2003-2004 GMC SIERRA, YUKON, YUKON XL, SAVANA BRAKE HYDRO-BOOST RELIEF VALVE SEAL FRACTURE

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Filed Under (GMC) by admin on 07-06-2013

download General Motors has decided that certain 2003 and 2004 model year Cadillac Escalade, Escalade EXT and Escalade ESV; Chevrolet Silverado, Avalanche, Suburban, and Express; GMC Sierra, Yukon, Yukon XL, and Savana; and 2004 model year Chevrolet Tahoe vehicles fail to conform to either Federal/Canada Motor Vehicle Safety Standard 105, “Hydraulic and Electric Brake System”, or Standard 135, “Light Vehicle Brake Systems”. These vehicles may have a relief valve bore within the brake hydro-boost module that is not to specification. An out-of-specification bore could result in fracture of the relief valve 0-ring seal within the module. If this happens, during braking applications the driver may be able to hear an engine compartment noise similar to the sound that occurs when the steering wheel is turned to a full stop position. The driver could also experience a slight increase in steering efforts while braking and parking. Under certain driving conditions, a fractured seal may require a slight increase in the applied brake pedal effort to achieve the same vehicle deceleration rate as prior to the seal fracture. If this were to occur, it could result in a vehicle crash without prior warning.

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2000 GMC Truck GMC K Sierra Secondary Air Injection System Description

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Filed Under (GMC) by admin on 07-06-2013

download The system includes the following components: AIR System (10) Shutoff Valve Outlet Hose (11) Shutoff Valve Outlet Hose To AIR Pump Base Retaining Clamp (12) Shutoff Valve Outlet Hose Clamp (13) AIR Shutoff Valve (14) Fresh AIR Inlet Hose • The AIR pump–The AIR pump assembly is mounted in the right rear corner of the engine compartment and supplies the air to the AIR system. The electric air pump sends air to the check valves near the exhaust manifolds. The AIR pump is controlled by the powertrain control module (PCM) through the AIR pump solenoid relay. Battery voltage to the AIR pump is controlled by the AIR pump solenoid relay. A vacuum operated shut off valve prevents air flow during OFF periods. When the PCM provides a ground circuit for the secondary AIR pump solenoid relay, battery voltage applies power to the AIR pump and the solenoid. Intake manifold vacuum is then applied through the solenoid to the vacuum operated shut off valve. The vacuum operated shut off valve then opens up and allows air to be delivered to the check valves. • The AIR solenoid–The AIR solenoid is activated by the AIR pump solenoid relay. The activated AIR solenoid allows intake manifold vacuum to the shut off valve. The shut off valve then opens allowing air flow. • The shut-off valve–The AIR shut-off valve allows air to be delivered to the AIR system. The shut-off valve is vacuum operated through the solenoid. The shut-off valve is normally closed. When the AIR pump solenoid relay is activated by the PCM, vacuum is applied through the solenoid and to the shut-off valve. • The AIR pump solenoid relay–The PCM controls the operation of the AIR system through the AIR pump solenoid relay. When the PCM provides a ground circuit for the secondary AIR pump solenoid relay, battery voltage is allowed to power up the AIR pump and the solenoid. • The check valves–The check valves prevent the back flow of hot exhaust gases getting to the AIR pump. • The necessary plumbing: – Hoses – Vacuum lines – Pipes – Clamps

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GMC Antilock Brake (ABS) Activation At Low Speeds (Clean Wheel Speed Sensor Mounting Surface)

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Filed Under (GMC) by admin on 07-06-2013

download This bulletin is being revised to add the 2007 Silverado/Sierra Classic models. Please discard Corporate Bulletin Number 03-05-25-007C (Section 05 — Brakes). Condition Some customers may comment on ABS activation at low speeds, usually below 8 km/h (5 mph). Upon investigation, the technician will find no DTCs set. Cause The cause of this condition may be an increased air gap between the wheel speed sensor and the hub reluctor ring due to rust and debris built up on the sensor mounting surface. Correction Measure AC voltage and clean the wheel speed sensor mounting surfaces. 1. Raise and support the vehicle. 2. Disconnect both the front wheel speed sensor connectors at the frame and harness. 3. Place a Digital Volt Meter (DVM) across the terminals of each wheel speed sensor connector. 4. Rotate the wheel clockwise approximately one revolution per second. The minimum reading should be at least 350 ACmV’s. If the reading is less than 350 ACmV’s, remove the wheel speed Page 2 sensor. 5. Plug the wheel speed sensor bore in order to prevent debris from falling into the hub during service. 6. Clean the wheel speed sensor mounting surface using a wire brush, sand paper, emery cloth, scotch brite, or other suitable material. Be sure to thoroughly clean the wheel speed sensor surface. There should be no rust or corrosion. 7. Check the sensor head to determine if it has been warped/distorted due to the corrosion build up or other causes. Check the mounting surface on the sensor head for flatness by placing it on the edge of a metal machinists scale or other suitable straight edge to measure the flatness. Check the sensor for flatness in multiple (minimum 3) positions/directions. If the sensor head is distorted, replace the sensor. 8. Apply (spray) two thin coats of the specified rust penetrating lubricant (corrosion inhibitor) to the complete sensor mounting surface on the bearing hub. Allow to dry for 3-5 minutes between coats. Use ONLY Rust Penetrating Lubricant, P/N 89022217 (in Canada, P/N 89022218). 9. When the corrosion inhibitor is dry to the touch (about 10 minutes), apply a thin layer of bearing grease to the hub surface and sensor O-ring prior to sensor installation. Use ONLY Wheel Bearing Lubricant, P/N 01051344 (in Canada, P/N 993037). 10.Install either the original sensor or a new one in the hub. Ensure that the sensor is seated flush against the hub. Refer to the applicable Wheel Speed Sensor Replacement procedure in the ABS sub-section of the Service Manual. 11.Place the DVM across the sensor terminals and recheck the voltage while rotating the wheel. The voltage should now read at least 350 ACmV’s

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GMC ABS Light On, DTCs C0265, C0201, U1041 Set and/or Loss of Communication with Brake Module

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Filed Under (GMC) by admin on 03-06-2013

download Some customers may comment that the ABS light is on. Upon further inspection, DTCs C0265 and C0201 may be set in the brake module. It is also possible for DTC U1041 to set in other modules. There may also be a loss of communication with the brake module. Cause A poor connection at the EBCM ground is causing unnecessary replacement of brake modules. Important: The EBCM ground is different for each application. Refer to the list below for the proper ground reference: Correction Important: Do not replace the brake module to correct this condition. Perform the following Subject: ABS Light On, DTCs C0265, C0201, U1041 Set and/or Loss of Communication with Brake Module (Reground EBCM Ground) • Midsize Utilities = Ground 304 • SSR = Ground 400 • Fullsize Trucks and Utilities = Ground 1Perform the following steps to improve the connection of the EBCM Ground: 1. Remove the EBCM Ground. The EBCM Ground is located on the frame beneath the driver’s side door. If multiple grounds are found in this location, the EBCM ground can be identified as the heavy (12-gauge) wire. 2. If the original fastener has a welded on nut, remove the nut from the frame, and if required, enlarge the bolt hole to accommodate the new bolt and nut. 3. Clean the area, front and back, using a tool such as a *3M™ Scotch-Brite™ Roloc disc or equivalent. 4. Install the ground, then the washer and then the bolt to the frame. Important: It is important to use the bolts, washers and nuts specified in this bulletin. These parts have been identified due to their conductive finish. 5. Install a washer and nut to the back side of the frame. Tighten Tighten the nut to 9 N·m (79 lb in). 6. Cover the front and back side of the repair area using Rubberized Undercoating. An additional check can be made to ensure a good connection for the battery cable to frame ground. It is possible for this ground to cause similar symptoms with the ABS as described above. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources

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2006 GMC Truck Yukon 2WD Amplifier Replacement

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Filed Under (GMC) by admin on 03-06-2013

download REMOVAL PROCEDURE 1. If equipped with a Bose(TM) amplifier, remove the radio amp fuse located under the hood electrical center. 2. Remove the floor console bezel. 3. Remove the cupholder. 4. Remove the bolts (1) retaining the console to the instrument panel (I/P). 5. Remove the console storage bin. 6. Remove the center console end panel. 7. Disconnect the audio amplifier electrical connectors. 8. Remove the 4 screws retaining the upper console bracket to the lower console bracket. The front 2 screws (1) are shown in the graphic. 9. Move both front seats to the fully forward. 10. Reposition the inboard seat track trim (1) in order to gain access to the rear console side panel screw (2). 11. Remove both rear console side panel screws. 12. Move both front seats to the fully rearward. 13. Remove both front console side panel screws (1). 14. Disconnect the floor console electrical connector. 15. Remove the console assembly from the vehicle. 16. Remove the audio amplifier screws (1). 17. Remove the audio amplifier from the vehicle. INSTALLATION PROCEDURE 1. Install the audio amplifier to the floor console lower bracket. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the amplifier screws 3. Install the floor console. 4. Connect the floor console electrical connector. 5. Install the screws (1) that retaining the upper console bracket to the lower console bracket

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GMC DTC P1626 Theft Deterrent Fuel Enable Signal Not Received

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Filed Under (GMC) by admin on 03-06-2013

download Conditions for Setting the DTC The VCM has not established communications with the VTD (Passlock) control module and has not received a valid password before reaching the fuel enable decision point. Action Taken When the DTC Sets When the failure occurs before the VCM receives a Fuel Continue Password (during engine cranking): When the failure is present on an ignition cycle after the VTD system went into Fail Enable Mode (VCM lost communication with the VTD after receiving the Fuel Continue Password): Conditions for Clearing the MIL/DTC Diagnostic Aids Important: Do not clear DTCs unless directed by a diagnostic procedure. Clearing DTCs will also clear valuable Freeze Frame and Failure Records data. • The vehicle does not start, or it starts and stalls. • The VCM disables fuel delivery, until the fault is corrected and a valid password is received from the VTD (Passlock) Control Module. • A DTC P1626 is stored in the VCM memory. • The VCM will not illuminate the MIL. • The vehicle starts. • The VCM continues to enable fuel delivery (Fuel Enabled after Security Fault mode) until the fault is corrected and a valid password is received from the VTD (Passlock) Control Module. • A DTC P1626 is stored in the VCM memory. • The VCM will not illuminate the MIL. • A history DTC will clear if no fault conditions have been detected for 40 warm-up cycles. • A warm-up cycle occurs when the coolant temperature has risen 22°C (40°F) from the startup coolant temperature and the engine coolant temperature exceeds 70°C (160°F) during the same ignition cycle. • Use the scan tool Clear Information function. • Check for published service bulletins relating to exhibited symptoms or component operation. • Inspect all related wiring and connections including the VCM and VTD (Passlock) Control Module connections. These may cause an intermittent malfunction. • If the Class 2 serial data circuit is shorted to ground or shorted to voltage, then all systems connected to the serial data circuit will not be able to communicate properly. Systems capable of storing loss of communications DTCs (DTCs with the letter U as a prefix) will have these codes stored in their memory. If a DTC U1192 is stored in the VCM memory along with the P1626, then a fault occurred at some point after the VCM received the correct password. The VTD must also be checked for intermittent operation due to a loss of power or ground to

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2005 GMC Truck Envoy 2WD Instruments – Erratic Speedometer Operation

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Filed Under (GMC) by admin on 03-06-2013

download Subject: Erratic Speedometer Operation Or Speedometer Needle Shakes Above 60 mph (96 km/h) (Repair Poor Connection At Ground G108) Some customers may comment on erratic operation of the speedometer. Others may comment that the speedometer needle shakes above 96 km/h (60 mph). Cause This condition may be caused by a loose or poor connection at Powertrain Control Module/Engine Control Module (PCM/ECM) ground G108 Technicians are to inspect and repair ground G108 as necessary. Refer to callout 1 in the illustration above for the location of G108. Refer to the Testing for Intermittent Conditions and Poor Connections and the Wiring Repair procedures in SI for more information

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2002 GMC Truck C 1500 Truck 2WD Distributor Replacement

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Filed Under (GMC) by admin on 03-06-2013

download REMOVAL PROCEDURE NOTE: There are two procedures available to install the distributor. Use Installation Procedure 1 when the crankshaft has NOT been rotated from the original position. Use Installation Procedure 2 when any of the following compartments are removed: ● The intake manifold ● The cylinder head ● The camshaft ● The timing chain or sprockets ● The complete engine If the malfunction indicator lamp (MIL) turns on and DTC P1345 sets after installing the distributor, this indicates an incorrectly installed distributor. Engine damage or distributor damage may occur. Use Procedure 2 in order to install the distributor. 1. Turn OFF the ignition. Remove air cleaner assembly replacement. Remove the spark plug wires from the distributor cap ● Twist each spark plug goof 1/2 turn. ● Pull only on the wire goof in order to remove the wire from the distributor cap. 2. Remove the electrical connector from the base of the distributor 3. Remove the two screws that hold the distributor cap to the housing. 4. Discard the screws. 5. Remove the distributor cap from the housing. 6. Use a grease pencil in order to note the position of the rotor in relation to the distributor housing (1). 7. Mark the distributor housing and the intake manifold with a grease pencil.

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GMC (1965-74) Switches, Gauges, Speedometer

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Filed Under (GMC) by admin on 03-06-2013

download NSTRUMENT CLUSTER Chevrolet “C”, “K” & “P” Models (1965-66) – Disconnect negative battery cable. Disconnect speedometer cable and in- strument cluster wiring harness connectors. Disconnect oil pressure line, air gauge pipe and tachometer leads (if equipped). Remove live (three for each cluster on flat face cowl models) screws attaching cluster housing to dash panel, and pull cluster toward rear of vehicle out of panel opening. GMC 1000, C-1500, & C-2500 (1965-66) – Cluster is retained in panel with six screws. To remove cluster, remove screws, disconnect multiple plug and speedometer drive cable, and remove cluster. Chevrolet & GMC “C” & “K” Models (1967- 72) — Disconnect negative battery cable. Disconnect speedometer cable and wiring harness connector at rear of in- strument panel. Remove choke control knob trom choke rod, remove setscrew from windshield wiper knob and remove knob. Pull light switch out to extreme position, then press on spring-loaded reléase button on top of switch assembly and

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2005 GMC Truck Sierra 2500HD 4WD 6.6L Turbo Diesel 8cyl Removal & Installation

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Filed Under (GMC) by admin on 03-06-2013

download 1. Disconnect the electrical connection at the blend door actuator (10). Fig. Blend door actuator and related components Remove the blend door actuator mounting screws from the HVAC module. 3. Remove the blend door actuator as an assembly with the actuator cam. Fig. Remove the blend door actuator mounting screws from the HVAC module 4. To install: Install the blend door actuator as an assembly with the actuator cam. Line up the heater/defroster valve lever with the blend door actuator cam slot. a. Line up the A/C valve lever with the blend door actuator cam b. 1. Install the blend door actuator mounting screw to the HVAC module. Tighten the blend door actuator mounting screw to 14 inch lbs. (1.6 Nm). a. 2. Connect the electrical connection at the blend door actuator (10). 3. Blend door actuator and related components Install the floor air outlet duct extension (1) to the floor air duct (2). 4. Remove the floor air outlet duct extension (1) from the floor duct (2). Fig. Remove the floor air outlet duct extension (1) from the floor duct (2) 1. Disconnect the electrical connection at the blend door actuator (10). 2. 2005 GMC Truck Sierra 2500HD 4WD 6.6L Turbo Diesel 8cyl | Fig. Blend door actuator and related components Remove the blend door actuator mounting screws from the HVAC module. 3. Remove the blend door actuator as an assembly with the actuator cam. Fig. Remove the blend door actuator mounting screws from the HVAC module 4. To install: Install the blend door actuator as an assembly with the actuator cam. Line up the heater/defroster valve lever with the blend door actuator cam slot. a. Line up the A/C valve lever with the blend door actuator cam b. Install the blend door actuator mounting screw to the HVAC module. Tighten the blend door actuator mounting screw to 14 inch lbs. (1.6 Nm). a. 2. Connect the electrical connection at the blend door actuator (10). Fig. Blend door actuator and related components 3. Install the floor air outlet duct extension (1) to the floor air duct (2).

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