1999-2007 Chevrolet Silverado DTC P0446 (Restricted/ Blocked Evap Vent Path) Set, Check Engine Light On

1999-2007 Chevrolet Silverado DTC P0446 (Restricted/ Blocked Evap Vent Path) Set, Check Engine Light On

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Subject: DTC P0446 (Restricted/Blocked EVAP Vent Path) Set, Check Engine Light On (Replace Evaporative Emission (EVAP) Vent Valve Solenoid Assembly and Add/Relocate Filter Box Using Service Kit) Condition Some customers whose vehicles are operated in dusty type environments, such as farming or mining off-road type applications, may comment about the illumination of the check engine light, with a DTC of P0446 (Restricted/Blocked EVAP Vent Path) being set. 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector, if equipped. 3. Disengage the two vent valve pipe clips securing the pipe to the underbody.

Remove the clips from the underbody and discard. 4. Disconnect the vent valve pipe at the EVAP canister. 5. Remove and retain the EVAP canister vent valve bracket mounting bolt. 6. Remove the complete EVAP canister vent valve assembly with bracket attached and discard. Important: The new canister vent valve will be installed in a new location, outside of the frame. 7. Position and secure the new valve assembly to the frame bracket on the outside of the frame using the existing hole and mounting bolt. Tighten Tighten the bracket mounting bolt to 12 N m (106 lb in). Connect the vent valve pipe to the EVAP canister. Install the two vent valve pipe clips into the existing underbody holes.

Connect the EVAP canister vent valve electrical connector, if equipped. Attach bulk 5/8″ heater hose to the vent valve port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 12. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 8. 9. 10. 11. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch- points and heat sources. 17. Lower the vehicle. 2004-2007 Model Year (Use Service Kit P/N 19152349) Raise the vehicle. Suitably support the vehicle. Disconnect the EVAP canister vent valve electrical connector. Disconnect the canister pipe from the vent valve. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. Discard the old valve. 5. Cut back the existing canister pipe approximately 51 mm (2 in) to remove the quick connect end. 1. 2. 3. 4. Crew Cab Short Box Shown Below, Other Configurations Similar

1999-2002 Chevrolet Silverado Front Wheel Speed Sensor Corrosion

1999-2002 Chevrolet Silverado Front Wheel Speed Sensor Corrosion

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Service Procedure The following procedure provides instructions for repairing a corrosion condition where the front wheel speed sensor mounts on the front wheel bearing assembly. 1. Raise the vehicle on a suitable hoist and support as necessary. 2. Remove both front tires and wheels. 3. Compress the front brake caliper pistons. 3.1. Install a large C-clamp over the top of the caliper housing and against the back of the outboard pad. 3.2. Slowly tighten the C-clamp until the pistons are pushed completely into the caliper bores. 3.3. Remove the C-clamp from the caliper. Important: It is not necessary to remove the front brake caliper from the bracket when removing the bracket in the next step. 4. Remove the two bolts that attach the front brake caliper mounting brackets to the knuckle. Notice: Support the brake caliper with heavy mechanic’s wire, or equivalent, whenever it is separated from its mount, and the hydraulic flexible brake hose is still connected.

Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak. 5. Remove the brake caliper and bracket as an assembly and support it with heavy mechanic’s wire or equivalent. DO NOT disconnect the hydraulic brake flexible hose from the caliper. 6. Mark the relationship of the rotor to the bearing hub. 7. If equipped, remove the rotor retaining push nuts from the wheel studs 8. Remove the rotor. 9. Remove the bolt (1) that attaches the wheel speed sensor to the bearing hub. Notice: Carefully remove the sensor by pulling it straight out of the bore. DO NOT use a screwdriver or other device to try to pry the sensor out of the bore. Prying will cause the sensor body to break off in the bore. 10.Remove the wheel speed sensor from the bearing hub assembly. Important: The mounting surface on the sensor must be flat in the next step in order to be mounted correctly on the bearing hub assembly. If the mounting surface on the sensor is warped or bent, the sensor must be replaced.

11.Inspect to see if the mounting surface on the sensor is flat. Check the mounting surface on the sensor head for flatness by placing it on the edge of a metal machinist’s scale or other suitable straight edge to measure the flatness. Check the sensor for flatness in multiple positions/directions (minimum 3). • If the sensor mounting surface is NOT flat (1), the sensor must be replaced. Proceed to the next step and replace the sensor. • If the sensor mounting surface IS flat (2), the sensor IS to be reused. Proceed to Step 16. 12.Remove the wheel speed harness mounting clips from the knuckle (4) upper control arm (3) and frame (2). 13.Disconnect the wheel speed harness electrical connector (1) from the vehicle wiring harness. 14.Connect the new wheel speed sensor harness electrical connector to the vehicle wiring harness. 15.Attach the wheel speed sensor harness to the frame, upper control arm, and the knuckle. 16.Temporarily plug the wheel speed sensor hole (1) in the bearing hub to prevent debris from entering it when you clean it. Important: All rust and corrosion must be removed from the wheel speed sensor mounting surfaces on the bearing hub in the next step. 17.Using a wire brush, sandpaper, emery cloth, scotch brite, or equivalent, thoroughly clean the wheel speed sensor mounting surface (2) on the bearing hub to remove any rust or corrosion.

2007-2009 Chevrolet Impala Key Cannot Be Removed from Ignition with Gear Selector in Park

 2007-2009 Chevrolet Impala Key Cannot Be Removed from Ignition with Gear Selector in Park

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Subject: EI08045 – Key Cannot Be Removed from Ignition with Gear Selector in Park, Shifter Cannot Be Moved from Park Position (Repair/Reroute Brake Transmission Shift Interlock (BTSI) Solenoid Harness) Condition Some customers may comment on either of the following conditions: – The key cannot be removed from the ignition. – The transmission gear selector (shifter) cannot be moved out of the PARK position. Cause This condition may be caused by an incorrectly routed brake transmission shift interlock (BTSI) solenoid harness which can make it difficult to install. In some instances, the wiring looms are tangled, causing stress on the wires in the connector at the BTSI.

If the BTSI harness is routed incorrectly, it may also result in a wire pinching issue. Correction Important DO NOT use force to move the gear selector (shifter). Using force may cause damage to the BTSI. Inspection/Routing and Repair of the BTSI Wiring Harness/Connector 1. Check for wire damage at the BTSI connector terminal ends. Refer to SI for repair procedures. 2. For very intermittent issues, check the BTSI wire harness individual circuits for broken or crimped wires. Refer to SI for repair procedures. BTSI Wiring Harness Incorrectly Routed 3. Inspect the routing of the wiring harness leading to the BTSI connector. The illustrations above show the BTSI harness routed incorrectly. BTSI Wiring Harness Routed Correctly 4. Reroute the wiring to create available slack and avoid future occurrences.

2001-2003 Chevrolet Silverado Ignition Distributor System Corrosion – Inspect / Replace

2001-2003 Chevrolet Silverado Ignition Distributor System Corrosion – Inspect / Replace

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Recall involving certain 2001-03 Chevrolet Silverado and GMC Sierra model vehicles, equipped with a 4.3L V6 (RPO L35 – VIN W or RPO LU3 – VIN X) engine. The ignition distributor cap and rotor in these vehicles may corrode and cause ignition system failure. This condition may result in rough engine idle, misfire, stalls, engine cranks but does not run and/or illumination of the Malfunction Indicator Lamp (MIL). Service Procedure 1. Raise the engine hood and inspect the ignition distributor ventilation holes, located in the base of the distributor, to see if the External Ignition Protection (EIP) screens are present. 2. If the EIP vent screens are present: • Remove the vent EIP screens using the procedure listed in Step 3.

• Refer to the appropriate procedure in the Engine Controls sub-section of the applicable Service Manual and replace the distributor cap and rotor. 3. Remove the vent screens (1), located in the base of the distributor, by inserting a plastic- handled, long blade awl or pick (2) into each of the two airflow vent holes and popping out the screen. If there are no EIP vent screens in the airflow vent holes, check the vent holes for debris and clear as necessary before reassembling the distributor. 4. If the EIP vent screens are not present, the distributor cap and rotor do not require replacement. 5. Install the foam sleeve, P/N 15190971, around the section of the A/C accumulator line that is routed directly above the distributor. Cut a slit in the sleeve and secure it to the line using tie- straps. Do not install a new foam sleeve if a sleeve is already in place on the A/C accumulator line. 6. 2001-03 CALIFORNIA, 2003 MASSACHUSETTS & MAINE VEHICLES ONLY : Install a Recall Identification Label. Also, for California vehicles, complete a “Proof Of Correction” certificate upon recall completion.

1994 Chevrolet Corvette How to Remove and Install Distributor

1994 Chevrolet Corvette How to Remove and Install Distributor

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See Figures 1, 2, 3, 4 and 5 1. For 1995-96 vehicles, inspect the distributor ventilation system for proper ventilation. 2. Be sure the ignition is in the OFF or LOCK position. Disconnect the negative battery cable. 3. Detach the Intake Air Temperature (IAT) electrical connector. 4. Remove the air intake duct. Fig. Fig. 1: Unfasten the retainers, then remove the air intake duct 5. Remove the accessory drive belt, as outlined in General Information & Maintenance of this repair guide. 6. Drain the engine cooling system into a suitable container.
7. Disconnect the water pump coolant hoses, and allow any remaining coolant to drain. 8. Detach the Engine Coolant Temperature (ECT) sensor electrical connector. Fig. Fig. 2: Unplug the electrical connector from the ECT sensor 9. Remove the water pump and crankshaft balancer, as outlined in Engine & Engine Overhaul of this repair guide. Fig. Fig. 3: The water pump must be removed for access to the distributor Fig. Fig. 4: You must also remove the crankshaft torsional damper, also known as the balancer

10. Remove the drive belt tensioner. The spark plug wire boots should be twisted1/2turn in each direction while removing. Do not pull on the wires to remove them from the spark plugs. Pull on the boots or use a tool specifically designed for this purpose. 11. Label and disconnect the spark plug wires/harness from the distributor. 12. Unplug the 4-terminal ECM/PCM electrical connector from the distributor. 13. If equipped, disconnect the distributor vacuum harness from the distributor. 14. Loosen and remove the distributor attaching bolts. 15. Pull the distributor assembly forward until the driveshaft disengages from the end of the camshaft. Fig. Fig. 5: Exploded view of the distributor mounting-5.7L (VIN P and 5) engines
16. Mark the top surface of the driveshaft for proper alignment during installation. To install: Replace the O-rings on the coupling shaft or ignition system performance may suffer. Lubricate the O-rings and the end of the camshaft. WARNING Don’t try to fully seat the distributor using the distributor retainers. If the distributor will not seat by hand, it’s not properly aligned with the camshaft. Rotate the crankshaft until the engine is at the number 1 cylinder TDC (camshaft sprocket pin at the 9 o’clock position). Rotate the distributor coupling until the camshaft sprocket pin slot aligns with the distributor base timing mark. Install the distributor using hand pressure to fully seat the distributor.

17. Install the distributor assembly into position with the driveshaft in the end of the camshaft. Rotate the distributor coupling until the camshaft sprocket pin slot aligns with the camshaft sprocket pin. Slide the distributor onto the end of the camshaft until fully seated on the engine front cover. 18. Install the distributor mounting bolts. Tighten to 8-9 ft. lbs. (11-12 Nm). 19. Attach the 4-pin ECM/PCM connector. 20. If equipped, attach the distributor vacuum harness to the distributor. 21. Connect the spark plug wires to the distributor, as tagged during removal. 22. Install the drive belt tensioner. 23. Install the crankshaft balancer and water pump, as outlined in Engine & Engine Overhaul of this repair guide. 24. Attach the ECT sensor connector. 25. Refill the cooling system with the proper type and amount of coolant. 26. Install the accessory drive belt. 27. Install the air intake duct and attach the IAT sensor electrical connector. 28. Connect the negative battery cable.

2000 Chevrolet Cavalier How to Remove and Install Headlight

2000 Chevrolet Cavalier How to Remove and Install Headlight

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This 2000 Chevrolet Cavalier headlight was removed as an assembly. First the upper radiator shield had to be removed. I used tack puller to pry up on thecenter of the clip, then I pried up on the outer ring of the clip. View of retainer clips with center up. To reuse the clips, push the base in first, then push in the center pin to lock the retainer in place. These clips are used all over the average car, to hold various plastic panels in place. I removed the upper radiator cover and placed it on top of the engine. View of the clip attaching the park lamp to the headlight assembly. The park lamp assembly needs to be removed before the headlight assembly can be removed for the bulb to be changed.

To remove the parking lamp, I used a large screwdriver to pry against the headlight adjuster, applying pressure on the clip to release it. (This photo is looking almost straight down… the parking lamp is at the bottom of the picture.) The green arrows show where thealignment studs go when the parking lamp assembly is replaced on the car. Removing The Park Lamp Bulb: I pressed in on the lever-type clip on the socket (green arrow) and turned the socket. I removed the bulb by pulling it straight out. The park lamp bulb is # 3157 clear. View of area with park lamp assembly removed. Removing The Headlight Assembly: I used a 13mm socket to remove the headlamp housing bolt on the left side (green circle).

Then I removed the bolt on the right. (green circle). View of special headlight mounting bolts. I lifted up on mounting panel (the black plastic piece behind the headlight) to detach the studs on the mounting panel from the metal core support. The green arrows show the hole and the plastic stud that goes in it. Using a flat screwdriver I pried up the clip on the wire connector to the headlight bulb. Then I pulled the wiring connector out of the back of the headlight bulb. To remove the number 6004 headlight bulb I turned the outer retainer (green arrow) counterclockwise. Then I just pulled out the plastic bulb-holder and replaced the head light bulb. Caution: Avoid touching the new light bulb with your bare hands… the oil from your skin can damage the light bulb and cause it to burn out early. Use a tissue or paper towel to handle the new bulb. View of metal core support area. The green arrows show the holes that the lower studs of headlight housing go into.

1996 Chevrolet Chevy C Pickup Fuel System Diagnosis (System Check)

1996 Chevrolet Chevy C Pickup Fuel System Diagnosis (System Check)

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Circuit Description When you turn ON the ignition switch, the Vehicle Control Module (VCM) turns ON the in-tank fuel pump. The pump remains ON as long as the engine is cranking or running and the VCM is receiving reference pulses. If there are no reference pulses, the VCM shuts the fuel pump OFF within 2 seconds after the ignition was switched to the ON position or if the engine stops. The VCM will also turn ON the fuel pump for 2 seconds when the ignition is turned to the OFF position.

An electric fuel pump pumps the fuel through an in-line filter to the Central SFI unit. The pump is attached to the fuel level meter assembly inside of the fuel tank. The pump is designed to provide fuel pressure above what is needed by the fuel injectors. The pressure regulator keeps the fuel available to the injectors at a regulated pressure. Unused fuel is returned to the fuel tank by the fuel return pipe. Diagnostic Aids Tools Required • J 34730-1A Fuel Pressure Gage in J 34730-E or • J 34730-1A Fuel Pressure Gage with J 34730-250 Fuel Pressure Adapter Kit. Test Description The numbers below refer to the step numbers on the diagnostic table. 2. Wrap a shop towel around the fuel pressure connection to absorb any small amount of fuel leakage that may occur when installing the fuel pressure gauge. Turn ON the ignition, the fuel pressure should be 415-455 kPa (60-66 psi) for the Central SFI and 385-430 kPa (56-62 psi) for the SFI. This pressure is controlled by a spring pressure within the regulator assembly. 4. The fuel pressure that continues to fall is caused by one of the following items:

• The in-tank fuel pump check valve not holding. • A partially disconnected fuel pulse dampener (pulsator). • The fuel pressure regulator valve leaking. • A central SFI injector and poppet valve leaking. • An SFI injector is leaking 5. When the engine is idling, the manifold pressure is low (high vacuum) and is applied to the fuel pressure regulator diaphragm. This will offset the spring and result in a lower fuel pressure. This idle pressure will very somewhat depending on the barometric pressure; however, the pressure idling should be less indicating the pressure regulator control. 16.The fuel pressure less than 415 kPa (60 psi) for Central SFI or 385 kPa (56 psi) for SFI, falls into the following 3 areas: • A regulated pressure but less than 415 kPa (60 psi) for Central SFI or 385 kPa (56 psi) for SFI. Amount of fuel to injector OK, but pressure is too low. System will run lean and may set a DTC. Also, hard starting cold and overall poor performance or may not start at all. Refer to Engine Cranks but Does Not Run • A restricted flow causing pressure drop — Normally, a vehicle with a fuel pressure of less than 300 kPa (44 psi) at idle is undrivable. However, if the pressure drop occurs only while driving, the engine will normally surge then stop running as the pressure begins to drop rapidly. This is most likely caused by a restricted fuel line or plugged filter. • A leaking or contaminated pressure regulator valve or seat interface may not allow the regulated pressure to be achieved. Refer to . 22.Notice: DO NOT allow the fuel pressure to exceed 517 kPa (75 psi). Excessive pressure may damage the fuel system. Restricting the fuel return line allows the fuel pressure to build above regulated pressure. With the battery voltage applied to the fuel pump test terminal, the pressure should rise above 455 kPa (66 psi) for Central SFI 430 kPa (62 psi) for SFI, as the valve in the return line is partially closed.

2007 Chevrolet Impala 4T65E Transmission 1-2 Shift Shudder at Light to Moderate Acceleration

2007 Chevrolet Impala 4T65E Transmission 1-2 Shift Shudder at Light to Moderate Acceleration

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Some customers may comment on a 1-2 shift shudder at light to moderate acceleration. Typically, the throttle plate angle parameter is 12-20% at time of condition with vehicle speed of approximately 24-40 km/h (15-25 mph). The customer may describe the condition as slip or delayed shift into second. Correction Replace the complete second clutch assembly with service kit, P/N 24240561. Refer to the GM Unit Repair Service Manual for the year and model of the vehicle being serviced for the 2nd Clutch service procedure. This service kit contains: Second Clutch Housing Fluid Seal Rings (613), a Second Clutch Assembly (617), a Case Cover (Channel Plate) Upper Gasket (430), and a Case Cover (Channel Plate) Lower Gasket (429).

In addition to the content of this service kit, other gaskets not included in this service kit will also be needed to complete the repair – a Case Cover Lower Gasket (429), and a Case Cover Upper Gasket (430). These gaskets can be obtained by ordering gasket kit 24206391. Be sure to use ONLY the Second Clutch Assembly and Second Clutch Housing Fluid Seal Rings provided in this service kit. DISCARD the Second Clutch Assembly and Second Clutch Housing Fluid Seal Rings removed from the transmission being serviced.

Disassemble ONLY the Oil Pump Assembly from the Case Cover (Complete). DO NOT disassemble the Control Valve Body from the Case Cover. Remove ONLY the Case Cover-to-Case bolts to remove the Case Cover and Valve Body from Transmission Case AS AN ASSEMBLY . To access all Case Cover-to-Case bolts, it is necessary to remove the Pressure Control Solenoid Valve Assembly (322), and 1-2 & 3-4 Shift Solenoid Valve

1996 Chevrolet Chevy C Pickup Fuel System Diagnosis (System Check)

1996 Chevrolet Chevy C Pickup Fuel System Diagnosis (System Check)

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Circuit Description When you turn ON the ignition switch, the Vehicle Control Module (VCM) turns ON the in-tank fuel pump. The pump remains ON as long as the engine is cranking or running and the VCM is receiving reference pulses. If there are no reference pulses, the VCM shuts the fuel pump OFF within 2 seconds after the ignition was switched to the ON position or if the engine stops. The VCM will also turn ON the fuel pump for 2 seconds when the ignition is turned to the OFF position.

An electric fuel pump pumps the fuel through an in-line filter to the Central SFI unit. The pump is attached to the fuel level meter assembly inside of the fuel tank. The pump is designed to provide fuel pressure above what is needed by the fuel injectors. The pressure regulator keeps the fuel available to the injectors at a regulated pressure. Unused fuel is returned to the fuel tank by the fuel return pipe. Diagnostic Aids Tools Required • J 34730-1A Fuel Pressure Gage in J 34730-E or • J 34730-1A Fuel Pressure Gage with J 34730-250 Fuel Pressure Adapter Kit. Test Description The numbers below refer to the step numbers on the diagnostic table. 2. Wrap a shop towel around the fuel pressure connection to absorb any small amount of fuel leakage that may occur when installing the fuel pressure gauge. Turn ON the ignition, the fuel pressure should be 415-455 kPa (60-66 psi) for the Central SFI and 385-430 kPa (56-62 psi) for the SFI. This pressure is controlled by a spring pressure within the regulator assembly. 4. The fuel pressure that continues to fall is caused by one of the following items:

• The in-tank fuel pump check valve not holding. • A partially disconnected fuel pulse dampener (pulsator). • The fuel pressure regulator valve leaking. • A central SFI injector and poppet valve leaking. • An SFI injector is leaking 5. When the engine is idling, the manifold pressure is low (high vacuum) and is applied to the fuel pressure regulator diaphragm. This will offset the spring and result in a lower fuel pressure. This idle pressure will very somewhat depending on the barometric pressure; however, the pressure idling should be less indicating the pressure regulator control. 16.The fuel pressure less than 415 kPa (60 psi) for Central SFI or 385 kPa (56 psi) for SFI, falls into the following 3 areas: • A regulated pressure but less than 415 kPa (60 psi) for Central SFI or 385 kPa (56 psi) for SFI. Amount of fuel to injector OK, but pressure is too low. System will run lean and may set a DTC. Also, hard starting cold and overall poor performance or may not start at all. Refer to Engine Cranks but Does Not Run • A restricted flow causing pressure drop — Normally, a vehicle with a fuel pressure of less than 300 kPa (44 psi) at idle is undrivable. However, if the pressure drop occurs only while driving, the engine will normally surge then stop running as the pressure begins to drop rapidly. This is most likely caused by a restricted fuel line or plugged filter. • A leaking or contaminated pressure regulator valve or seat interface may not allow the regulated pressure to be achieved. Refer to . 22.Notice: DO NOT allow the fuel pressure to exceed 517 kPa (75 psi). Excessive pressure may damage the fuel system. Restricting the fuel return line allows the fuel pressure to build above regulated pressure. With the battery voltage applied to the fuel pump test terminal, the pressure should rise above 455 kPa (66 psi) for Central SFI 430 kPa (62 psi) for SFI, as the valve in the return line is partially closed.

2005 Chevrolet Chevy K Silverado Adjustment – Instrument Panel Cluster Gauge Needle Function

2005 Chevrolet Chevy K Silverado Adjustment – Instrument Panel Cluster Gauge Needle Function

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Important: There are pre-programming instructions for 2003 model year instrument panel clusters (IPC). In order for the engine hours to set to their current value when the IPC is replaced, carefully read and follow the instructions below. This information is applicable for 2003 model year IPCs only. An add time of 0.1 for the pre-programming requirement is published in the Claim section of the bulletin. 2003 Model Year Instrument Panel Cluster (IPC) Pre-Programming Instructions 1. Install the IPC. Ensure everything is connected properly. The replacement IPC requires SPS Programming and IPC Setup procedures to be performed. It does not matter which procedure is performed first. 2. Start the engine and then select IPC Setup. You must have the engine running before performing the IPC Setup. 3. Select IPC Setup. With the engine running, enter the appropriate mileage and engine hours.

4. Select “OK”. Review the pop up asking you to verify the mileage and engine hours. Move the pop up out of the way if necessary to view the verification screen. This may require a click and drag of the dialog box. 5. Verify that the mileage and engine hours are correct and select “OK”. DO NOT turn the ignition OFF until the engine has “run” for approximately seven (7) minutes. Allowing the engine to idle for this period of time allows the IPC to accumulate 1/10th of an hour and write the correct engine hour value to the permanent memory. The engine must be running before set up is performed and run for approximately seven minutes after the user selects “OK” confirming their mileage/engine hour inputs. After approximately seven minutes, shut the engine OFF and complete the event. The seven minute clock starts after you select “OK”, confirming the entries. Note: Based on feedback from technicians, we are currently making changes to the “IPC Setup” application which will include several enhancements to the set up screens. These are scheduled to be released and available in TIS2WEB very soon. Important: Only IPC conditions listed in the Condition section of the bulletin are covered under this special coverage program. In a small number of vehicles, the condition may be intermittent and the gauge sweep test may not always verify the condition. IPC Performance IPC performance may be affected by the following conditions: • Cold temperatures • Temperature fluctuations • High humidity • Driving over rough surfaces such as dirt roads or potholes Customer Comments and Observations Customers who describe gauge performance as jumpy, sticky, slow or erratic. Gauge performance may also be described as being inoperative or inaccurate. For example, for a period of time the speedometer may appear to move normally but be inaccurate and not return to zero (0) after the vehicle comes to a stop. This inaccurate condition may be more or less pronounced during the drive cycle and may, for a time, return to normal operation. A Tech 2 sweep test may not reveal the condition.

1999-2002 Chevrolet and GMC C/K Pickup Engine Knock on Cold Start

1999-2002 Chevrolet and GMC C/K Pickup Engine Knock on Cold Start

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Models: 1999-2002 Chevrolet and GMC C/K Pickup and Utility Models 2002 Cadillac Escalade (2WD) with 4.8L, 5.3L or 6.0L Engine (VINs V, T, Z, U — RPOs LR4, LM7, L59, LQ4) This bulletin is being revised to add an additional engine to the models section. Please discard Corporate Bulletin Number 01-06-01-028 (Section 06-Engine). Some of the above vehicles may exhibit an engine knock noise that begins in the first 19,000-24,000 km (12,000-15,000 mi) of use. The knock noise is most often noticed during initial start- up and typically disappears within the first 5-30 seconds (may last longer in extreme cold temperatures). The noise is usually more noticeable on the initial start-up when the temperature is below 10°C (50°F) and may be more pronounced on the first cold start following a long trip. This noise may be caused by an interaction between carbon that has formed on the piston, the piston motion and the cylinder wall.

GM Powertrain Engineering, and an analysis of engines with this condition, has confirmed that the noise is not detrimental to the performance, reliability or durability of the engine. THIS NOISE DOES NOT HAVE ANY EFFECT ON THE LONGEVITY OF ANY OF THE ENGINE COMPONENTS. Important: At this time, attempts to repair this condition by replacing the engine assembly or pistons are not recommended. Please share the information found in this bulletin with customers who inquire about this condition. In the event they have additional questions or concerns, please advise your Area Service Manager.

1998 Chevrolet/ Geo Malibu Trim Panel Replacement – Instrument Panel (I/P) Cluster Chevrolet

1998 Chevrolet/ Geo Malibu Trim Panel Replacement – Instrument Panel (I/P) Cluster Chevrolet

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Removal Procedure 1. Disable the SIR system. Refer to Disabling the SIR System in SIR. 2. 3. 4. 5. 6. Remove the screws (5) from the cluster trim plate (1). Gently pry out the cluster trim plate (1). Disconnect the electrical connector (3) from the instrument panel lamp dimmer . Disconnect the hazard warning switch (4). Remove the cluster trim plate (1). Installation Procedure 1. Connect the hazard warning switch (4). 2. Connect the electrical connector (3) from the instrument panel lamp dimmer. 3. Align the cluster trim plate (1) tabs to the retainers. Notice Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application.

Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. 4. Install the screws (5) to the cluster trim plate (1). Tighten Tighten the screws to 2 N·m (18 lb in). 5. Enable the SIR system. Refer to Enabling the SIR System in SIR.

2007 Chevrolet Malibu Headlamp Assembly Removal Procedure

2007 Chevrolet Malibu Headlamp Assembly Removal Procedure

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Headlamp Assembly or Headlamp Bulb and/or Cornering, Sidemarker, Park, Turn Signal Bulb Replacement Removal Procedure Caution: Refer to Halogen Bulb Caution. 1. Open the hood. Important: Hold the headlamp to prevent damage to the headlamp or to the fascia. 2. Remove the bolts from the headlamp assembly. 3. Lift the headlamp assembly to unseat the tabs on the bottom and the edge of the fender. 4. Disconnect the electrical connector from the headlamp assembly. 5. Remove the headlamp assembly away from the vehicle, if necessary. 6. Remove the headlamp bulb access cover by rotating the headlamp bulb access cover counterclockwise, if necessary. 7. Remove the headlamp bulb from the housing by rotating the socket counterclockwise, if necessary. 8. Disconnect the headlamp bulb electrical connector, if necessary. 9. Remove the park/turn bulb access cover by rotating the cover counterclockwise, if necessary. 10. Remove the park/turn bulb from the housing by rotating the socket counterclockwise, if necessary. 11. Gently pull the park/turn bulb from the socket, if necessary. Installation Procedure 1. Install the park/turn bulb into the bulb socket. 2. Install the park/turn bulb socket into the headlamp housing by rotating the socket clockwise. 3. Install the park/turn bulb access cover by rotating the cover clockwise. 4. Connect the headlamp bulb to the headlamp electrical connector. 5. Install the headlamp bulb into the headlamp housing. Rotate the socket clockwise until locked. 6. Install the headlamp bulb access cover by rotating the cover clockwise. 7. Connect the electrical connector to the headlamp assembly.

2004 Chevrolet Impala LS Brake Pads Replacement

2004 Chevrolet Impala LS Brake Pads Replacement

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BRAKE PADS REPLACEMENT – REAR Removal Procedure CAUTION: Refer to Brake Dust Caution in Cautions and Notices. 1. Inspect the fluid level in the brake master cylinder reservoir. 2. If the brake fluid level is midway between the maximum-full point and the minimum allowable level, then no brake fluid needs to be removed from the reservoir before proceeding. If the brake fluid level is higher than midway between the maximum-full point and the minimum allowable level, then remove brake fluid to the midway point before proceeding. 3. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information. 4. Remove the rear tire and the wheel assembly. Refer to Tire and Wheel Removal and Installation in Tires and Wheels. 5. Install a hand tightened lug nut to retain the rotor to the hub. 6. Compress the caliper piston enough for clearance. Use a C-clamp (3). 7. Remove the upper caliper bolt (2).

Fig. 19: Removing The Upper Caliper Bolt – Rear NOTE: NOTE: Use care to avoid damaging pin boot when rotating caliper. Support the brake caliper with heavy mechanic’s wire, or equivalent, whenever it is separated from its mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak. 8. Pivot the caliper down in order to access the pads. It is not necessary to remove the caliper. 9. Remove the brake pads (2) from the caliper bracket. 10. Remove the 2 pad clips (1) from the caliper bracket. 11. Inspect the caliper mounting hardware for the following conditions: Cuts Tears Deterioration Replace any hardware if damage exists. Refer to Disc Brake Mounting and Hardware Inspection – Rear . 12. Inspect the caliper dust boot for the following conditions: Cuts Tears Deterioration Replace the caliper dust boot if damage exists. Refer to Brake Caliper Inspection . 13. Inspect the caliper bolts for corrosion or damage. If corrosion exists, use new caliper bolts when installing the caliper. Installation Procedure 1. Bottom the piston into the caliper bore. Use a C-clamp before installing new brake pads in order to compress the piston. Use an old brake pad or wooden block across the face of the piston to avoid damage to the piston or the caliper boot. 2. Install the 2 retainers (1) to the caliper bracket. IMPORTANT: The wear sensor is on the outside pad. The sensor is positioned at the trailing or downward edge of the pad during forward wheel rotation. 3. Install the pads (2) to the caliper bracket.

2001 Chevrolet Malibu Ignition Lock Cylinder Removal & Installation

 2001 Chevrolet Malibu Ignition Lock Cylinder Removal & Installation

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1. Remove the knee bolster. 2. Turn ignition switch to the RUN position. 3. Push the ignition lock cylinder tab. 4. Remove the ignition lock cylinder. Fig. The removal and installation of the ignition lock cylinder To install: 1. General Information. 2. Install the ignition lock cylinder. 3. Install the knee bolster. 1. Remove the knee bolster. 2. Turn ignition switch to the RUN position. 3. Push the ignition lock cylinder tab. 4. Remove the ignition lock cylinder. Fig. The removal and installation of the ignition lock cylinder To install: 1. Install the ignition lock cylinder. 2. Install the knee bolster.

1998 Chevrolet C1500 Lock Cylinder Removal & Installation Part I

1998 Chevrolet C1500 Lock Cylinder Removal & Installation Part I

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1988-94 Models See Figures 1 and 2 1. Remove the steering wheel. Fig. Fig. 1: Installing the lock cylinder Fig. Fig. 2: Ignition switch 2. Remove the turn signal switch. It is not necessary to completely remove the switch from the column. Pull the switch rearward far enough to slip it over the end of the shaft, but do not pull the harness out of the column. 3. Turn the lock to Run. 4. If necessary, remove the ignition key. 5. If equipped, remove the buzzer switch assembly. 6. Remove the lock retaining screw and remove the lock cylinder. WARNING If the retaining screw is dropped on removal, it may fall into the column, requiring complete disassembly of the column to retrieve the screw. To install:

7. Rotate the key to the stop while holding onto the cylinder. 8. Push the lock all the way in. 9. Install the screw. Tighten the screw to 40 inch lbs. (5 Nm) for regular columns, 22 inch lbs. (2.5 Nm) for tilt columns. 10. Install the turn signal switch and the steering wheel. 1995-98 Models See Figures 3, 4 and 5 CAUTION When performing service around the SIR system components or wiring, the SIR system MUST be disabled. Failure to do so could result in possible air bag deployment, personal injury or unneeded SIR system repairs. When carrying a live inflator module, make sure that the bag and trim cover are pointed away from you. Never carry the inflator module by the wires or connector on the underside of the module. In case of accidental deployment, the bag will then deploy with minimal chance of injury. When placing a live inflator module on a bench or other surface, always face the bag and trim cover up, away from the surface. 1. Disconnect the negative battery cable and disable the SIR system. 2. Remove the upper and lower shroud, air bag module and the steering column. Fig. Fig. 3: Exploded view of the removal of the SIR coil assembly

1998 Chevrolet C1500 Lock Cylinder Removal & Installation

1998 Chevrolet C1500 Lock Cylinder Removal & Installation

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TESTING No-Load Test See Figure 1 1. With the carbon pile “OFF”, make connections as shown in the accompanying figure. Close the switch, adjust the carbon pile to get 10 volts, and compare with the following RPM, current and voltage readings: 1984-87 5.7L (VIN 8) engine: No load test @ 10.6 volts-70-110 amps, RPM at drive pinion-6,500-10,700 rpm 1988 5.7L (VIN 8) engine: No load test @ 10.6 volts-90 amps (max.), RPM at drive pinion-3,300 rpm 1989-90 5.7L (VIN 8) engine: No load test @ 10 volts-45-90 amps, RPM at drive pinion-3,300-5,000 rpm 5.7L (VIN J) engine: No load test @ 10 volts-45-90 amps, RPM at drive pinion-3,300-5,500 rpm 5.7L (VIN P) engine:

No load test @ 10 volts-45-90 amps, RPM at drive pinion-2,800-5,000 rpm 5.7L (VIN 5) engine: No load test @ 10 volts-45-90 amps, RPM at drive pinion-3,500-5,000 rpm 2. Rated current draw and no load speed indicates normal condition of the starter motor. Fig. Fig. 1: Starter motor no-load test connections 3. Low free speed and high current draw indicates: Too much friction. Tight, dirty, or worn bushings, bent armature shaft allowing armature to drag. Shorted armature. This can be further checked on a growler after disassembly. Grounded armature or fields. Check further after assembly. 4. Failure to operate with high current draw indicates: A direct ground in the terminal or fields.

“Frozen” bearings. 5. Failure to operate with low or no current draw indicates: Open solenoid windings. Open field circuit. This can be checked after disassembly by inspecting internal connections and tracing the circuit with a test lamp. Open armature coils. Inspect the commutator for badly burned bar after disassembly. Broken brush springs, worn brushes, high insulation between the commutator bars of other causes which would prevent good contact between the brushes and commutator. 6. Low no-load speed and low current draw indicates: High internal resistance due to poor connections, defective leads, dirty commutator and causes listed under Step 6. 7. High free speed and high current drain usually indicate shorted fields. If shorted fields are suspected, replace the field and frame assembly. Also check for shorted armature using a growler. REMOVAL & INSTALLATION 5.7L (VIN 8) Engine See Figures 2 through 20 1. Disconnect the negative battery cable. 2. Raise and safely support the vehicle. 3. For 1984-88 vehicles, perform the following: a. Remove the retainers and the flywheel cover.

2001 Chevrolet Silverado 2500 Brake Caliper Removal & Installation

 2001 Chevrolet Silverado 2500 Brake Caliper Removal & Installation

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1. Remove or disconnect the following: 2 / 3 of the brake fluid from the master cylinder Tire and wheel assembly 2. Using a C-clamp or the equivalent, compress the caliper piston until the caliper piston bottoms in the bore. Brake hose at caliper by removing the inlet fitting bolt. Plug the line. Caliper mounting bolts Caliper 3. Inspect the caliper assembly. Fig. Front caliper removal-Avalanche, Sierra & Silverado To install: 1. Install or connect the following: Caliper Caliper mounting bolts. Tighten the caliper guide pin bolts to 74 ft. lbs. (100 Nm) on 15 series or 80 ft. lbs. (108 Nm) on 25/35 series.. Brake hose at caliper by installing the inlet fitting bolt. Tighten the inlet fitting bolt to 33 ft. lbs. (45 Nm). 2. Bleed the brakes. Tire and wheel assembly Fig. Rear caliper removal-15 Series Silverado/Sierra Fig. Rear pad removal-15 Series Silverado/Sierra Fig. Rear pad removal-25 Series Silverado Fig. Sleeve and bushing removal-15 Series Silverado/Sierra

Fig. Compressing the rear caliper piston-15 Series Silverado/Sierra Fig. Rear caliper removal-25 Series Silverado CAUTION Dust and dirt accumulating on brake parts during normal use may contain asbestos fibers from production or aftermarket brake linings. Breathing excessive concentrations of asbestos fibers can cause serious bodily harm. Exercise care when servicing brake parts. Do not sand or grind brake lining unless equipment used is designed to contain the dust residue. Do not clean brake parts with compressed air or by dry brushing. Cleaning should be done by dampening the brake components with a fine mist of water, then wiping the brake components clean with a dampened cloth. Dispose of cloth and all residue containing asbestos fibers in an impermeable container with the appropriate label. Follow practices prescribed by the Occupational Safety and Health Administration (OSHA) and the Environmental Protection Agency (EPA) for the handling, processing, and disposing of dust or debris that may contain asbestos fibers. NOTE There are 2 caliper designs and they can be identified by the method used to secure the assembly to the spindle bracket. The Delco caliper is secured by a bolt and sleeve combination. The Bendix caliper assembly is secured by a slider, spring and bolt. 1. Remove the cover on the master cylinder and siphon enough fluid out of the reservoirs to bring the level to 1 / 3 full. This step prevents spilling fluid when the piston is pushed back. 2. Raise and support the vehicle safely. Remove the front wheels and tires. 3. Position a C-clamp around the outside pad and caliper; tighten the C-clamp until the caliper piston bottoms in its bore.

1994 Chevrolet Corvette Door Panels Removal & Installation

1994 Chevrolet Corvette Door Panels Removal & Installation

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1984-89 Vehicles See Figure 1 1. Raise the hood, then disconnect the negative battery cable. 2. Unfasten the 2 screws attaching the armrest to the trim panel. Push the armrest inward to remove the plastic hooks on the armrest from the slot on the door trim panel. 3. If equipped, remove the armrest filler. 4. Remove the retaining screws, then remove the speaker grille. 5. If equipped, remove the manual lock knob. 6. Unfasten the accessory trim plate screws. Note there is a hidden screw behind the door release handle. 7. Detach the electrical connectors from the hatch lid release switch, door lock courtesy light and, if removing the drivers side door panel, the wiper switch. Fig. Fig. 1: Exploded view of the door trim panel-1984-88 vehicles 8. Remove the accessory trim plate. 9. Remove the remote control plate and the courtesy lamp. 10. Remove the upper molding an air outlet.

11. Unfasten the door trim panel retaining screws, the pull the panel partially away from the door. 12. Detach the hatch lid release switch electrical connector. 13. Remove the door panel from the vehicle. 14. Installation is the reverse of the removal procedure. 1990-96 Vehicles See Figures 2 and 3 1. Disconnect the negative battery cable. 2. Remove the accessory/inside handle bezel, as follows: 3. Remove the courtesy lamp from the bezel by gently prying down on the top edge, about 1 / corners and rotating the lamp downward and out. a. Remove the remote control lock knob from the rod by carefully prying it outward. b. If removing the right door panel, remove the armrest filler panel by unfastening the screws retaining the armrest filler. c. Remove the bezel screws. The right and left side bezels may have different numbers of screws. d. Pull the inside handle outward, then reposition the bezel. e. Detach the courtesy lamp harness from the wiring harness connector. f. Unplug the electrical connector from the door lock switch. g. Remove the bezel.

2006 Chevrolet TrailBlazer Fuel Level Sensor Replacement

2006 Chevrolet TrailBlazer Fuel Level Sensor Replacement

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1. Remove the fuel sender assembly. Refer to Fuel Sender Assembly Replacement. 2. 3. 4. 5. 6. Disconnect the fuel pump electrical connector. Remove the retaining clip from the fuel level sensor connector. Disconnect the electrical connector from under the fuel sender cover. Remove the sensor retaining clip. Squeeze the locking tangs and remove the fuel level sensor (3). Installation Procedure 1. 2. 3. 4. Install the fuel level sensor (3). Install the sensor retaining clip. Connect the electrical connector to the fuel level sensor. Install the retaining clip to the fuel level sensor electrical connector. 5. Connect the fuel pump electrical connector. 6. Install the fuel sender assembly. Refer to Fuel Sender Assembly Replacement.

FUEL SENDER ASSEMBLY REPLACEMENT Tools Required J 45722 Fuel Tank Sending Unit Wrench. See Special Tools. Removal Procedure 1. Remove the fuel tank. Refer to Fuel Tank Replacement (TrailBlazer EXT, Envoy XL, Envoy XUV) or Fuel Tank Replacement (TrailBlazer, Envoy, Rainier). NOTE: Do Not handle the fuel sender assembly by the fuel pipes. The amount of leverage generated by handling the fuel pipes could damage the joints. IMPORTANT: Do NOT use impact tools. Significant force will be required to release the lock ring. The use of a hammer and screwdriver is not recommended. Secure the fuel tank in order to prevent fuel tank rotation. 2. Use the J 45722 and a long breaker-bar in order to unlock the fuel sender lock ring. See Special Tools. Turn the fuel sender lock ring in a counterclockwise direction.