ignition key is inserted into the ignition lock 100 malfunction-free ignition cycles.
cylinder and the ignition is switched ON, the
transponder embedded in the key is energized by the Reference Information
exciter coil surrounding the ignition lock cylinder. The Schematic Reference
transponder transmits a signal to the body control
module (BCM).The BCM then compares this value to a Immobilizer Schematics on page 13-4
value stored in memory. if the value is correct, the BCM
will send the prerelease password via the serial data Connector End View Reference
circuit to the engine control module (ECM).if the Component Connector End Views on page 11-269
learned key code does not match or a transponder
value is not received, the BCM will send the start Description and Operation
disable password to the ECM. Immobilizer Description and Operation on page 13—31
With BTM andlor ATHIATS Electrical Information Reference
When a keyless entry transmitter is inserted into the
transmitter pocket/slot and the ignition mode switch is - Circuit Testing on page 11—526
pressed, the transponder embedded in the transmitter - Connector Repairs on page 11—548
is energized by the immobilizer antenna exciter coil. . Testing for IntermittentConditions and Poor
The transponder transmits a signal to the body control Connections on page 11531
module (BCM).The BCM then compares this value to a - Wiring Repairs on page 11-537
value stored in memory. lfthe value is correct, the BCM
will send the prerelease password via the serial data Scan Tool Reference
circuit to the engine control module (ECM).Ifthe
learned key code does not match or a transponder Control Module References on page 6-3 for scan tool
value is not received, the BCM will send the start information
disable password to the ECM. CircuitlSystem Verification
Conditions for Running the DTC 1. IgnitionON.
- ignition is in the Accessory or Run position 2. Verify all available keys/transmitters are correct for
. Battery voltage is greater than 9 volts the vehicle. This can be accomplished by
comparing the part number that is laser etched on
- Transponder authentication has occurred the key to the part number listed in the parts
the DTC catalog.
Conditions for Setting
=>If a key is not correct
' The programed transponder type does not match
the equipped system on the vehicle. Replace the appropriate key.
- A transponder used for vehicles without BTM ii If all keys are correct
andlor ATHIATS has been programmed to a 3. Verify the scan tool Key Part Number parameter
vehicle with BTM andlor ATHIATS. displays a Key Part Numberwhen turning the
- A transponder used for vehicles with BTM and/or ignition ON with each key.
ATH/ATS has been programmed to a vehicle :> lfa Key Part Number is not read
without BTM andlor ATH/ATS.
Replace the appropriate key.
Action Taken When the DTC Sets <=If a Key Part Number is read for each key
No action is taken. 4. All OK.

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
*MM
“\w“
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 immobilizer 13:13

DTC B3060

Diagnostic Instructions
- Perform the Diagnostic System Check - Vehicle
on page 6—66prior to using this diagnostic
procedure.
- Review Strategy Based Diagnosis on page 6—58
for an overview of the diagnostic approach.
- Diagnostic Procedure Instructions on page 6—59
provides an overview of each diagnostic category.
DTC Descriptor
DTC B3060: Unprogrammed Transponder Identification Code Received
For symptom byte information, refer to Symptom Byte Conditions for Clearing the DTC
List on page 6-85. - A current DTC will be cleared when the BCM
Description detects a valid transponder value from the
CircuitlSystem ignition key.
Without BTM andlor ATHIATS - A history DTC will be cleared after
When an ignition key is inserted into the ignition lock 100 malfunction-free ignition cycles.
cylinder and the ignition is switched ON, the Reference Information
transponder embedded in the key is energized by the
exciter coil surrounding the ignition lock cylinder. The Schematic Reference
transponder transmits a signal to the body control
module (BCM). The BCM then compares this value to a Immobilizer Schematics on page 13—4
value stored in memory.If the value is correct, the BCM Connector End View Reference
will send the prerelease password via the serial data
circuit to the engine control module (ECM). Ifthe Component Connector End Views on page 11-269
learned key code does not match or a transponder Description and Operation
value is not received, the BCM will send the start
disable password to the ECM. Immobilizer Description and Operation on page 13-31
With BTM andlor ATHIATS Electrical Information Reference
When a keyless entry transmitter is inserted into the . Circuit Testing'on page 11-526
transmitter pocket/slot and the ignition mode switch is
pressed, the transponder embedded in the transmitter - Connector Repairs on page 11-548
is energized by the immobilizer antenna exciter coil. - Testing for IntermittentConditions and Poor
The transponder transmits a signal to the body control Connections on page 11-531
module (BCM). The BCM then compares this value to a - Wiring Repairs on page 11—537
value stored in memory.If the value is correct, the BCM
will send the prerelease password via the serial data Scan Tool Reference
circuit to the engine control module (ECM).If the Control Module References on page 6—3for scan tool
learned key code does not match or a transponder information
value is not received, the BCM will send the start
disable password to the ECM. CircuitlSystem Verification

Conditions for Running the DTC 1. Perform the Replacing Keys procedure. Refer to
Key with Integrated Transmitter Programming on
ignition is in the Accessory or Run position. page 13—30.
Conditions for Setting the DTC 2. Verify the K9 Body Control Module learns the
by the BCM is vehicle key. The scan tool Master Keys Learned
The transponder value measured parameter should increment to indicate another
incorrect or not learned to the vehicle. key has been learned.
Action Taken When the DTC Sets :> If the BCM does not learn the key
- Vehicle starting will be disabled. Replace the key.
- The security indicator in the instrument cluster will ii if the BCM learns the key
be illuminated. The driver information center will 3. All OK.
display a service message.

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
13-‘l4 immobilizer

DTC B389A

Diagnostic Instructions
- Perform the Diagnostic System Check —Vehicle
on page 6-66 prior to using this diagnostic
procedure.
' Review Strategy Based Diagnosis on page 6-58
for an overview of the diagnostic approach.
- Diagnostic Procedure Instructions on page 6-59
provides an overview of each diagnostic category.
DTC Descriptor
DTC B389A: Environment Identification
For symptom byte information,refer to Symptom Byte Reference Information
List on page 6-85.
Schematic Reference
CircuitlSystem Description
Immobilizer Schematics on page 13-4
When certain modules are programmed and configured
during installation, the module learns a specific Connector End View Reference
environment identifier which is unique to the vehicle. Component Connector End Views on page 11—269
The environment identifier is used to prevent the
swapping modules between vehicles. The body control Description and Operation
module (BCM) is the keeper of the environment
identifier.The InstrumentCluster, Electronic Brake Immobilizer Description and Operation on page 13—31
Control Module, HVAC Control Module, Inflatable Electrical Information Reference
Restraint Sensing and Diagnostic Module, engine
control module (ECM), and Steering Column Lock - Circuit Testing on page 11-526
Module (if equipped) each learn the environment - Connector Repairs on page 11-548
identifier during their configuration process. During - Testing for IntermittentConditions and Poor
vehicle operation, the BCM sends the immobilizer Connections on page 11-531
identifier as a challenge and each module responds to
the challenge by sending the environment identifier - Wiring Repairs on page 11-537
back to the BCM. lfthe BCM sends an incorrect Scan Tool Reference
immobilizer identifier or a specific number of incorrect
environment identifiers are received; vehicle starting is Control Module References on page 6—3for scan tool
disabled. information

Conditions for Running the DTC CircuitlSystem Verification

Ignitionis in the ACCESSORY or RUN position. 1. Verify DTC 8389A did not set immediately
following the replacement and programming of the
Conditions for Setting the DTC K9 Body Control Module.
An incorrect immobilizer identifierwas broadcast by 2 If the DTC set immediately after the
the BCM. replacement and programming of the K9 Body
Control Module
Action Taken When the DTC Sets
The immobilizer learn procedure was not
0 The security indicator in the instrument cluster will properly completed. Perform the BCM
illuminate. immobilizer learn using the body control module
' Vehicle starting will be disabled. IMMO Function with Existing Transponder or
Remote Key in SPS. Refer to Immobilizer
Conditions for Clearing the DTC System Component Programming on
A current DTC will be cleared when the BCM page 13-29.
broadcasts a correct immobilizer identifier. U If the DTC did not set immediately after the
replacement and programming of the K9 Body
Diagnostic Aids Control Module
IfBCM programming is not completed after BCM
replacement, the immobilizer identifier will not be
learned. If DTC B389A sets immediately after the
replacement and programming ofa BCM, perform the
programming procedure again.

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
 immobilizer 13-15

2. Verify DTC B3902 is not set in any of the control
modules listed below:
K20 Engine Control Module
K36 Inflatable Restraint Sensing and Diagnostic
Module
K17 Electronic Brake Control Module
K33 HVAC Control Module
P16 InstrumentCluster
K60 Steering Column Lock Module (if
equipped)
=>If DTC B3902 is set in any of the modules
Refer to DTC B3902 on page 13-16.
ii If DTC B3902 is not set in any of the modules
3. Perform the K9 Body Control Module immobilizer
learn using body control module lMMO Function
with Existing Transponder or Remote Key in SPS.
Refer to Immobilizer System Component
Programming on page 13—29.
4. Verify DTC 8389A does not set after programming.
:> If the DTC sets after programming
Replace the K9 Body Control Module.
ii If the DTC does not set after programming
5. All OK.
Repair Instructions
Perform the Diagnostic Repair Verification on
page 6-92 after completing the repair.
Control Module References on page 6-3 for body
control module replacement, programming, and setup.

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
13-16 immobilizer

DTC B3902

Diagnostic Instructions
- Perform the Diagnostic System Check - Vehicle
on page 6-66 prior to using this diagnostic
procedure.
. Review Strategy Based Diagnosis on page 6-58
for an overview of the diagnostic approach.
- Diagnostic Procedure Instructions on page 6-59
provides an overview of each diagnostic category.
DTC Descriptor
DTC B3902: Incorrect Immobilizer IdentifierReceived
For symptom byte information, refer to Symptom Byte Connector End View Reference
List on page 6—85.
Component Connector End Views on page 11—269
CircuitlSystem Description
Description and Operation
When certain modules are programmed and configured
during installation, the module learns a specific Immobilizer Description and Operation on page 13—31
environment identifier which is unique to the vehicle. Electrical Information Reference
The environment identifier is used to prevent the
swapping modules between vehicles. The body control - Circuit Testing on page 11-526
module (BCM) is the keeper of the environment - Connector Repairs on page 11—548
identifier.The InstrumentCluster, Electronic Brake - Testing for IntermittentConditions and Poor
Control Module, HVAC Control Module, Inflatable Connections on page 11-531
Restraint Sensing and Diagnostic Module, engine
control module (ECM), and Steering Column Lock - Wiring Repairs on page 11—537
Module (if equipped) each learn the environment Scan Tool Reference
identifier during their configuration process. During
vehicle operation, the BCM sends the immobilizer Control Module References on page 6—3for scan tool
identifier as a challenge and each module responds to information
the challenge by sending the environment identifier
back to the BCM. if the BCM sends an incorrect CircuitlSystem Verification
immobilizer identifier or a specific number of incorrect 1. Perform the Programming and Setup procedure for
environment identifiers are received, vehicle starting is the control module that set DTC 83902.
disabled. 2. Verify DTC 83902 does not set after programming.
Conditions for Running the DTC =>If the DTC sets after programming
Ignitionis in the ACCESSORY or RUN position. Replace the control module that set the DTC.
the DTC ii If the DTC does not set after programming
Conditions for Setting
3. All OK.
The control module's environment identifier does not
match the environment identifier stored by the BCM. Repair Instructions
Action Taken When the DTC Sets Perform the Diagnostic Repair Verification on
page 6-92 after completing the repair.
- The security indicator in the instrument cluster will
illuminate. Control Module References on page 6—3for instrument
Cluster, Electronic Brake Control Module, HVAC
- Vehicle starting will be disabled. Control Module, inflatable Restraint Sensing and
Conditions for Clearing the DTC Diagnostic Module, engine control module, or Steering
Column Lock Module replacement, programming, and
A current DTC will be cleared when the module learns a setup.
correct environment identifier.
Reference Information
Schematic Reference
Immobilizer Schematics on page 13-4

—
2013 (US/Canada)
Sonic (5377994)
Manual
Service
 immobilizer 13-17

DTC B3935

Diagnostic Instructions
- Perform the Diagnostic System Check - Vehicle
on page 6—66prior to using this diagnostic
procedure.
' Review Strategy Based Diagnosis on page 6-58
for an overview of the diagnostic approach.
- Diagnostic Procedure Instructions on page 6-59
provides an overview of each diagnostic category.
DTC Descriptor
DTC B3935: Transponder Authentication
For symptom byte information, refer to Symptom Byte Conditions for Clearing the DTC
List on page 6-85. ' A current DTC will be cleared when a valid
transponder value has been read and
CircuitlSystem Description
authenticated.
Without BTM andlor ATHIATS - A history DTC will be cleared after 100
When an ignition key is inserted into the ignition lock malfunction-free ignition cycles.
cylinder and the ignition is switched ON, the Reference Information
transponder embedded in the key is energized by the
exciter coil surrounding the ignition lock cylinder. The Schematic Reference
transponder transmits a signal to the body control
module (BCM). The BCM then compares this value to a Immobilizer Schematics on page 13-4
value stored in memory.If the value is correct, the BCM Connector End View Reference
will send the prerelease password via the serial data
circuit to the engine control module (ECM). if the Component Connector End Views on page 11-269
learned key code does not match, the BCM will send Description and Operation
the start disable password to the ECM.
Immobilizer Description and Operation on page 13-31
With BTM andlor ATHIATS
Electrical Information Reference
When a keyless entry transmitter is inserted into the
transmitter pocket/slot and the ignition mode switch is - Circuit Testing on page 11-526
pressed, the transponder embedded in the transmitter
— Connector Repairs on page 11-548
is energized by the immobilizer antenna exciter coil.
The transponder transmits a signal to the body control - Testing for IntermittentConditions and Poor
module (BCM). The BCM then compares this value to a Connections on page 11-531
value stored in memory. lfthe value is correct, the BCM - Wiring Repairs on page 11-537
will send the prerelease password via the serial data
circuit to the engine control module (ECM).if the Scan Tool Reference
learned key code does not match, the BCM will send Control Module References on page 6—3for scan tool
the start disable password to the ECM. information
Conditions for Running the DTC CircuitlSystem Verification
- Ignitionis in the Accessory or Run position. 1. Replace the suspected inoperative or
° A valid transponder value has been read. malfunctioning key.
for Setting the DTC 2. Verify DTC B3935 does not set while operating the
Conditions vehicle under the conditions for running the DTC.
The transponder calculation of the challenge from the :> If the DTC is set
BCM does not match the BCM calculation.
Replace the K9 Body Control Module.
Action Taken When the DTC Sets
ii if the DTC is not set
- Vehicle starting will be disabled. 3. All OK.
- The security indicator will illuminate. The driver
information center will display a service message. Repair Instructions
Perform the Diagnostic Repair Verification on
page 6—92after completing the repair.
Control Module References on page 6—3for body
control module replacement, programming, and setup.

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
13-18 immobilizer

DTC 83976

Diagnostic Instructions
. Perform the Diagnostic System Check —Vehicle
on page 6-66 prior to using this diagnostic
procedure.
- Review Strategy Based Diagnosis on page 6-58
for an overview of the diagnostic approach.
- Diagnostic Procedure Instructions on page 6-59
provides an overview of each diagnostic category.
DTC Descriptor
DTC B3976: Unconfigured Transponder
For symptom byte information,refer to Symptom Byte Action Taken When the DTC Sets
List on page 6-85. ,
- Vehicle starting will be disabled.
CircuitlSystem Description - The security indicator in the instrument cluster will
be illuminated. A service message will be
Without BTM andlor ATHIATS displayed in the driver information center.
When an ignition key is inserted into the ignition lock
cylinder and the ignition is switched ON, the Conditions for Clearing the DTC
transponder embedded in the key is energized by the o A current DTC will be cleared when the BCM
exciter coil surrounding the ignition lock cylinder. The detects a properly configured vehicle key.
transponder transmits a signal to the body control - A histow DTC will be cleared after 100
module (BCM). The BCM then compares this value to a malfunction-free ignition cycles.
value stored in memory.Ifthe value is correct, the BCM
will send the prerelease password via the serial data Reference Information
circuit to the engine control module (ECM). if the
learned key code does not match or a transponder Schematic Reference
value is not received, the BCM will send the start
disable password to the ECM. Immobilizer Schematics on page 13-4

With BTM andlor ATHIATS Connector End View Reference

When a keyless entry transmitter is inserted into the Component Connector End Views on page 11-269
transmitter pocket/slot and the ignition mode switch is Description and Operation
pressed, the transponder embedded in the transmitter
is energized by the immobilizer antenna exciter coil. Immobilizer Description and Operation on page 13—31
The transponder transmits a signal to the body control
Electrical information Reference
module (BCM). The BCM then compares this value to a
value stored in memory. Ifthe value is correct, the BCM - Circuit Testing on page 11-526
will send the prerelease password via the serial data - Connector Repairs on page 11~548
Circuitto the engine control module (ECM). Ifthe
learned key code does not match or a transponder - Testing for IntermittentConditions and Poor
value is not received, the BCM will send the start Connections on page 11-531
disable password to the ECM. ~ Wiring Repairs on page 11-537
Conditions for Running the DTC Scan Tool Reference
- Ignition is in the Accessory or Run position. Control Module References on page 6—3for scan tool
' The BCM is in the learn coded key state. information

Conditions for Setting the DTC CircuitlSystem Verification

The BCM has determined the current key is not
configured as a proper vehicle key.
1. Verify the engine starts with each available key.
:> If the engine does not start with a key
Replace the key.
ii If the engine starts with all keys
2. All OK.

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2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Immobilizer 13-19

DTC 33984

Diagnostic Instructions
- Perform the Diagnostic System Check —Vehicle
on page 6-66 prior to using this diagnostic
procedure.
- Review Strategy Based Diagnosis on page 6-58
for an overview of the diagnostic approach.
' Diagnostic Procedure Instructions on page 6—59
provides an overview of each diagnostic category.
DTC Descriptor
DTC B3984: Device 1 Environment identifier Not Programmable
For symptom byte information, refer to Symptom Byte Connector End View Reference
List on page 6-85. Component Connector End Views on page 11-269
CircuitlSystem Description Description and Operation
When certain modules are programmed and configured Immobilizer Description and Operation on page 13—31
during installation, the module learns a specific
environment identifier which is unique to the vehicle. Electrical Information Reference
The environment identifier is used to prevent the
- Circuit Testing on page 11-526
swapping modules between vehicles. The body control
module (BCM) is the keeper of the environment - Connector Repairs on page 11—548
identifier. The instrument cluster, electronic brake - Testing for IntermittentConditions and Poor
control module, HVAC control module, inflatable Connections on page 11-531
restraint sensing and diagnostic module, engine control - Wiring Repairs on page 11-537
module (ECM), and steering column lock module (if
equipped) each learn the environment identifier during Scan Tool Reference
their configuration process. During vehicle operation,
Control Module References on page 6-3 for scan tool
the BCM sends the immobilizer identifier as a challenge information
and each module responds to the challenge by sending
the environment identifier back to the BCM. if the BCM CircuitlSystem Verification
sends an incorrect immobilizer identifier or a specific
number of incorrect environment identifiers are 1. Perform the Programming and Setup procedure for
received, vehicle starting is disabled. the control module that set DTC 83984.
2. Verify DTC 83984 does not set after programming.
Conditions for Running the DTC
=>If the DTC sets after programming
ignition is in the ACCESSORY or RUN position. Replace the control module that set the DTC.
Conditions for Setting the DTC ti If the DTC does not set after programming
An incorrect environment identifier is programmed or no 3. All OK.
environment identifier is programmed.
Repair Instructions
Action Taken When the DTC Sets Perform the Diagnostic Repair Verification on
- The security indicator in the instrument cluster will page 6—92after completing the repair.
illuminate. Control Module References on page 6-3 for instrument
- Vehicle starting will be disabled. cluster, electronic brake control module, HVAC control
module, inflatable restraint sensing and diagnostic
Conditions for Clearing the DTC module, engine control module, and steering column
A current DTC will be cleared when the module learns a lock module replacement, programming, and setup.
correct environment identifier.
Reference Information
Schematic Reference
Immobilizer Schematics on page 13—4

(US/Canada)
«Sonic
2013 (5377994)
Manual
Service
13~20 immobilizer

DTC P0513

Diagnostic Instructions
- Perform the Diagnostic System Check - Vehicle
on page 6—66prior to using this diagnostic
procedure.
- Review Strategy Based Diagnosis on page 6-58
for an overview of the diagnostic approach.
- Diagnostic Procedure Instructions on page 6-59
provides an overview of each diagnostic category.
DTC Descriptor
DTC P0513: Immobilizer Key Incorrect

CircuitlSystem Description Electrical Information Reference

The body control module (BCM) sends the pre—release - Circuit Testing on page 11—526
information to the engine control module (ECM) via the ' Connector Repairs on page 11-548
serial data circuit. The ECM then sends a challenge to
the BCM. Both the ECM and BCM perform a calculation . Testing for IntermittentConditions and Poor
on this challenge. Ifthe calculated response from the Connections on page 11-531
BCM equals the calculation performed by the ECM, the - Wiring Repairs on page 11—537
ECM will allow vehicle starting.
Scan Tool Reference
Conditions for Running the DTC Control Module References on page 6-3 for scan tool
Ignitionis in the ACCESSORY or RUN position. information
Conditions for Setting the DTC CircuitlSystem Verification
The calculated response from the BCM does not equal 1. Verify there are no immobilizer DTCs set in the K9
the calculation performed by the ECM. Body Control Module.
=>If any immobilizer DTCs are set in the K9 Body
Action Taken When the DTC Sets
Control Module
- The security indicator in the instrument cluster will
Refer to Diagnostic Trouble Code (DTC) List -
illuminate.
Vehicle on page 6—69.
' Vehicle starting will be disabled.
it If no immobilizer DTCs are set in the K9 Body
Conditions for Clearing the DTC Control Module
. A current DTCwill be cleared when a valid 2. Perform the K9 Body Control Module immobilizer
calculation is received. learn using the body control module IMMO
Function with Existing Transponder or Remote Key
- A history DTC will be cleared after in SPS. Refer to Immobilizer System Component
40 malfunction—freeignition cycles. Programming on page 13-29.
Reference Information 3. Verify the engine starts after the K9 Body Control
Module completes the learn procedure.
Schematic Reference
2:»If the engine does not start
Immobilizer Schematics on page 13-4 Perform the K20 Engine Control Module
Connector End View Reference immobilizer learn using the engine control
module iMMO Learn in SPS. Refer to
Component Connector End Views on page 11-269 Immobilizer System Component Programming
Description and Operation on page 13-29.
c If the engine starts
Immobilizer Description and Operation on page 13—31
4. All OK.

-~W
”em
m
mm.
3M.
,.‘4
,‘ M—
2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 immobilizer 13-21

DTC P0633

Diagnostic Instructions
- Perform the Diagnostic System Check - Vehicle
on page 6—66prior to using this diagnostic
procedure.
- Review Strategy Based Diagnosis on page 6-58
for an overview of the diagnostic approach.
- Diagnostic Procedure Instructions on page 6-59
provides an overview of each diagnostic category.
DTC Descriptor
DTC P0633: immobilizer Key Not Programmed
CircuitlSystem Description
When learning the immobilizer data, as well as the
challenge and response sequence, the engine control
module (ECM) is placed in learn mode. DTC P0633 will
set automatically as an indicator that the system is in
learn mode and not as a fault indicator. Once the
immobilizer data and challenge/response are learned,
learn mode will be exited when the engine is
successfully started. Ifthe ECM does not exit learn
mode, DTC P0633 will remain current and indicate a
fault.
Conditions for Running the DTC
The ECM is in learn mode.
Conditions for Setting the DTC
DTC P0633 will set any time the ECM enters
learn mode.
Action Taken When the DTC Sets
The security indicator in the instrument cluster will
illuminate.
Conditions for Clearing the DTC
- A current DTC will be cleared upon a successful
engine start after exit of learn mode.
' A history DTC will be cleared after
100 malfunction-free ignition cycles.
Reference Information
Schematic Reference
Immobilizer Schematics on page 13-4
Connector End View Reference
Component Connector End Views on page 11—269
Description and Operation
Immobilizer Description and Operation on page 13-31
Electrical Information Reference
- Circuit Testing on page 11-526
- Connector Repairs on page 11-548
' Testing for IntermittentConditions and Poor
Connections on page 11—531
- Wiring Repairs on page 11-537
Scan Tool Reference
Control Module References on page 6—3for scan tool
information
CircuitlSystem Verification
Note: DTC P0633 will clear upon a successful engine
start. Any malfunction that will cause a no-start ‘
condition will prevent DTC P0633 from clearing. Prior to
diagnosing DTC P0633, ensure that all power moding
and engine control systems are operating properly and
all conditions that may cause a no-start have been
corrected. Do not replace the K20 Engine Control
Module. Replacing the K20 Engine Control Module will
not correct the no-start condition. ‘
1. Verify there are no immobilizer DTCs set in the
K9 Body Control Module.
=>If any immobilizer DTCs are set in the K9 Body
Control Module
Refer to Diagnostic Trouble Code (DTC) List -
Vehicle on page 6—69.
ii If no immobilizer DTCs are set in the K9 Body
Control Module
2. Perform the K20 Engine Control Module
immobilizer learn using the engine control module
lMMO Learn in SPS. Refer to Immobilizer System
Component Programming on page 13-29.
Verify the engine starts after the K20 Engine
3.
Control Module completes the learn procedure.
=>If the engine does not start
An undiagnosed no—startcondition exists. Refer
to the appropriate subsection and diagnostic to
correct the no—startcondition.
it If the engine starts
4. All OK.

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
13-22 immobilizer

DTC P1629

Diagnostic Instructions
- Perform the Diagnostic System Check - Vehicle
on page 6-66 prior to using this diagnostic
procedure.
- Review Strategy Based Diagnosis on page 6-58
for an overview of the diagnostic approach.
. Diagnostic Procedure Instructions on page 6-59
provides an overview of each diagnostic category.
DTC Descriptor
DTC P1629: Immobilizer Fuel Enable Signal Not Received

CircuitlSystem Description - Testing for IntermittentConditions and Poor

Connections on page 11—531
The body control module (BCM) sends the pre—release
information to the engine control module (ECM) via the - Wiring Repairs on page 11-537
serial data circuit. The ECM then sends a challenge to Scan Tool Reference
the BCM. Both the ECM and BCM perform a calculation
on this challenge. Ifthe calculated response from the Control Module References on page 6-3 for scan tool
BCM equals the calculation performed by the ECM, the information
ECM will allow vehicle starting. The BCM follows this
CircuitlSystem Verification
action by sending the remaining immobilizer data,
referred to as the fuel enable or fuel continue signal, to 1. Verify there are no immobilizer DTCs set in the K9
the ECM. Ifthe immobilizer data sent by the ECM Body Control Module.
matches that stored by the ECM. the ECM will allow the =>If any immobilizer DTCs are set in the K9 Body
engine to remain running. Control Module
Conditions for Running the DTC Refer to Diagnostic Trouble Code (DTC) List -
Vehicle on page 6-69.
ignition is in the ACCESSORY or RUN position.
ii If no immobilizer DTCs are set in the K9 Body
Conditions for Setting the DTC Control Module
The ECM does not receive a correct fuel enable 2. Perform the K9 Body Control Module immobilizer
password from the BCM. learn using the Body Control Module IMMO
Function with Existing Transponder or Remote Key
Action Taken When the DTC Sets in SPS. Refer to Immobilizer System Component
- The security indicator in the instrument cluster will Programming on page 13-29.
illuminate. 3. Verify the K9 Body Control Module successfully
- Vehicle starting will be disabled. completes the learn procedure and the engine
starts.
Conditions for Clearing the DTC =>If the BCM does not successfully learn or the
- A current DTC P1629 will be cleared when a engine does not start
correctfuel enable password is received. Perform the K20 Engine Control Module
- A history DTC will be cleared after immobilizer learn using the Engine Control
40 malfunction—freeignition cycles. Module IMMO Learn in SPS. Refer to
Immobilizer System Component Programming
Reference Information on page 13—29.
Schematic Reference U If the vehicle starts
Immobilizer Schematics on page 13-4 4. All OK.

Connector End View Reference Repair Instructions

Component Connector End Views on page 11-269 Perform the Diagnostic Repair Verification on
page 6—92after completing the repair.
Description and Operation Control Module References on page 6—3for engine
Immobilizer Description and Operation on page 13—31 control module replacement, programming,and setup.
Electrical Information Reference
- Circuit Testing on page 11—526
- Connector Repairs on page 11-548

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
 immobilizer 13:23

DTC P1628

Diagnostic Instructions
- Perform the Diagnostic System Check - Vehicle
on page 6—66prior to using this diagnostic
procedure.
- Review Strategy Based Diagnosis on page 6—58
for an overview of the diagnostic approach.
- Diagnostic Procedure Instructions on page 659
provides an overview of each diagnostic category.
DTC Descriptor
DTC P1628: Remote Vehicle Speed Limiting Signal Message Counter Incorrect

CircuitlSystem Description Connector End View Reference

When a remote slow—down request is sent from OnStar, Component Connector End Views on page 11-269
the vehicle communication interface module sends a Description and Operation
serial data message to the engine control module
(ECM) indicating that reduced vehicle speed has been Remote Vehicle Speed Limiting Description and
requested. Once the request is active, the ECM begins Operation on page 13-32
reducing engine torque to match requested vehicle
speed and the REDUCED ENGINE POWER message Electrical Information Reference
is displayed. - Circuit Testing on page 11—526
Conditions for Running the DTC - Connector Repairs on page 11—548
- The engine run time is greaterthan 5 s - Testing for IntermittentConditions and Poor
Connections on page 11-531
- A remote slow—downrequest is sent from OnStar
- Wiring Repairs on page 11-537
Conditions for Setting the DTC
Scan Tool Reference
- The VIN embedded in the slow-down request
does not match the VlN stored in the ECM. Control Module References on page 6-3 for scan tool
information
. The rolling code counter embedded in the
slow-down request does not increment for ten CircuitlSystem Verification
consecutive messages.
1. Perform the Stolen Vehicle Slow—DownClear
Action Taken When the DTC Sets procedure with the scan tool.
- ECM ignores all reduced vehicle speed request 2. Verify DTC P1628 is not set.
messages from the vehicle communication =>If DTC P1628 is set
interface module. Replace the K73 Telematics Communication
' The ECM stores DTC P1628 in history. InterfaceControl Module.
Conditions for Clearing the DTC ii If DTC P1623 is not set
3. All OK.
- The condition responsible for setting the DTC no
longer exists. Repair Instructions
- A history DTC will clear after 40 malfunction—free Perform the Diagnostic Repair Verification on
ignition cycles have occurred. page 6—92after completing the repair.
Reference Information Control Module References on page 6—3for Telematics
Communication Interface Control Module replacement,
Schematic Reference programming, and setup
OnStar Schematics on page 8—6

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
13-24 immobilizer

DTC P1630

Diagnostic Instructions
- Perform the Diagnostic System Check - Vehicle
on page 6-66 prior to using this diagnostic
procedure.
- Review Strategy Based Diagnosis on page 6—58
for an overview of the diagnostic approach.
~ Diagnostic Procedure Instructions on page 6-59
provides an overview of each diagnostic category.
DTC Descriptor
DTC P1630: immobilizer Learn Mode Active

CircuitlSystem Description - Testing for IntermittentConditions and Poor

When learning the security code, as well as the
challenge and response sequence, the engine control
module is placed in learn mode. Once the security code
and challenge/response are learned, learn mode will be
exited when the engine is successfully started.
Connections on page 11-531
- Wiring Repairs on page 11-537
Scan Tool Reference
Control Module References on page 6-3

Conditions for Running the DTC CircuitlSystem Verification

The engine control module is in learn mode. 1. Verify there are no immobilizer DTCs set in the
K9 Body Control Module.
Conditions for Setting the DTC :> If any immobilizer DTCs are set in the K9 Body
The engine control module has not learned a Control Module
security code. Refer to Diagnostic Trouble Code (DTC) List -
Vehicle on page 6—69.
Action Taken When the DTC Sets
U If no immobilizer DTCs are set in the K9 Body
The security indicator in the InstrumentCluster will Control Module
illuminate.
2. Perform the K20 Engine Control Module
Conditions for Clearing the DTC immobilizer learn using the engine control module
IMMO Learn in SPS. Refer to Immobilizer System
- A current DTC P1649 will be cleared upon a
successful engine start after exit of learn mode. Component Programming on page 13—29.
3. Verify the engine starts after the K20 Engine
- A history DTC will be cleared after
Control Module completes the learn procedure.
100 malfunction—freeignition cycles.
=>If the engine does not start
Reference Information
Replace the K20 Engine Control Module.
Schematic Reference U If the engine starts
Immobilizer Schematics on page 13-4 4. All OK
Connector End View Reference Repair Instructions
Component Connector End Views on page 11-269 Perform the Diagnostic Repair Verification on
page 6-92 after completing the repair.
Description and Operation
Control Module References on page 6-3 for engine
Immobilizer Description and Operation on page 13-31 control module replacement, programming, and setup
Electrical Information Reference
- Circuit Testing on page 11-526
- Connector Repairs on page 11—548

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
 immobilizer 13-25

DTC P1631

Diagnostic Instructions
- Perform the Diagnostic System Check - Vehicle
on page 6—66prior to using this diagnostic
procedure.
0 Review Strategy Based Diagnosis on page 6—58
for an overview of the diagnostic approach.
- Diagnostic Procedure Instructions on page 6—59
provides an overview of each diagnostic category.
DTC Descriptor
DTC P1631: immobilizer Fuel Enable Signal Not Correct
CircuitlSystem Description
The body control module (BCM) sends the pre—release
information to the engine control module (ECM) via the
serial data circuit. The ECM then sends a challenge to
the BCM. Both the ECM and BCM perform a calculation
on this challenge. Ifthe calculated response from the
BCM equals the calculation performed by the ECM, the
ECM will allow vehicle starting. The BCM follows this
action by sending the remaining immobilizer data to the
ECM. if the immobilizer data sent by the BCM matches
that stored by the ECM, the ECM will allow the engine
to remain running.
Conditions for Running the DTC
Ignitionis in the ACCESSORY or RUN position.
Conditions for Setting the DTC
The ECM receives incorrect immobilizer data from
the BCM.
Action Taken When the DTC Sets
- The security indicator in the instrument cluster will
illuminate.
' Vehicle starting will be disabled.
Conditions for Clearing the DTC
- A current DTC will becleared when correct
immobilizer data is received.
' A history DTC will be cleared after
40 malfunction-free ignition cycles.
Reference Information
Schematic Reference
Immobilizer Schematics on page 13-4
Connector End View Reference
Component Connector End Views on page 11-269
Description and Operation
Immobilizer Description and Operation on page 13—31
Electrical Information Reference
' Circuit Testing on page 11—526
. Connector Repairs on page 11-548
- Testing for IntermittentConditions and Poor
Connections on page 11—531
0 Wiring Repairs on page 11-537
Scan Tool Reference
Control Module References on page 6-3 for scan tool
information
CircuitlSystem Verification
1. Verify there are no immobilizer DTCs set in the
K9 Body Control Module.
=>If any immobilizer DTCs are set in the K9 Body
Control Module
Refer to Diagnostic Trouble Code (DTC) List -
Vehicle on page 6-69.
U If no immobilizer DTCs are set in the K9 Body
Control Module
2. Perform the K9 Body Control Module immobilizer
learn using the body control module IMMO
Function with Existing Transponder or Remote Key
in SPS. Refer to Immobilizer System Component
Programming on page 13-29.
3. Verify the engine starts after the K9 Body Control
Module completes the learn procedure.
=>If the engine does not start
Perform the K20 Engine Control Module
immobilizer learn using the engine control
module lMMO Learn in SPS. Refer to
Immobilizer System Component Programming
on page 13-29.
U If the engine starts
4. All OK.

(US/Canada)
«Sonic
2013 (5377994)
Manual
Service
13-26 immobilizer

DTC P1649

Diagnostic Instructions
- Perform the Diagnostic System Check - Vehicle
on page 6—66prior to using this diagnostic
procedure.
- Review Strategy Based Diagnosis on page 6-58
for an overview of the diagnostic approach.
- Diagnostic Procedure Instructions on page 6-59
provides an overview of each diagnostic category.
DTC Descriptor
DTC P1649: Immobilizer Security Code Not Programmed

CircuitlSystem Description CircuitlSystem Verification

When learning the security code, as well as the 1. Verify there are no immobilizer DTCs set in the K9
challenge and response sequence, the engine control Body Control Module.
module (ECM) is placed in learn mode. Once the =>If any immobilizer DTCs are set in the K9 Body
security code and challenge/response are learned, Control Module
learn mode will be exited when the engine is
successfully started. Refer to Diagnostic Trouble Code (DTC) List -
Vehicle on page 6—69.
Conditions for Running the DTC U If no immobilizer DTCs are set in the K9 Body
The ECM is in learn mode. Control Module
2. Perform the K20 Engine Control Module
Conditions for Setting the DTC immobilizer learn using the engine control module
The ECM has not learned a security code. IMMO Learn in SPS. Refer to Immobilizer System
Component Programming on page 13-29.
Action Taken When the DTC Sets
3. Verify the engine starts after the K20 Engine
The security indicator in the instrument cluster will Control Module completes the learn procedure.
illuminate.
=>If the engine does not start
Conditions for Clearing the DTC Replace the K20 Engine Control Module.
- A current DTC will be cleared upon a successful U If the engine starts
engine start after exit of learn mode. 4. All OK.
- A history DTC will be cleared after
100 malfunction-free ignition cycles. Repair Instructions
Perform the Diagnostic Repair Verification on
Reference Information
page 6-92 after completing the repair.
Schematic Reference Control Module References on page 6-3 for engine
control module replacement, programming, and setup.
Immobilizer Schematics on page 13-4
Connector End View Reference Symptoms - Immobilizer
Component Connector End Views on page 11-269 Important: The following steps must be completed
before using the symptom tables.
Description and Operation
1. Perform the Diagnostic System Check —Vehicle on
Immobilizer Description and Operation on page 13-31 page 6-66 before using the symptom tables in
order to verify that all of the following are true:
Electrical Information Reference
' There are no DTCs set.
' Circuit Testing on page 11-526 - The control modules can communicate via the
- Connector Repairs on page 11-548 serial data links.
- Testing for IntermittentConditions and Poor 2. Review the system operation in order to familiarize
Connections on page 11—531 yourself with the system functions. Refer to
- Wiring Repairs on page 11—537 Immobilizer Description and Operation on
page 13-31.
Scan Tool Reference
Control Module References on page 6-3

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(5377994)

Inspection
Visual/Physical
- Inspect for aftermarket devices which could affect
the operation of the systems. Refer to Checking
Aftermarket Accessories on page 11-525.
' inspect the easily accessible or visible system
components for obvious damage or conditions
which could cause the symptom.
Intermittent
Faulty electrical connections or wiring may be the
cause of intermittentconditions. Refer to Testing for
IntermittentConditions and Poor Connections on
page 11—531 .
Symptom List
Refer to OnStar Stolen Vehicle Slowdown Active on
page 13-27 to diagnose the symptom.
OnStar Stolen Vehicle Slowdown
Active
Diagnostic Instructions
Note: This procedure is not used in Brazil.
- Perform the Diagnostic System Check - Vehicle
on page 6-66 prior to using this diagnostic
procedure.
- Review Strategy Based Diagnosis on page 6-58
for an overview of the diagnostic approach.
. Diagnostic Procedure Instructions on page 6-59
provides an overview of each diagnostic category.
CircuitlSystem Description
When a remote slow—downrequest is sent from OnStar,
the Telematics Communication interface Control
Module sends a serial data message to the engine
control module (ECM) indicating that reduced vehicle
speed has been requested. Once the request is active,
the ECM begins reducing engine torque to match
requested vehicle speed and the REDUCED ENGINE
POWER message is displayed.
—
2013 (US/Canada)
Sonic (5377994)
Manual
Service
immobilizer 13:27
Reference Information
Schematic Reference
OnStar Schematics on page 8-6
Connector End View Reference
Component Connector End Views on page 11-269
Description and Operation
Remote Vehicle Speed Limiting Description and
Operation on page 13—32
Electrical Information Reference
- Circuit Testing on page 11-526
' Connector Repairs on page 11-548
- Testing for IntermittentConditions and Poor
Connections on page 11-531
- Wiring Repairs on page 11-537
Scan Tool Reference
Control Module References on page 6-3 for scan tool
information
CircuitlSystem Verification
1. Verify the vehicle is not in the OnStar initiated
Stolen Vehicle Slowdown mode. This can be
accomplished by verifying the scan tool Telematics
Enhanced Service immobilization parameter is No.
2 If the scan tool Telematics Enhanced Service
Immobilization parameter is Yes
1.1. Perform the Remote Vehicle Speed Limiting
Reset procedure with the scan tool.
1.2. Press the blue OnStar button and inform the
advisor that you need to be transferred to the
stolen vehicle team to update the vehicle
account.
U If the scan tool BCM Telematics Enhanced
Service Immobilization parameter is No
2. All OK.
13-28 immobilizer

Repair Instructions

Theft Deterrent Module Replacement

2502272
Theft Deterrent Module Replacement
Callout Component Name
Preliminary Procedure
1. Removethesteeringcolumnuppertrimcover.Referto SteeringColumnUpperTrimCoverReplacementonpage15-28.
2. Removethesteeringcolumnlowertrimcover.Referto SteeringColumnLowerTrimCoverReplacementonpage 15-29.
1 TheftDeterrentModuleBolt/Screw(Qty:2)
Caution: Referto FastenerCautiononpage0-8.
TheftDeterrentModule
2 Procedure
1. Disconnecttheelectricalconnector.
2. Referto ControlModuleReferencesonpage6-3forprogramming
andset upprocedures.

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 immobilizer 13:29

Immobilizer System Component

Programming
This procedure will learn the immobilizer function and
require greater than 15 minutes to complete. Ifthe
battery voltage is low, charge the battery before
proceeding with the learn. Ifthe body control module
(BCM) or engine control module (ECM) have been
replaced, they must be programmed before performing
this learn procedure.
Depending on the immobilizer function being learned or
the component replaced, different learn functions are
required to be performed. These learn functions are as
follows:

Immobilizer System Component Programming

When the function should
Function description: be used: Notes:
Function nameon SPS tool:
. The BCM has beenreplaced
BodyControlModuleIMMO The 8.0Mw'“
.immobilizer relearnthe andthe existingvehicle keys
asswordsand are beingreusedor a ~-
FunctionwithExisting datawhile reupsinthe existin
Transponderor RemoteKey vehicleSe 3 g diagnostichas instructedto
y performthelearn

BodyControlModuleIMMO irlgitgfizhgrwgsrgfgrgstgfid The BCM has beenreplaced

datawhilgusin new andnewvehiclekeys are -
FunctionwithNew
Transponderor RemoteKey vehiclekeygs beingreused

. The ECM willrelearnthe The ECM has beenreplaced

|MMO immobilizerpasswords
EngineContfiglamodule
anddata
EngineControlModuleand The ECM andBCM willlearn
BodyControlModuleIMMO newimmobilizerpasswords
Learn anddata
A newvehiclekeywill learn
ProgramTransponderor theimmobilizerpasswords
RemoteKey (Add) anddata
All existingvehiclekeyswill
ProgramTransponderor be invalidatedandany
RemoteKey (Delete) desired(keysarerelearned
or a diagnostichas instructed -
to performthelearn
Because boththe ECM and
BoththeECM andBCM have BCM havebeen replacedand
beenreplaced(thisselection arelearningnewimmobilizer
willREQUIRE newvehicle passwordsand data,all
keys be used) vehiclekeys mustalso be
replaced
Thisfunctionmaynotbe
availablein all sales regions.
A newvehicle key is being Referto theSPS application
added(doesnotaffectother todetermineif a particular
vehiclekeys) vehicleis ableto addkeys
usingthis method.
Thisproceduremaybe usedif
All vehiclekeys are desiredto a customerhas hadtheirkeys
be invalidatedandcertain lostor stolenand wishesto
keysrelearnedor a diagnostic invalidatethekeys, making
has instructedto performthe themunableto startthe
learn vehicle

1. Connect a scan tool to the vehicle and
access SP8.
2. Turn ON the ignition. with the engine OFF.
3. Ensure that all power consuming devices are
turned OFF on the vehicle.
. 4. Select SPS application and follow the on-screen
instructions.
5. Select Reprogram ECU.
O). Select IMMO immobilizer Learn —Setup.
7. Select the appropriate programming function
based on the component that was replaced or is
being programmed. Refer to the table at the top of
this document for assistance in choosing the
correct programming function.
8. Follow the on-screen instructions.
9. After programming all keys “Programming
Complete” is displayed.
10. Press the lock and unlock button on each
transmitter that was programmed. This will awaken
each transmitter and allow keyless entry functions
to be established.
11. With a scan tool, clear any DTCs.
12. Verify each key is operating properly. Operate each
of the keyless entry functions using the buttons on
the transmitter and then start the vehicle. When
verifying operation, make sure that no other keys
are near the vehicle.

(US/Canada)
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2013 (5377994)
Manual
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13-30 immobilizer
Key with Integrated Transmitter
Programming
Keys can be programming in various ways using the
procedures outlined below. Using the Replacing Keys
procedures will first erase all the known keys from the
vehicle. Any existing keys and any new keys will then
be programmed. This procedure should be used any
time a key is required to be unleamed or erased from a
vehicle. if a new key is being learned to a vehicle to
replace a damaged, inoperative, or stolen key, the
Replacing Keys procedure must be used. This ensures
that the old key cannot be used to access or start the
vehicle after programming.
The Adding Keys procedure does not erase any keys
prior to programming. The procedure will simply
program the key into the next available slot. The Adding
Keys procedure should only be used when adding an
additional key to the vehicle. The Adding Keys
procedure should never be used to program a key to a
vehicle that is having a key replaced, regardless of the
cause for the replacement.
Replacing Keys (With SPS)
Note:
- This procedure may be used with or without
existing learned keys being present.
- This procedure will take more than 15 minutes to
complete.
- A total of eight keys maybe be learned to a single
vehicle.
' This procedure will only learn the vehicle key
information. This procedure will not learn any
immobilizer information between the body control
module (BCM) and engine control module (ECM).
- Ifthe battery voltage is low, charge the battery
before continuing with the procedure.
1. Connect a scan tool to the vehicle and
access SP8.
2. Ensure that all power consuming devices are
turned OFF on the vehicle.
3. Select the SPS application and follow the
on-screen instructions.
4. Select Reprogram ECU.
5. Select lMMO Immobilizer Learn - Setup.
6. Select the Program Transponder or Remote Key
(Delete) function.
7. Follow the on-screen instructions.
8. After programming all keys, “Programming
Complete" is displayed.
9. Press the lock and unlock button on each key that
was programmed. This will awaken each key and
allow keyless entry functions to be established.
10. With a scan tool, clear any DTCs.
11. Verify each key is operating properly. Operate each
of the keyless entry functions using the buttons on
the key and then start the vehicle. When verifying
operation, make sure that no other keys are near
the vehicle.
Replacing Keys (Without SPS) — United
States only
Note:
o This procedure should be used withoutexisting
learned keys being present.
~ This procedure will take more than 30 minutes to
complete.
' A total of eight keys maybe be learned to a single
vehicle.
' This procedure will only learn the vehicle key
information. This procedure will not learn any
immobilizer information between the body control
module (BCM) and engine control module (ECM).
° Ifthe battery voltage is low, charge the battery
before continuing with the procedure.
1. With an unlearned master vehicle key, turn ON the
ignition, with the engine OFF.
2. Observe the security indicator, after approximately
10 min the indicator will turn off.
3. Turn OFF the ignition and wait 5 s.
4. Repeat steps 1 - 3 two more times for a total of
3 cycles or 30 min.
Note: The body control module learns the key
transponder information upon the ignition transition
from OFF to ON. You must turn the ignition OFF before
attempting to start the vehicle.
5. Start the vehicle. The vehicle has now learned the
key transponder information.
6. Additional keys may be learned using the Adding
Keys procedure.
7 Clear all DTCs.
Adding Keys (Without SPS) — North
America, except Canada
Notet I
- To initiate, this procedure requiresthat1 learned
key be available.
. A total of eight keys maybe be learned to a single
vehicle.
~ This procedure adds keys only. The procedure
does not erase previously learned keys.
- The keys to be learned must duplicate the
mechanical cut of the current key.
1. With a previously learned key, turn the ignition ON.
2. Turn the ignition OFF and remove the key.
3. Within 10 seconds of turning OFF the ignition,
insert the key to be learned and turn ON the
ignition. The vehicle has now learned the new key
and key.
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(5377994)
 immobilizer 13-31

SPS) — Canada, 11. Verify each key is operating properly. Operate each
Adding Keys (Without of the keyless entry functions using the buttons on
Europe, South America, Asia, and the key and then start the vehicle. When verifying
Middle East operation, make sure that no other keys are near
the vehicle.
Note:
and Operation
' To initiate, this procedure requires that 2 learned Description
key be available.
- A total of eight keys maybe be learned to a single Description and
vehicle. Immobilizer
- This procedure adds keys only. The procedure Operation
does not erase previously learned keys. The immobilizer system functions are provided by the
° The keys to be learned must duplicate the body control module (BCM) and the engine control
mechanical cut of the current key. module (ECM), as well as any modules which store and
1. With a previously learned key, turn the ignition ON. report the environment identifier.
2. Turn the ignition OFF and remove the key. When an ignition key is inserted into the ignition lock
cylinder and the ignition is switched ON, the
3. With a second previously learned key, turn the transponder in the key is energized by the immobilizer
ignition ON. coil surrounding the ignition lock cylinder. This
4. Turn the ignition OFF and remove the key. immobilizer coil is part of the immobilizer antenna. The
5. Within 10 seconds of turning OFF the ignition, transponder transmits a signal that contains its unique
insert the key to be learned and turn ON the value, which is received by the BCM through the
ignition. The vehicle has now learned the new key immobilizer coil. The BCM then compares this value to
and key. a value stored in memory. The BCM also monitors
various modules to determine if the stored environment
Adding Keys (With SPS) — North identifiers match.
America if both the environment identifier and the value received
Note: from the transponder match, the BCM will send the
prerelease password via serial data to the ECM. if the
- This procedure may be used with or without encrypted code's unique value is incorrect or the
existing learned keys being present. environment identifier does not match. the BCM will
. This procedure will take more than 15 minutes to send the fuel disable message to the ECM.
complete. When the ECM receives the BCM prerelease
. A total of eight keys maybe be learned to a single password, the ECM will challenge the password. The
vehicle. ECM sends this challenge to the BCM via serial data.
- This procedure will only learn the vehicle key Both the ECM and BCM perform a calculation on this
information. This procedure will not learn any challenge. it the BCM calculated response to the
immobilizer information between the body control challenge equals the calculation performed by the
module (BCM) and engine control module (ECM). ECM, the ECM will allow vehicle starting.
The components of the theft system are as follows:
' Ifthe battery voltage is low. charge the battery
before continuing with the procedure. - BCM
1. Connect a scan tool to the vehicle and - ECM
access SP8. - Immobilizer antenna
2. Ensure that all power consuming devices are ~ Ignition key
turned OFF on the vehicle. - Security indicator
‘rwww—MM‘F
M
m..
3. Select the SPS application and follow the - Various modules which store and report the
on-screen instructions. environment identifier
4. SelectReprogram ECU.
Body Control Module (BCM)
5. Select lMMO Immobilizer Learn - Setup.
6. Select the Program Transponder or Remote The immobilizer system is an integral part of the BCM
Key (Add) function. and is controlled internally within the BCM. The BCM
can learn up to 8 keys (transponder values).
7. Follow the on-screen instructions.
The BCM uses the following inputs:
8. After programming all keys, “Programming
Complete” is displayed. 0 Environment identifier exchange with various
modules
9. Press the look and unlock button on each key that
was programmed. This will awaken each key and - Encrypted code from the vehicle key, received by
allow keyless entry functions to be established. the immobilizer antenna
10. With a scan tool, clear any DTCs. The BCM uses the following outputs:
. Prerelease password communication with ECM
- Challenge/response with ECM

(US/Canada)
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2013 (5377994)
Manual
Service
13:32 immobilizer
When an ignition key is inserted into the ignition lock
cylinder and the ignition is switched ON, the encrypted
code in the key is energized by the immobilizer antenna
surrounding the ignition lock cylinder. The energized
transponder transmits a signal that contains its unique
value, which is received by the BCM. The BCM then
compares this value to the learned key code stored in
memory. The BCM then performs one of the following
functions:
- Ifthe encrypted code value matches the values
stored in the BCM memory,the BCM will send the
prerelease password to the ECM via serial data.
- Ifthe encrypted code unique value does not match
the value stored in the BCM, the BCM will send
the start disable message to the ECM via
serial data.
- Ifthe BCM is unable to measure the ignition key
encrypted code value, the BCM will not send any
messages to the ECM.
Engine Control Module (ECM)
When the ECM receives the BCM prerelease
password, the ECM will challenge the password. The
ECM sends this challenge to the BCM via the serial
data circuit. Both the ECM and BCM perform a
calculation on this challenge. lfthe calculated response
from the BCM equals the calculation performed by the
ECM, the ECM will allow vehicle starting.
The ECM will disable vehicle starting it any of the
following immobilization conditions occur:
' The prerelease password is invalid.
- The start disable password is sent by the BCM.
- No passwords are received. There is no
communication with the BCM.
- The BCM calculated response to the challenge
does not equal the calculation performed by
the ECM.
Immobilizer Antenna
The immobilizer antenna contains an immobilizer coil
which surrounds the ignition cylinder. The coil passively
powers the transponder located in the ignition key
when the key is in the ignition. When powered, the key
transmits its unique value to the immobilizer antenna,
which is then relayed to the BCM via a LIN serial data
circuit. The immobilizer antenna also receives 8+ and
ground from the BCM.
The immobilizer antenna is used to:
1. Learn keys
2. To start vehicle
Ignition Key
Each ignition key contains a transponder with a unique
encrypted value. The transponder's encrypted value is
fixed and unable to be changed. The immobilizer
system uses the ignition key transponder value to
determine if a valid ignition key is being used to start
the vehicle.
Environment Identifier
Various modules throughout the vehicle learn a specific
environment identifier during the module programming
process. The environment identifier is learned by each
individual module and matches the environment
identifier stored in the BCM. Prior to starting after a
battery disconnect, each of the modules which store a
environment identifier will compare their identifier to
that of the identifier stored in the BCM. Ifall the
identifiers match, the engine starting process will
continue. Ifthe environment identifiers do not match,
engine starting will be disabled.
Security Indicator
The BCM will command the instrument panel cluster to
illuminate the security indicator when the ignition key is
in the ON position to indicate a fault has occurred within
the immobilizer system and when the engine starting is
disabled.
Remote Vehicle Speed Limiting
Description and Operation
Certain vehicles equipped with OnStar®now have an
additional feature that allows for remote limiting of the
vehicle's speed. This OnStar®feature is called Stolen
Vehicle Slow—Downand is now part of the OnStar®
Stolen Vehicle Assistance service. This feature. when
used in conjunction with local law enforcement and
strict guidelines at the OnStar®Call Center, will slow
the vehicle by interacting with the engine control
system.
When the engine control system receives a valid
request from the OnStar®telematics communications
interface module, it will enter into a reduced engine
power/vehicle speed limiting mode, which will
decelerate the vehicle. Once the request is active the
engine control module begins reducing engine torque
to match requested vehicle speed and a REDUCED
ENGINE POWER indication is displayed. No DTCs will
be set during this process.
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(US/Canada)
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Manual
(5377994)
 Remote Functions 13-33

Remote Functions

Schematic and Routing Diagrams

(US/Canada)
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2013 (5377994)
Manual
Service
13-34 Remote Functions IIIIIIIIIIIIIIIIlllllllllllllllllllflmld

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(US/Canada)
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2013 (5377994)
Manual
Service

_.
 Remote Functions 13-35

Information and Procedures

Diagnostic

DTC B3101

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

DTC Descriptor
DTC B3101: Keyless Entry Data Link Circuit
Symptom Byte
For symptom byte information, refer to
List on page 6-85.
Diagnostic Fault Information

Opeanigh Signal
Resistance Short to Voltage Performance
Circuit Short to Ground
8310100 -— —-
83101 00
8+ 83101 00 83101 00
83101 00 8310100
Serial Data—EnableLine 83101 00 83101 00
83101 00 8310100
Serial Data—Receive — —-
—- 8310100
Low Reference
Reference Information
CircuitlSystem Description
module communicates with the Schematic Reference
The body control
receiver through the keyless
remote control door lock
button on the Remote Function Schematics on page 13-34
entry serial data circuits. When any
keyless entry transmitter is pressed, the transmitter Component Connector End Views
lock receiver.
sends a signal to the remote control door Component Connector End Views on page
11-269
door lock receiver sends a function
The remote control on
request to the body control module, depending Description and Operation
the transmitter. The body
which button is pressed on Operation on
receives the message and performs the Keyless Entry System Description and
control module
appropriate function. page 13—44
the DTC Electrical Information Reference
Conditions for Running
transmitter. - Circuit Testing on page 11-526
A button is pressed on the keyless entry
- Connector Repairs on page 11—548
for Setting the DTC Poor
Conditions ‘ Testing for IntermittentConditions and
control door 11-531
No response is received from the remote requests Connections on page
body control module
lock receiver after the
commands to - Wiring Repairs on page 11-537
information from or sends configuration
the remote control door lock receiver. Scan Tool Reference
for scan tool
Action Taken When the DTC Sets Control Module References on page 6-3
control door lock information
Inthe case of power loss, the remote
receiver is disabled for 65 8. Otherwise no action is
taken.
Conditions for Clearing the DTC
fault is no longer
- A current DTC will clear when the
present.
consecutive
- A history DTC will clear after 40
ignition cycles without a fault present.

—
2013 (US/Canada)
Sonic (5377994)
Manual
Service
13-36 Remote Functions

CircuitlSystem Testing 2 if less than 2 Q, replace the K9 Body Control

Module.
1. ignition OFF and all vehicle systems OFF,
disconnect the harness connector at the 2 If greater than 6 V
K77 Remote Control Door Lock Receiver. Itmay 5.1. IgnitionOFF, disconnect the harness
take up to 2 min for all vehicle systems to connector at the K9 Body Control Module,
power down. ignition ON.
Test for less than 30 Q between the low reference 5.2. Test for less than 1 V between the serial data
circuitterminal 1 and ground. circuit and ground.
If 30 Q or greater 2 If 1 V or greater, repair the short to voltage on
2.1. IgnitionOFF, disconnect the harness the circuit.
connector at the K9 Body Control Module. 2 Ifless than 1 V, replace the K9 Body Control
2.2. Test for less than 2 Q in the low reference Module.
circuit end to end. c If between 3—6V
2 If2 Q or greater, repair the open/high resistance 6. IgnitionOFF, disconnect the X1 and X2 harness
in the circuit. connectors at the K9 Body Control Module,
2 Ifless than 2 Q, replace the K9 Body Control ignition ON.
Module. 7. Test for less than 1 V between the K9 Body Control
if less than 30 Q Module serial data circuitterminai 26 X1 and
ground.
9° IgnitionON.
2 If 1 V or greater
Test for greater than 11.5V between the B+ circuit
terminal 4 and ground. Repair the short to voltage on the circuit.
If 11.5 Vor less If less than 1 V
4.1. IgnitionOFF, disconnect the harness po<=
IgnitionOFF.
connector at the K9 Body Control Module. 9. Test for infinite resistance between the K9 Body
4.2. Test for infinite resistance between the 8+ Control Module serial data circuit terminal 26 X1
circuit and ground. and ground.
2 Ifless than infinite resistance, repair the short to 2 If less than infinite resistance
ground on the circuit. Repair the short to ground on the circuit.
U lf infinite resistance. U If infinite resistance
4.3. Test for less than 2 Q in the 8+ circuit end 10. Test for less than 2 Q between the K9 Body Control
to end. Module serial data circuit terminal 26 X1 and the
2 If2 Q or greater, repair the open/high resistance K77 Remote Control Door Lock Receiver serial
in the circuit. data circuit terminal 3.
2 if less than 2 Q, replace the K9 Body Control 2 If 2 Q or greater
Module. Repair the open/high resistance in the circuit.
if greater than 11.5 V U If less than 2 Q '
Test for 1—6V between the serial data circuit 11. Replace the K77 Remote Control Door Lock
terminal 2 and ground. Receiver.
If less than 1 V 12. Verify DTC 83101 does not set while operating the .M_
\Aw
5.1. ignition OFF, disconnect the harness vehicle under the conditions for running the DTC.
connector at the K9 Body Control Module. 2 If the DTC sets M
5.2. Test for infinite resistance between the serial Replace the K9 Body Control Module
data circuit and ground.
U If the DTC does not set
2 Ifless than infinite resistance. repair the short to
ground on the circuit. 13. All OK.
U Ifinfinite resistance Repair instructions
5.3. Test for less than 2 Q in the serial data circuit Perform the Diagnostic Repair Verification on
end to end. page 6-92 after completing the repair.
2 lf2 Q or greater, repair the open/high resistance Control Module References on page 6-3 for body
in the circuit. control module or remote control door lock receiver
replacement, programming,and setup.

2013
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Sonic
(US/Canada)
Service
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w
-“.M”
Awu
~2
 Remote Functions 13-37

DTC 33105

Diagnostic Instructions
' Perform the Diagnostic System Check —Vehicle
on page 6-66 priorto using this diagnostic
procedure.
' Review Strategy Based Diagnosis on page 6-58
for an overview of the diagnostic approach.
- Diagnostic Procedure Instructions on page 6-59
provides an overview of each diagnostic category.
DTC Descriptor
DTC 83105: Keyless Entry Transmitters
For symptom byte information,refer to Symptom Byte - Testing for IntermittentConditions and Poor
List on page 6—85. Connections on page 11-531
- Wiring Repairs on page 11-537
CircuitlSystem Description
Scan Tool Reference
The body control module monitors the number of
keyless entry transmitters programmed. Until at least Control Module References on page 6—3for scan tool
one transmitter is programmed, the body control information
module determines a malfunction condition exists.
CircuitlSystem Verification
Conditions for Running the DTC 1. Verify that the transmitter is a .correct transmitterfor
The body control module has been set up without the vehicle. This can be accomplished by
transmitters being programmed. comparing the part number printed on the
transmitterto the appropriate part number in the
Conditions for Setting the DTC parts catalog.
No keyless entry transmitter programmed to the body 2 If the transmitter is incorrect
control module. Replace the transmitter.
Action Taken When the DTC Sets U If the transmitter is correct
The keyless entry system is inoperative. 2. Program the transmitter. Refer to Key with
Integrated Transmitter Programming on
Conditions for Clearing the DTC page 13-30.
A current DTC is cleared when at least one transmitter 3. Verify the transmitter has successfully completed
has been programmed to the body control module. the programming procedure.
Reference Information 2 If the transmitter does not program
successfully
Schematic Reference Replace the transmitter.
Remote Function Schematics on page 13—34 U If the transmitter programs successfully
Connector End View Reference 4. All OK.
Component Connector End Views on page 11—269 Repair Instructions
Description and Operation Perform the Diagnostic Repair Verification on
page 6—92after completing the repair.
Keyless Entry System Description and Operation on
Key with Integrated Transmitter Programming on
page 13—44
page 13-30
Electrical Information Reference
- Circuit Testingon page 11—526
- Connector Repairs on page 11-548

(US/Canada)
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2013 (5377994)
Manual
Service
13-38 Remote Functions

DTC B3106

Diagnostic Instructions
- Perform the Diagnostic System Check - Vehicle
on page 6-66 prior to using this diagnostic
procedure.
. Review Strategy Based Diagnosis on page 6-58
for an oven/iew of the diagnostic approach.
- Diagnostic Procedure Instructions on page 6-59
provides an overview of each diagnostic category.
DTC Descriptor
DTC B3106: Keyless Entry Data Link
For symptom byte information, refer to Symptom Byte Component Connector End Views
List on page 6-85.
Component Connector End Views on page 11-269
CircuitlSystem Description Description and Operation
The body control module communicates with the
remote control door lock receiver through the keyless Keyless Entry System Description and Operation on
entry serial data circuits. When any button on the page 13—44 ‘
keyless entry transmitter is pressed, the transmitter Electrical Information Reference
sends a signal to the remote control door lock receiver.
The remote control door lock receiver sends a function ' Circuit Testing on page 11-526
request to the body control module, depending on ' Connector Repairs on page 11-548
which button is pressed on the transmitter.The body - Testing for IntermittentConditions and Poor
control module receives the message and performs the Connections on page 11—531
appropriate function.
. Wiring Repairs on page 11-537
Conditions for Running the DTC
Scan Tool Reference
A keyless transmitter button is pressed.
Control Module References on page 6-3 for scan tool
Conditions for Setting the DTC information
The transmitterthat is sending a signal to the remote CircuitlSystem Verification
control door lock receiver is differentfrom those
transmitters stored in the body control module. 1. With a valid and learned transmitter, press and
release a button on the transmitter.
Action Taken When the DTC Sets 2. Verify that DTC 83106 is not set.
No action is taken. 2 If DTC 83106 is set
Conditions for Clearing the DTC Replace the K77 Remote Control Door Lock
Receiver.
' A current DTC will clear when the fault is no longer
present and the ignition switch is cycled. U If DTC B3106 is not set
- A history DTC will clear after 40 consecutive 3. All OK.
ignition cycles without a fault present.
Repair Instructions
Reference Information Perform the Diagnostic Repair Verification on
page 6-92 after completing the repair.
Schematic Reference
Control Module References on page 6-3 for remote
Remote Function Schematics on page 13-34 control door lock receiver replacement, programming,
and setup.

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 Remote Functions 13-39

DTC B3109-B3113

Diagnostic Instructions
- Perform the Diagnostic System Check —Vehicle
on page 6—66prior to using this diagnostic
procedure.
. Review Strategy Based Diagnosis on page 6—58
for an overview of the diagnostic approach.
6-59
- Diagnostic Procedure Instructions on page
provides an overview of each diagnostic category.
DTC Descriptors
DTC B3109: Keyless Entry Transmitter 1 Battery
DTC B3110: Keyless Entry Transmitter 2 Battery
DTC B3111: Keyless Entry Transmitter 3 Battery
DTC B3112: Keyless Entry Transmitter 4 Battery
DTC B3113: Keyless Entry Transmitter 5 Battery
Byte Electrical Information Reference
For symptom byte information, refer to Symptom
List on page 6-85. 0 Circuit Testing on page 11-526
CircuitlSystem Description - Connector Repairs on page 11-548
With each press of a keyless entry transmitter button, a ° Testing for IntermittentConditions and Poor
containing the current battery state of the Connections on page 11-531
message
transmitter is sent to the remote control door lock - Wiring Repairs on page 11-537
receiver, along with the commanded keyless entry Scan Tool Reference
sends
function. The remote control door lock receiver
tool
this to the body control module to perform the Control Module References on page 6-3 for scan
requested function. information
Conditions for Running the DTC CircuitlSystem Verification
A keyless transmitter button is pressed. 1. Verify none of the DTCs listed below are set:
for Setting the DTC - DTC 83109
Conditions
signals are received . DTC 83110
Three consecutive low battery
from the same transmitter. - DTC 83111
- DTC 83112
Action Taken When the DTC Sets - DTC 83113
The keyless entry system is inoperative. 2 If any of the DTCs are set
Conditions for Clearing the DTC 1.1. Replace the battery in the appropriate keyless
entry transmitter and operate the transmitter
The DTC is cleared when a normal transmitter voltage three consecutive times.
DTC.
signal is received from the transmitter that set the
1.2. Verify the DTC does not set.
Information
Reference 2 Ifthe DTC sets, replace the keyless entry
Schematic Reference transmitter.
U if the DTC does not set
Remote Function Schematics on page 13-34
1.3. All OK.
Connector End View Reference
U If none of the DTCs are set
Component Connector End Views on page 11—269 2. All OK.
Description and Operation
Keyless Entry System Description and Operation on
page 13—44

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113-40 Remote Functions

DTC B310D-B310F

Diagnostic Instructions
- Perform the Diagnostic System Check - Vehicle
on page 6—66prior to using this diagnostic
procedure.
- Review Strategy Based Diagnosis on page 6—58
for an overview of the diagnostic approach.
- Diagnostic Procedure Instructions on page 6-59
provides an overview of each diagnostic category.
DTC Descriptors
DTC B310D: Keyless Entry Transmitter 6 Battery
DTC 8310E: Keyless Entry Transmitter 7 Battery
DTC B310F: Keyless Entry Transmitter 8 Battery
For symptom byte information.refer to Symptom Byte Scan Tool Reference
List on page 6—85.
Control Module References on page 6-3 for scan tool
CircuitlSystem Description information
With each press of a keyless entry transmitter button, a CircuitlSystem Verification
message containing the current battery state of the
transmitter is sent to the remote control door lock 1. Verify none of the DTCs listed below are set:
receiver, along with the commanded keyless entry - DTC 8310D
function. The remote control door lock receiver sends . DTC 8310E
this to the body control module to perform the
requested function. - DTC 8310F
2 If any of the DTCs are set
Conditions for Running the DTC 1.1. Replace the battery in the appropriate keyless
A keyless transmitter button is pressed. entry transmitter and operate the transmitter
three consecutive times.
Conditions for Setting the DTC
1.2. Verify the DTC does not set.
Three consecutive low battery signals are received
2 Ifthe DTC sets, replace the keyless entry
from the same transmitter.
transmitter.
Action Taken When the DTC Sets U Ifthe DTC does not set
The keyless entry system is inoperative. 1.3. All OK.
Conditions for Clearing the DTC U If none of the DTCs are set
2. All OK.
The DTC is cleared when a normal transmitter voltage
signal is received from the transmitterthat set the DTC.
Symptoms - Remote Functions
Reference Information Note: The following steps must be completed before
Schematic Reference using the symptom tables.
1. Perform Diagnostic System Check - Vehicle on
Remote Function Schematics on page 13-34 page 6-66 before using the Symptom Tables in
Connector End View Reference order to verify that all of the following are true:
Component Connector End Views on page 11~269 - There are no DTCs set.
o The control modules can communicate via the
Description and Operation serial data link.
Keyless Entry System Description and Operation on 2. Review the system operation in orderto familiarize
page 13-44 yourself with the system functions. Refer to
Keyless Entry System Description and Operation
Electrical Information Reference on page 13-44.
- Circuit Testing on page 11-526
- Connector Repairs on page 11-548
0 Testing for IntermittentConditions and Poor
Connections on page 11—531
- Wiring Repairs on page 11-537

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Inspection
VisuallPhysical
- inspect for aftermarket devices which could affect
the operation of the Keyless Entry System. Refer
to Checking Aftermarket Accessories on
page 11-525.
. inspect the easily accessible or visible system
components for obvious damage or conditions
which could cause the symptom.
Intermittent
Faulty electrical connections or wiring may be the
cause of intermittentconditions. Refer to Testing for
IntermittentConditions and Poor Connections on
page 11-531 .
Symptom List
Refer to a symptom diagnostic procedure from the
following list in order to diagnose the symptom:
- Keyless Entry System Malfunction on page 13—41
- Remote Vehicle Start Malfunction on page 13-42
Keyless Entry System Malfunction
. Remote Function Schematics on page 13—34
Diagnostic Instructions
' Perform the Diagnostic System Check - Vehicle
on page 6-66 prior to using this diagnostic
procedure.
- Review Strategy Based Diagnosis on page 6-58
for an overview of the diagnostic approach.
- Diagnostic Procedure Instructions on page 6-59
provides an overview of each diagnostic category.
CircuitlSystem Description
The keyless entry transmitter is part of the vehicle key.
The keyless entry system will unlock the vehicle doors
or open/unlock the rear compartment when a
corresponding buttonon the keyless entry transmitter is
pressed. This is accomplished by the keyless entry
transmitter sending a radio frequency to the remote
control door lock receiver, which then sends the signal
to the body control module (BCM). The BCM interprets
the signal and activates the requested function. A low
transmitter batteryor radio frequency (RF) interference
from aftermarket devices such as 2-way radios, power
inverters, cellular phone chargers, computers, etc. may
cause a system malfunction. High RF traffic areas,
such as gas stations which use pay-at-the-pump RF
transponders, may also cause interference that could
lead to a malfunction.
Diagnostic Aids
- Unwanted or inadvertent door lock/unlock
activation may be requested by the OnStar®
Remote Link app. Itis possible that a customer
may be unaware of account usage, result in an
unwanted or phantom door lock/unlock. Ifnormal
system diagnosis does results in an inability to
verify the customer’s concern, contact Technical
Assistance Center (TAC).
—
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Remote Functions 13-41
- if available, the EL 43241 Keyless Entry Tester
may be used to diagnose a low transmitter battery
or a malfunctioning transmitter. To test, place the
transmitter on the test pad of the EL 43241 and
press each transmitter button one at a time,
holding each buttonfor three seconds. if the green
light on the tester does not illuminate and a tone
does not sound, first replace the transmitter
battery and retest. if the malfunction continues
after replacing the transmitter battery, replace the
transmitter.
- When using the EL 43241 KeyleSs Entry Tester,
first inspect the keyless entry transmitter part
number to determine that it is the correct model for
the vehicle. An incorrect part number transmitter
may pass the test, but it will not activate the
keyless entry system.
° When the vehicle key is in the ignition, the keyless
entry functions are disabled from all keyless entry
transmitters.
Reference Information
Schematic Reference
Connector End View Reference
Component Connector End Views on page 11-269
Description and Operation
Keyless Entry System Description and Operation on
page 13-44
Electrical Information Reference
- Circuit Testing on page 11-526
- Connector Repairs on page 11-548
' Testing for IntermittentConditions and Poor
Connections on page 11—531
. Wiring Repairs on page 11-537
Scan Tool Reference
Control Module References on page 6-3 for scan tool
information
Special Tools
EL 43241 Keyless Entry Tester
CircuitlSystem Verification
1. Verify that the vehicle key is correct for the vehicle.
This can be accomplished by comparing the part
number printed on the key to the appropriate part
number in the parts catalog.
2 If the vehicle key is incorrect
Replace the vehicle key.
U If the vehicle key is correct
2. Operate the transmitter while observing the scan
tool Key Fob Function parameter for the
appropriate transmitter.
113-42 Remote Functions
3. Verify the scan tool Key Fob Function parameter
corresponds with the function selected on the
transmitter.
2 If the Key Fob Function parameter does not
correspond with the transmitter selection
Note: Before replacing the transmitter,inspect the
transmitter battery contacts for any corrosion or
damage. Ifno corrosion or damage is found, replace
the transmitter battery and retest before replacing the
transmitter.
3.1. Replace the vehicle key.
3.2. Operate the new transmitterwhile observing
the scan tool Key Fob Function parameter for
the transmitter.
3.3. Verify the scan tool Key Fob Function
parameter correspond with the function
selected on the transmitter.
2 Ifthe Key Fob Function parameter does not
correspond with the transmitterselection,
replace the K9 Body Control Module
U Ifthe Key Fob Function parameter corresponds
with the transmitter selection
3.4. All OK.
U If the Key Fob Function parameter corresponds
with the transmitter selection
4. All OK.
Repair Instructions
Perform the Diagnostic Repair Verification on
page 6-92 after completing the repair.
. Key with Integrated TransmitterProgramming on
page 13-30
- Control Module References on page 6-3 for body
control module replacement, programming, and
setup
Remote Vehicle Start Malfunction
Diagnostic Instructions
' Perform the Diagnostic System Check - Vehicle
on page 6-66 prior to using this diagnostic
procedure.
- Review Strategy Based Diagnosis on page 6-58
for an overview of each diagnostic approach.
- Diagnostic Procedure Instructions on page 6-59
provides an overview of each diagnostic category.
CircuitlSystem Description
Remote vehicle start begins as an radio frequency
message received by the body control module (BCM)
from a keyless entry transmitter.The BCM monitors
system conditions such as content theft deterrent, hood
ajar status, and body DTCs to determine if a remote
vehicle start event will occur. if conditions are
determined to be acceptable, the remote vehicle start
message is sent to the Engine Control Module (ECM).
The ECM monitors system conditions such as engine
control parameters and vehicle theft deterrentto
determine if engine starting will be allowed.
Ifconditions are acceptable, the ECM will initiate
engine starting. During the engine run time in a remote
vehicle start attempt, before the operator enters the
vehicle, the ECM may discontinue engine operation if
system conditions require it or a message is received
from the BCM requesting the engine be turned OFF.
Diagnostic Aids
~ Unwanted or inadvertent door Iock/unlock
activation may be requested by the OnStar®
Remote Link app. Itis possible that a customer
may be unaware of account usage, result in an
unwanted or phantom door Iock/unlock.Ifnormal
system diagnosis does results in an inability to
verify the customer‘s concern, contact Technical
Assistance Center (TAC).
' Ifthe vehicle has a current DTC that illuminates
the malfunction indicator lamp (MIL),the cause of
the DTC must be diagnosed before proceeding
with the Remote Vehicle Start lnoperative
diagnostic.
- The remote vehicle start system will not operate if
any ofthe following conditions are present:
—A current vehicle DTC that illuminates the
malfunction indicator lamp (MIL)
—The vehicle is in valet mode.
—More than 2 remote starts have been attempted.
—The hazard switch is in the ON position.
—A current hazard switch DTC is set.
—The vehicle hood is ajar.
—A current hood ajar DTC is set.
—incorrect BCM software is installed and vehicle
start is not enabled.
—The content theft deterrent system detects an
alarm trigger.
—Excessive engine RPM
—Excessive coolant temperature
—Accelerator pedal position greater than
0 percent
——Vehicle not in park
—Vehicle theft deterrent malfunction
—A current automatic transmission shift lock
control system DTC is set.
—A vehicle speed sensor signal is detected by
the ECM.
Reference Information
Schematic Reference
Remote Function Schematics on page 13—34
Connector End View Reference
Component Connector End Views on page 11-269
Description and Operation
Keyless Entry System Description and Operation on
page 13—44
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 Remote Functions 13-43

Electrical Information Reference . Verify that no Diagnostic Status History or Start

' Circuit Testing on page 11—526
- Connector Repairs on page 11—548
‘ Testing for IntermittentConditions and Poor
Connections on page 11—531
' Wiring Repairs on page 11-537
Scan Tool Reference
Control Module References on page 6-3 for scan tool
information
CircuitlSystem Verification
1. Verify that the keyless entry functions operate with
all available keyless entry transmitters.
2 If any keyless entry functions do not operate
properly
Refer to Keyless Entry System Malfunction on
page 13—41.
U If all keyless entry functions operate properly
Disable items are present in the scan tool BCM
Remote Start Diagnostic Status History and the
ECM Remote Vehicle Start Disable History
parameters.
If remote vehicle start disable history items are
present
Refer to the appropriate subsection in which the
malfunction occurred.
If remote vehicle start disable history items are
not present
. Verify all scan tool BCM Content Theft Trigger
History parameters display None.
If any BCM Content Theft Trigger History
parameter does not display None
Refer to Content Theft Deterrent Malfunction on
page 153—150.
if all BCM Content Theft Trigger History
parameters display None
. All OK.

Repair Instructions

Remote Control Door Lock Receiver Replacement

2742466

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13-44 Remote Functions

Remote Control Door Lock Receiver Replacement

Callout | Component Name
Preliminary Procedure
Removethewindshieldoutsidemoisturesensorcover.Referto WindshieldOutsideMoistureSensorCoverReplacementon
page4-383.
RemoteControlDoorLock Receiver
Procedure
1 1. Disconnecttheelectricalconnector.
2. Unsnapthereceiverfromthewindshieldbracket.
3. Forprogrammingandset up,referto ControlModuleReferencesonpage 6-3.

Keyless Entry Transmitters

Description and Operation
Keyless Entry System Description
and Operation
The keyless entry system is a vehicle entry device. The
keyless entry system is used in conjunction with the
door locks to unlock the vehicle. Keyless entry will
Iock/unlock the vehicle doors or open the rear
compartment lid when a corresponding button on the
keyless entry transmitter is pressed. This is
accomplished by the transmitter sending a radio
frequency to the Remote Control Door Lock Receiver
antenna that has a direct link to the Body Control
Module (BCM). The BCM interprets the signal and
activates the requested function or request the
appropriate control module to activate the function via a
serial data message. A low transmitter battery or radio
frequency interference from aftermarket devices, such
as 2-way radios, power inverters, computers, etc., may
cause a system malfunction. High radio frequency
traffic areas, such as gas stations that use
pay—at—the-pump radio frequency transponders, may
also cause interference that could lead to a
malfunction. Keyless entry allows you to operate the
following features:
- Door lock/unlock
- Liftgate lock/unlock, if equipped
- Trunk release, if equipped
° Power liftgate, if equipped
. Vehicle locator/Panic alarm
- Remote vehicle starting, if equipped
The keyless entry system has the following
components:
. Keyless entry transmitters
- Body Control Module
' Remote Control Door Lock Receiver
Note: When the vehicle key is in the ignition, keyless
entry functions from all keyless entry transmitterare
disabled.
The keyless entry transmitters are used to perform
various entry functions while away from the immediate
are of the vehicle. Keyless entry functions may work at
up to 20 m (65 ft) away from the vehicle. Ambient
conditions may affect the performance of the keyless
entry transmitter and reduce the range at which keyless
entry functions operate. Up to eight transmitters may be
programmed to a single vehicle. The keyless entry
transmitter is an integral part of the vehicle key.
OnStar® Remote Link (if equipped)
A vehicle operator may have the ability to performsome
of the keyless entry functions using applications on
personal devices such as a smart phone. Unwanted or
inadvertent door Iock/unlock activation may be
requested by the OnStar®Remote Link app. Itis
possible that a customer may be unaware of account
usage, result in an unwanted or phantom door
Iock/unlock. Ifnormal system diagnosis does results in
an inability to verify the customer’s concern, contact
Technical Assistance Center (TAC).
Body Control Module (BCM)
The BCM is a multifunction module that operates the
keyless entry system. When an radio frequency
message is received from a keyless entry transmitter,
the BCM interprets this signal and performs the specific
function, i.e. door lock, door unlock, or vehicle locate.
Remote Control Door Lock Receiver
The Remote Control Door Lock Receiver acts as an
antenna for the keyless entry system and
communicates with the BCM through a dedicated serial
data link. When a button is pressed on a keyless entry
transmitter,the Remote Control Door Lock Receiver
receives this signal and sends the request to the BCM.
The BCM interprets the signal and performs the specific
function, i.e. door lock, door unlock, or vehicle locate.

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 Remote Functions 13-45

Remote Vehicle Start, if equipped

Unlock Doors engine starting
in The remote vehicle start function allows
Momentarily press the transmitter UNLOCK button while not in the vehicle. Italso allows the vehicle HVAC
order to perform the following functions: vehicle systems to enable, providing
system and other
and liftgate vehicle
~ Unlock only the driver door or all doors a comfortable vehicle upon entry. The remote
(if equipped); this is customized through the BIG. begins by pressing and releasing the
start sequence remote
pressing and holding the
~ illuminate the interior lamps for a determined lock button and then
transmitter.
length of time or until the ignition is turned ON. vehicle start buttons on the keyless entry
lamps will illuminate to indicate the
The turn signal
~ Flash the exterior lights; this is customized start request. Each
through the DlC. vehicle has received the remote
vehicle
time an remote vehicle start is performed, theunlocked/
- Disarm the content theft deterrent system, doors are locked, however they may then be
any time.
if equipped. locked with the transmitter or vehicle key at
system to run for
- Deactivate the content theft deterrent Once activated, the engine is allowed
when in the alarm mode. minutes. The remote vehicle start time may be
10
extended by an additional 10 minutes by again
then
Lock All Doors pressing and releasing the lock button and
vehicle start buttons
Press the transmitter LOCK button to perform
the pressing and holding the remote
This feature is called a remote
following functions: on the transmitter. of
- Lock all vehicle doors. vehicle start continue and allows a maximum vehicle start
20 minutes of engine running. Ifthe remote
' Immediately turn OFF the interior lamps. continue is performed at seven minutes into the initial
horn; engine
- Flash the exterior lights andlor sound the 10 minute time—out,a total of 17 minutes of event
this is customized through the DIC. running would occur. The remote vehicle start
at any time by pressing only the
- Arm the content theft deterrent system. may be suspended
the transmitter or by
remote vehicle start button on
lamp
Trunk Release, if equipped entering the vehicle and pressing the hazard
to switch.
Press the trunk release button on the transmitter vehicle start
open the trunk. In between ignition cycles, only two remote events or
events may occur or be attempted. Once two
start
Power Liftgate, if equipped attempts have been made, future remote vehicle
the be suspended until the vehicle is started
Press and hold the power liftgate button to perform events will
following functions: using the ignition.
liftgate
' Open or close the liftgate using the power EnablelDisable Remote Vehicle Start
function. remote vehicle start
Using the driver information center,
° Flash the tail lamps. may be enabled or disabled as a part of vehicle
for
- Sound the interior power liftgate chime. personalization. Refer to the vehicle owners manual
Alarm more information.
Vehicle LocatorIPanic
A single press of the panic button performs the Hood Ajar Switch
may be dependent to the
following functions. Some functions The hood switch provides status of the hood switch is
on personalization settings: BCM for remote vehicle start purposes. The
- Pulse the horn three times. integrated into the hood latch assembly.
- Flash the exterior lamps three times. Remote Vehicle Start Circuit
the
A press and hold of the panic button performs Descflpfion
following functions: entry
The BCM receives a signal from the keyless request.
- illuminate the interior lamps. transmitter indicating a remote vehicle start
lamps for determines if
~ Pulse the horn and flash the exterior occur: A message is then sent to the BCM which ECM to
30 seconds or until the following conditions to the
a crank request message will be sent are
—The panic button is pressed. allow engine starting. To determine if conditions will
remote vehicle start event, the BCM
——The ignition switch is turned to the RUN position correct for an
with a valid key. ensure the following conditions are met:
present.
- A valid hood ajar switch closed signal is
- The doors are locked.
- The hazard switch is OFF.
- The vehicle power mode is correct.
- No content theft deterrent alarm triggers are
present.

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113-46 Remote Functions
When the BCM determines all conditions meet those Keyless Entry Personalization
required for an remote vehicle start event, a message is
sent via serial data to the ECM. The ECM relies on the Vehicle Iock/unlockfunctions and remote vehicle start
remote vehicle start message from BCM to enable remote vehicle start settings may be personalized. For
remote vehicle start when the crank request signal is functional descriptions and personalization instructions,
received. if the ECM does not receive a valid remote refer to the vehicle owners manual.
vehicle start message, it will not attempt to start the
engine. While the ECM is in remote vehicle start mode Special Tools and Equipment
it will suspend engine operation if any of the following
additional conditions occur:
Illustration Tool Number/Description
- Vehicle speed is greater than 0.
- Transmission is not in PARK. Imus:
EMT"VETER
- Excessive engine coolant temperature
@249 g
- Low oil pressure
' The malfunction indicator lamp (MIL) is EL 43241
commanded ON. Keyless EntryTester
- Engine crank time is greater than 30 seconds.
- Excessive engine speed
- Accelerator pedal position too high
0 Remote start timer equals 0. 441447
- Immobilizer system indicates tamper

2013
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 Seat Belts

Seat Belts

Specifications

Fastener Tightening Specifications

Specification
Metric English
Application
45N-m 331bft
Driveror PassengerSeat Belt BuckleFastener
45Wm 33lbft
Driveror PassengerSeat ShoulderBelt Fastener
45N-m 33lbft
FrontSeat ShoulderBeltGuideAdjusterBolt
45N-m 33lbft
Rear SeatBelt Buckle Fastener
45N-m 33lbft
RearSeat CenterShoulderBelt BuckleFastener
45N-m 33 lbft
RearSeat ShoulderBeltAnchorPlate Fastener
45N-m 33lbft
Rear Seat ShoulderBelt RetractorFastener

Schematic and Routing Diagrams

(US/Canada)
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2013 (5377994)
Manual
Service
13-48 Seat Belts

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2013
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(US/Canada)
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Manual
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Diagnostic Information and
Procedures
Seat Belt System Operational and
Functional Checks
Note: Ifthe vehicle has been in a collision, refer to
Repairs and Inspections Required After a Collision on
page 13-57for additional information.
Perform the following inspection from the driver seat:
1. Turn the ignition switch to the ON position. Verify
proper operation of the seat belt reminder lamp
with the belt buckled and with the belt unbuckled.
Inspect the shoulder belt guide in order to ensure
that the following conditions are met:
- The shoulder belt guide swivels freely.
- The seat belt webbing is seated flat in the
guide slot.
- The seat belt webbing does not bind.
Verify that the seat belt buckle faces inboard and is
accessible.
. Verify that the seat belt retractor units are securely
attached.
Verify that the seat belt anchor bolts are secure.
Fully extend the seat belt webbing. Verify that the
seat belt webbing does not have any twists or
tears.
Allow the seat belt webbing to retract. Verify that
the seat belt webbing returns freely and completely
back into the retractor. Ifthe seat belt webbing will
not retract. refer to Seat Belt Does Not Retract on
page 13-53.
Snap the seat belt latch plate into the buckle.
. Sharply tug on the seat belt latch plate and the
buckle. Verify that the seat belt latch plate and the
buckle remain locked when tugged.
. Push the button on the buckle:
- Verify that the seat belt latch plate releases
easily from the buckle.
- Verify that the button returns to its original
position.
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Manual
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Seat Belts 113-49
Perform the following inspection procedure from the
passenger seat.
1. Verify the automatic locking retractor (ALR) feature
operates properly by performing the following
checks:
1.1. Pull the seat belt all the way out of the
retractor until it stops.
1.2. Slowly allow the belt to retract partially, while
listening for a ratcheting sound.
1.3. Sharply tug on the belt ensuring that the
retractor lock sets and does not allow the belt
to be pulled from the retractor.
1.4. After performing steps 1.1 through 1.3 ensure
the belt fully retracts.
2. Repeat the inspection procedure steps 2 through
10 from the passengers seat.
Perform the following steps in order to inspect the left
and right rear seat belts:
1. Inspect the shoulder belt guide in order to ensure
that the following conditions are met:
o The seat belt webbing is seated flat in the
guide slot.
- The seat belt webbing does not bind.
. Verify that the seat belt buckle is accessible.
. Verify that the seat belt retractor units are securely
afiached.
. Verify that the seat belt anchor bolts are secure.
. Fully extend the seat beltwebbing. Verify that the
seat belt webbing does not have any twists or
tears.
. Allow the seat belt webbing to retract. Verify that
the seat belt webbing returns freely and completely
back into the retractor.
. Snap the seat belt latch plate into the buckle.
. Sharply tug on the seat belt latch plate and the
buckle. Verify that the seat belt latch plate and the
buckle remain locked when tugged.
. Push the button on the buckle:
- Verify that the seat belt latch plate releases
easily from the buckle.
~ Verify that the button returns to its original
position.
'13-50 Seat Belts

Emergency Locking Retractors

Warning: Perform this test in an area clear of other
vehicles or obstructions. Do not conduct this test
on the open road. A large, empty parking lot is
suitable. Failure to observe this precaution may
result in damage to the vehicle and possible
personal injury.
1. Fasten the seat belts, an assistant is needed when
the retractor under test is not part of the driver
seat belt.
2. Accelerate the vehicle slowly to 16 km/h (10 mph)
and apply the brakes firmly.
3. Verify that the seat belt looks when braking firmly.
Note: When performing this check, note the position
that the retractors are mounted. Some retractors are
not mounted at a zero degree inclination.
4. Ifthe belt does not lock, proceed with the following
steps:
4.1. Remove the seat belt retractor assembly. 157277
4.2. Tilt the seat belt retractor slowly.
4.3. Ensure that the seat belt webbing can be
pulled from the retractor at an inclination of
15 degrees forward or less, from the retractors
mounted position.
4.4. Ensure the retractor cannot be pulled from the
retractor at an inclination of 45 degrees
forward or more.
4.5. Ifa seat belt retractor does not operate as
described, replace the retractor assembly.

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2013 (5377994)
Manual
Service
 Seat Belts 13-51

DTC 80072 or 80073

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

DTC Descriptors
DTC 80072: Driver Seat Belt Switch Circuit
DTC 80073: Passenger Seat Belt Switch Circuit
Byte
For symptom byte information refer to Symptom
List on page 6-85.
Diagnostic Fault Information

Open Short to Signal

Short to High Performance
Resistance Voltage
Circuit Ground
8007204, 8007201, 8007208
8007202, 8007204,
DriverSeat Belt SwitchSignal 8007208 8007206, 8007206 8007205
80072DC
8007304, 8007304,
(3% 3007306, 8007306 %%%7733%1§ 3007308
PassengerSeat Belt SwitchSignal 33%?)7733
8007300

80072 08 or 80073 08
CircuitlSystem Description
is within The seat belt switch signal is above threshold.
The inflatable restraint seat belt buckle switch
the seat belt buckle and provides an input to the 80072 0C or 80073 0C
inflatable restraint sensing and diagnostic module The seat belt switch signal is below threshold.
(SDM). The inflatable restraint sensing and diagnostic
module supplies a low reference circuit and a
seat belt Action Taken When the DTC Sets
switch signal circuit to determine a buckled or module
The inflatable restraint sensing and diagnostic
unbuckled condition. The inflatable restraint sensing will store a DTC and illuminate the air bag indicator in
switch
and diagnostic module monitors the seat belt the instrument cluster.
circuits and if a fault is detected a DTC will be set.
Conditions for Clearing the DTC
Conditions for Running the DTC
exists.
6 V. The condition for setting the DTC no longer
Ignition voltage is between 9—1
Reference Information
Conditions for Setting the DTC
Schematic Reference
80072 01 or 80073 01
SIR Schematics on page 13—69
The seat belt switch circuit is shorted to voltage.
Connector End View Reference
80072 02 or 80073 02
The seat belt switch circuit is shorted to ground. Component Connector End Views on page 11-269
80072 04 or 80073 03 Description and Operation
The seat belt switch circuit is open. Supplemental Inflatable Restraint System Description
and Operation on page 13—145
80072 05 or 80073 05
Electrical Information Reference
The seat belt switch circuit is shorted to voltage
or open. - Circuit Testing on page 11—526
80072 06 or 80073 06 ' Testing for IntermittentConditions and Poor
Connections on page 11-531
The seat belt switch circuit is shorted to ground
or open. - Wiring Repairs on page 11—537
- Connector Repairs on page 11-548
80072 08 or 80073 08
The seat belt switch signal is invalid.

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Manual
Service
13- 52 Seat Belts
Scan Tool Reference
Control Module References on page 6-3 for scan tool
information
CircuitlSystem Verification
1. Ignition ON.
2. Verify the appropriate scan tool Seat Belt Status
parameter changes between Buckled and
Unbuckled when the seat belt is buckled and
unbuckled.
If the parameter does not change
Refer to CircuitlSystem Testing.
U If the parameter changes
3. All OK.
CircuitlSystem Testing
Note: When removing connectors inspect for damage
or corrosion. Damage or corrosion in the following
requires repair or replacement of the affected
component/connector.
8153B Seat Belt Buckle-Driver
8153P Seat Belt BuckIe-Passenger
K36 Inflatable Restraint Sensing and Diagnostic
Module
1. IgnitionOFF. Scan tool disconnected. Disconnect
the harness connector at the appropriate 8153
Seat Belt Buckle. Itmay take up to 2 min for all
vehicle systems to power down.
. Test for less than 5 Q between the low reference
circuit terminal 2 and ground.
If 5 Q or greater
2.1. IgnitionOFF, disconnect the harness
connector at the K36 inflatable Restraint
Sensing and Diagnostic Module.
2.2. Test for less than 2 Q in the low reference
circuit end to end.
2 If2 Q or greater, repair the open/high resistance
in the circuit.
2 Ifless than 2 Q, replace the K36 Inflatable
Restraint Sensing and Diagnostic Module.
If less than 5 Q
9° IgnitionON.
. Verify the appropriate scan tool Seat Belt Status
parameter is Buckled.
If not Buckled
4.1. Ignition OFF, disconnect the harness
connector at the K36 Inflatable Restraint
Sensing and Diagnostic Module.
4.2. Test for infinite resistance between the signal
circuit terminal 1 and ground.
2 Ifless than infinite resistance, repair the short to
ground on the circuit.
2 if infinite resistance, replace the K36 Inflatable
Restraint Sensing and Diagnostic Module.
If Buckled
Install a 3 A fused jumperwire between the signal
circuit terminal 1 and the low reference circuit
terminal 2.
Verify the appropriate scan tool Seat Belt Status
parameter is Unbuckled.
If not Unbuckled
6.1. Ignition OFF, disconnect the harness
connector at the K36 inflatable Restraint
Sensing and Diagnostic Module, ignition ON.
6.2. Test for less than 1 V between the signal
circuit and ground.
2 If 1 V or greater, repair the short to voltage on
the circuit.
U Ifless than 1V
6.3. Test for less than 2 Q in the signal circuit end
to end.
2 If2 Q or greater, repair the open/high resistance
in the circuit.
2 if less than 2 Q, replace the K36 Inflatable
Restraint Sensing and Diagnostic Module.
U If Unbuckled
7. Test or replace the 8153 Seat Belt Buckle.
Component Testing
1. IgnitionOFF. Scan tool disconnected. Disconnect
the harness connector at the appropriate 8153
Seat Belt Buckle. Itmay take up to 2 min for all
vehicle systems to power down.
. Test for infinite resistance between the signal
terminal 1 and the low reference terminal 2.
if less than infinite resistance
Replace the 8153 Seat Belt Buckle.
If infinite resistance
Insertthe seat belt into the buckle.
Test for less than 5 Q between the signal terminal 1
and the low reference terminal 2.
If 5 Q or greater
Replace the 8153 Seat Belt Buckle.
U If less than 5 Q
5. All OK.
Repair Instructions
Perform the Diagnostic Repair Verification on
page 692 after completing the repair.
Front Seat Belt Buckle Replacement on
page 13-59
'
SIR/SRS Wiring Repairs on page 11—548
Control Module References on page 6-3 for
inflatable restraint sensing and diagnostic module
replacement, programming, and setup.
(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
 Seat Belts 13-53

- Seat Belts Symptom List

Symptoms
Refer to the following symptom diagnostic procedure in
Note: Review the seat belt system description and
operation in order to familiarize yourself with the system order to diagnose the symptom:
and how it functions. Refer to Seat Belt System - Seat Belt Indicator Malfunction —Driver on
Description and Operation on page 13—66. page 13—53
- Seat Belt Indicator Malfunction - Passenger on
Visual/Physical Inspection page 13-55
- inspect for aftermarket devices which could affect
the operation of the seat belt system. Refer to Seat Belt Does Not Retract
Checking Aftermarket Accessories on 1. Grab the seat belt webbing and slowly and firmly
page 11-525. extract 15—25mm (5/8—1in) of webbing from the
' Inspect the easily accessible or visible system seat belt. .
components for obvious damage or conditions 2. Release the seat belt and allow the webbing to
which could cause the symptom. slowly retract back into the retractor.
Intermittent 3. Check to see if the seat belt is released. Ifthe seat
belt is not released, repeat steps 1 and 2, two
Faulty electrical connections or wiring may be the times more.
cause of intermittentconditions. Refer to Testing for
IntermittentConditions and Poor Connections on 4. if the retractor does not release after repeating the
page 11—531 . steps, replace with a new retractor.

Seat Belt Indicator Malfunction - Driver

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

Open/High Signal
Short to Ground Resistance Short to Voltage Performance
Circuit
1 2 2 -
DriverSeat BeltSwitch Signal
— 2 —— —-
DriverSeat BeltSwitchLow Reference
1.IndicatorwillremainON withseat beltbuckled.
2. Indicatorwillilluminateonlyforthe bulbcheck.

CircuitlSystem Description Description and Operation

The driver seat belt switch is a 2—wireswitch wired to Seat Belt System Description and Operation on
the Inflatable Restraint Sensing and Diagnostic Module page 13-66
(SDM) using a signal circuit and a low reference circuit. Electrical Information Reference
When the seat belt is unbuckled the switch is closed,
and when the seat belt is buckled the switch is open. - Circuit Testing on page 11-526
The inflatable Restraint Sensing and Diagnostic - Connector Repairs on page 11—548
Module sends the status of the driver seat belt via serial
data to the instrument cluster. After receiving the - Testing for IntermittentConditions and Poor
Connections on page 11—531
message, the instrument cluster controls the
illumination ofthe driver seat belt indicator. - Wiring Repairs on page 11-537

Reference Information Scan Tool Reference

Schematic Reference Control Module References on page 6—3for scan tool

information
Seat Belt Schematics on page 13-48
Connector End View Reference
Component Connector End Views on page 11—269
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2013 (5377994)
Manual
Service
13-54 Seat Belts

CircuitlSystem Verification 2 if infinite resistance, replace the K36 inflatable

1. Verify the driver seat belt indicator turns ON and
OFF when commanding the instrument cluster all
indicators ON and OFF with a scan tool.
if the driver seat belt indicator does not turn ON
and OFF as commanded.
Replace the P16 instrument Cluster.
If the driver seat belt indicator does turn 0N
and OFF as commanded
. Verify the scan tool Diver Seat Belt Switch
parameter changes between Buckled and
Unbuckled when buckling and unbuckling the
driver seat belt. , 6.2. Test for less than 1 V between the signal
If the parameter does not change
Refer to CircuitlSystem Testing.
U If the parameter changes
3. All OK.
CircuitlSystem Testing
Note: When removing connectors inspect for damage
or corrosion. Damage or corrosion in the following
requires repair or replacement of the affected
component/connector.
8153D Seat Belt Buckle—Driver
Seat belt switch harness connector
K36 Inflatable Restraint Sensing and Diagnostic
Module
Inflatable Restraint Sensing and Diagnostic
Module wiring harness connector
. IgnitionOFF and all vehicle systems OFF,
disconnect the harness connector at the
8153D Seat Belt Buckle—Driver.Itmay take up to
2 minutes for all vehicle systems to power down.
. Test for less than 5 Q between the low reference
circuit terminal 2 and ground.
If 5 Q or greater
2.1. Disconnect the X2 harness connector at the
K36 Inflatable Restraint Sensing and
Diagnostic Module.
2.2. Test for less than 2 Q in each low reference
circuit end to end.
2 If2 Q or greater, repair the open/high resistance
in the circuit.
2 Ifless than 2 Q. replace the K36 Inflatable .
Restraint Sensing and Diagnostic Module.
if less than 5 Q
.03 Ignition ON.
. Verify the scan tool Driver Seat Belt Status
parameter is Buckled.
if not Buckled
4.1. ignition OFF, disconnect the X2 harness
connector at the K36 Inflatable Restraint
Sensing and Diagnostic Module.
4.2. Test for infinite resistance between the seat
belt switch signal circuit terminal 1 and ground.
2 Ifless than infinite resistance, repair the short to
ground on the circuit.
Restraint Sensing and Diagnostic Module.
If Buckled
. Install a 3 A fused jumper wire between the signal
circuit terminal 1 and the low reference circuit
terminal 2.
6. Verify the scan tool Driver Seat Belt Status
parameter is Unbuckled.
:> If Unbuckled
6.1. IgnitionOFF, disconnect the X2 harness
connector at the K36 Inflatable Restraint
Sensing and Diagnostic Module, ignition ON.
circuit and ground.
2 If 1 V or greater, repair the short to voltage on
the circuit.
U If less than 1 V
6.3. Test for less than 2 Q in each circuit end
to end.
2 If2 Q or greater, repair the open/high resistance
in the circuit.
2 Ifless than 2 Q, replace the K36 Inflatable
Restraint Sensing and Diagnostic Module.
U If Unbuckled
7. Test or replace the B153D Seat Belt Buckle-Driver.
Component Testing
1. ignition OFF, disconnect the harness connector at
the 8153D Seat Belt Buckle-Driver, buckle the
driver seat belt.
Test for infinite resistance between the signal
circuit terminal 1 and the low reference terminal 2.
If not infinite resistance
Replace the 8153D Seat Belt Buckle-Driver.
If infinite resistance
Unbuckle the driver seat belt.
Test for less than 1 Q between the signal circuit
termina|1 and the low reference terminal 2.
If 1 Q or greater
Replace the B1538 Seat Belt Buckle-Driver.
U If less than 1 Q
5. All OK.
Repair Instructions
Perform the Diagnostic Repair Verification on
page 6-92 after completing the repair.
0 Front Seat Belt Buckle Replacement on
page 13-59
Control Module References on page 6-3 for
Inflatable Restraint Sensing and Diagnostic
Module or instrument cluster replacement,
programming and setup

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
xF—
Mm
+\~
--x.
.MN
”W—
w
2
M
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_
fl
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 Seat Belts 13-55

Seat Belt Indicator Malfunction - Passenger

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

Opeanigh Signal
Short to Ground Resistance Short to Voltage Performance
Circuit
1 2 2 -
PassengerSeatBelt SwitchSignal
3 3 4 -
PassengerSeatBelt IndicatorControl
— 2 — —-
PassengerSeatBelt SwitchLow Reference _.
— 3 __
Ground
1. indicatorwillremainON withseat beltbuckled.
2. Indicatorwillilluminateonlyforthe bulbcheck.
3. Indicatorwillnotilluminate.
4. IndicatoralwaysON.

Description Connector End View Reference

CircuitlSystem
When an individual is sitting in the passenger seat the
passenger presence sensor detects the individual.
A signal to the Inflatable Restraint Sensing and
Diagnostic Module indicates a person is in the
passenger seat. The Inflatable Restraint Sensing and
Diagnostic Module will turn the passenger seat belt
indicator. The passenger seat belt switch is a 2-wire
switch wired to the Inflatable Restraint Sensing and
Diagnostic Module using a signal circuit and a low
reference circuit. When the seat belt is unbuckled the
switch is closed, and when the seat belt is buckled the
switch is open. The Inflatable Restraint Sensing and
Diagnostic Module sends the status of the passenger
seat belt via a hard wire to the passenger air bag
disable indicator. After receiving the message, the
passenger air bag disable indicator controls the
illumination of the passenger seat belt indicator.
Diagnostic Aids
Objects on the passenger seat can cause the
passenger seat belt reminder to be commanded on.
Depending on the sensing technology used, a
conductive object (computers, MP3 players, cell
phones, diagnostic scan tool, wires, a hand, etc.)
placed on the passenger seat may cause the
Passenger Presence Detection Module to command
the passenger air bag indicator ON and/or command
the passenger seat belt indicator ON. The fasten seat
belt chime will also sound. '
Reference Information
Component Connector End Views on page 11-269
Description and Operation
Seat Belt System Description and Operationon
page 13-66
Electrical Information Reference
- Circuit Testing on page 11—526
- Connector Repairs on page 11-548
' Testing for IntermittentConditions and Poor
Connections on page 11-531
- Wiring Repairs on page 11-537
Scan Tool Reference
Control Module References on page 6-3 for scan tool
information
CircuitlSystem Verification
1. IgnitionON.
2. Verify the passenger seat belt indicator turns ON
and OFF when commanding the Passenger Seat
Belt Reminder Indicator with a scan tool.
2 If the passenger seat belt indicator does not
turn ON and OFF
Refer to Seat Belt Indicator Malfunction in
CircuitlSystem Testing.
U If the passenger seat belt indicator turns ON
and OFF

Schematic Reference
Seat Belt Schematics on page 13-48

—
2013 (US/Canada)
Sonic (5377994)
Manual
Service
13-56 Seat Belts
3. Verify the scan tool Passenger Seat Belt Status
parameter changes between Buckled and
Unbuckled when buckling and unbuckling the
seat belt.
=>If the parameter (1°95 "0t change between
Bugklektiammanuckgeflwhen buckling and
un uc mg e seat e . . , .
Refer to Seat Belt Switch Malfunction InCircwt/
System Testing.
U If the parameter changes between Bucltled and
Unbuckled when buckling and unbuckling the
seat belt
4‘ A" OK'
CircuitlSystem Testing
' . . 2 if less than 2 Q, replace the K36 Inflatable
Passenger Seat Belt SW'tCh Malfunction
1. ignition OFF. Disconnect the harness connector at
the 8153P Seat Belt Buckle—Passenger.
2. Test for less than 5 Q between the low reference
circuit terminal 2 and ground.
—_->If 5 Q or greater
2.1. Disconnect the X2 harness connector at the
K36 Inflatable Restraint Sensing and
Diagnostic Module.
2.2. Test for less than 2 Q in each control circuit
end to end.
2 if 2 Q or greater, repair the open/high resistance
in the circuit.
2 If less than 2 Q, replace the K36 Inflatable
Restraint Sensing and Diagnostic Module.
U If less than 5 Q
9’ IgnitionON.
Verify the scan tool Passenger Seat Belt Status
parameter listed below is Buckled.
If not Buckled
4.1. Disconnect the X2 harness connector at the
K36 inflatable Restraint Sensing and
Diagnostic Module.
4.2. Test for infinite resistance between the seat
belt switch signal circuit terminal 1 and ground.
2 Ifless than infinite resistance, repairthe short to
ground on the circuit.
2 Ifless than 2 Q, replace the K36 Inflatable
Restraint Sensing and Diagnostic Module.
4: If Buckled
. Install a 3 A fused jumper wire between the signal
circuit terminal 1 and the low reference circuit
terminal 2.
6. Verify the scan tool Passenger Seat Belt Status
parameter is Unbuckled.
2;. If not Unbuckled
6.1. ignition OFF. Disconnect the X2 harness
connector at the K36 inflatable Restraint
Sensing and Diagnostic Module. IgnitionON.
6.2. Test for less than 1 V between the signal
circuit and ground.
2 If 1 V or greater, repair the short to voltage on
the circuit.
6.3. Test for less than 2 Q in each circuit end
to end.
2 lf2 Q orgreater, repairthe open/high resistance
1“the CWCUIt-
Restraint Sensing and Diagnostic Module.
U If Unbuckled
7. Test or replace the 8153P Seat Belt
Buckle—Passenger.
Passenger Seat Belt Indicator Malfunction
1. Ignition OFF and all vehicle systems OFF,
disconnect the harness connector at the
P14 Passenger Air Bag Disable Indicator.
Test for less than 10 Q between the ground circuit
terminal 4 and ground.
If 10 Q or greater
2.1. IgnitionOFF.
2.2. Test for less than 2 Q in the ground circuit end
to end.
2 If2 Q or greater, repair the open/high resistance
in the circuit.
2 Ifless than 2 Q, repair the open/high resistance
in the ground connection.
If less than 10 Q
IgnitionON. With a scan tool, command the
Passenger Seat Belt Reminder indicator OFF.
Test for less than 11V between the control circuit
terminal 6 and ground.
If 11V or greater
4.1. IgnitionOFF. Disconnect the X1 harness
connector at the K36 Inflatable Restraint
Sensing and Diagnostic Module. IgnitionON.
4.2. Test for less than 1 V between the control
circuit terminal 6 and ground.
2 If 1V or greater, repair the short to voltage on
the circuit.
2 if less than 1 V, replace the K36 Inflatable
Restraint Sensing and Diagnostic Module.
If less than 11 V
With a scan tool, command the Passenger Seat
Belt Reminder IndicatorON.
2013
—
Sonic
(US/Canada)
Service
Manual
(5377994)

6. Test for greater than 4 V between the control circuit
terminal 6 and ground.
:> If 4 V or less
6.1. ignition OFF. Disconnect the X 1 harness
connector at the K36 Inflatable Restraint
Sensing and Diagnostic Module.
6.2. Test for infinite resistance between the control
circuit terminal 6 and ground.
2 Ifless than infinite resistance, repair the short to
ground on the circuit.
6.3. Test for less than 2 Q between the control
circuit terminal 6 and ground.
2 If2 Q or greater repair the open/high resistance
in the circuit.
2 if less than 2 Q replace the K36 Inflatable
Restraint Sensing and Diagnostic Module.
U If greater than 4V
7. Replace the P14 Passenger Air Bag Disable
indicator.
Component Testing
1. Ignition OFF. Disconnect the harness connector at
the 8153P Seat Belt Buckle—Passenger. Buckle
the 8153P Seat Belt Buckle—Passenger.
Test for infinite resistance between the signal
circuit terminal 1 and the low reference terminal 2
at the 8153P Seat Belt Buckle—Passenger.
If less than infinite resistance
Replace the B153P Seat Belt
Buckle-Passenger.
If infinite resistance
Unbuckle the 8153P Seat Belt Buckle-Passenger.
Test for less than 1 Q between the signal circuit
terminal 1 and the low reference terminal 2 at the
8153P Seat Belt BuckIe—Passenger.
If 1 Q or greater
Replace the 8153P Seat Belt
Buckle—Passenger.
U If less than 1 Q
5. All OK.
Repair Instructions
Perform the Diagnostic Repair Verification on
page 6—92after completing the repair.
Front Seat Belt Buckle Replacement on
page 13—59
Instrument Panel Airbag Arming Status Display
Replacement on page 13-128
Control Module References on page 6-3 for
Inflatable Restraint Sensing and Diagnostic
Module and Instrument Cluster replacement,
programming and setup
(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
Seat Belts 13-57
Precautions
Seat Belt Service
Note: if the vehicle has been in a collision, refer to
Repairs and Inspections Required After a Collision on
page 13—57for additional information.
Use
. Do not bleach or dye the seat belt webbing.
only the following items in order to clean the seat
belt webbing:
—A mild soap and water solution
—A soft brush or cloth
- Keep sharp edges and damaging objects away
from the seat belts. Avoid bending or damaging
any part of the seat belt buckle or the latch plate.
Replace any seat belts which are cut or damaged
in any way.
- Use only the correct seat belt anchor boltslscrews
and tighten the anchor boltslscrews to the correct
torque value. Refer to Fastener Tightening
Specifications on page 13—47.When installing
seat belt anchor bolts, start the bolt by hand to
ensure that the bolt is threaded straight.
as
- Some seat belts and retractors require service
a set, with service replacement parts only. Do not
attempt to repair to individual components that
require service as a set.
- Verify that the replacement part number is correct
for the vehicle at that seating position. Do not
substitute a seat belt from a different seating
position.
Instructions
Repair
Repairs and Inspections Required
After a Collision
Warning: Restraintsystems can be damaged in a
collision. To help avoid injury and ensure that all
parts in need of replacement are replaced:
- Replace any seat belt system that was in use
during the collision serious enough to deploy
any automatic restraint device such as air bags
and seat belt pretensioners. This not only
includes seat belt systems in use by people of
adult size, but seat belt systems used to secure
child restraints, infant carriers and booster
seats, including LATCH system and top tether
anchorages.
- Replace any seat belt system that has torn,
worn, or damaged components. This not only
includes adult seat belt systems, but buiIt-in
child restraints and LATCH system '
components, if any.
the
- Replace any seat belt system if you observe
words “REPLA CE” or “CAUTION", or if a
yellow tag is visible. Do not replace a seat belt
if only the child seat caution label is visible.
- Replace any seat belt system if you are
doubtful about its condition. This not only
includes adult seat belt systems, but built-in
child restraints, LATCH system components,
and any restraint system used to secure infant
carriers, child restraints, and booster seats.
13-58 Seat Belts
Do NOT replace single seat belt system After a minor collision where no automatic restraint
components in vehicles that have been in a device was deployed, seat belt system replacement
collision as described above. Always replace may not be necessary, unless some of the parts are
the entire seat belt system with the buckle, torn, worn, or damaged.
guide and retractor assembly, which includes
the latch and webbing material.

Seat Belt Latch Stop Installation

ii

1\~«\ 0/7 ”’fl)

<2 1

1923784

Seat Belt Latch Stop Installation

Callout L Component Name
PreliminaryProcedure
1. Locatetheholein theseatbeltwebbingwheretheoriginalseatbeltstopbuttonwas located.
2. Iftheoriginalholein theseatbeltwebbingis notvisible,performthefollowing:
- Ifeithertherightor leftstopbuttonis missinguse theopposingseatbeltas a reference.
- Withtheopposingseat beltfullystowed,measurethedistancebetweentheseatbeltloweranchorandthestopbutton.
' Usingthemeasurementobtainedabove,measureandmarkthelocationof themissingstopbuttononthecenterofthe
seatbeltwebbing.
3. Ensuretheseat beltlatchplateis locatedabovethemarkor originalhole.
Seat BeltStopButton
Procedure
1. Workthemalehalfof thestopbuttonthroughtheholeinthewebbingor atthemarkedlocation.
2. Alignthefemalehalfof thestopbuttonwiththemalehalfofthe stopbutton.
3. Snapthetwohalvestogether.
4. Trimoffanyaccess ofthemalehalfofthe stopbuttonflushwiththefemalehalfofthestopbutton.
Tip: Ensurethemalehalfof thestopbuttonis facingforwardin thevehiclein orderto ensurethestopbuttonwill
notsnagcustomersclothing.

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
 Seat Belts 13=59

Front Seat Belt Buckle Replacement

2506891

Front Seat Belt Buckle Replacement

Callout Component Name
Preliminary Procedures
onpage 14-4.
Removethefrontseat. Referto Driveror Passenger SeatRemovaland Installation
Driveror PassengerSeat BeltBuckle Fastener
Caution: Referto FastenerCautionon page0—8.
1 Tighten
45N°m(33lbft)
Driveror PassengerSeat BeltBuckleAssembly
2 Procedure
Disconnecttheelectricalconnector,if equipped.

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
13~6O Seat Belts

Rear Seat Belt Buckle Replacement

2507300

Rear Seat Belt Buckle Replacement

Callout Component Name
Preliminary Procedure
Removetherearseatcushion.Referto Rear SeatCushionRemovalandInstallationonpage 14-24.
Rear Seat BeltBuckleFastener(Qty:2)
Caution: RefertoFastenerCautiononpage 0—8.
1 Tighten
45N'm(33lbft)
2 Rear SeatBeltBuckleAssembly(Qty:2)

—
2013 (US/Canada)
Sonic (5377994)
Manual
Service
M‘W
‘~_
 SeatBeHs 13=61

Rear Seat Center Shoulder Belt Replacement (Sedan)

2507368

Rear Seat Center Shoulder Belt Replacement (Sedan)

Callout Component Name

Preliminary Procedures
Removethe rearseat cushion.Referto Rear Seat CushionRemovalandInstallationonpage 14-24.
RearSeat CenterShoulderBeltBuckle Fastener
Caution: Referto FastenerCautiononpage 0-8.
_\
Tighten
45N-m(33lbft)
N RearSeat CenterShoulderBelt

HM
MVHV..#-
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A...
a

—
2013 (US/Canada)
Sonic (5377994)
Manual
Service
132-62 Seat Belts

Rear Seat Center Shoulder Belt Replacement (Hatchback)

-N'J 77 jflil
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2511421

Rear Seat Center Shoulder Belt Replacement (Hatchback)

Callout I Component Name
Preliminary Procedures
1. Removetherearseatcushion.Referto Rear Seat CushionRemovalandInstallationonpage 14-24.
2. Removetherearseat backcushion.Referto Rear SeatBack CushionRemovalandInstallation(40%)onpage 14-26or
Rear SeatBack CushionRemovalandInstallation(60%)onpage 14-27.
3. Removetherearseatcushioncoverandpad.Referto RearSeat CushionCoverandPad Replacementonpage 14-23.
RearSeat CenterShoulderBelt Fastener(Qty:2)
Caution: Referto FastenerCautiononpage0-8.
Tighten
45N-m(33lbft)
2 RearSeat CenterShoulderBeltAssembly

(US/Canada)
-Sonic
2013 (5377994)
Manual
Servlce
--~M
M
Mflw
n,
A...
NW,__
 Seat Baits ‘13=63

Shoulder Belt Replacement - Rear (Sedan)

2507622

Shoulder Belt Replacement - Rear (Sedan)

Callout Component Name
PreliminaryProcedure
Removethe rearwindowpaneltrim.Referto Rear WindowPanel TrimReplacementonpage 2-81.
RearSeat ShoulderBeltAnchorPlate Fastener
Caution: Referto FastenerCautiononpage 0-8.
Tighten
45Nm(33lb ft)
RearSeat ShoulderBelt RetractorFastener
2 Tighten
45N-m(33lbft)
3 RearSeat ShoulderBelt

—
2013 (US/Canada)
Sonic (5377994)
Manual
Service
13-64 Seat Belts

Shoulder Belt Replacement - Rear (Hatchback)

Shoulder Belt Replacement - Rear (Hatchback)

Callout Component Name
Preliminary Procedures
1. Removetherearseatcushion.Referto Rear Seat CushionRemovalandInstallationonpage 14-24.
2. Removethebodylockpillaruppertrim.Referto BodyLockPillar UpperTrimPanel Replacement(Hatchback)onpage2—77
or BodyLockPillar UpperTrimPanel Replacement(Sedan)onpage2—78.
3. Removethequarterinnertrimfinishpanel.Referto Quan‘erlnnerTrimFinishPanel Replacement(Hatchback)on
page2—79.
RearSeat ShoulderBeltFastener
Caution: RefertoFastenerCautiononpage0—8.
M,,
WM
WA
“m.
_..
Tighten
45Nm (33lbft)
RearSeat ShoulderBeltRetractorFastener
2 Tighten
45N-m(33lbft)
RearSeat ShoulderBeltBracketFastener
3 Tighten
45N-m(33lbft)
4 RearSeat ShoulderBeltAssembly

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
 Seat Belts 13265

Front Seat Belt Guide Adjuster Replacement (with AHU)

2506720

Front Seat Belt Guide Adjuster Replacement (with AHU)

Callout I Component Name

Preliminary Procedures
onpage 2-75.
Removethe centerpillaruppertrimpanel.Referto CenterPillar UpperTrimPanel Replacement
Driveror PassengerSeat ShoulderBelt Fastener
Caution: Referto FastenerCautiononpage 0-8.
Tighten
45NW(33lbft)
FrontSeat ShoulderBelt GuideAdjusterBolt(Qty:2)
2 Tighten
45N-m(33lbft)
3 FrontSeat ShoulderBelt GuideAdjuster

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
13=66 Seat Belts
Description and Operation
Seat Belt System Description and
Operation
Restraint System
Note: Ifthe vehicle has been in a collision, refer to
Repairs and Inspections Required After a Collision on
page 13-57.
The vehicle has front and rear seat belts that are the
primary means of occupant restraint. Seat belts help to
keep the occupants inside the passenger compartment
and to gradually reduce the impact forces during the
following events:
- Frontal impact type crashes
- Rear impact type crashes
. Side impact type crashes
o RolI—overtype crashes
All seat belt retractors have emergency locks. The
retractors remain unlocked during normal operation and
under normal driving conditions. The retractors remain
unlocked during normal conditions in order to allow free
movement of the upper body of each occupant.
A pendulum locks the seat belt webbing into position.
The pendulum causes a locking bar to engage a cog on
the spool of the retractor mechanism when the
following conditions occur:
o A rapid extraction of the seat belt webbing from
the retractor
- An abrupt change in vehicle speed
- An abrupt change in vehicle direction
- Operation of the vehicle on a steep upgrade
- Operation of the vehicle on a downgrade
The seat belts have an automatic locking (cinch)
feature. The cinch feature is activated when the seat
belt webbing is completely extended from the retractor.
The cinch feature prevents the webbing from extending
beyond the position from which it is allowed to retract.
Use of the cinch feature is recommended for securing a
child seat. The cinch feature may be cancelled by
allowing the webbing to wind back completely into the
retractor.After the cinch feature is cancelled, the
webbing is unlocked. After the cinch feature is
cancelled, the webbing will extend from the retractor.
This vehicle is also equipped with a supplemental
inflatable restraint (SIR) system. Refer to Supplemental
Inflatable Restraint System Description and Operation
on page 153-145.
Front Seat Belt System
The front seat belt system includes a driver and
passenger seat belt pretensioner retractor and anchor.
Both front seat belt pretensioners includes a seat belt
switch in the seat buckle which controls a reminder
lamp and a tone alarm.
Note: The front passenger seat is equipped with a
passenger presence detection sensor, which detects
an occupant. lf the passenger presence detection
sensor detects an empty front passenger seat, then the
passenger fasten safety belt indicator will be disabled.
- When the driver seat belt is buckled and the
ignition switch is turned ON, the following events
will occur:
—The tone alarm will not operate.
—The reminder lamp will not operate.
- When the passenger seat belt is buckled with an
occupant sitting in the passenger front seat, then
the ignition switch is turned ON, the following
events will occur:
—The tone alarm will not operate.
—The reminder lamp, which is located within the
hazard warning switch, will not be turned ON.
. When the driver seat belt is not buckled and the
ignition switch is in the ON position, the following
events will occur:
—The tone alarm will operate for 4—8seconds and
then go OFF.
—The fasten safety belt indicator will turn ON for
20 seconds, until the driver seat belt is buckled.
- When the passenger seat belt is not buckled with
an occupant sitting in the passenger front seat,
then the ignition switch is turned ON, the following
events will occur:
—The tone alarm will operate for 4—8seconds and
then go OFF.
—The reminder lamp, which is located within the
hazard warning switch, will be turned ON.
Rear Seat Belt System
The Rear Seat Belt System includes the following
components:
- The rear seat belt retractor is located at the
wheelhouse panel and attached to the floor panel
by the rear seat shoulder belt retractor bracket.
- The rear seat belt buckles and the center seat belt
buckle are attached to each seat.
- Each of the rear seat belts include a seat belt
switch in the seat buckle which controls a
reminder lamp and a tone alarm.
- When the ignition switch is turned ON, a rearseat
belt is buckled, the rear doors are closed and the
speed exceeds 10 kph (6.5 mph) the following
events will occur:
—The tone alarm will not operate.
—The rear seat belt indicator in the Driver
InformationCenterwill illuminate for
35 seconds.
(US/Canada)
-Sonic
2013 (5377994)
Manual
Service

- When the ignition switch is turned ON, a rear seat
belt is not buckled for the duration of the ignition
cycle, the rear doors are closed and the speed
exceeds 10 kph (6.5 mph) the following events will
occur:
—The tone alarm will not operate.
—The rear seat belt indicator in the Driver
InformationCenter will not operate.
- When the ignition switch is turned ON, a rear seat
belt is buckled and during that ignition cycle is
unbuckled with the rear doors closed at all times
and the speed exceeding 10 kph (6.5 mph) the
following events will occur:
—The tone alarm will operate for 3 seconds.
—-The rear seat belt indicator in the Driver
InformationCenter will illuminate and remain on
until the seat belt is buckled again or the ignition
cycle ends.
Child Seat Restraint System
Warning: A child in a rear—facing child restraint can
be seriously injured if the right-front passengers air
bag inflates. This is because the back of a
rear-facing child restraint would be very close to
the inflating air bag. NEVER use a rear-facing child
restraint in this vehicle. If a forward-facing child
restraint is suitable for your child, ALWAYS move
the front passenger seat as far back as it will go and
then install the child restraint. Be sure the child
restraint position does not conflict with any
additional requirements provided by the
manufacturer. For more information, refer to the
vehicle owners manual and the instruction that
came with the child restraint.
A child in a rear-facing child restraint can be seriously
injured if the right-frontpassengers air bag inflates.
This is because the back of a rear-facing child restraint
would be very close to the inflating air bag. NEVER use
a rear—facingchild restraint in this vehicle. Ifa
fonNard-facing child restraint is suitable for your child,
ALWAYS move the front passenger seat as far back as
it will go and then install the child restraint. Be sure the
child restraint position does not conflict with any
additional requirements provided by the manufacturer.
(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
Seat Belts 113-67
For more information, refer to the vehicle owners
manual and the instruction that came with the child
restraint.
The child seat may only be used in a forward facing
seating location. The child seat should be installed and
secured according to the manufacturer's directions.
if the child seat has a top strap, the seat will need to be
anchored. Passengers should not be allowed to sit at
locations where the seat belts are being used to secure
the child seat.
All vehicles are equipped with a dual-mode type
retractor with emergency and automatic locking
features. The automatic locking feature is for restraint
of a child seat. The child seat can be secured by pulling
the seat belt all the way out to lock it. Then tighten the
seat belt around the child seat.
if a child seat is to be used in the second seat position,
a special dealer—installedanchor must be used in order
to anchor the child seat top strap. This only applies to
the seats designed with the top strap provision and for
the vehicles sold in Canada. Inorder to ensure the
correct top strap angle, the child seat is only to be used
at the seating position for which the top strap anchor is
installed.
Safety Belt Indicators
Fasten
There are three fasten safety belt indicators for this
vehicle. The driver fasten safety belt reminder is
displayed in the instrument cluster, the passenger
fasten safety belt reminder is displayed in the hazard
warning switch, and the rear fasten safety belt reminder
is displayed in the driver information center. The fasten
safety belt indicator may only be ON during RUN. The
fasten safety belt indicator illuminates under the
following conditions:
- During the bulb check
- The inflatable restraint sensing and diagnostic
module (SDM) sends the status of the driver seat
belt to the instrument cluster via serial data. The
passenger seat belt status is sent to the hazard
warning switch via a hard wire. The rear seat belt
status is sent to the driver information center via
serial data. if any of the seat belts are unfastened,
the instrument cluster will send a message
requesting a chime sound to be turned ON after a
bulb check.
13-68 Supplemental inflatable Restraints

Supplemental Inflatable Restraints

Specifications

Fastener Tightening Specifications

Specification
Application Metric English
Driveror PassengerSeat BeltTensionerCoverFastener 7.5N-m 66lb in
Driveror PassengerSeat BeltTensionerFastener 45N'm 33lbft
Driveror PassengerSeatShoulderBeltFastener 45 Nm 33lbft
Driveror PassengerSeatSide InflatableRestraintModuleFastener 4 N'm 35lb in
Driveror PassengerShoulderBeltRetractorFastener 45N'm 33lbft
FrontSeat BeltAnchorPlateFastener 8N'm 70lb in
FrontSeat BeltRetractorD RingFastener 45N-m 33Ibft
FrontSeatShoulderBeltRetractorFastener 45 N-m 33lbft
InflatableRestraintFrontEnd DiscriminatingSensor 7.5N-m 66lb in
InflatableRestraintRoofSide Rail Fastener 9.5N-m 84lb in
InflatableRestraintSensingandDiagnosticModuleFastener 10N-m 89lb in
InflatableRestraintSide ImpactSensor 7.5N-m 66lb in
Instrument Panel LowerAir Bag Fastener 9N'm 80lb in
RearSeat Side InflatableRestraintModuleBracketBolt 3.5N'm 31lb in
RearSeatSide inflatableRestraintModuleNut 3.5N-m 31lb in

Schematic and Routing Diagrams

2013
—
Sonic
(US/Canada)
Service
Manual
(5377994)
 ma Supplemental inflatable Restraints 13=89

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(US/Canada) (5377994)
Manual m >>u
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113-70 Supplemental inflatable Restraints

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(US/Canada)
«Sonic
2013 (5377994)
Manual
Service
 Supplemental Inflatable Restraints ’13-7'l

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(US/Canada)
~Sonic
2013 (5377994)
Manual
Service
 E

113—72 Supplemental lnilatable Restraints _

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—
2013 (US/Canada)
Sonic (5377994)
Manual
Service
 Supplemental inflatable Restraints ’l3=73

Component Locator

SIR Identification Views

The SlR IdentificationViews shown below illustrate the
approximate location of all SlR components available
for the vehicle. This will assist in determining the
appropriate SlR Disabling and Enabling for a given
service procedure, refer to SIR Disabling and Enabling
on page 13—112.
Supplemental Inflatable Restraint Identification Views

3456 78 9 1O

M /

18 171615 1413 12

Legend
(1) Right Front Impact Sensor - Located under
the hood at the front right side of the vehicle
(2) Front Hood Assist Rod 4A gas shock located
under the front hood on the passenger side
(3) Passenger InstrumentPanel Air Bag —
Located at the top right under the instrument
panel
(4) Right Roof Rail Air Bag —Located under the
headliner, extending from the passenger
front windshield pillar to the passenger rear
windshield pillar
(5) Right Front Side Impact Sensor - Located
behind door panel on the passenger
front door
(6) Inflatable Restraint Sensing and Diagnostic
Module - Located underneath the VGhiCIG
carpet under the center console
1552576
(7) Passenger Seat Side Air Bag —Located on
the seat back of passenger seat
(8) Passenger Seat Belt Retractor Pretensioner -
Located under the trim near the bottom of the
center pillar on the passenger side Ofvehicle
(9) InflatorModule for Right Roof Rail Air Bag -
Located behind the garnish molding on the
upper rear pillar
(10) Rear Hood Assist Rod - A gas shock located
under the rear truck lid on the passenger side
(11) Rear Hood Assist Rod —A gas shock located
under the rear truck lid on the driver side
(12) InflatorModule for Left Roof Rail Air Bag -
Located behind garnish molding on the upper
rear pillar
(13) Driver Seat Belt Retractor Pretensioner — .
Located under the trim near the bottom of the
center pillar on the driver side of vehicle

(US/Canada)
~Sonic
2013 (5377994)
Manual
Service
13—74 Supplemental inflatable Restraints
(14) Driver Seat Side Air Bag —Located on the (17) Driver Steering Wheel Air Bag —Located on
seat back of driver seat the steering wheel
(15) Left Front Side ImpactSensor —Located (18) Front Hood Assist Rod - A gas shock located
behind door panel on the driver front door under the front hood on the driver side
(16) Left Roof Rail Air Bag —Located under the (19) Vehicle Battery - Located at the front left of
headliner, extending from the driver front the engine compartment
the driver rear windshield
windshield pillar 120 (20) Left Front Impact Sensor _Located under the
pillar hood at the front left side of the vehicle

Diagnostic Information and Procedures

DTC 30012 or BOO13

Diagnostic Instructions
- Perform the Diagnostic System Check —Vehicle
on page 6-66 prior to using this diagnostic
procedure.
- Review Strategy Based Diagnosis on page 6-58
for an overview of the diagnostic approach.
- Diagnostic Procedure Instructions on page 6-59
provides an overview of each diagnostic category
DTC Descriptors
DTC 30012 01: Driver Steering Wheel Air Bag Deployment Loop Stage 1 Short to Battery
DTC 30012 02: Driver Steering Wheel Air Bag Deployment Loop Stage 1 Short to Ground
DTC 30012 04: Driver Steering Wheel Air Bag Deployment Loop Stage 1 Open
DTC B0012 0D: Driver Steering Wheel Air Bag Deployment Loop Stage 1 High Resistance
DTC 80012 0E: Driver Steering Wheel Air Bag Deployment Loop Stage 1 Low Resistance
DTC BOO1301: Driver Steering Wheel Air Bag Deployment Loop Stage 2 Short to Battery
DTC B0013 02: Driver Steering Wheel Air Bag Deployment Loop Stage 2 Short to Ground
DTC BOO1304: Driver Steering Wheel Air Bag Deployment Loop Stage 2 Open
DTC BOO130D: Driver Steering Wheel Air Bag Deployment Loop Stage 2 High Resistance
DTC BOO130E: Driver Steering Wheel Air Bag Deployment Loop Stage 2 Low Resistance

Diagnostic Fault Information

Short to High Short to Signal

Circuit Ground Resistance Open Voltage Performance

W 2331233 333133 -

W 23:31.33 38815813 -

W 22131332; 33313:; -

3%313‘625' 38813335 -

CircuitlSystem Description steering wheel air bag stage 2 high control circuit and
steering wheel air bag stage 2 low control circuit when
During a frontal crash of sufficient force the Inflatable the connector is disconnected. This will help to prevent
Restraint Sensing and Diagnostic Module (SDM) will unwanted deployment of the steering wheel air bag
allow current to flow through the deployment loop in during servicing.
order to deploy the steering wheel air bag. The SDM
performs continuous diagnostic tests on the Conditions for Running the DTC
deployment loops to check for proper circuit continuity Ignitionvoltage is between 9—16V.
and for shorts to ground or voltage. There are
2 shorting bars used within the steering wheel air bag
coil connector which will short together both steering
wheel air bag stage 1 high control circuit and steering
wheel air bag stage 1 low control circuit and both
(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
 Supplemental inflatable Restraints 1375

the DTC Reference Information

Conditions for Setting
Schematic Reference
B0012 01 stage1 or BOO1301 stage 2
The Steering Wheel Air Bag deployment loop is shorted SIR Schematics on page 13-69
to voltage for 2 seconds. Connector End View Reference
80012 02 stage1 or BOO1302 stage 2 Component Connector End Views on page 11-269
The Steering Wheel Air Bag deployment loop is shorted Description and Operation
to ground for 2 seconds.
Supplemental Inflatable Restraint System Description
80012 04 stage1 or BOO1304 stage 2
and Operation on page 153—145
The Steering Wheel Air Bag deployment loop is open Reference
Electrical Information
for 2 seconds.
30012 0D stage1 or BOO130D stage 2 . Circuit Testing on page 11-526
The Steering Wheel Air Bag deployment loop ~ Testing for IntermittentConditions and Poor
Connections on page 11-531
resistance is greater than 4.4 Q for 2 seconds.
- Wiring Repairs on page 11—537
B0012 0E stage1 or BOO130E stage 2
- Connector Repairs on page 11-548
The Steering Wheel Air bag deployment loop
resistance is less than 1.7 Q for 2 seconds. Scan Tool Reference

Taken When the DTC Sets
Action
- The Inflatable Restraint Sensing and Diagnostic
Module requests the instrument cluster to
illuminate the AIR BAG indicator.
- The Inflatable Restraint Sensing and Diagnostic
Module will store a DTC, however if an event
occurs the system will still attempt deployment.
Conditions for Clearing the DTC
° The condition for setting the DTC is no longer
exists.
- A history DTC will clear once 100 malfunction-free
ignition cycles have occurred.
Diagnostic Aid
Note: The following diagnostic aids apply for both
current and history DTCs.
Aworn steering wheel air bag coil can cause a
repeated history DTC to set. To verify this condition,
turn the steering wheel 360 degrees in one direction
then back 360 degrees in the other direction, multiple
times, while viewing the scan tool Deployment Loop
Resistance parameters.
An incorrectly installed connector position assurance
(CPA) or incorrectly seated connector can cause a
shorting bar to short both control circuits together.
Check the connectors and CPAs if a DTC with
symptom byte 02 or CE is set, to ensure the shorting
bars are not causing the circuits to be shorted together.
Shorting bars are used in the locations listed below:
- Steering Wheel Air Bag assembly
- Steering Wheel Air Bag Coil assembly
' lnline harness connectors
- Harness side of the Inflatable Restraint Sensing
and Diagnostic Module connector
Terminal frettingor incorrectly seated connector can
cause an open/high resistance condition. Check the
circuit terminals for fretting or incorrectly seated
connector if a DTC with symptom byte 04 or 0D is set.
Control Module References on page 6—3for scan tool
information
Special Tools
EL-38125—580Terminal Release Tool Kit
CircuitlSystem Verification
Note:
- Refer to SIR Service Precautions on page 13-113.
when
' inspect all terminals for damage or corrosion in
disconnecting connectors. Damage or corrosion
the following requires repair or replacement of the
affected component/oonnector.
—Steering wheel air bag
—Steering wheel air bag coil
—Inflatable Restraint Sensing and Diagnostic
Module
—Air bag wiring harness connector
—Inflatable Restraint Sensing and Diagnostic
Module wiring harness connector
- The connector and connector position assurance
(CPA) may seat independent of each other. Both
the connector and CPA should seat with an
audible andlor tactile click. The CPA isolates the
shorting-bars within the connector allowing the
deployment circuit to operate properly. Replace
any CPA that is damaged or missing.
' Ifthe condition is intermittentor cannot be
duplicated, disconnect the connectors and add
dielectric grease /lubricant (Nyogel 760G or
equivalent, meeting GM specification 9986087).
This procedure will correct the high resistance
condition due to terminal fretting corrosion.

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
13-76 Supplemental inflatable Restraints
1. Verify the appropriate scan tool Deployment Loop
Resistance parameters stay consistently between
2.1—4.0(2without any spikes or dropouts while
turning the steering wheel 360 degrees in one
direction then back 360 degrees in the other
direction.
=>if less than 2.1 Q or greater than 4.0 (2
Refer to CircuitlSystem Testing.
:;>If there are spikes or dropouts
Replace the X85 Steering Wheel Air Bag Coil.
U If between 2.1—4.09 without any spikes or
dropouts
2. Verify DTC B0012 or BOO13is only set as a
history DTC.
=>If the DTC is set as current
Refer to CircuitlSystem Testing.
U If the DTC is set as history
3. Verify the scan tool Deployment Loop Resistance
parameters stay consistently between 2.1—4.0Q
without any drop outs or spikes while moving the
harness near each connector listed below.
- X85 Steering Wheel Air Bag Coil
- F107 Steering Wheel Air Bag
' Any inline harness connector
- K36 inflatable Restraint Sensing and Diagnostic
Module
:> If the reading is erratic while meving the
harness, perform the following
- Inspect each connector terminal for damage or
corrosion and repair as necessary.
. Apply dielectric grease /lubricant (Nyogel 7606
or equivalent, meeting GM specification
9986087) to each connector terminal.
- Ensure each connector and CPA is correctly
seated.
ii If between 2.1—4.0(2without any spikes or
dropouts
4. All OK.
CircuitlSystem Testing
1. ignition OFF, disconnect the scan tool and
disconnect the appropriate harness connector
listed below at the F107 Steering Wheel Air Bag.
- DTC B0012 connector X1
- DTC B0013 connector X2
2. Test for greater than 25 0 between the control
circuitterminal 1 and the control circuit terminal 2
at the harness connector.
:> If 25 Q or less
2.1. Disconnect the X1 harness connector at the
K36 Inflatable Restraint Sensing and
Diagnostic Module.
Note: Some connectors may be equipped with
shorting bars as a safety component to prevent
accidental deployment. When testing on a connector
with shorting bars, the shorting bars must be disabled
to ensure accurate test results. Insertan appropriate
pick from EL-38125-58O and depress the shorting bars
above the appropriate terminals. This will liftthe
shorting bar from the terminal and allow accurate test
results. Take care not to damage the connector,
shorting bar, or terminal when depressing the
shorting bar.
2.2. Test for infinite resistance between the two
control circuits.
=>Ifless than infinite resistance, repair the short
between the two circuits.
=>Ifinfinite resistance, replace the K36 Inflatable
Restraint Sensing and Diagnostic Module.
ii If greater than 25 Q
9° ignition ON.
4. Test for less than 11V between each control circuit
terminal listed below and ground:
. Control circuit terminal 1
. Control circuit terminal 2
:> If 11 Vor greater
4.1. IgnitionOFF, disconnect the X1 harness
connector at the K36 Inflatable Restraint
Sensing and Diagnostic Module, ignition ON.
4.2. Test for less than 1 V between the control
circuit and ground.
=>If 1 V or greater, repair the short to voltage on
the circuit.
=>Ifless than 1V, replace the K361nf|atable
Restraint Sensing and Diagnostic Module.
If less than 11 V
91:IgnitionOFF.
2.,«
2,2
«-
-,
6. Test for greater than 25 0 between each control
circuit terminal listed below and ground:
- Control circuit terminal 1
- Control circuit terminal 2
=>If 25 Q or less
6.1. Disconnect the X1 harness connector at the
K36 inflatable Restraint Sensing and
Diagnostic Module.
Note: Some connectors may be equipped with
shorting bars as a safety component to prevent
accidental deployment. When testing on a connector
with shorting bars, the shorting bars must be disabled
to ensure accurate test results. Insertan appropriate
pick from EL-38125—580and depress the shorting bars
above the appropriate terminals. This will liftthe
shorting barfrom the terminal and allow accurate test
results. Take care not to damage the connector,
shorting bar, or terminal when depressing the
shorting bar.
6.2. Test for infinite resistance between the control
circuit and ground.
=>Ifless than infinite resistance, repairthe short to
ground on the circuit.
—
2013 (US/Canada)
Sonic (5377994)
Manual
Service

:> lfinfinite resistance, replace the K36 Inflatable
Restraint Sensing and Diagnostic Module.
If greater than 25 Q
. Install a 3 A fusedjumperwire between the control
circuitterminal 1 and the control circuitterminal 2,
ignition ON.
. Verify the appropriate scan tool Deployment Loop
Resistance parameter is consistently less than 2 0
while turning the steering wheel 360 degrees in
one direction then back 360 degrees in the other
direction.
If the reading is erratic while turning the
steering wheel
Replace the X85 Steering Wheel Air Bag Coil.
If 2 Q or greater
8.1. ignition OFF, disconnect the X1 harness
connector at the K36 Inflatable Restraint
Sensing and Diagnostic Module.
8.2. Test for less than 2 Q in the X85 Steering
Wheel Air Bag Coil and each control circuit
end to end.
=>If2 Q or greater, replace the X85 Steering
Wheel Air Bag Coil or repair the open/high
resistance in the circuit.
:> Ifless than 2 Q, replace the K36 Inflatable
Restraint Sensing and Diagnostic Module.
if less than 2 Q
ww/ng-
“W
(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
Supplemental lnflatable Restraints 13=77
9. IgnitionOFF, connect the harness connector at the
F107 Steering Wheel Air Bag, press in the CPA
(if equipped) until an audible andlor tactile click is
heard.
10. IgnitionON, clear DTCs. Operate the vehicle within
the Conditions for Running the DTC.
. Verify DTC 80012 or 80013 is not set.
If DTC 80012 or 80013 is set
Replace the F107 Steering Wheel Air Bag.
U If DTC 80012 or 80013 is not set
12. All OK.
Repair Instructions
Perform the Diagnostic Repair Verification on
page 6-92 after completing the repair.
Steering Wheel Airbag Coil Replacement on
page 13—119
Airbag Steering Wheel Module Replacement on
page 13-118
SlR/SRS Wiring Repairs on page 11-548
Control Module References on page 6-3 for
inflatable Restraint Sensing and Diagnostic
Module replacement, programming and setup
13-78 Supplemental inflatable Restraints

DTC 30014, 30021, 30031, or B0038-

Diagnostic Instructions
. Perform the Diagnostic System Check - Vehicle
on page 6—66prior to using this diagnostic MMfl
..._
A
procedure.
- Review Strategy Based Diagnosis on page 6—58
for an overview of the diagnostic approach.
- Diagnostic Procedure Instructions on page 6-59
provides an overview of each diagnostic category.
DTC Descriptors
DTC 80014 01: Driver Seat Side Air Bag Deployment Loop Short to Battery
DTC 80014 02: Driver Seat Side Air Bag Deployment Loop Short to Ground
DTC 80014 04: Driver Seat Side Air Bag Deployment Loop Open
DTC 80014 0D: Driver Seat Side Air Bag Deployment Loop High Resistance
DTC 80014 0E: Driver Seat Side Air Bag Deployment Loop Low Resistance
DTC 80021 01: Passenger Seat Side Air Bag Deployment Loop Short to Battery
DTC 80021 02: Passenger Seat Side Air Bag Deployment Loop Short to Ground
DTC 80021 04: Passenger Seat Side Air Bag Deployment Loop Open
DTC 80021 0D: Passenger Seat Side Air Bag Deployment Loop High Resistance
DTC 80021 0E: Passenger Seat Side Air Bag Deployment Loop Low Resistance

Diagnostic Fault Information

Short to High Short to Signal

Circuit Ground Resistance Open Voltage Performance

LeftFrontSeatAir Bag HighControl 300111401? 3001400 33311400 3001401 -

LeftFrontSeatAir Bag LowControl 3001140? 3001403 300114315 3001401 -

RightFrontSeatAir Bag HighControl @0021g}? 3002103 338%}(5‘3 3002101 -

RightFrontSeatAir Bag LowControl $021323 30021CD 30321gg 3002101 -

CircuitlSystem Description 80014 04, 80021 04

During a side or frontal crash of sufficient force the
Inflatable Restraint Sensing and Diagnostic Module will
allow current to flow through the deployment loop in
order to deploy an air bag. There are 2 shorting bars
used within the connector that will short together the
control circuits, when the connector is disconnected.
This will help to prevent unwanted deployment of the air
bag or retractor pretensioner during servicing.
Conditions for Running the DTC
Ignitionvoltage is between 9—16V.
Conditions for Setting the DTC
30014 01, 30021 01
The air bag control circuit is shorted to voltage for
2 seconds.
30014 02, B0021 02
The air bag control circuit is shorted to ground for
2 seconds.
The air bag control circuit is open for 2 seconds.
BOO140D, 80021 0D
The air bag deployment loop resistance is greater than
4.2 Q for 2 seconds.
800140E, 80021 0E
The air bag deployment loop resistance is less than
1.4 Q for 2 seconds.
Action Taken When the DTC Sets
- The inflatable Restraint Sensing and Diagnostic
Module requests the instrument cluster to
illuminate the AIR BAG indicator.
. The Inflatable Restraint Sensing and Diagnostic
Module will store a DTC, however if an event
occurs the system will still attempt deployments.

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
 Supplemental Inflatable Restraints 13=79

Conditions for Clearing the DTC CircuitlSystem Verification

° The condition for setting the DTC no longer exists.
- A history DTC will clear once 100 malfunction—free
ignition cycles have occurred. , - Inspect all terminals for damage or corrosion when
Diagnostic Aid
Note: The following diagnostic aids apply for both
current and history DTCs.
An incorrectly installed connector position assurance
(CPA) or incorrectly seated connector can cause a
shorting bar to short both control circuits together.
Check the connectors and CPAs if a DTC with
symptom byte 02 or CE is set, to ensure the shorting
bars are not causing the circuits to be shorted together.
Shorting bars are used in the locations listed below:
- Left and right seat air bags
- lnline harness connector
- Harness side of the Inflatable Restraint Sensing
and Diagnostic Module connector
Terminal frettingor incorrectly seated connector can
cause an open/high resistance condition. Check the
circuit terminals for frettingor incorrectly seated
connector if a DTC with symptom byte 04 or 0D is set.
DTCs of deployment loops which are in the seat can
occur because of stress or damage to the harness due
to seat movement. Move the seat to the full extent of
travel while using the scan tool to observe deployment
type loop parameters.
Reference Information
Schematic Reference
SIR Schematics on page 13-69
Connector End View Reference
Component Connector End Views on page 11-269
Description and Operation
Supplemental Inflatable Restraint System Description
and Operation on page 13-145
Electrical Information Reference
- Circuit Testing on page 11-526
0 Testing for IntermittentConditions and Poor
Connections on page 11-531
' Wiring Repairs on page 11-537
- Connector Repairs on page 11-548
Scan Tool Reference
Control Module References on page 6-3 for scan tool
information
Special Tools
EL-38125—580Terminal Release Tool Kit
Note: Refer to SIR Service Precautions on
page 153—113.
disconnecting connectors. Damage or corrosion in
the following requires repair or replacement of the
affected component/connector:
—Seat air bag
—Inflatable Restraint Sensing and Diagnostic
Module
—AIIwiring harness connectors
—Inflatable Restraint Sensing and Diagnostic
Module wiring harness connector
- The connector and connector position assurance
(CPA) may seat independent of each other. Both
the connector and CPA should seat with an
audible andlor tactile click. The CPA isolates the
shorting—barswithin the connector allowing the
deployment circuit to operate properly.
- Ifthe condition is intermittentor cannot be
duplicated, disconnect the connectors and add
dielectric grease/lubrioant (Nyogel 760G or
equivalent, meeting GM specification 9986087).
This procedure will correct the high resistance
condition due to terminal fretting corrosion.
1. Verify the appropriate scan tool Deployment Loop
Resistance parameters stay consistently between
2.1 and 4.0 Q without any spikes or dropouts while
moving the harness near each connector.
~ F106 Seat Air Bag
- Any inline harness connector
' K36 Inflatable Restraint Sensing and Diagnostic
Module
=>If less than 2.1 or greater than 4.0 Q
Refer to CircuitlSystem Testing.
=>Ifthere are spikes or dropouts, perform the
following:
- inspect each connectorterminal and harness
for damage or corrosion and repair as
necessary.
- Apply dielectric grease/Iubricant (Nyogel 7606
or equivalent, meeting GM
specification 9986087) to each connector
terminal.
- Ensure each connector and CPA is correctly
seated.
it Ifwithin 2.1 and 4.0 Q without any spikes or
dropouts
2. All OK.

—
2013 (US/Canada)
Sonic (5377994)
Manual
Service
13=80 Supplemental inflatable Restraints
CircuitlSystem Testing
1. IgnitionOFF, disconnect the scan tool and then
disconnect the appropriate F106 Seat Air Bag
harness connector. it may take up to 2 minutes for
all vehicle systems to power down.
2. Test for greater than 25 Q between the control
circuit terminals1 and 2.
=>If 25 Q or less
2.1. Disconnect the X2 harness connector at the
K36 Inflatable Restraint Sensing and
Diagnostic Module.
Note: Some connectors may be equipped with
shorting bars as a safety component to prevent
accidental inflator deployment. When testing on a
connector with shorting bars, the shorting bars must be
disabled to ensure accurate test results. Insertan
appropriate pick from EL—38125—580 and depress the
shorting bars above the appropriate terminals. This will
liftthe shorting bar from the terminal and allow accurate
test results. Take care not to damage the connector,
shorting bar, or terminal when depressing the
shorting bar.
2.2. Test for infinite resistance between the two
control circuits.
:> Ifless than infinite resistance, repair the short
between the two Circuits.
=>Ifinfinite resistance, replace the K36 Inflatable
Restraint Sensing and Diagnostic Module.
U If greater than 25 Q
9° ignition ON.
4. Test for less than 11V between the control circuit
terminals listed below and ground:
- Control Circuitterminal 1
~ Control circuit terminal 2
=>if 11Vor greater
4.1. ignition OFF, disconnect the X2 harness
connector at the K36 inflatable Restraint
Sensing and Diagnostic Module, ignition ON.
4.2. Test for less than 1 V between the control
circuit and ground.
=>If 1 V or greater, repair the short to voltage on
the circuit.
=>Ifless than 1 V, replace the K36 Inflatable
Restraint Sensing and Diagnostic Module.
U If less than 11V
5. IgnitionOFF.
6. Test for greater than 25 Q between the control
circuit terminals listed below and ground:
- Control circuit terminal 1
. Control circuit terminal 2
=>If 25 Q or less
6.1. Disconnect the X2 harness connector at the
K36 Inflatable Restraint Sensing and
Diagnostic Module.
6.2. Test for infinite resistance between the control
circuit and ground.
=>Ifless than infinite resistance, repair the short to
ground on the circuit.
=>Ifinfinite resistance, replace the K36 Inflatable
Restraint Sensing and Diagnostic Module.
If greater than 25 Q
71<=
Ignition OFF, install a 3 A fused jumperwire
between the control circuit terminals 1 and 2.
Ignition ON.
8. Verify the scan tool Deployment Loop Resistance
parameter is less than 2 Q.
=>If 2 Q or greater
8.1. IgnitionOFF, disconnect the X2 harness
connector at the K36 Inflatable Restraint
Sensing and Diagnostic Module.
8.2. Test for less than 2 Q in each control circuit
end to end.
=>If2 Q or greater, repair the open/high resistance
in the circuit.
=>Ifless than 2 Q, replace the K36 Inflatable
Restraint Sensing and Diagnostic Module.
U If less than 2 Q
9. Ignition OFF, connect the harness connector at the
F106 Seat Air Bag, press in the CPA (ifequipped)
until an audible andlor tactile click is heard.
10. Ignition ON, clear DTCs. Operate the vehicle within
the Conditions for Running the DTC.
11. Verify DTC 80014, 80021, 80031, or 80038 is
not set.
=>If DTC 80014, 80021, 80031, or 80038 is set
Replace the appropriate F106 Seat Air Bag.
U If DTC 80014, 80021, 80031, or 80038 is not set
12. All OK.
Repair Instructions
Perform the Diagnostic Repair Verification on
page 6-92 after completing the repair.
- Front Seat Outboard Seat Back Airbag
Replacement on page 13-125
- Control Module References on page 6—3for
Inflatable Restraint Sensing and Diagnostic
Module replacement, programming and setup
2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Supplemental inflatable Restraints 13-81

DTC 80015, 8001A, 80018, or 80022

Diagnostic Instructions
- Perform the Diagnostic System Check —Vehicle
on page 6—66prior to using this diagnostic
procedure.
- Review Strategy Based Diagnosis on page 6-58
for an overview of the diagnostic approach.
1 Diagnostic Procedure Instructions on page 6—59
provides an overview of each diagnostic category.
DTC Descriptors
Short to Battery
DTC 80015 01: Driver Seat Belt Retractor Pretensioner Deployment Loop
Short to Ground
DTC 80015 02: Driver Seat Belt Retractor Pretensioner Deployment Loop
DTC 80015 04: Driver Seat Belt Retractor Pretensioner Deployment Loop Open
High Resistance
DTC 80015 0D: Driver Seat Belt Retractor Pretensioner Deployment Loop
Low Resistance
DTC 80015 0E: Driver Seat Belt Retractor Pretensioner Deployment Loop
Deployment Loop Short to Battery
DTC 8001A 01: Driver Seat Belt Anchor Pretensioner
to Ground
DTC 8001A 02: Driver Seat Belt Anchor Pretensioner Deployment Loop Short
DTC 8001A 04: Driver Seat Belt Anchor Pretensioner Deployment Loop Open
High Resistance
DTC 8001A OD: Driver Seat Belt Anchor Pretensioner Deployment Loop
Resistance
DTC 8001A 0E: Driver Seat Belt Anchor Pretensioner Deployment Loop Low
Short to Battery
DTC 80018 01: Passenger Seat Belt Anchor Pretensioner Deployment Loop
Deployment Loop Short to Ground
DTC 80018 02: Passenger Seat Belt Anchor Pretensioner
Open
DTC 80018 04: Passenger Seat Belt Anchor Pretensioner Deployment Loop
Loop High Resistance
DTC 80018 OD: Passenger Seat Belt Anchor Pretensioner Deployment
Deployment Loop Low Resistance
DTC 80018 0E: Passenger Seat Belt Anchor Pretensioner
Loop Short to Battery
DTC 80022 01: Passenger Seat Belt Retractor Pretensioner Deployment
Short to Ground
DTC 80022 02: Passenger Seat Belt Retractor Pretensioner Deployment Loop
Pretensioner Deployment Loop Open Circuit
DTC 80022 04: Passenger Seat Belt Retractor
Loop High Resistance
DTC 80022 OD: Passenger Seat Belt Retractor Pretensioner Deployment
Loop Low Resistance
DTC 80022 0E: Passenger Seat Belt Retractor Pretensioner Deployment
Diagnostic Fault Information

Short to High Short to Signal

Ground Resistance Open Voltage Performance
Circuit
8001502, 8001504,
DriverSeat BeltRetractorPretensioner 30015OD 30°1501 *
HighControl 3001503 80015CD
DriverSeat BeltRetractorPretensioner 8001502, 8001504,
800150E 3001500 3001503 3001501 '-
LowControl
DriverSeat BeltAnchorPretensionerLow 8001A02,
8001AOE 8001AOD 8001A04 8001A01 —-
Control
DriverSeat BeltAnchorPretensionerHigh 8001A02,
8001AOE BOO1AOD 8001A04 8001A01 —-
Control
PassengerSeat BeltAnchorPretensioner 8001802,
800180E 800180D 8001804 8001801 —-
LowControl
PassengerSeat BeltAnchorPretensioner 80018 02,
800180E BOO180D 8001804 8001801 —-
HighControl
PassengerSeatBelt Retractor 8002202, 8002204,
300220E 30022CD 3002203 30°2201 "
PretensionerHighControl
PassengerSeatBelt Retractor 8002202, 8002204,
30022OE 30022OD 3002203 80°2201 _
PretensionerLowControl

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
13-82 Supplemental inflatable Restraints

CircuitlSystem Description Terminal fretting or incorrectly seated connectors can

cause an open/high resistance condition. Check the
During a side or frontal crash of sufficient force the circuit terminals for fretting or incorrectly seated
Inflatable Restraint Sensing and Diagnostic Module will connector if a DTC with symptom byte 04 or 0D is set.
allow current to flow through the deployment loop in DTCs of deployment loops which are in the seat can
order to deploy an air bag or pretensioner. There are 2 occur because of stress or damage to the harness due
shorting bars which will short together control circuits, to seat movement. Move the seat to the full extent of
when the connector is disconnected. This will help to travel while using the scan tool to observe deployment
prevent unwanted deployment ofthe air bag or type loop parameters.
pretensioner during servicing.
Reference Information
Conditions for Running the DTC
Ignitionvoltage is between 9—16V. Schematic Reference
SIR Schematics on page 13-69
Conditions for Setting the DTC
Connector End View Reference
80015 01, 8001A 01, 80018 01, 80022 01
The pretensioner control circuit is shorted to voltage for Component Connector End Views on page 11-269
2 seconds. Description and Operation
80015 02, 8001A 02, 80018 02, 80022 02 Supplemental Inflatable Restraint System Description
The pretensioner control circuit is shorted to ground for and Operation on page 13—145
2 seconds. Electrical Information Reference
80015 04, 8001A 04, 80018 04, 80022 04 - Circuit Testing on page 11-526
The pretensioner control circuit is open for 2 seconds. - Testing for IntermittentConditions and Poor
B0015 0D, B001A 0D, BOO1B CD, B0022 0D Connections on page 11—531
The pretensioner deployment loop resistance is greater - Wiring Repairs on page 11-537
than 4.2 Q for 2 seconds. - Connector Repairs on page 11—548
80015 0E, BOO1AOE, 3001B 0E, B0022 0E Scan Tool Reference
The pretensioner deployment ioop resistance is less Control Module References on page 6—3for scan tool
than 1.4 Q for 2 seconds. information
Action Taken When the DTC Sets Special Tools
- The inflatable Restraint Sensing and Diagnostic EL-38125-580 Terminal Release Tool Kit
Module requests the instrument cluster to
illuminate the AIR BAG indicator. CircuitlSystem Verification
- The Inflatable Restraint Sensing and Diagnostic Note: Refer to SIR Service Precautions on
Module will store a DTC, however if an event page 153—113.
occurs the system will still attempt deployments.
Inspect all terminals for damage or corrosion when
Conditions for Clearing the DTC disconnecting connectors. Damage or corrosion in the
following requires repair or replacement of the affected
- The condition for setting the DTC no longer exists. component/connector.
- A history DTC will clear once 100 malfunction—free ' Seat Belt Anchor Pretensioner
ignition cycles have occurred.
0 Seat Belt Retractor Pretensioner
Diagnostic Aid - inflatable Restraint Sensing and Diagnostic
Note: The following diagnostic aids apply for both Module
current and history DTCs. 0 Seat Belt Anchor Pretensioner wiring harness
connector
An incorrectly installed connector position assurance
(CPA) or incorrectly seated connector can cause a - Seat Belt Retractor Pretensioner wiring harness
shorting bar to short both control circuits together. connector
Check the connectors and CPAs if a DTC with - Inflatable Restraint Sensing and Diagnostic
symptom byte 02 or CE is set, to ensure the shorting Module wiring harness connector
bars are not causing the circuits to be shorted together.
Shorting bars are used in the locations listed below:
- Driver and passenger anchor or retractor
pretensioners
- lnline harness connectors
- Harness side of the Inflatable Restraint Sensing
and Diagnostic Module connector

(US/Canada)
-Sonic
2013 (5377994)
Manual
Servlce

Note: The connector and connector position
assurance (CPA) may seat independent of each other.
Both the connector and CPA should seat with an
audible andlor tactile click. The CPA isolates the
shorting—barswithin the connector allowing the
deployment circuit to operate properly.
if the condition is intermittentor cannot be duplicated,
disconnect the connectors and add dielectric grease/
lubricant (Nyogel 760G or equivalent, meeting GM
specification 9986087). This procedure will correct the
high resistance condition due to terminal fretting
corrosion.
1. Verify the appropriate scan tool Deployment Loop
Resistance parameters stay consistently between
2.1 and 4.0 Q without any spikes or dropouts while
moving the harness near each connector listed
below:
- F112 Seat Belt Retractor Pretensioner
- F113 Seat Belt Anchor Pretensioner
- Any inline harness connector
- K36 Inflatable Restraint Sensing and Diagnostic
Module
=>If less than 2.1 or greater than 4.0 Q
Refer to CircuitlSystem Testing.
=>If there are spikes or dropouts, perform the
following
. Inspect each connector terminal and harness
for damage or corrosion and repair as
necessary
1 Apply dielectric grease / lubricant (Nyogel 760G
or equivalent, meeting GM specification
9986087) to each connector terminal
1 insure each connector and CPA is correctly
seated.
U If within 2.1 and 4.0 Q without any spikes or
dropouts
2. All OK
CircuitlSystem Testing
1. Ignition OFF. Scan tool disconnected. it may take
up to 2 minutes for all vehicle systems to power
down. Disconnect the appropriate harness
connector listed below:
- F112 Seat Belt Retractor Pretensioner
- F113 Seat Belt Anchor Pretensioner
2. Test for greater than 25 Q between the control
circuit terminals 1 and 2.
=>If 25 Q or less
2.1. Disconnect the X2 harness connector at the
K36 inflatable Restraint Sensing and
Diagnostic Module.
(US/Canada)
-Sonic
2013 (5377994)
Manual
Sen/ice
Supplemental inflatable Restraints 13-83
Note: Some connectors may be equipped with
shorting bars as a safety component to prevent
accidental inflator deployment. When testing on a
connector with shorting bars, the shorting bars must be
disabled to ensure accurate test results. Insert an
appropriate pick from EL-38125—58Oand depress the
shorting bars above the appropriate terminals. This will
liftthe shorting barfrom the terminal and allow accurate
test results. Take care not to damage the connector,
‘ shorting bar, or terminal when depressing the
shorting bar.
2.2. Test for infinite resistance between the two
control circuits.
:> Ifless than infinite resistance, repair the short
between the two circuits.
:> If infinite resistance, replace the K36 Inflatable
Restraint Sensing and Diagnostic Module.
U If greater than 25 Q
9’ Ignition ON.
4. Test for less than 11V between the control circuit
terminals listed below and ground:
- Control circuit terminal 1
- Control circuit terminal 2
=>If 11 V or greater
4.1. Ignition OFF. Disconnect the X2 harness
connector at the K36 Inflatable Restraint
Sensing and Diagnostic Module. Ignition ON.
4.2. Test for less than 1 V between the control
circuit and ground.
=>lf1 V or greater, repair the short to voltage on
the circuit.
=>If less than 1 V, replace the K36 Inflatable
Restraint Sensing and Diagnostic Module.
U If less than 11 V
S“ Ignition OFF.
6. Test for greater than 25 Q between the control
circuit terminals listed below and ground:
~ Control circuit terminal 1
' Control circuit terminal 2
=>If 25 Q or less
6.1. Disconnect the X2 harness connector at the
K36 Inflatable Restraint Sensing and
Diagnostic Module.
6.2. Test for infinite resistance between the control
circuit and ground.
=>Ifless than infinite resistance, repair the short to
ground on the circuit.
:> If infinite resistance, replace the K36 inflatable
Restraint Sensing and Diagnostic Module.
U If greater than 25 Q
7. Ignition OFF. Install a 3 A fused jumper wire
between the appropriate control circuit terminals 1
and 2. Ignition ON.
1384 Supplemental inflatable Restraints
8. Verify the scan tool Deployment Loop Resistance
parameter is less than 2 Q.
:> If 2 Q or greater
8.1. ignition OFF.’
8.2. Disconnect the X2 harness connector at the
K36 Inflatable Restraint Sensing and
Diagnostic Module.
8.3. Test for less than 2 Q in each control circuit
end to end.
=>If2 Q or greater, repair the open/high
resistance in the circuit.
=>Ifless than 2 Q, replace the K36 Inflatable
Restraint Sensing and Diagnostic Module.
If less than 2 Q
Ignition OFF, connect the harness connector at the
F112 Seat Belt Retractor Pretensioner or F113
Seat Belt Anchor Pretensioner, press in the CPA
(if equipped) until an audible and/or tactile click is
heard.
10. Ignition ON, clear DTCs. Operate the vehicle within
the Conditions for Running the DTC.
11. Verify DTC 80015, 8001A, 80018, or 80022 is
not set.
:> If DTC B0015, B001A, 8001B, or 30022 is set
Replace the appropriate F112 Seat Belt
Retractor Pretensioner or F113 Seat Belt
Anchor Pretensioner.
U If DTC 80015, 8001A, 80018, or 80022 is
not set
12. All OK.
Repair Instructions
Perform the Diagnostic Repair Verification on
page 6-92 after completing the repair.
- Front SeatBeltAnchor Plate Tensioner
Replacement on page 113-130
' Driver or Passenger Seat Shoulder Belt
Replacement (withoutA69) on page 13—131or
Driver or Passenger Seat Shoulder Belt
Replacement (withA69) on page 13—133
- SIR/SRS Wiring Repairs on page 11—548
- Control Module References on page 6-3 for
Inflatable Restraint Sensing and Diagnostic
Module replacement, programming and setup
(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
 Supplemental inflatable Restraints 113-85

DTC 80016, 80018, 80023, or 80025

Diagnostic Instructions
- Perform the Diagnostic System Check —Vehicle
on page 6-66 prior to using this diagnostic
procedure.
- Review Strategy Based Diagnosis on page 6-58
for an overview of the diagnostic approach.
- Diagnostic Procedure Instructions on page 6-59
provides an overview of each diagnostic category.
DTC Descriptors
DTC 80016 01: Left Roof Rail Air Bag Deployment Loop Short to Battery
DTC 80016 02: Left Roof Rail Air Bag Deployment Loop Short to Ground
DTC 80016 04: Left Roof Rail Air Bag Deployment Loop Open
DTC 80016 0D: Left Roof Rail Air Bag Deployment Loop High Resistance
DTC 80016 0E: Left Roof Rail Air Bag Deployment Loop Low Resistance
Battery
DTC 80023 01: Right Roof Rail Air Bag Deployment Loop Short to
DTC 80023 02: Right Roof Rail Air Bag Deployment Loop Short to Ground
DTC 80023 04: Right Roof Rail Air Bag Deployment Loop Open
Resistance
DTC 80023 OD: Right Roof Rail Air Bag Deployment Loop High
Resistance
DTC 80023 0E: Right Roof Rail Air Bag Deployment Loop Low
Diagnostic Fault Information

Short to High Short to Signal

Ground Resistance Open Voltage Performance
Circuit
Eggflggé 3001600 330116630 8001601 -
LeftRoof RailAir Bag HighControl

133%?)1120238001603 3213112013 8001601 -

LeftRoof Rail Air Bag LowControl

[309%(6%, 3002300 330%:3‘3 3002301 -

RightRoof RailAir Bag HighControl

(5%
3%?)2291’3 30023OD 30323013 3002301 -
RightRoof RailAir Bag LowControl

80016 04, 80023 04

CircuitlSystem Description
crash of sufficient force the The air bag control circuit is open for 2 seconds.
During a side or frontal
Inflatable Restraint Sensing and Diagnostic Module will 80016 0D, 80023 OD
allow current to flow through the deployment loop in The air bag deployment loop resistance is greater than
order to deploy an air bag or pretensioner. There are 4.2 Q for 2 seconds.
2 shorting bars which will short together control circuits,
when the connector is disconnected. This will help to 80016 DE, 80023 0E
prevent unwanted deployment of the air bag or The air bag deployment loop resistance is less than
pretensioner during servicing. 1.4 Q for 2 seconds.
Conditions for Running the DTC Taken When the DTC Sets
Action
Ignitionvoltage is between 9—16 V. . The inflatable Restraint Sensing and Diagnostic
for Setting the DTC Module requests the instrument cluster to
Conditions illuminate the AIR BAG indicator.
B0016 01, B0023 01 - The inflatable Restraint Sensing and Diagnostic
The air bag control circuit is shorted to voltage for Module will store a DTC, however if an event
2 seconds. occurs the system will still attempt deployments.
B0016 02, B0023 02 Conditions for Clearing the DTC
The air bag control circuit is shorted to ground for - The condition for setting the DTC no longer exists.
2 seconds. - A history DTC will clear once 100 maifunction-free
ignition cycles have occurred.

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
113-86 Supplemental inflatable Restraints
Diagnostic Aid
Note: The following diagnostic aids apply for both
current and history DTCs.
An incorrectly installed connector position assurance
(CPA) or incorrectly seated connector can cause a
shorting bar to short both control circuits together.
Check the connectors and CPAs if a DTC with
symptom byte 02 or CE is set, to ensure the shorting
bars are not causing the circuits to be shorted together.
Shorting bars are used in the locations listed below:
- Left and right Roof Rail Air Bags
- lnline harness connectors
- Harness side of the Inflatable Restraint Sensing
and Diagnostic Module connector
Terminal fretting or incorrectly seated connectors can
cause an open/high resistance condition. Check the
circuit terminals for frettingor incorrectly seated
connector if a DTC with symptom byte 04 or 0D is set.
DTCs of deployment loops which are in the seat DTC
can occur because of stress or damage to the harness
due to seat movement. Move the seat to the full extent
of travel while using the scan tool to observe
deployment type loop parameters.
Reference Information
Schematic Reference
SIR Schematics on page 13—69
Connector End View Reference
Component Connector End Views on page 11-269
Description and Operation
Supplemental Inflatable Restraint System Description
and Operation on page 13—145
Electrical Information Reference
- Circuit Testing on page 11-526
- Testing for IntermittentConditions and Poor
Connections on page 11-531
- Wiring Repairs on page 11—537
- Connector Repairs on page 11—548
Scan Tool Reference
Control Module References on page 6-3 for scan tool
information
Special Tools
EL-38125-580 Terminal Release Tool Kit
CircuitlSystem Verification
Note:
~ Refer to SIR Service Precautions on page 13-113.
- Inspect all terminals for damage or corrosion when
disconnecting connectors. Damage or corrosion in
the following requires repair or replacement of the
affected component/connector.
—Roof Rail Air Bag
—Inflatable Restraint Sensing and Diagnostic
Module
—Roof Rail Air Bag wiring harness connector
—Inflatable Restraint Sensing and Diagnostic
Module wiring harness connector
' 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.
' Ifthe condition is intermittentor cannot be
duplicated, disconnect the connectors and add
dielectric grease /lubricant (Nyogel 760G or
equivalent, meeting GM specification 9986087).
This procedure will correct the high resistance
condition due to terminal fretting corrosion.
1. Verify the appropriate scan tool Deployment Loop
Resistance parameters stay consistently between
2.1 and 4.0 Q without any spikes or dropouts while
moving the harness near each connector listed
below:
- F105L Roof Rail Air Bag —Left
- F105R Roof Rail Air Bag —Right
- Any inline harness connector
0 K36 inflatable Restraint Sensing and Diagnostic
Module
:3 If less than 2.1 or greater than 4.0 Q
Refer to CircuitlSystem Testing.
:> If there are spikes or dropouts, perform the
following:
- Inspect each connectorterminal and harness
for damage or corrosion and repair as
necessary
- Insure each connector and CPA is correctly
seated.
U If within 2.1 and 4.0 Q without any spikes or
dropouts
2. All OK
.M»—
«WW
_
m
A
M
__
Wsw
,\_
2..
M-“
w-_
.fi
(US/Canada)
-Sonic
2013 (5377994)
Manual
Service

' Supplemental
6. Test for greater than 25 Q between the control
CircuitlSystem Testing
1. Ignition OFF. Scan tool disconnected. Itmay take
up to 2 minutes for all vehicle systems to power
down. Disconnect the appropriate harness
connector at the Roof Rail Air Bag listed below:
- DTC 80016 —F105L Roof Rail Air Bag ~— Left
Rail Air Bag —Right
- DTC 80023 —F105R Roof
2. Test for greater than 25 Q between the control
circuit terminals 1 and 2.
:> If 25 Q or less
2.1. Disconnect the X2 harness connector at the
K36 Inflatable Restraint Sensing and
Diagnostic Module.
Note: Some connectors may be equipped with
shorting bars as a safety component to prevent
accidental inflator deployment. When testing on a
connector with shorting bars, the shorting bars must be
disabled to ensure accurate test results. Insert an
appropriate pick from EL-38125—580and depress the
shorting bars above the appropriate terminals. This will
lift the shorting bar from the terminal and allow accurate
test results. Take care not to damage the connector,
shorting bar, or terminal when depressing the
shorting bar.
2.2. Test for infinite resistance between the two
control circuits.
=>If less than infinite resistance, repair the short
between the two circuits.
=>lf infinite resistance, replace the K36 Inflatable
Restraint Sensing and Diagnostic Module.
U If greater than 25 Q
9’ Ignition ON.
4. Test for less than 11V between the control circuit
terminals listed below and ground:
- Control circuitterminal 1
- Control circuit terminal 2
=>If 11 Vor greater
4.1. IgnitionOFF. Disconnect the X2 harness
connector at the K36 Inflatable Restraint
Sensing and Diagnostic Module. Ignition ON.
4.2. Test for less than 1 V between the control
circuit and ground.
=>lf1 V or greater, repair the short to voltage on
the circuit.
:> Ifless than 1 V, replace the K36 Inflatable
Restraint Sensing and Diagnostic Module.
U If less than 11 V
5. Ignition OFF.
(US/Canada)
-Sonic
2013 (5377994)
Manual
Sen/ice
inflatable Restraints 13-87
circuit terminals listed below and ground:
- Control circuit terminal 1
1 Control circuit terminal 2
:> If 25 Q or less
6.1. Disconnect the X2 harness connector at the
K36 Inflatable Restraint Sensing and
Diagnostic Module.
6.2. Test for infinite resistance between the control
circuit and ground.
=>If less than infinite resistance, repair the short to
ground on the circuit.
=>If infinite resistance, replace the K36 Inflatable
Restraint Sensing and Diagnostic Module.
U If greater than 25 Q
7. Ignition OFF. Install a 3 A fused jumper wire
between the appropriate control circuit terminals 1
and 2. Ignition ON.
8. Verify the scan tool Deployment Loop Resistance
parameter is less than 2 Q.
:> If 2 Q or greater
8.1. Ignition OFF. Disconnect the X2 harness
connector at the K36 Inflatable Restraint
Sensing and Diagnostic Module.
8.2. Test for less than 2 Q in each control circuit
end to end.
=>lf2 Q orgreater, repair the open/high
resistance in the circuit.
=>Ifless than 2 Q, replace the K36 Inflatable
Restraint Sensing and Diagnostic Module.
U If less than 2 Q
the
9. Ignition OFF, connect the harness connector at
F105L Roof Rail Air Bag, press in the CPA
(if equipped) until an audible andlor tactile click is
heard.
within
10. Ignition ON, clear DTCs. Operate the vehicle
the Conditions for Running the DTC.
11. Verify DTC 80016 or 80023 is not set.
=>If DTC 80016 or 80023 is set
Replace the appropriate F105L Roof Rail
Air Bag.
U lf DTC 80016 or 80023 is not set
12. All OK.
Repair Instructions
Perform the Diagnostic Repair Verification on
page 6-92 after completing the repair.
- Airbag Roof Side Rail Module Replacement —Rear
on page 13-129
- SIR/SRS Wiring Repairs on page 11—548
- Control Module References on page 6—3for
Inflatable Restraint Sensing and Diagnostic
Module replacement, programming and setup
13=88 Supplemental inflatable Restraints
W
2....
DTC B0017 or 80024

Diagnostic Instructions
- Perform the Diagnostic System Check - Vehicle
on page 6—66prior to using this diagnostic
procedure.
- Review Strategy Based Diagnosis on page 6—58 \,M,
s.22.
for an overview of the diagnostic approach.
. Diagnostic Procedure Instructions on page 6-59
provides an overview of each diagnostic category.
DTC Descriptors
DTC 80017 01: Driver Knee Air Bag Deployment Loop Short to Battery
DTC 80017 02: Driver Knee Air Bag Deployment Loop Short to Ground
DTC 80017 04: Driver Knee Air Bag Deployment Loop Open
DTC 80017 0D: Driver Knee Air Bag Deployment Loop High Resistance
DTC 80017 0E: Driver Knee Air Bag Deployment Loop Low Resistance
DTC 80024 01: Passenger Knee Air Bag Deployment Loop Short to Battery
DTC 80024 02: Passenger Knee Air Bag Deployment Loop Short to Battery
DTC 80024 04: Passenger Knee Air Bag Deployment Loop Open
DTC 80024 0D: Passenger Knee Air Bag Deployment Loop High Resistance
DTC 80024 0E: Passenger Knee Air Bag Deployment Loop Low Resistance

Diagnostic Fault Information

Short to High Short to Signal

Circuit Ground Resistance Open Voltage Performance

DriverKneeAir Bag HighControl 3001110? 300170D 300111313 3001701 -

DriverKneeAir Bag LowControl 200111315 3001703 33011180 3001701 -

PassengerKneeAir Bag HighControl gggg: g? 800240D ggggfigas 8002401 -

PassengerKneeAir Bag LowControl (3%

3%?)ng 800240D E63313% 8002401 -

CircuitlSystem Description 80017 04, 80024 04

During a side or frontal crash of sufficient force the The air bag control circuit is open for 2 seconds.
Inflatable Restraint Sensing and Diagnostic Module 80017 0D, 80024 0D
(SDM) will allow current to flow through the deployment
loop in order to deploy an air bag. There are two The air bag deployment loop resistance is greater than
shorting bars used within the connector that will short 4.2 Q for 2 seconds.
together the control circuits, when the connector is 80017 DE, 80024 0E
disconnected. This will help to prevent unwanted
deployment of the air bag or retractor pretensioner The air bag deployment loop resistance is less than
during servicing. 1.4 Q for 2 seconds.

Conditions for Running the DTC Action Taken When the DTC Sets
Ignitionvoltage is between 9—16V. - The Inflatable Restraint Sensing and Diagnostic
Module requests the instrument cluster to
Conditions for Setting the DTC illuminate the AIR BAG indicator.
- The Inflatable Restraint Sensing and Diagnostic
B0017 01, B0024 01 Module will store a DTC, however if an event
The air bag control circuit is shorted to voltage for occurs the system will still attempt deployments.
2 seconds.
Conditions for Clearing the DTC
B0017 02, B0024 02
' The condition for setting the DTC no longer exists.
The air bag control circuit is shorted to ground for
- A history DTC will clear once 100 malfunction-free
2 seconds. ignition cycles have occurred.

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service

Diagnostic Aid
Note: The following diagnostic aids apply for both
current and history DTCs.
An incorrectly installed connector position assurance
(CPA) or incorrectly seated connector can cause a
shorting bar to short both control circuits together.
Check the connectors and CPAs if a DTC with
symptom byte 02 or CE is set, to ensure the shorting
bars are not causing the circuits to be shorted together.
Shorting bars are used in the locations listed below:
1 Driver and passenger knee air bags
1 lnline harness connectors
1 Harness side of the inflatable restraint sensing
and diagnostic module connector
Terminal frettingor incorrectly seated connector can
cause an open/high resistance condition. Check the
circuit terminals for fretting or incorrectly seated
connector if a DTC with symptom byte 04 or 0D is set.
Reference Information
Schematic Reference
SIR Schematics on page 13—69
Connector End View Reference
Component Connector End Views on page 11—269
Description and Operation
Supplemental Inflatable Restraint System Description
and Operation on page 153-145
Electrical Information Reference
- Circuit Testing on page 11-526
1 Testing for IntermittentConditions and Poor
Connections on page 11-531
1 Wiring Repairs on page 11-537
1 Connector Repairs on page 11-548
Scan Tool Reference
Control Module References on page 6—3for scan tool
information
Special Tools
EL—38125-580Terminal Release Tool Kit
CircuitlSystem Verification
Note:
1 Refer to SIR Service Precautions on page 13-113.
1 Inspect all terminals for damage or corrosion when
disconnecting connectors. Damage or corrosion in
[M
.... the following requires repair or replacement of the
affected component/connector.
—Knee air bag
—inflatable restraint sensing and diagnostic
module
—All wiring harness connectors
—Inflatable restraint sensing and diagnostic
module wiring harness connector
1 The connector and connector position assurance
(CPA) may seat independent of each other. Both
the connector and CPA should seat with an
—
2013 (US/Canada)
Sonic (5377994)
Manual
Service
Supplemental inflatable Restraints 113-89
audible andlor tactile click. The CPA isolates the
shorting-bars within the connector allowing the
deployment circuit to operate properly.
1 Ifthe condition is intermittentor cannot be
duplicated, disconnect the connectors and add
dielectric grease/lubricant (Nyogel 760G or
equivalent, meeting GM specification 9986087).
This procedure will correct the high resistance
condition due to terminal fretting corrosion.
1. Verify the scan tool Deployment Loop Resistance
parameters stay consistently between 2.1 and
4.0 Q without any spikes or dropouts while moving
the harness near each connector listed below:
1 F114D Knee Air Bag —Driver
1 F114P Knee Air Bag —Passenger
1 Any inline harness connector
1 K36 inflatable Restraint Sensing and Diagnostic
Module
=>if less than 2.1 or greater than 4.0 Q
Refer to CircuitlSystem Testing.
:> If there are spikes or dropouts, perform the
following:
1 Inspect each connector terminal and harness
for damage or corrosion and repair as
necessary.
1 Apply dielectric grease/lubricant (Nyogel 760G
or equivalent, meeting GM specification
9986087) to each connector terminal
1 Ensure each connector and CPA is correctly
seated
U If between 2.1 and 4.0 Q without any spikes or
dropouts
2. All OK
CircuitlSystem Testing
1. ignition OFF, disconnect the scan tool and
disconnect the harness connector at the
appropriate F114 Knee Air Bag.
2. Test for greater than 25 Q between the control
circuit terminals1 and 2.
:> If 25 Q or less
2.1. Disconnect the X1 harness connector at the
K36 Inflatable Restraint Sensing and
Diagnostic Module.
Note: Some connectors may be equipped with
shorting bars as a safety component to prevent
accidental inflator deployment. When testing on a
connector with shorting bars, the shorting bars must be
disabled to ensure accurate test results. Insert an
appropriate pick from EL—38125-580and depress the
shorting bars above the appropriate terminals. This will
lift the shorting bar from the terminal and allow accurate
test results. Take care not to damage the connector,
shorting bar, or terminal when depressing the
shorting bar.
2.2. Test for infinite resistance between the
2 control circuits.
=>Ifless than infinite resistance, repair the short
between the 2 circuits.
13-90 Supplemental Inflatable Restraints
:> Ifinfinite resistance, replace the K36 inflatable 7. install a 3 A fused jumper wire between the control
Restraint Sensing and Diagnostic Module. circuit terminals 1 and 2, ignition ON.
If greater than 25 Q 8. Verify the scan tool Deployment Loop Resistance
9° ignition ON. parameter is less than 2 Q.
Test for less than 11V between the control circuit If 2 Q or greater
terminals listed below and ground: 8.1. IgnitionOFF, disconnect the X1 harness
1 Control circuit terminal 1 connector at the K36 Inflatable Restraint
Sensing and Diagnostic Module.
1 Control circuit terminal 2
8.2. Test for less than 2 Q in each control circuit
if 11 V or greater end to end.
4.1. IgnitionOFF, disconnect the X1 harness :> if 2 Q or greater, repair the open/high resistance
connector at the K36 Inflatable Restraint in the circuit.
Sensing and Diagnostic Module, ignition ON.
=>Ifless than 2 Q, replace the K36 Inflatable
4.2. Test for less than 1 V between the control
Restraint Sensing and Diagnostic Module.
circuit and ground.
If less than 2 Q
=>If 1 V or greater, repair the short to voltage on
the circuit. ignition OFF, connect the harness connector at the
F114 Knee Air Bag, press in the CPA (ifequipped)
:> lfless than 1 V, replace the K36 Inflatable until an audible andlor tactile click is heard.
Restraint Sensing and Diagnostic Module.
10. ignition ON, clear DTCs. Operate the vehicle within
If less than 11 V the Conditions for Running the DTC.
.0" IgnitionOFF. 11. Verify DTC 80017 or 80024 is not set.
Test for greater than 25 Q between the control =>If DTC B0017 or B0024 is set
circuit terminals listed below and ground:
Replace the appropriate F114 Knee Air Bag.
1 Control circuit terminal 1
1 Control circuit terminal 2 U If DTC 80017 or 80024 is not set
12. All OK.
If 25 Q or less
6.1. Disconnect the X1 harness connector at the Repair Instructions
K36 Inflatable Restraint Sensing and Perform the Diagnostic Repair Verification on
Diagnostic Module. page 6-92 after completing the repair.
6.2. Test for infinite resistance between the control Instrument Panel LowerAirbag Replacement -
circuit and ground. Driver Side on page 13-122
=>Ifless than infinite resistance, repair the short to InstrumentPanel LowerAirbag Replacement -
ground on the circuit. Passenger Side on page 13—123
=>Ifinfinite resistance, replace the K36 inflatable Control Module References on page 6-3 for K36
Restraint Sensing and Diagnostic Module. inflatable Restraint Sensing and Diagnostic
lf greater than 25 Q Module replacement, programming, and setup

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
 Supplemental inflatable Restraints 113-91

DTC B0019 or B0020

Diagnostic Instructions
1 Perform the Diagnostic System Check —Vehicle
on page 6-66 priorto using this diagnostic
procedure.
1 Review Strategy Based Diagnosis on page 6-58
for an overview of the diagnostic approach.
1 Diagnostic Procedure Instructions on page 6—59
provides an overview of each diagnostic category.
DTC Descriptors
DTC 80019 01: Passenger instrument Panel Air Bag Deployment Loop Stage 1 Short to Battery
DTC 80019 02: Passenger InstrumentPanel Air Bag Deployment Loop Stage 1 Short to Ground
DTC 80019 04: Passenger InstrumentPanel Air Bag Deployment Loop Stage 1 Open
DTC 80019 0D: Passenger InstrumentPanel Air Bag Deployment Loop Stage 1»High Resistance
DTC 80019 0E: Passenger InstrumentPanel Air Bag Deployment Loop Stage 1'Low Resistance
DTC 80020 01: Passenger instrument Panel Air Bag Deployment Loop Stage 2 Short to Battery
DTC 80020 02: Passenger InstrumentPanel Air Bag Deployment Loop Stage 2 Short to Ground
DTC 80020 04: Passenger InstrumentPanel Air Bag Deployment Loop Stage 2 Open
DTC 80020 0D: Passenger InstrumentPanel Air Bag Deployment Loop Stage 2 High Resistance
DTC 80020 0E: Passenger InstrumentPanel Air Bag Deployment Loop Stage 2 Low Resistance
Diagnostic Fault Information

Shortto High Shortto Signal

Ground Resistance Open Voltage Performance
Circuit

21.1551319132112111111'111111 313112131 2331231 -

311231 331231; -
21:91:11.1;11311121111111'11111

3321111.» swoon 332331; -

:1:;:213311.11211111111111

21:5:295111313111111'111119 333151.11 semen 3322331 -

Description 80019 04, 80020 04

CircuitlSystem
The air bag control circuit is open for 2 seconds.
During a side or frontal crash of sufficient force the
Inflatable Restraint Sensing and Diagnostic Module 80019 0D, 80020 OD
(SDM) will allow current to flow through the deployment
The air bag deployment loop resistance is greater than
loop in order to deploy an air bag or pretensioner. There 4.2 Q for 2 seconds.
are 2 shorting bars which will short the control circuits
together when the connector is disconnected. This will 80019 0E, 80020 0E
help to prevent unwanted deployment of the air bag or The air bag deployment loop resistance is less than
pretensioner during servicing. 1.4 Q for 2 seconds.
Conditions for Running the DTC
Action Taken When the DTC Sets
ignition voltage is between 9—16V. 1 The Inflatable Restraint Sensing and Diagnostic
Conditions for Setting the DTC Module requests the instrument cluster to
illuminate the AIR BAG indicator.
30019 01, 80020 01 1 The Inflatable Restraint Sensing and Diagnostic
The air bag control circuit is shorted to voltage for Module will store a_DTC, however if an event
2 seconds. occurs the system will still attempt deployments.
30019 02, B0020 02 Conditions for Clearing the DTC
The air bag control circuit is shorted to ground for 1 The condition for setting the DTC no longer exists.
2 seconds. 1 A history DTC will clear once 100 malfunction—free
ignition cycles have occurred.

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
1392 Supplemental inflatable Restraints
Diagnostic Aid
Note: The following diagnostic aids apply for both
current and history DTCs.
An incorrectly installed connector position assurance
(CPA) or incorrectly seated connector can cause a
shorting bar to short both control circuits together.
Check the connectors and CPAs if a DTC with
symptom byte 02 or CE is set, to ensure the shorting
bars are not causing the circuits to be shorted together.
Shorting bars are used in the locations listed below:
1 Passenger instrument Panel Air Bag
1 lnline harness connectors
1 Harness side of the Inflatable Restraint Sensing
and Diagnostic Module connector
Terminal fretting or incorrectly seated connectors can
cause an open/high resistance condition. Check the
circuit terminals for fretting or incorrectly seated
connector if a DTC with symptom byte 04 or OD is set.
DTCs of deployment loops which are in the seat can
occur because of stress or damage to the harness due
to seat movement. Move the seat to the full extent of
travel while using the scan tool to observe deployment
type loop parameters.
Reference Information
Schematic Reference
SIR Schematics on page 13—69
Connector End View Reference
Component Connector End Views on page 11-269
Description and Operation
Supplemental Inflatable Restraint System Description
and Operation on page 13-145
Electrical Information Reference
1 Circuit Testing on page 11-526
1 Testing for IntermittentConditions and Poor
Connections on page 11-531
1 Wiring Repairs on page 11—537
1 Connector Repairs on page 11-548
Scan Tool Reference
Control Module References on page 6-3 for scan tool
information
Special Tools
EL-38125-580 Terminal Release Tool Kit
CircuitlSystem Verification
Note:
1 Refer to SIR Service Precautions on page 13-113.
1 Inspect all terminals for damage or corrosion when
disconnecting connectors. Damage or corrosion in
the following requires repair or replacement of the
affected component/connector.
—Passenger InstrumentPanel Air Bag
—Inflatable Restraint Sensing and Diagnostic
Module
—Passenger instrument Panel Air Bag wiring
harness connector
—Inflatable Restraint Sensing and Diagnostic
Module wiring harness connector
1 The connector and connector position assurance
(CPA) may seat independent of each other. Both
the connector and CPA should seat with an
audible andlor tactile click. The CPA isolates the
shorting-bars within the connector allowing the
deployment circuit to operate properly.
1 Ifthe condition is intermittentor cannot be
duplicated, disconnect the connectors and add
dielectric grease / lubricant (Nyogel 760G or
equivalent, meeting GM specification 9986087).
This procedure will correct the high resistance
condition due to terminal fretting corrosion.
1. Verify the scan tool Deployment Loop Resistance
parameters stay consistently between 2.1—4.0Q
without any spikes or dropouts while moving the
harness near each connector listed below:
1 F101 Passenger InstrumentPanel Air Bag
1 Any inline harness connector
1 K36 Inflatable Restraint Sensing and Diagnostic
Module
:> If less than 2.1 Q or greater than 4.0 Q
Refer to CircuitlSystem Testing.
2:»If there are spikes or dropouts, perform the
following
1 Inspect each connector terminal and harness
for damage or corrosion and repair as
necessary
1 Apply dielectric grease /lubricant (Nyogel 7606
or equivalent, meeting GM specification
9986087) to each connector terminal
1 insure each connector and CPA is correctly
seated.
U If between 2.1-—4.0 Q without any spikes or
dropouts
2. All OK.
CircuitlSystem Testing
1. IgnitionOFF, scan tool disconnected, disconnect
the X203 inline harness connector for the
F101 Passenger InstrumentPanel Air Bag. Itmay
take up to 2 minutes for all vehicle systems to
power down.
2. Test for greater than 25 Q between the appropriate
control circuit terminals listed below on the
K36 InflatableRestraint Sensing and Diagnostic
Module side of the connector:
1 F101 Passenger InstrumentPanel Air Bag
stage 1 X203 terminal 1 and 2
1 F101 Passenger InstrumentPanel Air Bag
stage 2 X203termina| 4 and 5
=>If 25 Q or less
2.1. Disconnect the X1 harness connector at the
K36 InflatableRestraint Sensing and
Diagnostic Module.
(US/Canada)
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2013 (5377994)
Manual
Service

Note: Some connectors may be equipped with
shorting bars as a safety component to prevent
accidental inflator deplOyment. When testing on a
connector with shorting bars, the shorting bars must be
disabled to ensure accurate test results. insert an
appropriate pick from EL-38125—580and depress the
shorting bars above the appropriate terminals. This will
lift the shorting bar from the terminal and allow accurate
test results. Take care not to damage the connector,
shorting bar, or terminal when depressing the
shorting bar.
2.2. Test for infinite resistance between the two
control circuits.
=>Ifless than infinite resistance, repair the short
between the two circuits.
:> if infinite resistance, replace the K36 inflatable
Restraint Sensing and Diagnostic Module.
U If greater than 25 Q
91’ IgnitionON.
4. Test for less than 11V between each control circuit
terminal listed below and ground:
1 X203 control circuitterminal 1
1 X203 control circuit terminal 2
1 X203 control circuit terminal 4
1 X203 control circuit terminal 5
=>If 11 Vor greater
4.1. IgnitionOFF, disconnect the X1 harness
connector at the K36 Inflatable Restraint
Sensing and Diagnostic Module, ignition ON.
4.2. Test for less than 1 V between each control
circuit and ground.
=>If 1 V or greater, repair the short to voltage on
the circuit.
:> Ifless than 1 V, replace the K36 Inflatable
Restraint Sensing and Diagnostic Module.
U If less than 11V
S1“ignition OFF.
6. Test for greater than 25 Q between each control
circuit terminal listed below and ground:
1 X203 control circuitterminal 1
1 X203 control circuit terminal 2
1 X203 control circuit terminal 4
1 X203 control circuitterminal 5
=>If 25 Q or less
6.1. Disconnect the X1 harness connector at the
K36 Inflatable Restraint Sensing and
Diagnostic Module.
6.2. Test for infinite resistance between the control
circuit and ground.
=>If less than infinite resistance, repair the short to
ground on the circuit.
=>Ifinfinite resistance, replace the K36 Inflatable
Restraint Sensing and Diagnostic Module.
U If greater than 25 Q
(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
Supplemental inflatable Restraints 113-93
7. Install a 3 A fused jumper wire between the control
circuit terminals listed below:
1 F101 Passenger instrument Panel Air Bag
stage1 X203 terminal 1 and 2
1 F101 Passenger instrument Panel Air Bag
stage 2 X203 terminal 4 and 5
8. ignition ON.
9. Verify the scan tool Deployment Loop Resistance
parameter is less than 2 Q.
=>lf 2 Q or greater
9.1. Ignition OFF, disconnect the X1 harness
connector at the K36 Inflatable Restraint
Sensing and Diagnostic Module.
9.2. Test for less than 2 Q in each control circuit
end to end.
=>lf 2 Q or greater, repair theopen/high resistance
in the circuit.
:> if less than 2 Q, replace the K36 Inflatable
Restraint Sensing and Diagnostic Module.
U if less than 2 Q
10. IgnitionOFF, connect the X203 inline harness
connector and disconnect the appropriate
X1 (DTC 80019) or X2 (DTC 80020) harness
connector at the F101 Passenger Instrument Panel
Air Bag, ignition ON.
11. Test for less than 11V between each control circuit
terminals listed below and ground:
1 F101 Passenger InstrumentPanel Air Bag
control circuit terminal 1 X1
1 F101 Passenger InstrumentPanel Air Bag
control circuit terminal 2 X1
1 F101 Passenger Instrument Panel Air Bag
control circuit terminal 1 X2
1 F101 Passenger Instrument Panel AirBag
control circuit terminal 2 X2
:> If 11V or greater
Repair the short to voltage on the circuit.
U If less than 11 V
12. IgnitionOFF.
13. Test for greater than 25 Q between each control
circuit terminals listed below and ground:
1 F101 Passenger Instrument Panel Air Bag
control circuit terminal 1 X1
1 F101 Passenger Instrument Panel Air Bag
control circuit terminal 2 X1
1 F101 Passenger Instrument Panel Air Bag
control circuit terminal 1 X2
1 F101 Passenger Instrument Panel Air Bag
control circuit terminal 2 X2
=>If 25 Q or less
Repair the short to ground on the circuit.
U If greater than 25 Q
13=94 Supplemental inflatable Restraints
14. Install a 3 A fused jumper wire between the control
circuit terminals listed below:
1 F101 Passenger InstrumentPanel Air Bag
stage1 control circuit terminal 1 X1 and 2 X1
1 F101 Passenger InstrumentPanel Air Bag
stage 2 control circuit terminal 1 X2 and 2 X2
15. lgnition ON.
16. Verify the scan tool Deployment Loop Resistance
parameter is less than 2 Q.
=>lf 2 Q or greater
16.1. lgnition OFF, disconnect the X1 harness
connector at the K36 Inflatable Restraint
Sensing and Diagnostic Module.
16.2. Test for less than 2 Q in each control circuit
and to end.
=>If2 Q or greater, repair the open/high resistance
in the circuit between the F101 Passenger
InstrumentPanel Air Bag connector and the
X203 inline harness connector.
=>if less than 2 Q, replace the K36 Inflatable
Restraint Sensing and Diagnostic Module.
U If less than 2 Q
17. IgnitionOFF, connect the harness connector at the
F101 Passenger instrument Panel Air Bag, press
in the CPA (if equipped) until an audible andlor
tactile click is heard.
18. lgnition ON, clear DTCs. Operate the vehicle within
the Conditions for Running the DTC.
19. Verify DTC 80019 or 80020 is not set.
2 If DTC 80019 or 80020 is set
Replace the F101 Passenger InstrumentPanel
Air Bag.
U If DTC 80019 or 80020 is not set
20. All OK.
Repair Instructions
Perform the Diagnostic Repair Verification on
page 6—92after completing the repair.
1 Airbag InstrumentPanel Module Replacement on
page 13—121
1 SIR/SRS Wiring Repairs on page 11-548
1 Control Module References on page 6—3for
Inflatable Restraint Sensing and Diagnostic
Module control module replacement, programming
and setup
(US/Canada)
-Sonlc
2013 (5377994)
Manual
Service
 Supplemental inflatable Restraints 13-95

DTC 80052

Diagnostic Instructions
1 Perform the Diagnostic System Check - Vehicle
on page 6—66prior to using the diagnostic
procedure.
1 Review Strategy Based Diagnosis on page 6—58
for an overview of the diagnostic approach.
1 Diagnostic Procedure Instructions on page 6-59
provides an overview of each diagnostic category.
DTC Descriptors
DTC 80052 00: Deployment Commended
DTC 80052 56: Deployment Commanded Too Many Transitions

Description Connector End View Reference

CircuitlSystem
The inflatable restraint sensing and diagnostic module
(SDM) senses vehicle impacts and provides
deployment signals to the air bags and anchor and/or
retractor pretensioners when warranted. The inflatable
restraint sensing and diagnostic module sets
DTC 80052 after each command for deployment.
DTC 80052 will latch and not clear after 3 commanded
deployments by the inflatable restraint sensing and
diagnostic module. Therefore the inflatable restraint
sensing and diagnostic module has to be replaced.
Conditions for Running the DTC
lgnition voltage is between 9—16V.
Component Connector End Views on page 11—269
Description and Operation
Supplemental Inflatable Restraint System Description
and Operation on page 13—145
Electrical Information Reference
1 Circuit Testing on page 11—526
1 Testing for IntermittentConditions and Poor
Connections on page 11-531
1 Wiring Repairs on page 11-537
1 Connector Repairs on page 11-548

Conditions for Setting the DTC Scan Tool Reference

1 The inflatable restraint sensing and diagnostic
module detects a frontal impact of sufficient force
to warrant deployment of the frontal air bags.
1 The inflatable restraint sensing and diagnostic
module detects a side impact or rollover
(if equipped) of sufficient force to warrant
deployment of a seat air bag andlor roof rail
air bag.
Action Taken When the DTC Sets
The inflatable restraint sensing and diagnostic module
requests the instrument cluster to illuminate the AIR
BAG indicator.
Conditions for Clearing the DTC
1 DTC 80052 00 is a DTC that may be Cleared with
a scan tool without replacing the inflatable
restraint sensing and diagnostic module. This
DTC will not clear if deployment has been
commanded more then two times, and the
inflatable restraint sensing and diagnostic module
would have to be replaced.
1 DTC 80052 56 is a latched DTC. The DTC cannot
be cleared with the scan tool. Replacement of the
inflatable restraint sensing and diagnostic module
is required.
Reference Information
Schematic Reference
SIR Schematics on page 13-69
Control Module References on page 6-3 for scan tool
information
Verification
CircuitlSystem
1. Verify that DTC 80052 00 is not set.
=>If DTC 30052 00 is set
Clear the DTC. Ifthe DTC will not clear, replace
the K36 Inflatable Restraint Sensing and
Diagnostic Module.
U If DTC 80052 00 is not set
2. Verify that DTC 80052 56 is not set.
=>If DTC 80052 56 is set
Replace the K36 Inflatable Restraint Sensing
and Diagnostic Module.
U If DTC 80052 56 is not set
3. All OK.
Repair Instructions
Perform the Diagnostic Repair Verification on
page 6-92 after completing the repair.
Control Module References on page 6-3 for inflatable
restraint sensing and diagnostic module replacement,
programming and setup

—
2013 (US/Canada)
Sonic (5377994)
Manual
Service
13196 Supplemental inflatable Restraints

DTC 80074

Diagnostic Instructions
1 Perform the Diagnostic System Check - Vehicle
on page 6-66 prior to using this diagnostic
procedure.
1 Review Strategy Based Diagnosis on page 6-58
for an overview of the diagnostic approach.
1 Diagnostic Procedure Instructions on page 6-59
provides an overview of each diagnostic category.
DTC Descriptors
DTC 80074 00: Passenger Presence Sensor Circuit Malfunction
DTC 80074 04: Passenger Presence Sensor Open

CircuitlSystem Description resets then perform this diagnostic. Ifthe DTC

The passenger presence module monitors the
passenger presence sensor status continuously.
Whenever the passenger presence sensor has an
internal malfunction, the passenger presence module
will set DTC 80074.
Conditions for Running the DTC
lgnition voltage is between 9—16V.
Conditions for Setting the DTC
80074 00
The passenger presence module has detected a
disconnection from the passenger presence sensor.
80074 04
The passenger presence module has detected an open
circuit.
Action Taken When the DTC Sets
The Inflatable Restraint Sensing and Diagnostic
Module will set a DTC 80081 00 after receiving a fault
present message from the passenger presence module
and requests the instrument cluster to illuminate the
AIR BAG indicator.
Conditions for Clearing the DTC
1 The condition for setting the DTC no longer exists.
1 A history DTC will clear once 100 malfunction-free
ignition cycles have occurred.
Diagnostic Aids
1 Ifeither the inflatable Restraint Sensing and
Diagnostic Module or Passenger Presence
System were replaced verify that the correct part
numbers were used for the vehicle application.
1 Ifthis DTC is set as either current or history it may
have been caused by an electronic device. Ifan
electronic device (Computers, MP3 Players, Cell
Phones, Diagnostic Scan Tool, Power Inverter,
etc.) was placed on the passenger seat the
passenger presence module may command the
passenger air bag indicator to turn on andlor
command the passenger seat belt indicator to turn
on. Make sure there are no objects on the
passenger seat and clear the DTCs. Ifthis DTC
does not reset there is no further work needed on
the passenger presence system.
1 Ifthis DTC is set as either current or history it may
have been caused by an aftermarket seat heater.
The aftermarket seat heater may command the
passenger air bag indicator to turn on andlor
command the passenger seat belt indicator to turn
on. Remove the aftermarket seat heater from the
passenger seat and clearthe DTCs. Ifthis DTC
resets then perform this diagnostic. lfthe DTC
does not reset there is no further work needed on
the passenger presence system.
Reference Information
Schematic Reference
SIR Schematics on page 13-69
Connector End View Reference
Component Connector End Views on page 11-269
Description and Operation
Supplemental Inflatable Restraint System Description
and Operation on page 13-145
Electrical Information Reference
1 Circuit Testing on page 11-526
1 Testing for IntermittentConditions and Poor
Connections on page 11—531
1 Connector Repairs on page 11—548
1 Wiring Repairs on page 11-537
Scan Tool Reference
Control Module References on page 6-3 for scan tool
information
CircuitlSystem Verification
Note: This system allows you to service each
component separately (module and sensor/sensing
mat). Perform a Passenger Presence System
Rezeroing on page 13—109
1 Passenger presence sensor
1 Passenger presence sensor harness connector

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service

1 Passenger presence module
1 Passenger presence module harness connector
1 Seat wiring harness to vehicle harness connector
The connector and connector position assurance (CPA)
may seat independent of each other. Both the
connector and CPA should seat with an audible andlor
tactile click.
1. Observe with the scan tool if the fault changes
status while moving the passenger seat forward
and backward through its full range of motion. The
status should stay consistent.
=>The status changes
if the status changes this could be indication of
a seat to vehicle harness connection issue,
refer to CircuitlSystem Testing.
U The status does not change
2. Observe with the scan tool if the fault changes
status while moving the harness near each
connector listed below. The status should stay
consistent.
1 Passenger presence module
1 Passenger presence sensor
1 Any seat harness inline
:9 The status changes
(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
Supplemental inflatable Restraints '13-97
if the reading is erratic while moving the
harness, perform the following:
1 Inspect each connector terminal for damage or
corrosion and repair as necessary.
1 insure each connector and CPA is correctly
seated.
U The status does not change
3. All OK.
CircuitlSystem Testing
Note: This system allows you to service each
component separately (module and sensor/sensing
mat). Perform a Passenger Presence System
Rezeroing on page 153-109
1. Verify that all K85 Passenger Presence Module
and 860 Passenger Presence Sensor connectors
are fully seated.
2. Verify DTC 80074 is not set.
:> DTC 80074 is set.
=>Replace the B60 Passenger Presence Sensor.
U DTC 80074 does not set.
3. All OK.
Repair Instructions
Perform the Diagnostic Repair Verification on
page 6-92 after completing the repair.
Control Module References on page 6-3 for Passenger
Presence Sensor, Passenger Presence Module,
or inflatable Restraint Sensing and Diagnostic Module
replacement, programming, and setup
1398 Supplemental inflatable Restraints
DTC 80081 (Inflatable Restraint Sensing
Diagnostic Instructions
1 Perform the Diagnostic System Check —Vehicle
on page 6—66prior to using this diagnostic
procedure.
1 Review Strategy Based Diagnosis on page 6-58
for an overview of the diagnostic approach.
1 Diagnostic Procedure Instructions on page 6-59
provides an overview of each diagnostic category.
DTC Descriptors
DTC 80081 00: Passenger Presence Module Malfunction
DTC 80081 3A: Passenger Presence Module Incorrect Component Installed
DTC 80081 71: Passenger Presence Module invalid Serial Data Received
CircuitlSystem Description
When the ignition is turned ON, the Inflatable Restraint
Sensing and Diagnostic Module and the Passenger
Presence Module performtests to diagnose critical
malfunctions. Upon a successful power-up mode the
Inflatable Restraint Sensing and Diagnostic Module will
illuminate both PASSENGER AIRBAG ON/OFF
indicators located in the overhead center console. if the
Inflatable Restraint Sensing and Diagnostic Module
detects a fault in the Passenger Presence Module, it
may disable the front passenger air bag deployment
loop, set DTC 80081 00 or DTC 80081 3A and
illuminate the AIRBAG indicator.
Conditions for Running the DTC
Ignitionvoltage is between 9—16 V.
Conditions for Setting the DTC
80081 00
The Inflatable Restraint Sensing and Diagnostic
Module has received a fault present message from the
Passenger Presence Module.
80081 3A
The Inflatable Restraint Sensing and Diagnostic
Module has received a message from the Passenger
Presence Module indicating a vehicle to Passenger
Presence Module mismatch.
80081 71
The Inflatable Restraint Sensing and Diagnostic
Module sets this DTC when the Inflatable Restraint
Sensing and Diagnostic Module has received invalid
serial data from the Passenger Presence Module.
Action Taken When the DTC Sets
1 The Inflatable Restraint Sensing and Diagnostic
Module requests the instrument cluster to
illuminate the AIR BAG indicator.
1 The passenger instrument panel air bag
deployment loop will be disabled.
Conditions for Clearing the DTC
1 The condition for setting the DTC no longer exists.
1 A history DTC will clear once 100 malfunction-free
ignition cycles have occurred.
and Diagnostic Module)
/»r-
,,,/_
_5
Diagnostic Aids
1 Ifeither the inflatable Restraint Sensing and
Diagnostic Module or Passenger Presence
Module were replaced verify that the correct part
numbers were used for the vehicle application.
1 Ifthis DTC is set as either current or history it may
have been caused by an electronic device. Ifan
electronic device (Computers, MP3 Players, Cell
Phones, Diagnostic Scan Tool, Power inverter,
etc.) was placed on the passenger seat the
Passenger Presence Module may command the
passenger air bag indicator to turn on andlor
command the passenger seat belt indicator to turn
on. Make sure there are no objects on the
passenger seat and clear the DTCs. lfthis DTC
resets then perform this diagnostic. Ifthe DTC
does not reset there is no further work needed on
the passenger presence system.
1 if this DTC is set as either current or history it may
have been caused by an aftermarket seat heater.
The aftermarket seat heater may command the
passenger air bag indicator to turn on andlor
command the passenger seat belt indicator to turn
on. Remove the aftermarket seat heater from the
passenger seat and clear the DTCs. lfthis DTC
resets then perform this diagnostic. Ifthe DTC
does not reset there is no further work needed on
the passenger presence system.
Reference Information
Schematic Reference
SIR Schematics on page 13—69
Connector End View Reference
Component Connector End Views on page 11-269
Description and Operation
Supplemental Inflatable Restraint System Description
and Operation on page 13-145
Electrical Information Reference
1 Circuit Testing on page 11—526
1 Testing for IntermittentConditions and Poor
Connections on page 11-531
1 Connector Repairs on page 11-548
1 Wiring Repairs on page 11—537
(US/Canada)
-Sonic
2013 (5377994)
Manual
Service

Scan Tool Reference
Control Module References on page 6—3for scan tool
information
CircuitlSystem Verification
Note: This system allows you to service each
component separately (module and sensor/sensing
mat). Perform a passenger presence system rezero
procedure whenever a component is replaced.
Note: Both the inflatable Restraint Sensing and
Diagnostic Module and Passenger Presence Module
set DTC 80081 but with different symptom bytes.
Therefore it is important to identify which module has
set the DTC 80081. Use the symptom bytes as a way
of identity the correct module to diagnose. Use the
table below in identifying specific module DTC 80081
application and symptom byte that sets with it.
1. Verify that DTC 81001 is not set in the Inflatable
Restraint Sensing and Diagnostic Module.
=>If DTC 81001 is set in the Inflatable Restraint
Sensing and Diagnostic Module
Refer to DTC 81001 on page 13—106.
U lf DTC B1001 does not set in the Inflatable
Restraint Sensing and Diagnostic Module
2. Verify that DTC 80074, 8101D, or 8101 E is not set
in the Passenger Presence Module.
=>If any of these DTCs are set in the Passenger
Presence Module, refer to Diagnostic Trouble
Code (DTC) List - Vehicle on page 6-69
U If none of these DTCs are set in the Passenger
Presence Module
(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
Supplemental inflatable Restraints 113-99
Note: The inflatable Restraint Sensing and Diagnostic
Module sets a redundant 80081 00 DTC when the
Passenger Presence Module sets a DTC 80081 11 or
80081 42.
3. Verify that DTC 80081 00 is not set in the inflatable
Restraint Sensing and Diagnostic Module
=>If DTC 80081 00 is set
Refer to the Passenger Presence Module DTC
80081 (Inflatable Restraint Sensing and
Diagnostic Module) on page 13-98 or DTC '
80081 (Passenger Presence Module) on
page 13—100.
U If DTC 80081 00 is not set
Note: The Inflatable Restraint Sensing and Diagnostic
Module sets a 80081 3A when an incorrect Passenger
Presence Module is installed.
4. Verify that DTC 80081 3A is not set in the Inflatable
Restraint Sensing and Diagnostic Module.
=>lf DTC 80081 3A is set
Replace the K85 Passenger Presence Module.
U lf DTC 80081 3A is not set
5. Verifythat DTC 80081 71 is not set in the Inflatable
Restraint Sensing and Diagnostic Module.
:> If DTC 80081 71 is set
Replace the 860 Passenger Presence Sensor.
U If DTC 80081 71 is not set
6. All OK.
Repair Instructions
Perform the Diagnostic Repair Verification on
page 6-92 after completing the repair.
Control Module References on page 6-3 for Passenger
Presence Module and Inflatable Restraint Sensing and
Diagnostic Module replacement, programming and
setup
13-100 Supplemental inflatable Restraints

DTC 80081 (Passenger Presence Module)

Diagnostic Instructions
1 Perform the Diagnostic System Check - Vehicle
on page 6—66prior to using this diagnostic
procedure.
1 Review Strategy Based Diagnosis on page 6-58
for an overview of the diagnostic approach.
1 Diagnostic Procedure Instructions on page 6-59
provides an overview of each diagnostic category.
DTC Descriptors
DTC 80081 11: Passenger Presence Module High Input
DTC 80081 48: Passenger Presence Module Calibration Not Learned

CircuitlSystem Description 1 An aftermarket seat heater may command the

passenger air bag indicator to turn on andlor
When the ignition is turned ON, the Inflatable Restraint command the passenger seat belt indicator to turn
Sensing and Diagnostic Module and the Passenger on. Remove the aftermarket seat heater from the
Presence Module perform tests to diagnose critical passenger seat and clearthe DTCs. lfthis DTC
malfunctions. Upon a successful power-up mode the resets then performthis diagnostic. Ifthe DTC
Inflatable Restraint Sensing and Diagnostic Module will does not reset there is no further work needed on
illuminate both PASSENGER AlRBAG ON/OFF the passenger presence system.
indicators. Ifthe Inflatable Restraint Sensing and
Diagnostic Module detects a fault in the Passenger 1 Ifthis DTC is set as either current or history it may
Presence Module, it may disable the passenger have been caused by:
instrument panel air bag deployment loop, set —An aftermarket seat heater
DTC 80081 and illuminate the AlRBAG indicator. —A scan tool, laptop, or other electronic device is
in the seat
Conditions for Running the DTC
—The seat is damp or wet
lgnition voltage is between 9—16 V.
—An object is in the seat
Conditions for Setting the DTC
Reference Information
Any of the following conditions must exist for
5 seconds. Description and Operation
80081 11 Supplemental Inflatable Restraint System Description
and Operation on page 13—145
The Passenger Presence Module has failed the
preload procedure. Scan Tool Reference
80081 48 Control Module References on page 6-3 for scan tool
The'Passenger Presence Module is not calibrated. information

Action Taken When the DTC Sets CircuitlSystem Verification

1 The Inflatable Restraint Sensing and Diagnostic Use the table below in identifying specific module
Module requests the instrument Clusterto DTC 80081 application and symptom byte that sets
illuminate the AIR BAG indicator. with it.
1 The passenger instrument panel air bag DTC Symptom Bytes
deployment loop will be disabled.
80081—inflatable
Conditions for Clearing the DTC RestraintSensing
and Diagnostic 00 3A
1 The condition for setting the DTC no longer exists. Module
1 A history DTC will clear once 100 malfunction—free 80081-
ignition cycles have occurred. Passenger 11 48
PresenceModule
Diagnostic Aids
1 if either the Inflatable Restraint Sensing and
Diagnostic Module or passenger presence system
were replaced verify that the correct part numbers
were used for the vehicle application.

2013
.Sonic
(US/Canada)
Service
Manual
(5377994)

Note:
1 This system is serviced as a kit (seat foam,
module and sensing mat). Perform a passenger
presence system preload procedure whenever a
component is replaced. Refer to Passenger
Presence System Programming and Setup on
page 6-12.
1 Both Inflatable Restraint Sensing and Diagnostic
Module and Passenger Presence Module set
DTC 80081 but with different symptoms bytes.
Therefore it is important to identify which module
has set the DTC 80081. Use the symptom bytes
as a way of identify the correct module to
diagnose.
1 The Inflatable Restraint Sensing and Diagnostic
Module sets a 80081 3A when an incorrect
Passenger Presence Module is installed.
1. Verify that DTC 80081 3A is not set in the inflatable
Restraint Sensing and Diagnostic Module.
:> If DTC 80081 3A is set in the Inflatable Restraint
Sensing and Diagnostic Module
Replace the K85 Passenger Presence Module.
U lf DTC 80081 3A is not set in the Inflatable
Restraint Sensing and Diagnostic Module
(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
Supplemental inflatable Restraints 13-101
Note: The Inflatable Restraint Sensing and Diagnostic
Module sets a 80081 00 DTC when the Passenger
Presence Module sets a DTC 80081 11 or 80081 48.
2. Verify that DTC 80081 11 or DTC 80081 48 is not
set in the Passenger Presence Module.
=>lf DTC 80081 11 or DTC 80081 48 is set in the
Passenger Presence Module
Perform the passenger presence system rezero
procedure. Refer to Passenger Presence
System Programming and Setup on page 6—12.
U If DTC 80081 11 or DTC 80081 48 is not set in
the Passenger Presence Module
3. All OK.
Repair Instructions
Perform the Diagnostic Repair Verification on
page 6-92 after completing the repair.
Control Module References on page 6-3 for Passenger
Presence Module or Inflatable Restraint Sensing and
Diagnostic Module replacement, programming and
setup
113-102 Supplemental inflatable Restraints

DTC 80083-80088

Diagnostic Instructions M2
.\_M
1 Perform the Diagnostic System Check - Vehicle
’ on page 6—66prior to using this diagnostic
procedure.
1 Review Strategy Based Diagnosis on page 6-58
for an overview of the diagnostic approach.
1 Diagnostic Procedure Instructions on page 6-59
provides an overview of each diagnostic category.
DTC Descriptors
DTC 80083 01: Left Front Impact Sensor Short to Battery
DTC 80083 02: Left Front Impact Sensor Short to Ground
DTC 80083 04: Left Front Impact Sensor Open
DTC 80083 05: Left Front Impact Sensor HighNoltage Open
DTC 80083 0C: Left Front Impact Sensor Low Current
DTC 80083 39: Left Front Impact Sensor Internal Electronic Failure
DTC 80083 3A: Left Front Impact Sensor Incorrect Component Installed
DTC 80083 71: Left Front Impact Sensor Invalid Serial Data Received
DTC 80084 01: Right Front Impact Sensor Short to Battery
DTC 80084 02: Right Front impact Sensor Short to Ground
DTC 80084 04: Right Front impact Sensor Open
DTC 80084 05: Right Front Impact Sensor High/Voltage Open
DTC 80084 00: Right Front Impact Sensor Low Current
DTC 80084 39: Right Front Impact Sensor Internal Electronic Failure
DTC 80084 3A: Right Front Impact Sensor incorrect Component Installed
DTC 80084 71: Right Front Impact Sensor Invalid Serial Data Received
DTC 80085 01: Left Front Side Impact Sensor Short to Battery
DTC 80085 02: Left Front Side Impact Sensor Short to Ground
DTC 80085 04: Left Front Side Impact Sensor Open
DTC 80085 05: Left Front Side Impact Sensor High/Voltage Open
DTC 80085 0C: Left Front Side Impact Sensor Low Current
DTC 80085 39: Left Front Side Impact Sensor internal Malfunction
DTC 80085 3A: Left Front Side Impact Sensor Incorrect Component Installed
DTC 80085 71: Left Front Side Impact Sensor Invalid Serial Data Received
DTC 80086 01: Right Front Side ImpactSensor Short to Battery
DTC 80086 02: Right Front Side Impact Sensor Short to Ground
DTC 80086 04: Right Front Side Impact Sensor Open
DTC 80086 05: Right Front Side Impact Sensor High/Voltage Open
DTC 80086 0C: Right Front Side impact Sensor Low Current
DTC 80086 39: Right Front Side Impact Sensor InternalMalfunction
DTC 80086 3A: Right Front Side ImpactSensor Incorrect Component installed
DTC 80086 71: Right Front Side Impact Sensor Invalid Data
DTC 80087 01: Left Rear Side Impact Sensor Short to Battery
DTC 80087 02: Left Rear Side Impact Sensor Short to Ground
DTC 80087 04: Left Rear Side Impact Sensor Open
DTC 80087 05: Left Rear Side Impact Sensor High/Voltage Open
DTC 80087 00: Left Rear Side Impact Sensor Low Current
DTC 80087 39: Left Rear Side Impact Sensor InternalMalfunction
DTC 80087 3A: Left Rear Side Impact Sensor Incorrect Component Installed
DTC 80087 71: Left Rear Side Impact Sensor Invalid Serial Data Received
DTC 80088 01: Right Rear Side Impact Sensor Short to Battery
DTC 80088 02: Right Rear Side ImpactSensor Short to Ground

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 Supplemental inflatable Restraints 131-103

DTC 80088 04: Right Rear Side Impact Sensor Open

DTC 80088 05: Right Rear Side impact Sensor High/Voltage Open
DTC 80088 0C: Right Rear Side Impact Sensor Low Current
DTC 80088 39: Right Rear Side Impact Sensor internal Malfunction
DTC 80088 3A: Right Rear Side Impact Sensor Incorrect Component Installed
DTC 80088 71: Right Rear Side Impact Sensor Invalid Data

Diagnostic Fault Information

Open/High Short to Voltage Signal

Short to Ground Resistance Performance
Circuit
333333% 333883331 8008301 800833A
LeftFrontImpactSensorHighSignal

E33333% @3333345' 8008301 800833A

LeftFrontImpactSensorLow Reference

3%
3333‘}1 3833883331 8008401 800843A
RightFrontImpactSensorHighSignal

3332: 3% %%%%i%é‘ 8008401 800843A

RightFrontImpactSensorLow Reference

333333% 33333331 8008501 8008539

LeftFrontSide ImpactSensorHighSignal

33333 3% 3338855331 8008501 8008539

LeftFrontSide ImpactLowReference

333333% 3833883331 3008601 3008639

RightFrontSide ImpactSensorHighSignal

3%
333333 @333333 8008601 8008639
RightFrontSide ImpactSensorLow Reference

3333; 3% 3833377331 3008701 8008739

LeftRear Side ImpactSensorHighSignal

3333; 3% 333377331 8008701 8008739

LeftRear Side ImpactSensorLow Reference

333333% 33333331 3008801 8008839

RightRear Side ImpactSensorHighSignal

333333% 333883331 3008801 3008839

RightRear Side ImpactSensorLow Reference

CircuitlSystem Description Conditions for Setting the DTC

sensors are equipped on vehicles to
The impact
supplement the Supplemental Inflatable Restraint (SIR)
System performance. The impact sensors are
electronic and are not part of the deployment loops, but
instead provide inputs to the Inflatable Restraint
Sensing and Diagnostic Module. The impact sensors
can assist in determining the severity of some frontal
and side collisions. The Inflatable Restraint Sensing
and Diagnostic Module uses the input from the impact
sensors to assist in determining the severity of a
collision further supporting air bag deployment. Ifthe
inflatable Restraint Sensing and Diagnostic Module
determines a deployment is warranted, the inflatable
Restraint Sensing and Diagnostic Module will cause
current to flow through the deployment loops deploying
the air bags.
Conditions for Running the DTC
Ignitionvoltage is between 9—16V.
Any of the following conditions exist for 10 seconds:
80083 01, 80084 01, 80085 01, 80086 01, 80087 01,
80088 01
The sensor has been shorted to voltage.
80083 02, 80084 02, 80085 02, 80086 02, 80087 02,
80088 02
1 The sensor has been shorted to ground.
1 The sensor current is greater than 23 mA for
greater than 5 milliseconds.
80083 04, 80084 04, 80085 04, 80086 04, 80087 04,
80088 04
1 The sensor circuit is open.
1 The Inflatable Restraint Sensing and Diagnostic
Module has not received a message from the
sensor for greater than 375 milliseconds.

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113-104 Supplemental inflatable Restraints
80083 05, 80084 05, 80085 05, 80086 05, 80087 05,
80088 05
1 The sensor circuit is open or high resistance.
1 The inflatable Restraint Sensing and Diagnostic
Module has not received a message from the
sensor for greater than 375 milliseconds.
80083 DC, 80084 0C, 80085 DC, 80086 DC, 80087 DC,
80088 0C
1 The sensor has been shorted to ground.
1 The sensor current is greater than 23 mA for
greater than 5 milliseconds.
80083 39, 80084 39, 80085 39, 80086 39, 80087 39,
80088 39
1 The Inflatable Restraint Sensing and Diagnostic
Module has received a Not OK message from the
senson
1 The Inflatable Restraint Sensing and Diagnostic
Module has not received a message.
80083 3A, 80084 3A, 80085 3A, 80086 3A, 80087 3A,
80088 3A
1 The inflatable Restraint Sensing and Diagnostic
Module has received identification message from
the sensor, which does not match the identification
stored in the Inflatable Restraint Sensing and
Diagnostic Module memory.
1 The inflatable Restraint Sensing and Diagnostic
Module has reset the sensor twice without
detecting the correct identification message.
80083 71, 80084 71, 80085 71, 80086 71, 80087 71,
80088 71
The Inflatable Restraint Sensing and Diagnostic
Module has received invalid serial data from the
senson
Action Taken When the DTC Sets
The Inflatable Restraint Sensing and Diagnostic
Module requests the instrument panel cluster to
illuminate the AIR BAG indicator.
Conditions for Clearing the DTC
1 The condition for setting the DTC no longer exists.
1 A history DTC will clear once 100 malfunction-free
ignition cycles have occurred.
1 An ignition cycle is required for the DTC to go from
current to history.
Reference Information
Schematic Reference
SIR Schematics on page 13-69
Connector End View Reference
Component Connector End Views on'page 11—269
Description and Operation
Supplemental Inflatable Restraint System Description
and Operation on page 13-145
Electrical information Reference
1 Circuit Testing on page 11-526
1 Testing for IntermittentConditions and Poor
Connections on page 11-531
1 Connector Repairs on page 11-548
1 Wiring Repairs on page 11~537
Scan Tool Reference
Control Module References on page 6-3 for scan tool
information
CircuitlSystem Verification
Note:
1 Refer to SIR Service Precautions on page 13-113.
1 Inspect all terminals for damage or corrosion when
disconnecting connectors. Damage or corrosion in
the following requires repair or replacement of the
affected component/connector.
—Impactsensor
—inflatable Restraint Sensing and Diagnostic
Module
—Impactsensorwiring harness connector
—Inflatable Restraint Sensing and Diagnostic
Module wiring harness connector
1 The connector and connector position assurance
(CPA) may seat independent of each other. 80th
the connector and CPA should seat with an
audible and/or tactile click. The CPA isolates the
shorting—barswithin the connector allowing the
deployment circuit to operate properly. Replace
any CPA that is damaged or missing.
1 Ifthe condition is intermittentor cannot be
duplicated, disconnect the connectors and add
dielectric grease / lubricant (Nyogel 760G or
equivalent, meeting GM specification 9986087).
This procedure will correct the high resistance
condition due to terminal fretting corrosion.
1. Verify that DTC 80083~80088 symptom byte 3A,
39, or 71 is not set as current.
=>lf DTC 80083—80088 symptom byte 3A, 39 or 71
is set as current
Replace the appropriate 859 or 863 Impact
Senson
U If DTC 80083—80088 symptom byte 3A, 39 or 71
is not set as current
2. Verify that DTC 80083—80088 symptom byte O1,
02, 04, or 05 is not set as current.
:> If DTC 80083-80088 symptom byte 01, 02, 04,
or 05 is set as current
Refer to CircuitlSystem Testing.
U If DTC 80083—80088 symptom byte 01,02, 04,
05 is not set as current
3. All OK.
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 Supplemental inflatable Restraints 131-105

CircuitlSystem Testing 5. Disconnect the harness connector at the

1. IgnitionOFF, disconnect the harness connector at
the appropriate 859 or 863 Impact Sensor, wait
120 seconds.
. Test for less than 10 Q between the low reference
circuit terminal 2 and ground.
If 10 Q or greater
2.1. IgnitionOFF, disconnect the harness
connector at the K36 inflatable Restraint
Sensing and Diagnostic Module.
2.2. Test for less than 2 Q in the low reference
circuit end to end.
:> If2 Q or greater, repair the open/high resistance
in the circuit.
=>if less than 2 Q, replace the K36 inflatable
Restraint Sensing and Diagnostic Module.
If less than 10 Q
. Test for greater than 50k Q between the signal
circuit terminal 1 and ground.
If 50k Q or less
3.1. Disconnect the harness connector at the K36
inflatable Restraint Sensing and Diagnostic
Module.
3.2. Test for infinite resistance between the signal
circuit and ground.
=>if less than infinite resistance, repair the short to
ground on the circuit. . the Conditions for Running the DTC.
=>Ifinfinite resistance, replace the K36 Inflatable
Restraint Sensing and Diagnostic Module.
4: If greater than 50k Q
lgnition ON, test for less than 1 V between the
signal circuit terminal 1 and ground.
If greater than 1 V
4.1. Disconnect the harness connector at the K36
Inflatable Restraint Sensing and Diagnostic
Module.
4.2. lgnition ON, test for less than 1 V between the
signal circuit and ground.
:1; Ifgreater than 1 V, repair the short to voltage on
the circuit.
=>if less than 1 V, replace the K36 Inflatable
Restraint Sensing and Diagnostic Module.
U If less than 1 V
K36 Inflatable Restraint Sensing and Diagnostic
Module.
Test for less than 2 Q between the 859 or 863
Impact Sensor signal circuit end to end from the
impact sensor terminal 1 and the appropriate K36
Inflatable Restraint Sensing and Diagnostic
Module terminal listed below:
1 863LF Side Impact Sensor —Left Front -
Terminal 19 X2
1 859L Front Impact Sensor —Left -
Terminal 23 X2
1 863RF Side impact Sensor— Right Front -
Terminal 22 X2
1 859R Front impact Sensor —Right -
Terminal 26 X2
1 863LR Side Impact Sensor —Left Rear -
Terminal 27 X2
1 863RR Side Impact Sensor —Right Rear -
Terminal 30 X2
lf 2 Q or greater
Repair the open/high resistance in the circuit.
If less than 2 Q
IgnitionOFF, connect all harness connectors,
press in the CPA (if equipped) until an audible and/
or tactile click is heard.
lgnition ON, clear DTCs. Operate the vehicle within
S0 Verify the DTC does not set.
if the DTC sets
Replace the 859 or 863 Impact Sensor.
U If the DTC does not set
10. All OK.
Repair Instructions
Perform the Diagnostic Repair Verification on
page 6-92 after completing the repair.
Airbag Side Impact Sensor Replacement (with
AYF/AYO) on page 13-116
Front End Inflatable Restraint Discriminating
Sensor Replacement on page 13-115
Control Module References on page 6—3for
inflatable Restraint Sensing and Diagnostic
Module replacement, programming and setup

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Manual
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13406 Supplemental inflatable Restraints

DTC B1001

Diagnostic Instructions
1 Perform the Diagnostic System Check —Vehicle
on page 6-66 prior to using this diagnostic
procedure.
1 Review Strategy Based Diagnosis on page 6-58
for an overview of the diagnostic approach.
1 Diagnostic Procedure Instructions on page 6-59
provides an overview of each diagnostic category
DTC Descriptor
DTC 81001 00: Option Configuration

CircuitlSystem Description Reference Information

The inflatable restraint sensing and diagnostic module
(SDM) stores a primary data key, which is a 4—digit
number. When the ignition is turned ON, the inflatable
restraint sensing and diagnostic module compares this
information to the informationstored in the Body
Control Module (BCM) via serial data. Ifthere is a
mismatch between the information stored in the
inflatable restraint sensing and diagnostic module and
Body Control Module, DTC 81001 will set.
Conditions for Running the DTC
System voltage is between 9—16V.
Conditions for Setting the DTC
The 4—digitPrimary Data Key stored in the inflatable
restraint sensing and diagnostic module does not
match the 4 digits stored in the Body Control Module.
Action Taken When the DTC Sets
1 The inflatable restraint sensing and diagnostic
module requests the instrument cluster to
illuminate the AIR BAG indicator.
1 The inflatable restraint sensing and diagnostic
module disables all deployments.
Conditions for Clearing the DTC
The last 4—digitPrimary Data Key in the inflatable
restraint sensing and diagnostic module matches the
last 4 digits stored in the Body Control Module.
Diagnostic Aids
1 This DTC is an indication that an incorrect
inflatable restraint sensing and diagnostic module
is installed in the vehicle, or that the inflatable
restraint sensing and diagnostic module andlor
the Body Control Module was replaced without
reprogramming the Body Control Module with the
new information.
1 Ifthe inflatable restraint sensing and diagnostic
module was previously programmed and
DTC 81001 is now set, the setup portion of
program was not completed. Proceed to the
inflatable restraint sensing and diagnostic module
Setup portion of the Inflatable Restraint Sensing
and Diagnostic Module Programming and Setup
on page 6-10
Schematic Reference
SIR Schematics on page 13—69
Connector End View Reference
Component Connector End Views on page 11—269
Description and Operation
Supplemental Inflatable Restraint System Description
and Operation on page 13—145
Electrical Information Reference
1 Circuit Testing on page 11-526
1 Testing for IntermittentConditions and Poor
Connections on page 11-531
1 Wiring Repairs on page 11-537
1 Connector Repairs on page 11-548
Scan Tool Reference
Control Module References on page 6-3 for scan tool
information
CircuitlSystem Verification
1. Verify the scan tool K36 Inflatable Restraint
Sensing and Diagnostic Module Primary Key
Status parameter is Valid.
=>If the K36 Inflatable Restraint Sensing and
Diagnostic Module Primary Key Status
parameter is Invalid
Perform the K36 Inflatable Restraint Sensing
and Diagnostic Module setup. Refer to
Inflatable Restraint Sensing and Diagnostic
Module Programming and Setup on page 6-10.
U If the K36 Inflatable Restraint Sensing and
Diagnostic Module Primary Key Status
parameter is Valid
2. All OK.
Repair Instructions
Perform the Diagnostic Repair Verification on
page 6-92 after completing the repair.
1 S/R/SRS Wiring Repairs on page 11—548
1 Control Module References on page 6—3for K36
Inflatable Restraint Sensing and Diagnostic
Module replacement, programming and setup

2013
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DTC B1019
Diagnostic Instructions
1 Perform the Diagnostic System Check —Vehicle
on page 6-66 prior to using this diagnostic
procedure.
1 Review Strategy Based Diagnosis on page 6—58
for an overview of the diagnostic approach.
1 Diagnostic Procedure Instructions on page 6-59
provides an overview of each diagnostic category.
DTC Descriptor
DTC B1019 00: System Configuration Error
CircuitlSystem Description
The inflatable restraint sensing and diagnostic module
monitors the number of safety components installed on
the vehicle. When the ignition is turned ON, the
inflatable restraint sensing and diagnostic module
evaluates the number of safety components installed
and compares it to the number of components the
inflatable restraintsensing and diagnostic module
expects to see on the vehicle with its current
calibration. Ifthere is a mismatch between detected
components and the components programmed with the
inflatable restraint sensing and diagnostic module
calibration, DTC B1019 will set. The components
(if equipped) that the inflatable restraint sensing and
diagnostic module will detect include inflatable restraint
deployment loops, impact sensors, passenger
presence system components, seat position sensors,
disable switches, and seat belt switches.
the DTC
Conditions for Running
lgnition voltage is between 9—16V.
Conditions for Setting the DTC
The setup for the inflatable restraint sensing and
diagnostic module has not been completed and the
inflatable restraint sensing and diagnostic module
does not detect the passenger presence system
(if equipped), the correct number of sensors,
or deployment loops, that is expected with this
calibration.
Action Taken When the DTC Sets
1 The inflatable restraint sensing and diagnostic
module requests the instrument cluster to
illuminate the AIR BAG warning indicator.
1 The DTC must be cleared before running the
setup inflatable restraint sensing and diagnostic
module.
1 Air bag indicator will continue to flash until
inflatable restraint sensing and diagnostic module
setup procedure is complete.
Conditions for Clearing the DTC
1 The condition for setting the DTC is no longer,
present.
1 A history DTC will clear once 100 malfunction—free
ignition cycles have occurred.
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Supplemental inflatable Restraints 13-107
Diagnostic Aids
The inflatable restraint sensing and diagnostic module
scan tool deployment loop, impact sensor, and
passenger presence (if equipped) data will match what
the inflatable restraint sensing and diagnostic module
has been programmed to expect to see on the vehicle.
B1019 DTC will set if a deployment loop or impact
sensor is added or removed from the system, or if the
passenger presence is not detected.
DTC B1019 will set when an open/high resistance DTC
sets for a deployment loop or impact sensor. This
causes mismatch between the learned and actual
components connected to the inflatable restraint
sensing and diagnostic module. '
DTC 31019 can set with no other DTCs if an unused
deployment loop or impact sensor circuit is shorted to
ground. This causes a mismatch between the learned
and actual components connected to the inflatable
restraint sensing and diagnostic module.
Reference Information
Schematic Reference
1 Seat Belt Schematics on page 13-48
1 SIR Schematics on page 13-69
Connector End View Reference
Component Connector End Views on page 11—269
Description and Operation
1 Seat Belt System Description and Operation on
page 13-66
1 Supplemental Inflatable Restraint System
Description and Operation on page 13—145
Electrical Information Reference
1 Circuit Testing on page 11-526
1 Testing for IntermittentConditions and Poor
Connections on page 11-531
1 Connector Repairs on page 11-548
1 Wiring Repairs on page 11~53?
Scan Tool Reference
Control Module References on page 6—3for scan tool
information
13-108 Supplemental inflatable Restraints
CircuitlSystem Verification
Note: DTC B1019 can set after the inflatable restraint
sensing and diagnostic module has been replaced
and/or reprogrammed before the setup procedure is
completed. The setup procedure cannot be completed
if DTC B1019 is set as current or history. Ifa short or
open is detected in a deployment circuit prior to the
setup procedure being performed, the inflatable
restraint sensing and diagnostic module will set
DTC B1019.
1. lgnition ON.
2. Verify no other K36 inflatable Restraint Sensing
and Diagnostic Module DTCs are set.
=>If other K36 inflatable Restraint Sensing and
Diagnostic Module DTCs are set
Diagnose those DTCs first. Refer to Diagnostic
Trouble Code (DTC) List - Vehicle on page 6-69
U if no other K36 Inflatable Restraint Sensing and
Diagnostic Module DTCs are set
3. Verify the enabled impact sensors identified in the
scan tool data list match the number of actual
impact sensors installed on the vehicle.
=>If the number of enabled impact sensors do not
match
3.1. Verify the correct K36 Inflatable Restraint
Sensing and Diagnostic Module calibration file
is loaded in the K36 inflatable Restraint
Sensing and Diagnostic Module.
=>Ifthe K36 InflatableRestraint Sensing and
Diagnostic Module calibration file is correct and
the vehicle contains an incorrect number of
sensors, identifywhich sensors are missing to
make the vehicle match the K36 inflatable
Restraint Sensing and Diagnostic Module
impact sensor calibration scan tool data list.
it Ifthe calibration file is incorrect
3.2. Reprogram the K36 Inflatable Restraint
Sensing and Diagnostic Module. Refer to
Inflatable Restraint Sensing and Diagnostic
Module Programming and Setup on page 6-10
U If the number of enabled impact sensors match
4. Verify the enabled deployment loops identified in
the scan tool data list match the deployment loops
installed on the vehicle.
=>if the number of enabled deployment loops do
not match ' U if the DTC is not set as current
4.1. Verify the correct K36 Inflatable Restraint
Sensing and Diagnostic Module calibration file
is loaded in the K36 Inflatable Restraint
Sensing and Diagnostic Module.
::>Ifthe K36 Inflatable Restraint Sensing and
Diagnostic Module calibration file is correct and
the vehicle contains an incorrect number of
loops, identify which deployment loops are
missing to make the vehicle match the K36
Inflatable Restraint Sensing and Diagnostic
Module impact sensor calibration scan tool
data list.
U if the calibration file is incorrect
4.2. Program the K36 inflatable Restraint Sensing
and Diagnostic Module. Refer to Inflatable
Restraint Sensing and Diagnostic Module
Programming and Setup on page 6—70
If the number of enabled deployment loops
match
. Verify a passenger presence system is equipped
on the vehicle.
If a passenger presence system is not
equipped on the vehicle
Replace the K36 Inflatable Restraint Sensing
and Diagnostic Module.
If a passenger presence system is equipped on
the vehicle
. Verify the Passenger Presence System Enable
Status parameter identified in the scan tool data list
is Enabled.
If the Passenger Presence System Enable
Status parameter is not Enabled
Refer to Inflatable Restraint Sensing and
Diagnostic Module Programming and Setup on
page 6-10
If the Passenger Presence System parameter is
Enabled
. Verify the Passenger Presence System Learn
Status parameter identified in the scan tool data list
is Learned.
If the Passenger Presence System Learn Status
parameter is not Learned
7.1. Verify the scan tool can communicate with the
passenger presence system.
:> Ifthe scan tool will not communicate with the
passenger presence system, referto Scan Tool
Does Not Communicate with Low Speed
GMLAN Device on page 11—62
U Ifthe scan tool communicates
7.2. IgnitionOFF, disconnect the scan tool, wait
2 min.
7.3. IgnitionON, connect the scan tool, verify DTC
81019 is not set as current.
=>Ifthe DTC is set as current, refer to Inflatable
Restraint Sensing and Diagnostic Module
Programming and Setup on page 6-10
7.4, All OK.
If the Passenger Presence System Learn status
is Learned
. Replace the K36 Inflatable Restraint Sensing and
Diagnostic Module.
Repair Instructions
Perform the Diagnostic Repair Verification on
page 6-92 after completing the repair.
SIR/SRS Wiring Repairs on page 11—548
Control Module References on page 6-3 for
inflatable restraint sensing and diagnostic module
replacement, programming and setup
2013
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(US/Canada)
Service
Manual
(5377994)
\%
“w,
~_W

Presence System
Passenger
Rezeroing
Introduction
The inflatable restraints passenger presence system is
a calibrated system that requires re-zeroing or a zero
check anytime the seat cushion trim attachments have
been removed or the passenger presence system has
been replaced. The procedures below are designed to
assist in the re-zeroing of the passenger presence
system. Before you start, read these procedures
carefully and completely. For further information
regarding the passenger presence system refer to
Supplemental Inflatable Restraint System Description
and Operation on page 13-145.
Note: The following procedures must be followed:
1. Read this procedure carefully and completely.
2. The passenger presence system will not function
properly if the passenger presence system
re-zeroing procedure is not performed.
3. Perform the Diagnostic Repair Verification on
page 6—92after successfully completing the
re—zeroingprocedure to ensure the system is
functioning properly.
Passenger Presence System
Re-zeroing Procedure
Note:
1 Before the passenger presence system can be
re-zeroed the front passenger seat must be
completely empty of all items. The presence of
any liquid or items on the front passenger seat will
affect the calibration and operation of the
passenger presence system.
1 DTC BOO81will set if the re-zero system test is
performed with:
—An aftermarket seat heater located too close to
the sensor mat
—A scan tool, laptop, or other electronic device is
in the seat
—The seat is damp or wet
—An object or person is in the seat
1. Verify that the temperature is between 32°F to
100°F before running a re-zero procedure.
2. Verify the seat is completely dry.
3. Empty the front outboard passenger seat.
4. Verify that all SIR and passenger presence system
components, connectors, and connector position
assurances are properly connected and mounted.
5. Install a scan tool.
6. Tum ON the ignition, with the engine OFF.
Note: The presence of current DTCs, except
DTC 80081 11 or 80081 48, will prevent the passenger
presence system from re—zeroingand may set
additional DTCs.
7. With a scan tool, perform the Passenger Presence
Sensor Learn procedure.
H2...M‘/
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AAW'WW’2013 Service
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Manual
Supplemental inflatable Restraints 13-109
8. if the test fails, confirm that the seat is empty and
completely dry. Perform the Passenger Presence
Sensor Learn test again. Ifthe test fails again,
verify DTC 80081 is not set as current, if the DTC
is set refer to Diagnostic Trouble Code (DTC) List -
Vehicle on page 6—69.Ifthe test successfully
completed, cycle the ignition OFF.
9. After the passenger presence system has been
successfully re—zeroed,perform the Diagnostic
Repair Verification on page 6-92.
Symptoms - SIR
Note: Complete the following steps before using the
symptom tables:
1. Perform Diagnostic System Check ~Vehicle on
page 6-66 before using the symptom tables in
order to verify that all of the following are true:
1 There are no DTCs set.
1 The inflatable restraint sensing and diagnostic
module (SDM) can communicate via the serial
data link.
2. Review the SIR system description and operation
in order to familiarize yourself with the system
functions. Refer to Supplemental Inflatable
Restraint System Description and Operation on
page 13-145.
VisuallPhysical Inspection
1 Inspect for aftermarket devices which could affect
the operation of the SIR system. Refer to
Checking Aftermarket Accessories on
page 11-525.
1 Inspect the easily accessible or visible system
components for obvious damage or conditions
which could cause the symptom.
Intermittent
Faulty electrical connections or wiring may be the
cause of intermittentconditions. Refer to Testing for
IntermittentConditions and Poor Connections on
page 11—531 .
Symptom List
Refer to Air Bag Indicator Circuit Malfunction (Driver)
on page 13-109 or Air Bag Indicator Circuit Malfunction
(Passenger) on page 13-110in order to diagnose the
symptom.
Air Bag Indicator Circuit Malfunction
(Driver)
Diagnostic Instructions
1 Perform the Diagnostic System Check - Vehicle
on page 6—66prior to using this diagnostic
procedure.
1 Review Strategy Based Diagnosis on page 6—58
for an overview of the diagnostic approach.
1 Diagnostic Procedure Instructions on page 6-59
provides an overview of each diagnostic category.
'13-110 Supplemental inflatable Restraints

CircuitlSystem Description Description and Operation

When the ignition is turned ON the driver air bag
indicator will illuminate, and then turn OFF after the
bulb check is complete. The inflatable restraintsensing
and diagnostic module (SDM) performs diagnostic tests
on the SIR system during the bulb check. if any
malfunction exists the inflatable restraint sensing and
diagnostic module will request the instrument cluster to
illuminate the air bag indicator steady, via serial data.
Ifa preexisting malfunction exists, the air bag indicator
will illuminate steady immediately after the ignition is
turned ON. Ifthe ignition 1 voltage is outside of the
normal operating voltage range of 9-16 V, the inflatable
restraint sensing and diagnostic module will command
the instrument cluster to illuminate the air bag indicator
ON, even with no DTCs present, and then disable all
deployment loops.
Diagnostic Aids
1 A DTC B1370 may set if the ignition 1 circuit is
outside the 9—16V range.
1 A flashing driver air bag indicator is displayed if
the inflatable restraint sensing and diagnostic .
module was programmed but did not fully
complete the programming. For a flashing driver
airbag indicator, refer to Inflatable Restraint
Sensing and Diagnostic Module Programming and
Setup on page 6—10.
Reference Information
Schematic Reference
SIR Schematics on page 13—69
Connector End View Reference
Component Connector End Views on page 11-269
Supplemental Inflatable Restraint System Description
and Operation on page 13—145
Electrical Information Reference
1 Circuit Testing on page 11-526
1 Testing for IntermittentConditions and Poor
Connections on page 115’31
1 Connector Repairs on page 11—548
1 Wiring Repairs on page 11-537
Scan Tool Reference
Control Module References on page 6-3 for scan tool
information
CircuitlSystem Verification
1. Verify the test lamp turns ON and OFF when
commanding the Passenger Seat Belt Reminder
Indicator ON and OFF with a scan tool.
:> If the air bag indicator does not turn ON or OFF
Replace the P16 InstrumentCluster.
U If the air bag indicator does turn ON or OFF
2. Replace the K36 inflatable restraint sensing and
diagnostic module.
Repair Instructions
Perform the Diagnostic Repair Verification on
page 6—92after completing the repair.
1 SlR/SRS Wiring Repairs on page 11—548
1 Control Module References on page 6-3 for
InstrumentCluster or inflatable restraint sensing
and diagnostic module replacement, programming
and setup

Air Bag Indicator Circuit Malfunction (Passenger)

Diagnostic Instructions
1 Perform the Diagnostic System Check - Vehicle
on page 6—66prior to using this diagnostic
procedure.
1 Review Strategy Based Diagnosis on page 6-58
for an overview of the diagnostic approach.
1 Diagnostic Procedure Instructions on page 6-59
provides an overview of each diagnostic category.
Diagnostic Fault Information
Open/High Signal
Circuit Short to Ground Resistance Short to Voltage Performance
PassengerAir Bag OFF IndicatorControl 2 2* 4 ~-
PassengerAir Bag ON IndicatorControl 3 3* 5 -
PassengerAir Bag DisableIndicatorGround — 1 1 -
1. BothindicatorsalwaysOFF
2. The OFF indicatorwill notilluminate
3. The ON indicatorwillnotilluminate
4. The OFF indictoralwaysON
5.The ON indicatoralwaysON
*Highresistancemaycausetheappropriateindicatorto illuminateless brightthannormal

—
2013 (US/Canada)
Sonic (5377994)
Manual
Service

Description
CircuitlSystem
The passenger air bag ON/OFF indicators are used to
notify the driver when the passenger presence system
has enabled or disabled the passenger instrument
panel air bag. When the ignition is turned ON, the
ignition voltage is supplied to the passenger presence
module. When the Inflatable Restraint Sensing and
Diagnostic Module receives the appropriate serial data
message from the passenger presence module the
inflatable Restraint Sensing and Diagnostic Module will
then provide voltage to the appropriate indicator.
Reference Information
Schematic Reference
SIR Schematics on page 13-69
Connector End View Reference
Component Connector End Views on page 11-269
Description and Operation
Supplemental Inflatable Restraint System Description
and Operation on page 13-145
Electrical Information Reference
1 Circuit Testing on page 11-526
1 Connector Repairs on page 11-548
1 Testing for IntermittentConditions and Poor
Connections on page 11-531
1 Wiring Repairs on page 11-537
Scan Tool Reference
Control Module References on page 6-3 for scan tool
information
Verification
CircuitlSystem
1. lgnition ON.
2. Verify no other Inflatable Restraint Sensing and
Diagnostic Module DTCs are set.
=>If other Inflatable Restraint Sensing and
Diagnostic Module DTCs are set
Diagnose those DTCs first. Refer to Diagnostic
Trouble Code (DTC) List - Vehicle on page 6—69
U If no other Inflatable Restraint Sensing and
Diagnostic Module DTCs are set
3. Verify the passenger air bag ON indicator and
passenger air bag OFF indicators turn ON and
OFF when commanded ON and OFF with a
scan tool.
=>If the passenger air bag indicators do not
change
Refer to CircuitlSystem Testing
ii If the passenger air bag indicators change
4. All OK.
(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
Supplemental inflatable Restraints 13-111
CircuitlSystem Testing
Note: When removing connectors inspect for damage
or corrosion. Damage or corrosion in the following
requires repair or replacement of the affected:
1 Passenger air bag disable on/off indicator.
1 Passenger air bag disable on/off indicator wiring
harness.
1. lgnition OFF, discOnnect the harness connector at
the P14 Passenger Air Bag Disable Indicator.
2. Test for less than 10 0 between the ground circuit
terminal 4 and ground.
=>If 10 Q or greater
2.1. Test for less than 2 Q in the ground circuit end
to end.
2>If2 Q or greater, repair the open/high resistance
in the circuit.
=>Ifless than 2 Q, repair the open/high resistance
in the ground connection.
it If less than 10 Q
3. lgnition ON, command the passenger air bag OFF
indictor OFF with a scan tool.
4. Test for less than 11V between the control circuit
terminal 5 and ground.
=>If 11V or greater
4.1. lgnition OFF, disconnect the X1 harness
connector at the K36 Inflatable Restraint
Sensing and Diagnostic Module. lgnition ON.
4.2. Test for less than 1 V between the control
circuit and ground.
=>lf1 V or greater, repair the short to voltage on
the circuit.
=>If less than 1 V, replace the K36 inflatable
Restraint Sensing and Diagnostic Module.
U If less than 11 V
5. Command the passenger air bag OFF indicator ON
with a scan tool.
6. Test for greater than 4 V between the control circuit
terminal 5 and ground.
:> If 4 V or less
6.1. lgnition OFF, disconnect the X1 harness
connector at the K36 Inflatable Restraint
Sensing and Diagnostic Module.
6.2. Test for infinite resistance between the control
circuit and ground.
=>Ifless than infinite resistance, repair the short to
ground on the circuit.
6.3. Test for less than 2 Q in each control circuit
end to end.
=>lf 2 Q or greater, repair the open/high resistance
in the circuit.
:> Ifless than 2 Q, replace the K36 inflatable
Restraint Sensing and Diagnostic Module.
13-112 Supplemental inflatable Restraints
ii If greater than 4 V
7. Command the passenger air bag ON indicator OFF
with a scan tool.
8. Test for less than 11V between the control circuit
terminal 2 and ground.
:> If 11 Vor greater
8.1. lgnition OFF, disconnect the X1 harness
connector at the K36 Inflatable Restraint
Sensing and Diagnostic Module. lgnition ON.
8.2. Test for less than 1 V between the control
circuit and ground.
=>lf1 V or greater, repair the short to voltage on
the circuit.
=>Ifless than 1 V, replace the K36 Inflatable
Restraint Sensing and Diagnostic Module.
ii If less than 11V
9. Command the passenger air bag ON indicator ON
with a scan tool.
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 Supplemental
Inflatable Restraint System Description and Operation
on page 153-145.
Condition
Ifthevehiclewas involvedin an accidentwithan air bag
deployment.
WhenperformingSIR diagnostics.
Whenmoving,removingor replacingan SIR componentora
componentattachedto an SIR component.(Anytimeyou
removefasteners.)
Ifthevehicleis suspectedof havingshortedelectricalwires. Disconnectthenegativebatterycab|e(s)*
Whenperformingelectricaldiagnosisoncomponentsother
thantheSIR system.
*DTCs willbe lostwhenthenegativebatterycableis disconnected.
10. Test for greater than 4 V between the control circuit
terminal 2 and ground.
=>|f4Vor less
10.1. IgnitionOFF, disconnect the X1 harness
connector at the K36 Inflatable Restraint
Sensing and Diagnostic Module.
10.2. Test for infinite resistance between the
control circuit and ground.
=>If less than infinite resistance, repair the shortto
ground on the circuit.
10.3. Test for less than 2 Q in each control circuit
end to end.
=>If2 Q or greater, repair the open/high resistance
in the circuit.
:> If less than 2 Q, replace the K36 Inflatable
Restraint Sensing and Diagnostic Module.
U If greater than 4 V
11. Replace the P14 PassengerAir Bag Disable
Indicator.
Repair Instructions
Perform the Diagnostic Repair Verification on
page 6—92after completing the repair.
1 InstrumentPanel Airbag Arming Status Display
Replacement on page 153—128
1 Control Module References on page 6-3 for K36
Inflatable Restraint Sensing and Diagnostic
Module replacement, programming and setup
There are several reasons for disabling the SIR system,
such as repairs to the SIR system or sewicing 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 informationcovers the proper procedures
for disabling/enabling the SIR system.
Action
Disconnectthenegativebatterycable(s)*.Referto Repairs
andInspectionsRequiredAftera Collisiononpage 13-134.
FollowtheappropriateSIR servicemanualdiagnostic
procedure(s)*
Disconnectthenegativebatterycab|e(s)*
RemovetheSlR/Airbagfuse(s)whenindicatedbythe
diagnosticprocedureto disabletheSIR system
2013
-Sonic
(US/Canada)
Service
Manual
(5377994)

SIR Service Precautions
Warning: 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 Inflatable Restraint Sensing
and Diagnostic Module loses battery power during a
collision. Deployment power is available for as much as
2 minutes after disconnecting the vehicle power.
Waiting 2 minutes 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:
1 Do not expose air bags to temperatures above
65°C (149°F).
1 Verify the correct replacement part number. Do not
substitute a component from a different vehicle.
1 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 92 cm (3feet) or greater:
1 Inflatable Restraint Sensing and Diagnostic
Module (SDM)
1 Any air bag
1 Driver steering wheel air bag coil
1 Any impact sensor
1 Seat belt anchor and/or retractor pretensioners
1 Passenger presence module andlor occupant
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.
Warning: 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 SlR system
malfunction.
3. Locate and remove the fuse(s) supplying power to
the Inflatable Restraint Sensing and Diagnostic
Module. Refer to SIR Schematics on page 13-69 or
Electrical Center Identification Views on
page 11—240.
4. Wait 2 minutes before working on the system.
(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
Supplemental inflatable Restraints 113-113
Enabling Procedure —Air Bag Fuse
1. Place the ignition in the OFF position.
2. install the fuse(s) supplying power to the inflatable
Restraint Sensing and Diagnostic Module. Refer to
SIR Schematics on page 13—69or Electrical Center
Identification Views on page 11-240.
3. Turn the ignition switch to the ON position. The AIR
BAG indicator will illuminate or 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 on page 6-66.
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 on page 9-713.
4. Wait 2 minutes 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 on page 9-713.
3. Turn the ignition switch to the ON position. The AIR
BAG indicator will illuminate or 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 on page 6-66.
Repair Instructions
SIR Service Precautions
General Service Instructions
Warning: When performing service on or near the
SIR components or the SIR wiring, the SIR system
must be disabled. Refer to SIR Disabling and
Enabling. Failure to observe the correct procedure
could cause deployment of the SIR components,
personal injury, or unnecessary SIR system repairs.
Note: The Inflatable Restraint Sensing and Diagnostic
Module (SDM) maintains a reserved energy supply.
The reserved energy supply provides deployment
power for the SIR air bags. Deployment power may be
available for up to 2 minutes after disconnecting the
vehicle power. Disabling the SIR system prevents
deployment of the SIR air bags from the reserved
energy supply.
'l3-‘l’l4 Supplemental inflatable Restraints

Note: The following are general service instructions
which must be followed in order to properly repair the
vehicle and return it to its original integrity:
1 Do not expose air bags to temperatures above
65°C (149°F)
1 Verify the correct replacement part number. Do not
substitute a component from a differentvehicle
1 Use only original GM replacement parts available
from your authorized GM dealer. Do not use
salvaged parts for repairs to the SIR system
Note: Discard any of the following components if it has
been dropped from a height of 92 cm (3ft) or greater:
Inflatable Restraint Sensing and Diagnostic
Module
. Passenger instrument panel air bag
. Driver steering wheel air bag
Driver steering wheel air bag coil
Roof rail air bags
' Front and /or side impact sensors
Seat belt achor andlor retractor pretensioners
Front seat side air bag

Inflatable Restraint Remote Impact Sensor Replacement

2675751

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Supplemental inflatable Restraints 13-115

Inflatable Restraint Remote Impact Sensor Replacement

Callout l Component Name

theSIR system must be disabled.
Warning: Whenperforming service on or near the SIR components or the SIR wiring,could cause deploymentof the SIR
Refer to SIR Disabling and Enabling. Failure to observe the correct procedure
components,personal injury,or unnecessary SIR system repairs.
applying power to theSIS make
Warning: Do not strike orjolt theinflatable restraintside impact sensor (SIS).Before
procedures could cause SIR deployment,
sure thatit is securely fastened.Failure to observe thecorrect installation
personal injury,or unnecessary SIR system repairs.
Preliminary Procedures
Enablingon page 113-112.
1. Disablethesupplementalinflatablerestraint(SIR)system.Referto SIR Disablingand
o npage 2-67.
2. Removefrontsidedoortrimpanel.Referto FrontSide Door TrimReplacement
InflatableRestraintRemoteImpactSensor Assembly
Caution: Referto FastenerCautionon page 0—8.
Procedure
1 1. Loosenthefastenerand slidethe sensoroutof keyholeslot.
2. Theboltis integralto thesensorassembly,DO NOTremoveseparately.
3. Disconnectthe electricalconnector.
Tighten
7.5N1m(66lb in)

Inflatable Restraint Discriminating Sensor Replacement

Front End

1: illilr'mw:
, . ,,/,1~1_$\
4J Mr
WW
I"I ‘
4"“. ‘ -f
.
\

2675623

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
13-116 Supplemental inflatable Restraints

Front End inflatable Restraint Discriminating Sensor Replacement

Callout I Component Name
Warning: Refer to SIR Warningon page 0-7.
Warning: Refer to SIR InflatorModule Handling and Storage Warningon page 0-6.
Warning: Following thedeploymentof a side impact air bag, inspect the followingparts for damage.Replace these
parts if necessary:
1 Theseat cushion frame
1 Theseat recliner;if equipped
1 Theseat adjuster
1 Theseat back frame
Failure to do so may cause futurepersonal injury.
Preliminary Procedures
1. Disablethesupplementalinflatablerestraint(SIR)system.Referto SIR DisablingandEnablingonpage 13-112.
2. Ifreplacingtheleftsidesensor,repositionthesurgetankwithoutdrainingthecoolant.Referto RadiatorSurgeTank
Replacementonpage9—630. 1
FrontEnd InflatableRestraintDiscriminatingSensorAssembly(Qty:2)
Caution: RefertoFastenerCautiononpage0-8.
Procedure
1 1. Disconnectelectricalconnector.
2. Loosentheboltsandslide thesensoroutofthekeyholeslots.
3. The boltsare integraltothesensorassemblyandDO NOTremoveseparately.
Tighten
7.5N1m(66lb in)

Airbag Side Impact Sensor Replacement (with AYFIAYO)

_.
,hm
WM

2509433

2013
—
Sonic
(US/Canada)
Service
Manual
(5377994)
 Supplemental inflatable Restraints 13-117

Airbag Side Impact Sensor Replacement (with AYFIAYO)

Callout l Component Name
Warning: Refer to SIR Warningon page 0-7.
Warning: Refer to SIR InflatorModule Handling and Storage Warningon page 0-6.
these
Warning: Following thedeployment of a side impact air bag,inspect thefollowing parts for damage.Replace
parts if necessary:
1 Theseat cushion frame
1 Theseat recliner,if equipped
1 Theseat adjuster
1 Theseat back frame
Failure to do so may cause futurepersonal injury.
Preliminary Procedures
1. Disable.theSIR system.Referto SIR Disablingand Enablingonpage 13-112.
2-76.
2. Removethecenterpillarlowertrimpanel.Referto CenterPillar LowerTrimPanel Replacementonpage
InflatableRestraintSide ImpactSensorAssembly
Caution: Referto FastenerCautiononpage0-8.
Procedure
1 1. Disconnectelectricalconnector.
2. Loosenthefastenersand slidethesensoroutofthe keyholeslots.
3. Theboltsare integraltothesensorassembly,DO NOT removeseparately.
Tighten
7.5N1m(66lb in)

Airbag Sensing and Diagnostic Module Replacement

2509560

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
13-118 Supplemental inflatable Restraints

Airbag Sensing and Diagnostic Module Replacement

Callout I Component Name
Warning: Refer to SIR Warningon page 0-7.
Warning: Do not strike orjolt theinflatablerestraintsensing and diagnostic module (SDM).Before applyingpower to
the SDM,make sure thatit is securely fastened with the arrowfacing towardthe front of thevehicle. Failure to observe
the correct installation procedure could cause SIR deployment,personal injury,or unnecessary SIR system repairs.
Preliminary Procedures
1. Disablethesupplementalinflatablerestraint(SIR)system.Referto SIR DisablingandEnablingonpage 113-112.
2. Removethefrontfloorconsoleextension.Referto FrontFloorConsoleExtensionReplacement—LeftSide onpage2-60or
FrontFloor ConsoleExtensionReplacement-RightSide onpage2-59.
3. Disconnecttheelectricalconnector.
inflatableRestraintSensingandDiagnosticModuleFastener(Qty:3)
Caution: Referto FastenerCautiononpage0-8.
Tighten
10N1m(89lbin)
inflatableRestraintSensingandDiagnosticModuleAssembly
Tip:
1 Wheninstalling,ensurethearrowon themoduleis pointedtowardsthefrontofthevehicle.
1 Ifinstallinga replacementmodule,programthemodule.Referto ControlModuleReferencesonpage 6-3.

Airbag Steering Wheel Module

Replacement

Removal Procedure

2543255
Warning: Refer to SIR Inflator Module Handling and
Storage Warning on page 0-6.
Warning: Refer to SIR Warning on page 0-7.
2543256
3. Using a qunt-ended tool, push the spring fastener
inward through the access hole (1) located on the
rear of the steering wheel by pulling the tool
outwards.
4. Keeping the tool inserted, repeat the step for other
opening.
5. Keeping the upper step pull the steering wheel
waggable restraint module out of the steering

1. Disable the SIR system. Refer to SIR Disabling 6, Disconnect the electrical connectors.
and Enabl/ng 0” page 13‘772' 7. Remove the steering wheel inflatable restraint
2. Rotate the steering wheel 180 degrees. module,

—
2013 (US/Canada)
Sonic (5377994)
Manual
Service
 Supplemental inflatable Restraints 13=119

Installation Procedure 2. Align the steering wheel module fasteners to the

steering column fastener holes.
1. Connect the electrical connectors.
3. Push the steering wheel module (1) firmly into the
steering column in order to engage the fasteners.
4. Enable the SIR system. Refer to SIR Disabling and
Enabling on page 13-112.
After replacing the module, fully deploy the module
before disposal. Ifthe module was replaced under
warranty,fully deploy and dispose of the module
after the required retention period. Refer to
Inflatable Restraint Module Handling and
Scrapping on page 13-135.

2543263

Steering Wheel Airbag Coil Replacement

2019039

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
'l 3-120 Supplemental inflatable Restraints

Steering Wheel Airbag Coil Replacement

Callout l Component Name
Preliminary Procedures
1. Removethesteeringwheel.Referto SteeringWheelReplacementonpage 15-32.
2. Removethesteeringcolumnuppertrimcover.Referto SteeringColumnUpperTrimCoverReplacementonpage 15—28.
3. Removethesteeringcolumnlowertrimcover.Referto SteeringColumnLowerTrimCoverReplacementonpage 15—29.
SteeringWheelinflatableRestraintModuleCoil Bolt(Qty:4)
1
Caution: Referto FastenerCautiononpage 0-8.
SteeringWheelinflatableRestraintModuleCoil
Procedure
1. Disconnectanyelectricalconnectorsas necessary.
Use tapein ordertosecuretheoldcoil in thecenterposition.
Removetheold coilfromthesteeringcolumn.
Transferthesteeringanglesensor.Referto SteeringAngle SensorReplacementonpage 15—36.
WPPN
Ensurethecoil is centeredduringinstallation.Ifyouare installinga NEW coil,ensurethecenteringtabis on
thecoil.Ifthecoil is notcentered,refertoAirbagSteeringWheelModuleCoil Centeringonpage 13-120.

Airbag Steering Wheel Module Coil

Centering
Note: Ifa double wire harness strap is installed onto
the wire harness assembly and steering column, the
original holder for the wire strap(s) MUST be reused
during installation.
1. Remove the wire harness strap(s) where
necessary.

2912544
3. Ifthe coil needs to be centered, perform the
following preliminary steps:
1 The wheels on the vehicle are straight ahead.
1 The block tooth (1)on the steering shaft is in
the 12 o'clock position.
1 The ignition switch is in the LOCK position.

2912546
Caution: The new SIR coil assembly will be centered.
improper alignment of the SIR coil assembly may
damage the unit, causing an inflatable restraint
malfunction.
2. Inspect the inflatable restraint steering wheel
module coil. lfthe yellow lock pin (1) is present, the
uplead post (2)is at the 12:00 position and the loop
(u—turn) appears in the centering window (3)then
the coil is already in the centered position and no
further action is required.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Supplemental inflatable Restraints 131-121
4. To center the coil, perform the following steps:
1 Hold the coil with the face up.
1 Slowly rotate the coil hub clockwise until the coil
ribbon stops.
1 Slowly rotate the coil hub counterclockwise
approximately 2.5 turns until the uplead post (2)
is at the 12:00 position.
1 View the centering window (3)and ensure the
loop (u-tum)is visible. Ifthe loop is visible then
the coil is in the CENTER position.
1 While holding the coil hub in the CENTER
position, align the coil with the steering column
components and slide onto the steering shaft.
5. Ifa double wire harness strap is installed onto the
wire harness assembly and steering column, the
wires must be routed up against the column. One
wire harness strap will surround one lead from the
coil to the steering column. The other wire harness
strap will surround all other leads to the steering
column.
2912546

Airbag Instrument Panel Module Replacement

2511217

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
13-122 Supplemental inflatable Restraints

Airbag Instrument Panel Module Replacement

Callout l Component Name
Warning: Refer to SIR InflatorModule Handling and Storage Warningon page 0-6.
Warning: Refer to SIR Warningon page 0-7.
Preliminary Procedure
1. DisabletheSlR system.Referto SIR DisablingandEnablingonpage 13-112.
2. Removetheinstrumentpaneluppertrimpanelassembly—rightside. Referto Instrument Panel UpperTrimPanel
Replacement-RightSide onpage2-34.
InstrumentPanel InflatableRestraintModuleAssembly
Procedure
1 1. Ensurethattheinstrumentpanelinflatablerestraintmoduleis fullydeployedbeforedisposal.lfthe module
was replacedunderwarranty,fullydeployanddisposeofthemoduleaftertherequiredretentionperiod.
Referto InflatableRestraintModuleHandlingandScrappingonpage 13-135.
2. EnabletheSIR system.Referto SIR DisablingandEnablingonpage 13-112.

Instrument Panel Lower Airbag Replacement - Driver Side

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4; Q‘ g. ~1-
/ \

2676834

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Supplemental inflatable Restraints 13-123

Instrument Panel Lower Airbag Replacement - Driver Side

Callout ' Component Name
Warning: Refer to SlR InflatorModule Handling and Storage Warningon page 0-6.
Warning: Refer to SIR Warningon page 0-7.
Preliminary Procedure
1. DisabletheSIR system.Referto SIR DisablingandEnablingonpage 153-112.
2. Removetheinstrumentpanellowertrimpadcover.Referto InstrumentPanel LowerTrimPad CoverReplacement(Without
AAL) onpage2-40or InstrumentPanel LowerTrimPad CoverReplacement(WithAAL) onpage 2-41.
Instrument Panel LowerAirbag Fastener(Qty:2)
Caution: Referto FastenerCautiononpage 0—8.
1 Tighten
9 N-m(80lbin)
InflatableRestraintInstrumentPanel LowerModuleAssembly—DriverSide
Procedure
2 1. Ensurethatthe instrumentpanelinflatablerestraintmoduleis fullydeployedbeforedisposal.Ifthemodule
wasreplacedunderwarranty, fullydeployand disposeofthe moduleafterthe requiredretentionperiod.
Referto InflatableRestraintModuleHandlingand Scrappingonpage 13-135.
2. EnabletheSIR system.Referto SIR DisablingandEnablingonpage 153-112.

Instrument Panel Lower Airbag Replacement - Passenger Side

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-411 M‘_// A77 E

2676838

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
113-124 Suppiemental inflatable Restraints

Instrument Panel Lower Airbag Replacement - Passenger Side

Callout l Component Name
Warning: Refer to SIR InflatorModule Handling and Storage Warningon page 0-6.
Warning: Refer to SIR Warningon page 0-7.
Preliminary Procedure
1. DisabletheSlR system.Referto SIR DisablingandEnablingonpage 13-112.
2. Removetheinstrumentpanellowercompartment. Referto InstrumentPanel LowerCompartmentReplacementon
page 2-44.
instrumentPanel CompartmentReinforcementFastener(Qty:3)
1
Caution: RefertoFastenerCautiononpage 0-8.
InstrumentPanel LowerAirbagFastener(Qty:2)
2 Tighten
9 N1m(80lb in)
InflatableRestraintInstrumentPanelLowerModuleReplacement—PassengerSide
Procedure
3 1. Ensurethattheinstrumentpanelinflatablerestraintmoduleis fullydeployedbeforedisposal.Ifthemodule
was replacedunderwarranty,fullydeployanddisposeof themoduleaftertherequiredretentionperiod.
Referto InflatableRestraintModuleHandlingandScrappingonpage 153-135.
2. EnabletheSIR system.Referto SIR DisablingandEnablingonpage 13-112.

Airbag Front Passenger Presence Sensor Replacement

1986699

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 Supplemental inflatable Restraints 13-125

Airbag Front Passenger Presence Sensor Replacement

Callout I Component Name
Warning: Replace thepassenger presence system as a completeassembly toprevent possible injury to the occupant.
All thecomponents in theservice kit are assembled and calibrated as a unit. Using only some of the components in the
service kit will cause thepassenger presence system to operateimproperly.
Warning: Toavoid personal injury,perform a preload test on thepassenger presence system wheneveryou remove or
replace theseat cushion trim.Failure to do so may cause thesystem to malfunction.
Preliminary Procedure
1. Removethefrontpassengerseat.Referto Driveror PassengerSeat Removaland Installationonpage 14-4.
2. Removethefrontseatcushioncover andpad.Referto FrontSeat CushionCoverand Pad Replacementonpage 14-14.
PassengerSeat CushionHeater(ifequipped)
Procedure
1 1. Disconnecttheelectricalconnector.
2. Ifeitherthe seat cushionheateror oneofthe componentsof thepassengerpresencesystemneed
replacement,boththeseat cushionheaterandthecompletepassengerpresencekitmustbe replaced.
InflatableRestraintPassengerPresenceSystem
Procedures
1. Re-zerothe inflatablerestraintpassengerpresencesystemwhenevertheseatcushionor anycomponent
ofthepassengerpresencesystemis removed.Referto ControlModuleReferencesonpage 6-3.
2 2. Programtheinflatablerestraintpassengerpresencesystemafterreplacement.Referto ControlModule
Referencesonpage 6-3.
Tip:
1 Thepassengerpresencesystemis an integralpartofthepad onthepassengerseatcushion.
1 Thesensor,moduleandseatcushionpadmustbe replacedas a unit.
1 Notetheroutingof thewiringharnessandconnectorlocationforinstallation.

Front Seat Outboard Seat Back Airbag Replacement

2541050

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13-126 Supplemental inflatable Restraints

Front Seat Outboard Seat Back Airbag Replacement

Callout I Component Name
Warning: Following thedeploymentof a side impact air bag, inspect the followingparts for damage.Replace these
parts if necessary:
1 Theseat cushion frame
1 Theseat recliner, if equipped
1 Theseat adjuster
1 Theseat back frame
Failure to do so may cause futurepersonal injury.
Warning: Do not repair or replace theseat stitching or seams in theseat back trim cover with an internal mountedseat
side airbag module.Replace thecompleteseat back trimcover from the OEM.Non-OEMseat stitching may cause
improper airbag deploymentwhich could result in personal injury.
Preliminary Procedure
1. DisabletheSIR system.Referto SIR DisablingandEnablingonpage 13-112.
2. Removethedriveror passengerseat.Referto DriverorPassengerSeatRemovalandInstallationonpage 14-4.
3. Removethedriveror passengerseatbackcushioncoverandpad.Referto Driveror PassengerSeatBack CoverandPad
Replacementonpage 14—15.
Seat Side InflatableRestraintModuleNut(Qty:2)
Caution: RefertoFastenerCautiononpage0-8
1 Tighten
4 N1m(35lbin)
Driveror PassengerSeatSide inflatableRestraintModule
Procedure
1. Disconnecttheelectricalconnector.
2 2. Removetheseatside inflatablerestraintmodule.
3. Fullydeploythemodulebeforedisposal.if themodulewas replacedunderwarranty,fullydeployand
disposeofthemoduleaftertherequiredretentionperiod.Referto InflatableRestraintModuleHandlingand
Scrappingonpage 13-135.

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 Supplemental inflatable Restraints 113-127

Rear Seat Outboard Seat Back Airbag Replacement

\«Mr
1‘A

2668177

Rear Seat Outboard Seat Back Airbag Replacement

Callout Component Name
Warning: Following thedeploymentof a rear seat side air bag, inspect the following parts for damage.Replace these
parts if necessary:
1 Therear seat side bolster, attachments,brackets and wiring
1 Therear seat back frame,cushion and cover
1 Therear seat cushion frame,cushion and cover
Failure to do so may cause futurepersonal injury.
PreliminaryProcedures
1. DisabletheSIR system,if equipped.Referto SIR DisablingandEnablingonpage 113-112.
2. Removetherearseatback cushionbolster.Referto Rear SeatBack BolsterReplacementonpage 14-21.
RearSeatSide InflatableRestraintModuleBracketBolt(Qty:4)
Caution: Referto FastenerCautiononpage0—8.
Tighten
3.5N1m(31lb in)
RearSeatSide inflatableRestraintModuleNut(Qty:2)
Caution: Referto FastenerCautiononpage 0—8.
Tighten
3.5N1m(31lb in)
3 RearSeatSide inflatableRestraintModuleBracket

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113-128 Supplemental inflatable Restraints

Rear Seat Outboard Seat Back Airbag Replacement (cont'd) Fh\'

,
Callout Component Name
RearSeatSide inflatableRestraintModule
Procedure
1. Removetheconnectorpositionassurance(CPA)fromthemoduleelectricalconnector.
2. Disconnecttheelectricalconnector.
3. Slideairbagoutofairbagchute.
4. installseatsideairbagintoairbagchutewithconnectorfacingdown.Airbagmountingstudsmustfitthrough
airbagchuteholesandthenintothe modulebracket.
5. Ifthemodulewas replacedunderwarranty,fullydeployanddisposeofthe moduleaftertherequired
retentionperiod.Referto InflatableRestraintModuleHandlingandScrappingon page 113-135.

Instrument Panel Airbag Arming Status Display Replacement

m.
\\\\\\\\\\\\\
,

2908565

Instrument Panel Airbag Arming Status Display Replacement

Callout I Component Name
Preliminary Procedure
Removetheheaterandairconditioningcontrol.Referto HeaterandAir ConditioningControlReplacementonpage 10-79.
1 instrumentClusterDisplaySwitchFastener(Qty:2)
Caution: RefertoFastenerCautiononpage 0-8.
InflatableRestraintInstrumentPanel ModuleIndicator
2 Procedure
Disconnecttheelectricalconnector.

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 Supplemental inflatable Restraints ‘l3-129

Airbag Roof Side Rail Module Replacement - Rear

41 2 3 2

2675863

Airbag Roof Side Rail Module Replacement - Rear

Callout Component Name
Warning: Inorder to prevent SIR deployment,personal injury,or unnecessary SIR system repairs, do not strike the
door or the doorpillar in the area of theside impact sensor (SIS).Turn OFF theignition and remove thekey when
performing service in the area of the SIS.
Warning: Wheninstalling theroof rail airbag,do not twist or turn the airbag 360degrees. Securing theroof rail airbag
with an airbag twistedor turned360degrees may cause theairbag not to deploy correctly and could cause personal
injury.
Warning: Refer to SIR Warningon page 0-7.
Warning: Referto SIR InflatorModule Handling and Storage Warningon page 0-6.
Preliminary Procedures
1. DisabletheSIR system.Referto SIR DisablingandEnablingonpage 13-112
2. it is onlynecessaryto lowertheheadliner.Onlydo thosestepsin headlinerreplacementthatwilllowerthe headliner
enoughtogain access to thepart.Referto HeadliningTrimPanel Replacement(SedanwithSunroof)onpage2—26 or
HeadliningTrimPanel Replacement(HatchbackwithSunroof)onpage2-24or HeadliningTrimPanel Replacement
(HatchbackwithoutSunroof)onpage 2—25 or HeadliningTrimPanel Replacement(SedanwithoutSunroof)onpage 2—27
1 inflatableRestraintRoofSide Rail ModuleRetainer
InflatableRestraintRoofSide Rail ModuleFastener(Qty:4)
Caution: Referto FastenerCautionon page0—8.
Tighten
9.5N1m(84lbin)

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'13-130 Supplemental inflatable Restraints

Airbag Roof Side Rail Module Replacement - Rear (cont'd)

Callout Component Name
InflatableRestraintRoofSide Rail ModuleAssembly
Procedure
1. Disconnecttheelectricalconnector.
2. Releasetheintegralroofside railmoduleretainers.
3. Removetheroofside railinflatablerestraintmodulefromthevehicle.
4. Fullydeploythemodulebeforedisposal.Ifthemodulewas replacedunderwarranty,fullydeployand
disposeof themoduleaftertherequiredretentionperiod.Referto InflatableRestraintModuleHandlingand
Scrappingonpage 153-135.

Front Seat Belt Anchor Plate Tensioner Replacement

2510031
Front Seat Belt Anchor Plate Tensioner Replacement
Callout Component Name
Warning: Refer to SIR Warningon page 0-7.
Warning: In order to preventaccidental deploymentand therisk of personal injury,do not dispose of an undeployed
inflatablerestraintseat beltpretensioner as normal shop waste.Undeployedseat belt pretensioners contain
substances thatcould cause severe illness or personal injury if their sealed containers are damagedduring disposal.
Use the following deploymentprocedures to safely dispose of an undeployedseat belt pretensioner.Failure to observe
the following disposal methodsmay be a violation of federal,state,or local laws.
Preliminary Procedures
1. Movethefrontseattothefullforwardandfullupposition.
2. DisabletheSIR. Referto SIR DisablingandEnablingonpage 113-112.
3. Forpretensionerhandlingandscrapping.Referto PretensionerHand/ing
and Scrappingonpage 13—142.

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 Supplemental inflatable Restraints '13-131

Front Seat Belt Anchor Plate Tensioner Replacement (cont'd)

~\W‘_//
Callout Component Name
1 Driveror PassengerSeat BeltTensionerCover
Driveror PassengerSeat BeltTensionerCover Fastener
Caution: RefertoFastenerCautiononpage 0-8
Tighten
7.5N1m(66lb in)
Driveror PassengerSeat BeltTensionerCover
Driveror PassengerSeat BeltTensionerSeat BeltLatch
Procedure
Removetheseatbeltwithlatchfromfrontseatbelttensioner.
Driveror PassengerSeat BeltTensionerFastener
Tighten
45N1m(33lbft)
Driveror PassengerSeat BeltTensionerAssembly
Procedure
Disconnectthe electricalconnector.

Driver or Passenger Seat Shoulder Belt Replacement (without A69)

.Wwfiw
m2
1»2.

2510127

“s_rs‘fl,
2..
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Manual
13-132 Supplemental inflatable Restraints

Driver or Passenger Seat Shoulder Belt Replacement (without A69)

Callout I Component Name
Warning: Refer to SIR Warningon page 0-7.
Warning: Refer to SIR Seatbelt PretensionerHandling Warningon page 0-6.
Warning: In order to prevent accidental deploymentand therisk of personal injury,do not dispose of an undeployed
inflatablerestraintseat belt pretensioner as normal shop waste.Undeployedseat belt pretensioners contain
substances thatcould cause severe illness or personal injury if theirsealed containers are damagedduring disposal.
Use thefollowing deploymentprocedures to safely dispose of an undeployedseat beltpretensioner:Failure to observe
the following disposal methods may be a violation of federal,state,or local laws.
Preliminary Procedures
1. Removethecenterpillaruppertrimpanel.Referto CenterPillar UpperTrimPanel Replacementonpage2-75.
2. Removethefrontseatlowerfinishcover.Referto FrontSeatBeltAnchorPlate TensionerCoverReplacement(4Way)on
page 14-10.
FrontSeat BeltAnchorPlateFastener
Caution: Referto FastenerCautiononpage 0-8.
Tighten
8N1m(70lb in)
FrontSeat BeltRetractorD RingFastener
2 Tighten
45N1m(33lbft)
3 FrontSeatShoulderBeltGuideRetainer
FrontSeat ShoulderBeltRetractorFastener
4 Tighten
45N1m(33lbft)
5 FrontSeatShoulderBeltAssembly

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 Supplemental inflatable Restraints 13-133

Driver or Passenger Seat Shoulder Belt Replacement (with A69)

2510106

Driver or Passenger Seat Shoulder Belt Replacement (with A69)

Callout I Component Name
Warning: Refer to SIR Warningon page 0-7.
Warning: Refer to SIR InflatorModule Handling and Storage Warningon page 0-6.
Warning: Refer to SIR Seatbelt Pretensioner Handling Warningon page 0-6.
Warning: In order to preventaccidental deploymentand therisk of personal injury, do not dispose of an undeployed
inflatablerestraintseat belt pretensioner as normal shop waste. Undeployedseat belt pretensioners contain
substances thatcould cause severe illness or personal injury if theirsealed containers are damagedduring disposal.
Use thefollowing deploymentprocedures to safely dispose of an undeployedseat belt pretensioner.Failure to observe
thefollowing disposal methods may be a violation of federal,state, or local laws.
PreliminaryProcedures
1. Movethefrontseattoa fullforwardandfullupposition.
2. DisabletheSIR. Referto SIR DisablingandEnablingon page 13-112.
3. Removethecenterpillaruppertrimpanel.Referto CenterPillar UpperTrimPanel Replacementonpage 2—75.
1 Driveror PassengerSeat BeltTensionerCover
Driveror PassengerSeat BeltTensionerCover Fastener
Caution: Referto FastenerCautiononpage 0—8.
2
Tighten
7.5N1m(66lb in)
3 Driveror PassengerSeat BeltTensionerCover
Driveror PassengerSeat ShoulderBeltFastener
4 Tighten
45N1m(33lbft)

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13-134 Supplemental inflatable Restraints
Driver or Passenger Seat Shoulder Belt Replacement
Callout Component Name
Driveror PassengerShoulderBeltRetractorFastener
5 Tighten
45N1m(33lbft)
Driveror PassengerSeat BeltPushOn Retainer
6 Procedure
Use a flat-bladedtoolto removelockingpinin retainer.
Driveror PassengerSeat ShoulderBeltRetractorAssembly
Procedure
7 1. Disconnecttheelectricalconnector.
2. Fulldeploythemodulebeforedisposal.Ifthemodulewas replacedunderwarranty,fulldeployanddispose
ofthemoduleaftertherequiredretentionperiod.Referto PretensionerHandlingandScrappingon
page 113-142.
Repairs and Inspections Required
After a Collision
Accident With or Without Air Bag
Deployment — Component Inspections
Warning: Proper operation of the Supplemental
Inflatable Restraint (SIR) sensing system requires
that any repairs to the vehicle structure return the
vehicle structure to the original production
configuration. Not properly repairing the vehicle
structure could cause non-deployment of the air
bag(s) in a frontal collision or deployment of the air
bag(s) for conditions less severe than intended.
After any collision, inspect the following components as
indicated. Ifyou detect any damage, replace the
component. if you detect any damage to the mounting
points or mounting hardware, repairthe component or
replace the hardware as needed.
1 The steering column—Inspect the steering column
for bending, twisting, buckling or any type of
damage.
1 The instrument panel knee bolsters and mounting
points—lnspect the knee bolsters for bending,
twisting, buckling, or any other type of damage.
1 The instrument panel brackets, braces, etc.-
Inspect for bending, twisting, buckling, or any
other type of damage.
1 The seat belts—Perform the seat belt operational
and functional checks. Refer to Repairs and
Inspections Required After a Collision on
page 13-57.
1 The instrument panel cross car beam—Inspect for
bending, twisting, buckling, or any other type of
damage.
1 The instrument panel mounting points and
brackets—lnspect for bending, twisting, buckling,
or any other type of damage.
1 The seats and seat mounting points~—|nspectfor
bending, twisting, buckling, or any other type of
damage.
1 The roof and headliner mounting points.
1 The brake pedal —lnspectthe brake pedal for
bending, twisting, buckling or any type of damage.
(with A69) (cont'd)
Accident With Frontal Air Bag
Deployment — Component Replacement
and Inspections
After a collision involving air bag deployment, replace
the following components.
1 Driver Steering Wheel Air Bag
1 Passenger instrument panel air bag, if deployed
1 Inflatable Restraint Sensing and Diagnostic
Module (SDM), if the inflatable Restraint Sensing
and Diagnostic Module has set DTC 80052 and
will not clear
1 Front andlor Side Impact Sensors
1 Driver/Passenger Seat Side Air Bag, if deployed
1 Seat back cover if Side Seat Air Bag is deployed
1 Driver/Passenger Seat Belt Anchor andlor
Retractor Pretensioners
Perform additional inspections on the following
components.
1 Steering wheel air bag coil and the coil wiring
pigtaiI—lnspect for melting, scorching, or other
damage due to excessive heat.
1 Mounting points or mounting hardware for the
passenger instrument panel air bag, steering
wheel air bag, Inflatable Restraint Sensing and
Diagnostic Module, seat side air bag (if deployed)
and seat belt anchor andlor retractor
pretensioners—Inspect for any damage and repair
or replace each component as needed.
Accident With Side Seat Air Bag
Deployment — Component Replacement
and Inspections
After a collision involving driver/passenger side seat air
bag deployment, replace the following components.
1 Left/rightside impact sensors on the side of the
impact.
1 Left/rightroof rail air bag on the side of the impact.
1 Inflatable Restraint Sensing and Diagnostic
Module (SDM), if the Inflatable Restraint Sensing
and Diagnostic Module has set DTC 80052 and
will not clear.
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1 inflatable Restraint Seat Belt Anchor andlor
Retractor Pretensioner.
1 Driver or passenger seat back cushion cover
replacement.
_,___.,._“\
Warning: Do not repair or replace the seat stitching
or seams in the seat back trim cover with an
internal mounted seat side airbag module. Replace
the complete seat back trim cover from the OEM.
Non-OEM seat stitching may cause improper airbag
deployment which could result in personal injury.
Perform additional inspections on the following
components.
1 Mounting points or mounting hardware for the side
impact sensors, and driver/passenger side seat air
bags on the side of impact~|nspect for any
damage and repair or replace each component as
needed.
1 Mounting points, mounting hardware, headliner
and trim pieces for the left/rightroof rail air bag on
the side of impact—lnspect for any damage and
repair or replace each component as needed.
1 Mounting points or mounting hardware for the
Inflatable Restraint Sensing and Diagnostic
Module and seat belt anchor and/or retractor
pretensioners—lnspect for any damage and repair
or replace each component as needed.
1 The seat cushion frame
1 The seat recliner and cover, ifequipped
1 The seat adjuster
1 The seat back frame
1 Door trim assembly
1 Impacted seat cushion side covers and switches
Accident With Seat Belt Pretensioner
Deployment Only — Component
Replacement and Inspections
After a collision involving driver/passenger Seat Belt
Retractor or Anchor Pretensioner deployment, replace
the following components.
1 Driver and Passenger Inflatable restraint seat belt
anchor pretensioner and/or retractor pretensioner
1 Inflatable Restraint Sensing and Diagnostic
Module (SDM), if the Inflatable Restraint Sensing
and Diagnostic Module has set DTC 80052 and
will not clear
Perform additional inspections for any damage and
repair or replace each component as needed on the
following components.
1 Mounting points or mounting hardware for the
Inflatable Restraint Sensing and Diagnostic
Module
1 Mounting points or mounting hardware for the
Seat Belt Anchor Pretensioners
1 Mounting points or mounting hardware for the
Seat Belt Retractor Pretensioners
Impact Sensor Replacement Guidelines
The impact sensor replacement policy requires
replacing sensors in the area of the accident damage.
The area of accident damage is defined as the portion
of the vehicle which is crushed, bent, or damaged due
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Supplemental inflatable Restraints 13-135
to a collision. An example of this would be a moderate
collision where the front of the vehicle impacts a object.
if the vehicle has an impact sensor mounted forward of
the radiator, it must be replaced.
1 Replace the impact sensor whether or not the air
bags have deployed.
1 Replace the impact sensor even if it appears to be
undamaged.
Impactsensor damage which is not visible, such as
slight bending of the mounting bracket or cuts in the
wire insulation, can cause improper operation of the
SIR system. Do not try to determine whether the impact
sensor is undamaged, replace the impact sensor. Also,
if you follow a diagnostic trouble code (DTC) procedure
and a malfunctioning impact sensor is indicated,
replace the impact sensor.
Inflatable Restraint Module Handling
and Scrapping
Special Tools
1 EL—38826SIR Deployment Harness
1 EL-39401-B SlR Deployment Fixture
For equivalent regional tools, refer to Special Tools on
page 13-147.
Live and Undeployed Air Bag
Warning: Refer to SIR Inflator Module Handling and
Storage Warning on page 0-6.
Take special care when handling or storing an
undeployed air bag. An air bag deployment produces a
rapid generation of gas. This may cause the air bag,
or an object in front of the air bag, to project through the
air in the event of an unlikely deployment.
Dual Stage Air Bags
Dual stage air bags have two deployment stages.
Ifstage1 was used to deploy a dual stage air bag,
stage 2 may still be active. Therefore, a deployed dual
stage air bag must be treated as an active air bag.
Ifdisposal of a dual stage air bag is required, both
deployment loops must be energized to deploy the
air bag.
Procedure
Scrapping
During the course of a vehicle's useful life, certain
situations may arise which will require the disposal of a
live and undeployed air bag. Do NOT dispose a live
and undeployed air bag through normal disposal
channels until the air bag has been deployed.
Do not deploy the air bag in the following situations:
1 After replacement of an air bag under warranty-
the air bag may need to be returned undeployed to
the manufacturer.
1 Ifthe vehicle is the subject of a product liability
claim, related to the SIR system and is subject to a
preliminary investigation — do NOTalter the SIR
system in any manner.
1 Ifthe vehicle is involved in a campaign affecting
the air bags — follow the instructions in the
campaign service bulletin for proper SlR handling
procedures.
13-136 Supplemental lnflatable Restraints

Deployment Procedures 3. Clear a space on the ground about 1.85 m (6ft) in

diameter for deployment of the air bag or
Note: Some countries, states or localities may not deployment fixture. If possible, use a paved,
allow service deployment of air bags without special outdoor location free of activity. Otherwise, use a
permission or training. Local laws regarding deploying space free of activity on the shop floor. Ensure you
and scrapping of air bags/devices with pyrotechnics have sufficient ventilation.
must be followed.
4. Clear the area of loose or flammable objects.
You can deploy the air bag either inside or outside of Note: Dual stage deployments are only used in
the vehicle. The method used depends upon the final steering wheel and instrument panel air bags. Ifstage 1
disposition of the vehicle. Review the following was used to deploy a dual stage air bag, stage 2 may
procedures in order to determine which will work best in still be active. Ifdisposal of a dual stage air bag is
a given situation: required, both deployment loops must be energized to
Deployment Outside Vehicle —Steering Wheel Air deploy the air bag.
Bag, Instrument Panel Air Bag, and Roof Rail 5. Ifyou are deploying a steering wheel air bag, place
Air Bag the air bag in the center of the space with the vinyl
Deploy the air bag outside of the vehicle when the trim cover facing up and away from the surface.
vehicle will be returned to service. Situations that
require deployment outside of the vehicle include the
following:
1 Using the SIR diagnostics, you determine that the
air bag is malfunctioning.
1 The air bag is cosmetically damaged, scratched,
or ripped.
1 The air bag pigtail is damaged.
1 The air bag connector is damaged.
1 The air bag connector terminals are damaged.
Deployment and disposal of a malfunctioning air bag is
subject to any required retention period.
Warning: Refer to SIR Inflator Module Disposal
Warning on page 0-6.
1. Turn OFF the ignition.
Warning: Refer to SIR Inflator Module Handling and
Storage Warning on page 0-6.
2. Remove the air bag.

453892
6. When deploying an instrument panel air bag,
perform the following instructions:
<—1.85m (6ft) 6.1. Place the EL-39401-B fixture in the center of
the cleared area.
6.2. Fill the deployment fixture with water or sand.
6.3. Using the proper nuts and bolts, mount the
instrument panel air bag (1) to the deployment
fixture (2),with the vinyl trim facing up.
6.4. Securely tighten all fasteners that hold the
instrument panel air bag (1) to the deployment
fixture (2).

68646

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 Supplemental Inflatable Restraints 13-137
10. Connect the appropriate pigtail adapter (2) to the
SIR deployment harness (1).

816848
7. When deploying a roof rail air bag, perform the
following instructions: 68655
7.1. Place the EL-39401-B fixture (3) in the center
of the cleared area. 11. Extend the SIR deployment harness and adapter
to the full length from the deployment fixture
7.2. Fill the deployment fixture with water or sand or area.
to provide sufficient stabilization of fixture
during deployment.
7.3. Adjust and secure the fixture arms (4) to the
deployment fixture (3), using the proper nuts
and bolts.
7.4. Attach the roof rail air bag in the deployment
fixture and securely tighten all fasteners.

~.__W~_—W,
.22“,

68645
8. Inspect the EL-38826 harness and the appropriate
pigtail adapter (2)for damage. Replace as needed.
9. Short the 2 SIR deployment harness leads (1)
together using one banana plug seated into the
other.
68656
Note: On a dual stage air bag, both connectors must
be attached to the deployment harness adapter. This
will ensure that both stage 1 and stage 2 of the
deployment loops are energized, regardless of the
deployment state.
12. Connect the air bag (1)to the adapter(2) on the
SIR deployment harness (3).

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13-138 Supplemental inflatable Restraints
Note: 15. Place a 12 V minimum/2A minimum power source,
such as a vehicle battery, near the shorted end of
1 The rapid expansion of gas involved with the harness.
deploying an air bag is very loud. Notify all the
people in the immediate area that you intend to 16. Connect the SIR deployment harness wires to the
deploy the air bag. power source. Deployment of the air bag will occur
when contact is made.
1 When the air bag deploys, the deployment
fixture mayjump about 30 cm (1ft) vertically.
This is a normal reaction of the air bag due to
the force of the rapid expansion of gas inside
the air bag.
1 if you are deploying a dual stage air bag with
stage 1 already deployed, the fixture may not
move and the noise may have been reduced.
13. Clear the area of people.

9581
17. Disconnect the SIR deployment harness from the
power source after the air bag deploys.
18. lfthe air bag did not deploy, disconnect the adapter
and discontinue the procedure and contact the
04:}; Technical Assistance Group.
Ifdeployment was successful, proceed to the
following steps.
39382 Warning: Refer to SIR Deployed Inflator Modules
14. Separate the 2 banana plugs on the SIR Are Hot Warning on page 0-6.
deployment harness that were shorted together 19. Seat one banana plug into the other in order to
earlier in the procedure. short the deployment harness leads.
20. Put on a pair of shop gloves.
21. Disconnect the pigtail adapter from the air bag as
soon as possible.
22. Inspect the pigtail adapter and the SIR deployment
harness. Replace as needed.
23. Dispose of the deployed air bag through normal
refuse channels.
24. Wash your hands with a mild soap.
Deployment Inside Vehicle —Vehicle Scrapping
Procedure
Deploy the air bags inside of the vehicle when
destroying the vehicle or when salvaging the vehicle for
parts. This includes, but is not limited to, the following
situations:
1 The vehicle has completed all useful life.
1 Irrepairabledamage occurred to the vehicle in a
non-deployment type accident.
1 Irrepairabledamage occurred to the vehicle during
a theft.
39388

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 Supplemental inflatable Restraints 13-139

1 The vehicle is being salvaged for parts to be used

on a vehicle with a different VIN, as opposed to
rebuilding as the same VIN.
Warning: Refer to SlR Inflatable Module
Deployment Outside Vehicle Warning on page 0-6.
1. Lower the driver and passenger windows.
2. Turn the ignition switch to the OFF position and
remove the ignition key.
3. Check that all air bags which will be deployed are
mounted securely.
4. Remove all loose objects from the front seats.

812533 bags the steering wheel air bag and instrument panel
Warning: A deployed dual stage inflator module
will look the same whether one or both stages were
used. Always assume a deployed dual stage
inflator module has an active stage 2. Improper
handling or servicing can activate the inflator
module and cause personal injury.
5. Disconnect the steering wheel air bag yellow
connector (1) from vehicle harness yellow
connector (3).
566915
Note: Ifthe vehicle is equipped with dual stage air
air bag will each have 4 wires. Refer to Component
Connector End Views on page 11-269for determining
high and low circuits.
6. Cut the yellow harness connector out of the
vehicle, leaving at least 16 cm (6 in) of wire at the
connector.
7. Strip 13 mm (0.5 in) of insulation from each of the
connector wire leads.

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13-140 Supplemental inflatable Restraints
1"
JJ :
I'l'
<—6.1 m (20 tt)———>I
68651
8. Cut two 6.1 m (20 ft) deployment wires from a
0.8 mm (18 gauge) or thicker multi—strandwire. Use
these wires to fabricate the driver deployment
harness.
9. Strip 13 mm (0.5 in) of insulation from both ends of
the wires.
10. Twist together one end from each of the wires in
order to short the wires. Deployment wires shall
remain shorted, and not connected to a power
source until you are ready to deploy the air bag.
566918
11. Twist together the 2 connector wire leads from the
high circuits from both stages of the steering wheel
air bag, to one set of deployment wires. Refer to
Component Connector End Views on page 11-269
in order to determine the correct circuits.
12. inspect that the 3-wire connection is secure.
13. Secure and insulate the 3—wireconnection to the
deployment harness using electrical tape.
,4_/
566932
14. Twist together the 2 connector wire leads from the
low circuits from both stages of the steering wheel
air bag, to one set of deployment wires. Refer to
Component Connector End Views on page 11—269
in order to determine the correct circuits.
15. Inspect that the 3-wire connection is secure.
16. Secure and insulate the 3-wire connection to the
deployment harness using electrical tape.
1'7. Connect the deployment harness to the connector
on the steering wheel air bag.
18. Route the deployment harness out of the driver
side of the vehicle.
19. Disconnect the yellow left roof rail harness
connectorfrom the vehicle harness connector.
20. Cut the harness connector out of the vehicle,
leaving at least 16 cm (6 in) of wire at the
connector.
21. Strip 13 mm (0.5 in) of insulation from each of the
connector wire leads.
22. Cut two 6.1 m (20ft) deployment wires from a
0.8 mm (18 gauge) or thicker multi-strandwire.
These wires will be used to fabricate the roof rail
air bag deployment harness.
23. Strip 13 mm (0.5 in) of insulation from both ends of
the wires.
24. Twist together one end from each of the wires in
orderto short the wires.
25. Twist together one connector wire lead to one
deployment wire.
26. Secure and insulate the connection using
electrical tape.
27. Twist together and tape the remaining connector
wire lead to the remaining deployment wire.
28. Connect the deployment harness to the yellow
connector of the roof rail air bag.
29. Route the deployment harness out of the driver
side of the vehicle.
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30. Disconnect the instrument panel air bag yellow
harness connector (1) from the vehicle harness
connector (2).
Note: Ifthe vehicle is equipped with dual stage air
bags the steering wheel air bag and instrument panel
air bag will each have 4 wires. Refer to Component
Connector End Views on page 11-269 for determining
high and low circuits.
31. Cut the yellow harness connector out of the
vehicle, leaving at least 16 cm (6 in) of wire at the
connector.
32. Strip 13 mm (0.5 in) of insulation from each of the
connector wire leads.
33. Cut two 6.1 m (20ft) deployment wires from a
0.8 mm (18 gauge) or thicker multi—strandwire.
These wires will be used to fabricate the
passenger deployment harness.
34. Strip 13 mm (0.5 in) of insulation from both ends of
the wires.
35. Twist together one end from each of the wires in
order to short the wires.
36. Twist together the 2 connector wire leads from the
high circuits from both stages of the instrument
panel air bag to one set of deployment wires. Refer
to Component Connector End Views on
page 11—269in order to determine the correct
circuits.
37. Inspect that the 3—wireconnection is secure.
38. Secure and insulate the 3—wireconnection to the
deployment harness using electrical tape.
39. Twist together the 2 connector wire leads from the
low circuits from both stages of the instrument
panel air bag to one set of deployment wires. Refer
to Component Connector End Views on
page 11-269in order to determine the correct
circuits.
40. Inspect that the 3—wireconnection is secure.
41. Secure and insulate the 3—wireconnection to the
deployment harness using electrical tape.
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Supplemental inflatable Restraints 13-141
42. Connect the deployment harness to the instrument
panel air bag in-line connector.
43. Route the deployment harness out of the
passenger side of the vehicle.
44. Disconnect the yellow harness connector to the
right roof rail air bag from the vehicle harness
connector.
45. Cut the harness connector out of the vehicle,
leaving at least 16 cm (6 in) of wire at the
connector.
46. Strip 13 mm (0.5 in) of insulation from each of the
connector wire leads.
47. Cut two 6.1 m (20 ft) deployment wires from a
0.8 mm (18 gauge) or thicker multi-strand wire.
These wires will be used to fabricate the roof rail
air bag deployment harness.
48. Strip 13 mm (0.5 in) of insulation from both ends of
the wires.
49. Twist together one end from each of the wires in
order to short the wires.
50. Twist together one connector wire lead to one
deployment wire.
51. Secure and insulate the connection using
electrical tape.
52. Twist together and tape the remaining connector
wire lead to the remaining deployment wire.
53. Connect the deployment harness to the roof rail air
bag yellow connector.
54. Route the deployment harness out of the
passenger side of the vehicle.
55. Completely cover the windshield and the front door
window openings with a drop cloth.
56. Stretch to the full length all of the deployment
harness wires on the right side ofthe vehicle.
57. Deploy each deployment loop one at a time.
58. Place a power source, 12V minimum/2A minimum,
such as a vehicle battery,near the shorted end of
the harnesses.
59. Separate one set of wires and touch the wire ends
to the power source in order to deploy the selected
air bag.
60. Disconnect the deployment harness from the
power source and twist the wire ends together.
61. Continue the same process with the remaining
deployment harnesses.
62. Disconnect all harnesses from the vehicle.
63. Discard the harnesses.
64. Scrap the vehicle in the same manner as a
non—SIRequipped vehicle.
65. Ifone or all of the air bags did not deploy, remove
the undeployed air bags from the vehicle.
131-142 Supplemental inflatable Restraints

Pretensioner Handling and Warning: In order to prevent accidental

deployment of the pretensioner which could cause
Scrapping personal injury, do not dispose of an undeployed
pretensioner as normal shop waste. The
Scrapping Procedure undeployed pretensioner contains substances that
During the course of a vehicles useful life, certain could cause severe illness or personal injury if the
situations may arise which will necessitate the disposal sealed container is damaged during disposal. Use
of a live (undeployed) pretensioner. The following the following deployment procedures to safely
information covers the proper procedures for the dispose of an undeployed pretensioner. Failure to
disposing of a live (undeployed) pretensioner. Deploy dispose of a pretensioner as instructed may be a
the pretensioner before disposal. Do not dispose of a violation of federal, state, or local laws.
live (undeployed) pretensioner through normal disposal
channels until the pretensioner has been deployed. The Warning: When you are deploying a pretensioner
following informationcovers the proper procedures for for disposal, perform the deployment procedures in
the disposing of a live (undeployed) pretensioner. the order listed. Failure to follow the procedures in
the order listed may result in personal injury.
1 After replacement of a pretensioner under
warranty.The pretensioner may need to be Special Tools
returned undeployed to the original manufacturer
1 EL-39401—BSIR Deployment Fixture
of pretensioner.
1 EL—38826SlR Deployment Harness
1 Ifthe vehicle is the subject of a Product Liability
report related to the SIR system and is subject to a
Preliminary Investigation (GM-1241). Do not alter
the SIR system in any manner.
1 if the vehicle is involved in a campaign affecting
the pretensioners. Follow the instructions in the
Campaign Service Bulletin for proper SlR handling
procedures.
Deployment Procedures
Note: Some countries, states or localities may not
allow service deployment of air bags without special
permission or training. Local laws regarding deploying
and scrapping of air bags/devices with pyrotechnics
must be followed.
The pretensioner can be deployed inside or outside of
the vehicle. The method used depends upon the final
disposition of the vehicle. Review the following
procedures in order to determine which will work best in
a given situation.
Deployment Inside the Vehicle
Refer to Inflatable Restraint Module Handling and 483842
Scrapping on page 13—135for deploying the Turn the ignition switch to the OFF position.
pretensioner inside vehicle under Vehicle Scrapping
Procedure. Remove the ignition key.
Put on safety glasses.
Deployment Outside Vehicle for Seat 99°83?
Remove the seat belt pretensioner from the
Belt Pretensioners vehicle. '
Deploy the seat belt pretensioners outside of the 5. When carrying a pretensioner to the deployment
vehicle when the vehicle will be returned to service. area keep the open end of pretensioner pointed
Situations that require deployment outside of the away from the body.
vehicle include the following:
1 Using the SIR diagnostics, you determine that the
seat belt pretensioner is malfunctioning.
1 The pretensioner pigtail (if equipped) is damaged.
1 The pretensioner connector is damaged.
1 The pretensioner connector terminal is damaged.
Deployment and disposal of a malfunctioning seat belt
pretensioner is subject to any required retention period.

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 Supplemental inflatable Restraints 131-143
10. Mount the pretensioner(1) in the SIR deployment
fixture (3)with the open and facing up using the
following mounting method.
<—1.85m(6fi.)——>~ 10.1. Adjust and secure the EL—39401—B arms (4)
to the deployment fixture (3).
10.2. To mount, use the proper size bolt (2) and
nut (5) with washers in order to secure the
pretensioner (1) to the deployment fixture
brackets (4).
10.3. Securely tighten all fasteners prior to
deployment.

483844
6. Clear a space on the ground about 1.85 M (6ft) in
diameter for deployment of the pretensioner.
If possible, use a paved, outdoor location free of
activity. Othen/vise,use a space free of activity on
the shop floor. Make sure you have sufficient
ventilation.
7. Make sure no loose or flammable objects are in
the area.
8. Place the EL-39401-B SIR deployment fixture in
the center of the cleared area.
9. Fill the fixture plastic reservoir with water or sand. 68645
11. Inspect the EL-38826 SIR deployment harness
and the appropriate pigtail adapter for damage.
Replace as needed.
12. Short the 2 SIR deployment harness (1) leads
MMA
g.
..
y“
_ together using one banana plug seated into the
other.
13. Connect the appropriate pigtail adapter (2) to the
SIR deployment harness (1).

483846

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1311144 Supplemental inflatable Restraints

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483848
14. Extend the SIR deployment harness and adapter
to full length from the deployment fixture.
39382
Warning: When you are deploying a pretensioner
for disposal, perform the deployment procedures in
the order listed. Failure to follow the procedures in
the order listed may result in personal injury.
17. Separate the 2 banana plugs on the SIR
deployment harness.

+
BATTERY

+
BATTERY

483850
15. Connect the pretensioner(1) to the adapter(2) on
the deployment harness (3).
Note: The rapid gas expansion involved with deploying
a pretensioner is very loud. Notify all the people in the
immediate area that you intend to deploy the seat belt
pretensioner.
16. Clear the area of people.
483854
Note: When the seat belt pretensioner deploys, the
deployment fixture may jump about 30 cm (1 ft)
vertically. This is a normal reaction of the seat belt
pretensioner due to the force of the rapid expansion of
gas inside the pretensioner.
18. Place a 12 V minimum/2A minimum power source
(i.e., vehicle battery) near the shorted end of the
harness.
19. Connect the SIR deployment harness wires to the
power source. Pretensioner deployment will occur
when contact is made.
20. Disconnect the SIR deployment harness from the
power source after the pretensioner deploys.

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9581
21. Seat one banana plug into the other in order to
short the deployment harness leads.
22. if the pretensioner did not deploy, disconnect the
adapter and discontinue the procedure. Contact
the Technical Assistance Group. Otherwise,
proceed to the following steps.
23. Put on a pair of shop gloves.
24. Disconnect the pigtail adapter from the
pretensioner as soon as possible.
25. Inspect the pigtail adapter and the SIR deployment
harness. Replace as needed.
26. Dispose of the deployed pretensioner through
normal refuse channels.
<_/
.,
~22 27. Wash hands with a mild soap.
Description and Operation
Supplemental Inflatable Restraint
Operation
System Description and
SIR System Overview
The supplemental inflatable restraint (SIR) system
supplements the protection offered by the seat belts.
The SIR system contains an inflatable restraint sensing
and diagnostic module (SDM), air bags, seat belt
pretensioners (anchor and retractor),and impact
sensors. The SDM determines the severity of a
collision with the assistance of side impact sensors
located at strategic points on the vehicle. When the
SDM detects a collision, the SDM will process the
information provided by the sensors to further support
air bag or pretensioner deployment. The SDM will
deploy the air bags and pretensioners if it detects a
collision of sufficient force. If the force of the impact is
not sufficient to warrant air bag deployment, the SDM
may still deploy the seat belt pretensioners. The SDM
contains a sensing device that converts vehicle velocity
changes to an electrical signal. The SDM compares
these signals to values stored in memory. Ifthe signals
exceed a stored value, the SDM will determine the
severity of the impact and either cause current to flow
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Supplemental inflatable Restraints 123-145
through the frontal deployment loops deploying the
frontal air bags and pretensioners, or it will deploy the
pretensioners only. The SDM continuously monitors the
deployment loops for malfunctions and illuminates the
AIR BAG indicator if a fault is detected. The SDM
performs continuous diagnostic monitoring of the SlR
system electrical components. Upon detection of a
circuit malfunction, the SDM will set a DTC and inform
the driver by illuminating the AIR BAG indicator. The
steering column and knee bolsters are designed to
absorb energy and compress during frontal collisions in
order to limit leg movement and decrease the chance of
injuryto the driver and passenger.
AIR BAG Indicator (Driver)
The AIR BAG indicator, located in the instrument
cluster, is used to notify the driver of SIR system
malfunctions and to verify that the inflatable restraint
sensing and diagnostic module (SDM) is
communicating with the instrument cluster. When the
ignition is turned ON, the SDM is supplied with ignition
positive voltage. The instrument cluster will
momentarily turn on the AIR BAG indicator. While the
indicator is on, the SDM conducts tests on all SlR
system components and circuits. If no malfunctions are
detected the SDM will communicate with the instrument
cluster through the serial data circuit and command the
AIR BAG indicator OFF. The SDM provides continuous
monitoring of the air bag circuits by conducting a
sequence of checks. Ifa malfunction is detected the
SDM will store a diagnostic trouble code (DTC) and
command the instrument cluster to illuminate the AIR
BAG indicator via serial data. The presence of a SIR
system malfunction could result in non-deployment of
the air bags or deployment in conditions less severe
than intended. The AIR BAG indicator will remain ON
until the malfunction has been repaired.
Inflatable Restraint Sensing and
Diagnostic Module (SDM)
The inflatable restraint sensing and diagnostic module
(SDM) is a microprocessor and the control center for
the supplemental inflatable restraint (SIR) system. The
SDM contains internal sensors along with external
impact sensors, mounted at strategic locations on the
vehicle. In the event of a collision, the SDM compares
the signals from the internal and external impact
sensors to a value stored in memory. When the
generated signals exceed the stored value, the SDM
will cause current to flow through the appropriate
deployment loops to deploy the air bags. The SDM
records the SIR system status when a deployment
occurs and illuminates the AIR BAG indicator located in
the instrument cluster. The SDM performs continuous
diagnostic monitoring of the SIR system electrical
components and circuitry when the ignition is turned
ON. if the SDM detects a malfunction, a DTC will be
stored and the SDM will request the instrument cluster
to illuminate the AR BAG indicator, notifying the driver
that a malfunction exists. Inthe event that ignition
positive voltage is lost during a collision, the SDM
maintains a 23-volt loop reserve for deployment of the
air bags. Itis importantwhen disabling the SIR system
for servicing or rescue operations to allow the 23-volt
loop reserve to dissipate, which could take up to
1 minute.
131146 Supplemental inflatable Restraints
Air Bags
This vehicle contains 10 air bags. The 10 air bags are
located in the steering wheel (dual inflators), instrument
panel (passenger side) (dual inflators),driver side
(B-pillar), passenger side (B-pillar), driver side
(C-pillar), passenger side (C-pillar), driver side knee,
passenger side knee, left roof rail, and right roof rail. To
view the locations of the air bags refer to SIR
Identification Views on page 13—73.Air bags contain a
housing, inflatable air bag, two initiating devices (if dual
inflator),canister of gas generating material and, in
some cases, stored compressed gas. The deployment
loops supply current through the inflator modules to
deploy the air bags. The steering wheel and instrument
panel passenger side air bags have two stages of
deployment, which varies the amount of restraint to the
occupant according to the collision severity. For
moderate frontal collisions the air bags deploy at less
than full deployment which consists of stage1 of the air
bag. For more severe frontal collisions a full
deployment is initiated which consists of stage 1 and
stage 2 of the air bag. The current passing through the
air bag, ignites the material in the canister producing a
rapid generation of gas and is some cases, the release
of compressed gas. The gas produced from this
reaction rapidly inflates the air bag. Once the air bag is
inflated it quickly deflates through the air bag vent holes
and/or the bag fabric. Each air bag is equipped with a
shorting bar located in the connectors of the module.
The shorting bar shorts the air bag deployment loop
circuitry to prevent unwanted deployment of the air bag
when it is disconnected.
Seat Belt Pretensioners (Anchor and
Retractor)
The seat belt pretensioners (driver and passenger)
consist of a housing, seat belt retractor (located in the
B-pillar), seat belt anchor (located on the floor), seat
belt webbing, an initiator,and a canister of gas
generating materials. To view the locations of the seat
belt pretentioners refer to SIR Identification Views on
page 13-73. The initiator is part of the seat belt
pretensioner deployment loop. When the vehicle is
involved in a collision of sufficient force, the SDM
causes current to flow through the seat belt deployment
loops to the initiator.Current passing through the
initiator ignites the material in the canister producing a
rapid generation of gas. The gas produced from this
reaction deploys the seat belt pretensioners which
removes all ofthe slack in the seat belts. Depending on
the severity of the collision, the seat belt pretensioners
may deploy without the frontal air bags deploying,
or they will deploy immediately before the frontal air
bags deploy. Each seat belt pretensioner is equipped
with a shorting bar that is located in the connector of
the seat belt pretensioner. The shorting bar shorts the
seat belt pretensioner circuitry to prevent unwanted
deployment of the seat belt pretensioner when the
connector is disconnected.
Impact Sensors
This vehicle contains 6 impact sensors. The 6 impact
sensors are located in the front of the vehicle (2), 2 in
the B-pillars (left and right),and 2 in the C-Pillars (left
and right).To view the locations of the impact sensors
refer to SIR Identification Views on page 13-73. The
impact sensors contain a sensing device which
monitors vehicle acceleration and velocity changes to
detect side collisions that are severe enough to warrant
air bag deployment. The impact sensors are not part of
the deployment loop, but instead provide input to the
SDM. The SDM contains a microprocessor that
performs calculations using the measured
accelerations and compares these calculations to a
value stored in memory.When the generated
calculations exceed the stored value, the SDM will
cause current to flow through the deployment loops
deploying the appropriate impact module air bags.
Passenger Presence Detection System
and Air Bag Indicator (Passenger)
Note: The passenger presence system (PPS) is a
calibrated unit. When replacing the assembly all parts
in the service kit must remain together. Do not mix any
of the old parts with the new parts. After repairing or
replacing the PPS, the preload test must be performed
in order to function properly.
The passenger presence system (PPS) is used to
monitor the type of occupant that is sitting in the front
passenger seat and communicate the status to the
inflatable restraint sensing and diagnostic module
(SDM). The SDM then uses this informationto
determine whether to enable or suppress the
passenger instrument panel air bag. The PPS consists
of an electronic control module, a sensor mat in the
seat, a harness, and PASSENGER AIR BAG ON/OFF
indicators. The PPS transmits and receives a Iow-level
electric field. The measured capacitance value of this
field is used to determine the type of occupant sitting in
the front passenger seat. Ifthe measured capacitance
is less than a calibrated value, then the PPS module
will send a serial data signal to the SDM to disable the
passenger instrument panel air bag. Ifthe measured
capacitance is greater than a calibrated value, then the
passenger presence module will send a serial data
signal to the SDM to enable the passenger instrument
panel air bag. The SDM will notifythe customer of the
enableldisable status by illuminating one ofthe
PASSENGER AIR BAG ON/OFF indicator. The
passenger presence module monitors itself for faults
and will displays diagnostic trouble codes (DTCs) on
the scan tool. When a fault is detected, the passenger
presence module sends out a message to the SDM.
The SDM responds by sending a command message to
the IPC to illuminate the AIR BAG indicator.
Seat Belt Indicators
The seat belt indicators are controlled through the
inflatable restraint sensing and diagnostic module
(SDM). For further information on seat belt indicators
refer to Seat Belt System Description and Operation on
page 13-66.
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 Supplemental inflatable Restraints 113-147

Special Tools and Equipment Illustration Tool Number/Description

1.22/1
\H

Illustration Tool Number]Description

EL 39401-B
J 39401-B
EL 38826 SIR DeploymentFixture
J 38826
KM 799-3
SlR DeploymentHarness 456738

9062

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131148 Theft Deterrent

Theft Deterrent

Schematic and Routing Diagrams

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1 Theft Deterrent 113-149

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(US/Canada)
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2013 (5377994)
_ Manual
Service om<rIIIL_
J 28180
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13-150 Theft Deterrent

Diagnostic Information and CircuitlSystem Description

Procedures
Symptoms - Theft Deterrent
Note: The following steps must be completed before
using the symptom tables.
1. Perform Diagnostic System Check - Vehicle on
page 6—66in order to verify that all of the following
are true:
1 There are no DTCs set.
1 The control modules can communicate via the
serial data link.
2. Review the system operation in order to familiarize
yourself with the system functions. Refer to the
following Theft Systems Description and Operation
on page 13—153.
VisuaIIPhysical Inspection
1 Inspect for aftermarket devices which could affect
the operation of the Theft Deterrent System. Refer
to Checking AftermarketAccessories on
page 11-525.
1 Inspect the easily accessible or visible system
components for obvious damage or conditions
which could cause the symptom.
Intermittent
Faulty electrical connections or wiring may be the
cause of intermittentconditions. Refer to Testing for
IntermittentConditions and Poor Connections on
page 11—531.
Symptom List
Refer to a symptom diagnostic procedure from the
following list in order to diagnose the symptom:
1 Content Theft Deterrent Malfunction on
page 13—150
1 Security Indicator Malfunction on page 153—151
Content Theft Deterrent Malfunction
Diagnostic Instructions
1 Perform the Diagnostic System Check - Vehicle
on page 6—66prior to using this diagnostic
procedure.
1 Review Strategy Based Diagnosis on page 6-58
for an overview of the diagnostic approach.
1 Diagnostic Procedure Instructions on page 6-59
provides an overview of each diagnostic category.
The content theft deterrent system is a software based
system in which the Body Control Module (BCM)
actively monitors certain inputs to determine if
unauthorized vehicle access is being attempted. Based
on inputs such as the door ajar switches, the rear
compartment ajar switch, and the hood ajar switch, the .
BCM determines whether a content theft deterrent
alarm is warranted. lf unauthorized access is being
detected, the BCM will pulse the vehicle horn and flash
the exterior lamps as a means of theft deterrence.
Diagnostic Aids
The scan tool BCM Content Theft Deterrent Trigger
History 1, 2, and 3 parameters can be used to help
isolate an intermittentunwanted content theft deterrent
alarm. These parameters are a rolling history of the
previous three causes of a theft deterrent alarm. if all
three parameters are indicating the same alarm trigger,
the indicated input should be the starting point when
diagnosing an intermittentconcern.
Reference Information
Schematic Reference
Theft Deterrent System Schematics on page 13—149
Connector End View Reference
Component Connector End Views on page 11-269
Description and Operation
Theft Systems Description and Operation on
page 1.3-153
Electrical Information Reference
1 Circuit Testing on page 11-526
1 Connector Repairs on page 11-548
1 Testing for IntermittentConditions and Poor
Connections on page 11-531
1 Wiring Repairs on page 11—537
Scan Tool Reference
Control Module References on page 6-3 for scan tool
information
CircuitlSystem Verification
1. IgnitionON.
2. Verify each indicator/message transition between
the ajar and closed state while opening and closing
each vehicle door, hood, and rear compartment.
=>If the indicatorlmessage does not change
Refer to Door Ajar Indicator Malfunction on
page 4-268 or Hood Ajar lndicator/Message
Malfunction on page 3-6.

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 Theft Deterrent 131151

U If each indicator/message changes
3. Completely lower the driver door window and close
all vehicle doors, ignition OFF.
4. Arm the content theft deterrent system by locking
the door with the keyless entry transmitter.
5. Verify the scan tool BCM Content Theft Deterrent
Alarm Status parameter is Armed.
=>If not Armed
Refer to Keyless Entry System Malfunction on
page 13—41.
U If Armed
6. Without disarming the system, reach in through the
open driver window and open the driver door.
7. Verify the scan tool BCM Content Theft Deterrent
Alarm Status parameter is Alarm.
=>If not Alarm
Replace the K9 Body Control Module.
U lf Alarm
8. All OK.
Repair Instructions
Perform the Diagnostic Repair Verification on
page 692 after completing the repair.
Control Module References on page 6-3 for Body
Control Module replacement, programming, and setup

Security Indicator Malfunction

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

OpenIHigh Signal
Circuit Short to Ground Resistance Short to Voltage Performance
Control 1 1 2
Ground 1
1.SecurityIndicatorlnoperative
2. SecurityIndicatorAlwaysON

CircuitlSystem Description Connector End View Reference

The security indicator is an LED controlled by the Body Component Connector End Views on page 11—269
Control Module (BCM) based on commands from the
content theft deterrent system. The security indicator is Description and Operation
located in the dash as part of the Ambient Light Sensor Theft Systems Description and Operation on
and is supplied ground at all times. When the content page 13-153
theft deterrent system requests the indicator be
illuminated, the BCM applies voltage to the control Electrical Information Reference
circuit, illuminating the LED. 1 Circuit Testing on page 11-526
Reference Information 1 Connector Repairs on page 11-548
Reference 1 Testing for IntermittentConditions and Poor
Schematic Connections on page 11—531
Theft Deterrent System Schematics on page 13-149 1 Wiring Repairs on page 11-537

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13-152 Theft Deterrent
Scan Tool Reference :> If the test lamp is always OFF
Control Module References on page 6-3 for scan tool 4.1. lgnition OFF, disconnect the harness
information connector at the K9 Body Control Module.
4.2. Test for infinite resistance between the control
CircuitlSystem Verification circuit and ground.
1. Arm the content theft deterrent system. :> Ifless than infinite resistance, repair the short to
2. Verify the security LED illuminates or flashes ground on the circuit.
during the arming sequence. U Ifinfinite resistance
=>If the security LED does not illuminate or flash 4.3. Test for less than 2 Q in the control circuit end
Refer to CircuitlSystem Testing. to end. , M%fl
,M2
2
.2
,.
U If the security LED illuminates or flashes =>H2 0 or greater, repair the open/high resistance
in the circuit.
3. All OK.
=>Ifless than 2 Q, replace the K9 Body Control
CircuitlSystem Testing Module.
1. Ignition OFF and all vehicle systems OFF, :> If the test lamp is always ON
disconnect the harness connector at the B10 4.1. IgnitionOFF, disconnect the harness
Ambient Light Sensor. Itmay take up to 2 minutes connector at the K9 Body Control Module,
for all vehicle systems to power down. ignition ON.
2. Test for less than 30 (2between the ground circuit 4.2. Test for less than 1 V between the control
terminal 6 and ground. circuit and ground.
:> If 30 Q or greater =>If 1 V or greater, repair the short to voltage on
2.1. lgnition OFF. the circuit.
2.2. Test for less than 2 Q in the ground circuit end =>Ifless than 1 V, replace the K9 Body Control
to end. Module.
=>If2 Q or greater, repair the open/high resistance U If the test lamp turns ON and OFF
in the circuit. 5. Test or replace the B10 Ambient Light Sensor.
=>Ifless than 2 Q, repair the open/high resistance
in the ground connection. Repair Instructions
U If less than 30 Q Perform the Diagnostic Repair Verification on
page 6-92 after completing the repair.
3. lgnition ON, connect a test lamp between the
control circuit terminal 1 and the ground circuit 1 Sun Load Temperature Sensor Replacement on
terminal 6. page 10-83
4. Verify the test lamp turns ON and OFF when 1 Control Module References on page 6-3 for Body
commanding the Security Indicator On and Off with Control Module replacement, programming,and
a scan tool. setup

.~.,,
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“22.
2-.
.2

2013
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Description and Operation
Theft Systems Description and
Operation
When armed, the content theft deterrent system is
designed to deter vehicle content theft by pulsing the
horns and exterior lamps for approximately 30 seconds
when an unauthorized vehicle entry is detected.
However, the content theft deterrent system does not
affect engine starting.
An unauthorized entry can be any of the following with
the content theft deterrent system armed:
1 Unauthorized entry into the underhood area
1 Unauthorized entry into the rear compartment
1 When any door is opened without using the
UNLOCK command from a keyless entry
transmitter
1 After a battery reconnect, if the battery was
disconnected with the content theft deterrent
system armed
The components of the content theft deterrent
system are:
1 Body Control Module (BCM)
1 Remote control door lock receiver
1 Door ajar switches
1 Rear compartment ajar switch
1 Hood ajar switch
Arming the Content Theft Deterrent
System
Use the following procedure in order to arm the system:
1. Place the shift lever in P (park).
2. Turn OFF the ignition.
3. Open any door.
Note: The system is not armed if the doors are locked
manually; the power door lock switch or remote keyless
entry transmitter must be used to arm the content theft
deterrent system.
4. Lock the doors with the power door lock switch or
by pressing the LOCK buttonon the transmitter.
The system is in standby mode and will not start
the arming timer until all doors are closed.
5. The system will begin the arm sequence
immediately after the last door is closed. lfthe
keyless entry transmitter is used to arm the system
after the vehicle doors are closed, the arm
sequence will begin as soon as the LOCK
command is received from the transmitter.
6. Pressing the LOCK button on the keyless entry
transmittera second time will bypass the delayed
arming function and force the system to arm.
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Theft Deterrent 13-153
Locking the Vehicle Without Arming the
Content Theft Deterrent System
Locking the vehicle may be accomplished without
arming the content theft deterrent system. Use of the
manual door locks will lock the vehicle, but will not arm
the content theft deterrent system.
Disarming an Armed SystemISilencing
an Alarm
lf system arming has been requested by the power door
lock switch or the keyless entry transmitter, it must be
disarmed.
Note: Disconnecting the battery or removing fuses
does not disable the arm or alarm modes, since the
BCM stores the content theft deterrent mode status in
memory.
1 To disarm the content theft deterrent system in
standby mode, perform one of the following:
—Press the UNLOCK buttonon the keyless entry
transmitter.
—Insert a valid key into the ignition and switch to
the ON position.
1 To disarm the content theftdeterrent system in the
armed mode (non-event)or when activated
(during an alarm event):
—Press the UNLOCK buttonon the keyless entry
transmitter.
—Inserta valid key into the ignition and switch to
the ON position
Content Theft Deterrent Circuit
Description
The following is a description of each component used
in the content theft deterrent system:
Body Control Module
The content theft deterrent system is an internal
function of the BCM which utilizes serial data and
various switch inputs informationto perform content
theft deterrent functions. When the BCM detects an
unauthorized entry, it activates the horns and exterior
lamps. The BCM has 4 basic modes (disarmed,
standby, armed, and alarm) for operating the content
theft deterrent system. The different modes are
described below.
1. The BCM has the content theft deterrent system in
a disarmed mode until the following conditions are
detected:
1 lgnition key turned to the OFF position.
1 Doors locked by either the power door lock
switch or the LOCK buttonon the transmitter.
2. The BCM enters the standby mode when the
above conditions are detected. Ifa door was
already opened when the arm mode was
requested, the standby mode does not start the
timer until the last door is closed.
13-1 54 Theft Deterrent
3. When the last door is closed, a 15 second timer is
activated. Once the timer has expired, the BCM
enters the armed mode. After this delay, any
unauthorized entrywill activate the alarm mode.
4. When the BCM detects an unauthorized entry,the
BCM enters the alarm mode. The BCM activates
the horns and exterior lamps for 30 seconds. This
is followed by a three minute time-out with the horn
no longer active. Ifno new intrusions are detected
after the time-out,the horn is not active. The
system must be disarmed or the intrusion condition
removed after the time-out for the system to exit
alarm mode.
Remote Control Door Lock Receiver
The keyless entry system can arm and disarm the
content theft deterrent system. When the remote
control door lock receiver receives a door lock or unlock
signal from the transmitter,the remote control door lock
receiver sends a message to the BCM via serial data to
perform the appropriate arm/disarm functions.
Door Ajar Switches
The content theft deterrent system uses the door ajar
switches as a status indicator to activate the alarm. The
door ajar switches are monitored by the body control
module via a discrete input from each door ajar switch.
Itthe BCM receives a signal indicating a door is opened
when the content theftdeterrent system is armed, the
BCM activates the alarm.
Hood Ajar Switch
The content theft deterrent system uses the hood ajar
switch as a status indicator to activate the alarm. The
BCM monitors the hood ajar switch via a discrete input
from the switch. it the BCM receives a signal indicating
the hood has been opened when the content theft
deterrent system is armed, the BCM activates the
alarm.
Rear Compartment Ajar Switch
The content theft deterrent system uses the rear
compartment ajar switch as a status indicator to
activate the alarm. The BCM monitors the rear
compartment ajar switch via a discrete inputfrom the
switch. Ifthe BCM receives a signal indicating the rear
compartment has been opened when content theft
deterrent system is armed, the BCM activates the
alarm.
Inputs
The BCM monitors the following inputs for content theft
deterrent:
1 Door ajar switches
1 Keyless entry transmitter LOCK/UNLOCK buttons;
a message from the remote control door lock
receiver
1 Immobilizer status—The BCM uses the
immobilizer status for disarming the system or
silencing an alarm when the correct vehicle key is
used to start the vehicle '
1 Rear compartment ajar switch
1 Hood ajar switch
Outputs
The BCM controls the following for content theft
deterrent:
1 Hornrelay
1 Exteriorlamps

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 Table of Contents 141-1

Section 14

Seats

Seat Hardware, Trim, and Upholstery ....... 14—3
Specifications ................................... 14-3
Fastener Tightening Specifications ............. 14—3
Diagnostic Information and Procedures . . .. . . .14—3
Manual Seat Adjuster Locks Between Lock
Positions ...................................... 14—3
Seats —Adjuster Track Locks Ahead of Other
Track .......................................... 14-3
Repair Instructions .............................. 14—4
Driver or Passenger Seat Removal and
Installation ..................................... 14-4
Front Seat Riser Finish Cover Replacement .... 14-5
Driver or Passenger Seat Adjuster Handle
Replacement (4 Way Uplevel) ................. 14-6
Front Seat Armrest Replacement ............... 14-7
Driver or Passenger Seat Head Restraint
Replacement .................................. 148
Driver or Passenger Seat Head Restraint Guide
Replacement .................................. 14-9
Front Seat Belt Anchor Plate Tensioner Cover
Replacement (4 Way) ........................ 14—10
Driver or Passenger Seat Cushion Frame
Replacement ................................. 14—11
Front Seat Cushion Outer Trim Panel
Replacement ................................. 14—12
Front Seat Cushion InnerTrim Panel
Replacement ................................. 14-13
Front Seat Cushion Cover and Pad
Replacement ................................. 14—14
Driver or Passenger Seat Back Cover and Pad
Replacement ................................. 14-15
Driver or Passenger Seat Back Cushion Frame
Replacement ................................. 14-16
Front Seat Back Recliner Handle
Replacement ................................. 14—17
Child Seat Back Cushion Cover
Replacement ................................. 14—18
Rear Seat Head Restraint Replacement . . 14-19
Rear Seat Head Restraint Guide
Replacement ................................. 14-20
Rear Seat Back Bolster Replacement ......... 14-21
Rear Seat Back Cushion Pivot Support
Replacement ................................. 14—22
Rear Seat Cushion Cover and Pad
Replacement ................................. 14—23
Rear Seat Cushion Removal and
Installation ................................... 14—24
Rear Seat Latch Replacement ................ 14—25
Rear Seat Back Cushion Removal and
Installation (40%) ............................ 14-26
Rear Seat Back Cushion Removal and
Installation (60%) ............................ 14—27
Rear Seat Shoulder Belt Guide Opening Bezel
Replacement ................................. 14-28
Rear Seat Back Cushion Panel
Replacement ................................. 14-29
Rear Seat Back Cushion Cover and Pad
Replacement (AMA 40% w/Split Back) . . 14-30
Rear Seat Back Cushion Cover and Pad
Replacement (AMA 60% w/Split Back) . . 14-31
Rear Seat Back Cushion Hinge
Replacement ................................. 14-32
Rear Seat Back Cushion Latch Release Knob
Bezel Replacement .......................... 14-33
Seat Heating and Cooling .................. 14—34
Schematic and Routing Diagrams ............ 14—34
Heated/Cooled Seat Schematics .............. 14—35
Diagnostic Information and Procedures ...... 14-36
DTC B1925 or B2170 .......................... 14-36
DTC B2345 .................................... 14—38
DTC B2425 or B2430 .......................... 14-40
DTC B242A .................................... 14-43
Symptoms —Seat Heating and Cooling ........ 14-44
Front Heated Seat Malfunction ................ 14—45
Repair Instructions ............................. 14-46
Front Seat Heater Control Module
Replacement ................................. 14-46
Driver or Passenger Seat Back Cushion
Heater Replacement ......................... 14—47
Driver or Passenger Seat Cushion Heater
Replacement ................................. 14—48
Description and Operation .................... 14-49
Heated Seats Description and Operation ...... 14—49

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1412 Table of Contents

BLANK

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-Sonic
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 Seat Hardware, Trim, and Upholstery '14-3

Seat Hardware, Trim, and Upholstery

Specifications

Fastener Tightening Specifications

Specification
Application Metric English
FrontSeat MountingBolt 40N1m 30lbft
FrontSeatArmrestMountingBolt 45N1m 33lbft
FrontSeat CushionFrameBolt 22N1m 16lbft
FrontSeat CushionOuterTrimPanel Fastener 8 N1m 71 lb in
FrontSeat lnnerReclinerFinishCover Fastener 8 N1m 71lb in
FrontSeat Back CushionFrameBolt 22N1m 16lbft
RearSeat BackOuterPivotBolt 23N1m 17lbft
RearSeat LatchBolt 45Nm 33lbft
RearSeat BackCushionBolt (AN1FixedBench) 22Nm 16lbft
RearSeat BackCushionHingeBolt 43N1m 32lbft
RearSeat BackCushionHingeNut 43N1m 32lbft

Diagnostic Information and Procedures

Manual Seat Adjuster Locks Between Lock Positions

Problem
The adjustersaremisaligned.
The adjustersarenew,notbrokenin.
Theadjustersare improperly
lubricated.
The adjustersarebentordamaged.
The adjustersarebindingor
damaged.
Theseat componentsareloose,
damaged,or broken.
The seat mountingboltsare loose.
Action
Aligntheadjusters.
Operatetheseatto thefullytoward andfullyrearwardpositionsseveraltimesin order
toworkthetightnessoutofthechannels.
Lubricatetheadjusterchannels.
Replacetheadjusters.
Lubricateor replacetheadjusters.
Repairor replacetheseat.
Tightenthemountingboltstospecifications.Referto FastenerTightening
Specificationsonpage 14—3.‘

Seats - Adjuster Track Locks Ahead of Other Track

Condition Action
1
Important:Replaceallseat adjustersas an assemblyReplaceboth sides at thesametime.
Theadjustersareoutof time. Removeandreinstallthefrontbucketseat. Referto Driveror PassengerSeatRemoval
andInstallationonpage 14-4.

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'14-4 Seat Hardware, Trim, and Upholstery
,.</
Repair Instructions

Driver or Passenger Seat Removal and Installation

2495843
Driver or Passenger Seat Removal and Installation
Callout I Component Name
Warning: Refer to SIR Warningon page 0-7.
Preliminary Procedures
1. DisabletheSIR system.Referto SIR DisablingandEnablingonpage 13-112.
2. Disconnectthefrontseatbeltlowerfastener.Referto Driveror PassengerSeatShoulderBeltReplacement(withoutA69)
or DriverorPassengerSeatShoulderBeltReplacement(withA69)onpage 13—133.
onpage 133-131
3. Disablethefrontseatbelttensionerfastenerby removingthecap,andcover,ifequipped.Referto SIR Disablingand
Enablingonpage 153-112.
FrontSeat RiserFinishCover(Qty:2)
1 Procedure
Removethefrontseatrisercover.Referto FrontSeatRiser FinishCoverReplacementonpage 14-5.
FrontSeat MountingBolt(Qty:4)
Caution: RefertoFastenerCautiononpage0-8.
2 Procedure
Adjusttheseattothefullforwardpositiontogainaccess to therearbolts.
Tighten
4o N1m(30lbft)

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 Seat Hardware, Trim, and Upholstery ’14-5

Driver or Passenger Seat Removal and Installation (cont'd)

Callout Component Name
Driveror PassengerSeat Assembly(Qty:2)
Procedure
3 1. Disconnecttheelectrical.
2. Withtheaid ofan assistantremovethefrontseat,bytiltingtheseat forwardandthenliftingandpullingthe
seatrearwardsto disengagethefronthooks.
3. Transfercomponentsas necessary.

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Front Seat Riser Finish Cover Replacement

1
.,_.,_....._M«-

2495850

Front Seat Riser Finish Cover Replacement

Callout Component Name
FrontSeat Riser FinishCover
Caution: Do nottwistthecoverduringremoval.Twistingthecovermaycause thecomponentto break.
1 Procedure
Removethefinishcover byfirmlygraspingthe frontor rearofthecoverand pullingthecoveroutwardthen
upwardtodisengageitfromthetrack.

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Manila!
Service
14-6 Seat Hardware, Trim, and Upholstery

Driver or Passenger Seat Adjuster Handle Replacement (4 Way Uplevel)

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2507337
Driver or Passenger Seat Adjuster Handle Replacement (4 Way Uplevel)
Callout Component Name
FrontSeatAdjusterHandleCover
1 Procedure
Use a flat-bladedtoolto pushinwardonthethreetabsto releasethehandlecoverfromthehandleassembly.
FrontSeatAdjusterHandleFastener(Qty:2)
Caution: RefertoFastenerCautiononpage0-8.
FrontSeatAdjusterHandle
3 Procedure
Use a flat—bladed
toolto releasetheadjusterhandlefromtheseatframeassembly.

2013
-Sonic
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Service
Manual
{5377994)
 Seat Hardware, Trim, and Upholstery 14-7

Front Seat Armrest Replacement

2495839

Front Seat Armrest Replacement

Callout Component Name
..
..W.\.W_w2\2_ww.
a_fwxfl
MyAvvwasfi
2““2
M .2 FrontSeatArmrestCoverZipper
1 Procedure
Openthezipperto access thefrontseatarmrestmountingboltandto removethearmrestcover
FrontSeatArmrestCover
2 Procedure
Slide thearmrestcoveroffthearmrestassembly.
FrontSeatArmrestMountingBolt
Caution: RefertoFastenerCautiononpage0-8.
Tighten
45N1m(33lbft)
FrontSeatArmrestSpringWasher
FrontSeatArmrestWasher
FrontSeatArmrestAssembly

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14-8 Seat Hardware, Trim, and Upholstery

Driver or Passenger Seat Head Restraint Replacement

/\
2495829
Driver or Passenger Seat Head Restraint Replacement
Callout Component Name
Driveror PassengerSeat HeadRestraint
Procedure
1 1. Raise theheadresttothefullupwardposition.
2. Depresstheflushbuttonontheheadrestraintguide.
3. Removetheheadrestraintby pullingupontherestraint.

2013
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 Seat Hardware, Trim, and Upholstery 14-9

Driver or Passenger Seat Head Restraint Guide Replacement

\
2495832

Driver or Passenger Seat Head Restraint Guide Replacement

Callout I Component Name
PreliminaryProcedure
Removetheseathead restraint.Referto Driveror PassengerSeatHead RestraintReplacementonpage 14-8.
DriverorPassengerSeat HeadRestraintGuide (Qty:2)
1 Procedure
Usinga suitableflat-bladedtool,slidethetoolon theinsideoftheguideuntilitfindstheslot.Thenpushthetool
forwardpullingtheguidetabinward,whilepullingupwardtoremovetheguidefromtheseat backframe.

(US/Canada)
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Manual
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'14-'10 Seat Hardware, Trim, and Upholstery

Front Seat Belt Anchor Plate Tensioner Cover Replacement (4 Way)

2508311
Front Seat Belt Anchor Plate Tensioner Cover Replacement (4 Way)
Callout Component Name
Driveror PassengerSeat BeltTensionerCover
Procedure
Removethetensionercoverbypushingdownwardon therearandcenterofthecover.Thenapplyinglight
pressuretothefrontof thecover,pushthecoverreanlvardto removeitfromtheseatframe.

2013
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 Seat Hardware, Trim, and Upholstery 14111

Driver or Passenger Seat Cushion Frame Replacement

2505609

Driver or Passenger Seat Cushion Frame Replacement

Callout I Component Name
Preliminary Procedures
1. Removethedriveror passengerseat.Referto Driveror PassengerSeatRemovalandInstallationonpage 14-4
2. Removethefrontseatcushionoutertrimpanel.Referto FrontSeat CushionOuterTrimPanel Replacementonpage 14—12
3. Removethefrontseatcushioninnerrecliner.Referto FrontSeatCushionInnerTrimPanel Replacementonpage 14-13
FrontSeatCushionFrameBolt(Qty:4)
Caution: Referto FastenerCautiononpage 0-8.
1 Tighten
22N1m(16lbft)
Driveror PassengerSeat CushionFrame
2 Procedure
1. Disconnectelectricalconnectorsas needed.
2. Ifreplacingwitha newfrontseatcushionframe,transfercomponentsas necessary.

2013
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Service
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14-12 Seat Hardware, Trim, and Upholstery

Front Seat Cushion Outer Trim Panel Replacement

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2507891
Front Seat Cushion Outer Trim Panel Replacement
Callout Component Name
Preliminary Procedures
1. Removethedriveror passengerseatreclinerhandle.Referto FrontSeat Back ReclinerHandleReplacementon
page 14-17 .
2. Removethefrontseat adjusterhandle.Referto DriverorPassengerSeatAdjusterHandleReplacement(4 WayUplevel)
onpage 14-6
FrontSeat CushionOuterTrimPanel Fasteners(Qty:3)
1 Caution: Referto FastenerCautiononpage0-8.
FrontSeat CushionOuterTrimPanel
Procedure
1. Makesuretheseatis inthefullup position.
2 2. Gentlypulloutboardonthefronthalfofthefinishcovertodisengagethepanelribfromtheseatframe.
3. Firmlygrasptheupperareaofthefinishcoverthatfoldsovertheseatcushionframe,thisareaneedsto be
flexedoutwardwhileslidingthefinishcoverupward.
4. if replacingthecover,transfercomponentsas necessary.

2013
-Sonic
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Manual
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 Seat Hardware, Trim, and Upholstery '14-‘13

Front Seat Cushion Inner Trim Panel Replacement

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2495823

Front Seat Cushion Inner Trim Panel Replacement

Callout Component Name
Driveror PassengerSeat InnerReclinerFinishCoverCap
Procedure
Use a flat-bladedtooltoreleasethecap fromthereclinercover.
Driveror PassengerSeat InnerReclinerFinishCoverFastener(Qty:2)
Caution: RefertoFastenerCautiononpage 0—8.
Tighten
8 N-m(71lbin)
Driveror PassengerSeat InnerReclinerFinishCover
Procedure
Firmlygrasptheupperarea ofthefinishcoverthatfoldsovertheseatcushionframe,pullupwardandthen
outboardto disengagethefinishcoverfromthe seatcushionframe.

(US/Canada)
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Service
1444 Seat Hardware, Trim, and Upholstery

Front Seat Cushion Cover and Pad Replacement

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2506030
Front Seat Cushion Cover and Pad Replacement
Callout Component Name
Warning: Refer to SIR Warningon page 0-7.
Preliminary Procedures
1. Removethedriveror passengerseat.Referto Driveror PassengerSeatRemovalandInstallationonpage 14-4.
2. Removethefrontseatcushionoutertrimpanel.Referto FrontSeat CushionOuterTrimPanel Replacementon
page 14-12.
3. Removethefrontseatcushioninnertrimpanel.Referto FrontSeat CushionInnerTrimPanel Replacementonpage 14-13.
FrontSeat CushionCover
Procedure
1. DisengagetheJ-channelandhogringretainersfromtheseatcushionframe.
2. Disconnecttheelectricalconnectorsthatattachtotheseatcushion,if equipped.
3. Removetheseatcushioncoverandpadfromtheseat cushionframeas an assembly.
4. Separatetheseatcushionfromtheseatcushionpadby pullingthecoverawayfromthepad.
FrontSeat CushionHeater
2 Procedure
Removethedriveror passengerseatcushionheater,if equipped.Referto Driveror PassengerSeatCushion
HeaterReplacementonpage 14-48
3 FrontSeat CushionPad
Note: The seatbeltpresencesensorandheatmat,if equippedareintegralpartsoftheseatcushionpad.

2073
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Seat Hardware, Trim, and Upholstery ’14-15

Driver or Passenger Seat Back Cover and Pad Replacement

2507916

Driver or Passenger Seat Back Cover and Pad Replacement

Callout I Component Name
Warning: Referto SIR Warningon page 0-7.
Warning: Do notrepair or replace theseat stitching or seams in theseat back trim cover with an internalmounted seat
side airbag module.Replace the completeseat back trimcover from the OEM.Non-OEM seat stitching may cause
improper airbagdeployment which couldresult in personal injury.
Preliminary Procedure
1. Removethedriveror passengerseat. Referto Driveror PassengerSeat Removaland Installationonpage 14-4.
2. Removethefrontseatcushionoutertrimpanel.Referto FrontSeat CushionOuterTrimPanel Replacementon
page 14-12.
3. Removethefrontseatcushioninnertrimpanel.Referto FrontSeat CushionInnerTrimPanel Replacementonpage 14—13
P Removethefrontseat armrest.Referto FrontSeatArmrestReplacementonpage 14—7
Removethedriveror passengerseathead restraintguide.Referto DriverorPassengerSeat HeadRestraintGuide
Replacementonpage 14-9
SeatBackCushionCover
Procedure
1 1. Disengagethej-channelretainersandtabsatthe bottomoftheseat backcoverfromtheseatback cushion
frame.
2. Disconnecttheelectricalconnectorthatis attachedtotheseat backcushion,if equipped.
3. Removetheseatback cushioncoverand padfromtheseat cushionframeas an assembly.
FrontSeatBack CushionPad
Procedure
2 Pullthecushioncoverassemblyoffofthepad.
Tip: Seatbackcovercan be damageduponreinstallingcovertoseatback pad.When reinstallingtheseat
cushioncoverto theseat pad,startin upperoutboardcornerandinstalloutboardside ofthecover.Thenstartat
theupperinboardcornerand installinboardside ofcover.

(US/Canada}
-Sonic
2013 (5377994)
Manual
Service
14-16 Seat Hardware, Trim, and Upholstery

Driver or Passenger Seat Back Cushion Frame Replacement

2504789

Driver or Passenger Seat Back Cushion Frame Replacement

Callout I Component Name
Preliminary Procedures
‘1. Removethedriveror passengerseat.Referto Driveror PassengerSeat RemovalandInstallationonpage 14-4
2. Removethefrontseatcushionoutertrimpanel.Referto FrontSeat CushionOuterTrimPanel Replacementonpage 14-12
3. Removethefrontseatcushioninnerrecliner.Referto FrontSeat CushionInnerTrimPanel Replacementonpage 14—13
FrontSeat Back CushionFrameBolt(Qty:4)
Caution: RefertoFastenerCautiononpage 0-8.
Tighten
22N-m(16Ibft)
Driveror PassengerSeat Back CushionFrame
Procedure
1. Disconnectelectricalconnectorsas needed.
2. Ifreplacingwitha newfrontseatbackcushionframe,transfercomponentsas necessary.

—
2013 (US/Canada)
Sonic (5377994)
Manual
Service
 Seat Hardware, Trim, and Upholstery ’14-”:7

Front Seat Back Recliner Handle Replacement

2673883

Front Seat Back Recliner Handle Replacement

Callout Component Name
FrontSeat ReclinerHandIeCoverCap
1 Procedure
Use a flat-bladedtoolto releasethehandlecoverfromthehandleassembly.
FrontSeat ReclinerHandle
2 Procedure
Use a flat-bladedtoolto releasethehandlefromtheseat.

(US/Canada)
~Sonic
2013 (5377994)
Manual
Service
’14-18 Seat Hardware, Trim, and Upholstery

Child Seat Back Cushion Cover Replacement

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,....
..

2510156
Child Seat Back Cushion Cover Replacement
Callout Component Name
ChildSeatBack CushionCover
Procedure
Removethechildseatbrackettrimcoverusinga suitableflat-bladedtool.

2013
—Sonic
(US/Canada)
Service
Manual
(5377994)
 Seat Hardware, Trim, and Upholstery 14-19

Rear Seat Head Restraint Replacement

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“J

2509448

Rear Seat Head Restraint Replacement

Callout Component Name
RearSeat HeadRestraint
Preliminary Procedures
1. Depressthelargebuttonon theheadrestraintguideand raisetheheadrestrainttothefullup position.
2. Depressthesmallbuttonon theoppositeheadrestraintguideandpullupwardto removefromtheseat.

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
14-20 Seat Hardware, Trim, and Upholstery

Rear Seat Head Restraint Guide Replacement

2509450
Rear Seat Head Restraint Guide Replacement
Callout Component Name
Preliminary Procedure
Removetherearseatheadrestraint.Referto Rear SeatHeadRestraintReplacementonpage 14-19
RearSeat HeadRestraintGuide
Procedure
Usinga suitableflat-bladedtool,slidethetoolbetweenthecushionandtheguideuntilyoufindthesloton the
outboardsideoftheguide.Push inwardontheguideslottab , whilepullingupwardto removetheguidefromthe
seat backframe.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Seat Hardware, Trim, and Upholstery 14:21

Rear Seat Back Bolster Replacement

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2373109

Rear Seat Back Bolster Replacement

Callout Component Name
Preliminary Procedures
DisabletheSIR system.Referto SIR DisablingandEnablingon page 13-112
Rear SeatBack CushionBolster
Warning: Refer to SIR Warningon page 0-7
Warning: Do not repair or replace theseat stitching or seams in the seat back trimcover with an internal
mountedseat side airbag module.Replace the completeseat back trim cover from the OEM. Non-OEM
seat stitching may cause improperairbag deploymentwhich couldresult in personal injury.
1 Procedure
1. Pull bolsterveryhardfromtop todisengageretainers.
Replaceall damagedretainersandtapbackholesin bodysheetmetal,if necessary.
Disconnectelectricalconnector.
Removerearseatbackcushionbolster.
Removetherearseatside inflatablemodule,if equipped.Referto Rear Seat OutboardSeatBackAirbag
WP?!“
Replacementonpage 153-127

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
14—22 Seat Hardware, Trim, and Upholstery
/~—
W.
Rear Seat Back Cushion Pivot Support Replacement

2509455
Rear Seat Back Cushion Pivot Support Replacement
Callout Component Name
Preliminary Procedure
Removetherearseatbackcushion.Referto Rear SeatBack CushionRemovalandInstallation(40%)onpage 14-26or Rear
SeatBack CushionRemovalandInstallation(60%)onpage 14-27
RearSeat Back OuterPivotBolt(Qty:2)
Caution: RefertoFastenerCautiononpage0-8.
Tighten
23N-m(17lbft)
RearSeat Back CushionOuterPivotBushing
RearSeat Back CushionOuterPivotBoltSpring x.
-m.
RearSeat Back CushionPivotSupportHousing
01th RearSeat Back CenterFinishCover

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Seat Hardware, Trim, and Upholstery 14-23

Rear Seat Cushion Cover and Pad Replacement

2509452

Rear Seat Cushion Cover and Pad Replacement

Callout Component Name
Preliminary Procedure
Removetherearseatcushion.Referto Rear Seat CushionRemovalandInstallationonpage 14—24
,W.WM.___
WM...
M... RearSeatCushionCover
Procedure
1 1. Removethehogringsthatsecuretherearseatcushioncovertothe pad.
2. Pullthecoverawayfromthepadto disengageanyretainers.
Note: Wheninstallingtherearseat cushioncover,pullthecovertightlyin all cornerstoensurethatnocreasing
occurs.
2 RearSeatCushionPad

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
'14-24 Seat Hardware, Trim, and Upholstery

Rear Seat Cushion Removal and Installation

2....
A
AHV

2509447
Rear Seat Cushion Removal and Installation
Callout Component Name
Rear Seat CushionReplacement
Procedure
1. Releasetherearseatcenterseatbelts.
2. Liftuponthefrontoftheseatcushionat thelatchlocationsto disengagethecushionretainersfromthe
floor.
3. Push downontherearoftheseatcushionto unhookthecushionfromthefloorwires.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Seat Hardware, Trim, and Upholstery ’l4-25

Rear Seat Latch Replacement

2509457
Rear Seat Latch Replacement
Callout Component Name
Preliminary Procedures
1. Removetherearseatbackcushion.Referto Rear SeatBack CushionRemovalandInstallation(40%)onpage 14-26or
Rear SeatBack CushionRemovalandInstallation(60%)onpage 14-27.
2. Removetherearseatbackcushioncoverandpad.Referto Rear SeatBack CushionCoverandPad Replacement(AMA
40%w/SplitBack)onpage 14-30or Rear SeatBack CushionCoverandPad Replacement(AMA 60%w/Sp/itBack)on
page 14-31.
RearSeatLatchFasteners(Qty:2)
Caution: RefertoFastenerCautiononpage 0—8.
Tighten
45N-m(33Ibft)
2 RearSeat Latch

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
14-26 Seat Hardware, Trim, and Upholstery

Rear Seat Back Cushion Removal and Installation (40%)

\\

Rear Seat Back Cushion Removal and Installation (40%)

Callout I Component Name
Preliminary Procedure
1. Removetherearseatcushion.Referto Rear Seat CushionRemovaland Installationonpage 14-24.
2. Removetherearseat backcushionbolster.Referto Rear SeatBack BolsterReplacementonpage 14-21
RearSeat Back CushionPivotSupport
Procedure
1 1. Pulltherearseatbackcushionlatchreleaselocatedon thetopoftherearseat backcushion,andfoldthe
rearseatbackcushionforward.
2. Push in ontherearseatbackcushionpivotsupport,andreleasefrombracket.
Rear Seat Back Cushion
Procedure
1. Pull upontheoutersideoftherearseatbackcushionandremovetherearseatbackcushionfromthe
bracketandhinge.
2. Transfercomponentsas necessary.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Seat Hardware, Trim, and Upholstery 14-27

Rear Seat Back Cushion Removal and Installation (60%)

/\

2510225

Rear Seat Back Cushion Removal and Installation (60%)

Callout I Component Name
Preliminary Procedure
1. Removetherearseatcushion.Referto Rear Seat CushionRemovalandInstallationonpage 14—24.
2. Removetherearseatcenterretractorside beltlowerfastener.Referto Rear Seat CenterShoulderBeltReplacement
(Hatchback)onpage 13-62or Rear Seat CenterShoulderBeltReplacement(Sedan)onpage 13—61.
3. Removetherearseatbackcushionbolster.Referto Rear SeatBack BolsterReplacementonpage 14—21
RearSeat Back CushionPivotSupport
Procedure
1. Removetherearseat backcushion40%side.
1 2. Removetherearoutboardshoulderbeltsfromtheshoulderbeltbezeland positionitoutoftheway.
3. Pulltherearseat backcushionlatchreleaselocatedonthetopoftherearseatbackcushion,andfoldthe
rearseat backcushionforward.
4. Pushin ontherearseat backcushionpivotsupport,andreleasefrombracket.
RearSeatBack Cushion
Procedure
2 1. Pullupontheouterside oftherearseatbackcushionand removetherearseat backcushionfromthe
bracketand hinge.
2. Transfercomponentsas necessary.

(US/Canada)
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2013 (5377994)
Manual
Service
'14-28 Seat Hardware, Trim, and Upholstery

Rear Seat Shoulder Belt Guide Opening Bezel Replacement

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Wm

2673885

Rear Seat Shoulder Belt Guide Opening Bezel Replacement

Callout Component Name
Rear SeatShoulderBeltOpeningBezel
Procedure
1 Push inwardandupwardfromthefrontofthebezelto releasefromtheseatback.
Note: Therearseatshoulderbeltopeningbezelis partof therearseatcenterbeltassemblyandis replacedas
an assembly.

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
 Seat Hardware, Trim, and Upholstery 14-29

Rear Seat Back Cushion Panel Replacement

mswm
.

2510276

Rear Seat Back Cushion Panel Replacement

Callout Component Name
PreliminaryProcedure
1. Removetherearseatbackcushion.Referto Rear SeatBack CushionRemovalandInstallation(40%)onpage 14-26or
RearSeatBack CushionRemovalandInstallation(60%)onpage 14-27
2. Removetherearseatheadrestraintguide.Referto Rear SeatHeadRestraintGuideReplacementonpage 14-20
3. Removetherearseatbackcushionlatchreleaseknobbezel.Referto Rear SeatBack CushionLatchRelease KnobBezel
22m,.W.WW_WWMW
.r..
Replacementonpage 14-33
Removethechildseatbackcushioncover.Referto ChildSeatBack CushionCoverReplacementonpage 14-18
Removetherearseatbackcushionpivotsupport.Referto Rear SeatBack CushionPivotSupportReplacementon
page 14-22
. Removetherearseatlatch.Referto Rear SeatLatchReplacementonpage 14—25
Rear Seat Back CushionPanel
Procedure
1. Removetheseat backcarpet.
2. Ifreplacingtheseat backpanel,transfercomponentsas necessary.

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
14—30 Seat Hardware, Trim, and Upholstery

Rear Seat Back Cushion Cover and Pad Replacement (AMA 40% w/Split Back)

-fN.
«~A
.flfifl

2509456

Rear Seat Back Cushion Cover and Pad Replacement (AMA 40% wISplit Back)
Callout I Component Name
Preliminary Procedures
1. Removetherearseatbackcushion.Referto Rear Seat Back CushionRemovaland Installation(40%)onpage 14-26or
Rear SeatBack CushionRemovalandInstallation(60%)onpage 14-27.
2. Removetherearseatheadrestraintguide.Referto Rear SeatHeadRestraintGuideReplacementonpage 14-20.
22.2
A,
N.
3. Removetherearseatbackcushionlatchreleasehandlebezel.Referto Rear Seat Back CushionLatchReleaseKnob
Bezel Replacementonpage 14-33
Removethechildseatbackcushioncover.Referto ChildSeatBack CushionCoverReplacementonpage 14-18
Removetherearseatbackcushionpivotsupport.Referto Rear SeatBack CushionPivotSupportReplacementon
page 14-22.
RearSeat Back CushionCover
Procedure
1. Removetheseat backcarpet.
2. DisengagetheJ-channelretainersfromtheseatbackcushionframe.
1 3. Removethehogringsfromtheundersideoftherearseat backcushioncover.
4. Pull thecoverawayfromthepadto disengagethehookandloopretainers.
5. Ifreplaceingtheseatbackpanel,transfercomponentsas necessary.
Note: Wheninstallingtherearseatbackcushioncover,pullthecovertightlyin all cornerstoensurethatno
creasingoccurs.
2 RearSeat BackCushionPad

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
 Seat Hardware, Trim, and Upholstery 14-31

Rear Seat Back Cushion Cover and Pad Replacement (AMA 60% wISplit Back)

'4"22M,"
. .”.w-.«

2511275
Rear Seat Back Cushion Cover and Pad Replacement (AMA 60% wISplit Back)
Callout | Component Name
PreliminaryProcedure
1. Removetherearseatbackcushion.Referto Rear SeatBack CushionRemovalandInstallation(40%)onpage 14-26or
Rear SeatBack CushionRemovalandInstallation(60%)onpage 14-27
2. Removetherearseatheadrestraintguide.Referto Rear SeatHeadRestraintGuideReplacementonpage 14-20
3. Removetherearseatbackcushionlatchreleaseknobbezel.Referto Rear SeatBack CushionLatchRelease KnobBezel
Replacementonpage 14-33
RemovetheChildseatbackcushioncover.Referto ChildSeatBack CushionCoverReplacementonpage 14-18
Removetherearseatbackcushionpivotsupport.Referto Rear SeatBack CushionPivotSupportReplacementon
page 14-22
Removetherearseatshoulderbeltguideopeningbezel,if equipped.Referto Rear SeatShoulderBelt GuideOpening
Bezel Replacementonpage 14-28
Rear SeatBack CushionCover
Procedure
1. Removetheseat backcarpet.
Removetherearseatcenterheadrestraint,if equipped.
DisengagetheJ-channelretainersfromtheseatbackcushionframe.
Removethehogringsfromtheunderside oftherearseatbackcushioncover.
9P9!“
Pullthecoverawayfromthepadtodisengagethehookandloopretainers.
6. Ifreplacingtheseat backpanel,transfercomponentsas necessary.
Note: Wheninstallingtherearseat backcushioncover,pullthecovertightlyin all cornersto ensurethatno
creasingoccurs.
2 Rear SeatBack CushionPad

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
’14-’32 Seat Hardware, Trim, and Upholstery

Rear Seat Back Cushion Hinge Replacement

n
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2509460

Rear Seat Back Cushion Hinge Replacement

Callout Component Name
Preliminary Procedure
1. Removetherearseat‘cushion.Referto Rear Seat CushionRemovalandInstallationonpage 14—24
32. Removetherearseatbackcushion.Referto Rear SeatBack CushionRemovalandInstallation(40%)onpage14-26or
Rear SeatBack CushionRemovalandInstallation(60%)onpage 14-27
3. Removetherearcompartment floorpanelcarpet.Referto Rear CompartmentFloorPanel CarpetReplacement
(Hatchback)onpage2-23or Rear CompartmentFloorPanel CarpetReplacement(Sedan)onpage2-22
RearSeatBack CushionHingeBolt(Qty:2)
Caution: Referto FastenerCautiononpage0-8.
Tighten
43NW(32Ibft)
RearSeatBack CushionHingeNut(Qty:2)
2 Tighten
43NW(32Ibft)
3 RearSeatBack CushionHinge

—
2013 (US/Canada)
Sonic (5377994)
Manual
Service
 Seat Hardware, Trim, and Upholstery 14-33

Rear Seat Back Cushion Latch Release Knob Bezel Replacement

.Mm
._._

2510155

Rear Seat Back Cushion Latch Release Knob Bezel Replacement

Callout Component Name
RearSeatBack CushionLatchRelease HandleBezel
Procedure
Use a flat-bladedtooltotilttherearofthehandleupward,thenliftingandpullingthebezelrearwardtodisengage
thefronthooks.

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
14-34 Seat Heating and Cooling
.Wm
Seat Heating and Cooling

Schematic and Routing Diagrams

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4
MWm

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
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2013
—Sonic
(US/Canada}
Service
Manual
(5377994)
J
'14-'36 Seat Heating and Cooling

Diagnostic Information and Procedures

DTC B1925 or B2170

Diagnostic Instructions
- Perform the Diagnostic System Check - Vehicle
on page 6-66 prior to using this diagnostic
procedure.
- Review Strategy Based Diagnosis on page 6-58
for an overview of the diagnostic approach.
. Diagnostic Procedure Instructions on page 6-59
provides an overview of each diagnostic category.
DTC Descriptors
DTC B1925 02: Driver Seat Cushion Heater Sensor Circuit Short to Ground
DTC B1925 05: Driver Seat Cushion Heater Sensor Circuit High Voltage/Open
DTC 82170 02: Passenger Seat Cushion Heater Sensor Circuit Short to Ground
DTC B2170 05: Passenger Seat Cushion Heater Sensor Circuit High Voltage/Open
Diagnostic Fault Information

Open/High Signal
Circuit Short to Ground Resistance Short to Voltage Performance
?gp’nfiggfggfg
seat Elementcomm' B242A02 132425
OD B242A01 532242229)?

seat E'ement00”"0'
?;I‘Ifiirngfiagfg B242A02 82425OD B242A01 132241225512)?

ggxggrggfigl seat CUShiO“Temperature B192502 B192505 B192505 5234513

32125551633214?”me — -
Seat ElementControl
?:frrsfilrggngI-lzeated B242A02 824300D B242A01 ?3221%%%Eé’

Seat ElementControl
$2f§§12$3rxléeated 8242A02 82430OD B242A01 Béigggg,

g::::?%‘fgg‘fatedseat CUShiO”Temperature B217002 3217005 3217005 132345

13
CushionTemperature
g::::?gL:INHl§:ftgrdegggt _ B217005 _ B234513

CircuitlSystem Description Conditions for Running the DTC

The heated seat temperature sensor is located in the - DTC B1325 must not be present.
seat cushion just under the seat cover with the seat - The seat heating control module must be
heating element. The seat heating control module powered.
supplies a 5 V reference voltage through the
temperature sensor signal circuit and a ground through Conditions for Setting the DTC
the low reference circuit to the sensor. The module
monitors the voltage of the sensor signal circuit to B1925 02 or B2170 02
determine the temperature of the seat. The temperature The temperature sensor voltage drops below 0.6 V for
sensor varies in resistance based on the temperature of more than 1 second.
the heating element causing the signal voltage to
change. Once the seat reaches the set temperature, B1925 05 or B2170 05
the module will then cycle the control circuit of the The temperature sensor voltage is greater than 5 V for
heating elements ON and OFF in order to maintain the more than 1 second.
desired seat temperature based on the feedback
voltage from the sensor. Action Taken When the DTC Sets
The heated seat function for the affected seat will be
disabled.

2013
—
Sonic
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Service
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W,W
W.
W
.W.
_
_,
wm
 Seat HeatingLand Cooling ’14-37

Conditions for Clearing the DTC 4. Test for 4.8—5.2V between the signal Circuit
terminal 3 and ground.
- The current DTC will clear and set the code to
history 3 seconds after the reference voltage =>If less than 4.8 V
returns to normal operating range and the ignition 4.1. lgnition OFF, disconnect the X3 harness
is cycled OFF then back to ACC or RUN. connector at the K29 seat heating control
- The history DTC will clear after 40 consecutive module.
fauIt—free ignition cycles have occurred. 4.2. Test for infinite resistance between the signal
WWWW
2 circuit and ground.
Reference Information
2:»Ifless than infinite resistance, repair the short to
1MW.” Schematic Reference ground on the circuit.
Heated/Cooled Seat Schematics on page 14—35 it If infinite resistance
4.3. Testfor less than 2 Q in the signal circuit end
Connector End View Reference to end.
Component Connector End Views on page 11-269 =>If2 Q or greater, repair the open/high resistance
Description and Operation in the circuit.
=>If less than 2 Q, replace the K29 seat heating
Heated Seats Description and Operation on control module.
page 14-49
=>lf greater than 5.2 V
Electrical Information Reference 4.1. IgnitionOFF, disconnect the X3 harness
- Circuit Testing on page 11-526 connector at the K29 seat heating control
module, ignition ON.
- Connector Repairs on page 11-548
Testing for IntermittentConditions and Poor 4.2. Test for less than 1 V between the signal
-
circuit and ground.
Connections on page 11—531
' Wiring Repairs on page 11-537 =>If 1 V or greater, repair the short to voltage on
the circuit.
Scan Tool Reference =>if less than 1 V, K29 seat heating control
Control Module References on page 6-3 for scan tool module.
information U If between 4.8-5.2 V
CircuitlSystem Testing 5. Test or replace the E14 seat cushion heating
element.
1. lgnition OFF, disconnect the harness connector at
the appropriate E14B or E14D seat cushion Component Testing
heating element.
E14B or E14D Seat Cushion Heating Element
2. Test for less than 5 Q between the low reference
circuit terminal 2 and ground. 1. lgnition OFF, disconnect the harness connector at
the appropriate E14B or E14D seat cushion
=>If 5 Q or greater heating element.
2.1. lgnition OFF, disconnect the X2 harness 2. Test for 500 Q—3OOkQ between the signal circuit
connector at the K29 seat heating control terminal 3 and the low reference circuit terminal 2.
module.
:> If not between 500 Q—300kn
2.2. Test for less than 2 Q in the low reference
Circuitend to end. Replace the E14 seat cushion heating element.
=>lf 2 Q or greater, repair the open/high resistance ii If between 500 fl—300 k!)
in the circuit. 3. All OK.
=>Ifless than 2 Q, replace the K29 seat heating
control module. Repair Instructions
ii If less than 5 Q Perform the Diagnostic Repair Verification on
page 6-92 after completing the repair.
3. lgnition ON.
- Driver or Passenger Seat Cushion Heater
Replacement on page 14—48
- Control Module References on page 6—3for seat
heating control module replacement, programming
and setup

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
14-38 Seat Heating and Cooling

DTC B2345

Diagnostic Instructions
- Perform the Diagnostic System Check - Vehicle
on page 6—66prior to using this diagnostic
procedure.
- Review Strategy Based Diagnosis on page 6-58
for an overview of the diagnostic approach.
. Diagnostic Procedure Instructions on page 6-59
provides an overview of each diagnostic category.
DTC Descriptors
DTC B234513: Seat Heater Disable Circuit Low Voltage/High Temperature
Diagnostic Fault Information

Openhfigh SMnal
Circuit Short to Ground Resistance Short to Voltage Performance

$$$$$ch seat E'emem00”“ 3242A02 32425OD 3242Ao1 382242255936

?;I‘Ifiiagfiagfgseat E'ementcomm' 3242A02 32425OD 3242A01 @22122%%%’

Temperature
seat CUShion B192502 3192505 3192505 3234513
561311331
3:11:12?

22122155133323.2315“Temperature — -
Seat ElementControl
?:fnifiqgglngl-Izeated 8242A02 824300D B242A01 BB22‘4%%%BE’

Seat ElementControl
?:rsrfigggngl-lzeated B242A02 B24300D 8242A01 23.31353)???

seat CUShiO“Temperature
g::::?98?grf'afated 3217002 3217005 3217005 3234513
CushionTemperature
ggfizgth—glI/Hggftgrdefiggt _ 3217005 _ 8234513

CircuitlSystem Description Action Taken When the DTC Sets

The seat heating control module controls seat heating The heated seat function for both seats will be disabled.
operation for the driver and front passenger seats. The
heating elements are controlled through individual high Conditions for Clearing the DTC
side and low side control circuits. The low side control ' The current DTC will clear and set the code to
circuits for both seats are connected to a common history 3 seconds after the reference voltage
reference point internal to the module. This reference returns to the normal operating range and the
point is biased to approximately 2.5 V. Before the seat ignition is cycled OFF then back to ACC or RUN.
heating control module will allow heated seat operation, - The history DTC will clear after 40 consecutive
it checks to see if this biased voltage is shorted to fault—freeignition cycles have occurred.
ground or voltage. Once the module verifies that it is
not closing to a shorted heating element, it allows for Reference Information
heated seat operation. The module will then continue to
monitor the heating elements for a shorted Circuit. Schematic Reference

Conditions for Running the DTC Heated/Coo/ed Seat Schematics on page 14-35
- Engine must be running. Connector End View Reference
- The seat heating control module must be Component Connector End Views on page 11—269
powered.
Description and Operation
Conditions for Setting the DTC ~
W
._
W.
.2.
_w/
Heated Seats Description and Operation on
82345 13 page 14-49
Any temperature sensor input that remains below 1.5 V
for more than 1 second.

2013
<Sonic
(US/Canada)
Service
Manual
{5377994)
 Seat Heatingflm Cooling 14-39

Electrical Information Reference =>If infinite resistance, test or replace the

~ Circuit Testing on page 11-526
- Connector Repairs on page 11-548
- Testing for IntermittentConditions and Poor
Connections on page 11-531
- Wiring Repairs on page 11—537
Scan Tool Reference
Control Module References on page 6—3for scan tool
information
CircuitlSystem Testing
1. lgnition OFF, disconnect the X2 and X3 harness
connectors at the K29 seat heating control module.
2. Test for greater than 3 k0 between the signal and
the low reference circuit terminals listed below:
- Driver seat cushion terminal 3X3 and
terminal13 X2
- Passenger seat cushion terminal 4 X3 and
termina|14 X2
=>If less than 3 k!)
2.1. IgnitionOFF, disconnect the harness
connector at the appropriate E14B or
E14D seat cushion heating element.
2.2. Test for Infiniteresistance between the signal
and low reference circuits.
=>Ifless than infinite resistance, repair the short
between the circuits.
E14 seat cushion heating element.
ii if greater than 3 k!)
3. Replace the K29 seat heating control module.
Component Testing
Seat Cushion Heating Element
1. IgnitionOFF, disconnect the harness connector at
the appropriate E14B or E14D seat cushion
heating element.
2. Test for 500 0—300k0 between the signal circuit
terminal 3 and the low reference circuit terminal 2.
=>If not between 500 Q—300kn
' Replace the E14 seat cushion heating element.
11 If between 500 9400 kQ
3. AMOK.
Repair Instructions
Perform the Diagnostic Repair Verification on
page 6-92 after completing the repair.
- Driver or Passenger Seat Cushion Heater
Replacement on page 14-48
- Control Module References on page 6—3for
K29 seat heating control module replacement,
programming and setup

—
2013 (US/Canada)
Sonic (5377994)
Manual
Service
 1440 Seat Heating and Cooling

DTC 82425 or B2430

Diagnostic Instructions
- Perform the Diagnostic System Check - Vehicle
on page 6-66 prior to using this diagnostic
procedure.
- Review Strategy Based Diagnosis on page 6-58
for an overview of the diagnostic approach.
- Diagnostic Procedure Instructions on page 6-59
provides an overview of each diagnostic category.
DTC Descriptors
DTC B2425 0B: Driver Seat Cushion Heater Circuit High Current
DTC B2425 0D: Driver Seat Cushion Heater Circuit High Resistance
DTC 32425 0E: Driver Seat Cushion Heater Circuit Low Resistance
DTC B2430 0B: Passenger Seat Cushion Heater Circuit High Current
DTC B2430 0D: Passenger Seat Cushion Heater Circuit High Resistance
DTC 82430 0E: Passenger Seat Cushion Heater Circuit Low Resistance
Diagnostic Fault Information

Open/High Short to Voltage Signal

Circuit Short to Ground Resistance Performance
?;‘I‘firngfgfg seat E'ememcomm' 3242A02 32425OD 3242A01 324250E

?g'r‘firngffgfgseat Ham“ 00””0' 3242A02 32425OD 3242A01 32425OE

DriverHeatedSeatTemperature SensorSignal B192502 B192505 B1925O5 -
greiygglr-Iltegted
SeatTemperature
SensorLow _ B192505 _ __

?:fnffigggrxgeated89““ E'ementcontro' 3242A02 32430OD 3242A01 32430OE

?jfgggfi’grxgeatedseat E'ementcontm' 3242A02 32430OD 3242A01 32430OE

ggsnsginger
HeatedSeatTemperatureSensor B217002 8217005 8217005 __

Egvsvsgggeerreficegted
SeatTemperatureSensor _ B217005 _ _

CircuitlSystem Description Conditions for Setting the DTC

The driver and front passenger heated seats are
controlled by the front seat heating control module that
is located under the driver seat cushion. When the
heated seat is active, the module applies power
through a common voltage supply circuit to the seat
heater elements. The module controls the seat
temperature by providing a pulse width modulation
(PWM) ground through the seat heater element control
circuit to the heater elements. The module then
monitors the current flow through the heating elements
and the rate of change of the temperature sensor to
verify correct heated seat operation.
B2425 0D or B2430 0D
By measuring current and voltage outputto the seat
heating elements every 10 seconds, the seat heating
control module calculates that the heating element
resistance is above the maximum resistance.
B2425 0B, B2425 0E, B2430 0B, or B2430 0E
By measuring current and voltage outputto the seat
heating elements every 10 seconds, the seat heating
control module calculates that the heating element
resistance is below the minimum resistance.

Conditions for Running the DTC Action Taken When the DTC Sets
- DTC B1325 must not be present. The heated seat function for the affected seat will be
disabled.
- Engine must be running.
~ The seat heating control module must be powered
and the heated seat must be enabled.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Seat Heating and Cooling 14-41

Conditions for Clearing the DTC
~ The current DTC clears when the malfunction is
no longer present, and the power mode changes
to OFF then back to ACC or RUN.
' The history DTC will clear after 40 consecutive
fault—freeignition cycles have occurred.
Reference Information
Schematic Reference
Heated/Cooled Seat Schematics on page 14—35
Connector End View Reference
Component Connector End Views on page 11269
Description and Operation
Heated Seats Description and Operation on
page 14—49
Electrical information Reference
- Circuit Testing on page 11-526
- Connector Repairs on page 11-548
- Testing for IntermittentConditions and Poor
Connections on page 11-531
- Wiring Repairs on page 11-537
Scan Tool Reference
Control Module References on page 6-3 for scan tool
information
CircuitlSystem Testing
32425 DB, B2425 OD, or B2425 DE
1. IgnitionOFF, disconnect the harness connector at
the E14A driver seat back heating element.
Note: Element resistance must be measured twice to
ensure that all failure conditions are simulated. First
with the seat unoccupied, then with the seat occupied.
2. Test for 0.5—2Q between control circuit terminal 1
and control circuitterminal 2.
=>If not between 0.5—2Q
Replace the E14A driver seat back heating
element.
U lf between 0.5—2(2
3. Connect the harness connector at the E14A driver
seat back heating element and disconnect the X2
harness connector at the K29 seat heating control
module.
Note: Element resistance must be measured twice to
ensure that all failure conditions are simulated. First
with the seat unoccupied, then with the seat occupied.
4. Test for 1—5(2between control circuit terminal 3
and control circuit terminal 1.
=>If less than 1 (2
4.1. lgnition OFF, disconnect the harness
connector at the E148 driver seat cushion
heating element.
4.2. Test for infinite resistance between the control
circuits.
:> Ifless than infinite resistance, repair the short
between the circuits.
:> Ifinfinite resistance, test or replace the
E148 driver seat cushion heating element.
:> If greater than 5 (2
4.1. lgnition OFF, disconnect the harness
connector at the E14B driver seat cushion
heating element.
4.2. Test for less than 2 0 between the control
circuits end to end.
=>If2 Q or greater, repair the open/high resistance
in the circuit.
:> Ifless than 2 (2,test or replace the E148 driver
seat cushion heating element.
U If between 1—5(1
5. Replace the K29 seat heating control module.
B2430 OB, 32430 0D, or B2430 DE
1. lgnition OFF, disconnect the harness connector at
the E140 passenger seat back heating element.
Note: Element resistance must be measured twice to
ensure that all failure conditions are simulated. First
with the seat unoccupied, then with the seat occupied.
2. Test for 0.5—20 between control circuit terminal 1
and control circuit terminal 2.
:> If not between 0.5—2(2
Replace the E14C passenger seat back heating
element.
U it between 0.5-2 Q
3. Connect the harness connector at the
E140 passenger seat back heating element and
disconnect the X2 harness connector at the
K29 seat heating control module.

2013
—Sonic
(US/Canada)
Service
Manual
(5377994)
14-42 Seat Heating and Cooling
Note: Element resistance must be measured twice to
ensure that all failure conditions are simulated. First
with the seat unoccupied, then with the seat occupied.
4. Test for 1——5 0 between control circuit terminal 5
and control circuit terminal 2.
=>If less than 1 0
4.1. lgnition OFF, disconnect the harness
connector at the E14D passenger seat
cushion heating element.
4.2. Test for infinite resistance between the control
circuits.
=>Ifless than infinite resistance, repair the short
between the circuits.
=>Ifinfinite resistance, test or replace the
E14D passenger seat cushion heating element.
=>If greater than 5 (2
4.1. lgnition OFF, disconnect the harness
connector at the E14D passenger seat
cushion heating element.
4.2. Test for less than 2 0 between the control
circuits end to end.
=>if 2 Q or greater, repairthe open/high resistance
in the circuit.
=>lf less than 2 0, test or replace the
E14D passenger seat cushion heating element.
U If between 1—5(I
5. Replace the K29 seat heating control module.
Repair instructions
Perform the Diagnostic Repair Verification on
page 6-92 after completing the repair.
0 Driver or Passenger Seat Back Cushion Heater
Replacement on page 14-47
~ Driver or Passenger Seat Cushion Heater
Replacement on page 14-48
' Control Module References on page 6-3 for front
seat heating control module replacement,
programming and setup

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Seat Heating and Cooling 14-43

DTC 8242A

Diagnostic Instructions
- Perform the Diagnostic System Check - Vehicle
on page 6-66 prior to using this diagnostic
procedure.
0 Review Strategy Based Diagnosis on page 6—58
for an overview of the diagnostic approach.
- Diagnostic Procedure Instructions on page 6-59
provides an overview of each diagnostic category.
DTC Descriptors
DTC B242A 01: Seat Heaters Common Circuit Short to Battery
DTC 8242A 02: Seat Heaters Common Circuit Short to Ground
Diagnostic Fault Information

Opeanigh Signal
Circuit Short to Ground Resistance Short to Voltage Performance
?;‘I‘I’IfI’ng'Ieffg
seat E'emem00“"0' 3242A02 32425OD 3242A01 83221122551183

$$$$$de seat E'ementcontro‘ 3242A02 324250D 3242A01 832212251)?

ggxggfsefgfgseat CUShiO"Temperature 3192502 3192505 3192505 3234513

32122152133123.2283“Temperature - -
?:fnsfiqgglingi-lzeated
Seat ElementControl B242A02 82430OD 8242A01 BBéiggthBE

~liefirsrfifiIrIthingrxl-lzeated
Seat ElementControl B242A02 32430OD BZ42A01 ggigggBE

ggfizgg‘grfiated seat CUShiO“Temperature 3217002 3217005 3217005 3234513

giggingngsgftggersIggt
CushionTemperature _ 8217005 _ 8234513

CircuitlSystem Description Conditions for Setting the DTC

The seat heating control module controls seat heating
operation for both the driver and front passenger seats.
The heating elements are controlled through individual
high side and low side control circuits. The low side
control circuits for both seats are connected to a
common reference point internal to the module. This
reference point is biased to approximately 2.5 V. Before
the seat heating control module will allow heated seat
operation, it checks to see if this biased voltage is
shorted to ground or voltage. Once the module verifies
that it is not closing to a shorted heating element, it
allows for heated seat operation. The module will then
continue to monitor the heating elements for a shorted
circuit.
Conditions for Running the DTC
- DTC B1325 must not be present.
~ The seat heating control module must be
powered.
3242A 01
The seat heating control module detects a short to
voltage on the heater element control circuits.
B242A 02
The seat heating control module detects a short to
ground on the heater element control circuits.
Action Taken When the DTC Sets
The heated seat function for both seats will be disabled.
Conditions for Clearing the DTC
. The current DTC will clear and set a history code
3 seconds after the reference voltage returns to
normal operating range and the ignition is cycled
OFF then back to ACC or RUN.
- The history DTC will clear after 40 consecutive
fauIt—freeignition cycles have occurred.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
'14-44 Seat Heating and Cooling

Reference Information Repair Instructions

Schematic Reference Perform the Diagnostic Repair Verification on
page 6-92 after completing the repair.
Heated/Coo/ed Seat Schematics on page 14—35 Control Module References on page 6-3 for seat
Connector End View Reference heating control module replacement, programming and
setup
Component Connector End Views on page 11-269
Description and Operation Symptoms - Seat Heating and
Heated Seats Description and Operation on Cooling
page 14-49 Note: The following steps must be completed before
using the symptom tables.
Electrical Information Reference
1. When diagnosing a heated seat system condition
- Circuit Testing on page 11-526 perform the Diagnostic System Check - Vehicle on
° Connector Repairs on page 11-548 page 6-66 , before using the symptom tables in
- Testing for IntermittentConditions and Poor order to verify that all of the following are true:
Connections on page 11~531 - There are no DTCs set.
- Wiring Repairs on page 11—537 - The control module(s) can communicate via the
Scan Tool Reference serial data link.
2. Review the system operation in order to familiarize
Control Module References on page 6-3 for scan tool yourself with the system functions. Refer to Heated
information Seats Description and Operation on page 14—49.
CircuitlSystem Testing VisuallPhysical Inspection
1. lgnition OFF, disconnect the X2 harness connector - inspect for aftermarket devices which could affect
at the K29 seat heating control module. the operation of the power seats. Refer to
2. Test for infinite resistance between the control Checking Aftermarket Accessories on
circuit terminals listed below and ground: page 11-525.
- Terminal 3 0 Inspect the easily accessible or visible system
- Terminal 5 components for obvious damage or conditions
which could cause the symptom.
=>If less than infinite resistance
- Inspect the seat adjuster track for conditions
Repair the short to ground on the circuit. which may cause binding or objects within the
ii If infinite resistance seat adjustment range which obstruct movement
.03 lgnition ON. or interfere with wiring.
4. Test for less than 1 V between the control circuit Intermittent
terminals listed below and ground: Faulty electrical connections or wiring may be the
- Terminal 3 cause of intermittentconditions. Refer to Testing for
- Terminal 5 IntermittentConditions and Poor Connections on
=>lf1Vor greater page 11-531.
Repair the short to voltage on the circuit. Sym ptom List
ii If less than 1 V Refer to the Front Heated Seat Malfunction on
5. Replace the K29 seat heating control module. page 14-45 diagnostic procedure in order to diagnose
the symptom.

2013
—
Sonic
(US/Canada)
Service
Manual
(5377994)
 Seat Heating and Cooling 14-45

l Front Heated Seat Malfunction

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

Opeanigh Short to Voltage Signal

Circuit Short to Ground Resistance Performance

$$$$$ng seat E'emem00””0' 3242A02 324250D B242A01 3322;111:212)?

$$$$$ng seat E'emem00””0' 3242A02 324250D B242Ao1 ggizzggBE'

DriverHeatedSeatTemperatureSensorSignal B192502 B192505 B192505 -

SeatTemperatureSensorLow
ggygglr-Ilcegted _ 3192505 _ _

SeatElementControl
?:rsniigglingi-éeated 8242A02 B24300D 8242A01 géiggtég,

SeatElementControl
?:rsmsitigggrxl-éeated B242A02 B24300D B242A01 BB221%%%BI’E,

HeatedSeatTemperatureSensor
ggsnsaelnger 3217002 3217005 8217005 _

SeatTemperatureSensor
Egisgggeeglalggted _ 8217005 _ _

CircuitlSystem Description - Testing for IntermittentConditions and Poor

The driver and passenger heated seats are controlled
by separate heated seat switches that are located in
the HVAC control module. Engine ON, when a heated
seat switch is pressed, a serial data message is sent
from the HVAC control module to the seat heating
control module control module indicating the heated
seat command. In response to this message, the seat
heating control module applies battery positive voltage
through the element supply voltage circuit to the
appropriate seat heating elements. The seat heating
control module then sends a serial data message back
to the HVAC control module to either illuminate or turn
off the appropriate temperature indicator.
Reference Information
Schematic Reference
Heated/Coo/ed Seat Schematics on page 14-35
Connector End View Reference
Component Connector End Views on page 11—269
Description and Operation
Heated Seats Description and Operation on
page 14—49
Electrical Information Reference
- Circuit Testingon page 11—526
0 Connector Repairs on page 11—548
Connections on page 11-531
- Wiring Repairs on page 11-537
Scan Tool Reference
Control Module References on page 6-3 for scan tool
information
CircuitlSystem Verification
1. lgnition ON.
2. Verify that no heated seat DTCs are set.
=>If any heated seat DTC is set
Refer to Diagnostic Trouble Code (DTC) List -
Vehicle on page 6-69.
ii If no heated seat DTCs are set
9° Engine ON.
4. Verify the scan tool Front Seat Heating Control
Module Driver Seat Heating/Venting/Cooling Mode
parameter changes between Off and
Back & Cushion Heat after pressing the driver
heated seat switch.
:> if the parameter does not change
Replace the K33 HVAC control module.
ii if the parameter changes

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
14-46 Seat Heating and Cooling
5. Verify the scan tool Passenger Front Seat Heating/ Repair Instructions
Venting/Cooling Mode Switch parameter changes
between Off and Back & Cushion Heat after Perform the Diagnostic Repair Verification on
pressing the passenger heated seat switch. page 6-92 after completing the repair.
- Heater and Air Conditioning Control Replacement
=>If the parameter does not change
on page 10—79
Replace the K33 HVAC control module. - Control Module References on page 6-3 for seat
ii If the parameter changes heating control module replacement, programming
6. Replace the K29 seat heating control module. and setup '

Repair Instructions

Front Seat Heater Control Module Replacement

2507904
Front Seat Heater Control Module Replacement
Callout Component Name
FrontSeat HeaterControlModuleFastener(Qty:2)
1
Caution: Referto FastenerCautiononpage0-8.
FrontSeat HeaterControlModule
Procedure
2 1. Disconnecttheelectricalconnectors.
2. Removethemodulefromtheheatercontrolbracket.
3. Referto ControlModuleReferencesonpage6-3forreplacementandsetupinformation.

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
 Seat Heating and Cooling 14.-47

Driver or Passenger Seat Back Cushion Heater Replacement

2506309

Driver or Passenger Seat Back Cushion Heater Replacement

. Callout I - Component Name
Warning: Refer to SIR Warningon page 0-7.
Preliminary Procedure
1. Removethedriveror passengerseat.Referto DriverorPassengerSeatRemovalandInstallationonpage 14-4.
2. Removethedriveror passengerseat backcushioncoverand‘pad.Referto Driveror PassengerSeatBack CoverandPad
Replacementonpage 14-15.
Driveror PassengerSeat Back CushionCover
1 Procedure
Separatetheseatcushionfromtheseatcushionpad.
2 Driveror PassengerSeat Back CushionPad
Driveror PassengerSeat Back CushionHeater
Procedure
3 1. Disconnecttheelectricalconnector.
2. Removetheheaterelementleavingtheold adhesivestripsintacton theseat cushion.The newseatheater
adhesivestripswill be placedovertheoldadhesivestrips.

2013
—Sonic
(US/Canada)
Service
Manual
(5377994)
14- 48 Seat Heating and Cooling

Driver or Passenger Seat Cushion Heater Replacement

2506114
Driver or Passenger Seat Cushion Heater Replacement
Callout I Component Name
Warning: Refer to SIR Warningon page 0-7.
Preliminary Procedures
1. Removethedriveror passengerseat.Referto Driveror PassengerSeatRemovalandInstallationonpage 14-4.
2. Removethefrontseatcushioncoverandpad.Referto FrontSeat CushionCoverandPad Replacementonpage 14-14.
FrontSeat CushionCover
1 Procedure
Separatetheseatcushionfromtheseatcushionpadby pullingthecoverawayfromthepad.
FrontSeat CushionHeater
2 Procedure
The heateris retainedtothepadwithadhesive,carefullypeeltheheaterfromtheseatcushionpadtoremove.
FrontSeat CushionPad
Note: Theseat beltpresencesensorandheatmat,ifequippedare integralpartsoftheseatcushionpad.

2013
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(US/Canada)
Service
Manual
(5377994)
 Seat Heating and Cooling 14=49

Description and Operation module then serves as a gateway to transmit the

Heated Seats Description and
Operation
Heated Seat Components
The driver and passenger heated seats consist of the
following components:
- Left heated seat switch
0 Right heated seat switch
- HVAC control module
' Seat heating control module
- Driver seat cushion heating element
- Driver seat back heating element
- Driver seat cushion temperature sensor
- Passenger seat cushion heating element
- Passenger seat back heating element
- Passenger seat cushion temperature sensor
Power and Ground
Battery positive voltage is supplied at all times to the
seat heating control module through a 30 A fuse
located in the underhood fuse block. This voltage is
used by the module to supply power to the seat heating
elements. Ground for the module is provided through
the module ground circuit and ground connection.
Heated Seat Operation
The driver and passenger heated seats are controlled
by a single seat heating control module that is located
under the driver seat cushion. Both heated seats are
controlled by separate heated seat switches that are
located in the HVAC control. When a heated seat
switch is pressed, a serial data message is sent from
the HVAC control to the HVAC control module
indicating the heated seat command. The HVAC control
message to the seat heating control module via the
serial data line. In response to this signal, the seat
heating control module applies battery positive voltage
through the element supply voltage circuit to the
appropriate seat heating elements. The seat heating
control module then sends a serial data message back
to the HVAC control module to gateway the information
to the HVAC control to either illuminate or turn off the
appropriate temperature indicator.
Temperature Regulation
When the engine ON, the heated seats will initialize in
the OFF state. With each activation of the heated seat
switch, the seat heating control module will cycle the
temperature setting in the following manner: HIGH,
MEDIUM, LOW, and OFF.
The seat heating control module monitors the seat
temperature through the temperature sensor signal
circuit and the temperature sensor (thermistor)that is
located in the seat cushion. The temperature sensor is
a variable resistor, it's resistance changes as the
temperature of the seat changes. When the
temperature sensor resistance indicates to the seat
heating control module that the seat has reached the
desired temperature, the module opens the ground
path of the seat heating elements through the heated
seat element control circuit. The module will then cycle
the element control circuit open and closed in order to
maintain the desired temperature.
Load Shed Management
The electrical power management function is designed
to monitor the vehicle electrical load and determine
when the battery is potentially in a high discharge
condition. The heated seat system is one of the vehicle
loads that is subject to reduction during a battery
discharge condition. For more information on load
management refer to Electrical Power Management
Description and Operation on page 9-731.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 I.
1% O0 Seat Heating and Cooling

BLANK

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)

Section
Steering
Power Steering ............................... 15—3
Specifications ................................... 15—3
Fastener Tightening Specifications ............. 15-3
Adhesives, Fluids, Lubricants, and Sealers ..... 15—3
Schematic and Routing Diagrams .............. 153
Power Steering Schematics .................... 15-4
Diagnostic Information and Procedures . . .. . . .15-5
DTC 00176 ..................................... 15-5
DTC 00475 ..................................... 15-7
DTC 00545 ..................................... 15-9
DTC 0056D ................................... 15-10
Symptoms —Power Steering System .......... 15-11
Rattle, Clunk, or Shudder Noise from the
Power Steering System ...................... 15-11
Whine or Growl Noise from the Power Steering
System ....................................... 15-11
Increase in Effort While Turning Steering
Wheel ........................................ 15-12
Poor Return of Steering Wheel ................ 15-13
Steering Wheel Surges/Jerks While
Turning ....................................... 15—14
Steering Wheel Kickback ...................... 15-14
Steering Effort Hard or Too Easy in One or
Both Directions ............................... 15—15
Repair Instructions ............................. 15-15
Steering Linkage InnerTie Rod Inspection 15—15
Steering Linkage Outer Tie Rod Inspection 15—16
Steering Linkage Outer Tie Rod
Replacement ................................. 15—17
Steering Gear Boot Replacement ............. 15—18
Steering Gear Replacement ................... 15-20
2013
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Sonic
(US/Canada)
Service
Manual
(5377994)
Table of Contents 15-1
15
Steering Linkage InnerTie Rod
Replacement ................................. 15—22
Description and Operation .................... 15—23
Power Steering System Description and
Operation .................................... 15—23
Special Tools and Equipment ................. 15-23
Steering Wheel and Column ............... 15—25
Specifications .................................. 15-25
Fastener Tightening Specifications ............ 15-25
Adhesives, Fluids, Lubricants, and Sealers 15—25
Diagnostic Information and Procedures . . .. . .15—25
Symptoms —Steering Wheel and Column .... . 15—25
Noise in Steering Column ..................... 15-25
Looseness in Steering Column ................ 15-26
Repair Instructions ............................. 15-27
IntermediateSteering Shaft Replacement ..... 15-27
Steering Column Upper Trim Cover
Replacement ................................. 15-28
Steering Column Lower Trim Cover .
Replacement ................................. 15-29
Turn Signal Switch Bracket Replacement ... . 15-30
Turn Signal Multifunction Switch
Replacement ................................. 15—31
Steering Wheel Replacement ................. 15-32
Steering Column Replacement ................ 15-33
Steering Angle Sensor Replacement .......... 1536
Description and Operation .................... 15—36
Steering Wheel and Column Description and
Operation .................................... 15-36
’15-2 Table of Contents

BLANK

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
‘WW
W.W
WW
_
 Power Steering 15—3

Power Steering

Specifications

Fastener Tightening Specifications

Specification
4W“,
WW
WW_\ Application Metric I English
SteeringGear Bolt
FirstPass 100N-m | 741511
FinalPass 97degrees
SteeringLinkageInnerTie Rod 100N-m I 74 lbft
SteeringLinkageOuterTie Rod Nut
FirstPass 30N-m | 221311
FinalPass 128degrees

Adhesives, Fluids, Lubricants, and Sealers

GM Part Number
Application Type of Material United States Canada

SteeringLinkageInnerTie Rod Hi9h_3£dnfighc£tgr§3%'§°ker89021297 10953488

Schematic and Routing Diagrams

2013
~Sonic
(US/Canada)
Service
Manual
(5377994)
 .-
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2013 Service
(US/Canada) (5377994)
Manual
 Power Steering 15-5

Diagnostic Information and Procedures

DTC C0176

Diagnostic Instructions
- Perform the Diagnostic System Check —Vehicle
on page 6-66 prior to using this diagnostic
procedure.
- Review Strategy Based Diagnosis on page 6-58
”#4,.
WWWWN
A...
.w
WW-
WWN_ for an overview of the diagnostic approach.
- Diagnostic Procedure Instructions on page 6-59
provides an overview of each diagnostic category.
DTC Descriptor
DTC C0176: Control Module Temperature Sensor
For symptom byte information, refer to Symptom Byte Reference Information
List on page 6-85.
Schematic Reference
CircuitlSystem Description
Power Steering Schematics on page 15-4
The power steering control module monitors the
temperature of the power steering system. The power Connector End View Reference
steering control module uses voltage, current levels
and input from an internal temperature sensor to Component Connector End Views on page 11—269
calculate an estimated system temperature. Ifthe Description and Operation
power steering control module detects a high system
temperature event is occurring, the amount of assist is Power Steering System Description and Operation on
reduced to lower system temperature to prevent page 15-23
thermal damage to the power steering components. Electrical Information Reference
Conditions for Running the DTC - Circuit Testing on page 11-526
. The ignition is ON, with the engine ON. . Connector Repairs on page 11-548
1 0 Power steering system voltage is 9—16volts. - Testing for IntermittentConditions and Poor
l - Repetitive steering input is present. Connections on page 11-531
- Wiring Repairs on page 11-537
l Conditions for Setting the DTC
i Scan Tool Reference
1 The power steering control module detects a high
l system temperature. Control Module References on page 6-3 for scan tool
l information
Action Taken When the DTC Sets
1 CircuitlSystem Verification
i - DTC C0176 54 is stored in memory.
l ' Steering assist is reduced. Note: Since most occurrences of this DTC are caused
by excessive driver inputs, review the conditions under
Conditions for Clearing the DTC which the DTC sets with the customer.
l
- A current DTC will clear on the next 1. Verify the DTC sets outside the conditions for
malfunction—freeignition cycle. running and setting the DTC.
i
- A history DTC will clear after 40 consecutive :> If the DTC sets within the conditions for
1
malfunction-free ignition cycles. running and setting the DTC
Diagnostic Aids The power steering system is operating as
i designed
- DTC C0176 54 does not indicate that a
l malfunction has occurred. Rather that the power U If the DTC sets outside the conditions for
steering control module had to limit current to the running and setting the DTC
i power steering motor to avoid thermal damage to 2. Operate the vehicle within the conditions that the
i1 the power steering system components. Discuss customer experienced.
‘1 with the customer about driving conditions when
11
i the steering assist was reduced.
- Ensure that no steering components down stream
of the power steering column assembly, such as
ball joints, tie rod ends, universal joints, or the
l steering gear assembly, are mechanically binding.

1 2013
-Sonic
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Manual
(5377994)
15-6 Power Steering
3. Verify that the DTC does not set. Repair Instructions
=>If the DTC sets Perform the Diagnostic Repair Verification on
Replace the K43 Power Steering Control page 6—92after completing the repair.
Module - Steering Gear Replacement on page 15-20
ii If the DTC does not set 0 Control Module References on page 6—3for power
4. All OK. steering control module replacement,
programming and setup.

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—
2013 (US/Canada)
Sonic (5377994)
Manual
Service
 Power Steering 15-7

DTC C0475

Diagnostic Instructions
- Perform the Diagnostic System Check —Vehicle
on page 6-66 prior to using this diagnostic
We
2.
WWW-
procedure.
- Review Strategy Based Diagnosis on page 6—58
for an overview of the diagnostic approach.
- Diagnostic Procedure Instructions on page 6-59
provides an overview of each diagnostic category.
DTC Descriptor
DTC C0475: Electric Steering Motor Circuit
For symptom byte information, referto Symptom Byte C0475 59
List on page 6-85. This DTC cannot be cleared.
CircuitlSystem Description Reference Information
00475 00 Schematic Reference
The power steering control module continuously
monitors the voltage and current levels being Power Steering Schematics on page 15-4
commanded to the 3-phase steering motor. The power Connector End View Reference
steering control module compares the desired and
actual current levels to detect malfunctions in the power Component Connector End Views on page 11—269
steering motor,or the Circuits to the motor. Description and Operation
C0475 59 Power Steering System Description and Operation on
The power steering control module continuously page 15-23
monitors the thermal cycle counter of the steering gear.
Ifthe thermal cycle counter exceeds the maximum Electrical Information Reference
allowable limit,the steering gear has reached its end of - Circuit Testing on page 11-526
life and must be replaced.
° Connector Repairs on page 11-548
Conditions for Running the DTC - Testing for IntermittentConditions and Poor
The ignition is ON. Connections on page 11-531
- Wiring Repairs on page 11-537
Conditions for Setting the DTC
Scan Tool Reference
C0475 00
Control Module References on page 6-3 for scan tool
The power steering control module detects a short to information
ground, short to voltage, or an open/high resistance on
any of the internal motor circuits. CircuitlSystem Verification
C0475 59 1. IgnitionON
The power steering control module detects the thermal 2. Verify with a scan tool that DTC 00475 57 is
cycle counter has exceeded the maximum allowable not set.
limit and the whole steering gear system must be :> If the DTC is set
replaced. Replace the steering column.
Action Taken When the DTC Sets U If the DTC is not set
- The DTC is stored in memory. 3. All OK.
° The driver information center displays a message CircuitlSystem Testing
andlor a warning indicator will be displayed on the
instrument cluster. Note: Please perform the CircuitlSystem Verification
before performing the CircuitlSystem Testing.
- No steering assist.
1. lgnition OFF and all vehicle systems OFF. it may
Conditions for Clearing the DTC take up to 2 min for all vehicle systems to
C0475 00 power down.
o A current DTC will clear on the next 2. Disconnect the harness connector X2 at the
malfunction—freeignition cycle. K43 Power Steering Control Module.
- A history DTC will clear after 40 consecutive
malfunction-free ignition cycles.

2013
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15-8 Power Steering
3. Test for less than 5 Q between the ground circuit :> if less than 2 Q, verify the fuse is OK and there
terminal B and ground. is voltage at the fuse.
=>lf 5 Q or greater =>If the test lamp does not illuminate and the
3.1. lgnition OFF, disconnect the harness circuit fuse is open
oonnectorX2 at the K43 Power Steering 5.1. lgnition OFF.
Control Module. 5.2. Test for infinite resistance between the B+
3.2. Test for less than 2 Q in the ground circuit end circuit and ground.
to end. =>Ifless than infinite resistance, repair the short to
=>If2 Q or greater, repair the open/high resistance ground on the circuit.
in the circuit. :> Ifinfinite resistance, replace the steering
=>Ifless than 2 Q , repair the open/high resistance column.
in the ground connection. U If the test lamp illuminates
it less than 5 Q 6. Replace the steering column.
;|>-<:
IgnitionON.
Repair Instructions
5. Verify a test lamp illuminates between the B+
circuit terminal A and ground. Perform the Diagnostic Repair Verification on
page 6-92 after completing the repair.
=>If the test lamp does not illuminate and the
circuit fuse is good - Steering Column Replacement on page 15—33
5.1. lgnition OFF. - Control Module References on page 6-3 for power
steering control module replacement,
5.2. Test for less than 2 Q in the B+ circuit end
programming and setup.
to end.
=>lf 2 Q or greater, repair the open/high resistance
in the circuit.

WM
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2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Power Steering 15-9

DTC C0545

Diagnostic Instructions
- Perform the Diagnostic System Check - Vehicle
on page 6—66prior to using this diagnostic
procedure.
- Review Strategy Based Diagnosis on page 6-58
for an overview of the diagnostic approach.
. Diagnostic Procedure Instructions on page 6-59
provides an overview of each diagnostic category.
WWWW DTC
firm
~«
‘WNWWW‘ Descriptor
DTC C0545: Steering Wheel Torque Sensor
For symptom byte information, referto Symptom Byte - Connector End View Reference
List on page 6-85.
Component Connector End Views on page 11-269
CircuitlSystem Description
Description and Operation
The power steering control module continuously
monitors the digital torque sensor's torque and index Power Steering System Description and Operation on
current signals. As the steering wheel is turned and page 15—23
torsional twist is applied to the steering shaft, the Electrical Information Reference
steering input and output shafts are monitored via the
torque signal circuit and then processed by the power - Circuit Testing on page 11-526
steering control module to calculate the steering torque. - Connector Repairs on page 11-548
Conditions for Running the DTC - Testing for IntermittentConditions and Poor
Connections on page 11—531
The ignition is ON.
- Wiring Repairs on page 11-537
Conditions for Setting the DTC Scan Tool Reference
The power steering control module detects a short to
ground, short to voltage, or an open/high resistance on Control Module References on page 6-3 for scan tool
any of the internal motor position sensor circuits. information

Action Taken When the DTC Sets CircuitlSystem Verification

DTC C0545 ISstored Inmemory. 1. IgnitionON.
- The driver information center displays a message 2. Verify with a scan tool that DTC 00545 is not set.
and/or a warning indicator will be displayed on the =>If the DTC is set
instrumentcluster. Replace the steering column.
- No steering assist. U If the DTC is not set
Conditions for Clearing the DTC 3. All OK.
- A current DTC will clear on the next Repair Instructions
malfunction-free ignition cycle.
Perform the Diagnostic Repair Verification on
. A history DTC will clear after 40 consecutive
page 6—92after completing the repair.
malfunction-free ignition cycles.
- Steering Column Replacement on page 15-33
Reference Information ~ Control Module References on page 6-3 for power
Schematic Reference steering control module replacement,
programming and setup.
Power Steering Schematics on page 15-4

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
15-10 Power Steering

DTC C056D

Diagnostic Instructions
- Perform the Diagnostic System Check —Vehicle
on page 6-66 prior to using this diagnostic
procedure.
- Review Strategy Based Diagnosis on page 6-58
for an overview of the diagnostic approach.
- Diagnostic Procedure Instructions on page 6—59
provides an overview of each diagnostic category.
DTC Descriptor
DTC C056D: Electronic Control Unit Hardware
For symptom byte information, refer to Symptom Byte Description and Operation
List on page 6-85.
Data Link Communications Description and Operation
CircuitlSystem Description on page 11-68
The internal fault detection is handled inside the device. Electrical Information Reference
The symptom byte information is for engineering
reference only. No external circuit diagnosis is involved. ~ Circuit Testing on page 11-526
- Connector Repairs on page 11-548
Conditions for Running the DTC
~ Testing for IntermittentConditions and Poor
The device runs the program to detect an internal fault Connections on page 11-531
when power up is commanded. The only requirements ' Wiring Repairs on page 11-537
are voltage and ground. This program runs even if the
voltage is out of the valid operating range. Scan Tool Reference
Conditions for Setting the DTC Control Module References on page 6—3for scan tool
information
The device has detected an internal malfunction.
CircuitlSystem Verification
Action Taken When the DTC Sets
1. lgnition ON.
The device refuses all additional inputs.
2. Verify DTC 0056D is not set.
Conditions for Clearing the DTC =>If DTC C056D is set in a device that can be
' A current DTC clears when the malfunction is no programmed
longer present. 2.1. Program the device that set the DTC.
- A history DTC clears when the device ignition 2.2. Verify the DTC does not set.
cycle counter reaches the reset threshold of 50, =>Ifthe DTC sets, replace the device that set
without a repeat of the malfunction.
the DTC.
Diagnostic Aids U if the DTC does not set
- This DTC may be stored as a history DTC without 2.3. AMOK.
affecting the operation of the device. =>If DTC C056D is set in a device that cannot be
- Ifstored only as a history DTC and not retrieved programmed
as a current DTC, do not replace the device.
Replace the device that set the DTC.
- Ifthis DTC is retrieved as both a current and
history DTC, replace the device that set the DTC. U If DTC C056D is not set
3. All OK
Reference Information
Repair Instructions
Schematic Reference
Perform the Diagnostic Repair Verification on
- Data Communication Schematics on page 11-4 page 6—92after completing the repair.
- Control Module References on page 6—3 Control Module References on page 6—3for device
replacement, programming and setup
Connector End View Reference
Component Connector End Views on page 11—269

(US/Canada}
-Sonic
2013 (5377994)
Manual
Service
 Power Steering 15-11

Symptoms - Power Steering System Refer to a symptom diagnostic procedure from the
following list in order to diagnose the symptom:
Note: Review the system description and operation in
order to familiarize yourself with the system functions. Rattle, Clunk, or Shudder Noise from the Power
Refer to Power Steering System Description and Steering System on page 15-11
Operation on page 15—23. Whine or Growl Noise from the Power Steering
System on page 15-11
WLW/
~
. Visual/Physical Inspection Increase in Effort While Turning Steering Wheel
. Inspect for aftermarket devices which could affect on page 15-12
the operation of the power steering system. Poor Return of Steering Wheel on page 15—1 3
- Inspect the easily accessible or visible system Steering Wheel Surges/Jerks While Turning on
components for obvious damage or conditions page 15—14
which could cause the symptom. Steering Wheel Kickback on page 15-14
Steering Effort Hard or Too Easy in One or Both
Directions on page 15-15

Rattle, Clunk, or Shudder Noise from the Power Steering System

Step Action Yes No
Go toPowerSteering
1 DidyoureviewthePowerSteeringSystemDescriptionand Go to Ste 2 SystemDescription
Operationandperformthenecessaryinspections? p and Operationon
page 15-23
Verifythata rattle,clunkor shuddernoiseis present.
2 Isa rattle,clunkor shuddernoisepresent? GOto Step3 SystemOK
Inspectthepowersteeringgearfortheproperinstallation.Referto
3 SteeringGearReplacementonpage 15-20. Go to Step4 Go to Step6
Isthepowersteeringgearinstallationcorrect?
Inspecttheintermediateshaft.
4 Istheintermediateshaftworn? Go to Step7 GOto Step5
> Go to NoiseDiagnosis
5 Inspectthesuspenswn; -FrontSuspensionon Go to Step2
Isthesuspenstonworn. page 16-39
Installthepowersteeringgearcorrectly.Referto SteeringGear
5 Replacementonpage 15-20. Go to Step8 -
Didyoucompletetherepair? '
Replacetheintermediateshaft.Referto Intermediate SteeringShaft
7 Replacementonpage 15-27. Go to Step8 . _
Didyoucompletetherepair?
Operatethesysteminorderto verifytherepair.
8 Didyoucorrectthecondition? SystemOK Go to Step3

Whine or Growl Noise from the Power Steering System

Step Action I Yes I No
Special Tools
CH-39570Chassis Ear
Forequivalentregionaltools,referto Special Toolsonpage 15-23.
DidyoureviewthePowerSteeringSystemDescriptionand Go to Symptoms-
1 Operationandperformthenecessaryinspections? PowerSteering
Go to Step2 Systemonpage 15—11
2 Verifythata whineor growlnoiseis present.
Isa whineor growlnoisepresent? Go to Step3 SystemOK
Inspectthepowersteeringgearforloosenessandlorworn
3 bushings.
Isthesteeringgearlooseor are thebushingsworn? Go to Step6 Go to Step4
Inspectthepowersteeringmotorfora whineor growlnoiseusing
4 theCH-39570ear.
Isthenoisepresentatthepowersteeringmotor? Go to Step7 Go to Step5

(US/Canada)
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2013 (5377994)
Manual
Service
15-12 Power Steering

Whine or Growl Noise from the Power Steering System (cont'd)

Step Action Yes No
Inspectthepowersteeringgearfora whineor growlnoiseusingthe
CH-39570ear.
Isthenoisepresentat thepowersteeringgear? Go to Step8 Go to Step3
Tightenthepowersteeringgearfastenersor replacethepower
steeringgearduetowornbushings.Referto SteeringGear
Replacementonpage 15—20.
Didyoucompletetherepair? Go to Step9
Replacethesteeringcolumn,whichincludestheelectronicpower
steeringassistmotorcontrolunit.Referto SteeringColumn
Replacementonpage 15-33.
Didyoucompletetherepair? Go to Step9
Replacethepowersteeringgear.Referto SteeringGear
Replacementonpage 15-20.
Didyoucompletetherepair? Go to Step9
Operatethesystemin ordertoverifytherepair.
Didyoucorrectthecondition? SystemOK Go to Step3

increase in Effort While Turning Steering Wheel

Step Action Yes No
DidyoureviewthePowerSteeringSystemDescriptionand Go to Symptoms-
Operationandperformthenecessaryinspections? PowerSteering
Go to Step2 Systemonpage 15-11
Verifythatthereis an increasein effortwhileturningis present.
Doesthesystemoperatenormally? SystemOK Go to Step3
Checkforthefollowingtirerelatedconditions:
' Incorrecttireinflation—RefertoVehicleCertification,Tire
Placard,Anti-Theft,andServicePartsIDLabelonpage 1-13.
- Impropertiresize
Didyoufindandcorrectthecondition? Go to Step10 Go to Step4
1. Raise andsupportthevehicle.Referto LiftingandJackingthe
Vehicleonpage 1-31.
2. Checkfora bindingorworntierodend.
Isthetie rodbindingor worn? Go to Step7 Go to Step5
Checkfora wornor bindingintermediateshaft.
Istheintermediateshaftwornor binding? Go to Step8 Go to Step6
Checkfora wornor bindingsteeringgear.
Isthesteeringgearwornor binding? Go to Step9 SystemOK
Replacetheoutertierod.Referto SteeringLinkageOuterTieRod
Replacementonpage 15-17.
Didyoucompletetherepair? Go to Step 10
Replacetheintermediateshaft.Referto IntermediateSteeringShaft
Replacementonpage 15-27.
Didyoucompletetherepair? Go to Step 10
Replacethesteeringgear.Referto SteeringGearReplacementon
page 15—20.
Didyoucompletetherepair? Go to Step10
Operatethesystemin ordertoverifytherepair.
1O
Didyoucorrectthecondition? SystemOK

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Power Steering '35-13

Poor Return of Steering Wheel

Step Action Yes No
DEFINITION:Aftercompletinga turn,extrasteeringinputis requiredforthesteeringwheelto returnto center.
DidyoureviewthePowerSteeringSystemDescriptionand Go to Symptoms-
1 Operationand performthenecessaryinspections? PowerSteering
Go to Step2 Systemonpage 15-11
Verifythatpoorreturnofthesteeringwheelis present.
Doesthesystemoperatenormally? SystemOK Go to Step3
1. Raiseand supportthevehicle.Referto LiftingandJackingthe
Vehicleonpage 1-31.
2. Lubricatethetie rodendsandballjoints,ifapplicable.
3. Inspectthesuspensionsystemforwornor damaged.
components.
4. Repairas necessary.
Didyoufindandcorrectthecondition? Go to Step12 Go to Step4
1. RotatethesteeringwheelONE revolutionin bothdirections.
2. Rotatethesteeringwheelbacktotheoriginalposition.
Was thesteeringwheelabnormallydifficultto rotatein either
direction? Go to Step5 Go to Step 10
Note: Positionthewheelsstraightahead.Do NOT rotatethe
steeringwheelmorethanonecompleterevolutionfromcenter.
1. Disconnectthe intermediateshaftfromthesteeringcolumn.
2. Notethepositionofthesteeringwheelandrotatethesteering
wheelONE revolutionin bothdirections.
3. Rotatethesteeringwheelbacktotheoriginalposition.
Wasthesteeringwheelabnormailydifficultto rotatein either
direction? Go to Step11 Go to Step6
Inspecttheintermediateshaftforstiffor loosejoints.Repair or
replaceas necessary.
Didyoufindandcompletetherepair? Go to Step12 Go to Step7
1. Removethefronttireandwheelassemblies.Referto Tireand
WheelRemovalandInstallationonpage 16-60.
2. Disconnectbothoutertierodendsfromthesteeringknuckles.
3. Useyourhandsin orderto movethetierodendstuds.
4. Ifabnormallydifficultto move,replacethetie rodend.
Ifequippedwithrecirculatingbailsteering,ensurethatidler
andpitmanarmjointsarenottostiff.Repairas necessary.
Didyoufindandcompletetherepair? Go to Step12 Go to Step8
1. Use yourhandsto rotatethesteeringknuckleinboardand
outboardinorderto inspectfora bindingstrutbearings,ball
joints,or axle.
2. Repairor replaceanyabnormallystiffor loosecomponents.
Didyoufindandcompletetherepair? Go to Step12 Go to Step9
inspectforbindingin thesteeringgear.if a bindingis present,repair
or replacethesteeringgear.
Didyoufindandcompletetherepair? Go to Step12 Go to Step 10
inspectthewheelalignmentandadjustas necessary.Referto
10 WheelA/ignment Measurementonpage 16-69.
Didyoufindandcompletetherepair? Go to Step12
inspectthesteeringcolumnfora binding.Ifa bindingis present,
11 repairor replacethesteeringcolumnas necessary.
Didyoufindandcompletetherepair? Go to Step 12
Operatethesystemin ordertoverifytherepair.
12
Didyoucorrectthecondition? SystemOK

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
15-14 Power Steering

Steering Wheel Surges/Jerks While Turning

Step Action Yes No
Didyou reviewthePowerSteeringSystemDescriptionand Go to Symptoms-
1 Operationandperformthenecessaryinspections? PowerSteering
Go to Step2 Systemonpage 15-11
2 Verifythatthesteeringwheelsurgesorjerks whileturning.
Doesthesystemoperatenormally? SystemOK Go to Step3
3 inspectthefrontsuspensionforwornor bindingcomponents.
Didyoufindandcorrectthecondition? Go to Step14 Go to Step4
1. Raise andsupportthevehicle.Referto LiftingandJackingthe
Vehicleonpage 1-31.
4 2. Inspectthesteeringlinkageoutertie rodforwearor a binding
condition.
Isthesteeringlinkageoutertierodwornor binding? Go to Step10 Go to Step5
Inspecttheintermediatesteeringshaftforwearor a binding ‘
5 condition.
~lstheintermediatesteeringshaftwornor binding? Go to Step 11 Go to Step6
6 Inspectthesteeringgearforwearor a bindingcondition.
is thesteeringgearwornor binding? Go to Step12 Go to Step7
7 Inspectthesteeringcolumnforwearor a bindingcondition. y
is thesteeringcolumnwornor binding? Go to Step13 Go to Step8
inspectthepowersteeringassistmotorforan indicationof
8 excessiveheat.
Doesthepowersteeringassist motorappearto be overheated? Go to Step9 Go to Step 13
Note: Do notperformexcessiveparkinglotmaneuversduring ‘
testing.Excessiveparkinglotmaneuverscan causethepower
9 steeringassistmotorto heatup.
Allowthepowersteeringassistmotorto coolandretestthesystem.
Didyoucorrectthecondition? Go to Step14 Go to Step 13
Replacethesteeringlinkageoutertierod.Referto SteeringLinkage
10 OuterTieRod Replacementonpage 15-17.
Didyoucompletetherepair? Go to Step14 —-
Replacetheintermediatesteeringshaft.Referto Intermediate ,A
”we.
<MN
23.-
-_».m
~
mm
__fl
-~\
11 SteeringShaftReplacementonpage 15-27.
Didyoucompletetherepair? . . Go to Step 14 -
Replacethesteeringgear.Referto SteeringGearReplacementon '
12 page 15—20.
Didyoucompletetherepair? Go to Step14 -
Replacethesteeringcolumn.Referto SteeringColumn
13 Replacementonpage 15-33.
Didyoucompletetherepair? Go to Step14 -
14 Operatethesysteminordertoverifytherepair.
Didyoucorrectthecondition? SystemOK Go to Step3

Steering Wheel Kickback

Condition
Thesteeringcolumnmountingboltsare loose.
The steeringgearis looselymounted.
The steeringlinkagetierodsarelooseordamaged.
Action
Tightenthepivotboltandthemountingboltsto specification.
Tightenthesteeringgearmountingboltsto specification.
Inspectthesteeringlinkagetierods.Ifnecessary,replacethe
steeringlinkagetierods.Referto SteeringLinkageOuterTie
Rod Replacementonpage 15-17orto SteeringLinkageInner
TieRod Replacementonpage 15-22.

2013
-Sonic
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Manual
(5377994)
 Power Steering 15:15

Steering Effort Hard or Too Easy in One or Both Directions

Condition Action
The batterypoweris low. Confirmproperbatteryvoltage.
The intermediateshaftdashseal is binding. Adjustthedashseal,or replacethe intermediateshaftassembly
if necessary.Referto IntermediateSteeringShaftReplacement
onpage 15-27.
The intermediateshaftjointsare looseorworn. Inspectthejointsandthepinchboltsfordamage,and replace
theintermediateshaftif necessary.Referto Intermediate
SteeringShaftReplacementonpage 15-27.
The steeringgearis binding. if necessary,inspectandreplacethesteeringgear.Referto
SteeringGearReplacementonpage 15—20.
The uppersteeringshaftis bent. Ifnecessary,replacethesteeringcolumn.Referto Steering
ColumnReplacementonpage 15-33.
The assist mechanismhubgearis misalignedor damaged. Replacethesteeringcolumn.Referto SteeringColumn
Replacementonpage 15-33.
The sensorwireis damaged. Replacethesteeringcolumn.Referto SteeringColumn
Replacementonpage 15-33.
The controlleris malfunctioning. ConfirmtheDTC. Ifnecessary,replacethesteeringcolumn,
whichincludesthemotorandmoduleassembly.Referto
SteeringColumnReplacementonpage 15—33.
The motorshaftis binding. ConfirmtheDTC. Ifnecessary,replacethesteeringcolumn,
whichincludesthemotorandmoduleassembly.Referto
SteeringColumnReplacementonpage 15—33.

Repair Instructions

Steering Linkage Inner Tie Rod

Inspection
Special Tools
GE-8001 Dial lndicatorSet
For equivalent regional tools, refer to Special Tools on
page 1523‘.
Note: This inspection procedure does not supersede
local government required inspections that have more
stringent requirements.
1. Turn the ignition key to the ON position with the
engine OFF.

M4

111

1958478
2. With the aid of an assistant, turn the steering wheel
to the full stop position and hold the steering wheel
in that position until the test is complete. Part of the
steering linkage inner tie rod (2) being tested
should be inside the steering gear housing. The

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
151-16 Power Steering
inner tie rod housing (1) being tested should be
inside the steering gear housing and seated
against the steering stop.
3. Raise and support the vehicle. Refer to Lifting and
Jacking the Vehicle on page 1—31.
4. Ifthere is not a good location for the GE—8001dial
indicator pointer at the steering gear housing,
install a large worm gear hose clamp (3) to the
steering gear housing over the larger steering gear
boot clamp and align the clamp so that the screw
can be a location for the 658001 dial indicator
pointer.
5. Install the GE-8001 dial indicator between the inner
tie rod and the steering gear housing or the worm
gear clamp in such a way as to measure the lash
between the inner tie rod and the steering gear
housing. The lash between the inner tie rod and
the steering gear housing is equal to the lash
between the inner tie rod and the inner tie rod
housing because the inner tie rod housing is inside
the steering gearhousing during this procedure.
Steering Linkage Outer Tie Rod
Inspection
Special Tools
GE—8001Dial Indicator Set
For equivalent regional tools, refer to Special Tools on
page 15-23.
Note: This inspection procedure does not supersede
local government required inspections that have more
stringent requirements.
1. Inspect the outertie rod seal. Ifthe outer tie rod
seal is torn, replace the outer tie rod. Refer to
Steering Linkage Outer Tie Rod Replacement on
page 15-17.
2. Raise the side of the vehicle being inspected with a
floorjack while maintaining contact between the
opposite wheel and the shop floor. Support the
lower control arm with a floorjack stand as far
outboard as possible and remove the floorjack.
Refer to Lifting and Jacking the Vehicle on
page 1-31.

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2211822
Note: Only move the tire enough to feel any lash 1855622
between the innertie rod and the inner tie rod housing
without moving the steering gear rack. 3. Install the GE—8001dial indicator between the
outer tie rod and the steering knuckle as shown in
6. Grasping the tire at the 3 o'clock (2) and the graphic. Note that the tire and wheel assembly
9 o'clock (1) positions, gently push in on one side is shown removed only for clarification of the GE-
of the tire in order to remove any lash. 8001dia| indicator position.
7. Zero the GE—8001dial indicator.
8. On the same side of the tire previously pushed in,
gently pull out and measure the lash.
9. Record the measurement shown on the GE-8001
diai indicator. .WM
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.__m
» .
10. lfthe measured value exceeds 0.5 mm (0.02 in),
replace the inner tie rod. Refer to Steering Linkage
Inner Tie Rod Replacement on page 15—22.
11. Repeat the procedure for the other side.

2013
-Sonic
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(5377994)
 Power Steering 15-17
. Grasping the tire at the 3 o'clock (2) and
9 o‘clock (1) positions, gently push in on one side
of the tire to remove any lash.
. Zero the GE—8001dial indicator.
. On the same side of the tire previously pushed
inwards, gently pull outwards and measure
the lash.
. Record the measurement shown on the 658001
diai indicator.
. if the measured value exceeds 0.5 mm (0.02 in),
replace the outer tie rod. Refer to Steering Linkage
Outer Tie Rod Replacement on page 15-17.
. Repeat the procedure for the other side.

2211822

Steering Linkage Outer Tie Rod Replacement

1779542

2013
-Sonic
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'15-'18 Power Steering

Steering Linkage Outer Tie Rod Replacement

Callout l Component Name
Preliminary Procedures
1. Raise andsupportthevehicle.Referto LiftingandJackingthe Vehicleonpage 1-31.
2. Removethefronttireandwheelassembly.Referto Tireand WheelRemovalandInstallationonpage 16-60.
SteeringLinkageOuterTieRod Nut
Warning: This componentis equippedwith torque-to-yieldfasteners.Installa NEW torque-to-yield
fastener wheninstalling this component.Failure to replace the torque-to-yieldfastener could cause
bodily injury and damageto the vehicle or component.
Caution: Referto FastenerCautiononpage0-8.
Procedure
1. Removethesteeringlinkageoutertierodnut.
DISCARDthenut.
2. Installa NEW outertie rodnut.
3. Use theEN-45059meterin ordertotightentheoutertie rodnuttothespecification.
Tighten
1. 3ON-m(221bft)
2. 128degrees
Special Toots
EN-45059AngleMeter
For equivalentregionaltools,referto SpecialToolsonpage 15-23.
SteeringLinkageInnerTieRod Nut
Procedure
1. Use paintin orderto placematchmarkson thesteeringlinkageinnertierodnutandonthesteeringlinkage
2 innertierod.
2. Duringinstallation,alignthematchmarks.
3. Do nottightenthenutduringinstallation.Tightenthenutafteradjustingthefronttoe.Referto Wheel
Alignment—SteeringWheelAngleand/orFrontToeAdjustmentonpage 16-70.
SteeringLinkageOuterTie Rod
Caution: Do notfreetheballstudby usinga pickleforkor a wedge-typetool.Damagetotheseal orbushing
mayresult.
Procedure
1. Use theCH-161-Bpuilerin ordertoseparatethesteeringlinkageoutertierodfromthesteeringknuckle.
2. Inspectthesteeringlinkageinnertierodforbentor damagedthreads.
3. Cleanthetaperedsurfaceofthesteeringknuckle.
4. Aftertheinstallationis complete,measureandadjustthefronttoe.Referto WheelAlignment- Steering
WheelAngleand/orFrontToeAdjustmentonpage 16-70.
Special Tools
CH-161—B BearingPuller
For equivalentregionaltools,referto SpecialToolsonpage 15-23.

Steering Gear Boot Replacement

Special Tools
CH-804 Tensioner
For equivalent regional tools, refer to Special Tools on
page 15—23.
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and
Jacking the Vehicle on page 1—31.
2. Remove the steering linkage outer tie rod. Refer to
Steering Linkage Outer Tie Rod Replacement on
page 15—17.

2013
-Sonic
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 Power Steering 15-19

Installation Procedure

2028056
Note: Place match marks on the steering linkage inner
tie rod nut and the steering linkage inner tie rod before 2375391
removing. During installation ofthe nut, align the match
marks. 1. Install a new steering gear boot inner
clamp (3) loosely on the steering gear boot (2).
3. Remove the steering linkage inner tie rod nut (1).
2. Apply the lubricant from the service kit to the
4. Remove the steering gear boot outer clamp (2). steering linkage inner tie rod and to the steering
gear boot (2).
Note: The steering gear boot must seat in the
appropriate groove on the steering gear.
3. Install the steering gear boot (2)over the steering
linkage innertie rod and onto the steering gear.

2375391
5. Remove the steering gear boot inner clamp (3).
Discard the clamp.
6. Remove the steering gear boot (2).
7. Clean the steering linkage inner tie rod and the
steering gear boot contact area of any lubricant 0r 2028057
debris.
4. Use the CH—804tensioner in order to crimp the
inner steering gear boot clamp (1).

2013
-Sonic
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15-20 Power Steering
5. Installthe steering gear outer boot clamp (2).
6. Installthe steering linkage inner tie rod nut (1).
7. Installthe steering linkage outer tie rod. Refer to
Steering Linkage Outer Tie Rod Replacement on
page 15—17.
8. After installation is complete, measure and adjust
the front toe. Refer to Whee/Alignment —Steering
Wheel Angle and/or Front ToeAdjustment on
page 16—70.

2028056

Steering Gear Replacement

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2511581

2013
-Sonic
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Manual
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 Power Steering 15-21

Steering Gear Replacement

Callout Component Name
Caution: Withwheelsofthevehiclefacingstraightahead,securethesteeringwheelutilizingsteeringcolumnanti-rotationpin,
steeringcolumnlock,ora strapto preventrotation.Lockingofthesteeringcolumnwill preventdamageand a possible
malfunctionoftheSIR system.The steeringwheelmustbesecuredin positionbeforedisconnectingthefollowingcomponents:
- The steeringcolumn
' The intermediateshaft(s)
- The steeringgear
Afterdisconnectingthesecomponents,do notrotatethesteeringwheelor movethefronttiresandwheels.Failuretofollowthis
proceduremaycausetheSIR coil assemblyto becomeun-centeredandcause possibledamagetotheSIR coil.Ifyouthinkthe
SIR coil has becomeun-centered,refertoyourspecificSIR coil’scenteringproceduretore—center SIR Coil.
Preliminary Procedure
1. Withthesteeringwheelinthestraightaheadposition,LOCK thesteeringcolumn.
Disconnecttheintermediatesteeringshaftfromthesteeringgear.Referto SteeringColumnReplacementonpage 15-33.
Disconnectthesteeringcolumndash sealfromthedash panel.
Raise andsupportthevehicle.Referto LiftingandJackingtheVehicleon page 1—31.
91:59)!“
Discor112e1c;
theoutertie rodsfromthesteeringknuckles.Referto SteeringLinkageOuterTieRod Replacementon
page - .
9’ Partiallylowertherearofthedrivetrainandfrontsuspensionframeinorderto gainclearanceforthesteeringgear.Referto
DrivetrainandFrontSuspensionFrameReplacementonpage3-144.
SteeringGear Nut(Qty:2)
1 Procedure
Duringinstallation,holdthesteeringgearnutswhiletighteningthesteeringgearbolts.
2 SteeringGear Washer(Qty:2)
SteeringGear Bolt(Qty:2)
Warning: This componentis equipped with torque-to-yieldfasteners.Installa NEW torque-to-yield
fastenerwhen installing this component.Failure to replace the torque-to-yieldfastenercould cause
bodily injury and damageto thevehicle or component.
Caution: Referto FastenerCautiononpage0-8
Procedure
1. Removethe2 steeringgearbolts.
Discardthebolts.
3 2. Install2 NEW steeringgearbolts.
3. Holdthesteeringgearnutswhiletighteningthesteeringgearbolts.Use theEN-45059meterin orderto
tightenthesteeringgearboltstothe specification.
Tighten
1. 100N-m(74lbft)
2. 97degrees
Special Tools ,
EN-45059Angie Meter
Forequivalentregionaltools,referto Special Toolsonpage 15-23.
SteeringGear
Procedure
4 1. Carefullyremovethesteeringgearthroughtheleftfrontwheelopening.
2. Transferpartsit necessary.
3. Aftertheinstallationis complete,measureandadjustthefronttoe.Referto WheelA/ignment—Steering
WheelAngle and/orFrontToeAdjustmentonpage 16-70.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
15-22 Power Steering

Steering Linkage Inner Tie Rod Replacement

2264216

Steering Linkage Inner Tie Rod Replacement

Callout Component Name
Preliminary Procedures -
1. Raise andsupportthevehicle.Referto LiftingandJackingtheVehicleonpage 1-31.
2. Removethesteeringgearboot.Referto SteeringGearBootReplacementonpage 15-18.
SteeringLinkageInnerTieRod
Caution: Do notchangethesteeringgearpreloadadjustmentbeforemovingtheinnertie rodfromthesteering
gear.Changingthesteeringgearpreloadadjustmentbeforemovingtheinnertierodcouldresultindamageto
thepinionandthesteeringgear.
Caution: Referto FastenerCautiononpage0-8.
Procedure
1. Place a pipewrenchontheflatsofthesteeringgearrack.Positionthepipewrenchbetweenthesteering
gearhousingandthesteeringlinkageinnertierodhousing.
1 2. Place a wrenchontheflatsofthesteeringlinkageinnertierodhousing.
3. Rotatethesteeringlinkageinnertierodhousingcounterclockwisein orderto removethesteeringlinkage
innertierodfromthesteeringgearrack.
4. Applythreadlockingadhesiveto thesteeringlinkageinnertierodthreadspriorto installingittothesteering
gearrack.RefertoAdhesives,Fluids,Lubricants,andSealersonpage 15-3.
5. Rotatethesteeringlinkageinnertierodhousingclockwisein orderto installthesteeringlinkageinnertie
rodtothesteeringgearrack.
Tighten
100Mm(74Ibft)

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service

Description and Operation
Power Steering System Description
and Operation
The power steering system reduces the amount of
effort needed to steer the vehicle. The system uses the
powertrain control module (PCM), body control module
(BCM), power steering control module (PSCM),
discrete batteryvoltage supply circuit, steering shaft
torque sensor, steering wheel position sensor, power
steering motor and the serial data circuit to perform the
system functions. The PSCM and the power steering
motor are serviced with the steering column assembly.
The steering shaft torque sensor and the steering
wheel position sensor are not serviced separately from
each other orfrom the steering column assembly.
Steering Shaft Torque Sensor
The power steering control module (PSCM) uses the
steering shaft torque sensor as it's main input for
determining steering direction and the amount of
assists needed. The steering column has an input
shaft, from the steering wheel to the torque sensor, and
an output shaft, from the torque sensor to the steering
shaft coupler. The input and output shafts are
separated by a section of torsion bar, where the torque
sensor is located. The sensor is a 5-volt dual analog
inverse signal device with a valid signal voltage range
of 0.25—4.75volts. When applying torque to the
steering column shaft during a right turn,the sensor's
signal 1 voltage increases, while the signal 2 voltage
decreases within the valid signal voltage range. When
applying torque to the steering column shaft during a
left turn, the signal 1 voltage decreases, wile the
signal 2 voltage increases within the valid signal
voltage range. The PSCM recognizes this change in
signal voltage as steering direction and steering column
shaft torque.
Steering Wheel Position Sensor
The power steering control module (PSCM) uses the
steering position sensor to determine the steering
system on center position. Since the power steering
motor provides a slight amount of return to center
assist, the PSCM will command the power steering
motor to the steering system center position and not
beyond. The sensor is a 5—voltdual analog triangle
signal device with a valid signal voltage range of 0-
5 volts. The sensors signal 1 and signal 2 voltage
values will increase and decrease within the valid
voltage range, and stay within 2.5—2.8volts of each
other as the steering wheel is turned.
Power Steering Motor
The power steering motor is a 12-volt brushless DC
reversible motorwith a 65—amprating. The motor
assists steering through a worm gear and reduction
gear located in the steering column housing.
Power Steering Control Module (PSCM)
The power steering control module (PSCM) uses a
combination of steering shaft torque sensor input,
vehicle speed, calculated system temperature and
steering tuning to determine the amount of steering
2013
—
Sonic
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(5377994)
Power Steeriflg 15-23
assist. When the steering wheel is turned, the PSCM
uses signal voltage from the steering shaft torque
sensor to detect the amount of torque and steering
direction being applied to the steering column shaft and
then command the proper amount of current to the
power steering motor.The PSCM receives a vehicle
speed message from the powertrain control module
(PCM) via the serial data circuit. At low speeds more
assist is provided for easy turning during parking
maneuvers. At high speeds, less assist is provided for
improved road feel and directional stability. The PSCM
nor the power steering motor are designed to handle
65 amps continuously. Ifthe power steering system is
exposed to excessive amounts of static steering
conditions, the PSCM will go into a protection mode to
avoid thermal damage to the power steering
components. Inthis mode the PSCM will limit the
amount of current commanded to the power steering
motor which reduces system temperature and steering
assist levels. The PSCM must also be setup with the
correct steering tuning which are different in relation to
the vehicles powertrain configuration, sedan, coupe,
tire and wheel size etc. The PSCM has the ability to
detect malfunctions within the power steering system.
Any malfunction detected will cause the driver
information center (DlC) to turn ON a warning indicator.
Special Tools and Equipment
Illustration Tool Number/Description
CH-161-B
DT-161-B
KM-161-B
J-22888-20A
@ BearingPuller
1936794
CH-804
CH-49692
MKM-804
Tensioner
1938587
CH-39570
J-3957O
Chassis Ear
643842
°- 24 Power Steering

Illustration Tool Number]Description Illustration Tool Number/Description

EN-45059 GE-8001
J-45059 J—8001
AngleMeter Dial IndicatorSet

1197696

2013
-Sonic
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Manual
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 Steering Wheel and Column 15-25

SteerI ng Wheel and Column

Specrflcations

Fastener Tightening Specifications

Specification
Application Metric English
IntermediateSteeringShaftLowerBolt 49N-m 36lbft
intermediateSteeringShaftUpperBolt 49N-m 36lbft
SteeringColumnLowerSupportBracketBolt 22N-m 16lbft
SteeringColumnUpperSupportBracketNut 22N-m 16lbft
SteeringWheelBolt 30N-m 22 lbft

Adhesives, Fluids, Lubricants, and Sealers

GM Part Number
Application Type of Material United States Canada
1 MediumStrength
SteeringWheelBoltThreadLockingAdhesive Threadlocker- Blue 12345382 10953489
Loctite®
242

Visual/Physical Inspection
Diagnostic Information and
- Inspect for aftermarket devices which could affect
Procedures the operation of the steering wheel and column.
- Inspect the easily accessible or visible system
components for obvious damage or conditions
Symptoms - Steering Wheel and which could cause the symptom.
Cdumn Symptoms List
Review the system description and operation in order to Refer to a symptom diagnostic procedure from the
familiarize yourself with the system functions. Refer to following list in order to diagnose the symptom:
Steering Wheel and Column Description and Operation
on page 15-36. - Noise in Steering Column on page 15—25
- Looseness in Steering Column on page 15—26

Noise in Steering Column

Step Action Yes No
DidyoureviewtheSteeringWheelandColumnDescriptionand Go toSymptoms-
1 Operationandperformthenecessaryinspections? SteeringWheeland
Go to Step2 Columnonpage 15-25
2 Verifythatnoiseis presentin thesteeringcolumnduringoperation.
ls noisepresentin thesteeringcolumnduringoperation? Go to Step3 SystemOK
Inspectthesteeringcolumnmountingfeaturesforthefollowing
conditions:
3 - Thesteeringcolumnmountingfastenersare loose.
- Thesteeringcolumnmountingfeaturesaresheared.
Are thesteeringcolumnmountingfeaturesloose? Go to Step9 Go to Step4
4 InspecttheSIR/SRS coilfornoise.
is theSIR/SRScoil noisy? Go to Step 10 Go to Step5
Ifequipped,inspectthelockplateretainingringforcorrect
5 installation.
is thelockplateretainingringinstalledincorrectly? Go to Step 11 Go to Step6

2013
-Sonic
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’15-26 SteeringLWheel and Column

Noise in Steering Column (cont'd)

Step Action Yes No
Inspectthesteeringcolumnupperandlowerbearingsforthe
followingconditions:
- Damage
5 - Lubrication
- Wear
- Properseating
Are thebearingsin needof repairor replacement? Go to Step12 Go to Step7
7 Doesthetiltjointneedto be lubricated? Go to Step13 Go to Step8
Note: inspecttheintermediateshaftfornoisewhiledrivingthe
vehicle,turningthesteeringwheel,andapplyingthebrakes.
8 Inspecttheintermediateshaftfornoise.
Istheintermediateshaftnoisy? Go to Step14 Go to Step 15
Note: Ifthesteeringcolumnmountingfeatureis damagedor
sheared,replacethesteeringcolumn.Referto SteeringColumn
Replacementonpage 15-33.
9 Tightenthesteeringcolumnmountingfastenertospecifications. -
Referto FastenerTighteningSpecificationsonpage 15-25.
Didyoucompletetherepair? Go to Step 15
ReplacetheSIR/SRS coil.Referto SteeringWheelAirbagCoil
10 Replacementonpage 13-119. _
Didyoucompletetherepair? Go to Step15
11 Installthelockplateretainingringcorrectly. _
Didyoucompletetherepair? Go to Step15
Note: Ifthesteeringcolumnupperandlorlowerbearingsare not
serviceable,replacethesteeringcolumn.Referto SteeringColumn
12 Replacementonpage 15-33. _
Replacetheupperand/orlowerbearings,ifserviceable.
Didyoucompletethereplacement? Go to Step15
13 Lubricatethetiltjoint. _
Didyoucompletetherepair? Go to Step15
14 Replacetheappropriatesteeringintermediateshaftcomponent.
Didyoucompletetherepair? Go to Step15
15 Operatethesystemin ordertoverifytherepair.
Didyoucorrectthecondition? SystemOK Go to Step3

Looseness in Steering Column

Step Action Yes No
DidyoureviewtheSteeringWheelandColumnDescriptionand Go to Symptoms-
1 Operationandperformthenecessaryinspections? SteeringWheeland
Go to Step2 Columnonpage 15-25
2 Verifythatthesteeringcolumnis loose.
Isthesteeringcolumnloose? Go to Step3 SystemOK
Inspectthesteeringcolumnmountingfeaturesforthefollowing
conditions.
3 - Thesteeringcolumnmountingfastenersareloose.
- Thesteeringcolumnmountingfeaturesaresheared.
Are thesteeringcolumnmountingfeaturesloose? Go to Step5 Go to Step4
4 inspecttheupperandlorlowerbearingsfor looseness.
Are anyofthebearingswornor loose? Go to Step6 Go to Step7

2013
-Sonic
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Manual
(5377994)
 Steering Wheel and Column 15-27

Looseness in Steering Column (cont'd)

Step Action Yes No
Note: if thesteeringcolumnmountingfeatureis damagedor
sheared,replacethesteeringcolumn.Referto SteeringColumn
Replacementonpage 15—33.
Tightenthesteeringcolumnmountingfastenertospecifications.
Referto FastenerTighteningSpecificationsonpage 15-25.
Didyoucompletetherepair? Go to Step7
Note: Ifthesteeringcolumnupperand/orlowerbearingsare not
serviceable,replacethesteeringcolumn.Referto SteeringColumn
6 Replacementonpage 15-33.
Replacetheupperand/orlowerbearings,if serviceable.
Didyoucompletetherepair? Go to Step 7
Operatethesteeringcolumnin ordertoverifytherepair.
Didyoucorrectthecondition? SystemOK Go to Step3

Repair Instructions

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Intermediate Steering Shaft Replacement

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2511344

2013
—Sonic
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Manual
(5377994)
‘15-28 Steering Wheel and Column

Intermediate Steering Shaft Replacement

Callout I Component Name
Preliminary Procedure
Removethesteeringcolumnandtheintermediatesteeringshaftas an assembly.Referto SteeringColumnReplacementon
page 15-33.
Intermediate SteeringShaftUpperBolt
Caution: Referto FastenerCautiononpage0-8.
1 Tighten
49 N-m(36lbft)
Intermediate SteeringShaft
Procedure
1. Place matchmarkson theintermediatesteeringshaftandthesteeringcolumnshaft.
2. Ifreplacingtheintermediatesteeringshaftor thesteeringcolumn,copythematchmarksfromtheoldparts
2 to thenewparts.
3. Alignthematchmarkswheninstallingtheintermediatesteeringshafttothesteeringcolumnshaft.
4. Set upthepowersteeringcontrolmodule.Referto PowerSteeringControlModuleProgrammingandSetup
onpage6-12.
5. Centerthesteeringanglesensor.Referto SteeringAngle SensorCenteringonpage5-39.

Steering Column Upper Trim Cover Replacement

2498066

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-Sonic
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Manual
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 Steering Wheel and Column 15-29

Steering Column Upper Trim Cover Replacement

Callout Component Name
InstrumentPanel SteeringColumnUpperTrimCover Fasteners(Qty:2)
Caution: Referto FastenerCautiononpage0—8.~
Procedure .
Turnthesteeringwheelto therightandtotheleftin ordertogainaccess tothefasteners.
instrumentPanel SteeringColumnUpperTrimCoverAssembly
Procedures
1. Use a flat bladedplastictrimtoolalongtherightandleftsides ofthetrimpanelinorderto releasethe
retainerssecuringtheuppertrimcovertothelowertrimcover.
2. Lifttheuppertrimcoverupwardandrearwardin orderto releasetheretainersalongthefrontforwardedge
oftheuppertrimcover.
.W~v«v\_._2.
,fi.‘.~.—.—-——~———'

Steering Column Lower Trim Cover Replacement

2498067
Steering Column Lower Trim Cover Replacement
Callout Component Name
PreliminaryProcedure
Removetheinstrumentpanelsteeringcolumnuppertrimcover.Referto SteeringColumnUpperTrimCoverReplacementon
page 15-28.
1 instrumentPanel SteeringColumnLowerTrimCover Fastener
Caution: Referto FastenerCautiononpage 0-8.
2 InstrumentPanel SteeringColumnLowerTrimCoverAssembly

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
15-30 Steering Wheel and Column

Turn Signal Switch Bracket Replacement

2508972
Turn Signal Switch Bracket Replacement
Callout Component Name
PreliminaryProcedure
Removetheinflatablerestraintsteeringwheelmodulecoil.Referto SteeringWheelAirbagCoil Replacementonpage 13-119.
TurnSignalSwitchBracketFastener(Qty:2)
1 Caution: Referto FastenerCautiononpage 0-8.
TurnSignalSwitchBracket
Procedure
2 1. Disconnectanyelectricalconnectorsas necessary.
2. Releasethelockingtabin ordertodisconnecttheturnsignalswitchbracketfromthesteeringcolumn.
3. Transfercomponentsas necessary.

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
 Steering Wheel and Column ’15-31

Turn Signal Multifunction Switch Replacement

2508964
Turn Signal Multifunction Switch Replacement
Callout Component Name
Preliminary Procedure
Removetheuppertrimcoverandthelowertrimcoverfromthesteeringcolumn.Referto SteeringColumnLowerTrimCover
Replacementonpage 15-29.
TurnSignalSwitch
Procedure
1 1. Disconnectanyelectricalconnectorsas necessary.
2. Releasetheplasticretainingtabsandremovetheturnsignalmultifunction
switchfromtheturnsignal
switchbracket. *

‘M
aV/«v——..Ms

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
15-32 Steeriflg Wheel and Column

Steering Wheel Replacement

2018623

Steering Wheel Replacement

Callout Component Name
Preliminary Procedure
1. Removethe inflatablerestraintsteeringwheelmodule.RefertoAirbagSteeringWheelModuleReplacementon
page 13-118.
2. Use paintin orderto placematchmarkson thesteeringwheelandonthesteeringcolumnshaft.
SteeringWheelBolt
Caution: RefertoFastenerCautiononpage 0—8.
Procedure
1 1. Cleanthreadofthebolt.
2. ApplyNEW lockingcompoundtothethread.RefertoAdhesives,Fluids,Lubricants,andSealerson
page 15-25.
Tighten
SON'm(22Ibft)
SteeringWheel
Procedure
1. Disconnectall electricalconnectorsas necessary.
Loosenthesteeringwheelboltuntil2 to 3 threadsareleftengaged.
Wigglethesteeringwheeluntilthesteeringwheeldisengagescompletely.
Removethesteeringwheelbolt.
Removethesteeringwheel.
Copythematchmarksfromtheold steeringwheeltothenewsteeringwheel.
Transferanypartsas necessary.
$939195;an

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
 Steering Wheel and Column 15-33

Steering Column Replacement 7. Remove the intermediate steering shaft lower

bolt (2).
\WH
A Removal Procedure 8. Disconnect the intermediate steering shaft from the
Caution: With wheels of the vehicle facing straight steering gear pinion shaft.
ahead, secure the steering wheel utilizing steering Caution: Do not support the steering coiumn by only
column anti—rotationpin, steering column lock, or a the lower or upper support bracket. Damage to the
strap to prevent rotation. Locking of the steering column column lower bearing adapter could result.
will prevent damage and a possible malfunction of the 9. Support the steering column.
SIR system. The steering wheel must be secured in
position before disconnecting the following
components:
- The steering column
- The intermediate shaft(s)
- The steering gear
After disconnecting these components, do not rotate
the steering wheel or move the front tires and wheels.
Failure to follow this procedure may cause the SIR coil
assembly to become un-centered and cause possible
damage to the SIR coil. Ifyou thinkthe SIR coil has
become un-centered, refer to your specific SIR coil’s
centering procedure to re-center SIR Coil.
1. With the steering wheel in the straight ahead
position, LOCK the steering column.
2. Remove the upper trim cover and the lower trim
cover from the steering column. Refer to Steering
Column Lower Trim Cover Replacement on
page 15-29.
3. Remove the instrument panel lower trim pad cover.
Refer to InstrumentPanel Lower TrimPad Cover
Replacement (WithoutAAL) on page 2-40 or
InstrumentPanel Lower TrimPad Cover
Replacement (WithAAL) on page 2-41.
4. Remove the left side floor air outlet duct. Refer to
FloorAir Outlet Duct Replacement -Left Side
(LHD) on page 10—56.
5. Disconnect any electrical connectors as
necessary.

2511150
W‘*WW«2~WW-22V,W”,
MW
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v.\v
,_
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_
M
__
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,.3...
10. Remove the 2 steering column lower support
bracket bolts (1,2).

2511142
6. Use paint in order to place match marks on the
intermediate steering shaft (1) and on the steering
gear pinion shaft (3).
2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
15-34 Steering Wheel and Column
Installation Procedure
1. Ifyou are replacing the steering column or the
intermediate steering shaft, copy the match marks
from the old parts to the new parts.

2511151
11. Remove the 2 steering column upper support
bracket nuts (1,2).

2511152
Caution: Do NOT allow the wiring harness to be
pinched between the motor/moduleassembly and the
steering column during installation. A pinched harness
will cause diagnostic trouble codes to be set and may
require replacement of the steering column.
2. Position the steering column assembly (1) in the
vehicle.
3. Align the match marks and connect the
intermediate steering shaft to the steering gear
pinion shaft.

2511152
Caution: Once the steering column is removed from
the vehicle, the column is extremely susceptible to
damage. Dropping the column assembly on the end
could collapse the steering shaft or loosen the plastic
injections, which maintain column rigidity.Leaning on
the column assembly could cause the jacket to bend or
deform. Any of the above damage could impair the
columns collapsible design. Do NOT hammer on the
end of the shaft, because hammering could loosen the
plastic injections, which maintain column rigidity. if you
need to remove the steering wheel, refer to the Steering
Wheel Replacement procedure in this section.
12. Remove the steering column assembly (1) from the 2511151
vehicle.
13. Transfer components as necessary.

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
 Steering Wheel and Column ’15-35
Warning: In order to ensure the intended function 5. install, but do not tighten, the 2 steering column
of the steering column in a vehicle during a crash lower support bracket bolts (1, 2).
and in order to avoid personal injury to the driver,
perform the following:
- Tighten the steering column lower fasteners
before you tighten the steering column upper
fasteners. Failure to do this can damage the
steering column.
- Tighten the steering column fasteners to the
specified torque. Overtightening the upper
steering column fasteners could affect the
steering column collapse.
Caution: Ensure all fasteners are securely seated
before applying needed torque. Failure to do so may
result in component damage or malfunctioning of
steering column.
4. install, but do not tighten, the 2 steering column
upper support bracket nuts (1,2).

2511142
Caution: Refer to Fastener Caution on page 0-8.
6. Installthe intermediate steering shaft lower bolt (2)
and tighten to 49 N-m(36 lb ft).
7. Tighten the 2 steering column lower support
bracket bolts to 22 Nm (16 lb ft).
8. Tighten the 2 steering column upper support
bracket nuts to 22 Nm (16 lb ft).
9. Connect any electrical connectors as necessary.
10. Install the left side floor air outlet duct. Refer to
FloorAir Outlet Duct Replacement - Left Side
(LHD) on page 10-56.
11. Installthe instrument panel lower trim pad cover.
Refer to InstrumentPanel Lower TrimPad Cover
Rep/acement (WithoutAAL) on page 2-40 or
InstrumentPanel Lower TrimPad Cover
Replacement (WithAAL) on page 2-41.
12. Installthe upper trim cover and the lower trim cover
to the steering column. Refer to Steering Column
Lower Trim Cover Replacement on page 15-29.
13. Setup the power steering control module. Refer to
Power Steering Control Module Programming and
Setup on page 6—12.
14. Center the steering angle sensor. Refer to Steering
Angle Sensor Centering on page 5-39.

2511150

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
15-36 Steering Wheel and Column

Steering Angle Sensor Replacement _/._

-~—
.,_—
w
~W

W._

2018866

Steering Angle Sensor Replacement

Callout Component Name
Preliminary Procedure
Removethesteeringwheelairbagcoil.Referto SteeringWheelAirbagCoil Replacementonpage 13—119.
SteeringAngleSensor
Procedure
1 1. Press in thecliponthesteeringwheelairbagcoil in orderto removethesteeringanglesensor.
2. Aftertheinstallationis complete,centerthesteeringanglesensor.Referto SteeringAngleSensor
Centeringonpage5-39.

Vehicle Steering
Description and Operation
The steering wheel is the first link between the driver
and the vehicle. The steering wheel is fastened to a
steering shaft within the steering column. At the lower
Steering Wheel and Column end of the steering column, the intermediate steering
Description and Operation shaft connects the steering column to the steering gear.
The steering wheel and column have the following Vehicle Security
4 primary functions:
The steering wheel and column may have theft
. Vehicle steering deterrent components mounted and designed into the
- Vehicle security steering column.
- Driver convenience
Driver Convenience
- Driver safety
The steering wheel and column may have driver
controls attached for convenience and comfort.

(US/Canada)
-Sonic
2013 (5377994)
Manual
Ser/ce
 Steering Wheel and Column 15-37
Driver Safety of injury to the driver. The energy-absorbing feature,
collapsible steering shaft, and break away mounting
The steering column has safety features to protect the features help reduce the injury in the event of an
driver. accident.
Energy-Absorbing Steering Column: The
energy—absorbingsteering column compresses in the
event ofa front-end collision, which reduces the chance

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
-
15-38 Steemg Wheel and Column

BLANK

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Table of Contents 16-1

Section 16

Suspension

Front Suspension ............................ 16-3 Suspension General Diagnosis ............ 16-35

Specifications ................................... 16-3
Fastener Tightening Specifications ............. 16—3
Repair Instructions .............................. 16—3
Stabilizer Shaft Replacement ................... 16—3
Stabilizer Shaft Link Replacement .............. 16—8
Front Wheel Bearing and Hub Replacement 16-9
Steering Knuckle Replacement ................ 16-11
Lower Control Arm Replacement .............. 16-12
Wheel Stud Replacement ..................... 16—15
Strut and Shock Absorber Inspection . . . . . 16-16
Strut Assembly Removal and Installation ...... 16-17
Shock Absorber Disposal ..................... 16-20
Strut, Strut Component, or Spring
Replacement ................................. 16-20
Description and Operation .................... 16-22
Front Suspension Description and
Operation .................................... 16—22
Special Tools and Equipment ................. 16-23
Rear Suspension ............................
1624
Specifications .................................. 16—24
Fastener Tightening Specifications ............ 16-24
Repair Instructions ............................. 16—24
Rear Wheel Bearing and Hub Replacement
(Drum Brake) ................................. 1624
Rear Wheel Bearing and Hub Replacement
(Disc Brake) .................................. 16-25
Strut and Shock Absorber Inspection (Shock
Absorber) .................................... 16-28
Shock Absorber Replacement ................. 16-29
Rear Spring, insulator, and Jounce Bumper
Replacement ................................. 16-30
Rear Axle Replacement ....................... 16—31
Wheel Stud Replacement ..................... 16—33
Description and Operation .................... 16—34
Rear Suspension Description and
Operation .................................... 16-34
Special Tools and Equipment ................. 16-34
Specifications .................................. 16-35
Trim Height Specifications ..................... 16—35
Diagnostic Information and Procedures ...... 16—35
Symptoms —Suspension General
Diagnosis .................................... 16—35
Ride Diagnosis ................................ 16-35
Vehicle Leads/Pulls ........................... 16-36
Body Leans or Sways in Corners .............. 16—36
Suspension Bottoms .......................... 16—37
Torque Steer ................................... 16-37
Memory Steer ................................. 16-38
Noise Diagnosis —Front Suspension .......... 16—39
Noise Diagnosis - Rear Suspension ........... 16-40
Ball Joint Inspection ........................... 16-41
Suspension Strut and Shock Absorber Testing
- On Vehicle .................................. 16-41
Wheel Bearings Diagnosis .................... 16-41
Trim Height inspection ........................ 16-42
Special Tools and Equipment ................. 16-44
Tire Pressure Monitoring ................... 16-45
Diagnostic Information and Procedures ...... 16—45
DTC 00569 .................................... 16-45
DTC C0750, C0755, C0760, or 00765 . . . . 16—46
DTC C0775 .................................... 16-48
Symptoms —Tire Pressure Monitoring ......... 16—48
Low Tire Pressure Indicator Malfunction . . 16—49
Repair Instructions ............................. 16—50
Tire Pressure Indicator Sensor
Replacement ................................. 16—50
Tire Pressure Indicator Sensor Learn .... . . . . . 16—52
Description and Operation .................... 16-53
Tire Pressure Monitor Description and
Operation .................................... 1653
Special Tools and Equipment ................. 16-54

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
16-2 Table of Contents
Tires and Wheels ............................ 16-55
Specifications .................................. 16—55
Tire and Wheel Specifications ................. 16-55
Fastener Tightening Specifications ............ 16-55
Adhesives, Fluids, Lubricants, and Sealers 16-55
Diagnostic Information and Procedures . . .. . .16-56
Tire Diagnosis —Irregularor
Premature Wear .............................. 16-56
Tire Diagnosis - Waddle Complaint ............ 16-56
Wheel Mounting Surface Check ............... 16-57
Radial Tire Lead/Pull Correction ............... 16-58
Repair Instructions ............................. 16-59
Aluminum Wheel Porosity Repair ............. 16-59
Aluminum Wheel Refinishing .................. 16-59
Tire and Wheel Removal and Installation ...... 16—60
Tire Dismounting and Mounting ............... 16-63
Tire Rotation ................................... 16—63
Description and Operation .................... 16-64
All Seasons Tires Description ................. 16—64
General Description ........................... 16-64
Metric Wheel Nuts and Bolts Description .... . . 16-64
P-Metric Sized Tires Description .............. 16-64
Replacement Wheels Description ............. 16—65
Steel Wheel Repair Description ............... 16-65
Tire InflationDescription ....................... 16—65
Tires and Wheels Description and
Operation .................................... 16-66
Tread Wear Indicators Description ............ 16-67
Special Tools and Equipment ................. 16—68
Wheel Alignment ............................ 16-69
Specifications .................................. 16—69
Wheel Alignment Specifications ............... 16-69
Fastener Tightening Specifications ............ 16—69
Repair Instructions ............................. 16—69
Wheel Alignment Measurement ............... 16-69
Front Camber Adjustment ..................... 16-70
Wheel Alignment —Steering Wheel Angle and/
or Front Toe Adjustment ...................... 16—70
Description and Operation .................... 16-70
Camber Description ........................... 16-70
Caster Description ............................. 16-71
Lead/Pull Description .......................... 16-71
Memory Steer Description ..................... 16—71
Scrub Radius Description ..................... 16-71
Thrust Angles Description ..................... 16—72
Toe Description ................................ 16-72
Torque Steer Description ...................... 16—72
Wander Description ........................... 16—73

(US/Canada)
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2013 (5377994)
Manual
Service
 Front Suspension 16-3

Front Suspension

Specifications

Fastener Tightening Specifications

Specification
Application Metric English
FrontBrakeDustShield 9N-m 80 lbin
FrontLowerControlArmBallJointNut
FirstPass 30N-m | 22 lbft
SecondPass loosen120degrees
ThirdPass 30N-m | 221bft
,‘V
‘22.“.
W
..
-MN_ FinalPass plus35degrees
FrontLowerControlArmFrontBolt
FirstPass 115N-m | 85lbft
FinalPass plus65degrees
FrontLowerControlArmRear Nut
FirstPass 160N-m | 118Ibft
FinalPass plus35degrees
FrontSuspensionStabilizerShaftClampBolts 22Nm 16lbft
FrontSuspensionStabilizerShaftLinkNuts 65NW 48 lbft
FrontSuspensionStruttoSteeringKnuckleNuts 110Nm 82 lbft
FrontSuspensionStrutUpperMountNut 65Nm 481bft'
FrontSuspensionStrutLowerMountNut 65NW 48 lbft
SteeringKnuckleLowerBall StudNuts '
FirstPass 20N-m 15lbft
FinalPass plus45degrees

. Remove the front bumper impact bar lower

Repair Instructions bracket. Refer to Front Bumper Impact Bar Lower
Bracket Replacement on page 3—54.
. Remove the stabilizer shaft links from the stabilizer
Stabilizer Shaft Replacement shaft. Refer to Stabilizer Shaft Link Replacement
on page 16—8.
Removal Procedure . Remove the lower control arm ball joint bolt and
nut from the steering knuckle. Refer to Lower
1. Remove the intermediate steering shaft lower bolt.
Control Arm Replacement on page 16-12.
Refer to IntermediateSteering Shaft Replacement
on page 15-27. . Disconnect the steering linkage tie rod end from
the steering knuckle. Referto Steering Linkage
2. Raise and support the vehicle. Refer to Lifting and
Outer Tie Rod Replacement on page 15-17.
Jacking the Vehicle on page 1~31.
. Remove the transmission rear mount to bracket
3. Remove the tire and wheel assembly. Refer to Tire
retaining bolt. Referto Transmission Mount
and Wheel Removal and Installation on
Bracket Replacement - Rear on page 17—215.
page 16-60.
4. Remove the front wheelhouse inner liner front
extension. Refer to Front Wheelhouse Linerlnner
Front Extension Replacement (Left Side) on
page 3—147or Front Wheelhouse Liner Inner Front
Extension Replacement (Right Side, LUV) on
page 3-148 or Front Wheelhouse Liner Inner Front
Extension Replacement (Right Slde, LWE, LUW)
on page 3-149.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
16-4 Front Suspension

. fl - .s" "L-
F" ___. "31.-w,-
-_—' '

2506950
10. Remove the exhaust pipe insulators (1).

2506890
14. Remove the stabilizer shaft insulator bolts (1).

2506954
11. Release the front suspension frame front bolts
about 10 mm.
12. Usingf a suitable support, support the
crossmember area of the cradle.
Note: Itis not necessary to remove the front bumper
facia in this procedure.
13. Using a suitable support, lower the front
suspension frame (1) about 500 mm enough to gain
access to the stabilizer shaft insulator bolts and to
remove the stabilizer shaft. Refer to Drivetrain and
Front Suspension Frame Replacement on
page 3—144

2013
-Sonic
(US/Canada)
Sen/ice
Manual
(5377994)
 Front Suspension 16-5

~_/-~/
‘th‘f'. i .b‘ o
3! VQ9§H>D 9
. 4 531/2
'J/V’JI s" AKET§\ ..
- 7 t \ ’(7 \\\‘.O l—\\
. / - —\ \ 0 “»
C. (:: ‘
\

2506943
Note: Itmaybe necessary to maneuver the front
stabilizer shaft in such away as to remove it from the
front suspension frame.
15. Remove the front stabilizer shaft (1)from the front
suspension frame.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
16-6 Front Suspension

Installation Procedure

-QIIpa-vgjg
\rss‘

2506943
1. Position the front stabilizer shaft (1)in the front
suspension frame.

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
 Front Suspension ’16-?
install the transmission rear mount to bracket
retaining bolt. Refer to Transmission Mount
Bracket Replacement —Rear on page 17—215
Connect the steering linkage tie rod end from the
steering knuckle. Refer to Steering Linkage Outer
Tie Rod Replacement on page 15—1 7
install the lower control arm baitjoint to steering
knuckle bolts. Refer to Lower Control Arm
Replacement on page 16-12.
Installthe stabilizer shaft link to the stabilizer shaft.
Refer to Stabilizer Shaft Link Replacement on
page 16—8.

2506890
Caution: Refer to Fastener Caution on page 0-8.
2. Install the front stabilizer shaft insulator 2506950
bolts (1) and tighten to 22 N~m(16 lb ft).
Install the exhaust pipe insulators (1).
Install the front bumper impact bar lower bracket.
Refer to Front Bumper Impact Bar Lower Bracket
Replacement on page 3-54.
Install the front wheelhouse inner liner front
extension. Refer to Front Wheelhouse Linerlnner
Front Extension Replacement (Left Side) on
page 3—147or Front Wheelhouse Liner Inner Front
Extension Replacement (Right Side, LUV) on
page 3—148or Front Wheelhouse Liner Inner Front
Extension Replacement (Right Side, LWE, LUW)
«—:1 '71.. on page 3—149.
4; 11. Installthe tire and wheel assembly. Refer to Tire
and Wheel Removal and Installation on
page 1660.
12. Remove the support and lower the vehicle.
13. Install the intermediate steering shaft lower bolt.
Refer to Intermediate Steering Shaft Replacement
on page 15—27.

2506954
3. Lift the front suspension frame (1) into the proper
position and tighten the front suspension frame
bolts. Refer to Drivetrain and Front Suspension
Frame Replacement on page 3-144.

(US/Canada)
-Sonic
2013 (5377994)
Manual
Selvice
16-8 Front Suspension

Stabilizer Shaft Link Replacement

.
\t
t \
43!“?
\‘ ’\
1).».
11'
.3:
L " ,-

2497993
Stabilizer Shaft Link Replacement
Callout Component Name
Preliminary Procedure
1. Raise andSupportthevehicle.RefertoLiftingandJackingtheVehicleonpage 1-31.
2. Removethetireandwheelassembly.Referto Tireand WheelRemovalandInstallationonpage 16—60.
FrontStabilizerShaftLinkUpperNut
Caution: Referto FastenerCautiononpage0-8.
Procedure
1 Use thepropersize Allenwrenchto holdthestabilizershaftlinkstudwhenlooseningor tighteningthestabilizer
shaftlinknut.
Tighten
65Wm(48lbft)
FrontStabilizerShaftLinkLowerNut
Procedure
Use thepropersize Allenwrenchto holdthestabilizershaftlinkstudwhenlooseningor tighteningthestabilizer
shaftlinknut.
2 Tip: Whenremovingthestabilizershaftlinklowernut,removebothoftheuppernutsfirstandtheliftupthe
stabilizerends in ordertogetthetoolaccess tothelowernut.
Tighten
65N-m(48lbft)
3 FrontStabilizerShaftLink

2013
—
Sonic
(US/Canada)
Service
Manual
(5377994)
 Front Suspension 16-9

Front Wheel Bearing and Hub

Replacement
Special Tools
CH—50559Wheel Hub/Bearing Remover Kit
For equivalent regional tools, refer to Special Tools on
page 16—23.
¥---~m--~\
#¥__
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and
Jacking the Vehicle on page 1-31.
2. Remove the steering knuckle assembly from the
vehicle. Refer to Steering Knuckle Replacement on
page 16-11.

2549118
6. Ifthe inner race of the bearing is pulled out with the
hub, remove the inner race from the using the
appropriate tools (1, 2).

2549116 9
3. Position the steering knuckle assembly (1) in a 91’
56‘ fl
suitable vise.
4. Position the CH-50059—1wheel hub/bearing ' .' /’
@J .
removal/installation bridge assembly (1) and the 4
CH-50559-2 wheel hub/bearing removal/ ?—
, q/ ’ J
a
installation adapter (2)on the wheel bearing — ‘1'
inner hub. i ‘1’
U
5. Using the CH-50059-1 and the CH—50559—2,
remove the wheel hub from the wheel bearing. 2549316
7. Using the appropriate tool, remove the retaining
ring (1)from the steering knuckle.

—
2013 (US/Canada)
Sonic (5377994)
Manual
Service
'16-‘10 Front Suspension
. Using the CH-50559—4wheel hub/bearing
installation adapter (1) and the appropriate
extension and press, install the new bearing into
the steering knuckle until it is correctly seated.

MM_
,,

2549119
8. Position the CH—50559—1 wheel hub/bearing
removal/installation bridge assembly (1) and the
CH—50559-3wheel bearing removal adapter (2)on
the steering knuckle.
2549121
9. Remove the wheel bearing from the steering
knuckle and discard it. Inspect the bore of the of Position the CH—50559-4(1)wheei hub/bearing
the steering knuckle for pitting,scoring wear, installation adapter and the appropriate extension
or corrosion. Ifdamage cannot be easily cleaned to the inside of the bearing and position the
up with light sanding, replace the steering knuckle. CH-50559-2 wheel hub removal/installation
adapter and the appropriate extension on the
Installation Procedure wheel hub.
Press in the hub until it is correctly seated.

2549120
2549316
- The bearing must be installed with the rubber Using the appropriate tool, install the retaining
seal facing inboard. ring (1).
- Ensure that the wheel bearing is evenly seated .0“ Verify the hub rotates smoothly.
in the steering knuckle. . Install the steering knuckle assembly in the
vehicle. Refer to Steering Knuckle Replacement on
page 16-11.
. Lower the vehicle.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Front Suspension 16-11

Steering Knuckle Replacement

Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and
Jacking the Vehicle on page 1~31. @irffiu»
v’l/‘g”
2. Remove the tire and wheel assembly. Refer to Tire
%
and Wheel Removal and Installation on
page 16—60.
3. Remove the wheel speed sensor from the steering t
knuckle. Refer to Front Wheel Speed Sensor alum: 1.1
n}.ti
Replacement on page 5-44. :1éIIIIIII
4. Separate the wheel drive shaft from the steering
knuckle. Refer to Front Wheel Drive Shaft
Replacement on page 7-5.
5. Remove the brake rotor from the steering knuckle.
Refer to Front Brake Rotor Replacement on
page 5-77.

2497931
8. Remove the bolts (2)and the nuts (1)from the front
strut to the steering knuckle. Refer to Strut
Assembly Removal and Installation on page 16-17

\/

2504707
6. Remove the front brake dust shield bolts (2) and
the shield (1).
7. Remove the lower ball joint bolt and nut from the
steering knuckle. Refer to Lower ControIArm
Replacement on page 16—12.
2504711
9. Remove the steering knuckle assembly (1)from
the vehicle.
10. Remove the wheel bearing and hub assembly from
the steering knuckle. Refer to Front Wheel Bearing
and Hub Replacement on page 16—9.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
16-12 Front Suspension
Installation Procedure
1. Installthe wheel bearing and hub assembly in the
steering knuckle. Refer to Front Wheel Bearing
and Hub Replacement on page 16-9.
2504711
2. Position the steering knuckle (1) in the front strut
and lower ball joint.
Removal
2497931
3. Installthe bolts (2)and the nuts (1)from the front
strut assembly to the steering knuckle. Refer to
Strut Assembly Removal and Installation on
page 16—17.
4. Installthe lower ball joint bolt and nut to the
steering knuckle. Refer to Lower ControlArm
Replacement on page 1612.
2504707
Caution: Refer to Fastener Caution on page 0-8.
5. Install the front brake dustshield (1) bolts(2)and
the bolts to 9 N-m(80 lb in).
6. Install the brake rotor on the steering knuckle.
Refer to Front Brake Rotor Replacement on
page 5-77.
7. Install the NEW wheel drive shaft nut. Refer to
Front Wheel Drive Shaft Replacement on
page 7—5.
8. Install the wheel speed sensor in the steering
knuckle. Refer to Front Wheel Speed Sensor
Replacement on page 5—44.
9. Install the tire and wheel assembly the tire and
wheel assembly. Refer to Tire and Wheel Removal
and Installation on page ,16—60.
10. Remove the supports and lower the vehicle.
11. Check the front wheel alignment measurements,
it the vehicle had a camber adjustment repair.
Refer to Wheel Alignment Specifications on
page 16-69.
Lower Control Arm Replacement
Procedure
1. Raise and support the vehicle. Refer to Lifting and
Jacking the Vehicle on page 1-31.
2. Remove the tire and wheel assembly. Referto Tire
and Wheel Removal and Installation on
page 16-60.
3. Remove the front wheelhouse rear liner. Referto
Front Wheelhouse Liner Replacement (Rear) on
page 3-151 or Front Wheelhouse Liner
Replacement (Front)on page 3-150.
4. Remove the front wheelhouse liner inner front
extension. Refer to Front Wheelhouse Liner inner
Front Extension Replacement (Left Side) on
page 3—147or Front Wheelhouse Liner Inner Front
Extension Replacement (Right Side, LUV) on
page 3-148 or Front Wheelhouse Liner Inner Front
Extension Replacement (Right S/de, LWE, LUW)
on page 3—149.
2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Front Suspension 1 6-13

5. Disconnect the steering linkage tie rod end from

the steering knuckle. Refer to Steering Linkage jg®e .
Outer Tie Rod Replacement on page 15-17.
1 e

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2497309
Note: DO NOT reuse the rear lower control arm nut.
The nut is NOT reusable.
control arm rear nut (1) and
2497213 8. Remove the front lower
bolt (2).
Note: DO NOT reuse the ball joint nut. The nut is NOT
reusable.
6. Remove the lower ball joint nut (1) and bolt (2).
"4«“01“
\\\\\\\\I\

2497520
9. Push the front brake corner forward and then
remove the front lower control arm (1).
2497356
7. Remove and discard the front lower control bolt (1).
Replace with NEW only.
(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
'16-14 Front Suspension

Installation Procedure

5” ~/ ’2 11V , A.‘ ",..-.tt-\

f’gx‘m‘r \

2497520
1. Push the front brake corner forward and then
position the lower control arm (1) in the vehicle.

2497309
3. Tighten the NEW front lower control arm rear
nut (1) to:
- First Pass: 160 Nm (118 lb ft)
0 Final Pass: plus 35 degrees

2497356
Note: Install the front lower control arm rear bolt and
nut hand tight to hold the lower control arm in place
while tightening the front lower control arm bolt.
2. Install the NEW front lower control arm front
bolt (1) and tighten to.
- First Pass: 115N-m(85 lb ft)
- Final Pass: plus 65 degrees

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
 Front Suspension 16-15
For equivalent regional tools, refer to Special Tools on
page 16-23.
Removal Procedure
. Raise and support the vehicle. Refer to Lifting and
Jacking the Vehicle on page 1~31.
. Remove the tire and wheel assembly. Referto Tire
and Wheel Removal and Installation on
-: ,( (”—‘it page 16-60.
. Without disconnecting the hydraulic brake flex
I .éég-lzllxgééég?) hose, remove and support the brake caliper and
—-"‘a\i‘l|i;5fi.—T-“h
bracket as an assembly. Refer to Front Brake
Rotor Replacement on page 5-77.
. Remove the frontwheel hub. Refer to Front Wheel
/ V /§ Bearing and Hub Replacement on page 16—9.

,, @171 . _ -\
3Q;
{L399 ? §— ,,

2497213
. Install the NEW lower ball joint
bolt (2)and nut (1)and tighten the to nut (1):
- First Pass: 30 N-m(22 lb ft)
- Second Pass: release 120 degrees 2327498
- Third Pass: 30 N-m(22 lb ft)
- Final Pass: plus 35 degrees 5. Using the CH 43631 separator (2), remove the
wheel stud (1)from the wheel bearing and hub.
. install the steering linkage tie rod end on the
steering knuckle. Refer to Steering Linkage Outer Installation Procedure
Tie Rod Replacement on page 15-17.
. Install the front wheelhouse liner inner front
extension. Refer to Front Wheelhouse Liner Inner
Front Extension Replacement (Left Side) on
page 3—147or Front Wheelhouse Liner Inner Front
Extension Replacement (Right Side, LUV) on
page 3—148or Front Wheelhouse Liner Inner Front
Extension Replacement (Right Side, LWE, LUW)
on page 3-149.
Install the front wheelhouse rear liner. Refer to
Front Wheelhouse Liner Replacement (Rear) on
page 3-151 or Front Wheelhouse Liner
Replacement (Front) on page 3-150.
Install the tire and wheel assembly. Refer to Tire
and Wheel Removal and Installation on
page 1660.
9. Lower the vehicle.

Wheel Stud Replacement

Special Tools
CH 43631 Ball Joint Separator 2327497

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
16-16 Front Suspension
1. install a NEW wheel stud to the wheel hub
flange (2).
2. Position three washers (3)and an old lug nut (1)on
the stud to be replaced.
3. Position the pry bar to hold the wheel bearing
flange while tightening the wheel lug nut.
4. Tighten the old lug nut (1)unti|the wheel stud is
firmly seated in the wheel hub flange.
5. Remove the washers (3)and the old lug nut (1)
and the pry bar.
6. Install the front wheel hub. Refer to Front Wheel
. Bearing and Hub Replacement on page 16-9.
7. Install the front brake rotor. Referto FrontBrake
Rotor Replacement on page 5-77.
8. Install the tire and wheel assembly. Refer to Tire
and Wheel Removal and Installation on
page 16—60.
9. Lower the vehicle.

Strut and Shock Absorber Inspection

Note: The strut assembly DOES NOT have to be
removed from the vehicle to performthe following
inspection procedure.
Note: A light film of oil on the top portion of the strut is
normal. DO NOT replace the strut for this condition.

.A_,-
,_.‘,
A‘W
..mw

Condition 1
Oil or fluid residue only on the bottomof the strut tube
or on other strut components and not originating from
the shaft seal, is not a strut related problem. DO NOT
replace the strut, look for other external leaks.
Condition 2
Light fiIm/residue on the strut tube, but not on the spring
seat and originating from the shaft seal, is a NORMAL
condition. DO NOT replace the strut.
2355944
Condition 3
Oil drip or trail down the strut tube and originating from
the shaft seal, is an ABNORMAL condition. Replace
the strut.
Condition 4
Extreme wet film of oil covering the strut tube and .
pooling in the spring seat and originating from the shaft
seal, is an ABNORMAL condition. Replace the strut.

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
 Front Suspension 16-17
Inspection
1. Verify the customer's concern is present. Ifthe
concern is present, continue to the next step. Ifthe
concern is not present, then the vehicle is
operating normally.
Note: The strut assembly DOES NOT have to be
removed from the vehicle to perform the following
inspection procedure. \Y/A
2. Raise and support the vehicle. Refer to Lifting and tut
I Q2
Jacking the Vehicle on page 1-31. l .\.
:53; 1111!”,.7
I 1I'21W
"£7
3. Visually inspect each of the shock absorbers or .41,' II.
struts for external fluid leaks. Refer to the following / 1.
conditions1, 2, 3, and 4 for visual inspection. L
- Ifconditions 1 or2 are found, continue to step 4.
- Ifconditions 3 or4 are found, replace strut.
Refer to Strut Replacement.
4. Ifequipped with electronic suspension control
system, ensure that the system is working properly.
Refer to Diagnostic Starting Point-Electronic
Suspension Control. 2497949
5. Use your hands in order to lift up and push down 5. Remove the front brake hose (1)from the front strut
on each corner of the vehicle 3 times. Remove your assembly.
hands from the vehicle. Ifthe corner motion
exceeds 2 cycles, replace the strut. Ifthe strut does 6. Remove the speed sensor wring harness from the
not exceed 2 cycles, NO repair is necessary. front strut assembly, if needed.
7. Remove the outer tie rod end from the steering
Strut Assembly Removal and knuckle. Refer to Steering Linkage Outer Tie Rod
Replacement on page 15-17.
Installation
8. Support the lower control arm with a jack stand.
Special Toots
OH 49375 Strut Rod Nut Socket
For equivalent regional tools, refer to Special Tools on
page 16-23
Removal Procedure
1. Remove the air inlet grille panel. Refer to Airlnlet
Grille Panel Replacement on page 4-374.
2. Raise and support the vehicle. Refer to Lifting and
Jacking the Vehicle on page 1-31.
3. Remove the tire and wheel assembly. Refer to Tire
and Wheel Removal and Installation on
page 16—60.
4. Remove the stabilizer shaft link from the front strut
assembly. Refer to Stabilizer Shaft Link
Replacement on page 16-8.

2497931
9. Remove the front strut nut (1)and the bolt (2)from
the front strut.

—
2013 (US/Canada)
Sonic (5377994)
Manual
Service
16-18 Front Suspension

t. ty/I-I'“ K
3.. ‘11-."

:1.“ £41“ ?’iug ' "

2424066 2497960
10. Usin the OH 49375 socket (2)and the propersize 12. Remove the front strut assembly from the
Torx wrench, loosen the front strut nut. vehicle (1).
13. If removing the front strut assembly to service any
of the front strut components, refer to Strut, Strut
Component, or Spring Replacement on
page 16—20.
Installation Procedure

2497571
11. Remove the front strut nut (1) and the retaining
plate (2).

2497960
1. Position the front strut assembly (1) in the vehicle.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Front Suspension 16-19

X4m—i—t- \m
\)\‘©\‘WQKQ%‘
‘lIn-J’ \v’l/I~'—' \s

2497571 2497931
2. Install the front strut nut (1)and the retaining 4. Installthe front strut nut (1)and the bolt (2)from the
plate (2). front strut and tighten the nut to 110 N-m(82 lb ft).
5 . Installthe stabilizer shaft link in the front strut
assembly. Refer to Stabilizer Shaft Link
Replacement on page 16—8.
6 . Remove the jack stand from the lower control arm.
7 . Install the outer tie rod end in the steering knuckle.
Refer to Steering Linkage Outer Tie Rod
Replacement on page 15-17.
CD. Install the speed sensor wiring harness 0n the front
strut assembly, if needed.

2424066
Caution: Refer to Fastener Caution on page 0-8.
3. Using the CH 49375 socket (2)and the proper size
Torx wrench to hold the strut shaft, tighten the nut
to 65 N-m(48 lb ft).

2497949
9 . Installthe front brake hose (1)on the front strut
assembly.
10. Install the tire and wheel assembly. Refer to Tire
and Wheel Removal and Installation on
page 16-60.
11. Remove the support and lower the vehicle.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
16-20 Front Suspension
12. install the air inlet grille panel. Refer to Airlnlet Strut, Strut Component, or Spring
Grille Panel Replacement on page 4-374.
Replacement
Shock Absorber Disposal Disassembly Procedure
Warning: Use the proper eye protection when 1. Remove the strut assembly from the vehicle. Refer
drilling to prevent metal chips from causing to Strut Assembly Removal and Installation on
physical injury. page 16-17.

743246
Note: The spring is compressed when the strut moves
freely.
2. Install the strut assembly (2) in a suitable spring
compressor (1) and compress the front spring.

606886
. Clamp the strut in a visa horizontally with the
rod (1) completely extended.
Drill a hole in the strut at the‘center of the end
cap (3) using a 5 mm (3/16in) drill bit. Gas or a
gas/oil mixture will exhaust when the drill bit
penetrates the strut. Use shop towels in order to
contain the escaping oil.
9” Remove the strut from the vise.
Hold the strut over a drain pan vertically with the
hole down.
. Move the rod (1) in and out of the tube (2) to
completely drain the oil from the strut.

2452042
3. Use a suitable bit (1)and socket (2)to loosen the
front suspension strut mount nut.

(US/Canada)
-Son/c
2013 (5377994)
Manual
Sen/ice
 Front Suspension '16-21

Assembly Procedure

O 0

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7/11
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743241
4. Slowly loosen the spring compressor (2)to remove
the front suspension strut components to be
serviced.

2511340
2‘5 1. Install the front suspension strut (5),front
suspension strut bumper (4),front spring (3),front
spring insulator (2)and the front suspension strut
mount assembly (1) in the spring compressor.

Oi
nuumuumm

2511340
5. Remove the front suspension strut mount
assembly (1), front spring insulator (2),front
spring (3),front suspension strut bumper (4) and 743241
the front strut (5)from the spring compressor.
2. Use the spring compressor(1)to compress the
front spring (2).

2013
«Sonic
(US/Canada)
Service
Manual
(5377994)
16-22 Front Suspension
3. Install the front suspension strut mount nut and
tighten as much as possible by hand.
2452042 alone. Each and of the strut is designed as the
Caution: Refer to Fastener Caution on page 0—8.
4. Use a suitable bit (1) and socket (2)to tighten the
front suspension strut mount nut to 65 N'm
(48 lb ft).
5. Remove the strut assembly from the spring
compressor.
6. Installthe strut assembly. Refer to StrutAssemb/y
Removal and Installation on page 16-17.
Description and Operation
Front Suspension Description and
Operation
The front suspension has 2 primary purposes:
. Isolate the driver from irregularities in the road
surface.
- Define the ride and handling characteristics of the
vehicle.
The front suspension absorbs the impact of the tires
travelling over irregular road surfaces and dissipates
this energy throughout the suspension system. This
process isolates the vehicle occupants from the road
surface. The rate at which the suspension dissipates
the energy and the amount of energy that is absorbed
is how the suspension defines the vehicles ride
characteristics. Ride characteristics are designed into
the suspension system and are not adjustable. The ride
characteristics are mentioned in this description in
order to aid in the understanding of the functions of the
suspension system. The suspension system must allow
for the vertical movement of the tire and wheel
assembly as the vehicle travels over irregular road
surfaces while maintaining the tire's horizontal
relationship to the road.
This requires that the steering knuckle be suspended
between a lower control arm and a strut assembly. The
lower control arm attaches from the steering knuckle at
the outermost point of the control arm. The attachment
is through a ball and socket type joint. The innermost
end of the control arm attached at 2 points to the
vehicle frame through semi-rigid bushings. The upper
portion of the steering knuckle is attached to a strut
assembly. The strut assembly then connects to the
vehicle body by way of an upper bearing. The steering
knuckle is allowed to travel up and down independent
of the vehicle body structure and frame.
This up and down motion of the steering knuckle as the
vehicle travels over bumps is absorbed predominantly
by the coil spring. This spring is retained under tension
over the strut assembly. A strut is used in conjunction
with this system in order to dampen out the oscillations
of the coil spring. A strut is a basic hydraulic cylinder.
The strut is filled with oil and has a moveabie shaft that
connects to a piston inside the strut.Valves inside the
shock absorber offer resistance to oil flow and
consequently inhibit rapid movement of the piston and
shaft. Each and ofthe shock absorber is connected in
such a fashion to utilize this recoil action of a spring
connection point of the suspension system to the
vehicle and acts as the coil spring seat. This allows the
strut to utilize the dampening action to reduce the recoil
of a spring alone. The lower control arm is allowed to
pivot at the vehicle frame in a vertical fashion. The ball
joint allows the steering knuckle to maintain the
perpendicular relationship to the road surface.
Front suspensions systems utilize a stabilizer shaft.
The stabilizer bar connects between the left and right
lower control arm assemblies through the stabiiizer link
and stabilizer shaft insulators. This bar controls the
amount of independent movement of the suspension
when the vehicle turns. Limiting the independent
movement defines the vehicles handling characteristics
on turns.
2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Front Suspension 16-23

Special Tools and Equipment Illustration Tool Number/Description

Illustration Tool Number]Description

CH-24319—B
CH 43631
J-24319—B
CH-49375 J-43631
CH-8803109 Ball JointRemover
K-8803109
StrutRod NutSocket
400167

2330185

CH 50559
WheelHub/Bearing
Kit
Remover/installer

2548684

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
16-24 Rear Suspension

Rear Suspension

Specifications

Fastener Tightening Specifications

Specification
Application Metric English
RearAxle to BodyBolts 175N-m 129lbft
RearWheelBearingand HubBolts 58Nm 43lbft
ShockAbsorber-to-AxleBolt—Lower 120N-m 89lbft
ShockAbsorberNut 25Nm 18lbft
ShockAbsorber-to-UpperMountBolts 58NW 43lbft

Repair Instructions

Rear Wheel Bearing and Hub Replacement (Drum Brake)

2500384

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
 Rear Suspension '16-25

Rear Wheel Bearing and Hub Replacement (Drum Brake)

Callout I Component Name
Preliminary Procedures
1. Raise andsupportthevehicle.Referto LiftingandJackingtheVehicleonpage 1-31.
2. Removethetireandwheelassembly.Referto Tireand WheelRemovaland Installationonpage 16-60.
3. Removetherearbrakedrum.Referto BrakeDrumReplacement(J93,J94) onpage5—90.
RearWheelBearing/HubMountingBolt(Qty4)
Caution: Referto FastenerCautiononpage0-8.
1 Procedure
Removetheelectricalconnectorfortherearwheelspeedsensor.
Tighten
58Nm (43lbft)
RearWheelBearing/HubAssembly
2 Procedure
Ensurethattherearwheelbearing/hubis properlyalignedwiththerearaxletoallowaccess tothewheelspeed
sensorconnector.

Rear Wheel Bearing and Hub

Replacement (Disc Brake)
Special Tools
EN—45059 Angle Meter
For equivalent regional tools, refer to Special Tools on
page 16-34.
Removal Procedure
1. Raise and suitably support the vehicle. Refer to
Lifting and Jacking the Vehicle on page 1-31.
2. Remove the tire and wheel assembly. Referto Tire
and Wheel Removal and Instal/at/onon
page 16-60.
Caution: Support the brake caliper with heavy
mechanic wire, or equivalent, whenever it is separated
from its mount and the hydraulic flexible brake hose is
still connected. Failure to support the caliper in this
manner will cause the flexible brake hose to bear the
weight of the caliper, which may cause damage to the 2027694
brake hose and in turn may cause a brake fluid leak.
5. Remove the wheel speed sensor bolt (1).
3. Without disconnecting the hydraulic brake flex
hose, remove and support the rear brake caliper 6. Remove the wheel speed sensor (2).
and bracket as an assembly. Refer to Rear Brake
Caliper Replacement on page 5-66.
4. Remove the rear brake rotor. Refer to Rear Brake
Rotor Replacement on page 5-79.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
’16-26 Rear Suspension
Installation Procedure

2027695
7. Remove and DISCARD the 4 wheel bearing/hub
mounting bolts (1). 2027698
1. Position the rear brake shield (1) and wheel
bearing/hub assembly (2) in the rear axle.

2027698
8. Remove the wheel bearing/hub assembly (2) and
rear brake shield (1) from the rear axle.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Rear Suspension 16-27

2027695
Caution: Refer to Fastener Caution on page 0—8.
2. Install the 4 NEW wheel bearing/hub mounting
bolts (1) and tighten a first pass to 58 Nm (43 lb ft).
Tighten the bolts evenly, in a cross-pattern.
2027694
. Install the wheel speed sens0r(2).
. Install the wheel speed sensor bolt (1) and tighten
to 6N-m(53 lb in).
. Install the brake rotor. Refer to Rear Brake Rotor
Replacement on page 5-79.
. Install the brake caliper and bracket as an
assembly. Refer to Rear Brake Caliper
Replacement on page 5-66.
. Install the tire and wheel assembly. Refer to Tire
and Wheel Removal and Installation on
page 16-60.
. Lower the vehicle.>

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
16-28 Rear Suspension

Strut and Shock Absorber Inspection (Shock Absorber)

Note: The shock absorber assembly DOES NOT have
to be removed from the vehicle to perform the following
inspection procedure.
Note: A light film of oil on the top portion of the lower
shock absorber tube is normal. DO NOT replace the
shock absorber for this condition.

I;
v_t_

AL

2355938
Condition 1 Inspection
Oil or fluid residue only on the bottom or top of the 1. Verify the customer's concern is present. Ifthe
shock absorber and not originating from the shaft seal, concern iS present, continue to the next step. if the
is not a shock absorber related problem. DO NOT concern is not present, then the vehicle is
replace the shock absorber, look for other external operating normally.
leaks. Note: The shock absorber assembly DOES NOT have
Condition 2 to be removed from the vehicle to performthe following
. . . . inspection procedure.
Light fiIm/resrdueon apprOXImater 1/3(a)or less of the
lower shock tube (A) and originating from the shaft seal, 2' R313?and SUPP?” the vehicle. Refer to Lifting and
is a NORMAL condition. DO NOT replace the shock Jacking the Vehicle on page 1-31.
absorber. 3. Visually inspect each of the shock absorbers for
external fluid leaks. Refer to the following
Condition 3 conditions 1, 2 , 3, and 4forvisual inspection.
Oil drip or trail down the lower shock tube and ~ Itconditions1 or2 are found, continue to step 4.
originating from the shaft seal, is an ABNORMAL
- - Replace the shock absorber.
condition. - absorber.
Ifconditions 3 orto
Refer 4 are found,
Shock replace shock
Absorber
Condition 4 Replacement on page 16-29.
An extreme wet film of oil covering more than 1/3(b)of 4- if equipped With919090010suspension control
the lower shock tube and originating from the shaft system, ensure that the system is working properly.
seal (B), is an ABNORMAL condition. Replace the Refer to Diagnostic Starting Point —Electronic
shock absorber. Refer to Shock Absorber Replacement Suspension COWGI-
on page 16-29.
2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Rear Suspension 16-29
5. Use your hands in order to lift up and push down exceeds 2 cycles, replace the shock absorber.
on each corner of the vehicle 3 times. Remove your Ifthe shock absorber does not exceed 2 cycles,
hands from the vehicle. Ifthe corner motion NO repair is necessary.

Shock Absorber Replacement

.9 .'

1"! V

2498857
Shock Absorber Replacement
Callout Component Name
Preliminary Procedure
1. Raise andsupportthevehicle.Referto LiftingandJackingtheVehicleon page 1-31.
2. Removethetireandwheelassembly.Referto Tireand WheelRemovalandInstallationonpage 16-60.
RearShockAbsorberUpperBolt(Qty:2)
Caution: Referto FastenerCautiononpage 0-8.
1 Procedure
Supporttherearaxlewitha hydraulicjack.
Tighten
58N-m(43Ibft)
RearShockAbsorberLowerBolt
Tighten
2 - FirstPass: 100N-m(74lb ft)
' FinalPass: plus 90 degrees
3 RearShockAbsorberAssembly
ShockAbsorberNut
4 Tighten
25N-m(18lb ft)

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
'16-30 Rear Suspension

Shock Absorber Replacement (cont'd)

Callout Component Name
5 ShockAbsorberMount
6 ShockAbsorberBumper
7 RearShockAbsorber

Rear Spring, Insulator, and Jounce Bumper Replacement

_. '56?

2 F

2500313

Rear Spring, Insulator, and Jounce Bumper Replacement

Callout I Component Name
Preliminary Procedure
Raise andsupportthevehicle.RefertoLiftingandJackingtheVehicleon page 1-31.
RearSpring
Procedure
1 1. Ifremovingtherearspringto serviceothersuspensioncomponents,notethepositionoftherearspringin
relationshiptotheinsulators.
2. Supporttherearaxlewitha hydraulicjack.
3. Removethelowerrearshockabsorberbolt.Referto ShockAbsorberReplacementonpage 16-29.
UpperRearSpringInsulator
Tip: Ensurethattherearspringinsulatoris properlyseatedin therearframerail.
LowerRearSpringInsulator
Tip: Ensurethattherearspringinsulatoris properlyseatedin therearaxle.

—
2013 (US/Canada)
Sonic (5377994)
Manual
Service
 Rear Suspension 16-31

Rear Axle Replacement

Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and
Jacking the Vehicle on page 1-31.
2. Remove the tires and wheel assembly. Refer to
Tire and Wheel Removal and Installation on
page 16-60. '
3. Remove the park brake cables from the rear axle.
Refer to Parking Brake Cable Replacement (Drum
Brake) on page 5-189 or Parking Brake Cable
Replacement (Disc Brake) on page 5—192.
Note: Cap the rear brakes lines so as to prevent the
hydraulic brake system from being contaminated.
4. Remove the rear brake line from the rear axle.
Refer to Brake Pipe Replacement on page 5-158. 1
Note: Relocate the rear brake assembly to the side
using mechanics wire.
5. Remove the rearwheel bearing/hub from the rear 2500476
axle. Refer to Rear Wheel Bearing and Hub remove the rear axle mounting bolts at
Note: DO NOT
Replacement (Drum Brake) on page 16—24or Rear
this time.
Wheel Bearing and Hub Replacement (Disc Brake)
0" P899 16-25- 9. Loosen the mounting bolts(1) forthe rear axle.
6- Using a hydrauliciack stand, SUPP011the rear 3X19 10. Withthe aide of an assistant, remove the mounting
assembly. bolts.

2539862 2500672
7. Using a bright colored paint, mark (1)the outline of 11. With the mounting bolts removed, lower the rear
the rear axle mounting bracket to the chassis to axle assembly (1).
properly align the rear axle to the chassis for
installation.
Note: Before removing the spring and insulator‘s, note
the relationship of the spring and insulators to the body
and the rear axle.
8. Lower the rear axle and remove the rear springs
and the insulators. Refer to Rear Spring, Insulator,
and Jounce Bumper Replacement on page 16-30.

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
’16-32 Rear Suspension

Installation Procedure

2500672 3. Install the rear axle mounting bolts (1) and
1. Using a hydraulicjack stand and the aide of an
assistant, position the rear axle assembly (1) in the
vehicle.
2539862
2. Align the mounting points of the rear axle to the
painted outline (1)on the chassis.
2500476
Caution: Refer to Fastener Caution on page 0-8.
tighten to:
' First Pass: 160 N-m(118 lb ft)
- Final Pass: plus 30 degrees
Note: Ensure that the rear springs and insulators are
properly aligned seated in the rear axle.
4. Install the rear spring and the insulators. Refer to
Rear Spring, Insulator,and Jounce Bumper
Replacement on page 16—30.
Install the rearwheel bearing/hub mounting bolts to ,
the rear axle. Refer to Rear Wheel Bearing and .vv.\
flma
Wu.
2,.
...,“
w...
Hub Replacement (Drum Brake) on page 16-24 or
Rear Wheel Bearing and Hub Replacement (Disc
Brake) on page 16-‘25.
install the rear park brake cables. Refer to Parking
Brake Cable Replacement (Drum Brake) on
page 5—189or Parking Brake Cable Replacement
(Disc Brake) on page 5-192.
Install the rear brake lines on the rear axle. Refer
to Brake Pipe Replacement on page 5158.
Bleed the hydraulic brake system. Refer to
Hydraulic Brake System Bleeding (Pressure) on
page 5-169 or Hydraulic Brake System Bleeding
(Manual) on page 5—170.
Install the tire and wheel assembly. Refer to Tire
and Wheel Removal and Installation on
page 16-60.
10. Remove the supports and lower the vehicle.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
“\‘m
aa—
.w
,W..
N.
‘22..
_
.
 Rear Suspension 16-33

Wheel Stud Replacement Installation Procedure

Special Tools
CH 43631 Ball Joint Separator
For the regional equivalent tool, referto Special Tools
on page 16-34.
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and 1
Jacking the Vehicle on page 1-31.
2. Remove the wheel bearing and hub assembly.
Refer to Rear Wheel Bearing and Hub
Replacement (Drum Brake) on page 16-24 or Rear
Wheel Bearing and Hub Replacement (Disc Brake)
on page 16-25.

2500978
Note: Ensure that the wheel stud is properly aligned in
the wheel hub flange.
lllllllllfl
1. Position the NEW wheel stud (1) in the wheel
bearing and hub assembly.

2501244
Note: Ensure that the wheel bearing and hub flange is
securely tighten in the vise.
3. Install the wheel bearing and hub assembly (2)in a
suitable vise.
4. Using the CH43631separator (1),remove and
discard the wheel stud from the wheel bearing and
hub assembly.

2501147
2. Using three washers (2)and an old wheel nut (1),
tighten the wheel nut (1) until the wheel stud is
seated in the wheel bearing and hub flange.
3. Remove the wheel bearing and hub assembly from
the vise.
4. Installthe wheel bearing and hub assembly. Refer
to Rear Wheel Bearing and Hub Replacement
(Drum Brake) on page 16-24 or Rear Wheel
Bearing and Hub Replacement (Disc Brake) on
page 16—25.
5. Remove the support and lower the vehicle.

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
16-34 Rear Suspension

Description and Operation Illustration Tool Number/Description

Rear Suspension Description and N

Operation
(314—51035
This vehicle has a beam rear suspension system
consisting of the following components: RearAxle Supporter
Adapter
- An axie with integral trailing arms
~ A cross beam
- Two coil springs
- Two standard shock absorbers 2866875

Axle Assembly ('1. 22,.

W
._
- .
A
The axle assembly attaches to the underbody through a 62 V-
rubber bushing and bracket located at the front of each V
integral trailing arm. The brackets are bolted to the 011—51095
underbody side rails. The axle structure itself maintains J-39642
the geometrical relationship of the wheels relative to Shock NutRemovalToolSet
the centerline of the body.
Rear camber and tow are not adjustable. Replace any
damaged suspension components as necessary.
2866882
Coil Spring
The coil springs support the weight of the vehicle in the
rear. Rubber insulators isolate the coil spring at the
upper and lower spring seat.
Shock Absorber DT—50187
The shock absorbers are connected to the rear axle RearAxle Supporter
and the vehicle underbody. The shock absorbers are
non-adjustable and non-retiliable. Service of the shocks
requires replacement of the shock assembly.
Wheel Bearing/Hub Assembly 2329964
A single hub and bearing assembly is bolted to both
ends of the rear axle assembly. The hub and bearing %
2W
assembly is a sealed unit that eliminates the need for
wheel bearing adjustment or periodic maintenance.
Although the rear suspension components are CH-50559
lubricated for life and require no routine lubrication, WheelHub/Bearing
they should be inspected periodically for damage Remover/InstallerKit
and wear.

Special Tools and Equipment

2548684

Illustration Tool Number/Description

CH—24319—B
CH-43631
J—24319—B
J-43631
BallJointRemover

400167

(US/Canada)
-Sonic
2013 {5377994)
Manual
Sen/ice
 Suspension General Diagnosis 16-35

Suspension General Diagnosis

Specifications

Trim Height Specifications

Model Tire Size Option Z D P R

mm W (0115.18.2‘91) (33:38.51) (2632:1822) (23.212322)

QLG (07.15.1889?) (3159:1829?) (333:8???) (53.215431)

03° (0113:182‘91m (3159:1828) (2632:3322) (53.216322,

Visual/Physical Inspection
Diagnostic Information and
- Inspect for aftermarket devices which could affect
Procedures the operation of any of thesuspension
subsystems.
- inspect the easily accessible or visible system
Symptoms - Suspension General components for obvious damage or conditions
Diagnosis which could cause the symptom.
Note: The following step must be completed before - Inspect for proper tire size and inflation pressure.
using the symptom tables. Symptom List
Review the system description and operation in order to Refer to a symptom diagnostic procedure from the
familiarize yourself with the system functions. Refer to following list in order to diagnose the symptom:
the appropriate description and operation: . . Ride Diagnosis on page 16-35
' Front SuspenSIon Description and Operation on . Vehicle Leads/Pul/s on page 16-36
page 16-22. .
. , , , - Body Leans or Sways In Corners on page 16-36
° Rear SuspenSIon Description and Operation on .
page 16-34. - SuspenSIon Bottoms on page 16-37
- Tires and Wheels Description and Operation on ' R/de Diagn03/s 0" page 1635
page 16—66. ' Memory Steer on page 16-38

Ride Diagnosis
Step Action Yes No
Didyoureviewthe GeneralDescriptionandperformthenecessary Go to Symptoms-
1 inspections? SuspensionGeneral
Diagnosison
Go to Step2 page 16-35
Important:VerifythevehiclesuspensionpackageRPO.
2 Verifythattherideis toosoftor toohard.
Doesthevehicleridenormally? SystemOK Go to Step3
Checkthetireinflationandadjustto specifications.Referto Vehicle
Certification,TirePlacard,Anti-Theft,andServiceParts IDLabelon
3 page 1-13.
Didyouadjustthetirepressure? Go to Step6 Go to Step4
Inspectthevehicletrimheight.Referto TrimHeightInspectionon
4 page 16-42.
Didyoufindandcorrectthecondition? Go to Step6 Go to Step5
Inspectthefollowingsuspensioncomponentsforwearor damage:
- ShockAbsorbers—Referto SuspensionStrutandShock
5 AbsorberTesting- On Vehicleonpage 16-41. _
- Springs
Didyoufindandcorrectthecondition? Go to Step6
6 Drivethevehiclein ordertoverifytherepair.
Didyoucorrectthecondition? SystemOK Go to Step3

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
16-36 Suspension General Diagnosis

Vehicle Leads/Pulls
Step Action Yes No
DEFlNlTl0N1Ata constanthighwayspeedon a typicalstraightroad,lead/pullis theamountofeffortrequiredatthesteering
wheelto maintainthevehicle'sstraightpath.
Didyou reviewtheGeneralDescriptionandperformthevisual/ Go to Symptoms-
physicalinspections? SuspensionGeneral
Diagnosison
Go to Step2 page 16-35,
2 Roadtestthevehiclein ordertoverifythecomplaint.
Doesthevehicleoperatenormally? SystemOK Go to Step3
Inspectthetire/wheelassembliesforthefollowingconditions:
- Correcttirepressure—Refertothetireplacard.
3 - Correcttiresize—Refertothetireplacard.
- Abnormaltirewearor damage
Didyoufindandcorrectthecondition? Go to Step9 Go to Step4
4 PerformtheRadial TireLead/Pu/lCorrectiononpage 16-58.
Didyoufindandcorrectthecondition? Go to Step9 Go to Step5
Inspectandcorrect/adjustthesuspensionandsteeringsystemsfor
thefollowingconditions:
~Vehicletrimheight—Referto TrimHeightSpecificationson
5 page 16-35.
- Excessivelyworn,loose,or damagedComponents
Didyoufindandcorrectthecondition? Go to Step9 Go to Step6
Inspectthebrakesystemforbrakedrag.Withthevehicle
suspendedon a hoist,brakedragcan beidentifiedby rotatingeach
wheelseveraltimesand observingwhethermoreforceis needto
6 rotatetheleftwheelor therightwheel.Referto BrakeRotor
ThicknessVariationMeasurementonpage5—55.
Didyoufindandcorrectthecondition? Go to Step9 Go to Step7
Inspectthewheelalignmentandadjustas necessary.Referto
7 WheelAlignmentMeasurementonpage 16-69.
Didyou correctthecondition? Go to Step9 Go to Step8
Inspectthesteeringgearforunequaleffort.The vehiclemustbe
suspendedon a hoist,theenginerunning,andthetransmissionin
PARK or NEUTRAL.Graspthetireassemblyandmanuallysimulate
8 a turnfromtheleftofcenterandtherightofcenterobserving
whethermoreforceis neededtoturntotheleftor totheright.Ifthis
conditionexistsreplacethesteeringgear.
Didyoucorrectthecondition? SystemOK Go to Step3
9 Operatethevehiclein ordertoverifytherepair.
Didyou correctthecondition? SystemOK Go to Step3

Body Leans or Sways in Corners

Step Action Yes No
Didyou reviewtheGeneralDescriptionandperformthenecessary Go to Symptoms-
1 inspections? SuspensionGeneral
Diagnosison
Go to Step2 page 16—35
2 Verifythevehicleleansor swaysin corners.
Doesthevehicleoperatenormally? SystemOK Go to Step3
Inspectthefollowingcomponentsforwearor damage:
3 - Rear Coil Springs
' FrontCoil Springs
Are thecomponentswornor damaged? Go to Step 5 Go to Step4

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Suspension General Diagnosis 16-3’7

Body Leans or Sways in Corners (cont'd)

Step Action Yes No
1. Inspectthestabilizershaftlinkforwearor damage.
4 2. Repairas necessary.
Didyoufindandcorrectthecondition? Go to Step 6 Go to Step2
5 Replacethespringsas necessary.
Didyoucompletethe repair? Go to Step 6 -
6 Operatethevehicleinordertoverifytherepair.
Didyoucorrectthecondition? SystemOK Go to Step3

Suspension Bottoms
Step Action I Yes , No
DEFINITION:A loudbangor thumpthatcan usuallybefeltandlorheardwhenthevehicleis drivenoverbumps.This conditionis
commonlynoticedwhenthevehicletrimheightis toolow.
DidyoureviewtheGeneralDescriptionandperformthenecessary Go to Symptoms-
inspections? SuspensionGeneral
Diagnosison
Go to Step2 page 16-35
Verifythatthesuspensionbottoms.
Doesthevehicleoperatenormally? SystemOK Go to Step3
Inspectforvehicleoverloadingandcorrecttheoverloading
conditionas necessary.Referto VehicleCertification,TirePlacard,
Anti-Theft,andServiceParts IDLabelonpage 1-13for
specifications.
Didyoufindandcorrectthecondition? Go to Step6 Go to Step4
Inspectthefollowingcomponents:
. Inspecttheshockabsorbers.Referto StrutandShockAbsorber
Inspectiononpage 16-16forfrontandStrutandShockAbsorber
Inspection(ShockAbsorber)onpage 16-28forrear.
' Inspectfordamagedcoilsprings,torsionbaror leafspringsand
replaceas necessary.
Didyoufindandcorrectthecondition? Go to Step6 Go to Step5
Inspectthevehicletrimheight.Referto TrimHeightInspectionon
page 16-42.
Didyoucompletethetrimheightinspectionprocedure? Go to Step6
Operatethevehicleinordertoverifytherepair.
Didyoucorrectthecondition? SystemOK Go to Step3

Torque Steer
Step Action Yes No
DEFINITION:On a dry,smooth,fiatroad,thevehiclehas a leftor rightsteeringforceonlyduringacceleration.
DidyoureviewtheGeneralDescriptionandperformthenecessary Go to Symptoms-
inspections? SuspensionGeneral
Diagnosison
Go to Step2 page 16-35
1. Drivethevehicleona straight,smooth,fiatroad.
2. Presstheacceleratoranddetermineif anyadditionalsteering
inputis requiredto maintaina straightaheaddirection.
3. Repeatthistestwiththevehicletravelingin theopposite
2 directionin ordertoeliminatecrosswindeffects.Lead/puil
causedby unlevelroadsandcrosswindsare considered
normal.
Doesthevehicleexhibittorquesteerwhentheacceleratoris
pressed? Go to Step3 SystemOK

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
16-38 Suspension General Diagnosis

Torque Steer (cont'd)

Step Action Yes No
1. Drivethevehicleona straight,smooth,fiatroadat 64—97km/h
(40—60 mph).
2. Removeyourfootfromtheaccelerator.
3. ShiftthetransmissionintoNEUTRAL in ordertoallowthe
vehicleto coast.
._ww
.,M_
4. Isanyadditionalsteeringinputrequiredto maintaina straight
3 aheaddirection.
5. Repeatthistestwiththevehicletravelingin theopposite
directioninordertoeliminatecrosswindeffects.Lead/pull
causedby unlevelroadsandcrosswindsare considered
normal.
Doesthevehicledirectionchangewhenthesteeringwheelis Go to VehicleLeads/
momentarilyreleased? Pulls onpage 16-36 Go to Step4
Inspectthefrontsuspensionandpowertrainmountsforwornor
4 damagedcomponentsandrepairas necessary.
Didyoufindandcorrectthecondition? Go to Step6 Go to Step5
inspectthevehicletrimheight.Referto TrimHeightlnspeotion0n
5 page 16—42. __
Didyoufindandcorrectthecondition? Go to Step6
6 Operatethevehiclein ordertoverifytherepair.
Didyou correctthecondition? SystemOK

Memory Steer
Step Action I Yes No
DEFlNiTiON:A leador pullin thedirectionthedriverpreviouslyturnedthevehicle.Additionally,afterturningintheopposite
direction,thevehiclewillwantto leador pullinthatdirection.
Didyou reviewtheGeneralDescriptionand performthenecessary Go to Symptoms-
inspections? SuspensionGeneral
Diagnosison
Go to Step2 page 16-35
Verifythatmemorysteeris present.
Doesthesystemoperatenormally? SystemOK Go to Step3
1. Raise andsupportthevehicle.Referto LiftingandJackingthe
Vehicleonpage 1-31.
2. Lubricatethetierodendsandtheballjointsif applicable.
3. inspectthesuspensionsystemforwornor damaged
components.
4. Repairas necessary.
Didyoufindandcorrectthecondition? Go to Step7 Go to Step4
Inspectforbindingstrutbearings.
1. Disconnectthestrutfromthesteeringknuckle.
2. Ifthestrutis abnormallydifficultto rotate,repairor replacethe
upperbearingmount.
Didyoufindandcompletetherepair? Go to Step7 Go to Step5
inspectforbindingin thelowerballjoints.lfjointis binding,replace
thejoint.
Didyoufindandcompletetherepair? Go to Step7 Go to Step6
Inspectthewheelalignmentandadjustas necessary.Referto
WheelAlignmentMeasurementonpage 16—69.
Didyou completethewheelalignment? Go to Step7
Operatethevehiclein ordertoverifytherepair.
Didyou correctthecondition? SystemOK

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
 Suspension General Diagnosis 16239

Noise Diagnosis - Front Suspension

Step Action I Yes I No
DEFINITION:Any noiseemittedfromthefrontof thevehiclethatis inducedbyVEHICLE SPEED or DRIVINGTERRAiN as
relatedtothefrontsuspension.
DidyoureviewtheGeneralDescriptionandperformthenecessary Go to Symptoms-
inspections? SuspensionGeneral
Diagnosison
Go to Step2 page 16-35
Attempttoduplicatethecondition.Roadtestthevehicle.
Didyouduplicatethecondition? Go to Step3 SystemOK
Isthenoisereactivetovehicleloadorspeed? Go to Step4 Go to Step7
MWNW—N,M
“MW
“~N. inspectthetiresforthefollowingcondition:
- PropertireInflationandadjustas necessary.Referto Tire
InflationDescriptiononpage 16-65.
- Unusualtirewear.Referto VibrationAnalysis- Tireand Wheel
onpage 1-43.
' Inspectthewheelnutsforloosenessandtightenas necessary.
RefertoFastenerTighteningSpecificationsonpage 16—55.
Didyoufindandcorrectthecondition? Go to Step14 Go to Step5
inspectthefrontwheelbearings.Referto WheelBearings
Diagnosisonpage 16-41.
Didyoufindandcorrectthecondition? Go to Step 14 Go to Step6
Inspectthefrontaxle or transaxlenoises.
' Forthe6T/6T40/6T45/6T50 automatictransmission,referto
Symptoms-AutomaticTransmissiononpage 17—1 57
' FortheF13—5/F15—5/F1 7—5manualtransmission,referto
Symptoms-ManualTransmissiononpage 17-445
° FortheM20/M32manualtransmission,referto Symptoms-
ManualTransmissiononpage 17-562
Didyoufindandcorrectthecondition? Go to Step14 Go to Step7
Bouncethefrontof thevehiclein ordertoduplicatethenoise.
Didyouduplicatethenoise? Go to Step8 Go to Step9
1. Raiseandsupportthevehicle.Referto LiftingandJackingthe
Vehicleonpage 1-31
2. Inspectthefrontsuspensioncomponentsforlooseness.Refer
toFastenerTighteningSpecificationsonpage 16-3.
3. Inspectthefrontsuspensioncomponentsfordamageand
repairas necessary. -
Didyoufindandcorrectthecondition? Go to Step14 Go to Step9
1. InstalltheJ 39570Chassis Ear or equivalent.
2. Bouncethefrontofthevehicle,usingtheJ 39570Chassis Ear
orequivalentin orderto locatethesourceofthenoise.
if necessaryroadtestthevehicle.
3. Repairor replaceanydamagedcomponentsas necessary.
Didyoufindandcorrectthecondition? , Go to Step 14 Go to Step10
Inspecttheballjointsandsteeringcomponentsforthefollowing
conditions.
- Lackof lubricationwhereapplicable.
10 - Loosenessinthebailjoints.Referto Ball JointInspectionon
page 16—41.
- Loosenessinthetierods.Referto SteeringLinkageOuterTie
Rod Replacementonpage 15-17.
Didyoufindandcorrectthecondition? Go to Step 14 Go to Step 11
inspectfordamagedshockabsorbers.Referto SuspensionStrut
11 andShockAbsorberTesting- On Vehicleonpage 16-41.
Didyoufindandcorrectthecondition? Go to Step14 Go to Step12
inspectthefrontstabilizershaftandstabilizershaftlinksfordamage
12 and repairas necessary.Referto StabilizerShaftReplacementon
page 16—3 or StabilizerShaftLinkReplacementonpage 16—8. Go to Step14 Go to Step13

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
16-40 Suspension General Diagnosis

Noise Diagnosis - Front Suspension (cont'd)

Step Action Yes No
Didyoufindandcorrectthecondition?
Inspectforcontrolarmdamageandrepairas necessary.Referto
13 LowerControlArmReplacementonpage 16-12. __
Didyoufindandcorrectthecondition? Go to Step14
14 Operatethesystemin ordertoverifytherepair.
Didyoucorrectthecondition? SystemOK Go to Step3

Noise Diagnosis - Rear Suspension

gw,‘
‘M
mMm
,2.
.
Step Action Yes No
DEFINITION: Any noiseemittedfromtherearof thevehiclethatis inducedbyVEHICLE SPEED 0r DRIVINGTERRAiN as
‘reiatedtotherearsuspension.
Didyou reviewtheGeneralDescriptionandperformthenecessary Go to Symptoms-
inspections? SuspensionGeneral
Diagnosison
Go to Step2 page 16-35
Attempttoduplicatethecondition.Roadtestthevehicle.
Didyouduplicatethecondition? G0 to Step3 SystemOK
Isthenoisereactivetovehicleloador speed? Go to Step4 Go to Step6
Performthefollowinginspections:
' InspectandadjustthetireInflation.Referto TireInflation
Descriptiononpage 16—65.
- Inspectforunusualtirewear.Referto VibrationAnalysis- Tire
and Wheelonpage 1-43.
- inspectthewheelnutsforlooseness.Referto Fastener
TighteningSpecificationsonpage 16-55.
Didyoufindandcorrectthecondition? Go to Step 10 Go to Step5
Inspecttherearwheelbearings.Referto WheelBearingsDiagnosis
onpage 16-41.
Didyoufindandcorrectthecondition? Go to Step 10 Go to Step6
Bouncetherearofthevehicleinordertoduplicatethenoise.
Didyouduplicatethenoise? Go to Step7 Go to Step9
1. Raise thevehicle.RefertoLiftingandJackingtheVehicleon
page 1-31.
2. Inspecttherearsuspensioncomponentsforlooseness.Refer
to FastenerTighteningSpecificationsonpage 16-24.
3. inspecttherearsuspensioncomponentsfordamageand
repairas necessary.
Didyoufindandcorrectthecondition? Go to Step 10 Go to Step8
Inspecttherearshockabsorber.Referto SuspensionStrutand
ShockAbsorberTesting- On Vehicleonpage 16-41.
Didyoufindandcorrectthecondition? Go to Step10 Go to Step9
1. InstalltheJ 39570chassisearor equivalent.
2. Bouncetherearofthevehicle,usingtheJ 39570chassis ear
or equivalent,in orderto locatethesourceofthenoise.
if necessary,roadtestthevehicle.
3. Repairor replaceanydefectivecomponentas necessary.
Didyoufindandcorrectthecondition? Go to Step 10 SystemOK
Operatethesystemin ordertoverifytherepair.
1O
Didyoucorrectthecondition? SystemOK Go to Step3

2013
-Sonic
(US/Canade)
Servlce
Manual
(5377994)
 Suspension General Diannosis 16-41
Ball Joint Inspection Ball Stud inspection
Caution: Refer to Vehicle Lifting and Jacking Caution Make sure to check the tightness of the ball stud in the
on page 0-10. knuckle boss during each inspection of the ball joint.
1. Raise the front of the vehicle to allow the front One way to inspect the ball stud for wear is to shake the
suspension to hang free. wheel and feet for movement of the stud end or the nut
at the steering knuckle.
2. Grasp the tire at the top and the bottom.
Another way to inspect the ball stud for wear is to check _
3. Move the top of the tire in an in-and-out motion. the fastener torque at the nut. A loose nut can indicate
vN
'_/.‘
. Look for any horizontal movement of the knuckle a stressed stud or a hole in the knuckle boss.
relative to the control arm. Worn or damaged bali joints and knuckies must be
‘i _
2M
,__.
_. . Bail joints must be replaced under the following replaced.
conditions:
The joint is loose.
The ball seal is cut.
The ball stud is disconnected from the knuckle.
The ball stud is loose at the knuckle.
The belt stud can be twisted in its socket with
finger pressure.
Suspension Strut and Shock Absorber Testing - On Vehicle
Step Action Yes No
DidyoureviewtheGeneralDescriptionandperformthenecessary Go to Symptoms-
inspections? SuspensionGeneral
Diagnosison
Go toStep2 page 16—35
Verifythatthecustomer'sconcernis present.
Doesthevehicleoperatenormally? SystemOK Go to Step3
Note: A lightfilmof oil on thetopportionoftheshockreservoiris
normal. '
Inspecteachstrutor shockabsorberforexternalfluidleakage.
Isa strutor shockabsorberleaking? Go to Step5 Go to Step4
1. Use yourhandsin ordertoliftupandpushdowneachcorner
ofthevehicle3 times.
2. Removeyourhandsfromthevehicle.
3. Locatea shockor strutthatexceeds2 cycles.
Didyoulocateshockor strutthatexceeds2 cycles? Go to Step5 Go to Step 6
Note: inspectthevehicletrimheightin orderto correctanypossible
causesofshock/strutfailures.Referto TrimHeightInspectionon
page 16-42.
Replacethestrutor shockabsorber.Referto Strut,Strut
Component,or SpringReplacementonpage 16-20or Shock
AbsorberReplacementonpage 16-29.
Didyoucompletetherepair? Go to Step6
Operatethevehiclein ordertoverifytherepair.
Didyoucorrectthecondition? SystemOK Go to Step3

Wheel Bearings Diagnosis

Step Action Yes No
DidyoureviewtheGeneralDescriptionandperformthenecessary Go to Symptoms
inspections? - Suspension
General
Diagnosison
Go to Step2 page 16-35
Roadtestthevehiclein ordertoverifythecustomer'scomplaint.
Doesthevehicleoperatenormally? SystemOK Go to Step3

2013
—
Sonic
(US/Canada)
Service
Manual
(5377994)
16-42 Suspension General Diagnosis

Wheel Bearings Diagnosis (cont'd)

Step Action Yes No
1. Raise andsupportthevehicle.Referto LiftingandJackingthe Vehicleon
page 1-31.
2. Inspectfortireorwheeidamage.
Didyoufindandcorrectthecondition? Go to Step6 Go to Step4
Roadtestthevehicleto verifythelocationofthewheelbearingnoise.
Didyoulocatethesourceofthewheelbearingnoise? Go to Step5 Go to Step2
Replacethewheelbearing.Referto FrontWheelBearingandHub
Replacementonpage 16-9or Rear WheelBearingandHubReplacement
5 (DrumBrake)onpage 16-24or Rear WheelBearingandHub Replacement _
(DiscBrake)onpage 16-25.
Didthiscompletetherepair? Go to Step6
Roadtestthevehicleto verifytherepair.
Doesthevehicleoperatenormally? SystemOK Go to Step3

Trim Height Inspection Measuring the P and R Dimension

Trim Height Measurement

Trim height is a predetermined measurement relating to
vehicle ride height. incorrect trim heights can cause the
vehicle to bottom 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:
Note: One U.S. gallon of gasoline weights
approximately 6.5 lbs. One titerof gasoline weights
approximately 0.7 kg.
- Check the fuel level. Add additional weight if
necessary to simulate a full tank.
- Make sure the passenger and rear compartments
are empty, except for the spare tire.
- Make sure the vehicle is on a flat and level
surface, such as an alignment rack.
- Check that all the vehicle doors are securely 2698473
closed.
Measurement Definitions
- Check that the vehicle hood and rear deck lids are
securely closed. P Height: The vertical distance from the ground to the
top of the wheel opening through the centerline of the
- Check for installed after market accessories or front wheel.
modifications that could affect trim height
measurement: R Height: The vertical distance from the ground to the
top of the wheel opening through the centerline of the
- Larger or Smaller than production wheels and rearwheel.
tires
Use the following procedures to measure
' Lifting or Lowering Kits the P and R dimensions:
. Wheel Opening Flares or Ground Affects Note:
- Measure from the TOP of the wheel well
opening to the ground.
- The left and right P and R height differences
should be no more than 10 mm (0.39 in).
1. Push the front bumper down a minimum of 25 mm
(1 in) and release. Perform this step three times.
2. Measure and record the trim height per the
“Measurement Definitions" above.
3. Lift the bumper up a minimum of 25 mm (1 in) and
release. Perform this step three times.
(US/Canada)
-Soni’c
2013 (5377994)
Manual
Service
 Suspension General Diagnosis 16-43
4. Measure and record the trim height per the D Height Measurement
“Measurement Definitions" above.
5. The true P height measurement is the average of
the measurements taken in step 2 and 4. Refer to
TrimHeight Specifications on page 16—35.
6. Repeat the above steps at the rear of the vehicle
for the R heights.
7. if the P and R heights are outside of the
specifications, measure the Z & D heights.
Measuring the Z Dimension

2697841
Measurement Definitions
The D Height: The vertical distance from the bottom
surface of the body side rail (a)to the center of the
lower shock attaching bolt head (b).
Use the following procedure to check the D dimension:
Note: The left and right D height difference should be
no more than 10 mm (0.39 in).
2698189 1. Push the rear bumper down a minimum of 25 mm
(1 in) and release. Perform this step three times.
Measurement Definitions 2. Measure and record the trim height per the
The Z Height: The vertical distance from the bottom “Measurement Definitions” above.
surface of the cradle (b), in line fore/aftwith the center 3. Lift the rear bumper up a minimum of 25 mm (1 in)
of the ball joint (a). and release. Perform this step three times.
Use the following procedures to measure 4. Measure and record the trim height perthe
the Zdimensions: “Measurement Definitions” above.
Note: The left and rightZ height differences should be 5. The true D height is the average of the
no more than 10 mm (0.39 in). measurements taken in steps 2 and 4. Refer to
1. Push the front bumper down a minimum of 25 mm TrimHeight Specifications on page 16—35.
(1 in) and release. Perform this step three times. 6. Ifthese measurements are out of specifications,
2. Measure and record the trim height per the inspect for the following conditions:
“Measurement Definitions" above. - Worn or damaged suspension components
3. Lift the front bumper a minimum of 25 mm (1 in) - Collision damage
and release. Perform this step three times.
4. Measure and record the trim height perthe
“Measurement Definitions” above.
5. The true 2 height dimension is the average of the
measurements taken in steps 2 and 4. Refer to
TrimHeight Specifications on page 16—35.
6. if these measurements are out of specifications,
inspect for the following conditions:
- Worn or damaged suspension components
- Collision damage

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
16-44 Suspension General Diagnosis

Special Tools and Equipment

illustration Tool NumberlDescription

CH-39570
J-39570
Chassis Ear

643842

—
2013 (US/Canada)
Sonic (5377994)
Manual
Service
 Tire Pressure Monitoring '16-45

Tire Pressure Monitoring

Diagnostic Information and Procedures

DTC C0569

Diagnostic Instructions
- Perform the Diagnostic System Check - Vehicle
on page 6-66 prior to using this diagnostic
procedure.
- Review Strategy Based Diagnosis on page 6—58
for an overview of the diagnostic approach.
0 Diagnostic Procedure Instructions on page 6-59
provides an overview of each diagnostic category.
DTC Descriptor
DTC C0569 00: System Configuration Malfunction

CircuitlSystem Description Diagnostic Aids

Ifthe tire type and pressure information is not entered
during the body control module (BCM) setup, the tire
pressure monitor system indicator icon on the
instrument cluster will flash for 1 min and then remain
illuminated afterthe ignition is cycled ON and the
instrument cluster bulb check is complete. Ifequipped,
the driver information center will also display a service
tire monitor type message. Under these circumstances,
DTC 00569 will be set and the tire type and pressure
informationwill need to be entered for the system to
function correctly.
Conditions for Running the DTC
IgnitionON.
Conditions for Setting the DTC
The tire type and pressure information is not entered
into the BCM during programming and setup.
Action Taken When the DTC Sets
- The tire pressure monitor system indicator icon on
the instrument cluster flashes for 1 min and then
remains illuminated after the ignition switch is
cycled ON and the instrument cluster bulb check
is complete.
° lf equipped, the driver information center displays
a service tire monitor type message.
Conditions for Clearing the DTC
A current DTC will Clear when the BCM has undergone
the tire type and pressure selection setup procedure
and one ignition cycle has occurred.
A newly replaced BCM will set DTC 00569 after
programming on it’s initial ignition ON cycle if the
module setup information has not been entered.
Reference Information
Description and Operation
Tire Pressure Monitor Description and Operation on
page 16-53
Scan Tool Reference
Control Module References on page 6-3 for scan tool
information
CircuitlSystem Verification
1. lgnition ON.
2. Enter the tire type and pressure information into
the K9 Body Control Module with a scan tool. Refer
to Vehicle Certification, Tire Placard, Anti-Theft,
and Service Parts ID Label on page 1-13.
3. lgnition OFF, then IgnitionON.
P‘ Verify DTC 00569 is not set.
:> If the DTC is set
Replace the K9 Body Control Module.
U If the DTC is not set.
5. All OK.
Repair Instructions
Perform the Diagnostic Repair Verification on
page 6—92after completing the repair.
Control Module References on page 6—3for BCM
replacement, programming, and setup.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
'l6-46 Tire Pressure Monitorirg;

DTC 00750, C0755, C0760, or 00765

Diagnostic Instructions
' Perform the Diagnostic System Check - Vehicle
on page 6-66 prior to using this diagnostic
procedure.
- Review Strategy Based Diagnosis on page 6—58
for an overview of the diagnostic approach.
- Diagnostic Procedure Instructions on page 6-59
provides an overview of each diagnostic category.
DTC Descriptor
DTC 00750 03: Left Front Tire Pressure Sensor Low Voltage
DTC 00750 29: Left Front Tire Pressure Sensor Too Few Pulses
DTC 00750 39: Left Front Tire Pressure Sensor Internal Malfunction
DTC 00755 03: Right Front Tire Pressure Sensor Low Voltage
DTC 00755 29: Right Front Tire Pressure Sensor Too Few Pulses
DTC 00755 39: Right Front Tire Pressure Sensor Internal Malfunction
DTC 00760 03: Left Rear Tire Pressure Sensor Low Voltage
DTC 00760 29: Left Rear Tire Pressure Sensor Too Few Pulses
DTC 00760 39: Left Rear Tire Pressure Sensor Internal Malfunction
DTC 00765 03: Right Rear Tire Pressure Sensor Low Voltage
DTC 00765 29: Right Rear Tire Pressure Sensor Too Few Pulses
DTC 00765 39: Right Rear Tire Pressure Sensor Internal Malfunction

CircuitlSystem Description Diagnostic Aids

The tire pressure monitor system has a radio frequency
(RF) transmitting pressure sensor in each wheel/tire
assembly. As vehicle speed increases, centrifugal force
closes the sensors internal roll switch, which puts the
sensor into Drive mode. The body control module
(BCM) receives and translates the data contained in the
tire pressure sensor RF transmissions into sensor
presence, sensor mode, and tire pressure. Once
vehicle speed is greater than 40 km/h (25 MPH), the
BCM waits for the first sensor to go into Drive mode,
then checks if all sensors have gone into Drive mode.
if one or more sensors does not go into these modes,
or does not transmit at all, the BCM will set DTC 00750,
00755, 00760, or 00765 respectively.
Conditions for Running the DTC
Vehicle speed is greater than 40 km/h (25 MPH).
Conditions for Setting the DTC
- A sensor does not transmit or transmits invalid
data to the BCM.
o A sensor low battery condition.
Action Taken When the DTC Sets
- The tire pressure monitor system indicator icon on
the instrument cluster flashes for 1 min and then
remains illuminated after the ignition switch is
cycled ON and the instrument cluster bulb check
is complete.
- Ifequipped, the driver information center displays
a service tire monitor type message.
Conditions for Clearing the DTC
A current DTC will clear when the malfunction is no
longer present and one ignition cycle occurs.
- Some aftermarket wheel valve stem holes are
located further from the wheel rim than original
equipment wheels. When using the tire pressure
monitor special tool to activate a sensor, ensure
the tool is placed along the tire sidewall and no
further than 15 cm (6 in) from the sensor and the
antenna is aiming upward.
- Aftermarket wheel valve system locations can
cause a sensor to not function correctly.
- A sensor may have been damaged due to a
previous wheel/tire service or flat tire event.
- The use of other than GM approved tire sealants
can obstruct the sensor pressure sensing port and
cause inaccurate tire pressure readings. Ifthis
condition is verified, remove the sealer from the
tire and replace the sensor. Refer to Tire Pressure
Indicator Sensor Replacement on page 16-50.
- Occasionally sensor transmissions are not
received by the BCM due to vehicle level radio
frequency interference from items such as but not
limited to aftermarket ignition systems, DVD
players, 0B radios, or metallic type window tinting.
~ The sensor activation procedure may have to be
repeated up to 3 times before determining a
sensor is malfunctioning. Inthe event a particular
sensor information is displayed on the special tool
upon activation but the horn does not chirp, it may
be necessary to rotate the wheel valve stem to a
different position due to the RF signal being
blocked by another component.
(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
«~—
W
A
M
M”.
«ne
N
 Tire Pressure Monitoring 16=47
- Occasionally sensors can become mislocated due . Perform the Tire Pressure Indicator Sensor Learn
to previous tire rotations where the sensor learn on page 16-52.
procedure was not performed. Always learn the Verify the scan tool Tire Pressure Sensor Mode
sensors to ensure the DTC set is for that actual parameters change to Drive while driving the
physical corner of the vehicle. Refer to Tire vehicle above 40 km/h (25 mph) for greater
Pressure Indicator Sensor Learn on page 16-52. than 2 min.
- A sensor low battery condition will set a sensor
If a Tire Pressure Sensor Mode parameter does
DTC but will not illuminate the low tire pressure
not change to Drive
indicator or display a message on the driver
information center, if equipped. The sensor battery 3.1. Replace the appropriate B2 Tire Pressure
condition can be verified in the scan tool BCM Sensor.
data list. Ifa sensor low battery condition is 3.2. Perform the Tire Pressure Indicator Sensor
indicated on the scan tool, the sensor will need to Learn on page 16-52.
be replaced. Refer to Tire Pressure Indicator U If the Tire Pressure Sensor Mode parameter
Sensor Replacement on page 16-50. changes to Drive
Reference Information 4. All OK.
Description and Operation Repair Instructions
Tire Pressure Monitor Description and Operation on Perform the Diagnostic Repair Verification on
page 16—53 page 6-92 after completing the repair.
Tire Pressure Indicator Sensor Replacement on
Scan Tool Reference
page 16—50
Control Module References on page 6-3 for scan tool Tire Pressure Indicator Sensor Learn on
information page 16-52
CircuitlSystem Verification
1. Verify there are no communication DTCs set along
with DTC 00750, 00755, 00760, and 00765.
=>if a communication DTC is set
Refer to Diagnostic Trouble Code (DTC) List -
Vehicle on page 6-69.
U If a communication DTC is not set

2013
—
Sonic
(US/Canada)
Service
Manual
(5377994)
'16-48 Tire Pressure Monitoring

DTC 00775

Diagnostic Instructions
- Perform the Diagnostic System Check - Vehicle
on page 6-66 prior to using this diagnostic
procedure.
- Review Strategy Based Diagnosis on page 6-58
for an overview of the diagnostic approach.
- Diagnostic Procedure Instructions on page 659
provides an overview of each diagnostic category.
DTC Descriptor
DTC 00775 00: Tire Pressure Monitoring System Sensors Malfunction

CircuitlSystem Description CircuitlSystem Verification

lfthe body control module (BCM) has been
reprogrammed or replaced and the tire pressure sensor
learn procedure has not been performed, the tire
pressure monitor system indicator icon on the
instrument clusterwill flash for1 min and then remain
illuminated afterthe power switch is cycled ON and the
instrument cluster bulb check is complete. Ifequipped,
the driver information center will also display a service
tire monitor type message. Under these circumstances,
DTC 00775 will be set in the BCM and the tire pressure
sensor learn procedure will need to be performed for
the system to function correctly.
Conditions for Running the DTC
Vehicle ON or Vehicle in Service Mode.
Conditions for Setting the DTC
The body control module (BCM) has not learned tire
pressure sensor ID and location informationfrom the
tire pressure sensors.
Action Taken When the DTC Sets
. The tire pressure monitor system indicator icon on
the instrument cluster will flash for 1 min and then
remain illuminated after the power switch is cycled
ON and the instrument cluster bulb check is
complete.
- Ifequipped, the driver information center displays
a service tire monitor type warning message.
Conditions for Clearing the DTC
A current DTC will clear when the BCM has received
tire pressure sensor ID and location informationfrom
the tire pressure indicator module and at least 1 power
switch cycle has occurred.
Reference Information
Description and Operation
Tire Pressure Monitor Description and Operation on
page 16-53
Scan Tool Reference
Control Module References on page 6—3for scan tool
information
1. Perform the Tire Pressure Indicator Sensor Learn
on page 16-52.
2. Verify DTC 00775 is not set.
:> If the DTC is set
Replace the K9 Body Control Module.
U If the DTC is not set
3. All OK.
Repair instructions
Perform the Diagnostic Repair Verification on
page 692 after completing the repair.
Control Module References on page 6—3for BCM
replacement, programming, and setup.
Symptoms - Tire Pressure
Monitoring
1. Perform the Diagnostic System Check - Vehicle on
page 6-66 , before using the Symptom Tables in
order to verify that all of the following are true:
- There are no DTCs set.
- The control modules can communicate via the
serial data link.
2. Review the system operation in order to familiarize
yourself with the system functions. Refer to Tire
Pressure Monitor Description and Operation on
page 16-53.
VisuallPhysicaI Inspection
- Inspect for aftermarket devices which could affect
the operation of the Tire Pressure Monitoring
(TPM) System. Refer to Checking Aftermarket
Accessories on page 11-525.
- inspect the easily accessible or visible system
components for obvious damage or conditions
which could cause the symptom.
Intermittent
Faulty electrical connections or wiring may be the
cause of intermittentconditions. Referto Testing for
IntermittentConditions and Poor Connections on
page 11~531.
Symptom List
Refer to Low Tire Pressure Indicator Malfunction on
page 16-49 in order to diagnose the symptom.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)

Low Tire Pressure Indicator
Malfunction
Diagnostic Instructions
- Perform the Diagnostic System Check - Vehicle
on page 6—66prior to using this diagnostic
procedure.
' Review Strategy Based Diagnosis on page 6—58
for an overview of the diagnostic approach.
- Diagnostic Procedure Instructions on page 6-59
provides an overview of each diagnostic category.
CircuitlSystem
Description
The tire pressure monitor system has a radio frequency
transmitting pressure sensor in each wheel/tire
assembly. As vehicle speed increases, centrifugal force
closes the sensors internal roll switch, which puts the
sensor into Drive mode. The sensors send the tire
pressure data to the body control module (BCM). The
BCM translates the data contained in the tire pressure
sensor radio frequency transmissions into sensor
presence, sensor mode, and tire pressure. Once
vehicle speed is greater than 40 km/h (25 MPH), the
BCM waits for the sensors to go into Drive mode.
Each sensor has its own unique identification (lD) code,
which it transmits as part of each RF message, that
must be learned into the BCM memory. Once all 4 IDs
have been learned and vehicle speed is greater than
40 km/h(25 mph),the BCM continuously compares IDs
and pressure data in the received transmissions to the
learned IDs and pressures to determine if all 4 sensors
are present and if one or more tires are low. Ifthe BCM
detects a low tire pressure condition or a malfunction in
the system, it will send a serial data message to the
instrument cluster requesting the appropriate tire
pressure monitor indicator illumination and also to
display the appropriate data message on the driver
information center, if equipped.
Diagnostic Aids
- Ifunsure about the condition, cycle the ignition
and observe the tire pressure monitor indicator
icon. Ifthe tire pressure monitor indicator icon is
continuously illuminated after the instrument
cluster bulb check is completed, a low tire
pressure condition is present. Check the tires for
damage or leaks and inflate to the tire placard
specifications. Refer to Vehicle Certification, Tire
P/acard, Anti—Theft,and Service Parts ID Label on
page 1—13.Ifthe tire pressure monitor indicator
icon flashes for 1 min after the instrument cluster
bulb check is completed and then remains
illuminated, a tire pressure monitor system DTC is
set. Perform the Diagnostic System Check -
Vehicle on page 6—66to proceed with the proper
diagnosis.
- Temperature can greatly effect tire pressures. Low
tire pressure on a cold morning may cause the tire
pressure monitor indicator icon to turn ON. The air
pressure in the tire increases as the ambient
temperature rises or as the tire warms up while the
vehicle is driven. The pressure may increase
enough to exceed the predetermined low pressure
threshold which will turn OFF the tire pressure
monitor indicator icon .
2013
—
Sonic
(US/Canada)
Service
Manual
(5377994)
Tire Pressure Monitoring 16-49
- Some aftermarket wheel valve stem holes are
located further from the wheel rim than original
equipment wheels. When using the tire pressure
monitor special tool to activate a sensor, ensure
the tool antenna is no further than 15 cm (6 in)
from the sensor and is aiming upward.
- Aftermarket wheel value stem locations can cause
a sensor to not function correctly.
- A sensor may have been damaged due to a
previous wheel/tire service or flat tire event.
- The use of other than GM approved tire sealants
can obstruct the sensor pressure sensing port and
cause inaccurate tire pressure readings. Ifthis
condition is verified, remove the sealer from the
tire and replace the sensor. Refer to Tire Pressure
Indicator Sensor Replacement on page 16-50.
. The sensor activation procedure may have to be
repeated up to 3 times before determining a
sensor is malfunctioning. Inthe event a particular
sensor's information is displayed on the special
tool upon activation but the horn does not chirp, it
may be necessary to rotate the wheel valve stem
to a different position due to the RF signal is being
blocked by another component.
- Occasionally sensor transmissions are not
received by the BCM due to vehicle level RF
interference from items such as but not limited to
aftermarket ignition systems, DVD players, CB
radios, or metallic type window tinting.
Reference Information
Description and Operation
Tire Pressure Monitor Description and Operation on
page 16-53
Scan Tool Reference
Control Module References on page 6-3 for scan tool
information
CircuitlSystem Verification
Note: Low tire pressure in one or more tires is
indicated by a continuously illuminated tire pressure
monitor indicator icon after the instrument cluster bulb
check is completed. Ifequipped with a driver
information center, a check tire pressure type message
will also be displayed.
When a tire pressure monitor DTO is set, the tire
pressure monitor indicator icon will flash for 1 min after
the instrument cluster bulb check is completed and
then remains illuminated. lf equipped with a driver
information center, a service tire monitor type message
will also be displayed.
1. Adjust all tire pressures to the correct pressure.
Refer to Vehicle Certification, Tire Placard,
Anti—Theft,and Service Parts ID Label on
page 1—13.
2. Drive the vehicle over 40 km/h(25 mph) for greater
than 2 min.
16-50 Tire Pressure Monitoring
3. Verify the low tire pressure indicator is OFF. Repair Instructions
2 If the low tire pressure indicator is ON Perform the Diagnostic Repair Verification on
3.1. Perform the Tire Pressure Indicator Sensor page 6—92after completing the repair.
Learn on page 16-52. - Tire Pressure Indicator Sensor Replacement on
3.2. Record all 4 Tire Pressure Parameters values page 16-50
from the scan tool. - Tire Pressure Indicator Sensor Learn on
3.3. Check and record the tire pressures with a page 16-52
known accurate hand held tire pressure - Control Module References on page 6-3 for
gauge. instrument cluster or BCM replacement,
3.4. Verify that the scan tool Tire Pressure programming, and setup.
parameters do not differ more than
27.6 kPa (4 psi) from the actual tire pressure Repair Instructions
readings.
=>lfthe scan tool Tire Pressure parameters differ
more than 27.6 kPa (4 psi), replace the Tire Pressure Indicator Sensor
appropriate B2 Tire Pressure Sensor then Replacement
perform the Tire Pressure Indicator Sensor
Learn on page 16-52. Removal Procedure
U lfthe scan tool Tire Pressure parameters do not 1. Raise the vehicle on a suitable support. Refer to
differ more than 27.6 kPa (4 psi) Lifting and Jacking the Vehicle on page 1-31.
3.5. Verify the BCM Tire Type and Pressure 2. Remove the tire/wheel assembly from the vehicle.
selections are setup correctly with a scan tool. Refer to Tire and Wheel Removal and Installation
Refer to the Vehicle Certification, Tire P/acard, on page 16-60.
Anti—Theft,and Service Parts ID Label on 3. Dismount the tire from the rim. Refer to Tire
page 1-13. Dismounting and Mounting on page 16—63.
:> lfthe BCM Tire Type and Pressure selections
are incorrect, input the proper placard values
for the vehicle with the scan tool then drive the
vehicle over 40 km/h(25 mph) for greater
than 2 min.
U Ifthe BCM Tire Type and Pressure selections
are correct
3.6. lgnition ON.
3.7. Verify the low tire pressure monitor indicator
icon turns ON and OFF when commanding All
Indicators ON and OFF with a scan tool.
=>Ifthe low tire pressure monitor icon does not
turn ON and OFF, replace the P16 Instrument
Cluster.
U Ifthe low tire pressure monitor icon turns ON
and OFF
3.8. All OK
U If the tire pressure indicator is OFF
4. All OK
1748887
Note: When servicing the tire pressure sensor always
use a new Schrader®tire pressure monitoring (TPM)
sensor and a new TORX screw during installation.
4. Remove the TORX screw (1) from the tire pressure
sensor (2) and pull it straight off the tire pressure
valve stem (3).
Caution: 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.
5. Remove the tire pressure valve stem by pulling it
through the rim.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Tire Pressure Monitoring 16-51
Installation Procedure

W“
h
.\_.~
,W
._.,~M
M ‘.

1748899
Caution: Refer to Fastener Caution on page 0—8.
Note:
- Ensure the flat of the valve, lines up with the
flats of the snap in the enclosure.
- TPM valves and TORX screws are single use
items.
1. Assemble the tire pressure sensor (2) to the valve
stem and install the new TORX screw (3),tighten
to 1.3 MW (11.5 lb in).
Note: Use an approved tire mounting lubricant. DO
NOT use silicon or corrosive base compounds to
lubricate the tire bead and the wheel rim. A corrosive
type compound can cause tire or rim deterioration.
2. Apply tire soap to the rubber portion of the valve
stem (1).
1749045
3. Using a tire valve stem mounting tool, pull the
valve stem through in a direction parallel to the
valve hole on the rim.
Note: Snap Fit TPM sensors are shipped in the OFF
mode. The sensor will exit its OFF state when the tire is
inflated. -
4. Mount the tire to the rim. Refer to Tire Dismounting
and Mounting on page 16-63.
5. Install the tire/wheel assembly on the vehicle.
Refer to Tire and Wheel Removal and Installation
on page 16-60.
6. Lower the vehicle.
7. Learn the tire pressure sensors. Referto Tire
Pressure Indicator Sensor Learn on page 16—52.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
'16-52 Tire Pressure Monitoring

Tire Pressure Indicator Sensor Learn Tire Pressure Monitor Learn Procedure
Note: in the event when a particular sensor is
Special Tools
activated and the horn does not chirp, it may be
~ EL-46079 Tire Pressure Monitor Diagnostic Tool necessary to rotate the wheel valve stem to a different
- EL—50448Tire Pressure Monitor Sensor position due to the sensor signal is being blocked by
Activation Tool another component.
For equivalent regional tools, refer to Special Tools on 1. Apply park brake (manual transmission only).
page 16-54. 2. lgnition ON, using a scan tool or driver information
Learn Mode Description center buttons (refer to owners manual), initiate the
Tire Pressure Sensors Learn mode. A double horn
The tire pressure monitor system uses the instrument chirp will sound indicating the Learn mode has
cluster, body control module (BCM), 4 radio frequency been enabled. The left front turn signal will also be
transmitting pressure sensors, and the serial data illuminated.
circuit to perform the tire pressure monitor learn mode
functions. The sensor learn procedure must be 3. Starting with the left front tire, active the sensor by
performed after every tire rotation, BCM replacement, holding the antenna of the tire pressure monitor
or sensor replacement. Once the Learn mode has been special tool aimed upward against the tire sidewall
enabled, each of the sensors unique identification close to the wheel rim at the valve stem location.
codes can be learned into the BCM memory.When a Press and release the activate button. Ensure that
sensor ID has been learned, the BCM sounds a horn the transmit indicator on the special tool indicates
chirp indicating the sensor has transmitted its lD and that the sensor activation signal is being
the BCM has received and learned it. The BCM must transmitted. Wait for a horn chirp. if the horn does
learn the sensor le in the proper sequence to not chirp, repeat the sensor activation sequence
determine correct sensor location. The first learned ID with the tool. Once the horn chirp has sounded, the
is assigned to the left front location, the second to right sensor information is learned and the turn signal in
front, the third to right rear and the fourth to left rear. the next location to be learned will illuminate.
The turn signals will individually illuminate indicating 4. After the horn chirp has sounded and the right front
which location is to be learned in the proper sequence. turn signal is illuminated, repeat step 3 for the
remaining 3 sensors in the following order:
Sensor Functions Using EL-46079, EL-50448,
4.1. Rightfront
or Equivalent
4.2. Right rear
Each sensor has an internal low frequency coil. When
the tire pressure monitor special tool is used in activate 4.3. Left rear
mode, it produces a low frequency transmission that 5. When the left rear sensor has been learned and a
activates the sensor. The sensor responds to a low double horn chirp has sounded, the learn process
frequency activation by transmitting in Learn is complete and the BCM exits the Learn mode.
Mode—RemotelyTriggered. When the BCM receives a
learn mode transmission while in Learn mode, it will
assign that sensors 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. Ifthe relearn mode is
cancelled before the first sensor is learned, the original
sensor IDs will be maintained. Ifthe relearn mode is
canceled after the first sensor is learned, the following
will occur:
o All stored sensor IDs will be invalidated in the
BCM memory.
. Ifequipped, the driver information center will
display dashes instead of tire pressures.
- DTC 00775 will be set.
These conditions will now require the Learn procedure
to be repeated for the system to function properly.

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
 Tire Pressure Monitoring 'l6-53

Description and Operation

Tire Pressure Monitor Description and Operation

P9
B2 B2
P16
1

K9

N ‘ t1

B2 K77 B2

2736220
The system uses the body control module (BCM),
Solid Line —HardWire ”0 driver information center, instrument cluster, a radio
Dash Line —Serial Data frequency (RF) transmitting pressure sensor in each
82 Tire PressureSensor wheel/tire assembly, and the serial data circuit to
perform the system functions. Each sensor has an
K9 BodyControlModule(BCM) internal power supply with an approximate 10 year
K77 RemoteControlDoorLock Receiver service life.
P9 DriverInformationCenterDisplay When the vehicle is stationary, the sensor's internal
accelerometer is inactive, which puts the sensors into a
P16 Instrument Cluster Stationary state. In this state the sensors sample tire
T10 KeylessEntryAntenna pressure once every 30 seconds and do not transmit at
all if the tire pressure does not change. As vehicle
Special Tools speed increases, centrifugal force activates the
- EL-46079/J-46079 Tire Pressure Monitor sensors internal accelerometer causing the sensors to
Diagnostic Tool go into Wake and then Drive mode. In Drive mode, the
sensors sample tire pressure once every 30 seconds
- EL-50448 Tire Pressure Monitor Sensor and transmit in Drive mode once every 60 seconds.
Activation Tool The BCM receives and translates the data contained in
For equivalent regional tools, refer to Special Tools on each sensors RF transmission into sensor presence,
page 16—54. sensor mode, and tire pressure. The BCM sends the
The tire pressure monitor system warns the driver when tire pressure and tire location data to the driver
a significant loss, or gain of tire pressure occurs in any information center via the serial data circuit where they
of the 4 tires and allows the driver to display the are displayed.
individual tire pressures and their locations on the
driver informationcenter.

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'16—54 Tire Pressure Monitoring
The sensors continuously compare their last pressure Any malfunction detected will cause the driver
sample to their current pressure sample and will information center to display a service tire monitor
transmit in Learn Mode—PressureTriggered if a system type message. For more informationon other
8.3 kPa (1.2 psi) change in tire pressure has been functions of the BCM, refer to Keyless Entry System
detected in either a Stationary or Drive state. When the Description and Operation on page 13-44.
tire pressure monitor system detects a significant loss,
or gain oftire pressure, the tire pressure monitor Special Tools and Equipment
indicator icon is illuminated on the instrument cluster
and if equipped, a check tire pressure type message is
displayed on the driver information center. Both the Illustration Tool Number/Description
indicator icon and driver information center message
can be cleared by adjusting the tire pressures to the
recommended pressures and driving the vehicle above
40 km/h(25 mph) for at least 2 minutes.
Ifpower is disconnected from the BCM or if the vehicle EL 46079
battery is disconnected, each tire pressure monitor TirePressureMonitor
sensor ID is retained but all of the tire pressure DiagnosticTool
information is lost. Under these circumstances the BCM
cannot assume that the tire pressures were maintained
over an unknown period of time. Ifequipped, the driver
information center will display all dashes and the scan
tool will indicate a default tire pressure value of
1020 kPa (148 psi) for each tire. Driving the vehicle
above 40 km/h(25 mph)for at least 2 minutes will
activate the sensors causing the driver information
center to display the current tire pressures. The
EL-46079/J—46079tire pressure monitor diagnostic EL 50448
tool, EL-50448 tire pressure monitor sensor activation TirePressureMonitor
tool, or equivalent may also be used to activate the SensorActivationTool
sensors as well.
The BCM has the ability to detect malfunctions within
the tire pressure monitorsystem. In the event a DTO is
set, the tire pressure monitor indicator icon on the 2563769
instrument cluster will flash for 1 minute and then
remain illuminated after the ignition is turned ON and
the instrument cluster bulb check has been completed.

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 Tires and Wheels 16-55

Tires and Wheels

Specifications

Tire and Wheel Specifications

Inflation Pressure At Full Load

Front Rear
Tires Wheel kPa psi kPa psi
15x6.0J(steel
RPO Code RRL)
1955235315130 15x6_0J 207 30 207 30
(AluminumRPO
Code RRL)
16x6.0J(RPO
20%23213188'30 Code RRV 207 30 207 30
Aluminum)

Fastener Tightening Specifications

Specification
Application Metric English
WheelNuts 140Nm 103lbft

Adhesives, Fluids, Lubricants, and Sealers

Application Type of Material GM Part Number Canadian Part Number
AluminumWheel Adhesive/Sealant 12378478 88900041
Wheel MountingLubricant 12345884 88863415
Wheelto Hub Lubricant 1051344 993037

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'16-56 Tires and Wheels

Diagnostic Information and Procedures

Tire Diagnosis - Irregular or Premature Wear

Tire Wear

”._2
,2,_
mm
...“.
.‘M.
_,_

386773
Legend
(1) Under—lnflation,Hard Cornering, Lack of (4) Over—lnflation,Heavy Acceleration, Lack of
Regular Rotation Regular Rotation
(2) lncorrectWheel Alignment, Hard Cornering, (5) Normal Wear to the Wear Indicator
Lack of Regular Rotation
(3) incorrect Wheel Alignment

Inspection Procedure; Tire Diagnosis - Waddle Complaint

,—
~m
1. Inspect the front tire wear.
2. Inspect the rear tire wear.
3. Rotate the tires if any of the following conditions
exist:
The amount oftime or mileage since the last tire
rotation matches the maintenance schedule.
The outer tread blocks are worn more than the
middle tread blocks (1).
The outer tread blocks are worn more than the
inner tread blocks (2).
The middle tread blocks are worn more than the /é \
outer tread blocks (4).
Measure the wheel alignment if any of the following \
conditions exist: E‘: 7’
The tread blocks have feathered edges (3).
The outer tread blocks are worn more than the
inner tread blocks (2).
The inner tread blocks are worn more than the
outer tread blocks (2).
Inspect the struts or the shock absorbers ifthe tire 175760
tread exhibits a cupped appearance (3).

(US/Canada)
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2013 (5377994)
Manual
Service
 Tires and Wheels '16-57
Tire waddle is a side to side movement at the front of
the vehicle andlor the rear of the vehicle. Tire waddle
can be caused by the following conditions:
- A steel belt not being straight within the tire
- Excessive lateral runout of the tire
- Excessive lateral runout of the wheel
The tire waddle is most noticeable at a low speed of
about 8—48km/h (5—30mph).Tire waddle may appear
as ride roughness at 80—113km/h (50—70mph). Tire
waddle may appear as a vibration at 80—113km/h (50-
70 mph).
Inspection Procedure
1. Raise and support the vehicle with safety stands.
Refer to Lifting and Jacking the Vehicle on
page 1-31.
Warning: Wear gloves when inspecting the tires in
order to prevent personal injury from steel belts
sticking through the tire.
2. Perform the following preliminary inspection: 979
2.1. Mark the tire with a crayon in order to note the
1. Use a straight edge 203—229mm (8—91n)long.
start and the stop position.
Place the straight edge on the wheel inboard
2.2. Rotate each tire and wheel by hand. mounting surface. Try to rock the straightedge up
2.3. Inspect the tire for bulges or bent wheels. and down within the mounting surface.
Replace as necessary.
3. Use tire substitution in order to identify the faulty
tire. Perform the following steps for a tire
substitution check:
3.1. Use a comparable tire in order to replace each
tire, one at a time.
3.2. Test drive the vehicle.
3.3. if the problem is tire or wheel related, you will
eliminate the problem when you remove the
faulty tire from the vehicle.

Wheel Mounting Surface Check

Replace any wheels that are bent or dented, or have
excessive lateral or radial runout.Wheels with runout
greater than specified may cause objectionable
vibrations.

980
2. Repeat this procedure on at least 3—4different
positions on the inboard mounting surface.
- The outer ring of the mounting surface normally
is raised above everything inside the mounting
surface.
' The mounting surface will be raised above the
outer ring if the wheel mounting surface has
been bent on a tire changer.
- Ifyou can rock the straight edge, the mounting
surface is bent and you must replace the wheel.

2013
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’16-58 Tires and Wheels
- A wheel of the incorrect size or type may affect
the following conditions:
—Wheel and hub-bearing life
—Brake cooling
—Speedometer/odometer calibration
—Vehicle ground clearance
gfi: —Tire clearance to the body and the chassis
4. Replace the wheel if the wheel is bent.
5. Replace the wheel if the wheel/nut boss area is
cracked.
Identifysteel wheels with a 2 or S-Iettercode stamped
into the rim near the valve stem. Aluminum wheels
have the code, the part number, and the manufacturer
identification cast into the back side of the wheel.

Radial Tire Lead/Pull Correction

Lead/pull is the deviation of the vehicle from a straight
path on a level road with no pressure on the steering
wheel. Lead is usually caused by:
981
' Incorrect alignment
3. Inspect the mounting wheel/nut holes for damage ~ Uneven brake adjustment
caused from over—torquingthe wheel/nuts. Inspect
for collapsed wheel/nut bosses. inspect for - Tire construction
cracked wheel bosses. The way in which a tire is built can produce lead/pull in
the vehicle. Off—centerbelts on radial tires can cause
Caution: The use of non—GMoriginal equipment
the tire to develop a side force while the vehicle rolls
wheels may cause:
straight down the road. Ifone side of the tire has even a
- Damage to the wheel bearing, the wheel fasteners little larger diameter than the diameter of the other side,
and the wheel the tire will tend to roll to one side. Unequal diameters
- Tire damage caused by the modified clearance to will cause the tire to develop a side force which can
the adjacent vehicle components produce vehicle lead/pull.
- Adverse vehicle steering stability caused by the The radial lead/pull diagnosis chart should be used to
modified scrub radius determine whether the problem originates from an
- Damage to the vehicle caused by the modified alignment problem or from the tires. Part of the lead
ground clearance diagnosis procedure calls for tire rotation that is
different from the proper tire rotation pattern. Ita
- Speedometer and odometer inaccuracy medium-mileage to high—mileagetire is moved to the ~me
*—
KM“
m_f
_
-«-«
“h
-2
..M
,M,‘
‘n__
m,..
.
Note: other side of the vehicle, be sure to check for ride
- Replacement wheels must be equivalent to the roughness. Rear tires will not cause lead/pull.
original equipment wheels in the
following ways:
—The load capacity
—The wheel diameter
—The rim width
—The wheel offset
—The mounting configuration

Radial Tire Lead/Pull Correction

Step Action Yes No
1. Performwheelalignmentpreliminaryinspection.
2. Checkthebrakesfordragging.
3. Roadtestthevehicle.
Does thevehiclelead/pull? Go to Step2 SystemOK
1. Cross switchthefronttireandwheelassemblies.
2 2. Roadtestthevehicle.
Does thevehiclelead/pull? Go to Step3 SystemOK
Check thefrontwheelalignment.
is thealignmentwithinspecifications? Go to Step4 Adjustalignment

—
2013 (US/Canada)
Sonlc (5377994)
Manual
Service
 Tires and Wheels '16-59

Radial Tire Lead/Pull Correction (cont'd)

Step Action Yes No
Comparethefrontcamberandfrontcastertospecifications.
Are theywithinspecifications? Go to Step7 Go to Step5
Checkthevehicleframe.
is theframebent? Go to Step6 Go to Step 1
Straightentheframe.
is therepaircomplete? Go to Step3
1. Theprobablecause is thetires.
2. Switchtheleftfronttireandwheelassemblywiththeleftrear
tireandwheelassembly.
3. Roadtestthevehicle.
Doesthevehiclestill lead/pull? Go to Step9 Go to Step8
Switchtheleftfronttireand wheelassemblywiththeleft reartire
andwheelassembly,and replacetheleftfronttire.
Istherepaircomplete? SystemOK Go to Step 1
1. Switchtherightfronttireandwheelassemblywiththeright
reartireandwheelassembly.
2. Roadtestthevehicle.
Doesthevehiclestill lead/pull? Go to Step 1 Go to Step10
Switchtherightfronttireandwheelassemblywiththerightreartire
10 andwheelassembly,and replacetherightfronttire.
is therepaircomplete? SystemOK Go to Step 1

13. install the tire to the wheel. Refer to Tire

Repair Instructions Dismounting and Mounting on page 16-63.
14. Inflatethe tire to the manufacturer specified
pressure as stated on the tire.
Aluminum Wheel Porosity Repair 15. Submerge the tire/wheel into a water bath in order
1. Raise and support the vehicle. Refer to Lifting and ensure the leak is sealed.
Jacking the Vehicle on page 1-31. 16. Balance the tire and wheel. Refer to Tire and
2. Remove the tire and wheel. Refer to Tire and Wheel Assembly Balancing - Off Vehicle on
Wheel Removal and Installation on page 16-60. page 1-72.
3. inflate the tire to the manufacturer specified 17. Installthe tire and wheel. Refer to Tire and Wheel
pressure as stated on the tire. Removal and Installation on page 1660.
4. Submerge the tire/wheel into a water bath in order 18. Lower the vehicle.
to locate the leak.
5. Inscribe a mark on the wheel in order to indicate Aluminum Wheel Refinishing
the leak areas.
6. Inscribe a mark on the tire at the valve stem in Finish Damage Evaluation Procedure
order to indicate the orientation of the tire to the Note:
wheel.
- lf the wheels are chrome—plated,do not re-plate
7. Remove the tire from the wheel. Refer to Tire 0r refinish the wheels.
Dismounting and Mounting on page 16-63.
- Ifthe wheels are polished aluminum, do not
Important: Do not damage the exterior surface of the refinish the wheels in the dealer environment.
wheel. Utilize a refinisher that meets manufacturer
8. Use number 80 grit sandpaper to scuff the inside of guidelines.
the rim surface at the leak area. . inspect the wheels for damage from uncoated
9. Use general purpose cleaner such as 3M®,P/ wheel balance weights or from automatic car wash
N 08984 or equivalent, to clean the leak area. facilities.
10_ Apply 3 mm (0.12 in) thick layer Ofadhesive/ 2. Inspect the wheels for the following conditions:
sealant, GM P/N 1052366 or equivalent, to the - Corrosion
leak area. . Scrapes
11. Allow for the adhesive/sealant to dry. . Gouges
12. Align the inscribed mark on the tire with the valve 3_ Verify the damage is not deeper than what sanding
stem on the wheel. can remove.

..2
.WM.
..M_
_...
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16-60 Tires and Wheels
4. inspect the wheels for cracks. Ifa wheel has Tire and Wheel Removal and
cracks, discard the wheel.
Installation
5. inspect the wheels for bent rim flanges. Ifa rim
flange is bent, discard the wheel. Special Tools
Refinishing Procedure ‘ CH-41013 Rotor Resurfacing Kit
Warning: To avoid serious personal injury when - CH-42450—AWheel Hub Resurfacing Kit
applying any two part component paint system, For equivalent regional tools, refer to Special Tools on
follow the specific precautions provided by the page 16-68.
paint manufacturer: Failure to follow these
precautions may cause lung irritation and allergic Removal Procedure
respiratory reaction. 1. Raise and support the vehicle. Refer to Lifting and
1. Remove the tire and wheel assembly from the Jacking the Vehicle on page 1-31.
vehicle. Refer to Tire and Wheel Removal and 2. Remove the wheel center cap, if equipped.
Installation on page 16-60.
2. Remove the balance weights from the wheel.
3. Remove the tire from the wheel. Refer to Tire
Dismounting and Mounting on page 16-63.
4. Use a suitable cleaner in order to remove the
following contaminants from the wheel:
- Lubricants
- Wax
- Dirt

- Do not re-machine the wheel.

- Do not use chemicals in order to strip the paint
from the wheel.
5. Use plastic media blasting in order to remove the
paint from the wheel.
6. Ifthe wheel had a machined aluminum finish, spin
the wheel and use sand paper in order to restore
the circular machined appearance.
Note: The wheel mounting surface and the wheel nut
contact surface must remain free of paint. 2890552
7. Mask the wheel mounting surface and the wheel 3. Remove the wheel nut caps (1), if equipped.
nut contact surface.
8. Follow the paint manufacturer's instructions for
painting the wheel.
9. Unmaskthe wheel.
10. Install a new valve stem.
Note: Use new coated balance weights in order to
balance the wheel.
11. install the tire to the wheel. Refer to Tire
Dismounting and Mounting on page 16-63.
12. Use a suitable cleaner in order to remove the
following contaminants from the wheel mounting
surface:
- Corrosion
- Overspray
- Dirt
13. Install the tire and wheel assembly to the vehicle.
Refer to Tire and Wheel Removal and Installation
on page 16—60.

2890553
4. Remove the wheel nuts (1).

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 Tires and Wheels 162-61
Installation Procedure
Warning: Before installing the wheels, remove any
buildup of corrosion on the wheel mounting surface
and brake drum or disc mounting surface. Installing
wheels with poor metaI-to-metal contact at the
mounting surfaces can cause wheel nuts to loosen.
This can cause a wheel to come off when the
vehicle is moving, causing loss of control and
possibly personal injury.
Note: Do not use power grinding tools to clean the
brake rotor or drum to wheel mating surfaces.
1. Using a wire brush or wire wheel, clean the wheel
to brake rotor or drum mating surface.
2. Using the CH-41013 Rotor Resurfacing Kit, clean
the rotor or drum to wheel contact area.
3. Using the CH—42450-AWheel Hub Resurfacing
Kit, clean the surfaces around the wheel studs.
4. Clean the threads of the wheel studs.
2890554 5. lfthe threads of the wheel stud are damaged,
replace the wheel stud. Refer to Wheel Stud
5. Remove the tire and wheel assembly (1). Replacement on page 16-15 or Wheel Stud
Warning: If penetrating oil gets on the vertical Replacement on page 16—33.
surfaces between the wheel and the rotor or drum it 6. After cleaning all of the wheel and brake rotor or
could cause the wheel to work loose as the vehicle drum contact areas, use brake cleaner or
is driven, resulting in loss of control and an injury denatured alcohol to remove any dirt and debris
accident. from the wheel nuts and the brake rotor or drum.
Caution: Removing the wheel may be difficult because 7. Inspect and clean the contact areas of the wheel.
of foreign materials or a tight fit between the wheel and Refer to Wheel Mounting Surface Check on
the hub/rotor.Slightly tap the tire side wall with a rubber page 16-57.
mallet in order to remove the wheel. Failure to follow
these instructions may result in damage to the wheel.
Caution: Never use heat to loosen a tight wheel bolt or
nut. This can shorten the life of wheel and damage
wheel bearings.
6. Ifthe tire and wheel assembly is difficult to remove
or cannot be removed, perform the following steps:
' Hand install the wheel nuts.
- Loosen the wheel nuts 2 complete turns.
- Lower the vehicle.
- Rock the vehicle from side to side.
- Repeat the procedure if necessary.
7. When the tire and wheel assembly loosens, raise
and support the vehicle. Refer to Lifting and
Jacking the Vehicle on page 1-31.
8. Remove the wheel nuts.
9. Remove the tire and wheel assembly.

2372540
8. Apply a small amount of lubricant to the inner
diameter of the wheel hub pilot hole (1)where it
contacts the wheel hub flange. Refer to Adhesives,
Fluids, Lubricants, and Sealers on page 16-55.

2013
-Sonic
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'16-62 Tires and Wheels

_L

,M.»
NVU

2890554 2027828
9. Install the tire and wheel assembly (1). Caution: Improperlytightened wheel bolts or nuts can
lead to brake pulsation and rotor damage. Inorder to
avoid expensive brake repairs, evenly tighten the wheel
bolts or nuts to the proper torque specification.
Caution: Refer to Fastener Caution on page 0-8.
11. Using a torque wrench and the appropriate socket,
alternately and evenly tighten the wheel nuts
to 140 Nm (103 lb ft) in the sequence illustrated.

2890553
Warning: Never grease or lubricate wheel nuts,
studs and mounting surfaces. Wheel nuts, studs,
and mounting surfaces must be clean and dry.
Tightening the lubricated parts can cause damage
to the wheel studs. This can cause a wheel to come
off when the vehicle is moving, causing loss of
control and possibly personal injury. 2890552
10. Hand install the wheel nuts (1). 12. Install the wheel nut caps (1), if equipped.
13. Install the wheel center cap, it equipped.

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2013 (5377994)
Manual
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 Tires and Wheels 16—63
Tire Dismounting and Mounting Radial tires tend to wear faster in the shoulder area,
particularly in front positions, due to design. Radial tires
Caution: Use a tire changing machine in order to in non-drive locations may develop an irregular wear
dismount tires. Do not use hand tools or tire irons alone pattern that can generate tire noise. This especially
in order to remove the tire from the Wheel. Damage to makes regular tire rotation necessary.
the tire beads or the wheel rim could result.
~ Remove the tires and wheels. Refer to Tire and
Caution: Do not scratch or damage the clear coating Wheel Removal and Installation on page 16-60.
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.
Caution: Damage to either the tire bead or the wheel
mounting holes can result from the use of improper
wheel attachment or tire mounting procedures. Ittakes
up to 70 seconds for all of the air to completely exhaust
from a large tire. Failure to follow the proper procedures
could cause the tire changer to put enough force on the
tire to bend the wheel at the mounting surface. Such
damage may result in vibration andlor shimmy, and
under severe usage lead to wheel cracking.
1. Deflate the tire completely.
Note: Rim— —clamp,sometimes called--European—type
tire changers are recommended.
2. Use the tire changer Inorder to remove the tire
from the wheel. @
i
3. Use a wire brush or coarse steel wool in order to
remove any rubber, light rust or corrosion from the
wheel bead seats.
Caution: When mounting the tires, use an approved 1014
tire mounting lubricant. DO NOT use silicon or - For vehicles with single rearwheels (4 tires),
corrosive base compounds to lubricate the tire bead rotate the tires as shown. '
and the wheel rim. A silicon base compound can cause
the tire to slip on the rim. A corrosive type compound
can cause tire or rim deterioration.
4. Apply GM P/N 12345884 (Canadian P/N 5728223)
or equivalent to the tire bead and the wheel rim.
5. Use the tire changer in order to install the tire to the
wheel.
Warning: 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 (40psi) pressure when inflating any
tire if beads are not seated. If 275 kPa (40psi)
pressure will not seat the beads, deflate, relubricate
the beads and reinflate. Overinflation may cause
the bead to break and cause serious personal
injury.
6. Inflatethe tire to the proper air pressure.
7. Ensure that the locating rings are visible on both
sides of the tire in order to verify that the tire bead t4
is fully seated on the wheel.

Tire Rotation 156806

Inorder to equalize wear, rotate the tires at the - For vehicles with single rearwheels (5 tires),
specified intervals. Also, rotate the tire and wheel rotate the tires as shown.
assembly whenever you notice uneven tire wear.

2013
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'16-64 Tires and Wheels

Description and Operation Metric Wheel Nuts and Bolts

Description
Description Metric wheel/nuts and bolts are identified in the
All Seasons Tires
following way:
. The wheeI/nuthas the word Metric stamped on
the face.
- The letter M is stamped on the end of the
wheel bolt.
The thread sizes of metric wheeI/nutsand the bolts are
indicated by the following example: M12 x 1.5.
111440007
' M = Metric
gipflacsaJGM9£BGtagg - 12 = Diameter in millimeters
9275/45R17 0 1.5 = Millimeters gap per thread

P-Metric Sized Tires Description

wag
..v‘2
.,..—

E 245 / 50R
__ -_ 16 958'I
l
TIRE TYPE LOAD INDEt
$183888 [:9
70080 LT—LIGHTTRUCK SPEED SYMBO
Most GM vehicles are equipped with steel belted
all-season radial tires as standard equipment. These SECTION
tires qualify as snow tires, with a higher than average -- WIDTH RIM
(MILLIMETERS) DIAMETER
rating for snow traction than the non-all season radial 235 (INCHES)
tires previously used. Other performance areas, such 245 15
as wet traction, rolling resistance, tread life, and air 275 17’
retention, are also improved. This is done by
improvements in both tread design and tread
compounds. These tires are identified by an M +S A8851? CONSTRUCTION
molded in the tire side wall after the tire size. The suffix (SECTIONHEIGHT) WREAPLE
MS is also molded in the tire side wall after the TPC (SECT'0g15W'DTH) B—BlAS—BELTED
specification number. 50 D—DIAGONAL(BIAS)
The optional handling tires used on some vehicles now 4o
also have the MS marking after the tire size and the
TPC specification number.

General Description SECTION

WIDTH SECTION
The factory installed tires are designed to operate HEIGHT
satisfactorily with loads up to and including the full
rated load capacity when these tires are inflated to the _t_
recommended pressures.
The following factors have an important influence on
tire life: 70078
- Correct tire pressures Replacement tires should be of the same tire
- Correct wheel alignment performance criteria (TPC) specification number.This
- Proper driving techniques will ensure the same size, the same load range, and the
same construction as those originally installed on the
- Tire rotation vehicle.
The following factors increase tire wear:
- Heavy cornering
- Excessively rapid acceleration
- Heavy braking

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2013 (5377994)
Manual
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 Tires and Wheels 16-65
Replacement Wheels Description Tire Inflation Description
Replace the wheel if any ofthe following conditions When you inflate the tires to the recommended inflation
exist: pressures, the factory-installed wheels and tires are
' The wheel exhibits excessive runout. designed in order to handle loads to the tire's rated load
- The wheel is bent. capacity. Incorrecttire pressures, or under-inflated
tires, can cause the following conditions:
o The wheel is cracked.
' Vehicle handling concerns
- The wheel is severely rusted.
- Poor fuel economy
- The wheel is severely corroded.
~ Shortened tire life
Note: Air leaks caused by porosity on aluminum
- Tire overloading
wheels are repairable.
Inspect the tire pressure when the following conditions
- The wheel leaks air. apply:
Warning: If you are replacing the wheel(s), the - The vehicle has been sitting at least 3 hours.
wheel stud(s), the wheel nut(s) or the wheel bolt(s), . The vehicle has not been driven for more than
install only new GM original equipment parts. 1.6 km (1 mi).
Installation of used parts or non-GM original
equipment parts may cause the wheel to loosen, - The tires are cool.
loss of tire air pressure, poor vehicle handling and Inspect the tires monthly or before any extended trip.
loss of vehicle control resulting in personal injury. Adjust the tire pressure to the specifications on the tire
label. Install the valve caps or the extensions on the
Caution: The use of non-GM original equipment valves. The caps or the extensions keep out dust and
wheels may cause: water.
- Damage to the wheel bearing, the wheel fasteners The kilopascal (kPa) is the metric term for pressure.
and the wheel The tire pressure may be printed in both kilopascal
- Tire damage caused by the modified clearance to (kPa) and psi. One psi equals 6.9 kPa.
the adjacent vehicle components
- Adverse vehicle steering stability caused by the Inflation Pressure Conversion
modified scrub radius (Kilopascals to PSI)
. Damage to the vehicle caused by the modified kPa pSl kPa psi
ground clearance
140 20 215 31
- Speedometer and odometer inaccuracy
Replace the wheel, the wheel studs and the wheel/ 145 21 220 32
nuts, or the wheel bolts if applicable, Ifany of the 155 22 230 33
following conditions exist: 160 23 235 34
' The wheel has elongated bolt holes.
165 24 240 35
- The wheellnuts, or bolts if applicable, loosen
repeatedly. 170 25 250 36
Steel wheel identification is stamped into the wheel 180 26 275 40
near the valve stem. 185 27 310 45
Aluminum wheel identification is cast into the inboard 190 28 345 50
side of the wheel.
200 29 380 55
Steel Wheel Repair Description 205 30 415 60
Caution: Do not heat wheels in an attempt to soften Conversion:6.9kPa =1psi
them for straightening or repair damage from striking
curbs, etc. Do not weld wheels. The alloy used in these Tires with a higher than recommended pressure can
wheels is heat-treated and uncontrolled heating from cause the following conditions:
welding affects the properties of the material. - A hard ride
Caution: The use of tubes in tubeless tires is not a ° Tire bruising
recommended repair due to the fact that speed ratings
are greatly reduced. - Rapid tread wear at the center of the tire
You can repair porosity in aluminum wheels. If leaks are Tires with a lower than recommended pressure can
found in a steel wheel, replace the wheel with a wheel cause the following conditions:
of original equipment quality. 0 Atire squeal on turns
- Hard steering
- Rapid wear and uneven wear on the edge of the
tread
- Tire rim bruises and tire rim rupture
- Tire cord breakage
- High tire temperatures

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16-66 Tires and Wheels
- Reduced vehicle handling
- High fuel consumption
- Soft riding
Unequal pressure on the same axle can cause the
following conditions:
- Uneven braking
. Steering lead
- Reduced vehicle handling
Refer to the Tire Placard for specific tire and wheel
applications and tire pressures.

Tires and Wheels Description and

Operation
There are two types of tire and wheel balancing: static
and dynamic.
Static balance is the equal distribution of weight around
the wheel. Assemblies that are statically unbalanced
cause a bouncing action called wheel tramp. This
condition may eventually cause uneven tire wear. 1290869
Legend
(1) Heavy Spot
(2) Centerline of Spindle
(3) Corrective Weights
(4) Add Balance Weights Here

General Balance Precautions

Remove all deposits of foreign material from the inside
of the wheel.
Warning: Stones should be removed from the tread
to provide accurate wheel balancing and to avoid
operator injury (from stones becoming dislodged
while wheel is in motion) during the procedure.
Inspect the tire for any damage. Balance the tire
according to the equipment manufacturer's
recommendations.
Wheel Weights
If more than 85 grams (3.0ounces) are needed to static
balance the wheel, split the wheel weights as equally
1290868 as possible between the inboard and the outboard
Legend flanges.
(1) Heavy Spot Balancing the assemblies with factory alloy wheels
(2) Centerline of Spindle requires the use of special nylon-coated, clip-on wheel
(3) Corrective Weights weights. These weights are designed to fit over the
thicker rim flange of the alloy wheel. Installthese
(4) Add Balance Weights Here weights with a plastic-tipped hammer.
Dynamic balance is the equal distribution of weight on Adhesive wheel weights are also available. Use the
each side of the centerline so that when the assembly following procedure to install adhesive wheel weights
spins there is no tendency for it to move from side to
side. Assemblies that are dynamically unbalanced may
cause wheel shimmy.

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 Tires and Wheels 16-67
Manufacturers of tire chains have a specific chain size
for each tire size to ensure a proper fit when the chain
is installed. Be sure to purchase the correct chains for
the tires on which they are to be used. Use rubber
adjusters to take up any slack or clearance in loose
Chains.
Use of chains may adversely affect vehicle handling.
When tire chains are installed, follow these
precautions:
- Adjust speed to road conditions
- Avoid sharp turns
. Avoid locked—wheelbraking
To prevent chain damage to the vehicle, install the
chains on the front tires as tightlyas possible. Tighten
them again after driving 0.4—0.8kilometer (0.3-
0.5 mile). The use of chains on the rear tires is not
recommended because they may contact the vehicle
and possibly damage it. Ifchains must be used on the
rear tires, be sure there is sufficient clearance between
the chains and the body. Do not exceed 70 km/h
1290867 (45 mph) or the chain manufacturer's speed limit,
if lower. Avoid large bumps, potholes, severe turns and
(1) Centerline any other maneuvers which could cause the tires to
(2) Inside Flange bounce. Follow any other instructions of the chain
(3) manufacturer which do not disagree with the above
Clip-on Weight
instructions.
(4) Dynamic Balance Adhesive Weight
(5) Static Balance Adhesive Weight Tread Wear indicators Description
(6) Mounting Face

Adhesive Wheel Weight Installation

1. Clean the wheel by sending it to bare alloy where 5840 IN}?
the wheel weight will be installed.
\1
2. Use a clean cloth or paper towel saturated with a
mixtureof half isopropyl alcohol and half water to
wipe the place where the wheel weight will be
installed.
3. Dry the area with hot air. The surface of the wheel
should be warm to the touch.
4. Warm the adhesive backing on the wheel weights
to room temperature. g
g .
5. Remove the tape from the back of the weights. Do
not touch the adhesive surface.
4 jI
7#1475782}
6. Apply the wheel weight and press it on with hand
pressure
7. Secure the wheel weight with a 70—110N (16-25 lb)
force applied with a roller. 491 FJFEI'Ei’

Tire Chain Usage

Due to limited tire—to—body 143383
clearance on certain
vehicles, recommendations for tire chain use are The original equipment tires have tread wear indicators
published in the Owner's Manual. When tire chains that show when you should replace the tires.
need to be used, most current General Motors vehicles The location of these indicators are at 60 degree
require SAE Class "S" tire chains. These may also be intervals around the outer diameter of the tire. The
designated as 1100Series, type PL tire chains. These indicators appear as a 6 mm (0.25 in) wide band when
chains are specifically designed to limit the "fly off" the tire tread depth becomes 1.6 mm (2/32in).
effect which occurs when the wheel rotates.
Be sure that only fine—linkchains are used which do not
add more than 15 mm (0.590 in), including the lock, to
the tread surface and the inner sides of the tires.

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'16-68 Tires and Wheels

Special Tools and Equipment

Illustration Tool Number]Description

Illustration Tool Number/Description

0H 42450—A
CH 41013 J 42450—A
J41013 WheelHubResurfacingKit
0"
RotorResurfacingkit

380097
573333

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 Wheel Alignment ’16-69

Wheel Allgnment

S pecifications

Wheel Alignment Specifications

Alignment Condition: Full tank offuel, no passengers
and placed on flat level surface.

Wheel Alignment Specifications

RPO Wheels Caster Cross Caster Camber Cross Total Steering Thrust
Restriction i 0.8° i 0.8° : 0.8° 0amber Toe Wheel Angle
i0.8° 202° Angle :o.4°
i-2.5°
(Left+ (Left -
Right) Right)/
Left Right (Left- Right) Left Right (Left- Right) 2
FE1 Front 44° 44° 0.0° -O.8° -0.8° 0.0" 01" 0.0” -
Rear — — — -1.0° -1.0° —— 0.4° — 0.0°
FE4 Front 44° 44° 00° —0.7° -0.7° 00° 01° 0.0° —-
Rear — ~— — e1.0° —1.0° — 0.4° — 0.0“
Front 46° 46° 00° -1.0° —1.0° 0.0° 01° 00° -
ECO
Rear — — —— -1.0° -1.0° — 0.4° — 0.0°

Fastener Tightening Specifications

Application
FrontStrutNut
OuterTie End Nut
.W4,\
’ng
__—WW.“
Repair Instructions
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.
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.
- Inspect the runout of the wheels and the tires.
- Inspect the wheel bearings for backlash and
excessive play. Refer to Suspension Strut and
Shock Absorber Testing - On Vehicle on
page 16-41.
Specification
Metric English
110N-m 81|bft
65NW 48 Ibft
- Inspect the ball joints for looseness or wear.
- Inspect the 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.
. Inspect the struts/shock absorbers for wear, leaks,
and any noticeable noises. Refer to Suspension
Strut and Shock Absorber Testing —On Vehicle on
page 16-41.
' 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

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'16-70 Wheel Alignment
the alignment to the service preferred specifications. Wheel Alignment - Steering Wheel
Refer to Wheel Alignment Specifications on
page 16—69. Angle andlor Front Toe Adjustment
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. -
t_,
Note: -
-IILI".‘II‘
a 1.
- Record the "Before" and "After" alignment ...-III I
measurements.
. 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 on page 16—69.

Front Camber Adjustment

2508322
1. Ensure that the steering wheel is set in a straight
ahead position.
2. Loosen the tie rod jam nut (1).
3. Adjust the toe to specification by turning the inner
tie rod (2). Refer to WheelA/ignment Specifications
on page 16—69.
Caution: Refer to Fastener Caution on page 0-8.
4. Tighten the tie rod nut (1)to 60 N-m(44 lb ft).

Description and Operation

Camber Description

2497931
Note: DO NOT grind the front strut bores for the bolts
to allow adjustment of the front camber. There are
service bolts available to allow the front camber to be
adjusted, if needed.
1. Ifthe front camber is out of specifications, perform
the following:
- Remove the front strut to steering knuckle
nuts (1) and the bolts (2).
- Replace the front strut to steering knLIckle
bolts (2)with the service bolts.
- Install the service bolts and adjust the front
camber to specifications. Refer to Wheel
Alignment Specifications on page 16—69.
Caution: Refer to Fastener Caution on page 0-8. 141955
2. Tighten the front strut nuts (1)to 110N°m(81|bft).

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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 excessive wear
on the suspension parts.
Unequal side-to-side camber of1 degree or more will
cause the vehicle to pull or lead to the side with the
most positive camber.
Cross Camber is the difference between the left
camber value and the right camber value.
Cross Camber = L camber —R camber
Caster Description
141954 better the directional stability. Installing aftermarket
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 importantto 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. Ifthe rear of the vehicle is higher than its
designated trim height, the front suspension moves to a
less positive caster.
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Wheel Alignment '16-71
With too little positive caster, steering may be touchy at
high speed and wheel returnability may be diminished
when coming out ofa turn. Ifone 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.
Cross Caster is the difference between the left caster
value and the right caster value.
Cross caster =L caster —R caster
Lead/Pull Description
At a constant highway speed on a typical straight road,
Ieadlpull is the amount of effortrequired at the steering
wheel to maintain the vehicle's straight path.
Important: Vehicles will tend to Ieadlpull 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 (frontcross 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 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.
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
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.
'16—‘72 Wheel Aligfltment

Thrust Angles Description Toe Description

3 1
E2) I

7 05021-421
<2: .

143187
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).
Inthe illustration, toe-in is shown on the left rearwheel, '
moving the thrust line (1) off center. The resulting
deviation from the centerline is the thrust angle.
Ifthe thrust angle is not set properly the vehicle may
“dog track", the steering wheel may not be centered or
it could be perceived as a bent axle. Thrust angle can
be checked during a wheel alignment.
Positive thrust angle means the thrust line is pointing to
the right hand side (RHS) of the vehicle.
Negative thrust angle means the thrust line is pointing
to the left hand side (LHS) of the vehicle.
Ifthe thrust angle is out of specification, moving the
axle to body relationship will change the thrust angle
reading.
lfthe vehicle is out in the Positive (+)direction-moving
the RHS forward andlor LHS rearward will move the
thrust angle towards zero degrees.
Ifthe vehicle is out in the Negative (—)direction-moving
the RHS rearward andlor LHS forward will move the
thrust angle towards zero degrees.
141956
Toe is a measurement of how much the frontandlor
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
fon/vard.Inother 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.
Impropertoe adjustment will cause prematuretire wear
and cause steering instability. .\.22
,.
N
«M_...
Description
Torque Steer

VVI "I _

156932

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A vehicle pulls or leads in one direction during hard
acceleration. A vehicle pulls or leads in the other
direction during deceleration.
The following factors may cause torque steer to be
more apparent on a particular vehicle:
- A slightly smaller diameter tire on the right front
increases a right torque lead. Inspect the front
tires for differences in the brand, the construction,
or the size. Ifthe tires appear to be similar, change
the front tires from side—to—side and retest the
vehicle. Tire and wheel assemblies have the most
significant effect on torque steer correction.
- A large difference in the right and left front tire
pressure
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Wheel Angnment 16—73
- Left-to—right differences in the front view axle angle
may cause significant steering pull in a vehicle.
The pull will be to the side with the most
downward sloping axle from the differential to the
wheels. Axles typically slope downward from the
differential. The slope of the transaxle pan to level
ground may be used as an indication of bias axle
angles. The side with the higher transaxle pan
(shown on the left side of the illustration) has the
most downward sloping axle angle.
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.
16-74 Wheel Alignment

BLANK

_/_
N
,....
<._
“...
.2
“M
...
A

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 Table of Contents '17-1

Section 17

Transmission

Automatic Transmission - 6T30l6T40/6T45/ DTC P0776 or P0777 (Gen 1) ................. 17-97

6T50 (MH8, MH9) ............................ 17—7
Specifications ................................... 17—7
Fastener Tightening Specifications (On
Vehicle) ........................................ 17-7
Fastener Tightening Specifications (Off
Vehicle) ........................................ 17—8
Transmission General Specifications (6T30) 17—9
Transmission General Specifications (6T40/
45/50) ......................................... 17-9
Adhesives, Fluids, Lubricants, and Sealers 17-10
Fluid Capacity Specifications (6T30) .......... 17-10
Fluid Capacity Specifications (6T40/45/50) 17-10
Fluid Pump Selective Specifications .......... 17-10
Range Reference .............................. 17-10
Shift Solenoid Valve State and Gear Ratio .... 17—11
Transmission Fluid Pressure Switch Logic 17-11
Transmission InternalMode Switch Logic . 17-12
Solenoid Valve Pressure (Gen 1) .............. 17-12
Transmission Parts Kit Specifications ......... 17—1 3 DTC P2719—P2721...........................
Schematic and Routing Diagrams ............ 17-29
Automatic Transmission Controls
Schematics .................................. 17—30
Component Locator ............................ 17-33
Disassembled Views .......................... 17-33
Component Location .......................... 17-60
Bushing, Bearing, and Washer Locations
(Gen 1) ....................................... 17—61
Bushing, Bearing, and Washer Locations
(Gen 2) ....................................... 17-62
Seal Locations (Gen 1) ........................ 17—63
Ball Check Valve Locations (Gen 1) ........... 17-65
Ball Check Valve Locations (Gen 2) ........... 17—66
Diagnostic Information and Procedures ...... 17-67
DTC P057B-P057D ........................... 17-67
DTC P0601, P0603, P0604, or P062F ......... 17—70
DTC P0634 . . . .. ............................... 17—72
DTC P0658 or P0659 .......................... 17—74
DTC P0667, P0668, or P0669 ................. 17-76
DTC PO6AC, P06AD, or P06AE ............... 17-78
DTC PO711-P0713 ............................ 17-80
DTC P0716, P0717, P07BF, or P0700 . . .. 17-82
DTC PO71D ................................... 17-85
DTC P0722, P0723, P0770, or PO77D ........ 17—88
DTC P0741 or P0742 .......................... 17—91
DTC P0751 or P0752 .......................... 17-94
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DTC P0776 or P0777 (Gen 2) ................ 17—100
DTC P0796 or P0797 (Gen 1) ................ 17-103
DTC P0796 or P0797 (Gen 2) ................ 17-106
DTC P0815, P0816, or P0826 ............... 17—109
DTC P0842 or P0843 ......................... 17-111
DTC P0850—P0852........................... 17-114
DTC P0872 or P0873 ........................ 17-117
DTC P0877 or P0878 ........................ 17-119
DTC P0961-P0963 ........................... 17-121
DTC P0965-P0967 ........................... 17-123
DTC P0969—P0971........................... 17-125
DTC P0973 or P0974 ........................ 17-127
DTC P0989 or P0990 ........................ 17-129
DTO P1761 .................................. 17-132
DTC P182E orP1915 ........................ 17—134
DTC P1876 .................................. 17-137
DTC P2714 or P2715 (Gen 1) ................ 17-139
DTC P2714 or P2715 (Gen 2) ................ 17-142
17-145
DTC P2723 or P2724 (Gen 1) ................ 17—147
DTC P2723 or P2724 (Gen 2) ................ 17-150
DTC P2728-P2730 ........................... 17-153
DTC P2762, P2763, or P2764 ............... 17—155
Symptoms - Automatic Transmission .... . . . . 17-157
Control Solenoid Valve and Transmission
Control Module Assembly Inspection ....... 17—158
Control Solenoid Valve and Transmission
Control Module Assembly InputShaft
Speed/Output Shaft Speed InputTest . . 17—159
Control Solenoid Valve and Transmission
Control Module Assembly Solenoid
Performance Test ........................... 17—160
Transmission Adaptive Values Learn . . . . 17-163
Brake Pedal Position Sensor Learn .......... 17-164
Manual Mode or Tap Up/Down Diagnosis 17-164
Transmission Fluid Level and Condition
Check ....................................... 17-164
Line Pressure Check ......................... 17-166
Road Test .................................... 17—167
Torque Converter Diagnosis ................. 17-169
Clutch Plate Diagnosis ....................... 17-172
Engine Coolant/Water in Transmission . . 17-172
Fluid Leak Diagnosis (Non Hybrid) ........... 17—172
Case Porosity Repair ......................... 17-174
17-2 Table of Contents
Transmission Fluid Cooler Flushing and
Flow Test ...................................
Bushing and Mating Shaft Inspection . . . . 17-180
Noise and Vibration Analysis .................
Whine/Growl Noise ..........................
Automatic Transmission Fluid Leaks ......... 17—183
Shift Indicator Indicates Wrong Gear
Selection ....................................
No Park ......................................
Harsh Garage Shift ...........................
No Drive in All Ranges .......................
No First and Reverse Gears .................
No First, Second, Third, and Fourth Gear . . .. 17-186
No Second and Sixth Gear ...................
Harsh or Late First, Second, Third, and
Fourth Shift .................................
Harsh First and Reverse Shift ................
No Third, Fifth, and Reverse Gear ...........
Harsh or Late Second and Sixth Shift ........ 17-188
No Fourth, Fifth, and Sixth Gear .............
Harsh or Late Third, Fifth, and Reverse
Shift .........................................
Harsh Fourth, Fifth, and Sixth Shift ........... 17-189
No Torque Converter Clutch Apply ...........
No Torque Converter Clutch Release ........ 17—190
Harsh Torque Converter Clutch Apply, or
lnoperative or No Electronically Controlled
Capacity Clutch Control .....................
No Reverse Gear .............................
Fluid Pressure High or Low ..................
Repair Instructions - On Vehicle .............
Manual Shift Detent Lever with Shaft Position
Switch Assembly Replacement .............
Transmission Control Lever Knob
Replacement ...............................
Transmission Control Replacement .......... 17—193
Automatic Transmission Range Selector
Lever Replacement .........................
Range Selector Lever Cable
Replacement ...............................
Range Selector Lever Cable Adjustment .... 17-196
Range Selector Lever Cable Bracket
Replacement ...............................
Transmission Fluid Drain and Fill ............
Transmission Fluid Cooler Pipe Connector
Replacement - Radiator .....................
Transmission Fluid Cooler Hose/Pipe
QuiCk-Connect Fitting Disconnection and
Connection .................................
Fluid Cooler Inlet Hose Replacement ........ 17—203
Fluid Cooler Outlet Hose Replacement . . .. . . 17—204
Automatic Transmission Fluid Pressure Test
Hole Plug Replacement .....................
Front Wheel Drive Shaft Seal Replacement -
Left Side ....................................
Front Wheel Drive Shaft Seal Replacement -
Right Side ...................................
Manual Shift Shaft and Seal Replacement 17-208
17—175 Control Solenoid Valve and Transmission
Control Module Assembly Replacement .... 17—209
17—180 Control Valve Body Cover Replacement . . .. . 17—210
17-181 Control Valve Body Replacement ............ 17-213
Output Speed Sensor Replacement . . . . . . . . . 17—214
InputSpeed Sensor Replacement ........... 17—215
17-183 Transmission Mount Bracket Replacement
17-183 - Rear ....................................... 17—215
17-184 Transmission Mount Replacement -
17-184 Left Side .................................... 17-216
17-186 Transmission Rear Mount Replacement . . .. . 17-217
Transmission Replacement (With 1.2L or 1.4L
17-187 Engine) ..................................... 17-218
Transmission Replacement (With 1.6L or 1.8L
17—187 Engine) ..................................... 17-221
17—188 Repair Instructions - Off Vehicle ............. 17-225
17-188 Lift Plate and Holding Fixture Installation ... 17—225
Torque Converter Removal .................. 17—226
17—189 Control Valve Body Assembly Removal ...... 17-227
Inputand Output Speed Sensor Removal 17—230
17-189 Torque Converter Housing with Fluid Pump
Assembly Removal (Non Hybrid) ........... 17—231
17-189 Differential Carrier Removal (6T30) .......... 17-232
Differential Carrier Removal (6T40/45/50)... 17—233
Drive and Driven Sprocket, Drive Link, and
Park Pawl Removal (6T30) ................. 17-234
17-190 Drive and Driven Sprocket, Drive Link, and
17—190 Park Pawl Removal (6T40/45/50)........... 17—235
17-191 Internal Components Removal ............... 17—236
17—191 2-6 Clutch Piston Removal ................... 17-237
Manual Shift Detent Lever with Shaft Position
17-191 Switch Assembly and Park Pawl Actuator
Removal .................................... 17-238
17—193 Manual Shift Shaft Seal Removal ............ 17-240
InputShaft Support Replacement (Gen 1) 17—241
InputShaft Support Replacement (Gen 2) 17-242
17—194 3-5-Reverse and 4-5-6 Clutch Fluid Seal Ring
Replacement (Gen 1) ....................... 17—243
17-195 3-5-Reverse and 4-5-6 Clutch Fluid Seal Ring
Replacement (Gen 2) ....................... 17—244
Front Wheel Drive Shaft Seal Replacement -
17-197 Case Side ................................... 17-245
17-198 Transmission Case Cleaning and
Inspection ................................... 17-246
17-199 Manual Shift Detent Lever with Shaft Position
Switch Assembly and Park Pawl Actuator
Installation .................................. 17-248
17—200 Manual Shift Shaft Seal Installation .......... 17—250
2—6Clutch Piston Installation (6T30) ......... 17—251
2-6 Clutch Piston Installation (6T40/
45/50) ....................................... 17-252
17-206 Low and Reverse and 1-2-3-4 Clutch
Housing, Low and Reverse Clutch
17-207 Assembly, Output Sun Gear, and 2—6Clutch
Plate Disassemble (Gen 1) ................. 17-253
17-208

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)

Low and Reverse and 1—2—3—4 Clutch
Housing, Low and Reverse Clutch
Assembly, Output Sun Gear, and 2—6Clutch
Plate Disassemble (Gen 2) ................. 17-254
Input,Reaction, and Output Carrier
Disassemble ................................ 17-255
3-5—Reverseand 4—5—6 Clutch Housing
Disassemble (6T30/40/45/5O- Gen 2) ...... 17—256
3-5-Reverse and 4—5—6 Clutch Housing
Assemble (6T30/40/45/50- Gen 2) ......... 17-261
Input,Reaction, and Output Carrier Assemble
(Gen 1) ...................................... 17-267
Input,Reaction, and Output Carrier Assemble
(Gen 2) ...................................... 17-268
3—5-Reverseand 4-5—6Clutch Housing, and
Input,Reaction, and Output Carrier
Installation .................................. 17—269
Low and Reverse Clutch Assembly and Low
and Reverse Clutch Plate Installation ....... 17—270
Low and Reverse and 1-2-3-4 Clutch Housing
Disassemble ................................ 17—271
Low and Reverse and 1-2—3-4Clutch Housing
Cleaning and Inspection .................... 17—273
Low and Reverse and 1-2-3—4Clutch Housing
Assemble (6T30) ........................... 17-274
Low and Reverse and 1-2-3-4 Clutch Housing
Assemble (6T40l45/50) ..................... 17-276
Low and Reverse and 1-2-3-4 Clutch
Housing, and 1-2-3-4 Clutch Plate
Installation (6T30) .......................... 17-278
Low and Reverse and 1-2-3-4 Clutch
Housing, and 1-2-3-4 Clutch Plate
Installation (6T40l45/50) .................... 17-279
Drive Sprocket, Driven Sprocket and Drive
Link Cleaning and Inspection ............... 17 280
Drive and Driven Sprocket, Drive Link, and
Park Pawl Installation(6T30) ............... 17-281
Drive and Driven Sprocket, Drive Link, and
Park Pawl Installation(6T40l45/50) . . . . 17-282
Front Differential Carrier Cleaning and
Inspection ................................... 17-283
Front Differential Carrier
Installation (6T30) .......................... 17—284
Front Differential Carrier Installation (6T40/
45/50) ....................................... 17-285
Transmission Fluid Pump, Front Differential
Carrier Baffle, and Front Differential Ring
Gear Removal (6T30) ....................... 17—286
Transmission Fluid Pump, Front Differential
Carrier Baffle, and Front Differential Ring
Gear Removal (6T40l45) ................... 17-287
Front Wheel Drive Shaft Seal Replacement -
Torque Converter Housing Side ............ 17-288
Torque Converter Housing Cleaning and
Inspection ................................... 17—289
Transmission Fluid Pump
Disassemble (6T30) ........................ 17—290
2013
-Sonic
(US/Canada)
Servlce
Manual
(5377994)
Table of Contents 17=3
Transmission Fluid Pump Disassemble
(6T40l45/50) ................................ 17-292
Fluid Pump Selective Measurement . . . . . 17-294
Transmission Fluid Pump
Assemble (6T30) ........................... 17-295
Transmission Fluid Pump Assemble (6T40/
45/50) ....................................... 17—297
Transmission Fluid Pump, Front Differential
Carrier Baffle, and Front Differential Ring
Gear Installation (6T30) ..................... 17-299
Transmission Fluid Pump, Front Differential
Carrier Baffle, and Front Differential Ring
Gear Installation (6T40l45) ................. 17—300
Torque Converter Housing with Fluid Pump
Assembly Installation (6T30) ............... 17-301
Torque Converter Housing with Fluid Pump
Assembly Installation (6T40l45/50 Non
Hybrid) ...................................... 17—302
Inputand Output Speed Sensor
Installation .................................. 17-303
Control Valve Body Assembly Disassemble
(Gen 1) ...................................... 17—304
Control Valve Body Assembly Disassemble
(Gen 2) ...................................... 17-305
Control Valve Body Cleaning and Inspection
(Gen 2) ...................................... 17-306
Control Valve Channel Plate Cleaning and
Inspection (6T30/40/45/50- Gen 2) ......... 17-307
Control Valve Body Assembly Assemble
(Gen 1) ...................................... 17-308
Control Valve Body Assembly Assemble
(Gen 2) ...................................... 17-309
Control Valve Body Assembly Installation 17-310
Control Solenoid Valve and Transmission
Control Module Assembly Installation ....... 17-311
Control Valve Body Cover Installation ........ 17-312
Torque Converter Fluid Seal Replacement ... 17—313
Torque Converter Installation ................ 17—314
Lift Plate and Holding Fixture Removal . . 17-315
Description and Operation ................... 17-315
Definitions and Abbreviations ................ 17—315
Transmission Identification Information . . 17-317
Transmission General Description ........... 17—317
Transmission Component and System
Description .................................. 17—31 8
Transmission Adaptive Functions ............ 17—31 8
Transmission Indicators and Messages ...... 17—318
Electronic Component Description ........... 17-319
Park —Engine Running (Gen 1) .............. 17-321
Park - Engine Running (Gen 2) .............. 17-323
Reverse (Gen 1) ............................. 17-325
Reverse (Gen 2) ............................. 17—327
Neutral —Engine Running (Gen 1) ............ 17—329
Neutral —Engine Running (Gen 2) ............ 17-331
Drive Range, First Gear Engine Braking
(Gen 1) ...................................... 17-333
Drive Range, First Gear Engine Braking
(Gen 2) ...................................... 17-335
174 Table of Contents
Drive Range, First Gear (Gen 1) ............. 17-337 Manual Transmission - F13-5lF15-5l
Drive Range, First Gear (Gen 2) ............. 17—339 F17-5 (M26) ................................ 17-426
Drive Range, Second Gear (Gen 1) .......... 17-341 Specifications ................................. 17—426
Drive Range, Second Gear (Gen 2) .......... 17-343 Fastener Tightening Specifications .......... 17-426
Drive Range, Third Gear (Gen 1) ............ 17-345 Adhesives, Fluids, Lubricants, and
Drive Range, Third Gear (Gen 2) ............ 17-347 Sealers ..................................... 17-427
Drive Range - Fourth Gear (Gen 1) .......... 17-349 Lubrication Specifications .................... 17-428
Drive Range - Fourth Gear (Gen 2) . . . . . . 17—351 Transmission Gear Ratio ..................... 17-428
Drive Range - Fourth Gear Default (Gen 2/ Schematic and Routing Diagrams ........... 17—428
Hybrid) ...................................... 17-353 Manual Transmission Schematics ........... 17—429
Drive Range, Fifth Gear (Gen 1) ............. 17-356 Component Locator .......................... 17-430
Drive Range, Fifth Gear (Gen 2) ............. 17-358 Disassembled Views ......................... 17-430
Drive Range, Fifth Gear Default (Gen 1) . 17-360 Diagnostic Information and Procedures . . .. 17-438
Drive Range, Fifth Gear Default (Gen 2) . 17-363 DTC P0502 or P0503 ........................ 17-438
Drive Range, Sixth Gear (Gen 1) ............. 17—366 DTC P0806—P0808........................... 17—440
Drive Range, Sixth Gear (Gen 2) ............. 17-368 DTC P080A .................................. 17-443
Fluid Passages (Gen 1) ...................... 17-370 DTC P0812 .................................. 17-444
Fluid Passages (Gen 2) ...................... 17—382 Clutch Pedal Position Sensor Learn . . . . . 17-445
Special Tools and Equipment ................ 17—394 Symptoms - Manual Transmission ........... 17—445
Clutch ....................................... 17—400 Transmission Fluid Leak Diagnosis .......... 17-446
Specifications ................................. 17—400 Repair Instructions - On Vehicle ............. 17-448
Fastener Tightening Specifications . . . . . . 17-400 Gear Position Sensor Replacement .......... 17—448
General Specifications ....................... 17-400 Transmission Rear Mount Replacement . . .. . 17—449
Diagnostic Information and Procedures . . .. 17—401 Transmission Mount Replacement -
Symptoms - Clutch ........................... 17-401 Left Side .................................... 17-449
Clutch Does Not Disengage .................. 17-401 Transmission Rear Mount Bracket
Clutch Slipping ............................... 17-402 Replacement ............................... 17—450
Clutch Grabbing .............................. 17-403 Transmission Mount Bracket Replacement -
Clutch Rattle ................................. 17-404 Left Side .................................... 17-451
Release Bearing Noisy with Clutch Transmission Fluid Level and Condition
Engaged .................................... 17—405 Check ....................................... 17-452
Clutch Noisy .................................. 17-405 Transmission Fluid Drain and Fill ............ 17-452
Clutch Pedal Hard to Push ................... 17-405 Manual Transmission Shift Lever Cable
Repair Instructions ........................... 17-405 Adjustment .................................. 17—453
Clutch Pedal Replacement ........... 17—405 Manual Transmission Shift Lever and
Clutch Master Cylinder Reservoir Hose Selector Lever 0able Replacement ......... 17—455
Replacement ......... '...................... 17-407 Selector and Shift Lever Cable Bracket
Clutch Master Cylinder Replacement .... . . . . 17—408 Replacement ........ '....................... 17—457
Clutch Actuator Cylinder Front Pipe Front Wheel Drive Shaft Seal Replacement -
Replacement ‘............................... 17-410 Left Side .................................... 17—458
Clutch Actuator Cylinder Pipe Front Wheel Drive Shaft Seal Replacement -
Replacement (F17) ......................... 17-412 Right Side ................................... 17-459
Clutch Actuator Cylinder Pipe Replacement Transmission Control Replacement .......... 17-459
(M20/32) .................................... 17-413 Vehicle Speed Sensor Replacement ......... 17-461
Hydraulic Clutch System Bleeding ........... 17-415 Transmission Control Lever Boot
_0|utchPedal Position Sensor Replacement ............................... 17-462
Replacement ............................... 17—415 Backup Lamp Switch Replacement .......... 17-463
Clutch Pressure and Driven Plate Transmission Replacement .................. 17-463
Replacement (1.4L) ......................... 17—416 Repair Instructions - Off Vehicle ............. 17—469
Clutch Pressure and Driven Plate Transmission Disassemble .................. 17-469
Replacement (1.8L) ......................... 17—419 Transmission Case Disassemble (Gen 1) 17—472
Clutch Actuator Cylinder Transmission Case Disassemble (Gen 2) 17-478
Replacement (F17) ......................... 17—422 Main Shaft Disassemble (Gen 1) ............. 17—484
Clutch Actuator Cylinder Replacement Main Shaft Disassemble (Gen 2) ............. 17—493
(M20l32) .................................... 17—423 InputShaft Disassemble ..................... 17-496
Description and Operation ................... 17-425 Differential Case Disassemble ............... 17-496
Clutch System Description and Operation 17-425 Clutch and Differential Housing
Special Tools and Equipment ................ 17-425 Disassemble ................................ 17-498

—
2013 (US/Canada)
Sonic (5377994)
Manual
Service

Clutch and Differential Housing Cleaning and
Inspection ................................... 17-500
Clutch and Differential Housing Assemble 17—501
Gears Cleaning and Inspection (Gen 1) ...... 17—503
Gears Cleaning and Inspection (Gen 2) ...... 17-504
Thrust Washer and Bearing Cleaning and
Inspection ................................... 17—506
Synchronizers Disassemble ................. 17—506
Synchronizers Cleaning and Inspection ...... 17-507
Synchronizers Assemble ..................... 17—509
Shift Fork Cleaning and Inspection
(Gen 1) ...................................... 17-509
Shift Fork Cleaning and Inspection
(Gen 2) ...................................... 17-510
_
a,‘7‘.
#M.\,IWW
InputShaft Assemble ........................ 17511
Main Shaft Assemble (Gen 1) ................ 17-512
Main Shaft Assemble (Gen 2) ................ 17-514
Differential Case Assemble .................. 17—517
Transmission Case Assemble (Gen 1) ....... 17—518
Transmission Case Assemble (Gen 2) ....... 17—524
Transmission Assemble ...................... 17-531
Description and Operation ................... 17-534
Transmission System Description and
Operation ................................... 17-534
Special Tools and Equipment ................ 17-535
Manual Transmission - M20lM32
(MR5, MZ4) ................................
Specifications .................................
Fastener Tightening Specifications ..........
Manual Transmission Specifications ......... 17-539
Schematic and Routing Diagrams ...........
Manual Transmission Schematics ...........
Component Locator ..........................
“WA--W
4M“
,0»
me.--“
0V”,
....u.
..
.2 Manual Transmission Component Views
Diagnostic Information and Procedures . . .. 17—555
DTC P0502 or P0503 ........................
DTC P0806-P0808 ...........................
DTC P080A ..................................
DTC P0812 ..................................
Clutch Pedal Position Sensor Learn . . . . . 17—562
Symptoms —Manual Transmission ...........
Transmission Shifts Hard ....................
Transmission Gear Clash When Shifting
Gears .......................................
2013
—
Sonic
(US/Canada)
Service
Manual
(5377994)
Table of Contents 175
Repair Instructions - 0n Vehicle ............. 17—567
Transmission Fluid Drain and Fill ............ 17—567
Transmission Control Lever Boot
Replacement ............................... 17-568
Manual Transmission Shift Lever and
Selector Lever Cable Replacement ......... 17-569
Selector and Shift Lever Cable Bracket
Replacement ............................... 17-571
Transmission Control Replacement .......... 17-572
Manual Transmission Shift Lever and
Selector Lever Cable Adjustment ........... 17-574
Vehicle Speed Sensor Replacement ......... 17—575
Backup Lamp Switch Replacement .......... 17—576
Shift Control Housing Replacement .......... 17-577
Transmission Rear Mount Replacement . 17—580
Transmission Mount Replacement -
Left Side .................................... 17—581
Transmission Mount Bracket Replacement
- Rear ....................................... 17-582
Transmission Mount Bracket Replacement -
Left Side .................................... 17—583
Front Wheel Drive Shaft Seal Replacement -
Left Side .................................... 17-584
Front Wheel Drive Shaft Seal Replacement -
Right Side ................................... 17-585
Transmission Replacement .................. 17-586
Description and Operation ................... 17-589
17-539
Transmission System Description and
17-539
Operation ................................... 17-589
17—539
Transmission Identification Information . . 17-593
Special Tools and Equipment ................ 17-593
17-540
17-541 Shift Lock Control ......................... 17-594
17—542 Schematic and Routing Diagrams ........... 17-594
17—542 Shift Lock Control Schematics ............... 17-595
Diagnostic Information and Procedures . . .. 17—596
17-555 DTC 8270A .................................. 17—596
17-557 Symptoms —Automatic Transmission Shift
17—560 Lock Control ................................ 17—598
17-561 Transmission Control Lever Malfunction . 17598
Description and Operation ................... 17-600
17—562 Automatic Transmission Shift Lock Control
17—564 Description and Operation .................. 17-600
17-566
 ,n
17=0 Table of Contents

BLANK

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
 Automatic Transmission - 6T30/6T40/6T45/6T50 (MH8, MH9) 'l7-7

Automatic Transmission - 6T30l6T40/6T45/6T50 (MH8, MH9)

Specifications

Fastener Tightening Specifications (On Vehicle)

Specification
Application Ref No.* Quantity Size Metric I English
A/TransFluidPumpBoltto ConverterHousing
FirstPass 200 M8x33 10N'm I 89lb in
FinalPass 200 M8x33 45°
A/TransFluidPumpCoverBolt 302 M6X18.5 12N-m 106lb in
A/TransFluidPumpCoverBolt 320 20 M6x21.5 12Mm 106lbin
fifig‘ffiflggflgyfig’ggggflfi'y 4 12 M6x97 12N-m 1061bin

81611213881182.3283” e 3
(08:11ng
9%";ofio‘jyAssemb'y 400 1 M5x40.5 7N-m 62lb in
ControlValveBodyto Case Bolt 9 2 M6x53 11Nm 97lb in
ControlValveBodyto Case Bolt 10 9 M6x60 11Nm 97lbin
ControlValveBodyCoverBolt 1 13 M6x30 12Nm 106lbin
DrainPlug 64 1 1/8"—27
NPTF 12Nm 106lb in
FluidLevelHolePlug 63 1 1/8"—27
NPTF 12Nm 106lb in
FluidPressureTestHolePlug 51 1 1/8"—27
NPTF 12Mm 106lbin
328?:g‘gfig’r‘g'fofi; $2133“ 204 2 M6x25 12Nm 106lbin

ggfipfgiggenfia'GamerBaffle e1 2 M6x18.5 12Mm 106lbin

GrommetFasteners — 2 — 9 N-m 80lb in
Input
Mvgww_n_vw,
vzme-rvu—A‘KWW‘
-A».~4.,M—~
w,
.4 ShaftSupportBolt 57 3 M6x50 12Nm 106lb in
InputSpeedSensorBolt 21 1 M6x23 9 N'm 80lbin
ManualShiftDetentSpring 17 1 M6x16 12N'm 106lbin
Oil CoolerFitting —- 2 — 20NW 15lbft
Oil CoolerFittingto Radiator — —— — 20NW 15lbft
OutputSpeed SensorBolt 15 1 M6x18 9 N-m 80 lbin
TorqueConverterand DifferentialHousingBolt
FirstPass 27 14 M8x30 10NW 89lb in
FinalPass 27 14 M8x30 50°
TorqueConverterto FlywheelBolt — — —— 60NW 44 lbft

12.181111551221111 2' ) — — -
TransmissionBolt(2,3,4)—6T30
(1.6LLDE, LFJ and 1.8L — — —- 60N-m 44 lbft
LUW,LWE)

Isériasgmimg;6L — — -
TransmissionBracketMountto _ _ _ 80N-mplus45— 591bft plus45-
MountThroughBolt 60 degrees 60 degrees
TransmissionControlFasteners —— 4 — 9N-m 80lbin
TransmissionFluidCoolerOutlet __ __ _ 22N-m 17lbft
Pipe Nut

2013
-Sonic
(US/Canada)
Sen/lce
Manual
(5377994)
17=8 Automatic Transmission .. 6T30/6T40l6T45/6T50 (MH8, MH9)

Fastener Tightening Specifications (On Vehicle) (cont'd)

Specification
Application Ref No.* Quantity Size Metric English
TransmissionFluidCoolerPipe .
InletNut — — —— 22N m 17|bft
TransmissionMountBolt—Left .
Side to Body —— — — 58N m 43|bft
TransmissionMountBolt—Left _ _ _ 50N-mplus60— 37lbft plus60-
Side to Transmission 75 degrees 75 degrees
TransmissionMountBracketto _ _ _ 100Nmplus 74lbft plus30-
TransmissionBolt—Rear 30—45degrees 45 degrees
TransmissionMountto FrameBolt — — — 100N-m 74Ibft
TransmissionMountNut—Left . 43lbft
Side to Body — — —~ 58N m
TransmissionNut(1)—BT30(1.6L _ _ _ _
LDE, LFJ and 1.8LLUW,LWE) 40” m 30”3“
TransmissionNut(1)andBolt(3)— _ _ .
6T30(1.4LLDD,L2N,L2l) — 40” m 30””1
TransmissionRangeSelector _
Cable BracketBolt —_ _ _ 18Mm 14Ibft
TransmissionRangeSelector _ __ _ 30Wm 22Ibft
LeverNut
*Referencenumberreferstothecomponentcalloutnumberin DisassembledViews

Fastener Tightening Specifications (Off Vehicle)

Specification
Application Ref No.* Quantity Size Metric English
AlTransAuxiliaryFluidPump .
OutletBolt(HybridModels) 350 4 — 22N m 16'b“
AlTransAuxiliaryFluidPump _ .
Bolt(HybridModels) 355 1 22N m 16”3“
AlTransAuxiliaryFluidPump
(Pumpto Motor)Bolt(Hybrid 370 4 — N-m
10—12 89—106lbin
Models)
AlTrans FluidPumpBoltto ConverterHousing
FII’StPass 200 7 _ 6T30.8 _ M8x33 10N-m 89lb in
Final Pass 200 6T40/45/50 M8x33 45°
AlTrans FluidPumpCover Bolt 302 363325;)? M6x25 12N-m 106lbin

AlTrans FluidPumpCover Bolt 320 20—6T30, M6x21.5 12N-m 106lbin

ControlSolenoidValveAssembly . .
(w/TCMandBody)to Case Bolt 4 12 M6X97 ‘0 N m 89'b '“
ControlSolenoidValveAssembly . .
(wlTCMandBody)toCase Bolt 6 3 M5X40'5 7N m 62lbIn
.
ControlValveBodyAssembly
(Complete)Bolt 400 1 M5x40.5 7N.m 62lbIn
ControlValveBodyto Case Bolt 9 2 M6x53 11NW 97lbin
ControlValveBodyto Case Bolt 10 9 M6x60 11N-m 97lbin
ControlValveBodyCoverBolt 1 13 M6X30 12NW 106lbin
DrainPlug 64 1 NPTF
1/8”—27 12N-m 106lbin
FluidLevelHolePlug 63 1 NPTF
1/8"—27 12N-m 106lbin
FluidPressureTestHolePlug 51 1 NPTF
1/8"—27 12N-m 106lbin

2013
—Sonic
(US/Canada)
Service
Manual
(5377994)
 Automatic Transmission - 6T30/6T40l6T45/6T50 (MH8, MH9) 17=9

Fastener Tightening Specifications (Off Vehicle) (cont'd)

, Specification
Application, Ref No.* Quantity Size Metric English
521th:
gigfifi'r‘tif'lfoaljgfigBaffle 204 2 M6x25 12Mm 106lbin

igiggéenfialCarrierBaffle
15511” 61 2 6—
69486118631 12N‘m 106lbIn
6T40/45/50
InputShaftSupportBolt 57 3 M6x50 12N-m 106lbin
InputSpeedSensorBolt 21 1 M6x23 9 N-m 80 lbin
ManualShiftDetentSpring 17 1 M6x16 12Nm 106lbin
OutputSpeedSensorBolt 15 1 M6x18 9 N-m 80lbin
TorqueConverterand DifferentialHousingBolt
FirstPass 27 14_ 6T30,15_ M8X3O 10N-m 89 Ibin
FinalPass 27 6T40/45/50 M8x30 50°
*Referencenumberreferstothecomponentcalloutnumberin DisassembledViews

Transmission General Transmission General Specifications

Specifications (6T30) (6T40l45/50)
Name 6T30 Name 6T40/6T45/6T50
RPO Codes MH9 RPO Codes MH8,MH7,MHK, MHH,
ProductionLocation Korea/China MHC, MHJ, MNH,MHB
TransmissionDrive FrontWheelDrive ProductionLocation Korea/China/Mexico/Toledo
ReverseGear Ratio 2.87 TransmissionDrive FrontWheelDrive
1stGear Ratio 4449 ReverseGear Ratio 294
“M
,.\__
___.\_‘w—.uvr———-»»M
I......_
.N
2~MM~
. 2ndGear Ratio 2.908 1stGear Ratio 4584
3rdGear Ratio 1.893 20dGear Ratio 2.964
4thGear Ratio 1.446 3rdGear Ratio 1912
5thGear Ratio 1.000 4thGear Ratio 1446
6thGear Ratio 0.742 5‘“ Gear Ratio 1000
. . . 6thGear Ratio 0.746
EfieCt'VeFF'EIODWB Gear 2.84/3.14/3.37/3.72/4.11 EffectiveFinalDriveGear
Ratio 2.64/2.89/3.23/3.53/3.87
TorqueConverterSize-
DiameterofTorque 220mm TorqueConverterSize-
ConverterTurbine DiameterofTorque 236mm
. ConverterTurbine
PressureTaps LInePressure
TransmissionFluidType DEXRON VI® PressureTapsLIne Pressure
TransmissionFluid TransmissionFluidType DEXRON Vl®
Capacity 7.5L/8.0qtsQuarts
TransmissionFluid 8.0L/8.5Quarts
TransmissionType:6 Six ForwardGears Capacity
TransmissionType:T TransverseMount TransmissionType:6 Six ForwardGears
TransmissionType:30 ProductSeries TransmissionType:T TransverseMount
TransmissionType:40/ ProductSeries
PositionQuadrant P. R. N, D,**(Refertothe 45l50
applicableowner‘smanual)
Case Material Die CastAluminum PositionQuadrant P,R. N, D,**(Refertothe
applicableowner'smanual)
TransmissionNetWeight 72kg (159le) Case Material Die Cast Aluminum
,.2
.-
f_
J..-
.....2
4.‘—
_Afifl MaximumTrailerTowing
Capacity N/A TransmissionNetWeight ' 81/86kg (178/190lbs)
MaximumGross Vehicle MaximumTrailerTowing
2268kg (5,000lbs) Capacity N/A
Weight(GVW)

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
‘17-'10 Automatic Transmission - 6T30/6T40/6T45/6T50 (MH8, MH9)

Transmission General Specifications

(6T40l45l50) (cont'd)
Name 6T40l6T45/6T50
6T40—2000kg (4,4091bs)
MaximumGross Vehicle 6T45—2200kg (4,850lbs)
Weight(GVW)
6T50—2500kg (5,511lbs)

Adhesives, Fluids, Lubricants, and Sealers

GM Part Number
Application Type of Material UnitedStates Canada
AutomaticTransmissionFluid DEXRON®VI 88861037 19264717

Fluid Capacity Specifications (6T30)

Specification
Application Metric English
ValveBodyCover Removal—ApproximateCapacity 4.0—5.01iters 4.2—5.3quarts
Capacity
FluidChange—DrainPlug—Approximate 4.5—5.5liters 4.75—5.8quarts
Overhaul—ApproximateCapacity 7.62liters 8.05quarts

Fluid Capacity Specifications (6T40l45l50)

Specification
Application Metric English
Capacity
ValveBodyCover Removal—Approximate 5.0—7.0liters 5.3—7.4quarts
Capacity
FluidChange—DrainPlug—Approximate 4.0—6.0liters 4.2—6.3quarts
Overhaul—ApproximateCapacity 8.0—8.5liters 8.5—9.0quarts

Fluid Pump Selective Specifications

Fluid Pump Body Pocket Depth Fluid Pump Gear Thickness
Metric English Metric English
12617—12625mm 04967—04970in 12580—12588mm 04952—04955in
12626—12636mm 04970—04974in 12589—12599mm 04956—04960in
12637—12645mm 04975—04978in 12600—12608mm 04960—04963in

Range Reference
Drive
1st
Range Park Reverse Neutral Braking 1st 2nd 3rd 4th 5th 6th
1—2—3—4 Clutch — — — Applied Applied Applied Applied Applied — -
3—5 R . . .
ClUtCheverse —— AppIIed —— — — — AppIIed — AppIIed -
4—5—6 Clutch — — — — — —— — Applied Applied Applied
2—6Clutch - —— —— — — Applied — — — Applied
LR3332: Clutch . ,, . . * .
Applied AppIIed AppIIed AppIIed —- — — — — -

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
 Automatic Transmission - 6T30/6T40l6T45/6T50 (MH8, MH9) 17:11

Range Reference (cont'd)

Drive
1st
Range Park Reverse Neutral Braking 1st 2nd 3rd 4th 5th 6th
kggeflififlowu — — — Holding Holding — — — -
*=AppliedwithNO load

Shift Solenoid Valve State and Gear Ratio

1-2-3-4CL 3-5 REV CL Low REV
PC SOL 2-60L P0 P0 SOL 4-5-60L PC Gear Gear Ratio
Gear Shift SOL 1 5 N.L. SOL 4 N.L. 2 N.H. SOL 3 N.H. Ratio 6T30 6T40l45/50
Park ON OFF OFF OFF ON —— -
Reverse ON OFF OFF ON ON 2.87 2.940
Neutral ON OFF OFF OFF ON — -
1stBraking ON ON OFF OFF ON 4.449 4.584
1st OFF ON OFF OFF OFF 4.449 4.584
2nd OFF ON ON OFF OFF 2.908 2.964
3rd OFF ON OFF ON OFF 1.893 1.912
4th OFF ON OFF OFF ON 1.446 1.445
5th OFF OFF OFF ON ON 1.000 1.000
6th OFF OFF ON OFF ON 0.742 0.746
Forshiftsolenoid1,“ON"=SolenoidEnergized(Pressurized)“OFF"=SolenoidDe-energized(NoPressure).
For pressurecontrolsolenoids,“ON"=Pressurized,"OFF"=No Pressure

Transmission Fluid Pressure Switch Logic

Transmission Fluid Pressure Switch
2W2
2W
A‘- States
*Switch
Gear Switch 1 3 Switch 4 Switch 5
Park Low Low Low Low
Reverse Low Low Low Low
Neutral Low Low Low Low
Drive1st-
Engine Low High Low Low
Braking
Drive1st High High Low High
Drive2nd High Low Low High
Drive3rd Low High Low High
Drive4th High High Low Low
Drive5th Low High High Low
Drive6th High Low High Low
High=12V (SwitchOpenor Pressurized)
Low=0V (SwitchClosedor No Pressure)
Note:All transmissionfluidpressureswitchesare normally
closed(NC)
*Transmissionfluidpressureswitch2 does notexist

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
171-12 Automatic Transmission - 6T30/6T40l6T45/6T50 (MH8, MH9)

Transmission Internal Mode Switch Logic

Gear Selector Position Signal A Signal B Signal 0 Signal P
Park LOW HI HI LOW
Park/Reverse LOW LOW HI LOW
Reverse LOW LOW HI HI
Reverse/Neutral HI LOW HI HI
Neutral HI LOW HI LOW
6
Neutral/Drive HI LOW LOW LOW
Drive6 HI LOW LOW HI
Drive6/Drive4 LOW LOW LOW HI
Drive4 LOW LOW LOW LOW
Drive4/Drive3 LOW HI LOW LOW
Drive3 LOW HI LOW HI
Drive3/Drive2 HI Hl LOW HI
Drive2 HI HI LOW LOW
Open HI HI HI HI
Invalid HI HI HI LOW
Invalid LOW HI HI HI
HI=Ignitionvoltage
LOW =0 volts

Solenoid Valve Pressure (Gen 1) Line P0 Solenoid Valve Pressure (cont'd)

Actual Pressure
Line P0 Solenoid Valve Pressure Requested
Pressure (kPa) Metric English
Actual Pressure
Requested 1000 1860—2275 kPa 270—330 psi
Pressure (kPa) Metric English
1200 1860—2275 kPa 270—330 psi
None 345—550kPa 50—80psi
1400 1860—2275 kPa 270—330 psi
200 690—900kPa 100—130 psi
1600 1860—2275 kPa 270—330 psi
400 1100—1310 kPa 160—190 psi
1800 1860—2275 kPa 270—330 psi
600 1520—1725 kPa 220—250 psi
2000 1860~2275 kPa 270—330 psi
800 1860—2275 kPa 270—330 psi

(US/Canada}
-Sonic
2013 (5377994)
Manual
Service
 Automatic Transmission - 6T30l6T40/6T45/6T50 (MH8, MH9) 172-13
Transmission Parts Kit Specifications
AlTrans Seal Kit (Gen 1& 2) 24251028

..VW._
.,

2660570
Note: Callouts with boxes around them indicate part is
included in the service kit. Callouts without boxes are
shown for relationship purposes only.

AlTrans Seal Kit (Gen 1& 2) 24251028

Callout Quantity Component Name
20 3 AlTrans InputSpeedSensorAssemblyO-Ring Seal

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
1744 Automatic Transmission - 6T30/6T40l6T45/6T50 (MH8, MH9)

Front Wheel Seal Kit (Gen 1& 2) 19258415

2660572
Note: Callouts with boxes around them indicate part is
included in the service kit. Callouts without boxes are
shown for relationship purposes only.

Front Wheel Seal Kit (Gen 1& 2) 192584152

Callout Quantity Component Name
209 1 FrontWheelDriveShaftOil Seal Assembly

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Automatic Transmission - 6T30/6T40/6T45/6T50 (MH8, MH9) 17-15
Front Wheel Seal Kit (Gen 1& 2) 19258416

2660582
Note: Callouts with boxes around them indicate part is
Included in the service kit. Callouts without boxes are
shown for relationship purposes only.

Front Wheel Seal Kit (Gen 1& 2) 19258416

Callout Quantity Component Name
65 1 DriveShaftOil Seal Assembly

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
17-16 Automatic Transmission - 6T30/6T40l6T45/6T50 (MH8, MH9)

AlTrans Seal Kit (Gen 1) 24251353 (1 of 2)

@Ivv uu
.-
IIIIIIIIIIIIIIIIIIIIII
II III -
5| 1UI_| UU
Di
II _.'_r\

.~\.
-.-»
"W2
..,

2660578

AlTrans Seal Kit (Gen 1) 24251353 (1 of 2)

Callout Quantity Component Name
3 1 ControlValveBodyCoverGasket
24 1 TorqueConverterHousingGasket
58 4 3-5-Reverseand4-5-6ClutchFluidSeal Ring
65 1 DriveShaftOil Seal Assembly
202 1 TorqueConverterandDifferentialHousingSeal
209 1 FrontWheelDriveShaftOil Seal Assembly
301 1 TorqueConverterFluidSeal Assembly
319 1 TorqueConverterFluidSeal Assembly
504 1 3—5-ReverseClutchPistonInnerSeal
505 1 3-5-ReverseClutchPistonInnerSeal
506 1 3-5-ReverseClutchPistonDarnSeal
518 1 4-5-6ClutchPistonOuterSeal
519 1 4-5-6ClutchPistonOuterSeal
(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
 Automatic Transmission - 6T30l6T40/6T45/6T50 (MH8, MH9) 17-17
AlTrans Seal Kit (Gen 1) 24251353 (1 of 2) (cont'd)
Callout Quantity Component Name
521 1 4-5—6
ClutchPistonInnerSeal

AlTrans Seal Kit (Gen 1) 24251353 (2 of 2)

2660688
Note: Callouts with boxes around them indicate part is
included in the service kit. Callouts without boxes are
shown for relationship purposes only.

AlTrans Seal Kit (Gen 1) 24251353 (2 of 2)

Callout Quantity Component Name
5 1 ControlValveBodyCover HoleSeal
8 1 ControlValveBodyFilterPlateAssembly
12 1 ControlValveBodySpacer PlateAssembly
14 1 AlTransFluidLevelControlValveGasket
20 3 AlTransInputSpeedSensorAssemblyO-RingSeal
25 1 AlTransFluidPumpSeal Assembly
59 1 DriveLinkLubeFluid Seal
67 1 1-2-3-4andLowReverseClutchFluidPassageSeal
203 1 AlTransFluidFilterAssembly
403 1 ChannelPlatet0ValveBody SpacerPlateAssembly
604 1 ManualShiftShaftSeal
605 1 Park PawlActuatorGuideSeal

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
17-18 Automatic Transmission - 6T30/6T40l6T45/6T50 (MH8, MH9)

AlTrans Seal Kit (Gen 2) 24260603 (1 of 2)

202

i O.1.

61'

y.{/2
-v-
m8

AlTrans Seal Kit (Gen 2) 24260603 (1 of 2)

Callout Quantity Component Name
3 1 ControlValveBodyCoverGasket
24 1 TorqueConverterHousingGasket
58 3 3-5-Reverseand4-5-6ClutchFluidSeal Ring
65 1 DriveShaftOil Seal Assembly
202 1 TorqueConverterand DifferentialHousingSeal
209 1 FrontWheelDriveShaftOil Seal Assembly
301 1 TorqueConverterFluidSeal Assembly
319 1 TorqueConverterFluidSeal Assembly
504 1 3—5-ReverseClutchPistonInnerSeal
505 1 3-5—ReverseClutchPistonInnerSeal
506 1 3—5-ReverseClutchPistonDamSeal
518 1 4-5-6ClutchPistonOuterSeal
519 1 4-5—6ClutchPistonOuterSeal
(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
 Automatic Transmission - 6T30/6T40/6T45/6T50 (MH8, MH9) '17-19
AlTrans Seal Kit (Gen 2) 24260603 (1 of 2) (cont'd)
Callout Quantity Component Name
521 1 4-5—6
ClutchPistonInnerSeal
524 1 4-5—6
ClutchPistonFluid DamRetainerRing

AlTrans Seal Kit (Gen 2) 24260603 (2 of 2)

2660699
Note: Callouts with boxes around them indicate part is
included in the service kit. Callouts without boxes are
shown for relationship purposes only.

AlTrans Seal Kit (Gen 2) 24260603 (2 of 2)

Callout Quantity Component Name
5 1 ControlValveBody CoverHoleSeal
8 1 ControlValveBody FilterPlateAssembly
12 1 ControlValveBody SpacerPlateAssembly
14 1 AlTransFluidLevel ControlValveGasket
20 3 AlTransInputSpeed SensorAssemblyO-RingSeal
23 1 Fill Cap Seal
25 1 AlTransFluidPumpSeal Assembly
59 1 DriveLinkLubeFluidSeal
67 1 1-2—3-4 and LowReverseClutch FluidPassageSeal
203 1 AlTransFluidFilterAssembly
403 1 ChannelPlatetoValve BodySpacerPlateAssembly
407 5 ActuatorFeedAccumulatorSpring

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
17-20 Automatic Transmission - 6T30/6T40/6T45/6T50 (MH8, MH9)

AlTrans Seal Kit (Gen 2) 24260603 (2 of 2) (cont'd)

Callout Quantity Component Name
408 5 ActuatorFeedAccumulatorPiston
604 1 ManualShiftShaftSeal
605 1 Park PawlActuatorGuideSeal

Transmission Kit (Gen 1) 24260701

Note: Callouts with boxes around them indicate part is

included in the service kit. Callouts without boxes are
shown for relationship purposes only.

Transmission Kit (Gen 1) 24260701

Callout Quantity Component Name
523 1 4-5-6ClutchPistonFluidDamAssembly
524 1 4-5-6ClutchPistonFluidDamRetainerRing
531 1 ReactionCarrierHubAssembly

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Automatic Transmission - 6T30/6T40/6T45/6T50 (MH8, MH9) 17-21
Control Valve Body Kit (Gen 1) 24248473

2660711
Note: Callouts with boxes around them indicate part is
included in the service kit. Callouts without boxes are
shown for relationship purposes only.

Control Valve Body Kit (Gen 1) 24248473

Callout Quantity Component Name
3 1 ControlValveBodyCover Gasket
2”»,
42-.“
WWW‘
,-..~U_‘W..V.,HW
5 1 ControlValveBodyCover HoleSeal
8 1 ControlValveBodyFilterPlateAssembly
12 1 ControlValveBodySpacer PlateAssembly
14 1 AlTransFluidLevelControlValveGasket
67 2 1—2-3-4andLowReverseClutch FluidPassage Seal
403 1 ChannelPlatetoValve BodySpacerPlateAssembly

2013
~Sonic
(US/Canada)
Service
Manual
(5377994)
1722 Automatic Transmission - 6T30/6T40I6T45I6T50 (MH8, MH9)

Control Valve Body Kit (Gen 2) 24260702

2660715
Note: Callouts with boxes around them indicate part is
included in the service kit. Callouts without boxes are
shown for relationship purposes only.

Control Valve Body Kit (Gen 2) 24260702

Callout Quantity Component Name
3 1 ControlValveBodyCoverGasket
5 1 ControlValveBodyCoverHoleSeal
8 1 ControlValveBodyFilterPlateAssembly
12 1 ControlValveBodySpacerPlateAssembly
14 1 AlTransFluidLevelControlValve Gasket
67 2 1-2-3-4andLowReverseClutchFluidPassage Seal
403 1 ChannelPlatetoValveBodySpacerPlate Assembly
407 5 ActuatorFeedAccumulatorSpring
408 5 ActuatorFeedAccumulatorPiston

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
 Automatic Transmission - 6T30/6T40/6T45/6T50 (MH8, MH9) 17-23
Clutch Plate Package (Gen 1) 24249460

go
\i\
.7
7i

2660717
Note: Callouts with boxes around them indicate part is
included in the service kit. Callouts without boxes are
shown for relationship purposes only.

Clutch Plate Package (Gen 1) 24249460

Callout Quantity Component Name
509 3 3—5ReverseClutch(w/FrictionMaterial)PlateAssembly
527 4 4-5-6Clutch(w/FrictionMaterial)PlateAssembly
542 2 2-6Clutch(w/FrictionMaterial)PlateAssembly
545 3 Lowand ReverseClutch(w/FrictionMaterial)PlateAssembly
559 2 1-2-3-4Clutch(w/FrictionMaterial)PlateAssembly

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
17-24 Automatic Transmission - 6T30/6T40/6T45/6T50 (MH8, MH9)

Clutch Plate Package (Gen 2) 24260695

II.
\
I:
i
Imi/n/‘f-
\im‘ii ’\_
r“

508
2660718
Note: Callouts with boxes around them indicate part is
included in the service kit. Callouts without boxes are
shown for relationship purposes only.

Clutch Plate Package (Gen 2) 24260695

Callout Quantity Component Name
509 3 3-5ReverseClutch(w/FrictionMaterial)PlateAssembly
527 5 4-5-6Clutch(w/FrictionMaterial)PlateAssembly
542 2 2—6Clutch(w/FrictionMaterial)PlateAssembly
545 3 Lowand ReverseClutch(w/FrictionMaterial)PlateAssembly
559 2 1-2-3—4Clutch(w/FrictionMaterial)PlateAssembly

2013
-Sonic
(US/Canada)
Sen/ice
Manual
(5377994)
 Automatic Transmission - 6T30/6T40/6T45/6T50 (MH8, MH9) 17-25
4-5-6 Plate Assembly (Gen 2) 24260700

527

.vwwwnflv

MW
hm“
2660719
Note: Callouts with boxes around them indicate part is
included in the service kit. Callouts without boxes are
shown for relationship purposes only.

4-5-6 Plate Assembly (Gen 2) 24260700

Callout Quantity Component Name
527 5 4-5-6Clutch(w/FrictionMaterial)PlateAssembly

Low and Reverse Plate Assembly (Gen 2) 24260696

545

546
2660722
Note: Callouts with boxes around them indicate part is
included in the service kit. Callouts without boxes are
shown for relationship purposes only.

Low and Reverse Plate Assembly (Gen 2) 24260696

Callout Quantity Component Name
545 3 LowandReverseClutch(w/FrictionMaterial)PlateAssembly

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 17-26 Automatic Transmission - 6T30/6T40/6T45/6T50 (MH8, MH9)
3-5 Reverse Plate Assembly (Gen 2) 24260697

WW

11;;
li‘
ti
:-

«x
,3

2660723
Note: Callouts with boxes around them indicate part is
included in the service kit. Callouts without boxes are
shown for relationship purposes only.

3-5 Reverse Plate Assembly (Gen 2) 24260697

Callout Quantity Component Name
509 3 3-5ReverseClutch(w/FrictionMaterial)PlateAssembly

2-6 Plate Assembly (Gen 2) 24260698

541
2660728
Note: Callouts with boxes around them indicate part is
included in the service kit. Callouts without boxes are
shown for relationship purposes only.

2-6 Plate Assembly (Gen 2) 24260698

Callout Quantity Component Name
542 2 2-6Clutch(w/FrictionMaterial)PlateAssembly

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Automatic Transmission - 6T30/6T40/6T45/6T50 (MH8, MH9) 17-27

1-2-3-4 Plate Assembly (Gen 2) 24260699

2660729
Note: Callouts with boxes around them indicate part is
included in the service kit. Callouts without boxes are
shown for relationship purposes only.

1-2-3-4 Plate Assembly (Gen 2) 24260699

Callout Quantity Component Name
559 2 1-2-3-4Clutch(w/FrictionMaterial)PlateAssembly

2013
—Sonic
(US/Canada)
Service
Manual
(5377994)
1‘7—28 Automatic Transmission - 6T30/6T40l6T45/6T50 (MH8, MH9)
A/Trans Seal Kit (Gen 2) 24260704

2660731
Note: Callouts with boxes around them indicate part is
included in the service kit. Callouts without boxes are
shown for relationship purposes only.

AlTrans Seal Kit (Gen 2) 24260704

Callout Quantity Component Name
352 2 AlTransAuxiliaryFluidPumpOutletPipe Seal Assembly
356 1 PressureRegulatorValveSpringSpacer
361 1 AlTransAuxiliaryFluidPumpGasket
362 1 AlTransAuxiliaryFluidPumpSeal
363 1 AlTransAuxiliaryFluidPumpCoverSeal
367 1 AlTransAuxiliaryFluidPumpMotorCoverSeal—O—Ring
371 1 AlTransAuxiliaryFluidInletPumpSeal
373 1 A/TransFluidTroughCheck Ball

2013
—
Sonic
{US/Canada)
Service
Manual
(5377994)
 Automatic Transmission =6T30/6T40/6T45/6T50 (MH8, MH9) 17=29
AlTrans Auxiliary Seal Kit (Gen 2) 24260705

2660733
Note: Callouts with boxes around them indicate part is
included in the service kit. Callouts without boxes are
shown for relationship purposes only.

AlTrans Auxiliary Seal Kit (Gen 2) 24260705

Callout Quantity ' Component Name
352 2 AlTransAuxiliaryFluidPumpOutletPipe Seal Assembly
356 1 PressureRegulatorValveSpringSpacer
361 1 AlTransAuxiliaryFluidPumpGasket
362 1 AlTransAuxiliaryFluidPumpSeal
363 1 A/TransAuxiliaryFluidPumpCoverSeal
367 1 AlTransAuxiliaryFluidPumpMotorCoverSeal—O-Ring

Schematic and Routing Diagrams

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 romN
romw
moszocom w
m.
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17-30 Automatic Transmission - 6T30/6T40I6T45/6T50 (MH8, MH9)
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L_—__——____—-l

2013
—Sonic
(US/Canada)
Service
Manual
(5377994)
 :ofiflEchF —
.28
__ _
FNr 29.28E.
I
6:80 m
.0380 Automatic Transmission - 6T30/6T40/6T45/6T50 (MH8, MH9) 17=31
n
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(mmO co_ww_EmcmF

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L——__———__————__———___———____———____———_—.l

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 50:25 IIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIII
1 7-32 Automatic Transmission - 6T30/6T40/6T45/6T50 (MH8, MH9)
_
IIIIIIIIIIIIIIIIIIIIIIIIIIII rwhw
Eb
.9600
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|_________________J

u.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Automatic Transmission - 6T30/6T40/6T45/6T50 (MH8, MH9) 17-33

Component Locator

Disassembled Views
Case and Associated Parts

r.'
3A
4va
r;

1891276
Le end
9 (1) Control Valve Body Cover Bolt (14) A/Trans Fluid Level Control Valve Gasket
(2) Control Valve Body Cover Assembly (15) A/Trans Output Speed Sensor Bolt
(3) Control Valve Body Cover Gasket (16) A/Trans Output Speed Sensor Assembly
(4) Control Valve Body Bolt (17) Manual Shaft Detent Spring Bolt
(5) Control Valve Body Cover Hole Seal (18) Manual Shaft Detent Lever Spring Assembly
(6) Control Solenoid Valve Heat Sink Bolt (19) A/Trans InputSpeed Sensor Assembly
(7) Control Solenoid (w/Body and TCM) Valve (20) A/Trans InputSpeed Sensor Assembly 0-
Assembly Ring Seal
(8) Control Valve Body Filter Plate Assembly (21) AlTrans InputSpeed Sensor Bolt
(9) Control Valve Body Bolt (22) Fill Cap
(10) Control Valve Body Bolt (23) Fill Cap Seal
(11) Control Valve Body Assembly (24) Torque Converter Housing Gasket
(12) Control Valve Body Spacer Plate Assembly (25) A/Trans Fluid Pump Seal Assembly
(13) A/Trans Fluid Level Control Valve
2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
17-34 Automatic Transmission - 6T30/6T40l6T45/6T50 (MH8, MH9)
(26) Torque Converter with Fluid Pump Housing (28) A/Trans Fluid Fill Tube Plug Assembly
Assembly (29) Torque Converter Assembly
(27) Torque Converter and Differential
Housing Bolt

Transmission Case Assembly — 6T30 —Gen 1

2202182
AlTrans Case Assembly (61) Front Differential Carrier Baffle Bolt
AlTrans Fluid Pressure Test Hole Plug (62) Front Differential Carrier Baffle
Transmission Case Cover Locator Pin (63) Oil Level Plug
A/Trans Fluid Check Bail (64) Drain Plug
InputShaft Support (65) Drive Shaft Oil Seal Assembly
InputShaft Support Bolt (65) Control Valve Body Locator Pin
3—5—Reverseand 4—5—6Clutch Fluid (67) 1—2—3—4 and Low Reverse Clutch Fluid
Seal Ring Passage Seal
Drive Link Lube Fluid Seal (68) Drive Link Lube Fluid Seal
Drive Link Lube Scoop (69) Baffle Retainer

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Automatic Transmission . 8T30/6T40/6T45/6T50 (MH8, MH9) 17-35

Transmission Case Assembly —6T30 — Gen 2

66

”Q
N
67 7\
66

2772775
Legend
(50)AlTrans Case Assembly (61) Front Differential Carrier Baffle Bolt
(51)A/Trans Fluid Pressure Test Hole Plug (62) Front Differential Carrier Baffle
(53)Transmission Case Cover Locator Pin (63) Oil Level Plug
(55)AlTrans Fluid Check Ball (64) Drain Plug
(56)InputShaft Support (65) Drive Shaft Oil Seal Assembly
(57)input Shaft Support Bolt (66) Control Valve Body Locator Pin
(58)3—5—Reverseand 4—5—6Clutch Fluid (67) 1—2—3—4 and Low Reverse Clutch Fluid
Seal Ring Passage Seal
(59) Drive Link Lube Fluid Seal (68) Drive Link Lube Fluid Seal
(60) Drive Link Lube Scoop (69) Baffle Retainer

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
17-36 Automatic Transmission - 6T30/6T40/6T45I6T50 (MH8, MH9)

Transmission Case Assembly - 6T40/6T45/6T50 —Gen 1

Legend
(50) A/Trans Case Assembly
(51) A/Trans Fluid Pressure Test Hole Plug
(53) Transmission Case Cover Locator Pin
(55) A/Trans Fluid Check Bali
(56 InputShaft Support
(57 InputShaft Support Bolt
(58vvv3-5—Reverseand 4—5—6 Clutch Fluid
Seal Ring
(59) Drive Link Lube Fluid Seal
(50) Drive Link Lube Scoop
1891279
(61) Front Differential Carrier Baffle Bolt
(62) Front Differential Carrier Baffle
(63) Oil Level Plug
(64) Drain Plug
(65) Drive Shaft Oil Seal Assembly
(66) Control Valve Body Locator Pin
(67) 1—2-3-4and Low Reverse Clutch Fluid
Passage Seal
(68) Drive Link Lube Fluid Seal

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Automatic Transmission - 6T30/6T40/6T45/6T50 (MH8, MH9) 17-37

Transmission Case Assembly —6T40/6T45/6T50 - Gen 2

2552202
Legend
(50)A/Trans Case Assembly (61) Front Differential Carrier Baffle Bolt
(51)A/Trans Fluid Pressure Test Hole Plug (62) Front Differential Carrier Baffle
(53)Transmission Case Cover Locator Pin (63) Oil Level Plug
(55)A/Trans Fluid Check Bali (64) Drain Plug
(56)InputShaft Support (65) Drive Shaft Oil Seal Assembly
(57)input Shaft Support Bolt (66) Control Valve Body Locator Pin
(58)3—5—Reverse and 4-5-6 Clutch Fluid Seal (67) 1—2—3-4 and Low Reverse Clutch Fluid
Ring (Qty:3) Passage Seal
(59) Drive Link Lube Fluid Seal (68) Drive Link Lube Fluid Seal
(60) Drive Link Lube Scoop

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
‘17=38 Automatic Transmission - 6T30/6T40/6T45/6T50 (MH8, MH9)

Torque Converter and Fluid Pump Housing Assembly— 6T30

F-.A
....W
M.“
mm
\-..»
#W
2
.-2.

2202183
Legend MW
WW
..
(200) AlTrans Fluid Pump Bolt (206) Front Differential Ring Gear Retainer
(201) A/Trans Fluid Pump Assembly (207) Front Differential Ring Gear
(202) Torque Converter and Differential (208) Torque Converter and Differential Housing
Housing Seal (209) Front Wheel Drive Shaft Oil Seal Assembly
(203) AlTrans Fluid FilterAssemny (210) A/Trans Fluid Filter Seal
(204) Front Differential Carrier Baffle Bolt (233) Front Differential Carrier Bearing Assembly
(205) Front Differential Carrier Baffle

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
 Automatic Transmission =6T30/6T40/6T45/6T50 (MH8, MH9) 17-39

Torque Converter and Fluid Pump Housing Assembly— 6T40I6T45/6T50

200

2395537
Legend
(200) A/Trans Fluid Pump Bolt (205) Front Differential Carrier Baffle
(201) A/Trans Fluid Pump Assembly (206) Front Differential Ring Gear Retainer
(202) Torque Converter and Differential (207) Front Differential Ring Gear
Housing Seal (208) Torque Converter and Differential Housing
(203) AlTrans Fluid Filter Assembly (209) Front Wheel Drive Shaft Oii Seal Assembly
(204) Front Differential Carrier Baffle Bolt

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
17-40 Automatic Transmission - 6T30/6T40/6T45/6T50 (MH8, MH9)

Drive Link Assembly

1891282
Legend
(50) A/Trans Case (226) Drive Sprocket Thrust Washer
(220) Park Gear Retainer Ring (227) Drive Sprocket Retainer Ring
(221) Park Gear (228) Driven Sprocket Bearing Assembly
(222) Output Carrier Transfer Drive Gear Hub (229) Driven Sprocket
(223) Drive Sprocket Bearing Assembly (230) Final Drive Sun Gear
(224) Drive Sprocket (232) Differential Carrier Assembly
(225) Drive Link Assembly (233) Front Differential Carrier Bearing Assembly

2013
-Sonic
(US/Canada)
Sen/ice
Manual
(5377994)
 Automatic Transmission . 8T30/6T40/6T45/6T50 (MH8, MH9) 1741

Oil Pump Assembly— 6T30

318

2202190
Legend
(300) Torque Converter Fluid Seal Retainer (311) Torque Converter Clutch Blowoff Ball Valve
(301) Torque Converter Fluid Seal Assembly Spflng
(302) AlTrans Fluid Pump Cover Bolt (312) Torque Converter Clutch Control Valve
(303) AlTrans Fluid Pump Body (313) Torque Converter Clutch Control Valve
(304) Pump Blowoff Ball Valve Spfing
(305) Pump Blowoff Valve Spring (314) Torque Converter Clutch Control Valve
(306) Pressure Regulator Valve Bore Plug Retainer Spring Retainer
(307) Pressure Regulator Valve Bore Plug (315) A/Trans Fluid Pump Drive Gear
(308) Pressure Regulator Valve Spring (316) A/Trans Fluid Pump Driven Gear
(309) Pressure Regulator Valve (318) A/Trans Fluid Pump Cover Assembly
(310) Torque Converter Clutch Blowoff Ball Valve (319) Torque Converter Fluid Seal Assembly
(320) A/Trans Fluid Pump Cover Bolt

2013
—Sonic
(US/Canada)
Service
Manual
(5377994)
1742 Automatic Transmission - 6T30/6T40/6T45/6T50 (MH8, MH9)

Oil Pump Assembly— 6T40I6T45/6T50— Gen 1

318

1891283
Legend
(300) Torque Converter Fluid Seal Retainer (311) Torque Converter Clutch Blowoff Ball Valve
(301) Torque Converter Fluid Seal Assembly Spring
(302) A/Trans Fluid Pump Cover Bolt (312) Torque Converter Clutch Control Valve
(303) AlTrans Fluid Pump Body (313) Torque Converter Clutch Control Valve
(304) Pump Blowoff Ball Valve Spring
(305) Pump Blowoff Valve Spring (314) Torque Converter Clutch Control Valve
(306) Pressure Regulator Valve Bore Plug Retainer Spring Retainer ,
(307) Pressure Regulator Valve Bore Plug (315) A/Trans Flufd Pump Drive Gear
(308) Pressure Regulator Valve Spring (316) A/Trans Flufd Pump Driven Gear
(309) Pressure Regulator Valve (318) A/Trans F|u1dPump Qover Assembly
(310) Torque Converter Clutch Blowoff Ball Valve (319) Torque Converter FIundSeal Assembly

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Automatic Transmission —6T30/6T40/6T45/6T50 (MH8, MH9) 1743

Oil Pump Assembly— 6T40I6T45/6T50— Gen 2

318

2552614
Legend
(300) Torque Converter Fluid Seal Retainer (311) Torque Converter Clutch Blowoff Ball Valve
(301) Torque Converter Fluid Seal Assembly Spflng
(302) A/Trans Fluid Pump Cover Bolt (312) Torque Converter Clutch Control Valve
(303) AlTrans Fluid Pump Body (313) Torque Converter Clutch Control Valve
(304) Pump Blowoff Ball Valve Spflng
(305) Pump Blowoff Valve Spring (314) Torque Converter Clutch Control Valve
(306) Pressure Regulator Valve Bore Plug Retainer Spring Retainer
(307) Pressure Regulator Valve Bore Plug (315) A/Trans Fluid Pump Drive Gear
(308) Pressure Regulator Valve Spring (316) A/Trans Fluid Pump Driven Gear
(309) Pressure Regulator Valve (318) A/Trans Fluid Pump Cover Assembly
(310) Torque Converter Clutch Blowoff Ball Valve (319) Torque Converter Fluid Seal Assembly

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
1744 Automatic Transmission - 6T30/6T40/6T45I6T50 (MH8, MH9)

Auxiliary Fluid Pump and Hybrid Components — Hybrid Models

356 355
77‘7“~1:S!§Sr””-
357
358

350

352

Legend
(350) A/Trans Auxiliary Fluid Pump Outlet (363)
Bolt (Qty:4) (364)
(351) A/Trans Auxiliary Fluid Pump Outlet Pipe (365)
Assembly .. . _ (366)
(352) AlTrans Auxmary FIUIdPump Outlet P196 (367)
Seal Assembly
(353) AlTrans Auxiliary Fluid Pump Assembly
(354) A/Trans Auxiliary Fluid Pump Bolt
(355) Pressure Regulator Valve Spring Retainer
(356) Pressure Regulator Valve Spring Spacer
(357) Pressure Regulator Valve Spring
(358) Pressure Regulator Valve
(359) A/Trans Auxiliary Fluid Pump Cover
(360) AlTrans Auxiliary Fluid Pump Cover
Hoie Plug
(361) A/Trans Auxiliary Fluid Pump Gasket
(362) AlTrans Auxiliary Fluid Pump Seal
2552230
AlTrans Auxiliary Fluid Pump Cover Seal
A/Trans Auxiliary Fluid Pump Outer Rotor
A/Trans Auxiliary Fluid Pump Inner Rotor
A/Trans Auxiliary Fluid Pump Body
AlTrans Auxiliary Fluid Pump Motor Cover
Seal _ O-ring
A/Trans Auxiliary Fluid Pump Motor
Assembly
A/Trans Auxiliary Fluid Pump (Pump to
Motor) Bolt (Qty:4)
Torque Converter and Differential Housing
A/Trans Auxiliary Fluid InletPump Seal
AlTrans Fluid Pump Assembly
A/Trans Fluid Trough Check Bail
AlTrans Case

2013
—
Sonic
(US/Canada)
Service
Manual
(5377994)
 Automatic Transmission . 6T30/6T40/6T45/6T50 (MH8, MH9) 17-45

Control Valve Body Assembly (1 of 2 —Gen 1)

400

402

403

405

1891285
Legend
(400) Control Valve Body Bolt (403) Channel Plate to Valve Body Spacer Plate
(401) Control Solenoid Valve Support Assembly
(402) Valve Channel Plate (404) Control Valve Body Bail Check Valve
(405) Control Valve Body Assembly

.....W
“M
3W.._Ww..w...w.m.,
“N.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
17-46 Automatic Transmission - 6T30/6T40l6T45/6T50 (MH8, MH9)

Control Valve Body Assembly (2 of 2 —Gen 1)

Legend
(410) Reverse and 4—5—6 Clutch Regulator Valve
Spfing
(411) Reverse and 4—5-6Clutch Regulator Vaive
(412) Clutch Valve Bore Plug
(413) Valve Spring Retainer
(414) 1-2-3—4Clutch Boost Valve
(415) 1—2—3-4 Clutch Boost Valve Spring
(416) 1—2-3-4Clutch Regulator Valve Spring
(417) 1—2—3—4 Clutch Regulator Valve
(418) 2—6Clutch Regulator Valve Spring
(419) 2—6Clutch Regulator Valve
(420) 3—5-ReverseClutch Regulator Valve Spring
(421) 3—5-ReverseClutch Regulator Valve
(422) Clutch Piston Dam Feed Regulator Valve
1891288
(423) Clutch Piston Dam Feed Regulator Valve
Spflng
(424) Torque Converter Clutch Regulator Apply
Valve Spring
(425) Torque Converter Clutch Regulator Apply
Valve
(426) Torque Converter Clutch Regulator Apply
Shuttle Valve
(427) Clutch Select Valve Spring
(428) Clutch Select Valve
(429) Default Override Shuttle Valve
(430) Actuator Feed Limit Valve
(431) Actuator Feed Limit Valve Spring
(432) Manual Valve
(433) Control Valve Body Assembly

,_..’—
m».
“M.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Automatic Transmission - 6T30/6T40/6T45/6T50 (MH8, MH9) 17-47

Control Valve Body Assembly (1 of 2 —Gen 2)

2552205
Legend
(400) Control Valve Body Bolt (406) Control Valve Body Spacer Plate
(401 Control Solenoid Valve Support Retainer (Qty:2)
(402 Vaive Channel Plate (407) Actuator Feed Accumulator Spring (Qty:5)
"2*“ (403VVV
Channel Plate to Valve Body Spacer Plate (408) Actuator Feed Accumulator Piston (Qty:5)
Assembly (409) Variable Hi and 2—3—4
Clutch Housing
(404) Control Valve Body Bail Check Valve (Qty26) Valve Ball
(405) Control Valve Body Assembly (434) Control Valve Channel Plate Ball Spring
Assembly

,-4
2......“
MW

2013
—Sonic
(US/Canada)
Service
Manual
(5377994)
17-48 Automatic Transmission - 6T30/6T40/6T45/6T50 (MH8, MH9)

Control Valve Body Assembly (2 of 2 —Gen 2)

Le end
"(1410)Low—Reverseand 4-5-6 Clutch Regulator
Valve Spring
(411) Low—Reverseand 4-5—6Clutch Regulator
Valve
(412) Clutch Valve Bore Plug
(413) Valve Spring Retainer
(414) 1-2-3-4 Clutch BoostVaIve
(415) 1—2-3-4Clutch Boost Valve Spring
(416) 1-2-3-4 Clutch Regulator Vaive Spring
(417) 1—2—3—4 Clutch Regulator Valve
(418) 2-6 Clutch Regulator Valve Spring
(419) 2—6Clutch Regulator Valve
(420) 3-5-Reverse Clutch Regulator Valve Spring
(421) 3-5-Reverse Clutch Regulator Valve
(422) Default Override Valve
(423) Defualt Override Valve Spring
(424) Torque Converter Clutch RegulatorAppiy
Vaive Spring
2552207
(425) Torque Converter Clutch Regulator Apply
Vaive
(426) Torque Converter Clutch Regulator Apply
Shuttle Vaive
(427) Clutch Select Valve Spring
(428) Clutch Select Valve
(429) Clutch Select (Shuttle) Vaive
(430) Actuator Feed Limit Valve
(431) Actuator Feed Limit Valve Spring
(432) Manual Valve
(433) Control Valve Body Assembly
(435) Control Valve Body Bore Plug Retainer
(436) Low-Reverse and 4-5-6 Clutch Boost Valve
(437) Low-Reverse and 4-5-6 Clutch Boost Valve
Spring
(438) 3-5 Reverse Clutch Regulator (Shuttle)Vaive

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Automatic Transmission - 6T30/6T40/6T45/6T50 (MH8, MH9) 17-49

3—5 Reverse Clutch Assembly —Gen 1

500

1891289
Legend
(500) AlTrans InputShaft Speed Sensor Reiuctor (506) 3—5-ReverseClutch Piston Dam Seal
Wheel Retainer Ring (507) 3-5-Reverse Clutch Apply Plate
(501) A/Trans InputShaft Speed Sensor Reluctor (508) 3—5—Reverse Clutch Plate
Wheel (509) 3-5-Reverse Clutch (w/Friction Material)
(502) 3-5-Reverse Clutch Piston Plate Assembly
(503) 3—5—Reverse Clutch Piston Return Spring (510) 3-5-Reverse Clutch Backing Plate
Assembly (511) 3~5~ReverseClutch Backing Plate
(504) 3-5-Reverse Clutch Piston Inner Seal Retainer Ring
(505) 3—5-ReverseClutch Piston Inner Seal

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
17-50 Automatic Transmission - 6T30/6T40/6T45/6T50 (MH8, MH9)

3—5 Reverse Clutch Assembly —Gen 2

2552211
Legend
(500) AlTrans InputShaft Speed Sensor Reluctor (506) 3-5-Reverse Clutch Piston Dam Seal
Wheel Retainer Ring (507) 3-5—ReverseClutch Apply Plate
(501) A/Trans InputShaft Speed Sensor Reluctor (508) 3-5-Reverse Clutch Plate
Wheel (509) 3-5—ReverseClutch (w/Friction Material)
(502) 3-5-Reverse Clutch Piston Plate Assembly
(503) 3-5—ReverseClutch Piston Return Spring (510) 3—5—Reverse Clutch Backing Plate
Assembly (511) 3-5—ReverseClutch Backing Plate
(504) 3—5-ReverseClutch Piston inner Seal Retainer Ring
(505) 3-5—ReverseClutch Piston inner Seal

WW
2
...

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
._4.~
~42
«...
 Automatic Transmission - 6T30/6T40/6T45/6T50 (MH8, MH9) 17-51

4—5—6 Clutch Assembly— Gen 1

519
518

517 ( /

”“3“

(515) Turbine Shaft Retainer Ring
(516) 3—5-Reverseand 4-5-6 Clutch Housing
Assembly
) Turbine Shaft
) 4—5-6Clutch Piston Outer Seal
) 4—5-6Clutch Piston Outer Seal
) 4—5-6Clutch Piston
(521) 4-5-6 Clutch Piston InnerSeal
) 4—5-6Clutch Piston Return Spring Assembly
) 4-5-6 Clutch Piston Fluid Dam Assembly
) 4—5-6Clutch Piston Fluid Dam Retainer Ring
1591290
(525) 4—5-6Clutch (Waved) Plate
(526) 4—5—6 Clutch Apply Plate
(527) 4—5—6 Clutch (w/Friction Material) Plate
Assembly
(528) 4—5—6 Clutch Plate
(529) 4—5-6Clutch Backing Plate
(530) Reaction Carrier Hub Thrust Bearing
Assembly
(531) Reaction Carrier Hub Assembly
(532) 4-5-6 Clutch Backing Plate Retainer Ring

,..W...
-1
.2....~,_,._
W‘_.4...
._<W,

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
17-52 Automatic Transmission - 6T30/6T40/6T45/6T50 (MH8, MH9)

4—5—6 Clutch Assembly- Gen 2

_2_.
.W
.

Legend
(515) Turbine Shaft Retainer Ring
(516) 3-5—Reverseand 4-5-6 Clutch Housing
Assembly
(517) Turbine Shaft
(518) 4-5-6 Clutch Piston Outer Seal
(519) 4—5-6Clutch Piston Outer Seal
(520) 4-5—6Clutch Piston
(521) 4—5-6Clutch Piston InnerSeal
(522) 4-5—6Clutch Piston Return Spring Assembly
(523) 4—5-6Clutch Piston Fluid Dam Assembly
2552216
(524) 4-5—6Clutch Piston Fluid Dam Retainer Ring
(527) 4-5—6Clutch (w/FrictionMaterial) Plate
Assembly Gen 1 (Qty:4), Gen 2 (Qty:5)
(528) 4-5-6 Clutch Plate— Gen 1 (Qty:3), Gen
2 (Qty:5)
(529) 4-5-6 Clutch Backing Plate
(530) Reaction Carrier Hub Thrust Bearing
Assembly 1
(531) Reaction Carrier HUb Assembly
(532) 4-5-6 ClutCh Backing Plate Retainer Ring

NW.
.W4M
2m..
.__.
..

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
 Automatic Transmission =6T30/6T40/6T45/6T50 (MH8, MH9) 17=53

2—6, Low and Reverse and 1—2—3—4Clutch Plate Assemblies —Gen 1

541
542
54. ©®
540

1891291
Legend
(50) A/Trans Case (547) Low and Reverse Clutch Apply (Waved)
(535) 2-6 Clutch Piston Assembly Plate
(536) 2-6Clutch Spring (548) Low and Reverse Clutch Spring Retainer
(537) 2—6Clutch Spring Retainer Ring (549) Low and Reverse Clutch Spring
(538) 3-5-Reverse and 4-5-6 Clutch Housing (550) Low and Reverse Clutch Piston
Thrust Bearing (551) Low and Reverse and 1—2—3—4 Clutch
(539) 3-5-Reverse and 4-5-6 Clutch Housing Housing
Assembly (552) 1-2—3-4Clutch Piston
(540) 2-6 Clutch Apply (Waved) Plate (553) 1-2-3—4Clutch Spring
(541) 26 Clutch Plate (554) 1-2-3-4 Clutch Piston Retainer
(542) 2-6 Clutch (w/Friction Material) Plate (555) Output Sun GearAssembly
Assembly (556) Output Sun Thrust Bearing Assembly
(543) Low and Reverse Clutch Assembly (557) 1—2-3—4 Clutch (Waved) Plate
(544) Low and Reverse Clutch Backing Plate (558) 1—2-3—4 Clutch Plate -
(545) Low and Reverse Clutch (w/Friction Material) (559) 1—2—3—4 Clutch (w/Friction Materiai) Plate
Plate Assembly Assembly
(546) Low and Reverse Clutch Plate (560) 1—2—3—4 Clutch Backing Plate

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
17-54 Automatic Transmission - 6T30/6T40I6T45I6T50 (MH8, MH9)
(561) 1—2-3-4Clutch Backing Plate Retainer Ring

2—6, Low and Reverse and 1—2—3—4Clutch Plate Assemblies —Gen 2

2552222
Legend
(50) A/Trans Case (546) Low and Reverse Clutch Plate (Qty:3)
(535) 2-6 Clutch Piston Assembly (547) Low and Reverse Clutch Apply (Waved)
(536) 2-6 Clutch Spring Plate
(537) 2-6 Clutch Spring Retainer Ring (548) Low and Reverse Clutch Spring Retainer
(538) 3-5-Reverse and 4-5-6 Clutch Housing (549) Low and Reverse Clutch Spring
Thrust Bearing (550) Low and Reverse Clutch Piston
(539) 3-5—Reverseand 4—5—6 Clutch Housing (551) Low and Reverse and 1-2-3-4 Clutch
Assembly Housing
(540) 2-6 Clutch Apply (Waved) Plate (552) 1—2—3-4 Clutch Piston
(541) 2—6Clutch Plate (Qty:2) (553) 1-2-3-4 Clutch Spring
(542) 2-6 Clutch (w/Friction Material) Plate (554) 1—2-3—4 Clutch Piston Retainer
Assembly (Qty:2) ' M00191 Dependent ' (555) Output Sun Gear Assembly
(543) LOWand Reverse ClUtChAssembly (556) Output Sun Thrust Bearing Assembly
(544) Low and Reverse Clutch Backing Plate (557) 1-2—3-4Clutch (Waved) Plate
(545) Low and Reverse Clutch (w/Friction Material) (558) 1-2-3-4 Clutch Plate (Qty;2)
Plate Assembly (Qty:3)
.,1
...
...H
2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Automatic Transmission . 6T30/6T40/6T45/6T50 (MH8, MH9) 17-55
(559) 1-2-3-4 Clutch (w/Friction Material) Plate (561) 1—2-3—4
Clutch Backing Plate Retainer Ring
Assembly (Qty:2)
(560) 1—2—3-4 Clutch Backing Plate

Input, Output and Reaction Gearsets— 6T30/6T40

2395536
Legend
(565) Reaction Sun Gear Thrust Bearing Assembly (570) InputCarrier Assembly
(566) Reaction Sun Gear Assembly (571) InputSun Gear
(567) Reaction Carrier Assembly (572) InputSun Gear Thrust Bearing Assembly
(568) InputCarrier Thrust Bearing Assembly (573) Output Carrier Thrust Bearing Assembly
(569) InputSun Gear Thrust Bearing Assembly (574) Output Carrier Assembly

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
17:56 Automatic Transmission - 6T30/6T40/6T45/6T50 (MH8, MH9)

Input, Output and Reaction Gearsets— 6T45/6T50

1891293
Le end
9(1565)Reaction Sun Gear Thrust Bearing Assembly (570) InputCarrier Assembly
(566) Reaction Sun Gear Assembly (571) InputSun Gear
(567) Reaction CarrierAssembly (572) input Sun Gear Thrust Bearing Assembly
(568) input Carrier Thrust Bearing Assembly (573) Output Carrier Thrust Bearing Assembly
(569) InputSun Gear Thrust Bearing Assembly (574) Output CarrierAssembly

2013
—
Sonic
(US/Canada)
Service
Manual
(5377994)
 Automatic Transmission - 6T30/6T40/6T45/6T50 (MH8, MH9) 1 7—57

Front Differential Carrier Assembly (2 Pinion)

580

1891295
Legend
(580) Differential Sun Gear t0 Differential Housing (587) Front Differential Pinion Gear Shaft
Bearing Assembly (588) Front Differential Pinion Gear Shaft Pin
(581) Final Drive Retainer (589) Front Differential Pinion Gear Thrust Washer
(582) Differential Carrier Assembly (590) Front Differential Pinion Gear
(583) Final Drive Pinion Pin (591) Front Differential Side Gear Thrust Washer
(584) Final Drive Innerand Outer Washer (592) Front Differential Side Gear
(585) Final Drive Roller
(586) Pinion Final Drive Gear

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
17-58 Automatic Transmission - 6T30/6T40/6T45/6T50 (MH8, MH9)

Front Differential Carrier Assembly (4 Pinion)

702
709
704 708 l
E _| 705 /

| 707 fl 7
I 706 ©%

I / Q
700

\299
704

@562 \6/

714
715

2369197
Legend
(700) Front Differential Pinion Gear Shaft (709) Front Differential Carrier Cover Bolts
(701) Differentiai Carrier Assembly (710) Front Differential Pinion Gear Shaft Washer
(702) Front Differential Pinion Gear Shaft (711) Front Differential Drive Pinion Gear
(703) Front Differential Pinion Gear Shaft (712) Front Differential Carrier Pinion Gear Bearing
(704) Front Differential Pinion Thrust Washer ROHBFS
(705) Front Differential Pinion Gear (713) Front Differential Pinion Gear Shaft Pin
(706) Front Differential Side Gear (714) Front Differential Pinion Gear Shaft Retainer
(707) Front Differential Side Gear Thrust Washer (715) Front Differential Bearing
(708) Front Differential Carrier Cover

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Automatic Transmission - 6T30/6T40/6T45/6T50 (MH8, MH9)

Park System Components

600

1891298
Legend
(50) AlTrans Case (606) Park Pawl Actuator Guide
(600) Park Pawl Shaft (607) Park Pawl Actuator Assembly
(601) Park Pawl Spring (608) Manual Shift Detent Lever Shaft
(602) Park Pawl (609) Manual Shift Detent (w/Shaft Position
(603) Park Pawl Actuator Guide Pin Switch) Lever Assembly
(604) Manual Shift Shaft Seat (610) Manual Shift Detent Lever Pin
(605) Park Pawl Actuator Guide Seal (611) Manual Shift Shaft Pin

2013
«Sonic
(US/Canada)
Service
Manual
(5377994)
17-60 Automatic Transmission - 6T30/6T40/6T45/6T50 (MH8, MH9)

Component Location

1O

II II II II
II II

17 16 15
6 7i \

12
\.
...W
«...
_.._
3

\
14 13
1891270
Legend
(1) Reaction Carrier Assembly (12) Differential Carrier Assembly
(2) Control Valve Body Assembly (13) Front Differential Ring Gear
(3) InputCarrier Assembly (14) Driven Sprocket
(4) Valve Channel Plate (15) 1—2—3—4 Clutch Assembly
(5) Output CarrierAssemny (16) Low and Reverse Clutch Assembly
(6) Park Gear (17) 2—6Clutch Assembly
(7) Control Solenoid (w/Body and TCM) Valve (18) 3—5Reverse Clutch Assembly
Assembly (19) 4—5—6Clutch Assembly
(8) Drive Link Assembly (20) A/Trans InputSpeed Sensor Assembly
(9) Drive Sprocket (21) Reaction Sun Gear Assembly
(10) Torque Converter Assembly
(11) A/Trans Fluid Pump Assembly

(US/Canada)
«Sonic
2013 (5377994)
Manual
Service
 Automatic Transmission - 6T30/6T40/6T45/6T50 (MH8, MH9) 17—61

Bushing, Bearing, and Washer Locations (Gen 1)

i__._-
|mai- .-
1' 31151911.
1111111
".1111 .. '1
1 ’1
' 1 51315" _
55%;" I

1751.1
1°-

Legend
(223)Drive Spocket Bearing Assembly
(226)Drive Sprocket Thrust Washer
(228)Drive Sprocket Bearing Assembly
(231) DifferentialSun Gearto Differential Housing
Bearing Assembly
(233) Front Differential Carrier Bearing Assembly
(530) Reaction Carrier Hub Thrust Bearing
Assembly
1891271
(538) 3—5—Reverseand 4—5—6Clutch Housing
Thrust Bearing
(556) Output Sun Thrust Bearing Assembly
(565) Reaction Sun GearThrust Bearing Assembly
(568) InputCarrier Thrust Bearing Assembly
(569) InputSun Gear Thrust Bearing Assembly
(572) InputSun Gear Thrust Bearing Assembly
(573) Output Carrier Thrust Bearing Assembly

2013
—Sonic
(US/Canada)
Service
Manual
(5377994)
17=62 Automatic Transmission - 6T30/6T40I6T45/6T50 (MH8, MH9)

Bushing, Bearing, and Washer Locations (Gen 2)

226

W
.W
.__.
.._.

W 223

.W,-
..
,-.,4
“(\M
\_
M
,__

f 233

Legend
(211) Front Differential Carrier Bearing
Assembly —AWD Models
223 Drive Spocket Bearing Assembly
226 Drive Sprocket Thrust Washer
228 Drive Sprocket Bearing Assembly
231 Differential Sun Gear to Differential Housing
AAAAVVVV
Bearing Assembly
(233) Front Differential Carrier Bearing Assembly
(530) Reaction Carrier Hub Thrust Bearing
Assembly
2608978
(538) 3—5—Reverseand 4—5—6Clutch Housing
Thrust Bearing
(556) Output Sun Thrust Bearing Assembly
(565) Reaction Sun Gear Thrust Bearing Assembly
(568) InputCarrier Thrust Bearing Assembly
(569) InputSun Gear Thrust Bearing Assembly
(572) InputSun Gear Thrust Bearing Assembly
(573) Output Carrier Thrust Bearing Assembly

WW
-l.“
.__.
_
t-
,..3.
w-mw
...

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
 Automatic Transmission - 6T30/6T40/6T45/6T50 (MH8, MH9) 17x63
Seal Locations (Gen 1)
Seal Locations (1 of 2)

552

202

301

—- 319
58 D

[j .

65 /
209
a 7/1
24 2 :

ufiu

1891273
Legend
(3) Control Valve Body Cover Gasket (504) 3—5—ReverseClutch Piston Inner Seal
(24) Torque Converter Housing Gasket (505) 3—5—ReverseClutch Piston Inner Seal
(58) 3—5—Reverseand 4—5—6Clutch Fiuid (506) 3—5—ReverseClutch Piston Dam Seal
Seal Ring (518) 4—5—6Clutch Piston Outer Seal
(65) Drive Shaft Oil Seal Assembly (519) 4—5—6Clutch Piston Outer Seal
(202) Torque Converter and Differential (521) 4—5—6Clutch Piston Inner Seal
Housmg Seal . _ (535) 2—6Clutch Piston Assembly
(209) Front Wheel DrIVeshaft 0118981Assembly (550) LOWand Reverse Clutch Piston
(301) Torque Converter Fluid Seal Assembly (552) 1_2_3_4 Clutch Piston
(319) Torque Converter Fluid Seal Assembly

2013
—
Sonic
(US/Canada)
Service
Manual
(5377994)
Automatic Transmission - 6T30/6T40I6T45l6T50 (MH8, MH9)

Seal Locations (2 of 2)

Control Valve Body Cover Hole Seal
AlTrans InputSpeed Sensor Assembly 0—
Ring Seal
Fili Cap Seal
AlTrans Fluid Pump Seal Assembly
Drive Link Lube Fluid Seal
1891274
(67) 1—2—3—4 and Low Reverse Clutch Fluid
Passage
(68) Drive Link Lube Fluid Seal
(604) Manual Shift Shaft Seal
(605) Park Pawl Actuator Guide Seal

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Automatic Transmission - 6T30/6T40/6T45/6T50 (MH8, MH9) 17-65

Bail Check Valve Locations (Gen 1)

1891275
Ball Check Valve Locations (Gen 1)
|.D. InputOil InputOil Output Oil
1 PS4 456 CL FD CSV2 Latch
2 35 Rev FD/Drive1—6 Drive1—6 35 Rev FD
3 35 Rev FD — 35 Rev FD
4 CompFD 35 Rev FD 35 Rev CL FD/ExhBF
5 Act FD LM — R1/456CL FD
6 Act FD LM — 35 Rev CL

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
17=66 Automatic Transmission - 6T30/6T40l6T45/6T50 (MH8, MH9)

Ball Check Valve Locations (Gen 2)

24.—

2608983

Ball Check Valve Locations (Gen 2)

I.D. InputOil InputOil OutputOil
1 Latch 456CL Latch
2 35 Rev CL FD Drive1—6 35 Rev CL FD/Drive1—6
3 35 Rev CL FD/Drive1—6 ~— 35 Rev CL FD/Drive1-6
4 Act FD LM ~— 35 Rev CL
5 Drive — Drive
6 Line AuxiliaryLine Line

w~.
.m..
WNW

2013
-Sonic
(US/Canada)
Sen/ice
Manual
(5377994)
 Automatic Transmission . 6T30/6T40l6T45/6T50 (MH8, MH9) 1767

Diagnostic Information and Procedures

DTC P057B-P057D

Diagnostic Instructions
- Perform the Diagnostic System Check - Vehicle
on page 6-66 prior to using this diagnostic
procedure.
~ Review Strategy Based Diagnosis on page 6-58
for an overview of the diagnostic approach.
- Diagnostic Procedure Instructions on page 659
provides an overview of each diagnostic category.
DTC Descriptors
DTC P057B: Brake Pedal Position Sensor Performance
DTC P057C: Brake Pedal Position Sensor Circuit Low Voltage
DTC P057D: Brake Pedal Position Sensor Circuit High Voltage
Diagnostic Fault Information

Open/High Signal
Circuit Short to Ground Resistance Short to Voltage Performance
Signal P057C P057C PO57D P057B
P0570
5 V Reference P057C P0651
P0651
Low Reference P057B P057D

Typical Scan Tool Data

Brake Pedal Position Sensor

Circuit | Short to Ground Open Short to Voltage
Operating Conditions: IgnitionON.
Brake Pedal Position Sensor ParameterNormal Range:0.25—4.75V
5 V Reference 0V 0V —-
Signal 0V 0V 5V
LowReference _ 5V _

CircuitlSystem Description circuit will vary from a voltage greater than 0.25 V when
the brake pedal is released to a voltage less than
The brake pedal position (BPP) sensor is part of the 4.75 V when the brake pedal is fully applied.
engine brake pedal override feature. The engine control
module (ECM) continuously monitors the vehicle speed For information on the Stop Lamps side of the BPP
and the position of the brake pedal. These two main Sensor, refer to Exterior Lighting Systems Description
inputs, along with other ECM inputs are used to and Operation on page 4—217.
determine if the vehicle is decelerating at the proper
Conditions for Running the DTC ‘
speed and rate with the brake pedal applied. When the
engine brake pedal override system is active, the ECM ' Ignitionvoltage is greater than 10 V.
reduces engine torque to assist in reducing vehicle - DTC runs continuously when above condition
speed. ‘ is met.
The BPP sensor is a six wire sensor, and is part of a
dual brake position sensor. One BPP Sensor is used for Conditions for Setting the DTC
the stop lamps and the other BPP Sensor is used for P057B
the engine brake pedal override feature. The BPP
Sensor for engine brake pedal override communicates ECM detects the BPP sensor signal is stuck in a range.
with the ECM. The ECM supplies a 5 V reference P057C
circuit, low reference circuit, and signal circuit to the
BPP sensor. The BPP sensor sends a voltage signal to ECM detects the BPP sensor voltage is less than
the ECM on the signal circuit. The voltage on the signal 0.25 V for 1 s.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
1768 Automatic Transmission - 6T30/6T40/6T45/6T50 (MH8, MH9)
P057D 4. Verify the scan tool Brake Pedal Position Sensor
ECM detects the BPP sensor voltage is greater than parameter voltage changes as the brake pedal is
4.75 V for 1 8. applied and displays less than 4.75 V when the
brake pedal is fully applied.
Action Taken When the DTC Sets =>If the voltage does not change, or is greater
- P057B, P057C, and P057D are Type A DTCs. than 4.74 V
. Engine torque is reduced to 50% of available Refer to CircuitlSystem Testing.
engine torque during brake torque management. U If the voltage changes and less than 4.75 V
- Brake torque management is active at 25 kPa 5. Verify the scan tool Brake Pedal Position Sensor
(3.7 PSI) of brake apply pressure. Learned Release Position parameter is within 0.1 V
of the Brake Pedal Position Sensor parameter
Conditions for Clearing the DTC
when the brake pedal is fully released.
P057B, P057C, and P057D are Type A DTCs =>If difference is greater than 0.1V
Reference Information Perform the Brake Pedal Position Sensor Learn
on page 17—164.
Schematic Reference
U If difference is 0.1 Vor less
- Exterior Lights Schematics on page 4—85 6. Verify the Brake Pedal Position Sensor parameter
Connector End View Reference transitions smoothly without any spikes or dropouts
when slowly applying and releasing the brake
- Component Connector End Views on page 11—269 pedaL
- lnline Harness Connector End Views on =>lf parameter does not transition smoothly or
page 11—465 has spikes or dropouts
Electrical Information Reference Refer to CircuitlSystem Testing.
- Circuit Testing on page 11—526 U lf parameter transitions smoothly and there are
- Connector Repairs on page 11—548 no spikes or dropouts
- Testing for IntermittentConditions and Poor 7. Operate the vehicle within the Conditions for
Connections on page 11—531 Running the DTC. You may also operate the
vehicle within the conditions that you observed
- Wiring Repairs on page 11-537 from the Freeze Frame/Failure Records data.
DTC Type Reference 8. Verify the DTC does not set.
Powertrain Diagnostic Trouble Code (DTC) Type =>If the DTC sets
Definitions on page 6—68 Refer to CircuitlSystem Testing.
Scan Tool Reference U If the DTC does not set
Control Module References on page 6—3for scan tool 9. All OK.
information
CircuitlSystem Testing
CircuitlSystem Verification Note: You must perform the CircuitlSystem Verification
1. Verify DTC P0641, P0651, P0697, or P06A3 is first.
not set. 1. lgnition OFF and all vehicle systems OFF,
=>If any of the DTCs are set disconnect the harness connector at the B22
Refer to Diagnostic Trouble Code (DTC) List - Brake Pedal Position Sensor. Itmay take up to
2 minutes for all vehicle systemsto power down.
Vehicle on page 6—69.
Note: All terminal references are for the vehicle
U If none of the DTCs are set harness brake pedal position sensor connector.
2. lgnition ON, transmission in Park, and service
brake pedal released. 2. Test for less than 10 0 between the low reference
circuit terminal 6 and ground.
3. Verify the scan tool Brake Pedal Position Sensor
parameter in the ECM displays greater than 0.25 V. :> If 10 Q or greater
=>lf 0.25 V or less 2.1. Disconnect the harness connector at the K20
Engine Control Module.
Refer to CircuitlSystem Testing.
2.2. Test for less than 2 Q in the low reference
U If greater than 0.25 V circuit end to end.
=>If2 Q or greater, repair the open/high resistance
in the circuit.
=>Ifless than 2 Q, replace the K20 Engine Control
Module.
U If less than 10 Q
3. lgnition ON.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Automatic Transmission
4. Test for 4.8—5.2V between the 5 V reference circuit
terminal 5 and ground.
2) If less than 4.8 V
4.1. lgnition OFF, disconnect the harness
connector at the K20 Engine Control Module.
4.2. Test for infinite resistance between the 5 V
reference circuit and ground.
=>Ifless than infinite resistance, repair the short to
ground on the circuit.
U lf infinite resistance.
4.3. Test for less than 2 Q in the 5 V reference
circuit end to end.
=>lf 2 Q or greater, repair the open/high resistance
in the circuit.
=>Ifless than 2 Q, replace the K20 Engine Control
Module.
If greater than 5.2 V
4.1. lgnition OFF, disconnect the harness
connector at the K20 Engine Control Module,
ignition ON.
4.2. Test for less than 1 V between the 5V
reference circuit and ground.
=>If 1 V or greater, repair the short to voltage on
the circuit.
=>Ifless than 1 V, replace the K20 Engine Control
Module.
lf between 4.8—5.2V
Verify the scan tool Brake Pedal Position Sensor '
parameter is less than 0.25 V,
If 0.25 V or greater
5.1. lgnition OFF, disconnect the harness
connector at the K20 Engine Control Module,
ignition ON.
5.2. Test for less than 0.25 V between the signal
circuit terminal 4 and ground.
=>lf 0.25 V or greater, repair the short to voltage
on the circuit.
= 6T30/6T40/6T45/6T50 (MH8, MH9) 1769
=>Ifless than 0.25 V, replace the K20 Engine
Control Module.
If less than 0.25 V
install a 3 A fused jumper wire between the signal
Circuit terminal 4 and the 5 V reference circuit
terminal 5.
Verify the scan tool Brake Pedal Position Sensor
parameter is greater than 4.8 V.
lf 4.8 V or less
7.1. lgnition OFF, remove the jumper wire, and
disconnect the harness connector at the K20
Engine Control Module.
7.2. Test for infinite resistance between the signal
circuit terminal 4 and ground.
=>If less than infinite resistance, repair the short to
ground on the circuit.
U Ifinfinite resistance.
7.3. Test for less than 2 Q in the signal circuit end
to end.
=>lf 2 Q or greater, repair the open/high resistance
in the circuit.
:9 Ifless than 2 Q, replace the K20 Engine Control
Module.
U If greater than 4.8 V
8. Replace the B22 Brake Pedal Position Sensor.
Repair Instructions
Perform the Diagnostic Repair Verification on
page 6-92 after completing the repair.
Brake Pedal Position Sensor Replacement on
page 4-186
Perform the Brake Pedal Position Sensor Learn
on page 17-164 following the replacement of the
ECM or BPP sensor, or any repair that effects the
BPP sensor alignment.
Control Module References on page 6-3 for
Engine Control Module replacement,
programming and setup.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
17-70 Automatic Transmission - 6T30/6T40/6T45/6T50 (MH8, MH9)

DTC P0601, P0603, P0604, or P062F

Diagnostic Instructions
- Perform the Diagnostic System Check - Vehicle
on page 6—66prior to using this diagnostic
procedure.
- Review Strategy Based Diagnosis on page 6-58
for an overview of the diagnostic approach.
- Diagnostic Procedure Instructions on page 6-59
provides an overview of each diagnostic category.
W,M
—
. ._
DTC Descriptors
Note: DTCs P0601, P0603, P0604 or P062F could set
in other control modules. Verify the DTCs are set in the
transmission control module (TCM).
DTC P0601: Control Module Read Only Memory Performance
DTC P0603: Control Module Long Term Memory Reset
DTC P0604: Control Module Random Access Memory Performance
DTC P062F: Control Module Long Term Memory Performance

CircuitlSystem Description ° TCM commands the high side driver OFF.

This is an internal fault detection ofthe control solenoid - TCM defaults the transmission to 4th gear and
valve assembly. This‘fault is handled inside the control reverse. ‘
solenoid valve assembly and no external circuits are ' Torque management is enabled.
involved. - TCM inhibits neutral idle.
Conditions for Running the DTC - TCM inhibits Tap Up/Down function.
- TCM inhibits manual shifting offonNard gears.
P0601 or P0604
Runs continuously when TCM is powered up. Conditions for Clearing the DTC
P0601, P0603, P0604, and P062F are Type A DTCs.
P0603 ,
One time at TCM power up. Reference Information
P062F Schematic Reference
One time at TCM power down. Automatic Transmission Controls Schematics on
page 17—30
Conditions for Setting the DTC
Connector End View Reference
P0601 "
0 Component Connector End Views on page 11-269
TCM has detected a read only memory (ROM)
checksum error 5 times. - lnline Harness Connector End Views on
page 11-465
P0603
Description and Operation
TCM has detected a non-volatile memory checksum
error at TCM powerup. - Transmission General Description on page 17—317
P0604 ' Transmission Component and System Description
on page 17-318
TCM has detected a random access memory (RAM)
. Electronic Component Description on
test error 5 times.
page 17-319
P062F
Electrical Information Reference
TCM has detected a non—volatilememory error during
power—down. 0 Circuit Testing on page 11-526
- Connector Repairs on page 11—548
Action Taken When the DTC Sets - Testing for IntermittentConditions and Poor
- P0601, P0603, P0604, and P062F are Connections on page 11-531
Type A DTCs. 1 Wiring Repairs on page 11-537
- TCM commands maximum line pressure.
DTC Type Reference
’ TCM forces the torque converter
clutch (TCC) OFF. Powertrain Diagnostic Trouble Code (DTC) Type
0 TCM inhibits TCC engagement. Definitions on page 6—68
- TCM freezes transmission adaptive functions.

2013
-Sonic
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Service
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 Automatic Transmission —6T30/6T40/6T45/6T50 (MH8, MH9) 17:71
Scan Tool Reference 4. Operate the vehicle within the Conditions for
Running the DTC. You may also operate the
Control Module References on page 6-3 for scan tool vehicle within the conditions that you observed
information from the Freeze Frame/Failure Records data.
CircuitlSystem Verification Verify the DTC does not set.
Caution: Before programming a control module, the if the DTC sets
following must be observed, or control module damage Replace the Q8 Control Solenoid Valve
may occur: Assembly.
The TlS terminal, MDI, andlor scan tool must have U If the DTC does not set
the latest software. 6. All OK.
The vehicle battery must be fully charged. The
battery voltage should be between 12—14volts. Repair Instructions
The TIS terminal, MDI, and/or scan tool Perform the Diagnostic Repair Verification on
-44. connections must be secure.
.vww.MM_._.—M~
W._
.m‘
< page 6-92 after completing the repair.
A battery charger must NOT be connected to the Perform the Transmission Adaptive Values Learn
battery when programming a control module. on page 17—163followingall transmission repairs.
. lgnition OFF and all vehicle systems OFF. Itmay Control Module References on page 6—3for
take up to 2 minutes for all vehicle systems to Control Solenoid Valve Assembly replacement,
power down. programming and setup
lgnition ON.
Verify that DTC P0601, P0603, P0604, or P062F is
not set.
If any of the DTCs are set
Replace the Q8 Control Solenoid Valve
Assembly.
if none of the DTCs are set

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
17:72 Automatic Transmission - 6T30/6T40I6T45/6T50 (MH8, MH9)

DTC P0634

Diagnostic Instructions
- Perform the Diagnostic System Check - Vehicle
on page 6—66prior to using this diagnostic
procedure.
- Review Strategy Based Diagnosis on page 6-58
for an overview of the diagnostic approach.
- Diagnostic Procedure Instructions on page 6-59
provides an overview of each diagnostic category.
DTC Descriptor
DTC P0634: Control Module Overtemperature

CircuitlSystem Description DTC Type Reference

The transmission control module (TCM) temperature Powertrain Diagnostic Trouble Code (DTC) Type
sensor is located inside of the control solenoid valve Definitions on page 6—68
assembly which has no serviceable components. The
TCM monitors the TCM sensor for over temperature Scan Tool Reference
protection. Control Module References on page 6—3for scan tool
Conditions for Running the DTC information
- TCM temperature is between 0°C (32°F) and CircuitlSystem Verification
240°C (464°F) for 0.25 seconds or greater. 1. lgnition ON.
~ DTC P0634 is not set. 2. Verify the scan tool Engine Coolant Temperature
- lgnition voltage is 9.0 volts or greater. parameter was less than 125°C (257°F)when DTC
set by reviewing the scan tool Freeze Frame/
Conditions for Setting the DTC Failure Records.
Condition 1 =>If 125°C (257°F) or greater
TCM has detected an internal temperature condition Refer to Engine Overheating on page 9-625.
greater than 144°C (291°F) for 5 seconds or greater. U If less than 125°C (257°F)
Condition 2 3. Verify the scan tool TCM Temperature parameter is
lgnition voltage is 18 volts or greater and the TCM less than 146°C (295°F).
temperature is greater than 50°C (122°F) for 2 seconds. =>If 146°C (295°F) or greater
Action Taken When the DTC Sets Replace the Q8 control solenoid valve
assembly.
- DTC P0634 is a Type A DTC.
U If less than 146°C (295°F)
- TCM limits the transmission to 5th gear and
reverse. 4. Verify correct fluid level and condition. Refer to
Transmission Fluid Level and Condition Check on
- TCM inhibits Tap Up/Down function. page 17—164.
° TCM enables torque management. 5. Clear the DTCs from the TCM using a scan tool.
- TCM shuts down. 6. Operate the vehicle within the conditions for
- TCM commands maximum line pressure. running and setting the DTC until normal engine
temperature is reached.
Conditions for Clearing the DTC
7. Verify the scan tool Transmission Fluid
DTC P0634 is a Type A DTC. Temperature parameter is less than 140°C (284°F)
and DTC P0634 did not set.
Diagnostic Aids
=>If 140°C (284°F) or greater
During a road test, the TCM temperature should
steadily increase to a normal operating temperature, Inspect the transmission cooling system for
and then stabilize. obstructions to the airflow of the radiator or
transmission due to debris, kinked or damaged
Reference Information transmission fluid lines, or damage to the
transmission cooler.
Description and Operation
=>Ifproblems with cooling system are found,
Electronic Component Description on page 17-319 for repair or replace as necessary.
control solenoid valve assembly information.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Automatic Transmission
=>if no problems are found, refer to Refer to
Transmission Fluid Cooler Flushing and Flow
Test on page 17—175.
If less than 140°C (284°F) and DTC P0634 set
Replace the Q8 control solenoid valve
assembly.
if less than 140°C (284°F) and DTC P0634 did
not set
. After performing the above steps, verify that the
DTC does not reset by operating the vehicle within
the Conditions for Running the DTC. You may also
operate the vehicle within the conditions you
observe from the Freeze Frame/Failure Records
data. Ifthe vehicle passes the CircuitlSystem
Verification procedure, refer to Testing for
IntermittentConditions and Poor Connections on
page 11—531.
- 6T30/6T40/6T45/6T50 (MH8, MH9) 17-73
Repair Instructions
Perform the Diagnostic Repair Verification on
page 6-92 after completing the repair.
Refer to Control Module References on page 6—3
for control solenoid valve assembly replacement,
programming and setup.
Perform the Transmission Adaptive Values Learn
on page 17-163 following all transmission related
repairs.
Before replacing the TCM, perform the Control
Solenoid Valve and Transmission Control Module
Assembly Inspection on page 17—158.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
17-74 Automatic Transmission - 6T30/6T40l6T45/6T50 (MH8, MH9)

DTC P0658 or P0659

Diagnostic Instructions
- Perform the Diagnostic System Check - Vehicle
on page 6—66prior to using this diagnostic
procedure.
- Review Strategy Based Diagnosis on page 6-58
for an overview of the diagnostic approach.
- Diagnostic Procedure Instructions on page 6-59
provides an overview of each diagnostic category.
DTC Descriptors
DTC P0658: Actuator High Control Circuit Group 1 Low Voltage
DTC P0659: Actuator High Control Circuit Group 1 High Voltage

CircuitlSystem Description P0659

The transmission control module (TCM) high side P0659 is a Type C DTC.
driver1 is located inside the control solenoid valve
assembly which has no serviceable components. The Conditions for Clearing the DTC
high side driver1 provides power to the TCM pressure - P0658 is a Type A DTC.
control solenoids and shift solenoids. . P0659 is a Type C DTC.
Conditions for Running the DTC Reference Information
P0658 Schematic Reference
- DTC P0658 is not set.
Automatic Transmission Controls Schematics on
' High side driver1 is enabled. page 17-30
- Runs continuously when above conditions
are met. Connector End View Reference

P0659 - Component Connector End Views on page 11-269

° DTC P0659 is not set. - lnline Harness Connector End Views on
page 11465
~ Runs one time when ignition transitions from OFF
to ON. Description and Operation
Conditions for Setting the DTC - Electronic Component Description on
page 17~319
P0658 - Transmission Component and System Description
TCM detects an internal open or short to ground in the on page 17—31 8
high side driver1 circuit for 1 s. - Transmission General Description on page 17—31
7
P0659 Electrical Information Reference
TCM detects an internal short to voltage on the high - Circuit Testing on page 11-526
side driver1 circuit for 1 8.
- Connector Repairs on page 11-548
Action Taken When the DTC Sets . Testing for IntermittentConditions and Poor
Connections on page 11—531
P0658
- Wiring Repairs on page 11-537
- P0658 is a Type A DTC.
- TCM turns the high side driver OFF. DTC Type Reference
- TCM commands all solenoids OFF. Powertrain Diagnostic Trouble Code (DTC) Type
- TCM commands the TCC OFF. Definitions on page 6—68
' TCM commands maximum line pressure. Scan Tool Reference
- TCM freezes transmission adaptive functions.
Control Module References on page 6-3 for scan tool
- TCM inhibits neutral idle. information
- TCM inhibits the Tap Up/Tap Down function.
Special Tools
o TCM inhibits manual shifting of forward gears.
- TCM defaults the transmission to 5th gear and DT—48616-10Adapter Harness
reverse. For equivalent regional tools, refer to Special Tools on
° TCM enables torque management. page 17-394.

2013
—
Sonic
(US/Canada)
Service
Manual
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 Automatic Transmission =6T30/6T40/6T45/6T50 (MH8, MH9) 17-75
CircuitlSystem Verification 3. Verify the resistance is within the specified range
for each solenoid listed in the Control Solenoid
1. lgnition ON.
Valve and Transmission Control Module Assembly
2. Verify the scan tool High Side Driver1 parameter Inspection on page 17-158.
displays On.
If the resistance is not within range
lf 0n is not displayed
Replace the Q8 Control Solenoid Valve
Refer to CircuitlSystem Testing. Assembly.
If On is displayed If the resistance is within range
Engine Running and gear selector lever in the Park Place the Q8 Control Solenoid Valve Assembly on
position. a Clean work surface near the transmission
Verify the scan tool parameters listed below do not assembly.
display malfunction. . Connect the DT—48616-10harness between the
.__.»w
m—wwr—
-.#
w
N
,NW - High Side Drvr1 th Short Gnd Test Status vehicle harness connector, and the 08 Control
- High Side Drvr1 th Open Test Status Solenoid Valve Assembly connector. lgnition ON.
- High Side Drvr1 th Short Volts Test Status . Verify the scan tool parameters listed below do not
display Malfunction.
lf Malfunction is displayed
- High Side Drvr1 th Short Gnd Test Status
Refer to CircuitlSystem Testing. 1 High Side Drvr1 th Open Test Status
If Malfunction is not displayed - High Side Drvr1 th Short Volts Test Status
Operate the vehicle within the Conditions for lf Malfunction is displayed
Running the DTC. You may also operate the
vehicle within the conditions that you observed Replace the Q8 Control Solenoid Valve
from the Freeze Frame/Failure Records data. Assembly.
Verify the DTC does not set. U If Malfunction is not displayed
=>If the DTC sets 7. All OK.
Refer to Circuit/System Testing. Repair Instructions
U If the DTC does not set Perform the Diagnostic Repair Verification on
7 All OK. page 6-92 after completing the repair.
Perform the Transmission Adaptive Values Learn
CircuitlSystem Testing on page 17-163 following all transmission repairs.
Note: You must perform the CircuitlSystem Verification Refer to Control Module References on page 6-3
first. for Control Solenoid Valve Assembly replacement,
1. lgnition OFF, remove the QB Control Solenoid programming and setup.
Valve Assembly.
2. Verify the Q8 Control Solenoid Valve Assembly is
not contaminated with any debris. Refer to Control
Solenoid Valve and Transmission Control Module
Assembly Inspection on page 17—158.
If contaminated
Repair as necessary.
If not contaminated

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
17:76 Automatic Transmission - 6T30/8T40I6T45/6T50 (MH8, MH9)

DTC P0667, P0668, or P0669

Diagnostic Instructions
- Perform the Diagnostic System Check - Vehicle
on page 6—66prior to using this diagnostic
procedure.
- Review Strategy Based Diagnosis on page 6—58
for an overview of the diagnostic approach.
- Diagnostic Procedure Instructions on page 6-59
provides an overview of each diagnostic category.
DTC Descriptors
DTC P0667: Control Module Temperature Sensor Performance
DTC P0668: Control Module Temperature Sensor Circuit Low Voltage
DTC P0669: Control Module Temperature Sensor Circuit High Voltage

CircuitlSystem Description Conditions for Setting the DTC

The transmission control module (TCM) temperature
sensor is located inside of the Control Solenoid Valve
Assembly which has no serviceable components. The
TCM temperature sensor provides the temperature of
the TCM. This temperature reading is used in various
shifting and diagnostic routines in the TCM software.
This fault is handled inside the TCM and no external
circuits are involved.
Conditions for Running the DTC
P0667
- DTI)PO101,PO102,P0103,P0106,P0101
P0108,P0171,P0172,P0174,P0175,P0201,
P0202,P0203,P0204,P0205,P0206,P0207,
P0208,P0300,P0301,P0302,P0303,P0304,
P0305,P0306,P0307,P0308,PO401,P042E,
P0658,P0667,P0668,P0669,P06AD,PO6AE,
P0712,PO713,PO716,PO717,PO722,P072&
P0962,P0963,P0966,P0967,P0970,P097L
P2150,P2720,P2721,P2729,orP2730is
ndsm.
- Engine torque signal is valid.
- lgnition voltage is 9—32V.
- Engine speed is 400—7,500RPM for 5 s.
- Throttle position signal is valid.
' Runs continuously when above conditions
are met.
P0668
' DTC P0668 is not set.
- Ignitionvoltage is 9—32V.
- Engine speed is 400-7,500 RPM for 5 s.
- Runs continuously when above conditions
are met.
P0669
- DTC P0669, P0716, P0717, P0722, or P0723 is
not set.
' lgnition voltage is 9-32 V.
- Engine speed is 400—7,500RPM for 5 s.
- Runs continuously when above conditions
are met,
P0667
~ TCM detects a 20—50°C(36—90°F)or greater
difference between the transmission fluid
temperature and TCM substrate temperature,
which depends on the average of the transmission
fluid temperature, TCM substrate temperature,
and TCM power up temperature.
- TCM detects a 8—10°C(14—18°F)or greater
difference between the TCM power up
temperature and TCM substrate temperature,
which depends on the average of the transmission
fluid temperature, TCM substrate temperature,
and TCM power up temperature.
- Above conditions have to be met for 5 min within a
6 min period.
P0668
TCM internal temperature is 254°C (489°F) or greater
for 1 min.
P0669
TCM internal temperature is —254°C(—425°F)or less
for 1min.
Action Taken When the DTC Sets
- P0667, P0668, and P0669 are Type B DTCS.
- TCM defaults the TCM substrate temperature to a
calculated temperature based on the TCM power
up temperature.
Conditions for Clearing the DTC
P0667, P0668, and P0669 are Type B DTCs.
Diagnostic Aids
The TCM temperature sensor is located inside of the
Control Solenoid Valve Assembly and its output should
resemble that of the transmission fluid temperature
sensor output. During a road test, the TCM temperature
should steadily increase to a normal operating
temperature, and then stabilize.
Reference Information
Schematic Reference
Automatic Transmission Controls Schematics on
page 17—30
2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Automatic Transmission - 6T30/6T40/6T45/6T50 (MH8, MH9) 17-77
Connector End View Reference 3. Verify the scan tool TCM Temperature parameter
increases greater than 2°C (3.6°F) after operating
' Component Connector End Views on page 11-269 the vehicle at 64 km/h (40 mph) for 10 min.
- lnline Harness Connector End Views on
=>if the temperature does not increase greater
page 11—465
than 2°C (3.6°F)
Description and Operation Replace the QB Control Solenoid Valve
- Transmission General Description on page 17—31
7 Assembly.
- Transmission Component and System Description U If the temperature increases greater than
on page 17—318 2°C (3.6°F) '
~ Electronic Component Description on 4. Verify the scan tool Transmission Fluid
page 17—31 9 Temperature and TCM Temperature parameters
are within 20°C (36°F) of each other.
Electrical information Reference
=>If the temperatures are not within 20°C (36°F)
- Circuit Testing on page 11-526 Replace the Q8 Control Solenoid Valve
' Connector Repairs on page 11—548 Assembly.
- Testing for IntermittentConditions and Poor U if the temperatures are within 20°C (36°F)
Connections on page 11—531
5. Operate the vehicle within the Conditions for
- Wiring Repairs on page 11-537 Running the DTC. You may also operate the
DTC Type Reference vehicle within the conditions that you observed
from the Freeze Frame/Failure Records data.
Powertrain Diagnostic Trouble Code (DTC) Type 6. Verify the DTC does not set.
Definitions on page 6-68
=>If the DTC sets
Scan Tool Reference
Replace the Q8 Control Solenoid Valve
Control Module References on page 6-3 for scan too Assembly.
information , U if the DTC does not set
CircuitlSystem Verification ’ 7. All OK.
1. lgnition ON. Repair Instructions
2. Verify the scan tool TCM Temperature parameter is Perform the Diagnostic Repair Verification on
between -254 and +254°C (.-425and +489°F). page 6-92 after completing the repair.
=>If not between -254 and +254°C (-425 and - Perform the Transmission Adaptive Values Learn
+489°F) on page 17-163 following all transmission repairs.
Replace the Q8 Control Solenoid Valve - Control Module References on page 6-3 for
Assembly. Control Solenoid Valve Assembly replacement,
U if between —254and +254°C (-425 and +489°F) programming and setup.

...-WM.W.
M
. M”

2013
«Sonic
(US/Canada)
Service
Manual
(5377994)
17-78 Automatic Transmission - 6T30/6T40l6T45/6T50 (MH8, MH9)

DTC P06AC, P06AD, or P06AE

Diagnostic instructions
- Perform the Diagnostic System Check —Vehicle
on page 6-66 prior to using this diagnostic
procedure.
- Review Strategy Based Diagnosis on page 6-58
for an overview of the diagnostic approach. -
- Diagnostic Procedure Instructions on page 6-59
provides an overview of each diagnostic category.
DTC Descriptors
DTC P06AC: Control Module Power Up Temperature Sensor Performance
DTC P06AD: Control Module Power Up Temperature Sensor Circuit Low Voltage
DTC P06AE: Control Module Power Up Temperature Sensor Circuit High Voltage

CircuitlSystem Description Conditions for Setting the DTC

The transmission control module (TCM) power up
temperature sensor is located inside of the Control
Solenoid Valve Assembly which has no serviceable
components. The TCM power up temperature sensor
provides the temperature of the TCM when the TCM
power is on. This temperature reading is used in
various shifting and diagnostic routines in the TCM
software. This fault is handled inside the TCM and no
external circuits are involved.
Conditions for Running the DTC
P06AC
- DTI2P0101,P0102,P0103,P0106,P0107
P0108,P0171,P0172,P0174,P0175,P020L
P0202,P0203,P0204,P0205,P0206,P0207,
P0208,P0300,P0301,P0302,PO303,P0304,
P0305,P0306,P0307,P0308,P0401,PO42E,
P0658,P0668,P0669,P06AC,P06AD,P06AE,
P0712,P0713,P0716,P0717,PO722,P072&
P0962,P0963,P0966,P0967,P0970,P097L
P2150,P2720,P2721,P2729,orP2730is
ndsa.
' Throttle position signal is valid.
- Engine speed is 400—7,500RPM for 5 s.
- lgnition voltage is 9—32V.
- Engine torque signal is valid.
- DTC runs continuously when the above conditions
are met.
P06AD
. DTC P06AD, P0716, P0717, P0722, or P0723 is
not set.
- Engine speed is 400—7,500RPM for 5 s.
- lgnition voltage is 9—32V.
- DTC runs continuously when the above conditions
are met.
P06AE
' DTC P06AE is not set.
~ Engine speed is 400—7,500RPM for 5 s.
. Ignitionvoltage is 9—32V.
0 DTC runs continuously when the above conditions
are met.
P06AC
- TCM detects a 20—50°C(36—90°F),or greater
difference between the transmission fluid
temperature and TCM power up temperature,
which depends on the average of transmission
fluid temperature, TCM substrate temperature,
and TCM power up temperature.
- TCM detects an 8—10°C(14—18°F),or greater
difference between the TCM substrate
temperature and TCM power up temperature,
which depends on the average of the transmission
fluid temperature, TCM substrate temperature,
and TCM power up temperature.
- Above conditions have to be met for 5 min within a
6 min period.
P06AD
TCM power up temperature is -254°C (-425°F) or less
for 1 min.
P06AE
TCM power up temperature is 254°C (489°F) or greater
for 1min.
Action Taken When the DTC Sets
- P06AC, P06AD, and P06AE are Type B DTCs.
. TCM defaults the TCM power up temperature to a
calculated temperature based on the TCM
substrate temperature.
Conditions for Clearing the DTC
P06AC, P06AD, and P06AE are Type B DTCs.
Reference Information
Schematic Reference
Automatic Transmission Controls Schematics on
page 17-30
Connector End View Reference
- Component Connector End Views on page 11—269
- lnline Harness Connector End Views on
page 11-465

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Automatic Transmission - 6T30/6T40/6T45/6T50 (MH8, MH9) 17-79
Description and Operation 3. Verify DTC P06AC, P06AD, or P06AE is not set.
- Transmission General Description on page 17—31
7 =>If any of the DTCs are set
- Transmission Component and System Description Replace the QB Control Solenoid Valve
on page 17—318 Assembly.
- Electronic Component Description on U If none of the DTCs are set
page 17—31 9 4. Operate the vehicle within the Conditions for
Electrical information Reference Running the DTC. You may also operate the
vehicle within the conditions that you observed
o Circuit Testing on page 11-526 from the Freeze Frame/Failure Records data.
- Connector Repairs on page 11-548 5. Verify the DTC does not set.
- Testing for IntermittentConditions and Poor =>if the DTC sets
Connections on page 11-531
Replace the Q8 Control Solenoid Valve
- Wiring Repairs on page 11-537 Assembly.
DTC Type Reference U If the DTC does not set
Powertrain Diagnostic Trouble Code (DTC) Type 6. All OK.
Definitions on page 6-68
Repair Instructions
Scan Tool Reference Perform the Diagnostic Repair Verification on
Control Module References on page 6-3 for scan tool page 6-92 after completing the repair.
information ° Perform the Transmission Adaptive Values Learn
on page 17—163followingall transmission repairs.
CircuitlSystem Verification - Control Module References on page 6-3 for
1. Ignition ON, clear the DTCs with a scan tool. Control Solenoid Valve Assembly replacement,
2. Operate the vehicle at 64 km/h (40 mph) for 10 min. programming and setup.

"‘m
www.ww
NM.”
M.~_.M<~N~WMA-WW'

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
17-80 Automatic Transmission - 6T30/6T40l6T45/6T50 (MH8, MH9)

DTC P0711-P0713

Diagnostic Instructions
- Perform the Diagnostic System Check - Vehicle
on page 6-66 prior to using this diagnostic
procedure.
- Review Strategy Based Diagnosis on page 6-58
for an overview of the diagnostic approach.
- Diagnostic Procedure Instructions on page 6-59
provides an overview of each diagnostic category.
DTC Descriptors
DTC P0711: Transmission Fluid Temperature Sensor Performance
DTC P0712: Transmission Fluid Temperature Sensor Circuit Low Voltage
DTC P0713: Transmission Fluid Temperature Sensor Circuit High Voltage

CircuitlSystem Description Conditions for Setting the DTC

The transmission fluid temperature sensor is located
inside of the transmission Control Solenoid Valve
Assembly which has no serviceable components. The
transmission fluid temperature sensor provides
transmission fluid temperature to the transmission
control module (TCM). This fault is handled inside the
TCM and no external circuits are involved.
Conditions for Running the DTC
P0711
- DTC P0101, P0102, P0103, P0106, P0107,
P0108, P0171, P0172, P0174, P0175, P0201,
P0202, P0203, P0204, P0205, P0206, P0207,
P0208, P0300, P0301, P0302, P0303, P0304,
P0305, P0306, P0307, P0308, P0401, PO42E,
P0658, P0668, P0669, P06AD, P06AE, P0711,
P0712, P0713, P0716, P0717, P0722, P0723,
P0962, P0963, P0966, P0967, P0970, P0971,
P2150, P2720, P2721, P2729, or P2730 is
not set.
. Engine speed is 400—7,500RPM for 5 s.
- lgnition voltage is 9—32V.
- Accelerator position signal is valid.
- Engine torque signal is valid.
- Brake torque is not active.
- DTC runs continuously when above conditions
are met.
P0712
° DTC P0712, P0716, P0717, P0722, or P0723 is
not set.
' Engine speed is 400—7,500RPM for 5 s.
- Ignitionvoltage is 9—32V.
- DTC runs continuously when above conditions
are met.
P0713
- DTC P0713, P0716, P0717, P0722, or P0723 is
not set.
~ Engine speed is 400—7,5OORPM for 5 s.
- lgnition voltage is 9—32V.
. DTC runs continuously when above conditions
are met.
P0711
- TCM detects a 20—50°C(36—90°F)or greater
difference between the transmission fluid
temperature and the TCM substrate temperature,
which depends on the average of the transmission
fluid temperature, TCM substrate temperature,
and TCM power up temperature.
- TCM detects a 20—50°C(36—90°F)or greater
difference between the transmission fluid
temperature and the TCM power up temperature,
which depends on the average of the transmission
fluid temperature, TCM substrate temperature,
and TCM power up temperature.
- Above conditions have to be met for 5 min within a
6 min period.
P0712
Transmission fluid temperature is 254°C (489°F) or
greater for 1 min.
P0713
Transmission fluid temperature is -254°C (—425°F)or
less for 1 min.
Action Taken When the DTC Sets
' P0711, P0712, and P0713 are Type B DTCs.
- TCM defaults to a calculated transmission fluid
temperature based on the TCM temperature.
Conditions for Clearing the DTC
P0711, P0712, and P0713 are Type B DTCs.
Diagnostics Aids
The TCM temperature sensor is located inside of the
Control Solenoid Valve Assembly and its output should
resemble that of the transmission fluid temperature
sensor’s output. During a road test, the transmission
fluid temperature should steadily increase to a normal
operating temperature, and then stabilize.
Reference Information
Schematic Reference
Automatic Transmission Controls Schematics on
page 17—30

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Automatic Transmission =6T3D/6T40/6T45/6T50 (MH8, MH9) 'l7-81
Connector End View Reference 3. Verify the scan tool Transmission Fluid
Temperature parameter increases greater than 2°C
- Component Connector End Views on page 11—269 (3.6°F) after operating the vehicle at 64 km/h
° lnline Harness Connector End Views on (40 mph) for 10 minutes.
page 11-465 =>If the temperature does not increase greater
Description and Operation than 2°C (3.6°F)
- Electronic Component Description on Replace the Q8 Control Solenoid Valve
page 17—319 Assembly.
- Transmission General Description on page 17-317 U If the temperature increases greater than 2°C
(3.6°F)
- Transmission Component and System Description
on page 17-318 4. Verify the scan tool Transmission Fluid
Temperature and the TCM Temperature
Electrical Information Reference parameters are within 20°C (36°F).
- Circuit Testing on page 11-526 :> if the temperatures are not within 20°C (36°F)
- Connector Repairs on page 11-548 Replace the QB Control Solenoid Valve
' Testing for IntermittentConditions and Poor Assembly.
Connections on page 11—531 U If the temperatures are within 20°C (36°F)
- Wiring Repairs on page 11-537 5. Operate the vehicle within the Conditions for
DTC Type Reference Running the DTC. You may also operate the
vehicle within the conditions that you observed
Powertrain Diagnostic Trouble Code (DTC) Type from the Freeze Frame/Failure Records data.
Definitions on page 6—68 6. Verify the DTC does not set.
Scan Tool Reference =>If the DTC sets
Control Module References on page 6—3for scan tool Replace the Q8 Control Solenoid Valve
information Assembly.
U If the DTC does not set
CircuitlSystem Verification
7. All OK.
1. Engine idling at the normal operating temperature.
2. Verify the scan tool Transmission Fluid Repair Instructions
Temperature parameter is between —254and Perform the Diagnostic Repair Verification on
+254°C (-425 and +489°F). page 6-92 after completing the repair.
=>if not between -254 and +254°C (-425 and - Perform the Transmission Adaptive Values Learn
+489°F) on page 17—163followingall transmission repairs.
Replace the Q8 Control Solenoid Valve - Control Module References on page 6-3 for
Assembly. Control Solenoid Valve Assembly replacement,
U If between -254 and +254°C (-425 and +489°F) programming and setup

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
'17-82 Automatic Transmission - 6T30/6T40/6T45/6T50 (MH8, MH9)

DTC P0716, P0717, P07BF, or P07C0

Diagnostic Instructions
- Perform the Diagnostic System Check —Vehicle
on page 6—66prior to using this diagnostic
procedure.
- Review Strategy Based Diagnosis on page 6-58
for an overview of the diagnostic approach.
° Diagnostic Procedure Instructions on page 6-59
provides an overview of each diagnostic category.
DTC Descriptors
DTC P0716: InputSpeed Sensor Performance
DTC P0717: InputSpeed Sensor Circuit No Signal
DTC P07BF: InputSpeed Sensor Circuit Low Voltage
DTC P07C0: InputSpeed Sensor Circuit High Voltage
Diagnostic Fault Information

Openhfigh SMnal
Circuit Short to Ground Resistance Short to Voltage Performance
lnputSpeedSensorSupmbeHage PO7;%&E$717’ P07gg§g2717’ —— P0716

InputSpeedSensorSignal P0716,P0717 P07gg'7g2717’ P07g,%7%%717’ P0716

Typical Scan Tool Data

Transmission ISS
Circuit I Short to Ground Open Short to Voltage
OperatingConditions: Enginerunning,normaloperatingtemperature,
transmissionin Park.
ParameterNormalRange:500—5,8OO RPM
12V 0 RPM 0 RPM -
Signal 0 RPM 0 RPM 0 RPM

ISS/OSS Supply Voltage

Circuit IShort to Ground 1 Open Short to Voltage
OperatingConditions: Key ON, EngineOFF or Enginerunning,normaloperatingtemperature
ParameterNormal Range:OK
Sbnm OK OK OK
12V Outof Range OK OK

CircuitlSystem Description determine commanded line pressure, transmission shift

patterns, torque converter clutch (TCC) slip speed and
The input shaft speed (ISS) sensor is a hall—effecttype gear ratio.
sensor. The ISS sensor mounts to the inside of the
automatic transmission case assembly and connects to Conditions for Running the DTC
the control solenoid valve assembly through a 2—wire
harness and connector. The sensor faces a reluctor P0716
wheel, which is attached to the 4-5—6clutch and 3-5—R ° DTC P0101, P0102, P0103, P0121, P0122,
clutch housing assembly. The sensor receives battery P0123, P0716, P0717, P0752, P0973, or P0974 is
voltage on the ISS sensor Supply Voltage circuit from not set.
the transmission control module (TCM). As the 4-5-6 . Vehicle speed is 10 km/h (6 mph) or greater.
clutch and 3-5-R clutch housing rotates, the sensor
produces a signal frequency based on the teeth of the - Engine speed is 400—7,500RPM for 5 s.
reluctor wheel. This signal is transmitted through the - lgnition voltage is 9—32V.
ISS sensor signal circuit to the TCM. The TCM uses the ' Engine torque signal is valid.
ISS sensor signal to calculate input shaft speed to
2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Automatic Transmission , 6T30/6T40/6T45/6T50 (MH8, MH9) 17:83
- Throttle position signal is valid. ~ TCM inhibits manual up, manual down shifts with
- DTC runs continuously when above conditions the shift selector.
are met. - TCM limits the transmission to reverse and
4th gear.
P0717
- DTC P0101, P0102, P0103, P0717, P0722, P07BF or P0700
or P0723 is not set. - P07BF and P07CO are TypeA DTCs.
- Engine speed is 400—7,5OORPM for 5 s. - TCM freezes transmission adaptive functions.
- Ignitionvoltage is 9—32V. - TCM commands maximum line pressure.
- Vehicle speed is 16 km/h (10 mph) or greater. - TCM inhibits neutral idle.
0 Engine torque is 50 N-m(37 lb ft) or greater. - TCM inhibits Tap—Up/Tap—Down functions.
- DTC runs continuously when above conditions ' TCM inhibits manual up, manual down shifts with
are met. the shift selector.
P07BF or P07C0 - TCM limits the transmission to reverse and
4th gear.
- Ignitionvoltage is 9—32V.
- DTC runs continuously when above Condition Conditions for Clearing the DTC
is met. P0716, P0717, P07BF, and PO7C0 are TypeA DTCs.
Conditions for Setting the DTC Diagnostic Aids
P0716 ~ Inspect the ISS sensor harness and connector for
TCM detects the transmission input shaft speed signal metallic debris and the reluctor wheel for damage
dropped greater than 1,350 RPM for 1 s. or misalignment.
- Ifthe scan tool ISS/OSS Supply Voltage indicates
P0717 out of range, the fault could also be caused by the
Transmission input shaft speed is less than 67 RPM transmission output shaft speed sensor.
for 5 s.
Reference Information
PO7BF
Schematic Reference
Transmission ISS sensor analog signal voltage is
0.25 V or less for 4 s. Automatic Transmission Controls Schematics on
P0700 page 17—30
Transmission ISS sensor analog signal voltage is Connector End View Reference
4.75 V or greater for 4 3. - Component Connector End Views on page 11—269
Action Taken When the DTC Sets - lnline Harness Connector End Views on
page 11—465
P0716
Description and Operation
- P0716 is a Type A DTC.
- TCM freezes transmission adaptive functions. - Electronic Component Description on
page 17—319
- TCM forces TCC OFF.
- Transmission Component and System Description
- TCM inhibits neutral idle. on page 17—31 8
- TCM inhibits Tap—Up/Tap—Down functions. - Transmission General Description on page 17—31
7
«
A -
./...—MWM‘W
MWVM~M TCM inhibits manual up, manual down shifts with
the shift selector. Electrical Information Reference
- TCM commands maximum line pressure. ' Circuit Testing on page 11—526
' TCM enables torque management. - Connector Repairs on page 11-548
' TCM limits the transmission to reverse and - Testing for IntermittentConditions and Poor
5th gear. Connections on page 11-531
- TCM commands the high side driver off. ~ Wiring Repairs on page 11-537
P0717 DTC Type Reference
- P0717 is a Type A DTC. Powertrain Diagnostic Trouble Code (DTC) Type
- TCM freezes transmission adaptive functions. Definitions on page 6-68
- TCM forces TCC OFF. Scan Tool Reference
- TCM commands maximum line pressure.
- TCM inhibits neutral idle. Control Module References on page 6—3for scan tool
information
- TCM inhibits Tap-Up/Tap—Downfunctions.
Special Tools
DT—48616—10
Adapter Harness
2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
1 7-84 Automatic Transmission - 6T30/6T40/6T45/6T50
For equivalent regional tools, refer to Special Tools on
page 17-394.
CircuitlSystem Verification
1. lgnition ON.
2. Verify with a scan tool lSS/OSS Supply Voltage
test status parameter displays OK.
:> If 0K is not displayed
Refer to CircuitlSystem Testing.
If 0K is displayed
9° Engine idling, transmission in Park.
Verify the scan tool Transmission ISS parameter
changes without spikes or dropouts, while varying
the engine speed.
If the Transmission ISS does not change with
engine speed or has spikes or dropouts
Refer to CircuitlSystem Testing.
If the Transmission ISS changes with engine
speed and there are no spikes or dropouts
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.
Verify the DTC does not set.
=>If the DTC sets
Refer to CircuitlSystem Testing.
U if the DTC does not set
7 All OK.
CircuitlSystem Testing
Note: You must perform the CircuitlSystem Verification
first.
1. IgnitionOFF, remove the QB Control Solenoid
Valve Assembly.
2. Place the Q8 Control Solenoid Valve Assembly on
a clean work surface near the transmission
assembly.
Connect the DT—48616-10adapter harness
between the vehicle harness connector and the QB
Control Solenoid Valve assembly. lgnition ON.
(MH8, MH9)
4. Test for 11—13 V between the ISS 12 V circuit
terminal B on the Q8 Control Solenoid Valve
Assembly X3 connector and ground.
If not between 11—13V
Replace the OS Control Solenoid Valve
Assembly.
If between 11—13V
Verify the scan tool Transmission ISS parameter is
between 495—505RPM when performing the input
shaft speed test. Refer to Control Solenoid Valve
and Transmission Control Module Assembly Input
Shaft Speed/Output Shaft Speed Input Test on
page 17-159.
If not between 495—505RPM
Replace the QB Control Solenoid Valve
Assembly.
If between 495—505RPM
Verify there is no damage to the reluctor,which is
attached to the 4-5—6clutch and 3—5—R clutch
housing assembly, or misalignment between the
3140 Transmission InputShaft Speed Sensor and
reluctor.
If the reluctor is damaged or misaligned
Repair or replace as necessary.
If the reluctor is not damaged or misaligned
Replace the 8140 Transmission InputShaft Speed
Sensor.
Repair Instructions
Perform the Diagnostic Repair Verification on
page 6—92after completing the repair.
Perform the Transmission Adaptive Values Learn
on page 17-163 following all transmission repairs.
Input and Output Speed Sensor Installation on
page 17—303
Input and Output Speed Sensor Removal on
page 17—230
Control Module References on page 6—3for
Control Solenoid Valve Assembly replacement,
programming and setup.
(US/Canada)
<Sonic
2013 (5377994)
Manual
Service
 Automatic Transmission - 6T30/6T40/6T45/6T50 (MH8, MH9) 'l7=85
DTC P071 D

Diagnostic Instructions
° Perform the Diagnostic System Check - Vehicle
on page 6-66 prior to using this diagnostic
procedure.
- Review Strategy Based Diagnosis on page 6-58
for an overview of the diagnostic approach.
- Diagnostic Procedure Instructions on page 6-59
provides an overview of each diagnostic category.
DTC Descriptor
DTC P071D: Transmission Sport Mode Switch Circuit
Diagnostic Fault Information

Open/High Signal
Circuit Short to Ground Resistance Short to Voltage Performance
TransModeSwitchB Signal PO71D — — P071D

CircuitlSystem Description Reference Information

The engine control module (ECM) supplies 5 V Schematic Reference
reference voltage, through the 5 V reference voltage
circuit, to the fuel economy mode switch. The 5 V Automatic Transmission Controls Schematics on
reference voltage causes current to flow through a page 17-30
series of resistors in the switch to the switch ground
circuit. The ECM also supplies a signal circuit to detect Connector End View Reference
voltage within the resistor network. When the fuel - Component Connector End Views on page 11-269
economy mode switch button is momentarily pressed, ‘ lnline Harness Connector End Views on
the switch contacts allow the current to by-pass one of page 11-465
the resistors. The ECM detects the resulting change in
voltage drop as a fuel economy mode request and Description and Operation
sends a GMLAN message to the transmission contrOl
module (TCM) indicating the request. When the TCM - Transmission General Description on page 17-317
receives the request, and if operating conditions are - Transmission Component and System Description
correct, the transmission shift points are modified to on page 17—318
optimize fuel efficiency. The TCM sends a confirmation - Electronic Component Description on
message to the ECM and the instrument panel page 17-319
.-M-~ww4
A.M.W~____MM
cluster (IPC) also receives the fuel economy mode
request message from the TCM and illuminates the fuel Electrical Information Reference
economy mode indicator lamp. - Circuit Testing on page 11-526
Conditions for Running the DTC - Connector Repairs on page 11-548
- Engine speed is 500—7500 RPM for 5 s. ' Testing for IntermittentConditions and Poor
Connections on page 11—531
. lgnition voltage is between 9—18V.
o Wiring Repairs on page 11-537
Conditions for Setting the DTC DTC Type Reference
TCM detects that the Economy Mode Switch has been
continuously activated for 10 min. Powertrain Diagnostic Trouble Code (DTC) Type
Definitions on page 6-68
Action Taken When the DTC Sets Scan Tool Reference
- DTC PO71D is a type C DTC.
Control Module References on page 6—3for scan tool
- TCM inhibits the sport mode shift pattern. information
- TCM inhibits Tap Up/Down function.
- TCM inhibits manual shifting of fonNardgears.
Conditions for Clearing the DTC
DTC P071 D is a Type C DTC
Diagnostic Aids
Diagnose all communication and body DTCs first.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
17~86 Automatic Transmission - 6T30/6T40/6T45/6T50
CircuitlSystem Verification
1. lgnition ON.
2. Verify the Fuel Economy Mode parameter changes
between Active and Inactive each time the S112
fuel economy mode switch is depressed.
If Inactive or Active is not displayed
Refer to CircuitlSystem Testing.
If Inactive or Active is displayed
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.
Verify the DTC does not set.
=>If the DTC sets
Refer to CircuitlSystem Testing.
U If the DTC does not set
5 All OK.
CircuitlSystem Testing
Note: You must perform the CircuitlSystem Verification
before proceeding with CircuitlSystem Testing.
1. IgnitionOFF, disconnect the harness connector at
the S112 fuel economy mode switch.
2. Test for less than 10 0 between the ground circuit
terminal 1 of the harness connector and ground.
If 10 Q or greater
Test for less than 2 Q in the ground circuit, end
to end.
=>If2 Q or greater, repair the open/high resistance
in the ground circuit.
=>Ifless than 2 Q, repair the open/high resistance
in the ground connection.
If less than 10 Q
()0
. lgnition ON.
. Test for 4.8—5.2V between the 5 V reference circuit
terminal 3 of the harness connector and ground.
If less than 4.8 volts
4.1. lgnition OFF, remove the harness connector at
the ECM. ‘ ground in the signal circuit.
4.2. Test for infinite resistance between the 5 V
reference circuit terminal 3 of the harness
connector and ground.
: Ifless than infinite resistance, repairthe short to
ground in the circuit.
U Ifinfinite resistance.
4.3. Test for less than 2 Q in the 5 V reference
circuit, end to end.
=>If2 Q or greater, repair the open/high resistance
in the 5 V reference circuit.
(MH8, MH9)
:> Ifless than 2 Q, replace the K20 engine control
module.
=>If greater than 5.2V ’
4.1. lgnition OFF, disconnect the harness
connector at the ECM, ignition ON.
4.2. Test for less than 1 V between 5V reference
circuit terminal 3 and ground.
2 lf 1 V or greater, repair the short to voltage on
the circuit.
=>if less than 1 V, replace the K20 engine control
module.
U If between 4.8—5.2volts .
. Verify the scan tool Fuel Economy Mode Switch
parameter displays Circuit Low Voltage.
If the Fuel Economy Mode Switch parameter
does not display Circuit Low Voltage
5.1. lgnition OFF, disconnect the harness
connector at the K20 engine control module,
ignition ON.
5.2. Test for less than 1 V between the fuel
economy signal circuit terminal 4 and ground.
=>If 1 V or greater, repair the short to voltage on
the circuit.
2:»lf less than 1V, replace the K20 engine control
module.
If the Fuel Economy Mode Switch parameter
displays Circuit Low Voltage
. Connect a 3 A fused jumper wire between 5 V
reference circuit terminal 3 of the harness
connector and signal circuit terminal 4 of the
harness connector.
. Verify the scan tool Fuel Economy Mode Switch
parameter displays Circuit High Voltage.
If the Fuel Economy Mode Switch parameter
does not display Circuit High Voltage
7.1. lgnition OFF, remove the connector at the K20
engine control module.
7.2. Test for infinite resistance between signal
circuit terminal 4 and ground.
:> if less than infinite resistance, repairthe short to
U If infinite resistance.
7.3. Test for less than 2 Q in the fuel economy
mode signal circuit, end to end.
=>If2 Q or greater, repair the open/high resistance
in the signal Circuit.
=>If less than 2 Q, replace the K20 engine control
module.
If the Fuel Economy Mode Switch parameter
displays Circuit High Voltage
. lgnition OFF.
. Test for 266—294Q between the 5 V reference
voltage circuit terminal 3 and the signal circuit
terminal 4 on the S112 fuel economy mode switch.
If not between 266—294(2
Replace the S112 fuel economy mode switch.
If between 266-294 (2
2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Automatic Transmission - 6T30/6T40/6T45/6T50 (MH8, MH9) 17-87
10. Test for 927—1024Q between signal circuit Repair Instructions
terminal 4 and low reference circuit terminal 1 on
the S112 fuel economy mode switch. Perform the Diagnostic Repair Verification on
page 6-92 after completing the repair.
:> If not between 927—1024Q
Control Module References on page 6—3for Control
Replace the S112 fuel economy mode switch. Solenoid Valve Assembly or Engine Control Module
U If between 927—1024Q replacement, programming and setup.
11. Test for 220—244Q between terminal 4 and
terminal 1 on the S112 fuel economy mode switch,
with the switch pressed.
=>If not between 220—244Q
Replace the S112 fuel economy mode switch.
U if between 220—244Q
12. Replace the K20 Engine Control Module.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
17-88 Automatic Transmission - 6T30/6T40/6T45/6T50 (MH8, MH9)

DTC P0722, P0723, P077C, or P077D

Diagnostic Instructions
' Perform the Diagnostic System Check —Vehicle
on page 6—66prior to using this diagnostic
procedure.
- Review Strategy Based Diagnosis on page 6-58
for an overview of the diagnostic approach.
. Diagnostic Procedure Instructions on page 6-59
provides an overview of each diagnostic category.
DTC Descriptors
DTC P0722: Output Speed Sensor Circuit No Signal
DTC P0723: Output Speed Sensor Circuit Intermittent
DTC P0770: Output Speed Sensor Circuit Low Voltage
DTC P077D: Output Speed Sensor Circuit High Voltage

Diagnostic Fault Information

Openflfigh Sgnal
Circuit Short to Ground Resistance Short to Voltage Performance
. P0722,P0723, P0722,P0723,
PO77C P0722,P0723,
PO77D —-
OumutSpeedSensorSQnal P077C

OuudepeedSensorSupmbehage P07g%}:2323' P07g%§:2323’ —— —-

Typical Scan Tool Data

Transmission OSS
Circuit I Short to Ground Open Short to Voltage
OperatingConditions: Drivevehicle,normaloperatingtemperature
ParameterNormalRange: 0—7,000 RPM
OutputSpeedSensor SupplyVoltage 0 RPM 0 RPM 0 RPM
OutputSpeedSensor Signal 0RPM 0 RPM 0 RPM

ISSIOSS Supply Voltage

Circuit I Short to Ground | Open Short to Voltage
Operating Conditions: Key ON, EngineOFF or n
Enginerunning, ormalo peratingtemperature
ParameterNormalRange: OK
OutputSpeedSensor Signal OK OK OK
OumutSpeedSensorSupMbeMage OutofRange OK OutofRange

CircuitlSystem Description Conditions for Running the DTC

The output shaft speed (088) sensor is a hall-effect P0722
type sensor. The 088 sensor mounts to the automatic ° DTC P0101, P0102, P0103, P0121, P0122,
transmission case assembly and connects to the P0123, P0716, P0717, P0722, 0r P0723 is not set.
control solenoid valve assembly through a 2—wire
harness and connector. The sensor faces the park gear ' lgnition voltage is 9—32V.
teeth. The sensor receives battery voltage on the OSS - Engine speed is 400—7,500RPM for 5 s.
supply voltage circuit from the transmission control - Engine torque signal is valid.
module (TCM). As the output shaft rotates, the sensor
produces a signal frequency based on the park gear - Throttle position signal is valid.
teeth. This signal is transmitted through the OSS ~ Transmission input speed is between 1,000-
sensor signal circuit to the TCM. The TCM uses the 8,191 RPM.
OSS signal to calculate output shaft speed to ' Calculated throttle position is 8% or greater.
determine commanded line pressure, transmission shift v Engine torque is 30 N-m(22 lb ft) or greater.
patterns, vehicle speed and gear ratio.
(US/Canada)
~Sonic
2013 (5377994)
Manual
Service
 Automatic Transmission - 6T30/6T40/6T45/6T50 (MH8, MH9) 17=89
- Transmission fluid temperature is greater than P0723, P0776 or P077D
-40°C (-40°F). - P0723, P0770, and P077D are Type A DTCs.
° DTC runs continuously when the above conditions - TCM freezes transmission adaptive functions.
are met.
' TCM forces TCC OFF.
P0723 ° TCM commands the high side driver OFF.
- DTC P0101, P0102, P0103, P0121, P0122, - TCM commands maximum line pressure.
P0123, P0723, P0973, P0974, P0976, or P0977 is
not set. . - TCM enables torque management.
- Ignitionvoltage is 9—32V. - TCM limits the transmission to reverse and
5th gear.
' Greater than 5 3 since last transmission upshift or
downshift. ' TCM inhibits neutral idle.
- Engine speed is 400—7,500RPM for 5 s. - TCM inhibits Tap—Up/Tap-Downfunctions.
- DTC runs continuously when the above conditions ' TCM inhibits manual up, manual down shifts with
are met. the shift selector.

P077C Conditions for Clearing the DICIDTC

- DTC PO77D is not set. P0722, P0723, P0770, and P077D are Type A DTCs.
- lgnition voltage is 9—32V. Diagnostic Aids
- DTC runs continuously when the above conditions
- Inspect the OSS, harness, and connector for
are met.
metallic debris and proper alignment of the 083
P077D with the park gear. Proper torque of the OSS
- DTC P077C is not set. mounting bolt is critical to proper OSS operation.
- Ignitionvoltage is 9—32V. - Ifthe scan tool ISS/OSS Supply Voltage indicates
out of range, the fault could also be caused by the
- DTC runs continuously when the above conditions transmission input shaft speed sensor.
are met.
Reference Information
Conditions for Setting the DTC
Schematic Reference
P0722
Transmission output speed is 35 RPM or less for Automatic Transmission Controls Schematics on
5 seconds. page 17-30

P0723 Connector End View Reference

' Transmission output speed is 105 RPM or greater. - Component Connector End Views on page 11~269
' Transmission output speed drops 1,000 RPM for - lnline Harness Connector End Views on
greater than 3 s. page 11—465
P077C Description and Operation
Transmission OSS sensor analog signal voltage is - Electronic Component Description on
0.25 V or less for 4 s. page 17—319for output speed sensor (088)
P077D - Transmission Component and System Description
on page 17-318
Transmission OSS sensor analog signal voltage is
4.75 V or greater for 4 3. ' Transmission General Description on page 17—31
7
Electrical Information Reference
Action Taken When the DTC Sets
- Circuit Testing on page 11-526
P0722
- Connector Repairs on page 11-548
- P0722 isa Type A DTC.
- Testing for IntermittentConditions and Poor
N
..flw
W2.
-w.
.H.. - TCM freezes transmission adaptive functions. Connections on page 11-531
- TCM commands maximum line pressure. - Wiring Repairs on page 11—537
- TCM forces the torque converter
clutch (TCC) OFF. DTC Type Reference
' TCM Enables torque management. Powen‘rain Diagnostic Trouble Code (DTC) Type
~ TCM limits the transmission to reverse and Definitions on page 6-68
2nd gear. Scan Tool Reference
- TCM inhibits neutral idle.
Control Module References on page 6-3 for scan tool
~ TCM inhibits Tap-Up/Tap—Downfunctions. information
0 TCM inhibits manual up, manual down shifts with
the shift selector.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
17-90 Automatic Transmission - 6T30/6T40/6T45/6T50
Special Tools
DT—48616—10 Adapter Harness
EL 38522 Variable Signal Generator
For equivalent regional tools, refer to Special Tools on
page 17-394.
CircuitlSystem Verification
1. lgnition ON.
2. Verify with a scan tool the transmission lSS/OSS
Supply Voltage test status parameter displays OK.
z) If OK is not displayed
Refer to CircuitlSystem Testing.
lf OK is displayed
Verify the scan tool Transmission 088 parameter
changes with vehicle speed or does not drop out,
while operating the vehicle at 16—32km/h(10-
20 mph).
If the Transmission 088 does not vary with
vehicle speed or drops out
Refer to CircuitlSystem Testing.
If the Transmission OSS varies with vehicle
speed and does not drop out
. 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.
Verify the DTC does not set.
:> If the DTC sets
Refer to CircuitlSystem Testing.
U If the DTC does not set
6 All OK.
CircuitlSystem Testing
Note: You must perform the CircuitlSystem Verification
first.
1. lgnition OFF, remove the Q8 Control Solenoid
Valve Assembly.
2. Connect the DT—48616-10harness between the
vehicle wire harness connector, and the Q8 Control
Solenoid Valve Assembly connector.
(MH8, MH9)
3. lgnition ON.
4. Test for 11—13 volts between the OSS voltage
circuit terminal B at the 08 Control Solenoid Valve
Assembly X4 connector and ground.
If not between 11—13V
Replace the Q8 Control Solenoid Valve
Assembly.
If between 11—13V
Verify the scan tool Transmission 088 parameter
is between 745—825RPM when performing the
output shaft speed test. Refer to Control Solenoid
Valve and Transmission Control Module Assembly
Input Shaft Speed/Output Shaft Speed Input Test
on page 17-159.
If not between 745—825RPM
Replace the QB Control Solenoid Valve
Assembly.
If between 745—825RPM
Verify there is no damage to the park gear,
or misalignment between the B14A Transmission
Output Speed Sensor and the park gear.
If the park gear is damaged or misaligned
Repair or replace as necessary.
If the park gear is not damaged or misaligned
Replace the B14A Transmission Output Speed
Sensor.
Repair Instructions
Perform the Diagnostic Repair Verification on
page 6-92 after completing the repair.
Perform the Transmission Adaptive Values Learn
on page 17—163followingall transmission related
repairs.
Input and Output Speed Sensor Installation on
page 17-303
Input and Output Speed Sensor Removal on
page 17—230
Refer to Control Module References on page 6—3
for Control Solenoid Valve Assembly replacement,
programming and setup.
,1~.
2,.
,AM
2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Automatic Transmission , 6T30/6T40/6T45/6T50 (MHB, MH9) 17=91

DTC P0741 or P0742

Diagnostic Instructions
- Perform the Diagnostic System Check —Vehicle
on page 6—66prior to using this diagnostic
procedure.
~ Review Strategy Based Diagnosis on page 6-58
for an overview of the diagnostic approach.
- Diagnostic Procedure Instructions on page 6-59
provides an overview of each diagnostic category.
DTC Descriptors
DTC P0741: Torque Converter Clutch (TCC) System Stuck Off
DTC P0742: Torque Converter Clutch (TCC) System Stuck On

CircuitlSystem Description —4th gear ratio is between 1.35—1.55.

The torque converter clutch (TCC) pressure control
solenoid is part of the control solenoid valve assembly
which has no serviceable components. The TCC
pressure control solenoid is a normally low pressure
control solenoid. The TCC pressure control solenoid
regulates transmission fluid pressure to the TCC
regulator valve in the lower valve body and the TCC
control valve Inthe fluid pump assembly. When vehicle
operating conditions are appropriate to apply the torque
converter clutch the transmission control
module (TCM) will Increase TCC pressure control
solenoid current flow thereby increasing pressure to
move the TCC control valve into the apply position.
When the TCC is fully applied, the engine is coupled
directly to the transmissiOn. TCC release is
accomplished by the TCM decreasing current flow,
dropping the apply pressure thereby allowing the TCC
control valve to move to the release position. The TCM
calculates torque converter slip speed based on the
speed signal from the input shaft speed (ISS) sensor
and engine RPM provided by the engine control
module (ECM).
Conditions for Running the DTC
P0741
- DTC P0101, P0102, P0103, P0106, P0107,
P0108, P0171, P0172, P0174, P0175, P0201,
P0202, P0203, P0204, P0205, P0206, P0207,
P0208, P0300, P0301, P0302, P0303, P0304,
P0305, P0306, P0307, P0308, P0401, P042E,
P0716, P0717, P0722, P0723, P0741, P0742,
P2763, or P2764 is not set.
- Engine speed is 400—7,500RPM for 5 s.
- Ignitionvoltage is 9—32V.
- Transmission fluid temperature is between —7to
+137°C (19—279°F).
- Throttle position is 8% or greater.
- Engine torque is 50 Nm (36 lb ft) or greater.
- Engine torque signal is valid.
- Throttle position signal is valid.
- TCM detects the transmission gear ratios listed
below for the commanded gear when TCC is
commanded ON:
—2nd gear ratio is between 2.75—3.17.
——3rd gear ratio is between 1.78—2.04.
—5th gear ratio is between 0.93—1.07.
—6th gear ratio is between 0.70—0.80.
- DTC runs continuously when the above conditions
are met.
P0742
- DTC P0101, P0102, P0103, P0106, P0107,
P0108, P0171, P0172, P0174, P0175, P0201,
P0202, P0203, P0204, P0205, P0206, P0207,
P0208, P0300, P0301, P0302, P0303, P0304,
P0305, P0306, P0307, P0308, P0401, P042E,
P0716, P0717, P0722, P0723, P0741, P0742,
P2763, or P2764 is not set.
° Engine speed is greater than 400—7,500RPM
for 5 s.
- Ignitionvoltage is 9—32V.
- Transmission fluid temperature is between 15-
137°C (59—279°F).
- Calculated throttle position was 10% or greater
and has not dropped below 2%.
- Engine torque is greater than 60 Nm (44 lb ft).
- Vehicle speed is greater than 1 km/h (0.6 mph).
- TCC is commanded OFF.
° Engine torque signal is valid.
- Throttle position signal is valid.
- DTC runs continuously when the above conditions
are met.
Conditions for Setting the DTC
P0741
- TCC pressure command is 500 kPa (73 PSI) or
greater for 2 s.
- TCM detects TCC slip is 130 RPM or greater
for 5 s.
- The above conditions must occur 2 times.
P0742
- TCM detects the TCC slip is between —50and
+30 RPM for 1 s or greater when the TCC is
commanded OFF.
- The above condition must occur 8 times.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
‘17-92 Automatic Transmission - 6T30/6T40/6T45/6T50 (MH8, MH9)

Action Taken When the DTC Sets CircuitlSystem Verification

P0741 1. lgnition ON, engine OFF.
- P0741 is a Type B DTC. 2. Verify DTC P0716, P0717, P07BF, or P0700 was
not set by reviewing the scan tool TCM Failure
- TCM inhibits 6th gear. Records.
- TCM initiates the Hot Mode shift pattern.
2 If any of the DTCs were set
- TCM commands the TCC OFF.
Refer to DTC P0716, P0717, P07BF, or P0700
P0742 on page 17-82.
- P0742 is a Type A DTC. U If none of the DTCs were set
- TCM initiates Hot Mode shift pattern. 3. Engine idling, transmission in Park, with parking MAN
- TCM freezes transmission adaptive functions. brake applied and drive wheels chocked.
- TCM commands the TCC ON. 4. Verify the transmission fluid level and condition is
- TCM inhibits neutral idle. correct. Refer to Transmission Fluid Level and
Condition Check on page 17—164.
Conditions for Clearing the DTC 2 If the transmission fluid level and condition is
. DTC P0741 is a Type B DTC. not correct
~ DTC P0742 is a Type A DTC. Repair as necessary.
U If the transmission fluid level and condition is '
Reference Information
correct
Schematic Reference 5. lgnition ON, clear the TCM DTCs with a scan tool.
Automatic Transmission Controls Schematics on 6. Verify DTC P0741 or P0742 does‘not set while
page 17-30 performing a road test. Refer to Road Test on
page 17—167.
Connector End View Reference
2 If DTC P0742 or P0743 sets
° Component Connector End Views on page 11-269 Refer to CircuitlSystem Testing.
0 lnline Harness Connector End Views on U If DTC P0741 or P0742 does not set
page 11-465
7. Operate the vehicle within the Conditions for
Description and Operation Running the DTC. You may also operate the
- Electronic Component Description on vehicle within the conditions that you observed
page 17—31 9 from the Freeze Frame/Failure Records data.
- Transmission Component and System Description 8. Verify the DTC does not set.
on page 17—31 8 2 If the DTC sets
- Transmission General Description on page 17—317 Refer to CircuitlSystem Testing.
Electrical information Reference U If the DTC does not set
9 All OK.
- Circuit Testing on page 11-526
‘ Connector Repairs on page 11-548 CircuitlSystem Testing
- Testing for IntermittentConditions and Poor 1. Engine idling at the normal operating temperature.
Connections on page 11~531 2. Verify the transmission line pressures are within
- Wiring Repairs on page 11-537 range. Refer to Line Pressure Check on
DTC Type Reference page 17—166and Solenoid Valve Pressure (Gen 1)
on page 17-12.
Powertrain Diagnostic Trouble Code (DTC) Type 2 If the pressures are not within range
Definitions on page 6-68
Refer to Fluid Pressure High or Low on
Scan Tool Reference page 17-191. '
Control Module References on page 6—3for scan tool U If the pressures are within range
information 3. lgnition OFF, remove the QB Control Solenoid
Valve Assembly.

2013
—
Sonic
(US/Canada)
Servlce
Manual
(5377994)
 Automatic Transmission
4. Verify the pressure changes for all solenoids when
performingthe solenoid test. Refer to Control
Solenoid Valve and Transmission Control Module
Assembly Solenoid Performance Test on
page 17—160
2 If the pressure change does change
Replace the 08 Control Solenoid Valve
Assembly.
U If the pressure changes
5. Verify the mechanical conditions listed below do
not exist. Repair or replace as necessary.
P0741 Upper Valve Body
Release exhaust port/orifice plugged or blocked.
P0741 or P0742 —Upper Valve Body
Torque converter clutch regulator valve stuck/sticking -
debris, binding, damaged valve, or scored bore.
P0741 —Channel Plate and Spacer Plate
Oil channels or orifices blocked by debris.
P0741 or P0742 —Fluid Pump Assembly
Torque converter clutch control valve stuck/sticking -
debris, binding, damaged valve, or scored bore.
P0741 - Torque Converter
- Torque converter clutch delamination or material
worn off.
0 Converter bolts too long damaging the clutch
apply surface.
0 Damaged seal.
P0741 —Support
Damaged seal.
=6T30/6T40/6T45/6T50 (MH8, MH9) 17-93
P0741 or P0742 —AlTrans Case Cover (403)
- Pressure release blow-off not seating/sealing.
- Damaged spring.
P0741 —Turbine Shaft
O-ring seal Cutor damaged.
P0741 or P0742 —Q8 Control Solenoid Valve
Assembly
- Torque converter clutch pressure control solenoid
stuck OFF or leaking.
- Torque converter clutch pressure control solenoid
stuck ON.
- Control signal fluid supply leak due to valve body
filter plate assembly cracked, or damaged
gasketseaL
Repair Instructions
Perform the Diagnostic Repair Verification on
page 692 after completing the repair.
0 Perform the Transmission Adaptive Values Learn
on page 17-163 following all transmission related
repairs.
- Control Valve Body Assembly Removal on
page 17—227
- Torque Converter Installation on page 17-314.
- Torque Converter Removal on page 17-226
- Control Module References on page 6-3 for
Control Solenoid Valve Assembly replacement,
programming and setup.

24.2.223WWN
WWW;
2
..M~Wf.wn
-.s

(US/Canada)
~Sonic
2013 (5377994)
Manual
Service
17-94 Automatic Transmission - 6T30/6T40/6T45/6T50 (MH8, MH9)

DTC P0751 or P0752

Diagnostic Instructions
- Perform the Diagnostic System Check - Vehicle
tonpage 6-66 prior to using this diagnostic
procedure.
~ Review Strategy Based Diagnosis on page 6-58
for an overview of the diagnostic approach.
- Diagnostic Procedure Instructions on page 6-59
provides an overview of each diagnostic category.
DTC Descriptors
DTC P0751: Shift Solenoid Valve 1 Performance - Stuck Off
DTC P0752: Shift Solenoid Valve 1 Performance - Stuck On

CircuitlSystem Description - Gearbox slip is 400 RPM or greater for 2 s.

Shift solenoid valve 1 is part of the control solenoid - Conditions listed above have to occur 8 times.
valve assembly, which has no serviceable components. P0752
The solenoid operates by the transmission control
module (TCM) turning the low side driver ON or OFF. ~ Commended gear is 3rd.
When the shift solenoid valve1 is commanded OFF, the ' Transmission has achieved 1st or 2nd.
plunger forces the metering ball against the actuator - Gear slip is 400 RPM or greater for 1.5s.
feed limit seat, blocking the flow and any existing - TCM commands 4th gear it above conditions exist
pressure is exhausted through the exhaust port. When and detects a gear ratio of4.35—4.81for‘1.5 s.
the shift solenoid valve 1 is commanded ON, the
internal plunger moves, allowing the metering valve to - Conditions listed above have to occur 5 times.
move away from the actuator feed limit seat and Action Taken When the DTC Sets
against the exhaust seat, creating signal fluid pressure.
The signal fluid pressure acts against the clutch select P0751 _
valve 2 to overcome the valve spring force, moving the - P0751 is a type B DTC.
valve to the apply position. Fluid pressure from the R1/
4—5—6 regulator valve flows through clutch select valve 2 - TCM inhibits 1stgear.
and is directed to either the low and reverse clutch or - TCM inhibits Neutral idle.
the 4—5—6 clutch, depending on the position of clutch
P0752
select valve 2.
- P0752 is a type A DTC.
Conditions for Running the DTC . TCM limits the transmission to 2nd range and
- DTC P0101, P0102, P0103, P0106, P0107, reverse.
P0108, P0171, P0172, P0174, P0175, P0201, - TCM inhibits Tap Up/Down function.
P0202, P0203, P0204, P0205, P0206, P0207, ‘ TCM inhibits manual shifting of fon/vardgears.
P0208, P0300, P0301, P0302, P0303, P0304,
P0305, P0306, P0307, P0308, P0401, P042E, ' TCM disables neutral idle.
P0716, P0717, P0722, P0723, or P182E is - TCM freezes adapts.
not set. - TCM commands maximum line pressure.
° Transmission fluid temperature is -6.6°C (~20°F) - TCM commands 2nd gear if transmission is in a
or greater. fon/vardrange and the output speed is less than
- Engine speed is 400—7,500RPM for 5 s. 1,350 RPM, or neutral if the output speed is 1,350
. Output shaft speed is 100 RPM or greater or the RPM or greater.
throttle is 0.5% or greater.
Conditions for Clearing the DTC
- lgnition voltage is 9—32V.
- P0751 is a type B DTC.
- Shift is complete.
- P0752 is a type A DTC.
- Engine torque signal is valid.
- Throttle position signal is valid. Diagnostic Aids
' High—Sidedriver is enabled. Before performing a road test, configure and setup the
- DTC runs continuously when above conditions scan tool for snapshot mode. This allows you to display,
are met. monitor,and verify multiple transmission data
parameters at one time, after the road test.
Conditions for Setting the DTC
Reference Information
P0751
Schematic Reference
- Commended gear is 1st.
- TCM detects gear ratio 1.37—1.52. Automatic Transmission Controls Schematics on
page 17-30
2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
...»
‘ms’w
.._,,
«4
 Automatic Transmission
Connector End View Reference
- Component Connector End Views on page 11—269
- lnline Harness Connector End Views on
page 11-465
Description and Operation
- Transmission General Description on page 17-317
~ Transmission Component and System Description
on page 17—31 8
- Electronic Component Description on
page 17-319
- Drive Range, First Gear Engine Braking (Gen 1)
on page 17—333or Drive Range, First Gear Engine
Braking (Gen 2) on page 17-335
DTC Type Reference
Powertrain Diagnostic Trouble Code (DTC) Type
Definitions on page 6—68
Scan Tool Reference
Control Module References on page 6—3for scan tool
information
CircuitlSystem Verification
Note: Ifother DTCs are set, diagnose those DTCs first.
1. lgnition ON, engine OFF.
2. Verify no other TCM DTCs are set using a
scan tool.
2 If another DTC is set
Refer to Diagnostic Trouble Code (DTC) List -
Vehicle on page 6-69.
U If no other DTCs are set
3. Engine idling at the normal operating temperature,
transmission in Park, with parking brake applied
and drive wheels chocked.
4. Verify the transmission fluid level and condition is
correct. Refer to Transmission Fluid Level and
Condition Check on page 17-164.
2 If the transmission fluid level and condition is
not correct
Repair as necessary.
U if the transmission fluid level and condition is
correct
5. lgnition ON, Clear the TCM DTCs with a scan tool.
6. From a stop, accelerate to 72 km/h (45 mph) with
the throttleposition greater than 15%. Perform this
test 8 times.
7. Verify DTC P0751 or P0752 did not set.
2 If DTC P0751 or P0752 sets
Refer to CircuitlSystem Testing.
U If DTC P0751 or P0752 does not set
8. 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.
- 6T30/6T40/6T45/6T50 (MH8, MH9) 17-95
9. Verify the DTC does not set.
2 if the DTC sets
Refer to CircuitlSystem Testing.
U If the DTC does not set
10. All OK.
CircuitlSystem Testing
Note: You must perform the CircuitlSystem Verification
first.
1. Engine idling at the normal operating temperature.
2. Verify the transmission line pressures are within
the specified range. Refer to Line Pressure Check
on page 17-166 and Solenoid Valve Pressure (Gen
1) on page 17—12.
2 If the pressures are not within range
Refer to Fluid Pressure High or Low on
page 17—191.
U if the pressures are within range
3. IgnitionOFF, remove the QB Control Solenoid
Valve Assembly.
4. Verify the pressure changes for all solenoids when
performing the solenoid test. Refer to Control
Solenoid Valve and Transmission Control Module
Assembly Solenoid Performance Test on
page 17-160.
2 If the pressure does not change
Replace the Q8 Control Solenoid Valve
Assembly.
U If the pressure changes
5. Verify the mechanical conditions listed below do
not exist. Repair or replace as necessary.
P0751 —— Control Valve Body
- Clutch select valve bore plug undersized. Plug
should be a valve fit in the bore.
- Check ball #1 missing, damaged/malformed.
- Seat for check ball #1 damaged or leaking.
P0751 or P0752 —Control Valve Body
- Clutch select valve stuck from debris, sediment,
binding, or a scored bore.
- Low and reverse and 4-5-6 clutch regulator
valve stuck or sticking from debris, sediment,
binding, or a scored bore.
P0751 or P0752 —Channel Plate and Spacer Plate
Oil channels or orifices blocked by debris.
P0752 Output Carrier Assembly
Output carrier pinion pins too high or too low.
P0751 or P0752 —QB Control Solenoid Valve
Assembly
- Not pressurizing due to shift solenoid valve1
being stuck OFF or leaking.
' Pressure not exhausting due to shift solenoid
valve1 being stuck ON.
- Control signal fluid supply leak due to valve body
filter plate assembly cracked, blocked,
or damaged gasket seal.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
17=96 Automatic Transmission - 6T30/6T40/6T45/6T50 (MH8, MH9)
Repair |nstructions - Control Module References on page 6—3for
Control Solenoid Valve Assembly replacement,
Perform the Diagnostic Repair Verification on programming and setup.
page 6-92 after completing the repair.
- Perform the Transmission Adaptive Values Learn
on page 17—163followingall transmission repairs.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Automatic Transmission . 6T30/6T40/6T45/6T50 (MH8, MH9) 17-97

DTC P0776 or P0777 (Gen 1)

Diagnostic Instructions
' Perform the Diagnostic System Check - Vehicle
on page 6-66 prior to using this diagnostic
procedure.
' Review Strategy Based Diagnosis on page 6-58
for an overview of the diagnostic approach.
- Diagnostic Procedure Instructions on page 659
provides an overview of each diagnostic category.
DTC Descriptors
DTC P0776: Pressure Control Solenoid Valve 2 Stuck Off
DTC P0777: Pressure Control Solenoid Valve 2 Stuck On

CircuitlSystem Description - Throttle position signal is valid.

The clutch pressure control solenoid 2 is part of the - High side driver is enabled.
control solenoid valve assembly which has no
Conditions for Setting the DTC
serviceable components. Pressure control solenoid 2
regulates transmission fluid pressure to the 3-5-R P0776
regulator valve which controls pressure to the 3-5-R
clutch. The transmission control module (TCM) The TCM detects an incorrect on-coming clutch gear
calculates gear ratio based on the speed signals from ratio, or flare, when the 3-5—Rclutch is commanded ON
the input shaft speed (ISS) sensor and the output shaft for 4 seconds and the transmission input shaft speed is
speed (088) sensor. The TCM compares the expected 400 RPM or greater from the anticipated input shaft
transmission gear ratio to the calculated gear ratio for speed. This must occur 3 times.
each commanded gear. P0777
”- Conditions for Running the DTC The TCM detects an incorrect off-going clutch gear
ratio, or tie-up, when the 3-5-R clutch is commanded
P0776 OFF for 1 second and the transmission input shaft
- DTC P0101, P0102, P0103, P0106, P0107, speed is 400 RPM or less from the anticipated input
P0108, P0171, P0172, P0174, P0175, P0201, shaft speed. This must occur 3 times.
P0202, P0203, P0204, P0205, P0206, P0207,
P0208, P0300, P0301, P0302, P0303, P0304, Action Taken When the DTC Sets
P0305, P0306, P0307, P0308, P0401, P042E, P0776
P0716, P0717, P0722, P0723, or P182E is
- DTC P0776 is a Type A DTC.
not set.
~ TCM commands maximum line pressure.
' Engine speed is between 400—7500RPM for
5 seconds. - TCM limits the transmission to reverse and
2nd gear.
- lgnition voltage is between 9—32V.
- TCM freezes transmission adaptive functions.
. Transmission fluid temperature is —7°C(19°F) or
greater. - TCM inhibits TAP Up/TAP Down function.
- Transmission output speed is 650 RPM or greater, ‘ TCM inhibits manual shifting of fon/vardgears.
or the throttle position is 0.5 percent or greater. P0777
o Throttle position signal is valid. . DTC P0777 is a Type A DTC.
- High side driver is enabled. - TCM commands maximum line pressure.
P0777 - TCM limits the transmission to reverse and
- DTC P0101, P0102, P0103, P0106, P0107, 3rd gear.
P0108, P0171, P0172, P0174, P0175, P0201, - TCM freezes transmission adaptive functions.
P0202, P0203, P0204, P0205, P0206, P0207, 0 TCM inhibits TAP Up/TAP Down function.
P0208, P0300, P0301, P0302, P0303, P0304,
P0305, P0306, P0307, P0308, P0401, P042E, o TCM inhibits manual shifting of forward gears.
P0716, P0717, P0722, P0723, or P182E is Conditions for Clearing the DICIDTC
not set.
DTCs P0776 and P0777 are TypeA DTCs.
' Engine speed is between 400—7500RPM for
5 seconds. Reference Information
- lgnition voltage is between 9-32 V.
Schematic Reference
- Transmission fluid temperature is -7°C (19°F) or
greater. Automatic Transmission Controls Schematics on
- Transmission output shaft speed is 200 RPM or page 17—30
greater.
2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
17-98 Automatic Transmission - 6T30/6T40/6T45/6T50
Connector End View Reference
- Component Connector End Views on page 11-269
- lnline Harness Connector End Views on
page 11—465
Description and Operation
- Transmission General Description on page 17-317
. Transmission Component and System Description
on page 17-318
- Reverse (Gen 1) on page 17-325 or Reverse (Gen
2) on page 17-327
' Drive Range, Third Gear (Gen 1) on page 17-345
or Drive Range, Third Gear (Gen 2) on
page 17-347
- Drive Range, Fifth Gear (Gen 1) on page 17—356
or Drive Range, Fifth Gear (Gen 2) on
page 17-358
DTC Type Reference
Powertrain Diagnostic Trouble Code (DTC) Type
Definitions on page 6-68
Scan Tool Reference
Control Module References on page 6—3for scan tool
information
CircuitlSystem Verification
Warning: Refer to Parking Brake and Drive Wheels
Warning on page 0-5. ‘ ranges
Note: Ifother DTCs are set, diagnose those DTCs first.
1. Engine idling in Park, with parking brake applied
and drive wheels chocked.
2. Verify the transmission fluid level and condition is
correct. Refer to Transmission Fluid Level and
Condition Check on page 17—164.
3. Verify the scan tool TFP Switch 1 parameter
displays the correct state for each gear range while
placing the gear select lever in Park, Reverse, and
Neutral range. Refer to Transmission Fluid
Pressure Switch Logic on page 17—11.
2 If the correct state for each gear range is not
displayed
Refer to CircuitlSystem Testing.
U If the correct state for each gear range is
displayed
4. Gear select lever in Drive range.
Note: Use Drive 1st —Engine Braking to determine
expected 1st gear Transmission Fluid Pressure Switch
parameter states.
5. Verify the scan tool TFP Switch 1 parameter
displays the correct state for each gear range while
commanding the scan tool Shift Transmission Gear
through all fonNardranges. Refer to Transmission
Fluid Pressure Switch Logic on page 17-11.
2 If the correct state for each gear range is not
displayed
Refer to CircuitlSystem Testing.
U if the correct state for each gear range is
displayed
(MH8, MH9)
6. lgnition ON, engine OFF. Clear the TCM DTC
informationwith a scan tool.
7. Perform the Road Test on page 17-167.
8. Verify DTC P0776 or P0777 did not set.
2 If a DTC sets
Refer to CircuitlSystem Testing.
U lfa DTC does not set
9. 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.
10. Verify the DTC does not set.
2 If the DTC sets
Refer to CircuitlSystem Testing.
U If the DTC does not set
11. AMOK.
CircuitlSystem Testing
Note: You must perform the CircuitlSystem Verification
first.
1. Engine idling at the normal operating temperature.
2. Verify the transmission line pressures are within
range. Refer to Line Pressure Check on
page 17-166 and Solenoid Valve Pressure (Gen 1)
on page 17—12.
2 If the line pressures are not within the specified
Refer to Fluid Pressure High or Low on
page 17-191.
U If line pressures are within the specified ranges
9° Engine Idling,shift selector in the Drive position.
4. Verify the scan tool parameters listed below
display the correct state for each gear range while
each gear range while commanding the scan tool
Shift Transmission Gear through all fon/vard
ranges. Refer to Transmission Fluid Pressure
Switch Logic on page 17—11 for the correct gear
range states.
- TFP Switch 1
. TFP Switch 3
- TFP Switch 4
- TFP Switch 5
2 If the correct state for each gear range is not
displayed
4.1. lgnition OFF.
4.2. Remove the Control Valve Body. Refer to
Control Valve Body Replacement on
page 17-213.
4.3. Verify the Control Valve Body is not
contaminated with any debris and there is no
damage or sticking valves, refer to Control
Valve Body Cleaning and Inspection (Gen 2)
on page 17—306.
2 Ifthere is contamination, damage, or sticking
valves, repair or replace the control valve body
as necessary.
(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
 Automatic Transmission - 6T30/6T40/6T45/6T50 (MH8, MH9) '17-99
2 lfthere is no contamination, damage, or sticking DTC P0776 or P0777 —Q8 Control Solenoid Valve
valves, replace the Q8 Control Solenoid Valve Assembly
Assembly. . Clutch Pressure Control Solenoid 2 stuck
U If the correct state for each gear range is ON/OFF.
displayed - O—ringseals leaking.
5. Verify the conditions listed below do not exist. - Valve body filter plate assembly cracked, blocked,
Carefully inspect each component for that or damaged gasket seal.
condition. Repair or replace as necessary.
DTC P0776 or P0777 —3-5-R and 4-5-6 Clutch Repair Instructions
.4.2“...“
W
4. Housing Assembly Perform the Diagnostic Repair Verification on
page 6—92after completing the repair.
3-5—Rclutch backing plate retaining ring not seated,
causing clutch pack over—travel. Perform the Transmission Adaptive Values Learn on
page 17-163 following all transmission related repairs.
DTC P0776 or P0777 —Torque Converter (w/Fluid
. Internal Components Removal on page 17—236
Pump) Housing Assembly
0 3-5-Reverse and 4-5—6Clutch Housing
Fluid pump housing/gear damaged/scored. Disassemble (6T30/40/45/50- Gen 2) on
DTC P0776 or P0777 —Control Valve Body page 17-256
Assembly . 3—5—Reverse and 4-5-6 Clutch Housing Assemble
- Actuator feed limit circuit supply fluid to solenoids (6T30/40/45/50- Gen 2) on page 17-261
restricted or not available —debris or sediment - 3—5-Reverseand 4-5-6 Clutch Housing, and Input,
blockage. Reaction, and Output Carrier Installation on
- 3—5-RRegulator Valve stuck/sticking —debris, page 17—269
binding, damaged valve, or scored bore. - Refer to Control Module References on page 6—3
- Control valve body ball check valve not seating for control solenoid valve assembly replacement,
correctly —debris. programming and setup.
DTC P0776 —Channel Plate and Spacer Plate
Oil channels or orifices blocked by debris.
«
_
.2...“
,_.
.,W
,2
-..
.,2..ss-.-..,...
22.

2013
—
Sonic
(US/Canada)
Service
Manual
(5377994)
17-100 Automatic Transmission - 6T30/6T40l6T45/6T50 (MH8, MH9)

DTC P0776 or P0777 (Gen 2)

Diagnostic Instructions
- Perform the Diagnostic System Check —Vehicle
on page 6—66prior to using this diagnostic
procedure.
- Review Strategy Based Diagnosis on page 6-58
for an overview of the diagnostic approach.
- Diagnostic Procedure Instructions on page 6-59
provides an overview of each diagnostic category.
DTC Descriptors
DTC P0776: Pressure Control Solenoid Valve 2 Stuck Off
DTC P0777: Pressure Control Solenoid Valve 2 Stuck On

CircuitlSystem Description ' Transmission fluid temperature is —6.7°C(20°F) or

Pressure control solenoid valve 2 is part of the control
solenoid valve assembly, which has no serviceable
components. Pressure control solenoid valve 2
regulates transmission fluid pressure to the 3—5—R
regulator valve, which controls pressure to the 3-5-R
clutch. The transmission control module (TCM)
calculates gear ratio based on the speed signals from
the input shaft speed (ISS) sensor and the output shaft
speed (088) sensor. The TCM compares the expected
transmission gear ratio to the calculated gear ratio for
each commanded gear.
greater.
- Transmission output shaft speed is 100 RPM or
greater, or the throttle position is 0.5% or greater.
' Throttle position signal is valid.
- High side driver is enabled.
- Throttle position is 10%or greater and the engine
torque is 45 Nm (33 lb ft) or greater.
- DTC runs continuously during shift when the 3-5-R
clutch is commanded OFF, until commanded
range is attained.

Conditions for Running the DTC
P0776
- DTC P0101, P0102, P0103, P0106, P0107,
P0108, P0171, P0172, P0174, P0175, P0201,
P0202, P0203, P0204, P0205, P0206, P0207,
P0208, P0300, P0301, P0302, P0303, P0304,
P0305, P0306, P0307, P0308, P0401, P042E,
P0716, P0717, P0722, P0723, or P182E is
not set.
- Engine speed is 400—7,500RPM for 5 s.
- lgnition voltage is 9—32V.
' Transmission fluid temperature is —6.7°C(20°F) or
greater.
. Transmission output speed is 100 RPM or greater,
or the throttle position is 0.5% or greater.
- Throttle position signal is valid.
' High side driver is enabled.
- Commanded range is reverse, 3rd gear or
5th gear.
0 DTC runs continuously when the above conditions
are met.
P0777
- DTC P0101, P0102, P0103, P0106, P0107,
P0108, P0171, P0172, P0174, P0175, P0201, Action
P0202, P0203, P0204, P0205, P0206, P0207,
P0208, P0300, P0301, P0302, P0303, P0304,
P0305, P0306, P0307, P0308, P0401, P042E,
P0716, P0717, P0722, P0723, or P182E is
not set.
- Engine speed is 400—7,500RPM for 5 s.
- Ignitionvoltage is 9—32V.
Conditions for Setting the DTC
P0776 —Condition 1
- Commanded gear is 3rd.
- Gearbox slip of 400 RPM or greater is detected
for 2.5 s.
o TCM commands 4th gear if the above conditions
exist and detects a gear ratio of 1.37—1.52for 3 s.
- Conditions listed above have to occur 2 times.
P0776 —Condition 2
- Commanded gear is 5th.
- Gearbox slip of 400 RPM or greater is detected
for 3 s.
- TCM commands 6th gear if the above conditions
exist and detects 6th gear ratio for 3.5 s.
. Conditions listed above have to occur 3 times.
P0777
- The TCM detects an incorrect off-going clutch
gear ratio, or tie-up, when the 3-5-R clutch is
commanded OFFfor 1 s.
. The transmission input shaft speed is 400 RPM or
less from the anticipated input shaft speed.
0 The conditions listed above must occur 3 times.
Taken When the DTC Sets
P0776
- P0776 is a Type A DTC.
- TCM commands maximum line pressure.
- TCM freezes transmission adaptive functions.
- TCM inhibits TAP Up/TAP Down function.
- TCM inhibits manual shifting offonNard gears.

2013
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Service
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 Automatic Transmission
0 TCM inhibits powertrain braking.
' TCM inhibits auto grade braking.
- TCM inhibits neutral idle.
- TCM commands 2nd gear ifthe transmission is in
a fon/vardgear and the output speed is less than
700 RPM.
' TCM commands neutral Ifthe output speed' Is
700 RPM or greater
P0777
- P0777 is a Type A DTC.
- TCM commands maximum line pressure.
' TCM limits the transmission to reverse and
3rd gear.
- TCM freezes transmission adaptive functions.
- TCM inhibits TAP Up/TAP Down function.
' TCM inhibits manual shifting of fon/vardgears.
- TCM inhibits neutral idle.
- TCM inhibits powertrain braking.
- TCM inhibits auto grade braking.
Conditions for Clearing the DTC
P0776 and P0777 are Type A DTCs.
Diagnostic Aids
Before performing a road test, configure and setup the
scan tool for snapshot mode. This will allow you to
display, monitor,and verify multiple transmission data
parameters at one time, after the road test.
Reference Information
Schematic Reference
Automatic Transmission Controls Schematics on
page 17—30
Connector End View Reference
- Component Connector End Views on page 11-269
- lnline Harness Connector End Views on
page 11—465
Description and Operation
- Drive Range, Fifth Gear (Gen 1) on page 17—356
or Drive Range, Fifth Gear (Gen 2) on
page 17-358
o Drive Range - Foun‘h Gear (Gen 1) on
page 17—349or Drive Range - Fourth Gear (Gen
2) on page 17—351
- Drive Range, Third Gear (Gen 1) on page 17-345
or Drive Range, Third Gear (Gen 2) on
page 17-347
- Electronic Component Description on
page 17-319
~ Transmission Component and System Description
on page 17-318
- Transmission General Description on page 17-317
DTC Type Reference
Powertrain Diagnostic Trouble Code (DTC) Type
Definitions on page 6-68
—6T30/6T40/6T45/6T50 (MH8, MH9) 17-101
Scan Tool Reference
Control Module References on page 6-3 for scan tool
information
CircuitlSystem Verification
Warning: Refer to Parking Brake and Drive Wheels
Warning on page 0-5.
Note: Ifother DTCs are set, diagnose those DTCs first.
1. lgnition ON.
2. Verify DTC P0716, P0717, P0722, P0723, P0770.
P077D, P07BF, or P07CO was not set by reviewing
the scan tool Freeze Frame/Failure Records data.
2 If any of the DTCs were set
Refer to Diagnostic Trouble Code (DTC) List -
Vehicle on page 6-69.
U if none of the DTCs were set
3. Engine idling, transmission in Park, with parking
brake applied and drive wheels chocked.
4. Verify the transmission fluid level and condition is
correct. Refer to Transmission Fluid Level and
Condition Check on page 17—164.
2 if the transmission fluid level and condition is
not correct
Repair as necessary.
U If the transmission fluid level and condition is
correct
5. lgnition ON, clear the TCM DTCs with a scan tool.
6. Verify DTC P0776 or P0777 does not set while
performing a road test. Refer to Road Test on
page 17-167.
2 if DTC P0776 or P0777 sets
Refer to CircuitlSystem Testing.
U If DTC P0776 or P0777 does not set
7. 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.
8. Verify the DTC does not set.
2 If the DTC sets
Refer to CircuitlSystem Testing.
U If the DTC does not set
9. All OK.
CircuitlSystem Testing
Note: You must perform the CircuitlSystem Verification
first.
1. Engine idling at the normal operating temperature.
2. Verify the transmission line pressures are within
the specified range. Refer to Line Pressure Check
on page 17—166and Solenoid Valve Pressure (Gen
1)on page 17—12.
2 If the pressures are not within range
Refer to Fluid Pressure High or Low on
page 17-191.
U If the pressures are within range

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
17402 Automatic Transmission - 6T30/6T40l6T45/6T50
3. lgnition OFF, remove the Q8 Control Solenoid
Valve Assembly.
4. Verify the pressure changes for all solenoids when
performing the solenoid test. Refer to Control
Solenoid Valve and Transmission Control Module
Assembly Solenoid Performance Test on
page 17—160.
2 if the pressure does not change
Replace the QB Control Solenoid Valve
Assembly.
U If the pressure changes
5. Verify the mechanical conditions listed below do
not exist. Repair or replace as necessary.
DTC P0776 or P0777 —Control Valve Body
Assembly
- Actuator feed limit circuit supply fluid to solenoids
restricted or not available —debris or sediment
blockage.
- 3-5—RRegulator Valve stuck/sticking —debris,
binding, damaged valve, or scored bore.
° Control valve body ball check valve not seating
correctly —debris.
DTC P0776 —3-5-R and 4-5-6 Clutch Housing
Assembly
3-5—RClutch backing plate retaining ring not seated,
causing clutch pack over-travel.
(MH8, MH9)
DTC P0776 or P0777 —Torque Converter (w/Fluid
Pump) Housing Assembly
Fluid pump housing/gear damaged/scored.
DTC P0776 —Channel Plate and Spacer Plate
Oil channels or orifices blocked by debris.
DTC P0776 or P0777 —QB Control Solenoid Valve
Assembly
- Clutch Pressure Control Solenoid 2 stuck
ON/OFF.
- O—ringseals leaking.
. Valve body filter plate assembly cracked, blocked,
or damaged gasket seal. '
Repair Instructions
Perform the Diagnostic Repair Verification on
page 6—92after completing the repair.
- Perform the Transmission Adaptive Values Learn
on page 17-163 following all transmission repairs.
- Control Module References on page 6-3 for
Control Solenoid Valve Assembly replacement,
programming and setup

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Automatic Transmission . 6T30/6T40/6T45/6T50 (MH8, MH9) 171103

DTC P0796 or P0797 (Gen 1)

Diagnostic Instructions
- Perform the Diagnostic System Check - Vehic/e
on page 6-66 prior to using this diagnostic
procedure.
- Review Strategy Based Diagnosis on page 6—58
for an overview of the diagnostic approach.
- Diagnostic Procedure Instructions on page 6-59
provides an overview of each diagnostic category.
DTC Descriptors
DTC P0796: Pressure Control Solenoid Valve 3 Stuck Off
DTC P0797: Pressure Control Solenoid Valve 3 Stuck On

CircuitlSystem Description - Transmission fluid temperature is —7°C(19°F) or

greater.
The clutch pressure control solenoid 3 is part of the
control solenoid valve assembly which has no - High side driver is enabled.
serviceable components. Pressure control solenoid 3 ° Transmission output shaft speed is 200 RPM or
regulates transmission fluid pressure to the R1/ greater.
4—5—6 regulator valve which controls pressure to the
reverse and low clutch and the 4-5-6 clutch. The Conditions for Setting the DTC
transmission control module (TCM) calculates gear P0796
ratio based on the speed signals from the automatic
transmission input shaft speed (ISS) sensor and the TCM detects an incorrect on-coming clutch gear ratio
output shaft speed (088) sensor. The TCM compares (incorrect gear ratio), or flare.
the expected transmission gear ratio to the calculated P0797
gear ratio for each commanded gear.
TCM detects an incorrect off-going clutch gear ratio
Conditions for Running the DTC (incorrect gear ratio), or shift tie-up.
P0796 Action Taken When the DTC Sets
~ DTC P0101, P0102, P0103, P0106, P0107,
P0108, P0171, P0172, P0174, P0175, P0201, P0796
P0202, P0203, P0204, P0205, P0206, P0207, ° DTC P0796 is a Type A DTC.
P0208, P0300, P0301, P0302, P0303, P0304, - TCM commands maximum line pressure.
P0305, P0306, P0307, P0308, P0401, P042E, - TCM freezes transmission adaptive functions.
P0716, P0717, P0722, P0723, or P182E is
not set. ° TCM inhibits TAP Up/TAP Down functions.
- Engine speed is between 400—7500RPM for - TCM inhibits manual up, manual down shifts with
5 seconds. the shift selector.
- Transmission output speed is 650 RPM or greater ' TCM limits the transmission to reverse and
or the throttle position is 0.5 percent or greater. 3rd gear.
- Ignitionvoltage is between 9—32V. P0797
- Transmission fluid temperature is —7°C(19°F) or - DTC P0797 is a Type A DTC.
greater. - TCM commands maximum line pressure.
- High side driver is enabled. ° TCM freezes transmission adaptive functions.
° Throttle position signal is valid. o TCM inhibits TAP Up/TAP Down functions.
P0797 - TCM inhibits manual up, manual down shifts with
- DTC P0101, P0102, P0103, P0106, P0107, the shift selector.
P0108, P0171, P0172, P0174, P0175, P0201, - TCM limits the transmission to reverse and
P0202, P0203, P0204, P0205, P0206, P0207, 4th gear.
P0208, P0300, P0301, P0302, P0303, P0304,
P0305, P0306, P0307, P0308, P0401, P042E, Conditions for Clearing the DICIDTC
P0716, P0717, P0722, P0723, or P182E is DTCs P0796 and P0797 are TypeA DTCs.
not set.
' Engine speed is between 400—7500RPM for Diagnostic Aids
5 seconds. Before performing a road test, configure and setup the
- Transmission output speed is 650 RPM or greater, scan tool for snapshot mode. This allows you to
or the throttle position is 0.5 percent or greater. monitor,display, and verify multiple transmission data
parameters at one time, after the road test.
° Throttle position signal is valid.
- Ignitionvoltage is between 9—32V.
2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
17-104 Automatic Transmission —6T30/6T40/6T45/6T50
Reference Information
Schematic Reference
Automatic Transmission Controls Schematics on
page 17—30
Connector End View Reference
- Component Connector End Views on page 11-269
- lnline Harness Connector End Views on
page 11—465
Description and Operation
- Transmission General Description on page 17-317
' Transmission Component and System Description
on page 17-318
- Electronic Component Description on
page 17—3 19
0 Reverse (Gen 1) on page 17—325or Reverse (Gen
2) on page 17-327
- Drive Range, First Gear Engine Braking (Gen 1)
on page 17-333 or Drive Range, First Gear Engine
Braking (Gen 2) on page 17—335
° Drive Range - Fourth Gear (Gen 1) on
page 17-349 or Drive Range —Fourth Gear (Gen
2) on page 17-351
0 Drive Range, Fifth Gear (Gen 1) on page 17—356
or Drive Range, Fifth Gear (Gen 2) on
page 17—358
- Drive Range, Sixth Gear (Gen 1) on page 17—366
or Drive Range, Sixth Gear (Gen 2) on
page 17—368
DTC Type Reference
Powertrain Diagnostic Trouble Code (DTC) Type
Definitions on page 6—68
Scan Tool Reference
Control Module References on page 6—3for scan tool
information
CircuitlSystem Verification
Warning: Refer to Parking Brake and Drive Wheels
Warning on page 0-5.
Note: Ifother DTCs are set, diagnose those DTCs first.
1. Engine idling in Park, with parking brake applied
and drive wheels chocked.
2. Verify the transmission fluid level and condition is
correct. Refer to Transmission Fluid Level and
Condition Check on page 17-164.
3. Verify the scan tool TFP Switch 5 parameter
displays the correct state for each gear range while
placing the gear select lever in Park, Reverse, and
Neutral range. Refer to Transmission Fluid
Pressure Switch Logic on page 17—11.
2 if the correct state for each gear range is not
displayed
Refer to CircuitlSystem Testing.
U If the correct state for each gear range is
displayed
4. Gearselect lever in Drive range.
(MH8, MH9)
Note: Use Drive1st— Engine Braking to determine
expected 1st gear Transmission Fluid Pressure Switch
parameter states.
5. Verify the scan tool TFP Switch 5 parameter
displays the correct state for each gear range while
commanding the scan tool Shift Transmission Gear
through all forward ranges. Refer to Transmission
Fluid Pressure Switch Logic on page 17—11.
2 If the correct state for each gear range is not
displayed
Refer to CircuitlSystem Testing.
U If the correct state for each gear range is
displayed
6. lgnition ON, engine OFF. Clear the TCM DTC
information with a scan tool.
7. Perform the Road Test on page 17—167.
8. Verify DTC P0796 or P0797 did not set.
2 If a DTC set
Refer to CircuitlSystem Testing.
U If a DTC does not set
9. 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.
10. Verify the DTC does not set.
2 If the DTC sets
Refer to CircuitlSystem Testing.
U If the DTC does not set
11. All OK.
CircuitlSystem Testing
Note: You must performthe CircuitlSystem Verification
first.
1. Engine idling at the normal operating temperature.
2. Verify the transmission line pressures are within
range. Refer to Line Pressure Check on
page 17-166 and Solenoid Valve Pressure (Gen 1)
on page 17-12.
2 If the line pressures are not within the specified
ranges
Refer to Fluid Pressure High or Low on
page 17—191.
U If line pressures are within the specified ranges
5° Engine Idling,shift selector in the Drive position.
4. Verify the scan tool parameters listed below
display the correct state for each gear range while
commanding the scan tool Shift Transmission Gear
through all forward ranges. Refer to Transmission
Fluid Pressure Switch Logic on page 17—11 for the
correct gear range states.
- TFP Switch 1
' TFP Switch 3
2013
—
Sonic
(US/Canada)
Service
Manual
(5377994)
 Automatic Transmission
- TFP Switch 4
- TFP Switch 5
2 If the correct state for each gear range is not
displayed
4.1. lgnition OFF.
4.2. Remove the Control Valve Body. Refer to
Control Valve Body Replacement on
page 17—213.
4.3. Verify the Control Valve Body is not
contaminated with any debris and there is no
damage or sticking valves, refer to Control
Valve Body Cleaning and Inspection (Gen 2)
on page 17—306.
2 Ifthere is contamination, damage, or sticking
valves, repair or replace the control valve body
as necessary.
2 Ifthere is no contamination, damage, or sticking
valves, replace the Q8 Control Solenoid Valve
Assembly.
U If the correct state for each gear range is
displayed
5. Verify the conditions listed below do not exist.
Carefully inspect each component for that
condition. Repair or replace as necessary.
P0796 - Transmission CoolinglLubrication
- Restriction/Ieak in OAC, oil to air, cooler/radiator.
- Restricted/leaking/kinked/damagedtransmission
oil cooler lines.
. Restriction/leak in transmission fluid pump
assembly.
P0796 —Input Shaft Support
Inputshaft tower seals damaged or leaking.
P0796 —4-5-6 Clutch Housing Assembly
4-5-6 Clutch Piston Assembly damaged/leaking.
2013
~Sonic
(US/Canada)
Service
Manual
(5377994)
- 6T30/6T40/6T45/6T50 (MH8, MH9) 17-105
P0796 —Torque Converter (wIFluid Pump) Housing
Assembly
- Fluid pump housing vanes/rotor/slide damaged/
scored.
0 Fluid pump or torque converter overstressed due
to high temperature.
P0796 —4-5-6 Reaction Carrier Hub Assembly
4—5—6reaction carrier Hub/Shaft —broken hub weld.
P0796 or P0797 ~Control Valve Body Assembly
4-5-6 Regulator Valve stuck/sticking —debris, binding,
damaged valve, or scored bore.
P0796 Output Carrier Assembly
Output carrier pinion pins too high or too low.
P0796 or P0797 —QB Control Solenoid Valve
Assembly
- Clutch Pressure Control Solenoid 3 stuck
ON/OFF.
- O-ring seals leaking.
- Valve body filter plate assembly cracked, blocked,
or damaged gasket seal.
Repair Instructions
Perform the Diagnostic Repair Verification on
page 6—92after completing the repair.
- Internal Components Removal on page 17-236
- 3-5-Reverse and 4-5-6 Clutch Housing
Disassemble (6T30/40/45/50- Gen 2) on
page 17—256
. 3-5-Reverse and 4-5-6 Clutch Housing Assemble
(6T30/40/45/50- Gen 2) on page 17-261
— 3-5-Reverse and 4-5-6 Clutch Housing, and Input,
Reaction, and Output Carrier Installation on
page 17—269
- Perform the Transmission Adaptive Values Learn
on page 17—163followingall transmission related
repairs.
- Refer to Control Module References on page 6-3
for Q8 Control Solenoid Valve Assembly
replacement, programming and setup.
17-106 Automatic Transmission - 6T30/6T40l6T45/6T50 (MH8, MH9)

DTC P0796 or P0797 (Gen 2)

Diagnostic Instructions
Perform the Diagnostic System Check - Vehicle
on page 6—66prior to using this diagnostic
procedure.
Review Strategy Based Diagnosis on page 6-58
for an overview of the diagnostic approach.
Diagnostic Procedure Instructions on page 6—59
provides an overview of each diagnostic category.
DTC Descriptors
DTC P0796: Pressure Control Solenoid Valve 3 Stuck Off
DTC P0797: Pressure Control Solenoid Valve 3 Stuck On

CircuitlSystem Description ' Transmission fluid temperature is —6.7°C(20°F) or

Pressure control solenoid 3 is part of the control
solenoid valve assembly, which has no serviceable
components. Pressure control solenoid 3 regulates
transmission fluid pressure to the R1/4—5-6regulator
valve which controls pressure to the reverse and low
clutch and the 4-5—6clutch. The transmission control
module (TCM) calculates gear ratio based on the speed
signals from the automatic transmission input shaft
speed (ISS) sensor and the output shaft speed (088)
sensor. The TCM compares the expected transmission
gear ratio to the calculated gear ratio for each
commanded gear.
Conditions for Running the DTC
P0796
DTC P0101, P0102, P0103, P0106, P0107,
P0108, P0171, P0172, P0174, P0175, P0201,
P0202, P0203, P0204, P0205, P0206, P0207,
P0208, P0300, P0301, P0302, P0303, P0304,
P0305, P0306, P0307, P0308, P0401, P042E,
P0716, P0717, P0722, P0723, or P182E is
not set.
Engine speed is 400—7,500RPM for 5 3.
Transmission output speed is 100 RPM or greater
or the throttle position is 0.5% or greater.
lgnition voltage is 9—32V.
Transmission fluid temperature is —6.7°C(20°F) or
greater.
High side driver is enabled.
Throttle position signal is valid.
P0797
DTC P0101, P0102, P0103, P0106, P0107,
P0108, P0171, P0172, P0174, P0175, P0201,
P0202, P0203, P0204, P0205, P0206, P0207,
P0208, P0300, P0301, P0302, P0303, P0304,
P0305, P0306, P0307, P0308, P0401, P042E,
P0716, P0717, P0722, P0723, or P182E is
not set.
Engine speed is 400—7,500RPM for 5 3.
Transmission output speed is 100 RPM or greater
or the throttle position is 0.5% or greater.
Throttle position signal is valid.
lgnition voltage is 9—32V.
greater.
' High side driver is enabled.
- The throttle position is 10% or greater and the
engine torque is 45 N-m(33 lb ft) or greater if
attained gear is 1st free wheel.
' DTC runs continuously during shift when the 4—5—6
clutch is commanded OFF, until commanded
range is attained.
Conditions for Setting the DTC
P0796
The TCM detects an incorrect gear ratio when the 4-5-6
clutch is commanded ON. This condition must occur 3
times.
P0797
The TCM detects an incorrect gear ratio change when
the 4-5-6 clutch is commanded OFF during a shift. This
must occur 3 times.
Action Taken When the DTC Sets
‘ P0796 and P0797 are Type A DTCs.
- TCM commands maximum line pressure.
- TCM freezes transmission adaptive functions.
- TCM inhibits TAP Up/TAP Down functions.
- TCM inhibits manual up, manual down shifts with
the shift selector.
- TCM inhibits powertrain braking.
- TCM inhibits neutral idle.
0 TCM inhibits auto grade braking.
. TCM limits the transmission to reverse and 3rd
gear —DTC P0796 only.
' TCM limits the transmission to reverse and 4th
gear —DTC P0797 only.
Conditions for Clearing the DICIDTC
P0796 and P0797 are Type A DTCs.
Diagnostic Aids
Before performing a road test, configure and setup the
scan tool for snapshot mode. This allows you to
monitor,display, and verify multiple transmission data
parameters at one time, after the road test.

l
2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
~2n
‘-.
 Automatic Transmission , 6T30/6T40/6T45/6T50 (MH8, MH9) 17-107
Reference Information 4. Verify the transmission fluid level and condition is
correct. Refer to Transmission Fluid Level and
Schematic Reference Condition Check on page 17-164.
Automatic Transmission Controls Schematics on 2 If the transmission fluid level and condition is
page 17-30 not correct
Connector End View Reference Repair as necessary.
- Component Connector End Views on page 11-269 U If the transmission fluid level and condition is
correct
- lnline Harness Connector End Views on
5. lgnition ON, Clear the TCM DTCs with a scan tool.
page 11-465
6. Verify DTC P0796 or P0797 does not set while
Description and Operation performing a road test. Refer to Road Test on
- Transmission General Description on page 17—317 page 17-167.
' Transmission Component and System Description 2 If DTC P0796 or P0797 sets
on page 17-318 Refer to CircuitlSystem Testing.
- Electronic Component Description on U If DTC P0796 or P0797 does not set
page 17-319
7. Operate the vehicle within the Conditions for
- Drive Range - Fourth Gear (Gen 1) on Running the DTC. You may also operate the
page 17-349 or Drive Range - Fourth Gear (Gen vehicle within the conditions that you observed
2) on page 17-351 from the Freeze Frame/Failure Records data.
- Drive Range, Fifth Gear (Gen 1) on page 17—356 8. Verify the DTC does not set.
or Drive Range, Fifth Gear (Gen 2) on
page 17-358 2 If the DTC sets
- Drive Range, Sixth Gear (Gen 1) on page 17—366 Refer to CircuitlSystem Testing.
or Drive Range, Sixth Gear (Gen 2) on U if the DTC does not set
page 17—368 9. All OK.
Electrical Information Reference
CircuitlSystem Testing
- Circuit Testing on page 11-526 Note: You must performthe Circuit/System Verification
' Connector Repairs on page 11-548 first.
' Testing for IntermittentConditions and Poor 1. Engine idling at the normal operating temperature.
Connections on page 11-531
2. Verify the transmission line pressures are within
° Wiring Repairs on page 11-537 the specified range. Refer to Line Pressure Check
DTC Type Reference on page 17—166and Solenoid Valve Pressure (Gen
1) on page 17-12.
Powertrain Diagnostic Trouble Code (DTC) Type
Definitions on page 6-68 2 If the pressures are not within range
Refer to Fluid Pressure High or Low on
Scan Tool Reference page 17—191.
Control Module References on page 6-3 for scan tool U If the pressures are within range
information 3. lgnition OFF, remove the Q8 Control Solenoid
CircuitlSystem Verification Valve Assembly.
Warning: Refer to Parking Brake and Drive Wheels 4. Verify the pressure changes for all solenoids when
Warning on page 0-5. performing the solenoid test. Refer to Control
Solenoid Valve and Transmission Control Module
1. IgnitionON. Assembly Solenoid Performance Test on
2. Verify DTC P0716, P0717, P0722, P0723, P0770, page 17-160.
P077D, PO7BF, or P07C0 was not set by reviewing 2 If the pressure does not change
the scan tool Freeze Frame/Failure Records data. Replace the Q8 Control Solenoid Valve
2 if any of the DTCs were set Assembly.
Refer to Diagnostic Trouble Code (DTC) List - U If the pressure changes
Vehicle on page 6-69. 5. Verify the mechanical conditions listed below do
U If none of the DTCs were set not exist. Repair or replace as necessary.
3. Engine idling, transmission in Park, with parking P0796 or P0797 —Control Valve Body Assembly
brake applied and drive wheels chocked.
4-5-6 Regulator Valve stuck/sticking —debris, binding,
damaged valve, or scored bore.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
1‘7-108 Automatic Transmission - 6T30/6T40l6T45/6T50
P0796 —Transmission Cooling/Lubrication
. Restriction/leak in OAC, oil to air, cooler/radiator.
' Restricted/Ieaking/kinked/damagedtransmission
oil cooler lines.
- Restriction/Ieak in transmission fluid pump
assembly.
P0796 - Automatic Transmission Fluid Filter
Assembly
Oil filter or filter seal loose or damaged.
P0796 —Input Shaft Support
Inputshaft tower seals damaged or leaking.
P0796 —4-5-6 Clutch Housing Assembly
4-5-6 Clutch Piston Assembly damaged/Ieaking.
P0796 —Torque Converter (wIFluid Pump) Housing
Assembly
° Fluid pump housing vanes/rotor/slide damaged/
scored.
- Fluid pump or torque converter overstressed due
to high temperature.
P0796 - 4-5-6 Reaction Carrier Hub Assembly
4-5—6Reaction Carrier Hub/Shaft ~broken hub weld.
(MH8, MH9)
P0796 - 3-5-R and 4-5-6 Clutch Housing Assembly
4—5—6 Clutch Backing Plate Retaining Ring not seated/
oriented, causing clutch pack/piston overtravel.
P0796 Output Carrier Assembly
Output carrier pinion pins too high or too low. 2.2.
W,
4,...
P0796 or P0797 —QB Control Solenoid Valve
Assembly
- Clutch Pressure Control Solenoid 3 stuck
ON/OFF.
- O-ring seals leaking.
' Valve body filter plate assembly cracked, blocked,
or damaged gasket seal.
Repair Instructions
Perform the Diagnostic Repair Verification on
page 6—92after completing the repair.
- Perform the Transmission Adaptive Values Learn
on page 17—163followingall transmission repairs.
. Control Module References on page 6-3 for
Control Solenoid Valve Assembly replacement,
programming and setup.

l
-Sonic
2013 Service
(US/Canada) (5377994)
Manual 4”,,“
 Automatic Transmission =6T30/6T40/6T45/6T50 (MH8, MH9) 17~109
DTC P0815, P0816, or P0826
Diagnostic Instructions
° Perform the Diagnostic System Check - Vehicle
on page 6-66 prior to using this diagnostic
procedure.
- Review Strategy Based Diagnosis on page 6—58
for an overview of the diagnostic approach.
- Diagnostic Procedure Instructions on page 6-59
provides an overview of each diagnostic category.
DTC Descriptors
WWFW
Wevw
2..
_,__,A DTC P0815: Upshift Switch Circuit
DTC P0816: Downshift Switch Circuit
DTC P0826: Up and Down Shift Switch Circuit
Typical Scan Tool Data

Driver Shift Request

, , Opeanigh Short to Voltage
Circuit Short to Ground Resistance
TapUp/TapDownSwitchSignal Circuit invalid None lnvalid/None

CircuitlSystem Description P0815 —Condition 2

When the shift lever is placed in manual mode (M), the TCM detects an upshift request for 10 minutes with the
driver shift request (DSR), also known as the tap shift shift lever in a forward range.
function is activated. The DSR allows the vehicle
P0816 —Condition 1
operator to shift gears by pushing the plus (+)button for
an upshift or minus (-)button for a downshift. The body TCM detects a downshift request for 1 second with the
control module (BCM) supplies a signal circuit to the shift lever‘in PARK, or NEUTRAL.
shift controller. The shift controller has switches P0816 - Condition 2
connected to a resistor array. When the lever is in the M
position, a voltage drop occurs across the resistor TCM detects a downshift request for 10 minutes with
network. When the plus or minus button is pushed, a the shift lever in a fonNard range.
.m%_,.2
Mm.--
M corresponding voltage drop occurs across the resistor P0826
network.This voltage drop is monitored by the BCM.
The BCM will send the request to the transmission TCM detects an invalid voltage on the TAP up/down
control module to perform the upshift or downshift. signal circuit for 1 minute. .

Conditions for Running the DTC Action Taken When the DTC Sets
WM”. ' DTCs P0815, P0816, and P0826 are
P0815 or P0816
Type C DTCs.
- Engine speed is 400 RPM or greater for
- TCM disables TAP shift operation.
5 seconds.
- Ignitionvoltage is 9.0 V or greater. Conditions for Clearing the DTC
- DTC P0815, P0816, P0826, P1761, P182E, DTCs P0815, P0816, and P0826 are Type C DTCs.
P1876, P1877, or P1915 is not set.
- Time since the last gear range change is greater Reference information
than 1 second. Schematic Reference
P0826 Automatic Transmission Controls Schematics on
- Engine speed is 400 RPM or greater for page 17-30
5 seconds.
Connector End View Reference
0 Ignitionvoltage is 9.0 V or greater.
- DTC P0826 or P1761 is not set. Component Connector End Views on page 11-269
Description and Operation
Conditions for Setting the DTC
- Transmission General Description on page 17-317
P0815 —Condition 1
- Transmission Component and System Description
Transmission control module (TCM) detects an upshift on page 17—318
request for 1 second with the shift lever in PARK,
or NEUTRAL.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
17:110 Automatic Transmission —6T30/6T40/6T45/6T50 (MH8, MH9)
Electrical Information Reference 2 Ifless than 2 Q, repair the open/high resistance
in the ground connection.
Circuit Testing on page 11-526
If less than 10 Q
Connector Repairs on page 11-548
0). lgnition ON.
Testing for IntermittentConditions and Poor
Connections on page 11-531 . Test for 11V or greater at the S3 transmission shift
lever harness connector between signal circuit
Wiring Repairs on page 11—537 terminal 3 and ground.
DTC Type Reference If less than 11 V
Powertrain Diagnostic Trouble Code (DTC) Type 4.1. Ignition OFF, remove the connector at the K9
Definitions on page 6-68 body control module.
4.2. Test for infinite resistance between the S3 2..
WW
\W
Scan Tool Reference
transmission shift lever harness connector
Control Module References on page 6-3 for scan tool signal circuit terminal 3 and ground.
information 2 Ifless than infinite resistance, repair the short to
CircuitlSystem Verification ground in the circuit.
Warning: Refer to Parking Brake and Drive Wheels U Ifinfinite resistance.
Warning on page 0-5. 4.3. Test for less than 2 Q in the signal circuit and
to end.
1. lgnition ON.
2 If2 Q or greater, repair the open/high resistance
2. Verify with a scan tool there were no internal mode in the circuit.
switch (lMS) DTCs set.
:> if IMS DTCs were set 2 Ifless than 2 Q, replace the K9 body control
module.
Refer to Diagnostic Trouble Code (DTC) List - If 11Vor greater
Vehicle on page 6-69.
.0" lgnition OFF.
if IMS DTCs were not set
Test for 5.8—6.4kQ between the 83 transmission
Shift lever in the M position, verify the scan tool shift lever connector terminal 3 and terminal 2.
Driver Shift Request parameter changes from
None to Upshift when the plus button is pressed, ' If not between 5.8—6.4kQ
and from None to Downshift when the minus button Replace the S3 transmission shift lever.
is pressed. lf between 5.8—6.4kQ
If the parameter does not display the correct Test for 1.8—2.2kQ between the s3 shift lever
values connector terminal 3 and terminal 2 with the tap
Refer to CircuitlSystem Testing belOw. down button depressed.
<: If the parameter displays the correct value If not between 1.8—2.2kQ
After performing the above steps, verify that the Replace the 83 transmission shift lever.
DTC does not reset by operating the vehicle within If between 1.8—2.2kQ '
the Conditions for Running the DTC. You may also
operate the vehicle within the conditions you Test for 580—680Q between the 83 shift lever
observe from the Freeze Frame/Failure Records connector terminal 3 and terminal 2 with the tap up
data. Ifthe vehicle passes the CircuitlSystem button depressed.
Verification procedure, then STOP. Do not perform If not between 580—680Q
the CircuitlSystem Testing or Component Testing
Replace the S3 transmission shift lever.
as this may result in an unnecessary part
replacement. Refer to Testing for Intermittent If between 580—680Q
Conditions and Poor Connections on page 11-531. Test for less than 2 Q in the signal circuit and
to end. .'
CircuitlSystem Testing
If 2 Q or greater
1. IgnitionOFF, disconnect the harness connector
from the S3 transmission shift lever. Repair the open/high resistance in the circuit.
2. Test for less than 10 Q between the S3 U If less than 2 Q
transmission shift lever harness connector 10. Replace the K9 body control module.
terminal 2 and ground.
2) if 10 Q or greater Repair Instructions
Perform the Diagnostic Repair Verification on
Test for less than 2 Q in the ground circuit end
page 6-92 after completing the diagnostic repair.
to end.
Refer to Control Module References on page 6—3
2 |f2Q or greater, repair the open/high resistance for BCM replacement, programming and setup.
in the circuit.
Refer to Transmission Control Replacement on
page 17—193for AT TAP shift switch replacement.

2013
»Sonic
(US/Canada)
Service
Manual
(5377994)
 Automatic Transmission - 6T30/6T40/6T45/6T50 (MH8, MH9) 17:111

DTC P0842 or P0843

Diagnostic Instructions
- Perform the Diagnostic System Check —Vehicle
on page 6-66 prior to using this diagnostic
procedure.
- Review Strategy Based Diagnosis on page 6—58
for an overview of the diagnostic approach.
~ Diagnostic Procedure Instructions on page 6-59
provides an overview of each diagnostic category.
DTC Descriptors
DTC P0842: Transmission Fluid Pressure Switch 1 Circuit Low Voltage
DTC P0843: Transmission Fluid Pressure Switch 1 Circuit High Voltage
Diagnostic Fault Information

Open/High ' Signal

Circuit Short to Ground Resistance Short to Voltage Performance
TFP Switch1 Signal P0842 P0843 P0843 -
TFP Switch3 Signal P0872 P0873 P0873 —-
TFP Switch4 Signal P0877 P0878 P0878 -
TFP Switch5 Signal P0989 P0990 P0990 -

Typical Scan Tool Data

Transmission Fluid Pressure Switch1

Opeanigh
Circuit Short to Ground Resistance Short to Voltage
Operating Conditions: Enginerunning,normaloperatingtemperature
ParameterNormalRange:Highor Low
TransmissionFluidPressureSwitch1 Signal I Low I High I High

CircuitlSystem Description Conditions for Running the DTC

The transmission fluid pressure (TFP) switch 1
assembly is part of the control solenoid valve assembly
which has no serviceable components. The
transmission control module (TCM) supplies a signal
circuit to the TFP switch 1. The TFP switch 1 has an
internal case ground. TFP switch 1 is normally closed
on
,__....“
”2..-
..
MR“.
or Low. When oil pressure is present at the TFP
switch 1, the switch is open or High. The normally high
clutch pressure control (PC) solenoid 2 controls
pressure to the 3—5reverse clutch regulator valve. The
TCM monitors the TFP switch 1 to determine the
position of the 3—5reverse clutch regulator valve.
When the 3—5reverse clutch is commanded OFF,
pressure is present on the TFP switch 1. When the 3—5
reverse clutch is commanded ON, the 3—5reverse
clutch regulator valve moves and pressure to the TFP
switch 1 is exhausted through the 3—5reverse clutch
regulator valve.
P0842 or P0843
' DTC P0711, P0712, P0713, P0716, P0717,
P0722, P0723, P0742, P0751, P0756, P0757,
P0973, P0974, P0976, P0977, P182E, or P1915
is not set.
' Engine speed is 400 RPM or greater for
5 seconds.
- Ignitionvoltage is 9.0 volts or greater.
' Transmission fluid temperature (TFT) is —7to
+110°C (19—230°F).
- High Side Driver is ON.
- Engine speed is 550 RPM or greater.
Conditions for Setting the DTC
P0842
The TCM detects that the TFP switch 1 signal voltage
remains LOW after the 3—5—R clutch transitions from a
HIGH pressure state to a LOW pressure state. The
TCM counts each incident. The DTC sets when
42 counts are accumulated.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
17:112 Automatic Transmission - 6T30/6T40/6T45/6T50 (MH8, MH9)
P0843 CircuitlSystem Verification
The TCM detects that the TFP switch 1 signal voltage Warning: Refer to Parking Brake and Drive Wheels
remains HlGH after the 3-5—Rclutch transitions from a Warning on page 0-5.
LOW pressure state to a HIGHpressure state. The
TCM counts each incident. The DTC sets when 1. Engine idling in PARK with parking brake applied,
57 counts are accumulated. and drive wheels chocked.
2. Verify with a scan tool the Transmission Fluid
Action Taken When the DTC Sets Pressure Switch 1, Transmission Fluid Pressure
0 DTCs P0842 and P0843 are Type C DTCs. Switch 3, Transmission Fluid Pressure Switch 4,
- TCM freezes transmission adaptive functions on and Transmission Fluid Pressure Switch 5
the 3-5-R clutch. parameter states are correct for the Park, Reverse,
and Neutral gear select lever positions. Refer to
Conditions for Clearing the DTC Transmission Fluid Pressure Switch Logic on
page 17-11.
DTCs P0842 and P0843 are Type C DTCs.
2 If any parameter value is not correct for a given
Diagnostic Aids gear range
ATFP switch may malfunction due to normal debris in Refer to CircuitlSystem Testing below.
the transmission fluid causing a TFP Switch DTC to U If the parameter values are correct for all gear
intermittentlyset. This type of condition should not be ranges
immediately noticeable to a customer, as the switch
outputs are used for shift adaptive pressure and do not 3. Verify the Transmission Fluid Pressure Switch 1,
cause transmission symptoms unless the switch Transmission Fluid Pressure Switch 3,
malfunctions continuously for an extended period Transmission Fluid Pressure Switch 4, and
of time. Transmission Fluid Pressure Switch 5 parameter
states are correct for each forward range with the
Reference Information gear select lever in Drive, using the scan tool to s\._
W-
,2,"
—
N.M
-..
-.
command all forward ranges. Refer to
Schematic Reference Transmission Fluid Pressure Switch Logic on
page 17-11.
Automatic Transmission Controls Schematics on
page 17-30 2 If any parameter value is not correct for a given
gear range
Connector End View Reference
Refer to Circuit/System Testing below.
0 Component Connector End Views on page 11-269
U If the parameter values are correct for all gear
- lnline Harness Connector End Views on ranges
page 11-465
4. After performing the above steps, verify that the
Description and Operation DTC does not reset by operating the vehicle within
the Conditions for Running the DTC. You may also
- Transmission General Description on page 17—31 7 operate the vehicle within the conditions you
- Electronic Component Description on observe from the Freeze Frame/Failure Records
page 17-319 for control solenoid valve assembly data. Ifthe vehicle passes the CircuitlSystem
- Transmission Component and System Description Verification procedure, then STOP. Do not perform
on page 17-318 the CircuitlSystem Testing or Component Testing
as this may result in an unnecessary part
Electrical information Reference replacement. Refer to Testing for Intermittent
- Circuit Testing on page 11-526 Conditions and Poor Connections on page 11—531 .
- Connector Repairs on page 11-548 CircuitlSystem Testing
- Testing for IntermittentConditions and Poor 1. lgnition OFF, remove the Q8 control solenoid valve
Connections on page 11-531 assembly. Refer to Control Solenoid Valve and
- Wiring Repairs on page 11-537 Transmission Control Module Assembly
Replacement on page 17-209.
DTC Type Reference
2. Inspect the 08 control solenoid valve assembly,
Powertrain Diagnostic Trouble Code (DTC) Type channel plate, and spacer plate for debris and «MW
2..
m_w
.W.
.2
Definitions on page 6—68 blocked orifices.
Scan Tool Reference 2 If debris or blocked orifices are observed
Control Module References on page 6-3 for scan tool Clean or replace as necessary.
information 2 if no debris or blocked orifices are observed
Replace the 08 control solenoid valve
assembly.

2013
-Sonlc
(US/Canada)
Service
Manual
(5377994)
 Automatic Transmission - 6T30/6T40/6T45/6T50 (MH8, MH9) 17-113
Repair Instructions Perform the Diagnostic Repair Verification on
page 6-92 after completing the diagnostic procedure.
Note:
Control Module References on page 6-3 for control
- Perform the Transmission Adaptive Values Learn solenoid valve assembly replacement, setup,
on page 17—163followingall transmission related or programming
repairs.
- Before replacing the TCM, perform the Control
Solenoid Valve and Transmission Control Module
Assembly Inspection on page 17-158.

2013
<Sonic
(US/Canada)
Service
Manual
(5377994)
17-114 Automatic Transmission —6T30/6T40l6T45/6T50 (MH8, MH9)

DTC P0850-P0852

Diagnostic Instructions
- Perform the Diagnostic System Check - Vehicle
on page 6-66 prior to using this diagnostic
procedure.
- Review Strategy Based Diagnosis on page 6-58
for an overview of the diagnostic approach.
- Diagnostic Procedure Instructions on page 6-59
provides an overview of each diagnostic category.
DTC Descriptors
DTC P0850: Park/Neutral Position Switch Circuit
DTC P0851: Park/Neutral Position Switch Circuit Low Voltage
DTC P0852: Park/Neutral Position Switch Circuit High Voltage
Diagnostic Fault Information

Open/High Signal
Circuit Short to Ground Resistance Short to Voltage Performance
Signal P0850,P0851 P0850,P0852 P0850,P0852 -

Typical Scan Tool Data

ParklNeutraI Position Switch

Open/High
Circuit Short to Ground Resistance Short to Voltage
OperatingConditions: Enginerunning,transmissionin parkat normaloperatingtemperature
ParameterNormal Range: Park/Neutral
Signal I Park/Neutral ln-Gear I In-Gear

CircuitlSystem Description - Vehicle speed is 10 km/h (6 mph) or greater.

The transmission manual shift shaft switch assembly,
also known as the internal mode switch (IMS), is a
sliding contact switch attached to the manual shift shaft
inside the transmission case. The park/neutralposition
switch is integrated into the IMS and connects to the
transmission control module (TCM) lead-frame through
a short wire harness. The park/neutral signal circuit
uses the TCM as a pass-through connector only. The
TCM provides the low reference circuit to the PNP
switch.
The Park/Neutral Signal is sent from the park/neutral
switch directly to the Engine Control Module (ECM) and
is used for engine start enable.
- Above conditions must be met for .2 seconds.
P0852
ECM detects the Park/Neutral switch signal equals
12 volts (In-Gear) when the NS reports a Park/Neutral
range for 0.2 second.
Action Taken When the DTC Sets
- DTCs P0850, P0851, and P0852 are
Type C DTCs.
‘ ECM uses IMS position, which is determined by
the transmission control module and broadcast
over GMLAN, for engine start—up.

Conditions for Running the DTC Conditions for Clearing the DTC
- lgnition voltage is between 8—18V. DTCs P0850, P0851, and P0852 are Type c DTCs.
- Engine speed is 1000 RPM or greater. Reference Information
Conditions for Setting the DTC Schematic Reference
P0850 and P0851 Automatic Transmission Controls Schematics on
- ECM detects the Park/Neutral switch signal page 17-30
equals 0volts (Park/Neutral) when the IMS reports Connector End View Reference
a Drive range.
. Throttle position is 10 percent or greater. - Component Connector End Views on page 11-269
- Engine torque is 75 Nm (55 lb ft)or greater. - lnline Harness Connector End Views on
page 11-465

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
 Automatic Transmission .. 6T30/6T40/6T45/6T50 (MH8, MH9) 17415
Description and Operation 8. Verify the DTC does not set.
- Transmission General Description on page 17—31
7 2 If a DTC sets
- Electronic Component Description on Refer to CircuitlSystem Testing.
page 17-319 U if a DTC does not set
° Transmission Component and System Description 9. All OK
on page 17—31 8
CircuitlSystem Testing
Electrical Information Reference
Note: You must perform the CircuitlSystem Verification
- Circuit Testing on page 11-526 first.
- Connector Repairs on page 11-548
1. IgnitionOFF, disconnect the X1 QB Control
- Testing for IntermittentConditions and Poor Solenoid Valve Assembly harness connector at the
Connections on page 11-531 automatic transmission.
- Wiring Repairs on page 11—537 2. Install the DT—48616-10adapterharness to the
DTC Type Reference vehicle harness connector.
Note: All testing in steps 3 through 5 will be performed
Powertrain Diagnostic Trouble Code (DTC) Type at the DT-48616-10 adapter harness connector.
Definitions on page 6—68
3. Test for less than 5 Q between the ground circuit
Scan Tool Reference terminal 2 and ground.
Control Module References on page 6-3 for scan tool 2 if 5 Q or greater
information 3.1. lgnition OFF.
Special Tools 3.2. Test for less than 2 Q in the ground circuit and
to end.
DT-48616—10Adapter Harness
2 if 2 Q or greater, repair the open/high resistance
For equivalent regional tools, refer to Special Tools on
page 17—394. in the circuit.
2 if less than 2 Q, repair the open/high resistance
CircuitlSystem Verification in the ground connection.
1. lgnition ON. If less than 5 Q
2. Verify that DTC P182E or P1915 is not set. P<=lgnition ON.
2 If any of the DTCs are set 5. Test for 11—13V between signal circuit terminal 3
Refer to DTC P182E or P1915 on page 17-134. and ground.
U If none of the DTCs are set 2 If not between 11—13 V
3. Verify the range selector lever cable is adjusted 5.1. lgnition OFF, remove the harness connector at
properly. Refer to Range Selector Lever Cable the K20 Engine Control Module.
Adjustment on page 17—196. 5.2. Test for infinite resistance between signal
2 If the cable adjustment is not OK circuit terminal 3 and ground.
2 Ifless than infinite resistance, repair the short to
Adjust, repair or replace as necessary.
ground in the circuit.
U If the cable adjustment is OK
U If infinite resistance.
4. lgnition ON.
5.3. Test for less than 2 Q in the signal circuit end
5. Verify the scan tool transmission control module to end.
InternalMode Switch parameter matches the gear
shift lever position while slowly moving the gear 2 If2 Q or greater, repair the open/high resistance
shift leverfrom Park through all gear ranges. in the circuit.
2 If any gear shift lever position does not match 2 if less than 2 Q, replace the K20 Engine Control
Module.
Refer to DTC P182E or P1915 on page 17-134.
U If between 11—13V
_____,..~\U If all gear positions match
.WMMMW 6. lgnition OFF, disconnect the DT-48616-10 adapter
6. Verify the scan tool engine control module Park/ harness from the vehicle wire harness.
Neutral Position Switch parameter displays Park/
Neutral when in Park or Neutral and In-Gear when 7. Remove the transmission control valve body cover.
in Reverse or Drive. 8. Connect the vehicle harness connector to the Q8
Control Solenoid Valve Assembly.
2 if ParklNeutraI or In Gear is not displayed
9. Disconnect the B15 Transmission Internal Mode
Refer to CircuitlSystem Testing. Switch electrical connector from the Q8 Control
U If Park/Neutral and In Gear is displayed Solenoid Valve Assembly.
7. Operate the vehicle within the Conditions for 10. lgnition ON.
Running the DTC. You may also operate the
vehicle within the conditions that you observed
from the Freeze Frame/Failure Records data.
2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
17=116 Automatic Transmission - 6T30/6T40/6T45/6T50 (MH8, MH9)
11. Verify the scan tool ECM Park/Neutral Position 2 Ifless than 2 Q, replace the K20 Engine Control
Switch parameter displays In Gear. Module.
2) If In Gear is not displayed U If Park/Neutral is displayed
11.1. Ignition OFF, disconnect the X1 harness 14. Replace the B15 Transmission InternalMode
connector at the Q8 Control Solenoid Valve Switch.
Assembly.
Repair Instructions
11.2. Install the DT—48616-10adapter harness to
the Q8 Control Solenoid Valve Assembly X1 Perform the Diagnostic Repair Verification on
connector. page 6-92 after completing the repair.
11.3. Test for infinite resistance between the Perform the Transmission Adaptive Values Learn
DT—48616—10 adapter harness connector on page 17-163following all transmission repairs.
terminals 2 and 3. Range Selector Lever Cable Adjustment on
2 If less than infinite resistance, replace the QB page 17-196
Control Solenoid Valve Assembly. Control Valve Body Cover Replacement on
2 If infinite resistance, replace the K20 Engine page 17-210
Control Module. Manual Shift Detent Lever with Shaft Position
U If In Gear is displayed Switch Assembly Replacement on page 17-191
12. Connect a 3A fused jumper between the QB Control Valve Body Cover Replacement on
Control Solenoid Valve Assembly connector signal page 17-210
circuit terminal A and ground. Control Module References on page 6—3for ECM
13. Verify the scan tool engine control module Park/ or control solenoid valve assembly replacement,
Neutral Position Switch parameter displays Park/ programming and setup
Neutral.
If ParkINeutraI is not displayed
13.1. IgnitionOFF, disconnect the X1 harness
connector at the QB Control Solenoid Valve
Assembly.
13.2. Install the DT—48616—10 adapter harness to
the Q8 Control Solenoid Valve Assembly X1
connector.
13.3. Test for less than 2 Q between adapter
harness connector terminal 3 and the Q8
Control Solenoid Valve Assembly connector
signal circuit terminal A.
2 If2 Q or greater, replace the QB Control
Solenoid Valve Assembly.
m»~
2-M
~.W
_,
222
-2..

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Automatic Transmission —6T30/6T40/6T45/6T50 (MH8, MH9) 17-117

DTC P0872 or P0873

Diagnostic Instructions
- Perform the Diagnostic System Check - Vehicle
on page 6—66prior to using this diagnostic
procedure.
- Review Strategy Based Diagnosis on page 6-58
for an overview of the diagnostic approach.
' Diagnostic Procedure Instructions on page 659
provides an overview of each diagnostic category.
DTC Descriptors
DTC P0872: Transmission Fluid Pressure Switch 3 Circuit Low Voltage
DTC P0873: Transmission Fluid Pressure Switch 3 Circuit High Voltage
Diagnostic Fault Information

Opeanigh Signal
Circuit Short to Ground Resistance Short to Voltage Performance
TFP Switch1 Signal ' P0842 P0843 P0843 —-
TFP Switch3 Signal 1 P0872 P0873 P0873 -
TFP Switch4 Signal P0877 P0878 P0878 -
TFP Switch5 Signal P0989 P0990 P0990 -

Typical Scan Tool Data

Transmission Fluid Pressure Switch 3

Openflfigh
Circuit Short to Ground Resistance Short to Voltage
OperatingConditions: Enginerunning,normaloperatingtemperature
ParameterNormal Range:High,Low
TransmissionFluidPressureSwitch3 Signal I Low I High I High

CircuitlSystem Description ' Ignitionvoltage is 9.0 volts or greater.

The transmission fluid pressure (TFP) switch 3 - Transmission fluid temperature (TFT) is —7to
assembly is part of the control solenoid valve assembly +110°C (19—230°F).
which has no serviceable components. The - High Side Driver is ON.
transmission control module (TCM) supplies a signal - Engine speed is 550 RPM or greater.
circuit to the TFP switch 3. The TFP switch 3 has an
internal case ground. TFP switch 3 is normally closed, Conditions for Setting the DTC
or Low. When oil pressure is present at the TFP
switch 3, the switch is open, or High. The normally low P0872
clutch pressure control (PC) solenoid 4 controls The TCM detects that the TFP switch 3 signal voltage
pressure to the 2—6clutch regulator valve. The TCM remains LOW after the 2—6clutch transitions from a
monitors the TFP switch 3 to determine the position of HIGH pressure state to a LOW pressure state. The
the 2—6clutch regulator valve. When the 2—6clutch is TCM counts each incident. The DTC sets when
commanded OFF, pressure is present on the TFP 8 counts are accumulated.
switch 3. When the 2—6clutch is commanded ON, the
2—6clutch regulator valve moves and pressure to the P0873
TFP switch 3 is exhausted through the 2—6clutch The TCM detects that the TFP switch 3 signal voltage
regulator valve. , remains HIGH after the 2—6clutch transitions from a
LOW pressure state to a HIGH pressure state. The
Conditions for Running the DTC TCM counts each incident. The DTC sets when
- DTC P0711, P0712, P0713, P0716, P0717, 11counts are accumulated.
P0722, P0723, P0742, P0751, P0756, P0757,
P0973, P0974, P0976, P0977, P182E, or P1915 Action Taken When the DTC Sets
is not set. - DTCs P0872 and P0873 are type C DTCs.
~ Engine speed is 400 RPM or greater for - TCM freezes transmission adaptive functions on
5 seconds. the 2—6clutch.

2013
~Sonic
(US/Canada)
Service
Manual
(5377994)
17-118 Automatic Transmission - 6T30/6T40I6T45/6T50 (MH8, MH9)

Conditions for Clearing the DTC
DTCs P0872 and P0873 are type C DTCs.
Diagnostic Aids
ATFP switch may malfunction due to normal debris in
the transmission fluid causing a TFP Switch DTC to
intermittentlyset. This type of condition should not be
immediately noticeable to a customer, as the switch
outputs are used for shift adaptive pressure and do not
cause transmission symptoms unless the switch
malfunctions continuously for an extended period
of time.
Reference Information
Schematic Reference
Automatic Transmission Controls Schematics on
page 17—30
Connector End View Reference
- Component Connector End Views on page 11—269
- lnline Harness Connector End Views on
page 11—465
Description and Operation
- Transmission General Description on page 17—31 7
- Electronic Component Description on
page 17-319 for control solenoid valve assembly
- Transmission Component and System Description
on page 17-318
Electrical Information Reference
- Circuit Testing on page 11-526
' Connector Repairs on page 11—548
- Testing for IntermittentConditions and Poor
Connections on page 11-531
- Wiring Repairs on page 11—537
DTC Type Reference
Powertrain Diagnostic Trouble Code (DTC) Type
Definitions on page 6-68
Scan Tool Reference
Control Module References on page 6-3 for scan tool
information
CircuitlSystem Verification
Warning: Refer to Parking Brake and Drive Wheels
Warning on page 0-5.
1. Engine idling'In PARK with parking brake applied,
and drive wheels chocked.
2. Verify with a scan tool, the Transmission Fluid
Pressure Switch 1, Transmission Fluid Pressure
Switch 3, Transmission Fluid Pressure Switch 4,
and Transmission Fluid Pressure Switch 5
parameter states are correct for the Park, Reverse
and Neutral gear select lever positions. Refer to
Transmission Fluid Pressure Switch Logic on
page 17—11. L solenoid valve assembly replacement, setup,
2 If any parameter value is not correct for a given
gear range
Refer to CircuitlSystem Testing below.
U If the parameter values are correct for all gear
ranges
3. Verify the Transmission Fluid Pressure Switch 1,
Transmission Fluid Pressure Switch 3,
Transmission Fluid Pressure Switch 4, and
Transmission Fluid Pressure Switch 5 parameter
states are correct for each fonivardrange with the
gear select lever in Drive, using the scan tool to
command all forward ranges. Refer to
Transmission Fluid Pressure Switch Logic on
page 17-11.
..W#
um.
N
.2 M
2 If any parameter value is not correct for a given
gear range
Refer to CircuitlSystem Testing below.
U If the parameter values are correct for all gear
ranges
4. After performing the above steps, verify that the
DTC does not reset by operating the vehicle within
the Conditions for Running the DTC. You may also
operate the vehicle within the conditions you
obsen/e‘from the Freeze Frame/Failure Records
data. Ifthe vehicle passes the CircuitlSystem
’ Verification procedure, then STOP. Do not perform
the CircuitlSystem Testing or Component Testing
as this may result in an unnecessary part
replacement. Refer to Testing for intermittent
Conditions and Poor Connections on page 11-531.
CircuitlSystem Testing
Note: You must perform the CircuitlSystem Verification
first.
1. IgnitionOFF, remove the QB control solenoid valve
assembly, filter plate, channel plate and spacer
plate. Refer to Control Solenoid Valve and
Transmission Control Module Assembly
Replacement on page 17-209 and Control Valve
Body Replacement on page 17-213.
2. Inspect the Q8 control solenoid valve
assembly,filter plate, channel plate, and spacer
plate for debris and blocked orifices.
2 If debris or blocked orifices are observed
Clean or replace as necessary.
2 If no debris or blocked orifices are observed
Replace the QB control solenoid valve
assembly.
Repair Instructions
Note:
- Perform the Transmission Adaptive Values Learn
on page 17-163 following all transmission related N.H.
"www
2.»
~
2m]
.3..
v-4”
..2
_-
M<
—
repairs.
. Before replacing the TCM, perform the Control
Solenoid Valve and Transmission Control Module
Assembly Inspection on page 17—158.
Perform the Diagnostic Repair Verification on
page 6—92after completing the diagnostic procedure.
Control Module References on page 6-3 for control
or programming.
(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
 Automatic Transmission =-6T30/6T40/6T45/6T50 (MH8, MH9) 17-119
DTC P0877 or P0878

Diagnostic Instructions
- Perform the Diagnostic System Check - Vehicle
on page 6—66prior to using this diagnostic
procedure.
- Review Strategy Based Diagnosis on page 6-58
for an overview of the diagnostic approach.
o Diagnostic Procedure Instructions on page 659
provides an overview of each diagnostic category.
.2.-..“
M
”'2-
._
,2.
DTC Descriptors
DTC P0877: Transmission Fluid Pressure Switch 4 Circuit Low Voltage
DTC P0878: Transmission Fluid Pressure Switch 4 Circuit High Voltage

Diagnostic Fault Information

Open/High Signal
Circuit Short to Ground Resistance Short to Voltage Performance
TFP Switch1 Signal P0842 P0843 P0843 -
TFP Switch3 Signal P0872 P0873 P0873 -
TFP Switch4 Signal P0877 P0878 P0878 -
TFP Switch5 Signal ' P0989 P0990 P0990 ~-

Typical Scan Tool Data

Transmission Fluid Pressure Switch 4

OpenHfigh
Circuit Short to Ground Resistance Short to Voltage
OperatingConditions: Enginerunning,normaloperatingtemperature
ParameterNormalRange:High,Low
TransmissionFluidPressureSwitch4 Signal I I High I High

mWWWWWHWWW.
-__-flww
W
M
2“
.W
.....
., muflw, CircuitlSystem Description
The transmission fluid pressure (TFP) switch 4
assembly is part of the control solenoid valve assembly
which has no serviceable components. The
transmission control module (TCM) supplies a signal
circuit to the TFP switch 4. The TFP switch 4 has an
internal case ground. TFP switch 4 is normally closed,
or Low. When oil pressure is present at the TFP
switch 4, the switch is open, or High. The normally low
clutch pressure control (PC) solenoid 5 controls
pressure to the 1-2-3—4clutch regulator valve. The TCM
monitors the TF P switch 4 to determine the position of
the 1-2—3-4clutch regulator valve. When the 1-2-3-4
clutch is commanded OFF, pressure is present on the
TFP switch 4. When the 1-2-3-4 clutch is commanded
ON, the 1-2-3-4 clutch regulator valve moves and
pressure to the TFP switch 4 is exhausted through the
1—2—3-4 clutch regulator valve.
Conditions for Running the DTC
- DTC P0711, P0712, P0713, P0716, P0717,
P0722, P0723, P0742, P0751, P0756, P0757,
P0973, P0974, P0976, P0977, P182E or P1915 is
not set.
' Engine speed is 400 RPM or greater for
5 seconds.
- lgnition voltage is 9.0 volts or greater.
- Transmission fluid temperature (TFT) is -7 to
+110°C (19—230°F).
° High Side Driver is ON.
- Engine speed is 550 RPM or greater.
Conditions for Setting the DTC
P0877
The TCM detects that the TFP switch 4 signal voltage
remains LOW after the 1—2—3—4clutch transitions from a
HIGH pressure state to a LOW pressure state. The
TCM counts each incident. The DTC sets when
12 counts are accumulated.
P0878
The TCM detects that the TFP switch 4 signal voltage
remains HIGH after the 1—2—3—4clutch transitions from a
LOW pressure state to 3 HIGH pressure state. The
TCM counts each incident. The DTC sets when
12 counts are accumulated.
Action Taken When the DTC Sets
- DTCs P0877 and P0878 are Type C DTCs.
- TCM freezes transmission adaptive functions on
the 1-2—3-4clutch.

2013
—
Sonic
(US/Canada)
Service
Manual
(5377994)
17-120 Automatic Transmission - 6T30/6T40/6T45/6T50 (MH8, MH9)

Conditions for Clearing the DTC
DTCs P0877 and P0878 are Type C DTCs.
Diagnostic Aids
ATFP switch may malfunction due to normal debris in
the transmission fluid causing a TFP Switch DTC to
intermittentlyset. This type of condition should not be
immediately noticeable to a customer, as the switch
outputs are used for shift adaptive pressure and do not
cause transmission symptoms unless the switch
malfunctions continuously for an extended period
of time.
Reference Information
Schematic Reference
Automatic Transmission Controls Schematics on
page 17-30
Connector End View Reference
- Component Connector End Views on page 11—269
. lnline Harness Connector End Views on
page 11—465
Description and Operation
- Transmission General Description on page 17—31 7
- Electronic Component Description on
page 17—319for control solenoid valve assembly
- Transmission Component and System Description
on page 17—318
Electrical Information Reference
- Circuit Testing on page 11-526
. Connector Repairs on page 11-548
- Testing for IntermittentConditions and Poor.
Connections on page 11—531
- Wiring Repairs on page 11-537
DTC Type Reference
Powertrain Diagnostic Trouble Code (DTC) Type
Definitions on page 6-68
Scan Tool Reference
Control Module References on page 6-3 for scan tool
information
CircuitlSystem Verification
Warning: Refer to Parking Brake and Drive Wheels
Warning on page 0-5.
1. Engine idling in PARK with parking brake applied,
and drive wheels chocked.
2. Verify the Transmission Fluid Pressure Switch 1,
Transmission Fluid Pressure Switch 3,
Transmission Fluid Pressure Switch 4, and
Transmission Fluid Pressure Switch 5 parameters
parameter states are correct for the Park, Reverse,
and Neutral gear select lever positions. Refer to
Transmission Fluid Pressure Switch Logic on
page 17-11.
2 If any parameter value is not correct for a given
gear range
Refer to CircuitlSystem Testing below.
U If the parameter values are correct for all gear
ranges
3. Verify the Transmission Fluid Pressure Switch 1,
Transmission Fluid Pressure Switch 3,
Transmission Fluid Pressure Switch 4, and
Transmission Fluid Pressure Switch 5 parameter
states are correct for each forward range with the
gear select lever in Drive, using the scan tool to
command all forward ranges. Refer to
Transmission Fluid Pressure Switch Logic on
page 17-11.
2 If any parameter value is not correct for a given
gear range
Refer to CircuitlSystem Testing below.
U If the parameter values are correct for all gear
ranges
4. After performing the above steps, verify that the
DTC does not reset by operating 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. Ifthe vehicle passes the CircuitlSystem
Verification procedure, referto Testing for
IntermittentConditions and Poor Connections on
page 11-531.
CircuitlSystem Testing
1. Ignition OFF, remove the Q8 control solenoid valve
assembly, filter plate, channel plate and spacer
plate. Refer to Control Solenoid Valve and
Transmission Control Module Assembly
Replacement on page 17—209.
2. Inspect the QB control solenoid valve assembly,
filter plate, channel plate, and spacer plate for
debris and blocked orifices.
2 If debris or blocked orifices are observed
Clean or replace as necessary.
2 If no debris or blocked orifices are observed
Replace the Q8 control solenoid valve
assembly.
Repair Instructions
Note:
0 Perform the Transmission Adaptive Values Learn
on page 17-163 following all transmission related
repairs.
' Before replacing the TCM, perform the Control
Solenoid Valve and Transmission Control Module
Assembly Inspection on page 17—158. Wr‘_
.wm
2
s“.__.
22..
..,
MW
.wa
Perform the Diagnostic Repair Verification on
page 6-92 after completing the diagnostic procedure.
Control Module References on page 6—3for control
solenoid valve assembly replacement, setup,
or programming.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Automatic Transmission - 8T30/6T40/6T45/6T50 (MH8, MH9) 17-121

DTC P0961-P0963

Diagnostic Instructions
- Perform the Diagnostic System Check —Vehicle
on page 6-66 prior to using this diagnostic
procedure.
- Review Strategy Based Diagnosis on page 6-58
for an overview of the diagnostic approach.
- Diagnostic Procedure Instructions on page 6-59
provides an overview of each diagnostic category.
DTC Descriptors
DTC P0961: Line Pressure Control Solenoid Valve Performance
DTC P0962: Line Pressure Control Solenoid Valve Control Circuit Low Voltage
DTC P0963: Line Pressure Control Solenoid Valve Control Circuit High Voltage

CircuitlSystem Description Action Taken When the DTC Sets

The line pressure control solenoid is part of the control P0961 or P0963
solenoid valve assembly which has no serviceable
components. The normally high line pressure control - P0961 and P0963 are Type B DTCs.
solenoid regulates and directs the line pressure control ° TCM freezes transmission adaptive functions.
solenoid oil pressure to the pressure regulator valve. ~ TCM commands maximum line pressure.
Increasing line pressure control solenoid pressure
increases transmission line pressure. The transmission P0962
control module (TCM) varies the current to the line - P0962 is a Type A DTC.
pressure control solenoid by controlling the amount of - TCM limits the transmission to 4th gear and
time the low side driver is ON and OFF. Decreasing the reverse.
ON time, decreases the current to the line pressure
control solenoid, which increases line pressure control ° TCM inhibits the torque converter clutch (TCC).
solenoid oil pressure by closing OFF the solenoid ~ TCM commands maximum line pressure.
exhaust port. Increasing the current to the line pressure - TCM freezes transmission adaptive functions.
control solenoid decreases line pressure control oil - TCM turns the high side driver OFF.
pressure by opening the solenoid exhaust port. Line
pressure control solenoid power is supplied by the TCM - TCM inhibits neutral idle.
through a high side driver. The high side driver protects - TCM inhibits Tap Up/Down function.
the circuit and components from excessive current flow. ' TCM inhibits manual shifting of forward gears.
Ifexcessive current flow is detected, the high side
' TCM enables torque management.
driver will turn OFF. When the fault is corrected, the
high side driverwill reset. Conditions for Clearing the DTC
Conditions for Running the DTC - P0961 and P0963 are Type B DTCs.
- Engine speed is 400—7,500RPM for 5 s. - P0962 is a Type A DTC.
- lgnition voltage is 9—32V. Reference Information
- Runs continuously when above conditions
are met. Schematic Reference
Automatic Transmission Controls Schematics on
Conditions for Setting the DTC page 17—30
P0961 Connector End View Reference
TCM detects an internal electrical malfunction of the
line pressure control solenoid circuit where the ‘ Component Connector End Views on page 11—269
measured line pressure control solenoid current does - lnline Harness Connector End Views on
not equal the commanded line pressure control page 11-465
solenoid current for 5 s. Description and Operation
P0962
- Electronic Component Description on
TCM detects a short to ground on the line pressure page 17-319
control solenoid control circuit for 2 s. - Transmission Component and System Description
P0963 on page 17—318
TCM detects an open circuit or short to voltage on the - Transmission General Description on page 17—31
7
line pressure control solenoid control circuit for 5 s.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
17-122 Automatic Transmission - 6T30/6T40l6T45/6T50
Electrical Information Reference
- Circuit Testing on page 11—526
- Connector Repairs on page 11—548
- Testing for IntermittentConditions and Poor
Connections on page 11—531
- Wiring Repairs on page 11-537
DTC Type Reference
Powen‘rain Diagnostic Trouble Code (DTC) Type
Definitions on page 6-68
Scan Tool Reference
Control Module References on page 6-3 for scan tool
information
Special Tools
DT—48616—10 Adapter Harness
For equivalent regional tools, refer to Special Tools on
page 17—394.
CircuitlSystem Verification
Warning: Refer to Parking Brake and Drive Wheels
Warning on page 0-5.
1. Engine idling, transmission in Park, with service
brake applied. Move the 83 Transmission Shift
Lever into each gear position for 2—3s and back
into the Park position.
2. Verify the scan tool parameters listed below do not
display Malfunction:
- Line Pressure Control Solenoid Valve
Performance Test Status
- Line Pressure Control Solenoid Valve Control
Circuit Low Voltage Test Status
‘ Line Pressure Control Solenoid Valve Control
Circuit High Voltage Test Status
2 If Malfunction is displayed
Refer to CircuitlSystem Testing.
U If Malfunction is not displayed
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.
4. Verify the DTC does not set.
2 If the DTC sets
Refer to CircuitlSystem Testing.
U If the DTC does not set
5. All OK.
(MH8, MH9)
CircuitlSystem Testing
Note: You must perform the Circuit/System Verification
first.
1. IgnitionOFF, remove the Q8 Control Solenoid
Valve Assembly.
2. Verify the Q8 Control Solenoid Valve Assembly is
not contaminated with any debris and clean as
necessary. Refer to Control Solenoid Valve and
Transmission Control Module Assembly Inspection
on page 17-158.
2 If contaminated
Repair as necessary.
U If not contaminated
3. Verify the resistance Iswithin the specified range
for each solenoid listed in the Control Solenoid
Valve and Transmission Control Module Assembly
Inspection on page 17—158.
2 If the resistance is not within range
Replace the QB Control Solenoid Valve
Assembly.
U If the resistance is within range
4. Place the QB Control Solenoid Valve Assembly on
a clean work surface near the transmission
assembly.
5. Connect the DT—48616-10adapter harness
between the vehicle harness connector and the Q8
Control Solenoid Valve Assembly connector.
lgnition ON.
6. Verify the scan tool parameters listed below do not
display Malfunction:
- Line Pressure Control Solenoid Valve
Performance Test Status
- Line Pressure Control Solenoid Valve Control
Circuit Low Voltage Test Status
- Line Pressure Control Solenoid Valve Control
Circuit High Voltage Test Status
2 If Malfunction is displayed
Replace the QB Control Solenoid Valve
Assembly.
U If Malfunction is not displayed
7. All OK.
Repair Instructions
Perform the Diagnostic Repair Verification on
page 6-92 after completing the repair.
° Perform the Transmission Adaptive Values Learn
on page 17-163 following all transmission repairs.
- Control Module References on page 6-3 for
Control Solenoid Valve Assembly replacement,
programming and setup
2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Automatic Transmission - 6T30/6T40/6T45/6T50 (MH8, MH9) '17=123
DTC P0965-P0967

Diagnostic Instructions
- Perform the Diagnostic System Check —Vehicle
on page 6—66prior to using this diagnostic
procedure.
- Review Strategy Based Diagnosis on page 6—58
for an overview of the diagnostic approach.
- Diagnostic Procedure Instructions on page 6—59
provides an overview of each diagnostic category.
DTC Descriptors
DTC P0965: Pressure Control Solenoid Valve 2 Performance
DTC P0966: Pressure Control Solenoid Valve 2 Control Circuit Low Voltage
DTC P0967: Pressure Control Solenoid Valve 2 Control Circuit High Voltage

CircuitlSystem Description Action Taken When the DTC Sets

Pressure control solenoid 2 is part of the control P0965
solenoid valve assembly which has no serviceable
components. The normally high pressure control - P0965 is a Type C DTC.
solenoid 2 regulates and directs the pressure control - TCM freezes transmission adaptive functions on
solenoid 2 pressure to the 3—5reverse clutch regulator the 3—5Reverse clutch.
valve. Increasing pressure control solenoid 2 pressure
increases pressure to the 3—5reverse clutch. The P0966 or P0967
transmission control module (TCM) varies the current to - P0966 and P0967 are Type A DTCs.
the pressure control solenoid 2 by controlling the - TCM limits the transmission to 5th gear and
amount of time the low side driver is ON and OFF. reverse.
Decreasing the current to the pressure control - TCM commands maximum line pressure.
solenoid 2 increases pressure control solenoid 2 oil
pressure by closing OFF the solenoid exhaust port. - TCM freezes transmission adaptive functions.
Increasing the current to the pressure control - TCM forces the torque converter
solenoid 2 decreases pressure control solenoid 2 oil clutch (TCC) OFF.
pressure by opening the solenoid exhaust port. Power . TCM forces the high side driver OFF.
to pressure control solenoid 2 is supplied by the TCM ° TCM inhibits neutral idle.
through a high side driver. The high side driver protects
the circuit and components from excessive current flow. - TCM inhibits Tap Up/Down function.
Ifexcessive current flow is detected, the high side . TCM inhibits manual shifting of forward gears.
driver will turn OFF. When the fault is corrected, the ' TCM enables torque management.
high side driver will reset.
Conditions for Clearing the DTC
Conditions for Running the DTC
- P0965 is a Type C DTC.
P0965, P0966, or P0967 - P0966 and P0967 are TypeA DTCs.
- Engine speed is 400—7,500RPM for 5 s.
Reference Information
- Ignitionvoltage is 9—32V.
- Runs continuously when above conditions Schematic Reference
““—2....“
—
M
-«
M.
3....
”-2-2W—w—w
_.
A
.2.“..-H
‘-
WW.
,.W
--NMN‘N. are met.
Automatic Transmission Controls Schematics on
Conditions for Setting the DTC page 17-30

P0965 Connector End View Reference

TCM detects an internal electrical performance
malfunction of the pressure control solenoid 2 control
circuit where the measured pressure control solenoid 2
current does not equal the commanded pressure
control solenoid 2 current for 5 s. Description
P0966
TCM detects a short to ground on the pressure control
solenoid 2 control circuit for 1 s.
P0967
TCM detects an open or short to voltage on the
pressure control solenoid 2 control circuit for 1 s.
- Component Connector End Views on page 11—269
- lnline Harness Connector End Views on
page 11-465
and Operation
- Transmission General Description on page 17-317
- Transmission Component and System Description
on page 17—318
- Electronic Component Description on
page 17-319

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
'17-’124 Automatic Transmission - 6T30/6T40/6T45/6T50 (MH8, MH9)
Electrical Information Reference CircuitlSystem Testing
- Circuit Testing on page 11—526 Note: You must perform the Circuit/System Verification
- Connector Repairs on page 11—548 first.
- Testing for IntermittentConditions and Poor 1. lgnition OFF, remove the Q8 Control Solenoid
Connections on page 11—531 Valve Assembly.
- Wiring Repairs on page 11-537 2. Verify the Q8 Control Solenoid Valve Assembly is
not contaminated with any debris and clean as
DTC Type Reference necessary. Refer to Control Solenoid Valve and
Powertrain Diagnostic Trouble Code (DTC) Type Transmission Control Module Assembly Inspection
Definitions on page 6—68 on page 17-158.
Scan Tool Reference 2 If contaminated
Repair as necessary.
Control Module References on page 6-3 for scan tool
information U If not contaminated
3. Verify the resistance is within the specified range
Special Tools for each solenoid listed in the Control Solenoid
DT—48616—10 Adapter Harness Valve and Transmission Control Module Assembly
For equivalent regional tools, refer to Special Tools on Inspection on page 17—158.
page 17-394. 2 If the resistance is not within range
Replace the QB Control Solenoid Valve
CircuitlSystem Verification
Assembly. '
1. Operate the vehicle in second gear long enough to
c If the resistance is within range
ensure at least a 3°C (5°F) rise in TCM
temperature, then operate the vehicle in Park 4. Place the Q8 Control Solenoid Valve Assembly on
for 5 s. a clean work surface near the transmission
2. Operate the vehicle in drive range. Allow the assembly.
transmission to shift through all forward gear 5. Connect DT—48616—10 adapter harness between
ranges. the vehicle harness connector, and the QB Control
3. Verify the scan tool parameters listed below do not Solenoid Valve Assembly connector. IgnitionON.
' display Malfunction: 6. Verify the scan tool parameters listed below do not
- Pressure Control Solenoid Valve 2 Performance display Malfunction:
Test Status - Pressure Control Solenoid Valve 2 Performance
- Pressure Control Solenoid Valve 2 Control Test Status
Circuit Low Voltage Test Status ° Pressure Control Solenoid Valve 2 Control
. Pressure Control Solenoid Valve 2 Control Circuit Low Voltage Test Status
Circuit High Voltage Test Status - Pressure Control Solenoid Valve 2 Control
Circuit High Voltage Test Status
2 If Malfunction is displayed
2 If Malfunction is displayed
Refer to CircuitlSystem Testing.
Replace the Q8 Control Solenoid Valve
U If Malfunction is not displayed Assembly.
4. Operate the vehicle within the Conditions for
U If Malfunction is not displayed
Running the DTC. You may also operate the
vehicle within the conditions that you observed 7. All OK.
from the Freeze Frame/Failure Records data.
Repair Instructions
5. Verify the DTC does not set.
Perform the Diagnostic Repair Verification on
2 If the DTC sets page 6-92 after completing the repair.
Refer to CircuitlSystem Testing. - Perform the Transmission Adaptive Values Learn
U If the DTC does not set on page 17-163 following all transmission repairs.
0 Control Module References on page 6-3 for _
«”2.
,MM
M
”N".
2.2.2
g
__.
W»
“~.
6. All OK.
Control Solenoid Valve Assembly replacement,
programming and setup.

NMM
. ..s

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Automatic Transmission - 6T30/6T40/6T45/6T50 (MH8, MH9) 17-125

DTC P0969-P0971

Diagnostic Instructions
- Perform the Diagnostic System Check - Vehicle
on page 6-66 prior to using this diagnostic
procedure.
0 Review Strategy Based Diagnosis on page 6-58
for an overview of the diagnostic approach.
- Diagnostic Procedure Instructions on page 6-59
provides an overview of each diagnostic category.
DTC Descriptors
DTC P0969: Pressure Control Solenoid Valve 3 Performance
DTC P0970: Pressure Control Solenoid Valve 3 Control Circuit Low Voltage
DTC P0971: Pressure Control Solenoid Valve 3 Control Circuit High Voltage

CircuitlSystem Description Action Taken When the DTC Sets

4...
M22-
-.W’va
.2
_,,~.HW Pressure control solenoid 3 is part of the control
4,.
P0969
solenoid valve assembly which has no serviceabie
components. The normally high pressure control ' P0969 is a Type C DTC.
solenoid 3 regulates and directs oil pressure to the R1/ - TCM freezes transmission adaptive functions on
4-5-6 regulator valve. Increasing pressure control the low and reverse clutch and the 4-5-6 clutch.
solenoid 3 pressure increases pressure to the low and P0970 or P0971
reverse clutch or 4—5—6 clutch, depending on the
position of the clutch select valve. The transmission - P0970 and P0971 are Type A DTCs.
control module (TCM) varies current to pressure control - TCM limits the transmission to 4th gear and
Solenoid 3 by controlling the time the low side driver is reverse.
ON and OFF. Decreasing the current to pressure - TCM commands maximum line pressure.
control solenoid 3 increases oil pressure by closing off
the solenoid exhaust port. Increasing the current to the ~ TCM freezes transmission adaptive functions.
pressure control solenoid 3 decreases oil pressure by - TCM enables torque management.
opening the exhaust port. Power is supplied to the » . TCM inhibits Tap Up/Down function.
pressure control solenoid 3 by the TCM through a high 0 TCM inhibits manual shifting of forward gears.
side driver. The high side driver protects the circuit and
components from excessive current flow. Ifexcessive - TCM inhibits auto grade braking.
current flow is detected, the high side driver will turn - TCM forces the high side driver OFF -
OFF. When the fault is corrected, the high side driver P0970 only.
will reset. - TCM forces the torque converter clutch (TCC)
OFF —P0970 only.
Conditions for Running the DTC
- Engine speed is 400—7,500RPM for 5 s. Conditions for Clearing the DTC
- Ignitionvoltage is 9—32V. - P0969 is aType C DTC.
- Runs continuously when above conditions - P0970 and P0971 are Type A DTCs.
are met.
Reference Information
Conditions for Setting the DTC
Schematic Reference
P0969
Automatic Transmission Controls Schematics on
TCM detects an internal electrical performance page 17-30
malfunction of the pressure control solenoid 3 control
circuit where the measured pressure control solenoid 3 Connector End View Reference
currents does not equal the commanded clutch - Component Connector End Views on page 11—269
pressure control solenoid 3 current for 5 s.
- lnline Harness Connector End Views on
P0970 page 11-465
TCM detects a short to ground on the pressure control Description and Operation
solenoid 3 control circuit for 1 s.
- Transmission General Description on page 17—31
7
P0971
- Transmission Component and System Description
TCM detects an open or short to voltage on the on page 17—318
pressure control solenoid 3 control circuit for 1 s. - Electronic Component Description on
page 17—319

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
17-126 Automatic Transmission - 6T30I6T40/6T45I6T50
Electrical Information Reference
- Circuit Testing on page 11—526
’ Connector Repairs on page 11-548
- Testing for IntermittentConditions and Poor
Connections on page 11—531
- Wiring Repairs on page 11—537
DTC Type Reference
Powertrain Diagnostic Trouble Code (DTC) Type
Definitions on page 6-68
Scan Tool Reference
Control Module References on page 6-3 for scan tool
information
Special Tools
DT—48616—10 Adapter Harness
For equivalent regional tools, refer to Special Tools on
page 17-394.
CircuitlSystem Verification
1. Operate the vehicle in second gear long enough to
ensure at least a 3°C (5°F) rise in TCM
temperature, then operate the vehicle with the
transmission in Park for 5 s.
2. Operate the vehicle in drive range. Allow the
transmission to shift through all forward gear
ranges.
3. Verify the scan tool parameters listed below do not
display Malfunction:
~ Pressure Control Solenoid Valve 3 Performance
Test Status
- Pressure Control Solenoid Valve 3 Control
Circuit Low Voltage Test Status
. Pressure Control Solenoid Valve 3 Control
Circuit High Voltage Test Status
2 If Malfunction is displayed
Refer to CircuitlSystem Testing.
U If Malfunction is not displayed
4. 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.
. Verify the DTC does not set.
U‘I
2 If the DTC sets
Refer to CircuitlSystem Testing.
U If the DTC does not set
6. All OK.
(MH8, MH9)
CircuitlSystem Testing
Note: You must perform the CircuitlSystem Verification
first.
1. lgnition OFF, remove the Q8 Control Solenoid
Valve Assembly.
2. Verify the 08 Control Solenoid Valve Assembly is
not contaminated with any debris and clean as
necessary. Refer to Control Solenoid Valve and
Transmission Control Module Assembly Inspection
on page 17—158.
Wm
WM
-~.
-.2
2 If contaminated
_ Repair as necessary.
U If not contaminated
3. Verify the resistance is within the specified range
for each solenoid listed in the Control Solenoid
Valve and Transmission Control Module Assembly
Inspection on page 17—158.
2 If the resistance is not within range
Replace the QB Control Solenoid Valve
Assembly.
c If the resistance is within range
4. Place the QB Control Solenoid Valve Assembly on
a clean work surface near the transmission
assembly.
5. Connect the DT—48616-10adapter harness
between the vehicle harness connector and the QB
Control Solenoid Valve Assembly connector.
lgnition ON. . ‘
6. Verify the scan tool parameters listed below do not
display Malfunction:
. - Pressure Control Solenoid Valve 2 Performance
Test Status
- Pressure Control Solenoid Valve 2 Control
_Circuit Low Voltage Test Status
- Pressure Control Solenoid Valve 2 Control
Circuit High Voltage Test Status
2 If Malfunction is displayed
Replace the Q8 Control Solenoid Valve
Assembly.
U If Malfunction is not displayed
7. All OK.
Repair Instructions
Perform the Diagnostic Repair Verification on
page 6-92 after completing the repair.
0 Perform the Transmission Adaptive Values Learn
on page 17-163 following all transmission repairs.
- Control Module References on page 6-3 for
Control Solenoid Valve Assembly replacement,
programming and setup.

—
2013 (US/Canada)
Sonic (5377994)
Manual
Service
‘1
“....
 Automatic Transmission - 6T30/6T40/6T45/6T50 (MH8, MH9) 17-127

DTC P0973 or P0974

Diagnostic Instructions
° Perform the Diagnostic System Check —Vehicle
on page 6-66 prior to using this diagnostic
procedure.
- Review Strategy Based Diagnosis on page 6-58
for an overview of the diagnostic approach.
0 Diagnostic Procedure Instructions on page 659
provides an overview of each diagnostic category.
DTC Descriptors
DTC P0973: Shift Solenoid Valve 1 Control Circuit Low Voltage
DTC P0974: Shift Solenoid Valve 1 Control Circuit High Voltage

CircuitlSystem Description Conditions for Clearing the DICIDTC

The shift solenoid valve1 is part of the control solenoid ° DTC P0973 is a Type A DTC.
valve assembly which has no serviceable components. - DTC P0974 is a Type B DTC.
Shift solenoid valve 1 is a normally closed ON/OFF
solenoid and is controlled by the transmission control Reference Information
module (TCM) through a low side driver. When the shift
solenoid valve1 is energized (ON), fluid pressure is Schematic Reference
directed to the clutch select valve. Power to shift Automatic Transmission Controls Schematics on
solenoid 1 is supplied by the TCM through a high side page 17—30
driver. The high side driver protects the circuit and
components from excessive current flow. Ifexcessive Connector End View Reference
current flow is detected, the high side driver will turn
OFF. When the fault is corrected, the high side driver - Component Connector End Views on page 11-269
will reset. - lnline Harness Connector End Views on
page 11-465
Conditions for Running the DTC
Description and Operation
' Engine speed is 400—7500RPM for 5 s.
' Ignitionvoltage is 9—32V. 0 Transmission General Description on page 17-317
. Transmission Component and System Description
Conditions for Setting the DTC on page 17—318
P0973 - Electronic Component Description on
page 17-319
TCM detects a short to ground on the shift solenoid
valve 1 control circuit for 2 s. Electrical Information Reference
P0974 0 Circuit Testing on page 11-526
TCM detects an open or short to voltage on the shift - Connector Repairs on page 11-548
solenoid valve 1 control circuit for 2 3. - Testing for IntermittentConditions and Poor
Connections on page 11—531
Action Taken When the DTC Sets - Wiring Repairs on page 11—537
P0973 DTC Type Reference
° DTC P0973 is a Type A DTC.
Powertrain Diagnostic Trouble Code (DTC) Type
- TCM freezes transmission adaptive functions. Definitions on page 6—68
- TCM commands maximum line pressure.
Scan Tool Reference
- TCM limits the transmission to neutral or 2nd gear
and reverse. Control Module References on page 6-3 for scan tool
- TCM inhibits neutral idle. information
- TCM inhibits auto grade braking. Special Tools
- TCM inhibits the Tap Up/Tap Down function. DT—48616-10Adapter Harness
- TCM inhibits manual shifting of forward gears. For equivalent regional tools, refer to Special Tools on
P0974 page 17-394.
- DTC P0974 is a Type B DTC.
- TCM inhibits 1st gear.
‘ TCM inhibits neutral idle.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
17-128 Automatic Transmission - 6T30/6T40I6T45/6T50
CircuitlSystem Verification
1. Operate the vehicle in 2nd gear long enough to
ensure at least a 3°C (5°F) rise in TCM
temperature.
. Place the gear selector in Reverse for 5 seconds
and then idle vehicle for 5 s.
. Verify the scan tool parameters listed below do not
display Malfunction:
- Shift Solenoid Valve1 Control Circuit Low
Voltage Test Status
- Shift Solenoid Valve 1 Control Circuit Open Test
Status
- Shift Solenoid Valve1 Control Circuit High
Voltage Test Status
If Malfunction is displayed
Refer to Circuit/System Testing.
If Malfunction is not displayed
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.
Verify the DTC does not set.
2 If the DTC sets
Refer to CircuitlSystem Testing.
U If the DTC does not set
6 All OK.
CircuitlSystem Testing
Note: You must perform the CircuitlSystem Verification
first.
1. IgnitionOFF, remove the 08 Control Solenoid
Valve Assembly.
2. Verify the Q8 Control Solenoid Valve Assembly is
not contaminated with any debris and clean as
necessary. Refer to Control Solenoid Valve and
Transmission Control Module Assembly Inspection
on page 17—158.
2) If contaminated
Repair as necessary.
U If not contaminated
(MH8, MH9)
3. Verify the resistance is within the specified range
for each solenoid listed in the Control Solenoid
Valve and Transmission Control Module Assembly
Inspection on page 17-158.
If the resistance is not within range
Replace the Q8 Control Solenoid Valve
Assembly.
If the resistance is within range
Place the QB Control Solenoid Vaive Assembly on
a clean work surface near the transmission
assembly.
Connect the DT-48616-10 adapter harness
between the vehicle harness connector and the Q8
Control Solenoid Valve Assembly connector.
lgnition ON.
Verify the scan tool parameters listed below do not
display Malfunction:
- Shift Solenoid Valve 1 Control Circuit Low
Voltage Test
° Shift Solenoid Valve1 Control Circuit Open Test
- ShiftSolenoid Valve1 Control Circuit High
Voltage Test
2 If Malfunction is displayed
Replace the QB Control Solenoid Valve
Assembly.
U If Malfunction is not displayed
7. All OK.
Repair Instructions
Perform the Diagnostic Repair Verification on
page 6-92 after completing the repair.
Control Solenoid Valve and Transmission Control
Module Assembly Replacement on page 17—209
Perform the Transmission Adaptive Values Learn
on page 17—163followingall transmission repairs.
Control Module References on page 6-3 for
Control Solenoid Valve Assembly replacement,
programming and setup
2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Automatic Transmission =6T30/6T40/6T45/6T50 (MH8, MH9) 17-129
DTC P0989 or P0990

Diagnostic Instructions
- Perform the Diagnostic System Check - Vehicle
on page 6-66 prior to using this diagnostic
procedure.
' Review Strategy Based Diagnosis on page 6-58
for an overview of the diagnostic approach.
- Diagnostic Procedure Instructions on page 6—59
provides an overview of each diagnostic category.
DTC Descriptors
DTC P0989: Transmission Fluid Pressure Switch 5 Circuit Low Voltage
DTC P0990: Transmission Fluid Pressure Switch 5 Circuit High Voltage

Diagnostic Fault Information

Opeanigh Signal
Circuit Short to Ground Resistance Short to Voltage Performance
TransmissionFluidPressureSwitch1Signal , P0842 P0843 P0843 -
TransmissionFluidPressureSwitch3 Signal P0872 P0873 P0873 —-
TransmissionFluidPressureSwitch4 Signal P0877 P0878 P0878 —-
TransmissionFluidPressureSwitch5 Signal P0989 P0990 P0990 -

Typical Scan Tool Data

Transmission Fluid Pressure Switch 5

Open/High
Circuit Short to Ground Resistance Short to Voltage
OperatingConditions: Enginerunning,normaloperatingtemperature
ParameterNormalRange: High,Low
TransmissionFluidPressureSwitch5 Signal I I High I High

CircuitlSystem Description Conditions for Running the DTC

The transmission fluid pressure (TFP) switch 5
assembly is part of the control solenoid valve assembly
which has no serviceable components. The
transmission control module (TCM) supplies a signal
circuit to the TFP switch 5. The TFP switch 5 has an
internal case ground. TFP switch 5 is normally closed,
or Low. When oil pressure is present at the TFP
switch 5, the switch is open, or High. The normally high
clutch pressure control (PC) solenoid 3 controls
pressure to the R1/4-5-6 clutch regulator valve. The
TCM monitors the TFP switch 5 to determine the
position of the R1/4—5-6clutch regulator valve. When
the low and reverse clutch and 4-5-6 clutch are
commanded OFF, pressure is present on the TFP
switch 5. When the low and reverse clutch or
4—5-6clutch is commanded ON, the R1/4-5-6 clutch
regulator valve moves and pressure to the TFP switch 5
is exhausted through the R1/4—5—6 clutch regulator
valve. , 456 clutch transitions from a HIGH pressure state to a
- DTC P0711, P0712, P0713, P0716, P0717,
P0722, P0723, P0742, P0751, P0756, P0757,
P0973, P0974, P0976, P0977, P1915, or P182E
is not set.
- Engine speed is 400 RPM or greater for
5 seconds.
° Ignitionvoltage is 9.0 volts or greater.
- Transmission fluid temperature (TFT) is —7to
+110°C (19—230°F).
' High side driver is ON.
- Engine speed is 550 RPM or greater.
Conditions for Setting the DTC
P0989
The TCM detects that the TFP switch 5 signal voltage
remains LOW after the low and reverse clutch or
LOW pressure state. The TCM counts each incident.
The DTC sets when 17 counts are accumulated.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
17-130 Automatic Transmission - 6T30/6T40l6T45/6T50 (MH8, MH9)
P0990 CircuitlSystem Verification
The TCM detects that the TFP switch 5 signal voltage Warning: Refer to Parking Brake and Drive Wheels
remains HIGH after the low and reverse clutch or Warning on page 0-5.
4-5—6clutch transitions from a LOW pressure state to a
HIGH pressure state. The TCM counts each incident. 1. Engine idling in PARK with parking brake applied,
The DTC sets when 30 counts are accumulated. and drive wheels chocked.
2. Verify with a scan tool, the Transmission Fluid
Action Taken When the DTC Sets Pressure Switch 1, Transmission Fluid Pressure
- DTCs P0989 and P0990 are Type C DTCs. Switch 3, Transmission Fluid Pressure Switch 4,
- TCM freezes transmission adaptive functions on and Transmission Fluid Pressure Switch 5
the low and reverse clutch and 4—5—6
clutch. parameter states are correct for the Park, Reverse,
and Neutral gear select lever positions. Refer to
Conditions for Clearing the DTC Transmission Fluid Pressure Switch Logic on
page 17-11.
DTCs P0989 and P0990 are Type C DTCs.
2 If any parameter value is not correct for a given
Diagnostic Aids gear range
ATFP switch may malfunction due to normal debris in Refer to CircuitlSystem Testing below.
the transmission fluid causing a TFP Switch DTC to U If the parameter values are correct for all gear
intermittentlyset. This type of condition should not be ranges
immediately noticeable to a customer, as the switch
outputs are used for shift adaptive pressure and do not 3. Verify the Transmission Fluid Pressure Switch 1,
cause transmission symptoms unless the switch Transmission Fluid Pressure Switch 3,
malfunctions continuously for an extended period Transmission Fluid Pressure Switch 4, and
of time. Transmission Fluid Pressure Switch 5 parameter
states are correct for each forward range with the
Reference Information gear select lever in Drive, using the scan tool to
command all forward ranges. Refer to
Schematic Reference Transmission Fluid Pressure Switch Logic on
Automatic Transmission Controls Schematics on page 17—11.
page 17—30 2 If any parameter value is not correct for a given
gear range
Connector End View Reference
Refer to Circuit/System Testing below.
- Component Connector End Views on page 11-269
U If the parameter values are correct for all gear
- lnline Harness Connector End Views on ranges
page 11-465
4. After performing the above steps, verify that the
Description and Operation DTC does not reset by operating the vehicle within
the Conditions for Running the DTC. You may also
- Transmission General Description on page 17-317 operate the vehicle within the conditions you
- Electronic Component Description on observe from the Freeze Frame/Failure Records
page 17—319 data. Ifthe vehicle passes the CircuitlSystem
- Transmission Component and System Description Verification procedure, then STOP. Do not perform
on page 17—31 8 the CircuitlSystem Testing or Component Testing
as this may result in an unnecessary part
Electrical Information Reference replacement. Refer to Testing for Intermittent
- Circuit Testing on page 11-526 Conditions and Poor Connections on page 11-531.
- Connector Repairs on page 11-548 CircuitlSystem Testing
- Testing for IntermittentConditions and Poor Note: You must perform the CircuitlSystem Verification
Connections on page 11-531 first.
. Wiring Repairs on page 11-537
1. lgnition OFF, remove the QB control solenoid valve
DTC Type Reference assembly, filter plate, channel plate and spacer
plate. Refer to Control Solenoid Valve and
Powertrain Diagnostic Trouble Code (DTC) Type Transmission Control Module Assembly
Definitions on page 6-68 Replacement on page 17-209 and Control Valve
Scan Tool Reference Body Replacement on page 17—213.
2. Inspect the Q8 control solenoid valve assembly,
Control Module References on page 6-3 for scan tool filter plate, channel plate, and spacer plate for
information debris and blocked orifices.
2 If debris or blocked orifices are observed
Clean or replace as necessary.
2 If no debris or blocked orifices are observed
Replace the Q8 control solenoid valve assembly.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Automatic Transmission - 6T30/6T40/6T45/6T50 (MH8, MH9) 17-131

Repair Instructions Perform the Diagnostic Repair Verification on

page 6—92after completing the diagnostic procedure.
Note:
Control Module References on page 6—3for control
- Perform the Transmission Adaptive Values Learn solenoid valve assembly replacement, setup,
on page 17—163followingaIItransmission related or programming.
repairs.
- Before replacing the TCM, perform the Control
Solenoid Valve and Transmission Control Module
Assembly Inspection on page 17—158.

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
'17-’132 Automatic Transmission - 6T30/6T40/6T45/6T50 (MH8, MH9)

DTC P1761

Diagnostic Instructions
- Perform the Diagnostic System Check - Vehicle
on page 6-66 prior to using this diagnostic
procedure.
. Review Strategy Based Diagnosis on page 6-58
for an overview of the diagnostic approach.
’ Diagnostic Procedure Instructions on page 6-59
provides an overview of each diagnostic category.
DTC Descriptor
DTC P1761: Up and Down Shift Switch Signal Message Counter Incorrect

CircuitlSystem Description Connector End View Reference

When the shift lever is placed in the M position, ' Component Connector End Views on page 11—269
electronic range select or manual mode, which allows ~ lnline Harness Connector End Views on
for the selection of the range of gears available, is page 11—465
activated. This is also known as the tap shift function.
The manual mode allows the vehicle operator to Description and Operation
increase the highest range attainable by pressing the
plus (+)button or decrease the highest attainable range 0 Transmission General Description on page 17-317
by pressing the minus (-) button. The body control ° Transmission Component and System Description
module (BCM) supplies a signal circuit to the shift on page 17-318
controller. The shift controller has switches connected o Electronic Component Description on
to a resistor array. A voltage drop occurs across the page 17-319
resistor network. When the plus or minus button is
pushed, a corresponding voltage drop occurs across Electrical Information Reference
the resistor network. This voltage drop is monitored by - Circuit Testing on page 11-526
the BCM. The BCM will send the request to the
transmission control module (TCM) to increase or - Connector Repairs on page 11-548
decrease the available gear ranges. The BCM internal - Testing for IntermittentConditions and Poor
counter increments each time the tap shift signal status Connections on page 11-531
is sent and the BCM sends the rolling count with the tap - Wiring Repairs on page 11-537
shift signal status. The TCM counter increments each
time the tap shift signal status is received. The DTC will DTC Type Reference
set if the rolling count value of the TCM does not match Powertrain Diagnostic Trouble Code (DTC) Type
the rolling count sent from the BCM. Definitions on page 6-68
Conditions for Running the DTC Scan Tool Reference
- Engine speed is 400—7,500RPM for 5 s. Control Module References on page 6—3for scan tool
- Runs continuously when above condition is met. information
Conditions for Setting the DTC CircuitlSystem Verification
TCM detects the internal rolling count value does not Note:
match the expected BCM count value, 3 times
within 10 3. - DTC P1761 is an informational DTC.
. Diagnose all other body control module DTCs
Action Taken When the DTC Sets prior to DTC P1761.
- P1761 is a Type C DTC. 1. Verify there are no other body control module or
- TCM inhibits the Tap Up Tap Down function. communication DTCs set.
- TCM inhibits manual shifting of forward gears. 2 If a DTC is set
Refer to Diagnostic Trouble Code (DTC) List -
Conditions for Clearing the DTC Vehicle on page 6—69.
P1761 is a Type C DTC. U If a DTC is not set
Reference Information
Schematic Reference
- Automatic Transmission Controls Schematics on
page 17—30
- Data Communication Schematics on page 11-4
- Body Control System Schematics on page 11-8 W_.’
.__
—W
‘1’“
2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Automatic Transmission
2. Complete the diagnosis by looking for a GMLAN
circuit fault. Refer to Scan Tool Does Not
Communicate with High Speed GMLAN Device on
page 11—58.
2 If a GMLAN circuit fault is found
Repair as necessary.
U If a GMLAN circuit fault is not found
3. All OK.
=6T30/6T40/6T45/6T50 (MH8, MH9) 17-133
Repair Instructions
Perform the Diagnostic Repair Verification on
page 6-92 after completing the repair.
- Perform the Transmission Adaptive Values Learn
on page 17—163followingall transmission repairs.
- Control Module References on page 6—3for Body
Control Module and Control Solenoid Valve
Assembly replacement, programming and setup.

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
’17-134 Automatic Transmission - 6T30/6T40l6T45/6T50 (MH8, MH9)

DTC P182E or P1915

Diagnostic Instructions
' Perform the Diagnostic System Check - Vehicle
on page 6-66 prior to using this diagnostic
procedure.
- Review Strategy Based Diagnosis on page 6-58
for an overview of the diagnostic approach.
- Diagnostic Procedure Instructions on page 6-59
provides an overview of each diagnostic category.
DTC Descriptors
DTC P182E: Internal Mode Switch Indicates Invalid Range
DTC P1915: Internal Mode Switch Does Not Indicate Park/Neutral During Start
Diagnostic Fault Information

Open/High Short to Voltage Signal

Circuit Short to Ground Resistance Performance
SignalA P182E P1915 P1915 P182E,P1915
SignalB P1915 P182E P182E P182E,P1915
SignalC P1915 P182E P182E P182E,P1915
SignalP P182E P1915 P1915 P182E,P1915
Ground — P182E P182E P182E,P1915

Typical Scan Tool Data

Internal Mode Switch AIB/C/P

Circuit I Short to Ground I Open Short to Voltage
OperatingConditions: lgnitionON, rangeselectorin Park
ParameterNormalRange:LowHighHighLow
SwitchSignalA Low High High
SwitchSignalB Low High High
SwitchSignalC Low High High
SwitchSignalP Low High High
th=12vd$
Low=0 volts

CircuitlSystem Description The park/neutral signal is sent from the park/neutral

switch directly to the engine control module (ECM) and
The manual shift detent lever with shaft position switch is used for engine start enable.
assembly, also known as the transmission internal
mode switch assembly, is a sliding contact switch Conditions for Running the DTC
attached to the manual shift detent lever shaft inside ,~_—
_MW
IN
..
.....
M.,§
RV
V
the transmission. The 4 inputs to the transmission P182E
control module (TCM) from the switch indicate which ' DTC P0101, P0102, P0103, P0106, P0107,
position is selected by the transmission manual shaft. P0108, P0171, P0172, P0174, P0175, P0201,
The input voltage at the TCM is high when the switch is P0202, P0203, P0204, P0205, P0206, P0207, ”-...W
.22
open and low when the switch is closed to ground. The P0208, P0300, P0301, P0302, P0303, P0304,
state of each input is displayed on the scan tool as P0305, P0306, P0307, P0308, P0401, P042E,
Internal Mode Switch A/B/C/P parameter. The internal P0716, P0717, P0722, P0723, P07CO, P07BF,
mode switch input parameters represented are P077C, OR P077D is not set.
transmission range Signal A, Signal B, Signal C, and ' Engine speed is 400—7,500RPM for 5 s.
Signal P. The park/neutral position switch is integrated
into the transmission internal mode switch. The circuit ° lgnition voltage is 9~32V.
uses the TCM as a pass-through connector only. 0 Engine torque signal is valid.
- DTC runs continuously when the above conditions
are met.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Automatic Transmission - 6T30/6T40/6T45/6T50 (MH8, MH9) 17-135
P1915 Electrical Information Reference
° DTC P0722, P0723, 0r P1915 is not set. - Circuit Testing on page 11—526
- Transmission output shaft speed is 90 RPM - Connector Repairs on page 11-548 I
or less.
° Testing for IntermittentConditions and Poor
- Ignitionvoltage is 6~32V. Connections on page 11-531
- DTC runs when conditions above are met during ° Wiring Repairs on page 11—537
engine start sequence.
DTC Type Reference
Conditions for Setting the DTC
Powertrain Diagnostic Trouble Code (DTC) Type
P182E Definitions on page 6-68
Internal mode switch does not indicate a valid Park, Scan Tool Reference
Reverse, Neutral, or Drive Range position for 7 s.
Control Module References on page 6—3for scan tool
P1915 information
Internal mode switch does not indicate Park or Neutral Special Tools
during the following sequence:
- Engine speed is less than 50 RPM for greater DT—48616-10Adapter Harness
than 0.10 s. For equivalent regional tools, refer to Special Tools on
- Engine speed is 50—480RPM for greater page 17-394.
than 0.07 s.
CircuitlSystem Verification
- Engine speed is greater than 500 RPM and the
transmission input speed is greater than 100 RPM 1. Verify the range selector lever cable is adjusted
for greater than 1.253. properly. Refer to Range Selector Lever Cable
Adjustment on page 17—196.
Action Taken When the DTC Sets 2 If cable adjustment is not OK
- P182E and P1915 are TypeADTCs. Repair as necessary.
- TCM commands maximum line pressure. U If cable adjustment is OK
- TCM turns OFF aIIsolenoids. 2. IgnitionON.
' TCM freezes transmission adaptive functions. 3. Verify the scan tool TCM InternalMode Switch A/B/
. TCM limits the transmission to reverse and C/P parameter matches the Transmission Internal
5th gear. Mode Switch Logic on page 17—12tablefor each
- TCM forces the torque converter transmission shift lever position.
clutch (TCC) OFF. 2 If the parameter does not match
- TCM inhibits neutral idle. Refer to CircuitlSystem Testing.
- TCM inhibits the Tap Up/Tap Down function. 4: If the parameter matches
- TCM inhibits manual shifting of fonNardgears. 4. Verify the scan tool engine control module Park/
- TCM turns the high side driver OFF. Neutral Position Switch parameter displays Park/
- TCM enables torque management. Neutral with the gear shift lever in Park or Neutral
and In Gear in Reverse or Drive.
Conditions for Clearing the DTC 2 If Park/Neutral or In Gear is not displayed
P182E and P1915 are TypeA DTCs. Refer to CircuitlSystem Testing.
Reference Information U If ParklNeutral and In Gear is displayed
Schematic Reference 5. Operate the vehicle within the Conditions for
Running the DTC. You may also operate the
Automatic Transmission Controls Schematics on vehicle within the conditions that you observed
page 17-30 from the Freeze Frame/Failure Records data.
Connector End View Reference 6. Verify the DTC does not set.
2 If the DTC sets
. Component Connector End Views on page 11269
- lnline Harness Connector End Views on Refer to CircuitlSystem Testing.
page 11-465 U If the DTC does not set
Description and Operation 7. All OK.

- 7
Transmission General Description on page 17—31
- Transmission Component and System Description
on page 17-318
- Electronic Component Description on
page 17—319

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
17-136 Automatic Transmission - 6T30/6T40I6T45/6T50
CircuitlSystem Testing
Note: You must perform CircuitlSystem Verification
first.
1. lgnition OFF, remove the control valve body cover.
2. Connect the vehicle harness connector to the Q8
Control Solenoid Valve Assembly. ,
3. Disconnect the B15 Transmission InternalMode
Switch connector at the Q8 Control Solenoid Valve
Assembly.
4. lgnition ON.
5. Verify the scan tool engine control module Park/
Neutral Position Switch parameter displays
In Gear.
2 IfIn Gear is not displayed
5.1. IgnitionOFF, disconnect the vehicle harness
X1 connector at the QB Control Solenoid Valve
Assembly.
5.2. Install the DT-48616-10 adapter harness to
the X1 connector at Q8 Control Solenoid Valve
Assembly.
5.3. Test for infinite resistance between the
DT—48616-10adapter harness connector
terminals 2 and 3.
2 Ifless than infinite resistance, replace the QB
Control Solenoid Valve Assembly.
U Ifinfinite resistance.
5.4. Disconnect the harness connector at the
K20 Engine Control Module.
5.5. Test for infinite resistance between the signal
circuit and ground at the vehicle harness K20
Engine Control Module connector.
2 Ifless than infinite resistance, repair the short to
ground on the circuit.
2 Ifinfinite resistance, replace the K20 Engine
Control Module.
U If In Gear is displayed
6. Verify the scan tool transmission control module
InternalMode Switch A/B/C/P parameter displays
High High High High.
2 If High High High High is not displayed
Replace the QB Control Solenoid Valve
Assembly.
U If High High High High is displayed
7. Install a 3 A fused jumperwire between the low
reference circuit terminal F and each signal circuit
listed below one at a time at the Q8 Control
Solenoid Valve Assembly.
- SignalA—terminalB
- SignalB—terminalC
- SignalC—terminaID
° SignaIP—terminalE
(MH8, MH9)
8. Verify the scan tool transmission control module
A/B/C/P displays 1 Low and 3 High when a signal
circuit is grounded.
If 1 Low and 3 High is not displayed
Replace the Q8 Control Solenoid Valve
Assembly.
If1 Low and 3 High is displayed
. Connect a 3—ampfused jumper wire between
terminal A and terminal F.
10. Verify the engine control module Park/Neutral
Position Switch parameter displays Park/Neutral.
If Park/Neutral is not displayed
10.1. IgnitionOFF, remove thejumperwire and
disconnect the X1 connector at the Q8
Control Solenoid Valve Assembly.
10.2. Install the DT-48616-10 adapter harness to
the X1 connector at the Q8 Control Solenoid
Valve Assembly.
10.3. Test for less than 2 Q between the adapter
harness terminal 2 and the X2 connector
terminal F at the Q8 Control Solenoid Valve
Assembly.
2 Ifgreater than 2 Q, replace the Q8 Control
Solenoid Valve Assembly.
U Ifless than 2 Q .
10.4. Disconnect the connector at the K20 Engine
Control Module.
10.5. Test for less than 2 Q in the vehicle harness
park/neutralsignal circuit, end to end.
2 If2 Q or greater, repair the open/high resistance
in the circuit.
2 Ifless than 2 Q, replace the K20 Engine Control
Module.
U If Park/Neutral is displayed
11. Replace the B15 Transmission InternalMode
Switch.
Repair Instructions
Perform the Diagnostic Repair Verification on
page 6-92 after completing the repair.
Perform the Transmission Adaptive Values Learn
on page 17—163followingall transmission related
repairs.
Control Valve Body Cover Replacement on
page 17-210
Manual Shift Detent Lever with Shaft Position
Switch Assembly Replacement on page 17-191
Control Module References on page 6-3 for
Control Solenoid Valve Assembly replacement,
programming and setup
2013
-Sonic
(US/Canada)
Sen/ice
Manual
(5377994)
 Automatic Transmission . 6T30/6T40/6T45/6T50 (MH8, MH9) 17-137

DTC P1876

Diagnostic Instructions
- Perform the Diagnostic System Check - Vehicle
on page 6—66prior to using this diagnostic
procedure.
- Review Strategy Based Diagnosis on page 6—58
for an overview of the diagnostic approach.
- Diagnostic Procedure Instructions on page 6-59
.2vswflmw»...
m
__
_. provides an overview of each diagnostic category.
DTC Descriptor
DTC P1876: Up and Down Shift Enable Switch Circuit Low Voltage

CircuitlSystem Description Description and Operation

When the shift lever is placed in manual mode (M), the - Transmission General Description on page 17-317
driver shift request (DSR), also known as the tap shift - Electronic Component Description on
function, is activated. The DSR allows the vehicle page 17-319
operator to shift gears by pushing the plus (+)buttonfor
an upshift or minus (-) buttonfor a downshift. The body Electrical Information Reference
control module (BCM) supplies a signal circuit to the
shift controller. The shift controller has switches - Circuit Testing on page 11-526
connected to a resistor array. When the lever is in the o Connector Repairs on page 11-548
M position, a voltage drop occurs across the resistor - Testing for IntermittentConditions and Poor
network. When the plus or minus button is pushed, a Connections on page 11—531
corresponding voltage drop occurs across the resistor - Wiring Repairs on page 11-537
network. This voltage drop is monitored by the BCM.
The BCM will send the request to the transmission DTC Type Reference
control module (TCM) to perform the upshift or
downshift. Powertrain Diagnostic Trouble Code (DTC) Type
Definitions on page 6-68
Conditions for Running the DTC Scan Tool Reference
~ Engine speed is greater than 400 RPM for
5 seconds. Control Module References on page 6-3 for scan tool
information
0 Ignitionvoltage is 9.0 V or greater.
- DTC P0815, P0816, P0826, P1761, P1825, CircuitlSystem Verification
P1876, P1877, P1915, or U0100 is not set. Warning: Refer to Parking Brake and Drive Wheels
Warning on page 0-5.
Conditions for Setting the DTC
Transmission control module (TCM) detects a TAP 1. Verify there were no internal mode switch (IMS)
Enable Switch request for 3 seconds when the shift DTCs set.
lever is in Park, Reverse, or Neutral, a total of 5 times. 2 If IMS DTCs were set
Action Taken When the DTC Sets Refer to Diagnostic Trouble Code (DTC) List -
Vehicle on page 6—69.
. DTC P1876 is a Type C DTC. ‘
U If IMS DTCs are not set
- TCM inhibits Tap—Up/Tap—Down functions.
[\3 lgnition ON.
- TCM inhibits manual up, manual down shifts with
the shift selector. 3. Verify the gear shift lever position matches the
scan tool TCM InternalMode Switch parameter
Conditions for Clearing the DICIDTC while slowly moving the gear shift lever from Park
through all ranges.
DTC P1876 is a Type C DTC.
2 If the specified values are not correct
Reference Information Refer to Range Selector Lever Cable
Schematic Reference Adjustment on page 17—196.
U If the specified values are correct
Automatic Transmission Controls Schematics on
page 17—30
Connector End View Reference
Component Connector End Views on page 11—269

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
17-138 Automatic Transmission - 6T30/6T40/6T45/6T50
4. Shift lever in the M position, verify the scan tool
Driver Shift Request parameter changes from
None to Upshift when the plus button is pressed,
and from None to Downshift when the minus button
is pressed.
If the Driver Shift Request parameter does not
display the correct values
Refer to CircuitlSystem Testing below.
If the Driver Shift Request parameter displays
the correct values
After performing the above steps, verify that the
DTC does not reset by operating the vehicle within
the Conditions for Running the DTC. You may also
operate the vehicle within the conditions you
observe from the Freeze Frame/Failure Records
data. Ifthe vehicle passes the CircuitlSystem
Verification procedure, then STOP. Do not perform
the CircuitlSystem Testing or Component Testing
as this may result in an unnecessary part
replacement. Refer to Testing for Intermittent
Conditions and Poor Connections on page 11—531.
CircuitlSystem Testing
Note: You must perform CircuitlSystem Verification
first.
1. Ignition OFF, disconnect the 83 transmission shift
lever electrical connector.
2. Test for less than 10 ohms between the S3
transmission shift lever harness connector
terminal 2 and ground.
If 10 Q or greater
Test for less than 2 Q in the ground circuit end
to end.
2 If2 Q or greater, repair the open/high resistance
in the circuit
2 If less than 2 Q, repair the open/high resistance
in the ground connection.
If less than 10 Q
.03 lgnition ON.
. Test for 11V or greater at the S3 transmission shift
lever harness connector between signal circuit
terminal 3 and ground.
If less than 11 V
4.1. Ignition OFF, remove the connector at the K9
body control module.
4.2. Test for infinite resistance between the 83
transmission shift lever harness connector
signal circuit terminal 3 and ground.
2 If less than infinite resistance, repair the short to
ground in the circuit.
U If infinite resistance.
4.3. Test for less than 2 Q in the signal circuit end
to end.
2 If2 Q or greater, repair the open/high resistance
in the signal circuit wire.
(MH8, MH9)
2 Ifless than 2 Q, replace the K9 body control
module.
If 11 V or greater
.01 IgnitionOFF.
Test for 5.8—6.4kQ between the 83 transmission
shift lever connector terminal 3 and terminal 2.
If not between 5.8—6.4kQ
Replace the S3 transmission shift lever.
If between 5.8—6.4kQ #
.”....
m W
Test for 1.8—2.2kQ between the SS shift lever
connector terminal 3 and terminal 2 with the tap
down button depressed.
If not between 1.8—2.2kQ
Replace the S3 transmission shift lever.
If between 1.8—2.2kQ
Test for 580—680Q between the 83 shift lever
connector terminal 3 and terminal 2 with the tap
down button depressed.
If not between 580—680Q
Replace the 83 transmission shift lever.
If between 580—680Q
Test for less than 2 Q in the signal circuit end
to end.
If 2 Q or greater
Repair the open/high resistance in the circuit.
U If less than 2 Q
10. Replace the K9 body control module.
Repair Instructions
Perform the Diagnostic Repair Verification on
page 6—92after completing the diagnostic repair.
Note:
Perform the Transmission Adaptive Values Learn
on page 17—163followingall transmission related
repairs.
Before replacing the TCM, perform the Control
Solenoid Valve and Transmission Control Module
Assembly Inspection on page 17—158.
Transmission Control Replacement on
page 17-193for AT TAP shift switch replacement.
Control Module References on page 6-3 for BCM
or control solenoid valve assembly replacement,
programming and setup.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Automatic Transmission - 6T30/6T40/6T45/6T50 (MH8, MH9) 17=139

DTC P2714 or P2715 (Gen 1)

Diagnostic Instructions
- Perform the Diagnostic System Check - Vehicle
on page 6-66 priorto using this diagnostic
procedure.
° Review Strategy Based Diagnosis on page 6-58
for an overview of the diagnostic approach.
0 Diagnostic Procedure Instructions on page 6—59
provides an overview of each diagnostic category.
DTC Descriptors
DTC P2714: Pressure Control Solenoid Valve 4 Stuck Off
DTC P2715: Pressure Control Solenoid Valve 4 Stuck On

CircuitlSystem Description . 2-6 clutch is commanded OFF.

The clutch pressure control solenoid 4 is part of the - Transmission fluid temperature is 0°C (32°F) or
control solenoid valve assembly which has no greater.
serviceable components. The pressure control - Attained range is not 1st gear.
....Wwwm
~22.”
...“FWH
wen...“—
‘_W
wW solenoid 4 regulates transmission fluid pressure to the - High side driver is enabled.
2—6regulator valve which controls pressure to the - Transmission input speed is 200 RPM or greater.
2—6clutch. The transmission control module (TCM)
calculates gear ratio based on the speed signals from Conditions for Setting the DTC
the input shaft speed (ISS) sensor and the output shaft
speed (088) sensor. The TCM compares the expected P2714
transmission gear ratio to the calculated gear ratio for TCM detects an incorrect on-coming clutch gear ratio,
each commanded gear. or shift flare.
Conditions for Running the DTC P2715
P2714 TCM detects an incorrect oft-going clutch gear ratio,
or shift tie-up.
- DTC P0101, P0102, P0103, P0106, P0107,
P0108, P0171, P0172, P0174, P0175, P0201, Action Taken When the DTC Sets
P0202, P0203, P0204, P0205, P0206, P0207,
P0208, P0300, P0301, P0302, P0303, P0304, P2714
P0305, P0306, P0307, P0308, P0401, P042E, - DTC P2714 Is a Type A DTC.
P0716, P0717, P0722, P0723, or P182E is
- TCM commands maximum line pressure.
not set.
- TCM freezes transmission adaptive functions.
' High side driver is enabled.
- TCM inhibits the Tap Up/Tap Down function.
- Throttle position signal is valid.
- TCM inhibits manual shifting of forward gears.
- Ignitionvoltage is between 9—32V.
- TCM limits the transmission to reverse and
- Transmission fluid temperature is —7°C(19°F) or
3rd gear.
greater.
- Engine speed is between 400—7500RPM for P2715
5 seconds. - DTC P2715 is a Type A DTC.
- 2-6 clutch is commanded ON. - TCM commands maximum line pressure.
- Output speed is 650 RPM or greater, or the throttle - TCM freezes transmission adaptive functions.
position is greater than 0.5 percent. - TCM inhibits the Tap Up/Tap Down function.
P2715 - TCM inhibits manual shifting of forward gears.
- DTC P0101, P0102, P0103, P0106, P0107, - TCM limits the transmission to reverse and
P0108, P0171, P0172, P0174, P0175, P0201, 2nd gear.
P0202, P0203, P0204, P0205, P0206, P0207,
P0208, P0300, P0301, P0302, P0303, P0304, Conditions for Clearing the DICIDTC
P0305, P0306, P0307, P0308, P0401, P042E, DTCs P2714 and P2715 are TypeA DTCs.
P0716, P0717, P0722, P0723, or P182E is
not set. Diagnostic Aids
- Ignitionvoltage is between 9—32V. Before performing a road test, configure and setup the
- Transmission output shaft speed is 200 RPM or scan tool for snapshot mode. This allows you to
greater. monitor,display, and verify multiple transmission data
- Engine speed is between 400—7500RPM for parameters at one time, after the road test.
5 seconds.

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
'17-'140 Automatic Transmission - 6T30/6T40I6T45/6T50
Reference Information
Schematic Reference
Automatic Transmission Controls Schematics on
page 17—30
Connector End View Reference
- Component Connector End Views on page 11-269
- lnline Harness Connector End Views on
page 11—465
Description and Operation
' Transmission General Description on page 17-317
0 Transmission Component and System Description
on page 17-318
- Electronic Component Description on
page 17-319
- Drive Range, Second Gear (Gen 1) on
page 17-341 or Drive Range, Second Gear (Gen
2) on page 17-343
- Drive Range, Sixth Gear (Gen 1) on page 17—366
or Drive Range, Sixth Gear (Gen 2) on
page 17-368
DTC Type Reference
Powertrain Diagnostic Trouble Code (DTC) Type
Definitions on page 6-68
Scan Tool Reference
Control Module References on page 6—3for scan tool
information
CircuitlSystem Verification
Warning: Refer to Parking Brake and Drive Wheels
Warning on page 0-5.
Note: Ifother DTCs are set, diagnose those DTCs first.
1. Engine idling in Park, with parking brake applied
and drive wheels chocked.
2. Verify the transmission fluid level and condition is
correct. Refer to Transmission Fluid Level and
Condition Check on page 17—164.
3. Verify the scan tool TFP Switch 3 parameter
displays the correct state for each gear range while
placing the gear select lever in Park, Reverse, and
Neutral range. Refer to Transmission Fluid
Pressure Switch Logic on page 17-11.
2 If the correct state for each gear range is not
displayed
Refer to CircuitlSystem Testing.
U If the correct state for each gear range is
displayed
4. Gear select lever in Drive range.
Note: Use Drive 1st —Engine Braking to determine
expected 1st gear Transmission Fluid Pressure Switch
parameter states.
(MH8, MH9)
5. Verify the scan tool TFP Switch 3 parameter
displays the correct state for each gear range while
commanding the scan tool Shift Transmission Gear
through all fon/vardranges. Refer to Transmission
Fluid Pressure Switch Logic on page 17—11.
2 If the correct state for each gear range is not
displayed
Refer to CircuitlSystem Testing.
U If the correct state for each gear range is
displayed
6. lgnition ON, engine OFF. Clear the TCM DTC
informationwith a scan tool.
Perform the Road Test on page 17-167.
9°.“Verify DTC P2714 or P2715 did not set.
2 If a DTC set
Refer to CircuitlSystem Testing.
U If a DTC does not set
9. 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.
10. Verify the DTC does not set.
2 If the DTC sets
Refer to CircuitlSystem Testing.
U If the DTC does not set
11. All OK.
CircuitlSystem Testing
Note: You must perform the CircuitlSystem Verification
first.
1. Verify the transmission line pressures are within
range. Refer to Line Pressure Check on
page 17-166 and Solenoid Valve Pressure (Gen 1)
on page 17—12.
2 If the line pressures are not within the specified
ranges
Refer to Fluid Pressure High or Low on
page 17-191.
U If the line pressures are within the specified
ranges
2. Engine Idling,shift selector in the Drive position.
3. Verify the scan tool parameters listed below
display the correct state for each gear range while
commanding the scan tool Shift Transmission Gear
through all forward ranges. Referto Transmission
Fluid Pressure Switch Logic on page 17-11for the
correct gear range states.
' TFP Switch 1
. TFP Switch 3
2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Automatic Transmission
' TFP Switch 4
- TFP Switch 5
2 If the correct state for each gear range is not
displayed
3.1. IgnitionOFF.
3.2. Remove the Control Valve Body. Refer to
Control Valve Body Replacement on
page 17—213.
3.3. Verify the Control Valve Body is not
contaminated with any debris and there is no
damage or sticking valves, refer to Control
Valve Body Cleaning and Inspection (Gen 2)
on page 17—306.
2 Ifthere is contamination, damage, or sticking
valves, repair or replace the control valve body
as necessary.
2 lfthere is no contamination, damage, or sticking
valves, replace the Q8 Control Solenoid Valve
Assembly.
U If the correct state for each gear range is
displayed
4. Verify the conditions listed below do not exist.
Carefully inspect each component for that
condition. Repair or replace as necessary.
P2714 AlTrans Fluid Filter Assembly
Oil filter or filter seal loose or damaged.
P2714 Torque Converter (w/fluid pump) Housing
Assembly
Fluid pump housing/gear damaged/scored.
P2714 Trans case and 1-2-3-4 clutch backing plate
retainer ring
1-2—3—4 clutch backing plate retaining ring not seated/
oriented correctly at trans case groove.
P2714 or P2715 Trans case, 2-6 clutch piston,
spring retaining ring, reaction sun gear
- 2-6 clutch return spring retaining ring not seated in
groove
- 2—6clutch piston assembly —seal damaged or‘
leaking
(US/Canada)
»Sonic
2013 (5377994)
Manual
Service
- 6T30/6T40/6T45/6T50 (MH8, IVIH9) 17-141
. 2—6clutch plates worn or damaged
- 2-6 clutch plates will not slide over the reaction
sun gear shell freely
P2714 Channel Plate and Spacer Plate
Oil channels or orifices blocked by debris.
P2714 or P2715 Control Valve Body Assembly
26 clutch regulator valve stuck/sticking, debris,
binding, damaged valve, or scored bore.
P2714 or P2715 Q8 Control Solenoid Valve
Assembly
- Pressure Control Solenoid Valve 4 Stuck ON/OFF.
- Control signal fluid supply leak —valve body filter
plate assembly cracked or damaged gasket seal.
° O-ring seals leaking.
Repair Instructions
Perform the Diagnostic Repair Verification on
page 6-92 after completing the repair.
Perform the Transmission Adaptive Values Learn on
page 17-163 following all transmission related repairs.
- Internal Components Removal on page 172%
- 2-6 Clutch Piston Removal on page 17-237
- Low and Reverse and 1-2-3-4 Clutch Housing,
Low and Reverse Clutch Assembly, Output Sun
Gear, and 2-6 Clutch Plate Disassemble (Gen 1)
on page 17-253 or Low and Reverse and 1-2-3-4
Clutch Housing, Low and Reverse Clutch
Assembly, Output Sun Gear, and 2-6 Clutch Plate
Disassemble (Gen 2) on page 17-254
- 2-6 Clutch Piston Installation (6T30) on
page 17-251 or 2-6 Clutch Piston Installation
(6T40/45/50)on page 17-252
- 3-5-Reverse and 4-5—6Clutch Housing, and Input,
Reaction, and Output Carrier/nsta/lation on
page 17-269
- Refer to Control Module References on page 6—3
for control solenoid valve assembly replacement,
programming and setup.
'17-’142 Automatic Transmission - 6T30/6T40l6T45/6T50 (MH8, MH9)

DTC P2714 or P2715 (Gen 2)

Diagnostic Instructions
- Perform the Diagnostic System Check —Vehicle
on page 6—66prior to using this diagnostic
procedure.
- Review Strategy Based Diagnosis on page 6-58
for an overview of the diagnostic approach.
- Diagnostic Procedure Instructions on page 6-59
provides an overview of each diagnostic category.
DTC Descriptors
DTC P2714: Pressure Control Solenoid Valve 4 Stuck Off
DTC P2715: Pressure Control Solenoid Valve 4 Stuck On

CircuitlSystem Description ° Pressure control solenoid 4 is commanded OFF,

releasing the 2—6clutch.
Pressure control solenoid 4 is part of the control
solenoid valve assembly which has no serviceable ° Transmission fluid temperature is —6.6°C(20°F) or
greater. Wm
M—
“Hm
A...
,...
__._
"..-.
.2..
M
components. Pressure control solenoid 4 regulates
transmission fluid pressure to the 2-6 regulator valve ' Engine speed is 400—7,500RPM for 5 s.
which controls pressure to the 2—6clutch. The - Engine torque is 45 Wm (33 Ibft) orgreater.
transmission control module (TCM) calculates gear
- The attained range is not 1st gear.
ratio based on the speed signals from the input shaft
speed (ISS) sensor and the output shaft speed (088) - High side driver is enabled.
sensor. The TCM compares the expected transmission ° Runs continuously when above conditions
gear ratio to the calculated gear ratio for each are met.
commanded gear.
Conditions for Setting the DTC
Conditions for Running the DTC
P2714
P2714 TCM detects an incorrect on-coming clutch gear ratio,
- DTC P0101, P0102, P0103, P0106, P0107, or shift flare. This condition'must occur 3 times.
P0108, P0171, P0172, P0174, P0175, P0201,
P0202, P0203, P0204, P0205, P0206, P0207, P2715
P0208, P0300, P0301, P0302, P0303, P0304, TCM detects an incorrect off-going clutch gear ratio,
P0305, P0306, P0307, P0308, P0401, P042E, or shift tie-up. This condition must occur 3 times.
P0716, P0717, P0722, P0723, or P182E is
not set. Action Taken When the DTC Sets
- High side driver is enabled. P2714
- Throttle position signal is valid. - P2714 is a Type A DTC.
0 Ignitionvoltage is 9—32V. - TCM commands maximum line pressure.
o Transmission fluid temperature is ~6.6°C (20°F) or - TCM freezes transmission adaptive functions.
greater.
° TCM inhibits the Tap Up/Tap Down function.
- Engine speed is 400—7,500RPM for 5 s.
- TCM inhibits manual shifting of fon/vardgears.
- Pressure control solenoid 4 is commanded ON,
applying the 2-6 clutch. . TCM limits the transmission to reverse and
3rd gear.
- Output speed is 100 RPM or greater, or the throttle
' position is greater than 0.5%. ° TCM inhibits powertrain braking.
0 Runs continuously when above conditions ° TCM inhibits neutral idle.
are met. . TCM inhibits auto grade braking. xxsm
.s
...
P2715 P2715
- DTC P0101, P0102, P0103, P0106, P0107, ' P2715 is a Type A DTC.
P0108, P0171, P0172, P0174, P0175, P0201, - TCM commands maximum line pressure.
P0202, P0203, P0204, P0205, P0206, P0207, ° TCM freezes transmission adaptive functions.
P0208, P0300, P0301, P0302, P0303, P0304,
P0305, P0306, P0307, P0308, P0401, PO42E, - TCM inhibits the Tap Up/Tap Down function.
P0716, P0717, P0722, P0723, or P182E is ' TCM inhibits manual shifting of fon/vardgears.
not set. ° TCM inhibits powertrain braking.
- lgnition voltage is 9—32V. ° TCM inhibits auto grade braking.
- Transmission output shaft speed is 100 RPM or - TCM inhibits neutral idle.
greater, or throttle position is 0.5% or greater.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Automatic Transmission - 6T30/6T40/6T45/6T50 (MH8, MH9) 17-143
o TCM commands 2nd gear if the output speed is Note: Ifother DTCs are set, diagnose those DTCs first.
less than 700 RPM.
1. IgnitionON.
- TCM commands neutral if the output speed is
700 RPM or greater. 2. Verify DTC P0716, P0717, P0722, P0723, PO77C,
P077D, P07BF, or P0700 was not set by reviewing
Conditions for Clearing the DTC the scan tool Freeze Frame/Failure Records data.
P2714 and P2715 are Type A DTCs. 2 ‘If any of the DTCs were set
Refer to Diagnostic Trouble Code (DTC) List -
Reference Information Vehicle on page 6-69.
Schematic Reference U If none of the DTCs were set
Automatic Transmission Controls Schematics on 3. Engine idling, transmission in Park, with parking
page 17—30 brake applied and drive wheels chocked.
4. Verify the transmission fluid level and condition is
Connector End View Reference
correct. Refer to Transmission Fluid Level and
- Component Connector End Views on page 11-269 Condition Check on page 17-164.
- lnline Harness Connector End Views on 2 If the transmission fluid level and condition is
page 11—465 not correct
Description and Operation Repair as necessary.
- Drive Range, Second Gear (Gen 1) on U Ifthe transmission fluid level and condition is
page 17-341 or Drive Range, Second Gear (Gen correct
2) on page 17-343 5. IgnitionON, clear the TCM DTCs with a scan tool.
- Drive Range, Sixth Gear (Gen 1) on page 17—366 6. Verify DTC P2714 or P2715 does not set while
or Drive Range, Sixth Gear (Gen 2) on performing a road test. Refer to Road Test on
page 17-368 page 17—167.
- Electronic Component Description on 2 If DTC P2714 or P2715 sets
page 17—319 Refer to CircuIt/System Testing.
- Transmission Component and System Description U If DTC P2714 or P2715 does not set
on page 17-318
.‘1 Operate the vehicle within the Conditions for
~ Transmission General Description on page 17—31
7 Running the DTC. You may also operate the
Electrical Information Reference vehicle within the conditions that you observed
from the Freeze Frame/Failure Records data.
0 Circuit Testing on page 11-526
9° Verify the DTC does not set.
- Connector Repairs on page 11548
2 If the DTC sets
- Testing for IntermittentConditions and Poor
Connections on page 11—531 Refer to CircuitlSystem Testing.
- Wiring Repairs on page 11~537 U Ifthe DTC does not set
DTC Type Reference 9 All OK.

Powertrain Diagnostic Trouble Code (DTC) Type CircuitlSystem Testing

Definitions on page 6—68 Note: You must perform the CircuitlSystem Verification
Scan Tool Reference first.
1. Engine idling at the normal operating temperature.
Control Module References on page 6-3 for scan tool
information 2. Verify the transmission line pressures are within
the specified range. Refer to Line Pressure Check
Special Tools on page 17—166and Solenoid Valve Pressure (Gen
DT—48616Solenoid Assembly Test Kit & Adapter 1)on page 17—12.
Harness 2 If the pressures are not within range
For equivalent regional tools, refer to Special Tools on Refer to Fluid Pressure High or Low on
page 17—394. page 17-191.
CircuitlSystem Verification U If the pressures are within range
Warning: Refer to Parking Brake and Drive Wheels 3. IgnitionOFF, remove the QB Control Solenoid
Warning on page 0-5. Valve Assembly.

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
17-144 Automatic Transmission - 6T30/6T40/6T45/6T50
4. Verify the pressure changes for all solenoids when
performing the solenoid test. Refer Control
Solenoid Valve and Transmission Control Module
Assembly Solenoid Performance Test on
page 17-160.
2 If the pressure does not change
Replace the Q8 Control Solenoid Valve
Assembly.
U If the pressure changes
5. Verify the conditions listed below do not exist.
Repair or replace as necessary.
P2714 Channel Plate and Spacer Plate
Oil channels or orifices blocked by debris.
P2714 or P2715 Control Valve Body Assembly
26 clutch regulator valve stuck/sticking, debris,
binding, damaged valve, or scored bore.
P2714 Automatic Transmission Fluid Filter
Assembly
Oil filter or filter seal loose or damaged.
P2714 Torque Converter (w/fluid pump) Housing
Assembly
Fluid pump housing/gear damaged/soored.
P2714 Trans case and 1-2-3-4 clutch backing plate
retainer ring
1—2—3-4 clutch backing plate retaining ring not seated/
oriented correctly at trans case groove.
(MH8, IVIH9)
P2714 or P2715 Transmission case, 2-6 clutch
piston, spring retaining ring, reaction sun gear
- 2—6clutch return spring retaining ring not seated in
groove
- 2-6 clutch piston assembly —seal damaged or
leaking
- 2—6clutch plates worn or damaged
- 2-6 clutch plates will not slide over the reaction
sun gear shell freely
P2714 or P2715 QB Control Solenoid Valve
Assembly
° Pressure Control Solenoid Valve 4 Stuck ON/OFF.
. Control signal fluid supply leak —valve body filter
plate assembly cracked or damaged gasket seal.
- O-ring seals leaking.
Repair Instructions
Perform the Diagnostic Repair Verification on
page 6-92 after completing the repair.
- Perform the Transmission Adaptive Values Learn
on page 17—163followingall transmission repairs.
0 Control Module References on page 6—3for
Control Solenoid Valve Assembly replacement,
programming and setup.

2013
—
Sonic
(US/Canada)
Service
Manual
(5377994)
 Automatic Transmission .. 6T30/6T40/6T45/6T50 (MH8, MH9) 17-145

DTC P2719-P2721

Diagnostic Instructions
- Perform the Diagnbstic System Check - Vehicle
on page 6—66prior to using this diagnostic
procedure.
- Review Strategy Based Diagnosis on page 6—58
for an overview of the diagnostic approach.
- Diagnostic Procedure Instructions on page 6-59
provides an overview of each diagnostic category.
DTC Descriptors
DTC P2719: Pressure Control Solenoid Valve 4 Performance
DTC P2720: Pressure Control Solenoid Valve 4 Control Circuit Low Voltage
DTC P2721: Pressure Control Solenoid Valve 4 Control Circuit High Voltage

CircuitlSystem Description Action Taken When the DTC Sets

Pressure control solenoid 4 is part of the control P2719
solenoid valve assembly which has no serviceable
components. The normally low pressure control - P2719 is a Type C DTC.
solenoid 4 regulates and directs oil pressure to the ~ TCM freezes transmission adaptive functions on
2-6 clutch regulator valve. Increasing pressure control the 2-6 clutch.
solenoid 4 pressure increases pressure to the P2720
2-6 clutch. The transmission control module (TCM)
varies current to the pressure control solenoid 4 by - P2720 is a Type A DTC.
controlling the amount of time the low side driver is ON - TCM limits the transmission to 2nd gear and
and OFF. Increasing the ON time increases current to reverse.
the clutch PC solenoid 4. Increasing current to pressure - TCM commands maximum line pressure.
control solenoid 4 increases oil pressure by closing off - TCM freezes transmission adaptive functions.
the solenoid exhaust port. Decreasing the current to the
pressure control solenoid 4 decreases oil pressure by - TCM inhibits neutral idle.
opening the exhaust port. Pressure control solenoid 4 - TCM inhibits auto grade braking.
power is supplied by the TCM through a high side - TCM inhibits Tap Up/Tap Down function.
driver. The high side driver protects the circuit and
components from excessive current flow. Ifexcessive . TCM inhibits manual up, manual down shifts with
current flow is detected, the high side driver will turn the shift selector.
OFF. When the fault is corrected, the high side driver . TCM commands 2nd gear if the transmission is in
will reset. a forward gear and the outputspeed is less than
700 RPM, or neutral if the output speed is
Conditions for Running the DTC 700 RPM or greater.
- Engine speed is 400—7,500RPM for 5 s. P2721
- lgnition voltage is 9—32V. . P2721 is a Type A DTC.
- DTC runs continuously when above conditions ' TCM limits the transmission to 3rd gear and
are met. reverse.
Conditions for Setting the DTC - TCM commands maximum line pressure.
- TCM freezes transmission adaptive functions.
P2719
- TCM inhibits neutral idle.
TCM detects an internal electrical performance ° TCM inhibits Tap Up/Tap Down function.
malfunction on the clutch pressure solenoid 4 control
circuit where the measured clutch pressure control . TCM inhibits manual shifting of fonNardgears.
solenoid 4 current does not equal the commanded for Clearing the DTC
Conditions
clutch pressure control solenoid 4 current for 5 s.
' P2719 is a Type C DTC.
P2720
- P2720 and P2721 are Type A DTCs.
TCM detects a short to ground on the clutch pressure
control solenoid 4 control circuit for 1 s. Reference Information
P2721 Schematic Reference
TCM detects an open or short to voltage on the clutch Automatic Transmission Controls Schematics on
pressure control solenoid 4 control circuit for 1 s. page 17-30

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
‘17-'146 Automatic Transmission - 6T30/6T40/6T45/6T50
Connector End View Reference
- Component Connector End Views on page 11-269
o lnline Harness Connector End Views on
page 11-465
Description and Operation
- Transmission General Description on page 17—31
7 CircuitlSystem
- Transmission Component and System Description
on page 17-318
- Electronic Component Description on
page 17-319
Electrical Information Reference
0 Circuit Testing on page 11-526
- Connector Repairs on page 11-548
- Testing for IntermittentConditions and Poor
Connections on page 11—531
- Wiring Repairs on page 11—537
DTC Type Reference
Powertrain Diagnostic Trouble Code (DTC) Type
Definitions on page 6-68
Scan Tool Reference
Control Module References on page 6-3 for scan tool
information
Special Tools
DT—48616—10 Adapter Harness
For equivalent regional tools, refer to Special Tools on
page 17-394.
CircuitlSystem Verification
1. Operate the vehicle in second gear long enough to
ensure at least a 3°C (5°F) rise in TCM
temperature.
2. Operate the vehicle in drive range. Allow the
transmission to shift through all fonivardgear
ranges.
3. Ignition ON.
4. Verify the scan tool parameters listed below do not
display Malfunction:
- Pressure Control Solenoid Valve 4 Performance
Test Status
- Pressure Control Solenoid Valve 4 Control
Circuit Low Voltage Test Status
- Pressure Control Solenoid Valve 4 Control
Circuit High Voltage Test Status
2 If Malfunction is displayed
Refer to CircuitlSystem Testing.
U If Malfunction is not displayed
5. 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.
(MH8, MH9)
6. Verify the DTC does not set.
2 If the DTC sets
Refer to CircuitlSystem Testing.
U If the DTC does not set
7. All OK.
Testing
Note: You must perform the CircuitlSystem Verification
first.
1. IgnitionOFF, remove the Q8 Control Solenoid
Valve Assembly.
2. Verify the QB Control Solenoid Valve Assembly is
not contaminated with any debris and clean as
necessary. Refer to Control Solenoid Valve and
Transmission Control Module Assembly Inspection
on page 17-158.
2 If contaminated
Repair as necessary.
U If not contaminated
3. Verify the resistance is within the specified range
for each solenoid listed in the Control Solenoid
Valve and Transmission Control Module Assembly
Inspection on page 17-158.
2 If the resistance is not within range
Replace the Q8 Control Solenoid Valve
Assembly.
4: If the resistance is within range
4. Place the Q8 Control Solenoid Valve Assembly on
a clean work surface near the transmission
assembly.
5. Connect the DT—48616—10 adapter harness
between the vehicle harness connector and the Q8
Control Solenoid Valve Assembly connector.
IgnitionON.
6. Verify the scan tool parameters listed below do not
display Malfunction:
- Pressure Control Solenoid Valve 2 Performance
Test Status
- Pressure Control Solenoid Valve 2 Control
Circuit Low Voltage Test Status
- Pressure Control Solenoid Valve 2 Control
Circuit High Voltage Test Status
2 If Malfunction is displayed
Replace the Q8 Control Solenoid Valve
Assembly.
U If Malfunction is not displayed
7. All OK.
Repair Instructions
Perform the Diagnostic Repair Verification on
page 6-92 after completing the repair.
- Perform the Transmission Adaptive Values Learn
on page 17—163followingall transmission repairs.
' Control Module References on page 6-3 for
Control Solenoid Valve Assembly replacement,
programming and setup.
2013
~Sonic
(US/Canada)
Service
Manual
(5377994)
 Automatic Transmission - 6T30/6T40/6T45/6T50 (MH8, MH9) 17-147

DTC P2723 or P2724 (Gen 1)

Diagnostic Instructions
. Perform the Diagnostic System Check —Vehicle
on page 6-66 prior to using this diagnostic
procedure.
.W.
-...
m
- Review Strategy Based Diagnosis on page 6-58
for an overview of the diagnostic approach.
- Diagnostic Procedure Instructions on page 659
provides an overview of each diagnostic category.
DTC Descriptors
DTC P2723: Pressure Control Solenoid Valve 5 Stuck Off
DTC P2724: Pressure Control Solenoid Valve 5 Stuck On

CircuitlSystem Description - High side driver is enabled.

The clutch pressure control solenoid 5 is part of the - Transmission output shaft speed is 100 RPM or
control solenoid valve assembly, which has no greater, or the throttle position is 0.5 percent or
serviceable components. The pressure control greater.
solenoid 5 regulates transmission fluid pressure to the - Ifcommanded range is 1st gear, throttle position is
1-2-3—4regulator valve which controls pressure to the 10 percent or greater and engine torque is 45 N-m
1-2—3—4 clutch. The transmission control module (TCM) (33 lb ft) or greater.
calculates gear ratio based on the speed signals from
the input shaft speed (ISS) sensor and the output Conditions for Setting the DTC
shaft (088) speed sensor. The TCM compares the P2723
expected transmission gear ratio to the calculated gear
ratio for each commanded gear. TCM detects an incorrect on-coming clutch gear ratio,
or shift flare.
Conditions for Running the DTC
P2724
P2723 TCM detects an‘incorrect of'f-goingclutch gear ratio,
- DTC P0101, P0102, P0103, P0106, P0107, or shift tie-up.
P0108, P0171, P0172, P0174, P0175, P0201,
P0202, P0203, P0204, P0205, P0206, P0207, Action Taken When the DTC Sets
P0208, P0300, P0301, P0302, P0303, P0304, P2723
P0305, P0306, P0307, P0308, P0401, P042E,
P0716, P0717, P0722, P0723, or P182E is - DTC P2723 is a Type A DTC.
not set. . TCM freezes transmission adaptive functions.
- Ignitionvoltage is between 9—32V. - TCM commands maximum line pressure.
- Throttle position signal is valid. - TCM inhibits Tap Up/Tap Down.
- Engine speed is between 400—7500RPM for - TCM inhibits Manual Up/Manual Down with the
5 seconds. gear selector.
- High side driver is enabled. - Torque management is enabled.
- Transmission fluid temperature is —7°C(19°F) or - TCM inhibits neutral idle.
greater. - TCM inhibits powertrain braking.
- Transmission output speed is 100 RPM or greater ° TCM inhibits autograde braking.
or the throttleposition is 0.5 percent or greater.
- TCM limits the transmission to reverse and 5th
P2724 range.
- DTC P0101, P0102, P0103, P0106, P0107, P2724
P0108, P0171, P0172, P0174, P0175, P0201,
- DTC P2724 is a Type A DTC.
P0202, P0203, P0204, P0205, P0206, P0207,
P0208, P0300, P0301, P0302, P0303, P0304, - TCM freezes transmission adaptive functions.
P0305, P0306, P0307, P0308, P0401, P042E, - TCM commands maximum line pressure.
P0716, P0717, P0722, P0723, or P182E is - TCM inhibits Tap Up/Tap Down.
not set.
- TCM inhibits Manual Up/Manual Down with the
- Engine speed is between 400—7500RPM for gear selector.
5 seconds.
- TCM limits the transmission to reverse and 3rd
- Ignitionvoltage is between 9—32V. range.
0 Throttle position signal is valid. - TCM inhibits powertrain braking.
- Transmission Fluid Temperature is —7°C(19°F) or - TCM inhibits neutral idle.
greater.
- TCM inhibits auto grade braking.

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
17-148 Automatic Transmission - 6T30/6T40I6T45/6T50
Conditions for Clearing the DICIDTC
DTCs P2723 and P2724 are TypeA DTCs.
Reference Information
Description and Operation
- Transmission General Description on page 17-317
- Transmission Component and System Description
on page 17—318
- Electronic Component Description on
page 17—31 9
0 Drive Range, First Gear (Gen 1) on page 17-337
or Drive Range, First Gear (Gen 2) on
page 17-339
0 Drive Range, Second Gear (Gen 1)on
page 17-341 or Drive Range, Second Gear (Gen
2) on page 17—343
0 Drive Range, Third Gear (Gen 1) on page 17—345
or Drive Range, Third Gear (Gen 2) on
page 17-347
' Drive Range - Fourth Gear (Gen 1) on
page 17-349 or Drive Range - Fourth Gear (Gen
2) on page 17—351
- Drive Range, Fifth Gear (Gen 1) on page 17-356
or Drive Range, Fifth Gear (Gen 2) on
page 17—358
- Drive Range - Fourth Gear Default (Gen 2/Hybrid)
on page 17—353
- Drive Range, Sixth Gear (Gen 1) on page 17—366
or Drive Range, Sixth Gear (Gen 2) on
page 17—368
DTC Type Reference
Powertrain Diagnostic Trouble Code (DTC) Type
Definitions on page 6-68
Scan Tool Reference
Control Module References on page 6-3 for scan tool
information
CircuitlSystem Verification
Warning: Refer to Parking Brake and Drive Wheels
Warning on page 0-5.
Note: Ifother DTCs are set, diagnose those DTCs first.
1. Engine idling in Park, with parking brake applied
and drive wheels chocked.
2. Verify the transmission fluid level and condition is
correct. Refer to Transmission Fluid Level and
Condition Check on page 17-164.
3. Verify the scan tool TFP Switch 4 parameter
displays the correct state for each gear range while
placing the gear select lever in Park, Reverse, and
Neutral range. Refer to Transmission Fluid
Pressure Switch Logic on page 17-11.
2 If the correct state for each gear range is not
displayed
Refer to CircuitlSystem Testing.
U If the correct state for each gear range is
displayed
4. Gear select lever in Drive range.
(MH8, MH9)
5. Verify the scan tool TFP SWitch 4 parameter state
displays the correct state for each gear range while
commanding the scan tool Shift Transmission Gear
through all forward ranges. Refer to Transmission
Fluid Pressure Switch Logic on page 17-11.
2 If the correct state for each gear range is not
displayed
Refer to Circuit/System Testing.
U If the correct state for each gear range is
displayed
m
.erw
..
6. lgnition ON, engine OFF. Clearthe TCM DTC
information with a scan tool.
7. Perform the Road Test on page 17-167.
8. Verify DTC P2723 or P2724 did not set.
2 If a DTC set
Refer to Circuit/System Testing.
U If a DTC does not set
9. 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.
10. Verify the DTC does not set.
2 If the DTC sets
Refer to Circuit/System Testing.
U If the DTC does not set
11. All OK.
CircuitlSystem Testing
Note: You must performthe CircuitlSystem Verification
first.
1. Verify the transmission line pressures are within
range. Refer to Line Pressure Check on
page 17-166 and Solenoid Valve Pressure (Gen 1)
on page 17—12.
2 If line pressures are not within the specified
ranges
Refer to Fluid Pressure High or Low on
page 17—191.
U If line pressures are within the specified ranges
N Engine Idling,shift selector in the Drive position.
3. Verify the scan tool parameters listed below
display the correct state for each gear range while
commanding the scan tool Shift Transmission Gear
through all forward ranges. Refer to Transmission
Fluid Pressure Switch Logic on page 17-11for the
correct gear range states.
' TFP Switch 1
° TFP Switch 3
2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Automatic Transmission
- TFP Switch 4
- TFP Switch 5
2 If the correct state for each gear range is not
displayed
Replace the Q8 control solenoid valve
assembly.
3.1. lgnition OFF.
3.2. Remove the Control Valve Body. Refer to
Control Valve Body Replacement on
page 17—213.
3.3. Verify the Control Valve Body is not
contaminated with any debris and there is no
damage or sticking valves, refer to Control
Valve Body Cleaning and Inspection (Gen 2)
on page 17-306.
2 lfthere is contamination, damage, or sticking
valves, repair or replace the control valve body
as necessary. ,
2 Ifthere is no contamination, damage, or sticking
valves, replace the Q8 Control Solenoid Valve
Assembly.
U If the correct state for each gear range is
displayed
4. Verify the conditions listed below do not exist.
Carefully inspect each component for that
condition. Repair or replace as necessary.
P2723 - Automatic Transmission Fluid Filter
Assembly
Oil filter or filter seal loose or damaged.
P2723 —Torque Converter (wIFluid Pump) Housing
Assembly
' Fluid pump housing/gear damaged/scored.
- Fluid pump or torque converter overstressed due
to high temperatures.
P2723 —Trans Case and 1-2-3-4 Clutch Backing
Plate Retaining Ring
1-2-3-4 clutch backing plate retaining ring not seated/
oriented, causing clutch pack/piston over travel.
P2723 —Output Sun Gear Assembly
Housing/hub weld cracked/leaking.
2013
—
Sonic
(US/Canada)
Service
Manual
(5377994)
- 6T30/6T40/6T45/6T50 (MH8, MH9) '17-149
P2723 —Lo and Reverse and 1-2-3-4 Clutch Housing
Assembly (51)
1-2-3—4clutch piston (414) cracked/damaged/Ieaking.
P2723 - Channel Plate and Spacer Plate
Oil channels or orifices blocked by debris.
P2723 or P2724 —Control Valve Body Assembly
1-2—3-4clutch regulator valve stuck/sticking —debris,
binding, damaged valve, or scored bore.
P2723 or P2724 —Q8 Control Solenoid Valve
Assembly (314)
' Pressure Control Solenoid Valve 5 Stuck ON/OFF.
- O-ring seals leaking.
' Valve body filter plate assembly cracked, blocked,
or damage gasket seal.
Repair Instructions
Perform the Diagnostic Repair Verification on
page 6-92 after completing the repair.
' Perform the Transmission Adaptive Values Learn
on page 17-163 following all transmission related
repairs.
- Internal Components Removal on page 17—236
- Low and Reverse and 1-2-3-4 Clutch Housing
Disassemble on page 17-271
' Low and Reverse and 1-2-3-4 Clutch Housing
Cleaning and Inspection on page 17-273
- Low and Reverse and 1-2-3-4 Clutch Housing
Assemble (6T30) on page 17—274or Low and
Reverse and 1-2-3-4 Clutch Housing Assemble
:
(6T40/45/50)on page 17-276
. Low and Reverse and 1-2-3-4 Clutch Housing,
and 1-2-3-4 Clutch Plate Installation (6T30) on
page 17—278or Low and Reverse and 1-2-3-4
Clutch Housing, and 1—2—3-4 Clutch Plate
Installation (6T40/45/50)on page 17—279
0 Refer to Control Module References on page 6—3
for control solenoid valve assembly replacement,
programming and setup
17-150 Automatic Transmission - 6T30/6T40l6T45/6T50 (MH8, MH9)

DTC P2723 or P2724 (Gen 2)

Diagnostic Instructions
° Perform the Diagnostic System Check —Vehicle
on page 6-66 prior to using this diagnostic
procedure.
- Review Strategy Based Diagnosis on page 6-58
for an overview of the diagnostic approach.
° Diagnostic Procedure Instructions on page 6-59
provides an overview of each diagnostic category.
DTC Descriptors
DTC P2723: Pressure Control Solenoid Valve 5 Stuck Off
DTC P2724: Pressure Control Solenoid Valve 5 Stuck On

CircuitlSystem Description - TCM commands maximum line pressure.

Pressure control solenoid 5 is part of the control - TCM inhibits Tap Up/Tap Down.
solenoid valve assembly, which has no serviceable - TCM inhibits Manual Up/Manual Down with the
components. The pressure control solenoid 5 regulates gear selector.
transmission fluid pressure to the 1-2-3-4regulator ' Torque management is enabled.
valve which controls pressure to the 1—2-3-4 clutch. The - TCM inhibits powertrain braking.
transmission control module (TCM) calculates gear
ratio based on the speed signals from the input shaft ' TCM inhibits neutral idle.
speed (ISS) sensor and the output shaft speed (088) - TCM inhibits auto grade braking.
sensor. The TCM compares the expected transmission ~ TCM limits the transmission to reverse and 5th
gear ratio to the calculated gear ratio for each range —P2723 only.
commanded gear.
- TCM limits the transmission to reverse and 3rd
Conditions for Running the DTC range —-P2724 only.
- DTC P0101, P0102, P0103, P0106, P0107, Conditions for Clearing the DICIDTC
P0108, P0171, P0172, P0174, P0175, P0201,
P0202, P0203, P0204, P0205, P0206, P0207, P2723 and P2724 are Type A DTCs. ‘
P0208, P0300, P0301, P0302, P0303, P0304, Diagnostic Aids
P0305, P0306, P0307, P0308, P0401, P042E,
P0716, P0717, P0722, P0723, or P182E is Before performing a road test, configure and setup the
not set. scan tool for snapshot mode. This will allow you to
display, monitor,and verify multiple transmission data
° Ignitionvoltage is 9—32V. parameters at one time, after the road test.
- Throttle position signal is valid.
0 Engine speed is 400—7,500RPM for 5 s. Reference Information
- High side driver is enabled. Schematic Reference \-W
2......
4»
0 Transmission fluid temperature is —6.6°C(20°F) or Automatic Transmission Controls Schematics on
greater.
page 17—30
- Transmission output speed is 100 RPM or greater
or the throttle position is 0.5% or greater. Connector End View Reference
' DTC runs continuously when above conditions - Component Connector End Views on page 11—269
are met. - lnline Harness Connector End Views on
Conditions for Setting the DTC page 11-465
Description and Operation
P2723
TCM detects an incorrect on-coming clutch gear ratio, - Transmission General Description on page 17-317
or shift flare when the 1—2—3—4
Clutch is commanded ° Transmission Component and System Description
ON. This condition must occur 3 times. on page 17—318
P2724 o Electronic Component Description on
page 17—319
TCM detects an incorrect off-going clutch gear ratio,
- Drive Range, First Gear (Gen 1) on page 17—337
or shift tie-up when the 1—2—3-4
clutch is commanded
or Drive Range, First Gear (Gen 2) on
OFF. This condition must occur 3 times.
page 17—339
Action Taken When the DTC Sets ~ Drive Range, Second Gear (Gen 1) on
‘ P2723 and P2724 are Type A DTCs. page 17-341 or Drive Range, Second Gear (Gen
2) on page 17—343
- TCM freezes transmission adaptive functions.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
2%-
”ANM
,._NM
.”WM
.,\.-N
 Automatic Transmission
0 Drive Range, Third Gear (Gen 1) on page 17-345
or Drive Range, Third Gear (Gen 2) on
page 17—347
- Drive Range —Fourth Gear (Gen 1) on
page 17-349 or Drive Range —Fourth Gear (Gen
2) on page 17-351
Electrical Information Reference
0 Circuit Testing on page 11-526
- Connector Repairs on page 11-548
- Testing for IntermittentConditions and Poor
Connections on page 11-531
- Wiring Repairs on page 11-537
DTC Type Reference
Powertrain Diagnostic Trouble Code (DTC) Type
Definitions on page 6-68
Scan Tool Reference
Control Module References on page 6-3 for scan tool
information
CircuitlSystem Verification
Warning: Refer to Parking Brake and Drive Wheels
Warning on page 0-5.
Note: Ifother DTCs are set, diagnose those DTCs first.
1. Engine idling, transmission in Park, with parking
brake applied and drive wheels chocked.
2. Verify the transmission fluid level and condition is
correct. Refer to Transmission Fluid Level and
Condition Check on page 17-164.
2 If the transmission fluid level and condition is
not correct
Repair as necessary.
U If the transmission fluid level and condition is
correct
.03 lgnition ON, clear the TCM DTCs with a scan tool.
4. Verify DTC P2723 or P2724 does not set while
performing a road test. Refer to Road Test on
page 17—167.
2 If DTC P2723 or P2724 sets
Refer to CircuitlSystem Testing.
U If DTC P2723 or P2724 does not set
5. Operate the vehicle within the Conditions for
Running the DTC. You may also operate the
22,—...»2w-
.-..w..w...w_~u_+._/-M
MW-..W
......» vehicle within the conditions that you observed
from the Freeze Frame/Failure Records data.
6. Verify the DTC does not set.
2 If the DTC sets
Refer to CircuitlSystem Testing.
U If the DTC does not set
7. All OK.
. 6T30/6T40/6T45/6T50 (MH8, MH9) 17—151
CircuitlSystem Testing
Note: You must perform the Circuit/System Verification
first.
1. Engine idling at the normal operating temperature.
2. Verify the transmission line pressures are within
the specified range. Refer to Line Pressure Check
on page 17-166 and Solenoid Valve Pressure (Gen
1) on page 17-12.
2 If the pressures are not within range
Refer to Fluid Pressure High or Low on
page 17-191.
U If the pressures are within range
3. IgnitionOFF, remove the QB Control Solenoid
Valve Assembly.
4. Verify the pressure changes for all solenoids when
performing the solenoid test. Refer to Control
Solenoid Valve and Transmission Control Module
Assembly Solenoid Performance Test on
page 17—160.
2 If the pressure does not change
Replace the Q8 Control Solenoid Valve
Assembly.
U If the pressure changes
5. Verify the mechanical conditions listed below do
not exist. Repair or replace as necessary.
P2723 or P2724 - Control Valve Body Assembly
1-2-3-4 clutch regulator valve stuck/sticking - debris,
binding, damaged valve, or scored bore.
P2723 —Automatic Transmission Fluid Filter
Assembly
Oil filter or filter seal loose or damaged.
P2723 —Torque Converter (wIFluid Pump) Housing
Assembly
- Fluid pump housing/gear damaged/scored.
' Fluid pump or torque converter overstressed due
to high temperatures.
P2723 —Trans Case and 1-2-3-4 Clutch Backing
Plate Retaining Ring
1-2-3-4 clutch backing plate retaining ring not seated/
oriented, causing clutch pack/piston over travel.
P2723 —Output Sun Gear Assembly
Housing/hub weld cracked/leaking.
P2723 —Lo and Reverse and 1-2-3-4 Clutch Housing
Assembly
clutch piston cracked/damaged/Ieaking.
1—2—3-4
P2723 - Channel Plate and Spacer Plate
Oil channels or orifices blocked by debris.
P2723 or P2724 - QB Control Solenoid Valve
Assembly
- Pressure Control Solenoid Valve 5 Stuck ON/OFF.
o O—ringseals leaking.
' Valve body filter plate assembly cracked, blocked,
or damage gasket seal.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
17-152 Automatic Transmission - 6T30/6T40/6T45/6T50 (MH8, MH9)
Repair Instructions - Control Module References on page 6-3 for
Control Solenoid Valve Assembly replacement,
Perform the Diagnostic Repair Verification on programming and setup.
page 6-92 after completing the repair.
- Perform the Transmission Adaptive Values Learn
on page 17—163followingall transmission repairs.

.W»
A...
.2

..fl.«
.._s

.-m
”N,“
.,...”.
Aw—
.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Automatic Transmission - 6T30/6T40/6T45/6T50 (MH8, MH9) 17-153
DTC P2728-P2730

Diagnostic Instructions
. Perform the Diagnostic System Check —Vehicle
on page 6-66 prior to using this diagnostic
procedure.
- Review Strategy Based Diagnosis on page 6-58
for an overview of the diagnostic approach.
. Diagnostic Procedure Instructions on page 6—59
provides an overview of each diagnostic category.
DTC Descriptors
DTC P2728: Pressure Control Solenoid Valve 5 Performance
DTC P2729: Pressure Control Solenoid Valve 5 Control Circuit Low Voltage
DTC P2730: Pressure Control Solenoid Valve 5 Control Circuit High Voltage

CircuitlSystem Description Action Taken When the DTC Sets

Pressure control solenoid 5 is part of the control P2728
solenoid valve assembly which has no serviceable
components. The normally high pressure control - P2728 is a Type C DTC.
solenoid 5 regulates and directs oil pressure to the - TCM freezes transmission adaptive functions on
1—2—3—4 clutch regulator valve. Increasing pressure the 1—2-3-4clutch.
control solenoid 5 pressure increases pressure to the
P2729
1-2—3—4 clutch. The transmission control module (TCM)
varies the current to the pressure control solenoid 5 by - P2729 is a Type A DTC.
controlling the amount of time the low side driver is ON ° TCM commands the high side driver OFF.
and OFF. Increasing the current to pressure control 0 TCM forces the torque converter clutch OFF.
solenoid 5 decreases pressure control solenoid 5 oil
pressure by opening the solenoid exhaust port. - TCM limits the transmission to 4th gear and
Decreasing the current to pressure control solenoid 5 reverse.
increases pressure control solenoid 5 oil pressure by - TCM commands maximum line pressure.
closing OFF the solenoid exhaust port. Pressure - TCM freezes transmission adaptive functions.
control solenoid 5 power is supplied by the TCM ' TCM inhibits Tap Up/Tap Down.
through a high side driver. The high side driver protects
the circuit and components from excessive current flow. - TCM inhibits manual up, manual down with the
Ifexcessive current flow is detected, the high side shift selector.
driver will turn OFF. When the fault is corrected, the ' TCM inhibits neutral idle.
high side driver will reset. - TCM inhibits powertrain braking.
Conditions for Running the DTC P2730
- Engine speed is 400—7,500RPM for 5 s. - P2730 is a Type A DTC.
- lgnition voltage is 9—32V. - TCM limits the transmission to reverse and
' DTC runs continuously when above conditions 4th gear.
are met. - TCM inhibits powertrain braking.
- TCM inhibits neutral idle.
Conditions for Setting the DTC
° TCM inhibits Tap Up/Tap Down function.
P2728 ' TCM inhibits manual shifting of fonNardgears.
TCM detects an internal electrical performance - TCM commands maximum line pressure.
malfunction of the pressure control solenoid 5 control - TCM freezes transmission adaptive functions.
circuit where the measured clutch pressure control
solenoid 5 current does not equal the commanded Conditions for Clearing the DTC
clutch pressure control solenoid 5 current for 5 s.
- P2728 is a Type C DTC.
P2729 - P2729 and P2730 are Type A DTCs.
TCM detects a short to ground on the clutch pressure
control solenoid 5 control circuit for 1 s. Reference Information
P2730 Schematic Reference
TCM detects an open or short to voltage on the clutch Automatic Transmission Controls Schematics on
pressure control solenoid 5 control circuit for 1 s. page 17—30

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
17-154 Automatic Transmission - 6T30/6T40I6T45/6T50
Connector End View Reference
- Component Connector End Views on page 11-269
- lnline Harness Connector End Views on
page 11-465
Description and Operation
- Transmission General Description on page 17-317
- Transmission Component and System Description
on page 17-318
- Electronic Component Description on
page 17—31 9
Electrical Information Reference
- Circuit Testing on page 11-526
- Connector Repairs on page 11—548
- Testing for IntermittentConditions and Poor
Connections on page 11-531
. Wiring Repairs on page 11-537
DTC Type Reference
Powertrain Diagnostic Troub/eCode (DTC) Type
Definitions on page 6-68
Scan Tool Reference
Control Module References on page 6-3 for scan tool
information
Special Tools
DT-48616-10 Adapter Harness
For equivalent regional tools, refer to Special Tools on
page 17—394.
CircuitlSystem Verification
1. Operate the vehicle in second gear long enough to
ensure at least a 3°C (5°F) rise in TCM
temperature.
2. Operate the vehicle in drive range. Allow the
transmission to shift through all forward gear
ranges.
3. Verify the scan tool parameters listed below do not
display Malfunction:
- Pressure Control Solenoid Valve 5 Performance
Test Status
' Pressure Control Solenoid Valve 5 Control
Circuit Low Voltage Test Status
- Pressure Control Solenoid Valve 5 Control
Circuit High Voltage Test Status
2 If Malfunction is displayed
Refer to CircuitlSystem Testing.
U If Malfunction is not displayed
4. 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.
(MH8, MH9)
5. Verify the DTC does not set.
2 If the DTC sets
Refer to CircuitlSystem Testing.
U If the DTC does not set
6. All OK.
CircuitlSystem Testing
Note: You must perform the CircuitlSystem Verification
first.
1. IgnitionOFF, remove the Q8 Control Solenoid
Valve Assembly.
2. Verify the Q8 Control Solenoid Valve Assembly is
not contaminated with any debris and clean as
necessary. Refer to Control Solenoid Valve and
Transmission Control Module Assembly Inspection
on page 17-158.
2 If contaminated
Repair as necessary.
U If not contaminated
3. Verify the resistance is within the specified range
for each solenoid listed in the Control Solenoid
Valve and Transmission Control Module Assembly
' Inspection on page 17—158.
2 If the resistance is not within range
Replace the Q8 Control Solenoid Valve
Assembly.
<=If the resistance is within range
4. Place the 08 Control Solenoid Valve Assembly on
a clean work surface near the transmission
assembly.
5. Connect the DT-48616-10 adapter harness
between the vehicle harness connector and the QB
Control Solenoid Valve Assembly connector.
lgnition ON.
6. Verify the scan tool parameters listed below do not
display Malfunction:
. Pressure Control Solenoid Valve 5 Performance
Test Status
- Pressure Control Solenoid Valve 5 Control
Circuit Low Voltage Test Status
- Pressure Control Solenoid Valve 5 Control
Circuit High Voltage Test Status
2 If Malfunction is displayed
Replace the Q8 Control Solenoid Valve
Assembly.
U If Malfunction is not displayed
7. All OK.
Repair Instructions
Perform the Diagnostic Repair Verification on
page 6-92 after completing the repair.
- Perform the Transmission Adaptive Values Learn
on page 17—163followingall transmission repairs.
- Control Module References on page 6-3 for
Control Solenoid Valve Assembly replacement,
programming and setup.

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2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Automatic Transmission .. 6T30/6T40/6T45/6T50 (MH8, MH9) 17-155

DTC P2762, P2763, or P2764

Diagnostic Instructions
' Perform the Diagnostic System Check —Vehicle
on page 6—66prior to using this diagnostic
procedure.
- Review Strategy Based Diagnosis on page 6-58
for an overview of the diagnostic approach.
- Diagnostic Procedure Instructions on page 6-59
provides an overview of each diagnostic category.
DTC Descriptors
DTC P2762: Torque Converter Clutch (TCC) Pressure Control Solenoid Valve Performance
DTC P2763: Torque Converter Clutch (TCC) Pressure Control Solenoid Valve Control Circuit High Voltage
DTC P2764: Torque Converter Clutch (TCC) Pressure Control Solenoid Valve Control Circuit Low Voltage

CircuitlSystem Description Conditions for Setting the DTC

The torque converter clutch (TCC) pressure control P2762
solenoid is part of the control solenoid valve assembly
which has no serviceable components. The normally TCM detects an internal electrical performance
low TCC pressure control solenoid regulates oil malfunction on the TCC pressure control solenoid
pressure to the TCC regulator valve and TCC control control circuit where the measured TCC pressure
valve. Increasing TCC pressure control solenoid oil control solenoid current does not equal the
pressure increases oil pressure to the torque converter commanded TCC pressure control solenoid for 5 s.
to apply the clutch. The transmission control P2763
module (TCM) varies the current to the TCC pressure
control solenoid by controlling the amount of time the TCM detects an open/high resistance or short to
low side driver is ON and OFF. Increasing current to the voltage on the TCC pressure control solenoid control
TCC pressure control solenoid increases oil pressure circuit for 5 s.
by closing OFF the solenoid exhaust port. Decreasing P2764
current to the TCC pressure control solenoid decreases
oil pressure by opening up the solenoid exhaust port. TCM detects a short to ground on the TCC pressure
TCC pressure control solenoid power is supplied by control solenoid control circuit for 5 s.
the TCM through a high side driver. The high side Action Taken When the DTC Sets
driver protects the circuit and components from
excessive current flow. Ifexcessive current flow is P2762
detected, the high side driver will turn OFF. When the
P2762 is a Type C DTC.
fault is corrected, the high side driver will reset.
P2763
Conditions for Running the DTC
' P2763 is a Type B DTC.
P2762 - TCM inhibits 6th gear.
- P2762 is not set. - TCM forces TCC OFF.
- Engine speed is 400—7,500RPM for 5 s. - TCM changes to a Hot Mode shift pattern.
- Ignitionvoltage is 9—32V. P2764
- DTC runs continuously when above conditions - P2764 is a Type A DTC.
are met.
- TCM inhibits TCC.
P2763 or P2764 - TCM commands maximum line pressure.
- P0658 or P0659 is not set. - TCM freezes transmission adaptive functions.
- Engine speed is 400—7,500RPM for 5 s. . TCM defaults thetransmission to 4th gear and
- lgnition voltage is 9—32V. reverse.
- High side driver is enabled. 0 TCM inhibits neutral idle.
- DTC runs continuously when above conditions ' TCM inhibits Tap Up/Down function.
are met. - TCM inhibits manual shifting offorward gears.
- TCM forces the high side driver OFF.
. TCM enables torque management.
~ TCM inhibits auto grade braking.
- TCM inhibits powertrain braking.

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
171-156 Automatic Transmission - 6T30/6T40/6T45l6T50 (MH8, MH9)

Conditions for Clearing the DICIDTC 4. Operate the vehicle within the Conditions for
Running the DTC. You may also operate the
o P2762 is a Type C DTC. vehicle within the conditions that you observed
' P2763 is a Type B DTC. from the Freeze Frame/Failure Records data.
° P2764 is a Type A DTC. 5. Verify the DTC does not set.
Reference Information 2 If the DTC sets
Refer to CircuitlSystem Testing.
Schematic Reference
U If the DTC does not set
Automatic Transmission Controls Schematics on
6 All OK.
page 17—30
Connector End View Reference CircuitlSystem Testing
Note: You must perform the CircuitlSystem Verification
~ Component Connector End Views on page 11-269
first.
° lnline Harness Connector End Views on
page 11-465 1. Ignition OFF, remove the QB Control Solenoid
Valve Assembly.
Description and Operation 2. Verify the Q8 Control Solenoid Valve Assembly is
. Transmission General Description on page 17—317 not contaminated with any debris and clean as
° Transmission Component and System Description necessary. Refer to Control Solenoid Valve and
on page 17-318 Transmission Control Module Assembly Inspection
on page 17—158.
0 Electronic Component Description on
page 17-319 2 If contaminated
Repair as necessary.
Electrical Information Reference
U If not contaminated
~ Circuit Testing on page 11—526
3. Verify the resistance is within the specified range
- Connector Repairs on page 11—548 for each solenoid listed in the Control Solenoid
- Testing for IntermittentConditions and Poor Valve and Transmission Contro/Module Assembly
Connections on page 11—531 Inspection on page 17—158.
- Wiring Repairs on page 11—537 2 If the resistance is not within range
DTC Type Reference Replace the QB Control Solenoid Valve
Assembly.
Powertrain Diagnostic Trouble Code (DTC) Type
Definitions on page 6-68 <=If the resistance is within range
4. Place the OS Control Solenoid Valve Assembly on
Scan Tool Reference a clean work surface near the transmission
Control Module References on page 6—3for scan tool assembly.
information 5. Connect the DT—48616-10adapter harness
between the vehicle harness connector and the Q8
Special Tools Control Solenoid Valve Assembly connector.
DT—48616—10 Adapter Harness Ignition ON.
For equivalent regional tools, refer to Special Tools on 6. Verify the scan tool parameters listed below do not
page 17—394. display Malfunction:
- TCC Pressure Control Solenoid Valve
CircuitlSystem Verification Performance Test Status
1. Operate the vehicle in 2nd gear long enough to - TCC Pressure Control Solenoid Valve Control
ensure at least a 3°C (5°F) rise in TCM Circuit Low Voltage Test Status
temperature.
° TCC Pressure Control Solenoid Valve Control
2. Operate the vehicle in drive range and ensure TCC Circuit High Voltage Test Status
is commanded ON for1 min.
2 If Malfunction is displayed
3. Verify the scan tool parameters listed below do not
display Malfunction: Replace the 08 Control Solenoid Valve
Assembly.
- TCC Pressure Control Solenoid Valve
Performance Test Status U If Malfunction is not displayed
- TCC Pressure Control Solenoid Valve Control 7. All OK.
Circuit Low Voltage Test Status
~ TCC Pressure Control Solenoid Valve Control
Circuit High Voltage Test Status
2 If Malfunction is displayed
Refer to CircuitlSystem Testing.
U If Malfunction is not displayed

2013
-Sonic
(US/Canada)
Sen/ice
Manual
(5377994)
 Automatic Transmission =-6T30/6T40/6T45/6T50 (MH8, IVIH9) 17-157

Repair Instructions Noise and Vibration Diagnosis

Perform the Diagnostic Repair Verification on
page 6-92 after completing the repair.
0 Perform the Transmission Adaptive Values Learn
on page 17—163followingall transmission repairs.
- Control Module References on page 6—3for
Control Solenoid Valve Assembly replacement,
programming and setup.
Symptoms - Automatic Transmission
Note: Use the symptom tables only if the following
conditions are met:
- Refer to Diagnostic Starting Point - Vehicle on
' page 6-66.
- There are no DTCs set.
- The control modules can communicate via the
serial data link.
- Review the system operation in order to familiarize
yourself with the system functions. Refer to
Transmission General Description on page 17—31
and Transmission Component and System
Description on page 17-318.
Visual/Physical Inspection
Inspect the easily accessible or visible system
components for obvious damage or conditions which
could cause the symptom.
Intermittent
Faulty electrical connections or wiring may be the
cause of intermittentconditions. Refer to Testing for
IntermittentConditions and Poor Connections on
page 11-531.
Symptom List
Refer to a symptom diagnostic procedure from the
following list in order to diagnose the symptom:
- Fluid Diagnosis
—Transmission Fluid Level and Condition Check
on page 17—164
—Fluid Pressure High or Low on page 17-191 .
—Automatic Transmission Fluid Leaks on
page 17—183 .
—Fluid Leak Diagnosis (Non Hybrid) on
page 17—1 72
—Whine/Grow/Noise on page 17-181
—Noise and Vibration Analysis on page 17—180
—Torque Converter Diagnosis on page 17-169
Range Performance Diagnosis
—No Park on page 17-183
—-No Drive in All Ranges on page 17-184
—No Reverse Gear on page 17—190
Shift Quality Feel Diagnosis
—Harsh Garage Shift on page 17—184
—Harsh or Late First, Second, Third, and Fourth
Shift on page 17-187
—Harsh First and Reverse Shift on page 17—188
~Harsh or Late Second and Sixth Shift on
page 17—188
—Harsh or Late Third, Fifth, and Reverse Shift on
page 17—189
—Harsh Fourth, Fifth, and Sixth Shift on
7 page 17—189
Shift Pattern
—No First and Reverse Gears on page 17—186
- No First, Second, Third, and Fourth Gear on
page 17-186
—No Second and Sixth Gear on page 17—187
—No Fourth, Fifth, and Sixth Gear on page 17-189
—No Third, Fifth, and Reverse Gear on
page 17-188
Torque Converter Diagnosis
- Torque Converter Diagnosis on page 17-169
—No Torque Converter Clutch Apply on
page 17-189
—No Torque Converter Clutch Release on
page 17-190
Symptom Not Found or No Symptom Detected
—Transmission Fluid Level and Condition Check
on page 17-164
—Road Test on page 17-167
—Line Pressure Check on page 17-166

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
17-158 Automatic Transmission - 6T30/6T40I6T45/6T50 (MH8, MH9)

Control Solenoid Valve and Transmission Control Module Assembly

Inspection

1. Verify the conditions listed below do not exist.
Carefully inspect the control solenoid valve
assembly connectors and pins (1, 2, 4, 6) for the
condition. Repair or replace as necessary.
. Damage
- Bentpins
- Debris
- Brokenretainingtab
- Contamination
2. Verify there is no metallic debris inside the
connectors near the terminal pins. Clean as
necessary.
1880311
. Verify the control solenoid valve assembly solenoid
leads (3) do not have contamination or metallic
debris. Clean as necessaIy.
. Verify the resistance between the leads of each
solenoid is within the range in the table below, with
the solenoids at room temperature. Ifthe
resistance of any solenoid is not within range,
replace the Control Valve Body Assembly.
. Inspect the 2 control solenoid valve assembly filter
plate retaining tabs (5) for cracks and ensure
proper tension when filter plate is attached.

Solenoid Resistance
Solenoid Name Illustration Number Expected Resistance Q
PressureControlSolenoid3 7 3.42—4.18
PressureControlSolenoid2 8 342—418
TCC PressureControlSolenoidValve 9 342—418
ShiftSolenoidValve1 10 162—198
PressureControlSolenoid5 11 342—418
PressureControlSolenoid4 12 3.42—4.18
LinePressureControlSolenoidValve 13 342—418

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Automatic Transmission - 6T30/6T40/6T45/6T50 (MH8, MH9) 17-159

Control Solenoid Valve and Transmission Control Module Assembly Input

Shaft Speeleutput Shaft Speed Input Test
Special Tools
' EL 35616 GM—ApprovedTerminal Test Kit
- EL 38522 Variable Signal Generator
For equivalent regional tools, refer to Special Tools on
page 17-394.

The purpose of this test is to provide a simulated input/
output speed sensor (ISSIOSS) signal to the control
solenoid valve assembly ISS/OSS input circuits.
Transmission Input Speed Sensor
1. lgnition OFF, disconnect the ISS wiring harness
connectorX3 (1) from the control solenoid valve
assembly.
2. IgnitionON, test for 11—14volts at terminal B.
2 Ifnot within the specified range, replace the
control solenoid valve assembly. Refer to
Control Solenoid Valve and Transmission
Control Module Assembly Replacement on
page 17—209.
3. IgnitionOFF, using the EL 35616 terminal test kit,
connect the EL 38522 variable signal generator red
lead to the ISS signal circuit terminal A on
the TCM.
4. Connect the black lead from the EL 38522 variable
signal generator to ground.
1880312
Set the EL 38522 variable signal generator to
5 volts, the frequency to 300 Hz, and the percent
duty cycle to 50 or the normal position.
IgnitionON, verify with a scan tool the
Transmission ISS parameter is between 495-
505 RPM.
2 If not within the specified range, replace the
control solenoid valve assembly. Refer to
Control Solenoid Valve and Transmission
Control Module Assembly Replacement on
page 17-209.
Transmission Output Speed Sensor
1. Ignition OFF, disconnect the OSS wiring harness
connector X4 (2)from the control solenoid valve
assembly.
lgnition ON, test for 11—14volts at terminal B.
2 Ifnot within the specified range, replace the
control solenoid valve assembly. Refer to
Control Solenoid Valve and Transmission
Control Module Assembly Replacement on
page 17—209.

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
17-160 Automatic Transmission - 6T30/6T40/6T45I6T50
3. Ignition OFF, using the EL 35616 terminal test kit,
connect the EL 38522 variable signal generator red
lead to the OSS signal circuit terminal A on
the TCM.
4. Connect the black lead from the EL 38522 variable
signal generator to ground.
5. Set the EL 38522 variable signal generator to
5 volts, the frequency to 300 Hz, and the percent
duty cycle to 50 or the normal position.
(MH8, MH9)
6. IgnitionON, verify with a scan tool the
Transmission 088 parameter is between 745-
825 RPM.
2 If not within the specified range, replace the
control solenoid valve assembly. Refer to
Control Solenoid Valve and Transmission
Control Module Assembly Replacement on
page 17-209.

Control Solenoid Valve and Transmission Control Module Assembly Solenoid

Performance Test

Special Tools
DT—48616Solenoid Assembly Test Kit & Adapter
Harness
For equivalent regional tools, refer to Special Tools on
page 17-394.

Note: Air inlet may be installed at either end of the
DT—48616—1 test plate.
The purpose of this procedure is to test the functionality
of the control solenoid valve assembly solenoids for a
gross stuck open or stuck closed condition. DT—48616
test plate is bolted to the control solenoid valve
assembly on the valve body mounting surface.
Pressurized air is passed into the aluminum test block,
through the control solenoid valve assembly solenoid
' 1880313
passage and back to a pressure gauge on the test
block. The pressure gauge indicates open if air
pressure is passed through the solenoid, or closed if
the solenoid is unable to pass air through. A scan tool is
used to command the solenoids ON and OFF. While
watching the pressure gauge, one can determine the
valve functionality.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Automatic Transmission
Note: The scan tool output control will not work on
Gen 1 transmissions, thus the QB Control Solenoid
Valve Assembly performance test cannot be performed
on these models. Gen 2 and later transmissions do not
contain transmission fluid pressure switches. As a
result, Gen 2 and later transmissions cannot have a
valid Transmission Fluid Pressure Switch DTC. Steps 1
and 2 in the test procedure will determine if you are
working with a Gen 1 or Gen 2 and later transmission.
1. IgnitionON, use a scan tool to check for Specific
DTC P0842.
2. Verify that DTC P0842 shows invalid.
2 If parameter does not indicate Invalid
2.1. Do not attemptto complete the performance
test as it will not work on a Gen 1 Q8 Control
Solenoid Valve Assembly.
2.2. Verify the vehicle model year, engine, and
options to make certain the correct diagnostic
is selected.
U lf parameter indicates Invalid
3. Remove the control solenoid valve assembly and
filter plate from the transmission. Refer to Control
Solenoid Valve and Transmission Control Module
Assembly Replacement on page 17-209.
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(US/Canada)
~Sonic
2013 (5377994)
Manual
Service
- 6T30/6T40/6T45/6T50 (MH8, MH9) 17-161
Caution: Refer to Fastener Caution on page 0-8.
Note: Drain the TCM of excess transmission fluid
before attaching to test block and use caution when
attaching air to test block air inlet.
4. Bolt the DT-48616-1 test plate to the filter plate,
and control solenoid valve assembly. Use the bolts
and washers supplied with the tool to attach the
test block. Tighten the bolts to 5 N-m(44 lb in)
using a center out alternating torque sequence.
. Install the pressure gauge to the affected solenoid
air port. Reference the Control Solenoid Valve
Assembly Solenoid Performance Test Plate to
Component Identificationfor test plate port
identification.
Note: Ifair pressure greater than 345 kpa (50 psi) is
applied, an accurate test of the shift solenoid cannot be
performed.
6. Regulate the shop air pressure to 310—345kpa
(45—50psi) and connect the line to the DT-48616—1
test plate air inlet port.
7. Connect the DT—48616-10harness to the vehicle
harness and the control solenoid valve assembly.
17-162 Automatic Transmission - 6T30/6T40/6T45/6T50 (MH8, MH9)

2400940
Note: The TCM limits the time the solenoids are 9. Verify the pressure gauge changes when
commanded on to prevent overheating of the commanding the appropriate solenoid ON and
solenoids. Once the time limit is reached, the TCM OFF with a scan tool. Repeat test as necessary.
prevents the test from being continued for 5 minutes. 2 If the pressure gauge does not change
The ignition must remain ON during the 5 minute
countdown period. Replace the Q8 Control Solenoid Valve
Assembly.
8. lgnition ON.
U If the pressure gauge changes
Note:
10. Solenoids are not grossly stuck.
- Release the air pressure in the gauge between
pressurization tests.
‘ lfthe solenoid valve is stuck, no pressure
change will occur.

Control Solenoid Valve Assembly Solenoid Performance Test Plate to Component

Component
PC Solenoid2, 35R
PC Solenoid3, R1/456
PC Solenoid4, 2—6
PC Solenoid5, 1234
ShiftSolenoid
Identification
Commanded State
Port On Test Plate ON OFF
GEN 2 - C Fullpressuretogauge No pressuretogauge
G FulIpressuretogauge No pressuretogauge
B Fullpressuretogauge No pressuretogauge
GEN 2 - F Fullpressuretogauge N0 pressuretogauge
D Fullpressuretogauge Belowfullpressuretogauge

2013
—
Sonic
(US/Canada)
Service
Manual
(5377994)
 Automatic Transmission - 6T30/6T40/6T45/6T50 (MH8, MHQ) 17=163

Control Solenoid Valve Assembly Solenoid Performance Test Plate to Component

Identification (cont'd)
Commanded State
Component Port On Test Plate 0N OFF
Line PressureControl A Commandto highestsetting, Commandto lowestsetting,
SolenOId fullpressuretogauge belowfull pressuretogauge
TCC PC Solenoid E Fullpressuretogauge No pressureto gauge
Note: Withthekeyonengineoff(KOEO),theTCM willnormallycycle someof thetransmissionsolenoidsOn andOffto
facilitatekeepingtheportsandsolenoidscleanandfreeofdebris.This ditherfunctionis a normalactivityandwillcausethe
valvesto cycleopenandclosedquicklywhentheTCM is poweredup.This can causethepsi gaugetoflickerhighandlowas
thevalvesopenandclose.This maycausesomeair toexittheportswherethepsigaugeis notconnectedas thosesolenoids
cycle on andoff.

Transmission Adaptive Values Learn
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Transmission Adaptive Values Learn is a procedure for
6 speed automatic transmissions in which a series of
tests are run to allow the transmission control
module (TCM) to learn individual clutch characteristics.
Once the clutch data is learned, Transmission Adaptive
Values Learn translates it into the adaptive data cells,
which the TCM uses for clutch control during shifts. The
scan tool provides initiation of the Transmission
Adaptive Values Learn procedure. This procedure is to
be used following transmission repair.
The Transmission Adaptive Values Learn procedure
must be performed when one of the following repairs
have been made to the vehicle. Failure to perform the
procedure after one of the following repairs may result
in poor transmission performance, as well as
transmission DTCs being set:
. Transmission internal service/overhaul
- Valve body repair or replacement
° Control solenoid valve assembly replacement
- TCM software/calibration update
- Any service in response to a shift quality concern
Note: Ensure the following conditions are met before
performing the Transmission Adaptive Values Learn
procedure:
- Drive wheels are blocked
- Parking brake is applied
- Service brake is applied
1 Zero percent throttleand no external engine RPM
control
. Transmission fluid temperature is between values
listed below:
—MY 2011 and prior 70—95°o(158—203°F)
—MY 2012 Gen1 70—95°C(158—203°F)
—MY 2012 Gen 2 60—90°C(140—194°F)
—MY 2013 Gen 1 70—95°c (158—203°F)
—MY 2013 Gen 2 58—70°C(136—158°F)
- Transmission gear selector has been cycled from
Park to Reverse 3 times in order to purge air from
the reverse clutches.
Note: Ifat any time during the procedure, required
conditions are not met, Service Fast Learn Adapts may
abort and the process may need to be started again
from the beginning. Ifthis occurs, the transmission will
be left in a neutral state until the controller is shut down,
key OFF and remove the scan tool and wait for more
than 30 seconds prior to retry procedure. Ifthe
procedure repeatedly fails, a limit that engineering set
is being exceeded and there is possibly a transmission
hardware issue.
1. Use the scan tool to navigate to Transmission
Adaptive Values Learn by selecting the following:
1.1. Module Diagnostics
1.2. Transmission Control Module
1.3. Configurations/Reset Functions
1.4. Transmission Adaptive Values Learn
Note: Ifat any time during the procedure, required
conditions are not met, Transmission Adaptive Values
Learn may abort and the process may need to be
started again from the beginning.
2. Use the scan tool to perform the Transmission
Adaptive Values Learn procedure. As the
procedure is being performed, the scan tool data
display will provide operator instructions. Follow
the scan tool instructions, as required.
3. Once the procedure is complete, shut OFF the
engine and power down the TCM. You will lose
communication to the scan tool.
Note: When the Service Fast Learn Adapts procedure
is completed, the transmission will remain in a neutral
state until the controller shuts down. Ifafter
1—2minutes of sitting, with the key OFF and scan tool
removed, the vehicle remains in a neutral state,
disconnect the battery and wait 5—10minutes and then
hook the battery back up. Reverse and drive should
return.
4. Restart the engine. This will complete the
Transmission Adaptive Values Learn procedure.
Troubleshooting
Ifthe Transmission Adaptive Values Learn will not run
and the above stated conditions have been met, ensure
the following:
Note: The generation of transmission can be
determined by using a scan tool to check for Specific
DTC P0842. IfDTC does not show Invalid, the
transmission is Gen 1. If DTC shows Invalid,
transmission is Gen 2.
- Determine if transmission is Gen 1 or Gen 2.
- Verify vehicle model year.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
—’2—'H-m-wwmww—Mgu
.
17-164 Automatic Transmission - 6T30/6T40/6T45/6T50
- Verify transmission fluid temperature is between
the temperatures listed above for the vehicle
model year and generation of transmission.
- Brakes and brake switch are functioning properly
- No active DTCs
- Closed throttleand engine RPM increases above
1,500 RPM while at entrance of the test
- Park/Neutral position switch is properly adjusted
and functioning
- Line pressure control is able to provide 1,000 kPa
and is within specifications
' Vehicle is not moving or vibrating excessively
. Clutches are properly assembled
Brake Pedal Position Sensor Learn
Brake Pedal Position Sensor Learn is a procedure for
the ECM to determine the position of the brake pedal
position sensor when the brake pedal is in the released
position.
Note: The Brake Pedal Position Sensor Learn
procedure is required when the following service
procedures have been performed:
- An Engine Control Module Replacement
- A BPP Sensor Replacement
- Any repair procedure that effects the brake pedal
position sensor alignment
1. Install asoan tool.
2. Monitor the ECM for DTCs with a scan tool. Ifother
DTCs are set, referto Diagnostic Trouble Code
(DTC) List - Vehicle on page 6-69 for the
applicable DTC that set.
3. Navigate to the scan tool Brake Pedal Position
Sensor Learn command by selecting the following:
3.1. Module Diagnosis
3.2. Engine Control Module
3.3. Configuration/Reset Functions
3.4. Learn Functions
3.5. Brake Pedal Position Sensor Learn
4. Ignition ON, Engine OFF, transmission in Park,
brake pedal in the fully released position, select
Learn.
5. Verify Brake Pedal Position Sensor and Brake
Pedal Position Sensor Learned Home Position are
within .1 Volts.
6. Select Exit.
7. Perform the body control module (BCM) brake
pedal position sensor calibration. Refer to Brake
Pedal Position Sensor Ca/ibration on page 4-185.
Manual Mode or Tap UplDown
Diagnosis
1. Ifany DTCs are set, diagnose those DTCs first.
Refer to Diagnostic Trouble Code (DTC) List -
Vehicle on page 6-69.
2. Ifthe Manual Mode or Tap Up/Down does not
function, refer to the CircuitlSystem Verification for
DTC P0815, P0816, or P0826 on page 17-109.
(MH8, MH9)
Transmission Fluid Level and
Condition Check
This procedure checks both the transmission fluid level,
as well as the condition of the fluid itself.
Caution: Use Dexron Vl transmission fluid only.
Failure to use the proper fluid may result in
transmission internal damage.
Note: Ensure the transmission has enough fluid in it to
safely start the vehicle without damaging the
transmission. With the vehicle off and the transmission
fluid temperature at approximately 20—25°C(68—77°F)
there must be at least enough fluid to drain out of the
fluid level hole. This will ensure that there is enough
fluid in the sump to fill the components once the vehicle
is started.
Non Dipstick Level Checking Procedure
1. Start the engine.
2. 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).
3. Allow the engine to idle 500—800rpm for at least
3 minutes to allow any fluid foaming to dissipate
and the fluid level to stabilize. Release the brake
pedaL
Note: lfthe TFT reading is not at the required
temperature, allow the vehicle to cool, or operate the
vehicle until the appropriate TFT is reached. Ifthe fluid
temperature is below the specified range, performthe
following procedure to raise the fluid temperature to the
specification.
Drive the vehicle in second gear until the fluid
temperature is at the specified temperature.
4. Keep the engine running and observe the
transmission fluid temperature (TFT) using the
Driver InformationCenter or‘a scan tool.
Caution: The transmission fluid level must be checked
when the transmission fluid temperature (TFT) is at 85-
95°C (185—203°F).Ifthe TFT is not at this temperature,
operate the vehicle or allow the fluid to cool as
required. Setting the fluid level with a TFT outside this
temperature will result in either an under or over—filled
transmission. TFT 95°C under—filled,TFT 85°C over-
filled. An under—filledtransmission will cause premature
component wear or damage. An over—filled
transmission will cause fluid to discharge out the vent
tube, fluid foaming, or pump cavitation.
5. Raise the vehicle on a hoist. The vehicle must be
level, with the engine running and the shift lever in
the PARK range.
—
2013 (US/Canada)
Sonic (5377994)
Manual
Service
 Automatic Transmission
"‘W
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2201841
6. While the vehicle is idling, remove the oil level set
plug. Allow any fluid to drain.
Oil Level Plug (1)
- Ifthe fluid is flowing as a steady stream, wait
until the fluid begins to drip.
- Ifno fluid comes out, add fluid until fluid
drips out.
7. Inspect the fluid color. The fluid should be red or
dark brown.
0 Ifthe fluid color is very dark or black and has a
burnt odor, inspect the fluid for excessive metal
particles or other debris. A small amount of
“friction”material Is a “normal” condition. Iflarge
pieces and/or metal particles are noted in the
fluid, flush the oil cooler and cooler lines and
overhaul the transmission. lfthere are no signs
of transmission internal damage noted, replace
the fluid, 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 on page 17—172.
8. Inspect for external leaks. Refer to Fluid Leak
Diagnosis (Non Hybrid) on page 17—172.
9. lfthe fluid was changed, reset the transmission oil
life monitor if applicable.
Dipstick Level Checking Procedure (If equipped)
1. Park the vehicle on a level surface, apply the
parking brake and place the shift lever in PARK (P).
Start the engine.
2. 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).
(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
. 6T30/6T40/6T45/6T50 (MH8, MH9) 17-165
3. Allow the engine to idle 500—800rpm for at least
3 minutes to allow any fluid foaming to dissipate
and the fluid level to stabilize. Release the brake
pedaL
4. Keep the engine running and observe the
transmission fluid temperature (TFT) using the
Driver InformationCenter or a scan tool.
Caution: The transmission fluid level must be checked
when the transmission fluid temperature (TFT) is at 85-
95°C (185—203°F).Ifthe TFT is not at this temperature,
operate the vehicle or allow the fluid to cool as
required. Setting the fluid level with a TFT outside this
temperature will result in either an under or over—filled
transmission. TFT 95°C under-filled, TFT 85°C over-
filled. An under—filledtransmission will cause premature
component wear or damage. An over-filled
transmission will cause fluid to discharge out the vent
tube, fluid foaming, or pump cavitation.
Note:
- Ifthe TFT reading is not at the required
temperature, allow the vehicle to cool,
or operate the vehicle until the appropriate TFT
is reached. Ifthe fluid temperature is below the
specified range, perform the following
procedure to raise the fluid temperature to the
specification.
- Check the transmission fluid level when the
TFT is at between 85—95°C(185—203°F).The
fluid level rises as fluid temperature increases,
so it is importantto ensure the transmission
fluid temperature is at the specified
temperature.
Drive the vehicle in second gear until the fluid
temperature is at the specified temperature.
5. The vehicle must be level, with the engine running
and the shift lever in the PARK range.
6. Remove the dipstick and wipe it with a clean rag or
paper towel.
7. Inspect the fluid color. The fluid should be red or
dark brown.
» - Ifthe fluid color is very dark or black and has a
burnt odor, inspect the fluid for excessive metal
particles or other debris. A small amount of
“friction"material is a “normal” condition. Iflarge
pieces andlor metal particles are noted in the
fluid, flush the oil cooler and cooler lines and
overhaul the transmission. Ifthere are no signs
of transmission internal damage noted, replace
the fluid, 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 on page 17—172.
8. Install the dipstick. Wait three seconds and then
remove it again.
Note: Always check the fluid level at least twice.
Consistent readings are importantto maintaining
proper fluid level. Ifinconsistent readings are noted,
inspect the transmission vent cap to ensure it is clean
and unologged.
'17-166 Automatic Transmission - 6T30/6T40/6T45l6T50
Note: Itis not necessary to get the fluid level all the
way up to the MAX mark. Anywhere within the
crosshatch band is acceptable.
9. Check both sides of the dipstick and read the lower
level.
10. Install and remove the dipstick again to verify the
reading.
Note: Do not add more than one half pint (0.25L) at a
time without rechecking the level. Once the oil is on the
dipstick bullet, it will not take much more fluid to raise
the fluid level into the crosshatch band. Do not overfill.
Also, if the fluid level is low, inspect the transmission for
leaks. Refer to‘Fluid Leak Diagnosis (Non Hybrid) on
page 17-172.
11. Ifthe fluid level is not within the crosshatch band,
and the transmission temperature is at 90°C (194°
F), add or drain fluid as necessary to bring the level
into the crosshatch band. Itthe fluid level is low,
add only enough fluid to bring the level into the
crosshatch band.
12. Ifthe fluid level is in the acceptable range, Install
the dipstick.
13. Ifthe fluid was changed, reset the transmission oil
Iife monitor if applicable.
Fluid Condition Inspection
- Inspect the fluid color.’The fluid should be red in
color. The fluid may also turn brown form normal
use, and does not always indicate contamination.
Note: Fluid that is very dark or black and has a burnt
odor usually indicates contamination or overheating.
- Ifthe fluid color is very dark or black and has a
burnt odor, inspect the fluid for excessive metal
particles or other debris which may indicate
transmission damage. Refer to Road Teston,
page 17—167to verify transmission operation.
Change the transmission fluid if no other
conditions are found.
- Fluid that is cloudy or milky or appears to be
contaminated with water indicates engine coolant
or water contamination. Refer to Engine Coo/ant/
Water in Transmission on page 17—172.
Line Pressure Check
Special Tools
GE—21867—A Oil Pressure Gauge Kit
For equivalent regional tools, refer to Special Tools on
page 17—394.
(MH8, MH9)
1897993
Warning: Keep the brakes applied at all times in
order to prevent unexpected vehicle motion.
Personal injury may result if the vehicle moves
unexpectedly.
1. Install a scan tool.
2. Start the engine.
3. Inspect the transmission for the properfluid level.
Refer to Transmission Fluid Level and Condition
Check on page 17—164.
4. Use the scan tool to inspect for any active or stored
diagnostic trouble codes.
5. Inspect the manual linkage at the transmission for
proper function.
Turn the engine OFF.
Remove the line pressure test hole plug.
Install the GE—21867—A pressure gauge.
8°9°N9°
Access the Scan Tool Transmission Output
Controls for the Line PC Solenoid.
10. Start the engine. '
Note: ‘
- Inorder to achieve accurate line pressure
readings, the following procedure must be
performed at least 3 times in order to gather
uniform pressure readings.
' The scan tool is only able to control the line PC
solenoid in PARK and NEUTRAL with engine
speeds below 1500 RPM. This protects the
clutches from extreme high or low line
pressures.
11. Use the scan tool to increase and decrease the
Line PC Solenoid in increments of approximately
100 KPa (15 psi). The scan tool commands the
increment values automatically.
12. Allow the pressure to stabilize between
increments.
13. Compare the pressure readings on the scan tool to
those indicated on the GE—21867—A pressure
gauge. Refer to Solenoid Valve Pressure (Gen 1)
on page 17-12.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
“/«M
.rh\_
2
._M”
2.22
..__,
’22
 Automatic Transmission - 6T30/6T40/6T45/6T50 (MH8, MH9) 17-167
14. Ifthe pressure readings vary greatly, refer to Fluid - Monitor the scan tool data for any abnormal
Pressure High or Low on page 17—191. readings or data.
15. Turn the engine OFF. ' Inspect for fluid leaks. Refer to Fluid Leak
16. Remove the GE—21867—A pressure gauge. Diagnosis (Non Hybrid) on page 17—172.
Caution: Refer to Fastener Caution on page 0—8. Electrical Function Check
17. Installthe line pressure test hole plug. Tighten the Perform this procedure first in order to ensure the
pressure test hole plug to 12 Nm (106 lb in). electronic transmission components are functioning
properly. Ifthese components are not checked, a
Road Test simple electrical condition could be misdiagnosed.
Note: The Road Test Procedure should be performed 1. Connect the scan tool.
only as part of the Symptom Diagnosis. 2. Ensure the gear selector is in PARK and set the
Perform the road test in conjunction with the symptom parking brake.
diagnosis. Refer to Symptoms - Automatic 3. Start the engine.
Transmission on page 17—157. 4. Verify that the following scan tool data can be
The following test provides a method of evaluating the obtained and is functioning properly.
condition of the automatic transmission. The test is Refer to Control Module References on page 6—3
structured so that most driving conditions would be for typical data values. Data that is questionable
achieved. The test is divided into the following parts: may indicate a concern.
- Electrical Function Check - Engine Speed
- Upshift Control and Torque Converter - Transmission ISS
Clutch (TCC) Apply
- Transmission OSS
- Part Throttle Step-In Downshifts
- Vehicle Speed
~ Manual Downshifts
- IMS
- Coasting Downshifts
- Commanded Gear
- Manual Gear Range Selection
0 Gear Ratio
—REVERSE
~ Line PC Sol. Pressure Cmd.
—Driver Shift Control
. Brake Switch
Note: Complete the test in the sequence given.
Incomplete testing cannot guarantee an accurate ' ECT, Engine Data List
evaluation. - Trans. Fluid Temp.
Before the road test, ensure the following: - TCM Temperature
. The engine is performing properly. 0 CaIc. Throttle Position
- Transmission fluid level is correct. Refer to - IgnitionVoltage
Transmission Fluid Level and Condition Check on - TFP Switch 1
page 17-164. - TFP Switch 3
- Tire pressure is correct. - TFP Switch 4
During the road test: - TFP Switch 5
- Perform the test only when traffic conditions - PC Sol. 2 Pressure Cmd.
permit. - PC Sol. 3 Pressure Cmd.
- Operate the vehicle in a controlled, safe manner. ' PC Sol. 4 Pressure Cmd.
- Observe all traffic regulations. - PC Sol. 5 Pressure Cmd.
- View the scan tool data while conducting this test. - Shift Solenoid 1
Take along qualified help in order to operate the ' Shift Solenoid 2
vehicle safely.
- TCC PC Sol. Duty Cycle
- Observe any unusual sounds or smells.
- TCC Slip Speed
- Ensure the transmission fluid temperature is at
least 90°C (194°F). 5. Check the garage shifts.
After the road test, check the following: 5.1. Apply the brake pedal and ensure the parking
brake is set.
- Inspect for proper transmission fluid level. Refer to
Transmission Fluid Level and Condition Check on 5.2. Move the gear selector through the following
page 17-164. ranges:
- Inspect for any diagnostic trouble codes (DTCs) 5.2.1. PARK to REVERSE
that may have set during the testing. Refer to the 5.2.2. REVERSE to NEUTRAL
applicable DTC. 5.2.3. NEUTRAL to DRIVE
5.2.4. DRIVE to REVERSE
5.2.5. REVERSE to DRIVE

—
2013 (US/Canada)
Sonic (5377994)
Manual
Service
17-168 Automatic Transmission - 6T30/6T40l6T45/6T50
5.3. Pause 2 to 3 seconds in each gear position.
5.4. Verify the gear engagements are immediate
(less than 2 seconds to complete if
transmission fluid temperature is above 20°C
(68°C) and not harsh. Note that these shifts
may be almost imperceptible in some
applications. Using the scan tool to monitor
Transmission ISS achieving 0 rpm can be
used to check delay in these cases.
Note: Harsh engagement may be caused by any of the
following conditions:
° High engine idle speed—Compare engine idle
speed to desired idle speed.
0 Incorrect line pressure—Investigate Line PC
Sol. Pressure Cmd. kPa (psi), also perform Line
Pressure Check on page 17—166.
- A default condition caused by certain DTCs that
result in maximum line pressure to prevent
clutch slippage.
° Incomplete adapting or incorrect adapting-
Repeat maneuver multiple times to see if shift
quality improves. If it does not, refer to the
service procedures for Harsh Garage Shift on
page 17—184.
Note: Delayed engagement may be caused by any of
the following conditions:
- Low Idlespeed—Compare engine idle speed to
desired idle speed.
- Low fluid level
- Incorrect line pressure—lnvestigate Line PC
Sol. Pressure Cmd. kPa (psi), also perform Line
Pressure Check on page 17—166.
’ Cold transmission fluid temperature (TFT)-
Use the scan tool to determine TFT.
- Selector linkage—Inspeot and adjust as
necessary.
- Incomplete adapting or incorrect adapting-
Repeat maneuver multiple times to see if delay
improves. Ifit does not, refer to the service
procedures for Harsh First and Reverse Shift on
page 17—188.
6. Monitor transmission range on the scan tool,
transmission data list.
6.1. Apply the brake pedal and ensure the parking
brake is set.
6.2. Move the gear selector through all ranges.
6.3. Pause 2 to 3 seconds in each range.
6.4. Return gear selector to PARK.
6.5. Verify that all selector positions match the
scan tool display.
7. Check throttleposition input.
7.1. Apply the brake pedal and ensure the parking
brake is set.
7.2. Ensure the gear selector is in PARK.
7.3. Monitor the scan tool Calc. Throttle Position
while increasing and decreasing engine speed
with the throttlepedal. The scan tool Calc.
Throttle Position percentage should increase
and decrease with engine speed.
(MH8, MH9)
Ifany of the above checks do not perform properly,
record the result for reference after completion of the
road test.
Upshift Control and Torque Converter
Clutch (TCC) Apply
The TCM calculates the upshift points based primarily
on 2 inputs: throttle position and vehicle speed. When
the TCM determines that conditions are met for a shift
to occur, the TCM commands the shift by varying
current to the appropriate PC solenoids to control
oncoming and offgoing clutch pressures.
Perform the following steps:
1. Monitor the following scan tool parameters:
. Calc. Throttle Position
- Vehicle Speed
- Engine Speed
° Transmission ISS
- Transmission OSS
. Commanded Gear
° TCC PC Sol. Pressure Cmd.
- TCC Slip Speed
- TFP Switch 1
- TFP Switch 3
- TFP Switch 4
~ TFP Switch 5
~ PC Sol. 2 Pressure Cmd.
- PC Sol. 3 Pressure Cmd.
- PC Sol. 4 Pressure Cmd. W2W
- PC Sol. 5 Pressure Cmd.
o ShiftSolenoid 1 and 2
2. Place the gear selector in the DRIVE position.
3. Accelerate the vehicle using a steady throttle
position between 15 and 20 percent. Hold the
throttle steady.
4. As the transmission upshifts, there should be a
noticeable shift feel or engine speed change within
1 to 2 seconds of the commanded gear change.
The PC solenoid pressure command should Chang
to “YES" for the oncoming clutch and the PC
solenoid pressure command should change to
“NO” for the offgoing clutch.
5. Note any harsh, soft or delayed shifts or slipping.
Note any noise or vibration.
6. The TCC feel may not be noticeable. Inmany
applications the TCC will apply after the 1-2 shift
and TCC events will not be easily detected using
engine speed.
Note: This transmission is equipped with an
electronically controlled capacity clutch (ECCC), which
allows operation of the clutch without fully looking to the
torque converter cover. The clutch maintains a small
amount of slippage, approximately 20 RPM, in 2nd, 3rd,
4th, 5th, and 6th gears, depending on the vehicle
application. ECCC was developed to reduce the
2013
. Sonic
(US/Canada)
Sen/ice
Manual
(5377994)
 Automatic Transmission
possibility of noise, Vibration or chuggle caused by TCC
apply. Full lockup is available at highway speeds on
some applications. ’
7. Monitor TCC PC solenoid pressure command
while driving and check TCC slip speed when the
pressure command indicates that the TCC is
commanded to apply:
When the TCC applies, slip speed should be
controlled to below 100 RPM when the
transmission is not shifting and the throttle is held
steady. Ifthe TCC slip exceeds this value for more
than 6 seconds after the TCC PC Sol. Pressure
Command indicates that the TCC is
commanded on:
- Check for DTCs.
- Refer to Torque Converter Diagnosis on
page 17-169.
- 6T30/6T40/6T45/6T50 (MH8, MH9) 171169
Reverse
Perform the following test using a 10—15percent
throttle position.
1. With the vehicle stopped, move the gear selector
to REVERSE.
2. Slowly accelerate the vehicle.
3. Verify that there is no noticeable slip, noise or
vibration.
Driver Shift Control (DSC)
Refer to the owner's manual for specific instructions on
the type of DSC available Inthis application. Utilize the
DSC to ensure that the transmission responds
appropriately to driver's commands. The TCM wiII
upshift automatically when maximum engine speed is
achieved and will protect from any downshift which may
cause excessive engine RPMs.

Part Throttle Step-ln Downshifts Torque Converter Diagnosis

1. Place the gear selector in the DRIVE position.
2. Accelerate the vehicle at light throttle Torque Converter Stator
(5—15 percent) until 3rd gear is just achieved. The torque converter stator roller clutch can have
3. Quickly increase throttleangle until commanded 2 different malfunctions.
gear indicates that a downshift to 2nd gear is - The stator assembly freewheels in both directions.
commanded. - The stator assembly remains locked up in both
4. Verify that the transmission downshifts within directions.
2 seconds of the throttle movement.
Poor Acceleration at Low Speed -
5. Repeat steps 2 to 4 at higher speed to achieve 4th
gear and then step in to command a 4th gear to 3rd Stator Roller Clutch Freewheels at All
gear downshift. Times
6. Repeat steps 2 to 4 at higher speed to achieve 5th Ifthe stator is freewheeling at all times, the vehicle
gear and then step in to command a 5th to 4th gear tends to have poor acceleration from a standstill and at
downshift. speeds below 48—55km/h (30—34mph). At speeds
7. Repeat steps 2 to 4 at higher speed to achieve 6th above 48—55km/h (30—34mph),the vehicle may act
gear and then step in to command a 6th gear to 5th normally.
gear downshift. For poor acceleration at low speeds, you should first
8. Note any harsh, soft or delayed shifts or slipping. determine that the exhaust system is not blocked, and
Note any noise or vibration. the transmission is in First gear when starting out. Ifthe
engine freely accelerates to high RPM in NEUTRAL,
Manual Downshifts you can assume that the engine and the exhaust
Manual downshift testing is not required since all system are normal. Check for poor performance in
vehicles equipped are also equipped with some form of DRIVE and REVERSE to help determine if the stator is
Driver Shift Control(DSC). The TCM will automatically freewheeling at all times.
override DSC downshifts to protect the transmission
from damage. Poor Acceleration at High Speed -
mew.
.22,
, Stator Roller Clutch is Locked Up at All
Coasting Downshifts
Times
1. Place the gear selector in the DRIVE position.
2. Accelerate the vehicle to 6th gear with the TCC Itthe stator is locked up at all times, performance is
applied. normal when accelerating from a standstill. Engine
RPM and vehicle speed are limited or restricted at
3. Release the throttleand apply the brakes speeds above 48—55km/h (30—34mph). Visual
4. Verify that the downshifts occur as commanded by examination of the converter may reveal a blue color
monitoring gear ratio, which should change after from overheating.
commanded gear changes.
Torque Converter Bearing Noise
Manual Gear Range Selection Note: Do not confuse this noise with pump whine
This application does not utilize manual fonNardgear noise, which is usually noticeable in all gear ranges.
ranges. Pump whine will vary with line pressure.

2013
—
Sonic
(US/Canada)
Service
Manual
(5377994)
'17-’170 Automatic Transmission - 6T30/6T40/6T45/6T50 (MH8, MH9)
Torque converter whine is noticed when the vehicle is Refer to Symptoms - Engine Controls on page 9-511
stopped and the transmission is in DRIVE or (1.6L LDE or 1.8L) in order to avoid misdiagnosis of
REVERSE. This noise will increase as you increase the TCC shudder and the unnecessary disassembly of a
engine RPM. The noise will stop when the vehicle is transmission or the unnecessary replacement of a
moving or when you apply the torque converter clutch, torque converter.
because there is no slip speed across the bearings.
Torque Converter Vibration Test
Perform a stall test to verify that the noise is actually
coming from the torque converter: Note: The Noise and Vibration Analysis on
1. Place yourfoot on the brake. page 17-180 procedure should be performed prior to
performing this test.
2. Put the gear selector in DRIVE.
Caution: You may damage the transmission if you Indexing Torque Converter
depress the accelerator for more than 6 seconds. To determine and correct a torque converter vibration,
3. Depress the accelerator to approximately the following procedure may have to be performed
1,200 RPM for no more than six seconds. several times to achieve the best possible torque
A torque converter noise will increase under this load. converter to flexplate balance.
1. Remove the torque converter bolts.
Torque Converter Clutch
2. Rotate the torque converter one bolt position from
The torque converter clutch (TCC) is applied by fluid the original marked position.
pressure, which is controlled by a TCC pressure
control (PC) solenoid. This solenoid is part of the
control solenoid valve assembly, which is located inside
the automatic transmission assembly. The solenoid is
controlled through a combination of computer
controlled switches and sensors. Electronically
controlled capacity clutch (ECCC) is controlled slip
across the TCC.
Torque Converter Clutch Shudder
The key to diagnosing torque converter clutch (TCC)
shudder is to note when it happens and under what
conditions. TCC shudder should only occur during the
apply, release, or ECCC conditions of the converter
clutch. Shudder should never occur after the TCC is
fully locked (approximately 0 RPM slip).
If Shudder Occurs During TCC Apply,
Release, and ECCC
Ifthe shudder occurs while the TCC is applying, the
problem can be within the transmission or the torque
converter. Something is causing one of the following
conditions to occur: 572368
° The clutch is not engaging completely. Caution: When installing the torque converter to the
- The clutch is not releasing completely. flexplate, make sure to use specified bolts. DO NOT
use longer bolts. Using longer bolts will result in
. The clutch is releasing and applying rapidly and deformation of the torque converter cover and cause
continuously. internal damage.
One of the following conditions may be causing the Caution: Refer to Fastener Caution on page 0-8.
TCC Shudder to occur:
3. Align the torque converter pilot (2) in the engine
- Leaking turbine shaft/TCC seals crankshaft (3). Installthe torque converter to
. A restricted release orifice flexplate bolts, and tighten according to Fastener
- A distorted clutch or converter cover due to long Tightening Specifications (On Vehicle) on
flexplate to converter bolts page 17-7 or Fastener Tightening Specifications
- Defective friction material on the TCC plate (Off Vehicle) on page 17-8.
WW
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4. Lowerthe vehicle.
If Shudder Occurs After TCC has 5. With the engine at idle speed and the transmission
Locked in PARK or NEUTRAL, observe the vibration.
Engine problems may go unnoticed under Iightthrottle Repeat this procedure until the best possible
and load, but they become noticeable after the TCC balance is obtained.
has locked when going up a hill or accelerating. 6. Install the torque converter access cover and
bolts (if equipped) and tighten according to
Fastener Tightening Specifications (On Vehicle) on
page 17—7or Fastener Tightening Specifications
(Off Vehicle) on page 17—8.
2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Automatic Transmission . 6T30/6T40/6T45/6T50 (MH8, MH9) 17—171

' Torque Converter Replacement Guide

Condition Action
- TransmissionFluidOxidized/Discolored Do notreplacethetorqueconverter.
- ClutchFiberMaterial Referto TransmissionFluidLeveland ConditionCheckon
page 17—164.
“. Wm“.«K
TransmissionFluidContaminatedwithMetalParticles Note: Do notreplacethetorqueconverterforclutchsystemor
gearsetcomponentdamage.Fine metallicdebrisor clutch
platematerialthatis suspendedin thefluidwIIInotcause
damageto theinternaltorqueconvertercomponentsnorany
internaltransmissioncomponents.
HarshGearShifts Do notreplacethetorqueconverter.
Referto Symptoms-AutomaticTransmissiononpage 17—157.
Noise—Whine - Referto Symptoms-AutomaticTransmissionon
page 17-157.
' Donotreplacethetorqueconverterif noiseis presentin
Neutral/Park.Referto Symptoms-EngineMechanicalon
page9-944 (1.6LLDE or 1.8L).
Vibration—OutofBalance RefertoTorqueConverterVibrationTestin thisprocedure.
No Drive/Slipsin Drive Do notreplacethetorqueconverteruntilcompletingall engine
andtransmissiondiagnostics.
IdleSurge/RoughIdle Do notreplacethetorqueconverter.
Referto Symptoms- EngineControlsonpage 9-511
(1.6LLDE or 1.8L).
TCC Apply/ReleaseShudder Donotreplacethetorqueconverter.
RefertoTorqueConverterClutchShudderinthisprocedure.
TCC Chuggle Do notreplacethetorqueconverter.
Referto Symptoms-EngineControlsonpage 9-511
(1.6LLDE or 1.8L).
DTC P0741—TCCStuckOFF/HighSlip—Intermittent
Only Do notreplacethetorqueconverter.
Referto DTC P0741orP0742onpage 17-91diagnostictable.
DTC P0741—TCCStuckOFF/HighSlip Do notreplacethetorqueconverter.
Referto DTC P0741orP0742onpage 17-91diagnostictable.
DTC P0742—TCCStuckON Do notreplacethetorqueconverter.
Referto DTC P0741orP0742onpage 17—91 diagnostictable.
..‘flmw
“.__-
....
TransmissionFluidContaminatedwithSIudge/MetalParticles Replacethetorqueconverter.
as a resultof:
- EngineCoolant/Oil
- Pumpdamage
- Drivesprocketsupportdamage
' Turbine/stator
shaftdamage
- Internalconverterdamagewithnodamagefoundin the
transmission
PoorAccelerationabove48 km/h(30mph)—GoodLaunch Do notreplacethetorqueconverteruntilcompletingall engine
andtransmissiondiagnostics.
- RefertoTorqueConverterStatorinthisprocedure.
' Referto Symptoms-EngineControlsonpage 9-511
(1.6LLDE or 1.8L).
Poor Launch—GoodAccelerationabove48 km/h(30mph) Do notreplacethetorqueconverteruntilcompletingall engine
andtransmissiondiagnostics.
- RefertoTorqueConverterStatorinthis procedure.
- Referto Symptoms- EngineControlsonpage9—5 11
(1.6LLDE or 1.8L).
StrippedConverterBoltHoles ° Replacethetorqueconverter.
' Inspectflexplateandreferto LowerEngineNoise,
RegardlessofEngineSpeedonpage9—952(1.6Lor 1.8L).
TorqueConverterPilotDamaged Replacethetorqueconverter.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
'I7-172 Automatic Transmission - 6T30/6T40l6T45/6T50 (MH8, MH9)

Torque Converter Replacement Guide (cont'd)

Condition Action
TorqueConverterHubsurfaceis damaged—scored,raised/ Replacethetorqueconverter.
transferredmetal.
ExternalLeaks in theweldareas—hub,lugor closureweld. Replacethetorqueconverter.
Broken/CrackedFlexplate Replacethetorqueconverter.
TorqueConverterDiscolored/Overheated Replacethetorqueconverter.

Clutch Plate Diagnosis Ifantifreeze or water has entered the transmission,

perform the following:
Composition Plates 1. Disassemble the transmission.
Dry the plates and inspect the plates for the following 2. Replace all of the rubber type seals. The coolant
conditions: will attack the seal material which will cause
- Pitting leakage.
- Flaking 3. Replace the composition-faced clutch plate
assemblies. The facing material may separate from
- Delamination—splitting or separation of bonded the steel center portion.
clutch material
Replace all of the nylon parts —washers.
- Wear
9‘? Replace the torque converter.
- Glazing
6. Thoroughly clean and rebuild the transmission,
- Cracking using new gaskets and oil filter.
- Charring 7. Flush the cooler lines after the transmission cooler
- Chips or metal particles embedded in the lining has been properly repaired or replaced.
Replace a composition plate which shows any of these V 8. Inspect the rubber hose portion of the oil cooler
conditions. lines for damage, if applicable. Referto _
Transmission Fluid Cooler Flushing and Flow Test
Steel Plates on page 17—175.
Wipe the plates dry and check the plates for’heat
discoloration. Ifthe surfaces are smooth, even if color Fluid Leak Diagnosis (Non Hybrid)
smear is indicated, you can reuse the plate. Itthe plate
is discolored with heat spots or if the surface is scuffed, General Method
replace the plate. 1. Verify that the leak is transmission fluid.
Causes of Burned Clutch Plates Caution: Do not clean using brake cleaner or other
The following conditions can result in a burned clutch reactive solvents as these solvents can damage rubber
plate: gaskets, seals and bushings.
'0 Incorrect usage of clutch or apply plates 2. Thoroughly clean the suspected leak area using
a rag.
- Engine coolant or water in the transmission fluid
Note: Do not idle vehicle, this will not actuate
- A cracked clutch piston transmission systems, and do not drive the vehicle on
- Damaged or missing seals the freeway as this will splatter oil inhibiting leak
- Low line pressure diagnosis.
' Valve body conditions 3. Operate the vehicle for 15—20minutes under city
—The valve body face is not flat. driving conditions until normal operating
—Porosity in between channels. temperatures are reached.
Park the vehicle over clean paper or cardboard.
—The valve train retainers are improperly
installed. Shut OFF the engine.
—The checkballs are misplaced. Look forfluid spots on the paper.
—Malfunctioning valves. “93.01:“
. Make the necessary repairs.
- The Teflon®seal rings are worn or damaged. Powder Method
Engine Coolant/Water in Caution: Do not clean using brake cleaner or other
reactive solvents as these solvents can damage rubber
Transmission gaskets, seals and bushings.
Caution: The antifreeze or water will deteriorate the 1. Thoroughly clean the suspected leak area using
seals, gaskets and the glue that bonds the clutch a rag.
material to the pressure plate. Both conditions may 2. Apply an aerosol type leak tracing powder to the
cause damage to the transmission. suspected leak area.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Automatic Transmission =6T30/6T40/6T45/6T50 (MH8, MH9) 17-173
Note: Do not idle vehicle, this will not actuate - Damaged seal bore
transmission systems, and do not drive the vehicle on ~ Damaged or worn seal
the freeway as this will splatter oil Inhibitingleak - Improper installation
diagnosis.
0 Cracks in component
3. Operate the vehicle for 15—20minutes under city - Manual shaft or output shaft surface is scratched,
driving conditions until normal operating nicked, or damaged
temperatures are reached.
- Loose or worn bearing causing excess seal wear
4. Shut OFFthe engine.
5. Inspect the suspected leak area. Possible Points of Fluid Leaks
6. Trace the leak path through the powder in order to Transmission Valve Body Cover
find the source of the leak.
- Incorrectly tightened bolts
7. Make the necessary repairs.
° Improperly installed or damaged gasket/seal
Dye and Black Light Method - Damaged mountingface
A fluid dye and black light kit is available from various ' Incorrect gasket seal
tool manufacturers.
Case Leak
1. Follow the manufacturer's instructions in order to
determine the amount of dye to use. - Damaged input speed sensor seal
2. Operate the vehicle for 24 km (15 mi) or until - Damaged manual shaft seal
normal operating temperatures are reached. - Loose or damaged oil cooler Iines/seals
3. Detect the leak with the black light. - Worn or damaged axle shaft oil seal
4. Make the necessary repairs. - Loose line pressure pipe plug or fluid level
pipe plug
Find the Cause of the Leak - Porous casting
Pinpoint the leak and trace the leak back to the source. - Warped torque converter housing
You must determine the cause of the leak in order to
' Damaged converter housing to case seal
repair the leak properly. For example, if you replace a
gasket, but the sealing flange is bent, the new gasket Leak at the Torque Converter End
will not repair the leak. You must also repair the bent - Converter leak in the weld area
flange. Before you attempt to repair a leak, check for
the foIlowIngconditions, and make repairs as . Converter seal lip out. Check the converter hub for
necessary: damage
- Converter seal bushing moved forward and
Gaskets damaged
- Fluid leveI/pressure is too high - Converter seal garter spring missing from the seal
' Plugged vent or drain—backholes - Porous casting of the torque converter housing
' Improperlytightened fasteners
Leak at the Vent
' Dirty or damaged threads
- Overfllled system
- Warped flanges or sealing surface
- Water or coolant in the fluid; The fluid will appear
- Scratches, burrs, or other damage to the sealing milky
surface
0 Transmission case porous
- Damaged or worn gasket
- Incorrectfluid level indicator causing an overfilled
- Cracking or porosity of the component system
- Impropersealant used, where applicable - Plugged vent
- Incorrect gasket
Seals
' Fluid levellpressure is too high
- Plugged vent or drain—backholes

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
‘I7-174 Automatic Transmission - 6T30/6T40l6T45/6T50 (MH8, IVIH9)

Leak Inspection Points

1891269
Legend
(1) Fill Cap Seal (8) A/Trans InputSpeed Sensor Assembly
(2) Control Valve Body Cover Hole Seal O—RingSeal
(3) Line Pressure Tap Plug (9) Torque Converter Assembly
(4) Converter Housing to Case Joint (10) Front Wheel Drive Shaft Oil Seal Assembly
(5) Control Valve Body Cover Gasket (11) Torque Converter Fluid Seal Assembly
(6) Drive Shaft Oil Seal Assembly (12) Manual Shift Shaft Seal
(7) Oil Level Plug (13) Drain Plug

Case Porosity Repair . Using instructions from the manufacturer,mix a

Some external leaks are caused by case porosity in
non-pressurized areas.
1. Thoroughly clean the area to be repaired with a
cleaning solvent. Air dry the area.
Warning: Epoxy adhesive may cause skin
irritations and eye damage. Read and follow all
information on the container label as provided by
the manufacturer.
sufficient amount of an epoxy to make the repair.
. Apply the epoxy. A clean, dry soldering acid brush
can be used to clean the area and also to apply the
epoxy cement. Make certain that the area to be
repaired is fully covered.
. Allow the epoxy cement to cure for three hours
before assembling the components.
. Repeat the fluid leak diagnosis procedures.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Automatic Transmission - 6T30/6T40/6T45/6T50 (MH8, MH9) 17-175

Transmission Fluid Cooler Flushing Machine Set-up

and Flow Test
GM studies indicate that plugged or restricted
transmission oil coolers and pipes cause insufficient IMPORTANT:
ATqustbe 65Fsupply
machine,
Toostealer
perate
than .
transmission lubrication and elevated operating
temperatures which can lead to premature transmission IDLE
GT3
FLUIDOO @075F
failure. Many repeat repair cases could have been 32
IMPORTANT: mmdmum
qvessel.
uart
prevented by following published procedures for capadty
supply
transmission oil cooler flushing and flow checking. This
procedure includes flow checking and flushing the
auxiliary transmission oil cooler, if equipped.
Note: Use the DT—45096flush and flow test tool or
equivalent to flush and flow test the transmission oil
cooler and the oil cooler pipes after the transaxle is
removed for repairs.
Only GM Goodwrench DEXRON®VI automatic
transmission fluid should be used when doing a repair
on a GM transmission.
Time allowance for performing the cooler flow checking
and flushing procedure has been included in the
appropriate labor time guide operations since the 1987
model year. The service procedure steps for oil cooler 1212328
flushing and flow testing are as follows:
1. Verify that the main power switch (1) is in the OFF
Cooler Flow Check and Flushing Steps position.
Machine Set—up' 2. Place the main function switch (2) in the IDLE
Determine Minimum Flow Rate position.
Back Flush
Forward Flush
Flow Test
Code Recording Procedure
93.01.42wa
7. Clean-up
Special Tools
- DT-45096 Transmission Oil Cooling System Flush
and Flow Test Tool
- DT—45096—50 Transmission Cooler Flush Adapter
- Shop air supply with water/oil filters, regulator and
pressure gauge —— minimum 90 psi
- Eye protection
- Rubbergloves
For equivalent regional tools, refer to Special Tools on
page 17-394.

1212329
3. Connect DT-45096 flush and flow test tool to the
vehicle 12V DC power source by connecting the
red battery clip to the positive, +, battery post on
the vehicle and connect the negative lead to a
known good chassis ground.
4. Turn the main power switch to the ON position.

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
17-176 Automatic Transmission - 6T30/6T40I6T45/6T50 (MH8, MH9)

Determine Minimum Flow Rate

IMPORTANT:
ATF To
must
beogperate
machine,
85Fsuppty
reater
than .
IDLE
FLUID
200T5@U75F
IMFORTANF:
32
capanityqvessel.
uart
suppiymmdmum

IDLE /

FLUID 18 QTS @ O75F

1212332
Caution: Do not overfill the supply vessel. Damage to
the unit may result. To verify the fluid level, view the 1212334
LCD screen display while filling the unit, to ensure the
fluid level does not exceed 30 L (32 qt). 1. From the machine display, identify the temperature
of the automatic transmission fluid that is stored in
5. Fill the supply tank with Dexron®V|through the
the supply vessel of DT—45096flush and flow
fill port.
test tool.
6. Reinstall and tighten the fill cap.

1212335
1212333
2. Determine whether the transmission oil cooler is
7. Connect a shop air supply hose to the quick- steel or aluminum by using a magnet(1) at the
disconnect on the rear panel marked SUPPLYAIR. cooler flange (2) at the radiator.
3. Refer to the table below. Using the temperature
from step1, locate on either the Steel MINIMUM
Flow Rate table or the Aluminum MINIMUM Flow
Rate table the minimum flow rate Ingallons per
minutes (GPM). Record the minimum flow rate in
GPMs and the supply fluid temperature for further
reference.

2013
—
Sonic
(US/Canada)
Service
Manual
(5377994)
 Automatic Transmission - 6T30/6T40/6T45/6T50 (MH8, IVIH9) 17:177
Example Back Flush Procedure
- Fluid temperature:75°F
- Cooler type: Steel
The MINIMUM flow rate for this example would
be 0.8 GPM.
4. Inspect transmission oil cooler lines for damage or
kinks that could cause restricted oil flow. Repair as
needed and refer to the appropriate GM service
manual procedures.

Minimum Flow Rate in Gallons Per

Minute (gpm)
TemperatureRange Steel Aluminum
65—66°F 0.6gpm 0.5gpm
67—70°F 0.7gpm 0.6gpm
71—75°F 0.8gpm 0.7gpm
76—80°F 0.9gpm 0.8gpm
81—84°F 1.0gpm 0.9gpm
85—89°F 1.1gpm 1.0gpm
90—94°F 1.2gpm 1.1gpm 1765256
95—98°F 1.3gpm 1.2gpm 1. Connect the DT—45096—50 cooler flush adapter (1)
99—103°F 1.4gpm 1.3gpm to the vehicle transmission oil cooler supply and
return lines at the transmission.
104—108°F 1.5gpm 1.4gpm
109—112°F 16 gpm 1.5gpm
113—117°F 1.79pm 1.69pm
118—120°F 1.8gpm 1.7gpm

1765259
2. Connect the black supply hose (1) to the return
line, top connector of the transmission, and the
clear waste hose (2) to the feed line, bottom
connector of the transmission, to the vehicle cooler
lines. This is the reverse flow —backflush direction.

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
17-178 Automatic Transmission - 6T30/6T40/6T45/6T50 (MH8, MH9)

Forward Flush

IMPOR‘I’AN'I’:T0
operate
machine.
suppty
ATFmust
begreater
then
65F.
FLUSH
IMPORTANT:
Tnapemie
machine,
supply FLUID
18
OTS
ATF
must
be
greater
than
65F.
IMPORTANT:
32quart
rnaxlrmm
PLEASE capacity
auppty
vessel.
WAIT
IMPORTANT:
32quart
maximum
capacity
suppiy
vessel.

”LE
“-01” Pl.us"

1212339
3. Turn the main function switch to the FLUSH
position. Allow the machine to operate for 1765261
30 seconds. 1. Disconnect the supply and waste hoses from the
vehicle cooler lines. Reverse the supply and waste
hoses to provide a normal flow direction.

IMPORTANT:
Tooperate
machine,
supply
ATFmust
begreater
than65F.
IDLE
FLUID
16QTS@ 075F IMPORTANT:
Tooperate
machine,
supply
IMPORTANT:
32quart
maximum ATFmust
begreater
than
65F.
capacity
supply
vessel.
FLUSH
FLUID
18QTS
IULE' IMPORTANT:
32quart
maximum
FLU”! PLHSH
capacity
suppIy
vessel.
CH” I
101.5
F 1.91” PL ”5;”
EH”

1212341
4. Turn the main function switch to the IDLE position
and allow the supply vessel pressure to dissipate. 1212343
2. Turn the main function switch to the FLUSH
position and allow machine to operate for
30 seconds.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Automatic Transmission - 6T30/6T40/6T45/6T50 (MH8, MH9) 17-179

Flow Test Code Recording Procedure

IMPORTANT:
Tooperate
machine,
supply machine,
Tooperate
IMPORTANT: supply
ATFmust
begreater
than
65F. ATFmust
begreater
than
65F.
FLOW 1.0 GPM FLOW1.0@ 75FCYCLEe
FLUIDI4
QTS@75F A1ODFB2
IMPORTANT:
32quart
maximum IMPORTANT: maximum
32quart
capacity
supply
vessel. vessel.
supply
capacity

IDLE IDLE;
Fl. ”Ill PLUSH FL ”III Fl- ”5”
£11” EU”

1212345 1212346
Note: Ifthe flow rate is less than 0.5 gpm, the LCD 1. Turn the main function switch to the CODE
displays an error message. Refer to the position.
Troubleshooting section ofthe operation manual.
Note:
1. Turn the main function switch to the FLOW position
and allow the oil to flow for 15 seconds. Observe 0 If power Is interrupted prior to the recording of
and note the flow rate; this is the TESTED the seven-charaoter code, the code will be lost
flow rate. and the flow rate test will need to be repeated.
2. Compare the TESTED flow rate to the MINIMUM - The flow test must run for a minimum of
flow rate informationpreviously recorded. 8—10 seconds and be above 0.5 GPM for a
code to be generated.
. Ifthe TESTED flow rate is equal to or greater
than the MINIMUM flow rate recorded, the oil 2. Record TESTED flow rate, temperature, cycle and
cooling system is functioning properly. Perform seven-character flow code information on repair
Code Recording Procedure. order.
- Ifthe TESTED flow rate is less than the
MINIMUM flow rate previously recorded, repeat
the back flush and forward flush procedures.
3. Ifthe TESTED flow rate is less than the MINIMUM
flow rate after the second test, perform Code
Recording Procedure.
3.1. Replace the transmission oil cooler.
3.2. Reconnect supply and waste hoses to the
cooler lines in the normal flow direction.
Perform Flow Test.
3.3. Perform Code Recording Procedure.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
17—180 Automatic Transmission - 6T30/6T40l6T45/6T50 (MH8, MH9)

CIean-up Bushing and Mating Shaft Inspection

Note: Proper bushing and corresponding mating shaft
inspection should be performed before replacing the
bushing, shaft, and in some cases, the component
IMPom’ANT:
ATF Tuu{perute
must
be machine.
65Fsupply
yeatal
Ihan . which houses the bushing. Thoroughly clean and dry
IDLE the bushing and shaft surfaces before inspecting for
FLUID
00GTS@075F damage.
IMPORTANT:
32quad
capacity maximum
suppty
vessel. Any of the following bushing conditions require
replacement of the bushing andlor housing:
IHLE FLUSH
l-'(.0111 - Discoloration due to heat distress
- Misalignment or displacement of bushing as a
result of spinning in housing
1 Medium to heavy scoring that can be easily
detected with fingernail. Light scoring is a normal
condition.
- Debris embedded into the bushing lining material
0 Obvious damage, including excessive and
uneven wear
' Excessive polishing. Minor polishing of the
bushing is an indication of normal wear and does
not require replacement.
1212328 Any of the following conditions require replacement
of
1. Turn the main function switch (2) to the IDLE the bushing's mating shaft:
position and allow the supply vessel pressure to - Discoloration due to heat distress
dissipate. ° Rough surface finish that can be easily detected
2. Turn the main power switch (1) to the OFF position. with finger
Note: A small amount of water may drain from the - Obvious shaft abnormalities, including warping or
bottom of the unit when the air supply is disconnected. uneven surfaces
This is a normal operation of the built—inwater - Obvious damage or cracking
separator.
3. Disconnect the supply and waste hoses and the Noise and Vibration Analysis
12-volt power source from the vehicle. A noise or vibration that is noticeable when the vehicle
is in motion MAY NOT be the result of the transmission.
Ifnoise or vibration is noticeable in PARK and
NEUTRAL with the engine at idle, but is less noticeable
as RPM increases, the vibration may be a result of poor
engine performance.
. Vibration may also be caused by a small amount
of water inside the converter.
o Inspect the engine and transmission mounts for
damage and loose bolts.
- Inspect the transmission case mounting holes for
the following conditions:
—Missing bolts, nuts, and studs
—Stripped threads
—Cracks
~ Inspect the flywheel for the following conditions:
—Missing or loose bolts
—Cracks
—Imbalance
' Inspect the torque converter for the following
1212333 conditions:
4. Disconnect the air supply hose from DT—45096 —Missing or loose bolts or lugs
flush and flow test tool. —Missing or loose balance weights
5. Dispose of the waste ATF in accordance with all —Imbalance caused by heat distortion or fluid
applicable federal, state, and local requirements. contamination

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Automatic Transmission - 6T30/6T40/6T45/6T50 (MH8, MH9) 17-181
o Ifthe noise or vibration is noticeable In PARK and
NEUTRAL with the engine at idle, but is more
noticeable as RPM increases, the vibration may
be an engine imbalance or a transmission
imbalance. Refer to Torque Converter Diagnosis
on page 17—169.

WhineIGrowI Noise
Checks Causes
DifferentialAssembly(232) - Inspectforwornwheelbearingsor axles.
- Inspectforwornor damagedSide Gear ThrustWasher)or PinionGear Thrust
Washer
' InspectforlooseorwornSide Gear Axle Splines
- InspectferdamagedorwornSide Gear
- Inspectforwornor damagedFinal DriveInnerandOuterWashers(584)
v Inspectforloose,damagedor wornFrontDifferentialCarrierThrustBearings,
(228,231,233)
- Inspectforbroken,wornor disengagedFinalDrivePinionPin Retainer(581)
..
.www
,2.2....
MW
,22.“... - InspectfordamagedorwornPinionGears
DriveLinkAssembly(225) - Inspectforworn,looseor damagedlinks
- Inspectforbroken,wornor loose DriveLinkLubeScoop(60)
DriveSprocketAssembly(224) - InspectforimproperDriveSprocket(224)toothsurfacefinish
- InspectforbrokenordamagedDriveSprocket(224)teeth
- Inspectforwornor damagedDriveSprocketThrustBearings(223,556)
- Inspectforwornor damagedOutputCarrierTransferDriveGear HubAssembly
splines(222)
- Inspectforloose,wornor damagedOutputCarrierTransferDriveGear Hub
Assemblybushing
DrivenSprocketAssembly(229) ' Inspectforworn,bindingordamagedDrivenSprocketBearingAssembly(228)
‘HVV—
... - Inspectforwornor damagedDrivenSprocketBall BearingAssembly
o InspectforimproperDrivenSprocket(229)toothsurfacefinish
0 InspectforbrokenordamagedDrivenSprocket(229)teeth
InputCarrierAssembly(570) v Inspectforpitted/spalledPinionGear teeth
- Inspectforwornor damagedPinionGearThrustWashersandBushings
- Inspectforwornor damagedPinionGears,Pins or NeedleBearings
- Inspectforlooseor brokenHUband RingGear
- Inspectforlooseor brokenOutputInternalGear Retainer
- InspectforlooseorwornSun Gear ThrustBearings(569,572)
OutputCarrierAssembly(574) - InspectforwornordamagedPinionGearThrustWashersandBushings
- InspectforwornordamagedPinionGears,Pins or NeedleBearings
- Inspectforloose HubandRing Gear
OutputSun GearAssembly(555) - InspectforwornordamagedOutputSun GearThrustBearing(556)
- Inspectforloose,wornor damagedOutputSun Gear bushing
- InspectforwornordamagedOutputSun Gearteeth
ReactionCarrierAssembly(567) - Inspectforwornor damagedPinionGearThrustWashersandBushings
- Inspectforwornor damagedPinionGears,Pins or NeedleBearings
° InspectforloosehubandRingGear
~Inspectforwornor damagedReactionCarrierThrustBearings(565)
ReactionSun GearAssembly(566) Inspectforloose,wornor damagedReactionSun GearAssemblybushing
FluidPumpAssembly(201) 1. Inspectforproperfluidlevel
2. InspectforleakingPumpFluidOutletSeal Assembly(24)or FilterSeal
3—5—Reverse
ClutchAssembly - InspectforinadequateClutchPlateClearance
' Inspectforstrippedor shearedClutchPlateSplines(508—510)
~InspectforlooseorwornBackingPlateRetainer(511)
- InspectforlooseSpeedSensor ReluctorWheel(501)or Retainer(500)

—
2013 (US/Canada)
Sonic (5377994)
Manual
Service
17-182 Automatic Transmission - 6T30/6T40I6T45/6T50 (MH8, MH9)

WhinelGrowl Noise (cont'd)

Checks Causes
4—5—6
ClutchAssembly - InspectforinadequateClutchPlateClearance .
- Inspectforstrippedor shearedClutchPlateSplines(425—428)
- Inspectforlooseor wornClutchDamRetainer(524)
- Inspectforlooseor worn3—5—Reverse/4—5—6 ClutchHousingBushing
1—2—3—4
ClutchAssembly - InspectforinadequateClutchPlateClearance
- Inspectforstrippedor shearedClutchPlateSplines(557—559)
- Inspectforlooseor wornClutchSpringRetainer(561)
LowandReverseClutch - Inspectforstrippedor shearedLowandReverseClutchAssembly(543)
Assembly(OWC)(543) spHnes
- Inspectfornon-rotatingLowandReverseClutchAssembly(543)
LowandReverseClutch 0 InspectforinadequateClutchPlateClearance
v Inspectforstrippedor shearedClutchPlateSplines(545—547)
- Inspectforlooseor wornClutchSpringRetainer(548)
2—6ClutchAssembly ' InspectforinadequateClutchPlateClearance
' Inspectforstrippedor shearedClutchPlateSplines(540—542)
- Inspectforlooseor wornClutchSpringRetainer(537)
Case Assembly(50) - Inspectforlooseor brokenTransmissionMountBolts
- InspectforlooseTorqueConverterandDifferentialHousingBolts(26)
- Inspectforloose,wornordamageddifferentialbushing
- Inspectforlooseor brokenInputShaftSupportBolts(57)
~Inspectforlooseor brokenFrontDifferentialCarrierBaffleBolts(61)
- Inspectforstrippedor shearedsplines
- Inspectforloose,wornor damagedbushing
TorqueConverterHousingAssembly(208) ' Inspectforlooseor brokenFrontDifferentialRingGear Retainer(206)
' Inspectforloose,wornor damageddifferentialbushing 2.
VM‘.
.M..
....
~Inspectforlooseor brokenPinionGearShaftRetainerPin
- Inspectforlooseor brokenFrontDifferentialCarrierBaffleBolts(204)
' Inspectforlooseor brokenFluidPumpBolts(200)
- InspectforlooseTorqueConverterandDifferentialHousingBolts(26)
- Inspectforloose,wornordamagedbushing
ControlValveBodyCoverAssembly(2) Inspectforloose,missingor brokenValveBodyCoverBolts(1)
TorqueConverter(28) - InspectforimproperalignmentofTorqueConvertertotheCrankshaft
- InspectforballooningoftheTorqueConverter
DifferentialCarrierAssembly(232) ' InspectforwornordamagedDifferentialCarrier(582)
- Inspectforwornor damagedPinionPins (583)
- Inspectforbroken,wornor damagedDifferentialSun Gear Bearing(231)or
DrivenSprocketBearing(228)
. InspectforwornordamagedDifferentialSide Gearteeth,FinalDrivePinion
Gear(586)teethor FinalDriveSun Gear(230)teeth
- Inspectforwornor damagedDifferentialSide GearThrustWashersor Final
DriveInnerandOuterWashers(584) \
' Inspectforwornor damagedFinalDriveRollers(585)
' Inspectforbrokenor damagedDifferentialPinionGear ShaftRetainer

,_.
.2
2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Automatic Transmission - 6T30l6T40/6T45/6T50 (MH8, MH9) '17-183

Automatic Transmission Fluid Leaks

Checks Causes
TorqueConverter(28) Inspectfordamage
Case Assembly(50) - Inspectforcrackedor brokenCase (50)
- Inspectforporosityor damageon thesealingsurfaces
- InspectforlooseOil CoolerLine BoltsordamagedOil CoolerLine Seals
- InspectfordamagedManualShiftShaftSeal(604)
- Inspectfordamagedor wornAxle Seal (65)orAxle Seal Slingeron theaxle
shafts
- InspectforpluggedVentCap (52)
- InspectforloosePressureTestPlug(51),DrainPlug(64)and FluidLevel
Plug(63)
- InspectfordamagedPark PawlActuatorGuideSeal (605)
- InspectfordamagedorwornInputSpeedSensorSeals (19)
TorqueConverterHousingAssembly(208) - InspectfordamagedTorqueConverterHousingAssembly(208)
- Inspectforporosityor damageonthesealingsurfaces
- InspectfordamagedTorqueConverterHousingSeal (23)
- InspectfordamagedorwornTorqueConverterFluidSeal (301)
-LInspectforlooseTorqueConverterandDifferentialHousingBolts(26)
- InspectfordamagedorwornAxle Seal (209)orAxle Seal Slingersontheaxle
shafts
- Inspectforloose,missingor damagedFluidFiIITubePlugAssembly(27)
- InspectfordamagedTorqueConverterandDifferentialHousingSeal (202)
ValveBodyCoverAssembly(2) - InpsectfordamagedorwarpedValveBodyCoverAssembly(2)
0 Inspectfordamagedor ImproperlyinstalledValveBodyCoverGasket(3)
. InspectforlooseValve BodyCoverBolts(1)
° Inspectfordamagedor improperlyinstalledWireConnectorHoleSeal (5)

Shift Indicator Indicates Wrong Gear Selection

,.,.
.v,m_..n—\,_,_.,_ Checks Causes
ShiftCable - Inspectfordamage.
- Verifyproperattachmenttoshifter.
- Verifycableis lockedintoshifterbracket.
- Verifycableis properlyattachedtothetransmission.
- Verifythatthecable is lockedintothetransmissionbracket.
- Verifypropercable adjustment.Referto RangeSelectorLeverCable
Adjustmentonpage 17—196.
ManualShaft ° Verifyshiftleveris properlyattachedtothemanualshaft.
- Verifymanualshaftis nottwistedordamaged.
ManualShiftDetentLeverwithShaft Verifyproperoperation.Referto TransmissionInternalModeSwitchLogicon
PositionSwitchAssembly,IMS page 17-12.

No Park
Checks Causes
DifferentialCarrierAssembly(232) - Inspectfordamagedor brokenFrontDifferentialAssembly(232).
- Inspectfordamagedor brokenFrontDifferentialSide Gearor PinionGear.
- Inspectfordamagedor brokenFrontDifferentialPinionGear Shaft.
- Inspectfordamagedor brokenFrontDifferentialPinionGear ShaftPin.
- Inspectforworn,strippedor shearedFrontDifferentialSide Gear splines.
' Inspectfordamagedor brokenFinalDriveSun,Pinionor RingGear.
- Inpsectforworn,strippedor shearedFinalDriveSun Gearsplines.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
17-184 Automatic Transmission - 6T30/6T40I6T45/6T50 (MH8, MH9)

No Park (cont'd)
Checks Causes
OutputCarrierTransferDriveGear Hub - InspectforbrokenDriveGear Hub(222).
Assembly(222) 1 Inspectforworn,strippedor shearedDriveGear hub(222)splines.
1 Inspectfordisengagedor brokenPark Gear RetainerRing(220).
- Inspectfordamagedor brokenparkGear(221).
1 Inspectfordisengagedor brokenDriveSprocketRetainerRing(227).
DriveLinkAssembly(225) 1 Inspectforbroken,wornor damagedDriveLinkAssembly(225).
1 Inspectforbroken,wornor damagedDriveSprocket(224).
1 Inspectforbroken,wornor damagedDrivenSprocketAssembly(229).
1 Inspectforworn,strippedor shearedDrivenSprocketsplines.
1 InspectforbrokenDriveGear Hub(222).
Case Assembly(50) 1 InspectforbrokenordamagedCase.
1 Inspectforbrokenor bentPark PawlShaft(600).
1 Inspectforbrokenor missingPark PawlActuatorGuidePin (603)or Manual
ShaftPin (611).
1 Inspectforbrokenor missingManualShaftDetentLeverPin (610).
1 Inspectforbrokenor missingManualShiftShaftPin (611).
1 Inspectfordamagedor brokenManualShiftDetentLeverShaft(608).
1 Inspectforloose,damagedor brokenDetentLeverSpringAssembly(17).
1 Inspectforbroken,looseor misalignedPark PawlActuatorGuide(606).
1 Inspectforbinding,bentor brokenPark Pawl(602)orActuatorAssembly(607).

Harsh Garage Shift

Checks Causes
InputCarrierAssembly(570) Inspectforwornor strippedOutputInternalGear Splines.
Low-Reverseand 1—2—3—4 Clutch 1 Inspectfordamagedorfatigued1—2—3—4 ClutchWavePlate(557)and Low
Housing(551) and ReverseClutchWavePlate(547).Referto ClutchPlateDiagnosison
page 17—172.
Inspectforstrippedor shearedsplineson 1—2—3—4 ClutchPlate(546).Referto
ClutchPlateDiagnosisonpage 17—172.
Inspectforimproperlypositionedor pluggedLowReversePiston(550)air
bleed.
1 Inspectforcorrectfluidlevel.
Lowand ReverseClutch Inspectforstrippedor shearedinternalandexternalsplineson LowandReverse
Assembly(OWC)(543) ClutchAssembly(543).

No Drive in All Ranges

Checks Causes
Case Assembly(50) 1 Inspectforcrackedor brokenCase (50).
1 Inspectforstrippedor shearedsplines.
1 InspectforbindingManualShiftDetentLeverAssembly(609).
1 InspectformissingManualShiftShaftPin (611).
1 InspectformissingManualShaftLeverPin (610).
- Inspectforinterferenceor bindingParkPawlActuatorAssembly(607).
1 Inspectforbrokenor disengaged1—2—3—4 ClutchBackingPlateRetainer
Ring(561).
- Inspectforlooseor damagedcase bushing.
1 InspectAlTransFluidPumpSeal Assembly(25)fordamage.
TorqueConverter(28) 1 Inspectforstrippedor shearedsplinesonTurbineShaft.
1 InspectformissingTorqueConverterto Flywheelbolts.
1 Inspectfordamagedor disengagedTorqueConverterHubto Oil Pump
DriveGear.

2013
-Sonic
(US/Canada)
Sen/ice
Manual
(5377994)
222—
”.2.—
N
 Automatic
No Drive
Checks
TorqueConverterHousing(208)
35R/456HousingAssembly(516)
Oil PumpAssembly(201)
Low& ReverseClutchAssembly(543)
InputCarrierAssembly(570)
ReactionCarrierAssembly(567)
ReactionSun GearAssembly(566)
OutputCarrierAssembly(574)
OutputSun GearAssembly(555)
Low—Reverse and1—2—3—4 Clutch
Housing(551)
DriveLinkAssembly(225)
DifferentialCarrierAssembly(232)
2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
Transmission =6T30/6T40/6T45/6T50 (MH8, MH9) 17—185
in All Ranges (cont'd)
Causes
Inspectforstrippedor shearedDifferentialRingGear splines.
Inspectforbrokenor disengagedDifferentialRing Gear Retainer(206).
Inspectforloose,missingor brokenTorqueConverterand DifferentialHousing
bolts(26).
Inspectforloose,missingor brokenFluidPumpbolts(200).
Inspectfordamagedor brokenInputShaftThrustBearingAssembly(538).
Inspectforstrippedor shearedsplineson theInputShaftto the3—5Reverse/
4—5—6 ClutchHousing(516).
Inspectforfluidleaks/improperfluidlevel.
InspectforleakingFluidOutletSeal Assembly(24).
Inspectforlooseor missingOil PumpBolts(200).
Inspectfordamaged,restrictedor improperlyinstalledOil Filter
Assembly(203).
Inspectfordamagedor leakingOil FilterNeckSeal.
Inspectforbrokenor seized FluidPumpDriveGear(315)and FluidPump
DrivenGear(316).
Inspectforstrippedor shearedsplinesto theReactionCarrier(567).
Inspectforstrippedor shearedcastlesplinesto ringgear.
Inspectforimproperlyinstalledcarrierpiniongearpins.
Inspectfordamagedor brokenPinionGears.
Inspectforstrippedor shearedsplineson theInputSun Gear(571).
Inspectfordamagedor brokenOutputInternalGear.
Inspectforbrokenor disengagedOutputInternalGear RetainerRing.
Inspectfordamagedor brokenInputCarrierThrustBearingAssembly(568)
andOutputCarrierThrustBearingAssembly(573).
Inspectfordamagedor brokenInputCarrierThrustBearings(569,572).
Inspectforstrippedor shearedReactionCarrierAssembly(567)splines.
Inspectfordamagedor brokenInputCarrierThrustBearings(568).
Inspectfordamagedor brokenPinionGearteeth.
Inspectfordamagedor brokenReactionInternalGearteeth.
Inpsectfordisengagedor brokenReactionInternalGearretainerring.
Inspectfordamagedor brokenweldat Sun Gear.
InspectforlooseorwornReactionSun GearAssemblybushing.
Inspectforstrippedor shearedsplinesto reactioninternalringgear.
Inspectfordamagedor brokenInputSun GearThrustBearings(572).
Inspectfordamagedor brokenPinionGear teeth.
Inspectfordamagedor brokenInputCarrierThrustBearings(573).
Inspectforbrokenor damagedOutputInternalGear.
o Inspectforstrippedor shearedOutputSun GearAssembly(555)splines.
0 InspectforbrokenOutputSun GearAssembly(555)hubor weld.
Inspectfordisengagedor broken1—2—3—4 ClutchPistonSpringRetainer(554).
Inspectforbroken,wornor damagedDriveLinkAssembly(225).
Inspectforbroken,wornor damagedDriveSprocket(224).
Inspectforbroken,wornor damagedDrivenSprocketAssembly(229).
InspectforbrokenDriveGear Hub(222).
Inspectforstrippedor shearedsplineson DifferentialSide Gear.
Inspectforstrippedor shearedsplinesFinalDriveSun Gear(230).
Inspectforstrippedor shearedsplinesDifferentialCarrierto PTU (AWDonly).
Inspectforstrippedbrokenor disengagedFinalDriveRetainer(581).
Inspectfordamagedor brokenPinionGearteeth.
17-186 Automatic Transmission - 6T30l6T40/6T45/6T50 (MH8, MH9)

No Drive in All Ranges (cont'd)

Checks Causes
1 Inpsectfordamagedor brokenFinalDriveRollers(585).
1 Inspectforbroken,wornor damagedFinalDriveInnerandOuterThrust
Washers(584).
ControlSolenoid(w/BodyandTCM)Valve CheckthattheManualValve(432)is engagedwithManualShiftDetentLever
Assembly Assembly(609).
InspecttheControlSolenoid(w/BodyandTCM)ValveAssembly(7)andverify
thatitis functioningproperly.

No First and Reverse Gears

Checks Causes
Lowand ReverseClutchAssembly(543) 1 Inspectforstrippedor shearedinternalor externalsplineson LowandReverse
ClutchAssembly(543)
1 Inspectforbrokenor disengagedretainerring
Lowand ReverseClutch 1 Inspectforstrippedor shearedsplineson Lowand ReverseClutch
Plates(545—547)
1 Inspectfordamaged,deformedor impropersurfacefinishontheLowand
ReverseClutchPlates(545—547)
1 Inspectforstrippedor shearedsplineson Lowand ReverseClutchBacking
Plate(544)
1 Inspectforworn,damagedor debondingLowand ReverseClutchPiston
Seals (550)
1 InspectforbrokenorfatiguedLowand ReverseClutchPistonReturn
Spring(549)
Low-Reverseand 1—2—3—4
Clutch 1 Inspectfordisengagedor brokenLowand ReverseClutchPistonSpring
Housing(551) Retainer(548)
1 Inspectforbrokenor deformedLowand ReverseClutchPiston(550)
1 Inspectfordamagedor impropersurfacefinishin thepistonbore

No First, Second, Third, and Fourth Gear

Checks
ControlSolenoid(w/BodyandTCM)Valve
Assembly
ControlValveBodyAssembly
1-2—3—4
ClutchAssembly
OutputSun Gear Assembly(555)
ReactionCarrierAssembly(567)
OutputCarrierAssembly(574)
Causes
Check 1234PC Solenoid5 forproperoperation.Referto ControlSolenoidValve
and TransmissionControlModuleAssemblySolenoidPerformanceTeston
page 17-160.
Inspect1-2-3-4ClutchRegulatorValve(417)and 1-2—3-4ClutchBoostValve(414)
fordebrisandstickyness.
1 Inspectfordamaged,strippedor shearedsplineson 1-2-3-4Clutch
Plates(557—559), BackingPlate(560).
1 Inspectfordamagedor broken1—2-3-4 ClutchPiston(552)andPistonSeals
damaged,wornor delaminating.
1 Inspectforbrokenorfatigued1—2-3—4 ClutchPistonReturnSpring(553).
1 Inspectforbrokenor disengaged1-2-3-4ClutchPistonReturnSpring
Retainer(554).
1 Inspectforbrokenorfatigued1-2-3-4ClutchWavedPlate(557).
1 Inspectfordisengagedor broken1-2-3-4ClutchBackingPlateRetainer(561).
1 Inspectforbroken,porousor impropersurfacefinishor pluggedoil passagesof
theLow-Reverse/1-2—3—4 ClutchHousing(551).
1 Inspectforwornor damagedLow-Reverse/1-2-3-4ClutchHousing(551)
splines.
Inspectforstrippedor shearedsplinesontheOutputSun Gearshell.
1 Inspectforstrippedor shearedsplinesontheInputRingGear
1 Inspectfordisengagedor brokenInputRingGear Retainer.
1 Low/ReverseClutchAssembly(OWC)(543)splinesstrippedorsheared.
1 Inspectfordisengagedor brokenReactionRingGear Retainer.

(US/Canada)
—Sonic
2013 (5377994)
Manual
Service
 Automatic Transmission - 6T30/6T40/6T45/6T50 (MH8, MH9) 17-187

No First, Second, Third, and Fourth Gear (cont'd)

Checks Causes
N...
Case Assembly(50) 1. Inspectforleakingor damaged1-2-3-4andLew-ReVerseClutchFluid
Passage Seals (67).
2. Inspectforwornor damagedcase splinesor retainerringgrooves.
InputSun Gear(571) Inspectfordamagedgearteethanddamagedsplines.
TurbineShaft(517) InspectfordamagedsplinestotheInputShaftSun Gear.

No SeCond and Sixth Gear

Checks
2—6ClutchAssembly
ReactionCarrierAssembly(567)
ReactionSun GearAssembly(566)
Case Assembly(50)
OutputCarrierAssembly(574)
ControlValveBodyAssembly
ControlSolenoid(w/BodyandTCM)Valve
Assembly
Causes
1 Inspectfordamagedorworn2—6ClutchPlates(540—542).
1 Inspectfordamaged,worn,broken,impropersurfacefinishor shearedsplines
on theLow-ReverseClutchAssembly(543).
1 Inspectfordamagedor broken2—6ClutchPiston(535)and pistonseals
damaged,wornor delaminating.
1 Inspectforbrokenor binding2—6clutchPistonReturnSpring(536).
1 Inspectforstrippedor shearedsplineson theInputRingGear.
1 Inspectfordisengagedor brokenInputRingGear Retainer.
1 Inspectfordamagedor brokenReactionSun GearAssemblyhub.
1 Inspectfordamagedor brokensungearweld.
1 InspectforlooseorwornReactionSun GearAssemblybushing.
1 Inspectforstrippedor shearedsplines.
1 Inspectforbrokenor diSengaged2—6ClutchPistonReturnSpring
Retainer(537).
1 Inspectfordamaged;worn,or impropersurfacefinishinthepistonbore.
Inspectforreactionringgeardamageor missingringgearsnap ring.
Inspect2-6ClutchRegulatorValve(419)fordebrisandstickyness.
Check 2-6PC Solenoid4 forproperoperation.Referto ControlSolenoidValve
and TransmissionControlModuleAssemblySolenoidPerformanceTeston
page 17-160.

Harsh or Late First, Second, Third, and Fourth Shift

Checks Causes
Low-Reverseand 1—2—3—4
Clutch 1 Inspectfordamagedor broken1—2—3—4 ClutchPiston(552)andpistonseals
Housing(551) damaged,wornor Ieakingi
1 Inspectforfatiguedor binding1—2—3—4ClutchPistonReturnSpring(553).
1 Inspectforimpropersurfacefinishon 1—2—3—4 ClutchPlates(557—559).Refer
to ClutchPlateDiagnosisonpage 17-172.
1 Inspectforbrokenorfatigued1—2—3—4 ClutchWavedPlate(557).
1 Inspectforpluggedor restrictedLow-Reverseand 1—2—3—4 ClutchPiston
Housing(551)air bleed.
Case Assembly(50) 1 Inspectforleakingor loosefittingFluidCheckValve(55).
1 Inspectforleakingor damaged1—2—3—4 and Low—ReverseClutchFluid
Passage Seals (67).

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
17-188 Automatic Transmission - 6T30/6T40l6T45/6T50 (MH8, MH9)

Harsh First and Reverse Shift

Checks Causes
Low-Reverseand 1—2—3—4
Clutch Inspectforpluggedor restrictedLow-Reverse/1—2—3—4
ClutchPiston
Housing(551) Housing(551)air bleed
LowandReverseClutch 1 Inspectforimpropersurfacefinishon LowandReverseClutch
Plates(545—547)
1 InspectforbrokenorfatiguedLowand ReverseClutchApplyPlate(547)
1 Inspectfordamagedor brokenLowand ReverseClutchPiston(550)and
pistonseals damaged,wornor leaking
1 Inspectforfatiguedor bindingLowand ReverseClutchPistonReturn
Spring(549)

No Third, Fifth, and Reverse Gear

Checks Causes
3—5ReverseClutchAssembly 1 Inspectfordamaged,strippedor shearedsplineson 3—5ReverseClutch
Plates(507—509), BackingPlate(510)
1 Inspectforshearedor strippedsplineson 3—5Rev/4—5—6 Housing(516)to
TurbineShaft(517)
1 Inspectfordamage,impropersurfacefinish,porosity,deformedor unbalanced
3—5Rev/4—5—6 Housing(516)
1 Inspectfordamaged,worn,loose or seized hubbushingin the3—5Rev/4—5—6
Housing
1 Inspectforbroken,porousor impropersurfacefinishor pluggedoil passagesof
the3—5Rev/4—5—6 Housing(516)
1 InspectforfailureoftheInputShaftThrustBearing(538)
1 Inspectfordisengagedor broken3—5ReverseClutchBackingPlate(511)
1 Inspectfordamaged,wornor leaking3—5ReverseClutchPiston
Seals (504—506)
1 Inspectfordamagedor broken3—5Rev/4—5—6 ClutchHousing(516)
1 Inspectforwarped,damaged,impropersurfacefinishor debonding3—5
ReverseClutchPiston(502)
1 Inspectforbrokenorfatigued3—5ReverseClutchSpring(503)
1 Inspectfordisengagedor brokenSpeedSensorReluctorRetainer(500)
1 Inspectforworn,brokenor damagedSpeedSensorReluctorWheel(501)
ReactionSun GearAssembly(566) Inspectforstrippedor shearedsplines
ReactionCarrier(567) 1 InspectforbrokenordisengagedInputInternalGear Retainer
1 Inspectforstrippedor shearedsplineson theInputInternalGear
OutputCarrier(574) Inspectforstrippedor shearedsplinesfortheReactionInternalRingGear
4—5—6ClutchAssembly 1 Inspectforpluggedor missing4—5—6PistonDamOil Feedhole
1 Inspectforleaking4—5—6 PistonDam

Harsh or Late Second and Sixth Shift

Checks Causes
2—6ClutchAssembly 1 Inspectforwornor impropersurfacefinishonthe2—6ClutchPlates(540—542)
1 Inspectforfatigued2—6ClutchPistonApply Plate(540)
1 Inspectforplugged,restrictedor incorrectorientationofthe2—6Clutch
Piston(535)air bleed
Case Assembly(50) 1 Inspectfordamagedor broken2—6ClutchPiston(535)andpistonseals
damaged,wornor delaminating
1 Inspectforfatigued2—6ClutchPistonReturnSpring(536)

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Automatic Transmission 1 6T30/6T40/6T45/6T50 (MH8, MH9) 17-189

No Fourth, Fifth, and Sixth Gear

Checks Causes
ClutchAssembly
4—5—6 1 Inspectfordamaged,strippedorshearedsplineson4—5—6 ClutchPlates(526—-
528),BackingPlate(529)
1 Inspectforbrokenor fatiqued4-5—6ClutchWavedPlate(525)
1 Inspectfordamagedor broken4—5—6 ClutchPiston(520)and Piston
Seals (518,519,521)
1 Inspectforbrokenorfatigued4—5—6 PistonReturnSpring‘(522)
1 Inspectf orbrokenor disengaged4—5—6 BackingPlateRetainer(532)
1 Inspectfordamagedor broken4—5—6 ClutchDamPiston(523)andpiston
seals damaged,wornor delaminating
1 Inspectforbrokenor disengaged4—5—6 ClutchDamRetainer(524)
1 Inspectforstrippedor shearedsplineson theReactionCarrierHub(531)
1 Inspectforstrippedor shearedsplineson 3—5Rev/4—5—6 HousingtoTurbine
Shaft(516)
1 Inspectforloose,wornor damaged3—5Rev/4—5—6 HousingBushing
1 Inspectforbroken,porousor impropersurfacefinishor pluggedoil passagesof
the3—5Rev/4—5—6 Housing(516)
TransmissionCase Assembly Inspecttheinputshaftsupport(56)formissingordamagedfluidringseals (58).
ControlValveBodyAssembly Inspectthereverseand4—5-6regulatorvalve(411)andballcheckvalve(404)for
debrisandstickyness.
ControlSolenoid(w/BodyandTCM)Valve Checkthepressurecontrolsolenoid3 (R1/456)forproperoperation.Referto
Assembly ControlSolenoidValveand TransmissionControlModuleAssemblySolenoid
PerformanceTestonpage 17—160.

Harsh or Late Third, Fifth, and. Reverse Shift

Checks Causes
3—5ReverseClutchAssembly 1 Inspectfordamagedsplinesor impropersurfacefinishon 3—5ReverseClutch
Plates(507—509),BackingPlate(510)
1 Inspectfordamaged,wornor leaking3—5ReverseClutchPiston
Seals (504—506)
1 lnspectforwarped3—5Rev/4—5—6 ClutchHousing(516)
1 Inspectforbrokenorfatigued3—5ReverseClutchWavedPlate(507)

Harsh Fourth, Fifth, and Sixth Shift

Checks Causes
4—5—6
ClutchAssembly 1 Inspectforleakingordamaged4—5—6 ClutchPiston(520)and Piston
Seals (518,519,521)
1 Inspectforpluggedor restricted4—5—6 PistonDamairbleed
1 Inspectforleakingor damaged4—5—6 ClutchDam(523)
1 Inspectforpluggedor restrictedDamoil feedholeinthe4—5—6 Piston(520)
1 Inspectforfatiqued4—5—6 ClutchPistonSpring(522)
1 Inspectforleaking4—5—6 ClutchDamSeals (523)
1 Inspectforimpropersurfacefinishon4—5—6 ClutchPlates(525—528)
1 Inspectforfatigued4—5—6 ClutchWavedPlate(525)
1 Inspectfor porous,impropersurfacefinish,seal groovedamageor pluggedor
restrictedoil passagesofthe3—5Rev/4—5—6 Housing(516)

No Torque Converter Clutch Apply

Checks Causes
TorqueConverterAssembly(28) 1 InspectfordamagedTorqueConverterClutchSeal (insideconverter
assembly). ,
1 DiagnoseTorqueConverterAssemblyfor possibleinternaldamage.Referto
TorqueConverterDiagnosisonpage 17—169.

—
2013 (US/Canada)
Sonic (5377994)
Manual
Service
17-190 Automatic Transmission - 6T30/6T40/6T45/6T50 (MH8, MH9)

No Torque Converter CIUtch Apply (cont'd)

Checks
ValveBodyAssembly(433)
Oil PumpAssembly(201)
TorqueConverterHousingAssembly(29)
Causes
Inspectforworn,damagedor stickingTCC RegulatorApply(425)andTCC
RegulatorApplyShuttle(426)Valves.Referto ControlSolenoidValveand
TransmissionControlModuleAssemblyInspectiononpage 17-158.
Inspectforwornor damagedTorqueConverterFluidSeal Assembly(301).
Inspectforleakingor damagedTorqueConverterFluidSeal Assembly(301),
TorqueConverterFluidSeal Assembly(319)andA/TransFluidPump
Assembly(201).

No Torque Converter Clutch Release

Checks
TorqueConverterAssembly(28)
ValveBodyAssembly(433)
Causes
DiagnoseTorqueConverterAssemblyforpossibleinternaldamage.Referto
TorqueConverterDiagnosisonpage 17-169.
Inspectforworn,damagedor stickingTCC RegulatorApply(425)andTCC
RegulatorApplyShuttle(426)Valves.

Harsh Torque Converter Clutch Apply, or lnoperative or No Electronically Controlled

Capacity Clutch Control
Checks Causes
TorqueConverterAssembly(28) 1 Inspectforleakingor damagedTorqueConverterClutchHubSeal.
1 DiagnoseTorqueConverterAssemblyforpossibleinternaldamage.Referto
TorqueConverterDiagnosisonpage 17—169.
ValveBodyAssembly(433) Inspectforworn,damagedor stickingTCC RegulatorApply(425)andTCC
' RegulatorApplyShuttle(426)Valves.

Checks
ControlSolenoid(w/BodyandTCM) Valve
Assembly
ControlValveBodyAssembly
TransmissionCase Assembly
3-5ReverseClutchAssembly
No Reverse Gear
Causes
Checkthe35R PC Solenoid2 forproperoperation.Referto ControlSolenoid
Valveand TransmissionControlModuleAssemblySolenoidPerformanceTeston
page 17-160.
1 Inspectthe3—5-Reverse ClutchRegulatorValve(421)andControlValveBody
Ball CheckValve(404)fordebrisandstickyness.
1 InspecttheClutchSelectValve(428)andtheActuatorFeed LimitValve(430)
fordebrisandstickyness.
InspecttheInputShaftSupport(56)formissingordamagedFluidSeal Rings(58).
1 Inspectfordamaged,strippedor shearedsplineson 3-5ReverseClutch
Plates(507—509), BackingPlate(510).
1 Inspectforstrippedor shearedsplineson 3-5Rev/4-5-6HousingtoTurbine
Shaft(516).
Inspectfordamage,impropersurfacefinish,porosity,deformedor unbalanced
3-5Rev/4-5-6Housing(516).
Inspectfordamaged,worn,looseorseized hubbushingin the3-5Rev/4-5-6
Housing.
1 Inspectforbroken,porousor impropersurfacefinishor pluggedoil passagesof
the3—5Rev/4-5-6Housing(516).
1 InspectforfailureoftheInputShaftThrustBearing(538).
1 Inspectfordisengagedor broken3-5ReverseClutchBackingPlate
Retainer(511).
1 Inspectfordamaged,wornor leaking3-5ReverseClutchPiston
Seals (504—506).
1 Inspectfordamagedor broken3-5Rev/4-5-6ClutchHousing(516).
1 Inspectforwarped,damaged,impropersurfacefinishor debonding3-5
ReverseClutchPiston(502).
1 Inspectforbrokenor fatiqued3-5ReverseClutchSpring(503).

2013
—Sonic
(US/Canada)
Service
Manual
(5377994)
 Automatic Transmission - 6T30/6T40/6T45/6T50 (MH8, MH9) 17—191

No Reverse Gear (cont'd)

Checks Causes
1 Inspectfordisengagedor brokenSpeed SensorReluctorRetainer(500).
1 InspectforbrokenSpeedSensor ReluctorWheel(501).

Fluid Pressure High or Low

Checks Causes
FluidPumpAssembly(201) 1 Inspectforloosefluidpumpbolts(204).
1 Inspectforleakingor damagedfluidpumpoutletseals (24)andoil filterseal.
1 Inspectforimproperlyinstalled,restrictedor damagedoilfilter(203).
1 Inspectforstickinglinepressureblowoffvalve(304).
1 Inspectforworn,stickingor damagedpressureregulatorvalve(309)or
pressureregulatorvalvespring(308).
1 Inspectfordamagedor restrictedoil portsIntheoil pumpbody(303).
1 Inspectformissing,leaking,or damagedauxiliaryfluidinletpump
seal (371)—HybridModels.
TorqueConverterHousing(208) 1 Inspectformissingor restricteddifferentiallubeoil circuitorifice.
1 Inspectformissingfrontdifferentialcarrierbaffle(205).
ControlSolenoidValveAssembly(w/Body 1 Inspectforleakingor damagedfilterplateassemblyseals(8).
andTCM)(7) 1 VerifyVBS operationis notstuckhighor low.
Case Assembly(50) 1 Inspectforproperfluidlevel.
1 Inspectformissinglubeoil circuitorificeorfrontdifferentialcarrierbaffle(62).
1 Inspectforleakingor damagedvalvebodyspacerplateassembly(12).
1 Inspectfordamagedor leakingfluidcheckvalve(55).
1 Inspectforleaking,damagedor brokenfluidlevelcontrolvalve(13).
TorqueConverterAssembly(28) 1 Inspectfordamagedtorqueconverterclutchseal (insideconverterassembly).
1 Inspectfordamagedordisengagedtorqueconverterhubto oil pump
drivegear.

Repair Instructions - 0n Vehicle

Manual Shift Detent Lever with Shaft

Position Switch Assembly
Replacement
Special Tools
1 DT—41229Manual Shaft Pin Installer
1 DT—48550Detent Lever Pin Remover
For equivalent regional tools, refer to Special Tools on
page 17—394.
Removal Procedure
1. Remove the control valve body cover. Refer to
Control Valve Body Cover Replacement on
page 17-210.
2. Remove the control valve body. Refer to Control
Valve Body Replacement on page 17-213. 1998834
3. Remove the manual shaft detent lever hub pin (1)
using DT-48550 remover.
4. Remove the manual shift shaft pin (5) using
diagonal pliers or equivalent tool. Discard the pin.
5. Remove the manual shaft(2).

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
17-192 Automatic Transmission - 6T30l6T40/6T45/6T50
Note:
1 Disconnect the actuator rod (3) from the detent
lever assembly. Do not remove the actuator rod
from the transmission case.
1 Do not pull the park actuator rod end out
beyond the machined oil passage surface in the
case. A no park condition will exist ifthe park
pawl actuator assembly is pulled out of the
transmission too far and the actuator rod
disengages from the park pawl. The
transmission assembly will require disassembly
to reinstall the actuator rod over the park pawl.
6. Remove the manual shaft detent (w/shiftposition
switch) lever assembly (4).
Installation Procedure
1998832
Note: Connect the actuator rod (3) to the detent lever
assembly.
1. Install the manual shaft detent (w/shiftposition
switch) lever assembly (4).
Note: Lubricate the shaft with automatic transmission
fluid to prevent damage to the manual shift shaft seal
during installation.
(MH8, MH9)
2. Install the manual shaft (2).
3. Install the manual shaft detent lever hub pin (1)
using DT-48550 remover.
Specification
Install the Manual Shaft Detent Lever Hub Pin to
height of (b) 7.9 mm (0.38 in).
Caution: Use the manual shaft pin installer to install
the pin at the correct height in order to properly secure
the manual shaft. Ifyou install the pin too deep, the
case bore may crack.
4. Install the NEW manual shift shaft pin (5) using
DT-41229 installer. Use a NEW pin to ensure
proper engagement with the case.
Specification
Inspect pin installed height is within (a) 7.2—8.2mm
(0.28—0.32in).
. Install the control valve body. Refer to Control
Valve Body Replacement on page 17—213.
. Install the control valve body cover. Refer to
Control Valve Body Cover Replacement on
page 17—210.
7. Perform the service fast learn adapt procedure.
2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Automatic Transmission 1 6T30/6T40/6T45/6T50 (MH8, MH9) 17-193

Transmission Control Lever Knob

Replacement
The transmission control lever knob is not serviceable
separately. Refer to Transmission Control Replacement
on page 17—193.

Transmission Control Replacement

2506947

Transmission Control Replacement

Callout Component Name
PreliminaryProcedures .
1. Removethefrontfloorconsole.Referto FrontFloorConsoleReplacementonpage 2-61.
2. Disconnecttherangeselectorlevercable.Referto RangeSelectorLeverCableReplacementonpage 17-195.
3. Disconnectthetransmissioncontrolelectricalconnectors.
TransmissionControlFastener(Qty:4)
Caution: Referto FastenerCautiononpage0-8.
Tighten
9 N1m(80lbin)
2 TransmissionControl

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
17-194 Automatic Transmission - 6T30/6T40/6T45/6T50 (MH8, MH9)

Automatic Transmission Range 4. Remove the transmission range selector

lever nut (1).
Selector Lever Replacement
5. Remove the transmission range selector lever (2).
Removal Procedure Installation Procedure
1. Set the park brake and chock the wheels.

/
/ W

2492632
2. Disconnect the transmission range selector lever
cable terminal (1) from the transmission manual
shift lever pin.
3. Press the locking tabs inward in order to release
the transmission range selector lever cable (2)
from the cable bracket.
2001183
Warning: Hold the transmission range selector
lever while removing or installing the lever
retaining nut. Failure to hold the lever can cause
damage to the transmission internal park system
components which could allow the vehicle to roll
when placed in the park position.
1. Install the transmission range selector lever (2).
Caution: Refer to Fastener Caution on page 0—8.
2. Install the transmission range selector lever nut (1)
and tighten to 30 N1m(22 lb ft).

.,2.
«. 2.

2001183
Warning: Hold the transmission range selector
lever while removing or installing the lever
retaining nut. Failure to hold the lever can cause 2492632
damage to the transmission internal park system
components which could allow the vehicle to roll 3. Install the transmission range selector lever
when placed in the park position. cable (2) to the cable bracket.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
t Automatic Transmission - 6T30/6T40/6T45/6T50 (MH8, MH9) 17—195
4. Connect the transmission range selector lever
cable terminal (1)to the transmission manual shift
lever pin.
5. Check the range selector cable adjustment. Refer
to Range Selector Lever Cable Adjustment on
page 17—196.

Range Selector Lever Cable

Replacement

-”—2.1%;
w, Removal Procedure
1. Set the park brake and chock the wheels.

2492809
5. Disconnect the transmission range selector lever
, W cable terminal (2) from the shift lever pin.
\ 6. Release the transmission range selector lever
cable retainer (1) and remove the transmission
range selector cable from the transmission control
lever base.

A
.-.wvwm"
W
”h. (0,
L/
2492632
2. Disconnect the transmission range selector lever
cable terminal (1) from the transmission manual
shift lever pin.
3. Press the locking tabs inward in orderto release
the transmission range selector lever cable (2)
from the cable bracket.
4. Remove the console. Refer to Front Floor Console
Replacement on page 2-61.

2526950
7. Move the floor carpet in order to gain access to the
gear shift cabte grommet (2).
8. Remove the grommet fasteners (1) and the
transmission range selector lever cable grommet
from the cowl panel.
9. Remove the transmission range selector lever
cable from the vehicle.
Installation Procedure
1. Install the transmission range selector lever cable
to the vehicle.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
17-196 Automatic Transmission - 6T30/6T40/6T45l6T50 (MH8, MH9)

_.,-.
,2.
...

2526950 2492632
2. Install the transmission range selector lever cable 7. lnstalt the transmission range selector lever
grommet to the cowl panel. cable (2)to the cable bracket.
Caution: Refer to Fastener Caution on page 0-8. 8. Connect the transmission range selector lever
3. Install the grommet fasteners (2) and tighten to cable terminal (1) to the transmission manual shift
9N-m(80lbin). ' ‘ lever pin.
. Adjust the automatic transmission range selector
lever cable. Refer to Range Selector Lever Cable
Adjustment on page 17—196.

Range Selector Lever Cable

Adjustment
Note: Adjust the automatic transmission range
selector cable while the transmission and the gear
selector are in the Park position only. Failure to do so
may cause mis—adjustment.
1. Set the park brake and chock the wheels.
2. Verify the transmission range select lever is in the
park position.
3. Verify the transmission manual shift lever is in the
park position.

2492809
4. Install the transmission range selector lever cable
to the transmission control lever base. Insure the
cable retainer (1) is fully secured to the
transmission control lever base.
5. Connect the transmission range selector lever
cable terminal (2) to the shift lever pin.
6. Install the console. Refer to Front Floor Console
Replacement on page 2-61.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Automatic Transmission - 6T30/6T40/6T45/6T50 (MH8, MH9) 17-197

Range Selector Lever Cable Bracket

Replacement

Removal Procedure
1. Set the park brake and chock the wheels.

2527095
. Disconnect the range selector cable (2) from the
range selector cable bracket.
. Disconnect the range selector cable end (1) from
the range selector lever.
. Release the range select cable adjuster clip from
the cable end (1). 2527095
. Connect the range selector cable (2) to the range . Disconnect the range selector cable end (1) from
selector cable bracket. the range selector lever.
. Connect the range selector cable end (1) to the . Disconnect the range selector cable (2)from the
range selector lever. range selector cable bracket.

2492897 2527104
. Depress the adjuster clip (1) locking the adjuster . Remove the transmission range selector cable
clip completely. bracket bolts (1).
10. Ensure the cable tube (2) is secure. . Remove the transmission range selector cable
11. Check the transmission range select lever in all bracket (2).
gear selections for proper operation.

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
17-198 Automatic Transmission - 6T30/6T40/6T45/6T50 (MH8, MH9)

Installation Procedure Transmission Fluid Drain and Fill

Removal Procedure

m_fl
\‘x
~M~
.2..-
..‘MV
FWW
H
,
2527104
1. Install the transmission range selector cable 1998836
bracket (2).
Caution: Refer to Fastener Caution onpage 0—8. 1. Raise and support the vehicle. Refer to Lifting and
Jacking the Vehicle on page 1~31.
2. Install the transmission range selector cable
bracket bolts (1) and tighten to 18 N-m(14 lb ft). 2. Remove the drivetrain and front suspension frame
skidplate. Refer to Drivetrain and Front
Suspension Frame Skid Plate Replacement on
page 3—143.
3. Remove the fluid drain plug (1).
4. Drain transmission fluid into a suitable container.
Caution: Refer to Component Fastener Tightening
Caution on page 0—8.
*‘«,m
..
A_g
5. Installthe fluid drain plug (1) and tighten to 12 N-m
(1061bin).
Installation Procedure
1. Installthe drivetrain and front suspension frame
skidplate. Refer to Drivetrain and Front
Suspension Frame Skid Plate Replacement on
page 3-143.

2527095
3. Connect the range selector cable (2) to the range
selector cable bracket.
4. Connect the range selector cable end (1) to the
range selector lever.
5. Check the range selector cable adjustment. Refer
to Range Selector Lever Cable Adjustment on
page 17—196.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Automatic Transmission - 6T30/6T40/6T45/6T50 (MH8, MH9) 17-199

1998835
2. Lower the vehicle.
3. Remove the fluid fill cap (1).
4. Fill the transmission to the proper level with the
correct fluid. Refer to Transmission Fluid Level and
Condition Check on page 17—164and Fluid
Capacity Specifications (6T30) on page 17—1 0 or
Fluid Capacity Specifications (6T40/45/50)on
page 17-10.
5. Install the fluid fill cap (1).
1443001
Note: Do not remove the upper and lower transaxle oil
cooler fittings from the radiator at the same time other
wise the transaxle oil cooler will fall inside the radiator
end tank.
3. Remove the oil cooler fittingfrom the radiator.
Installation Procedure
1. Inspect the new O-ring seals for cracks, cuts or
damage. Replace if necessary.

Transmission Fluid Cooler Pipe

Connector Replacement - Radiator

Removal Procedure
1. Drain the cooling system. Refer to Cooling System
Draining and Filling on page 9-628
2. Remove the transaxle oil cooler hoses from the oil
cooler fittings on the radiator. Refer to
Transmission Fluid Cooler Hose/Pipe
Quick—ConnectFitting Disconnection and
Connection on page 17-200

1443001
Caution: Refer to Fastener Caution on page 0-8
Note: The correct thread engagement is critical.
Cross—threadedfittings can achieve proper tightness
and still leak.
2. Install the oil cooler fitting to the radiator and
tighten to 20 N-m(15 lb ft).

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
17-200 Automatic Transmission - 6T30/6T40/6T45/6T50 (MH8, MH9)
3. Install the transaxle oil cooler hoses to the oil
cooler fittings on the radiator. Refer to
Transmission Fluid Cooler Hose/Pipe
Quick—ConnectFitting Disconnection and
Connection on page 17—200
4. Fill the cooling system. Refer to Cooling System
Draining and Filling on page 9-628
5. Adjust the transmission fluid level.
6. Inspectforfluid leaks.

Transmission Fluid Cooler Hose/Pipe

Quick-Connect Fitting Disconnection
and Connection

Removal Procedure

2027467
5. Pull the cooler line (1) straight out from the quick
connect fitting (2).
Installation Procedure
Note:
~ 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
connectfittings. 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:
2027466
Note: Perform the following procedure when removing
the retaining rings and cooler lines from the quick
connect fittings located on the radiator andlor 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—tipscrewdriver, pull on one of the
open ends of the retaining ring (1) 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.

2027468
2. Hook one of the open ends of the retaining ring (1)
in one of the slots in the quick connect fitting.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Automatic Transmission - 6T30/6T40/6T45/6T50 (NIH8, MH9) 17:201

‘23 “a

2027469 2027473
1 3. Rotate the retaining ring (1) around the fitting until 5. Ensure that the three retaining ring ears are seen
1 the retaining ring is positioned with all three ears from inside the fitting(1) and that the retaining ring
1 through the three slots on the fitting. moves freely in the fitting slots.

l
l
l
l

l /

l
Q1 \
. (
l O
[J 4
‘ n

2027470
4. Do not install the new retaining ring (1) onto the
fitting by pushing the retaining ring.
2027475
6. Install the cooler line (1) into the quick connect
fitting (2).
7. Insertthe cooler line end into the quick connect
fitting until a click is either heard or felt.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
17-202 Automatic Transmission - 6T30/6T40l6T45/6T50 (MH8, MH9)

Iifigfifi
._ng

2027476 2027484
8. Do not use the plastic cap (1) on the cooler line in 12. Ensure that no gap is present between the plastic
order to install the cooler line into the fitting. cap (1) and the fitting(2).
9. Pull back sharply on the cooler line in order to
ensure that the cooler line is fastened into the
quick connectfitting.

2027485
13. Ensure that the yellow identification band (1) on the
tube is hidden within the quick connect fitting.
2027482
Note: Do not manually depress the retaining clip when
installing the plastic cap.
10. Position (snap) the plastic cap (1) 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.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Automatic Transmission =6T30/6T40/6T45/6T50 (MH8, MH9) 17-203

[It]

2027486 2508163
14. A hidden yellow identification band (1) indicates . Remove the trans fluid cooler nut.
proper joint seating. . Remove and unclip the trans fluid cooler hose from
15. Fill the transmission to the proper level. Refer to the transmission.
Transmission Fluid Level and Condition Check on
page 17-164.

Fluid Cooler Inlet Hose Replacement

Removal Procedure
1. Remove the battery tray. Refer to Battery Tray
Replacement on page 9-721
2. Remove the front bumper fascia opening lower
cover. Refer to Front Bumper Fascia Opening
Lower Cover Replacement on page 3—58
3. Remove the front wheelhouse liner inner front
extension. Refer to Front Wheelhouse Liner Inner
Front Extension Replacement (Left Slde) on
page 3-147 or Front Wheelhouse Liner Inner Front
Extension Replacement (Right Side, LUV) on
page 3-148 or Front Wheelhouse Liner Inner Front
Extension Replacement (Right Side, LWE, LUW)
on page 3-149

2508153
6. Remove the transmission fluid cooler hose from
the radiator. Refer to Transmission Fluid Cooler
Hose/Pipe Quick—ConnectFitting Disconnection
and Connection on page 17-200
. Unclip the transmission fluid cooler hose from fan
shroud and remove from vehicle.
Installation Procedure
1. inspect the seals for cracks, cuts or damage.
Replace if necessary.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
17-204 Automatic Transmission - 6T30/6T40I6T45/6T50 (MH8, MH9)
7. Install the front bumper fascia opening lower cover.
Refer to Front Bumper Fascia Opening Lower
Cover Replacement on page 3-58
8. Install the battery tray. Refer to Battery Tray
Replacement on page 9-721
9. Adjust the transmission fluid level.
10. lnspectforfluid leaks.

Fluid Cooler Outlet Hose

'ZI. Replacement

Removal Procedure
/ 2 .,, 1. Remove the front bumper fascia opening lower
T2 cover. Refer to Front Bumper Fascia Opening
Lower Cover Replacement on page 3-58
2. Remove the front wheelhouse liner inner front
extension. Refer to Front Wheelhouse Liner Inner
Front Extension Replacement (Left Slde) on
page 3-147 or Front Wheelhouse Liner Inner Front
2508153 Extension Replacement (Right Side, LUV) on
page 3-148 or Front Wheelhouse Liner Inner Front
2. Install the transmission fluid cooler hose to the Extension Replacement (Right Slde, LWE, LUW)
radiator. Refer to Transmission Fluid Cooler Hose/ on page 3—149
Pipe Quick-Connect Fitting Disconnection and
Connection on page 17—200
3. Clip the transmission fluid cooler hose to the fan
shroud.

- 2.2
‘ y

\ \ .
, a’é

t2 - J411'
... .22 L
C“‘u

2508165
3. Remove the trans fluid cooler nut.
4. Remove and unclip the trans fluid cooler hose from
2508163 the transmission.
Caution: Refer to Fastener Caution on page 0-8
4. Install and clip the trans fluid cooler hose to the
transmission.
5. Install the trans fluid cooler nut and tighten to
22 N-m(17 lb ft).
6. Install the front wheelhouse liner inner front
extension. Refer to Front Wheelhouse Liner Inner
Front Extension Replacement (Left Slde) on
page 3—147or Front Wheelhouse Liner Inner Front
Extension Replacement (Right Side, LUV) on
page 3—148or Front Wheelhouse Liner Inner Front
Extension Replacement (Right Slde, LWE, LUW)
on page 3-149

2013
-Sonic
(US/Canada)
Sen/ice
Manual
(5377994)
 Automatic Transmission .. 6T30/6T40/6T45/6T50 (MH8, MH9) 17—205

2508158
5. Remove the transmission fluid cooler hose from
the radiator. Referto Transmission Fluid Cooler
Hose/Pipe Quick—ConnectFitting Disconnection
and Connection on page 17-200
6. Unclip the transmission fluid cooler hose from fan
shroud and remove from vehicle.
Installation Procedure
1. Inspect the seals for cracks, cuts or damage.
Replace if necessary.
2508165
Caution: Refer to Fastener Caution on page 0-8
4. Install and clip the trans fluid cooler hose to the
transmission.
5. Install the trans fluid cooler nut and tighten to
22 N-m(17 Ibft).
6. Install the front wheelhouse liner inner front
‘ extension. Refer to Front Wheelhouse Liner Inner
Front Extension Replacement (Left Slde) on
page 3-147 or Front Wheelhouse Liner Inner Front
Extension Replacement (Right Side, LUV) on
page 3-148 or Front Wheelhouse Liner Inner Front
Extension Replacement (Right Side, LWE, LUW)
on page 3-149
lnstall the front bumper faScia opening lower cover.
Refer to Front Bumper Fascia Opening Lower
Cover Replacement on page 3-58
Adjust the transmission fluid level.
Inspect for fluid leaks.

2508158
2. Install the transmission fluid cooler hose to the
radiator. Refer to Transmission Fluid Cooler Hose/
Pipe Quick—ConnectFitting Disconnection and
Connection on page 17—200
3. Clip the transmission fluid cooler hose to the fan
shroud.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
’17-206 Automatic Transmission - 6T30/6T40/6T45/6T50 (MH8, iVlH9)
Automatic Transmission Fluid Pressure Test Hole Plug Replacement

1998837
Automatic Transmission Fluid Pressure Test Hole PIugReplacement
Callout Component Name
FluidPressureTestPlug , :
Caution: Referto ComponentFastenerTighteningCautiononpage0-8.
Tighten
12N-m(106lb in)

2013
-Sonic
(US/Canada)
Sen/ice
Manual
(5377994)
 Automatic Transmission - 5T30/6T40/6T45/6T50 (MH8, MH9) 17:207
Front Wheel Drive Shaft Seal Replacement - Left Side

-_
W.M
V

1998842
Front Wheel Drive Shaft Seal Replacement - Left Side
Callout Component Name
PreliminaryProcedures
1. Raise andsupportthevehicle.Referto LiftingandJackingthe Vehicleonpage 1-31.
2. Removetheleftwheeldriveshaft.Referto FrontWheelDriveShaftReplacementonpage 7—5.
LeftFrontWheelDriveShaftOil Seal
Procedure
1. Forseal removaluse GE—6125-1B slide hammerwithDT—23129 universalseal remover.
2. Forseal installationuse GE-8092driverhandlewithDT-47790seal installer.
1 Special Tools
' DT-23129UniversalSeal Remover
- DT-47790Seal Installer
- GE—6125—1B Slide Hammer
- GE—8092 DriverHandle
For equivalentregionaltools,referto Special Toolsonpage 17-394.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
17-208 Automatic Transmission - 6T30/6T40I6T45/6T50 (MH8, MH9)

Front Wheel Drive Shaft Seal Replacement - Right Side

*(R‘ -

0M5“
, ‘m

1998843
Front Wheel Drive Shaft Seal Replacement - Right Side
Callout I Component Name
Preliminary Procedures
1. Raise andsupportthevehicle.Referto LiftingandJackingtheVehicleonpage 1-31.
2. Removetherightwheeldriveshaft.Referto FrontWheelDriveShaftReplacementonpage 7—5.
RightFrontWheelDriveShaftOil Seal
Procedure
1. Forseal removaluse GE—6125-1B slide hammerwithDT—23129universalseal remover.
2. Forseal installationuse GE-8092driverhandlewithDT-47790seal installer.
1 Special Tools
- DT—23129 UniversalSeal Remover
- DT-47790Seal Installer
' GE-6125-1BSlide Hammer
' GE-8092DriverHandle
For equivalentregionaltools,referto Special Toolsonpage 17—394.

Manual Shift Shaft and Seal Removal Procedure

Replacement 1. Remove the battery tray. Refer to Battery Tray
. Replacement on page 9—721.
SpeCIal TOOIS _ 2. Remove the manual shaft and position switch
- DT-45201 Cooler LIne Seal Remover assembly. Refer to Manual Shift DetentLever with
- DT—49101Seat Installer Shaft Position Switch Assembly Replacement on
For equivalent regional tools, refer to Special Tools on page 17'191'
page 17—394.

2013
—
Sonic
(US/Canada)
Service
Manual
(5377994)
 Automatic Transmission , 6T30/6T40/6T45/6T50 (MH8, MH9) 17=209

Control Solenoid Valve and

Transmission Control Module
Assembly Replacement

Removal Procedure
1. Remove the transmission control valve body cover.
Refer to Control Valve Body Cover Replacement
on page 17—210.

2079285
3. Remove the manual shaft seal (1) using DT—45201
remover.
Installation Procedure
1. Install the manual shaft and position switch
assembly. Refer to Manual Shift Detent Lever with
Shaft Position Switch Assembly Replacement on
page 17-191.
1998829
2. Disconnect the output speed sensor electrical
connector (2).
3. Disconnect the shift position switch electrical
connector (3).
4. Disconnect the input speed sensor electrical
connector (1).

2079287
2. Install the manual shaft seal (1) using DT—49101
seal installer.
3. Install the battery tray. Refer to Battery Tray
Replacement on page 9-721.

1998830
5. Remove the 3 control solenoid valve assembly
bolts (1) M5 x 40.5.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
17-210 Automatic Transmission —6T30/6T40/6T45/6T50
6. Remove the 12 control solenoid valve assembly
bolts (2) M6 x 97.
7. Remove the control solenoid valve assembly with
transmission control module (3).
Caution: Use care when removing or installing the
filter plate assembly. A broken or missing retaining tab
may not adequately secure the filter plate to the control
solenoid valve assembly, resulting in possible damage
or contamination.
8. Remove the control solenoid valve assembly filter
plate (4). Discard the filter plate. Itis not reusable.
9. Inspect the pressure switch seals for damage or
contamination. Replace the control solenoid valve
assembly as necessary.
10. Inspect the channel plate bolt pass through holes
for damage or burnelling. Any damage could cause
leaking. Replace as necessary.
Installation Procedure
1998830
Caution: Use care when removing or installing the
filter plate assembly. A broken or missing retaining tab
may not adequately secure the filter plate to the control
solenoid valve assembly, resulting in possible damage
or contamination.
1. install a NEW control solenoid valve assembly filter
plate (4) to prevent fluid leaks past the fluid seals.
2. Install the control solenoid valve assembly with
transmission control module (3).
3. Hand start the control valve body bolts (1, 2).
(MH8, MH9)
(D2 .2
2000158
Caution: Refer to Fastener Caution on page 0—8.
4. Secure the 12 control soienoid valve assembly
bolts (2) M6 x 97 and tighten in sequence to 12 N-m
(106 lb in).
5. Secure the 3 control valve body bolts (1)M5 x 40.5
and tighten in sequence to 7 N-m(62 lb in).
6. Connect the input speed sensor electrical
connector (1).
7. Connect the output speed sensor electrical
connector (2).
8. Install the transmission control valve body cover.
Refer to Control Valve Body Cover Replacement
on page 17-210.
9. After repairs, refer to Control Module References
on page 6-3 for programming and set up
procedures.
10. Perform the transmission adaptive values learn.
Refer to Transmission Adaptive Values Learn on
page 17-163.
Control Valve Body Cover
Replacement
Removal Procedure
1. Disconnect the battery negative cable. Refer to
Battery Negative Cable Disconnection and
Connection on page 9-713.
2. Raise and support the vehicle. Refer to Lifting and
Jacking the Vehicle on page 1-31.
3. Remove the front bumper fascia opening lower
cover. Refer to Front Bumper Fascia Opening
Lower Cover Replacement on page 3-58.
4. Remove the front wheel house liner inner front
extension. Refer to Front Wheelhouse Liner Inner
Front Extension Replacement (Left Slde) on
page 3-147 or Front Wheelhouse Liner Inner Front
Extension Replacement (Right Side, LUV) on
page 3-148 or Front Wheelhouse Liner Inner Front
Extension Replacement (Right Slde, LWE, LUW)
on page 3—149.
5. Drain the transmission fluid.
(US/Canada)
«Sonic
2013 (5377994)
Manual
Service
 Automatic Transmission - 6T30/6T40/6T45/6T50 (MH8, MH9) 17-211

II (i ‘13- . ;
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2536225 1999445
6. Remove oil cooler inlet (1) and outlet (2) hoses 8. Remove the control valve body cover bolts (1).
from the retainer(3) on the control valve body 9. Remove the control valve body cover (2).
covet
10. Remove the control valve body cover gasket (3).
Caution: Support the control solenoid valve assembly
around the connector when removing the seal.
Excessive pulling force can damage the internal
electrical connections.
11. Remove the control valve body cover wiring
connector hole seal (4).
12. Remove all traces of the old gasket material. Clean
the transmission case and control valve body
cover gasket surfaces.
Installation Procedure

-§§7 /
‘ 1'01“"
($1

1999448
7. Disconnect the control valve body transmission
control module electrical connector(1), then unclip
the wiring harness from the cover.

1999445
1. Installthe control valve body cover wiring
connector hole seal (4).
2. Installthe control valve body cover gasket (3) to
the control valve body cover.

2013
—
Sonic
(US/Canada)
Service
Manual
(5377994)
17-2’12 Automatic Transmission - 6T30/6T40l6T45/6T50 (MH8, MH9)
3. Install the control valve body cover (2).
4. Hand start the control valve body cover bolts (1). 3 1

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2536225
Install the oil cooler inlet (1) and outlet (2) hoses to
the retainer (3) on the control valve body cover.
1999447
Install the front wheel house liner inner front
Caution: Refer to Fastener Cautionon page 0-8. extension. Refer to Front Wheelhouse Linerlnner
Note: Install all control valve body cover bolts and Front Extension Replacement (Left Slde) on
studs by hand then torque all bolts and studs in page 3-147 or Front Wheelhouse Liner Inner Front
sequence. Extension Replacement (Right Side, LUV) on
page 3-148 or Front Wheelhouse Liner Inner Front
5. Installthe control valve body cover bolts. Tighten Extension Replacement (Right Side, LWE, LUW)
the bolts in sequence to 12 N-m(106 lb in). on page 3-149.
10. Install the front bumper fascia opening lower cover.
Refer to Front Bumper Fascia Opening Lower
Cover Replacement on page 3-58.
11. Fill the transmission with correct fluid.
12. Check transmission fluid level. Refer to
Transmission Fluid Level and Condition Check on
page 17-164.
13. Lower the vehicle.
14. Connect the battery negative cable. Refer to
Battery Negative Cable Disconnection and
Connection on page 9—713.
15. Check for leaks.

1999448
6. Connect the control valve body transmission
control module electrical connector (1), then clip
the wiring harness to the cover.
7. Raise the vehicle.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Automatic Transmission . 6T30/6T40/6T45/6T50 (MH8, MH9) 172213

Control Valve Body Replacement

l.2

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,.

1998831
Control Valve Body Replacement
Callout Component Name
PreliminaryProcedure
Removethecontrolsolenoidvalveand transmissioncontrolmoduleassembly.Referto ControlSolenoidValveand
TransmissionControlModuleAssemblyReplacementonpage 17-209.
1 FluidLevelControlValve
FluidLevelControlValveGasket
2 Procedure
DISCARDtheGasket.Use a NEW gasketONLY.
ControlValveBodyBoltM6x 60(Qty:9)
Caution: Referto FastenerCautiononpage 0-8.
3 Tip: Tightenin specifiedsequence.
Tighten
11NW(97Ibin)
ControlValveBodyBoltM6x 53(Qty:2)
Tip: Tightenin specifiedsequence.
Tighten
11N-m(97lb in)
ControlValveBodyAssembly
Procedure
5 1. Afterrepairs,referto ControlModuleReferencesonpage 6—3forprogramming andset upprocedures.
2. Performthetransmissionadaptivevalueslearn.Referto TransmissionAdaptiveValuesLearnon
page 17—163.
6 ControlValveBodySpacer PlateAssembly

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
17-214 Automatic Transmission - 6T30/6T40I6T45/6T50 (MH8, MH9)

Control Valve Body Replacement (cont'd)

Callout Component Name
ManualShaftDetentSpringBoltM6x 16(Qty:1)
7 Tighten
' 12N-m(106lbin)
8 ManualShaftDetentLeverSpringAssembly
9 1—2-3-4ClutchFluidPassageSeal
Tip: Discardtheseal. Itis notreusable.
10 Low/ReverseClutchFluidPassageSeal
Tip: Discardtheseal. Itis notreusable.

Output Speed Sensor Replacement

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wafl
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Mm
.2..

1998840
Output Speed Sensor Replacement
Callout Component Name
Preliminary Procedure
Removethecontrolvalvebody.Referto ControlValveBodyReplacementonpage 17-213.
OutputSpeedSensor BoltM6x 18
Caution: RefertoFastenerCautiononpage0—8.
Tighten
9N-m(80lbin)
OutputSpeedSensor
Procedure
Performthetransmissionadaptivevalueslearnprocedure.Referto TransmissionAdaptiveValuesLearnon
page 17-163. ‘
‘v-...
_
.__
2...
.2
2013
-Sonic
(US/Can’ada)
Service
Manual
(5377994)
‘HW
w‘
-2.»
M”—_
.._
.__
 Automatic Transmission - 6T30/6T40/6T45I6T50 (MH8, MH9) 179215

Input Speed Sensor Replacement Caution: Refer to Fastener Caution on page 0-8.
~——_~_—~.2_..,w___ 4. Install the input speed sensor bolt (2) M6 x 23 and
Removal Procedure tighten to 9 N-m(80 lb in).
1. Remove the control solenoid valve and 5. Install the control solenoid valve and transmission
transmission control module assembly. Refer to control module assembly. Refer to Control
Control Solenoid Valve and Transmission Control Solenoid Valve and Transmission Control Module
Module Assembly Replacement on page 17-209. Assembly Replacement on page 17—209.
6. Perform the transmission adaptive vaiues learn
procedure. Refer to Transmission Adaptive Values
Learn on page 17-163.
le97»
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Transmission Mount Bracket
Replacement - Rear

Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and
Jacking the Vehicle on page 1-31.
2. Using a suitable jack stand, support the rear of the
transmission.

1998841
2. Remove the input speed sensor bolt (2) M6 x 23.
3. Unlock the 2 retaining tabs inside the transmission
housing.
4. Remove the input speed sensor(3).
5. Remove the 3 input speed sensor seals (1).
Installation Procedure

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2492702
3. Remove and DISCARD the rear transmission
mount bracket to rear mount through bolt (1).

1998841
1. Install the 3 input speed sensor seals (1).
2. Install the input speed sensor (3).
3. Verify that the retaining tabs are locked completely.

2013
—
Sonic
(US/Canada)
Service
Manual
(5377994)
’17-216 Automatic Transmission - 6T30/6T40/6T45l6T50 (MH8, MH9)

ism
“1"?“
vhs- 9;: 4;:.

21: j/ 71

2507626 2492702
4. Remove and DISCARD the 3 rear transmission 3. Install the NEW rear transmission mount bracket to
mount bracket to transmission bolts (1). rear mount through bolt (1) and tighten to
5. Remove the rear transmission mount bracket (2). 80 N-m(59 lb ft) plus 45—60degrees.
4. Remove thejack stand.
Installation Procedure 5. Lowerthe vehicle. .M
......

Transmission Mount Replacement -

Left Side

Removal Procedure
1. Remove the battery tray. Refer to Battery Tray
Replacement on page 9—721 .
2. Install the engine support fixture. Refer to Engine
Support Fixture on page 9—1060.
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2507626
1. Install the rear transmission mount bracket (2).
Caution: Refer to Fastener Caution on page 0-8.
2. Install the 3 NEW rear transmission mount bracket
to transmission bolts (1) and tighten to
100 N-m(74 lb ft) plus 30—45degrees.

2492638
3. Remove and DISCARD the left transmission
mount to bracket bolts (1).
4. Remove the left transmission mount to body
bolts (2).

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Automatic Transmission - 6T30/6T40/6T45/6T50 (MH8, MH9) 17-217
5. Remove the left transmission mount to
body nut (3).
6. Remove the transmission mount (4) from the
vehicle.
Installation Procedure

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MVM—M.

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2492702
Remove and DISCARD the rear transmission
mount bracket to rear mount through bolt (1).
Remove rear transmission mount to frame bolt (3).
. Push and hold the powertrain assembly forward
and then remove rear transmission mount.
2492638
Installation Procedure
1. install the left transmission mount (4) to the
vehicle.
Caution: Refer to Fastener Caution on page 0-8.
2. Install the transmission mount to body bolts (2) and
tighten to 58 N~m(43 lb ft).
3. Install the transmission mount to body nut (3) and
tighten to 58 NW (43 lb ft).
4. Installthe NEW left transmission mount to
transmission bolts (1) and tighten to 50 N-m
(37 lb ft) plus 60—75degrees.
Remove the engine support fixture. Refer to
Engine Support Fixture on page 9-1060.
. Install the battery tray. Refer to Battery Tray
Replacement on page 9-721.

Transmission Rear Mount

Replacement

Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and
Jacking the Vehicle on page 1-31. 2492702
1. Push and hold the powertrain assembly forward
and then install rear transmission mount.
Caution: Refer to Fastener Caution on page 0—8.
2. install rear transmission mount to frame bolt (3)
and tighten to 100 N-m(74 lb ft).
3. Install the NEW rear transmission mount bracket to
rear mount through bolt (1) and tighten to 80 N'm
(59 lb ft) plus 45—60degrees.
. Lower the vehicle.

2013
—
Sonic
(US/Canada)
Service
Manual
(5377994)
17-218 Automatic Transmission - 6T30/6T40/6T45/6T50 (MH8, MH9)

Transmission Replacement (With

1.2L or 1.4L Engine) ,7 %@‘¢ flu, ‘Y'
]A.\> o ’7?@(,
Removal Procedure ...... kw...
1. Remove the battery tray. Refer to Battery Tray I
K‘5/79"’\i\1\\2 “‘1‘
Replacement on page 9-721.
2. Without draining the coolant or removing the
hoses, remove and position aside the radiator
surge tank. Refer to Radiator Surge Tank
Replacement on page 9-630.
3. Remove the transmission range selector lever
cable. Refer to Range Selector Lever Cable
Replacement on page 17-195.

2571900
8. Remove the upper transmission to engine bolts (1).
9. Installthe support fixture. Refer to Engine Support
Fixture on page 9-854.

1999448
4. Disconnect the control valve body transmission
control module electrical connector(1) then unclip
the connector from the transmission.
5. Remove the transmission fluid cooler inlet hose
from the transmission. Refer to Fluid Cooler Inlet
Hose Replacement on page 17—203.
6. Remove the transmission fluid cooler outlet hose
from the transmission. Refer to Fluid Cooler Outlet
Hose Replacement on page 17—204.
7. Plug andlor cap the pipes and transmission to 1998836
prevent contamination.
10. Drain the transmission fluid. Refer to Transmission
Fluid Drain and Fill on page 17-198.
11. Remove the front exhaust pipe. Referto Exhaust
Front Pipe Replacement (LUV,LUW) on
page 9-738.
12. Remove the front wheel drive shafts from the
transmission. Refer to Front Wheel Drive Shaft
Replacement on page 7—5.
13. Remove the starter motor. Refer to Starter
Replacement (LUW) on page 9-722 or Starter
Replacement (LUV) on page 9-724.

2013
~Sonic
(US/Canada)
Service
Manual
(5377994)
 Automatic Transmission - 6T30/6T40/6T45/6T5O (MH8, MHQ) 179219

mW..
W

1‘W

2571901
14. Mark the relationship of the flywheel to the torque
converter for reassembly.
15. Remove the torque converter to flywheel bolts (1).
16. Remove the drivetrain and front suspension frame.
Refer to Drivetrain and Front Suspension Frame
Replacement on page 3-144.
17. Remove the rear transmission mount bracket from
the transmission. Refer to Transmission Mount
Bracket Replacement - Rear on page 17—215.
2571892
20. Remove the lower transmission nut (1) and the
lower transmission bolts (2—4).
Note: Ensure the torque converter remains securely in
place on the transmission inputshaft while separating
and removing the transmission.
21. Separate the transmission from the engine.
22. Lower the transmission with the transmission jack
far enough to remove the transmission.
23. Flush and flow test the transmission oil cooler and
lines. Refer to Transmission Fluid Cooler Flushing
and Flow Test on page 17-175.
Installation Procedure
1. Raise the transmission with the transmission jack
and position the transmission to the engine.

2534715
18. Remove the lefttransmission mount (4). Refer to
Transmission Mount Replacement —Left Side on
page 17—216.
19. Use a transmission jack in orderto support the
transmission.
2571892
Caution: Refer to Fastener Caution on page 0-8.
2. Install the‘lower transmission bolts (2, 4) and
tighten to 60 Nm (44 lb ft).

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
179220 Automatic Transmission - 6T30/6T40/6T45l6T50 (MH8, MH9)
3. Install the lower transmission bolts (3) and the 9. Install the starter motor. Refer to Starter
lower transmission nut (1) and tighten to 40 N-m Replacement (LUW) on page 9—722or Starter
(30 Ibft). Replacement (LUV) on page 9-724.
4. Remove the transmission jack. 10. Install the front wheel drive shafts to the
transmission. Refer to Front Wheel Drive Shaft
Replacement on page 7-5.
11. Install the front exhaust pipe. Refer to Exhaust
Front Pipe Replacement (LU\/,LUW) on
page 9-738.

,, '/ %@.{//"{ 1
“699° ’7‘1'

2534715
5. Install the left transmission mount (4). Refer to
Transmission Mount Replacement —Left Side on
page 17-216.
6. Install the reartransmission mount bracket to the 2571900
transmission. Refer to Transmission Mount Bracket
Replacement —Rear on page 17—215. 12. Remove the support fixture. Refer to Engine
7. Install the drivetrain and front suspension frame. Support Fixture on page 9—854.
Refer to Drivetrain and Front Suspension Frame 13. Install the upper transmission to engine bolts (1)
Replacement on page 3-144. and tighten to 60 NW (44 lb ft).

2571901
Note: If reusing the torque converter bolts, clean the
threads and apply threadlocker to the threads prior to
installation.
8. Install the torque converter to flywheel bolts (1) and
tighten to 60 N-m(44 lb ft).
1999448
14. Connect the control valve body transmission
control module electrical connector (1)then clip the
connector to the transmission.

(US/Canada)
-Sonic
2013 (5377994)
Manual
Sen/ice
 Automatic Transmission 9 6T30/6T40/6T45/6T50 (MH8, MH9) 17-221
15. Install the transmission fluid cooler outlet hose to
the transmission. Refer to Fluid Cooler Outlet Hose
Replacement on page 17-204.
16. Install the transmission fluid cooler inlet hose to the
transmission. Refer to Fluid Cooler InletHose
Replacement on page 17-203.
17. Install the transmission range selector lever cable.
Refer to Range Selector Lever Cable Replacement
on page 17—195.
18. Adjust the automatic transmission range selector
lever cable. Referto Range Selector Lever Cable
Adjustment on page 17—196.
19. Install the radiator surge tank. Refer to Radiator
Surge Tank Replacement on page 9630.
20. Install the battery tray. Refer to Battely Tray
Replacement on page 9—721 .
21. Fill the transmission with fluid. Refer to
Transmission Fluid Drain and Fill on page 17—198.
22. ifa NEW transmission control module (TCM) has
been installed into the vehicle, the NEW module 1999448
needs to be reprogrammed. Refer to Service
Programming System (SP8) on page 6-13. 4. Disconnect the control valve body transmission
Note: The transmission adaptive values learn control module electrical connector (1) then unclip
procedure must be performed when one of the the connector from the transmission.
following repairs have been made to the vehicle. 5. Remove the transmission fluid cooler inlet hose
Failure to perform the procedure after one of the from the transmission. Refer to Fluid Cooler Inlet
following repairs may result in poor transmission Hose Replacement on page 17—203. ‘
performance, as well as transmission DTCs being set: 6. Remove the transmission fluid cooler outlet hose
Transmission internal service/overhaul
0 from the transmission. Refer to Fluid Cooler Outlet
Hose Replacement on page 17-204.
.
Valve body repair or replacement
7. Plug andlor cap the pipes and transmission to
Control solenoid valve assembly replacement
- prevent contamination.
TCM software/calibration update
-
.
Any service in response to a shift quality
concern
23. Perform the transmission adaptive values learn.
Refer to Transmission Adaptive Values Learn on
page 17—163.
24. Road test the vehicle.

Transmission Replacement (With

1.6L or 1.8L Engine)

Removal Procedure
1. Remove the battery tray. Refer to Batten/ Tray
Replacement on page 9-721.
2. Without draining the coolant or removing the
hoses, remove and position aside the radiator
surge tank. Refer to Radiator Surge Tank
Replacement on page 9-630.
. Remove the transmission range selector lever
cable. Refer to Range Selector Lever Cable
Replacement on page 17—195. 2534716
8. Remove the upper transmission to engine bolts (2).
9. install the support fixture. Refer to Engine Support
Fixture on page 9-1060.

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
17-222 Automatic Transmission - 6T30/6T40l6T45/6T50 (MH8, MH9)
17. Remove the rear transmission mount bracket from
the transmission. Refer to Transmission Mount
Bracket Replacement - Rear on page 17-215.

2W
_
.M2
‘ _.M

1998836
10. Drain the transmission fluid. Refer to Transmission
Fluid Drain and Fill on page 17-198.
11. Remove the front exhaust pipe. Refer to Exhaust 2534715
Front Pipe Replacement (LUV,LUW) on
page 9-738. ‘ 18. Remove the lefttransmission mount (4). Refer to
12. Remove the front wheel drive shafts from the Transmission Mount Replacement —Left Side on
transmission. Refer to Front Wheel Drive Shaft page 17—216.
Replacement on page 7—5. 19. Use a transmission jack in order to support the
13. Remove the starter motor.Refer to Starter transmission.
Replacement (LUW) on page 9—722or Starter
Replacement (LUV) on page 9-724.

2534714
14. Mark the relationship of the flywheel to the torque
converter for reassembly.
15. Remove the hole cover (1) and the torque
converter to flywheel bolts (2).
16. Remove the drivetrain and front suspension frame.
Refer to Drivetrain and Front Suspension Frame
Replacement on page 3-144.
‘“MN,
..2,
'xw
2534716
20. Remove the lower transmission
fasteners (1, 3, 4, 5).
Note: Ensure the torque converter remains securely in
place on the transmission input shaft while separating
and removing the transmission.
21. Separate the transmission from the engine.
22. Lower the transmission with the transmission jack
far enough to remove the transmission.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Automatic Transmission
23. Flush and flow test the transmission oil cooler and
lines. Refer to Transmission Fluid Cooler Flushing
and Flow Test on page 17—175.
Installation Procedure
1. Raise the transmission with the transmission jack
and position the transmission to the engine.
- 6T30/6T40/6T45/6T50 (MH8, MH9) 17-223
6. lnstall the rear transmission mount bracket to the
transmission. Refer to Transmission Mount Bracket
Replacement —Rear on page 17-215.
lnstall the drivetrain and front suspension frame.
Refer to Drivetrain and Front Suspension Frame
Replacement on page 3—144.

2534716 Note: if reusing the torque converter bolts, clean the
Caution: Refer to Fastener Caution on page 0-8.
2. lnstall the transmission bolts (3,4) and tighten to
60 Nm (44 lb ft).
3. install the transmission bolts (5) and the
transmission nut (1) and tighten to 40 N-m(30 lb ft).
4. Remove the transmission jack.
2534714
threads and apply threadlockerto the threads prior to
installation.
8. Install the torque converter to flywheel bolts (2) and
tighten to 60 Nm (44 lb ft)and install the hole
cover (1).
Instail the starter motor. Refer to Starter
Replacement (LUW) on page 9—722or Starter
Replacement (LUV) on page 9-724.
10. Install the front wheel drive shafts to the
transmission. Refer to Front Wheel Drive Shaft
Replacement on page 7-5.
11. Install the front exhaust pipe. Refer to Exhaust
Front Pipe Replacement (LUV,LUW) on
page 9-738.

2534715
5. install the left transmission mount (4). Refer to
Transmission Mount Replacement - Left Side on
page 17-216.

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
17-224 Automatic Transmission - 6T30/6T40l6T45/6T50 (MH8, MH9)
19 . Install the radiator surge tank. Refer to Radiator
Surge Tank Replacement on page 9-630.
20 . Install the battery tray. Refer to Batte/y Tray
Replacement on page 9-721.
21. Fill the transmission with fluid. Refer to
Transmission Fluid Drain and Fill on page 17-198.
22. lfa NEW transmission control module (TCM) has
been installed into the vehicle, the NEW module
needs to be reprogrammed. Refer to Service
Programming System (SP8) on page 6-13.
Note: The transmission adaptive values learn
procedure must be performed when one of the
following repairs have been made to the vehicle.
Fa ilure to perform the procedure after one of the
following repairs may result in poor transmission
pe rformance, as well as transmission DTCs being set:
'Transmission internal service/overhaul
-Valve body repair or replacement
'Control solenoid valve assembly replacement
2534716 'TCM software/calibration update
12. Remove the support fixture. Refer to Engine ~Any service in response to a shift quality
Support Fixture on page 9-1060. concern
13. Install the upper transmission to engine bolts (2) 23. Perform the transmission adaptive values learn.
and tighten to 60 Nm (44 lb ft). Refer to Transmission Adaptive Values Learn on
page 17-163.
24 . Road test the vehicle.

1999448
14. Connect the control valve body transmission
control module electrical connector (1) then clip the
connector to the transmission.
15. Install the transmission fluid cooler outlet hose to
the transmission. Refer to Fluid Cooler Outlet Hose
Replacement on page 17—204.
16. Install the transmission fluid cooler inlet hose to the
transmission. Refer to Fluid Cooler InletHose
Replacement on page 17-203.
17. Install the transmission range selector lever cable.
Refer to Range Selector Lever Cable Replacement
on page 17-195.
18. Adjust the automatic transmission range selector
lever cable. Refer to Range Selector Lever Cable
Adjustment on page 17—196.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Automatic Transmission - 6T30/6T40/6T45/6T50 (MH8, MH9) 17-225

Repair Instructions - Off Vehicle

Lift Plate and Holding Fixture Installation

1891300

Lift Plate and Holding Fixture Installation

Callout Component Name
DT-47811-ATransmissionLiftPlate
Warning: Handle with care, thetransmission assembly weighs over 83Kg (183lbs).Bodily injury could
occur if not handled properly.
Caution: Referto FastenerCautiononpage0-8.
Procedure
Tightenboltsand nut.
Tighten
12N'm(1061bin)
Special Tools
DT-478117A TransmissionLiftPlate
Forequivalentregionaltools,referto Special Toolsonpage 17-394.
DT-46625TransmissionHoldingFixture
Procedure
1. Raise thetransmissionwithan overheadhoist.
2. Adjustmountingblockonfixtureto matchbossesoncase, thentightenbolts.
Tighten
13N-m(10Ibft)
Special Tools
DT-46625—10 HoldingFixtureAdapter
Forequivalentregionaltools,referto Special Toolsonpage 17—394.

2013
—Sonic
(US/Canada)
Service
Manual
(5377994)
17-226 Automatic Transmission - 6T30/6T40/6T45I6T50 (MH8, MH9)

Torque Converter Removal

1891302
Torque Converter Removal
Callout Component Name
Lock Pin
Warning: Lock pin must be secured into thebench fixture to hold the transmission and prevent bodily
Injury.
Tip: EnsuretheDT3289-20holdingfixtureis mountedtoa benchthatis properlysupported'andwillsupportthe
weightofthetransmissionassemblywithouttipping.DT-39890holdingfixtureadapterandan enginestandcan
1 be usedas an alternativemethodforsupportingthetransmissionassemblyduringrepairs.
Special Tools
- DT3289-20HoldingFixture
- DT—39890 TransmissionHoldingFixtureAdapter
For equivalentregionaltools,referto Special Toolsonpage 17-394.
2 DT21366TorqueConverterHoldingStrap
TorqueConverterAssembly
Caution: Onlyinstalltheliftassist handlesuntilitstops.Do nottighten.Overtighteningthe liftassisthandles
can causedamagetothetorqueconverter.
3 Tip: Failureto raisethetorqueconverterstraightupcoulddamagethetorqueconverterclutch|ipseal insidethe
torqueconverterclutchassembly.
Special Tool
DT46409TorqueConverterLiftingHandles
For equivalentregionaltools,referto Special Toolsonpage 17-394.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Automatic Transmission - 6T30/6T40/6T45/6T50 (MH8, MH9) 17-227

Control Valve Body Assembly Removal

Control Valve Body Cover Removal

...22_22M.\w'
w,
k_vw_._2__...-—--

1891304

Control Valve Body Cover Removal

Callout Component Name
1 ControlValveBodyCoverBoltsM6x 30(Qty:13)
2 ControlValveBodyCover
3 ControlValveBodyGasket
Tip: Discardtheseal. Itis notreusable.
ControlValveBodyCoverWiringConnectorHoleSeal
4 Caqtion: Supportthecontroi-solenoid valveassemblyaroundtheconnectorwhenremovingtheseal. Excessive
pullingforcecan damagetheInternaleiectrloalconnections.
Tip: Discardtheseal. Itis notreusable.
5 ShiftPositionSwitchConnector
6 OutputSpeedSensorConnector
7 InputSpeedSensorConnector

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
’17-228 Automatic Transmission - 6T30/6T40/6T45/6T50 (MH8, MH9)

Control Solenoid (With Body and TCM) Valve Assembly Removal

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“fm
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_2.

1891305
Cohtrol Solenoid (With Body and TCM) Valve Assembly Removal
Callout Component Name
1 ControlValveBodyM5x 40.5(Qty:3)
2 ControlValveBodyBoltM6x 30(Qty:12)
3 ControlSolenoid(withBodyandTCM)ValveAssembly
ControlSolenoidValveAssemblyFilterPlate
Caution: Use carewhenremovingor installingthefilterplateassembly.A brokenor missingretainingtabmay
4 notadequatelysecurethefilterplatetothecontrolsolenoidvalveassembly,resultingin possibledamageor
contamination.
Tip: Discardthefilterplate.Itis notreusable.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Automatic Transmission - 6T30/6T40/6T45/6T50 (MH8, MH9) 17-229

Control Valve Body Assembly Removal

1891307

Control Valve Body Assembly Removal

Callout Component Name
1 FluidLevelControlValve
2 FluidLevelControlValveGasket
3 ControlValveBodyBoltM6x 60 (Qty:9)
4 ControlValveBodyBoltM6x 53 (Qty:2)
5 ControlValveBodyAssembly
6 ControlValveBodySpacer PlateAssembly
7 ManualShaftDetentSpringBoltM6x 16(Qty:1)
8 ManualShaftDetentLeverSpringAssembly
9 1-2-3-4ClutchFluidPassageSeal
Tip: Discardtheseal. Itis notreusable.
10 Low/ReverseClutchFluidPassageSeal
Tip: Discardtheseal. Itis notreusable.

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
17-230 Automatic Transmission - 6T30/6T40/6T45/6T50 (MH8, MH9)

Input and Output Speed Sensor Removal

1891309
Input and Output Speed Sensor Removal
Callout Component Name
1 A/TransOutputSpeedSensorBoltM6x 18(Qty:1)
2 AlTransOutputSpeedSensorAssembly
3 inputSpeedSensorBoltM6X23 (Qty:1)
4 InputSpeedSensorAssembly
Tip: Compressthelockingtabson theplugto releaseitfromthecase andto avoiddamagingtheretainers.
5 InputSpeedSensorAssemblySeals (Qty:3)
Tip: Discardtheseals.Theyare notreusable.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Automatic Transmission - 6T30/6T40/6T45/6T50 (MH8, MH9) 179231

Torque Converter Housing with Fluid Pump Assembly Removal (Non Hybrid)
1

1891311
Torque Converter Housing with Fluid Pump Assembly Removal (Non Hybrid)
Callout Component Name
1 TorqueConverterand DifferentialHousingBoltsM8x 30(Qty:15)
2' TorqueConverterwithFluidPumpHousingAssembly
3 TorqueConverterHousingGasket
Tip: Discardtheseal. Itis notreusable.
4 FluidPumpSeal Assembly
Tip: Discardtheseal. Itis notreusable.

2013
~Sonic
(US/Canada)
Service
Manual
(5377994)
179232 Automatic Transmission - 6T30/6T40/6T45I6T50 (MH8, MH9)

Differential Carrier Removal (6T30)

2202194
Differential Carrier Removal (6T30)
Callout Component Name
1 DifferentialCarrierAssembly
2 FinalDriveSun Gear

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Automatic Transmission - 6T30/6T40/6T45/6T50 (MH8, MH9) 17-233
Differential Carrier Removal (6T40l45l50)

1891312
Differential Carrier Removal (6T40l45l50)
Callout Component Name
FrontDifferentialCarrierBearingAssembly
2 DifferentialCarrierAssembly
3 FinalDriveSun Gear

2013
~Sonic
(US/Canada)
Service
Manual
(5377994)
’17-234 Automatic Transmission - 6T30/6T40/6T45/6T50 (MH8, MH9)

Drive and Driven Sprocket, Drive Link, and Park Pawl Removal (6T30)

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....

2202195
Drive and Driven Sprocket, Drive Link, and Park Pawi Removal (6T30)
Callout Component Name
DriveLinkLubeScoop
DriveLinkLubeScoop Seals
DriveLinkLubeFluidSeal
DrivenSprocketAssembly,DriveSprocketandParkGearAssemblyand DriveLink
Tip:
1. Thedrivelink,driveanddrivensprocketassembliesmustbe removedatthesametime.
2. Thedrivensprocketballbearinginnerracehas a slightinterferencefitwiththecase. Pullstraightupto ease
removal.
DrivenSprocketBearingAssembly
Tip: Thedrivensprocketbearingmaybe stucktothedrivensprocket.
BaffleRetainer
FrontDifferentialCarrierBaffleBoltsM6x 16(Qty:2)
FrontDifferentialCarrierBaffle
(DmVO) ParkPawlShaft
Park PawlSpring
_\A
A0 Park Pawl

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Automatic Transmission - 6T30/6T40/6T45/6T50 (MH8, MH9) 179235

Drive and Driven Sprocket, Drive Link, and Park Pawl Removal (6T40l45l50)

Drive and Driven Sprocket, Drive Link, and Park Pawl Removal (6T40l45l50)
Callout Component Name
1 DriveLinkLubeScoop
2 DriveLinkLubeScoop Seals
3 DriveLinkLubeFluidSeal
DrivenSprocketAssembly,DriveSprocketandPark GearAssemblyand DriveLink
Procedure
4 1. Thedrivelink,driveanddrivensprocketassembliesmustbe removedat thesametime.
2. Thedrivensprocketballbearinginnerracehas a slightinterferencefitwiththecase.Pull straightupto
ease removal.
5 DrivenSprocketBearingAssembly
Tip: Thedrivensprocketbearingmaybestucktothedrivensprocket.
6 FrontDifferentialCarrierBaffleBoltsM6X 16(Qty:2)
7 FrontDifferentialCarrierBattle
8 Park PawlShaft
9 Park PawlSpring
10 Park Pawl

2013
—Sonic
(US/Canada)
Service
Manual
(5377994)
'17-236 Automatic Transmission - 6T30/6T40/6T45/6T50 (MH8, MH9)

Internal Components Removal

1891318
Internal Components Removal
Callout Component Name
1—2—3—4 ClutchBackingPlateRetainerRing
Warning: Theretaineris under tension. Use care whenremoving or installing theretainer.Personal
injury couldresult.
Caution: Use cautionduringremovalor installationoftheretainerringtoavoiddamagetothecase machined
surfacein theparkpawlarea.Burrsor raisededgesonthecase machinedsurfacecancausetheparkpawlto
bindandprohibititfromengagingtheparkgear.
Tip: RemoveoneendoftheretainerusingDT-28585snap ringremoveror equivalentandworktheretainerout
ofthecase groove.
Special Tool
DT—28585 Snap RingRemoveror equivalent
For equivalentregionaltools,referto Special Toolsonpage 17-394.
3—5Reverseand4—5—6 ClutchHousingAssembly,Gearset,Low—Reverse ClutchAssemblyand Low-Reverse
and 1—2—3—4 ClutchHousing
Tip: This unitis heavy—weighs40 lbs.(18Kg).
2—6ClutchPlate(Qty:1)
2—6ClutchApply Plate(Waved)
35R and456 ClutchHousingThrustBearingAssembly

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Automatic Transmission - 6T30/6T40/6T45/6T50 (MH8, MH9) 17-237

2-6 Clutch Piston Removal

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.__.Aufi

1891319

2-6 Clutch Piston Removal

Callout Component Name
2—6ClutchSpringRetainer
Special Tool
DT—28585 Snap RingRemoveror equivalent
Forequivalentregionaltools,referto Special Toolsonpage 17—394.
2—6ClutchSpring
2—6ClutchPistonAssembly
Tip:
- Use pliersto removethepiston.
- Inspectthepistonseals fordamageandlorwear.The pistonis reusable.

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
179238 Automatic Transmission - 6T30/6T40/6T45/6T50 (MH8, MH9)
Manual Shift Detent Lever with Shaft Position Switch Assembly and Park Pawl
Actuator Removal
Manual Shaft Detent (wlShift Position Switch) Lever Assembly Removal

1891310
Manual Shaft Detent (wlShift Position Switch) LeverAssembly Removal
Callout Component Name
ManualShaftDetentLeverHub‘Pin
1
Tip: Use side cutterto removethepin(1)anddiscard.
ManualShiftShaftPin
Tip: Discardthepin.Itis notreusable.
Special Tools
- DT—23129 UniversalSeal Remover
' GE-6125-1BSlide Hammer
Forequivalentregionaltools,referto Special Toolsonpage 17-394.
ManualShaft
ManualShaftDetent(w/ShiftPositionSwitch)LeverAssembly
Park PawlActuatorAssembly

2013
—
Sonic
(US/Canada)
Service
Manual
(5377994)
 Automatic Transmission - 6T30/6T40/6T45/6T50 (MH8, MH9) 17-239
Park Pawl Actuator Guide Removal

1891314
Park Pawl Actuator Guide Removal
Callout Component Name
Park PawlActuatorGuidePin
1
Tip: Use side cutterto removethepin(1)anddiscard.
2 Park PawlActuatorGuideAssembly
3 Park PawlActuatorGuideAssemblySeal
Tip: Discardtheseal. it is notreusable.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
17-240 Automatic Transmission - 6T30/6T40l6T45/6T50 (MH8, MH9)

Manual Shift Shaft Seal Removal

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\ m
1891412
Manual Shift Shaft Seal Removal
Callout Component Name
ManualShiftShaftSeal
Tip: Use theDT—45201 seal removerto removetheseal to preventdamagetothecase surface.
1 Special Tools
DT—45201 Seal Remover
For equivalentregionaltools,referto Special Toolsonpage 17-394.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Automatic Transmission 9 6T30/6T40/6T45/6T50 (MH8, MH9) 17-241

Input Shaft Support Replacement (Gen 1)

1891321
Input Shaft Support Replacement (Gen 1)
Callout Component Name
3—5Reverseand4-5-6ClutchFluidSeals (Qty:4)
Tip:
Discardthefluidseals.Theyare notreusable.
Referto 3-5-Reverseand4-5—6 ClutchFluidSeal RingReplacement(Gen 1)onpage 17-243or 3-5-Reverse
and4-5-6ClutchFluidSeal Ring Replacement(Gen2)onpage 17—244.
InputShaftSupportBoltsM6x 50 (Qty:3)
Caution: RefertoFastenerCautiononpage0—8.
Tighten
12N'm(106|bin)
InputShaftSupport
Tip: Inspectthesupportforwear,damageor porosity.

2013
~Sonic
(US/Canada)
Service
Manual
(5377994)
17-242 Automatic Transmission - 6T30/6T40l6T45/6T50 (MH8, MH9)

Input Shaft Support Replacement (Gen 2)

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=2} 1

EI‘ ,l
'1v_¢
j

i”lull
‘2 2:.

2552948
Input Shaft Support Replacement (Gen 2)
Callout Component Name
3—5Reverseand4-5—6 ClutchFluidSeals (Qty:3)
Tip:
- Discardthefluidseals.Theyare notreusable.
° Referto 3—5-Reverse and4-5-6ClutchFluidSeal Ring Replacement(Gen1)onpage 17—243
or3-5-Reverse
and4-5-6ClutchFluidSeal RingReplacement(Gen2)onpage 17—244.
InputShaftSupportBoltsM6x 50 (Qty:3)
Caution: RefertoFastenerCautiononpage 0-8.
Tighten
12Mm(106lbin)
InputShaftSupport
Tip: Inspectthesupportforwear,damageor porosity.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Automatic Transmission 9 6T30/6T40/6T45/6T50 (MH8, MHQ) 179243

3-5-Reverse and 4-5-6 Clutch Fluid Seal Ring Replacement (Gen 1)

1891328
3-5-Reverse and 4-5-6 Clutch Fluid Seal Ring Replacement (Gen 1)
Callout I Component Name
Special Tools
DT—46620 Seal lnstalier
For equivalentregionaltools,referto Special Toolsonpage 17—394.
3—5Reverseand4—5—6 ClutchFluidSeals (Qty:4)
Procedure
1. Place DT—46620—3 whichis partof DT-46620seal installeroverthecase hubandadjustitso thatonlythe
bottomseal ringis exposed.
1 2. Place a NEW fluidseal ringontoDT-46620—3 whichis partof DT-46620seal installer.
3. Use DT—46620-2 whichis partof DT—46620 seal installerto pushthefluidseal ringdownoverDT-46620-3
whichis partof DT—46620 seal installerintothehubringgroove.
4. Repeattheabovestepsto installall 4 seal rings,adjustingDT-46620-3whichis partof DT—46620 seal
installertotheappropriateringgroove.
SmallChamferUp
Caution: Do notforcetheseal installerdownovertheseals as thiswillrollanddamagetheseats.The large
Chamferis designedtofitovertheoverstretchedseal.Use a handto helpshrinktheseal it theseal installeris
2 difficulttoinstallovertheseal rings.
Procedure
InstallDT-46620-1whichis partof DT—46620 seal installerwiththelargeChamferenddownoverthefluidseal
ringsandleaveDT—46620—1 whichis partof DT—46620 seal installerontheseals forat least60seconds.

2013
—
Sonic
(US/Canada)
Service
Manual
(5377994)
17-244 Automatic Transmission - 6T30/6T40/6T45/6T50 (MH8, MH9)

3-5-Reverse and 4-5-6 Clutch Fluid Seal Ring Replacement (Gen 1) (cont'd)
Callout Component Name
LargeChamferUp
Procedure
1. InstallDT-46620-1whichis partof DT—46620 seal installerwiththesmallChamferendfacingdownforat
3 least60seconds.Thiswill properlysize thebottomseal ring.
2. LeavingDT-46620-1whichis partof DT-46620seal installeronthefluidseal ringsforan extendedperiod
oftimecouldcausea fluidleakontheinitialclutchpistoncircuituntiltheseal ringswarmupandexpandto
theproperdimension.

3-5-Reverse and 4-5-6 Clutch Fluid Seal Ring Replacement (Gen 2)

2552950
3-5-Reverse and 4-5-6 Clutch Fluid Seal Ring Replacement (Gen 2)
Callout I Component Name
Special Tools
DT-46620Seal Installer
Forequivalentregionaltools,referto Special Toolsonpage 17—394.
3—5Reverseand4—5—6 ClutchFluidSeals (Qty:3)
Procedure
1. Place DT-46620-3whichis partof DT—46620 seal installeroverthecase hubandadjustitso thatonlythe
bottomseal ringis exposed.
1 2. Place a NEW fluidseal ringontoDT-46620-3whichis partof DT-46620seal installer.
3. Use DT-46620-2whichis partof DT—46620 seal installerto pushthefluidseal ringdownoverDT-46620-3
whichis partofDT—46620 seal installerintothehubringgroove.
4. Repeattheabovestepsto installall 3 seal rings,adjustingDT-46620-3whichis partof DT—46620 seal
installertotheappropriateringgroove.

2013
—
Sonic
(US/Canada)
Service
Manual
(5377994)
 Automatic Transmission - 6T30/6T40/6T45/6T50 (MH8, MH9) 179245

3-5-Reverse and 4-5-6 Clutch Fluid Seal Ring Replacement‘(Gen 2) (cont'd)

Callout Component Name
SmallChamferUp
Caution: Do notforcetheseal installerdownovertheseatsas thiswillrollanddamagetheseats.The large
Chamferis designedtofitovertheoverstretchedseal. Use a handto helpshrinktheseal if theseal installeris
2 difficulttoinstalloverthesea|rings.
Procedure
lnstallDT-46620—1 whichis partof DT-46620sea|installerwiththelargeChamferenddownoverthefluidsea|
ringsandleaveDT-46620-1whichis partof DT—46620 sea|installerontheseals forat least60seconds.
LargeChamferUp
Procedure
1. InstallDT—46620-1 whichis partof DT-46620sea|installerwiththesmallChamferendfacingdownforat
3 least60 seconds.Thiswillproperlysize thebottomseal ring.
2. LeavingDT-46620-1whichis partof DT—46620 seal installeronthefluidseal ringsforan extendedperiod
oftimecouldcausea fluidleakontheinitialclutchpistoncircuituntiltheseal ringswarmupandexpandto
theproperdimension.

Front Wheel Drive Shaft Seal Replacement - Case Side

4111111

1891323

2013
—Sonic
(US/Canada)
Service
Manual
(5377994)
17-246 Automatic Transmission - 6T30/6T40/6T45/6T50 (MH8, MH9)

Front Wheel Drive Shaft Seal Replacement - Case Side

Callout Component Name
FrontWheelDriveShaftOii Seal
Special Tools '
- DT—23129 UniversalSeal Remover
1 - DT—47790 Seal Installer
. GE—6125-1B Slide Hammer
- GE-8092DriverHandle
Forequivalentregionaltools,referto Special Toolsonpage 17-394.

Transmission Case Cleaning and Inspection

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.va
M,_~
‘4‘,
.2.
...
_.
.

2366241
Transmission Case Cleaning and Inspection
Callout Component Name
Caution: Do notuse abrasivepadsor bristledevicestocleanthesealingsurfaces.Abrasivepadsproducea finegritthatcan
effecttransmissionfunction.Abrasivepadscan also removeenoughmetalto createoil leaks.
Caution: Aftercleaningthetransmissioncomponents,allowto airdry.Do notuse clothor papertowelsin orderto dryany
transmissioncomponents.Lintfromthetowelscancausecomponentfailure.
Caution: Do notreusecleaningsolvents.Previouslyusedsolventsmaydepositsedimentwhichmaydamagethecomponent.
Preliminary Procedures
1. Thoroughlycleanthetransmissioncase assembly,includingcase threads,withcleansolvent.
2. Cleangasketsealingsurfaces.Removeall residualgasketmaterial.
3. inspectall threadedholes.Ifnecessary,repairanythreaddamage.
TorqueConverterHousingLocatingPin
1 Procedure
Inspectthetorqueconverterhousinglocatingpins.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Automatic Transmission - 6T30/6T40/6T45/6T50 (MH8, MH9) 1 7-247

Transmission Case Cleaning and Inspection (cont'd)

Callout Component Name
Specification
The locatingpinsinstalledheightis 7.4mm(0.29in).
FluidTroughCheck Ball
2 Specification
The checkball installeddepthis 11mm(0.43in).
3 ConverterHousingSealingSurface
4 ControlValveBodyCoverSealingSurface
5 Fill Cap Seal
6 TransmissionFluidCoolerPipe SealingSurface
FluidPressureTestPlug
7 Caution: RefertoFastenerCautiononpage 0—8.
Tighten
12N-m(106lb in)
8 ManualShiftShaftSeal Surface
9 FluidFill Cap SealingSurface
FluidLevelPlug
10 Tighten
12N-m(106lb in)
ValveBodyLocatingPin
Procedure
11 Inspectthevalve bodylocatingpins.
Specification
The locatingpinsinstalledheightis 5.8mm(0.22in).
DrainPlug
12 Tighten
12N°m(106lb in)

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
17-248 Automatic Transmission - 6T30/6T40/6T45/6T50 (MH8, MH9)

Manual Shift Detent Lever with Shaft Position Switch Assembly and Park Pawl
Actuator Installation
Park Pawl Actuator Guide Installation

1891435
Park Pawl Actuator Guide Installation
Callout Component Name
1 Park PawlActuatorGuideAssemblySeal
2 Park PawlActuatorGuideAssembly
Park PawlActuatorGuidePin
Caution: Referto FastenerCautiononpage0-8.
Procedure
Installtheparkpawlactuatorguidepintocorrectheight.
Tighten
7.2mm(0.28in)

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Automatic Transmission - 6T30/6T40/6T45/6T50 (MH8, MH9) 17-249
Park Pawl Actuator Installation

ttttuttttttttttt-‘x

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1891436
Park Pawl Actuator Installation
Callout Component Name
1 Park PawlActuatorAssembly
2 ManualShiftDetent(w/ShaftPositionSwitch)LeverAssembly
ManualShaft
3
Tip: LubricatetheshaftwithATF to preventdamageto themanualshiftshaftseal duringinstallation.
ManualShaftDetentLeverHubPin
Caution: Referto FastenerCautiononpage 0—8.
Procedure
Installthemanualshaftdetentleverhub pinto correctheight.
Tip: Use a NEW pinto ensureproperengagementwiththeshaft.
Specification
7.9mm(0.38in)(b)
Special Tools
DT—48550 DetentLeverPin Remover
Forequivalentregionaltools,referto Special Toolsonpage 17-394.

2013
—
Sonic
(US/Canada)
Service
Manual
(5377994)
17-250 Automatic Transmission 9 6T30/6T40/6T45/6T50 (MH8, MH9)

Park Pawl Actuator Installation (cont'd)

Callout Component Name
ManualShiftShaftPin
Caution: Use themanualshaftpininstallertoinstallthepinat thecorrectheightin orderto properlysecurethe
manualshaft.Ifyouinstallthepintoodeep,thecase boremaycrack.
Procedure
inspectpininstalledheightis withinspecifications.
Tip: Use a NEW pintoensureproperengagementwiththecase.
Specification
7.2—8.2 mm(0.28—O.321n)(a)
Special Tools
DT-41229ManualShaftPin Installer
For equivalentregionaltools,referto Special Toolsonpage 17-394.

Manual Shift Shaft Seal Installation

2033225
Manual Shift Shaft Seal Installation
Callout Component Name
ManualShiftShaftSeal
Special Tool
DT-49101Seal Installer
For equivalentregionaltools,referto Special Toolsonpage 17—394.

(US/Canada)
9Sonlc
2013 (5377994)
Manual
Service
 Automatic Transmission - 6T30/6T40/6T45/6T50 (MH8, MH9) 17-251

2-6 Clutch Piston Installation (6T30)

‘ 1

1891330
2-6 Clutch Piston Installation (6T30)
Callout Component Name
2—6ClutchPistonAssembly
Tip:
' Positionthe2—6pistonair bleedandlargeslottowardthetopof thecase.
1 - DT-48271sea|protectorpreventsthepistonsea|lipfromdamageduringinstallation.Applya thincoatof
ATF tothe1D.of theDT—48271 seal protectortoease Installationofthepiston.
Special Tool
DT—48271 Seal Protector
For equivalentregionaltools,referto Special Toolsonpage 17—394.
2 2—6ClutchSpring
2—6ClutchSpringRetainer
Caution: Regulatetheair pressureto 276kPa (40psi)maximum.Highpressurecouldcause thepistontoover
travelanddamagethepistonseals.
Tip:
- Place theretaineronthe2-6clutchspringandaligntheretaineropeningwiththe largestgap in thecase
3 tslféirggzéoward
thebottomofthecase.The retaineropeningshouldbe supportedbya splinetoothof

- Applyshopairtotheclutchfluidfeedholein thecase toverifyproperpistonoperation.

Special Tools
- DT—48272 SpringInstaller
- DT—48056 SpringCompressorBridge
For equivalentregionaltools,referto Special Toolsonpage 17—394.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
17-252 Automatic Transmission - 6T30/6T40/6T45/6T50 (MH8, MH9)

2-6 Clutch Piston Installation (6T40l45l50)

77> .

1891330
2-6 Clutch Piston Installation (6T40l45l50)
Callout Component Name
2—6ClutchPistonAssembly
Tip:
- Positionthe2—6pistonairbleedandlargeslottowardthetopof thecase.
0 DT—47796 seal protectorpreventsthepistonsea|lipfromdamageduringinstallation.Applya thincoatof W-M
wwm
.,.
,
ATF to theID. of theDT—47796 sea|protectortoease installationofthepiston.
Special Tool
DT-47796Seal Protector
For equivalentregionaltools,referto Special Toolsonpage 17-394.
2~6ClutchSpring
2—6ClutchSpringRetainer
Caution: Regulatetheair pressureto 276kPa (40psi)maximum.Highpressurecouldcausethepistontoover
travelanddamagethepistonseals.
Tip:
- Place theretaineron the2-6clutchspringandaligntheretaineropeningwiththelargestgapinthecase
splinestowardthebottomofthecase.The retaineropeningshouldbesupportedby a Splinetoothof
thecase.
- Applyshopairto theclutchfluidfeedholein thecase to verifyproperpistonoperation.
Special Tools
- DT—47797Spring Installer
- DT—48056 SpringCompressorBridge
For equivalentregionaltools,referto Special Toolsonpage 17—394.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Automatic Transmission 9 6T30/6T40/6T45/6T50 (MH8, MH9) 179253

Low and Reverse and 1-2-3-4 Clutch Housing, Low and Reverse Clutch
Assembly, Output Sun Gear, and 2-6 Clutch Plate Disassemble (Gen 1)

1891331

Low and Reverse and 1-2-3-4 Clutch Housing, Low and Reverse Clutch Assembly, Output
Sun Gear, and 2-6 Clutch Plate Disassemble (Gen 1)
Callout Component Name
1 1—2—3—4 ClutchBackingPlate
2 1—2—3—4 ClutchPlateAssembly(Qty:2)
3 1—2—3—4 ClutchPlate(Qty:2)
4 1—2—3—4 ClutchWavedPlate
5 OutputSun Gear ThrustBearingAssembly
Tip: Thesun gearthrustbearingmaybe stucktothedrivensprockethub.
6 OutputSun Gear Assembly
7 Low-Reverseand 1—2—3—4 ClutchHousingAssembly
8 LowandReverseClutchApplyPlate
9 LowandReverseClutchPlate(Qty:3)
10 LowandReverseClutchPlateAssembly(Qty:3)
11 LowandReverseClutchBackingPlate
12 LowandReverseClutchAssembly(OWC)
13 2—6ClutchPlateAssembly(Qty:2)
14 2—6ClutchPlate(Qty:1)

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
17-254 Automatic Transmission - 6T30/6T40/6T45/6T50 (MH8, MH9)

Low and Reverse and 1-2-3-4 Clutch Housing, Low and Reverse Clutch
Assembly, Output Sun Gear, and 2-6 Clutch Plate Disassemble (Gen 2)

Low and Reverse and 1-2-3-4 Clutch Housing, Low and Reverse Clutch Assembly, Output
Sun Gear, and 2-6 Clutch Plate Disassemble (Gen 2)
Callout Component Name
1 1—2—3—4
ClutchBackingPlate
2 1—2—3—4
ClutchPlateAssembly(Qty:2)
3 1—2—3—4
ClutchPlate(Qty:2)
4 1—2—3—4
ClutchWavedPlate
5 OutputSun GearThrustBearingAssembly
Note: Thesungearthrustbearingmaybe stucktothedrivensprockethub.
6 OutputSun GearAssembly
7 Low-Reverseand 1—2—3—4ClutchHousingAssembly
8 LowandReverseClutchApplyPlate
9 LowandReverseClutchPlate(Qty:3)
10 LowandReverseClutchPlateAssembly(Qty:3)
11 LowandReverseClutchBackingPlate
12 LowandReverseClutchAssembly(OWC)
13 2—6ClutchPlateAssembly(Qty:2)- ModelDependent
Note: The numberof groovesin theclutchplatefrictionmaterialvariesdependingon model.
14 2—6ClutchPlate(Qty:1)

2013
—
Sonic
(US/Canada)
Service
Manual
(5377994)
 Automatic Transmission - 6T30/6T40I6T45/6T50 (MH8, MH9) 179255
Input, Reaction, and Output Carrier Disassemble

1891335
Input, Reaction, and Output Carrier Disassemble
Callout Component Name
OutputCarrierAssembly
Note:
- The6T30andBT40have4 pinions.
- The6T45and6T50have 5 pinions.
OutputCarrierThrustBearingAssembly
InputSun Gear ThrustBearingAssembly
InputCarrierAssembly
Note:
- The6T30and6T4Ohave4 pinions.
- The6T45and6T50have5 pinions.
InputSun Gear
InputSun Gear ThrustBearingAssembly
InputCarrierThrustBearingAssembly
ReactionCarrierAssembly
Note: Startingin 2012,all 6T30/40/45/50
modelshave3 pinionreactioncarriers.The 3 pinionreactioncarriers
are backserviceableforall models.
Original Configuration:
- The6T30and6T4Ohad3 pinions.
- The6T45and6T50had4 pinions.
ReactionCarrierSun Gear Assembly
ReactionCarrierSun Gear ThrustBearing
10
Note: Thesun gearthrustbearingmaybe stucktothesun gear.
2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
17-256 Automatic Transmission - 6T30/6T40I6T45/6T50 (MH8, MH9)

Input, Reaction, and Output Carrier Disassemble (cont'd)

Callout Component Name
11 3—5Reverseand4—5—6
ClutchHousingAssembly

3-5-Reverse and 4-5-6 Clutch Housing Disassemble (6T30/40I45/50 - Gen 2)

Turbine Shaft, Reluctor Wheel and Piston Removal

-WM
...

2552953
Turbine Shaft, Reluctor Wheel and Piston Removal
Callout Component Name
TurbineShaftRetainerRing
Tip: Discardtheretainerring.Itis notre—usable.
Special Tools
GE 5586-ASnap Ring Pliersor equivalent
Forequivalentregionaltools,referto Special Toolsonpage 17-394.
TurbineShaft
ReactionCarrierHubAssembly
ReactionCarrierHubThrustBearingAssembly

2013
—Sonic
(US/Canada)
Service
Manual
(5377994)
 Automatic Transmission . 6T30/6T40I6T45/6T50 (MH8, MH9) 17-257
4—5—6 Clutch Plate Removal

2552955
4—5—6 Clutch Plate Removal
Callout Component Name
1 4~5—6
ClutchBackingPlateRetainingRing
2 4—5—6
ClutchBackingPlate
3 4—5—6
ClutchPlateAssembly(Qty:5)
4 4—5—6
ClutchPlate(Gen2 —Qty:5)

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
‘17-258 Automatic Transmission - 6T30/6T40I6T45/6T50 (MH8, MH9)

4—5—6 Clutch Piston Removal

2552957
4—5—6 Clutch Piston Removal
Callout Component Name
4—5—6 ClutchDamRetainingRing
Tip: The4-5-6clutchdamretainingringis notreusable.
Special Tools
' DT—47951-2 SpringCompressor
- GE 5586-ASnap RingPliersor equivalent
For equivalentregionaltools,referto SpecialToolsonpage 17-394.
4—5—6 ClutchPistonFluidDamAssembly
Procedure
1. Place the3—5reverseand4—5—6 clutchhousingontothesupporthubinthecase.
2. Applyshopairtothe4—5—6 clutchfeedholeusinga rubbertippedairguntodislodgethedampistonand
the4—5—6 clutchpistonfromtheclutchhousing.
4—5—6 ClutchPistonReturnSpringAssembly
4—5—6 ClutchPiston
Tip: Applyshopairtothe4—5—6 clutchfeedholeusinga rubbertippedairguntodislodgetheclutchpiston.
4—5—6 ClutchPistonInnerSeal
4—5—6 ClutchPistonOuterSeal (DarkBlue)(Stepped)
4—5—6 ClutchPistonOuterSeal (Large)(Rounded)

2013
—
Sonic
{US/Canada)
Service
Manual
(5377994)
 Automatic Transmission - 6T30/6T40I6T45/6T50 (MH8, MH9) 17-259
Reluctor Wheel and Piston Removal

1891344
Reluctor Wheel and Piston Removal
Callout Component Name
InputShaftSpeed SensorReluctorRing RetainerRing
Caution: Compressthereluctorwheeljustenoughto cleartheretainer.Overcompressingthereluctorwheel
willbreakthealignmenttabandtheclutchhousing.
Special Tool
DT—47694 PistonSpringCompressor
Forequivalentregionaltools,referto Special Toolsonpage 17-394.
inputShaftSpeed SensorReluctorWheel
3—5ReverseClutchPiston
3—5ReverseClutchPistonReturnSpringAssembly
3—5ReverseClutchPistonInner(Reluctor)Seal (Orange)
3—5ReverseClutchPistonInnerSeal
\lmm-POJN
3—5ReverseClutchPistonDamSeal (Black)

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
17-260 Automatic Transmission - 6T30/6T40I6T45/6T50 (MH8, MH9)
3—5 Reverse Clutch Plate Removal

__
2552958
3—5 Reverse Clutch Plate Removal
Callout Component Name
1 3—5ReverseClutchBackingPlateRingRetainerRing
Tip: Gentlypushdownonthebackingplateto getenoughclearancebetweenthebackingplateandretainer.
2 3—5ReverseClutchBackingPlate
3 3—5ReverseClutchPlateAssembly(Qty:3)
4 3—5ReverseClutchPlate(Qty:3)
5 3—5ReverseClutchApplyPlate(Waved)

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Automatic Transmission - 6T30/6T40/6T45/6T50 (MH8, MH9) 17-261

3-5-Reverse and 4-5-6 Clutch Housing Assemble (6T30/40/45l50 - Gen 2)

4—5—6 Clutch Piston Installation

2552959
4—5—6 Clutch Piston installation
Callout Component Name
1 4—5—6 ClutchPistonInnerSeal
2 4—5—6 ClutchPistonOuterSeal (Large)(Rounded)
3 4—5—6 ClutchPistonOuterSeal (DarkBlue)(Stepped)
4—5—6 ClutchPiston
Tip:
DT—47805 sea|protectorpreventsthepistonseal lipfromdamageduringinstallation.Applya thincoatof
ATF tothe l.D.of DT—
47805seal protectorto ease theinstallationof thepiston.
4 DT-47951-2 springcompressorcan be usedas a pusherif necessary.
Special Tools
- DT— 47805Seal Protector
. DT—47951-2 SpringCompressor
Forequivalentregionaltools,referto Special Toolsonpage 17—394.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
17-262 Automatic Transmission - 6T30/6T40I6T45/6T50 (MH8, MH9)

4—5—6 Clutch Fluid Dam Installation

2552961
4—5—6 Clutch Fluid Dam Installation
Callout Component Name
1 4—5—6 ClutchPistonReturnSpringAssembly
4—5—6 ClutchPistonFluidDamAssembly
Tip: The seal protectorpreventsthedamseal lipfromdamageduringinstallation.Applya thincoatofATF tothe
ID. oftheseal protectorto ease theinstallationofthedam.
2 Special Tools
- DT—47951-1 Seal Protectorfor6T40/45applications
- DT—50117 Seal Protectorfor6T50applications
For equivalentregionaltools,referto Special Toolsonpage 17-394.
4—5—6 ClutchDamRetainingRing
Caution: Regulatetheair pressureto276kPa (40psi)maximum.Highpressurecouldcausethepistontoover
travelanddamagethepistonseals.
Procedure
1. Leavetheseal protectoron theclutchhousingwhileinstallingtheretainingring.Installthedamnretainer
clipsDT50117-1seal protectorto holdtheseal protectorin place.
2. Use DT46620—2 retainingclipsandDT50573ringguideto installa NEW 4-5-6clutchdamretainingring.
3 Assemblethering“L”legfacingdown,DT50573andDT46620and insertas an assemblyontotheclutch
hubto installthering.
3. Place thehousingassemblyontotheinputshaftsupportinsidethecase.Applyshopair totheclutchfluid
feedholein thecase toverifyproperpistonoperation.
Special Tools
- DT—47951-2 SpringCompressor
- DT46620Seal Installer
' DT50117-1Seal Protector

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Automatic Transmission —6T30/6T40I6T45/6T50 (MH8, MH9) 17-263

4—5—6 Clutch Fluid Dam Installation (cont'd)

Callout Component Name
- DT50117—2 Seal ProtectorRetainingClips
- DT50573RetainingRing Installer
Forequivalentregionaltools,referto Special Toolsonpage 17-394.

3—5 Reverse Clutch Plates Installation

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2552963
3—5 Reverse Clutch Plates Installation
Callout Component Name
1 3—5ReverseClutchApplyPlate (Waved)
2 3—5ReverseClutchPlate (Qty:3)
3 3—5ReverseClutchPlate Assembly(Qty:3)
4 3—5ReverseClutchBackingPlate
5 3—5ReverseClutchBackingPlate Ring RetainerRing

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
17-264 Automatic Transmission - 6T30/6T40I6T45/6T50 (MH8, MH9)
Reluctor Wheel and Piston Installation

‘mfii
-fi

1891348
Reluctor Wheel and Piston Installation
Callout Component Name
1 3—5ReverseClutchPistonDamSeal (Black)
3—5ReverseClutchPistonlnnerSeal
3—5ReverseClutchPistonInner(Reluctor)Seal (Orange)
3—5ReverseClutchPistonReturnSpringAssembly
3—5ReverseClutchPiston
0301-waInputShaftSpeedSensorReluctorWheel
InputShaftSpeedSensorReluctorRingRetainerRing
Caution: Compressthereluctorwheeljustenoughtocleartheretainer.Overcompressingthereluctorwheel
willbreakthealignmenttabandtheclutchhousing.
Caution: Regulatetheair pressureto276kPa (40psi)maximum.Highpressurecouldcausethepistontoover
travelanddamagethepistonseals.
Procedure
Place thehousingassemblyontotheinputshaftsupportinsidethecase.Applyshopairtothe clutchfluidfeed
holein thecase toverifyproperpistonoperation.
Special Tools
DT—47694 PistonSpringCompressor
For equivalentregionaltools,referto Special Toolsonpage 17-394.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Automatic Transmission - 6T30/6T40I6T45/6T50 (MH8, MH9) 179-265
4—5-6 Clutch Plates Installation

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WM

4.
2%,.
.__..WM
2..

2552966
4—5—6 Clutch Plates Installation
Callout Component Name
1 ReactionCarrierHubThrustBearingAssembly
ReactionCarrierHubAssembly
4—5—6 ClutchPlateAssembly(Qty:5)
4—5—6 ClutchPlate(Qty:5)
495—6ClutchBackingPlate
OCJ'l-h-OJN
4—5—6 ClutchBackingPlateRetainingRing

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
17—266 Automatic Transmission - 6T30/6T40I6T45/6T50 (MH8, MH9)
Turbine Shaft Installation

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1891372
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ww
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.
Turbine Shaft Installation
Callout Component Name
1 TurbineShaft
TurbineShaftRetainerRing
Tip: Do notre—usetheturbineshaftretainerring.
2 Special Tools
GE 5586—A Snap Ring Pliersor equivalent
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,.
....-
Forequivalentregionaltools,referto Special Toolsonpage 17-394.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Automatic Transmission - 6T30/6T40I6T45/6T50 (MH8, MH9) 17-267

Input, Reaction, and Output Carrier Assemble (Gen -1)

12

13

12

1891373
Input, Reaction, and Output Carrier Assemble (Gen 1)
Callout Component Name
1 3—5Reverseand4—5—6 ClutchHousingAssembly
2 ReactionCarrierSun GearThrustBearing
3 ReactionCarrierSun GearAssembly
ReactionCarrierAssembly
Note: Startingin 2012,all 6T30/40/45/50
modelshave3 pinionreactioncarriers.The 3 pinionreactioncarriers
are backserviceableforall models.
OriginalConfiguration:
- The6T30and6T40had3 pinions.
' The6T45and6T50had4 pinions.
InputCarrierThrustBearingAssembly
InputSun Gear ThrustBearingAssembly
InputCarrierAssembly
Note:
- The6T30and6T40have4 pinions.
' The6T45and6T50have5 pinions.
InputSun Gear
InputSun Gear ThrustBearingAssembly
10 OutputCarrierThrustBearingAssembly

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
17-268 Automatic Transmission 9 6T30/6T40I6T45/6T50 (MH8, MH9)

Input, Reaction, and Output Carrier Assemble (Gen 1) (cont'd)

Callout Component Name
OutputCarrierAssembly
11 Note:
' The6T30and6T40have4 pinions.
' The6T45and6T50have5 pinions.
12 2—6ClutchPlateAssembly(Qty:2)
Note: Beginwiththeclutchplateassemblyandalternatewiththeclutchplate.
13 2—6ClutchPlate(Qty:1)
Note: Onlyinstallone 2—6ClutchPlateat thistime.The remainingclutchplateis installedintothecase.

Input, Reaction, and Output Carrier Assemble (Gen 2)

2552968
Input, Reaction, and Output Carrier Assemble (Gen 2)
Callout Component Name
1 3—5Reverseand4—5—6 ClutchHousingAssembly
2 ReactionCarrierSun GearThrustBearing
3 ReactionCarrierSun GearAssembly
ReactionCarrierAssembly
Note: Startingin 2012,all 6T30/40/45/50
modelshave3 pinionreactioncarriers.The 3 pinionreactioncarriers
4 are backserviceableforall models.
Original Configuration:
- The6T30and6T40had3 pinions.
~The6T45and6T50had4 pinions.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Automatic Transmission 996T30/6T40/6T45/6T50 (MH8, MH9) 179269

Input, Reaction, and Output Carrier Assemble (Gen 2) (cont'd)

Callout Component Name
5 InputCarrierThrustBearingAssembly
6 InputSun GearThrustBearingAssembly
InputCarrierAssembly
7 Note:
- The 6T30and6T40have4 pinions.
- The 6T45and6T50have5 pinions.
InputSun Gear
InputSun Gear ThrustBearingAssembly
10 OutputCarrierThrustBearingAssembly
OutputCarrierAssembly
Note:
11
' The6T30and6T40have4 pinions.
- The6T45and6T50have5 pinions.
2—6ClutchPlateAssembly(Qty:2)- ModelDependent
Note:
12
9 Beginwiththeclutchplateassemblyand alternatewiththeclutchplate.
- The numberofgroovesin theclutchplatefrictionmaterialvariesdependingonmodel.
13 2—6ClutchPlate(Qty:1)
Note: Onlyinstallone 2—6ClutchPlateat thistime.The remainingclutchplateis installedintothecase.

345-Reverse and 4-5-6 Clutch Housing, and Input, Reaction, and Output
Carrier Installation .

1891378

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
17-270 Automatic Transmission - 6T30/6T40I6T45/6T50 (MH8, MH9)

3-5-Reverse and 4-5-6 Clutch Housing, and Input, Reaction, and Output Carrier Installation
Callout Component Name
1 3—5Reverseand4—5—6 ClutchHousingThrustBearing
2 2—6 ClutchApplyPlate(Waved)
2—6ClutchPlate(Qty:1)
Tip:
3 - Onlyinstallone2—6ClutchPlate.The remainingclutchplateis installedwiththegearsetassembly.
- Alignthelargeflatareaswiththevalvebodyendof thecase andthe2 tabsontheclutchplatethatareclose
to each otherwiththeslotsatthebottomrightcornerof thecase.
3—5Reverseand4—5—6 ClutchHousingAssemblyandGearset
4 Tip: Alignthelargeflatareasof the2—6ClutchPlatewiththevalvebodyendofthecase andthe2 tabsonthe
clutchplatethatareclosetoeachotherwiththeslotsat thebottomrightcornerofthecase.

Low and Reverse Clutch Assembly and Low and Reverse Clutch Plate
Installation

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1891390

Low and Reverse Clutch Assembly and Low and Reverse Clutch Plate Installation
Callout Component Name
Lowand ReverseClutchAssembly(OWC)
Note:
' The LowandReverseClutchAssemblyshouldrotatefreelyin onedirectionandlockin theopposite
direction.
- AlignthelargeflatareasoftheLowandReverseClutchAssemblywiththevalvebodyendofthecase.
Lowand ReverseClutchBackingPlate
Lowand ReverseClutchPlateAssembly(Qty:3)

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
 Automatic Transmission - 6T30/6T40/6T45/6T50 (MH8, MH9) 17-271

Low and Reverse Clutch Assembly and Low and Reverse Clutch Plate Installation (cont'd)
Callout Component Name
4 Lowand ReverseClutchPlate(Qty:3)
Note: AlignthelargeflatareasoftheLowand ReverseClutchPlatewiththevalvebodyend ofthecase.
LowandReverseClutchApply (Waved)Plate
Note:
5 - Alignthe|argeflatareasoftheLowand ReverseClutchApplyPlatewiththevalvebodyendofthecase.
- Ensurethecorrectwavedplateis beinginstalled.The 1—2—3—4 clutchandlowandreverseciutchwaved
platesarevisuallysimilar,howeverthelowand reverseclutchwavedplateis thicker.

Low and Reverse and 1-2-3-4 Clutch Housing Disassemble

Low and Reverse Clutch Piston Removal

C 1

C, 2

C — 3

1891392
Low and Reverse Clutch Piston Removal
Callout Component Name
Lowand ReverseClutchSpringRetainer
1 Special Tool
GE-8059Snap Ring Pliers—ParallelJaw
Forequivalentregionaltools,referto Special Toolsonpage 17—394.
2 Lowand ReverseClutchSpring
3 Lowand ReverseClutchPiston

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
17-272 Automatic Transmission - 6T30/6T40I6T45/6T50 (MH8, MH9)

1—2—3—4 Clutch Piston Removal

6 .
Q

h
1891395
1—2—3—4Clutch Piston Removal
Callout Component Name
1—2—3—4 ClutchSpringRetainer
Special Tool
GE-8059Snap Ring Pliers—‘Paralie| Jaw
For equivalentregionaltools,referto SpecialToolsonpage 17-394.
1—2—3—4 ClutchSpring
1—2—3~4 ClutchPiston

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Automatic Transmission - 6T30/6T40I6T45/6T50 (MH8, MH9) 17-273
Low and Reverse and 1-2-3-4 Clutch Housing Cleaning and Inspection

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w H.222,
Low and Reverse and 1-2-3-4 Clutch Housing Cleaning and Inspection
Callout I Component Name
Caution: Aftercleaningthetransmissioncomponents,allowto airdry.Do notuse Clothor papertowelsin ordertodryany
transmissioncomponents.Lintfromthetowelscan cause componentfailure.
Caution: Do notreusecleaningsolvents.Previouslyusedsolventsmaydepositsedimentwhichmaydamagethecomponent.
PreliminaryProcedures
1. Thoroughlycleanthehousingwithclean solvent.
2. Inspectthepistonboresandretainerringgroovesforwear,damageor porosity.
1 1—2—3—4 ClutchSpringRetainerGroove
1—2—3—4 ClutchPistonBore
LowandReverseClutchSpringRetainerGroove
LowandReverseClutchPistonBore
ClutchOil Passages
0301-meAir BleedPassages

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
17-274 Automatic Transmission - 6T30/6T40I6T45/6T50 (MH8, MH9)

Low and Reverse and 1-2-3-4 Clutch Housing Assemble (6T30)

1—2—3—4 Clutch Piston Installation

-mw
.mfi

1891402
1—2—3—4Clutch Piston Installation
Callout Component Name
1—2—3—4 ClutchPiston
Tip: DT—48273 sea|protectorpreventsthepistonsea|lipfromdamageduringinstallation.Applya thincoatof
ATF totheID.of DT—48273 seal protectortoease theinstallationofthepiston.
Special Tool
DT-48273Seal Protector
For equivalentregionaltools,referto Special Toolsonpage 17—394.
1—2—3—4 ClutchSpring
1—2—3—4 ClutchSpringRetainer
Caution: Regulatetheair pressureto276kPa (40psi)maximum.Highpressurecouldcausethepistontoover
travelanddamagethepistonseals.
Tip:
1. Place theretainerontoDT-48274-1whichis partof DT—48274 springinstaller.Compressingthespringusing
DT-48274-2whichis partof DT—48274 springinstaller,willinstalltheretainerintotheretainergroove.
2. Applyshopairto theclutchfluidfeedholein theclutchhousingtoverifyproperpistonoperation.
Special Tool
DT—48274 ClutchPistonSpringInstaller
For equivalentregionaltools,referto Special Toolsonpage 17—394.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Automatic Transmission - 6T30/6T40I6T45/6T50 (MH8, MH9) 172275
Low and Reverse Clutch Piston Installation

22>”

1891404
Low and Reverse Clutch Piston Installation
Callout Component Name
LowandReverseClutchPiston
Tip: DT—48273 sea|protectorpreventsthepistonsea|tipfromdamageduringinstallation.Applya thincoatof
ATF totheID. of DT-48273sea|protectortoease theinstallationof thepiston.
Special Tool
DT—48273 ClutchPistonSeal Protector
For equivalentregionaltools,referto Special Toolsonpage 17—394.
LowandReverseClutchSpring
LowandReverseClutchSpringRetainer
Caution: Regulatetheair pressureto276kPa (40psi)maximum.Highpressurecouldcausethepistonto over
travelanddamagethepistonseals.
Tip:
1. Placethe retainerontoDT—48274-1 whichis partof DT-48274springinstaller.Compressingthespringusing
DT-48274-2whichis partof DT—48274 springinstaller,willinstalltheretainerintothe retainergroove.
2. Applyshopairtotheclutchfluidfeed holein theclutchhousingtoverifyproperpistonoperation.
Special Tool
DT—48274 SpringInstaller
Forequivalentregionaltools,referto Special Toolsonpage 17—394.

2013
-Sonic
(US/Canada}
Service
Manual
(5377994)
17-275 Automatic Transmission - 6T30/6T40I6T45/6T50 (MH8, MH9)

Low and Reverse and 1-2-3-4 Clutch Housing Assemble (6T40l45l50)

1—2—3—4 Clutch Piston Installation

1891402

1—2—3—4Clutch Piston Installation

Callout Component Name
1—2~3—4 ClutchPiston
Tip: DT—47798 seal protectorpreventsthepistonsea|lipfromdamageduringinstallation.Applya thincoatof
ATF to theID. of DT—47798 sea|protectortoease theinstallationofthepiston.
Special Tool
DT-47798Seal Protector
For equivalentregionaltools,referto Special Toolsonpage 17—394.
1_2_3_4ClutchSpring
1—2—3~4 ClutchSpringRetainer ‘
Caution: Regulatetheair pressureto276kPa (40psi)maximum. H ighpressurecouldcause thepistontoover
travelanddamagethepistonseals.
Tip:
1. Place theretainerontoDT-47799-1whichis partof DT-47799springcompressor.Compressingthespring
usingDT-47799—2 whichis partof DT—47799 springcompressor,willinstalltheretainerintotheretainer
groove.
2. Applyshopairto theclutchfluidfeedholein theclutchhousingtoverifyproperpistonoperation._
Special Tool
DT—47799 ClutchPistonSpringCompressor
For equivalentregionaltools,referto Special Toolsonpage 17—394.

—
2013 (US/Canada)
Sonic (5377994)
Manual
Service
 Automatic Transmission - 6T30/6T40I6T45/6T50 (MH8, MH9) 17-277

Low and Reverse Clutch Piston Installation

é;

1891404
Low and Reverse Clutch Piston Installation
Callout Component Name
LowandReverseClutchPiston
Tip: DT—47807 seal protectorpreventsthepistonseal lipfromdamageduringinstallation.Applya thincoatof
ATF totheID. of DT-47807sea|protectortoease theinstallationof thepiston.
1 Special Tool
DT—47807 ClutchPistonSeal Protector
For equivalentregionaltools,referto SpecialToolsonpage 17—394.
2 LowandReverseClutchSpring "
LowandReverseClutchSpringRetainer
Caution: Regulatetheair pressureto276kPa (40psi)maximum.Highpressurecouldcausethepistontoover
travelanddamagethepistonseals.
Tip:
1. PlacetheretainerontoDT—47794-1 whichis partof DT—47794springcompressor.Compressingthespring
3 usingDT-47794—2 whichis partof DT-47794springcompressor,willinstalltheretainerintotheretainer
groove.
2. Applyshopairto theclutchfluidfeedholein theclutchhousingtoverifyproperpistonoperation.
Special Tool _ ‘
DT-47794SpringCompressor
Forequivalentregionaltools,referto SpecialToolsonpage 17—394.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
172278 Automatic Transmission - 6T30/6T40I6T45/6T50 (MH8, MH9)

Low and Reverse and 1-2-3-4 Clutch Housing, and 1-2-3-4 Clutch Plate
Installation (6T30)

Bf KC”
7

1891407

Low and Reverse and 1-2-3-4 Clutch Housing, and 1-2-3-4 Clutch Plate Installation (6T30)
Callout Component Name
1 LowandReverseand 1—2—3—4 ClutchHousing
Tip: The longerlegsface thebottomofthecase andtheoil passagesfacethevalvebodyendofthecase.
2 OutputSun GearAssembly
3 1—2—3—4 ClutchWavedPlate
Tip: Alignthesinglepairof tabswiththebottomvalvebodyendofthecase.
4 1—2—3—4 ClutchPlate(Qty:2) .._
\.e
.2m_
V
5 1—2—3—4 ClutchPlateAssembly(Qty:2)
6 1—2—3—4 ClutchBackingPlate
Tip: Alignthesingletabwiththecase splinefacingthebottomofthecase.
1—2—3—4 ClutchBackingPlate RetainerRing
Warning: Theretaineris under tension. Use care whenremoving or installing theretainer.Personal
injury could result.
Caution: Use cautionduringremovalor installationoftheretainerringto avoiddamageto thecase machined
surfaceintheparkpawlarea.Burrsor raisededgesonthecase machinedsurfacecan causetheparkpawlto
7 bindandprohibititfromengagingtheparkgear.
Tip:
- Installtheretainerwiththetaperfacingawayfromthebackingplate.
- Aligntheretaineropeningwiththelargestgapinthecase splinestowardthebottomofthecase.
. installone endof theretainerintotheretainerringgroove.Use DT—28585 snap ringremoverandworkthe
retainerintothecase groove.Use a screwdriverto holdtheretainerawayfromthecase whilepushingdown
ontheretainerwithDT—28585 snap ringremover.

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
 Automatic Transmission - 6T30/6T40I6T45/6T50 (MH8, MH9) 17-279

Low and Reverse and 1-2-3-4 Clutch Housing, and 1-2-3-4 Clutch Plate Installation (6T30)
(cont'd)
Callout Component Name
Special Tool
DT-28585Snap RingRemoveror equivalent
For equivalentregionaltools,referto Special Toolsonpage 17-394.
AM.
_MM_
Low and Reverse and 1-2-3-4 Clutch Housing, and 1-2-3-4 Clutch Plate
Installation (6T40l45l50)

5' ”<3 (>4

1891407
Low and Reverse and 1-2-3-4 Clutch Housing, and 1-2-3-4 Clutch Plate Installation (6T40/
45/50)
Callout Component Name
1 LowandReverseand 1—2—3—4 ClutchHousing
Note: Thelongerlegsface thebottomofthecase andtheoil passagesfacethevalvebodyendofthecase.
2 OutputSun GearAssembly
1—2—3—4ClutchWavedPlate
Note:
3 - Alignthesinglepairoftabswiththebottomvalvebodyendofthecase.
' Ensurethecorrectwavedplateis beinginstalled.The 1—2—3—4 clutchandlowandreverseclutchwaved
platesarevisuallysimilar,howeverthelowand reverseclutchwavedplateis thicker.
4 1—2—3—4ClutchPlate(Qty:2)
5 1—2—3—4ClutchPlateAssembly(Qty:2)
6 1—2—3—4 ClutchBackingPlate
Note: Alignthesingleskinnytabwiththecase splinefacingthetopof thecase.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
17-280 Automatic Transmission - 6T30/6T40I6T45/6T50 (MH8, MH9)

Low and Reverse and 1-2-3-4 Clutch Housing, and 1-2-3-4 Clutch Plate Installation (6T40/
45/50) (cont'd)
Callout Component Name
1—2—3—4 ClutchBackingPlateRetainerRing
Warning: Theretaineris under tension. Use care when removing or installing theretainer.Personal
injury could result.
Caution: Use cautionduringremovalor installationoftheretainerringtoavoiddamagetothecase machined
surfacein theparkpawlarea.Burrsor raisededgeson thecase machinedsurfacecancausetheparkpawlto
bindand prohibititfromengagingtheparkgear.
Note:
- Installtheretainerwiththetaperfacingawayfromthe backingplate.
- Aligntheretaineropeningwiththelargestgapin thecase splinestowardthebottomofthecase.
- lnstalloneendoftheretainerintotheretainerringgroove.Use DT-28585snapringremoverandworkthe
retainerintothecase groove.Use a screwdriverto holdtheretainerawayfromthecase whilepushingdown
on theretainerwithDT-28585snapringremover.
Special Tool
DT—28585 Snap Ring Removeror equivalent
Forequivalentregionaltools,referto Special Toolsonpage 17-394.

Drive Sprocket, Driven Sprocket, and Drive Link Cleaning and Inspection

2ka
..m
..2-“
,...

1891326

Drive Sprocket, Driven Sprocket, and Drive Link Cleaning and Inspection
Callout Component Name
1 DriveSprocketThrustWasher
2 DriveSprocketRetainerRing
3 DriveSprocket

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
 Automatic Transmission - 6T30/6T40I6T45/6T50 (MH8, MH9) ’17-281

Drive Sprocket, Driven Sprocket, and Drive Link Cleaning and Inspection (cont'd)
Callout Component Name
4 DriveSprocketBearingAssembly
5 ParkGear
6 DrivenSprocket
7 DriveLinkAssembly
Ewew
w.
,

Drive and Driven Sprocket, Drive Link, and Park Pawl Installation (6T30)

M
.,”_
22.2,22..-
2202232
Drive and Driven Sprocket, Drive Link, and Park Pawl Installation (6T30)
Callout Component Name
1 FrontDifferentialCarrierBaffle
2 BaffleRetainer
FrontDifferentialCarrierBaffleBoltM6x 16(Qty:2)
Caution: RefertoFastenerCautiononpage 0-8.
Tighten
12N-m(106lbin)
DriveLinkLubeScoopSeal
DriveLinkLube FluidSeal
DriveLinkLubeScoop
DrivenSprocketBearingAssembly
oowoacnh
DriveSprocketBearingAssembly

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
’17-282 Automatic Transmission - 6T30/6T40I6T45/6T50 (MH8, MH9)

Drive and Driven Sprocket, Drive Link, and Park Pawl Installation (6T30) (cont'd)
Callout Component Name
DrivenSprocketAssembly,DriveSprocketAssemblyand DriveLink
Tip:
- installthedrivelinkwiththecoloredlinksandlorpartnumberfacingup.
9 - Thedrivelink,drive,anddrivensprocketassembliesmustbe installedatthesametime.
- The ballbearingshouldspinfreelyandsmoothly.
- Thedrivensprocketballbearinginnerracehas a slightinterferencefitwiththecase.Tapgentlywiththe
palmofa handor a softtiphammertoinstall.
10 Park Pawl
11 Park PawlSpring
Park PawlShaft
12
Tip: Check toensurethattheparkpawloperatesfreelyand is notbinding.

Drive and Driven Sprocket, Drive Link, and Park Pawl Installation (6T40l45l50)

1891417
Drive and Driven Sprocket, Drive Link, and Park Pawl Installation (6T40l45l50)
Callout Component Name
1 FrontDifferentialCarrierBaffle
FrontDifferentialCarrierBaffleBoltM6x 16(Qty:2)
Caution: Referto FastenerCautiononpage0—8.
2 Tighten
12N°m(106lb in)
DriveLinkLubeScoop Seal
DriveLinkLubeFluidSeal

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Automatic Transmission . 6T30/6T40I6T45/6T50 (MH8, MH9) 17-283
Drive and Driven Sprocket, Drive Link, and Park Pawl Installation (6T40l45l50) (cont'd)
Callout Component Name
5 DriveLinkLubeScoop
6 DrivenSprocketBearingAssembly
7 DriveSprocketBearingAssembly
DrivenSprocketAssembly,DriveSprocketAssemblyandDriveLink
Tip:
- Installthedrivelinkwiththecoloredlinks andlorpartnumberfacingup.
8 Thedrivelink,drive,anddrivensprocketassembliesmustbe installedat thesametime.
Theball bearingshouldspinfreelyandsmoothly.
~ Thedrivensprocketballbearinginnerracehas a slightinterferencefitwiththecase.Tapgentlywiththe
palmof a handor a softtiphammerto install.
9 Park Pawl
10 Park PawlSpring
11 Park PawlShaft
Tip: Checktoensurethattheparkpawloperatesfreelyandis notbinding.

Front Differential Carrier Cleaning and Inspection

1891418

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
17-284 Automatic Transmission - 6T30/6T40I6T45/6T50 (MH8, MH9)

Front Differential Carrier Cleaning and Inspection

Callout I Component Name
Caution: Aftercleaningthetransmissioncomponents,allowtoair dry.Do notuse clothor papertowelsin orderto dryany
transmissioncomponents.Lintfromthetowelscan causecomponentfailure.
Caution: Do notreusecleaningsolvents.Previouslyusedsolventsmaydepositsedimentwhichmaydamagethecomponent.
Caution: Keepthrustwasherswiththegearitwas matchedto.Thethrustwashersareselectivesizes anditis difficulttoidentify
theproperwasherthickness.Improperassemblycan cause prematurefailureof thedifferentialassembly.
Preliminary Procedures
- Clean andinspectthedifferentialassembly,piniongearsandthrustwashersforscoring,wearor damage.
~The differentialassemblyis onlyservicedas an assembly.
FrontDifferentialPinionGear ShaftRetainer
FrontDifferentialPinionGear Pin
Sun Gear to DifferentialHousingBearingAssembly
FrontDifferentialPinionGearWasher
FrontDifferentialPinionGear
oam-me—xFrontDifferentialPlanetaryPinionGear BearingRoller

Front Differential Carrier Installation (6T30)

2202201
Front Differential Carrier Installation (6T30)
Callout Component Name
1 FinalDriveSun Gear
2 DifferentialCarrierAssembly

2013
—
Sonic
(US/Canada)
Service
Manual
(5377994)
 Automatic Transmission =6T30/6T40I6T45/6T50 (MH8, MH9) 17-285
Front Differential Carrier Installation (6T40l45l50)

0
Fl

1891420
Front Differential Carrier Installation (6T40I45/50)
Callout Component Name
1 FinalDriveSun Gear
2 DifferentialCarrierAssembly
3 FrontDifferentialCarrierBearingAsembly
,W
....
M
. 2.

_\_.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
'17-286 Automatic Transmission - 6T30/6T40I6T45/6T50 (MH8, MH9)

Transmission Fluid Pump, Front Differential Carrier Baffle, and Front

Differential Ring Gear Removal (6T30)

2202202
Transmission Fluid Pump, Front Differential Carrier Baffle, and Front Differential Ring
Gear Removal (6T30)
Callout Component Name
1 FrontDifferentialCarrierBaffleBoltsM6x 25(Qty:2)
2 FrontDifferentialCarrierBaffle
3 FrontDifferentialRingGear Retainer
Tip: Notethedirectionofthetapertoensureproperinstallation.
4 FrontDifferentialRing Gear
5 FrontDifferentialCarrierBearingAssembly
6 FluidPumpBoltsM8x 33(Qty:7)
7 FluidPumpAssembly
8 TorqueConverterand DifferentialHousingSeal

aw—
WW
2--

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Automatic Transmission - 6T30/6T40I6T45/6T50 (MH8, MH9) ’17-287

Transmission Fluid Pump, Front Differential Carrier Baffle, and Front

Differential Ring Gear Removal (6T40l45)

1891422
Transmission Fluid Pump, Front Differential Carrier Baffle, and Front Differential Ring
Gear Removal (6T40l45)
Callout Component Name
1 FrontDifferentialCarrierBaffleBoltsM6x 25 (Qty:2)
‘A
._
M
-AM”.
«w
AA~_~,._
2
“,2,”
_
2_
.2..“
MA..M<
___.._....
.. 2 FrontDifferentialCarrierBaffle
3 FrontDifferentialRingGear Retainer
Tip: Notethedirectionofthetaperto ensureproperinstallation.
4 FrontDifferentialRingGear
5 FluidPumpBoltsM8x 33(Qty:8)
6 FluidPumpAssembly
7 TorqueConverterandDifferentialHousingSeal

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
17-288 Automatic Transmission - 6T30/6T40I6T45/6T50 (MH8, MH9)

Front Wheel Drive Shaft Seal Replacement - Torque Converter Housing Side

1891410
Front Wheel Drive Shaft Seal Replacement - Torque Converter Housing Side
Callout Component Name
FrontWheelDriveShaftOil Seal Assembly
Special Tools
- DT—23129 UniversalSeal Remover
- DT-47790Seal Installer
- GE-6125-1BSlide Hammer "W_
“2.“
,4
. GE—8092 DriverHandle
Forequivalentregionaltools,referto Special Toolsonpage 17—394.

2013‘
Sonic
(US/Canada)
Service
Manual
(5377994)
 Automatic Transmission - 6T30/6T40I6T45/6T50 (MH8, MH9) 17-289
Torque Converter Housing Cleaning and Inspection

1902422
Torque Converter Housing Cleaning and Inspection
Callout Component Name
Caution: Aftercleaningthetransmissioncomponents,allowtoair dry.Do notuse clothor papertowelsinorderto dryany
transmissioncomponents.Lintfromthetowelscancause componentfailure.
Caution: Do notreusecleaningsolvents.Previouslyusedsolventsmaydepositsedimentwhichmaydamagethe component.
Caution: Do notuse abrasivepadsor bristledevicestocleanthesealingsurfaces.Abrasivepadsproducea finegritthatcan
effecttransmissionfunction.Abrasivepadscan also removeenoughmetalto createoil leaks.
Preliminary Procedure
Thoroughlycleanthetorqueconverterhousing,includingcase threadswithcleansolvent.
1 ThreadedHole
2 GasketSealingSurface

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
’17-290 Automatic Transmission - 6T30/6T40I6T45/6T50 (MH8, MH9)

Transmission Fluid Pump Disassemble (6T30)

Fluid Filter Assembly and Torque Converter Fluid Seal Disassemble

2202206

Fluid Filter Assembly and Torque Converter Fluid Seal Disassemble

Callout Component Name
FluidFilterAssembly
_\
Tip: Rotatefilter90degreestodisengagelockingtangs.
AlTransFluidFilterSeal
TorqueConverterFluidSeal Retainer
TorqueConverterFluidSeal
TorqueConverterFluidSeal Assembly
O1-P-COM

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
 Automatic Transmission :-6T30/6T40/6T45/6T50 (MH8, MH9) 17‘291
Fluid Pump Disassemble

2215840
Fluid Pump Disassemble
Callout Component Name
Warning: Valvesprings can be tightly compressed. Use care whenremoving retainers andplugs. Personal injury could
result.
Caution: Aftercleaningthetransmissioncomponents,allowtoair dry.Do notuse clothor papertowelsin orderto dryany
transmissioncomponents.Lintfromthetowelscancause componentfailure.
Caution: Do notreusecleaningsolvents.Previouslyusedsolventsmaydepositsedimentwhichmaydamagethe component.
Preliminary Procedure
Cleanandinspectall valvecomponentsandthepumpbodyforwear andlordamage.
FluidPumpCover BoltsM6x 21.5(Qty:20)
1
Tip: Thereare 3 boltsonthepumpcoverside and20 boltsonthepumpbodyside.
FluidPumpCover
FluidPumpDrivenGear
FluidPumpDriveGear
TCC ControlValveTrain
FluidPumpBlowOffBall ValveTrain
PressureRegulatorValveTrain
TCC BlowOffBallValveTrain
(OOJNODU'I-ROJN
FluidPumpCover BoltsM6x 18.5(Qty:3)

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
'17-292 Automatic Transmission - 6T30/6T40I6T45/6T50 (MH8, MH9)

Transmission Fluid Pump Disassemble (6T40l45l50)

Fluid Filter Assembly and Torque Converter Fluid Seal Disassemble

1891423
Fluid Filter Assembly and Torque Converter Fluid Seal Disassemble
Callout Component Name
FluidFilterAssembly
Tip: Rotatefilter90degreestodisengagelockingtangs.
TorqueConverterFluidSeal Retainer
TorqueConverterFluidSeal
Special Tools
- DT—23129 UniversalSeal Remover
- GE—6125-1B Slide Hammer
For equivalentregionaltools,referto SpecialToolsonpage 17-394.
TorqueConverterFluidSeal Assembly
Special Tools
- DT-23'129UniversalSeal Remover
- GE—6125-1B Slide Hammer
Forequivalentregionaltools,referto SpecialToolsonpage 17-394.

2013
—
Sonic
(US/Canada)
Service
Manual
(5377994)
 Automatic Transmission - 6T30/6T40I6T45/6T50 (MH8, MH9) 17293
Fluid Pump Disassemble

2552989
Fluid Pump Disassemble
Callout Component Name
Warning: Valvesprings can be tightly compressed. Use care whenremovingretainers and plugs. Personal injury could
result.
Caution: Aftercleaningthetransmissioncomponents,allowtoair dry.Do notuse clothor papertowelsin orderto dryany
transmissioncomponents.Lintfromthetowelscancause componentfailure.
Caution: Do notreusecleaningsolvents.Previouslyusedsolventsmay depositsedimentwhichmaydamagethe component.
Preliminary Procedure
Clean andinspectall valvecomponentsandthepumpbodyforwear andlordamage.
FluidPumpCover BoltsM6x 25(Qty:23)
1
Tip: Thereare 3 boltson thepumpcoverside and20 boltsonthepumpbodyside.
FluidPumpCover
FluidPumpDrivenGear
FluidPumpDriveGear
TCC ControlValveTrain
TCC BlowOffBallValveTrain
PressureRegulatorValveTrain
FluidPumpBlowOffBall ValveTrain
(DOOVGO‘I-D-OJN
A/TransFluidPumpBody

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
1742.94 Automatic Transmission - 6T30/6T40I6T45I6T50 (MH8, MH9)

Fluid Pump Selective Measurement

I III
.'/':'I
’I'II:
It'o'l.
'ln'ln'lll'll

1898044
Fluid Pump Selective Measurement
Callout ‘ Component Name
AlTrans FluidPumpBody
Tip: Measurethedistancefromthebottomof a gaugebartothebottomofthepumprotorcavity.Referto Fluid
1 PumpSelectiveSpecificationsonpage 17-10_.
Special Tools
GE 34673FlatGaugeBar or equivalent
A/TransFluidPumpDrivenGear
Tip: RefertoFluidPumpSelectiveSpecificationsonpage 17—10
toselectthecorrectgear.
A/TransFluidPumpDriveGear
Tip: RefertoFluidPumpSelectiveSpecificationsonpage 17—10
toselectthecorrectgear.

2013
«Sonic
(US/Canada)
Service
Manual
(5377994)
 Automatic Transmission . 6T30/6T40I6T45/6T50 (MH8, MH9) 17-295
Transmission :Fluid Pump Assemble (6T30)
Fluid Pump wNalve Trains Assemble

2202547
Fluid Pump wNalve Trains Assemble
Callout Component Name
1 TCC BlowOffBall ValveTrain
2 PressureRegulatorValveTrain
3 FluidPumpBlowOffBallValveTrain
4 TCC ControlValveTrain
5 FluidPumpDriveGear
Tip: TheChamferonthedrivegearteethface towardsthepumpbody.
6 FluidPumpDrivenGear
Tip: TheChamferon thedrivengearO.D.facesthepumpbody.
7 FluidPumpCover
FluidPumpCover BoltsM6x 21.5(Qty:20)
Caution: Referto FastenerCautiononpage 0-8.
8 Tighten
12N-m(106lbin)
FluidPumpCover BoltsM6x 18.5(Qty:3)
9 Tighten
12N-m(106lbin)

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
’17-296 Automatic Transmission - 6T30/6T40I6T45/6T50 (MH8, MH9)

Torque Converter Fluid Seal and Fluid Filter Assembly Assemble

2202549
Torque Converter Fluid Seal and Fluid Filter Assembly Assemble
Callout Component Name
TorqueConverterFluidSeal Assembly
Tip: Thefluidseal assemblymustbestakedin placeusingDT-49131seal stakingtoolto ensurepropersea|
retention.
Special Tool
- DT—48270 Seal installer
' DT—49131Seal StakingTool
For equivalentregionaltools,referto Special Toolsonpage 17—394.
TorqueConverterFluidSeal
Special Tool
DT-47791Seal Installer
Forequivalentregionaltools,referto Special Toolsonpage 17-394.
TorqueConverterFluidSeal Retainer
A/TransFluidFilterSeal
FluidFilterAssembly
Tip: Rotatefilter90degreestoengagelockingtangs.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Automatic Transmission - 6T30/6T40I6T45/6T50 (MH8, MH9) ‘i7u297
Transmission Fluid Pump Assemble (6T40l45l50)
~W.
....“
Fluid Pump wNalve Trains Assemble

2552971
Fluid Pump wNalve Trains Assemble
Callout Component Name
1 AlTransFluidPumpBody
FluidPumpBlowOffBallValveTrain
.26
2%
v-«~VW%_J——-‘.___t2
/N_,v_,.
_. PressureRegulatorValveTrain
TCC BlowOffBallValveTrain
01th TCC ControlValveTrain
FluidPumpDriveGear
Tip:
' AlignlD featuredotswiththedrivengearas shownabove.
- TheChamferonthedrivegearteethfacesthepumpbody.
FluidPumpDrivenGear
Tip:
' Align IDfeaturedotswiththedrivegearas shownabove,somemodels.
- TheChamferonthedrivengearO.D.facesthepumpbody.
FluidPumpCover
FluidPumpCover BoltsM6x 25 (Qty:23)
Caution: Referto FastenerCautiononpage0-8.
Tighten
12N-m(106lb in)

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
17-298 Automatic Transmission - 6T30/6T40I6T45/6T50 (MH8, MH9)

Torque Converter Fluid Seal and Fluid Filter Assembly Assemble

WNW
‘2

WNW
-.MM
_
N
,2
tm_«

1891430
Torque Converter Fluid Seal and Fluid Filter Assembly Assemble
Callout Component Name
TorqueConverterFluidSeal Assembly
Tip: Thefluidsea|assemblymustbe stakedin placeusingDT—49131 sea|stakingtooltoensurepropersea|
retention.
Special Tool
- DT—47792 Seal Installer
- DT—49131 Seal StakingTool
For equivalentregionaltools,referto Special Toolsonpage 17-394.
TorqueConverterFluidSeal
Special Tool .
DT—47791-A Seal Installer
For equivalentregionaltools,referto Special Toolsonpage 17-394.
TorqueConverterFluidSeal Retainer
FluidFilterAssembly
Tip: Rotatefilter90degreestoengagelockingtangs.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Automatic Transmission - 6T30/6T40I6T45/6T50 (MH8, MH9) 17-299
Transmission Fluid Pump, Front Differential Carrier Baffle, and Front
Differential Ring Gear Installation (6T30)

2202209
Transmission Fluid Pump, Front Differential Carrier Baffle, and Front Differential Ring
Gear Installation (6T30)
Callout Component Name
1 TorqueConverterand DifferentialHousingSeal
2 FluidPumpAssembly
FluidPumpBoltsM8x 33(Qty:7)
Caution: RefertoFastenerCautiononpage0—8.
Tighten
10Nm (89lb in)thenrotatetheboltan additional45degrees
Special Tool
EN-45059Angle Meteror equivalent
Forequivalentregionaltools,referto Special Toolsonpage 17—394.
FrontDifferentialCarrierBearingAssembly
FrontDifferentialRingGear
FrontDifferentialRingGear Retainer
Tip: Installtheretainerwiththetaperfacingawayfromtheringgear.
FrontDifferentialCarrierBaffle
FrontDifferentialCarrierBaffleBoltsM6x 25(Qty:2)
Tighten
12Nm (106.21lb in)

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
17=300 Automatic Transmission - 6T30/6T40I6T45/6T50 (MH8, MH9)

Transmission Fluid Pump, Front Differential Carrier Baffle, and Front

Differential Ring Gear Installation (6T40l45)

1891432

Transmission Fluid Pump, Front Differential Carrier Baffle, and Front Differential Ring
Gear Installation (6T40l45)
Callout Component Name
1 TorqueConverterand DifferentialHousingSeal
2 FluidPumpAssembly
FluidPumpBoltsM8X33(Qty:8)
Caution: Referto FastenerCautiononpage0-8.
Tighten
1ON-m(89lbin)thenrotatetheboltan additional45degrees
Special Tool
EN-45059AngleMeteror equivalent
For equivalentregionaltools,referto Special Toolsonpage 17-394.
FrontDifferentialRingGear
FrontDifferentialRingGear Retainer
Tip: Installtheretainerwiththetaperfacingawayfromthe ringgear.
FrontDifferentialCarrierBaffle
FrontDifferentialCarrierBaffleBoltsM6x 25(Qty:2)
Tighten
12N-m(106.21lbin)

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
 Automatic Transmission - 6T30/6T40I6T45/6T50 (MH8, MH9) ‘17-301
Torque Converter Housing with Fluid Pump Assembly Installation (6T30)

2372258
Torque Converter Housing with Fluid Pump Assembly Installation (6T30)
Callout Component Name
1 FluidPumpSeal Assembly
2 TorqueConverterHousingGasket
TorqueConverter(wIFluidPump)HousingAssembly
Tip: Rotatethedifferentialslightlyin eachdirectionusingDT—48277
rotatingtoolto aligntheDifferentialPinion
Gearswiththe DifferentialRingGear in theTorqueConverterHousing.
Special Tool
DT—48277 DifferentialRotatingTool
Forequivalentregionaltools,referto Special Toolsonpage 17—394.
TorqueConverterand DifferentialHousingBoltsM8x 30(Qty:14)
Caution: Referto FastenerCautiononpage 0-8.
Procedure
Tightentheboltsin sequenceshown.
Tighten
10NW (89lb in)thenrotatetheboltan additional50degrees
Special Tool
EN-45059Angle Meterorequivalent
Forequivalentregionaltools,referto Special Toolsonpage 17—394.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
'17-302 Automatic Transmission - 6T30/6T40I6T45/6T50 (MH8, MH9)

Torque Converter Housing with Fluid Pump Assembly Installation (6T40l45/50

Non Hybrid)

1891439
Torque Converter Housing with Fluid Pump Assembly Installation (6T40/4 5/50 Non Hybrid)
Callout Component Name
1 FluidPumpSeal Assembly
2 TorqueConverterHousingGasket
TorqueConverter(w/FluidPump)HousingAssembly
Tip: Rotatethedifferentialslightlyin eachdirectionusingtherotatingtoolto aligntheDifferentialPinionGears
withtheDifferentialRingGear in theTorqueConverterHousing.
- DT-47793DifferentialRotatingToolfor6T40/45applications
- DT-49938DifferentialRotatingToolfor6T50applications
Special Tools
0 DT-47793DifferentialRotatingTool
' DT—49938 DifferentialRotatingTool
Forequivalentregionaltools,referto SpecialToolsonpage 17-394.
TorqueConverterand DifferentialHousingBoltsM8x 30(Qty:15)
Caution: Referto FastenerCautiononpage0-8.
Procedure
Tightentheboltsin sequenceshown.
Tighten
10Nm (89lb in)thenrotatetheboltan additional50degrees
Special Tool
EN-45059Angle Meteror equivalent
Forequivalentregionaltools,referto Special Toolsonpage 17—394.

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 Automatic Transmission - 6T30/6T40I6T45/6T50 (MH8, MH9) '17-303
Input and Output Speed Sensor Installation

1891444
Input and Output Speed Sensor Installation
Callout Component Name
1 InputSpeedSensorAssemblySeals
2 InputSpeedSensorAssembly
inputSpeedSensorBoltM6 X23(Qty:1)
Caution: RefertoFastenerCautiononpage 0-8.
3 Tighten
9 N-m(80lb in)
4 A/TransOutputSpeedSensor Assembly
AlTransOutputSpeedSensor BoltM6X 18(Qty:1)
5 Tighten
9N-m(80lbin)

2013
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17-304 Automatic Transmission - 6T30/6T40I6T45/6T50 (MH8, MH9)

Control Valve Body Assembly Disassemble (Gen 1)

1891440
Control Valve Body Assembly Disassemble (Gen 1)
Callout Component Name
1 ControlSolenoidValveSupport
2 ControlValveBodyBoltM5x 40.5(Qty:1)
ValveChannelPlate
3 Tip: Inspectthechannelplateboltpass throughholesfordamageor brinelling.Any damagewillcauseincorrect
pressureswitchoperation.Replaceas necessary.
4 ControlValveChannelPlateSpacerPlateAssembly
5 ValveBodyBallCheckValves(Qty:6)

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 Automatic Transmission . 6T30/8T40/6T45/6T50 (MH8, MH9) 17-305
Control Valve Body Assembly Disassemble (Gen 2)

2552972
Control Valve Body Assembly Disassemble (Gen 2)
Callout Component Name
1 ControlSolenoidValveSupport
2 ControlValveBody BoltM5X40.5(Qty:1)
ValveChannelPlate
3 Tip: Inspectthechannelplateboltpassthroughholesfordamageor brinelling.Any damagewillcause incorrect
pressureswitchoperation.Replaceas necessary.
4 ValveBodyBall CheckValves(Qty:6)

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17-306 Automatic Transmission - 6T30/6T40I6T45/6T50 (MH8, MH9)

Control Valve Body Cleaning and inspection (Gen 2)

2552973
Control Valve Body Cleaning and Inspection (Gen 2)
Callout Component Name
Warning: Valvesprings can be tightly compressed. Use care whenremovingretainers andplugs. Personal injury could
result.
Caution: Aftercleaningthetransmissioncomponents,allowtoairdry.Do notuse clothor papertowelsin ordertodryany
transmissioncomponents.Lintfromthetowelscancausecomponentfailure.
Caution: Do notreusecleaningsolvents.Previouslyusedsolventsmaydepositsedimentwhichmaydamagethecomponent.
PreliminaryProcedure
Clean andinspectallvalvecomponentsandthevalvebody.Thecontrolvalvebodyassemblyis onlyreplaceableas an
assembly.
1 Low-Reverseand4—5—6 ClutchBoostValveTrain
Low—Reverse and4—5—6 ClutchRegulatorValveTrain
1—2—3—4 ClutchBoostValveTrain
1—2—3—4 ClutchRegulatorValveTrain
2—6ClutchRegulatorValveTrain
3—5ReverseClutchRegulatorValveTrain
DefualtOverrideValveTrain
TCC RegulatorApplyValveTrain
(DCDNCDU‘l-POON
ClutchSelectValveTrain
O
_x ActuatorFeed LimitValveTrain
.3.
..x ManualValve

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 Automatic Transmission - 6T30/6T40/6T45/6T50 (MH8, MHQ) 17-307

Control Valve Channel Plate Cleaning and Inspection (6T30I40l45/50 - Gen 2)

2552974

Control Valve Channel Plate Cleaning and Inspection (6T30I40l45/50 - Gen 2)

Callout ComponentName
1 ControlValveBodySpacer Plate Retainer
2 ChannelPlateto ValveBodySpacer PlateAssembly
3 ActuatorFeedAccumulatorPiston(Qty:5)
4 ActuatorFeedAccumulatorSpring(Qty:5)
5 VariableHi and2-3-4ClutchHousingValveBall
ValveChannelPlate
5 Tip: Inspectthechannelplateboltpass throughholesfordamageor brinelling.Any damagewillcause incorrect
pressureswitch operation.Replaceas necessary.
7 ControlValveChannelPlate Ball SpringAssembly

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17-308 Automatic Transmission - 6T30/6T40/6T45/6T50 (MH8, MH9)

Control Valve Body Assembly Assemble (Gen 1)

1891443

Control Valve Body Assembly Assemble (Gen 1)

Callout Name
Component
1 ValveBodyBall CheckValve(Qty:6)
2 ControlValveChannelPlateSpacerPlateAssembly
ValveChannelPlate
3 Tip: Inspectthechannelplateboltpassthroughholesfordamageor brinelling.Any damagecouldcause
leaking.Replaceas necessary.
ControlValveBodyBoltM5x 40.5(Qty:1)
Caution:Referto FastenerCautiononpage 0-8.
Tighten
7N-m(62lbin)
5 ControlSoIenoidValveSupport

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 Automatic Transmission - 6T30/6T40/6T45/6T50 (MH8, MH9) 17-309

Control Valve Body Assembly Assemble (Gen 2)

2552975

Control Valve Body Assembly Assemble (Gen 2)

Callout ComponentName
1 ValveBody Ball CheckValve(Qty:6)
2 ValveChannelPlate
ControlValveBodyBolt M5x 40.5(Qty:1)
Caution:Referto FastenerCautiononpage 0-8.
Tighten
7 N-m(62lbin)
ControlSolenoidValveSupport

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17-310 Automatic Transmission - 6T30/6T40/6T45/6T50 (MH8, MH9)

Control Valve Body Assembly Installation

1891445
Control Valve Body Assembly Installation
Callout Component Name
1 Lowand ReverseClutchFluidPassage Seal
2 1-2-3~4 ClutchFluidPassage Seal
3 ControlValveBodySpacer PlateAssembly
4 ControlValveBodyAssembly
Tip: Alignthemanualvalvetotherodonthemanualshaft.
ControlValveBodyBoltM6x 60 (Qty:9)
Caution: Referto FastenerCautiononpage 0-8.
5 Tighten
11N-m(97lb in)
ControlValveBodyBoltM6x 53(Qty:2)
6 Tighten
11N-m(97lb in)
7 ManualShaftDetentLeverSpringAssembly
ManualShaftDetentSpringBoltM6x 16(Qty:1)
8 Tighten
12N-m(106lb in)
9 FluidLevelControlValveGasket
10 FluidLevelControlValve

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 Automatic Transmission - 6T30/6T40/6T45/6T50 (MH8, MH9) 17-311
Control Solenoid Valve and Transmission Control Module Assembly
Installation

1891446
Control Solenoid Valve and Transmission Control Module Assembly Installation
Callout Component Name
ControlSolenoidValveAssemblyFilterPlate
Caution: Use carewhenremovingor installingthefilterplateassembly.A brokenor missingretainingtabmay
1 notadequatelysecurethefilterplatetothecontrolsolenoidvalve assembly,resultingin possibledamageor
contamination.
Tip: Installa NEW filterplateto preventfluidleaks pastthefluidseals.
2 ControlSolenoid(w/BodyandTCM) ValveAssembly
ControlValveBody BoltM5x 40.5(Qty:3)
Caution: Referto FastenerCautiononpage 0-8.
3 Tighten
7N-m(62lbin)
ControlValveBodyBoltM6x 97 (Qty:12)
4 Tighten
10N-m(89lbin)

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17-312 Automatic Transmission - 6T30/6T40/6T45/6T50 (MH8, MH9)

Control Valve Body Cover Installation

1891447

Control Valve Body Cover Installation

Callout Component Name
1 InputSpeedSensorConnector
2 OutputSpeedSensorConnector
3 ShiftPositionSwitchConnector
4 ControlValveBodyCover WiringConnectorHoleSeal
Tip: Do notre-usethevalvebodycoverwiringconnectorhole seal.
5 ControlValveBodyCoverGasket
Tip: Do notreuse thevalvebodycovergasket.
6 ControlValveBodyCover
ControlValveBodyCoverBolts M6x 30(Qty:13)
7 Caution: Referto FastenerCautiononpage 0-8.
Tighten
12N-m(106Ibin)

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 Automatic Transmission - 6T30/6T40/6T45/6T50 (MH8, MH9) 17-313

Torque Converter Fluid Seal Replacement

k/ 0
/ ’
J 0
'
HM!
3mm \ 'r .
1.4.
’ ‘91—’14 U\L " u I

\Q) 3%! I,I v

2362106
Torque Converter Fluid Seal Replacement
Callout Component Name
1 TorqueConverterFluidSeal Retainer
TorqueConverterFluidSeal
Special Tools
- DT-47791—A Seal Installer
- DT-6125-BSlide Hammer
- EN-23129UniversalSeal Remover
For equivalentregionaItools,referto Special Toolsonpage 17—394.

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17-314 Automatic Transmission - 6T30/6T40/6T45/6T50 (MH8, MH9)

Torque Converter Installation

1891448
Torque Converter Installation
Callout Component Name
TorqueConverterAssembly
Tip: Failureto lowerthetorqueconverterstraightdowncoulddamagethetorqueconverterclutchlip seal inside
thetorqueconverterclutchassembly.
Special Tool
DT-46409TorqueConverterLiftingHandles
For equivalentregionaltools,referto Special Toolsonpage 17-394.
DT-21366ConverterHoldingStrap
Warning: Thetorque converter must be held to the torqueconverter housing by a retaining device such
2 as shipping brackets. Withoutthe retaining device, the torque converter may slide forward,disengaging
the oil pump, or may fall completely out of the transmission causing personal injury and/orproperty
damage.

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 Automatic Transmission - 6T30/6T40/6T45/6T50 (MH8, MH9) 17-315

Lift Plate and Holding Fixture Removal

1891449
Lift Plate and Holding Fixture Removal
Callout Component Name
DT—46625 TransmissionHoldingFixture
1 For equivalentregionaltools,referto Special Toolsonpage 17-394.
Tip: Raise thetransmissionin orderto removetheholdingfixture.
DT—47811-S1 TransmissionLiftPlate
2 For equivalentregionaltools,referto Special Toolsonpage 17-394.
Tip: Lowerthetransmissionassemblyontothetransmissionjack in orderto removetheliftplate.

Medium Throttle: Approximately 1/2 of accelerator

Description and Operation pedal travel, 50 percent throttle position.
Minimum Throttle: The least amount of throttle
opening required for an upshift.
Definitions and Abbreviations
Wide Open Throttle (WOT): Full travel of the
Throttle Positions accelerator pedal, 100 percent throttle position.
Zero Throttle Coastdown: A full release of the
Engine Braking: A condition where the engine is used accelerator pedal while the vehicle is in motion and in
to slow the vehicle by manually downshifting during a drive range.
zero throttle coastdown.
Full Throttle Downshift: A quick apply of the Shift Condition Definitions
accelerator pedal to its fulltravel, forcing a downshift. Bump: A sudden and forceful apply ofa clutch or
Heavy Throttle: Approximately 3/4 of accelerator a band.
pedal travel, 75 percent throttle position. Chuggle: A bucking orjerklng. This condition may be
Light Throttle: Approximately 1/4 of accelerator pedal most noticeable when the converter clutch is engaged.
travel, 25 percent throttle position. Itis similar to the feel of towing a trailer.

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17-316 Automatic Transmission - 6T30/6T40/6T45/6T50 (MH8, MH9)
Delayed: A condition where a shift is expected but Planetary Gear Noise: A whine related to vehicle
does not occur for a period of time. This could be speed. which is most noticeable in FIRST gear,
described as a clutch or band engagement that does SECOND gear, FOURTH gear or REVERSE. The
not occur as quickly as expected during a part throttle condition may become less noticeable, or go away,
or wide open throttle apply of the accelerator, or during after an upshift.
manual downshifting to a lower range. This term is also Pump Noise: A high pitched whine that increases in
defined as LATE or EXTENDED. intensity with engine RPM. This condition may also be
Double Bump —Double Feel: Two sudden and noticeable in all operating ranges with the vehicle
forceful applies of a clutch or a band. stationary or moving.
Early: A condition where the shift occurs before the Torque Converter Noise: A whine usually noticed
car has reached proper speed. This condition tends to when a vehicle is stopped, and the transmission is in
labor the engine after the upshift. DRIVE or REVERSE. The noise will increase with
End Bump: A firmer feel at the end of a shift than at engine RPM.
the start of the shift. This is also defined as END FEEL Driver Shift Control
or SLIP BUMP.
Driver shift control (DSC) allows the driver to change
Firm: A noticeably quick apply of a clutch or band that gears similar to a manual transmission. Refer to the
is considered normal with a medium to heavy throttle. vehicle owner's manual for specific DSC operating
This apply should not be confused with HARSH or instructions.
ROUGH.
Flare: A quick increase in engine RPM along with a Transmission Abbreviations
momentary loss of torque. This most generally occurs AIC: Air Conditioning
during a shift. This condition is also defined as
SLlPPING. AC: Alternating Current
Harsh —Rough: A more noticeable apply of a clutch AT: Automatic Transmission
or band than FIRM. This condition is considered CC: Climate Control
undesirable at any throttle position. DC: Direct Current
Hunting: A repeating quick series of upshifts and DIC: Driver InformationCenter
downshifts that causes a noticeable change in engine
RPM, such as a 4—3—4shift pattern. This condition is DLC: Diagnostic Link Connector
also defined as BUSYNESS. DMM: Digital Multimeter
Initial Feel: A distinctly firmer feel at the start of a shift DSC: Driver Shift Control
than at the finish of the shift.
DTC: Diagnostic Trouble Code
Late: A shift that occurs when the engine RPM is
EBTCM: Electronic Brake/Traction Control Module
higher than normal for a given amount of throttle.
ECCC: Electronically-Controlled Capacity Clutch
Shudder: A repeating jerking condition similar to
CHUGGLE but more severe and rapid. This condition ECT: Engine Coolant Temperature
may be most noticeable during certain ranges of EMI: Electromagnetic Interference
vehicle speed.
lAT: intake Air Temperature
Slipping: A noticeable increase in engine RPM
without a vehicle speed increase. A slip usually occurs lGN: Ignition
during or after initial clutch or band apply. IMS: Internal Mode Switch
Soft: A slow, almost unnoticeable clutch or band apply ISS: InputSpeed Sensor
with very little shift feel. MAP: Manifold Absolute Pressure
Surge: A repeating engine related condition of MIL: Malfunction Indicator Lamp
acceleration and deceleration that is less intense than
CHUGGLE. NC: Normally Closed
Tie-Up: A condition where two opposing clutch and/or NO: Normally Open
bands are attempting to apply at the same time causing OBD: On Board Diagnostic
the engine to labor with a noticeable loss of
engine RPM. OSS: Output Speed Sensor
PC: Pressure Control
Noise Conditions
PCM: Powertrain Control Module
Drive Link Noise: A whine or growl that increases or PCS: Pressure Control Solenoid
fades with vehicle speed, and is most noticeable under
a light throttle acceleration. Itmay also be noticeable in PS: Pressure Switch
PARK or NEUTRAL operating ranges with the vehicle PWM: Pulse Width Modulation
stationary. RPM: Revolutions Per Minute
Final Drive Noise: A hum related to vehicle speed
SS: Shift Solenoid
which is most noticeable under a light throttle
acceleration. STL: Service Transmission Lamp
TAP: Transmission Adaptive Pressure
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 Automatic Transmission - 6T30/6T40/6T45l6T50 (MH8, MH9) 17-317
TCC: Torque Converter Clutch mechanical clutch assemblies, and a hydraulic
TFP: Transmission Fluid Pressure pressurization and control system. There are 3 variants
of the transmission, based on torque capacity.
TFT: Transmission Fluid Temperature Architecture is common between the variants, and
TP: Throttle Position component differences are primarily related to size.
VSS: Vehicle Speed Sensor The 4-element torque converter contains a pump, a
turbine, a pressure plate splined to the turbine, and a
WOT: Wide Open Throttle stator assembly. The torque converter acts as a fluid
coupling to smoothly transmit power from the engine to
Transmission Identification the transmission. Italso hydraulically provides
Information additional torque multiplication when required. The
pressure plate, when applied, provides a mechanical
direct drive coupling of the engine to the transmission.
The planetary gear sets provide the 6fon/vardgear
ratios and reverse. Changing gear ratios is fully
automatic and is accomplished through the use of a
transmission control module (TCM) located inside the
transmission. The TCM receives and monitors various
electronic sensor inputs and uses this information to
shift the transmission at the optimum time.
The TCM commands shift solenoids and variable bleed
pressure control solenoids to control shift timing and
feel. The TCM also controls the apply and release of
the torque converter clutch which allows the engine to
deliver the maximum fuel efficiency without sacrificing
8 DAW vehicle performance. All the solenoids, including the
TCM, are packaged into a self—containedcontrol
solenoid valve assembly.
llllllllll Illllllllllllllllllillilllllllllillllllllll The hydraulic system primarily consists of a gear-type
g1 gggyygzom 0029 pump, a control valve body assembly and case. The
/Ill\\\\\ pump maintains the working pressures needed to
123456789 stroke the clutch pistons that apply or release the
friction components. These friction components, when
1898124 applied or released, support the automatic shifting
Legend qualities of the transmission.
(1) Code for Automatic Transmission The friction components used in this transmission
(2) Model Year consist of 5 multiple disc clutches. The multiple disc
(3) Model for Transmission clutches combine with one way clutch to deliver
7 different gear ratios, 6 forward and one reverse,
(4) Transmission Family
through the gear sets. The gear sets then transfer
(5) Source Code for Plant torque through the transfer drive gear, transfer driven
(6) Calender Year gear and differential assembly.
(7) Julian Date The transmission may be operated in any of the
(8) Shift/Line (NB) following gear ranges:
(9) Numeric sequence starting at 0001 @ 12:01 PARK (P): This position locks the front wheels and
AM each day prevents the vehicle from rolling either forward or
Source Code for Plant backward. PARK is the best position to use when
starting the vehicle. Because the transmission utilizes a
- 4 —Ramos Arizpe, Mexico shift lock control system, it is necessary to fully depress
- H—Ypsilanti, Michigan the brake pedal before shifting out of PARK. For safety
- J —Windsor, Ontario reasons, use the parking brake in addition to the PARK
position.
- S —Strasbourg, France
- W—Warren, Michigan REVERSE (R): This position allows the vehicle to be
operated in a rearward direction.
- Y —Toledo, Ohio
NEUTRAL (N): This position allows the engine to be
- R —Boryeong, Korea started and operated while driving the vehicle.
- M—Yan Tai, Shan Dong, China if necessary, you may select this position in order to
- P—San Luis Potosi, Mexico restart the engine with the vehicle moving. This position
should also be used when towing the vehicle.
Transmission General Description DRIVE (D): Drive range should be used for all normal
The Hydra-matic 6T30/40/45/50 is a fully automatic, driving conditions for maximum efficiency and fuel
6-speed, front—wheeldrive, electronic-controlled economy. Drive range allows the transmission to
transmission. it consists primarily of a 4-element torque operate in each of the 6 forward gear ratios. Downshifts
converter, a compound planetary gear set, friction and to a lower gear, or higher gear ratio, are available for

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17-318 Automatic Transmission - 6T30/6T40/6T45/6T50
safe passing by depressing the accelerator or by
manually selecting a lower gear in the manual mode
range.
Driver Shift Control (DSC) or Electronic Range
Selection (ERS): This position (M—Manual/L—Low)
allows the driver to utilize the DSC/ERS system. When
the shift selector lever is moved to this position, the
driver may select upshifts or downshifts by using the
paddle switches located on the steering wheel/shifter.
An upshift is requested by pushing either +button.
Refer to the vehicle owner's manual for more specific
DSC/ERS information.
Transmission Component and
Description
System
The mechanical components of the 6T30/40/45/50 are
as follows:
~ A torque converter with an electronically controlled
capacity clutch (ECCC)
- Gear-type fluid pump assembly
' 1—2—3—4 and low and reverse clutch housing
assembly
- 4—5—6and 3—5reverse clutch housing assembly
- 2—6clutch assembly
- Low and reverse clutch (one way clutch) assembly
- Control valve body assembly
- Drive sprocket. driven sprocket and link assembly
- Front differential carrier assembly
. InputCarrier Assembly
- Reaction Carrier Assembly
- Output Carrier Assembly
The electrical components of the 6T30/40/45 are as
follows:
- Output speed sensor assembly
- Inputspeed sensor assembly
- Manual shift shaft with internal mode switch
- Control solenoid valve assembly, which contains
the following components:
—Transmission control module (TCM)
—5 variable bleed line pressure control (PC)
solenoids
—Transmission fluid pressure (TFP) switch
assembly
—Torque converter clutch (TCC) pressure control
solenoid
—shift solenoid
—Transmission fluid temperature sensor
For more information, refer to Electronic Component
Description on page 17-319.
(MH8, MH9)
Transmission Adaptive Functions
The 6T30/40/45/50 transmission utilizes a line pressure
control system during upshifts to compensate for the
normal wear of transmission components. As the apply
components within the transmission wear or change
over time, shift time (the time required to apply a clutch)
increase or decreases. in order to compensate for
these changes, the transmission control module (TCM)
adjusts the pressure commands to the various PC
solenoids, to maintain the originally calibrated shift
timing. The automatic adjusting process is referred to
as “adaptive learning” and it is used to ensure
consistent shift feel plus increase transmission
durability. The TCM monitors the NT input speed
sensor(lSS) and the A/Toutput speed sensor(OSS)
during commanded shifts to determine if a shift is
occurring too fast (harsh) or too slow (soft) and adjusts
the corresponding pressure control (PC) solenoid
signal to maintain the set shift feel.
The purpose of the adapt function is to automatically
compensate the shift quality for the various vehicle shift
control systems. The adapt function is a continuous
process that will help to maintain optimal shift quality
throughout the life of the vehicle.
Transmission Indicators and
Messages
The following transmission-related indicators and
messages may be displayed on the Instrument Panel
Cluster (IPC). For a complete listing and description of
all vehicle indicators and messages, refer to Indicator/
Warning Message Description and Operation on
page 8-108.
"TRANSMISSION HOT IDLE ENGINE": This
message is displayed when the TCM detects a
transmission fluid temperature (TFT) equal to or greater
than 132°C (270°F) for 5 seconds.
“SERVICE TRANSMISSION”: This message displays
when there is a problem with the transmission.
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 Automatic Transmission - 6T30l6T40/6T45/6T50 (MH8, MH9) 17-319

Electronic Component Description

Control Solenoid Valve Assembly

1880316
Legend
Pressure Control Solenoid 3 (R—1/4-5—6) Line Pressure Control Solenoid
(GEN 1) Pressure Control Solenoid 2 (3-5-R) (GEN 1) Transmission Fluid Pressure (TFP)
(GEN 2) Pressure Control Solenoid 5 (1-2- Switch 1 (3-5-R)
3-4) (GEN 1) Transmission Fluid Pressure (TFP)
Torque Converter Clutch (TCC) Pressure Switch 3 (2-6)
Control Solenoid (GEN 1)Transmission Fluid Pressure (TFP)
Shift Solenoid 1 (On/Off) Switch 4 (1-2-3—4)
(GEN 1) Pressure Control Solenoid 5 (1-2- Pass Through Connector
3-4) (GEN 1)Transmission Fluid Pressure (TFP)
(GEN 2) Pressure Control Solenoid 2 (3-5-R) Switch 5 (4-5—6/R—1)
Pressure Control Solenoid 4 (2—6)

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17-320 Automatic Transmission - 6T30/6T40/6T45/6T50 (MH8, MH9)

Manual Shift Detent Lever with Shaft and TCM) valve assembly through a wire harness and
connector. The sensor faces the 3-5-R clutch piston
Position Switch Assembly housing machined teeth surface. The sensor receives
8.3—9.3volts on the lSS/OSS Supply Voltage circuit
from the TCM. As the 3-5-R/4-5-6 clutch piston housing
rotates, the sensor produces a signal frequency based
on the machined surface of the 3-5-R/4-5-6 clutch
piston housing. This signal is transmitted through the
ISS signal circuit to the control solenoid (w/body and
TCM) valve assembly. The TCM uses the ISS signal to
determine line pressure, transmission shift patterns,
torque converter clutch (TCC) slip speed and gear ratio.
Output Speed Sensor (OSS)

1880317
The transmission shaft position switch assembly is a
sliding contact switch attached to the manual shaft
detent lever assembly inside the transmission case.
The five inputs to the TCM from the transmission
manual shift shaft switch assembly indicate the
transmission gear selector lever position. This
information is used for engine controls as well as
determining the transmission shift patterns. The state of
each input is available for display on the scan tool. The
five input parameters represented are Signal A, Signal
1880319
B, Signal C, Signal P (Parity) and Signal N (P/N Start).
The output speed sensor (088) is a hall-effect type
Input Speed Sensor (ISS) sensor. The 088 mounts to the transmission case
below the control valve body assembly and connects to
the control solenoid (w/body and TCM) valve assembly
through a wire harness and connector. The sensor
faces the Park gear machined teeth surface. The
sensor receives 8.3—9.3volts 0n the lSS/OSS supply
voltage circuit from the TCM. As the front differential
transfer drive gear assembly rotates, the sensor
produces a signal frequency based on the machined
surface of the Park gear. This signal is transmitted
through the OSS signal circuit to the TCM. The TCM
uses the OSS signal to determine line pressure,
transmission shift patterns, torque converter
clutch (TCC) slip speed and gear ratio.

1880318
The input speed sensor (ISS) is a hall-effect type
sensor. The ISS mounts to the transmission case
assembly and connects to the control solenoid (w/body

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 Automatic Transmission
Park - Engine Running (Gen 1)
When the gear selector lever is in the Park (P) position,
fluid is drawn into the pump through the transmission
fluid filter assembly. Line pressure is then directed to
the following valves:
Fluid Pressure Directed in Preparation
for a Shift
Manual Valve
Mechanically controlled by the gear selector lever, the
manual valve is in the Park (P) position and prevents
line pressure from the pressure regulator valve from
entering the reverse and drive fluid circuits.
Actuator Feed Limit Valve
Line pressure is regulated through the valve into the
actuator feed limit circuit. Actuator feed limit fluid
passes through orifice #10 to a differential area to move
the valve against actuator feed limit valve spring
pressure. Actuator feed limit fluid is routed to the
pressure control solenoids, the shift solenoid, and to
the #5 and #6 ball check valves.
Compensator Feed Regulator Valve
Line pressure is regulated through the valve into the
compensator feed fluid circuit. Compensator feed fluid
pressure is routed through orifice #30 to the
3-5-reverse clutch regulator valve, and also fills the
3—5—reverse clutch and 4-5-6 clutch piston dam areas.
3-5-Reverse Clutch Regulator Valve
35 reverse clutch feed/compensator feed fluid is routed
through the valve into the 35 reverse clutch fluid circuit.
35 reverse clutch fluid passes through orifice #6to
assist spring pressure in keeping the valve open.
35 reverse clutch fluid is routed to the 3-5-reverse
clutch, and through orifice #33 to the #6 ball check
valve.
3-5-Reverse Clutch Assembly
35 reverse clutch fluid fills the 3-5—reverseclutch piston
apply cavity in preparation for a shift to Reverse range.
However, in Park range, 35 reverse clutch pressure is
limited to compensator feed pressure of 9 PSI and is
not strong enough to apply the clutch.
TCC Regulated Apply Valve
Shift solenoid fluid is routed to the TCC regulated apply
valve and moves the valve against TCC regulated
apply valve spring force.
(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
- 6T30I6T40/6T45/6T50 (MH8, MH9) 17-321
Low and Reverse Clutch Applies
R1/456 Pressure Control (PC) Solenoid 3
The R1/456 PC solenoid is energized (ON) allowing
actuator feed limit fluid to enter the PCS R1/456 clutch
fluid circuit. PCS R1/456 clutch fluid is then routed
through orifice #11to the R1/4-5—6clutch regulator
valve.
R1I4-5-6 Clutch Regulator Valve
PCS R1/456 clutch fluid at the R1/4-5—6clutch regulator
valve, opposes R1/4-5-6 clutch regulator spring force
and R1/456 clutch feed fluid pressure to regulate line
pressure into the R1/456 clutch feed circuit. R1/456
clutch feed fluid is routed to the clutch select valve and
through orifice #34 to the #5 ball check valve.
Shift Solenoid
The shift solenoid is energized (ON) allowing actuator
feed limit fluid to enter the shift solenoid circuit. Shift
solenoid fluid is routed to the clutch select valve
through orifice #13, and to the TCC regulated apply
valve through orifice #14.
Clutch Select Valve
Shift solenoid fluid is routed to the clutch select valve
and moves the valve against clutch select valve spring
force. This allows R1/456 clutch feed fluid to pass
through the valve and enterthe R1 circuit. R1 fluid is
then routed through orifice #38 to the low and reverse
clutch assembly in preparation for a shift into low or
reverse gear.
Low and Reverse Clutch
R1/456 fluid enters the transmission case assembly
and moves the low and reverse clutch piston against
spring force to apply the low and reverse clutch plates.
ln Park range, the low and reverse has no effect.
However, when Reverse or a forward range is selected,
only one apply device has to be energized, which helps
create a smooth starting motion.
#5 Ball Check Valve
R1/456 clutch feed fluid unseats the #5 ball check
valve, allowing excess pressure to pass into the
actuator feed limit circuit. This helps to control clutch
apply fluid pressure and clutch apply feel.
17-322 Automatic Transm ISSIOH- 6T30/6T40I6T45/6T50 (MH8, MH9)
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(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
IQ
II B.
 Automatic Transmission - 6T30/6T40I6T45/6T50 (MH8, MH9) 17-323

Park - Engine Running (Gen 2)
When the gear selector lever is in the Park (P) position.
fluid is drawn into the pump through the transmission
fluid filter assembly. Line pressure is then directed to
the following valves:
Fluid Pressure Directed in Preparation
for a Shift
Manual Valve
Mechanically controlled by the gear selector lever, the
manual valve is in the Park (P) position and prevents
line pressure from the pressure regulator valve from
entering the reverse and drive fluid circuits.
Actuator Feed Limit Valve
Line pressure is regulated through the valve into the
actuator feed limit circuit. Actuator feed limit fluid
passes through orifice #10 to a differential area to move
the valve against actuator feed limit valve spring
pressure. Actuator feed limit fluid is routed to the
pressure control solenoids, the shift solenoid, and to
the #4 ball check valve.
TCC Regulated Apply Valve
Shift solenoid fluid is routed to the TCC regulated apply
valve and moves the valve against TCC regulated
apply valve spring force.
Default Override Valve
Shift solenoid fluid is routed to the default override
valve and moves the valve against default override
valve spring force.
Low and Reverse Clutch Applies
R1/456Pressure Control (PC)Solenoid
The R1/456 PC solenoid is energized (ON) allowing
actuator feed limit fluid to enter the PCS R1/456 clutch
fluid circuit. PCS R1/456 clutch fluid is then routed
through orifice #11to the R1/4-5-6 clutch regulator
valve, and through orifice #34 to the R1/4-5-6 clutch
boost valve.
R1/4-5-6 Clutch Regulator Valve
PCS R1/456 clutch fluid at the R1/4-5—6clutch regulator
valve, opposes R1/4-5-6 clutch regulator spring force
and orificed R1/456 clutch feedback fluid pressure to
regulate line pressure into the R1/456 clutch feed
circuit. R1/456 clutch feed fluid is routed to the R1/4-5-6
clutch boost valve and to the clutch select valve.
R1/4-5-6 Clutch Boost Valve
PCS R1/456 clutch fluid pressure acts on a differential
area, moving the R1/4-5-6 clutch boost valve against
R1/4—5—6 clutch boost valve spring force, to regulate
R1/456 clutch feed fluid into the R1/456 clutch
feedback circuit. As PCS R1/456 clutch fluid pressure
is increased to a given value, the R1/4-5-6 clutch boost
valve opens the R1/456 clutch feedback circuit to
exhaust backfill. This results in the R1/4—5—6 clutch
regulator valve moving to the full feed position, sending
full R1/456 clutch feed pressure (full line pressure) to
the low and reverse clutch.
Shift Solenoid
The shift solenoid is energized (ON) allowing actuator
feed limit fluid to enter the shift solenoid circuit. Shift
solenoid fluid is routed to the clutch select valve
through orifice #13, to the TCC regulated apply vaive
through orifice #14, and through orifice #44 to the
default override valve.
Clutch Select Valve
Shift solenoid fluid is routed to the clutch select valve
and moves the valve against clutch select valve spring
force. This allows R1/456 clutch feed fluid to pass
through the valve and enterthe R1 circuit. R1 fluid is
then routed through orifice #42 to the low and reverse
clutch assembly in preparation for a shift into low or
reverse gear.
Low and Reverse Clutch
R1/456 fluid enters the transmission case assembly
and moves the low and reverse clutch piston against
spring force to apply the low and reverse clutch plates.
In Park range, the low and reverse clutch has no effect.
However, when Reverse or a forward range is selected,
only one apply device has to be energized, which helps
create a smooth starting motion.
Accumulator
PCS R1/456 clutch fluid is also routed to an
accumulator valve. The accumulator valve is used to
dampen any pressure irregularities occurring in the
PCS R1/456 clutch fluid circuit. This helps to control
clutch apply fluid pressure and clutch apply feel.

(US/Canada)
»Sonic
2013 (5377994)
Manual
Service
 H
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2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Automatic Transmission
Reverse (Gen 1)
When the gear selector lever is moved to the Reverse
(R) position (fromthe Park position) the normally-high
35R pressure control solenoid 2 is commanded ON and
the following changes occur in the transmission’s
hydraulic and electrical systems:
3-5-Reverse Clutch Applies
Manual Valve
With the manual valve in the reverse position, line
pressure is directed into the reverse fluid circuit and
routed to the clutch select valve.
Clutch Select Valve
Reverse fluid is routed to a differential area of the
default override shuttle valve and assists shift solenoid
fluid, present at the valve from Park position, in holding
the clutch select valve against clutch select valve
spring force. Reverse fluid passes through the clutch
select valve into the 35 reverse clutch feed circuit and
is routed to the #2 ball check valve. R1/456 clutch feed
fluid, present at the valve from Park position, continues
to pass through the valve into the R1 circuit in order to
keep the low and reverse clutch applied.
#2 Ball Check Valve
3-5 reverse fluid passes through orifice #5, seats the #2
ball check valve against the drive 1-6 fluid passage,
and enters the 35 reverse/drive 1-6 circuit. 35 reverse/
drive 1-6 fluid is routed through orifice #25 to the
3-5-reverse clutch regulator valve.
(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
- 6T30/6T40l6T45/6T50 (MH8, MH9) 17-325
35R Pressure Control (PC)Solenoid 2
The 35R PC solenoid 2 is energized (ON), allowing
actuator feed limit fluid to enter the PCS 35 reverse
clutch circuit. PCS 35 reverse clutch fluid is then routed
through orifice #26 to the 3-5-reverse clutch regulator
valve.
3-5-Reverse Clutch Regulator Valve
PCS 35 reverse clutch fluid, at the 3-5-reverse clutch
regulator valve, opposes 3-5-reverse clutch regulator
valve spring force and orificed 35 reverse clutch
feedback fluid pressure to regulate 35 reverse clutch
feed/drive 1-6 pressure into the 35 reverse clutch
circuit. 35 reverse clutch fluid is then routed to the
3-5—reverseclutch, and through orifice #33 to the #6
ball check valve.
3-5-Reverse Clutch
35 reverse clutch fluid enters the 3-5—reverseand 4-5-6
clutch housing assembly to move the 3-5 reverse clutch
piston against spring force and compensator feed fluid
pressure to applythe 3—5-reverseclutch plates.
#6 Ball Check Valve
35 reverse clutch feed fluid unseats the #6 ball check
valve, allowing excess pressure to pass into the
actuator feed limit circuit. This helps to control clutch
apply fluid pressure and clutch apply feel.
 E
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-Sonic
(US/Canada)
Service
Manual
(5377994)
Hamumwilli
 Automatic Transmission
Reverse (Gen 2)
When the gear selector lever is moved to the Reverse
(R) position (fromthe Park position) the normally—low
35R pressure control solenoid is commanded ON and
the following changes occur in the transmission’s
hydraulic and electrical systems:
3-5-Reverse Clutch Applies
Manual Valve
With the manual valve in the reverse position, line
pressure is directed into the reverse fluid circuit.
Reverse fluid is then routed to the clutch select valve
and to the default override valve.
Clutch Select Valve
Reverse fluid is routed to a differential area of the clutch
select shuttle valve and assists shift solenoid fluid,
present at the valve from Park position, in holding the
clutch select valve against clutch select valve spring
force. Reverse fluid passes through the clutch select
valve into the 35 reverse clutch feed circuit and is
routed to the #2 ball check valve. R1/456 clutch feed
fluid, present at the valve from Park position, continues
to pass through the valve into the R1 circuit in order to
keep the low and reverse clutch applied.
#2 Ball Check Valve
3-5 reverse fluid seats the #2 ball check valve against
the drive 1-6 fluid passage, and enters the 35 reverse/
drive 1-6 circuit. 35 reverse/drive 1-6 fluid is routed to
the #3 ball check valve.
#3 Ball Check Valve
35 reverse/drive 1-6 fluid unseats the #3 ball check
valve and is routed to the 3-5-reverse clutch regulator
valve.
35R Pressure Control (PC)Solenoid
The 35R PC solenoid is energized (ON), allowing
actuator feed limit fluid to enter the PCS 35 reverse
clutch fluid circuit. PCS 35 reverse clutch fluid is then
routed through orifice #26 to the 3—5-reverseclutch
regulator valve.
3-5-Reverse Clutch Regulator Valve
PCS 35 reverse clutch fluid, at the 3-5-reverse clutch
regulator valve, opposes 3—5—reverse clutch regulator
valve spring force and orificed 35 reverse clutch
(US/Cansda)
-Sonic
2013 (5377994)
Manual
Service
- 6T30/6T40/6T45/6T50 (MH8, MH9) 17-327
feedback fluid pressure to regulate 35 reverse clutch
feed/drive 1-6 pressure into the 35 reverse clutch
circuit. 35 reverse clutch fluid is then routed through
orifice #25 to the 3—5-reverseclutch, and through orifice
#33 to the #4 ball check valve.
3-5-Reverse Clutch
35 reverse clutch fluid enters the 3—5-reverseand 4-5—6
clutch housing assembly to move the 3-5-reverse
clutch piston against spring force to apply the
3-5-reverse clutch plates.
#4 Ball Check Valve
35 reverse clutch feed fluid unseats the #4 ball check
valve, allowing excess pressure to pass into the
actuator feed limit circuit. This helps to control clutch
'apply fluid pressure and clutch apply feel.
Accumulator
PCS 35 reverse clutch fluid is also routed to an
accumulator valve. The accumulator valve is used to
dampen any pressure irregularities occurring in the
PCS 35 reverse clutch fluid circuit. This helps to control
clutch apply fluid pressure and clutch apply feel.
Fluid Pressure Directed in Preparation
for a Possible Default Action
Reverse fluid is directed to the default oVerride valve in
preparation for Reverse (R) range operation in the
event of a transmission default action. Ifa transmission
electrical component malfunction occurs, all solenoids
will default to their normal state. The shift solenoid will
default to its normalIy-closed state (OFF), and shift
solenoid fluid will exhaust, allowing default override
valve spring force to move the default override valve to
the released position. With the default override valve in
the released position, reverse fluid pressure passes
through the valve into the default circuit and is routed to
the 3-5-reverse clutch regulator shuttle valve. Default
fluid pressure replaces exhausting PCS 35 reverse
clutch fluid pressure to keep the 3—5-reverseclutch
regulator valve in the applied position, and allow
continued Reverse (R) range operation. Refer to Drive
Range— Fourth Gear Default for a complete description
of the default actions that occur during an electrical
component malfunction.
17-328 Automatic Transm ission - 6T30/6T40/6T45/6T50 (MH8, MH9)

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(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
coo
Pmé
 Automatic Transmission - 6T30/6T40I6T45I6T50 (MH8, MH9) 17-329

Neutral - Engine Running (Gen 1) 3-5-Reverse Clutch Regulator Valve

When the gear selector is moved to the Neutral (N)
position, the hydraulic and electrical system operation
is identical to Park (P) range. However, if Neutral is
selected after the vehicle was operating in Reverse (R),
the normalIy-high 35R pressure control solenoid 2 is
commanded OFF and the following changes would
occur in the hydraulic system.
3-5 Reverse Clutch Releases
Manual Valve
The manual valve is moved to the Neutral position and
blocks line pressure from entering the reverse fluid
circuit. Reverse fluid, from the 3—5-reverseclutch
regulator valve and the clutch select valve, is opened to
an exhaust passage at the manual valve.
35R Pressure Control Solenoid 2
The 35R PC solenoid 2 is commanded OFF allowing
PCS 35 reverse clutch fluid from the 3-5-reverse clutch
regulator valve to exhaust.
PCS 35 reverse clutch fluid exhausts, allowing
3-5-reverse clutch regulator valve spring force to move
the 3-5—reverseclutch regulator valve to the released
position. This allows 35 reverse clutch fluid pressure to
exhaust into the compensator feed circuit in order to
assist the 3-5—reverseclutch piston spring to quickly
release the 3-5-reverse clutch.
3-5-Reverse Clutch
3-5-reverse clutch spring force, assisted by
compensator feed pressure, moves the 3—5—reverse
clutch piston to release the 3—5—reverse clutch plates
and force 35 reverse clutch fluid to exhaust from the
3-5-reverse and 475—6clutch housing assembly. The
exhausting 35 reverse clutch fluid pressure is routed to
the 3-5—reverseclutch regulator valve where it enters
the 35 reverse clutch feed/compensator feed circuit.
Clutch Select Valve
When reverse fluid exhausts from the default override
shuttle valve, shift solenoid fluid continues to hold the
clutch select valve against clutch select valve spring
force allowing 35 reverse clutch feed fluid to exhaust
into the reverse circuit.

(US/Canada)
7Sonic
2013 (5377994)
Manual
Service
17-330 Automatic Transm Ission - 6T30/6T40I6T45I6T50 (MH8, MH9)
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EH -Sonic
2013 Service
(US/Canada) (5377994)
Manual
 Automatic Transmission - 6T30l6T40/6T45l6T50 (MH8, MH9) 17-331

Neutral - Engine Running (Gen 2) 3-5-Reverse Clutch Regulator Valve

When the gear selector is moved to the Neutral (N)
position, the hydraulic and electrical system operation
is identical to Park (P) range. However, if Neutral is
selected after the vehicle was operating in Reverse (R),
the normalIy-low35R pressure control solenoid is
commanded OFF and the following changes would
occur in the hydraulic system.
3-5 Reverse Clutch Releases
Manual Valve
The manual valve is moved to the Neutral position and
blocks line pressure from entering the reverse fluid
circuit. Reverse fluid, from the 3-5-reverse clutch
regulator valve, the clutch select valve. and the default
override valve is opened to an exhaust passage at the
manual valve.
35R Pressure Control Solenoid
The 35R PC solenoid is commanded OFF allowing
PCS 35 reverse clutch fluid from the 3-5-reverse clutch
regulator valve to exhaust.
PCS 35 reverse clutch fluid exhausts, allowing
3-5~reverseclutch regulator valve spring force to move
the 3-5—reverseclutch regulator valve to the released
position. This allows exhausting 35 reverse clutch fluid
pressure to pass into the exhaust backfill circuit in order
to assist the 3-5-reverse clutch piston spring to quickly
release the 3—5-reverseclutch.
3-5-Reverse Clutch
3-5-reverse clutch spring force, assisted by exhaust
backfill pressure, moves the 3-5—reverseclutch piston
to release the 3-5-reverse clutch plates and force 35
reverse clutch fluid to exhaust from the 3-5-reverse and
4—5-6clutch housing assembly. The exhausting 35
reverse clutch fluid pressure is routed to the
3—5—reverse clutch regulator valve where it enters the
exhaust backfill circuit.
Clutch Select Valve
When reverse fluid exhausts from the clutch select
shuttle valve, shift solenoid fluid continues to hold the
clutch select valve against clutch select valve spring
force allowing 35 reverse clutch feed fluid to exhaust
into the reverse circuit.

(US/Canada)
. Sonic
2013 (5377994)
Manual
Service
 3:52

17-332 Automatic 55:228..

Transm Ission - 6T30l6T40/6T45I6T50 (MH8, MH9)

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(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
18.2.6
 Automatic Transmission
Drive Range, First Gear Engine
Braking (Gen 1)
When the gear selector lever is moved to the Drive (D)
range from the Neutral (N) position, the transmission
will provide engine braking. In this operating range, the
normally-low 1234 pressure control solenoid 5 is
commanded ON and, in the engine braking mode, the
following changes occur within the hydraulic,circuits.
1-2-3-4 Clutch Applies
Manual Valve
The manual valve is moved to the Drive (D) position
and allows line fluid pressure to enter the drive fluid
circuit. Drive fluid is then routed to the clutch select
valve, the 1—2-3-4 clutch regulator valve through orifice
#19 and to the 2-6 clutch regulator valve through
orifice #22.
1234 Pressure Control (PC)Solenoid 5
The 1234 PC solenoid 5 is commanded ON allowing
actuator feed limit to enter the PCS 1234 clutch fluid
circuit. PCS 1234 clutch fluid is then routed through
orifice #20 to the 1-2-3-4 clutch regulator valve, and
through orifice #17 to the 1—2-3—4 clutch boost valve.
1-2-3-4 Clutch Regulator Valve
PCS 1234 clutch fluid, at the 1—2-3-4clutch regulator
valve, opposes 1-2-3-4 clutch regulator valve spring
force and 1234 clutch feedback fluid pressure to
regulate drive fluid pressure into the 1234 clutch fluid
circuit. The 1234 clutch fluid is then routed to the 1234
clutch boost valve and through orifice #36 to the
1-2-3-4 clutch.
1-2-3-4 Clutch Boost Valve
PCS 1234 clutch fluid pressure acts on a differential
area, moving the 1234 clutch boost valve against 1234
clutch boost valve spring force, to regulate 1234 clutch
(US/Canada)
-Sonic
2013 {5377994)
Manual
Service
- 6T30l6T40/6T45/6T50 (MH8, MH9) 17-333
fluid into the 1234 clutch feedback circuit. As PCS 1234
clutch fluid pressure is increased to a given value, the
1234 clutch boost valve opens the 1234 clutch
feedback circuit to exhaust. This results in the 1234
clutch regulator valve moving to the full feed position,
sending full 1234 clutch feed pressure (full line
pressure) to the 1—2—3-4 clutch.
1-2-3-4 Clutch
The 1234 clutch fluid enters the transmission case
assembly and moves the 1234 clutch piston against
spring force to apply the 1-2-3—4clutch plates.
2-6 Clutch Regulator Valve
Drive fluid passes through the 2-6 clutch regulator
valve into the P82 circuit.
#2 Pressure Switch
P52 fluid is routed to the normally-closed #2 pressure
switch and opens the switch.
Low and Reverse Clutch Remains
Applied to Provide Engine Braking
Clutch Select Valve
Shift solenoid fluid, present at the valve from Park
position, continues to hold the clutch select valve
against clutch select valve spring force. R1/456 clutch
feed fluid, also present at the valve from Park position,
continues to pass into the R1 circuit to feed the low and
reverse clutch. Drive fluid is present at the valve in
preparation for a change of gears.
Low and Reverse Clutch
The low and reverse clutch remains applied until just
before the 1-2 shift in order to provide engine braking.
 .,
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(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
I
m
 Automatic Transmission
Drive Range, First Gear Engine
Braking (Gen 2)
Note: Some models of the 6T30/40/45/50automatic
transmission are equipped with an electric auxiliary
fluid pump for use in hybrid vehicles (BAS+). Hybrid
vehicles do not require internal combustion engine
(ICE) operation at all times. After a successful engine
start, the hybrid powertrain control module (HPCM)
may turn OFF the engine (Auto Stop) when not required
for the current vehicle conditions. The engine will
remain OFF while in Auto Stop mode, until such time
that vehicle conditions require the engine to run. During
Auto Stop mode the main fluid pump is no longer driven
by the engine, and the auxiliary fluid pump is
commanded ON to provide hydraulic fluid pressure to
operate the transmission. This functional description of
Drive Range— First Gear (Engine Braking), and its
accompanying hydraulic circuit, is written for a
non—hybridtransmission. For a hybrid (BAS+)
transmission, the description and illustration are the
same, with the exception that, when the engine is OFF,
the main fluid pump is not operating and the auxiliary
fluid pump is ON.
When the gear selector lever is moved to the Drive (D)
range from the Neutral (N) position, the transmission
will provide engine braking. Inthis operating range, the
normally-high 1234 pressure control solenoid is
commanded ON and, in the engine braking mode, the
following changes occur within the hydraulic circuits.
1-2-3-4 Clutch Applies
Manual Valve
The manual valve is moved to the Drive (D) position
and allows line fluid pressure to enter the drive fluid
circuit. Drive fluid is then routed to the clutch select
valve, the #5 ball check valve, and to the 2-6 clutch
regulator valve.
#5 Ball Check Valve
Drive fluid unseats the #5 ball check valve and is routed
to the 1-2-3-4 clutch regulator valve.
1234 Pressure Control (PC)Solenoid
The 1234 PC solenoid is commanded ON allowing
actuator feed limit fluid to enter the PCS 1234 clutch
fluid circuit. PCS 1234 clutch fluid is then routed
through orifice #20 to the 1-2-3-4 clutch regulator valve,
and through orifice #17 to the 1-2-3-4 clutch boost
valve.
Samoa
(US/Canada)
~Sonic
2073 (5377994)
Manual
- 6T30l6T40/6T45I6T50 (MH8, MH9) 17-335
1-2-3-4 Clutch Regulator Valve
PCS 1234 clutch fluid, at the 1-2-3—4clutch regulator
valve, opposes 1-2—3—4 clutch regulator valve Spring
force and 1234 clutch feedback fluid pressure to
regulate drive fluid pressure into the 1234 clutch fluid
Circuit.The 1234 clutch fluid is then routed to the
1-2—3—4 clutch boost valve and through orifice #19to
the 1-2-3-4 clutch.
1-2-3-4 Clutch Boost Valve
PCS 1234 clutch fluid pressure acts on a differential
area, moving the 1-2—3-4clutch boost valve against
1-2—3—4 clutch boost valve spring force, to regulate
1234 clutch fluid into the 1234 clutch feedback circuit.
As PCS 1234 clutch fluid pressure is increased to a
given value, the 1—2-3-4clutch boost valve opens the
1234 clutch feedback circuit to exhaust backfill. This
results in the 1-2—3—4 clutch regulator valve moving to
the full feed position, sending full 1234 clutch feed
pressure (full line pressure) to the 1—2-3-4clutch.
1-2-3-4 Clutch
The 1234 clutch fluid enters the transmission case
assembly and moves the 1-2-3-4 clutch piston against
spring force to apply the 1-2-3—4clutch plates.
Accumulator
PCS 1234 clutch fluid is also routed to an accumulator
valve. The accumulator valve is used to dampen any
pressure irregularities occurring in the PCS 1234 clutch
fluid circuit. This helps to control clutch apply fluid
pressure and clutch apply feel.
Low and Reverse Clutch Remains
Applied to Provide Engine Braking
Clutch Select Valve
Shift solenoid fluid, present at the valve from Park
position, continues to hold the clutch select valve
against clutch select valve spring force. R1/456 clutch
feed fluid, also present at the valve from Park position,
continues to pass into the R1 circuit to feed the low and
reverse clutch. Drive fluid is present at the valve in
preparation for a change of gears.
Low and Reverse Clutch
The low and reverse clutch remains applied until just
before the 1-2 shift in order to provide engine braking.
17-336 Automatic Transm Ission - 6T30l6T40/6T45I6T50 (MH8, MH9)

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(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
553282
o.m.v
 Automatic Transmission
Drive Range, First Gear (Gen 1)
As the vehicle speed increases, the transmission
control module (TCM) receives input signals from the
automatic transmission input and output speed
sensors, throttle position sensor and other vehicle
sensors to determine the precise moment to
deenergize or “turn OFF" the shift solenoid, and to
command OFF the normally—highR1/456pressure
control solenoid 3.
Low & Reverse Clutch Releases
Shift Solenoid
The shift solenoid is “commanded OFF" allowing shift
solenoid fluid pressure to exhaust from the clutch select
valve and the TCC regulator apply valve.
Clutch Select Valve
Shift solenoid fluid is exhausted from the clutch select
valve and clutch select valve spring force moves the
valve to the released position. This allows R1 fluid
pressure to pass through the valve into the exhaust
backfill circuit where it exhausts. Drive fluid from the
manual valve passes through the clutch select valve
and enters the drive 1-6 fluid circuit. Drive 1-6 fluid is
routed to the R1/456clutch reguIatorvalve, the 35
reverse clutch regulator valve, and the TCC regulator
valve.
Low and Reverse Clutch
Low and reverse clutch spring force moves the low and
reverse clutch piston to release the low and reverse
clutch plates and force R1 fluid to exhaust from the
case assembly. The exhausting R1 fluid is routed to the
Clutch select valve where it enters the exhaust backflll
circuit.
Fluid Pressure Directed in Preparation
for a Shift
R1/456Pressure Control (PC)Solenoid 3
The R1/456PC solenoid 3 is commanded OFF allowing
PCS R1/456clutch fluid to exhaust from the R1/456
clutch regulator valve.
- 6T30l6T40/6T45l6T50 (MH8, MH9) 17-337
R1/456Clutch Regulator Valve
R1/456clutch regulator valve spring force moves the
valve to the released position, allowing R1/456clutch
feed fluid to enter the exhaust backfill circuit, and drive
1-6 fluid to enter the P84 fluid circuit. PS4 fluid is then
routed to the normalIy-closed #4 pressure switch and
opens the switch. PS4 fluid is also routed to the #1 ball
check valve and flows into the CSV2 latch fluid circuit.
#1 Ball Check Valve
PS4 fluid pressure seats the #1 ball check valve
against the 456 clutch fluid circuit. PS4 fluid is then
directed into the CSV2 latch circuit and routed to the
clutch select valve. CSV2 latch fluid combines with
clutch select valve spring force and holds the valve in
this position during all six forward gear ranges.
#2 Ball Check Valve
Drive 1-6 fluid pressure seats the #2 ball check valve
against the 35 reverse clutch feed fluid passage, and is
directed into the 35 reverse clutch feed/drive 1—6circuit.
35 reverse clutch feed/drive 1-6 fluid is routed through
orifice #25 to the 35 Reverse clutch regulator valve.
3-5-Reverse Clutch Regulator Valve
35 reverse clutch feed/drive 1-6 fluid passes through
the 3—5-reverse clutch regulator valve into the P83 fluid
circuit. PS3 fluid is then routed to the normalIy-closed
#3 pressure switch and opens the switch.
Fluid Pressure Directed in Preparation
for Torque Converter Clutch (TCC)
Apply
TCC Regulator Apply Valve
Drive 1-6 fluid is routed to the TCC regulator apply
valve in preparation for TCC apply.

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
 l
17-338 Automatic Transm Ission - 6T30l6T40/6T45I6T50 (MH8, MH9)
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a 2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
2
a .i
 Automatic Transmission
Drive Range, First Gear (Gen 2)
As the vehicle speed increases, the transmission
control module (TCM) receives input signals from the
automatic transmission input and output speed
sensors, throttle position sensor and other vehicle
sensors to determine the precise moment to
de-energize or “turn OFF” the shift solenoid, and to
command OFF the normaIIy-highR1I456 pressure
control solenoid.
Low & Reverse Clutch Releases
Shift Solenoid
The shift solenoid is commanded OFF allowing shift
solenoid fluid pressure to exhaust from the clutch select
valve, the default override valve, and the TCC regulator
apply valve.
Clutch Select Valve
Shift solenoid fluid is exhausted from the clutch select
valve and clutch select valve spring force moves the
valve to the released position. This allows R1 fluid
pressure to pass through the valve into the exhaust
backfill circuit. Drive fluid from the manual valve passes
through the clutch select valve and enters the drive 1-6
fluid circuit. Drive 1—6fluid is routed to the R1/4-5-6
clutch regulator valve, the 3-5-reverse clutch regulator
valve, and the TCC regulator apply valve.
Low and Reverse Clutch
Low and reverse clutch spring force moves the low and
reverse clutch piston to release the low and reverse
clutch plates and force R1 fluid to exhaust from the
case assembly. The exhausting R1 fluid is routed to the
clutch select valve where it enters the exhaust backfill
circuit.
(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
- 6T30l6T40/6T45/6T50 (MH8, MH9) 17-339
Fluid Pressure Directed in Preparation
for a Shift
R1I456 Pressure Control (PC)Solenoid
The R1I456 PC solenoid is commanded OFF allowing
PCS R1/456clutch fluid to exhaust from the R1/4-5-6
clutch regulator valve and the R1/4-5-6
clutch boost
valve.
R1/4-5-6 Clutch Regulator Valve
R1/4—5-6 clutch regulator valve spring force moves the
valve to the released position, allowing R1I456 clutch
feed fluid to enter the exhaust backflll circuit, and drive
1-6 fluid to enter the latch fluid circuit. Latch fluid is
routed to the #1 ball check valve.
#1 Ball Check Valve
Latch fluid pressure seats the #1 ball check valve
against the 456 clutch fluid circuit. Latch fluid is then
directed to the clutch select valve. Latch fluid combines
with clutch select valve spring force and holds the valve
in this position during all six forward gear ranges.
#2 Ball Check Valve
Drive 1-6 fluid pressure seats the #2 ball check valve
against the 35 reverse clutch feed fluid passage, and is
directed into the 35 reverse clutch feed/drive 1-6 circuit.
35 reverse clutch feed/drive 1-6 fluid is routed to the #3
ball check valve.
#3 Ball Check Valve
35 reverse clutch feed/drive 1—6fluid pressure unseats
the #3ball check valve and is directed to the
3-5-reverse clutch regulator valve.
Fluid Pressure Directed in Preparation
for Torque Converter Clutch (TCC)
Apply
TCC Regulator Apply Valve
Drive 1-6 fluid is routed to the TCC regulator apply
valve in preparation for TCC apply.
17-340 Automatic Transm Ission - 6T30l6T40/6T45l6T50 (MH8, MH9)

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2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
:uSG
 Automatic Transmission
Drive Range, Second Gear (Gen 1)
As vehicle speed increases and operating conditions
become appropriate, the transmission control module
(TCM) processes input signals from the automatic
transmission input and output speed sensors, the
throttle position sensor and other vehicle sensors to
determine the precise moment to command ON the
normally-Iow2-6 pressure control solenoid 4 and shift
the transmission into Second gear. The manual valve
remains in the Drive (D) position and line pressure
continues to feed the drive fluid circuit.
2-6 Clutch Applies
26 Pressure Control (PC)Solenoid 4
The 26 PC solenoid 4 is commanded ON, allowing
actuator feed limit fluid to enter the PCS 26 clutch fluid
circuit. PCS 26 clutch fluid is then routed through orifice
#24 to the 2-6 clutch regulator valve.
(US/Canada)
-Sonic
2013 (5377994)
Manual
SeNice
- 6T30l6T40/6T45l6T50 (MH8, MH9) 17-341
2-6 Clutch Regulator Valve
PCS 26 clutch fluid, at the 2—6clutch regulator valve,
opposes 2-6 clutch regulator valve spring force and
orificed 26 clutch fluid pressure to regulate drive fluid
pressure into the 26 clutch circuit. 26 clutch fluid is then
routed through orifice #37 to the 2-6 clutch assembly in
the transmission case, and through orifice #4to the
spring end of the 2-6 clutch regulator valve. With the
2-6 clutch regulator valve in this position, P82 fluid is
allowed to exhaust and the normalIy-closed P82 switch
closes.
2-6 Clutch
The 26 clutch fluid from the 2-6 clutch regulator valve is
routed through the transmission case to the 2-6 clutch
piston assembly. The 26 clutch fluid pressure moves
the piston against 2—6clutch spring force to apply the
2—6clutch plates.
 o.“ mxammwxam

17-342 Automatic Transm ISSIOn- 6T30l6T40/6T45I6T50 (MH8, MH9)

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 Automatic Transmission - 6T30l6T40/6T45/6T50 (MH8, MH9) 17-343

Drive Range, Second Gear (Gen 2) 2-6 Clutch Regulator Valve

As vehicle speed increases and operating conditions
become appropriate, the transmissioncontrol module
(TCM) processes input signalsfrom the automatic
transmissioninput and output speed sensors, the
throttle positionsensor and other vehicle sensors to
determine the precise moment to command ON the
normally-Iow 26 pressure controIsolenoid and shift the
transmissioninto Second gear. The manual valve
remains inthe Drive (D) positionand line pressure
continues to feed the drive fluid circuit.
2-6 Clutch Applies
26 Pressure Control (PC)Solenoid
The 26 PC solenoid is commanded ON, allowing
actuator feed limitfluidto enter the PCS 26 clutch fluid
circuit.PCS 26 clutch fluidis then routed through orifice
#24 t0 the 2—6clutch regulator valve.
PCS 26 clutch fluid, at the 2-6 clutch regulator valve,
opposes 2-6 clutch regulator valve springforce and
orificed26 clutch fluid pressure to regulate drive fluid
pressure into the 26 clutch circuit.26 clutch fluidis then
routed through orifice #22 to the 2—6clutch assembly in
the transmissioncase, and through orifice #4to the
springend of the 2-6 clutch regulator valve.
2-6 Clutch
The 26 clutch fluidfrom the 2—6clutch regulator valve is
routed through the transmission case to the 2-6 clutch
piston assembly. The 26 clutch fluidpressure moves
the piston against 2-6 clutch springforce to apply the
2—6clutch plates.
Accumulator
PCS 26 clutch fluidis also routed to an accumulator
valve. The accumulator valve is used to dampen any
pressure irregularities occurringinthe PCS 26 clutch
fluidcircuit.This helps to control clutch apply fluid
pressure and clutch apply feel.

(US/Canada)
,Sonic
2013 (5377994)
Manual
Service
 :25333‘ E553 .520
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17-344 Automatic Transm ISSIOI’I
- 6T30l6T4OI6T45/6T50 (MH8, MH9)
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2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Automatic Transmission
Drive Range, Third Gear (Gen 1)
As vehicle speed increases and operating conditions
become appropriate, the transmission control module
(TCM) processes input signalsfrom the automatic
transmissioninput and output speed sensors,the
throttle position sensor and other vehicle sensorsto
determine the precise moment to commandOFF the
normally—low26 pressure control solenoid 4. At the
same time the 35R pressure control solenoid 2 is also
commanded ON to regulate 3—5clutch apply, and the
transmissionshifts into Third gear. The manualvalve
remains inthe Drive (D) position and line pressure
continues to feed the drive fluidcircuit.
3-5-Reverse Clutch Applies
35R Pressure Control (PC)Solenoid 2
The 35R PC solenoid 2 is commanded ON, allowing
actuator feed limit fluidto enter the PCS 35 reverse
clutch fluidcircuit. PCS 35 reverse clutch fluidis routed
through orifice #26 to the 3-5-reverse clutch regulator
valve.
3-5-Reverse Clutch Regulator Valve
PCS 35 reverse clutch fluid,at the 3-5-reverse clutch
regulator valve, opposes 3-5—reverseclutch regulator
valve springforce and 35 reverse clutch feedback fluid
pressure to regulate 35 reverse clutch feed/drive 1-6
pressure into the 35 reverse clutch circuit. The 35
reverse clutch fluidis then routed to the 3-5-reverse
clutch assembly,through orifice #6 to the springend of
the 3-5-reverse clutch regulator valve and through
orifice #33 to the #6 ball check valve. When the
3-5-reverse clutch regulator valve is inthis position,
P83 fluidexhausts through the valve allowingthe
normally—closed#3 pressure switch to close.
—
2013 (US/Canada)
Sonic {5377994)
Manual
Service
- 6T30l6T40/6T45/6T50 (MH8, MH9) 17-345
3-5-Reverse Clutch
35 reverse clutch fluidenters the 3-5-reverse and 4-5-6
clutch housingassembly to move the 3-5 reverse clutch
piston against springforce and compensator feed fluid
pressure to apply the 3-5-reverse clutch plates.
#6 Ball Check Valve
#6 Ball Check Valve 35 reverse clutch feed fluid
unseats the #6 ball check valve, allowingexcess
pressure to pass into the actuator feed limit circuit. This
helps to control clutch apply fluidpressure and clutch
apply feel.
2-6 Clutch Releases
26 Pressure Control (PC)Solenoid 4
The 26 PC solenoid 4 is commanded OFF, allowing
PCS 26 clutch fluidto exhaust from the 2-6 clutch
regulator valve.
2-6 Clutch Regulator Valve
2—6clutch regulator valve springforce moves the valve
to the released position, allowing26 clutch fluidfrom
the 2-6 clutch to passthrough the valve and enter the
exhaust backfill fluidcircuit. With the 2-6 clutch
regulator valve inthis position, drive fluidpasses
through the valve into the P82 circuit. PS2 fluidis
routed to the normaIIy-closed#2 pressure switch and
opens the switch.
2-6 Clutch
2-6 clutch springforce moves the 2—6clutch piston to
release the 2-6 clutch plates and force 26 clutch fluidto
exhaust from the transmission case assembly. The
exhausting 26 clutch fluidpressure is routed to the 2-6
clutch regulator valve where it enters the exhaust
backfitl fluidcircuit.
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2013
-Sonic
(US/Canada)
Selvice
Manual
(5377994)
 Automatic Transmission
Drive Range, Third Gear (Gen 2)
As vehicle speed increases and operating conditions
become appropriate, the transmissioncontrol module
(TCM) processes input signalsfrom the automatic
transmissioninput and output speed sensors,the
throttle position sensor and other vehicle sensorsto
determine the precise moment to command OFF the
normaiiy—low26 pressure control solenoid. At the same
time the 35R pressure control solenoid is also
commanded ON to regulate 3—5clutch apply, and the
transmission shifts into Third gear. The manual valve
remains in the Drive (D) position and line pressure
continues to feed the drive fluid circuit.
3-5-Reverse Clutch Applies
35R Pressure Control (PC)Solenoid
The 35R PC solenoid is commanded ON, allowing
actuator feed limit fluid to enter the PCS 35 reverse
clutch fluid circuit. PCS 35 reverse clutch fluid is routed
through orifice #26to the 3-5-reverse clutch regulator
valve.
3-5-Reverse Clutch Regulator Valve
PCS 35 reverse clutch fluid, at the 3-5-reverse clutch
regulator valve, opposes 3-5—reverseclutch regulator
valve spring force and 35 reverse clutch feedback fluid
pressure to regulate 35 reverse clutch feed/drive 1-6
pressure into the 35 reverse clutch circuit. The 35
reverse clutch fluid is then routed through orifice #25 to
the 3-5-reverse clutch assembly, through orifice #6to
the spring end of the 3-5-reverse clutch regulator valve
and through orifice #33 to the #4 ball check valve.
3-5-Reverse Clutch
35 reverse clutch fluid enters the 3—5-reverseand 4-5-6
clutch housing assembly to move the 3-5-reverse
clutch piston against spring force and exhaust backfill
fluid pressure to apply the 3-5—reverseclutch plates.
(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
- 6T30l6T4076T45/6T50 (MH8, MH9) 17-347
#4 Ball Check Valve
35 reverse clutch feed fluid unseats the #4 ball check
valve, allowing excess pressure to pass into the
actuator feed limit circuit. This helps to control clutch
apply fluid pressure and clutch apply feel.
Accumulator
PCS 35 reverse clutch fluid is also routed to an
accumulator valve. The accumulator valve is used to
dampen any pressure irregularities occurring in the
PCS 35 reverse clutch fluid circuit. This helps to control
clutch apply fluid pressure and clutch apply feel.
2-6 Clutch Releases
26 Pressure Control (PC)Solenoid
The 26 PC solenoid is commanded OFF, allowing PCS
26 clutch fluid to exhaust from the 2—6clutch regulator
valve.
2-6 Clutch Regulator Valve
2-6 clutch regulator valve spring force moves the valve
to the released position, allowing 26 clutch fluid from
the 2—6clutch to passthrough the valve and enter the
exhaust backfill fluid circuit.
2-6 Clutch
2-6 clutch spring force moves the 2—6clutch piston to
release the 2—6clutch plates and force 26 clutch fluid to
exhaust from the transmission case assembly. The
exhausting 26 clutch fluid pressure is routed to the 2-6
clutch regulator valve where it enters the exhaust
backfili fluid circuit.
17-348 Automatic Transm Ission - 6T30l6T40/6T45/6T50 (MH8, MH9)

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2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Automatic Transmission
Drive Range - Fourth Gear (Gen 1)
As vehicle speed increases, the transmission control
module (TCM) processes input signalsfrom the
automatic transmission input and output speed
sensors,the throttle position sensor and other vehicie
sensorsto determine the precise moment to command
OFF the normaIIy-high35R pressure control solenoid 2.
At the same time, the normalIy-low R1/456 pressure
control solenoid 3 is commanded ON to regulate 4—5-6
clutch apply and the transmission shifts into
, the 3-5—reverseclutch regulator valve to the released
Fourth gear.
4-5-6 Clutch Applies
R1I456 Pressure Control (PC)Solenoid 3
The R1/456 PC solenoid 3 is commanded ON allowing
actuator feed limit fluid to enter the PCS R1/456 clutch
fluid circuit. PCS R1/456 clutch fluid is routed through
orifice #11to the R1I456 clutch regulator valve.
R1/4-5-6 Clutch Regulator Valve
PCS R1/456 clutch fluid, at the R1/4-5-6 clutch
regulator valve, opposes R1/4—5-6clutch regulator
valve spring force and orificed R1I456 clutch feed fluid
pressure to regulate iine pressure into the R1I456
clutch feed circuit. R1I456 clutch feed fluid is then
routed to the clutch seiect valve, through orifice #12 to
the spring end of the R1/4-5-6 clutch regulator valve,
and through orifice #34to ball check valve #5. When
the R1/4-5-6 clutch regulator valve is in this position,
PS4 fluid exhausts through the valve allowing the
normalIy—closed#4 pressure switch to close.
Clutch Select Valve
R1I456 clutch feed fluid passesthrough the clutch
select valve and enters the 456 clutch Circuit.456
clutch fluid is routed to the 4-5—6clutch assembly, and
through orifice #2 to the #1 ball check valve.
#1 Ball Check Valve
Orificed 456 clutch fluid pressure seats the #1 ball
check valve against the exhausting PS4 fluid passage.
456 clutch fluid is then directed into the CSV2 latch
Circuit to replace the exhausting PS4 pressure and is
routed to the clutch select valve. CSV2 latch fluid
combines with clutch select valve spring force and
holds the valve in this position during all six forward
gear ranges.
4-5-6 Clutch
and 4-5-6 clutch
456 clutch fluid enters the 3—5—reverse
housing assembly, and moves the 4-5-6 clutch piston
against spring force and compensator feed pressure to
apply the 4- 5-6 clutch plates.
#5 Ball Check Valve
R1I456 clutch feed fluid unseats the #5 ball check
valve, allowing excess pressure to pass into the
actuator feed limit circuit. This helps to control clutch
apply fluid pressure and clutch apply feel.
—
2013 (US/Canada)
Sonic (5377994)
Manual
Service
- 6T30l6T40/6T45fi6T 50 (MH8, MH9) 17-349
3-5-Reverse Clutch Releases
35R Pressure Control (PC)Solenoid 2
The 35R PC solenoid 2 is commanded OFF allowing
PCS 35 reverse clutch fluid from the 3—5-reverseclutch
regulator valve to exhaust.
3-5-Reverse Clutch Regulator Valve
PCS 35 reverse clutch fluid exhausts, allowing
3-5—reverseclutch regulator valve springforce to move
position. This allows35 reverse clutch fluid pressure to
exhaust into the compensator feed circuit in order to
assist the 3-5-reverse clutch piston spring to quickly
release the 3-5—reverseclutch. With the 3—5-reverse
clutch regulator valve in this position, orificed (#25)35
reverse clutch feed/drive 1-6 fluid passesthrough the
valve into the P83 circuit. P83 fluid is routed to the
normaIIy-closed#3 pressure switch and opens the
switch.
3-5-Reverse Clutch
3-5-reverse clutch spring force, assisted by
compensator feed pressure, moves the 3-5-reverse
clutch piston to release the 3—5-reverseclutch plates
and force 35 reverse clutch fluid to exhaust from the
3—5-reverseand 4-5—6clutch housing assembly. The
exhausting 35 reverse clutch fluid pressure is routed to
the 3-5-reverse clutch regulator valve where it enters
the 35 reverse clutch feed/compensator feed circuit.
Torque Converter Clutch (TCC) Applies
Torque Converter Ctutch (TCC) Pressure Control
(PC)Solenoid
The TCC PC solenoid is commanded ON, allowing
actuator feed iimit fluid'to enter the PCS TCC fluid
circuit. PCS TCC fluid is routed through orifice #15to
the TCC regulator applyvalve and through orifice #3 to
the TCC control valve.
TCC Regulator Apply Valve
PCS TCC fluid, at the TCC regulator apply valve,
opposes TCC regulator apply valve spring force and
orificed regulated apply fluid pressure to regulate drive
1-6 fluid into the regulated apply circuit. Regulated
apply fluid is routed to the TCC control valve and
through orifice #16 to the spring end of the TCC
regulator apply valve.
TCC Control Valve
PCS TCC fluid moves the TCC control valve against
TCC control valve spring force, allowing regulated
apply fluid to pass through the valve into the TCC apply
fluid circuit and apply the torque converter clutch.
Converter feed fluid passesthrough orifice #28t0 the
TCC control valve, replacing TCC apply fluid, to supply
the cooler feed circuit. TCC release fluid passes
through the TCC control valve and is exhausted.
 m
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2013
»Sonic(US/Canada)
Service
Manual
(5377994)
J. §—
 Automatic Transmission
Drive Range - Fourth Gear (Gen 2)
As vehicle speed increases, the transmission control
module (TCM) processes input signals from the
automatic transmission input and output speed
sensors, the throttle position sensor and other vehicle
sensors to determine the precise moment to command
OFF the normaliy-low 35R pressure control solenoid. At
the same time, the normaIIy—high R1I456 pressure
control solenoid is commanded ON to regulate 4-5-6
clutch apply and the transmission shifts into
Fourth gear.
4-5-6 Clutch Applies
R1I456 Pressure Control (PC)Solenoid
The R1/456PC solenoid is commanded ON allowing
actuator feed limit fluid to enter the PCS R1I456 clutch
fluid circuit. PCS R1I456 clutch fluid is routed through
orifice #11to the R1/4-5-6 clutch regulator valve, and
through orifice #34to the R1/4-5-6 clutch boost valve.
R1/4-5-6 Clutch Regulator Valve
PCS R1I456 clutch fluid, at the R1/4-5-6 clutch
regulator valve, opposes R1/4-5-6 clutch regulator
valve spring force and orificed R1I456 clutch feed fluid
pressure to regulate line pressure into the R1/456
clutch feed circuit. R1I456 clutch feed fluid is then
routed to the clutch select valve, the R1/4-5-6 clutch
boost valve, and through orifices #9 and #12 to the
spring end of the R1/4-5-6 clutch regulator valve. When
the R1/4-5-6 clutch regulator valve is in this position,
latch fluid exhausts through the valve allowing 456
clutch fluid to shuttle the #1 ball check valve.
R1I4-5-6 Clutch Boost Valve
PCS R1I456 clutch fluid pressure acts on a differential
area, moving the R1/4-5-6 clutch boost valve against
R1/4-5-6 c|utch boost valve spring force, to regulate
R1I456 feed clutch fluid into the R1/456clutch
feedback circuit. As PCS R1I456 clutch fluid pressure
is increased to a given value, the R1/4-5-6 clutch boost
valve opens the R1I456 clutch feedback circuit to
exhaust backfill. This results in the R1/4-5—6clutch
regulator valve moving to the full feed position, sending
fufl R1/456clutch feed pressure (full line pressure) to
the 4—5-6clutch.
#1 Ball Check Valve
Orificed 456 clutch fluid pressure seats the #1 ball
check valve against the exhausting latch fluid passage.
456 clutch fluid is then directed into the latch circuit to
replace the exhausting latch pressure and is routed to
the clutch select valve. Latch fluid combines with clutch
select valve spring force and holds the valve in this
position during all six forward gear ranges.
Clutch Select Valve
R1I456 clutch feed fluid passes through the clutch
select valve and enters the 456 clutch circuit. 456
clutch fluid is routed to the 4-5-6 clutch assembly, and
through orifice #2 to the #1 ball check valve.
4—5-6Clutch
456 clutch fluid enters the 3-5—reverseand 4—5-6clutch
housing assembly, and moves the 4-5-6 clutch piston
against spring force and exhaust backfill pressure to
apply the 4-5-6 clutch plates.
(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
- 6T30l6T4076T45/6T50 (MH8, MH9) 17-351
Accumulator
PCS R1/456clutch fluid is also routed to an
accumulator valve. The accumulator valve is used to
dampen any pressure irregularities occurring in the
PCS R1I456 clutch fluid circuit. This helps to control
clutch applyfluid pressure and clutch apply feel.
3-5-Reverse Clutch Releases
35R Pressure Control (PC)Solenoid
The 35R PC solenoid is commanded OFF allowing
PCS 35 reverse clutch fluid from the 3—5-reverseclutch
regulator valve to exhaust.
3-5-Reverse Clutch Regulator Valve
PCS 35 reverse clutch fluid exhausts. allowing
3-5-reverse clutch regulator valve spring force to move
the 3-5-reverse clutch regulator valve to the released
position. This allows exhausting 35 reverse clutch fluid
pressure to pass into the exhaust backfill circuit in order
to assist the 3-5-reverse clutch piston spring to quickly
release the 3-5-reverse clutch.
3-5-Reverse Clutch
3-5-reverse clutch spring force, assisted by exhaust
backfill pressure, moves the 3-5-reverse clutch piston
to release the 3—5-reverseclutch plates and force 35
reverse clutch fluid to exhaust from the 3-5—reverseand
4-5-6 clutch housing assembly. The exhausting 35
reverse clutch fluid pressure is routed to the
3-5-reverse clutch regulator valve where it enters the
exhaust backfill feed circuit.
Torque Converter Clutch (TCC) Applies
Torque Converter Clutch (TCC) Pressure Control
(PC) Solenoid
The TCC PC solenoid is commanded ON, alIowing
actuator feed limit fluid to enter the PCS TCC fluid
circuit. PCS TCC fluid is routed through orifice #15 to
the TCC regulator apply valve and through orifice #3to
the TCC control valve.
TCC Regulator Apply Valve
PCS TCC fluid, at the TCC regulator apply valve,
opposes TCC regulator apply valve spring force and
orificed regulated apply fluid pressure to regulate drive
1—6fluid into the regulated apply circuit. Regulated
apply fluid is routed to the TCC control valve and
through orifice #16 to the spring end of the TCC
regulator apply valve.
TCC Control Valve
PCS TCC fluid moves the TCC control valve against
TCC control valve spring force, allowing regulated
apply fluid to pass through the valve into the TCC apply
fluid circuit and apply the torque converter clutch.
Converter feed fluid passes through orifice #28to the
TCC control valve, replacing TCC apply fluid, to supply
the cooler feed circuit. TCC release fluid passes
through the TCC control valve and is exhausted,
17-352 Automatic Transm Ission - 6T30l6T40/6T45/6T50 (MH8, MH9)

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2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
«.mé
 Automatic Transmission
Drive Range - Fourth Gear Default
(Gen 2/Hybrid)
Ifthe transmission encounters an electrical component
malfunction, the transmission will default to Fourth
gear. All solenoids will default to their normal state.
lfthe torque converter clutch is applied, it will release.
The transmission will remain in Drive Range— Fourth
Gear Default until the condition is corrected. Reverse
(R) range can also still be selected. This default action
enables the vehicle to be safely driven to a service
center.
1-2-3-4 Clutch Applies or Remains
Applied
1234Pressure Control (PC)Solenoid
The 1234 PC solenoid defaults to its normally-high
state (ON). allowing actuator feed limit fluid to enter the
PCS 1234 clutch fluid circuit. PCS 1234 clutch fluid is
routed through orifice #20 to the 1-2—3-4clutch
regulator valve, and through orifice #17to the 1-2-3—4
clutch boost valve. Ifthe transmission is operating in
Fifth or Sixth gear when an electrical malfunction
occurs, the 1-2—3-4clutch will apply. Ifthe transmission
is operating in First, Second, Third or Fourth gear when
the electrical malfunction occurs, the 1-2-3~4clutch
remains applied.
1-2-3-4Clutch Boost Valve
PCS 1234 clutch fluid pressure acts on a differential
area, moving the 1-2—3—4 clutch boost valve against
1—2—3-4 clutch boost valve spring force, to block 1234
clutch fluid from entering the 1234 clutch feedback
circuit, and opening the 1234 clutch feedback circuit to
exhaust backfill. This results in the 1-2—3-4clutch
regulator valve moving to the full feed position, sending
full 1234 clutch feed pressure (full line pressure) to the
1-2-3—4clutch.
1-2-3-4Clutch Regulator Valve
PCS 1234clutch fluid moves the 1-2-3—4clutch
regulator valve, against 1-2—3—4 Clutch regulator valve
spring force, to the applied position. This allows drive
fluid pressure to pass through the valve into the 1234
clutch fluid circuit. The 1234 clutch fluid is then routed
to the 1-2—3-4clutch boost valve and through orifice
#19 to the 1—2-3-4clutch.
1-2-3—4 Clutch
1234 clutch fluid enters the transmission case
assembly and moves the 1-2-3-4 clutch piston against
spring force to apply the 1—2-3—4clutch plates.
Accumulator
PCS 1234 clutch fluid is also routed to an accumulator
valve. The accumulator valve is used to dampen any
pressure irregularities occurring in the PCS 1234 clutch
fluid circuit. This helps to control clutch apply fluid
pressure and clutch apply feel.
{US/Canada)
-Sonic
2013 (5377994)
Manual
Service
- 6T30l6T40/6T45l6T50 (MH8, MH9) 17-353
4-5-6 Clutch Applies or Remains
Applied
R1I456Pressure Control (PC)Solenoid
The R1I456 PC solenoid defaults to its normalIy—high
state (ON), allowing actuator feed limit fluid to enter the
PCS R1I456 clutch fluid circuit. PCS R1I456 clutch fluid
is routed through orifice #11to the R1/4-5-6 clutch
regulator valve, and through orifice #34 to the R1/4—5-6
clutch boost valve. Ifthe transmission is operating in
First, Second or Third gear when an electrical
malfunction occurs, the 4-5-6 clutch will apply. Ifthe
transmission is operating in Fourth, Fifth or Sixth gear
when the electrical malfunction occurs, the 4-5—6clutch
remains applied.
R1l4-5-6 Clutch Boost Valve
PCS R1I456 clutch fluid pressure acts on a differential
area, moving the R1/4-5-6 clutch boost valve against
R1/4-5—6 clutch boost valve spring force, to block R1/
456 clutch feed fluid from entering the R1I456 clutch
feedback circuit, and opening the R1I456 clutch
feedback circuit to exhaust backflll. This results in the
R1/4—5-6clutch regulator valve moving to the full feed
position, sending full R1/456 clutch feed pressure (full
line pressure) to the 4—5—6 clutch.
R1/4-5-6 Clutch Regulator Valve
PCS R1/456 clutch fluid moves the R1/4-5-6 clutch
regulator valve, against R1/4—5-6clutch regulator valve
spring force, to the applied position. This allows line
fluid pressure to pass through the valve into the R1I456
clutch feed circuit. R1/456 clutch feed fluid is then
routed to the clutch select valve, the R1/4—5-6clutch
boost valve, and through orifices #9 and #12 to the
spring end of the R1/4-5-6 clutch regulator valve. When
the R1/4-5-6 clutch regulator valve is in this position,
latch fluid exhausts through the valve allowing 456
clutch fluid to shuttle the #1 ball check valve.
#1 Ball Check Valve
Orificed 456 clutch fluid pressure seats the #1 ball
check valve against the exhausting latch fluid passage.
456 clutch fluid is then directed into the latch circuit to
replace the exhausting latch pressure and is routed to
the clutch select valve. Latch fluid combines with clutch
select valve spring force and holds the valve in this
position during all six fon/vardgear ranges.
Clutch Select Valve
R1I456 clutch feed fluid passes through the clutch
select valve and enters the 456 clutch circuit. 456
clutch fluid is routed to the 4-5~6clutch assembly, and
through orifice #2to the #1 ball check valve.
4-5-6Clutch
456 clutch fluid enters the 3-5—reverseand 4-5—6clutch
housing assembly, and moves the 4-5-6 clutch piston
against spring force and exhaust backflll pressure to
apply the 4-5-6 clutch plates.
Accumulator
PCS R1I456 clutch fluid is also routed to an
accumulator valve. The accumulator valve is used to
dampen any pressure irregularities occurring in the
PCS R1/456clutch fluid circuit. This helps to control
clutch apply fluid pressure and clutch apply feel.
17-354 Automatic Transmission - 6T30/6T40/6T45l6T50
3-5-Reverse Clutch Releases
35R Pressure Control (PC)Solenoid
lfthe transmission is in Third or Fifth gear when an
electrical condition commands a protection mode, the
35R PC solenoid defaults to its normaIIy-lowstate
(OFF), allowing PCS 35R clutch fluid pressure to
exhaust and the 3-5-reverse clutch to release. See
Drive Range—Fourth Gear for a complete description of
3—5-reverseclutch release.
2-6 Clutch Releases
26 Pressure Control (PC)Solenoid
Ifthe transmission is in Second or Sixth gear when an
electrical condition commands a protection mode, the
26 PC solenoid defaults to its normaIIy-lowstate (OFF),
(MH8, MH9)
allowing PCS 26 clutch fluid pressure to exhaust and
the 2—6clutch to release. See Drive Range—Third Gear
for a complete description of 2-6 clutch release.
Torque Converter Clutch (TCC)
Releases
Torque Converter Clutch (TCC) Pressure Control
(PC)Solenoid
lfthe TCC is applied when an electrical condition
commands a protection mode, the TCC PC solenoid
defaults to its normally—lowstate (OFF), allowing PCS
TCC fluid to exhaust and the TCC to release. See Drive
Range—Sixth Gear for a complete description of TCC
release.

(US/Canada)
-Sonic
2013 (5377994)
Manual
Sen/ice
 Automatic Transm Ission - 6T30l6T40/6T45I6T50 (MH8, MH9) 17-355

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2013 (US/Canada)
-Sonic 5:5 (5377994)
Manual
Service
17-356 Automatic Transmission - 6T30l6T40/6T45I6T50
Drive Range, Fifth Gear (Gen 1)
As vehicle speed increases, the transmission control
module (TCM) processes input signals from the
automatic transmission input and output speed
sensors, the throttle position sensor and other vehicle
sensors to determine the precise moment to command
ON the normalIy-high35R pressure control solenoid 2.
At the same time, the normaIIy—low 1234 pressure
control solenoid 5 is commanded OFF and the
transmission shifts into Fifth gear.
3-5-Reverse Clutch Applies
35R Pressure Control (PC)Solenoid 2
The 35R PC solenoid 2 is commanded ON, allowing
actuator feed limit fluid to enter the PCS 35 reverse
clutch fluid circuit. PCS 35 reverse clutch fluid is routed
through orifice #26 to the 3-5-reverse clutch regulator
valve.
3-5-Reverse Clutch Regulator Valve
PCS 35 reverse clutch fluid, at the 3-5-reverse clutch
regulator valve, opposes 3-5—reverseclutch regulator
valve spring force and 35 reverse clutch feedback fluid
pressure to regulate 35 reverse clutch feed/drive 1-6
pressure into the 35 reverse clutch circuit. The 35
reverse clutch fluid is then routed to the 3-5-reverse
clutch assembly, through orifice #6to the spring end of
the 3—5-reverseclutch regulator valve and through
orifice #33 to the #6 ball check valve. When the
3-5—reverseclutch regulator valve is in this position,
P83 fluid exhausts through the valve allowing the
normally—closed#3 pressure switch to close.
3-5-Reverse Clutch
35 reverse clutch fluid enters the 3-5-reverse and 4—5-6
clutch housing assembly to move the 3—5reverse clutch
piston against spring force and compensator feed fluid
pressure to apply the 3—5-reverseclutch plates.
(MH8, MH9)
#6 Ball Check Valve
35 reverse clutch feed fluid unseats the #6 ball check
valve, allowing excess pressure to pass into the
actuator feed limit circuit. This helps to control clutch
apply fluid pressure and clutch apply feel.
1-2-3-4 Clutch Releases
1234 Pressure Control (PC)Solenoid 5
The 1234 PC solenoid 5 is commanded OFF, allowing
PCS 1234 clutch fluid to exhaust from the 1-2-3-4
clutch regulator valve and the 1-2—3-4clutch boost
valve.
1-2-3-4 Clutch Regulator Valve
1-2-3-4 clutch regulator Valve spring force moves the
valve to the released position, allowing 1234 clutch fluid
pressure from the 1-2-3-4 clutch to pass through the
valve and enter the exhaust backfill circuit. The
exhausting 1234 clutch fluid pressure is routed through
orifice #21 in order to help control the release of the
1-2-3-4 clutch. With the 1-2-34 clutch regulator valve in
this position, drive fluid passes through the valve into
the PS1 circuit. PS1 fluid is routed to the #1 pressure
switch and opens the normaIIy—closedswitch.
1-2-3-4 Clutch Boost Valve
1-2—3-4clutch boost valve spring force moves the
1-2—3-4clutch boost valve to the released position,
allowing 1234 clutch feedback fluid pressure to exhaust
from the 1-2—3-4clutch regulator valve into the 1234
clutch circuit.
1-2-3-4 Clutch
1-2—3-4clutch spring force moves the 1-2—3—4 clutch
piston to release the 1-2-3—4clutch plates and force
1234 clutch fluid to exhaust from the transmission case
assembly. The exhausting 1234 clutch fluid is routed to
the 1—2-3-4clutch regulator valve where it enters the
exhaust backfill circuit.
(US/Canada)
7Sonic
2013 (5377994)
Manual
Service
 m
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(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
.
V
17-358 Automatic Transmission - 6T30l6T40/6T45I6T50
Drive Range, Fifth Gear (Gen 2)
As vehicle speed increases, the transmission control
module (TCM) processes input signals from the
automatic transmission input and output speed
sensors, the throttle position sensor and other vehicle
sensors to determine the precise moment to command
ON the normalIy-Iow35R pressure control solenoid. At
the same time, the normaIIy-high1234 pressure control
solenoid is commanded OFF and the transmission
shifts into Fifth gear.
3-5-Reverse Clutch Applies
35R Pressure Control (PC)Solenoid
The 35R PC solenoid is commanded ON, allowing
actuator feed limit fluid to enter the PCS 35 reverse
clutch fluid circuit. PCS 35 reverse clutch fluid is routed
through orifice #26 to the 3-5-reverse clutch regulator
valve.
3-5-Reverse Clutch Regulator Valve
PCS 35 reverse clutch fluid, at the 3-5—reverseclutch
regulator valve, opposes 3-5-reverse clutch regulator
valve spring force and 35 reverse clutch feedback fluid
pressure to regulate 35 reverse clutch feed/drive 1-6
pressure into the 35 reverse clutch circuit. The 35
reverse clutch fluid is then routed through orifice #25 to
the 3-5-reverse clutch assembly, through orifice #6to
the spring end of the 3-5-reverse clutch regulator valve
and through orifice #33 to the #4 ball Check valve.
3-5-Reverse Clutch
35 reverse clutch fluid enters the 3-5-reverse and 4-5-6
Clutch housing assembly to move the 3—5—reverse
clutch piston against spring force and exhaust backfill
fluid pressure to apply the 3—5—reverse clutch plates.
#4 Ball Check Valve
35 reverse clutch feed fluid unseats the #4 ball check
valve, allowing excess pressure to pass into the
actuator feed limit circuit. This helps to control clutch
apply fluid pressure and clutch apply feel.
(MH8, MH9)
Accumulator
PCS 35 reverse clutch fluid is also routed to an
accumulator valve. The accumulator valve is used to
dampen any pressure irregularities occurring in the
PCS 35 reverse clutch fluid circuit. This helps to control
clutch apply fluid pressure and clutch apply feel.
1-2-3-4 Clutch Releases
1234 Pressure Control (PC)Solenoid
The 1234 PC solenoid is commanded OFF, allowing
PCS 1234 clutch fluid to exhaust from the 1-2-3-4
clutch regulator valve and the 1-2-3—4clutch boost
valve.
1-2-3-4 Clutch Regulator Valve
1-2-3-4 clutch regulator valve spring force moves the
valve to the released position, allowing 1234 clutch fluid
pressure from the 1-2—3-4clutch to pass through the
valve and enter the exhaust backfill circuit. The
exhausting 1234 clutch fluid pressure is routed through
orifice #21 in order to help control the release of the
1-2-3-4 clutch.
1-2-3-4 Clutch Boost Valve
1-2-3-4 clutch boost valve spring force moves the
1—2-3-4clutch boost valve to the released position,
allowing 1234 clutch feedback fluid pressure to exhaust
from the 1-2-3-4 clutch regulator valve into the 1234
clutch circuit.
1-2-3-4 Clutch
1-2—3—4 clutch spring force moves the 1-2-3-4 clutch
piston to release the 1-2-3—4clutch plates and force
1234 clutch fluid to exhaust from the transmission case
assembly. The exhausting 1234 clutch fluid is routed to
the 1-2—3-4clutch regulator valve where it enters the
exhaust backfill circuit.
(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
 5.31:3
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(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
17-360 Automatic Transmission - 6T30l6T40/6T45/6T50
Drive Range, Fifth Gear Default
(Gen 1)
Ifthe transmission encounters an electrical component
malfunction, the transmission will default to Fifth gear.
All solenoids will default to their normal state. Ifthe
torque converter clutch is applied, it will release. The
transmission will remain in Drive Range— Fifth Gear
Default until the condition is corrected. Reverse (R)
range can also still be selected. This default action
enables the vehicle to be safely driven to a service
center.
3-5 Reverse Clutch Applies or Remains
Applied
35R Pressure Control (PC)Solenoid 2
The 35R PC solenoid 2 defaults to its normally—high
state (ON), allowing actuator feed limit fluid to enter the
PCS 35 reverse clutch fluid circuit. PCS 35 reverse
clutch fluid is routed through orifice #26to the
3-5-reverse clutch regulator valve. lfthe transmission is
operating in First, Second, Fourth or Sixth gear when
an electrical malfunction occurs, the 3—5-reverseclutch
will apply. Ifthe transmission is operating in Third or
Fifth gear when the electrical malfunction occurs, the
3—5—reverse clutch remains applied.
3-5-Reverse Clutch Regulator Valve
PCS 35 reverse clutch fluid, at the 3-5-reverse clutch
regulator valve, opposes 3-5-reverse clutch regulator
valve spring force and 35 reverse clutch feedback fluid
pressure to regulate 35 reverse clutch feed/drive 1-6
pressure into the 35 reverse clutch circuit. The 35
reverse clutch fluid is then routed to the 3-5-reverse
clutch assembly, through orifice #6 to the spring end of
the 3-5-reverse clutch regulator valve and through
orifice #33 t0 the #6 ball check valve. When the
3-5-reverse clutch regulator valve is in this position,
P83 fluid exhausts through the valve allowing the
normally-closed #3 pressure switch to close.
3-5-Reverse Clutch
35 reverse clutch fluid enters the 3-5-reverse and 4—5—6
clutch housing assembly to move the 3-5 reverse clutch
piston against spring force and compensator feed fluid
pressure to apply the 3-5-reverse clutch plates.
#6 Ball Check Valve
35 reverse clutch feed fluid unseats the #6 ball check
valve, allowing excess pressure to pass into the
actuator feed limit circuit. This helps to control clutch
apply fluid pressure and clutch apply feel.
4-5-6 Clutch Applies or Remains
Applied
R1I456 Pressure Control (PC)Solenoid 3
The R1I456 PC solenoid 3 defaults to its normally-high
state (ON), allowing actuatorfeed limit fluid to enter the
PCS R1I456 clutch fluid circuit. PCS R1I456 clutch fluid
is routed through orifice #11to the R1I456 clutch
regulator valve. Ifthe transmission is operating in First,
Second or Third gear when an electrical malfunction
occurs, the 4—5-6clutch will apply. Ifthe transmission is
(MH8, MH9)
operating in Fourth, Fifth or Sixth gear when the
electrical malfunction occurs, the 4-5-6 clutch remains
applied.
R1/4-5-6 Clutch Regulator Valve
PCS R1/456 clutch fluid, at the R1/4-5—6clutch
regulator valve, opposes R1/4-5-6 clutch regulator
valve spring force and orificed R1/456 clutch feed fluid
pressure to regulate line pressure into the R1I456
clutch feed circuit. R1/456 clutch feed fluid is then
routed to the clutch select valve, through orifice #12 to
the spring end of the R1/4-5—6clutch regulator valve,
and through orifice #34 to ball check valve #5. When
the R1/4-5—6clutch regulator valve is in this position,
PS4 fluid exhausts through the valve allowing the
normaIIy-closed#4 pressure switch to close.
Clutch Select Valve
R1/456 clutch feed fluid passes through the clutch
select valve and enters the 456 clutch circuit. 456
clutch fluid is routed to the 4-5-6 clutch assembly, and
through orifice #2to the #1 ball check valve.
#1 Ball Check Valve
Orificed 456 clutch fluid pressure seats the #1 ball
check valve against the exhausting PS4 fluid passage.
456 clutch fluid is then directed into the CSV2 latch
circuit to replace the exhausting PS4 pressure and is
routed to the clutch select valve. CSV2 latch fluid
combines with clutch select valve spring force and
holds the valve in this position during all six forward
gear ranges.
4-5-6 Clutch
456 clutch fluid enters the 3-5-reverse and 4-5—6clutch
housing assembly, and moves the 4-5-6 clutch piston
against spring force and compensator feed pressure to
apply the 4-5—6clutch plates.
#5 Ball Check Valve
R1I456 clutch feed fluid unseats the #5 ball check
valve, allowing excess pressure to pass into the
actuator feed limit circuit. This helps to control clutch
apply fluid pressure and clutch apply feel.
1-2-3-4 Clutch Releases
1234 Pressure Control (PC)Solenoid 5
Ifthe transmission is in First, Second, Third or Fourth
gear when an electrical condition commands a
protection mode, the 1234 PC solenoid 5 defaults to its
normally—Iowstate (OFF), allowing PCS 1234 clutch
fluid pressure to exhaust and the 1-2—3-4clutch to
release.
2-6 Clutch Releases
26 Pressure Control (PC)Solenoid 4
Ifthe transmission is in Second or Sixth gear when an
electrical condition commands a protection mode, the
26 PC solenoid 4 defaults to its normally—lowstate
(OFF), allowing PCS 26 clutch fluid pressure to exhaust
and the 2—6clutch to release.
(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
 Automatic Transmission - 6T30l6T4016T45/6T50 (MH8, MH9) 17-361

Torque Converter Clutch (TCC) Drive Range— Fourth Gear Default

Releases
Torque Converter Clutch (TCC) Pressure Control
(PC)Solenoid
lfthe TCC is applied when an electrical condition
commands a protection mode, the TCC PC solenoid
defaults to its normally—lowstate (OFF), allowing PCS
TCC fluid to exhaust and the TCC to release.
(Some Models)
The transmission default gear may be Fourth, rather
than Fifth gear, depending on engine size and effective
final drive ratio. Ifthe transmission encounters an
electrical component malfunction, the transmission will
default to Fourth gear. AIIsolenoids will default to their
normal state. Ifthe torque converter clutch is applied, it
will release. The transmission will remain in Drive
Range— Fourth Gear Default until the condition has
been corrected. Reverse (R) range can also still be
selected. This default action enables the vehicle to be
safely driven to a service center.

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
 e
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17-362 Automatic Transm Ission - 6T30l6T40/6T45/6T50 (MH8, MH9)
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I (US/Canada)
-Sonic
2013 (5377994)
Manual
.
u
 Automatic Transmission
Drive Range, Fifth Gear Default
(Gen 2)
Ifthe transmission encounters an electrical component
malfunction, the transmission will default to Fourth
gear. All solenoids will default to their normal state.
if the torque converter clutch is applied, it will release.
The transmission will remain in Drive Range— Fourth
Gear Default until the condition is corrected. Reverse
(R) range can also still be selected. This default action
enables the vehicle to be safely driven to a service
center.
1-2-3-4 Clutch Applies or Remains
Applied
1234Pressure Control (PC)Solenoid
The 1234PC solenoid defaults to its normally-high
state (ON), allowing actuator feed limit fluid to enter the
PCS 1234clutch fluid circuit. PCS 1234clutch fluid is
routed through orifice #20to the 1-2-3-4clutch
regulator valve, and through orifice #17to the 1-2-3-4
clutch boost valve. Ifthe transmission is operating in
Fifth or Sixth gear when an electrical malfunction
occurs, the 1-2—3-4 clutch will apply. if the transmission
is operating in First, Second, Third or Fourth gear when
the electrical malfunction occurs, the 1—2—3—4 clutch
remains applied.
1-2-3-4Clutch Boost Valve
PCS 1234clutch fluid pressure acts on a differential
area, moving the 1-2-3—4 clutch boost valve against
1-2—3-4 clutch boost valve spring force, to block 1234
clutch fluid from entering the 1234clutch feedback
circuit, and opening the 1234clutch feedback circuit to
exhaust backfill. This results in the 1-2—3-4 clutch
regulator valve moving to the full feed position, sending
full 1234clutch feed pressure (full line pressure) to the
1-2-3-4clutch.
1-2-3-4Clutch Regulator Valve
PCS 1234clutch fluid moves the 1-2-3—4 clutch
regulator valve, against 1-2-3-4clutch regulator valve
spring force, to the applied position. This allows drive
fluid pressure to pass through the valve into the 1234
clutch fluid circuit. The 1234clutch fluid is then routed
to the 1-2-3-4clutch boost valve and through orifice
#19 to the 1-2—3-4 clutch.
1-2-3-4Clutch
1234clutch fluid enters the transmission case
assembly and moves the 1-2-3-4clutch piston against
spring force to apply the 1-2-3-4clutch plates.
Accumulator
PCS 1234clutch fluid is also routed to an accumulator
valve. The accumulator valve is used to dampen any
pressure irregularities occurring in the PCS 1234clutch
fluid circuit. This helps to control clutch apply fluid
pressure and clutch apply feel.
(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
- 6T30l6T40/6T45/6T50 (MH8, MH9) 17-363
4-5-6 Clutch Applies or Remains
Applied
R1I456Pressure Control (PC)Solenoid
'The R1/456PC solenoid defaults to its normally-high
state (ON), allowing actuator feed limit fluid to enter the
PCS R1I456clutch fluid circuit. PCS R1I456clutch fluid
is routed through orifice #11to the R1/4-5-6 clutch
regulator valve, and through orifice #34to the R1/4—5-6
clutch boost valve. lfthe transmission is operating in
First, Second or Third gear when an electrical
malfunction occurs, the 4-5—6clutch will apply. Ifthe
transmission is operating in Fourth, Fifth or Sixth gear
when the electrical malfunction occurs, the 4-5-6 clutch
remains applied.
R1I4-5-6 Clutch Boost Valve
PCS R1I456clutch fluid pressure acts on a differential
area, moving the R1/4-5—6 clutch boost valve against
R1/4'-5—6 clutch boost valve spring force, to block R1/
11456 clutch feed fluid from entering the R1/456clutch
feedback circuit, and opening the R1/456clutch
feedback circuit to exhaust backfill. This results in the
R1/4—5—6 clutch regulator valve moving to the full feed
position, sending full R1/456clutch feed pressure (full
line pressure) to the 4—5-6clutch.
R1/4—5-6 Clutch Regulator Valve
PCS R1I456clutch fluid moves the R1/4—5—6 clutch
regulator valve, against R1/4-5-6 clutch regulator valve
spring force, to the applied position. This allows line
fluid pressure to pass through the valve into the R1/456
clutch feed circuit. R1/456clutch feed fluid is then
routed to the clutch select valve, the R1/4-5-6 clutch
boost valve, and through orifices #9 and #12 to the
spring end of the R1/4—5-6 clutch regulator valve. When
the R1/4-5-6 clutch regulator valve is in this position,
latch fluid exhausts through the valve allowing 456
clutch fluid to shuttle the #1 ball check valve.
#1 Ball Check Valve
Orificed 456 clutch fluid pressure seats the #1 ball
check valve against the exhausting latch fluid passage.
456 clutch fluid is then directed into the latch circuit to
replace the exhausting latch pressure and is routed to
the clutch select valve. Latch fluid combines with clutch
select valve spring force and holds the valve in this
position during all six forward gear ranges.
Clutch Select Valve
R1I456clutch feed fluid passes through the clutch
select valve and enters the 456 clutch circuit. 456
clutch fluid is routed to the 4—5-6clutch assembly, and
through orifice #2to the #1 ball check valve.
4-5-6Clutch
456 clutch fluid enters the 3-5-reverse and 4—5-6clutch
housing assembly, and moves the 4-5-6 clutch piston
against spring force and exhaust backfill pressure to
apply the 4—5-6clutch plates.
Accumulator
PCS R1I456clutch fluid is also routed to an
accumulator valve. The accumulator valve is used to
dampen any pressure irregularities occurring in the
PCS R1I456clutch fluid circuit. This helps to control
clutch apply fluid pressure and clutch apply feel.
17-364 Automatic Transmission - 6T30l6T40/6T45/6T50 (MH8, MH9)

3-5-Reverse Clutch Releases
35R Pressure Control (PC) Solenoid
lfthe transmission is in Third or Fifth gear when an
electrical condition commands a protection mode, the
35R PC solenoid defaults to its normally-Iow state
(OFF), allowing PCS 35R clutch fluid pressure to
exhaust and the 3—5-reverseclutch to release. See
Drive Range—Fourth Gear for a complete description of
3-5-reverse clutch release.
2-6 Clutch Releases
26 Pressure Control (PC)Solenoid
lfthe transmission is in Second or Sixth gear when an
electrical condition commands a protection mode, the
26 PC solenoid defaults to its normally—Iowstate (OFF),
allowing PCS 26 clutch fluid pressure to exhaust and
the 2-6 clutch to release. See Drive Range— Third Gear
for a complete description of 2—6clutch release.
Torque Converter Clutch (TCC)
Releases
Torque Converter Clutch (TCC) Pressure Control
(PC)Solenoid
Ifthe TCC is applied when an electrical condition
commands a protection mode, the TCC PC solenoid
defaults to its normally~lowstate (OFF), allowing PCS
TCC fluid to exhaust and the TCC to release. See Drive
Range—Sixth Gear for a complete description of TCC
release.

(US/Canada)
»Sonic
2013 (5377994)
Manual
Service
 ,
Automatic Transm Ission - 6T30l6T40/6T45l6T50 (MH8, MH9) 17-365
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(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
 17-366 Automatic Transmission - 6T30l6T40/6T45/6T50
Drive Range, Sixth Gear (Gen 1)
As vehicle speed increases, the transmission control
module (TCM) processes input signals from the
automatic transmission input and output speed
sensors, the throttle position sensor and other vehicle
sensors to determine the precise moment to command
ON the normally-Iow 26 pressure control solenoid 4. At
the same time, the normally—high35R pressure control
solenoid 2 is commanded OFF and the transmission
shifts into Sixth gear.
_ 2-6 Clutch Applies
26 Pressure Control (PC) Solenoid 4
The 26 PC solenoid 4 is commanded ON, allowing
actuator feed limit fluid to enter the PCS 26 clutch fluid
circuit. PCS 26 clutch fluid is then routed through orifice
#24to the 2-6clutch regulator valve.
2-6Clutch Regulator Valve
PCS 26 clutch fluid, at the 2-6clutch regulator valve,
opposes 2-6clutch regulator valve spring force and
orificed 26 clutch fluid pressure to regulate drive fluid
pressure into the 26 clutch circuit. 26 clutch fluid is then
routed through orifice #37to the 2-6clutch assembly in
the transmission case, and through orifice #4to the
spring end of the 2-6clutch regulator valve. With the'
2-6clutch regulator valve in this position, P82 fluid is
allowed to exhaust and the normaIIy-closed P82 switch
closes.
2-6Clutch
The 26 clutch fluid from the 2-6clutch regulator valve is
routed through the transmission case to the 2—6clutch
piston assembly. The 26clutch fluid pressure moves
the piston against 2-6clutch spring force to apply the
2-6clutch plates.
(MH8, MH9)
3-5 Reverse Clutch Releases
35R Pressure Control (PC)Solenoid 2
The 35R PC solenoid 2 is commanded OFF allowing
PCS 35 reverse clutch fluid from the 3-5—reverseclutch
regulator valve to exhaust.
3-5-Reverse Clutch Regulator Valve
PCS 35 reverse clutch fluid exhausts, allowing
3-5-reverse clutch regulator valve spring force to move
the 3-5-reverse clutch regulator valve to the released
position. This allows 35 reverse clutch fluid pressure to
exhaust into the compensator feed circuit in order to
assist the 3-5-reverse clutch piston spring to quickly
release the 3-5-reverse clutch. With the 3-5-reverse
clutch regulator valve in this position, orificed (#25)35
reverse clutch feed/drive 1-6 fluid passes through the
valve into the P83 circuit. P83 fluid is routed to the
normaIIy—closed#3 pressure switch and opens the
switch.
3-5-Reverse Clutch
3-5—reverseclutch spring force, assisted by
compensator feed pressure, moves the 3-5—reverse
clutch piston to release the 3—5-reverse clutch plates
and force 35 reverse clutch fluid to exhaust from the
3—5—reverse and 4-5—6 clutch housing assembly. The
exhausting 35 reverse clutch fluid pressure is.routed to
the 3-5- reverse clutch regulator valve where it enters
the 35 reverse clutch feed/compensator feed circuit.
(US/Canada)
<Sonic
2013 (5377994)
Manual
Service
 - :.

Automatic Transm Ission - 6T30l6T40/6T45l6T50 (MH8, MH9) 17-367

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2013 (US/Canada)
-Sonic (5377994)
Manual
Service m
Is II
.258
W E
17-368 Automatic Transmission - 6T30l6T40/6T45I6T50
Drive Range, Sixth Gear (Gen 2)
As vehicle speed increases, the transmission control
module (TCM) processes input signals from the
automatic transmission input and output speed
sensors, the throttle position sensor and other vehicle
sensors to determine the precise moment to command
ON the normally~low26pressure control solenoid. At
the same time, the normaIIy-Iow35R pressure control
solenoid is commanded OFF and the transmission
shifts into Sixth gear.
2-6 Clutch Applies
26 Pressure Control (PC)Solenoid
The 26 PC solenoid is commanded ON, allowing
actuator feed limit fluid to enter the PCS 26 clutch fluid
circuit. PCS 26 clutch fluid is then routed through orifice
#24to the 2-6 clutch regulator valve.
2-6 Clutch Regulator Valve
PCS 26 clutch fluid, at the 2-6 clutch regulator valve,
opposes 2-6 clutch regulator valve spring force and
orificed 26 clutch fluid pressure to regulate drive fluid
pressure into the 26 clutch circuit. 26 clutch fluid is then
routed through orifice #22to the 2-6 clutch assembly in
the transmission case, and through orifice #4to the
spring end of the 2—6clutch regulator valve.
2-6 Clutch
The 26 clutch fluid from the 2-6 clutch regulator valve is
routed through the transmission case to the 2-6 clutch
piston assembly. The 26 clutch fluid pressure moves
the piston against 2-6 clutch spring force to apply the
2-6 clutch plates.
(MH8, MH9)
Accumulator
PCS 26 clutch fluid is also routed to an accumulator
valve. The accumulator valve is used to dampen any
pressure irregularities occurring in the PCS 26 clutch
fluid circuit. This helps to control clutch apply fluid
pressure and clutch apply feel.
3-5 Reverse Clutch Releases
35R Pressure Control (PC) Solenoid
The 35R PC solenoid is commanded OFF allowing
PCS 35 reverse clutch fluid from the 3-5—reverseclutch
regulator valve to exhaust.
3-5-Reverse Clutch Regulator Valve
PCS 35 reverse clutch fluid exhausts, allowing
3—5-reverseclutch regulator valve spring force to move
the 3—5-reverseclutch regulator valve to the released
position. This allows exhausting 35 reverse clutch fluid
pressure to pass into the exhaust backfill circuit in order
to assist the 3-5-reverse clutch piston spring to quickly
release the 3-5—reverseclutch.
3-5-Reverse Clutch
3-5—reverseclutch spring force, assisted by exhaust
backfill pressure, moves the 3—5-reverseclutch piston
to release the 3-5-reverse clutch plates and force 35
reverse clutch fluid to exhaust from the 3-5-reverse and
4-5-6clutch housing assembly. The exhausting 35
reverse clutch fluid pressure is routed to the
3—5-reverseclutch regulator valve where it enters the
exhaust backfill circuit.
(US/Canada)
ASonic
2013 (5377994)
Manual
Service
 “Eoégn

Automatic Transm Ission - 6T30l6T40/6T45/6T50 (MH8, MH9) 17-369

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(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
17-370 Automatic Transmission - 6T30l6T40/6T45/6T50 (MH8, MH9)

Fluid Passages (Gen 1)

Case —Control Valve Body Side (Left)

1898199
Legend
(2) Line (20) 35 Reverse Clutch Feed
(7) Cooler Feed (21) 35 Reverse Clutch
(9) Regulated Apply (25) 1234 Clutch
(10) Compensator Feed (31) 26 Clutch
(13) PCS Line (32) 456 Clutch
(16) R1I456 Clutch Feed (33) PCS TCC
(17) R1 (37) Void
(19) Reverse

{US/Canada)
-Sonic
2013 (5377994)
Manual
Service
 Automatic Transmission - 6T30/6T40/6T45/6T50 (MH8, MHQ) 17-371

Case —Pump Side (Back)

/32
/7
~31

\ 9

_\ 33

1898202
Line (21) 35 Reverse Clutch
Cooler Feed (31) 26 Clutch
Lube (32) 456 Clutch
Regulated Apply (33) PCS TCC
(10) Compensator Feed (38) Seal Drainback
(13) PCS Line (39) Vent

2013
~Sonic
(US/Canada)
Service
Manual
(5377994)
17-372 Automatic Transmission - 6T30/6T40l6T45/6T50 (MH8, MH9)

Control Valve Body —Case Side (Left)

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1898205
Legend
(2) Line (21) 35 Reverse Clutch
(7) Cooler Feed (23) Drive
(9) Regulated Apply (25) 1234 Clutch
(10) Compensator Feed (27) Drive 1—6
(13) PCS Line (31) 26 Clutch
(16) R1/456 ClutchFeed (32) 456 Clutch
(17) R1 (33) PCS TCC
(19) Reverse (36) Exhaust
(20) 35 Reverse ClutchFeed (37) Void

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Automatic Transmission : 6T30/6T40/6T45/6T50 (MH8, MHQ) 17=373

Control Valve Body —Channel Plate Side (Right —No Valves)

.[37H37]
0%:’ w.

géWQE .W 36 '—=;7
[“36
_.:_€]: 0 ?]M

mg] (‘23—) l 221 )g 20/2771L)

GEL: LD37(—__—] 8m:
7 [—323 [:1 36

1898210
Legend
(2) Line (23) Drive
(9) Regulated Apply (24) P82
(10) Compensator Feed (25) 1234 Clutch
(11) Actuator Feed Limit (26) 1234 Clutch Feedback
(12) P83 (27) Drive 1—6
(13) PCS Line (28) PS4
(14) PCS R1/456 Clutch (29) CSV2 Latch
(15) Shift Solenoid (30) PCS 26 Clutch
(16) R1/456 Clutch Feed (31) 26 Clutch
(17) R1 (32) 456 Clutch
(18) PCS 35 Reverse Clutch (33) PCS TCC
(19) Reverse (34) PS1
(20) 35 Reverse Clutch Feed (35) Exhaust Backfill
(21) 35 Reverse Clutch (36) Exhaust
(22) P081234 Clutch (37) Void

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
17-374 Automatic Transmission - 6T30/6T40l6T45/6T50 (MH8, MHQ)

Pump Body —Pump Cover Side (Front)

1898215
Legend
(1) Suction (9) Regulated Apply
(2) Line (13) PCS Line
(4) Converter Feed (33) PCS TCC
(5) TCC Released (36) Exhaust
(6) TCC Apply (37) Void
(7) Cooler Feed (38) Seal Drainback

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Automatic Transmission a 6T30/6T40/6T45/6T50 (MH8, MH9) 17-375

Pump Cover— Pump Body Side (Back)

1898220
Legend
(1) Suction (7) CoolerFeed
(2) Line (9) Regulated Apply
(4) ConverterFeed (13) PCS Line
(5) TCC Released (33) PCS TCC
(6) TCC Apply

NW.-.
,
A

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
17-376 Automatic Transmission - 6T30/6T40/6T45/6T50 (MH8, MHQ)

Spacer Plate (12) —Case Side (Left)

1898233
Legend
(2) Line 35 Reverse Clutch Feed
(7) CoolerFeed 35 Reverse Clutch
(9) Regulated Apply 1234 Clutch
(10) CompensatorFeed 26 Clutch
(13) PCS Line 456 Clutch
(16) R1/45601utchFeed PCS TCC
(17) R1 Exhaust
(19) Reverse

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Automatic Transmission . 6T30/6T40/6T45/6T50 (MH8, MHQ) 17-377

Spacer Plate (402) —Channel Plate Side (Right)

1898238
(2) Line (23) Drive
(9) Regulated Apply P82
(10) Compensator Feed 1234 Clutch Feedback
(11) Actuator Feed Limit Drive 1—6
(12) P83 PS4
(13) PCS Line CSV2 Latch
) PCS R1/456 Clutch PCS 26 Clutch
) Shift Solenoid PCS TCC
(16) R1/456 Clutch Feed PS1
) PCS 35 Reverse Clutch (35) Exhaust Backfill
) 35 Reverse Clutch Feed Exhaust
(22) PCS 1234 Clutch

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
17-378 Automatic Transmission - 6T30/6T40I6T45/6T50 (MH8, MHQ)

Torque Converter Clutch Housing —Pump Side (Front)

1898245
Legend
(8) Lube (38) SealDrainback

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Automatic Transmission - 6T30/6T40/6T45/6T50 (MH8, MH9) 17-379

Control Solenoid Valve Assembly with Filter Plate —Channel Plate Side (Front)

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1,
4y
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1.~_.WM__

1898250
Legend
(2) Une (22) PCS 1234 Clutch
(11) Actuator Feed Limit (24) P82
(12) P83 (28) PS4
(13) PCSLme (30) PCS 26 Clutch
(14) PCSR1M56cmmh (33) PCS TCC
(15) Shift Solenoid (34) PS1
(18) PCS 35 Reverse Clutch

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
172-380 Automatic Transmission - 6T30/6T40/6T45/6T50 (MH8, MHQ)

Channel Plate —Control Solenoid Valve Assembly Side (Right)

1898261
Legend
(2) Line (24) P82
(11) ActuatorFeed Limit (28) PS4
(12) P83 (30) PCS 26C|utch
(13) PCS Line (33) PCS TCC
(14) PCS R1/4560Iutch (34) PS1
(15) ShiftSolenoid (36) Exhaust
(18) PCS 35 Reverse Clutch (37) Void
(22) P081234 Clutch

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
 Automatic Transmission =6T30/6T40/6T45/6T50 (MH8, MH9) 17-381

Channel Plate —Control Valve Body Side (Left)

1898263
Legend
(2) Une Drive
(9) Regulated Apply PS2
(10) Compensator Feed 1234 Clutch Feedback
(11) Actuator Feed Limit Drive 1—6
(12) PS3 PS4
(13) PCSLMe PCS 26 Clutch
(14) PCSR1M56Cwmh PCS TCC
(15) Sobnom PS1
(16) R1/456 Clutch Feed Exhaust Backfill
(18) PCS 35 Reverse Clutch Exhaust
(20) 35 Reverse Clutch Feed Void
(22) PCS1234Cmmh

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
17882 Automatic Transmission - 6T30/6T40/6T45I6T50 (MH8, MH9)

Fluid Passages (Gen 2)

Torque Converter and Differential Housing —Case Side

2681122
Legend
(8) Lube (38) Seal Drainback
(23) Auxiliary Suction (BAS+ Oniy)

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
 Automatic Transmission . 6T30/6T40/6T45/6T50 (MH8, MHQ) 17-383

Fluid Pump Body— Fluid Pump Cover Side

2681124
Legend
(1) Suction (9) Regulated Apply
(2) Line (12) PCS Line
(4) Converter Feed (34) PCS TCC
(5) TCC Release (36) Exhaust
(6) TCCApply (37) Void
(7) CoolerFeed (38) Seal Drainback

2013
~Sonic
(US/Canada)
Service
Manual
(5377994)
17-384 Automatic Transmission - 6T30/6T40/6T45/6T50 (MH8, MHQ)

Fluid Pump Cover— Fluid Pump Body Side

2681128
Legend
(1) Suction (7) Cooler Feed
(2) Line (9) Regulated Apply
(4) Converter Feed (12) PCS Line
(5) TCC Release (34) PCS TCC
(6) TCC Apply

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Automatic Transmission - 6730/6T40/6T45/6750 (MH8, MH9) 17-385

Case —Torque Converter and Differential Housing Side

/33
/7
~32

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VMwor—hww 3 ./\.‘-‘

2681128
(2) Line (21) 35 Reverse Clutch
(7) CoolerFeed (32) 26 Clutch
(8) Lube (33) 456 Clutch
(9) Regulated Apply (34) PCS TCC
(10) ExhaustBackfill (38) SealDrainbaCk
(12) PCS Line (39) Vent

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
17-386 Automatic Transmission - 6T30/6T40/6T45/6T5O (MH8, MHQ)

Case —Control Valve Body Side

2681129
Legend
(2) Line (21) 35 Reverse Clutch
(7) Cooler Feed (24) Auxiliary Line (BAS+ Only)
(9) Regulated Apply (27) 1234 Clutch
(10) Exhaust Backfill (28) 1234 Clutch Feedback
(12) PCS Line (32) 26 Clutch
(16) R1/456 Clutch Feedback (33) 456 Clutch
(17) R1 (34) PCS TCC
(19) Reverse (37) Void
(20) 35 Reverse Clutch Feed

2013
—
Sonic
(US/Canada)
Service
Manual
(5377994)
 Automatic Transmission - 6T30/6T40/6T45/6T50 (MH8, MH9) 17-387

Control Valve Body Spacer Plate Assembly —Case Side

2681130
Legend
(2) Line (21) 35 Reverse Clutch
(7) CoolerFeed (24) Auxiliary Line (BAS+ Only)
(9) Regulated Apply (27) 1234 Clutch
(10) ExhaustBackfilI (28) 1234 Clutch Feedback
(12) PCS Line (30) Latch
(16) R1/456 Clutch Feedback (32) 26 Clutch
(17) R1 (33) 456 Clutch
(19) Reverse (34) PCS TCC
(20) 35 Reverse Clutch Feed (35) Exhaust

2::22:
A 2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
17-388 Automatic Transmission - 6T30/6T40I6T45/6T50 (MH8, MHQ)

Control Valve Body —Case Side

2681133

Line (24 Auxiliary Line (BAS+ Only)

Cooler Feed (26 Drive
Regulated Apply (27 1234 Clutch
Exhaust Backfill (28 1234 Clutch Feedback
PCS Line (29 Drive 1-6
Shift Solenoid (30 Latch
R1/456 Clutch Feedback (32vvvvvvv
26 Clutch
R1 (33) 456 Clutch
Reverse (34) PCS TCC
35 Reverse Clutch Feed (35) Exhaust
35 Reverse Clutch (37) Void

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Automatic Transmission - 6T30/6T40/6T45/6T50 (MH8, MH9) 17-389

Control Valve Body —Channel Plate Side

1:37:93.C3::E7 m.fib [:73_J

fig“
UTE]
3722.
2823' ‘ E:.Li:1.mlo.u 37

10,11 10 11:9 10
271 [‘32: [—363
-[l—] L263©

@737 [17815769 20/292029

LL39.
.W‘J.

mm_ ‘2

2681134
Legend
(2) Line (22) Default
(9) Regulated Apply (25) PCS 1234 Clutch
(10) Exhaust Backfill (26) Drive
(11) Actuator Feed Limit (27) 1234 Clutch
(12) PCS Line (28) 1234 Clutch Feedback
(13) PCS R1/456 Clutch (29) Drive 1—6
(14) Shift Solenoid (30) Latch
(15) R1/456 Clutch Feed (31) PCS 26 Clutch
(16) R1/456 Clutch Feedback (32) 26 Clutch
(17) R1 (33) 456 Clutch
(18) PCS 35 Reverse Clutch (34) PCS TCC
(19) Reverse (36) Exhaust
(20) 35 Reverse Clutch Feed (37) Void
(21) 35 Reverse Clutch

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
17-390 Automatic Transmission - 6T30l6T40/6T45/6T50 (MH8, MHQ)

Channel Plate to Valve Body Spacer Plate Assembly —Channel Plate Side

20/299
20/29 0
O\© D©26 @ 10 O 13160
O 18G 26
(.) o 36.
0 C) .25/36 O . ©13010
1o© ‘10 0 G10

©25 ©25
-10
@ O 031 1C?) -

2681135
Legend
(2) Line (19) Reverse
(9) Regulated Apply (20) 35 Reverse Clutch Feed
(10) Exhaust Backfill (22) Default
(11) Actuator Feed Limit (25) PCS 1234 Clutch
(12) PCS Line 1 (26) Drive
(13) PCS R1/456 Clutch (29) Drive 1-6
(14) ShiftSolenoid (30) Latch
(15) R1/456 ClutchFeed (31) PCS 26 Clutch
(16) R1/456 Clutch Feedback ‘ (34) PCS TCC
(18) PCS 35 Reverse Clutch (36) Exhaust

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
 Automatic Transmission - 6T30/6T40/6T45/6T50 (MH8, MHQ) 17=391

Channel Plate —Control Valve Body Side

2681136
(2) Line (20) 35 Reverse Clutch Feed
) Regulated Apply (22) Default
) Exhaust Backfill (25) PCS 1234 Clutch
(11) Actuator Feed Limit (26) Drive
) PCS Line (29) Drive 1-6
) PCS R1/456 Clutch (30) Latch
) Shift Solenoid (31) PCS 26 Clutch
(16) R1/456 Clutch Feedback (34) PCS TCC
(18) PCS 35 Reverse Clutch (36) Exhaust
(19) Reverse (37) Void

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
17-392 Automatic Transmission - 6T30/6T4OI6T45/6T50 (MH8, MHQ)

Channel Plate —Control Solenoid (w/Body and TCM) Valve Assembly Side

2681137
Legend
(2) Lme PCS 1234 Clutch
(11) Actuator Feed Limit PCS 26 Clutch
(12) PCSLme PCS TCC
(13) PCS R1/456 Clutch Exhaust
(14) ShfitSomnow Void
(18) PCSBSRmmmecmmh

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Automatic Transmission - 8T30/6T40/6T45/6T50 (MH8, MHQ) 17-393

Control Solenoid (wlBody and TCM) Valve Assembly —Channel Plate Side

2681138
Legend
(2) Line (18) PCS 35 Reverse Clutch
(11) Actuator Feed Limit (25) PCS 1234 Clutch
(12) PCS Line (31) PCS 26 Clutch
(13) PCS R1/456 Clutch (34) PCS TCC
(14) ShiftSolenoid (37) Void

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
17-394 Automatic Transmission =6T30/6T40l6T45/6T50 (MH8, MHQ)

Special Tools and Equipment Illustration Tool Number/Description

Illustration Tool NumberlDescription

DT—8092
J—8092
KM-J-8092
DW340-010
3-9607433 DriverHandle
TransmissionSupport
2015

2753054

DT—21366
J-21366
DT—586 ConverterHoldingStrap
~J-23129
@ KM-586
UniversalSeal Remover
47935

36152
DT—28585
J-28585
KM-J—28585
DT—3289-20 SnapRingRemover
J-3289-20
HoldingFixture
13077

144067

DT—39890
J-39890
TransmissionHolding
DT—7004 FixtureAdapter
Efi-«(mc u J-6125-1B
C60 KM-J-7004
Slide HammerwithAdapter
1936120

166875

DT-41229
J-41229
DT—8059 ManualShaftPin Installer
J-8059
KM-396
Snap Ring
PIiers-ParallelJaw 20884

5616

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
 Automatic Transmission - 6T30/6T40/6T45/6T50 (MH8, MH9) 17-395

Illustration Tool NumberlDescription Illustration ToolNumber/Description

DT—45096
J—45096 DT-46625
TransmissionOil Cooling J-46625
SystemFlushand Flow HoldingFixture
TestTool

1215917 1760599

DT'45096'50 DT—46625-1O
T Jj45'096C-)5'|0C
I J—46625-10
ransmlssmn I oo er
FlushAdapter . .
Holdmgleture Adapter

1768144 1913013

DT—45201
J-45201 ‘ DT—47694
DT-48203 PA\ SpringCompressor
CoolerLineSeal Remover

792892 1760496
“~62,
W
V
2“

DT—46409
J—46409
DT—47790
2.2-2,..-MMM
-2
M
_ KM-922
Seal Installer
TorqueConverterLifting
Handles
$3

1200548 1909710

DT-46620
DT—47791—A
J-46620
Seal Installer
Seal Installer

1760574 1909711

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
W2W27W~/
[22.2%
«#2,..M-‘
.._
“v.2
-~N
,1
,2
22
17-396 Automatic Transmission - 6T30/6T40/6T45/6T50 (MH8, MHQ)

Illustration Tool Number/Description Illustration Tool NumberlDescription

DT—47792 DT—47798
Seal Installer Seal Protector

\
1909715 1909725

DT—47793 g E % Cl t 53479: _
. . . u 0 ISon prlng
DifferentialRotatlngTool @ Compressor

1760502 1909728

@ DT—47794 DT—47805
@ SpringCompressor Seal Protector

1913012 1909733

DT—47796 DT—47807
Seal Protector ClutchPistonSeal Installer

1909719 1909732

DT—47797 DT—47811-S1
SpringInstaller LiftPlate

1909722 1760510

2013
~Sonic
(US/Canada)
Service
Manual
(5377994)
 Automatic Transmission - 6T30/6T40/6T45/6T50 (MH8, MH9) ’17-397
Illustration Tool Number/Description Illustration ToolNumber/Description

DT—47951 -1 DT-48272
Seal Protector SpringInstaller

@
1909738 2202658

DT—47951-2 DT—48273
SpringCompressor Seal Protector

%
1909744 2202676

DT-48056 @ DT-48274
SpringCompressorBridge @ SpringCompressor

1760566 2202672

DT—48270 DT-48277
SpringInstaller DifferentialRotatingTool

X
2202656 2202673

DT-48271 DT—48550
Seal Protector Detent
LeverPin Remover

9
2202657 1909749

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
'17-398 Automatic Transmission - 6T30/6T40/6T45/6T50 (MH8, MH9)

Illustration Tool NumberlDescription Illustration Tool Number/Description

DT—48616 DT—491 31
Control
SolenoidTestPlate Seal StakingTool

1883590 2033981

DT—48616-10 DT—50369
AdapterHarness Seal Protector

1883591 2660871

EL-35616
DT—48866
J 35616
SpringCompressor
TerminalTestProbeKit

2202652 1423781

EL-38522
DT—48903
J-38522
SpringCompressor
VariableSignalGenerator

2202654 416666

EN-21867
DT-49101 GE 21867
Seal Installer J-21867
PressureGauge

2033666 29339

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
 Automatic Transmission 2 6T30/6T40/6T45/6T50 (MH8, MH9) ‘17-399

Illustration Tool Number/Description Illustration Tool Number/Description

EN-45059 GE-5586-A
J~45059 J—5586-A
Angle Meter Snap Ring Pliers
\

1197696 1909734

EN-680770 GE-21867—A
M-68077O J—21867-A
UniversalSlidingMalet Oil PressureGaugeKit

2259215 3021165

EN-9703392 GE-34673
J-9703392 J-34673
HydraulicJack FlatGaugeBar

2259210 38548

2013
"\‘2w22fi/
W
_. -Sonic
(US/Canada)
Service
Manual
(5377994)
'17-400 Clutch

Clutch

Specifications

Fastener Tightening Specifications

Specification
Application Metric English
ClutchMasterCylinderBolts 4.5N-m 40lbin
ClutchActuatorCylinderBolts
D16(MFH,MXP) 8N-m 71|bin
F17 (M26,MEM) 5N-m 44lbin
M20(MZ7)and M32(MZ4) 6N-m 531bin
Y4M SHD (MX3) 8NW 71lbin
ClutchActuatorCylinderPipe Fitting 14Nm 124lbin
ClutchPedal PositionSensorBolt 3N'm 27lbin
ClutchPressurePIate-to-Flywheel Bolts
1.2L(LDC, LWD)and 1.4L(L2l,L2N,LDD)—F17 (M26) 15N-m 11|bft
1.4L(LCU)and 1.5L(L2B)— Y4M SHD (MX3) 28N-m 21|bft
1.4L(LUV)—M32(MZ4) 28Nm 21lbft
1.6L(LDE,LED, LFJ)—D16(MFH,MXP) 15N-m 11lbft
1.3LDiesel(LDV,LSF)—F17(M26,MEM) 14N-m 124lbin
1.3LDiesel(LSF)—M20(MZ7) 14Mm 124lbin

General Specifications
Specification
Application Metric English
Fluid Use onlyGM approvedbrakefluidfroma clean,
sealedbrakefluidcontainer
InsideDiameter
1.2LLCD, LWD(F17ManualTransmission) 134mm 5.276in
1.4LL2|,L2N, LDD (F17ManualTransmission) 145mm 5.276in
1.4LLCU (Y4MSHD ManualTransmission) 145mm 5.709in
1.5LL2B (Y4MSHD ManualTransmission) 145mm 5.709in
1.6LLDE, LED, LFJ (D16ManualTransmission) 145mm 5.709in
1.3LLDV,LSF (F17ManualTransmission) 146mm 5.748in
1.3LLSF (M20ManualTransmission) 146mm 5.748in
1.4LLUV (M32ManualTransmission) 146mm 5.748in
OutsideDiameter
1.2LLCD, LWD(F17ManualTransmission) 200mm 7.874in
1.4LL2],L2N,LDD (F17ManualTransmission) 200mm 7.874in
1.4LLCU (Y4MSHD ManualTransmission) 215mm 8.465in
1.5LL2B (Y4MSHD ManualTransmission) 215mm 8.465in
1.6LLDE, LED, LFJ (D16ManualTransmission) 215mm 8.465in
1.3LLDV,LSF (F17ManualTransmission) 216mm 8.504in
1.3LLSF (M20ManualTransmission) 216mm 8.504in
1.4LLUV (M32ManualTransmission) 216mm 8.504in

2013
«Sonic
(US/Canada)
Service
Manual
(5377994)
 Clutch '17-401

General Specifications (cont'd)

Specification
Application Metric | English
Thickness
1.2LLCD, LWD(F17ManualTransmission) 1311119311109?) 0337 in (atwithoutload)

1.4LL2l, L2N,LDD (F17ManualTransmission) 17315513319109?)0.337in (atwithoutload)

1.4LLCU (Y4MSHD ManualTransmission) gégmrgézt) 0.331in (atwithoutload)

1.5LL28 (Y4MSHD ManualTransmission) veififlrgg) 0.331in (atwithoutload)

1.6LLDE, LED, LFJ (D16ManualTransmission) flfim’l‘géfi) 0.331in (atwithoutload)

1.3LLDV,LSF(F17ManualTransmission) xifim’gg‘) 0.313in (atwithoutload)

1.3LLSF (M20ManualTransmission) 1711111913120?) 0313 in (atwithoutload)

1.4LLUV (M32ManualTransmission) , 011-1112131011?) 0.313in (atwithoutload)

Type SingleDryPlate

Diagnostic Information and

Procedures

Symptoms - Clutch
Symptom List
Refer to a symptom diagnostic procedure from the
-2_ WW... following list in order to diagnose the symptom.
2W2W.WW2WWW',MWWM,MM
.22.
2...”
W
- Clutch Slipping on page 17-402
- Clutch Grabbing on page 17—403
- Clutch Rattle on page 17-404
- Release Bearing Noisy with Clutch Engaged on
page 17—405
- Clutch Noisy on page 17—405
- Clutch Pedal Hard to Push on page 17-405.

Clutch Does Not Disengage

Cause
DEFINITION:Whenthepedalis pressedtothefloor,theshiftleverdoes notmovefreelyin andoutof reversegear.
Damagedclutchdisc.
Clutchdischubbindingontheinput
shaftsplines.
Warpedor bentclutchdisc.
Pedal blockedfromfulltravel.
I Actions
Replacetheclutchassembly.Referto ClutchPressureandDrivenPlateReplacement
(1.4L)onpage 17-416or ClutchPressureandDrivenPlate Replacement(1.8L)on
page 17—419.
Replacetheclutchassembly.Referto ClutchPressureandDrivenPlate Replacement
(1.4L)onpage 17—416 or ClutchPressureandDrivenPlate Replacement(1.8L)on
page 17-419.
Replacetheclutchassembly.Referto ClutchPressureandDrivenPlate Replacement
(1.4L)onpage 17—416 or ClutchPressureandDrivenPlateReplacement(1.8L)on
page 17—419.
1. Inspectforobstaclesthatwillpreventthepedalfromgoingtothe floor.
2. Clear anyobstaclesfromunderthepedalarea,such as floormatsor interior
panels.

2013
-Sonic
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Service
Manual
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2%
~
.W
2..
-2”_,.._..Vv2/
_~,A~
’17-402 Clutch
Clutch
Cause
Toomuchtravelbetweenpedaland
hydraulicclutchmastercylinder.
Hydraulicclutchmastercylinder
seized or binding.
Air in thehydraulicclutchsystem.
Hydraulicclutchactuatorcylinder
seized or binding
Hydraulicclutchmastercylinder
leakinginternally.
Cause
DEFINITION:The clutchdoes notengagecompletelyafterthepedalis released,aftershiftinggears,or theclutchslipsduring
maximumengineloads,suchas climbinghillsor highvehiclespeeds.Clutchslippingis identifiedby increasein engineRPM
withoutincreasein vehiclespeed.ReviewtheSymptoms~Clutchonpage 17—401
Incorrectclutchpedalheight,not
allowingtheclutchmastercylinderto
return.
The clutchpedalreturnspringis
brokenor missing.
The clutchpedalis bindingor sticking. 1. Clear awayanyitemsthatmaybe contactingthe pedal.
Clutchmastercylinderbindingor
seized.
Clutchactuatorcylinderbindingor
seized.
Kinkedor damagedclutchactuator
cylinderfrontpipe.
Greaseor oil contaminationofthe
clutchdisc.
Oil-soakedclutchdisc.
Does Not Disengage (cont'd)
Actions
1. Inspectthepedalforwornbushings.
2. Replacethepedalbushingsifworn.
1. Inspectthemastercylinderforthepistonbeingableto movefreelyandfullrange
of travel.
2. Replacetheclutchmastercylinderas required.Referto ClutchMasterCylinder
Replacementonpage 17-408.
Bleedthehydraulicclutchsystem.Referto HydraulicClutchSystemBleedingon
page 17-415.
1. Inspecttheclutchactuatorpistonformovingfreely.
2. Replacetheclutchactuatorcylinderif thepistonis binding.Referto Clutch
ActuatorCylinderReplacement(F17)onpage 17-422or ClutchActuatorCylinder
Replacement(M20/32)onpage 17-423.
1. Inspectforproperpedalreserve.
1.1. Letup halfwayon pedal.
1.2. Applythepedala fewtimes.
1.3. Inspectto ensurethereis stilltheproperpedalreserve.
2. Replacetheclutchmastercylinderif itwillnotholdpedalreserve.Referto Clutch
MasterCylinderReplacementonpage 17—408.
Clutch Slipping
Actions
andperformthenecessaryinspections.
Adjusttheclutchpedalpositionswitch.Referto ClutchPedal PositionSensor
Replacementonpage 17-415.
Replacetheclutchpedalreturnspring,if equipped.Referto ClutchPedalReplacement
onpage 17-405.
2. Inspectthepedalbushingsforease of movement.
3. Replacetheclutchpedalif it is faulty.Referto ClutchPedal Replacementon
page 17—405.
Replacetheclutchmastercylinder.Referto ClutchMasterCylinderReplacementon
page 17-408.
Replacetheclutchactuatorcylinder.Referto ClutchActuatorCylinderReplacement
(F17)onpage 17-422or ClutchActuatorCylinderReplacement(M20/32)on
page 17-423.
1. Inspectforthecorrectroutingof theclutchactuatorcylinderfrontpipe.
2. Routetheclutchactuatorcylinderfrontpipeproperly.
3. Inspectforlooseorfaultyenginemountsthatmayallowtheclutchactuator
cylinderfrontpipetobe kinkedor pinched.
4. Repairor replacefaultyenginemounts.
5. Replacetheclutchactuatorcylinderfrontpipeif it is damaged.Referto Clutch
ActuatorCylinderFrontPipe Replacementonpage 17—410.
Repairthesourceoftheoil leak.
Repairthesourceofthegreaseleak.
Clean thecontamination fromtheclutchcomponents.
?PNT‘
Ifcontaminantscannotberemoved,replacetheclutchassembly.Referto Clutch
PressureandDrivenPlateReplacement(1.4L)onpage 17-416or Clutch
PressureandDrivenPlateReplacement(1.8L)onpage 17-419.
Correcttheleakat itssourceandinstalla newclutchdisc.
2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Clutch 17-403

Clutch Slipping (cont'd)

Cause
Weakdiaphragmspring.
Drivenplatethatis notseated.
Drivenplateis overheated.
Wornor damagedflywheel.
WornClutchdiscfacing.
Burntor glazedclutchdiscs.
Improperresurfacingoftheflywheel.
Actions
Replacetheclutchassembly.Referto ClutchPressureandDrivenPlateReplacement
(1.4L)onpage 17—41 6 or ClutchPressureandDrivenPlateReplacement(1.8L)on
page 17—419.
Starttheengine30—40times.Do notoverheattheengine.
Allowthedrivenplateto cool.
Replacetheengineflywheel.
Replacetheclutchassembly.Referto ClutchPressureandDrivenPlateReplacement
(1.4L)onpage 17-416or ClutchPressureandDrivenPlateReplacement(1.8L)on
page 17—419.
Replacetheclutchassembly.Referto ClutchPressureandDrivenPlate Replacement
(1.4L)onpage 17-416or ClutchPressureandDrivenPlateReplacement(1.8L)on
page 17-419.
Replacetheflywheelif it has beenimproperlyresurfaced,allowingcontactoftheclutch
dischubor insufficientclampingloadofthepressureplate.

Clutch Grabbing
Cause | Action
DEFINITION:Theclutchgrabs,or chatters,or theclutchis unableto releasewithoutthevehiclejerking.An abruptengagement
of theclutch.
ReviewtheSymptoms- Clutchonpage 17-401and performthenecessaryinspections.
Greaseor oil contamination
on theclutchfacings 1. Repairthecauseoftheoil leakorgreasecontamination.
2. Clean theclutchfacings.
3. Replacetheclutchcomponentsif theywillnotclean.
Referto ClutchPressureandDrivenPlateReplacement
(1.4L)onpage 17-416or ClutchPressureandDriven
PlateReplacement(1.8L)onpage 17-419.
Looseorfaultyenginemounts 1. Inspecttheenginemountsforbeingloose orfaulty.
2. Repairor replacetheengine/transmission mountsas
required.
um“.-
2....2«.-——~—
2
«
._.
_._.
..--..2Hw Clutchpedalsticking 1. Inspecttheclutchpedalforcorrectoperation.
2. Replacetheclutchpedalif it is faulty.Referto Clutch
Pedal Replacementonpage 17—405.
C'UtCh
actuatorbinding 1. lnspecttheclutchactuatorforthepistonseals bindingor
stickingon thehub.
2. Replacetheclutchactuatorif it is binding.Referto Clutch
ActuatorCylinderReplacement(F17)onpage 17-422or
ClutchActuatorCylinderReplacement(M20/32)on
page 17-423.
C'UtCh
mastercylinderbinding 1. inspecttheclutchmastercylinderforthepistonbindingor
stickingin thecylinder.
2. Replacethemastercylinderif it is faulty.Referto Clutch
MasterCylinderReplacementonpage 17-408.
WarpedClUtChCOVGT 1. lnspecttheclutchcoverfordistortioncausedby
improperlytighteningtheclutchcoverbolts.
2. Replacetheclutchcoverif it is distorted.Referto Clutch
PressureandDrivenPlate Replacement(1.4L)on
page 17-416or ClutchPressureandDrivenPlate
Replacement(1.8L)onpage 17-419.
Improperclutchinstallation‘ 1. Inspectthepressureplatefordistortioncausedby
improperlytighteningthepressureplatebolts.
2. Inspecttheclutchdiscfora benthubcausedbyforcing
theinstallationofthetransmission.
3. Inspectforthecorrectclutchdisc.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
17-404 Clutch

Clutch Grabbing (cont'd)

Cause Action
4. Inspecttheclutchdiscforbeinginstalledbackwards.
5. Replacetheclutchassemblyif it is damagedorthewrong
componentswereinstalled.Referto ClutchPressureand
DrivenPlateReplacement(1.4L)onpage 17—41 6 or
ClutchPressureandDrivenPlateReplacement(1.8L)on
page 17-419.
Clutchdiscbindingontheinputshaft 1. Inspecttheinputshaftforrustdirtor debris.
Note: Do notuse mineralor paraffinbasedoil to lubricatethe
splines.
2. Clean and lubricatetheinputshaft.
3. Inspecttheclutchdiscfora benthub.
4. Replacetheclutchassemblyiftheclutchdiscis faulty.
Referto ClutchPressureandDrivenPlateReplacement
(1.4L)onpage 17-416or ClutchPressureandDriven
Plate Replacement(1.8L)onpage 17-419.
5. Inspecttheinputshaftforexcessivewearonthesplines,
causingtheclutchdiscto bind.
6. Replacethetransmissionif inputshaftis worn.
Clutchpressureplatedamaged 1. Inspectthepressureplateforbentdrivestrapscausedby
impropervehicleuse.
2. Replacetheclutchassemblyif theclutchpressureplate
isdamaged.Informthecustomer.Referto Clutch
PressureandDrivenPlate Replacement(1.4L)on
page 17-416or ClutchPressureandDrivenPlate
Replacement(1.8L)onpage 17—419.
Flywheelimproperlymachined 1. Inspecttheflywheelforbeingimproperlymachined,and
causinginterferencewiththeclutchdisc.
2. Replacetheflywheelifit has beenimproperlymachined.
Flywheeluneven 1. Inspecttheflywheelsurfaceforbeingwarpedor uneven.
2. Replacetheflywheelifit isfaulty.

Clutch Rattle
Cause Actions
DEFINITION:A rattlenoisecomingfromtheclutchcomponentswiththeclutchdisengagedor engaged.ReviewtheSymptoms-
Clutchonpage 17-401andperformthenecessaryinspections.
ldlerattleclutchengaged Replacetheclutchdisc,duetofaultydampersprings.Referto ClutchPressureand
DrivenPlateReplacement(1.4L)onpage 17-416or ClutchPressureandDrivenPlate
Replacement(1.8L)onpage 17—419.
Clutchisimproperlyinstalled Removetheclutchandinstallitcorrectly.Referto ClutchPressureandDrivenPlate
Replacement(1.4L)onpage 17-416or ClutchPressureandDrivenPlateReplacement
(1.8L)onpage 17—419.
Clutchdiscdamperwornor damaged 1. inspecttheclutchdiscfora brokenorworndamper.
2. Replacetheclutchassembly.Referto ClutchPressureandDrivenPlate
Replacement(1.4L)onpage 17-416or ClutchPressureandDrivenPlate
Replacement(1.8L)onpage 17-419.
Oil in thedrivenplatedamper CorrectthecauseoftheOilleakandreplacetheclutchassembly.Referto Clutch
PressureandDrivenPlateReplacement(1.4L)onpage 17-416or ClutchPressureand
DrivenPlateReplacement(1.8L)onpage 17-419.
Clutchdiscsplinesandinputshaft 1. Inspecttheclutchdischubto inputshaftsplinesforexcessiveclearance.
splinesworn ‘ 2. Replacetheclutchassemblyiftheclutchsplinesareworn.Referto Clutch
PressureandDrivenPlateReplacement(1.4L)onpage 17-416or Clutch
PressureandDrivenPlateReplacement(1.8L)onpage 17-419.

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
 Clutch 17-405

Release Bearing Noisy with Clutch Engaged

Checks Actions
Checkfora bindingclutchactuator Clean andre-lubricatetheclutchactuatorcylinder.Inspecttheclutchactuatorcylinder
cylinder. forburrsandnicks.

Clutch Noisy
Cause Actions
Clutchactuatorcylinderdamaged Replacetheclutchactuatorcylinder.Referto ClutchActuatorCylinderReplacement
orworn. (F17)onpage 17—422 or ClutchActuatorCylinderReplacement(M20/32)on
page 17-423.

Clutch Pedal Hard to Push

Cause
DEFINITION:Theclutchpedalrequireshigheffortto operate.ReviewtheSymptoms—Clutchonpage 17-401and performthe
necessaryinspections.
Incorrecthydraulicfluid.
Contaminatedhydraulicfluid.
Clutchpedalbinding.
Clutchpedalspringworn.
Kinkedor damagedclutchactuator
cylinderfrontpipe.
Clutchdiscworntoothin.
page 17-419.
Actions
1. Inspectforthecorrectfluidin themastercylinder.Referto HydraulicClutch
SystemBleedingonpage 17-415.
2. Ifmineraloil isfound,replacetheclutchmastercylinder,theclutchactuator
cylinder,andflushthehydraulicsystemandfillwiththecorrectfluid.Referto
ClutchMasterCylinderReplacementonpage 17-408andHydraulicClutch
SystemBleedingonpage 17—415.
1. Inspectthehydraulicfluidforwater.
2. Inspectthehydraulicfluidfordirtor debris.
3. Inspecttheclutchhydraulicfluidforcontaminationof mineraloil.if contaminated,
replacetheclutchmastercylinderandtheclutchactuatorcylinder.Referto Clutch
MasterCylinderReplacementonpage 17-408.
4. Flushthehydraulicsystemandfill withthecorrectfluid.Referto HydraulicClutch
SystemBleedingonpage 17-415.
Inspectthepedalforbinding.
inspecttheclutchpedalspringforwear.
1. lnspectfora kinkedor damagedclutchactuatorcylinderfrontpipe.
2. Replacetheclutchactuatorcylinderfrontpipe.Referto ClutchActuatorCylinder
FrontPipe Replacementonpage 17—410.
Replacetheclutchassembly.Referto ClutchPressureandDrivenPlate Replacement
(1.4L)onpage 17-416or ClutchPressureandDrivenPlate Replacement(1.8L)on

Repair Instructions

Clutch Pedal Replacement

Removal Procedure
1. Remove the instrument panel lower trim panel
cover. Refer to InstrumentPanel Lower TrimPad
flyflmvxwmw
4,
ax
..
..._/
2. Cover Replacement (WithoutAAL) on page 2-40 or
InstrumentPanel Lower TrimPad Cover '
Replacement (WithAAL) on page 2-41.

2013
—
Sonic
(US/Canada)
Service
Manual
(5377994)
MH—wvu-
-2.-.
_,
_,.,.,..._v
2,,”
17406 Clutch

2888191 2609494
2. Remove the clutch pedal return spring (1). 4. Using a 10 mm (3/8in) alien wrench, remove the
clutch pedal pivot (1) by rotating the pin 1/4turn
counterclockwise.
5. Remove the clutch pedal assembly.
Installation Procedure
1. Install the clutch pedal assembly.

2530987
Note: Press the 2 latches (arrows)together.
3. Disconnect the push rod retainer(1)from the
clutch pedal.

2530987
Note: An audible click will be heard when the clip is
correctlyseated.
2. Connect the push rod retainer (1)to the clutch
pedaL

—
2013 (US/Canada)
Sonic (5377994)
Manual
Service
 Clutch 17-407

Clutch Master Cylinder Reservoir

Hose Replacement

Removal Procedure

2609494
3. Using a 10 mm (3/8in) allen wrench, install the
clutch pedal pivot(1) by rotating the pin 1/4turn
clockwise until the pivot pin locks in place.

2530990
Note: Before disconnecting the reservoir tank hose,
remove the clutch/brake fluid from the reservoir tank.
1. Remove the clutch master cylinder reservoir
hose (1) from the reservoirtank.
2. Remove the clutch master cylinder reservoir hose
from the Clutch master cylinder.
Installation Procedure

2888191
4. Install the clutch pedal return spring (1).
5. Installthe instrument panel lower trim panel cover.
Refer to InstrumentPanel Lower TrimPad Cover
Replacement (WithoutAAL) on page 2-40 or
InstrumentPanel Lower TrimPad Cover
Replacement (WithAAL) on page 2—41.

2530990
1. Install the clutch master cylinder reservoir hose (1)
to the reservoir tank and the master cylinder.
2. Bleed The hydraulic clutch system. Refer to
Hydraulic Clutch System Bleeding on page 17-415.

e“...
W
/
”2.2/2“..-
W- 2013
—
Sonic
(US/Canada)
Service
Manual
(5377994)
’17-408 Clutch
3. Fill the reservoir with GM approved brake fluid from
a clean, sealed brake fluid container up to the MAX
level.

Clutch Master Cylinder Replacement

Removal Procedure
1. Remove the battery tray. Refer to Battery Tray
Replacement on page 9-721.
2. Remove as much brake fluid out of brake fluid
reservoir as possible.

2530985
5. Remove the retaining clip (1).
6. Disconnect the clutch actuator cylinder front
pipe (3) from the clutch master cylinder(2).
7. Remove the brake pedal assembly. Refer to Brake
Pedal Assembly Replacement on page 5—151.

2530990
3. Remove the Clutch master cylinder reservoir
hose (1) from the clutch master cylinder.

2530987
Note: Press the 2 latches (arrows) together.
8. Disconnect the push rod retainer(1) from the
clutch pedal.

2536478
4. Unclip the clutch actUator cylinder front pipe from
the 2 retainers (1).

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Clutch 17-409

2492203 2530987
9. Remove the 2 clutch master cylinder fasteners (1). Note: An audible click will be heard when the clip is
correctly seated.
10. Remove the clutch master cylinder from the brake
pedal assembly. 3. Connect the push rod retainer (1) to the clutch
pedaL
Installation Procedure 4. Install the brake pedal assembly. Refer to Brake
1. Installthe clutch master cylinder into the brake Pedal Assembly Replacement on page 5—151.
pedal assembly.

2530985
2492203
5. Connect the clutch actuator cylinder front pipe (3)
Caution: Refer to Fastener Caution on page 0—8.
to the clutch master cylinder (2).
2. Install the 2 clutch master cylinder fasteners (1)
6. Install the retaining clip (1).
and tighten to 4.5N'm (40 lb in).

2013
—
Sonic
(US/Canada)
Service
Manual
(5377994)
17-410 Clutch
2. Remove as much brake fluid out of brake fluid
reservoir as possible.

2536478
7. Clip the clutch actuator cylinder front pipe into the
2 retainers (1).
2536478
3. Unclip the clutch actuator cylinder front pipe from
the 2 retainers (1).

®/ '7’

2530990
8. Install the clutch master cylinder reservoir hose (1)
to the clutch master cylinder.
2530985
9. Install the battery tray. Refer to Battery Tray
Replacement on page 9-721. 4. Remove the retaining clip (1).
10. Bleed the hydraulic clutch system. Refer to 5. Disconnect clutch actuator cylinder front pipe (3)
Hydraulic Clutch System Bleeding on page 17-415. from the clutch master cylinder (2).
11. Fill the reservoir with GM approved brake fluid from
a clean, sealed brake fluid container up to the MAX
level.

Clutch Actuator Cylinder Front Pipe

Replacement

Removal Procedure
1. Remove the battery tray. Refer to Battery Tray
Rep/acement on page 9—721 .

(US/Canada)
-Sonic
2013 {5377994)
Manual
Service
 Clutch 17-411

1 2

2028267 2530985
6. Remove the retaining clip (1). . Connect clutch actuator cylinder front pipe (3) to
7. Disconnect the clutch actuator cylinder front the clutch master cylinder (2).
pipe (2)from the clutch actuator cylinder pipe . install the retaining clip (1).
elbow.
8. Remove the clutch actuator cylinder front pipe from
the vehicle.
Installation Procedure
1. Install the clutch actuator cylinderfront pipe in the
vehicle.

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2536478
. Clip the clutch actuator cylinder front pipe into the
2 retainers (1).
. Install the battery tray. Refer to Battery Tray
Replacement on page 9-721.
. Bleed the hydraulic clutch system. Refer to
2028267 Hydraulic Clutch System Bleeding on page 17-415.
. Fill the reservoir with GM approved brake fluid from
2. Connect the Clutch actuator cylinder front pipe (2)
a clean, sealed brake fluid container up to the MAX
to the clutch actuator cylinder pipe elbow.
level.
3. Install the retaining clip (1).

2013
—
Sonic
(US/Canada)
Service
Manual
(5377994)
17-412 Clutch

Clutch Actuator Cylinder Pipe 5. Remove the fastening sleeve (3) carefully out of
the transmission housing and clutch actuator
Replacement (F17) cylinder pipe.
Removal Procedure
1. Remove the transmission. Referto Transmission
Replacement on page 17—463.

2567342
6. Remove the clutch actuator cylinder pipe (2) from
the transmission housing and clutch actuator
2191453 cylinder (1).

2. Loosen the clutch actuator cylinder pipe nut (1) Installation Procedure
from the clutch actuator cylinder.

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2567342
2587329 Note: Check the seal rings for cracks and damage.
Replace if necessary.
3. Remove the clutch actuator cylinder pipe
connector elbow clip (1). 1. Position the clutch actuator cylinder pipe (2) to the
4. Remove the clutch actuator cylinder pipe transmission housing and clutch actuator
connector elbow (2) from the clutch actuator cylinder (1).
cylinder pipe end.
Note: Release the fastening sleeve key (arrows) using
a screwdriver or equivalent to remove the fastening
sleeve.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Clutch 17-413

Clutch Actuator Cylinder Pipe

Replacement (M20/32)
Removal Procedure
1. Remove the transmission. Refer to Transmission
Replacement on page 17-586.

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2567329 1. II}i‘\\\
2. Install the fastening sleeve (3) carefully to the
transmission housing and clutch actuator
cylinder pipe.
3. Install the clutch actuator cylinder pipe connector
elbow (2) to the clutch actuator cylinder pipe end.
4. Install the clutch actuator cylinder pipe connector
elbow clip (1). 2551912
2. Remove the clutch actuator cylinder pipe
connector elbow clip (1) from the clutch actuator
elbow.
3. Remove the connector elbow (2) from the clutch
actuator cylinder pipe end.
Note: Release the fastening sleeve key (arrows) using
a screwdriver or equivalent to remove the fastening
sleeve.
4. Remove the fastening sleeve (3) from the
transmission housing and clutch actuator
cylinder pipe.

./

2191453
Caution: Refer to Fastener Caution on page 0-8.
5. Install the clutch actuator cylinder pipe nut (1) to
the clutch actuator cylinder and tighten to 14N-m
(124 lb in).
6. Install the transmission. Referto Transmission
Replacement on page 17—463.

2551925

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
'17-414 Clutch
5. Remove the 3 clutch actuator cylinder bolts (1).

2551925
Caution: Refer to Fastener Caution on page 0—8.
2551931 4. Install the 3 clutch actuator cylinder bolts (1) and
6. Remove the clutch actuator cylinder (1) and the tighten to 6 N-m(53 lb in).
clutch actuator cylinder pipe (2) at the same time.
Note: Discard the clutch actuator cylinder seal.
7. Remove the seal (3).
Installation Procedure
1. Clean the 3 clutch actuator cylinder threaded holes
in the transmission housing. “ \‘.-“\:
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I&gllggni 2

2551912
5. Install the fastening sleeve (3) to the transmission
housing and clutch actuator cylinder pipe.
6. Install the clutch actuator cylinder pipe connector
elbow (2) to the clutch actuator cylinder pipe end.
7. Install the connector elbow clip (1).
8. Install the transmission. Referto Transmission
2551931 Replacement on page 17—586.
2. Install a NEW clutch actuator cylinder seal (3).
3. Install the Clutch actuator cylinder(1) and Clutch
actuator cylinder pipe (2).

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
 Clutch 171415
Hydraulic Clutch System Bleeding Undertake road test using varying RPM ranges
and frequent gear changes, bring vehicle to
Warning: Refer to Brake Fluid Irritant Warning on operating temperature during this process. Ensure
page 0-4. the brake and Clutch system is operating correctly.
Caution: Brake fluid must not come in contact with
mineral oils and greases. The smallest amount of such Clutch Pedal Position Sensor
could lead to malfunction or breakdown of the clutch. Replacement
Caution: Refer to Brake Fluid Effects on Paint and
Electrical Components Caution on page 0—7. Removal Procedure
Note: The hydraulic clutch actuation must only be bled 1. Remove the instrument panel lower trim pad cover.
from "below", i.e. from the bleeder valve. Refer to Instrument Panel Lower TrimPad Cover
Replacement (WithoutAAL) on page 2-40 or
InstrumentPanel Lower TrimPad Cover
Replacement (With AAL) on page 2-41.

2498555
Note: The following operational stages must be
undertaken to fill the pressure line between the master
cylinder and the clutch actuator cylinder. When 2498838
bleeding, ensure that the brake fluid reservoir is always 2. Remove the clutch pedal position sensor bolt (2).
full and does not run dry.
.03Remove the clutch pedal position sensor (1).
1. Bleed pressure line between the clutch master 4. Disconnect the ciutch pedal position sensor wiring
cylinder and the clutch actuator cylinder using the harness connector.
following procedure:
1.1. Remove the valve cap (3) from the bleeder Installation Procedure
valve. 1. Connect the clutch pedal position sensor wiring
1.2. Fill brake fluid reservoir up to "MAX" marking. harness connector.
1.3. Press and hold clutch pedal.
1.4. Open bleeder valve until air or air/brake fluid
mixture emerges.
Note: Do not close the bleeder valve too fast.
1.5. Close the bleeder valve.
1.6. Release the clutch pedal slowly.
1.7. Wait approximately 5 seconds.
1.8. Repeat this bleeding process 4 times.
1.9. Tighten bleedervalve .
1.10. Push valve cap on to bleeder valve to
protect the bleeder valve.
2. Check shifting for ease of movement with vehicle
stationary, with engine running and with clutch
disengaged.
3. Road test the vehicle to ensure proper operation.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
\,.._
4,2.
.._.-Wflm__.
‘17-416 Clutch

2498838
2. Install the clutch pedal position sensor(1).
Caution: Refer to Fastener Caution on page 0-8.
3. Install the clutch pedal position sensor bolt (2) and
tighten to 3 N-m(27 lb in).
4. Install the instrument panel lower trim pad cover.
Refer to InstrumentPanel Lower TrimPad Cover
Replacement (WithoutAAL) on page 2—40or
InstrumentPanel Lower TrimPad Cover
Replacement (WithAAL) on page 2—41 .
2028117
Note: DT-6263 remover/installer may only be attached
to the engine block and not to the oil pan.
2. Attach DT—6263remover/installer (1) or equivalent
to the engine block. .
Note: Do not tighten the bolts yet.
3. Install 4 bolts (arrows)to engine block.

Clutch Pressure and Driven Plate

Replacement (1 .4L)
Special Tools
DT-6263 Remover/Installer
For equivalent regional tools, refer to Special Tools on
page 17—425.
Removal Procedure
Note:
- To prevent damage to the spring fangs of
pressure plate use DT-6263 remover/installer to
remove and install clutch pressure plate.
- Note the different lengths of the brackets for
attaching DT-6263 remover/installer to lower
engine block.
1. Remove the transmission. Refer to Transmission 2191651
Replacement on page 17-463.
4. Attach a suitable clutch center guide (5) to
DT—6263—30 centering drift (4).
5. Fasten DT-6263 remover/installer.
- Align DT-6263 remover/installerto center.
- Insert DT-6263-30 centering drift (2) in
conjunction with clutch center guide through
DT-6263 remover/installer into clutch pressure
plate and crankshaft center (arrow).
~ Tighten knurled wheel (1).
- Tighten bolt (3).
~ Tighten 4 bolts of DT—6263remover/instalier to
the engine block.
2013
-Sonic
(US/Canada)
Service
Manual
{5377994)
 Clutch 17-417

.Hm
.w
V.

2028119 2028122
6. Preload clutch springs using DT-6263 remover/ 8. Release DT-6263 remover/installer (1).
installer. - Tum D716263remover/installer
- Move DT—6263remover/installer (1) that it rests counterclockwise to the stop.
against the spring tangs of clutch pressure - Remove DT-6263—30centering drift (2) in
plate. conjunction with clutch center guide.
' Turn DT-6263 remover/installer clockwise to
the stop.

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2.2...wmefl/2
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,‘

2191626

2191625 9. Remove clutch pressure plate (2) and driven

plate (1).
Note: Discard the bolts.
7. Remove 6 ciutch pressure plate bolts (1).

2013
—
Sonic
(US/Canada)
Service
Manual
(5377994)
17-418 Clutch

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51
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2028217 2191652
Note: Clutch pressure plate and driven plates Note: Lettering transmission side faces the
contaminated by foreign bodies (oil, cleaning agent transmission.
etc.) have to be replaced. Check clutch driven plate for
damage and friction rust in the hub profile and replace if Center clutch driven plate using DT-6263—30centering
necessary. Do not clean ciutch pressure plate and drift in conjunction with clutch center guide.
driven plate with a high pressure cleaner or component 2. Install driven plate (1) and clutch pressure plate (2).
washing machine.
10. lnspect clutch pressure plate and driven plate (1)
and replace it necessary. lnspect for the following
conditions:
- Excessive wear
- Burned friction surface
- Oil on friction surface
- Damaged spline hub
- Damaged springs
Note: The ciutch driven plate has to be replaced if the
lining projection is less than 0.5 mm (0.020 in)(arrows).
11. Inspect projection of lining at the clutch lining
rivets.
12. Slide clutch driven plate onto the transmission
input shaft and check for easy movement.
Installation Procedure
1. Clean 6 threads in flywheel for fastening clutch
pressure plate.
2028119
3. Preload clutch springs using DT-6263 remover/
installer.
' Move DT—6263remover/installer (1) that it rests
against the spring tangs of clutch pressure
plate.
- Turn DT-6263 remover/installer clockwise to
the stop.

2013
~Sonic
(US/Canada)
Service
Manual
(5377994)
 Clutch 17-419

Clutch Pressure and Driven Plate

Replacement (1.8L)
Special Tools
DT-6263 Remover/lnstalter
For equivalent regional tools, refer to Special Tools on
page 17-425.
22
..
222
.2_../W
.2
2.22...
”/2
2..
Removal Procedure
Note:
' To prevent damage to the spring fangs of
pressure plate use DT-6263 remover/installer to
remove and install clutch pressure plate.
- Note the different lengths of the brackets for
attaching DT-6263 remover/installer to lower
engine block.
1. Remove the transmission. Refer to Transmission
Replacement on page 17-463.
2191625
Caution: Refer to Fastener Caution on page 0-8.
4. Install 6 NEW clutch pressure plate bolts (1) and
tighten crosswise to 15 N-m(11 lb ft).

24<.22M—Ww22222wuwnm.
«-
.2.
222 4’"2
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“411,477 -
“"471” X

2028117
Note: DT—6263remover/installer may only be attached
to the engine block and not to the oil pan.
2. Attach DT-6263 remover/installer (1) or equivalent
to the engine block.
2028222
Note: Do not tighten the bolts yet.
5. Remove DT-6263 remover/installer (1) from engine
block. 3. Install 4 bolts (arrows) to engine block.
- Turn DT-6263 remover/installer (3)
counterclockwise t0 the stop.
. Remove DT-6263—30centering drift (2) in
conjunction with clutch center guide (arrow).
- Remove 4 bolts of DT-6263 remover/installer
from engine block.
6. install the transmission. Refer to Transmission
Replacement on page 17—463.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
2
»2
2.2““.2222222,
22.22.22v—
2222*,
_2.,22\~
.
17-420 Clutch
6. Preload clutch springs using DT-6263 remover/
installer.
. Move DT—6263remover/installer (1) that it rests
against the spring tangs of clutch pressure
plate.
- Turn DT-6263 remover/instailer clockwise to
the stop.

2191651
4. Attach a suitable clutch center guide (5) to
DT-6263—30centering drift (4).
5. Fasten DT—6263remover/installer.
- Align DT—6263remover/instailer to center.
- Insert DT-6263-30 centering drift (2) in
conjunction with clutch center guide through
DT-6263 remover/instailer into clutch pressure 2531060
plate and crankshaft center (arrow).
Note: Discard the bolts.
- Tighten knurled wheel (1).
7. Remove 6 clutch pressure plate bolts (1).
- Tighten bolt (3).
- Tighten 4 bolts of DT-6263 remover/installerto
the engine block.

2028122
8. Release DT-6263 remover/installer (1).
2028119 - Turn DT—6263remover/installer
counterclockwise to the stop.
° Remove DT-6263-30 centering drift (2) in
conjunction with clutch center guide.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Clutch 17-421
Note: The ciutch driven plate has to be replaced if the
lining projection is less than 0.5mm (0.020 in)(arrows).
11. inspect projection of lining at the clutch lining
rivets.
12. Slide ciutch driven plate onto the transmission
input shaft and check for easy movement.
Installation Procedure
1. Clean 6 threads in flywheel for fastening clutch
pressure plate.

2531085
9. Remove clutch pressure plate (2) and driven
plate (1).

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2
222___~»—«w—-—w
_..2222—222222
2531085
Note: Lettering transmission side faces the
transmission.
Center clutch driven plate using DT-6263-30 centering
drift in conjunction with clutch center guide.
2. Install driven plate (1) and clutch pressure plate (2).

.114
2028217
Note: Clutch pressure plate and driven plates
contaminated by foreign bodies (oil, cleaning agent
etc.) have to be replaced. Check clutch driven plate for
damage and friction rust in the hub profile and replace if
necessary. Do not Clean clutch pressure plate and
driven plate with a high pressure cleaner or component
washing machine.
10. Inspect ciutch pressure plate and driven plate (1)
and replace if necessary. lnspect for the foilowing
conditions:
° Excessive wear
- Burned friction surface
- Oil on friction surface
- Damaged spline hub 2028119
- Damaged springs

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
17-422 Clutch
3. Preload Clutch springs using DT—6263remover/ 6. Install the transmission. Referto Transmission
installer. Replacement on page 17—463.
- Move DT-6263 remover/installer (1) that it rests
against the spring tangs of clutch pressure Clutch Actuator Cylinder
plate. Replacement (F17)
- Turn DT—6263remover/installer clockwise to
the stop. Removal Procedure
1. Remove the transmission. Refer to Transmission
Replacement on page 17—463.

2531060
Caution: Refer to Fastener Caution on page 0-8.
4. Install 6 NEW clutch pressure plate bolts (1) and 2191453
tighten crosswise to 15 N~m(11 lb ft).
2. Loosen the clutch actuator cylinder pipe fitting(1)
from the clutch actuator cylinder.

2028222
5. Remove DT—6263remover/installer (1) from engine 2191454
block.
3. Remove the 3 ciutch actuator cylinder
- Turn DT-6263 remover/instailer (3) fasteners (3).
counterclockwise to the stop.
4. Remove the Clutch actuator cylinder (1).
- Remove DT-6263-30 centering drift (2) in
Note: Discard clutch actuator cylinder seal.
conjunction with clutch center guide (arrow).
. Remove 4 bolts of DT-6263 remover/instalier 5. Remove the seal (2).
from engine block.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Clutch 17-423
Installation Procedure Clutch Actuator Cylinder
1. Clean the 3 clutch actuator cylinder threaded holes Replacement (M20I32)
in the clutch housing.
Removal Procedure
1. Remove the transmission. Refer to Transmission
Replacement on page 17—586.

2191454
2. Install a NEW clutch actuator cylinder seal (2).
3. Install the clutch actuator cylinder (1).
2551912
Caution: Refer to Fastener Caution on page 0-8.
4. Install the 3 clutch actuator cylinder fasteners (3) 2. Remove the Clutch actuator cylinder pipe
WNWW
’22“th
22..
22_,«~—__-2__.2~222_
and tighten to 5N'm (44 lb in). connector elbow clip (1) from the clutch actuator
elbow.
3. Remove the connector elbow (2) from the clutch
actuator cylinder pipe end.
Note: Release the fastening sleeve key (arrows) using
a screwdriver or equivalent to remove the fastening
sleeve.
4. Remove the fastening sleeve (3) from the
transmission housing and clutch actuator
cylinder pipe.

2191453
5. install the clutch actuator cylinder pipe fitting (1)
and tighten to 14N-m (124 lb in).
6. Install the transmission. Refer to Transmission
Replacement on page 17—463.

2551925

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
'17-424 Clutch
5. Remove the 3 ciutch actuator cylinder bolts (1).

2551925
Caution: Refer to Fastener Caution on page 0—8.
2551931 4. Install the 3 clutch actuator cylinder bolts (1) and
6. Remove the Clutch actuator cylinder (1) and the tighten to 6 N-m(53 lb in).
clutch actuator cylinder pipe (2) at the same time.
Note: Discard the clutch actuator cylinder seal.
7. Remove the seal (3).
Installation Procedure
1. Clean the 3 clutch actuator cylinder threaded holes
in the transmission housing.
\ .3 .4.

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r
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._.
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it

2551912
5. Install the fastening sleeve (3)to the transmission
housing and clutch actuator cylinder pipe.
6. Install the clutch actuator cylinder pipe connector
elbow (2) to the clutch actuator cylinder pipe end.
7. Install the connector elbow clip (1).
8. Install the transmission. Referto Transmission
2551931 Replacement on page 17—586.
2. install a NEW clutch actuator cylinder seal (3).
3. install the clutch actuator cylinder(1) and clutch
actuator cylinder pipe (2).

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
 Clutch 17-425

Description and Operation motion forces hydraulic fluid through the hose
assembly from the master cylinder to the Clutch
actuator cylinder. The clutch actuator cylinder then
pushes the release bearing into the diaphragm spring
Clutch System Description and to disengage the clutch. A hole in the bulkhead
Operation accommodates the master cylinder. A quick connect
coupling attaches the ciutch actuator cylinder front pipe
Clutch Spin Down Time assembly to the actuator cylinder. The actuator cylinder
Inspect the clutch spin down time as follows: is inside the transmission and on the input bearing
retainer. The master cylinder and clutch actuator
1. Apply the parking brake and block the vehicle cylinder front pipe assembly can be replaced without
wheels. having to gain access to the clutch system internal
Shift the manual transmission into NEUTRAL. components; simply disengage/engage the quick
Start the engine. Run the engine at idle speed. connect coupling mounted through the transmission
Engage the clutch. housing. No adjustments to the clutch system are
necessary. As the ciutch wears, the fluid level in the
Disengage the clutch. Wait 9 seconds. Clutch reservoir changes to compensate for clutch
awaww
. Shift the transmission into REVERSE. wear. A new system has fluid in the reservoir. The
clutch pedal position sensor on the clutch pedal/bracket
Clutch Driving Members assembly has 2 functions. One function is a clutch
The clutch driving members are 2 flat surfaces interlock, ensuring the engine does not start unless the
machined to a smooth finish. They include the clutch pedal is positioned on the floor.-The second
following: function is to cut off the cruise control system,
- The rear face of the engine flywheel if equipped, when the clutch pedal is pushed
downward.
- The front face of the clutch pressure plate
Clutch Driven Members Special Tools and Equipment
The driven member is the clutch driven plate. The
ciutch driven plate has a splined hub. The splined hub Illustration Tool Number/Description
slides lengthwise along the splines of the input shaft.
The splined hub drives the input shaft through these
same splines. The driving and driven members are held
together with a spring pressure. This pressure is
exerted by a diaphragm spring in the clutch cover.
DT-6263
Hydraulic Clutch Fluid Bfifieg KM-6263
Caution: Do not use mineral or paraffin-base oil in the Remover/lnstaller
MWWM—ww.
22m
..
.fl
222.22.
_
4
2
~22.
~’
clutch hydraulic system. These fluids may damage the
rubber parts in the cylinders.
Hydraulic Clutch Operating Members 2027936
The clutch system consists of the following
components:
- A master cylinder with a remote reservoir and with
the clutch actuator cylinder front pipe
DT—6263—26
- A clutch pedal position sensor
KM-6263—26
- An clutch actuator cylinder ClutchCenterGuide
' The ciutch pressure plate
- The clutch cover
- The diaphragm spring
2670413
- The ciutch driven plate
- The torsional springs
With the depression of the clutch pedal, the clutch
master cylinder becomes pressurized from the force of
the push rod into the master cylinder. This push rod

2013
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17-426 Manual Transmission - F13-5/F15-5/F17-5 (N126)

Manual Transmission - F13-5lF15-5/F17-5 (M26)

Specifications

Fastener Tightening Specifications

Specification
Application Metric English
5thSpeedConnectingClaw SupportBolts 9 N'm 80lb in
5thSpeed ForkBolts 22N-m 16Ibft
5thSpeed ForkSupportBolts 22N-m 16lbft
AdjustingSleeve RetainingPlateBolt 9NW 80lb in
BackupLampSwitch 40N~m 30lbft
Bar Boltsat ControlArmPivotArea 100Nm 74lbft
BearingCoverand RetainingPlate Bolts—M8 20N-m 15lbft
BrakeBoosterHoseConnectionat IntakeManifold 18N-m 13lbft
ClutchBearingGuide-to-Transmission Boits 5 N'm 44lb in
ClutchCoverBolts 15N-m 11lbft
ClutchForkBolt 35N-m 26ibft
ClutchHousingCoverBolts 6N-m 53lbin
ClutchHousingCoverPlateBolts 6 N-m 53lbin
ClutchLineBracketBolts 25N-m 18Ibft
ClutchReleaseCylinderBolts 12N-m 106lb in
CompressorBolts 45.5N-m 34lbft
ConnectingBridgeBolts 7 N'm 62lb in
ControlLeverHousingBolts 12Nm 106lb in
CouplingClampBolt 31.5N-m 23Ibft
DampingWeight-to—Linkage Bolt 20N-m 15lbft 2.22
,222
,
DifferentialCase BearingAdjustingSleeve Lock Bolt 9 N-m 80lb in
DifferentialCover—to—Transmission
Bolts
LightAiloyVersion 18N-m 13Ibft
SheetMetalVersion 30N-m 22lbft
DifferentialCoverBolts 7N-m 62lbin
DrainPlug 39N-m 291bft
EngineMountand RearEngineMountBracketBolts 67.5N-m 50lbft
EngineRear Bracket—to-EngineMountBolt 62.5N-m 46lbft
Fill Plug 39N-m 29Ibft
FrontShiftLeverBali StudRetainer 12.5N~m 111lbin
FrontSuspensionSteeringKnucklePivot—Ball Joint,Bolt 31.5N'm 231bft
FrontSuspensionTensionBar Nut 90N-m 661bft
FrontTransmissionMountBolts 68N-m 50ibft
Guide Bolts 5N-m 44lb in
GroundCabie Bolts 13N-m 115lb in
InspectionPlug 4N-m+45°+90° 35lbin +45°+90°
LeftEngineBracketBolts—AII 62.5N~m 46 Ibft
LeftEngineMountBracketandEngineMountBolts 67.5N'm 5OIbft
LeftTransaxleMountBracketBolts 52N-m 38lbft
LeftTransaxleMountBolts 52N-m 38lbft

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 Manual Transmission - F13-5/F15-5/F17-5 (M26) 17-427

A Fastener Tightening Specifications (cont'd)

Specification
Application Metric English
LeftTransaxleMountThroughBolt 80N-m 59ibft
LinkageCIamp-to-Shift
ControlGuideBolt 26.5N-m 20 lbft
Linkage-to—Shift
ControlGuideCouplingClampBolt 31.5N-m 23 ibft
LockBallAssembly 29N-m 22lbft
LockPin BridgeBolts 7 N-m 62lb in
LowerTransmissionto EngineBolts
#1Bolts 64N-m 47 lbft
#2Bolts 47N-m 35 lbft ,: ..
#3Bolts 23N-m 17Ibft
OutputSpeedSensor 24N-m 18Ibft
PedalShaftNut 20N-m 151bft
PedalSupport-to-Dash Panel Nut 20N-m 15lbft
PedalSupportwithBrakeBoosterSupport—to-Dash Panel Nuts 20Wm 15lbft
Pivot—to-Steering
KnuckleBolt 31.5N-m 23 lbft
RearTransmissionMountBolts 68N-m 50 lbft
RetainingPlateBolts 22N-m 16lbft
RetainingPlateCoverBolts—M7 15Wm 11lbft
Reverse/Backu p LampSwitch 20Nm 15lbft
ReverseLampSwitchatTransmission 20Nm 15lbft
RightEngineMount—to-Engine BracketBoltandNut 62.5N-m 46 Ibft
RingGear Bolts 90NW 66 lbft
.M’2
24....
_
A
2.22,222“
. ShiftControlCover—to-TransmissionBolts 15Nm 11lbft
ShiftLeverBracket-to-Floor
PanelTunnelBolt 6 N'm 53lb in
ShiftLeverShaftAssembly 19N‘m 14lbft
SpeedometerSensorBolt 5 N-m 44 lb in
StarterWireNut 10N-m 87 lbin
StarterMotorRetainingBolts 37Nm 28 lbft
TensionBar Bolts—to-Front
SuspensionControlArm 100Nm 74 lbft
Tie Rod End Nuts—to-Front
SuspensionSteeringKnuckle 34NW 25 lbft
TransmissionBolts—Plate 22N-m 16lbft
TransmissionBracketBolts 72.5N-m 53 lbft
TransmissionCoverBoIts—Short 8N'm 71lb in
TransmissionCoverBolts—Long 24N-m 18lbft
Transmission-to—Engine
Bolts—All 70N-m 52lbft
WheelBolts 110N-m 81Ibft

Adhesives, Fluids, Lubricants, and Sealers

Application Type of Material
AssemblingShiftLeverSupportSet SiliconeGrease
ClutchBearingGuide LubricatingGrease
Clutch/BrakePedalShaft No.2 LithiumSoap Based Grease
withGlycerol
ClutchCable End,at Pedal No.2 LithiumSoap Based Grease
ClutchLeverHousingBushing LubricatingGrease
2013
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Service
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’17-428 Manual Transmission - F13-5/F15-5/F17-5 (N126)

Adhesives, Fluids, Lubricants, and Sealers (cont'cl)

Application Type of Material
ControlGuideLock-Pin SiliconeGrease
ControlGuideRod SiliconeGrease
ChemicalLocking
FifthGear ForkBracketAttachingBolt Compound—Loctite—271,High
Torque
ChemicalLocking
FifthGear ForkConnectingBridgeAttachingBolt Compound—Loctite—271, High
Torque
ChemicalLocking .
FifthGear ForkConnectingClaw BracketAttachingBolt Compound—Loctite—271,High
Torque
inputShaftSeal No.2 LithiumSoap BasedGrease
inputShaftSplineat ClutchDisc HousingArea No.2 LithiumSoap BasedGrease
ThreadLocking
OutputSpeedSensor Compound—Loctite~516
ShiftLeverAssembly SiliconeGrease
ShiftLeverSeal No.2 LithiumSoap BasedGrease
ShiftLever-to-Control
GuideLockPin —CompanionJoint SiliconeGrease
LubricantOil,as perSAE 75W85
TransmissionAssembly SAE 75W85—usedforhelicalgear
(redcoloration)

Lubrication Specifications

Transmission Fluid
Transmission Filling Quantity GM Part Number Canadian
F15 Approx.1.60L (1.69qt) 88862472 88862473
TransmissionFluidLevel:
All transmissions,aftera transmissionrepair,shouldbefilledas faras theloweredgeoftheinspectionaperture.
Thetransmissionfluidis suppliedbyweightin production.Thereis noneedto correctit duringscheduledservicingifno leaks
arefound.

Transmission Gear Ratio (cont'd)

Transmission Gear Ratio
Transmission Type
Transmission Type
F-17M25 F-17-5M26
F-17M25 F-17-5M26
Range CR WR
Range CR WR
5thGear 0.89 0.76
1stGear 3.73 3.73
Reverse 3.31 3.31
2ndGear 2.14 1.96
OR =Close Ratio(closeratiogearset)
3rdGear 1.41 1.32 WR =WideRatio(wideratiogearset)
4thGear 1.12 0.95

Schematic and Routing Diagrams

2013
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Manual
(5377994)
 lllllllll
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.200 mo

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2013
-Sonic
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Manual
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’17-430 Manual Transmission - F13-5/F15-5/F17-5 (N126)

Component Locator

Disassembled Views
Case Components (1 of 2)

2264743
Back Up Lamp Switch Assembly (14) Front Differential Bearing Adjuster
Clutch Yoke Shaft Retaining Bolt (15) Front Differential Bearing Adjuster Lock
Ciutch Yoke Shaft Bushing (16) Front Differential Bearing Adjuster Lock Bolt
Clutch Yoke Shaft (17) Front Differential Bearing Retainer
Clutch Yoke Shaft Seal O—ringSeal
Clutch Lever Assembly Brace (18) Front Wheel Drive Shaft Oil Seai Assembly
Vehicle Speed Sensor Bolt (19) Transmission inspection PIug/Magnet
Vehicle Speed Sensor Assembly (20) Transmission Case Gasket
Shift Control Housing Cover Gasket (21) Main Shaft Front Bearing Assembly
(10) Shift Control Housing Locating Pin (22) Main Shaft Assembly
(11) M/Trans Control Lever Housing Assembly (23) InputShaft
(12) Shift Control Housing Bolt (24) InputShaft Front Bearing Assembly
(13) Front Differential Bearing Race (25) Clutch and Differential Housing Cover Bolt
(26) Front Differential Carrier Cover
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 Manual Transmission , F13-5/F15-5lF17-5 (M26) 17-431
(27) Front Differential Carrier Cover Gasket (32) Clutch Release Bearing Collar O—ringSeal
(28) Transmission Case Locating Pin (33) Clutch Release Bearing Collar
(29) Front Differential Assembly (34) Clutch Release Bearing
(30) Front Differential Bearing Race (35) Clutch Release Bearing Collar Bolt
(31) Clutch and Differential Housing (36) Front Wheel Drive Shaft Oil Seal Assembly

Case Components (2 of 2) (Gen 1)

2264746
Legend
(1) 3rd and 4th Shift Shaft Bushing (13) 5th Shift Blocking Pin
(2) 3rd and 4th Shift Fork Pin (14) 1st and 2nd Shift Fork Pad
(3) 3rd and 4th Shift Fork Pad (15) 1st and 2nd Shift Shaft
(4) 3rd and 4th Shift Fork Shoe (15) 5th Shift Fork Bracket
(5) 3rd and 4th Shift Fork Assembly (17) 5th Shift Fork Bracket Bolt
(6) 5th Shift Blocking Guide (18) 5th Shift Fork Shoe
(7) 3rd and 4th Shift Shaft (19) 5th Shift Fork Assembly
(8) 1st and 2nd Shift Shaft Bushing (20) Transmission Cover Bolt
(9) 1st and 2nd Shift Fork Pin (21) Transmission Case Bolt
(10) 1st and 2nd Shift Fork Assembly (22) Transmission Cover Assembly
(11) Shift Shaft Interlock Pin Connector Bolt (23) Transmission Cover Gasket
(12) Shift Shaft interlock Pin Connector (24) 5th Gear Synchronizer Hub Retaining Ring

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17-432 Manual Transmission - F13-5/F15-5lF17-5 (M26)
(25) 5th Gear Synchronizer Hub (39) Reverse Shift Fork Pin Washer
(26) 5th Gear Synchronizer insert Assembly (40) Reverse Shift Shaft
(27) 5th Gear Synchronizer Sleeve (41) Reverse Shift Fork Assembly
(28) 5th Gear Blocking Ring (42) Reverse Shift Fork Pin
(29) 5th GearAssembly~ Driven (43) Transmission Case
(30) 5th Gear Retaining Ring (44) Transmission Magnet
(31) 5th Gear— Driving (45) Shift Shaft Detent Sleeve
(32) 5th Gear Bearing Assembly (46) Gearshift Rod
(33) 5th Gear Bearing Race (47) Parking Pawl
(34) Parking Pawl Bolt (48) Main Shaft Rear Bearing Assembly
(35) Transmission Case Bolt (49) Main Shaft Rear Bearing Retaining Ring
(36) Reverse IdlerGear Shaft Bail (50) input Shaft Rear Bearing Assembly
(37) Reverse IdlerGear Shaft (51) input Shaft Rear Bearing Retaining Ring
) Reverse IdlerGear Assembly

Case Components (2 of 2) (Gen 2)

2749168
Legend
(1) 3rd and 4th Shift Fork Padv (4) 5th Shift Blocking Guide
(2) 3rd and 4th Shift Fork Pin (5) 5th Shift Blocking Guide Bushing
(3) 3rd and 4th Shift Fork (6) 3rd and 4th Shift Shaft
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Manual
{5377994)
 Manual Transmission =F13-5/F15-5/F17-5 (M26) 17—433
(7) 1st and 2nd Shift Shaft (33) Parking Pawl Bolt
(8) 1st and 2nd Shift Fork (34) Reverse idler Gear Shaft Bail
(9) 1st and 2nd Shaft Block (35) Reverse idler Gear Shaft
(10) 1st and 2nd Shaft Block Pin (36) Reverse Helical Gear Washer
(11) 1st and 2nd Shift Fork Pin (37) Reverse Helical Gear
(12) Shift Shaft Interlock Pin Connector Bolt (38) Reverse Synchro Assembly
(13) Shift Shaft Interlock Pin Connector (39) Reverse Spur Gear
(14) 5th Shift Blocking Pin (40) Reverse Spur Gear Bearing
(15) 5th Shift Fork Bracket (41) Reverse Spur Gear Washer
(16) 5th Shift Fork Bracket Bolt (42) Reverse Gear Shaft Snap Ring
(17) 5th Shift Fork Shoe (43) Reverse Shift Fork
(18) 5th Shift Fork Assembly (44) Reverse Fork Block
(19) Transmission Cover Bolt (45) Reverse Shift Shaft
(20) Transmission Case Bolt (46) Reverse Shift Shaft Pin
(21) Transmission Cover Assembly (47) Reverse Fork Block Pin
(22) Transmission Cover Gasket (48) Transmission Case Bolt
(23) 5th Gear Synchronizer Hub Retaining Ring (49) Transmission Case
(24) 5th Gear Synchronizer Hub (50) Transmission Magnet
(25) 5th Gear Synchronizer insert Assembly (51) Shift Shaft Detent Sleeve
(26) 5th Gear Synchronizer Sleeve (52) Gearshift Rod
(27) 5th Gear Blocking Ring (53) Parking Pawl
(28) 5th Gear Assembly —Driven (54)" Main Shaft Rear Bearing Assembly
(29) 5th Gear Retaining Ring (55) Main Shaft Rear Bearing Retaining Ring
(30) 5th Gear— Driving (56) input Shaft Rear Bearing Assembly
(31) 5th Gear Bearing Assembly (57) InputShaft Rear Bearing Retaining Ring
(32) 5th Gear Bearing Race

2013
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17-434 Manual Transmission - F13-5/F15-5lF17-5 (N126)

Main Shaft Components (Gen 1)

24

2264749
Legend
(1) Main Shaft (15) 2nd Gear Bearing Assembly
(2) 4th Gear Bearing Assembly (16) 2nd Gear
(3) 3rd Gear Bearing Assembly (17) 1st Gear Inner Blocking Ring
(4) 4th Gear Assembly (18) 1st Gear Intermediate Ring
(5) 3rd Gear Blocking Ring (19) 1st Gear Outer Blocking Ring
(6) 3rd and 4th Gear Synchronizer Insert (20) 1st and 2nd Gear Synchronizer insert
(7) 3rd and 4th Gear Synchronizer Hub Assembly
(8) 3rd Gear Thrust Washer (21) 1st and 2nd Gear Synchronizer Hub
(9) 3rd and 4th Gear Synchronizer Hub (22) 131and 20d Gear Synchronizer HUb
Retaining Ring Retaining Ring
(10) 3rd and 4th Gear Synchronizer Sleeve (23) 1st and 2nd Gear Synchronizer Sleeve
(11) 3rd Gear Blocking Ring (24) 1st Gear Outer Blocking Ring
(12) 3rd Gear Assembly (25) 1st Gear Intermediate Ring
(13) 2nd and 3rd Gear Thrust Washer (26) 1st Gear Inner Blocking Ring
Retaining Ring (27) 1st Gear
(14) 2nd and 3rd Gear Thrust Washer (28) 1st Gear Thrust Washer

2013
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 Manual Transmission - F13-5/F15-5lF17-5 (M26) '17-435

Main Shaft Components (Gen 2)

2749066
Legend
(1) Main Shaft 2nd and 3rd Gear Thrust Washer
(2) 4th Gear Bearing Assembly Retaining Ring
(3) 3rd Gear Bearing Assembly 2nd and 3rd Gear Thrust Washer
(4) 4th Gear Assembly 2nd Gear Bearing Assembly
(5) 4th Gear InnerBlocking Ring 2nd Gear
(6) 4th Gear IntermediateBlocking Ring 1st Gear Inner Blocking Ring
(7) 4th Gear Outer Blocking Ring 1st Gear intermediate Ring
(8) 3rd and 4th Gear Synchronizer insert 1st Gear Outer Blocking Ring
(9) 3rd and 4th Gear Synchronizer Hub 1st and 2nd Gear Synchronizer Insert
(10) 3rd Gear Thrust Washer Assembly
(11) 3rd and 4th Gear Synchronizer Hub 1st and 2nd Gear Synchronizer Hub
Retaining Ring 1st and 2nd Gear Synchronizer Hub
(12) 3rd and 4th Gear Synchronizer Sleeve Retaining Ring
(13) 3rd Gear Outer Blocking Ring 1st and 2nd Gear Synchronizer Sleeve
(14) 3rd Gear Intermediate Blocking Ring 1st Gear Outer Blocking Ring
(15) 3rd Gear InnerBlocking Ring 1st Gear Intermediate Ring
(16) 3rd GearAssemny 1st Gear inner Blocking Ring
1st Gear
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17-436 Manual Transmission - F13-5/F15-5/F17-5 (M26)

(32) 1st Gear Thrust Washer

Differential Components

2264750

Front Differential Bearing Assembly (7) Front Differential Housing

Front Differential Ring Gear Bolt
Front Differential Ring Gear
Front Wheel Speed Sensor Reiuctor Wheel
Pinion Gear Shaft Retaining Washer
Front Differential Pinion Gear Shaft
(8) ' Front Differential Pinion/Side Gear Thrust
Washer
(9) Front Differential Side Gear
(10) Front Differential Pinion Gear

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 Manual Transmission .. F13-5/F15-5/F17-5 (N126) 17-437

Shifter Components

2264751
M/Trans Control Lever Assembly (15) Control Lever Washer
M/Trans Control Front Shift Lever Bail Stud (16) M/Trans Control Lever Pivot Pin Bushing
Retainer Control Lever Stop Spring Retaining Ring
(17)
Control Lever Pin Control Lever Stop Spring Spacer
(18)
Selection Lever Slider (19) Control Lever Stop Spring —Outer
Selection Lever Control Lever Stop Spring —Inner
(20)
Quick Adjuster Assembly (21) Control Lever Stop Spring Spacer
Quick Adjuster Assembly Pin (22) Upper Bearing Assembly O—ringSeal
Selection Lever Sleeve (23) Upper Bearing Assembly Bolt
Selection Lever Bushing Upper Bearing Assembly
(24)
Positioner Upper Bearing Assembly Seal
(25)
M/Trans Control Lever Housing Assembly (26) Control Lever Shaft
IntermediateShift lever M/Trans Control Front Shift Lever Bail Stud
(27)
IntermediateShift Lever Pin Washer
IntermediateShift Lever Guide Pin (28) M/Trans Control Front Shift Lever Ball Stud

2013
—
Sonic
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17-438 Manual Transmission - F13-5/F15-5/F17-5 (M26)

Diagnostic Information and Procedures

DTC P0502 or P0503

Diagnostic instructions
- Perform the Diagnostic System Check - Vehicle
on page 6-66 prior to using this diagnostic
procedure.
o Review Strategy Based Diagnosis on page 6-58
for an overview of the diagnostic approach.
~ Diagnostic Procedure Instructions on page 6-59
provides an overview of each diagnostic category.
DTC Descriptors
DTC P0502: Vehicle Speed Sensor (VSS) Circuit —Low Voltage
DTC P0503: Vehicle Speed Sensor (VSS) Circuit —Intermittent
Diagnostic Fault Information

Open/High Signal
Circuit Short to Ground Resistance Short to Voltage Performance
OperatingConditions: EngineRunning,drivewheelsturning.
VSS HighSignal P0502,P0503 P0502,P0503 P0502,P0503 P0503
VSS LowSignal — P0502,P0503 —— —-

Diagnostic Fault Information

Open/High Signal
Circuit Short to Ground Resistance Short to Voltage Performance
OperatingConditions: EngineRunning,drivewheelsturning.
VSS HighSignal 0 km/h(0MPH) Okm/h(0MPH) 0 km/h(0MPH)
VSS LowSignal 0 km/h(0MPH)

CircuitISystem Description Action Taken When the DTC Sets

The vehicle speed sensor is provided to the engine P0502 and P0503 are Type B DTCs.
control module by the vehicle speed sensor (VSS). The
ECM provides a 5 V circuit, a low reference circuit, and Conditions for Clearing the DTC
a signal circuit to the VSS. The VSS provides a P0502 and P0503 are Type B DTCs.
frequency signal that is proportional to an increase in
vehicle speed. Diagnostic Aids
Conditions for Running the DTC The battery must be fully charged. Refer to Battery
lnspection/Test on page 9-702.
P0502
Reference Information
The ignition is ON.
Schematic Reference
P0503
' Ignitionvoltage is between 11—18 V. Manual Transmission Schematics on page 17-429
- Engine speed is between 1 500—6500 RPMs. Connector End View Reference
- VSS signal is between 150—200RPMs for 2 8. Component Connector End Views on page 11-269
Conditions for Setting the DTC Description and Operation
P0502 Transmission System Description and Operation on
VSS signal is less than 60 RPMs for 4.5 s. page 17—534

P0503 Electrical Information Reference

VSS signal is greater than 350 RPMs for 3.25 3. - Circuit Testing on page 11—526
~ Connector Repairs on page 11-548
(US/Canada)
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2013 (5377994)
Manual
Service
 Manual Transmission - F13-5/F15-5/F17-5 (N126) 17-439
Testing for IntermittentConditions and Poor U lf infinite resistance
Connections on page 11—531 4.1.1. Disconnect the X3 harness connector
Wiring Repairs on page 11—537 at the K20 Engine Control Module.
DTC Type Reference 4.1.2. Test for less than 2 Q in the 5 V
reference circuit end to end.
Powertrain Diagnostic Trouble Code (DTC) Type
Definitions on page 6-68 if 2 Q or greater, repair the open/high resistance in
the circuit.
Scan Tool Reference Ifless than 2 Q, replace the K20 Engine Control
Engine Control Module Scan Tool Informationon Module.
page 6—33 if greater than 5.2 V
CircuitISystem Verification 4.1. Disconnect the X3 harness connector at the
K20 Engine Control Module.
1. Operate the vehicle on the road at various speeds
up to 64 km/h(40 MPH). 4.2. Test for less than 0.3 V between the 5 V
reference circuit terminal 35 and ground.
2. Verify with a scan tool that the B14ATransmission
Output Shaft Speed Sensor parameter and the :> If0.3 V or greater, repair the short to voltage on
speedometer display on the instrument Cluster the circuit.
match. =>if less than 0.3 V, replace the K20 Engine
if the parameter does not match Control Module.
Refer to CircuitISystem Testing. If between 4.8—5.2V
If the parameter matches 01. Ignition OFF.
Operate the vehicle within the conditions for . Test for less than 1 V between the signal circuit
running the DTC to verify the DTC does not reset. terminal 3 and ground.
You may also operate the vehicle within the If 1 V or greater
conditions that you observed from the Freeze 6.1. Disconnect the X3 harness connector at the
Frame/Failure Records. K20 Engine Control Module.
If the DTC resets 6.2. Test for less then 0.3 V between the signal
Refer to Circuit/System Testing. circuit terminal 55 and ground.
U if the DTC does not reset :> if 0.3 V or greater, repair the short to voltage on
the circuit.
4. All OK.
=>Ifless than 0.3 V, replace the K20 Engine
CircuitISystem Testing Control Module.
1. IgnitionOFF, disconnect the B14ATransmission If less than 1 V
Output Shaft Speed Sensor harness connector. . Ignition OFF, disconnect the X3 harness connector
2. Test for less than 5 (2 between the low reference at the K20 Engine Control Module.
circuit terminal 2 and ground. . Test for less than 2 Q between the signal circuit
2) If 5 Q or greater terminal 55 at the K20 Engine Control Module and
2.1. Disconnect the X3 harness connector at the the signal circuit terminal 3 at the
K20 Engine Control Module. B14ATransmission Output Shaft Speed Sensor.
2.2. Test for less than 2 Q in the circuit end to end. If 2 Q or greater
=>If2 Q or greater, repair the open/high resistance Repair the open/high resistance in the circuit.
in the circuit. If less than 2 Q
=>If less than 2 Q, replace the K20 Engine Control . Test for infinite resistance between the signal
Module. circuit terminal 3 at the B14ATransmission Output
if less than 5 Q Shaft Speed Sensor.
()0
. IgnitionON. If less than infinite resistance
Test for greater than 4.8—5.2V between the 5 V Repair the short to ground on the circuit.
reference circuit terminal 1 and ground. U if infinite resistance
If less than 4.8 V 10. Replace the B14ATransmission Output Shaft
4.1. Test for infinite resistance between the 5 V Speed Sensor.
reference circuit and ground.
Repair Instructions
=>If less than infinite resistance
Perform the Diagnostic Repair Verification on
Repair the short to ground on the Circuit. page 6—92after completing the repair.
VehiC/eSpeed Sensor Replacement on
page 17-461
Control Module References on page 6-3 for ECM
replacement, programming and setup.
2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
17-440 Manual Transmission . F13-5/F15-5/F17-5 (M26)

DTC P0806-P0808

Diagnostic Instructions
- Perform theDiagnostic System Check - Vehicle
on page 6-66 prior to using this diagnostic
procedure.
- Review Strategy Based Diagnosis on page 6-58
for an overview of the diagnostic approach.
- Diagnostic Procedure Instructions on page 6-59
provides an overview of each diagnostic category.
DTC Descriptors
DTC P0806: Clutch Pedal Position (CPP) Sensor Performance
DTC P0807: Clutch Pedal Position (CPP) Sensor Circuit Low Voltage
DTC P0808: Clutch Pedal Position (CPP) Sensor Circuit High Voltage
Diagnostic Fault Information

Open/High Signal
Circuit Short to Ground Resistance Short to Voltage Performance
5V Reference P0642,P0807 P0807 P0642,P0808 -
Signal P0807 P0807 P0808 P0806
LowReference —— P0808 P0808 -

Typical Scan Tool Data

CPP Sensor Voltage

Circuit I Short to Ground Open Short to Voltage
OperatingConditions: IgnitionON.
CPP Sensor Voltage ParameterNormal Range:0V withclutchpedalappliedto5 V whenclutchpedalis released.
5V Reference 0V 0V 5V
Signal 0V 0V 5V
LowReference — 5V -

CPP Sensor Percentage

Circuit IShort to Ground | Open Short to Voltage
OperatingConditions: ignitionON.
CPP Sensor Percent ParameterNormal Range:0%withclutchpedalreleasedto 100%whenclutchpedalis applied.
5V Reference 100% 100% 0—100%
Signal 100% 100% 100%
LowReference — 0% —-

CircuitISystem Description Conditions for Running the DTC

The clutch pedal position (CPP) sensor is a three wire P0806, P0807 and P0808
sensor, connected to a 5 V reference circuit, a low
reference Circuit,and a signal circuit. The engine . DTCs P0642, P0643, P0335, P0336, P0607 or
P080A are not set.
control module supplies 5V to the CPP sensor, and
also provides a sensor ground path on the low ~ The system voltage is more than 9 V.
reference circuit. The CPP sensor sends a voltage . The ignition is in the RUN position.
signal to the ECM on the signal circuit. The voltage on
the signal circuit will vary from a voltage less than or Conditions for Setting the DTC
equal to 5 V when the clutch pedal is released, to a
voltage less than or equal to 1.5 V when the clutch P0806
pedal is applied. The CPP sensor is stuck in range.

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
 Manual Transmission - F13-5/F15-5/F17-5 (M26) 17-441
P0807 5. Operate the vehicle within the conditions for
The CPP sensor voltage is less than 0.1 V for more running the DTC to verify the DTC does not reset.
than 1 s. You may also operate the vehicle within the
conditions that you observed from the Freeze
P0808 Frame/Failure Records data.
The CPP sensor voltage is more than 5.2 V for more =>if the DTC resets
than 1 3. Refer to CircuitISystem Testing.
Action Taken When the DTC Sets U If the DTC does not reset
DTC P0806 —P0808 are Type A DTCs. 6. All OK.
Conditions for Clearing the DTC CircuitISystem Testing
DTC P0806 —P0808 are Type A DTCs. 1. IgnitionOFF, disconnect the harness connector of
the B25B Clutch Pedal Position Sensor.
Reference Information 2. Test for less than 5 Q between the low reference
Schematic Reference circuit terminal C (for LHD) or terminal A (for RHD)
and ground:
Manual Transmission Schematics on page 17—429 :> If 5 Q or greater
Connector End View Reference 2.1. Disconnect the X3 harness connector at the
Component Connector End Views on page 11—269 K20 Engine Control Module.
2.2. Test for less than 2 Q in the circuit and to end.
Description and Operation
=>If2 Q or greater, repair the open/high resistance
Transmission System Description and Operation on in the circuit.
page 17-534 =>If less than 2 Q, replace the K20 Engine Control
Electrical Information Reference Module.
. Circuit Testing on page 11-526 U If less than 5 Q
- Connector Repairs on page 11-548 3. IgnitionON.
- Testing for IntermittentConditions and Poor 4. Test for greater than 4.8—5.2V between the 5 V
Connections on page 11-531 reference circuit terminal A (for LHD) or terminal C
(for RHD) and ground:
0 Wiring Repairs on page 11-537
=>If less than 4.8 V
DTC Type Reference 4.1. Test for infinite resistance between the 5 V
Powertrain Diagnostic Trouble Code (DTC) Type reference circuit and ground.
Definitions on page 6—68 =>if less than infinite resistance
Scan Tool Reference Repair the short to ground on the circuit.
Engine Control Module Scan Tool Informationon U If infinite resistance
page 6-33 for scan tool information 4.1.1. Disconnect the X3 harness connector
at the K20 Engine Control Module.
CircuitISystem Verification
4.1.2. Test for less than 2 Q in the 5V
1. If DTC P0642, P0643, P0335, P0336, P0607 or reference circuit end to end.
P080A is set, refer to Diagnostic Trouble Code
=> If2 Q or greater, repair the open/high resistance in
(DTC) List —Vehicle on page 6—69.
the circuit.
2. IgnitionON.
=> if less than 2 Q, replace the K20 Engine Control
3. Observe the scan tool CPP sensor percent Module.
parameter. The percentage should vary from 0%
when the clutch pedal is released, to 100%when =>If greater than 5.2 V
the clutch pedal is in the apply position. 4.1. Disconnect the X3 harness connector at the
=>If the percentage does not vary K20 Engine Control Module.
Refer to CircuitISystem Testing. 4.2. Test for less than 0.3 V between the 5 V
reference circuit terminal 38 and ground.
<2 If the percentage varies
=>If0.3 V or greater, repair the short to voltage on
4. Perform the CPP learn procedure. Refer to Clutch the circuit.
Pedal Position Sensor Learn on page 17—445.
=>If less than 0.3 V, replace the K20 Engine
Control Module.
U If between 4.8—5.2V
5. IgnitionOFF.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
17-442 Manual Transmission - F13-5/F15-5/F17-5
6. Test for less than 1 V between the signal circuit
terminal B and ground.
2) if 1 V or greater
6.1. Disconnect the X3 harness connector at the
K20 Engine Control Module.
6.2. Test for less then 0.3 V between the signal
circuit terminal 58 and ground.
=>If0.3 V or greater, repair the short to Voltage on
the circuit.
=>Ifless than 0.3 V, replace the K20 Engine
Control Module.
If less than 1 V
Ignition OFF, disconnect the X3 harness connector
at the K20 Engine Control Module.
Test for less than 2 Q between the signal circuit
terminal 58 at the K20 Engine Control Module and
the signal circuit terminal B at the B25B Clutch
Pedal Position Sensor.
If 2 Q or greater ,
Repair the open/high resistance in the circuit.
If less than 2 Q
Test for infinite resistance between the signal
circuit terminal B at the B25B Clutch Pedal Position
Sensor.
If less than infinite resistance
Repair the short to ground on the circuit.
If infinite resistance
. Test or replace the B25B Clutch Pedal Position
Sensor.
(M26)
Component Testing
Static Test
1. Ignition OFF, disconnect the harness connector of
the B25B Clutch Pedal Position Sensor.
2. Measure the resistance between the signal
terminal B and the low reference terminal C (for
LHD) or terminal A (for RHD) at the B25B Clutch
Pedal Position Sensor. Depress the clutch pedal
through the entire range. The resistance should
vary from low to high and vice versa without any
spikes or dropouts.
=>If the resistance is erratic with spikes or
dropouts
Replace the B25B Clutch Pedal Position
Sensor.
U If the resistance is not erratic without spikes or
dropouts
3. All OK.
Repair Instructions
Perform the Diagnostic Repair Verification on
page 6—92after completing the repair.
° Clutch Pedal Position Sensor Replacement on
page 17-415
° Control Module References on page 6—3for ECM
replacement, programming and setup.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Manual Transmission - F13-5/F15-5/F17-5 (M26) '17-443
DTC P080A

Diagnostic Instructions
- Perform the Diagnostic System Check —Vehicle
on page 6—66prior to using this diagnostic
procedure.
' Review Strategy Based Diagnosis on page 6-58
for an overview of the diagnostic approach.
. Diagnostic Procedure Instructions on page 6-59
provides an overview of each diagnostic category.
DTC Descriptor
DTC P080A: Clutch Pedal Position (CPP) Not Learned

CircuitISystem Description Description and Operation

The clutch pedal position (CPP) sensor is a three wire Transmission System Description and Operation on
sensor, connected to a 5 V reference circuit, a low page 17—534
reference circuit, and a signal circuit. The engine
control module supplies 5 V to the CPP sensor, and Electrical Information Reference
also provides a sensorground path on the low - Circuit Testing on page 11-526
reference circuit. The CPP sensor sends a voltage
signal to the ECM on the signal circuit. The voltage on ~ Connector Repairs on page 11-548
the signal circuit will vary from a voltage less than or - Testing for IntermittentConditions and Poor
equal to 5 V when the clutch pedal is released to a Connections on page 11-531
voltage less than or equal to 1.5V when the clutch - Wiring Repairs on page 11-537
pedal is applied.
DTC Type Reference
Conditions for Running the DTC
Powertrain Diagnostic Trouble Code (DTC) Type
Clutch pedal fully applied. Definitions on page 6-68
Conditions for Setting the DTC Scan Tool Reference
Clutch pedal position not learned. Engine Control Module Scan Tool Informationon
page 6-33 for scan tool information
Action Taken When the DTC Sets
P080A is a Type B DTC. CircuitISystem Verification
Perform the clutch pedal position sensor learn
Conditions for Clearing the DTC procedure. Refer to Clutch Pedal Position Sensor
P080A is a Type B DTC. Learn on page 17—445.
Reference Information Repair Instructions
Schematic Reference Perform the Diagnostic Repair Verification on
page 692 after completing the repair.
Manual Transmission Schematics on page 17—429 - Clutch Pedal Position Sensor Learn on
Connector End View Reference page 17-445
Component Connector End Views on page 11—269 - Control Module References on page 6—3

2013
—
Sonic
(US/Canada)
Service
Manual
(5377994)
17-444 Manual Transmission ‘ F13-5/F15-5/F17—5 (M26)

DTC P0812

Diagnostic Instructions
. Perform the Diagnostic System Check —Vehicle
on page 6—66prior to using this diagnostic
procedure.
- Review Strategy Based Diagnosis on page 6-58
for an overview of the diagnostic approach.
- Diagnostic Procedure Instructions on page 6-59
provides an overview of each diagnostic category.
DTC Descriptor
DTC P0812 00: Reverse Position Switch Circuit —Malfunction

Diagnostic Fault Information

Open/High Signal
Circuit Short to Ground Resistance Short to Voltage Performance
ReverseSwitchSignal P081200 1 P081200 —-
Ground — 1 1 -
1.BackupLampsMalfunction

CircuitISystem Description Scan Tool Reference

The reverse gear switch is a normally open switch that Control Module References on page 6—3for scan tool
Closes with the reverse gear engagement. When the information
switch is open the engine control module should detect
a high signal voltage input. When the switch is closed CircuitISystem Verification
the ECM should detect a low signal voltage input. 1. IgnitionON.
Conditions for Running the DTC 2. Observe the scan tool Reverse Switch parameter.
The reading should be Off and change to On when
- No vehicle speed sensor faults exist. the transmission is shifted into reverse.
- Reverse switch is ON.
:> If the parameter does not change from Off to On
Conditions for Setting the DTC Refer to CircuitISystem Testing.
The ECM detects circuit malfunction of the reverse U If the parameter changes from Off to On
input switch. 3. All OK.
Action Taken When the DTC Sets CircuitISystem Testing
DTC P0812 00 is Type C DTC. 1. ignition OFF, disconnect the harness connector at
Conditions for Clearing the DTC the B16 Backup Lamp Switch.
2. Test for less than 5 Q between the ground circuit
DTC P0812 00 is Type C DTC.
terminal 2 and ground.
Reference Information :» If 5 Q or greater
Schematic Reference 2.1. Test for less than 2 Q in the ground circuit and
to end.
Manual Transmission Schematics on page 17-429 2 If2 Q or greater, repair the open/high resistance
Connector End View Reference in the circuit.
Component Connector End Views on page 11-269 =>If less than 2 Q, repair the open/high resistance
in the ground connection.
Description and Operation U If less than 5 Q
Transmission System Description and Operation on 3. IgnitionON, transmission in neutral position.
page 17—534
Electrical Information Reference
° Circuit Testing on page 11-526
- Connector Repairs on page 11-548
- Testing for IntermittentConditions and Poor
Connections on page 11-531
- Wiring Repairs on page 11—537

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
 Manual Transmission - F13-5/F15-5/F17-5 (111126) 17-445
4. Verify the scan tool Reverse Switch parameter - Any repairs which affect the CPP sensor
is Off. relationship
=>If the parameter is not OFF 1. install a scan tool.
4.1. Disconnect the X3 harness connector at the 2. Monitor the ECM for DTCs with a scan tool. Ifother
K20 Engine Control Module. DTCs are set, except DTC P080A, refer to
4.2. Test for infinite resistance between the signal Diagnostic Trouble Code (DTC) List - Vehicle on
circuit terminal 1 and ground. page 6-69 for the applicable DTC that set.
:> Ifless than infinite resistance, repair the short to 3. With a scan tool, select Clutch Pedal Position
ground on the circuit. Learn under Module Setup in Manual
Transmission, and perform the following
:> if infinite resistance, replace the K20 Engine instructions displayed on the scan tool screen.
Control Module. Note: The CPP sensor learn procedure cannot be
U If the parameter is OFF performed more than once per ignition cycle. The clutch
5. IgnitionON, install a 3 A fused jumper wire pedal needs to be fully depressed and held steady
between the signal circuit terminal 1 at the throughout this procedure in order to perform a correct
B16 Backup Lamp Switch harness connector and learning.
ground. 4. The scan tool will display under CPP Learn Status:
6. Verify the scan tool Reverse Switch parameter Not Learned, In Process, Complete, Fail —Low
is On. Volt, Fail —High Volt, or Fail Moving. The scan tool
=>If the parameter is Off will display under CPP Learn Status Complete if
the process was successful.
6.1. Disconnect the X3 harness connector at the
K20 Engine Control Module. 5. Ifthe scan tool indicates that DTC P080A ran and
passed this ignition the CPP sensor learn
6.2. Test for less than 2 Q in the signal circuit end procedure is complete. Ifthe scan tool indicates
to end. - DTC P080A failed or did not run this ignition, refer
2 If2 Q or greater, repair the open/high resistance to DTC P080A on page 17—443.Ifany other DTC is
in the circuit. set, refer to Diagnostic Trouble Code (DTC) List -
=>Ifless than 2 Q, replace the K20 Engine Control Vehicle on page 6-69 for the applicable DTC.
Module. 6. Turn OFF the ignition for 30 s after the learn
U If the parameter is On procedure has successfully completed in order to
store the CPP sensor variation values in ECM
7. Test or replace the B16 Backup Lamp Switch. history.
Component Testing
Symptoms - Manual Transmission
1. IgnitionOFF, disconnect the harness connector at
the B16 Backup Lamp Switch. Strategy Based Diagnostics
2. Test for less then 5 Q between the signal circuit Review the system operations in order to familiarize
terminal 1 and the ground Circuitterminal 2 at the yourself with the system functions. Refer to
B16 Backup Lamp Switch. Transmission System Description and Operation on
=>If 5 Q or greater page 17—534.
Replace the B16 Backup Lamp Switch. VisualIPhysical Inspection
U If less than 5 Q - inspect the easily accessible or visible system
3. All OK. components for obvious damage or conditions
which could cause the symptom.
Repair instructions
- Inspect the manual transaxle for the correct fluid
Perform the Diagnostic Repair Verification on level.
page 6-92 after completing the repair. - Inspect the manual transaxle for fluid leaks.
Control Module References on page 6-3 for ECM - inspect the manual transaxle for broken or loose
replacement, programming and setup. transaxle mounts.
Clutch Pedal Position Sensor Learn Intermittent
Note: The clutch pedal position (CPP) sensor learn Test the vehicle under the same conditions that the
procedure is required when the following service customer reported in order to verify the system is
procedures have been performed regardless of operating properly. '
whether DTC PO8OA is set:
- An engine control module (ECM) replacement
- A CPP sensor replacement

ka—B/v—m
2
~W2222
_.2. 2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
17=446 Manual Transmission - F13-5/F15-5lF17-5 (M26)

Transmission Fluid Leak Diagnosis Test Description

. . . The number below refers to the ste number on the
D'agnOSt'c AIdS diagnostic table. p
Using the incorrect type of transaxle fluid may affect the 5. Use an approved method to clean the transaxle to
3931an abll'ty 0f the seals. Ensure the use Ofthe ensure the leak location is correctly identified.
correct type of transaxle fIUId.The incorrect type of If using a powder method or dye method, ensure
sealer may not be compatible with the transaxle fluid or the products are compatible with the transaxle
may not have the correct characteristics for sealing the fluid_
affected components. Ensure the use of the correct
type of sealers. Refer to Adhesives, Fluids, Lubricants,
and Sealers on page 17-427.
Transmission Fluid Leak Diagnosis
Step Action I Yes No
DEFINITION:Visiblesignofthetransaxlefluidleakingfromthetransaxle.
DidyoureviewtheSymptoms- ManualTransmissionon Go to Symptoms-
1 page 17—445 andperformthenecessaryinspections? ManualTransmission
Go to Step2 onpage 17—445
1. Inspectforthetransaxlefluidlevelhigherthanthe
recommendedlevel.Referto LubricationSpecificationson
2 page 17-428.
2. Adjustthetransaxlelevelif incorrect.
Wasthetransaxlefluidleveltoohigh? Go to Step21 Go to Step3
3 inspectthetransaxleventfora blockage.
is thetransaxleventblocked? Go to Step4 _ Go to Step5
4 Repairor replacethetransaxlevent.
Didyoufindandrepairthecondition? - Go to Step21 ' Go to Step5
Verifythelocationoftheleak.
1. Clean thetransaxleassembly.
2. Operatethevehiclefor24 km(15mi),or untilnormaloperating
5 temperaturesare reached.
3. Visual inspector usethepowdermethodor dyeandblacklight' 2.2,
.2.
2M
methodtolocatetheleak.
is theleakoccurringat thedrainorfill plug? Go to Step6 Go to Step7
Replacethedrainorfillplug.Referto LubricationSpecificationson
6 page 17—428.
Didyoufindandrepairthecondition? Go to Step21 Go to DiagnosticAids
7 is theleakatthetransaxleoutputshaftseal? Go to Step8 Go to Step9
Removetheoutputshaftseal and inspectforthefollowing.Referto
FrontWheelDriveShaftSeal Replacement-LeftSide on
page 17-458.
- Damagedorwornseal
8 . Damagedseal bore
- improperinstallation
- Cracks inthecomponent
~Looseorwornbearingcausingexcessivesealwear
Didyoufindandrepairthecondition? Go to Step21 Go to DiagnosticAids
9 is theleakattheshiftleverarea? Go to Step 10 Go to Step 11
1. inspecttheshiftcontrolleverlowerbootfordamage.
2. lnspectforlooseshiftcontrollevermountingbolts.
3. Removetheshiftcontrollever.Referto TransmissionControl
Replacementonpage 17-459.
10
4. Replacetheshiftcontrolleverlowerbootif damaged.
5. Inspecttheshiftcontrolleversealingsurfacesforscratched,
nickedordamaged.
Didyoufindandrepairthecondition? Go to Step21 Go to DiagnosticAids
11 Istheleakatthefrontofthetransaxle? Go to Step12 Go to Step 15

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
 Manual Transmission - F13-5/F15-5/F17-5 (M26) 17-447

Transmission Fluid Leak Diagnosis (cont'd)

Step Action Yes No
1. Removethetransaxle.Referto TransmissionReplacementon
page 17-463.
2. Inspecttheinputshaftretainerforleaking.
12 3. Removetheinputshaftbearingretainer.Referto FrontWheel
DriveShaftSeal Replacement- LeftSide onpage 17—458
and
FrontWheelDriveShaftSeal Replacement- RightSide on
page 17—459.Replacetheseal.
Didyoufindandrepairthecondition? Go to Step21 Go to Step 13
1. lnspectfortheleakat theinputshaftseal.
2. Inspectforthefollowingiftheinputshaftseal is leaking:
- Damagedor wornseal
‘ Damagedseal bore
' improperinstallation
- Cracksin thecomponent
13 - inputshaftsealingsurfaceis scratched,nicked,damaged
or worn
- Looseorwornbearingcausingexcessiveseal wear
3. Replacetheinputshaftseal if leaking.Referto FrontWheel
DriveShaftSeal Replacement-LeftSide onpage 17-458and
FrontWheelDriveShaftSeal Replacement-RightSide on
page 17—459.
Didyoufindandrepairthecondition? Go to Step21 Go to Step 14
1. Inspectthecase forcracksorporosity.
14 2. Replacethetransaxlecase or clutchhousingif it is faulty.
Didyoufindandrepairthecondition? Go to Step21 Go to DiagnosticAids
15 Istheleakatthebackuplightswitch? Go to Step 16 Go to Step 17
1. Removethebackuplightswitch.Referto BackupLampSwitch
Replacementonpage 17-463.
2. inspectforthefollowing:
- Cross threadedor damagedthreads
16
0 Insufficientsealant
' Leakingswitch
' Improperinstallation
Didyoufindandrepairthecondition? (30to Step21 Go to Step 1
17 is theleakatthesealingflangesofthetransaxlecase? Go to Step18 Go to Step 19
1. Removethetransaxle.Referto TransmissionReplacementon
page 17—463.
2. Disassemblethetransaxle.Referto TransmissionCase
18 Disassemble(Gen 1)onpage 17—472 or TransmissionCase
Disassemble(Gen2)onpage 17-478.
3. inspectthesealingsurfaces.
Didyoufindandrepairthecondition? Go to Step21 Go to Step 19
19 Istheleakcomingfroma crackor porosityin thetransaxlecase? Go to Step20 Go to DiagnosticAids
1. Removethetransaxle.Referto TransmissionReplacementon
page 17—463.
2. Disassemblethetransaxle.
20 3. Replacethefaultytransaxlecase or clutchhousing.Referto
TransmissionCase Assemble(Gen 1)onpage 17-518or
TransmissionCase Assemble(Gen2)onpage 17—524.
Didyoufindandrepairthecondition? Go to Step21 Go to DiagnosticAids
Operatethesystemin ordertoverifytherepair.
21
Didyoucorrectthecondition? SystemOK Go to Step 1

2013
«Sonic
(US/Canada)
Service
Manual
(5377994)
2222’
2.22.22.22.22.
‘W.
2
g
22
..2...
17-448 Manual Transmission - F13-5IF15-5lF17-5 (M26)

Repair Instructions - On Vehicle

Gear Position Sensor Replacement

2512735
Gear Position Sensor Replacement
Calicut Component Name
Preliminary Procedure
Uncliptheenginecontrolmodule(ECM)andbracketfromthebatterytray.
Gear PositionSensorMagnetBolt
Caution: RefertoFastenerCautiononpage 0-8.
Tighten
8 N-m(71|bft)
2 Gear PositionSensor Magnet
Gear PositionSensor Bolt
3 Tighten
8N'm(71|bft)
Gear PositionSensor
Procedure
1. Disconnectelectricalconnector
2. Afterinstallationis complete,learnneutralgearsensor.Referto ControlModuleReferencesonpage6-3.

2013
-Sonic
(US/Canada)
Service
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 Manual Transmission - F13-5/F15-5/F17-5 (M26) "17-449
Transmission Rear Mount 1. Push and hold the powertrain assembly fonNard
R l and then install the transmission mount (3),
ep acement if necessary.
Removal Procedure Caution: Refer to Fastener Caution on page 0—8.
. . . . 2. install the transmission rear mountfastener(2) and
1. Raise and support the vehicle. Refer to Lifting and tighten to 100 N-m(74 lb ft).
Jacking the Vehicle on page 1—31. _ _
3. install the NEW transmISSIonmount to bracket
2. Using a suitable jack stand, support the rear of the through fastener (1) and tighten to 80 Nm (59 lb ft)
powertram- plus 45—60degrees.
4. Remove the jack stand.
5. Lower the vehicle.

Transmission Mount Replacement -

<// / Left Side
_ / - .- RemovalProcedure
1. Remove the battery tray. Refer to Battery Tray
Replacement on page 9-721.
2. Install the engine support fixture. Refer to Engine
Support Fixture on page 9-1060.

2503662
3. Remove and DISCARDthe transmission mount to
bracket through fastener (1).
4. Remove the transmission rear mount fastener (2).
5. Push and hold the powertrain assembly forward
«HWW2222
‘"‘v-«-—-.H
2,2
222,—» and then remove the transmission rear mount (3),
if necessary.
installation Procedure

2512886
3. Remove and DISCARDthe left transmission
mount to bracket bolts (1).
4. Remove the left transmission mount to body
bolts (2).
5. Remove the left transmission mount to
body nut (3).
6. Remove the left transmission mount (4)from the
vehicle.

2503662

2013
-Sonic
(US/Canada)
Service
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‘17-450 Manual Transmission - F13-5/F15-5lF17-5 (M26)

Installation Procedure

2503662
4. Remove and DISCARDthe transmission mount to
2512886 bracket through bolt (1).
1. install the left transmission mount (4) to the
vehicle.
Caution: Refer to Fastener Caution on page 0-8.
2. Install the transmission mount to body bolts (2) and
tighten to 58 N-m(43 lb ft).
3. Installthe left transmission mount to body nut (3)
and tighten to 58 Nm (43 lb ft).
4. Installthe NEW left transmission mount to ”M22
2m2-
.22
transmission bolts (1) and tighten to 50 N-m )1
(37 lb ft) plus 60-75 degrees.
5. Remove the engine support fixture. Refer to e IN%,§\
Engine Support Fixture on page 9—1060. ‘V‘J/
6. Installthe battery tray. Refer to Battery Tray
Replacement on page 9-721. ‘7 "Es; ..-,_2 Q \E\
71k /

Transmission Rear Mount Bracket

Replacement

Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and 2512927
Jacking the Vehicle on page 1-31.
2. Remove the front suspension skid plate, 5. Remove and DISCARDthe transmission mount
if equipped. Refer to Drivetrain and Front bracket bolts (1).
Suspension Frame Skid Plate Replacement on 6. Remove the transmission rear mount bracket (2).
page 3-143.
3. Using a suitable jack stand, support the rear of the
powertrain.

2013
-Sonic
(US/Canada)
Service
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 Manual Transmission - F13-5/F15-5/F17-5 (M26) 17-451
installation Procedure Transmission Mount Bracket
Replacement - Left Side

Removal Procedure
1. Remove the left transmission mount. Referto
Transmission Mount Replacement - Left Side on
page 17-449.

2512927
1. Install the transmission rear mount bracket (2).
Caution: Refer to Fastener Caution on page 0-8.
2. Install the NEW transmission mount bracket
bolts (1) and tighten to 100 N-m(74 lb ft) plus 30-
45 degrees.
2512906
2. Remove the three left transmission mount bracket
3 1 to transmission bolts (1).
3. Remove the left transmission mount bracket (2)
from the transmission.
/
\Vfi: // Installation Procedure

I
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2503662
3. install the NEW transmission mount to bracket
through bolt(1) and tighten nut to 80 N'm (59 lb ft)
plus 45-60 degrees.
4. Remove the jack stand.
5. install the front suspension skid plate, if equipped.
Refer to Drivetrain and Front Suspension Frame 2512905
Skid Plate Replacement on page 3-143.
6. Lower the vehicle. 1. install the left transmission mount bracket (2) to the
transmission.
Caution: Refer to Fastener Caution on page 0-8.

2013
—
Sonic
(US/Canada)
Service
Manual
(5377994)
17-452 Manual Transmission =F13-5/F15-5/F17-5 (M26)
2. install the left transmission mount bracket to Installation Procedure
transmission bolts (1) and tighten to
62 N-m(46 lb ft).
3. Install the left transmission mount. Referto
Transmission Mount Replacement - Left Side on
page 17-449.

Transmission Fluid Level and

Condition Check

Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and
Jacking the Vehicle on page 1-31
2. Remove the front suspension skid plate,
if equipped. Refer to Drivetrain and Front
Suspension Frame Skid Plate Replacement on
page 3-143
3. Place a basin underneath the vehicle.
4. Clean away all dirt and debris from the
transmission case plug.

2191523
Caution: Refer to Fastener Caution on page 0-8.
1. Install a NEW case plug (1) and tighten to 4N-m
(35 lb in) plus 45-135 degrees.
2. Install the front suspension skid plate, if equipped.
Refer to Drivetrain and Front Suspension Frame
Skid Plate Replacement on page 3-143
3. Lower the vehicle.

Transmission Fluid Drain and Fill

Removal Procedure
2 ‘ / Warning: The transmission fluid is hot. Caution
V23?) --' must be taken to prevent personal injury when the
transmission fluid drains from the transmission.

é—s/ 2' 1. Raise and support the vehicle. Refer to Lifting and
Jacking the Vehicle on page 1-31.
2. Remove the front suspension skid plate,
2191523 if equipped. Refer to Drivetrain and Front
Suspension Frame Skid Plate Replacement on
5. Remove the transmission case plug (1). DISCARD page 3-143.
the case plug. 9’ Place basin underneath.
6. Add transmission fluid until it seeps out of the 4. Clean away all dirt and debris from transmission
plug hole. case plug area.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Manual Transmission - F13-5/F15-5lF17-5 (M26) 17-453

2566682 2191523
Note: Ifthe frontdifferential carrier cover is removed, Warning: Use care when working around exhaust
the transmission fluid is discharged. heat shields. The heat shields may have sharp
5. Remove the clutch and differential housing cover edges and can cause personal injury if contact is
bolts (1). , made. Always install a temporary cover to the heat
shield to reduce the risk of injury.
6. Remove the clutch and differential housing
cover (2) and allow the transmission to drain 4. Remove and DISCARDthe transmission case
completely. plug (1).
7. Remove and DISCARDthe clutch and differential 5. Add transmission fluid until it seeps out of
housing cover gasket. plug hole.
6. Installthe NEW transmission case plug (1) and
Installation Procedure tighten to 4 Wm (35 lb in) plus 45—135degrees.
7. install the front suspension skid plate, if equipped.
Refer to Drivetrain and Front Suspension Frame
Skid Plate Replacement on page 3-143.
8. Lower the vehicle.

Manual Transmission Shift Lever

Cable Adjustment
Special Tools
DT—527-AAdjuster or 5mm drill bit
For equivalent regional tools, refer to Special Tools on
page 17—535.
Note: Not using the specified tools may lead to shift
system mis-adjustment. .
1. Remove the floor console. Refer to Front Floor
Console Replacement on page 2-61.

2566682
1. install the NEW clutch and differential housing
cover gasket.
2. Install the clutch and differential housing cover (2).
Caution: Refer to Fastener Caution on page 0—8.
3. Install the clutch and differential housing cover
bolts (1) and tighten to 18 Nm (13 lb ft).

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2.2”
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2.
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22
.2 2013.Sonic
(US/Canada)
Service
Manual
(5377994)
17=454 Manual Transmission - F13-5/F15-5IF17-5 (M26)

2505111
2. Lift upward and disengage (do not remove) cable
lock adjuster (1) to release the internal cable
assembly, one for each cable.
2526642
4. Lock the position of the shifter control lever by
rotating the reverse lockout device with the
following instructions:
4.1. Push down on tab (1) and pull up on device (2)
to release from installed position.
4.2. Rotate device 180 degrees so tab (1) is in the
rear of the shift control assembly.
4.3. Secure integral pins in holes located on shifter
base by pushing down device (2) until seated.

2342591
Note: The hole of the transmission gear control (2)
must be aligned to the hole in the base so the pin (1)
can pass thru both. The transmission gear control will
be locked in the 1—2neutral position.
3. Lock the transmission gear control with DT—527-A
pin (1) or 5mm drill bit. 2726170
5. Secure adjuster locks (3) by pushing down until
locked. One for each cable.
Note: During‘this procedure DO NOT touch or preload
the fixed shift lever as this may cause mis—adjustment
to the shift system. ,

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
 Manual Transmission - F13-5/F15-5/F17-5 (N126) 17-455
6. Reposition the reverse lockout device with the
following instructions:
6.1. Push down on tab (1) and pull up on device (2)
to release from installed position.
6.2. Rotate device (2) 180 degrees so tab (1) is in
the front of the shift control assembly.
6.3. Push downward on the reverse lockout
device (2) until tab (1) snaps into detent.
7. Remove the DT—527-Alock pin or drill bit from the
transmission gear control.
8. Install the floor console. Refer to Front Floor
Console Replacement on page 2-61.
9. Verify correct operation of the transmission control
assembly.

Manual Transmission Shift Lever and

Selector Lever Cable Replacement

Removal Procedure
1. Remove the battery tray. Refer to Battery Tray 2510324
Replacement 0” page 9'727- 6. Move the floor carpet in order to get access to the
gear shift lever and selector cable grommet (1).
7. Remove the grommet nuts (2).

2512882
2. Disconnect the shift lever and selector cable
ends (1) from the transmission shift lever and 2505111
selector levers. . , 8. Lift both cable adjustment retainers (1), one for
3. Pull the cable retainers (2) to release the shift lever each cable to release the shift lever and selector
and selector cable from the shift lever and selector cable. ’
cable bracket.
4. Disconnect the shift lever and selector cables (3)
from the shift lever and selector cable bracket.
5. Remove the floor console. Refer to Front Floor
Console Replacement on page 2—61.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
17-456 Manual Transmission - F13-5/F15-5lF17-5 (M26)
4. Install the shift lever and the selector lever cable
(3) to the shift lever and selector lever cable
1 2
bracket.
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2504879
9. Pull the shift lever‘and selector cable retainers (1)
from the transmission control assembly (3)
10. Remove the shift lever and selector cable from the 2510324
shift lever and selector controt.
11. Pull the shift lever and selector cable assembly 5. Move the floor carpet in order to get access to the
through the cowl into the passenger compartment. shaft lever and selector lever cable grommet (1).
12. Remove the shift lever and selector cable Caution: Refer to Component Fastener Tightening
assembly from the vehicle. Caution Onpage 0-8.
6. Install the grommet nuts and tighten to 9 N-m
Installation Procedure (80 lb in)
1. Position the shift lever and selector cable N2.
2“
y
assembly in the vehicle.
2. Gently pull the shift lever and selector cable
assembly through the cowl into the engine
compartment.

2504879
. Connect the shift levet and selector lever cables to
the shaft and selector control adjusters (2).
. Install the shift lever and selector lever cable
retainers (1) to the transmission control (3).
2512882
3. Connect the shift lever and selector cable ends (1)
to the transmission shift lever and selector lever.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Manual Transmission - F13-5/F15-5/F17-5 (M26) 17-457
2. Disconnect the shift cable and selector cable
ends (1) from the transmission shift lever and
selector levers.
3. Pull the cable retainers (2) to release the shift lever
and selector lever cable from the shift lever and
selector lever cable bracket.
4. Disconnect the shift lever and selector lever cable
(3) from the shift lever and selector lever cable
bracket.

2505111
9. Press down and Look both cable adjustment
retainers (1) one for each cable, to adjust the shift
lever and selector lever cable.
10. Adjust the shift lever and selector lever cables.
Refer to Manual Transmission Shift Lever Cable
Adjustment on page 17-453.
11. Installthe floor console. Refer to Front Floor
Console Replacement on page 2-61.
12. Install the battery tray. Refer to Battery Tray 2512931
Replacement on page 9-721.
13. Verify correct operation of the transmission control 5. Remove the two shift lever and selector lever cable
assembly. bracket fasteners (1).
6. Remove the shift lever and selector lever cable
Selector and Shift Lever Cable bracket (2) from the transmission.
Bracket Replacement installation Procedure
Removal Procedure
1. Remove the batterytray. Refer to Battery Tray
Replacement on page 9-721.

2512931
1. Position the shift lever and selector lever cable
bracket (2) on the transmission.
2512882 Caution: Refer to Fastener Caution on page 0-8.
2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 17-458 Manual Transmission - F13-5/F15-5/F17-5 (M26)
2. install the two shift lever and selector lever cable
bracket fasteners (1) and tighten to 22 N-m
(16 ibft).

2191375
4. Remove the left front wheel drive shaft oil seal (3)
using the DT-7004 hammer and the DT-23129
2512882 remover (1).

3. Connect the shift lever and selector lever cable Installation Procedure
ends (1) to the transmission shift levers.
4. Install the shift lever and selector lever cable (3),to
the shift lever and selector lever cable bracket.
5. Adjust the shift lever and selector lever cables.
Refer to Manual Transmission Shift Lever Cable
Adjustment on page 17-453.
6. Install the battery tray. Refer to Battery Tray
Replacement on page 9-721.
7. Verify correct operation of the transmission control
assembly.

Front Wheel Drive Shaft Seal

Replacement - Left Side
Special Tools
- DT-446 Installer Drift
° DT-7004 Slide Hammer
- DT-23129 Universal Seal Remover
For equivalent regional tools, refer to Special Tools on
page 17-535.
2191376
Removal Procedure
1. Coat the NEW left front wheel drive shaft oil
1. Raise and support the vehicle. Refer to Lifting and seal (2) with transmission fluid.
Jacking the Vehicle on page 1-31.
2. Install the NEW left front wheel drive shaft oil
2. Remove the front suspension skid plate, seal (2) using the DT—446drift and hammer (1).
if equipped. Refer to Drivetrain and Front
Suspension Frame Skid Plate Replacement on 3. Install the left wheel drive shaft. Refer to Front
page 3—143. Wheel Drive Shaft Replacement on page 7-5.
3. Remove the left wheel drive shaft from the 4. Install the front suspension skid plate, if equipped.
transmission. Refer to Front Wheel Drive Shaft Refer to Drivetrain and Front Suspension Frame
Replacement on page 7-5. Skid Plate Replacement on page 3—143.
5. Lower the vehicle.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994) ”1.7.—
—~
‘22...
__
2....
.2
 Manual Transmission 2 F13-5/F15-5/F17-5 (M26) 17-459

Front Wheel Drive Shaft Seal Installation Procedure

Replacement - Right Side
Special Tools
- DT-446 Installer Drift
' DT—7004Slide Hammer
- DT-23129 Universal Seal Remover
For equivalent regional tools, refer to Special Too/son
page 17—535.
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and
Jacking the Vehicle on page 1-31.
2. Remove the front suspension skid plate,
if equipped. Referto Drivetrain and Front
Suspension Frame Skid Plate Replacement on
page 3-143.
3. Remove the right wheel drive shaft from the
transmission. Refer to Front Wheel Drive Shaft
Replacement on page 7-5.

2191374
1. Coat the NEW right front wheel drive shaft oil
seal (1) with transmission fluid.
2. Install the NEW right frontwheel drive shaft oil
seal (1) using the DT-446 drift and hammer(2).
3. Install the wheel drive shaft. Refer to Front Wheel
Drive Shaft Replacement on page 7-5.
4. Install the front suspension skid plate, if equipped.
Refer to Drivetrain and Front Suspension Frame
Skid Plate Replacement on page 3-143.
5. Lower the vehicle.

Transmission Control Replacement

Removal Procedure
1. Remove the floor console. Refer to Front Floor
Console Replacement on page 2-61.

2191373
4. Remove the right front wheel drive shaft oil seal (1)
using the DT—7004hammer and the DT-23129
remover (2).

2505111

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
17-460 Manual Transmission - F13-5/F15-5lF17-5 (M26)
2. Lift both cable adjustment retainers (1), one for Installation Procedure
each cable, to release the shift lever and selector
lever cable.

2504879
3. Pull the shift lever and selector lever cable
retainers (1) from the transmission control
assembly (3).
4. Remove the shift lever and selector cable from the
shift and selector control
2531689
1. Position the transmission control in the vehicle.
Caution: Refer to Fastener Caution on page 0—8.
2. install the 4 transmission control bolts (1) and
tighten to 9 NW (80 lb in).

2531689
5. Remove the 4 transmission control bolts (1).
6. Remove the transmission control from the vehicle.
2504879
3. Connect the shift lever and selector lever cables to
the shift and selector control adjusters (2).
4. Install the shift lever and selector lever cable
retainers (1) to the transmission control (3)

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Manual Transmission - F13-5/F15-5/F17-5 (N126) 17-461

2505111 2512921
5. Press down and lock both cable adjustment 2. Remove the speedometer housing retaining
retainers (1), one for each cable, to adjust the shift bolt (2).
lever and selector lever cable. 3. Remove the speedometer-driven gear (1).
6. Adjust the shift lever and selector level cables. .
Refer to Manual Transmission Shift Lever Cable InStallatlon Procedure
Adjustment on Page 77-453- 1. Coat the O-ring with transmission fluid.
7. Install the floor console. Refer to Front Floor
Console Replacement on page 2-61.
8. Verify the correct operation of the transmission
control assembly.

Vehicle Speed Sensor Replacement

Removal Procedure
1. Disconnect the speedometer speed sensor
electrical connector. ~ DL_-

2512921
2. install the speedometer—drivengear(1).
Caution: Refer to Fastener Caution on page 0-8.
3. Install the speedometer housing retaining bolt (2)
and tighten to 4N°m(35 lb in).
4. Connect the speedometer speed sensor electrical
connector.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
17-462 Manual Transmission :-F13-5/F15-5lF17-5 (M26)
Transmission Control Lever Boot Replacement

2.22
v_eg
2,2

2595753
Transmission Control Lever Boot Replacement
Callout Component Name
Preliminary Procedure
Removethefrontfloorconsole.Referto FrontFloorConsoleReplacementonpage2-61.
ShiftControlLeverKnob Cover
1 Procedure
Usinga flat—bladed
tool,removetheshiftknobcover.
2 Fastener
3 ShiftControlLeverKnoband BootAssembly

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Manual Transmission - F13-5/F15-5/F17-5 (M26) 17.463
Backup Lamp Switch Replacement 3. Connect the electrical connector to the backup
lamp switch (1). '
Removal Procedure
Transmission Replacement
Removal Procedure
1. Remove the battery and battery tray. Refer to
Batteiy Tray Replacement on page 9—721 .
2. Without draining the coolant or removing the
hoses, remove and position aside the radiator
surge tank. Refer to Radiator Surge Tank
Replacement on page 9—630.

~i‘
Mr»
1 "> .V
.1832/

2512913
1. Disconnect the electrical connector from the
backup lamp switch (1).
2. Remove the backup lamp switch (1) from the
transmission.
3. Remove and DISCARDthe backup lamp switch
washer from the backup lamp switch.
Installation Precedure
2511350
3. Disconnect the brake booster vacuum hose (1)
from the engine intake manifold.

2512913
1. Install a NEW backup lamp switch washer on the
backup lamp switch (1).
2512882
Caution: Refer to Component Fastener Tightening
Caution on page 0-8. 4. Disconnect the shift lever and selector lever cable
2. Install the backup lamp switch (1) into the and (1) from the transmission shift lever and
transmission case, and tighten to 20 Nm (15 lb ft). selector lever.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
17-464 Manual Transmission - F13-5/F15-5/F17-5 (M26)
5. Pull the cable retainers (2)to release the shift lever
and selector lever cable from the shift lever and
selector lever cable bracket.
6. Disconnect the shift lever and selector lever cable
from the shift lever and selector lever cable
bracket.

[25¢77J 1 -—.‘
, '1‘1-
o I r
'1t t .

(I)
lit
1
8
2511276
10. Disconnect the speedometer driven gear electrical
connector (1).

2028267
Note: Before disconnecting the clutch actuator cylinder
front pipe, remove the clutch/brake fluid from the
reservoir tank.
7. Remove the clutch actuator cylinder front pipe
retaining clip (1).
8. Disconnect the clutch actuator cylinder front
pipe (2) from the clutch actuator cylinder pipe
elbow.

2191679
11. Remove the upper transmission bolts (1).
12. Install the engine support fixture. Refer to Engine
Support Fixture on page 9-854.
13. Drain the transmission fluid. Refer to Transmission
Fluid Drain and Fill on page 17-452.
14. Remove the front exhaust pipe. Refer to Exhaust
Front Pipe Replacement (LUV,LUW) on
page 9738.

2505611
9. Disconnect the electrical connector (1) from the
backup lamp switch (2). ..,.M
.

2013
-‘Sonic
(US/Canada)
Sen/ice
Manual
(5377994)
 Manual Transmission - F13-5/F15-5lF17-5 (M26) ‘17-465

’ ii[.-... ' 111.81.. mitt”

‘ ‘1‘”.
2A?! / W’

2508569
15. Remove the right front wheel drive shaft from the
transmission. Refer to Front Wheel Drive Shaft
Replacement on page 7—5.
16. Remove the left frontwheel drive shaft from the
transmission. Refer to Front Wheel Drive Shaft
Replacement on page 7—5.
2512886
19. Remove the lefttransmission mount(4). Refer to
Transmission Mount Replacement —Left Side on
page 17-449.
20. Remove the left transmission mount bracket. Refer
to Transmission Mount Bracket Replacement - Left
Side on page 17—451 .
21. Use a transmission jack in order to support the
transmission.

2503662
17. Remove the reartransmission mount (3). Refer to
Transmission Rear Mount Replacement on 2566444
page 17-449. 22. Remove the lower transmission bolt (3) and nut (4).
18. Remove the drivetrain and front suspension frame. 23. Remove the lower transmission bolts (1,2)
Refer to Drivetrain and Front Suspension Frame
Replacement on page 3—144. 24. Separate the transmission from the engine.
25. Lower the transmission with the transmission jack
far enough to remove the transmission.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
17-466 Manual Transmission - F13-5/F15-5/F17-5 (M26)
Installation Procedure
Warning: Use care when cleaning the clutch hub.
The clutch hub may have sharp edges and can
cause personal injury if contact is made. Wear
protective gloves to avoid personal injury.
1. Clean the clutch hub and the input shaft from any
debris and contaminates with a iint-free towel.

2665891
Caution: Ensure that no grease remains on the lead
surface of the transmission input shaft. Clean the lead
surface of the transmission input shaft prior to the
assembly of the transmission to the engine. Failure to
maintain a clean surface may cause clutch slippage or
failure.
2
3. Clean the entire lead surface of the input shaft with
a NEW, lint-free towel (1).
2665890
4. Raise the transmission with the transmission jack
Caution: Applying too much or the wrong type of and position the transmission to the engine.
grease on the transmission input shaft may cause
damage, clutch slippage or failure. Always apply the
correct type of grease. Never apply more grease than is
necessary to coat the transmission input shaft with a
very thin film of grease.
2. Use a clean flat brush (1) to apply very light coating
of multi—purposegrease to input shaft until the
metal is only shiny. No visible clumps of grease
are permissible regardless of size. Smear away
from the transmission in direction of the shown
arrow.

2566444
Caution: Refer to Fastener Caution on page 0—8.
5. install the lower transmission bolts (1) and tighten
to 60 Nm (44 lb ft).
6. Install the lower transmission bolts (2) and tighten
to 40 N-m(32 lb ft).
7. Install the lower transmission boit(3) and nut (4)
and tighten to 40 N-m(32 lb ft).
8. Remove the transmission jack.

2013
—Sonic
(US/Canada)
Service
Manual
(5377994)
 Manual Transmission - F13-5/F15-5/F17-5 (M26) 17-467
9. Install the left transmission mount bracket. Refer to
Transmission Mount Bracket Replacement - Left
Side on page 17—451.
>,.1Io/ ' ”4 . :11'/‘{t.
' h. 1 7 "1=--.\ “.11" "i
o_—- -»§;‘ 1 7,5411“

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[Iiuzfivsfi‘z’ r vg_ ‘ "

2512886
10. Install the lefttransmission mount (4). Refer to
Transmission Mount Replacement - Left Side on
page 17-449.
11. Install the drivetrain and front suspension frame.
Refer to Drivetrain and Front Suspension Frame
Replacement on page 3-144.
2508569
13. Instail the left front wheel drive shaft to the
transmission. Refer to Front Wheel Drive Shaft
Replacement on page 7-5.
14. Install the right front wheel drive shaft to the
transmission. Refer to Front Wheel Drive Shaft
Replacement on page 7-5.
15. Install the front exhaust pipe. Refer to Exhaust
Front Pipe Replacement (LUV,LUW) on
page 9-738.

2,

6:22."?
- %2“ s.2 ‘22
“1".” p
.- _&i‘ 1‘
’

2191679
2503662
16. Remove the engine support fixture. Refer to
12. install the reartransmission mount (3). Refer to Engine Support Fixture on page 9-854.
Transmission Rear Mount Replacement on 17. Install the upper transmission to engine bolts (1)
page 17-449.
and tighten to 60 N-m(44 lb ft).

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
17-468 Manual Transmission - F13-5/F15-5/F17-5 (M26)

121 .L i ,W V l “j

1111111
\\2‘,:‘\:5%22 ‘ 2 .

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2511276 2028267
18. Connect the speedometer driven gear electrical Note: The clutch actuator cylinder front pipe must
connector (1). engage noticeably.
21. Connect the Clutch actuator cylinder front pipe (2)
to the clutch actuator cylinder pipe elbow.
22. Lock the clutch actuator cylinder front pipe
retaining clip (1).

2505611
19. Connect the electrical connector (1) to the backup
lamp switch (2).
20. Connect the wiring harness clamp to the
transmission. 2512882
23. Connect the shift lever and selector lever cable
ends (1) to the transmission shift lever and selector
lever.
24. install the shift lever and the selector lever
cable (3) to the shift lever and the selector lever
cable bracket.
25. Adjust the shift lever and selector lever cables.
Refer to Manual Transmission Shift Lever and
Selector Lever Cable Adjustment on page 17—5 74.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Manual Transmission - F13-5/F15-5/F17-5 (W126) '17-469

'\
31)] , A \t \\
/Qfl
, 1!}? (31" '
\f," /

2511350 2262246
26. Connect the brake booster vacuum hose (1 )to the 1. Attach R-0007758 holding fixture (2) to the
engine intake manifold. transmission.
27. Fill the transmission with fluid. Refer to 2. Attach R-0007758 holding fixture (2) with
Transmission Fluid Drain and Fill on page 17-452. transmission to the 3—9506289Universal
28. Install the radiator surge tank. Refer to Radiator Adapter (1).
Surge TankReplacement on page 9-630.
29. Install the battery and battery tray. Refer to Battery
Tray Replacement on page 9-721.
30. Bleed the clutch hydraulic system. Refer to
Hydraulic Clutch System Bleeding on page 17-415.
31. Road test the vehicle.

Repair Instructions - Off Vehicle

Transmission Disassemble
Special Tools
- 3—9506289Universal Adapter
- R-0007758 Holding Fixture
- S-9407198 Differential Bearing Race Wrench
For equivalent regional tools, refer to Special Tools on
page 17—535.

2276933
3. Remove the clutch release bearing (1).

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
17.470 Manual Transmission =F13-5/F15-5IF17-5 (N126)

2262247 2262250
4. Remove the clutch fork shaft retaining bolt (2). 8. Remove the transmission cover bolts (3).
5. Remove the clutch fork shaft (1). 9. Remove the transmission cover (2) and gasket (1).

-222
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“.
,fl‘m
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7 >3. 1:!)

11%| 1

.1 ‘ n’

2262248 2252253
6. Remove the transmission control lever housing 10. Remove the back up lamp switch (1).
bolts (1).
7. Remove the control lever housing (2)and
gasket (3).

~24w
,2“.
2,
.‘w»-

2013
—
Sonic
(US/Canada)
Service
Manual
(5377994)
 Manual Transmission - F13-5/F15-5/F17-5 (M26) 17-471

2262252 2262256
11. Remove the transmission case bolts (3). 16. Remove the differential bearing adjuster lock
12. Remove the transmission case (2) and gasket (1). b0“ (1)- . ‘ _ _
13_ Remove the case magnet (4), may stay with case. 17. Remove the differentlal bearing adjuster lock (2).
14. Remove thereverse idler gear washer (5), may
stay on the reverse idler gear shaft. .

t]

2262258
18. Using 8-9407198 differential bearing race wrench
2262255 remove the front differential bearing adjuster (1).
15. Mark the differential bearing adjuster and case (1) 19' Remove the front differential bearing retainer
before removal. O-rmg seal (2).

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
17-472 Manual Transmission - F13-5/F15-5/F17-5 (M26)
For equivalent regional tools, refer to Special Tools on
page 17-535.

2262259
20. Removethe front differential carrier cover bolts (1).
21. Remove the differential carrier cover (2) and 2263763
gasket (3).
1. Install both plates of the R—0007770holding fixture
adapter piates to the transmission case
assembly (1). ‘

2262260
22. Remove the front differential carrier (1).
2263765
Transmission Case Disassemble
2. Install the transmission case, with the R-0007770
(Gen 1) holding fixture adapter plates (1) to the R-0007758
Special Tools holding fixture (2) and 3-9506289 universal
adapter.
3—9506289Universal Adapter
J—810700Mainshaft Bearing Remover
J-810704 Center Bar Puller
M—680770Universal Sliding Mallet
R-0007758 Holding Fixture
R—0007770Holding Fixture Adapter Plates
T-0307000 Extractor and Driver Fixture
T—9807671Slide Hammer

2013
—
Sonic
(US/Canada)
Service
Manual
(5377994)
 Manual Transmission - F13-5/F15-5lF17-5 (M26) 17-473

:,\—/
2744/7/11”
K!)
‘ "e1; \\

2263766 2263770
3. Remove the 5th shift fork bracket retaining 6. Using the J—810704puller, remove the 5th gear
bolts (1). synchronizer assembly (1).
4. Remove the 5th shift fork bracket assembly (2).

2263772
2263767 7. Remove the 5th gear blocking ring (1).
5. Remove the 5th gear synchronizing hub retaining 8. Remove the 5th gear assembly, driven (2).
ring (1). 9. Remove the 5th gear bearing assembly (3).

2013
-Sonic
(US/Canada)
Sen/ice
Manual
(5377994)
17-474 Manual Transmission - F13-5/F15-5IF17-5 (M26)

g/1
‘k-
i
O -16)7‘.ifilagiii‘
1:‘Llltw'
i

2263774 2263781
10. Remove the 5th gear retaining ring (1). Note: The parking pawi bolts are micro-encapsuiated
and may require that the transmission case be heated
to 80°C (176°F) with a heat gun.
12. Remove the parking pawl retaining bolts (1).
13. Remove the parking pawl (2).

.. 611$”
‘ [§\\\\\\V .- /
" I7.11.1
V \\ A.7 _.
1"
“ .Iil '
2263775
11. Using the J—810704puller, remove the 5th gear,
driving (1).

2263784
14. Using the M—680770sliding mallet adapter (2) and
the T-9807671slide hammer (1), remove the 4
shift shaft detent sleeves (3—6)from the
transmission case.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994) 2,222
«222
”TA'
.4
22.
 Manual Transmission - F13-5/F15-5/F17-5 (M26) 17-475

.,)§ ‘1 , . \
7 \ t IE
{lflglll‘é'mu I/"

V—éilkw E ‘
' £I.§ " k_

2263785 2263812
“MWAWWH/WV
M22
2... 20. Use a block of wood (1) to relieve the pressure on
- The bolts are micro-encapsulated and may the gearshift rod guides.
require that the transmission case be heated to
80°C (176°F) with a heat gun.
- Engage the shift shafts into 3rd gear and 5th
gear as indicated with arrows to remove the
interlock pin connector.
15. Remove the shift shaft interlock pin connector
bolts (2).
16. Remove the shift shaft interlock pin connector (1).

yyyyyy

2263813
21. Remove the 3rd and 4th shift fork pin (3).
22. Remove the 3rd and 4th shift shaft (1).
23. Remove the 3rd and 4th shift fork (2).

2263811
17. Remove the reverse shift fork pin (3).
18. Remove the reverse shift shaft (1).
19. Remove the reverse shift fork (2).

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
17-476 Manual Transmission - F13-5/F15-5lF17-5 (M26)

”117277711 |\
ti==A.,...-.‘.-.-t‘~\t.
OW////A§\~\»\\A\&x\\\\\\\‘\
is; , "'<\ \\\:
‘ 7 §\f§"‘\\‘¢\.\.‘s .. .I_i.l..-.t.%}.\~\\\-\\\‘-“-‘¥t~
‘t g. m iiii'fiiiii'] 7 .

2263787 2263789
24. Remove the 5th shift blocking guide (1)from the 27. Remove the 1st and 2nd shift fork pin (3).
transmission case. 28. Remove the 1st and 2nd shift shaft (1).
29. Remove the 1st and 2nd shift fork (2).

9.2%

Oik"?! m
"E!

2263788
25. Remove the gearshift rod (1) from the 2263804
transmission case.
30. Remove the input shaft bearing retaining ring (1)
26. Insert a block of wood (2) to relieve pressure on the from the bore, and leave it on the shaft.
gearshift rod guides.

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service ‘EVV
IT”W
.,mg‘
._.._
2..
,.
 Manual Transmission - F13-5/F15-5/F17-5 (M26) 17-477

2263805 2263807
31. Remove the transmission case from R-0007770 35. Remove the mainshaft bearing retaining ring (1).
adapter plates and install onto the T-0307000
fixture.
Note: Be prepared to support the reverse idler gear,
input shaft and mainshaft as they are pressed from
the case.
32. Support the mainshaft (3), input shaft (2) and
reverse idler gear(1) while pressing the shafts
from the case.

2263808
36. Using J-810700 mainshaft bearing remover,
remove the mainshaft bearing (1) from the case.

2263806
33. Remove the inputshaft(4), reverse idler gear(3)
and mainshaft (2) from the T-0307000 fixture.
34. Remove the 5th gear bearing race (1) from the
transmission case.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
17=478 Manual Transmission - F13-5/F15-5/F17-5 (M26)

2263810 2263763
37. Remove the reverse idler gear shaft (1)from 1. Install both plates of the R—0007770holding fixture
the case. adapter plates to the transmission case
38. Remove the reverse idler gear shaft retaining assembly (1).
ball (2).

Transmission Case Disassemble

(Gen 2)
Special Toots
° 3—9506289Universal Adapter
. J—810700Mainshaft Bearing Remover
0 J-810704 Center Bar Puller
- M—680770Universal Sliding Mallet
' R—0007758Holding Fixture
- R-0007770 Holding Fixture Adapter Plates ‘1” \\\\ \\‘\\\<\\\“
.1
- T—0307000Extractor and Driver Fixture
- T-9807671 Slide Hammer
For equivalent regional tools, refer to Special Tools on 991111111“
page 17—535. \ \\‘

2263765
2. Installthe transmission case, with the R-0007770
holding fixture adapter plates (1) to the R-0007758
holding fixture (2) and 3-9506289 universal
adapter.

2013
-Sonic
{US/Canada)
Service
Manual
(5377994)
 Manual Transmission - F13-5/F15-5/F17-5 (M26) 17-479

@M/M/I/m
q?!)
-‘ -:-:i\\

2263766 2263770
3. Remove the 5th shift fork bracket retaining 6. Using the J-810704 puller, remove the 5th gear
bolts (1). synchronizer assembly (1).
4. Remove the 5th shift fork bracket assembly (2).

__—-

2263772
2263767
. 7. Remove the 5th gear blocking ring (1).
5. Remove the Sth gear synchronizing hub retaining 8. Remove the 5th gear assembly, driven (2).
ring (1). 9. Remove the 5th gear bearing assembly (3).

2013
»Sonic
(US/Canada)
Service
Manual
(5377994)
17-480 Manual Transmission - F13-5/F15-5/F17-5 (M26)

‘-

K91 ‘

2263774 2263781
10. Remove the 5th gear retaining ring (1). Note: The parking pawl bolts are micro—encapsulated
and may require that the transmission case be heated
to 80°C (176°F) with a heat gun.
12. Remove the parking pawl retaining bolts (1).
13. Remove the parking pawl (2).

‘... Ir
’uJflflflggiE=====llE%%%%%%fi
.i

2263775
11. Using the J-810704 puller, remove the 5th gear,
driving (1).
2263784
14. Using the M-680770 sliding mallet adapter(2) and
the T-9807671 slide hammer (1), remove the 4
shift shaft detent sleeves (3—6)from the
transmission case.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Manual Transmission - F13-5/F15-5/F17-5 (N126) 17-481

2263785 2263812
22. Use a block of wood (1) to relieve the pressure on
- The bolts are micro-encapsulated and may the gearshift rod guides.
require that the transmission case be heated to
80°C (176°F) with a heat gun.
. Engage the shift shafts into 2nd gear, 5th gear,
and 3rd gear as indicated with arrows to
remove the interlock pin connector.
15. Remove the shift shaft interlock pin connector
bolts (2).
16. Remove the shift shaft interlock pin connector (1).

KEMAA/m—WWQW

2263813
'\ \\\(.ll
cry va..‘...{1‘\\
W[22.2.-39d
'!//,,~....v 23. Remove the 3rd and 4th shift fork pin (3).
I
-—-,///////.‘\\\\\§\}‘}-_=
24. Remove the 3rd and 4th shift shaft (1).
5 .I |"“i ’th“
1‘:
25. Remove the 3rd and 4th shift fork (2).

2748405
17. Remove the reverse shift fork pin (4).
18. Remove the reverse shift shaft (3).
19. Remove the reverse shift fork (5).
20. Remove the reverse fork biock pin (2).
21. Remove the reverse fork block (1).
.,4,
MW-—
..w_
,Ww,v.ve¢,____,._
__W
._.W~_._,MMM_

2013
-Sonic
(US/Canada}
Service
Manual
(5377994)
17-482 Manual Transmission - F13-5/F15-5/F17-5 (N126)

:za.

2263787 2748407
26. Remove the 5th shift blocking guide (1) from the . Remove the 1st and 2nd shift fork pin (5).
transmission case. . Remove the 1stand 2nd shift shaft(1).
. Remove the 1st and 2nd shift fork (4).
. Remove the 1st and 2nd shaft block pin (3).
. Remove the 1st and 2nd shaft block (2).

‘2 «2. .
:1.
' I[4.424 ‘1'
.1;\

0L1
.MM
»-»~
M22
«\M
2263788 . \.
27. Remove the gearshift rod (1) from the
transmission case. .
28. Inserta block of wood (2) to relieve pressure on the 2263804
gearshift rod guides.
34. Remove the input shaft bearing retaining ring (1)
from the bore, and leave it on the shaft.

fl..-W
.2-.V
A_.
9...

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Manual Transmission - F13-5/F15-5lF17-5 (M26) 17-483

2748409 2645574
35. Remove the reverse gear shaft snap ring (3), . 38. Remove the following components from the
reverse spur gear washer (2),and reverse spur T—0307000fixture.
gear bearing (1). - Main shaft (2)
- Reverse spur gear (3)
- Reverse synchro assembly (4)
- Reverse helical gear(5)
InputShaft (6)
39. Remove the 5th gear bearing race (1) from the
transmission case.

_-.\WW‘NW
4.2%”
“.24
..
.2”
Va“

2263805
36. Remove the transmission case from R—0007770
adapter plates and install onto the T-0307000
fixture.
Note: Be prepared to support the reverse idler gear,
input shaft and mainshaft as they are pressed from
the case.
2845580
37. Support the mainshaft (3), input shaft (2) and I I . . .
reverse idler gear(1) while pressing the shafts 40- Remove the mamshafi bearmg retalmng mg (1)-
from the case.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
17-484 Manual Transmission - F13-5/F15-5lF17-5 (M26)

2263808
41. Using J-810700 mainshaft bearing remover,
remove the mainshaft bearing (1)from the case.
2845581
42. Remove the reverse idler gear shaft (1) from
the case.
43. Remove the reverse idler gear shaft retaining
ball (2).
44. Remove the reverse helical gear washer (3).

Main Shaft Disassemble (Gen 1)

1st Gear Removal

2192590

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Manual Transmission - F13-5/F15-5/F17-5 (M26) '17-485

1st Gear Removal

Callout Component Name
Preliminary Procedure
A hydraulicpressis requiredtocompleteprocedure.Preparehydraulicpressfor procedure.
1stGearThrustWasher
1 SpecialTools
- DT—307—B RemoverPlate
- DT-736ClutchArbor
2 1stGear

1st Gear Blocking Rings Removal

2371631
1st Gear Blocking Rings Removal
Callout Component Name
1 1stGear Bearing
2 1stGear InnerBlockingRing
3 1stGear IntermediateBlockingRing
4 1stGearOuterBlocking Ring

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
17-486 Manual Transmission . F13-5/F15-5/F17-5 (M26)
1st and 2nd Gear Synchronizer Hub Retaining Ring Removal

2192598
1st and 2nd Gear Synchronizer Hub Retaining Ring Removal
Callout Component Name
1stand2ndGear SynchronizerHubRetainingRing
1 SpecialTools
GE-8059Snap RingPliers

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Manual Transmission - F13-5/F15-5lF17-5 (M26) 17=487
1st and 2nd Gear Synchronizer Hub and 2nd Gear Removal

2192606
1st and 2nd Gear Synchronizer Hub and 2nd Gear Removal
Callout I Component Name
Preliminary Procedure
A hydraulicpressis requiredto completeprocedure.Preparehydraulicpressforprocedure.
2ndGear .
Special Tools
- DT—307-B RemoverPlate
' DT—736 ClutchArbor

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
17—488 Manual Transmission - F13-5/F15-5lF17-5 (M26)

2nd Gear Bearing Removal

2192607
2nd Gear Bearing Removal
Callout Component Name
1 1stand2ndGear SynchronizerHubRetainingRing
2 2ndand3rdGearThrustWasher
3 2ndGear Bearing

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Manual Transmission - F13-5/F15-5IF17-5 (M26) 17-489
3rd Gear Removal

1 l"\>i>-~ 41"!
Wnpqyfini “'\ \

2192608
3rd Gear Removal
Callout Component Name
1 3rdGear
2 3rdGearBearing

2013
—
Sonic
(US/Canada)
Service
Manual
(5377994)
’17-490 Manual Transmission - F13-5/F15-5/F17-5 (M26)
3rd and 4th Gear Synchronizer Hub Retaining Ring Removal

2192610
3rd and 4th Gear Synchronizer Hub Retaining Ring Removal
Callout Component Name
3rdand4thGearSynchronizerHubRetaining
1 Special Tools
GE—8059 Snap Ring Pliers

2013
—
Sonic
(US/Canada)
Sen/ice
Manual
(5377994)
 Manual Transmission - F13-5/F15-5/F17-5 (M26) 17-491
3rd and 4th Gear Thrust Washer Removal

1‘

'l i’1‘ii"’ii'i“"| I
Hlll

2192611
3rd and 4th Gear Thrust Washer Removal
Callout Component Name
3rdand4thGear SynchronizerHubRetainingRing
1 SpecialTools
M
1,.”
.,m
lW
\M.v.t~yt
W‘N‘- GE-8059Snap RingPliers

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
17-492 Manual Transmission - F13-5/F15-5/F17-5 (M26)
3rd and 4th Gear Synchronizer Hub and 4th Gear Removal

Hmt
«MW
Afi_-
22b.
_
2
1.,
~
.A.,.4
-2
,__

2192612
3rd and 4th Gear Synchronizer Hub and 4th Gear Removal
Callout I Component Name
Preliminary Procedure
A hydraulicpressis requiredto completeprocedure.Preparehydraulicpressforprocedure.
3rdand4thGear SynchronizerHub
Special Tools
1
- DT-307—B RemoverPlate
' DT-736ClutchArbor
2 4thGear

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Manual Transmission - F13-5/F15-5/F176 (N126) '17-493
4th Gear Bearing Removal

2192613
4th Gear Bearing Removal
Callout Component Name
1 4thGear Bearing

Main Shaft Disassemble (Gen 2)

Special Tools
69604356 Gear Pullers
For equivalent regional tools, refer to Special Tools on
page 17-535.

2262542
1. Remove the 1st gear thrustwasher (1) and the 1st
gear(2) using 69604356 pullers and a hydraulic
press.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
’17-494 Manual Transmission —F'13-5/F‘15-5lF1 7=5 (M26)

Vv\ /\' ‘
’0‘’G‘l'il
Ht:LLL‘

2262544
2. Remove the following components:
. 1st gear bearing assembly (1)
. 1st/2ndgear inner blocking ring (2)
- 1st/2ndgear intermediate cone ring (3)
- 1st/2ndgear outer blocking ring (4)
2262548
4. Remove the 1st/2ndgear synchronizer
assembly (1) and 2nd gear assembly (2) as a unit
usmg 69604356 pullers and a hydraulic press.

2262549
5. Separate the following components:
2262547 ' 1st/2ndgear synchronizer assembly (1)
- 1st/2ndgear outer blocking ring (2)
3. Remove and discard the 1st/2ndgear synchronizer
assembly retaining ring (1). ' 1st/2ndgear intermediate cone ring (3)
' 1st/2ndgear inner blocking ring (4)
~ 2nd gear assembly (5)

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
 Manual Transmission - F13-5/F15-5IF17-5 (M26) ’17-495

,.....4.2.._
...‘_
-m
.2
_4w»;/_._.
...

2748476 2262553
6. Remove the following components: 8. Remove the 3rd/4th gear synchronizer
- 2nd gear bearing assembly (1) assembly (1) and the 4th gear assembly (2) as a
unit using 69604356 pullers and a hydraulicpress.
- 3rd gear thrust washer retaining ring (2)
- 3rd gear thrust washer (3)
- 3rd gear assembly (4)
° 3rd gear bearing assembly (5)
- 3rd gear inner blockingring (6)
° 3rd gear intermediate blockingring(7)
° 3rd gear outer blocking ring (8)

9. Separate the following components:
2262552
. Remove and discard the 3rd/4thgear synchronizer
assembly retaining ring (1) and the 3rd/4thgear
synchronizer assemblythrustwasher(2 ). ‘
2748477
~ 3rd/4thgear synchronizer assembly (1)
- 4th gear outer blocking ring (2)
- 4th gear intermediate blocking ring (3)
- 4th gear inner blockingring(4)
- 4th gear assembly (5)

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
'l7-496 Manual Transmission - F13-5/F15-5lF17-5 (M26)
0 R-0007761 Universal Handle for Pullers and
Installers
o S-9407195 Pinion Gear Case Bearing Installer
- T—9804678Speed Sensor Reiuctor Wheel
Remover
For equivalent regional tools, refer to Special Tools on
page 17-535.

2262558
10. Remove the 4th gear bearing assembly (1).

Input Shaft Disassemble

Ly
2265930
1. Remove the front wheel drive shaft oil seal (1) from
the front differential bearing adjuster (2).

2264238
Note: The input shaft rear bearing retaining ring (2)
remains loose on the shaft.
1. Remove the input shaft rear bearing assembly (1)
using a hydraulic press.
2. Remove the retaining ring (2).
2265938
Differential Case Disassemble
Note: Do not interchange outer and inner races
Special Tools respectively when re—usingtapered roller bearings.
- 6-9607346 Sensor Ring Gear Puller 2. Remove the front differential bearing race (1) from
- J—810704Steering Column Center Bar Puller the front differential bearing adjuster usingthe
- J-810721 Axle Shaft Seal Remover Support Base R-0007761 handle (2), R-0407011 remover (3),
and the J—810721supportbase (4).
- R—0006749Support Base
- R—0407011Bearing Race Remover

—
2013 (US/Canada)
Sonic (5377994)
Manual
Service
 Manual Transmission - F13-5/F15-5/F17=5 (M26) 1749?

féfiéfifléflmifle
w:
$7
'

2265943
3. Remove the ring front wheel speed sensor reluctor
wheel (1) usingthe 6-9607346 puller (2),
8-9407195 installer (3), and the T-9804678
remover (4).
2265951
5. Place a mark (3) on the differential and the
differential ring gear for realigningparts during
assembly in case both components are reused.
6. Remove the front differential ring gear bolts (1) and
the front differential ring gear (2).

2265947
4. Remove the front differential bearing
assemblies (3) using the J-810704 puller (1) and
R-0006749 support base (2) .
2265956
7. Remove the pinion gear shaft retaining washers (1)
and the front differential piniongear shaft (2).
8. Remove the front differential pinion gears (3) and
side gears (4).
9. Remove the front differential pinionand side gear
thrust washer (5).

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
17-498 Manual Transmission - F13-5/F15-5/F17-5 (M26)

Clutch and Differential Housing

Disassemble
Special Tools
' M-680770 Universal SlidingMallet
- R—0007758Holding Fixture
- R—0407008Counter Shaft Bearing Remover
- R-0407010InputShaftNeedle Bearing Puller and 1};
Driver \
\1 /_I
' R—0407013Gearshift Device BushingPuller
..-'
- R-0007761 Universal Handle for Pullers and
Installers W _w'u' E
:2;-
- T-0207928 Retainer Remover
For equivalent regionaltools, refer to Special Tools on
page 17-535. Ii. -
Iw
t:/ g \
40?).
.4_
0. 1§\\.
2264226

2264225
1. Remove the vehicle speed sensor bolt (1) and
vehicle speed sensor assembly (2).
2. Remove and discard the vehicle speed sensor
O—ring seal (3).
2264227
4. Using the T—0207928retainer remover (3)with the
M—680770slidingmallet (2) remove the front wheel
drive shaft oil seal assembly (1).

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Manual Transmission - F‘l3-5/F15-5/F17-5 (M26) 17-499

2264228 2264229
5. Remove the clutch yoke shaft bushings (1). 9. Remove the input shaft front bearing assembly (3)
using the R-0407010 driver (2) and the R-0007761
handle (1).

2276938
6. Remove the clutch release bearing collar bolt (1).
2264230
7. Remove the clutch release bearing collar (2).
8. Remove the clutch release bearing collar O-ring 10. Remove the main shaft front bearing assembly (1)
seal (3). using the R-0407008 remover.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
17-500 Manual Transmission - F13-5/F15-5/F17-5 (M26)

Clutch and Differential Housing

Cleaning and Inspection

,wW
..

.2...“
,__
4‘

2264232
11. Remove the shift shaft bushings(3) usingthe
R—0407013puller (2) and the M—680770mallet (1).
2264233
Warning: Wear safety glasses to avoid injury when
using compressed air or any cleaning solvent.
Bodily injury may occur if fumes are inhaled or if
skin is exposed to chemicals.
1. Clean the Clutch housing (1) with a suitable
solvent. Air dry all the parts.
2. Inspect the clutch housing for the following
conditions:
- Cracks
Replace the clutch housing if cracks are found.
- Scratches
- Burrs
' Nicked mounting surfaces
- Damaged sealing surfaces
- Damaged front or rear bearing bores
- Damaged alignment pins
Inspect the machined mating surfaces for flatness.
2276940 Check the mating surfaces with a straight edge.
. Inspect the bearing bores forwear, scratches or
12. Remove the clutch and differential housing(1)from grooves.
the R—0007758holding fixture.
. Inspect the bushings for excessive wear. Replace
worn bushings.
Use a fine millfile to dress minorscratches or
burrs.
if scratches, or grooves or scoringcannot be
removed by hand with a soft stone or crocus cloth,
replace the component.

2013
—
Sonic
(US/Canada)
Service
Manual
(5377994)
 Manual Transmission - F13-5/F15-5/F17-5 (W126) ’17-501
Clutch and Differential Housing 2. install the main shaft front bearing assembly (3)
using the R-0407009 driver (2) and the R—0007761
Assemble handle (1).
Special Tools
~ R-0007761 Universal Handle for Pullers and
Installers
- R—0407009Countershaft Front Bearing Driver
0 R-O4070101nput8haft Needle Bearing Puller and
Driver
- R—0407014Gearshift Device Bushing Driver—Use
with R—0007761
- 8-9707500 Axle Shaft Seal Installer
For equivalent regional tools, refer to Special Tools on
page 17—535.

2264236
3. Install the input shaft front bearing assembly (3)
using the R-0407010 driver (2) and the R-0007761
handle (1).

2264234
1. Install the shift shaft bushings (3) using the
R-0407014 bushing driver (2) and R-0007761
handle (1).

2264228
Note: Alignthe tabs on the clutch yoke shaft bushings
to the slots in the clutch and differential housing.
4. Install the clutch yoke shaft bushings (1).

2264235

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
17-502 Manual Transmission - F’i3-5/F15-5IF17-5 (M26)

,,\
\-
i: I,ili/
t' .."/
\
7—7/4 6 V.
aw:
// EE
570‘!
kl.
\\.
\ 73!"«Ev;
r. \‘ C
II. . / ‘. 2 Wl
"“ilf’\ ' 1. i —-‘’ ’
Q / ‘ c"

2276938 2264226
5. install the clutch release bearing collar seal (3). 9. Install the transmission magnet (1).Tighten to
6. Install the clutch release bearing coilar(2). 4N'm (35.4 lb in) plus 45° plus an additional 90°.
Caution: Refer to Fastener Caution on page 0-8.
7. Install the clutch release bearing collar bolt (1) and
tighten to 5 N-m(44.3 lb in).

2264225
10. Install the NEW vehicle speed sensor O-ring
seal (3).
2264237 11. Install the vehicle speed sensor assembly (2).
8. Install the front wheel drive shaft oii seal 12. Install the vehicle speed sensor bolt (1).Tighten to
assembly (3) usingthe 8-9707500 seal installer 5N'm (44 lb in).
(2) and the R-0007761 handle (1).

—
2013 (US/Canada)
Sonic (5377994)
Manual
Service
#777
.
 Manual Transmission - F'i3-5/F15-5/F17-5 (M26) 17-503
Gears Cleaning and Inspection Input Shaft
(Gen 1)

Gears

2262531
. Clean the input shaft (1) in a suitable solvent.
. Clean and air dry the oil gallery.
2262529
. Inspect the input shaft bearing surfaces for the
Warning: Wear safety glasses to avoid injury when
following conditions:
using compressed air or any cleaning solvent.
Bodily injury may occur if fumes are inhaled or if - Wear
skin is exposed to chemicals. - Lack oflubricant
1. Clean the following gears in a suitable solvent and - Debris embedded in the oil grooves
air dry all the parts. - Brinelling
° 1st gear (1) . Inspect the input shaft splines for wear or damage.
- 2nd gear assembly (4) . Replace the input shaft if any of the above
- 3rd gear assembly (3) conditions are found.
- 4th gear assembly (2) Main Shaft
- Reverse idler gear (5)
2. Inspect the gear tooth surfaces on all the gears for
the following conditions:
- Cracks
- Pitting
' Nicks
- Chipped gearteeth
- High spots — small shiny spots on the gear
teeth mating surfaces

2262537
1. Clean the main shaft (1) in a suitable solvent.
2. Clean and air dry the oil gallery.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
’17-504 Manual Transmission - F13-5/F15-5lF17-5 (M26)
3. Inspect the main shaft bearing surfaces for the Gears Cleaning and Inspection
following conditions:
- Wear (Gen 2)
- Lack of lubricant Gears
- Debris embedded in the oil grooves
- Brinelling
4. Inspect the main shaft splines for wear or damage.
5. Replace the main shaft if any of the above
conditions are found.
Reverse Idler Gear and Shaft

2845551
Warning: Wear safety glasses to avoid injury when
using compressed air or any cleaning solvent.
Bodily injury may occur if fumes are inhaled or if
skin is exposed to chemicals.
1. Clean the following gears in a suitable solvent and
air dry all the parts.
2262540 - 1st Gear (1)
1. Clean the reverse idler gear(1)and shaft (2) in a - 2nd Gear Assembly (4)
suitable solvent and air dry all the parts. - 3rd Gear Assembly (3)
2. Inspect the reverse idler gear bushing (3) for the - 4th Gear Assembly (2)
following conditions:
- 5th GearAssembly— Driven (5)
- Excessive wear
. 5th Gear- Driving (6)
- Scoring
2. Inspect the gear tooth surfaces on all the gears for
6 Pitting the following conditions:
3. Replace the reverse idler gear if the bushing is . Cracks
faulty.
- Pitting
4. Inspect the reverse idler gear shaft for the following
conditions: - Nicks
- Excessivewear - Chipped gearteeth
o Scoring ' High spots — small shiny spots on the gear
teeth mating surfaces
' Pitting
5. Replace the reverse idler gear shaft if it is faulty.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Manual Transmission - F13-5/F15-5lF17-5 (M26) 17-505
Input Shaft 3. Inspect the main Shaft bearing surfaces for the
following conditions:
- Wear
- Lack of lubricant
- Debris embedded in the oil grooves
- Brinelling
4. Inspect the main shaft splines for wear or damage.
5. Replace the main shaft if any of the above
conditions are found.
Reverse Gears and Shaft

2748673
1. Clean the input shaft(1) in a suitable solvent.
2. Clean and air dry the oil gallery.
3. Inspect the input shaft bearing surfaces for the
following conditions:
- Wear
- Lack oflubricant
' Debris embedded in the oil grooves
' Bnnemng
4. Inspect the input shaft splines for wear or damage. 2748674
5. Replace the input shaft if any of the above 1. Clean the reverse spur gear(1), reverse helical
conditions are found. gear(2), and shaft (5) in a suitable solvent and air
dry all the parts.
Main Shaft
2. Inspect the reverse spur gear bushings (4) and
reverse helical gear bushings (3) for the following
conditions:
....
WW.
M.
—_.._W.M..
.. . Excessive wear
- Scoring
- Pitting
3. Replace the reverse gears if the bushings are
faulty.
4. Inspect the reverse gear shaft for the following
conditions:
° Excessive wear
- Scoring
- Pitting
5. Replace the reverse gear shaft if it is faulty.

2262537
1. Clean the main shaft (1) in a suitable solvent.
WWWWWMW
vv
422...“.HVM.._.V._2
M
,W
2. Clean and air dry the oil gallery.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
17-506 Manual Transmission - F13-5/F15-5/F17-5 (M26)

Thrust Washer and Bearing Cleaning Synchronizers Disassemble

and Inspection
1st/2nd Gear Synchronizer

1485489 2262605
Warning: Wear safety glasses to avoid injury when Note: When servicing the synchronizers, retain them in
using compressed air or any cleaning solvent. the same order that they are removed. Keep the
Bodily injury may occur if fumes are inhaled or if synchronizer components together and mark them to
skin is exposed to chemicals. identify correct location.
Caution: Do not allow the bearings to spin. Turn them 1. Remove the 1st/2nd gear synchronizer hub (2)
slowly by hand. Spinning the bearings may damage the from the 1st/2ndgear synchronizer sleeve (3).
race and the rollers.
2. Remove the synchronizer inserts (1)from the 1st/
1. Mark or tag the bearings in order to ensure they 2nd gear synchronizer hub (2).
are properly installed in the correct location.
2. Clean all of the roller bearings, needle bearings, 3rd/4th Gear Synchronizer
and ball bearings in a suitable solvent and air dry
all the parts.
3. Inspect the bearings and races for the following
conditions:
- Roughness
. Brinelling
- Pitting
4. inspect the cage bearings for being bent or for
having damaged cages.
5. Replace the bearings with any of the above
conditions.
6. Replace mated bearing parts when only one part is
damaged.
7. Inspect the thrust washers for scoring or wear.
8. Replace any faulty thrust washers.
9. Do not file surfaces which have been hardened
and precision ground.

2262606
1. Remove the 3rd/4thgear synchronizer hub (2)from
the 3rd/4thgear synchronizer sleeve (3).
2. Remove the synchronizer inserts (1) from the 3rd/
4th gear synchronizer hub (2).

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Manual Transmission - F13-5/F15-5/F17-5 (W126) 172507
5th Gear Synchronizer 3. Replace synchronizer hubs that do not require a
force fit.
4. lnspect the synchronizer hubs for wear on the
external splines. A stepped effect on the teeth, due
to wear, may cause shift concerns.
5. Replace a worn hub.
6. Correct the cause, such as, but not limited to the
following conditions:
' Engine related vibrations
- Driving at a low speed in a high gear
~ Defective vibration damper or crankshaft

2262607
. Remove the 5th gear synchronizer hub (3) from the
5th gear synchronizer sleeve (2).
. Remove the synchronizer inserts (1) from the 5th
gear synchronizer hub (3).

Synchronizers Cleaning and

Inspection

2262608
7. Inspect the synchronizer sleeve teeth (1) for the
following conditions, which may cause shift
concerns:
- Gratedteeth
- Chipped offteeth
- Bluntedteeth
inspect the synchronizer sleeve detent stops (2) for
wear or for being chipped off.
. Replace the synchronizer assembly if the teeth or
stops show the above conditions.

648209
Note: When servicing the synchronizers, retain them in
the order that they are removed. Mark the parts to
ensure the correct position for inspection and
assembly.
1. Clean all the synchronizer parts in a suitable
cleaning solvent and air dry all the parts.
2. Inspect the 1st/2ndgear, 3rd/4thgear, and 5th
gear synchronizer hubs for a force fit on the main
shaft.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
17-508 Manual Transmission - F13-5/F15-5/F17-5 (M26)

2262609 681125
10. lnspect the synchronizer blocker rings for worn 16. Installthe synchronizer blocking rings to the
away grooves (1). correct speed gear.
11. Replace the blocker ring assembly if the blocker 17. Inspect the braking effect 0fthe blocking ring. Turn
ring grooves are worn. the blocking ring in one direction while pushing to
the gear cone. Ensure the ring locks.
18. lfthe ring does not lock, replace the synchronizer
assembly.

648208
12. Inspect the synchronizer blocker rings for worn
shift teeth. 2262610
13. Inspect the internal ring for being warped or
damaged. 19. Inspect the pressure pieces (1)for wear or
14. Inspect the outer ring for worn grooves. damage. .
15. Replace the synchronizer assembly for any of the 20- Replace the worn pressure pieces.
above conditions.

2013
-Sonlc
(US/Canada)
Service
Manual
(5377994)
lN
..,.wo
 Manual Transmission - F13-5/F15-5/F17-5 (M26) 17509
Synchronizers Assemble 5th Gear Synchronizer
1st/2nd Gear Synchronizer

2262607
2262605 1. Install the synchronizer inserts (1) into the 5th gear
Note: When servicing the synchronizers, retain them in synchronizer hub (3).
the same order that they are removed. Keep the 2. Install the 5th gear synchronizer hub (3) into the
synchronizer components together and mark them to 5th gear synchronizer sleeve (2).
identify correct location.
Shift Fork Cleaning and Inspection
1. Install the synchronizer inserts (1) into the 1st/2nd
gear synchronizer hub (2). (Gen 1)
2. install the 1st/2nd gear synchronizer hub (2) into
the 1st/2ndgear synchronizer sleeve (3).
3rd/4th Gear Synchronizer

./«- 2265960
Warning: Wear safety glasses to avoid injury when
using compressed air or any cleaning solvent.
Bodily injury may occur if fumes are inhaled or if
2262606 skin is exposed to chemicals.
1. Install the synchronizer inserts (1) into the 3rd/4th 1. Clean the following components with a suitable
gear synchronizer hub (2). solvent. Air dry all the parts.
2. Install the 3rd/4thgear synchronizer hub (2) into - 3rd and 4th shift fork assembly (1)
the 3rd/4thgear synchronizer sleeve (3). - 5th shift blocking guide (2)
- 3rd and 4th shift shaft (3)
2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
'l7-510 Manual Transmission - F13-5/F15-5/F17-5 (M26)
- 1st and 2nd shift fork assembly (4)
- 1st and 2nd shift shaft (5)
- 5th shift fork assembly (6)
- Reverse shift shaft (7)
' Reverse shift fork assembly (8)

2265973
4. Inspect the shift fork nylon inserts (1) for wear.
5. Replace parts that are fractured, excessively worn,
or distorted.
6. Replace an excessively worn or burred shift shaft.

2265968 Shift Fork Cleaning and Inspection

2. lnspect the following components for excessive (Gen 2)
wear, fractures or distortion.
- 3rd and 4th shift fork assembly (1)
- 5th shift blocking guide (2)
- 1st and 2nd shift fork assembly (3)
- 5th shift fork assembly (4)
- Reverse shift fork assembly (5)

2748675
Warning: Wear safety glasses to avoid injury when
using compressed air or any cleaning solvent.
Bodily injury may occur if fumes are inhaled or if
skin is exposed to chemicals.
1. Clean the following components with a suitable
463422 solvent. Air dry all the parts.
° 3rd and 4th shift fork assembly (1)
3. Inspect the shift shaft lever bushings for
excessive wear. - 5th shift blocking guide (2)
° 3rd and 4th shift shaft (3)
- 1st and 2nd shaft block (4)

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Manual Transmission =F13-5/F15-5/F17-5 (M26) 17-511
1st and 2nd shift fork assembly (5) 3. Inspect the shift shaft lever bushings for
1st and 2nd shift shaft (6) excessive wear.
5th shift fork assembly (7)
Reverse shift shaft (8)
Reverse shift fork assembly (9)
Reverse fork block (10)

2265973
4. Inspect the shift fork nylon inserts (1) for wear.
5. Replace parts that are fractured, excessively worn,
or distorted.
2748676 6. Replace an excessively worn or burred shift shaft.
2. Inspect the following components for excessive
wear, fractures or distortion. Input Shaft Assemble
3rd and 4th shift fork assembly (1) Special Tools
._2_/
W M
5th shift blocking guide (2) J-840733 Driver
1st and 2nd shift fork assembly (3) For equivalent regional tools, refer to Special Tools on
1st and 2nd shaft block (4) page 17—535.
5th shift fork assembly (5)
Reverse shift fork assembly (6)
Reverse fork block (7) ,

2264239
Note: Ensure the input shaft rear bearing retaining
ring (2) is placed on the input shaft before installing the
input shaft rear bearing assembly (1).
463422
1. Place the input shaft rear bearing retaining ring (2)
on the input shaft.
2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
17-512 Manual Transmission - F13-5/F15-5IF17-5 (N126)
2. Install the inputshaft rearbearing assembly(1) 2. Assemble the following components:
USlngthe J‘840733 driver and a hydraulic press. a 3rd/4thgear synchronizer assembly (1)

Main Shaft Assemble (Gen 1) ' 3rd gearb'OCkm "ngm

' 4th gear assembly (4)
Special Tools
3-0207944 Main Shaft Tapered Bearing InsertTool '
For equivalent regional tools, refer to Special Tools on
page 17—535.

Il
>t
l.”

2488846
3. Install the 3rd/4thgear synchronizer assembly (2)
and the 4th gear assembly (1) as a unit using 3-
0207944 bearing insert tool (3) and a hydraulic
2262558 press.
1. Install the 4th gear bearing assembly (1).

2262552
' 2262600 4. Install the 3rd/4thgear synchronizer assembly
Note: The 3rd gear blocking ring lugs must be aligned thrust washer (2) and the NEW 3rd/4thgear
with the 3rd/4thgear synchronizer assembly grooves. synchronizer assembly retaInIng““9 (1)-
Note: The groove on the 3rd/4thgear synchronizer
assembly (2) should point toward the 4th gear
assembly. -. .

2013
—
Sonic
(US/Canada)
Service
Manual
(5377994)
 Manual Transmission - F13-5/F15-5lF17-5 (M26) 17.513

(C i): 4
‘\\.\?§::;.\\,\t\>\>“
'I u:

2488850
5. Installthe following components: 2262551 7. Instatlthe 1st/2nd gear synchronizer assembly (2)
- 3rd gear blocking ring (6) and the 2nd gear assembly (1) as a unit using 3-
- 3rd gear bearing assembly (5) 0207944 bearing insert tool (3) and a hydraulic
press.
- 3rd gear assembly (4)
- 3rd gear thrustwasher (3)
- 3rd gear thrustwasher retaining ring (2)
- 2nd gear bearing assembly (1)

\v.v-.. \.IIv/v|l'. ‘
0\\
II»
_”W._
.Wmmmwn—m Ii
:ILI-l
31!!.,..ml
"”wt‘

2262547
8. Install the NEW 1st/2ndgear synchronizer
assembly retaining ring (1).

2262549
Note: The lugs on the blocking rings must be aligned
with the 2nd gear assembly and the ‘lst/2nd gear
synchronizer assembly.
6. Assemble the following components:
- 13t/2ndgear synchronizer assembly (1)
- 1st/2ndgear outer blocking ring (2)
' 1st/2ndgear intermediate cone ring (3)
° 1st/2ndgear inner blocking ring (4)
- 2nd gear assembly (5)

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
17-514 Manual Transmission - F13-5/F15-5/F17-5 (M26)

Main Shaft Assemble (Gen 2)

Special Tools
3-0207944 Main Shaft Tapered Bearing InsertTool
For equivalent regional tools, refer to Special Tools on
page 17-535.

SitlmH .
WEI“

2262603
Note: The lugs on the blocking rings must be aligned
with the 1st/2nd gear synchronizer assembly grooves.
9. Install the following components:
- 1st/2ndgear outer blocking ring (5)
- 1st/2nd gear intermediate cone ring (4)
- 1st/2nd gear inner blocking ring (3) 2262558
- 1st gear bearing assembly (2)
1. Install the 4th gear bearing assembly (1).
0 1st gear (1)

2748497
2488856 Note: The 3rd gear blocking ring lugs must be aligned
10. Install the 1st gear thrust washer (1) and the thrust with the 3rd/4thgear synchronizer assembly grooves.
washer(2) in thea1st/2nd gear synchronizer , .
assembly using suitable tube (3) and a hydraulic Note. The groove on the 3rd/4thgear synchronizer
assembly (2) should point toward the 4th gear
press. assembly.
2. Assemble the following components:
2 3rd/4thgear synchronizer assembly (1)
- 4th gear outer blocking ring (3)
- 4th gear intermediate blocking ring (4)

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
 Manual Transmission - F13-5/F15-5IF17-5 (M26) 17=515
° 4th gear inner blocking ring (5)
- 4th gearassembly(6)

\\\\\\\\

2748476
5. Install the following components:
- 3rd gear outer blocking ring (8)
2488846
- 3rd gear intermediate blocking ring (7)
3. Installthe 3rd/4thgear synchronizer assembly (2)
- 3rd gear inner blocking ring (6)
and the 4th gear assembly (1) as a unit using
3-0207944 bearing insert tool (3) and a hydraulic - 3rd gear bearing assembly (5)
press. ' 3rd gear assembly (4)
' 3rd gear thrust washer (3)
' 3rd gear thrust washer retaining ring (2)
' 2nd gear bearing assembly (1)

2262552
4. Install the 3rd/4thgear synchronizer assembly
thrust washer (2) and the NEW 3rd/4thgear
synchronizer assembly retaining ring (1). 2262549
Note: The lugs on the blocking rings must be aligned
with the 2nd gear assembly and the 1st/2nd gear
synchronizer assembly.
6. Assemble the following components:
- 1st/2ndgear synchronizer assembly (1)
- 1st/2ndgear outer blocking ring (2)
- 1st/2ndgear intermediate cone ring (3)

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
172516 Manual Transmission - F13-5/F15-5IF17-5 (M26)
- '1st/2nd gear inner blocking ring (4)
- 2nd gear assembly (5)

2262603
Note: The lugs on the blocking rings must be aligned
with the 1st/2ndgear synchronizer assembly grooves.
2488850 9. Install the following components:
7. Install the 1st/2nd gear synchronizer assembly (2) . 1st/2ndgear outer blocking ring (5)
and the 2nd gear assembly (1) as a unit using ° 1st/2ndgear intermediate cone ring (4)
3—0207944bearing insert tool (3) and a hydraulic
- 1st/2ndgear inner blocking ring (3)
press.
' 1st gear bearing assembly (2)
0 1st gear (1)

v_
'lli‘l‘i‘wai
1mm’
zI‘. ,lJtit Ilé'
-1!]

2262547
8. Instali the NEW 1st/2ndgear synchronizer 2488856
assembly retaining ring (1).
10. Install the 1st gear thrust washer (1) and the thrust
washer (2) in the 1st/2ndgear synchronizer
assembly using a suitable tube (3) and a hydraulic
press.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Manual Transmission - F13-5/F15-5/F17-5 (M26) 172517
Differential Case Assemble Note: Lubricate rotating parts on their bearing,
running, seating, and pressure surfaces using
Special Tools transmission fluid.
”70727 ”'9 Shaft 333' Remover SUF’PO“Base 2. Install the front differential pinion gears (3) and side
R—0407011Bearing Race Remover gears (4)1
R-_0407012Differential Carrier Cone Bearing Cap 3. Install the front differential pinion gear shaft (2) and
Driver the pinion gear shaft retaining washers (1).
R—0007761Universal Handle for Pullers and
Installers
8-9407194 Speed Sensor Impeller Ring Installer
8-9407195 Pinion Gear Case Bearing Installer
8—9707500Seal Installer
For equivalent regional tools, refer to Special Tools on
page 17—535.

2265951
4. tf both components are reused align the assembly
marks (3).
5. Install the front differential ring gear (2).
Warning: Refer to Safety Glasses Warning on
page 0-5.
2265978 6. Install the front differential ring gear bolts (1).
Tighten to 90 N-m (66.4 lb ft).
1. Install the front differential pinion and side gear
thrust washer. Itmust be possible to insert the
collar (1) of the thrust washer into the guide for the
pinion gears in the housing.

2265983
7. Install the ring front wheel speed sensor reluctor
wheel (1) using the S-9407194 installer and a
2265981 hydraUIICpress.
2013
<Sonic
(US/Canada)
Service
Manual
(5377994)
17=518 Manual Transmission - F’i3-5lF15-5/F17-5 (M26)

2265986 2265989
8. Install the front differential bearing assemblies (1) 10. Installthe front differential bearing race (3) using
using the S—9407195instaiier and a hydraulic the R-0007761 handle (1) and the R—0407012
press. driver (2).

Transmission Case Assemble

(Gen 1)
Special Tools
- 3—9506289Universal Adapter
- J-840733 Driver
- R-0007758 Holding Fixture
- R—0007761Universal Handle
- R-0007770 Holding Fixture Adapter Plates
- T—9804669Seal Installer
- T-0307000 Extractor and Driver Fixture
For equivalent regional tools, refer to Special Tools on
page 17-535.

2265988
9. Install the front wheel drive shaft oil seal (3) using
the R-0007761 handle (1), 8-9707500 seal
installer (2), and the J-810721support base (4).

2263810
1. Installthe reverse idler gear shaft retaining ball (2).
—
2013 (US/Canada)
Sonic (5377994)
Manual
Service
 Manual Transmission - F13-5/F15-5lF17-5 (N126) 17-519
2. install the reverse idler gear shaft (1).

2264066
5. lnstail the input shaft(3), reverse idler gear(2) and
”64°63 mainshaft (1) onto the T-0307000 driver fixture with
3. Using T-9804669 seal installer (2) and R-0007761 top plate removed-
handle (1),install the mainshaft bearing (3) into
the case.

2264070
6. Guide the shafts (1—2)into the bores, and support
2263807
the reverse idler gear (3) while pressing into
4. Install the mainshaft bearing retaining ring (1). the case.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
1'7-520 Manual Transmission - F1 3-5/F15-5/F17-5 (N126)

2264072 2263804
7. Using the T—0307000driver fixture, press the 5th 9. Installthe input shaft bearing retaining ring (1).
gear bearing race (1) onto the mainshaft.

2264074
8. lnstail the case and shafts assembly onto the
R—0007770adapter plates (1) and R-0007758
holding fixture (2).
2264075
10. Install the 1st and 2nd shift fork (2).
11. Install the 1st and 2nd shift shaft (1).
12. Install the 1st and 2nd shift fork pin (3)to the
dimension “a” depth of 2 mm (0.80 in).

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
 Manual Transmission —F13-5/F15-5lF17-5 (N126) 17—521

ixxsgfil6.:

2264076 2264079
13. Install the gearshift rod (1) into the 15. Install the 3rd and 4th shift fork (2).
transmission case. 16. Install the 3rd and 4th shift shaft (1).
17. install the 3rd and 4th shift fork pin (3) to the
dimension “a” depth of 2 mm (0.80 in).

WWMM
wmam
-mwfl_m,.2
2,

2263787
14. Install the 5th shift blocking guide (1) into the
transmission case. 2264082
18. install the reverse shift fork (2).
19. install the reverse shift shaft (1).
20. Install the reverse shift fork pin (3)to the dimension
“a” depth of 2 mm (0.80 in).

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
 17-522 Manual Transmission —F13-5/F15-5/F17-5 (M26)

9*-

2264087 ' 2263781

21. Using a plastic hammer or equivalent install the 4
shift shaft detent sleeves (1—4)into the
transmission case until they stop.
Note: Move shift forks into neutral position.
24. Install the parking pawl (2).
Caution: Refer to Fastener Caution on page 0—8.
25. Using thread locking compound install the parking
pawl retaining bolts (1) and tighten to 7N'm
(62 lb in).

2263785
Note: Engage the shift shafts into 3rd gear and 5th
gear as indicated with arrows to install the interlock pin
connector.
2264088
22. Install the shift shaft interlock pin connector (1).
26. Remove case and shafts assembly from
23. Using thread locking compound install the shift
R-0007770 adapter plates and install onto
shaft interlock pin connector bolts (2) and tighten to
7 Mom(62 lb in). T-0307000 driver fixture.
27. Using J—840733driver, press the 5th gear,
driving (1) onto the input shaft.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Manual Transmission - F1 3-5/F15-5lF17-5 (M26) 17-523

2263774 2264089
28. Install a NEW 5th gear retaining ring (1). 32. Ensure that the synchronizer assembly (1) is
functioning properly, refer to Synchronizers
Cleaning and Inspection on page 17—507and
Synchronizers Assemble on page 17—509.
33. Using the J—840733driver and a press, install the
5th gear synchronizer assembly (1).

2263772
29. lnstail the 5th gear bearing assembly (3).
30. Installthe 5th gear assembly, driven (2).
31. Installthe 5th gear blocking ring (1).
2263767
34. Install the 5th gear sychronizing hub retaining
ring (1).

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
17-524 Manual Transmission - F13-5/F15-5lF17-5 (M26)

§§§§. .m‘ g
\
‘kwfi \\\\\\\\\
. .. \\

: V-
\0‘ .....
?;E.i.Y/!;\\\\\\\\\{‘

2276942 2263765
35. Remove the case and shafts assembly from the 40. Remove the transmission case, from the
T-0307000 driver fixture. R—0007770adapter plates (1) the R-0007758
36. Install R-0007770 adapter plates (1) onto case (2) holding fixture and 3-9506289 adapter.
and then attach to R-0007758 holding fixture (3).
Transmission Case Assemble
(Gen 2)
Special Tools
- 3—9506289Universal Adapter
- J—840733Driver
- R-0007758 Holding Fixture
- R-0007761 Universal Handle
- R-0007770 Holding Fixture Adapter Plates
- 719804669Seal Installer
- 710307000Extractor and Driver Fixture
For equivalent regional tools, refer to Special Tools on
page 17-535.
M
..
2W

2264090
37. Installthe 5th shift fork shoes (3).
38. Install the 5th shift fork bracket assembly (2).
39. Using thread locking compound install the 5th shift
fork bracket bolts (1) and tighten to 22 N-m
(16 lb ft).

2845581

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
 Manual Transmission - F13-5/F15-5/F17-5 (M26) 17-525
1. Installthe reverse helical gear washer (3)onto the
reverse idler gear shaft.
2. install the reverse idler gear shaft retaining ball (2).
3. Installthe reverse idler gear shaft (1).

2845574
6. tnstail the following components onto the
710307000driver fixture with top plate removed.
- Main shaft (2)
2264063 - Reverse helical gear(5)

4 . Usung
' T9804669
- sea l' Insa
t uer (2) an (:11?
-0007761 . Reverse Syncmo assemb'Y(4)
handle (1), install the mainshaft bearing (3) into Reverse spur gear(3)
the case. . - |nputShaft(6)

Vl/fli‘ --“|Il
17,”...W
m
“W
.W.../‘__._2MM..VMMW
_._
Tt\\\\\\\\\\\\
!.~\t\‘ge\\\\\,\,\‘
“
V

2845580 2264070
. _ . , _ Note: While pressing, pay attention to the input shaft
5- Installthe mainshaft bearing retaining rl“9 (1)- bearing retaining ring, because it can be pressed into
the first gear.
7. Guide the shafts (1—2)into the bores, and support
.22-,V.2.2._\._..’,
.. the reverse idler gear (3) while pressing into
the case.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
17-526 Manual Transmission - F13-5/F15-5lF17-5 (M26)

2264072 2264074
8. Using the T—0307000driver fixture, press the 5th 10. Install the case and shafts assembiy onto the
gear bearing race (1) onto the mainshaft. R—0007770adapter plates (1) and R-0007758
holding fixture (2).

"1....
. . .YY‘
. '55".
L'flulghhruw

2748409
2263804
9. Install the reverse spur gear bearing (1), reverse
spur gear washer (2), and reverse gear shaft snap 11. Install the input shaft bearing retaining ring (1).
ring (3).

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Manual Transmission - F13-5/F15-5/F17-5 (M26) 17~527

VeV’

‘5 12‘ "W\\\ :
&

2748407 2263787
12. Installthe 1st and 2nd shaft block (2). 18. Install the 5th shift blocking guide (1) into the
13. Installthe 1st and 2nd shaft block pin (3) to the transmission case.
dimension “a" depth of 2 mm (0.80 in).
14. Installthe 1st and 2nd shift fork (4).
15. lnstail the 1st and 2nd shift shaft (1).
16. install the 1st and 2nd shift fork pin (5) to the
dimension “a” depth of 2 mm (0.80 in).

2264079
19. Installthe 3rd and 4th shift fork (2).
20. Install the 3rd and 4th shift shaft (1).
21. Installthe 3rd and 4th shift fork pin (3) to the
dimension “a” depth of 2 mm (0.80 in).
2264076
17. Install the gearshift rod (1) into the
transmission case.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
17-528 Manual Transmission - F13-5/F15-5lF17-5 (M26)

0, V?\‘\\\\‘ !'
_\ 'l'r, #22:»? .,4 {
//|:\\\\\§‘\_>
--r--,I//
."-~‘,,,,’//// 24‘ E)
. [IIIIIIIILII L .1.g
7”" *~,

2748405
22. Install the reverse fork block (1).
23. Install the reverse fork block pin (2) to the
dimension “a” depth of 2 mm (0.80 in).
24. lnstail the reverse shift fork (5).
25. Install the reverse shift shaft (3).
26. lnstail the reverse shift fork pin (4) to the dimension
“a” depth of 2 mm (0.80 in).
2263785
Note: Engage the shift shafts into 2nd gear, 5th gear,
and 3rd gear as indicated with arrows to install the
interlock pin connector.
28. lnstail the shift shaft interlock pin connector (1).
29. Using thread locking compound install the shift
shaft interlock pin connector bolts (2) and tighten to
7N-m (62 lb in).

2264087
27. Using a plastic hammer or equivalent install the 4
shift shaft detent sleeves (1—4)into the
transmission case until they stop.
2263781
Note: Move shift forks into neutral position.
30. install the parking pawl (2).
Caution: Refer to Fastener Caution on page 0—8.
31. Using thread locking compound install the parking
pawl retaining bolts (1) and tighten to 7 N'm
(62 lb in).

2013
-Sonic
(US/Canada)
Service
Manual
(5377994) ¢
..
2._._
fl
A
. me
.
 Manual Transmission - F13-5/F15-5/F17-5 (M26) 17=529

'1
2...
1
\ v|
my:
1‘8va

2264088 2263772
32. Remove case and shafts assembly from 35. lnstail the 5th gear bearing assembly (3).
R-0007770 adapter plates and install onto 36. Installthe 5th gear assembly, driven (2).
T-0307000 driver fixture.
37. lnstail the 5th gear blocking ring (1).
33. Using J-840733 driver, press the 5th gear,
driving (1) onto the input shaft.

.
‘ ?i-l'l,‘;‘\5§"\"‘"“‘
\\\'\\ \

2264089
2263774 38. Ensure that the synchronizer assembly (1) is
functioning properly, refer to Synchronizers
34. install a NEW 5th gear retaining ring (1).
Cleaning and Inspection on page 17—507and
Synchronizers Assemble on page 17—509.
39. Using the J-840733 driver and a press, install the
5th gear synchronizer assembly (1).

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
17-53() Manual Transmission 2 F13~5IF15-5lF17-5 (M26)

’I/,7///

2263767 2264090
40. Ihstail the 5th gear sychronizing hub retaining 43. Install the 5th shift fork shoes (3).
ring (1)- 44. Install the 5th shift fork bracket assembly (2).
45. Using thread locking compound install the 5th shift
fork bracket bolts (1) and tighten to 22 N-m
(16 lb ft).

._.._
.22..
.2...
2-.

2276942
41. Remove the case and shafts assembly from the
710307000driver fixture.
42. lnstail R-0007770 adapter plates (1) onto case (2) 2263765
and then attach to R‘0007758 holding fixture (3)- 46. Remove the transmission case, from the
R-0007770 adapter plates (1) the R-0007758
holding fixture and 3-9506289 adapter.

—
2013 (US/Canada)
Sonic (5377994)
Manual
Service
 Manual Transmission - F13-5/F15-5/F17-5 (W126) 17-531
Transmission Assemble
Special Tools
° 3-9506289 Universal Adapter
- R—0007758Holding Fixture
- 8-9407197 Differential Rotating Tool
- S—9407198Differential Bearing Race Wrench
For equivalent regional tools, refer to Special Tools on
page 17—535.

2262259
3. lnstail the gasket (3) and differential carrier
cover (2).
4. Install the front differential carrier cover bolts (1).
Tighten to 7 N-m(61.96 lb in).

2276940
1. Install the clutch and differential housing
assembly (1) onto the R-0007758 holding fixture.

2262258
5. Lubricate the O-ring seal (2)with multipurpose
grease and install onto the differential bearing
adjuster (1).
6. Lubricate the threads on the differential bearing
adjuster with multipurpose grease.
7. Using S-9407198 differential bearing race wrench
install the front differential bearing adjuster (1).
2262260
2. Install the front differential carrier (1).

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
17-532 Manual Transmission - F13-5/F15-5lF17-5 (M26)

2276943 2262256
Note: Ifall the components are re—usedalign adjuster 12. Install the differential bearing adjuster lock (2).
to marks. Ifany component was replaced go to the
next step. 13. Apply thread locking compound and install the
differential bearing adjuster lock bolt (1). Tighten to
8. Align marks on the differential bearing adjuster and 9 N-m(79.66 lb in).
case (1).

« ...2.
0
V(Kg‘
‘
2:21;

@Wjfigfll
4.1/I,
.4 .
"14> L9,
/ "
\\© \ j!
nah .¢

2262253
2264220
Note: if no components were replaced, the bearing 14. Install the back up Iamp switch (1).Tighten to
20 N'm (14.75 Ibft).
adjuster can be aligned to the marks. Ifany component
was replaced, the following procedure must be
performed.
9. Using the S-9407197 differential rotatingtool and a
torque wrench, rotate the differential (1)
1 revolution per second.
10. The breakaway bearing torque should be:
- Re-use bearing —60—100Ncm
' .New Bearing —150—21ONcm
11. Using the 8—9407198bearing race wrench and the
R—0007761handle, adjust the breakaway torque
by tightening or loosing the differential bearing
adjuster.
2013
-Sonic
(US/Canada)
Service
Manual
(5377994) 2...._
..
 Manual Transmission - F13-5/F15-5lF17-5 (M26) 17-533

2262252 2276933
15. install the reverse idler gear washer (5).
16. Verify fork alignment before installation.
17. Installthe case .
18. Installthe gasket (1) and transmission case (2).
19. Installthe transmission case bolts (3).Tighten to
15N-m(11|bft).

2262248
24. install the gasket (3) and control lever housing (2).
25. Install the transmission control lever housing
bolts (1).Tighten to 12 N-m(106 lb in).

2262250
20. Installthe gasket (4) and transmission cover (3).
21. Install the long transmission cover boits (2).
Tighten to 24 NW(18 lb ft).
22. Install the short transmission cover bolts (1).
Tighten to 8 N-m(71 lb in).

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
17-534 Manual Transmission - F13-5/F15-5IF17-5 (M26)

Description and Operation

Transmission System Description

and Operation

“'\I)‘ : u
\.(51* US)!

2262247
26. Install the clutch fork shaft (1).
27. Install the clutch fork shaft retaining bolt (2).
Tighten to 35 Nm (26 lb ft).

2262246
28. Remove the R-0007758 holding fixture (2) and the
3-9506289 Universal Adapter (1).
2487582
The F17 is a 5 speed manual transmission assembly.
Note: Use only transmission fluid listed within the
Adhesives, Fluids, Lubricants, and Sealers on
page 17—427forthis manual transmission assembly.
Other lubricants or additives may affect the shift
performance.
The F17 (Gen 1) 5 Speed manual transmission has the
following features:
- First and second gear double coned synchronizer
- Third, fourth, and fifth gear single coned
synchronizer
- Two shaft design consisting of an input shaft, and
main shaft
- Reverse inhibit feature
- One piece clutch actuator —no bleed screw
- Transmission venting system is part of the fill cap
- Vehicle speed sensor (VSS)
The F17 (Gen 2) 5 Speed manual transmission has the
following features:
- First, second, third, and fourth gear double coned
synchronizer
° Fifth gear single coned synchronizer
. Two shaft design consisting of an input shaft, and
main shaft
- Synchronized Reverse Gear
. One piece clutch actuator —no bleed screw
- Transmission venting system is part of the fill cap
v Vehicle speed sensor (VSS)
The manual transmission shift cables must be adjusted
for proper shifter performance.

(5377994)
Manual 2.2.-
2T-M
.._...2
-W
_2..
.‘b..
-Sonic
2013 Service
(US/Canada)
 Manual Transmission - F13-5/F15-5lF17-5 (M26) 17-535

Special Tools and Equipment Illustration Tool Number/Description

Illustration Tool Number/Description

J 810704
SteeringColumnCenterBar
Puller
3-0207944
MainShaftTaperedBearing
InsertTool
2259802

2488551

J 810721
SupportBase
39506289
UniversalAdapter,2.5LHST
Engine
2259812

2259430

J 840733
Driver
69604356
Gear Pullers
2269801

2259786

J 9703392
HydraulicJack
69607346
SpeedSensor ImpellerRing
Puller
2259210

M 680770
UniversalSlidingMallet
J 810700
CenterBar Puller
2259215

2269799

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
17-536 Manual Transmission - F13-5/F15-5IF17-5 (M26)

Illustration Tool Number/Description Illustration Tool NumberlDescription

'

M 840911 R 0007761
UniversalHandleforPullers UniversalHandle300mm
and Installers for Pullersand installers
(%

2259220 2259825

R 0006747-1 R 0007770
EngineandTransmission SupporttoAssembleand
Removaland installation DisassembletheGear
DeviceCrossmember Assembly

2259558 2259835

R 0407008
R 0006747-5
DeviceforRemovingthe
TransmissionSupport, CountershaftBearing,Use
Attachto R 0006747—1 withR 0007761

2259818 2259839

R 0006749 D . CR0437039flF t
. river oun ers a ron
Bearing,Usewith
SupportBgifigosrUniversal
R0007761 ,

2259224 2259841

R 0007758 R 0407910
DevicetoAttachthe PullerandDriver—Input
ShaftNeedleBearing,Use
Transmission withR 0007761

2259820 2259887

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
 Manual Transmission - F13-5/F15-5/F17-5 (M26) 17-537
Illustration Tool Number/Description Illustration Tool Number/Description

‘
P uller [I:f?
I erenIa
4072110amer
‘ . 89406190. .
TaperBearingCap, Use with Sh'ftRoclingtigfigrBushmg
R 0007761 p

2259888 2259571

D , £24073“: . s—9407194
nver l erenia amer .
Cone BearingCap, Use with SpeedSe?::t;{{2leeller
ng
R 0007761

2259889 2259901

R 0407013 I S-9407195
GearshiftDeviceBushing PinionGear Case Bearing
Puller,UsewithM 6807770 installer

.4

2259890 2259902

R 0407014 , 39407197 h
GearshiftDeviceBushing Dewcet0
Driver,Use withM 6807770 PinionGear Measuret e
Case Bearings
Preload,F13/15

2259892 2259904

R 0407015 8-9407198
DeviceforRemovingthe Wrenchto Loosenand
SpeedGear Engaging TightentheDifferential
Cable BearingRace, F13/15

@
2259893 2259905

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
17-538 Manual Transmission - F13-5/F15-5lF17-5 (M26)

Illustration Tool Number/Description Illustration Tool NumberIDescription

T-9804678
8'9707500 F23RPM SensorRingGear
Axle ShaftSeal Installer Puller.Removein thePress
69607346Optional
\

2259912

T-0207928 T—9807671
RetainerRemover Slide Hammer

2488552 2269800

@113
3 “0307009 X-0206951
2-.. EXtfigéojtgzineg‘gfiffl FrontSuspensionBushing
ez©fifl Assembly Pullerandinstaller

2259940 2259335

T—9804669
Axle ShaftSeal Installer

2259945

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Manual Transmission - M20/M32 (MR5, MZ4) 17-539

Manual Transmission - M20/M32 (MR5, MZ4)

Specifications

Fastener Tightening Specifications

Specification
Application Metric English
BackupLampSwitch 35Nm 26lbft
FrontDifferentialCarrierFlangeBolt '
FirstPass 20N-m(1) | 15Ibft(1)
FinalPass 45 degrees
Oil DrainPlug 20N-m 15lbft
Oil FillerPlug 30N-m 22 lbft
ShiftControlLeverBracketBolt 20N-m 15lbft
ShiftControlHousing—toTransmission 20N-m 15lbft
TransmissionControl—to Chassis 8 N-m 71lb in
TransmissionFrontandRear Bolt(M12) 60N'm 44 lbft
TransmissionFrontMountBolt—to FrontSuspensionFrame 100Nm 74Ibft
TransmissionFrontMountBolt—toTransmission 100N-m 74lbft
TransmissionLowerBolt(M10) 40N-m 30lbft
TransmissionMountBracketBolt—LeftSide—toTransmission 100N-m 74lbft
TransmissionMountBolt—LeftSide —toChassis 62Nm 46 lbft
TransmissionMountNut—LeftSide—toChassis 62N'm 461bft
TransmissionMountBolt-— LeftSide —toBracket
FirstPass 50Nm(1) | 37|bft(1)
FinalPass 60to75degrees
TransmissionMountBracket—Rear Bolt—toTransmission 100Mm 74lbft
TransmissionMount—Rear Bolt—to FrontSuspensionFrame 110NW 81lbft
TransmissionMount—RearBolt—to MountBracket 100N-m 74lbft
TransmissionNutandBolt(M10) 4ON-m 30lbft
.22
.2...
.WM_
.2.42222
2,2...
.22222. TransmissionUpperBolt(M12)
60Nm 44 lbft
1=Use NEW Fastener.

Manual Transmission Specifications

Application Specification
TransmissionType M32-6
ProductionLocation GMPT Europe
TransmissionDrive TransverseMounted— FrontWheelDrive
MaximumEngineTorque 320N-m(236lbft)
TransmissionRPO Codes MR5 l MZ4
EngineRPO Code LUV (U14NFT)
1stGear Ratio 4.273 3.818
2ndGear Ratio 2.353 2.053
3rdGear Ratio 1.475 1.302
4thGear Ratio 1.067 0.959
5thGear Ratio 0.875 0.744

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
’17-540 Manual Transmission - M20/M32 (MR5, MZ4)

Application Specification
6thGear Ratio 0.744 0.614
ReverseGear Ratio 3.818 3.545
FinalDriveRPO Codes FV2 FXB
FinalDriveRatio 4.176 3.650
TransmissionFluidType Referto ElectronicPartsCatalog
FluidCapacityTotal 1.9Liters(2.0quarts)
FluidCapacityRefill 1.8Liters(1.9quarts)
TransmissionWeightDry(Approximate) 53.5-55.5kg

Schematic and Routing Diagrams

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 2
84
e >m|
r
Manual Transmission - M20/M32 (MR5, MZ4) 17-541
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2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
17-542 Manual Transmission - M20/M32 (MR5, MZ4)

Component Locator

Manual Transmission Component Views

Shift Control and Shift Lever/Selector Lever Cable Components

2547309
Legend
(1) Manual Transmission Shift Lever and (4) Manual Transmission Selector and Shift
Selector Lever Cable Lever Cable Bracket Bolts (Qty:2)
(2) Shift Control Housing Bolts (Qty:4) (5) Manual Transmission Selector and Shift
(3) Shift Control Housing Lever Cable Bracket

(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
 Manual Transmission - M20/M32 (MR5, MZ4) 17-543

Shift Shaft Components

2190480
Legend
(1) Shift Shaft Bolts (Qty:2) (3) Shift Shaft O-Rlng
(2) Shift Shaft

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
17-544 Manual Transmission - M20/M32 (MR5, MZ4)

Clutch Housing Components — Right Hand View

_-.W
22..
2‘.
,..
2
M
.2.

2190481
Legend
(1) Clutch Actuator Cylinder (3) Front Wheel Drive Shaft Oil Seal
(2) Clutch Actuator Cylinder Bolts (Qty:3)

wx-_
“me

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Manual Transmission - M20/M32 (MR5, MZ4) 17-545

Clutch Housing Components— Left Hand View

2190482
(1) Front Differential Carrier Flange Seal (6) Transmission Oil Drain Plug
(2) Front Differential Carrier Flange (7) Backup Lamp Switch Washer
(3) Front Wheel Drive Shaft Oil Seal (8) Backup Lamp Switch
(4) Front Differential Carrier Flange Bolts (Qty:4) (9) Clutch Actuator Cylinder Pipe Elbow
(5) Front Differential Carrier Flange Bolt (10) Clutch Actuator Cylinder Pipe Sleeve
Washers (Qty:4)

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
17-546 Manual Transmission - M20/M32 (MR5, MZ4)

Transmission Housing Components

2190483
Legend
(1) Transmission Oil Filler Plug

—
2013 (US/Canada)
Sonic (5377994)
Manual
Service
 Manual Transmission - M20lM32 (MR5, MZ4) 17-547

Transmission Shafts Overview

2791267
Legend
(1) InputShaft (3) Lower Main Shaft
(2) Upper Main Shaft

2013
2Sonic
(US/Canada)
Service
Manual
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17-548 Manual Transmission - M20/M32 (MR5, MZ4)

Input Shaft

Legend
U) InputShafi B) OumrBea
(2) InnerBeaNng
 Manual Transmission —M20/M32 (MR5, MZ4) 17-549

Upper Main Shaft

‘ - —. ’4‘ _ -

[j }%E ii]
’ "3 [/1-J

1 '7 lflig
Q f- \ lat.
‘ 1:, 1’43. 1%,;

’34 £/! 2 _

”I - -” l/él
6 5

Legend 2791270
(1) Upper Main Shaft (4) Outer Bearing
(2) 3rd Gear Gearwheel (5) Reverse Gear Gearwheel
(3) 4th Gear Gearwheel (6) Inner Bearing

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
17-550 Manual Transmission - M20/M32 (MR5, MZ4)

Lower Main Shaft

{I'll}
x
...

mm

2791271
Legend .I.”h.f|lsl|
(1) Lower Main Shaft (5) 2nd Gear Gearwheel
m e8
(( 56 ee88rrG666
tthhGG 38mm68
me ((00 mm GB89
mmem
(4) Outer Bearing .lI.

)) . 3.5.5.!!4'.

23 89
(US/Canada)
-Sonic
2013 (5377994)
Manual
Service
 Manual Transmission - M20/M32 (MR5, MZ4) 17-551

1st /2nd Gear Synchronizer

2791272
(1) 2nd Gear Gearwheel (8) Spacer
(2) 2nd Gear Inner Synchronizer Ring (9) 1st Gear Outer Synchronizer Ring
(3) 2nd Gear Middle Synchronizer Ring (10) 1st Gear Middle Synchronizer Ring
(4) 2nd Gear Outer Synchronizer Ring (11) 1st Gear inner Synchronizer Ring
(5) 1st/2ndGear Selector Sleeve (12) 1st Gear Gearwheel
(6) Spring Catches (13) 1st GearAxiaI Needle Bearing
(7) 1st/2ndGear Sleeve Carrier

2013
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Sonic
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17-552 Manual Transmission - M20/M32 (MR5, MZ4) i

3rd/4th Gear Synchronizer

l
2791273 I
Legend
(1) 4th Gear Gearwheel (7) 3rd/4thGear Sleeve Carrier
(2) 4th Gear InnerSynchronizer Ring (8) 3rd Gear Outer Synchronizer Ring 1
(3) 4th Gear Middle Synchronizer Ring (9) 3rd Gear Middle Synchronizer Ring ‘
(4) 4th Gear Outer Synchronizer Ring (10) 3rd Gear lnner Synchronizer Ring ‘
(5) 3rd/4th Gear Selector Sleeve (11) 3rd Gear Gearwheel
(6) Spring Catches r
l
l
l

.....
2013
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(US/Canada)
Service
Manual
(5377994)
 Manual Transmission - M20/M32 (MR5, MZ4) 17653

5th /6th Gear Synchronizer

2791274
Legend
(1) 6th Gear Gean/vheel (5) 5th/6thGear Sleeve Carrier
(2) 6th Gear Synchronizer Ring (6) 5th Gear Synchronizer Ring
(3) 5th/6thGear Selector Sleeve (7) 5th Gear Gearwheel
(4) Spring Catches

2013
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Service
Manual
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17-554 Manual Transmission - M20/M32 (MR5, MZ4)

Reverse Gear Synchronizer

2791275
Legend
(1) Reverse Gear Selector Sleeve (4) Reverse Gear Synchronizer Ring
(2) Spring Catches (5) Reverse Gear Gearwheel
(3) Reverse Gear Sleeve Carrier

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-Sonic
2013 (5377994)
Manual
Service
 Manual Transmission - M20/M32 (MR5, MZ4) ’17-555

Diagnostic Information and Procedures

DTC P0502 or P0503

Diagnostic Instructions
- Perform the Diagnostic System Check - Vehicle
on page 6—66prior to using this diagnostic
procedure.
- Review Strategy Based Diagnosis on page 6-58
for an overview of the diagnostic approach.
- Diagnostic Procedure Instructions on page 6-59
provides an overview of each diagnostic category.
DTC Descriptors
DTC P0502: Vehicle Speed Sensor (VSS) Circuit —Low Voltage
DTC P0503: Vehicle Speed Sensor (VSS) Circuit —intermittent

Diagnostic Fault Information

Open/High Signal
Circuit Short to Ground Resistance Short to Voltage Performance
OperatingConditions: EngineRunning,drivewheelsturning.
VSS HighSignal P0502,P0503 P0502,P0503 P0502,P0503 P0503
VSS LowSignal —- P0502,P0503 — -

Diagnostic Fault Information

Open/High Signal
Circuit Short to Ground Resistance Short to Voltage Performance
OperatingConditions: EngineRunning,drivewheelsturning.
VSS HighSignal 0 km/h(0MPH) 0 km/h(0MPH) 0km/h(0MPH) -
VSS LowSignal - 0 km/h(0MPH) — -
CircuitISystem Description Action Taken When the DTC Sets
The vehicle speed sensor is provided to the engine P0502 and P0503 are Type B DTCs.
control module by the vehicle speed sensor (VSS). The
ECM provides a 5 V circuit, a low reference circuit, and Conditions for Clearing the DTC
a signal circuit to the VSS. The VSS provides a P0502 and P0503 are Type B DTCs.
frequency signal that is proportional to an increase in
vehicle speed. Diagnostic Aids
Conditions for Running the DTC The battery must be fully Charged. Refer to Battery
Inspection/Test on page 9-702.
P0502
The ignition is ON. Reference Information

P0503 Schematic Reference

- Ignitionvoltage is between 11—18V. Manual Transmission Schematics on page 17-541
- Engine speed is between 1 500—6500 RPMs. Connector End View Reference
- VSS signal is between 150—200RPMs for 2 8.
Component Connector End Views on page 11-269
Conditions for Setting the DTC Description and Operation
P0502 Transmission System Description and Operation on
VSS signal is less than 60 RPMs for 4.5 s. page 17—589
P0503 Electrical Information Reference
VSS signal is greater than 350 RPMs for 3.25 s. 0 Circuit Testing on page 11-526
0 Connector Repairs on page 11-548
2013
—Sonic
(US/Canada)
Service
Manual
(5377994)
'17-556 Manual Transmission - M20/M32 (MR5, MZ4)
- Testing for IntermittentConditions and Poor
Connections on page 11-531
- Wiring Repairs on page 11-537
DTC Type Reference
Powen‘rain Diagnostic Trouble Code (DTC) Type
Definitions on page 6—68
Scan Tool Reference
Engine Control Module Scan Tool Informationon
page 6-33
CircuitISystem Verification
1. Operate the vehicle on the road at various speeds
up to 64 km/h (40 MPH).
2. Verify with a scan tool that the B14ATransmission
Output Shaft Speed Sensor parameter and the
speedometer display on the instrument cluster
match.
=>If the parameter does not match
Refer to CircuitISystem Testing.
ii If the parameter matches
3. Operate the vehicle within the conditions for
running the DTC to verify the DTC does not reset.
You may also operate the vehicle within the
conditions that you observed from the Freeze
Frame/Failure Records.
=>If the DTC resets
Refer to CircuitISystem Testing.
ii If the DTC does not reset
4 All OK.
CircuitISystem Testing
1. IgnitionOFF, disconnect the B14ATransmission
Output Shaft Speed Sensor harness connector.
2. Test for less than 5 Q between the low reference
circuit terminal 2 and ground.
=>If 5 Q or greater
2.1. Disconnect the X3 harness connector at the
K20 Engine Control Module.
2.2. Test for less than 2 Q in the circuit end to end.
=>If2 Q or greater, repair the open/high resistance
in the circuit.
:> Ifless than 2 Q, replace the K20 Engine Control
Module.
ii If less than 5 Q
3. ignition ON.
4. Test for greater than 4.8—5.2V between the 5 V
reference circuit terminal 1 and ground.
:> if less than 4.8 V
4.1. Test for infinite resistance between the 5 V
reference circuit and ground.
=>Ifless than infinite resistance
Repair the short to ground on the circuit.
U lf infinite resistance
4.1.1. Disconnect the X3 harness connector
at the K20 Engine Control Module.
4.1.2. Test for less than 2 Q in the 5 V
reference circuit end to end.
=> lf 2 Q or greater, repair the open/high resistance in
the circuit.
=> Ifless than 2 Q, replace the K20 Engine Control
Module.
=>If greater than 5.2 V
4.1. Disconnect the X3 harness connector at the
K20 Engine Control Module.
4.2. Test for less than 0.3 V between the 5 V
reference circuit terminal 35 and ground.
:> If0.3 V or greater, repair the short to voltage on
the circuit.
=>Ifless than 0.3 V, replace the K20 Engine
Control Module.
ii If between 4.8—5.2V
.07 ignition OFF.
6. Test for less than 1 V between the signal circuit
terminal 3 and ground.
=>If 1 V or greater
6.1. Disconnect the X3 harness connector at the
K20 Engine Control Module.
6.2. Test for less then 0.3 V between the signal
circuit terminal 55 and ground.
2:»lf 0.3 V or greater, repair the short to voltage on
the circuit.
=>if less than 0.3 V, replace the K20 Engine
Control Module.
0 If less than 1 V
7. Ignition OFF, disconnect the X3 harness connector
at the K20 Engine Control Module.
8. Test for less than 2 0 between the signal circuit
terminal 55 at the K20 Engine Control Module and
the signal circuit terminal 3 at the
B14ATransmission Output Shaft Speed Sensor.
=>If2 Q or greater
Repair the open/high resistance in the circuit.
it If less than 2 Q
9. Test for infinite resistance between the signal
circuit terminal 3 at the B14ATransmission Output
Shaft Speed Sensor.
2, If less than infinite resistance
Repair the short to ground on the circuit.
it If infinite resistance
10. Replace the B14ATransmission Output Shaft
Speed Sensor.
Repair Instructions
Perform the Diagnostic Repair Verification on
page 6—92after completing the repair.
- Vehicle Speed Sensor Replacement on
page 17—575
' Control Module References on page 6-3 for ECM
replacement, programming and setup.
2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Manual Transmission - M20/M32 (MR5, MZ4) 17-557
DTC P0806-P0808
Diagnostic Instructions
- Perform the Diagnostic System Check - Vehicle
on page 6—66prior to using this diagnostic
procedure.
- Review Strategy Based Diagnosis on page 6-58
for an overview of the diagnostic approach.
. Diagnostic Procedure Instructions on page 6-59
provides an overview of each diagnostic category.
DTC Descriptors
DTC P0806: Clutch Pedal Position (CPP) Sensor Performance
DTC P0807: Clutch Pedal Position (CPP) Sensor Circuit Low Voltage
DTC P0808: Clutch Pedal Position (CPP) Sensor Circuit High Voltage

Diagnostic Fault Information

Open/High Signal
Circuit Short to Ground Resistance Short to Voltage Performance
5V Reference P0642,P0807 P0807 P0642,P0808 —-
Signal P0807 P0807 P0808 P0806
LowReference — P0808 P0808 —--

Typical Scan Tool Data

CPP Sensor Voltage

Circuit I Short to Ground Open Short to Voltage
OperatingConditions: IgnitionON.
CPP Sensor Voltage ParameterNormal Range:0V withclutchpedalappliedto 5 V whenclutchpedalis released.
5V Reference 0V 0V 5V
Signal 0V OV 5V
LowReference —— 5V -

CPP Sensor Percentage

Circuit I Short to Ground I Open Short to Voltage
OperatingConditions: IgnitionON.
CPP Sensor Percent ParameterNormal Range:0%withclutchpedalreleasedto 100%whenclutchpedalis applied.
5V Reference 100% 100% 0—100%
Signal 100% 100% 100%
LowReference — 0% -

CircuitISystem Description Conditions for Running the DTC

The clutch pedal position (CPP) sensor is a three wire P0806, P0807 and P0808
sensor, connected to a 5 V reference Circuit,a tow
reference circuit, and a signal circuit. The engine - DTCs P0642, P0643, P0335, P0336, P0607 or
control module supplies 5 V to the CPP sensor, and . P080A are not set.
also provides a sensor ground path on the low - The system voltage is more than 9 V.
reference circuit. The CPP sensor sends a voltage - The ignition is in the RUN position.
signal to the ECM on the signal circuit. The voltage on
the signal circuit wiii vary from a voltage less than or Conditions for Setting the DTC
equal to 5 V when the clutch pedal is released, to a
voltage less than or equal to 1.5V when the clutch P0806
pedal is applied. The CPP sensor is stuck in range.

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17-558 Manual Transmission - M20/M32 (MR5, MZ4)
P0807 5. Operate the vehicle within the conditions for
running the DTC to verify the DTC does not reset.
The CPP sensor voltage is less than 0.1 V for more
You may also operate the vehicle within the
than 1 s.
conditions that you observed from the Freeze
P0808 Frame/Failure Records data.
The CPP sensor voltage is more than 5.2 V for more :> If the DTC resets
than 1 3. Refer to CircuitISystem Testing.
Action Taken When the DTC Sets U If the DTC does not reset
DTC P0806 —P0808 are Type A DTCs. 6. All OK.

Conditions for Clearing the DTC CircuitISystem Testing

DTC P0806 —P0808 are Type A DTCs.
Reference Information
Schematic Reference
Manual Transmission Schematics on page 17-541
Connector End View Reference
Component Connector End Views on page 11-269
Description and Operation
Transmission System Description and Operation on
page 17-589
Electrical Information Reference
- Circuit Testing on page 11-526
- Connector Repairs on page 11—548
- Testing for IntermittentConditions and Poor
Connections on page 11-531
- Wiring Repairs on page 11-537
DTC Type Reference
Powertrain Diagnostic Trouble Code (DTC) Type
Definitions on page 6—68
Scan Tool Reference
Engine Control Module Scan Tool Informationon
page 6-33 for scan tool information
CircuitISystem Verification
1. If DTC P0642, P0643, P0335, P0336, P0607 or
P080A is set, refer to Diagnostic Trouble Code
(DTC) List - Vehicle on page 6—69.
2. IgnitionON.
3. Observe the scan tool CPP sensor percent
parameter. The percentage should vary from 0%
when the clutch pedal is released, to 100%when
the clutch pedal is in the apply position.
=>lf the percentage does not vary
Refer to CircuitISystem Testing.
c If the percentage varies
4. Perform the CPP learn procedure. Refer to Clutch
Pedal Position Sensor Learn on page 17-562.
1. ignition OFF, disconnect the harness connector of
the B25B Clutch Pedal Position Sensor.
2. Test for less than 5 0 between the low reference
circuit terminal C (for LHD) or terminal A (for RHD)
and ground:
:> If 5 Q or greater
2.1. Disconnect the X3 harness connector at the
K20 Engine Control Module.
2.2. Test for less than 2 Q in the circuit end to end.
=>If2 Q or greater, repair the open/hlgh resistance
in the circuit.
:> Ifless than 2 Q, replace the K20 Engine Control
Module.
U If less than 5 Q
3. IgnitionON.
4. Test for greater than 4.8~5.2V between the 5 V
reference circuit terminal A (for LHD) or terminal C
(for RHD) and ground:
2;»If less than 4.8 V
4.1. Test for infinite resistance between the 5 V
reference circuit and ground.
=>Ifless than infinite resistance
Repair the short to ground on the circuit.
0 Ifinfinite resistance
4.1.1. Disconnect the X3 harness connector
at the K20 Engine Control Module.
4.1.2. Test for less than 2 Q in the 5V
reference circuit end to end.
=> If2 Q or greater, repair the open/high resistance in
the circuit.
=> Ifless than 2 Q, replace the K20 Engine Control
Module.
=>If greater than 5.2 V
4.1. Disconnect the X3 harness connector at the
K20 Engine Control Module.
42. Test for less than 0.3 V between the 5 V
reference circuit terminal 38 and ground.
:> If0.3 V or greater, repair the short to voltage on
the circuit. .‘A.
..
_
,M
=>Ifless than 0.3 V, replace the K20 Engine
Control Module.
U If between 4.8—5.2V
5. IgnitionOFF.

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-Sonic
2013 (5377994)
Manual
Service
 Manual
Test for less than 1 V between the signal circuit
terminal B and ground.
[H V or greater
6.1. Disconnect the X3 harness connector at the
K20 Engine Control Module.
6.2. Test for less then 0.3 V between the signal
circuit terminal 58 and ground.
=>If0.3 V or greater, repair the short to voltage on
the circuit.
:> If less than 0.3 V, replace the K20 Engine
Control Module.
If less than 1 V
. IgnitionOFF, disconnect the X3 harness connector
at the K20 Engine Control Module.
. Test for less than 2 0 between the signal circuit
terminal 58 at the K20 Engine Control Module and
the signal circuit terminal B at the 8258 Clutch
Pedal Position Sensor.
If 2 Q or greater
Repair the open/high resistance in the circuit.
If less than 2 (2
Test for infinite resistance between the signal
Circuitterminal B at the BZSB Clutch Pedal Position
Senson
If less than infinite resistance
Repair the short to ground on the circuit.
If infinite resistance
. Test or replace the B258 Clutch Pedal Position
Sensor.
Transmission - M20/M32 (MR5, MZ4) 17-559
Component Testing
Static Test
1. IgnitionOFF, disconnect the harness connector of
the BZSB Clutch Pedal Position Sensor.
2. Measure the resistance between the signal
terminal B and the low reference terminal C (for
LHD) or terminal A (for RHD) at the 8258 Clutch
Pedal Position Sensor. Depress the clutch pedal
through the entire range. The resistance should
vary from low to high and vice versa without any
spikes or dropouts.
If the resistance is erratic with spikes or
dropouts
Replace the B258 Clutch Pedal Position
Sensor.
U If the resistance is not erratic without spikes or
dropouts
3. All OK. ,
Repair Instructions
Perform the Diagnostic Repair Verification on
page 6-92 after completing the repair.
Clutch Pedal Position Sensor Replacement on
page 17—415
Control Module References on page 6-3 for ECM
replacement. programming and setup.

2013
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17-560 Manual Transmission - M20/M32 (MR5, MZ4)

DTC P080A

Diagnostic Instructions
- Perform the Diagnostic System Check —Vehicle
on page 6—66prior to using this diagnostic
procedure. ,
- Review Strategy Based Diagnosis on page 6—58
for an overview of the diagnostic approach.
- Diagnostic Procedure Instructions on page 6-59
provides an overview of each diagnostic category.
DTC Descriptor
DTC P080A: Clutch Pedal Position (CPP)Not Learned

CircuitISystem Description Description and Operation

The clutch pedal position (CPP)sensor is a three wire Transmission System Description and Operation on V
sensor, connected to a 5 V reference circuit, a low page 17-589
reference circuit, and a signal circuit. The engine
control module supplies 5 V to the CPP sensor, and Electrical Information Reference
also provides a sensor ground path on the low ' Circuit Testing on page 11-526
reference circuit. The CPP sensor sends a voltage
signal to the ECM on the signal circuit. The voltage on - Connector Repairs on page 11-548
the signal circuit will vary from a voltage less than or - Testing for IntermittentConditions and Poor
equal to 5 V when the clutch pedal is released to a Connections on page 11—531 .
voltage less than or equal to 1.5 V when the clutch ° Wiring Repairs on page 11-537
pedal is applied.
DTC Type Reference
Conditions for Running the DTC
Powertrain Diagnostic Trouble Code (DTC) Type
Clutch pedal fully applied. Definitions on page 6—68
Conditions for Setting the DTC Scan Tool Reference
Clutch pedal position not learned. Engine Control Module Scan Tool Informationon
page 6-33 for scan tool information
Action Taken When the DTC Sets
PO8OA is a Type B DTC. CircuitISystem Verification
Perform the clutch pedal position sensor learn
Conditions for Clearing the DTC procedure. Refer to Clutch Pedal Position Sensor
P080A is a Type B DTC. Learn on page 17-562.
Reference Information Repair Instructions
Schematic Reference Perform the Diagnostic Repair Verification on
page 6-92 after completing the repair.
Manual Transmission Schematics on page 17-541 - Clutch Pedal Position Sensor Learn on
Connector End View Reference page 17-562
~ Control Module References on page 6-3
Component Connector End Views on page 11-269

2013
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 Manual Transmission - M20/il/l32 (MR5, MZ4) 17-561

DTC P0812

Diagnostic Instructions
- Perform the Diagnostic System Check - Vehicle
on page 6-66 prior to using this diagnostic
procedure.
' Review Strategy Based Diagnosis on page 6—58
for an overview of the diagnostic approach.
- Diagnostic Procedure Instructions on page 6—59
provides an overview of each diagnostic category.
DTC Descriptor
DTC P0812 00: Reverse Position Switch Circuit ——
Malfunction
Diagnostic Fault Information

Opeanigh Signal
Circuit Short to Ground Resistance Short to Voltage Performance
ReverseSwitchSignal P081200 1 P081200 -
Ground — 1 1 -
1.BackupLampsMalfunction

CircuitISystem Description Scan Tool Reference

The reverse gear SWitChis a normally open SWitChthat Control Module References on page 6-3 for scan tool
closes with the reverse gear engagement. When the information
switch is open the engine control module should detect . . __ .
a high signal voltage input. When the switch is closed Circmt/System Verification
the ECM should detect a low signal voltage input. 1. ignition ON.
Conditions for Running the DTC 2. Observe the scan tool Reverse Switch parameter.
The reading should be Offand change to On when
' No vehicle speed sensor faults exist.
the transmission is shifted into reverse.
' Reverse switch is ON.
:> If the parameter does not change from Off to On
Conditions for Setting the DTC Refer to Circuit/System Testing.
The ECM detects circuit malfunction of the reverse U If the parameter changes from Off to On
input switch. 3. All OK.
Action Taken When the DTC Sets CircuitISystem Testing
DTC P0812 00 is Type C DTC. 1. IgnitionOFF, disconnect the harness connector at
Conditions for Clearing the DTC the B16 Backup Lamp Switch.
DTC P0812 00 is Type C DTC. 2. Test for less than 5 Q between the ground Circuit
terminal 2 and ground.
Reference Information =>lf 5 Q or greater
Schematic Reference 2.1. Test for less than 2 Q in the ground circuit end
to end.
Manual TransmISSIonSchematics on page 17'541 =>If2 Q or greater, repair the open/high resistance
Connector End View Reference in the circuit.
Component Connector End Views on page 11—269 =>if less than 2 Q, repair the open/high resistance
in the ground connection.
Description and Operation
If less than 5 Q
Transmission System Description and Operation on IgnitionON, transmission in neutral position.
page 17—589
Electrical information Reference
- Circuit Testing on page 11-526
- Connector Repairs on page 11-548
- Testing for IntermittentConditions and Poor
Connections on page 11-531
- Wiring Repairs on page 11-537
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Sonic
(US/Canada)
Service
Manual
(5377994)
'17-562 Manual Transmission - M20/M32 (MR5, MZ4)
4. Verify the scan tool Reverse Switch parameter Repair Instructions
is Off.
Perform the Diagnostic Repair Verification on
=>If the parameter is not OFF page 6-92 after completing the repair.
4.1. Disconnect the X3 harness connector at the Control Module References on page 6—3for ECM
K20 Engine Control Module. replacement, programming and setup.
4.2. Test for infinite resistance between the signal
circuit terminal1 and ground. Clutch Pedal Position Sensor Learn
=>lfless than infinite resistance, repair the short to Note: The clutch pedal position (CPP)sensor learn
ground on the circuit. procedure is required when the following service
=>If infinite resistance, replace the K20 Engine procedures have been performed regardless of
Control Module. whether DTC P080A is set:
U if the parameter is OFF - An engine control module (ECM)replacement
5. Ignition ON, install a 3 Afused jumper wire 0 A CPP sensor replacement
between the signal circuit terminal 1 at the ' Any repairs which affect the CPP sensor
B16 Backup Lamp Switch harness connector and relationship
ground. A. Install a scan tool.
6. Verify the scan tool Reverse Switch parameter 2. Monitor the ECM for DTCs with a scan tool. Ifother
is On. DTCs are set, except DTC P080A, referto
=>If the parameter is Off Diagnostic Trouble Code (DTC) List - Vehicle on
6.1. Disconnect the X3 harness connector at the page 6-69 for the applicable DTC that set.
K20 Engine Control Module. 3. With a scan tool, select Clutch Pedal Position
6.2. Test for less than 2 Q in the signal circuit end Learn under Module Setup in Manual
to end. Transmission, and perform the following
instructions displayed on the scan tool screen.
=>If2 Q or greater, repair the open/high resistance
in the circuit. Note: The CPP sensor learn procedure cannot be
performed more than once per ignition cycle. The clutch
=>Ifless than 2 Q, replace the K20 Engine Control pedal needs to be fully depressed and held steady
Module. throughout this procedure in order to performa correct
U If the parameter is On learning.
7. Test or replace the B16 Backup Lamp Switch. 4. The scan tool will display under CPP Learn Status:
Not Learned, In Process, Complete, Fail —Low
Component Testing Volt, Fail —High Volt, or Fail Moving. The scan tool
1. Ignition OFF, disconnect the harness connector at will display under CPP Learn Status Complete if
the B16 Backup Lamp Switch. the process was successful.
2. Test for less then 5 Q between the signal circuit 5. if the scan tool indicates that DTC P080A ran and
terminal 1 and the ground circuit terminal 2 at the passed this ignition the CPP sensor learn ‘
B16 Backup Lamp Switch. procedure is complete. Ifthe scan tool indicates
=>If 5 Q or greater DTC P080A failed or did not run this ignition,refer
to DTC P080A on page 17—560.if any other DTC is
Replace the B16 Backup Lamp Switch. set, refer to Diagnostic Trouble Code (DTC) List -
U If less than 5 Q Vehicle on page 6-69 for the applicable DTC.
3. All OK. 6. Turn OFF the ignition for 30 s after the learn
procedure has successfully completed in order to
store the CPP sensor variation values in ECM
history.
Symptoms - Manual Transmission
Complaint/Condition Possible Cause correction
Knockat LowSpeeds ' Worndriveaxlejoint - lnspectdriveaxlejointandreplaceit
~Wornside gearor piniongearbores necessary. 2.24
.,
._,
- lnspectdifferentialcase andreplaceit
necessary.
NoisyAroundTurns Worndifferentialgears lnspectdifferentialgearsandreplaceif
necessary.
Clunkor Accelerationor Deceleration - Looseenginemounts - Inspectenginemountsandtightenif
- Worninboarddriveaxlejoint necessary.
- Worndifferentialpinionshaft - Inspectinboarddriveaxlejointand
replaceif necessary.
- Wornside gearhubcounterbore

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Symptoms
ComplaintICondition
Click NoiseOn Turns
Noisyin NeutralWithEngineRunning
Noisyin FirstGearOnly
Noisyin SecondGear Only
Noisyin ThirdGearOnly
Noisyin FourthGearOnly
Noisyin FifthGearOnly
Noisyin ReverseOnly
NoisyinAll Gears
Slips OutofGear
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Manual Transmission
- Manual Transmission
Possible Cause
WornoutboarddriveaxleCN joint
Worninputgear bearing
Wornspeedgear bearing
Wornbearingraces
Worn,shipped,or scored1stspeed
constant—meshgears
Worn,shipped,or scored15t/2nd
synchronizer
Worn,chipped,or scored2ndspeed
constant—meshgears
Worn,chipped,or scored1st/2nd
synchronizer
Worn,chipped,or scored3rdspeed
constant—meshgears
Worn,chipped,or scored3rd/4th
synchronizer
Worn,chipped,or scored4thspeed
constant—meshgears
Worn,chipped,or scored3rd/4th
synchronizer
Worn,chipped,or scoredoutputgear
Worn,chipped,or scoredoutputgear
Worn,chipped,or scored5thspeed
constant—meshgears
Worn,chipped,or scored5th
synchronizer
Worn,chipped,or scoredoutputgear
Worn,chipped,or scoredreverse
speedconstant—mesh gears
Wornor damagedoutputgear
Fluidlevellow
Wornor damagedwheelbearings
Worn,chipped,or scoredinput/output
shaftgear
Wornoutputgear bearing
Looseshiftrailguidebolt
Worn,chipped,or scored1st,2nd,
3rd,4rd,5th,or Reversegears.
Loosetransaxlemounts
Bentorworncables
Brokenor looseinputgearbearing
retainer
Wornor bentshiftfork
Dirtyclutchhousingand engine
Stiffshiftleverseal
Manualtransaxleinternalshift
mechanismmalfunction
- M20/M32 (MR5, MZ4) 17-563
(cont'd)
correction
lnspectdifferentialpinionshaftand
replaceif necessary.
lnspectsidegearhubcounterbore
and replaceif necessary.
lnspectC/Vjointandreplaceif
necessary.
lnspectbearingandreplaceit
necessary.
lnspectbearingandreplaceif
necessary.
lnspectbearingraceandreplaceif
necessary.
lnspectgearsandreplaceif
necessary.
lnspectsynchronizerandreplaceif
necessary.
lnspectgearsandreplaceif
necessary.
lnspectsynchronizerandreplaceif
necessary.
lnspectgearsand replaceif
necessary.
lnspectsynchronizerandreplaceif
necessary.
lnspectgearsand replaceif
necessary.
lnspectsynchronizerandreplaceif
necessary.
lnspectgearandreplaceif necessary.
lnspectgearandreplaceif necessary.
lnspectgearsandreplaceif
necessary.
lnspectsynchronizerandreplaceif
necessary.
lnspectgearandreplaceitnecessary.
lnspectgearandreplaceif necessary.
lnspectgearandreplaceif necessary.
Add fluidtoproperlevel.
Inspectwheelbearingandreplaceif
necessary.
lnspectgearandreplaceif necessary.
lnspectoutputgearbearingand
replaceit necessary.
Tightenshiftrailguidebolt.
lnspectcomponentsandreplaceas
necessary.
Tightenor replacemounts.
lnspectcablesandreplaceif
necessary.
lnspectshiftforkandreplaceif
necessary.
lnspectshiftforkandreplaceif
necessary.
Clean clutchhousingandengine.
lnspectsealandreplaceif necessary.
Disassembletransaxle,repairas
necessary.
17-564 Manual Transmission - M20/M32 (MR5, MZ4)

Symptoms - Manual Transmission (cont'd)

Complainthondition
Slips Outof Gear WhileAccelerating
Slips OutofGear WhileCoasting
FluidLeakage
Possible Cause
Missingor misadjustedfirstgear
thrustbearingorwasher
Wornor damagedfistgearsplinelock
on 1st/2ndsynchronizer
Wornofdamagedsecondgearspline
lockon 1st/2ndsynchronizer
Wornor damagedthirdgearspline
lockon 3rd/4thsynchronizer
Wornor damagedfourthgearspline
lockon 3rd/4thsynchronizer
Wornor damaged5thgearsplinelock
on the5th/Reversesynchronizer
Wornor damagedReversegear
splinelockonthe5th/Reverse
synchronizer
Wornor damaged1st,2nd,3rd,4th,
5thor reversegearsplinelock
Manualtransaxleinternalshift
mechanismmalfunction
Damaged,worn,or missingshiftrails
Manualtransaxleinternalshift
mechanismmalfunction
Fluidlevelhigh
Damagedaxleshaftseals
Ventcap plugged
Poor sealingon shiftcover
Poorsealingbetweencase andclutch
housing
Poorsealingon rearcover
Poorsealingor looseback-uplamp
switch
Poorsealingor loosevehiclespeed
sensor
correction
lnspectbearingandwasherand
replaceit necessary.
lnspectsplinelockandreplaceif
necessary.
Inspectsplinelockandreplaceif
necessary.
Inspectsplinelockandreplaceif
necessary.
lnspectsplinelockandreplaceif
necessary.
Inspectsplinelockandreplaceif
necessary.
lnspectsplinelockandreplaceif
necessary.
lnspectsplinelockandreplaceif
necessary.
Disassembletransaxle,repairas
necessary.
Inspectshiftrailsandreplaceif
necessary.
Disassembletransaxle,repairas
necessary.
Drainexcessfluid.
lnspectaxleshaftseals andreplaceif
necessary.
Clearor replaceventcap.
Replacesealeron shiftcover.
Replacesealerbetweencase and
clutchhousingandtighten.
Replacesealanton rearcoverand
tighten.
Tightenswitchor replacesealantas
needed.
Tightensensoror replacesealantas
needed.

Transmission Shifts Hard rails. You should be able to feel the detent plungers
operating when coming out of a gear and going
Diagnostic Aids into a gear.
An intermittenthard shift may be caused by an 6. A dynamic shift test is performed by shifting into
intermittentclutch condition. the gear positions with the engine operating. Test
for the correct mesh of the synchronizers and for .2./4
..
Test Description the clutch releasing correctly. When shifting into
and out of a gear, feel for the shift detent plungers
The numbers below refer to the step numbers on the
and for the synchronizers sleeve for moving freely.
diagnostic table.
8. The transmission uses a synthetic transmission
3. A static shift test is performed by shifting into all of
fluid that allows proper synchronizer operation.
the gear positions with the engine not operating.
The incorrect fluid may cause hard shifting by
While performing the test one should note how the
varnish buiId—up, or not enough lubrication for
shift lever movement is felt. Also while shifting from
proper synchronizer operation.
one gear to the other feel for binding in the shift
Transmission Shifts Hard
Step Action I Yes No “\‘M
2.
.,..
\m
‘._M
DEFINITION:The transmissiondoes notshiftsmoothly,orwithoutdifficulty,fromonegeartotheother.
Didyou reviewtheSymptoms—ManualTransmissionon Go to Symptoms-
1 page 17-562and performthenecessaryinspections? ManualTransmission
Go to Step2 onpage 17—562

AflA
~
‘24.
»2-“
2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Manual Transmission - M20/M32 (MR5, MZ4) 17-565

Transmission Shifts Hard (cont'd)

Step Action Yes No
inspecttheclutchsystemforproperoperation.Referto Clutch
2 SystemDescriptionand Operationonpage 17—425.
Didyoufindor repairthecondition? Go to Step 12 Go to Step3
1. Performa staticshiftteston thetransmission.
2. Testforthefollowing:
- Blockagepreventingfullshiftlevermovement
- Excessivemovementin theshiftlever
3 - Bindingin theshiftlever
- Detentplungersor shiftrails binding
- Shiftcablebinding
- Shiftcableproperadjustment
Are youabletoshiftintoall gears? Go to Step6 Go to Step4
1. Removethefloorconsole.Referto FrontFloorConsole
Replacementonpage 2-61.
2. Inspectforthefollowing:
4 - Loosemounting
- Foreigndebris
Didyoufindandrepairthecondition? Go to Step12 Go to Step5
Inspectforpropershiftcableadjustment.Referto Manual
TransmissionShiftLeverand SelectorLeverCableAdjustmenton
5 page 17—574.
Didyoufindandrepairthecondition? Go to Step12 Go to Step 6
1. Performa dynamicshiftteston thetransmission.
2. Testforthefollowing:
- Detentplungersor shiftrails binding
6 - Synchronizersleeve binding
- Gear clashintoonlyonegear
° Gear clashintoall gears
Didthetransmissionshifthardintoall gears? Go to Step7 Go to Step11
Inspectthetransmissionforthecorrectfluidlevelandtypeof the
transmissionfluid.Referto TransmissionFluidDrainandH” on
7 page 17-567.
is thetransmissionat thecorrectlevelandtheproperfluid
beingused? Go to Step9 Go to Step8
Drainandrefillthetransmissionwiththecorrecttypefluid.Referto
8 TransmissionFluidDrainandFill onpage 17-567.
Didyoufindandrepairthecondition? Go to Step12 Go to Step9
1. Removethetransmission.Referto TransmissionReplacement
onpage 17-586.
9 2. Inspecttheclutchpressureplateand/orclutchdrivenplate.
Istheclutchpressureplateand/orclutchdrivenplatewornorfaulty? Go to Step 10 Go to Step11
Replacetheclutchassembly.Referto ClutchPressureandDriven
PlateReplacement(1.4L)onpage 17—41 6 or ClutchPressureand
10 DrivenPlateReplacement(1.8L)onpage 17-419.
Didyoufindandrepairthecondition? Go to Step 12 . Go to Step11
ReplacetheTransmission.Referto TransmissionReplacementon
11 page 17—586.
Didyoufindandrepairthecondition? Go to Step12 Go to DiagnosticAids
12 Operatethesystemin ordertoverifytherepair. '
Didyoucorrectthecondition? SystemOK Go to Step1

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
17-566 Manual Transmission - M20lM32 (MR5, MZ4)

Transmission Gear Clash When 7. A static shift test is performed by shifting into all of
the gear positions with the engine not operating.
Shifting Gears While performing the test, you should note how the
shift lever movement is felt. Also, while shifting
Diagnostic Aids from one gear to another, feel for binding in the
Gear clashing may be caused by shifting at too high of shift rails. You should be able to feel the detent
an engine RPM or by rushing the shift. Ifgear clashing plungers operating when coming out of a gear and
is occurring in more than one gear, the clutch may not going into a gear. Excessive play in the gear shift
be releasing properly for proper synchronizer operation. lever may prevent the shift forks from fully
engaging the synchronizer.
Test Description . A dynamic shift test is performed by shifting into all
The numbers below refer to the step numbers on the of the gear positions with the engine operating.
diagnostic table. Test for the correct mesh of the synchronizers, and
2. This step tests for the proper releasing of the for the clutch releasing correctly. Move the shift
clutch. Ifthe clutch reserve is not proper, the lever and feel for the synchronizer sleeve to just
mainshaft gears may still be turning causing the release from the gear, then let up on the clutch
gear clashing. pedal. Depress the clutch pedal and move the shift
lever to engage that gear again. Ifit shifts back into
5. This step inspects for the proper transaxle fluid.
the gear without clashing, the clutch is releasing
A special fluid is required for the correct lubrication
correctly and the synchronizer is working.
of the synchronizers.
Ifclashing occurs, test on another gear. Ifall gears
clash, the clutch is not releasing correctly.

Transmission Gear Clash When Shifting Gears

Step Action I Yes No
DEFlNlTION:Noisefromthetransaxlewhenshiftinggears.A grindingor gratingsound,whenthesynchronizersleeveis
engagingwiththeselectorteethonthespeedgear.A suspectedinternaltransaxlecondition,if thenoiseonlyoccursin one gear.
DidyoureviewtheSymptoms-ManualTransmissionon Go to Symptoms-
1 page 17-562andperformthenecessaryinspections? ManualTransmission
Go to Step2 onpage 17-562
2 Withtheengineoperating,doesthetransaxleshiftfromneutralto
anygear,withoutthevehiclelurchingor gearclashing? Go to Step5 Go to Step3
Inspectforproperclutchoperation.Referto ClutchSystem
3 DescriptionandOperationonpage 17-425.
Doestheclutchoperateproperly? G0 to Step5 Go to Step4
Repairtheclutchsystem.Referto Symptoms-Clutchon ‘
4 page 17-401.
Didyoufindandrepairthecondition? Go to Step 11 Go to Step5
lnspectforthecorrecttransaxlefluidlevelandtheproperfluid.
5 Referto TransmissionFluidDrainandFill onpage 17-567.
Isthetransaxlefluidlevelcorrectandattheproperlevel? Go to Step7 Go to Step6
Fill thetransaxleto thecorrectlevel,or changethetransaxlefluidif
6 it is notthecorrecttype.
Doesthetransaxlestillhavegearclash? Go to Step7 Go to Step 11
1. Performa staticshifttestonthetransaxle.
2. Testforthefollowing:
- Blockagepreventingfullshiftlevermovement
' Excessivemovementin theshiftlever
7 - Bindingin theshiftlever
- Detentplungersor shiftrailsbinding
- Shiftcablebinding
- Shiftcableproperadjustment
Didthetransaxleshiftsmoothlyintothegearthatis clashing? Go to Step10 Go to Step8
Removethefloorconsole.Referto FrontFloorConsole
Replacementonpage2—61 .
Inspectforthefollowing:
- Loosemounting
' Foreigndebris
Didyoufindandrepairthecondition? Go to Step12 Go to Step10

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
 Manual Transmission - M20lM32 (MR5, MZ4) 17-567

Transmission Gear Clash When Shifting Gears (cont'd)

Step Action Yes No
. lnspectfor propershiftcableadjustment.Referto Manual
TransmissionShiftLeverandSelectorLeverCableAdjustmenton
9 page 17-574.
Didyoufindandrepairthecondition? Go to Step12 Go to Step 10
1. Performa dynamicshifttestonthetransaxle.
2. Testforthefollowing:
- Detentplungersor shiftrailsbinding
10
- Synchronizersleeve binding
Go to Transmission
- Gear clashingin morethanthesuspectedgear ShiftsHardon
Isthetransaxlehardtoshiftintoall gears? page 17-564 Go to Step 11
ReplacethetransmissionReferto TransmissionReplacementon
11 ' page 17-586.
Didyoureplacethetransmission? Go to Step12 Go to DiagnosticAids
Operatethesystemandverifytherepair.
12 Didyoucorrectthecondition? SystemOK Go to Step 1

Repair Instructions - On Vehiele

Transmission Fluid Drain and Fill

Draining Procedure
Note:
- The fluid check bolt at the front of the transmission
may not be opened.
- The transmission fluid drained out during the
pre-delivery inspection may be re-used. New
transmission fluid must be used during
servicing work.
The transmission fluid must be brought up to
operating temperature before draining.
1. Raise and support the vehicle. Refer to Lifting and
Jacking the Vehicle on page 1-31.
2. Remove the drivetrain and front suspension frame
skid plate, if equipped. Refer to Drivetrain and 2020402
Front Suspension Frame Skid Plate Replacement
on page 3—143. 3. Clean away all dirt and debris from the
transmission fluid drain fastener area.
4. Position an appropriate container under the
transmission.
5. Remove the transmission fluid drain fastener (1).
6. Allow the transmission fluid to drain into the
container. 4
Caution: Refer to Fastener Caution on page 0—8.
7. Install a new transmission fluid drain fastener and
tighten to 20 N-m(15 lb ft).
8. Remove the container used to catch the used
transmission fluid from under the vehicle.
9. Install the drivetrain and front suspension frame
skid plate, if equipped. Refer to Drivetrain and
Front Suspension Frame Skid Plate Replacement
on page 3-143.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
17-568 Manual Transmission - M20lM32 (MR5, MZ4)

Filling Procedure . 1- Lower the vehicle.

2. Remove the engine control module with the
bracket from the battery tray. Refer to Engine
Control Module Replacement on page 9-242 for
the 1.2L or 1.4L engine, or Engine Control Module
Replacement on page 9-531 for the 1.6L or 1.8L
engine.
Clean away all dirt and debris from the
transmission fluid fill fastener area.
Remove the transmission fluid fill fastener (1).
Fill the transmission with the appropriate amount of
fluid. Refer to Fluid and Lubricant
Recommendations on page 1-35 and Manual
Transmission Specifications on page 17—539.
install a new transmission fluid fill fastener and
tighten to 30 Nm (22 lb ft).
Install the engine control module with the bracket
to the battery tray. Refer to Engine Control Module
Replacement on page 9-242 for the 1.2L or 1.4L
engine, or Engine Control Module Replacement on
page 9-531 for the 1.6L or 1.8L engine.

2020403

Transmission Control Lever Boot Replacement

“I \ --\

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(US/Canada)
-Sonic
2013 (5377994)
Manual
Sen/ice
 Manual Transmission - M20lM32 (MR5, MZ4) 17-569

Transmission
Control Lever Boot Replacement
Callout Component Name
Preliminary Procedure
Removethefrontfloorconsole.Referto FrontFloorConsoleReplacementonpage2—61
.
ShiftControlLeverKnobCover
1 Procedure
Usinga flat—bladedtool,removetheshiftknobcover.
Fastener
ShiftControlLeverKnobandBootAssembly

Manual Transmission Shift Lever and

Selector Lever Cable Replacement
Removal Procedure
1. Remove the battery tray. Refer to Batteiy Tray
Replacement on page 9-721.

\ '5 f(éfgL-Q I
f' ‘ i=1)?
‘5

2510324
l 6. Move the floor carpet in order to get access to the
5 @ shift lever and selector lever cable grommet (1).
7. Remove the grommet fasteners (2).

2551785
2. Disconnect the shift lever and selector lever cable
end (1) from the transmission shift lever and
selector lever.
3. Pull the cable retainers (2) to release the shift lever
and selector lever cable from the shift lever and
selector lever cable bracket.
4. Disconnect the shift lever and selector lever cable
from the shift lever and selector lever cable
bracket.
5. Remove the floor console. Refer to Front Floor
Console Replacement on page 2—61.

2505111
8. Lift both cable adjustment retainers (1), one for
each cable, to release the shift lever and selector
lever cable.

2013
-Sonic
(US/Canada)
Service
Manual
(5377994)
17-570 Manual Transmission - M20lM32 (MR5, MZ4)
3. Connect the shift lever and the selector lever cable
ends (1)to the transmission shift lever and the
selector lever.
4. Install the shift lever and the selector lever cable to
the shift lever and the selector lever cable bracket.

2504879
9. Pull the shift lever and the selector lever cable
retainers (1) from the transmission control
assembly (3), then remove the shift lever and
selector lever cable from the shift and selector
control.
2510324
10. Pull the shift lever and the selector lever cable
assembly through the cowl into the passenger 5. Move the floor carpet in order to get access to the
compartment. shift lever and selector lever cable grommet (1).
11. Remove the shift lever and the selector lever cable Caution: Refer to Fastener Caution on page 0—8.
assembly from the vehicle. 6. Install the grommet fasteners (2) and tighten to
Installation Procedure 9N-m (80 lb in).
1. Position the shift lever and the selector lever cable
assembly in the vehicle.
2. Gently pull the shift lever and the selector lever
cable assembly through the cowl into the engine
compartment.

’ .‘
W\

2504879
7. Connect the shift lever and selector lever cables to
the shift and selector control adjusters (2).
8. Install the shift lever and selector lever cable
retainers (1) to the transmission control (3).
2551785

(US/Canada)
-Sonic
2013 (5377994)
Manual
Sen/i'ce